Chevrolet 40 SERIES 1971 Service Manual
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Chevrolet 40 SERIES 1971 Service Manual

Chevrolet 40 SERIES 1971 Service Manual

Truck chassis
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Summary of Contents for Chevrolet 40 SERIES 1971

  • Page 2 This manual should be kept in a handy place for ready referen ce. If properly used, it will enable the AND CLUTCHES technician to b e tte r se rv e the owners of Chevrolet built vehicles. FUEL TANK & EXHAUST All inform ation, illu stratio n s and specifications con­...
  • Page 3 Chevrolet Truck. Every effort has been made to include timely and adequate information on the various units and systems used on Chevrolet Trucks. The general maintenance and light repair procedures in the various manual sections are the result of extensive service experience. This information should serve not only as a reference for the experienced mechanical force, but also as a comprehensive text for training purposes.
  • Page 4 This manual contains “on-the-vehicle” main­ the various design and construction differences. tenance and light repair information on Chevrolet Manufacturers model or part numbers are used Truck Models listed on page v. Since many truck in many instances in the “Specifications”...
  • Page 5 285V ,3 2 5 V ,56 5 2 B , 30DSC 34DSC 542G L, MT40, 6041 A u x., 7041 A u x. TE-60 13"-1 12"-2 F070 F090, F120 H170 T 1 7 0 ,17121, 435GL 282V, 285V, 542G L, 17221,19201 5752C, AT540 CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 6 IN S T A L L E D D E S C R I P T I O N D E S C R I P T I O N IMPORTANT: RETAIN THIS PLATE AS A PERMANENT RECORD CHEVROLET 40-50 TRUCK SERVICE MANUAL...
  • Page 7 M anner T hat They W ill Be C lean and F re e of C ontam ination, Due to D irt o r O th e r F o reig n M atte r. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 8 Sec. 0-2 LUBRICATION Figure 1 —Lubrication Chart I A ll Except Steel Tilt Cab M odelsI CHEVROLET 40-60 TRUCK SERVICE MANUAL...

  • Page 9: Table Of Contents

    NOTE: Engine oil is u se d a lso to lu b ric a te cle v is p in s, linkage, c le v ise s, door hin ges, e tc . A pplication should be m ade by b ru sh o r sp ra y . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 10 Sec. 0-4 LUBRICATION E N G IN E D IA G RA M T-8191 Figure 2 —Lubrication Chart (Steel Tilt Cab M odels) CHEVROLET 40-60 TRUCK SERVICE MANUAL...

  • Page 11: Lubrication Data (Chart On Opposite Page)

    NOTE: Engine oil is u se d a lso to lu b ric a te c le v is p in s, linkage, c le v ise s, door h in g es, e tc . A pplication should be m ade by b ru s h o r sp ra y . CHEVROLET 40-60 TRUCK SERVICE MANUAL...

  • Page 12: To Level Of F Ille R P L U G

    (d) O ptional oil lu b ric a te d type re q u ire no p e rio d ic s e rv ic e . Figure 3—Lubrication Chart Tandem B evel 30DSC and 34DSC CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 13 (2) If u se d (V8) fill hinge type o ile r w ith engine oil (1) Som e M odels. ev ery 12,000 m ile s. (3) V ehicles w ith a i r b ra k e s. Figure 4 —Engine and Accessories Lubrication Chart (Typical) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 14 T T 0 U.S. IM P. P o w e r S t e e r i n g ........... 8 P ts . 6% P ts . CHEVROLET 40-40 TRUCK SERVICE MANUAL...
  • Page 15 — “ Engine O il Supplem ent” — o r g ra d e s a r e changed. is av a ilab le . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 16 Figure 5 —Engine Viscosity Charts ta in e r s . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 17 (except ST b a tte rie s ). CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 18 ­ b ility and p e rfo rm a n c e fro m your C h ev ro let engine. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 19 . a r e re q u ire d when o rd e rin g o r making new keys. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 20 . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 21 FRAME (SEC. 2). To s tra ig h te n the b lack o r o th e r autom otive la c q u e r. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 22 (fig. 1). Figure 1 —Cross Section of W indshield W eatherstrip (Conventional Cab M odel) Figure 2 —Loosening W eatherstrip (Conv. Cab M odel) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 23 TPM-9027 th e sid e w h ere block o r blocks could not be in ­ s ta lle d . Figure 6 —Installing Insert-Retained C lass (Tilt Cab M odel) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 24 3. P la c e p ro te c tiv e covering o v e r the plenum g r ille , fro n t fen d e rs and hood. Apply s e a le r to CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 25 (fig. 6). No sealin g b o lts to 55-65 foot-pounds to rq u e . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 26 If n e c e s s a ry , rem o v e a r m s a s follow s: p la cem e n t. Figure 9 - W iper Blade Installed (Tilt Cab M odel) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 27 1. If tra n s m is s io n sh aft w as s e p a ra te d fro m so a s to p ro v id e an e le c tric a l ground fo r m o to r. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 28 4. D isconnect w ip e r d riv e ro d s fro m c ra n k a r m . R em ove c ra n k a r m nut and a r m fro m m o to r sh a ft. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 29 W iper Housing 24 OHM Resistor L - c r p Battery Ammeter n t u r p —5 Arm ature T-030 HIGH SPEED CIRCUITS Figure 16—H igh-Low Speed Circuit Figure 17—Troubleshooting W iper Motor Circuit CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 30 P a rk in g sw itch co n ta c ts, th e dash sw itch . H ow ever, c u rre n t fro m b a tte ry CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 31 . S e rv ic e k its p ro v id e all BRUSH HOLDER REMOVE BRUSH SPRING FROM SLOT AND PLACE IT IN GROOVE AS SHOWN Figure 19—Releasing Brush Spring Tension Figure 2 0 —End Play W ave W asher Installation CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 32 4. P u ll end p la te fro m a rm a tu re . Note th ru s t 1. C heck w ip er m o to r ground connection to the plug betw een tip of a rm a tu re shaft and end p la te . cab. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 33 "LOW " sp e e d . If o p e ra to r w ishes high sp e e d w ip e r actio n he m u st m anually sw itch to Figure 2 2 —Separating Pump From M otor CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 34 O n -V eh icle Check o r p o o r so ld e r connections. 1. If w ash er pum p s continuously when w iper CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 35 ­ 3. D isconnect ra tc h e t paw l sp rin g . R em ove tion a s o rig in a l p o sitio n . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 36 H ow ever, th e s e v e h ic le s. The fro n t mount c o n sists of an CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 37 Transmission Cover W /S Wiper Linkage Body Mounting T-3650 Dash Mats and Floor Insulators W /S Wiper Blades Figure 1— Cab and Components (Typical) Figure 3 —Cab Rear M ounting Figure 2 —Cab Front M ounting CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 38 R e fe r to fig u re 6. The quality of m aintenance is a s im p o rtan t a s the re g u la rity w ith w hich it is se rv ic e d . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 39 To get full b enefit fro m the optional lev el rid e s e a t, p ro p e r ad ju stm e n t is of p rim a ry im p o rta n ce . Figure 8 —Level Ride Adjustm ent CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 40 Sec. IB-22 CONVENTIONAL CAB Figure 9 —Exp lo d ed V iew of Level Ride Seat CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 41 59 F a s te n e r C lip, C ushion 20 R oll P in 60 R ide L evel In d ica to r 39 T h ru st B all B earin g Legend for Figure 9 CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 42 1, of "T o rs io n B a r R em ov al." 2. Rem ove p re lo a d on to rsio n b a r s follow ing Figure 14—Seat Lubrication Fitting CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 43 NOTE: D oor lock s t r ik e r and attaching sc re w s a r e im p o rtan t a tta c h in g p a r ts in th at they could Figure 15—Door Hinge Bolt Wrench J-2 2 58 5 (Typical) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 44 R e fe r to fig u re 15. Rem ove the door to u p p er hinge reta in in g Figure 17—Lock Rotor Cover Assem bly and Striker Plate b o lts. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 45 Figure 2 0 —Vent W in dow A ssem bly Removal th e door v e n tila to r a sse m b ly . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 46 (level) and ra is e stra ig h t up and out. Figure 2 2 —Regulator A ssem bly and Glass 8. R e v e rse above p ro c e d u re fo r in sta lla tio n . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 47 8. R e in s ta ll s ill p la te and s ill p la te re ta in in g Figure 2 4 —Installing Trim Panel Seal s c re w s . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 48 4. Apply cem ent to s e a l if n e c e s s a ry , then s t a r t at one end of groove applying se a l. Figure 2 6 —Lock Cylinder Installed Figure 2 7 —Remote Control and Side Door Lock CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 49 , a so lid hardw ood 4 x 4, TA feet s t a r t engine, then final check a ll connections and long, p o sitio n e d throu gh th e cab w ith h o ist chain linkage. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 50 . TEM PERATURE D O O R BLO W ER A SSEM BLY D EFR O STER D O O R Figure 2 8 —D eluxe A ir-Flow Heater Schematic CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 51 W A T tR W A TER PUMP PUMP B U b H , N G T-6429 Figure 3 2 —Hearer hoses ( OU Series) (typ ica l) Figure 3 0 —D eluxe A ir-Flow Heater Control Panel CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 52 DEFROSTER DUCT ASSEM BLY The d e fro s te r hose and o u tle ts a s se m b lie s a r e illu s tra te d in fig u re 34. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 53 , re fin ish in g , and p ainting of cab w hich w ill apply. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 54 6. Always follow d ire c tio n s sp ecified by the m anufac­ t u r e r of the p ro d u ct u se d (label d ire c tio n s). CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 55 -ty p e sc re w re ta in e d to door Figure 1—Tilt Cab Interior Construction and have a pu sh b u tto n -ty p e la tc h co n tro l. CHEVROLET 40-60 TRUCK SERVICE MANUAL...

  • Page 56: Cab Mountings

    • ^ r ’ ' r x i ^ i u Check Link Frame Bracket "0 Frame Bracket Release Rod Check Link and Release Rod CAB FRONT M OUNTING CAB REAR M OUNTING Figure 3 —Cab M ountings CHEVROLET 40-60 TRUCK SERVICE MANUAL...

  • Page 57: Insulation

    . A fte r ad ju stin g tr a c k asse m b ly . CHEVROLET 40-60 TRUCK SERVICE MANUAL...

  • Page 58: Doors

    . pan el. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 59 . S p acers w a sh e r on door p illa r u sin g p en cil o r crayon . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 60 R em ove eight s c re w s w hich a tta c h a c c e s s p an el to low er p o rtio n of d o o r. Rem ove a c c e s s Figure 11—Door H andle Installation pan el. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 61 2. W hile holding c y lin d e r, in s e r t le g s of r e - Figure 15—D isengaging Door Inside Handle CHEVROLET 40-60 TRUCK SERVICc MANUAL...
  • Page 62 NOTE: The lo w er view in fig u re 15 show s how sp rin g becom es fully engaged. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 63 "R em oval" p ro c e d u re s . IMPORTANT: M ake s u r e to u se th e th re e Figure 19—Low ering Regulator from Door CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 64 1.24-in ch fro m low er rig h t c o rn e r (fig. 21) and then p r e s s channel o v e r g la ss and glazing Figure 2 1 —Door G lass A ssem bly (Right Side Shown) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 65 . sp rin g s c a le p o sition ed a t r e a r edge of g la s s . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 66 1. T horoughly c le a n in sid e of g la s s channels b ecom e bonded to door s u rfa c e . CHEVROLET 40-60 TRUCK SERVICE MANUAL...

  • Page 67: Cab Ventilation And Heating

    A ll co n tro l le v e r s a r e in th e "O F F " p o sitio n w ith knobs a t top of p an el. TPM -9054 Figure 2 7 —O utside A ir Intake Figure 2 8 —Heater Installation CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 68 2. C heck the b low er m o to r. s tru m e n t p anel, th en rem o v e duct and se a l g ask et. CHEVROLET 40-60 TRUCK SERVICE MANUAL...

  • Page 69: Cab Replacement

    . R em ove two re ta in in g b o lts Lifting Sling / 10 Hold-Down Catch •M 7406 Figure —Lifting Sling A ttached to Cab Figure 31 —Rear Hold-Down Catch on W ood Block CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 70 . A lso, the a id of Figure 3 3 —Torsion Bar Tension A djustm ent Lever Installed one o r m o re a s s is ta n ts is reco m m ended. CHEVROLET 40-60 TRUCK SERVICE MANUAL...

