Chevrolet 30 Series 1967 Service Manual
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Chevrolet 30 Series 1967 Service Manual

Chevrolet 30 Series 1967 Service Manual

Chassis
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Table of Contents

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CHASSIS
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  • Page 1 ^ s W U 'gw CHASSIS *V3» a - « n...
  • Page 3 35 - Forward Control Panel (Square-Front) 36000-48000# (tandem axle) 36 - Deluxe Suburban (Panel Rear Doors) 42 - Forward Control Chassis 45 - Forward Control Panel (Round-Front) 62 - Flat Face Cowl (full air brakes) CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 4 A typical serial number is explained in the following 10 - Day of manufacture (tenth) chart. FA - Transmission and engine type CHEVROLET M A X IM U M G V W RATING - -------------------- VEHICLE IDENTIFICATION NUMBER w 1 C S 107047P10 0 0 ^ 5 1 D P I Fig.
  • Page 5 GENERAL INFORMATION 0-3 Fig . 7 - Tandem A x le , Rear U n it - Unit Fig . 8 - 3-Speed Transmission U nit Fig. 9 - 4 -Speed Transmission Unit and Assembly Numbers Stamped on Number Located on Lower Left Side Number Stamped on Rear of C ase, Upper Portion o f C arrier o f Case A d jacen t to Rear o f Cover...
  • Page 6 Case, Toward Rear Service Parte Identification Plate Fig . 23 - Se rv ic e Parts Id entification Pla te The Chevrolet Truck Service Parts Identification Plate REFER THIS INFORMATION WHEN ORDERING (fig. 23) is provided on all Truck models. On most series PARTS.
  • Page 7 In cases where a code book is not available, the dia­ gram shown on Figure 25 may be used to determine the tumblers required to assemble an uncoded lock cylinder. Fig. 2 6 - Assembling Lock C ylin d er CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 8 GENERAL INFORMATION 0-6 4. Reverse the lock cylinders so that the head of the vehicle is to be towed at speeds above 30 MPH. cylinder is now toward you. Insert the spring re ­ Both manual and automatic transmissions should be tainer so that one of its six prongs enters into each towed in neutral only, with parking brakes fully released.
  • Page 9 GENERAL INFORMATION 0-7 GROSS VEHICLE WEIGHTS FOR 1967 CHEVROLET TRUCKS AND SCHOOL BUS CHASSIS T IR E S A N D E Q U IP M E N T 1 R E C O M M E N D E D T IR E S M IN IM U M M A N D A T O R Y E Q U IP M E N T F O R W H E E L ­...
  • Page 10 GENERAL INFORMATION 0-8 GROSS VEHICLE WEIGHTS FOR 1967 CHEVROLET TRUCKS AND SCHOOL BUS CHASSIS T IR E S A N D E Q U IP M E N T S W H E E L ­ F R O N T...
  • Page 11 GENERAL INFORMATION 0-9 GROSS VEHICLE WEIGHTS FOR 1967 CHEVROLET TRUCKS AND SCHOOL BUS CHASSIS T IR E S A N D E Q U IP M E N T J R E A R R E C O M M E N...
  • Page 12 GENERAL INFORMATION 0-10 GROSS VEHICLE WEIGHTS FOR 1967 CHEVROLET TRUCKS AND SCHOOL BUS CHASSIS T IR E S A N D E Q U I P M E N T W H E E L ­ F R O N T...
  • Page 13 327 Cu. In. V (Gasoline) 500-600 Series Repl. Element 366 Cu. In. V (Gasoline) Repl. Element 159 Cu. In. L3 (Diesel) 11.5 Repl. Element 212 Cu. In. L4 (Diesel) Repl. Element 318 Cu. In. V (Diesel) CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 14 Lubricating Oils". These oils provide better lubrication, long runs at high speeds and high loads, driving under possess more heat resistance, and counteract sludge severe dust conditions, and short runs in cold weather formation more effectively than the non-detergent type CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 15 Connecting hoses, fittings, flame arrestor and With engine running, check for flow of air from air crankcase breather cap (where used) should be cleaned. box drain tubes every miles and, if tubes are 6 , 0 0 0 CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 16 1. Start engine, set parking brake and move control Recommended Lubricants lever into (3"-HI") position. Run engine at 1000 rpm until engine and transmission have reached NOTE Lubricate with water resistant EP normal operating temperature. lubricant. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 17 Then end of the shell approximately " from the bottom of the remove the front wheel hub to lubricate the bearings. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 18 Note 1. Engine operation at altitudes above 5,000 feet requires More frequent lubes may be required on heavy duty use of next lighter class of fuel oil than would normally or "off the road" operations. be used. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 19 Heavy Duty Off-the-road Heavy Load and high Equipment, Trucks, No. 2-D* 675° F. 0.50% speed. Tractors. ♦NOTE: For most satisfactory engine life, use only those No. 2-D diesel fuel oils containing 0.50% or less sulfur. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 20 Brake Master Cylinder 6,000 Miles Brake Fluid Delco As required Check - Add fluid when Supreme #11 necessary Parking Brake Linkage 6,000 Miles Chassis Lubricant Lubricate Linkage, Pulleys and Cables *Replace at 24,000 M ile Intervals CHEVROLET TRUCK SERVICE MANUAL...
  • Page 21 As required Universal Joints 6,000 Miles Not shown As required Propeller Shaft Slip Joint 6,000 Miles Chassis Lubricant Check Multi-Purpose As required Rear Axle 6,000 Miles See Lubrication Section ♦Replace Lubricator at 24,000 m ile intervals. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 22 Propeller Shaft Slip Joint 6,000 Miles Chassis Lubricant place as required Master Cylinder 6,000 Miles Delco Supreme As required Check - add fluid No. 11 when necessary ^Replace Lubricator at 24,000 mile intervals. **D iesel Engine not illustrated. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 23 6,000 Miles Chassis Lubricant 3 places as required Spring Hanger 6,000 Miles Chassis Lubricant places as required Rear Axle 6,000 Miles Multi-Purpose As required Check See Lubrication Section ^Replace Cam Lubricator at 24,000 m ile intervals. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 24 4 places as required Spring Hangers 6,000 Miles Chassis Lubricant places as required Cam surfaces Rear Axle 6,000 Miles As required Multi-Purpose Check See Lubrication Section ♦Replace Lubricator at 24,000 m ile intervals. **D iesel Engine not illustrated. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 25 6,000 Miles Multi-Purpose Rear Axle See Lubrication Section MA50 Trailing Axle places as required See Lubrication Section Multi-Purpose 6,000 Miles Wheel Bearings - MA60 Series *Under favorable driving conditions, 25,000 miles. **Diesel Engines not illustrated. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 26 6,000 Miles Engine Oil Keep even w /filler plug 6,000 Miles Multi- Purpose As required Transmission - Synchromesh See Lubrication Section Rear Spring Hanger Chassis Lubricant places as required 6,000 Miles *Replace Lubricator at 24,000 mile intervals. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 27 6,000 miles. additional lube fitting is provided on the hold-down catch pivot. This should be lubricated every 6,000 miles with chassis lubricant. F ig . 35 - T ilt Cab M odels CHEVROLET TRUCK SERVICE MANUAL...
  • Page 29 The second vary the air temperature. The bypass channel is a de- lever opens the air door and operates the three speed fan CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 30 TILT CAB HEATER through the floor outlets. Intermediate positions of the knob split the airflow between the floor and defroster The Tilt Cab Heater is mounted on the toe board inside outlets in proportion to knob setting. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 31 O U T L E T S A S S E M B L Y H E A T E R C O R E Fig. 3 - C h evy Van Heater Schem atic Fig. 5 - G -10 Heater Assembly CHEVROLET TRUCK SERVICE MANUAL...
  • Page 32 DUCT HEATER AND Tilt Cab DEFROSTER ASM. DISTRIBUTOR Removal 1. Disconnect the battery ground cable. Roll the floor mat back from the heater motor area. Fig . 7 - T ilt Cab H eater Assembly CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 33 . (10-30 Series) In order to gain access to the lower F ig . 1 0 - Heater Distributor and Ducts CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 34 4. Loosen the clamp at the top of each rubber elbow Fig. 13 - T ilt Cab Thermostatic V a lv e C a p illa ry Fig. 12 - T ilt Cab Heat C ab le Access Plate CHEVROLET TRUCK SERVICE MANUAL...
  • Page 35 12. At the front of the cab, tighten the sheet metal nut to the core case stud. 13. Connect the rubber elbows to the core tubes and clamp securely. F ig . 14 - Defroster Hoses 14. Replace air intake grille. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 36 Check cable adjustment before installing control assembly in dash. F ig . 1 6 - G -1 0 Heater W iring Fig . 15 - Heater W iring CHEVROLET TRUCK SERVICE MANUAL...
  • Page 37 Tilt Cab 4. Disconnect the blower harness connector and remove the resistor unit mounting screws. Remove resistor Replacement of the thermostatic valve (tilt cab only) unit. is covered under BLOWER AND CORE CASE AND CORE. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 38 Therefore, control adjustment is a matter of properly setting these bowden cables. The following paragraphs explain each control. F ig . 18 - Four-Season System Controls CHEVROLET TRUCK SERVICE MANUAL...
  • Page 39 HEATER AND AIR CONDITIONING 1A-11 EVAPORATOR OUTLET F ig . 20 - A irflo w Schematic CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 40 In most instances, heating the drum or can eyes are protected with goggles or glasses, no is required to raise the pressure in the container serious damage can resu lt Just remember, any higher than the pressure in the system during the CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 41 • Sealing beads on hose clamp connections must be free of nicks and scratches to assure a perfect seal. • Use only sealed lines from parts stock. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 42 HEATER AND AIR CONDITIONING 1A-14 MAINTAINING CHEMICAL STABILITY IN THE REFRIGERATION SYSTEM The metal internal parts of the Chevrolet refrigeration system and the refrigerant and oil contained in the sys­ tem are designed to remain in a state of chemical sta­...
  • Page 43 Since R-12 is heavier than air, it is good practice to place open end of sampling tube immediately below point being tested, particu­ larly in cases of small leaks. F ig . 25 - Leak Detector CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 44 • If the pump is being utilized to evacuate a bumt-out plate is dirty. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 45 1. Doors and windows closed. (Car inside or in shade.) • Check evaporator drain tubes regularly for dirt or 2. Hood up and engine exhaust suitably ventilated. restrictions. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 46 Pressure Evaporator Pressure Dependent Upon Altitude at STV See Chart Under Evaporator Con­ trol Valve (POA) Discharge Air Temp, at Right Hand Outlet F ig . 28 - Evaporator Pressure Control V a lv e POA CHEVROLET TRUCK SERVICE MANUAL...
  • Page 47 When the pressure is reduced to below 100 pounds frigerant reaches desired level (see "Air Condition­ on the high pressure gauge, open the low pressure ing System Capacities"), close valve at bottom of gauge valve and continue discharging until all r e ­ CHEVROLET TRUCK SERVICE MANUAL...
  • Page 48 If a new service compressor is being installed, drain all oil from it and replace only the amount specified in Steps 3a and 3b above. F ig . 30 - Charging Station Controls d. If a field repaired compressor is being installed, CHEVROLET TRUCK SERVICE MANUAL...
  • Page 49 V A L V E V A L V E R EFR IG ER A N T SU PPLY ► T O V A C U U M SU PPLY F ig . 31 - Charging Schematic CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 50 "O" bead. Hose must butt against this fourth bead. ring. Do not overtighten. Again leak test the joint. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 51 To do so may damage the "O" ring seal. 4. Evacuate and recharge the system. SEA LIN G LOCATING BEADS BEAD CONTROL ASSEMBLY Removal F ig . 32 - Hose Clamp Connections 1. Disconnect battery ground cable. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 52 (cap the condenser inlet and outlet if it is to be reused). Installation 1. Mount upper condenser mounting brackets Installation (loosely) to the condenser frame. 1. Lower the replacement condenser into position and Lower the condenser into position behind the grille. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 53 2. Uncap any previously capped connections and con­ nect the fittings using new "O" ring seals. 3. Evacuate recharge system. If receiver-dehydrator was installed, add one fluid ounce refrigerant oil to the system. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 54 3. Connect the equalizer line to the P.O.A. and mount the capillary bulb to the evaporator outlet pipe. 4. Evacuate and charge the system. Check perform­ ance. F ig. 3 6 - Evaporator and Blower Assembly CHEVROLET TRUCK SERVICE MANUAL...
  • Page 55 4. Disconnect heater hoses at the core tubes. 5. Disconnect the refrigerant lines at the P.O.A. valve Installation outlet and the expansion valve inlet. Cap all open 1. Assemble evaporator core and inboard case half to connections. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 56 4. Remove the screw attaching the distributor to the heater case, slide the distributor rearward and remove it. 5. Unplug the resistor unit connector. . Remove the resistor unit retaining screws. Remove the unit. F ig . 38 - Heater and Ducts CHEVROLET TRUCK SERVICE MANUAL...
  • Page 57 2. Remove hoses at the compressor inlet and muffler 3. Remove actuator bracket mounting screws. outlet pipes. Cap the connections. 4. Disconnect one link pin and remove actuator as­ 3. Remove muffler outlet pipe clamp. sembly. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 58 1. Attach the valve to the actuator link. 2. Insert the lower pivot pin into the lower hole, retract KICK PAD VALVE Fig. 43 - A ir Inlet V a lv e and Recirculating A ir V a lv e CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 59 Remove valve Removal return spring. 1. Remove cowl grille panel. Refer to Section 11. 5. Pull the rear valve pivot pin forward against spring F ig . 45 - Vacuum Diagram CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 60 . Before beginning any compressor disassembly, drain Adjust the compressor belt to the specifications shown in the Tune-Up chart in the Engine section of this manual. and measure oil in the compressor. Check for CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 61 B TO L & M B TO L & H HIGH ---------- EXISTING WIRING ---------- WIRING PART OF EQUIPMENT ----------- AIR CONDITION WIRING BATTERY UNFUSED FUSE PANEL F ig . 47 - System A nalysis W iring Diagram CHEVROLET TRUCK SERVICE MANUAL...
  • Page 62 29. J-21508 Seal Seat " O " Ring Installer J-6435 ^26 Snap Ring Pliers 30. J — 21303 Shaft Seal Protector J-9396 Compressor Holding Fixture 31. J-9527 Pressure Test Connector J-9397 Compressing Fixture 32. J-9402 Parts Tray CHEVROLET TRUCK SERVICE MANUAL...
  • Page 63 Seat tracks are strengthened, as are floor pans. service installation. Windshield and back window glass replacement proce­ The Chevrolet Truck body is designed to provide a strong, fully welded unit which has a universal application dures are revised. The basic cab is used on Models 10-60, with reinforce­...
  • Page 64 Dust leaks will be evident when these pads and mats at windshield, backglass, bolt holes, weatherstripping and are removed. Leaks can be located sometimes by putting joints is as follows: a bright light under the cab or body, while checking the CHEVROLET TRUCK SERVICE MANUAL...
  • Page 65 CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 66 STANDARD C USTO M WINDSHIELD GLASS The windshield is a one-piece type and is retained in Fig . 7 - Cross Section of W indshield W eatherstrip (Typ ical) F ig . 8 - Loosening Weatherstrip CHEVROLET TRUCK SERVICE MANUAL...
  • Page 67 . Check the relationship of glass to opening as follows: a. Inside edge of glass to body flange. F ig . 11 - Pulling String to Seat Rubber Lip CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 68 1. Remove windshield wiper arms from wiper pivot shafts. 2. Raise hood and remove screws, retaining cowl venti­ lator grille and cowl hood ledge seal. F ig . 12 - Rear V ie w Mirrors CHEVROLET TRUCK SERVICE MANUAL...
  • Page 69 4. Reinstall windshield wiper arms on pivot shafts. WINDSHIELD WIPERS COWL AIR VENTILATOR VALVE ASSEMBLY Windshield wiper units on all models are of the two- speed electric type. A single wiper motor unit, mounted CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 70 If opposite pivot shaft and link rod was removed, install it at the same time. 3. Install outside air cowl ventilator grille to top of cowl using screws (fig. 15). F ig . 19 - Endgates - Stepside and Fleetside CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 71 Remove and re­ place four bolts for replacing the striker plate at the door lock pillar and adjust as required below. F ig . 21 - Striker Assembly on Body Lock P illa r CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 72 Step Van, Chevy Van and Tilt Cab models. The the door rear edge within 1/16”. Refer to Figure 23. new front door check hinge combination allows a friction CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 73 3. Attach the two screws below the regulator assembly. VENTILATOR ASSEMBLY ADJUSTING NUT AND TAB LOCK F ig . 24 - Vent Assembly Inner Door Panel Attachment F ig . 26 - Adjusting V en tila to r Operating Tension CHEVROLET TRUCK SERVICE MANUAL...
  • Page 74 Trim off the ex- 1. Wind window all the way up. F ig . 27 - Rubber Run Removal from Door F ig . 29 - Regulator Assembly & G lass (Side Door) CHEVROLET TRUCK SERVICE MANUAL...
  • Page 75 JOINT TO B " , INSTALLED SO THATj JOINT FALLS IN § VIEW A THIS AREA v F ig . 30 - Door Opening W eatherstrip F ig . 31 - Installing Trim Panel Seal CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 76 1. Raise door window and remove door trim pad. 2. With a screwdriver, or other suitable tool, slide lock cylinder retaining clip (on door outer panel) out of engagement and remove lock cylinder. 3. To install, reverse removal procedure. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 77 A pointed wooden tool, if available, should be used. Fig. 35 - Rear W indow W eatherstrip Installation Fig. 37 - Cutting W eatherstrip Insert at 4 5 ° Angle CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 78 5. Immerse third cloth, wring out, allow evaporation and apply to both the soiled and the area surrounding same, using a light, brisk motion. . Repeat brushing operation. 7. If a cleaning ring should form, the entire area of the CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 79 Engage yoke (No. 26) hooked ends over lugs on ad­ juster pin (No. 40). 7. Preload torsion bars by rotating adjuster lever as­ sembly (No. 30) clockwise (figs. 41 and 43). . Remove wood shims. F ig . 40 - Ride Level Indicator CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 80 BODY IB-18 Fig. 41 - Exploded V ie w of Level Ride Seat CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 81 . Remove hinge shaft (No. 18) by tapping out from left hand to right hand side. This operation frees (2) washers (No. 15). 7. Remove (2) roll pins (No. 20) from hinge shaft at Fig. 43 - Adjuster Lever CHEVROLET TRUCK SERVICE MANUAL...

