Chevrolet Chevelle 1977 Repair Manual page 419

Fig. 7 B -2 3 K --ln s ta llin g F ro n t M ain B e a rin g
2. Install the countergear in the case, aligning the bore
of the countergear with the case opening. W ith the thrust
washers in place, slide the loading tool to the front of the case
and install the countergear shaft from the rear of the case.
Install the woodruff key and tap shaft into gear until shaft
is flush with rear face of transmission case.
3. Install front reverse idler gear (teeth forward) and
thrust washer in case. Use a heavy grease to hold thrust
washer in position.
4. Using a heavy grease install sixteen (16) roller
bearings and washer into main drive gear. Mate main drive
gear with mainshaft assembly. Position 3rd-4th clutch sliding
sleeve forward. This will provide clearance for installation as
well as hold the assembly together.
5. Position new rear bearing retainer to case extension
gasket on rear of case. Install mainshaft and drive gear
assembly into case.
6. Align rear bearing retainer with transmission case.
Install retainer to case locating pin and retainer locking bolt.
Torque to recommended specifications.
7. Place bearing snap ring on front main bearing.
Position front main bearing to case opening and with a hollow
shaft, or tool J-5590, tap bearing into case (Fig. 7B-23K).
Install spacer washer and selective fit snap ring to secure
main drive bearing.
8. Install front bearing retainer and gasket. Apply sealer
to bolts and torque to recommended specification.
9. Install rear reverse idler gear engaging the splines with
the portion of the gear within the case.
10. Place new rear bearing retainer to case extension
gasket into position on rear face of bearing retainer. Slide
reverse gear on shaft. Install speedometer gear and two
selective fit snap rings.
11. Install idler shaft into extension until hole in shaft
MANUAL TRANSMISSION
lines up with hole in boss. Insert reverse idler shaft lock pin
in transmission boss opening and drive the pin into the
extension until the shaft is securely locked in place. Install
new welch plug, with sealer, in boss opening.
12. Install reverse shifter shaft and detent plate into
extension. Locate reverse shift fork in reverse shifter shaft.
Use a heavy grease to hold reverse shift fork in position.
NOTE:
on reverse shifter shaft after the shaft has been installed
in the extension housing.
13. Install tanged thrust washer on reverse idler shaft
with tang of washer in notch of idler thrust face of extension.
14. Place the lst-2nd speed and 3rd-4th speed clutch
sliding sleeve in neutral position. Pull reverse shift shaft
partially out of extension and reverse shift fork as far forward
in as possible. Start the extension onto the m ainshaft while
pushing in on the shifter shaft to engage the shift fork with
the reverse gear shift collar. W hen the fork engages, rotate
the shifter shaft to move the reverse gear rearw ard permitting
the extension to mate against the transmission case.
15. Install reverse shifter shaft lock pin.
16. Install rear extension housing-to-case bolts. Install
rear extension to rear bearing retainer bolts (short bolts).
Torque all bolts to recommended specification.
NOTE:
bolt as indicated in Fig. 7B-24K.
17. Position lst-2nd speed clutch sliding sleeve into 2nd
gear and 3rd-4th speed clutch sliding sleeve into neutral.
Position forward shift forks in sliding sleeves.
18. Position lst-2nd speed gear shifter shaft and detent
plate into 2nd gear position and using a sealer, install cover
gasket and side cover assembly to transmission.
19. Check operation of transmission.
USE SEALER
O N THIS BOLT
¥
Fig. 7 B -2 4 K --E xte n sio n B o lt
Be sure reverse shifter shaft "O" ring is placed
It is essential that sealer be used on the extension
7B-39