Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSCHEVROLET1983CHEVETTE SCOOTER, 2D HATCHBACK, STANDARD, MY1REPAIR AND DIAGNOSIS (SINGLE PAGE)TRANSMISSIONMANUAL TRANSOVERHAUL - GM 77 MM 5-SPEEDCOMPONENT DISASSEMBLY & REASSEMBLYTRANSMISSION COVERREASSEMBLY
1983 Chevrolet Chevette Scooter, 2D Hatchback, Standard, MY1
Transmission Cover: Reassembly
1983 Chevrolet Chevette Scooter, 2D Hatchback, Standard, MY1SECTION Reassembly
- Install Nylon inserts and selector arm plates in shift forks. If removed, install shift rail plug. Coat edges of plug with sealant before installing.
- Coat shift rail and rail bores with lightweight grease and insert shift rail in cover. Install rail until flush with inside edge of cover.
- Place 1st-2nd shift fork in cover with fork offset facing rear of cover and push shift rail through fork. The 1st-2nd shift fork is the larger of the 2 forks.
- Position selector arm and "C" shaped interlock plate in cover and insert shift rail through arm. Widest part of interlock plate must face away from cover. Selector arm roll pin must face downward and toward rear of cover.
- Position 3rd-4th shift fork in cover with fork offset facing rear of cover. The 3rd-4th shift fork selector arm plate must be under 1st-2nd shift fork selector arm plate.
- Push shift rail through 3rd-4th shift fork and into front bore in cover. Rotate shift rail until selector arm plate at forward end of rail faces away from, but is parallel to cover.
- Align roll pin holes in selector arm and shift rail. Install roll pin. Roll pin must be flush with surface of selector arm to prevent pin from contacting selector arm plates during shifts.
- Install a new shift cover to extension housing "O" ring seal. Coat "O" ring seal with transmission lubricant.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.