Page 2 Chevrolet Light Duty Trucks. Procedures involv ing disassembly and assembly of m ajor components for these vehi cles are contained in the 1977 Chevrolet Passenger Car and Light Duty Truck Overhaul Manual. W iring diagrams for 1977 trucks are contained in a separate W iring Diagram Booklet.
Page 3 IMPORTANT SAFETY NOTICE P r o p e r s e r v ic e and re p a ir is im p o rta n t to the safe, re lia b le o p e ra tio n a ll m otor v e h ic le s .
Page 4 SECTION NAME GENERAL INFORMATION LUBRICATION 1977 HEATER MANUAL LIGHT DUTY AIR CONDITIONING FRAME TRUCK BUMPERS SHEET METAL (SERIES 10-35) BODY FRONT ALIGNMENT CHASSIS SERVICE STEERING MANUAL FRONT SUSPENSION REAR SUSPENSION WHEELS AND TIRES PROPSHAFT DRIVE AXLE CA U TIO N FOUR WHEEL DRIVE This vehicle contains some parts dimensioned in the metric system as well as in the customary system.
Page 5: General Information
SECTION OA GENERAL INFORMATION C O N T E N TS OF TH IS SEC TIO N Truck Model Identification..........OA-1 Service Parts Identification P la te ........ 0A-3 Vehicle Identification N u m b e r and Rating Plate... OA-1 Keys and Locks..............
Page 6 TRUCK MODEL IDENTIFICATION 0703 + E63 + LG9 1. C = C h e vro le t; T = GM C Truck 2. C h assis Type_________________________ 3. G V W R a n g e _________________________ 4. CA Dimension/Model Type_ 5.
Page 7 M FD. BY GENERAL M OTORS CORPORATION GVWRI □ S E R V I C E P A R T S I D E N T I F I C A T I O N GAW R FRONT GAW R REAR ! V I N —...
Page 8 T I P S F O R T O W I N G F O U R W H E E L D R I V E V E H I C L E S F R O N T W H E E L S O F F T H E G R O U N D F U L L T I M E ( 4 X 4 ) P A R T T I M E (4 X 4) M A N U A L T R A N S M I S S I O N...
Page 9: Table Of Contents
SECTION OB LUBRICATION INDEX M aintenance S c he d ule............OB-1 R ear A x le ..............OB-4 E n g in e ..................OB-1 Propeller Shaft Slip Joints........OB-4 Oil and Filter R e c om m end ation s......OB-l Universal J o i n t s ............
Page 10: Drive Belts
oil each • L ig h t D uty Em ission V eh icles-C h an ge 12 months or 7,500 miles. If more than 7,500 miles are driven in a 12 month period, change oil each 7,500 miles. ____________SOW 2 0 . 2 0 W 4 0 ? 0 w 5 0 oil each 4 •...
Page 11: Air Injection Reactor System (A .L.r
be tested for pro per function and serviced, if necessary On V8 engine, lubricate the ball stud at the (Also see m aintenance schedule at end o f this section.) carburetor lever. On L6 engine, lubricate the two ball studs at the Air Injection Reactor System carburetor lever and lubricate the lever m ounting stud.
Page 12 • If it feels hot (cannot be held comfortably), the linkage idler lever at fitting) every 7,500 miles or 12 level should be between the marks. months (6,000 miles or 4 months Heavy Duty Emission A D D FU LL Vehicles) with water resistant EP chassis lubricant which Drain Intervals meets G eneral Motors Specification G M 6 0 3 l-M.
Page 13 bearings trucks. Wheel bearings should lubricated every 30,000 miles (24.000 miles Heavy Duty Emission Vehicles) - lubricate every 12,000 miles in four wheel drive trucks. Do not mix wheel bearing lubricants. "Lo n g fibre" type greases should CAUTION: not be used on roller bearing front wheels. Rear The rear wheel bearings receive their lubrication from the rear axle.
Page 14 allowed remain, these materials result M ake hood hinge a n d latch m echanism functional check to assure the assembly is working accelerated rusting deterioration underbody correctly. components such as fuel lines, fram e and floor pan, exhaust system, etc. At least once each year, preferably after a w in te r’s exposure these corrosive materials should BODY L U B R IC A T IO N be removed by flushing the underbody with plain water.
Page 15 *Also An Emission Control Service (1) Applies to 305 C ID engine only Your 1977 Chevrolet has been certified to m eet emission standards at either high or low altitude as designated on the underhood Vehicle Emission Control Information Label. Vehicle driveability will be optimum at the altitude designated on the Label but will be satisfactory at all altitudes.
Page 16 Series 10 w ith L-6 Engine and Light D u ty Emission System This Maintenance Schedule is applicable to all Chevrolet engines which contain the letter “U” in the engine identification code (which begins with the numeral “7”) shown in the upper left corner of the under hood “Vehicle Emission Control Information”...
Page 17 Any significant fluid loss in any of these systems A-10 MANUAL STEERING GEAR-Check for seal leakage EXPLANATION OF COMPLETE or units could mean that a malfunction is devel around the pitman shaft and housing. If leakage 1977 VE H ICLE MAINTENANCE SCH EDU LE oping and corrective action should be taken is evident (solid grease oozing out—not just oily Presented below is a brief explanation of each of the...
Page 18 celerator pedal. Be prepared to turn off ignition (I) REARVIEW MIRRORS AND SUN VISORS-Check rotors while wheels are removed during tire ro switch immediately if engine should start. that friction joints are properly adjusted so tation (see Item A-5). Check tires for excessive wear or damage.
Page 19 to compensate for compression of the gasket. B-9 UNDERBODY—Corrosive material used for ice and C-14 EVAPORATOR CONTROL SYSTEM (ECS)-Check all snow removal and dust control can accumulate fuel and vapor lines and hoses for proper con C-6 VACUUM ADVANCE SYSTEM AND HOSES-Check on the underbody.
Page 20 nections and correct routing as well as condi torque carburetor attaching bolts and/or nuts to be removed or other conditions above are noted, tion. Remove canister and check for cracks or compensate for compression of the gasket. replace wire. damage. Replace damaged or deteriorated parts C-10 IDLE SPEED-UP SOLENOID—Check for proper oper...
Page 21 COMPLETE VEHICLE MAINTENAHCE SCHEDULE Heavy Duty Emission System Item When To P erfo rm S e r v ic e s S e r v ic e s (Months or Miles, Whichever Occurs First) (For Details, See Numbered Paragraghs) Every 4 months or 6,000 miles Chassis Lubrication •Fluid Levels *Engine Oil...
Page 22 engine coolant also provides corrosion protec 10 AUTOMATIC TRANSMISSION FLUID-Under normal EXPLANATION OF COMPLETE tion. driving conditions, change the transmission 1977 VEH ICLE MAINTENANCE SCHEDULE fluid and service the sump filter every 24,000 Any significant fluid loss in any of these systems Presented below is a brief explanation of each of the miles.
Page 23 (c) STARTER SAFETY SWITCH (AUTOMATIC TRANS (m) HORN—Blow the horn occasionally to be sure bent or cracked and that wheel nuts have been MISSION) — Check starter safety switch by that it works. Check all button locations. tightened to torque value specified in Owner’s attempting to start the engine with the trans...
Page 24 pressed air and replace the filter. The PCV valve -S o m e engines are — Lubricate as covered in 26 M A N I F O L D H E A T V A L V E 20 T H R O T T L E L I N K A G E should be replaced at 12-month or 12,000-mile equipped with a manifold heat valve which...
Page 25 RECOMMENDED FLUIDS & LUBRICANTS USAGE FLU ID /LU BRICAN T Power steering system and GM power steering fluid Part No. pump reservoir 1050017 or equivalent D if f e r e n t ia l- s t a n d a r d & p o s i- SAE-80W or SA E-80W -90 G L-5 tr a c t io n f r o n t a x le &...
Page 26 C O N V E N T IO N A L AND FORWARD CONTROL MODELS L U B R IC A T IO N P O IN T S Wheel Bearings T h ro ttle Bell C rank - L-6 Low er C o n tro l Arm s C a rbu re tor Linkage - V-8 Upper C o n tro l Arm s...
Page 27 1 / 2 TON " G " MODELS L U B R IC A T IO N P O IN T S C o n tro l A rm Bushings and Trans. C o n tro l S ha ft Rear A x le Ball Jo in ts A ir Cleaner - Elem ent...
Page 29 SECTION 1A HEATER C O N T E N T S OF T H IS SEC TIO N Stan dard H e a t e r ................1A-1 Auxiliary H e a te r................1A-14 Specifications..................1A-18 STANDARD HEATER INDEX G e n e ra l D e s c rip tio n .............
Page 30 HEATER & DEFROSTER A S M HEATER A DEFROSTER A S M (HEATER IN OFF P O S I T I O N ) AIR OUTLET V I E W A I R F L O W L E G E N D O U T S ID E AIR TEMPERATURE V A L V E [ HEATER A S M...
Page 31 BLOWER AN D AIR IN LET ASSEMBLY radio o f heated to unheated air (controlled by the temperature door). T he blower and air inlet assembly draws outside air through the outside air inlet grille located forward o f the CO NTRO LS windshield reveal m olding and channels the air into the heater distributor assembly.
Page 32 the system. Moving the lever to the right (toward Tem perature Lever HEATER) opens the air door with the AIR door being This lever controls the positioning o f the TEM PER - fully open at the H EATER position. Incoming air is ATURF.
Page 33 DIAGNOSIS TROUBLE CAUSE AND CORRECTION Temperature of heater a ir a t outlets too low to heat up pas See "In s u ffic ie n t Heat Diagnostic Chart". senger compartment. Temperature of heater a ir a t outlets adequate but the v e h i c l e Check fo r body leaks such as: w ill not build up s u ffic ie n t heat.
Page 34 INSUFFICIENT HEAT DIAGNOSIS P osition th e c o n tro ls so th a t the: Tem perature lever is o n fu ll heat. Selector o r heater lever is o n Heater. Fan sw itch is o n H i. | *C H E C K DUM P DO O R O U T L E T FOR A IR FLO W ~| NO A IR FLO W A d ju st d um p d o o r fo r no air flo w .
Page 35 HEATER C IRC U IT DIA GN O SIS* B L O W E R M O T O R IN O P E R A T IV E ( A N Y SP E E D) Check fuse in fuse pane!. I_ J L _ FU S E B L O W N FU S E O K...
Page 36 BLOWER MOTOR RESISTOR • DASH r T t p p i — ■ 1 4B LBL STR- | 7 2 1 - 1 4 14B ORN STR -------- 14B LBL STR — □ 3 ■ 1 4B ORN STR--------- -14 BRN 14B ORN STR---------- BLOWER SWITCH Q £...
Page 37 ON VEHICLE SERVICE BLOWER M O TO R If the motor m ounting flange sealer has hardened, or is not intact, remove the old sealer and Removal (Fig. 1A-7) apply a new bead o f sealer to the entire circumference o f the mounting flange.
Page 38 N O TE : Be sure core to case and case to dash pane! o f the core tube attachm ent seams whenever undue force sealer is intact before assembling unit. is exerted on them. W henever the heater core hoses do not readily come off the tubes, the hoses should be cut G Models just forward o f the core tubes.
Page 39 A U T O M A TIC TRANSMISSION MODELS EXCEPT C -K IO 3 5 0 V 8 W / O V O I OR C 6 0 C -K M O D EL S G M O D EL S Fig.
Page 40 LEFT DISTRIBUTOR DUCT CENTER DISTRIBUTOR DUCT HEATER CORE CASE Fig. 1A-11 -D istrib u to r Ducts--G Models To install, reverse Steps 1-7 above. NOTE: If cable adjustment is required, see below. Adjustm ent Be careful not to kink the cable C A U TIO N : during installation.
Page 41 Fig. 1A-14-C ontrol Assembly G Models C - K M O D E L S DEFROSTER HOSES G M O D E L S Fig. 1A 1 2 -D e fro ster Outlets Disconnect the switch electrical harness. Remove the swith attaching screws and remove the switch.
Page 42 Remove the two resistor m ounting screws and To install a new resistor, reverse Steps 1 and 2 remove the resistor. above. AUXILIARY HEATER INDEX G eneral D e s c r ip tio n ................ 1A-14 C o n tr o l....................1A-15 D ia g n o sis .....................
Page 43 auxiliary core during w arm weather an d eliminate the in the core inlet line). D uring the sum m er months, this r a d ia n t heat tha t would result. valve should be placed in the "off" position. CO N TR O LS Fan Sw itch (Fig.
Page 44 I N S T A L L V A L V E W I T H A R R O W P O I N T I N G A W A Y F R O M TEE. O R I E N T V A L V E S O " O N " " O F F ” IS VISIBLE Fig.
Page 45 1-1/2" m inim um clearance between hoses and M odels-D raw hoses tight to prevent sag or rub propshaft and a 1 -1 /4 " m inim um clearance against other components. Be sure to route between the auxiliary heater core lines an d the hoses through all clamps as originally installed.
Page 46 SPECIFICATIONS SECTION 1A H E A T E R A m p s. V o lts (Cold) (Cold) Blower Motor C-K Models..... 13.5 6.25 Max. 2550 Min. 2950 Max. G M o d e ls....13.5 7.1 Max. 2850 Min. 3250 Max. Fuses C-K Models................20 Amp.