  • Page 71: Torsion Bar Tension Adjustment

    4. In s ta ll cab stop b ra c k e ts (if p re v io u sly r e ­ le v e r and s e r r a te d s p a c e r block to th e cab fra m e CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 72 - cab tilte d com pletely fo rw a rd o r in o p e ratin g p o sitio n . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 73 SIDE VIEW END VIEW 1 Frame Side Rail Wood Filler Block 8 Lock Nut 2 Longitudinal Sill Clip Plate 9 Nut 3 Spacer Block Metal Channel 10 Cross Sill Mounting Bolt Figure 1—Typical Body M ountings CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 74 (stu ds) can a lso be su c c e ssfu lly m ounting of s ill ch an n els. em ployed. If desig n of body does not p e rm it use CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 75 . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 76 Sec. I D - 58 BODY MOUNTINGS IMPORTANT DO NOT drill additional holes in frame. Refer to F R A M E (SEC. 2) for additional cautions. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 77 . A ir e n te rin g the v ehicle m u st p a s s e ith e r thro u gh the cooling unit (e v a p o r­ Figure 1 —A ir C onditioning Controls CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 78 FORWARD Figure 2 —A ir Conditioning System Components EVAPORATOR CENTER DASH OUTLET BLOWER ASSEMBLY DEFROSTER OUTLETS RECIRCULATING AIR INLET VALVE DEFROSTER FLOOR DOOR T-3873 OUTLET Figure 3 - A ir - F lo w Schematic CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 79 "H EA TER " p o sitio n w ill a c tiv a te the c o m p re s s o r CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 80 The p u rp o se of the cap is to dan g ero u s p r e s s u r e build-up in th e sy ste m . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 81 Capping the tubing w ill a lso p r e ­ lin e s. vent d ir t and fo reig n m a tte r fro m e n te rin g . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 82 , o r in evacuating both s id e s of the sy ste m . Figure 6 - J - 8 3 9 3 C harging Station CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 83 , d u sts, o r v a p o rs m ay be p r e s e n t. Figure 7—Leak Detector CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 84 Vacuum pum p (Tool J-5 4 2 8 -0 2 ) (fig. 8), is Station w hich u s e s the 25 pound d ru m of r e f r ig e r a n t. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 85 5. Check b e lt te n sio n r e g u la rly . ation. 6. E v ery w eek - d u rin g w in te r m onths o r CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 86 35% to 40% r e ­ 32.0 PSig. - - 5000 ft. g a r d le s s of the am bien t te m p e ra tu re of hum idity. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 87 Figure 11 —Expansion Valve b lo w er r e s i s t o r . P la c e the b low er on "LO W ." W ith CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 88 . V erify w ith a p e r ­ out s y s te m usin g p e rfo rm a n c e checks out­ fo rm a n c e check. lined in th is m anual. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 89 . Figure 12—C harging Station Controls CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 90 28-29 in ch es of vacuum is obtain ed . 4. When r e f r ig e r a n t flow sto p s, connect low CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 91 ­ 3. D isconnect the high p r e s s u r e lin e fro m the CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 92 Any r e f r ig e r a n t le a k s found in th e sy ste m should be r e p a ire d in the follow ing m ann er: Figure 14—Line Connections (Late M odels) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 93 . should be m ade. 2. Rem ove and re p la c e the defectiv e p a r t. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 94 5. In s ta ll a new r e c e iv e r-d e h y d ra to r. sw itch and m ounting b ra c k e t. 6. In sta ll the re p la c e m e n t c o m p re s s o r. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 95 9. C onnect th e coolant h o se s fro m the engine Figure 16 — A ir Conditioning Controls to the ra d ia to r in le t and o u tlet. Clam p se c u re ly . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 96 4. Cap the sy ste m if th e re c e iv e r-d e h y d ra to r valve. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 97 P u ll the c a se away fro m the mounting s c re w s . stu d s and in b o ard to rem o v e it. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 98 7. R efill the cooling s y ste m , and ev acu ate and h e a te r c a s e . c h a rg e the re f rig e ra tio n s y ste m . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 99 "H e a te r C a se ." w ith n o n -h a rd e n in g s e a le r . Figure 21 —W irin g Harness CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 100 1. D isco nn ect w irin g h a rn e s s a t c o m p re s s o r ing W iring D iag ram . CEN TER OUTLET T - 7 0 6 8 Figure 23 —A ir Outlets and Hoses CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 101 Rem ove a c tu a to r m ounting b ra c k e t fro m 2. In s ta ll vacuum lin e onto the valve. 3. R efill th e ra d ia to r . kick p an el. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 102 3. A ssem b le the connecting sh aft to th e valve and actu atin g d iap h rag m . 4. R ep lace th e cowl g r ille p an el. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 103 "CIG” Figure 2 8 —A ir Conditioning W iring D iagram D iscon n ect B a tte ry B efo re W orking on E le c tr ic a l E quipm ent. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 104 REMAINS THE SAME ature door. Valve is stuck open and too much refrig­ Check for clutch slippage, erant is entering evaporator. Replace belt slippage and listen expansion valve. See Note "E." for unusual n oises. T-7073 CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 105 ALWAYS WEAR PRO TECTIV E GOGGLES WHEN WORKING ON REFRIGERATION SYSTEMS. ALSO BEWARE O F THE DANGER O F CARBON MONOXIDE FUMES BY AVOIDING RUNNING THE ENGINE IN CLOSED OR IM PRO PERLY VENTILATED GARAGES. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 106 Rear Head to Shell Stud N uts............20 ft. lbs. RPM (C old)....................4000 Shaft Mounting N u t................15 ft. lbs. Compressor Clutch Coil Fuses...................... 25 Amp. Ohms (at 80° F)...................3.85 Amps (at 80° F)................3.2 12 volts CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 107 , a c o rre sp o n d in g point in clu ded betw een th e p o in ts of m e a su re m e n t m ay Figure 1—Typical Fram e A lignm ent Points CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 108 S.A .E . 1023 b a se r a ils . Max. Bending Moment T-7844 Figure 2 —Frame Bending M om ent (Typical Tractor) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 109 . c a u se s th e c e n te r of g ra v ity of the lo ad to move Figure 3 —Fram e Bending M om ent (Typical Straight Truck) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 110 , not through fla n g e s. ing re in fo rc e m e n ts . T he u se of riv e ts fo r attach in g CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 111 W hen w elding in the fla t p o sitio n u se high se c u re ly fa ste n e d to the sid e r a il. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 112 B a se r a ils of S .A .E. 1023 m a te ria l could u se Figure 6 —Scarfed (Tapered) Ends of Reinforcem ent re in fo rc e m e n ts of S.A .E . 950 m a te ria l.S .A .E . 1023 CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 113 . T he fo l­ th e web se c tio n (fig. 8). low ing g e n e ra l ru le s apply: CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 114 8 to 10 in ch e s. to g e n e ra tin g sy ste m . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 115 TE-TS 50 &TE60 . . 14% TE-TS 110% 160% 201% 5 0& T E 60 . . . 20 15% 17 20 15% TE-TS 19034 257% 50 & TE 6 0 . . . 17 20 15% 140% CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 116 = * ■ ----------1 rr 1 77— l- i 1 — " l _______ I [ \ ® r .... ’ L i DIMENSIONS TO HOLES OR SLOTS ARE MEASURED TO THE CENTER OF HOLE OR SLOT GAUGE HOLES ARE %" DIAMETER ©...
  • Page 117 > DIMENSIONS TO HOLES OR SLOTS ARE MEASURED TO THE CENTER OF HOLE OR SLOT GAUGE HOLES ARE 5 /s" 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 118 > £ Figure 1 1 —Tilt C ab Truck Frame (Typical) >...
  • Page 119 175-240 22-24 Alternate Electrode................. E-7018 S id e R ail M ate rial Identification (Location— C e n te rlin e of Front A xle) SAE1023 SA 9 5 0 1 \ ? STD. OPT. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 120 . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 121 2. R efer to "L oad and Inflation Table"(SE C .10) 3. O verloaded o r im p ro p e rly loaded. 3. Avoid ov erlo ad in g v eh ic le . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 122 , lo o sen th e pow er When se ttin g " to e -in " ad ju stm e n t, the fro n t CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 123 "A " and "B ." "B " SHOULD EXCEED "A " by am ount sp e c ifie d . C a m b er d im en ­ CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 124 6.15° + 0°15' ± 30' —0°15' ± 30' + 1°15' ± 30' T-60 Vz"~Vi" ^Regardless of maximum turning angles specified, adjustment of stop screws must provide Ms-inch minimum clearance of tire with any chassis components. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 125 6. In sp e ct kingpin and ste e rin g knuckle b u sh ­ in gs fo r w e a r. Figure 1— Typical Steering Knuckle Construction CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 126 IMPORTANT: When in sta llin g o v e rs iz e t i r e s , a r m . re c h e c k tu rn in g c le a ra n c e and stop sc re w se ttin g . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 127 A —Dimension varies with different size tires. Set stop screws to provide % " clearance between tires and chassis at extreme turn positions. -7608 t p m Figure 5 —Stop Screw Adjustm ent (F070, F090, and F I 20) (Typical) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 128 1. J a c k up axle and rem o v e hubs and b e a rin g s CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 129 9. In s ta ll new kingpin dust cap g ask et (5) a t CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 130 KING PIN N U T ..........250 Ft. Lbs. Then 250 Ft. Lbs. Then Advance to Next Advance to Next Cotter Pin Hole Cotter Pin Hole KING PIN BEARING CAP CAP-SCREW . .. 50-70 In.-Lbs. 60-70 In.-Lbs. — — CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 131 CE, ME40-60 SERIES B l l . RETAINER d o it I RETAIN ER BC^ \ ( ^ - rebound MODELS ONLY FRONT MOUNTING ALL MODELS T-7849 Figure 1 —Beam Suspension Figure 2— Spring Mounting (Typical) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 132 (J-21058) and r e c e iv e r and b rid g e (J - of th e offset type (F -050 , F -055 axle) bushing. 21830-4, 7) rem o v e bushing fro m s p rin g eye. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 133 (TORQUE 320-420 FT.-LBS.) " C ” & ” S " M ODELS FRONT M OUNTING—ALL MODELS REAR M O U N TIN G -A LL TILT CAB MODELS Figure 5 —Front Spring M ounting Figure 6 —Spring Eye Bushing CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 134 . enough to r e s tr ic t f r e e m ovem ent of le a v e s. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 135 U -b o lts m u st be re tig h te n e d to in itia l to rq u e lis te d in "S p ecificatio n s" a f te r 500 m ile s. CHEVROLET 40-<50 TRUCK SERVICE MANUAL...
  • Page 136 12 Lock Nut 19 Wheel (Budd Type) 6 Wheel Bolt 13 Inner Bearing Cup 20 Hub T-7846 7 Outer Bearing Cup 14 Inner Bearing ?one and R ollers 21 Wheel Clamo__________ Figure 1—Front Hub and Bearing CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 137 17 Hub to B ra k e D rum B olt 6 W heel and D ru m A sse m b ly O il S hield 18 Hub Cap 8170 Figure 3 —Front Hubs and Bearings (Cast Type W heels) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 138 ’’R e p a ir." CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 139 . by p r e s s in g out th e w heel stu d s, a s ap p licab le . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 140 ­ bly to a s s u r e p r o p e r re te n tio n of p a rt(s ). CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 141 A xle sh a fts a r e fu ll-flo a tin g ty p e. In n e r end of sh a ft is sp lin e d and engages s im ila r sp lin e s in Figure 1 —Clearance Betw een A x le Shaft Flange and Stud Nut CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 142 , it may be n e c e s s a ry to Axle L u b ric a tio n ." Some types of a x les re q u ire CHEVROLET 40-60 TRUCK SERVICE MANUAL...

  • Page 143: Pinion Oil Seal Replacement

    2. Hold p ro p e lle r sh a ft yoke w ith holding b a r 4. C onnect p r o p e lle r sh a ft to r e a r ax le yoke CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 144 Hold yoke w ith holding b a r (fig. 2) w hile tightening nut to reco m m en d ed to rq u e . Figure 3 —Propeller Shaft Yoke Puller (TypicalI CHEVROLET 40-60 TRUCK SERVICE MANUAL...

  • Page 145: A Xle Vent R E P L A C E M E N

    LUBRI­ m a rk s a r e p o sitio n ed a t top of w heel. M easu re CATION (SEC. 0) of th is m anual. CHEVROLET 40-60 TRUCK SERVICE MANUAL...

  • Page 146: G E N E Ra L D E Sc Rip Tio N And O P Eratio

    Figure 5 —Tw o-Speed A x le Shift Control (T ypical) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 147 . Figure 7—Position of Drive Screw in High and Low Range CHEVROLET 40-60 TRUCK SERVICE MANUAL...

  • Page 148: E Le C Tr Ic Shift U Nit R E P L A C E M E N

    "HIGH" o r "LOW ” ran g e p o sitio n . w ire is a ttac h e d to th e b o tto m te rm in a l. Figure 10—Position of Drive Nut W hen D isassem bling CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 149 24 Shift Housing Cover Gasket 25 Shift Housing Cover and Detent Spring 26 Lubricant Plug 27 Housing Cover to Housing Screw (with W asher) 28 Housing to C a rrie r Seal Figure 11—Electric Shift Unit Com ponents (Rockwell) CHEVROLET 40-60 TRUCK SERVICE MANUAL...

  • Page 150: E Le C Tr Ic Shift Unit O V Erh Au

    27 L ubricant Plug 28 Housing Cover to Housing Screw (with W asher) < ^ _ 5 > - 1 5 ■16 TP-8598 - 1 Figure 12—Electric Shift M otor Unit Com ponents (Eaton and Corporation) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 151 N ext, p la c e two len g th s of tubing o v e r ends of sp rin g , p u ll sp rin g Figure 15—Rem oving Mofor W ires CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 152 T ighten s c re w s and nu ts firm ly . Figure 17—Rem oving Torsion Spring (Rockw ell) 3. A ttach m o to r w ire s to sw itch te r m in a ls . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 153 4. W ith a s c r e w d r iv e r in s e rte d into slo t of d riv e s c re w (20), in s ta ll b e a rin g (12) on end of Figure 19—A ssem bling Torsion Spring and Levers (Eaton) CHEVROLET 40-60 TRUCK SERVICE MANUAL...

  • Page 154: D E Sc Rip Tio N And O P E R A T I O

    "H IM p o sitio n , r e a r axle p ow er sh ift c h am ­ Figure 2 0 —Arrangem ent of Tw o-Speed A xle Vacuum Control Units Typical) CHEVROLET 40-60 TRUCK SERVICE MANUAL...

