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Thread: new guy from tn

  1. #1

    Default new guy from tn

    Howdy. Im new on here from tn. I am a born and bred chevrolet lover. My dad raised me that way. All i have ever owned is chevys. I have always tinkered with stuff since i was little. I eventually started workin in a small mechanic shop. Im no professional but i can hold my own for the most part. I currently work for a local HVAC contractor. I have a 2002 Chevrolet Silverado 2500HD 4x4 with the Vortec 8100 8.1L/496c.i. V8 with a ZF S6-650 6 Speed Manual Trans. I got the truck on a deal. It came from florida and had some problems but ive made it my own. There is a couple problems i cant figure out though. I quickly figured out the trans would not go into 6tb gear. It would go to where it felt like 6th would be but it wouldnt grab itwould just grind and pop back out. Some people have said bent shift fork and some said synchronizer. I dont know. And then now i had my temp sensor mess up the other day. The motor would miss and carry on and the temp hand would bounce up and down. I replaced the sensor and it fixed it for about a week now back to the same thing. It will stay at 160 then all the sudden it will jump up to temp and then go back down, all the while the motor is buckin and jumpin revvin up and down. Ive tried tracing the wires but im not sure what to look for. Ive been researching but cant figure it out. Any help would be appreciated.

  2. #2
    Sr. Engineer ahm1127's Avatar
    Join Date
    Jan 2009
    Pennsylvania, United States


    Welcome. Nice ride once you get it running well.
    Did you clean any of the ground wires? Thats where I would start, there are a few of them & corrosion & paint ruin the connection.
    Heres some info on your Trans; I would rebuild your synchros on your truck, manual transmissions are pretty simple.
    Good luck
    Everyday I wake up is a great day! ;-)
    05' Chevy Suburban, 11' Ford Fiesta

  3. #3


    Hey thanks. It has been running fine until now. And which ground wires? I have an extra green wire coming off the sensor itself but im not sure what its for. I have a yellow and a blue wire in the factory plug but no wire for the slot where the green wire goes in the sensor side of the plug?

  4. #4


    Have you ever took one of these zf trans apart? I have never been inside one

  5. #5
    Sr. Engineer ahm1127's Avatar
    Join Date
    Jan 2009
    Pennsylvania, United States


    Remove every ground wire usually black or braided wires. Connected to battery, engine, firewall, fender & chassis.
    I have not, its one of the more complex but only cause of yhe pump. They are fairly straightforward & simple. Watch YouTube before you do it yourself

  6. #6
    Master Mechanic silverhobey's Avatar
    Join Date
    Oct 2010
    Cobourg, Ontario, Canada
    Blog Entries


    Welcome, an 8.1, I'd love to not pay the gas for
    Brian from Canada...
    Silverado Crew.....4.8 L

    ---Pendaliner BoxLiner and Side Rails....Van and Truck World
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    ---PUTCO chrome eyebrow Mirror Covers.... Van and Truck World
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    ---DeeZee TailGate Assist ....Van and Truck World ( now Action Car and Truck Accessories )

    ---Westin Series side steps....Apple Auto Glass
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    ---Chevrolet Bowtie Mudflaps...GM Dealer
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    ---GM Driver Information Center Upgrade...GM Dealer
    ---GM Front Tinted Bug Deflector...GM Dealer
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    ---Better Built rear hitch step .... Lowe's !!!
    ---AVS Window VentVisors...Canadian Tire
    ---AVS tinted License plate covers....Wal-Mart

  7. #7


    Eh it aint that bad. Fuel injection has came so far it gets about the same as my 91 model 4.3...

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