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Chevrolet 10 1971 Series Chassis Service Manual

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Table Of Contents
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Table of Contents

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Summary of Contents for Chevrolet 10 1971 Series

  • Page 2 30 Trucks. Procedures involving disassembly and assem­ bly of major components for these vehicles are contained FUEL SYSTEM in the 1971 Chevrolet Passenger Car and Series 10-30 Truck Overhaul Manual. EMISSION CONTROL The Section Index on this page enables the user to SYSTEMS quickly locate any desired section.
  • Page 3 Last number of model year 1971. - All - 30-35 Assembly plant, F = Flint. - 42-47” 600025 Twenty fifth vehicle built at that plant. - 48-53" Unit numbering starts at 600001 at all - 54-59" plants. - 60-65" 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 4 The engine number indicates manufacturing plant, month and day of manufacture, and transmission type. A The Chevrolet Truck Service Parts Identification Plate typical engine number would be F1210TFA, which would (fig. 2) is provided on all Truck models. On most series...
  • Page 5 Load capacity chart on the following not operating properly or when a speed of 35 MPH or dis­ pages. tance of 50 miles will be exceeded. 10-30 CHEVROLET TRUCK SERVICE MANUAL...

  • Page 6: Table Of Contents

    ENGINE-VEHICLE AVAILABILITY Body Base Engine W.B. Series 10 Series 20 Series 30 Body Base Engine W.B. Series 10 Series 20 Series 30 Convent. 250 L-6 Gas CS10703 Steel Step- 250 L-6 Gas PS10535 CS10903 CS20903 Van 7 106" BBC CS31003 Steel Step- 250 L-6 Gas PS20835...
  • Page 7 TOTAL W EIGH T AT G R O U N D : 5000 lbs. springs or tires. In loading the vehicle, the combined front and rear end 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 8 Refer to GVW plate on vehicle. Maximum fro n t and rear end loads on this Load Capacity Chart are based upon component m inim um capacity of axles, springs, or tires, t RPO J70 Power Brakes required B E. denotes "base equipm ent" July 10, 1970 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 9 91 Research Octane Number or higher, excessive knocking is considered misuse of the engine commonly sold in the United States and Canada. Use of for which the Chevrolet Motor Division is not responsible a fuel which is too low in anti-knock quality will result under...
  • Page 10 Chevrolet's obliga­ hose. tion under the provisions of the new vehicle warranty.
  • Page 11 12,000 miles when the vehicle is used in a fraying, cracking, and tension. Belts which are in poor service requiring more frequent engine oil change as condition should be replaced immediately. covered under “ Engine Oil Change Interval". 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 12 3. Run engine until normal operating tempreature is Battery Terminals The bolt-on battery cable terminals must be clean and reached. tight. When corrosion appears on the terminals they 4. Drain and refill the system as described in steps 1, 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 13 Radiator pressure the lubricant level. caps should be checked periodically for proper operation. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 14 Every 24,000 miles—after removing fluid from the ward speed until brake performance returns to transmission sump, add approximately 7.5 pints U.S. normal. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 15 Front wheels are equipped with tapered roller bearings The Chevrolet braking system requires very little on all trucks. Wheel bearings should be lubricated every care; however, the system should be checked occasion­...
  • Page 16 Motor Division, General Motors Corporation, Owner refilled with S.A.E. 90 "GL-5” gear lubricant when nec­ Relations Dept., Detroit, Michigan 48202, for detailed in­ essary. With the differential at operating temperature, structions on how to prepare your truck for storage. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 17 6,000 Miles Chassis Lubricant As required Universal Joints 6,000 Miles Chassis Lubricant As required Not shown Propeller Shaft Slip Joint Check As required Rear Axle 6,000 Miles GL-5 See Lubrication Section ♦Replace Lubricator at 24,000 mile intervals. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 18 Pedal Springs 6,000 Miles Engine Oil As required Transfer Case 6,000 Miles GL-5 As required Check See Lubrication Section Throttle Bell Crank - L-6 6,000 Miles Engine Oil As required ^Replace Lubricator at 24,000 mile intervals. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 19 The blower motor, heater core, and hose assembly receiving its airflow from the cowl vent plenum chamber. mount on the engine side of the firewall while the distri­ O U T L E T S Fig. 1— Heater A irflow Schematic 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 20 BLOWER, CORE CASE A N D CORE ASSEMBLY Removal (Fig. 3) 1. Drain radiator. 2. Disconnect battery ground cable. 3. Unclip the blower motor wire at the blower flange terminal. Fig. 3 — Heater Assembly 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 21 5. Connect the temperature door cable to the door and Installation 1. Replace the core in the case using non-hardening replace the seal. Fig. 5 — Heater Distributor and Ducts 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 22 Installation 1. Place resistor unit in distributor duct and drive in attaching screws. Connect harness connector to unit. £ 2. Install glove box assembly. CABLE DEFROST- TEMP FAN SWITCH Fig. 7 — Heater Control 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 23 “ HP'; at the full out purpose of the valve is to cut off coolant flow to the position, the fan is on “ LOW” . auxiliary core during warm weather and eliminate the radiant heat that would result. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 24 All Models—When replacing heater CAUTION: hoses, maintain a 1-1/8" minimum clearance between the auxiliary heater core outlet line and the exhaust pipe (fig. 12). Draw hoses tight to prevent sag or rub against other components. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 25 Roof-Mounted System .................1A-9 Blower A ss e m b ly ................1A-27 GM Chevrolet S y s te m ........... , ....1A-10 Evaporator C o r e ..................1A-27 General In fo rm a tio n ..................1A-12 Blower and Evaporator Case..............1A-28...
  • Page 26 (fig. 13). The resulting in a higher outlet air temperature. In the full control levers make use of bowden cables to activate the HOT position, all air flows through the heater core. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 27 DE-ICE position which sends the total airflow to the panel. The refrigerant lines are routed from the engine compartment to the blower-evaporator unit between the defroster ducts. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 28 OFF position to obtain maximum cooling. G M CHEVROLET SYSTEM The GM Chevrolet System is available as a dealer - installed accessory for CIO-30 and K10-20 series trucks. This system is also similar to the Four-Season System in placement of the compressor, condenser and receiver- Fig.
  • Page 29 D E H Y D R A T O R C O N D E N S E R Fig. 18— G M Chevrolet System Components The blower-evaporator unit is located under the glove compartment as indicated in Figure 18. An air duct,...
  • Page 30 R-12 be avoided. This caution is especially important if the area con­ tains a flame producing device such as a gas heater. While R-12 normally is nonpoisonous, heavy con­ Fig. 2 0 — System Contaminants 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 31 Therefore, it will quickly ab­ sorb any moisture with which it comes in contact. For this same reason the oil container should be F ig- 21— J-8393 Charging Station 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 32 • If this pump is subjected to extreme or prolonged cold, allow it to remain indoors until oil has reached approximate room temperature. Failure to warm oil will result in a blown fuse. Fig. 2 2 — Charging Station G auge Set 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 33 Since R-12 is heavier than air, it is The 15 oz. disposable cans are generally used for NOTE: good practice to place open end of sampling tube miscellaneous operations such as flushing. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 34 (fig. 25). Hose Clamp Connections - If clamp screw torque is Roof-Mounted and GM Chevrolet Systems - The low less than 10 in. lb., retighten to 20-25 in. lbs. Do not tighten to new hose specifications or hose leakage pressure fitting is located on the connector block and may occur.
  • Page 35 "Cold.” Air Entering 70° 80° 90° 100° 110° 120° GM Chevrolet System - Right knob at "City.” Condenser • High blower speed. 5. Gauge set installed. 2000 Engine rpm 6. System settled out (run-in approximately 10 minutes).
  • Page 36 33.5 psig. -- 8000 ft. 34.0 psig. — 9000 ft. 34.5 psig. — 10000 ft. THERMOSTATIC SWITCH Roof-Mounted and G M Chevrolet Systems These systems make use of a thermostatic switch with an air sensing capillary. This capillary controls the switch by sensing the temperature of the air leaving the fins (fig.
  • Page 37 The last two may be corrected by replacing the valve inlet drain tubes. screen and by properly installing the power element bulb. GM Chevrolet System - Lower the entire unit from Attachment of the expansion valve bulb to the evaporator its dash mounting, remove the duct assembly from outlet pipe is very critical.
  • Page 38 Evacuating and Charging System frigerant. Oil loss can be easily detected on rag at discharge line. 1. Install charging station and purge system as noted 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 39 HEATER AND AIR CONDITIONING 1A-21 Fig. 30— Charging Schematic (Four Season System Shown) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 40 15 minutes after the system oil. reaches 28-29 inches vacuum. 3. a. If the quantity drained was 4 fluid oz. or more, 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 41 1. Remove the compressor. 2. Remove the receiver-dehydrator and discard the unit. Hose Clamps 3. Flush the condenser to remove foreign material When hose clamp connections are encounted, special which has been pumped into it. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 42 1. Locate the leak. This may require removing the body inner side panels to gain access to the hoses. this case, retorque to 20-25 in. lbs. Further tight­ 2. Discharge the system. ening may damage the hose. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 43 Chassis Overhaul 4. Evacuate, charge and check the system. Manual. G M Chevrolet System Installation This system makes use of individual hoses, attached at 1. If oil previously drained from the compressor upon 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 44 3. Install the new glass and seal and retainer nut, being careful not to turn the nut past the face of the housing. To do so may damage the "O" ring seal. 4. Evacuate and recharge the system. Fig. 33— Condenser and Receiver-Dehydrator 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 45 3. Remount the hood hinge aligning it carefully with the oil. Install the pipe clamp. scribed lines. Check hood alignment. 5. Connect the evaporator oil bleed line to the POA 4. Connect battery ground cable. valve. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 46 2. Mount the core with the core straps and retaining 3. Connect temperature door cable and vacuum hoses screws. (hose to engine vacuum source attaches to vacuum Replace the heater case in the vehicle as outlined tank connection nearest the engine). under Heater Case. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 47 3. Disconnect the capillary bulb from the evaporator outlet hoses must be replaced as a unit. W A T ER V A L V E Fig. 36— A / C and Heater Hose Routing-Typical 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 48 2. Secure POA valve clamp and outlet line clamp. and the compressor inlet hose at the POA valve. Cap 3. Connect the evaporator oil bleed line and the ex- Fig. 3 8 — A ir Outlets and Hoses 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 49 3. Remove blower switch mounting screws and remove switch. Installation 1. Place blower switch in position and install mounting screws. 2. Connect wiring harness to switch. 3. Connect battery ground cable. Fig. 4 0 — A ir C onditioning Controls 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 50 3. Place the new relay in position (tang in bole in clip, and install the retaining screws. instrument panel) and install the mounting screw. 4. Mount the floor outlet duct to the firewall with the 4. Connect the wiring harness. attaching screw. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 51 V A C U U M SOURCE V A C U U M SW ITCH VA LVE Fig. 4 3 — A ir Inlet V a lv e and Recirculating A ir V alve Fig. 4 5 — Vacuum Diagram 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 52 5. Remove the two switch mounting screws and remove the switch assembly. Installation 1. Install the switch connectors to the switch assembly as noted in Figure 47. 2. Place the switch in position (connectors pointed 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 53 E V A P O R A T O R C O R E Replacement 1. Disconnect the battery ground cable. 2. Remove the rear duct as outlined previously. Fig. 4 9 — Thermostatic Switch C apillary Installation 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 54 7. Install the rear duct as described previously. 8. Connect the battery ground cable. 9. Evacuate, charge and performance test the system. Fig. 5 0 — Blower M otor Installation 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 55 C O R E M O U N T IN G BO LTS L O W E R C O R E C A S E Fig. 5 2 — Evaporator Core Installation Fig. 5 3 — Compressor Connector Block and M uffler 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 56 Figure 56. The coolant SWITCH CAPILLARY system need not be opened up to gain access to these switches. However, the entire unit must be lowered from its dash mounting. Fig. 5 6 — Thermostatic and Blower Switch Locations 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 57 CAPILLARY INSTALLED VALVE EXPANSIO N SWITCH IN BRACKET CAPILLARY VALVE Fig. 5 7 — Thermostatic Switch C a p illa ry Retaining Bracket Fig. 5 9 — Evaporate Core and Expansion V a lv e Location 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 58 4. Connect battery ground cable. lines using new "O" rings coated with clean refriger­ 5. Performance test the system. ation oil. Install the upper case half to the core and CHEVROLET TRUCK SERVICE MANUAL...
  • Page 59 R E P L A C E EXISTING H EATER FUSE WITH 25 A M P . FUSE irnrv- ~ —^120R______^ > 14 BRN ^-CONNECTOR R EC E PT A C LE "C IG " Fig. 6 0 — Four Season System W iring Diagram CHEVROLET TRUCK SERVICE MANUAL...
  • Page 60 R E L A Y czD ■ - ..10 R - ■ 12 OR- R E C E P T A C L E -14 DG- Fig. 6 1 — Roof Mounted System W iring Diagram CHEVROLET TRUCK SERVICE MANUAL...
  • Page 61 14 PL EXISTING—'■ "'* 1 • HEATER HARNESS CONNECTOR TO HEATER CONTROL SWITCH TEMP. CONTROL SWITCH -EVAPORATOR & BLCWER ASM. 14 TAN ■BLOWER CONTROL SWITCH Fig. 6 2 — G M Chevrolet System W iring Diagram CHEVROLET TRUCK SERVICE MANUAL...