  • Page 155: Acuum Shift S Y Stem M Aintenance

    Slip new s e a l rin g o v e r tube end. I n s e r t tube into fitting Figure 2 2 —Vacuum Tubing Connection Seal CHEVROLET 40-60 TRUCK SERVICE MANUAL...

  • Page 156: Acuum Shift C O N Tro L V A L V

    . c o v e r g a sk e t, valve body a s se m b ly , body g a sk et, CHEVROLET 40-60 TRUCK SERVICE MANUAL...

  • Page 157: Shift C H Am B Er (C Orp. A X L

    . 4. A ttach in tak e m anifold, a i r c le a n e r, sp e e d - CHEVROLET 40-60 TRUCK SERVICE MANUAL...

  • Page 158: C Heck V A L V

    D ra in c le a n ­ ing so lvent fro m elem en t. R e in sta ll d ry . Figure 2 6 —A dju stin g Push Rod (Corporation A x le ) CHEVROLET 40-60 TRUCK SERVICE MANUAL...

  • Page 159: Speedometer Adapter Shift Diaphragm

    ), th e c irc u it b re a k e r is s y s te m r a te d v o ltage. fau lty . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 160 . L am p should go out w ith c o n tro l sw itch in o u tlin ed in th is m anual. low ran g e p o sitio n . CHEVROLET 40-60 TRUCK SERVICE MANUAL...

  • Page 161: P Isto N A Ir Shift Unit R E P A I

    If te s t lam p in d ic a tio n s a r e not c o r r e c t, tro u b le is in w irin g h a rn e s s o r c o n tro l sw itch. Figure 3 1 —Clevis Pin Rem oval or Installation CHEVROLET 40-60 TRUCK SERVICE MANUAL...

  • Page 162: Tandem Rear Axle

    (Eaton M odels 30R CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 163 . C ontinuous u n n e c e ssa ry Figure 3 4 —D ifferential Lock Switch and W arning Light Installation u s e of lockout m ust be avoided. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 164 T e s t the s y ste m fo r vacuum le a k s. ing b ra k e re le a s e d and th e tra n s m is s io n in n e u tra l. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 165 (14) to rem o v e p lu n g e r th ro u g h top of c o n tro l valve Figure 3 7 —Sectional V iew of Control Valve body. R em ove p lu n g e r sp rin g (13). CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 166 Corporation Stud N u t - 1 / ? " ..................50-60 7 /ie"-20 Cap Screw ................75-90 Stud Nut—5 / 8" ..................90-110 9 /ie "-1 8 .....................130-170 Cap Screw— ................11-18 5 /i6 " -2 4 CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 167 . Spring eye o r ra d iu s le af sp rin g . M ake s u re veh icle is su p p o rted safely . Figure 1—Rear Springs Installed (Series 4 0 ) (Typical) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 168 3. F ile peen ed end of c e n te r bo lt and rem o v e c e n te r bolt nut. Figure 3 —Using C-Clamp at Radius Leaf CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 169 11. R em ove blocking and lo w er fra m e to p la c e w eight on s p rin g s . C heck U -b o lt n u ts fo r p ro p e r Figure 5 —Installing Rubber Type Eye Bushing CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 170 3. R em ove lock bolt se c u rin g sp rin g pin in fro n t b ra c k e t. R em ove lu b ric a tio n fitting fro m CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 171 25 Stud Nut 12 Lock Nut 26 Saddle C aps 13 Lock W ash er 14 Top Pad Slide 'b ■' B m COMPONENTS DISASSEMBLED T-6435 Figure 6 —Tandem Rear A x le Suspension (Hendrickson R.T.) (Typical) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 172 Figure 8 —Section Through Spring Eye le a v e s in v ise o r a rb o r p r e s s . and Front Bracket (Typical) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 173 4. L ow er th e c r o s s tube and b e a m s, th en slid e b e a m s fro m tube ends. Figure 10—Section Through Spring Saddle and Beam CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 174 E xam ine b a ll stu d s fo r dam aged th re a d s and fo r lo o se n e ss in bushings in to rq u e ro d ends. If any Figure 12—Equalizing Beam M ounting at A x le Bracket CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 175 S tra d d le Mount Type In s ta ll b a ll stu d in axle b ra c k e t w ith w a sh e r and nut. Figure 14—Straddle Type Torque Rod CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 176 Torque Rod Bracket to Side Rail Lower Flange B o lt..Nut 40-50 Torque Rod Bracket to Crossmember.......Bolt 100-120 x 11 90-110 Straddle Mount Vs" V 2 "x l3 50-60 Straddle Mount Torque Rod Ball Stud............Nut 450-500 *With Hardened Washers. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 177 . H ow ever, Figure 1 —Rear W heel Bearing A dju stin g Nuts CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 178 H170, T170, 17121, 17221, 18121, 18221, 19101, 19201, Stud 19 Bolt T-7130 30DSC, 34DSC A X L E S — w /C A S T W H EELS Figure 2 —Rear Hubs, Bearin gs, and O il Seals CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 179 2. On Type E in fig u re 2, lift w heel (hub) and CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 180 . sle e v e a ro u n d e n tire c irc u m fe re n c e w ith h a m m e r CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 181 BRAKES (SEC. 5) of th is m an u al. BRAKES (SEC. 5) of th is m anual. SPECIFICATIONS TORQUE SPECIFICATIONS ADJUSTING NUT FT. LBS. All Axles Except Corp. H-110.............. Corp. H-110......................75-100 LOCK NUT W/Rockwell and Eaton..................100-150 W Corp. T, H-150......................135 W/Corp. H-110......................250 CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 182 . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 183 14 D ust Cap 5 Snap Ring 10 G re a se R e ta in e r 15 C ushion R e ta in e r TPM-3603-2 Figure 1 —Typical Propeller Shaft and U niversal Joints CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 184 CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 185 Key n u m b e rs in te x t r e f e r to fig u re 2. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 186 . UNIVERSAL JOINT DO NOT IMMERSE SEALED BEARING IN W ash a ll p a r ts in clean in g fluid. M ake s u re CLEANING FLUID. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 187 T ighten d ust cap by hand only; use of w ren ch w ill dam age c o rk o r fe lt w a s h e r. 4. In sta ll lu b ric a tio n fittin g in slip yoke. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 188 Sec. 4D-6 PROPELLER SHAFTS E—CHECKING FORWARD REAR AXIE PINION ANGIE TPM-9995 Figure 5 —Checking Drive Line A ngles CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 189 2 -sp e e d sh ift m oto r ad ap­ e tc . ( r e f e r to "AUXILIARY TRANSMISSIONS" (SEC. te r , check angle of the fo rw a rd r e a r axle pinion by CHEVROLET 40-40 TRUCK SERVICE MANUAL...
  • Page 190 9. C heck r e a r w a rd r e a r ax le pinion angle a s r e p a ir kit only. See follow ing page fo r "S p ec ifica tio n s." CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 191 65-85 ft. lbs. PROPELLER SHAFT GUARD (N U T )................................50-60 ft. lbs. YOKE BOLT TO FRONT DIFFERENTIAL..............................90-130 ft. lbs. YOKE U-BOLT TO FRONT AND REAR DIFFERENTIAL (N U T )........................40-55 ft. lbs. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 192 U -b o lts should be m aintained to p re v e n t v ib ra tio n and dam age to needle b e a rin g s, and m ounting com ponents. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 193 The vacuum s y ste m on th e s e v eh icles contains flu id output of the vacuum b o o s te r is the sa m e a s a check valve w hich m ain tain s enough vacuum in CHEVROLET 40-60 TRUCK SERVICE MANUAL...

  • Page 194: B Ra K E S Y Stem M A In Te N A N C

    6. T w in-A ction au to m atic ad justing - REAR. 6. To s e r v ic e pow er c y lin d e r a ir c le a n e r, r e ­ CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 195 | j REAR AXLE ■ BRAKE LINE ..REAR SHOE A D JU STIN G STUD T-2938 Figure 2 —Type “ F” Brake Adjustm ent Figure 3 —Type “ FR -3" Brake Adjustm ent CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 196 . R efill sy ste m w ith recom m ended fluid. Figure 4 —Backing A dju stin g Screw (Cross Section V ie w ) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 197 Figure 6 —Brake Bleeding Tool for Split 1. M ain S y stem - fro n t w heel b ra k e s p lu s one System M aster Cylinder CHEVROLET 40-60 TRUCK SERVICE MANUAL...

  • Page 198: M Aster Cylinder

    PO W ER CYLINDER CYLIN DER TWIN ACTION f r o n t PO W ER CYLINDER x f f l / MASTER CYLIN DER 'F A ” T-7906 Figure 7—Hydraulic Brake Bleeding Sequence Chart CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 199 7 Support Bracket 12 Brake Pedal 8 Nut 13 Boot 9 Bushing 14 Push Rod Figure 8 —Clutch and Brake Pedal Installation (S50 M odels) Figure 9 —Clutch and Brake Pedal Installation (Conv. M odels) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 200 "P u sh Rod A d ju stm e n t.” p ed al tr a v e l w ill be re q u ire d to apply the b ra k e s . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 201 . 4. T ighten a d ju stin g nut. Figure 11 — Brake Pedal Free Movement 5. C heck o p e ra tio n of b ra k e s . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 202 Tighten b o lts firm ly . 2. C onnect hy d rau lic lin e s to b ra k e and clutch c y lin d e r o u tle ts. Figure 12—Split System M aster Cylinder Installed CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 203 . Make heading of "B leeding B r a k e s .” CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 204 " s u rfa c e , w hich is p ro d u ced by diam ond check v alve. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 205 8 B y - P a s s P o r t 22 R e ta in e r Ring -5245 9 R e s e rv o ir H ousing Figure 15—Split System M aster Cylinder CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 206 In sta ll sw itch in r e v e r s e o r d e r of rem o v al and follow ad ju stm e n t p ro c e d u re . Figure 17—Pedal Travel Tool Installed CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 207 ­ fittin g a s se m b ly . d e r a sse m b ly . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 208 Figure 18—W heel Cylinders Used w ith Type “ F ," “ F A ," “ FR-3” , and “ FR -3A " Brakes d ire c te d u n d er "B leeding B ra k e s ." CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 209 In sta ll b le e d e r valve. Figure 2 0 —Duo-Servo W heel Cylinder Figure 19—Checking Fit of Piston in W heel Cylinder CHEVROLET 40-60 TRUCK SERVICE MANUAL...

  • Page 210: Hydraulic Lines

    "B leeding B ra k e s ." cab) and fra m e connection, betw een fra m e and fro n t w heel c y lin d e rs, and betw een fra m e and r e a r CHEVROLET 40-60 TRUCK SERVICE MANUAL...

  • Page 211: Acuum P O W Er C Y Lin D Ers

    . If no actio n is fe lt, vacuum sy s te m is not functioning. Figure 2 2 —Pow er Cylinder Installed (ConventionalI CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 212 . See fig ­ of d irt, th a t s a tis fa c to ry clean in g cannot be done, u r e 24. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 213 , and ch eck Figure 2 6 —Vacuum Check V alve Installed (Typical) CHEVROLET 40-60 TRUCK SERVICE MANUAL...

  • Page 214: Acuum R E Se Rv E T A N

    CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 215 7. R em ove hold-dow n p in s and s p rin g s . R efer to fig u re 31. Figure 28 —Type “ F” Front Brake A ssem bly CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 216 "B ra k e D ru m s” in th is se c tio n . 2. C arefu lly pull low er edge of w heel cy lin d e r Figure 31 —Rem oving Hold Down Springs and Pins CHEVROLET 40-60 TRUCK SERVICE MANUAL...

  • Page 217: B Ra K E Shoe R Elining

    7. In s ta ll guide p la te o v e r an ch o r pin. Figure 3 3 —Brake Shoe Contact Surfaces and Backing Plate 8. In s ta ll actu atin g link. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 218 4. P u ll contact plug through shoe tab le . sp rin g loaded wedge m oves to keep the gap betw een 5. L ift off re ta in e r w a sh e r, wedge, and guide. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 219 0.005” above lining, clam p shoe in v ise jaw s se c tio n . b e a r ag ain st th e a d ju s te r le v e r and d re s s down the CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 220 A djusting w heels a r e a c c e s s ib le through 4. In sp e ct b ra k e shoe re tu rn sp rin g s. If b roken, ad ju stin g s lo ts in the backing p la te . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 221 12 W heel C y lin d e r Shield Figure 39 —Rem oving Pull Back Springs Figure 3 8 -T w in -A c tio n Rear Brake A ssem bly (Autom atic A dju ster) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 222 12. Check a ll flange p la te attach ing b o lts to m ake s u r e they a r e tig h t. C lean a ll d irt and ru s t the ad ju stin g sc re w (fig. 41). CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 223 Figure 4 3 —Positioning A dju stin g Lever p ed al height r e s u lts . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 224 . th e ir "S" hooks fro m th e a d ju s te r c ra n k s. CHEVROLET 40 60 TRUCK SERVICE MANUAL...
  • Page 225 . lo ck w ire . CHEVROLET 40-60 TRUCK SERVICE MANUAL...