Page 47 SECTION IB AIR CONDITIONING C O N T E N T S G e n e ra l D e sc rip tio n ............IB-2 Evaporator C o r e ............1B-44 Four-Season System (C-K M odels)......IB-2 Blower Motor Switch........... IB-45 C60 System (G M odels)..........
Page 48: General Description
GENERAL DESCRIPTION decreases which biases the amplifier off and compressor FOUR-SEASON SYSTEM (C-K MODELS) clutch coil is de-energized. Both h e a tin g a n d cooling functions The dash outlets are rectangular in design and can perform ed by this system. Air e ntering the vehicle must be rotated horizontally or vertically to direct air as pass through the cooling unit (evaporator) and through desired.
Page 49 EVAPORATOR CORE BLOWER & EVAPORATOR ASM CONTROL ASM A /C SHROUD R.H. OUTLET VIEW A CENTER OUTLET L.H. OUTLET R.H. OUTLET AIR C O N D IT IO N IN G OVERHEAD SYSTEM EVAPORATOR FLOOR CORE OUTLET R.H DASH PANEL CENTER OUTLET A /C DUCT ASM...
Page 50 EVAPORATOR CORE BLOWER & SHROUD EVAPORATOR A S M R.H. OUTLET CONTROL R.H. OUTLET VIEW A CENTER L.H. OUTLET OUTLET AIR CONDITIONING OVERHEAD SYSTEM R.H. CENTER OUTLET AIR INLET VALVE PLENUM DISTRIBUTOR VALVE DUCT HEATER CORE ^ T E M P ^ VALVE [ BLOWER &...
Page 51 3 . Liquid re frig e ra n t flo w rate is re g u la te d 4. H e a t rem oved from 2 . U p o n re m o v a l o f h e a t, h e re.
Page 52: Main Units Of The System
the only thing that expanded the refrigerant from a car body to help discharge the heat into the surrounding liquid to a v apor in the first place, removal of that same air. h e a t will let the vapor condense into a liquid again. Then Now let’s look at the compressor in detail, and some we can return the liquid refrig erant to the evaporator to o f the components that work with these m ain units to...
Page 53 FRONT DISCHARGE V A L VE PLATE SHAFT SEAL ASM. PULLEY PULLEY BEARING CLUTCH PLATE REAR HEAD HUB ASSEMBLY OIL PUMP SEAL SEAT GEARS RETAINER RING SEAL SLEEVE PRESSURE RELIEF V A L V E CLUTCH COIL OIL PICK-UP TUBE AND HOUSING THRUST OIL SUMP...
Page 54 used on a vehicle with a six cylinder engine. shaft and is tightened against the shaft. The rotor and hub is a welded assembly and contains six threaded holes T he compressor is m ounted to the engine for mounting the pulley rim. The pulley rim is secured to m ounting brackets (Fig.
Page 55 S c r e w 2 0 . B e l l e v i l l e W a s h e r L o c k i n g W a s h e r 2 1 . O - R i n g P u l l e y Rim 11 •...
Page 56 O U T L E T Fig. IB 6- Compressor M ou n tin g - L6 Engine T he receiver-dehydrator, used prim arily as a liquid storage tank, also functions to trap minute quantities of Fig. lB-7--Expansion Valve moisture and foreign material which may have rem ained in the system after installation or service operations.
Page 57 To employ our tire pu m p analogy once more for Therefore, flow out o f the accumulator to the clarity, it is the same situation that would exist if you compressor consists mostly of vapor with the addition of were inflating a tire with a very slow leak.
Page 58: System C O N Tro L
switch contact to open the compressor clutch system selector lever also determ ines disengages. direction o f outlet air flow. Moving the lever from mode to mode varies the position o f a sliding-type vacuum Low R efrigerant Charge P rotection System valve on the control.
Page 59 S Y S T E M O P E R A T IO N - C K T R U C K SELECTOR BLOWER HEATER A/C HEATER LEVER COMPRESSOR SPEEDS ENTERS DOOR- DEFROSTER SOURCE POSITION A V A IL VEHICLE OPEN TO: DOOR-OPEN TO: OUTSIDE...
Page 60 amplifier control th e rm iste r evaporator) to control compressor operation. (Heater-Defrost Modes) The tempeature lever determ ines the tem perature of outlet air flow by positioning the tem perature door in the heater distributor assembly, through the motion o f a bowden cable linking the control panel lever to the tem perature door.
Page 61 T h r e a d a n d A l u m . T u b i n g M e t a l T u b e O .D . F i t t i n g S i z e T o r q u e * 1 / 4 7 / 1 6...
Page 62: D Ia G N O S Is
DIAGNOSSS REFRIGERANT SYSTEM replacement. The last two may be corrected by replacing the valve inlet screen and by properly installing the following is a description o f the type o f power element bulb. sym ptom each refrig eran t com ponent will evidence if a Attachment o f the expansion valve bulb to the defect occurs: evaporator outlet line is very critical.
Page 63: Vacuum System Diagnosis
evidenced by low discharge and suction pressure, and improperly connected or plugged lines or a insufficient cooling. defective vacuum valve or valves. Specific Vacuum Circuit Check S ight Glass Diagnosis (G and M o to r Hom e Place selector lever in m alfunctioning Chassis U nits) position and check for vacuum at the pertinent...
Page 64 CO M PR ESSO R DIAGNOSIS Retrace electrical circuit back to source of power loss. (See wiring diagrams). C-K-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 E S S O R C O IL.
Page 65 INSUFFICENT COOLING-FOUR SEASON SYSTEM(C-K MODELS) M o v e te m p e ra tu re le v e r ra p id ly b a ck a nd fo rth fro m m ax h ea t to m a x c o ld Listen fo r te m p e ra tu re d o o r hitting a t e a c h end. H ittin g ] -------------------------------------------------------------------1 ------------------------------------------------------------------1 N o t H ittin g | Adjust D o or...
Page 66 INSUFFICIENT COOLING D IA GNO SIS CHART (EXCEPT C-K FOUR-SEASON SYSTEM) 5. Check fo r condenser air blockage due to foreign material. The following procedures should be applied before performance testing an A/C System. 6. Check fo r proper air ducting hose connections. 1.
Page 67 ELECTRICAL SYSTEM DIAGNOSTIC CHART B L O W E R M OTOR IN O P E R A T IV E B L O W E R M O T O R I N O P E R A T I V E (C E R T A IN S P E E D S - E X C E P T H IGH ( A N Y SPE E D ) ON C-K F O U R - SE A SO N )
Page 68 E L E C T R IC A L S Y S T E M D IA G N O S T IC CHART COMPRESSOR CLUTCH IN O P E R A T IV E * BLOWER M OTOR IN O P E R A T IV E A T HIG H SPEED O N LY ^^hed^use^ (C-K FOUR-SEASON SYSTEM)
Page 69 JU N C T IO N C O M P R E S S O R R E S IS T O R DISCHARGE B L O C K B L O W E R M O TO R / oN C U T - O U T J (^ 4 ' SW ITCH...
Page 72 Fig. IB -2 6 -C60 System W iring Diagram (G Models)
Page 73 V A C U U M R E S E R V O IR (IN E N G I N E C O M P A R T M E N T ) T O V A CUUM S O R C E g r a y DASH P A N E L H E A T E R C O R E C A S E...
Page 75 THERMOSTATIC SWITCH...
Page 76: Perform Ance D A T A
T E M P control set at " C O L D " all air Overhead System (C -K Models) c on ditioning outlets open. G a u g e set installed. System settled out (run-in approxim ately (R efrig e ra n t C harge - 5 lbs.-4 o z .) minutes).
Page 77 Overhead System (G Models) Dash M ounted U n it (M o to r Hom e Chassis) (R efrigerant Charge — 5 lbs.-4 o z.) (R efrig eran t Charge — 3 lb s.-4 oz.) T em p eratu re o f T em p eratu re o f Air E ntering 70°...
Page 78: R Efrig Eran T Quick-Check P Ro Ced U Re
REFRIGERANT Q U IC K -C H EC K PROCEDURE The following procedure can be used to quickly determ ine w hether or not an air conditioning system has a proper charge o f refrigerant. This check can be m ade in a m anner of m inutes thus facilitating system diagnosis by pinpointing the problem to the am ount of charge in th e system or by elim inating this possibility from the overall checkout.
Page 79: On Vehicle Service
Fig. IB -3 0 Checking Evaporator Inlet and A cu um ulator O utlet Tem peratures ON VEHICLE SERVICE not, the switch points are fused which will lead to T H E R M O S T A T IC S W ITCH evaporator freeze up.
Page 80: Expansion Valve
then adjust by rotating the pot until the compressor clutch engages. Reverse the adjustm ent by carefully rotating the pot until the compressor clutch just disengages. Reverse Steps l -4 above and check system operation. C A P I L L A R Y BULB E XP A N SIO N VALVE (Fig.
Page 81: C O M Presso R
factory installed air conditioning systems, the com pensa Remove connector attaching bolt and connector. tor is located w ithin the carbureto r and is accessible Cap or plug open connections at once. w hen the engine air cleaner is removed. Disconnect electrical lead to clutch actuating C O M PRESSO R Removal (Fig.
Page 82: Four-Season System-C-Kmodels
compressor brackets to the m ounting bracket. Remove Position compressor on the mounting bracket the compressor. and install all nuts, bolts, lock washers, and ground wire. Before beginning any compressor disassembly, Install the connector assembly to the compressor d ra in and measure oil in the compressor. Check for rear head, using new "...
Page 83: A C C U M U La To R
Purge the system o f refrigerant. Disconnect the accumulator inlet and outlet Remove the grille assembly. lines and cap or plug the open connections at once. Remove the ra d ia to r grille center support. Remove the accumulator bracket screws and Remove the left grille support to upper fender remove the accumulator from the vehicle.
Page 84: Expansion T U B E
Disconnect the condenser to evaporator line at the evaporator inlet. Cap the open line at once. Using needle-nose pliers, remove the expansion tube from the evaporator core inlet line (fig. IB-37). Remove the expansion tube " O " ring from the core inlet line.
Page 85: Control A Sse M B
UPPER CENTER DISTRIBUTO R DUCT R IG H T H A N D OUTLETS LEFT DISTRIB UTO R DUCT A N D F O O T COOLER LOW ER CENTER DISTRIBUTO R DUCT Fig. IB -39 -Air Selector and Ducts (C-K Models) Disconnect the vacuum and electrical harness To install reverse Steps 1-5 above.
Page 86: T Em P Eratu Re D Oor Cable A D Ju S Tm E N T
Remove the control. If a new unit is being installed, transfer the master blower switches to the new control. To reinstall, reverse Steps l -6 above. Check control operation. T E M P E R A T U R E DOOR CABLE A D J U S T M E N T Remove glove box and door assembly.
Page 87: T Herm Ostatic Switch
To install, reverse Steps 1 and 2 above. Remove electrical connectors to the switch. Remove screws to loosen body from evaporator BLOWER M O T O R RESISTO R case. A capillary line (small tube) extends from the The blower motor resistor is located in the blower swtich with the other end attached to the evaporator inlet side of the blower-evaporator case (fig.
Page 88: Fuse
Purge the system o f refrigerant. the rear o f the vehicle, and incorporates four adjustable Disconnect the w iring harness at the switch. air outlets (fig. IB-46). Remove the switch from the refrigerant line. Replacement To replace, reverse Steps 1-4 above. Disconnect the battery ground cable.
Page 89 Before removing the case screws, C A U TIO N : support the lower case to prevent damage to the case or motor assemblies. Remove the motor retaining strap and remove the motor and wheels. Remove the wheels from the motor shaft.
Page 90: Expansion V A Lv E
Remove expansion valve sensing bulb clamps. Disconnect the valve inlet and outlet lines and remove the expansion valve assembly. Cap or plug the open connections at once. Installation Remove caps or plugs from system connections and install the new valve assembly using new " O " rings coated with clean refrigeration oil.
Page 91: Blower Motor Switch
Install the wire screen to the front o f the core 20 am p in-line fuse, located between the junction block and insert the plastic pins. and the rear blower motor switch. Install the expansion valve inlet and outlet lines C60 SYSTEM-G MODELS using new "...
Page 92: Sight Glass Replacem Ent
Evacuate, charge and check the system. Disconnect the battery ground cable, and the compressor clutch connector. Purge the system o f refrigerant. S IG H T GLASS R E P LACEM ENT Remove left and right hand headlam p bezel and parking lam p lens.
Page 93: A /C Center And Right Dash O Utlets
RH D A S H O U TLE T Fig. lB-54--A ir D istrib u to r Ducts (C60 System - G MOdels) U nsn a p the engine cover latches, remove the NOTE: Make sure all ducts and seals are installed properly.
Page 94: Heater Core Case And C O R E
Make sure expansion valve sensing bulb makes To install, reverse Steps l -2 above. good physical contact with the evaporator core HEATER AIR D IS T R IB U T O R connector block. Evacuate, charge and check system operation. AN D EXTEN S IO N D U C T - G M O DEL A /C BLOWER M O TO R Replacement (Fig.
Page 95: Evaporator C O R E
W hen m aking evaporator core connections, use Follow Steps 1-10 o f "Fleater Air Distributor and new " O " rings coated with clean refrigeration oil. Extension Duct Extension Duct Replacem ent" procedure. Evacuate, charge and check system operation. Remove duct assembly.
Page 96: Blower Switch
install, reverse Steps l -7 above. Check To install, reverse Steps 1-3 above. tem perature door operation; adjust if necessary. BLOWER M O TO R RELAY BLOWER S W ITC H The blower motor relay is attached to the left end of Replacem ent (Fig.
