Chevrolet 1977 Monte Carlo, Repair Manual

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7E-2 TRANSFER CASE
POPPET NUTS
SHIFT RAIL
LINK
FRONT INPUT
SHAFT ASSEMBLY
FRONT OUTPUT
SHAFT ASSEMBLY
F ig . 7 E - 2 R ~ F r o n t V i e w o f T r a n s f e r C a s e
6
. Remove thrust washer and pin from shaft.
7. Remove gear, needle bearings (32 per row) and
spacer.
8
. I f necessary to replace front output shaft rear
bearing, support cover and press bearing from cover.
Position new bearing to outside face of cover and using a
piece of pipe or wood to cover outside diameter of bearing,
press bearing into cover until flush with opening.
S h ift Rail and Fork A ssem blies
1. Remove the two poppet nuts on top of case, two
poppet springs, and using a magnet, remove the poppet
bails.
2. Drive cup plugs into case using a 1/4 inch punch.
3. Position both shift rails in neutral and using a long,
narrow punch, drive shift fork pins through shift rails into
the case (Fig. 7E-6R).
4. Remove clevis pins and shift rail link.
5. Remove shift rails (Fig. 7E-7R), upper (range) rail
first, then lower (4-wheel) rail.
Fig.
7E-3R~Removing Front O utpu t S haft Rear Bearing
Retainer
6
. Remove shift forks and sliding clutch from case.
7. Remove the front output high gear, wahser, and
bearing from the case. Remove the shift rail cup plugs and
pins from the case.
In p u t S h a ft A ssem bly
8
. Remove snap ring in front of bearing. Using a soft
hammer, tap shaft out rear of case. Tap bearing out front
of case.
9. Tip case on P.T.O. and remove two interlock pins
from inside of case.
Idler G ear
1. Remove idler gear shaft nut.
2. Remove idler shaft rear cover.
3. Remove idler gear shaft using a soft hammer and
tool J-23429 (Fig. 7E-8R).
4. Roll idler gear to front output shaft hole and remove
from case.
5. Remove bearing cups (2) as required from idler
gear.
C L E A N IN G A N D IN S P E C T IO N
B earings -Place all bearings and rollers in cleaning
solution and allow to remain long enough to loosen all
accumulated lubricant. Bearings should be sloshed up and
down and turned slowly below surface of solution to remove
as much lubricant as possible. Remove bearings and blow
out with compressed air, being careful to direct air across
bearing so that bearings do not spin.
S h a fts and G ears -Clean all shafts in cleaning
solution to remove all accumulations. Dry with compressed
air.
Case, C over and B earing Cups -Transfer case,
cover, and bearing cups must be thoroughly cleaned in
solution to remove all accumulation of lubricant and dirt.
Remove all trace of gaskets from surface where used.
Inspection -Carefully inspect all bearings and rollers
for evidence of chipping, cracks, or worn spots that would
render bearing unfit for further service. Bearings are non-
adjustable and if worn or damaged, must be replaced with
new parts.
Inspect shaft splines and gears. I f any indication of
failure, such as chipped teeth or excessive wear, is indicated,
those parts should be replaced with new parts.
A S S E M B L Y OF T R A N S F E R C A S E (FIG. 7E-9R)
Idler G ear
1. Press the two bearing cups in the idler gear (if
previously removed) using Tool J-9276-2 and Handle J-8092
(Fig. 7E-10R).
2. Assemble the two bearing cones, spacer, shims and
idler gear on dummy shaft J-23429 with bore up. Check end
play (Fig. 7E-11R). Limits are .001 to .002 inch.
3. Install idler gear assembly with dummy shaft into
case through front output bore, large end first (Fig. 7E-
12R).
4. Install idler shaft from large bore side and drive
throuhg using a soft hammer (Fig. 7E-13R).
5. Install washer and new locknut. Check for end play
and free rotation. Torque nut to 150 ft. lbs.
FRONT
OUTPUT SHAFT
REAR BEARING
RETAINER
O V E R H A U L M A N U A L