  • Page 226: B Ra K E D R U M

    DO NOT EXCEED THESE LIMITS. THIS IS A SAFETY PRECAUTION. e s th e lin in g to d ru m fit. When m achining d ru m s, CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 227 10. Bellm outhed, b a r r e l- s h a p e d o r s c o re d d ru m s. 10. R eplace o r re s u rf a c e d ru m s in R.H . and L.H . p a ir s . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 228 4. D ragging b ra k e s . ALL BRAKES DRAG WHEN ADJUSTMENT IS KNOWN TO BE CORRECT REMEDY PROBABLE CAUSE 1. L u b ric ate the pedal. 1. Pedal does not re tu rn to stop. CHEVROLET 4<W0 TRUCK SERVICE MANUAL...
  • Page 229 9. R e su rfa c e o r re p la c e d ru m s in le f t- and rig h t- hand p a ir s (both fro n t and both r e a r ) . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 230 10. L in in g s lo c ated w rong on sh o e s. 10. In sta ll lin in g s c o rr e c tly . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 231 2. In te rn a l L eak s: P ast se c o n d ary s e a ls into 2. R ebuild m a s te r c y lin d e r. pow er unit. C heck vacuum hose fo r fluid. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 232 Lining Thickness......... 5 /ie" 5 / ie" Lining A re a -S q . In. per A xle..136.4 198.1 198.1 Cab Models—Only. < 2> Cowl Models— Only. ® Available w ith 15 x 3.5 Shoes. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 233 CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 234 (SEC. 5D) fo r in fo rm atio n re la tiv e to a ir com ­ heading of "M o istu re E je c to r V alve." p r e s s o r s and g o v e rn o rs. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 235 SA FETY . l a t e r in th is se c tio n . CHEVROLET <0-60 TRUCK SERVICE MANUAL...
  • Page 236 Clean or replace filters Remove, disassemble, clean, inspect, re-set 3000 Hrs.— 100,000 Miles (1) Where more than one interval is given, operation to be performed at time of whichever occurs first. (2) Determined by severity of service. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 237 3. T u rn stop s c re w down u n til a ll fr e e p lay is a s follow s: re m o v e d , then b ack s c re w out % tu rn and lock. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 238 , w ill be obtained w hen th e a r m tr a v e l of th e sla c k a d ju s te r is held to a m inim um so th a t the Figure 6 —Slack A djuster CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 239 W ith b ra k e s r e le a s e d , m ake s u r e th e angle s la c k a d ju s te r w ith c le v is p in and c o tte r p in . R e fe r CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 240 , heated d u ring c o m p re ssio n , CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 241 MAINTENANCE C heck sa fe ty valve p e rio d ic a lly fo r leak ag e, Figure 10—D ivided A ir Tank CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 242 Figure 11 —Safety V alve CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 243 5. S ta rt engine and bu ild up a i r p r e s s u r e in p an e l into th e valve p isto n cup a s shown in fig u re s b ra k e s y ste m . 2 and 3. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 244 D e- 2. C onventional and Cowl M odels. L u b ric a te CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 245 Figure 14—Trailer Hose Coupling c o n tro l v alv e. F lex ib le h o se s a r e u se d to m ake the CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 246 - a c t a s in su latio n . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 247 45 p s i. Figure 16—Trailer Brake Hand Control V alve Installed CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 248 . Then CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 249 CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 250 Lim iting—Quick Release V alv e Inlet V alv e V alv e Carrier Front Brake Chambers TPM-6583 SLIPPERY ROAD POSITION Figure 18—Front Brake Lim iting and Tw o-W ay Control V alve O peration CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 251 P la c e th e handle o r knob of th e tw o-w ay 5. C heck o p e ra tio n of b ra k e s . v alve in "DRY ROAD" p o sitio n and w ith th e tru c k CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 252 . R e le a se of a p a rk in g o r Figure 2 0 —Spring Com pressing A ssem bly Figure 19—Anchorlok Brake Cham ber Installed CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 253 8 C am (in te g ra l with shaft) Guide Pin 5 C am shaft Bushing 9 Cam R o ller Lock Ring Brake Shoe A nchor Pin t - 1584 Figure 2 1 —Front Brake A ssem bly CHEVROLET 40-<S0 TRUCK SERVICE MANUAL...
  • Page 254 12 Slack A djuster 17 R o ller Pin 8 C am shaft and Brake 18 Brake Shoe Lining 13 Lock Ring C ham ber Bracket TPM-7630 Figure 2 2 —Rear Brake A ssem bly CHEVROLET 40-40 TRUCK SERVICE MANUAL...
  • Page 255 W henever b ra k e d ru m s a r e re m o v e d fo r s e r v - o v e rs iz e s not be exceeded: CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 256 STOPMASTER STANDARD SINGLE AXLE "FAIL-SAFE” TANDEM AXLE TA IL-SA FE" T-8256 Figure 2 4 —Stopm aster Brake A ssem blies CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 257 19 Guide Screw 29 R ubber Boot 10 Hollow Cap Screw 20 G asket 30 P r e s s u r e Half -2293 Figure 2 6 —Autom atic A dju ster A ssem bled CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 258 ’’B ra k e A ctuation C o m p o n en ts.” Figure 2 8 —Standard Stopm aster A ir Cham ber Com ponents CHEVROLET 40-40 TRUCK SERVICE MANUAL...
  • Page 259 NOTE: M ark a d ju stin g end of b ra k e sh o e s to Figure 2 9 —Staking A ir Cham ber Lockwasher e n su re c o r r e c t re a s s e m b ly . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 260 C ham ber 30 Standard A ir Cham ber 31 Lock W asher 32 Nut T '2291 Figure 3 0 —Stopm aster Brake Com ponents IAutom atic A djuster with “ Fa il-S a fe") CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 261 3 R o ller 7 C o tte r Pin 4 Wedge R etain e r 8 Wedge W asher Figure 31 —W ed ge and Roller A ssem bly Figure 3 2 —Installing Seal on Anchor Plunger CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 262 3. In sta ll w edge in re ta in in g cage. c o rro s io n . L ight s c r a tc h e s m ay be p o lish e d out CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 263 . s u r e in the p ro te c te d tan k is d ep leted , b ra k e s w ill CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 264 . tr o l valve to r e le a s e a i r fro m c h a m b e r. B ra k e s CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 265 2. E xhaust a i r p r e s s u r e fro m p a rk in g b ra k e c h a m b e r by pulling p a rk in g b ra k e knob out. Figure 3 9 —Com pressing “ Fa il-S a fe" Pow er Spring CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 266 The component parts are not ex p erie n c e). serviced separately. 2. C lean a ll m etal p a r ts thoroughly, using a T-2336 Figure 41 —Rem oving Pressure Housing with “ Stra p” Wrench CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 267 "p ig gy-back" on th e a ir be pushed d e e p e r betw een the r o lle r s sp read in g CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 268 ^^BOLT- PISTON SEAL INNER OUTER BACK-UP SNAP RING BEARING WASHER RINGS WASHER — WASHER SCREW HEX NUT RUBBER SEAL “ O ” RING SQUARE NUT T-6919 Figure 4 5 —Super “ Fa il-Safe” Com ponents CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 269 . T h is fix ­ 2. I n s e rt a sse m b ly th ro u g h opening in cap. tu r e is sp e c ia l tool (J-23527). CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 270 STO PM ASTER BRAKE SPECIFICATIONS Brake Size........... 15 x 7 Brake Shoe Lining Width............7" Thickness..........%" Crescent Area (sq. in. per axle)....... Brake Chamber Standard Diameter (at clamp band)...... 5.66" “Fail-Safe” Diameter (at chamber body)....5.264" CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 271 9. F oot c o n tro l valve linkage im p ro p e rly a d ju ste d 9. A djust 10. C am sh aft bu sh in g s binding o r w orn 10. L u b ric a te o r re p la c e CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 272 4. C lo se, r e p a ir o r re p la c e . 5. D efective c o m p re s s o r g o v ern o r 5. R e p a ir o r re p la c e CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 273 2. See c h a rt on “ A ir p r e s s u r e above n o r m a l” 3. G o v ern o r out of ad ju stm e n t 3. A djust CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 274 4. A djusting b o lt th re a d e d into a c tu a to r too tig h t 4. Back off bolt 1 /4 tu rn 5. P lunger guide w a sh e r o m itted 5. R eplace w a sh e r CHEVROLET 40-60 TRUCK SERVICE MANUM...
  • Page 275 5. P lunger s e a l fa ilu re p a r ts 6. R eline b ra k e s and check s e a ls 6. G re a s e on linings CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 276 . T-6708 3. R em ove n uts fro m lo catin g b o lt, then r e ­ Figure 1 —External Contracting Band Parking Brake m ove bo lt. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 277 M ove o u te r end of s c re w d r iv e r away fro m d riv e Figure 2 —Internal Exp a n d in g Type Brake Adjustm ent sh a ft. C ontinue a d ju stm e n t u n til sh oes a r e tight CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 278 2. In s ta ll cam sh aft in c am sh aft b ra c k e t. Align ends of b ra k e sh o e s. A djusting w heel should be CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 279 In te rn a l..............— — — — External..............— Lining W idth....................3" 2" " Lining Thickness............5 /ie " 5 /l6 " " .............. Total Lining Area (Sq. In .)..............67.5 85.0 41.75 CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 280 Figure 2 —A ir Com pressor Installed Figure 1—A ir Com pressor Installed (Typical Right Side M ount) (Typical Left Side M ount) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 281 6. C heck c o m p re s s o r d riv e b e lt ten sio n and Figure 3 —Com pressor A ir Filter a d ju st if n e c e s s a ry . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 282 L ift p isto n s out of b o re s . If p isto n is th e m to th e c o m p re s s o r. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 283 4. In s ta ll new gask et a t a i r in le t and connect a i r in let elbow. 2. Slide plu n g er guide down o v e r unlo ad er CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 284 4. B uild up p r e s s u r e in s y ste m and check fo r a t the ex h au st valve s e a t o r ste m g ro m m et. In o p era tio n and le a k s. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 285 . F aulty o p e r ­ ation of the c o m p re s s o r w ill r e s u lt in im p ro p e r function of b ra k e s . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 286 . o p e ra tin g m ech an ism . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 287 , u se ten sio n gauge to p ro v id e c o r r e c t ten sio n . lo w e r "ADD" o r "ADD O IL ." Keep le v e l a s c lo se CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 288 C y lin d er H ead B olt T o rq u e and R o ck er A rm A d ju s tm e n ts ......6A-6 Choke and T h ro ttle A d j u s t m e n t .......6A-5 CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 289 . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 290 E quipm ent re q u ire d c o n s is ts of Figure 7 —Crankcase Ventilation System dw ell m e te r, ta c h o m e te r, vacuum gauge and tim ing on In-Line, 6 C ylinder Engine (Typical) lig h t. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 291 . Figure 8 —C rankcase Ventilation V a lve for Figure 9 —A rrangem ent of Crankcase In-Line and V8 Engines (Typical) Ventilation Units on V8 Engine CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 292 R e fe r to Next P a g e F o r "E ngine T une-U p S p e c ific a tio n s.” CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 293 ENGINE REMOVAL 9. D isconnect choke co n tro l and a c c e le ra to r 1. D rain ra d ia to r. linkage. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 294 3. T ilt the cab fo rw a rd and rem o v e r a d ia to r p re v io u sly and need not be rep e a te d . and sh ro u d . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 295 R e fe r to a p p ro p ria te p o rtio n of TRANS­ 9. In sp ec t a ll h o ses and fittin g s fo r le a k s. MISSIONS AND CLUTCHES (SEC. 7) in th is m anual CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 296 On engines w ith heat sto v e, a ss e m b le sto v e b ra c k e t a t m anifold attach in g p a r ts . (fig. 11) fro m ex h au st m anifold. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 297 4. R em ove c o v er attach in g s c re w s , then r e - Figure 1 2 - O il Filter and Bracket Com ponents move c o v er. (O pt. 2 Qt. Type on 292 Engine) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 298 E x c e ssiv e v a rn ish o r carb o n deposit c a u s ­ ing a b n o rm a l s tic k n in e s s . lif te r p lu n g e r). CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 299 5. A d ju st ignition tim in g and c a r b u r e to r idle Figure 15—Using Special Tool and Com pressed sp e e d and m ix tu re . A ir to Remove V alve Spring CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 300 8. F ill cooling s y s te m . Figure 17—Rem oving O il Seal from Bearing Cap 9. In s ta ll m anifold a sse m b ly . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 301 Figure 2 0 — Rem oving Crankshaft Damper Figure 18—Rem oving O il Seal Upper H alf (Typical) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 302 , then tu rn th re a d e d sle e v e to fo rc e hub s u rfa c e . hub onto c ra n k sh a ft. 4. W ith c e n te rin g T ool (J-0966) in p la c e (fig. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 303 A fte r rem oving Figure 2 4 — Installing Front Cover O il Seal (Cover Installed) Figure 2 6 —Flyw h eel Installation (Typical) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 304 Figure 2 7 —V 8 Engine O il Filter By-Pass V alve CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 305 FRONT SEAL Figure 3 0 —Intake M a n ifo ld Bolt Tightening Sequence on 366 and 4 2 7 V8 Engines Figure 2 8 —Intake M a n ifo ld G askets and Seals CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 306 P la c e in th e sa m e lo c a tio n s. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 307 3. In s ta ll and ad ju st v alve m ech an ism . Since valve lif te r s a r e h y d ra u lic ty p e, r e f e r to Figure 31 —Com pressing V alve Spring on V8 Engine CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 308 4. C oat th re a d s of cy lin d er head b o lts w ith Figure 33 —C ylinder Head Bolt Tightening se a lin g com pound and in s ta ll b o lts fin g e r-tig h t. Sequence on 366 and 427 Engine CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 309 3. In s ta ll o il pan a s p re v io u sly d ire c te d u n d er Figure 3 6 —Rem oving O il Seal Upper H alf a p p ro p ria te heading. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 310 366 and 427 c u .