  • Page 62: Pickup

    28. J-22974 Shaft Seal Protector 12. J-9396 Compressor Holding Fixture 29. J-9527 Pressure Test Connector 13. J-9397 Compressing Fixture 30. J-9402 Parts Tray 14. J-9403 Clutch Hub Holding Tool 15. J-9399 9/16" Thin W all Socket CHEVROLET TRUCK SERVICE MANUAL...
  • Page 63 An alternate method for locating leaks is as follows: 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 64 The procedure for removal of the windshield applies to the complete windshield assembly. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 65 Remove all high spots. 4. Check windshield glass to opening, by supporting glass with six spacers contained in packet J-22577. Fig. 5 — Dash Panel and Cowl Side Panel to Floor Panel Sealing 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 66 Removal and Installation ing on both ends of the cord at each corner. 1. Loosen or remove any necessary instrument panel This will insure proper positioning of the critical items, glove box, etc. upper corners. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 67 4. Remove the six (6) screws retaining the front of the plenum chamber. grille to the cowl. 5. Remove the two larger size screws from each end STANDARD CUSTOM Fig. 7 A — Cross Section of W indshield Weatherstrip (Typical) Fig. 9— Cord Installation 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 68 Arm can be reinstalled in any one of Fig. 13— Instrument Panel Cover Fig. 11— Rear View Mirrors Fig. 14— Cowl Ventilator G rille Intake - Cab M odels 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 69 INSTALL KN O B UNTIL THREADS BOTTOM OUT A N D TIGHTEN TO CORRECT POSITION DASH & TOE PANEL RIGHT HAND Fig. 16— Cowl A ir Ventilator V a lv e Fig. 18— Endgate - Stepside and Fleetside 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 70 2. Remove bolt and lock washer from each trunnion in carrier box endgate. Remove endgate. 4. Reverse procedure for installation. Align slot in trunnion to coincide with hole in endgate to permit Fig. 21 — Liftgate Adjustments 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 71 Remote and Push Button Control Assembly Removal and Installation (See Fig. 25) 1. Remove remote and push button control assembly access cover. ADJUSTABLE Fig. 2 3 — Endgate Replacement Fig. 2 4 — Endgate Adjustements 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 72 2. Remove two nuts securing the escutcheon. panel. However, in order to adjust the cab front side door 3. Remove escutcheon and gasket. assembly at the body hinge pillar it is necessary to use 4. Reverse procedure to install. 10-30 CHEVROLET TRUCK SERVICE MANUAL...

  • Page 73: Step-Van

    Figure 29. 3. Adjustment of the door lock and striker plate should a. Remove the door to upper hinge retaining bolts. Fig. 27— Endgate Remote and Push Button Control Replacement Fig. 29— Door Hinge Bolt Replacement 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 74 The striker inner edge must be parallel to NOTE: ing the door ventilator assembly. the striker mounting depression on the pillar. Fig. 3 3 — Adjusting Ventilator Operating tension Fig. 3 1 — Vent Assembly Inner Door Panel Attachment 10-30 CHEVROLET TRUCK SERVICE MANUAL...

  • Page 75: King

    Glass should be installed so that rear NOTE: edge is parallel to the division post. Allow full cure before water testing. Fig. 3 5 — Door O pening Weatherstrip 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 76 6. Remove screws retaining remote control. 7. Remove lock, push button rod and remote control rod bits of old weatherstrip. After removing all foreign ma­ as an assembly. terial from door opening surface, wipe down with prepsol 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 77 2. Remove control knobs and trim assembly. of engagement and remove lock cylinder (fig. 37). 3. Remove three (3) screws from the door end - at the 3. To install, reverse removal procedure. rotor lock. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 78 (fig. 44). Fig. 41— Side Rear Door Rear Remote Rod C lip Removal 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 79 Pull downward on run and forward. Remove stationary glass with rubber seal attached, and remove run by pulling through a glass opening, if necessary. Fig. 44— Lock Rotor Cover Assembly and Striker Plate Reverse above procedures to install. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 80 The glass is held in a channel within the weather­ opening. strip similar to the windshield glass and weatherstrip. 5. Start one end of the glass into its channel in the 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 81 It is sometimes more desirable to have a small stain than an enlarged stain as a result of careless cleaning. immediately by a soft brush to completely remove the spot. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 82 5 parts water, apply for 1 minute, rinse with dried residue. clean, wet cloth. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 83 Major re­ pairs such as torn panels, separated joints require the 1. Look for hidden damage. Apply force by hand around reinforcing qualities of the glass fibers. the damaged area. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 84 Figure 57 shows the top of a fender panel which has been scratched through to the plastic. Fig. 5 4 — G rin din g " V " at Damaged Area 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 85 2. Remove the paint down to the plastic from both plastic build-up. portions of the panel. Fig. 5 6 — A pplying Laminate to Body Fig. 5 8 — Repair Area Finish Sanded 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 86 1/8" between the panels or as neces­ Fig. 60— Typical Cracked Panel sary to provide proper alignment of panels, Figure 61. Fig. 6 1 — Cracked Panel Preparation - Typical Fig. 63— Liftgate Hinge 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 87 13. Liberally apply the plastic mixture with a spatula to fracture and surrounding area. Deposit enough material build-up to allow for filing and sanding operations. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 88 2. Remove the control assembly access hole cover as 2. Lower the tail gate completely. shown in Figure 64. 3. Remove the access hole plugs from the body to ex- 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 89 2. Remove the handle assembly. When the vehicle is equipped with the optional hard top, 3. Remove the screws which retain the control assem- the tail gate is sealed in the body opening with weather- 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 90 Models for Body Mount #1. Mounts two, three, Driver Seats four, and five are as shown in Figures 72 and 73. Both the standard seat and the optional driver’s bucket seat mount as shown in Figure 68. Torque mounts to specifications. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 91 4. Install by reversing steps 1, 2 and 3. Drivers’ Window Weatherstrip and/or Complete Window Assembly Removal Remove glass as outlined under "Driver's Window Sliding Glass Replacement". Fig. 7 4 — Weatherstrip Installed 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 92 7. From the outside of the door work the run channel ends into weatherstrip rubber with the paint scraper and mallet handle to tap them back. Channel ends are shown in Figure 75. Fig. 7 6 — Installing Slidin g G lass 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 93 The run channel at front of window should be opened 2. To install the new glass follow the instruction set up to allow for the extra thickness of the glass thumb forth for “ Complete Driver's Window Installation." 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 94 .040 x 2-1/4" glass glazing strip sure is applied to it. or its equivalent. Center the latch on leading edge of 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 95 Fig. 79— Special Tools 1. J - 2 189— Weatherstrip Tool Set 2. J-5742-01 and J -22577— Windshield Checking Block (Typical) 3. J-22585— Front Door Hinge Bolt Wrench 4. J —9316— ’ W indshield Checking Blocks 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 97 4. If front or rear end of frame is damaged and width is no longer within limits, frame centerline may be drawn through the intersection of any two previously drawn pairs of equal, intersecting diagonals. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 98 O.D. of the bolt as possible to pre­ ing points, with dimensions for various frames shown in vent bolt from working and wearing. Drill out and line the chart below. ream hole (or holes) to the bolt O.D. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 99 187-3/4 14 16-7/8 16-7/8 16-7/8 9-1/4 11-5/8 12-5/8 15-3/4 13-3/8 7-3/8 9-3/4 31132 ( 137) 9-3/4 11-1/2 11-1/8 13-1/8 31-1/2 131-3/4 207-3/4 14 31432 9-1/4 11-5/8 12-5/8 15-3/4 13-3/8, 7-3/8 9-3/4 16-7/8 16-7/8 16-7/8 (157) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 100 Fig. 4 10-30 Series Truck Frame...
  • Page 101 Special T ools - 4 W heel D r i v e ............ 3-19 GENERAL DESCRIPTION Chevrolet 10-30 series truck use an independent wheel located between the lower control arm and a formed seat front suspension incorporating a coil spring.
  • Page 102 Caster and Camber— Figure 2 (fig. 4) for the appropriate vehicle, shown below, find Positive caster is the amount in degrees of the back­ the recommended caster angle. Fig. 1— Front Suspension C - P - K Typical 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 103 2. Check bearing races for cracks or scoring, check soft hammer. 3. Position hub on spindle and install outer bearing, brake drums for out-of-round or scored condition and check bearing outer races for looseness in hubs. pressing it firmly into position in hub. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 104 2. Remove brackets and bushings at lower control arms spring can be removed. and remove stabilizer from vehicle. 7. Remove spring. Inspection Installation Inspect rubber bushings for excessive wear or aging - 1. Properly position spring on the control arm, and lift 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 105 1. Raise vehicle on hoist and remove spring as outlined under spring removal. 2. Remove cotter pin from lower ball stud and loosen stud nut unitl top of nut is slightly above top of the stud. Fig. 5 — Camber Caster Shims 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 106 1. Using Tools J-9519-10 and J-9519-7 as shown, turn assure proper retention of this part. down on hex head screw until the ball joint is pushed 4. Install a lube fitting into the ball stud assembly. out. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 107 Fig. 11— Removing Coil Spring with Tool J-23028 REMOVE REMOVE UPPER LOWER HEAVY ■ FLAT ■ W A S H E R ^ l J—23742S 1 Fig. 9— Shock Absorber - K Series Fig. 12— Loosening Ball Joint Stu d-T ypical 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 108 Do not use replace­ tighten nut. ment parts of lesser quality or substitute design. CP 10 CP 20-30 Fig. 16— Positioning Lower Control Arm Shaft Fig. 14— Removing and Installing Ball Joints - Typical 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 109 3. Withdraw wheel and tire, remove caliper as outlined under "Front Wheel Hub” and wheel hub and disc assembly from steering knuckle spindle. Remove disc splash shield bolts securing the shield to the steering knuckle. Fig. 18— Suspension Crossmember 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 110 7. Check and Adjust front end alignment as outlined Component parts of the front suspension may be ser­ under "Maintenance and Adjustments" in this section. viced separately as outlined in the preceding service 8. Remove vehicle from hoist. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 111 1. Raise vehicle on hoist then place jack stands just NOTE: Knuckle should turn smoothly through inside of front springs. turning arc but have no vertical end play. 2. Disconnect connecting rod and tie rod to allow inde­ pendent movement of each steering knuckle. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 112 1. Wash all parts in solvent and air dry. ring and actuating cam body. 2. Inspect all parts for wear, cracks or broken teeth. 4. Relieve pressure on the axle shaft snap ring and 3. Replace all “O” rings during assembly. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 113 12. Remove inner and outer hub bearing cups with brass drift. Install actuating knob with knob NOTE: "LOCK” position - - grooves in knob must fit into Inspection actuator cam body. 1. Discard all seals, gaskets and "O ” rings. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 114 12. Install alien head bolts securing the retainer cap as­ sembly to the wheel hub. Torque to specifications. Fig. 23 — Removing Bearing Cups 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 115 Remove the oil seal and bearing spacer. 8. Assemble propeller shaft to front axle differential. c. Remove the needle roller bearing. 9. Lower vehicle on hoist. 8. Remove the axle shaft and joint assembly. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 116 Repeat as required If Tie Rod and Steering A rm Were Rem oved: at the upper ball stud location. a. Assemble the steering arm using the three stud 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 117 10. Install the bronze thrust washer over the axle shaft wheeling hub assembly and installation procedures. and install the spindle as shown in Figure 30. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 118 3. J-8849 Bearing Race Installer 4. J-9276-2 Bearing Race Installer 5. J-8092 Driver Handle 6. J-9519-9 Ball Joint Installer 7. J-9519-10 " C " Clamp 8. J -23742-1 Ball Joint Remover 9. J -23028 Spring Remover 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 119 " C " Clamp 5. J-23445 Bearing Installer 6. J-23446 Bearing Adjuster Adapter 7. J-23447 Adjusting Sleeve Spanner 8. J -23448 Cup and Seal Installer 9. J-23454-1 Ball Joint Remover/Installer 10. J-23454-2 Ball Joint Remover/Installer 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 121 1. Raise vehicle on hoist. absorber with the air fitting pointed rearward. Fig. 1— Shock Absorber Installation— CP20, K 1 0 -2 0 M odels Fig. 2 — Shock Absorber Installation— C P I 0 M odels 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 122 Do not use re­ placement parts of lesser quality or substitute design. Torque values must be used as specified Fig. 4— Tie Rod Bushing Replacement (Series C -P 1 0 -C 2 0 ) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 123 Fig. 6— Removing Control Arm Spring Clamp Bolt (Series C -P1 0 -C 20 ) Fig. 8 ~ C o n tro l Arm and Spring Details (Series C -P 1 0 -C 2 0 ) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 124 1. Raise vehicle on hoist. Place adjustable lifting device under axle. Fig. 11— A u x ilia ry Rear Spring (Series C 1 0 -2 0 ) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 125 370 ft. lbs. and install cotter pin. 3. Remove nut and bolt securing shackle to spring hanger. 12— 30 11,000 Fig. Leaf Spring Installation— Series lb. Axle with Auxiliary Spring Shown Fig. 14— Pressing O u t Bushing 10-30 CHEVROLET TRUCK SERVICE MANUAL...

