Page 2 Chevrolet Light Duty Trucks. Procedures involving disassembly and assembly of major components for these vehicles are contained in the 1980 Chevrolet Passenger Car and Light Duty Truck Unit Repair (Overhaul) Manual. Wiring diagrams for 1980 trucks are contained in a separate Wiring Diagram Booklet.
Page 3 IMPORTANT SAFETY NOTICE Proper service and repair is im portant to the safe, reliable operation of all m otor vehicles. The service procedures recom m ended and described in this service manual are effective m ethods for performing service operations. Some of these service operations require the use of tools specially designed for the purpose.
Page 5 TABLE OF CONTENTS SECTION GENERAL INFORMATION General Inform ation M aintenance and Lubrication HEATING AND AIR CONDITIONING Heating and Ventilation A ir C onditioning 1980 FRAME AND BUMPERS Frame and Body M ounts Bumpers Sheet Metal LIGHT DUTY Body STEERING, SUSPENSION, WHEELS TRUCK AND TIRES Front A lign m en t...
Page 7: General Information
GENERAL IN FO R M A TIO N OA-1 SECTION OA GENERAL INFORMATION CONTENTS OF THIS SECTION General....................0-1 Vehicle Identification Number.............0-1 Service Parts Identification Sticker............0-1 Vehicle Loading..................0-1 Engine Code Number................0-1 Unit and Serial Number Locations............0-3 The plate lists the vehicle identification number, GENERAL wheelbase, and all Production options or Special Equipment Information to identify the vehicle and vehicle...
Page 8 GENERAL IN FO R M A TIO N LIGHT DUTY TRUCK (EXCEPT EL CAMINO) VIN SYSTEM IDENTIFICATION CCD13AF100007 PLANT SEQUENTIAL NUMBER DIVISION C - Chevrolet T - G M C ASSEMBLY PLANT GMAD-Lakewood GA. “A' CHASSIS TYPE GMAD-Baltimore MD. "B' Conventional Cab CHEVROLET-Flint Ml.
Page 9 GENERAL IN FO R M A TIO N OA-3 Always include the prefix in the number. Axles Chevrolet Built • On 10 Series, the Code is stamped on Top of Right Rear Axle Tube. • On 20-30 Series, the Code is stamped on Top of the Right Rear Axle Tube.
Page 10 OA-4 GENERAL IN FO R M A TIO N PRIMARY V .I.N . SECONDARY V .I.N . LOCATION LOCATION (M l 5) To be used only when suitable for stamping PRIMARY V .I.N . LOCATION (MV4 or M38) SECONDARY V .I.N . LOCATION To be used only when prim ary locationis not suitable for stamping...
Page 11: Table Of Contents
M A IN TEN A N C E AND LUBRICATIO N OB-1 SECTION OB MAINTENANCE AND LUBRICATION CONTENTS General....................OB-1 Maintenance Schedule..............OB-2 Lubrication and General Maintenance.........OB-4 Safety Maintenance................OB-14 Emission Control Maintenance............OB-15 Specifications..................OB-16 Recommended Fluids and Lubricants..........OB-16 Fluid Capacities................0B-17 GENERAL The maintenance schedule for a gasoline engine follows V-8 diesel engine (Fig.
Page 12 OB-2 M AINTENA NCE AND LUBRICATION VEHICLE MAINTENANCE SCHEDULE GASOLINE ENGINE - LIGHT DUTY EMISSIONS When To Perform Services Services Item (Months or Miles (km) Whichever Occurs First SECTION A — Lubrication and General Maintenance A Fluid Levels Check Clutch Pedal Free Travel Check/Adjust. Every 12 Months or 7,500 Miles (12 000 km) *Engine Oil Change *O il Filter Change...
Page 13 M A IN TEN A N C E AND LUBRICATION OB-3 VEHICLE MAINTENANCE SCHEDULE GASOLINE ENGINE - HEAVY DUTY EMISSIONS When To Perform Services (Months or Miles/km, Whichever Item Services Occurs First) (For Details, See Numbered Paragraphs) SECTION A — Lubrication and General Maintenance Every 4 months or 6,000 miles (9 600 km) •F lu id Levels Check Clutch Pedal Free Travel Check/Adjust...
Page 14: Maintenance Schedule
OB-4 M A INTENA NCE AND LUBRICATION VEHICLE MAINTENANCE SCHEDULE DIESEL-FUELED VEHICLE Services When To Perform Services Item (Months or Miles, Whichever Occurs First) (For Details, See Numbered Paragraphs) SECTION A — Lubrication and General Maintenance * Engine Oil C hange Every 3,000 Miles (4 800 km) * Oil Filter Change •...
Page 15 M A IN TEN A N C E AND LUBRICATION OB-5 Battery Care The original equipment battery (two batteries on diesel engine) needs no periodic maintenance. Its top is permanently sealed (except for two small vent holes) and has no filler caps. Water will never have to be added. The hydrometer (test indicator) in the top of the battery provides information for testing purposes only.
Page 16 OB-6 M AIN TEN A N C E AND LUBRICATION W indshield W asher Fluid (Also a Safety Service) Fill the washer jar only 3/4 full during the winter to allow for expansion if the temperature should fall low enough to freeze the solution. •...
Page 17 M A IN TEN A N C E AND LUBRICATION OB-7 whichever occurs first. • Change oil filter: Replace at the first oil Light Duty Emissions- change and then every second oil change if mileage 7,500 miles (12 000 km) determines oil change. If time (12 months) determines oil change, or you change the oil at 3,000 miles (4 800 km) or 3 months, replace filter at each oil change.
Page 18: Lower Control Arms
OB-8 M A IN TEN A N C E AND LUBRICATION Gas Tank Filler Door Hinge back down all the way. Now pull the dipstick out and look at the oil level on the dipstick. Some dipsticks are marked Clean area of dirt and old lubricant. Apply a few drops with "Add"...
Page 19 M A IN T EN A N C E AND LUBRICATIO N OB-9 Lower Control Arms Wheel Bearings Throttle Bell Crank — L-6 Upper Control Arms Steering Gear Carburetor Linkage - V-8 Upper and Lower Control Air Cleaner - Element Brake and Clutch Pedal Springs Arm Ball Joints...
Page 20 OB-10 M A IN TEN A N C E AND LUBRICATION LUBRICATION POINTS Control Arm Bushings and Trans. Control Shaft Rear Axle Ball Joints A ir Cleaner - Element Oil Filter Brake Master Cylinder Tie Rod Ends Transmission - Manual Parking Brake Linkage Wheel Bearings - Automatic...
Page 21 M A IN TEN A N C E A N D LUBRICATION OB-11 SERIES DESCRIPTION TORQUE 7/16” BO LTS (6) 70-90 FT. LBS. 95-120 N .m C10, G10, G20 1/2” BO LTS (5) 75-100 FT. LBS. AND P10 100-140 N .m C20, K20, C30, G30, 90-120 FT.
Page 22 OB-12 M A INTENA NCE A N D LUBRICATION carried by the vehicle and, therefore, is included in the range. Sustained driving at speeds over 85 mph GVW of the vehicle. (140 km /h), w here such speeds are permitted by unless vehicle is equipped with law, is not advised 4.
Page 23 M A IN T EN A N C E AND LUBRICATIO N OB-13 ethylene glycol antifreeze. 8. Add enough ethylene glycol solution, meeting GM Specification 1899-M, and water to provide the required Service cooling function as well as freezing and corrosion •...
Page 24: Safety Maintenance
OB-14 M AIN TEN A N C E AND LUBRICATION miles (160 000 km) on light duty emissions and diesel engine vehicle or 24,000 miles (38 400 km) on heavy duty A L L L6 E N G IN E S A N D A L L V 8 E N G IN E S E X C E P T D IE S E L emissions.
Page 25: Emission Control Maintenance
M A IN TEN A N C E AND LUBRICATION OB-15 B-10 Fuel Cap, Fuel Lines and Fuel Tank C -11 Spark Plugs (Also an Emission Control Service) Replace as shown on Schedule. Use the type listed in Check the fuel tank, cap and lines for damage or leaks. Owner’s and Driver’s Manual.
Page 26: Specifications
OB-16 M A INTENA NCE A N D LUBRICATION SPECIFICATIONS RECOMMENDED FLUIDS AND LUBRICANTS FLUID/LUBRICANT USAGE GM power steering fluid Part No. 1050017 or equivalent. Power steering system and pump reservoir Full tim e front wheel drive case SAE-10W-30 or 10W-40 SE or SF engine oil Manual steering gear Lubricant GM Part No.
Page 27 M A IN TEN A N C E AND LUBRICATION OB-17 CAPACITIES IMPERIAL U.S. MEASURE MEASURE Differential " Ring Gear 1.9L 4% pts. 31 /2 pts. 8-7/8" Ring Gear 31 /2 pts. 3 pts. 10%" Ring Gear (Chev.) 2.8L pts. 5% pts.
Page 28 OB-18 M A INTENA NCE AND LUBRICATION COOLING SYSTEM H.D. Capacity Transmission (Qts./Liters) Radiator Cond. U.S. Imperial Series Measure Measure Man. Auto Man. Auto Man. Auto Engine 121 /2 15 (14L) C K10-15 15% (14.5L) C 20-25 15 (14L) 121 / 2 250 CID 15% (14.5L) G 10-30,...
Page 29 HEATER 1 A-1 SECTION 1A HEATER CONTENTS OF THIS SECTION Standard Heater. 1A-1 Auxiliary Heater 1A-15 Specifications..1A-19 STANDARD HEATER INDEX General Description............1A-1 Heater Hoses..............1A-9 System Components.............1A-1 Center Distributor Duct - G Models......1A-9 System Controls............1A-3 Defroster D uct..............1 A -12 Diagnosis.................1A-4 Control Assembly............
Page 30 1A-2 HEATER H E A T E R & D E F R O S T E R A S M H E A T E R A D E F R O S T E R A S M ( H E A T E R I N O F F P O S I T I O N ) >...
Page 31 HEATER 1A-3 1A-3--Heater Control-G Models Fig. 1 A -2 -H e a te r Control-C-K M odels Fig. outlet air is dependent of the ratio of heated to unheated air (controlled by the temperature door). CONTROLS Heater controls for CK & G Models are shown in Figures 1A-2 and 1A-3.
Page 32 1A-4 HEATER DIAGNOSIS CAUSE AND CORRECTION TROUBLE See " I n s u f f i c i e n t Heat D i ag n o s t i c Cha r t ". Temperat ure o f h e a t e r a i r a t o u t l e t s too low t o h e a t up pa s se nge r compart ment .
Page 33 HEATER 1A-5 INSUFFICIENT HEAT DIAGNOSIS Position the co n tro ls so th a t the: Tem perature lever is on fu ll heat. Selector o r heater lever is on Heater. Fan sw itch is on Hi. •CHECK DUMP DOOR OUTLET FOR AIR FLOW NO AIR FLOW CHECK DEFROSTER OUTLETS FOR AIR FLOW A d ju st d u m p d oo r fo r no air flo w .
Page 34 HEATER C IR C U IT D IA G N O S IS * BLOW ER MOTOR IN O P E R A TIV E (A N Y SPEED) Check fuse in fuse panel. FUSE BLOWN FUSE OK The fo llo w in g tests should be made w ith W ith Ig n itio n sw itch in the ignition sw itch in "...
Page 35 HEATER 1A-7 LIG H T T R U C K S ER V ICE M ANUAL...
Page 36 1A-8 HEATER ON VEHICLE SERVICE b. If the motor mounting flange sealer has hardened, BLOWER MOTOR or is not intact, remove the old sealer and apply a new bead Removal (Fig. 1A-5) of sealer to the entire circumference of the mounting flange. 1.
Page 37 HEATER 1A-9 VIEW A Fig. 1A-7~Heater D istrib u to r - G M odels G Models HEATER HOSES Heater hoses are routed from the thermostat housing Replacement (Fig. 1A-7) or inlet manifold and water pump (radiator on some 1. Disconnect the battery ground cable. automatic transmission vehicles) to the core inlet and outlet pipes as shown in Figures 1A-8 thru 1A-11.
Page 38 1A-10 HEATER LIG H T T R U C K S ER V IC E M AN UAL...
Page 39 TEE AND V A LV E /C 36...
Page 40 1 A -12 HEATER Fig. 1 A-1 2~ D istrib u to r Ducts~G M odels DEFROSTER DUCT CONTROL ASSEMBLY Defroster assemblies attachment is illustrated in Figure C-K Models 1A-13. Replacement (Fig. 1A-14) 1. Disconnect the battery ground cable. 2. Remove the instrument panel bezel. 3.
Page 41 HEATER 1A-13 G Models 1A-17) Replacement (Fig. Heater and defroster cable routing and attachment to control and to distributor case is illustrated in Figure 1 A-17. If cable adjustment is required, see below. Adjustm ent - CK Series 1. Disconnect the battery ground cable. Remove glove box and door as an assembly.
Page 42 1A-14 HEATER VIEW A VIEW B Fig. 1 A-1 7 -C o n tro l Cable Routing--G M odels LIG H T T R U CK S ER V IC E M AN UAL...
Page 43 HEATER 1A-15 AUXILIARY HEATER INDEX General Description................I A-15 Control....................1A-15 Diagnosis On Vehicle Service................1A-17 Specifications..................1 A-19 GENERAL DESCRIPTION An auxiliary heater is available as a dealer installed CONTROLS accessory to provide additional heating capacity for the Two methods of control are employed with this system: rearmost extremities of the G (05 and 06) models.
Page 44 1 A -18 HEATER Fig. 1 A -2 3 -A u x ilia ry Heater - G M odels LIG H T T R U CK S ER V IC E M ANUAL...
Page 45 HEATER 1A-19 SPECIFICATIONS SECTION 1A HEATER Amps. (Cold) Volts (Cold) Blower Motor C-K Models 13.5 6.25 Max. 2550 Min. 2950 Max. G Models ..13.5 7.1 Max. 2850 Min. 3250 Max. Fuses C-K Models G Models AU XILIARY HEATER Amps.
Page 47 NOTICE: When performing air conditioning diagnosis on Chevrolet vehicles equipped with a catalytic converter, it will be necessary to warm the engine to a normal operating temperature before attempting to idle the engine for periods greater than five (5) minutes.
Page 48: General Description
1 B-2 AIR CO NDITIO NING GENERAL DESCRIPTION air circulation without the refrigerant function may be had C 60 A /C SYSTEM by operating the rear blower control switch. Both the heating and cooling functions are performed These units are self contained, operating on inside by this system.
Page 49 EVAPORATOR CORE BLOWER & SHROUD. EVAPORATOR ASM CONTROL VIEW A AIR INLET VALVE PLENUM VALVE HEATER CORE BLOWER & EVAPORATOR ASM L.H. OUTLET SELECTOR FOOT DEFLECTOR DASH PANEL DUCT EVAPORATOR CORE (CK) MODELS...
Page 50 1B-4 AIR C O N DITIO NING The valve consists primarily of the power element, body, actuating pins, seat and orifice. At the high pressure liquid inlet, is a fine mesh screen which prevents dirt, filings or other foreign matter from entering the valve orifice. When the valve is connected in the system, high pressure liquid refrigerant enters the valve through the screen from the receiver-dehydrator or condenser and...
Page 51: System Control
AIR C O N D ITIO N IN G 1B-5 Therm ostatic Switch - M otor Home Chassis OVERHEAD SYSTEM (G MODELS) This system operates in conjunction with the C60 Units Only system. Since refrigerant is controlled by the C60 system, System temperature is controlled by running the the only control provided on the rear overhead system is a compressor intermittently, automatically turning it on and...
Page 52 CO N D ITIO N E D AIR IS DIRECTED TH R U W/SHLD, I .P. & FLOOR DISTRIBUTOR OUTLETS A NON-COMPRESSOR OPERATING POSITION, C O N D ITIO N E D AIR IS DIRECTED THRU I.P. OUTLETS W ITH OUTSIDE AIR D E LIV E R E D TH R U I.P. OUTLETS IN THIS MODE LEVER POSITION, M A X IM U M COOLING IS OFFERED WITH THE CO NDITIO NED A NON-COMPRESSOR OPERATING POSITION,...
Page 53 AIR C O N D ITIO N IN G 1 B-7 SYSTEM OPERATION - CK TRUCK S E L E C T O R B L O W E R A IR H E A T E R A /C H E A T E R A IR L E V E R...
Page 54 1 B-8 AIR C O NDITIO NING HEATER HEATER BLOWER ENTERS DEFROSTER SPEEDS COMPRESSOR SOURCE VEHICLE DOOR DOOR A V A IL OPEN TO OPEN TO F LO O R O U T LE T S O U T S ID E O FF NONE H E A T E R -D E F...
Page 55 AIR C O N D ITIO N IN G 1B-9 Fig. 1B-1 2 -M o to r Home U nit Control • Always wear safety goggles when opening refrigerant lines. • When disconnecting any fitting in the refrigeration system, the system must first be discharged of all refrigerant-12.
Page 56 1B-10 AIR CO ND ITIO N IN G "HPV” HIGH PRESSURE VAPOR LEAVING COMPRESSOR. "HPL" VAPOR IS COOLED DOWN BY CONDENSER AIR FLOW AND LEAVES AS HIGH PRESSURE LIQUID. "LPL" ORIFICE METERS THE LIQUID R-12, INTO EVAPORATOR, REDUCING ITS PRESSURE, AND WARM BLOWER AIR ACROSS EVAPORATOR CORE CAUSES BOILING OFF OF LIQUID INTO VAPOR.
Page 57: Diagnosis
AIR C O N D ITIO N IN G 1B-11 making use of the Charging Station J-23500-01 which uses the 13.60 kg (30 lb.) of Refrigerant-12. 420 ml (14 oz) Refrigerant-12 disposable cans or R-12 drums are also used. DISCHARGING, ADDING OIL, EVACUATING AND Refrigerant Charge CHARGING PROCEDURES FOR C.C.O.T.
Page 58 1B-12 AIR CO N D ITIO N IN G darkened area. If the flame remains yellow when unit is CAUTION: Do not use lighted detector in removed from leak, insufficient air is being drawn in or the any place w here combustible or explosive reaction plate is dirty.
Page 59 AIR C O N D ITIO N IN G 1B-13 SERVICE DIAGNOSTIC PROCEDURE INSUFFICIENT COOLING — A/C SYSTEM S W ITH CYCLING CLUTCH — EXPANSION TUBE (PRESSURE SENSING) MOVE TEMP. LEVER RAPIDLY BACK AND FORTH FROM HOT TO COLD. LISTEN FOR DOOR HITTING AT EACH END This System Does Not Have a Sight Glass.
Page 60 1B-14 AIR CO N D ITIO N IN G ----------------------------- 1 OFF ALL THE TIM E | A tta ch Fused J u m p e r W ire fro m C o m pre ssor H ot Lead to P ositive ( + ) B attery Post and Check C o m p re ss o r O p era tio n NOT ENGAGED...
Page 61 AIR C O N D ITIO N IN G IB -1 5 ELECTRICAL/VACUUM TROUBLE DIAGNOSIS When diagnosing problems in the electrical and then the actuator is defective or the door is mechanically vacuum systems of the air conditioning system, consult bound.
Page 62: Compressor Diagnosis
COMPRESSOR DI AGNOSIS If previous step does not Check fo r proper air gap. C L U T C H S L IP P IN G . correct clutch slippage, Correct if necessary. repair compressor. (.022.057) COMPRESSOR EN G AG ED BU T NO T O P E R A T IO N A L.
