Chevrolet 70 1969 Series, Shop Manual

Page: 818 / 913

TRANSMISSION AND CLUTCH 7-72
4. Place 2nd and 3rd speed synchronizer assembly (59),
large end of hub tow ard rear, on splines of m ainshaft
(52) and drop into position. Install 3rd speed gear lo­
cating thrust washer (60) on shaft.
5. Position 3rd speed gear and bushing assembly (61)
over m ainshaft (52) with toothed hub down and drop
into place.
6. Position 4th speed gear locating washer (62) on m ain­
shaft (52).
7. W ith lock pin (72) in place in 4th speed gear bushing
sleeve (63), install bushing sleeve on m ainshaft (52)
with lock pin tow ard pilot or front end of m ainshaft.
F ig u re 2 5 — A d ju s t in g Latch P lu n g e r
It may be necessary to use a suitable sleeve and ham ­
m er to properly install sleeve.
N O T E : O il hole in sleeve m u st line u p w ith oil
hole in m a in sh a ft.
8. T o insure a proper tight stack-up between the 4th
speed locating washer (62), 4th speed gear bushing
sleeve (63), 4th speed gear selective retainer washer
(65), and snap ring (66), the following procedures
m ust be accomplished:
a. Before the 4th speed gear (64) is installed on bush­
ing sleeve (63), place retaining w asher (65) on
shaft and hold down securely against bushing
sleeve.
b. W hile holding snap ring (66) parallel to the re­
taining washer, slip snap ring into snap ring
groove in m ainshaft (52). Select variable thickness
retaining washers (65), until a w asher is selected
that will allow snap ring to fit securely in the
groove of m ainshaft (fig. 24).
c. Remove selected washer (65) and install 4th speed
gear and bushing assem bly (64) over bushing
sleeve (63).
d. Place selected washer (65) in position; then in­
stall snap ring (66) into groove of m ainshaft. Be
sure snap ring is well seated and securely locked
in groove.
N O T E : E n d p la y on 4th sp e e d g e a r (6 4 ) m u st
b e from 0 . 0 0 4 " to 0 .0 1 0 ". 4th sp e e d g e a r re­
tain e r w a s h e r s (6 5 ) are a v a ila b le in sizes listed
in "S p e c ific a tio n s " at e n d o f this section.
9. Install 4th and 5th speed synchronizer assembly (67)
with large end of hub tow ard the rear.
10. Press m ainshaft pilot bearing (68) on front end of
m ainshaft (52). Remove the assem bly from press and
cover with clean paper until ready for installation.
SHIFT B A R H O U S IN G A S S E M B L Y
N O T E : K e y n u m b e rs in text refer to F igure 12.
1. Install latch plunger spring (9), latch plunger (8), and
adjusting nut (II) in 1st and reverse shift lug (10).
2. Adjust latch plunger so rounded end is flush or slight­
ly below the two flat ends of lug (fig. 25).
3. Place shift bar housing (1) on work bench upside
down with welch plug openings tow ard repairm an.
4. Assem ble 1st and reverse shift rod (14), shift fork
(17), and lug (10) as follows:
a. S tarting at left side of housing (1), push shift
rod through forward opening in housing, through
forward support and 1st and reverse shift lug (10).
b. Place poppet spring (16) in position in well of
rod support. Position poppet ball (15) on spring
( !
6
).
c. Using installer tool (J-8633), com press spring and
ball in a m anner which will allow shift rod to
pass through support (fig. 27).
Figure 2 4 — Selecting 4th Speed G e a r V a ria b le Thickness
Retainer W asher
CHEVROLET SERIES 70-80 H EAVY DUTY TRUCK SH O P M A N U A L