Page 1 SECTION NAME I GENERAL INFORMATION MAINTENANCE AND 1979 LUBRICATION | HEATER, VENTILATION LIGHT DUTY AIR CONDITIONING f r am e TRUCK BUMPERS CHASSIS SHEET METAL (SERIES 10-35) b o d y FRONT ALIGNMENT CHASSIS SERVICE STEERING MANUAL FRONT SUSPENSION REAR SUSPENSION WHEELS AND TIRES PROPELLER SHAFT &...
Page 2: General
GENERAL INFORMATION OA-1 SECTIO N OA G E N E R A L IN F O R M A T IO N CO N TEN TS OF T H IS SECTIO N General..................... O A -1 Vehicle Identification Number............O A -1 Engine Code Number..............
Page 3 Serial No. © Plant Model Body Type or Division Code Engine Series Code Year Model Designator C-Chevrolet Chassis Code G.V.W . Class 1979 T = G M C Truck Type CHASSIS TYPE ENG INE CODE 2 Wheel Drive Forward Control...
Page 4 GENERAL INFORMATION OA-3 Axles • 8-Cylinder Gasoline Engine (454 CID) Code is located on a pad of the front top center of the engine block C h e v ro le t B u ilt immediately forward of the inlet manifold. •...
Page 5 OA-4 GENERAL INFO RM A TIO N PRIMARY V . I . N . L O C A T IO N ( M 15) S E C O N D A R Y V . I . N . L O C A T IO N [ N O T E | To b e used o n ly w hen s u ita b le fo r stam p in g PRIMARY V .
Page 6: General Information
GENERAL INFORMATION OA-5 E N G IN E V . I . N (O P T IO N A L ) E N G IN E V . I . N E N G IN E E N G IN E V . I . N (O P T IO N A L ) C A SE PA D E N G IN E V .
Page 7 OA-6 GENERAL INFO RMATIO N IMPORTANT: RETAIN THIS PLATE AS A PERMANENT RECORD Fig. O A-6-Service Parts Id e n tifica tio n Plate L O A D ED -M A XIM U M GVWR: 5600 LBS LO A D E D -M A X IM U M GVWR: 6200-LBS. FRONT GAWR: 3250 LBS.
Page 8: Table Of Contents
MAINTENANCE AND LUBRICATION OB-1 SECTION OB M A IN T E N A N C E A N D LU BRICATIO N C O N TEN TS General..................O B -1 Maintenance Schedule..............O B-2 Lubricant and General Maintenance ........O B-4 Safety Maintenance..............
Page 9: Gasoline Engine
OB-2 MAINTENANCE AND LUBRICATION VEHICLE MAINTENANCE SCHEDULE GASOLINE ENGINE When To Perform Services Item (Months or Miles, Whichever Occurs First) Services Light Duty Emissions Heavy Duty Emissions Section Lubrication and General Maintenance — • Fluid Levels Check Every 12 Months or 7,500 Miles Clutch Pedal Free Travel Check (12 000 km) Every 4 months or 6,000 Miles...
Page 10: Diesel Engine
M AINTENANCE AND LUBRICATION OB-3 VEHICLE MAINTENANCE SCHEDULE DIESEL ENGINE When To Perform Services Item Services (Months or Miles, Whichever Occurs First) (For Details, See Numbered Paragraphs) SECTION Lubrication and General Maintenance — * E ng in e O il C hange Every 3,000 Miles (4 800 km) * O il F ilte r C hange A -4...
Page 11: Maintenance Schedule
OB-4 M AINTENANCE AND LUBRICATION MAINTENANCE SCHEDULE This is an explanation of the service listed in the explosive. Vehicle Maintenance Schedule. • To lessen the risk of injury in case N ORM A L VEHICLE USE-The maintenance explosion does occur, wear instructions contained in the maintenance schedule are protection or shield your eyes when working...
Page 12 MAINTENANCE AND LUBRICATION OB-5 dipstick and read the fluid level (fig. OB-4). • If it felt cool, about room temperature, the level should be 1/8 to 3/8 inch (3 to 10mm) below the "Add" mark. The dipstick has two dimples below the "Add" mark to show this range.
Page 13 OB-6 MAINTENANCE AND LUBRICATION Be sure the oil used has both the SE and the CC A-2 M anual Transm ission Clutch A d ju stm en t designations, regardless of the order in which they appear Clutch adjustment should be checked and adjusted as on the oil can.
Page 14 MAINTENANCE AND LUBRICATION OB-7 • Extensive off-road use. REC O M M EN D ED SAE V IS C O S IT Y GRADES Ball joints must be at 10°F (-12°C) or more NOTICE: before lubricating. Transmission Shift Linkage (Manual and Automatic) (A/so a Safety Service) Lubricate shift linkage and manual transmission floor controls lever contacting faces with water resistant EP...
Page 15 OB-8 MAINTENANCE AND LUBRICATION C O N VEN TIO N AL AND FORWARD CONTROL MODELS L U B R IC A T IO N P O IN TS Low er C ontrol Arm s T h ro ttle Bell Crank - L-6 Wheel Bearings Upper C ontrol Arms Steering Gear...
Page 16 M AINTENANCE AND LUBRICATION OB-9 1 / 2 TON " G " MODELS LUBRICATION POINTS Rear A xle C o ntrol A rm Bushings and Trans. C ontrol Shaft O il F ilter A ir Cleaner - Element Ball Joints Brake Master C ylinder Tie Rod Ends Transmission...
Page 17 0B-10 MAINTENANCE AND LUBRICATION Oil Change Type of Operation (Interval-Miles) 24.000 Normal On-Off Road 12.000 Heavy Duty Work, Trailer Towing, Snowplowing, etc, 1,000 Severe Usage; Heavy Mud, Mining, Sand Dunes, etc. L g J L g j Severe Usage w ith Transfer Case Submerged. Daily [ E R f r , Fig.
Page 18 MAINTENA NCE AND LUBRICATION OB-11 serves to reduce "cold" inflation pressure and increase tire flexing which can result in tire damage and failure. Torque Series Description Passenger-Car-Type tires: 7/16” Bolts (6) 70-90 Ft. Lbs. K10, 15 For sustained driving at speeds of 75 mph of 75-100 Ft.
Page 19 OB-12 MAINTENANCE AND LUBRICATION the following is recommended: or equivalent. This is a premium high melting point lubricant. When towing trailers on dead-weight hitches, inflate tires to the pressures shown on the Certification Label (on NOTICE: "Long fiber" or "viscous" type lubricant either the left door latch post or the left door edge next to should not be used.
Page 20: Safety Maintenance
M AINTENANCE AND LUBRICATION OB-13 Gear Lubricant as noted below. 3. Stop engine and open radiator drain valve to drain coolant. (Drainage may be speeded by removing drain plugs in the block.) NOTICE: Use only 1052182 (13 oz. (.38L) container) Steering Gear Lubricant...
Page 21: Emission Control
OB-14 MAINTENANCE AND LUBRICATION TENSION SPECIFICATIO NS B-8 T h ro ttle Linkage Check for damaged or missing parts, interference or ADJUST TO 75 + 5 LBS. USED G ENERATO R binding. Fix any problems at once. 50 LB. A .I.R . PUMP MIN.
Page 22 M AINTENANCE AND LUBRICATION OB-15 C -16 Fuel Cap, Fuel Lines, and Fuel T an k C-10 S park Plug W ire s Clean wires. Remove corrosion on terminals. Check Check the fuel tank, cap and lines for damage or leaks. the wires for checks, burns, cracks or other damage.
Page 23: Specifications
OB-16 M AINTENANCE AND LUBRICATION SPECIFICATIONS RECOMMENDED FLUIDS AND LUBRICANTS F L U ID /L U B R IC A N T U SA G E Pow er steering system and pum p reservoir GM po w e r steering flu id Part No. 1050017 o r equivalent. Full tim e fo u r wheel drive case SAE-10W-30 o r 10W-40 enigne oil L u b ric a n t GM Part No.
Page 24 MAINTENA NCE AND LUBRICATION OB-17 CAPACITIES IM P E R IA L U.S. M E A S U R E M EA S U R E D ifferential 71/ 2” Ring Gear 31 /2 pts. 3 pts. 8V2” Ring Gear 4V4 pts.
Page 25: Cooling System
OB-18 M AINTENANCE AND LUBRICATION COOLING SYSTEM Capacity (Qts.) Transmission H.D. ■ U.S. Imperial Engine Series Measure Measure Man. Auto Man. Auto Man. Auto 250 CID C, K10-15 121 / 2 151 / 2 C 20-25 292 CID C, K30-35 141 / 2 P10-30, 15-35 13/4...
Page 26 HEATER 1A-1 SEC TIO N 1A HEATER ■ C O N TEN TS OF T H IS SECTIO N Standard Heater................1 A-1 Auxiliary Heater ................1 A-14 Specifications................. 1 A-17 STANDARD HEATER IN D E X Center Distributor Duct - G Models..... ..1A-9 General Description........
Page 27 1A-2 HEATER HEATER A DEFROSTER ASM HEATER & DEFROSTER ASM AIR OUTLET VIEW AIR F L O W LEGEND Q ) TEMPERATURE VALVE [ ] OUTSIDE AIR HEATER ASM [2] DEFROSTER VALVE E S E 3 M IXE D A,R DASH PANEL----- ' W / M/ / / A H E A T E D...
Page 28 HEATER 1A-3 LIGHT T R U CK SER V IC E MANUAL...
Page 29 1A-4 HEATER DIAGNOSIS TROUBLE CAUSE AND CORRECTION Temperature of heater a i r at ou tle ts too low to heat up pas See " I n s u f f i c i e n t Heat Diagnostic Chart". senger compartment.
Page 30 HEATER 1A-5 I NSUFFI CI ENT HEAT D I A G N O S I S C H A N G E IN A IR FLOW L IT T L E OR N O C H A N G E IN A IR FLOW N O R M A L A IR FLOW LOW OR NO A IR FLOW Check heater outlet temperature...
Page 31 HEATER C I R CU I T D I A G N O S I S * BLOW ER M OTO R IN O P E R A T IV E (A N Y SPEED) Check fuse in fuse panel. FUSE BLOWN FUSE OK The fo llo w in g tests should be made w ith...
Page 32 HEATER 1A-7 Fig. 1 A-5--Heater W irin g Diagrams LIG H T TR U CK S ER V IC E MANUAL...
Page 33 1A-8 HEATER ON VEHICLE SERVICE open end of the wheel away from the blower motor. B L O W E R M O T O R b. If the motor mounting flange sealer has hardened, R em o v al (Fig. 1 A -6) or is not intact, remove the old sealer and apply a new bead 1.
Page 34 HEATER 1 A-9 HEATER HOSES Heater hoses are routed from the thermostat housing or inlet manifold and water pump (radiator on some automatic transmission vehicles) to the core inlet and outlet pipes as shown in Figure 1A-9. Hoses are attached at each end with screw type clamps.
Page 35 1A-10 HEATER AUTOMATIC TRANSMISSION MODELS EXCEPT C-KIO 350 V8 W / O VOI CR C60 ) C-K MODELS G MODELS Fig. 1A-9--Heater Hose Routings CONTROL CABLES G M odels C-K M odels Replacement (Fig. 1A-13) 1 . Disconnect the battery ground cable. Replacement 1 .
Page 36 HEATER 1A-11 Fig. 1 A -10 --D istrib utor Ducts--G M odels G M odels Replacement (Fig. 1A-15) Heater and defroster cable routing and attachment to control and to distributor case is illustrated in Figure 1 A-14. NOTICE: If cable adjustment is required, see below. AIR CABLE HEATER C O N TRO L...
Page 37 1 A-1 2 HEATER damage to the cable could result. 6. Install the cable, reversing Steps 1-4 above. A d ju stm en t - G Van 1. Attach inner cable and sheath to I.P. Control. 2. With I.P. installed, move temperature cable to cold and attach loop on inner cable to temperature door on heater case.
Page 38 HEATER 1 A-13 V I E W V I E W Fig. 1 A -1 5--Control Cable Routing-G M odels G M odels Replacement (Fig. 1A-13) 1. Disconnect the battery ground cable. 2. Disconnect the blower switch wiring harness connector at the switch. 3.
Page 39: Auxiliary Heater
1A-14 HEATER AUXILIARY HEATER IN D E X General Description................1A-14 Control...................1A-14 Diagnosis..................1A-16 On Vehicle Service............... ..1A-16 Specifications...................1 A-17 GENERAL DESCRIPTION An auxiliary heater is available as a dealer installed off coolant flow to the auxiliary core during warm weather accessory to provide additional heating capacity for the and eliminate the radiant heat that would result.
Page 40 HEATER 1A-15 Fan S w itc h (Fig. 1A -20) The three speed fan switch (LOW-MED-HI) is located in the instrument panel, to the right of the steering column. Fig. 1A-19~W ater Valve Installation - G M odel Shown as DIAGNOSIS Refer to the "Standard Heater"...
Page 41 1A-16 HEATER f A W v i ! CIRCUIT HEATER OPERATION 6A T-B L0 SW-RES Rl R2- OFF BAT-ONLY v W r BLO MTR-GRD BAT-LO BLOWER B A r s r a sw-ftts R i- MED BAT-MED RESISTOR BLO I BLO MTR-GRD BAT-HI s w :.....
Page 42 HEATER 1A-17 LIGHT TR U C K S ER V ICE MANUAL...
Page 43 1 A-18 HEATER R O U T E H O S E U N D E R S P R IN G I - / ” M I N I M U M Z4" M IN IM U M C L E A R A N C E C L E A R A N C E Fig.
Page 44 AIR C O N D IT IO N IN G CAUTION: When performing temperature BEFORE attempting to idle conditioning diagnosis Chevrolet the engine for periods greater than five vehicles equipped with catalytic (5) minutes. Once the choke is open and...
Page 45: General Description
1 B-2 AIR CO NDITIO NING GENERAL DESCRIPTION FOUR-SEASON SYSTEM OVERHEAD SYSTEMS (C-K-G MODELS) Both the heating and cooling functions are performed These systems (C69 on C-K-G Models) operate in by this system. Air entering the vehicle must pass through conjunction with the Four-Season System (C-K Models) or the cooling unit (evaporator) and through (or around) the C60 System (G Models)-they do not operate independently.
Page 46 EVAPORATOR CORE BLOWER & SHROUD EVAPORATOR A SM R.H. OUTLET CONTROL R.H. OUTLET CENTER VIEW A L.H. OUTLET OUTLET AIR CONDITIONING OVERHEAD SYSTEM AIR INLET VALVE PLENUM VALVE HEATER CORE BLOWER & EVAPORATOR A SM L.H. OUTLET SELECTOR FOOT DEFLECTOR DUCT A SM EVAPORATOR CORE...
Page 47 IB -4 AIR CONDITIO NING Sight Glass (Motor Home Chassis Models Only) While having no real function to perform in the system, the sight glass is a valuable aid in determining whether or not the refrigerant charge is sufficient and for eliminating some guess work in diagnosing difficulties.
Page 48: System Control
AIR CONDITIONING 1 B-5 45°F (7.2°C) ambient the following components should be checked for continuity: 1 . Compressor discharge pressure switch. 2. Master switch (on control head). If both switches show proper continuity, check the harness for shorts or improper ground conditions. CK - Models Low refrigerant charge protection is afforded by the pressure cycling switch as a secondary function.
Page 49 C O N D ITIO N E D A IR IS D IR EC TED TH R U W /SHLD, I .P. 8c FLOOR D IS TR IB U TO R OUTLETS A NON-COMPRESSOR OPERATING POSITION, C O N D ITIO N E D AIR IS DIRECTED TH R U I.P. OUTLETS W ITH OUTSIDE AIR D ELIVER ED TH RU I.P.
Page 50 AIR CO NDITIO NING IB-7 SYSTEM OPERATION - CK TRUCK BLOWER SELECTOR HEATER A/C HEATER COMPRESSOR SPEEDS ENTERS LEVER DOOR- DEFROSTER SOURCE AVAIL POSITION VEHICLE OPEN TO: DOOR-OPEN TO: OUTSIDE HEATER FLOOR OUTLETS HEATER INSIDE% DASH OUTLETS MAX A/C HEATER OUTSIDE DASH OUTLETS HEATER...
Page 51 1B-8 AIR CO NDITIO NING BLOWER HEATER HEATER SPEEDS ENTERS DEFROSTER COMPRESSOR SOURCE A V A IL VEHICLE DOOR DOOR OPEN TO OPEN TO NONE OUTSIDE FLOOR OUTLETS HEATER HEATER-DEF A L L INSIDE % DASH OUTLETS HEATER OUTSIDE NORM A L L DASH OUTLETS HEATER...
Page 52 AIR CONDITIONING 1 B-9 Fig. 1B -12-M otor Home Unit Control A-6 Compressor Systems Remove Compressor A N D Accumulator. Drain, measure and record TOTAL oil from both components. Discard old oil. If less than 6 ounces, add 6 ounces of new oil to system. If more than 6 ounces, add same amount of new oil as drained.
Page 53 1B-10 AIR CO NDITIO NING Liquid refrigerant T H E R M O S T A T I C SWITCH flo w rate is regulated Heat rem oved from here. High pressure Upon removal of heat, air entering vehicle liquid becomes low va p o r becomes high vaporizes low pressure pressure liquid.
Page 54 AIR CO NDITIO NING IB-11 FROSTBITTEN O R FROZEN. All Refrigerant-12 drums are shipped with a heavy metal screw cap. The purpose of the cap is to protect the valve and safety plug from damage. It is good practice to replace the cap after each use of the drum for the same Four-Season A ir C o n ditioning (C -K Models) reason.
Page 55 1B-12 AIR CONDITIO NING burr or piece of dirt may cause a refrigerant leak. to prevent distortion of connecting lines or components. When connecting the flexible hose connections, it is Always replace the o-ring when a correction has been important that the swaged fitting and the flare nut, as well broken.
Page 56: Diagnosis
AIR CO NDITIO NING IB -1 3 A ND C H A R G IN G PROCEDURES C.C.O.T. PRESSURE VALVE/LINE TO LOW-SIDE SERVICE SYSTEMS are described on following pages in the Service FITTING ON ACCUMULATOR. Manual. TESTING THE REFRIGERANT SYSTEM W ith R-12 Drum or 14 oz.
Page 57 1B-14 AIR CO NDITIO NING A refrigerant leak in the high pressure side NOTICE: the accumulator. The switch performs two functions in the of the system may be more easily detected if the system system. In addition to cycling the compressor on and off to is operated for a few minutes, then shut off and checked control refrigerant flow, the switch shuts off the compressor immediately (before system pressures equalize).
Page 58 AIR CONDITIONING 1B-15 C .C .O .T. A /C S Y S T E M D IA G N O S T IC PR O C ED U R E NO BLOWER " IN S U F F IC IE N T C O O L IN G " O PE R A TIO N | - J b l o w e r _____ i...
Page 59 IB -1 6 AIR CO NDITIO NING C.C.O.T. A/C SYSTEM DIAGNOSTIC PROCEDURE "IN SU FFICIEN T COOLING" COMPRESSOR CLU TC H IS ENG AG ED OR C Y C LIN G FEEL L IQ U ID LIN E NEAR COMP. LOW-PRESS. C U T-O FF SWITCH R E S T R IC T IO N IN H IG H S ID E FE E L E V A P O R A T O R IN L E T PIPE N E A R O F S Y S T E M .
Page 60 AIR CONDITIONING IB -1 7 C.C.O.T. A/C SYSTEM DIAGNOSTIC PROCEDURE “ INSUFFICIENT COOLING" P ER FO R M ANC E P R E S S U R E -T E M P E R A T U R E C H A R T GRILLE TEMPERATURE V E H IC L E (80°F)
Page 61 1B-18 AIR CONDITIO NING Fig. 1B-17--A/C Compressor W iring CK Series • LIQH T T R U CK S ER V ICE M AN UAL...
