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Chevrolet 10 Series 1970 Service Manual

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Page 2 S E C T IO N IN D E X SECTION NAME GENERAL INFORMATION AND LUBRICATION 1 9 7 0 HEATER AND AIR CONDITIONING SERIES 10 through 60 BODY CHEVROLET TRUCK FRAME CHASSIS FRONT SUSPENSION 4-WHEEL DRIVE SERVICE MANUAL REAR SUSPENSION AND DRIVELINE BRAKES ENGINE...
Page 3 Deluxe Suburban (Pan el R ea r D oors) F orw ard Control Chassis First N u m b er—G V W Range Forw ard C ontrol (Aluminum Body) - A ll F lat Face Cowl (fu ll a ir brakes) CHEVROLET TRUCK SERVICE MANUAL...
Page 4 F ig . 1—V e h ic le Id e n tific a tio n N um b er and R ating D elcotron Unit S eria l Num ber--Top o f R ea r Housing. P late In fo rm a tio n CHEVROLET TRUCK SERVICE MANUAL...
Page 5 Push Starts—Trucks Equipped w ith Autom atic Transmission ENGINE-VEHICLE AVAILABILITY Do not attem pt to start the engine by pushing the truck. Should the b attery becom e discharged, it w ill be n eces See chart below: CHEVROLET TRUCK SERVICE MANUAL...
Page 6 4000 2600 CCS—Con trolled Combustion System; T C S —T ra n s m ission -C o n tro lled Spark (System ); A IR —A ir Induction R e a c to r (System ) CHEVROLET TRUCK SERVICE MANUAL...
Page 7 G VW -G C W springs o r tire s . ratin gs. C arefu l attention should be given to these codes, CHEVROLET TRUCK SERVICE MANUAL...
Page 8 GENERAL INFORMATION 0-6 LOAD CAPACITY CHART FOR 1970 CHEVROLET SERIES TRUCKS MINIMUM MANDATORY EQUIPMENT FOR GVW RATING RECOMMENDED MAXIMUM MAXIMUM MINIMUM TIRES FRONT END REAR END GASOLINE W HEEL FRONT FRONT WEIGHT AT REAR REAR WEIGHT AT FRONT REAR MODELS...
Page 9 B.E. B.E. 16160 Air Brakes 24000 35000 8.25-20-10 9.00-20-12 B.E. B.E. 7000 B.E. B.E. 17000 26000 42000 9.00-20-12 9.00-20-12 RPO F43 RPO F43 9000 B.E. B.E. 17000 30000 7.50-20-8 8.25-20-10 B.E. B.E. 6280 B.E. B.E. 28000 CHEVROLET TRUCK SERVICE MANUAL...
Page 10 L Frame Reinforcement required for dump and off road application. i. RPO L29 478 Engine for GCW rating, RPO M81 or M85 Transmission. m, RPO F06 Frame Reinforcements, o. CPO Frame Inner Channel Reinforcement, p. CPO Frame Reinforcement for GCW rating. CHEVROLET TRUCK SERVICE MANUAL...
Page 11: Table Of Contents
212 Cu. In. L4 (D ie s e l) 11-3/4* 478 Cu. In. V6 (D ie s e l) 10.5* Repl. Elem ent *Add 1 qt. if equipped with o il c o o le r CHEVROLET TRUCK SERVICE MANUAL...
Page 12 An MS and p erform an ce. o il, which m eets G eneral M otors Standards GM-6041M CHEVROLET TRUCK SERVICE MANUAL...
Page 13: Air Cleaner Care
. w ill be a d vers ely affected. T h e re fo re , if the CHEVROLET TRUCK SERVICE MANUAL...
Page 14: Electrical System Checks
Clean the points with a brea k er conditions a re m et by means o f an o v e r r id e switch. When point file . If the points do not clean up with a few strokes CHEVROLET TRUCK SERVICE MANUAL...
Page 15: C Oolant Recom M Endations
Starting M oto r should be used. Check the solenoid mounting and starting m otor mount ing attaching bolts p e rio d ic a lly . NOTE: A lco h ol o r methanol base coolants o r CHEVROLET TRUCK SERVICE MANUAL...
Page 16: Fuel System
*N O T E : F o r m ost sa tisfa cto ry engine life , use only those No. 2-D d ie s e l fu el o ils containing 0.50% o r less sulfur. CHEVROLET TRUCK SERVICE MANUAL...
Page 17: Diesel Engine O Il Recom M Endations
A ll D ie s e l engine - N orm al s e rv ic e The steerin g column manual shift mechanism on 1/2 Ton and 3/4 Ton m odels equipped with 3 speed tra n sm is CHEVROLET TRUCK SERVICE MANUAL...
Page 18: A U Tom Atic Transmissions
D rain the lubricant e v e ry 24,000 m iles. I f the veh icle fluid added as d escrib ed below . DO N O T O V E R F IL L . is operated in exceptionally heavy w ork o r at continuous CHEVROLET TRUCK SERVICE MANUAL...
Page 19: Positraction
“ M u lti-P u rp o se ” gea r lubricant to as tra ffic o r te rra in , and also the d rivin g tech be used during veh icle operation. niques o f individual custom ers. CHEVROLET TRUCK SERVICE MANUAL...
Page 20: Power Brake V A C U U M Units
The check va lve should the wheel nut torque must be checked at 100, 1,000 and 6,000 m ile s and e v e ry 6,000 m iles th erea fter. be dism antled and thoroughly cleaned. CHEVROLET TRUCK SERVICE MANUAL...
Page 21: Wheel Bearings
6,000 m ile s. Upon rotation, tire pressu re pump r e s e r v o ir —w hile hot and wheels in full le ft turn CHEVROLET TRUCK SERVICE MANUAL...
Page 22: Independent Front Suspension
PA -2 0 0 5/8” 125-175 Interior PA-300 5/8” 125-175 A ll Other 3/4” 230-250 A damp cloth w ill wipe dust from hard su rfaces. Rem ove upholstery stains as soon as possible b efore CHEVROLET TRUCK SERVICE MANUAL...
Page 23: Extended Vehicle Storage
LUBRICATION 0-21 N EVE R G ASO LINE N A P H T H A they set and becom e d ifficu lt to rem ove. Washday de A N Y C LE A N IN G PU RPO SE. tergen ts o r the s e v e ra l clean ers and spot re m o v e rs a v a il...
Page 24: Lubrication Diagrams
6,000 M iles Chassis Lubricant A s requ ired Not shown R ear A x le 6,000 M iles M u lti-Pu rpose A s requ ired Check See Lubrication Section ^Replace Lubricator at 24,000 mile intervals. CHEVROLET TRUCK SERVICE MANUAL...
Page 25 Check - add fluid No. 11 o r equivalent when n ecessary ^R eplace L u b ricator at 24,000 m ile in terva ls. * * D ie s e l Engine not illu strated . CHEVROLET TRUCK SERVICE MANUAL...
Page 26 6,000 M ile s C hassis Lubricant 6 places as requ ired M u lti-Pu rpose A s requ ired Check R ear A x le 6,000 M iles See Lubrication Section ^Replace Cam Lubricator at 24,000 mile intervals. CHEVROLET TRUCK SERVICE MANUAL...
Page 27 6 places as requ ired 6 Cam su rfaces R ear A xle 6,000 M iles M u lti-Pu rpose As requ ired Check See Lubrication Section ^Replace Lubricator at 24,000 mile intervals. **D iesel Engine not illustrated. CHEVROLET TRUCK SERVICE MANUAL...
Page 28 M u lti-Pu rpose 2 places as requ ired W heel B earings - MA60 S e ries *U nder favo ra b le d riving conditions, 25,000 m iles. ** D ie s e l Engines not illustrated. CHEVROLET TRUCK SERVICE MANUAL...
Page 29 M u lti-P u rp ose A s requ ired Check See Lubrication Section T h ro ttle B e ll Crank - L -6 6,000 M ile s Engine Oil A s requ ired ♦Replace Lubricator at 24,000 mile intervals. CHEVROLET TRUCK SERVICE MANUAL...
Page 30 . F ig . 10— L u b ric a tio n - T ilt C ab M odels CHEVROLET TRUCK SERVICE MANUAL...
Page 31 The b lo w er m otor, heater core, and hose as- The heater operates on outside a ir only with the blow er F ig . 1 — D eluxe A ir H e a te r S chem atic CHEVROLET TRUCK SERVICE MANUAL...
Page 32 In operation, three F ig . 3 — D eluxe A ir H e a te r C o n tro l Panel le v e r s control a ll heater operations (fig. 3). CHEVROLET TRUCK SERVICE MANUAL...
Page 33 Check hood alignment. Connect battery ground cable. Tilt Cab Removal 1. Disconnect the b attery ground cable. F ig . 5 — D e luxe A ir H eater Assembly CHEVROLET TRUCK SERVICE MANUAL...
Page 34 12. R em ove screw s which attach the inner co re retaining plate to the core case (not the screw s at the core corn ers). F ig . 6 — D eluxe A ir H e a te r Hoses (T y p ic a l) CHEVROLET TRUCK SERVICE MANUAL...
Page 35 11. Attach the a ir and d e fro s te r door cables and check adjustment. F ig . 10— D e luxe A ir H eater D is trib u to r and Ducts CHEVROLET TRUCK SERVICE MANUAL...
Page 36 T R O L A SSE M B LY replace the affected cable o r R em ove cables fro m the control unit one by one and cables. Check cable adjustment b efo re in stalling control CHEVROLET TRUCK SERVICE MANUAL...
Page 37 Replacem ent of the therm ostatic valve (tilt cab only) covered under B LO W ER, CORE CASE AND CORE A S S E M B LY . F ig . 14— D e luxe A ir H eater W irin g CHEVROLET TRUCK SERVICE MANUAL...
Page 38 HEATER AND AIR CONDITIONING 1A-8 CHEVROLET TRUCK SERVICE MANUAL...
Page 39 Sight Glass R eplacem en t......... 1A-11 1A-29 Four-Season S y s t e m ........... GM Chevrolet System ..........1A-12 Blower A ssem b ly ............1A-29 General I n fo r m a t io n ..........
Page 40 In the full con trol le v e r s make use of bowden cables to activate the H O T position, all a ir flow s through the heater core. F o r CHEVROLET TRUCK SERVICE MANUAL...
Page 41 The re frig e ra n t lin es are routed fro m the engine d e fro s te r ducts. com partm ent to the b lo w er-ev a p o ra to r unit between the CHEVROLET TRUCK SERVICE MANUAL...
Page 42 G M CHEVROLET SYSTEM The GM C h evrolet System is available as a d ea ler - in stalled a ccessory fo r C IO -30 and K10-20 s e r ie s trucks.
Page 43 Temp Knob Fig. T h is knob may be regulated to control the degree of 22 —G M C h e v ro le t System C o n tro ls CHEVROLET TRUCK SERVICE MANUAL...
Page 44: Precautions In Handling R E Frig E Ra N
• D ischarging la rge quantities of R-12 into a room can usually be done sa fely as the vapor would produce no il l effects; how ever, in the event of an accidental F ig . 23—System C ontam inants CHEVROLET TRUCK SERVICE MANUAL...
Page 45 F o r this sam e reason the o il container should not be J-8393 F ig . 2 4 — C ha rg in g S ta tio n CHEVROLET TRUCK SERVICE MANUAL...
Page 46: C Harging Station
F ailu re to warm o il w ill result in blown fuse. F ig . 2 5 —C h a rg in g S ta tio n G auge Set CHEVROLET TRUCK SERVICE MANUAL...
Page 47: Leak Testing The System
Since R-12 is h eavier than a ir, it is 15 oz. disposable cans are gen era lly used fo r good p ra ctice to p lace open end of sam pling tube m iscellan eou s operations such as flushing. CHEVROLET TRUCK SERVICE MANUAL...
Page 48: Compressor Oil
. The follow in g fixed condi • Inspect condenser re g u la rly to be sure that the fins tions must be adhered to in o rd e r to make it possible to CHEVROLET TRUCK SERVICE MANUAL...
Page 49: Perform Ance D A T
D isch arge A ir The follow in g P e rfo rm a n c e Data define norm al op era Tem p era tu re* tion of the system under the above conditions. R ela tive CHEVROLET TRUCK SERVICE MANUAL...
Page 50: Evaporator Control Valve (P O
34.0 psig. — 9000 ft. 34.5 psig. — 10000 ft. THERMOSTATIC SWITCH R oof-M ounted and G M Chevrolet Systems Th ese system s make use of a th erm ostatic switch with an a ir sensing ca p illa ry.
Page 51: Expansion V A L V
Be sure that EXTERNAL EQUALIZER LINE OUTLET F ig . 3 1 —Th erm ostatic S w itc h A dju stm e n t F ig . 3 2 — Expansion V a lv e CHEVROLET TRUCK SERVICE MANUAL...
Page 52: Engine Idle Compensator
Evacuating and Charging System frig e ra n t. O il lo ss can be e a s ily detected on rag at disch arge line. 1. Install charging station and purge system as noted CHEVROLET TRUCK SERVICE MANUAL...
Page 53 HEATER AND AIR CONDITIONING 1A-23 MUFFLER HIGH PRESSURE POA VALVE LOW PRESSURE GAUGE FITTING GAUG E FITTING COMPRESSOR CH ARG ING STATION CONTROLS F ig . 3 3 —C harging S chem atic (Four-Season System Shown) CHEVROLET TRUCK SERVICE MANUAL...
Page 54: Refrigerant Quick-Check Procedure
15 minutes after the system add 6 fluid oz. of new re frig e ra tio n o il to the reaches 28-29 inches vacuum. replacem ent com p ressor. CHEVROLET TRUCK SERVICE MANUAL...
Page 55: Component Replacement And Minor Repair
2. Rem ove the re c e iv e r-d e h y d ra to r and discard the unit. Hose Clamps 3. Flush condenser to rem ove fo reig n m a teria l which has been pumped into it. When hose clam p connections a re encounted, sp ecial CHEVROLET TRUCK SERVICE MANUAL...
Page 56 This may requ ire rem oving the cutting o ff the hose. Cutting the hose length body inner side panels to gain a ccess to the hoses. w ise may resu lt in this problem . 2. Discharge the system . CHEVROLET TRUCK SERVICE MANUAL...
Page 57 HEATER AND AIR CONDITIONING 1A-27 F ig . 3 5 —Compressor M o u n tin g s CHEVROLET TRUCK SERVICE MANUAL...
Page 58 4. Evacuate, charge and check the system . G M Chevrolet System Th is system makes use o f individual hoses, attached at eith er end by hose clam ps.
Page 59: Receiver-Dehydrator
Do not attempt to rep a ir 5. Rem ove the b low er assem bly mounting screw s. the re c e iv e r-d e h y d ra to r. CHEVROLET TRUCK SERVICE MANUAL...
Page 60: Evaporator C O R
1. Pu rge re frig e ra tio n system drain 5. Detach the expansion valve c ap illa ry bulb from the radiator. evap orator outlet pipe. 2. Disconnect battery ground cable. CHEVROLET TRUCK SERVICE MANUAL...
Page 61 1. Check the position of the blow er and evaporator case to fir e w a ll sea ls then position the case o v e r the studs F ig . 3 9 —A / C and H eater Hose Routing CHEVROLET TRUCK SERVICE MANUAL...
Page 62: Heater C A S
4. Disconnect the expansion va lve inlet and outlet con nections and cap the lines. 5. Rem ove expansion valve to bracket mounting screw F ig . 4 0 — H e a te r and Ducts and rem ove expansion valve. CHEVROLET TRUCK SERVICE MANUAL...
Page 63: Muffler, Connector Block And Hose Assembly
"O " ring sea ls coated with clean r e fr ig e r a tion oil. Tighten the connector block bolt to 20 ft. lbs. 5. Attach the com p ressor in let and outlet hoses at the Assem bly (T y p ic a l) CHEVROLET TRUCK SERVICE MANUAL...
Page 64: Control A S S E M B L
1. P la c e rela y in position and d rive mounting screw s. F ig . 4 3 —A ir C o n d itio n in g C ontrols 2. Connect w iring harness to relay. CHEVROLET TRUCK SERVICE MANUAL...
Page 65: Compressor Clutch Sw Itch
, and in stall the retaining screw s. Mount the flo o r outlet duct to the fir e w a ll with the attaching screw . CHEVROLET TRUCK SERVICE MANUAL...
Page 66: Plenum Air Valve
5. Rem ove the two switch mounting screw s and rem ove the switch assem bly. Installation 1. Install the switch connectors to the sw itch assem bly as noted in F igu re 50. F ig . 4 7 —V acuum Harness CHEVROLET TRUCK SERVICE MANUAL...
Page 67: Intermediate D U C
7. T o install, re v e rs e "R e m o v a l" Steps 1-6. F ig . 5 0 —C o n tro l S w itch C o n n e ctio n s CHEVROLET TRUCK SERVICE MANUAL...
Page 68: Thermostatic Switch, Blower Motor Relay And/Or Blower Motor R E S I S T O
F ig . 53— Blower M o to r In s ta lla tio n CHEVROLET TRUCK SERVICE MANUAL...
Page 69: Expansion V A L V
1. Disconnect the b attery ground cable. F ig . 54— Expansion V a lv e C a p illa r y Bulbs F ig . 5 5 — E vapo rato r C ore In s ta lla tio n CHEVROLET TRUCK SERVICE MANUAL...
Page 70: Muffler And Connector B Lock
F ig . 5 6 —Compressor C o n n e c to r B lock and M u ffle r F ig . 5 7 —W a te r V a lv e CHEVROLET TRUCK SERVICE MANUAL...
Page 71: Vacuum A C Tu A To
Check system operation a fte r the actuator has been installed. G M CHEVROLET SYSTEM BLOWER A N D /O R THERMOSTATIC SWITCHES COMPRESSOR, CONDENSER, RECEIVER- The blow er and therm ostatic switches are located inside DEHYDRATOR A N D SIGHT GLASS the duct assem bly as shown in Figu re 60.
Page 72: Evaporator Core, Expansion Valve, Blower Motor And W H E E Ls
R em ove F ig . 6 3 — E vaporator C ore and Expansion V a lv e L o cation m otor clamp s c re w rem ove the clam p. CHEVROLET TRUCK SERVICE MANUAL...
Page 73 Install the co re outlet line co ver, 4. Connect battery ground cable. making sure that the foam rubber strip is c o r re c tly 5. P erform a n ce test the system . installed. CHEVROLET TRUCK SERVICE MANUAL...
Page 74: Wiring Diagrams
VIEWS INDICATE WIRE E N TR Y SIDE OF CONNECTOR Q—1 2 0 R - ^ CONNE FrO R "R E c"£ PT AC LE "C IG " F ig . 64— Four-Season System W irin g Diagram CHEVROLET TRUCK SERVICE MANUAL...
Page 75 HEATER AND AIR CONDITIONING 1A-45 F ig . 65— R o o f-M o u n te d System W irin g Diagram CHEVROLET TRUCK SERVICE MANUAL...
Page 76 F ig . 66— G M C h e v ro le t System W irin g Diagram...
Page 77 C lu tc h Hub H o ld in g Tool 30 . J -9 4 0 2 Parts Tray 15. J -9 3 9 9 9 /1 6 " T h in W a ll S ocket CHEVROLET TRUCK SERVICE MANUAL...
Page 79 Body mounting is b a sica lly unchanged fo r 1970. Note in te r io r of the cab o r body at joints and weld lines. CHEVROLET TRUCK SERVICE MANUAL...
