GMC 1986 P-Truck Service Manual

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LIGHT DUTY TRUCKS

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Summary of Contents for GMC 1986 P-Truck

Page 1 LIGHT DUTY TRUCKS...
Page 2 Where the fasteners are not satisfactory for re-use, care should be taken to select a replacement that matches the original. For information and assistance, see your authorized dealer. GMC TRUCK & COACH OPERATION TRUCK & BUS GROUP General Motors Corporation...
Page 3 CAUTION To reduce the chance of personal injury and/or property damage, the follow ing instructions must be carefully observed. Proper service and repair are important to the safety of the service techni cian and the safe, reliable operation of all motor vehicles. If part replacement is necessary, the part must be replaced with one of the same part number or with an equivalent part.
Page 4: General Information
NAME GENERAL INFORMATION General Information Maintenance and Lubrication 1986 HEATING AND AIR CONDITIONING Heating Air Conditioning FRAME AND CAB Frame and Body Mounts Bumpers Sheet Metal and Fiberglass LIGHT DUTY STEERING, SUSPENSION, WHEELS AND TIRES TRUCK Front End Alignment 3B1 Steering Linkage 3B2 Manual Steering 3B3 Power Steering SERVICE...
Page 5 Mr. Goodwrench dealers you do the work yourself. selling Chevrolets, Pontiacs, Oldsmobiles, Buicks, Cadillacs, GMC and Chevy Trucks. That’s why Mr. Goodwrench wants to have a good stock of genuine GM Parts available. Everything from exclusive GM Goodwrench replacement engines and...
Page 6: Table Of Contents
O A - 1 SECTION 0 GENERAL INFORMATION CONTENTS SUBJECT PAGE General In fo rm a tio n ..............................OA- 1 Maintenance and L u b ric a tio n ..........................OB- 1 SECTION OA GENERAL INFORMATION CONTENTS SUBJECT PAGE Service Parts Identification L ab e l........................OA- 2 Vehicle Identification P la te ..........................OA- 2 C ertification L a b e l..............................
Page 7: Service Parts Identification Label
OA-2 GENERAL INFORMATION models, the plate is on the dash and toe panel. To find S E R V I C E P A R T S I D E N T I F I C A T IO N_________ out the manufacturer, model and chasis type, engine V .
Page 8 B Chevrolet Incomplete 0 Pickup/Panel Delivery Scarborough, ON C Chevrolet Truck 1 Hi-Cube/Cutaway Van Lordstown, OH D GMC Incomplete 2 Forward C ontrol Shreveport, LA E Cadillac Incomplete 3 Four-Door Cab H GM ot Canada Bus 4 Two-Door C ab...
Page 9 OA-4 GENERAL INFORMATION Chassis - Cab, Regular Cab C-K MODELS Pickup, Regular Cab Chassis - Cab, Bonus/Crew Cab Pickup, Bonus/Crew Cab Suburban U tility Vehicle Jimm y (Blazer) B-09177 Figure 5 C-K Models 1. Position the vehicle with the good (charged) JUMP STARTING INSTRUCTIONS battery so that the booster (jumper) cables will reach, but never let the vehicles touch.
Page 10 GENERAL INFORMATION OA-5 G VAN MODELS RALLY (SPORTVAN) VANDURA (CHEVY VAN) CUTAWAY VAN MAGNAVAN (HI-CUBE VAN) P MODELS VALUE VAN (STEP VAN) MOTOR HOME CHASSIS (ALUMINUM) VALUE VAN (STEP VAN) FORWARD CONTROL CHASSIS (STEEL) B-09178 Figure 6—G Van and P Models...
Page 11: Graphic Symbols
OA-6 GENERAL INFORMATION Dtional Location) 4. Engine I.D. {0[ L6 ENGINE 5. Engine Case F 6. Engine I.D. • 1. Engine I.D. 2. D istributor Pad V8 E N G I N E ^ A ^ ^ ^ ^ 3. Engine I.D. (Optional Location) 7.
Page 12 GENERAL INFORMATION OA-7 • • POWER TRAIN WINDSHIELD WINDSHIELD WINDSHIELD BRAKE VENTILATING FAN OIL TEMPERATURE WASHER WIPER & WASHER DEFROSTER t & r > REAR WINDOW REAR WINDOW FASTEN ENGINE OIL FUEL & DEFOGGER SEAT BELTS PRESSURE WIPER WASHER WINDSHIELD IDENTIFICATION LIGHTS OR HAZARD WARNING...
Page 13: Metric Fasteners
OA-8 GENERAL INFORMATION METRIC FASTENERS 1. Grade 2 (GM 200-M) 2. Grade 5 (GM 280-M) 3. Grade 7 (GM 290-M) 4. Grade 8 (GM 300-M) 5. Manufacturer’s Identification 6. Nut Strength Identification 7. Identification Marks (Posidriv Screw Head) 1. Customary B olt— 1 /4-20 2.
Page 14: Prevailing Torque Fasteners
GENERAL INFORMATION OA-9 nuts w ill be marked with single d ig it strength SIX LOBED SOCKET identification numbers on the nut face. Figure 10 HEAD FASTENERS shows the different strength markings. When replacing metric fasteners, be careful to use Six lobed socket head (Torx) fasteners are used in bolts and nuts of the same strength or greater than the some applications on vehicles covered in this manual...
Page 15 0A-10 GENERAL INFORMATION 6 & 6.3 4 ,5 In. Lbs. 1,2, 3, 6, In. Lbs. 7, 8, 9 .750 .437 .500 .562 .625 .250 .312 .375 4 ,5 In. Lbs. 1,2, 3, 6, 8, 9 In. Lbs. 6. Nylon Strip Or Patch A.
Page 16 GENERAL INFORMATION OA-11 T - Internal Drive E - External Drive B-02221 Figure 13—Six Lobed Socket Head (Torx) Fasteners...
Page 17 CONVERSION TABLE to get equivalent to get equivalent Multiply number of: Multiply number of: LENGTH ACCELERATION Inch 25.4 millimeters (mm) Foot/sec2 0.304 8 meter/sec2 (m/s2 ) Foot 0.304 8 meters (m) Inch/sec2 0.025 4 meter/sec2 Yard 0.9144 meters TORQUE Mile 1.609 kilometers (km) Pound-inch...
Page 18 GENERAL INFORMATION OA-13 DECIMAL AND METRIC EQUIVALENTS Fractions Decimal Metric Fractions Decimal Metric 33/64 .515625 13.09687 1/64 .015625 .39688 17/32 .53125 13.49375 .03125 .79375 1/32 35/64 .546875 13.89062 3/64 .046875 1.19062 1.58750 9/16 .5625 14.28750 1/16 .0625 14.68437 1.98437 37/64 .578125 5/64 .078125...
Page 19: Rpo Listing (Regular Production O P Tio N
OA-14 GENERAL INFORMATION RPO LISTING (REGULAR PRODUCTION OPTION) B32 Floor Mats - Front The RPO list contains RPOs used on C-K Models, G Vans, and Forward Control Chassis Models. Refer to B33 Floor Mats - Rear the Service Parts Identification Label for a list of the B84 Extra Molding - Body Side B85 Extra Molding - Belt Reveal RPOs used on each specific vehicle.
Page 20 GENERAL INFORMATION OA-15 UA1 Battery - High Capacity G51 Spring - Rear, Special Heavy UB4 Lamps - Rear Side Marker G52 Spring - Rear 15000 lbs. UD4 Alarm - Vehicle Speed G60 Spring - Rear Auxiliary UF2 Lamp - Cargo G80 Axle - Rear, Limited Slip UJ1 Indicator System, Brake Warning KC4 Engine Oil Cooler System...
Page 21 OA-16 GENERAL INFORMATION 18V Trim Combination - Charcoal, Vinyl Striped 90K Color Combination - Med. Grey (Auxiliary Top) 18W Trim Combination - Charcoal, Dual Grain Vinyl 90L Secondary Color - Grey Metallic 19A Stripe Accent - Black and Grey Two Tone 90U Primary Color - Grey Metallic 191 Interior Trim - Black 93U Primary Color - Lt.
Page 22 ___________________________________________________________________ OB-1 SECTION OB MAINTENANCE AND LUBRICATION CONTENTS SUBJECT PAGE C a p a citie s..................................OB- 1 L u b ric a tio n .................................. OB- 6 Maintenance Schedule and L o g ..........................OB- 7 CAPACITIES Figures 2 through 6 show the approximate capacities of the dif ferential gear, the transmission, the cooling system, the crankcase, the fuel tank, the front axle and the transfer case.
Page 23 OB-2 MAINTENANCE AND LUBRICATION Metric U.S. Items Measure Measure Cooling System (Approx.)▲ Code: H, L, M Without A/C 16.5 Liters 17.5 Quarts With A/C 17 Liters 18 Quarts Code: W Without A/C 22 Liters 23 Quarts With A/C 23 Liters 24.5 Quarts Diesel Engines Code: C, J...
Page 24 MAINTENANCE AND LUBRICATION OB-3 Metric U.S. Items Measure Measure Cooling System (approx.) 4.8L (L6) Engine Code (T) P30042 Models 13.1 Liters 13.8 Quarts With or Without A/C 5.7L (V8) Engine Code (M) P30042 Models 14.6 Liters 15.5 Quarts With or Without A/C 7.4 L (V8) Engine Code (W) P30032 Models 21.2 Liters...
Page 25 OB-4 MAINTENANCE AND LUBRICATION Metric U.S. ITEMS Measure Measure Cooling System (Approx.) Code N-V6 W ith or W ithout A/C 10.3 Liters 10.9 Quarts Code T-L-6 W ithout A/C 14.7 Liters 15.5 Quarts With A/C 15.1 Liters 16 Quarts Code F, H, L & M — V-8 W ithout A/C 16.6 Liters 17.5 Quarts...
Page 26: Maintenance And Lubrication
MAINTENANCE AND LUBRICATION OB-5 METRIC U.S. ITEMS MEASURE MEASURE Cooling System (Approx.)▲ 4.3 L (N) V6 All 10.5 Liters 11.1 Quarts V8’s Except Diesel Without A/C 16 Liters 17 Quarts With A/C 16 Liters 17 Quarts 6.2 L (C) Diesel With Automatic or 23 Liters 24 Quarts...
Page 27 OB-6 MAINTENANCE AND LUBRICATION LUBRICATION Figures 7, 8 and 9 show chassis lubrication points for the C, K, G and P chassis. 9. Master Cylinder 1. Lower Control Arms 10. Transmission - Manual 2. Upper Control Arms 3. Upper and Lower Control Arm Ball Joints - Automatic 4.
Page 28 MAINTENANCE AND LUBRICATION OB-7 1. Control Arm Bushings and Ball Joints 5. Transmission Control Shaft 8. Rear Axle 2. Tie Rod Ends 6. A ir Cleaner - Element 9. Oil Filter 3. Wheel Bearings 7. Transmission - Manual 10. Brake Master Cylinder - Automatic 4.
Page 29 OB-8 MAINTENANCE AND LUBRICATION SELECTING YOUR VEHICLES MAINTENANCE DETERMINING GVWR AND EMISSIONS CLASSIFICATION To determine the emissions classification for gasoline engine equipped vehicles, refer to the certification label located on the edge of the driver’s door. If the Gross Vehicle Weight Rating (GVWR) in the u p p e r le ft c o rn e r of the c e rtific a tio n la b e l is less tha n 8600 lbs./3 900 kg, your vehicle is equipped with “...
Page 30 SECTION A -SCH ED U LED MAINTENANCE SERVICES FOR YOUR 1986 VEHICLE WITH LIGHT DUTY EMISSIONS - UNDER 8600 GVWR O O fl The corvlroc chnuun in this cchgriylg un In fin nnn mjjoc (inn o Maintenance Schedule are to be performed after 60,000 miles (100 000 km) at the same intervals. •...
Page 31 SECTION A-SCHEDULED MAINTENANCE SERVICES FOR YOUR 1986 VEHICLE WITH HEAVY DUTY EMISSIONS - OVER 8600 GVWR (EXCEPT CALIFORNIA) Maintenance Schedule 1 The services shown in this schedule up to 60,000 miles (100 000 km) • Maintenance Schedule 2 are to be performed after 60,000 miles (100 000 km) at the same intervals. Item Miles (000) 95 100...
Page 32 SECTION A -S C H E D U L E D MAINTENANCE SERVICES FOR YOUR 1986 VEHICLE WITH HEAVY DUTY EMISSIONS - OVER 8600 GVWR (CALIFORNIA ONLY) The services shown in this schedule up to 60,000 miles (100 000 km) o Maintenance Schedule 1 m maintenance Schedule 2 are io se performed after 60,000 miles (100 000 km) ai the same intervals.
Page 33 SECTION A-SCH ED U LED MAINTENANCE SERVICES FOR YOUR 1986 VEHICLE WITH A 6.2 L DIESEL ENGINE Maintenance Schedule 1 The services shown in this schedule up to 47,500 miles (76 000 km) • Maintenance Schedule 2 are to be performed after 47,500 miles (76 000 km) at the same intervals. 20 22.5 25 27.5 30 32.5 35 37.5 40 42.5 45 47.5 7.5 10 12.5 15 Miles (000) 2.5...
Page 34 SECTION B — EXPLANATION OF TRANSMISSION SERVICE Transmission — Change the transmission fluid and SCHEDULED MAINTENANCE SERVICES Automatic filter every 15,000 miles (25 000 km) for vehicles under 8600 GVWR or every 12,000 miles (20 000 km) for vehicles over 8600 The services listed in the preceding Maintenance Schedules are further explained below.
Page 35 tight. Also check to be sure that the air cleaner housing is prop 13. SPARK PLUGS * — Replace spark plugs with the type listed in erly seated on the carburetor, that the cover fits tightly, and the your Owner's Manual. wingnut is tight.
Page 36 SECTION C — OWNER AT EACH FUEL FILL SERVICES INSPECTIONS AND Engine oil ievei check t — Check engine oii ievei and add if nec essary. See your Owner’s Manual for further details. Listed below are inspections and services which should be made Engine coolant level and condition f —...
Page 37 proper level. A low fluid level can indicate worn disc brake pads may cause a heat buildup in the floor pan or could let exhaust fumes seep need to be serviced. into the passenger compartments. — Note the clutch pedal free travel. It Clutch pedal free travel Throttle linkage inspection —...
Page 38 AT LEAST ONCE A YEAR Lap and shoulder belts condition and operation — Inspect belt system, including: webbing, buckles, latch plates, retractors, guide Starter safety switch operation — loops and anchors. Movable head restraint operation — On vehicles with movable head restraints, make sure restraints stay in the desired position.
Page 39 SECTION D — MAINTENANCE RECORD SECTION E — RECOMMENDED FLUIDS & LUBRICANTS After each of the preceding Scheduled Maintenance Services is performed, record the date, odometer reading, services performed Chassis grease m eeting requirem ents C hassis Lubrication (list item numbers) and who performed the services in the appropriate of GM-6031-M (GM Part No.
Page 40: Heating And Air Conditioning
1A-1 SECTION 1 HEATING AND AIR CONDITIONING CONTENTS SUBJECT PAGE H e a tin g ....................................1A-1 A ir C o n d itio n in g ..................................1B-1 SECTION 1A HEATING CONTENTS SUBJECT PAGE C-K And G Series Heaters — General D e sc rip tio n ..................... 1 A - 2 Blower And A ir Inlet A ssem bly...........................
Page 41: H E A Tin
1A-2 HEATING C-K AND G SERIES HEATERS — GENERAL DESCRIPTION Heating components are attached to the right side of HEATER DISTRIBUTOR the cowl. The blower and air inlet assembly and water ASSEMBLY hoses are located on the forward side of the cowl panel while the heater core and distributor duct are on the The heater distributor assembly houses the heater passenger side.
Page 42: Insufficient Heat Diagnosis
HEATING 1A-3 INSUFFICIENT HEAT DIAGNOSIS P o s itio n th e c o n tro ls so th a t the: T e m p e ra tu re lever is on fu ll heat. S e le c to r o r h e a te r lever is on Heater. Fan S w itc h is on HI.
Page 43: Healer C Ircuit D Ia G N O S Is
HEATER CIRCUIT DIAGNOSIS* BLOWER MOTOR INOPERATIVE BLOWER MOTOR INOPERATIVE (CERTAIN SPEEDS) (ANY SPEED) — Check fuse Disconnect resistor connector, connect one lead in fuse panel. of a self powered test light to any one terminal and use the other lead to probe each of the other ..
Page 44: Diagnosis Of Heater System
HEATING 1A-5 DIAGNOSIS OF HEATER SYSTEM PROBLEM POSSIBLE CAUSE CORRECTION Temperature Of 1. Refer to “ Insufficient Heat Diagnostic 1. Refer to “ Insufficient Heat Diagnostic Heater A ir At The Chart.” Chart.” O utlets Is Too Low To Heat Up Passenger Compartment Temperature Of...
Page 45: C-K Series Heater - On-Vehicle Service
1A-6 HEATING DIAGNOSIS OF HEATER SYSTEM (CONT.) CORRECTION PROBLEM POSSIBLE CAUSE Erratic Heater 1. Check the coolant level. 1. Fill to the proper level. Operation 2. Check for kinked heater hoses. 2. Relieve kinks or replace hoses. 3. Check the operation of all bowden ca 3.
Page 46: Heater Distributor And Core Assembly
HEATING 1A-7 11. Connector 21. Shaft 12. Screw 22. Valve 13. Motor 23. Valve 14. Case 24. Case 15. Fan 25. Shaft 16. Nut 26. Shroud 17. Bolt 27. Plate 18. Clamp 28. Bolt 19. Clamp 29. Elbow 20. Core 30.
Page 47 V8 (5.0, 5.7 and 7.4 Liter) Gas Engines V8 (6.2 Liter) Diesel Engine 1. Heater/Blower Assem bly 40. Hose - Inlet 41. Hose - O utlet V6 (4.3 Liter) Gas Engine L6 (4.8 Liter) Gas Engine 42. Radiator — —......
Page 48: Control Assembly Replacement
HEATING 1A-9 3. Control to instrument panel screws. 4. Cable push nuts and tab attaching screws. • Raise or lower the control as necessary. 5. Instrument panel compartment. 6. Cable push nut and tab attaching screws at the door end of the cable. 7.
Page 49 1A-10 HEATING F-00656 Figure 7—Control Assembly And Cables...
Page 50: Blower Switch Replacement
HEATING 1A-11 1. Heater/Blower Assembly 45. Grille 46. Nozzle Assembly 47. Instrument Panel 48. Outlet B-09822 Figure 8—Defroster Vents BLOWER SWITCH • Lower control onto the radio. REPLACEMENT 4 Switch wiring harness. 5 Switch. Remove or Disconnect (Figure 9) -►«- Install or Connect (Figure 9) 1 Battery ground cable.
Page 51: Resistor R E P La Ce M E N
1A-12 HEATING Bezel 66 . Valve Assembly Instrument Panel Garnish Kickpanel Control Cable Figure 11—Vent Assembly — CK 4. Instrument panel bezel. Install or Connect 5. Battery ground cable. 1. Resistor. 2. Mounting screws. RESISTOR REPLACEMENT 3. Wiring harness. 4. Battery ground cable. Remove or Disconnect (Figure 10) VENT 1.
Page 52 HEATING 1A-13 75. Upper Case 92. Clamp 76. Seal 93. Auxiliary Heater Inlet Rear Hose 77. Core 94. Auxiliary Heater Outlet Rear 78. Lower Case 95. Clip 79. Screw 96. Screw * 80. Fan 97. Water Heater Outlet Hose 81. Support 98.
Page 53 1A-14 HEATING Resistor W iring Harness 108. Auxiliary Heater 109. Platform F-00662 Figure 13—Resistor Location Install or Connect (Figure 13) ON-VEHICLE SERVICE 1. Resistor. RESISTOR PRELACEMENT 2. Screws. 3. Wiring connector. Remove or Disconnect (Figure 13) 4. Battery ground cable. 1.