Page 62: Air Conditioning
------ "W JP AIR CONDITIONING 1B-19 --------------------------------SERVICE DIAGNOSTIC PROCEDURE---------------------------- INSUFFICIENT COOLING — A/C SYSTEM S W ITH CYCLING CLUTCH — EXPANSION TUBE (PRESSURE SENSING) MOVE TEMP. LEVER RAPIDLY BACK AND FORTH FROM HOT TO COLD. LISTEN FOR DOOR HITTING AT EACH END This System Does Not Have a S ight Glass.
Page 63 IB -2 0 AIR CO NDITIO NING OFF ALL THE TIME A ttach Fused Jum p er W ire fro m C o m pre ssor H ot Lead to P ositive (+ ) B attery Post and Check C om pressor O p era tio n NOT ENGAGED ENGAGED...
Page 64 AIR CONDITIONING IB-21 ELECTRICAL/VACUUM TROUBLE DIAGNOSIS When diagnosing problems in the electrical and Place the selector lever in the malfunctioning position vacuum systems of the air conditioning system, consult and check for vacuum at the pertinent vacuum actuators. electrical wiring diagrams and vacuum diagrams. If vacuum exists at the actuator but the door does not move, then the actuator is defective or the door is mechanically bound.
Page 65 COMPRESSOR DIAGNOSIS Retrace electrical circuit back to source of power loss. (See wiring diagrams). G MODELS: NO V O L T A G E A T Check for defective discharge Pressure Switch by jumping switch connector terminals. If compressor C O M P R ES SO R CO IL. operates, check for low refrigerant charge.
Page 66 INSUFFICIENT COOLING DIAGNOSIS CHART 5. Check for condenser air blockage due to foreign material. The following procedures should be applied before performance testing an A/C System. 6. Check for proper air ducting hose connections. 1. Check for proper belt installation and tension with J-23600. 7.
Page 67 ELECTRICAL SYSTEM DIAGNOSTIC CHART B L O W E R MOTOR IN O P E R A T IV E BLOWER M OTOR IN O P E R A TIV E (C ER T A IN S P E E D S - E X C E P T HIGH (A N Y SPEED) ON C-K FO U R-SEA SO N ) Check for proper...
Page 68 ELECTRICAL SYSTEM D IA GNOSTIC CHART COMPRESSOR CLUTCH INOPERATIVEH BLOWER MOTOR INOPERATIVE A T HIGH SPEED ONLY I Check fuse| (C-K FOUR-SEASON SYSTEM) I:.. - i Check f FUSE BLOWN | FUSE O K | in-line fuse Check Compressor Solenoid Ground With ignition switch in "R u n "...
Page 69 IB -2 6 AIR CONDITIO NING AIR CONDITIONING R R 0 C -6 0 Fig. 1 B-22--Four-Season System W irin g Diagram (C-K Models) LIG H T T R U CK SERV ICE M AN UAL...
Page 71 1 B-28 AIR CONDITIO NING AIR CONDITIONING RPO.C-69 Fig. 1 B -24-O verhead System W irin g Diagram (C-K M odels) ■ft > C r^ & w m n r'r*. **•> -3 5 LIG H T T R U C K SERV ICE M AN UAL...
Page 72 AIR CONDITIONING IB -2 9 SOLENOID § p H 8 LT G R ^ B L K -j ^-12004268 -I8 W H T------I S 3 G£Z] AIR CONDITIONING RP.0.-C60 Fig. 1B -2 5 -C 6 0 System W irin g Diagram (G Models) indicate broken parts or excessive clearances due to abnormal condition and will lead to evaporator freeze-up.
Page 73 IB -3 0 AIR CO NDITIO NING V A C U U M R E S E R V O IR (IN E N G IN E C O M P A R T M E N T ) T O V A C U U M S O R C E g r a y DA S H P A N E L H E A T E R C O R E C A S E...
Page 74 AIR CO NDITIO NING 1B-31 REAR BLOWER RESISTOR -12004 752 GROMMET 8 9 l7 5 4 2 -\ /—8917541 Ll BLU/BLK-872— i IT BLU/BLK-872- LT B L U /B LK - - 8 5 b l k YE L/B LK----- YEL/BLK-851—...
Page 75 - l l [ t o FUSE PANEL l | l GROUND COMPRESSOR RESISTOR. £ 16 DK BLU 7 2 16 LT BLU' BLOWER SWITCH - 5 1 16 YEL SET AT CONNECTION N TO NONE N TO I & 2 N TO 1 &...
Page 76: Insufficient Cooling
AIR CONDITIONING IB -3 3 CORRECTION CONDITION AND CAUSE Heater outlet Temperature too low. Check duct work for proper installation. Check blower operation. Inspect TEMP lever and cable for proper operation. Check heater hoses for function. On A, B and G Series check water r f.
Page 77: On Vehicle Service
1B-34 AIR CONDITIO NING ON VEHICLE SERVICE EVACUATING AND CHARGING PROCEDURES PRECAUTIONARY SERVICE MEASURES DISCHARGING EVACUATING ADDING OIL AND CHARGING PROCEDURES FOR C.C.O.T. Before any service is attempted which requires opening A /C SYSTEMS of refrigerant lines or components, the person doing the The refrigerant system may be Discharged, Evacuated work should be thoroughly familiar with the information and Charged using J-23500-01 air conditioning service...
Page 78 AIR CONDITIONING IB -3 5 23500-01 Charging Station Method Four-Season Air Conditioning (C-K Models) • Disposable Can Method i (Refrigerant Charge 3 Lbs. -12oz.) • Drum Method Overhead System (C-K Models) (R e frig e ran t Charge - 5 lbs.-4 o z .) CAUTION: Under circumstances...
Page 79 IB -36 AIR CONDITIO NING CLOSE A L L CO NTRO LS J 23500-01 S ER VIC E C H A R G IN G S T A T IO N R E F R IG E R A N T -1 2 ' 3 F U L L Y OPEN GAUGE SET V A C U U M V A L V E O ff.
Page 80 AIR CONDITIONING IB -3 7 TO BEGIN CHARGING OF THE C.C.O.T. A/C SYSTEM 1. Start engine, run with choke open and fast idle speed reduced to normal idle, set A /C control lever on OFF. 2. With the Refrigerant-12 drum or can(s) inverted, open R-12 source valve(s) and allow one (1) pound or 1-2 14 oz.
Page 81: Engine Idle Compensator
1B-38 AIR CONDITIO NING J5725-04 MANIFOLD GAUGE SET T H ,S H|GH PRESSURE VALVE IS OPEN AND VACUUM PUMP LINE DISCONNECTED ONLY DURING USING J-5420 OPEN DURING EVACUATION ADAPTER EVACUATION AND CHARGING THIS HIGH PRESSURE V ALVE IS CLOSED AND LINE DISCONNECTED HIGH DURING DISCHARGING...
Page 82: C60 System-C-K Models
AIR CONDITIONING IB -3 9 Before beginning any compressor disassembly, drain and measure oil in the compressor. Check for evidence of contaimination to determine if remainder of system requires servicing. Compressor Servicing information is located in the Overhaul Manual. Installation 1.
Page 83: Condenser
IB -4 0 AIR CONDITIO NING 3 0 5 - 3 5 0 V - 8 C - K M O D E L S 3 0 5 - 3 5 0 V - 8 M O D E L S A N D M O T O R H O M E C H A S S I S 4 5 4 V - 8 C - M O D E L S 4 5 4 V - 8...
Page 84: Blower Assembly
AIR CONDITIONING 1B-41 7. To install the new accumulator, reverse Steps 1-4 check the accumulator for frost. The above. Connect all lines using new "O" rings, coated with presence of frost indicates that the clean refrigeration oil. system fully discharged. complete purging, connect the vacuum line to the vacuum pump, turn on the CAUTION: Do not uncap the new unit...
Page 85: Expansion Tube-Ail
1 B-42 AIR CO NDITIO NING Fig. 1 B-37--Expansion Tube (C-K and G Four-Season System) center upper ducts. 5. Disconnect the bowden cable at the temperature door. 6. Remove the nuts from the three selector duct studs Use new "O" rings, coated with clean NOTICE: projecting through the dash panel.
Page 86: Control Assembly
AIR CONDITIONING IB -4 3 RIGHT H A N D OUTLETS UPPER CENTER DISTRIBUTOR DUCT LEFT DISTRIBUTOR DUCT A N D FOOT COOLER LOWER CENTER DISTRIBUTOR DUCT Fig. 1B-39--Air Selector and Ducts (C-K Models) TEMPERATURE DOOR CABLE ADJUSTMENT - CONTROL ASSEMBLY - CK MODELS CK MODELS Removal (Fig.
Page 87: Vacuum Tank
1B-44 AIR CONDITIO NING BLOWER MOTOR RESISTOR The blower motor resistor is located in the blower side of the blower-evaporator case (fig, IB-43). Replacement 1. Disconnect the wiring harness at the resistor. 2. Remove the resistor to case attaching screws and remove the resistor.
Page 88: Fuse
AIR CONDITIONING 1B-45 Fig. 1 B-44~Engine C om partm ent W irin g Harness (C-K M odels) panel and rear header brackets. Replacement 1 . Disconnect the wiring harness at the relay. 4. Remove the duct. 2. Remove the relay to case attaching screws and 5.
Page 89: Blower Motor Assembly
IB -4 6 AIR CONDITIO NING Fig. 1 B-46--Overhead System Front W irin g (C-K Models) 2. Install the blower motor retaining strap and foam. Replacement 1 . Disconnect battery ground cable. 3. Place the blower motor and wheel assembly into the lower case.
Page 90: Expansion Valve
AIR CONDITIONING 1 B-47 EVAPORATOR BLOWER-EVAPORATOR SCREEN UPPER CASE EXPAN SION EVAPORATOR VALVE CORE SEN SIN G BULB Fig. 1 B-49--Expansion Valve C69 System EVAPORATOR CORE (Fig. IB-49) Fig. 1 B-48--Blower M otor (C-K Overhead System) Removal 1. Disconnect the battery ground cable. 2.
Page 91: Blower Motor Switch
1B-48 AIR CO NDITIO NING 10. Evacuate, charge and check the system. BLOWER MOTOR SWITCH The three-speed (LO-MED-HI) blower motor switch is located in the instrument panel, just to the left of the ash tray (fig. IB-50). outlet connections, compressor refrigerant line Replacement...
Page 92 AIR CO NDITIO NING 1 B-49 screws (below windshield). f'1 'u to assure proper installation: 11. Working from the engine compartment, disconnect heater hoses and plug to prevent water spillage. , & „ , • a- Assemble the blower wheel to the motor with the 12.
Page 93: Evaporator Core
1B-50 AIR CONDITIO NING Fig. 1 B-54--Heater D is trib u to r Duct Fig. 1 B -55--D istributor Gasket 7. Remove screws attaching thermostatic switch to case b. If the motor mounting flange sealer has hardened, and remove cappliary tube insulation. or is not intact, remove the old sealer and apply a new bead of sealer to the entire circumference of the mounting flange.
Page 94: Control
AIR CONDITIONING IB-51 Fig. 1B-56--Air D eflector - O utlets (G M odel C60 System) BLOWER SWITCH TEMPERATURE DOOR CABLE - G MODEL Replacement Replacement (Fig. 1B-57) Follow Steps 1-10 of "Heater Air Distributor and 1. Disconnect the battery ground cable. Extension Duct Replacement"...
Page 95: Blower Motor Relay
IB -5 2 AIR CO NDITIO NING 5. To install, reverse Steps 1-4 above. on the inlet pipe from where it was removed. replacement switch's tube should be installed at RESISTORS this location. The heater blower motor resistor is mounted in the right hand plenum (in the same position as without air Installation conditioning).
Page 96: Vacuum Tank
AIR CONDITIONING IB -5 3 COMPRESSOR Compressor mounting is illustrated in Figures IB-71 TEMPERATURE DOOR CABLE through IB-73. Temperature cable attachment routing illustrated in Figure IB-78. HEATER HOSE VACUUM TANK - G MODELS Heater hose routing is illustrated in Figure IB-74 and IB-75.
Page 97: Overhead System-G Models
IB -5 4 AIR CONDITIO NING v i e w Fig. 1 B-64— F itting and M u ffle r Assem bly Fig. 1 B-66--Refrigerant Lines-Diesel Engine O VERHEAD S Y S T E M -G M O DELS This system is used in conjunction with the C60 system. Since replacement of the C60 System Components has been covered previously, only those components peculiar to the Overhead system will be covered in this section.
Page 98 AIR CONDITIONING 1B-55 LIGHT TRU CK SER V IC E MANUAL...
Page 99 1B-56 AIR CO NDITIO NING L IG H T TR U CK S ER V ICE MANUAL...
Page 100 AIR CONDITIONING 1B-57 LIG H T T R U CK S ER V IC E MANUAL...
Page 101 IB -5 8 AIR CO NDITIO NING Fig. 1 B-77--Defroster Duct-G Series DASH MOUNTED SYSTEM -MOTOR HOME CHASSIS This system is installed on the vehicle and checked at shipped with the chassis unit to the body supplier. For this assembly. The blower-evaporator is then disconnected and reason, it will only be possible to give basic replacement LIG H T T R U CK S ER V ICE MANUAL...
Page 102: Condenser
AIR CONDITIONING 1 B-59 © & Fig. 1 B-79--Condenser (M otor Home Chasis Unit) procedures on some components. SIGHT GLASS REPLACEMENT If damage to the sight glass should occur, a new sight CONDENSER glass kit should be intalled. The kit contains the sight glass, Replacement (Fig.
Page 103: Blower Assembly
1B-60 AIR CONDITIONING RETAINER W A S H E R GLASS " O ” RING Fig. 1 B-8 1 --Sight Glass Replacement BLOWER ASSEMBLY Installation 1. Install the blower wheels on the motor so that the Removal (Fig. 1 B-84) lower blades curve toward the dash panel side of the unit when the motor is placed in the case as illustrated in Figure 1 .
Page 104: Thermostatic And/Or Blower Switches
AIR CONDITIONING 1B-61 THERMOSTATIC SWITCH AIR SENSING CAPILLARY BUMPER BLOWER SWITCH CORRECT BLOWER Fig. 1 B-86-Thermostatic and Blower Switches BLADE ANGLE 4. Remove blower motor and harness assembly from case. Fig. 1B-84-Blow er Assembly (Motor Home Chassis Unit) In s ta lla tio n 1 .
Page 105: Specifications
IB -6 2 AIR CO NDITIO NING SPECIFICATIONS AIR CONDITIONING Compressor C-K Four-Season System ......... Frigidaire Make....C-K-G Overhead Systems........ 6 Cylinder Axial Type....G Floor System............12.6 Cu. In. Motor Home Chassis U n it ....Rotation....
Page 106: Special Tools
AIR CONDITIONING 1B-63 SPECIAL TOOLS t ) 1 1. J - 2 5 0 3 0 C lu t c h H u b H o l d i n g To ol 2 . J - 2 5 0 2 9 R ot or B e a r i n g R e m o v e r a n d R ot or Assy.
Page 107 1B-64 AIR CONDITIONING SPECIAL TOOLS 1. J - 8 3 9 3 C h a r g in g S ta tio n 1 1 . J - 5 4 2 1 -0 2 Pocket T h e rm o m eters (2 ) 2 2 .
Page 108 FRAME 2A-1 SECTIO N 2A F R A M E C O N TE N TS General Description..............2A-1 On-Vehicle Service................ .2A-1 Maintenance and Inspection............2A-1 Underbody Inspection..............2A-1 Frame Inspection...............2A-1 Frame Alignment................ .2A-1 Underbody Alignment..............2A-4 Excessive Body Damage............2A-4 GENERAL DESCRIPTION Misalignment of the underbody can affect door Light duty 10-30 Series frames are of the ladder channel...
Page 109 2A-2 FRAME Fig. 2A-1--Frame H orizontal C h eckin g-T ypical points of measurement may be considered in alignment. Tram m ing Sequence (Fig. 2A -1) If front or rear end of frame is damaged and width 1 . Dimensions to bolts and/or holes in frame extend is no longer within limits, frame centerline may be drawn to dead center of the hole or bolt.
Page 110 FRAME 2A-3 M odel 16-7/8 16-7/8 17-3/4 17-3/4 19-7/8 16-3/4 15-5/8 17-3/4 69-5/8 76-1/2 CA107 13-3/8 15-1/4 19-7/8 14-7/8 17-3/4 86-1/2 16-7/8 16-7/8 14-7/8 17-3/4 17-3/4 19-7/8 16-3/4 15-5/8 69-5/8 CA109 13-3/8 15-1/4 19-7/8 16-7/8 16-7/8 17-3/4 17-3/4 16-3/4 15-5/8 17 3/4 69-5/8 86-1/2...
Page 111 2A-4 FRAME Do not weld into corners of frame or along NOTICE: edges of side rail flanges. Welding at these points will The vertical dimension from the datum line to the tend to weaken the frame and encourage new cracks. points to be trammed.
Page 112 BUMPERS 2B-1 SECTIO N 2B B U M P E R S C O N TE N TS Front Bumper G Series..........2B-2 General Description...........2B-1 Service Procedures - 10 thru 30 series......2B-1 Rear Bumper G Series..........2B-2 Front Bumper - C, K and P Models.......2B-1 Rear Bumper - C and K Models......2B-1 Rear Bumper G Series..........
Page 113 2B-2 BUMPERS .1 6 0 . / . 1 8 0 REF. (C LEAR AN C E) remove brace. Installation Fig. 2B-4--Rear Step Bum per C and K M odels Install rear step bumper by reversing removal Installation procedure. Connect license lamp wiring. Reverse removal steps to install bumpers.
Page 114 BUMPERS 2B-3 Fig. 2B-8--G-Model Rear Step Bumper Fig. 2B-6~G -M odels Front Bum per Guards TORQUE SPECIFICATIONS C, P AND K Front Bumper ..............35 ft.-lbs. Front Bumper Bracket and Brace ......70 ft.-lbs. Rear Bumper to Outer Bracket .........35 ft.-lbs. Rear Bumper Outer Bracket and Brace ....50 ft.-lbs. License Plate B ra c k e t.....
Page 116 CHASSIS SHEET METAL 2C-1 SECTIO N 2C C H A S S I S SH EE T M ETA L C O N TEN TS Radiator Support...........2C-7 General Description............2C-1 On Vehicle Service............2C-1 Front Fender............2C-8 Hood Assembly - CK Series........2C-1 Front Fender and Skirt........
Page 117: Hood Lock Assembly
2C-2 CHASSIS SHEET METAL Installation 1 . Install hinge assembly to fender and align within scribe marks. Install bolts. 2. Install hood hinge spring. 3. Install bolts and align hood. See Hood Alignment in this section. Fig. 2C-3~Hood Lock Catch and S upport-C K M odels Hood Lock Assem bly A bolt-type hood lock is used as shown in Figure 2C-5.
Page 118: Hood Assembly
CHASSIS SHEET METAL 2C-3 REINFORCEMENT (0 6-16 MODELS, Fig. 2C-6--Hood Stop B olt CK M odels Installation 1 . If original hood is to be installed, position hood to hinges and install four cap screws snug which attach hinges to hood. Fig.
Page 119 2C-4 CHASSIS SHEET METAL Integral with the striker plate is the combination lock release lever and safety catch. 1. Scribe a line around the entire hinge plate to be repositioned. 2. Loosen the appropriate screws and shift the position of the hood into correct alignment using the scribe marks HOOD LATCH CABLE RELEASE - CK MODELS to check amount of movement.
Page 120: Hood Bumper
CHASSIS SHEET METAL 2C-5 Fig. 2C-10~Hood Release Cable - CK M odels HOOD EMBLEM - CK MODELS (FIG. 2C-11) Hood Assembly-G M odel (Fig. 2C-9) Hood Bumper Removal Adjust hood bumpers so that hood top surface is flush with the fender and grille top surfaces. Refer to Figure 17 1 .