Page 80 2. Do not try to rem ove re v e a l mouldings while wind shield in body opening. R em ove fro m custom F ig . 2 — Body M o u n tin g N o . 1 CHEVROLET TRUCK SERVICE MANUAL...
Page 81 6. Roof O u te r & Back Panel U pper Cab & D rip M o ld in g C ab - W in d sh ie ld p illa r to W in d s h ie ld H eater to Rocker CHEVROLET TRUCK SERVICE MANUAL...
Page 82 BODY IB -4 F ig . 8 —Cross S ection o f W in d s h ie ld W e a th e rs trip (T y p ic a l) of the rubber w eatherstrip channel o v e r the pinch- w eld flange with a fla t bladed tool such as a tongue d ep ressor, or shaped m ycarta blade (fig .
Page 83 P u ll on loop until cord is within 2" of the upper co rn ers. F ig . 11—W in d s h ie ld G lass and W e a th e rs trip —T iIt Cabs CHEVROLET TRUCK SERVICE MANUAL...
Page 84 - ' .. .i. . > , F ig . 13— P u llin g S trin g to Seal Rubber T ip F ig . 15—Rear V ie w M ir r o r —C o n v . Trucks CHEVROLET TRUCK SERVICE MANUAL...
Page 85 F ig . 17—Instrum ent Panel C om partm ent D oor (G lo v e Box) F ig . 19—C o w l V e n tila to r G r ille In ta ke CHEVROLET TRUCK SERVICE MANUAL...
Page 86 3. Install outside a ir cow l ven tila tor g r ille to top of cowl using screw s (fig . 19). INSTRUMENT PNL. REINF. DASH & F ig . 2 1 —C o w l V e n ti la to r —F /F C ow ls CHEVROLET TRUCK SERVICE MANUAL...
Page 87 3. Rem ove hinges and rubber grom m ets. F ig . 2 3 —E ndgage— Stepside and F le e tsid e F ig . 2 4 —S uburban— L iftg a te R eplacem ent CHEVROLET TRUCK SERVICE MANUAL...
Page 88 R e fe r to R e a r Door G lass in this section. ADJUSTABLE LIFT GATE LATCH ADJUSTABLE] <1 H IN G E S F ig . 2 6 —L iftg a te A djustm ents F ig . 2 8 —Endgate Replacem ent CHEVROLET TRUCK SERVICE MANUAL...
Page 89 6. R e v e rs e the procedu re to install. o r endgate latch as shown in F igu re 29. F ig . 3 0 —Suburban Endgate Assem bly CHEVROLET TRUCK SERVICE MANUAL...
Page 90 F igu re 33. Adjust to dim ension shown and add spacers F ig . 3 4 —Door H inge B olt R e p la c e m e n t-J -2 2 5 8 5 as required. CHEVROLET TRUCK SERVICE MANUAL...
Page 91 They must be rep laced with parts of the sam e p art numbers o r with F ig . 3 6 —Rear Door In s ta lla tio n Panel and Suburban CHEVROLET TRUCK SERVICE MANUAL...
Page 92 1. Install hinge snugly on p illa r in sam e location as F ig . 3 8 —Lock Rotor C o ve r Assem bly and S trik e r P late hinge rem oved. CHEVROLET TRUCK SERVICE MANUAL...
Page 93 1. R egulate the door window gla ss to the fu ll down position. F ig . 4 2 —V e n ti la to r Assem bly Removal CHEVROLET TRUCK SERVICE MANUAL...
Page 94 F ig . 4 4 —R egulator Assem bly & Glass (S ide Door) CHEVROLET TRUCK SERVICE MANUAL...
Page 95 Handles a re retained by clips. F ig . 4 6 —In s ta llin g Trim Panel Seal F ig . 4 8 — Lock C y lin d e r In s ta lle d CHEVROLET TRUCK SERVICE MANUAL...
Page 96 6. R em ove r e a r rem ote con trol through la rg e door ac stallin g trim and handles. cess hole. 6. In stall rem ote con trol s ill knob. 7. Guide the attaching rod with the fron t rem ote control CHEVROLET TRUCK SERVICE MANUAL...
Page 97 F ig . 5 1 —Side Rear D oor C e n te r Remote A ssem bly Removal CHEVROLET TRUCK SERVICE MANUAL...
Page 98 5. Start one end of the glass into its channel in the w eatherstrip. Using a pointed tool, follo w around F ig . 5 3 —Side Rear D oor Front Remote & Rod Removal CHEVROLET TRUCK SERVICE MANUAL...
Page 99 The ap plication of too much clean er may d estroy these F ig . 5 6 —In s ta llin g W e a th e rs trip Insert w ith J -2 1 8 9 CHEVROLET TRUCK SERVICE MANUAL...
Page 100 C o v e r A s s y ., Back C ushion Pad, Back C ushion 5 8 . U n ive rsa l Riser K it 5 9 . Fastener C lip , C ushion 6 0 . Ride Level In d ic a to r CHEVROLET TRUCK SERVICE MANUAL...
Page 101 BODY IB-23 <s> ADJUSTER SCREW AN D LEVER ASSY. F ig . 5 9 —E xploded V ie w o f Level Ride Seat CHEVROLET TRUCK SERVICE MANUAL...
Page 102 6. Replace preload adjuster assem bly being sure that Any point within the 4” tr a v e l may be selected by m ov Nos. 38 through 41 a re in th eir p ro p er positions. CHEVROLET TRUCK SERVICE MANUAL...
Page 103 T his operation fr e e s (2) w ashers (No. 15). F ig . 6 1 —A d ju s te r Lever F ig . 6 3 —Seat L u b ric a tio n CHEVROLET TRUCK SERVICE MANUAL...
Page 104 These p rovid e a quick and lasting re p a ir in the squeegee, Figure W ork the m a te ria l into the case of sm a ll cracks, surface im perfection s, dents, etc. CHEVROLET TRUCK SERVICE MANUAL...
Page 105 F ig . 6 8 —A p p ly in g Resin to F ib er glass F ig . 6 6 —F in is h in g P lastic S older Repair CHEVROLET TRUCK SERVICE MANUAL...
Page 106 4. P ro te c t surrounding panels by masking b efore p e r R ep a ir Kit. form in g paint refinishing operations. U se only non staining type masking tapes. F ig . 7 2 —T y p ic a l P itte d Panel CHEVROLET TRUCK SERVICE MANUAL...
Page 107 B e v el the attaching edges of the panels F ig . 7 3 —T y p ic a l C racke d Panel F ig . 7 4 —C ra cke d Panel P reparation (T y p ic a l) CHEVROLET TRUCK SERVICE MANUAL...
Page 108 2. Install screw s into the hinges and torque to 25 in. lbs. F ig . 7 5 —T o p -to -H e a d e r Panel A tta ch m e n ts F ig . 7 6 —L iftg a te H inge CHEVROLET TRUCK SERVICE MANUAL...
Page 109 2. Rem ove the screw s which retain the control assem bly to the liftgate. 3. R em ove the con trol assem bly by disconnecting the F ig . 7 8 —T a il G a te W e a th e rs trip CHEVROLET TRUCK SERVICE MANUAL...
Page 110 F ig u re 80. Fig. 8 1 —D rivers Seat M o u n tin g Provisions F ig . 8 3 —Passengers B ucket Seat M o u n tin g Provisions CHEVROLET TRUCK SERVICE MANUAL...
Page 111 REAR COMPARTMENT FLOOR M A T Removal and Installation 1. L o w e r ta il gate. 2. Rem ove the spare tir e and its mounting bracket. 3. R em ove the re a r seat. CHEVROLET TRUCK SERVICE MANUAL...
Page 112 Item s not co vered herein may be s e rv ic e d as out- DEFROSTER DIFFUSERS ENGINE COMPARTMENT SEAT FORE A N D AFT ADJUSTMENT 1 SEAT PEDESTAL LOCK P-20-30 SERIES F ig . 8 7 —P20 and 30 In te rio r CHEVROLET TRUCK SERVICE MANUAL...
Page 113 WINDSHIELD A N D FRONT QUARTER GLASS R elease catch and open the lid of the engine housing to s e rv ic e or rem ove the battery. Both windshield and fron t qu arter glass are retained in CHEVROLET TRUCK SERVICE MANUAL...
Page 114 1. R elea se catch, open engine box lid and lock hinge a rm in open position. F ig . 9 0 —D rivers W in d o w W e a th e rs trip CHEVROLET TRUCK SERVICE MANUAL...
Page 115 sonable ease. 14. Install sliding window lock keeper on fro n t edge of F ig . 9 2 — In s ta llin g S lid in g Glass CHEVROLET TRUCK SERVICE MANUAL...
Page 116 "C o m p le te D r iv e r ’ s Window im portant that they be in stalled c o r re c tly . Without .’ ’ Installation Begin with operation 3 and continue CHEVROLET TRUCK SERVICE MANUAL...
Page 117 CAB H O L D -D O W N C ATCH H O L D -D O W N CATCH F ig . 9 5 —T ilt Cab Latch M e chanism F ig . 9 6 —C o n tro l Panel CHEVROLET TRUCK SERVICE MANUAL...
Page 118: Service O P E Ra Tio N
C H E C K LIN K A N D RELEASE R O D RELEASE R O D LEVER CAB REAR MOUNTING CAB FRONT MOUNTING F ig . 9 7 —T ilt C ab M o u n tin g CHEVROLET TRUCK SERVICE MANUAL...
Page 119 9. R aise cab sligh tly, to c le a r cab lift m echanism , then F ig . 9 9 —T i lt C a b P o s itio n — Torsion Bar U n lo a d e d CHEVROLET TRUCK SERVICE MANUAL...
Page 120 C H E C K LEFT CAB SU PPO R T BRACKET F ig . 101—A lig n in g B racke t Bolt Holes F ig . 103—R ight Hand Support B racket and C heck Link Fastenings CHEVROLET TRUCK SERVICE MANUAL...
Page 121: Removal
22-7/8" fro m center of hole in c le v is to center of hole in rod to insure positive engagem ent of cab lock in latch. F ig . 105—T ilt C ab Latch M echanism CHEVROLET TRUCK SERVICE MANUAL...
Page 122: Cab Insulation
CA U TIO N : A lw ays w ear heavy glo ves to p r e s a ry to rem ove the undercoating fro m that area. vent p ossib le injury when handling glass. CHEVROLET TRUCK SERVICE MANUAL...
Page 123: Removal
B locks are then rotated 1/2 turn so that BODY VENTILATION wide notch engages glass and narrow notch engages pinchweld. Outside a ir enters cab through a vent (fig . I l l ) d irectly CHEVROLET TRUCK SERVICE MANUAL...
Page 124 ATTACHING HOLES ASSEMBLE SPRING IN PROPER HOLE SHOW N. THIS IS A SAFETY ITEM, TO INSURE CHECK LINK OPERATION WHEN TILTING CAB. F ig . 108—C heck Link Assem bly (T y p ic a l) CHEVROLET TRUCK SERVICE MANUAL...
Page 125: Windshield Wipers
D O O R S ADJUSTMENTS Door Assem bly in Cab Opening DOOR ADJUSTMENTS D oors can be adjusted fo r alignment or clearan ce in cab door opening, and fo r proper latching. Door CHEVROLET TRUCK SERVICE MANUAL...
Page 126 10. R e ta in in g Bolts 6 . Shaft Ferrule 11. M o to r Assem bly R eta in ing N u t F ig . 112—Fresh A ir V e n t Assy. (In cludes B racket) CHEVROLET TRUCK SERVICE MANUAL...
Page 127 "S t r ik e r Bolt A dju stm en t." To Reposition Door In or O ut (Fig. 117) NOTE: H orizon tal cap screw slots exist in cab F ig . 115— Instrum ent Panel C om partm ent CHEVROLET TRUCK SERVICE MANUAL...
Page 128 ___tfH B . NOTE: A ll door s tr ik e r parts, including shims F ig . 118— Door S trik e r Bolt and bolts, are im portant attaching parts in that CHEVROLET TRUCK SERVICE MANUAL...
Page 129 Make sure the thin pla stic w asher is located F ig . 120—S ight C h e c k in g S trik e r B olt A lig n m e n t next to cab p illa r. CHEVROLET TRUCK SERVICE MANUAL...
Page 130 O -rin g seal in handle. F ig . 121— D oor O u ts id e H andle F ig . 122— D isengaging H and le Spring R eta in er CHEVROLET TRUCK SERVICE MANUAL...
Page 131 F ig . 124— D oor Lock In s ta lla tio n obtain sa tisfa ctory lock operation. CHEVROLET TRUCK SERVICE MANUAL...
Page 132: W Indow R E G U La To R
In stall door window regu la tor in r e v e r s e o rd e r of screw s. CHEVROLET TRUCK SERVICE MANUAL...
Page 133 If binding occurs, around edge of glass approxim ately 1.24 inch fro m edge (fig . 129). WINDOW ASSEMBLY F ig . 127—Rem oving D oor Glass CHEVROLET TRUCK SERVICE MANUAL...
Page 134 Steel W asher — Bushing Clam p.___ N ylon Friction Bushing F ig . 130— Door V ent W in d o w F ig . 132—V e n t W in d o w Disassembled CHEVROLET TRUCK SERVICE MANUAL...
Page 135 4. Install run channel into door fram in g and channel F ig . 133— Door W e a th e rs trip In sta lle d F ig . 135—D riv e r's Seat Assem bly CHEVROLET TRUCK SERVICE MANUAL...
Page 136: Rear Glass W I N D O
Cleaning of soft trim and s e r v ic e of optional le v e l rid e cess to engine. CHEVROLET TRUCK SERVICE MANUAL...
Page 137 BODY IB-59 VIEW IN DIRECTION OF ARROW A Fig . 137—A u x ilia r y Seat CHEVROLET TRUCK SERVICE MANUAL...
Page 138: Special T O O L
3. J -2 2 5 8 5 — Front D oor H inge B olt W ren ch 4. J — 9 3 16—' W in d s h ie ld C h e c k in g Blocks CHEVROLET TRUCK SERVICE MANUAL...
Page 139 Fig . 2 - 4 0 - 6 0 Series Frame—T y p ic a l Fig . 1 - 1 0 - 3 0 Series Frame—T y p ic a l CHEVROLET TRUCK SERVICE MANUAL...
Page 140 B with a v e r tic a l vent bolt from working and w earing. D r ill out and line poin ter length o f 8-1/4 inches, and at point E with a ream hole (o r holes) to the bolt O.D. CHEVROLET TRUCK SERVICE MANUAL...
Page 141 — — ^-T- i - f — ^ o * O f l L ^ J } ^ " ------------------- N -------------------- M----------------► ^ ---------------------------------------- ► F ig . 4 —K A 1 0 5 Frame CHEVROLET TRUCK SERVICE MANUAL...
Page 142 Fig . 5 — 1 0 -3 0 Series T ruck Frame...
Page 143 --------------- , © N ♦-V—1 ® M ----------- — ------------ -i-.... e s ----------------- 1 ..DIM EN SIO N S TO HOLES OR SLOTS ARE MEASURED TO THE CENTER OF HOLE OR SLOT G AUG E HOLES ARE % " DIAMETER ©...
Page 144 D IM EN SIO N S TO HOLES OR SLOTS ARE MEASURED TO THE CENTER OF HOLE OR SLOT G AUG E HOLES ARE % " DIAMETER © IN D IC A T E S THAT THE D IM E N S IO N IS TO THE UNDERSIDE OF THE FRAME TOP SURFACE OR INSIDE OF THE FRAME OUTER SURFACE.
Page 146 149-1/8 MA5, 617 15-7/8 13-1/2 20 15-3/4 15-3/4 15-3/4 20 36 137-1/4 168-1/4 222-1/4 14-5/8 16-3/4 16-3/4 167-1/8 M A5, 620 15-7/8 13-1/2 20 15-3/4 15-3/4 15-3/4 20 36 137-1/4 192-1/4 252-1/4 14-5/8 16-3/4 16-3/4 185-1/8 CHEVROLET TRUCK SERVICE MANUAL...
Page 147 13-1/8 14-1/8 T A 620 190-1/4 2 57 -1/ 2 33-1 /2 26 -3 / 8 14-1/8 16-7/8 15-3/4 20 15-3/4 17 20 15-3/8 140-1/2 16-3/4 16-3/4 11-3/4 1 3-1 / 8 14-1/2 T A 625 CHEVROLET TRUCK SERVICE MANUAL...
Page 149 These control arm s are The unequal length control arm c o il spring independent connected to the steerin g knuckle through pivoting b a ll suspension is used on the forw ard control P - 10-20-30 CHEVROLET TRUCK SERVICE MANUAL...
Page 150 This adjusting nut to spindle fasten er is assem bly. Rem ove dust cap fro m end of hub and important attaching part in that it could withdraw spindle cotter pin. a ffect the perform an ce o f vital components and CHEVROLET TRUCK SERVICE MANUAL...
Page 151 front wheel on an alignm ent machine and adjust stop ment is obtained. This adjustment should resu lt in screw s , as shown in F igu re 3 to the follow ing dim ensions: CHEVROLET TRUCK SERVICE MANUAL...
Page 152 “ A ” and the c a ste r-ca m b e r chart should inspected c o rre c te d w here necessary. F ig . 4 —Front End A lig n m e n t CHEVROLET TRUCK SERVICE MANUAL...
Page 153 Fron t A xle R epair la te r in this section. F ig . 7—C a s te r-C a m b e r Shims— 1 0 -3 0 Series CHEVROLET TRUCK SERVICE MANUAL...
Page 154 (fig . 13). ings-A dju st, then low er veh icle on hoist. F ig . 8—C aste r Shinns— I Beam F ig . 9 —T iltin g Tie Rod Sockets CHEVROLET TRUCK SERVICE MANUAL...
Page 155 3. W ithdraw shock ab sorb er and inspect rubber eye Removal bushings. d e fective, rep la ce shock absorber 1. R aise veh icle on hoist and rem ove nuts and bolts assem bly. CHEVROLET TRUCK SERVICE MANUAL...
Page 156 F ig . 14—Shock A bsorber L o c a tio n —C P I0 -C 2 0 -3 0 F ig . 12— In s ta llin g Bearing Cup (T y p ic a l) CHEVROLET TRUCK SERVICE MANUAL...
Page 157 F ig . 16—Tool J -2 2 7 3 9 M o u n te d on J a c k F ig . 18—C h e c k in g Lower B all J o in t (T y p ic a l) CHEVROLET TRUCK SERVICE MANUAL...
Page 158 3. Install B all Stud R em o ver J-8806 (fig . 19), p osition F ig . 2 1 — P o sitio n in g Lower C o n tro l Arm S h a ft CHEVROLET TRUCK SERVICE MANUAL...
Page 159 Tape shim s and spherical spacers to gether and tag fo r p ro p er relocation when con- Ball tr o l arm is rein stalled . F ig . 2 3 — Removing Low er J o in t CHEVROLET TRUCK SERVICE MANUAL...
Page 160 B efore tightening nuts, in sert ca ster and cam retention of this part. b e r shims in the sam e o rd e r as when rem oved. CHEVROLET TRUCK SERVICE MANUAL...
Page 161 1. Jack c ro s s m e m b e r into p osition under fra m e with spring eye to ensure p rop er alignm ent of in sta ll fra m e side r a il lo w e r flange mounting bolts. spring with spring hanger. CHEVROLET TRUCK SERVICE MANUAL...
