Chevrolet 1980 Light Duty Truck Repair Manual page 361

TABBED THRUST
WASHER (SHARP
EDGE MUST FACE
OUT)
Fig. 7B-1 8 B -ln s ta llin g T abbed T hrust W asher
2. Install First-Reverse sleeve and gear half-way onto
hub with gear end o f sleeve facing rear o f shaft. Index sleeve
to hub w ith marks m ade during disassembly.
3. Install spring in First-R everse hub. (M ake sure
spring is bottom ed in hub and covers all three key slots.)
P osition three synchronizer keys in hub, with sm all ends in
hub slots and large ends inside hub. Push keys fully into hub
so they seat on spring. Then slide First-Reverse sleeve and
gear over keys until the keys engage in the synchronizer
sleeve (Fig. 7B-13B).
4. Place first gear blocking ring on tapered surface o f
gear. Install First gear on output shaft. R otate gear until
notches in blocking ring engages keys in First-Reverse hub.
5. Install tabbed thrust washer (sharp edge facing out)
and retaining snap ring on output shaft (Fig. 7B-18B).
SECOND
G E A R
BLOCKING
RING
Fig. 7 B -1 9 B -ln s ta llin g Second Gear
M A N U A L T R A N S M IS S IO N
Fig. 7 B -2 0 B -M e a s u rin g O utpu t S h a ft End Play
6. Place second gear blocking ring on tapered surface
o f gear and install second gear on output shaft with tapered
surface o f gear facing front o f output shaft (Fig. 7B-19B).
7. Install Second-Third synchronizer assembly w ith flat
portion o f synchronizer hub facing rearward on output
shaft. R otate Second gear until notches in blocking ring
engages keys in Second-Third synchronizer assem bly. It
may be necessary to tap synchronizer w ith a plastic ham m er
to ease assembly.
8. Install retaining snap ring on output shaft and
measure end play between snap ring and Second-Third
synchronizer hub w ith feeler gauge (Fig. 7B-20B). End play
should be 0.004 to 0.0014 inch. If end play exceeds 0.014
inch, replace thrust washer and all snap rings on output
shaft assembly.
A S S E M B L Y OF T R A N S M IS S IO N
1. Coat transm ission case reverse idler gear thrust
washer surfaces w ith vaseline (or equivalent) and position
thrust washer in case. Be sure to engage locating tabs on
thrust washers in locating slots in case.
2. Install reverse idler gear w ith helical cut gear
towards front o f case. A lign gear bore, thrust washers, case
bores, and install reverse idler gear shaft from rear o f case.
Be sure to align and seat roll pin in shaft into counterbore
in rear o f case.
3. M easure reverse idler gear end play by inserting
feeler gauge between thrust washer and gear. End play
should be 0.004 to 0.018 inch. If end play exceeds 0.018
inch, rem ove idler gear and replace thrust washer.
4. Install shaft tool J-25232 in bore o f countergear and
load a row o f needle bearing (25) in each end o f gear. U se
heavy grease or equivalent to hold them in place. Install one
needle bearing retainer on each end o f gear.
5. Position countergear thrust washer in case, use
vaseline or equivalent to hold washers in place. Be sure to
engage locating tabs on thrust washer in locating slots in
case.
7B-15
O V E R H A U L M A N U A L