Page 97: Vacuum T A N K
Disconnect the electrical harness at the switch. Remove the switch from the refrigerant line. To install, reverse Steps 1-4 above. N O T E: Use a new " O " ring coated with clean regrigeration oil, when installing switch. Evacuate, charge and check system opeation. V A C U U M TA N K Replacement (Fig.
Page 98: Expansion Valves
CORRECT BLADE ANGLE V A L V E S E N S I N G B U L B S LOWER CASE HALF V A L V E S Fig. IB -65-E xpansion Valves (G Overhead System) Fig. lB-64--Blow er M otors (G Overhead System) D isconnect battery gro un d...
Page 99: Evaporator C O R
R em ov e b lo w e r-ev a p o rato r shroud outlined previously. B O W Disconnect the blower m otor ground straps and leads. Disconnect the refrig eran t lines at the rear o f the blower-evaporator assembly.
Page 100: Resistor
Fig. lES-67~Rear Blower M otor Switch Fig. IB -6 8 -R e a r Blower M otor Relay Evacuate, charge and check the system. To install, reverse Steps 1-3 above. Check system operation. R ESISTO R See "R esistor" in the G Model C60 System Section T IE RELAY o f this m a n ual (fig.
Page 101: Receiver-Dehyd Rato R
Fig. lB-69~C ondenser (M o to r Flome Chasis U n it) Fig. IB -70-R eceiver-D ehydrator (M o to r Flome Chassis U nit) Purge the system o f ref rigerant. Evacuate, charge and check the system. Disconnect the condenser inlet and outlet lines and cap or plug all open connections at once.
Page 102: Blower Assembly
Disconnect battery ground cable. Purge system of refrigerant. Disconnect inlet and outlet refrigerant lines from the back o f unit. Cap or plug all open connections at once. Disconnect d rain tubes from evaporator case. Disconnect electrical connector from com pres sor.
Page 103: Thermostatic A N D / O R Blower S W Itches
Reverse steps 1-8 o f the "Blower Evaporator A ssembly" removal procedure. Evacuate, charge and check the system. T H E R M O S T A T IC A N D /O R BLOWER SW ITCHES Replacement Remove the cover plate assembly from evaporator case.
Page 104: Special Tools
SPECIAL TOOLS 1 . J - 2 5 0 3 0 C l u t c h H u b H o l d i n g To ol J - 2 5 0 2 9 R o t o r B e a r i n g R e m o v e r a n d R o t o r Assy.
Page 105 % ■ 1. J - 8 3 9 3 C h a r g in g S t a tio n 11. J - 5 4 2 1 - 0 2 P o c k e t T h e rm o m e te rs (2 ) 2 2 .
Page 107 SECTION 2A FRAME C O N T E N T S G eneral D e s c rip tio n ................2A-1 On-Vehicle Service................2A-1 M aintenance and In spectio n............2A-1 U nd erb ody Inspection..............2A-1 F ram e In sp e c tio n ................. ■ 2A-1 Fram e A lig n m en t................
Page 108 Support vehicle so that fram e sidemem bers are length. Opposite side m easurem ent should correspond parallel to the ground. within 3/16". Measure diagonals marked A, B and C. If the Tram m ing Sequence (Fig. 2A -1) lengths o f intersecting diagonals are equal and these D im ensions to bolts a n d / o r holes in fram e diagonals intersect the centerline, frame area included extend to dead center of the hole or bolt.
Page 109 DIMENSIONS TO HOLES OR SLOTS ARE MEASURED TO THE CENTER OF HOLE OR SLOT GAUGE HOLES ARE 5/8" DIAMETER © INDICATES THAT THE DIMENSION IS TO THE UNDERSIDE OF THE FRAME TOP SURFACE OR INSIDE OF THE FRAME OUTER SURFACE NOTE: FRAME ILLUSTRATED IS TYPICAL.
Page 110 M o d e l CA107 13-3/8 15-1/4 19-7/8 14-7/8 17-3/4 17 3/4 19-7/8 16 3/4 15-5/8 17-3/4 69 5/8 76-1/2 16-7/8 16-7/8 CA109 13-3/8 15-1/4 19-7/8 14-7/8 17-3,4 17-3/4 16-3/4 19-7/8 15-5/8 17-3/4 69-5/8 86-1/2 16-7/8 16-7/8 CA209 15-1/4 13-3/8 19-7/8 14 7/8...
Page 111 SECTION 2B BUMPERS C O N T E N TS G e n e ra l D escrip tion ............2B-1 Rear Step Bumper - C and K M odels....2B-2 Service Procedures - 10 thru 30 Series....2B-1 Front Bumper G Series..........2B-2 Fron t Bumper - C, K and P M o dels.....
Page 112 Remove nuts securing bumpers to brackets and braces from left and right side. Remove bumper. Remove the license plate support nut and bolts. If necessary to remove the braces and brackets, remove screws securing brackets and braces to sheet metal. NOTE: The bum per may be removed with the brackets and braces attached.
Page 113 Fig. 2B-8--G-Model Rear Step Bum per Fig. 2B-7 -Rear Bumper-G Models Installation N OTE: The bum per may be removed with brackets and braces attached if necessary. Instal1 in reverse order o f removal.
Page 114 SPECIFICATIONS TO R Q U E S P E C IF IC A TIO N S C , P A N D K Front Bum per ................. 35 ft.-lb s . Front Bum per Bracket a n d B race .......
Page 115 SECTION 2C CHASSIS SHEET METAL C O N T E N T S Hood Assem bly..............2C-4 G e n e ra l D escription............2C-1 Front Sheet Metal - CK S e rie s........2C-6 O n Vehicle S e rv ic e ............2C-1 Radiator Su p p o rt............2C-8 Hood Assembly - CK Series........
Page 116 H O O D L O C K N U T .110 S U P P O R T L O C K I N G P L A T E L O C K N U T G U I D E H O O D L O C K B O L T...
Page 117: Hood Assembly - Ck Series
replaced, scribe a line around lock for alignment Perform hood lock adjustment as outlined in on installation. this section if necessary. Place hood lock assembly in position. Hood Assembly - G Series Adjust as outlined under Adjustments. Adjustment (Fig. 2C-4) The alignment o f the hood is controlled by the position o f the hood hinges and the height o f the two Loosen lock nut on lock bolt and adjust lock bolt...
Page 118: Hood Assembly - G S E R Ie
Replacement assembly so that it is just "sn u g " enough to hold lock bolt in position. O pen hood and remove the four bolts holding Close hood in a normal m anner. the com bination lock catch and lock bolt. Raise hood again;...
Page 119 Fig. 2C-8- Hood Release Cable ■ CK Models necessary to align hood perform procedure as outlined under "A lignm ent” which follows. Alignment Loosen hood hinge bolts. Note that rear bolt holes in hinge is slotted to allow hood trailing edge to move up and down.
Page 120 R A D IA TO R GRILLE M O LD IN G - CK MODELS (FIG. 2C -12) FRO NT SHEET M ETA L ASSEMBLY-CK SERIES Removal o f entire front sheet metal assembly including radiator involves disassembly mounts, disconnecting rad iato r hoses and removal of front...
Page 121 FLUSH HOOD HOOD ASS’ •FENDER /-F E N D E R ASSY ASSY / ASSY -FENDER FENDER DOOR ASSY ASSY HOOD ASSY FLUSH •FLUSH ASSY SECTION E -E SECTION B -B SECTION D -D SE CTION C-C ] Hood su rfa c e . 06 below N O T E a t Section C -C to flush a t Section B -B an d S ection D -D .
Page 122: Radiator Su P P O
Connect hood latch plate. Connect ra d iato r support brackets to fenders. Connect support to fenders. Connect screws from underside o f fender skirts to support bottom. Attach grille upper panel to fenders loosely. Attach grille lower panel to fenders. Tighten radiator support bolts.
Page 123: Front F Ender S K I R
R A D I A T O R S U P P O R T U P P E R P A N E L R A D I A T O R M O U N T I N G P A N E L B R A C K E T L O W E R...
Page 124: Sheet Metal C H Ecking
COWL TO HOOD ± 3 / 1 6 1 /3 2 NOTE H o o d s u r f a c e flu sh 1 / 1 6 b e l o w c o w l v e n t g r i l l e a n d c o n s t a n t f r o m...
Page 125 Fig. 2C 19 Fender S kirt, Dash and Toe Pan—P Series S h elf life of the transfer material is 90 days at a remove pap er backing from transfer and align upper tem perature not to exceed 105 F. edge with pierced holes in fender and press on lightly.
Page 126: Specifications
SPECIFICATIONS SHEET METAL S E C T IO N 2 C 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 127 SECTION 2D BODY The following caution applies to one or more steps in the assembly procedure o f components in this portion o f the m anual as indicated at a p propriate locations by the terminology "See Caution on page 1 o f this Section".
Page 129 Fig. 2 D -5-T ypical ” 0 5 " and " 0 6 " Vans...
Page 130 Fig. 2D-6--Typical ” 0 3 '' Van ON VEHICLE SERVICE C-K M O D ELS INDEX Rear Side D o o rs............2D-17 Front End R ep lacem ent............. 2D-17 W indshield W ip ers............2D-5 Hinges................. 2D-17 Glove Box................ 2D-5 Stationary G la ss.............
Page 131 FRONT END W IN D S H IE LD W IPERS pivot shaft assembly to windshield frame. Remove wiper linkage and transmission from plenum. W indshield wiper units on all models are o f the two- Installation speed electric type. A single wiper motor unit, mounted Place wiper linkage...
Page 132 N OTE: C am p er mirror installation is similar to the Fig. 2D-10--Rear View M irrors below eyeline mirror installation. bu m p e r is gained by reaching into c om partm ent opening with door partially open. IN S ID E REAR VIEW M IR R O R - FIG URE 2D- A d ju stm ent E ngagem ent of lock in striker may be adjusted by...
Page 133 Fig. 2D-12 Cowl Vent Valves BODY GLASS W A R N IN G : Always w ear gloves when handling glass. W IN D S H IE L D GLASS T he windshield is a one-piece type and is retained windshield opening molded...
Page 134 applying firm, controlled pressure to the edge o f the w in dsh ie ld applies o th e r sta tio n a ry glass glass. At the same time assist the lip o f the rubber applications, such as in figures 2D-20 and 2D-21. weatherstrip channel over the pinchweld flange with a Removal flat bladed tool.
Page 135 2ZBS Fig. 2D -17-C hecking W indshield Opening Recheck windshield opening satisfactory proceed as follows: Installation Place a protective covering over front fenders and hood, then apply soapy w ater to all grooves of the w eatherstrip. Install w e a th e rstrip centrally body opening,...
Page 137 Fig. 2D-21--Body Side W indow (14 and 06) BODY SIDE DOORS Striker Bolt Adjustm ent DOOR A D JU S T M E N T S With the use o f J-23457, shown in figure 2D-23. the Doors can be adjusted for alignm ent o f clearance in striker bolt can be adjusted in any o f three ways.
Page 138 Fig. 2D-22 -Door Hinge Fig. 2D-24--Typical Striker Bolt A djustm ent make this adjust front door check-hinge assembly is replaced as a Foreward and R e a rw a rd -T o ment, loosen striker bolt, shim to desired position, and complete unit as follows.
Page 139 Fig. 2D-27--Door Trim Pad Fig. 2D-2b--Door T rim Panel Fig. 2D-28--Removing V entilator Assembly Thoroughly clean the inside of the glass channel Fig. 2D -26-D oor V e n tila to r Assembly with sandpaper, removing all rust, etc. Using new glass channel filler, cut the piece to R em ove screws a tta c h in g...
Page 140 seal. Trim off the excess filler material around Adjustment channel and at the ends o f the channel. Adjust the ventilator by placing wrench on N O T E : Glass should be installed so that rear edge adjusting nut thru access hole and turning vent window is parallel to the division post.
Page 141 N O T C H ROLLER Fig. 2D 32 Removing Door Glass Install regulator reversing above steps. Lubricate regulator gear with lubriplate or equivalent. W IN D O W REG ULATO R - POW ER - CK Fig. 2D-34--Power W indw Regulator, M otor and MODELS Connector In the case that window will not operate, check...
Page 142 N O T E : The lubrication used must be cold w eather Door Outside Handle--Fig. 2D -36 approved to a m inim u m of minus 20° fahrenheit. Replacement Install regulator m otor to regulator. Make sure the motor pinion gear teeth mesh properly with the Raise window to gain access to lock.
Page 143 To install, reverse steps 1 through 5 above. DOOR TO BODY O P EN IN G W E A TH ER S TR IP - -FIGS. 2D -39, 2D -40 Side door sealing incorporates an inner seal. The inner seal is mounted on the body opening welding flange and goes completely around the periphery of the opening.
Page 144 alignment o f the glass to the rear glass run channel for S T A T IO N A R Y G LA S S -R E A R DOOR full up and down travel. Replacem ent W IN D O W G LA SS-FIG . 2D 4 5 Lower window to full down position.
Page 145 Install regulator by reversing above procedure. Lubricate regulator gear with lubriplate or equivalent. LOCKS HANDLES AND RODS Lock Assem bly-Fig. 2D-46 Replacement Remove window regulator handle and remote control push button knob. Remove trim pad. Disengage three clips which retain control rods to lock assembly.