-in . en g ines. Figure 39 —Installing Dam per A ssem bly (Typical) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 311 Figure 41 _ Installing Cover O il Seal with Figure 40 —Installing Front Cover O il Seal on 366 or 4 2 Engine (Cover Rem oved) Cover Installed (366 or 4 2 7 Engine Shown) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 312 DEPRESSED ^EN G IN E \ J TRAN S. SYN C H RO M ESH A U TO M A TIC T - 3 Figure 45 —Flyw heel Installation Figure 4 3 —Installing Crankshaft Sprocket CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 313 Spark Plugs 1 3 /ie " Wrench Size—Gasket Type P lug.. Oil Pan Spark Plugs—5 / s " Wrench Size—Tapered Seat Plug. End Bolts......... Connecting Rod Bolt Nuts Bolts (Exc. Ends)....250 Engines......?........292 Engines..............Oil Pan Drain Plug....CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 314 R e fe r to ENGINE MOUNTINGS (SEC. 6D) fo r engine m ounting inform atio n . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 315 4. In sp ect w iring and c o r r e c t as re q u ire d . 4. D efective w irin g . 5. Set ignition tim ing. 5. Ignition out of tim e . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 316 3. C lean float valve and s e t float lev el. 4. R ich m ix tu re at idle sp eed . 4. A djust c a rb u r e to r idle m ix tu re. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 317 3. R eplace g a sk e t, o r tighten m anifold b o lts. Check 3. Vacuum leak (a ir e n te rin g intake m anifold). a n d /o r re p la c e vacuum b ra k e hose (when used). CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 318 5. P istons a n d /o r rin g s w orn, o r p isto n s dam aged; c y lin d e r b o re s s c o re d o r w orn. 5. O verhaul engine. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 319 . Rem oval of a c c e s s o ry d riv e b e lts w ill elim in ate any n o ise s cau sed by th ese u n its. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 320 * 70-80 40-50 TS50 55-75 55-75 C E50-60; ME50 30-40 366 Engine *30-40 55-75 30-40 427 Engine *30-40 80-120 *180-260 40-50 55-75 C S-S S-40-50 55-75 CE40; C E -M E -60 30-40 55-75 *Nut Torque CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 321 T orq ue C h a rt on p re v io u s page. Figure 5 —Engine Front Mounting (TE50) Figure 3 —Engine Rear Mounting (CE, M E, and TE60) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 322 T orque CS40, CS, SS50; TS50) (Typical) nu ts to 30-40 foot-pou nds. In s ta ll c o tte r p in s. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 323 m fSSr :...
  • Page 324 . The tra p p e d a i r w ill lea k CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 325 T h is connection m ust be a ir- tig h t. d ra in p lu g s. Run engine w ith tra n s m is s io n in n e u tra l a t a safe CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 326 2. Connect a te s t lig ht c o n sistin g of a 12 -volt, ly fo r le a k s. 2-can d lep o w er bulb and a p a ir of te s t le a d s in c i r ­ CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 327 , rem o v e th e rm o s ta t a sse m b ly . If c u it by clipping one le a d to a hot te rm in a l and CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 328 . B e lts a r e a v a ila b le in m atch­ o il n o rm a lly c irc u la te d through the c o o le r. ed s e ts only. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 329 35-45 FT.-LBS t-7943 Figure 5 —Fan and Drive Pulleys (CE, M E60) Figure 7 —Fan and Drive Pulleys (TE50) CHEVROLET 40-<50 TRUCK SERVICE MANUAL...
  • Page 330 Sec. 6K-7 ENGINE COOLING SYSTEM th e fro n t of engine. In sta ll b o lts and w a sh e rs hold­ ing pum p to engine. T ighten b o lts to p ro p e r to rq u e a s shown.
  • Page 331 In th is d isp laced po sitio n it allow s the o th e r p a r ts . S lack can be taken up betw een c lip s. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 332 FULLY OPEN NUMBER MEAN TEMP. STARTS TO ENGINE USED OPEN (°F.) (°F.) (°F.) ... 192-198 250;292.......... 192-198 350........366; 427..........177-183 ENGINE OVERHEAT SW ITCH SWITCH CONTACTS CLOSE AT: V8 Gasoline Engines................250° F. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 333 50 and optional on CE, CS 40 and CS, SS 50. fu el in le t to the c a r b u r e to r . T h is s c re e n should be CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 334 Sec. 6M-2 FUEL SYSTEM— GASOLINE ENGINES SPRING CARBURETOR INLET FILTER GASKET Figure 1—Pleated Paper Type Fuel Filter FILTER INSTALLED Fuel Filter Assembly FUEL PUMP Figure 3 —D isposable Line Type Filter Frame Right Side Rail FILTER INSTALLED Bowl Gasket Filter Element OUTLET FILTER DISASSEMBLED Figure 2 —Frame M ounted Fuel Filter...
  • Page 335 T ighten any lo o se lin e connections and look fo r bends o r kinks in lin e s w hich could red u c e flow of fuel. Figure 5 —Installing V8 Engine Fuel Pump CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 336 PUMP W IR IN G H A R N E S S FUEL PUMP FUEL PUMP FUEL T A N K CHECK VA LV E FUEL FILTER FUEL OUTLET FITTING T-7036 Figure 7 —Electric Fuel Pump Installation CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 337 -c y c lin g fu m es fro m the c ra n k c a se and c a rb u r e to r a d ju stm e n ts. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 338 (som e m odels), sp e c ia lly c a lib ra te d c a r b u r ­ of th is m anual. e to r and d is trib u to r. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 339 Smooths Action Spring Acts Through M anifold Ott-center Cam , Opposes Closing Throttle Shaft of Throttle V alve OPENING FORCE STABILIZING FORCE CLOSING FORCE 3849 Figure 12—M a jo r Controlling Forces of Governor O peration CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 340 ­ u to r advance in re la tio n to th ro ttle opening. above g o v ern o r th ro ttle v alv e, and is open on out­ CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 341 "A" is ad ju sted . vacuum p a ssa g e in som e c a rb u r e to rs and u n d er no CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 342 . engine sp e ed and y et allow a w id e r th ro ttle opening Figure 16—Governor and O verspeed W arning Light CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 343 . If the actio n is stic k y o r binding to lin e up w ith th e vacuum p a ssa g e in the housing. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 344 . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 345 VALVE WEIGHT GOVERNOR ADJUSTING VACUUM SCREW PASSAGES REAR VIEW VALVE SLEEVE GOVERNOR VACUUM LINE GOVERNOR SPRING GOVERNOR LEVER GOVERNOR VACUUM UNE GOVERNOR VACUUM PASSAGE DIAPHRAGM ROD BOTTOM VIEW DIAPHRAGM T-6609 Figure 17—H olley Internal—Vacuum Type Governor CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 346 CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 347 ID EN TIFIC ATIO N NUM BER IDLE MIXTURE SCREW IDLE SPEED PUMP LEVER SCREW PUMP FAST IDLE THROTTLE G O V E R N O R LEVER T-7708 Figure 19—Rochester M odel 2G Carburetor CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 348 . and s e c u re the c o r r e c t r e p a ir kit. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 349 PUMP DISCHARGE CHECK Out-of-round, damaged seat, stuck, distorted spring ★ ★ ★ ★ ★ CHOKE VALVE Dirty, damaged, sticking ★ ★ ★ ★ DRIVER Driving habits, correct procedures HOT IDLE COMPENSATOR Dirty, damaged, sticking T-7828 CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 350 OUT fo u r full sc re w to 500 rp m , if n e c e s s a ry . tu rn s . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 351 . Link can be rem o ved fro m pum p le v e r. Figure 2 4 —Float Drop A djustm ent (M odel 2G) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 352 Figure 2 6 —Accelerator Pump Rod Adjustm ent 5. If equipped w ith A utom atic tra n s m is s io n , (M odel 2G) d isco n n ect TV linkage. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 353 A vacuum sig n a l to the sp rin g loaded vacuum d ia­ p r im a r y b o re s , the in c re a s e d p rim a ry v en tu ri CHEVROLET 40-<J0 TRUCK SERVICE MANUAL...
  • Page 354 SECO N D A RY DIAPHRAGM G O V ER N O R CHECK BALL VACUUM DIAPHRAGM LINE Figure 3 2 —Secondary Throttle System Figure 3 0 —H o lley Carburetor (Right Front V iew ) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 355 BTC m ean s B e fo re Top C e n te r. r a i s e fuel le v el, then tighten lock sc re w . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 356 4. Connect th ro ttle r e tu r n sp rin g and in s ta ll out d rain in g the fuel fro m th e bow l. The contents a i r c le a n e r. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 357 Accelerator Pump Metering Rod 0.070 0.070 Idle Vent .025 .025 Fast Idle (B en c h ) .100 .100 Fast Idle (Running) 2400 RPM Governor (Vacuum 4250 RPM (No Load) Spinner Type) 4000 RPM (Full Load) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 358 ’ W ith En gine broken-in. Full load is approxim ately 300 R P M less than N o Load R P M and will vary from engine to engine. FUEL PUMP PRESSURE VOLUME ENGINE 1 pint in 35-40 seconds In-Line 1 pint in 20-25 seconds 350 V8 1 pint in 10-15 seconds 366 or 427 V8 CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 359 N on -clean ab le dry e lem en ts, if upon in sp e c ­ tion , a r e dam aged o r d irt clogged, the elem ent m ust be rep la c e d . Figure 1—A ir Cleaner (Gas-Dry Elem ent) (Typical) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 360 Figure 3 —Typical Cleanable Dry Elem ent Decal c le a n e r on the engine. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 361 In s ta ll elem ent, g ask et and co v e r and r e in s ta ll asse m b ly to c a rb u re to r. Figure 6 —Oil Bath Pre-Cleaner (CS40-50) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 362 A ll v eh ic le s w ith a 366 o r 427 engine o r an 6. W ipe accu m u lated d irt fro m cov er a sse m b ly . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 363 , it is m o st im p o rtan t th a t a ir c le a n e r e le m e n ts a r e s e rv ic e d at recom m end ed in te rv a ls . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 364 S e rie s C E /C S-40; C E /C S -50 ........1980145 E-5000 S e rie s C E /M E -60 ............1980145 E-5000 S e rie s S E /SS-50 ............1980149 E-5000 CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 365 ­ MANIFOLD A N D VENT PLUG HOLD D O W N SLOT Figure 2 —Side Terminal Battery (Typical) Figure 1—Battery w ith One-Piece Cover (Typical) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 366 . O v erfillin g should be avoided at should be added to the b a tte ry , not e le c tro ly te . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 367 CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 368 . "E m e rg e n cy B o o s tC h a rg e ." Although an em ergency CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 369 (1) If sp ec ific g rav ity is 1.215 o r m o re, no c h a rt follow ing "S p ecificatio n s" at end of se c tio n . s e rv ic e is re q u ire d . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 370 (50 points) o r m o re , the b a tte ry s h o u ld b e re p la c e d . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 371 O n e o r m o re ce lls re a d 1.95 or h igh er ( 5 ) A ll cells re a d less th a n 1.95 .05 volt difference REPLACE BATTERY B00ST-CHARGE AND RETEST T-508 - Figure 7—Battery Light Load Test CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 372 "F u ll C harge H y d ro m e ter T e s t." age drop in s ta r te r cab le. Low voltage a t s ta r te r CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 373 CHART NO. 1 - V 0 L T A G E AND T E M P E R A T U R E CHART Electrolyte Temperature.... 80°F 70°F 60°F 50°F 40°F 30°F 20°F 10°F 0°F Voltage (M inim um )....CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 374 BATTERY TEST PROCEDURE N O T E : C h a r t N o . 1 is in S p e c i f i c a t i o n s 8 0 3 CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 375 O V E R R U N N IN G CLUTCH SPIRAL SPLINES INSULATED BRUSH HOLDER BRUSH SPRIN G G R O U N D E D BRUSH HOLDER TPM-6606-2 Figure 1 —O verrunning Clutch Type Starting Motor (Typical) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 376 To im u m efficiency fro m the s ta rtin g sy ste m . C ause CHEVROLET 40-40 TRUCK SERVICE MANUAL...
  • Page 377 (fig. 3). fro m being a cc id en tally engaged by tu rn in g the CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 378 "P inio n C le a ra n c e C heck." CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 379 STARTER S OLE NOI D M O D E L 1114344 1114356 1115518 Rated Voltage............. Current Consumption Pull-In Winding Amps............13-15.5 13-15.5 26-29 V o lts............Hold-ln Winding Amps............14.5-16.5 14.5-16.5 18-20 V o lts............CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 380 Make s u re ig nition sw itch is in "O F F " Check ignition tim ing w ith tim in g light as p o sitio n . d ire c te d la te r u n d er "Ignition T im ing." CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 381 . 4. C onnect b a tte ry neg ativ e cable to p o st and check o p era tio n of sw itch. Figure 2 —Timing M arks (In-Line Engine) (Typical) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 382 . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 383 M odel n u m b e r is stam p ed on th e d is trib u to r housing. Figure 5 -B re a k e r Plate Attaching Parts CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 384 . The p r e s s u r e Figure 7 —D isengaging Distributor Cap Latches (V8 Engine) (Typical) can be ad ju ste d by bending the b re a k e r le v e r sp rin g . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 385 . cle a n housing of o il, sm udge and d irt. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 386 , then back out o n e-h alf tu rn . T his Figure 11—Setting D w ell A n gle (V8 Engine) (Typical) p ro v id e s the ap p ro x im ate dwell angle re q u ire d . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 387 . T his advances th e cam , causing th e con­ ta c t p o in ts to open e a r lie r , thu s advancing the Governor Figure 13—A dju stin g Spinner s p a rk . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 388 5.0 clockw ise d ire c tio n p a s t the m a rk p rev io u sly p laced CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 389 . a . R em ove No. 1 s p a r k plug and w ith fin g e r on CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 390 . A co n d en ser of in c o r r e c t capacity w ill re s u lt in te rn a l d efects often fail to show up on a cold coil in point p ittin g . te s t. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 391 . B ut, u n d e r high sp e e d o r h a rd p u ll, the pow ­ an im p ro p e r H eat Range fo r the engine, m ay have d e r oxide d ep o sits m elt and fo rm a heavy g laze CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 392 If ta p e re d s e a t plugs a re o v e r- tig h tened , they w ill be v e ry d ifficu lt to rem o v e. Figure 14—Wrench Socket Installed on Plug (Typical) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 393 BUTTERFLY V A LV E CARBURETOR ACTUATO R IG N IT IO N SW IT C H LAM P BATTERY T-8028 Figure 15—Engine O verspeed W arning System CHEVROLET 40-60 TRUCK SERVICE MANUAL...