  • Page 126: Rear Axle

    No-Spin Differential U n i t .............. 4-21 4 - 1 5 Installation ..................4 - 1 5 On The Vehicle Check .............. 4-21 Axle Vent ............. ..4-16 Specifications ............See Specification Section 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 127 10. Differential Bearing 16. Side G ear Pinion Rear 5. Pinion Bearing Spacer 11. “ C ” Lock 17. Bearing Cap Bearing 6. Differential Carrier 12. Pinion Shaft Lock Bolt 18. Axle Shaft Drive Pinion 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 128 15. Thrust Washer Deflector 10. Shim 16. Differential Pinion G ear 22. Drive Pinion Rear Bearing 5. Seal 11. Differential Side Bearing 17. Thrust Washer 23. Drive Pinion Front Bearing 6. Slinger 12. Gasket 18. Differential Case 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 129 The 11,000 lb. capacity, single-speed hypoid axle, while others use a four-pinion differential. illustrated in Figure 17 have a straddle mounted drive 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 130 This design provides for the driving torque to be trans­ case and also between differential pinions and the dif­ mitted from the axle shaft to the hub through the mating ferential case. splines. A thrust pad mounted on the end of an adjusting screw 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 131 4. Connect axle vent hose to vent connector at carrier. 5. Connect hydraulic brake hose to connector on axle housing, connect parking brake cable to actuating levers. Install brake drum and wheel and tire as­ Fig. 18— Differential Pinion Shaft Removal CHEVROLET TRUCK SERVICE MANUAL...
  • Page 132 2. Remove four nuts securing flange plate to axle hous­ ing (fig. 19). 3. Install new flange plate to axle housing and torque nuts to specifications. Fig. 19— Sectional View of Housing at Wheel Bearing Fig. 21A — Seal Installation 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 133 (EXCEPT 5500 LB. D A N A AXLE) (Fig. 22) Removal 1. Raise vehicle on hoist allowing axle to hang freely TO O L J-6627 or J-55 0 4 Fig. 22— Pressing O u t Wheel Stud Fig. 24— Drive Pinion N ut Removal 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 134 J-9458 after flange is seated. NOTE: This propeller shaft to pinion flange fastener is an important attaching part in that Fig. 27— Drive Pinion Flange O il Seal Installation (Heavy Duty) Fig. 25— D rive Pinion Flange Removal 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 135 20-30, 5200 - 7200 lb. capacity axles service nuts, and tighten securely. (On P30 series vehicles procedures for service on wheel hubs, bearings, make sure that stabilizer anchor plates are properly and axle shafts. positioned on forward “ U” bolts.) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 136 By turning these bolts alternately the axle shaft may be easily started and then removed from the housing (fig. 31). Fig. 32— Removing A xle Shaft (11,000 lb. A xle) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 137 5. Hub Outer Bearing Retainer 12. Thrust Washer 6. Wheel Bolt 13. Bearing Adjusting Nut 7. Drum 14. Adjusting Nut Lock 8. O il Deflector 15. Gasket Fig. 35— Bearing Adjustment N u t Removal (Typical) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 138 Tool J-2223 for 5200, 7200 axles; Tool J-8114 with J-8092 drive handle for 11,000 lb. axle. Fig. 38— Bearing Retainer Ring Removal (5200 and 7200 lb. Axle) Fig. 36— Removing Hub Inner Bearing Cup 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 139 Wheel bolts are serrated and may also be swaged in place; however, replacement procedure remains the same for both types of installation. REMOVAL INSTALLATION Fig. 40— Removing Wheel Hub O uter Bearing Retainer Ring Fig. 41— Wheel Bolt Replacement 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 140 J-2222 for 5200, 7200 axles. b. J-0870 for 11,000 lb. axles. Adjust wheel bearings according to the following procedure. Fig. 42— Installing Wheel Hub O il Seal Fig. 43— Tightening Wheel Hub Bearing Adjustment N u t (Typical) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 141 It must be replaced with one of the 8. If wheels cannot be rotated freely as described same part number or with an equivalent part if replacement becomes necessary. Do not use a above, remove and inspect the No-Spin. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 142 3. Using a suitable socket or rod, press on trunnion until bearing cup is almost out (fig. 47). Grasp cup in vise and work cup out of yoke. The bearing cup cannot be fully pressed NOTE: out. Fig. 45— “ U ” Bolt Attachment 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 143 U-joint axle. Torque bolts to specifications. Fig. 48— Universal Joint Repair Kit 1. Trunnion 4. Cap 2. Seal 5. Snap Ring 3. Bearings Fig. 49— “ U ” Joint Trunnion Seal Installer 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 144 (fig. 51). Then, note rela­ Keep rear portion of propeller shaft up NOTE: tionship of front shaft and rear shaft spline po­ to avoid interference of rear yoke half with sition. For all models except model CE31403 center yoke. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 145 Gently pull rear yoke half from prop shaft. Remove with a heavy grease. Assemble seals to bearing all loose needle bearings. Remove spring seal. cups. Fig. 53— Bearing C up Removal Fig. 52— D riving O u t Bearing Cups 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 146 Series C -P lO T ie Rod Bushing I nstal I er 4. J-8118 Rear Spring Pin Puller (Used with J—261 9) 5. J-8448 Series C -P lO a n d C -3 0 Control Arm Bushing Installer 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 147 Heavy Duty Axle J—1313 Torque Weench-ft. lbs. 8. J-23690 Axle Shaft Bearing In sta lle r- J-6627 Heavy Duty Axle or 5504 Wheel Bolt Remover 9. J-21128 Axle Shaft Seal Instal ler— Heavy Duty Axle 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 148 Wheel Bearing Installer 3. J-22281 Pinion Flange O il Seal Installer J—8114 Wheel Bearing Installer 4. J-2223 Wheel Bearing Installer J-22380 Tru-Arc Pliers 5. J-2222 Wheel Bearing Nut Wrench J-2619 Slide Hammer with Adapter J—81 17 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 149 3. Replace all rubber parts of the system, including In the event that improper fluid has entered the system, brake hoses. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 150 Place the 1. Clean all dirt from top of main cylinder and remove loose end of bleeder hose into the container. Be sure cylinder cover and rubber diaphragm. the hose end is submerged in the fluid. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 151 (fig. 6). Fig. 3 — Front Disc Brake Fig. 5 — Brake Bleeder J —23518 and J -2 370 9 - Installed 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 152 The hose should enter the bracket with a NOTE: slight twist of about 20° of the hose. 4. Install the clip retainer. 5. Install the steel line to the flex line. 6. Bleed brakes as outlined in this section. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 153 The proper size die blocks and upset flare punches are as follows: Upset Finish Tubing Size Die Block Flare Punch Flare Punch 3/16' J-2185-27 J-2185-3 J-2185-26 1/4' J-2185-28 J-2185-37 J-2185-26 Fig. 10— Tubing Flaring Tool J-2 185 5/16' J-2185-4 J-2185-29 J-2185-26 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 154 UPSET FLARE PUNCH RAM GUIDE LATCH PLATE- DIE BLOCK TUBE STOP PLATE Fig. 12— Positioning Tube Fig. 14— First and Second Flare 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 155 C " C LA M P OUTER BRAKE S H O E Fig. 15— " C " Clamp For Removal Aid Fig. 16— C aliper Removal and Installation 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 156 “C” 10. Remove the clamp and position the caliper over is firm. Do not move vehicle until a firm pedal the brake disc, lining up the hole in the caliper ears is obtained. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 157 1. Disconnect the hose from the steel brake line and Fig. 19— Installing Support Spring Fig. 2 1 — Fitting Shoe to Caliper 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 158 This may damage rubber parts when they come 7. Remove the bleeder valve from the caliper. in contact after reassembly. PULL BACK SPR IN G S PRIMARY SH O E Fig. 25— Rear Brakes Fig. 23— Installing Boot to Piston 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 159 (directional). 5. Install the brake hose in the caliper inlet using a 7. Both surfaces must be square with bearing cup new copper gasket. centerline within .003 T.I.R. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 160 4. Unhook brake shoe pull back springs from anchor pin and link end, using Tool J-8049. 5. Remove the actuator return spring. Fig. 2 9 — Backing Plate Contact Surfaces 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 161 Fig. 3 2 — Using D rum -to-Brake G auge J —21177 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 162 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 163 A brake drum must not be rebored more than .060” parts, causing them to become soft and swollen over the maximum standard diameter, removal of more in an extremely short time. metal will effect dissipation-of heat. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 164 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 165 If slight rust is found inside either line tube nut into each outlet hole and turn the nuts down the front or rear half housing assemblies, polish clean until the insert bottoms. (Remove the tube nut and check 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 166 8. Connect battery ground strap or stop light wires and cover and install the cover on the main cylinder. brake warning switch wire (whichever was discon­ Assemble the bail wires into position to retain nected at removal). the reservoir cover. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 167 8. Install reservoir cover and seal. scratches or corrosion. Minor blemishes can be removed 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 168 2. After tightening the locknut on the adjustable push rod, recheck free travel. All brake attachments are important at­ NOTE: taching parts in that the could affect the per­ formance of vital components and systems, and/ 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 169 This switch will illuminate the lamp on the that electrical contact is made when pedal travel instrument panel whenever the brake pedal travel is in measures .38” to .64” . excess of 5.10 inches. Fig. 41— Brake Pedal Free Movement 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 170 Adjustment of the cable connected “ rear wheel type” parking brake used on 1/2, 3/4, and 1 ton models must be performed each time the service brakes are adjusted and can be accomplished only when service brakes are in adjustment. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 171 4. Remove the guide plate from anchor pin. It may be necessary to knock out lanced 5. Remove shoe hold down cups, springs, and washers NOTE: area in brake drum with punch and hammer to from hold down pins - remove pins. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 172 2. Install transmission output flange on spline of main- shaft and fasten with flange nut. Torque nut to 100 foot pounds. 3. Install cable assembly from back of backing plate. Push retainer through hole in backing plate until 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 173 NOTE: valve must be held in the open position (not end of the metering portion of the combination allowed to close). This can be accomplished by valve must be held in the open position (not 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 174 Retracting Self Adjusters Access holes are located in the flange plate. These Fig. 54— Brake Shoe and Self Adjuster Assembly 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 175 10. Locate the adjusting lever .020” to .039” above the emery cloth. outside diameter of the adjusting screw thread by 13. Thoroughly clean adjusting screws and threads in loosening the cap screw and turning the adjusting the anchor brackets. cam. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 176 13. Adjust the brakes by making several forward and reverse stops until a satisfactory brake pedal height results. TOP VIEW Fig. 57— Plug G a ge Positioning for Correct Actuator Lever Adjustment 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 177 4. Connect brake lines to main cylinder outlets. disassembly. 5. Bleed brakes as necessary and fill fluid reservoirs to within 1/4” of top of the reservoirs. Installation 1. Mount power brake assembly to dash. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 178 2. J-8000 Tube Cutter 6. J-22904 Dust Boot Installer 3. J-8049 Spring Remover/Installer 7. J —23518 or J-23339 Bleeder Adapter 4. J -21177 or J-22348 Brake Shoe Adjustment G age 8. J-23709 Combination Valve Bleeder 10-30 CHEVROLET TRUCK SERVICE MANUAL...