Page 162 F ig . 2 8 — ( C - P l0 - 2 0 -3 0 ) Shock A bsorber L o c a tio n F ig . 3 0 —Removing S pring Eye Bushing CHEVROLET TRUCK SERVICE MANUAL...
Page 163 “ U ” bolt sp acers, and allow to drop. R em ove c a ster shims and set aside fo r rein stallation . F ig . 3 3 — Removing S pring Eye Bushing CHEVROLET TRUCK SERVICE MANUAL...
Page 164 F ig . 37—F ro n t S pring Rear H anger F lo a tin g Cam- 5000^ A x le Shown F ig . 3 5 — In s ta lle d P osition o f O ffs e t Bushing CHEVROLET TRUCK SERVICE MANUAL...
Page 165 Tap kingpin out fro m bottom and withdraw s t e e r I f kingpin is damaged, it must be replaced during r e a s ing knuckle, shim, and thrust b earin g pack. sem bly o f steerin g knuckle. CHEVROLET TRUCK SERVICE MANUAL...
Page 166 This kingpin upper nut to kingpin fa s ten er is an im portant attaching part in that it F ig . 4 0 —C h e c k in g S te e rin g K n u ckle Free Play CHEVROLET TRUCK SERVICE MANUAL...
Page 167 6. L o w e r axle cen ter and rem ove fro m under veh icle. replacem en t becom es n ecessa ry . Do not use a Tape o r w ire cam ber shims to spring seats. CHEVROLET TRUCK SERVICE MANUAL...
Page 168 8. L o w er veh icle on hoist. CHEVROLET TRUCK SERVICE MANUAL...
Page 169 S picer hypoid g e a r axle unit each front wheel. The tra n sfer case con trol le v e r must equipped with s teerin g knuckles. A xle assem bly number CHEVROLET TRUCK SERVICE MANUAL...
Page 170 19. S pindle 5 . Lock Ring 9 . W h e e l Bearing Seal 12. S te e rin g K n u ckle 16. A x le 20. Brake B acking P late CHEVROLET TRUCK SERVICE MANUAL...
Page 171 5. O u te r C lu tc h R e ta in in g Ring 13. A c tu a tin g Cam Body F ig . 4 6 —Hub Key Positions (K -1 0 ) 6 . In te rn a l Snap Ring CHEVROLET TRUCK SERVICE MANUAL...
Page 172 " L O C K ” p osition — g ro o ve s in knob must fit into 6. Back o ff inner adjusting nut and retighten to 30-40 actuator cam body. ft. lbs. while hub is being rotated. CHEVROLET TRUCK SERVICE MANUAL...
Page 173 They must be replaced with parts A x le Joint Components— Repair o f the same part numbers o r with equivalent a. Rem ove lock rin gs by rem oving p ressu re fro m CHEVROLET TRUCK SERVICE MANUAL...
Page 174 Do not use a replacem ent part of these parts. le s s e r quality or s u b s t i t u t e design. Torque CHEVROLET TRUCK SERVICE MANUAL...
Page 175 35 ft. lbs. expense. It must be replaced with one o f the L o w er ve h icle on hoist. CHEVROLET TRUCK SERVICE MANUAL...
Page 176 Remover and In s ta lle r (Use w ith J — 2 3 4 5 4 — 1 and -2 ) L o ckin g N uts Torquing 6. J -2 3 4 4 8 In s ta Ile r— Hub Inn er B earing Cup (use w ith J -8 0 9 2 ) CHEVROLET TRUCK SERVICE MANUAL...
Page 177 Series C20, place tool on bushing and p re s s bush NOTE: A ll tie rod attachments a re important attaching parts in that they could a ffect the p e r ing into rod eye until tool contacts rod. CHEVROLET TRUCK SERVICE MANUAL...
Page 178 placem ent becom es n ecessary. Do not use r e placem ent parts o f le s s e r quality o r substitute design. Torque values must be used as sp ecified CHEVROLET TRUCK SERVICE MANUAL...
Page 179 F iq . 6 —S prinq C lam p In s ta lla tio n (Series C - F ig . 4 —C o n tro l Arm Bushing R eplacem ent P10 and C 20) (Series C -P 1 0 and C 20) CHEVROLET TRUCK SERVICE MANUAL...
Page 180 Torqu e values must be used as specified during reassem bly to assure prop er retention o f these parts. F ig . 8 —A u x ilia r y Rear S pring (Series C 1 0 -C 2 0 ) CHEVROLET TRUCK SERVICE MANUAL...
Page 181 5. Disassemble and remove bushing installation tools. F ig . 11— In s ta llin g S pring Eye Bushing (K 1 0 -2 0 Series) CHEVROLET TRUCK SERVICE MANUAL...
Page 182 F ig . 13— In s ta llin g S pring Eye Bushing (Series 40 , 50 and 60) CHEVROLET TRUCK SERVICE MANUAL...
Page 183 5. Inspect s p rin g --re p la c e bushing, rep a ir or replace to maintain alignm ent, but not tight enough to spring unit as outlined in this section. bind spring action. CHEVROLET TRUCK SERVICE MANUAL...
Page 184 TORQUE ROD BRACKETS TOP P L A T E S ^ *. SPRING SADDLE SADDLE CROSS TUBE EQUALIZING BEAMS F ig . 16—Tandem Rear Suspension CHEVROLET TRUCK SERVICE MANUAL...
Page 185 1. A x le B racket 5. Bolt 2. E q u a liz e r Beam 6. N u t 3. End Bushing 7. Washer Fig. 20— Torque Rod Stud 4. A d a p te r CHEVROLET TRUCK SERVICE MANUAL...
Page 186 2. Inspect each spring le a f fo r cracks o r breaks and F ig . 2 1 — Removing and In s ta llin g S pring Eye replace any that are damaged. Bushing w ith Tool J -8 4 5 9 CHEVROLET TRUCK SERVICE MANUAL...
Page 187 Assembly spring ends in place at fra m e hangers. Coat spring le a ve s with a light film o f graphite g rea se. CHEVROLET TRUCK SERVICE MANUAL...
Page 188 8. Position veh icle so suspension supports weight and tighten a ll nuts to specifications. F ig . 2 3 —A d a p te r and R e ta in in g B o lt a t A x le B racket CHEVROLET TRUCK SERVICE MANUAL...
Page 189 3. Rem ove nut fro m torque rod stud at axle housing 1. Position torque in a vise and in stall fra m e bracket. bracket and nut. Torqu e nut to sp ecification s. Install CHEVROLET TRUCK SERVICE MANUAL...
Page 190 NOTE: Recheck the torque on these nuts after specification s. approxim ately 500 m iles of d rivin g. DRIVE LINE REAR AXLE (CHEVROLET) SINGLE-SPEED INDEX Page Page 4-14 4-23 General D e s crip tio n ................
Page 191 The 11,000 and the 13,500, 15,000 and 17,000 lb. capac w hile others use a four-pinion d iffe re n tia l. ity, sin gle-sp eed hypoid axles, illu strated in Figu res 27 CHEVROLET TRUCK SERVICE MANUAL...
Page 192 CHEVROLET TRUCK SERVICE MANUAL...
Page 193 5. P inion Bearing Assem bly 10. D iffe r e n tia l S pider 14. A x le S haft 18. D iffe r e n tia l Case (R ight H a lf) CHEVROLET TRUCK SERVICE MANUAL...
Page 194 Such p ra c tice s as ra isin g tir e p ressu re to e lim i nate tir e noise, listen ing fo r the noise at va ry in g speeds test. CHEVROLET TRUCK SERVICE MANUAL...
Page 195 . Install brake drum and wheel and tire a s F ig . 2 9 — D iffe r e n tia l P inion S h a ft Removal CHEVROLET TRUCK SERVICE MANUAL...
Page 196 F ig . 3 0 —S e c tio n a l V ie w o f Housing a t W hee l Bearing F ig . 3 2 —W heel Bearing a n d /o r O i l Seal In s ta lla tio n CHEVROLET TRUCK SERVICE MANUAL...
Page 197 Pinion Flange, Dust Deflector a n d /o r O il Seal Replacement 1. R aise veh icle on hoist. A llo w axle to hang fr e e . F ig . 3 4 — M easuring P inion Bearing Preload CHEVROLET TRUCK SERVICE MANUAL...
Page 198 F i g . 3 6 — D r i v e P in io n F l a n g e R e m o v a l ( H e a v y D u t y ) CHEVROLET TRUCK SERVICE MANUAL...
Page 199 4. On C, K and P20 s e rie s veh icles, connect hand brake form ance vital components system s, cables and adjust parking brakes as specified in and/or could resu lt in m ajor re p a ir expense. Section 5. CHEVROLET TRUCK SERVICE MANUAL...
Page 200 F ig . 4 3 —Removing A x le S haft (1 1,00 0, 13, 50 0 attaching b o lts --to rq u e b olts to sp ecifications. and 15,000 lb . A x le CHEVROLET TRUCK SERVICE MANUAL...
Page 201 B o lt N u t O i l D e f l e c t o r 1 4 . B e a r in g A d ju s t in g N u t CHEVROLET TRUCK SERVICE MANUAL...
Page 202 6. Rem ove o il seal. F ig . 4 6 — Removing Bearing A d ju s tin g N u t (T y p ic a l) CHEVROLET TRUCK SERVICE MANUAL...
Page 203 F ig . 4 9 — Removing Bearing R eta in er Ring b earin gs (if req u ired ) b efore p roceeding. (5200 and 7200 lb . A x le ) CHEVROLET TRUCK SERVICE MANUAL...
Page 204 F ig . 5 1 —Removing Hub O u te r Bearing (1 1,00 0, fo r 15,000 lb. axle with 15 x 5 brake and M50 tra ilin g 13,500 and 15,000 lb . A xles) CHEVROLET TRUCK SERVICE MANUAL...
Page 205 W heel b olts a re s e rra te d and may also be swaged in using appropriate tool until seal is p ro p erly seated p lace; how ever, replacem ent procedure rem ains sam e fo r both types o f installation. (fig . 55). CHEVROLET TRUCK SERVICE MANUAL...
Page 206 4 . O u t e r B e a r in g A s s e m b ly 8 . D e f l e c t o r sition o f adjusting nut slot. CHEVROLET TRUCK SERVICE MANUAL...
Page 207 F ig . 5 8 —T ig h te n in g W heel Hub B earing A d ju s tm e n t N u t (T y p ic a l) CHEVROLET TRUCK SERVICE MANUAL...
Page 208 , checking fo r fr e e rotation. above, rem ove and inspect the No-Spin. DRIVE LINE REAR AXLE (CHEVROLET) TWO-SPEED INDEX Page Page 4.39 General D e s c rip tio n ................... 4-32 Shifter Spring R e p la ce m e n t..............
Page 209 2 5 . M a g n e t i c C h i p C o l l e c t o r 9 . D i f f e r e n t i a l C a r r i e r CHEVROLET TRUCK SERVICE MANUAL...
Page 210 (thru the autom atic switch) to the other field m oves the nut toward the bottom of the screw (fig. 64). CHEVROLET TRUCK SERVICE MANUAL...
Page 211 F ig . 6 5 —S h ift U n it in Low Range P osition F ig . 6 3 — E le c tric S h ift U n it M o unte d CHEVROLET TRUCK SERVICE MANUAL...
Page 212 6. Push down on d riv e screw assem bly (23) until b e a r ing assem bly (10) is fr e e o f housing. F ig . 6 8 —Removing S h a ft, A c tu a tin g Lever and S pring CHEVROLET TRUCK SERVICE MANUAL...
Page 213 placed by new gaskets to assure p rop er sealing o f the unit. F ig . 70— Removing M o to r W irin g Lock N uts CHEVROLET TRUCK SERVICE MANUAL...
Page 214 1. R em ove clam ps on hose connections at the vacuum with new gasket and the three retaining bolts and lock cylin d er and slip hoses o ff the connecting fittin gs. w ashers and tighten secu rely. CHEVROLET TRUCK SERVICE MANUAL...
Page 215 T es t operation of shift system . F ig . 74—V acuum C o n tro l S h ift C a b le Removal F ig . 7 2 —A d ju s tin g Push Rod CHEVROLET TRUCK SERVICE MANUAL...
Page 216 Both axles are equipped with a straddle mounted d rive shafts have been rem oved. pinion. Pinion bearings are o f the opposed tapered r o lle r CHEVROLET TRUCK SERVICE MANUAL...
Page 217 installation o f w heel bearin g nuts. ing p re -lo a d and ring g e a r -d r iv e pinion backlash. CHEVROLET TRUCK SERVICE MANUAL...
Page 218 If no clearan ce exists, this indicates ex cessive w ear at studs, tapered dow F ig . 77—A x le V e n t R eplacem ent els, o r flange h oles— replace worn part if n ecessary. CHEVROLET TRUCK SERVICE MANUAL...
Page 219 I.D. p a rtic le s o f gasket a re rem oved from outer end of hub bearing contact su rface on O.D. o f axle hub, axle shaft, and hub cap. housing tube. CHEVROLET TRUCK SERVICE MANUAL...
Page 220 C h evrolet Single-Speed axle. R e fe r to “ R ear A x le (Chev- axles are p erfo rm ed the same as those outlined fo r the ro le t) Single-Speed” . CHEVROLET TRUCK SERVICE MANUAL...
Page 221 T h ere may be occasions, how ever, when it w ill be n ecessary. n ecessa ry to rem ove the com plete assem b ly as a resu lt CHEVROLET TRUCK SERVICE MANUAL...
Page 222 If test lamp does not light, trouble may be a short See “ A x le Vent R ep lacem en t” Eaton Single-Speed A xle. circu it in w irin g harness o r control switch, o r a w ire CHEVROLET TRUCK SERVICE MANUAL...
Page 223 Rem ove piston housing c o v e r and " O ” ring The test lamp should ligh t in low range position of sea l, replace seal w henever co v e r rem oved. CHEVROLET TRUCK SERVICE MANUAL...
Page 224 F ig . 8 4 —C le v is Pin Removal o r In s ta lla tio n fe lt w ipers fo r distortion . F e lt w ipers are o il soaked CHEVROLET TRUCK SERVICE MANUAL...
Page 225 Torque values must be used as sp ecified with c a r r ie r assem bly in stalled during rea ssem b ly to assure p ro p e r retention o f veh icle. this part. CHEVROLET TRUCK SERVICE MANUAL...
Page 226 Both sys- F ig . 87—Tandem Rear A x le and Power D iv id e r CHEVROLET TRUCK SERVICE MANUAL...
Page 227 As a ir pressu re fo rc e s the piston outward, Rem ove the cotter pin and the c le v is pin which s e the d ifferen tia l lock is shifted into locked position. CHEVROLET TRUCK SERVICE MANUAL...
Page 228 REAR SUSPENSION AND DRIVE LINE 4-52 ■'I Fig. 88 — Forward Rear A x le A ssem bly— E xploded V ie w CHEVROLET TRUCK SERVICE MANUAL...
Page 229 Inspect a ll p arts fo r w ear, replace if damaged in any F ig . 89— D iffe r e n tia l Lock S w itc h and W a rn in g L ig h t In s ta lla tio n way. CHEVROLET TRUCK SERVICE MANUAL...
Page 230 17. L o c k -O u t S h ift Lever 9. C y lin d e r (In n e r H a lf) F ig . 9 2 —D iffe r e n tia l Lock C o n tro l Knob CHEVROLET TRUCK SERVICE MANUAL...
Page 231 The ball bearin g is a perm anently sealed (fig . 94). and lubricated type. CHEVROLET TRUCK SERVICE MANUAL...
Page 232 -life feature. packing in a retain er which screw s on the end of the s lee v e . CHEVROLET TRUCK SERVICE MANUAL...
Page 233 In sert trunnion in p ro p e lle r shaft yoke and p ress grea se reta in ers slin g ers ( i f used) fro m bearings into yoke and o v e r trunnion hubs fa r bearing. enough to in sta ll lock rings. CHEVROLET TRUCK SERVICE MANUAL...
Page 234 (28 total). Retain bearings with a heavy grea se. A ssem ble seals to bearing F ig . 9 6 — D riv in g O u t Bearing Cups cups. CHEVROLET TRUCK SERVICE MANUAL...
Page 235 4 . J -7 5 7 4 - 6 Series C 20 T ie Rod Bushing In s ta lle r 9. J -2 2 6 2 0 S pring Eye Bushing Remover and In s ta lle r 5. J — 8518 Series C -P 1 0 Tie Rod Bushing In s ta lle r CHEVROLET TRUCK SERVICE MANUAL...
Page 236 16. J -1 3 1 3 Torque W re n c h -ft. lbs. In s ta lle r - L ig h t D uty A x le -U s e d w ith J -8 0 9 2 CHEVROLET TRUCK SERVICE MANUAL...
Page 237 9. J -0 8 7 0 S lid e Hammer w ith A d a p te r 20. J — 2 619 10. J -2 2 3 5 9 W heel Bearing In s ta lle r CHEVROLET TRUCK SERVICE MANUAL...
Page 239 A dual system is standard on school bus m odels and and r e v e r s e motion. optional on other m odels. CHEVROLET TRUCK SERVICE MANUAL...
Page 240 The shoes anchor at F ig . 2 —S e lf A d ju s tin g Brake CHEVROLET TRUCK SERVICE MANUAL...
Page 241 G u id e B olt N u t Lock Lower W heel C y lin d e r 4— F ig . W agn er Type “ F ” Front L e ft Brake W ire 13. B acking P late CHEVROLET TRUCK SERVICE MANUAL...
Page 242 F ig . 6 —W agner Type "F R -3 A " Rear and "F A " Front G u id e Piston Spring Push Rod S e lf A d ju s tin g Brake Piston C y lin d e r CHEVROLET TRUCK SERVICE MANUAL...
Page 243 5. R em ove mounting sc re w and rem ove switch fro m veh icle. Installation 1. Make sure new switch is clean and fr e e of dust and lint. If any doubt exists, wash switch in D eclene or equivalent, and dry with a ir. CHEVROLET TRUCK SERVICE MANUAL...
Page 244 2. A t one adjusting slot, in sert suitable tool such as J-4707 through slot and engage adjusting w heel (fig . Fig . 10—Pedal T ra v e l Tool In sta lle d CHEVROLET TRUCK SERVICE MANUAL...
Page 245 "D e c le n e ” or equivalent. d irection . Back o ff adjustment as follow s: F ig . 12—A d ju s tin g Type “ F R -3 " Rear Brakes CHEVROLET TRUCK SERVICE MANUAL...
Page 246 (fig . 16) one end o f the hose into the container (fig . 16). F ig . 15—C o rre c t M a in C y lin d e r F lu id Level CHEVROLET TRUCK SERVICE MANUAL...
Page 247 CA U TIO N : DO N O T M OVE THE V E H IC LE U N - T I L A FIR M P E D A L IS O B T A IN E D . CHEVROLET TRUCK SERVICE MANUAL...
Page 248 Install c le v is pin and co tter pin, then tighten lock wheels. No drag should be present. nut on rod end. CHEVROLET TRUCK SERVICE MANUAL...
Page 249 L o w er re a r w heels. Rem ove jack and wheel against drum by a le v e r —operated cam. blocks. CHEVROLET TRUCK SERVICE MANUAL...
Page 250 F ig . 2 2 — P -2 0 -3 0 P arking Brake System Fig. 2 3 —In te rn a l E xpanding P arking Brake CHEVROLET TRUCK SERVICE MANUAL...