Page 54 HEATING 1A-15 G SERIES HEATER— ON-VEHICLE SERVICE 121. Housing 110. Nut 122. Core 111. Fan Assem bly 112. Washer 123. Strap 124. Case 113. M otor 114. Tube 125. Bracket 115. Fitting 126. Valve 116. Case 127. Shaft Assem bly 117.
Page 55 1A-16 HEATING 7. Distributor duct to the heater case. 11 /4-inch (32 mm) minimum clearance between the auxiliary heater core lines and the exhaust pipe. Refer 8. Defroster duct to the distributor case. to figure 15. 9. Instrument panel. 10. Steering column. 11.
Page 56 HEATING 1A-17 Figure 15—Heater Hose Distribution...
Page 57 1A-18 HEATING 133. Left-hand Outlet Assembly 134. Duct Assembly F-00659 Figure 16—Distributor Ducts...
Page 58 HEATING 1A-19 124. Heater Assembly 130. Defroster Plenum 145. Temperature Cable 146. Defroster Cable 147. Control Assembly F-00658 Figure 17—Control Assembly And Cables Install or Connect (Figure 17) 4. Cable push nuts and tab attaching screws. • Raise or lower control as necessary. 1.
Page 59 1A-20 HEATING 4. Instrument panel compartment. 5. Cable push nuts and the tab attaching screws. 6. Instrument panel to control assembly screws. 7. Instrument panel bezel. 8. Battery ground cable. CABLE ADJUSTMENT Adjust (Figure 14) 1. Attach inner cable and sheath to the instrument panel control.
Page 60 HEATING 1A-21 200. Seal 203. Clip 206. Rod 209. Seal 201. Outlet 204. Screw 207. Guide 210. Inlet Assembly 202. Valve Assembly 205. Knob 208. Outlet F-00657 211. Cover Figure 19—Vents G SERIES AUXILIARY HEATER FAN SWITCH GENERAL DESCRIPTION For heating, the fan switch is placed in any position An auxiliary heater provides additional heating for except off.
Page 61 1A-22 HEATING 150. Case 151. Core 152. Seal 153. Tube 154. Resistor 155. Case 156. Washer 157. Fan 158. Nut 159. Plate 160. Screw 161. Screen Assembly 162. Harness 163. Stud 164. Motor 165. Strap 166. Terminal 167. Screw 168. Screw B-09752 Figure 20—Auxiliary Heater Component View...
Page 62 HEATING 1A-23 182172 170. Heater Assembly 171. Seal 172. Clamp 173. Screw 174. Washer 175. Clip 176. Screw 177. Strap 178. Material 179. Hose 189. Screw 180. Hose 190. Hose 181. Strap 191. Nut 182. Clip 192. Switch 180 179 176 183.
Page 63 1A-24 HEATING SPECIFICATIONS C-K AND G SERIES HEATER Amps. Volts (Cold) (Cold) Blower Motor C-K M o d e ls ................13.5 6.25 Max. 2550 Min. 2950 Max. G M odels.................. 13.5 7.1 Max. 2850 Min. 3250 Max. Fuses C-K M o d e ls ............................ 20 Amp. G M odels............................
Page 64 1B-1 SECTION 1B AIR CONDITIONING CONTENTS SUBJECT PAGE D e s c rip tio n .................................. 1B- 3 CCOT System Components, Temperature and Pressure R elationships............ 1B- 5 Handling Refrigerant-12............................1B- 5 System C o m p o n e n ts .............................1B- 4 Refrigerant-12 Operating C h a ra c te ris tic s ......................
Page 65 1B-2 AIR CONDITIONING CONTENTS (CONTINUED) CCOT A/C System—C-K S e r ie s ..........................1P-32 Condenser R e p la ce m e n t............................1B-33 A ccum ulator Replacement............................1B-34 Blower Assembly Replacem ent........................... 1B-34 Evaporator Core R e p la c e m e n t........................... 1B-34 O rifice (Expansion Tube) R e p lace m e n t......................1B-35 Selector Duct and Heater Core R e p la ce m e n t....................
Page 66 AIR CONDITIONING 1B-3 CONTENTS (CONTINUED) Dash Mounted System—Motor Home C h a s s is ....................1B-64 Condensor R e p lacem ent............................1B-64 Receiver—Dehydrator R eplacem ent........................1B-65 Sight Glass Replacement............................1B-65 Blower—Evaporator Assembly R e p la c e m e n t....................1B-66 Blower Assembly Replacement...........................
Page 67 1B-4 AIR CONDITIONING passes on to the seat and orifice where it changes into a low pressure liquid. The low pressure liquid leaves the valve and flows into the evaporator core where it absorbs heat from the evaporator core and changes to a low pressure vapor and leaves the evaporator core.
Page 68: Ccot System Components, Temperature And Pressure Relationships
AIR CONDITIONING 1B-5 SWITCH SETTING CYCLING PRESSURE (ACCUMULATO R READINGS) COMPRESSOR CUT IN COMPRESSOR CUT OUT PRESSURE RANGE PRESSURE RANGE 21-24 43-49 F-00333 Figure 5—Cycling Pressure Switch Settings (Accum ulator Readings) Figure 4—Pressure Cycling Switch REFRIGERANT-12 OPERATING CHARACTERISTICS If Refrigerant-12 touches exposed flesh do the CCOT SYSTEM COMPONENTS, following: TEMPERATURE AND...
Page 69 1B-6 AIR CONDITIONING “ HPV” - High pressure vapor leaving compressor. “ HPL” - Vapor is cooled down by condenser air flow and leaves as high pressure liquid. “ LPL” - O rifice meters the liquid R-12 into evapora-. tor, reducing its pressure and warm blower air 33.
Page 70 AIR CONDITIONING 1B-7 In Front Of Condenser Relative Discharge A ir High H um idity Temp. Evaporator Engine Speed Temp. Pressure C° F° Pressure (rpm) C° F° 29.5 2000 1034.25 29.5 1310.05 30.0 1689.27 31.0 2102.97 29.5 2000 1034.25 30.0 1413.47 31.0 1827.17...
Page 71: Maintaining Chemical Stability
1B-8 AIR CONDITIONING • W hen m a kin g stee l a lu m in u m REFRIGERANT CHARGE connections, use torque for aluminum tubing. (Refer to figure 10). C60 System C-K Models 3 lbs. 8 ozs. MAINTAINING CHEMICAL G Models 3 lbs.
Page 72: Diagnosis
AIR CONDITIONING 1B-9 DIAGNOSIS NOTICE: When performing air conditioning di Operating Detector agnosis on vehicles equipped with a catalytic 1. Determine if there is sufficient refrigerant in the converter, warm the engine to a normal oper sytem for leak testing. ating temperature before attempting to idle the engine for periods greater than five (5) CAUTION: Do not breathe the fumes that are...
Page 73 1B-10 AIR CONDITIONING INSUFFICIENT COOLING-A/C SYSTEMS WITH CYCLING CLUTCH-EXPANSION TUBE (PRESSURE SENSING) Move Temp. Lever Rapidly Back And Forth From Hot to Cold. Listen For Door Hitting At Each End Hitting ..1 1 Set Temp Lever Full Cold 4 Open Doors And Hood Adjust Temp.
Page 74 AIR CONDITIONING 1B -1 1 INSUFFICIENT COOLING-A/C SYSTEMS WITH CYCLING CLUTCH- EXPANSION TUBE (PRESSURE SENSING) Off A lim s Time Attach Fused Jum per Wire From Compressor Hot Lead To Positive ( + ) _____________ Battery Post And Check Compressor Operation Engaged Apply External Ground To Compressor, Remove Jumper And Check Refrigerant...
Page 75 1B-12 AIR CONDITIONING INSUFFICIENT COOLING DIAGNOSIS CHART D A S H M O U N T E D U N IT (M O TO R H O M E C H AS SIS U N ITS ) THE FOLLOWING PROCEDURES SHOULD BE APPLIED BEFORE PERFORMANCE TESTING AN A/C SYSTEM. 6.
Page 76 AIR CONDITIONING 1B-13 INSUFFICIENT COOLING DIAGNOSIS CHART (CONTINUED) D A S H M O U N T E D U N IT (M O TO R H O M E C H ASS IS U N ITS ) FOAMING NO FOAMING SYSTEM IS PROBABLY LOW ON REFRIGERANT.
Page 77 1B-14 AIR CONDITIONING INSUFFICIENT COOLING DIAGNOSIS CHART (Cont.) DASH MOUNTED UNIT (MOTOR HOME CHASSIS UNITS) DASH MOUNTED UNIT (MOTOR HOME CHASSIS) Refrigerant Charge 1.474 kg (3 lbs., 4 oz.) Temperature of Air Entering 21 °C - (70° F) 27° C - (80° F) 32°...
Page 78 COMPRESSOR DIAGNOSIS Check for proper air gap. If previous step does not Clutch slipping. Correct if necessary correct clutch slippage, 0.56 - 1.45 mm (0.022 - 0.057 in. repair compressor. — I Belt slipping! Check and correct belt tension. Com pressor engaged but not operational.
Page 79: Electrical/Vacuum Trouble D Ia G N O S
1B-16 AIR CONDITIONING ELECTRICAL/VACUUM TROUBLE DIAGNOSIS 1. Operate the blower at four speeds and check the When diagnosing problems in the electrical and vac compressor clutch engagement. This indicates uum systems consult electrical wiring diagrams and that the electrical circuits are working. vacuum diagrams (figures 17, 18, 19, and 20).
Page 80 AIR CONDITIONING 1B-17 j" 1 ^ Port Select Lever Valve Operation Chart Connection Max A/C Norm A/C Bi-Level Vent Heat Defrost Source Vacuum Vacuum Vacuum Vacuum Vacuum Vacuum Vacuum Bi Level Vacuum Vacuum Vent Vacuum Vacuum Vacuum Vent Heat/Defrost Vacuum Vacuum Vacuum Vacuum...
Page 81 1B-18 AIR CONDITIONING ELECTRICAL SYSTEM DIAGNOSTIC CHART BLOW MOTOR INOPERATIVE (ANY SPEED) CHECK FOR PROPER FUSE. FUSE B L O W N ""] FUSE OK THE FOLLOWING TESTS SHOULD BE MADE WITH WITH IGNITION SWITCH IN “ RUN” POSITION AND THE IGNITION SWITCH IN “...
Page 82 AIR CONDITIONING 1B -1 9 ELECTRICAL SYSTEM DIAGNOSTIC CHART (CONTINUED) F-00168 Figure 19—Electrical System Diagnostic Chart (Cont.)
Page 83 1B-20 AIR CONDITIONING Port Select Lever Valve Operation Chart Defrost Connection Max A/C Norm A/C Bi-Level Vent Heat Source vac ....■ A/C Mode Vent Vacuum Vacuum Heater/Mode Vent Optional Optional Vent Optional Vent OSA/REC Vacuum Vent Vent Vent Vent Vacuum Vacuum...
Page 84: Vacuum System Diagnosis
AIR CONDITIONING 1B-21 VACUUM SYSTEM DIAGNOSIS • Vacuum normal at all positions. C-K AND G SERIES If vacuum was normal and even at all positions, then the malfunction may be Start the engine and allow it to idle. Move the caused by improperly connected or plugged selector lever to each position and refer to the vacuum lines or a malfunctioning vacuum valve or...
Page 85: A/C Evacuating And Charging P Ro C E D U Re
1B-22 AIR CONDITIONING A/C EVACUATING AND CHARGING PROCEDURES EVACUATION AND CHARGING PROCEDURES Before opening any refrigerant hose or component, read the information furnished in: • Refrigerant-12 Operating Characteristics. 55. Gage Set • D isch a rg in g , E va cu a tin g , A dd in g O il and 56.
Page 86 AIR CONDITIONING 1B-23 65. Accum ulator F-00030 Figure 22—Charging The System With A Disposable Can Or Drum a. If charging station J-23500-01 is not being container. If no discharge occurs, check for used, discharge the system by slowly missing or defective schrader depressor in connecting a gage hose to the low side the hose fitting.
Page 87: Ccot Refrigerant Oil D Is Trib U Tio
1B-24 AIR CONDITIONING • If a new accumulator is installed add 90 ml num ber 4 and CCOT R e frig eran t Oil (3 ounces) additional oil to compensate for D is trib u tio n fo r s p e c ific q u a n tity that absorbed by the original accumulator instructions).
Page 88: Vacuum System C H E C
AIR CONDITIONING 1B-25 VACUUM SYSTEM CHECK • SLOWLY open high and low side gage valves and begin vacuum pum p operation. Pump the system until the Before connecting the vacuum pump to the A/C low side gage reaches 459 - 475 mm system run the pump connected to the low pressure (28 to 29 inches of mercury [vacuum]) gage to determine the vacuum pump capability.
Page 89: Accum Ulator A S S E M B
1B-26 AIR CONDITIONING CAUTION: Never remove a gage line from its ACCUMULATOR ASSEMBLY adapter when the line is connected to the A/C system. Always remove the line adapter The a c c u m u la to r a s se m b ly has a s e rv ic e from the service fittin g to disconnect a line.
Page 90: Evaporator
AIR CONDITIONING 1B-27 DIAGNOSIS FOR MALFUNCTIONING VALVE 2. Discharge Line—A restriction will cause the Use the follo w in g procedure to determ ine a pressure relief valve to open. malfunctioning valve. 3. Liquid Line—A restriction will be caused by low 1.
Page 91: On Vehicle Service
1B-28 AIR CONDITIONING ON VEHICLE SERVICE F-00157 Figure 24—C-K C om pressor M o unting C om ponent View L6 (4.8 Liter) Gas Engine Important COMPRESSOR REPLACEM ENT (C-K) • Use new seals (o-rings) coated with clean refrigeration oil. Remove or Disconnect (Figures 24, 25, 26 and 5.
Page 92: Compressor Belt Tension Adjustm Ent (G And Motor Home Chassis M O D E
AIR CONDITIONING 1B-29 F-00158 Figure 25—C-K Compressor Mounting Component V6 and V8 (4.3 and 5.0 Liter) Gas Engines 9. Engine oil tube support bracket bolt and nut. 6. Compressor belt. 10. Clutch ground lead. 11. Compressor. Adjust Im portant • Refer to COOLING (SEC. 6B) •...
Page 93 1B-30 AIR CONDITIONING V8 (7.4 Liter) Gas Engine - Federal Emissions C-K Series Compressor Mounting Component View V8 (7.4 Liter) Gas Engine - California Emissions F-00159 Figure 26—C-K Compressor Mounting Component View V8 (7.4 Liter) Gas Engine...
Page 94 AIR CONDITIONING 1B-31 F-00160 Figure 27—C-K Compressor M ounting Component View V8 (6.2 Liter) Diesel Engine Figure 28—G Compressor Mounting Component View V8 (5.7 Liter) Gas Engine...
Page 95: Ccot A/C System-C-K S E R Ie
1B-32 AIR CONDITIONING F-00152 Figure 29—G Compressor Mounting Component View V8 (6.2 Liter) Diesel Engine CCOT A/C SYSTEM— C-K SERIES CONDENSER REPLACEMENT Remove or Disconnect (Figure 30) 1. Battery ground cable. 2. Discharge the system. 3. Grille assembly. 4. Radiator grille center support. 5.
Page 96: Accumulator Replacement
AIR CONDITIONING 1B-33 84 oc 81 I I 8,5 109- 80. Harness Assembly 96. Nut 81. Resistor 70. Condenser 82. Screw 97. Hose 83. Screw 98. Clip 84. Tank 99. Screw 85. Screw 100. Clamp 86. Hose 101. Cap 87. Bolt 103.
Page 97: Blower Assembly Replacement
1B-34 AIR CONDITIONING 105. Relay 110. Accum ulator Dehydrator Assembly 120. Screw Grommet Case 123. Grommet 124. Core 125. Clamp 126. Screw Rivet Bracket 129. Plate 130. Orifice Gasket Motor Assembly 133. Hose 134. Wire Assembly 135. Switch Assembly 136. Case 137.
Page 98: O Rifice (Expansion Tube) R E P Lace M E N
AIR CONDITIONING 1B-35 umiHinumjm ^ ^ < 1 5 3 } 47 148 149 150 ^ — 152 •i 4=^) ^154 53. Actuator 154. Connector 145. Valve 146. Housing 155. Screw 163. Valve 156. Bracket 147. Screw 164. Nut 148. Core 157.
Page 99 1B-36 AIR CONDITIONING 180. Adapter 181. Screw 193. Retainer 182. Adapter 194. Adapter 183. Hose 195. Felt 184. Duct Assembly 196. Deflector 185. Screw 197. Outlet 186. Duct Assembly 198. A ir Conditioning Assembly 187. Seal 199. Bolt 188. Seal 200.
Page 100: Selector Duct And Heater Core R E P La Ce M E N
AIR CONDITIONING 1B-37 Figure 36—Actuator-Plenum Side Vent ♦«“ Install or Connect (Figures 4 and 33) 3. Heater hoses from the core tubes (148). • Plug the core tubes to prevent spillage. 1. Expansion tube seal (o-ring) to the core inlet line. 4.
Page 101: Actuator-Plenum Side Vent R E P Lace M E N
1B-38 AIR CONDITIONING Figure 39—C-K Control Assembly 8. Center duct to selector duct. 9. Instrument panel bar and door. 10. Heater hoses. 11. Coolant to the radiator. 12. Battery ground cable. Adjust T e m p eratu re d oo r c a b le .
Page 102: Plenum Valve Replacement
AIR CONDITIONING 1B-39 3. Actuator bracket mounting screws. CONTROL ASSEMBLY 4. Cam to actuator arm screw (213). REPLACEMENT 5. Actuator and bracket from the cam. 6. Actuator to bracket nuts. + + Remove or Disconnect 7. Actuator from the bracket (53). 1.
Page 103: Cable A D Ju Stm E N
1B-40 AIR CONDITIONING TEMPERATURE DOOR CABLE ADJUSTMENT A djust (Figure 38) 1. Remove instrument panel compartment and door. 2. Loosen the cable attaching screw at the selector duct assembly. • Make sure the cable is installed in the bracket on the selelctor duct assembly. 3.
Page 104 AIR CONDITIONING 1B-41 C36 And C60 C36, C60 And K34 7. Vacuum Hose 260. Rear Heater Harness 261. K34 Vacuum Harness C36 Or C60 F-00353 Figure 43—C-K Vacuum Hose - Diesel Engine...
Page 105: Blower Motor Resistor R E P La Ce M E N
1B-42 AIR CONDITIONING 266. Plenum Valve (Actuator) 7. Vacuum Harness 267. Recirc A ir Valve (Actuator) 53. Actuator 268. Heater Assembly 236. Cable E. Vacuum Line—Gray To Source 269. A ir Cond. Valve (Actuator) 244. Cam F. Vacuum Line—Orange 270. Defrost (Actuator) 265.
Page 106 AIR CONDITIONING 1B-43 Figure 47—C-K V8 (5.0 Liter and 5.7 Liter) Refrigerant Hose Assembly...
Page 107 1B-44 AIR CONDITIONING Figure 49—C-K V8 (6.2 Liter - Diesel) Refrigerant Hose Assembly...
Page 108: Blower Motor Relay Replacement
AIR CONDITIONING 1B-45 Install or Connect (Figure 31) BLOWER MOTOR RELAY REPLACEMENT 1. Relay (105). 2. Mounting screws. The blower motor relay is located on the blower side 3. Wiring harness. of the blower-evaporator case. FUSE REPLACEMENT Remove or Disconnect (Figure 31) □...
Page 109: Expansion Valve R E P La Ce M E N
1B-46 AIR CONDITIONING 301. Washer 306. Deflector 302. Screw 307. Outlet 303. Shroud 308. Bracket 304. Screw 309. Nut 305. Clip 310. Screw F-00224 Figure 50—C-K Rear Interior Roof Mounted A/C Shroud Im portant EXPANSION VALVE REPLACEMENT • Before removing the case screws, support the lower case and motor assemblies to This system incorporates an expansion valve which prevent damage to the case or motor...