  • Page 179: Chassis

    It is essential that improper compression be cor­ wires and remove plugs. rected before proceeding with the engine tune up. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 180 D O NO T BEND! (BEND TO ADJUST G AP) 2. Clean serviceable spark plugs thoroughly, using an abrasive-type cleaner such as sand blast. File the center electrode flat. Fig. 2— Spark Plug Detail 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 181 3. Examine distributor points and clean or replace if necessary. • Contact points with an overall gray color and BREAKER PLATE only slight roughness or pitting need not be ATTACHING SCREWS rep laced. Fig. 4 — Distributor (In Line) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 182 " TAKE READING AT EYE LEVEL CORRECT LATERAL MISALIGNMENT BY L -| BENDING FIXED CONTACT SUPPORT NEVER BEND BREAKER LEVER Fig. 7— Testing Specific G ra vity of Battery Fig. 6 — Point Alignm ent 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 183 Section 6Y. Service Belts (Fig. 8) Inspect belt condition. Check and adjust if necessary for correct tension of belt, as follows: Fig. 10— M anifold Heat Control V a lv e (Typical V8) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 184 In a “ Closed Positive” ventilation system, air is drawn through the engine crankcase (through a regulating valve) (fig. 12) into the manifold, drawing crankcase vapors and fumes with it to be burned. The “Closed Fig. 12— Crankcase Ventilation V a lv e 10-30 CHEVROLET TRUCK SERVICE MANUAL...

  • Page 185: Home

    1. Start engine then check ignition dwell. timing light as recommended by the manufacturer of the 2. If dwell is not within specifications, adjust dwell as equipment being used. follows: Fig. 14— Automatic Choke Adjustment 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 186 « 307 Cu. In. (Two-Barrel Carburetor) Disconnect “ Fuel Tank” line from Evaporation 5. Stop engine and remove timing light and reconnect the spark advance hose. Emission vapor canister. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 187 “locked in” by these caps - no fast idle to 1350 rpm with manual transmission in attempt should be made to adjust mixture. Do not remove mixture screw caps. neutral; 1500 rpm with automatic transmission in "Park” . 10-30 CHEVROLET TRUCK SERVICE MANU.
  • Page 188 Turn air conditioning “OFF” . Turn mixture screw in until lightly contacting seat, then back screws out four turns. Adjust carburetor speed screw to obtain 600 rpm with transmission in neutral. Reconnect distributor spark advance hose. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 189 (by­ passing resistance wire) are in good condition. b. If below 9 volts, check circuit until difficulty is located. Fig. 20— Testing Cranking Voltage Fig. 21— C oolin g System Pressure Check 10-30 CHEVROLET TRUCK SERVICE MANUAL...

