Chevrolet 70 1969 Series, Shop Manual

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TRANSMISSION AND CLUTCH 7-102
AUXILIARY TRANSMISSION
(4-SPEED—MODEL 6041)
OVERHAUL
DISASSEMBLY
N O T E : K ey n u m b e rs in text refer to Figure 1.
1. Rem ove drain plug (42) and drain fluid from trans­
mission. Remove cover to case bolts and lift cover
(15) from transm ission case.
2. Lock transm ission by locking both shift collars (14
and 22) into engagem ent with m ating gears at same
time. Rem ove m ainshaft nut (31); then remove rear
flange (32).
3. If front support has not been removed, then remove
front support from maindrive gear bearing cap (50).
4. Rem ove countershaft rear bearing cap (37), noting
num ber of shims (36) under cap.
5. Remove m ainshaft rear bearing cap (27) and gasket
(35) with oil seal (29) and speedom eter driven gear
(33) in cap, then remove oil seal (29) and speedom eter
driven gear (33) from cap (27) and sleeve.
6. Remove main drive gear bearing cap (50) with bear­
ings (6-7 and 53-54), m ain drive gear (3), seal and
seal cap (55).
7. Remove speedom eter drive gear (28). Then using pul­
ler (J-4558) as shown in figure 5, press m ainshaft with
front pilot bearing (52), m ainshaft overdrive gear snap
ring (11), overdrive and direct clutch gear (13), collar
(14), and overdrive gear (17) out through front of
case, leaving 1st speed gear (18), 1st and 2nd speed
clutch gear (23) and collar (22) and m ainshaft 2nd
speed gear (24) and sleeve (34) in case. Rem ove these
items from case after removing mainshaft.
8. Remove m ainshaft rear bearing assem bly (26) from
transm ission case.
9. Drive countershaft tow ard rear far enough to force
rear bearing cup (39) out of case. Using snap ring
pliers, remove countershaft 2nd speed gear front snap
ring (40) from groove, slide 2nd speed gear (41) for­
ward, then lift countershaft assembly out of case.
10. Rem ove countershaft front bearing cup (48) from
case.
11. Rem ove power take-off covers and filler plug from
case.
DISASSEMBLY OF SUBASSEMBLIES
Key numbers in text refer to Figure 1.
M A IN D R IV E G E A R A N D B E A R IN G S
1. Rem ove oil seal and oil seal cap (55) with gasket (5)
from m ain drive gear bearing cap (50). Seal can then
be removed from cap.
2. S upport cap (50) at flange; then press m ain drive gear
(3) out of cap.
3. Remove spacer (8) and bearing cone (54) from main
drive gear shaft. W asher (4) and bearing cone (6) m ay
be lifted from bearing cap.
4. If inspection reveals dam age or wear at bearing cups
(7 and 53), they may be driven out of cap and re­
placed with new parts.
5. If bearing (52) has rem ained in pocket of drive gear
(3), remove with suitable puller.
M A IN S H A F T A N D G E A R S
1. Remove shift collar (14) from clutch gear (13). If
bearing (52) has rem ained on m ainshaft, it will first
be necessary to remove this part.
2. Rem ove snap ring (11). Pull clutch gear (13) off
splines at front of m ainshaft; then remove overdrive
gear (17).
C O U N T E R SH A F T G E A R S A N D B E A R IN G S
N O T E : K e y n u m b e rs in text refer to F igure 1.
C ountershaft gears should be m arked so that correct
position will be known when installing.
1. Using suitable puller, remove bearing cones (49 and
38) from countershaft.
2. Remove countershaft 2nd speed gear rear snap ring
(40) from end of countershaft, then rem ove 2nd speed
gear (41) from countershaft.
3. Remove countershaft drive gear snap ring (51) from
front of countershaft.
4. Using arbor press, press drive gear (46) and co unter­
shaft overdrive gear (44) from countershaft.
C O V E R A N D S H IF T IN G M E C H A N IS M
N O T E : K e y n u m b e rs in text refer to F igu re 3.
1. M ount cover in vise and remove lock wires (3) and
shift fork clam p screws (4).
2. Rem ove poppet screw from each side of cover and jar
springs, balls, and retainer out through poppet screw
holes.
CHEVROLET SERIES 70-80 H EAVY DUTY TRUCK SH O P M A N U A L