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 MANUALSCHEVROLET1983STEP VAN P20, 5.7 M, AUTOMATIC, 400/M40REPAIR AND DIAGNOSISTRANSMISSIONAUTOMATIC TRANSOVERHAUL - THM 400COMPONENT DISASSEMBLY & REASSEMBLYGEAR UNITPINION GEAR REPLACEMENT
1983 Chevrolet Step Van P20, 5.7 M, Automatic, 400/M40
Pinion Gear Replacement
1983 Chevrolet Step Van P20, 5.7 M, Automatic, 400/M40SECTION Pinion Gear Replacement
- Support carrier assembly on front face. To avoid damage to carrier when removing pin, use a 1/2" drill bit and remove stake marks from end of pin. DO NOT remove any material from carrier as it will weaken and possibly crack.
- Using a tapered punch, remove pinion pins from carrier. Remove pinion gears, thrust washers and roller needle bearings. Check pinion pocket thrust faces for burrs.
- Install 18 needle bearings into each pinion. Use pinion pin as guide and petroleum jelly to hold bearings in place. Place a bronze and steel washer on each side of pinion so steel washer is against pinion.
- Place pinion gear assembly in carrier. Install pilot shaft through rear face of assembly to hold parts in place. Drive in new pinion pin from front while rotating pinion gear.
- Ensure headed end is flush or below face of carrier. Use punch held in bench vise for an anvil. Place carrier over punch and stake pinion pin in 3 places with blunt radius chisel.
NOTE:
Both ends of pinion pin must lie below face of carrier or interference may occur.
RENDER: 1.0x
NO RELATED
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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.