Gearshift Lever Case Replacement 4WD

1. Remove the following components from the bottom of the gearshift lever case:

1.1.	The four screws (2, 3)

1.2.	The gearshift lever case plate (1)




2. Remove the following components from the gearshift shaft (3):

2.1.	One inner roll pin and one outer roll pin (2)

2.2.	The gearshift arm (1)




3. Remove the gearshift control lever bushing (1) from the gearshift arm (2).



4. Remove one roll pin (1) from the gearshift shaft (2) in order to release tension on the gearshift limit spring (3).



5. Remove the following components from the gearshift lever (2):

•	One inner roll pin

•	One outer roll pin

6. Remove one roll pin from the reverse gearshift limit yoke (1).
7. Unstake the gearshift lever case plug.



8. Remove the gearshift lever case plug (1) from the gearshift lever case (2).



9. Remove the gearshift shaft (4) from the gearshift lever case while removing the following components from the gearshift shaft:

9.1.	The gearshift lever (3)

9.2.	The reverse gearshift limit yoke (1)

9.3.	The gearshift limit spring (2)




10. Remove the gearshift limit bolt from the gearshift lever case.




Important: The left side of the gearshift lever case contains an inner and an outer select return spring.

The right side of the gearshift lever case contains only one select return spring.
Note the location of these springs in order to ensure correct assembly.
11. Remove the following components from the gearshift lever case:

11.1.

The two select return spring bolts (1)

11.2.

The three select return springs (2)

11.3.

The two select guide pins (3)




12. Remove the following components from the gearshift lever case:

12.1.

The two lever locating bolts

12.2.

The two washers




13. Remove the gearshift lever case seat from the gearshift lever case.
14. Clean the gearshift lever case mating surfaces.
15. Use solvent in order to clean all of the gearshift lever case components. Air dry the components.
16. Inspect the gearshift shaft:

16.1.

Insert the gearshift shaft into the gearshift lever case.

16.2.

Move the gearshift shaft back and forth. Ensure that the gearshift shaft does not bind.

16.3.

If the gearshift shaft does not move freely in and out of the gearshift lever case, replace the gearshift lever case and the gearshift shaft.

17. Inspect the following components for smooth fit and movement on the gearshift shaft:

•	The gearshift lever

•	The reverse gearshift limit yoke

•	The gearshift arm

•	If any of these components bind on the gearshift shaft, replace them all.

18. Inspect the gearshift limit spring for weakness or distortion.

Replace as necessary.

19. Inspect the gearshift control lever bushing for excessive wear.

Replace as necessary.

20. Inspect the gearshaft lever case seat for excessive wear.

Replace as necessary.

Tools Required

J 36850 Transjel® Transmission Assembly Lubricant

1. Apply a thin coat of J 36850 to all of the components prior to assembly.
2. Install the gearshift lever case seat into the gearshift lever case.



3. Install the following components into the gearshift lever case:

3.1.	The two lever locating bolts

3.2.	The washers

Tighten
Tighten the lever locating bolts to 20 N·m (15 lb ft).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.




4. Install the following components into the gearshift lever case:

4.1.	The two select guide pins (3)

4.2.	The three select return springs (2)

4.3.	The two select return spring bolts (1)

Tighten
Tighten the select return spring bolts to 23 N·m (17 lb ft).

5. Apply Loctite™ 414 GM P/N 1345493 or equivalent to the threaded portion of the reverse gearshift limit bolt.



6. Install the reverse gearshift limit bolt into the gearshift lever case.

Tighten
Tighten the reverse gearshift limit bolt to 35 N·m (26 lb ft).





Important: Position the portion of the gearshift shaft which has been machined flat so that it faces downward, toward the inside of the gearshift lever case, in order to ensure correct installation.

7. Install the gearshift shaft (4) into the gearshift lever case while installing the following components onto the gearshift shaft:

7.1.	The gearshift lever (3)

7.2.	The reverse gearshift limit yoke (1)

7.3.	The gearshift limit spring (2)

8. Install the gearshift lever case plug into the gearshift lever case.
9. Stake the gearshift lever case plug in two places.
10. Install one roll pin into the reverse gearshift limit yoke.



11. Install the following components into the gearshift arm and the gearshift shaft:

•	One inner roll pin

•	One outer roll pin

12. Install one roll pin into the gearshift shaft in order to retain tension on the gearshift limit spring.
13. Install the gearshift control lever bushing into the gearshift arm.
14. Install one inner and one outer roll pin into the gearshift arm and the gearshift shaft.



