Chevrolet 70 1969 Series, Shop Manual

Page: 839 / 913

TRANSMISSION AN D CLUTCH 7-93
2. Apply sealing cem ent to new gasket and install gasket
and m ain drive gear bearing cap (2) to transm ission case.
Tighten cap screws to 25-32 ioo -pounds torque.
IM P O R T A N T : Be sure the oil p a s s a g e s in the
b e a r in g cap, gaske t, a n d tran sm issio n case are
all a lig n e d .
3. C o a t the pocket of m ain drive gear with grease (such
as, N L G I N o. 0 Light W eight Ball and Roller Bearing
Grease).
4. Place the fourteen pilot bearing rollers in m ain drive
gear pocket. Rollers will be retained in pocket of gear by
the previously m entioned grease.
12. C oat countershaft rear bearing cap gasket with seal­
ing cement. Install gasket and countershaft rear bearing
cap. Tighten cap screws to 60-80 foot-pounds torque.
N O T E : The projection on the cou n tersh aft rear
b e a rin g c a p locks the reverse idler s h a ft into
prop er position.
13. Shift transm ission into neutral and rotate m ain drive
gear to check for free rotation of all gears and shafts.
14. Use pressure type oil can (filled with transm ission lu­
bricant) to force oil through holes and end slots of all
m ainshaft gears to flush out grease and open all oil pas­
sageways.
INSTALLATION OF MAINSHAFT
(Key N um bers Refer to Figure 1)
1. Place 1st and reverse sliding grear (27) on an angle in
the rear of the transm ission case with shift fork collar fac­
ing tow ard front of case.
2. Place 4th and 5th synchronizer (5) on m ainshaft (28).
Shift synchronizer clutch collar into engagem ent with 4th
speed gear (13) to help lock synchronizer in place during
installation in case.
3. Lower rear of m ainshaft into case through 1st and
reverse sliding gear and out m ainshaft rear bearing bore.
N O T E : C h e c k m a in d riv e g e a r pocket to verify
th a t all fourteen pilot b e a r in g rollers (4) are in
their p ro p e r position.
4. Lower front of m ainshaft into mesh with countershaft
gears. Raise rear of m ainshaft slightly, and slide into
pocket of m ain drive gear.
5. Slide m ainshaft rear bearing (29) into position on
m ainshaft with snap ring on bearing tow ard rear.
6. Align bearing with bore of case and using suitable
sleeve top bearing into place. T he bearing snap ring
should be flush with rear of transm ission case.
7. Press speedom eter drive gear (32) or spacer onto the
m ainshaft and seat against bearing.
8. C o at m ainshaft rear bearing cap gasket with sealing
cem ent and install gasket and m ainshaft rear bearing cap
(31). Tighten cap screws to 60-80 foot-pounds torque.
9. Engage 2nd and 3rd synchronizer (23), with m ainshaft
2nd speed gear (25), and 4th and 5th synchronizer (5) with
m ainshaft 4th speed gear (13) to lock transm ission in two
gears.
10. Install com panion flange (34) or yoke on m ainshaft
using tool J-7801-01 or equivalent. Install m ainshaft
flange or yoke washer and nut. Tighten nut to 400-450
foot-pounds torque.
11. Rem ove countershaft rear bearing cap. Tighten coun­
tershaft nut to 400-450 foot-pounds torque. Secure with
cotter pin.
INSTALLATION OF SHIFTER
H O U SIN G
(Key N um bers Refer to Figure 1)
1. C oat Shifter housing gasket with sealing cem ent, then
position the gasket on the transm ission case.
N O T E : Be su re sh ift forks a n d tran sm ission
clutch collars a re in n eutral position.
2. Carefully position shifter housing (7) on transm ission
case and m ake sure all three shift forks are in their prop­
er place in corresponding shift collar.
3. Secure shifter housing to case with cap screws and
washers. Tighten cap screws firmly.
4. Use large screwdriver or small pry-bar and check
m ovem ent of each shift rod to m ake sure transm ission
will shift readily and completely into each gear position.
R eturn shift rods to neutral.
5. Place the three poppet balls (17) in their proper loca­
tion in top of shifter housing over shift rods. Place the
three poppet springs (16) on the poppet balls.
INSTALLATION OF REMOTE
CONTROL ASSEMBLY
(Refer to Figure 2)
1. C o at rem ote control assem bly gasket with sealing ce­
m ent and position on shifter housing.
2. Position plunger in 1st and reverse shift finger; then
carefully install rem ote control assem bly, as shown, keep­
ing the assembly slightly tilted to the left to prevent the
plunger from falling into the transm ission.
3. Install plunger pin, plunger pin spring, and retainer.
4. Install rem ote control assembly- to- shifter housing
attaching p a n s. Tighten cap screws firmly.
CHEVROLET SERIES 70-80 H EAVY DUTY TRUCK SH O P M A N U A L