Page 251 “ Secondary Piston b ilitie s a p a rticu la r m aster cylin d er. These CHEVROLET TRUCK SERVICE MANUAL...
Page 252 Pump the rem aining fluid fro m the cylin d er by P la ce a fla t washer on a one inch sc re w (threaded to d epressin g the push rod. scre w into tapped h ole), thread s crew into CHEVROLET TRUCK SERVICE MANUAL...
Page 253 F ig . 2 8 —D ual M a in C y lin d e r —E x p lo d e -1 0 - 2 0 -3 0 CHEVROLET TRUCK SERVICE MANUAL...
Page 254 4. A ssem b le a new p rim a ry seal p ro tector and p rim a ry seal o v e r the end of the secondary piston with the lined in this section. CHEVROLET TRUCK SERVICE MANUAL...
Page 255 CHEVROLET TRUCK SERVICE MANUAL...
Page 256 15 Gasket 21 Stop Plate -5245 9 Reservoir Housing 22 Retainer Ring F ig . 3 2 —D ual System M a in C y lin d e r 4 0 -5 0 - 6 0 CHEVROLET TRUCK SERVICE MANUAL...
Page 257 F ig . 3 3 —Tool fo r B leedin g 4 0 -6 0 Dual C y lin d e r CHEVROLET TRUCK SERVICE MANUAL...
Page 258 9. Separate brake shoes by rem oving adjusting sc re w and spring. F ig . 3 5 —Brake A d ju s te r Access H ole CHEVROLET TRUCK SERVICE MANUAL...
Page 259 7. Secure the p rim a ry brake shoe (sh ort lining faces F ig . 3 8 —C h e c k in g A c tu a tin g Lever O p e ra tio n CHEVROLET TRUCK SERVICE MANUAL...
Page 260 F ig . 4 0 —B acking P late C o n ta c t Surfaces F ig . 4 2 —C h e c k in g Brake Shoe L in in g C le a ra n c e Using Tool J -2 1 1 7 7 CHEVROLET TRUCK SERVICE MANUAL...
Page 261 F ig . 4 4 —T w in p le x S e lf A d ju s tin g Rear Brakes 40 and 50 Series F ig . 4 6 —Removing Brake Shoe H old Down Pins Using J -2 2 3 4 8 CHEVROLET TRUCK SERVICE MANUAL...
Page 262 10. C a refu lly pull lo w e r edges o f wheel cylin d er boots away fro m cylin d ers. If brake fluid flow s out, o v e r F ig . 4 7 —Brake Shoe and S e lf A d ju s te r Assembly CHEVROLET TRUCK SERVICE MANUAL...
Page 263 F ig . 4 9 — P o s itio n in g A c tu a to r Lever resu lts. CHEVROLET TRUCK SERVICE MANUAL...
Page 264 6 0 Series—Front (W a g n e r Type “ F” ) Removal (Figs. 51 and 52 ) Jack 52— assem bly. Fig. W agn er Type “ F” R ight Front Brake CHEVROLET TRUCK SERVICE MANUAL...
Page 265 G u id e Bolt Low er W hee l C y lin d e r s c re w openings in anchor supports. G u id e B olt N u t Lock W ire B acking Plate CHEVROLET TRUCK SERVICE MANUAL...
Page 266 10. To rem ove w heel cylinder, rem ove connecting tubing, 5. Recondition o r replace drum as necessary. Inspect anchor bolt and mounting screw s. brake flange plate fo r o il leakage past axle shaft o il CHEVROLET TRUCK SERVICE MANUAL...
Page 267 L ay wedge on web with s e r r a 0.005-inch below lining su rface, rep la ce with new tions against matching serra tio n s on the wedge guide, plug. CHEVROLET TRUCK SERVICE MANUAL...
Page 268 U-hooks c le a r the until drag just is re lie v e d . eccen trics on shoe webs, then rem ove th e ir s m a lle r CHEVROLET TRUCK SERVICE MANUAL...
Page 269 Install adjuster spring with short hook G u id e Piston Spring Push Rod Piston 7. C y lin d e r on starw heel crank fin ger so that its long shank hook CHEVROLET TRUCK SERVICE MANUAL...
Page 270 Push pistons, cups and spring out of c y l inder. Duo-Servo and Tw inplex type wheel cylin d ers are N A TU R E AS THESE SO LVENTS D E T E R IO R A T E CHEVROLET TRUCK SERVICE MANUAL...
Page 271 PA10 CA-KA10-20, CA30 PA 20-30 F ig . 6 1 —P arking Brake Levers C - K - P 1 0 -2 0 -3 0 M o dels CHEVROLET TRUCK SERVICE MANUAL...
Page 272 F ig . 6 3 —P arking Brake Levers C -P -M and S 4 0 -6 0 Series CHEVROLET TRUCK SERVICE MANUAL...
Page 273 3. On re a r, assem ble drum assem bly o v e r hub studs d ire cted under “ B leeding B ra k e s and in stall retaining screw s, if used. CHEVROLET TRUCK SERVICE MANUAL...
Page 274 V IE W A V IEW C VIEW D V IEW A EW B VIEW C CA 30 CA314 F ig . 6 4 — P arking Brake System C -1 0 -2 0 -3 0 Series CHEVROLET TRUCK SERVICE MANUAL...
Page 275 See Maintenance and Adjustments fo r brake pedal adjustment. 2. Disconnect main cylin d er push rod c le v is at lo w er CHEVROLET TRUCK SERVICE MANUAL...
Page 276 R e fe r to hand brake le v e r s and cable routing as shown 2. Back o ff nuts fro m “ J ” bolt slow ly because of spring p ressu re. by F ig u re s 60 through 65. CHEVROLET TRUCK SERVICE MANUAL...
Page 277 3o Check lining to band a ir gap. A .010" fe e le r must not to output shaft by a cen ter bolt, place lock washer en ter at any point. special s e rra te d fla t w asher on bolt. Install CHEVROLET TRUCK SERVICE MANUAL...
Page 278 9. Rem ove the clip holding the brake le v e r to the p r i o f w asher o v e r rein forcem en t and side of washer m ary shoe (shoe with short linin g). o v e r hex of anchor pin. CHEVROLET TRUCK SERVICE MANUAL...
Page 279 Continue adjustment until shoes are tight against 5. Rem ove bolts attaching plate to transm ission re a r drum and drum cannot be rotated by hand. Back o ff bearing cap, then rem ove plate. CHEVROLET TRUCK SERVICE MANUAL...
Page 280 F i g . 7 1 — H y d ra u lic Brake Tube F la rin g Tool F ig . 7 2 —S in g le and D oub le Lap F lare CHEVROLET TRUCK SERVICE MANUAL...
Page 281 The M a ster-V a c pow er brake unit p erm its the use o f m anifold vacuum and atm ospheric p ressu re fo r its pow er. a low brake pedal as w e ll as le ss pedal e ffo rt than is CHEVROLET TRUCK SERVICE MANUAL...
Page 282 4. Disconnect p ressu re b leed er. pedal to tra v e l only 3/4 strok e. C lose pow er c y l 5. Apply brakes and check a ll lin es fo r leaks. inder valve. CHEVROLET TRUCK SERVICE MANUAL...
Page 283 If the plunger assem b ly m oves outward fo llow in g procedu res. CHEVROLET TRUCK SERVICE MANUAL...
Page 284 F ig . 7 8 —Frame M o u n te d S in g le D iaphragm Power Brake System (D u a l System) F ig . 7 9 —Frame M o u n te d D ual D iaphragm Power Brake System (S in g le System) CHEVROLET TRUCK SERVICE MANUAL...
Page 285 4. U nscrew adjusting bolt fro m actuator. coated with lubricant to assure smooth, fr e e op- F ig . 8 1 —Vacuum Booster U n it F ig . 8 2 — D ual Vacuum Booster U n it CHEVROLET TRUCK SERVICE MANUAL...
Page 286 F ig . 8 4 —A u to m a tic A d ju s te r C om ponents F ig . 8 6 —In s ta llin g A d ju s te r Bolt CHEVROLET TRUCK SERVICE MANUAL...
Page 287 2. Position p ressu re housing on non-pressure housing that scrib e m arks made at disassem bly are F ig . 88—T ig h te n in g C ham ber C o lle t N u t aligned. CHEVROLET TRUCK SERVICE MANUAL...
Page 288 Roller Retaining Cage Wedge Spring Retainer 24 Wedge Spring 25 Washer 26 Cotter Pin 27 ’’Failsafe” Air Chamber 28 Standard Air Chamber 29 Lock Washer 30 Nut Fig. 8 9 —Stopm aster Brake Components —E xplode CHEVROLET TRUCK SERVICE MANUAL...
Page 289 “ F a il-S a fe " cham ber s e rv ic e . F ig . 9 1 — In s ta llin g Seal on A n c h o r P lunger CHEVROLET TRUCK SERVICE MANUAL...
Page 290 8. R em ove autom atic adjuster components as d escribed in applicable p roced u res. F ig . 9 3 —P lunger Seal In s ta llin g Tool Dim ensions F ig . 9 5 —W edge C a v ity in Housing CHEVROLET TRUCK SERVICE MANUAL...
Page 291 Use drain cock o r r e should be cleaned o r replaced. m ove head and/or block pipe plugs. CHEVROLET TRUCK SERVICE MANUAL...
Page 292 If the co m p ressor does not function as d escrib ed above, F ig . 9 7 —R elay V a lv e CHEVROLET TRUCK SERVICE MANUAL...
Page 293 5 psi high o r sure to use the c o r r e c t spring, otherw ise uneven recom m ended. Many state m otor veh icle braking w ill result. CHEVROLET TRUCK SERVICE MANUAL...
Page 294 9. A lign co m p ressor d riv e adjust p ro p er belt tension. F ig . 9 9 —A ir Brake C ham ber In s ta lle d CHEVROLET TRUCK SERVICE MANUAL...
Page 295 1. Disconnect a ir line and push rod yoke. 8. R elea se hold on push rod and in sta ll rem aining clamp 2. R em ove brake cham ber. rin g nut and bolt. CHEVROLET TRUCK SERVICE MANUAL...
Page 296 11. Rem ove seal (8) fro m va lve (9). Cleaning and Inspection 1. ■ Check mounting flange fo r cracks o r breakage. 2. D iscard a ll rubber p arts. F ig . 100— G o v e rn o r CHEVROLET TRUCK SERVICE MANUAL...
Page 297 8. V e e Seal 19. G aske t tion obtained. Adjust the stop sc re w as 9. Shim W asher 20. Stop Screw 10. S pring fo llow s: 21. C age CHEVROLET TRUCK SERVICE MANUAL...
Page 298 Replace diaphragm if any piston. P la c e o rig in a l shim s o r 2 s e r v ic e shims o f these conditions are found. CHEVROLET TRUCK SERVICE MANUAL...
Page 299 3. Enter sm all end o f w orm shaft through hole in body 9. C o ve r P late 4. Lever and w orm . P r e s s w orm shaft into w orm and body, 5. Plug CHEVROLET TRUCK SERVICE MANUAL...
Page 300 2. R em ove c o tter pin, spindle nut, sp acer and outer bearing. F ig . 105—Removing C am shaft (T y p ic a l) CHEVROLET TRUCK SERVICE MANUAL...
Page 301 With brakes relea sed , the angle fo rm ed by the push U nscrew and rem ove. rod and cam shaft le v e r must be g re a te r than 90° and CHEVROLET TRUCK SERVICE MANUAL...
Page 302 8. Shoe Return S pring 4. Brake Shoe 1. Position va lve stop bushing, sprin g and disc va lve in 9. R o lle r Pin 5. A n c h o r Pin Lock Ring body. CHEVROLET TRUCK SERVICE MANUAL...
Page 303 12. Lock Ring 2. S pacing Washers 6. Cam shaft B racket Cham ber B racke t 13. S la ck A d ju s tin g 3. Seal 7. Seal R etainer 10. Spacer N u t CHEVROLET TRUCK SERVICE MANUAL...
Page 304 1. Position diaphragm, spring cap and spring on low er panel. body. 3. R eplace lamp socket and gauge line. 2. A lign upper body with lo w er body, in stall four screw s 4. Thoroughly check gauge connection fo r leakage. and secure. CHEVROLET TRUCK SERVICE MANUAL...
Page 305 D IA P H R A G M F ig . 110—S a fe ty V a lv e LOW ER BO D Y F ig . 113— Pressure P ro te c tio n V a lv e (Cross S ection ) CHEVROLET TRUCK SERVICE MANUAL...
Page 306 “ p iggy back” on the a ir cham ber non pow er spring b efore attem pting to m ove the p ressu re housing o f the S TO P M A S T E R B RAKE (F ig . 114). veh icle. CHEVROLET TRUCK SERVICE MANUAL...
Page 307 6. R em ove sealin g compound located at joint between and c o v e r the head of it with plastic tape until the s e a le r cap and housing. 7. R em ove lock ring fro m housing. sets. CHEVROLET TRUCK SERVICE MANUAL...
Page 308 The option includes a hand con trol v a lve, T estin g and se rvic in g o f these units is outlined in this double check valve, push pull va lve, tr a ile r connectors, section. CHEVROLET TRUCK SERVICE MANUAL...
Page 309 P“5U -SERVICE LINE SHUT-OFF VALVE DOUBLE CHECK VALVE — ! QUICK RELEASE VALVE PP 3 CONTROL VALVE (WITH MANUAL CONTROL) DRAIN COCK -BRAKE CHAMBER BRAKE CHAMBER F ig . 120—A ir Brake System—T ra iIe r CHEVROLET TRUCK SERVICE MANUAL...
Page 310 Secure by in sta ll cup from piston. ing c o lla r. 9. Rem ove piston return spring fro m body. 10. Install operating le v e r and secure with nut. CHEVROLET TRUCK SERVICE MANUAL...
Page 311 T W O -W A Y CONTROL VALVE (Figs. 124 and 1 2 5 ) A combination limiting and quick release valve and a F ig . 123— D oub le C heck V a lv e CHEVROLET TRUCK SERVICE MANUAL...
Page 312 , they must be smooth and fr e e of nicks. Examine piston b ore in body; b ore must be smooth. Assembly 1. In stall spring on exhaust valve stem position in cage, CHEVROLET TRUCK SERVICE MANUAL...
Page 313 Valve SLIPPERY ROAD POSITION F ig . 125— Front Brake L im itin g and T w o -W a y C o n tro l V a lv e O p e ra tio n CHEVROLET TRUCK SERVICE MANUAL...
Page 314 10. M o u n t i n g N u t 19. C a p S c r e w I I . L o c k W a s h e r secu re with cap screw . CHEVROLET TRUCK SERVICE MANUAL...
Page 315 The tra c to r protection va lv e autom atically c lo ses the “ O” 3. Install ring in va lve seat. s e r v ic e and em ergen cy lines between the tra cto r and CHEVROLET TRUCK SERVICE MANUAL...
Page 316 3. Hold down on the inner spring reta in er and rem ove the snap ring fro m the upper body piston. Removal 4. Rem ove the inner piston spring. 1. Exhaust a ll a ir fro m the system . CHEVROLET TRUCK SERVICE MANUAL...
Page 317 P lu n g e r w it h “ O ” R in g 6 . B o lts a n d L o c k w a s h e r tight F ig. 134. 1 1 . L o w e r B o d y CHEVROLET TRUCK SERVICE MANUAL...
Page 318 NOTE: If the spring, spring housing o r spring plate should need replacin g it is recom m ended F ig . 134—C agin g Tool In s ta lle d CHEVROLET TRUCK SERVICE MANUAL...
Page 319 (See 7. Check fo r leaks. F igu re 136). Check overhaul manual fo r disassem bly and overhaul. CHEVROLET TRUCK SERVICE MANUAL...
Page 320 46. Pipe Plug 3 / 8 " 11. U n lo a d e r Spring 23. C rankcase Assem bly 12. U n lo a d e r S pring Saddle 35. Key 24. Flange G asket CHEVROLET TRUCK SERVICE MANUAL...
Page 321 If binding occu rs, the pump should be rem oved fro m the installation, disassem bled, and inspected fo r faulty parts. F ig . 137— Vacuum Pump CHEVROLET TRUCK SERVICE MANUAL...
Page 322 9. J -2 2 3 6 4 Drum to Brake Shoe C le a ra n c e G a u g e 18. J -2 3 3 3 9 Pressure B leeder A d a p te r CHEVROLET TRUCK SERVICE MANUAL...
Page 323 It is essen tial that im p ro p er com pression be c o r blowing out with com p ressed a ir, then disconnect w ir e s and rem ove plugs. rected b e fo re proceedin g with the engine tune up. CHEVROLET TRUCK SERVICE MANUAL...
Page 324 2. Clean serv ic e a b le spark plugs thoroughly, using an ab ra sive-typ e clean er such as sand blast. F ile the F ig . 2 —Spark Plug D e ta il cen ter electrod e flat. CHEVROLET TRUCK SERVICE MANUAL...
Page 325 Any stiffn ess in the operation o f the vacu F ig . 4 —D is trib u to r (In Line ) CHEVROLET TRUCK SERVICE MANUAL...
Page 326 NEVER BEND BREAKER LEVER F ig . 7 —Testing S p e c ific G r a v ity o f B atte ry Fig . 6 —P o in t A lig n m e n t CHEVROLET TRUCK SERVICE MANUAL...
Page 327 Check and adjust if n ecessa ry fo r c o rre c t tension of F ig . 10—M a n ifo ld Heat C o n tro l V a lv e (T y p ic a l V 8) b elt, as follow s: CHEVROLET TRUCK SERVICE MANUAL...
Page 328 F ig . 12—C rankcase V e n tila tio n F ilte r with it to be burned. The "C lo s e d P o s it iv e " ventilation CHEVROLET TRUCK SERVICE MANUAL...
Page 329 1. Start engine then check ignition dw ell. tim ing light as recom m ended by the m anufacturer o f the 2. If dw ell is not within specification s, adjust dw ell as equipment being used. follow s: CHEVROLET TRUCK SERVICE MANUAL...
Page 330 If dw ell variation exceeds sp ecification s, check fo r worn manual transm ission neutral; 600 rpm with F ig . 15— Ig n itio n Tuning M arks F ig . 16—T u n e -U p D ecal CHEVROLET TRUCK SERVICE MANUAL...
Page 331 700 rpm with manual transm ission in neutral. Adjust m ixture screw s equally in to obtain a 20 F ig . 17—A d ju stin g Id le S oleno id CHEVROLET TRUCK SERVICE MANUAL...
Page 332 F ig . 18—C rankcase V e n tila tio n V a lv e CHEVROLET TRUCK SERVICE MANUAL...
Page 333 1. Rem ove rad iator cap. F ig . 2 0 —Testing C ra n k in g V o lta g e F ig . 2 1 —C o o lin g System Pressure Test CHEVROLET TRUCK SERVICE MANUAL...
Page 334 T h is is v e ry specifications. CHEVROLET TRUCK SERVICE MANUAL...
Page 335 ON PS 10-20-30-40 SERIES: • Disconnect throttle cable at carb u retor and r e • R em ove the engine box and hood as outlined in taining brackets. Section 11. CHEVROLET TRUCK SERVICE MANUAL...
Page 336 a. P osition engine adjacent to the transm ission m em ber and disconnect fro m transm ission. align con vertor with the flyw h eel. CHEVROLET TRUCK SERVICE MANUAL...