Page 63 INSUFFICIENT COOLING DIAGNOSIS CHART DASH M OUNTED UNIT (MOTOR HOME CHASSIS UNITS) The following procedures should be applied before performance testing an A/C System. 5. Check for condenser air blockage due to foreign material. 1. Check for proper belt installation and tension with J-23600. 6.
Page 64 ELECTRICAL SYSTEM DI AGNOSTIC CHART B LO W E R M O T O R IN O P E R A T IV E BLOWER MOTOR IN O PER ATIVE (C E R T A IN S P E E D S -E X C E P T H IG H (A N Y SPEED) ON C-K F O U R -S E A S O N ) Check fo r proper...
Page 65 AIR C O N D IT IO N IN G 1B-19 P osition th e c o n tro ls so th a t the: Tem perature lever is on fu ll heat. Selector o r heater lever is on Heater. Fan sw itch is on Hi.
Page 66 1B-20 AIR C O N D ITIO N IN G Fig. 1B-14-C60 System Wiring Diagram (C-K Series) 2 j - 4 = F = p - l - K l i I SELECTOR CONTROL - 2 BRN I P HARN ACC FUSED 2 0 A Fig.
Page 68 1B-22 AIR CO N D ITIO N IN G REAR BLOWER RESISTOR c ! St < -12004752 GROM MET •917542- - 2 LT BLl/BLK-872 — I t r i l - r r i — 2 LT BLUfcLK-872 -2LTBLIVBLK- H4I I M I - 2 YEL/BLK-851 —...
Page 69: Insufficient Cooling
AIR C O N D ITIO N IN G 1B-23 VACUUM RESERVOIR (IN ENGINE CO M P A RT M EN T) TO VACUUM SORCE G R A Y = T \ DASH P A N E L / * \ _______ H EA TE R CO RE CASE GRAY...
Page 70 ] T O FUSE PANEL | l G R O U N D COMPRESSOR RESISTOR 52 16 DK BLU 72 16 LT BLU BLOW ER SW ITC H 51 16 YEL SET AT C O N N E C T IO N N TO N O N E LO W N TO I &...
Page 71 AIR C O N D ITIO N IN G IB -2 5 LIG H T TR U CK S E R V IC E MANUAL...
Page 72: Evacuating And Charging Procedures
1B-26 AIR C O N D ITIO N IN G ENGINE HARNESS N U T — y HARNESS ASM / _ JUNC1 JUNCTION BLOCK COMPRESSOR SOLENOID Carburetor P.C. SWITCH CONNECTOR HARNESS ASM ACCUMULATOR PRESSURE CYCLING SWITCH RELAY COMPRESSOR VIEW A Fig.
Page 73 AIR C O N D ITIO N IN G 1B-27 • Compressor - Remove, drain oil, measure, replace same amount of new oil plus 30 ml (1 oz.). • Evaporator - Add 90 ml (3 fluid ounces). • Condenser - Add 30 ml (1 fluid ounce). •...
Page 74 1 B-28 AIR C O N D ITIO N IN G IB-23). As hose is slowly tightened down onto schrader Refrigerant Charge valve, Refrigerant-12 will be in to discharge from the system into the container. If no discharge occurs, check for missing Overhead System System or defective schrader depressor in hose fitting.
Page 75 AIR C O N D ITIO N IN G 1B-29 CLOSE ALL CONTROLS J 23500-01 SERVICE CHARGING STATION REFRIGERANT-12 3 FULLY OPEN GAUGE SET VACUUM VALVE CONNECT LOW-SIDE GAUGE HOSE TO LOW-SIDE PRESSURE SERVICE FITTING ON VEHICLE'S ACCUMULATOR ASM. USING J 5420 ADAPTER 5 "SLOWLY"...
Page 76 IB -3 0 AIR C O N D ITIO N IN G 1. Connect Manifold Gage Set J-5725-04 as shown in Figure IB-24. • LOW pressure gage set valve to Accumulator fitting • Gage set center hose to Refrigerant-12 source •...
Page 77 AIR C O N D ITIO N IN G 1B-31 J5725-04 MANIFOLD GAUGE SET T H ls H j GH PRESSURE V A L V E IS OPEN AND VACUUM PUMP LINE USING J-5420 DISCONNECTED ONLY DURING OPEN DURING EVACUATION ADAPTER EVACUATION AND CHARGING...
Page 78: Engine Idle Compensator
1B-32 AIR C O N D ITIO N IN G Installation 1. If oil previously drained from the compressor upon removal shows no evidence of contamination, replace a like amount of fresh refrigeration oil into the compressor before reinstallation. If it was necessary to service the entire system because of excessive contamination in the oil removed, install a full charge of fresh refrigeration oil into the compressor.
Page 79 AIR C O N D IT IO N IN G IB -3 3 Fig. 1 B -2 6 -C o m p re s s o r M ounting LIG H T T R U C K S ER V IC E MANUAL...
Page 80: Condenser
1 B-34 AIR C O N D ITIO N IN G Use new "O" rings, coated with clean refrigeration oil, when connecting all refrigerant lines. 11. Evacuate, charge and check the system. A CC U M U LA TO R - ALL Replacement 1.
Page 81: Expansion Tube-All
AIR C O N D ITIO N IN G IB -3 5 10. Remove the core mounting strap screws and remove the core. 11. To install, reverse Steps 1-10 above. 12. Refill coolant system and connect the battery ground strap. Check temperature door cable adjustment. KICK PAD VALVE - CK SERIES Replacement (Fig.
Page 82 1B-36 AIR C O N D ITIO N IN G Fig. 1 B-29--Heater Hose Routings (C-K Series) LIG H T T R U CK S E R V IC E M AN U AL...
Page 83: Vacuum Tank
AIR C O N D ITIO N IN G IB -3 7 UPPER CENTER DISTRIBUTOR DUCT RIGHT HAND OUTLETS LEFT DISTRIBUTOR DUCT AND FOOT COOLER LOWER CENTER DISTRIBUTOR DUCT Fig. 1B-30~Air Selector and Ducts (C-K Series) R e p la c e m e n t R e p la ce m e n t 1.
Page 84: Overhead System-C-K Models
IB -3 8 AIR CO ND ITIO N IN G REAR DUCT This duct covers the blower-evaporator assembly, at the rear of the vehicle, and incorporates four adjustable air outlets (fig. IB-36). Replacement 1. Disconnect the battery ground cable. 2. Disconnect the drain tube from the rear duct. Fig.
Page 85 AIR C O N D ITIO N IN G 1B-39 GRAY-TO /PLENUM VALVE VIEW Fig. 1 B-34--Vacuum Line Routing - CK Models VIEW A Fig. 1B-35~Engine Compartment Wiring Harness (C-K Series) LIG H T T R U C K S E R V IC E MANUAL...
Page 86: Expansion Valve
1B-40 AIR C O N D ITIO N IN G 4. Place the lower case and blower motor assembly in position in the vehicle and install the lower to upper case screws. Rotate the blower wheels to make sure that NOTICE: they do not rub on the case.
Page 87: Evaporator Core
AIR C O N D ITIO N IN G 1B-41 EVAPORATOR BLOWER-EVAPORATOR SCREEN UPPER CASE EVAPORATOR LEAD WIRE EXPANSION EVAPORATOR VALVE CORE SENSING BULB EVAPORATOR Fig. 1 B-40-Expansion Valve C69 System OUTLET LINE INLET LINE EVAPORATOR 4. Disconnect the blower motor lead and ground wire connections.
Page 88: Fuse
1 B-42 AIR CO N D ITIO N IN G Fig. 1 B-4 1--Blower Switch (C-K Overhead System) Replacement 1. Disconnect the battery ground cable. 2. Remove the switch retaining screws. 3. Disconnect the wiring harness at the switch and remove the switch.
Page 89 AIR C O N D ITIO N IN G 1B-43 Fig. 1 B-43--Heater D is trib u to r Duct-G Series 12. Remove three (3) nuts from bolts attaching heater b. If the motor mounting flange sealer has hardened, core case to dash panel and one (1) screw at lower right or is not intact, remove the old sealer and apply a new bead corner (inside).
Page 90: Evaporator Core
1 B-44 AIR C O N D ITIO N IN G 4. Disconnect all electrical connectors from core case assembly. 5. Remove bracket at evaporator case. 6. Remove right hand marker lamp for access. 7. Disconnect accumulator inlet and outlet lines and 2 brackets attaching accumulator to case.
Page 91 AIR C O N D ITIO N IN G 1 B-45 Fig. 1B-47~Air Deflector Outlets (G Series C60 System) 3. To install, reverse Steps 1-3 above. 3. To install, reverse Steps 1-3 above. CENTER A.C OUTLET - G SERIES BLOWER MOTOR RELAY - G SERIES Replacement Replacement (Fig.
Page 92 1B-46 AIR C O N D ITIO N IN G A /C DUC TW O RK Air Conditioning duct attachment is illustrated in Figure IB-63. 7. Remove duct (distributor) attaching screws. DEFROSTER DUCT 8. Remove center deflector. Defroster duct mounting is illustrated in Figure IB-64. 9.
Page 93: Circuit Breaker
AIR C O N D ITIO N IN G IB -4 7 V A C U U M TANK - G SERIES (Figures 1B-60 & IB -6 1 ) Replacement 1. Raise the hood. 2. Disconnect the vacuum harness at the tank. 3.
Page 94 1B-48 AIR CO N D ITIO N IN G COMPRESSOR COMPRESSOR ASSEMBLY 'O" RING HOSE & TUBE ASSEMBLY COND. OUTLET HOSE & TUBE ASSEMBLY ACCUM DEHYDR ASSEMBLY OUTLET PIPE G MOD. V ENG. C60/69 SIDE RAIL HOSE & TUBE ASSEMBLY G MOD.
Page 95 AIR C O N D ITIO N IN G 1B-49...
Page 96 1 B-50 AIR CO N D ITIO N IN G LIG H T T R U C K S ER V IC E M AN U AL...
Page 97 AIR C O N D IT IO N IN G 1B-51 LIG H T T R U C K SER V IC E M ANUAL...
Page 98: Condenser
1B-52 AIR C O N D ITIO N IN G Fig. 1 B-64--Defroster Duct-G Series Fig. 1 B-65--Temperature Cable-G Series DASH MOUNTED SYSTEM -M O TO R HOME CHASSIS 4. Remove the receiver-dehydrator bracket attaching This system is installed on the vehicle and checked at assembly.
Page 99: Sight G Lass
AIR C O N D ITIO N IN G 1 B-53 BLOWER ASSEM BLY Removal (Fig. 1B-71) 1. Remove the cover plate and separate the upper and lower case halves. Remove blower motor mounting strap screw and remove strap. 2. Remove blower assembly. Remove the wheels from the motor shaft.
Page 100: Resistor
IB -5 4 AIR C O N D ITIO N IN G Fig. 1B-68--Sight Glass R eplacem ent FUSE RESISTOR The blower motor resistor is located on the top of the This Unit does not incorporate an in-line fuse. The lead wire is connected to the Heater Wiring Harness and unit.
Page 101 AIR C O N D ITIO N IN G IB -5 5 Fig. 1 B -73~T herm ostatic and B lo w e r Switches Fig. 1B-7 1 -B lo w e r A ssem bly (M o to r Home Chassis Unit) THERMOSTATIC SWITCH SCREEN CAPILLARY TUBE...
Page 102: Specifications
1B-56 AIR C O N D ITIO N IN G SPECIFICATIONS AIR CONDITIONING Compressor Type ..Cylinder Axial 4 Cylinder Radial Displacement ....12.6Cu. In. Cylinder Axial ....10.0 Cu. In. 4 Cylinder Radial Rotation Amps. Torque Specifications (Cold) (Cold) Volts...
Page 103: Special Tools
AIR C O N D ITIO N IN G IB -5 7 SPECIAL TOOLS 1. J-25030 Clutch Hub Holding Tool 2. J-25029 Rotor B earing Remover and Rotor Assy. Installer 3. J-24895 Main Bearing Installer 4. J-24896 M ain B earing Remover 5.
Page 104 1B-58 AIR C O N D ITIO N IN G SPECIAL TOOLS 1. J -8 3 9 3 C h a rg in g S tation 11. J -5 4 2 1 -0 2 Pocket Thermometers (2) 22. J -93 9 8 Pulley B ea rin g Remover 2.
Page 105 FRAME 2A-1 SECTION 2A FRAME CONTENTS General Description................2A-1 On Vehicle Service................2A-1 Maintenance and Inspection............2A-1 Underbody Inspection..............2A-1 Frame Inspection................2A-1 Frame Alignment................2A-1 Underbody Alignment..............2A-4 Excessive Body Damage..............2A-4 GENERAL DESCRIPTION Light duty 10-30 Series frames are of the ladder channel The G-Van frame side rails, cross sills and outriggers section riveted type.
Page 106 2A-2 FRAME Fig. 2A-1-Frame Horizontal Checking-Typical Support vehicle so that frame sidemembers are 3. Measure diagonals marked A, B and C. If the lengths of intersecting diagonals are equal and these parallel to the ground. diagonals intersect the centerline, frame area included Tramming Sequence (Fig.
Page 107 FRAME Fig. 2A-2--C-K-P Series Truck Frame M ode l 13-3/8 19-7/8 17-3/4 17-3/4 16-3/4 CA107 15-1/4 14-7/8 19-7/8 15-5/8 17-3/4 69-5/8 76-1/2 16-7/8 16-7/8 16-3/4 CA109 13-3/8 15-1/4 19-7/8 14-7/8 17-3/4 17-3/4 19-7/8 15-5/8 17-3/4 69-5/8 86-1/2 120 16-7/8 16-7/8 CA209 13-3/8 15-1/4...
Page 108 2A -4 FRAME Fig. 2A-4-G Van Truck Reference Dimensions Frame Repair required. Welding 1. The horizontal dimension between the two points Before welding up a crack in frame, a hole should be to be trammed. drilled at the starting point of the crack to prevent spreading.
Page 109 BUMPERS 2B-1 SECTION 2B BUMPERS CONTENTS General Description............2B-1 Front Bumper G Series..........2B-2 Service Procedures - 10 thru 30 series...... .2B-1 Rear Bumper G Series..........2B-2 Front Bumper - C, K and P Models......2B-1 Rear Bumper G Series..........2B-2 Rear Bumper - C and K Models........2B-1 Rear Step Bumper G Series........
Page 110 2B-2 BUMPERS .160/.180 (CLEARANCE) Installation Install rear step bumper by reversing removal procedure. Connect license lamp wiring. Fig. 2B-4--Rear Step Bumper C and K Models FRONT BUMPER ■ G MODELS Removal Fig. 2B-5, 2B-6 braces and remove the bumper. 1. Remove nuts securing bumpers to brackets and braces from left and right side.
Page 111 BUMPERS 2B-3 SPECIFICATIONS T O R Q U E S P E C IF IC A T IO N S C , P A N D K Front B u m p e r ................3 5 f t .-lb s . Fro n t B u m p e r B ra c k e t a n d B ra c e ........
Page 113 CHASSIS SHEET METAL 2C-1 SECTION 2C CHASSIS SHEET METAL CONTENTS General Description............2C-1 Front Sheet Metal - CK Series........2C-6 On Vehicle Service............2C-1 Radiator Support............2C-7 Hood Assembly - CK Series........2C-1 Front Fender............. ..2C-9 Hood Hinge Spring Replacement......2C-1 Front Fender and Skirt..........2C-9 Hood Hinge...............
Page 114: Hood Lock Assembly
2 C-2 CHASSIS SHEET M ETAL APPROX. Q " Installation 1. Install hinge assembly to fender and align within scribe marks. Install bolts. 2. Install hood hinge spring. 3. Install bolts and align hood. See Hood Alignment in this section. Hood Lock Assembly A bolt-type hood lock is used as shown in Fig.
Page 115: Hood Assembly
CHASSIS SHEET METAL 2C-3 Installation 1. If original hood is to be installed, position hood to hinges and install four cap screws snug which attach hinges to hood. Fig. 2C -4~Hood Lock Catch and S u p p o rt-C K M odels w ith If a new hood is to be installed, perform procedures as T- 44 outlined under Alignment, directly below.
Page 116: Hood Bumper
2C-4 CHASSIS SHEET METAL 1. Scribe a line around the entire hinge plate to be repositioned. 2. Loosen the appropriate screws and shift the position of the hood into correct alignment using the scribe marks to check amount of movement. Check alignment by tightening screws and closing the hood.
Page 117 CHASSIS SHEET METAL 2C-5 Hood Assembly-G Model (Fig. 2C-9) Removal 1. Lay a fender cover along cowl top to prevent hood from scratching painted surfaces. 2. Open hood and prop in full open position. If hood is to be reinstalled and present alignment is satisfactory, mark each hinge in relation to hood, to assure original alignment.
Page 118 2C-6 CHASSIS SHEET METAL SNORKEL LOCATION L6 SNORKEL Fig. 2C -13--C arburetor O utside A ir Inle t S norkels-C K M odel Shims which are found at various locations should be recorded to ease installation of sheet metal assembly. Refer to Fig.
Page 119: Radiator Support
CHASSIS SHEET M ETAL 2C-7 Radiator Support Removal 1. Remove hood as described in this section. 10. With a helper, remove front sheet metal assembly, 2. Drain radiator, saving coolant, loosen attachments with radiator, battery, horn and voltage regulator attached. and remove radiator and coolant recovery tank.
Page 120 2C-8 CHASSIS SHEET M ETAL FLUSH HOOD ASSY SECTION D-D SECTION C-C I Hood surface . 06 below n o t e at Section C-C to flush at Section B-B and Section D-D. FENDER-* I' V I DOOR SECTION F-F^ - 1 - 0 0 ASSY I Shim front fender to obtain NOTE...
Page 121: Front Fender
CHASSIS SHEET M ETAL 2C-9 11. Install radiator coolant recovery tank hoses and 6. Remove two (2) screws attaching support bracket shroud. to fender. 12. Connect removed wiring to radiator support. 7. Remove five (5) screws attaching radiator support to front fender. 13.
Page 122: Running Board
2C -10 CHASSIS SHEET METAL W O O D GRAIN APPLIQ UE (INSTALLATIO N PROCEDURE) General The wood grain applique (transfer film) is a vinyl material with a pressure sensitive adhesive backing. The transfers are serviced in precut panels. The transfers are designed with an appealing wood grain pattern and a 50 degree or semigloss finish.
Page 123 CHASSIS SHEET METAL 2 C -1 1 COWL TO HOOD .18 ± .03 GAP NOTE Hood surface flush to .06 below cowl vent grille & constant from < £ to hood rear corners. FENDER TO COWL .07 GAP (Ref) NOTE Cowl vent grille surface flush to .03 below front fender.
Page 124: Specifications
2C -12 CHASSIS SHEET METAL or moisture bubbles by piercing each at an acute angle with 8. If the wrap-around of the transfer has trouble a fine pin or needle and by pressing the bubble down. sticking to fender edges, brush vinyl adhesive onto the fender or transfer area.
Page 125: General Description
BODY 2D-1 SECTION 2D CAB AND BODY The following notice applies to one or more steps in the assembly procedure of components in this portion of the manual as indicated at appropriate locations by the terminology "See Notice on page 1 of this Section".
Page 126 2D-2 BODY LIG H T T R U CK S E R V IC E M AN UAL...
Page 127 BODY 2D-3 Fig. 2 D - 5 - T y p i c a l "0 5 " and "0 6 " Vans Fig. 2 D -6 -T y p ic a l "0 3 " Van LIG H T T R U C K SER V IC E M ANUAL...
