Chevrolet Light Duty Truck 1978 Service Manual

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Summary of Contents for Chevrolet Light Duty Truck 1978

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Page 2 Chevrolet Light Duty Trucks. Procedures involv ing disassembly and assembly of major components for these vehi cles are contained in the 1978 Chevrolet Passenger Car and Light Duty Truck Overhaul Manual. Wiring diagrams for 1978 trucks are contained in a separate W iring Diagram Booklet.
Page 3: Heater 1A
SECTION NAME GENERAL INFORMATION LUBRICATION 1978 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 C A U TIO N FOUR WHEEL DRIVE This vehicle contains some parts dimensioned in the metric system as well as in the customary system.
Page 4 ■ . ■ ' • v- • • . — _ _ — , ___...
Page 5 GENERAL IN FO R M A T IO N CONTENTS OF THIS SECTION Axles Truck Model Identification.......... 0-1 Chevrolet Built Vehicle Identification Number and Rating Plate..0-1 • On 10 Series, the Code is stamped on Front of Right Engine Number............0-1 Rear Axle Tube.
Page 6 TRUCK MODEL IDENTIFICATION 0703 + E63+LG9 1. C = Chevrolet; T = GMC Truck 2. Chassis Type_________________ 3. GVW Range_________________ 4. CA Dimension/Model Type. 5. Cab or Body Style_______ 6. Body Ordering Code_____ 7. Engine Ordering Code_ _ _ ©...
Page 7 towing the steering must be locked, transmission in neutral MFD. BY GENERAL MOTORS CORPORATION and parking brake released. Attachments must be made to G VW RI main structural members of the vehicle. Do not attach to GAWR FRONT I GAWR REAR 1 bumpers or associated brackets.
Page 8 Serial No. Body Type or Model Plant Division Code Engine Series Model Designator Year Code C-Chevrolet Chassis Code G.V.W. Class = GMC Type Truck ENGINE CODE CHASSIS TYPE Light Duty C o n v e n tio n a l Cab...
Page 9 I M P O R T A N T : R E T A IN TH IS P L A T E A S A P E R M A N E N T R E C O R D Fig.
Page 10 LOADED— M A X IM U M GVWR: 6200-LBS. FRONT G A W R : 32 5 0 LBS. REAR G A W R : 35 82 LBS. * R e a r C u r b 1 5 4 9 lbs. ^Front C ur b 2261 lbs.
Page 11 S E C T IO N LUBRICATION IN D E X Maintenance Schedule..........OB-1 ..OB-4 Engine............... OB-1 Propeller Shaft Slip Joints........OB-4 Oil and Filter Recommendations......OB-1 Universal Joints............OB-4 Drive B elts............. OB-3 Wheel Bearings.............
Page 12 °F - 2 0 1 0 0 °C - 3 0 - 2 0 - 1 0 T e m p e r a tu r e R a n g e A n tic ip a te d B e fo re N e x t O il C h a n g e Fig.
Page 13 To check the level, remove the oil gauge rod (dipstick), wipe it clean and reinsert it firmly for an accurate reading. The oil gauge rod is marked "FULL" and "ADD". The oil level should be maintained in the safety margin, neither going above the "FULL"...
Page 14 low reading is normal since the level will rise as the fluid 3-AND 4-SPEED M A N U A L TR A N M ISS IO N temperature increases. A level change of over 3/4 inch will Lubricant occur as fluid temperature rises from 60°F to 180°F (16°C Every 12 months or 7,500 miles (12 000 km) on Light to 82°C).
Page 15 (9 600 km) on Diesel and 6,000 miles (9 600 km) or 4 months on Heavy Duty Emission vehicles with water resistant EP chassis lubricant which meets General Motors Specification GM 6 0 3 1-M. More frequent lubes may be required on heavy duty or "Off the Road"...
Page 16 Easy access to the working parts may be made by removing HOOD LATCH AND HOOD HINGE the trim. Door weatherstrips and rubber hood bumpers Every 7,500 miles (12 000 km) or 12 months (6,000 should be lightly coated with a rubber lubricant. miles (9 600 km) or 4 months on Heavy Duty Emission vehicles), whichever occurs first, lubricate hood latch assembly and hood hinge assembly as follows:...
Page 17 COMPLETE VEHICLE MAINTENANCE SCHEDULE I Light Duty Emission System t h i s M a in te n a n c e S chedule is a p p lic ab le to all engines which do not c ontain the letter " I T in the engine id en tification code (w hich begins with the numeral "S ”...
Page 18 Check fo r seal leakage m ediately. A lo w flu id level in th e brake m aster A-9 MANUAL STEERING GEAR— cylin d e r reservoir(s) c o u ld also be an in d ic a to r a ro u n d the p itm a n s h a ft and h o u sin g.
Page 19 (k) DEFROSTER — Check p e rfo rm a n ce b y m o v in g cracked and th a t w h e e l nuts have been tig h te n e d c o n tro ls to " D e f" and n o tin g a m o u n t o f air to the to rq u e v a lu e sh o w n in th e O w n e r's and s w itc h im m e d ia te ly if e n g in e sh o u ld start.
Page 20 w ith p lain water. P a rticu la r a tte n tio n s h o u ld be C-9 SPARK PLUG WIRES — Clean e x te rio r o f w ire s ; re o f a ss is ta n c e in d e te rm in in g th e p ro p e r re g ive n to cle a n in g o u t th o s e areas w h e re m ud p la c e m e n t fre q u e n c y fo r the c o n d itio n s u n d e r m ove any e vidence o f co rro sio n on end te rm i...
Page 21 COMPLETE VEHICLE MAINTENANCE SCHEDULE I I Light Duty Emission System This Maintenance Schedule is applicable to all engines which contain the letter "U " in the engine identification code (which begins with the num eral"8'') shown in the upper left'corner of the under hood “...
Page 22 o r u n its c o u ld m ean th a t a m a lfu n c tio n is d e is e v id e n t (solid grease o o zin g o u t— n o t ju s t o ily v e lo p in g and c o rre ctiv e actio n s h o u ld be taken film ), it s h o u ld be co rre cte d im m e d ia te ly.
Page 23 ca u tio n s a re n 't fo llo w e d v e h icle m ay m ove un cracked and th a t w h e e l n u ts have been tig h te n e d (k) DEFROSTERS —...
Page 24 w ith p la in water. P a rticu la r a tte n tio n s h o u ld be b in d in g c o n d itio n m u s t be c o rre c te d . C heck C-8 POSITIVE CRANKCASE VENTILATION SYSTEM (PCV)—...
Page 25 COMPLETE VEHICLE MAINTENANCE SCHEDULE Heavy Duty Emission System When To Perform Services Item Services (M o n th s or M ile s /K ilo m e tre s , W hichever (For D e ta ils . See Num bered P aragraphs) Occurs First) S e c t io n A L u b r ic a t io n a n d G e n e r a l M a in t e n a n c e...
Page 26 o f ve hicle o p e ra tio n .* P roper e n g in e c o o la n t also (38 400 km ), d ra in , flu s h , and re fill th e c o o lin g syste m w ith a ne w c o o la n t s o lu tio n as d e scrib e d p ro vid e s c o rro s io n p ro te c tio n .
Page 27 M anual. (See- "In Case o f E m e rg e n cy " se ctio n ) a p p ly th e re g u la r brake. Do n o t depress ac (k) DEFROSTER — Check p e rfo rm a n c e by m o v in g For trucks w ith dual w h e e ls, also set w h e e l nut c e le ra to r pedal.
Page 28 proper o p e ra tio n . A m a lfu n c tio n in g sw itch m ust d e te rio ra tio n o f u n d e rb o d y c o m p o n e n ts such as NOTICE: Do n o t o p e ra te th e e n g in e w ith o u t th e be replaced.
Page 29 COMPLETE VEHICLE MAINTENANCE SCHEDULE V -8 DIESEL ENGINE Item Services When To Perform Services (For D etails, See Numbered Paragraphs) (M onths or M iles, Whichever Occurs First) S E C T IO N A — L u b ric a tio n and G e n e ra l M a in te n a n c e Every 3,000 Miles ‘...
Page 30 A-5 REAR AXLE — Check lu b ric a n t e v e ry 6,000 m ile s B-1 SAFETY CHECKS TO BE PERFORMED BY OWNER OR (9 600 km). DRIVER — The fo llo w in g checks sh o u ld be m ade re g u la rly d u rin g o p e ra tio n at no g re a te r in te rva l —...
