Chevrolet 1977 Monte Carlo, Repair Manual

Page: 410 / 428

7E-6 TRANSFER CASE
J-8092
J-9276-2
FR O N T O U T P U T
BORE
IDLER G E A R ASSEMBLY
F ig . 7 E - 1 0 R--I n s ta 11 i n g N e w B e a r in g C u p s F ig . 7 E -1 2 R —I n s ta 11 i n g I d le r G e a r
sealant. Install bolts and torque to 30 ft. lbs.
7. Install front output yoke, washer and lock nut.
Torque nut to 150 ft. lbs.
Rear O u tp u t S h a ft A ssem bly
1. Install two rows of needle bearings (32 each)
separated by a spacer into the output low gear. Use
sufficient grease to retain needles.
2. Install thrust washer onto rear output shaft, tang
down in clutch gear groove. Install output low gear onto
shaft with clutch teeth facing down.
3. Install thrust washer over gear with tab pointing up
and away from gear. Install washer pin and also large thrust
washer over shaft and pin. Rotate washer until tab fits into
slot approximately 90 degrees away from pin. Finally, install
snap ring using Tool J-23423 and J-23423-1 and check end
play which should be within .002-.027 inch.
4. Grease pilot bore or rear output shaft and install
needle bearings (15). Install thrust washer and new snap
ring in bore.
5. Clean, grease, and install new bearing in retainer
housing using Tool J-23431 (Fig. 7E-17R).
6
. Install housing onto output shaft assembly, install
spacer and speedometer gear, then install bearing (Fig. 7E-
18R).
7. Install rear bearing retainer seal using Tool J-21359
or J-22834-2 (Fig. 7E-19R).
8
. Install bearing retainer assembly onto housing with
one or two gaskets, depending on clearance. Torque bolts
to 30 ft. lbs.
Fig. 7E-1 1R -C hecking Idle r Gear End Play
Fig. 7E-13R—Installin g Idle r S haft
O V E R H A U L M A N U A L