  • Page 394: Ignition S Y Stem S P Ecifications

    IGNITION S Y S T E M SPE C IFIC A TIO N S E N G I N E D I S T R I B U T O R M a k e ..................D e lc o -R e m y D e lc o -R e m y D e lc o -R e m y D elc o -R em y...

  • Page 395: M Odel A Pplication C H A

    1119515 62-Amp. - CE/CS-40; CE/CS/SE/SS-50; CE/ME-60 ....1100548 Integral 62-Emp. - TE/TS-50; TE-60 ............. 1117782 1116378 100-Amp. - SE/SS-50 ................1117754 1116378 130-Amp. - SE/SS-50 ................1117141 Integral 1117128 9000590* ♦Requires Relay 1116972. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 396 - Figure 2 —Schematic Diagram of A .C . Charging Circuit Figure 1 —Schematic Diagram of A .C . C harging Circuit with Transistor Type Regulator (Typical) with Two-Unit Type Regulator (Typical) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 397 . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 398 . g ra v ity . R eplenish e le c tro ly te lev e l, a s n e c e s s a ry . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 399 - 5. E x c e ssiv e g e n e ra to r n o ise. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 400 "B A T" te rm in a l and "GRD" te rm in a l. Figure 8 —Checking Indicator Lamp W iring 4. P u ll la tc h on re g u la to r upw ard to disengage CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 401 (L ead E, fig. 3). CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 402 V IEW C -C H E C K IN G GENERATOR FIELD VIEW D -C H E C K IN G FOR EXCESSIVE CIRCUIT USING OHMMETER RESISTANCE -1547 Figure 11—Using A dapter (J-21600) To Check Generator Output (9000590 Type RegulatorI CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 403 “ G e n e ra to r” se c tio n explained la te r . u se of sp e c ia l a d a p te r and ju m p er le a d at re g u la to r. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 404 Figure 15—Testing Voltage Setting (Two-Unit Regulator) CHEVROLET 40-40 TRUCK SERVICE MANUAL...
  • Page 405 "V oltage R egu­ la to r ." SYSTEM WITH 1116378 REGULATOR Figure 17— Connections for Testing 1116378 Make connections as shown in View A, Regulator Voltage Setting (Typical) fig u re 17. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 406 , re p la c e o r r e p a ir Figure 19—Generator Brush Replacem ent th e re g u la to r. (M odel 1117754) (Typical) CHEVROLET 40-40 TRUCK SERVICE MANUAL...
  • Page 407 NOTE: B ru sh re p la c e m e n t on 3 7-, 4 2 -, 61-, CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 408 NOTE: Only an ap p ro x im ate a ir gap settin g should be m ade by the fe e le r gauge m ethod above. T he fin al settin g m u st be w hatever is re q u ire d to CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 409 - s e t value and com ponents in the th e in d ic a to r lam p w ill "lig h t," to in d icate the CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 410 NOTE: A fte r two notches in e ith e r d ire c tio n th e r e is a p o sitiv e sto p. 3. C onnect b a tte ry cab le to b a tte ry te rm in a l. CHEVROLET 40-60 TRUCK SERV.CE MANUAL...
  • Page 411 NOTE: P ro c e d u re s f o r analyzing o r checking c h a rg in g s y s te m tro u b le a r e explained p re v io u sly Figure 2 4 —Regulator with Bottom Plate Rem oved CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 412 . H i g h s y s t e m v o l t a g e . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 413 NOTE: R e fe r to fig u re s 25 and 26 fo r id e n tifi­ reco m m en d ed . The low range sc a le on the ohm ­ cation and lo cation of following com ponents: m e te r should be u sed . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 414 P a r t E , th e p o te n tio m e te r is open. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 415 CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 416 Sec. 6Y-53 A. C. GENERATING SYSTEM (NON-INTEGRAL TYPE) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 417 Sec. 6Y-54 A. C. GENERATING SYSTEM (NON-INTEGRAL TYPE) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 418 1115841 field relay or to "R" terminal of generator on vehicles equipped with the 1115827 field relay. If voltmeter reading was obtained, field relay is defective. Remove relay and replace. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 419 (a) Allowable Range at “ 0” Position of Adjusting Screw. T EM P ER A T U R E -V O LT A G E CHART NO. 2 Regulator Ambient Temp. (Deg. F.).... Voltage Setting Range........14.1-14.8 13.9-14.7 13.7-14.5 13.6-14.3 13.4-14.2 13.2-14.0 13.1-13.8 CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 420 With 37-, or 42-Amp. Generator............25-30 Bolt 45-55 With 61-Amp. Generator..............25-35 Bolt 45-55 With 62-Amp. Generator..............Bolt 40-50 With 130-Amp. Generator..............Bolt 40-50 ^Tighten Pivot Bolts prior to tightening other mounting bolts. CHEVROLET 40-40 TRUCK SERVICE MANUAL...