Page 337 10. In stall a ir clean er, start engine, check fo r leaks and • Connect em ergen cy brake cable at em ergen cy brake and retaining brackets. adjust carbu retor id le speed and m ixture. CHEVROLET TRUCK SERVICE MANUAL...
Page 338 F ig . 1 L—V a lv e A dju stm e n t an extent that the return sprin g can no lon ger push CHEVROLET TRUCK SERVICE MANUAL...
Page 339 #600 wet/dry Fig . 2 L —A ir A d a p te r Tool F ig . 3 L—Compressing V a lv e Spring CHEVROLET TRUCK SERVICE MANUAL...
Page 340 L o w er engine, install front mount bolts and torque F ig . 4 L —O i l Pan G a s k e t and Seal L o cation to specification s. CHEVROLET TRUCK SERVICE MANUAL...
Page 341 AREAS O N LY F ig . 5 L —Removing O i l Seal (L ow er H a lf) T y p ic a l F ig . 7 L —S e a ling Bearing Cap CHEVROLET TRUCK SERVICE MANUAL...
Page 342 F ig . 9 L — In s ta llin g T o rsional Damper CHEVROLET TRUCK SERVICE MANUAL...
Page 343 F ig . 12L— In s ta llin g O i l Seal (C o ve r In s ta lle d ) F ig . 14L—Tim ing G e a r M arks CHEVROLET TRUCK SERVICE MANUAL...
Page 344 ( 2 9 2 cu. in. Engines) 1. R em ove tran sm ission and/or clutch housing clutch fro m engine. F ig . 16L—C h e c k in g T im in g G e a r Backlash CHEVROLET TRUCK SERVICE MANUAL...
Page 345 F ig . 19L— F ly w h e e l In s ta lla tio n (T y p ic a l) fro m tran sm ission hole c o v e r to allow the engine CHEVROLET TRUCK SERVICE MANUAL...
Page 346 1/4 inch o f mount. then bend tabs of french lock to lock the bolt in place. 5. A lign mount so that guide dowel enters hole in mount, CHEVROLET TRUCK SERVICE MANUAL...
Page 347 • Rem ove the hood as outlined in Section 11. • Rem ove bolts retaining control island to support • Rem ove the rad iator and shroud as outlined in and swing control island forw ard. Section 13. • Disconnect hoses at radiator surge tank. CHEVROLET TRUCK SERVICE MANUAL...
Page 348 Install con verter housing underpan and sta rter. • Continue to ra is e engine until high enough to com e d. Connect throttle linkage and vacuum modulator out eith er side. line. CHEVROLET TRUCK SERVICE MANUAL...
Page 349 F ill with coolant, start engine, adjust ignition tim ing • Install the rad iator, ra d ia tor support and shroud and carburetor idle speed and m ixture and check fo r as outlined in Section 13. leaks. CHEVROLET TRUCK SERVICE MANUAL...
Page 350 2. D isconnect A ir Injection R ea ctor hose at check valve. 3. Disconnect crankcase ven tilation hoses at ro ck er Exhaust - 1, 3, 4, 8 arm c o v e rs . Intake - 1, 2, 5, 7 CHEVROLET TRUCK SERVICE MANUAL...
Page 351 , and rein sta lled in the engine. rem aining portion o f the spark plug and a ssem If d irt, corrosion , carbon, etc. is shown to exist in one ble as shown (fig . 3 V ) . CHEVROLET TRUCK SERVICE MANUAL...
Page 352 7. Install intake m anifold as outlined. 8. Install adjust va lve mechanism as outlined. O il Pan Removal 1. D rain engine oil. F ig . 4 V — •Compressing V a lv e Spring CHEVROLET TRUCK SERVICE MANUAL...
Page 353 3. Install o il pan and torque bolts to specification s. 4. In stall sta rter b race and attaching b olts. Torqu e b olts to specification s. F ig . 6 V —Removing O i l Seal (Low er H a lf) CHEVROLET TRUCK SERVICE MANUAL...
Page 354 6. Install fan belt and adjust to specification s using strand tension gauge. F ill cooling system , start engine and check fo r leaks. F ig . 8 V —S ealing Bearing Cap CHEVROLET TRUCK SERVICE MANUAL...
Page 355 F ig . 12 V — In s ta llin g O il Seal (C ove r In s ta lle d ) CHEVROLET TRUCK SERVICE MANUAL...
Page 356 F ig . 16V —Removing C ra n ksh a ft S pro cket (M ark IV V 8) F ig . 14V —Removing C ra n k s h a ft S pro cket (S m all V 8 ) CHEVROLET TRUCK SERVICE MANUAL...
Page 357 F ig . 18 V — M easurin g C am shaft Lobe L ift F ig . 2 0 V —F lyw h e e l In s ta lla tio n (T y p ic a l) CHEVROLET TRUCK SERVICE MANUAL...
Page 358 5. Lu bricate tim in g chain with engine o il. 5. Torqu e bolts to sp ecification s then bend lock tabs 6. Install fuel pump push rod as outlined in Section 6M. to bolt head. CHEVROLET TRUCK SERVICE MANUAL...
Page 359 'M A R K IV V 8 " SM A LL V8 ■ IN T A K E M A N IF O L D TO RQ UE SEQUENCE •SMALL V 8 ‘ " MARK IV V8' F ig . IT —Torque Sequence CHEVROLET TRUCK SERVICE MANUAL...
Page 360 C rankcase C over Tool & Seal In s ta lle r J -7 0 4 9 34. J -2 2 3 8 2 -1 ( 3 /8 " ) O pe n Hood S a fe ty Stop CHEVROLET TRUCK SERVICE MANUAL...
Page 361 247°F. as fo llo w s: CHEVROLET TRUCK SERVICE MANUAL...
Page 362 The rad iator cap should be washed with clean w ater and in the rad iator, leaky w ater pump o r loose hose connec p ressu re checked at regu lar tune-up in terva ls. Inspect CHEVROLET TRUCK SERVICE MANUAL...
Page 363 2. Rem ove therm ostat housing bolts and rem ove w ater bolts secu rely. outlet and gasket fro m therm ostat housing (fig. 3). CHEVROLET TRUCK SERVICE MANUAL...
Page 364 4. Install fan belt and adjust as previo u sly outlined. w ill aid in aligning hub, pulley and fan. 5. Start engine and check fo r leaks. CHEVROLET TRUCK SERVICE MANUAL...
Page 365 2. Make sure choke is p ro p e rly adjusted and in wide F ig . l c —Transm ission C o n tro lle d Spark E le c tric a l Lead open position - engine w arm . CHEVROLET TRUCK SERVICE MANUAL...
Page 366 F ig . 3 c —Fast Id le A d ju s tm e n t (Rochester M and M V ) F ig . 5 c —Fuel Level S ight Plug (H o lle y ) CHEVROLET TRUCK SERVICE MANUAL...
Page 367 TYPICAL ROCHESTER 2GV VALVE IDLE SCREW ROCHESTER 4 M V F ig . 7 c—T h ro ttle Return C h e ck V a lv e F ig . 6 c —V acuum Break A djustm ent CHEVROLET TRUCK SERVICE MANUAL...
Page 368 7. Connect and adjust a c c e le ra to r and TV linkage. F ig . 9 c —Fuel F ilte r (P ap er-T ype) 8. Connect choke cable o r choke rod. CHEVROLET TRUCK SERVICE MANUAL...
Page 369 • M ove shield to best fit along m anifold and con nect upper end of choke rod. F ig . 11c—C h o ke C o il—V 8 Engine CHEVROLET TRUCK SERVICE MANUAL...
Page 370 F ig . l g —D is trib u to r and G o v e rn o r M o u n tin g CHEVROLET TRUCK SERVICE MANUAL...
Page 371 R em ove the govern or CAUTION: Since the idle ports in the throttle le v e r fro m the throttle shaft, then detach it fro m the CHEVROLET TRUCK SERVICE MANUAL...
Page 372 Vacuum in Check fo r e x ces siv e frictio n in throttle shaft and the go vern or housing can be checked by rem ovin g the throttle le v e r. CHEVROLET TRUCK SERVICE MANUAL...
Page 373 (fig . 4A). A ir tem perature is autom atically controlled by sists o f an accordian pleated oiled paper filt e r supported a therm ostatic va lve which selects warm ed a ir fro m the CHEVROLET TRUCK SERVICE MANUAL...
Page 374 1. R em ove a ir clean er elem ent and rem ove p olyu re thane band fro m paper elem ent. F ig . 3a—O i l Bath A ir C le a n e r CHEVROLET TRUCK SERVICE MANUAL...
Page 375 F ig . 5 a —C le a n in g P o lyure than e Element F ig . 6a—T h erm ostatic A ir V a lv e P e lle t R eplacem ent CHEVROLET TRUCK SERVICE MANUAL...
Page 376 SPRING SNORKEL TUBE AIR INLET AIR INLET HOT AIR PIPE CONTROL DAMPER ASSM CONTROL DAMPER ASSM. HOT AIR PIPE F ig . 8a—A ir C le a n e r O p e ra tio n CHEVROLET TRUCK SERVICE MANUAL...
Page 377 85°F and 115°F. Removal 1. Rem ove a ir clea n er fro m engine. F ig . 12a— Removing Sensor U n it F ig . 10a—C h e c k in g Vacuum Diaphragm CHEVROLET TRUCK SERVICE MANUAL...
Page 378 450-1,000 rpm. If pressu re is CHEVROLET TRUCK SERVICE MANUAL...
Page 379 10 to 12 inches o f vacuum. L e s s than 10 inches fin gers o r heavy grea se may be used to hold fuel o f vacuum indicates an inoperative vacuum pump. CHEVROLET TRUCK SERVICE MANUAL...
Page 380 (See Figu re 5P fo r c o r r e c t placem ent o f a ll parts in rock er arm F ig . 4p—Removing Vacuum D iaphragm and link assem b ly.) CHEVROLET TRUCK SERVICE MANUAL...
Page 381 22. With one hand push pump down against spring tension so it tra vels through half a stroke and hold. With the F ig . 6p— In s ta llin g R ocker Arm and L in k Assembly CHEVROLET TRUCK SERVICE MANUAL...
Page 382 Have flat o f pull rod p a ra lle l to push diaphragm to flexin g stop in body. Tighten a ll vacuum links. c o ver screw s secu rely. CHEVROLET TRUCK SERVICE MANUAL...
Page 383 ENGINE FUEL 6M -19 F i g . I t — E n g in e F u e l S p e c i a l T o o ls CHEVROLET TRUCK SERVICE MANUAL...
Page 385 driven to p erm it transm ission to upshift noid and the distributor. Full vacuum should be obtained into high gear. CHEVROLET TRUCK SERVICE MANUAL...
Page 386 1 — T ra n s m is s io n C o n t r o l l e d V a c u u m S p a r k A d v a n c e S y s te m CHEVROLET TRUCK SERVICE MANUAL...
Page 387 COMBUSTION PIPE ASSEMBLY DIVERTER VALVE AIR INJECTION PUMP CHECK VALVE Fig . 2 —A ir In je c tio n R eactor System F ig . 3 —S chem atic o f A .I.R . System CHEVROLET TRUCK SERVICE MANUAL...
Page 388 • M ove pump until b elt is tight 75 ± 5 lb. used belt or • Install a new d riv e belt and adjust as outlined above. CHEVROLET TRUCK SERVICE MANUAL...
Page 389 With the pump running, bubbles w ill form i f a leak exists (fig. 10). Fig. 8 — Removing C e n trifu g a l F ilte r CHEVROLET TRUCK SERVICE MANUAL...
Page 390 11—A ir Flow Through C heck V a lv e F ig . 13—C h e ckin g fo r V acuum S ig n a l a t D iv e rte r V a lv e CHEVROLET TRUCK SERVICE MANUAL...
Page 391 • Rem ove any carbon build up with a w ire brush. r e lie f valve. • W arped or burnt tubes must be replaced. CHEVROLET TRUCK SERVICE MANUAL...
Page 393 The elem ents a re im m ersed in an ele c tro ly te composed ONE PIECE CELL COVER ELECTROLYTE LEVEL INDICATOR VENT PLUG HOLD-DOWN SLOT HOLD DOWN SLOT TOP TERMINAL SIDE TERMINAL F ig . l b —B atte ry CHEVROLET TRUCK SERVICE MANUAL...
Page 394 IN D IC A T O R F ig . 2 b —In te rn a l V ie w o f C e lls F ig . 3 b —E le c tro ly te a t Proper Level CHEVROLET TRUCK SERVICE MANUAL...
Page 395 N orm al B attery w ater usage is ap p rox im a tely one to two ounces p e r month p er battery. F ig . 5 b —V ie w Inside V ent W e ll CHEVROLET TRUCK SERVICE MANUAL...
Page 396 4. B attery age and condition. te r s fo r the term in als to p rovid e a place fo r attachment Exam ple: A battery that has been subjected to o f the charging leads. CHEVROLET TRUCK SERVICE MANUAL...
Page 397 When using these te s te rs , the p ro tem peratu re indicate that the c e lls have been im cedure recom m ended by the te s te r m anufacturer should CHEVROLET TRUCK SERVICE MANUAl...
Page 398 80 °F. e le c tro ly te tem peratu re is bolt until the term in al is snug with the post. above or below 80 °F., additions o r subtractions must CHEVROLET TRUCK SERVICE MANUAl...
Page 399 4c) consists o f two m ajor parts, a stator and a “ BATT” TERM INAL "F" TERMINAL RELAY TERMINAL ’GRD” TERMINAL "BAT” TERMINAL LIG H T RELAY 5.5" SERIES ID DELCOTRON 6.2" SERIES 2D, TYPE 150 DELCOTRON F ig . l c — D elcotrons CHEVROLET TRUCK SERVICE MANUAL...
Page 400 . On m ost m odels there is a 16 gauge, red w ire CHEVROLET TRUCK SERVICE MANUAL...
Page 401 V O L T A G E S E T T IN G ) FUSIBLE LINK NEG." GENERATOR BATTERY F ig . 4 c —V o lta g e R egulator fo r 130 A M P Sys. CHEVROLET TRUCK SERVICE MANUAL...
Page 402 T e s t-V o ltm e te r M ethod." F ig . 5 c —A d ju st V o lta g e S e ttin g CHEVROLET TRUCK SERVICE MANUAL...
Page 403 3. Connect a v o ltm e ter from battery term in al to a good ground on the gen erator. F ig . 7 c —A m m eter M e th o d O u tp u t Test C o n n e c tio n CHEVROLET TRUCK SERVICE MANUAL...
Page 404 D elcotron - (see D elcotron output test). a. Connect ohm m eter fro m “ F ” term inal to 4. A t norm al idle - p a ra lle l resistance w ire open (See CHEVROLET TRUCK SERVICE MANUAL...
Page 405 2. Turn re s is to r to " o p e n " position. o f the 2 bulbs causes am perage to be too low. CHEVROLET TRUCK SERVICE MANUAL...
Page 406 2. Make the battery light load test. 3. Make a com plete charging system test as follow s: F ig . 12c—A d ju s tin g F ie ld R elay C lo sin g V o lta g e CHEVROLET TRUCK SERVICE MANUAL...
Page 407 4. If the ohm m eter reads high, there is an open, o r 14c— ex cessive resistan ce in the fie ld winding, o r in lead. F ig . V o lta g e Tests CHEVROLET TRUCK SERVICE MANUAL...
Page 408 Figu re 14c, P a r t 1. 2. Connect an am m eter in the c ircu it at the " B A T ” term in al on the gen erator. F ig . 17c—P u lle y Removal CHEVROLET TRUCK SERVICE MANUAL...
Page 409 M O U N T IN G SCREW STUD LEAD -2958 F ig . 18c—T o rqu in g P u lle y N u t Fig. 19c— D e lc o tro n Brush H o ld e r Assem bly CHEVROLET TRUCK SERVICE MANUAL...
Page 410 F ig . 2 1 c —C h e c k in g F ie ld Relay P oint O p e n in g F ig . 2 2 c —C h e ckin g F ie ld Relay A ir G ap CHEVROLET TRUCK SERVICE MANUAL...
Page 411 Tw o brushes c a rry current through F ig . Id — 10-SI Series D e lc o tro n CHEVROLET TRUCK SERVICE MANUAL...
Page 412 • When connecting a ch a rger or a booster E n e rg iz e r be operating norm ally. CHEVROLET TRUCK SERVICE MANUAL...
Page 413 END FRAME FRAME HOLE DIODE CAPACITOR ATTACHING TRI° RECTIFIER n uts BRIDGE F ig . 4 d —D e lc o tro n End V ie w F ig . 5 d —S lip Ring End Frame CHEVROLET TRUCK SERVICE MANUAL...
Page 414 CHARGED E N E R G IZ E R ” , Step 3. If not grounded, check the fie ld winding, diode trio , r e c tifie r bridge rep lace the regu lator. and stator as previou sly covered . CHEVROLET TRUCK SERVICE MANUAL...
Page 415 . fo r p ra ctica l purposes it can be assumed full throttle CHEVROLET TRUCK SERVICE MANUAL...
Page 416 The p ressu re can be adjusted by bending F ig . 2 i — Breaker P late and A tta c h in g Parts CHEVROLET TRUCK SERVICE MANUAL...
Page 417 F ig . 6 i — In a c c u ra te G auge o f Rough Points F ig . 5 i —Top V ie w o f D is trib u to r CHEVROLET TRUCK SERVICE MANUAL...
Page 418 F ig . 8 i —S e ttin g P oint O p e n in g F ig . 9 i — A d ju s tin g D w e ll A n g le CHEVROLET TRUCK SERVICE MANUAL...
Page 419 5. R em ove the r o ll pin retaining the driven gear to the NOTE: Make sure that new condenser lead is mainshaft, slide the gea r from the shaft. installed in prop er position (fig . 6i). CHEVROLET TRUCK SERVICE MANUAL...
Page 420 7. R em ove the weight c o v e r and stop plate screw s, 6. Inspect the cam fo r w ea r or roughness. Then check CHEVROLET TRUCK SERVICE MANUAL...
Page 421 9. Check break er le v e r spring tension which should be 19-23 ounces. (See contact point replacem en t.) 2. Install govern or w eights on th eir p ivot pins, replace CHEVROLET TRUCK SERVICE MANUAL...
Page 422 5.0 inches. Replace hose, then repeat adjustment until reading returns to 5.0 each tim e the and mainshaft. Check shaft for fr e e rotation. On hose is pinched. heavy duty m odels, install shock mounting assem bly. CHEVROLET TRUCK SERVICE MANUAL...
Page 423 Installation—Engine Not Disturbed (A ll M odels) felt. W hile p ressin g fir m ly down on distribu tor housing, 1. Turn the ro to r about 1/8 turn in a clockw ise d ire c - CHEVROLET TRUCK SERVICE MANUAL...
Page 424 It is im portant that the w ire s be installed in th eir location in the supports. Fig . 18i —A d v a n c e W eights In s ta lle d CHEVROLET TRUCK SERVICE MANUAL...
Page 425 (Vacuum Spinner T yp e) d escribed in Section 6M o f this Shop Manual. Cleaning and Regapping In operation, when the engine reaches its governed speed (4000 rpm with standard transm ission o r with Clean the spark plugs thoroughly, using an a b ra sive - CHEVROLET TRUCK SERVICE MANUAL...
Page 426 The aluminum d riv e end hous engine. extended to enclose the entire shift le v e r and CHEVROLET TRUCK SERVICE MANUAL...