Page 146 Remove two screws securing each remote control W EATH ERSTRIP--FIG . 2D -49 lever to door panel. The procedure outlined in Front Door W eatherstrip Remove remote control levers and rods through may be applied to the R ear Side Door Weatherstrip, door opening.
Page 147 attaches to the pillar with three screws; the strap is fastened to the door panel with two screws and an attaching bar. REAR D O O R -S TR IK E R AND WEDGE A D JU S TM E N TS Figure 2D-54 illustrates the rear door latch strikers and door wedges.
Page 148 Fig. 2D-51--Rear Door Controls...
Page 149 Fig. 2D-52- Rear Door O utside Handle and Lock Cylinder UPPER W E D G E STRIKER A D J U S T M E N T A D J U S T M E N T .1 7 ± ,0 3 ( 1 1 / 6 4 DRILL) IN S E C O N D A R Y L A T C H E D .0 4 M A X .
Page 150 Fig. 2D-55 W eatherstrip--L.H. and R.H. Rear Door ENDGATES (06 AND 14) To install, reverse removal procedure. Coach models (06) and utility models (14) use endgates similar, distinct design. Separate HINGES procedures follow for service on each of these endgates. Replacement E N D G A TE ASSEMBLY - (0 6 ) MODELS ONLY If necessary to remove hinges, remove endgate as...
Page 151 ACCESS Fig. 2D-58- Latch and Remote Controls (06 Only) W A R N IN G : Step 10 must be perform ed if the window is removed or disengaged from the regulator lift arms. The lift arms are under tension from th e counter balance spring, and can cause injury if the m otor is removed without locking the sector gears in position.
Page 152 Fig. 2D -61-Endgate, Hinges and Support (14) Fig. 2 D -62 -P u llin g Hinge Away From Body (14) Fig. 2D -60 -Outside Flandle (06 and 14) hinge to body on each side. See figure 2D-61. Disconnect HING E wiring harness, if so equipped.
Page 153 BRACKET SILENCER TORQUE FRAME Fig. 2D-65 -Torque Rod In sta lla tion (14) Fig. 2D-63 -Grasping Torque Rod (14) Lift torque rod up and slide from endgate as sure to install hinge into e ndgate first, then into the shown in figure 2D-66. body.
Page 154 Fig. 2D 6 7 -Latches and Rods Fig. 2D 68 Removing Side Latch Fig. 2D-70--Removing Control Assembly and Inside control assembly, then remove screws which secure inside Handle handle to inner panel. TAILG ATES (03, 63 and 14) Remove three screws which retain...
Page 155 Fig. 2D-73--Removing Regulator Fig. 2D-72- D isconnecting Sash from Regulator Fig. 2D-74--Outside Handle Attach one brace to the holes exposed in Step REM O VABLE TO P-FO LDING TO P (1 6 ONLY) Removal Slide top forward to expose the front bottom Remove the bracket-to-roof bolt from each o f top-to-pickup box attaching holes.
Page 156 Fig. 2D-77--Roof-to-Header Brackets cases, impossible to completely remove. W hen cleaning this type of stain or soilage, care must be taken not to enlarge the soiled area. It is sometimes more desirable to have a small stain than an enlarged stain as a result of careless cleaning.
Page 157 Fig. 2D-78--Removable Top im m ediately by a soft brush to completely remove Always clean at least a full trim panel or section o f trim. the spot. Mask adjacent trim along stitch or weld lines. Mix detergent type foam cleaners in strict accordance with Cleaning Fabrics with D etergent Foam directions on label o f container.
Page 158 Fig. 2D-79--Folding Top Assembly...
Page 159 Fig. 2D-80--Folding Top Side M oldings and Header...
Page 160 Remove excess with dull knife, moisten with fabric cleaning fluid, scrape again, rub lightly with additional cleaner. Blood restore the luster o f the trim and to eliminate any dried residue. Wipe with clean cloth moistened with cold water. Use no soap. Rem oval of Specific Stains Urine Candy...
Page 161 Fig. 2 D -8 5 -D n v e r’s Bucket Seat (14) Fig. 2D-86--Passenger's Bucket Seat (14)
Page 162 Fig. 2D -89-R ear Folding Seat (06) Fig. 2D 9 0 -Rear Bench Seat (14)
Page 166 M O U N T ^ M O U N T M O U N T 2 M O U N T ^ M O U N T 3 Fig. 2D 94- Body M ounting (14) G MODELS INDEX Front Fnd Locks, Handles, R o d s ..........
Page 167: W Indshield W Ip E
FRONT END Attach end o f link rod to motor drive and arm. W IN D S H IE L D WIPERS Secure rod with the two attaching nuts. W indshield wiper units on all models are o f the two- Install outside air cowl ventilator grille to top of speed electric type.
Page 168: Rear View M I R R O
Replacement Remove screws retaining valve guide to panel, as shown in figure 2D-98. Remove valve assembly by depressing pins at top and bottom o f valve. Reverse the above steps for installation. REAR VIEW M IR R O R S Inside Rear View Mirror Replacement The inside m irror m ay be removed by removing...
Page 169: Windshield G La S
Fig. 2D-100--Outside Rear View M irrors BODY GLASS glass is installed. Otherwise, it is highly possible that a small obstruction or high spot somewhere around the W A R N IN G : Always wear gloves when windshield opening will continue to crack or break the handling glass.
Page 170: Weatherstrip
Check flange area for solder, weld high spots, or hardened spot-weld sealer. Remove all high spots. Check windshield glass to opening, by support ing glass with six spacers contained in packet J-22577, as shown in figure 2D-102. Do not strike glass against body C A U TIO N : metal.
Page 171: H In G E
Fig. 2D 103- Cord Insta lla tion Seal windshield to weatherstrip and w eather strip to body. S W IN G O U T W IN D O W Removal Swing out the window. See figure 2D-105. Remove screws retaining latch to body. Remove window hinge retaining screws and w'indow.
Page 172 Fig. 2D-107-Loosening S trike r Bolt Striker Bolt Adjustment With the use o f J-23457. shown in figure 2D-107, the striker bolt can be adjusted in any of three ways. See figure 2D-108. adjust striker up or down, Up and d o w n -T o loosen bolt, adjust to center of lock entry, and tighten bolt securely.
Page 173: E N Tila To
top of vent window, m aking sure that plastic nails align with holes in door. Install weatherstrip by pressing each nail into the door. T R IM PANEL, ARM REST AND HANDLES Removal Remove screws retaining arm rest to trim panel. Remove door handles with Tool J-7797 and pull from shaft.
Page 174: Window And R Egulator
Install and tighten the three screws at the upper front o f the door. Adjustm ent Adjust the ventilator adjusting nut by turning clockwise to increase operating tension, as shown in figure 2 D - 1 1 I . A fter m aking adjustm ent bend tabs over the hex nut.
Page 175: Sliding Side Door
Secure remote handle. Check all controls for proper operation before reinstalling trim and handles. Install remote control sill knob. REMO TE C O N TR O L AND C O N N E C T IN G ROD -Fig. 2D-113 Replacement Raise door window and remove door trim pad.
Page 176: Front L A Tc
STRIKER FORE-AND-AFT ADJUSTMENT SLOTS CENTER ROLLER VERTICALLY IN TRACK SO IT DOES NOT CONTACT THE TRACK ---- ----- IN FULL OPEN UP-AND-DOWN OR FULL 1 , ....J ADJUSTMENT SLOTS CLOSED POSITION UPPER R EA R HINGE-AND-ROLLER SECTION B-B TOP VIEW UPPER LEVER.
Page 177 Center the striker vertically to door striker opening. Adjust the striker laterally to match outer panel to the body panel surfaces, view E o f figure 2 D - 1 16. Apply grease to the striker. Gently push the door in until the rear lock contacts the striker enough to make an impression in the grease.
Page 178 Fig. 2D-117--Hold-Open Catch Fig. 2 D -1 1 9 -Sliding Door Front Latch Fig. 2 D -11 8 -Adjusting the Rear Wedge Assembly Fig. 2D-120--Disconnecting Lower Latch Rod from Latch F R O N T LATCH ASSEMBLY Installation Removal Install latch assembly into door by working latch Remove trim panel, if so equipped.
Page 179: Upper Rear H In G
Fig. 2D-122--Rear Track Cover Fig. 2D-121--Sliding Door Rear Latch Disconnect rear latch rods from front latch Disengage spring from bolt, using a spring removal tool. assembly, shown in figure 2D. Close the door. Remove rear latch attaching screws. See figure 2 D -1 2 1.
Page 180 Roller B olt 15. Screw Lockwashers Plate Guide Block Bushing N ut Upper lines Hinge (Body Half) Hinge (D oor Half) 11. Spacer N ut Spring 5. Washer 12. Spring (Upper Lever) Bushing Spring retainer Bushing 13. Spring (Low er Level) Bushing Hinge liner Bushing...
Page 181: Rear Door H In G
Fig. 2D-124--Checking Assembly of Hinge REAR DOORS REAR DOOR HING E STR A P REAR DOOR HING E Replacement Removal Remove strap release pin. See figure 2D-125. Open door. Support door so that when hinge Remove screws retaining strap to door. screws are removed d oo r weight will be on support.
Page 182 Adjust latch to strikers. REAR DOOR O UTSIDE HANDLE Removal Remove trim panel. Remove door handle retaining screws, handle and gaskets. See figure 2D-127. Installation Apply grease to remote control where handle plunger makes contact. Install handle and gaskets. Torque screws to specifications.
Page 183: Seats
provide equal clearances between body and door around perim eter of door. Adjust door in and out so that door panel is flush with body. Install door strikers and wedges and adjust as outlined under door striker adjustment. REAR DOOR STRIKER AND WEDGE A D J U S T M E N T CAUTION: See C A U T IO N on page 1 o f this section regaring Rear Door Striker fasteners.
Page 184: Passenger S E A
Fig. 2D -129--D river’s Seat Install seat and torque nuts to specifications. plates are used. W hen the latch assemblies are depressed, their cams and the hooks o f the retainers are drawn tightly onto the anchor pins for secure seat attachment. PASSENGER S E A T -M O U N T IN G BRACKETS Removal accomplished...
Page 187 SPECIFICATIONS BODY SECTION 2D C AND K MODELS F R O N T E N D E N D G A T E (0 6 ) Windshield Wiper Linkage to Plenum ......25 in. lb. Hinges— Hinge to B o d y ..........35 ft. lb. Sunshade S u p p o r t ............
Page 188 BODY MOUNTING (C-K MODELS)-FT. LBS. Model (03) — — — — (06) — — (14) — (63) G MODELS M IR R O R S A N D S U N S H A D E S L I D I N G S ID E D O O R Inside Rear View Mirror to Bracket ......15 in.
Page 189 SPECIAL TOOLS 1. J-2189 W eatherstrip T o o l Set 2. J-22585 F ro n t D o o r Hinge, B o lt W rench 3. J-22577 W indshield C hecking Blocks 4. J-7797 D o o r Handle C lip Remover 5.
Page 191 SECTION 3A FRONT ALIGNMENT C O N T E N T S G eneral D e sc rip tio n ....3 A- 1 M aintenan ce and Adjustments 3A-2 Specifications......... 3A-6 GENERAL DESCRIPTION from a side elevation. Caster is designed into the front F R O N T A L IG N M E N T axle assembly on all K series vehicles (l'our-wheel drive), The term "...
Page 192 1 O F W HEEL <t O F V E H IC LE <t O F W HE EL CAMBER ANGLE CASTER ANGLE F R O N T V IE W SIDE V IE W Fig. 3A-1 Caster Cam ber - Toe-In MAINTENANCE AND ADJUSTMENTS Check loose...
Page 193 a procedure for determ ining the presence o f a tire lead A L IG N M E N T A D J U S T M E N T S problem. N O TE: A norm al shim pack will leave at least two FRONT ALIGNMENT REQUIREMENTS (2) threads of the bolt exposed beyond the nut.
Page 194 Draw graphic Fig. 3A-4 that a dding or subtracting shims from the front or rear bolt representative o f the fra m e angle (either " u p " in rear or on the upper control arm shaft, shown in Figure 3A-2. "d ow n"...
Page 195 w n D i7 r> M T A i FRAME ANG LE — H O R IZO N TAL D O W |sj FRAME ANG LE = D O W N ANG LE READING - ( l ’/ 4 ° ) CASTER ANGLE READING + ( 2' A°...
Page 196 SPECIFICATIONS W HEEL A L IG N M E N T SP EC IFIC A TIO N S CASTER* SION “A ' IN INC DIMEN HES* MODELS 2 1/2" 2 3 /4 " 3" 3 1/4" 3 1/2" 3 3/4" 4"...
Page 197 SECTION 3B STEERING The following caution applies to one or more steps in the assembly procedure o f components in this portion of the m anual as indicated at a ppropriate locations by the terminology "See Caution on page l o f this Section".
Page 198: G E N E Ra L D E Sc Rip Tio
GENERAL DESCRIPTION The steering gear is o f the recirculating ball type. coupling deflection from exceeding the length o f the coupling alignm ent pins. This gear provides for ease o f handling by transmitting The trucks incorporate "F o rw ard Steering" whereas forces from the w orm shaft to the pitm an shaft through the steering linkage is located forward o f the front the use o f ball bearings.
Page 199 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. Worn upper ball joints. Check and replace if necessary. Steering wheel loose on shaft, Tighten to specified torque, loose pitman arm, tie rods, or replace if necessary.
