Chevrolet 1977 10 Series, Руководство по ремонту, Страница: 432 / 468

7B-52
OVERHAUL MANUAL
NEW PROCESS MODEL 205 (PART TIME) TRANSFER CASE
INDEX
Disassembly of Transfer C ase............................................7B-52
Rear O utput Shaft A ssem bly...................................... ..7B-52
Front O utput Shaft A ssem bly..................................... ..7B-52
Shift Rail and Fork A ssem blies....................................7B-52
Idler G e a r......................................................................... ..7B-52
Cleaning and In sp ectio n ......................................................7B-52
Assembly of Transfer Case............................................... .7B-55
Idler G e a r......................................................................... .7B-55
Shift Rail and Fork A ssem blies...................................7B-55
Front O utput Shaft A ssem bly..................................... .7B-57
R ear O utput Shaft A ssem bly ...................................... .7B-58
M iscellaneous.................................................................. .7B-59
D IS A S S E M B L Y OF T R A N S F E R C A S E
(FIG. 7B-1R)
Rear Output Shaft and Yoke Assembly
1. Loosen rear output shaft yoke nut.
2. Remove rear output shaft housing bolts and remove
housing and retainer assembly from case.
3. Remove retaining nut and yoke from shaft, then
remove shaft assembly from housing.
4. Remove snap ring using Tool J-23432 and discard.
5. Remove thrust washer and washer pin.
6. Remove tanged bronze washer. Remove gear needle
bearings (32 per row), spacer and second row of needle
bearings.
7. Remove tanged bronze thrust washer from shaft.
8. Remove pilot rollers (15), retainer ring and washer.
9. Remove oil seal retainer, ball bearing, speedometer
gear and spacer. Discard all gaskets. Press out bearing as
required.
10. Remove oil seal from the retainer.
Front Output Shaft Assembly (Fig. 7B-3R)
1. Remove lock nut, wahser and yoke.
2. Remove front bearing retainer attaching bolts and
retainer.
3. Remove front output shaft rear bearing retainer
attaching bolts.
4. Tap on output shaft with a soft ham m er (Fig. 7B-4R)
and remove shaft, gear assembly, and rear bearing retainer
from case.
NOTE:
Remove the sliding clutch from output high
gear, washer, and bearing which will have remained in
the case.
5. Using large snap ring picks, such as J-23432-1, remove
the gear retaining ring from the shaft (Fig. 7B-5R) and
discard.
6. Remove th ru st washer and pin from shaft.
7. Remove gear, needle bearings (32 per row) and spacer.
8. If 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 diam eter of bearing, press bearing into
cover until flush with opening.
Shift Rail and Fork Assemblies
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. 7B-6R).
4. Remove clevis pins and shift rail link.
5. Remove shift rails (Fig. 7B-7R), upper (range) rail
first, then lower (4-wheel) rail.
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.
Input Shaft Assembly
8. Remove snap ring in front of bearing. Using a soft
ham m er, 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 Gear
1. Remove idler gear shaft nut.
2. Remove idler shaft rear cover.
3. Remove idler gear shaft using a soft ham m er and tool
J-23429 (Fig. 7B-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 e a r in g s --Place all bearings and rollers in cleaning
solution and allow to remain long enough to loosen all
accum ulated 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 f t s a n d G e a r s -C le a n all shafts in cleaning
solution to remove all accum ulations. D ry with compressed
air.
C a s e , C o v e r a n d B e a r in g C u p s -Transfer case,
cover, and bearing cups must be thoroughly cleaned in
solution to remove all accum ulation of lubricant and dirt.
Remove all trace of gaskets from surface where used.