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This manuai includes procedures for diagnosis, maintenance and adjustments, minor service operations, removal disassembly and installation for components of GMC Truck & Coach Division Series 1500-3500 Light Duty Trucks. Procedures for “ S-15” and Caballero are contained in separate service manuals.
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IMPORTANT SAFETY NOTICE Proper service and repair is important to the safe, reliable operation o f all m otor vehicles. The service procedures recomm ended and described in this service manual are effective m ethods for performing service operations. Som e o f these service operations require the use o f tools specially designed for the purpose.
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SECTION TABLE OF CONTENTS GENERAL INFORMATION G e n e ra l In fo rm a tio n M a in te n a n c e a nd Lu b ricatio n HEATING AND AIR CONDITIONING H e a tin g a n d V e n tila tio n A ir C o n d itio n in g R -4 C o m p re s s o r A -6 C o m p re s s o r...
GENERAL INFORMATION OA-1 SECTION OA GENERAL INFORMATION CONTENTS OF THIS SECTION G e n e r a l........................0-1 Vehicle Identification N u m b e r ................0-2 Service Parts Identification S tic k e r..............0-3 Vehicle L o a d in g ....
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OA-2 GENERAL INFORMATION VEHICLE IDENTIFICATION NUMBER GCEC14D9CF123456 N A T IO N O F O R IG IN H P L A N T S E Q U E N T IA L N U M B E R ] U S A M O D E L Y E A R A S S E M B L Y P L A N T...
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GENERAL INFORMATION OA-3 SERVICE PARTS ID E N TIFIC A TIO N STICKER Axles The Service Parts Identification Sticker (Fig. OA-6) is provided on all Truck models. On C and K models, the C hevrolet Built identification sticker be located on the inside of the glove box •...
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OA-4 GENERAL INFORMATION TYPICAL TRANSMISSION - I D LOCATIONS THM 350C STAMPED I D LOCATION K. THM 400 I D TAG LOCATION THM 350C VIN LOCATION THM 400 VIN LOCATION THM 350C OPTIONAL VIN LOCATIONS M. THM 700 R4 STAMPED I D LOCATION N.
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GENERAL INFORMATION OA-5 ENGINE V.I.N . ENGINE ENGINE V .I.N . (OPTIONAL) CASE PAD (OPTIONAL) ENGINE V .I.N . DISTRIBUTOR PAD V8 ENGINE L6 ENGINE V8 E N G IN E - D IE S E L 1Q0820 Fig. 0A-7--Engine V.I.N. Location G enerators Engines (Fig.
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MAINTENANCE AND LUBRICATION OB-1 SECTION OB MAINTENANCE AND LUBRICATION CONTENTS Maintenance S c h e d u le ..................OB-6 General M a in te n a n c e ..................OB-6 Emission Control M aintenance..............OB-11 Recommended Fluids and L u b ric a n ts............OB-13 Fluid C apacities....................
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OB-2 MAINTENANCE AND LUBRICATION 1982 VEHICLE MAINTENANCE SCHEDULE Item To Be Serviced When to Perform SECTION A - GENERAL MAINTENANCE • • Chassis Lubrication • • • • Lubricate every 12 Months or 7,500 Miles (12 000 km) • • •...
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MAINTENANCE AND LUBRICATION OB-3 1982 VE H IC LE M A IN TEN A N C E S CHEDULE Item To Be Serviced When to Perform SECTION A - GENERAL MAINTENANCE • • • • • • Chassis Lubrication Lubricate every 12 Months or 7,500 Miles (12 000 km) •...
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OB-4 MAINTENANCE AND LUBRICATION 1982 VEHICLE MAINTENANCE SCHEDULE Item To Be Serviced When to Perform SECTION A - GENERAL MAINTENANCE Chassis Lubrication • • • • Every 4 Months or 6,000 Miles (9 600 km) • • • • • Fluid Levels •...
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1982 VEHICLE MAINTENANCE SCHEDULE Item To Be Serviced When to Perform SECTION A - GENERAL MAINTENANCE • Lubricate every 12 Months or 5,000 Miles (8 000 km) • • • • • • • • Chassis • • • • •...
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OB-6 MAINTENANCE AND LUBRICATION M A IN TEN A N C E SCHEDULE This is an explanation of the service listed in the 3. Apply light engine oil to all pivot points in release Vehicle M aintenance Schedule. mechanism, as well as primary and secondary latch mechanisms.
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MAINTENANCE AND LUBRICATION OB-7 loss of fluid. Transmission damage can result. Low fluid level can cause slipping or loss of drive. A u to m atic transmissions are sometimes overfilled because the fluid level is checked when the fluid is cold. W hen cold, the dipstick shows that fluid should be added.
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OB-8 MAINTENANCE AND LUBRICATION the proper viscosity. See O w n e r’s M anual for further details. U S E T H E S E S A E V IS C O S I T Y G R A D E S Engine Oil Additives - The engine should not need these extra engine oil helpers or additives if SF quality engine oil 20W -20] '20W -40,'...
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MAINTENANCE AND LUBRICATION OB-9 A -6 Exhaust System F R O N T F R O N T Inspect the complete exhaust system, including the catalytic converter. Inspect body areas near the exhaust system and also the tailgate. Look for braken, damaged, missing or out-of-position parts.
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OB-10 MAINTENANCE AND LUBRICATION abnormal tire wear, adverse vehicle handling, and reduced • Alcohol or methanol base coolants or plain water alone fuel mileage. Too high an air pressure can result in should not be used in a vehicle at any time. abnormal wear, harsh ride, and also increase the chance of The cooling system should be serviced each year as damage from road hazards.
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MAINTENANCE AND LUBRICATION OB-11 15,000 miles (24 000 km) on light duty emissions or 12,000 miles (19 200 km) on heavy duty emission and diesel engine vehicles if the vehicle has been driven under one or more of these hot conditions: •...
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OB-12 MAINTENANCE AND LUBRICATION B -10 Exhaust G as Recirculation System (EGR) B - l 5 Fuel Filter C O N D U C T E G R O P E R A T I O N system check as Replace carburetor fuel filter at mileage shown on covered in Service M anual.
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MAINTENANCE AND LUBRICATION OB-13 RECOMMENDED FLUIDS AND LUBRICANTS FLU ID /LU BRICA NT USAGE G M p o w e r s te e rin g flu id P a rt N o. 1 0 5 0 0 1 7 o r e q u iv a le n t. P o w e r s te e rin g system and p u m p re se rv o ir Transfer case D E X R O N ®...
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OB-14 MAINTENANCE AND LUBRICATION CAPACITIES U.S. MEASURE D iff e r e n t ia l 8 1 / 2" R in g Gear ptS. I . 9 L 8 - 7 / 8 ” R in g Gear 3 y2 pts. 0 V 2 "...
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MAINTENANCE AND LUBRICATION OB-15 T hrottle Bell Crank - L-6 Wheel Bearings Lower Control Arms Carburetor Linkage - V-8 Steering Gear Upper C ontrol Arms Brake and Clutch Pedal A ir Cleaner - Element Upper and Lower Control Springs Master Cylinder Arm Ball Joints Universal Joints Transmission...
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OB-16 MAINTENANCE AND LUBRICATION 1/ 2 TON " G " MODELS L U B R IC A T IO N PO IN TS C ontrol Arm Bushings and Trans. Control Shaft Rear Axle Ball Joints A ir Cleaner - Element Oil Filter Tie Rod Ends Transmission...
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HEATER 1 A-1 SECTION 1A HEATER CONTENTS Standard H e a te r....................1 A - 1 Auxiliary H e a t e r ....................1A-15 Specifications..................... 1A-20 STANDARD HEATER INDEX Heater H o se s..............1A-9 General Description.............1 A - 1 Center Distributor Duct ..........
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1A-2 HEATER HEATER A D EFROSTER A S M H EATER A D E F R OS T E R A S M ( HEATER I N OFF P O S I T I O N ) A IR OUTLET A I R O U T L VIEW VIEW...
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HEATER 1A-3 Fig. lA -2 -H ea te r Control-C-K Models Fig. lA -3 -H e ate r Control-G Models...
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1A-4 HEATER DIAGNOSIS TROUBLE CAUSE AND CORRECTION Temperature o f heater a ir a t o u tle ts too low to heat up pas See " In s u f f ic ie n t Heat D iagnostic C h a rt". senger compartment.
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HEATER 1A-5 I N S U F F I C I E N T H E A T D I A G N O S I S Position th e contro ls so th a t the: Tem p erature lever is on fu ll heat. Selector or heater lever is on Heater.
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HEATER C I R C U I T D I A G N O S I S * BLOWER MOTOR INOPERATIVE (ANY SPEED) Check fuse in fuse panel. FUSE BLOWN FUSE OK ~ ' I----- The following tests should be made with With Ignition switch in the ignition switch in "R U N "...
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HEATER 1A-7 C-K MODELS J W V W r - 7 | C I R C U I T HEATER O P E R A T I O N B A T - B L O S W - R E S Rl R 2 - B A T - O N L Y BLO M T R - G R D B L O W ER...
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1A-8 HEATER O N VEHICLE SERVICE 4. Remove the blower wheel to motor shaft nut and separate the wheel and motor assemblies. 5. To install a new motor, reverse Steps 1 -4 above. The following steps should be taken to assure proper installation: a.
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HEATER 1A-9 Fig. lA -7-H ea ter Distributor - G Models R eplacem ent 3. Place a clean pan under the vehicle and then disconnect the h eater core inlet and outlet hoses at the core The heater core can be easily damaged in the area of connections (see "...
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1A-10 HEATER AUTOMATIC TRANSMISSION MODELS EXCEPT C-K 10 350 V8 W /O VOI OR C60 ) C- K M O D E LS G MODELS Fig. lA-8--Heater Hose Routings wiring harness. Be careful not to kink the bowden 2. Remove I.P. bezel as outlined in Section 8C of this cables.
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HEATER 1A-11 Fig. 1 A-l0--Heater Hose Routing V8 A djustm ent - G V a n CONTROL CABLES (Fig. 1 A -1 6 , 1 A -1 7 ) 1. Attach inner cable and sheath to I.P. Control. C-K M odels 2.
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T E E ' V A L V E A S M TEE A N D V A L V E /C 36...
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HEATER 1A-13 Fig. 1 A-l2--Distributor Ducts--G Models Fig. 1 A -l5--C ontrol Assembly, G Models...
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1A-14 HEATER V IE W V IE W Fig. 1 A-l7--Control Cable Routing, G Models...
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HEATER 1A-15 Fig. A -l 8--Resistor - Models AU XILIARY HEATER INDEX General D escription ..................1A-15 Control....................... I A - 15 Diagnosis....................... 1A-17 On Vehicle Service.................... 1A-18 Specifications....................... 1A-20 GENERAL DESCRIPTION An auxiliary heater is available accessory to provide CONTROLS additional heating capacity for the rearmost extremities of Two methods of control are employed with this system:...
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1A-18 HEATER M31H.! g’lTTI Rire.ia^» TnH .’ r ^'m r u n r u 2973781- 8 9 0 5 4 2 6 1 - 3 B R N /W H T -5 0 - •3 B R lV W H T -5 0 — W H T-952A - ----- 2 W H T-952B -...
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1A-20 HEATER SPECIFICATIONS SECTION 1A H E A T E R A m p s. (Cold) (C old ) V o lts Blower Motor 2550 Min. C-K Models 13.5 6.25 Max. 2950 Max. G Models ..13.5 7.1 Max.
AIR CONDITIONING IB-1 SECTION IB AIR CONDITIONING N O TIC E : W hen perform ing air conditioning diagnosis on vehicles equipped with a catalytic converter, it will be necessary to warm the engine to a normal operating tem perature before attempting to idle the engine for periods greater than five (5) minutes.
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E V A P O R A T O R C O R E B LO W E R & S H R O U D E V A P O R A T O R A S M R.H. OUTLET C O N T R O L R.H.
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AIR CONDITIONING IB-3 These units are self contained, operating on inside (recirculated) air only. Air is drawn into the unit, passed through the evaporator core and then directed into the passenger compartment through the air distributor duct. System control is through the front system. The only control on the overhead system is a three speed blower switch.
IB-4 AIR CONDITIONING The expansion tube is located in the evaporator inlet line (Fig. 1 B-4). Therm ostatic Sw itch - M otor Hom e Chassis Units O nly System te m p e ra tu re is controlled by running the compressor intermittently, automatically turning it on and off as necessary to m aintain proper tem peratu res.
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C O N D I T I O N E D A I R IS D I R E C T E D T H R U W/SHLD, I P. & F L O O R D I S T R I B U T O R O U T L E T S A N O N C O M P R E S S O R O P E R A T IN G P O S IT IO N , C O N D I T I O N E D A I R IS D I R E C T E D T H R U I P.
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IB-6 AIR CONDITIONING S Y S T E M O P E R A T IO N - C K T R U C K S E L E C T O R B LO W ER A IR H E A T E R A /C H E A T E R A IR L E V E R...
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AIR CONDITIONING IB-7 B L O W E R A I R H E A T E R H E A T E R A I R S P E E D S E N T E R S D E F R O S T E R A / C C O M P R E S S O R S O U R C E...
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IB-8 AIR CONDITIONING Fig. IB -12-M otor Home Unit Control CCOT SYSTEM C O M P O N E N TS C C O T R efrigerant System com ponents refrigerant flow are shown in Fig. 1B -13. C h art 1 B-1 shows pressure tem perature relationships of R - 12.
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AIR CONDITIONING IB-9 P R ESSU R E C Y C L IN G SY STEM ‘HPV” H IG H PRESSURE VAPOR LE A V IN G COMPRESSOR. *HPL" VAPOR IS COOLED DOWN BY CONDENSER A IR FLOW A N D LEAVES AS HIGH PRESSURE LIQ U ID . 'L P L "...
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1 B-10 AIR CONDITIONING pressure is noticed when fitting is loosened, allow it to bleed off as described under D I S C H A R G I N G , A D D IN G OIL, E V A C U A T IN G A N D C H A R G I N G P R O C E D U R E S FOR C.C.O .T.
AIR CONDITIONING IB-11 should be properly Evacuated before recharging with making connections. parts should be at room R efrigerant-12 according to the D I S C H A R G I N G temperature before uncapping (this prevents condensation A D D I N G O IL , E V A C U A T I N G & C H A R G I N G of moisture from the air entering the system).
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IB-12 AIR CONDITIONING B LO W ER M O T O R UPPER CASE E X P A N S IO N (O R IF IC E ) T U B E A C C U M U L A T O R LO W ER CASE ,C A S E IN L E T...
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AIR CONDITIONING IB-13 Chart 1 B-4--Pressure Cycling CCOT System Diagnosis...
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IB - 14 AIR CONDITIONING ELECTRICAL/VACUUM TROUBLE DIAGNOSIS Operation of the air conditioning blower at all four W hen diagnosing problems in the electrical and speeds and engagement of the compressor clutch would vacuum systems of the air conditioning system, consult indicate th a t electrical circuits are...
