Chevrolet 1977 Monte Carlo, Repair Manual, Page: 361 / 428

M A N U A L T R A N S M IS S IO N 7B -15
Fig. 7 B -2 0 B -M e a s u rin g O u tp u t S h a ft End Play Fig. 7B-1 8 B -ln s ta llin g T abbed T h ru st W asher
TABBED THRUST
WASHER (SHARP
EDGE MUST FACE
OUT)
2. Install First-R everse sleeve and gear half-w ay onto
hub with gear end o f sleeve facing rear o f shaft. Index sleeve
to hub w ith m arks m ade during disassem bly.
3. Install spring in First-R everse hub. (M ake sure
spring is bottom ed in hub and covers all three key slots.)
P osition three synchronizer keys in hub, w ith sm all ends in
hub slots and large ends inside hub. Push keys fully into hub
so they seat on spring. Then slide First-R everse sleeve and
gear over keys until the keys engage in the synchronizer
sleeve (Fig. 7B-13B).
4. Place first gear blocking ring on tapered surface o f
gear. Install First gear on output shaft. R otate gear until
notches in blocking ring engages keys in First-R everse hub.
5. Install tabbed thrust w asher (sharp edge facing out)
and retaining snap ring on output shaft (Fig. 7B-18B).
Fig. 7 B - 1 9 B - ln s t a llin g Second Gear
6. Place second gear blocking ring on tapered surface
o f gear and install second gear on ou tp ut shaft w ith tapered
surface o f gear facing front o f output shaft (Fig. 7B -19B ).
7. Install Second-T hird synchronizer assem bly w ith flat
portion o f synchronizer hub facing rearward on output
shaft. R otate Second gear until notches in blocking ring
engages keys in Second-T hird synchronizer assem bly. It
m ay be necessary to tap synchronizer w ith a plastic ham m er
to ease assem bly.
8. Install retaining snap ring on output shaft and
measure end play between snap ring and Second-Third
synchronizer hub w ith feeler gauge (Fig. 7B-20B). End play
should be 0.004 to 0.0014 inch. I f end play exceeds 0.014
inch, replace thrust washer and all snap rings on output
shaft assembly.
A S S E M B L Y OF T R A N S M IS S IO N
1. Coat transm ission case reverse idler gear thrust
w asher surfaces w ith vaseline (or equivalent) and position
thrust washer in case. Be sure to engage locating tabs on
thrust washers in locating slots in case.
2. Install reverse idler gear w ith helical cut gear
towards front o f case. A lign gear bore, thrust washers, case
bores, and install reverse idler gear shaft from rear o f case.
Be sure to align and seat roll pin in shaft into counterbore
in rear o f case.
3. M easure reverse idler gear end play by inserting
feeler gauge between thrust washer and gear. End play
should be 0.004 to 0.018 inch. I f end play exceeds 0.018
inch, rem ove idler gear and replace thrust washer.
4. Install shaft tool J-25232 in bore o f countergear and
load a row o f needle bearing (25) in each end o f gear. U se
heavy grease or equivalent to hold them in place. Install one
needle bearing retainer on each end o f gear.
5. Position countergear thrust w asher in case, use
vaseline or equivalent to hold w ashers in place. Be sure to
engage locating tabs on thrust washer in locating slots in
case.
BLOCKING
RING
SECOND
G E A R
O V E R H A U L M A N U A L