Page 121 2C-6 CHASSIS SHEET METAL SNORKEL LO C A T IO N L6 SNORKEL Fig. 2C -13~C arburetor Outside A ir Inlet Snorkels-C K Model RADIATOR GRILLE AND BRACKETS CK, G- Fig. 2C-12--Hood Rod S up po rt - G-Model MODELS (FIG. 2C-15) Alignment RADIATOR GRILLE MOLDING - CK, G MODELS 1 .
Page 122: Radiator Support
CHASSIS SHEET METAL 2C-7 Figure 2C-19). Fig. 2C-1 5--Radiator and G rille Brackets 4. Install two bolts and shims required at each fender rear lower edge to hinge pillar. 5. Install bolt in each fender skirt to underbody. Removal 6. Install bolts at steering column skirt reinforcement, Drain radiator remove radiator...
Page 123: Front Fender
2C-8 CHASSIS SHEET METAL 13. Install both head lamp assemblies. Fig. 2C-1 5 -R a d ia to r and G rille Brackets 14. Tighten all previously installed bolts and screws. 15. Install battery and connect leads and wires. 10. Remove screws securing front fenders to radiator 16.
Page 124 CHASSIS SHEET METAL 2C-9 •FLUSH HOOD ■FENDER HOOD ASS' /-FENDER ASSY ASSY / ASSY FENDER -FENDER DOOR ASSY ASSY ASSY HOOD -FLUSH FLUSH ASSY SECTION E-E SE CTION B-B SECTION D-D SECTION C-C I Hood surface . 06 below n o t e at Section C-C to flush at Section B-B and Section D rD .
Page 125: Front Fender And Skirt
2C-10 CHASSIS SHEET METAL Fig. 2C -2 0 -R a d ia to r Upper and Lower G rille Panels-CK M odels FRONT FENDER AND SKIRT (FIGS. 2C-18 AND Installation 2C-19) Install front fender and skirt assembly in reverse order of removal.
Page 126 CHASSIS SHEET METAL 2 C -1 1 65 degrees Fahrenheit (18°C). The transfer should not be subjected to temperature greater than 175°F (79°C) and should not be left at or near this temperature for extended periods of time. Shelf life of the transfer material is 90 days at a temperature not to exceed 105°F (40°C).
Page 127 2C-12 CHASSIS SHEET METAL C O W L TO H O O D .1 8 ± .0 3 G A P NOTE H ood surface flush to .0 6 b e lo w cowl vent g r ille & constant from <£...
Page 128: Specifications
CHASSIS SHEET METAL 2C-13 SPECIFICATIONS SHEET METAL SECTION 2C TORQUE SPECIFICATIONS Lock Support to Hood 150 in. lbs. 150 in. lbs. Lock Bolt Nut 30 ft. lbs. 40 ft. lbs. Bumper Bolt Nut 85 in. lbs. 150 in. lbs. Hood Hinge 35 ft.
Page 129 ;■ ? \l m Q c i - SC 5 3...
Page 130: General Description
SEC TIO N 2D C A B A N D B O D Y The following caution applies to one or more steps in the assembly procedure of components in this portion of the manual as indicated at appropriate locations by the terminology "See Caution on page 1 of this Section".
Page 131 2D-2 BODY Fig. 2D-2--Typical Crew C ab/C hassis Fig. 2 D -4-T ypica l U tility V ehicle Vans G-Series Vans are available in three model number designations. See figures 2D-5 and 2D-6. Vans without body windows use number "05"; vans with body windows are "06"...
Page 132 BODY 2D-3 Fig. 2D-5--Typical "0 5 " and "0 6 " Vans LIGH T TR U CK SER V IC E MANUAL...
Page 133 2D-4 BODY Fig. 2D-6--Typical "0 3 " Van ON VEHICLE SERVICE C-K MODELS IN D E X Front End Hinges..............2D-16 Windshield Wipers..........2D-5 Stationary Glass..........2D-16 Glove Box............. .2D-5 Window and Regulator........2D-17 Rear View Mirrors..........2D-5 Locks, Handles, Rods........2D-18 Body Glass Weatherstrip.............
Page 134: Front End
BODY 2D-5 FRONT END momentarily which should rotate pivot shafts to park WINDSHIELD WIPERS position. Install arms and shafts. Windshield wiper units on all models are of the two- speed electric type. A single wiper motor unit, mounted to INSTRUMENT PANEL COMPARTMENT AND the left side of the dash panel inside the engine LOCK compartment, powers both wiper arms.
Page 135: Body Glass
2D-6 BODY BODY GLASS CK TRUCK WINDSHIELD REPLACEMENT CAUTION: Always wear gloves and eye The windshield is a one-piece type and is retained in glasses when handling glass to avoid the windshield opening by a urethane bonded rubber personal injury. weatherstrip.
Page 136 BODY 2D-7 Fig. 2D-1 4 -A p p ly in g Pressure to W ind shie ld can enter large end of adhesive material tube. 4. Commercial type razor knife (for cutting around edge of glass). Fig. 2D-13--Typical W ind shie ld 5.
Page 137 2D-8 BODY Fig. 2D-1 6-R em oving W in d sh ie ld from Opening Fig. 2D-1 7-C he cking W in d sh ie ld Opening 4. With the aid of an assistant outside the cab, remove Repairing and Refinishing Pinch-W eld Flange the windshield from the opening.
Page 138: Stationary Body Glass
BODY 2D-9 12. On windshields equipped with embedded antenna, primer will be applied (around edge of inside surface) by tape pigtail of antenna to inside surface of windshield glass wiping with a clean, alcohol dampened cloth. Allow to air in a convenient and accessible position. dry.
Page 139 2D-10 BODY Fig. 2D -19 — I nsta 1 1 ng Reveal M oldin g Fig. 2D-21--Body Side W in d o w - (16 and 06) Fig. 2D-20--Back W in d o w Glass - (03, 63) BODY SIDE DOORS DOOR ADJUSTMENTS S trik e r Bolt A d ju stm e n t Doors can be adjusted for alignment of clearance in the...
Page 140 BODY 2D-11 With aid of an assistant to support weight of door, bolt, adjust horizontally to desired position and tighten bolt remove the door to lower hinge retaining bolts and remove securely. door. -To make this Foreward and Rearward adjustment, loosen striker bolt, shim to desired position, and Installation tighten bolt securely.
Page 141 2D-12 BODY Fig. 2D -2 7 -D o o r Trim Pad 3. Using new glass channel filler, cut the piece to be installed two inches longer than necessary for the channel. Place this piece of filler (soapstoned side of filler away from DOOR VENTILATOR ASSEMBLY -Fig.
Page 142 BODY 2D-13 Fig. 2D-29~Rem oving V e n tila to r A ssem bly Fig. 2D -31~Bend Tabs Over Hex Nut DOOR W IN D O W ASSEMBLY--FIG. 2D-32 Installation Replacement 1. Lower the ventilator assembly into the door frame. 1.
Page 143 2D-14 BODY Fig. 2D-33~Rem oving Door Glass 4. Remove regulator by sliding regulator rearward, disengaging rollers from sash channel. Fig. 2D-35--Power W in d o w Regulator, M otor and C onnector A notch is provided in the sash channel to allow disengagement of the forward roller on the window regulator (Fig.
Page 144 BODY 2D-15 Fig. 2D -37~O utside Handle and Lock C ylinder panel. 5. Remove handle and control rod. . Reverse above procedures to install outside handle. Door Lock C ylinder -Fig 2D -37 Replacement 1. Raise door window. 2. Remove trim panel as outlined. 3.
Page 145 2D-16 BODY removing all foreign material from door opening surface STATIONARY GLASS-REAR DOOR proceed as follows: Replacement 1. Open door and block open. 1. Lower window to full down position. 2. Remove sill plate retaining screws and remove sill plate. 2.
Page 146 BODY 2D-17 W IN D O W GLASS-FIG. 2D-46 W IN DO W REGULATOR ASSEMBLY-FIG. 2D-46 Replacement Replacement 1. Lower glass to full down position. 1. Remove trim pad, stationary glass, and window glass as outlined earlier. 2. Remove remote control push botton knob, window regulator handle and trim pad.
Page 147 2D-18 BODY LOCKS HANDLES AND RODS Inside Handle--Fig. 2D -47 Replacement Lock Assembly--Fig. 2D-47 1 . Remove regulator handle, remote control knob and trim pad as outlined previously. 2. Disconnect control rod from inside handle by Replacement removing clip as shown in figure 2D-47. 1 .
Page 148: Adjustments
BODY 2 D -1 9 Be sure that adjustments are as shown to insure proper latching of the rear doors. LOCKS, HANDLES AND RODS The rear door lock, outside handle, lock cylinder, control rods and latch are shown in figures 2D-51 and 2D- 52.
Page 149 2D-20 BODY Fig. 2D-5 1-Rear Door Controls Fig. 2D -52-R ear Door Outside Handle and Lock Cylinder LIG H T T R U C K SER V IC E M ANUAL...
Page 150 BODY 2D-21 UPPER WEDGE STRIKER ADJUSTMENT ADJUSTMENT .17 ± .03 ( 11/64 DRILL) IN SECONDARY LATCHED .04 MAX. c l e a r a n c e IN SECONDARY LATCHED POSITION OR .OTOT© 7 0 050 INTERFERENCE IN FULL LATCHED POSITION. Fig.
Page 151 2D-22 BODY ENDGATES (06 AND 16) Coach models (06) and utility models (16) use endgates handle. of similar, yet distinct design. Separate procedures follow 5. Remove R.H. torque rod bracket screws, figure 2D- for service on each of these endgates. 58, then remove torque rod from endgate.
Page 152: Adjustments
BODY 2D-23 Fig. 2D-59~Latch and Remote Controls--(06 Only) with control rods. See figure 2D-59. Detach wiring harness body, figure 2D-63, then grasping torque rod with one hand and pulling torque rod over gravel deflector, as shown in from R.H. latch if so equipped. figure 2D-64.
Page 153: Endgates
2D-24 BODY Fig. 2D-63--Puiling Hinge Away From Body (16) Fig. 2D-65--Removing Access Cover (16) TORQUE ROD ENDGATE DISASSEMBLY (16) MODELS ONLY M an u al W in d o w Replacement 1 . Lower endgate and remove acess cover. 1. Lower endgate and remove access cover, as shown 2.
Page 154 BODY 2D-25 Fig. 2D-67~Removing Torque Rod (16) Fig. 2D-69--Removing Side Latch 10. Refer to figure 2D-72 for window and regulator D rive Cable installation. The drive cable can be replaced by disengaging the 11. Roll window to up position. cable from the motor and jackscrew assembly and removing 12.
Page 155: Tailgates
2D-26 BODY Fig. 2D-7 1--Removing Control Assembly and Inside Handle Fig. 2D-73--Disconnecting Sash from Regulator 4. Reverse removal procedures for installation. and remove the jackscrew assembly. 4. Reverse removal procedure for installation. Jacks crew (Fig. 2 D -7 6) TAILGATES (03, 63 and 16) Removal For endgates with electric window, secure the window Fleetside...
Page 156 BODY 2D-27 B LO C K O U T S W IT C H M O T O R I V IE w f~ B l v i e w Fig. 2D-75--Power W in d o w M o to r and S w itches (16) Only Fig.
Page 157 aluminum tubing. Drill two (2) 3/8" diameter holes, 63 inches apart in the brace. b. Attach one brace to the holes exposed in Step 5. c. Slide top forward to expose the front bottom top-to- pickup box attaching holes. d. Attach the second brace to these holes. With assistance, lift the top and move it rearward for removal.
Page 158 BODY 2D-29 1 CAUTION ] S trap m u st be placed over b o w asm. H E A D E R V I E W Fig. 2D -79--Folding Top Assem bly LIGHT T R U C K SER V IC E MANUAL...
Page 159: Seat Belts
2D-30 BODY SEATS position by a pendulum that causes a locking bar to engage SEAT BELTS a cog of the retractor mechanism. SERVICING LAP AND SHOULDER Removal and Installation BELTS - ALL MODELS Before servicing or Refer to illustrations on following pages and select the replacing lap and shoulder belts, including single loop belt appropriate illustration for removing and installing lap belts systems, refer to the following precautionary items:...
Page 160 BODY 2D-31 LIGHT T R U CK S ER V IC E MANUAL...
Page 161 2D-32 BODY B ELTS —2N D SEAT IviEwfp] B E L T S -F R O N T S E A T B E LTS —3R D S EA T Fig. 2D-82--Seat Belt Installatio n (06) M odels LIG H T T R U CK S ER V ICE MANUAL...
Page 162 BODY 2D-33 LIGHT T R U C K S ER V IC E MANUAL...
Page 163 2D-34 BODY LIG H T T R U CK SER V IC E MANUAL...
Page 164 BODY 2D-35 Fig. 2 D - 8 9 - C K ( 1 6 ) S e a t A t t a c h m e n t s LIGHT TRU CK S ER V IC E MANUAL...
Page 165 2D-36 BODY Fig. 2D-90~Seat Separator C om partm ent and D oor-C K M odels LIG H T T R U C K SER V IC E MANUAL...
Page 166 BODY 2D-37 Fig. 2 D - 9 2 ~ B o d y M o u n t i n g ( 6 3 ) LIGHT T R U C K S ER V IC E MANUAL...
Page 167 2D-38 BODY MOUNT 1 MOUNT 2 AM O UNT 4 , 5 , 6 Fig. 2D-93--Body M ounting (06) MOUNT 4 MOUNT 2 \ MOUNT 3 Fig. 2 D - 9 4 - B o d y M o u n t i n g ( 1 6 ) LIG H T T R U CK SER V IC E MANUAL...
Page 168 BODY 2D-39 G MODELS IN D E X Description.............2D-49 Front End Windshield Wipers..........2D-39 Adjustments............2D-49 Cowl Ventilator Grille....;......2D-40 Front Latch............2D-51 Side Ventilator Valve..........2D-40 Rear Latch............2D-5 2 Rear View Mirror..........2D-40 Upper Rear Hinge..........2D-52 Body Glass Strikers..............
Page 169 2D-40 BODY Fig. 2D -96--W indshield W ip e r Linkage Fig. 2D-98--Side Cowl V e n tila to r Before installing wiper arms, operate wiper motor REAR VIEW MIRRORS momentarily which should rotate pivot shafts to park position. Install arms. Inside Rear V ie w M irro r COWL VENTILATOR GRILLE Replacement...
Page 170 BODY 2D-41 Fig. 2D-1 OO-Outside Rear V iew M irrors BODY GLASS pressures, extremes of temperature, motion of the vehicle, CAUTION: Always wear gloves and eye etc. glasses when handling glass to avoid personal injury. The precedure for removal of the windshield applies to the complete windshield assembly and to other stationary WINDSHIELD GLASS glass, such as in figure 2D-104.
Page 171 2D-42 BODY APPLY LU B R IC A N T Fig. 2D-102--Checking W in d sh ie ld Opening 5. With the windshield supported and centered in its opening, check the relationship of the glass to the body opening flange around the entire perimeter of the glass. .
Page 172: Front Door
BODY 2D-43 Fig. 2D -10 5~ S w in go ut W in d o w Fig. 2D -104~B ody W in d o w Glass a. Pull on loose ends until each is within 2" of its assembly at hinge. respective upper corner.
Page 173 2D-44 BODY -r<fzv7zM/ B - 5 tv /rtv t & s z Fig. 2 D -1 0 7 -L o o s e n in g S triker Bolt Fig. 2D -108--Typical S triker B olt A djustm en t DOOR WEATHERSTRIP S triker Bolt A d ju s tm e n t Success of weatherstrip replacement depends entirely...
Page 174 BODY 2D-45 Ventilator Glass Replacement 1 . Using an oil can or similar means, squirt prepsol on the glass filler all around the glass channel or frame to soften the old seal. When the seal has softened, remove the glass from the channel.
Page 175 2D-46 BODY 1 . Disconnect battery ground cable. 2. Remove door trim panel. 3. Disconnect harness from regulator. 4. Remove screws securing regulator to inner panel. 5. Push regulator out of door opening while holding rear of assembly, then slide assembly to the notches in the carrier channel and out through the door access hole.
Page 176 BODY 2D-47 RELAY W IT H P O W E R W IN D O W S C IR C U IT FUSE W I N D O W RELAY PA NEL' BREAKER | VIE W W IT H P O W E R LO CKS d o o r V IE W...
Page 177 2D-48 BODY LOCK CYLINDER ASSEMBLY-FIG. 2D-115 Replacement 1 . Raise door window and remove door trim pad. 2. With a screwdriver, or other suitable tool, slide lock cylinder retaining clip (on door outer panel) out of engagement and remove lock cylinder. 3.
Page 178: Sliding Side Door
BODY 2D-49 SLIDING SIDE DOOR assembly, rear latch striker, upper front roller and front DESCRIPTION latch striker as outlined later in "Adjustments". The weight of the sliding side door is supported by the upper rear hinge-and-roller assembly, and by the lower front Fore and Aft catch-and-roller assembly.
Page 179: Top View
2D-50 BODY STRIKER FORE-AND-AFT ADJUSTMENT SLOTS CENTER ROLLER VERTICALLY IN TRACK SO IT DOES NOT CONTACT fr ==Z=r^) \ THE TRACK IN FULL OPEN U P-AN D-DO W N OR FULL ADJUSTMENT SLOTS CLOSED POSITION UPPER REAR HINGE-AND-ROLLER SECTION B-B TOP VIEW UPPER LEVER._ _ ,LOWER LEVER U P-AND-DO W N...
Page 180 BODY 2D-51 Fig. 2D-1 20 --A djusting the Rear W edge Assem bly Fig. 2D-1 18--Hinge Cover The upper rear hinge must be positioned as shown in Rear W ed g e Assem bly A d ju stm en t view A of figure 2D-117, in order to insure proper latching.
Page 181 2D-52 BODY LOCKING ROD REAR |V IE W LATCH RODS LOCK CYLINDER ROD Fig. 2 D-1 2 1— S lidin g Door Front Latch REAR LATCH AND/OR LATCH ACTUATING Fig. 2D-1 2 3--SIiding Door Rear Latch RODS Removal 2. Connect rods to front latch assembly. 1.
Page 182 BODY 2D-53 Fig. 2D -124~Rear Track Cover Screw B olt Roller Guide Block Bushing Plate Lockwashers Hinge (D oor Half) Hinge (Body Half) Upper lines Spring 11. Spacer Spring retainer Bushing Spring (Upper Lever) 19. 5. Washer Bushing Hinge liner 13.
Page 183 2D-54 BODY Fig. 2D-1 26 -C h e c k in g Assem bly of Hinge REAR DOORS REAR DOOR HINGE STRAP REAR DOOR HINGE Removal Replacement 1 . Open door. Support door so that when hinge screws are removed door weight will be on support. 1.
Page 184 BODY 2D-55 Fig. 2D-1 29--Outside Handle and Lock C ylinder REAR DOOR LOCK CYLINDER Removal 1. Remove trim panel. 2. Remove remote control. Fig. 2D-1 28 -R e m o te C ontrol and Latch 3. Remove lock cylinder retainer and lock cylinder. Installation 1 .
Page 185 2D-56 BODY .04 MAX. CLEARANCE IN SECONDARY LATCHED POSITION ,010 TO .050 INTERFERENCE IN FULL LATCHED POSITION. UPPER STRIKER ADJUSTMENT ,17 ± .0 3 (1 1 /6 4 DRILL) IN SECONDARY LATCHED POSITION LOWER STRIKER A D JU S TM E N T Fig.