COMPRESSOR D I A GNO SI S Check for proper air gap. CLUTCH SLIPPING. Correct if necessary. (.022.057) COMPRESSOR ENGAGED BUT NOT OPERATIONAL. BELT SLIPPING. Check and correct belt tension. REFRIGERATION CHARGE HIGH TORQUE COMPRESSOR. IS DEPLETED. (SEIZED) SYSTEM HAS SOME REFRIGERANT.
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I N S U F F I C I E N T C O O L I NG D I A G N O S I S C H A R T D A S H M O U N T E D U N IT (M O T O R H O M E C H A S S IS U N IT S ) The follow ing procedures should be applied before performance testing an A/C System, 5.
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ELECTRICAL SYSTEM DI AGNOSTI C CHART BLOWER MOTOR INOPERATIVE BLOWER MOTOR INOPERATIVE (CERTAIN SPEEDS-EXCEPT HIGH (AN Y SPEED) ON P-K FD IIR -'iFA 'inN l f u s e b l o w n Disconnect resistor connectors, connect one lead of a self powered test light to any one terminal The following tests should be made With ign.
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IB -18 AIR CONDITIONING _________ i _ __________ P o sitio n th e c o n tro ls so th a t the: T e m p e ra tu re lever is o n fu ll heat. S ele ctor o r heater lever is on H eater. Fan s w itch is o n H i.
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AIR CONDITIONING IB-19 S H E E T M E T A L « > N O TE : FUSED FEED ~ 1 2 U J SELECTOR SWITCH FROM IGN 3 ' ’ l USE WITH 12010191 RETAINER AIR CONDITIONING RP0C-60 Fig.
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IB -20 AIR CONDITIONING REAR BLOWER RESI$TgS. C J l 1 ST 7341 ■ 2 LT BUV&LK-872 — 2 LT BLU*LK-872 -2LT BLlVBLK- Itri Irr-i - 2 Y E L ^ L K -B S I- — 2 YE -85I- -2 Y E L /B L K —...
IB -26 AIR CONDITIONING O N VEHICLE SERVICE EVA C U A TIN G A N D CH ARG ING PROCEDURES opening the refrigeration system. If liquid refrigerant comes into contact with the skin or eyes injury can result. O W S m i n •...
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AIR CONDITIONING IB-27 C L O S E A L L C O N T R O L S J 23500-01 S E R V I C E C H A R G I N G S T A T I O N R E F R I G E R A N T - 1 2 3 F U L L Y O P E N G A U G E S E T V A C U U M V A L V E...
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IB-28 AIR CONDITIONING If a new Accumulator must be added to A-6 system, add 2 additional ounces (60 ml) of oil to compensate for that held/absorbed by the original accumulator dessicant. R-4 Compressor Systems A. With no signs of excessive oil leakage, add: •...
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AIR CONDITIONING IB-29 J5725-04 M A N I F O L D G A U G E SET TH(S H1GH P R E S S U R E V A L V E IS OPEN A N D V A C U U M PUMP LINE U SING J-5420 D IS C O N N E C T E D O N L Y D U R IN G OPEN D U R IN G...
IB -30 AIR CONDITIONING C A U TIO N : N ever rem ove a g a g e line from its can(s) following instructions included with the tapping a d a p te r w h e n line is connected to A /C system. valve or tapping manifold adapter.
AIR CONDITIONING IB-31 first three conditions require valve replacem ent. The last two E X P A N S IO N TUBE (ORIFICE) may be corrected by replacing the valve inlet screen and by Rem oval a n d Installation properly installing the power element bulb.
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IB-32 AIR CONDITIONING service the entire system because of excessive contam ination in the oil removed, install a full charge of fresh refrigeration oil into the compressor. 2. Position com pressor on the m ounting b rack et and install all nuts, bolts and lock washers. 3.
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AIR CONDITIONING IB-33 Fig. 1 B-26--Compressor Mounting...
IB-34 AIR CONDITIONING AC C U M U LA TO R - ALL R eplacem ent 1. D isconnect b atte ry ground cable compressor clutch connector. 2. Discharge system. 3. Disconnect the accum ulator inlet and outlet lines and cap or plug the open connections at once.
AIR CONDITIONING IB-35 4. Remove the cover to dash and cover to case screws and 12. Refill coolant system and connect the battery ground remove the evaporator case cover. strap. Check tem perature door cable adjustm ent. 5. Disconnect the evaporator core inlet and outlet lines KICK PAD V A LV E - C-K SERIES and cap or plug all open connectins at once.
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IB -36 AIR CONDITIONING S K I R T G E N B R K T I N L E T H OSE A / C H O SE B A T T C A B L E 1 0 2 0 4 0 Fig.
AIR CONDITIONING IB-37 Fig. 1 B-30-Air Selector and Ducts (C-K Series) R eplacem ent Replacem ent 1. Disconnect the vacuum lines at the tank. 1. Disconnect the battery ground cable. 2. Remove the tank to dash panel screws and remove the 2.
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IB-38 AIR CONDITIONING KICK PAD VALVE Fig. 1 B-31 —Air Inlet Valves (C-K Models) G R A Y -TO /P L E N U M VALVE V IE W Fig. 1 B-34-Vacuum Line Routing - C-K Models...
AIR CONDITIONING IB-39 attaching screws. FUSE 4. C onnect the resistor wiring harness. A 25 am p fuse, located in the junction block protects the entire air conditioning system except for the blower BLOWER M O TO R RELAY - ALL circuit, the fuse for the blower circuit is located in the electrical wiring between the junction block and the blower The blower motor relay is located on the blower side of...
IB-40 AIR CONDITIONING Fig. 1 B-37-Overhead System Front Wiring (C-K Models) 5. Remove the lower to upper blower-evaporator case screws and lower the lower case and motor assembly. NOTICE: Before removing the case screws, support the lower case to prevent dam age to the case or motor assemblies.
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AIR CONDITIONING IB-41 EVAPO RATO R CORE (Fig. IB -4 0 ) E V A P O R A T O R B L O W E R -E V A P O R A T O R Removal SCREEN UPPER CASE 1.
IB-42 AIR CONDITIONING Fig. 1 B-42-Condenser-G Series 4. D isconnect condenser inlet and outlet lines at 10. Evacuate, charge and check the system. condenser. BLOWER M O TO R SW ITCH 5. Remove screws attaching left side condenser bracket to radiator.
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AIR CONDITIONING IB-43 Fig. 1 B-43--Heater Distributor Duct-G Series screws and radio support bracket attaching screw. HEATER CORE - G SERIES 5. Raise and support right side of instrum ent panel. R eplacem ent 1. Disconnect battery ground cable. 6. Remove right lower instrum ent panel support bracket. 2.
IB-44 AIR CONDITIONING 9. Remove three (3) nuts and one (1) screw attaching module to dash panel. 10. Remove core case assembly from vehicle. 11. Remove screws and separate case sections. 12. Remove evaporator core. 13. To install new core, reverse Steps 3 thru 14 above. 14.
AIR CONDITIONING IB-45 Fig. lB -4 7 -A ir Deflector Outlets (G Series-C60 System) 5. To install, reverse Steps 1 thru 4 above. RESISTORS R eplacem ent (Fig. IB -4 9 ) 1. Disconnect electrical harness at the resistor. 2. Remove the resistor m ounting screws and remove the resistor.
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IB-46 AIR CONDITIONING Fig. 1 B-53--Condenser Installation-G Series CENTER A /C OUTLET - G SERIES Replacem ent 1. Disconnect negative battery cable. 2. Remove engine cover ( Refer to Section 6A). 3. Remove steering column to I.P. attaching screw. 4. Remove radio support bracket screw. 5.
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AIR CONDITIONING IB-47 C O M PRESSOR COM PRESSOR ASSEMBLY R IN G H O S E & TUBE ASSEMBLY C O N D . OUTLET HOSE & TUBE ASSEMBLY A C C U M DEHYDR ASSEMBLY OUTLET PIPE G M O D . V 8 E N G . C 60 /69 E X T SIDE...
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AIR CONDITIONING IB-49 A /C DUCTW ORK DEFROSTER DUCT A ir Conditioning duct attachm ent is shown in Fig. 1 B- Defroster duct m ounting is shown in Fig. 1 B-64. TEMPERATURE DOOR CABLE T em perature cable attachm ent and routing is shown in Fig.
IB-50 AIR CONDITIONING CIRCUIT BREAKER The entire air conditioning system is protected by a 45 am p circuit breaker located on the left side of the dash, in V A C U U M TA N K - G SERIES (Fig. 1 B-60 & IB -6 1 ) R eplacem ent the engine com partm ent.
AIR CONDITIONING IB-51 Fig. 1 B-68—Sight Glass Replacement receiver-dehydrator and cap or plug the open lines at lines. once. 6. Evacuate, charge and check the system. 4. Rem ove th e re ceiv er-d eh y d rato r b rack et atta c h in g screw s rem ove b ra c k e t...
IB-52 AIR CONDITIONING Fig. 1B-71--Blower Assembly (Motor Home Chassis Unit) panel. Remove wire from grom m et through slit. E X P A N S IO N VA LV E , EVAPO RATO R A N D /O R 7. Disconnect electrical lead at connector. EVAPORATOR CASE 8.
AIR CONDITIONING IB-53 3. Install replacem ent switch, reinstall cover plate and reverse steps th e "B lo w er-E v apo rato r A ssem bly" removal precedure. W hen installing therm ostatic switch, be sure to position AIR SENSING CAPILLARY— 7 -^-THERMOSTATIC SWITCH sensing capillary as when unit was removed.
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1B-54 AIR CONDITIONING SPECIAL TOOLS r«i □ n 9 /1 6 " T H IN W A LL S O C K ET | j 2 ] J 9553-01 O R IN G R E M O V E R H U B A N D D R IV E P LA TE A S S E M B L Y p i ? ] J 9398 R O T O R B E A R IN G R E M O V E R...
AIR CONDITIONING IB-55 SPECIAL TOOLS r y~— ; - “i r y-r— f ' T I— t_..J i— 1 ' r> « § o D | D j j i 22 . J -9 3 9 8 P ulley B e a rin g Remover Pocket Therm om eters (2) 1.
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AIR C O N D ITIO N IN G COMPRESSOR O VERHAUL 1C1-1 SECTION 1C1 R-4 AIR CONDITIONING COMPRESSOR OVERHAUL For Compressor REMOVAL AND INSTALLATION, see FOR C.C.O.T. A/C SYSTEMS, see Air Conditioning Air Conditioning Section. For DISCHARGING, ADDING Section. OIL, EVACUATING AND CHARGING PROCEDURES CONTENTS Minor R-4 Compressor Repair Procedures........................1C 1-1...
1C1-2 AIR C O N D ITIO N IN G COMPRESSOR O VERHAUL 3. Align the shaft key with the shaft key way and place the R - 4 C O M P R E S S O R Clutch Plate and Hub assembly onto the compressor shaft. (1 0 .0 C U .
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AIR C O N D ITIO N IN G COMPRESSOR O VERHAUL 1C1-3 R E T A I N E R R I N G i 2 | S E A L S E A T [~3~l S H A F T S E A L [ T ] O - R I N G , S E A L S E A T [ T ] S H A F T S E A L K I T S C R E W A N D W A S H E R...
1C1-4 AIR C O N D ITIO N IN G COM PRESSO R OVERHAUL [ T 3 ] S H A F T S E A L H ~ l C O M P R E S S O R S H E L L Q 4 ] S E A L S E A T [ 2 | T H R U S T A N D...
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AIR C O N D ITIO N IN G COM PRESSOR OVERHAUL 1C1-5 [ T ] C L U T C H m S U C T I O N P L A T E ____ P O R T A N D H U B | 2 | O - R I N G A S S E M B L Y...
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1C1-6 AIR C O N D ITIO N IN G COM PRESSOR O VERHAUL [ 1 ~ ~ | J 25031 1 R O T O R A N D B E A R I N G P U L L E R G U I D E P U L L E Y A R M P U L L E Y R I M...
AIR C O N D ITIO N IN G COMPRESSOR O VERHAUL 1C1-7 J-25031-2 G U I D E J-25031-2 R O T O R & B E A R I N G P U L L E R p o l y G R O O V E P U L L E Y R O T O R...
1C1-8 AIR C O N D IT IO N IN G COMPRESSOR OVERHAUL Replace - V Groove Drive 2. Remove the pulley rim mounting screws and special lock washers. Discard the lock washers and screws. 1. Assemble the Clutch Coil, Pulley Rim and the Clutch Rotor 3.
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AIR C O N D ITIO N IN G COMPRESSOR OVERHAUL 1C1-9 1) No Inertia Ring installed; no installation is required unless ~1~| C L E A R A N C E N O T C H directed by a diagnostic procedure. If a ring is to be added, use Procedure I.
1C 1-10 AIR C O N D ITIO N IN G COMPRESSOR O VERHAUL COMPLETELY PURGED OF REFRIGERANT before proceeding 6. Inspect the drive surfaces of the Rotor and Drive Plate to be and/or because major internal operating and sealing sure they are still in good condition.
AIR C O N D ITIO N IN G COM PRESSOR O VERHAUL 1C1-11 C E R A M I C S E A L S E A T | J 2 3 1 2 8 2 0 4 2 9 9 Fig.
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1C 1-12 AIR C O N D IT IO N IN G COMPRESSOR O VERHAUL | 3 I J 9553 S E A L |~5~l J 21508 S P E C IF IC A T IO N P A R T S r~2~| J 9392 [~4 | "...
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AIR C O N D ITIO N IN G COMPRESSOR O VERHAUL 1C 1-13 housing. Be sure retaining ring is properly seated in the J22974 switch cavity retainer ring groove. S H A F T S E A L P R O T E C T O R f T ] S H A F T S E A L R E D I N S U L A T O R r r i J9392...
1C 1-14 AIR C O N D ITIO N IN G COMPRESSOR OVERHAUL t h r u s t O I L H O L E W A S H E R T O S H A F T A R E A [~2~| B E L L E V I L L E W A S H E R |~2~| F R O N T...
AIR C O N D ITIO N IN G COMPRESSOR O VERHAUL 1C 1-15 compressor to cool to room temperature before removing compressor shell. J 2 50 08 -1 H O L D I N G F I X T U R E H H S H E L L T O C Y L I N D E R O - R I N G...
1C 1-16 AIR C O N D ITIO N IN G COMPRESSOR OVERHAUL J 2 5 0 0 8 2 [ T I 2 5 0 0 8 1 [ T I L T . V A L V E P L A T E C O M P R E S S O R ------- H O L D I N G 'T I G H T E N...
Page 115
AIR C O N D ITIO N IN G COM PRESSOR OVERHAUL 1C 1-17 “Evacuate and Charge the Refrigerant System” according to 11. Using a box-end wrench or socket and handle, rotate the the directions in Section 1B1. compressor crankshaft or clutch drive plate on the crankshaft several turns to ensure piston assembly to cylinder wall lubrication.
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1C 1-18 AIR C O N D IT IO N IN G COM PRESSOR O VERHAUL [III n ° i r« i 9 /1 6 ” T H I N W A L L S O C K E T J 9553-01 O - R I N G R E M O V E R |T31...
