Chevrolet 1977 10 Series, Repair Manual, Page: 381 / 468

MANUAL TRANSMISSION 7B-1
S E C T IO N 7B
MANUAL TRANSMISSION
C O N T E N T S
3-Speed (Saginaw) 76mm Transm ission......................... 7B-1
3-Speed (Trem ac) 77mm Transm ission.......................... 7B-9
3-Speed (Muncie) 83mm Transm ission.......................... 7B-17
4-Speed (Saginaw) 76mm Transm ission......................... 7B-23
4-Speed (W arner) 83mm Transm ission.......................... 7B-30
4-Speed (M uncie CH465) 117mm Transm ission......... 7B 40
New Process M odel 205 Transfer C ase......................... 7B-52
New Process M odel 203 Transfer C ase......................... 7B-59
A dapter A ssem blies............................................................ 7B-70
Specifications........................................................................ 7B-72
Special T o o ls........................................................................ 7B-74
3-SPEED (SAGINAW) 7 6 M M TRANSMISSION
IN D E X
Disassembly of T ransm ission........................................... 7B-1
Disassembly of M ainshaft.................................................. 7B-1
Cleaning and Inspection.................................................... 7B-4
Transmission Case........................................................... 7B-4
F ront and Rear B earings.............................................. 7B-4
Bearing R ollers................................................................ 7B-4
G ears.................................................................................. 7B 4
Reverse Idler G ear B ushing......................................... 7B-4
Repairs......................................................................................7B-4
Clutch Keys and S p rin g ............................................... ..7B-4
Extension Oil Seal or B u sh in g .................................... ..7B-5
Clutch Bearing R etainer Oil Seal..................................7B-5
Assembly of M ainshaft...................................................... ..7B-5
Assembly of T ransm ission................................................ ..7B-6
DISASSEMBLY OF TR A N SM ISSIO N (FIG. 7B-1A)
1. Remove side cover attaching bolts and side cover
assembly.
2. Remove drive gear bearing retainer and gasket.
3. Remove drive gear bearing-to-gear stem snap ring,
then remove clutch gear bearing by pulling outw ard on clutch
gear until a screwdriver or other suitable tool can be inserted
between bearing large snap ring and case to complete removal
(Fig. 7B-2A). The clutch gear bearing is a slip fit on the gear
and into the case bore. (This provides clearance for removal
of clutch gear and mainshaft assembly.)
4. Remove speedometer driven gear from extension.
5. Remove extension to case attaching bolts.
6. Remove the reverse idler shaft "E" ring (Fig. 7B-3A).
7. Remove drive gear, m ainsahft and extension assembly
together through the rear case opening. Remove drive gear,
needle bearings and synchronizer ring from mainshaft
assembly.
8. Using snap ring pliers, expand the snap ring in the
extension which retains the m ainshaft rear bearing (Fig. 7B-
4A) and remove the extension.
9. Using J-22246 at the front of the countershaft, drive
the shaft and its woodruff key out the rear of the case (Fig.
7B-5A). Tool J-22246 will now hold the roller bearings in
position within the countergear bore. Remove the gear,
bearings and thrust washers.
10. Use a long drift or punch through the front bearing
case bore and drive the reverse idler shaft and woodruff key
through the rear of the case (Fig. 7B-6A).
DISASSEMBLY OF M A IN S H A FT
1. Using snap ring pliers, remove the 2nd and 3rd speed
sliding clutch hub snap ring from mainshaft and remove
clutch assembly, second speed blocker ring and second speed
gear from front of m ainshaft. See Fig. 7B-7A.
2. Depress speedometer retaining clip and slide or tap
gear from mainshaft.
3. Remove rear bearing snap ring from mainshaft
groove. See Fig. 7B-8A.
4. Support reverse gear with press plates and press on
rear of m ainshaft to remove reverse gear, thrust washer,
spring washer, rear bearing, and snap ring from rear of
mainshaft. See Fig. 7B-9A.
5. Remove the 1st and Reverse sliding clutch hub snap
ring from the m ainshaft and remove the clutch assembly, 1st
speed blocker ring and first speed gear from rear of the
mainshaft.
NOTE:
U nder certain tolerance conditions, it may be
necessary to press the synchronizer hub and gear from
the mainshaft.