  • Page 82: Table Of Contents

    A partial front end panel is available for service; also the integral frame. All outer panels are welded to a flat plenum and instrument panel as separate items for floor. replacement. CHEVROLET TRUCK SERVICE MANUAL...

  • Page 83: Side Panels

    1. Latch: Remove 2 screws on jamb and a pin at frame at­ tachment. 2. Frame: Remove 4 screws on hinge to jamb plus 2 latch Fig. 47 - W indshield G lass and Sealer screws. CHEVROLET TRUCK SERVICE M ANUAL...

  • Page 84: Outside Rear View M Irrors

    4. Disengage the compartment by sliding rearward and out. Fig. 50 - Windshield W iper Linkage Removal (T y p ica l) Fig. 49 - Heater Duct and Distributor Removal CHEVROLET TRUCK SERVICE MANUAL...

  • Page 85: Dash M A T

    Parts to be removed and installed for replacement of the dash mat are as follows: Fig. 52 - Dash Mat and Seal Fig. 53 - Front Side Door CHEVROLET TRUCK SERVICE M ANUAL...

  • Page 86: Rear And Side Cargo Doors

    The forward load door is serviced the same as rear doors (fig. 60). Rear Door Outside Handle (Fig. 61) Replacement 1. Remove spring retainer from inside door panel Fig. 54 - Trim Panel and Hardware Fig. 56 - Channel Assembly Attachment CHEVROLET TRUCK SERVICE MANUAL...

  • Page 87: Hinge Adjustm Ent

    Fasten 2 screws, washers and nuts to rocker. 3. Lower vehicle and install 7 bolts in Van floor. Fig. 58 - Front Side Door W ind o w Replacement Fig. 60 - Forward Side Load Door - Sport Van CHEVROLET TRUCK SERVICE MANUAL...

  • Page 88: Seats

    (retract) step. . From underside tighten 2 inboard bolts. Fig. 63 - Side Cargo Door Hinge Adjustment Fig. 62 - Hinge Strap and Hinge Assembly (Rear Door - T yp ica l) CHEVROLET TRUCK SLXVICE M ANUAL...
  • Page 89 BODY IB-27 CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 90 Windshield and Front Quarter G l a s s ..... IB-30 Window G l a s s ............IB-33 Access Doors and C o v e r s ........IB-30 P-20-30 IB-30 Special T o o ls ..............I B -36 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 91 Transmission W here A p p lica b le . Engine Box Lid. Removable Floor Pla te G iv e s Access As Follows: Right Hand W indshield W ip er Inspection Plate. 1. To M ain Brake C ylin d er. CHEVROLET TRUCK SERVICE M ANUAL...

  • Page 92: Front End Panel

    The following information is intended as an accessi­ bility guide. Components are removed as outlined for Open door in floor below the right rear corner of en­ gine box to service or remove the battery. conventional vehicles unless otherwise stated. CHEVROLET TRUCK OVERHAUL M ANUAL...
  • Page 93 Open door in instrument panel just back of windshield M A IN C YLIN D ER ifg jPif Fig . 73 - P10 Main C ylin d e r and 6 C ylin d e r Radiator Access CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 94 (B) in center of front end header panel and also up and down by means of elongated holes in above windshield. the brackets (fig. 74). Fig. 74 - Door Track and Roller Assys, CHEVROLET TRUCK SERVICE MANUAL...
  • Page 95 2. Remove the upper panel on the door pocket just to the rear of the above panel. Note the special washer between the pivot bearing and top of mounting bracket. 3. Remove the nut and lockwasher from the bolt that Fig. 77 - W eatherstrip Installed CHEVROLET TRUCK SERVICE M...
  • Page 96 Push glass for­ ward as far as possible (fig. 78). 4. Set lower edge of stationary glass in weatherstrip Fig. 79 - Installing Stationary G lass CHEVROLET TRUCK SERVICE MANUAL...
  • Page 97 13. The run channel at front of window should be opened tionary glass replacement. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 98 (operating) position by a positive locking mecha­ The underside of cab is completely insulated to deaden* nism located at rear of cab (fig. 81). sound and prevent corrosion. Access for minor engine servicing, such as oil and en­ CHEVROLET TRUCK SERVICE MANUAL...

  • Page 99: Service Operations

    SUPPO RT BRACKET BRACKET SAFETY CH A IN C H ECK LINK A N D RELEASE ROD RELEASE ROD LEVER CAB FRONT M OUNTING CAB REAR M O UN TING Fig. 83 - T ilt Cab Mounting CHEVROLET TRUCK SERVICE MANUAL...

  • Page 100: C A B A Ssem Bly

    Disconnect brake lines and clutch line. slightly open (fig. 5. Disconnect speedometer cable and all electric con­ Raise cab and install (if previously removed) left, Fig. 85 - T ilt Cab Position - Torsion Bar Unloaded CHEVROLET TRUCK SERVICE MANUAL...
  • Page 101 CHECK LINK LEFT C A B SU P P O R T BRACKET Fig. 87 - A lign in g Bracket Bolt Holes Fig. 89 - Right Hand Support Bracket and Check Link Fastenings CHEVROLET TRUCK SERVICE MANUAL...

  • Page 102: Tilting Mechanism

    1. Release check link at right front mounting (see inset view) by pulling rearward on link release rod then pull cab back to operating position. 2. Safety catch at rear of cab will automatically become Fig. 91 - T ilt Cab Latch Mechanism CHEVROLET TRUCK SERVICE MANUAL...

  • Page 103: Cab Rear Hold-Down And Safety Hook Assembly

    22-7/8" from center of hole in clevis to cen­ hole in lever as near center of slot in frame bracket CHEVROLET TRUCK SERVICE M ANUAL...

  • Page 104: Cab Insulation

    2. In same manner, remove insert from seal around IMPORTANT: Before spraying new undercoat­ ing, clean area thoroughly. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 105 BODY IB-43 Fig. 94 - Check Link Assembly (T yp ica l) CHEVROLET TRUCK SERVICE MANUAL...

  • Page 106: Installation

    2. Reposition rubber seal on flange. Raise new glass to outside of seal, then with hook end of installer Tool (J-2189) in glass groove of seal as shown in Figure 95 move tool around glass to force outer lip CHEVROLET TRUCK SERVICE M ANUAL...

  • Page 107: Windshield Wipers

    INSTRUMENT PANEL COMPARTMENT Figure 101 illustrates installation and assembly details of the instrument panel compartment. Note that if truck 98 - Vent is equipped with heater, it will be necessary to remove Fig. Fresh A ir Assy. CHEVROLET TRUCK SERVICE M ANUAL...

  • Page 108: Doors

    The adjacent striker support is mounted on door ledge of cab as shown in View F, Figure 102. Upper striker and striker support is employed at top of door to restrict the up and down movement of door in cab CHEVROLET TRUCK SERVICE MANUAL...
  • Page 109 E— D O O R L O W E R H IN G E V I E W D— D O O R L O W E R ST R IK ER Fig. 102 - Door Adjustment Points CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 110 Doors can be removed, how­ ever, without prior removal of above components. Re­ IMPORTANT: Excessive pressure will damage moval and installation of door window glass is described door paneling. under Door Window Glass. Fig. 104 - Door Lock Striker Plate CHEVROLET TRUCK SERVICE MANUAL...

  • Page 111: Window Regulator

    Lower both units of mechanism from access smooth side of channel is located as shown in opening in door. Figure 109. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 112 1. Remove small access panel from inner side of door taching retainer to door edge framing. below vent window. Figure 111 shows access panel 9. Raise and lower door window to check for binding. If removed. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 113 . Insert pivot stud of vent lower channel into hole of vent frame as shown in Figure 111. Through small access hole at top of door install vent upper pivot screw. Install two screws which attach bracket of Fig. 107 - Replacing Regulator Arm Retainer CHEVROLET TRUCK SERVICE MANUAL...
  • Page 114 G L A Z I N G C L A M P S C R E W R U B B E R Fig. 109 - Door Window G lass Assembly Fig. I l l - Door Vent Window CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 115 T Y P IC A L IN S T A L L IN G IN S E R T IN S E A L Fig. 113 - Insert-Type Seat Fig. 115 - D river's Seat Adjuster Assembly CHEVROLET TRUCK SERVICE MANUAL...

  • Page 116: Rear Glass W I N D O W

    Figure 116 illustrates exploded window. Feed in rubber insert while proceeding view of auxiliary seat with seat back in position for ac­ around window. Use a hitching movement to avoid cess to engine. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 117 BODY IB-55 Fig. 116 - A u x ilia ry Seat CHEVROLET TRUCK SERVICE M ANUAL...

  • Page 118: Special Tools

    Fig. 117 - Sp ecial Tools 1. J-2189—Weatherstrip Tool Set J-5742-01 and J-22577—W indshield Checking Blocks (T yp ical) J-22585— Front Door Hinge Bolt Wrench J — 9316— W indshield Checking Blocks CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 119 Fig. 2-50-60 Series Frame—Typical Fig. 1-10-30 Series Frame—Typical CHEVROLET TRUCK SERVICE MANUAL...
  • Page 120 B with a vertical vent bolt from working and wearing. Drill out and line pointer length of 8-1/4 inches, and at point E with a ream hole (or holes) to the bolt O.D. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 121 Fig . 4 - 1 0 - 3 0 Series Truck Frame...
  • Page 122 Fig . 5 - 4 0 - 6 0 Single A x le Truck Frames (E x c . T ilt Cab)
  • Page 123 DIM ENSIONS TO HOLES OR SLOTS ARE MEASURED TO THE CENTER OF HOLE OR SLOT GAUGE HOLES ARE % " DIAMETER © IN D IC A T E S THAT THE DIM ENSIO N IS TO THE UNDERSIDE OF THE FRAME TOP SURFACE OR INSIDE OF THE FRAME OUTER SURFACE.
  • Page 124 • 1 Ficu 7 - 4 0 - 6 0 Series T ilt Cab Truck Frames...
  • Page 125 SS414 15-7/8 13-1/2 106-1/4 171-3/4 14-5/8 16-3/4 16-3/4 149-3/8 15-3/4 15-3/4 PS414 15-3/4 13-1/2 15-3/4 15-3/4 156-1/4 185-1/2 16-1/4 16-3/4 16-3/4 45-1/2 106-1/2 PS421 15-3/4 13-1/2 15-3/4 15-3/4 45-1/2 124-1/2 174-1/4 215-1/2 16-1/4 16-3/4 16-3/4 CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 126 14-1/2 11-3/4 13-1/8 14-1/8 16-7/8 15-3/4 20 15-3/4 17 20 15-3/8 128-1/2 177-1/2 246-1/2 33-1/2 26-3/8 16-3/4 16-3/4 TG623 TT. _ 14-1/2 11-3/4 13-1/8 14-1/8 16-7/8 15-3/4 20 15-3/4 1 7 20 15-3/8 140-1/2 190-1/4 257-1/2 33-1/2 26-3/8 16-3/4 16-3/4 TD ’ TG625 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 127 The tram bar should be on a parallel to that of the there usually is an undamaged area suitable as a begin­ body plane. The exception to this would be when one ning reference point. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 128 Fig. 8 —Underbody Reference Points and Dimensions—C h e vy Van G10 and 20 ¥...
  • Page 129 Repairs ............... 3-12 In s ta lla tio n ..............3-22 B u s h in g s ............3-12 Special T o o l s ............... 1 3-22 Ball J o in t............3-12 CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 130 AND BRAKE DRUM LOWER CONTROL ARM F ig . 1 - Independent Front Suspension The Chevrolet Truck line incorporates two different crossmem ber with U-bolts. These control arms are connected to the steering knuckle through pivoting ball types of front suspension systems: Independent coil, and...
  • Page 131 Chevrolet Vari-Rate, bushed at the front eye only and The "I-Beam " axle is of the conventional reverse mounted to a rigid hanger. The rear end of the spring Elliott type, with spring and steering stop screw seats rides in a special hanger designed to provide a relatively forged integral with the "I-Beam ".
  • Page 132 Positive caster is the amount in degrees of the back­ ward tilt of the kingpin. Positive camber is the amount in degrees that the front wheels are tilted outward at the F ig . 5 - Wheel Bearing Adjustment - P20-30 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 133 1. Measure frame angle ’B" at location shown in Fig- Toe-in is the amount in fractions of an inch that wheels are closer together in front than at rear. Check steering F ig . 7 Front End Alignment CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 134 Tighten clamp bolts securely after proper adjustment is made. After toe-in adjustment on 4000, 5000 and 7000 F ig . 10 - Caster-Cam ber Shims - 10-30 Series CHEVROLET TRUCK SERVICE MANUAL...
  • Page 135 Front Axle Repair later in this section. arm as outlined under Steering Knuckle/Steering Arm F ig . 13 - Wheel Hubs and Bearings CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 136 (fig. 16). F ig . 1 4 - Wheel Hub Bearing Cup Removal F ig . 1 5 - Installing Bearing Cup (Typ ica l) CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 137 1. Remove nuts and eye bolts securing upper and lower shock absorber eyes. NOTE: Remove burr formed by lockwashers on control arm and on frame. 2. Withdraw shock absorber and inspect rubber eye bushings. defective, replace shock absorber assembly. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 138 Back Nut Up To End of Threads I F ig . 20 - Checking Lower Ball Jo in t (Typ ica l) F ig . 1 9 - Loosening Lower Ball Jo in t Stud CHEVROLET TRUCK SERVICE MANUAL...
  • Page 139 I - ---- -----H 2 V *" I-1 V i"-J REMOVER SUPPORT CP10, C20-30 REMOVER CP10 REMOVER—INSTALLER TOOLS F ig . 21 - Removing Control Arm Bushing F ig . 23 - Ball Jo in t Tools CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 140 At this point or after Step 1, compres­ sor J-6874 may be installed to safely retain spring. 3. Remove nuts securing control arm shaft studs to crossmember bracket. Withdraw control assembly. F ig . 26 - Positioning Upper Control Arm Shaft CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 141 3. Place brake backing plate and wheel cylinder in posi­ tion on steering knuckle and insert anchor pin. F ig . 27 - Suspension Crossmember F ig . 28 - P20-30 Sta b ilize r CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 142 . Tighten mounting bracket 25 lb. ft. F ig . 29 - Front S ta b ilize r - C hevy Van F ig . 30 - Shock Absorber Location (P20-30) CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 143 2. Place Tool J-21058-15 with J-22620-1 through bush­ ing and eye of spring. Center Tool J - 21058-6 and J - 21058-7 and screw Tool J - 21058-8 on threaded end of Tool J-21058-15. Pull bushing into spring eye (fig. 35). CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 144 Pull bolt out and remove spring assembly. Inspection Inspect all bushings for excessive wear, check spring F ig . 35 - Installing Spring Eye Bushing leaves for breaks and spring clips for tightness. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 145 4. Drop spring and pull out of rear hanger. HANGER 4 0 -6 0 SERIES REAR HANGER FRONT MOUNTING T50, 60 SERIES ALL MODELS F ig . 37 - Installing Threaded Eye Bushing F ig . 38 - 40-60 Spring Mounting CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 146 J-21978-1, 2 to remove and reinstall bushing. 7 0 0 0 # AXLES F ig . 4 0 - Installing Spring Eye Bushing F ig . 42 - Spring Eye Bushing CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 147 9000#-11,000# models, if this clearance exceeds Inspection .015", add shims as required to obtain a clearance 1. Wash all parts in solvent and air dry. of .003" to .008" (fig. 46). 2. Inspect steering knuckle for distortion, cracks or CHEVROLET TRUCK SERVICE MANUAL...
  • Page 148 Torque nut 250 knuckle and install two upper locking plate to steer­ lb. ft. and insert new cotter pin. ing knuckle retaining bolts. Raise steering and tie 4. Insert threaded end of lockpin through axle end from CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 149 Steering Knuckle. and U-bolt spacers. . Lower axle center and remove from under vehicle. A x le Center Tape or wire camber shims to spring seats. There are two conditions which, if either exists, will CHEVROLET TRUCK SERVICE MANUAL...
  • Page 150 Spring Bushing Rem over/Installer 12. J- 2 1 106 Inner Cup Installer - 11,000^ 5. J-21058 Spring Bushing Rem over/Installer 13. J- 2 1 107 O uter Cup Installer - 11,000^ J-0554 Hub Bolt Peening Tool (not shown) CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 151 7000^ A x le Spring Bushing Rem over/Installer 5. J-21978-1 4-5000^ A x le Spring Bushing Remover J-22620-1, 2 Spring Bushing Remover and Installer 6. J — 21978— 2 4-5000^ A x le Spring Bushing Installer CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 152 The power unit is driven through a Muncie three-speed the unit which transmits power from the transmission to or Chevrolet four-speed transmission and consists of an the rear and/or front axles and power take-off (fig. adapter and a two speed transfer case with a steering Engagement of front wheel drive, power take-off or speed and driving front axle.
  • Page 153 Removal From Wheel Hub The free wheeling hub assembly used on the front 1. Turn hub key to set hub to "free" or "disengage" wheels is serviceable. Service operations are as follows: position (fig. 3). CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 154 Slide on until bushing 6. Spring 12. Extension Housing Gaskets bottoms in wheel hub and install snap ring in axle 7 . O uter Clutch G e a r 13. Extension Housing shaft. Assembly 14. Snap Ring CHEVROLET TRUCK SERVICE MANUAL...
  • Page 155 On K20 models, remove stud nuts and washers, . Remove upper and lower bearing retainers and shims remove drive flange and gasket. from knuckle. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 156 4 . Lock Ring 10. Sea 1 Ri ng 16. Bearing Cone 22. W h eel Hub 5. Adjusting Nut 11. Rubber Seal 17. Bearing Retainer 23. D rive Flange 6. Steering Knuckle 12. Felt Seal 18. Spindle CHEVROLET TRUCK SERVICE MANUAL...
  • Page 157 1 1 - 2 0 lbs. pull. Add shim to decrease preload, remove (fig. 1). Push assembly to one side. shim to increase preload. 2. Remove two bolts from mounting assembly. Fig . 7 - Transfer Case Assembly (Typ ical) CHEVROLET TRUCK SERVICE MANUAL...
  • Page 158 Installation 10. Connect prop shafts to yoke at transfer case. Torque 1. Using chassis lubricant install new gaskets to bolts to specifications. adapter case. 11. F ill transfer case with proper lubricant. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 159 "U" bolt at the control arm (fig. 4). Fig. 1 - Rear Suspension (Series C and P10) CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 160 The front eye has a rubber insulated steel bushing through which the spring is bolted to the spring front hanger. The rear eye is shackle mounted F ig . 6 - Series K10 and K20 Rear Suspension CHEVROLET TRUCK SERVICE MANUAL...
  • Page 161 Separate frame-mounted, cam-type hangers are utilized to provide a deflection surface for the auxiliary springs. F ig . 10 - Rear Suspension (Series 4 0 , 5 0 , and 60) CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 162 11 - A u x ilia ry Rear Spring (Series 40, 50, and 60) Fig . 13 - Removing Control Arm Spring Clamp Bolt F ig . 12 - T ie Rod Bushing Replacement (Series C -P 10 and C20) (Series C-P10 and C20) CHEVROLET TRUCK SERVICE MANUAL...
  • Page 163 "U" bolts and lower the rear of the arm (fig. 13). 4. Disconnect parking brake lever at clip on bracket at­ tachment on control arm. 5. Remove pivot bolt and remove arm from vehicle. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 164 Push pin in until slot lines up with locking bracket control arm and shock absorber bracket; bolt hole in bracket. Install locking bolt, washer and install and alternately torque "U" bolt retaining nuts nut. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 165 (Refer to Figure 18). Install locking bolt and secure with washer and nut. Lower vehicle to floor and remove jack. Install lu­ brication fitting in retainer pin and lubricate bushing. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 166 5. Disassemble and remove bushing installation tools. . Lower vehicle to align spring eye and hanger. F ig . 2 4 - G - K 1 0 and G - K 2 0 Installing Spring Eye Bushing CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 167 Make b. Spring shackle retaining nuts sure spring is in position at rear shackle and at front 155 ft. lbs. hanger, then install bolts. " U " CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 168 3. Install "U" bolt spacer over center bolt on top leaf of F ig . 2 7 - 4 0 , 5 0 , and 60 Spring Removal (Typ ica l) CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 169 Each spring is mounted at its center on a saddle sup­ in spring rear hangers. ported on the end of a cross tube which passes through TORQUE ROD BRACKETS TOP PLATES SPRING SADDLE x' c; SADDLE EQUALIZING BEAMS F ig . 28 - Tandem Rear Suspension CHEVROLET TRUCK SERVICE MANUAL...
  • Page 170 T-699 Fig . 30 - Beam to A x le Mounting Bolt A x le Bracket N ut Equalizer Beam End Bushing 7. Washer F ig . 32 - Torque Rod Stud 4 . Adapter CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 171 Tool J-8459 (See Figure 33). 5. Replace rebound clip bolts or center bolt if damaged 33 - Fig . Removing and Installing Spring Eye Bushing in any way. with Tool J-8459 CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 172 Tighten top pad set screws to 140 ft. lbs. free movement. torque, then tighten set screw lock nuts. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 173 A D A P T E R of opposite beam. . Position vehicle so suspension supports weight and tighten all nuts to specifications. F ig . 35 - Adapter and Retaining Bolt at A x le Bracket CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 174 500 miles of driving. 5. Position torque rod and frame bracket in a vise and remove stud nut, then press stud from frame bracket in an arbor press. DRIVE LINE REAR AXLE (CHEVROLET) SINGLE SPEED INDEX Page Page General Description ............