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AIR CONDITIONING COMPRESSOR OVERHAUL ID-1 SE C T IO N 1 D AIR CONDITIONING C O M P R E SS O R OVERHAUL F o r C om pressor R EM O V A L A N D IN ST A L L A T IO N , see A ir C onditioning Section. F or D IS C H A R G IN G , A D D IN G O IL, E V A C U A T IN G A N D C H A R G IN G P R O C E D U R E S FO R C.C.O.T.
ID -2 AIR CONDITIONING COMPRESSOR OVERHAUL and dried off w ith dry air. W hen necessary to use a cloth added to the com pressor (See Fig. ID-1, and “ C.C.O.T. Refrigerant Oil D istribution” in the A ir Conditioning on any part, it should be o f a non-lint producing type.
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O-RING FRO N T HEAD S H A F T S E A L A S S E M B L Y S E A L S E A T S E A L S E A T R E T A I N E R R I N G A B S O R B E N T S L E E V E O - R I N G S J f j...
Page 120
1D-4 AIR CONDITIONING COMPRESSOR OVERHAUL CLUTCH ASSEMBLY SCORING OF DRIVE AND DRIVEN PLATES IS NORMAL. DO NOT FOR THIS CONDITION. REPLA C E THINWALL SOCKET HOLDING J-9399 FIXTURE J-9396 CLUTCH HUB HOLDING TOOL DRIVEN PLATE J-25030 OR J-9403 204970 Fig. 1D-3 Removing A-6 Shaft Lock Nut CLUTCH PLATE &...
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AIR CONDITIONING COMPRESSOR OVERHAUL 1 D-5 SNAP RING PLIERS J-6435 #26) RETAINER PULLEY RING ASSEMBLY 204962 Fig. 1D-9 Removing A-6 Pulley Retainer Ring Fig. 1D-7 Installing A-6 Drive Plate NOTICE: It is im portant that Puller Pilot J 9395 be used to prevent internal dam age to com pressor when removing pulley.
ID -6 AIR CONDITIONING COMPRESSOR OVERHAUL Remove pulley bearing retainer ring w ith a small 2. C heck bearing for brinelling, excessive looseness, screwdriver or pointed tool (Fig. I D - 12). noise, and lubricant leakage. If any o f these conditions exist, bearing should be replaced.
AIR CONDITIONING COMPRESSOR OVERHAUL ID -7 CLUTCH COIL AND HOUSING ASSEMBLY SNAP RING PLIERS J -6435 (#26) UNIVERSAL HANDLE J-8092 THIS RIDGE OF TOOL MUST BE ■ ■ P i *'• I P S — “ UP WHEN INSTALLING 5065 BEARING Fig.
ID -8 AIR CONDITIONING COMPRESSOR OVERHAUL M A J O R A-6 C O M P R E S S O R REPA IR P R O C E D U R E S Service repair procedures to the Compressor Shaft SH O U L D A N A-6 CO M PR ESSO R S H A F T SEA L Seal, Pressure Relief Valve, or disassembly of the E V ER H A V E TO BE R E P L A C E D BECA U SE IT WAS...
Page 125
AIR CONDITIONING COMPRESSOR OVERHAUL 1 D-9 SNAP RING PLIERS O-RING (#21) J-5403 INSTALLER J 21508 SEAL SEAT RETAINER RING FRONT HEAD SEAL INSTALLER SEAL J 9392 PROTECTOR J 22974 5064 Fig. 1D-18 Removing or Installing A-6 Shaft Seal Seat Retaining Ring S E A L S E A T O -R IN G R E M O V E R...
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ID -1 0 AIR CONDITIONING COMPRESSOR OVERHAUL LEAK TEST A DAPTER J-9625 ' / 3 2 (APPROX.) STRAIGHT EDGE "" GAUGE w ir e .0 2 6 SHOULD "GO" .0 7 5 SHOULD"NOT GO* OR SHOULD '^JUST GO" SLEEVE SLEEVE RETAINER SEAT O IL D R A IN FITTIN G RETAINER RING...
AIR CONDITIONING COMPRESSOR OVERHAUL 1D-11 oil drain plug down. R ecord the am ount of oil drained from A - 6 C O M P R E S S O R P R E S S U R E R E L I E F com pressor (See “...
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1D-12 AIR CONDITIONING COMPRESSOR OVERHAUL 7. M ake an identifying m ark on exposed face of inner OIL PICK-UP TUBE and outer Oil Pum p G ears and then rem ove gears. REMOVER J-5139 Identifying m arks are to assure th at gears, if re-used, will OIL PICK-UP TUBE be installed in identical position.
AIR CONDITIONING COMPRESSOR OVERHAUL 1D-13 Exam ine Internal Cylinder and Shaft Assembly for any obvious damage. If Internal Assembly has sustained m ajor damage, due to loss of refrigerant or oil, it may be necessary to use the Service Internal Cylinder and Shaft Assem bly rather than replace individual parts.
1D-14 AIR CONDITIONING COMPRESSOR OVERHAUL with bearing identification m arks up. Use Needle Bearing Installer J 9432 and drive bearing into cylinder head (Fig. ID-35 until Installer “bottom s” on the cylinder face. Two different width needle bearings are used in Production com pressors - a 13mm (1 /2 ") size and a 16mm (5 /8 ") size.
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AIR CONDITIONING COMPRESSOR OVERHAUL 1D-15 8. R otate shaft and axial plate until high point of axial 5. Now install a zero th ru st race on rear end of com pressor axial shaft (Fig. ID-36), so th at it rests on hub plate is over the No.
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ID -1 6 AIR CONDITIONING COMPRESSOR OVERHAUL 204963 Fig. 1D-39 Assembling A-6 Cylinder Halves Fig. 1D-40 Gaging A-6 Rear Piston Ball of 14 steel thrust races, including a basic Z E R O race, are 17. R o tate shaft a n o th e r 12(P and again re p ea t Step provided in increm ents o f ,01mm (.0005") thickness to 15 betw een th ese sam e p a rts and re c o rd m easu rem en ts.
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AIR CONDITIONING COMPRESSOR OVERHAUL 1D-17 SHOE DISC THRUST BEARING RACE PART NO. IDENTIFICATION M IN.FEELER PART NO. IDENTIFICATION DIA L INDICATOR ENDING IN STAMP GAGE READING ENDING IN STAMP READING .0000 .0000 17-1/2 .0175 .0050 .0180 5-1/2 .0055 18-1/2 .0185 .0060 .0190 6-1/2...
1D-18 AIR CONDITIONING COMPRESSOR OVERHAUL 4. Install a Teflon ring on the Ring Installer G uide J 24605-2 as shown in Fig. ID-47, w ith the dished or dull-side CHECKING FOR down and glossy-side up. REAR 5. Push the Ring Installer J 24608-5 dow n over the THRUST Installer G uide J 24608-2 to install the Teflon ring in the AND RACE...
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AIR CONDITIONING COMPRESSOR OVERHAUL 1D-19 > J -2 4 6 0 8 -5 J -2 4 6 0 8 -2 A R IN G IN S T A L L E R R IN G IN S T A L L E R J -2 4 6 0 8 -6 G U ID E R IN G S IZ IN G T O O L...
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ID -2 0 AIR CONDITIONING COMPRESSOR OVERHAUL "S E L E C T E D " PISTON AND R E A R T H R U S T R AC E "S E L E C T E D " RING ASSEMBLY R E A R SHOE D IS q T H R U S T B E A R IN G...
AIR CONDITIONING COMPRESSOR OVERHAUL ID-21 P IS T O N S IN " S T A IR S T E P " P O S IT IO N O-Ring R E A R T H R U S T — f—...
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ID -22 AIR CONDITIONING COMPRESSOR OVERHAUL SUCTION BUSHING REED LARGER DIA. HOLE REAR DISCHARGE FRONT DISCHARGE VALVE PLATE VALVE PLATE 2 0 4 9 5 3 Fig. 1D-57 Installing O-Ring On A-6 Discharge Cross-Over Tube Fig. 1D-60 Front and Rear A-6 Discharge Valve Plates DISCHARGE TUBE FRONT HEAD...
Page 139
AIR CONDITIONING COMPRESSOR OVERHAUL ID -2 3 COMPRESSOR SHELL OIL PUMP FRONT HEAD O-R IN G O-RING SUPPORT < BLOCK J-21352 IL INTAKE TUBE HOLE SUPPORT BLOCK J-21351 204957 204950 Fig. 1D-63 Installing A-6 Compressor Shell Fig. 1D-62 A-6 Front Head O-Ring Installed slides down, line up oil sum p with oil intake tube hole (Fig.
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1D-24 AIR CONDITIONING COMPRESSOR OVERHAUL If R ear H ead assembly will not slide down over dowels CAVITY BETWEEN GEAR TEETH in Internal Cylinder and Shaft Assembly, twist F ro n t Head (3 O'CLOCK) assembly back-and-forth very slightly by-hand until Rear H ead drops over dowel pins (Fig.
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1D-25 AIR CONDITIONING COMPRESSOR OVERHAUL A - 6 C O M P R E S S O R L E A K 12. Connect the Charging Station high pressure line or a high pressure gage and Gage A dapter J 5420 to the Test T E S T I N G ( E X T E R N A L A N D I N T E R N A L ) Plate J 9625 high side connector.
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1D-26 AIR CONDITIONING COMPRESSOR OVERHAUL L I P “ — U l c (j | j a £ C il J 2 3 500 Charqing S ta tio n No. 21 Snap R ing Pliers J 5403 J 9 4 32 Needle Bearing Installer J 2 4 0 9 5 O il In d u c e r...
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FRAME 2A-1 SECTION 2A FRAME CONTENTS G eneral D escrip tio n ...................2 A -1 On Vehicle S ervice....................2A-J M aintenance and Inspection................2A-1 U nderbody Inspection ..................2A-1 Fram e Inspection.....................2A-1 Fram e A lig n m en t....................2A-1 U nderbody A lignm ent..................2A-4 Excessive Body D am age................
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2 A -2 FRAME E rror will result if a tram bar is not level and centered V ertical Check at the reference points. V ertical dimensions are checked with a tram m ing bar 4. O btain vertical dimensions and com pare the differences from indicated points on the fram e (Figs.
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FRAME 2A-3 D IM E N S IO N S TO H O LES OR SLO TS A R E M E A S U R E D TO TH E C E N TE R OF H O LE OR SLO T G A U G E H O LES A R E 5 /8 "...
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2 A -4 FRAME Fig. 2 A -4--G Van Truck Reference Dimensions Bolting 2. The vertical dimension from the datum line to the points to be tram m ed. W herever rivets or failed bolts are replaced, bolt hole The tram bar should be on a parallel to th at of the body must be as near the O.D.
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BUMPERS 2B-1 SECTION 2B BUMPERS NOTICE: Fasteners are im portant attaching parts in replacem ent part of lesser quality or substitute design, th a t they could affect the perform ance of vital T orque values m ust be used as specified during com ponents and systems, an d /o r could result in m ajor reassem bly to assure proper retention of these parts, repair expense.
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2B-2 BUMPERS C -K R E A R B U M P E R Fig. 2B-3--Rear Bumper - K Models Fig. 2B-5--Front Bumper - G Models right bum per bracket. Installation 3. Remove bum per from vehicle. Install re ar step bum per by reversing rem oval 4.
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BUMPERS 2B-3 REAR BU M PER-G MODELS Rem oval Fig. 2B -7 1. Remove nuts securing bum per to left hand and right hand brackets and braces and remove the bum per. 2. Remove the license plate support nut and bolts. 3.
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CHASSIS SHEET METAL 2C-1 SECTION 2C CHASSIS SHEET METAL NOTICE Fasteners are im portant attaching parts in th at they could affect the perform ance of vital com ponents and systems, an d /o r cpuld result in m ajor repair expense. They m ust be replaced with one of the sam e part num ber or with an equivalent part if replacem ent becomes necessary.
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2C-2 CHASSIS SHEET METAL 5. Remove two bolts hinge to rear reinforcem ent at the body and remove hinge. 6. Replace by reversing the above procedure. Hood Lock M echanism The hood latch assembly and bracket are m ounted to the R adiator Support.
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CHASSIS SHEET METAL 2C-3 m ovem ent of the hood while the vehicle is in m otion. In teg ral w ith the strik er plate is the com bination lock release lever and safety catch. 1. S cribe a line around the en tire hinge p late to be repositioned.
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2C-4 CHASSIS SHEET METAL H O O D CABLE RELEASE - CK MODELS (FIG. 2C -8) R eplacem ent 1. Release the hood from below, using a suitable rod, by pressing on the hood release tab at the right side of the lock assembly.
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CHASSIS SHEET METAL 2C-5 A lig n m en t 1. Loosen hood hinge bolts. Note th a t the rear bolt holes in hinge is slotted to allow hood trailing edge to move up and down. 2. A djust hood bum pers so th a t hood and a d jac en t surfaces are flush.
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2C-6 CHASSIS SHEET METAL Fig. 2C-12--Lower Radiator Grille - G Models Fig. 2C-11--Typical Carburetor A ir Inlet Snorkel - CK Model FRONT SHEET METAL - CK MODEL Shim s which are found a t various locations should be recorded to ease installation of sheet m etal assembly. Rem oval 1.
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CHASSIS SHEET METAL 2C-7 11. Connect upper and lower radiator hoses. Connect oil cooler lines to the radiator on models so equipped. 12. Connect battery and fill radiator. S ta rt engine and check for leaks. 13. Install Hood. R adiator Support Rem oval 1.
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2C-8 CHASSIS SHEET METAL Installation To install, reverse the removal procedure using sealing tape between filler panel and fender. Check sheet metal alignm ent. FRONT FENDER A N D SKIRT (FIGS. 2 C -1 5 A N D 2 C -1 6 ) Rem oval 1.
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CHASSIS SHEET METAL 2C-9 Fig. 2 C -18 -F e n d e r Skirt, Dash and Toe Pan-P Series The surface m ust be free of any im perfections that b. If 3M Super W eath erstrip Adhesive (or equivalent) m ight high-light through the film.
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2C-10 CHASSIS SHEET METAL transfer area. Allow the adhesive to set for one minute then press transfer to fender for adhesion. 9. Inspect transfer installation from critical angle using adequate light reflection to detect any irregularities th at may have developed during installation. Remove all air or m oisture bubbles by piercing each at an acute angle with a fine pin or needle and by pressing the bubble down.
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CHASSIS SHEET METAL 2C -11 REMOVAL piercing them with an ordinary safety pin will relieve the en- trapped air so th a t the bubble can be sm oothed Removal of decal should cause it to be perm anently out. dam aged.
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BODY 2D-1 SECTION 2D CAB AND BODY N O TIC E Fasteners are im portant attaching parts in th a t they could affect the perform ance of vital com ponents and systems, an d /o r could result in m ajor repair expense. They m ust be replaced with one of the sam e part num ber or with an equivalent part if replacem ent becomes necessary.
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2D-2 BODY Fig. 2D-4--Typical Utility Vehicle Model...
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BODY 2D-3 Fig. 2D-5--Typical Vans and Sport Vans Models Fig. 2D-6--Typical Commercial Cutaway Model Van...