15. Attach the hooked end of the gearshift limit spring (3) around the roll pin (1).

Wind the gearshift limit spring until the straight end can be fitted into the groove on the reverse gearshift limit yoke.




16. Apply Loctite™ 599 RTV silicone sealer or equivalent to the gearshift lever case plate mating surface (1) on the gearshift lever case (2).
17. Install the gearshift lever case plate (3) onto the bottom of the gearshift lever case (2).

Secure the gearshift lever case plate (3) with the four screws.

Gearshift Lever Case Replacement 2WD

Important: The select return components are located in either side of the extension case. For select return component removal and inspection procedures, refer to Extension Case Replacement .

1. Remove the following components from the gearshift shaft (12):

•	The two roll pins (6)

•	The gearshift arm (5)

2. Remove the gearshift control lever bushing (4) from the gearshift arm (5).
3. Remove one roll pin (6) from the gearshift shaft (12).

The removal will release tension on the gearshift limit spring (7).

4. Remove the following components from the gearshift lever (8):

4.1.	One inner pin

4.2.	One outer pin

5. Unstake the gearshift lever case plug (11).
6. Remove the gearshift lever case plug (11) from the gearshift lever case (1).
7. Remove the gearshift shaft (12) from the gearshift lever case (1) while removing the following components as a unit from the gearshift shaft (12):

•	The gearshift lever (8)

•	The reverse gearshift limit yoke (10)

•	The gearshift limit spring (7)

8. Remove the reverse gearshift limit bolt (13) from the gearshift lever case (1).
9. Remove the following components from the gearshift lever case (1):

•	The lever locating bolts (2)

•	The washers

10. Remove the gearshift lever case seat (3) from the gearshift lever case (1).
11. Clean all the components thoroughly with solvent. Air dry the components.
12. Use the following procedure in order to inspect the gearshift shaft:

12.1.

Insert the gearshift shaft into the lever case.

12.2.

Work the gearshift shaft back and forth in order to feel for any binding.

12.3.

If the gearshift shaft does not move freely in and out of the gearshift lever case, replace the gearshift lever case and the gearshift shaft.

13. Inspect the following components for smooth fit and movement on the gearshift shaft:

•	The gearshift lever

•	The reverse gearshift limit yoke

•	The gearshift arm

•	If any of the following components bind on the gearshift shaft, replace the components:

-	The gearshift shaft

-	The gearshift lever

-	The reverse gearshift limit yoke

-	The gearshift arm

14. Inspect the gearshift limit spring for weakness or distortion. Replace the spring as necessary.
15. Inspect the gearshift control lever bushing for excessive wear. Replace the bushing as necessary.
16. Inspect the gearshift lever case seat for excessive wear. Replace the gearshift lever case seat as necessary.

Tools Required

J 36850 Transjel® Transmission Assembly Lubricant

1. Apply J 36850 to all of the components prior to assembly.
2. Install the gearshift lever case seat into the gearshift lever case.
3. Install the following components into the gearshift lever case:

•	The lever locating bolts

•	The washers

Tighten
Tighten the lever locating bolts to 20 N·m (15 lb ft).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

4. Apply Loctite™ 414 GM P/N 12345493 or equivalent to the threaded portion of the reverse gearshift limit bolt.
5. Install the reverse gearshift limit bolt into the gearshift lever case.

Tighten
Tighten the reverse gearshift limit bolt to 35 N·m (26 lb ft).

Important: The portion of the gearshift shaft which has been machined flat must be facing downward toward the inside of the gearshift lever case for correct installation.

6. Install the gearshift shaft into the gearshift lever case while installing the following components as a unit onto the gearshift shaft:

•	The gearshift lever

•	The reverse gearshift limit yoke

•	The gearshift limit spring

7. Install the gearshift lever case plug into the gearshift lever case.



8. Stake the gearshift lever case plug in two places (1).
9. Install the following components into the gearshift lever:

9.1.	One inner roll pin

9.2.	One outer roll pin

10. Install a roll pin into the gearshift shaft in order to retain tension on the gearshift limit spring.
11. Install the following components into the gearshift arm and the gearshift shaft:

11.1.

One inner roll pin

11.2.

One outer roll pin




12. Attach the hooked end of the gearshift limit spring around the roll pin.

Wind the gearshift limit spring until the straight end can be fitted into the groove on the reverse gearshift limit yoke.