Page 186 BODY 2D-57 retainers, which fit onto anchor pins in floor anchor plates are used. When the latch assemblies are depressed, their cams and the hooks of the retainers are drawn tightly onto the anchor pins for secure seat attachment. Removal accomplished using following...
Page 187 2D-58 BODY Fig. 2D -1 3 3 - - Q u i c k R ele a s e S e a t A s s e m b ly LIGHT TRU CK SER V IC E MANUAL...
Page 188 BODY 2D-59 Fig. 2 D - 1 3 5 ~ R o o f V e n t - G S er ies Fig. 2 D - 1 3 7 - - 2 n d an d 3 r d S e a t Lap B elt In sta llatio n LIGHT T R U CK SER V IC E MANUAL...
Page 189 2D-60 BODY SPECIAL TOOLS *£L 1. J-22 58 5 F ro n t D o o r Hinge, B o lt W rench 2. J-22577 W indshield C hecking Blocks 3. J-7797 D o o r H andle C lip Remover 4.
Page 190 BODY 2D-61 SPECIFICATIONS FRONT END END GATE (06) Windshield Wiper Linkage to Plenum....25 in. lb. Hinges-Hinge to Body........... 35 ft. lb. Sunshade Support..........20 in. lb. -Hinge to End Gate........20 ft. lb. Inside Rear View Mirror to Bracket......45 in. lb. Support Cable Bolts..........
Page 191 2D-62 BODY BODY MOUNTING (C-K MODELS)-FT. LBS. Model (03) — — — — (06) — — (14) — (63) G MODELS MIRRORS AND SUNSHADE SLIDING SIDE DOOR Inside Rear View Mirror to Bracket ....15 in. lb. Remote Control (front latch) to D o o r....90 in.
Page 192 FRONT ALIG NMENT 3A-1 SECTION 3A FRONT ALIGNMENT CONTENTS General Description..............3A-1 Maintenance and Adjustments........... 3A-2 Specifications.,...„................ 3A-6 GENERAL DESCRIPTION FRONT ALIGNMENT CAMBER The term "front alignment" refers to the angular relationships between the front wheels, the front suspension attaching parts and the ground.
Page 193 3A-2 FRONT ALIG NM ENT <£. OF WHEEL ■ POSITIVE DIRECTION CAMBER ANGLE CASTER ANGLE FRONT V IE W SIDE V IE W Fig. 3A-1~C aster - Cam ber - Toe-In MAINTENANCE AND ADJUSTMENTS as tool boxes. If this excess load is normally carried in the PRELIMINARY CHECKS PRIOR TO...
Page 194 FRONT ALIG NM ENT 3A-3 PIVOT SHAFT OUTBOARD OF FRAME CAMBER FORWARD Fig. 3A-2--Caster - Cam ber A djustm en t repairmen as guidelines in vehicle diagnosis either for and permit shim removal. repairs under the new vehicle warranty or for maintenance G30 Models, C20 and 30 Models with 7/8"...
Page 195 3A-4 FRONT ALIG NM ENT contrcl arm shaft, shown in Figure 3A-2. B” IS LESS THAN " A ” W H EN WHEELS TOE-IN C am ber 1 Determine the camber angle from the alignment equip nent. Add or subtract shims from both the front and rear bolts affect a change.
Page 196 FRONT ALIG NMENT 3A-5 HORIZONTAL FRAME ANGLE HORIZONTAL iy 4 ° DOW N FRAME ANGLE = ’ / a0 DO W N CASTER ANGLE READING CASTER ANGLE READING ACTUAL (CORRECTED) CASTER ANGLE ACTUAL (CORRECTED) CASTER ANGLE = + ( 1 ° ) HORIZONTAL HORIZONTAL FRAME ANGLE...
Page 197 3A-6 FRONT ALIG NM E NT SPECIFICATIONS WHEEL ALIGNMENT SPECIFICATIONS CASTER DIM ENSION "A " 3%" MODELS 21 / 2" 2 %" 3 " 314" 31 / 2" 4 " 414" 4 % " 5 " (mm) 63.5 69.8 76.2 82.5 89.0 95.2...
Page 198: Steering Linkage
STEERING LINKAGE 3B1-1 SECTION 3B1 STEERING LINKAGE The following caution applies to one or more steps in the assembly procedure of components in this portion of the manual as indicated at appropriate locations by the terminology "See Caution on page 1 of this Section".
Page 199 f * r f f f ' i ■ w m r 3B1-2 STEERING LINKAGE CONDITION POSSIBLE CAUSE CORRECTION Excessive Play or Looseness in Front wheel bearings loosely Adjust bearings to obtain proper Steering System. adjusted. end play. Worn steering shaft couplings. Replace part.
Page 200 7 » " * V ' . V ^ STEERING LINKAGE 3B1-3 POSSIBLE CAUSE CORRECTION CONDITION Inflate to specified pressures. Low or uneven tire pressure. Hard Steering - Excessive Effort Required at Steering Wheel. Lube with specified lubricant. Steering linkage or bolt joints need lubrication.
Page 201: Maintenance And Adjustments
3B1-4 STEERING LINKAGE MAINTENANCE AND ADJUSTMENTS LUBRICATION A. Any fluid leakage during this check. LUBRICATION OF STEERING LINKAGE B. Seizing or binding condition during travel of damper. The steering linkage under normal conditions should be lubricated with any water resistant EP type chassis C.
Page 202: Relay Rod
STEERING LINKAGE 3B1-5 j~A~| All clamps must be b e tw e e n & c a u t i o n clea r of dim ples b e fo re torquing nut. Exposed socket thread length must be equal w ithin ± .0 6 at each end o f a d ...
Page 203 3B1-6 STEERING LINKAGE PRODUCTION NUT IM P O R TA N T WHENEVER ANY OF THE CRIMP NUTS OR STUDS AT THE (5) LOCATIONS SHOWN ARE LOOSENED OR REMOVED, THE FOLLOWING STEPS MUST BE TAKEN: A. WHEN RE-ATTACHING ANYTWO COMPONENTS BY MEANS OF A BALL STUD, CAREFULLY POSITION THE TWO PARTS.
Page 204 STEERING LINKAGE 3B1-7 NOTE Slot in adjuster C A U TIO N Clamps must be between sleeve must not be & clear o f dim ples before torqu in g nut. w ith in this area o f clamp jaws. ,TIE ROD - OUTER 'ADJUSTER R E L A Y ROD...
Page 205 3B1-8 STEERING LINKAGE Figure 3B1-9. Center protractor bubble indicator and record reading. d. Rotate tie rod end clockwise (down) to maximum position. Center protractor bubble indicator and record reading. e. Compare protractor readings obtained in Speps c and d. Total rotation of tie rod assembly should measure at least 35°.
Page 206: Steering Connecting Rod
STEERING LINKAGE 3B1-9 shaft. Do not spread pitman arm more Removal than required to slip over pitman shaft 1. Raise vehicle on a hoist. with hand pressure. Do not hammer or 2. Remove the cotter pin and castellated nut from ball damage to steering gear may result.
Page 207 3B1-10 STEERING LINKAGE CAUTION: ENDS OF A D JU STA BLE T I E ROD MUST BE HELD IN CORRECT R ELA TIO N SH IP TO EACH OTHER A FTER ADJUSTMENT W ITHIN + 2 ° . CAUTION: CLAMPS MUST BE BETWEEN AND CLEAR OF DIM PLES BEFORE TORQUING NUT.
Page 208 M A N U A L STEERING GEAR 3B2-1 SECTION 3B2 MANUAL STEERING GEAR The following caution applies to one or more steps in the assembly procedure of components in this portion of the manual as indicated at appropriate locations by the terminology "See Caution on page 1 of this Section".
Page 209 3B2-2 M A N U A L STEERING GEAR CONDITION POSSIBLE CAUSE CORRECTION Rattle or Chuck in Steering Gear, Insufficient or improper lubricant Add lube specified. in steering gear. Pitman arm loose on shaft or Tighten to specified torque. steering gear mounting bolt loose. Loose or worn steering shaft Replace steering shaft bearing.
Page 210: Specifications
M A N U A L STEERING GEAR 3B2-3 POSSIBLE CAUSE CORRECTION CONDITION Front wheel bearings loosely Adjust to obtain proper end play. Excessive Play or Looseness in Steering System. adjusted. Worn upper ball joints. Check and replace ball joints if necessary.
Page 211 3B2-4 M A N U A L STEERING GEAR MAINTENANCE AND ADJUSTMENTS of the pitman arm to the pitman shaft. Remove the pitman LUBRICATION OF MANUAL STEERING GEAR arm with Tool J-6632 or J-5504 as shown in Figure 3B2-4. The manual steering gear is factory-filled with steering 4.
Page 212 M A N U A L STEERING GEAR 3B2-5 with a wedge, to slip the arm onto the pitman shaft. Do not spread the clamp more than required to slip over pitman shaft with hand pressure. Do not hammer the pitman arm onto the pitman shaft. Be sure to install the hardened steel washer before installing the nut.
Page 213 3B2-6 M A N U A L STEERING GEAR T O O L —J -5 5 0 4 Fig. 3B2-7--Steering Gear A tta chm e nt, C-K M odels Fig. 3B2-9--Removing Pitman A rm -Typical the pinch bolt and torque to specifications. the marks made at removal.
Page 214 M A N U A L STEERING GEAR 3B2-7 equivalent). Position the seal in the pitman shaft bore and tap into position using a suitable size socket. 5. Remove the lash adjuster lock nut. Remove the side cover from the pitman shaft assembly by turning the lash adjuster screw clockwise.
Page 215 ;:& HO!ycv\.uoi«;3 -mo : 7 • : ■ : ■ «v . - . ‘T ; .. ■ ;; H i . ; " ; p . J . .. ; (y . - i- :',€ - D iy r ■...
Page 216: Power Steering System
POWER STEERING SYSTEM 3B3-1 SECTION 3B3 POWER STEERING SYSTEM The following caution applies to one or more steps in the assembly procedure of components in this portion of the manual as indicated at appropriate locations by the terminology "See Caution on page 1 of this Section".
Page 217 3B3-2 POWER STEERING SYSTEM System Checks without hitting stops. Maintain fluid level just above Many factors affect power operation of the steering internal pump casting. Fluid with air in it will have a light system, of which the most common are: tan or red appearance.
Page 218 POWER STEERING SYSTEM 3B3-3 CONDITION POSSIBLE CAUSE CORRECTION SYSTEM NOISE There is some noise in all power steering systems. Common complaints are listed as .fjviy/g follows: Pump noise-“chirp”. Loose belt. Adjust belt tension to specification. Belt squeal. Loose belt. Adjust belt tension to specification. Gear noise (“hissing”...
Page 219 3B3-4 POWER STEERING SYSTEM CONDITION POSSIBLE CAUSE CORRECTION Pump growl Scored pump pressure plates, thrust Replace affected parts, flush system. Note: Most noticeable at full plate or rotor. wheel travel and stand still parking Extreme wear of pump cam ring. Replace affected parts.
Page 220 POWER STEERING SYSTEM 3B3-5 CONDITION POSSIBLE CAUSE CORRECTION Poor return of steering. (Cont’d.) Steering gear adjustments over Check adjustment with pitman arm specifications. disconnected. Readjust if necessary. Sticky or plugged valve spool. Remove and clean or replace valve. Rubber spacer binding in shift tube. Make certain spacer is properly seated.
Page 221 3B3-6 POWER STEERING SYSTEM CONDITION POSSIBLE CAUSE CORRECTION Hard Steering or Lack of lubricant in suspension Lubricate, relubricate at proper lack of assist (Continued) or ball joints. intervals. Tires not properly inflated. Inflate to recommended pressure. Steering gear to column misalignment. Align steering column.
Page 222 POWER STEERING SYSTEM 3B3-7 POSSIBLE CAUSE CONDITION CORRECTION Loose belt. Low oil pressure due to steering Adjust tension to specification pump: Low oil level. Fill reservoir to proper level. (See pump pressure test.) Air in the oil. Locate source of leak and correct. Bleed system.
Page 223 3B3-8 POWER STEERING SYSTEM connections). B. Check oil level in pump’s reservoir and adjust as directed in maintenance section. C. Start engine and turn steering wheel from stop to stop several times. Do not hold in corner for any length of time as this can damage the power steering pump.
Page 224 POWER STEERING SYSTEM 3B3-9 3. Replace rotary valve assembly. Pump Leakage D iagram s (Fig. 3B 3-10 ) 4. Seat ball flush with punch and restake. If seepage 10. Tighten hose fitting nut to 40 pounds foot. If persists, replace housing. leakage persists, replace discharge fitting and reface hose 5.
Page 225 3B3-10 POWER STEERING SYSTEM RESERVOIR DEFECTS RESERVOIR CAP DRIVE SHAFT SEAL RETURN HOSE & CLAMPS HOUSING DEFECT RESERVOIR ADJUSTER PLUG " 0 " RING " 0 " RING TORSION BAR RING & " 0 " RING STUD/BOLT " 0 " RINGS PRESSURE HOSE PRESSURE &...
Page 226 POWER STEERING SYSTEM 3 B 3 -1 1 LEAKAGE AREAS Fig. 3 B 3 - 9 - - P o w e r S te e r in g G e a r L e a k a g e LIGHT T R U CK SER V IC E MANUAL...
Page 227 3B3-1 2 POWER STEERING SYSTEM Fig. 3 B 3 - 1 0 - - P o w e r S te e rin g P u m p L e a k a g e LIG H T T R U C K S ER V IC E MANUAL...
Page 228 POWER STEERING SYSTEM 3B3-13 MAINTENANCE AND ADJUSTMENTS 5. Readjust toe-in as outlined in Section 3A Of LUBRICATION OF POWER STEERING PUMP necessary). Check the fluid level in the pump reservoir according . Be sure to properly orient sleeves and clamps, as to the intervals listed in Section OB.
Page 229 3B3-14 POWER STEERING SYSTEM 1 . With engine runnning disconnect pressure hose from pump and install Tool J-5176 using a spare pressure hose between gauge and pump. Gauge must be between shut-off valve and pump (Fig. 3B3-12), Open shut- off valve. POWER STEERING ADAPTER 2.
Page 230: Power Steering Gear
POWER STEERING SYSTEM 3B3-15 REPLACEMENT COMPONENT 2. Place the steering gear in position, guiding the POWER STEERING GEAR ccoupling bolt into the steering shaft flange. Removal 3. Install the steering gear to frame bolts and torque 1 . Disconnect hoses at gear. When hoses are to specifications.
Page 231: Power Steering Pump
3B3-16 POWER STEERING SYSTEM 3. Fill reservoir. Bleed pump by turning pulley POWER STEERING PUMP (3B3-15 THROUGH backward (counter-clockwise as viewed from front) until air 3B3-21) bubbles cease to appear. Removal 4. Install pump belt over pulley. 1 . Disconnect hoses at pump. When hoses are 5.
Page 232 POWER STEERING SYSTEM 3B3-17 Fig. 3B3-1 9 -P o w e r Steering P um p-350 V-8 M otor Home SPECIFICATIONS AND SPECIAL TOOLS Refer to Specifications and Special Tools at NOTICE: end of Section 3B4. orientate pressure hose when installing, rotate pipe ends to rest against pump support lower.
Page 233 3B3-18 POWER STEERING SYSTEM Rotate hose assembly against- hydraboost housing assembly before tightening nut. .64 INCH M IN IM U M C LE A R A N C E Rotate hose assembly, against steering gear housing before tightening nut. 292 L-6 G 30 V IE W W /H Y D R A B O O ST...
Page 234 POWER STEERING SYSTEM 3B3-19 Clip must be installed parallel w ith in ±3° o f brace. Hose must be located against pump assembly. b i N u n n o V IE W Hose assembly must be located against hydra boost m ounting V IEW 350 V-8...
Page 235 3B3-20 POWER STEERING SYSTEM Hose must be located V IE W against pump assembly. V IE W Hose assembly must be 454 V-8 located against hydraboost m ounting bracket. MOTOR HOME Fig. 3B 3-35--P ow er S teering Hose Routing Fig.
Page 236 STEERING COLUMNS 3B4-1 SECTION 3B4 STEERING COLUMNS The following caution applies to one or more steps in the assembly procedure of components in this portion of the manual as indicated at appropriate locations by the terminology "See Caution on page 1 of this Section".
Page 237 3B4-2 STEERING CO LUM NS DIAGNOSIS GENERAL INFORMATION STEERING COLUMN ELECTRICAL ANALYZER J-23980 This section contains diagnostic information to help locate the cause of the problem in the column. Reference For C-Series and K-Series (Fig. 3B 4-2) should be made to the correct method of column Tool J-23980 will help the technician analyze the disassembly, repair, adjustment and reassembly.
Page 238 STEERING COLUMNS 3B4-3 TURN", "RIG H T TURN", "K EY BUZZER", and C O L U M N JA C K E T "H A Z A R D ". (Trucks do not incorporate a Key Buzzer Inspect jacket section of column for looseness, and/or Switch) if the systems function properly while using the bends.
Page 239 3B4-4 STEERING CO LUM NS SURFACE “A’ Instrument Panel Bracket Capsule Damage NOTE: The bolt head must not contact surface “ A ” . If contact is made, the capsule shear load will be increased. If this condition exists replace the bracket. AUTOMATIC TRANSMISSION COLUMNS LOCK SYSTEM-WILL NOT UNLOCK Solution...
Page 240 STEERING COLUMNS 3B4-5 LOCK SYSTEM HIGH EFFORT (CONT'D.) Cause Solution Replace rack. Distorted coupling slot in rack (tilt). Bent or restricted actuator rod. Straighten remove restriction or replace. Straighten or replace. Ignition switch mounting bracket bent HIGH EFFORT LOCK C YLIN D ER BETWEEN "...
Page 241 3B4-6 STEERING COLUMNS IG N IT IO N SYSTEM - ELECTRICAL S Y S T E M - W ILL NOT FU N C TIO N (CONT'D.) Cause Solution D. Replace ignition switch. D. Defective ignition switch. E. Ignition switch not adjusted properly. E.
Page 242 STEERING COLUMNS 3B4-7 HIGH STEERING SH A FT EFFO R T Cause Solution A. Column assembly misaligned in vehicle. A. Realign. B. Improperly installed or deformed dust seal. B. Remove and replace. C. Replace affected bearing or bearings. C. Tight or frozen upper or lower bearing. D.
Page 243 3B4-8 STEERING CO LUM NS M A N U A L TRANSMISSION COLUMNS GENERAL INFORMATION All of the preceding diagnosis information for automatic transmission will apply to the manual transmission. The following information is supplied in addition to and specifically for manual transmission columns. D R IV E R CAN LOCK STEERING IN SECOND GEAR Cause...
Page 244 STEERING COLUMNS 3B4-9 TILT COLUMNS GENERAL INFORMATION All of the preceding diagnosis will generally apply to tilt columns. The following is supplied in addition to and specifically for tilt columns. HOUSING SCRAPING ON BOWL Cause Solution A. Bowl bent or not concentric with hub. A.
Page 245 3B4-10 STEERING CO LUM NS Fig. 3 B 4 -10--Checking Harm onica C onnector on Column lamps light when hazard warning is depressed, but flashing does not occur, replace hazard warning flasher. (On Fig. 3B 4-9~C hecking Fuses on Fuse Block fuse block) (Figure 3B4-11).
Page 246 STEERING COLUMNS 3 B 4 -1 1 2. Check the return from lane change by holding the lever in lane change and releasing (both left and right). If the lever does not return to neutral, disassemble the upper part of the column. 3.
Page 247 3B4-12 STEERING COLUMNS SIGNAL SWITCH DIAGNOSIS CORRECTION CONDITION POSSIBLE CAUSE Loose switch Tighten to specified Turn signal will not cancel mounting screws torque (25 in-lbs) Switch or anchor Replace switch bosses broken Reposition or replace Broken, missing or out of position detent, return springs as required or cancelling spring Uneven or incorrect...