Page 427 1. If this voltage drop exceeds 3.5 volts, excessive r e F ro m battery negative post starting m otor sistance in the solenoid control circu it is indicated and should be co rre cted . housing. CHEVROLET TRUCK SERVICE MANUAL...
Page 428 C O M M U T A T O R POLE SHOE SHAFT SEAL BRONZE CLUTCH T-1041 F ig . 3s—S ta rtin g M o to r Cross S e c tio n — H eavy D uty CHEVROLET TRUCK SERVICE MANUAL...
Page 429 6. Connect the battery ground cable and check operation F ig . 4s—S ta rte r M o u n tin g and S oleno id C o n n e ctio n s o f the unit. CHEVROLET TRUCK SERVICE MANUAL...
Page 430 ENGINE-ELECTRICAL 6Y-38 SPECIAL TOOLS J-21501 J 9 6 0 0 -2 J-9717-2 PULLY SHOULDERED SUPPORT ADAPTER INSTALLER TOOL CHECKING J -2 1 6 0 0 SCALE HARNESS ADAPTER F ig . 5s—S p e cia l Tools CHEVROLET TRUCK SERVICE MANUAL...
Page 431 1,000 m iles and r e fille d each 6,000 clutch fo rk and throwout bearing. m iles. When the clutch pedal is depressed, brake fluid is fo rc e d from the main cylinder into the slave cylinder CHEVROLET TRUCK SERVICE MANUAL...
Page 432 F ig . 1—C lu tc h L in ka g e (E x ce p t P 2 0 -4 0 Series)
Page 433 CLUTCHES AND TRANSMISSIONS 7-3 F ig . 2 —C lu tc h Linkage (S tep V an P 2 0 -4 0 Series) CHEVROLET TRUCK SERVICE MANUAL...
Page 434 W here com plaints of fir s t o r r e v e r s e gear clash due to insu fficien t clutch re le a s e are encountered, the follow in g may be helpful. Cut off the existin g clutch pedal stop CHEVROLET TRUCK SERVICE MANUAL...
Page 435 2. Rem ove upper to lo w e r clutch pedal arm bolt and slid e upper arm through flo o r boards. Fig. 6 —A d ju s tin g S lave C y lin d e r Push Rod CHEVROLET TRUCK SERVICE MANUAL...
Page 436 2. Adjust pedal fr e e tra v e l as outlined under M ainte veh icles equipped with a dual m aster cylin der, nance and Adjustm ents. use the same hydraulic fluid and r e s e r v o ir as CHEVROLET TRUCK SERVICE MANUAL...
Page 437 F lu id Entry Port Piston C y lin d e r Body Fig . 13— In s ta lla tio n o f S lave C y lin d e r Boot Piston Seals Push Rod Boot CHEVROLET TRUCK SERVICE MANUAL...
Page 438 C A -K A 1 0 0 -2 0 0 , CA 3 0 0 MODELS CD 5 0 0 -6 0 0 MODELS CG 50 0 MODELS CE-ME-SE 5 0 0 -6 0 0 MODELS CE-ME 6 0 0 MODELS W /R P O CE-CS-SS 4 0 0 , CS-SS 5 0 0 MODELS F ig .
Page 439 3. Replace the other retra ctin g springs in the sam e F ig . 15—C h e c k in g Pressure P late L ift W /D ia l In d ic a to r manner. CHEVROLET TRUCK SERVICE MANUAL...
Page 440 11 ft. lbs. torque. The clutch is now ready to be in stalled. F ig . 17— L u b ric a tio n Points on C lu tc h Throw out CHEVROLET TRUCK SERVICE MANUAL...
Page 441 B e fo re rem oving clutch fro m flyw heel, m ark with a be sure to m ark flyw h eel side. punch the flyw heel, clutch c over and one p ressu re plate CHEVROLET TRUCK SERVICE MANUAL...
Page 442 3. L ift com plete clutch assem bly (with one hole held to top) and slide upper bolt hole o v e r alignm ent stud in Fig. 19—C lu tc h Removal or In s ta lla tio n CHEVROLET TRUCK SERVICE MANUAL...
Page 443 -tr a v e l 5. T o install, r e v e r s e rem ova l procedu re Steps 1-4. in a ll positions. CHEVROLET TRUCK SERVICE MANUAL...
Page 444 9. V isu ally inspect to determ ine i f other equipment, F ig . 2 C —R eplacing Transmission G e a rs h ift Lever CHEVROLET TRUCK SERVICE MANUAL...
Page 445 T o o l J-8109 as shown in F igu re 2C. F ig . 3 C — R epla cing Transfer Case G e a rs h ift Lever CHEVROLET TRUCK SERVICE MANUAL...
Page 446 A ssem b le a good bearin g on the clutch gear righ t side case and rem ove case from shaft and secure it with the clutch gea r bearin g snap adapter. ring. Attach a suitable dial indicator to the rod. CHEVROLET TRUCK SERVICE MANUAL...
Page 447 22834 with A dapter J-22834-1 as required. g. Clean a ll gasket surfaces, then install the re a r bearing cap with a new gasket on the tran sm is sion. Tighten cap screw s fir m ly . CHEVROLET TRUCK SERVICE MANUAL...
Page 448 T r a n s f e r C a s e C o n t r o l A s s y . - B l a z e r M a n u a l CHEVROLET TRUCK SERVICE MANUAL...
Page 449 F ig . 7C —Transfer Case C o n tro l A ssy.— B lazer M a n u a l Transmission 2. P osition sh ifter shaft lip seals (if rem oved) in shaft CHEVROLET TRUCK SERVICE MANUAI...
Page 450 Check and tighten all bolts to sp eci l^VIEW B fied torques. NOTE: B efore connecting prop shafts to com panion flanges be sure locknuts are torqued 250 ft. lbs. Fig. 9 C — Transfer Case M o u n tin g CHEVROLET TRUCK SERVICE MANUAL...
Page 451 2 Island Panel 7 Shift Finger 3 Selector Finger Selector and Shift Rods 4 Clevis 9 Selector and Shift Levers 5 Lock Nuts F ig . I D —T ilt Cab Transmission C o n tro l Linkage CHEVROLET TRUCK SERVICE MANUAL...
Page 452 F ig . 3 D —S picer Remote C o n tro l Assem bly CHEVROLET TRUCK SERVICE MANUAI...
Page 453 (12) to ball joint assem bly (13). R e c o v e r (5), with fla t on r a il toward gasket face. m ove s e le c to r fro m the assem bly (13). CHEVROLET TRUCK SERVICE MANUAL...
Page 454 9. Install ball joint assem bly (13) on r a il se le c to r (12) stall new “ O” ring seal (20) on shift r a il against the retaining with nut (10) and lock washer (11). snap ring. CHEVROLET TRUCK SERVICE MANUAL...
Page 455 3. P osition s e le c to r fin g er (23) in control housing (13); then install sh ifter shaft in housing, aligning splines (15). CHEVROLET TRUCK SERVICE MANUAL...
Page 456 T o o l (J-8109) as shown in Figu re 3C. P r e s s down firm ly on tool and rotate counter clockw ise to relea se g earsh ift le v e r. CHEVROLET TRUCK SERVICE MANUAL...
Page 457 1. Apply a light coating o f High T em p eratu re G rease m ission, follow ing installations o f gearsh ift le v e r to the main d riv e gea r bearing reta in er and splined CHEVROLET TRUCK SERVICE MANUAL...
Page 458 2. Rem ove knob and nut; then rem ove cap, spring cup, plate. and spring. 3. Install in r e v e r s e o rd er. 3. A ssem ble in re v e rs e o rd er. CHEVROLET TRUCK SERVICE MANUAL...
Page 459 1. Mount co ver in v is e and rem ove lock w ire s (3) and 1. P la c e tran sm ission on suitable lift and ra is e into shift fo rk clamp s crew s (4). position. CHEVROLET TRUCK SERVICE MANUAL...
Page 460 2. Insert 1st and 2nd shift rod (6) (longest rod) in bot screw (4) fir m ly and retain with lo ck w ire (3). tom hole o f c o v e r (2) being carefu l not to damage o il seal. CHEVROLET TRUCK SERVICE MANUAL...
Page 461 R e fill capacity is approxim ately 2 qts. also occur. (U.S. m easure 1-3/4 qts. Im p eria l m easu re). If the tran sm ission is found consistently low on oil, a CHEVROLET TRUCK SERVICE MANUAL...
Page 462 2. T o check fo r p ro p er shift linkage adjustment, lift the tran sm ission s e le c to r le v e r towards the s teerin g CHEVROLET TRUCK SERVICE MANUAL...
Page 463 Section 6M fo r each carbu retor installation. T .V . rod. F ig . 3 P G — P o w e rg lid e T .V . Linka ge A d ju stm e n t CHEVROLET TRUCK SERVICE MANUAL...
Page 464 P o w e rg lid e Section of the O verhaul Manual fo r a ll other modulator, and s e r v o co v e r or gasket s e r v ic e may be s e r v ic e operations not co v ere d here. CHEVROLET TRUCK SERVICE MANUAL...
Page 465 2. Im m ed iately check the flu id le v e l with the s e le c to r le v e r in the P A R K position. The engine should be F ig . 5 P G —Pressure Test Plug CHEVROLET TRUCK SERVICE MANUAL...
Page 466 16” Hg. 10” Hg. L -6 250 93-113 125-138 53-75 83-102 48-53 L -6 292 93-113 53-75 83-102 125-138 48-53 V -8 308 103-121 53-75 83-102 125-138 48-53 V -8 350 105-121 53-75 83-102 125-138 48-53 CHEVROLET TRUCK SERVICE MANUAL...
Page 467 L -6 (250) Base Detent Detent (350) LS9 (292) L25 Touch Touch 4.57 A x le 4.57 A x le Wide Open Wide Open 8.75-16.5 T ir e 8.85-16.5 T ir e T h rottle Th rottle CHEVROLET TRUCK SERVICE MANUAL...
Page 468 “ ADD” m ark on the The transm ission o il le v e l should be checked p erio d dip stick with o il hot or at operating tem peratu re. The o il CHEVROLET TRUCK SERVICE MANUAL...
Page 469 H y d r a - M a t i c 3 5 0 C o n t r o l R o d L in k P - M o d e l s C - M o d e Is CHEVROLET TRUCK SERVICE MANUAL...
Page 470 F i g . 3 — T r a n s f e r C a s e S h i f t L e v e r & C o n t r o l L in k K - M o d e l s proceeding. CHEVROLET TRUCK SERVICE MANUAL...
Page 471 Tie lines out tra n s fer case to fra m e bracket attaching b o l t s . of the way. Torqu e to 110 to 150 ft. lbs. CHEVROLET TRUCK SERVICE MANUAL...
Page 472 With the s e le c to r le v e r in the P ark position, the park F ig „ 5 — Pressure Tap Locations ing pawl should fr e e ly engage and preven t the veh icle CHEVROLET TRUCK SERVICE MANUAL...
Page 473 5. O IL COMES OUT V E N T P IP E and with sufficient engine speed to maintain 16 inches a. T ra n sm ission o v e r -fille d . Hg absolute m anifold p ressu re. CHEVROLET TRUCK SERVICE MANUAL...
Page 474 Once the m odulator assem bly passes a ll of the above sures ov e r 6 psi m ay damage the modulator. tests, it is an acceptable part and should be re-used. CHEVROLET TRUCK SERVICE MANUAL...
Page 475 3-2 dn T h ro ttle Position 1-2 up 2-1 dn 2-3 up C losed T h rottle 7-11 13-16 16-13 47-55 50-40 26-36 Detent Tho Touch 63-51 36-19 54-66 W ide Open T h rottle 29-43 CHEVROLET TRUCK SERVICE MANUAL...
Page 476 2-3 up 3-2 dn C losed T h rottle 12-15 14-11 7-11 13-16 16-13 Detent Tho Touch 21-30 44-34 40-48 26-36 47-55 50-40 W ide Open T h rottle 23-35 30-16 46-56 54-43 29-43 36-19 54-66 63-51 CHEVROLET TRUCK SERVICE MANUAL...
Page 477 A hydraulic system p re s s u rize d by a gear type pump ration when ex tra perform ance desired. p rovid es the working p ressu re requ ired to operate the Range can also be used fo r engine braking. CHEVROLET TRUCK SERVICE MANUAL...
Page 478: Fluid Checking Procedure
Fig. I T — C o n t r o l L in k a g e ( C A 10-20, C A 3 0 ) M o d e l s CHEVROLET TRUCK SERVICE MANUAL...
Page 479: Fluid Level Ind Ic A To R
See Section 9 fo r alignment of and allow the le v e r to be positioned in neutral (N ) by steerin g column assem bly i f n ecessary. the transm ission detent. CHEVROLET TRUCK SERVICE MANUAL...
Page 480: Detent Switch Adjustment
12. When p ro p e rly adjusted the follow in g conditions must be m et by manual operation of the steerin g column an opportunity to cool. shift le v e r. T o drain o il proceed as follow s: CHEVROLET TRUCK SERVICE MANUAL...
Page 481: Pressure Regulator Valve
5. R em ove the govern or pipes and manual v a lv e fro m rem ova l. Use new seal and cup plug, if rem oved, and new con trol va lv e body. bottom pan gasket. CHEVROLET TRUCK SERVICE MANUAL...
Page 482: Rear Seal
E r r a tic shifting, pump noise, o r other m alfunctions can The fo llo w in g sequence, based on fie ld experien ce, p ro in som e cases be tra ced to im p ro p er o il le v e l. CHEVROLET TRUCK SERVICE MANUAL...
Page 483: Manual Linkage
- Conditions * A "b la c k light” testing unit may be obtained fro m s e v e r a l d ifferen t tool supplies. CHEVROLET TRUCK SERVICE MANUAL...
Page 484 , the crim ped upper to low er altitude o r b a ro m e tric p ressu re when the housing seam, and the threaded screw sea l (F ig . 5T). vacuum tube is connected. CHEVROLET TRUCK SERVICE MANUAL...
Page 485: Pressure Switch Check
1893 o r s m a ller T e s t lam ps which use s iz e assem bly. bulb, w ill not damage the switch. CHEVROLET TRUCK SERVICE MANUAL...
Page 486 1-2 up 2-1 dn 2-3 up 3-2 dn 1-2 up 2-1 dn 2-3 up 3-2 dn C losed 13-17 15-11 12-15 13-10 Thru d eten t(W .O .T ) 27-37 25-14 55-42 44-54 50-38 49-60 24-33 23-13 CHEVROLET TRUCK SERVICE MANUAL...
Page 487 4. J -5 8 2 4 C lu tc h P ilo t Tool 10. J — 7816 Release Lever A d ju s tin g Tool 5. J — 1448 P ilo t B earing P u lle r CHEVROLET TRUCK SERVICE MANUAL...
Page 488 Speedom eter D riv e G e a r Rsmover In s ta lle r J -5 8 1 4 -1 5 and A d a p te r 15. J -5 7 5 2 Transmission H o ld in g F ix tu re CHEVROLET TRUCK SERVICE MANUAL...
Page 489 M a in s h a ft Rear B earing Lock N u t 6. J -2 2875 3rd Speed Bushing In s ta lle r Instal ler 7. J -2 2 8 3 0 Snap Ring In s ta lle r CHEVROLET TRUCK SERVICE MANUAL...
Page 490 M a in s h a ft and Bearing Assem bly Remover and R eplacer 17. J -6 4 1 6 Rear Bearing R eta in er Seal In s ta lle r 9 . J -6 3 8 2 Reverse Id le S h a ft Remover CHEVROLET TRUCK SERVICE MANUAL...
Page 491 3. J -8 1 0 7 (T R -278 -R ) - D iffe r e n tia l Side Bearing Remover 4 . J — 6418 S y n c h ro n iz e r Hub Remover CHEVROLET TRUCK SERVICE MANUAL...
Page 492 M a in s h a ft B earing Remover 2. J -6 3 8 2 Reverse Id le r G e a r S haft Remover 3. J — 6419 B earing In s ta lle r Set CHEVROLET TRUCK SERVICE MANUAL...
Page 493 A d a p te r Seal In s ta lle r. 6. J -2 1 3 5 9 Rear O u tp u t S haft Bearing R eta in er Seal In s ta lle r. CHEVROLET TRUCK SERVICE MANUAL...
Page 494 A d a p te r Seal In s ta lle r. 5. J -5 5 9 0 Bearing In s ta lle r. 10. J— 6219 Front O u tp u t S haft Bearing In s ta lle r. CHEVROLET TRUCK SERVICE MANUAL...
Page 495 Transmission Case Rear Bushing Remover and Bushing Remover ( N o t Illu s tra te d ) In s ta lle r and G o v e rn o r S upport Bushing Remover J -9 5 3 4 CHEVROLET TRUCK SERVICE MANUAL...
Page 496 12. J -2 3 0 6 2 -2 S ta to r S h a ft Rear Bushing In s ta lle r J -9 5 3 9 -0 1 S tato r S haft Front Bushing Remover CHEVROLET TRUCK SERVICE MANUAL...
Page 497 14. J -2 1 7 9 5 -2 Part o f A b o v e H o ld in g Tool In s ta lle r (N o t Illu s tra te d ) CHEVROLET TRUCK SERVICE MANUAL...
Page 498 Seal P ro te c to r - Forw ard and D ire c t C lu tc h - Inn er 16. J -1 3 1 3 Torque W rench 0 -1 4 0 F t. Lbs. CHEVROLET TRUCK SERVICE MANUAL...
Page 499 T h e follow in g procedure 2. Insert a sm all pipe nipple (sligh tly la rg e r O.D. than recommended. the hose I.D .) into the opposite end of hose. CHEVROLET TRUCK SERVICE MANUAL...
Page 500 It is connected to the cab mounted tank as shown cable is disconnected. in F igu re 3. F ig . 2 —C ab M o unte d Fuel Tank (E xcep t T ilt) CHEVROLET TRUCK SERVICE MANUAL...
Page 501 Removal and Installation n ecessary. 1. Drain tank. 7. T o in stall, r e v e r s e the rem ova l procedu re. Replace 2. R aise veh icle on hoist. all anti-squeak m aterial. CHEVROLET TRUCK SERVICE MANUAL...
Page 502 A ll fu el lin es must be p ro p e rly routed and retained. CHEVROLET TRUCK SERVICE MANUAL...
Page 503 A vacu u m -pressu re cap is used with this system . No The gasoline tank in corporates a special in ternal f ill other type of cap is to be used. lim ite r and also external hose connections. CHEVROLET TRUCK SERVICE MANUAL...
Page 504 cured with clam ps. of the exhaust pipe and c r o s s o v e r pipe assem bly on V-8 CHEVROLET TRUCK SERVICE MANUAL...
Page 505 FUEL TANK AND EXHAUST SYSTEMS 8-7 F ig . 9 —S in g le Fuel F ilfe r System (C G 5 0 -6 0 , Shown as T y p ic a l) CHEVROLET TRUCK SERVICE MANUAL...
Page 506 FUEL TANK AND EXHAUST SYSTEMS 8-8 F ig . 10—V e n t Lines Cab M o u n te d Tanks CHEVROLET TRUCK SERVICE MANUAL...
Page 507 Be sure to clean m anifold stud threads with a w ire brush before installing the new nuts. F ig . 12— In s ta llin g Fuel Line R etainer CHEVROLET TRUCK SERVICE MANUAL...
Page 508 I n s t a l l e r 2 . J - 7 7 7 7 F u e l L in e C l i p I n s t a l l e r CHEVROLET TRUCK SERVICE MANUAL...
