Chevrolet Chevelle 1977 Repair Manual page 397

Fig. 7 B -2 4 B --ln s ta llin g S p e e d o m e te r R e ta in e r and Gear
upward. Move rail inward until setscrew hole in fork and
setscrew bore in shift rail are aligned. Secure fork to rail with
setscrew and place First Reverse sleeve and gear into N eutral
(centered) position (Fig. 7B-20B).
23. Install large snap ring on front bearing.
24. Install front bearing on clutch gear shaft by hand
drive bearing on clutch gear shaft using tool J-24433 (Fig.
7B-22B).
3-SPEED (MUNCIE) 8 3 M M TRANSMISSION
Disassembly of T ransm ission......................................... ... 7B-17
Disassembly of M ainshaft...................................................7B-17
Cleaning and Inspection.....................................................7B-17
Transmission Case..............................................................7B-19
Front and Rear B earing...................................................7B-19
Bearing Rollers.................................................................. .7B-19
G ears.................................................................................... .7B-19
Reverse Idler G ear B ushing............................................7B-19
DISASSEMBLY OF TRANSM ISSIO N (Fig. 7B-1C)
1. Remove side cover attaching bolts, side cover
assembly, gasket and shift forks.
2. Remove drive gear bearing retainer bolts, retainer and
gasket.
3. Remove drive gear bearing to gear stem snap ring,
then remove drive gear bearing by pulling outward on drive
gear until a screw driver or other suitable tool can be inserted
between bearing, large snap ring and case to complete
removal. The drive gear bearing is a slip fit on the gear and
into the case bore. (This provides clearance for removal of
drive gear and mainshaft assembly.)
4. Remove extension to case attaching bolts.
5. R otate extension to left until groove in extension
housing flange lines up with the reverse idler shaft. Using a
drift or other suitable tool, drive reverse idler shaft out of gear
and case (Fig. 7B-2C).
6. Remove drive gear, mainshaft and extension assembly
MANUAL TRANSMISSION
25. Install smaller snap ring on clutch gear shaft.
26. Position bearing retainer gasket on case. Be sure cut­
out in gasket is aligned with oil return hole in case.
27. Install front bearing retainer and tighten attaching
bolts to 30 to 36 foot-pounds of torque. Be sure to index cap
to case with alignment marks, and that oil return slot in cap
is aligned with oil return hole in case.
28. Install large snap ring on rear bearing.
29. Install rear bearing on output shaft by hand. Drive
bearing onto shaft and into case with tool J-22609, make sure
snap ring groove is facing rear of shaft (Fig. 7B-23B).
30. Install smaller snap ring on output shaft to hold rear
bearing in place.
31. Engage speedometer gear retainer in hole provided
in output shaft, with retainer loop forward, slide speedometer
gear over output shaft and into position (Fig. 7B-24B).
32. Position extension housing gasket on case and install
extension housing to case. Tighten bolts to 42 to 50 foot
pounds torque.
33. Install expansion plug in Second-Third shift rail bore
in front of case. Be sure plug is fully seated in bore and is
approximately 1/16 inch below front face of case.
34. Install upper detent plug in detent bore, then install
long detent spring on top of plug. Install transmission fill plug
and tighten 10 to 20 foot pounds torque.
35. Install top cover and gasket on case and secure with
attaching bolts. Tighten bolts 20 to 25 foot pounds torque.
36. If removed, install backup light switch in extension
housing and TCS switch in case. Tighten switches to 15 to
20 foot pounds torque.
IN D E X
Repairs......................................................................................7B-19
Clutch Keys and Springs...................................................7B-19
R eplacem ent.........................................................................7B-19
Extension Oil Seal or B u shing...................................... ..7B-19
Clutch Bearing Retainer Oil Seal....................................7B-20
Assembly of M ainshaft...................................................... ..7B-20
Assembly of Transm ission................................................ ..7B-21
together through case rear opening. Remove reverse idler
gear from case.
7. Remove drive gear from mainshaft. Remove pilot
bearings.
8. Using snap ring pliers, expand the snap ring in the
extension which retains the mainshaft rear bearing (Fig. 7B-
3C). Tap gently on end mainshaft and remove extension from
mainshaft.
9. Using a brass drift, drive countergear shaft and
woodruff key from case.
DISASSEMBLY OF M A INSHA FT (Fig. 7B-4C)
1. Depress speedometer gear retaining clip and slide gear
from mainshaft.
2. Remove rear bearing snap ring from mainshaft
groove.
3. Support reverse gear with press plates and press on
rear of mainshaft to remove reverse gear, thrust washer and
rear bearing from shaft.
7B-17