Chevrolet 1977 light duty truck, Service Manual

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SERVICE OPERATIONS
T R A N S M IS S IO N R E P LA C E M E N T
(A ll Except K M odel)
N O T E : If necessary, the catalytic converter may
have to be disconnected to provide adequate
clearance for transm ission removal. This procedure
will include removal o f the converter support
bracket.
1. Before raising the vehicle, disconnect the
negative battery cable detent downshift cable at
carb u reto r and release the p ark in g brake.
2. Raise vehicle on hoist.
3. Remove propeller shaft.
4. Disconnect speedom eter cable, detent downshift
cable, m odulator vacuum line and oil cooler pipes at
transmission.
5. Disconnect shift control linkage.
6. Support transm ission with suitable transm ission
jack.
7. D isco n n ect r e a r m o u n t from f ra m e
crossm em ber.
8. Remove two bolts at each end o f fram e
crossm em ber. Remove crossmember.
9. Remove converter u n d e r pan.
10. Remove converter to flywheel bolts.
11. Lower tran sm issio n until ja c k is barely
supporting it.
12. Remove transm ission to engine m ounting bolts
an d remove oil filler tube at transmission.
13. Raise transmission to its norm al position,
su p p o rt engine with jack and slide transmission rearw ard
from engine and lower it away from vehicle.
CAUTION:
Use suitable converter holding tool
when lowering transmission or keep rear o f
transmission lower than front so as not to lose
converter.
The installation o f the transmission is the reverse of
the rem oval with the following added step. Before
installing the flex plate to converter bolts, make certain
that the attaching lugs on the converter are flush with the
flex plate and the converter rotates freely by hand in this
position. Then, h a n d start all three bolts and tighten
finger tight before torqueing to specification. This will
insure p roper converter alignment.
A fter installation of transm ission, lower vehicle and
rem ove vehicle from hoist. Check linkage for p roper
adjustm ent.
Check transmission fluid level.
T R A N S M IS S IO N R E P LA C E M E N T
(K M o d el)
Removal
4. Remove transfer case shift lever knob and boot.
5. Raise vehicle on hoist.
6. Remove flywheel cover.
7. Remove torque converter to flywheel attaching
bolts. (Secure the converter.)
8. D isconnect tran sm issio n shift linkage and
speedometer cable.
9. Remove engine crossunder pipe to manifold
bolts.
10. Disconnect vacuum m odulator line, line to filler
tube clip and detent downshift cable to filler tube strap.
11. Disconnect detent downshift cable at the
transmission.
12. Disconnect transmission oil cooler lines at the
transmission.
13. Remove transfer case a d ap ter to crossm em ber
bolts.
14. Raise engine as necessary.
15. R em ove c ro ssm em b er bolts and remove
crossmember.
16. Remove exhaust system h a n g e r bolts.
17. Disconnect rear propeller shaft at transfer
case.
18. Disconnect parking brake cable.
19. Disconnect exhaust system. (Tie aside.)
20. Disconnect front propeller shaft at front axle.
(Tie aside.)
21. Support transmission and transfer case with
jack (use safety chains).
22. Remove transfer case to fram e bracket bolts.
23. Remove transmission to engine bolts, remove
transmission and tran sfer case.
24. Rem ove tra n s f e r case from tran sm issio n
(includes: new " O " ring seal).
25. Move transm ission to bench fixture.
26. D rain transmission.
27. Remove torque converter.
28. Remove and discard front pu m p seal.
29. Refill tran sfer case.
In s ta lla tio n
Reverse removal procedure to install.
E XT EN S IO N H O U S IN G OIL SEAL
1. Disconnect battery cable. Removal
2. Remove transm ission dipstick.
3. Disconnect detent dow nshift cable at carburetor. 1. Remove propeller shaft.