Page 509 DO N O T O V E R - F IL L the gear hous- s ecto r shaft. Rem ove pitman arm . Use T o o l J-6632 ing. J-5504 (fig. fo r 10, 20 and 30 S eries and CHEVROLET TRUCK SERVICE MANUAL...
Page 510 1. Set fron t wheels in straight ahead position. T h is can through center position. Specifications fo r be checked by d rivin g ve h icle a short distance on a CHEVROLET TRUCK SERVICE MANUAL...
Page 511 F i g . 4 — S t e e r i n g W h e e l A l i g n m e n t p rop er retention of this part. CHEVROLET TRUCK SERVICE MANUAL...
Page 512 1. With front wheels in the straigh t ahead position place 4. In stall horn button assem bly. steerin g wheel on ste e rin g shaft and align. 5. Connect battery ground cable. CHEVROLET TRUCK SERVICE MANUAL...
Page 513 F i g . 9 — F l e x i b l e T y p e S t e e r i n g C o u p l i n g — 4 0 - 6 0 ship rem o ve bolt fro m coupling clamp. S e r i e s T r u c k s CHEVROLET TRUCK SERVICE MANUAL...
Page 514 Be sure to maintain a coupling to flange 2. P o sitio n bushing and new cork washer on center dim ension o f .250" to .375". On 10-30 s e r ie s trucks, cross. In stall retaining snap ring. CHEVROLET TRUCK SERVICE MANUAL...
Page 515 T h is w ill cause sticky o r binding bearin gs when F ig . 13—C h e c k in g C o u p lin g Pin C e n te rin g reassem bled. CHEVROLET TRUCK SERVICE MANUAL...
Page 516 Do not ham m er the pitm an arm onto the center cavity. CHEVROLET TRUCK SERVICE MANUAL...
Page 517 F ig . 1 6 - 1 0 - 3 0 Series S teering C olum n In s ta lla tio n CHEVROLET TRUCK SERVICE MANUAL...
Page 518 , rotating so that the shift le v e r s c le a r the toe pan D rive out the shift le v e r pivot pin and rem ove the opening. shift le v e r. CHEVROLET TRUCK SERVICE MANUAL...
Page 519 6. In stall lo w e r bearing in the adjusting ring and then sitioning spring and interm ediate coupling housing in stall the adjusting ring, clamp and screw s. (C -K M odels) clam p M odels) to maintain CHEVROLET TRUCK SERVICE MANUAL...
Page 520 The rag joint to 9. Install steerin g wheel as outlined under "S teerin g steerin g shaft flange clearan ce should be .250" to W h eel—In stallation ." .375". 10. Connect battery ground cable. CHEVROLET TRUCK SERVICE MANUAL...
Page 521 6. Connect d irection al signal w irin g harness. 7. Install steerin g wheel as outlined under "S teerin g W h eel—Installation." F ig . 20—C - P l 0 - 2 0 -3 0 Series S teering Linkage CHEVROLET TRUCK SERVICE MANUAL...
Page 522 Lu bricate tie rod ends. 5. R em ove veh icle fro m hoist. F ig . 2 2 — K 1 0 -2 0 Series S teering Linkage 6. Adjust to e-in as d escrib ed in Section 3. CHEVROLET TRUCK SERVICE MANUAL...
Page 523 If rem ova l is d ifficu lt, it may be b olt fro m pitman arm , and m ark relation of arm p osition to shaft. n ecessary to back o ff brake adjustment to in crease CHEVROLET TRUCK SERVICE MANUAL...
Page 524 Loosen secto r lash adjusting sc re w locknut and back (approxim ately 10° each d irection ). Note o ff adjusting s c re w to the lim it of its tra v e l. highest reading. CHEVROLET TRUCK SERVICE MANUAL...
Page 525 10. Check o il le v e l and r e f ill as required. bolt nut. 11. If o il is e x tre m e ly foam y, a llow veh icle to stand a CHEVROLET TRUCK SERVICE MANUAL...
Page 526 F ig . 2 8 — O il Pressure G au ge J — 5176 In s ta lle d g ea r is at fault. CHEVROLET TRUCK SERVICE MANUAL...
Page 527 "M aintenance and Adjustm ents." G rease b a ll joint. 2. Check steerin g gea r fo r p rop er lubricant le v e l. CHEVROLET TRUCK SERVICE MANUAL...
Page 528 F ig . 3 1 —T y p ic a l Power S te e rin g Hose Routings...
Page 529 In . Lb, Torque W ren ch 35 . ^23 In te rn a l P liers 17. J -4 2 4 5 F t. Lb. Torque W ren ch Belt Tension G au ge 18. J -7 3 1 6 CHEVROLET TRUCK SERVICE MANUAL...
Page 531 CHEVROLET TRUCK SERVICE MANUAL...
Page 532: Jacking Instructions
They *C a rg o load reduced by 225# when the veh icle is a re available on m odels as indicated in the table. equipped with hard top. CHEVROLET TRUCK SERVICE MANUAL...
Page 533 *W ith 6” R im s 2930 at 80 - 3060 at 85 - 3170 at 90. A L S O R E F E R TO SIX (1. TH R U 6.) T IR E NOTES ON PAG E 10-2. CHEVROLET TRUCK SERVICE MANUAL...
Page 534 PSI above those s p ecified in the above table for the load being ca rried . ALSO R E F E R TO SIX (1. TH R U 6.) T IR E NOTES ON PAG E 10-2. CHEVROLET TRUCK SERVICE MANUAL...
Page 535 F o r single wheel s e r v ic e consult rim and wheel m anufacturers to determ in e if the rim and wheel a re o f suf ficien t strength fo r the intended s e rv ic e . CHEVROLET TRUCK SERVICE MANUAL...
Page 536 F o r single wheel s e r v ic e consult rim and wheel m anufacturers to determ ine if the rim and wheel a re o f suf ficien t strength fo r the intended s e rv ic e . CHEVROLET TRUCK SERVICE MANUAL...
Page 537 F o r single wheel s e r v ic e consult rim and wheel m anufacturers to determ ine i f the rim and wheel are o f suf ficien t strength fo r the intended s e rv ic e . CHEVROLET TRUCK SERVICE MANUAL...
Page 538: C Orrecting Irregu Lar T Ire Wear
C orn erin g w ea r is discussed fu rther on. along the inside edge of each row in the trea d pattern. F ig . 2 — Front W heels and A tta ch m e n ts CHEVROLET TRUCK SERVICE MANUAL...
Page 539: W Heel And Tire Balancing
It is p o ssib le to m ix d iffe r e n t-s iz e wheel d iscs and d irt on the rim w ill always rotate by its e lf until the heavy CHEVROLET TRUCK SERVICE MANUAL...
Page 540: Tire Removal A N D Installation
40 pounds, assem bly should be deflated, r e positioned rim , re-lu b ric a ted and re-in fla ted . F ig . 4 — In s ta lla tio n o f Spacer Ring CHEVROLET TRUCK SERVICE MANUAL...
Page 541 1. R em ove a ll rust sca le fr o m the rim , side rin g and clam p ring. ing the p rocedu re in Step 4. CHEVROLET TRUCK SERVICE MANUAL...
Page 542 Inflate fro m side opposite the rin g. If no solid w all is a v a il F ig . 12— Iron in O p e ra tin g N o tc h CHEVROLET TRUCK SERVICE MANUAL...
Page 543 9. Retain p ressu re with tool and strik e side rin g down F ig . 14— D isengaging Side Ring from Rim G u tte r ward at a point between operating notch and cutaway CHEVROLET TRUCK SERVICE MANUAL...
Page 544 F ig . 19—C h e c k in g Side Ring fo r Bind on Rim sealing bead may resu lt. CHEVROLET TRUCK SERVICE MANUAL...
Page 545 Using spoon end of t ir e iron with stop F ig . 21 — L iftin g Bead O v e r Rim tow ard rim , w ork p r o g re s s iv e ly around bead using CHEVROLET TRUCK SERVICE MANUAL...
Page 546 F ig . 2 5 —W o rk in g Bead on to Rim F ig . 2 6 —W o rk in g Second Bead o n to Rim F ig . 27— RHP C ontin uou s Side Ring CHEVROLET TRUCK SERVICE MANUAL...
Page 547: Rhp Rims Replacement
• Insure that side ring is com pletely seated b efo re in flatin g tir e . p rie d up so both cutouts a re v is ib le . CHEVROLET TRUCK SERVICE MANUAL...
Page 548 F ig . 3 1 —A p p ly in g Second Bead F ig . 34— Removing Ring F ig . 3 2 — Forcing Ring in to G u tte r F ig . 35— Prying Bead o v e r Edge o f Rim CHEVROLET TRUCK SERVICE MANUAL...
Page 549 4. P r o g r e s s around rim , using 2 to ols, as shown. of rim (fig . 36). T h is w ill fr e e the t ir e fro m the rim . CHEVROLET TRUCK SERVICE MANUAL...
Page 551 Running B o a r d ..............11-11 Hood Assem bly Removal and In s ta lla tio n ......11-4 F ig . 1—F ront End Sheet M e ta l 1 0 -3 0 Series CHEVROLET TRUCK SERVICE MANUAL...
Page 552 Conventional Truck sub-section. F ig . 2 —F ro n t End Sheet M e ta l 4 0 -6 0 Series CHEVROLET TRUCK SERVICE MANUAL...
Page 553 Adjust lock bolt to obtain a secure hood closu re and F ig . 3 —Removing o r In s ta llin g Hood H inge S pring reasonable lock re le a s e e ffo rt. CHEVROLET TRUCK SERVICE MANUAL...
Page 554 V eh icles equipped with a ir conditioning and/or pow er steerin g w ill req u ire sp ecial handling. F ig . 5 — Hood Lock A ssem bly 4 0 -6 0 Series CHEVROLET TRUCK SERVICE MANUAL...
Page 555 F i g . 8 — H o o d L o c k A d ju s t m e n t ( 1 0 th r u 6 0 S e r i e s ) fin a l torque 25 ft. lbs. CHEVROLET TRUCK SERVICE MANUAL...
Page 556 12. R em ove bolts fro m radiator support mount. F ig . 10—R adia tor S upport M o u n tin g CHEVROLET TRUCK SERVICE MANUAL...
Page 557 • R em ove bolt and plug at low er re a r fen d er location. and rem ove. • F o r installation, r e v e rs e the above added procedure. F ig . 11—Fender to Body A tta ch m e n ts CHEVROLET TRUCK SERVICE MANUAL...
Page 558 11. Rem ove bolt securing center g r ille support to radia to r support. 12. Rem ove bolts secu ring hood catch assem bly to radia to r support. CHEVROLET TRUCK SERVICE MANUAL...
Page 559 25. In stall battery and connect leads and w ire s . F ill rad iator with coolant as sp e c ifie d in Section 13. F ig . 17—Fender A tta ch m e n ts 4 0 -6 0 Series CHEVROLET TRUCK SERVICE MANUAL...
Page 560 10. R em ove bolts connecting g r ille to fron t fen d er fro m inside o f engine com partm ent. F ig . 2 0 —Running Board M o d e l 3104 CHEVROLET TRUCK SERVICE MANUAL...
Page 561 Removal and Installation tern a l tooth w ashers, bolts and nuts. Tape is used b efore 1. T ilt the cab to expose engine area. installation. CHEVROLET TRUCK SERVICE MANUAL...
Page 562 F ig . 2 2 — Fron t F end er and Surge Tank Access D oor SPECIAL TOOLS F ig . 2 5 — Hood H inge S pring Remover and In s ta lle r CHEVROLET TRUCK SERVICE MANUAL...
Page 563 CHEVROLET TRUCK SERVICE MANUAL...
Page 564 T ir e s must be inflated to the sp ecified p ressu res. Some states have sp ecia l requirem ents fo r headlamp aim ing adjustment and these requirem ents must be known and follow ed. CHEVROLET TRUCK SERVICE MANUAL...
Page 565 The bulbs may be r e term inals. 6. T o install, r e v e r s e rem ova l procedure. placed by rem ovin g the lamp lens attaching screw s and CHEVROLET TRUCK SERVICE MANUAL...
Page 566 ELECTRICAL—BODY AND CHASSIS 12-4 F ig . 3 —Front L ig h tin g Assemblies CHEVROLET TRUCK SERVICE MANUAL...
Page 567 ELECTRICAL—BODY AND CHASSIS 12-5 F ig . 4 —C le a ra n c e and Id e n tific a tio n Lamps CHEVROLET TRUCK SERVICE MANUAL...
Page 568 ELECTRICAL—BODY AND CHASSIS 12-6 F ig . 5 —Rear L ig h tin g C om posite CHEVROLET TRUCK SERVICE MANUAL...
Page 569 1. Disconnect w irin g harness connector fro m switch and screw s. rem o ve switch retaining nut. 5. Replace flo o r mat. F ig . 6— E le c tric a l C om ponents—T iIt Cab CHEVROLET TRUCK SERVICE MANUAL...
Page 570 4. Position switch tran sm ission and install d riv e tang and tighten screw s. R em ove clamp and switch attaching bolt. 5. Loosen transm ission le v e r extension bolt and with pin. CHEVROLET TRUCK SERVICE MANUAL...
Page 571 4. Pull the ignition switch out fro m under the dash and 2. Rem ove lock cylinder by positioning switch in “ A C C ” position and in sertin g w ire in sm a ll hole in cylinder rem ove the w irin g connector. CHEVROLET TRUCK SERVICE MANUAL...
Page 572 3. Rem ove windshield w ip er knob and b e zel nut. 1. Disconnect battery ground cable. F ig . 9 — Instrum ent C lu s te r Assem bly - C o n v e n tio n a l Cab CHEVROLET TRUCK SERVICE MANUAL...
Page 573: Laminated Circuit Replacement
5. R em ove laminated c irc u it fro m re a r of instrument clu ster. A ll Other M odels 6. To in stall, re v e r s e rem o val procedure and check To replace any indicator or illuminating bulb, unsnap operation of unit. CHEVROLET TRUCK SERVICE MANUAL...
Page 574 HI-BEAM TELL-TALE (LT. G R N . & BLK.) SPEEDOMETER INST. PANEL W IR IN G HARNESS T - 6 7 1 4 F ig . 11— Instrum ent C lu s te r—T ilt C ab CHEVROLET TRUCK SERVICE MANUAL...
Page 575: Speedometer Replacement
5. To in stall, re v e r s e rem ova l procedu re and check 3. Lubricate the lo w e r 3/4 length o f cable with speed operation of unit. CHEVROLET TRUCK SERVICE MANUAL...
Page 576 15. Tem perature G au ge 8 . L. H. D ire c tio n a l 12. G e n e ra to r (A m m eter) 16. Fuel G au ge 4 . Tem perature Ind. CHEVROLET TRUCK SERVICE MANUAL...
Page 577: Temperature Sender Unit R E P La Ce M E N T
Make sure printed circ u it edge is not 4. To in stall, re v e rs e rem o v a l procedu re and check pinched between c o v e r and clu ster housing. operation of unit. CHEVROLET TRUCK SERVICE MANUAL...
Page 578 6. To W ip e r M o to r 13. To Instrum ent C lu s te r C onn . 7. Ig n itio n S w itch 14. G ro und W ire , C lu s te r C onn. CHEVROLET TRUCK SERVICE MANUAL...
Page 579 6. Instr. C lu s te r C o n n e c to r 13. Dim m er S w itch 7. To W ip e r M o to r 14. G ro u n d W ire , C lu s te r C onn . CHEVROLET TRUCK SERVICE MANUAL...
Page 580 7. D ire c tio n a l S ig n a l C o n n . 15. A ir Brake B uzzer 8 . Fuel G au ge C o n n . 16. D im m er S w itc h CHEVROLET TRUCK SERVICE MANUAL...
Page 581 H azard switch knob must be pushed in prevent damage to switch when rem oving 8. To in stall, re v e r s e rem ova l procedure and check operation of unit. fro m switch c o v e r. CHEVROLET TRUCK SERVICE MANUAL...
Page 582 «ICAL bo d y a m d h a s s i s >2. 2 0 " 4 - 3 0 ' ° ' 2° 2-’ D°rl Cell’ng & * > • / « , er < * * * * * 6 ’...
Page 583 Depending on the w irin g harness of m otor is coupled to a train consisting of a h elica l d rive the d ifferen t trucks, the w iper m otors are equipped with CHEVROLET TRUCK SERVICE MANUAL...
Page 584 11. M o to r A ssem bly (In cludes B racket) F ig . 18—W ip e r M o to r In s ta lla tio n —C o n v e n tio n a l Cab N u t CHEVROLET TRUCK SERVICE MANUAL...
Page 585 18. End P late 4 . R eta in ing Ring S haft A ssem bly M o u n tin g Brackets 15. A rm a ture 19. T ie Bolts (Tw o R equired) CHEVROLET TRUCK SERVICE MANUAL...
Page 586 “ A C C ” position and in sertin g a w ire in the sm a ll rein stallation . CHEVROLET TRUCK SERVICE MANUAL...
Page 587 O N S H A F T ) SPRING C A M FOLLOWER UPPER PIN ’ RING RATCHET PAWL F ig . 2 4 —W asher Pump D riv e Cam F ig . 2 6 —W asher Pump M echanism CHEVROLET TRUCK SERVICE MANUAL...
Page 588 . To separate the pump and pump actuator plate fro m the fra m e, pull the pump housing in the 7. To assem ble washer unit, r e v e r s e above procedures. CHEVROLET TRUCK SERVICE MANUAL...
Page 589 E X H A U S T S T R O K E VALVES OPEN F ig . 2 9 —Cross S e ctio n o f W in d s h ie ld W asher Pump V a lv e CHEVROLET TRUCK SERVICE MANUAL...
Page 590 18B/W' FUSE 12R— . 12R > 12R, FUSE SHUNT^“ 18b" AMMETER RESISTOR 20DG« TEMP GAGE 18B — AMMETER GAGE 18B/W« F ig . 30— Engine C om p a rtm e n t— PS 1 0 CHEVROLET TRUCK SERVICE MANUAL...
Page 591 > u l S i e ' K \^>-18T >»18B — BRAKE WARNING 12DG 8BRN' LEFT FRT. MARKER HORN LP. CONN. F ig . 31 — Engine C om p a rtm e n t— PE-PS20-30 CHEVROLET TRUCK SERVICE MANUAL...
Page 592 . « « r « ENG TEMP 2 0 D G - ■ ✓ A M M E T E R G A G E F ig . 32— Engine C om p artm ent— PS40 CHEVROLET TRUCK SERVICE MANUAL...
Page 593 F R T . M A R K E R L P . 12DG- F ig . 3 3 — Engine C o m p a rtm e n t—C S 1 0 -2 0 , CS30 CHEVROLET TRUCK SERVICE MANUAL...
Page 594 ELECTRICAL—BODY AND CHASSIS 12-32 J U N C T IO N B L O C K F ig . 34— Engine C om p a rtm e n t—C E -K E 1 0 -2 0 , CE30 CHEVROLET TRUCK SERVICE MANUAL...
Page 595 -© 6B (292 E N G . ) 1 / m R . H. D IR . F ig . 3 5 — Engine C o m p a rtm e n t—C S 40-5 0 CHEVROLET TRUCK SERVICE MANUAL...
Page 596 T A I L & S T O P L A M P W IR IN G S H E E T F ig . 3 6 — Engine C om p artm ent— CE40, C E -M E 5 0 CHEVROLET TRUCK SERVICE MANUAL...