Page 110 AIR CONDITIONING 1B-47 320. Screw 333. Bracket 321. Bracket 334. Screw 322. Screw 335. Seal 323. Screw 336. Case 324. Support 337. Clip 325. Screw 338. Seal 326. Case 339. Core Asm. 327. Plate 340. Seal (O-ring) 341. Refrigerant Lines 328.
Page 111: Evaporator Core R E P La C E M E N
1B-48 AIR CONDITIONING 366. Clip 367. Clip 351. Fittings 356. Bracket 361. Hose Assembly 368. Screw 352. Clip 357. Screw 362. Seal 369. Hose Assembly 353. Screw 358. Clamp 363. Screw 370. Hose Assembly 354. Cover 359. Hose 364. O-ring 371.
Page 112: Blower Motor Switch Replacement
AIR CONDITIONING 1B-49 • Use new seals (o-rings) coated with clean «--► Remove or Disconnect rerfrigeration oil. Battery ground cable. 4. Sensing bulb to the evaporator outlet line (342). • Bulb must make good contact with the line. Switch retaining screws. •...
Page 113: Heater Core R E P La Ce M E N
1B-50 AIR CONDITIONING ^ = a r = 70. Condenser Assembly 401. Material (Trim) 402. Hose Assembly 411. Screw 403. Clip 413. Nut 404. Screw 414. Grommet 405. Fitting Assembly 415. Strap 406. Fitting Assembly 416. Screw 407. Seal (O-ring) 417.
Page 114 AIR CONDITIONING 1B-51 456. Valve Assembly 457. Core 458. Clamp 459. Valve 460. Shaft 461. Connector 462. Link 463. Connector 464. Shaft 465. Valve Assem bly 466. Valve Assembly 467. Case 468. Duct 470. Housing 471. Retainer 472. Duct 473. Seal 474.
Page 115 1B-52 AIR CONDITIONING Figure 55—G Blower Motor Cover (Diesel) 9. Heater distributor duct. 17. Heater core (457). 10. Defroster duct to dash panel attaching screws (below the windshield). Install or Connect (Figure 54) 11. Heater hoses (457). • Plug to prevent spillage. 1.
Page 116 AIR CONDITIONING 1B-53 491. Control Assembly 495. Defroster Duct 496. Temperature Cable 497. Heater And Defroster Assembly 498. Bracket 499. Retainer F-00324 Figure 57—Temperature Control Cable Orange Double Black Stripe Wire 491. Control Assembly 495. Defroster Duct 501. Body Wiring Harness 502.
Page 117: O Rifice (Expansion Tube) R E P Lace M E N
1B-54 AIR CONDITIONING Figure 59—Vacuum Harness Assembly ORIFICE (EXPANSION TUBE) 3. Expansion tube from the evaporator core inlet line. REPLACEMENT • Use a needle nose pliers to remove the orifice from the tube. The orifice tube is located in the evaporator core 4.
Page 118: Evaporator Core (W/Diesel) R E P La C E M E N
AIR CONDITIONING 1B-55 502. A/C Harness 510. Resistor Assembly 418. Compressor 511. Relay Assembly 433. Motor 512. Junction Block 435. Accumulator/Dehydrator Assembly 513. Throttle Solenoid 497. Evaporator Blower Motor Assembly F-00327 Figure 61—A/C W iring - Engine Compartment im portant Remove or Disconnect (Figure 55) •...
Page 119: Evaporator Core R E P La C E M E N
1B-56 AIR CONDITIONING 525. Duct Assembly 531. Screw 537. Heater Assembly 543. Seal 526. Screw 532. Seal 538. Support 544. Duct 527. Duct Assembly 533. O utlet Assembly 539. Outlet Assembly 545. Nut 528. Washer 534. Gasket 540. Screw 546. Duct 529.
Page 120: Blower Motor Replacement
AIR CONDITIONING 1B-57 Vacuum Hood Vacuum Line Vacuum Fitting F-00328 Figure 64—G - V6 (4.3 Liter) Vacuum Tank Assembly 6. Accumulator inlet and outlet lines. 5. Bracket at the evaporator case. 6. Right marker lamp for access. 7. Two brackets that hold the accumulator to the case.
Page 121: Control Assembly R E P La Ce M E N
1B-58 AIR CONDITIONING 4. Blower motor lead wire. 4. Instrument panel bezel. 5. Motor and wheel assembly (433). 5. Headlmap switch control knob. • Five blower motor mounting screws. 6. Battery ground cable. • Pry gently on the blower flange if the sealer acts as an adhesive.
Page 122: Blower Motor Relay Replacement
AIR CONDITIONING 1B-59 502. A/C Wiring Harness 550. Vacuum Tank 552. Vacuum Line __ - C36 And C60 Figure 65—G - V8 (5.0 and 5.7 Liter) Vacuum Tank BLOWER MOTOR RELAY • Pull the right side of the instrument panel rearward.
Page 123: Vacuum Tank Replacem Ent
1B-60 AIR CONDITIONING VACUUM TANK REPLACMENT VACUUM LINES ENGINE COMPARTMENT |+ + | Remove or Disconnect (Figures 63 and 65) For vacuum line assemblies, refer to figures: 1. Raise the hood. 1. L6 Engine (4.6 Liter) (figure 64). 2. Vacuum harness at the tank (552). 2.
Page 124: Liter
AIR CONDITIONING 1B-61 Figure 66—G - V8 (6.2 Liter - Diesel) Vacuum Hose Assembly...
Page 125: Rear Interior Roof Mounted Systems-G S Eries
1B-62 AIR CONDITIONING 70. Condenser 97. Refrigerant Hose 107. Evaporator and Blower Assembly 275. Compressor «------ 276 276. Radiator F-00325 Figure 67-----L6 (4.8 Liter) Refrigerant Hose Assembly 70. Condenser 97. Refrigerant Hose 107. Evaporator And Blower Assembly 275. Compressor 276. Radiator F-00387 Figure 69—G - V8 (6.2 Liter - Diesel) Refrigerant Hose...
Page 126 AIR CONDITIONING 1B-63 401. Hose Assembly 107. Evaporator and Blower Assembly 565. Rear Evaporator and Blower Assembly 566. Hose Drain 567. Hose Outlet 568. Hose Inlet 569. Hose and Plate Assembly F-00283 Figure 70—G Rear Interior Roof Mounted A/C Hoses and Drain Component View 575.
Page 127: Ccot A/C System-P S E R Ie
1B-64 AIR CONDITIONING CCOT A/C SYSTEM — P SERIES F-00369 Figure 72—P Truck Condenser Installation Figure 73—P Truck Compressor Installation V8 (5.7 Liter) Engine The compressor and condenser are installed on the vehicle during assembly. They are removed and shipped separately. For reference refer to the following figures: 1.
Page 128: Receiver-Dehydrator Replacement
AIR CONDITIONING 1B-65 900. Retainer 901. Washer 902. Glass 903. Seal F-00397 Figure 76—Sight Glass Replacement |+ + | Install or Connect (Figure 75) 1. Bracket and receiver-dehydrator. 2. Screws. 3. Inlet and outlet lines at the receiver-dehydrator. • Use new seals (o-rings) coated with clean re frig e ra tio n oil when c o n n e c tin g all refrigerant lines.
Page 129: Blower-Evaporator Assembly R E P La C E M E N
1B-66 AIR CONDITIONING P . Correct Blower Blade Angle F-0040Q Hose Assem blies Evaporator Assembly Motor Blower Assembly Figure 79—Blower Assembly A/C W iring Harness F-00398 10. Unit mounting bolts. 11. Unit from the vehicle carefully pulling the compressor electrical lead through the dash. Figure 77—Blower - Evaporator Assembly -►*- Install or Connect (Figures 77 and 78) BLOWER-EVAPORATOR...
Page 130: Expansion Valve, Evaporator And/Or Evaporator Case Replacement
AIR CONDITIONING 1B-67 920. Thermostatic Switch Capillary Tube 922. Bumper 923. Blower Switch 924. Thermostatic Switch F-00411 920. Thermostatic Switch 922. Bumper Figure 81—Therm ostatic and Blower Switches Capillary Tube 923. Expansion Valve 921. Screen Mesh p 0041Q THERMOSTATIC AND/OR BLOWER SWITCHES Figure 80—Therm ostatic and Blower Switches REPLACEMENT...
Page 131: S Pecifica Tio
1B-68 AIR CONDITIONING SPECIFICATIONS A-6 COMPRESSOR Type................................6 Cylinder Axial Displacement...............................12.6 Cu. In. Rotation................................... Clockwise SYSTEM CAPACITIES R efrigerant........................1 587 6 kg (3 lbs. 8 ounces) 525 Viscosity Compressor O i l ....................330 ml (11 ounces) TORQUE SPECIFICATIONS Compressor Suction and Discharge Connector B o lt ..............24 N m (18 ft.
Page 132 AIR CONDITIONING 1B-69 SPECIFICATIONS (CONT.) Amps Volts (Cold) (Cold) Blower Motor C-K All Weather 12.0 12.8 Maximum 3400 Minimum C-K-G Rear Interior Roof Mounted G Floor and Motor Home Units 12.0 13.7 Maximum 3400 Minimum Compressor Clutch Coil Ohms (at 80° F ) ................................3.70 Amps (at 80°...
Page 133 2A-1 SECTION 2 FRAME AND CHASSIS SHEET METAL CONTENTS SUBJECT PAGE F ra m e ..................................... 2A-1 B u m p e rs ..................................2B-1 Sheet M etal..................................2C-1 SECTION 2A FRAME CONTENTS SUBJECT PAGE C/K And P Model F ra m e s ............................2A-1 D e s c rip tio n ................................
Page 134: D Iagnosis
2A-2 FRAME 9. TRACKING—This refers to the alignment of the 6. DIAMOND—This refers to the condition where vehicle axles with each other. A misaligned frame one entire frame rail is moved forward from, or to can cause improper tracking. If the vehicle is the rear of, its correct alignment with the other tracking correctly, all axles will be parallel to each rail.
Page 135: Minim Izing Frame S E Rv Ic
FRAME 2A-3 DIAGNOSIS OF THE FRAME (CONT.) PROBLEM POSSIBLE CAUSE CORRECTION Sidesway 1. A collision involving the vehicle. 1-4. Straighten and reinforce the frame as 2. A fire involving the vehicle. described later in this section. See 3. The use of equipment such as snow “...
Page 136: Checking Frame A Lig N M E N
2A-4 FRAME Figure 1—C/K And P Model Frames It is possible to check certain portions of frame • Do not cut holes with a torch. alignment without the proper gages. The procedure is • Do not overheat the frame rails. described later in this section.
Page 137: Straightening Fram
FRAME 2A-5 b. Using a plumb bob, transfer the remaining determine the correct sequence of steps in the repair. points from the outside of the web to the (See “ Possible Causes” under “ Diagnosis” and floor. Mark the points. The actual placement “...
Page 138: W E Ld In
2A-6 FRAME Over-welding can be harmful, especially if it is in an area of the frame that receives high concentrations of stress. Small cracks in a crossmember may be welded (see “ Repairing Cracks” previously outlined in this section). When welding: 1.
Page 139: G Model Underbody
FRAME 2A-7 G MODEL UNDERBODY 15. Front Gage Holes 16. Rear Gage Holes A. 789.4 mm (31.08-inch) B. 1041.4 mm (41.0-inch) C. 1340 mm (52.76-inch) D. 1041.4 mm (41.0-inch) E. 126 mm (4.96-inch) F. 123 mm (4.8-inch) L. 1465 mm (57.66-inch) 110-inch wheelbase G.
Page 140 BUMPERS 2B-1 SECTION 2B BUMPERS CONTENTS SUBJECT PAGE C/K Model B um pers..............................2B - 1 Front Bumper Replacement..........................2B - 1 Rear Bumper Replacement (U tility Vehicle and S u b u rb a n )................. 2B- 4 Rear Bumper Replacement (Regular Cab, Bonus Cab, and Crew C a b ) ............2B- 6 Rear Step Bumper Replacem ent.........................
Page 141 2B-2 BUMPERS Tighten Tighten • Bolts to 50 N m (37 ft. lbs.). • Nuts to 95 N m (70 ft. lbs.). 4. Bumper bolts (6) onto the bumper. 3. Brace bolts and washers (17 and 18) through the 5. Rub strips to the bumper and guards (where frame rails and into the braces.
Page 142 BUMPERS 2B-3 4. Brace 5. Bracket 11. Bolt 12. Washer 13. Nut 14. Nut 15. Washer 16. Bolt 17. Bolt 18. Washer 19. Washer 20. Tow Hook A. Frame B. Weld Nut F-00131 Figure 4—C/K Front Bumper Brackets, Braces, and Tow Hooks...
Page 143: Rear Bumper Replacement (Utility Vehicle And Suburban)
2B-4 BUMPERS 21. Nut Brace Bracket 25. Washer 27. Nut 28. Washer Bolt 30. Bolt 31. Bumper Bar Bolt F-00132 Figure 5—U tility Vehicle and Suburban Rear Bumper Components Tighten • Braces (22). 8. Bracket nuts, washers, and bolts (27, 28 and 29). •...
Page 144 BUMPERS 2B-S 31. Bumper Bar 33. Bar 34. “ U” Nut 35. Nut & Washer 36. Support 37. Bolt 38. Filler Panel F-00133 Figure 6—Rear Bumper Fiiler Strip • Place the filler panel bolts through the panel Tighten and into the support “ U” nuts. •...
Page 145: Rear Bumper Replacement (Regular Cab, Bonus Cab, And Crew Cab)
2B-6 BUMPERS 42. Brace 43. Nut 44. Spring Washer 45. Washer 46. Bracket 47. Washer 48. Spring Washer 49. Nut 50. Nut 51. Nut 52. Spring Washer 53. Bolt 54. Bolt 55. Bumper Bar F-00128 56. Bolt Figure 9—Regular Cab, Bonus Cab, and Crew Cab Rear Bumper Components •...
Page 146: Rear Step Bumper Replacement
BUMPERS 2B-7 REAR STEP BUMPER REPLACEMENT + + Remove or Disconnect (Figure 11) 1. Bracket to bumper nuts (63), and bolts (64). 2. Brace to bumper nuts (73), spring washers (72), washers (71), and bumper bolts. 3. Bumper from the vehicle. 4.
Page 147: Dead Weight Trailer Hitch Replacement (Utility Vehicle And Suburban)
2B-8 BUMPERS 60. Nut 61. Bolt 62. Bolt 63. Bolt 64. Bolt 65. Bracket 66. Reinforcement 67. Washer 68. Nut 69. Bolt 70. Brace 71. Washer 72. Spring Washer 73. Nut 74. Bumper Bar Figure 11—Rear Step Bumper Components ■+«- Install or Connect (Figure 12) DEAD WEIGHT TRAILER HITCH REPLACEMENT...
Page 148: Weight D Istribution Hitch Replacement (Suburban O N
BUMPERS 2B-9 31. Bumper Bar Bumper Bar 95. Bolt Bolt 96. Washer Washer 97. Nut 98. Washer Washer 99. Bolt Bolt 100. Nut 101. Washer 86 . Washer 102. Chain Bracket Chain Bracket 103. Bolt Bolt 104. Support Support 105. Bar Assembly Bar Assembly 106.
Page 149: Weight Distribution Hitch Replacement (Utility Vehicle Only)
2B-10 BUMPERS 31. Bumper Bar 31. Bumper Bar 110. Nut 119. Nut 111. Washer 120. Washer 112. Bolt 121. Nut 113. Washer 122. Washer 114. Spring Washer 123. Washer 115. Bolt 124. Spring Washer 116. Nut 125. Bolt " 117. Washer 126.
Page 150: P Model Bumpers
BUMPERS 2B-11 P MODEL BUMPERS Washer 129. Spring Washer 130. 131. 132. Bracket 133. Washer 141 140 134. Spring Washer 138. Washer 135. 139. Brace 136. 140. Washer 142. Spacer 137. Spring Washer 141. Bolt 143. Bumper Bar Figure 17—P-Front Bumper Components Tighten FRONT BUMPER REPLACEMENT...
Page 151 2B-12 BUMPERS • Brackets (162). 5. Brace to bumper nuts (155), spring washers (156), washers (157), and bolts (161). • Braces (158). +«- Install or Connect (Figures 19 and 20) 1. Braces to the bumper with bolts (161), washers (157), spring washers (156), and nuts (155). Tighten •...
Page 152: Front Bumper Replacement
BUMPERS 2B-13 158. Brace 159. Bumper Bar 160. Washer 161. Bolt 162. Bracket 164. Washer 165. Spring Washer 166. Nut 167. Bolt 168. Washer 169. Washer 170. Nut 171. Nut 172. Spring Washer 173. Washer 174. Spacer F-00127 Figure 20—P-Front Bumper Braces, and Brackets (RPO FS3 Front Axle) G MODEL BUMPERS FRONT BUMPER Install or Connect (Figures 21 and 22)
Page 153: Rear Bumper Replacement
2B-14 BUMPERS 175. Bumper Bar 176. Brace 177. Bracket 178. Nut 179. Bolt 180. Nut 181. Bolt 182. Bolt F-00108 Figure 21—G-Front Bumper Components Tighten REAR BUMPER REPLACEMENT • Bolts to 41 N m (30 ft. lbs.). Remove or Disconnect (Figure 23) 7.
Page 154: Rear License Plate Bracket R E P Lace M E N
BUMPERS 2B-15 191. Bolt 186. Outer Brace 192. Nut 187. Washer 193. Bolt 188. Bolt 194. Bolt 189. Bracket 195. Bumper Bar 190. Inner Brace 196. Bolt F-00110 Figure 23—G-Rear Bumper Components Tighten Tighten • Bolts to 41 N m (30 ft. lbs.). •...
Page 155: Weight Distribution Hitch Replacement
2B-16 BUMPERS Tighten WEIGHT DISTRIBUTION HITCH REPLACEMENT • Bar assembly to chain bracket nut to 68 N m (50 ft. lbs.). □ Remove or Disconnect (Figure 26) • Bar assembly to hitch bracket bolt to 68 N m (50 ft. lbs.). 1.
Page 156 BUMPERS 2B-17 Figure 26—W eight D istribution Hitch 3. Front bolts and washers. 3. Rear washers and nuts. 4. Hitch from the vehicle. Install or Connect (Figure 26) • Nuts to 63 N m (47 ft. lbs.). 1. Hitch to the vehicle. 4.
Page 157 2C-1 SECTION 2C SHEET METAL NOTICE: All hood latch fasteners are im portant attaching parts in that they could affect the perform ance of vital parts and systems, and/or could result in major repair expense. They must be replaced w ith one of the same part number of w ith an equivalent part if replacement becomes necessary.
Page 158: C/K Models
2C-2 SHEET METAL C/K MODELS Tighten • Bolts to 25 N m (18 ft. lbs.). SPRING ASSEMBLY REPLACEMENT ♦♦ Remove or Disconnect (Figure 1) • Raise and support the front of the hood. 1. Spring assembly to hood bolts (4). 2.
Page 159: Primary Hood Latch Replacement
SHEET METAL 2C-3 Figure 2—Hood Primary Latch Components Install or Connect (Figure 2) • Bolts to 25 N m (18 ft. lbs.). 1. Bracket to the radiator support. 4. Cowl vent grille. Refer to “ Cowl Vent Grille 2. Bracket to support bolts (10) loosely. Repacement.”...
Page 160: Secondary Hood Latch And Spring Replacement
2C-4 SHEET METAL HOOD RELEASE CABLE REPLACEMENT + + Remove or Disconnect (Figure 4) • If the cable is broken, release the hood by pressing the primary latch tab on the right side of the lock assembly. Use a rod to press the tab. •...
Page 161: Cowl Vent Grille Replacement
SHEET METAL 2C-5 3. Cowl vent grille plastic fasteners from the COWL VENT GRILLE windshield frame. REPLACEMENT 4. Cowl vent grille from the vehicle. + + Remove or Disconnect (Figure 6) Install or Connect (Figure 6) 1. Wiper arms. 1. Cowl vent grille to the vehicle. 2.
