Chevrolet 70 1969 Series, Shop Manual

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TRANSMISSION AND CLUTCH 7-90
N O T E : If s n a p rin gs are not d a m a g e d or d is ­
torted a n d a re not u sed for s e a lin g a s w ell a s
retain in g, the y m a y b e reused.
2. Check all threaded fasteners and m ating parts for
dam aged, stripped, or crossed threads. C orrect as neces­
sary.
3. Check keys and keyways for condition and fit.
4. Check surfaces of all thrust washers. W ashers scored
or reduced in thickness should be replaced.
5. Inspect the breather assem bly to see that it is open
and not dam aged.
ASSEMBLY OF SUBASSEMBLIES
T h e im p o r ta n c e of c le a n lin e ss c a n n o t be o v e r e m ­
phasized. Rebuild of the transm ission should not be a t­
tem pted in a dirty working area. All parts, except those
actually being w orked on should be covered with clean
lint-free paper or cloth. Avoid nicking, m arring, or bur­
ring any surfaces.
IM P O R T A N T : C o a t all thrust w ash e rs, splin es of
shafts, a n d bores of all g e a r s w ith lu b rican t to
pro vid e initial lubrication, th u s p re v e n tin g scor­
in g or g a llin g .
ASSEMBLY OF COUNTERSHAFT
(Key N um bers Refer to Figure 9)
1. Position first countershaft gear key (9) in slot of
countershaft (8). Using a suitable sleeve, press 2nd speed
gear (7) on countershaft.
2. Place 2nd and 3rd gear spacer (6) on countershaft
against 2nd speed gear.
3. Install the rem aining countershaft gear keys (9) on
countershaft. Dress keys with a file, if necessary.
4. Align keyway of 3rd speed gear (5) with key and
press gear on the countershaft. Seat 3rd speed gear firmly
against 2nd and 3rd gear spacer.
5. Align 4th speed gear (4) with key and press gear on
the countershaft. Install 4th gear snap ring (3) in groove
of countershaft.
6. Align countershaft drive gear (2) with key and press
gear on the countershaft. Install countershaft drive gear
snap ring (1) in groove of countershaft.
ASSEMBLY OF M A IN DRIVE GEAR
(Key N um bers Refer to Figure 8)
1. Using a suitable sleeve, press or drive m ain drive gear
bearing (2) on shaft of main drive gear (3).
2. Install m ain drive gear bearing retaining snap ring (1)
in groove on main drive gear. Install large snap ring on
main drive gear bearing.
ASSEMBLY OF M AIN SH AFT
(Key N um bers Refer to Figure 7)
1. Install the two m ainshaft keys (8) on the m ainshaft
(13). If necessary, file keys to rem ove any burrs.
2. Position m ainshaft vertically in a vise with bottom
end resting on bed and soft jaw s clam ping on long splined
portion.
3. Assem ble 2nd speed gear (11) to shaft.
N O T E : C lu tc h in g g e a r teeth a n d synchronize r
cone m u st poin t up.
4. Slide 2nd and 3rd speed clutch gear (9) down on shaft
and align keyways with keys. Using a suitable sleeve,
press 2nd speed gear against shoulder of shaft.
5. Position 2nd and 3rd synchronizer (10) on clutch
gear.
N O T E : Synch ronize r is sy m m e trica l a n d can be
a sse m b le d either w a y .
6. Place 3rd speed gear (7) on m ainshaft with clutch
teeth and synchronizer cone down.
7. Align notches in 3rd speed gear sleeve (6) with keys
and start sleeve onto shaft. Press sleeve into place.
N O T E : D O N O T force sleeve the last 1/4 -in c h o f
travel a s notches in sleeve m a y not be exactly
a lig n e d w ith keys.
U
t h
A N D 5TH 2 N D A N D 3RD 1ST A N D REVERSE
E X P A N S IO N PLUG
O P E N I N G S
Figure 11— Assembled Shifter Housing
CHEVROLET SERIES 70-80 HEAVY DUTY TRUCK S H O P M A N U A L