Page 31 Be a le rt to illu m in a tio n o f the brake — C heck to m ake su re h o o d (g) BRAKES— HOOD LATCHES etc.). Parking brake a d ju s tm e n t also s h o u ld be w a rn in g lig h t o r ch a n ge s in braking action, closes fir m ly by liftin g on th e ho o d a fte r each c h e c k e d w h e n e v e r d ru m...
Page 32 Ethylene Glycol base type anti freeze conform ing to GM Spec. 1899-M NOTE: Fluids and lubricants identified w ith G M part num bers o r G M specification num bers m ay be obtained from your Chevrolet dealer.
Page 33 Lower Control Arms Wheel Bearings T h ro ttle Bell Crank - L-6 Upper Control Arms Steering Gear Carburetor Linkage - V-8 Upper and Lower Control A ir Cleaner - Element Brake and Clutch Pedal A rm Ball Joints Master Cylinder Springs Transmission Manual...
Page 34 1 / 2 TON "G " MODELS LUBRICATION POINTS Rear Axle Trans. Control Shaft Control Arm Bushings and Oil Filter Ball Joints A ir Cleaner - Element Brake Master Cylinder Transmission - Manual Tie Rod Ends Parking Brake Linkage - A utom atic Wheel Bearings Steering Gear Clutch Cross-Shaft...
Page 35 HEATER 1 A-1 SECTION 1A HEATER CONTENTS OF THIS SECTION Standard Heater................1A-1 Auxiliary Heater................1A-13 Specifications................. 1 A-17 STANDARD HEATER INDEX General Description..........Center Distributor Duct - G Models....... 1 A-1 1A-9 System Components..........1A-1 Defroster D uct............1A-9 System Controls............
Page 36 HEATER & DEFROSTER ASM HEATER & DEFROSTER ASM AIR OUTLET V I E W A I R F L O W L E G E N D Q ] TEMPERATURE VALVE L ] OUTSIDE AIR [ 2 ] DEFROSTER VALVE 1 ^ 3 M ,XED A,R DASH P A N E l-...
Page 37 Fig. 1A -2--H eater C ontrol--C -K M o d e ls Fig. 1 A -3 --H e a te r C ontrol--G M o d e ls...
Page 38 DIAGNOSIS CAUSE A N D CORRECTION TROUBLE See " I n s u f f i c i e n t Heat Diagnostic Chart". Temperature of heat er a i r a t o u t l e t s too low to heat up pas senger compartment.
Page 39 I NSUFFI CI ENT HEAT D I A G N O S I S Position th e c o n tro ls so th a t the: T e m p e ra tu re lever is o n fu ll heat. S electo r or heater lever is on H eater.
Page 40 HEATER C IR CU I T D I A G N O S I S * BLOW ER M O TO R IN O P E R A TIV E (A N Y SPEED) Check fuse in fuse panel. FUSE BLOW N FUSE OK 1 ..
Page 41 CIRCUIT HEATER O PERATION BAT -BLO SW-RES Rl R 2 , B A T -O N L Y BLO MTR-GRD BLOWER BA T -LO RESISTOR B AT -BLO SW-RES Rl- BAT -M ED BLO MTR-GRD BA T -H I BA T -B LO SW- BLO M TR-G RD ■16 LBL* 16 YEL...
Page 42: On-Vehicle Service
ON VEHICLE SERVICE HEATER DISTRIBUTOR AND CORE BLOWER MOTOR ASSEMBLY Removal (Fig. 1A-6) 1. Disconnect battery ground cable. C-K Models G Models - Remove the battery. Replacement (Fig. 1A-7) 2. Disconnect the blower motor lead wire. 1. Disconnect the battery ground cable. 3.
Page 43 be free from kinks or binding and doors should close properly. If cable adjustment is necessary, see "Bowden Cable-Adjustment." DEFROSTER DUCT Defroster assemblies attachment is illustrated in Figure 1 A-11. CONTROL ASSEMBLY Models Replacement (Fig. 1A-12) 1. Disconnect the battery ground cable. 2.
Page 44 A U TO M A TIC TRAN SM ISSIO N M ODELS ( EXCEPT C - K IO 350 V8 W / O V O I OR C 6 0 ) C-K MODELS MODELS Fig. 1A-9--Heater Hose Rou tin g s 3.
Page 45 Fig. 1 A - 1 0 -- D is t r ib u to r D u c ts -G M o d e ls 2. Remove the two resistor mounting screws and To install a new switch, reverse Steps 1-3 above. remove the resistor.
Page 46 Fig. 1 A-1 3--Contro l A s se m b ly -G M o d e ls...
Page 47 AUXILIARY HEATER IN D E X General Description...............1A-13 Control..................1A-13 Diagnosis On Vehicle Service................1A-15 Specifications...................1 A-17 GENERAL DESCRIPTION CONTROLS An auxiliary heater is available as a dealer installed accessory to provide additional heating capacity for the Two methods of control are employed with this system: rearmost extremities of the C-K (06) and G (05 and 06) models.
Page 48 Fig. 1 A-1 - A u x i l i a r y He ater In s ta lla tio n s (G M od e ls ) INSTALL VALVE WITH ARROW POINTING AW A Y FROM TEE. ORIENT VALVE SO " O N " "O FF” IS VISIBLE Fig.
Page 49 CIRCUIT HEATER OPERATION I r v / W V V BAT-BLO SW-RES Rl R2- OFF BAT-ONLY BLO MTR-GRD BAT-LO BLOWER B A t-6 L 6 SW-RES R2- MED BAT-MED RESISTOR BLO MTR-GRD BAT-HI BAT-BLO SW- jMED LO BLO MTR-GRD 'H i----------- 1 medi 52 A BAT____...
Page 51 SPECIFICATIONS SECTION 1A HEATER Amps. Volts (Cold) (Cold) Blower Motor C-K Models... 13.5 6.25 Max. 2550 Min. 2950 Max. G M odels....13.5 7.1 Max. 2850 Min. 3250 Max. Fuses C-K Models..............20 Amp. G M odels..............20 Amp. A U X IL IA R Y HEATER Amps.
Page 53: Table Of Contents
S E C T IO N 1 B AIR C O N D IT IO N IN G C O N T E N T S General Description............1 B-1 Blower Motor Assembly......... IB-32 Four-Season System (C-K Models)......1 B-1 Expansion Valve............IB-33 C60 System (G Models).........
Page 54 E V A P O R A T O R C O R E B L O W E R & S H R O U D E V A P O R A T O R A S M R.H.
Page 55: Overhead Systems (C-K-G Models)
operation by sensing the evaporator inlet line temperature. System operation is as follows" Air, either outside air or recirculated air, enters the system and is forced through the system by the blower. As the air passes through the evaporator core, it receives maximum cooling if the air conditioning controls are calling for cooling.
Page 56 Fig. 1 B - 4 -E x p a n s io n Tub e A bag of desiccant (dehydrating agent) is located in the base of the accumulator as a moisture collecting device. NOTE: There is no sight glass in the accumulator- clutch cycle system.
Page 57 Season System is ON. In any of the three blower positions (LOW, MED, HI), the blower will be operative regardless if the Four-Season System is ON. NOTE: To obtain maximum cooling, the Four-Season System should be on A/C, temperature lever on COLD, blower switch on HI and the overhead unit blower switch should be on HI.
Page 58 Fig. 1 B-7— A ir C o n d it io n in g V a c u u m S c h e m a tic - CK T ru c k REFRIGERANT LINE CONNECTIONS Hose Clamps When hose clamp connections are encountered, special procedures are necessary for both removal and installation.
Page 59 BLO W E R A IR H E A T E R H E A T E R A I R SPEEDS EN TERS D E F R O S T E R A / C COMPRE SSOR SOURCE A V A I L V E H I C L E DO OR DOOR...
Page 60: Diagnosis
Alum. Tubing Thread and Metal Tube O.D. Fitting Size Torque* M A KE A N G U L A R CUT FOR H O S E R E M O V A L 7/16 7 / 8 1-1/16 *Foot Pounds H OSE CLA MP L O C A T I N G HOSE...
Page 61: Insufficient Cooling
Attachment of the expansion valve bulb to the indicate refrigerant shortage. evaporator outlet line is very critical. The bulb must be If the sight glass consistently shows foaming or a attached tightly to the line and must make good contact broken liquid column, it should be observed after partially with the line along the entire length of the bulb.