Page 128 2D -4 BODY ON VEHICLE SERVICE C-K MODELS INDEX Replacement............2D-16 Front End Hinges..............2D-16 Windshield Wipers............2D-5 Stationary Glass.............2D-17 Glove Box..............2D-5 Window and Regulator.........2D-17 Rear View Mirrors............2D-5 Locks, Handles, Rods......... ..2D-17 Body Glass Weatherstrip............2D -18 Windshield Glass............2D-6 Rear Doors Stationary Body Glass..........
Page 129: Front End
BODY 2D-5 FRONT END Before installing wiper arms, operate wiper motor W IN D SH IE LD W IPERS momentarily which should rotate pivot shafts to park Windshield wiper units on all models are of the two- position. Install arms and shafts. speed electric type.
Page 130: Body Glass
2D-6 BODY CO W L VENT VALVE - FIGURE 2 D -1 2 ,, . . attaching screws allows removal of the valve from the side Two styles are shown in Figure 2D-12. Removing the panels. BODY GLASS CAUTIO N: Always w ea r gloves and eye CK TRUCK W IN D S H IE LD REPLACEMENT glasses w hen handling glass to avoid personal injury.
Page 131 BODY 2D-7 Fig. 2 D - 1 4 - A p p l y i n g Pressure to W in ds hie ld a. Widen end slot to accept dispensing end of adhesive material tube. b. Reduce diameter of plunger disc on rod so that disc Fig.
Page 132 2D -8 BODY ■ ----------- - * Fig. 2D-1 7--Checking W in ds hie ld Opening Fig. 2 D -1 6 -R e m o v in g W in ds hie ld from Opening Recheck windshield opening same time assist the lip of the rubber weatherstrip channel satisfactory proceed as follows: over the pinchweld flange with a flat bladed tool.
Page 133: Windshield Glass
BODY 2D-9 5. Thoroughly clean surface of glass to which blackout 12. On windshields equipped with embedded antenna, primer will be applied (around edge of inside surface) by tape pigtail of antenna to inside surface of windshield glass wiping with a clean, alcohol dampened cloth. Allow to air in a convenient and accessible position.
Page 134 2D -10 BODY Fig. 2 D - 1 9 — Installing Reveal Molding Fig. 2 D -21--Bod y Side W i n d o w - (16 and 0 6 ) Fig. 2D-20 --B a ck W i n d o w Glass - (03, 63) BODY SIDE DOORS DOOR A D JU S TM E N TS Striker Bolt Adjustm ent...
Page 135 BODY 2D-11 - To adjust striker in and out, loosen a. Remove the door to upper hinge retaining bolts. In and O u t bolt, adjust horizontally to desired position and tighten bolt b. With aid of an assistant to support weight of door, securely.
Page 136 2D -12 BODY Fig. 2 D -27--Doo r Trim Pad 3. Using new glass channel filler, cut the piece to be installed two inches longer than necessary for the channel. Place this piece of filler (soapstoned side of filler away from DOOR VENTILATOR ASSEM BLY-Fig.
Page 137 BODY 2D -13 BEND TAB OVER HEX NUT Fig. 2 D-29~Rem oving Ventilator Assembly Fig, 2D-31--Bend Tabs Over Hex Nut Installation 3. Mask or cover upper portion of door window frame. 1. Lower the ventilator assembly into the door frame. Remove ventilator assembly as previously outlined.
Page 138 2D -14 BODY NOTCH Fig. 2D-3 3 ~ R e m ov ing Door Glass Install regulator by reversing above steps. Lubricate regulator gear with lubriplate or equivalent. W IN D O W REGULATOR - POWER - CK Fig. 2 D -35 --P o w e r W i n d o w Regulator, M otor and Connector MODELS In the case that window will not operate, check 2.
Page 139 BODY 2D -15 Fig. 2 D -37 ~ O u ts id e Handle and Lock Cylinder Door Lock Cylinder -Fig 2D-37 Replacement 1. Raise door window. 2. Remove trim panel as outlined. 3. Use a screwdriver or other suitable tool to slide the lock cylinder retaining clip out of engagement with the lock cylinder.
Page 140: Side Doors
2D -16 BODY removing all foreign material from door opening surface proceed as follows: 1. Open door and block open. POWER DOOR LOCKS - CK MODELS (Fig. 2D- 2. Remove sill plate retaining screws and remove sill plate. Replacement 3. Remove side door inner weatherstrip seal. 1.
Page 141 BODY 2D-17 S TA TIO N A R Y GLASS-REAR DOOR Replacement 1. Lower window to full down position. 2. Remove remote control knob and window regulator handle. W IN D O W GLASS-FIG. 2D -46 3. Remove screws retaining door trim pad, and remove Replacement trim pad.
Page 142: Adjustments
2D -18 BODY a. Inside handle control rod. Remote Control-Fig. 2D -48 b. Remote control lower rod. Replacement 1. Remove regulator handle, remote control knob and c. Outside handle control rod. trim pad. 3. Remove screws retaining lock assembly to door 2.
Page 143 BODY 2D -19 LOCKS, HANDLES AND RODS The rear door lock, outside handle, lock cylinder, control rods and latch are shown in figures 2D-51 and 2D- 52. The rods can be disconnected from the lock, latch or handle by disengaging the retaining clips, as shown. The lock cylinder is removed in the same manner as the front side door lock cylinder.
Page 144 2D -20 BODY LIG H T T R U C K S ER V IC E MANUAL...
Page 145 BODY 2D-21 PRESS FASTENERS INTO HOLES Fig. 2 D - 5 4 ~ W e d g e and Striker Adjustments Fig. 2 D -56 ~ W e a th e rs trip ~ R .H . Rear Door ENDGATES (06 AND 16) Coach models (06) and utility models (16) use endgates 2.
Page 146: Hinges
2D -22 BODY Fig. 2 D -59 ~ L atc h and Remote Controls~(06 Only) 7. To install, reverse removal procedure. 5. Remove R.H. torque rod bracket screws, figure 2D- 58, then remove torque rod from endgate. HINGES 6. Remove screws connecting cam assemblies to sash Replacement assembly, figure 2D-60, then remove cam assemblies.
Page 147: Hinges
BODY 2D -23 A djustm ents To install endgate, reverse the above procedure. Loosen bolts, adjust at either endgate hinge position or HINGE endgate latch, then retighten bolts. Replacement 1. Lower endgate and disconnect hinge to be replaced ENDGATE ASSEMBLY--(16) MODELS ONLY by removing hinge-to-body bolts.
Page 148: Endgates
2D -2 4 BODY Fig. 2D-64--Grasping Torque Rod (16) 3. Loosen four bolts retaining endgate hinge to body. 6. Disconnect blockout rod from control assembly by detaching spring and removing two screws retaining rod to 4. Move endgate slightly away from body. inner panel.
Page 149 BODY 2D -25 Fig. 2 D - 6 8 - L a t c h e s and Rods 16. Reverse the above steps for reassembly. 4. To install, reverse removal procedure. ELECTRIC W IN D O W (16) MODELS Blockout S w itch (Fig.
Page 150 2D -28 BODY Finally, reconnect the courtesy light and reinstall the upper spare tire brace using 2 bolts (1 bolt being the # 2 top-to-side panel bolt). Fig. 2 D -79 ~ F o ld in g Top Assem bly LIG H T T R U C K S ER V IC E M AN UAL...
Page 151 BODY 2D -29 SEATS SEAT BELTS SEAT MOUNTING SERVICING LAP AND SHOULDER Typical Seat Mounting provisions are shown in figures BELTS - ALL MODELS 2D-83 through 2D-89. Before servicing or replacing lap and shoulder belts, including single loop belt systems, refer to the following precautionary items: See NOTICE on page 1 of this section NOTICE:...
Page 152 2D -30 BODY LIG H T T R U C K S E R V IC E M AN UAL...
Page 153 BODY 2D-31 Fig. 2D-84~Driver's Bucket Seat (03 and 0 6 ) LIG H T T R U CK SER V IC E M ANUAL...
Page 154 2D -32 BODY LIG H T T R U C K S ER V IC E M ANUAL...
Page 155 BODY 2D -33 LIG H T T R U C K SER V IC E M AN UAL...
Page 156 2D -34 BODY LIG H T T R U C K S E R V IC E M ANUAL...
Page 157 BODY 2D -35 Fig. 2 D - 9 0 ~ S e a t S ep ara tor Co m p artm ent and D o o r-C K Models LIG H T T R U C K S ER V ICE M ANUAL...
Page 158: Seat Belts
2D -38 BODY G MODELS INDEX Sliding Side Door Front End Description..............2D-48 Windshield Wipers........... 2D-38 Adjustments..............2D-48 Cowl Ventilator Grille..........2D-39 Front Latch..............2D-50 Side Ventilator Valve..........2D-39 Rear L atch ............. ..2D-51 Rear View M irror............ 2D-39 Upper Rear Hinge............2D-51 Body Glass Strikers...............2D-52...
Page 159: Cowl Ventilator Grille
BODY 2D-39 Fig. 2 D -9 6 ~ W in d s h ie ld W i p e r Linkage CO W L VENTILATOR GRILLE REAR V IE W MIRRO RS Replacement 1. Remove windshield wiper arms. Inside Rear V iew M irror 2.
Page 160: Body Glass
2D -40 BODY Fig. 2 D - I 0 0 ~ 0 u t s i d e Rear V i e w Mirrors BODY GLASS pressures, extremes of temperature, motion of the vehicle, CAUTION: Alw ays w ear gloves and eye etc.
Page 161 BODY 2D-41 CHECKING BLOCKS APPLY LUBRICANT Fig. 2 D -1 0 2 ~ C h e c k in g W in ds hie ld Opening 5. With the windshield supported and centered in its opening, check the relationship of the to the body glass opening flange around the entire perimeter of the glass.
Page 162: Front Door
2D -42 BODY S W IN G O U T W IN D O W Replacement 1. Swing out the window. See figure 2D-105. 2. Remove screws retaining latch to body. 3. Remove window by swinging glass out, separating assembly at hinge. 4.
Page 163: Ventilator
BODY 2D-43 4. Apply adhesive to door. 5. Position weatherstrip by locating part number at top of vent window, making sure that plastic nails align with holes in door. 6. Install weatherstrip by pressing each nail into the door. T R IM PANEL, A R M REST AND HANDLES Removal 1.
Page 164 2D -44 BODY Fig. 2D-1 1 1 -A d ju s tin g V e n tila to r Tension 4. Reinstall all screws and tighten. 5. Install and tighten the three screws at the upper front of the door. Adjustment 1.
Page 165 BODY 2D -45 1. Disconnect battery ground cable. 2. Remove door trim panel. 3. Disconnect harness from regulator. 4. Remove screws securing regulator to inner panel. 5. Push regulator out of door opening while holding rear of assembly, then slide assembly to the notches in the carrier channel and out through the door access hole.
Page 166 2D-46 BODY LOCK NOTE | Rod and clip must be assembled to lock asm before lock asm is installed to door. REMOTE CONTROL AND CO NNECTING v i e w ROD-Fig. 2 D -1 14 2D-1 14-Lock and Remote Control Assembly Fig.
Page 167 BODY 2D-47 SWITCH CONTACT (DOOR) IviwfBl SWITCH CONTACT (PILLAR ) Fi g. 2 D - 1 1 6 - P o w e r D o o r L o c k A c t u a t o r s L IG H T T R U C K SERV ICE M ANUAL...
Page 168: Sliding Side Door
2D -48 BODY SLIDING SIDE DOOR 3. Loosen lower front roller bracket-to-arm bolts. DESCRIPTION 4. Adjust front of door in or out, then tighten bolts to The weight of the sliding side door is supported by the specifications. upper rear hinge-and-roller assembly, and by the lower front 5.
Page 169: Front Latch
BODY 2D-49 STRIKER FORE-AND-AFT ADJUSTMENT SLOTS CENTER ROLLER VERTICALLY IN TRACK SO IT DOES N O T C O N TAC T THE TRACK IN FULL OPEN U P -A N D -D O W N OR FULL ... J ADJUSTMENT SLOTS c l o s e d POSITION...
Page 170 2D -50 BODY Fig. 2D-1 19--Hold-Open Catch Upper Rear Hinge-To-Striker Adjustm ent FRONT LATCH ASSEM BLY Removal If door has been removed and is being NOTICE: 1. Remove trim panel, if so equipped. reinstalled, adjust striker-to-lower hinge lever before 2. Remove access cover. closing door.
Page 171: Upper Rear Hinge
BODY 2D-51 Installation 1. Install latch assembly into door by working latch assembly behind the lower hinge door catch. 3. Disconnect rear latch rods from front latch 2. Connect lower hinge door catch, lock cylinder rod, assembly, shown in figure 2D-121. door lock rod, and both rear latch rods.
Page 172: Rear Door Hinge
2D -54 BODY Fig. 2D-1 2 6 -C h e ck in g Assem bly of Hinge REAR DOORS REAR DOOR HINGE STRAP REAR DOOR HINGE Removal Replacement 1. Open door. Support door so that when hinge screws are removed door weight will be on support. 1.
Page 173: Adjustments
BODY 2D -55 2. Install handle and gaskets. Torque screws to REAR DOOR UPPER OR LOWER LATCHES specifications. A N D /O R LATCH RODS 3. Install trim panel. Removal REAR DOOR LOCK CYLINDER 1. Remove trim panel. Removal 2. Disengage rod from remote control assembly. See 1.
Page 174: Passenger Seat
2D-56 BODY REAR DOOR STRIKER A N D WEDGE A D JU S TM E N T See NOTICE on page 1 of this section NOTICE: regaring Rear Door Striker fasteners. 1. Adjust striker by adding or deleting shims as necessary to obtain dimension as shown in figure 2D-130.
Page 175 BODY 2D-57 are used. When the latch assemblies are depressed, their cams and the hooks of the retainers are drawn tightly onto the anchor pins for secure seat attachment. Removal accomplished using following procedure: 1. Pull up on quick release latches located at lower front of seat legs (right and left hand sides).
Page 177 BODY 2D-59 Fig. 2D -134--Sw ivel B ucket Seat Assem bly - G Series Fig. 2D -136--Front Lap B elt Installatio n L IG H T T R U C K SER V IC E M AN UAL...
Page 178 2D -62 BODY BODY MOUNTING (C-K MODELS)-FT. LBS. Model (03) — (06) (14) — (63) G MODELS SLIDING SIDE DOOR MIRRORS AND SUNSHADE Inside Rear View Mirror to Bracket ......15 in. lb. Remote Control (front latch) to D o o r...... in.
Page 179 BODY 2D-63 SPECIAL TOOLS 1. J-2 2 5 8 5 F ro n t D o o r Hinge, B o lt W rench 2. J-22 57 7 W ind shie ld C hecking B locks 3. J-7797 D o o r H andle C lip Rem over 4.
Page 181 FRONT A LIG N M E N T 3A-1 SECTION 3A FRONT ALIGNMENT CONTENTS General Description....3A-1 Maintenance and Adjustments 3A-2 Specifications......3A-6 GENERAL DESCRIPTION FRONT A LIG N M E N T CAMBER The term "front alignment" refers to the angular Camber is the tilting of the front wheels from the relationships between the front wheels, the front suspension attaching parts and the ground.
Page 182 3A-2 FRONT A LIG N M E N T <[. OF WHEEL DIRECTION CAMBER ANGLE CASTER ANGLE FRONT VIEW SIDE VIEW Fig. 3 A -1 -C a s te r - C am b er - Toe-In MAINTENANCE AND ADJUSTM ENTS 10.
Page 183 FRONT A LIG N M E N T 3A-3 PIVOT SHAFT OUTBOARD OF FRAME CASTER CAMBER FORWARD Fig. 3 A -2 -C a ste r - Cam ber A d ju s tm e n t of this manual should be used by owners, dealers and G 30 Models, C 2 0 and 30 Models w ith 7 /8 "...
Page 184 3A-4 FRONT A LIG N M E N T Camber 1. Determine the camber angle from the alignment ''B” IS LESS THAN “ A” WHEN WHEELS TOE-IN equipment. 2. Add or subtract shims from both the front and rear bolts to affect a change. Toe-In 1.
Page 185 FRONT A LIG N M E N T 3A-5 SPECIFICATIONS W HEEL A L IG N M E N T SPEC IFIC ATIO NS CASTER DIMENSION " A " MODELS 2%" 2%" 3 " 314" 3%" 3 % " 41 A " 43 A "...
Page 187 STEERING LINKAGE 3B1-1 SECTION 3B1 STEERING LINKAGE The following notice applies to one or more steps in the assembly procedure of components in this portion of the manual as indicated at appropriate locations by the terminology "See Notice on page 1 of this Section".
Page 188 3B1-2 STEERING LINKAGE POSSIBLE CAUSE CONDITION CORRECTION Front wheel bearings loosely Adjust bearings to obtain proper Excessive Play or Looseness in adjusted. end play. Steering System. Worn steering shaft couplings. Replace part. Worn upper ball joints. Check and replace if necessary. Steering wheel loose on shaft, Tighten to specified torque, loose pitman arm, tie rods,...
Page 189 STEERING LINKAGE 3B1-3 POSSIBLE CAUSE CORRECTION CONDITION Inflate to specified pressures. Low or uneven tire pressure. Hard Steering - Excessive Effort Required at Steering Wheel. Lube with specified lubricant. Steering linkage or bolt joints need lubrication. Lube replace or reposition Tight or frozen intermediate rod, tie rod or idler socket.
Page 190: Maintenance And Adjustments
3B1-4 STEERING LINKAGE MAINTENANCE AND ADJUSTM ENTS LUBRICATION A. Any fluid leakage during this check. LUBRICATION OF STEERING LINKAGE B. Seizing or binding condition during travel of The steering linkage under normal conditions should damper. be lubricated with any water resistant EP type chassis lubricant every 7,500 miles (12 000 km) or six months, C.
Page 191: Relay Rod
STEERING LINKAGE 3B1-5 RELAY ROD IDLER ARM TIE ROD ASSEMBLY- ASSEMBLY f~A] All clamps must be b e tw e e n & ica u t ion i clear o f dimples b e fo re torquing nut. KNUCKLE |~ B ~ | Exposed socket thread length must be STEERING GEAR equal w ithin ±...
Page 192 3B1-8 STEERING LINKAGE Check the total rotation of the tie rod assembly using the following procedure: a. Lubricate inner and outer tie rod ends. b. Attach vise grip pliers to the outer tie rod end. c. Rotate outer tie rod end counterclockwise (up) to maximum position.
Page 193: Steering Connecting Rod
STEERING LINKAGE 3B1-9 Removal pressure. Do not hammer or damage to steering gear 1. Raise vehicle on a hoist. may result. Be sure to install the hardened steel washer 2. Remove the nut from ball stud at the relay rod. before installing the nut.
Page 194 3B2-2 M A N U A L STEERING GEAR POSSIBLE CAUSE CORRECTION CONDITION Rattle or Chuck in Steering Gear. Insufficient or improper lubricant Add lube specified. in steering gear. Tighten to specified torque. Pitman arm loose on shaft or steering gear mounting bolt loose. Loose or worn steering shaft Replace steering shaft bearing.
Page 195 M A N U A L STEERING GEAR 3B2-3 CONDITION POSSIBLE CAUSE CORRECTION Excessive Play or Looseness in Front wheel bearings loosely Adjust to obtain proper end play. Steering System. adjusted. Worn upper ball joints. Check and replace ball joints if necessary.