Page 200: Steering L In K Ag
CONDITION POSSIBLE CAUSE CORRECTION Hard Steering — Excessive Effort Low or uneven tire pressure. Inflate to specified pressures. Required at Steering Wheel. Steering linkage or bolt joints Lube with specified lubricant. need lubrication. Tight or frozen intermediate rod, Lube replace or reposition tie rod or idler socket.
Page 201 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 202 CONDITION POSSIBLE CAUSE CORRECTION Excessive Play or Looseness in Front wheel bearings loosely Adjust to obtain proper end play. Steering System. adjusted. Worn upper ball joints. Check and replace ball joints if necessary. Steering wheel loose on shaft, Tighten to specification, replace loose pitman arm, tie rods, if worn or damaged.
Page 203: Steering Column (C And
DIAGNOSIS C AND K STEERING COLUMNS evident or whenever the vehicle is being repaired due to This section contains diagnostic inform ation to help locate the cause of the problem in the column. Reference a front end collision. W henever a force has been exerted should be m a de to the correct method o f column steering wheel...
Page 204 SU RFA CE “A” Instrument Panel Bracket Capsule Damage The bolt head must not contact surface “A”. If NOTE: contact is made, the capsule shear load w.ill be increased. If = □ =□ this condition exists replace the bracket. A U T O M A T IC T R A N S M IS S IO N C O L U M N S LOCK S Y S T E M - W I L L N O T U N L O C K Cause...
Page 205 LOCK S Y S TE M H IG H E F F O R T (C O N T 'D .) Cause Solution H. Replace rack. H. D istorted coupling slot in rack (tilt). Bent or restricted actuator rod. I. Straighten remove restriction or replace. J.
Page 206 IG N IT IO N S Y S T E M E L E C T R IC A L S YSTEM W IL L N O T F U N C T IO N (C O N T 'D .) Cause Solution D.
Page 207 H IG H S T E E R IN G S H A F T E F F O R T Cause Solution A. Realign. A. Column assembly misaligned in vehicle. B. Remove and replace. B. Improperly installed or deformed dust seal. C.
Page 208 M A N U A L T R A N S M IS S IO N C O LU M N S 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.
Page 209 S T E E R IN G W H EE L LOOSE Solution Cause A. Replace either or both. A. Excessive clearance between holes in support or housing and pivot pin diameters. B. Defective or missing anti-lash spring in spheres. B.
Page 210 F ig.-3B -11-S teering Colum n Electrical Analyzer J -23980 Fig. 3B 12- Checking Fuses on Fuse Block connector on the column and plug the harness from J-23980 into the vehicle chassis harness. The "A ", "B", and " C " term inals on the tester will overhang the chassis connector.
Page 211 in both directions. If the lever does not return to the neutral position, disassemble the upper p art o f the column until the switch is visible. Check the return from lane change by holding the lever in lane change and releasing (both left and right).
Page 212 SIGNAL SWITCH DIAGNOSIS C O N D ITIO N POSSIBLE CAUSE CORRECTION T u rn signal w ill not cancel Loose switch T ig h ten to specified m ounting screws to rq u e (2 5 in-lbs) Sw itch or anchor Replace switch bosses broken B roken, missing or o ut...
Page 213 SIGNAL SWITCH DIAGNOSIS C O N D ITIO N POSSIBLE CAUSE CORRECTION Hazard switch w ill not Loose switch T ighten m ou n ting stay on o r d iffic u lt m ounting screws screws (2 5 in-lbs) to tu rn o ff In terference w ith Remove interference...
Page 214 SIGNAL SWITCH DIAGNOSIS C O N D ITIO N POSSIBLE CAUSE CORRECTION F ro n t o r rear tu rn signal Burned o u t fuse Replace fuse and lights not flashing check o p eratio n Burned o u t or Replace bulb damaged tu rn signal bulb...
Page 215 S IG N A L S W IT C H D IA G N O S IS C O N D IT IO N C O R R E C T IO N P O S S IB L E C A U S E Inoperative tu rn Replace tu rn signal T u rn signal lights flash...
Page 216 adjustm ent or disassembly o f the power steering gear or 75 pounds. A belt that has never been tensioned is p u m p is attem pted. considered to be a new belt and should be tightened to 125 pounds. System Checks Place belt tension...
Page 217 CONDITION POSSIBLE CAUSE CORRECTION SYSTEM NOISE There is some noise in all power steering systems. Common complaints are listed as follows: Pump noise-“chirp” . Loose belt. Adjust belt tension to specification. Belt squeal. Loose belt. Adjust belt tension to specification. Gear noise ( “...
Page 218 CONDITION POSSIBLE CAUSE CORRECTION Scored pump pressure plates, thrust Pump growl 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. Swish in pump Defective pump flow control valve Replace valve Whine in pump...
Page 219 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 220 CONDITION POSSIBLE CAUSE CORRECTION Hard Steering or Lubricate, relubricate at proper Lack of lubricant in suspension lack of assist (Continued) or ball joints. intervals. Tires not properly inflated. Inflate to recommended pressure. Steering gear to column misalignment. Align steering column. Steering gear adjusted too tight.
Page 221 CONDITION POSSIBLE CAUSE CORRECTION Loose belt. Adjust tension to specification pressure due to steering 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. Defective hoses or steering gear. Correct as necessary.
Page 222: Power Steering System
Check hose connections - tighten if necessary. Verify exact point o f leakage. HIGH PRESSURE HOSE FROM PUMP Example:Torsion bar, stub shaft and adjuster seals ADDITIONAL HIGH PRESSURE P/S are close together; exact leakage point could be confused. HOSE TO GEAR Example: The point oil drips from is not necessarily C TOOL J-5176 the leakage point - oil overflowing from reservoir for...
Page 223 RESERVOIR DEFECTS RESERVOIR CAP DRIVE SHAFT RETURN HOSE & CLAMPS DEFECT RESERVOIR ADJUSTER PLUG " 0 " RING "O " RING TORSION BAR RING & " 0 " RING STUD/BOLT " 0 " RINGS PRESSURE HOSE PRESSURE & RETURN PORTS STUB SHAFT SEAL SIDE COVER "...
Page 224 Housing or Cover Seepage - Both the power steering pump. It is easier if someone else operates the steering gear and pu m p assemblies are leakage checked before wheel while you search for the seepage. shipment. However, occasionally oil seepage m ay occur Find the exact area of leakage.
Page 227: Maintenance And Adjustments
MAINTENANCE AND ADJUSTMENTS Lubrication Turn the steering wheel gently in one direction until stopped by the gear; then turn back on e-half turn. m anual steering gear is factory-filled with steering gear lubricant. Seasonal change o f this lubricant CAUTION: Do not turn the steering wheel hard should not be perform ed and the housing should not be against the stops when the steering linkage is...
Page 228: Steering G E A R High Point C E N Te Rin
pre lo ad " is obtained (See specifications section). W hen turns or in different directions will disturb the toe- the p rop er preload been obtained, tighten the in setting o f the wheels. adjuster plug locknut to specifications recheck On K series if the gear has been moved off high torque.
Page 229 Fig. 3B-34--Shift Tube A djustm ent-A utom atic Transmission Power Steering G ear Adjustm ent Procedure Fig. 3B-32--Steering Column Lower Bearing Adjustment of the steering g ear in the vehicle is A djustm ent discouraged because o f the difficulty encountered in adjusting the worm thrust bearing preload and the confusing effects of the hydraulic fluid in the gear.
Page 230 Fig. 3B-37- B ottom ing Adjuster Plug Fig. 3B-35--Loosening Lock Nut Fig. 3B-38--M arking Housing Pump Belt Tension Loosen pivot bolt and pum p brace adjusting nuts. Fig. 3B 36 -Removing Lock Nut CAUTION: Do not move pum p by prying with the first mark is in line with second mark (Fig.
Page 231: Bleeding System
Fig. 3B-39-M easure Back and Remark Housing F ig . 3 B - 4 1 --T ig h te n L o c k N u t Fig. 3B-40 -Align Hole W ith Second M ark Tighten p u m p brace adjusting nut. Then tighten pivot bolt nut.
Page 232: System Checks
Raise front end o f vehicle so that wheels are off the ground. Increase engine speed to approximately 1500 HIGH PRESSURE HOSE FROM PUMP rpm. ADDITIONAL HIGH PRESSURE P/S HOSE TO GEAR T urn the wheels (off ground) right and left, TOOL J-5176 lightly contacting the wheel stops.
Page 233: C Om Ponent Replacement And R E P A Ir
Place the steering wheel onto the steering shaft, the valve open and turn (or have turned) the steering aligning the marks made at removal. wheel into both corners. Record the highest pressures an d com pare with the m axim um pum p pressures and Position into place and secure to proper torque com pare with the m axim um p u m p pressure recorded.
Page 234: Interm Ediate Steering Shafts With Pot Joint
N OTE: This is a special bolt and will require a 12 pt. socket or box wrench. Remove the steering g ear to fra m e bolts and lower the steering g ear f a r enough to remove the flexible coupling.
Page 235: Intermediate Steering Shaft With Universal
Place just enough 3 / 8 " flat washers on pin to prevent hearing block from bottom ing when installed. Measure distance from end o f pin to top of bearing with micrometer. Remove bearing and washers and place same bearing and washers on other end o f pin.
Page 236: Steering G E A
outlined in Steps a through d above. Remove and discard the seals. Assembly If the yoke trunnions were removed, reassemble as follows: Place the new trunnion into the lower yoke. Place new seals onto the trunnion and then press the new bushings into the yoke and over the tru nnion hubs far enough to install the snap rings.
Page 237: Pitman Shaft Oil Seal R Eplacem Ent
Install a new side cover gasket onto the gear mark the w orm shaft with the slit in the universal jo int yoke. housing. Install the side cover onto the lash adjuster Install the steering gear to fram e bolts and screw by reaching through the threaded hole in the side torque to specifications.
Page 238 harness cover by pulling toward the lower end o f the column, be careful not to dam age the wires. Remove the three switch m ounting screws and pull the switch straight up, guiding the wiring harness and cover through the column housing (fig. 3B-53). Installation CAUTION: It is extremely important that only the specified screws, holts and nuts be used at...
Page 239: Lock C Ylinder
and un der the m ounting bracket. Then install the cover on the harness. A D A P T E R Install the three m oun ting screws and clip the A N T I-T H E F T R IN G connector to the bracket on the jacket (fig.
Page 240 the lock cylinder assembly, push the ignition key the rest of the way in and rotate the lock cylinder clockwise. Rotate the lock counter-clockwise into "L O C K " position. Place the lock in a brass jawed vise or between two pieces o f wood (fig.
Page 241: Ignition Switch
Reinstall the steering column assembly follow ing the "M an d a to ry Installation Sequence" outlined later in this section. Steering Column All models which are equipped with the Function Locking Energy Absorbing Steering Columns are one of five basic designs. Synchromesh - The synchromesh column is used on models with the standard transmission and...
Page 242 Inspection is called for in all cases where dam age is evident or w henever the vehicle is being repaired due to a front end collision. W henever a force has been exerted steering wheel steering column, components, inspection should also be made. If dam age is evident, the affected parts must be replaced.
Page 243 Remove the two screws holding the back-up Remove the floor pan trim cover screws and remove the cover. switch or neutral-safety switch to the column and remove the switch. Remove the screws securing the two halves of the floor pan cover; then remove the screws securing the Remove the lower bearing retainer clip (fig.
Page 244 DESIGN J INTERMEDIATE ON SOME MODEIS ARE PERMANENUY STAKED ANO MUST BE SERVICED AS AN ASSEMBLY DESIGN 1 BUSHING Key No. Part Name Key No. Part Name Key No. Part Name 1 - C O LUM N ASM 20 - SWITCH ASM 2 - HO USING ASM 21 - PROTECTOR WIRE 3 9 -...
Page 245 SH IF T G A T E R A C K L O C K B O LT L O C K B O LT S P R IN G T H R U S T C U P S E C T O R Fig.
Page 246: Disassembly Tilt C O Lu M
Fig. 3B-71--Removing Lower Bearing Retainer Fig. 3 B -7 3 -In s ta llin g Gearshift Housing Lower Bearing Fig. 3 B -7 2 -In s ta llin g Rack Preload Spring Fig. 3B-74--Adjusting Lower Bearing-Typical Disassembly-Tilt Columns (Fig. 3B-75) cylinder and ignition switch as outlined previously in this section.
Page 247 Ig nition S w itch Rack 5 3 . Ig nition Switch Shaft N u t Lock Bolt Spring Cover Lock Shoes 3 6 . Ig n itio n S w itc h Rod 5 4 . M ast J a c k e t Lack Plate R etaining Ring Sector Shaft Upper Steering Shaft...
Page 248 Fig. 3B-77-R em oving Bearing Housing Pivot Pins Fig. 3B-79--Replacing Lock Bolt Spring...
Page 249: Assembly Tilt C O L U M
sliding it under the jacket opening. Remove the wave washer. All Columns - Remove the shift lever housing from the mast jacket (transmission control lock tube housing on floor shift models). Remove the shift lever spring by winding the spring up with pliers and pulling it out.
Page 250 Install the lock bolt and engage it with the sector cam surface. Then install the rack and spring. The block tooth on the rack should engage the block tooth on the sector (fig. 3B-81). Install the external tilt release RACK lever.
Page 251: Column Installation P S E Rie
the bearing housing over the steering shaft until the pivot pin holes line up. Install the pivot pins. Place the bearing housing in the full " u p " position and install the tilt lever spring guide, spring and CARROT STEERING spring retainer.