  • Page 190: Series

    Fig. 2 2 — O il Deflector Clips Installed Fig. 23— V a lv e Adjustment (Hydraulic) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 191 2. With the engine running at idle, back off valve covers, using new gaskets, and torque bolts to rocker arm nut until the valve rocker arm starts specifications. to clatter. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 192 • Power steering pump at engine bracket and lay Section 11. aside (if so equipped). • Remove the battery. • Ground straps at engine. • Remove the radiator and shroud as outlined in • Exhaust pipe at manifold. Section 13. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 193 • Remove automatic transmission (if so equipped), • Install the propeller shaft as outlined in Section 4. a. Lower engine, secured by the hoist, and sup­ port engine on blocks. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 194 (if not previously done). manifolds. b. Crank engine until distributor rotor points to 2. Position new gasket over manifold end studs on head number one cylinder position and breaker points and carefully install the manifold in position making 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 195 In most cases, where noise exists in one or more lifters, all lifter units should be removed, disassembled, cleaned in a solvent, reassembled, and reinstalled in the Fig. 1 L— V a lv e Adjustment Fig. 2 L— Compressing V a lve Spring 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 196 7. Remove cylinder head bolts, cylinder head and gas­ ket. Place cylinder head on two blocks of wood to prevent damage. Fig. 4 L — O il Seal Installation Tool Fig. 3 L — O il Pan Gasket and Seal Location 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 197 Fig. 5 L — Removing O il Seal (Lower Half) Typical Fig. 6 L — Removing O il Seal (Upper Half) Typical 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 198 Installation tool must remain in posi­ CAUTION: tion until seal is properly positioned with both ends flush with block. Fig. 8 L — Removing Torsional Damper Fig. 9 L— Installing Torsional Damper (D rive on Type) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 199 1. Remove oil pan as outlined. 2. Remove crankshaft pulley and hub or torsional J-23042 Fig. 11 L— Centering Tool (J-23042) In Cover Fig. 1 3 L— Installing O il Seal (C over Installed) (Typical) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 200 6. Continue to rotate the crankshaft until the indicator re$.ds zero. This will be a check on the accuracy of the original indicator reading. Fig. 15L— Timing G ear Alignm ent M arks 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 201 (fig. 15L). Push camshaft into position. Install camshaft thrust plate to block screws and torque to specifications. Fig. 1 8 L— Removing Crankshaft Gear Fig. 19L— Installing Crankshaft G ear 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 202 6. Lower engine completely and tighten mount bolt, mount. Observe mount for signs of separation then bend tabs of french lock to lock the bolt in place. and/or deterioration. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 203 ENGINE 6-25 Fig. 22 L— Engine Mounts 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 204 • Remove the radiator and shroud as outlined in • Accelerator linkage at manifold bellcrank Section 13. • Fuel line (from tank) at fuel pump. 4. Disconnect wires at: • Heater hoses at engine connection. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 205 Support transmission on blocks, 6. Connect: e. Disconnect throttle linkage and vacuum modu­ • Exhaust pipe at manifold. lator line. • Power steering pump (as required). f. Remove transmission-to-engine mounting bolts. • Vacuum lines at engine (as required). 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 206 • Spark advance hose and governor line (if so 4. Connect crankcase ventilation hoses (as required). equipped) at distributor. 5. Install air cleaner, start engine and check for leaks. • Crankcase ventilation lines (as required). 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 207 4. Intermittent Clicking--Probable causes are: a. A microscopic piece of dirt momentarily caught between ball seat and check valve ball. Fig. lV -ln ta k e M anifold Gasket and Seal Location 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 208 (fig. 3V). 5. Remove the valve stem oil seal. Fig. 2 V -V a lv e Adjustment Fig. 3V — Compressing V a lve Spring 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 209 4. Install starter brace and attaching bolts. Torque bolts to specifications. 5. On CE 10-20-30. a. Lower engine and install front mount through bolts. Fig. 4 V — O il Pan G asket and Seal Location 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 210 3. Remove accessory drive pulley then remove damper retaining bolt. Fig. 6 V — Removing O il Seal (Lower Half) Fig. 7 V — Removing O il Seal (Upper Half) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 211 3. Remove water pump as outlined in Section 6K. 4. Remove crankcase front cover attaching screws and remove front cover and gasket, then discard gasket. APPLY SEALANT SHADED AREAS ONLY Fig. 8 V — Sealing Bearing Cap Fig. 10V— Installing Torsional Damper 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 212 7. Draw camshaft sprocket onto camshaft, using the three mounting bolts. Torque to specifications. J-5825 Fig. 14 V — Removing Crankshaft Sprocket (Small V8) Fig. 12 V — Installing O il Seal (Cover Installed) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 213 3. Rotate the crankshaft slowly in the direction of w a s h e r (T O R SIO N A L DAMPER) Fig. 16V — Removing Crankshaft Sprocket (M ark IV V8) Fig. 18 V — Measuring Camshaft Lobe Lift 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 214 1. Lubricate camshaft journals with engine oil and in- serviceability by raising engine sufficiently to produce a light strain on rubber portion of mount. Observe mount for signs of separation and/or deterioration. Fig. 19V — Removing Camshaft 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 215 ENGINE 6-37 REAR M O U N T Fig. 2 1 V — Engine Mounts 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 216 F R O N T ° ' ' ® ® ®l • S M A L L V 8 ‘ ' M A R K I V V 8 J Fig. IT — Torque Sequence 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 217 Crankshaft Sprocket or Gear Installer 31. J -23042 12. J—8101 Valve Guide Cleaner Crankcase Cover Centering Gauge 13. J-5830 32. J -22102 (11/32") V alve Guide Reamer Set Crankcase Cover Tool & Seal Installer J-7049 (3/8") 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 219 I n s t a lla t io n ..............6K-4 GENERAL DESCRIPTION All Chevrolet trucks have pressure type engine cooling mospheric pressure. The higher pressure raises the systems with thermostatic control of coolant circulation. boiling point of the coolant which increases the efficiency The cooling system is sealed by a pressure type radiator of the radiator.
  • Page 220 2. Remove thermostat and replace thermostat housing. form acids which are harmful to both the radia­ 3. Add the liquid portion (No. 1) of the cooling system tor and engine. cleaner. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 221 Water Pump is full, turn on the air in short blasts. 4. Continue this flushing until the water from the lead- Removal 1. Drain radiator and break loose the fan pulley bolts. away hose runs clear. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 222 A bent or damaged 3. Connect hoses and fill cooling system. fan assembly should always be replaced with a 4. Install fan belt and adjust as previously outlined. new fan assembly! 5. Start engine and check for leaks. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 223 SECTION 6 M ENGINE FUEL INTRODUCTION Carburetors used with Chevrolet Trucks are designed Trucks. Also covered in this section are maintenance to meet the particular requirements of engine, trans­ procedures for choke coils, throttle linkage, accelerator mission and vehicles. Carburetors that look alike are and choke controls, air cleaners and fuel filters.
  • Page 224 As there are no steps on manual choke cam, the index line on side of cam should be lined up with contact point of the fast idle cam follower tang. Fig. 4 C — Choke Rod Adjustment (M V) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 225 Release accelerator. TO ADJUST PUSH DIAPHRAGM PLUNGER IN UNTIL IT SEATS VACUUM BREAK ADJUSTMENT Fig. 8 C — Vacuum Break Adjustment (2 G V ) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 226 CHOKE COIL ROD ADJUSTMENT M V (Fig. 12C) 1. Hold choke valve closed. Fig. 12C— Choke C o il Rod Adjustment (M V ) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 227 MV, 2G V and 4 M V This adjustment is to be made only after, (1) replace­ ment of the solenoid, (2) major overhaul of the carburetor is performed, or (3) after the throttle body is removed and replaced. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 228 2. Clearance should be .015” minimum; adjust by turn­ 2. With a flat tool, depress the choke diaphragm stem ing nut or screw as required while holding opposite until bottomed. end. 10-30 CHEVROLET TRUCK SERVICE M NUAL...
  • Page 229 2. Adjust fast idle to give specified opening of throttle 1. Remove air cleaner then remove the fuel level sight plugs (Fig. H8). Fig. H 2— Choke Rod Adjustment Fig. H 4— Choke Unloader Adjustment 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 230 4. If necessary to adjust (either or both bowls), loosen inlet needle lock screw and turn the adjusting nut Fig. H 6— Fast Idle Cam Adjustment (M echanical) Fig. H 8 — W et Fuel Level Adjustment 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 231 The contents of the fuel bowl may then be examined for con­ tamination as the carburetor is disassembled. 1. Remove air cleaner and gasket. 2. Disconnect fuel and vacuum lines from carburetor. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 232 2. Install new carburetor to manifold flange gasket (if required). 3. Install carburetor over manifold studs. 4. Start vacuum and fuel lines at carburetor. 5. Install attaching nuts and/or bolts and tighten securely. 6. Tighten fuel and vacuum lines. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 233 • Remove choke rod, bracket screw and choke coil assembly. Follow instructions on vehicle tune-up sticker be­ 3. Install a new choke coil assembly being sure the fore proceeding. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 234 CABLE ASM VIEW A Fig. K 4 — A ccelerator Controls, C E and KE 10 Fig. K 3 — A ccelerator Controls, C S and K S 10 thru 30 Series thru 30 Series 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 235 "D A M A G E D " in any way. VIEW A > Fig. K7— Accelerator Pedal and Controls C , K and Fig. K6— Accelerator Controls, P Series (Typical) P 10 thru 30 Series 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 236 (fig. 3G). and inspect for cracks or holes. If the diaphragm is damaged in any way, it must be replaced. 2. Detach and remove the governor spring. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 237 2. Diaphragm Assembly 6. Leather Seal calibration of vacuum versus spring tension is of extreme 3. Diaphragm Cover 7. Leather Seal Retainer importance in governor operation, it can readily be seen 4. Governor Lever 8. Governor Cover 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 238 This could result if that can be obtained w ith the vacuum hose the vacuum passages were to become clogged with "squeezed” should be possible if the seals are in dirt, oil, or other foreign materials. Areas most 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 239 BOTTOM ELEMENT COVER Fig. 2 A — O il Bath A ir Cleaner Fig. 1A— Paper Element A ir Cleaner 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 240 CAR BU R ET O R 4 FWD C A P A IR C LEAN ER CS MODELS CS100-150 (06-16) Fig. 3 A — A ir C leaner and Heat Stove, C S and C E Series 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 241 1. Remove sheet metal to air cleaner hose from the air cleaner cover. Fig. 5 A — Thermostatic A ir V a lv e Pellet Replacement Fig. 6 A — Thermostatically Controlled A ir Cleaner 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 242 Inspection Visual 1. Check for proper and secure connections of heat pipe and hoses. 2. Check for kinked or deteriorated hoses. Repair or replace as required. Fig. 8A — Temperatur 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 243 2. Connect vacuum motor linkage to damper door. Fasten retaining strap to air cleaner with sheet metal screw. 3. Replace air cleaner on engine and check operation of vacuum motor and control damper assembly. Fig. A — Removing Sensor Unit 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 244 GENERAL DESCRIPTION rocker arm. On V-8 engines, a push rod (located be­ The fuel pump (fig. IP and 2P) used on all Chevrolet tween the camshaft eccentric and fuel pump) actuates the vehicles covered in this manual is the diaphragm type.
  • Page 245 (fig. 4P). 3. Connect fuel pipes to pump. 4. Start engine and check for leaks. OUTLET INLET Fig. 3P— Fuel Pump (N on-Servicea b le) Fig. 4P— Installing V - 8 Engine Fuel Pump 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 246 Fig. 5P— Engine Fuel - Special Tools J-1137 Choke Rod Bending J-4552 Choke Rod Bending (1 and 2 bbl.) J-5197 Unloader Bending J-8328 Carburetor Holding Tool J-9789 Universal Carburetor Kit J— 10176 Fast Idle Wrench J-22973 Ther-M ac Thermometer 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 247 All vehicles equipped with the C.E.C. Valve will have ex­ pressor places on the engine brings it to a stop sooner, haust emission control stickers under the hood giving thereby, effectively reducing the tendency to diesel. tune-up specifications. Additional features of the system are: 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 248 T RA N SM ISS IO N SWITCH W ATER A P P R O X . (15 SEC.) (C L OS ED IN LO W G EA R S) TEMP. SWITCH Fig. 1— Combination Emission Control System Schematic 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 250 EMISSION CONTROL SYSTEMS 6T-4 Fig. 3 — Com bination Emission Control System Routing (V8) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 251 Hour rating found on batteries was based on the 20 hour rating. That is, a battery capable of furnishing three (3) amperes for 20 hours while maintaining a specified aver­ age individual cell voltage would be classified as a 60 F ig- lb— Battery 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 252 The Battery features an electrolyte level indicator, which is a specially designed vent plug with a transparent ing, checking should be more frequent because of more Fig. 2b-Internal V ie w of C ells Fig. 3b-Electrolyte at Proper Level 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 253 Care must be taken to keep vent plugs tight, so that the neutralizing solution does not enter the cells. Fig. 5 b -V ie w Inside Vent Well 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 254 The full charge specific vehicle metal components which would result in gravity is 1.260-1.280, corrected for electrolyte tem­ damage to the battery. perature with the electrolyte level at the split ring, 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 255 2. If able to obtain a specific gravity of 1.200 or more @ of time, such as during vehicle storage, should 80°F. in all cells, remove the vent caps and connect be tested by the hydrometer method. Energizers a 300 amp. load for 15 seconds. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 256 • Check polarity to be sure the Battery is not reversed at least 15 minutes at a rate high enough to cause vigorous gassing. with respect to the generating system. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 257 The frame and are jointed to the stator windings at three stator is composed of a large number of windings assem­ internally located terminals. Fig. lc -D e lco tro n 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 258 Make absolutely certain all connections in the circuit are secure. FIELD RELAY "F " TERMINAL NO. 2 TERMINAL VOLTAGE NO. 3 TERMINAL REGULATOR NO. 4 TERMINAL DOUBLE CONTACT Fig. 2c -D o u b le Contact Regulator 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 259 (both good and defective) and to isolate the malfunctioning unit if the system is defective. If reading is: Fig. 4 c -V o lta ge Setting Test Connection 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 260 This is to prevent regulator damage by short circuits. c u L J Fig. 6c-D elcotron Diode and Field Tests Fig. 5c-Am m eter Method Output Test Connection 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 261 (bulb goes out). tween connector ‘FF” and "4 ” terminals (fig. 7c, The indicator light should glow when ignition switch is Step 2), and note lamp: "ON” and go out almost immediately when engine starts. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 262 W IR IN G HARNESS W IRIN G H ARNESS CO N N E C T O R C O N N ECTO R Fig. 8c-Testing Field Relay Fig. 9 c -F ie ld Relay Closing Voltage Tes. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 263 Adapter J-21501 and a box wrench) on retaining nut, insert a 5/16” alien wrench through 15/16 SOCKET ADAPTER 5 /1 6 ALLEN Fig. l i e — Pulley Removal Fia. 12c-Torquing Pulley N u t 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 264 Tune-up, Section 6. battery ground cable and the wiring harness connector at the regulator, then remove the screws securing the regulator to the vehicle. V VIEW A VIEW B Fig. 13c-Delcotron Installation 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 265 (fig. 2i). Use an aligning condition in the ignition system, often the result of too tool to bend stationary contact support if points need much or too little condenser capacity, is indicated where alignment. point pitting is encountered. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 266 Use an aligning tool if available. 2. Turn or crank the distributor shaft until the breaker Fig. 2 i-C h e c k in g Breaker Arm Spring Tension 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 267 With the distributor mounted on a distributor test­ ing machine, connect the dwell meter to the dis­ tributor primary lead. PRIM ARY LEA D Fig. 3i-D istrib u tor Lead Arrangem ent Fig. 5i-Inaccu rate G au ge of Rough Points 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 268 2. Disconnect the distributor primary lead from the coil terminal. WINDOW "H EX” TYPE ADJUSTING SCREW Fig. 7i — Setting Point O pening Fig. 8i-A djustin g Dwell A ngle 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 269 Scribe a realignment mark on the distrbutor bowl 5. Slide the distributor mainshaft and cam-weight base assembly from the housing. and engine in line with the rotor segment. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 270 9. Check breaker lever spring tension which should be tion of vacuum control unit. 19-23 ounces. (See contact point replacement.) 3. Position rotor to point toward front of engine (with 10. Install dust shield and rotor. distributor housing held in installed attitude), then 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 271 Remove spark plugs using a 5/8" deep socket moved. It is important that the wires be installed in on the 5/8” hex tapered plugs. Use care in this opera­ their location in the supports. tion to avoid cracking spark plug insulators. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 272 Care­ fully follow the instructions of the manufacturer of the Fig. 11 i-A d va n ce Weights Installed (V -8) Fig. 13i-Setting Spark Plug G ap 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 273 The flange mounted solenoid switch operates the overrun­ The starting motor (fig. Is) consists primarily of the ning clutch drive by means of a linkage to the shift lever. drive mechanism, frame, armature, brushes, and field 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 274 LEVER GROMMET SPIRAL SPLINES BUSHING BUSHING PINION STOP O VERRUNNING BRUSH ASSIST CLUTCH INSULATED BRUSH HOLDER FIELD COIL SPRING BRUSH SPRING ARMATURE GROUNDED BRUSH HOLDER Fig. ls-Sta rting M otor Cross Section - Light Duty 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 275 Torque the mounting bolts 25-35 ft. lbs. 5. Connect all wiring leads at the solenoid terminals. 6. Connect the battery ground cable and check operation of the unit. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 276 ENGINE-ELECTRICAL 6Y-26 SPECIAL TOOLS J 9717-2 J-9600-2 J-21501 SUPPORT SHOULDERED PULLY TOOL INSTALLER ADAPTER J-5 1 8 4 CHECKING SCALE Fig. 3s-Special Tools 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 277 Special T o o ls ....Alum inum Powerglide 7-13 CLUTCH CONTROLS INDEX General Description........ Insufficient Clutch Release ..............Maintenance and A djustm ents....Clutch Pedal Replacement............... Clutch Free Pedal Travel Adjustment Clutch Cross Shaft Replacement ............GENERAL DESCRIPTION 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 278 5. Release push rod, connect return spring and tighten shaft assembly outboard enough to clear pedal stop, then allow return spring (or overcenter spring) to nut “ A” to lock swivel against nut “ B” . 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 279 3. Assemble pedal push rod lever over pedal shaft and install bolts, washers, and nut. Torque to 25 ft. lbs. 4. Adjust clutch pedal free travel as needed. Fig. 4 — C lu tch Pedal Free Travel 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 280 Measure pressure plate lift at 3 strap bolt posi­ tions with full pedal travel. Fig. 7— G a u g in g Shim Requirement Fig. 6— C he ckin g Pressure Plate Lift w/dial Indicator 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 281 8. Pack clutch fork ball seat with a small amount of high melting point grease and install a new retainer in the groove of the clutch fork if the old retainer is worn or damaged. Fig. 8— Lubrication Points on C lutch Throwout Rearing 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 282 NOTE: metal spacers (approximately 3/8 thick) between 3. After transmission has been assembled, adjust pedal the clutch levers and the cover to hold the levers as described under “ Clutch Pedal Adjustments” . 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 283 On vehicle equipped with Muncie 4-Speed transmission, remove the gear­ shift lever using Tool J-8109 as shown in Fig­ ure 11. Press down firmly and rotate counter­ clockwise to release gearshift lever. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 284 7. Disconnect shift control rods from the shifter levers forward, guiding the main drive gear shaft into the at the transmission. clutch disc splines. 8. Support rear portion of engine. Remove two (2) Avoid springing the clutch when adapter mount bolts. IMPORTANT: 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 285 NOTE: checking the transmission case rear bore align­ transmission guide pins J-1126. Use of the guide ment by the dial indicator method. pins will prevent damage to the clutch assembly. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 286 Reassemble the transmission. 8. Install the transmission assembly to the clutch hous­ ing, using the correct number of shims at the proper Fig. 13— Replacing Rear Retaining O il Seal 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 287 “ C” 5. Remove detent cam spring and pivot retainer ring. Remove both detent cams. 6. With detent spring tang projecting up over the 2nd Fig. 15— Transfer Case M ounting 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 288 6. Remove transfer case to frame mounting bracket bolts. Before connecting prop shafts to com­ NOTE: panion flanges be sure locknuts are torqued 250 7. Support transfer case and remove bolts attaching transfer case to transmission adapter. ft. lbs. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 289 Refill capacity is approximately 2 qts. If the transmission is found consistently low on oil, a (U.S. measure 1-3/4 qts. Imperial measure). 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 290 See Section 9 for alignment of steering column assembly if necessary. 2. To check for proper shift linkage adjustment, lift the transmission selector lever towards the steering Fig. 2 P G — Powerglide Control Rod Linkage 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 291 The adjustment of the throttle return check valve is described in Section 6M for each carburetor installation. T.V. rod. Fig. 3 P G — Powerglide T.V. Linkage Adjustment 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 292 “ O” ring, speedometer drive gear, Powerglide Section of the Overhaul Manual for all other case extension “ O” ring and rear oil seal, vacuum modulator, and servo cover or gasket service may be service operations not covered here. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 293 PARK, and start the engine. Note: Do Not Race the Engine. Move the selector lever through each range. 2. Immediately check the fluid level with the selector lever in the PARK position. The engine should be Fig. 5 P G — Pressure Test Plug 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 294 In Drive Range Engines Throttle Range @ (Coast) @ 20-35 MPH Upshift 1000 RPM (Approx. 20” Hg.) 10" Hg. 16" Hg. L-6 250 93-113 53-75 83-102 125-138 48-53 V-8 307 103-118 53-74 81-100 115-128 48-53 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 295 Wide Open Throttle Throttle Closed Closed PE 200 GE 100 Throttle Throttle V-8 (307) Base V-8 (307) Base Detent Detent 4.57 Axle 3.36 Axle Touch Touch 8.75-16.5 Tire C78-14 Tire Wide Open Wide Open Throttle Throttle 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 296 OIL LEVEL CHECK only when level is on or below the “ ADD” mark on the The transmission oil level should be checked period­ dip stick with oil hot or at operating temperature. The oil 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 297 Fig. 1— ' T urbo H ydra-M atic 350 Control Rod Link Fig. 2— Turbo H ydra-M atic 350 Control Rod Link P-M od els C -M o d e Is 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 298 Observe converter when moving the NOTE: transmission rearward. If it does not move with transmission, pry it free of flywheel before Fig. 3 — Transfer Case Shift Lever & Control Link proceeding. K -M odels 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 299 Disconnect the vacuum modulator line and the speed­ transfer case to frame bracket attaching b o l t s . ometer drive cable at the transmission. Tie lines out Torque to 110 to 150 ft. lbs. of the way. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 300 The neutral safety switch should be adjusted so that the engine will start in the Park and Neutral positions only. With the selector lever in the Park position, the park­ ing pawl should freely engage and prevent the vehicle Fig„ 5 —*Pressure Tap Locations 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 301 Porous casting (pump or case). and with sufficient engine speed to maintain 16 inches 5. OIL COMES OUT VENT PIPE Hg absolute manifold pressure. a. Transmission over-filled. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 302 Once the modulator assembly passes all of the above sures over 6 psi may damage the modulator. tests, it is an acceptable part and should be re-used. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 303 Throttle Position 1-2 up 2-1 dn 2-3 up 26-12 4-10 15-27 26-12 Closed Throttle 5-11 15-27 35-45 47-30 25-32 37-46 51-34 23-30 Detent Tho Touch 59-47 24-12 56-44 25-38 28-17 47-59 Wide Open Throttle 21-35 44-56 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 304 PS 100 Engine 4.11 Axle G78-15 Tire Throttle Position 1-2 up 2-1 dn 2-3 up 3-2 dn Closed Throttle 5-12 16-29 28-13 Detent Tho Touch 27-34 39-49 54-36 Wide Open Throttle 28-38 26-13 47-60 60-47 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 305 - or at one-to- above second speed to retain second speed accele­ one ratio. ration when extra performance is desired. L2 A hydraulic system pressurized by a gear type pump Range can also be used for engine braking. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 306 L I. - LI Range can be selected at any vehicle speed, sion serial and vehicle identification number and that all transmission parts returned to Chevrolet Motor Division and the transmission will shift to second gear and remain in second until vehicle is reduced to ap­...
  • Page 307 4. Lift the selector lever towards the steering wheel the mast jacket. See Section 9 for alignment of and allow the lever to be positioned in neutral steering column assembly if necessary. the transmission detent. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 308 12. When properly adjusted the following conditions must Drain oil immediately after operation before it has had be met by manual operation of the steering column an opportunity to cool. shift lever. To drain oil proceed as follows: 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 309 For Installation see Overhaul Manual. GO VERNOR SCREEN ASSY. GO VERNO R FEED PUMP COVER PIPE HOLE FOR IDENTIFICATION- SQUARED OFF PRESSURE REG. BOSS. Fig. 5T— Pressure Regulator V a lv e Fig. 6T— G overnor Screen Position 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 310 5. Support transmission with suitable transmission remove oil filler tube at transmission. jack. 12. Raise transmission to its normal position, support 6. Disconnect rear mount from frame crossmember. engine with jack and slide transmission rearward 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 311 - and the transmission will have to be removed. “ loading” one side of “ O” ring. *A “ black light” testing unit may be obtained from several different tool supplies. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 312 4. Using the instruction of the manufacturer, mix a suf­ After thorough investigation of field returned modulator ficient amount of epoxy cement, part #1360016, to assemblies, it has been found that over 50% of the parts make the repair. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 313 .8 amp of current at 12 volts. Fig. 9T — Electrical Connector For TCS (Two Term) Fig. 7T -V acu u m M odulator CM Model Has Detent Terminal O nly 10 30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 314 2-3 up 3-2 dn Throttle Position 1-2 up 2-1 dn 2-3 up 3-2 dn 1-2 up 20-12 10-5 15-23 Closed 5-10 14-21 18-11 6-11 50-62 57-44 24-35 25-16 45-56 51-39 27-39 28-18 Thru Detent (W.O.T.) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 315 CLUTCHES AND TRANSMISSIONS 7-39 SPECIAL TOOLS Fig . 1ST— C lutch Special Tools J -6456 Height Gauge J —1048 Gauge Plate J —1522 Pilot Bearing Drive J-5824 Clutch Pilot Tool J —1448 Pilot Bearing Puller 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 316 J-5590 Clutch Gear Bearing Installer J-5154 Extension Seal Installer J-9772 Clutch Gear Bearing Installer J —5814 —01 Speedometer Drive Gear Remover J-23096 Clutch Gear Retainer Seal J —5814—15 and Adapter Installer J-5752 Transmission Holding Fixture 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 317 Front Bearing Retainer Seal Installer J -22834-2 Rear Bearing Retainer Seal Installer J -22873 2nd Speed Bushing Installer J -23070 Mainshaft Rear Bearing Lock Nut J-22875 3rd Speed Bushing Installer Insta Her J-22830 Snap Rina Installer 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 318 Intermediate Gear Bearing Cup Installer J -22836 Front Output Shaft Bearing Retainer Seal Installer J -22875 Rear Output Shaft Rear Bearing Installer J —21359 Rear Output Shaft Bearing Retainer Seal Installer J -22303 Adapter Seal Installer 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 319 J-23422 Rear Output Shaft Front Bearing Cup Installer J-23420 Pilot Bearing Installer J-23423 Rear Output Shaft Rear Bearing Cup Installer J —7137 Adapter Seal Installer J-5590 Bearing Installer J — 6219 Front Output Shaft Bearing Installer 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 320 Reverse Piston Spring Compressor J-6585 Slide Hammers (N ot Illustrated) 14. J-9557 Transmission Case Rear Bushing Remover and J-6585-3 Slide Hammer Adapters (N ot Illustrated) Installer and Governor Support Bushing Remover J-9534 Bushing Remover (N ot Illustrated) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 321 1-2 Accumulator Cover Remover and Installer 11. J-23327 Clutch Spring Compressor 23. J -2619 Slide Hammer (Used with J —2619— 4 Adapter and 12. J-23062-2 Stator Shaft Rear Bushing Installer J-9539-01 Stator Shaft Front Bushing Remover 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 322 28. J - 2 1465-10 Part of Bushing Tool Set 29. J -22182 13. J -21795-1 Gear Unit Assembly Holding Tool Extension Bushing Remover and 14. J-21795-2 Part of Above Holding Tool Installer (N ot Illustrated) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 323 Accumulator Piston Installer 14. J-5586 Snap Ring Pliers 7. J -21369 Converter Pressure Check Fixture 15. J-5403 Snap Ring Pliers 8. J-21362 Seal Protector - Forward and Direct Clutch - Inner 16. J-1313 Torque Wrench 0-140.Ft. Lbs. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 325 Correct replacement caps may be obtained from pickup pipe. This screen is designed to prevent the your Chevrolet dealer. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 326 1. Drain tank to a level below gauge unit mounting loca­ tion and resultant poor engine performance. tion or if unit is inaccessible remove fuel tank. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 327 3. Unclamp filler neck and vent tube hose. 4. Unclamp gauge unit hose at frame end. It is connected to the cab mounted tank as shown 5. Support tank and remove support strap(s). in Figure 3. CHEVROLET CHASSIS SERVICE MANUAL...
  • Page 328 7. To install, reverse the removal procedures. Re­ place all anti-squeak material. Fig. 5 — Fuel Tank, P 10 Series Fig. 7 — Fuel Tank N e c k and Meter, P 20, 30 Series 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 329 14. Remove hose and connect fuel line to carburetor. 4. Remove fuel inlet filter at carburetor and inspect 15. Connect coil primary wire. FUEL LINES (Refer to Illustrations) Fig. 9— Fuel Lines, C 30 Series 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 330 FUEL TANK AND EXHAUST SYSTEMS 8-6 C A 10 BLAZER SERIES GROMMET PIPE V-8 ENGINE fw d C A 10-20 (EXCEPT BLAZER SERIES) Fig. 9a — Fuel Lines, C A 10 and 20 Series 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 331 FUEL TANK VENT FRONT PIPE U N IO N - INTER PIPE PA 200-250-300-350 REAR PIPE HOSE FUEL FEED INTER A N D REAR PIPE AN D HOSE Fig. 9b— Fuel Lines, P 10-30 Series 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 332 A good valve will hold vacuum. Installation 1. Install new filter. 2. Assemble bottom of canister to canister body. 3. Install canister and tighten clamp bolts. 10— Fig. Purge Valve 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 333 FUEL TANK AND EXHAUST SYSTEMS 8-9 Fig. 11— Canisters, Hoses and Front Vent Pipes C , K and P 10 Series Fig. 12— Upper Vent and Intermediate Hoses and Pipe, C, K 10 Series 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 334 1. Install separator and its retaining screw. 2. Connect lines to separator. 3. Lower vehicle and remove from hoist. FUEL TANK Removal and installation procedures are the same as 14— Fig. Fuel Vapor Sticker and Rear Vent Pipe P Series 10-30 CHEVROLET TRUCK SERVICE MANUAL...

