Chevrolet 1977 10 Series, Repair Manual, Page: 446 / 468

7B-66 OVERHAUL MANUAL
Fig. 7 B -1 3 S -R e m o v in g In p u t S h a ft-to -B e a rin g S nap Ring
Removing Input Gear Assembly
8. Remove input gear bearing retainer and seal assembly.
Discard gasket.
9. Remove large snap ring from bearing outer diameter.
10. Tap input gear and bearing from case.
11. Remove snap ring retaining input shaft bearing to
shaft and remove bearing from input gear.
NOTE:
This is a select fit snap ring. Snap rings, size A,
B, C, and D are released for service. Select tightest fit.
Removing Cluster Gear Assembly (Fig. 7B -15S)
12. From interm ediate case side, remove counter shaft
from cluster gear and case using Tool J-24745. Remove
cluster gear assembly from case.
NOTE:
Recover roller bearings (72 required) from gear
case and shaft.
13. Remove cluster gear thrust washers from case.
14. Clean and inspect all components. Replace worn and
defective parts.
Fig. 7B-1 4S~Removing Input Shaft Bearing-to-Retainer Snap
Ring
Fig. 7B-1 5S--R em oving C lu s te r Gear S h a ft
Assembly (Fig. 7B-11S)
Installing Countergear Assembly
1. Using Tool J-24745 and a heavy grease, install roller
bearings (72 required) and spacers in clustergear bore.
2. Using a heavy grease, position countershaft thrust
washers in case. Engage tab on washers with a slot in case
thrust surface.
3. Position cluster gear assembly in case and install
countershaft through front face of range box into gear
assembly. Countershaft face with flat should face forward
and m ust be aligned with case gasket.
Installing Input Gear Assembly
4. Install bearing (w ithout large snap ring) on input gear
shaft positioning snap ring groove outw ard and install new
retaining ring on shaft. Position input gear and bearing in
housing.
NOTE:
The retaining ring is a select fit. Use service ring
size A, B, C or D as required to provide tightest fit.
5. Install snap ring in outside diam eter of bearing.
6. Align oil slot in retainer with drain hold in case and
install input gear bearing retainer, gasket and retaining bolts.
Tighten bolts to specifications.
Installing S h ifter S h aft Assembly
7. If removed, install poppet plate and pivot pin
assembly in housing. Use sealant on pin.
8. Install new "O" rings on the inner and outer shifter
shiafts. Lubricate "O" rings and assemble inner shaft in the
outer shaft.
9. Push the shifter shafts into the housing, engaging the
long end of the lockout clutch connector link to the outer
shifter shaft before the shaft assembly bottoms out.
10. Install lower shift lever and retaining ring.
11. Install upper shift lever and shifter shaft retaining
nut.
12. Install shift fork and sliding clutch gear. Push fork
up into shifter shaft assembly to engage poppet plate, sliding
clutch gear forw ard onto the input shaft gear.
13. Install poppet spring, gasket and plug in top of
housing. Check spring engagement with poppet plate.
Input Gear Bearing Replacement
1. Remove bearing retainer attaching bolts, retainer and
gasket from housing. Discard gasket.
SNAP RING