Page 252 STEERING COLUMN SERVICE FOR G AND P SERIES S TEERING C O LU M N UPPER BEARING - G AND P SERIES Standard Column Removal Remove steering wheel as outlined this section. Remove directional signal cancelling cam. Pry out upper bearing. Installation CAUTION: See C A U T IO N on page 1 o f this...
Page 253 the cover flange (fig. 3B-87). Turn the tool center screw clockwise to pull the cover from the housing. Remove the three directional signal switch mounting screws and then carefully remove the switch assembly from the column while guiding the wiring harness through the opening in the shift lever housing.
Page 254 approxim ately 3 /1 6 ", rotate clockwise approximately 1/8 Assemble the bearing housing as follows: turn until the retainer ears align with the grooves in the Press the new upper and lower bearing races housing and remove the retainer and spring. into the bearing housing.
Page 255 CLUTCH A N D BRAKE PEDAL SUPPORT PROTR U SIO N EX SLOT V IE W A Fig. 3B-89--Steering Column InstaIlation-G Series Transm ission - Disconnect the conductor tube (for Rotate the directional signal switch housing transmission indicator) at the instrum ent panel. counterclockwise and remove the housing from Tilt...
Page 256 G A & PA 1 0 0 - 1 . U p p e r S te e rin g S h a ft 1 3 . S h ift T u b e F e lt W a s h e r 2 5 .
Page 257 then place the shift lever (or extension) housing onto the Using a suitable size punch, drive out the lock up per end o f the column. shoe retaining pin. Remove the shoes and shoe springs. Install switch housing plastic w asher Remove the steering shaft assembly through the assembly.
Page 258 COVER SHAFT ASSY W ED G E ------RACE INSTRU. PANEL SHAFT O P E N IN G C O V E R - , SCREW (3) SPRING S W ITC H ASSY. JACKET A S S Y .- YOKE SHAFT "...
Page 259 Fig. 3B-92 Securing Column with J-22573 Fig. 3B-94- Removing Bearing Housing Pivot Pin STEERING SHAFT BEARING LO CKNUT J -5 8 2 2 J-2 619 TILT LEVER SPR IN G RETAINER Fig. 3B-93--Removing T ilt Spring and Retainer Fig. 3B-95-R em oving Bearing Race Slide the shift lever housing over the upper end Pull up on the shift lever housing (to compress o f the column.
Page 260 Fig. 3ES-96 -Removing Release Lever Pivot Pin Fig. 3B 98--Revised Shift Tube Removing Tool J-22551 Fig. 3B-97 Removing Shift Tube Retaining Ring...
Page 261: Column Installation G S E Rie
until the shoes have fully engaged the support. Lubricate and install the bearing housing pivot pins. Press the pins in flush with the housing. Place the housing in the full " u p " position and then install tilt spring and retainer (tapered end o f spring first).
Page 262: Steering L In Kage
steering shaft (A). Position the spring and clamp to m aintain the dimension as shown in Figure 3B-38. Install the plastic spacers onto the flexible coupling alignment pins. From inside the vehicle, carefully insert the lower end o f the column through the toe pan opening guiding the steering shaft flange onto the flexible coupling.
Page 263: Relay R O
RELAY ROD IDLER ARM TIE ROD ASSEMBLY ASSEMBLY [A ] iCAUtlORI A ll clam ps must be b e tw e e n & cle a r o f dim ples b e fo re to rq u in g nut. KNUCKLE [~B ~| E xposed socket th re a d le n g th must be...
Page 264 CAUTION:A s a guide to correct orientation o f the inner tie rod end relative to the outer tie rod end, rotate both ends to the extremes o f travel in the same direction before clamping. The position o f each tie rod end m ust be m aintained as the clamps are tightened to ensure free movement o f each joint.
Page 265 in Figure 3B-107. C enter protractor bubble indicator and record reading. Rotate clockwise (down) m axim um position. Center protractor bubble indicator and record reading. Com pare protractor readings obtained Speps c and d. Total rotation of tie rod assembly should measure at least 35 °.
Page 266: Pitman A R
described u nd er "T ie. Rod- Installation". Lubricate the suspecting suspension or steering components, techni tie rod ends. cians should eliminate shim my excitation factors, such as Lower the vehicle to the floor. dynam ic imbalance, run-out or force variation o f wheel and tire assemblies and road surface irregularities.
Page 267: Steering Connecting R O
CAUTION: I f a clamp type p itm a n arm is used, NOTE: For proper alignment and orientation o f spread the pitm an arm ju s t enough, with a connecting rod clamps see figure 3B-109. wedge, to slip arm onto pitm an shaft. Do not POWER S TEERING SYSTEM spread pitm an arm more than required to slip over p itm a n shaft with hand pressure.
Page 268 CAUTION: ENDS OF ADJUSTABLE T I E ROD MUST BE HELD IN CORRECT RELA TIO N SH IP TO EACH OTHER AFTER ADJUSTMENT WITHIN + 2 ° . CAUTION: CLAMPS MUST BE BETWEEN AND CLEAR OF DIM PLES BEFORE TORQUING NUT.
Page 269 2 9 2 2 0 -3 0 1 0 -3 0 2 0 -3 0 P Series Fig. 3B-114--Power Steering Pump C, K Fig. 3B-112--Power Steering Pump 292 L-6 Power Steering Hoses Remove pu m p from attaching parts and remove pu m p from vehicle.
Page 270 3 5 0 V -8 M O T O R H O M E Fig. 3B-115-Power Steering Pump-350 V-8 Motor Fig. 3B-116 -Power Steering Pump-454 V-8 Home N O TE : W hen power steering fuid is added to power steering system, only clean new power steering fluid should be used.
Page 271 o orientate pressure hose when installing, rotate pipe ends to rest against pump support lower. V IE W Speedo cable and parking brake cable to be routed above power steering pipes and m aintain 2 5 0 or 2 9 2 clearance.
Page 272 Speedo cable and To orien ta te pressure parking brake hose when installing, cable to be routed rotate pipe ends to above power rest against steerinq steering pipes and mp housing. m aintain clearance. V IE W Clamp must be instal w ith b o lt head tow ard fro n t of vehicle.
Page 273 V IE W 4 5 4 V -8 C 30 Hose assembly must W /H Y D R A B O O S T be installed against E X C E P T steering gear cover. 4 .5 6 A X L E Fig.
Page 274 SPECIFICATIONS M A N U A L S T E E R IN G G E A R S T E E R IN G G E A R R A T IO S Power Manual Components G 1 0 - 3 0 P20 - 30 C1p i 03°...
Page 275 Special Tools « Shaft Seal Protector 1. J 6632 Pitman Arm Puller 19. J-6222 Belt Tension Gauge 5504 Pitman Arm Puller 20. J-23600 Rack-Piston Seal Compressor ■23073 S hift Tube Installer 21. J-8947 3. J Wormshaft Bearing Race Installer 23072 S hift Tube Remover 22.
Page 276: Special Tools
SPECIAL TOOLS P itm an S h a ft Bearing Rem over J-6632 P itm an A rm P uller J-6278 J-5504 Pitm an A rm P uller J-6278-2 P itm an S h a ft Bearing In sta lle r J-5176 Pressure Gauge J-7079-2...
Page 277: Front Suspension
SECTION 3C FRONT SUSPENSION The following caution applies to one or more steps in the assembly procedure o f components in this portion o f the m anual as indicated at a ppropriate locations by the terminology "See Caution on page 1 o f this section".
Page 278 C-10 C-20-30 G-10-20 G-30 P-10-30 Fig. 3C -l--Front Suspension, C P Series...
Page 279 SHOCK ABSORBER LOWER CONTROL ARMS Fig. 3C-2--Front Suspension G-30-Typical MAINTENANCE AND ADJUSTMENTS CAUTION: See C A U T IO N on page I o f this Spin wheel to check for unusual noise or section regarding the fasteners referred to in roughness.
Page 280 4. H A N D "S N U G -U P 1 THE NUT 5. LOOSEN NUT UNTIL EITHER HOLE IN THE SPINDLE LINES UP WITH A SLOT IN THE N U T -T H E N INSERT COTTER PIN. NOTE: BEND ENDS O F COTTER PIN A G A IN S T NUT, CUT OFF EXTRA LEN G TH T O PREVENT...
Page 281 H A R D S T E E R I N G Probable Cause Probable Remedy Ball joints and steering linkage need lubrication Lubricate ball joints and linkage Low or uneven front tire pressure b. Inflate tires to the proper recommended pressure Power steering partially or not operative c.
Page 282 NOISE IN F R O N T END Probable Remedy Probable Cause Lubricate at recommended intervals Ball joints and steering linkage need lubrication b. Tighten bolts and/or replace bushings b. Shock absorber loose or bushings worn Worn control arm bushings Replace bushings d.
Page 283 "D O G ' T R A C K IN G Probable Cause Probable Remedy LEAF TYPE REAR SPRING Rear leaf spring broken Replace spring Bent rear axle housing b. Replace housing Frame or underbody out of alignment Align frame COIL TYPE REAR SPRING Damaged rear suspension arm and/or worn bushings Replace suspension arm and/or bushings...
Page 284 BALL JO IN T D IAG NO STIC PROCEDURE...
Page 285 problem still exists (poor handling, bottoming, noise, • shocks m ay have glossy paint on them. Do ride sway, etc.), proceed. not confuse this paint with a leak condition. • a slight trace o f shock fluid around the seal Inspecting and Testing the Shocks cover area is cause for replacement.
Page 286 TYPICAL FRONT SHOCK TYPICAL REAR SHOCK BOTTOM D UST T U B E O T B O TTO M ' M O U N T \ M O U N T ROD EXTENDED (REBOUND) x S HO CK -« S HO CK ROD EXTENDED COLLAPSED COLLAPSED...
Page 287 stroked, a lag is noticed, it means the gas-filled cell has help diagnose the cause o f distress and comments are been ruptured, and the shock should be replaced. If no provided to help make elfective repairs. lag is noticed, the re m ain der o f the bench check is the Consider The Following Factors When same as given in the Spiral Groove Reservoir, Section 1, Bench Check Procedure.
Page 288 BEARINGS AND RACES F R O N T W HEEL, P IN IO N , DIFFER ENTIA L SIDE A N D REAR W HEEL ROLLER B E A R IN G S DIAGNOSIS EXCESS NOISE C O M P L A IN T D IA G N O S T IC PRO CEDURE Check tires for irregular wear Check tire pressure...
Page 289 FRONT WHEEL BEARING DIAGNOSIS 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 E N 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 O F A L L P A R TS D U R IN G D IS A S S E M B L Y A N D IN SPEC TIO N .
Page 290 FRONT WHEEL BEARING DIA G N O SIS (C O N T’D) C R A C K E D I N N E R RACE 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 C R A C K E D D U E T O IM P R O PER F IT , F L A K IN G OF S U R FA C E M E T A L R E S U L T IN G FROM...
Page 291 COMPONENT PARTS REPLACEMENT CAUTION: Use care when installing new race W HEEL HUBS, BEA R IN G S (Fig. 3 C -1 4) to start it squarely into hub, to avoid distortion Removal C, G and P Series a n d possible cracking. Raise vehicle on hoist and remove wheel and Thoroughly lubricate bearing assemblies with new tire assembly.
Page 292 bushings. If defective, replace shock absorber assembly. Installation Place shock absorber into position over m ounting bolts or into mounting brackets. Install eye bolts and nuts and torque as shown in Specifications Section. Lower vehicle to floor. S TA B IL IZE R BAR Removal (Fig.
Page 293 Torque nut to specifications. Remove the shaft end nuts and remove shaft from arm. Install shock absorber to lower control arm and install stabilizer bar. Bushing Replacement (Steel Bushings) Remove tool J-23028 and safety chain. Remove grease fittings from bushing outer ends and unscrew bushings from control arm and shaft.
Page 294 Slide new seal on each end of shaft and insert sh aft into control arm. S tart new bushings on shaft and into control arm. Adjust shaft until it is centered in control arm. then 3C-21. Remove the nut from the ball stud and raise turn bushings in and torque to specifications.
Page 295 Place control arm in position on bracket and Upper Control Arm Inner Pivot Shaft a n d / install nuts. Before tightening nuts, insert caster and or Bushing R eplacem ent cam ber shims in the same order as w hen removed. Torque the nuts to specifications.
Page 296 Raise vehicle on hoist and support the fram e so that the control arm s hang free. Position an adjustable floor jack u nd e r the lower control arm inbo ard of spring and into depression of control arm. Install a chain over the upper arm inboard of the stabilizer and outboard o f shock absorber as a safety measure.
Page 297 CAUTION: Be sure spacer J -24435-6 is in Remove cotter pin from upper ball stud and position as shown in Figure 3C-26 to avoid loosen stud nut (two turns) but do not remove nut. collapsing control arm during assembly. Install J-23742 between the ball studs as shown in Figure 3C-27.
Page 298 C U T T O O L O N FIT PIPE O N T O O L D O T T E D LINE J - 9 5 1 9 - 1 0 3 " W A T E R 2 5 /e "...
Page 299 notch to insert cotter pins. Do not loosen nut to insert cotter pin. Refer to Ball Joint text fo r proper nut installation sequence. Reverse rem aining removal procedure, tighten splash shield m ounting bolt. Tighten two caliper assembly m ounting bolts to 35 ft. lb. torque. Adjust wheel bearings as outlined u nder Front W heel Bearing Adjustment.