Page 162 2C-6 SHEET METAL 29. Radiator Grille 30. Bolt 31. Radiator Support 32. Bolt 33. Nut 34. Nut 35. Bolt 36. Side Molding 37. Nut 38. Bolt 39. Bolt 40. Bolt 41. Lower Molding 42. Lower Radiator Grille 43. Upper Molding 44.
Page 163: Front Fender Replacement
SHEET METAL 2C-7 + + Install or Connect (Figure 7) Lower radiator grille to the vehicle. Lower radiator grille to the sheet metal support bolts (40). Lower radiator grille to fender bolts (38). Upper molding to the radiator support with clips (44), and nuts (33).
Page 164: Wheelhouse Panel Replacement
2C-8 SHEET METAL 3. Upper fender to the door pillar bolt (48) and 7. Wheelhouse panel to underbody shield bolts. shim(s) (46) as required. 8. Wheelhouse panel reinforcement to underbody • Assemble loosely. bolts (52) and (53). 4. Fender to cowl bolt (47) and shim(s) (46) as 9.
Page 165: Rear Fender Replacement
SHEET METAL 2C-9 3. Cross sill to brace bolt (63). 11. Wheelhouse panel from the vehicle. • Slide the panel forward to clear the lower • Assemble loosely. back side of the fender well. 4. Brace (58) to the vehicle. •...
Page 166 2C-10 SHEET METAL Figure 10—Fenderside Rear Fender Attachm ent Figure 11—Dual Rear Wheel Rear Fender Attachment...
Page 167: Radiator Support Replacement
SHEET METAL 2C-11 Bolt Washer Retainer Cushion - Upper Bracket Cushion - Lower Retainer Radiator Support B-07280 Figure 12—Radiator Support Mounting Radiator support to frame nuts (80), lower RADIATOR SUPPORT re taine rs (79), lower cushions (78), upper REPLACEMENT cushions (76), retainers (75), bolts (73), and washers (74).
Page 168: Sheet Metal Unit R E P La Ce M E N
2C-12 SHEET METAL 6. Sheet metal support to radiator support bolts. 11. Wheelhouse panel to fender bolts (50). 12. Fender to cowl bolts (47). Tighten 13. Upper fender to door pillar bolt (48). 14. Wheelhouse panel to shield bolts. • Bolts to 17 N-m (13 ft. lbs.). 15.
Page 169 SHEET METAL 2C-13 82. Hood 83. Fender 84. Door 85. Cowl Vent Grille 86. Rocker Panel 87. Radiator Support Upper Panel A. Flush Fit B. Flush + or - 1mm (0.03-inch) C. Flush + 0.00 mm or - 1.5 mm (0.00-inch or -0.06-inch) D.
Page 170: Sheet Metal A Djustm E N
2C-14 SHEET METAL 17. Radiator to the vehicle. Refer to ENGINE 3. Align the hood with the cowl vent grille, so that COOLING (SEC. 6B). there is a gap of 8 mm ± 1 mm (0.31-inch ± 0.03-inch) between the rear edge of the hood and 18.
Page 171: Primary Hood Latch R E P La Ce M E N
SHEET METAL 2C-15 PRIMARY HOOD LATCH REPLACEMENT NOTICE: See “Notice” on page 2C-1 of this section. + + Remove or Disconnect (Figure 15) Adjust • Raise and support the hood. 1. Hood latch release cable from the latch. 1. Hood latch bracket left and right until the striker 2.
Page 172: Secondary Hood Latch And Spring Replacement
2C-16 SHEET METAL HOOD RELEASE CABLE REPLACEMENT Remove or Disconnect (Figure 17) □ • If the cable is broken, release the hood by pressing the primary latch tab on the right side of the lock assembly. Use a rod to press the tab. •...
Page 173 SHEET METAL 2C-17 101. Bolt F-07277 Figure 18—Cowl Vent Grille Components...
Page 174: Grille Replacement
20-18 SHEET METAL 107. Grille B-07287 108. Nut Figure 19—Radiator Grille GRILLE REPLACEMENT 4- + Remove or Disconnect (Figures 19 and 20) • Raise and support the hood. 1. Headlamp bezels. 2. Sheet metal cross panel to grille bolts. 3. Grille to lower front end panel boits. Figure 21—Front End Sheet Metal Cross 4.
Page 175: Sheet Metal Vertical Support Replacement
SHEET METAL 2C-19 4. Air intake snorkel. 5. Upper radiator mount to sheet metal cross panel bolts. 6. Upper radiator mounts. 7. Sheet metal cross panel to fender bolts (114). 8. Sheet metal cross panel to the hood latch bracket bolts (91).
Page 176: Front End Panel Replacement
2C-20 SHEET METAL Tighten • Bolt to 10 N-m (7 ft. lbs.). Grille. Refer to “ Grille Replacement.’ FRONT END PANEL REPLACEMENT Remove or Disconnect (Figure 23) 1. Headlamp bezels. 2. Grille. Refer to “ Grille Replacement.” 3. Front end panel to headlamp bezel support bolts 116.
Page 177 SHEET METAL 2C-21 SPECIFICATIONS TORQUE Ft. Lbs. C/K Models Hood Hinge to Hood B o lts ....................Hood Hinge to Cowl Bolts..................... Spring Assembly to Hood B o lts ..................Spring Assembly to Fender B o lts..................Primary Hood Latch Bracket to Radiator Support B o lts ..........Bracket to Primary Hood Latch B olts..................
Page 178 3A-1 SECTION 3 STEERING, SUSPENSION, WHEELS AND TIRES CONTENTS SUBJECT PAGE Front End A lig n m e n t..............................3A-1 Steering L in k a g e ................................3B1-1 Manual S te e rin g ................................3B2-1 Power S tee rin g ................................3B3-1 Steering C o lu m n ................................3B4-1 Front S uspension................................3C-1 Rear S u s p e n s io n ................................3D-1...
Page 179 3A - 2 FRONT END ALIGNMENT DESCRIPTION CASTER (Figure 1) “ Front End Alignment” refers to the angular relation Caster is the tilting of the wheel axis either forward ship between the front wheels, the front suspension attaching parts and the ground. or backward from the vertical (when viewed from the side of the vehicle).
Page 180 FRONT END ALIGNMENT 3A-3 ON-VEHICLE SERVICE Front View Side View A minus B .. .Camber (Inches) C . .Camber (Degrees Positive) D . . .Caster (Degrees Positive) E minus F ..Toe-In (Inches) B-07371 Figure 1—Caster - Camber - Toe-In INSPECTION 8.
Page 181 3A-4 FRONT END ALIGNMENT Subtract shims here to increase caster Camber Add shims here to increase caster Add shims equally to increase camber B-07372 Figure 2—Caster - Camber Adjustm ent Pivot Shaft Outboard Of Frame 3. Determine whether the frame angle is “ up in ALIGNMENT ADJUSTMENTS rear”...
Page 182 FRONT END ALIGNMENT 3A-5 A. Dimension “ BC” B. Jounce Bumper Bracket C. Crossmember A “ DOWN IN REAR” frame angle must be SUB A “ DOWN IN REAR” frame angle must be ADDED TRACTED from a POSITIVE caster reading. to a NEGATIVE caster reading.
Page 183 P200 + 300 P200 + 300 P30/3500 (42) Except (42) W/R05 P300 P300 (32) Dimension Dimension (32,42) G300 FS3, R05, Except FS3, w/JB8 or JB9 w/JB8 or JB9 K100 + 200 “ BC” “ BC” C100 C200 + 300 G100 + 200 Except FS3 W/FS3 (00)
Page 184 FRONT END ALIGNMENT 3A-7 SPECIFICATIONS (CONTINUED) CAMBER AND TOE-IN CHART Model Camber Toe Angle Total Toe-In C100 (00) 0.70° 0.36° 4.5 mm (0.18 inch) C200 + 300 (00) 0.25° + 1.5° K100 + 200 + 300 (00) Nominal (Reference only no means of adjustment provided).
Page 185 STEERING LINKAGE 3B1-1 SECTION 3B1 STEERING LINKAGE The following “ Notice” applies to one or more steps in the assembly procedure of components in this portion of the manual as indicated at appropriate locations by the terminology: “ NOTICE: See ‘Notice’ on page 3B1-1 of this section.”...
Page 186: Diagnosis Of Steering Linkage
3B1-2 STEERING LINKAGE DIAGNOSIS OF STEERING LINKAGE Refer to MANUAL STEERING (SEC. 3B2) or POWER STEERING (SEC. 3B3) in this manual, depending on vehicle equipment. ON-VEHICLE SERVICE 1. Idler Arm 2. Relay Rod 3. Tie Rod Assembly 4. Steering Knuckle 5.
Page 187: Idler Arm Adjustment (P30(32) Motorhome)
STEERING LINKAGE 3B1-3 1. Idler Arm 2. Relay Rod 3. Tie Rod Assem bly 4. Steering Knuckle 5. Pitman Arm 6. Steering Gear 7. Shock A bsorber 9. Bracket B-09659 Figure 2—Steering Linkage (G Model) IDLER ARM ADJUSTMENT IDLER ARM REPLACEMENT (P30(32) MOTORHOME) Important The frame mounted idler support assembly (10) is...
Page 188 3B1-4 STEERING LINKAGE Idler Arm Relay Rod Tie Rod Assembly Steering Knuckle Pitman Arm Steering Gear Shock Absorber Connecting Rod Support Assem blies Relay Arm Washer Grommet B-09656 Figure 3—Steering Linkage (P30(32) Motorhome) 3. Prevailing torque nut to the idler arm ball stud. -►«- Install or Connect (Figures 1 and 2) Tools Required: J-29193 Steering Linkage Installer (12mm).
Page 189: Relay Rod Replacement
STEERING LINKAGE 3B1-5 RELAY ROD REPLACEMENT Im portant • Use the proper tool to separate all tie rod and ball joints. + + Remove or Disconnect (Figures 1 through 3) Tool Required: J-24319-01 Steering Linkage Puller. • Raise the vehicle. Inspect 1.
Page 190: Pitman Arm Replacement
3B1-6 STEERING LINKAGE Tie Rod Assembly Steering Knuckle Pitman Arm Steering Gear Shock Absorber Connecting Rod Assembly B-07367 Figure 7—Steering Linkage (P30(00)FS3) Tighten Mark the pitman arm and the pitman shaft. This will permit proper alignment at assembly. • Nuts to “ Specifications” at the end of this section.
Page 191: Steering Shock Absorber Inspection
STEERING LINKAGE 3B1-7 A. Tie Rod Assem bly (K30) 3. Tie Rod Assembly 4. Steering Knuckle 5. Pitman Arm 7. Shock Absorber 8. Connecting Rod Assembly B-09660 Figure 8—Steering Linkage (K Model) 3. Relay rod (2) or connecting rod (8) to the pitman NOTICE: For steps 2 and 4 see ‘Notice”...
Page 192: Steering Shock Absorber Replacement
3B1-8 STEERING LINKAGE Inspect (Figures 2, 3, 7 and 8) Tighten 1. Shock absorber for fluid leakage. A slight film of • Castellated nut to “ S pecifications” as fluid is allowable near the shaft seal. If there is instructed at the end of this section. excessive fluid leakage, be sure it’s from the shock absorber and then replace the shock TIE ROD REPLACEMENT...
Page 193: Tie Rod Replacement (K And P30(00)Fs3 Models)
STEERING LINKAGE 3B1-9 Adjust • Toe-in. Refer to FRONT END ALIGNMENT (SEC. 3A) in this manual. 6. Adjuster tube clamp bolts (figures 10, 11 and 12). Before tightening the clamp bolts, be sure the following conditions have been met: • The clamp must be positioned between the locating dim ples at e ithe r end of the adjuster tube.
Page 194 3B1-10 STEERING LINKAGE VIEW A 4. Steering Knuckle C. Clamps Must Be Between And Clear Of Dimples Before Torquing Nuts D. Adjuster Tube Slot E. Slot In Adjuster Tube Must Not Be W ithin This Area Of Clamp Jaws. F. Rearward Rotation G.
Page 195: Connecting Rod Replacement (K And P30(00)Fs3 M O D E Ls)
STEERING LINKAGE 3B1-11 Clean Remove or Disconnect (Figures 7 and 8) — The tapered surfaces. Tool Required: J-24319-01 Steering Linkage Puller. — Threads on the ball stud and in the ball stud nut. • Raise the vehicle. 1. C astellated nuts and cotter pins from the + + Install or Connect (Figures 7 and 8) connecting rod (8).
Page 196: Connecting Rod Replacement (P30(32) Motorhome)
3B1-12 STEERING LINKAGE Tighten • Castellated nut to “ S pecifications” as instructed at the end of this section. 4. Outer connecting rod ball stud to the steering knuckle (4). 5. Castellated nut and cotter pin to the outer connecting rod ball stud. Tighten •...
Page 197 STEERING LINKAGE 3B1-13 C. Slot Of Adjuster Tube May Be In Any Position On Arc Shown But Not Closer Than 2.54 mm (0.10 Inch) To The Edge Of Clamp Jaws Or Between. Figure 14—Connecting Rod d a m p And Adjuster Tube P ositioning (K Model) Clean Im portant •...
Page 198: Specifications
SPECIFICATIONS Model P20 AND 30(42) G Model P30(32) otorhome P30(00)FS3 Model F t. Lbs. F t. Lbs. F t. Lb s. Ft. Lbs. F t. Lbs. F t. Lb s. Tie Rod (3) End To Steering Knuckle (4)* Tie Rod (3) Adjuster Tube Bolts —...
Page 199: Special Tools
STEERING LINKAGE 3B1-15 SPECIAL TOOLS J-6627-A Wheel Stud Remover & Tie Rod Remover Pitman Arm Remover J-6632-01 J-29107 Pitman Arm Puller J-24319-01 Steering Linkage Puller J-29193 Steering Linkage Installer (12mm) J-29194 Steering Linkage Installer ( 1 4 m m )
Page 200: Description
3B2-1 SECTION 3B2 MANUAL STEERING GEAR The following notice applies to one or more steps in the assembly procedure of components in this portion of the manual as indicated at appropriate locations by the terminology “ NOTICE: See ‘Notice’ on page 3B2-1 of this Section.”...
Page 201: Diagnosis Of Manual Steering System
3B2-2 MANUAL STEERING GEAR DIAGNOSIS OF MANUAL STEERING SYSTEM PROBLEM POSSIBLE CAUSE CORRECTION Rattle Or Chuckle In 1. Insufficient or improper lubricant in the 1. Add specified lube. The Steering Gear steering gear. 2. Pitman arm loose on the shaft or the 2.
Page 202: On-Vehicle Service
MANUAL STEERING GEAR 3B2-3 ON-VEHICLE SERVICE MAINTENANCE The steering gear is factory-filled with steering gear lubricant. Seasonal change of the lubricant should not be performed and the housing should not be drained. No additional lubrication is required for the life of the steering gear.
Page 203: Pitman Shaft Seal Replacement
3B2-4 MANUAL STEERING GEAR B-07353 Figure 3—Steering Gear Attachm ent (C-Models) 5. Steering gear to frame bolts. PITMAN SHAFT SEAL REPLACEMENT Tighten The pitman shaft seal may be replaced without removing the steering gear. Remove the pitman arm as • Bolts to 100 N m (75 ft. lbs.). outlined under “...
Page 204: Steering Gear Adjustments
MANUAL STEERING GEAR 3B2-5 Figure 6—Steering Gear Adjustm ent Points Remove or Disconnect • Place the pitman shaft in the steering gear so that the center tooth of the pitman shaft sector Tools Required: enters the center tooth space of the ball nut. J-6632-01 Pitman Arm Remover •...
Page 205: Steering Gear High Point Centering
3B2-6 MANUAL STEERING GEAR Important If maximum torque is exceeded, turn over ce n te r a d ju s te r screw counter-clockwise, then come up on adjustment by turning the jam nut (11) in a clockwise motion. -►4- Install or Connect 1.
Page 206: Specifications
MANUAL STEERING GEAR 3B2-7 SPECIFICATIONS MANUAL STEERING GEAR Manufacturer........................Saginaw Steering Gear R a tio ................................24 to 1 Type...............................Recirculating Ball PRELOAD ADJUSTMENTS In. Lbs. 0.6-1.0 Worm Thrust Bearing Preload 0.5-1.2* 4-10* Over Center Sector Preload 16 Max. Total Steering Gear Preload 1.8 Max.
Page 207 3B3-1 SECTION 3B3 POWER STEERING The following “ Notice” applies to one or more steps in the assembly procedure of components in this portion of the manual as indicated at appropriate locations by the terminology: “ NOTICE: See ‘Notice’ on page 3B3-1 of the section.”...
Page 208: Description
3B3-2 POWER STEERING DESCRIPTION 1. Pitman Shaft 2. Housing Ball Plug 3. Adjuster Plug 4. Stub Shaft 5. Torsion Bar 6. Adjuster Plug Nut 7. Return Line 8. Stud Bolt O-ring Seals 9. Reservoir 10. Reservoir Cap 11. Reservoir O-ring Seal 12.
Page 209 POWER STEERING 3B3-3 26. Adjuster Plug Seal Pitman Shaft 27. Torsion Bar Seal Adjuster Plug 28. Stub Shaft Seal Stub Shaft 29. Upper Thrust Bearing Torsion Bar 30. Valve Body Seal Rings And Backup O-Rings Gear Housing 31. Spool Valve Side Cover 32.
Page 210 3B3-4 POWER STEERING 4. Stub Shaft 48. Exit Hole 9. Reservoir 49. Orifice 10. Reservoir Cap 50. Filter 11. Reservoir O-Ring Seal 51. Pump Union 12. Shaft Seal 52. Seals 13. Pump Housing 53. End Plate 40. Dip Stick 54. Retaining Ring 41.
Page 211: Diagnosis Of Power Steering System
POWER STEERING 3B3-5 DIAGNOSIS OF POWER STEERING SYSTEM PROBLEM POSSIBLE CAUSE CORRECTION O bjectionable “ H iss” 1. Noisy relief valve in the hydraulic 1. There is some noise in all power pump. steering systems. One of the most common is a hissing sound most evi dent at standstill parking.
Page 212 3B3-6 POWER STEERING DIAGNOSIS OF POWER STEERING SYSTEM (CONT.) CORRECTION PROBLEM POSSIBLE CAUSE 1. Adjust to specifications. 1. Front end misaligned. Vehicle Leads To 2. Unbalanced steering gear valve. If this 2. Replace the gear valve. One Side Or The Other (Keep In Mind is cause, steering effort will be very The Road And Wind...
Page 213 POWER STEERING 3B3-7 DIAGNOSIS OF POWER STEERING SYSTEM (CONT.) PRO BLEM ’” POSSIBLE CAUSE CORRECTION Hard Steering Effort 5. Low fluid level in reservoir. 5. Fill to proper level. Inspect lines and In Both Directions joints for external leakage. (Continued) 6.
Page 214: Oil Leak Check
3B3-8 POWER STEERING DIAGNOSIS OF POWER STEERING SYSTEM (CONT.) CORRECTION POSSIBLE CAUSE PROBLEM 1. Adjust belt tension. 1. Loose belt. Chirp Noise In Steering Pump 1. Adjust belt tension. 1. Loose belt. Belt Squeal (Particularly Noticeable At Full Wheel Travel And Standstill Parking) 1.
Page 215 POWER STEERING 3B3-9 Replace the drive shaft seal. Make cer tain that the drive shaft is clean and free of pitting in the seal area. Replace the resen/oir O-ring seal. Torque hose fittin g nut to 35 N m (25 ft. lbs.).
Page 216 3B3-10 POWER STEERING B-07325 Figure 6—Tools For Power Steering System Test Tires for correct air pressure. Important Power steering system, replacing parts as • To prevent scrubbing flat spots on the tires, necessary. do not turn the steering wheel more than five times without rolling the vehicle to Im portant change the tire-to-floor contact area.