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2D-4 BODY O N VEHICLE SERVICE C-K M O D E L S I N D E X Front End H in g e s ................2D-15 W indshield W ip e r s ............2D-4 S tationary G lass ............2D-15 W indow and R egulator ..........
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BODY 2D-5 Fig. 2D -8--G love Box IN S TR U M E N T PANEL C O M P A R TM E N T A N D LOCK R eplacem ent Removal of the entire assem bly including door may be accom plished by removing four screws which attach hinge ju st below box.
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2D-6 BODY INSIDE REAR V IE W M IRRO R - FIGURE 2 D -1 1 R eplacem ent 1. Remove screw retaining m irror to its glass-m ounted bracket and remove m irror. 2. Install m irror into its m ounting bracket. Torque screw to specifications.
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BODY 2D-7 applying firm, controlled pressure to the edge of the glass. A t the same tim e assist the lip of the rubber w eatherstrip channel over the pinchweld flange with a flat bladed tool. See figures 2D-14 and 2D-15. 4.
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2D-8 BODY are shown in View A. Allow prim er to cure for at least 30 m inutes (30 day m axim um ). Thoroughly clean surface of glass to which blackout prim er will be applied (around edge of inside surface) by wiping with a clean, alcohol dam pened cloth.
Page 171
BODY 2D-9 OUTSIDE OF CLASS BLACKOUT PRIMER INSIDE SURFACE OF GLASS CLEANER- VIEW [vie w j A Fig. 2D-18--W indshield Installation-CK Truck S TA TIO N A R Y BO DY GLASS 15. U se J - 2 189 w e a th e rstrip tool install lockstrip in channel of w eatherstrip.
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2D-10 BODY BODY SIDE DOORS DOOR ADJUSTM ENTS Doors can be adjusted for alignm ent of clearance in the cab door opening, and for proper latching. Door alignm ent adjustm ents are m ade at the striker bolt, and at door hinges. The door, when properly located in door opening, will have .19 inch clearance at the top and side edges, and .25 inch clearance at the bottom .
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BODY 2D-11 b. W ith aid of an assistant to support weight of door, remove the door to lower hinge retaining bolts and remove door. Installation 1. Install hinge snugly on pillar in sam e location as hinge removed. 2. W ith the aid of an assistant fasten the door to the hinge. 3.
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2D-12 BODY Fig. 2D-25--Door Trim Panel Fig. 2D-28--Door Ventilator Assembly 1. R e g u la te th e d o o r w in d o w glass to th e fu ll d o w n position. 2. Remove clip from the window regulator handle, and R E T A IN IN G S P R IN G knob from lock rod.
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BODY 2D-13 seal. Trim off the excess filler m aterial around the channel and at the ends of the channel. Glass should be installed so th at rear edge is parallel to [TO A D J U S T T E N S IO N , the division post.
Page 176
2D-14 BODY location of junctions, switch, relay and circuit breaker. Replacem ent C A U TIO N : Electrical connectors must be rem oved from w in d o w lift motor before perform ing an y o p eratio n on th e re g u la to r, or personal in ju ry could occur.
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BODY 2D-15 Door O utside H a n d le —Fig. 2 D -3 7 R eplacem ent 1. Raise window to full up position. 2. Remove trim panel as outlined. 3. Remove clip from outside handle rod-to-lock. Remove screws which retain outside handle to door panel.
Page 178
2D-16 BODY install seal on welded flange. 5. Remove door lock lever from rubber m ount at top of motor actu ato r and remove m otor through access hole. 5. Trim inner w eatherstrip with a notch and butt ends together.
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BODY 2D-17 Fig. 2D-44--G lass Run Channel Fig. 2D -42--R ear Door Hinge Location adjustm ent. The screw and locknut at th at bracket allow 3. Remove screws retaining door trim pad, and remove fo re-an d -aft a d ju stm en t. T ogether, this allow s proper trim pad.
Page 180
2D-18 BODY LOCKS HANDLES A N D RODS Lock Assem bly—Fig. 2 D -4 7 R eplacem ent 1. Remove window regulator handle, remote control push button knob and trim pad as outlined previously. 2. Disengage three clips which retain control rods to lock assembly.
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BODY 2D-19 retightening bolts. See figure 2D-54 for hinge bolt location. Outside Handle—Fig. 2D-49 Rear door wedges and strikers should be adjusted as shown in figure 2D-55. R eplacem ent Be sure that adjustments are as shown to insure proper 1.
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2D-20 BODY Fig. 2D-51--Rear Door Controls Fig. 2D-52--Rear Door Outside Handle and Lock Cylinder...
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BODY 2D-21 UPPER WEDGE STRIKER ADJUSTMENT ADJUSTMENT .17 ± .03 ( U / 6 4 DRILL) IN SECONDARY LATCHED POSITION .04 MAX. CLEARANCE / N IN SECONDARY LATCHED POSITION OR .010 TO T 0 .0 5 0 INTERFERENCE IN FULL LATCHED POSITION, Fig.
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2D-22 BODY to endgate, figure 2D-60, and remove regulator. C A U T IO N : Step 10 m ust be p erfo rm ed if the w in d o w is rem o ved or d is e n g a g e d from the reg ulator lift arms.
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BODY 2D-23 Fig. 2D-60--Window Glass and Regulator(Suburban) Fig. 2D-63--Pulling Hinge Away From Body (Utility) 2. Disconnect torque rod anchor plate on each side. It is necessary to remove lower bolt only, then let plate swing down. See figure 2D-66. 3. W ith an assistant, raise endgate p art way, then disconnect support cables from endgate.
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2D-24 BODY 6. Remove torque rod retaining clip on side edge of endgate. 7. Lift torque rod up and slide from endgate as shown in figure 2D-67. 8. Reverse the procedure above for installation. ENDGATE DISASSEMBLY-UTILITY MODELS ONLY Manual Window 1.
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BODY 2D-25 Fig. 2D-68--Latches and Rods Fig. 2D-71--Removing Control Assembly and Inside Handle 15. Remove outside handle by removing nuts from inside of outer panel. See figure 2 D -6 1. 16. Reverse the above steps for reassembly. ELECTRIC WINDOW-UTILITY MODELS The window is controlled by a jackscrew mounted to the regulator, drive cable and a 12V DC reversible motor m ounted to the endgate inner panel.
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2D -26 BODY Jackscrew (Fig. 2D-76) Rem oval For endgates with electric window, secure the window regulator lift arms before removing the jackscrew when the window glass has been removed or disengaged from the lift arms. C A U T IO N : Step 1 m ust be p erfo rm ed if the w in d o w is rem o ved or d is e n g a g e d from th e regulator lift arm s.
Page 189
BODY 2D-27 4. Remove ten top-to-side panel mounting bolts (5 on each side). 5. Remove upper spare tire brace by removing brace bolt. The spare tire brace must be reinstalled after top is removed. 6. Remove only the rear attaching screws for the side trim panel (12 for LH panel and 11 for RH panel) so that the rear of panel can be pulled away to gain access for removal of hidden top bolt.
Page 190
2D-28 BODY Fig. 2D-78--Removable Top M a n d a to ry Assem bly Sequence (Fig. 2 D -78) 6. Loosen bolts # 6 on both sides. To prevent possible dam age to the top and to ensure 7. Install and tighten bolts # 5 on both sides. proper weatherstrip sealing, the following procedure must 8.
Page 191
BODY 2D-29 IN V E H IC L E Fig. 2D-79--Folding Top Assembly LAP BELTS AND SHOULDER BELTS (ALL MODELS) Before servicing or replacing lap and shoulder belts, The shoulder belts and lap belts are attached to the including single loop belt systems, refer to the following front seat lap belt latch plate and connected to an inertia precautionary items: locking retractor installed to the floor or quarter inner panel...
Page 192
2D-30 BODY SEAT SEPARATOR COMPARTMENT Figure 2D-90 illustrates assembly and installation of the CK model seat separator compartment. BODY M OUNTING The removal of anyone bodymount necessitates the loosening of adjacent body mountings to permit the frame to be separated from the body. Care should be exercised to prevent breakage of plastic fan shroud, or damage to frame smoothly, it maybe necessary to run a tap through the cage attachm ents such as steering column, brake pipes, etc.,...
Page 193
BODY 2D-31 B ELTS—3 R D SEA T Fig. 2D-82--Seat Belt Installation (Suburban) Driver Seat (Suburban)
Page 194
2D-32 BODY Fig. 2D-85--Passenger's Bucket Seat (Chassis Cab)
Page 195
BODY 2D-33 Fig. 2D-88--Rear Bench Seats (Suburban)
Page 196
2D-34 BODY Fig. 2D-89--CK Utility Seat Attachments...
Page 197
BODY 2D-35 Fig. 2D-90--Seat Separator Compartment and Door--CK Models...
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2D-36 BODY M O U N T 1 CK-10 V M O U N T 2 Fig. 2D-91--Body Mounting (Chassis Cab) Fig. 2D-92--Body Mounting (Crew Cab)
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BODY 2D-37 M O U N T 1 ^ M O U N T 1 V M O U N T 2 M O U N T 4 , 5 , 6 Fig. 2D-93--Body Mounting (Suburban) Fig. 2D-94--Body Mounting (Utility)
Page 200
2D-38 BODY G MODELS INDEX Front End A d j u s t m e n t s ..............2D-51 Windshield W i p e r s ............2D-38 Strikers ................2D-51 Cowl Ventilator Grille ..........2D-39 Front L a t c h ..............2D-53 Side Ventilator V a l v e ...........
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BODY 2D-39 Fig. 2D-97--Cowl Ventilator Grille Fig. 2D-96--Windshieid W iper Linkage 3. Reverse the above steps for installation. COW L VENTILATOR GRILLE REAR VIEW MIRRORS Replacement 1. Remove windshield wiper arms. Inside Rear V ie w Mirror 2. Remove screws retaining grille, figure 2D-97. Replacement 3.
Page 202
2D-40 BODY O P T IO N A L Fig. 2D-100--Outside Rear View Mirrors BODY GLASS C A U TIO N : A lw a ys w e a r gloves a n d eye glasses especially when the strain on the glass caused by this w h e n h a n d lin g glass to avoid personal injury.
Page 203
BODY 2D-41 adhesive. See the instructions at the beginning of "Installation". Adhesive Service Kit or C artridge Material listed have a short shelf life. Be sure materials are fresh. Urethane adhesive cartridge Essex SD C 551.2 or the equivalent are provided singularly. Adhesive Kit No. 9631000 (urethane adhesive) or equivalent contains some of the items needed to remove and replace a urethane adhesive installed glass.
Page 204
2D-42 BODY adhesive kit 9631000 or Essex S C D 435.20 or equivalent around the entire perimeter of the glass edge. Allow to dry to touch (approxim ately minutes). Refer to Fig. 2D-102. 5. With the aid of a helper, lift the glass into the opening. Carry the glass with one hand on the inside of glass, and one hand on the outside.
Page 205
BODY 2D-43 leak can be repaired with addition urethane adhesive. Use the adhesive m aterial furnished in Kit. No. 9631000 or Essex 551.2 or equivalent. NOTICE: W ater may be leaking through a pinchweld seam and not the urethane bead. In these instances, the entry point must be determined and correction made at that point in the pinchweld.
Page 206
2D-44 BODY 7. Using warm or hot water, leak test to assure that 8. Install the support molding immediately. the leak has been corrected. SW INGOUT WINDOW R eplacem ent 1. Swing out the window. See figure 2D-109. 2. Remove screws retaining latch to body. 3.
Page 207
BODY 2D-45 3. Adjust door as outlined under " Door A d ju stm e n t". 4. Torque bolts to specifications. 5. Install hinge access hole covers. DOOR WEATHERSTRIP Success of weatherstrip replacement depends entirely upon the quality of the cement used and the care with which it is applied.
Page 208
2D-46 BODY filler away from glass) evenly over the edge of the glass which will fit in the channel. The extra filler extending beyond the rear edge of the glass should be pinched together to hold it in place during glass installation. One side of this filler (the outside of the roll) is soapstoned.
Page 209
BODY 2D-47 WINDOW REGULATOR - POWER In the case th a t window will not operate, check electrical connections first. Figure 2D-118 illustrates location of junctions, switch, relay and circuit breaker. Replacem ent C A U TIO N : Electrical connectors must be rem oved from w in d o w lift motor before perform ing any o p eratio n on th e re g u la to r, or personal injury could occur.
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2D-48 BODY Fig. 2D-117--Power W indow and Power Door Lock Wiring 11. Remove screw locking sector gear in a fixed position. 12. Install regulator in reverse order of removal, lubricate regulator gears rollers with lubriplate equivalent. DOOR LOCK-FIGURE 2D-118 Rem oval 1.
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BODY 2D-49 2. Remove bolts securing remote control to door inner panel. 3. Pivot remote inboard slightly, to disengage connecting rod, and remove remote control from door. Connecting rod can be removed at this point by disconnecting spring clip from lock. 4.
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2D-50 BODY WINDOW SWITCH ASSEMBLY DOOR LOCK SWITCH V I E W REAR DOOR MOTOR ACTUATOR (DOOR LOCK) VIEW MOTOR (POWER WINDOW) SWITCH CONTACT (DOOR) SWITCH CONTACT (PILLAR) Fig. 2D-12 0 -Power Door Lock Actuators, Power W indow M otor, W iring and Switches...
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BODY 2D-51 SLIDING SIDE DOOR 5. A djust door hold open catch bracket, rear wedge DESCRIPTION assembly, rear latch striker, upper front roller and front The weight of the sliding side door is supported by the latch striker as outlined later in " Adjustments ". upper rear hinge-and-roller assembly, and by the lower front catch-and-roller assembly.
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2D-52 BODY STRIKER FORE-AND-AFT ADJUSTMENT SLOTS CENTER ROLLER VERTICALLY IN TRACK SO IT DOES NOT CONTACT THE TRACK ------- ^ IN FULL OPEN U P-AN D-DO W N OR FULL ADJUSTMENT SLOTS CLOSED POSITION UPPER REAR HINGE-AND-ROLLER SECTION B-B TOP V IE W UPPER LEVER, .LOWER LEVER U P-AN D -D O W N...
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BODY 2D-53 2. Adjust c atch-to-striker engagem ent by sliding the bracket laterally. Catch should fully engage striker. Rear Wedge Assembly Adjustment 1. Loosen screws attaching rear wedge assembly to the body pillar, then close the door to the fully latched position.
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2D-54 BODY 6. A djust door front striker as outlined earlier under 1. Connect rods to latch and install latch to door. Torque "A d ju stm en ts". screws to specifications. 2. Connect rods to front latch assembly. REAR LATCH A N D /O R LATCH ACTUATING RODS 3.
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BODY 2 D -5 5 Screw 8. Bolt 1. Roller Bushing Guide Block 9. Plate Lockwashers Hinge (Door Half) Hinge (Body Half) 10. Upper lines 3. Nut Spring 11. Spacer 4. Cam Spring retainer Bushing 12. Spring (Upper Lever) 19. 5.
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2D-56 BODY Fig. 2D-129--Checking Assembly of Hinge REAR DOORS REAR DOOR HINGE Rem oval 1. Open door. Support door so that when hinge screws are removed door weight will be on support. 2. Remove hinge strap release pin. 3. Remove hinge-to-door bolts and remove door assembly. 4.