  • Page 175: General Description

    One of the cardinal points of axle noise diagnosis is the fact that all rear axles are noisy to a certain degree. The gaskets involved as described in this section. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 176 16. Side G e a r 22. Pinion Rear 5. Pinion Bearing Spacer 11. " C " Lock 17. Bearing Cap Bearing D ifferential C arrier 12. Pinion Shaft Lock Bolt 18. A x le Shaft Drive Pinion CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 177 9. Ring G e a r 13. D ifferential Case - Left H alf 4. O il Seal 10. Differential Spider 14. A x le Shaft Differential Case - Right H alf 5. Front Pinion Bearing CHEVROLET TRUCK SERVICE MANUAL...
  • Page 178 3. O il Seal Packing 9. Ring G e a r 18. D ifferential Case - Right H alf 10. D ifferential Spider 14. A x le Shaft 4. O il Seal 5. Front Pinion Bearing CHEVROLET TRUCK SERVICE MANUAL...
  • Page 179 D ifferential Side G e a r 4. Shims 9. Ring G e a r D ifferential Case (Left H alf) 17. Adjusting Nut Lock Pinion Bearing Assembly 10. D ifferential Spider A x le Shaft 18. Differential Case (Right H alf) CHEVROLET TRUCK SERVICE MANUAL...

  • Page 180: Axle Assembly

    Install and torque bearing cap retaining nuts to . Disconnect axle vent hose from vent connector and specifications. CHEVROLET TRUCK SERVICE M ANUAL...

  • Page 181: Axle Vent Replacement

    NOTE: On those models equipped with an oil deflector, make sure that deflector and gasket 2. Install axle shaft "C" lock on button end of axle shaft CHEVROLET TRUCK SERVICE MANUAL...

  • Page 182: Pinion Flange, Dust Deflector And/Or Oil Seal R Ep Lacem En T

    9. If deflector requires replacement, remove by tapping from flange, clean up stake points; install new de­ flector, and stake deflector at three new equally spaced positions. F ig . 4 4 - W heel Bearing Removal CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 183 P ress seal into bore until it seats against gear and pinion. internal shoulder. F ig . 47 - D rive Pinion N ut Removal F ig . 4 9 - Drive Pinion Flange O il Seal Installation (Light-D uty) CHEVROLET TRUCK SERVICE M ANUAL...

  • Page 184: Positraction Differential Unit

    Service procedures for the Positraction equipped axle 4. Disconnect hydraulic brake hose at connector on rear are the same as on a conventional axle except for the ”oji axle housing. (If vehicle is equipped with air brakes, CHEVROLET TRUCK SERVICE M ANUAL...

  • Page 185: Installation

    F ig . 5 6 - Removing A x le Shaft (1 1 ,0 0 0 , 13,500 and 15,000 Lb. A x le ) CHEVROLET TRUCK SERVICE M ANUAL...

  • Page 186: 17,000 Lb. Axle

    25. A x le Shaft-to-Hub Retaining Bolt 5 . Hub O uter Bearing Retainer 11. Hub Inner Bearing 15. Adjusting N u t Lock 20. O il Seal N ut 6. W h eel Bolt Assembly 16. G asket CHEVROLET TRUCK SERVICE MANUAL...

  • Page 187: Hub And Drum

    4. Use appropriate tool as specified in Step 2 to remove 3. Scrape old sealing compound out of oil seal bore in adjusting nut from housing tube. the hub. CHEVROLET TRUCK SERVICE M ANUAL...

  • Page 188: Inspection

    (fig. 62). Then 7200 lb. axles. remove retaining ring from hub—using pliers for re ­ b. J-8093 (Use with J-8092 driver handle)--11,000 moval of ring on 5200 and 7200 lb. axle (fig. 62), CHEVROLET TRUCK SERVICE MANUAL...

  • Page 189: Demountable-Type

    Drum Replacement Dem ountable-Type (Fig. 58) The demountable-type drum may be separated from the hub and removed from the vehicle without disturbing the F ig . 63 - Removing Wheel Hub O uter Bearing Retaining Ring CHEVROLET TRUCK SERVICE M ANUAL...

  • Page 190: Non-Demountable T Y P E

    REAR SUSPENSION AND DRIVE LINE 4-32 Fig. 66 - Removing Hub O u ter Bearing (15,000 17,000 Lb. Axles) Hub Stud Replacement Hub studs can be removed and replaced by using a con­ ventional stud remover and replacer. Make sure that studs are firmly bottomed in holes and that threads are not damaged during installation.

  • Page 191: Wheel Hub Oil Seal Replacement

    15.000 lb. two-speed axle 17.000 lb. single-speed axle (fig. 70) 17.000 lb. two-speed axle Seal should be installed flush with end of F ig . 6 9 - Installing Wheel Hub O il Seal hub. CHEVROLET TRUCK SERVICE M ANUAL...

