GM Service Manual Online
For 1990-2009 cars
Makes 🢒 Chevrolet 🢒 2004 🢒 C-Series Medium Duty Truck C6/7/8 - Mexico 🢒 Engine 🢒 Engine Electrical 🢒 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 the 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 shift knob lock nut.
    7.2. Unscrew the shift knob.
    7.3. Slide off the sheath, if necessary.

    Object Number: 791333 Size: SH
  8. If equipped, with the Eaton Fuller® 9 or 10 speed transmission, remove the control lever retainer bolts and retainer.
  9. Remove the control lever boot retainer plate bolts and plate.
  10. Remove the control lever boot bolts and boot.

    11. Object Number: 791332 Size: SH
  11. If equipped, with the Eaton Fuller® transmission, loosen the shift knob lock nut.
  12. Unscrew the shift knob.

    13. Object Number: 791338 Size: SH
  13. If equipped, with the 6.6/7.2L (1) or 8.1L (2) engine, and regular production options (RPOs) MSC/MSG, remove the retainer and bushing.
  14. Remove the retaining pin, and bushing.
  15. Remove the control lever.

    16. Object Number: 791340 Size: SH
  16. If equipped, with the 6.6/7.2L engine without RPOs MSC/MSG remove the retainer and bushing.
  17. Remove the retaining pin, and bushing.
  18. Remove the control lever.

    19. Object Number: 791337 Size: SH
  19. If equipped with the Spicer® transmission, RPOs MK8/MK9, remove the control lever boot retainer bolts and retainer.
  20. Remove the control lever boot bolts.
  21. Lift up the control lever boot.

    22. Object Number: 791331 Size: SH
  22. If equipped with the Spicer® transmission, RPOs MK8/MK9, loosen the set screw (1).
  23. Remove the control lever and boot.

Installation Procedure

    Object Number: 791331 Size: SH
  1. If equipped with the Spicer® transmission, RPOs MK8/MK9, install the control lever and boot.

    2. 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.

  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: 791337 Size: SH
  4. If equipped with the Spicer® transmission, RPOs MK8/MK9, install the control lever boot bolts.

    5. Tighten
    Tighten the control lever boot bolts to 2 N·m (18 lb in).

  5. Install the control lever boot retainer and bolts.

    6. Tighten
    Tighten the control lever retainer bolts to 2 N·m (18 lb in).


    Object Number: 791340 Size: SH
  6. If equipped, with the 6.6/7.2L engine without RPOs MSC/MSG, install the control lever.
  7. Install the retaining pin, and bushing.
  8. Install the retainer and bushing.

    9. Object Number: 791338 Size: SH
  9. If equipped, with the 6.6/7.2L (1) or 8.1L (2) engine, and RPOs MSC/MSG, install the control lever.
  10. Install the retaining pin, and bushing.
  11. Install the retainer and bushing.

    12. Object Number: 791332 Size: SH
  12. If equipped, with the Eaton Fuller® transmission, screw the shift knob on.
  13. Tighten the shift knob lock nut.

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


    Object Number: 791333 Size: SH
  14. If equipped, with the Eaton Fuller® 9 or 10 speed transmission, install the control lever boot and boot bolts.
  15. Install the control lever boot retainer plate and bolts.

    16. Tighten
    Tighten the control lever boot retainer plate bolts to 2 N·m (18 lb in).

  16. Install the control lever retainer and bolts.

    17. Tighten
    Tighten the control lever retainer bolts to 2 N·m (18 lb in).


    Object Number: 791047 Size: SH
  17. Perform the following steps in order to install the air shift control lever:
    18. 17.1. Slide on the sheath, if necessary.
    17.2. Screw on the shift knob.
    17.3. Tighten the shift knob lock nut.

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

  18. Remove the caps from the tube openings.
  19. If equipped with the 10 speed transmission, connect the following tubes:
    20. • 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
  20. If equipped with the 9 speed transmission, connect the following tubes:
    21. • Red tube (1) to the "S" port
    • Black tube (2) to the "P" port
  21. Slide the sheath up the shift lever.
  22. If equipped, with the Eaton Fuller® 9 or 10 speed transmission, install the screws to the control lever shift sheath.

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

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