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7 6-44
1977 PONTIAC SERVICE MANUAL
7. Install the 3rd and 4th speed gear clutch assembly
(hub and sliding sleeve) with taper toward the front, making
sure that the keys in the hub correspond to the notches in
the 3rd speed gear synchronizing ring.
8. Install new selective fit snap ring (thickest that will
install) in the groove in mainshaft in front of the 3rd and 4th
speed clutch assembly.
9. Install the rear bearing retainer over end of mainshaft.
Spread the snap ring to drop around the rear bearing. Release
snap ring when it aligns with groove in rear bearing.
10. Install the reverse gear (shift collar to rear).
11. Install a snap ring, the speedometer drive gear and
a second snap ring, onto the mainshaft.
Fig. 78-68 Installing Front Main Bearing
ASSEMBLY OF TRANSMISSION
1. Place the transmission case on its side, with the case
cover opening toward the assembler. Position the countergear
tanged washers in place, using heavy grease to retain them.
NOTE: Be sure the tangs are in the notches of the thrust
face.
2. Install the countergear in the case, aligning the bore
of the countergear with the case opening. With the thrust
washers in place, slide the loading tool to the front of the case
and install the countergear shaft from the rear of the case.
Install the woodruff key and tap shaft into gear until shaft
is flush with rear face of transmission case.
3. Install front reverse idler gear (teeth forward) and
thrust washer in case. Use heavy grease to hold thrust washer
in position.
4. Using heavy grease, install sixteen (16) roller bearings
and washer into main drive gear. Mate main drive gear with
mainshaft assembly. Position 3rd-4th clutch sliding sleeve
forward. This will provide clearance for installation as well
as hold the assembly together.
5. Position new rear bearing retainer to case extension
gasket on rear of case. Install mainshaft and drive gear
assembly into case.
6. Align rear bearing retainer with transmission case.
Install retainer to case locating pin and retainer locking bolt.
Torque to 25 lb. ft.
7. Place bearing snap ring on front main bearing.
Position front main bearing to case opening and, with a
hollow shaft or Tool J 5680, tap bearing into case (Fig. 7B-
68). Install spacer washer and selective fit snap ring to secure
main drive bearing.
8. Install front bearing retainer and gasket. Apply sealer
to bolts and torque to 18 lb. ft.
9.
Install rear reverse idler gear, engaging the splines
with the portion of the gear within the case.
10. Place new rear bearing retainer to case extension
gasket into position on rear face of bearing retainer. Slide
reverse gear on shaft. Install speedometer gear and two
selective fit snap rings.
11. Install idlei shaft into extension until hole in shaft
lines up with hole in boss. Insert reverse idler shaft lock pin
in boss opening and drive the pin into the extension until the
shaft is securely locked in place. Install new welch plug, with
sealer, in boss opening.
12. Install reverse shifter shaft and detent plate into
extension. Locate reverse shift fork in reverse shifter shaft.
Use heavy grease to hold reverse shift fork in position.
NOTE: Be sure reverse shifter shaft
"0"
ring is placed
on reverse shifter shaft after the shaft has been installed
in the extension housing.
13. Install tanged thrust washer on reverse idler shaft
with tang of washer in notch of idler thrust face of extension.
14. Place the 1st-2nd speed and 3rd-4th speed clutch
sliding sleeve in neutral position. Pull reverse shift shaft
partially out of extension and reverse shift fork as far forward
in as possible. Start the extension onto the mainshaft while
pushing in on the shifter shaft to engage the shift fork with
the reverse gear shift collar. When the fork engages, rotate
the shifter shaft to move the reverse gear rearward, permitting
the extension to mate against the transmission case.
15. Install reverse shifter shaft lock pin.
16. Install rear extension housing-to-case bolts (long
bolts). Install rear extension to rear bearing retainer bolts
(short bolts). Torque long bolts to 40 lb. ft. and short bolts
to 25 lb. ft.
NOTE: It is essential that sealer be used on the extension
bolt as indicated in Fig. 7B-69.
17. Position 1st-2nd speed clutch sliding sleeve into 2nd
gear and 3rd-4th speed clutch sliding sleeve into neutral.
Position forward shift forks in sliding sleeves.
18. Position 1st-2nd speed gear shifter shaft and detent
plate into 2nd gear position and, using a sealer, install cover
gasket and case cover assembly to transmission. Torque bolts
evenly to 18 lb. ft.
INSTALLATION OF TRANSMISSION
1. Place transmission on guide pins and rotate
transmission as necessary to start main drive gear splines into
clutch driven plate. Slide transmission forward.
NOTE: Make certain that main drive gear shaft is
aligned with pilot bearing in crankshaft and that clutch
release bearing is properly installed.
2. Install two (2) lower transmission-to-clutch housing
bolts. Remove guide pins and install two (2) upper bolts.
Torque bolts evenly to 55 lb. ft.
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