Chevrolet 70 1969 Series, Shop Manual

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TRANSMISSION AND CLUTCH 7-88
“ H O PP IN G G U A R D ”
RELIEFS —
M A C H IN E D O N
CLUTCHING G EARS
A N D SHAFTS
T-41 19
Figure 1 0 — Spicer H o p p in g G u a rd
4. Rem ove attaching parts that hold end cover (19) to
control housing (3).
5. Rem ove shift finger shaft (15), and end cover (19)
from control housing (3). Remove shift finger (4) from
control housing.
6. R otate selection lever shaft (20) 180 degrees, then re­
move selection lever shaft from shift finger shaft (15).
7. Remove shift finger shaft (15) and selection cam and
stud assembly (6) from end cover (19).
8. Rem ove attaching parts holding reverse shift finger
(23) to control housing (3), then remove reverse shift fin­
ger.
reverse shift rod bracket (1) is stopped by housing boss.
C ut lock wires and remove set screws (9 and 17) from
shift fork and bracket. Use soft rod to tap shift rod free
of fork and bracket and out of housing.
DISASSEMBLY OF M AINSH AFT
(Key N um bers Refer to Figure 7)
1. Rem ove the 1st and reverse sliding gear (12) from
m ainshaft (13).
2. R em ove 4th and 5th synchronizer (1).
3. R em ove 4th speed gear retaining snap ring (2) and
thrust washer (3).
4. Slide gear (4) from end of m ainshaft.
5. Rem ove snap ring (5), and tap 3rd speed gear (7) and
sleeve (6) from shaft.
6. Slide synchronizer (10) from shaft.
7. S upport 2nd speed gear (11) under arb o r and press
m ainshaft from 2nd and 3rd speed clutch gear (9) and 2nd
speed gear.
IM P O R T A N T : The tw o W o o d r u ff keys (8 )
sh o u ld d e a r th e bore o f 2 n d sp e e d g e a r. C h e c k
for cle aran ce after s h a ft h a s m o v e d a p p r o x i­
m a te ly 1 /2 -in c h . Do not force g e a r if sleeve
does not m o v e freely.
8. R em ove W oodruff keys from m ainshaft.
DISASSEMBLY OF M A IN DRIVE GEAR
DISASSEMBLY OF SHIFTER H O U SIN G
(Key N um bers Refer to Figure 6)
1. Using a m agnet, remove the three poppet springs (4),
and poppet balls (3) from top of shifter housing (7).
2. Position shifter housing on edge in a vise.
3. T ap 4th and 5th shift fork (12), forward to move 4th
and 5th shift rod (11) against expansion plug (16). Drive
plug free of shifter housing and tap fork until stopped by
housing boss. C ut lock wire and remove set screw (9)
from fork (12). Use soft rod to tap shift rod free of fork
and out of housing.
4. T ap 2nd and 3rd shift fork (10), forward to move
shift rod (15) against expansion plug (16). Drive plug free
of housing and tap fork until stopped by housing boss.
C ut lock wire and remove set screw (9) from fork. Use
soft rod to tap shift rod free of fork and out of housing.
Remove interlock pin (14) from shift rod and interlock
balls (13) from housing.
5. T ap 1st and reverse shift fork (5), forward to move
shift rod (2) against expansion plug (16).
6. Drive plug free of housing and tap fork until 1st and
(Key N u m bers Refer to Figure 8)
1. Using snap ring pliers, rem ove m ain drive gear bear­
ing retaining snap ring (1) from m ain drive gear (3).
2. Using suitable bearing rem over plates with an arbor
press, remove bearing (2) from m ain drive gear.
DISASSEMBLY OF COUNTERSHAFT
(Key N um bers Refer to Figure 9)
1. Rem ove countershaft drive gear snap ring (1). S u p­
port drive gear (2) with parallel bars under and as close to
hub as possible and press countershaft (8) free of gear.
2. Rem ove exposed countershaft gear key (9) and snap
ring (3). Support 4th speed gear (4) and press counter­
shaft free of gear.
3. R em ove exposed countershaft gear key (9). Support
3rd speed gear (5) and press countershaft free of gear.
4. Rem ove exposed countershaft gear key (9) and 2nd
and 3rd gear spacer. S upport 2nd speed gear (7) and press
countershaft free of gear.
5. Rem ove the rem aining countershaft gear key (9).
CHEVROLET SERIES 70-80 H EAVY DUTY TRUCK S H O P M A N U A L