  • Page 335: Exhaust System

    Particular care should be given to the installa­ 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 336 3/4 inch clearance from the floor pan to avoid possible overheating of the floor pan and possible damage to the passenger compartment carpets. Fig. 17— Exhaust System, C 10 and 20 Series Except Fleetside Pickup 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 337 LOW ER C L A M P Fig. 18— Exhaust System, C 20 Fleetside Pickup and C 30 Series Trucks Fig. 19— Crossover Pipe Assembly, C , K 10 thru 30 (V -8 ) Series 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 338 A SSEM B LY E XH A U ST PIPE VIEW VIEW D C T LOW ER C L A M P A SSE M B LY Fig. 21 — Exhaust System, K 10 Series 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 339 FUEL TANK AND EXHAUST SYSTEMS 8-15 SPECIAL TOOLS Fig. 22— Special Tools 1. J-23346 Fuel Tank G auge Remover and Installer...
  • Page 341 Do not use EP Chassis Lube, which NOTE: proper retention of this part. meets GM Specification GM 6031M, to lubricate the gear. DO NOT OVER-FILL the gear housing. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 342 5. Turn the steering wheel gently in one direction until come up on adjustment by turning the adjuster stopped by the gear; then turn back one-half turn. in a clockwise motion. Fig. 3 — Checking Torque at Steering Wheel 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 343 3-Speed Transmission 1. Loosen adjusting ring attaching screws and clamp 1. Set wheels in straight ahead position by driving bolt. vehicle a short distance. Fig. 6— Shift Tube Adjustment — 3-Speed Transmission 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 344 This is a special bolt and will require NOTE: a 12 pt. socket or box wrench. 3. Remove the steering gear to frame bolts and lower the steering gear far enough to remove the flexible coupling. Fig. 8— Steering Wheel Removal 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 345 Be sure to maintain a coupling to flange dimension of .250" to .375". The coupling alignment pins should be centered in the Fig. 11— Steering Shaft Intermediate Coupling flange slots. ( C - K 10-20-30) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 346 Separate the upper and lower portions of the shaft assembly. b. Remove the felt washer, plastic washer and dust cap. Discard the felt washer. Fig. 12— C he ckin g C oupling Pin Centering 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 347 Install the flexible coupling onto the steering gear systems, and/or could result in major repair wormshaft, aligning the flat in the coupling with expense. They must be replaced with one of the 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 348 1. Replace all component parts in reverse order of re­ the lower bearing and adapter onto the lower end of moval making sure that directional signal switch is the steering shaft and place in position in the lower 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 349 25 in. lbs. after screw head has been firmly seated. ing Wheel - Removal". Fig. 15— Removing W ires from Connector Fig. 16— Removing Directional Signal Housing Cover 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 350 4. Remove column clamp screw(s) on engine side of cap. firewall and remove or slide the clamp down the 4. Install the directional signal switch lever and hazard column. warning knob. 5. From inside the vehicle, remove the screws from the 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 351 Remove the lower bearing preload spring 8. Remove the cap screws from the column support bracket at the dash panel. and washer. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 352 IN STRU . PA N EL OPENING COVER HOUSING ASSY PIN RELEA SE —* - 0 SHOE R E LE A SE BEARING ASSY. — RET A IN ER Fig. 20— T ilt Steering Column - Explode...
  • Page 353 Automatic Columns - Align the three holes in the se­ lector plate with the three holes in the jacket, posi­ tion the clamping ring and install the three screws. Fig. 21— Securing Column with Holding Fixture J-22573 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 354 If it is b. Rotate the centering spheres 90° and remove the Fig. 23— Removing Bearing Housing Pivot Pin Fig. 25— Removing Release Lever Pivot Pin 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 355 Pilot the sleeve over the threaded end 18. If necessary, remove the dash panel seal, mounting H O O K END OF TOOL SLOT IN SHIFT TUBE Fig. 28— Removing Shift Tube Assembly 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 356 8. Assemble the steering shaft as follows: steering shaft is 15 in. oz. (column must be in a. Lubricate and assemble the centering spheres straight-ahead position). and preload spring. 15. Remove the tilt release lever. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 357 They must be replaced with parts of the tween the steering shaft lower tube and intermediate same part numbers or with equivalent parts if coupling must be maintained at 6.38 to 6.78 inches. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 358 EP Chassis lube and install ends on tie 4. Remove the relay rod from the pitman and idler arms Fig. 34— K 1 0 -2 0 Series Steering Linkage Fig. 35— Ball Stud Removal (Typical) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 359 3. Install the idler arm ball stud in the relay rod, mak­ 2. Install ball studs in steering arm and pitman arm. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 360 3. Disconnect the battery ground cable. NOTE: is an important attaching part in that it could 4. Remove the horn button. 5. Turn the steering wheel through its full travel, then affect the performance of vital components and 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 361 This test is divided into two parts. Test number one 4. Repeat above procedure until oil level remains con­ provides means of determining whether power steering stant after running engine. system hydraulic parts are actually faulty. If test num- 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 362 Remove the pitman shaft nut or pitman arm to prevent entrance of dirt. pinch bolt and then remove the pitman arm from the 2. Install two plugs in gear fittings to prevent entrance pitman shaft using Puller J-6632 (fig. 1). of dirt. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 363 When servicing power steering hoses, avoid twisting the flange bolt nuts to specifications. the hoses unnecessarily. Install hoses with the wheels 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 364 Note and correct any hose contact with other parts of hydraulic line system, the vehicle that could cause chafing or wear. Figure 44 illustrates typical installations. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 365 Fig. 4 3 — Power Steering Pump M o u n tin g...
  • Page 366 \ v i E W _ A _ _ y VIEW A VIEW B C-K 10-30 "400" V-8 CPK 10-30 ALL V-8 EXC. "400' F ig. 44— T yp ic al Power Steering Hose Routings...
  • Page 367 W orm shaft Bearing C up Installer 35. J -22549 Sh ift Tube Installer* 17. J-575 5 36. J -8433-1 & 2 Compressor Pu lley P u ller* 18. J —2619 Slid e Hammer * N o t Illustrated 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 369 Some commercial vehicles are equipped (at customer is available on Series 30 trucks. option) with synthetic rubber tires and tubes. The factory installed tires on Chevrolet trucks are selected to provide the best all around tire performance TIRE TRACTION for all normal operation.
  • Page 370 ALSO R E F E R TO “ T I R E L O A D AND I N F L A T I O N P R E S S U R E of each dual produces maximum tire life. T A B L E N O T E S ” 1 T HR OU G H 8. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 371 10 P S I. The total increase in cold infla­ mended cold inflation pressures for various loads must con­ tion pressures shall not exceed 10 PSI above those specified form to the table. in the above table for the load being carried. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 372 "flutter" and quite often half of the tire at the excessive rate. This type of tire to wheel "tramp." 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 373 Lower Control Arm Axle Housing CP10, 20, 30 All tubeless tires used on Chevrolet trucks with the Pivot exception of the 6.50-16 size should be demounted and mounted as described in this section. The 6.50-16 size...
  • Page 374 4. Check valve to be certain that hex nut at the valve mounted as follows: base is tight. Inflate tire to recommended operating pressure. Check assembly for air leaks. Fig. 5— Lifting Bead O v e r Rim Fig. 7— Prying Second Bead from Rim 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 375 The lower bead will be seated by the tire weight. When a tire mounting machine is not being used, beads may be seated by holding the tire and wheel assembly in Fig. 9— W orking Bead onto Rim 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 376 (fig. 13), making sure the opposite side of the ring is fitting into the rim gutter. Do not bend the ring. Fig. 14— Removal of Side Ring 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 377 6. Place half of side ring in rim gutter and push until Fig. 18— A p p lyin g Second Bead Fig. 16— Prying Second Bead From Rim 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 378 1. INSERT R IN G HALF O PPO SITE TOOL NOTCH INTO RIM GUTTER UNTIL CUT-OUTS ST R A D D L E THE RIM Fig. 20— Forcing Ring into Gutter Fig. 19— Assembling Side Ring 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 379 Skirt ......................ll-7 A d ju s tm e n t..................11-2 Running Board ....................11-7 Hood Assembly Removal and Installation ........11-3 Fig. 1 — Front End Sheet M e ta l— 10-30 Series 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 380 3. Adjust as outlined under Adjustments. Adjustment (Fig. 6) 1. Open hood and adjust tightness of lock bolt support so that they are just “ snug” enough to hold lock bolt in position. Fig. 4— Hood Striker and Safety Catch 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 381 Vehicles equipped with air conditioning and/or power steering will require special handling. Fig. 5 - 1 0 - 3 0 Series— Typical 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 382 4. Remove reinforcement on left fender skirt at steer­ ing column. 10 THROUGH 30 SERIES (Except Step Vans) 5. Remove front bumper bolts and remove bumper. Removal 1. Drain radiator and remove radiator hoses. Discon­ 6. Remove wiper arm assemblies and cowl grille. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 383 11. Install cowl grille and wiper arms. 12. Connect battery and fill radiator. Start engine and check for leaks. Fig. 9— Fender and Skirt Assem bly— 10-30 Series 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 384 15. Install remainder of skirt to right fender screws snugly. 16. Tighten right fender skirt front 3 bolts from under­ side to radiator support. 17. Place battery tray in position and fasten to radiator support. Fig. 11— Running Board and Braces 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 385 12. Remove (4) screws securing fender to grille. 13. Lift fender and skirt assembly from truck. R U N N IN G BOARDS Installation 1. Replace fender and skirt assembly. Refer to Figures 12 and 13. 10-30 CHEVROLET TRUCK SERVICE MANUAL...