  • Page 192: Installation

    The optionally available No-Spin differential unit is in­ stalled in a conventional 5200 or 7200 lb. rear axle hous­ ing. Service procedures are the same as conventional F ig . 71 - Tightening W heel Hub Bearing Adjusting Nut (Typ ical) CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 193 Vacuum Cylinder Oil Seal Replacement ..... 4-42 GENERAL DESCRIPTION The Chevrolet two-speed axle (fig. 73) is optionally vere service. A distinctive feature is that only the available in both the 15,000 and 17,000 lb. capacity. In straddle mounted drive pinion and the ring gears operate...
  • Page 194 24. D ifferential Side G e a r (Left) 33. Ring G e a r 25. M agnetic C hip C o lle c to r 9. D ifferential C arrier 17. Adjusting N u t Lock (Right) 34. Pinion and Bearing Retainer CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 195 Service operations in this section are restricted to the two-speed and single-speed axles, refer to applicable those operations pertaining to items peculiar to the two- procedure as outlined in "R ear Axle (Chevrolet) Single- speed axle only. For those operations common to both Speed."...
  • Page 196 (fig. 78). This winds the torsion spring for a shift to low range which is accomplished in the same manner as the gether, leaving the original tension in the spring. This shift to high range. preload tension holds the axle in either range. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 197 10,000 miles or 3 months, spring clamp to prevent axle lubricant from leaking whichever occurs first. into shift unit. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 198 Replace actuating lever, torsion spring and spring winding lever as an assembly. F ig . 7 9 - Shift Unit Removed from C a rrie r F ig . 81 - Removing Sh aft, Actuating Lever and Spring CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 199 At­ tach cover securely with screws and lock washers. F ig . 82 - Removing D rive Screw Bearing F ig . 83 - Removir^ Motor W iring Lock Nuts CHEVROLET TRUCK SERVICE MANUAL...
  • Page 200 12. Replace the hose connections and install clamps. nut from the push rod, remove the diaphragm plates 13. Test the operation of the shifting mechanism in all and diaphragm. speeds. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 201 2 -1 /4 ". Torque retaining screws to 40 in. lbs. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 202 DRIVE PINION AND CAGE two tapered roller bearings. Shims between the pinion cage and carrier provide a Both axles are equipped with a straddle mounted drive means for adjusting pinion depth in the ca rrie r to attain CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 203 27. A x le Shaft - L.H . 5. Adjust ng Shims 11. D rive Pinion 22. Ring G e a r Bolt 6. Bearing Cup - O u te r 12. D ifferen tial C arrier 17. Side G e a r CHEVROLET TRUCK SERVICE MANUAL...
  • Page 204 Installation Removal, Service and Installation 1. Install the wheels, then roll the axle assembly into See 17,000 lb. Chevrolet Single Speed "Hub and Drum." DRIVE LINE REAR AXLE (EATON) TWO-SPEED INDEX Page General Description ............
  • Page 205 Both models are equipped with a spiral bevel ring gear 17201 and 17221 Model axles are the same as those out­ lined in 17,000 lb. Chevrolet Single-Speed. and pinion. The two axles are sim ilar in construction, the only difference being the drive gear diameter is An improved lubrication system (fig.
  • Page 206 4. Remove the two trunnion bearing "U" bolts from the Axle Shaft—Removal and Installation pinion flange and split the rear universal joint. Swing See 17,000 lb. Chevrolet Single Speed Axle Shaft Re­ the propeller shaft to one side and tie it to the frame moval and Replacement.
  • Page 207 REAR SUSPENSION AND DRIVE LINE 4-49 F ig . 91 - Tandem Rear Axles and Power D ivid er CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 208 REAR SUSPENSION AND DRIVE LINE 4-50 GENERAL DESCRIPTION The tandem rear axle installation (fig. 91) consists of a allow differential action between the two axles. When rearward rear axle (Eaton Model 30R) and a forward rear extra traction is required to move the vehicle, the inter­ axle (Eaton Model 30D) which carries a single speed axle differential can be locked out so equal power can be power divider with an inter-axle differential.
  • Page 209 7. Snap Ring snap ring which secures the cylinder in the bracket, 8. Dowel 17. Lock-Out Shift and remove the assembly from the bracket. Remove 9. C y lin d e r (Inner H alf) Lever CHEVROLET TRUCK SERVICE MANUAL...
  • Page 210 12. To Shift C ylin d er Body 13. Plunger Spring F ig . 9 6 - D iffe re n tial Lock Control Lever and Plate (Typ ical) 14. Plunger 7 . V a lv e Disc CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 211 "U" clamps. Remove nuts and lockwash­ Single or Rear ers attaching bearing support to frame cross member and pull shaft assembly from vehicle. Remove rear trunnion "U" clamps, lower the rear of CHEVROLET TRUCK SERVICE MANUAL...
  • Page 212 Lower shaft and bearing support assembly from vehicle. front of the shaft and pull forward to disengage splines at rear of shaft. Remove shaft and bearing support assem­ bly from under vehicle. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 213 (3) Install retaining nut and tighten to 160-180 ft. lbs. torque. Install cotter pin. NOTE 1: Before installing a rear propeller CHEVROLET TRUCK SERVICE MANUAL...
  • Page 214 In some special types of operation, purchasers of yoke of the universal joint with the shoulder or chamfer Chevrolet trucks may desire to use tires of a different on the gear away from the universal joint. SPECIAL TOOLS F ig.
  • Page 215 14. J — 5810 Torque W rench Adapter (3/4" to 3 / 8 ") In sta ller— H eavy D u ty—Used w ith 15. J-1313 Torque W re n ch —ft. lbs. J -7079-2 CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 216 W heel Bearing N u t W rench J-22380 Tru-Arc Pliers Tools not Illustrated: 10. J-22359 W heel Bearing In staller J — 2619 Slid e Hammer w ith Adapter J-2230 W heel Bearing Remover CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 217 (Fig. 5). The “ F ” has two identical brake shoes mounted adjusting duo-servo brakes front and rear, ex­ on the backing plate so that their toes are diagonally cept those with 15,000 lb. single or two speed CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 218 BRAKES 5-2 PA 20-30 PA 40 CA-SA 40, CD-CG-MA 50, CD-CG 60 TA 40-50-60 EXTENSION SIDE RAIL-LEFT SIDE INBOARD FORWARD GA 10-20 CE-CS-SA 50-60 Fig . 1—M ain C ylin d e rs—A ll Models CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 219 11. Brake Shoe Anchors 6. G u id e Bolt 5. Brake Shoe Return Spring 7. G u id e Bolt N u t Lock W ire 13. Backing Plate 6. Brake Shoe Hold Down Bolt CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 220 WHEEL CYLINDERS and Wagner, “ F ” and “ FR -3” type brakes, two cylinders Four types of wheel cylinders are used on Chevrolet are used at each brake, mounted on the flange plate be­ Trucks. Wheel cylinders are identified with type of brake tween shoe ends as shown in Figures 3, and 4, and 5.
  • Page 221 2. Move wrench slightly in opposite direction until REAR SHOE ADJUSTING WHEEL Fig . 9—Adjusting Type “ F ” Front Brakes Fig . 10—Adjusting Type “ F R -3 ” Rear Brakes CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 222 Do not bleed enough fluid at one time to drain the reservoir completely. Replenish the reservoirs Fig . 12—Brake Bleeder Tool J-7 6 4 7 Fig. 11—Brake Bleeder Adapter Tool J-2 2 4 8 9 Installed CHEVROLET TRUCK SERVICE MANUAL...
  • Page 223 J-0628 over end bleeding valve (fig. 14). 5. Place other end of tube in transparent container holding sufficient fluid to cover end of tube. Fig . 14—Bleeding W heel C ylin d e r CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 224 Close bleeder valve as brake pedal is on down stroke. 5. Replace reservoir cover then readjust all brake shoes. . Apply approximately 75 pounds pressure on the brake pedal and check the pedal clearance from the Fig . 16—Brake Pedal Reserve Measurement CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 225 4. Tighten the check nut securely. 5. Fully release parking brake and rotate the rear wheels. No drag should be present. Fig . 18—Brake Pedal Free Movement CHEVROLET TRUCK SERVICE MANUAL...
  • Page 226 If necessary adjust front cable clevis-to-equalizer connection to eliminate drag. 7. Tighten all lock nuts and lower vehicle. Fig. 21—Ch evy V an Parking Brake Idler Linkage—Exploded V ie w CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 227 "ov er-cen ter” position required to lock loose connections, etc. the parking brake in the applied position. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 228 BRAKES 5-12 TD 50-60 Fig . 23—Parking Brake C ables—T Models CHEVROLET TRUCK SERVICE MANUAL...
  • Page 229 When servicing the Delco Moraine dual master cylin­ cles. When service procedures for CE-CS- der, follow the rules below when replacing either com­ SA50-60 series models are required, refer to plete master cylinder or the component pistons of the CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 230 5. V a lv e 11. Ring 17. V a lv e Seat 23. C h eck V a lv e 12. Retainer 6. Spring 18. V a lv e 24. C heck V a lv e Seat CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 231 The lips of mary piston spring to the primary piston. Remove this seal should face toward the small compensating the spring retainer, primary seal, primary seal holes in the opposite end of the primary piston. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 232 Use soap and water to stalled on PA-TA40, and TA50-60 models have clean hands. two pistons in the body casting, side by side. 2. Inspect cylinder bores to make sure they are smooth. One piston provides regular braking action and CHEVROLET TRUCK SERVICE MANUAL...
  • Page 233 This clearance should be .035 Fig . 30—M ain C y lin d e r—Cross Section Fig . 29—Checking M ain C ylin d e r Piston Fit CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 234 Since boots are recessed in grooves on wheel cylinders to prevent pistons from leaving cylinders, it is not necessary to install wheel F ig . 31—S e lf Adjusting Brake cylinder clamps when brake shoes are removed; CHEVROLET TRUCK SERVICE M ANUAL M sy...
  • Page 235 Clean all rust and dirt from shoe contact faces on flange plate, using fine emery cloth. Installation CAUTION: Make certain to install recom­ mended shoe and lining assemblies. Otherwise, series fade or permanent failure may occur. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 236 Do not hook the wire link over the anchor pin stud with the regular spring hook tool. This may damage the cylinder boot seals. Fig . 36—Inspecting for Proper Lubrication Fasten'the wire link to the actuator assembly CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 237 1. With brake drum off, disengage the actuator from the star wheel and rotate the star wheel by spinning or Fig. 40—Checking Brake Shoe Lining C learan ce turning with a small screwdriver. Using Tool J-21177 CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 238 STAR WHEEL Removal 1. Raise the vehicle and place on jack stands. Fig . 42 —Tw inplex S e lf Adjusting Rear Brake (40 and 50 Series) 2. Retract self adjusters and remove brake drums. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 239 9. Clean all dirt out of brake drum. Inspect drums for roughness, scoring or out of round. Replace or re ­ condition drums as necessary. NOTE: If, when reconditioning drums, an un- Fig . 45 —Brake Shoe and S e lf Adjuster Assembly CHEVROLET TRUCK SERVICE MANUAL...
  • Page 240 11. Secure the adjusting cam cap screw and retract the adjusting screw. 12. Install brake drums and wheels. 13. Adjust the brakes by making several forward and reverse stops until a satisfactory brake pedal height results. Fig . 4 7 —Positioning Actuator Lever CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 241 60 Series—Front (Wagner Type “ F” ) Removal (Figs. 49 and 50) 1. Jack up axle and remove hub and brake drum assembly. Fig. 50—W agner Type “ F ” Left Front Brake CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 242 Install new seals if necessary. Section 3. . Clean all dirt out of anchor pin holes and adjusting Adjust brakes as previously directed under Brake screw openings in anchor supports. Adjustments under Maintenance and Adjustments. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 243 1967 Conventional lining replacement equipment should be Chevrolet Trucks 50 as well as 60 Series have premium used. Make sure lining fits firmly against shoe, and that type facings. rivets are properly upset.
  • Page 244 Repair kits are available which contain the parts to be replaced when overhauling wheel cylinders. 1. Inspect cylinder bore for scores, scratches, or 5 3 —Duo Servo and Tw inplex C ylinders Fig. corrosion. Light scratches or slightly corroded CHEVROLET TRUCK SERVICE MANUAL...
  • Page 245 Tighten inlet connector and special bolt firmly. Fig . 55—C hecking Wheel C ylin d e r Piston Fit CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 246 2. Attach connecting tube fitting to lower opening in the drum. Chevrolet brake facing is not furnished larger than upper cylinder, and to the upper opening in the lower .030" oversize and this will not work efficiently in drums cylinder.
  • Page 247 VIEW A VIEW B CE-CS50-60 SA50-60 CA-KA-MAOO, PA10-40, SAOO VIEW A MAIN CYLINDER MAIN BRAKE TA40-50-60 CYLINDER PA20-30 Fig . 5 6 —Brake Pedal C , K , P, M , S and T Models CHEVROLET TRUCK SERVICE MANUAL — __________________...
  • Page 248 . Remove two screws from pivot sleeve and bracket rear of manual for correct torque value. assembly, and remove assembly from channel. 4. Connect clutch pedal over-center spring and brake 7. Withdraw lower pedal arm from channel. pedal return spring. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 249 Adjustment Removal 1. Place parking brake handle in released position. 1. Loosen check nut on the eccentric bolt attachment F ig . 58 —Parking Brake Levers—C , K , P10— 20— 30 Models CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 250 Connect return spring to outer shoe. bolts attaching center bearing bracket to cro ss­ 4. Adjust lining drum clearance as previously member, then lower center bearing and front directed under Parking Brake Adjustment. propeller shaft to floor (if necessary). CHEVROLET TRUCK SERVICE MANUAL...
  • Page 251 Tighten nuts to 5. P ress four serrated bolts from flange and drum 5-8 foot-pounds torque. assembly to separate drum from flange. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 252 Tighten bolt to 68-73 ft. lbs. torque. output shaft. 4. Place lock washer and special serrated flat washer 5. Connect propeller shaft at transmission and attach on flange retaining bolt and install bolt in output center bearing bracket to frame crossmember. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 253 1. Wipe clean mating surfaces of brake drum and output 1. Place band and lining assembly over brake drum. shaft flange. Line up brake drum and flange and Place anchor screw spring in depression in anchor CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 254 3. Turn hose fitting out of wheel cylinder inlet or junction block. Installation 1. If hose is to be installed in wheel cylinder, Fig . 66—Brake Tube Support CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 255 ASSEMBLY (Fig. 8) Removal 1. Disconnect battery cable. 2. Disconnect electrical lead from pressure differential switch. Fig. 70—Flaring O peration—First Flare Fig . 68—Single and Double Lap Flare CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 256 18. Mounting Stud 12. Poppet V a lv e Spring 5. Diaphragm Plate 25. Adjusting Screw 19. A ir V a lv e Lock Plate 13. Poppet Retainer 6. Rear Shell 7. Diaphragm Spring 14. Retainer CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 257 1. Check vacuum line and vacuum line connections as draulic leaks. well as vacuum check valve in front shell of power 3. Check brake assemblies for scored drums, grease or unit for possible vacuum loss. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 258 The reservoir should be filled to 1/4 inch of filler cap opening. 7. Check operation of the brakes as outlined in this section. Fig . 73—Power C ylin d e r Bracket and Spacer CHEVROLET TRUCK SERVICE MANUAL...
  • Page 259 11. Slide valve body off end of push rod (11). 12. Remove washer (24), spring (23), and snap ring (25). 7. Slide bushing (15), retainer (17), and washer (18) halfway down push rod. 13. Remove and discard valve insert (21). CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 260 3. Bleed all wheel cylinders until free of air bubbles. until greatest pedal height is obtained—maintain foot IMPORTANT: Do not apply brakes while en­ pedal pressure. gine is running or booster unit may be damaged. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 261 Inspect wheel cylinders. master cylinder for defects and repair. For flushing CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 262 Remove compressor discharge valve cap nuts and service the compressor air strainer. Remove and wash check for presence of excessive carbon deposits. Also, all parts. Strainer element should be cleaned or replaced. Fig . 78—A ir Brake System CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 263 Disassemble brake valve and clean all parts. Install the body around the key. Leakage of more than a one inch new inlet valves and piston seal. soap bubble in one second is not permissible. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 264 . Clean or replace any damage or dirty air or water following information should prove to be helpful. lines which may be corroded, before connecting them CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 265 2. Inspect all moving parts for wear or damage and R IN G bores for out of round condition. 3. Inspect diaphragm and bonded rubber valve for wear or deterioration. Fig . 80—A ir Brake Chamber (Clamp Ring Type) CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 266 1. After cleaning the exterior of the brake chamber, mark it in such a way that it can be assembled the same way. If the brake chamber is to be dismantled Fig . 8 2 —Governor CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 267 3. Adjusting Screw Lock N ut 8. Adjusting Screw 13. Grommet Spring 4. Upper Spring Seat 9. Exhaust Stem 14. Piston 18. Body 5. Pressure Setting Spring 10. Exhaust Stem Spring 15. Grommet 19. Filters CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 268 8. Seal 13. Seal 18. Boot 4. Ring 9. V a lv e 14. Piston Assembly 19. Bolt 5. Exhaust V a lv e Body 10. V a lv e Body 15. Snap Ring 20. Lockwasher CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 269 B O D Y S P R IN G C O V E R Fig. 86—Q u ic k Release V a lv e Installed Fig . 87—Q u ick Release V a lv e Components CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 270 P ress worm shaft into worm and body, making sure the groove in lock sleeve is aligned with Fig. 88—Lapping Exhaust Port Seat pin in body. P ress shaft in until distance from small CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 271 2. Roller 7. Flange Plate 3. Brake Shoe Facing 8. Shoe Return Spring 4. Brake Shoe 9. Roller Pin Fig . 90—Removing Camshaft (Front shown as T yp ica l) 5. Anchor Pin Lock Ring CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 272 11. Slack Adjuster Shaft) 5. Flange Plate 9. Camshaft and Brake 12. Lock Ring 2. Spacing Washers 6. Camshaft Bracket Chamber Bracket 13. S lack Adjusting 3. Seal 7. Seal Retainer 10. Spacer N ut CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 273 The brake shoe-to-drum freeplay adjustment of air 3. Remove mounting bracket nuts and bolts and remove brakes is accomplished by means of the slack adjuster reservoir. which is incorporated in the camshaft lever. Fig . 93—Front Wheel Brake Layout (Except Mounting) CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 274 A N D E N G A G E HEAD OF W O R M PORT OF SHAFT TO LOCK ADJUSTM ENT RESERVOIR Fig . 94—S lack Adjuster Nut Lock Sleeve Fig . 95—Safety V a lv e CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 275 Assembly SPRING 1. Position valve stop bushing, spring and disc valve in SPRING CAP body. DIAPHRAGM LOWER BODY Fig . 96-*-Single Check V a lve Fig . 97—Pressure Protection V a lv e —Cross Section CHEVROLET TRUCK SERVICE MANUAL...
  • Page 276 H A N D CONTROL VALVE DOUBLE CHECK VALVE A N D STOPLIGHT SWITCH TRAILER CO NNECTORS BREAKAWAY TO SERVICE VALVE BRAKE TO SERVICE TANK Fig . 98—T ra ile r Equipment C ircu its CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 277 11. Piston Return Spring 17. Cam Housing 23. Name Plate 5. Seal 12. Piston Cup 18. Adjusting Bearing 24. Lock Washer 6. N ut 13. Piston 19. C o lla r 25. Screw 7. V a lv e Disc CHEVROLET TRUCK SERVICE MANUAL...
  • Page 278 Place valve guide and shuttle valve in body. Position cover on body, using new gasket. Install cover cap screws and lock washers, and tighten evenly and firmly. Fig. 100—Double Check V a lv e CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 279 14. J-22489 Brake Bleeder Adapter 5. J-8049 Brake Spring Tool 11. J-21524 Power Piston Remover and 15. J-22657 Bushing Retainer 6. J-0628 (J-628 ) Brake Bleeding Tube 7. J-7647 Brake Bleeding W rench Installer Socket CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 281 Remove any foreign matter from around spark plugs fully. It is essential that improper compression be cor­ by blowing out with compressed air, then disconnect wires and remove plugs. rected before proceeding with the engine tune up. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 282 2. Clean serviceable spark plugs thoroughly, using an 1. Remove distributor cap, clean cap and inspect for abrasive-type cleaner such as sand blast. File the cracks, carbon tracks and burned or corroded ter­ center electrode flat. minals. Replace cap where necessary. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 283 (cam follower between lobes) and the read­ metals and should not be allowed to become greasy ing taken just as the points separate. If not within or dirty. Never use emery cloth or sandpaper to lim its, replace. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 284 If the battery has remained undercharged, check for loose or defective fan belt, defective Delcotron, Fig. 7—C hecking Belt Tension CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 285 A.I.R. System. Choke Adjustment 1. Remove air cleaner. F ig . 8—M anifold Heat Control V a lv e (In Line) CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 286 If dwell variation exceeds specifications, check for worn distributor shaft, worn distributor shaft bushing or loose ADJUSTING breaker plate. SCREW Check and Adjust Ignition Timing (Fig. 12) 1. Disconnect the distributor spark advance hose and plug the vacuum source opening. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 287 3 turns. “ A ” IDLE SP EE D S C R E W IDLE M IXTURE S C R E W F ig . 13—Idle Speed and M ixture Screws CHEVROLET TRUCK SERVICE MANUAL...
  • Page 288 (resistance wire side) and ground. 3. Operate starting motor. a. If voltage is 9 volts or more and cranking speed satisfactory, the battery, starter, cables, F ig . 14—Crankcase V en tilatio n V a lve CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 289 Use equipment as directed by manufacturer. a rubber mallet. • Uniform "normal readings" as specified by manu­ CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 290 (fig. 18). arm covers with degreaser then install rocker arm covers, using new gaskets, and torque bolts to 4. Turn nut down 1/4 additional turn and pause 10 specifications. seconds until engine runs smoothly. Repeat ad- CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 291 • Remove the radiator, radiator support and shroud radiator attached) as outlined in Section 11. as outlined in Section 13. • Disconnect shfft linkage at control island. ON GS 10-20 SERIES: • Remove engine splash shields. • Disconnect choke cable at carburetor. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 292 ON GS 10-20 SERIES: mounting bolt is removed and as it is being • Remove the flywheel housing bolt retaining starter pulled away from the engine, to prevent damage wire harness clip and engine ground strap. to clutch disc. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 293 5. Install fan and pulley as outlined in Section d. Install clutch housing rear cover bolts and . Connect: torque to specifications. • Exhaust pipe at manifold. • Install automatic transmission (if so equipped). • Power steering lines at pump (as required). CHEVROLET TRUCK SERVICE MANUAL...

  • Page 294: Removal

    Place rocker arms, rocker arm balls . Remove manifold attaching bolts and clamps then re ­ and push rods in a rack so they may be re ­ move manifold assembly and discard gaskets. installed in the same location. CHEVROLET TRUCK SERVICE M ANUAL...

  • Page 295: Installation And Adjustment

    5. Remove valve lifters. NOTE: Place valve lifters in a rack so they may be reinstalled in the same location. Installation 1. Install valve lifters. NOTE: Whenever new valve lifters are being Fig. 2L—V a lv e Adjustment CHEVROLET TRUCK SERVICE M ANUAL...

  • Page 296: Valve Stem Oil Seal And/Or Valve Spring

    5. Install coil (if removed). . Connect upper radiator hose and engine ground strap. 7. Connect temperature sending unit wires and install fuel and vacuum lines in clip at water outlet. Fig . 3L—A ir Adapter Tool CHEVROLET TRUCK SERVICE MANUAL...

  • Page 297: Oil Pan

    J-69 7 8 -1 and raise the engine enough to clear the front mounts (fig. 5L). Fig . 5 L—Supporting the Engine ( G .S . 100-200) Fig . 6L—O il Pan G asket and Seal Location CHEVROLET TRUCK SERVICE M ANUAL...

  • Page 298: Oil Pump

    Be sure tabs on seal are properly located in cross grooves. 4. To remove the upper half of the seal, use a small Fig . 7 L—Removing O il Seal (Lower H alf) CHEVROLET TRUCK SERVICE M ANUAL...

  • Page 299: Installation

    PULL ON TYPE (With retaining bolt) a. Use a 7/16"-20 x 4" bolt, nut and washer to pull torsional damper onto crankshaft. F ig . 9 L —Removing Torsional Damper Fig . 11L—J — 21742 Centering Tool in Cover CHEVROLET TRUCK SERVICE M ANUAL...

  • Page 300: Removal

    Measuring Lobe Lift NOTE: Procedure is sim ilar to that used for checking valve timing. If improper valve opera­ tion is indicated, measure the lift of each push Fig. — Installing O il Seal (C over Installed) CHEVROLET TRUCK SERVICE M ANUAL...