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BODY 2D-57 Fig. 2D-132--Outside Handle and Lock Cylinder REAR DOOR LOCK CYLINDER REAR DOOR UPPER OR LOWER LATCHES AN D/ Rem oval OR LATCH RODS 1. Remove trim panel. 2. Remove remote control. Rem oval 3. Remove lock cylinder retainer and lock cylinder. 1.
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2D-58 BODY REAR DOOR STRIKER AND W EDGE ADJUSTMENT NO TIC E: See N O T I C E on page 1 of this section regaring Rear Door Striker fasteners. 1. Adjust striker by adding or deleting shims as necessary to obtain dimension as shown in figure 2D-133.
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BODY 2D-59 retainers, which fit onto anchor pins in floor anchor plates 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...
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BODY 2D-61 Fig. 2D-139-Front Seat Belt Installation...
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2D-62 BODY S H O U L D E R O F B O L T M U S T B O T T O M O N W E L D S H O U L D E R NUT.
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BODY 2D-63 F R O N T E N D T A I L G A T E - F L E E T S I D E Sunshade Support..........18 in. lb. 2. N 'm Trunnion A s se m b ly ........1 8 f t . lb . 24. N 'm O utside Rear View M irror to Door Panel Linkage and Striker A ssem b ly - B ase M ir r o r .........
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2D-64 BODY BODY MOUNTING (C-K MODELS) MODEL 55 ft. Ib. 55 ft. lb. CHASSIS CAB 75 N- m 75 N- m 55 ft. Ib. 55 ft. lb. 35 ft. lb. CREW CAB 75 N- m 48 N- m 75 N* m 35 ft.
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BODY 2D-65 SPECIAL TOOLS 1. J-22585 F ro n t Door Hinge, B o lt Wrench 2. J-22577 Windshield Checking Blocks 3. J-7797 D oor Handle Clip Remover 4. J-23457 D oor S triker B olt Remover and Installer...
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FRONT ALIGNMENT 3A-1 SECTION 3A FRONT ALIGNMENT CONTENTS General D escription....3A-I Maintenance and Adjustments 3A-2 Specifications....... 3A-5 GENERAL DESCRIPTION viewed from a side elevation. Caster is designed into the FRONT ALIGNMENT front axle assembly on all K series vehicles (four-wheel The term "fro n t alig n m e n t"...
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3A-2 FRONT ALIGNMENT OF WHEEL DIRECTION CAMBER ANGLE CASTER ANGLE FR O N T V IE W SIDE V IE W Fig. 3A-1--Caster - Camber - Toe-In M A IN TEN A N C E A N D ADJUSTMENTS 11. Consider the condition of the equipment being used to PRELIMINARY CH ECKS PRIOR TO ADJUSTING check alignm ent and follow the m a n u f a c tu r e r’s FRONT ALIGNMENT...
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FRONT ALIGNMENT 3A-3 Caster G overnm ental Periodic M otor Vehicle Inspection programs usually include wheel alignment among items that All caster specifications are given assuming a frame are inspected. To provide useful information for such angle of zero. Therefore, it will be necessary to know the inspections, the specifications stated in column 2 of the angle of the frame (whether "...
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3A-4 FRONT ALIGNMENT Toe-In 1. Delermine the wheel toe-in from the alignment equipment. "B" IS LESS THAN “ A" WHEN WHEELS TOE-IN 2. Change the length of both tie rod sleeves to affect a toe change. Toe-in can be increased or decreased by changing the length of the tie rods.
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FRONT ALIGNMENT 3A-5 SPECIFICATIONS W H E E L A L IG N M E N T S P E C IF IC A T IO N S C ASTER D IM E N S IO N " A " MODELS 2 % "...
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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 ".
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3B1-2 STEERING LINKAGE CORRECTION CONDITION POSSIBLE CAUSE Adjust bearings to obtain proper Excessive Play or Looseness in Front wheel bearings loosely end play. Steering System. adjusted. 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,...
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STEERING LINKAGE 3B1-3 CORRECTION CONDITION POSSIBLE CAUSE Low or uneven tire pressure. Inflate to specified pressures. Hard Steering - Excessive Effort Required at Steering Wheel. Steering linkage or bolt joints Lube with specified lubricant. need lubrication. Lube replace or reposition Tight or frozen intermediate rod, tie rod or idler socket.
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3B1-4 STEERING LINKAGE M A IN TEN A N C E A N D ADJUSTMENTS LUBRICATIO N LUBRICATIO N OF STEERING LINKAGE The steering linkage under normal conditions should be lubricated with any water resistant EP type chassis lubri cant every 7,500 miles (12 000 km) or six months, whichever occurs first.
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STEERING LINKAGE 3B1-5 RELAY ROD IDLER ARM TIE ROD ASSEMBLY - ASSEMBLY SI All clamps must be betw een & clear of dimples before torquing nut. KNUCKLE Exposed socket thread length must be |~B~| STEERING GEAR equal within ± .0 6 at each end of a d justing sleeve on L.H.
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3B1-6 STEERING LINKAGE ON-VEHICLE SERVICE N O TIC E: See N O T I C E on page 1 of this section regarding all fasteners referred to in servicing steering linkage components. TIE RODS Rem oval 1. Raise vehicle on hoist. 2.
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STEERING LINKAGE 3B1-7 N O T E Slot in adjuster Clamps must be between C A U T IO N sleeve must not be & clear of dimples before torquing nut. TIE ROD - OUTER RELAY ROD STEERING KNUCKLE N O T E Equal w ithin three threads, Locate clamps N O T E...
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3B1-8 STEERING LINKAGE c. The relationship of the clamp slot with the slit in the Installation sleeve should be maintained as shown in Figure 3B1- NOTICE: See the NOTICE on page 1 of this section regarding the fasteners referred to in steps 2 and 3. d.
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STEERING LINKAGE 3B1-9 tapping on side of rod or arm (in which the stud It is also necessary that a scale or ruler be rested mounts) with a hammer while using a heavy hammer or against the frame and used to determine the amount of similar tool as a backing.
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3B1-10 STEERING LINKAGE SPECIFICATIONS A N D SPECIAL TOOLS Refer to Specifications and Special Tools at end of Section 3B4. CAUTION: ENDS OF ADJUSTABLE TIE ROD MUST BE HELD IN CORRECT RELATIONSHIP TO EACH OTHER AFTER ADJUSTMENT WITHIN + 2° . CAUTION: CLAMPS MUST BE BETWEEN AND CLEAR OF...
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MANUAL STEERING GEAR 3B2-1 SECTION 3B2 MANUAL STEERING GEAR 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 ".
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3B2-2 MANUAL STEERING GEAR CONDITION CORRECTION POSSIBLE CAUSE 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.
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MANUAL 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. Steering wheel loose on shaft, Tighten to specification, replace loose pitman arm, tie rods, if worn or damaged.
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3B2-4 MANUAL STEERING GEAR M A IN TEN A N C E A N D ADJUSTMENTS 6. Turn the steering wheel gently in one direction until LUBRICATIO N OF M A N U A L STEERING GEAR stopped by the gear; then turn back one-half turn. The manual steering gear is factory-filled with steering gear lubricant.
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MANUAL STEERING GEAR 3B2-5 11. Install the horn button cap or shroud and connect the improper adjustment; the gear must be disassembled battery ground cable. and inspected for replacement of damaged parts. 12. Lower the vehicle to the floor. 9. Adjust "over-center preload" as follows: a.
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3B2-6 MANUAL STEERING GEAR 4. Remove the steering gear to frame bolts and remove 3. Install the pitman arm onto the pitman shaft, lining up the marks made at removal. Install the pitman shaft the gear assembly. nut or pitm an pinch bolt and torque to...
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MANUAL STEERING GEAR 3B2-7 10. Install the side cover bolts and torque to specifications. 6. Place the pitman shaft in the steering gear such that the center tooth of the pitman shaft sector enters the center 11. Install the lash adjuster screw locknut, perform steerin tooth space of the ball nut.
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MANUAL STEERING GEAR 3 B 2 -9 1. REMOVE AND INSTALL WORM SHAFT SEAL-GEAR ASSEMBLED REMOVE INSTALL W rap 0 1 m m to 0.2 mm In sta ll parts as show n ( 005" to 008” ) shim stock a ro u n d sha ft and insert J -2 1421-01 b etw een shaft and seal...
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3B2-10 MANUAL STEERING GEAR 3. REMOVE AND INSTALL WORMSHAFT 4. DISASSEMBLE AND ASSEMBLE WORM AND BALL NUT BEARING ADJUSTER REMOVE INSTALL DISASSEM BLE ASSEM BLE Loosen lock n ut Use p u n c h Install parts as show n Pry low er bearing re...
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MANUAL STEERING GEAR 3B2-11 6. ADJUST WORM BEARING PRELOAD 1. T ig h te n w o rm b earing a d ju ster u n til it b o tto m s then loosen o n e -q u a rte r tu rn 2.
POWER STEERING SYSTEM 3B3-1 SECTION 3B3 POWER STEERING SYSTEM 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 ".
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3B3-2 POWER STEERING SYSTEM P O W E R S T E E R IN G P U M P 1 DRIVE SHAFT 13. RING, Shaft Retainer 2 SEAL 14. VANE KIT, Rotor 3. SEAL, Reservoir “ O” Ring 15. RING KIT, Pump Rotor 4.
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POWER STEERING SYSTEM 3B3-3 CONDITION POSSIBLE CAUSE CORRECTION SY ST E M N O IS E 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.
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3B3-4 POWER STEERING SYSTEM CORRECTION CONDITION POSSIBLE CAUSE Scored pump pressure plates, thrust Replace affectcd parts, flush system. Pump growl Note: Most noticeable at full plate or rotor. wheel travel and stand still parking Extreme wear of pump cam ring. Replace affectcd parts.
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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.
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3B3-6 POWER STEERING SYSTEM CONDITION POSSIBLE CAUSE CORRECTION Hard Steering or Lack of lubricant in suspension Lubricate, relubricate at proper lack of assist (Continued) or ball joints. intervals. Tires not properly inflated. Inflate to recommended pressure. Steering gear to column misalignment. Align steering column.
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POWER STEERING SYSTEM 3B3-7 CONDITION POSSIBLE CAUSE CORRECTION Loose belt. Low oil pressure to steering Adjust tension to specification pump: Low oil level. Fill reservoir to proper level. (See pump pressure test.) Air in the oil. Locate source of leak and correct. Bleed system.
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3B3-8 POWER STEERING SYSTEM A. With the vehicle’s engine off, wipe the complete power POW ER STEERING SYSTEM EXTERNAL LEAKAGE steering system (gear, pump, hoses, G eneral Procedure connections). 1. Wipe suspected area dry. B. Check oil level in p u m p ’s reservoir and adjust as directed in maintenance section.
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POWER STEERING SYSTEM 3B3-9 G E A R A N D P U M P L E A K D I A G N O S IS START ENGINE AND TURN STEERING WHEEL FROM STOP TO STOP SEVERAL TIMES. 0 0 NOT HOLD AT STOP FOR ANY LENGTH OF TIME AS THIS CAN DAMAGE THE POWER STEER INGPUMP.
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3B3-10 POWER STEERING SYSTEM M A IN TEN A N C E A N D ADJUSTMENTS 2. With front wheels set straight ahead, check position of L U B R IC A T IO N O F P O W E R S T E E R IN G P U M P mark on worm shaft designating steering gear high point.
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POWER STEERING SYSTEM 3B3-11 maintained approximately 1/2 to 1 inch from top with H Y D R A U L IC S Y S T E M C H E C K S wheels in full left turn position. The following procedure outlines methods to identify 2.
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3B3-12 POWER STEERING SYSTEM c. If the pressures recorded are constant, but more than 6. Close gate valve fully 3 times. Record the highest 100 PSI, below the low listed spec., replace the flow pressures attained each time. control valve and recheck. If the pressures are still NOTICE: Do not leave valve fully closed for more than 5 low, replace the rotating group in the pump.
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POWER STEERING SYSTEM 3B3-13 P Models P O W E R S T E E R IN G P U M P ( 3 B 3 -1 5 T H R O U G H a. Place the steering gear in position, guiding the stub 3 B 3 - 2 6 ) shaft into the universal joint assembly and lining up Rem oval...
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3B3-14 POWER STEERING SYSTEM Fig. 3B3-17--P/S Pump Mounting; CK100, CK200, Fig. 3B3-20-P/S Pump mounting; CK100 (03) with CK300 - LE4, LG9, LS9, LT9 (Exc. C60, JB8) I F9 Enaine Fig. 3B3-21--P/S Pump Mounting; G100, G200, Fig. 3B3-18--P/S Pump Mounting; CK100, CK200, CK300 - LE4, LG9, LT9 and C60 G300 with LE3 Engine Fig.
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POWER STEERING SYSTEM 3B3-15 Fig. 3B3-23-P/S Pump Mounting; P200, P300 (42) Fig. 3B3-26--P/S Pump Mounting; P300 (32) with LE8 with L25 Engine Engine P O W E R S T E E R IN G H O S E S When servicing the power steering hoses be sure to align the hoses in their correct position as shown in Figs.
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3B3-16 POWER STEERING SYSTEM Fig. 3B3-27-P/S Hose Routing; CK100, CK200 (03) with LE3 Engine with LE8 Engine L25 Engine Fig. 3B3-29-P/S Hose Routing; CK100, CK 200, CK 300 - LE4, LG9, LS9, LT9 (Exc. C60, JB8) LT9 and JB8...
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POWER STEERING SYSTEM 3B3-17 with LE3 Engine LE4, LG9, LF4, LS9, LT9 and JB7 (Exc. HC4) and JB8...
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3B3-18 POWER STEERING SYSTEM Fig. 3B3-41--P/S Hose Routing; P300 (32) with LT9 L25 Engine and JB7 Engine Fig. 3B3-42--P/S Hose Routing;P300 (32) with LE8 LT9 Engine and JB7 Engine...
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POWER STEERING SYSTEM 3B3-19 4. REMOVE AND IN S TA LL R O T A TIN G GROUP. REMOVE AND IN STALL DRIVE SHAFT SEAL W ITHO UT DISASSEMBLING THE PUMP. REMOVE INSTALL REMOVE INSTALL 1. USING A RUBBER M A LLE T, 1.
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3B3-20 POWER STEERING SYSTEM POWER STEERING GEAR (605 MODEL) G E N E R A L D E S C R IP T IO N Whenever a part which forms a This Integral Power Steering Gear has a control valve which directs oil to either side sealing surface for an “...
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POWER STEERING SYSTEM 3B3-21 1. REMOVE AND INSTALL PITMAN SHAFT 3. REMOVE AND INSTALL PITMAN SHAFT SEALS IN CAR AND SIDE COVER INSTALL REM O VE R E M O V E IN STA LL 1. If pitman shaft and 1.
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3B3-22 POWER STEERING SYSTEM RACK PISTON AND 5. REMOVE AND INSTALL 7. REMOVE AND INSTALL VALVE VALVE ASSEMBLY ASSEMBLY FROM WORM ASSEMBLY REM OVE INSTALL REM O VE INSTALL Install parts as 1. R e m o v e p a rts as 1.
