GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Kodiak C-Series (Crew) C4/C5 🢒 Body 🢒 Interior Trim 🢒 Control Lever and/or Boot Replacement

Removal Procedure

    Object Number: 791046 Size: SH
  1. Exhaust all air pressure from the system, if equipped.
  2. If equipped, with a Eaton® Fuller® 9 or 10 speed transmission, remove the screws from the control lever shift sheath.
  3. Slide the sheath down the shift lever.
  4. If equipped with the 9 speed transmission, disconnect the following tubes:
    5. • Red tube (1) from the "S" port
    • Black tube (2) from the "P" port

    Object Number: 791047 Size: SH
  5. If equipped with the 10 speed transmission, disconnect the following tubes:
    6. • Blue tube (1) from the "SP" port
    • Black tube (2) from the "P" port
    • Red tube (3) from the "S" port
    • Green tube (4) from the "H" port to "L" port
  6. Cap the tube openings.
  7. Perform the following steps in order to remove the air shift control lever:
    8. 7.1. Loosen the lock nut.
    7.2. Unscrew the shift control lever.
    7.3. Slide off the sheath, if necessary.
  8. If equipped, with the Eaton® Fuller® 9 or 10 speed transmission, remove the control lever .
  9. Remove the control lever boot pin.

    10. Object Number: 816151 Size: SH
  10. Remove the control lever.

    11. Object Number: 816150 Size: SH
  11. If equipped with a Spicer® transmission, RPOs MK8/MK9, remove the control lever boot retainer bolt.
  12. Remove the control lever boot.
  13. Lift up the control lever boot.

    14. Object Number: 816154 Size: SH
  14. If equipped with a Spicer® transmission, RPOs MK8/MK9, loosen the set screw (1).
  15. Remove the control lever and boot.

Installation Procedure

    Object Number: 816154 Size: SH
  1. If equipped with a Spicer® transmission, RPOs MK8/MK9, install the control lever and boot.

    2. Notice: Refer to Fastener Notice in the Preface section.

  2. Tighten the control lever set screw (1).

    3. Tighten
    Tighten the control lever set screw to 39 N·m (28 lb ft).

  3. Push down the control lever boot.

    4. Object Number: 816151 Size: SH
  4. Install the control lever.
  5. Install the retaining pin.

    6. Object Number: 816150 Size: SH
  6. If equipped, with the Eaton® Fuller® 9 or 10 speed transmission, install the control lever boot .

    7. Object Number: 791047 Size: SH
  7. Perform the following steps in order to install the air shift control lever:
    8. 7.1. Slide on the sheath, if necessary.
    7.2. Screw on the shift control lever.
    7.3. Tighten the lock nut.

    Tighten
    Tighten the shift lever lock nut to 25 N·m (18 lb ft).

  8. Remove the caps from the tube openings.
  9. If equipped with the 10 speed transmission, connect the following tubes:
    10. • Blue tube (1) to the "SP" port
    • Black tube (2) to the "P" port
    • Red tube (3) to the "S" port
    • Green tube (4) to the "H" port to "L" port

    Object Number: 791046 Size: SH
  10. If equipped with the 9 speed transmission, connect the following tubes:
    11. • Red tube (1) to the "S" port
    • Black tube (2) to the "P" port
  11. Slide the sheath up the shift lever.
  12. If equipped, with a Eaton® Fuller® 9 or 10 speed transmission, install the screws to the control lever shift sheath.

    13. Tighten
    Tighten the control lever shift sheath screws to 5 N·m (44 lb in).

  13. Pressurize the air system, if equipped.
  14. Operate the shift control lever to check for leaks, if equipped.