  • Page 301: Removal

    Support camshaft carefully when r e ­ moving so as not to damage camshaft bearings. Installation 1. Install the camshaft and gear assembly in the engine Fig . 16 L —Checking Camshaft G e ar Runout CHEVROLET TRUCK SERVICE MANUAL...

  • Page 302: Timing Gears

    (fig. 20L). CONVERTER l ^ R I N G BOLT AREA GEAR DEPRESSED WELDS ^ENGINE TRANS. SYNCHROMESH AUTOMATIC Fig . 20L—Flyw heel Installation (T y p ica l) F ig . 18L—Removing Crankshaft G ear CHEVROLET TRUCK SERVICE MANUAL...
  • Page 303 1 0 - 2 0 S e r i e s 9. Lower the vehicle and remove the cardboard from between the fan and radiator. The two piece rear support in transmission case ex­ tension may be removed without removing the transm is­ CHEVROLET TRUCK SERVICE MANUAL...
  • Page 304 SE 50-60 SERIES: • Disconnect choke cable at carburetor. • Remove the front end sheet metal (with hood and • Disconnect emergency brake cable at emergency radiator attached) as outlined in Section 11. brake and retaining brackets. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 305 ON CE 10-20-30 SERIES, GE 10-20 SERIES: NOTE: Place the cradle so the forward legs of • Remove synchromesh transmission and clutch (if the cradle straddle the fifth pan bolt from the so equipped). CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 306 • Oil Pressure Switch ON ALL SERIES EXCEPT CE 10-20-30, • Temperature Switch GE 10-20: • Delcotron • Install clutch assembly and clutch housing as out­ • Starter Solenoid lined in Section 7. . Complete installation as follows: CHEVROLET TRUCK SERVICE MANUAL...
  • Page 307 Adjust belt as outlined in Engine Tune Up. Installation . On vehicles so equipped, install carburetor heater. 1. Clean gasket and seal surfaces on manifold, block, 7. Start engine and check for leaks. and cylinder heads. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 308 ­ push rod then turn in adjusting nut until all lash installed in the same locations. is removed. This can be determined by checking CHEVROLET TRUCK SERVICE M ANUAL...

  • Page 309: Replacement (Rear)

    In this manner, equivalent. This will make the tool universal for the sound is localized making it easy to determine which all Chevrolet engines. Chisel the spark plug as shown, then drive the poreclain out of the plug lifter is at fault.
  • Page 310 5. Remove cylinder head bolts, cylinder head and gas­ ket. Place cylinder head on two blocks of wood to . Install oil dipstick tube and dipstick. prevent damage. 7. F ill with oil, start engine and check for leaks. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 311 NOTE: Always replace the upper and lower seal as a unit. Install with the lip facing toward the front of the engine. F ig . 8 V —Removing O il Seal (Upper H alf) CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 312 366 cu. in. ENGINE a. Place damper in position over key on crankshaft. Fig . 9 V —Removing Torsional Damper F ig . 11V —Installing Torsional Damper (366) CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 313 3. Install cover screws and torque to specifications. Then remove Aligning Tool J-22102. 4. Install water pump as outlined in Section 5. Install torsional damper as outlined. . Install oil pan as outlined. Fig . 14V—Installing O il Seal (C over Removed) 366 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 314 (fig. 20V). NOTE: Do not attempt to drive sprocket on camshaft as welsh plug at rear of engine can be dislodged. Fig . 18V—Removing Crankshaft Sprocket Fig . 16V—Installing O il Seal (C over Installed) 366 CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 315 At this point, the push rod will be in its lowest position. 4. Set dial indicator on zero, then rotate the balancer Fig . 20V —Instal ling Timing Chain Fig . 2 2V —Removing Camshaft CHEVROLET TRUCK SERVICE MANUAL...
  • Page 316 . Install fuel pump push rod as outlined in Section 7. Install grille as outlined in Section 13. . Install crankcase front cover as outlined. F ig . 24V —C heckin g Camshaft G e ar Runout CHEVROLET TRUCK SERVICE MANUAL...
  • Page 317 Overhaul Manual. mounting bracket. 3. Raise front of engine and remove mount-to-engine bolts and remove mount. Fig . 28V —Flyw heel Installation (T y p ic a l) Fig . 26V —Removing Crankshaft G ear CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 318 ENGINE 6-38 Fig. 29V—Engine Mounts CAUTION: Raise engine only enough for suf­ GE 10-20 Series ficient clearance. Check for interference be­ The two piece rear support in transmission case ex­ tween rear of engine and cowl panel. tension may be removed without removing the transm is­ sion from the vehicle.
  • Page 319 ENGINE 6-39 CYLINDER HEAD TORQUE SEQUENCE V8-396 & 427 V8-283-327 & 350 INTAKE MANIFOLD TORQUE SEQUENCE FRONT FRONT V8-283 & 327 V 8 -3 9 6 & 4 2 7 F ig . I T —Torque Sequence...
  • Page 320 (11/32") V a lv e G u id e Reamer Set 13. J-5830 Crankcase C over Seal In staller 35. J-8340 J-7049 (3/8") Crankcase C o ver Seal In staller 36. J-5595 14. J-8089 Carbon Removing Brush CHEVROLET TRUCK SERVICE MANUAL...
  • Page 321 Upon repeated coolant loss, the pressure radiator cap several times. At the same time note any appreci­ and seat should be checked for sealing ability. Also, the able water rise or the appearance of bubbles which CHEVROLET TRUCK SERVICE MANUAL...
  • Page 322 . If thermostat checks satisfactorily, re-install, using 1. Remove the upper and lower radiator hoses and re ­ place the radiator cap. a new housing gasket. 2. Attach a lead-away hose at the top of the radiator. 9. Refill cooling system. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 323 Remove stud after starting the remaining three bolts. 3. Connect hoses and fill cooling system, rig . 2 —Replacing Thermostat- 4. Install fan belt and adjust as previously outlined. 5. Start engine and check for leaks. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 325 Specifications for carburetors are located in the back changed with or replaced by a carburetor designed for an of this manual. engine without the Air Injection Reactor System. IDLE IDLE SPEED M IXTURE CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 326 . Repeat Steps 4 and 5 as needed for final adjustment. Choke Adjustment NOTE: If necessary, final adjustment of the 1. Remove air cleaner. carburetor may be made with the air cleaner 2. Push hand choke knob in to within 1/8" of instrument installed. panel. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 327 Operate the throttle several times and check the discharge from the pump jets before in­ stalling the carburetor. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 328 Adjustment of the spring pull is accomplished by changing the number of spring coils operating by turning the ad­ justment cap. Fig . 1G - Diagrammatic V ie w of Governor for 6 -C y lin d e r Engine CHEVROLET TRUCK SERVICE MANUAL...
  • Page 329 Thus when the throttle lever is moved to wide open position, the position of the throttle Fig . 3 G - Distributor and Governor Mounting CHEVROLET TRUCK SERVICE MANUAL...
  • Page 330 4. Remove the diaphragm assembly from the housing carburetor operation. and inspect for cracks or holes. If the diaphragm is CHEVROLET TRUCK SERVICE MANUAL...
  • Page 331 "plug­ 2. The system "over governs”: governs when it should ging" the valve hole in the shaft either with the not, causes loss of power, etc. This could result if CHEVROLET TRUCK SERVICE MANUAL...
  • Page 332 Three types of air cleaners are used on 1967 Chevrolet Diesel engine applications require the use of several trucks. They are the oil wetted paper element air types of oil bath air cleaners.
  • Page 333 (rpm) reading. Decelerate engine. 7. If the tachometer reading is at or below the follow­ Fig. 3A - O il Bath A ir C leaner CONVENTIONAL CAB Fig . 4A - Carburetor Heat Stove CHEVROLET TRUCK SERVICE MANUAL...
  • Page 334 (without the polyurethane band). Install the polyurethane band around the paper ele­ ment and install the air cleaner element. F ig . 5A - Testing Paper Element F ig . 7A - Cleaning Polyurethane Band CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 335 2. Remove the wing nut and cover. 3. Loosen the jam nut and unscrew the thermostatic element. Fig. 8A - Thermostatic A ir V a lv e P a llet Replacement AIR CLEANERS CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 336 ENGINE FUEL 6M-12 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 337 A leak on the pressure side, therefore, would be made apparent by Always test pump while it is mounted on the engine and be CHEVROLET TRUCK SERVICE MANUAL...
  • Page 338 The pump vacuum section is inoperative if the wind­ when removing cover. shield wiper operated properly on engine vacuum, but not on pump vacuum. . Lift vacuum diaphragm and remove vacuum valve CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 339 14. Remove all valves in fuel and vacuum covers in the 10. Drive new rocker arm pin through bushing and install same manner. F ig . 4P - Removing Vacuum Diaphragm F ig . 5P - Rocker Arm and Link Assembly CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 340 21. Place rocker arm in vise with vacuum flange of pump 22. With one hand push pump down against spring tension so it travels through half a stroke and hold. With the Fig. - Installing Fuel Diaphragm CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 341 This can be done by inserting a 3/32 inch SPECIAL TOOLS J —7825 J —1 1 37 J —5197 J —4552 J-6058A J —6556 J —54961 BENDING TOOLS F ig . IT - Engine Fuel Special Tools CHEVROLET TRUCK SERVICE MANUAL...
  • Page 343 The air injection pump (fig. 2) picks up fresh filtered quirements. However, if any A.I.R. component or any air from the air cleaner, compresses the air and injects Fig . 1—A ir Injectio n Reactor System CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 344 With the pump running, bubbles will form if a leak Replacement exists. • Remove drive belt as outlined above then replace Replacement drive pulley. • Install and adjust drive belt as outlined above. • To replace any hose and/or tube, note routing then CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 345 • Orally blow through the check valve (toward air manifold) then attempt to suck back through check valve. Flow should only be in one direction (toward the air manifold). CHEVROLET TRUCK SERVICE MANUAL...
  • Page 346 Use extreme care to avoid distort­ ing housing. NOTE: Various length pressure setting plugs (fig. ) designed for the particular requirements Fig. 6 —Removing Pressure R e lie f V a lv e of vehicle - engine combinations, determine the CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 347 SILVER-250 RED-292 GREEN-283 Fig. 8— Pressure Setting Plug SPECIAL TOOLS J-7055-5 J-6585 1-21844 J-21058 F ig . 9—Sp ecia l Tools CHEVROLET TRUCK SERVICE MANUAL...
  • Page 349 “ wet charge” type. The difference in types internal voltage drop is decreased resulting in improved depends on the method of manufacture. A “ dry charge” performance, particularly during engine cranking at low Battery contains fully charged elements which have been temperatures. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 350 The split vent is a visual level fill feature designed into the cell cover of Delco Batteries (fig. 4b). The electrolyte surface will appear distorted when it contacts the split vent. F ig . 3b—Vent W ell Construction Showing Seal CHEVROLET TRUCK SERVICE MANUAL...
  • Page 351 Fig . 5b—C u t- A w a y V ie w Showing Electro lyte at Proper Fig . 6b—C u t-A w ay V ie w Showing Electro lyte a t Low Le ve l, with Indicator Having Dark Appearance Lever, with Indicator Having Light Appearance CHEVROLET TRUCK SERVICE MANUAL...
  • Page 352 ''boosted” . In order to bring the Battery and free from corrosion before installing the Battery. to a fully charged condition, the charging cycle must be The carrie r should be in a sound mechanical condition finished by the Slow Charge method. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 353 3. If hydrometer has built-in thermometer, draw liquid replaced. into it several times to insure correct temperature • Note the electrolyte level. Levels that are too before taking reading. low or too high may cause poor performance, as CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 354 • Check polarity to be sure the Battery is not re ­ interpret the results as follows: versed with respect to the generating system. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 355 “ B A T " GRD 7 T ERM IN A L T ER M IN A LIGHT N tL L> RELAY RELAY 6.2" SERIES 2D, TYPE 150 DELCOTRON 5.5" SERIES ID DELCOTRON F ig . l c —Delcotrons CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 356 VOLTAGE ADJUSTMENT JUNCTION BLOCK IN D IC A TO R LAMP f , e ld "F” TERMINAL No. 2 TERMINAL No. 3 TERMINAL TRANSISTOR No. 4 TERMINAL Fig . 3 c—Transistor V oltage Regulator Assembly CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 357 2. When connecting a booster battery, make certain 3. An overcharged battery (usually evidenced by ex­ to connect the correct battery terminals together. cessive battery water usage). CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 358 (see Indicator Lamp Circuit tests) before continuing test. DO NOT TURN THIS NUT UNDER ANY CONDITION ADJUSTING SCREW (Turn To Adjust Voltage Setting) Fig . 6 c —Adjust V oltage Setting CHEVROLET TRUCK SERVICE MANUAL...
  • Page 359 Delcotron. 5. Connect the jumper wire between Delcotron “ F ” and battery terminals. . Connect the battery ground cable at the battery. F ig . 8 c —Ammeter Method Output Test Connections CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 360 “ R” terminal and “ GRD” and note reading, then 4. A shorted positive diode - (may also cause glow reverse the leads and note this reading. Meter Fig . 10c—In itia l Field Excitatio n C irc u it Tests CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 361 " F ” terminals - correct as needed. To check for a faulty relay proceed as follows: b. Fails to glow - Delcotron field has open circuit, 1. Connect a voltmeter into the system at the regulator see "Service Operations” to repair. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 362 BALL FRAME DIODES ASSEMBLY ROTOR ASSEMBLY RESERVOIR BEARING SLIP RINGS GREASE RESERVOIR BALL BEARING CASE HEAT SLIP RING STATOR DIODES SINK END FRAME ASSEMBLY F ig . 14c—130 Amp Series 4D , Type 150 Delcotron CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 363 2. Connect an ammeter in the circuit at the “ BAT” terminal on the generator. 3. Turn all accessories off. 4. Operate generator at approximately 3000 rpm (1500- engine rpm). F ig . 15c—Voltage Tests 2 0 0 0 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 364 5/16" alien wrench into shaft to hold shaft 4. Use the socket and adapter with a torque wrench while removing nut (fig. 17c). and tighten nut to 50 ft. lbs. torque. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 365 7. Attach terminal cover with two screws, making sure leads are not caught underneath the cover. F ig . 2 1 c—Lead Arrangement A fte r Assembly F ig . 19c—Torquing P u lle y Nut CHEVROLET TRUCK SERVICE MANUAL...
  • Page 366 The tim er core has the same number of equally-spaced projections, or vanes as engine cylinders. F ig . l i —M agnetic Pulse Distributor F ig . 2i —Ignition Pulse A m p lifie r U nit CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 367 Never install a condenser of any rating between the coil positive and ground. The use of a condenser at this location for radio suppression can damage the power transistor in the ignition amplifier unit. F ig . 3 i—Adjusting Spinner Governor CHEVROLET TRUCK SERVICE MANUAL...