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POWER STEERING SYSTEM 3B3-23 9. REMOVE AND INSTALL STUB SHAFT 10. REMOVE AND INSTALL PITMAN SHAFT SEALS AND BEARINGS SEALS AND BEARING REM OVE INSTALL REMOVE INSTALL B o tto m oil se a l in C lea n end of C le a n en d of h o u s in g to If re m o v e d , in s ta ll ne w housing th o ro u g h ly...
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3B3-24 POWER STEERING SYSTEM 1 2 . A D J U S T W O R M B E A R IN G P R E L O A D A Tighten adjuster plug u n til it Measure 13mm (1 / 2") counter C T u rn adjuster back u n til m ark D T igh ten lo c k n u t.
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POWER STEERING SYSTEM 3B3-25 POWER STEERING GEAR (800 MODEL) G E N E R A L D E S C R IP T IO N These Integral Power Steering Gears Repair procedures for these two have a control valve which directs oil models are different.
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»*y P o rt Nome K ty No Pori Nome Key No. P ort Nome 3 7 -S C R E W ASSY., LOCKWASHER & (2) 1 -H O U S IN G , STEERING GEAR 1 9 - PLUG, ADJUSTER 2 -R A C E , THRUST BEARING (WORM) 2 0 - B E A R IN G .
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POWER STEERING SYSTEM 3B3-27 1. REMOVE AND INSTALL PITMAN SHAFT REMOVE AND INSTALL HOUSING END SEALS IN CAR PLUG REM OVE REM OVE INSTALL INSTALL 1. Clean exposed end 1. Install parts as shown. 1. Remove parts 1. Install parts as shown. of pitman shaft and as shown.
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3B3-28 POWER STEERING SYSTEM 7. REMOVE AND INSTALL BEARING, WORM, 5. REMOVE AND INSTALL ADJUSTER PLUG AND VALVE ASSEMBLY ASSEMBLY INSTALL REMOVE INSTALL REMOVE 1. G ra s p s tu b s h a ft an d In s ta ll p a rts as L o o s e n lo c k n u t.
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POWER STEERING SYSTEM 3B3-29 DISASSEMBLE AND ASSEMBLE RACK 10. REMOVE AND INSTALL PITMAN SHAFT PISTON SEALS AND BEARING REMOVE INSTALL DISASSEM BLE ASSEM BLE 1. C le a n e n d o f 1. C oat seal lip and w ashe r face 1.
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3B3-30 POWER STEERING SYSTEM 13. PITMAN SHAFT “OVER-CENTER’ 11. REMOVE AND INSTALL CHECK VALVE SECTOR ADJUSTMENT R E M O V E IN STALL 1. R e m o v e p a rts as s h o w n . 1.
POWER STEERING SYSTEM 3B3-31 G E N E R A L SP EC IF IC A T IO N S L U B R IC A T IO N L u b r i c a n t ........................Po w er Steering Fluid N o.
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3B3-32 POWER STEERING SYSTEM POW ER STEERING PUMP J-25033 J 23600 J-25034 J-22616 J-7132-2 B T-7515 POW ER STEERING GEAR J-6221 J-7576 J-8947 i in i d u T J-29810 J-21552 J-6222 J-6217 J-5188 G IP J-29107 J-6278 J-24319-01 J-22407 J-7624 Rack-Piston Teflon Ring Compressor J-5176-01...
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STEERING COLUMNS 3B4-1 S E C T IO N 3 B 4 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".
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3B4-2 STEERING COLUMNS F ig . 3 B 4 - 1 - S t e e r in g C o lu m n D IA G N O S IS GENERAL INFORM ATION STEERING COLUMN ELECTRICAL ANALYZER J-23980 This section contains diagnostic information to help locate the cause of the problem in the column.
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STEERING COLUMNS 3B4-3 T U R N ", "R IG H T T U R N ", "K E Y BU ZZER", COLUMN JACKET "H A Z A R D ". (Trucks do not incorporate a Key Buzzer Inspect jacket section of column for looseness, a n d /o r Switch) if the systems function properly while using the bends.
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3B4-4 STEERING COLUMNS SURFACE “ A’ In s tru m e n t Panel B ra c k e t C apsule Damage N O T E : The bolt head must not contact surface “ A ” . It contact is made, the capsule shear load will be increased.
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STEERING COLUMNS 3B4-5 L O C K S Y S T E M H I G H E F F O R T ( C O N T ' D . ) Cause S o lu tio n Replace rack. D i s t o r t e d c o u p li n g slot in r a c k (tilt).
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3B4-6 STEERING COLUMNS I G N I T I O N S Y S T E M - E L E C T R I C A L S Y S T E M - W I L L N O T F U N C T I O N ( C O N T ' D .
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STEERING COLUMNS 3B4-7 H I G H S T E E R I N G S H A F T E F F O R T Cause S o lu tio n A. Column assembly misaligned in vehicle. A. Realign. B.
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3B4-8 STEERING COLUMNS M A N U A L T R A N S M I S S I O N C O L U M N S GENERAL INFORMATION All ot 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 tor manual transmission columns.
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STEERING COLUMNS 3B4-9 T ILT C O L U M N S GENERAL INFORMATION All o f 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 S o lu tio n A.
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3B4-10 STEERING COLUMNS F ig . 3 B 4 - 1 0 - - C h e c k in g H a r m o n ic a C o n n e c to r o n C o lu m n lamps light when hazard warning is depressed, but flashing does not occur, replace hazard warning flasher.
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STEERING COLUMNS 3B 4-11 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. 3. If the hazard warning button cannot be depressed or released, the switch must be replaced.
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3B4-1 2 STEERING COLUMNS S IG N A L S W IT C H D IA G N O S IS CORRECTION CONDITION P O S S IB L E C A U S E T ig h te n to sp ec ified T u rn signal w ill n o t cancel Loose sw itch m o u n tin g screws...
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STEERING COLUMNS 3B4-13 S IG N A L SW ITC H D IA G N O S IS C O N D IT IO N POSSIBLE CAUSE C O R R E C T IO N Hazard switch will not Tighten mounting Loose switch stay on or difficult...
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3B4-14 STEERING COLUMNS S IG N A L SW ITC H D IA G N O S IS C O N D IT IO N POSSIBLE CA USE C O R R E C T IO N Front or rear turn signal Burned out fuse Replace fuse and lights not flashing...
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STEERING COLUMNS 3B4-15 S IG N A L SW IT C H D IA G N O S IS CONDITION CORRECTION POSSIBLE CAUSE Inoperative turn Replace turn signal Turn signal lights flash signal flasher very slowly flasher System charging I ncrease voltage to voltage low specified.
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3B4-16 STEERING COLUMNS MAINTENANCE AND ADJUSTMENTS S T E E R IN G W H E E L A L IG N M E N T S H IF T E R T U B E A D J U S T M 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...
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STEERING COLUMNS 3B4-17 F ig . 3 B 4 - 1 9 - S h i f t T u b e A d ju s tm e n t-3 S p e e d M a n u a l T ra n s m is s io n...
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3B4-18 STEERING COLUMNS ON-VEHICLE SERVICE IN D E X C-Series and K -Series............3B4-18 Steering W heel..............3B4-35 Flexible Coupling............3B4-35 Steering W heel..............3B4-18 Flexible Coupling............3B4-18 Intermediate Shaft............3B4-36 Intermediate Shaft............3B4-19 Column Upper Bearing..........3B4-38 Directional Signal Sw itch..........3B4-20 Column Lower Bearing..........3B4-38 Lock Cylinder..............
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STEERING COLUMNS 3B4-19 BEARING F ig . 3 B 4 - 2 3 --S te e r in g S h a ft In te r m e d ia te C o u p lin g 2. Remove the coupling clamp bolt. This is a special bolt and will require a 12 pt.
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3B4-20 STEERING COLUMNS Fig. 3 B 4 - 2 6 -R e m o v in g L o c k P la te R e ta in in g R ing Rem oval (Fig. 3B4-25) 1. Remove the steering wheel as outlined under "Steering Wheel - Removal".
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STEERING COLUMNS 3B4-21 Fig. 3 B 4 -2 8 --R e m o v in g D ire c tio n a l S ig n a l S w itc h A s s e m b ly Fig. 3 B 4 -3 0 --ln s ta llin g S n a p R ing In s ta lla tio n 6.
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3B4-22 STEERING COLUMNS LOCK CYLINDER INSTALLATION DISA SSEM B LE ASSEMBLE 1. Place lock in "run”. 1. Rotate as shown, align cylinder key with keyway in housing. 2. Remove lock plate, turn signal switch and buzzer switch (see Push lock all the way in. service manual.) Install screw.
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STEERING COLUMNS 3B4-23 C A U T IO N : Use only the specified screw s since over-length screw s could prevent a portion assem bly from com pressing under impact, w hich could result in personal injury. Reinstall the steering column assembly following the "Mandatory Installation Sequence"...
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3B4-24 STEERING COLUMNS 10. Remove the two column bracket-to-instrument R e m o v a l 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.
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STEERING COLUMNS 3B4-25 B O W L , Gearshift Lever 1. S T E E R IN G C O L U M N S H R O U D , S h ift Bow l 2. R E T A IN E R B E A R IN G , Bow l Lower 3.
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STEERING COLUMNS 3B4-27 6. Install the gearshift housing lower bearing. Insert the bearing from the very end o f 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 o f the stops provided.
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3B4-28 STEERING COLUMNS SHIFT GATE LOCK BOLT LOCK BOLT SPRING THRUST SECTOR F ig . 3 B 4 - 4 3 - T u r n S i g n a l H o u s i n g A s s e m b l y F ig .
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STEERING COLUMNS 3B4-29 i v i m d M A S T J A C K E T . T O REDUCE C L E A R A N C E TO REDUCE C L E AR AN C E 2 3 S H IF T LEVE R ”...
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3B4-30 STEERING COLUMNS SCREW, S upport SPRING, Upper Bearing 1. STEERING COLUMN PIN, Dowel PROTECTOR, Wiring 2. B EAR IN G ASM S H AFT ASM, Lower Steering 3. PIN, Release Lever COVER, Lock Housing (Painted) SPHERE, Centering 4. SPRING, Release Lever SH IELD , T ilt Lever Opening SPRING, J o in t Preload 5.
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STEERING COLUMNS 3B4-31 <3 < § > Jcl'® \s> 1. B EAR IN G ASM 26. R ETA IN ER 51. PIN, Dowel 2. PIN, Release Lever 27. RING, Retainer 52. S H AFT ASM, Lower Steering 28. SPRING, Upper Bearing 3.
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3B4-32 STEERING COLUMNS J -2 3 0 7 2 Fig. 3 B 4 - 5 0 - - R e m o v in g T ilt L ever S p r in g R e ta in e r Fig.
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STEERING COLUMNS 3B4-33 Fig. 3 B 4 - 5 4 - R e m o v i n g S e c t o r D rive S h a f t Fig. 3 B 4 - 5 6 ~ l n s t a l l i n g B e a r in g H o u s in g and bearing housing.
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3B4-34 STEERING COLUMNS 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.
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STEERING COLUMNS 3B4-35 M a n d a t o r y I n s t a l l a t i o n S e q u e n c e 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).
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3B4-36 STEERING COLUMNS BEARING Fig. 1-Steering Shaft Intermediate Coupling 3 B 4 - 6 In s ta lla tio n N O T ICE: See NOTICE on page 1 o f this section regarding the fasteners referred to in steps 2, 4 and 5. 1.
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STEERING COLUMNS 3B4-37 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. b.
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3B4-38 STEERING COLUMNS S TE E R IN G C O L U M N UPPER B E A R IN G -G A N D 2. Pry out the lower bearing assembly. P SERIES In s ta lla tio n S tan d ard C oium n N O TIC E : See NOTICE not on page 1 of this section...
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STEERING COLUMNS 3B4-39 If the bearing housing support is being replaced, proceed as follows: Remove the four bearing housing support screws and remove the support. A ssem bly N O T ICE: See NOTICE on page 1 of this section regarding the fasteners referred to in steps 3, 9 and 11.
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3B4-40 STEERING COLUMNS J-22727 Fig. 3B4-69--Removing Wires from Connector 10. Column Shift Models - Install the shift lever and 5. Pry the wiring harness protector out of the column pivot pin. retaining slots as shown in Figure 3B4-68. 6. Mark the location of each wire in the half-moon 11.
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STEERING COLUMNS 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.
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3B4-42 STEERING COLUMNS STEERING SYSTEM M A N D A T O R Y REQUIREMENTS Using a 50 lb. force applied to the steering wheel end of Shaft Lower Clamp Nut j l i j must be tightened to the specified torque to give a compressed spring dimension of .50 ±...
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STEERING COLUMNS 3B4-43 1. U p p e r S te e rin g Shaft 13. S h ift Tube F e lt W asher ?5. Turn S ignal S w itc h S crew 2 . S h ift Housing.'Bushing 14.
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3B4-44 STEERING COLUMNS a. Press the upper and lower bearings out of the Automatic Columns - Align the three holes in the selector plate with the three loles in the jacket, position the housing. clamping ring and install tfe three screws. The shift tube b.
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COVER SHAFT ASSY. W E D G E ------ RACE INSTRU. PANEL RACE SHAFT O P E N IN G C O V E R - , SCREW (3) S P R IN G JACKET S W ITC H A S S Y .-n A S S Y .- YO KE PIN D O W EL...
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3B4-46 STEERING COLUMNS Fig. 3B4-76~Securing Column with J-22573 2. Column Shift Models - Press a new shift lever spring 6. Pull up on the shift lever housing (to compress the into the shift lever housing. wave washer) and install the thrust washer and retaining ring.
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STEERING COLUMNS 3B4-47 1 /1 6 ” 4 5 ° C H A M FE R R E M O V E D O TTED P O R T IO N F ig . 3 B 4 -8 0 ~ R e m o v in g R e le a s e L e v e r P iv o t P in Fig .
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3B4-48 STEERING COLUMNS 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. Remove the plastic spacer from the alignment pins using a wire hook.
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STEERING COLUMNS 3B4-49 STEERING SYSTEM M A N D A T O R Y REQUIREMENTS U sing a 5 0 lb . fo rc e a p p lie d to the s te e rin g w h e e l en d o f S h a ft | a | , L o w e r C la m p N u t |...
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3B4-50 STEERING COLUMNS STEERING SYSTEM M A N D A T O R Y REQUIREMENTS Using 5 0 lb . fo rc e a p p lie d to the ste e rin g w h e e l e n d o f S h a ft | A | / L o w e r C la m p N u t |~B~| m ust b e tig h te n e d to the sp ecified to rq u e to g iv e a co m p res se d s p rin g d im e n s io n | C |...
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STEERING COLUMNS 3B4-51 SPECIFICATIONS STEERIN G GEAR RATIOS Manual Power Veh ic le Gear Overall Gear O verall R a tio R a tio R a tio R a tio 29.4:1 21.4:1 G 10-20 24:1 14:1 36.7:1 26.7:1 29.4:1 21.4:1 14:1 24:1 26.5:1...