Page 196 3B2-4 M A N U A L STEERING GEAR MAINTENANCE AND ADJUSTMENTS 3. Remove the pitman arm nut. Mark the relationship LUBRICATION OF M A N U A L STEERING GEAR of the pitman arm to the pitman shaft. Remove the pitman The manual steering gear is factory-filled with steering arm with Tool J-6632 or J-5504 as shown in Figure 3B2-4.
Page 197 M A N U A L STEERING GEAR 3B2-5 to slip over pitman shaft with hand pressure. Do not hammer the pitman arm onto the pitman shaft. Be sure to install the hardened steel washer before installing the nut. 11. Install the horn button cap or shroud and connect the battery ground cable.
Page 198 3B2-6 M A N U A L STEERING GEAR Fig. 3B2-8--Steering Gear Attachment, G-P Models If flexible coupling alignment pin plastic spacers Installation were not used, center the pins in the slots in the steering shaft flange and then install and torque the flange bolt nuts See NOTICE on page 1 of this section NOTICE: to specifications.
Page 199 M A N U A L STEERING GEAR 3B2-7 Inspect the lubricant in the gear for NOTICE: 8. Install a new side cover gasket onto the gear contamination If the lubricant is contaminated in any housing. way, the gear must be removed from the vehicle and 9.
Page 200 3B3-2 POWER STEERING SYSTEM b. Snug all pump mounting bolts and remove pry bar. System Checks c. Tighten all pump mounting bolts to specified torque. Many factors affect power operation of the steering d. Check belt tension and remove the belt tension gage. system, of which the most common are: 1.
Page 201 POWER STEERING SYSTEM 3B3-3 CONDITION POSSIBLE CAUSE CORRECTION SYSTEM NOISE There is some noise in all power steering systems. Common complaints are listed as follows: Pump noise-“chirp” . Loose belt. Adjust belt tension to specification. Belt squeal. Loose belt. Adjust belt tension to specification. Gear noise ( “hissing”...
Page 202 3B3-4 POWER STEERING SYSTEM POSSIBLE CAUSE CORRECTION CONDITION Scored pump pressure plates, thrust Replace affected parts, flush system. Pump growl plate or rotor. Note: Most noticeable at full wheel travel and stand still parking Extreme wear of pump cam ring. Replace affected parts.
Page 203 POWER STEERING SYSTEM 3B3-5 CONDITION POSSIBLE CAUSE CORRECTION Poor return of steering. (Cont’d.) Steering gear adjustments over Check adjustment with pitman arm specifications. disconnected. Readjust if necessary. Sticky or plugged valve spool. Remove and clean or replace valve. Rubber spacer binding in shift tube. Make certain spacer is properly seated.
Page 204 3B3-6 POWER STEERING SYSTEM POSSIBLE CAUSE CORRECTION CONDITION Lack of lubricant in suspension Lubricate, relubricate at proper Hard Steering or lack of assist (Continued) or ball joints. intervals. Tires not properly inflated. Inflate to recommended pressure. Steering gear to column misalignment. Align steering column.
Page 205 POWER STEERING SYSTEM 3B3-7 CONDITION POSSIBLE CAUSE CORRECTION Loose belt. Low oil pressure due to steering Adjust tension to specification pump: Low oil level. Fill reservoir to proper level. (See pum p pressure test.) Air in the oil. Locate source of leak and correct. Bleed system.
Page 206 3B3-8 POWER STEERING SYSTEM connections). B. Check oil level in pump’s reservoir and adjust as directed in maintenance section. C. Start engine and turn steering wheel from stop to stop several times. Do not hold in corner for any length of time as this can damage the power steering pump.
Page 207 POWER STEERING SYSTEM 3B3-9 GEAR A N D PUMP LEAK DIAG NO SIS START ENGINE AND TURN STEERING WHEEL FROM STOP TO STOP SEVERAL TIM ES. DO NOT HOLD AT STOP FOR ANY LENGTH OF TIM E AS TH IS CAN DAMAGE THE POWER STEER INGPUMP. CHECK O IL LEV EL IF LEAKAGE P E R S IS T S WITH THE LEVEL CORRECT AND THE C A P TIGHT, REPLACE CAP.
Page 208 3B 3-12 POWER STEERING SYSTEM completely disassembled, cleaned, flushed 5. Start engine and check fluid level adding any fluid reassembled before further usage. if required. When engine is at normal operating temperature, the initial pressure read on the gage (valve open) should be in the 80-125 PSI range.
Page 209 POWER STEERING SYSTEM 3B 3-13 Fig. 3B3-1 4~Power Steering Gear Mounting-Typical Fig. 3B3-16--P/S Pump Mounting; CK200, CK300 With L25 Engine POWER STEERING P U M P (3B3-15 THROUGH P Models 3B3-26) a. Place the steering gear in position, guiding the stub shaft into the universal joint assembly and lining up the marks made at removal.
Page 210 3B 3-14 POWER STEERING SYSTEM Fig. 3B3-20-P/S Pump mounting; CK100 (03) Fig. 3B3-18-P/S Pump Mounting; CK100, CK200, CK300 With LF9 Engine LE4, LG9, LS9, LT9 and C60 Installation SPECIFICATIO NS AND SPECIAL TOOLS 1. Postion pump assembly on vehicle and install Refer to Specifications and Special Tools at end of attaching parts loosely.
Page 211 POWER STEERING SYSTEM 3B3-15 Fig. 3B3-22--P/S Pump Mounting; G100, G200, G300 Fig. 3B3-24-P/S Pump Mounting; P200, P300 (42) LE4, LF4, LG9, LS9, LT9 With LT9 (Exc. JB8) Fig. 3B3-23-P/S Pump Mounting; P200, P300 (42) Fig. 3B3-25--P/S Pump Mounting; P200, P300 (32) With LT9 Engine With L25 Engine LIG H T T R U C K S ER V ICE M ANUAL...
Page 212 3B 3-16 POWER STEERING SYSTEM Fig. 3B3-26-P/S Pump Mounting; P300 (32) Fig. 3B3-29-P/S Hose Routing; CK100, CK 200, CK 300 With LE8 Engine LE4, LG9, LS9, LT9 (Exc. C60, JB8) Fig. 3B3-27-P/S Hose Routing; CK100, CK200 (03) Fig. 3B3-30-P/S Hose Routing; C100, C200, C300 With LE3 Engine With LE8 Engine Fig.
Page 213 POWER STEERING SYSTEM 3B 3-17 Fig. 3B3-32--P/S Hose Routing; CK300 Fig. 3B3-35-P/S Hose Routing; C300 LE4, LF5, LT9, and JB8 LE8 and JB8/HC4 Fig. 3B3-33-P/S Hose Routing; CK 100 (03) Fig. 3B3-36-P/S Hose Routing; G100, G200, G300 With LF9 Engine; and JB3, JB5 With LE3 Engine Fig.
Page 214 3B 3-18 POWER STEERING SYSTEM Fig. 3B3-38--P/S Hose Routing; G300 Fig. 3B3-4 1-P/S Hose Routing; P300 (32) LE4, LG9, LT9, and JB8 With LT9 Engine Fig. 3B3-39-P/S Hose Routing; P200, P300 (42) Fig. 3B3-42--P/S Hose Routing;P300 (32) With LE8 Engine With L25 Engine and JB7 Fig.
Page 215 STEERING CO LUM NS 3B4-1 SECTION 3B4 STEERING COLUMNS The following notice applies to one or more steps in the assembly procedure of components in this portion of the manual as indicated at appropriate locations by the terminology "See Notice on page 1 of this Section".
Page 216 3B4-2 STEERING CO LUM NS Fig. 3B4-1-Steering Column DIAGNOSIS GENERAL IN FO R M A TIO N STEERING CO LUM N ELECTRICAL ANALYZER J -2 3 9 8 0 This section contains diagnostic information to help locate the cause of the problem in the column. Reference For C-Series and K-Series (Fig.
Page 217 STEERING CO LUM NS 3B4-3 TURN", "RIGHT TURN", "KEY BUZZER", and C O LUM N JACKET "HAZARD". (Trucks do not incorporate a Key Buzzer Inspect jacket section of column for looseness, and/or Switch) if the systems function properly while using the bends.
Page 218 3B4-4 STEERING CO LUM NS SURFACE “A” Instrument Panel Bracket Capsule Damage NOTE: The bolt head must not contact surface “ A” . contact is made, the capsule shear load will be increased. If this condition exists replace the bracket. A U TO M A TIC TRANSMISSION COLUMNS LOCK S Y S T E M -W IL L NOT UNLOCK Cause...
Page 219 STEERING CO LUM NS 3B4-5 LOCK SYSTEM HIGH EFFORT (CO NT'D.) Cause Solution H. D isto rte d co u p lin g slo t in rack (ti lt ). H. Replace rack. Bent or restricted actuator rod. Straighten remove restriction or replace. Ignition switch mounting bracket bent.
Page 220 3B4-6 STEERING CO LUM NS IG N IT IO N SYSTEM - ELECTRICAL SYSTEM - W ILL NOT FU N C TIO N (CONT'D.) Solution Cause D. Replace ignition switch. D. Defective ignition switch. E. Readjust ignition switch. E. Ignition switch not adjusted properly. SWITCH W ILL NOT ACTU A TE M EC H A N IC A LLY Cause Solution...
Page 221 STEERING CO LUM NS 3B4-7 HIGH STEERING SH A FT EFFO R T Cause Solution A. Column assembly misaligned in vehicle. A. Realign. B. Improperly installed or deformed dust seal. B. Remove and replace. C. Tight or frozen upper or lower bearing. C.
Page 222 3B4-8 STEERING CO LUM NS M A N U A L TRANSMISSION COLUMNS GENERAL INFORMATION All of the preceding diagnosis inform ation for autom atic transmission will apply to the manual transmission. The following information is supplied in addition to and specifically for manual transmission columns. D R IV E R CAN LOCK STEERING IN SECOND GEAR Solution...
Page 223 STEERING CO LUM NS 3B4-9 TILT COLUMNS GENERAL INFORMATION All of the preceding diagnosis will generally apply to tilt columns. The following is supplied in addition to and specifically for tilt columns. HOUSING SCRAPING ON BOWL Cause Solution A. Bowl bent or not concentric with hub. A.
Page 224 3B 4-10 STEERING CO LUM NS Fig. 3B4-10--Checking Harmonica Connector on Column If all lamps light when hazard warning is depressed, but flashing does not occur, replace hazard warning flasher. (On fuse block) (Figure 3B4-11). Fig. 3B4-9--Checking Fuses on Fuse Block If all directional lamps light when lane change or turn indicator is actuated, but no flashing occurs, replace TURN SIGNAL D IAG NO SIS C A ND K SERIES...
Page 225 STEERING CO LUM NS 3 B 4 -1 1 2. Check the return from lane change by holding the lever in lane change and releasing (both left and right). If the lever does not return to neutral, disassemble the upper part of the column.
Page 226 3B 4-12 STEERING CO LUM NS SIGNAL SWITCH DIAG NO SIS CO RRECTIO N CO N D ITIO N POSSIBLE CAUSE Loose switch Tighten to specified Turn signal will not cancel mounting screws torque (25 in-lbs) Switch or anchor Replace switch bosses broken Reposition or replace Broken, missing or out...
Page 227 STEERING CO LUM NS 3B 4-13 SIG NAL SWITCH DIAG NO SIS C O N D ITIO N POSSIBLE CAUSE CORRECTION Hazard switch will not Loose switch Tighten mounting stay on or difficult mounting screws screws (25 in-lbs) to turn off Interference with Remove interference other components...
Page 228 3B4-14 STEERING CO LU M N S SIGNAL SWITCH DIAG NO SIS CORRECTION POSSIBLE CAUSE CO N D ITIO N Replace fuse and Burned out fuse Front or rear turn signal check operation lights not flashing Replace bulb Burned out or damaged turn signal bulb Remove or repair...
Page 229 STEERING CO LUM NS 3B4-15 SIG N A L SWITCH DIAGNOSIS C O N D ITIO N POSSIBLE CAUSE CO RRECTIO N Inoperative turn Turn signal lights flash Replace turn signal signal flasher very slowly flasher System charging I ncrease voltage to voltage low specified.
Page 230 3B 4-16 STEERING CO LUM NS MAINTENANCE AND ADJUSTMENTS STEERING WHEEL ALIG N M EN T SHIFTER TUBE A D JU S TM E N T On all series vehicles, check steering gear for high point centering as shown in Sections 3B2 and 3B3 before checking G and P Series Only steering wheel alignment.
Page 231 STEERING CO LUM NS 3B 4-17 Fig. 3B4-19--Shift Tube Adjustment-3 Speed Manual Transmission LIG H T T R U C K SER V IC E M ANUAL...
Page 232 3B4-18 STEERING CO LUM NS ON-VEHICLE SERVICE INDEX C-Series and K-Series..........3B4-18 G-Series and P-Series..........3B4-35 Steering Wheel............3B4-18 Steering W heel............3B4-35 Flexible Coupling............3B4-18 Flexible Coupling............3B4-35 Intermediate Shaft............3B4-19 Intermediate Shaft............. 3B4-36 Directional Signal Switch.........3B4-20 Column Upper Bearing........... 3B4-38 Lock Cylinder............
Page 233 STEERING CO LUM NS 3B 4-19 BEARING Fig. 3B4-23--Steering Shaft Intermediate Coupling 2. Remove the coupling clamp bolt. This is a special bolt and will require a 12 pt. socket or box wrench. 3. Remove the steering gear to frame bolts and lower the steering gear far enough to remove the flexible coupling.
Page 234 3B 4-20 STEERING CO LUM NS J-23653 Fig. 3B4-26--Removing Lock Plate Retaining Ring Removal (Fig. 3B 4-25) 1. Remove the steering wheel as outlined under "Steering Wheel - Removal". Fig. 3B4-25--Directiorial Signal Switch 2. Remove the column to instrument panel trim cover. 3.
Page 235 STEERING CO LUM NS 3B4-21 Fig. 3B4-28~Removing Directional Signal Switch Assembly Fig. 3B4-30-lnstalling Snap Ring 6. Remove the directional signal lever screw and Installation remove the lever. CAUTIO N: It is extrem ely im portant th a t 7. Push the hazard warning knob in and unscrew the only the specified screws, bolts and nuts knob.
Page 236 3B 4-22 STEERING CO LUM NS LOCK CYLINDER INSTALLATION DISASSEMBLE ASSEMBLE Place lock in “run". R otate as show n, align c ylin d er key w ith keyw ay in housing. Rem ove lock plate, turn signal switch and bu zzer switch (see Push lock all the w a y in.
Page 237 STEERING CO LUM NS 3B 4-23 CAUTION: Use only the specified screws since over-length screws could prevent a portion assembly from compressing under impact, w hich could result in personal injury. Reinstall the steering column assembly following the "Mandatory Installation Sequence" outlined later in this section.
Page 238 3B 4-24 STEERING CO LUM NS Remove the two column bracket-to-instrument Removal panel nuts and carefull remove from vehicle. Additional Front of dash mounting plates must be loosened help should be obtained to guide the lower shift levers whenever the steering column is to be lowered from the through the firewall opening.
Page 239 STEERING CO LUM NS 3B4-25 BOWL, Gearshift Lever 1. STEERING COLUMN SHROUD, Shift Bowl 2. RETAINER BEARING, Bowl Lower 3. NUT, Hexagon Jam JACKET ASM, Steering Column 4. COVER, Shaft Lock SCREW, Washer Head 5. RING, Retaining SWITCH ASM, Ignition 6.
Page 240 3B4-26 STEERING CO LUM NS SPRING, Key Release 1. ROD, Switch Actuator 2 3 . LEVER, Key Release 2. RACK, Switch Actuator 2 4 . WASHER, Wave 3. SPRING, Rack Preload 2 5 . SHAFT ASSEMBLY, Steering 4. SECTOR, Switch Actuator 2 6 .
Page 241 STEERING CO LU M N S 3B 4-27 6. Install the gearshift housing lower bearing. Insert the bearing from the very end of the jacket. Aligning the indentations in the bearing with the projections on the jacket (Fig. 3B4-47). If the bearing is not installed correctly, it will not rest on all of the stops provided.
Page 242 3B 4-28 STEERING CO LU M N S SHIFT GATE RACK LOCK BOLT LOCK BOLT SPRING THRUST SECTOR Fig. 3B4-43--Turn Signal Housing Assembly Fig. 3B4-45~Removing Lower Bearing Retainer Fig. 3B4-44--Removing Ignition Switch Actuator Sector Fig. 3B4-46~lnstalling Rack Preload Spring 13. Install the neutral-safety or back-up switch as outlined in Section 8 of this manual.
Page 243 STEERING CO LU M N S 3B 4-29 . M A S T JA C K E T A. TO REDUCE CLEARANCE .M A S T JA C K E T A. TO REDUCE CLEARANCE . 2 - 3 S H IF T LEVER SLIDE THE CLAMPING SLIDE THE CLAMPING .
Page 244 3B 4-30 STEERING CO LUM NS 51. SCREW, Support SPRING, Upper Bearing 1. STEERING COLUMN 52. PIN, Dowel PROTECTOR, Wiring 2. BEARING ASM 53. SHAFT ASM, Lower Steering COVER, Lock Housing (Painted) 3. PIN, Release Lever 54. SPHERE, Centering SHIELD, Tilt Lever Opening 4.
Page 245 STEERING CO LU M N S 3B4-31 1. BEARING ASM RETAINER PIN, Dowel 2. PIN, Release Lever RING, Retainer SHAFT ASM, Lower Steering SPRING, Upper Bearing 3. SPRING, Release Lever SPHERE, Centering 4. SPRING, Shoe PROTECTOR, Wiring SPRING, Joint Preload RETAINER, Spring 5.
Page 246 3B 4-32 STEERING CO LU M NS J-23072 Fig. 3B4-50-Removing Tilt Lever Spring Retainer Fig. 3B4-52-Removing Shift Tube 11. Disassemble the steering shaft by removing the 16. Remove the bearing housing support lock plate by centering spheres and the anti-lash spring. sliding it out of the jacket notches, tipping it down toward the housing hub at the 12 o’clock position and sliding it 12.
Page 247 STEERING CO LUM NS 3B 4-33 Fig. 3B4-54~Removing Sector Drive Shaft Fig. 3B4-56~lnstalling Bearing Housing and bearing housing. shoes for pin installation. e. Remove the lock shoe retaining pin with a punch and c. Install the shoe release lever, spring and pin. To hammer.
Page 248 3B 4-34 STEERING CO LU M N S 3. Install the bearing support lock plate wave washer. 4. Install the bearing support lock plate. Work it into the notches in the jacket by tipping it toward the housing hub at the 12 o’clock position and sliding it under the jacket opening.
Page 249 STEERING CO LUM NS 3B 4-35 M andatory Installation Sequence 1. Position column in body and position flange to rag joint and install lock washers and nuts (F ) (May be tightened to specified torque at this time). Coupling (G ) on manual steering must be installed prior to column installation.
Page 250 3B4-36 STEERING CO LUM NS BEARING Fig. 3B 4 -61 ~ S tee rin g S haft Interm ediate C oupling Installation See NOTICE on page 1 of this section NOTICE: regarding the fasteners referred to in steps 2, 4 and 5. 1.
Page 251 STEERING CO LU M N S 3B 4-37 b. Remove the felt washer, plastic washer and dust cap. Discard the felt washer. If the trunnion assemblies are to be replaced, proceed as follows: a. Remove the snap rings retaining the trunnion bushings in one of the yokes.