  • Page 368 (fig. 5i). Use an aligning BREAKER PLATE tool to bend stationary contact support if points need ATTACHING SCREWS alignment. NOTE: F ig . 4 i—Breaker Plate and Attaching Parts The contact point pressure must fall CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 369 . If car has 20,000 to 25,000 miles (or sooner if desired) the cam lubricator wick (fig. 7i) should be changed. Using long nosed pliers squeeze assembly Fig . 7 i—Top V ie w of Distributor CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 370 1750 engine rpm may prove unreliable on some cam angle meters. Eight Cylinder Engine Distributor On the Vehicle With the engine running at idle and operating tempera­ tures normalized, the dwell is adjusted by first raising CHEVROLET TRUCK SERVICE MANUAL...
  • Page 371 Note position of vacuum advance mechanism relative to the engine. CAUTION: Avoid rotating the engine with the distributor removed as the ignition timing will be upset. F ig . 11 i —Adjusting Dw ell Angle CHEVROLET TRUCK SERVICE MANUAL...
  • Page 372 A ttaching Screws 17. M a in Shaft assembly from the housing. Housing Assembly . Remove vacuum advance mechanism retaining 18. Roll Pin screws, remove the vacuum advance assembly. 19. D rive G e a r CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 373 After lower seal has been loosened, use the 7. Inspect the condition of the distributor points. Dirty special punch shown in Figure 17i to push out points should be cleaned and badly pitted points seal. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 374 3. Lubricate and slide weight cam over mainshaft and matching hole in breaker plate. Connect primary install weights and spring (fig. condenser leads to contact set quick- 4. Insert mainshaft into housing, indexing it with drive disconnect terminal. gear and washers. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 375 Correct tension is 19-23 oz. 7. Install rotor to cam assembly, indexing round and square pilot holes. . Set spinner governor as outlined under “ Governor Setting.” F ig . 17i — Removing Lower Seal CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 376 4. Time ignition as previously described under Tune-Up in Section INSTALLATION—ENGINE DISTURBED (ALL MODELS) 1. Locate No. 1 piston in firing position by either of F ig . 19i—Distributor G overnor Assembly two methods described below. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 377 . Remove centrifugal weight support and timer core from drive shaft. Remove connector from pick-up coil leads. F ig . 2 2 i—Eight C ylin d e r Engine Distributor CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 378 . Attach distributor to coil primary wires. 7. Replace distributor cap. . Attach governor vacuum and air intake lines to distributor. 9. Adjust timing and then fully tighten distributor clamp screw. F ig . 2 3 i—Magnetic Pulse Distributor Components CHEVROLET TRUCK SERVICE MANUAL...
  • Page 379 If both readings are infinite, the Avoid excessive heat which may damage the panel board. resistor is open. Chip away any epoxy involved, and apply new epoxy which 9. Resistor R4: Select an ohmmeter scale on which the is commercially available. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 380 Push in on wire to depress plunger and continue electrode. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 381 2G Engine Governor time as the engine reaches its predetermined governed (Vacuum Spinner Type) described in Section M of this speed. Thus the driver has a quick check of the condition Shop Manual. of the warning light bulb. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 382 RETURN SPRING SHIFT LEVER SPIRAL SPLINES riNION STOP OVERRUNNING BRUSH CLUTCH INSULATED BRUSH HOLDER FIELD COIL BRUSH SPRING ARMATURE GROUNDED BRUSH HOLDER Fig . I s —Starting M otor Cross Section (T y p ica l) CHEVROLET TRUCK SERVICE MANUAL...
  • Page 383 BUSHING CO VER ARMATURE / "O ” RING RINGS BAND HEAVY-DUTY CLUTCH COMMUTATOR POLE SHOE SHAFT SEAL BRONZE ’BUSHING T-1041 F ig . 3s— Cross-Sectional V ie w of Motor with Heavy Duty C lu tch CHEVROLET TRUCK SERVICE MANUAL...
  • Page 384 Variations of the enclosed shift lever type starting flange mounted starting motor but a much heavier duty motor are used in the Chevrolet Truck Programs. Gas­ design (fig. 3s). Specific mention is made where differ­ oline powered engines use the conventional starting ences in service procedures between the two types of motor of either the flange or pad mounted (figs.
  • Page 385 SH O ULD ERED SUPPO RT PRESS ADAPTER INSTALLER TO O L TO O L J-5184 C H E C K IN G J-21 600 SCALE H A R N ESS ADAPTER F ig . 5s—Sp ecial Tools CHEVROLET TRUCK SERVICE MANUAL...
  • Page 386 —...
  • Page 387 (fig. 1). The pedal push rod is 1 , 0 0 0 6 , 0 0 0 miles. routed vertically, inside the cab, from the pedal lever CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 388 5. Release push rod, connect return spring and tighten nut "A" to lock swivel against nut "B ". 1. Loosen lock nut. . Check free pedal clearance at pedal (3/4" to 1" is 2. Turn adjustment bolt until clutch pedal is equal CHEVROLET TRUCK SERVICE MANUAL...
  • Page 389 Clutch Pedal Free Travel Adjustment Adjust clutch m aster cylinder adjustable push rod to obtain free travel between the clutch m aster cylinder F ig . 7 - C lu tch Pedal Free Travel CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 390 5. Remove grease fitting from pivot pin, install Tool J-8118 and use a slide hammer to remove the pin Fig . 10 - T ilt Cab Clutch Pedal Linkage CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 391 SLAVE CYLINDER of seals to solid end of piston. 2. Lubricate piston and seal assembly with brake fluid Removal then install in cylinder as shown in Figure 11. 1. Remove return spring from clutch fork. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 392 "Clutch Pedal Total Travel." 4. Remove clutch fork push rod from cross-shaft lever 3. Attach hydraulic line to slave cylinder and bleed air if necessary. from system at slave cylinder bleed fitting. 5. Reverse removal procedure to install. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 394 Use 5/8" thick board in place of floor mat to give a positive stop. All three readings should be within .010" and Fig . 16 - Checking Pressure Plate Lift with D ial Indicator within total lift readings. If more than .010" CHEVROLET TRUCK SERVICE MANUAL...
  • Page 395 CLUTCHES AND TRANSMISSIONS 7-9 check retracting springs per step 2. If trouble fore checking. NOTE: Excessively high readings indicate that still exists, loosen clutch-to-flywheel mounting bolt at position of lowest reading (leave other the diaphragm spring is being over stressed bolts tight), pry cover, away from flywheel, and which may eventually cause loss of load and insert feeler gauge (fig.
  • Page 396 TWO PLATE COIL SPRING CLUTCH Page General D e s c r ip t io n ............7-11 Service O p eratio n s............7-11 Removal from V eh icle........... 7-11 Installation in Vehicle & Lever Adjustment ....7-11 CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 397 Sec­ tion 7. . Adjust clutch pedal linkage as previously outlined. Fig . 20 - C lutch Removal or Installation CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 398 4. J-5824 C lutch Pilot Tool 9. J-7126 Release Lever Adjusting Tool 5. J - 1448 Pilo t Bearing Puller 10. J — 7816 Release Lever Adjusting Tool 6. J-5822 Ball Type Pilo t Bearing Remover CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 399 MAINSHAFT OIL SEAL adjustment and insure over-travel in all positions. Replacement NOTE: If mast jacket lower dash clamp has been disturbed at its mounting on dash, its ad- 1. Remove nuts and U-bolts retaining rear universal CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 400 ) must be toward rear of transmission. . Attach control rods to shifter levers. 9. Fill transmission with lubricant. Fig. 3 G - Transmission Controls (PS20 Models) F ig . 5 G - Removing Mainshaft O il Seal CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 401 SERVICING THE OVERDRIVE drive assembly should be removed and overhauled on the With the overdrive assembly removed from the trans­ bench. CHEVROLET TRUCK SFP.VICE MANUAL...
  • Page 402 (BEND TO ADJUST AIR GAP) ELECTRICAL UNIT CHECKS TOUCHING) Overdrive Relay — ■ ■ ■ * ..--..Specifications and checking procedures fo r this relay Fig . IB - Checking Relay A ir Gap CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 403 "SOL" terminal is grounded, but should not light when "SW" or "R E L " terminals Fig . 4B - O verdrive Linkage Adjustment CHEVROLET TRUCK S E R V O M ANUAL...
  • Page 404 3/16" before the throttle lever touches its stop. Occasionally the large nuts which clamp the F ig . 5B - O verdrive E le ctrica l C ircu it W iring Diagram CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 405 If this does not the other of the two terminals next to the stem of correct the trouble, replace the kickdown switch. the kickdown switch (identified as "SW" and CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 406 The forward end of the mainshaft is supported by a VIEW B TG 500-600 VIEW A TT 400, TD 500-600 MODELS TE-TS 400, TG 500-600 MODELS F ig . 1J - Remote Control Rods CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 407 Disassembly 1. With a small punch drive out pins that retain shifter yokes and reverse shifter head to shifter shafts. F ig . 3J - Staking Expansion Plug CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 408 1 / 2 peller shaft brake as outlined in Section 2. Remove speedometer driven gear from bearing — _ retainer. 3. Remove universal joint flange retaining bolt, lock- CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 409 Shift Rail Cover Oil Seal R ep lacem en t......7-28 Service O p e ra t io n s ............. 7-25 Transmission R ep lacem en t........... 7-25 Assem bly..............7-29 R em oval..............7-25 CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 410 4. Connect propeller shaft to output yoke as described locknuts against adjustable clevises. in PROPELLER SHAFT (SEC. 4). . Lubricate linkage as directed in Lubrication Sec­ 5. Install speedometer driven gear and connect speed­ tion CHEVROLET TRUCK SERVICE MANUAL...
  • Page 411 2. Shift Yoke G u id e 7. Roll Pin 12. N ut 16. Lock Washer 8. C over 3. Shift Rail Yoke 17. N ut 9. Shift Rail 13. Lock Washer 4. Shift Rail Boot Boot Retainer CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 412 1st and 2nd Shift Lug 1st and 2nd Shift Fork 14. Spring 19. Spring 1st and 2nd Shift Rail 7. Reverse Shift Fork 15. Shift Rail Detent Ball Detent Ball Lock Pin Interlock Plunger 21. Plunger 29. Spring CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 413 11. Partially insert 3rd and 4th shift rail (17) in bore of 1st & 2nd Shift Lug 5. 3rd & 4th Shift Rai 1 cover (2) and position 3rd and 4th shift form (23) on 1st & 2nd Shift Rail 6. Reverse Shift Rail rail (17). CHEVROLET TRUCK SERVICE MANUAL...
  • Page 414 Key Numbers in Text Refer to Fig. 4K rail ( 4. Loosen lock nut ( ) and remove shift yoke guide (7) On transmissions having remote controls, accomplish from cover (5). Remove lock nut ( ) from guide (7). the following procedures: CHEVROLET TRUCK SERVICE MANUAL...
  • Page 415 Rai I Shift Fork 12. 1st and 2nd Shift Rail Plugs 5. Rail Interlock Pin 2. Lock Pins 13. 1st and 2nd Shift Lug 1st and 2nd Shift Fork 6. Reverse Shift Fork 3. Reverse Shift Lug CHEVROLET TRUCK SERVICE MANUAL...
  • Page 416 CAUTION: Place a piece of cardboard over transmission cover opening, using two of the cover attaching screws to hold it in place. This Fig . 1 N P - Removing Retaining Pins CHEVROLET TRUCK SERVICE MANUAL...
  • Page 417 Put 2nd-3rd sliding clutch into 3rd gear position (move foward) and put 4th-5th sliding clutch slightly ahead of neutral. 3. Rotate mainshaft by turning clutch gear until the Fig. 3 N P - Installing O il Seal with Tool J-6416 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 418 Lift off cup, spring, cap and rear. seal (fig. IS). 2. Install slotted pin through housing and lever and in­ 2. Remove snap ring from groove in lever housing and CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 419 Remove interlock poppet through opening for shaft (fig. 7. Remove set screw from second-and-third shifter shaft and tap shaft out through hole in front of cover. F ig . 3S - Removing Inner Plunger Pin CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 420 2. Make sure all transmission gears are in neutral and SHIFTER HEAD FORWARD BOSS 1st & REVERSE SHIFTER SHAFT F ig . 8S - Installing Shifter Head F ig . 6S - Location of Interlock Poppets CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 421 Installation of T ra n s m is s io n ...........7-36 Shift Cover and Forks ............7-37 Gearshift Lever A sse m b ly ..........7-36 Shift Rod Adjustment............7-36 D isassem bly ..............7-37 Assem bly..............7-37 Lubrication...............7-36 Service Operations ............7-36 CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 422 TRANSMISSION INSTALLATION 4. Disconnect speedometer cable at rear of trans­ 1. Place transmission on suitable lift and raise into mission. 5. Using a suitable jack and some means to secure the position. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 423 2. Remove poppet screw from each side of cover and . Move rod (1) to neutral position, tighten fork clamp ja r springs, balls, and retainer out through poppet screw firmly and retain with lockwire (3). holes. (4 ) CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 424 Overheating may to the full mark on the dip stick. Refill capacity also occur. is approximately qts. If the transmission is found consistently low on oil, a CHEVROLET TRUCK SERVICE MANUAL...
  • Page 425 See Section 9 for alignment of steering column assembly if necessary. To check for proper shift linkage adjustment, lift the Fig. 2 P G - Powerglide Control Rod Linkage transmission selector lever towards the steering CHEVROLET TRUCK SERVICE MANUAL...
  • Page 426 % " HOLE long extension. Remove upper bolts. % " h-------------------------- 1 72 5 /32" CAUTION: It is best to have an assistant ob­ serve clearance of upper engine components Fig . 3PG - Converter Holding Tool CHEVROLET TRUCK SERVICE MANUAL...
  • Page 427 "N" (neutral). If the fluid level is low, either of the following procedures: CHEVROLET TRUCK SERVICE MANUAL...
  • Page 428 1. Pressure regulator valve stuck. 2. Vacuum modulator valve stuck. BASIC PRESSURE CHECKS 3. Hydraulic modulator valve stuck. 4. Leak at low servo piston ring (between ring and Four basic pressure checks are used fo r diagnosis and bore). CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 429 96 - 112 60 - 74 1 0 1 L-292 283 V 48 - 54 327 V 104 - 119 60 - 74 124 - 139 1 0 1 ^Partially open throttle until vacuum reads 10" Hg. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 430 TRUCK SHIFT POINTS CE 20 MODEL CS 10 MODEL TRUCK (MPH) CE 10 MODEL TRUCK (MPH) CS 20 MODEL TRUCK (MPH) TRUCK (MPH) L250 (BASE) L292 (L25) V283 (Base) V327 (L30) L250 (Base) L292 (L25) V283 (Base) Engine 3.73 Axle - 8.15-15 3.73 Axle - 8.15-15 3.73 Axle - 8.15-15 3.73 Axle - 8.15-15...
  • Page 431 D Range. External control connections to transmission are: CHEVROLET TRUCK SERVICE M ANUAL...