Page 248 STEERING COLUMNS 3B4-13 SIGNAL SWITCH DIAGNOSIS CONDITION POSSIBLE CAUSE CORRECTION Hazard switch will not Loose switch Tighten mounting stay on or difficult mounting screws screws (25 in-lbs) to turn off Interference with Remove interference other components Foreign material Remove foreign material Replace switch None of the above...
Page 249 3B4-14 STEERING COLUM NS SIGNAL SWITCH DIAGNOSIS CONDITION POSSIBLE CAUSE CORRECTION Front or rear turn signal Burned out fuse Replace fuse and check operation lights not flashing Burned out or Replace bulb damaged turn signal bulb Remove or repair High resistance defective connection connection to ground and check operation...
Page 250 STEERING COLUMNS 3B4-15 SIGNAL SWITCH DIAGNOSIS CORRECTION CONDITION POSSIBLE CAUSE I noperative turn Replace turn signal Turn signal lights flash signal flasher flasher very slowly System charging I ncrease voltage to voltage low specified. See Sec. 6Y High resistance ground Repair high resistance at light sockets grounds at light...
Page 251 3B4-1 6 STEERING COLUMNS MAINTENANCE AND ADJUSTMENTS STEERING WHEEL ALIGNMENT SHIFTER TUBE ADJUSTMENT NOTICE: On all series vehicles check steering gear for G and P Series Only high point centering as shown in Sections 3B2 and 3B3 before checking steering wheel alignment. 3-Speed Transmission 1.
Page 252 STEERING COLUMNS 3B4-17 Fig. 3B4-1 9 -S h ift Tube A djustm en t-3 Speed M anual T ransm ission COMPONENT REPLACEMENT IN D E X NOTICE: C-Series and K -Series............3B4-17 Do not ham m er on puller. The tool Steering W h eel..............i 3B4-17 centering adapters need not be used.
Page 253 3B4-18 STEERING COLUMNS BEARING CAPTURING BLOCKS COVER STRAP LOWER SNAP SHAFT RING SEAL SEAL CLAMP CLAMP TENSION SPRING Fig. 3B4-23--Steering Shaft Interm ediate C oupling COUPLING TO STEERING SHAFT FLANGE BOLTS Install the special bolt into the split clamp and torque to specifications.
Page 254 STEERING COLUMNS 3B4-19 INTERMEDIATE STEERING SHAFTS W ITH POT JOINT COUPLINGS Removal (Fig. 3B4-23) 1. Remove the lower shaft flange to flexible coupling bolts. 2. Remove upper shaft to interm ediate coupling bolt 3. If necessary, remove the steering gear to frame bolts and lower the steering gear far enough to remove the interm ediate shaft assembly.
Page 255 3B4-20 STEERING CO LUM NS J -2 3 6 5 3 Fig. 3B4-26--R em oving Lock Plate Retaining Ring Fig. 3B4-28--Rem oving D irectional S ignal S w itch Assem bly 5. Slide the directional signal cancelling cam, upper Installation bearing preload spring and thru st washer off the end of the shaft.
Page 256 STEERING COLUMNS 3B4-21 lowering the steering column (see steering column removal). The switch is actuated by a rod and rack assembly. A portion of the rack is toothed and engages a gear on the end of the lock cylinder, thus enabling the rod and rack to be moved axially (with respect to the colum n) to actuate the switch when the lock cylinder is rotated.
Page 257 3B4-22 STEERING COLUMNS LOCK CYLINDER INSTALLATION DISASSEMBLE ASSEMBLE Place lock in “run’ 1. Rotate as shown, align cylinder key with keyway in housing. 2. Remove lock plate, turn signal switch and buzzer switch (see 2. Push lock all the way in. service manual.) Install screw.
Page 258 STEERING COLUM NS 3B4-23 and seal to the floor pan and remove the covers (Fig. 3B4- 34). Move the front seat as far back as possible to provide m axim um clearance. 10. Remove the two column bracket-to-instrum ent panel nuts and carefull remove from vehicle. A dditional help should be obtained to guide the lower shift levers through the firewall opening.
Page 259 3B4-24 STEERING CO LUM NS 30. BOWL, Gearshift Lever 1. STEERING COLUMN 31. SHROUD, Shift Bowl 2. RETAINER 32. BEARING, Bowl Lower 3. NUT, Hexagon Jam 33. JACKET ASM, Steering Column 4. COVER, Shaft Lock 34. SCREW, Washer Head 5. RING, Retaining 35.
Page 260 STEERING COLUMNS 3B4-25 23. SPRING, Key Release 1. ROD, Switch Actuator 24. LEVER, Key Release 2. RACK, Switch Actuator 25. WASHER, Wave 3. SPRING, Rack Preload 26. SHAFT ASSEMELY, Steering 4. SECTOR, Switch Actuator 27. RING, Retaining 5. HOUSING, Steering Column 30.
Page 261 3B4-26 STEERING CO LUM NS Fig. 3B4-4 1--Installing S teering Colum n in Vise Fig. 3B4-43--Turn Signal Housing Assem bly Manual Transmission - Colum n Shift - Remove the 4. Assemble the locking bolt onto the crossover arm lower bearing adapter, bearing and the first reverse shift on the rack and insert the rack and lock bolt assembly into lever.
Page 262 STEERING COLUMNS 3B4-27 Fig. 3 B 4 -4 7 -ln s ta llin g G earshift Housing Low er Bearing Fig. 3B 4-45~R em oving Lower Bearing Retainer 8. W ith the shift lever housing in place, install the turn into the housing keyway.
Page 263 3B4-28 STEERING CO LUM NS M A S T J A C K E T A. TO REDUCE CLEARANCE A. TO REDUCE CLEARANCE . 2 - 3 S H IF T L E V E R SLIDE THE CLAMPING SLIDE THE CLAMPING .
Page 264 STEERING COLUM NS 3B4-29 SCREW, Support 26. SPRING, Upper Bearing 1. STEERING COLUMN PIN, Dowel 27. PROTECTOR, Wiring 2. BEARING ASM SHAFT ASM, Lower Steering 28. COVER, Lock Housing (Painted) 3. PIN, Release Lever SPHERE, Centering 29. SHIELD, Tilt Lever Opening 4.
Page 265 3B4-30 STEERING COLUM NS 1. BEARING ASM 26. RETAINER 51. PIN, Dowel 2. PIN, Release Lever 27. RING, Retainer 52. SHAFT ASM, Lower Steering 3. SPRING, Release Lever 28. SPRING, Upper Bearing 53. SPHERE, Centering 4. SPRING, Shoe 29. PROTECTOR, Wiring 54.
Page 266 STEERING COLUMNS 3B4-31 J-23072 Fig. 3B 4-50~R em oving T ilt Lever S pring Retainer Fig. 3B4-52~R em oving S hift Tube and jacket could result. 11. Disassemble the steering shaft by removing the centering spheres and the anti-lash spring. 16.
Page 267 3B4-32 STEERING COLUM NS Fig. 3B 4-54~R em oving Sector Drive Shaft relieve the load on the release lever, hold the shoes inward a suitable size socket. Be careful not to damage the housing and wedge a block between the top of the shoes (over slots) or bearing during installation.
Page 268 STEERING COLUMNS 3B4-33 3B4-50). Tighten the screw to 35 in. lbs. 2. Install the shift lever spring into the housing by windng it up with pliers and pushing it into the housing. On floor shift models, install the plunger, slide the gearshift lever housing onto the m ast jacket.
Page 269 3B4-34 STEERING COLUM NS COLUMN INSTALLATION-MANDATORY 6. Install attaching screws (L) and tighten to specified SEQUENCE torque. Mandatory Preliminary Instructions 7. Tighten two nuts (F) at capsules to specified torque 1. Assemble lower dash cover (A) and upper dash cover if not already done.
Page 270 STEERING COLUMNS 3B4-35 BEARING CAPTURING COVER ■BOLT LOWER BLOCKS STRAP SNAP SHAFT RING UPPER SHAF1 SEAL CLAMP CLAMP TENSION SPRING Fig. 3 B 4 -6 1 -S te e rin g Shaft Interm ediate C oupling COUPLING TO STEERING SHAFT FLANGE BOLTS Disassembly 1.
Page 271 3B4-36 STEERING COLUMNS Assembly 1. Be sure all parts are free of dirt. Slide seal onto steering shaft. W ith lip of seal against step in shaft clamp seal. 2. Press pin back into shaft from chamfered side. Locate pin in shaft using scribe m ark as reference. CAUTION: Pin must be centered within .012 in.
Page 272 STEERING COLUMNS 3B4-37 b. Align the arrow on the lower yoke assembly shaft with the arrow on the upper yoke assembly tube and push the two assemblies together. c. Push the dust cap, plastic washer and felt washer into position on the lower end of the upper yoke assembly and bend the tangs of the dust cap down against the yoke tube.
Page 273 3B4-38 STEERING CO LUM NS shift lever. 5. Install the tilt release lever and place the column in the full "up" position. Remove the tilt lever spring and retainer using a screwdriver that just fits into the slot opening. Insert the screwdriver into the slot, push in approximately 3/16", rotate clockwise approxim ately 1/8 turn until the retainer ears align with the grooves in the housing and remove the retainer and spring.
Page 274 STEERING COLUMNS 3B4-39 NOTICE: The coupling bolt must pass through the shaft undercut. 4. Assemble the bearing housing as follows: a. Press the new upper and lower bearing races into the bearing housing. b. Lubricate and install the bearings into the bearing races.
Page 275 3B4-40 STEERING COLUM NS J - 2 2 7 2 7 BEND TABS OUTWARD EACH SIDE Fig. 3 B 4 -69 -R em o vin g W ires from C onnector Fig. 3B4-7 1~Preparing W ire Retaining Tabs fo r Installation Installation A utom atic Transmission Model - Install the...
Page 276 STEERING COLUMNS 3B4-41 STEERING SYSTEM MAN DA T OR Y REQUI REMENTS Using 50 lb. force a p plied to the steering w heel end o f Shaft [ a ] , Lower Clamp Nut [b J must be tightened to the specified torque to give a compressed spring dim ension [ ^ ] o f .50 ±...
Page 277 3B4-42 STEERING CO LUM NS 1 6 k 15 GA & PA 100-200 Upper Steering Shaft 13. Shift Tube Felt Washer Turn Signal Switch Screw 2 . Shift Housing Bushing Shift Tube Assembly Turn Signal Switch Bushing Seat 15. Shift Lever Spacer 2 7.
Page 278 STEERING COLUM NS 3B4-43 shift lever housing (or housing extension) assemblies. reverse shift lever and lower adjusting ring. Place a block of wood on top of the adjusting ring and tap until the shift 11. Press the steering shaft upper bearing out of the tube bottoms.
Page 279 C O V E R SHAFT A SSY W E D G E ------ RACE IN S T R U . PA NEL RACE SHAFT O P E N IN G C O V E R - , SC R EW (3 ) S P R IN G JACKET S W IT C H A S S Y .- .
Page 280 STEERING COLUMNS 3B4-45 Fig. 3B4-76--S ecuring Colum n w ith J -2 2 5 7 3 Fig. 3B4-7 8--Removing Bearing Housing Pivot Pin the shaft proceed as follows: Pilot the sleeve over the threaded end of the tool and into the upper end of the shift tube.
Page 281 3B4-46 STEERING CO LUM NS 1 / 1 6 ” 4 5 ° C H A M F E R R E M O V E D O T T E D P O R T IO N Fig. 3B4-80--Rem oving Release Lever Pivot Pin Fig.
Page 282 STEERING COLUMNS 3B4-47 f. Lubricate the shoes and release lever. 12. Install the bearing housing assembly to the support. Hold the tilt release lever in the "up" position until the shoes have fully engaged the support. Lubricate and install the bearing housing pivot pins.
Page 283 3B4-48 STEERING COLUM NS STEERING SYSTEM MA N D A T OR Y REQUI REMENTS U s in g a 5 0 lb . fo rc e a p p l ie d to th e s te e r in g w h e e l e n d o f S h a f t | A | , L o w e r C la m p N u t | B | m u s t b e t ig h t e n e d to th e s p e c ifie d to r q u e to g iv e a c o m p re s s e d...
Page 284 STEERING COLUMNS 3B4-49 STEERING SYSTEM M A N D A T O R Y REQUIREMENTS U s in g a 5 0 lb . fo r c e a p p l ie d to th e s te e r in g w h e e l e n d o f S h a ft [ X | f L o w e r C la m p N u t |~B~| m u s t b e t ig h t e n e d to th e s p e c ifie d to r q u e...
Page 285: Specifications
3B4-50 STEERING CO LUM NS SPECIFICATIONS STEERING GEAR RATIOS MANUAL STEERING GEAR Power Manual Components G10 - 30 P20 - 30 C1p i 03° K10 - 20 Vehicle Thrust Bearing 6 to 11 4 to 6 9 to 12 Gear Overall Gear Overall...
Page 286: Special Tools
STEERING COLUMNS 3B4-51 SPECIAL TOOLS " 6222 Shaft Seal Protector 1. J-6632 Pitman Arm Puller 19. J 20. J -23600 Belt Tension Gauge J-5504 Pitman Arm Puller -8947 Rack-Piston Seal Compressor 21. J J-23073 S hift Tube Installer 22. J -5755 Wormshaft Bearing Race Installer S hift Tube Remover...
Page 287 3B4-52 STEERING COLUMNS 1. J-6632 Pitman A rm Puller 19. J-6278 Pitman Shaft Bearing Remover 2. J-5504 Pitman A rm Puller J-6278-2 Pitman Shaft Bearing Installer 3. J-5176 Pressure Gauge J-7079-2 Drive Handle 4. J-5822 W orm shaft Bearing Cup Puller J-8524-1 A djuster Plug Bearing Installer J-5860...
Page 288 FRONT SUSPENSION 3C-1 SEC TIO N 3C FRONT S U S P E N S IO N The following caution applies to one or more steps in the assembly procedure of com ponents in this portion of the m anual as indicated at appropriate locations by the terminology "See Caution on page 1 of this section".
Page 289 3C-2 FRONT SUSPENSION LIG H T T R U C K SER V IC E MANUAL...
Page 290 FRONT SUSPENSION 3C-3 MAINTENANCE AND ADJUSTMENTS CAUTION: See CAUTION on page 1 of 10. Replace the wheel cover or hub cap. this section regarding fasteners referred to in the maintenance and adjustment procedures below. 11. Lower vehicle to floor. WHEEL BEARINGS-CHECK ADJUSTMENT 12.
Page 291 3C-4 FRONT SUSPENSION DIAGNOSIS HARD STEERING Probable Cause Probable Remedy Ball joints and steering linkage need lubrication Lubricate ball joints and linkage Low or uneven front tire pressure Inflate tires to the proper recommended pressure Power steering partially or not operative Check power steering components for proper operation Steering gear not properly adjusted Adjust steering gear...
Page 292 FRONT SUSPENSION 3C-5 NOISE IN FRONT END Probable Cause Probable Remedy Ball joints and steering linkage need lubrica ion Lubricate at recommended intervals Shock absorber loose or bushings worn Tighten bolts and/or replace bushings Replace bushings Worn control arm bushings Worn tie rod ends Replace tie rod ends Worn or loose wheel bearings...
Page 293 3C-6 FRONT SUSPENSION “DOG' TRACKING Probable Cause Probable Remedy LEAF TYPE R E A R SPRING Rear leaf spring broken Replace spring Bent rear axle housing Replace housing Frame or underbody out o f alignment Align frame CO IL TYPE R E A R SPRING Damaged rear suspension arm and/or worn bushings Replace suspension arm and/or bushings Frame out o f alignment...
Page 294 FRONT SUSPENSION 3C-7 BALL JOINT DIAGNOSTIC PROCEDURE Fig. 3 C - 7 ~ B a l l J o in t D ia g n o s tic P ro c e d u r e LIGH T T R U CK S ER V IC E MANUAL...
Page 295 3C-8 FRONT SUSPENSION Inspecting Shock Mountings SH O C K ABSORBER D IA G N O S IS If noisy a n d /o r loose shock m ountings are suspected, ON VEHICLE CHECKS place vehicle on hoist that supports wheels and check all (Follow the Procedures O utlined Below in the O rder m ountings for the following conditions;...
Page 296 FRONT SUSPENSION 3C-9 Bench check procedures are discussed for three general types of shocks. SPIRAL GROOVE RESERVOIR If this type of shock has been stored or allowed to lay in a horizontal position for any length of time, an air void If shock has an internal noise condition, extend will develop in the pressure cham ber of the shock absorber.
Page 297 3C-10 FRONT SUSPENSION PLIACELL OR GENETRON the cause of distress and com m ents are provided to help Pliacell and G enetron are some o f the trade names used make effective repairs. to indicate a gas-filled cell in the shock reservoir. The reservoirs of Pliacell and G enetron shocks are smooth, Consider Th e Following Factors W h en com pared to the spiral groove type.
Page 298 FRONT SUSPENSION 3 C -1 1 BEARINGS AND RACES FRONT WHEEL, PINION, DIFFERENTIAL SIDE AND REAR WHEEL ROLLER BEARINGS DIAGNOSIS EXCESS IMOISE C O M P L A IN T D IA G N O S T IC PRO CED URE Check tires for irregular wear Check tire pressure Road Test...
Page 299 3C-12 FRONT SUSPENSION FRONT WHEEL BEARING DIAG NO SIS C O N S ID E R T H E F O L L O W IN G F A C T O R S W H EN D IA G N O S IN G B E A R IN G C O N D IT IO N : G E N E R A L C O N D IT IO N OF A L L P A R T S D U R IN G D IS A S S E M B L Y A N D INS PE CTIO N.
Page 300: Front Suspension
FRONT SUSPENSION 3C-13 FRONT WHEEL BEARING D IA G N O SIS (CONT’D) m i ii i v C R A C K E D I N N E R R A C E F A T I G U E S P A L L I N G B R I N E L L I N G RACE CRACKED DUE TO IMPROPER FIT,...
Page 301 3C-14 FRONT SUSPENSION COMPONENT PARTS REPLACEMENT WHEEL HUBS, BEARINGS (Fig. 3C-14) forming a dam to provide extra grease availability to the bearing and to keep thinned grease from flowing out of the Removal C, G and P Series bearing. 1. Raise vehicle on hoist and remove wheel and tire 5.
Page 302 FRONT SUSPENSION 3C-15 Fig. 3C-1 7-R em oving Coil Spring w ith Tool J-2 3 0 2 8 Fig. 3C -15~Shock A bsorber A ttachm ents Slit in bar to frame bushings should be facing forward. Installation 1. Place stabilizer in position on frame and install frame Place shock absorber into position over m ounting bolts brackets over bushings.
Page 303 3C-16 FRONT SUSPENSION Bushing Replacement (Steel Bushings) 1. Remove grease fittings from bushing outer ends and unscrew bushings from control arm and shaft. Slide new seal on each end of shaft and insert shaft into control arm. 3. Start new bushings on shaft and into control arm. A djust shaft until it is centered in control arm, then turn bushings in and torque to specifications.
Page 304 -- ------------ - - ------ — ’— !• t " F-I ■ — I ■ ......■ ■ " ..■ ....V I " I H " ' Jt «!f FRONT SUSPENSION 3C-17 Fig. 3 C -1 9 -P o sitio n in g U.C.A. S haft (Steel Bushings) bushings in and torque to specifications.
Page 305 3C-18 FRONT SUSPENSION J—24435-7 J—24435-3 J—24435-1 Fig. 3C-22--U.C.A. Rubber Bushing Removal Fig. 3C -2 4 -L o w e rin g C ontrol Arm fo r Bushing Replacem ent Bushing In s ta lla tio n nuts. Before tightening nuts, insert caster and cam ber shims in the same order as when removed.