Page 300 Remove bolts securing crossm em ber to fram e Install the shock absorber. bottom rail an d lower the assembly from vehicle. Install brake support struts previously Installation removed. Connect front brake m ain feeder line and bleed CAUTION: See C A U T IO N on page I o f this brakes as described in Section 5.
Page 301 H U B CAP O U T E R -W H E E L B E A R IN G D E F L E C T O R S N A P R IN G IN N E R -W H E E L B E A R IN G A X L E O U T E R S H A F T H U B D R IV E G E A R S P IN D L E...
Page 302 R E T A IN IN G P L A T E LO C K N U T O IL S E A L " 0 " R IN G L O C K -A D J . N U T SPACER P IN -A D J .
Page 303: Maintenance And Adjustments
H U B C A P S P IN D L E B E A R IN G LO W ER B E A R IN G S N A P R IN G S E A L S E A L H U B D R IV E G E A R D E F L E C T O R B E A R IN G CAP...
Page 304: Bearing Lubrication
Fig. 3 C -4K -D ete rm inin g Front Axle Ball Joint A djustm ent Torque the inner adjusting nut to 50 foot If the effort exceeds 25 lbs., remove the upper pounds, while rotating the hub-and-disc to seat the ball stud nut, and loosen the ball stud adjusting sleeve as bearings.
Page 305: Component Replacement
COMPONENT REPLACEMENT HUB REPLACEMENT Remove the inner and outer bearing cups using a brass drift an d hammer. CAUTION: See CAUTION on page 1 o f this Clean, inspect lubricate all parts section regarding the fasteners in the following required. procedures fo r hub replacement.
Page 306 into axle shaft sleeve and clutch ring assembly and Install new grease seal into inboard end of install as an assembly onto the axle shaft. Press in on hub. Use J-24428 for K30. assembly and install axle shaft snap ring. A fter lubricating the wheel bearings, install the hub-and-disc and the bearings to the spindle.
Page 307 Servicing Spindle Components Secure the spindle in a vise by locating on the high step diameter. Be sure that the machined surface o f the spindle will not be dam aged by the vise jaws. Remove the oil seal. Remove the needle roller bearing. Place the spindle in a vise on the high step and install needle roller bearing.
Page 308 J-23454-1 FLAT WASHER (HIDDEN) J-951 9 -1 0 Fig. 3 C -12 K -In sta llin g Lower Ball Joint Fig. 3C-10K--Removing Lower Ball Joint cotter pin hole in the stud end) is straight. Press the stud threads in the yoke can he easily dam aged by into the knuckle until properly seated using tools J-9519- the hardened threads in the adjusting sleeve i f 10.
Page 309 J - 2 3 4 4 7 Fig. 3C-16K--Knuckle w ith King Pins Fig. 3C-14K--Ball Stud A d ju stin g Sleeve as shown in Figure 3C-15K. A fter torquing the nut, do not loosen to install cotter pin, apply additional torque, if necessary, to line up hole in stud with slot in nut.
Page 310 Fig. 3C-19K-Rem oving Cap, Spring and Gasket Fig. 3C-21K--Removing Tapered Bushing axle shaft jo in t assembly and bearing. If w ear is evident, replace with a new one. See Figure 3C-17K. Remove four nuts from upper king pin cap. Remove nuts alternately as compression spring will force cap up.
Page 311 Fig. 3C-24K- In sta llin g Grease Retainer Fig. 3C -26K --lnstalling Upper King-Pin grease retainer, and seal all at the same time, as shown in Figure 3C-23K. Discard seal and replace with new one at time of assembly. If' grease retainer is dam aged, new lower king pin b earing oil seal, using J-22281, as replace with new one at time o f assembly.
Page 312: Shock A B S O R B E
Fig. 3C-28K --lnstalling Lower Bearing Cap-and-King Pin Fig. 3C-30K--Shock Absorber A tta ch m en t Assemble lower bearing cap-and-king pin with bolts or into m ounting brackets. Install eye bolts and four cap screws. Tighten cap screws alternately and nuts and torque as shown in Specifications Section.
Page 313 Remove front spring eye bolt. Remove spring-to-axle u-bolt nuts a n d remove spring, lower plate and spring pads. Remove shackle to spring bolt an d remove bushings and shackle. Bushing R eplacem ent Place spring on press and press out bushing using a suitable rod, pipe, or tool.
Page 314 SPECIFICATIONS F R O N T S U S P E N S IO N B O L T T O R Q U E (F t. Lbs.) $ G-30 CP-20-30 K-AII CP-10 G-10-20 L o w e r C o n tro l Arm S h a ft U -Bolt U pper C o n tro l A rm S h a ft N uts C o n tro l A rm R u b b er Bushings w /Spacer 190...
Page 315 SPECIAL TOOLS J-8457 Bearing Race Installer J-8092 D river Handle J-8458 Bearing Race Installer J-9519-9 Ball J o in t Installer J-8849 Bearing Race Installer J-9519-7 Ball J o in t Remover J-9276-2 Bearing Race Installer J -9519-10 " C " C lam p J-24435-1 Bushing Replacem ent Spring Remover...
Page 317 SECTION 3D REAR SUSPENSION The following caution applies to one or more steps in the assembly procedure o f components in this portion of the m anual as indicated at the a pp ro pria te locations by the terminology "See Caution on page l of this Section".
Page 318 Fig. 3D -2-T ypical G-Truck Rear Suspension Fig. 3D -3-T ypical P-30 H.D. Truck Rear Suspension COMPONENT PARTS REPLACEMENT SHO CK ABSORBERS shock absorber by removing nut and washers shown, and bolt on G-models. Replacement At the lower mounting location, remove nut, Refer to Figs.
Page 319 Fig. 3D-6 -Shock Absorber-G-10, 20, 30 Fig. 3D-8--Shock Absorber-P30 Lower vehicle and remove from hoist. Align lower end o f shock absorber with axle bracket, and install bolt, washers and nut, as shown. S TA B ILIZE R SHAFTS Tighten nuts to specifications. Refer to Fig.
Page 320 Fig. 3D-10~Rear Stabilizer Shaft-C-20(43), C-30 Remove nut, washer and grom m et from link bolt at the fram e side m e m b e r on each side. W ith draw link bolt, washers, grommets and spacer. R em ove brackets from a n c h o r...
Page 321 Fig. 3D-12 -Rear Spring Installation-G Models...
Page 323 Spring Leaf Replacement NOTE: Make certain that the bolts are free- turning in their bushings prior to torquing. Place spring assembly in a bench mounted vise Lower vehicle so that weight o f vehicle is on and remove spring clips. suspension components torque...
Page 324: Leaf Spring
SPECIFICATIONS TORQUE SPECIFICATIONS ( i l l ) Spring-to-Axle “ U ” Bolt Nuts G 2 0 170 (E xc. w /3 /4 ” Bolt) G 3 0 2 0 0 (W /3 /4 ” Bolt) Leaf Spring —Front Bushing Bolt 9 0 /1 3 5 * (G 3 1 6 ..
Page 327 SECTION 3E WHEELS AND TIRES INDEX G eneral D escription 3E-1 M a in te n a n c e 3E-2 W heel R eplacem ent C onsideration 3E-2 W heel N u t T o rq u e s 3E-2 T ire Inspection and R o ta tio n 3E-2...
Page 328 OUTER W HEEL W HEEL FRONT FRONT & REAR DUAL REAR W/SINGLE REAR W /D U A L REAR Fig. 1--Wheel A ttachm ents Fig. 2 -T ire Rotation MAINTENANCE W HEEL R E P LA C E M E N T C O N S ID E R A T IO N S WHEEL N U T TORQUES On a new vehicle or after the wheel has been Wheels must be replaced if bent, heavily rusted,...
Page 329 DUAL WHEEL T Y P I C A L W H E E L M A X I M U M L O A D / M A X I M U M / P R E S S U R E S T A M P R I M S I Z E : D I A .
Page 330 TIRE/WHEEL LOAD & INFLATION PRESSURE PASSENGER TYPE TIRES FOR LIGHT TRUCKS USED IN HIGHWAY SERVICE W heel Code T ire Load _____________ T ire Load L im its a t Various In fla tio n Pressures Size Range R egular R ally /S p o k e X U , X H , D T E 7 8 - 1 5...
Page 331 TIRE/WHEEL LOAD & INFLATION PRESSURE TIRES FOR LIGHT TRUCKS USED IN HIGHWAY SERVICE (Cont’d) TIRES USED AS DUALS W heel Code T ire Load Lim its at Various Inflation Pressures Ti re Load Size Range Regular Rally TUBE TYPE TIRES MOUNTED ON 5° TAPERED BEAD SEAT RIMS 6 .5 0 -1 6 1 1 2 0 1 2 2 5...
Page 332 Be sure to re-install the tire inflation valve W H E E L C O D E A N D L IM IT S caps, if so equipped, to prevent dirt and m ois ture from entering the valve core which could WHE EL LIM ITS cause air leakage.
Page 333 one will be affected. The scraping action against the face included in the balancing procedure and thereby have o f the tire causes a small feather edge of rubber to any existing unbalance corrected. ap p e a r on one side of the tread and this feather edge is Truck Wheel Balance Weights certain indication...
Page 334 housing; to raise fron t wheel o f C, G, P models, place tire beads and also the the rim side o f the tube. Do not jack under lower control arm pivot; to raise front wheel allow soap solution to run down into tire. of K models, place jack under front axle near spring W hen m ounting tire and tube on a drop center seat.
Page 335 smooth. Then place rim on floor with wide side down insert second tire iron and lubricate last 6 " o f bead before completing. ond lubricate first bead o f tire and upper bead seat of Check valve to be certain that hex nut at the rim.
Page 337 SECTION 4A PROPSHAFT The following caution applies to one or more steps in the assembly procedure o f components in this portion o f the m anual as indicated at appropriate locations by the terminology "See Caution on page l of this Section".
Page 338 Fig. 4A-2--Universal Joints Arranged for Constant Velocity of various loadings rear axle windup, during acceleration. W ithin the design angle variations the universal joints will operate safely efficiently. However, when the design angles are exceeded operational life o f the joints m ay decrease. Fig.
Page 339 PROPELLER SHAFT AND UNIVERSAL JOINT DIAGNOSIS Checking and Correcting ments for m ud undercoating o r other discrepancies. Make necessary corrections prior to running. Propeller Shaft Unbalance With vehicle running in gear at the indicated speed where disturbance is at its peak, observe the Place vehicle on a twin post hoist so that the intensity of the disturbance.
Page 340 C O M P L A IN T P O S S IB L E C A U S E C O R R E C T IO N Roughness, Vibration or a. . Bent or dented drive shaft. a. Replace. Body Boom at any speed.
Page 341 UNIT REPAIR N OTE: F or models using strap U-bolt PROPELLER SHAFT attachm ents to transmission or transfer case use Two methods are used to retain the propeller shaft same removal procedure as above. to the dilferential pinion flange. One method utilizes "...
Page 342 4 . W a s h e r 1. T r u n n io n 5 . C a p 2 . S e a l 6 . S n a p R in g B e a rin g s Fig.
Page 343 and bearing cup being removed, as shown in figure 4A- Complete the removal of the bearing cup, pressing it out o f the yoke. ROLLER B EA R IN G S Rotate the drive shaft, shear the opposite plastic B E A R IN G RETAINER retainer, and press the opposite bearing cup out o f the yoke as before, using Spacer J-9522.
Page 344 Assemble bearing support as follows: Install inner deflector on propeller shaft, if removed, and prick punch deflector at two opposite points to make sure it is tight on shaft. Fill space between in ner dust shield and bearing with lithium soap grease. Start bearing and slinger assembly straight on shaft journal.
Page 345 Fig. 4A -1 8 -Propeller Shaft, Universal Joint and Bearing Support Once the bearing cup protrudes 3 /8 " , release A L IG N M E N T vice. G rasp protruding portion o f cup in vice and strike center yoke as shown in Figure 4A-22 until cup is removed.
Page 346 REAR PROP SHAFT HORIZONTAL HANGER WITH SLOTTED HOLES FRONT PROP SHAFT FRONT YOKE OF REAR PROP SHAFT VERTICAL After assembly to hanger, front face of Bearing Support Asm must be perpendicular to Center- Line of Prop Shaft as shown. PROP SHAFT SPLINE SETTING K300(00) WITH 2 PIECE PROP SHAFT 2-Piece prop shaft must be assembled as follows to prevent...
Page 347 in front yoke (28 total). Retain bearings with a heavy grease. Assemble seals to bearing cups. Place front trunnion in drive shaft. Place center yoke on front trunnion. Install one bearing cup and seal assembly in front yoke. Drive in to a depth that the snap ring can be installed.
Page 348 Fig. 4A -28--lnstalling Tool J-23996 Over Ball Fig. 4A-26--Cross Sectional View of CV Joint Fig. 4 A 29 -Installing Outer Cylinder of Tool J-23996 Over Ball Fig. 4A-27--Exploded View of Centering Ball determ ined by the ball seating tightly in the proper M echanism location.
Page 349 Fig. 4A 30 Removing C entering Ball Fig. 4A-32 In sta llin g Centering Ball Seal Fig. 4 A -3 1 -In s ta llin g C entering Ball Fig. 4A-33-Reassem bling Flange Yoke LU B R IC A T IO N at the fitting until grease begins to leave through the vent hole.
