Table of Contents
Advertisement
78-38
1977 PONTIAC SERVICE MANUAL
4-SPEED 82MM BORG-WARNER TRANSMISSION
INDEX
Removal of Transmission
................................................................................
7B-38
Disassembly of Transmission
..........................................................................
7B-38
Disassembly of Mainshaft
...............................................................................
7B-39
Cleaning and Inspection
..................................................................................
7B-39
Transmission Case
.......................................................................................
7B-39
Bearing Rollers and Spacers
.....................................................................
7B-40
Gears
..........................................................................................................
7B-40
Front and Rear Bearings
............................................................................
7B-40
Repairs
............................................................................................................
7B41
Clutch Keys and Springs Replacement
......................................................
7B-41
Extension Oil Seal and/or Bushing Replacement
......................................
7B-41
Drive Gear Bearing Retainer Oil
................................................................
7B-41
Reverse Shifter Shaft and/or Seal Replacement
........................................
7B-41
Reverse Idler Shaft Replacement
...............................................................
7B-42
Transmission Side Cover
.............................................................................
7B-42
Assembly of Countergear..
..............................................................................
7B-42
Checking Countergear End Play
...................................................................
7B-42
Assembly of Mainshaft
..............................................................................
7B-43
Assembly of Transmission
..............................................................................
7B-44
Installation of Transmission
............................................................................
7B-44
REMOVAL OF TRANSMISSION
Before raising vehicle, disconnect battery and release
parking brake.
1. Raise vehicle on hoist and drain lubricant from
transmission.
2. Scribe a mark on companion flange yoke and propeller
shaft yoke to assure proper reassembly and remove propeller
shaft.
3. Disconnect speedometer cable and TCShack-up light
connector.
4. Disconnect transmission control rod and lower
assemblies from the shifter shafts. Tie rods up out of work
area.
5. Remove crossmember-to-transmission mount bolts,
catalytic converter-to-transmission bracket and remove
crossmember-to-frame bolts.
6. Raise transmission to take weight off support and
remove crossmember from vehicle.
7. Remove upper transmission-to-clutch housing bolts
and install aligning Guide Pins
J
1126 (or 1/2"-13 x 2"
threaded headless bolts).
NOTE: Aligning guide pins or studs must be used to
support transmission in order to prevent distortion of the
clutch driven plate hub while removing transmission.
8. Slide transmission straight back on guide pins until
main drive gear splines are free of clutch driven plate and
remove from vehicle.
DISASSEMBLY OF TRANSMISSION
1. Thoroughly clean the exterior of the transmission
assembly.
2. Shift transmission into second gear, remove drain plug
from lower right of case and drain lubricant from
transmission.
3. Remove case cover attaching bolts, cover assembly
and gasket. Remove both shift forks.
4. Remove drive gear bearing retainer bolts, retainer and
gasket from front of transmission.
5. Remove lock pin from reverse shifter lever boss (Fig.
7B-48) and pull shifter shaft partially out to disengage the
reverse shifter fork from the reverse gear.
Fig. 78-48 Removing Reverse Shifter Shaft Lock Pin
6. Remove rear extension attaching bolts, tap extension
rearward with a soft hammer to start removal. Slide extension
rearward until reverse idler shaft is clear of reverse idler
gears. Then rotate extension to the left to free shift fork from
collar of reverse gear and remove the case extension. Remove
and discard gasket.
7. Remove speedometer gear outer snap ring (Fig. 7B-
49). Tap or slide speedometer gear from mainshaft, then
remove second snap ring.
Advertisement
Table of Contents
