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78-30
1977 PONTIAC SERVICE MANUAL
ASSEMBLY OF MAINSHAFT (FIG. 7B-
Turn the front of the mainshaft upward. Install the
following components on the mainshaft:
1. Install the second speed gear with clutching teeth
upward; the rear face of the gear will butt against the flange
on the mainshaft.
.2. Install a blocking ring, with clutching teeth
downward, over the synchronizing surface of the second
speed gear. All three blocker rings used in this transmission
are identical.
3. Install the second and third synchronizer assembly
with the fork slot downward; press it onto splines on the
mainshaft until it bottoms out. Both synchronizer assemblies
used in this transmission are identical (if sleeve becomes
removed from 2-3 hub, notches on hub O.D. face forward end
of mainshaft).
CAUTION: Be sure the notches of the blocker
ring align with the keys o f the synchronizer
assembly.
4. Install snap ring retaining synchronizer hub to
mainshaft. Both snychronizer snap rings are identical.
5. Turn the rear of the mainshaft upward and install the
first speed gear with clutching teeth upward; the front face
of the gear will butt against the flange on the mainshaft.
6. Install a blocker ring with clutching teeth downward
over synchronizing surface of the first speed gear.
7. Install the first and reverse synchronizer assembly
with fork slot downward; push it onto splines on the
mainshaft.
CAUTION: Be sure the notches of the blocker
ring align with the keys of the synchronizer
assembly.
8. Install synchronizer hub to mainshaft snap ring.
9. Install reverse gear with clutching teeth downward.
10. Install reverse gear thrust washer (steel).
11. Install reverse gear spring washer.
12. Install rear ball bearing with snap ring slot
downward; press onto mainshaft.
13. Install rear bearing to mainshaft snap ring.
14. Install speedometer drive gear and retaining clip.
ASSEMBLY OF TRANSMISSION
1. Using Tool J 22246, load a row of roller bearings (27)
and a bearing thrust washer at each end of the countergear.
Use heavy grease to hold them in place (Fig. 78-29).
2. Place countergear assembly through case rear opening
along with a tanged thrust washer (tang away from gear) at
each end and install countergear shaft and woodruff key from
rear of case.
C A U TI 0 N: Be sure countershaft picks up both
thrust washers and that the tangs are aligned with
their notches in the case.
3. Install reverse idler gear and shaft with its woodruff
key from the rear of case. Do not install idler shaft
"E"
ring
yet.
4. Using snap ring pliers, expand the snap ring in the
extension and assemble extension over rear of mainshaft and
onto rear bearing. Seat snap ring in rear bearing groove.
/
ANTI-LASH
PLATE
C
5089
Fig. 78-29 Loading Roller Bearings
5. Load the mainshaft pilot bearings (14) into the drive
gear cavity and assemble the 3rd speed blocker ring onto the
drive gear clutching surface with its teeth toward the gear.
6. Pilot the drive gear, pilot bearings and 3rd speed
blocker ring assembly over the front of the mainshaft
assembly. Do not assemble bearing to gear yet.
CAUTION: Be sure the notches in the blocker
nng align with the keys in the 2-3 synchronizer
assembly.
7. Place extension to case gasket at rear of case, holding
in place with grease, and, from the rear of case, assemble the
drive gear, mainshaft and extension to case as an assembly.
CAUTION: Be sure the drive gear engages the
countergear anti-lash plate.
8. Install extension to case retaining bolts. Torque to 45
lb. ft.
9. Install front bearing outer snap ring to bearing and
position bearing over stem of drive gear and into front case
bore.
10. Install snap ring to drive gear stem and install drive
gear bearing retainer and gasket to case, torquing bolts to 10
Ib. ft.
NOTE: The retainer oil return hole should be at the
bottom.
11. Install reverse idler gear retainer
"E"
ring to shaft.
12. Shift synchronizer sleeves to neutral positions and
install cover, gasket and fork assembly to case. Be sure forks
align with their synchronizer sleeve grooves.
13. Tighten all bolts evenly to 10 lb. ft. to avoid case
cover distortion.
14. Rotate drive gear shaft and shift transmission to free
rotation in all gears.
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