Page 350 Slip Yoke Lubrication truck, remove the slip yoke, and wire brush the affected areas. W ipe clean before reinstallation. W hen installing the propshaft to transfer case front output flange attaching bolts, torque to specification (70-80 ft. lbs.).
Page 351: Specifications
SPECIFICATIONS PROPELLER SHAFT P ro p e lle r S h a ft 1 2 -1 7 1 2 -1 7 To Rear A x le (S tra p ) 1 2 -1 7 — 1 8 -2 2 1 8 -2 2 To R ear A x le ("...
Page 353: Rear Axle
On-Vehicle Service................4 B -13 8 -1 /2 " and 8 -7 /8 " Ring G e a r ..........4B-13 Chevrolet 10-1/2" Ring G e a r ........... 4B-18 D a n a 10-1/2" Ring G e a r ............4B-21 D an a 9 -3 /4 "R in g G e a r ...............
Page 354 Six distinct axles compromise the truck line-up. as an inner race. These six, categorized by ring gear diameter, are a) 8-1/ 2" and b) 8 -7 /8 " Ring G ear, c) Chevrolet 10-1/2" Ring Side bearing preload ring gear-to-pinion G ear, d) D a n a 10-1/2"...
Page 355 C o m p a n io n F la n g e D if f e r e n t ia l Case 13. C o v e r T h ru st W a sh e r D e fle c to r Shim D if f e r e n t ia l P in io n P in io n S h a ft...
Page 356 19. Reta in er Screw 10. S trad dle Bearing 1. C o m p a n io n Flange 20. Bearing Cap 11. Ring Gear 2. Oil D e fle c t o r 21. Case-to Ring Gear B o lt 12.
Page 357 P in io n N u t P in io n R ear B e aring D iffe r e n tia l S p id e r W asher D riv e P in io n D iffe r e n tia l S id e G ear C o m p a n io n Flange R in g G ear W asher...
Page 358 B o lt (Differential Shims (Inner Pinion Cover and Plug Bearing) Bearing Cap) Washer Lock Pin (Pinion Bolt (Ring Gear) Companion Flange Cup (Inner Pinion Shaft) Pinion Shaft Pinion Oil Seal Bearing) D ifferential Case Shims (D ifferential 27. Thrust Washer Gasket Cone and Roller Adjusting)
Page 359 R e ar P in io n B e a rin g H a lf Fig. 4B-8 Chevrolet 1 2 -1 /4 " Ring Gear Axle—1 1 ,0 0 0 # Capacity DIFFERENTIAL DIAGNOSIS S T A N D A R D DIFFERENTIAL but, locating and isolating axle noise can be an entirely different matter.
Page 360 having surfaces on non-skid divisions worn in saw-tooth must expected cann ot eliminated fashion, are usually noisy and m ay produce vibrations conventional repairs or adjustment. See figure 4B-9. which seem to originate elsewhere in the vehicle. This is Acceptable noise can be defined as a slight noise particularly true with low tire pressure.
Page 361 that noise is caused by rear axle assembly. The rear axle should be tested on a smooth level road to avoid road noise. It is not advisable to test rear axle for noise by r u n n in g with rear wheels jacked up. Noises in rear axle assembly may be caused by a faulty propeller shaft, faulty rear wheel bearings, faulty differential...
Page 362 A GENERAL DIAGNOSTIC PROCEDURE FOR IS OLATIN G REAR A XLE NOISE PROBLEMS Problem Cause Noise is the same in drive or coast 1. a) Road noise Tire noise Front wheel bearing noise Noise changes on a different type of road 2.
Page 363 DIFFERENTIAL A N D REAR AXLE BEARING DIAGNOSIS CO NSIDER THE FO LLOW IN G FACTORS W HEN DIA G N O SIN G BEAR IN G C O N D IT IO N : 1. G ENERA L C O N D IT IO N OF A L L PARTS D U R IN G DISASSEM BLY A N D INSPECTION. 2.
Page 364 DIFFERENTIAL A N D REAR AXLE BEARING DIAGNOSIS (C O N T ’D) C R A C K E D I N N E R RACE F A T I G U E S P A L L I B R I N E L L I N G R ACE C R A C K E D D U E TO IM P R 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 FRO 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 A U S E D BY...
Page 365 ON-VEHICLE SERVICE suspension com ponents and torque affected parts to 8 - 1 / 2 and 8 - 7 / 8 RING specifications. GEAR AXLE Lower vehicle and remove from hoist. AXLE ASSEMBLY AXLE SHAFT Construction o f the axle assembly is such that Removal service operations may be p erform ed with the housing installed in the vehicle or with the housing installed in a...
Page 366 Fig. 4B -15-R em oving Lock Screw Fig. 4B 17--Correct C-Lock Position Fig. 4 B -1 6 -P osition in g Case For Best Clearance Do not force or hammer the axle shaft in an Fig. 4B-18--Push Axle Shaft Inward attem pt to gain clearance.
Page 367 Fig. 4B-21-W heel Bearing Installation Fig. 4B-20- Wheel Bearing Removal Fig. 4B-22-S eal Installation See figure 4B-22. This tool installs the seal flush with the shaft do not damage oil seal and that they end of the tube. engage with splines o f differential side gear. Install axle sh aft "...
Page 368 Lower vehicle and remove from hoist. Wheel Bolt—Replacement Raise vehicle on hoist allowing axle to hang freely. Remove wheel and tire an d brake drum. Using Tool J-5504 or J-6627 press out stud as shown in figure 4B-23. Place new stud in axle flange hole. Slightly start stud serrations in hole by firmly pressing back o f stud with your hand.
Page 369 J-22804-l J-21057 Fig. 4B-26~Rem oving Nut from Drive Pinion Fig. 4B-28--Pinion Oil Seal Installation Using J-8614-11 as shown in figure 4B-29. install flange onto pinion. Install washer and nut, and tighten nut to original position. Refer to scribe marks and num ber o f exposed threads, recorded earlier.
Page 370 CHEVROLET 10-1/2 RING GEAR AXLE SHAFT AXLES Replacement Remove bolts that attach the axle shaft flange to AXLE ASSEMBLY the wheel hub. See figure 4B-30. Rap on flange with a soft-faced h a m m e r to Service operations on these axle assemblies may be loosen shaft.
Page 371 REAR AXLE 4 B -19 Fig. 4B 3 3 - Removing Outer Bearing and Cup Inspection and Cleaning o f Bearings Inspect bearing rollers excessive wear, chipped edges, and other damage. Slowly move rollers around cone to detect any flat or rough spots on rollers or cone.
Page 372 Drive cup back against snap ring by using Make sure inner bearing, oil seal, axle housing J-24426, as shown in figure 4B-33. oil deflector, and in n er bearing race and oil seal are To install inner bearing cup, use J-24427 on properly positioned.
Page 373 Removal identical to the procedure given earlier for "Chevrolet Use the procedure given for "Chevrolet 10-1/2" 10-1/2" Ring G e a r Axle". Ring G e a r Axle", and use J-0870 to remove the adjusting nut.
Page 374 The drum is held to the hub by countersunk, slotted screws, which are easily removed with a screw driver. WHEEL BOLT REPLACEM ENT Refer to figure 4B-34 and to procedure listed under "Chevrolet 10-1/2" Ring G e a r Axle..
Page 375 Fig. 4B-41 Pinion Oil Seal—1 2 -1 /4 " Axle Fig. 4B 4 0 --ln sta llin g Hub Oil Seal sam e time rotating hub to m ake sure all bearing surfaces IN S TA LLA TIO N OF HUB AND DRUM are in contact.
Page 376 SPECIFICATIONS DIFFERENTIAL S P E C IF IC A TIO N S □ > i £ >• > — o> — BOLT TO R Q U ES (F T .-L B S .)A G e a r Backlash .0 0 5 " - .0 0 4 "...
Page 377 SPECIAL TOOLS £ i ^ n A U — ‘“ i r * 5 t y g j v . J ll 87 / a" G. A X L E O N L Y « « ■ IO '/ " R .G . AXLE O N L Y J- 21 5 48 T ru n n io n Seal In sta ller 16.
Page 379: Front Wheel Drive
SECTION 4C FRONT WHEEL DRIVE The following caution applies to one or more steps in the assembly procedure o f components in this portion of the m anual as indicated at a ppropriate locations by the terminology "See Caution on page 1 o f this Section".
Page 380 DIAGNOSIS BEARINGS AND RACES F R O N T W HEEL, P IN IO N , DIFFERENTIAL SIDE A N D REAR W HEEL ROLLER B E A R IN G S DIAGNOSIS EXCESS NOISE C O M P L A IN T D IA G N O S T IC PRO CEDURE Check tires for irregular wear Check tire pressure...
Page 381 FRONT WHEEL BEARING DIAGNOSIS CONSIDER THE FOLLOWING FACTORS WHEN DIAGNOSING BEARING CO NDITION 1. GENERAL CO N D ITIO N OF ALL PARTS D U R IN G DISASSEMBLY AND INSPECTION CLASSIFY THE FAILU R E W ITH THE A ID OF THE ILLUSTRATIONS DETERM INE THE CAUSE MAKE ALL REPAIRS FOLLOW ING RECOMMENDED PROCEDURES M il *...
Page 382 FRONT W HEEL BEA RIN G D IA G N O S IS (C O N T’D) Hll A C R A C K E D I N N E R RACE F AT I GUE S P A L L I N G BRI NELLI NG RACE CRAC K ED DUE TO IMPROPER F IT , F L A K IN G OF SURFACE M E TA L R ESU LTIN G FROM...
Page 383 Fig. 4C -4-F ront Drive Axle Typical F R O N T AXLE ASSEMBLY (Refer to Fig. 4C- Installation See C A U T IO N on page I o f this CAUTION: section regarding the fasteners referred to in Removal steps 3, 5, 6 and 8.
Page 384 If the vehicle is not equipped with RPO F76 freewheeling hubs, remove the hub cap and snap ring. Remove the drive gear and pressure spring. Place a hand over the drive gear and use a screwdriver to pry the gear out. Remove the wheel bearing outer lock nut, lock ring, and wheel bearing inner adjusting as outlined in Section 3B.
Page 385 SECTION 5 BRAKES The following w arning and caution notes apply to one or more steps in the assembly procedure o f components in this portion o f the m anual as indicated at appropriate locations by the terminology "See W a r n in g / Caution on page l o f this section".
Page 386 if a failure should occur, and turns " o n " a red light in brake travel and then, w hen failed ch am b er is bottomed, the dash to w arn the operator of the failure. the pedal will harden. If a vehicle displays these symptoms, it is a good DISC BRAKES FRO NT indication that one o f the systems contains air or has...
Page 387 C O N D IT IO N POSSIBLE CAUSE CO R R E C TIO N Pulls 1. Incorrect tire pressures. 1. In fla te evenly on both sides to the recom m ended pressures. 2. Front e n d out o f lin e . 2.
Page 388 C O N D IT IO N POSSIBLE CAUSE CO R R E C TIO N B rake roughness o r c h a tte r 5. Shoe reversed (steel 5 . R eplace shoe a n d lin in g a n d (P e d a l Pulsates) —...
Page 389 C O N D IT IO N POSSIBLE CAUSE C O R R E C TIO N 3 . Incorrect p a rk in g b ra k e 3 . Check a n d re a d ju s t to D ra g g in g Brakes (A very lig h t d ra y is a d ju s tm e n t on re a r b rakes.
Page 390 s, \ • % \ tfc \ \ ■ y \ L e a k in g B ra ke L in e o r C o n n e c tio n L e a kin g W h e el C y lin d e r o r P is to n Seal L e a kin g M a s te r C y lin d e r A ir In B ra ke S ystem...
Page 391 DIAGNOSIS - HYDRO - BOOST SYSTEM N O TE: B efore checking the hydraulic p o w e r booster for the source o f trouble, refer to the trouble diagnosis procedures fo r S tandard Brakes. A fte r these possible causes have been elim inated, ch eck fo r the probable cause a nd rem edy as o u tlin ed below: Norm al O p erating Characteristics Brake pedal application o f the H ydro-boost system...
Page 392 DIAGNOSIS - HYDRO - BOOST SYSTEM SLO W BRAKE PEDAL RETURN R e m ed y P ro b a b le C ause E x c e s s i v e s e a l f r i c t i o n i n b o o s t e r .
Page 393 DIAGNOSIS - HYDRO-BOOST SYSTEM POWER STEERING PUMP NOISE O N BRAKE APPLY R e m e d y P ro b a b le C ause F l u i d l e v e l d e c r e a s e s a p p r o x i m a t e l y I n s u f f i c i e n t f l u i d i n pump r e s e r v o i r .
Page 394 ON-VEHICLE SERVICE PEDAL TRAVEL Open the bleeder valve and fully depress the brake pedal. At reasonably frequent intervals, the brakes should Close bleeder valve and release brake pedal. be inspected for pedal travel, which is the distance the Repeat steps 3 and 4 until all air is evacuated. pedal moves toward the floor from a fully-released position.
Page 398 inspection. If any o f the above conditions are observed on the brake hose, it will be necessary to replace it. Front Brake Hose R em o val (fig s . 5 -2 th ru 5 -4 ) Raise vehicle on hoist. Clean dirt and foreign material from both hose end fittings.
Page 399 female fitting will fit bracket in only 1 position (except G Remove nuts from the engine com partm ent on models), 2 positions (G models). W ithout twisting hose, C, K and G models or bolts from m ounting bracket on P position female end in bracket.

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