Page 252 3B 4-38 STEERING CO LU M N S Fig. 3B 4-64 ~S tee rin g Colum n U pper Bearing 2. Pry out the lower bearing assembly. STEERING CO LUM N UPPER BEARING-G AND P SERIES Installation Standard Column See NOTICE not on page 1 of this section NOTICE: regarding fasteners referred to in step 2.
Page 253 STEERING CO LUM NS 3B 4-39 If the bearing housing support is being replaced, proceed as follows: Remove the four bearing housing support screws and remove the support. Assembly See NOTICE on page 1 of this section NOTICE: regarding the fasteners referred to in steps 3, 9 and 11. 1.
Page 254 3B4-40 STEERING CO LUM NS Fig. 3 B 4 -6 7 ~ D ire ctio n a l S ignal S w itch Fig. 3B 4-69~R em oving W ires from C onnector 10. Column Shift Models - Install the shift lever and 5.
Page 255 STEERING CO LUM NS 3B4-41 out the lower end of the shift lever housing and under the dash seal. 2. Place the directional signal switch in position and install the three mounting screws; torque to 25 lbs. in. after screw head has been firmly seated. T ilt Columns Only- a.
Page 256 3B4-42 STEERING CO LU M N S STEERING SYSTEM MANDATORY REQUIREMENTS Using a 50 lb. force a p p lie d to the steering w heel end o f Shaft [ ] , Lower Clam p N ut [IT ] must be tightened to the specified torque to give a compressed spring dim ension o f .50 ±...
Page 257 STEERING CO LU M NS 3B 4-43 U pper S teering Shaft S h ift Tube F e lt W asher Turn S ignal S w itc h Screw S h ift Housing Bushing 14. S h ift Tube Assem bly Turn S ignal S w itc h Bushing Seat S h ift Leve r Spacer...
Page 258 3B 4-44 STEERING CO LUM NS a. Press the upper and lower bearings out of the Automatic Columns - Align the three holes in the housing. selector plate with the three holes in the jacket, position the clamping ring and install the three screws. The shift tube b.
Page 259 INSTRU. PANEL OPENING C O V E R -, HOUSING ASSY. PROTECTOR WIRE SPRING (2) SPRING RELEASE PIN RELEASE SHOE RELEASE------ JACKET DASH BEARING ASSY.— SEAL RETAINER DASH SEAL LEVER ADAPTER BEARING RETAINER...
Page 260 3B4-46 STEERING CO LUM NS Fig. 3 B 4 -7 6 -S e cu rin g Colum n w ith J-2 2 5 7 3 Fig. 3B4-78--R em oving Bearing Housing Pivot Pin 2. Column Shift Models - Press a new shift lever spring 6.
Page 261 STEERING CO LU M N S 3B4-47 1/16” 4 5 ° CHAM FER REMOVE DOTTED PO RTION Fig. 3B4-80--R em oving Release Lever Pivot Pin Fig. 3 B 4 -8 2 -R e v is e d S h ift Tube Removing T ool J -22 55 1 11.
Page 262 3B 4-48 STEERING CO LUM NS 5. Loosely install the column dash bracket and screws. 6. Push the column down until the steering shaft flange bottoms on the plastic spacers on the flexible coupling and then torque the dash bracket screws. 7.
Page 263 STEERING CO LU M N S 3B 4-49 STEERING SYSTEM MANDATORY REQUIREMENTS Using a 50 lb. force a p p lie d to the steering w h ee l end o f Shaft | A | , Lower Clam p Nut (~B~| must be tightened to the specified torque to give a compressed spring dim ension o f .50 ±...
Page 264 3B 4-50 STEERING CO LU M N S STEERI NG SYSTEM M A N D A T O R Y REQUI REMENTS Using a 50 lb. force a p p lie d to the steering w heel end o f Shaft | A 11 Low er Clamp Nut [~B ~] must be tightened to the specified torque to give a compressed spring dim ension | C | o f 1.26 ±...
Page 265 STEERING C O LU M N S 3B4-51 SPECIFICATIONS STEERING GEAR RATIOS MANUAL STEERING GEAR Power Manual Components C1p1030 K 10-20 P20 - 30 Vehicle 6 to 11 Gear Overall Gear 4 to 6 Overall 9 to 12 T hrust B earing Ratio lbs.
Page 266 3B 4-52 STEERING CO LU M N S SPECIAL TOOLS Pitman Arm Puller J-6222 Shaft Seal Protector J-6632 J-23600 Belt Tension Gauge J-5504 Pitman Arm Puller J-8947 Shift Tube Installer Rack-Piston Seal Compressor J-23073 J-5755 Wormshaft Bearing Race Installer J-23072 Shift Tube Remover J-2619 Slide Hammer...
Page 267 STEERING CO LU M NS 3B 4-53 1. J-6632 Pitman Arm Puller 19. J-6278 Pitman Shaft Bearing Remover 2. J-5504 Pitman Arm Puller 20. J-6278-2 Pitman Shaft Bearing Installer 3. J-5176 Pressure Gauge 21. J-7079-2 Drive Handle 4. J-5822 Wormshaft Bearing Cup Puller 22.
Page 269: Upper And Lower Control
FRONT SUSPENSION 3C-1 SECTION 3C FRONT SUSPENSION The following notice applies to one or more steps in the assembly procedure of components in this portion of the manual as indicated at appropriate locations by the terminology "See Notice on page 1 of this section".
Page 270 3C-2 FRONT SUSPENSION Fig. 3C-1~Front Suspension, C-P Series L IG H T T R U C K S ER V IC E M AN UAL...
Page 271 FRONT SUSPENSION 3C-3 MAINTENANCE AND ADJUSTM ENTS NOTICE: See NOTICE on page 1 of this section 9. Install dust cap on hub. regarding the fasteners referred to in the maintenance and adjustment procedures below. 10. Replace the wheel cover or hub cap. W HEEL BEARINGS-CHECK A D JU S TM E N T 11.
Page 272: Steering Gear
3C-4 FRONT SUSPENSION DIAGNOSIS H A R D S T E E R IN G Probable Remedy Probable Cause Ball joints and steering linkage need lubrication Lubricate ball joints and linkage Inflate tires to the proper recommended pressure Low or uneven front tire pressure Check power steering components for proper operation Power steering partially or not operative Adjust steering gear...
Page 273 FRONT SUSPENSION 3C-5 NOISE IN F R O N T END Probable Cause Probable Remedy Ball joints and steering linkage need lubrication Lubricate at recommended intervals Shock absorber loose or bushings worn Tighten bolts and/or replace bushings Worn control arm bushings Replace bushings d.
Page 274 3C-6 FRONT SUSPENSION “ D O G " T R A C K IN G Probable Remedy Probable Cause LEAF TYPE REAR SPRING a. Rear leaf spring broken a. Replace spring b. Bent rear axle housing b. Replace housing c. Align frame c.
Page 275 FRONT SUSPENSION 3C-7 BALL JO IN T D IA G N O STIC PROCEDURE Fig. 3 C -7 -B a ll Join t Diagnostic Procedure LIG H T T R U C K SER V ICE M ANUAL...
Page 276 3C-8 FRONT SUSPENSION Check Vehicle Ride and Handling After completing previous checks, ride vehicle with owner to determine if problem has been corrected or to definitely establish type of problem that still exists. If problem still exists (poor handling, bottoming, noise, ride sway, etc.), proceed.
Page 277 FRONT SUSPENSION 3C-9 THAT W ILL FIT THRU EXISTING HOLE Fig. 3C-10--Position for Purging Air From Shocks Fig. 3C-9--Gripping Methods 4. Observe or listen for the following conditions that will indicate a defective shock: • a skip or lag when reversing stroke at mid travel. •...
Page 278 3C -10 FRONT SUSPENSION BEARINGS AND RACES Common Causes For Bearing Distress BENCH DIAG NO STIC PROCEDURE Include The Following: This section describes common types of bearing distress and their causes. Illustrations are included to help diagnose 1. Improper adjustment or preloading. the cause of distress and comments are provided to help 2.
Page 279 FRONT SUSPENSION 3 C -1 1 BEARINGS AND RACES FRONT WHEEL, PINION, DIFFERENTIAL SIDE AND REAR WHEEL ROLLER BEARINGS D IAG N O SIS EXCESS NOISE COMPLAINT DIAGNOSTIC PROCEDURE Check tires for irregular wear Check tire pressure Road Test Check lubricant level Drive to warm-up rear axle Test at various speeds in drive, float, coast and cornering Change tire pressure to minimize noises...
Page 280 3C-12 FRONT SUSPENSION FRONT WHEEL BEARING DIAGNOSIS C O N S ID E R TH E F O L L O W IN G F A C T O R S W H EN D IA G N O S IN G B E A R IN G C O N D IT IO N : G E N E R A L C O N D IT IO N OF A L L P A R T S D U R IN G D IS A S S E M B L Y A N D IN S P E C TIO N .
Page 281 FRONT SUSPENSION 3C-13 FRONT WHEEL BEARING DIAGNOSIS (CONT’D) C R A C K E D I N N E R R A C E F A T I G U E S P A L L I N G B R I N E L L I N G R A C E C R A C K E D D U E TO IM PR O PER F IT , F L A K IN G OF S U R F A C E M E T A L R E S U L T IN G FR O M S U R F A C E IN D E N T A T IO N S IN R A C E W A Y C A U S E D BY...
Page 282 3C-14 FRONT SUSPENSION COMPONENT PARTS REPLACEMENT bearing. W HEEL HUBS, BEARINGS (Fig. 3C-14) 5. Fill the bearing cone and roller assemblies 100% fill Removal C, G and P Series of grease. A method for doing this is with a cone type grease 1.
Page 283 FRONT SUSPENSION 3C-15 J-23028 Fig. 3C-1 7~Removing Coil Spring with Tool J-23028 3. Lower vehicle to floor. STABILIZER BAR Removal (Fig. 3C-16) COIL SPRING 1. Raise vehicle on hoist and remove nuts and bolts Removal (Fig. 3C-17) attaching stabilizer brackets and bushings at frame location. 1.
Page 284 3C-18 FRONT SUSPENSION J—24435-7 Fig. 3C-23--U.C.A. Rubber Bushing Installation Fig. 3C-24~Lowering Control Arm for Bushing Replacement 4. The pivot shaft may now be removed from the 3. Install brake caliper assembly if removed (see control arm assembly. section 5). 4. Remove adjustable support from under lower 5.
Page 285 FRONT SUSPENSION 3C-19 1. Install new bushings as shown in Figure 3C-26 using spacer J-24435-6, installer J-24435-4 and clamp J- "C" 24435-7. 2. Turn clamp in until bushing seats firmly. J—24435-7 Be sure spacer J-24435-6 is in position as NOTICE: shown in Figure 3C-26 to avoid collapsing control arm during assembly.
Page 286 3C -20 FRONT SUSPENSION R E M O VE RE M O V E UPPER LO W ER H E A V Y FLAT W A S H E R J - 2 3 7 4 2 , J-23742 Fig. 3C -28--C otter Pin In sta lla tio n 2.
Page 287 FRONT SUSPENSION 3C-21 J-9519-2 (HIDDEN) J-9519-16 J-951 9-29 J-9519-10 J-951 9-10 BALL JO IN T BALL JO INT INSTALLATION REMOVAL Fig. 3C-3 1 — Installing Ball Joint Fig. 3C-30--Ball J o in t Removal 2. Turn hex head screw until ball joint is seated in 32") for all models, ball joint is worn and should be replaced control arm.
Page 288 3C-22 FRONT SUSPENSION Removal (Fig. 3C-32) 1. Raise hood and disconnect negative battery cable from battery. 2. Raise vehicle on hoist. 3. Remove front wheels. 4. Disconnect front brake hose clip from each upper control arm. 5. Support front of vehicle with jack stands at frame side rails.
Page 289 FRONT SUSPENSION 3C-23 Connect front shock absorbers to L.C.A.’s. Torque to 80 N*m (60 ft. lbs.) (C-models), 95 N-m (70 ft. lbs.) (G-models). If equipped, connect front stabilizer to L.C.A.’s. Torque to 34 N-m (25 ft. lbs.). Connect tie rod ends to steering knuckles. Refer to Section 3B.
Page 290 3C-24 FRONT SUSPENSION GENERAL DESCRIPTION Front drive axles used on K10, K20, and K30 trucks lower king pin is part of the bearing cap, and this king pin have several styles of wheel-end construction. rides in a tapered roller bearing. At the wheel ends of the axle tubes, two types of A free-wheeling hub is used on all four wheel drive steering knuckle attachment are used.
Page 291 FRONT SUSPENSION 3C-25 R ETAINING PLATE LOCK-ADJ. NUT UPPER BEARING CAP . " 0 " RING PIN-ADJ. NUT PRESSURE SPRING ADJUSTING NUT GASKET ACTUATOR KNOB OUTER WHEEL BEARING RETAINING PLATE BOLT BUSHING, KING-PIN INNER WHEEL BEARING A XLE SHAFT SNAP RING KIN G -PIN 18.
Page 292 3C -28 FRONT SUSPENSION RETAINING PLATE BOLTS OUTER CLUTCH RETAINING RING WASHER ACTUATING CAM BODY HUB RING RETAINING KNOB AXLE SHAFT SNAP RING ACTUATOR KN O B “ O" RING AXLE SHAFTSLEEVE AND RING ACTUATOR KNOB INNER CLUTCH RING " 0 " RING PRESSURE SPRING INTERNALSNAP RING SPRING RETAINER PLATE...
Page 293 FRONT SUSPENSION 3C-29 Remove nuts and disconnect the tie rod. If it is necessary to remove the steering arm, discard the self locking nuts (Fig. 3C-9K) and replace with new nuts at assembly. FREE POSITION 3. Remove the cotter pin from the upper ball socket nut.
Page 294 3C-32 FRONT SUSPENSION Fig. 3C-1 2K~Removing Upper Ball Joint Fig. 3C-14K--lnstalling Upper Ball Joint Do not distort oil seal. It will protrude slightly from SHOCK ABSORBER the surface of yoke flange when fully installed. Removal (Fig. 3C-30K) 1. Raise vehicle on hoist. 3.
Page 295 FRONT SUSPENSION 3C-33 Fig. 3C-1 8K~Removing Nuts Alternately Inspection LEAF SPRING AND BUSHINGS (Figs. 3C-32K and 3C-33K) Inspect rubber rushings for excessive wear or aging- replace where necessary. Use rubber lubricant when Removal installing bushings over stabilizer bar. 1. Raise vehicle on hoist. 2.
Page 296 3C-36 FRONT SUSPENSION F i g . 3 C - 3 2 K ~ L e a f S p r i n g A s s e m b l y TIGHTENING SEQUENCE Install all four nuts to uniform engagement on 'U' Bolts to retain and position anchor plate in design position (perpendicular to axis of 'U' Bolts).
Page 297 FRONT SUSPENSION 3C-37 SPECIFICATIONS FRONT SUSPENSION BOLT TORQUE (ft. lbs.) * f K-AII CP-10 CP-20-30 G-10-20 G-30 — Lower Control Arm Shaft U-Bolt Upper Control Arm Shaft Nuts — Control Arm Rubber Bushings — — — New 190 New 190 —...
Page 298 3D-2 REAR SUSPENSION Fig. 3D-3--Typical P-30 H.D. Truck Rear Suspension COMPONENT PARTS REPLACEMENT 5. To install shock absorber, place into position and SHOCK ABSORBERS reattach at upper mounting location. Be sure to install nuts and washers as shown. Replacement 6. Align lower end of shock absorber with axle Refer to Figs.
Page 299 REAR SUSPENSION 3D-3 Fig. 3D-8~Shock Absorber-P30 4. Remove brackets from anchor plates by removing attaching screws. 5. Remove stabilizer shafts. STABILIZER SHAFTS 6. Reverse above steps to install stabilizer shaft. On Refer to Fig. 3D-9, 3D-10 and 3D-11 for specific rear installation, position shaft so parking brake cable is routed stabilizer shaft mounting on C and P models.
Page 300 3D-6 REAR SUSPENSION 3. Jack frame as required to align spring and shackle with spring hangers. 4. Install shackle bolt and nut and again reposition spring, if necessary to align front eye. Install front eye bolt and nut. Torque hanger and shackle nuts to specifications. Make certain that the bolts are free-turning in their bushings prior to torquing.
Page 301 REAR SUSPENSION 3D-7 L IG H T T R U CK SER V IC E -MANUAL...
Page 302 3D-8 REAR SUSPENSION Fig. 3D-20--Rear Spring !nstallation-P10,20 Fig. 3 D -2 1 ~ R e a r Spring ln s ta llatio n -P 3 0 LIG H T T R U C K S ER V IC E M ANUAL...
Page 303 REAR SUSPENSION 3D-9 1. Install a ll four nuts to uniform engagement on 'U' Bolts to retain and position anchor plate in design position (perpendicular to axis of 'U' Bolts). 2. Torque a ll nuts in a diagonal sequence (e .g . 1-3-2-4) to 14-35 N.m.
Page 304 3D-10 REAR SUSPENSION SPECIFICATIONS TORQUE SPECIFICATION G10 120 P10 140 Spring-to-Axle "U " Bolt Nuts P20 140 G20 120 P30 170 (Exc. W/3/4" Bolt) G30 150 200 (W/3/4" Bolt) Leaf Spring 90/135* — Front Bushing Bolt (G316 . . .90) 90/135* —...
Page 305 WHEELS AND TIRES 3E-1 SECTION 3E WHEELS AND TIRES The Wheel bolt and nut fasteners are an important NOTICE: attaching part in that they could affect the performance of vital components and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary.
Page 306 3E-4 WHEELS AND TIRES WHEEL USAGE AND TIRE LOAD LIMITS (LBS) AT VARIOUS INFLATION PRESSURES BIAS LIGHT TRUCK (LT) TIRES Wheel Tire Load Inflation Pressures (PSI) Code Size Range TIRES USED AS SINGLES 1860 2030 2190 2350 2500 2650 9.50-16.5 2780 2190 2500...
Page 307 WHEELS A N D TIRES 3E-5 WHEEL USAGE AND TIR E LOAD LIM ITS (LBS) A T V A R IO U S IN F L A T IO N PRESSURES BIAS LIGHT TRUCK (LT) TIRES Wheel Tire Load Inflation Pressures (PSI) Code Size Range...
Page 308 3E-6 WHEELS AND TIRES MINIMUM TIRE INFLATION PRESSURE AT GROSS VEHICLE WEIGHT RATING GVWR LBS. WHEEL CODE AND LIMITS WHEEL LIMITS MAX. MAX. SIZE OF PRESS. WHEEL LOAD CODE S T A M P IN G L O C A T IO N (LBS.) (PS I) FOR RIM SIZE...
Page 309 WHEELS AND TIRES 3E-7 , the transfer of weight may also overload the Second outside tires so much that they are laterally distorted resulting in excessive wear on the outside half of the tire, producing a type of wear like that caused by excessive positive camber.
Page 310 3E-8 WHEELS AND TIRES Dual W heels When installing wheels on vehicles with dual rear wheels: 1. Install inner and outer wheel and clamp ring on rear, or wheel and clamp ring on front (be sure pins on clamp ring face outboard). 2.
Page 311 W HEELS AND TIRES 3E-9 RADIAL TIRES Series Description Torque Recommended truck tire mounting and inflation procedures are especially important with radial truck tires. 7/16” Bolts (6) 70-90 Ft. Lbs. Failure to follow these recommendations can cause bead C10,P10,G10,G20 1/2" Bolts (5) 75-100 Ft.
Page 313 PROPELLER SHAFT 4A-1 SECTION 4A PROPELLER SHAFT The following notice applies to one or more steps in the assembly procedure of components in this portion of the manual as indicated at appropriate locations by the terminology "See Notice on page 1 of this Section".