  • Page 432: Maintenance And Adjustments

    40 MPH, depending on axle ratio. Chevrolet Motor Division always be tagged with the LI Range position prevents the transmission from transmission serial number.
  • Page 433 11. Readjust neutral safety switch if necessary to pro­ lease. It must drop back into position with no vide the correct relationship to the transmission restrictions. detent positions. See Section 12. VIEW B VIEW A Fig . 3T - Lower Control Linkage (PS20) CHEVROLET TRUCK SERVICE M ANUAL...

  • Page 434: Neutral Safety Switch Adjustment

    ( ) check balls will stay in place above Installation the spacer plate. 1. Using Tool J-5154 or J-21359 install new seal. CAUTION: Do not drop manual valve. 2. Re-install propeller shaft. CHEVROLET TRUCK SERVICF M AN UAl...

  • Page 435: Transmission R Ep Lacem En T

    Before attempting to correct an oil leak, the actual Always check the oil level before road testing. Oil source of the leak must be determined. In many cases must be visible on dip stick prior to operating the vehi­ CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 436 Transmission over-filled. b. Water in oil. Drive, Neutral, Park L l or L2 Reverse c. Pump to case gasket mispositioned. *A "Black Light" testing unit may be obtained from several different service tool suppliers. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 437 J-7126 Release Lever Adjusting Tool 4. J-5824 C lutch Pilo t Tool J — 7816 Release Lever Adjusting Tool 5. J — 1448 Pilo t Bearing Puller 6. J-5822 Ball Type Pilo t Bearing Remover CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 438 CLUTCHES AND TRANSMISSIONS 7-52 Fig. 2ST - C hevrolet Truck (exc. C h evy Van) Three-Speed Transmission Special Tools 1. J-0936 (J-936) - C lutch G e a r Bearing Remover 6. J-5154A (J-5154) - Rear Bearing Retainer Seal Installer 2.
  • Page 439 2. J- 1 1 2 6 - Transmission G u id e Pins 6. J-8039 - (K M O 410) - Snap Ring Pliers 3. J-5590 - Transmission Front Bearing Installer 7. J-5750 - Transmission Holding Fixture 4. j-5154 - Rear Bearing Retainer Seal Installer CHEVROLET TRUCK SERVICE MANUAL...
  • Page 440 CLUTCHES AND TRANSMISSIONS 7-54 Fig. 4ST - Four-Speed Transmission Special Tools 1. J-2680 - Reverse Id ler G e a r Bushing Staking Tool 9. J — 1453 - Clutch G e a r Bearing Replacer 2. J- 1 6 1 9 - Transmission Mainshaft Bearing Puller 10.
  • Page 441 Replacer 8. J-1619 - Transmission M ainshaft Bearing 4. J-0358 - Press Plate Holder 2. J-2228 - Clutch G e a r Bearing Remover Pu ller 5. J-6382 - Reverse Idler Shaft Remover Plate CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 442 5. J — 6419 — Bearing Installer 2. J-4761 - Reverse Id ler Shaft Remover 6. J-0996 (J-996) Bearing Remover 3. J-8107 (TR-278-R) - Differential Side Bearing Remover 7. J-5740 - Bearing Remover 4. J — 6418 - Synchronizer Hub Remover CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 443 Fig. 7ST - Five-Speed (C lark) Transmission Special Tools 1. J-1619 - M ainshaft Bearing Remover 2. J-6382 - Reverse Idler G e a r Shaft Remover 3. J — 6419 — Bearing Installer Set CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 444 Slide Hammers (N o t Illustrated) 14. J-9557 Transmission Case Rear Bushing Remover and Slid e Hammer Adapters (N o t Illustrated) J-6585-3 Installer and Rear Pump Bushing Remover J-9534 Bushing Remover (N o t Illustrated) ■CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 445 CLUTCHES AND TRANSMISSIONS 7-59 F ig. 9ST - Turbo H yd ra-M atic Sp ecial Tools Converter Holding Strap 1. J- 6 1 16-01 Rear U nit Holding Fixture 15. J-5384 16. J- 2 1 465-01 Bushing Tool Set 2. J-8092 D river Handle Part of Bushing Too Set 3.
  • Page 446 7. J - 2 1369 C onverter Pressure Check Fixture 15. J-5403 Snap Ring Pliers Torque W rench 0-140 Ft. Lbs. 8. J - 2 1362 Seal Protector - Forward and D irect C lutch - Inner 16. J —1313 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 447 I.D. hose and cut a flap type slit 18" from one end. one foot higher than normal. See Figure 1. 4. Insert nipple end of hose into tank until it strikes NOTE: bottom. Hose with larger than 3/8", or slightly CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 448 1. Remove front seat and back cushions. F ig . 2 - Cab Mounted Fuel Tank (E x c . T ilt) CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 449 . Remove fuel tank. 3. Disconnect fuel line and wiring from tank unit. Igni­ 7. Install in the reverse order, being sure that the anti­ tion switch must be in OFF position. squeak material is replaced. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 450 3. Disconnect fuel pickup line and gauge wire from tank unit. 4. Unclamp filler neck and vent tube hoses and discon­ nect hoses at tank. 5. Remove tank support straps, disconnect sending unit wire and lower tank carefully. . To install, reverse the removal procedure. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 451 Index the This precaution will prevent gum formation and "blind rivet” and press hard (hand pressure should do) to resultant improper engine performance. expand rivet. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 452 FUEL TANK AND EXHAUST SYSTEMS 8-6 F ig . 7 - Fuel Lines and F ilte r - CD 50-60 CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 453 Always use the to rear. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 454 FUEL TANK AND EXHAUST SYSTEMS 8-8 SPECIAL TOOLS TAPER TO 1 / 2 " Fig . 10 - Special Tools 1. J-8950 Fuel Tank G auge Unit Spanner 2. J -7777 Fuel Line C lip Installer CHEVROLET TRUCK SERVICE MANUAL...
  • Page 455 (forward hole on Chevy Van); gear is now filled to correct level. ADJUSTMENTS Steering Gear Before any adjustments are made to the steering gear Fig. 1—Steering G e a r C over Retaining Screws CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 456 CAUTION: Turning sleeves an unequal Fig . 2—Removing Pitman Arm CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 457 2. Rotate adjusting ring to give .005" end play between adjusting ring and first and reverse shifter lever (fig. 7). 3. Tighten attaching screws and clamp bolt. Fig . 5 —Steering W heel Alignment F ig . 7 —Checking Adjusting Ring C learance CHEVROLET TRUCK SERVICE MANUAL...
  • Page 458 Removal 1. After marking wormshaft to steering shaft relation­ ship remove bolt from coupling clamp. Fig . 8 —Steering W heel Removal Fig . 9 —F le xib le Type Steering Coupling CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 459 2. Disconnect pitman arm from steering gear. Use Tool J-6632 on light-duty models and Tool J-3186 on Fig. 10— Universal Jo in t Type Steering Couplings and medium and heavy-duty models. Interm ediate Steering Shaft S lip Jo in t CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 460 1. Remove steering wheel. 2. Loosen and pull mast jacket seal away from floor pan. 3. Remove floor pan from around mast jacket. 4. Remove pitman arm from steering gear. 5. Remove steering gear to frame mounting bolts. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 461 . Install pitman arm to sector shaft and tighten nut. Installation (Figs. 15-16) 9. Install deflector and extension assembly. 1. From passenger side of firewall, carefully insert 10. Install steering wheel as outlined in this section. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 462 NOTE: For units without shifter tube, omit Steps 1, , 9, 10 and 11. panel. Fig . 17—3-Speed Mast Ja ck e t and Shifter Tube CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 463 14. Install nut and washer on steering wheel end of 2. Lubricate all bearing surfaces on shift tube. steering shaft to hold the shaft in position. F ig . 18—Medium and Heavy Duty Mast Ja ck e t Components CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 464 4. Install upper mast jacket bearing retainer (snap ring) attempting to tighten nut. in groove in steering shaft. 5. Adjust lower mast jacket bearing as outlined under Maintenance and Adjustments. 3. Install ball studs in steering arms and relay rod. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 465 Fig . 2 1 - 4 0 -5 0 -6 0 Series Steering Linkage - Typ ical CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 466 7. Following directions given in Section 3 to check cor­ arm boss with a heavy hammer and striking other nering wheel relationship and toe-in; correct as side of boss with lighter hammer (fig. 23). required. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 467 7. Tighten locknut and recheck pull as it must lie within specifications. Fig. 24-40-50-60 Series Power Steering G e a r and . Reassemble steering connecting rod to pitman arm. Control V a lv e (T y p ica l) CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 468 “ Type A” bearing the mark “ AQ-ATF” followed by a number and the suffix CAUTION: To prevent scrubbing flat spots on letter tires, do not turn steering wheel more than five “ A ” . CHEVROLET TRUCK SERVICE MANUAL...
  • Page 469 Fig. 28—C l 0-20-30 Control V a lv e and Power cylinder hoses. C ylin d er Installed CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 470 1. Disconnect the two hydraulic lines connected to the tachment, tighten screw, with ball stud in place power cylinder and drain fluid into a container. until it bottoms, then back off to nearest hole Do not reuse. and secure with cotter pin. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 471 When servicing power steering hoses, avoid twisting Figure 31 illustrates typical installations. the hoses unnecessarily. Install hoses with the wheels in CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 472 STEERING 9-18 Fig . 31—T yp ical Power Steering Hose Routing CHEVROLET TRUCK SERVICE MANUAL...
  • Page 473 C hecking G auge with J-5900 18. J-5176 Power Steering Pu lley Remover 33. J-8433-1 Adapter Kit 7. J -8524-2 Adjuster Plug Bearing and for Cast Pulleys J -8433-2 Seal Remover 19. J — 2619 S lid e Hammer CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 475 If payload mended for use on Chevrolet Trucks. distribution or special equipment is such as to impose heavy loads on the front axle, inflation of front tires...
  • Page 476 There is, of course, no correction for high cambered producing a type of wear like that caused by excessive roads. Cornering wear is discussed further on. positive camber. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 477 C30 W / D U A L REAR 50 SER IES 50, 60 SER IES F ig. 1 - Front W h eels and Attachments REAR WHEELS F ig . 2 - Rear Wheels and Attachments CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 478 When tires are mounted on dirty or corroded rim s, or "Maintenance". when they are not properly centered on rim s, the tire CHEVROLET TRUCK SERVICE MANUAL...
  • Page 479 (fig. 4). Fig. 5 - Raising End of Clamp Ring Fig . 6 - Removing T ire Clamp Ring F ig . 4 - Releasing Tire Clamp Ring CHEVROLET TRUCK SERVICE MANUAL...
  • Page 480 2. Loosen the tire bead from its seat in the side ring the tapered end of tire iron until the clamp ring gut- by driving the bead loosening end of a tire iron be- CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 481 1. Remove all rust scale from wheel rim and side ring. 2. Insert tube in tire and inflate until tube is nearly NOTE: It is not necessary to remove side ring rounded out. from tire bead if tire is to be removed for tube CHEVROLET TRUCK SERVICE MANUAL...
  • Page 482 1. Before installing tube in tire, clean inside of casing section, thereby engaging side ring over rim gutter thoroughly. at these points. 2. Insert tube in tire and inflate until it is nearly CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 483 Demounting and Mounting All tubeless tires used on Chevrolet trucks with the exception of the 7.75-15 and 6.50-16 sizes should be de­ mounted and mounted as described in this section. The Fig.
  • Page 484 Using straight end of tire iron and with necessary, push section of bead into rim well and stop resting on rim flange, work remaining section anchor with vise-grip pliers by pinching pliers on CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 485 A slight application of rubber lu­ sash cord to the circumference of the tire and bricant on the last 1/3 of each bead circle to be mounted will ease mounting. then tightening with a tire iron. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 487 A d ju s tm e n t..............11-3 Hood Assembly Removal and In stallatio n ....... 11-4 Hood Assembly A lignm en t..........11-4 F ig . 1 - Front Sheet M etal - 10 thru 30 Series Trucks CHEVROLET TRUCK SERVICE MANUAL...
  • Page 488 Conventional Truck sub-section. F ig . 2 - Front End Sheet Metal - 40 thru 60 Series Trucks CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 489 3. Adjust as outlined under Adjustments. Adjustment 1. Open hood and adjust tightness of lock bolt support so that they are just "snug" enough to hold lock bolt in position. F ig . 3 - Hood Spring Tool Installation CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 490 Vehicles equipped with air conditioning and/or power steering will require special handling. Refer to appropriate sections of this manual for F ig . 5 - Hood Lock Assembly (40 thru 60 Series) instructions. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 491 (See Figure 4. Install two bolts and shims required at each fender rear lower edge to hinge pillar. 5. Install bolt in each fender skirt to sill extension. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 492 12. Connect power steering fluid reservoir hose to pump. See Section 9. 9. Remove both head lamp assemblies. Complete. 10. Remove left fender gusset (5 screws). 13. Connect air cleaner intake hose to fender skirt. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 493 14. Remove radiator support bolts secured to fram e-- 5. Connect support to left fender. Note and record stackup. . Connect 3 screws from underside of left skirt to 15. Tilt radiator support rearward and lift up and off. support bottom. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 494 12. Using drift line up right fender skirt rearmost bot­ tom screw with fender flange and attach loosely. 13. Attach right fender skirt inner top bolts to fender underside. F ig . 9 - Fender to Cowl 40 to 60 Series CHEVROLET TRUCK SERVICE MANUAL...
  • Page 495 11. Remove 3 bolts fastening gusset to fender and grille (fig. 12. Remove two bolts fastening gusset to fender. 13. Remove all electrical connections. Installation To install, reverse the removal procedure using seal­ ing tape between filler panel and fender. Check sheet metal alignment. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 496 2. Underneath the skirt remove 2 screws at top at­ tached to fender. F ig . 14 - Running Board and Fender Extension Fig. 16 - Running Board and Braces (40 thru 60 Series) (See Illustration for Series) CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 497 The surge tank access door is retained with screws and a stud as shown. ENGINE SPLASH SHIELD EMBLEMS AND DESIGNATION PLATES Refer to Figure 18 Removal and Installation Refer to Illustrations (Figs. 19 and 20) 1. Tilt the cab to expose engine area. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 498 Torque all bolts. F ig . 21 - Radiator A ir Deflector and Splash Shields F ig . 22 - Installing Radiator A ir Deflector CHEVROLET TRUCK SERVICE MANUAL...
  • Page 499 CHASSIS SHEET METAL 11-13 Fig. 23 - Engine Compartment C over Assembly SPECIAL TOOLS Fig. 2 4 - J-5544-1 Hood Spring Remover CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 500 • • •...
  • Page 501 Whenever it is tightly mounted to provide good ground and that the head­ necessary to splice a wire or repair one that is broken, lamps are properly adjusted. Loose or corroded connec­ CHEVROLET TRUCK SERVICE MANUAL...
  • Page 502 £ c t r i C a l 12-2...
  • Page 503 When replacing wires, it is important that the correct size be used. Never replace a wire with one of a sm aller size. Fusible links in the Chevrolet wiring are four gauge sizes sm aller than the cable it is designed to pro­ tect.
  • Page 504 2. Loosen knob beneath the aimer arm and move the slider until the bubble is centered. 3. Record the numeral in the view window. (This Fig . 6 - Removing Aim er from Headlamp numeral is to be used only for re calibration.) CHEVROLET TRUCK SERVICE MANUAL...
  • Page 505 On vehicles using parking and taillight 1. Remove retaining screws and lens from housing. assemblies for directional signals; refer to ap­ 2. Replace bulb and check operation of unit. plicable light assemblies for bulb replacement. 3. Install lens and retaining screws. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 506 ELECTRICAL—BODY AND CHASSIS 12-6 VIEW C F ig . 9 - Front Lighting Assemblies CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 507 ELECTRICAL—BODY AND CHASSIS 12-7 CA 31 (04) (34) CA 30 (03-12) F/F COWLS CA 20-30-40 (09) F ig . 10 - Rear Lighting Composite CHEVROLET TRUCK SERVICE MANUAL...
  • Page 508 2. Disconnect wiring connector from switch terminals. 3. Connect wiring to replacement switch and check operation. 4. Position switch to toe pan and install retaining screws. F ig . 11 - Light Switch - C hevy Van CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 509 5. Place contact support drive slot over shifter tube . Tighten transmission lever extension bolt to 12-16 drive tang and tighten screws. Remove clamp and lbs. ft. torque and remove pin. pin. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 510 3. Position replacement switch to mast jacket, install switch from shift lever rod. retaining screws and connect wiring to switch 4. Mount replacement switch loosely to transmission terminals. side cover and connect wiring to switch terminals. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 511 10-30 Conventional Cab Models (Fig. 17) . Protect mast jacket with suitable covering. 7. Remove cluster retaining screws from face of as­ 1. Disconnect battery ground cable. sembly and remove cluster assembly from console. 2. Remove choke control knob. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 512 ELECTRICAL—BODY AND CHASSIS 12-12 Fig. 17 - Instrument Cluster Assembly - Conventional Cab Chevy Van To install, reverse removal procedure. 1. Disconnect battery ground cable. 2. Disconnect speedometer cable at speedometer head. 40-60 Conventional Cab Models (Fig. 17) 3. Remove two nuts attaching cluster to dash panel. Cluster may now be pulled clear of dash panel.
  • Page 513 Service Station. 2. Remove all instrument cluster lamp assemblies. Conventional Cab Models 3. Remove laminated circuit retaining screws. 1. Remove instrument cluster assembly and laminated NOTE: These screws serve as a ground fo r CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 514 Tilt Cab Models FUEL GAUGE REPLACEMENT 1. Remove instrument cluster as previously described 10-60 Conventional Cab Models in this section. 2. Remove eight screws securing cluster bezel to back 1. Remove instrument cluster assembly as previously CHEVROLET TRUCK SERVICE MANUAL...