Page 217 POWER STEERING 3B3-11 flow control valve and recheck. If the replace the flow control valve in the pump. If the pressures are still low, replace the rotating pressure recorded is above the maximum group in the pump. specification listed, the flow control valve in the 8.
Page 218: Power Steering System On-Vehicle Service
3B3-12 POWER STEERING POWER STEERING SYSTEM ON-VEHICLE SERVICE 1. Place belt tension gage, J-23600-B or equivalent, MAINTENANCE midway between the pulleys on drive belts being checked. The hydraulic system should be kept clean and at regular intervals the pump steering fluid level in the •...
Page 219: Bleeding The Power Steering System
POWER STEERING 3B3-13 contact wheel stops or hold the wheel in a corner BLEEDING THE POWER or fluid will stop and the pump will be in pressure STEERING SYSTEM relief mode. A sudden overflow from the reservoir may develop if the wheel is held at a stop. When a power steering pump or gear has been 4.
Page 220: Power Steering Gear Replacement
3B3-14 POWER STEERING Figure 7—Steering Gear Installation 4. Steering gear frame bolts and the steering gear. POWER STEERING GEAR • Tap lightly, using a soft mallet, on the flexible REPLACEMENT coupling to remove the coupling from the steering gear stub shaft (C, K and P300(32) models). Remove or Disconnect (Figures 7 and 8) C, K And P300(32) Models •...
Page 221 POWER STEERING 3B3-15 Figure 8—Steering Gear Installation 2. Pinch bolt into the split clamp. The pinch bolt 5. Pitman arm. Refer to STEERING LINKAGE (SEC. must pass through the shaft undercut. 3B1). • Remove the plugs and caps from the steering Tighten gear and hoses.
Page 222: Pitman Shaft Seal Replacement
3B3-16 POWER STEERING 3. Pitman arm. Refer to STEERING LINKAGE (SEC. STEERING GEAR 3B1). ADJUSTMENTS • Remove the plugs and caps from the steering gear and hoses. 4. Hoses to the steering gear. Torque hose fittings to Im portant “ Specifications” at the end of this section. •...
Page 223 POWER STEERING 3B3-17 5. Rotate the adjuster plug back (counterclockwise) until the hole in the plug is aligned with the second mark on the housing (figure 12). 6. Install the adjuster plug nut (6). Tighten • Nut to 110 N m (81 ft. lbs.). Be sure the adjuster plug does not turn when tightening the nut.
Page 224: Power Steering Pump Replacement
3B3-18 POWER STEERING 8. The torque required to turn the stub shaft should be 0.45-1.13 N m (4-10 in. lbs.). If the reading is above or below the specified torque; the adjuster plug may not be tightened properly or may have Stub Shaft turned when the adjuster plug nut was tightened, Side Cover...
Page 225: Liter
POWER STEERING 3B3-19 • Loosen the pump adjusting bolts and nuts. 3. Pump belt. 4. Pump adjusting bolts, nuts and brackets. 5. Pump assembly. 6. Pulley from the pump. • Install J-29785-A. Be sure the pilot bolt bottoms in the pump shaft by turning the nut to the top of the pilot bolt.
Page 226: Liter
3B3-20 POWER STEERING Figure 18—Power Steering Pump Mounting V8 (6.2 Liter)
Page 227: Liter
POWER STEERING 3B3-21 P300(00) V8 (7.4 Liter) L6 (4.8 Liter) P000(42) JB6/JB7 CKOOO(OO) NB2 B 07447 Figure 19—Power Steering Pump Mounting...
Page 228: Liter
3B3-22 POWER STEERING GOOO(OO) N40 V8 (5.0 And 5.7 Liter) V6 (4.3 Liter) Excluding V8 (6.2 Liter) C. 84 N-m (62 Ft. Lbs.) D. 44 N-m (32 Ft. Lbs.) E. 34 N-m (25 Ft. Lbs.) F. 25 N-m (18 Ft. Lbs.) P000(42) V8 (5.7 Liter) B-07341 Figure 20—Power Steering Pump Mounting...
Page 229: Power Steering Hoses
POWER STEERING 3B3-23 B-07363 Figure 21—Installing And Removing Pulley • Place pulley on the end of the pump shaft POWER STEERING HOSES and install J-25033-B. Be sure the pilot bolt When either a hose is reinstalled or replaced, the bottoms in the shaft by turning the nut to the following points are essential: top of the pilot bolt.
Page 230 3B3-24 POWER STEERING Figure 23—Power Steering Hoses...
Page 231: Liter
POWER STEERING 3B3-25 CK200(00) L6 (4.8 Liter) VIEW A VIEW B CK300(00) L6 (4.8 Liter) VIEW B CKOOO(OO) V6 (4.3 Liter) V8 5.0 And 5.7 Liter) CK300(00) V8 (5.7 Liter) B-07448 Figure 24—Power Steering Hoses...
Page 232 3B3-26 POWER STEERING Figure 25—Power Steering Hoses...
Page 233: Liter
POWER STEERING 3B3-27 4 | FRT VIEW A G100 + 200 V8 (5.0 And 5.7 Liter) G300 V8 (5.7 Liter) LS9 Or LT9 With JB7 G100 + 200 + 300 V8 (5.0 And 5.7 Liter) G313(03) V8 (5.7 Liter) B-07345 Figure 26—Power Steering Hoses...
Page 234 3B3-28 POWER STEERING Figure 27—Power Steering Hoses...
Page 235: Liter
POWER STEERING 3B3-29 VIEW C P300(42) V8 (7.4 Liter) JB8/JF9 P300(42) L6 (4.8 Liter) JB8/JF9 B-07449 Figure 28—Power Steering Hoses...
Page 236 3B3-30 POWER STEERING Figure 29—Power Steering Hoses...
Page 237: Specifications
POWER STEERING 3B3-31 SPECIFICATIONS STEERING GEAR ADJUSTMENTS Valve Assembly And Seal D rag................0.1-0.4 N m (1-4 in. lbs.) Thrust Bearing Preload (In Excess Of Valve Assembly And Seal Drag)..0.3-0.4 N m (3-4 in. lbs.) Pitman Shaft Over Center Preload New G ear......................
Page 238 3B3-32 POWER STEERING SPECIFICATIONS (CONTINUED) PUMP SPECIFICATIONS Minimum Maximum Relief Valve Settings Part Output (1) Output (2) Minimum Maximum Vehicle Number Model G PM L/Min. L/M in. 7838933 132-P-122 1.32 5.00 3.1-3.5 11.7-13.2 1200 8274 1300 8964 7838934 132-P-123 1.32 5.00 3.1-3.5 11.7-13.2...
Page 239: Special Tools
POWER STEERING 3B3-33 SPECIAL TOOLS J-5176-D Power Steering Gage Power Steering Gage Adapter — 18 mm J-5176-20 J-5421-02 Pocket Thermometer (0°-220°F) Power Steering Analyzer J-25323 J-29525 Power Steering Analyzer Adapter Belt Tension Gage J-24600-B J-29107 Pitman Arm Puller Internal Snap Ring Pliers J-4245 Steering Gear Pitman Shaft Oil Seal Installer J-6219...
Page 240 3B4-1 SECTION 3B4 STEERING COLUMN The following “ Notice” applies to one or more steps in the assembly procedure of components in this portion of this manual as indicated at appropriate locations by the terminology “ See NOTICE on page 3B4-1 of this section.” NOTICE: All steering column fasteners are important attaching parts in that they could affect the perform...
Page 241: Description
3B4-2 STEERING COLUMN DESCRIPTION The locking energy absorbing steering column in The column may be disassembled and reassem cludes three important features in addition to the bled. To insure the energy absorbing action, it is impor steering function: tant that the specified screws, bolts and nuts be used 1.
Page 242 STEERING COLUMN 3B4-3 DIAGNOSIS OF THE STEERING COLUMN (CONT.) PROBLEM POSSIBLE CAUSE CORRECTION Lock Cylinder—High 1. Burr on tang of shift gate. 1. Remove the burr. E ffort Between The 2. Distorted rack. 2. Replace the rack. “ O ff” and “...
Page 243 3B4-4 STEERING COLUMN DIAGNOSIS OF THE STEERING COLUMN (CONT.) CORRECTION PROBLEM POSSIBLE CAUSE 1. Align correctly. High Shift Effort 1. Column assembly is misaligned in the vehicle. 2. Lower bowl bearing is not aligned cor 2. Align correctly. rectly. 3. Lack of grease on the bearing or seal 3.
Page 244 STEERING COLUMN 3B4-5 DIAGNOSIS OF THE STEERING COLUMN (CONT.) PROBLEM POSSIBLE CAUSE CORRECTION Steering Wheel Loose fit between the lock shoe and Replace both. Loose Every Other pivot pin. Tilt Position (Tilt Column) Steering Column 1. Lock shoe grooves may have burrs or 1.
Page 245 3B4-6 STEERING COLUMN DIAGNOSIS OF THE STEERING COLUMN (CONT.) CORRECTION PROBLEM POSSIBLE CAUSE 1. Remove material and/or parts. Turn Signal W ill Not 1. Foreign material or loose parts im pending movement of the yoke. Stay In Turn Position 2. Replace the spring. 2.
Page 246 STEERING COLUMN 3B4-7 DIAGNOSIS OF THE STEERING COLUMN (CONT.) PROBLEM POSSIBLE CAUSE CORRECTION Front Or Rear Turn 5. Disconnect column to the chassis con 5. Replace the turn signal switch. Signal Lights Are nector. Connect a new switch into the Not Flashing (Cont.) system and operate the switch by hand.
Page 247 3B4-8 STEERING COLUMN DIAGNOSIS OF THE STEERING COLUMN (CONT.) PROBLEM POSSIBLE CAUSE CORRECTION 1. Blown fuse. 1. Replace fuse and check operation. Hazard Signal Lights W ill Not Flash—Turn 2. Inoperative hazard warning flasher. 2. Replace the hazard warning flasher. 3.
Page 248 STEERING COLUMN 3B4-9 DIAGNOSIS OF THE STEERING COLUMN (CONT.) PROBLEM POSSIBLE CAUSE CORRECTION Tone Alarm Does 13. If the tone alarm fault has not yet been 13. With the fault isolated in the column, Not Sound With Key detected, connect a continuity meter disassemble the upper end of the col...
Page 249: Steering Column Electrical Component Analyzer
3B4-10 STEERING COLUMN tester will overhang the chassis connector. This does STEERING COLUMN ELECTRICAL not affect the test results. These terminals are for COMPONENT ANALYZER vehicles with cornering lights. Move the analyzer switch (with the key in the “ on” Use J-23980-B, the steering column electrical position) to the various functions that may be checked.
Page 250: Steering Wheel Replacement
STEERING COLUMN 3B4-11 3. Shift lever operation on vehicles with automatic 1. Steering wheel onto the steering shaft. Align the transmission and column shift. If the shift lever is marks made at removal. able to move to the “ Park” position without raising the lever, the upper shift tube plastic Important bearing is broken.
Page 251 3B4-12 STEERING COLUMN C. 346.7 mm (13.64 inches) CK MODEL (Tilt Column) D. 72 mm (2.8 inches) CK MODEL (Standard Column-Column Shift) E. 353 mm (14 inches) CK MODEL (Standard Column-Floor Shift) F. 81.7 mm (3.21 inches) G MODEL (Tilt Col umn-Column Shift) G.
Page 252: Intermediate Shaft Replacement
STEERING COLUMN 3B4-13 K. Inspect for sheared injected plastic in the A. Capturing Strap shift tube. B. Reinforcement L. Inspect for sheared injected plastic in the 1. Clamp Bolt C. Alignm ent Pins steering shaft. 2. Nuts And Washers D. Wafer B-07382 B-07385 Figure 3—Inspecting The Steering Column...
Page 253 3B4-14 STEERING COLUMN Figure 7—Intermediate Shaft Installation 1. Intermediate shaft lower yoke onto the steering gear worm shaft. Align the marks made at * F R T removal. 2. Pinch bolt. The pinch bolt must pass through the shaft undercut. Tighten •...
Page 254: Steering Column On-Vehicle Service (C, K And G M Odels)
STEERING COLUMN 3B4-15 4. Pinch bolt to the upper yoke assembly. The pinch Measure bolt must pass through the shaft undercut. Carden joint operating angle (G-Model). The Tighten a ng le m ust not exceed 39 d e g re e s maximum or 34 degrees minimum (figure Pinch bolt to “...
Page 255: G Model Steering Column Replacement
3B4-16 STEERING COLUMN Tighten • Nuts (10) to 24 N m (18 ft. lbs.). • Screws (7) and nuts (8) to 30 N m (22 ft. lbs.). 7. Seal (4) and covers (3, 5) to the dash. 8. Screws (6). •...
Page 256: Turn Signal Switch Replacement
STEERING COLUMN 3B4-17 Figure 12—Removing The Turn Signal Wire Protector 3. Screws (6) through the cover and seal to the dash panel. • Pull the switch connector out of the bracket on the jacket and feed switch connector through 4. Connectors to the steering column harness. column support bracket and pull switch straight •...
Page 257: Lock Cylinder Replacement
3B4-18 STEERING COLUMN • On non-tilt columns, be sure the wiring harness is on the protector. Feed the connector and cover down through the housing and under the mounting bracket. • On tilt columns, feed the connector down through the housing and under the mounting bracket. A.
Page 258: Tone Alarm Switch Replacement
STEERING COLUMN 3B4-19 4. S teering wheel. Refer to “ S teering Wheel Replacement” in this section. TONE ALARM SWITCH REPLACEMENT Remove or Disconnect □ 1. Steering wheel. Refer to “ S teering Wheel Replacement” in this section. • Pull the turn signal switch up far enough to allow access to the tone alarm switch.
Page 259: Standard Steering Column Unit Repair (C, K And G M O D E Ls )
3B4-20 STEERING COLUMN STANDARD STEERING COLUMN UNIT REPAIR (C, K AND G MODELS) + + Remove or Disconnect • On floor shift models remove the transmis sion control lock tube housing and shroud. • Steering column assembly. Refer to “ CK or G 16.
Page 260 STEERING COLUMN 3B4-21 49 I 47 B-07396 Figure 17—Standard Steering Column—Column Shift (CK-Model)
Page 261 3B4-22 STEERING COLUMN 20. Retainer 47. Shaft Lock Bolt 77. Adapter 21. Nut 48. Switch Rack Preload Spring 78. Reinforcement 22. Lock Plate Cover 49. Actuator Rack 79. Adapter Clip 23. Retainer 50. Actuator Pivot Pin 80. Lower Bearing 24. Lock Plate 51.
Page 262 STEERING COLUMN 3B4-23 Figure 19—Standard Steering Column (CK-Model)
Page 263: Standard Steering Column Lower Bearing Adjustment
3B4-24 STEERING COLUMN 65. Dimmer Switch 39. Key Release Lever 20. Retainer 66. Ignition Switch Screw 40. Key Release Washer 21. Nut 67. Ignition Switch 41. Housing Assembly 22. Lock Plate Cover 68. Dash Seal 42. Bearing 23. Retainer 69. Adapter 43.
Page 264 STEERING COLUMN 3B4-25 B-07398 Figure 21—Standard Steering Column (G-Model)
Page 265 3B4-26 STEERING COLUMN 20. Retainer 41. Housing Assembly 61. Gear Shift Housing 42. Bearing Bearing 21. Nut 22. Lock Plate Cover 43. Bushing 62. Jacket 44. Horn Contact 63. Wiring Protector 23. Retainer 24. Lock Plate 45. Upper Bearing Retainer 64.
Page 266 STEERING COLUMN 3B4-27 62. Jacket 80. Lower Bearing 83. Bolt 84. Spacer 85. Lower Shift B-07401 Lever 88. Retainer 80 88 89. Adapter Clip Figure 25—Removing The Lower Bearing Retainer C. 2-3 Shift Lever B-07404 D. Shim 0.13 mm (0.005 inch) Figure 28—A djusting The Lower Bearing B-07402 Figure 26—Installing The Rack Preload Spring...
Page 267: Tilt Steering Column Unit Repair (C, K And G M O D E Ls)
3B4-28 STEERING COLUMN TILT STEERING COLUMN UNIT REPAIR (C, K AND G MODELS) Remove or Disconnect 13. Bearing reinforcement, bearing and bearing adapter assembly from the lower end of the mast Steering column assembly. Refer to “ CK or G jacket.
Page 268 STEERING COLUMN 3B4-29 Figure 29—Tilt Steering Column (CK And G Models)
Page 269 3B4-30 STEERING COLUMN 174. Housing Support 120. Retainer 146. Tilt Spring 147. Spring Guide 175. Pin 121. Nut 176. Shift Lever Gate 122. Lock Plate Cover 148. Screw 177. Detent Plate Screw 149. Bearing 123. Retainer 179. Retaining Ring 124. Lock Plate 150.
Page 270 STEERING COLUMN 3B4-31 Figure 31—Tilt Steering Column—Floor Shift (CK And G Models)
Page 271 3B4-32 STEERING COLUMN 120. Retainer 143. Actuator Pivot Pin 167. Ignition Switch Actuator 121. Nut 144. Cap 168. Sphere Spring 122. Lock Plate Cover 145. Retainer 169. Centering Spheres 123. Retainer 146. T ilt Spring 170. Spring 124. Lock Plate 147.
Page 272 STEERING COLUMN 3B4-33 Figure 38— In sta llin g The S h ift Tube A ssem bly 150. Lock Bolt 151. Lock Bolt Spring B-07409 NOTICE: Do not push or tap on the end of the shift tube. Be sure that teh shift tube lever is aligned with the slotted opening at the lower Figure 35—Replacing The Lock Bolt Spring end of the mast jacket or damage to the shift...
Page 273: Steering Column On-Vehicle Service P(32) Models
3B4-34 STEERING COLUMN 26. Tilt lever opening shield. • Remove the tilt release lever. 27. Turn signal housing and retaining screws. Tighten • Screws to 5 N-m (45 in. lbs.). 28. Tilt release lever and shift lever. 29. Ignition switch. Refer to “ Ignition Switch Replace ment”...
Page 274: Tilt Steering Column Replacement
STEERING COLUMN 3B4-35 Install or Connect NOTICE: For step 8 see “Notice” on page 3B4#1. • Wrap the ends of the turn signal switch wires with tape and then guide them through the opening at the lower left hand side of the bearing housing (tilt columns) out the lower end of the shift lever housing and under the dash seal.
Page 275: Tilt Steering Column Bearing Housing Replacement
3B4-36 STEERING COLUMN • Adjust the lower bearing preload. Refer to “ Steering Column Lower Bearing Adjustment” in this section. 1. Plastic spacers onto the flexible coupling alignment pins. 2. Lower end of the steering column through the toe panel opening. 3.
Page 276 STEERING COLUMN 3B4-37 1. Battery ground cable. 2. Steering wheel. Refer to “ Steering Wheel Replacement” in this section. 3. Turn signal switch. Refer to “ Turn Signal Switch Replacement” in this section. • On column shift models, use a suitable size punch to drive out the shift lever pivot and remove the shift lever.
Page 277 3B4-38 STEERING COLUMN 236. * 234 B-07418 Figure 44—Tilt Steering Column P(32) Model...
Page 278 STEERING COLUMN 3B4-39 215. Housing Cover 229. Lever 243. Guide 257. Spring 216. Turn Signal 230. Retainer 244. Jacket 258. Sphere Assembly Mounting Screw 231. Screws 245. Bearing 259. Lower Shaft 217. Turn Signal Switch 232. Spring Retainer Clip 260. Shaft Assembly 218.
Page 279: Tilt Steering Column Unit Repair P(32) Models
3B4-40 STEERING COLUMN 7. Spring (232) and retainer (230). Push the retainer • Lubricate and install the bearings into the into the housing about 5 mm (3/ie inch) and rotate bearing races. • Place the shoe springs in position in the counterclockwise 1 /s turn.
Page 280: Steering Column On-Vehicle Service P(42) Models
STEERING COLUMN 3B4-41 Assemble (Figures 44 and 45) • The shift lever housing key must bottom in the shift tube slot. Tools Required: Neutral-safety or back-up lamp switch and J-23073-01 Shift Tube Installer screws. Refer to SEC. 8B (CHASSIS ELECTRI •...
