Chevrolet 1980 Light Duty Truck Repair Manual page 406

7E-2 TRANSFER CASE
POPPET NUTS
SHIFT RAIL
LINK
FRONT OUTPUT
SHAFT ASSEMBLY
F ig . 7 E - 2 R ~ F r o n t V i e w o f T r a n s f e r C a s e
6
. Remove thrust washer and pin from shaft.
7. Remove gear, needle bearings (32 per row) and
spacer.
8
. I f necessary to replace front output shaft rear
bearing, support cover and press bearing from cover.
Position new bearing to outside face of cover and using a
piece of pipe or wood to cover outside diameter of bearing,
press bearing into cover until flush with opening.
S h ift Rail and Fork Assem blies
1. Remove the two poppet nuts on top of case, two
poppet springs, and using a magnet, remove the poppet
bails.
2. Drive cup plugs into case using a 1/4 inch punch.
3. Position both shift rails in neutral and using a long,
narrow punch, drive shift fork pins through shift rails into
the case (Fig. 7E-6R).
4. Remove clevis pins and shift rail link.
5. Remove shift rails (Fig. 7E-7R), upper (range) rail
first, then lower (4-wheel) rail.
FRONT
OUTPUT SHAFT
REAR BEARING
RETAINER
Fig.
7E-3R~Removing Front O utpu t S haft Rear Bearing
Retainer
bearing from the case. Remove the shift rail cup plugs and
pins from the case.
Inpu t S h a ft Assem bly
hammer, tap shaft out rear of case. Tap bearing out front
of case.
from inside of case.
Idler G ear
FRONT INPUT
SHAFT ASSEMBLY
tool J-23429 (Fig. 7E-8R).
from case.
gear.
C L E A N IN G A N D IN S P E C T IO N
solution and allow to remain long enough to loosen all
accumulated lubricant. Bearings should be sloshed up and
down and turned slowly below surface of solution to remove
as much lubricant as possible. Remove bearings and blow
out with compressed air, being careful to direct air across
bearing so that bearings do not spin.
solution to remove all accumulations. Dry with compressed
air.
cover, and bearing cups must be thoroughly cleaned in
solution to remove all accumulation of lubricant and dirt.
Remove all trace of gaskets from surface where used.
for evidence of chipping, cracks, or worn spots that would
render bearing unfit for further service. Bearings are non-
adjustable and if worn or damaged, must be replaced with
new parts.
failure, such as chipped teeth or excessive wear, is indicated,
those parts should be replaced with new parts.
A S S E M B L Y OF TR A N S FE R C A SE (FIG. 7E-9R)
Idler G ear
previously removed) using Tool J-9276-2 and Handle J-8092
(Fig. 7E-10R).
idler gear on dummy shaft J-23429 with bore up. Check end
play (Fig. 7E-11R). Limits are .001 to .002 inch.
case through front output bore, large end first (Fig. 7E-
12R).
throuhg using a soft hammer (Fig. 7E-13R).
and free rotation. Torque nut to 150 ft. lbs.
6
. Remove shift forks and sliding clutch from case.
7. Remove the front output high gear, wahser, and
8
. Remove snap ring in front of bearing. Using a soft
9. Tip case on P.T.O. and remove two interlock pins
1. Remove idler gear shaft nut.
2. Remove idler shaft rear cover.
3. Remove idler gear shaft using a soft hammer and
4. Roll idler gear to front output shaft hole and remove
5. Remove bearing cups (2) as required from idler
Bearings -Place all bearings and rollers in cleaning
S h a fts and Gears -Clean all shafts in cleaning
Case, Cover and Bearing Cups -Transfer case,
Inspection -Carefully inspect all bearings and rollers
Inspect shaft splines and gears. I f any indication of
1. Press the two bearing cups in the idler gear (if
2. Assemble the two bearing cones, spacer, shims and
3. Install idler gear assembly with dummy shaft into
4. Install idler shaft from large bore side and drive
5. Install washer and new locknut. Check for end play
O V E R H A U L M A N U A L