Page 62 COMPRESSOR DIAGNOSIS Retrace ele ctrical c irc u it back to source of pow er loss. (See w irin g diagram s). C - K - G M O D E L S : NO V O L T A G E A T C h e ck fo r d efective discharge Pressure S w itc h by ju m p in g sw itch co n n e cto r te rm in als.
Page 63 INSUFFICENT C O O LIN G -FO U R 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 c k a nd fo rth fro m m ax. h e a t to m ax.
Page 64 IN S U F F I C I E N T COOLING D I A G N O S I S C HA RT (EXCEPT C - K F O U R - S E A S O N S Y S T E M ) The following procedures should be applied before performance testing an A/C System.
Page 65 ELECTRICAL SYSTEM DIAGNOSTIC CHART B LO W E R M O TO R IN O P E R A T IV E B L O W E R M O T O R IN O P E R A T I V E (A N Y S P E E D ) ( C E R T A I N S P E E D S - E X C E P T H IG H ON C -K F O U R - S E A S O N )
Page 66 ELECTRICAL SYSTEM DIAGNOSTIC CHART COMPRESSOR CLU TCH IN O P ER A TIV E * BLOWER MOTOR IN O P ERA TIV E A T HIGH SPEED O N LY Check fuse (C-K FOUR-SEASON SYSTEM ) Check I FUSE OK | I FUSE BLOWN I in-line fuse Check Compressor Solenoid Ground...
Page 67 JU N C T IO N R E SIST O R B L O C K B L O W E R M O TO R...
Page 69 16 YEL' 1 4 O R N 10 PPL | HI BAT | CIRCUIT B A T T T O N O N E B L O W E R M O T O R B A T T T O LO B A T T T O M E D B A T T T O HI B L O W E R S W I T C H...
Page 70: Performance Test
S 0 L E N i r D ^ l8LT G R ^ BLK1 ^ -12 0 0 4 2 6 8 COMPRE S S O R SDK G RNJ L I8 WHT----- E H Ii57l 2977253 AIR CONDITIONING RP.Q-C60 Fig.
Page 71: Performance Data
S E L E C T V A L V E O P E R A T IN G CHART P O R T NC. O F F NORM D E F O G D EF HEAT VENT VENT D EF VENT VENT VENT VENT...
Page 73 a. Remove the compressor, drain, measure and discard Four-Season A ir C o nd ition in g (C-K Models) the oil. b. If the amount drained is more than 1-1/2 fluid oz. (R e frig e ra n t C harge - 3 Lbs. -1 2 o z .) and the system shows no signs of a major leak, add the same T e m p e ra tu re o f amount to the replacement compressor.
Page 74 Overhead System (G Models) Dash Mounted Unit (Motor Home Chassis) (R e frig era n t Charge — 5 lbs.-4 o z .) (R e frig era n t Charge — 3 lbs.-4 o z .) T em peratu re o f T em p eratu re o f Air E ntering 7 0 °...
Page 75: On Vehicle Service
Fig. 1 B -2 5 -- C h e c k in g E v a p o r a t o r In le t and A c u u m u l a t o r O u t le t T e m p e r a t u r e s ON VEHICLE SERVICE TH E R M O S TA T IC S W ITC H NOTE: Do not attempt to run a Performance Check...
Page 76: Engine Idle Compensator
an improperly located or installed power element bulb. Installation Attachment of the expansion valve bulb to the 1. If oil previously drained from the compressor upon evaporator outlet pipe is very critical. The bulb must be removal shows no evidence of contamination, replace a like attached tightly to the pipe and must make good contact amount of fresh refrigeration oil into the compressor before with the pipe along the entire length of the bulb.
Page 77 3 0 5 - 3 5 0 V - 8 M O D E L S A N D M O T O R H O M E C H A S S I S 4 5 4 V - 8 C - M O D E L S 4 5 4 V - 8 M O T O R H O M E C H A S S I S...
Page 78: Four Season System--C-K Models
compressor clutch connector. F O U R -S E A S O N S Y S T E M --C -K M O D E L S 2. Purge the system of refrigerant. CONDENSER W A R N IN G : Be sure system is completely purged of refrigerant before com pletely Replacem ent (Fig.
Page 79: Evaporator Core
Fig. 1 B - 3 0 - B l o w e r - E v a p o r a t o r (C-K M o d e ls ) Fig. 1 B-3 1 -E x p a n s io n T u b e (C-K and G F our-S eason System ) remove the blower assembly.
Page 80: Plenum Air Valve
RIG HT H A N D OUTLETS UPPER CENTER DISTRIBUTOR DUCT LEFT DISTRIBUTOR DUCT A N D FOOT COOLER LOWER CENTER DISTRIBUTOR DUCT Fig. 1B-33--A ir S e le c t o r and Ducts (C-K M o d e ls ) vehicle).
Page 81: Temperature Door Cable Adjustment
selector duct assembly. Place temperature lever in full COLD position and hold while tightening cable attaching screw. MASTER S W ITC H A N D /O R BLOWER S W ITC H The master switch is located on rear of the control K IC K P A D V A L V E assembly.
Page 82: Thermostatic Switch
3. Adjust each clamp before tightening so that width of the clamp covers the capillary tube’s formed end. Tighten to 1.6 to 2.3 N-m (15 to 20 in. lbs.) of torque. Do not Fig. 1 B - 3 7 - R e s is t o r , Relay and T h e r m o s t a t ic S w itc h (C-K overtorque.
Page 83: Blower Motor Resistor
JU N CTIO N BLOCK COM PRESSOR BLOW ER RESISTOR LINE DISCHARGE PRESSURE SW ITCH BLOW ER M OTOR v i e w Fig. 1 B -3 9 --E n g in e C o m p a r t m e n t W ir in g Harness (C-K M o d e ls ) BLOWER MOTOR RESISTOR Replacem ent The blower motor resistor is located on the cover side...
Page 84: Expansion Valve
Fig. 1 B-4 1--Overhead S yste m F ro n t W i r i n g (C-K M o d e ls ) 2. Install the blower motor retaining strap and foam. blower lead wire. 3. Place the blower motor and wheel assembly into the 6.
Page 85: Evaporator Core
E V A P O R A T O R B L O W E R - E V A P O R A T O R UPPER CASE SCREEN E X P A N S I O N E V A P O R A T O R V A LVE CORE S E N S I N G BULB...
Page 86: Condenser
screws on installation. 7. Disconnect speedometer cable at meter. HEATER CORE Replacement 1. Disconnect battery ground cable. 2. Remove engine cover as outlined in Section 6A of this manual. 3. Remove steering column to insrument panel attaching bolts and lower column. 4.
Page 87: Air Inlet Valve
Fig. 1 B -4 7 --H e a te r D is tr ib u to r Duct-G M o d e l AIR INLET VALVE - G MODEL Replacement (Fig. 1B-51) Follow Steps 1-10 of "Heater Air Distributor and Extension Duct Extension Duct Replacement"...
Page 88: Blower Switch
Fig. 1 B - 5 0 - D i s t r i b u t o r G a s k e t through the opening, then the upper tab and finally the lower right tab. 7. Disconnect electrical and vacuum connections and remove the control assembly.
Page 89: Blower Motor Relay
Fig. 1 B - 5 2 - C o n t r o l (G M o d e l C 6 0 Syste m ) Replacement 1. Follow Steps 1-8 of "A/C Air Distributor Duct- Replacement". RESISTORS 2. Disconnect electrical harness at the relay. The heater blower motor resistor is mounted in the 3.
Page 90: Vacuum Tank
Fig. 1 B -5 8 -- R e f rig e r a n t L in e -C o n d e n s e r O u tle t COMPRESSOR Fig. 1 B -5 6 -- C o n d e n s e r I n s ta lla tio n Compressor mounting is illustrated in Figures IB-23 through IB-25.
Page 91: Circuit Breaker
V A C U U M TANK Fig. 1 B - 6 2 ~ V a c u u m T ank-G Se rie s w i t h Cyl. En g in e Replacem ent (Fig. 16-62) 1. Raise the hood. The G Van C69 system is almost identical to the CK 2.