Page 281: Upper Bearing Replacement
3B4-42 STEERING COLUMN 275. Bolts 276. Clamp 277. Screws 278. Cover 279. Seal 280. Bolt 281. Clamp 282. Nut 283. Outer Brace B-07422 Figure 49—Steering Column Installation P(42) Model Tighten 3. Upper bearing (289). • Bolt to 25 N m (18 ft. lbs.). ♦«- Install or Connect (Figure 50).
Page 282 STEERING COLUMN 3B4-43 278. Seal 279. Cover 285. Horn Blow Wire 286. Cancelling Cam 287. Turn Signal Switch Screws 288. Hazard Control Switch 289. Upper Bearing 290. Control Support Switch 291. Screw 292. Control Lever 304. Shift Tube 293. Housing 305.
Page 283: Steering Column Lower Bearing Adjustment
3B4-44 STEERING COLUMN |-»<-| Install or Connect (Figures 50 and 51) NOTICE: For steps 2 and 3 see “ Notice ” on page 3B4#1. 1. New adjusting ring and bearing assembly (314, ------ ► 315). 2. Clamp (316), bolt (317), washer (318) and nut (319).
Page 284: Standard Steering Column Unit Repair P(42) Models
STEERING COLUMN 3B4-45 STANDARD STEERING COLUMN UNIT REPAIR P(42) MODELS Remove or Disconnect Assemble (Figure 50) Steering column assembly. Refer to “ Standard Apply a thin coat of lithium grease to all friction Steering Column Replacement” (P42 Model) in surfaces. this section.
Page 285: Intermediate Shaft Unit Repair P(42) Models
3B4-46 STEERING COLUMN INTERMEDIATE SHAFT UNIT REPAIR P(42) MODELS Figure 54—Intermediate Shaft P(42) Model Remove or Disconnect Assemble (Figure 54) Intermediate shaft. Refer to “ Intermediate Shaft • If the yoke trunnions were removed, assemble as Replacement” in this section. follows: 1.
Page 286: Specifications
STEERING COLUMN 3B4-47 SPECIFICATIONS Ft. Lbs. In. Lbs. Turn Signal Switch Attaching Screws..........Ignition Switch Attaching Screws............Dimmer Switch Attaching Screws............Steering Wheel N u t................Flexible Coupling Clamp B o lt............. Flexible Coupling To Flange Bolt N uts..........Steering Gear To Frame Bolts (C, K And G Models)....... Steering Gear To Frame Bolts P300 (32, 42) F S 3......
Page 287: Front Suspension
3C-1 SECTION 3C FRONT SUSPENSION The following “ Notice” applies to one or more steps in the assembly procedure of components in this portion of the manual as indicated at appropriate locations by the terminology “ NOTICE: Refer to ‘Notice’ on page 3C-1 of this section.”...
Page 288: General Description
3C-2 FRONT SUSPENSION GENERAL DESCRIPTION An independent suspension is standard on the C-G- road bumps. A special heavy duty front suspension is P series vehicles. This suspension features unequal available on P series vehicles. This suspension (RPO length control arms (the lower control arm is the load FS3), centered around a solid I-beam axle, includes carrying member), coil springs and shock absorbers to leaf springs, shock absorbers, and a stabilizer bar.
Page 289: Diagnosis Of Wheel Bearings
FRONT SUSPENSION 3C-3 DIAGNOSIS OF FRONT SUSPENSION (CONT.) PROBLEM POSSIBLE CAUSE CORRECTION Noise In The Front 1. Ball joints and steering linkage need 1. Lubricate at the recommended inter lubrication. vals. 2. Loose shock absorber or worn bush 2. Tighten the bolts or replace the ings.
Page 290 3C-4 FRONT SUSPENSION ABRASIVE ROLLER WEAR ABRASIVE STEP WEAR Pattern on races and rollers caused by fine Pattern on roller ends caused by fine abra sives. abrasives. Clean all parts and housings, check seals and Clean all parts and housings, check seals and bearings and replace if leaking, rough or bearings and replace if leaking, rough or noisy.
Page 291 FRONT SUSPENSION 3C-5 BENT CAGE BENT CAGE Cage damaged due to improper handling or Cage damaged due to improper handling or tool usage. tool usage. Replace bearing. Replace bearing. CAGE WEAR INDENTATIONS Wear around outside diameter of cage and Surface d e p re ssio ns on race and rollers roller pockets caused by abrasive material caused by hard particles of foreign material, and inefficient lubrication.
Page 292 3C-6 FRONT SUSPENSION FRETTAGE SMEARS Corrosion set up by small relative movement Smearing of metal due to slippage. Slippage of parts with no lubrication. can be caused by poor fits, lu b rica tio n , Replace bearing. Clean related parts. Check overheating, overloads or handling damage.
Page 293 FRONT SUSPENSION 3C-7 MISALIGNMENT CRACKED INNER RACE Outer race m isalignm ent due to foreign ob Race cracked due to improper fit, cocking, or ject. poor bearing seats. Clean related parts and replace bearing. Make Replace bearing and correct bearing seats. sure races are properly seated.
Page 294: On-Vehicle Service: Two Wheel Drive Independent Front Suspension
3C-8 FRONT SUSPENSION ON-VEHICLE SERVICE: TWO WHEEL DRIVE INDEPENDENT FRONT SUSPENSION — Do not clamp the vise jaws on the shock’s SHOCK ABSORBER reservoir tube. 2. Pump the shock absorber at various rates of «--► Remove or Disconnect (Figures 5, 6, 7, 8, and speed and observe the rebound force.
Page 295 FRONT SUSPENSION 3C-9 / 14 15 16 17 B-07466 Figure 5—C Series Front Suspension...
Page 296 3C-10 FRONT SUSPENSION Figure 6—G Series Front Suspension...
Page 297 FRONT SUSPENSION 3C-11 Figure 7—P Series Front Suspension...
Page 298: Wheel Hub/Rotor Assembly
3C-12 FRONT SUSPENSION Clamps (42), bolts (43), washers (39, 41) and 1. Bolt 36. Lower Control Arm nuts (38). 37. Lower Ball Joint 2. Washer 3. Nut 38. Nut 4. Bolt 39. Washer 40. Bushing 5. Washer • C and P series nuts (38, 58) to 33 N m (24 ft. 6.
Page 299 FRONT SUSPENSION 3C-13 B. G Series 16. Nut 21. Bolt 17. Washer 22. Washer 20. Shock Absorber 23. Nut B-07473 Figure 9—Shock Absorber Attachm ents Install or Connect (Figures 5 through 8,11 and • If either a bearing or its race is damaged or worn, replace both.
Page 300 3C-14 FRONT SUSPENSION 70. Steering Knuckle 76. Outer Wheel Bearing 71. Shield 77. Washer 72. Seal 78. Nut 73. Inner Wheel Bearing 79. Dust Cap 80. Cotter Pin 74. Wheel Hub Bolt B-07470 75. Outer Race 81. Wheel Hub/Rotor Figure 11—Steering Knuckle And Hub Assembly NOTICE: Start the races squarely inside the hub/rotor to avoid distortion and possible cracking.
Page 301 FRONT SUSPENSION 3C-15 NOTICE: Failure to completely pack the wheel WHEEL BEARING ADJUSTMENT bearing (cones, rollers, and cage) with grease will result in premature wheel bearing damage Important and/or wear. • The proper functioning of the front suspension 4. F ill each w heel b e a rin g (cone and ro lle r cannot be maintained unless the front wheel assembly) full of grease.
Page 302 3C-16 FRONT SUSPENSION WHEEL HUB BOLT Remove or Disconnect (Figures 5 through 8, and 13) Tools Required: J-9746-02 Hub/Rotor Support J-9746 1. Hub/rotor from the vehicle. • Refer to “ Wheel Hub, Bearing and Race” in this section. NOTICE: Place J-9746-02 between the press bars and the hub/rotor to protect the rotor surfaces.
Page 303 FRONT SUSPENSION 3C-17 B-06961 Figure 15—D isconnecting The Upper Ball Joint Figure 16—Disconnecting The Lower Ball Joint From The Steering Knuckle From The Steering Knuckle • Position a floor jack under the lower control • If any tap e re d hole is out of round, arm (36) near the spring seat.
Page 304 3C-18 FRONT SUSPENSION • Nuts (38), bolts (43), washers (41) and clamp (42). CAUTION: Failure to secure J-23028 to a suitable flo o r jack could result in personal injury. 3. J-23028-02 to a suitable jack. 4. Place J-23028-02 under the lower control arm shaft (50) as shown in figure 17.
Page 305 FRONT SUSPENSION 3C-19 J-9519-10 J-9519-16 J-9519-22 J-21474-13 A. Measure This Distance B-07486 Figure 18—Inspecting The Lower Ball Joint Tighten • For G 10/1500-20/2500 series vehicles, torque to 88 N m (65 ft. lbs.). • For all other series vehicles, torque to 115 N m (85 ft.
Page 306 3C-20 FRONT SUSPENSION • Mate the steering knuckle (31) to the lower ball joint (37). 3. Caliper if it was removed. • Refer to BRAKES (SEC. 5). NOTICE: Refer to “Notice” on page 3C#1 of this section. 4. Nut (35). Tighten •...
Page 307: Lower Control Arm Pivot Shaft And Bushings
FRONT SUSPENSION 3C-21 Figure 22—Removing The Lower Control Arm Bushings (C10/1500, G10/1500-20/2500 Series) Tighten • All 10/1500 series and G20/2500 series vehicle nuts (14) to 68 N m (50 ft. lbs.). • All 20/2500 and 30/3500 series (except G20/2500) vehicle’s nuts (14) to 122 N m (90 ft.
Page 308 3C-22 FRONT SUSPENSION J-24435-3 Lower Control Arm Bushing Remover J-24435-6 Lower Control Arm Bushing Spacer J-24435-7 Lower Control Arm Bushing Fixture If just the bushings (46) or the pivot shaft (50) need replacement, the lower control arm (36) does not have to be removed from the vehicle.
Page 309 FRONT SUSPENSION 3C-23 |-n-| Install or Connect (Figures 6, 8, 23 and 24) • Nuts (24) to 95 N-m (70 ft. lbs.). Tools Required: J-24435-4 Lower Control Arm Bushing 5. Stabilizer bar (59) to the lower control arm (28). Installer •...
Page 310 3C-24 FRONT SUSPENSION G. Washer, Collar and Flange A. Rear End D. Inner Pivot Shaft B. Front End E. Shaft Tube H. Bumper I. Shaft Restrictor B-07514 C. Insulators F. O-Ring Figure 24—Lower Control Arm Pivot Shaft (G10/1500-20/2500 W/O 6.2L Diesel) •...
Page 311: Upper Control Arm Pivot Shaft And Bushings
FRONT SUSPENSION 3C-25 Tighten Bushings (46) to 379 N m (280 ft. lbs.) • Pivot shaft (50) for free rotation. 2. Grease fitting (12). • Lubricate the bushings with an approved grease. • R efer M A IN TE N A N C E A.
Page 312 3C-26 FRONT SUSPENSION J-24435-4 J-24435-5 (Hidden) B-07481 Figure 28—Removing The Upper Control Arm Figure 29—Installing The Upper Control Arm Bushings (Cl 0/1500, G10/1500-20/2500 Series) Bushings (C10/1500, G10/1500-20/2500 Series) • Tighten the clamp (J-24435-7) to install the J-24435-3 Lower Control Arm Bushing Remover bushing (26).
Page 313: Lower Control A
FRONT SUSPENSION 3C-27 Do not allow the upper control arm (28) to Inspect swing too far from the frame crossmember. • Pivot shaft for free rotation. 2. Grease fitting (12). Im portant • G rease the b u s h in g s (29). R efer to MAINTENANCE AND LUBRICATION (SEC.
Page 314 3C-28 FRONT SUSPENSION 1. Caliper. UPPER CONTROL ARM • Refer to BRAKES (SEC. 5). + + Remove or Disconnect (Figures 5 through 8, 2. Coil spring (32). and 15) • Refer to “ Coil Spring,” in this section. Tools Required: •...
Page 315 FRONT SUSPENSION 3C-29 packs must not exceed 7.62 mm (0.30 5. Shock absorbers (20) from the lower control arms inches). The front shim pack must be at (36). least 6.09 mm (0.24 inches). • Nut (23), washer (22), and bolt (21). Always tighten the thinner shim pack’s nut 6.
Page 316 3C-30 FRONT SUSPENSION Figure 31—Suspension Unit Replacement • The upper control arm to frame bracket Tighten bolts must be tightened first. • The crossmember must be in contact with • Nuts (38) to “ Specifications” at the end of the frame side rails. this section.
Page 317: On-Vehicle Service: Two Wheel Drive Rpo Fs3 (I-Beam) Front S U S P E N S Io
FRONT SUSPENSION 3C-31 ON-VEHICLE SERVICE: TWO WHEEL DRIVE RPO FS3 (I-BEAM) FRONT SUSPENSION — Shock absorber should be held vertically in SHOCK ABSORBER the vise with its bottom end up. Remove or Disconnect (Figures 32 through 34) — Do not clamp the vise jaws on the shock’s reservoir tube.
Page 318 3C-32 FRONT SUSPENSION Figure 32—P Series Front Suspension (RPO FS3)
Page 319: Shock A B S O Rb E
FRONT SUSPENSION 3C-33 101. Spring Hanger 126. Spacer 150. Nut 102. Rivet 127. Steering Knuckle 151. Washer 103. Spring Stop 128. Fitting 152. Outer Wheel Bearing And Race 104. Hanger Bushing 129. Nut 153. Wheel Hub Bolt 105. Washer 130. Dust Seal 154.
Page 320 3C-34 FRONT SUSPENSION 118 \ ^ 1 1 8 1 166. Stabilizer Bar 167. Insulator 11 i j 114. 168. Clamp 115. 169. Bo*! 116. 170. Nut 117. 171. Washer 118. 136. B-07491 Figure 35—Stabilizer Bar Attachm ents Install or Connect (Figures 32, 33, and 35) Clamps (168), clamp bolts (169), washers (171), and nuts (170).
Page 321: Wheel Hub/Rotor Assembly
FRONT SUSPENSION 3C-35 NOTICE: Start the races squarely inside the WHEEL HUB/ROTOR ASSEMBLY hub/rotor (154) to avoid distortion and possible cracking. Remove or Disconnect (Figures 32 and 33) 1. Races into the hub/rotor (154). • Raise the vehicle and support it with suitable •...
Page 322 3C-36 FRONT SUSPENSION • If they do not line up, back off the nut until NOTICE: Refer to the “Notice” on page 3C#1 they do—not more than one additional flat. of this section. 9. Washer (151), nut (150) and cotter pin (149). Measure •...
Page 323: Steering Arm, Knuckle And S P In D
FRONT SUSPENSION 3C-37 • Do not score the king pin surface. Use a STEERING ARM, KNUCKLE AND proper lubricant if necessary. SPINDLE 3. Lock pin (134). • Washer (133) and nut (132). □ Remove or Disconnect (Figures 32 and 33) Tighten •...
Page 324 3C-38 FRONT SUSPENSION 101. Spring Hanger 105. Washer 106. Bolt 107. Shackle 108. Nut 135. Nut 157. Front Axle 158. Spring Spacer 162. Front Spring 165. U-Bolt 164. Spacer 173. Spring Hanger B-07492 Figure 36—Axle And Leaf Spring Attachm ents 2.
Page 325: Leaf S P Rin
FRONT SUSPENSION 3C-39 & Tighten • Nut (108), washer (105), bolt (106) and washer (105) to separate the spring from the • Nut (136) until the distance between each rear shackle (107). retainer (117) is 2.08 cm (0.82 inches) (figure •...
Page 326: Shock A B S O Rb E
3C-40 FRONT SUSPENSION Tighten 6. Wheel and tire assembly. Lower the vehicle to the ground. 7. Check the front end alignment. • Nut (115) to 68 N m (50 ft. lbs.). 5. Shock absorber (113) to the axle (157) (figure 34). •...
Page 327: Wheel Hub/Rotor Assembly
FRONT SUSPENSION 3C-41 Tighten J-23446 Torque Wrench Adapter J-26878-A Wheel Bearing Nut Wrench • Nut (212) to 88 N m (65 ft. lbs.). (30/3500 Series) • Nut (212) to 120 N m (89 ft. lbs.) on quad • Raise the vehicle and support it with suitable shocks (RPO Z75).
Page 328 3C-42 FRONT SUSPENSION 208 214 215 216 B-07494 Figure 37—K Series (4 x 4) Front Suspension...
Page 329 FRONT SUSPENSION 3C-43 216. Spacer 231. Nut 247. Bracket 201. Bolt 232. Washer 217. Washer 248. Bolt 202. Shackle 218. Nut 233. Bracket 203. Bushing A. K3500 Series 234. Bushing 219. Bolt 204. Nut Right Side 220. Shock Absorber 235. Rivet 205.
Page 330 3C-44 FRONT SUSPENSION Figure 40—Stabilizer Bar Attachm ents • Grease from the wheel bearings (253, 259). 4. F ill the w heel b e a rin g (cone and ro lle r • Use clean solvent and a small brush (no loose assemblies) full of grease.
Page 331 FRONT SUSPENSION 3C-45 • Use a flat plate to install the seal so it is • The hole in the ring must align with the pin flush with the rotor/hub flange. on the lock nut (250). Move the adjustment • Lubricate the seal lip with a thin layer of nut (252) to align the pin.
Page 332 3C-46 FRONT SUSPENSION B-07550 Figure 42—K30/3500 Series Knuckle, Wheel Hub/Rotor Assembly...
Page 333 FRONT SUSPENSION 3C-47 249. Locking Hub Assembly 263. Plate 276. Bolt 289. Gasket 250. Locking Nut 264. Bracket 278. Bolt 290. Steering Arm 251. Ring 265. Spindle 279. King Pin 291. Nut 252. Adjusting Nut 266. Shaft Bearing 292. Nut 280.
Page 334: Spindle
3C-48 FRONT SUSPENSION J-9746 265. Spindle 274. Steering Knuckle B-07502 Figure 46—Removing The Spindle • Tighten the nut until the bolt fully seats into the hub/rotor. • Remove the nut and washers. 2. Hub/rotor to the vehicle. A. Press Bars •...
Page 335 FRONT SUSPENSION 3C-49 Figure 47—Spindle Components • Spacer (268), seal (269), and oil deflector • Seal (269) onto the oil deflector (270) with (270) from the axle shaft (figure 47). the deflector lip toward the spindle (265). 3. Spacer (268) onto the axle shaft. Inspect •...
Page 336 3C-50 FRONT SUSPENSION 4. Tie rod from the steering arm (297). • Refer to STEERING LINKAGE (SEC. 3B1). 5. Steering arm (297) from the steering knuckle (274). • Nuts (295) and adapters (296). • Discard the nuts (295). NOTICE: Do not remove the adjusting ring (300) unless new ball joints are being installed.
Page 337 FRONT SUSPENSION 3C-51 1 ^ 1 Tighten • Nut (299) to 135 N-m (100 ft. lbs.). 5. Cotter pin (298) into the nut (299). • Do not loosen the nut. Apply additional torque, if necessary, to line up the hole in the ball joint with the slot in the nut.
Page 338 3C-52 FRONT SUSPENSION Figure 54—Installing The Retainer Into The Axle Figure 52—Removing The Upper King Pin Yoke 10. Retainer (281), race (282), bearing (283) and the seal (284) from the axle yoke. NOTICE: For steps 4, 6, 7, refer to “Notice” on page 3C#7 of this section.
Page 339: Ball J O In
FRONT SUSPENSION 3C-53 Figure 56—Installing The Upper King Pin Tighten NOTICE: Failure to com pletely pack the bearing (cones, rollers, and cage) with grease • Nuts (291) alternately and evenly to 108 N m will result in premature bearing damage (80 ft.
