Transfer Case - Chevrolet 1980 Light Duty Truck Repair Manual

Model 205 (Part Time) Transfer Case.........................................
Specifications................................................................................... 7E-8
Special Tools................................................................................... 7E-9
MODEL 2 0 5 (PART T IM E )T R A N S F E R CASE
Disassembly of Transfer Case......... .......................... .7E-1
Rear Output Shaft Assembly................................. .7 E -1
Front Output Shaft Assembly................................ .7E-1
Shift Rail and Fork Assemblies..............................7E-2
Idler Gear..................................................................7E-2
Cleaning and Inspection............................................. .7E-2
D IS A S S E M B L Y OF T R A N S FE R CA SE (FIG. 7E-
4R)
Rear O u tp u t S h a ft and Yoke Assem bly (Fig. 7E-
1 R)
1. Loosen rear output shaft yoke nut.
2. Remove rear output shaft housing bolts and remove
housing and retainer assembly from case.
REAR OUTPUT
ASSEMBLY
IDLER SHAFT COVER
FRONT OUTPUT SHAFT
REAR BEARING RETAINER
Fig. 7E-1R~Rear V ie w of T ransfer Case
S E C T IO N 7E

TRANSFER CASE

C O N T E N T S
IN D E X
Assembly of Transfer Case......................................... ..7E-2
Idler Gear................................................................. ..7E-2
Shift Rail and Fork Assemblies...............................7E-4
Front Output Shaft Assembly................................ ..7E-4
Rear Output Shaft Assembly................................. ..7E-6
Miscellaneous......................................................... ..7E-7
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
bearings (32 per row), spacer and second row of needle
bearings.
7. Remove tanged bronze thrust washer from shaft.
8
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 O u tp u t S h a ft Assem bly (Fig. 7E-2R)
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 hammer (Fig. 7E-
3R) and remove shaft, gear assembly, and rear bearing
retainer from case.
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. 7E-5R)
and discard.
TRANSFER CASE
7E-1
. Remove tanged bronze washer. Remove gear needle
. Remove pilot rollers (15), retainer ring and washer.
7E-1
OVERHAUL MANUAL