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There should be a short harness from the VSS to the now empty union conn.

If you have a 99 then the ISS speed sensor at the front of the trans will have DK BLU/WHT & RED/BLK wires. The VSS on the x-fer case will have LT GRN/BLK & PPL/WHT wires. The rear speed sensor on the trans is not used. I have seen these conns. get mixed up.

The conn. at the arrow should lead to the rear VSS, on the x-fer case. It is a "union" to the rear VSS conn. The speed sensor bracket is normally part of the speed sensor. Anyway, this is how they are bolted on.

Has the van worked correctly before these problems or did you buy it like it is? It would help if you could get the code and part number off the eprom chip in the TCM. EXAMPLE -

I just did that. OEM lines. From the front with rad support removed, and rad hoses out of the way. It is a 2wd 6.5 burb. It did require some manipulation.

That drawing is my own. The electrical schematics are in a separate 95 FSM. There are 5 or 6 in the set. It has DRIVABILITY, EMISSIONS, AND ELECTRICAL DIAGNOSIS on the front. You can download it on the other 6.5 site.

This is all you need to get the sync working.

Mystery TCM. I have never seen that part # and cannot find any evidence of it in any of my lists or the web. Could you pull the eprom cover off and see what numbers are on the chip?

If you have a vin "Y" L57 diesel engine and 4L80e transmission then the correct TCM is GM 16196390. Maybe you made a typo? 09357159 is workhorses part num for the same TCM. Does your TCM have a 4 letter code, like BJDM ? Could be a bad or wrong VSSB. What is the part num on the VSSB?

That "relay" #12182086 is not a normal relay and will not work like a normal relay. It is only used with the 5 pin updated actuator and a Borg Warner transfer case. It is a solid start controller. Check on the cost of a replacement for a shocker! When the actuator upgrade kit is used on a Borg...

I had the same problem with my 96 Burb, sometimes. It had the old thermal actuator.

Previous Owner = PO. Your 95 did not come with that 5 pin connector. That is part of the actuator upgrade harness. There is no telling what was done. The cable actuator usually indicates they could not get the wiring correct or working. Your 4401 transfer case also has a synchronizer circuit...

That conn. is for the updated actuator. The PO must have updated before going mechanical. Does your K3500 have a Borg Warner transfer case?

No. That is where the TC ends up when you bolt it on.

Part num is 15727309. Some OEM on Ebay. It is just 1/2" heater hose with a piece of wire loom at the front bend. That's what I do.

Exactly! With the TC not bolted and washers gone can you slide the TC forward until the bolt lugs contact the flexplate?

If B9 is hot in crank then the park/neutral switch on the trans is OK. I have repaired 2 trucks in the past with starter problems due to the PPL crank wire being shorted down behind the starter. One was a short to ground, easy to fix. The other was a short to the glow plug wires, that got...

Has or will the oil be analyzed? Very odd.

If the engine was bumped over with the starter with the IP removed, bad things could happen.

I was concerned about that years ago when I did my first IP. After much trying I could not get it out of time, had TC off for timing set at the time so was easy to check. I just went out and tried again on an engine with the TC loose and was not able to get the gear to jump. BUT, it is very...