  • Page 421: 100-A M P. G En Eratin G S Y S T E

    "B A T" te rm in a l. A s tr io fro m high vo ltag es, and s u p p re s s e s ra d io n o ise . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 422 CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 423 6. Do not s h o rt a c r o s s o r ground any of the s ta lle d new b e lts, check te n sio n of belt(s) tw ice in te r m in a ls in the charging c irc u it. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 424 Figure 4 —End V iew o f 42- or 6 1 -Am p. Integral Type Generator (Typical) on fo r extended p e rio d s. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 425 . U se a condition. fully c h a rg e d b a tte ry and a 10 ohm r e s is to r r a te d CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 426 ­ output, ground the g e n e ra to r fie ld (fig. 4). ju ste d . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 427 D1 conducts. T r a n s is to r TR2 then th e s ta to r A .C. vo ltag es to a D .C. voltage w hich Figure 7—100-Am p. Integral Type Alternating Current Generator (Typical) CHEVROLET 40-40 TRUCK SERVICE MANUAL...
  • Page 428 2. C heck g e n e ra to r m ounting and ad justing CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 429 "S p ecificatio n s" a t end of and low sp e cific g ra v ity re a d in g s, can be co v ered CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 430 , p o sition 2 is m edium low, p o s i­ n ected . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 431 5000 5000 5000 Rated Hot Output (Amps) (a )................(a) Rated Hot Output at Maximum Operating Speed. (b) Voltmeter not needed for Cold Output Check. Load Battery with a Carbon Pile to obtain Maximum Output. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 432 3. R em ove g e a rsh ift knob, boot r e ta in e r (1) linkage, if n e c e s s a ry , to obtain th e se conditions. and boot (2). CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 433 (3), s e le c to r fin g e r (9), w a sh e r and new c o tte r pin. Figure 2 —Control Islan d Shift M echanism CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 434 (13). R em ove r a il s e le c to r and b e llc ra n k NOTE: On m odels equipped w ith New P r o c e s s fro m b a ll joint a sse m b ly . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 435 3. In s ta ll r o ll p in (22) to re ta in sh ift fin g er attach in g sh ift fin g e r (18) to sh ift ra il. (21) on sh ift r a i l (2). CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 436 NOTE: Key n u m b e rs in te x t r e f e r to fig u re 6. c o n tro l c o v e r (17). 1. R em ove lo ck w ire and sh ift fin g e r sc re w CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 437 2. U sing a su itab le sle e v e , p r e s s o r d riv e new 8. R em ove s e le c to r a r m and sh aft a sse m b ly o il s e a l into b o re of housing. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 438 4. R em ove atta c h in g p a r ts th a t hold end c o v er (19) to c o n tro l housing (3). Figure 8 —Remote Control A ssem bly (Spicer Transm ission) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 439 The tr a n s m is s io n om m ended tu n e-u p p ro c e d u re s . It should be kept CARBURETOR THROTTLE LEVER Figure 9 —Accelerator and TV Linkage CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 440 IN C L U T C H S L IP P A G E 10. N ote th at gauge is in sta lle d on m anual s e le c to r TRANSMISSION F A IL U R E . nut. CHEVROLET 40-40 TRUCK SERVICE MANUAL...
  • Page 441 To lo w er sh ift point, lengthen ro d (L) in the sa m e m an n er a s p re c e d in g ste p . Figure 12—Position of TV Lever at Idle CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 442 U se a m ir r o r if unable to view w hen p e rfo rm in g th is s te p . d ire c tly . T-8008 Figure 14—Accelerator and TV Linkage (TG50) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 443 (M) and a c c e le r a to r p ed al m u st r e tu r n fre e ly c . W ith a c c e le ra to r linkag e a t ’ID L E " p o sitio n , CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 444 . R e a d ju st if n e c e s s a ry . th ro u g h a ll sh ift ra n g e s . R ead ju st if n e c e s s a ry . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 445 7. R ea d ju st lin k ag e, if n e c e s s a ry . to m ake s u r e the s t a r t e r w ill not o p e ra te w ith the CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 446 5. R econnect sec o n d a ry w ire to d is trib u to r in d is tr ib u to r cap and ground w ire to p re v e n t p o s ­ cap. sib le dam age to c o il. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 448 . looked du rin g the d isa sse m b ly . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 449 In te rfe re n c e re s is ta n c e in the sh ift tio n s in the pow er tr a in ; th is could be engine, CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 450 9. B roken g a s k e t s , g a sk e ts sh ifte d tra n s m is s io n . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 451 A s e p a ra te clu tch housing is u se d in ad dition to th e flyw heel housing. p e a r s when no lo o s e n e s s e x is ts . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 452 , guiding th e m ain d riv e g e a r shaft NOTE: On v e h ic le s w hich have the engine r e a r into the clu tch d isc s p lin e s . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 453 . T ighten cap sc re w s sio n a s d e s c rib e d in "P R O P E L L E R SHAFTS" (SEC. 4D) of th is m anual. firm ly . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 454 A llison M anual SA1126. sh ift le v e r at le ft-s id e of tra n s m is s io n . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 455 . fo r and cle a n away any fo re ig n m a te ria l in flyw heel CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 456 - to - c o n v e r te r co v e r b o lts CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 457 T h is w ill affe c t lu b ric a tio n , cooling, p ip e. and p r e s s u r e b u ild -u p . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 458 . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 460 . 5. L u b ric a te c o n tro l linkage w ith sa m e g rad e Figure 2— Front Mount Installed of o il u se d in engine. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 461 9. R efill tra n s m is s io n w ith lu b ric a n t re c o m ­ v e h ic le a s shown in fig u re 2. m ended in LUBRICATION (SEC. 0) of th is m anual. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 462 Figure 3 _ c iu tc h Linkage ( CE, M E60 with 4 2 7 Engine) T-6472 - 1 Figure 4 —Linkage Adjustm ent (A ll M o d els, Except Figure 2 —Clutch Linkage (CE, SESO; CE, M E60 ) Those Eq u ip p ed with 427 Engines) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 463 (B). C onnect re tu r n s p rin g . C heck o p e ra tio n of m it full engagem ent of th e clu tch. clu tch linkag e. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 464 A lw ays B e S u re To A djust The C lutch L inkage A fte r P e rfo rm in g C lutch M aintenance O p e ra tio n s. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 465 CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 466 P la in end of b le e d e r h o se can be slip p e d o v er be too long. end of b le e d e r valve. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 467 6. Connect slave cy lin d e r re tu rn sp rin g . Check o r e n tire pedal sleev e and bushing asse m b ly . o p eratio n of clutch. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 468 . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 469 . See "B leeding H ydraulic S ystem " a s d e s­ body (3) m u st be re p la c e d . c rib e d p re v io u sly . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 470 The follow ing p ro c e d u re s apply to a ll clutch Figure 1 —Use of Blocks Between Release Levers com ponents w ith exceptions a s indicated. and Cover (Long or Borg and Beck) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 471 Figure 3 —Release Bearing and Support A ssem bly (TypicalI tra n s m is s io n b e a rin g cap. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 472 , loose r iv e ts (when u sed), o r c ra c k s in the ra c e w ith fin g e r. d riv en d isc hub. E xam ine sp lin e s in hub fo r w ear CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 473 "TRANSMISSION ON-VEHICLE SERVICE O PE R ­ th e s e m a rk s . ATIONS” (SEC. 7B) in th is m anual. CHEVROLET 40-40 TRUCK SERVICE MANUAL...
  • Page 474 1. O verhaul m a s te r c y lin d e r. 2. T ighten all line fittin g s and check fo r lea k s 2. E x te rn a l le a k s. in lin e. t -6847 CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 476 . When n e c e s s a ry , re p la c e local fire and safety regulations. w ith o rig in a l type cap. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 477 Sec. 8A-2 FUEL TANK AN D EXHAUST Figure 1—Cab and Frame M ounted Fuel Tanks (Typical) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 478 1. Move s e a t fo rw a rd and rem o v e tan k c o v e r. 2. If n e c e s s a ry , d ra in tank to a lev e l below gauge unit m ounting. Figure 3 —Tank Siphon Construction CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 479 NOTE: T h e se sp e c ia l to o ls a r e also p a r t of K it J-8 0 5 1 . Figure 5 —Single and Double Lap Flare CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 480 . On m odels w h ere the fu el lin e p a s s e s thro u g h the fra m e th e re should be CHEVROLET 40-A0 TRUCK SERVICE MANUAL...
  • Page 481 . G rind end of sp a n n e r a r m s if ad d itional c le a ra n c e is needed. Figure 10—G asoline Tank Sending Unit CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 482 "F u el Gauge W iring D ia p h ra g m " is connected a c ro s s the two e x te rn a l Figure 14—Fuel G auge System W iring Diagram CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 483 F o r m axim um sa fe ty , rem o v e cable fro m n egative b a tte ry te rm in a l. CHEVROLET 40-A0 TRUCK SERVICE MANUAL...
  • Page 484 T ER IN G CA B . P a r tic u la r c a r e should be given to the in sta lla tio n CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 485 Keep cowl vent and h e a te r in tak es clo se d when o p eratin g in cong ested tra ffic to p re v e n t deadly exhaust g a s e s fro m en terin g cab. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 486 , and m ethods u sed fo r re p a ir a r e CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 487 NOTE: If e x c e ss lo o s e n e s s is evident in s t e e r ­ TENTION O F THESE PARTS. ing sy s te m , a ll com ponents of s te e rin g colum n CHEVROLET 40-40 TRUCK SERVICE MANUAL...
  • Page 488 -647 Side Cover Figure 3 —Steering Column Stop Clam p Adjustm ent (Conventional Cab) (Typical) Figure 4 —A dju stin g Sector G ear Lash CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 489 T u rn a d ju s te r sc re w un til a pull of 1 V 2 to 2 pounds CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 490 (fig. 15). CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 491 (1) and p itm an sh a ft CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 492 5 P itm an A rm 11 S teerin g G e ar -5684 Figure 9 - S te e rin g Linkage (“ T” M odels) Figure 1 0 -S te e rin g Tie Rod CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 493 If tie ro d w as d ism a n tled , p o sitio n clam p s ing a sse m b ly . on ends of ro d . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 494 . It is re ta in e d by a w a sh e r and lock nut. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 495 ­ ing w heel. m ove le v e r (1, fig. 16). CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 496 11 W heel A ssem bly 17 Knob 18 L e v e r 6 S crew 12 W ash er -8084 Figure 14—Steering W h eel, Hazard W a rning , and Directional Signal Components CHEVROLET 40-40 TRUCK SERVICE MANUAL...
  • Page 497 . In s ta ll d ire c tio n a l c o n tro l le v e r (1) 1. P r e s s b e a rin g (11) into low er end of s t e e r ­ CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 498 S ecu re a ll p a r ts w ith th re e s c re w s (2) and ing colum n attach in g b ra c k e ts , o r su p p o rts should CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 499 IMPORTANT: On o c casio n , a sc ra p in g o r ru b ­ colum n (6). bing n o ise in th e s te e rin g w heel (Conv. C ab Models) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 500 (2) (fig. 17), and tap yoke sidew ays to dislodge bu shings (1) of adjoining yoke; re p e a t NOTE: It is n e c e s s a ry to rem o v e m ultiple CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 501 Figure 2 2 —Reg-Type Flexib le Coupling Adjustm ent (Conventional Cab) it in p la c e in u p p er ja c k e t. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 502 , b o lts, and c la m p s. P o sitio n flo o r s e a l viously. T ighten a ll colum n clam p s to to rq u e lis te d a t flo o r. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 503 4. A djust ste e rin g g e a r a s d e sc rib e d p re v io u sly in th is se c tio n . A djust ste e rin g colum n m ounting clam p s, and stop clam p a s p re v io u sly d e sc rib e d in th is se ctio n . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 504 4. A d ju st, tig h ten and r e p a ir com ponents a s d e sc rib e d p rev io u sly in th is se c tio n . 5. A djust s te e rin g g e a r a s p re v io u sly d e sc rib e d in th is sectio n . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 505 F050, F055 ........... 115-165 (2) F070 ........180-240 (2) F090, F110, F120..............................(1) NOTE: All tapered ball studs must be clean and dry. (2) Tighten as indicated, then tighten to next notch to insert cotter pin. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 506 . by e ith e r a v an e-ty p e o r s lip p e r type oil pum p. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 507 L eave valve in p r e s ­ Figure 1 —Checking Pump Hydraulic Pressure s u r e gauge line open (fig. 1). (Vane Type Pump) (Typical) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 508 ADJUSTMENT chafing o r w e ar. NOTE: Gauge (J-23600) m ust be p lac ed at CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 509 21 Valve A ssem bly 22 T orsio n Bar Cap 23 Back-up W asher 24 W orm Bearing 25 W orm Oil Seal -9060 t p m Figure 3 —Pow er Steering Control V alve ITypical) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 510 . th en in s ta ll P itm a n a r m on sh a ft. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 511 V alve squaw k when tu rn in g o r when r e c o v e r­ 8. E ffo rtle s s tu rn . ing fro m a tu rn m ay be c a u s e d b y a w orn d am p en er CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 512 F ro m cavity (1) the oil flow s into p a ssa g e (2) w hich is c o n tro lle d in s iz e to pro v id e definitely Figure 4 —Power Steering H ydraulic Pump Installed (Typical) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 513 2. S lide p ulley on d riv e sh aft. DO NOT HAM­ w hich a tta c h pum p and m ounting b ra c k e t to engine. MER PU LLEY ON SHAFT. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 514 RESERVOIR A N D RETURN OIL R IN G -R O T O R LEAKAGE OIL VIEW B -P U M P O PERATIO N -H IGH SPEED T-1166 Figure 6 —Pow er Steering H ydraulic Pump O peration CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 515 S y ste m ." condition, p a r tic u la r ly when the w heel sto p s a r e CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 516 L ea k s in m etal p a r ts . . D am aged c a s t i n g s .......... R ep lace dam aged p a r ts . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 517 . sip a te ro a d shocks to th e o p e ra to r. Figure 8 —Pow er C ylinder O il Flow (Typical) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 518 9 W iper A ssem bly 4 Oil Seal 10 Guide A ssem bly 5 Oil Seal 11 Piston Rod 6 E x ten sio n P ort 12 Piston TPM-7398 Figure 1 1 —Pow er C ylinder (Typical) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 519 Full Left Turn Position and Set Piston Shaft to Dimension Shown in View “ E” . Tighten Bolts Evenly 25 to 30 Ft.-Lbs. Torque. Figure 12—A x le M ounted Pow er C ylinder A djustm ent CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 520 C h a rt” la te r fo r ad ditio nal in fo rm atio n . d e r s till le a k s a f te r re p la c in g the s e a ls , the p r e s - CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 521 . P r o p e r r e p a ir re q u ir e s the u se of CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 522 Loose nut in end of flow control valve. Tighten nut. Correct condition. Pressure plate not flat against ring. Replace pump ring. Extreme wear of pump ring. Lap away light scoring. Replace heavily scored parts. Scored pressure plate, thrust plate, and or rotor. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 523 Readjust if necessary. Adjust in truck to specification. Tight sector to ball nut adjustment. Remove gear and adjust to specifications. Thrust bearing adjustment too tight. Remove and clean valve or replace valve. Sticky valve spool. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 524 To eliminate the gear, close the gauge valve and quickly test pressure of the pump only with the engine at warm idle; then open the valve to avoid increasing oil temperature. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 525 Around welded joints. Adjust to specifications. 3. Excessive ball End play present. Replace seats. socket movement. Worn ball seats. 4. Piston rod end Loose bolts. Torque to specifications after proper positioning to specifications. clamp movement. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 526 170°F. When Operating Pump at 1500 R.P.M. Against 50 P.S.I. Pressure. M inim um ..................35 G.P.M. of Power Steering Fluid (Specified in LUBRICATION-Sec. O) at 170°F. When Operating Pump at Idle Speed Against 665/735 P.S.I. Pressure. Pressure Relief Valve Minimum P.S.I............................................900 Maximum P.S.I............................................1000 CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 527 T ilt Cab Models ( 2 ) ....................125-150 (2) Tie Rod to Steering Arm Stud F-050; F-055 Front A x le ..................150-160 (2) F-070 Front A xle...................... 150-180 (2) F-090; F-110; F-120 Front A xle................125-150 (2) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 528 — 95-105 Front Insert N ut......................(1) NOTE: All Tapered Ball Studs must be Clean and Dry. (2) Tighten Nut to Specified Torque, then Advance to Next Aligning Slot and Install a New Cotter Pin. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 529 . P r o p e r a lig n ­ m ent, and lu b ric a tio n w ill pay dividends in d riv e r s a tisfa c tio n , and in t i r e econom y. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 530 . All in n e r and o u te r nuts u sed on left side in d icated seq uen ce to 190 to 210 foot-pounds. have le ft-h a n d th re a d s . Both in n e r, and o u te r nuts CHEVROLET 40-60 TRUCK SERVICE MANUAL...

  • Page 531: Wheel Studs Or Bolts And Nuts

    If any w heel e x p e rie n c e s a sin g le stu d fa ilu re c a u se d by a lo o se -ru n n in g w heel, a ll stu d s should Figure 2 —W heel Nut Tightening Sequence (Cast Type W heels CHEVROLET 40-60 TRUCK SERVICE MANUAL...

  • Page 532: Wheel Inspection

    . If te s t s a r e w ithin lim its , the hub is s a tis fa c to ry , but w heel is sprung. 7. A dism ounted w heel m ay be checked fo r CHEVROLET 40-60 TRUCK SERVICE MANUAL...

  • Page 533: Inflation Of Tires

    CHEVROLET 40-60 TRUCK SERVICE MANUAL...

  • Page 534: Tire Rotation

    . Mount new t i r e s on fro n t. b u ild up w ithin the asse m b ly in an atte m p t to se a t CHEVROLET 40-60 TRUCK SERVICE MANUAL...

  • Page 535: Matching Side And Lock Rings

    Sim ply lo o sen tir e bead fro m w heel Figure 8 —Slide Ring A ssem bly Points rim a s shown in fig u re s 10 and 11 and rem o v e tube. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 536 , it is tig h t and r e q u ir e s fo rc e o r 9. R etain p r e s s u r e w ith tool and s tr ik e side Figure 10—Loosening Tire Bead Figure 13—Position Side Ring CHEVROLET 40-60 TRUCK SERVICE MANUAL...

  • Page 537: Three Section Rims

    Figure 17—Releasing Tire Rim Clamp Figure 15—Engaging Side Ring O ver Rim Gutter CHEVROLET 40-60 TRUCK SERVICE MANUAL...

  • Page 538: Selection Of Tires

    X-in c h on t i r e s up to and including siz e Figure 2 0 —Rim Cross Secf/on Chart CHEVROLET 40-60 TRUCK SERVICE MANUAL...

  • Page 539: Dynamic Balance

    . T his type of t ir e show s m uch the sa m e ap ­ CHEVROLET 40-60 TRUCK SERVICE MANUAL...