Page 306 FRONT SUSPENSION 3C-19 7. Lower jack SLOWLY to release spring compression (Fig. 3C-24) and gain clearance to remove bushings. CAUTION: Be sure all compression is released from coil springs. . Remove the stakes on the front bushing using tool J-22717 or equivalent tool. 9.
Page 307 3C-20 FRONT SUSPENSION Fig. 3C -28--C otter Pin Installatio n Upper-Removal 1. Raise vehicle on hoist. If a frame hoist is used, it will be necessary to support the lower control arm with a floor jack. 2. Remove cotter pin from upper ball stud and loosen stud nut (two turns) but do not remove nut.
Page 308 FRONT SUSPENSION 3C-21 Fig. 3 C -29 -C he cking Low er Ball J o in t Installation (Fig. 3C-31) 2. Accurately measure distance between tip of ball stud and tip of grease fitting below ball joint. CAUTION: See CAUTION on page 1 of 3.
Page 309 3C-22 FRONT SUSPENSION STEERING KNUCKLE It is recommended that vehicle be raised and supported as on a twin-post hoist so that the front coil spring remains compressed, yet the wheel and steering knuckle assembly remain accessible. If a frame hoist is used, support lower control arm with an adjustable jackstand to safely retain spring in its curb height position.
Page 310 FRONT SUSPENSION 3C-23 16. Lower hoist to lower front suspension unit from vehicle. Installation Raise hoist to align new suspension unit with frame rail holes. CAUTION: See CAUTION, on page 1 of this section regarding fasteners referred to in steps 2-14. 2.
Page 311 3C-24 FRONT SUSPENSION GENERAL DESCRIPTION steering knuckle attachment are used. Figures 3C-1K and Front drive axles used on K10, K20, and K30 trucks 3C-2K show the K10 and K20 knuckle attached with ball have several styles of wheel-end construction. joints. Figure 3C-3K shows the king-pin attachment used At the wheel ends of the axle tubes, two types of HUB CAP A X L E O U TE R S H A F T...
Page 312 FRONT SUSPENSION 3C-25 R E T A IN IN G P LA T E B O LT A X L E S H A F T SNAP RING D EFLE C TO R A D JU S T IN G N U T A C T U A T IN G CAM B O D Y A X L E O U T E R S H A F T PRESSURE P LATE...
Page 313 3C-26 FRONT SUSPENSION H U B C A P S PIN D LE B E A R IN G LOWER B E A R IN G SNAP R ING S E A L S E A L HUB D R IV E G EAR D EFLE C TO R B E A R IN G CAP A D JU S T IN G N U T ASM...
Page 314 FRONT SUSPENSION 3C-27 NOTE: SC A L E R E A D IN G , SH O U L D NOT E X C E E D 2 b L B S FOR EIT H ER K N U C K LE , IN E IT H E R D IR E C T IO N Fig.
Page 315 3C-28 FRONT SUSPENSION COMPONENT REPLACEMENT . Back off the inner adjusting nut again 3/8 turn HUB REPLACEMENT maximum. Assemble the adjusting nut lock by aligning the nearest hole in lock with the adjusting nut pin. Install outer CAUTION: See CAUTION on page 1 of lock nut and torque to 80 ft.
Page 316 FRONT SUSPENSION 3C-29 R E T A IN IN G P L A T E B O LT S O U T E R C LU TCH R E T A IN IN G RING W A S H E R A C T U A T IN G C A M B O D Y HUB RIN G R E T A IN IN G KN O B A X L E S H A F T SN A P RIN G...
Page 317 3C-30 FRONT SUSPENSION FREE P O S IT IO N L O C K P O S IT IO N Fig. 3C-7K~Removing S pindle and T hrust W asher SPINDLE Removal 1. Remove the hub-and-disc assembly as outlined Fig. 3C-6K--Hub Key Position - T ypical earlier.
Page 318 FRONT SUSPENSION 3C-31 SEAL SPINDLE .1 0 0 IN . DEPTH V -B L O C K SEAL Fig. 3C-8K--Front S pindle Grease Seals hammer to break the studs loose from the knuckle arm. KNUCKLE Remove nuts and disconnect the tie rod. If it is K10, K20, (WITH BALL JOINTS) necessary to remove the steering arm, discard the self...
Page 319 3C-32 FRONT SUSPENSION CHAMFER T O W A R D SEAL Fig. 3C -9K --lnstalling S pind le and T hrust W asher Fig. 3C-1 1K~Removing Ball S ocket Retaining Nut inserting a suitable wedge-shaped tool between the lower If Tool J-6382-3 is not available, a suitable tool may ball stud and the yoke and tapping on the tool to release be fabricated from 2-1/2"...
Page 320 FRONT SUSPENSION 3C-33 ==sJSALL JO INT KNUCKLE 1. Position the knuckle and sockets to the yoke. Install new nuts finger tight to the upper (the nut with the cotter K30 (WITH KING PINS) pin slot) and lower ball socket studs. Removal (Fig.
Page 321 3C-34 FRONT SUSPENSION Fig. 3 C -19K--Removing S pindle . Remove upper king-pin from yoke with large breaker the surface of yoke flange when fully installed. bar and J-26871, as seen in Figure 3C-24K. 3. Install upper king-pin, using J-28871 as shown in Torque specification is 500-600 ft.
Page 322 FRONT SUSPENSION 3C-35 Fig. 3C-23K--Rem oving Tapered Bushing Fig. 3 C -2 1 K~Removing Cap, S pring and Gasket Slit in bar to frame bushings should be facing forward. Installation 1. Place stabilizer in position on frame and install frame Place shock absorber into position over mounting bolts brackets over bushings.
Page 323 3C-36 FRONT SUSPENSION Fig. 3C -25K -R em oving Cup, Cone and Seal Bushing R eplacem ent fasteners referred to in steps 5 and 6. 1 . Place spring on press and press out bushing using a suitable rod, pipe, or tool. 2.
Page 324 FRONT SUSPENSION 3C-37 Fig. 3C-3 1 K -ln s ta llin g Bearing C a p/S teering Arm Fig. 3C -29K --lnstalling K nuckle to Yoke Fig. 3C -32K~Shock A bsorber A tta chm e nt Fig. 3 C -3 0 K -ln s ta llin g Lower Bearing Cap-and-King Pin Fig.
Page 325 ---.■ M lH frvi"’! ........ —---- - 3C-38 FRONT SUSPENSION TIG H TE N IN G SEQUENCE Install all four nuts to uniform engagement on 'U ' Bolts to retain and position anchor plate in design position (perpendicular to axis of 'U ' Bolts). Torque nuts in positions 1 and 3 to 10-25 ft.
Page 326 ~v— r " * r 'v j yfy ; ___________________________ FRONT SUSPENSION 3C-39 SPECIFICATIONS FRONT SUSPENSION BOLT TORQUE (ft. lbs.) * K-AII G-10-20 G-30 CP-10 CP-20-30 — Lower C ontrol Arm Shaft U-Bolt Upper C ontrol Arm Shaft Nuts — —...
Page 327 3C-40 FRONT SUSPENSION SPECIAL TOOLS J-8457 Bearing Race Installer J-8092 Driver Handle J-8458 Bearing Race Installer J-9519-9 Ball Joint Installer J-8849 Bearing Race Installer J-9519-7 Ball Joint Remover J-9276-2 Bearing Race Installer J-9519-10 Clamp " C " J-24435-1 Bushing Replacement J-23028-01 Spring Remover thru 7...
Page 328 REAR SUSPENSION 3D-1 SECTION 3D REAR S U S P E N S IO N The following caution applies to one or more steps in the assembly procedure of components in this portion of the manual as indicated at the appropriate locations by the terminology "See Caution on page 1 of this Section".
Page 329 3D-2 REAR SUSPENSION Fig. 3D -3~Typical P-30 H.D. T ruck Rear Suspension COMPONENT PARTS REPLACEMENT and washers as shown. SHOCK ABSORBERS . Align lower end of shock absorber with axle bracket, Replacement and install bolt, washers and nut, as shown. Refer to Figs.
Page 330 REAR SUSPENSION 3D-3 Fig. 3D -8~Shock Absorber-P 30 5. Remove stabilizer shafts. . Reverse above steps to install stabilizer shaft. On installation, position shaft so parking brake cable is routed STABILIZER SHAFTS over stabilizer. Refer to Fig. 3D-9, 3D-10 and 3D-11 for specific rear 7.
Page 331 3D-4 REAR SUSPENSION P300(32) NOTE Torque by running nut to unthreaded p o rtio n o f bolt. LEAF SPRING ASSEMBLY Refer to Figs. 3D-12 - 3D-19 for specific leaf spring mounting provisions of C, K, G and P models. Fig. 3D-21 illustrates a typical U-bolt anchor plate installation with the mandatory tightening sequence.
Page 332 REAR SUSPENSION 3D-5 specifications. Leaf Spring Installation . Lower vehicle and remove from hoist. 1. Clean axle spring pad and position spring assembly to axle. Position spring to insure clearance to hangers. The U-Bolt and Anchor Plate Installation shackle assembly must be attached to the rear spring eye Fig.
Page 333 3D-6 REAR SUSPENSION Fig. 3D-15--Rear Spring Installation-C-K M odels 7. Rest vehicle weight on suspension components and 4. Remove shackle-to-frame bracket retaining bolt then torque both shackle bolt retaining nuts to specifications. remove shackle bolt from spring eye. CAUTION: See CAUTION on page 1 of 5.
Page 334 REAR SUSPENSION 3D-7 Fig. 3 D - 1 9 ~ R e a r S p r in g ln s t a l l a t i o n - P 3 0 LIGHT TRU CK SER V IC E MANUAL...
Page 335 3D-8 REAR SUSPENSION 1. In s ta ll a l l fo u r nuts to u n ifo rm e n g a g e m e n t on 'U ' Bolts to r e ta in a n d p o s itio n a n c h o r p la t e in d e s ig n po sitio n ( p e r p e n d ic u la r to a x is o f 'U ' B olts).
Page 336 REAR SUSPENSION 3D-9 SPECIFICATIONS TORQUE SPECIFICATION P 10 1 40 S p r in g -to -A x le " U " B olt N uts 1 4 0 G 1 0 1 2 0 P 20 1 40 G 2 0 1 2 0 P 30 1 7 0 (Exc.
Page 337 ■ r . • ' i.; r . - v w ' : J i . ■ ■ : '•: bo :.J - f* ' i- jC - ■ • ..s th S O U ' ■ ' : > i ’,V ' ■...
Page 338 WHEELS AND TIRES 3E-1 SECTION 3E W H E E L S A N D T IR E S INDEX Tire Replacement............3E-1 three spots around the tire, the tire should be replaced. Wheel Replacement............3E-1 2. Tire thread or sidewall is cracked, but, or snagged Service Operations............3E-2 deep enough to expose the cord or fabric.
Page 339 3E-2 WHEELS AND TIRES SERVICE OPERATIONS Too low an air pressure can result in tire overloading, CAUTION: Servicing of tires mounted on abnormal tire wear, adverse vehicle handling, and reduced multi-piece rims requires proper tools, fuel economy. The tire flexes more and can build up safety equipment specialized...
Page 340 WHEELS AND TIRES 3E-3 Misalignment Wear This is wear due to excessive toe-in or toe-out. In either case, tires will revolve with a side motion and scrape the tread rubber off. If misalignment is severe, the rubber will be scraped off of both tires; if slight, only one will be affected.
Page 341 3E-4 WHEELS AND TIRES WHEEL USAGE AND TIRE LOAD LIMITS AT VARIOUS INFLATION PRESSURES* T IR E S FOR LIG H T TR U C K S USED IN H IG H W A Y SER V IC E T IR E S U S E D A S S IN G L E S ( P S I ) W h e e l C o d e T ire L o a d Lim its at V a rio u s In fla tio n P re s s u re s...
Page 342 WHEELS AND TIRES 3E-5 W HEEL USAGE AND TIRE LOAD LIM ITS AT VARIOUS INFLATION PRESSURES"1 TIRES FOR LIGHT TRUCKS USED IN HIGHWAY SERVICE (Cont’d.) WIDE BASE TUBELESS TIRES USED AS SINGLES Wheel Code Tire ( P S I ) Load Tire Load Limits at Various Inflation Pressures Regular...
Page 343 3E-6 WHEELS AND TIRES WHEEL USAGE AND TIRE LOAD LIMITS AT VARIOUS INFLATION PRESSURES* TIRES FOR LIGHT TRUCKS USED IN HIGHWAY SERVICE TIRES USED AS DUALS (PSI) Tire Load Limits at Various Inflation Pressures Wheel Code Tire Load Regular Rally Size Range TUBE TYPE TIRES MOUNTED ON 5°...
Page 344 WHEELS AND TIRES 3E-7 WHEEL USAGE AND TIRE LOAD LIMITS AT VARIOUS INFLATION PRESSURES* TIRES FOR LIGHT TRUCKS USED IN HIGHWAY SERVICE (Cont’d.) W ID E B A S E T U B E L E S S T IR E S U S E D A S D U A L S (P S I) W h e e l C o d e T ire...
Page 345 3E-8 WHEELS A N D TIRES WHEEL USAGE AND TIRE LOAD LIM ITS AT VARIOUS IN FLATIO N PRESSURES* P A S S E N G E R TY P E T IR E S FOR LIG H T T R U C K S USED IN H IG H W A Y S E R V IC E Wheel Code Tire Load...
Page 346 WHEELS AND TIRES 3E-9 WHEEL USAGE AND TIRE LOAD LIMITS AT VARIOUS INFLATION PRESSURES* TIRES FOR LIGHT TRUCKS USED IN HIGHWAY SERVICE WIDE BASE TUBELESS TIRES USED AS SINGLES Wheel Code Tire Load Tire Load Limits at Various Inflation Pressures (PSI) Regular Rally Size...
Page 347 • • s m /w c t iV - iw r - 5 'M:: 'j£-i | /. V^' H fe r ' P'1 ’ ..i • ■ ■ ;; ; .._ il.'- M - * - ,p; : ':jv “...
Page 348 PROPELLER SHAFT 4A-1 SECTION 4A PROPELLER SH A F T The following caution applies to one or more steps in the assembly procedure of components in this portion of the manual as indicated at appropriate locations by the terminology "See Caution on page 1 of this Section".
Page 349 4A-2 PROPELLER SHAFT in the yoke by either (depending on the manufacturer) snap rings or plastic injection. These joints usually are lubricated for life and cannot be lubricated while on the vehicle. C o n stan t V elo city J o in t-D o u b le Cardan Joint As mentioned previously, the simple universal joint will operate efficiently through small angles only.
Page 350 PROPELLER SHAFT 4A-3 PROPELLER SHAFT AND UNIVERSAL JOINT DIAGNOSIS C hecking and C orrecting 4. With vehicle running in gear at the indicated speed where disturbance is at its peak, observe the intensity of the Propeller S h a ft U nbalance disturbance.
Page 351 4A-4 PROPELLER SHAFT COMPLAINT POSSIBLE CAUSE CORRECTION Roughness, Vibration or a. Bent or dented drive shaft. a. Replace. Body Boom at any speed. b. Undercoating on drive shaft. b. Clean drive shaft. c. Tire unbalance. (30-80 mph, not c. Balance or replace as required. NOTE: With tachometer throttle conscious) installed in car, determine...
Page 352 PROPELLER SHAFT 4A-5 UNIT REPAIR PROPELLER SHAFT Snap Ring Type The rear universal joint to propshaft bolt on some CK Disassembly 1 ton dual wheel models requires a # 10 "Six Lobed Socket" 1. Remove bearing lock rings from trunnion yoke. (J-25085), for proper removal and installation.
Page 353 4A-6 PROPELLER SHAFT Fig. 4A -8~Bearing Cup Removal w ith Vise bearing cup being removed, as shown in figure 4A-12. Reassembly Fig. 4A-10 Complete the removal of the bearing cup, by pressing 1. Position trunnion into yoke. Paritally install one it out of the yoke.
Page 354 PROPELLER SHAFT 4A-7 SPACER J-9522-5 BEARING Fig. 4 A -1 4— I nsta 1 1 i ng T runnion in to Yoke Fig. 4A-12--Using Spacer to Remove Bearing Cup trunnions in the bearings. If there seems to be a hang-up, Reassembly stop pressing and recheck needle rollers, to determine if one A universal joint service kit is used when reassembling...
Page 355 4A-8 PROPELLER SHAFT 1. For models with one piece propeller shafts, slide shaft into transmission and attach rear U-joint to axle. On vehicles with two piece propshafts, the front propshaft yoke must be bottomed out in the transmission fully forward before installation to the hanger . 2.
Page 356 PROPELLER SHAFT 4A-9 Fig. 4A-1 7--Propeller Shaft, U niversal J o in t and Bearing Support installed. Install remaining cap and snap ring. trunnion in center yoke. Install rear yoke half bearing caps on rear trunnion. Install one rear trunnion bearing cap in 5.
Page 357 4A-10 PROPELLER SHAFT assembled as follows to prevent excessive drive line excitation: 1. Transmission yoke must first be placed in vertical position. 2. Front yoke of Rear Prop shaft is set horizontal as shown. Fig. 4A -19--A lignm ent fo r Phasing centering ball is pressed onto a stud and is part of the ball 1.
Page 358 PROPELLER SHAFT 4 A -1 1 FLANGE YOKE LUBE FITTING BALL SUPPORT COUPLING YOKE TUBE YOKE ALIGNMENT PUNCH MARKS Fig. 4A -24-R easse m bling Coupling Yoke Fig. 4A -22--Lubrication F itting Dana Style . Using grease provided in the ball seat kit, lubricate wear or are broken, replace the entire set with a service kit.
Page 359 4A-12 PROPELLER SHAFT Fig. 4A-26~Exploded V ie w of Centering Ball M echanism Fig. 4A -2 8--ln stalling Outer C ylind er of Tool J -2 3 9 9 6 Over Ball All Constant Velocity Joints (C/V) Reinstall the grease cap. The constant velocity (C/V) joint, located at the transfer case end of the front propshaft, must be lubricated If the slip spline is dry or corroded, it may be necessary...
Page 360 PROPELLER SHAFT 4A-13 Fig. 4A-32~Reassem bling Flange Yoke Fig. 4 A -3 0--ln stalling C entering Ball Fig. 4A-3 1 -ln s ta llin g C entering Ball Seal LIGHT T R U CK S ER V IC E MANUAL...
Page 361 4 A -14 PROPELLER SHAFT SPECIFICATIONS PROPELLER SHAFT Propeller Shaft To Rear Axle (Strap) 12-17 12-17 12-17 Bearing Support-to-H anger 20-30 20-30 20-30 Hanger-to-Fram e 40-50 — — To Transfer Case Dana Style 20-30 G M Style 70-80 Torque Specifications (Ft.-Lbs.) L IG H T T R U C K SER V IC E M ANUAL...
Page 362: Rear Axle
4B-7 Differential and Rear Axle Bearing Diagnosis......4B-11 On Vehicle Service................. 4B-13 8-1/2" and 8-7/8" Ring Gear............. 4B-13 Chevrolet 10-1/2" Ring G ear............. 4B-17 Dana 10-1/2" Ring Gear............4B-20 Dana 9-3/4"Ring Gear............... 4B-20 Chevrolet 12-1/4" Ring G ear............. 4B-20 Specifications.................
Page 363 " and b) assembly and the differential carrier. 8-7/8" Ring Gear, c) Chevrolet 10-1/2" Ring Gear, d) Dana 10-1/2" Ring Gear, e) Dana 9-3/4" Ring Gear and Dana 1 0 -1 /2 " Ring Gear A xle f)Chevrolet 12-1/4"...
Page 364 REAR AXLE 4B-3 19. Thrust W asher 1. C om panion Flange 13. C o v e r D iffe r e n tia l Case 2 0 . D iffe r e n tia l Pinion D e fle c to r P inion Shaft .