Page 340 3C-54 FRONT SUSPENSION J-23454-1 J-6382-3 OR J-23454-3 J-6382-3 OR •23454-3 J-9519-10 J-9519-10 A. Flat Washer 274. Steering Knuckle 274. Steering Knuckle B-07509 B-07510 293. Lower Ball Joint Figure 58—Removing The Upper Ball Joint Figure 59—Installing The Lower Ball Joint • Refer to “ Wheel Hub/Rotor Assembly,” in 2.
Page 341 FRONT SUSPENSION 3C-55 201. Bolt 202. Shackle 203. Bushing 204. Nut 205. Washer 207. Bumper 216. Spacer 217. Washer 218. Nut 221. Leaf Spring B-07460 Figure 61—Leaf Spring Components 4. Shackle (202) from the spring (221). • Refer to FRONT END ALIGNMENT (SEC. 4C).
Page 342 3C-56 FRONT SUSPENSION • Shackle (202) into position and attach bolt For the right side of K30/3500 series (201), washer (217) and nut (218). vehicles, attach the lower spacer (226), • Do not tighten. plate (224), U-bolt (227), washers (223), bolts (248) and nuts (222) (figure 61).
Page 343 FRONT SUSPENSION 3C-57 SPECIFICATIONS FRONT SUSPENSION BOLT TORQUE—N-m (FT. LBS.) W/FS3 Shock Absorber 103 (80) 190 (140) 88 (65) 103 (80) 190 (140) 190 (140) 88 (65) 103 (80) 190 (140) 185 (136) 190 (140) 88 (65) To Frame Shock A bsorber To 103 (80) 80 (59) 80 (59)
Page 344 3C-58 FRONT SUSPENSION SPECIFICATIONS (CONT.) FRONT SUSPENSION BOLT TORQUE—N-m (FT. LBS.) W/FS3 Crossmember To Side Frame Rail00 88 (65) 88 (65) 88 (65) 88 (65) 88 (65) 88 (65) 88 (65) 88 (65) Spring To — Hanger Nuts 122 (90) 122 (90) 122 (90) 125 (92)
Page 345 FRONT SUSPENSION 3C-59 SPECIAL TOOLS Tool Number Tool Name Driver Handle J-8092 J-8457 Wheel Bearing Race Installer Wheel Bearing Race Installer J-8849 Outer Bearing Race Installer J-29040 J-6893-D Wheel Bearing Nut Wrench (K10/1500-20/2500) J-26878-A Wheel Bearing Nut Wrench (K30/3500) Torque Wrench Adapter J-23446 Outer Bearing Race Installer J-6368...
Page 346 3D-1 SECTION 3D REAR SUSPENSION The following “ Notice” applies to one or more steps in the assembly procedure of components in this portion of the manual as indicated at appropriate locations by the terminology “ Notice: Refer to the ‘Notice’ on page 3D-1 of this section.
Page 347 3D-2 REAR SUSPENSION Figure 1—Rear Suspension (C-K 10/1500, 20/2500 Pickup, Suburban, And Blazer/Jimmy)
Page 348 REAR SUSPENSION 3D-3 Figure 2—Rear Suspension (C-K 30/3500 Series Vehicles)
Page 349 3D-4 REAR SUSPENSION Figure 3—Rear Suspension (G 10/1500-30/3500 Series Vehicles)
Page 350 REAR SUSPENSION 3D-5 Figure 4—Rear Suspension (G30/3500 Series Cutaway Van With RPO M40)
Page 351 3D-6 REAR SUSPENSION B-07519 Figure 5—Rear Suspension (P20/2500 Series Vehicles)
Page 352 REAR SUSPENSION 3D-7 32. Optional Rear 12. Spring Lock Washer 1. Bracket 23. Bracket 13. Rear Shock Absorber Auxiliary Spring 2. Bolt 24. Cushion 33. Bolt 3. Washer 14. Bolt 25. Rear Hanger 34. Washer 15. Spring Lock Washer 4. Rear Hanger Reinforcement 26.
Page 353 3D-8 REAR SUSPENSION ON-VEHICLE SERVICE SHOCK ABSORBERS «"► Remove or Disconnect (Figures 1 through 7) • Raise the vehicle on a hoist and support the rear axle independently of the rest of the vehicle. 1. Shock absorber (13) from the frame. •...
Page 354 REAR SUSPENSION 3D-9 B-07523 Figure 9—Rear Stabilizer Attachm ents (P(32) Series) Install or Connect (Figures 8, 9 and 10) 2. Stabilizer bar (108) from t^e anchor plates (107). • Nuts (105), washers (106), bolts (111), and the clamps (110). NOTICE: For steps 2 and 3, refer to the 3.
Page 355 3D-10 REAR SUSPENSION Tighten 3. Stabilizer bar (108) to the frame. • For the C 30/3500 series vehicles; position • Nuts (22), in a diagonal sequence 1-3-2-4 the link bolt (115), washers (116), grommets (figure 11), initially to 25 N m (18 ft. lbs.). (117), spacer (114), retainer (119) and nut Then final torque in a diagonal sequence (120).
Page 356 REAR SUSPENSION 3D-11 2. Bushings (26) from the leaf spring (10). • Pry the bushings out of each side of the spring eye. Install or Connect (Figures 2 and 4 through 7) 1. Bushings (26) into the leaf spring (10). •...
Page 357 3D-12 REAR SUSPENSION SPECIFICATIONS FASTENER NAME TORQUE N m (FT. LBS.) C10/15 C20/25 C30/35 K10/15 K20/25 K30/35 G10/15 G20/25 G30/35 P20/25 P30/35 Shock A bsorber To Fram e Nut 19 0 (1 4 0 ) *1 9 0 (1 40) 7 0 (52) 190 (1 40) 190 (1 40)
Page 358 3E-1 SECTION 3E WHEELS AND TIRES The following “ Notice” applies to one or more steps in the assembly procedure of components in this portion of the manual as indicated at appropriate locations by the terminology: “ NOTICE: Refer to the ‘Notice’ on page 3E-1 of this section.”...
Page 359: General Description
3E-2 WHEELS AND TIRES GENERAL DESCRIPTION This section details special service procedures that Correct tire pressures and driving techniques are not covered in the vehicle’s Owner’s Manual. For influence tire life. Underinflated tires can cause jacking instructions, basic tire changing and rotation handling problems, poor fuel economy, shortened tire instructions, and a detailed explanation of all other life, and tire overloading.
Page 360 WHEELS AND TIRES 3E-3 B-07463 Figure 1—Radial Tire Lead/Pull Diagnosis Chart...
Page 361: Diagnosis Of Wheels And Tires
3E-4 WHEELS AND TIRES DIAGNOSIS OF WHEELS AND TIRES The following information (including figure 1) will help to identify certain tire-related durability and drivability problems. PROBLEM POSSIBLE CAUSE CORRECTION Excessive Heel And High speed driving, excessive use of Correct as required, rotate tires regu Toe Wear brakes.
Page 362: On-Vehicle Service
WHEELS AND TIRES 3E- 5 ON-VEHICLE SERVICE MEASURING WHEEL AND TIRE RUNOUT Runout m easurem ents of the wheel and tire assembly can be taken both on and off the vehicle. These measurements can be taken radially and laterally. A dial indicator equipped with a roller contact point, m ounted on a heavy, solid base is the measurement device.
Page 363 3E-6 WHEELS AND TIRES A. Valve Stem And Tire Reference Mark Tire At 12 O’clock Tire Reference Mark At 12 O’clock B. First Measurement (High Spot) First Measurement (High Spot) C. Valve Stem At 12 O’clock Valve Stem At 12 O’clock D.
Page 364: Excessively Tight Wheels
WHEELS AND TIRES 3E-7 • Follow the tire changing machine manufacturer’s instructions to properly separate the tire from the wheel. MOUNTING THE TIRE ON THE WHEEL BIAS PLY TIRES 1. Clean the tire bead area. 2. Clean the rim bead seats with a wire brush or coarse steel wool to remove lubricants, old Figure —Tire And Wheel Assembly...
Page 365 3E-8 WHEELS AND TIRES Tube Type Tires • Do not allow the soap solution to run down into the tire. Important 5. Follow the standard procedure when mounting the tube and tire on a drop center rim. Be sure • Only use rims approved for radial tire usage by the tire is centered on the rim so the beads are the rim manufacturer.
Page 366: Aluminum Wheel Refinishing
WHEELS AND TIRES 3E-9 Tighten • Nuts to “ S pecifications” at the end of this section. • Tighten evenly and alternately to avoid excessive runout (figure 7). DUAL WHEELS Install or Connect (Figure 7) 1. Inner and outer wheel and clamp ring on the rear wheel, or wheel and clamp ring on the front wheel.
Page 367 3E-10 WHEELS AND TIRES • Hose off the rim with water and scrub with a small brush to remove excess compound, then air blow dry. 3. Recoat the wheels. • Clean the surface of any contaminants using Prekleno. • Apply #801 Metal Conditioner, taking care to use rubber gloves and a clean cloth during the application.
Page 368 WHEELS AND TIRES 3E-11 Figure 10—Side Panel Mounted Spare Tire Carrier (RPO P13)
Page 369: S P E C Ific A Tio N
3E-12 WHEELS AND TIRES SPECIFICATIONS WHEEL RUNOUT SPECIFICATIONS Alum inum Wheels Steel Wheels Radial Runout 1.01 mm (0.04 inches) 0.76 mm (0.03 inches) Lateral Runout 1.14 mm (0.045 inches) 0.76 mm (0.03 inches) WHEEL STUD NUT TORQUE (SINGLE FRONT AND REAR WHEELS) Series Number Of Studs Nut Torque...
Page 370: Tire Load Lim Its And Inflation P Re S S U
WHEELS AND TIRES 3E-13 TIRE AND WHEEL LOAD LIMIT CHARTS (TIRE & WHEEL LOAD LIMITS ARE SHOWN BELOW. VEHICLE LOADING MUST BE LIMITED SUCH THAT NEITHER THE WHEEL OR TIRE INFLATION PRESSURE OR LOAD LIMITS ARE Metric Radial Tires Used As Singles (Cont.) EXCEEDED).
Page 371 3E-14 WHEELS AND TIRES TIRE AND WHEEL LOAD LIMIT CHARTS (Tire and wheel load limits are shown below. Vehicle loading must be limited so that neither the wheel or tire inflation pressure or load limits are exceeded) _______________ Tire Load Limits: Bias Tires Used As Singles — kg (lbs) Wheel Max.
Page 372 WHEELS AND TIRES 3E-15 TIRE LOAD LIMIT CH A R TS Tire Load Limits: Bias Tire Used As Singles — kg (lbs.) (Cont.) Inflation Pressure — kPa (PSI) (Tire load limits at different inflation pressures are shown below. Vehicle loading must be limited such that neither the tire inflation pressures or load limits are exceeded).
Page 373 3E-16 WHEELS AND TIRES TIRE LOAD LIMIT CHARTS (CONT.) METRIC RADIAL TIRES (CONT.) - kg (LBS.) Inflation Pressure - kPa (PSI) 400 (58) 450 (65) 500 (73) 550 (80) 965 (2127) 1050(2315) 870 (1918) 955 (2105) 1100 (2425) 1190 (2623) 1100 (2425) 1190 (2623) 1290 (2844)
Page 374 4A-1 SECTION 4A PROPELLER SHAFT The following “ Notice” applies to one or more steps in the assembly procedure of components in this portion of this manual as indicated at appropriate locations by the terminology “ Notice: See ‘NOTICE’ on page 4A-1 of this section”...
Page 375: Description
4A-2 PROPELLER SHAFT DESCRIPTION Figure 1— P ro peller Shaft A ssem bly Phased PROPELLER SHAFT shafts have alignment marks or arrows stamped on the shaft at the time of production. Torque is transmitted from the transmission to the rear axle through one or more propeller shafts and CENTER BEARING universal joint assemblies.
Page 376 PROPELLER SHAFT 4A-3 Retainer Pinion Flange Yoke and Cross Assembly Splined Shaft Washer 12. Seal (Cork) 13. Nut 14. Transmission Yoke 15. Washer Bolt Universal Joint Hanger Assembly and Crossmember Slip Yoke Center Bearing Support Front Propeller Shaft Rear Propeller Shaft Bolt B-06720 F igure 2—...
Page 377: C Enter B E A R In G
4A-4 PROPELLER SHAFT DIAGNOSIS OF DRIVELINE VIBRATION (ROAD TEST) Four major component groups are usually the cause ROAD TEST of or are related to vibration. When a technician is road A technician should road test the vehicle to diagnose testing a vehicle for vibration he must remember the exactly what the complaint is.
Page 378 PROPELLER SHAFT 4A-5 DIAGNOSIS OF THE PROPELLER SHAFT AND UNIVERSAL JOINT (CONTINUED) PROBLEM POSSIBLE CAUSE CORRECTION K nocking Or 1. Worn or damaged universal joint. 1. Replace the worn or damaged uni versal joint. Clunking Noise In 2. Side gear hub counterbore in the dif 2.
Page 379: On-Vehicle Service
4A-6 PROPELLER SHAFT DIAGNOSIS OF THE PROPELLER SHAFT AND UNIVERSAL JOINT (CONTINUED) PROBLEM POSSIBLE CAUSE CORRECTION Whine Or Whistle Center support bearing. Place the vehicle on a hoist with rear wheels free to rotate and diagnose for source of noise, replace. Shudder On 1.
Page 380 PROPELLER SHAFT 4A-7 «=dj & A. Check Front Runout B. Check Center Runout C. Check Rear Runout D. Check Splined Shaft Runout At Tapered Hole In Splined End E. Check Front Runout 1. One Piece Propeller Shaft Or Rear Propeller Shaft In A Two-Piece Driveline 2.
Page 381: Propeller Shaft Replacement (Rear Drive)
4A-8 PROPELLER SHAFT 4. For twisted slip yoke splines or possibly the PROPELLER SHAFT wrong universal joint. REPLACEMENT (REAR DRIVE) Install or Connect (Figures 2 and 7) Remove or Disconnect (Figure 2) One-Piece Propeller Shaft Tool Required: 1. Propeller shaft (4) into the transmission. J-33051, Driveshaft Wrench.
Page 382: Propeller Shaft Replacement (Front Drive)
PROPELLER SHAFT 4A-9 Hanger Assembly Center Bearing Support Front Propeller Shaft Rear Propeller Shaft Transmission Yoke Slip Yoke Horizontal Center Line At The Yoke 90 ± 1 Degree Angle For Slotted Hanger Holes Vertical Center Line At The Yoke B-07562 Figure 7—Alignm ent For Two-Piece Propeller Shaft In Phase, G And K Models •...
Page 383 4A-10 PROPELLER SHAFT Front Axle Yoke Slip Yoke Propeller Shaft Assembly U-bolt Transfer Case Flange Bolt Constant Velocity Joint Bolt Boot Retainer Front Axle Assembly Washer Clamp B-07561 Figure 8 —Front Propeller Shaft and Driveline Detail Install or Connect (Figure Tighten Tools Required: •...
Page 384: L U B R Ic A Tio
__________________ PROPELLER SHAFT 4A-11 LUBRICATION The front axle propeller shaft found on four-wheel drive vehicles requires a special lubricant at two lo cations: the constant velocity joint, and the slip yoke. Constant V elocity Joint (C/V Joint) The constant velocity (C/V) joint, located at the transfer case end of the front propeller shaft, must be lubricated periodically with a special lubricant, 1050679 or equivalent.
Page 385: S P E C Ific A Tio N
4A-12 PROPELLER SHAFT SPECIFICATIONS TORQUE APPLICATION MODEL FT. LBS. Propeller Shaft: C, G, P C, K, G300, P Two Piece Propeller Shaft-Front .P300 .C, G, P Center Bearing Support: .P300 C, G Two Piece Propeller Shaft-Rear: •C, G, P C, K, G300, P300 Propeller Shaft: .K100, 200 .K300...
Page 386: Ring Gear-
4B-1 SECTION 4B REAR AXLE The following “ Notice” applies to one or more steps in the assembly procedure of components in this portion of the manual as indicated at appropriate locations by the terminology: “ NOTICE: See ‘Notice’ on page 4B-1 of this section.”...
Page 387: Description
4B-2 REAR AXLE DESCRIPTION Light duty trucks use various rear axles, classed by DANA 9 3 /4-INCH RING GEAR AXLE ring gear diameter such as: This Dana axle is similar to the Chevrolet -inch 1 0 1 ring gear axle however, the differential side bearing shims are located between the case and the side 8 V 2 -INCH AND 9 V 2 -INCH RING GEAR AXLES bearings.
Page 388: Diagnosis Of The Rear A X Le
REAR AXLE 4B-3 However, if it became necessary to turn a corner, the load developed on the right side clutch pack. This tires would scuff and slide because the outside wheel induced clutch torque capacity resists motion between would travel further than the inside wheel. To prevent the side gear and the rear axle differential case.
Page 389 4B-4 REAR AXLE assembly. Noise which originates in other places Other items that may also contribute to the noise cannot be corrected by adjustment or replacement of problem are as follows: parts in the rear axle assembly. 1. U ndercoating or mud on the shaft, causing Road Noise—Some road surfaces, such as brick or unbalance.
Page 390 REAR AXLE 4B-5 Gear Noise There are two basic types of gear noise. The first type is produced by broken, bent, or forcibly damaged gear teeth and is usually quite audible over the entire speed range and presents no particular problem in diagnosis.
Page 391 4B-6 REAR AXLE ABRASJVE STEP WEAR ABRASIVE ROLLER WEAR Pattern on races and rollers caused by fine Pattern on roller ends caused by fine abra sives. abrasives. Clean all parts and housings, check seals and Clean all parts and housings, check seals and bearings and replace if leaking, rough or bearings and replace if leaking, rough or noisy.
Page 392 REAR AXLE 4B-7 BENT CAGE BENT CAGE Cage damaged due to improper handling or Cage damaged due to improper handling or tool usage. tool usage. Replace bearing. Replace bearing. INDENTATIONS CAGE WEAR Surface d e p re ssio ns on race and rollers Wear around outside diameter of cage and caused by hard particles of foreign material.
Page 393 4B-8 REAR AXLE FRETTAGE SMEARS Corrosion set up by small relative movement Smearing of metal due to slippage. Slippage of parts with no lubrication. can be caused by poor fits, lu b rica tio n , Replace bearing. Clean related parts. Check overheating, overloads or handling damage.
Page 394 REAR AXLE 4B-9 CRACKED INNER RACE MISALIGNMENT Race cracked due to improper fit, cocking, or Outer race m isalignm ent due to foreign ob poor bearing seats. ject. Replace bearing and correct bearing seats. Clean related parts and replace bearing. Make sure races are properly seated.
Page 395: On-Vehicle Service
4B-10 REAR AXLE ON-VEHICLE SERVICE . Hydraulic brake lines to the connectors. Refer to REAR AXLE ASSEMBLY BRAKES (SEC. 5). REPLACEMENT (ALL AXLES) 9. Parking brake cable to the lever and the flange plate. Refer to BRAKES (SEC. 5). • Raise the vehicle on a hoist and support the axle 10.
Page 396 REAR AXLE 4B-11 . Drum . Bolt . Shaft 13. Lock 14. Seal 15. Bearing 16. Housing 17. Clip 18. Bolt 19. Carrier Cover F-00636 6 —Axle Shaft And Housing Detail Figure WITHOUT LOCKING DIFFERENTIAL 4. Screw (A) (figure 7). 5.
Page 397 4B-12 REAR AXLE Figure 9—P ositioning The Case Figure 12—Removing The Bearing And Seal For Best Clearance . Axle shaft (12). • Slide the axle shaft ( ) out. Be careful not B. Pinion Shaft to damage the seal (14). E.
Page 398 REAR AXLE 4B-13 WITHOUT LOCKING DIFFERENTIAL 4. Lock (13). • Lock on the button end of the axle shaft ), then push the shaft outward to seat the lock in the counterbore of the differential side gear. 5. Pinion shaft (B) figure •...
