Chevrolet 1977 10 Series, Repair Manual, Page: 442 / 468

7B-62 OVERHAUL MANUAL
Fig. 7 B -7 S --R e m o vin g S h ift F ork R e ta in in g Pin
Fig. 7 B -8 S -R e m o v in g o r In s ta llin g P o p p e t B all Plug
bearing retainer to transfer* case. Tap on front of shaft or
carefully pry retainer away from case. Remove retainer from
shaft and discard gasket. Recover any roller bearings which
may fall from rear cover.
NOTE:
If necessary to replace rear bearing, support
cover and press bearing from cover. Position new
bearing to outside face of cover and press bearing into
cover with a .06 inch overhang.
12. From lower side of case, remove (pry) output shaft
front bearing.
13. Disengage front output shaft from chain and remove
shaft from transfer case (Fig. 7B-9S).
14. Remove bolts attaching interm ediate chain housing
to range box. Lift or using a chain hoist, remove interm ediate
housing from range box (Fig. 7B-10S).
15. Remove chain from interm ediate housing.
16. Remove lockout clutch, drive gear and input shaft
assembly from range box.
NOTE:
A 1 1/2" to 2" hose clam p may be installed on
end of the input shaft to prevent loosing the roller
bearings (123) which may fall out of clutch assembly if
it is pulled off the input shaft.
17. Pull up on shift rail and disconnect rail from link.
18. Remove (lift) input shaft assembly from range box.
NOTE:
A t this point the transfer case is completely
disassembled into its subassemblies. Each of these
subassemblies should then be disassembled fro cleaning
and inspection.
CLEANING AN D INSPECTION
B E A R IN G S--Place all bearings and rollers in cleaning
solution and allow to remain long enough to loosen all
accum ulated lubricant. Bearings should be sloshed up and
down and turned slowly below surface of solution to remove
as m uch lubricant as possible. Remove bearings and blow dry
with compressed air, being careful to direct air across bearing
so that bearings do not spin.
SH A FTS A N D G E A R S -C lean all shafts and gears in
cleaning solution to remove all accum ulations. D ry with
compressed air.
Fig. 7B-9S--Removing Front O utput Shaft Fig. 7B-10S~Rem oving Interm ediate (Chain) Housing