Page 597 ELECTRICAL—BODY AND CHASSIS 12-35 F ig . 3 7 — Engine C om p a rtm e n t—C E -M E 60 CHEVROLET TRUCK SERVICE MANUAL...
Page 598 ELECTRICAL—BODY AND CHASSIS 12-36 TO FRAME i| f F ig . 3 8 — Engine C om p artm ent—C D -5 0 CHEVROLET TRUCK SERVICE MANUAL...
Page 599 T A I L L A M P W IR IN G S H E E T F ig , 3 9 — Engine C om p a rtm e n t— C G 5 0 CHEVROLET TRUCK SERVICE MANUAL...
Page 600 ELECTRICAL—BODY AND CHASSIS 12-38 ♦FOR WIRE GAGE - SEE CHASSIS & TAIL LAMP WIRING SHEET F ig . 4 0 — Engine C om p artm ent— S S40-50 CHEVROLET TRUCK SERVICE MANUAL...
Page 601 - 1 4 D G — LT. FRT. ♦FOR WIRE GAGE - SEE CHASSIS & S 4 L G — MARKER LP, TAIL LAMP WIRING SHEET F ig . 41 — Engine C ompartm ent-— SE50 CHEVROLET TRUCK SERVICE MANUAL...
Page 602 ....- ........................1 8 L G - F ig . 4 2 — Instrum ent P ane l— C A -K A 1 0 -2 0 , C A 3 0 (0 3 -0 4 -1 4 -3 4 ) CHEVROLET TRUCK SERVICE MANUAL...
Page 603 18LG < •18LG - F ig . 4 3 — Instrum ent P anel—C A - K A 1 0 -2 0 , C A 3 0 (0 3 -0 4 -1 4 -3 4 ) CHEVROLET TRUCK SERVICE MANUAL...
Page 604 12 B R N — 2 4 B R N / W F ig . 4 4 — Instrum ent P anel— C A -K A 1 0 -2 0 (0 5 -0 6 -1 6 ) CHEVROLET TRUCK SERVICE MANUAL...
Page 605 18T — 18BRN 18BRN 18DG - 18DG - 18LG - 18LG - F ig . 4 5 — Instrument- P anel—C A - K A 1 0 -2 0 (0 5 -0 6 -1 6 ) CHEVROLET TRUCK SERVICE MANUAL...
Page 606 2 0 T ---------- 1 2 P P L — - 18BRN- 18Y---- 18DG — I 8 L 6 - F ig . 4 6 — Instrum ent P anel—C A 3 1 0 -3 6 0 (02) CHEVROLET TRUCK SERVICE MANUAL...
Page 607 ■18BRN ■ - 1 8 Y ---- ■18Y---- -18DG — -18DG — -1 8 LG — ■18LG — F ig . 4 7 — Instrum ent P anel—C A 3 1 0 -3 6 0 ( 02) CHEVROLET TRUCK SERVICE MANUAL...
Page 608 ELECTRICAL—BODY AND CHASSIS 12-46 F ig . 4 8 — Instrum ent P ane l— C A 4 0 , C E -C S-M E 50 (Exc 02) CHEVROLET TRUCK SERVICE MANUAL...
Page 609 * DG - - *D G----------------------------------------------------------------------- - * LG----------------------------------------------------------------------- * LG- F ig . 4 9 — Instrum ent P ane l—C A 4 0 , C E -C S -M E 5 0 (Exc 02) CHEVROLET TRUCK SERVICE MANUAL...
Page 610 ELECTRICAL—BODY AND CHASSIS 12-48 F ig . 5 0 — Instrum ent P anel— C E -M E 6 0 (0 3 -1 3 ) CHEVROLET TRUCK SERVICE MANUAL...
Page 611 ■ * Y — ■ *DG - ■ *D G . * L G - .♦L G - F ig . 5 1 — Instrum ent P anel—C E -M E 6 0 (0 3 -1 3 ) CHEVROLET TRUCK SERVICE MANUAL...
Page 612 ♦ F O R W IR E G A G E - S E E C H A S S IS & T A I L L A M P W IR IN G S H E E T F ig . 5 2 — Instrum ent P anel—C A 4 0 - 5 0 - 6 0 - (02) CHEVROLET TRUCK SERVICE MANUAL...
Page 613 ♦ F O R W IR E G A G E - S E E C H A S S IS & T A I L L A M P W IR IN G S H E E T F ig . 5 3 — Instrument" P anel—C A 4 0 -5 0 -6 0 (02) CHEVROLET TRUCK SERVICE MANUAL...
Page 614 ELECTRICAL—BODY AND CHASSIS 12-52 F ig . 5 4 — Instrum ent P anel—S A 4 0 -5 0 CHEVROLET TRUCK SERVICE MANUAL...
Page 615 METER 14LBL- •14LBL 14W-------- ------14W — 18T------- — 18T — 14BRN---- — 14BRN' 14Y------- ----- 14Y---- 14DG----- ----- 14DG— 14LG----- ----- 14LG- F ig . 55— Instrum ent P ane l—S A 4 0 -5 0 CHEVROLET TRUCK SERVICE MANUAL...
Page 616 • F O R W IR E G A G E - S E E C H A S S IS & T A I L L A M P W IR IN G S H E E T F ig . 5 6 — Instrum ent P anel—C D -C G 5 0 CHEVROLET TRUCK SERVICE MANUAL...
Page 617 ♦ F O R W IR E G A G E - SEE C H A S S IS & T A I L L A M P W IR IN G S H E E T F ig . 57— Instrum ent P anel—C D -C G 5 0 CHEVROLET TRUCK SERVICE MANUAL...
Page 618 - * L G LAMP (02 MODELS ONLY) F ig . 5 8 —T a il & Stop Lamp—C A -K A - M A -S A 0 0 0 (Exc 0 5 -0 6 -1 6 ) CHEVROLET TRUCK SERVICE MANUAL...
Page 619 L A M P 18 L G • F ig . 5 9 - T a il & Stop L a m p - C A - K A l0 -2 0 (0 5 -0 6 -1 6 ) CHEVROLET TRUCK SERVICE MANUAL...
Page 620 —*DG - MARKER LP. H. SIDE — 18LG- ♦FOR WIRE GAGE - SEE CHART ABOVE ARKER LP. F ig . 6 0 —T a il & Stop Lamp—C A 3 0 -4 0 -5 0 -6 0 CHEVROLET TRUCK SERVICE MANUAL...
Page 621 CAl 0-20-30, KAOO PS20-30 WITH AUTO. TRANS. PE-PS20-30 PT20-30 F ig . 1— R adia tor & Shroud M o u n tin g —C A - K A and PA 2 0 -3 0 M o dels CHEVROLET TRUCK SERVICE MANUAL...
Page 622 PA 10 MODELS (Fig. 2) Radiator Replacement 1. Drain rad iator and disconnect w ater hoses and Pow - erg lid e coolant line o f applicable. Fig. 4— Radiator M ounting PT M odels CHEVROLET TRUCK SERVICE MANUAL...
Page 623 F ig . 5 — R adia tor Fan Shroud C A -4 0 , C A - M A - 5 0 - 6 0 S A -4 0 -5 0 M o dels Fig. 7—Radiator M ounting M E -6 0 M odels CHEVROLET TRUCK SERVICE MANUAL...
Page 624 F ig . 9— Radiator & Shroud M ounting PA -40 Models Fig. 11 — Fan Shroud M ounting T S -T E -4 0 -5 0 -6 0 M odels CHEVROLET TRUCK SERVICE MANUAL...
Page 625 TH E G R IL L E A R E A AS DISTORTION AND OR 3. R em ove bolts at center brace and hood lock from P A IN T P E E L COULD RESU LT. radiator mounting. CHEVROLET TRUCK SERVICE MANUAL...
Page 626 5. R em ove bolts securing battery tra y to g r ille . Fig. 14—G r ille M ounting C A -4 0 -5 0 -6 0 M A -5 0 -6 0 S A -4 0 -5 0 M odels CHEVROLET TRUCK SERVICE MANUAL...
Page 627 R e fe r to torque sp ecification s at re a r of manual 4. R eplace g r ille m o u n t i n g components as fo r c o rr e c t torque values. n ecessary. CHEVROLET TRUCK SERVICE MANUAL...
Page 628 ■...
Page 629 Fig. 3— Front Bumper P-20 -30 Models F ig . 2— Rear Bumper C - K M odels CHEVROLET TRUCK SERVICE MANUAL...
Page 630 R e fe r to torque sp ecification s in r e a r of manual fo r c o r r e c t torque values. FRONT B U M P E R -T MODELS (Fig. 5) Removal NOTE: On t ilt cab m odels equipped with a ir CHEVROLET TRUCK SERVICE MANUAL...
Page 631 POWER UNIT FROM REGULATOR ENGINE VACUUM ENGAGEMENT SWITCH VACUUM RELEASE VALVE METERED AIR TEE FITTING OUTPUT REGULATOR > — TO SPEEDOMETER IM PU T FRO M TRANSMISSION MANIFOLD VACUUM HOSE Fig. 1— Cruise M aster System CHEVROLET TRUCK SERVICE MANUAL...
Page 632 (veh icle speed in crea sin g), the vacuum in the cham ber drops and the diaphragm m oves away fro m the vacuum port. In operation, at cru ise speed, a prop er CHEVROLET TRUCK SERVICE MANUAL...
Page 633 The input shaft d riv e s both the m agnetic disk and the speedom eter d riv e cable. Fig. 4 —Servo U n it CHEVROLET TRUCK SERVICE MANUAL...
Page 634 When solenoid re tra c ts , it also shuts o ff vacuum to the " T e e " fittin g and opens the vacuum port atm ospheric p ressu re within the CHEVROLET TRUCK SERVICE MANUAL...
Page 635 5/16 inch m easured at turn signal le v e r and ste erin g wheel. the sw itch (fig. 7). Connect battery ground cable. CHEVROLET TRUCK SERVICE MANUAL...
Page 636 1. Bead chain p ro p e rly adjusted. way in. 2. A ll hoses in good condition, p ro p e rly attached, not T e s t #2 - Connect oh m m eter between term in al #1 CHEVROLET TRUCK SERVICE MANUAL...
Page 637 5 and 6 necting hoses can lik ew ise be checked using a vacuum ohms. A reading o f le s s than 4 ohms indicates short pump. CHEVROLET TRUCK SERVICE MANUAL...
Page 638 ACCESSORIES 15-8 CLUTCH CRUISE ENGAGEMENT WHITE SWITCH RELEASE SWITCH REGULATOR Fig. 10—V acuum and E le c tric a l D iagram CHEVROLET TRUCK SERVICE MANUAL...
Page 639 System can be engaged at idle by Wires reversed at regulator Reverse w ire s-Se e Fig. 10. depressing switch, but will drop out when switch is released. Solenoid can be heard when switch is depressed when the vehicle is standing still. CHEVROLET TRUCK SERVICE MANUAL...
Page 641 GM C hevrolet and Roof-M ounted System s . . 10 Amp. F o u r-S ea so n ....12 16.5 Max. 3700 Min. GM C h evrolet and R oof- Mounted ......12 13.7 Max. 3400 Min. CHEVROLET TRUCK SERVICE MANUAL...
Page 642 17° 1/4° 20° 11000# A x le s ................S M odels 17° 1/4° 20° 17° 1/4° 7000# A x le s ................20° P 40 M odels 17° 5000# A x le s ................20° CHEVROLET TRUCK SERVICE MANUAL...
Page 643 L e a f Spring - - Front L e a f Spring - - R e a r Kingpin Upper B rake Backing 5000# 140 P la te 7000# 185 Kingpin B earing Caps Kingpin L ock CHEVROLET TRUCK SERVICE MANUAL...
Page 644 Torqu e in Lbs. Ft. M odel 4 - 5000# axles 7/16" 105-130 5/8" 125-175 7000# axle 9 - 11000# axles 3/4" 175-250 “ U” Bolt Torqu es - R ea r A ll 3/4" 250-350 CHEVROLET TRUCK SERVICE MANUAL...
Page 645 $ B a rre l R o lle r on 11,000# and T a p ered R o lle r on 13,500#. UNIVERSAL JO IN T ATTACHMENT TORQUE SPECIFICATIONS (FT. LBS.) Torqu e B earin g Cap Ft. Lbs. Outside D ia m eter 1 1/16" ............1 3/16” ............1 3/8" ............CHEVROLET TRUCK SERVICE MANUAL...
Page 646 L ock ou t Shift L e v e r B r a c k e t to C a r r i e r B ra k e - B ack in g P la te CHEVROLET TRUCK SERVICE MANUAL...
Page 647 Adapter Bolts Saddle Cap Stud Nuts Spring Hinge Lock B olts Top Pad Set Screw Spacer Bolts Spring Saddle Top Pad Bolts Torque A rm — Nuts Torque A rm B racket B olts P rop Shaft CHEVROLET TRUCK SERVICE MANUAL...
Page 648 A ir C o m p ressor G overn or Cut in P r e s s u r e ..............102-108 psi Cut out P r e s s u r e ..............123-131 psi CHEVROLET TRUCK SERVICE MANUAL...
Page 649 SPECIFICATIONS 9 ENGINE SECTION 6 CHEVROLET TRUCK SERVICE MANUAL...
Page 650 O il Pan D rain Plug 20 lb. ft. F lyw h eel 110 lb. ft. Spark Plu g 15 lb. ft. 14mm 13/16 Spark Plu g 25 lb. ft. <D Inside bolts on 307-350 engines 30 lb. ft. CHEVROLET TRUCK SERVICE MANUAL...
Page 651 P O L Y U R E T H A N E B A N D -S e r v ic e e v e ry 12,000 m iles. O IL B A T H —Change o il at re g u la r engine o il change in tervals. CHEVROLET TRUCK SERVICE MANUAL...
Page 652 R OCHESTER H O LL E Y Carburetor 2GV (1 1/4) 2G (1 1/2) C arburetor 4150G Engine Displacem ent Engine Displacem ent (H orsepow er) (155) (170) (155) (155) (170) (170) (200) (200) (200) (215) (215) (255) (255) (255) (310) (310) (310)
Page 653 1100834 1100843 1117782 1100841 1117141 1100838 1100849 1100833* Model 1100842 3.7-4.4 2.2-2.6 2.2-2.4 F ie ld Am p D raw 2.2-2.6 2.2-2.6 2.2-2.6 Amp. Cold Output V olts *10SI S e ries In tegra l System CHEVROLET TRUCK SERVICE MANUAL...
Page 654 1108361, 1108362, 1107375 1107371, 1108350, 2444 35-75* 6000-9000 1108357, 1108363, 1108364, 1108369, 1108370, 1108372 1113184 2412 50-70* 1113202 1113686 3594 130-160* 5000-7000 1108418 3563 65-95* 7500-10500 1108425 3533 40-105* 3500-6500 1114101 2431 11.5 90-130* 5600-7600 *Includes Solenoid CHEVROLET TRUCK SERVICE MANUAL...
Page 655 400 Cu. In. - 310 HP V-8 1111500 900 RPM 8" Hg. 29°-31° 10° 1500 RPM 15° @ 15.5" Hg. RPO L47 15° @ 2000 RPM 28° @ 4200 RPM *In Neutral for Manual Transmissions, In D rive for Automatic Transmissions. CHEVROLET TRUCK SERVICE MANUAL...
Page 656 1.24-1.46 .38-.51 Secondary Resistan ce-O hm s 5,400-7,100 7,200-9,500 8,200-12,400 Type In W irin g Harness In W irin g Harness In W irin g Harness Ignition R e sis to r Ohms .43 & .68 CHEVROLET TRUCK SERVICE MANUAL...
Page 657 C ro ssm em b er to F ra m e N u t s ..........................25 ft. lbs. C ro ssm em b er to Mount and Mount to Extension B o l t s ................40 ft. lbs. CHEVROLET TRUCK SERVICE MANUAL...
Page 658 Shift C ontrol A ssem b ly B o l t s ....................... 22 ft. lbs. Shift Support C o v e r B o l t s ........................22 ft. lbs. Shift C ontrol Top B o l t s ......................... 22 ft. lbs. CHEVROLET TRUCK SERVICE MANUAL...
Page 659 C on verter Drain Plug ( T a x i e s ) ..........................20 ft. lbs. P arkin g Brake L ock & Range Selector Inner L e v e r A lle n Head S c r e w ..........2-1/2 ft. lbs. CHEVROLET TRUCK SERVICE MANUAL...
Page 660 Lin e P r e s s u r e T a k e -O ff P l u g ..........................13 lb. ft. S train er R eta in er B o l t .............................. 10 lb. ft. CHEVROLET TRUCK SERVICE MANUAL...
Page 661 F ire w a ll Bracket 98 in. lbs. 90 in. lbs. 90 in. lbs. 120 in. lbs. Clamp Bolt Low er Bearing 70 in. lbs. 70 in. lbs. 70 in. lbs. 70 in. lhs. Adjusting Ring Bolts CHEVROLET TRUCK SERVICE MANUAL...
Page 662 14 in. lbs. 20 in. lbs. 20 in. lbs. G ear P relo a d Max. Max. Max. Max. Max. Max. *In excess of ball drag. **In excess of ball d rag and thrust bearing preload. CHEVROLET TRUCK SERVICE MANUAL...
Page 663 550-625 lbs. ft. 550-625 lbs. ft. D isc W heels (3) WHEEL NUT TORQUE SEQUENCE TIRES— 10-60 S eries See inflation tables fo r applicable veh icle loads in text copy of Section 10 in this manual. CHEVROLET TRUCK SERVICE MANUAL...
Page 664 & 366 V -8 only) Headlamp 6012 50W-High Beam Conventional Cab 40W -L ow Beam F/F Cowl Side M arker Lam ps T ilt Cab 1895 C learance and Identification Lamps *C P-C an dle P ow er W-W atts CHEVROLET TRUCK SERVICE MANUAL...
Page 665 C ircu it breaker 2-Speed R ear D riv e r A x le w compartment E le c tric Shift In- Line P a rt of Gen. Am m eter & fwd. lamp 3AG/AGC harness (2 Reqd.) CHEVROLET TRUCK SERVICE MANUAL...
Page 666 L ow er R etainer to L o w er Center Panel S c r e w s ................150 in. T A M odels (G r ille ) Gusset to G r ille and G r ille Support Screws ..................18 ft. lb. CHEVROLET TRUCK SERVICE MANUAL...
Page 667 Gusset to F ra m e N u t s ............................100 ft. lb. B racket to F ram e N u t s ............................. 120 ft. lb. F a ce Bar to Gusset R ea r N u t s ......................... 100 ft. lb. CHEVROLET TRUCK SERVICE MANUAL...
Page 668 Maximum allow able Vacuum Leakage rate fo r S ervo Unit Not G rea ter than 1 inch of Vacuum p er 10 seconds ................60 M PH Operational T e s t S p eed ..............CHEVROLET TRUCK SERVICE MANUAL...
Page 669 WEIGHTS AND MEASURES L I N E A R M E A S U R E C O M M O N WE I G HT 1 6 ou n ces....... =1 p o u n d 1 / 1 2 fo o t (ft.)......=1 in c h (in .) 1 0 0 pou n ds....
Page 670 DECIMAL EQUIVALENTS ft ......... 015625 **4 ........ 515625 .........03125 ........53125 ........046875 3 K 4 ........546875 ........0625 % ......fe .........078125 ”/ < 4 ........578125 V k .........09375 ’ % 2 ........59375 % 4 ....

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