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3B4-52 STEERING COLUMNS SPECIAL TOOLS •VMM 1. J-6632 J-6222 Shaft Seal Protector P itm a n A rm P u lle r 2. J-5504 J-23600 Belt Tension Gauge P itm a n A rm P u lle r 3. J-23073 21.
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STEERING COLUMNS 3B4-53 ■ 1. J-6632 Pitman A rm Puller J-6278 Pitman Shaft Bearing Remover J-5504 Pitman A rm Puller J-6278-2 Pitman Shaft Bearing Installer 3. J-5176 Pressure Gauge J-7079-2 Drive Handle J-5822 W orm shaft Bearing Cup Puller J-8524-1 A djuster Plug Bearing Installer J-5860 Torque Wrench A dapter...
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".
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3C-2 FRONT SUSPENSION GENERAL DESCRIPTION C-G-P Series The C-G-P Series trucks incorporate an independent coil spring front suspension system, as shown in Figures 3C- 1 and 3C-2. The control arms are of unequal length (S.L.A. Type). This suspension system consists of upper and lower control arms pivoting on steel threaded or rubber bushings on upper and lower control arm shafts.
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FRONT SUSPENSION 3C-3 Fig. 3C-2--Front Suspension - G-Typical MAINTENANCE AND ADJUSTMENTS NOTICE: 2. Spin wheel to check for unusual noise or roughness. See N O T IC E on page 1 of this section regarding the fasteners referred to in the maintenance 3.
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3C-4 FRONT SUSPENSION AD JU STM EN T OF W HEEL B E A R IN G S (FIG. 3C-3) 1. Remove hub cap or wheel disc from wheel. 2. Remove dust cap from hub. 3. Remove cotter pin from spindle and spindle nut. 4.
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FRONT SUSPENSION 3C-5 H A R D S T E E R IN G Probable Remedy Probable Cause Ball jo in ts an d steering linkage need lubric ation L ubricate ball j o in ts and linkage Inflate tires to the pro p e r r e c o m m e n d e d pressure Low or uneven fro nt tire pressure Check p o w e r steering c o m p o n e n t s for p ro p e r o p e r a tio n Pow er steering partially or n o t operative...
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3C-6 FRONT SUSPENSION N O IS E IN F R O N T E N D Probable Cause Probable Remedy Ball joints and steering linkage need lubric ation Lubricate at r e c o m m e n d e d intervals Shock a b so r b e r loose or bushings w o rn T ighten bolts a n d /o r replace bushings Worn c o n tr o l arm bushings...
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FRONT SUSPENSION 3C-7 N O I S E F R O N T E N D P ro b a b le Cause P ro b a b le R e m e d y Ball joints and steering linkage need lubric ation Lubricate at re c o m m e n d e d intervals Shock a b so rb er loose or bushings worn T ighten bolts a n d /o r replace bushings...
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3C-8 FRONT SUSPENSION B A L L JO IN T D IAG N O STIC PROCEDURE Fig. 3C-7--Ball Joint Diagnostic Procedure Manually Operating Shock. It should aid the technician to (a) Disconnect each shock lower mounting as required and localize defective shocks caused by internal noise in the pull down on the shock until it is fully extended.
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FRONT SUSPENSION 3C-9 Certain precautions should be observed when in specting shocks for leaks: • shocks may have glossy paint on them. Do not confuse this paint with a leak condition. • a slight trace of shock fluid around the seal cover area is not cause for replacement.
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3C-10 FRONT SUSPENSION AIR ADJUSTABLE SHOCKS TYPICAL FRONT SHOCK TYPICAL REAR SHOCK This type of shock contains an air chamber like the spiral groove reservoir type, and must have the air purged from the working chamber. See Section 1, Spiral Groove BOTTOM MOUNT Reservoir.
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FRONT SUSPENSION 3C -11 BEARIN GS AND RACES F R O N T W H E E L , P IN I O N , D IF F E R E N T IA L S ID E A N D R E A R W H E E L R O L L E R B E A R I N G S DIAGNOSIS E X C E S S N O IS E C O M P L A IN T...
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3C-12 FRONT SUSPENSION FRONT WHEEL BEARING DIAGNOSIS C O N S I D E R T H E F O L L O W I N G F A C T O R S W H E N D I A G N O S I N G B E A R I N G C O N D I T I O N . 1.
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FRONT SUSPENSION 3C-13 FRONT WHEEL BEARING DIAGNOSIS (CONT’D) BRINELLING CAGE WEAR ABRASIVE ROLLER WEAR S U R F A C E I N D E N T A T I O N S IN R A C E W A Y W E A R A R O U N D O U T S I D E D I A M E T E R O F P A T T E R N R A C E S...
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3C-14 FRONT SUSPENSION COMPONENT PARTS REPLACEMENT WHEEL HUBS, BEARING S (Fig. 3 C -1 4 ) cleaning solvent. Use a small brush with no loose bristles to clean out all old grease. Do not spin the R e m o val C, G a n d P Series bearing with compressed air while drying it or the 1.
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FRONT SUSPENSION 3C-15 COIL SPRING S H O C K A B SO R BER Removal (Fig. 3C-17) R e m o va l (Fig. 3 C -1 5 ) 1. R a i s e v e h i c l e o n hoi st . 1.
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3C-16 FRONT SUSPENSION When installing the upper control arm be sure to UPPER CONTROL A R M IN N ER P IV O T SHAFT properly position the special aligning washers to the pivot A N D /O R B U S H IN G REPLACEMENT shaft with convex and concave sides together.
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FRONT SUSPENSION 3C-17 J— 24435-7 J— 24435-1 Fig. 3C-22-U.C.A. Rubber Bushing Removal 3. Install " U " bolts. Do not torque nuts at this time. 4. Torque cross-shaft end nuts. The shaft should roate by hand after the nuts are torqued. 5.
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3C-18 FRONT SUSPENSION 1. P l a c e c o n t r o l a r m in p o s i t i o n o n b r a c k e t a n d i n s t al l 5.
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FRONT SUSPENSION 3C -1 9 2. R e m o v e p i v o t s h a f t n u t s . Lower Control Arm Inner Pivot Shaft and/or 3. P l a c e c o n t r o l a r m in a n a r b o r p r e s s , p r e s s f r o n t e n d o f Bushing Replacement-On Vehicle p i vo t s h a f t t o r e m o v e r e a r b u s h i n g , a n d p i v ot s h a f t C IO (Rubber Bushings)
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3 C -2 0 FRONT SUSPENSION 1. Install new service ball joint, using bolts and nuts supplied with joint, to upper arm. Torque nuts to 60 N-m (45 ft. lbs.). 2. Mate ball stud to steering knuckle and install stud nut. 3.
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FRONT SUSPENSION 3C -21 STEERING KNUCKLE 4. Install J-23742 between the ball studs as shown in It is recommended that vehicle be raised and supported Figure 3C-27. as on a twin-post hoist so that the front coil spring remains It may be necessary to remove the brake caliper compressed, yet the wheel and steering knuckle assembly assembly and wire it to the frame to gain clearance for remain accessible.
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3 C -2 2 FRONT SUSPENSION CROSSMEMBER AND SUSPENSION UNIT 9. Disconnect fron shock absorbers from lower control Com ponent parts of the front suspension may be arms. serviced separately as outlined in the preceding service operations. However, if extensive service is to be performed 10.
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FRONT SUSPENSION 3 C -2 3 Installation 8. Install brake line clip bolt to front suspension cross member. Torque to 17 N-m (150 in. lbs.) (C-models), 1. Raise hoist to align new suspension unit with frame rail 12 N-m (100 in. lbs.) (G-models). holes.
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3 C -2 4 FRONT SUSPENSION 40. D U S T S E A L 27. S P A C E R 14. S P R IN G R E T A IN E R 1. R E T A IN IN G S C R E W 41.
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FRONT SUSPENSION 3 C -2 5 R E T A IN IN G SCREW C O V E R P LA T E C O V E R O -R IN G S P R IN G , BRG . R AC E B E A R IN G A S S E M B L Y W IR E R E T A IN IN G R IN G 'C ' T Y P E R E T A IN IN G...
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3 C -2 6 FRONT SUSPENSION M A IN TEN A N C E A N D ADJUSTMENTS Fig. 3 C -3 K --D e te rm in in g F ro n t A x le B all J o in t T u rn in g E ffo rt spindle bearings are accessible after removing the spindle, BALL JOINT ADJUSTMENT (K10, K20) as shown in Figure 3C-6K.
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FRONT SUSPENSION 3 C -2 7 C O M PO N EN T REPLACEMENT • Incomplete shift from 2W D to 4W D, or disengagement HUB REPLACEMENT of only one hub lock may cause an abnormal sound NOTICE: See N O T I C E on page 1 of this section, from the front axle.
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3 C -2 8 FRONT SUSPENSION IA . Machine Screw 11. (K10-20) Seal Bridge-Retainer 21. Cam Follower IB . 0-Ring Seal (K30) Assembly Aid-Retainer 22. Outer Cage 2. Cover Plate 1 2. Retaining Ring 23. Inner Cage 3. Cover 13. Spring Support Washer 24.
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FRONT SUSPENSION 3 C -2 9 9. Place the components assembled in steps 1 through 7 into the outer housing ( # 1 0 ) . The cam follower should be positioned with the two legs directed outboard. C" SHAPED 10.
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3 C -3 0 FRONT SUSPENSION 31. Hold the two tangs of the retaining ring in the clamped condition as the assembled components are assembled to the hub of the wheel. See step 29 for installation of drag sleeve washer. 32.
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FRONT SUSPENSION 3C -31 A X L E SLING ER SEAL .100 IN. DEPTH TH R UST WASHER V-BLO CK SEAL Fig. 3C-7K--Front Spindle Grease Seals Servicing Spindle Components install needle roller bearing. W hen servicing the spindle check the spindle grease a.
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3 C -3 2 FRONT SUSPENSION J-23454-1 F ig. 3 C -1 1 K --R em oving L o w e r B all J o in t Fig. 3 C -9 K --R e m o v in g S te e rin g A rm N u ts self-locking nuts (Fig.
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FRONT SUSPENSION 3 C -3 3 J-6382-3 OR J-23454-3 BALL JOINT J-23454-2* Fig. 3 C -1 3 K —In s ta llin g L o w e r B all J o in t Fig. 3 C -1 6 K -T o rq u in g U p p e r B all S oc k e t N u t 4.
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3 C -3 4 FRONT SUSPENSION Fig. 3C-18K~Removing Nuts Alternately Fig. 3C-20K~Removing Lower Bearing Cap 4. Torque the upper ball socket nut to 100 ft. lbs. as shown between axle shaft joint assembly and bearing. If wear in Figure 3C-16K. A fter torquing the nut, do not loosen is evident, replace with a new one.
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FRONT SUSPENSION 3 C -3 5 Fig. 3C-22K-Removing Upper King Pin Fig. 3C-25K--lnstalling Oil Seal 7. Remove lower king pin bearing cup, cone, grease retainer, and seal all at the same time, as shown in Figure 3C-23K. Discard seal and replace with new one at time of assembly.
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3 C -3 6 FRONT SUSPENSION Fig. 3C-27K--lnstalling Knuckle to Yoke Fig. 3C-29K--lnstalling Bearing Cap/Steering Arm assembly. 4. Assemble felt seal to king pin, assemble knuckle, assemble tapered bushing over king pin, as shown in Installation Figure 3C-27K. Place shock absorber into position over mounting bolts 5.
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FRONT SUSPENSION 3 C -3 7 6. Remove spring-to-axle u-bolt nuts and remove spring, lower plate and spring pads. 7. Remove shackle to spring bolt and remove bushings and shackle. Bushing Replacement 1. Place spring on press and press out bushing using a suitable rod, pipe, or tool.
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3 C -3 8 FRONT SUSPENSION Installation TIGHTENING SEQUENCE In s ta ll all fo u r nu ts to u n ifo rm engagem ent NOTICE: See N O T IC E on page one of this section on 'U ' B olts to re ta in and p o s itio n a n ch o r regarding the fasteners referred to in steps 5 and 6.
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FRONT SUSPENSION 3 C -3 9 SPECIFICATIONS FRONT SUSPENSION BOLT TORQUE (ft. lbs.) * G-30 C -10 CP-20-30 K-AII G-10-20 L o w e r C o n tro l A rm S h a ft U -B o lt —...
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3 C -4 0 FRONT SUSPENSION SPECIAL TOOLS J-8457 Bearing Race Installer J-8092 Driver Handle J-8458 Bearing Race Installer Ball Joint Installer J-9519-9 J-8849 Bearing Race Installer J-9519-7 Ball Joint Remover J-9276-2 Bearing Race Installer J-9519-10 " C " Clamp J-24435-1 Bushing Replacement Spring Remover...
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REAR SUSPENSION 3D-1 SECTION 3D REAR 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 the appropriate locations by the terminology "See Notice on page 1 of this Section".
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3D -2 REAR SUSPENSION Fig. 3D-2--Typical G-Truck 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.
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REAR SUSPENSION 3D -3 Fig. 3D-8--Shock Absorber-P30 4. Remove brackets from anchor plates by removing attaching screws. STABILIZER SHAFTS 5. Remove stabilizer shafts. Refer to Fig. 3D-9, 3D-10 and 3 D -1 1 for specific rear 6. Reverse above steps to install stabilizer shaft. On stabilizer shaft mounting on C and P models.
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3D -4 REAR SUSPENSION P300(32) NOTE Torque by running nut to unthreaded portion of bolt. Fig. 3D-10--Rear Stabilizer Shaft-C-20(43), C-30 LEAF SPRING ASSEMBLY Refer to Figs. 3D-12 - 3D-21 for specific leaf spring mounting provisions of C, K, G and P models. Fig. 3D-22 illustrates a typical U-bolt anchor plate installation with the mandatory tightening sequence.
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REAR SUSPENSION 3D -5 G 1 0 0 + 2 0 0 (0 5 + 0 6 ) ALL G 300 ( 0 5 + 0 6 ) exc G50 C 3 00 (0 5 + 0 6 ) & G50 Fig.
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3 D -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.
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REAR SUSPENSION 3D -7 Fig. 3D-17--Rear Spring Installation-C-K Models...
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3 D -8 REAR SUSPENSION Fig. 3D-20--Rear Spring lnstallation-P10,20 Fig. 3D-21--Rear Spring lnstallation-P30...
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REAR SUSPENSION 3D -9 1 . In s ta ll a ll fo u r nuts to u n ifo rm e n g a g e m e n t on 'U ' Bolts to re ta in a n d p o s itio n a n c h o r p la te in d e s ig n p o sitio n ( p e rp e n d ic u la r to a xis o f 'U ' Bolts).
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3 D -1 0 REAR SUSPENSION SPECIFICATIONS TORQUE SPECIFICATION (F T -L B S ) P10 140 S pring-to-A xle " U " Bolt Nuts P20 140 P30 170 (Exc. W /3 /4 " Bolt) 200 (W /3/4" Bolt) Leaf Spring —...
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WHEELS A N D TIRES 3E-1 SECTION 3E WHEELS AND TIRES NOTICE: The Wheel bolt and nut fasteners are an important attaching part in that they could affect the performance of vital components and systems, an d/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.