  • Page 387: Lighting System

    Headlamp Aiming size by used. Never replace a wire with one of a smaller size. Fusible links in the Chevrolet wiring are four The headlamps must be properly aimed to obtain maxi­ mum road illumination. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 388 PARKING LAMP HOUSING REPLACEMENT (Fig. 3) The number molded into lens face must NOTE: be at top. 1. R em ove headlam p bezel on P s e r ie s tru cks. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 389 1. Remove three screws which retain rear lens to lamp Column Shift— Switch Located on Transmission assembly and remove lens. (Fig. 7) 2. Replace bulb and check operation of lamp. 1. Raise and support vehicle. 3. Position lens and install attaching screws. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 390 ELECTRICAL— BODY AND CHASSIS 12-4 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 392 ELECTRICAL— BODY AND CHASSIS 12-6 Fig. 5 — Rear Lighting Composite 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 393 Position gear shift in neutral before as­ NOTE: sembling switch to mast jacket. 2. Disconnect switch wiring from engine wiring harness 4. Check operation of switch. and remove bolt attaching the switch wiring retaining clip to the transmission. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 394 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 395 8. To install, reverse removal procedure. 7. Place the switch into position from behind the dash INSTRUMENT CLUSTER REPLACEMENT and install the metal ignition switch nut. P-MODELS (Fig. 9) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 396 Oil pressure line connector may leak NOTE: 2. Remove all instrument cluster lamp assemblies. oil when opened; wrap with cloth. 3. Remove laminated circuit retaining screws. 3. Remove three screws attaching cluster housing to 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 397 2. Laminated Circuit 6. Generator Ind. 10. "H ig h " Beam Ind. 16. Fuel Gauge 12. Generator (Ammeter) 3. Instr. Cluster Lamp 7. R.H. Directional 4. Temperature Ind. 13. Battery (Ammeter) 8. L.H. Directional 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 398 1. Disconnect speedometer cable from the speedometer 5. To install, reverse removal procedure and check head. operation of unit. DO NOT KINK CABLE CASING. 2. Remove old cable by pulling it out from speedometer end of casing. Flatface Cowl Models 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 399 4. To install, reverse removal procedure and check operation of unit. Flatface Cowl Models (Fig. 10) OIL PRESSURE SENDER UNIT REPLACEMENT 1. Remove instrument cluster assembly as previously described in this section. All Models 2. Uncrimp bezel (7 places) and remove bezel. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 400 1. Disconnect wiring harness connector from sender engines). unit terminal (located in block above starter on L-6 2. Remove sender unit using Tool J-21757, replace with engines and at left front of distributor on V-8 new unit and check operation. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 401 GENERATOR INDICATOR 2. Open circuit or loose connection in the telltale light 10-30 Conventional Cab Models circuit. Telltale light stays on after engine is started; refer to Ignition on, engine not running and telltale light off: 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 402 Fig. 15— Directional Signal Assembly - Conv. Cab & P Series 1. Cancelling Cam 6. Bearing Support 2. Directional Lever Retaining Screw 7. Switch Cover 3. Switch Mounting Screw 8. Lever Arm 4. Switch 9. Washer 5. Upper Bearing 10. Wiring Connector 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 403 6. Remove output gear and shaft assembly, then slide intermediate gear and pinion assembly off shaft. Make certain wiper motor and blades NOTE: 7. If necessary, remove terminal board and park switch are in the "P ark" position. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 404 17. Frame and Field 3. Seal Cap 13. Wave Washers 18. End Plate 4. Retaining Cap 9. Wave Washer 19. Tie Bolts (Two Required) 10. Gear Box Housing 14. Flat Washers 5. Washer 6. Gear Box Cover 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 405 "ACC” position and inserting a wire in the small Access upper right bolt through ignition NOTE: hole in the cylinder face. Puch in on wire to switch opening using suitable extension. depress plunger and continue to turn key counter­ 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 406 O N SHAFT) PAW L SPRIN G C A M FOLLOW ER UPPER PIN "E ” R IN G RATCHET PAW L Fig. 21— Washer Pump Drive Cam Fig. 23— Washer Pump Mechanism 'W ' 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 407 V A LV E ASSEM BLY M OUNTING SCREW FRAME RATCHET PAW L RATCHET WHEEL G R O O V ES BOTH SIDES "E ” RING Fig. 24— Washer Pump - Exploded View Fig. 25— Releasing Pump From Lockout Position 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 408 WASHER I N T A K E S T R O K E E X H A U S T S T R O K E Fig. 26— Cross Section of Windshield Washer Pump Valve 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 409 ELECTRICAL— BO DY A N D C H A SSIS 12-23 Fig. 27— Engine Compartment CA30(02) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 410 ELECTRICAL— BO DY A N D CHASSIS 12-24 18 DK GRN-19 Fig. 2 8 — Instrument Panel C A30(02) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 411 ELECTRICAL— BO DY A N D CH A SSIS 12-25 Fig. 2 9 — Instrument Panel CA30(02) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 412 ELECTRICAL— BODY A N D CHASSIS 12-26 A r+r-~ kk 4~ ~ Fig. 3 0 — Engine Compartment C A - K A 1 0 -2 0 , CA30(03)
  • Page 413 YEL 18 - 14 LT BLU 10 - DK GRNI9 — 2 4 - lt g r n Fig. 3 1 — Instrument Panel C A - K A 1 0 -2 0 , CA30(03) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 414 ELECTRICAL— BODY AND CHASSIS 12-28 Fig. 32— Instrument- Panel CA-KA 10-2O , CA30(03) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 415 ELECTRICAL— BODY AND CHASSIS 12-29 LP ASM SI MRK & R E F L E X Fig. 3 3 -R e a r Lamps CA1 KA10-20, CA30(03) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 416 ELECTRICAL— BODY AND CHASSIS 12-30 Fig. 34— Engine Compartment C A -K A 1 0 -2 0 , CA30(04) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 417 •20 WHT 21 - 8BRN9B- YEL 18 - 14 IT BLU © - 18 DKGRNI9 — 18LT GRN 2 4 - Fig. 3 5 — Instrument Panel C A - K A 1 0 -2 0 , CA30(04) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 418 -18 Y E L I 3 ----- -18 YEL 18 - -14 LT BLU10 — -18 DKGRN 19 — -18 DKGRN 19- -18 LT GRN 24 - -18 LT GRN 24- Fig. 36— Instrument Panel CA-KA10--20, CA30(04) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 419 -18 YEL-18 -I8 8 R N -9 - -I8 LT GRN-24- -I8 D KG R N -I9 - Fig. 3 7 — Rear Lamps C A - K A 1 0 -2 0 , CA30(04) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 420 ELECTRICAL— BO DY A N D CH A SSIS 12-34 Fig. 3 8 — Engine Compartment C A - K A 1 0-20(06-16) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 421 BRN 9 B ----- YEL 1 8 ------- 14 LT BIU 10 — DKGRNI9 — I8LT CRN 2 4 - 16 LT GRN-IIA Fig. 3 9 — Instrument Panel C A - K A 10-20(06-16) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 422 ELECTRICAL— BODY AND CHASSIS 12-36 Fig. 40— Instrument Panel C A -K A 1 0-20(06-16) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 423 ELECTRICAL— BODY A N D C H A SSIS 12-37 Fig. 4 1 -R e a r Lamps C A - K A 1 0-20(06 -1 6) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 424 ELECTRICAL— BODY AND CHASSIS 12-38 Fig. 42— Engine Compartment C A -K A 1 0 -2 0 , CAl30(14-34) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 425 -18 Y E l 14 LT BLU O — 18 DK GRIM 19 — 18LT GRN 2 4 - ■ 16 LT GRN-IIA Fig. 43— Instalment- Panel C A -K A 1 0 -2 0 , CA30( 14-34) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 426 ELECTRICAL— BODY AND CHASSIS 12-40 Fig. 44— Instrument Panel C A -K A 1 0 -2 0 , CA30(14-34) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 427 ELECTRICAL— BODY AND CHASSIS 12-41 LP ASM 51 MRK& R E F L E X -18 YEL-18 -I8BRN -9 -!8 LT GRN-24 -I8DKGRN-I9 Fig. 45— Rear Lamps C A -K A 1 0 -2 0 , CA30( 14-34) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 429 The radiators are of copper-brass construction. All diators. The cross-flow radiator is similar to the con­ ventional down-flow radiator except is mounted radiators (except P10 models) incorporate drain cocks. sideways in the vehicle and attached in the conventional SERVICE PROCEDURES 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 430 DO NOT USE HARSH CHEMICALS TO CLEAN 2. Remove bolts at fender outer upper and lower edge. THE GRILLE AREA AS DISTORTION AND OR 3. Remove bolts at center brace and hood lock from PAINT PEEL COULD RESULT. radiator mounting. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 431 Assemble parts removed in the disassembly procedure --tighten all screws and bolts. Installation 1. Position grille and install bolts at fender. 2. Install bolts at center brace and lock plate. 3. Connect parking lamps. 4. Connect battery. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 433 FRONT B U M P E R -C A N D K MODELS (Fig. 1) and panels and pickup. Removal 2. Remove bolts attaching bumper to frame. 1. Remove parking lamp assemblies. (See Section 12). 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 434 Connect license lamp wiring on suburban, Installation panel, and pickup models. Place bumper in mounted position and secure to frame with bolts, washers, and nuts. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 435 3. When released completely, it holds the system in engagement. (The lowest speed at which the system These units are mounted on the brake pedal bracket and disengage the system electrically and pneumatically when should be used is 40 MPH.) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 436 However, one adjustment may be made to the Regulator to An inoperative switch must be replaced. Switch re­ correct speed drop or increase at the time of engagement. placement is identical to standard brake lamp switch replacement. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 437 R E G U L A T O R 4. Slide plastic wiring protector over harness and up column. 5. Connect cruise master wiring harness on column. 6. Attach battery ground cable. Fig. 3 — Regulator Unit 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 438 If a resistance either above or below the valve indi­ 3. Electric and vacuum release switches properly cated is shown, then disconnect the connector from adjusted. the Regulator and measure the resistance of the 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 439 B R O W N /W H IT E STRIPE WHITE REGULATOR 7 ^ 7 STRIPE CO N NECTO R REGULATOR Fig. 6-Cruise Master Wiring Diagram CLUTCH CRUISE ENGAGEM ENT SWITCH RELEASE SWITCH WHITE REGULATOR Fig. 7-Vacuum and Electrical Diagram 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 440 A reading of more than 7 ohms indicates leakage. excessive resistance in the coil circuit. Either The cruise release brake switch (vacuum) and connecting extremity indicates replacement of the Regulator hoses can likewise be checked using a vacuum pump. 10-30 CHEVROLET TRUCK SERVICE MANUAL...

  • Page 441: Heating And Air Conditioning

    See Tune Up Chart Amps Volts (Cold) (Cold) Fuses Four Season Systems........25 Amp. Blower Motor GM Chevrolet and Roof-Mounted Systems . . 10 Amp. Four-Season....12 16.5 Max. 3700 Min. GM Chevrolet and Roof- Mounted ..... 12 13.7 Max. 3400 Min.
  • Page 442 18 ft. lb. to F lo o r................................30 ft. lb. Body Mounts All Except Rear # 2 ..........................20 ft. lb. Rear # 2 ................................. 50 ft. lb. Seat B e lt................................... 40 ft. lb. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 443 ** Camber: Designed to be + 1-1/2° at curb weight with no provision for resetting. ***Caster: Designed to be +4° at curb weight with no provision for resetting. @ Camber and caster must not vary more than 1° from side to side. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 444 Plus additional torque to align cotter pin. Not to exceed 90 ft. lbs. maximum. ** Plus additional torque to align cotter pin. Not to exceed 130 ft. lbs. maximum. ***Plus additional torque to align cotter pin. # Back nut off to align cotter pin at nearest slot. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 445 10-20 Pinion Bearing Cage — — To Carrier Bolt Torques (Ft. Lbs.) Trust Pad Lock — — Carrier Cover — Brake - Backing Ring Gear Plate Differential Bearing Axle Shaft To Caps Hub Bolts — 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 446 * C-P10 Models - 135 Ft. Lbs. ** Models CE-CS 25903-04-34 - 250 Ft. Lbs. All others - 135 Ft. Lbs. # C20 Except 133” W.B. Models - 20 Ft. Lbs. C20 133” W.B. Models - 35 Ft. Lbs. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 447 Cable Clips to F r a m e ........................90 In. Lbs. Equalizer N uts............................ 140 Ft. Lbs. Rear Brake Anchor P i n ......................35 Ft. Lbs. Caliper Mounting B o lt ........................140 In. Lbs. Support Plate to K nuckle........................10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 448 12,000 m iles or less depending upon severity of operating conditions See "TUNE-UP" section. © Replace filter element located in carburetor inlet every 12 months or 12,000 m iles, whichever occurs first. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 449 SPECIFICATIONS 9 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 450 85 lb. ft. Oil Filter Hand Tight 25 lb. ft. Oil Pan Drain Plug 20 lb. ft. Flywheel 110 lb. ft. 14mm Spark Plug 15 lb. ft. ® Inside bolts on 307-350 engines 30 lb. ft. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 451 350 V-8 Base 7041208 7041208 350 V-8 LS-9 7041211 7041211 20-30 20-30 350 V-8 LS-9 7041208 7041208 402 M-4 L-47 7041209 7041209 20-30 402 M-4 L-47 7041206 7041206 * Start of Production # Interim Release 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 452 — .100 — 7041208 (A)(M) — — — — .100 .020 .260 — 7041209 (A)(M) 11/32 .100 .020 .260 — — — — — 7041211 ^)(M ) .100 .020 .260 — — — — — 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 453 (AMP. HR.) 1980140 (Y-88) 250 L-6 & 307 V-8 2350 1980141 (Y-86) 250 L-6 & 307 V-8, GS & GE 10-20-30 2300 1980145 (R-88) 350 V-8 & 402 V-8- 2900 1980149 (R88W) T-60 Option 3750 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 454 BRUSH SPRING FREE SPEED MODEL NO. SEC. NO. TENSION VOLTS AMPERES 1108365 1108367 3573 50-80* 5500-10500 1108368 1108338 2438 55-80* 3500-6000 1108360 1108385 3563 65-95* 7500-10500 — 1108425 3533 40-105* 3500-6500 — * Includes Solenoid 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 455 IGNITION RESISTOR @ 75°F. APPLICATION OHMS - OHMS - TYPE - OHMS - 3,000 - 20,000 In Wiring 1.41 - 1.65 L-6 Engines Harness 3,000 - 20,000 In Wiring 1.77 - 2.01 V-8 Engines Harness 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 456 Power Take Off Cover B o l t s ........................18 ft. lbs. Parking B r a k e ..............................22 ft. lbs. Countergear Front Cover Screws........................25 in. lbs. Rear Mainshaft Lock Nut (4 Wheel Drive Models)..................95 ft. lbs. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 457 Transfer Case to Frame B o lt s ......................45 ft. lbs. Adapter Mount Bolts ......................... 75 ft. lbs. Adapter to Transmission B o lt s ......................45 ft. lbs. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 458 L o w e r B e a r in g 70 in. lb s. 70 in. lb s. 70 in. lb s . 70 in. lb s . A d ju s tin g R in g B o lts 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 459 Locknut Total Steering 14 in. lbs. 14 in. lbs. 14 in. lbs. 14 in. lbs. Gear Preload Max. Max. Max. Max. *In excess of ball drag. **In excess of ball drag and thrust bearing preload. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 460 Hood Safety P la te ................20 ft. lbs. Hood Lock Bolt................... 30 ft. lbs. Hood Lock Bolt Plate................. 150 in. lbs. Hood H in g e ..................25 ft. lbs. Hood Bumper..................85 in. lbs. 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 461 Tail, Stop, Dome compartment License Lamps Marker Lights SAE/SFE Spotlamp, Park Lamps Radio - TCS 3AG/AGC Hazard Flash 3AG/AGC Headlamps Light Switch Circuit breaker In-Line Part of Gen. & fwd. Ammeter 3AG/AGC lamp harness (2 reqd.) 10-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 462 Solenoid Wire Resistance............................40 ohms Maximum allowable Vacuum Leakage rate for Servo u n it ........... 5 inches of Vacuum Per Minute Not Greater than 1 inch of Vacuum per 10 seconds Operational Test Speed..............................60 MPH 10-30 CHEVROLET TRUCK SERVICE MANUAL...

This manual is also suitable for:

20 1971 series30 1971 series

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