Page 92 tab mounting bolts and remove the engine cover. 5. Loosen both steering column instrument panel reinforcement screws; remove one screw. 6. Remove the left foot cooler bracket to instrument panel reinforcement screws, disconnect the outlet from the duct and remove the outlet and bracket assembly. 7.
Page 93 Fig. 1 B - 6 8 --C o m p re s s o r M o u n t in g - C K S e rie s-D ie sel E ngin e Fig. 1 B - 6 7 - C o m p r e s s o r M o u n t i n g G Se rie s-V 8 E ngin e Fig.
Page 94 Fig u re 1 B -7 0 --H e a te r Hose R outin g-G Series...
Page 95: Condenser
Fig. 1 B - 7 2 - D e f r o s t e r Duct-G S erie s Fig. 1 B -7 3 -- T e m p e ra t u r e Cable-G Serie s DASH MOUNTED SYSTEM -MOTOR HOME CHASSIS 4.
Page 96: Sight Glass
2. Purge the system of refrigerant. 5. Disconnect electrical connector from compressor. 3. Disconnect the inlet and outlet lines at the receiver- Remove the terminal (See Figure IB-78) and allow dehydrator and cap or plug the open lines at once. connector to hang on ground wire.
Page 97 CORRECT B L O W E R BLADE A N G L E Fig. 1 B -7 9 -- B lo w e r A s s e m b ly ( M o t o r H o m e C hassis Unit) Fig.
Page 98: Resistor
Install replacement switch, reinstall cover plate and FUSE reverse steps 1-8 of the "Blower-EVaporator Assembly" This Unit does not incorporate an in-line fuse. The lead removal precedure. wire is connected to the Heater Wiring Harness and NOTE: When installing thermostatic switch, be sure operates off the 20 amp Heater Fuse.
Page 99: 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 o l J - 2 5 0 2 9 R ot or B e a r i n g R e m o v e r a n d R ot or Assy.
Page 100 SPECIAL TOOLS 22. J-9398 1. J-8393 C h a rg in g S tation 11. J-5421-02 Pocket Thermometers (2) P ulley B e a rin g Remover 2. J-24095 O il Inducer 12. J-5403 N o. 21 Snap Ring Pliers 23.
Page 102: Maintenance And Inspection
SECTION 2A F R A M E CONTENTS General Description............... 2A-1 On-Vehicle Service................. 2A-1 Maintenance and Inspection............2A-1 Underbody Inspection..............2A-1 Frame Inspection............... 2A-1 Frame Alignment................. 2A-1 Underbody Alignment..............2A-2 Excessive Body Damage.............. 2A-4 GENERAL DESCRIPTION Light duty 10-30 Series frames are of the ladder channel are Part of the underbody assembly which is a welded unit, section riveted type.
Page 103: Underbody Alignment
Fig. 2 A -1 --F ra m e H orizontal C h e c kin g --T y p ic a l not be parallel. Placing the tram bar vertical pointers on Horizontal Check opposite sides of the frame side rail is preferable in that 1.
Page 104 collision misalignment present in underbody construction. M odel 13-3/8 15-1/4 CA107 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 15-1/4 CA109 13-3/8 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 86-1/2 16-7/8 16-7/8 CA209 13-3/8 15-1/4 19-7/8 14-7/8...
Page 105: Excessive Body Damage
Fig. 2A-4--G V a n T r u c k Reference D im e n sio n s should be set at the specified dimension to check the M E A S U R IN G accuracy of the repair operation. To measure the distance accurately between any two reference points on the underbody, two specifications are EXCESSIVE BODY D A M A G E...
Page 106 SECTION 2B B U M P E R S CONTENTS General Description............2B-1 Front Bumper G Series..........2B-2 Service Procedures - 10 thru 30 series......2B-1 Rear Bumper G Series..........2B-2 Front Bumper - C, K and P Models..... ..2B-1 Rear Bumper G Series..........2B-2 Rear Bumper - C and K Models......
Page 107 Installation Remove bolts securing bumper brace to frame and remove brace. Reverse removal steps to install bumpers. Installation REAR BUMPER-G M ODELS Install rear step bumper by reversing removal procedure. Connect license lamp wiring. Removal Fig. 2B-7, 2B-8 FRO NT BUMPER - G MO DELS 1.
Page 108 SPECIFICATIONS TORQUE SPECIFICATIONS C, P A N D K Front Bum per ..............35 ft.-lb s . Front Bumper Bracket a n d Brace ......70 ft.- lb s . Rear Bum per to O u te r B racke t ........
Page 110 S E C T IO N 2 C C H A S S IS SHEET M ETAL C O N T E N T S General Description...........2C-1 Front Sheet Metal - CK Series....... .2C-6 On Vehicle Service............ .2C-1 Radiator Support.............2C-8 Hood Assembly - CK Series........
Page 111 Installation 1. Install hinge assembly to fender and align within scribe marks. Install bolts. 2. Install hood hinge spring. 3. Install bolts and align hood. See Hood Alignment in this section. Hood Lock Assembly A bolt-type hood lock is used as shown in Figure 2C-5. The lock bolt, located on the hood dovetails with the mounted striker plate, preventing upward or downward movement of the hood while the vehicle is in motion.
Page 112: Hood Assembly
Installation 1. If original hood is to be installed, position hood to hinges and install four cap screws snug which attach hinges to hood. NOTE: If a new hood is to be installed, perform procedures as outlined under Alignment, directly below.
Page 113: Hood Bumper
^BUM PER ASSEMBLY PLATE ASSEMBLY I — .40 REFERENCE SPRING HING E ASSEMBLY RETAINER BOLT Fig. 2C-9--Hood, B u m p e r s a nd L a t c h - G M o d e l HOOD LATCH CABLE RELEASE - CK MODELS (FIG.
Page 114 Fig. 2C -10 --H o od Release C a b le - CK M o d e ls Alignm ent 1. Loosen hood hinge bolts. Note that rear bolt holes in hinge is slotted to allow hood trailing edge to move up and down.
Page 115 Fig. 2C-1 4 - L o w e r R a d ia t o r G rille - G M o d e ls Fig. 2C-1 2 - H o o d Rod S u p p o r t - G - M o d e l Removal LOW ER R AD IA TO R GRILLE - G M O DEL (FIG.
Page 116 5. Remove bolts attaching fender upper edge to cowl door frame. 6. Remove fan shroud. 7. Working from underneath rear of fender, remove attachment from each fender at the hinge pillar. 8. Remove bolt from each radiator support mounting. 9. Remove bolts at each fender skirt to cab underbody (fig.
Page 117: Radiator Support
6. Disconnect fan shroud and lay back on engine. 7. Remove both head lamp assemblies. 8. Remove grille assembly. 9. Remove upper and lower radiator grille panels. (Fig. 2C-20). 10. Remove screws securing front fenders to radiator support. 11. Remove screws securing fender skirts to radiator support bottom.
Page 118: Front Fender And Skirt
Fig. 2C-20 --R a dia to r U p p e r and L o w e r G rille P a n e ls - C K M o d e ls FRONT FENDER AND SKIRT (FIGS. 2C-18 A N D Installation 2C-19) Install front fender and skirt assembly in reverse order...
Page 119 subjected to temperature greater than 175°F (79°C) and should not be left at or near this temperature for extended periods of time. Shelf life of the transfer material is 90 days at a temperature not to exceed 105°F (40°C). Removal Remove the moldings from the affected panel.
Page 120 C O W L TO H O O D .18 ± .03 GAP NOTE H ood surface flu sh to .06 b e lo w cowl vent g r ille & constant fro m to hood re a r corners. FENDER TO CO W L .07 GAP (Ref) NOTE...
Page 121: 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 122: General Description
S E C T IO N 2 D CAB A N D B O D Y The following caution applies to one or more steps in the assembly procedure of components in this portion of the manual as indicated at appropriate locations by the terminology "See Caution on page 1 of this Section".
Page 123 Fig. 2 D - 4 - - T y p ic a l U t ilit y V e h ic le Vans G-Series Vans are available in three model number designations. See figures 2D-5 and 2D-6. Vans without body windows use number "05";...
Page 124 Fig. 2 D -5--Typ ic a l " 0 5 " and " 0 6 " V a n s...
Page 125 Fig. 2 D - 6 ~ T y p ic a l " 0 3 " Van ON VEHICLE SERVICE C-K MODELS IN D E X Replacement............2D-16 Front End Windshield Wipers..........2D-5 Hinges..............2D-16 Stationary G lass..........2D-16 Glove Box..............2D-5 Window and Regulator........