  • Page 515 4. To W ip e r Switch 11. To Dome Lamp Conn. 5. To D irectional Sw itch 12. Dimmer Switch 6. To W ip e r M otor 13. To Instrument Cluster Conn. Ignition Switch CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 516 4 . To W ip e r Switch 11. A ir Brake Buzzer 5. To Directional Switch 12. Dome Lamp Conn. 6 . Instr. Cluster Connector 13. Dimmer Switch 7. To W ip e r Motor CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 517 L. H. Turn Ind. Brake W arning Lamp Light Sw itch Conn. Bulkhead Conn. 15. A ir Brake Buzzer D irectio n al Signal Conn. 16. Dimmer Switch 8. Fuel G au g e Conn. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 518 R. H. Turn Ind. 3. Cluster Lamp G en erato r lnd„ 4. W ip e r Sw itch Ignition Switch Light Switch Conn. To D irectional Signal Switch 6. To H eater Switch 7. Hi Beam Ind. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 519 Laminated C ircu it 15. Temperature Gauge 11. Overspeed W arning/Low Vacuum R. H. D irectional 3. Instr. Cluster Lamp 16. Fuel Gauge 12. G en erator G auge L. H. D irectional 4. Temperature Ind. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 520 If the light does not come on when the ignition switch is To install, reverse removal procedure and check turned on, or if the light comes on and remains on after operation of unit. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 521 NOTE: Hazard switch knob must be pushed in . To install, reverse removal procedure and check to prevent damage to switch when removing operation of unit. from switch cover. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 522 ELECTRICAL—BODY AND CHASSIS 12-22 Fig. 25 - D irectio n al Signal Assembly—Conventional Cab and P10 Series 1. C ancel ling Cam .5. Upper Bearing 9. W irin g Connector 2. D irectio n al Lever Retaining Screw Bearing Housing 10.
  • Page 523 Fig . 26 - D irectional Signal Assembly - C h evy Van 1. C ancel ling Cam 3. Switch Mounting Screw 6. Switch Cover Lever Screw 4. Directional Switch 7. D irectional Lever 5. Upper Bearing Assembly CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 524 Wiper Motor ..R e m o v a l............... 12-28 R em oval.... Installation............12-28 Installation . . . Disassembly ........Disassembly Assem bly............... 12-28 Inspection ..CHEVROLET TRUCK SERVICE MANUAL ------------------------------------------------------------------------------------------...
  • Page 525 Figure 31 is an exploded view of the left hand wiper assembly installation. Right hand assem­ bly is identical, however, it will be necessary to F ig . 29 - W iper Motor Installation - C o n v. Cab CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 526 7. Output G e a r and 10. G e a r Box Housing 14. Flat Washers 18. End Plate 4. Retaining Ring Shaft Assembly 11. Brush Plate Assembly and 15. Armature 19. Tie Bolts (Two Required) Mounting Brackets CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 527 7. If necessary, remove terminal board and park switch assembly as follows: a. Unsolder motor leads from terminals. Coding of motor leads is not necessary on single-speed Fig. 36 - W asher Pump Attaching Screws wipers. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 528 A C TU A TO R A C TUA TO R PIN P LU N G E R ARM F ig . 38 - Washer Pump Mechanism F ig . 3 9 - Releasing Pump from Lockout Position CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 529 Remove actuator pin retaining spring and slide b. Slide ratchet wheel from shaft. . Valve Assembly pin from washer base. 9. Reverse disassembly procedure to assemble washer. a. To remove valve assembly remove screws that secure valve assembly to bellows housing. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 530 ELECTRICAL—BODY AND CHASSIS 12-30 TO CLUTCH HOUSING IGNITION . 12R SHUNT>“ AMMETER RESISTOR AMMETER GAGE Fig . 40 - Engine Compartment - PA10 CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 531 & M49 .------ 12P - g — — 18B •12PPL TRANS CONT ■ 12P---- TRANS 12R- ■ 18D G IGNITION TEMP GAGE 16B---- 16B/W* AMMETER GAGE F ig . 41 - Engine Compartment - PS 20-30-40 CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 532 ELECTRICAL—BODY AND CHASSIS 12-32 F ig . 42 - Engine Compartment - PT 20-30 CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 533 ♦"FOR W IRE GAGE SEE CHASSIS & T A IL L A M P W IRIN G SHEET F ig . 43 - Engine Compartment - C S -K S 10-20, CS30 (E x c . 02) CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 534 ♦F O R W IRE GAGE SEE CHASSIS & T A IL L A M P W IRIN G SHEET BRAKE W ARN IN G SW F ig . 44 - Engine Compartment - C E - K E 10-20, CE30 (E x c . 02) CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 535 ELECTRICAL—BODY AND CHASSIS 12-35 Fig . 45 - Engine Compartment - C S 40-50-60, MS60 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 536 -----s / W — T A IL & STOP L P HARN CONN V *B R W Y‘ •*DG“ •18LG- Fig . 46 - Engine Compartment - C E4 0 -5 0 -6 0 , M E50-60 CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 537 .18B — *Y - ' • DG — 1ST- -RAD IATO R ltDG* SUPPORT Fig. 47 - Engine Compartment - C D - C G 50, C D - C G - M G 6 0 CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 538 FUEL G A G E C O N K TAIL, STO P & D IRECTIO N LP. C O N N . 20D G Fig . 48 - Chassis W iring Harness and Engine W iring Harness TS 40-50-60 CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 539 Do/l O IL PRESS T A IL , STO P & DIRECTIO N L P . CONN. ■ 20DG F ig . 49 - Chassis Wiring Harness and Engine W iring Harness - TE 40-50-60 CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 540 ELECTRICAL—BODY AND CHASSIS 12-40 TAIL STOP & D IRECTIO N LP C O N N . F ig . 50 - Chassis W iring Harness and Engine W iring Harness - TT4 0, T D -T G 50-60 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 541 ♦F O R W IRE GAGE SEE CHASSIS & T A IL L A M P 16LG* W IRING SHEET F ig . 51 - Instrument Panel - C A - K A 10-20, C A30 (E x c . 02) CHEVROLET TRUCK SERVICE MANUAL...
  • Page 542 180R - 1 8 0 R - 18W— OUTSIDE F U E L T A N K Fig . 52 - Instrument- Panel - C A - K A 10-20, CA30 (E x c . 02) CHEVROLET TRUCK SERVICE MANUAL...
  • Page 543 ♦F O R W IRE GAGE SEE CHASSIS & T A I L L A M P W IRIN G SHEET. F ig . 53 - Instrument Panel - C E - C S 4 0 , C E -C S -M S 5 0 , CE-M E60 (E xc . 02-13) CHEVROLET TRUCK SERVICE MANUAL...
  • Page 544 ELECTRICAL—BODY AND CHASSIS 12-44 180R Fig . 54 - Instrument Panel - C E-C S40, C E- C S- M S- M E5 0 , C E- C S-M E6 0 (Exc. 02-13-62) CHEVROLET TRUCK SERVICE MANUAL...
  • Page 545 ♦F O R W IR E GAGE SEE CHASSIS & T A I L L A M P W IRIN G SHEET D IM M ER SW. Fig. 5 5 - Instrument Panel - C D - C G 5 0 , C D - C G - M G 6 0 CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 546 •*Y — -*D G - -*DG“ 200R - '200R- •18W- ■18W- Fig. 5 6 - Instrument Panel - C D - C G 5 0 , C D - C G - M G 6 0 CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 547 ELECTRICAL—BODY AND CHASSIS 12-47 ♦ FO R W IRE GAGE SEE CHASSIS & T A IL L A M P W IRIN G SHEET F ig . 57 - Instrument Panel - C A -S A 000 (02-12) CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 548 18T- *FOR W IRE G AG E, SEE C H A SSIS & TAIL LAM P W IR IN G SHEET. F ig . 58 - Instrument Panel - C A -S A 000 (02-12) CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 549 ♦ FO R W IRE G A G E SEE C H A SSIS & TAIL LAM P W IR IN G SHEET. F ig . 5 9 - Instrument Panel - C E-C S -M E 6 0 (13) CHEVROLET TRUCK SERVICE MANUAL...
  • Page 550 * Y — *DG — -2 0 0 R - 2 0 0 R - - 1 8 W - 18W - F ig . 60 - Insturment Panel - C E-C S-M E 6 0 (13) CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 551 ® r - i8 Fp L L . H. D IRE CTIO N SIG NAL F ig . 61 - Instrument Panel and Forward Lamp W iring Harness - TE-TS 40-50 (E x c . 13) CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 552 C L U S TE R L P C L U S TE R L P H I BEAM IND L P F ig . 62 - Instrument Panel - TE-TS 40-50-60 (E x c . 13) CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 553 S T " ln p L .H . D IR E C TIO N SIG N AL F ig . 63 - Instrument Panel and Forward Lamp - TT4 0, T D -T G 50-60 CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 554 ) C L U S TE R L P 18B i 2QLC > ~ r ^ HI BEAM IND. L P 20DG ■ 12DG F ig . 64 - Instrument Panel - TT40, T D -T G 50-60 CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 555 ELECTRICAL—BODY AND CHASSIS 12-55 R. H. D IRE C TIO N SIG N AL L . H. D IRE C TIO N SIG N AL F ig . 65 - Instrument Panel and Forward Lamp - TE60 (13) CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 556 L H.W/S WASHER & WIPER SW. OVERSPEED IND. LP. DIRECTION SIGNAL OIL PRESSURE LP. CLUSTER LP. CLUSTER LP. HIGH BEAM IND. LP. 10DG 20DG- Fig . 66 - Instrument Panel - TE60 (13) CHEVROLET TRUCK SERVICE MANUAL...
  • Page 557 & ♦F O R W IRE GAGE SEE C H A R T ABO VE. F ig . 67 - T a il and Stop Lamp - C A -K A - M A 00 CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 558 L . H. D IRE CTIO N, T A IL & STO P L P 18DG < D IRE C TIO N , T A IL & STO P L P CONN F ig . 68 - T a il and Stop Lamp - TA 00 CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 559 S T O P L P SW & DIR SIG L P ■12 R ---- •12 DG - ■20 B ---- ■14 O R - ■14 Y ---- •14 L B L Fig . 69 - Front End G A 10-20 CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 560 •14 Y — ■14 LBL 14 OR LEGEND 14 Y "" CHEVROLET WRG 14 LBL — FISHER BODY WRG — —* CHEVROLET RPO WRG F ig . 70 - Fuse Panel - G A 10-20 CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 561 ELECTRICAL—BODY AND CHASSIS 12-61 >18 DG 18 DG< Fig . 71 - Instrument Panel - G A 10-20 CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 562 ELECTRICAL—BODY AND CHASSIS 12-62 F ig . 72 - Engine and T ail Lamps - G A 10-20 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 563 ELECTRICAL—BODY AND CHASSIS 12-63 SPECIAL TOOLS .JUNCTION BLOCK OUTSIDE FUEL- TANK -----18T- BRAKE WARN HORN SWITCH ♦FOR WIRE GAGE SEE CHASSIS & TAIL LAMP WIRING SHEET F ig . 73 - Engine Compartment - CS 10-20-30 (02) CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 564 ELECTRICAL—BODY AND CHASSIS 12-64 .JUNCTION BLOCK HORN ♦FOR WIRE GAGE SEE CHASSIS & TAIL LAMP WIRING SHEET F ig . 74 - Engine Compartment - CE 10-20-30 (02) CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 565 ELECTRICAL—BODY AND CHASSIS 12-65 ♦FOR WIRE GAGE SEE CHASSIS & TAIL LAMP WIRING SHEET F ig . 75 - Engine Compartment - SS40-50 (02-62) CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 566 ELECTRICAL—BODY AND CHASSIS 12-66 F ig . 76 - Engine Compartment - SE50-60 CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 567 ELECTRICAL—BODY AND CHASSIS 12-67 SPECIAL TOOLS J-21 932 BEZEL N U T R EM O V E R F ig . 77 - Sp ecial Tools CHEVROLET TRUCK SERVICE MANUAL...
  • Page 569 Connect radiator hoses and transmission coolant line, fill cooling system and Radiator Replacement check for leaks. . Refer to torque specifications in rear of manual for correct torque values. 1. Drain radiator and disconnect water hoses CHEVROLET TRUCK SERVICE MANUAL...
  • Page 570 GS MODELS (Fig. 6) Figure 4.) 4. Drain radiator and disconnect radiator hoses and Radiator Replacement transmission coolant line if so equipped. 5. Remove lower shroud screws. 1. Raise vehicle and place on jack stands. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 571 MODELS (Fig. 8) bumpers. Radiator Replacement 4. Lift radiator up out of lower mounts. Lift shroud 1. Drain radiator and disconnect water hoses and trans­ out of vehicle if applicable. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 572 F ig . 8 - Radiator Mounting - C A 4 0 , C E -C S -M A -S A 5 0 , C E -C S -S A 6 0 Models CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 573 Figure 12. All other T models are equipped with the shroud shown in Figure 13. 12 - 50-60 Fig . Fan Shroud Mounting - TT 50-60 and T G Models CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 574 5. Remove screws attaching hood catch to radiator following the removal procedure in reverse order. Refer support. Remove screw securing bottom of center to torque specifications at rear of manual for correct support to radiator support. torque values. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 575 Assemble and install grille assembly and related components following the removal procedure in reverse order. Refer to torque specifications at rear of manual for correct torque values. F ig . 17 - G r ille Mounting - TA Models CHEVROLET TRUCK SERVICE MANUAL...
  • Page 577 2. Remove bolts attaching bumper to frame. 3. Remove bumper from vehicle. 4. If necessary, replace body dirt seal. Fig . 2 - Rear Bumper - C and K Models F ig . 1 - Front Bumper - C and K Models CHEVROLET TRUCK SERVICE MANUAL...
  • Page 578 Assemble and install front bumper following the re­ 2. Remove screws securing license plate bracket to moval procedure in reverse order. Refer to torque face bar and remove license plate bracket. Assembly and Installation Assemble and install front bumper following the re- CHEVROLET TRUCK SERVICE MANUAL...
  • Page 579 Install bumper following the removal procedure in re­ verse order. Refer to torque specifications in rear of manual for correct torque values. FRONT BUMPER—T MODELS (Fig. 8) Removal NOTE: On tilt cab models equipped with air CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 580 ’ ■ • ■ • -------------------- „------...
  • Page 581 V o l t s ..................14 Amps (Cold)..............20 (Max.) HEATERS RPM (C old )................4000 Compressor Clutch Coil Fuses Ohms (at 80 ° F ) ..............3.85 Amps (at 80°F ) ..........3.2 @ 12 volts Deluxe Heater............... 25 Amp. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 582 FRONT SUSPENSION SECTION 3 ALIGNMENT SPECIFICATIONS MA50 CA-SA TA40 CA-PA CA-20 C A -PA - TD50 CA-MA SA531 CA-MA Models G10, 20 K10, 20 PA20, 30 50 (Exc. TE-TS MA60 SA-40 CA-MA TA60 TA60 TA60 SA531) TG50 SA60 3000C20 4000 5000 2500 2200...
  • Page 583 1 2 0 1 2 0 1 2 0 U-Bolt Leaf Spring -- Front Leaf Spring - - Rear Kingpin Upper 5000# 140 Brake Backing 7000# 185 Plate Kingpin Bearing Caps — — — Kingpin Lock CHEVROLET TRUCK SERVICE MANUAL...
  • Page 584 15,000 and 17,000 2 0 0 Two Speed • Torque to Specification given, Back Off 1/8 Turn. Install Lock Nut and Torque @Trucks equipped with Disc Wheels Torque to 475 All Torques given in Foot Pounds CHEVROLET TRUCK SERVICE MANUAL...
  • Page 585 SPECIFICATIONS 5 Tie Rod Attaching Bolts - (Axle) - (Frame) — — — — — — — Axle to Control Arm U Bolts Spring U 1 2 0 Bolts Control Arm Front Attaching Bolts Coil Spring Attaching Bolt Lower Coil Spring Attaching —...
  • Page 586 SPECIFICATIONS 6 DIFFERENTIAL SPECIFICATIONS Gear Backlash .005"- .006"- .005"- .005"- .005"- .005"- .005"- .205"- .005"- .006"- .006"- .006"- Preferre .008" .008" .008" .008" .008" .008" .008" .016" .008" .016" .016" .016" .003"- .003"- .006" .003"- .006"- .006"- .006"- .003"- .003"- .003"- .003"- .003"-...
  • Page 587 SPECIFICATIONS 7 ENGINE SECTION 6 *8.25:1 on CE & TE400 Series. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 588 Service .001" (Max.) Production .0002" (Max.) Out of Round Service .001" (Max.) .0007" .0007" Production .0007"-.0027" .0007"-.0028" Rod Bearing .0028" .0027" Clearance Service .004" (Max.) .015"- Rod Side Clearance .0085"-.0135" .009"-.013" " 0 2 1 CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 589 @ 1.40" @ 1.30" @ 1.33" @ 1.27" 1-13/16" 1-21/32" Installed Intake Height 1-13/16" 1-5/8" 1-21/32" ± 1/32" Exhaust 1-21/32" 1.80" 1.94" N.A. Free Length 1.92" Damper 3 -5 /8 " N.A. Approx. # of Coils CHEVROLET TRUCK SERVICE MANUAL...
  • Page 590 SPECIFICATIONS 10 ENGINE TORQUES CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 591 AIR CONDITIONED VEHICLES—Set engine idle to specifications with air conditioning turned on and hot idle compensator held closed. Those indicated b y * Set engine idle to specifications with air conditioning turned “ off” . CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 592 0 0 C - 0 0 CD 0 0 C - 0 5 Tt< 0 5 ^ CO w CO w Float Level 1-9/32" 7/32" Float Drop 1-3/4" 1 3 /1 6 ’ Idle Vent .066" . 065" CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 593 All exc. with Air Injection Reactor 7037105 All Exc. O.D. All with Air Injection Reactor All with Air Injection Reactor 7037100’ Overdrive 7026113 All exc. with Air Injection Reactor 7027125 All with Air Injection Reactor 7037125 CHEVROLET TRUCK SERVICE MANUAL...
  • Page 594 283 V Optional P-Models Diesel Ground Neg. Neg. Neg. Neg. Neg. Neg. Neg. Neg. No. of Plates Cranking Power 2300 2300 2350 2900 3150 3150 (Watts) @ 0°F. Capacity @ 20 Hour Rate (Ampere Hour) GENERATOR CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 595 Governed @ 4000 RPM C-4448 A ll AC-C42N 600 RPM None 6° BTDC 1111303 V8 366 Cu. In. Truck 24° @ 2000 RPM 220 HP, RPO L41 - (Special Gear) 32° @ 4400 RPM 500-600 Series, 4000 Governed @ CHEVROLET TRUCK SERVICE MANUAL...
  • Page 596 STARTING MOTOR 1107399 1107496 1107497 1107274 1107321 1107372 1107591 1113183 1113184 1113659 1114101 1107365 1108332 1107370 1107383 250 L-6, 250 L-6, 250 L-6, Auto. 382 & 327 283 & 327 283 & 327 292 L-6, 366 V-8 D-351 3-53 4-53 D-478 6V-53 194 L-6...
  • Page 597 Engines .38-.51 Primary Resistance—Ohms 1.41-1.65 1.24-1.46 8,200-12,400 5,400-7,100 7,200-9,500 Secondary Resistance—Ohms In Wiring Harness In Wiring Harness In Wiring Harness Type Ignition Resistor .43 & Ohms . 6 8 1 . 8 1 . 8 CHEVROLET TRUCK O VERHAUL MANUAL...
  • Page 598 Extension and Retainer to Case Bolts - (Upper) ....................20 ft. lbs. - (L o w e r )....................30 ft. lbs. Lubrication Filler P l u g ..............................30 ft. lbs. Shift Lever to Shifter Shaft N ut............................20 ft. lbs. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 599 Rear Mount to Crossmember B o l t ..........................40 lb. Crossmember Mounting B o l t s ............................25 lb. ft. Oil Cooler Line ..................................113 lb. Line Pressure Take-Off P lu g ............................13 lb. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 600 1 to 3 + 1 to 3 1 to 3 * Adjuster Plug in. lbs. in. lbs. in. lbs. Pump Pressure 850 — 1,000 psi @In excess of worm bearing preload. * In excess of valve assembly drag. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 601 1895 Tilt Cab — Cigarette Lighter Overspeed Warning (327 1895 Differential Lockout & 366 V only) 50W - High Beam 6012 Headlamp 2 CP Conventional Cab 40W - Low Beam F /F Cowl 1895 Tilt Cab CHEVROLET TRUCK SERVICE MANUAL...
  • Page 602 Installed in Car—(Dry G l a s s ) ........S t a l l ................. WASHER Number of “ squirts” at full p r e s s u r e ..... Pressure ( P S I ) ............... 11-15 Coil Resistance (ohms)..........CHEVROLET TRUCK O VERHAUL MANUAL...
  • Page 603 Radiator Drain Plug..........; ....................113 lb. in. ME60 (Radiator Baffle to Radiator Support Screws ........................25 lb. in. Retainer to Radiator Support S c r e w s ........................ 150 lb. in. Radiator Drain Plug..............................113 lb. in. CHEVROLET TRUCK SERVICE M ANUAL...
  • Page 604 Hood Catch to Grille S cre w s........13 lb. ft. 22 lb. in. 150 lb. in. Lower Retainer to Lower Center Panel Screws....................150 lb. in. TA Models (Grille) Gusset to Grille and Grille Support Screws ....................18 lb. ft. CHEVROLET TRUCK SERVICE MANUAL...
  • Page 605 Face Bar to Filler Panel N u ts..........................100 lb. ft. Gusset to Frame N uts..............................100 lb. ft. Bracket to Frame N u t s ............................. 100 lb. ft. Face Bar to Gusset Rear N u ts..........................120 lb. ft. CHEVROLET TRUCK SERVICE MANUAL...

This manual is also suitable for:

20 series 196710 series 196760 series 196740 series 196750 series 1967

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