Page 365 1. C om panion Flange 10. Straddle Bearing 19. Retainer Screw 2. Oil D e flecto r 11. Ring Gear 20. Bearing Cap 3. Oil Seal 12. D iffe re n tia l Spider 21. Case-to-Ring Gear B olt 4. Bearing Retainer 13.
Page 366 REAR AXLE 4B-5 Differential Spider Pinion Rear Bearing Pinion Nut Differential Side Gear Drive Pinion Washer Washer Ring Gear Companion Flange Pinion Gear Differential Case Oil Seal Washer Ring Gear Bolt Oil Slinger Gasket Differential Side Bearing Pinion Front Bearing Cover Side Bearing Cup Front Bearing Cup...
Page 367 4B-6 REAR AXLE 1. Nut 11. Shims (Inner Pinion 17. Cover and Plug 24. Bolt (Differential 2. Washer Bearing) 18. Lock Pin (Pinion Bearing Cap) 3. Companion Flange 12. Cup (Inner Pinion Shaft) 25. Bolt (Ring Gear) 4. Pinion Oil Seal Bearing) 19.
Page 368: Differential Diagnosis
Differential Case-Left Drive Pinion Half Rear Pinion Bearing Fig. 4B-8--Chevrolet 1 2 -1 /4 " Ring Gear Axle-1 1 ,0 0 0 # C apacity DIFFERENTIAL DIAGNOSIS STANDARD DIFFERENTIAL Degree of Noise Any gear driven unit, and especially an automotive...
Page 369 4B-8 REAR AXLE rear axle. Rear axle noise usually ceases when coasting at speeds under 30 miles per hour; however, tire noise continues but with lower tone as vehicle speed is reduced. Rear axle noise usually changes when comparing "pull" and "coast"...
Page 370 REAR AXLE 4B-9 also fluctuate in the above wheel bearing test. Bearing Diagnosis Charts appear later in NOTICE: this section. Gear Noise There are two basic types of gear noise. The first type is produced by broken, bent, or forcibly damaged gear teeth and is usually quite audible over the entire speed range and presents no particular problem in diagnosis.
Page 371 4 B -1 0 REAR AXLE A GENERAL DIAGNOSTIC PROCEDURE FOR ISOLATING REAR AXLE NOISE PROBLEMS Problem Cause Noise is the same in drive or coast 1. a) Road noise Tire noise Front wheel bearing noise 2. a) Road noise Noise changes on a different type of road Tire noise Noiae tone lowers as car speed is lowered...
Page 372: Differential And Rear Axle Bearing Diagnosis
REAR A X L E 4 B - 1 1 DIFFERENTIAL A N D REAR AXLE BEARING DIAGNOSIS C O N SID ER TH E FO LLO W IN G FACTORS W HEN D IA G N O S IN G B E A R IN G C O N D IT IO N : 1.
Page 373 4 B -1 2 REAR A X L E DIFFERENTIAL A N D REAR AXLE BEARING DIAGNOSIS (C O N T ’D) C R A C K E D IN N E R RACE FATIG UE SPALLI BR INELLING R AC E C R A C K E D D U E TO IM PR O PER F IT , F L A K IN G OF S U R F A C E M E T A L R E S U L T IN G FR O M S U R F A C E IN D E N T A T IO N S IN R A C E W A Y C AU S E D BY C O C K IN G , OR POOR B E A R IN G S EATS.
Page 374: On Vehicle Service
REAR AXLE 4B-13 ON-VEHICLE SERVICE AXLE SHAFT 8 -1/2 " and 8-7/8" RING GEAR AXLE Removal AXLE ASSEMBLY 1. Raise vehicle on hoist. Remove wheel and tire Construction of the axle assembly is such that service assembly and brake drums. operations may be performed with the housing installed in 2.
Page 375 4 B -1 4 REAR AXLE Fig. 4 B -1 5--Removing Lock Screw Fig. 4B-1 7 -C o rre c t C-Lock Position shown in figure 4B-17. Carefully withdraw the axle shaft until the C-lock is clear of the thrust block. When both locks are installed, install the pinion shaft and lock screw.
Page 376 REAR A X L E 4B -15 Fig. 4 B -19— 0 iI Seal and W heel Bearing Fig. 4B-2 1-W he el Bearing Installatio n 2. Install axle shaft "C" lock on button end of axle shaft 5. Install a lug nut with flat side first (tapered face and push shaft outward so that shaft lock seats in outboard).
Page 377 4 B -1 6 REAR AXLE Fig. 4B-23--Pressing O ut W heel Stud Fig. 4B-25--Scribe M arks . Install Tool J-8614-11 on pinion flange and remove Installation pinion flange self-locking washer faced nut as shown in figure 4B-26. (Position J-8614-11 on flange so that the four 1.
Page 378: Chevrolet 1 0-1/2 Ring Gear
REAR A X L E 4B -17 Fig. 4 B -2 9 -ln s ta llin g Pinion Flange CHEVROLET 1 0-1/2 RING GEAR Do not attempt to hammer the flange onto NOTICE: pinion shaft. To do so may damage the ring gear and AXLES pinion.
Page 379 4 B -1 8 REAR A XLE Fig. 4B-30--Rem oving Flange-to-Hub Bolts system and adjust parking brake. Before reinstalling wheel hub and drum assembly replace hub oil seal. 5. Reassemble the rear universal joint, making sure that 1. Axle Shaft 8.
Page 380 REAR AX LE 4B-19 Fig. 4B-33--Rem oving O uter B earing and Cup Fig. 4B -34~W heel B olt Replacement Inspection and Cleaning o f Bearings Drum-Non-Demountable-Type-Fig. 4B-31 1. Inspect bearing rollers for excessive wear, chipped Replacement edges, and other damage. Slowly move rollers around cone Construction of the nondemountable-type hub and to detect any flat or rough spots on rollers or cone.
Page 381: Dana 10-1/2" Ring Gear
DANA 9-3/4" RING GEAR AXLE Procedures for service to axle assembly, axle shafts, hub and drum components and bearing adjustments are identical to those listed for "Chevrolet 10-1/2 Ring Gear Axle". Drive pinion oil seal replacement requires different special tools for the Dana axles. Follow the same procedure Fig.
Page 382 4. Remove the outer bearing by driving on the axle shaft spacer, using the splined flange cut from an old axle shaft, as shown in figure 4B-38. Inspection and Cleaning o f Bearings Refer to procedures listed for "Chevrolet 10-1/2" Ring Gear Axle. Bearing Cup-lnstallation 1. To install...
Page 383 4. Install tanged retainer against the inner adjusting Refer to figure 4B-34 and to procedure listed under nut. Align inner adjusting nut so short tang of retainer will "Chevrolet 10-1/2" Ring Gear Axle. engage nearest slot on inner adjusting nut. INSTALLATION OF HUB AND DRUM 5.
Page 384 REAR AX L E 4B -23 Fig. 4B-4 1--Pinion Oil S e a l-1 2 -1 /4 " Axle IrtWT T R U C K S ER V IC E MANUAL...
Page 385: Specifications
4 B -2 4 REAR AXLE SPECIFICATIONS DIFFERENTIAL S P E C IF IC A T IO N S > >■ ; £ > > > £ r->- O rf' S '- — — BOLT T O R Q U E S (FT.-LBS.)A G e a r Backlash .005"- .005"- .004"- .005"- .005"-...
Page 386 REAR AXLE 4B -25 R IN G G E A R S O U R C E M O D E L T Y P E /C A P A C IT Y S IZ E C 1 0 S a lis b u r y / 3 7 5 0 # 8 - 7 / 8 ”...
Page 387 4B -2 6 REAR A XLE SPECIAL TOOLS ■ "w 3tr " v l r 8 7 /s" R .G . A X L E O N L Y WRPI 1. J-2 15 4 8 T ru n n io n Seal In sta lle r 16.
Page 388 Conventional truck service brakes are provided on all 4-wheel drive units. K 10-20 Models use a Chevrolet or the Dana (44 Series) front axle, both incorporate a 8-1/2" ring gear. A 4500 lb.
Page 389 4C -2 F R O N T W H E E L D R IV E BEARINGS AND RACES FRONT WHEEL, PINION, DIFFERENTIAL SIDE AND REAR WHEEL ROLLER BEARINGS DIAGNOSIS EXCESS NOISE COMPLAINT DIAGNOSTIC PROCEDURE Check tires for irregular wear Check tire pressure Road Test Check lubricant level...
Page 390 FR O N T W H E E L D R IVE 4C -3 Fig. 4C-2--Front Drive Axle T ypical trunnion using a brass drift. If the disc or other brake components require repairs or replacement, refer to Section 5. 5.
Page 391 4C -4 F R O N T W H E E L D RIVE Bolt Torques Bolt Torques Axle Axle (Ft.-Lbs.) (Ft.-Lbs.) G e a r and Backlash Preferred .005-. 008 Carrier Cover Min. and M ax. .0 03 -.01 0 Ring G ear New Pinion Bearing Preload 15-30 in.-lbs.
Page 392 BRAKES SECTION 5 B R A K E S The following caution notes apply to one or more steps in the assembly procedure of components in this portion of the manual as indicated at appropriate locations by the terminology "See Caution on page of this section".
Page 393: Diagnosis
BRAKES and it is necessary to bleed or repair the brakes. DISC BRAKES FRONT All models have disc brakes on the front. The one piece MASTER CYLINDER caliper mounts on the steering knuckle/steering arm, which The system is designed with a separate hydraulic is also a one piece casting, and astride the brake disc.
Page 394 BRAKES HYDRO— BOOST SEAL LEAKAGE A. INPUT SEAL LEAK — Fluid leakage from housing cover end of booster near reaction bore. Replace seal(s). B. PISTON SEAL LEAK — Fluid leakage from vent at front of unit near master cylinder. Replace seal. C.
Page 395 BRAKES wear and the pump should be checked; Refer to Section 3B. one hour there should be at least two power assisted applications with the engine off. 2. At or near power runout, (brake pedal near fully depressed position) a high speed fluid noise (faucet type) 2.
Page 396 BRAKES HYDRO — BOOST DIAGNOSIS CONDITION CAUSE CORRECTION Excessive Brake Pedal Loose or broken power steering pump belt. Tighten or replace the belt. Effort No fluid in power steering reservoir. Fill reservoir and check for external leaks. Leaks in Hydro -Boost Replace faulty parts.
Page 397 BRAKES C O N D IT IO N CORRECTION POSSIBLE CAUSE Pulls 1. Inflate evenly on both sides to 1. Incorrect tire pressures. the recommended pressures. 2. Front end out of line. 2. Check and alig n to manufacturer's specifications. 3.
Page 398 BRAKES CORRECTION POSSIBLE CAUSE C O N D IT IO N Brake roughness or chatter 5. Shoe reversed (steel 5. Replace shoe and lining and machine rotor within (Pedal Pulsates) — Continued against iron). specifications. 1. Check power brake and re p a ir 1.
Page 399 BRAKES C O N D IT IO N POSSIBLE CAUSE CORRECTION Dragging Brakes 3. Incorrect parking brake 3. Check and readjust to (A very light d rag is adjustment on rear brakes. correct specifications. present in all disc 4. Check valve installed in 4.
Page 400 BRAKES V f c ' / s X ^ / \ v / < f v , X V ' & X *£ > \ 0 * \ Leaking Brake Line or Connection Leaking Wheel Cylinder or Piston Seal Leaking Master Cylinder Air In Brake System Contaminated or Improper Brake Fluid Leaking Vacuum System...
Page 401: On-Vehicle Service
5-1 0 BRAKES ON-VEHICLE SERVICE tube to hang submerged in brake fluid in a clean glass jar PEDAL TRAVEL (fig. 5-1). At reasonably frequent intervals, the brakes should be 3. Open the bleeder valve and fully depress the brake inspected for pedal travel, which is the distance the pedal pedal.
Page 402: Hydro-Boost Bleeding Procedure
BRAKES 5-11 out. Install metering valve actuator J-23709. few minutes with engine off and repeat above procedure. . Bleed the brakes in the following sequence: right a. Check belt tightness and check for a bent pulley. (Pulley should not wobble with engine running.) rear, left rear, right front and left front.
Page 403 5-1 2 BRAKES Fig. 5 -2 -F ro n t Brake Pipes and Hoses-C-K M odels L IG H T TRU CK SER V IC E M ANUAL...
Page 406 B RAKES 5-15 G MODELS CK MODELS CK10-20 (EXCEPT C20-43) C20 (43) CK30 v i e VIEW VIEW C20 (03 & 06) K20 CK10 P MODELS VIEW Fig. 5-5~Typical Rear Hose Fittings LIGHT T R U C K SER V IC E MANUAL...
Page 407: Parking Brake Pedal Or Handle
5-1 6 BRAKES bend bracket or pipe. Check to see that hose installation did Front Brake Hose not loosen frame bracket, re-torque bracket if necessary. Removal (figs. 5-2 thru 5-4) . Bleed system. 1. Raise vehicle on hoist. 7. Lower vehicle from hoist. 2.
Page 408 BRAKES 5-17 Fig. 5 -6 -P o w e r Steering Hose Routing-C -K M odels LIGHT T R U CK SER V IC E MANUAL...
Page 409 5 -1 8 BRAKES Fig. 5-7--Power S teering Hose R outing-G M odels LIG H T T R U CK SER V IC E M ANUAL...
Page 411 5-2 0 BRAKES IvtewfA] C-K MODELS P 0 0 0 ( 4 2 ) MODELS lVIEW G MODELS P 3 0 0 (3 2 ) MODELS Fig. 5-9--Parking Brake A sse m b ly-T yp ica l felt when the rear wheels are rotated forward. PARKING BRAKE (PROPELLER SHAFT)- INTERNAL EXPANDING CAUTION: See "Caution"...
Page 412 BRAKES 5-21 Fig. 5-10--Parking Brake S ystem -T ypica l LIG H T T R U C K S ER V IC E MANUAL...
Page 413 5-22 BRAKES V IE W A P 3 0 0 (4 2 ) & M 2 0 & JF9 P 3 0 0 (4 2 ) & M 4 0 & JF9 Fig. 5-1 1-P a rkin g Brake System (Propshaft) LIG H T T R U C K SER V IC E MANUAL...
Page 414: Parking Brake Cable
BRAKES 5-23 enough to overcome spring tension. Adjust clevis of pull rod COMBINATION VALVE or front cable to line up with hole in relay levers. Testing Electrical Circuit of Combination Valve a. Insert clevis pin and cotter pin, then tighten clevis 1.
Page 415: Brake Pedal Rod
5 -2 4 BRAKES Fig. 5-13--Brake Pedal and Stop Lamp A d ju stm e n t P30(32) Model Inspection Clean all parts and inspect for wear, cracks or any other damage that might impair operation; replace if required. Installation Reverse the above procedure and make certain the brake pedal is secure and adjusted properly before operating the vehicle.
Page 416: Master Cylinder
BRAKES 5-25 BAIL COVER STOP S C R E W RESERVOIR PRIMARY D I A P H RAG M PISTON ASSY. LOCK RING TUBE SEAT INSERTS SPRING Fig. 5 -1 5 -D e lc o Secondary Piston - Exploded V iew SPRING RETAINER PRIMARY SEAL S E C O N D A R Y PISTON...
Page 417 5-2 6 BRAKES blowing air through the outlet port. 9. Install a new reservoir diaphragm in reservoir cover where needed, and install cover on master cylinder. Beaded 5. Place master cylinder in vise, so that outlet holes are side faces master cylinder casting to insure positive sealing. up.
Page 418: Delco Disc Brake Shoe And Lining
BRAKES 5-27 C O V E R D I A P H R A G M F I L T E R R E S E R V O I R C O M P E N S A T I N G V A L V E S E A L V A L V E...
Page 419 5-2 8 BRAKES Caliper Removal CAUTION: See "Caution" on Page 5-1 of a noise when the linings wear to a degree where replacement this section. is required, (fig. 5-19). The spring clip is an integral part of the inboard shoe and lining. When the lining is worn, the Remove two thirds of the total fluid capacity from clip contacts the rotor and produces a warning noise.
Page 420 BRAKES 5-29 may be done by breaking the front line connection at the master cylinder and bleeding down the fluid level. Do not remove the brake line or completely empty the reservoir or it will be necessary to bleed the hydraulic system. Discard - do not attempt to reuse —...
Page 421 5-3 0 BRAKES B O O T If the vehicle has a brake problem and diagnosis on both ends of the shoe until the shoe is in a flat position, points to the rotor, it should be inspected and checked for resting on the piston.
Page 422 BRAKES 5-31 one jaw in notch on bottom of shoe opposite upper ear (fig. caliper ears and through the mounting bracket, making sure 5-30). that the ends of the bolts pass under the retaining ears on the inboard shoe (fig. 5-29). Push bolts on through to engage 10.
Page 423: Bendix Disc Brake Shoe And Lining
5-3 2 BRAKES Whenever the front wheel disc brakes are relined, the rear drum brakes should be checked also. BENDIX DISC BRAKE SHOE AND LINING may be necessary to tap the shoe to loosen it in the caliper housing. The brake linings should be inspected any time the wheels are removed.
Page 424: Caliper Overhaul
BRAKES 5-3 3 steering knuckle (or support) sliding surface. Make sure that the brake hose is not twisted NOTICE: or kinked since damage to the brake hose could result. . Place the spring over the caliper support key, install to become unseated. the assembly between the steering knuckle (or rear support) and lower caliper groove.
Page 425 5-3 4 BRAKES Fig. 5-37--Rem oving Piston Disassembly 1. Before beginning disassembly, thoroughly clean the exterior of the caliper using brake cleaner. Place the caliper on a clean work surface. 2. Remove the brake hose from the caliper, discarding Fig. 5-38--Seating Boot the copper gasket.
Page 426 BRAKES 5-35 Disassembly (Fig. 5-39) 1. Clean the exterior of the caliper using clean brake fluid and place on a clean work surface. 2. Drain the brake fluid from the caliper. CAUTION: Do not place the fingers in front of the piston in an attempt to catch or protect it when applying compressed air.
Page 427: Rotor Servicing
5-3 6 BRAKES Do not use emery cloth or any other form of abrasive. Thoroughly clean the caliper after the use of crocus cloth. If the bore cannot be cleaned up in this manner, replace the caliper. (fig. 5-41). Be sure boot is fully seated in the groove before Assembly proceeding.
Page 428 BRAKES 5-37 indicator as the rotor moves. Reinstall assembly and adjust wheel bearings. Lateral runout should not be over .004" total DRUM BRAKE SHOE AND LINING indicator reading. Service Brake Parallelism Check 1 . Parallelism is the measurement of the thickness of Adjustment the rotor at four or more points around the circumference 1 .
Page 429 5-38 BRAKES WHEEL CYLINDER SCRr “ ,p WHEEL CYLINDER LINK- SECONDARY SHOE & UNIN~ SHOE GUIDE PARKING BRAKE STRUT STRUT SPRING ADJUSTER LEVER ACTUATING LINK HOLD DOWN PINS PARKING BRAKE LEVER HEEL CYLINDER PRIMARY SHOE AND LINING ..OLD DOWN SPRING SPRING L-ADJUSTING SCREW SPRING &...
Page 430: Propeller Shaft Brake
BRAKES 5-39 brake linings for uneven wear, oil soaking, loose rivets or imbedded foreign particles. If linings are oil soaked, replacement is required. 7. If linings are otherwise serviceable, tighten or replace loose rivets and thoroughly clean all steel or other imbedded particles from surfaces and rivet counterbores of linings.
Page 431: Brake Drums
5-40 BRAKES R ET U R N S P R IN G S W A V E W A S H E R F L A N G E B R A K E L O C K L E V E R W A S H E R S H O E A N C H O R...