Page 126 FRONT IN S TR U M E N T PANEL C O M P A R T M E N T A N D W IN D S H IE L D W IPERS LOCK Windshield wiper units on all models are of the two- speed electric type.
Page 127 Fig. 2 D - 1 0 - R e a r V i e w M ir r o r s BODY GLASS W IND SH IELD GLASS The windshield is a one-piece type and is retained in the windshield opening by a molded rubber weatherstrip. See figure 2D-13.
Page 128 Fig. 2D-1 4 - A p p l y i n g Pr essu re to W i n d s h i e l d a template. VIEW A 1. Check for the following conditions at the previously marked point of fracture. Fig.
Page 129 4. Apply primer P /N 9985359 (or equivalent) to both channels of rubber weatherstrip that were cleaned in the previous step and are shown in View A. Allow primer to cure for at least 30 minutes. 5. Apply cleaner P /N 9981535 (or equivalent) in a 0.4 inch wide band on the inside of the windshield glass around the entire periphery as shown in View C.
Page 130 SURFACE "A' OUTSIDE OF GLASS SURFACE "B" BLACKOUT PRIM ER INSIDE SURFACE O F GLASS CLEANER PILLAR SIDE P IL L A R PRIM ER URE THA NE Fig. 2D-1 8 -- W in d s h ie ld I n s ta lla tio n -C 1 0 -3 0 T r u c k...
Page 131 S TA T IO N A R Y BODY GLASS Replacem ent The method used to remove the windshield glass may be applied to other stationary glass, such as shown in figures 2D-20 and 2D-21. Remember to check for cause of breakage, and to always wear gloves when handling glass.
Page 132 BODY SIDE DOORS DOOR A D JU S TM E N TS FRONT DOOR ASSEM B LY Doors can be adjusted for alignment of clearance in the Replacement cab door opening, and for proper latching. Door alignment Remove the door assembly from the body by removing adjustments are made at the striker bolt, and at door hinges.
Page 133 installed two inches longer than necessary for the channel. 2D-27. Place this piece of filler (soapstoned side of filler away from 4. Remove screws attaching ventilator lower assembly glass) evenly over the edge of the glass which will fit in the to door panel.
Page 134 Fig. 2 D - 2 8 - - R e m o v in g V e n t ila t o r A s s e m b ly Fig. 2 D - 3 0 ~ B e n d T a b s O ver He x N u t Installation DOOR W IN D O W A S S EM B LY -FIG .
Page 135 NOTCH Fig. 2 D - 3 2 ~ R e m o v in g D o o r Glass 3. Remove regulator assembly through door opening. 4. Install regulator by reversing above steps. Lubricate regulator gear with lubriplate or equivalent. Fig.
Page 136 16. Insert regulator into door in such a position that Door Lock Cylinder -Fig 2D-36 motor connector can be installed onto motor. 17. Reinstall regulator into door. Replacement LOCKS, HANDLES A N D RODS 1. Raise door window. The door lock, handles and control rods are shown in 2.
Page 137 Fig. 2 D - 3 9 ~ D o o r W e a t h e r s t r i p ( 0 3 - 6 3 -0 6 ) Fig. 2 D - 3 7 ~ ln s id e H a n d le upon the quality of the cement used and the care with which REAR SIDE DOOR (06 A N D 6 3 ONLY) it is applied.
Page 138 Fig. 2D-4 1 -R e a r D oor H in g e Location 6. Raise window up and out. Glas Run Channel Adjustment 7. Reverse above procedure for installation. Figure 2D-44 illustrates the front run channel. At the lower end, a slotted bracket provides for in-and-out W IN D O W REGULATOR A S S EM B LY -FIG .
Page 139 LOCKS HANDLES A N D RODS Inside Handle--Fig. 2D-46 Replacement Lock Assembly--Fig. 2D-46 1. Remove regulator handle, remote control knob and trim pad as outlined previously. Replacem ent 2. Disconnect control rod from inside handle by 1. Remove window regulator handle and remote removing clip as shown in figure 2D-46.
Page 140 REAR DOORS (06 ONLY) Adjustm ents Rear doors may be adjusted in the body opening by loosening hinge bolts and repositioning door, then retightening bolts. See figure 2D-53 for hinge bolt location. Rear door wedges and strikers should be adjusted as shown REAR DOOR-Fig.
Page 142 Fig. 2 D - 5 4 ~ W e d g e and S tr ik e r A d ju s t m e n t s W EA TH ER STR IP Weatherstrip installation is shown in figure 2D-55. Proper installation is dependent on completely cleaning all foreign material from old installation and using a quality cement on the new installation.
Page 143 6. Remove screws connecting cam assemblies to sash assembly, figure 2D-59, then remove cam assemblies. 7. Remove glass from endgate. 8. Unclip and remove inner and outer seal assemblies. 9. Remove screws connecting window regulator assembly to endgate, figure 2D-59, and remove regulator. W ARNING : Step 10 must be performed if the w indow is removed or disengaged from the regulator lift arms.
Page 144 5. Remove torque rod retaining bracket on lower edge HINGE of endgate. See figure 2D-65. Replacement 6. Remove torque rod retaining clip on side edge of 1. Lower endgate and disconnect hinge to be replaced endgate. by removing hinge-to-body bolts. See figure 2D-61. 7.
Page 145 Fig. 2 D - 6 3 - - G r a s p in g T o r q u e Rod (14) to inner panel. shown in figures 2D-75 and 2D-76. 8. Remove three screws which retain remote control The tailgate shown in figure 2D-75 can be removed by disconnecting both links from the tailgate, removing screws assembly to inner panel.
Page 146 Fig. 2 D - 6 7 - L a t c h e s and Rods connect the sides of the top with support braces as follows. SEATS a. Fabricate 2 braces 72" long from wood or square Care and Cleaning of Interior Soft Trim aluminum tubing.
Page 147 Fig. 2 D - 7 3 ~ R e m o v in g R e g u la t o r When cleaning in terior soft trim such CAUTION: as upholstery or carpeting, do not use volatile NOTE: Sometimes a difficult spot may require a second application cleaning...
Page 148 Catsup Removal of Specific Stains Wipe with cloth soaked in cool water. If further Candy cleaning is necessary, use a detergent foam cleaner. Chocolate, use cloth soaked in lukewarm water; other Grease, Oil, Butter, M argarine and Crayon than chocolate, use very hot water. Dry. If necessary, clean lightly with fabric cleaning fluid.
Page 149 Fig. 2 D -78 --R e m o va b le T op...
Page 150 Fig. 2 D - 7 9 ~ F o l d i n g T o p A s s e m b ly...
Page 151 Fig. 2 D - 8 0 - - F o ld in g T o p Side M o l d i n g s and H e a d e r...
Page 152 S E A T M O U N T IN G Typical Seat Mounting provisions are shown in figures BODY M O U N T IN G 2D-82 through 2D-90. CAUTION on page 1 of this CAUTION: 5ee section regarding fasteners used on seats and seat The sequence of mounting attachments is shown in belts.
Page 155 Fig. 2 D - 9 2 - - B o d y M o u n t in g (63)
Page 156 M O U N T 1 M O U N T 4 M O U N T 2 M O U N T 1 Fig. 2 D - 9 4 ~ B o d y M o u n t in g (14) G MODELS IN D E X Front End...
Page 157 COWL VENTILATOR GRILLE Arm A djustm ent Replacement To adjust sweep of blades turn on wipers, then note 1. Remove windshield wiper blades. sweep of arms. If necessary, remove one or both arms as 2. Remove screws retaining grille, figure 2D-97. follows: Pull outer end of arm away from glass which will 3.
Page 158 Outside Rear View Mirrors Outside rear view mirror installations are shown in figure 2D-100. Occasional tightening of mounting and assembly bolts and screws will sharply decrease occurence of failure due to door slamming or road shock. Fig. 2 D - 1 0 0 - - 0 u t s i d e Rear V i e w M ir r o r s Fig.
Page 159 BODY GLASS NOTE: The windshield glass rubber weatherstrip is one piece. The glass is held in a channel within the W A R N IN G : A lw ays w ear gloves when weatherstrip. handling glass. 2. Do not try to remove reveal moldings while windshield is in body opening.