Page 314 4A-2 PROPELLER SHAFT decrease. The bearings used in universal joints are the needle roller type. The needle rollers are held in place on the trunnion by round bearing cups. The bearing cups are held in the yoke by either (depending on the manufacturer) snap rings or plastic injection.
Page 315 PROPELLER SHAFT 4A-3 PROPELLER SHAFT AND UNIVERSAL JOINT DIAGNOSIS Checking and Correcting 4. With vehicle running in gear at the indicated speed where disturbance is at its peak, observe the intensity of the Propeller S h aft Unbalance disturbance. 1. Place vehicle on a twin post hoist so that the rear 5.
Page 316 4A -4 PROPELLER SHAFT CORRECTION COMPLAINT POSSIBLE CAUSE Roughness, Vibration or a. Replace. a. Bent or dented drive shaft. Body Boom at any speed. b. Clean drive shaft. b. Undercoating on drive shaft. c. Tire unbalance. (30-80 mph, not c. Balance or replace as required. NOTE: With tachometer throttle conscious) installed in car, determine...
Page 317 PROPELLER SHAFT 4A-5 UNIT REPAIR Due to length of the propeller shaft it may be more PROPELLER SHAFT convenient to use a bench vise, for removal and installation, The rear universal joint to propshaft bolt on some CK instead of an arbor press. In this case, proceed with 1 ton dual wheel models requires a # 10 "Six Lobed Socket"...
Page 318 4A-6 PROPELLER SHAFT 4. Washer 1. Trunnion 5. Cap 2. Seal 6. Snap Ring 3. Bearings Fig. 4A-10~Universal Joint Repair Kit Fig. 4A-8--Bearing Cup Removal with Vise 4. Disengage cross from yoke and remove. Production Injected Plastic Type universal joints cannot be reassembled. There are no bearing retainer grooves in production bearing cups.
Page 319 PROPELLER SHAFT 4A-7 Fig. 4A-1 2-Using Spacer to Remove Bearing Cup Fig. 4A-1 4-lnstalling Trunnion into Yoke properly seated. 8. Assemble the other half of the universal joint in the same manner. 2. Install one bearing cup part way into one side of the yoke, and turn this yoke ear to the bottom.
Page 320 4A-8 PROPELLER SHAFT b. Fill space between inner dust shield and bearing with lithium soap grease (Dana Style). STRIKE TUBE YOKE c. Start bearing and slinger assembly straight on shaft EAR IN THIS AREA journal. Support propeller shaft and, using suitable length of pipe over splined end of shaft, press bearing and inner slinger against shoulder on shaft.
Page 321 PROPELLER SHAFT 4A-9 On vehicles with two piece propshafts, the front propshaft yoke m ust be bottomed out in the transmission fully forward before installation to the hanger . 2. For C-P models with two-piece propeller shafts, proper phasing is accomplished with the alignment key, shown in figure 4A-18.
Page 322 4A -10 PROPELLER SHAFT F R O N T Y O K E R E A R T R U N N I O N R E A R Y O K E H A L F Fig. 4A-20--Driving Out Bearing Cups Fig.
Page 323 PROPELLER SHAFT 4 A -1 1 BALL Fig. 4A-23--Bearing Cap Removal Sequence Fig. 4A-25~Cross Sectional View of CV Joint W hen both bearing cups are free, disengage the flange yoke and trunnion from the centering Centering Ball Replacement ball. Note th a t the ball socket is part of the flange 1.
Page 324 4A -12 PROPELLER SHAFT Fig. 4A-29~Removing Centering Ball Fig. 4A-27~lnstalling Tool J-23996 Over Ball periodically (see Section 0) with special lubricant, 7. Lubricate seal lip and press seal flush with Tool J- # 1050679, or equivalent. If the fitting cannot be seen from 23694, as shown in figure 4A-31.
Page 325 PROPELLER SHAFT 4A -13 Fig. 4A-3 1 — Installing Centering Ball Seal Fig. 4A-32--Reassembling Flange Yoke SPECIFICATIONS PROPELLER S H A F T P r o p e lle r S h a ft To R e a r A x le (S tr a p ) 1 2 -1 7 1 2 -1 7 1 2 -1 7...
Page 327: Rear Axle
Differential and Rear Axle Bearing Diagnosis.......4B-11 On Vehicle Service................4B-13 8-1/2" and 8-7/8" Ring G ear............4B-13 Chevrolet 10-1/2" Ring G e a r............4B-17 Dana 10-1/2" Ring G ear..............4B-20 Dana 9-3/4"Ring Gear..............4B-20 Chevrolet 12-1/4" Ring G ear............4B-21 Specifications..................4B-25...
Page 328 8-1/2" and b) The hypoid ring gear is bolted to a one-piece 8-7/8" Ring Gear, c) Chevrolet 10-1/2" Ring Gear, d) differential case which is supported by two preloaded Dana 10-1/2" Ring Gear, e) Dana 9-3/4" Ring Gear and tapered roller bearings.
Page 329 REAR AXLE 4B-3 19. Thrust Washer . Cover 1. Companion Flange D iffe re n tial Case 20. D iffe re n tial Pinion . Pinion Shaft 2 . D eflector 8 . Shim 2 1 . Shim . Ring G ear 3 .
Page 330 4B-4 REAR AXLE 10. Straddle Bearing 1. Companion Flange 19. Retainer Screw 11. Ring Gear 20. Bearing Cap 2. Oil Deflector 12. D ifferential Spider 21. Case-to-Ring Gear Bolt 3. Oil Seal 13. D ifferential Case 4. Bearing Retainer 22. D ifferential Cover 14.
Page 331 REAR AXLE 4B-5 D iffe re n tia l Spider P inion Rear Bearing Pinion N u t D iffe re n tia l Side Gear Drive Pinion Washer Washer Ring Gear C om panion Flange P inion Gear D iffe re n tia l Case O il Seal Washer Ring Gear B o lt...
Page 332 4B-6 REAR AXLE 11. Shims (Inner Pinion 24. Bolt (Differential 1. Nut 17. Cover and Plug Bearing) 2. Washer Lock Pin (Pinion Bearing Cap) 3. Companion Flange 12. Cup (Inner Pinion 25. Bolt (Ring Gear) Shaft) Bearing) 4. Pinion Oil Seal 19.
Page 333 REAR AXLE 4B-7 1 4. Axle Shaft 8 Ring Gear Thrust Pad 1. Universal Joint Yoke 15. Differential Bearing 9. Ring Gear 2. Pinion Bearing Oil 16 Differential Bearing 10 Differential Spider Seal and Retainer Adjusting Nut 1 1. Differential Pinion 3.
Page 334 4B-8 REAR AXLE rear axle. Rear axle noise usually ceases when coasting at SOME NOISE / S \ speeds under 30 miles per hour; however, tire noise continues but with lower tone as vehicle speed is reduced. ACCEPTABLE Y< Rear axle noise usually changes when comparing "pull" and "coast"...
Page 335 REAR AXLE 4B-9 Diagnosis Charts appear later in this section. Gear Noise There are two basic types of gear noise. The first type is produced by broken, bent, or forcibly damaged gear teeth and is usually quite audible over the entire speed range and presents no particular problem in diagnosis.
Page 336 4B-10 REAR AXLE A GENERAL DIAGNOSTIC PROCEDURE FOR ISOLATING REAR AXLE NOISE PROBLEMS Cause Problem 1. a) Road noise Noise is the same in drive or coast b) Tire noise Front wheel bearing noise 2. a) Road noise Noise changes on a different type of road b) Tire noise Noise tone lowers as car speed is lowered 3.
Page 337 REAR AXLE 4 B -1 1 DIFFERENTIAL AND REAR A X LE BEARING DIAGNOSIS CO NSIDER THE FOLLO W IN G FACTORS W HEN D IA G N O S IN G B EA R IN G C O N D ITIO N : 1.
Page 338 4B-14 REAR AXLE Fig. 4B-1 5--Removing Lock Screw Fig. 4B-1 7--Correct C-Lock Position When installing C-locks keep the pinion shaft partially withdrawn. Place the C-lock in the same position shown in figure 4B-17. Carefully withdraw the axle shaft To install oil seal, place seal on J-21128 and drive until the C-lock is clear of the thrust block.
Page 339 REAR AXLE 4B-15 Fig. 4B-19— 0 iI Seal and Wheel Bearing Fig. 4B-21--Wheel Bearing Installation Axle S haft-ln stallatio n W heel B olt-Replacem ent 1. Raise vehicle on hoist allowing axle to hang freely. 1. Slide axle shaft into place. Exercise care that splines 2.
Page 340 4B-16 REAR AXLE Fig. 4B-23~Pressing Out Wheel Stud Fig. 4B-25--Scribe Marks Pry old seal out of bore, using a screw driver or a 3. Position propeller shaft to one side and tie it to hammer and chisel. frame side rail. Inspection 4.
Page 341 8. Lower vehicle and remove from hoist. 5. Using J-8614-11 as shown in figure 4B-29, install flange onto pinion. Install washer and nut, and tighten nut CHEVROLET 10-1/2" RING GEAR to original position. Refer to scribe marks and number of exposed threads, recorded earlier.
Page 342 4B-18 REAR AXLE Fig. 4B-30~Rem oving Flange-to-Hub Bolts Installation 1. Place axle assembly under vehicle, raise into position, install spring "U" bolts, anchor plates and nuts, and tighten securely. Hub Inner Bearing 1. Axle Shaft 2. Connect and secure shock absorbers to axle 2.
Page 343 REAR AXLE 4B-19 B earing/C up-lnstallation 1. Place bearing into hub. outer 2. Install cup of outer bearing into hub by using Handle J-8092 and J-8608, . Be installed upside-down sure J-8608 is upside down on driver handle, so that chamfer does contact bearing cup.
Page 344 3. Disengage tang of retainer and remove retainer hub and drum components and bearing adjustments are from axle housing tube. identical to those listed for "Chevrolet 10-1/2 Ring Gear 4. Torque adjusting nut to 50 ft. lbs., at the same time Axle".
Page 345 Fig. 4B-38~Removing Hub Outer Bearing Retainer Ring AXLE ASSEMBLY The axle assembly removal and installation is identical HUB AND DR U M ASSEMBLY to the procedure given earlier for "Chevrolet 10-1/2" Ring Removal Gear Axle". Use the procedure given for "Chevrolet 10-1/2" Ring Gear Axle", and use J-0870 to remove the adjusting nut.
Page 346 4B-24 REAR AXLE SPECIFICATIONS D IF F E R E N T IA L S P E C IF IC A T IO N S > ; > N? > £ £ r t ' r - Os — BOLT T O R Q U E S (F T .- L B S .)A G e a r B a c k la s h .
Page 347 S a l i s b u r y / 3 7 5 0 # 8 - 7 / 8 " 8-1/2" Chevrolet Salisbury /3750# S a l i s b u r y / 3 7 5 0 # Chevro let 8 - 7 / 8 "...
Page 348 8. J-6627 Wheel Bolt Remover 23. J-24428 Wheel Hub Oil Seal Installer 9. J-8092 Driver Handle 24. J-24434 Pinion Oil Seal Installer - Chevrolet 10. J-5853 Torque Wrench - Inch/Pound 25. J-870 Wheel Bearing Nut Wrench 11. J-8614-II Companion Flange Holder 26.
Page 349: Front Wheel Drive
GENERAL DESCRIPTION The front axle is a hypoid gear axle unit equipped with K 10-20 Models use a Chevrolet or the Dana (44 Series) steering knuckles. Axle assembly number and production front axle, both incorporate a 8-1/2" ring gear. A 4500 lb.
Page 350 4C-2 FRONT WHEEL DRIVE BEARINGS AND RACES FRONT WHEEL, PIN IO N , DIFFERENTIAL SIDE A N D REAR WHEEL ROLLER BEARINGS DIAGNOSIS EXCESS IMOISE COMPLAINT DIAGNOSTIC PROCEDURE Check tires for irregular wear Check tire pressure Road Test Check lubricant level Drive to warm-up rear axle Test at various speeds in drive, float, coast and cornering Change tire pressure to minimize noises...
Page 351 FRONT WHEEL DRIVE 4C-3 Fig. 4C-2~Front Drive Axle Typical If the disc or other brake components require repairs 4. Support the other side of the yoke in the vise and or replacement, refer to Section 5. drive the other bearing out by tapping on the end of the trunnion using a brass drift.
Page 352 4C-4 FRONT WHEEL DRIVE LIG H T T R U C K S E R V IC E M ANUAL...
Page 353 FRONT WHEEL DRIVE 4C-5 SPECIFICATIONS CHEVROLET Bolt Torques Bolt Torques Axle Axle (Ft.-Lbs.) (Ft.-Lbs.) Gear and Backlash Preferred .005-.008 Carrier Cover Ring Gear Min. and Max. .003-.010 New Pinion Bearing Preload 15-30 in.-lbs. Differential Bearing Caps Used Pinion Bearing Preload 5-10 in.-lbs.
Page 355 BRAKES SECTION 5 BRAKES The following notice applies to one or more steps in the assembly procedure of components in this portion of the manual as indicated at appropriate locations by the terminology "See Notice on page 1 of this section".
Page 356: Diagnosis
BRAKES If a vehicle displays these symptoms, it is a good DISC BRAKES FRONT indication that one of the systems contains air or has failed, All models have disc brakes on the front. The one piece and it is necessary to bleed or repair the brakes. caliper mounts on the steering knuckle/steering arm, which MASTER CYLINDER is also a one piece casting, and astride the brake disc.
Page 357 BRAKES HYDRO— BOOST SEAL LEAKAGE IN P U T SEAL LEAK — F lu id le a k a g e fro m housing cover en d o f b o o s ter n e a r re a c tio n b o re . R ep lace seal(s).
Page 358 BRAKES vehicle stopped and pedal pushed near fully depressed 2. If the reserve system will not retain a charge for one position. hour, but functions normally immediately following charging, the accumulator valves are at fault and the booster 3. Whenever the accumulator pressure is used, a slight must be disassembled and the accumulator valves replaced.
Page 359 BRAKES HYDRO — BOOST DIAGNOSIS CONDITION CAUSE CORRECTION Excessive Brake Pedal Loose or broken power steering pump belt. Tighten or replace the belt. Effort No fluid in power steering reservoir. Fill reservoir and check for external leaks. Leaks in Hydro-Boost Replace faulty parts.
Page 360 BRAKES C O N D IT IO N P O S SIB LE C A U S E C O R R E C T IO N P ulls In c o rre c t tir e pressures. In f la t e e v e n ly on b o th sid es to th e re c o m m e n d e d pressures.
Page 361 BRAKES C O R R E C T IO N PO S S IB L E C A U S E C O N D IT IO N R e p la c e shoe a n d lin in g a n d B ra k e ro u g h n e s s o r c h a tt e r S h o e re v e rs e d (s te e l m a c h in e ro to r w ith in...
Page 362 BRAKES C O N D IT IO N PO S SIB LE C A U S E C O R R E C T IO N In c o rre c t p a r k in g b r a k e D r a g g in g B ra k e s C h e c k a n d r e a d ju s t to a d ju s tm e n t on r e a r b ra k e s .
Page 363 BRAKES CAUSE Leaking Brake Line or Connection Leaking Wheel Cylinder or Piston Seal Leaking Master Cylinder A ir In Brake System Contaminated or Improper Brake Fluid Leaking Vacuum System Restricted A ir Passage in Power Head____________ Damaged Power Head Improperly Assembled Power Head Valvinq_________________ Worn Out Brake Lining - Replace Uneven Brake Lining Wear -...
Page 364: Pedal Travel
5-10 BRAKES ON-VEHICLE SERVICE position. PEDAL TRAVEL At reasonably frequent intervals, the brakes should be BLEEDING AND FLUSHING BRAKE SYSTEM inspected for pedal travel, which is the distance the pedal Bleeding Brake Hydraulic System moves toward the floor from a fully-released position. Inspection should be made with the brake pedal firmly A bleeding operation is necessary to remove air depressed (approximately 90 lbs.) while the brakes are cold.
Page 365: Hydro-Boost Bleeding Procedure
BRAKES 5-11 Check the brake pedal, feel for "sponginess" and HYDRO-BOOST BLEEDING PROCEDURE repeat entire bleeding procedure if necessary. Whenever the booster is removed and reinstalled, the steering system should be bled as outlined below. Pressure Bleeding Pressure bleeding equipment must be of the diaphragm Power steering fluid and brake fluid cannot NOTICE: type.
Page 366 5-12 BRAKES Fig. 5 -5 - F r o n t Brake Pipes and Hoses-C-K Models LIGHT T R U C K S ER V IC E M AN UAL...
Page 369 BRAKES 5-15 LIG H T T R U C K S ER V ICE M ANUAL...
Page 370: Brake Hoses
5-16 BRAKES 1/8" (3 mm) for each double flare. 6. Bleed brake system. 3. Double flare tubing ends using a suitable flaring tool 7. Lower vehicle from hoist. such as J-23530. Follow instructions included in tool set. Rear Brake Hose Make sure fittings are installed before starting second flare.
Page 371: Parking Brake Adjustment
BRAKES 5-17 view C-K MODELS POOO ( 4 2 ) MODELS lVIEW P 3 0 0 ( 3 2 ) MODELS G M ODELS Fig. 5-9--Parking Brake Assembly-Typical 1. Raise vehicle on hoist. PARKING BRAKE A D JU S TM E N T Loosen the equalizer adjusting nut.
Page 372 5-18 BRAKES Fig. 5-10--P arking Brake System -Typ ic al LIG H T T R U C K S E R V IC E M AN UAL...
Page 373 BRAKES 5-19 VIEW A P300I42) & M20 & JF9 P300 (42) & M 40 & JF9 Fig. 5-1 1~Parking Brake System (Propshaft) LIG H T TRU CK SER V IC E M AN UAL...
Page 374: Parking Brake Cable
5-20 BRAKES 5. Install cable by reversing removal procedure. PARKING BRAKE (PROPELLER SHAFT)- 6. Adjust parking brake. INTERNAL EXPANDING Center Parking Brake Cable Replacement Adjustm ent-Drum On 1. Raise vehicle on hoist. 1. Jack up at least one rear wheel. Block wheels and 2.
Page 375: Brake Pedal
BRAKES 5-21 2. Remove combination valve. 3. Install combination valve by reversing removal steps. 4. Bleed entire brake system. Do not move vehicle until a firm brake pedal is obtained. BRAKE PEDAL The brake pedal mounting is an integral design with cluth pedal (except...
Page 376: Master Cylinder
5-22 BRAKES BAIL COVER STOP SCREW RESERVOIR PRIMARY D IA P H R A G M PISTON ASSY. LOCK R IN G TUBE SEAT INSERTS SPR IN G S PR IN G RETAINER PRIMARY SEAL SEC O N D A R Y PISTON SEC O N D A R Y SEALS Fig.
Page 377 BRAKES 5-23 Remove two nuts holding master cylinder to dash Assemble new secondary seal into groove on end of or power cylinder and remove master cylinder from vehicle. the secondary piston. Be careful not to drip brake fluid on exterior paint. 5.
Page 378 5-24 BRAKES C O V E R D I A P H R A G M F I L T E R R E S E R V O I R C O M P E N S A T I N G V A L V E S E A L V A L V E...
Page 379: Delco Disc Brake Shoe And Lining
BRAKES 5-25 SUPPORT necessary to prevent reservoir overflow when the caliper piston is pushed back in its bore to remove the caliper. This may be done by breaking the front line connection at the master cylinder and bleeding down the fluid level. Do not remove the brake line or completely empty the reservoir or 8.