Page 432: Wheel Cylinder
BRAKES 5-41 grooved, the drum should be polished with fine emery cloth W H E E L C Y L IN D E R but should not be turned. At this stage, eliminating the R e m o v a l grooves in drum would necessitate removal of too much 1.
Page 433 5-42 BRAKES C-K MODELS Fig. 5 -4 8 -P o w e r Brake Vacuum Hose Filter Installation-C-K-P Trucks LIG H T T R U C K SER V IC E M ANUAL...
Page 434 BRAKES 5-43 Fig. 5 -4 9 -P o w e r Brake V acuum Hose Filter In s ta lla tio n -G M odels 3. Disconnect the power brake push rod from the brake P neum atic A ccu m u lato r pedal.
Page 435 5-44 BRAKES screwdriver, (fig. 5-51). accumulator easily compressed approximately 1/8", it is still charged. This indicates an internal problem with the accumulator valves and the booster must be disassembled. Slowly back off the clamp until tension on the accumulator is released; remove accumulator and "O" ring. Installation Using clean...
Page 436: Hydro-Boost U Nit
BRAKES 5-45 Spool V alve Plug Removal 1 . Turn engine off and pump brake pedal 4 or 5 times to deplete accumulator. 2. Remove two nuts from master cylinder, then move Bleed system. Refer "HYDRO-BOOST master cylinder away from booster with brake lines BLEEDIN G PROCEDURE".
Page 437 5-46 BRAKES G MODELS P MODELS (EXCEPT MOTOR HOME) MOTOR HOME CHASSIS MODELS Fig. 5 -5 6 -B o o s te r Installatio n (Hydro-Boost) cloth. support brackets, and remove the booster from the vehicle by sliding the booster off the rear support studs. It should not be necessary to disconnect the hydraulic lines from the master cylinder.
Page 438: Specifications
BRAKES 5-47 SPECIFICATIONS BRAKE SYSTEM DESCRIPTION SYSTEM FRONT BRAKES REAR BRAKES BRAKE ASSIST GASOLINE ENGINE VEHICLES Disc 11.86 x 1.28 Drum 11.00 x 2.00 None (Manual Brakes) Disc 11.86 x 1.28 Drum 11.00 x 2.00 Vacuum — Single Diaphragm Disc 11.86 x 1.28 Drum 11.15 x 2.75 Vacuum —...
Page 439 5-48 BRAKES BRAKE SYSTEM APPLICATION (continued) MERCHANDIZING BRAKE SYSTEM M O D E L GVW RATING OPTION TON RATING WHEELBASE GASOLINE ENGINE VEHICLES 6200 Base C10516 106.5 117.5 4900 Base C l 0703 5300-5600 5300-5600 J55* JB5* 6050-6200 C10903 4900 Base 131.5 5300-5600...
Page 440 BRAKES 5-49 BRAKE SYSTEM APPLICATION (continued) MERCHANDIZING BRAKE MODEL TON RATING WHEELBASE GVW RATING OPTION SYSTEM K10516 106.5 6200 Base K 10703 117.5 6200 Base K 10903 131.5 6200 Base K 10906 129.5 6200-7300 Base K20903 131.5 6800 Base 6800 J55* JB7* 7500-8400...
Page 441 5-50 BRAKES BRAKE SYSTEM APPLICATION (continued) M E R C H A N D IZ IN G B R A K E M O D E L TO N R A T IN G W H E E L B A S E GVW R A T IN G O P T IO N S Y S T E M...
Page 442 BRAKES 5-51 BRAKE SY S TE M APPLICATION (continued) M ERCHANDIZING BRAKE TON RATING WHEELBASE GVW RATING OPTION SYSTEM MODEL P10542 6200 Base 6800 Base P20842 JB7* 6800 J55* 7500-8000 6800 Base P21042 6800 J55* JB7* 7500-8000 7600-8200 Base P30842 7600-8200 J55* JB8*...
Page 443 5-52 BRAKES SPECIFICATIONS **25 ft. lbs. **25 ft. lbs. 25 ft. lbs. 25 ft. lbs. Master Cylinder - to Dash or Booster **25 ft. lbs. **25 ft. lbs. 25 ft. lbs. 25 ft. lbs. Booster to Dash or Frame 150 in. lbs. 150 in.
Page 444: Special Tools
BRAKES 5-53 SPECIAL TOOLS 1. J-25310 Tubing Bender 7. J-21472 or J-22364 Bleeder Wrench 2. J-23530 Flaring Tool 8. J-22904 Dust Boot Installer 3. J-23533 Tubing Cutter J-28735 Dust Boot Installer (JB7) 9. J-23518 Bleeder Adapter 4. J-25085 Socket 5. J-8049 or J-22348 Spring Remover 10.
Page 446: Engine Identification
ENGI NE M E C H A N I C A L 6A-1 SECTION 6A EN G IN E M E C H A N IC A L It should be kept in mind, while working on the engine, The following information is important in NOTICE: preventing engine damage and in providing reliable that the...
Page 447 6A- 2 ENGINE M E C H A N I C A L E N G IN E E N G IN E I.D . C O D E D IS TR IB U TO R VIEW B O P T IO N A L VIEW A O P T IO N A L VIEW A...
Page 448 ENGI NE M E C H A N I C A L 6A-3 Fig. 6 A -3 -V IN Locations (MK IV V-8) DIAGNOSIS ENGINE FAILS TO ST A R T h. Excessive moisture on plugs, caps or ignition system. a.
Page 449 6 A- 4 ENGI NE M E C H A N I C A L ENGINE MIS S E S W H IL E IDLING a. Check, inspect and regap spark plugs. Replace as Repair as necessary. necessary. j. Check distributor spark advance mechanism for b.
Page 450 ENGINE M E C H A N I C A L 6A-5 necessary. n. Check fuel system for leaks and/or obstructions. Repair as necessary. k. Check engine operating temperature. Correct as necessary. 1 . Check for loose, corroded or leaking wiring o.
Page 451 6A- 6 ENGINE M E C H A N I C A L f. Check fuel pump operation and replace if necessary. necessary. g. Check EFE system operation and repair or replace as necessary. 1 . Check engine operating temperature and correct as necessary.
Page 452 ENGI NE M E C H A N I C A L 6A-7 correct as necessary. correct as necessary. j. Check for excessively worn or scored cylinder walls and correct as necessary. k. Inspect oil too thin and replace if necessary. 1 .
Page 453 6A- 8 ENGINE M E C H A N I C A L NOIS Y PI STONS A N D RINGS a. Check for excessive piston to bore clearance. Correct necessary. as necessary. b. Inspect for improper fit of piston pin. Correct as necessary.
Page 454 ENGI NE M E C H A N I C A L 6A-9 N O IS Y VA LVE LIFTERS replace if necessary. a. Check for broken valve springs and replace as necessary. h. Check valve lifter oil feed holes plugged causing b.
Page 455 6 A - 1 0 ENGINE M E C H A N I C A L Condition Possible Cause Correction Engine Will Not Crank Loose or Corroded Check connections at battery, engine Battery Cables block and starter solenoid. Discharged Batteries Check generator output as described in Section Starter Inoperative...
Page 456 ENGINE M E C H A N I C A L 6 A - 1 1 Correction Possible Cause Condition Make certain that pum p timing mark is Pump Timing Incorrect Engine Cranks Normally - aligned with mark on adapter. Will Not Start (C ont’d) Disconnect wires from one glow plug on Glow Plug Control...
Page 457 6 A - 1 2 ENGINE M E C H A N I C A L Condition Possible Cause Correction Engine Starts But Will Not Restricted Fuel Return Disconnect fuel return line at injection Continue To Run At Idle System pump.
Page 458 ENGI NE M E C H A N I C A L 6 A - 13 Condition Possible Cause Correction Disconnect fuel return system from nozzles Engine Starts,Idles Rough, Internal Fuel on one bank at a time. With the engine Leak at Nozzle(s) W ithout Abnormal Noise or running, observe the normal fuel seepage...
Page 459 6 A - 1 4 ENGI NE M E C H A N I C A L Condition Possible Cause Correction Significant Loss o f Power Plugged Fuel Tank Vent Remove fuel cap. If “ hissing” noise is heard, (Cont’d) vent is plugged and should be cleaned.
Page 460 ENGINE M E C H A N I C A L 6 A- 1 5 Condition Possible Cause Correction Engine Overheats Coolant System Leak Check for leaks and correct as required. Oil Cooler System Leak Replace. Belt Failure Thermostat M alfunction See Engine Diagnosis and repair Head Gasket Failure procedures.
Page 461 6 A - 1 6 ENGINE M E C H A N I C A L LIGHT T R U CK S ER V IC E MANUAL...
Page 462 IN-LINE 6 6A1-1 Section 6A1 Contents 4.1 (D) L-6 - RPO LE3 (T) L-6 - RPO L25 Torsional Damper..........6A1-17 General Description..........6A1-1 Engine Lubrication..........6A1-2 Crankcase Front Cover........6A1-18 3n Vehicle Service..........6A1-9 Oil Seal (Front Cover)........6A1-18 Engine Mounts............ .6A1-9 Camshaft.............
Page 463: Engine Lubrication
6A1-2 IN-LINE 6 VALVE TRAIN plunger spring keeps the plunger in contact with the push A very simple ball pivot-type train is used. Motion is rod. The ball check valve will then move off its seat and the transmitted from the camshaft through the hydraulic lifters lifter reservoir will be refilled with oil.
Page 464 IN-LINE 6 6A1-3 OIL PRESSURE S EN D IN G U N IT Fig. 6 A 1-1— 1 n-Line Engine Lubrication LIGHT TR U CK SER V IC E M ANUAL...
Page 465 6A1-4 IN-LINE 6 2 5 0 CU. IN . ENGINE 4 i LEFT & RIGHT M O U N T & FRAME BRACKET 2 9 2 CU. IN . ENGINE LEFT M O U N T & FRAME BRACKEET ENGINE BRACKET ALL P SERIES W ITH L-6 ENGINE Fig.
Page 466 IN-LINE 6 6A1-5 LIGHT TRU CK SER V ICE MANUAL...
Page 467 Fig. 6 A 1 -5~ "C " Series - Engine Front Mount LIGHT TRU CK SERV ICE MANUAL...
Page 468 E N G IN E M O U N T F R A M E B R A C K E T _____ ~ ~ J ALL K SERIES W IT H L -6 E N G IN E E N G IN E M O U N T & B R A C K E T ALL K SERIES W IT H L -6 E N G IN E ..........................
Page 469 6A1-8 IN-LINE 6 LIGH T TRU CK SERVICE MANUAL...
Page 470: Vehicle Service
IN-LINE 6 6A1-9 ^ FWD REAR M O U N T FR O N T M O U N T Fig. 6A1-8--"G " Series - Engine M ounts ON VEHICLE SERVICE between a metal plate of the mount and its attaching points, ENGINE MOUNTS lower the engine on the mounts and tighten the screws or Engine mounts (Fig.
Page 471: Manifold Assembly-Non-Integrated Head
6 A 1 -10 IN-LINE 6 must be replaced. Front Mount Replacement 3. Assemble intake and exhaust manifolds using a new 1. Remove engine mount through bolt. gasket by reinstalling the one bolt and two nuts at the center 2. Raise engine and remove mount to frame bracket of the manifold to finger tight.
Page 472: Rocker Arm Cover
IN-LINE 6 6 A 1 -1 1 PUSH ROD SIDE COVER Removal (Front Cover) 1. Disconnect battery negative cable. 2. Remove three forward plug wires from spark plugs and remove distributor cap. 3. Mark position of rotor and remove distributor. 4.
Page 473: Valve Mechanism
6A 1-12 IN-LINE 6 2. Install dipstick tube bracket. 3. Connect three rear plug wires to appropriate spark plugs. 4. Connect battery negative cable. VALVE MECHANISM Removal 1. Remove rocker arm cover as outlined. 2. Remove rocker arm nuts, rocker arm balls, rocker arms and push rods.
Page 474: Valve Lifters
IN-LINE 6 6A1-1 3 valve can in place. Compress the spring with Tool J-5892 and install new oil seal in the lower groove of the stem, making sure the seal is flat and not twisted. A light coat of oil on the seal will help NOTICE: prevent twisting.
Page 475: Cylinder Head
6A 1 -1 4 IN-LINE 6 plunger assembly will be aligned (fig. 6A1-15). CAUTION: Do not attempt to force or pump the plunger. 5. Insert a 1/16" (1.6mm) drift pin through both oil holes to hold the plunger down against the lifter spring tension (fig.
Page 476 IN-LINE 6 6A1-15 L O C K S ' “ CAP — S E A L— SHIELD- SPRING * N OT USED O N 250 CU. IN. L6 Fig. 6 A 1 -1 7 -V a lv e Spring Installatio n indicator stem must contact the side of the valve stem just above the valve guide.
Page 477: Rocker Arm Studs
6 A 1-16 IN-LINE 6 OVERSIZE REAMER Fig. 6A1-1 8-R em oving Rocker Arm Stud - T ypical Fig. 6A1-19--Ream ing Rocker Arm Stud Bore - Typical 1 . Place the gasket in position over the dowel pins. 2. Carefully guide cylinder head into place over dowel pins and gasket.
Page 478: Valves
IN-LINE 6 6A1-17 it is essential that valve guide bores be free from carbon or dirt to ensure proper centering of pilot in the guide. Reconditioning 1. Install expanding pilot in the valve guide bore and expand pilot. 2. Place roughing stone or forming stone over pilot and just clean up the valve seat.
Page 479: Crankcase
6A 1 -1 8 IN-LINE 6 FR O M N E W SEAL Fig. 6A1-22--OH Pan Front Seal M o d ifica tio n CRANKCASE FRONT COVER (TIMING GEAR COVER) Removal (without removing oil pan) 1. Remove torsional damper as outlined. 2.
Page 480: Camshaft Bearings
IN-LINE 6 6A1-19 8520) on push rod (fig. 6A1-23). 3. Rotate the cranksahft slowly in the direction of rotation until the lifter is on the heel of the cam lobe. At this point, the push rod will be in its lowest position. 4.
Page 481: Oil Pan
6 A 1-20 IN-LINE 6 nut. After bearing has been pulled into bore, remove the remover and installer tool from puller screw and check alignment of oil hole in camshaft bearing. 5. Install remaining bearings in the same manner. It will be necessary to index pilot in the camshaft rear bearing to install the rear intermediate bearing.
Page 482: Oil Pump
IN-LINE 6 6A1-21 bracket. b. Remove transmission to bell housing upper bolt. c. Remove transmission rear mount bolts and install two 7/16" x 3" bolts. d. Raise transmission using jack and install 2" (51mm) block between mount and crossmember. 7. Remove starter and lay aside. .
Page 483: Connecting Rod Bearings
6A1-22 IN-LINE 6 damage to screen, pipe or relief grommet. 7. Check the pressure regulator valve for fit. NOTICE: The pump gears and body are not serviced separately. If the pump gears or body are damaged or worn, replacement of the entire oil pump assembly is necessary.
Page 484: Crankshaft Main Bearings
IN-LINE 6 6A1-23 Fig 6A 1-29~M easuring C onnecting Rod Side Clearance bearing (parallel to the crankshaft), on the crankpin or bearing surface (fig. 6A1-27). Plastic gage should be positioned in the NOTICE: middle of upper or lower bearing shell. (Bearings are eccentric and false readings could occur if placed elsewhere).
Page 485 6A1-24 IN-LINE 6 crankshaft all bearing cap bolts must be at their specified torque. In addition, preparatory to checking fit of bearings, the surface of the crankshaft journal and bearing must be wiped clean of oil. 1 . With the oil pan and oil pump removed, and starting with the rear main bearing, remove bearing cap and wipe oil from journal, both bearing shells and bearing cap.
Page 486: Oil Seal (Rear Main)
rrwvrr IN-LINE 6 6A1-25 b. Use a pair of pliers (with taped jaws) to hold the bearing thrust surface to the oil slinger and rotate the crankshaft to remove bearing (fig. 6A1-33). c. Oil new selected size upper bearing and insert plain (unnotched) end between crankshaft and indented or notched side of block.
Page 487 6 A 1-26 IN-LINE 6 Fig. 6A 1-35--Removing Oil Seal Low er H a lf- T y p ic a l rear main bearing cap. Roll seal around crankshaft using tool as a "shoe 2. Remove oil seal from the bearing cap by prying from horn"...
Page 488: Piston And Connecting Rod Assemblies
IN-LINE 6 6A1-27 PRESS PISTON PIN REMOVER J -2 4 0 8 6 -8 FIXTURE & SUPPORT ASSEMBLY J -2 4 0 8 6 -2 0 Fig. 6A 1-39~Removing C onnecting Rod & Piston Assem bly PISTON AND CONNECTING ROD ASSEMBLIES Removal Fig.
Page 489 6 A 1 - 2 8 IN-LINE 6 Remove piston and connecting rod assembly from tool and check piston for freedom of movement on piston pin. Piston Rings All compression rings are marked on the upper side of the ring. When installing compression rings, make sure the marked side is toward the top of the piston.
Page 490 IN-LINE 6 6 A 1 -2 9 Fig. 6A 1-44--P istons-lnstalled Position Installation Cylinder bores must be clean before piston NOTICE: installation. This may be accomplished with a hot water and detergent wash or with a light honing as necessary. After cleaning, the bores should be swabbed several times with light engine oil and a clean dry cloth.
Page 491 6 A 1 - 3 0 IN-LINE 6 4. Install each connecting rod and piston in its the high limit standard size piston. A cylinder bore of less then .005" wear or taper may not entirely clean up when respective bore. Pistons must have notches facing front of engine (fig.
Page 492: Flywheel
IN-LINE 6 6A 1-31 a clean cloth and then wiped with a clean dry cloth. Installation Cylinder should not be cleaned with kerosene or gasoline. A ll Except 4 .8 (T) Engines Clean the remainder of the cylinder block to remove the 1 .
Page 493 6 A 1 -3 2 IN-LINE 6 13. Raise vehicle. 18. If equipped, mount A /C compressor. 14. Remove fuel line hose from suction side of fuel 19. Fill crankcase with oil. pump. 20. Fill cooling system. 15. Drain crankcase. 21.
Page 494 IN-LINE 6 6 A 1 -3 3 specifications. 11. Install radiator. APPLY SEA LAN T 12. Connect heater hoses to engine. TO S H A D E D 13. Connect radiator hoses to radiator. A R EA S O N L Y 14.
Page 495 6 A 1 - 3 4 IN-LINE 6 Fig. 6A1-47~G ear Replacement LIG H T T R U C K SER V IC E MANUAL...
Page 496 PISTON PIN GENERAL DATA: .9270-.9273 D IA M E T E R IN LINE L-6 TYPE .00015-.00025 PRO DUCTIO N 4.8 (T) 4.1 (D) CLEARANCE D IS P LA C E M E N T LITRE (*) .001 MAX. SE RVIC E .0008-.0016 INTERFERENCE F IT IN ROD CRANKSHAFT...
Page 497 TORQUE SPECIFICATIONS Camshaft Thrust Plate........80 lb. in. Crankshaft Front Cover........80 lb. in. VALVE SYSTEM Flywheel Housing Cover ........ 80 lb. in. HYDRAULIC Oil Pan (To Crankcase) (1/4-20) .....80 lb. in. L IF T E R Oil Pan (To Front Cover) ........ 50 lb. in. 1.75:1 R O C K E R A R M R A T IO Oil Pump Cover..........
Page 498 S M A L L BLOCK 6A4-1 SECTION 6A4 5.0 (U) V-8 - RPO LG9 5.7 (L) V-8 - RPO LS9 6.6 (R) V-8 - RPO LF4 Contents General Description..........6A4-1 Torsional Damper..........6A4-19 Engine Lubrication..........6A4-2 Crankcase Front Cover........6A4-20 On Vehicle Service..........

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Chevrolet LIGHT DUTY TRUCK (SERIES 10-35) Service Manual

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