Page 160 opening flange around the entire perimeter of the glass. Installation . Check the relationship of glass to opening as follows: 1. Install latch to glass using escutcheon, spacer, a. Inside edge of glass to body flange. washer latch and screw. Torque to specifications. b.
Page 161 FRONT DOOR DOOR HINGE DOOR A D JU S TM E N TS Doors can be adjusted for alignment of clearance in the Remove cab door opening, and for proper latching. Door alignment 1. Remove hinge access hole cover from door hinge adjustments are made at the striker bolt, and at door hinges.
Page 162 Fig. 2 D - 1 0 8 -- T y p ic a l S tr ik e r B o lt A d ju s t m e n t NOTE: One side of this filler (the outside of the roll) T R IM PANEL, A R M REST AND HANDLES is soapstoned.
Page 163 Fig. 2D-1 1 1 ~ A d ju s t in g V e n t i l a t o r T e n s io n 5. From outside the door remove screws retaining lock A djustm ent to door edge and lower the lock assembly.
Page 164 REMOTE CONTROL A N D CO NNECTING ROD -Fig. 2 D -1 13 Replacement 1. Raise door window and remove door trim pad. 2. Remove bolts securing remote control to door inner panel. 3. Pivot remote inboard slightly, to disengage connecting rod, and remove remote control from door.
Page 165 STRIKER F O R E -A N D -A F T A D JU ST M E N T S LO T S CEN T ER RO LLER V E R T IC A LLY IN T R A C K S O IT D O E S N O T C O N T A C T THE T R A C K = = = = = i ^...
Page 166 Fig. 2D-1 1 7--H o ld -O pe n C a tc h If necessary to shim roller away from guide, shims Latch Striker Adjustments are added between the nylon block and hinge and between Front Striker roller and hinge. They must be installed in pairs. For 1.
Page 167 ( " l o c k i n g r o d R EA R L A T C H # " * * * R O D S ISlP SOlSilS JmJk 3... W lp ig lp .. - ,j£ L O W E R H I N G E D O O R C A T C H R O D...
Page 168 Installation NOTE: When holding hinge assembly as in figure 2D- 124, the lower latch must engage cam. 1. Install hinge assembly to door. Toique bolts to specifications. 2. Check and adjust latch to striker position as outlined under "Adjustments". 3. Open the door and reconnect the hinge spring. 4.
Page 169 15. Screw Roller B olt Bushing Guide Block Lockwashers Plate Hinge (D oor Half) Hinge (Body Half) Upper lines N ut Spring Spacer Spring (Upper Lever) Bushing Spring retainer Washer Hinge liner Spring (Low er Level) Bushing Bushing Lower Lever Bushing Fig.
Page 170 Fig. 2D-1 2 4 -C h e c k in g A ssem bly of Hinge REAR DOORS 3. Remove hinge-to-door bolts and remove door REAR D O O R H IN G E S TR A P assembly. R eplacem e nt 4.
Page 171 Installation 1. Install lock cylinder and retainer. Install remote control. Torque screws Fig. 2D-1 26--Remote C ontrol and Latch specifications. 3. Install trim panel. REAR DOOR GLASS A N D W EATH ERSTRIP Installation Removal and installation procedures are the same as 1.
Page 172 STRIKER ADJUSTMENT Fig. 2D-128--Rear Door S trike r and W edge A d ju stm e n t SEATS See CAUTION on page 1 of this CAUTION: section regarding fasteners used on seats and seat belts. D R IV E R S SE A T Seat Adjuster R eplacem ent 1.
Page 173 SEAT RISER Removal 1. Remove seat and mounting bracket as an assembly. 2. Remove riser from floor. Installation 1. Install riser to floor. Torque nuts to specifications. 2. Install seat riser. Torque nuts to specifications. All models equipped with 2nd, 3rd and 4th bench seat assemblies feature a quick release mechanism which facilitates removal of the seats for added cargo space.
Page 175 CARE AND CLEANING OF SEATS Instructions on care and cleaning of interior soft trim may be found in "C-K Models-Seats", earlier in this section.
Page 176 SPECIFICATIONS BODY SECTION 2D C AND K MODELS F R O N T END EN D G A T E (06) Windshield Wiper Linkage to Plenum....25 in. lb, Hinges— Hinge to B o d y .......... . 35 ft. lb. Sunshade Support..........
Page 177 BODY MOUNTING (C-K MODELS)-FT. LBS. Model (03) — — — (06) — — (14) — — (63) G MODELS M IRRO RS AND SUNSHADE S LID IN G SIDE DOOR Inside Rear View Mirror to Bracket .....15 in. lb. Remote Control (front latch) to D o o r ..... 90 in. lb. Outside Rear View Mirror to P a n el......40 in.
Page 178 SPECIAL TOOLS 1. J-2189 W eatherstrip Tool Set 2. J-22585 F ront Door Hinge, B olt Wrench 3. J-22577 W indshield Checking Blocks 4. J-7797 Door Handle Clip Remover 5. J-23457 Door S triker B olt Remover and Installer...
Page 180 SECTION 3A FRONT A L IG N M E N T CONTENTS General Description..............3A-1 Maintenance and Adjustments............ 3A-2 Specifications................3A-6 GENERAL DESCRIPTION designed into the front axle assembly on all K series vehicles FRONT A LIG N M E N T (four-wheel drive), and is non-adjustable.
Page 181 <£ OF WHEEL q OF VEHICLE <£ OF WHEEL IFWD DIRECTION CASTER ANGLE CAMBER ANGLE FRONT VIEW SIDE VIEW Fig. 3A -1~C aster - Camber - Toe-In MAINTENANCE AND ADJUSTMENTS to check alignment and follow the manufacturer’s P R E LIM IN A R Y CHECKS PRIOR TO instructions.
Page 182 PIVOT SHAFT OUTBOARD OF FRAME CASTER CAMBER ADD SHIMS HERE TO INCREASE CASTER FRAME FORWARD ^SUBTRACT SHIMS HERE - T O INCREASE CASTER Fig. 3A-2--Caster - Cam ber A d ju s tm e n t programs usually include wheel alignment among items that Caster are inspected.
Page 183 Camber 1. Determine the camber angle from the alignment equipment. “ B" IS LESS THAN “ A " WHEN WHEELS TOE-IN 2. Add or subtract shims from both the front and rear bolts to affect a change. Toe-In 1. Determine the wheel toe-in from the alignment equipment.
Page 185 SPECIFICATIONS WHEEL ALIGNMENT SPECIFICATIONS C A ST ER * P IM E N S IO N “A ” IN IN C H E S* 4” 4 1/4” 4 1/2” 4 3/4” 5” 3 3/4” M odels 1/2” 2 3/4" 3” 3 1/4”...
Page 186 S E C T IO N 3 B STEERING The following caution applies to one or more steps in the assembly procedure of components in this portion of the manual as indicated at appropriate locations by the terminology "See Caution on page 1 of this Section".
Page 187: General Description
GENERAL DESCRIPTION coupling alignment pins. The steering gear is of the recirculating ball type. This gear provides for ease of handling by transmitting forces from the wormshaft to the pitman shaft through the use of The trucks incorporate "Forward Steering" whereas ball bearings.
Page 188 CONDITION POSSIBLE CAUSE CORRECTION A d ju s t b e a rin g s to o b ta in p r o p e r E x ce ssiv e P la y o r L o o se n e s s in F r o n t w h e e l b e a rin g s lo o se ly S te e rin g S y s te m .
Page 189 POSSIBLE CAUSE CORRECTION CONDITION I n f la te to s p e c ifie d p re s s u re s . L o w o r u n e v e n tire p re ssu re . H a rd S te e rin g —...
Page 190 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 191 CORRECTION CONDITION POSSIBLE CAUSE F r o n t w h e e l b e a rin g s lo o se ly E x c e ssiv e P la y o r L o o s e n e s s in A d ju s t to o b ta in p r o p e r e n d p la y .
Page 192: Collision Diagnosis
COLLISION D IA G N O S IS (FIGS. 3B-6 THROUGH SHIFTER SHAFT 3B-11) Separation of the shifter shaft sections will be internal To determine if the energy absorbing steering column and cannot be visually identified. Hold lower end of the components are functioning as designed, or if repairs are "shifter shaft"...
Page 193 SURFACE “A” Instrum ent Panel Bracket Capsule Damage NOTE: T he b olt head m ust not c o n ta c t surface “ A ” . If . - J c o n ta ct is m ade, the capsule shear load will be increased. If this c o n d itio n exists replace the b ra ck e t.
