Section 7B4 · Pages 925–940 (16 pages)

Borg Warner Transmissions

From the 1989 GMC Light Duty Truck Unit Repair Manual

Overhaul of the Borg Warner 77 mm five-speed manual transmission. The description explains the main drive gear and mainshaft synchronizer, reverse idler on its own shaft, extension-mounted shift lever, top-cover shift shafts and forks, and pin-type interlock, with precautions for clean repair. Disassembly is shown step by step from the control lever, offset lever and extension housing through the 5th speed gear, synchronizer and fork, shift cover, main drive gear retainer and shim pack, mainshaft and countergear. Sub-assembly service covers the main drive gear, mainshaft, extension housing, bearing retainer and shift cover, then reassembly with mainshaft end play shimming.

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What this section covers

  • Description and repair precautions
  • Disassembly of the 77 mm transmission
  • 5th speed synchronizer and shift fork
  • Main drive gear and mainshaft
  • Extension housing and bearing retainer seals
  • Shift cover, forks and selector plates
  • Transmission assembly and end play shim selection
  • Specifications, lubrication and special tools
Year
1989
Make
GMC
Vehicle
Light Duty Trucks, Trucks
Type
Overhaul & Unit Repair
Publication
X-8937
Pages
998

What’s inside

General information

  1. 0AGeneral Informationpp. 7–18

Air conditioning

  1. 1B1A-6 Air Conditioning Compressorpp. 19–44
  2. 1B2V5 Air Conditioning Compressorpp. 45–58
  3. 1B3R-4 Air Conditioning Compressorpp. 59–76
  4. 1B4HR-6 Air Conditioning Compressorpp. 77–94
  5. 1B5SD-709 Air Conditioning Compressorpp. 95–102

Steering

  1. 3B2Manual Steering Gearpp. 103–114
  2. 3B3Power Steeringpp. 115–136

Axles

  1. 4B17 1/2- and 7 5/8-Inch Ring Gear Axlespp. 137–148
  2. 4B28 1/2-Inch Ring Gear Axlepp. 149–162
  3. 4B39 1/2-Inch Ring Gear Axlepp. 163–176
  4. 4B410 1/2-Inch Ring Gear Axlepp. 177–188
  5. 4B5Dana Rear Axlespp. 189–218
  6. 4B612-Inch Ring Gear (Rockwell)pp. 219–230
  7. 4B7Locking Differentialspp. 231–240
  8. 4C18 1/2-Inch Ring Gear Front Axlepp. 241–254
  9. 4C29 3/4-Inch Ring Gear Front Axlepp. 255–270
  10. 4C3T Truck Front Axlepp. 271–288
  11. 4C4K Truck Front Axlepp. 289–318

Brakes

  1. 5Brakespp. 319–334

Engine

  1. 6AGeneral Engine Mechanicalpp. 335–356
  2. 6A12.5 Liter L4 Enginepp. 357–392
  3. 6A22.8 Liter V6 Enginepp. 393–424
  4. 6A34.3 Liter V6 Enginepp. 425–454
  5. 6A44.8 Liter L6 Enginepp. 455–490
  6. 6A5V8 Engine (5.0, 5.7 and 7.4 Liter)pp. 491–536
  7. 6A76.2 Liter Diesel Enginepp. 537–576
  8. 6C1Model 1MEF Carburetorpp. 577–598
  9. 6C2Model M4MEF Carburetorpp. 599–624
  10. 6C3Model 220 Throttle Bodypp. 625–632
  11. 6C4Model 700 Throttle Bodypp. 633–640
  12. 6D1SI Series Generatorspp. 641–652
  13. 6D2CS-144 Generatorpp. 653–660
  14. 6D3SD (MT) Starting Motorspp. 661–672
  15. 6D4PG-200 (PMGR) Starting Motorpp. 673–680
  16. 6D5Distributorspp. 681–694

Transmission and transfer case

  1. 7A1700-R4 Automatic Transmissionpp. 695–760
  2. 7A2400/475 Automatic Transmissionpp. 761–808
  3. 7A3180C Automatic Transmissionpp. 809–836
  4. 7B1HM-290 Manual Transmissionpp. 837–892
  5. 7B2HM-117 Manual Transmissionpp. 893–912
  6. 7B3New Process Transmissionpp. 913–924
  7. 7B4Borg Warner Transmissionspp. 925–940
  8. 7D1New Process 205 Transfer Casepp. 941–952
  9. 7D2New Process 241 Transfer Casepp. 953–966
  10. 7D3New Process 231 Transfer Casepp. 967–978
  11. 7D4Borg Warner 1370 Transfer Casepp. 979–998

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