Chevrolet Chevelle 1977 Repair Manual page 439

7. Install rear bearing retainer seal using Tool J-2 1359
or J-22834-2 (Fig. 7B-19R).
8. Install bearing retainer assembly onto housing with
one or two gaskets, depending on clearance. Torque bolts to
30 ft. lbs.
9. Install yoke, washer, and lock nut output shaft.
10. Position range rail in 'high' and install output shaft
and retainer assembly on transfer case. Torque housing bolts
to 30 ft. lbs.
Miscellaneous
1. Install P.T.O. cover and gasket. Torque bolts to 15
ft. lbs.
2. Install and seal cup plugs at rail pin holes, if not
previously done.
3. Install drain and filler plugs and torque to 30 ft. lbs.
4. Install shift rail cross link, clevis pins and lock pins.
NEW PROCESS MODEL 203 (FULL TIME) TRANSFER CASE
Disassembly of Transfer C a se ............................................7B-59
Cleaning and Inspection......................................................7B-62
Subassembly R epairs.......................................................... ..7B-63
Differential Carrier A ssem bly....................................... ..7B-63
Lockout Clutch A ssem bly.............................................. ..7B-63
Input Shaft A ssem bly...................................................... ..7B-63
Range Box Assem bly....................................................... ..7B-63
DISASSEMBLY OF TRANSFER CASE
I
Refer to Figs. 7B-1S, 7B-11S and 7B-12S for cross
sectional and exploded views of the transfer case.
1. Position transfer case on work bench or suitable work
table.
NOTE:
If lubricant was not drained from unit prior to
removal from vehicle, remove front output rear cover
and P.T.O. cover lower bolts and drain lubricant into
waste container.
2. Using Tool J-8614-1, loosen rear output shaft flange
retaining nut (Fig. 7B-4S).
3. Using Tool J-8614-1, remove front output shaft flange
retaining nut, washer and flange.
NOTE:
Tap dust shield rearw ard on shaft (away from
bolts) to obtain clearance to remove bolts from flange
and allow installation of Tool J-8614-1.
MANUAL TRANSMISSION
Fig. 7 B -1 9 R — In s ta llin g Rear B e a rin g R e ta in e r Seal
INDEX
Input G ear Bearing R eplacem ent...................................7B-66
Input G ear Bearing Retainer Seal R eplacem ent.........7B-67
Rear O utput Shaft Housing A ssem bly..........................7B-67
Front O utput Shaft Bearing Retainer
Seal Replacement .............................................................7B-68
Front O utput Shaft Rear Bearing Replacem ent..........7B-68
Assembly of Transfer Case............................................... ..7B-68
4. Remove bolts retaining front output shaft front
bearing retainer (Fig. 7B-5S). Remove bearing retainer and
gasket from transfer case. Discard gasket.
5. Using a hoist or other suitable lifting tool, position
assembly on blocks (Fig. 7B-6S).
6. Remove bolts retaining rear section of rear output
housing from front section of rear output housing, and
disengage. Remove shims and speedometer gear from output
shaft.
a. Remove bolts retaining front section of rear output
housing assembly from transfer case. Remove housing from
case.
b. Remove "O" ring seal from front section of rear
output housing and discard.
c. Disengage rear output shaft from differential carrier
assembly.
7. Slide carrier unit from shaft.
J-21359
SEAL
7B-59