  • Page 540: Specifications

    CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 541 4580 10.00-20 4760 4380 4580 4760 4950 5120 3760 3970 4180 5300 10.00-20 4780 4990 5190 4100 4330 4560 11.00-20 5080 5300 4600 4840 5520 11.00-22 4350 NOTE: Bold face figures indicate maximum recommended load. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 542 F ig u re 1 show s ty p ic al F ro n t Sheet M etal C om ponents. HO O D ASSEM BLY C O W L GRILLE ASSEM BLY G RILLE FENDER EXTENSION T-8262 Figure 1—Typical Front End Sheet M etal Components CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 543 , s c rib e a lin e aro u n d lock fo r alignm ent on in sta lla tio n . Figure 3 —Rem oving Hood Spring CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 544 If n e c e s s a ry to alig n hood p e rfo rm p ro c e d u re a s o u tlin ed u n d e r "A lignm ent" which follow s: Figure 5 —Hood and Radiator Seals CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 545 V eh icles equipped w ith a i r conditioning Figure 6 —Hood Pads and Lock a n d /o r pow er s te e rin g w ill re q u ire sp e c ia l handling. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 546 CAUTION: Use care to prevent strip­ ping threads when installing two bolts from underneath front frame crossm em ­ ber (fig. 9). This could cause retaining nuts to loosen, and it would be necessary to remove the radiator. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 547 5. R em ove six sc re w s holding s k ir t to fen d er opening flange. 6. R em ove sc re w attach in g s k ir t to ra d ia to r Figure 11—Fender Cusset-To-Cow l Attachm ent g rille . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 548 R e in sta ll in r e v e r s e o r d e r of "R em oval" p r o ­ c e d u re . Figure 14—Running Board and Fender Extension CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 549 30 days a fte r d eliv ery . Apply a coat of p o lis h th e r e a fte r a t le a s t once a y e a r. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 550 V8 engine, re s is ta n c e value of the w ire is g ra m s and optional equipm ent is shown in b roken 1.35 ± .05 ohm s. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 551 Figure 2 —Lam inated Circuit Connector (Conventional Cab M odels) (Typical) attem p tin g to se p a ra te . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 552 T h is o ff-a n d -o n cycle w ill re p e a t Figure 5 —Chassis Junction Block (Tilt Cab M odels) (Typical) u n til th e sw itch c o n tro llin g the defective c irc u it is CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 553 1,000 rp m . The m ile s -p e r- h o u r hand should w ire o r la r g e r in a ll u n p ro te c te d c ir c u its of the Figure 6 —Typical Fuse Block CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 554 C u rre n t fro m the b a tte ry (No. 1 te rm in a l), then CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 555 , o r an o v erh e a te d engine. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 556 . p an el (fig. 9). CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 557 3 W asher 9 Knob - W/S W iper 14 "J" Nut 4 Choke Rod and Tube 10 S etscrew 15 Nut A ssem bly 5 Nut T-6324 Figure 7—Instrum ent Cluster (Conventional Cab M odelsI (TypicalI CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 558 . p r e s s in w ard to lock in p la c e . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 559 11 W indshield W iper M otor 26 D om e L am p C o n n ecto r 12 Choke Rod T-7072 Figure 9 —Instrument Panel W iring (Conventional Cab M odels) (Typical) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 560 CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 561 10 T a c h o m e te r 15 Fuel Gauge 5 D iffe re n tia l Lock T e ll-ta le T-7076 Figure 11 —Instrum ent Cluster (Tilt Cab M odels) (Typical) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 562 ILLUM. LT. (GRAY) (PINK & LT. GRN.) SPEEDOMETER HI-BEAM TELL-TALE (LT. GRN. & BLK.) INST. PANEL WIRING HARNESS T-6 7 1 4 Figure 12—Connections at Rear of Instrum ent Cluster (Tilt Cab M odelsI (Typical) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 563 , w ith a low rea d in g v o ltm e te r o r a conven- w ithout re q u irin g a la rg e w ork a r e a . A im ing is CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 564 Fig u re 1 4 —S in g le S e a le d -B e a m Unit 2. In s ta ll headlam p a sse m b ly in pan el opening A d ju stm e n t Points (Typical) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 565 (m echanical tra n s m is s io n ), 4. C onnect w iring of new unit to vehicle h a rn e ss. when the ignition sw itch is p la ce d in "ON" positio n CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 566 . To re p la c e the te ll- ta le lam p, disconnect Figure 17—Directional and Parking Light w irin g co n n ecto r fro m back of te ll- ta le lam p, then (Tilt Cab M odels! (Typical) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 567 9A) of th is m anual and check fo r a w orn o r d am ag­ Figure 19—M ain Light Switch Circuit Diagram (Conventional Cab M odels) (Typical) ed can cellin g cam . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 568 18 D ire c tio n a l L e v e r t -6600 7 U pper B e a rin g A ssem b ly Figure 21 —Directional Signal A ssem bly (Except Tilt Cab M odels) (Typical) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 569 ‘‘TRANSMISSION ON- by th is m anual. V EHICLE SERVICE” (SEC. 7B) in th is m anual. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 570 . Figure 2 2 —Directional and H azard W arning Switch 5. P o sitio n sw itch le v e r th ro ugh housing and (Tilt Cab M odels) (Typical) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 571 . T ighten sc re w s 9A) and check fo r a w orn o r dam aged cancelling firm ly ; how ev er, do not exceed 30 in .-lb s . to rq u e . cam . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 572 Brake Warning Light 1895 Temperature Gauge Light (T ilt Cab Models) Fuel Gauge Light (T ilt Cab Models) A ir Pressure Gauge Light Voltmeter Light Tachometer Gauge Light Ammeter Gauge Light Oil Pressure Gauge Light CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 573 Air Gap at Core Point Opening (In .)................0.017 Points Closed ( In .) ..............0.020 Closing Voltage..........Adjust to Buzz at .2S-.35 Point Opening (In .)................0.018 Amperes at 13.5-15.4 Volts Closing Voltage (Range)..............1.5-9.5 CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 574 Sec. 12-25 CHASSIS ELECTRICAL A N D INSTRUMENTS CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 575 Fig u re 2 5 — In stru m en t P a n e l— T E-T S5 0 , TE6 0...
  • Page 576 Sec. 12-27 CHASSIS ELECTRICAL A N D INSTRUMENTS CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 577 R H.PARK h e a d l p HORN LIGH TIN G CANADIAN M ARKER LIG H T S M IR R O R L P S . sblk R.P.O. 0 4 6 tr - 1 0 WHT.- "I ■ I L.H I8BLK -.- TR L.
  • Page 578 Sec. 12-29 CHASSIS ELECTRICAL A N D INSTRUMENTS CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 579 C IR C U IT LEGEND IDENTIFICATIO N L O C A T IO N S Y M B O L J U N C T IO N ON CONTROL ISLANO PNL S U P T FRT S IL L BRKT □...
  • Page 580 Sec. 12-31 CHASSIS ELECTRICAL A N D INSTRUMENTS Figure 3 0 —Engine Compartment—CS40-50 CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 581 12B - ..- ....- 18T — 18B — - 1 8 B - BRN-' LT. FRT. MARKER •FOR WIRE GAGE - SEE TAIL & STOP LAMP WIRING SHEET Figure 3 1 —Engine Compartment—CE40-50 CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 582 B"^ A r S 61 AMP GEN. ONLY LINK 18B- ■lbB/W—n R S iit ^ — 18B/W- 1 H R * 12 DC ♦FOR WIRE GAGE - SEE CHASSIS It TAIL LAMP WIRING SHEET Figure 32 —Engine Compartment—CE-ME60 CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 583 ---L’4 W -18B— M8T- •18B^-EI™H8B 12B/W' -14BRN— 12DG 18BRN « 1 4 Y — — 14DG---- ♦FOR WIRE GAGE - SEE CHASSIS S 4 L G — TAIL LAMP WIRING SHEET Figure 3 3 —Engine Compartment—5E50 CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 584 ■18B---- •18B^»rrT,^ 18B- — 14BRN- 18BRN 12DG- — 14Y---- — 14DG - LT. FRT. V -14LG - ♦FOR WIRE GAGE - SEE CHASSIS MARKER LP. TAIL LAMP WIRING SHEET Figure 34 —Engine Com partm ent—SS50 CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 585 Sec. 12-36 CHASSIS ELECTRICAL A N D INSTRUMENTS Figure 35 —Instrument Panel—CE-CS40-50 (03 ) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 586 - * BRN----------------------------------------------------------------------------- ■ * BRN- - * Y--------------------------------------------------------------------------------- ■ * Y ---- - * DG------------------------------------------------------------------------------- ■ * DG — • ♦ LG ■ * LG — Figure 3 6 —Instrument Panel—CE-CS40-50 (0 3 ) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 587 Sec. 12-38 CHASSIS ELECTRICAL A N D INSTRUMENTS Figure 37 —Instrument Panel—CE-M E60 (03-13) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 588 -180R— ■180R- ■18W — -18W— ■18T — •18T — ■ *BRN ■ *BRN ■ *Y — ■ ♦Y — ■ ♦DG - ■ ♦DG - .♦LG . .♦LG - Figure 3 8 —Instrument Panel—CE-ME60 (03-13) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 589 Sec. 12-40 CHASSIS ELECTRICAL A N D INSTRUMENTS *FOR WIRE GAGE - SEE CHASSIS & TAIL LAMP WIRING SHEET Figure 3 9 —Instrument Panel—C A 40-50 (02 ) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 590 WARN. LP. (V-8 ENG) ■16DG— ■16DG ■160R— "160R -14LBL ■14LBL- ■ 18T--------------------------------------------------------------------------------------- ■♦BRN ■*Y---------------------------------------------------------------------------------------- ■*DG--------------------------------------------------------------------------------------- ■ *LG--------------------------------------------------------------------------------------- ♦FOR WIRE GAGE - SEE CHASSE t TAIL LAMP WIRING SHEET Figure 4 0 —Instrument Panel—CA 40-50 (02 ) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 591 Sec. 12-42 CHASSIS ELECTRICAL A N D INSTRUMENTS Figure 41 —Instrument Panel—S A 5 0 (02) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 592 Sec. 12-43 CHASSIS ELECTRICAL A N D INSTRUMENTS SPEEDO­ METER ■16DG ■1®0R ■14LBL ------ 14W--------------------------------------------------------------------------------------- ------------------------------------------------------------------------— ------ 14W-------- 14DG- -14DO ■14LG- -14LG- Figure 4 2 —Instrument Panel—5A 50 (02 ) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 593 L. H. BACKING LAMP L. H. DIRECTION 6 TAEL LAMP LT REAR MARKER TAIL & STOP LAMP LAMP (02 MODELS ONLY) Figure 4 3 —Tail and Stop Lamp—S A 5 0 (0 2 ) M E60 CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 594 MARKER LP. .♦DG . L.KL SIDE .18 LG - MARKER LP. •FOR WIRE GAGE - SEE CHART ABOVE Figure 4 4 —Tail and Stop La m p -C A 4 0 -5 0 , CE60 CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 595 WIRING PART OF EQUIPMENT WITH PROVIDED 25 AMP. AIR CONDITIONING WIRING FUSE VIEWS INDICATE WIRE ENTRY SIDE OF CONNECTOR V .____________/ C ONNEC TOR REC E PTAC LE "CIG" Figure 4 5 —A ir Conditioning CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 596 Sec. 12-47 CHASSIS ELECTRICAL A N D INSTRUMENTS 12DG GEN. ft r*T3. LP. HARX. CONN. Figure 4 6 —Generator—62 A m p-C A40, C A -SA 50, CE-ME60 CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 597 Figure 4 7 — C a rg o La m p...
  • Page 598 Sec. 12-49 CHASSIS ELECTRICAL A N D INSTRUMENTS Figure 4 8 —Trailer Jum per Cable—CE50, CE-ME60 CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 599 — ♦DG - TRAILER CABLE CONN. ■14DG ^ ♦ L G - TRAILER CABLE JUNC. BLK. ♦FOR WIRE GAGE - SEE CHASSIS & TAIL LAMP WIRING SHEET Figure 4 9 —Trailer Jum per Cable—CE50, CE-ME60 CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 600 INST PNL TRLR STOP LAMP TRLR STOP LAMP HARNESS SW CONNECTOR SW CONNECTOR CONN EMER AIR BRAKE CONN INST PNL HARNESS ofl CONN J75-J77 ONLY Figure 5 0 —Trailer Jum per Cable—CE50, CE-ME60 CHEVROLET 4 0 6 0 TRUCK SERVICE MANUAL...
  • Page 601 Sec. 12-52 CHASSIS ELECTRICAL A N D INSTRUMENTS CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 602 . r a d ia to r f ille r cap. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 603 . Figure 2 —Radiator Installation (A ll Conv. and Cowl M odels 40 , 50) (Typical) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 604 Assem bly Speed Nut Control Island Flat W asher Frame Bracket Spring Nut ^ Radiator Core a nd Support CORE UPPER MOUNTING CORE LOWER MOUNTING T-6846 Figure 4 —Radiator M ountings (“ T” M odels) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 605 . T ilt cab fo rw a rd to gain Figure 6 —Surge Tank M ounting (Typical) CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 606 SPECIFICATIONS COOLING S Y S T E M PRESSURE R E L IE F V A L V E MODELS VALVE STAMPED OPENING PRESSURE A ll M odels R C -12-9# 9 p s i CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 607 When v eh icle is o p e ra te d in fre e z in g w eath er, p ro te c t cooling s y s te m by u se of p e rm a n e n t-ty p e a n tifre e z e . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 608 ♦ J-21058 R em o v er and R e p la c e r (P lain Spring J-0971 F ro n t C over Support Tool Eye Bushing) ♦Listed in more than one section. CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 609 Idle A d ju st W rench J-8 1 0 9 G e a rsh ift L e v e r R em ov er ♦ L iste d in m o re than one se c tio n . CHEVROLET 40-60 TRUCK SERVICE MANUAL...
  • Page 610 WEIGHTS AND MEASURES LIN EAR MEASURE COM M ON W EIGHT 16 o u n c e s ........= 1 pound 1/12 foot (ft.) .
  • Page 611 DECIMAL EQUIVALENTS ...... 015625 ......515625 33/i4 ............... 03125 ..53125 ....,7/32 ..............046875 ..546875 ..........> % 4 ...... 0625 9 /w 5625 ................. 078125 578125 ............37/*4 09375 59375 ....
  • Page 612 GAGES & U. S. STANDARD G A G E* AM ERICAN WIRE or B S G A G E G A G E NO. Approx. Thickness—Inches Thickness—Inches 0 0 0 0 0 0 0 0 .4 9 0 0 0 0 0 0 0 .4 60 0 .5 8 0 0 .5165...
  • Page 613 DRILL SIZES Wire Drill Drill Wire Drill Wire Drill Letter Gage Diam. Diam. Gage Diam. Gage Diam. Sizes Inches Sizes Inches Sizes Inches Sizes Inches 0.1405 0.0520 0.413 0.2280 0.1360 0.0465 0.404 0.2210 0.2130 0.1285 0.0430 0.397 0.0420 0.386 0.2090 0.1200 0.2055 0.1160...

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60 series 1971

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