Page 380 5-26 BRAKES Fig. 5-22-Removing Sleeves 5-21). Lift the caliper off the rotor and remove the inboard shoe. Dislodge the outboard shoe and position the caliper on the front suspension arm so that the brake hose will not support the weight of the caliper. Remove the shoe support spring from the cavity in the piston.
Page 381 BRAKES 5-27 4. Position the inboard shoe and lining assembly (with spring attached) in the caliper so that the ear end of the shoe and lining is down and the bottom end up at an angle with the spring resting on the piston I.D. (fig. 5-27). Press down on both ends of the shoe until the shoe is in a flat position, resting on the piston.
Page 382 5-28 BRAKES twisted. Start the bolts through the sleeves in the inboard caliper ears and through the mounting bracket, making sure that the ends of the bolts pass under the retaining ears on the inboard shoe (fig. 5-29). Push bolts on through to engage 10.
Page 383: Bendix Disc Brake Shoe And Lining
BRAKES 5-29 CALIPER INBOARD SHOE Removal (Front or Rear) Fig. 5-31--Bendix Front Disc Brake Assembly See "Notice" on page 1 of this section. NOTICE: BENDIX DISC BRAKE SHOE AN D LINING 1. Remove master cylinder cover and observe brake fuuid level in front reservoir is more than 1/3 full, siphon the necessary amount out to bring the level to 1/3 full.
Page 384 5-30 BRAKES SUPPORT BRASS ROD Fig. 5-34~R em oving the C a lip e r S upport Key 1. Lubricate the caliper and steering knuckle (or support) sliding surfaces and the support spring with Delco Silicone Lube (or equivalent). N O TICE: Do not use compressed air to clean the 2.
Page 385: Caliper Overhaul
BRAKES 5-31 Use just enough air pressure to ease the N O TICE: piston out of the bore. If the piston is blown out, even with padding provided, it may become damaged. 4. Use a screwdriver to pry the boot out of the caliper. Extend the screwdriver across the caliper bore, under the boot, and pry up.
Page 386 5-32 BRAKES 2. Remove the caliper assembly as described under "Shoe and Linings-Removal". D isassem bly (Fig. 5 -3 9 ) 1. Clean the exterior of the caliper using clean brake fluid and place on a clean work surface. Fig. 5 -3 8 -S e a tin g Boot 2.
Page 387: Rotor Servicing
BRAKES 5-33 N O TICE: The use of lubricated shop air will leave a film of mineral oil on the metal parts. This may damage rubber parts when they come in contact after reassembly. 2. Check the sliding surfaces of the caliper, steering knuckle (or rear support) and support spring for rust or Place the piston inside of Tool J-24548, force the corrosion.
Page 388 5-34 BRAKES ROTOR THICKNESS REPLACEMENT MINIMUM (DISCARD) AFTER REFINISHING 1.465 1.480 1.215 1.230 .965 .980 W h e e l Bolt R ep lac e m en t (Disc B rakes) See "Notice" on page 1 of this section. N O TICE: 1.
Page 389 BRAKES 5-35 WHEEL CYLINDER LINK" WHEEL CYLINDER SCR"“ " ‘ SECONDARY SHOE & LIN IN “ SHOE GUIDE PARKING BRAKE STRUT STRUT SPRING ADJUSTER LEVER ACTU ATING LINK HOLD DO W N PINS PARKING BRAKE LEVER '— WHEEL CYLINDER V— RY SHOE AND LINING p r i m a ‘—...
Page 390: Propeller Shaft Brake
5-36 BRAKES and may score brake drums. When linings are new, they must be given moderate use for several hundred miles of burnishing. R epair B rake Lining This procedure is to be used when brake action is unequal, severe, hard, noisy or otherwise unsatisfactory and when brake linings have had little wear.
Page 391 BRAKES 5-37 RETURN SPRINGS W AVE WASHER FLANGE LOCK BRAKE LEVER WASHER SHOE ANCHOR STRUT HOLD GUIDE D O W N STRUT PLATE SPRING WASHER DRUM HOLD D O W N SPRING WASHER, SPRING , CUP SOCKET ADJUSTING SCREW BACKING BRAKE PLATE CABLE...
Page 392: Brake Drums
5-38 BRAKES 13. Install pull back springs. DRUM DIAMETERS 14. Remove the "knock out" plug (if necessary) and REPLACEMENT install a new metal plug in the brake drum adjusting hole. ORIGINAL MAXIMUM REFINISH (DISCARD) 15. Install the brake drum. 11.000 11.060 11.090 16.
Page 393: Power Brake U Nit
BRAKES 5-39 2. Position hose clamp to retain filter. 3. Remove two nuts from master cylinder, then move master cylinder away from booster with brake lines PO W ER B R A K E UNIT attached. Vacuum Booster 4. Place the accumulator retaining cap Tool J-26889 over the master cylinder stud and install the nut as shown Replacement (Fig.
Page 394 5-40 BRAKES C-K MODELS Fig. 5-48--Power Brake Vacuum Hose F ilter lnstallation--C-K-P Trucks LIGHT T R U C K S ER V IC E M AN UAL...
Page 395: Hydro-Boost Unit
BRAKES 5-41 Fig. 5 -4 9 --P o w e r Brake Vacuum Hose Filter lnstallation--G M od els Fill and bleed system. Refer to "HYDRO-BOOST In sta lla tio n BLEEDING PROCEDURE". 1. Install "O" ring and spool valve plug (fig. 5-53). 2.
Page 396 5-42 BRAKES models). b. Remove the booster support bracket on C and K models, support braces on G and P30(42) models. c. Remove the booster bracket to dash panel or support bracket nuts and remove the booster assembly. 7. P30(32) Models- a.
Page 397 BRAKES 5-43 8. To install, reverse Steps 1-7 above. Torque all hydraullic lines and attaching bolts to specifications. Lubricate pedal rod and linkage pivot bolts, pins, sleeves and bushings with Delco Brake Lube (or equivalent). See "Notice" on Page 1 of this section. N O TICE: 9.
Page 398 5-44 BRAKES LIG H T T R U C K S ER V IC E MANUAL...
Page 399 BRAKES 5-45 Fig. 5 -5 7 -P o w e r S teering Hose R outing-C -K M odels LIG H T T R U C K SER V IC E M ANUAL...
Page 400 5-46 BRAKES Fig. 5-58--Power Steering Hose Routing~G M odels LIG H T T R U C K S E R V IC E M ANUAL...
Page 401 BRAKES 5-47 LIG H T T R U C K S ER V ICE M ANUAL...
Page 402: Specifications
5-48 BRAKES SPECIFICATIONS SPECIFICATIONS BRAKE SYSTEM DESCRIPTION FRONT BRAKES REAR BRAKES BRAKE ASSIST SYSTEM GASOLINE ENGINE VEHICLES Disc 11.86 x 1.28 None (Manual Brakes) Drum 11.00 x 2.00 Disc 11.86 x 1.28 Vacuum — Single Diaphragm Drum 11.00 x 2.00 Vacuum —...
Page 403 BRAKES 5-49 SPECIFICATIONS **25 ft. lbs. **25 ft. lbs. 25 ft. ibs. 25 ft. Ibs. Master Cylinder - to Dash or Booster **25 ft. lbs. **25 ft. lbs. 25 ft. Ibs. 25 ft. Ibs. Booster to Dash or Frame Com bination Valve - Mounting Bolts 150 in.
Page 404: Special Tools
5-50 BRAKES SPECIAL TOOLS 7. J-21472 or J-22364 Bleeder Wrench 1. J-2 5 3 1 0 Tubing Bender 8. J-22904 Dust Boot Installer 2. J-23530 Flaring Tool J-28735 Dust Boot Installer (JB7) 3. J-23533 Tubing Cutter 9. J-2 3 5 1 8 Bleeder Adapter 4.
Page 405 ENGINE M EC H A N IC A L 6A-1 SEC TIO N 6A ENGINE MECHANICAL The following information is important in N O TICE: any work where electrical terminals could possibly be preventing engine damage and in providing reliable grounded, the ground cable of the battery should be engine performance.
Page 406 6A-2 ENGINE M E CHA NICAL DIAGNOSIS ENGINE FAILS TO START h. Excessive moisture on plugs, caps or ignition system. a. Check for sufficient fuel to operate engine. b. Carburetor flooded and/or fuel level in carburetor i. Damaged distributor rotor or cracked distributor bowl not correct.
Page 407 ENGINE M ECH A N IC A L 6A-3 ENGINE MISSES AT VARIOUS SPEEDS a. Inspect carburetor fuel filter for presence of water camshaft lobes. Repair or replace as necessary. and/or impurities. Correct as necessary. Check engine operating temperature. Correct as b.
Page 408 6A-4 ENGINE M E C H A N IC A L p. Check transmission fluid level. Correct as necessary. k. Check power steering flow control valve operation. Repair or replace as necessary. q. Loss of power may be caused by using sub-standard 1.
Page 409 ENGINE M E CHA NICAL 6A-5 EXCESSIVE OIL CONSUMPTION DUE TO OIL ENTERING COMBUSTION CHAMBER THROUGH HEAD AREA a. Check for intake and exhaust valve "O" ring seals c. Inspect for plugged oil drain back holes in head. to be damaged, missing or loose. Repair or replace as Correct as necessary.
Page 410 6A-6 ENGINE M E CHA NICAL BURNED, STICKING OR BROKEN VALVES correct as necessary. a. Check for weak springs and replace as necessary. b. Check for improper valve lifter clearance and adjust as necessary. g. Check for exhaust back pressure and correct as c.
Page 411 ENGINE M ECHA NICAL 6A-7 NOISY MAIN BEARINGS a. Check low oil pressure and/or insufficient oil supply Check for excessive belt tension and adjust as and correct as necessary. necessary. b. Check for excessive bearing clearance and correct as necessary. c.
Page 412 6A-8 ENGINE M ECHA NICAL Correction Condition Possible Cause Check connections at battery, engine Loose or Corroded Engine Will Not Crank block and starter solenoid. Battery Cables Check generator o u tp u t as described in Discharged Batteries Section 6D. Refer to Starter Diagnosis as described Starter Inoperative in Section 6D .
Page 413 ENGINE M E CHA NICAL 6A-9 Condition Possible Cause Correction Engine Cranks Normally - Pump Timing Incorrect Make certain th at pum p tim ing mark is Will Not Start (C o n t’d ) aligned with mark on adapter. Glow Plug C ontrol Disconnect wires from one glow plug on System Inoperative...
Page 414 6A-10 ENGINE M E CHA NICAL Condition Possible Cause Correction Engine Starts But Will Not Restricted Fuel Return Disconnect fuel return line at injection Continue To Run At Idle System pump. Connect a hose from the return (C o n t’d ) line to a metal container.
Page 415 ENGINE M E CHA NICAL 6 A -1 1 Condition Possible Cause Correction Engine Starts,Idles Rough, Internal Fuel Disconnect fuel return system from nozzles Leak at N ozzle(s) on one bank at a time. With the engine W ithout A bnorm al Noise or running, observe the normal fuel seepage Smoke (C o n t’d ) at the nozzles.
Page 416 6A-12 ENGINE M E C H A N IC A L Correction Possible Cause Condition Remove fuel cap. If “hissing” noise is heard, Significant Loss o f Power Plugged Fuel Tank Vent vent is plugged and should be cleaned. (C o n t’d) Examine fuel supply system to determ ine Restricted Supply cause of restriction.
Page 417 ENGINE M ECHA NICAL 6A-13 C ondition Possible Cause Correction Engine Overheats Coolant System Leak Check for leaks and correct as required. Oil Cooler System Leak Belt Failure Replace. Therm ostat M alfunction See Engine Diagnosis and repair Head Gasket Failure procedures.
Page 419 IN-LINE 6 6A1-1 Section 6A1 Contents 4.1 L (D) L-6 - RPO LE3 L (T) L-6 - RPO L25 General Description..........6A1-1 Valves............... 6A1-16 Engine Lubrication..........6A1-2 Torsional Damper........... 6A1-16 On Vehicle Service........... 6A1-9 Crankcase Front Cover......... 6A 1 -16 Engine Mounts............
Page 420: Engine Lubrication
6A1-2 IN-LINE 6 V A LV E TRAIN rod. The ball check valve will then move off its seat and the A very simple ball pivot-type train is used. Motion is lifter reservoir will be refilled with oil. transmitted from the camshaft through the hydraulic lifters and push rods to the rocker arms.
Page 421 IN-LINE 6 6A1-3 Fig. 6A 1-1-In-Line Engine Lu brication LIG H T T R U C K SER V IC E M AN UAL...
Page 422 6A1-4 IN-LINE 6 Fig. 6A 1-2~ "P " Series - Engine Front M ou nt L IG H T T R U C K S E R V IC E M AN UAL...
Page 423 IN-LINE 6 6A1-5 Fig. 6A 1-4--"C " Series - Engine Rear M ounts...
Page 424 6A1-6 IN-LINE 6 Fig. 6A 1-5--"C " Series - Engine Front M ou nt...
Page 425 ENGINE MOUNT FRAME BRACKET ALL K SERIES WITH L-6 ENGINE ENGINE MOUNT & BRACKET ALL K SERIES WITH L-6 ENGINE...
Page 426 6A1-8 IN-LINE 6 LIG H T T R U C K S ER V IC E M AN UAL...
Page 427: On Vehicle Service
IN-LINE 6 6A 1-9 ^ FWD FRONT MOUNT Fig. 6A1-8-"G" Series - Engine Mounts ON VEHICLE SERVICE replace the mount. If there is relative movement ENGINE M O UNTS between a metal plate of the mount and its attaching points, Engine mounts (Fig.
Page 428: Manifold Assembly-Non-Integrated Head
6A 1-10 IN-LINE 6 Front M ount Replacement 1. Remove engine mount through bolt. 2. Raise engine and remove mount to frame bracket attaching bolts. Remove mount. Raise engine only enough for sufficient clearance. Check for interference between rear of engine and cowl panel. 3.
Page 429: Rocker Arm Cover
IN-LINE 6 6 A 1 -1 1 specification. wet (within 10 minutes). Install retaining bolts and torque to 50 lb. in. (5.6 N*m). 6. Lower vehicle. 3. "CK" Models - Clean dipstick tube and apply 7. Install PAIR pipes as outlined in Section 6E. sealant # 1 0 5 2 0 8 0 or equivalent around tube 1/2"...
Page 430: Valve Lifters
6 A 1 -1 2 IN-LINE 6 Lifter Body Push Rod Seat Retainer Push Rod Seat Plunger Metering Valve Check Ball Spring Check Ball Plunger Spring Check Ball Retainer Fig. 6A1-12-Hydraulic Valve Lifter Fig. 6A1-10--Valve Adjustment place while releasing the compressor tool. 8.
Page 431 IN-LINE 6 6 A 1 -13 Fig. 6A1-13--Removing Ball Check Valve Fig. 6A1-1 5--Assembling Hydraulic Lifter bore, if the bottom of the lifter is scuffed or worn inspect 2. Insert check ball spring on seat in ball retainer and the camshaft lobe, if the push rod seat is scuffed or worn place retainer over ball so that spring rests on the ball.
Page 432 6A 1-14 IN-LINE 6 CYLINDER HEAD ASSEM BLY Removal 1. Remove manifold assembly as previosuly outlined. 2. Remove rocker arm cover and valve mechanism as previously outlined. 3. Drain cooling system. 4. Remove fuel and vacuum line from retaining clips then disconnect wires from temperature sending units.
Page 433: Rocker Arm Studs
IN-LINE 6 6 A 1 -15 Fig. 6A1-1 8--Removing Rocker Arm Stud - Typical Fig. 6A1-19-Reaming Rocker Arm Stud Bore - Typical 5. Install the valve locks and release the compressor tool, making sure that the locks seat properly in the upper groove of the valve stem.
Page 434: Valve Seats
6A 1-16 IN-LINE 6 Fig. 6A1-22-Oil Pan Front Seal Modification - L25 Installation Fig. 6A1-21~Removing Torsional Damper 1. Coat front cover oil seal contact area of damper with engine oil. VALVE SEATS It is necessary to use installer Tool J-22197 NOTICE: Reconditioning the valve seats is very important, to prevent the inertia weight section from walking off...
Page 435: Oil Seal (Front Cover)
IN-LINE 6 6 A 1 -1 7 3. Install seal to front cover, pressing tips into holes provided in cover. On LE3 engine, place a 3/16" (5mm) diameter bead of RTV on cover sealing surface. 4. Coat the gasket with gasket sealer and place in position on cover.
Page 436: Camshaft Bearings
6A 1-18 IN-LINE 6 Fig. 6A1-25--Replacing Camshaft Front Bearing 5. Install remover and installer tool with shoulder toward bearing, making sure a sufficient amount of threads 3. To assemble camshaft gear thrust plate and gear are engaged. spacer ring to camshaft firmly support camshaft at back of 6.
Page 437: Oil Pan
IN-LINE 6 6 A 1 -19 12. Remove oil pan bolts. OIL PAN 13. Remove oil pan and clean gasket surfaces. All except 'G' Van Installation Removal 1. Install new gasket on cleaned gasket surface. 1. Disconnect battery negative cable. 2.
Page 438 6A 1-20 IN-LINE 6 Fig. 6 A 1-27~Gagin g Plastic on Crankpin 3. Install the drive gear and shaft in the pump body. 4. Install the idler gear in the pump body with the smooth side of gear towards pump cover opening. 5.
Page 439 IN-LINE 6 6A1-21 Remove the bearing cap and using the scale on the gaging plastic envelope, measure the gaging plastic width at the widest point (fig. 6A1-28). 6. If the clearance exceeds specifications, select a new, correct size, bearing and remeasure the clearance. Be sure to check what size bearing is being removed in order to determine proper replacement size bearing.
Page 440 6A 1-22 IN-LINE 6 Fig. 6 A 1 -3 2 --M e a s u r in g Cr an kshaft End Play - Typical Fig. 6 A 1 - 3 0 - G a g i n g Plastic on Journal - Typical be observed.
Page 441: Oil Seal (Rear M Ain)
IN-LINE 6 6 A 1-23 .004 SHIM STOCK > *— 1 / 2 —► ..J ... 11/64 Fig. 6 A 1 - 3 4 -Oil Seal Installation Tool Without Crankshaft Removal 1. With oil pan, oil pump and spark plugs removed, remove cap on main bearing requiring replacement and remove bearing from cap.
Page 442: Piston And Connecting Rod Assemblies
6A 1-24 IN-LINE 6 Fig. 6 A 1 -3 5 - R e m o v i n g Oil Seal Lower H a l f - T y p i c a l channel on the outside diameter of the seal. An installation Roll seal around crankshaft using tool as a "shoe...
Page 443 IN-LINE 6 6A 1-25 PRESS -PISTON PIN REMOVER J-24086-8 FIXTURE & SUPPORT ASSEMBLY J-24086-20 Fig. 6 A 1 -3 9 ~ R e m o v in g Connecting Rod & Piston Assembly top of the piston. 3. Use a ridge reamer to remove any ridge and/or Fig.
Page 444 6A 1-26 IN-LINE 6 After installer hub bottoms on support NOTICE: Fig. 6 A 1 -4 2 ~ R in g Gap Location assembly, do not exceed 5000 psi pressure, as this could cause structural damage to the tool. 7. Slip the outer surface of the top and second compression ring into the respective piston ring groove and Remove piston and connecting rod assembly from roll the ring entirely around the groove to make sure that...