Page 399: Pinion Flange, Dust Deflector/O Il Seal Replacement
4B-14 REAR AXLE Install or Connect • Brake components from the backing plate. Refer to BRAKES (SEC. 5). 1. Stud in the axle flange hole. Refer to figure 15. 4. Bolts and washers from the axle. • Start the new stud into the axle flange hole 5.
Page 400 REAR AXLE 4B-15 Im portant • Scribe a line on the pinion stem, pinion nut and the companion flange and record the number of exposed threads on the pinion stem. Use the scribed reference and the exposed threads as a reinstallation guide (figure 17).
Page 401: Axle Shaft Replacement ( 93 / 4 - 1 0 1 / 2 -Lnch Ring Gear-Full Floating A X Le
4B-16 REAR AXLE Figure 22—Installing Or Removing Flange-To-Hub Bolts • Pack the cavity between the end of the Tighten pinion splines and the pinion flange with a non-hardening sealer such as PERMATEX • The p in io n nut in a d d itio n a l sm a ll TYPE A or equivalent.
Page 402: Hub And Drum Assembly Replacement
REAR AXLE 4B-17 A. Chevrolet B. Dana 40. Nut 41. Lock 42. Adjusting Nut 43. Washer 44. Outer Bearing 45. Retaining Ring 46. Inner Bearing 47. Oil Seal 48. Drum 49. Hub 50. Stud 51. Gasket 52. Shaft 53. Axle Shaft Flange 54.
Page 403: Wheel Bearing/Cup Replacement
4B-18 REAR AXLE Inspect • All parts and replace as necessary. |~n-| Install or Connect (Figure 23) NOTICE: For steps 3, 4 and 5 see “Notice” on page 4B-1 of this section. Tool Required: J-2222-C Wheel Bearing Nut Wrench Hub and drum (48, 49) to the tube. •...
Page 404: Non-Demountable Type Drum Replacement
REAR AXLE 4B-19 • Drive the outer cup beyond the retaining ring groove. 2. Retaining ring (45) or (60) into the groove. • Drive the outer bearing cup against the retaining ring (45) or (60) using J-8092 and J-24426 (figure 25). 3.
Page 405: Pinion Oil Seal/Companion Flange Replacement
4B-20 REAR AXLE S h a ft 3. A xle s h a ft (52). R efer to “ A xle Replacement” earlier in this section. PINION OIL SEAL/COMPANION FLANGE REPLACEMENT • The pinion oil seal and the companion flange may be replaced with the carrier assembly installed in the vehicle.
Page 406: Axle Vent Replacement (12-Inch Ring Gear-Full Floating A X
REAR AXLE 4B-21 4. Propeller shaft. Refer to PROPELLER SHAFT • Tap the axle shaft (74) into position using (SEC. 4A). J-8117 and J-2619-01. • Index the axle shaft (74) splines into the hub ) splines. AXLE VENT REPLACEMENT 2. Gasket (73). (12-INCH RING GEAR-FULL 3.
Page 407 » 4B-22 REAR AXLE 70. Bolt 71. Washer 72. Hubcap 73. Gasket 74. Axle Shaft 75. Axle Housing 76. Bracket 77. Wheel Bolt Hex Bolt Deflector Oil Seal Inner Bearing Brake Disc Retaining Ring Outer Bearing Spacer Thrust Washer Adjusting Nut Lock Washer F-01012 Figure 29—Rockwell Axle And Hub Detail...
Page 408 REAR AXLE 4B-23 . Oil seal (96). bore shoulder. • Pry the oil seal (96) from the bore being . Oil seal retainer (95). careful not to dam age the m achined 3. Bolts to the retainer (97). surfaces. 4. Companion flange (94) use the scribed reference mark.
Page 409: Liter
4B-24 REAR AXLE SPECIFICATIONS TORQUES ROCKWELL DANA CHEVROLET 12" RING GEAR RING GEAR- RING " RING GEAR " RING GEAR- " - 1 0 1 /2" " AXLE-FULL GEAR AXLE-FULL AXLE-FULL SEMI FLOATING SEMI FLOATING FLOATING FLOATING FLOATING AXLE AXLE FT.
Page 410 REAR AXLE 4B-25 . J-8117 Axle Shaft Puller Adapter . J-6627-A Wheel Stud Remover 3. J-8092 Driver Handle 4. J-5853 Torque W rench— Inch/Pound 5. J-8614-01 Companion Flange Holder And Remover . J-2619-01 Slide Hammer With Adapter 7. J-2222-C Wheel Bearing Nut Wrench .
Page 411 4C-1 SECTION 4C FRONT AXLE The following “ Notice” applies to one or more steps in the assembly procedure of components in this portion of the manual as indicated at appropriate locations by the terminology: “ NOTICE: See ‘Notice’ on page 4C-1 of this section.”...
Page 412 4C-2 FRONT AXLE DESCRIPTION The front axle is a hypoid gear axle unit equipped and is rated at 4500 pound capacity. The Dana axle with steering knuckles and an automatic or manual has a -inch ring gear. Automatic hub locks are used locking hub.
Page 413 FRONT AXLE 4C-3 ON-VEHICLE SERVICE . Hub Lock . Ring . Retainer 23. Nut 24. Ring 25. Nut 26. Outer Bearing 27. Cup 28. Hub And Disc 30. Cup 31. Inner Bearing 32. Inner Seal 33. Outer Deflector 34. Seal 35.
Page 414: Front Axle Assembly
4C-4 FRONT AXLE • Pack the inner and outer wheel bearing (31, 26). NOTICE: For steps 3, 4 and 5, see “Notice” on page 4C#1 of this section. Install or Connect (Figure 1) 1. Seal (36) and spacer (35) to the axle shaft (46). 2.
Page 415 FRONT AXLE 4C-5 9. Ring (57) using needle nose plier. AXLE JOINT COMPONENT • Pull the remaining components from the REPLACEMENT wheel. 10. Retaining ring (77) from the sleeve (67) groove. Remove or Disconnect • Rotate the drag sleeve (75) until it drops into engagement with the gear (59).
Page 416 4C-6 FRONT AXLE 50. Screw 67. Sleeve 51. O-Ring Seal . Stop Ring 52. Cover 69. Spring 53. Seal 70. Cam 54. Spring 71. Outer Cage 55. Inner Race 72. Inner Cage 56. Bearing 73. Ring 57. Ring 74. Brake Band 58.
Page 417 FRONT AXLE 4C-7 9. Inner cage (72) into the outer cage (71). • Align the tab of the outer cage (71) with the “ window” of the inner cage (72). 10. Ring (73). • Into the groove of the clutch gear (59) above the outer cage (71).
Page 418 4C-8 FRONT AXLE pushed inward to allow the retaining ring Inspect (57) to expand when assem bling the automatic locking hub to the vehicle. All parts and replace as necessary. Install or Connect (Figure 5) AUTOMATIC HUB TO THE WHEEL ADJUSTMENT 1.
Page 419 FRONT AXLE 4C-9 85. Internal Snap Ring . Hub Body 87. Inner Drive Gear . Spring 89. Clutch Ring 90. Axle Shaft Snap Ring 91. Screw 92. Hub Cap 93. Compression Spring 94. Clutch Cup 95. O-Ring Seal 96. Dial Screw 97.
Page 420 4C-10 FRONT AXLE SPECIFICATIONS Nut-Splash Shield Retaining 65 ft. lbs. 50 ft. lbs. Nut With Pin < Bearin9 Preload) (Final Torque) 47 N m 35 ft. lbs. Cover Screw-Automatic Hub 5.1 N m 45 inch lbs. Adjusting Nut-Axle Shaft 247 N m 183 ft.
Page 421 SECTION 5 BRAKES The following notice applies to one or more steps in the assembly procedure of components in this portion of the manual as indicated at appropriate locations by the terminology NOTICE: See ‘Notice’ on page 5-1 of this section. NOTICE: This fastener is an important attaching part in that it could affect the performance of vital compo...
Page 422 5-2 BRAKES CONTENTS (CONT.) SUBJECT PAGE Hydraulic Brake Booster (H ydro-B oost)........................5-33 D e s c rip tio n ................................5-33 Hyrdro-Boost R e p la ce m e n t............................5-33 Bleeding the Hydro-Boost S y s te m ........................5-36 Disc B ra kes....................
Page 423 BRAKES 5-3 3. Check and fill the power steering reservior with power steering fluid. If fluid contains air refer to POWER STEERING (Sec. 3B3) for further diag nosis. 4. Check power steering pump belt for wear and tension. Adjust if needed, refer to POWER STEERING (Sec.
Page 424: Diagnosis Of Brake System
5 -4 BRAKES D. SPOOL VALVE PLUG SEAL. Damage to this housing cover must be replaced. If no excessive seal will be noticed by fluid leaking out past the scratches are present, then the booster seal kit can be used to replace the appropriate seals. plug.
Page 425 BRAKES 5-5 DIAGNOSIS OF BRAKE SYSTEM (CONT.) POSSIBLE CAUSE CORRECTION PROBLEM 1. Worn out linings. 1. Replace linings. Brakes Squeak. 2. Glazed brake lining. 2. Replace linings. 3. Heat spotted rotors or drums. 3. Check per instructions. If within spec ifications machine the rotor or drum.
Page 426 5-6 BRAKES DIAGNOSIS OF BRAKE SYSTEM (CONT.) PROBLEM POSSIBLE CAUSE CORRECTION Brakes Drag. 1. Malfunctioning caliper assembly. 1. Check for frozen or sluggish pistons and the lubrication of the retainer bolts. Caliper should slide. 2. Contaminated or improper brake fluid. 2.
Page 427: Diagnosis Of Hydro-Boost System
BRAKES 5-7 DIAGNOSIS OF HYDRO-BOOST SYSTEM CORRECTION PROBLEM POSSIBLE CAUSE Excessive seal friction in booster. Overhaul with new seal kit. Slow Brake Pedal 2. Flush steering system while pumping Return. 2. Faulty spool action. brake pedal. 3. Restriction in return line from booster 3.
Page 428: On Vehicle Service
5-8 BRAKES ON VEHICLE SERVICE BLEEDING THE BRAKE 6. If it is known that the calipers and wheel cylinders do not contain any air, then it will not be HYDRAULIC SYSTEM necessary to continue. Otherwise bleed each wheel in the following sequences. A bleeding operation is necessary if air has been •...
Page 429: Flushing The Brake Hydraulic System
BRAKES 5-9 2. Use J-23709 to depress and hold the valve stem on the combination valve during the bleeding op eration (figure 2). • Install the correct bleeder adapter (figures 3 and 4). 3. Bleed each wheel in the following sequence. •...
Page 430 5-10 BRAKES Install or Connect (Figure 5) • Use new copper washers when installing the hose. 1. Hose (32). • The hose must not be twisted. 2. Washers (33). • Bolt (34). 3. Clip or nut (31). • Steel pipe. 4.
Page 431 BRAKES 5-11 31. Nut or Clip 32. Flex Hose 33. Washer 34. Bolt B-07786 Figure 5—Flexible Hoses...
Page 432: Combination Valve
5-12 BRAKES in the event of a front brake system malfunction, also full front pressure is retained in the event of rear mal function. The pressure differential warning switch is designed to constantly compare front and rear brake pressure from the master cylinder and energize the warning lamp on the dash in the event of a front or rear system malfunction.
Page 433: Height Sensing Brake Proportioning Valve
BRAKES 5-13 • Make sure the master cylinder reservoir is 4. Bleed the brake system. Refer to “ Bleeding The Brake Hydraulic System” in this section. full. 3. Turn the ignition key to “ ON” . • Open the bleeder screw while a helper HEIGHT SENSING BRAKE applies moderate pressure to the brake PROPORTIONING VALVE...
Page 434 5-14 BRAKES A. G-Van B. C-K Truck C. P Model (42) D. P Model (32) B-07802 Figure 8—Combination Valves...
Page 435 BRAKES 5-15 Figure 9—Height Sensing Proportioning Valve PROPORTIONING VALVE ADJUSTMENT ADJUSTMENT GAGE CHART If a front wheel lockup is experienced when the vehicle is being operated near the maximum GVWR Part with a lower than desired brake application, the valve Number Code Color Vehicle Combination...
Page 436 5-16 BRAKES Figure 12—Severing The Adjustment Tang...
Page 437: Brake Pedal Assembly
BRAKES 5-17 BRAKE PEDAL ASSEMBLY Manual Transmission Automatic Transmission B-06947 Figure 13—C-K Brake Pedal Components CHECKING PEDAL TRAVEL • Pin (10) and washer (9). • Pushrod (8). At frequent intervals the brake pedal should be • Return spring (5). checked for travel. Travel is the distance the pedal 2.
Page 438 5-18 BRAKES 1. Bolt 2. Nut 3. Bushings 4. Spacer 5. Return Spring 6. Retainer 7. Washers 8. Pushrod 9. Washer 10. Pin 12. Brake Pedal B-07771 Figure 14—P30 (32) Brake Pedal Components 4. Washer (9) and pin (10). Install or Connect (Figure 15) •...
Page 439 BRAKES 5-19 3. Bushing 5. Return Spring 6. Retainer 7. Washer 8. Push rod 9. Washer 11. Clutch Pedal 12. Brake Pedal 13. Pin 14. Retainer 15. Clutch Attaching Components B-07770 Figure 15—G-Van Brake Pedai Components P 30 (42) MODEL •...
Page 440: Brake Pedal Rod Replacement
5-20 BRAKES 18. Bolt B-07772 Figure 16—P 30 (42) Brake Pedal Components BRAKE PEDAL Adjust ROD REPLACEMENT • Brake rod to 790 mm (31.00-inches) from the centers of the bolt holes. P 30 (32) MODEL 2. Brake rod (8). 3. Bolt (19) and washers (20 and 21). Remove or Disconnect (Figure 17) •...
Page 441 BRAKES 5-21 SWITCH REPLACEMENT 2. Electrical connectors. 3. Negative battery cable. «"► Remove or Disconnect SWITCH ADJUSTMENT 1. Depress the brake pedal and press the switch in 1. Remove the negative battery cable. until it is firmly seated in the clip. 2.
Page 442: Parking Brake System
5-22 BRAKES PARKING BRAKE SYSTEM Nuts Bolt Release Rod B-07774 Figure 18—Removing Parking Brake Pedal on C-K, and G Models PARKING BRAKE PEDAL OR +*• Install or Connect (Figure 18) HANDLE REPLACEMENT NOTICE: See “ N otice” on page 5-1 o f this section for steps 2 and 4.
Page 443: Cable Replacement
BRAKES 5-23 Tighten 4. Cable assembly (36). • Attach a piece of wire to the cable to help in • Refer to “ Torque Specifications” in this installation. section. 5. Check the parking brake adjustment, refer to Install or Connect (Figure 20 and 21) “...
Page 444 5-24 BRAKES Figure 19—Removing Parking Brake Lever on P Models...
Page 445 BRAKES 5-25 31. Nut 32. Equalizer 33. Connector B-07777 Figure 20—Equalizer Components 34. Frame Retaining Fingers 35. Pedal Retaining Fingers 36. Cable Assembly B-07778 Figure 21—C-K Front Cable Components...
Page 446 5-26 BRAKES 33. Connector 34. Frame Retaining Fingers 36. Cable Assembly 37. Bolt 38. Clip B-07780 Figure 22 —P Model Front Cable Components 3. Cable. -►+ Install or Connect (Figure 20) 1. Cable. 2. Connector (33). 3. Nut (31) onto the equalizer (32). Adjust •...
Page 447: Propeller Shaft Brake Replacement
BRAKES 5-27 3. Lever strut (55) and strut spring (57). Install or Connect (Figure 20) 4. Washers (63). • Hold down springs (64). 1. Cable assembly. • Make sure all the retaining fingers are completely • Hold down clips (65). through the backing plate.
Page 448 5-28 BRAKES 51. Support Plate 63. Washer 52. Washer 64. Hold Down Spring 53. Anchor Pin Nut 65. Hold Down Clip 54. Hold Down Pin 66. Drum 55. Lever Strut 67. Lever Retaining Ring 56. Return Spring 68. Shoe 57. Strut Spring 69.
Page 449 BRAKES 5-29 3. Loosen the equalizer nut. Adjust • Adjusting screw until the drum cannot be Adjust rotated by hand. • Equalizer nut until a light drag is felt • Back off the adjusting screw ten notches. The drum should rotate freely. while rotating the wheels forward.
Page 450: Master Cylinders
5-30 BRAKES MASTER CYLINDERS MASTER CYLINDER REPLACEMENT + + Remove or Disconnect (Figure 27) • Apply the vehicles parking brakes. 1. Brake pipes. • Cover the ends of the pipes to prevent dirt from entering the system. B-07803 2. Mounting nuts. 3.
Page 451 BRAKES 5-31 Figure 27—Master Cylinder Installations...
Page 452: Vacuum Boosters
5-32 BRAKES 4. Reposition the master cylinder in the vise to the Using a smooth rounded end tool, stroke the level position. Loosen the plugs one at a time and primary piston about 25 mm (1-inch) several push the piston into the bore to force the air from times.
Page 453: Hydraulic Brake Booster (Hydro-Boost)
BRAKES 5-33 Tighten • Mounting nuts to 34 N m (25 ft. lbs. 7. Release the parking brakes. HYDRAULIC BRAKE BOOSTER (HYDRO-BOOST) 5. Nuts (1). DESCRIPTION £ Tighten This system uses a hydraulic pump to power the system and a pneumatic accumulator as a reserve •...
Page 454 5-34 BRAKES Figure 29—C-K and G Model Hydro-Boost Replacement...
Page 455 BRAKES 5-35 1. Nut 2. Master Cylinder 3. Hydro-Boost 4. Nut 7. Washer 8. Washer B-07809 Figure 30—P 30 (42) Hydro-Boost Replacement 9. Release the parking brakes. P 30 (32) MODEL Remove or Disconnect (Figure 32) • Apply the vehicles parking brakes. 1.
Page 456: Bleeding The Hydro-Boost System
5-36 BRAKES Master Cylinder Hydro-Boost 10 . 11 . Washer 12 . Washer Washer Bolt Bolts Bolt B-07811 Figure 32—P 30 (32) Hydro-Boost Replacement • Washers (13) and nuts (12). Leave finger NOTICE: The power steering fluid and brake tight. fluid cannot be mixed.
Page 457: Disc Brakes
BRAKES 5-37 11. Check for the presence of air in the oil. Air in the obvious that the pump will not bleed the air after oil will have a milky appearance. Air in the system a few attempts, refer to POWER STEERING (Sec. will also cause the fluid level in the pump to rise 3B3) for futher diagnosis, when the engine is turned off.
Page 458: Brake Lining Replacement
5-38 BRAKES BRAKE LINING REPLACEMENT 3000/3100 MODELS Remove or Disconnect (Figure 35) • % of the brake fluid from the master cylinder. • Raise the vehicle and support it with suitable safety stands. • Mark the relationship of the wheel to the hub. 1.
Page 459 BRAKES 5-39 Im portant £ Tighten • Before moving the vehicle, pump the brake • Bolts to 50 N m (37 ft. lbs.) pedal several times to make sure that the pedal is firm. Do not move the vehicle until a 6.
Page 460 5-40 BRAKES 6. Inboard Pad Figure 41—Replacing Disc Brake Figure 43—Compressing The Caliper Piston Linings (Bendix Models) 3. Bolt (8). 1. Wheel and tire assembly, refer to WHEELS AND 4. Support key (9) and spring (10). TIRES (Sec. 3E). • Use a brass punch and a hammer to drive the CAUTION: See “...
Page 461: Servicing The Rotor
BRAKES 5-41 3. Caliper assembly. Im portant • Make sure that the brake hose is not twisted or kinked since damage to the hose could result. 4. Spring (10) and support key (9). • Use a brass punch and a hammer to drive the support key in (figure 46).
Page 462 5-42 BRAKES PARALLELISM Parallelism is the measurement of the thickness of the ro to r at fo u r or m ore p o in ts a round the circumference of the rotor. All measurements must be made at the same distance in from the edge of the rotor.

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GMC 1986 P-Truck Service Manual

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