Chevrolet 1980 Light Duty Truck Repair Manual page 408

7E-4 TRANSFER CASE
S N A P
F ig . 7 E - 5 R - R e m o v i n g G e a r R e ta in in g R in g
6
. Install idler shaft cover and gasket. Torque bolts to
20 ft. lbs. Flat on cover must be located adjacent to front
output shaft rear cover (Fig. 7E-14R).
S h ift Rail and Fork Assem blies
1. Press the two rail seals into the case. Seals should
be installed with metal lip outward.
2. Install interlock pins through large bore or P.T.O.
opening.
3. Start front output drive shift rail into case from
back, slotted end first, with poppet notches up.
4. Install shift fork (long end inward) into rail, push
rail through to neutral position.
5. Install input shaft bearing and shaft into case.
6
. Start range rail into case from front, with poppet
notches up.
7. Install sliding clutch onto fork, place over input
shaft in case. Position to receive range rail and push rail
through to neutral position.
8
. Install new lock pins through holes at top of case
and drive them into the forks (Fig. 7E-15R). Tip-case on
P.T.O. opening when installing range rail lock pin.
" T" HANDLE W / # 2 EASY
Fig. 7E-6R--Removing S h ift Fork Pins
R IN G
OUT W ELDED O N END
RANGE
SHIFT RAIL
F ig . 7 E - 7 R - - S h if t R a il R e m o v a l
Front O u tp u t S h a ft and G ear Assem bly
1. Install two rows of needle bearings (32 each)
separated by a spacer in the front low output gear and reatin
with a sufficient amount of grease.
2. Place front output shaft in soft jawed vise, spline end
down. Install front low gear over shaft with clutch gear
facing down and install throust washer pin, thrust washer
and new snap ring using Tool J-23432. Position the snap
ring so that the opening is opposite the pin.
3. Position front wheel hi-gear and washer in case.
Install sliding clutch in the shift fork, then put fork and rail
in the front wheel drive (4-Hi) position with the clutch teeth
in mesh with the teeth of the front wheel hi-gear.
4. Line up washer, high gear, and sliding clutch with
bearing bore. Insert front output shaft and low gear
assembly through the high gear assembly.
5. Install new seal in bearing retainer using Tool J-
22836 (Fig. 7E-16R) and install the front output bearing and
retiner in the case.
6
. Clean and grease rollers in front output rear bearing
retainer. Install onto case using one gasket. Dip bolts into
Fig. 7E-8R-Rem oving Idler Gear S haft
4-WHEEL
SHIFT RAIL
SHIFT RAIL
O V E R H A U L M A N U A L