Page 194 LOCK SYSTEM - HIGH EFFORT (CO NT'D.) Cause S olution Distorted coupling slot in rack (tilt). Replace rack. Bent or restricted actuator rod. Straighten remove restriction or replace. J. Ignition switch mounting bracket bent. J. Straighten or replace. HIGH EFFO R T LOCK C Y LIN D E R - BETWEEN "...
Page 195 IG N IT IO N S Y S T E M - E L E C T R IC A L S Y S T E M - W IL L N O T F U N C T IO N (C O N T 'D .) Solution Cause D.
Page 196 H IG H S T E E R IN G S H A F T E F F O R T Cause Solution A. Column assembly misaligned in vehicle. A. Realign. B. Improperly installed or deformed dust seal. B. Remove and replace. C.
Page 197 M A N U A L T R A N S M IS S IO N C O L U 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 198 S T E E R IN G W H E E L LO O SE Cause Solution A. Excessive clearance between holes in support or housing A. Replace either or both. and pivot pin diameters. B. Defective or missing anti-lash spring in spheres. B.
Page 199 2. Check for secure connection at the chassis to switch TURN SIG N AL D IA G N O S IS C A N D K SERIES connector. This is the harmonica connector on the column (FIGS. 3B-12 THRO UG H 3B-19) (Figure 3B-13).
Page 200 S w itch Visual Inspection 2. Check the position of the switch in the bowl. If it With the upper part of the column disassembled so appears cocked or crooked, loosen the securing screws (3) that the signal switch is visible (Figure 3B-15) check for and visually inspect the switch.
Page 201 S IG N A L SWITCH DIAGNOSIS C O N D IT IO N CO RRECTIO N POSSIBLE CAUSE Tighten to specified Turn signal will not cancel Loose switch mounting screws torque (25 in-lbs) Switch or anchor Replace switch bosses broken Reposition or replace Broken, missing or out springs as required...
Page 202 SIGNAL SWITCH D IA G N O S IS C O N D ITIO N POSSIBLE CAUSE C O R R E C TIO N Hazard switch will not Loose switch Tighten mounting stay on or difficult mounting screws screws (25 in-lbs) to turn off Interference with Remove interference...
Page 203 SIG N A L SWITCH DIAGNOSIS C O N D IT IO N CO RRECTIO N POSSIBLE CAUSE Replace fuse and Front or rear turn signal Burned out fuse check operation lights not flashing Replace bulb Burned out or damaged turn signal bulb Remove or repair High resistance...
Page 204: Turn Signal Switch Diagnosis
C O N D ITIO N C O R R E C TIO N POSSIBLE CAUSE Inoperative turn Replace turn signal Turn signal lights flash signal flasher very slowly flasher System charging Increase voltage to voltage low specified. See Sec. 6Y High resistance ground Repair high resistance at light sockets...
Page 205: Power Steering System Diagnosis
When checking fluid level after the steering system POW ER STEERING SYSTEM D IA G N O SIS has been serviced, air must be bled from the system. Proceed (FIGS. 3B-20 THRO UG H 3B-28) as follows: a. With wheels turned all the way to the left, add power Complaints of faulty steering are frequently the result steering fluid to "Cold"...
Page 206 Hydraulic System Checks 5. Start engine and check fluid level adding any fluid The following procedure outlines methods to identify if required. When engine normal operating and isolate power steering hydraulic circuit difficulties. The temperature, the initial pressure read on the gauge (valve test provides means of determining whether power steering open) should be in the 80-125 PSI range.
Page 207 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 ( “hissing” sound) There is some noise in all power steer...
Page 208 CONDITION POSSIBLE CAUSE CORRECTION Pump growl Scored pump pressure plates, thrust Replace affected parts, flush system. Note: Most noticeable at full plate or rotor. wheel travel and stand still parking Extreme wear of pump cam ring. Replace affected parts. Swish in pump Defective pump flow control valve Replace valve Whine in pump...
Page 209 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 210 POSSIBLE CAUSE CONDITION CORRECTION Hard Steering or Lack of lubricant in suspension Lubricate, relubricate at proper lack of assist (Continued) or ball joints. intervals. Tires not properly inflated. Inflate to recommended pressure. Steering gear to column misalignment. Align steering column. Steering gear adjusted too tight.
Page 211 POSSIBLE CAUSE CORRECTION CONDITION Loose belt. Adjust tension to specification Low oil pressure due to steering pump: Fill reservoir to proper level. Low oil level. (See pump pressure test.) Air in the oil. Locate source of leak and correct. Bleed system. Defective hoses or steering gear.
Page 212 leakage complaint and can be due to loose connection nuts. If leakage is observed at the hose connections, and the nut is not cross threaded, tighten the nuts at the gear to 30 foot pounds. The nut at the power steering pump should be tightened to 40 foot pounds.
Page 213 RESERVOIR DEFECTS RESERVOIR CAP DRIVE SHAFT SEAL RETURN HOSE & CLAMPS HOUSING DEFECT RESERVOIR ADJUSTER PLUG " 0 " RING " 0 " RING TORSION BAR RING & " 0 " RING STUD/BOLT " 0 " RINGS PRESSURE HOSE PRESSURE & RETURN PORTS STUB SHAFT SEAL SIDE COVER "...
Page 216: Maintenance And Adjustments
MAINTENANCE AND ADJUSTMENTS 5. Remove the horn shroud or button cap. LUBRICATION . Turn the steering wheel gently in one direction until Lubrication of Manual Steering Gear stopped by the gear; then turn back one-half turn. The manual steering gear is factory-filled with steering Do not turn the steering wheel hard CAUTION: gear lubricant.
Page 217: Steering Gear High Point Centering
Fig. 3 B - 3 0 A - -C h e c k in g T o r q u e at S te e rin g W h e e l adjustment by turning the adjuster in a clockwise motion.
Page 218: Steering Wheel Alignment
DO NOT M ISALIGN MORE THAN 1” FROM HORIZONTAL Fig. 3 B - 3 1--Steering W h e e l A l i g n m e n t Fig. 3 B - 3 3 -- S h ift T u b e A d ju s t m e n t - 3 Speed M a n u a l T ran s m is sio n Steering Wheel Alignment Shifter Tube Adjustment G and P Series...
Page 219 Fig. 3 B -3 7 ~ B o tto m in g A d ju s te r Plug Thrust Bearing Adjustm ent Fig. 3 B -3 5 --L o o s e n in g Lo ck N u t I f a gear is known to contain the new thrust bearing parts, thrust bearing adjustment in service is sim plified.
Page 220: Belt Tension
Fig. 3 B -3 9 --M e a s u re B a ck and R em ark H o u sin g 6. Turn adjuster plug counterclockwise until the hole in the face of the adjuster plug, which was even with the first m ark is in line with second m ark (Fig.
Page 221: Bleeding System
Bleeding Hydraulic System 1. F ill oil reservoir to proper level and let oil remain HIGH PRESSURE HOSE FROM PUMP ADDITIONAL HIGH PRESSURE P /S undisturbed for at least two minutes. HOSE TO GEAR 2. Start engine and run only for about two seconds. TO O L J-5176 3.
Page 222: Component Replacement And Repairs
COMPONENT REPLACEMENT AND REPAIRS Installation Steering Wheel See CAUTION on page 1 of this CAUTION: Removal G and P Series section regarding the fasteners referred to in step 1. Disconnect battery ground cable. 2. Remove horn button or shroud, receiving cup, 1.
Page 223: Intermediate Steering Shafts With Pot Joint
BEARING NOTE: It is not necessary to remove the pitman arm from the pitman shaft. Disassembly 1. M ark cover to shaft relationship. Pry off snap ring and slide cover from shaft. 2. Rm ove bearing blocks and tension spring from pivot pin.
Page 224: Intermediate Steering Shaft With Universal Joint Couplings
Disassembly 1. I f the upper or lower h alf of the intermediate steering shaft is to be replaced, proceed as follows: a. W ith the shaft assembly on a bench, straighten the tangs on the dust cap. Separate the upper and lower portions of the shaft assembly.
Page 225: Steering Gear
were not used, center the pins in the slots in the steering shaft flange and then install and torque the flange bolt nuts to specifications. P Models a. Place the steering gear in position, guiding the wormshaft into the universal joint assembly and lining up the marks made at removal.