Page 445 IN-LINE 6 6A 1-27 Fig. 6A1-4 5--ln sta lling Connecting Rod and Piston Assembly Fig. 6 A 1 -4 3 - M e a s u rin g Ring Groove Clearance engine (fig. 6A1-44). Use Tool J-8037 to compress the rings (fig. 6A1-45). Guide the connecting rod into place on the crankshaft Installation journal with Tool J-6305 (11/32").
Page 446: Flywheel
6A 1-28 IN-LINE 6 then .005" wear or taper may not entirely clean up when PISTON SELECTION fitted to a high limit piston. If it is desired to entirely clean 1. Check USED piston to cylinder bore clearance as up the bore in these cases, it will be necessary to rebore for follows: an oversize piston.
Page 447: Engine Assembly
IN-LINE 6 6 A 1 -29 3. Install flywheel retaining bolts and torque to Remove engine mount "through" bolts. specifications. 21. Lower vehicle. Attach lifting devise to engine. L25 Engine 1. Clean the mating surfaces of flywheel and Raise engine slightly and remove right hand mount crankshaft to make certain there are no burrs.
Page 448: Crankshaft
6A 1-30 IN LINE 6 7. Remove heater hoses from engine. APPLY 8. Remove radiator. SEALANT 9. Remove fan and water pump pulley. TO SHADED 10. Disconnect fuel line from fuel pump. AREAS ONLY 11. Remove vehicle hood. 12. Raise vehicle. 13.
Page 449 IN-LINE 6 6A1-31 Fig. 6A1-47--Gear Replacement rearward then forward with a lead hammer. This will line • On vehicles equipped with automatic transmissions, up rear main bearing and crankshaft thrust surfaces. install flywheel with the converter attaching pads towards Retorque all main bearing cap bolts to specifications. transmission.
Page 450 GENERAL DATA: PISTON PIN L E 3 L 2 5 D IA M E T E R T Y P E IN LIN E L-6 .9 2 7 0 - .9 2 7 3 .0 0 0 1 5 - .0 0 0 2 5 P R O D U C T IO N D IS P L A C E M E N T LITRE (*)
Page 451 TORQUE SPECIFICATIONS Camshaft Thrust P la te ........80 lb. in. Crankshaft Front C o v e r........80 lb. in. VALVE SYSTEM Flywheel Housing Cover .........80 lb. in. L IF T E R Oil Pan (To Crankcase) (1/4-20) ..... 80 lb. in. H Y D R A U L IC Oil Pan (To Front Cover) .........50 lb.
Page 453: General Description
SM ALL BLOCK 6A4-1 SECTION 6A4 5.0 L (G) V-8 - RPO LG9 5.7 L (L) V-8 - RPO LS9 5.7 L (M) V-8 - RPO LT9 6.6 L (R) V-8 - RPO LF4 6.6 L (X) V-8 - RPO LE4 Contents General Description..........
Page 454: Engine Lubrication
6A4-2 SM ALL BLOCK PISTONS AND CONNECTING RODS below the plunger. The plunger and lifter body then rise as The pistons are made of cast aluminum alloy using two a unit, pushing up the push rod and opening the valve. compression rings and one oil control ring.
Page 455 SM ALL BLOCK 6A 4-3 Fig. 6 A 4 -1 ~ E n g in e Lubrication L IG H T T R U C K SER V IC E M ANUAL...
Page 456 6A 4-4 SM ALL BLOCK Fig. 6A4-2--Engine Lubrication LIG H T T R U C K S E R V IC E M AN UAL...
Page 457: On Vehicle Service
SM ALL BLOCK 6A 4-5 ON VEHICLE SERVICE Rear Mount ENGINE M O UNTS Raise the vehicle on a hoist. Push up and pull down Engine mounts (fig. 6A4-3 - 6A4-8) are the non- transmission tailshaft while observing adjustable type and seldom require service. Broken or transmission mount.
Page 458 6A4-6 SM ALL BLOCK LIG H T T R U C K S ER V IC E M ANUAL...
Page 459 S M ALL BLOCK 6A 4-7 Fig. 6A4-5--"P" Series Engine Front M ou nt LIG H T T R U CK SER V ICE M ANUAL...
Page 460 6A4-8 SM ALL BLOCK Fig. 6A4-6--"G" Series Engine Mounts LIG H T TR U C K S E R V IC E M AN UAL...
Page 461 SM ALL BLOCK 6A 4-9 REAR MOUNT Fig. 6 A 4 - 7 - " K " Series Engine Mounts LIG H T T R U CK SER V IC E M AN UAL...
Page 462 6A 4-10 SM ALL BLOCK Fig. 6 A 4 -8 ~ * C " Series Engine Mounts L IG H T T R U C K S E R V IC E M AN U AL...
Page 463: Exhaust Manifold
SM ALL BLOCK 6 A 4 -1 1 4. Remove air compressor and bracket (if equipped), accelerator return spring and bracket, and accelerator bellcrank. 5. Remove generator upper mounting bracket. 6. Remove manifold attaching bolts, then remove manifold and carburetor as an assembly. Discard gaskets. 7.
Page 464: Rocker Arm Cover
6A 4-12 SM ALL BLOCK 5. Remove carburetor heat stove pipe from right W IN G N U T exhaust manifold. LO W E R S T O V E 6. If the vehicle is equipped with air conditioning, N O TE : In b o a rd fla n g e remove the A/C compressor rear brace (fig.
Page 465: Valve Stem Oil Seal And/Or Valve Spring
S M ALL BLOCK 6 A 4 -1 3 J -2 3 5 9 0 ADAPTER Fig. 6A4-1 2--Valve Adjustment Fig. 6A4-13--Compressing Valve Spring b. With the engine in the # 1 firing position as just the seal will help prevent twisting. determined, the following valves may be adjusted: 2.
Page 466: Cylinder Head Assembly
6 A 4-14 SM ALL BLOCK 6 Push Rod Seat I Lifter Body Retainer 2. Push Rod Seat 7. Plunger 3 Metering Valve 8. Check Ball Spring 4 Check Ball 9 Plunger Spring 5 Check Ball Retainer Fig. 6A4-14~Hydraulic Valve Lifter Fig.
Page 467 S M ALL BLOCK 6A 4-15 Fig. 6A4-19--Cleaning Combustion Chambers spring shims. Remove valves from cylinder head and place them Fig. 6A4-1 7--Assembling Hydraulic Lifter in a rack in their proper sequence so that they can be assembled in their original positions. Cleaning 3.
Page 468 6A 4-16 SM ALL BLOCK * NOT USED O N 250 CU. IN. L6 Fig. 6A4-22-Valve Spring Installation Assembly 1. Insert a valve in the proper port. 2. Assemble the valve spring and related parts as Fig. 6A4-20~Measuring Valve Stem Clearances follows: a.
Page 469: Rocker Arm Studs
SM ALL BLOCK 6A 4-17 GRIND OUT THIS PORTION ; j“ ,l ' [ » TTjTTTjrr1 i ■ j ' j 11> 111' 1 1 r'j 1 1 >1 J-TTIjTTTJ I [ T p 111 Tt T |i"i i j t h [ "...
Page 470: Valve Guide Bores
6A 4-18 SMALL BLOCK Fig. 6A4-30--Removing Torsional Damper - Typical Fig. 6A4-28--lnstalling Rocker Arm Stud to attain proper results. Do not attempt to install an oversize stud NOTICE: TO RSIONAL DAM PER without reaming stud hole as this could damage the head casting.
Page 471: Crankcase Front Cover
SM ALL BLOCK 6 A 4-19 J-23042 Fig. 6A4-3 1 --I nsta 1 1 i ng Torsional Damper Fig. 6A4-32--lnstalling Oil Seal Fill cooling system (see section 6B) and check for leaks. OIL SEAL (FRONT COVER) CRANKCASE FRONT COVER Replacement Removal With Cover Removed 1.
Page 472: Camshaft Bearings
6A 4-20 SMALL BLOCK #6 CYLINDER AT T.D.C. Fig. 6A4-35--Camshaft Sprocket Alignment Marks and care must be used in removing camshaft to avoid Fig. 6A4-33--Measuring Camshaft Lobe Lift damage to bearings. Inspection 7. Install and adjust valve mechanism as outlined. The camshaft bearing journals should be measured with a micrometer for an out-of-round condition.
Page 473: Oil P A N
SM ALL BLOCK 6A4-21 Fig. 6A4-36~R em oving C am shaft Bearings Fig. 6A4-37--Replacing Camshaft Front Bearing not be in the way while replacing camshaft bearings. 1. With camshaft and crankshaft removed, drive • Number five bearing oil hole must be in 12 o’clock camshaft rear plug from cylinder block.
Page 474: Oil Pump
6A 4-22 SM ALL BLOCK Fig. 6A4-39--lnsta!ling Screen Pressure Regulator Shaft Extension Pump Body Spring Drive Gear and Shaft . Retaining Pin 7. Check the pressure regulator valve for fit. Idler Gear Screws Pickup Screen and Pump Cover Assembly (Figure 6A 4-38) Pipe .
Page 475: Main Bearings
S M ALL BLOCK 6 A 4 -23 Fig. 6A4-40~Gaging Plastic On Crankpin Fig. 6A4-4 1--Measuring Gaging Plastic Inspection and Replacement . d. Remove the bearing cap and using the scale on the gaging plastic envelope, measure the gaging plastic width 1.
Page 476 6A 4-24 SMALL BLOCK Fig. 6A4-43-Gaging Plastic on Journal Fig. 6A4-42--Measuring Connecting Rod Side Clearance Identification of a reground crankshaft is by the of the crankshaft journal and bearing should be wiped clean following: of oil. • The crankshaft throw will be stamped on one side of 1.
Page 477: Oil Seal (Rear M Ain)
SM A LL BLOCK 6 A 4-25 Fig. 6A4-46-Oil Seal Installation Tool Measure crankshaft end play (see specifications) by forcing the crankshaft to the extreme front position. Measure at the front end of the rear main bearing with a feeler gage (fig. 6A4-45). Install a new rear main bearing oil seal in the cylinder block and main bearing cap.
Page 478 6A 4-26 SM ALL BLOCK DUST SEAL Fig. 6A4-47--Removing Oil Seal - Lower Half Fig. 6A4-49-Crankshaft Oil Seal - Rear Main should be exercised when installing this seal to protect the 8. Position seal between crankshaft and tip of tool so sealing bead located in the channel on the outside diameter that seal bead contacts tip of tool.
Page 479 SMALL BLOCK 6 A 4-27 PRESS -PISTON PIN REMOVER J - 2 4 0 8 6 -8 FIXTURE SUPPORT ASSEMBLY J -2 4 0 8 6 -2 0 F ig . 6 A 4 - 5 1 - - R e m o v i n g C o n n e c t i n g R o d & P i s t o n A s s e m b l y CONNECTING ROD AND PISTON ASSEMBLIES Removal 1.
Page 480 6A4-28 SMALL BLOCK PRESS PISTON PIN INSTALLER J -2 4 0 8 6 -9 F i g . 6 A 4 - 5 4 - - M e a s u r i n g R i n g G a p 4.
Page 481 SMALL BLOCK 6 A 4-29 ENGINE LEFT ENGINE FRONT ENGINE RIGHT " S M A L L V 8 ” " M A R K I V V 8 ' " A ” O IL R IN G SPACER G A P (T ang in H o le o r S lo t w ith in A rc ) B "...
Page 482: Cylinder Block
6A 4-30 SMALL BLOCK 3. When finish honing a cylinder bore to fit a piston, CYLINDER BLOCK the hone should be moved up and down at a sufficient speed Cleaning and Inspection to obtain very fine uniform surface finish marks in a cross- 1.
Page 483 SMALL BLOCK 6A4-31 4. Remove grille, upper radiator support and lower 13. Using a new gasket, install carburetor. Connect grille valance. accelerator cable. 5. Disconnect radiator hoses at radiator. 14. Install radiator. Install radiator to radiator support attaching brackets. • If equipped with automatic transmission, remove cooler lines from radiator.
Page 484: Crankshaft
6A4-32 SMALL BLOCK Installation (CK Series/Code U, L & R Engines) m a l l 1. Place engine in vehicle. 2. Raise vehicle. 3. Install engine mount bracket to frame bolts. 4. Install bell housing to engine retaining bolts. Remove transmission support. 5.
Page 485 SM ALL BLOCK 6 A 4 -33 2. Lubricate lips of seal with engine oil. Keep oil off up rear main bearing and crankshaft thrust surfaces. parting line surface. Retorque all main bearing cap bolts to specifications. 3. Install main bearings in cylinder block and main bearing caps then lubricate bearing surface with engine oil.
Page 486 LS9/LT9 LF4/LE4 P IS T O N P IN G E N E R A L D A T A : . 9 2 7 0 - . 9 2 7 3 D I A M E T E R T Y P E 9 0 °...
Page 487 TORQUE SPECIFICATIONS V A L V E SYSTEM LS9/LT9 LF4/LE4 C R A N K C A S E F R O N T C O V E R ......80 LB. IN. HYDRAULIC L I F T E R F L Y W H E E L HO USING C O V E R ......
Page 489 M A R K IV 6A5-1 SECTION 6A5 7.4 L (W) V-8 - RPO LE8 Contents General Description..........6A5-1 Crankcase Front Cover......... 6A5-17 Engine Lubrication..........6A5-4 Oil Seal (Front Cover)........... 6A5-18 On Vehicle Service............ 6A5-6 Camshaft..............6A5-18 Engine Mounts............6A5-6 Camshaft Bearings..........
Page 490 6A5-2 M A R K IV COVER DISTRIBUTO R BRKT STUD B A LL CLAMP O U TLE T STUD ------ GSKT GASKET THERM O STAT M A N IF O L D BOLT SPRING BOLT ROTATOR PLUG ‘GSKT GASKET BOLT M A N IF O LD V A L V E...
Page 491 M ARK IV 6A5-3 LIG H T TR U CK SER V ICE MANUAL...
Page 492: Engine Lubrication
6A5-4 M ARK IV INTAKE MAN IFOLD HYDRAULIC VALVE LIFTERS Hydraulic Valve Lifters are used to keep all parts of The intake manifold is of cast iron double level design for efficient fuel distribution. The carburetor pad is centrally the valve train in constant contact. located with a passage running underneath the pad (E.F.E.) The hydraulic lifter assembly consists of: the lifter through which exhaust gases are forced to promote faster...
Page 493 M ARK IV 6A5-5 TO OIL COOLER OIL COOLER BY-PASS VALVE OIL FILTER BY-PASS VALVE CAMSHAFT LOBE OILING OIL FILTER AND DISTRIBUTOR OILING FUEL PUMP PUSH ROD OILING CRANKCASE AND CRANKSHAFT OILING VALVE MECHANISM OILING Fig. 6 A 5 - 3 ~ " M a r k IV" Engine Lubrication LIG H T T R U C K SER V IC E M ANUAL...
Page 494: On Vehicle Service
6A5-6 M A R K IV ON VEHICLE SERVICE Front M ount Replacement ENGINE M O UNTS 1. Remove mount retaining bolt from below frame Engine mounts (fig. 6A5-4 - 6A5-7) are the non- mounting bracket. adjustable type and seldom require service. Broken or 2.
Page 495 M ARK IV 6A5-7 LIG H T TR U CK SER V IC E M AN UAL...
Page 496 6A5-8 M AR K IV Fig. 6 A 5 -6 ~ "P " Series Engine Front M ou nt LIG H T T R U C K S E R V IC E M ANUAL ■...
Page 497 M ARK IV 6A5-9 Fig. 6A5-7--"C " Series Engine Mounts LIGHT T R U C K SER V IC E M ANUAL...
Page 498: Exhaust Manifold
6A5-10 M ARK IV ____________________ ____________________ MARK IV V8 Fig. 6A5 -8 --lntake M anifold Torque Sequence 7. If manifold is to be replaced, transfer: • Carburetor and carburetor attaching bolts. • Temperature sending unit. • Thermostat with housing (use new gasket). •...
Page 499: Valve Mechanism
M A R K IV 6A5-11 3. Disconnect electrical wiring harness from rocker arm clips. Remove carburetor heat stove pipe from right exhaust manifold. 5. If the vehicle is equipped with air conditioning, remove the A/C compressor upper brace (fig. 6A5-10). 6.
Page 500: Valve Lifters
6A5-12 M ARK IV Push Rod Seat I. Lifte r Body Retainer Push Rod Seat Plunger M etering Valve Check Ball Spring Check Ball P lunger Spring Check Ball Retainer Fig. 6A5-1 4-Hydraulic Valve Lifter J-23590 VALVE LIFTERS Hydraulic valve lifters very seldom require attention. Fig.
Page 501: Cylinder Head Assembly
M AR K IV 6 A 5 -1 3 ? ’ • ' - r Fig. 6A5-1 5--Removing Ball Check Valve Fig. 6A5-1 7-Assembling Hydraulic Lifter plunger. or worn lifters should be replaced. 4. Fill the assembly with SAE 10 oil, then insert the •...
Page 502 6A 5-14 M AR K IV Fig. 6A5-1 8-Compressing Valve Spring Inspection tool and remove rotators or spring caps, springs and spring 1. Inspect the cylinder head for cracks in the exhaust damper, then remove oil seals and valve spring shims. ports, combustion chambers, or external cracks to the coolant chamber.
Page 503 MARK IV 6A5-15 Fig. 6A5-23~Valve Spring Installation 3. Install the remaining valves. 4. Check the installed height of the valve springs, using a narrow thin scale. A cutaway scale will help (fig. 6A5-24). Measure from the top of the shim or the spring seat to the top of the valve spring or valve spring shield (fig.
Page 504: Rocker Arm Studs
6A5-16 M A R K IV '[SEESPECIFICATIONS Fig. 6A5-25-Measuring Valve Spring Installed Height 6. Install exhaust manifolds as previously outlined. 7. Install intake manifold as previously outlined. Fig. 6A5-27--Ftocker Arm Stud & Push Rod Guide 8. Install and adjust valve mechanism as previously outlined.
Page 505: Torsional Damper
M AR K IV 6A5-17 Fig. 6A5-30~lnstalling Torsional Damper valve head due to the amount of metal that must be removed to completely reface. Knife edges lead to breakage, burning or pre-ignition due to heat localizing on this knife edge. If Fig.
Page 506: Oil Seal (Front Cover)
6 A 5-18 M ARK IV CUT THIS PORTION FROM NEW SEAL Fig. 6A5-32~Oil Pan Front Seal Modification J-23042 5. Apply a 1/8" (3mm) bead of RTV sealer, # 1052366 or equivalent, to the joint formed at the oil pan and cylinder block (fig.
Page 507: Camshaft Bearings
M ARK IV 6 A 5 -1 9 C Y L IN D E R A T T.D.C. Fig. 6A5-36--Removing Camshaft Fig. 6A5-37-Timing Sprocket Alignment Marks 2. Position indicator with ball socket adapter (Tool J- 8520) on push rod (fig. 6A5-35). Make sure push rod is in Inspection the lifter socket.
Page 508: Oil P An
6A5-20 MARK IV Fig. 6A5-38~Removing Camshaft Bearings Fig. 6A5-39--Replacing Camshaft Front Bearing 1. With camshaft and crankshaft removed, drive camshaft rear plug from cylinder block. 5. Install remaining bearings in the same manner. It 2. Using Tool J-6098 with nut and thrust washer will be necessary to index pilot in the camshaft rear bearing installed to end of threads, index pilot in camshaft front to install the rear intermediate bearing.

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Chevrolet 1980 Light Duty Truck Service Manual

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