Page 226: Directional Signal Switch
Fig. 3 B -5 1--R em oving L o ck P late R e ta in in g Ring Fig. 3 B -5 2 ~ R e m o v in g D ire c tio n a l S ig n a l W ire P ro te c to r 8.
Page 227: Lock Cylinder
Fig. 3 B -5 4 ~ ln s ta llin g S w itc h C o n n e c to r O n to J a c k e t C lip s is in the protector. Feed the connector and cover down Fig.
Page 228: Ignition Switch
Fig. 3 B -6 0 --ln s ta llin g A d a p te r Ring the shaft - do not pull the harness out of the column. 4. Rotate the lock counter-clockwise into " L O C K " position.
Page 229: Steering Column
2. Install the activating rod into the switch and assemble the switch on the column; tighten the mounting screws. Use only the specified screws since CAUTION: over-length screws could prevent a portion of the assembly from compressing under impact. 3. Reinstall the steering column assembly following the "M andatory Installation Sequence"...
Page 230: Removal
Fig. 3 B -6 3 --A u to m a tic T ra n s m is s io n In d ic a to r C o n n e c tio n -C K - T y p ic a l C and K Columns Inspection Removal...
Page 231 9. Move the front seat as far back as possible to provide A ssem bly-A ll Except T ilt Colum ns maximum clearance. NOTE: A pply a thin coat of lithium soap grease to all 10. Remove the two column bracket-to-instrument friction surfaces.
Page 232 Key No. Part Name Key No. Part Name Key No. Part Name 1 - C O LU M N ASM 20 - SW ITCH ASM 2 - HO USING ASM 21 - PROTECTOR W IRE - WASHER 3 - R A C K ASM 22 - HOUSING - SPRING...
Page 233 ✓ Fig. 3 B -6 7 --ln s ta llin g S te e rin g C o lu m n in V ise Fig. 3 B -6 9 -T u rn S ig n a l H o u s in g A s s e m b ly 15.
Page 234 Fig. 3 B -7 1--R em oving L o w e r B e a rin g R e ta in e r Fig. 3 B - 7 3 - ln s ta llin g G e a rs h ift H o u sin g L o w e r B e a rin g Tool J-2 1854-1 (fig.
Page 235 C J1 C /3 Ig nition Switch Rack 5 3 . Ig nition Switch Lock Bolt Spring 1. Shaft N u t 5 4 . M ast J ac k e t Ig nition Switch Rod Lock Shoes 2 . C over 3 7 .
Page 236 --------------— J-23072 Fig. 3B -7 --R em oving T ilt Lever S p rin g R e ta in e r Fig. 3 B -7 8 ~ R e m o v in g S h ift T ube sector (fig. 3B-80). Remove the drive shaft, sector and lock a.
Page 237 RACK A T T I i I k . a t o p Fig. 3 B -8 0 ~ R e m o v in g S e c to r D rive S h a ft Fig. 3 B -8 2 --ln s ta llin g B e a rin g H o u sin g enough to compress the wave washer.
Page 238: Column Installation-Mandatory Sequence
12. Assemble the bearing housing over the steering shaft and engage the rack over the end of the actuator rod (fig. 3B-82). 13. With the external release lever installed, hold the lock shoes in the disengaged position and assemble the bearing housing over the steering shaft until the pivot pin holes line up.
Page 239 Fig. 3 B -8 5 ~ R e m o v in g W ir in g H arness P ro te c to r Fig. 3 B -8 6 ~ R e m o v in g W ire s fro m C o n n e c to r retaining slots as shown in Figure 3B-85.
Page 240 TILT CO LUM N BEARING HOUSING ASSEMBLY - G AND P SERIES Removal (Column in Vehicle) 1. Disconnect the battery ground cable. 2. Remove the steering wheel as outlined under "Steering Wheel - Removal". 3. Remove the directional signal switch as outlined under "Directional Signal Switch - Removal".
Page 241 Install the lower shaft 90° to the upper shaft and over toe pan cover and slide the cover and seal up the column. the centering spheres. Slowly straighten the shafts while 6. Remove the steering wheel as outlined under compressing the preload spring. "Steering Wheel-Removal", and reinstall the shaft nut and 2.
Page 242 m v y' C L U TC H A N D BRAKE P E D A L S U PP O R T P R O T R U S IO N IN D E X S L O T VIEW A Fig.
Page 243 16 k 15 G A & PA 100-200 U pper S teering Shaft 13. S h ift Tube F elt W asher Turn S ignal S w itc h Screw 2 . S h ift Housing Bushing 14. S h ift Tube Assem bly Turn S ignal S w itc h Bushing Seat S h ift Lever Spacer...
Page 244 IN S TR U . PANEL O P E N IN G C O V E R H O U S IN G A S S Y . P R O TEC TO R W IRE S P R IN G (2 ) S P R IN G RELEASE P IN RELEASE S H O E RELEA SE-------...
Page 245 Fig. 3 B -9 4 ~ R e m o v in g B e a rin g H o u s in g P ivot Pin Fig. 3 B -9 2 ~ S e c u rin g C o lu m n w ith J -2 2 5 7 3 This allows the shift tube to be pushed further out of the spring by winding the spring up with pliers.
Page 246 R E M O V E D O T T E D P O R T IO N Fig. 3 B -9 8 -R e v is e d S h ift T u b e R e m oving T o o l J -2 2 5 5 1 Fig.
Page 247 L O C K PLATE Fig. 3 B - 10 0 --R e m o vin g L o ck P late A s s e m b ly Fig. 3 B - 1 0 2 - C o n d u c to r T u b e fo r A u to m a tic T ra n sm is s io n In d ic a to r have fully engaged the support.
Page 248: Steering Linkage
3B-89. Install the column to bracket clamp and torque the STEERING LINKAGE clamp bolt to specifications. See CAUTION on page 1 of this CAUTION: The toe pan bracket must not override the section regarding all fasteners referred to in NOTE: protrusions on the steering column.
Page 249: Tie Rod
/ RELAY ROD IDLER ARM TIE ROD ASSEMBLY ASSEMBLY l All clamps must be between & [ A ] c a u t i o n clear of dimples before torquing nut. KNUCKLE |~B] Exposed socket thread length must be STEERING GEAR equal within ±...
Page 250 Tighten clamps to specifications. Return tie rod assembly to the center of travel. e. All procedures for alignment, adjustment and assembly of tie rods applies to each side. f. Check each assembly to be sure that a total travel of at least 35° can be obtained using a bubble protractor and a pair of vise grips (Fig.
Page 251 Fig. 3 B -1 0 7 --T ie Rod In s p e c tio n their maximum limits, repeating Steps c and d. This recheck Fig. 3 B -1 0 8 --C h e c k in g Id le r M o v e m e n t of total rotation will result in a minimum of 35°...
Page 252: Steering Connecting Rod
may turn in sockets when attempting to tighten nut. Removal 3. Install pitman shaft nut or pitman arm clamp bolt 1. Raise vehicle on a hoist. and torque to specifications. 2. Remove the cotter pin and castellated nut from ball stud at the relay rod.
Page 253 CAUTION: ENDS OF ADJUSTABLE TIE ROD MUST BE HELD IN CORRECT RELATIONSHIP TO EACH OTHER AFTER ADJUSTMENT WITHIN + 2 ° . CAUTION: CLAMPS MUST BE BETWEEN AND CLEAR OF DIMPLES BEFORE TORQUING NUT. NOTE: STEERING CONNECTING ROD MUST BE INSTALLED WITH LONG END FORWARD.
Page 254 and hoses and connect the hoses to the gear. Tighten the Installation hose fittings to specified torque. 1. Postion pump assembly on vehicle and install attaching parts loosely. Power Steering Pump (3B-111 through 3B-117) 2. Connect and tighten hose fittings. 3.
Page 255 454 V-8 MOTOR HOME Fig. 3B-1 1 7 -P o w e r S te e rin g P u m p -4 5 4 V-8 M o to r Hom e 8. Lower the vehicle and turn wheels right and left on the ground.
Page 256 Hose assem bly m ust be C 30 in sta lle d against steering gear cover. W /H Y D R A B O O S T , Fig. 3B-1 2 1 -P o w e r S te e rin g H ose R o u tin g R o ta te hose assem bly against"...

Chevrolet Light Duty Truck 1978 Service Manual

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