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3E-2 WHEELS A N D TIRES INFLATION PRESSURE CONVERSION CHART METRIC TIRE SIZES (KILOPASCALS TO PSI) P 205 TIRE TYPE ....RIM DIAMETER ASPECT RATIO PAS S EN G E R (IN C H E S ) T - T E M P O R A R Y (S E C T IO N H E IG H T ) C - C O M M E R C IA L (S E C T IO N W ID T H )
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WHEELS A N D TIRES 3E-3 FRONT ^FRONT FRONT FRONT r l n p i n IXI I/I L|J L|J l| JjDjh) WHEEL 4 WHEEL » DTATION ROTATION R< • PREFERRED FOR • OPTIONAL FOR RADIAL TIRES RADIAL TIRES * •...
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3E-4 WHEELS A N D TIRES T IR E A N D W H E E L L O A D L IM IT C H A R T S (TIRE & WHEEL LO AD LIM IT S ARE SHOWN BELOW VEH IC LE LOADING MUST BE LIM IT E D SUCH T H A T NEITHER THE W HEEL OR TIR E IN F LA T IO N PRESSURE OR LOAD LIM ITS ARE EXCEEDEDI R A D IA L T IR E S IZE A N D L O A D L IM IT S - LBS (kg) Tire...
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WHEELS A N D TIRES 3E-5 TIR E A N D W HEEL LO A D L IM IT CHARTS ( T IR E & W H E E L L O A D L I M I T S A R E S H OW N B E L O W . V E H I C L E L O A D I N G M U S T BE L I M I T E D SUCH T H A T N E I T H E R T H E W H E E L OR T I R E I N F L A T I O N P R ES SURE OR L O A D L I M I T S A R E E X C E E D E D ) TIR E SIZE A N D LO A D LIM IT S - LBS (kg) Tire...
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3E -6 WHEELS A N D TIRES TIR E A N D W HEEL LO A D L IM IT CHARTS (T IR E & W H E E L L O A D L IM IT S A R E S H O W N B E L O W . V E H IC L E L O A D IN G M U S T BE L IM IT E D S U C H T H A T N E IT H E R T H E W H E E L O R T IR E IN F L A T IO N P R E S S U R E O R L O A D L IM IT S A R E E X C E E D E D ) R A D IA L TIR E SIZE A N D LO A D L IM IT S - LBS (kg) Load...
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WHEELS A N D TIRES 3E-7 of the tire causes a small feather edge of rubber to appear on outboard side of these wheels. Conventional weights fit only one side of the tread and this feather edge is certain the inboard side of these wheels. indication of misalignment.
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3E-8 WHEELS A N D TIRES 1. Before installing tube in tire, clean inside of casing thoroughly. 2. Insert tube in tire and inflate until it is nearly rounded out. 3. Inspect rim for rust scale and bent flanges-clean rust scale and straighten flanges where necessary.
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WHEELS A N D TIRES 3E-9 3. Inflation. Inflate tire to operating pressure. Due to the construction of radial truck tires, particularly in the lower sidewall and bead area, it may be difficult to get the tire to take air. An inflation aid may be necessary to help seat the bead of tubeless radial tires.
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3 E -1 0 WHEELS A N D TIRES mark the weights and remove. 9. Wipe over the painted surface with the alu m inu m cleaner, then apply the conversion coating, following 2. Using the general purpose pad and glaze cleaner, label directions.
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PROPELLER SHAFT 4 A -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".
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4 A -2 PROPELLER SHAFT Essentially, the constant velocity joint is two simple universal joints closely coupled by a coupling yoke, phased properly for constant velocity. A centering ball socket between the joints maintains the relative position of the two units. This centering device causes each of the two units to operate through one-half of the complete angle between the drive shaft and differential carrier.
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PROPELLER SHAFT 4 A -3 PROPELLER SHAFT A N D UNIVERSAL JOINT DIAGNOSIS 4. With vehicle running in gear at the indicated speed Checking and Correcting where disturbance is at its peak, observe the intensity of Propeller Shaft Unbalance the disturbance. 5.
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4 A -4 PROPELLER SHAFT COMPLAINT POSSIBLE CAUSE CORRECTION Roughness, Vibration or a. Bent or dented drive shaft. a. Replace. Body Boom at any speed. b. Undercoating on drive shaft. b. Clean drive shaft. c. Tire unbalance. (30-80 mph, not c.
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PROPELLER SHAFT 4 A -5 ON-VEHICLE SERVICE joint by removing trummion bearing " U " bolts or straps. T ape bearing cups to trunnion to prevent dropping and loss of bearing rollers. 2. For models with two-piece shafts remove bolts retaining bearing support to hanger.
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4 A -6 PROPELLER SHAFT SOCKET TO SUPPORT w- w..— Fig. 4A-9--Bearing Cup Removal with Press Fig. 4A -11--Pressing Out Bearing Cup 4. Press trunnion in opposite direction and remove other Injected Plastic Type cup as in Step 3. Disassembly 5.
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PROPELLER SHAFT 4 A -7 Reassembly A universal joint service kit is used when reassembling this joint. See figure 4A-13. This kit includes one pregreased cross assembly, four service bearing cup assemblies with seals, needle rollers, washers, grease and four bearing ROLLER BEARINGS retainers.
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4 A -8 PROPELLER SHAFT CENTER SUPPORT BEARING-FIG. 4A-17 NOTICE: See N O T I C E on page 1 of this section STRIKE TUBE YOKE EAR IN THIS AR EA regarding Center Support Bearing fasteners. 1. Remove strap retaining rubber cushion from bearing support.
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PROPELLER SHAFT 4 A -9 d. Install dust shield over shaft, small diameter. Install bearing retainer. e. Install rubber cushion onto bearing. A L IG N M E N T f. Install bracket onto cushion. g. Install retaining strap. Installation of Propshafts NOTICE: W hen reinstalling propshafts, it is necessary to place the shafts into particular positions to assure proper operation.
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4 A -1 0 PROPELLER SHAFT BALL W ASHER BALL SEAT SEAL TUBE BALL STUD C O U P L IN G YO KE YO KE FLA N G E YO KE Fig. 4A-20--Bearing Cap Removal Sequence Fig. 4A-22--Cross Sectional View of CV Joint apply a small amount (approximately 18 grams) of CONSTANT VELO CITY UNIVERSAL JOINT grease inside the slip yoke before installing propshaft.
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PROPELLER SHAFT 4 A -1 1 Fig. 4A-24--lnstalling Tool J-23996 Over Ball Fig. 4A-26-Removing Centering Ball figure 4A-27, until the ball can be seen to seat firmly 2. Clean and inspect seal and ball seats along with spring against the shoulder at the base of the stud. This is and washers.
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4 A -1 2 PROPELLER SHAFT Fig. 4A-28--lnstalling Centering Ball Seal Fig. 4A-29--Reassembling Flange Yoke LUBRICATION The front axle propshaft found on all four-wheel drive trucks requires special lubrication procedures at two locations: The C /V joint, and the slip yoke. Constant Velocity Joints (C/V) The constant velocity ( C /V ) joint, located at the transfer case end of the front propshaft, must be lubricated...
REAR AXLE 4B-1 SECTION 4B REAR AXLE 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".
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4 B -2 REAR AXLE 1 . C o m p a n io n F la n g e C o v e r 1 9 . T h ru s t W a s h e r D if f e r e n t i a l C a s e 1 3 .
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REAR AXLE 4B -3 Fig. 4B-2--9 1 / 2 " Ring Gear Axle The differential pinion gears are m ounted on a differ gears against the side gears. When both wheels have equal ential pinion shaft, and the gears are free to rotate on this traction, the pinion gears do not rotate on the pinion shaft because the input force on the pinion gear is equally di...
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4 B -4 REAR AXLE Straddle Bearing 19. Retainer Screw C om panion Flange Ring Gear 20. Bearing Cap Oil D e fle cto r D iffe re n tia l Spider 21. Case-to-Ring Gear B o lt Oil Seal D iffe re n tia l Case 22.
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REAR AXLE 4 B -5 D iffere n tial Spider P inion Rear Bearing Pinion N ut D iffe re n tia l Side Gear Drive Pinion Washer Washer Ring Gear C om panion Flange Pinion Gear D iffe re n tia l Case Oil Seal Washer Ring Gear B o lt...
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4B -6 REAR AXLE 24. B olt (D iffere n tia l . N ut . Shims (Inner Pinion 17. Cover and Plug Bearing Cap) . Washer Bearing) 18. Lock Pin (Pinion 25. B olt (Ring Gear) . Cup (Inner Pinion 3.
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REAR A X LE 4 B -7 101966 Fig. 4B-5a--Rockwell 12" Ring Gear Axle-11,000# Capacity DIAGNOSIS 90° turn in the drive line, produces a certain amount of NOISE noise. Therefore, an interpretation must be made for each The most essential part of rear axle service, as with any vehicle to determine whether the noise is normal or if a mechanical repair, is proper diagnosis of the problem, and, problem actually exists.
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4 B -8 REAR A X LE some weight off the bearing. Front wheel bearings may be indicative of trouble in the axle assembly. easily checked for noise by jacking up the wheels and Drive line noises may baffle even the best diagnostician. spinning them, and also be shaking wheels to determine if Vehicle noises coming from tires, transmission, propeller bearings are excessively loose.
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REAR A X LE 4 B -9 Side Bearing Preload is set to specifications in step 6 of ‘Differential Case-Installation and Adjustment1. Following service to the Differential assembly or to the Drive Pinion, the Pinion Depth and Ring-Gear-to-Pinion Backlash be checked, using a Gear Tooth Contact must Pattern Check as outlined below.
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4 B -1 0 R EAR A X LE A G E N E R A L D I A G N O S T I C P R O C E D U R E F O R I S O L A T I N G R E A R A X L E N O I S E P R O B L E M S Cause Problem 1.
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REAR A X L E 4 B -1 1 DIFFERENTIAL A N D REAR AXLE BEARING DIAGNOSIS CO NSIDER THE F O LLO W IN G FACTORS WHEN DIAG N O SIN G B EAR IN G C O N D IT IO N : 1.
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4 B -1 2 REAR A X L E DIFFERENTIAL A N D REAR A XLE BEA R IN G D IA G N O SIS (CO NT’D) j juy 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 B R I N E L L I N G...
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R EAR A X LE 4 B -1 3 L I G H T D U T Y T R U C K R E A R A X L E I D E N T I F I C A T I O N Chevrolet Light Duty Trucks use either Chevrolet or Dana produced rear axle assemblies.
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4 B -1 4 R EAR A X L E Fig. 4B-8--Gear Tooth Nomenclature Fig. 4 B -9 --G e a r Tooth C ontact Pattern Check...
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REAR A X LE 4 B 1 -1 SECTION 4B1 8-1/2 and 8-7/8 and 9-1/2 RING GEAR AXLE 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".
4 B 1 -2 R EAR A X LE Fig. 4B1 -3--Positioning Case For Best Clearance Fig. 4B1-1--Differential Pinion Shaft Removal which affects the removal of axle shafts as noted below. A X L E S H A F T 1.
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REAR A X L E 4 B 1 -3 Fig. 4Bl-5--Push Axle Shaft Inward Fig. 4Bl-7--Wheel Bearing Removal Remove the axle shaft and repeat steps 5 and 6 for the behind the bearing. Center receiver on axle tube and opposite axle shaft. tighten nut.
4 B 1 -4 R EAR A X LE 2. Remove bolts retaining flange plate to axle, and remove flange plate. 3. Install new flange plate to axle housing and torque nuts to specifications. 4. Install brake components on flange and connect hydraulic line to wheel cylinder inlet.
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REAR A X LE 4 B 1 -5 Fig. 4B1 -12-Scribe Marks Fig. 4B1-14-Drive Pinion Flange Removal for later reference. See figure 4 B 1 -12. new deflector, and stake deflector at three new equally spaced positions. Staking operation must be performed 6.
4 B 1 -6 R EA R A X L E Permatex Type A or equivalent) prior to installing washer and nut on pinion. 5. Using J - 8 6 14-11 as shown in figure 4B1-16, install flange onto pinion. Install washer and nut, and tighten nut to original position.
REAR AXLE 4 B 1 -7 holes, and press on ad ap to r plug J-8107-4 to initially J 2 2 8 8 8 start ring gear on case pilot, as show n in figure 4B1-20. 4. S tart all ring gear bolts during initial assembly to m aintain bolt hole adlignm ent.
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4 B 1 - 8 R EAR A X LE procedures, make sure the preload rem ains as established in step 9. If backlash is changed in later steps, be sure the total thickness of the two shim packs does not change. 13.
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REAR AXLE 4 B 1-9 E X A M P L E R IN G G E A R S ID E O PPO SITE SID E Thickness of Tool J-22779 Combined total of: required force ring Service Spacer (A ) .250”...
4 B 1 -1 0 REAR AXLE Fig. 4B1 -23--Measuring Gage Plate Thickness Fig. 4Bl-26--Checking Ring Gear Runout DRIVE P IN IO N Removal 1. Remove differential as previously outlined. 2. Check torque required to ro tate drive pinion, as described under "D rive Pinion - Installation and A djustm en t".
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REAR A X LE 4 B 1 -1 1 Fig. 4Bl-28--Drive Pinion Nut Removal Fig. 4B1-30--Removing Drive Pinion J-8614-3 while holding J-8 614 -11 as shown in figure Bearing Rem oval a n d C up Replacem ent 4B1-29. 1. If front pinion bearing is to be replaced, drive outer 6.
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4 B 1 -1 2 REAR A X L E machine which permits adjustment of pinion depth in ring gear until a point is reached where best operation and proper tooth contact under load is obtained. At this point, the setting of the pinion with reference to the centerline of the ring gear is indicated by the machine.
REAR A X L E 4 B 1 - 1 3 necessary alteration of the pinion shim thickness as determined in step 13. a. If the pinion is stamped with a plus ( + ) number, that many thousandths to the indicator reading. For example, if indicator reading is .019, and pinion is marked ( + 2), the correct depth shim for installation will be .019 + .002 = .021 inch.
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4 B 1 - 1 4 REAR A X L E "ZERO" THE INDICATOR, WITH THE PROBE ON THE HIGH POINT OF THE GAUGING SURFACE. SWING THE PROBE OFF THE GAUGE PLATE. THE INDICATOR NEEDLE WILL MOVE TOWARD..THE PROPER NUMBER, WHICH INDICATES THE REQUIRED SHIM FOR A...
R EAR A X L E 4 B 1 -1 5 set preload drag at 20-25 inch pounds on new bearings, or 10-15 inch pounds on reused bearings. Use an inch- pound torque wrench such as J-5853 as shown in figure 4B1-40, to measure the rotating torque.
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R EAR A X L E 4 B 2 -1 SECTION 4B2 CHEVROLET 10-1/2" RING GEAR AXLE 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 This fastener is an important attaching part in...
4B 2-2 REAR AXLE Remove shaft from axle tube. 3. Thoroughly clean both the axle shaft flange and the end of the wheel hub. Any lubricant on these surfaces tends to loosen axle shaft flange bolts. 4. Place a new gasket over the axle shaft and position the axle shaft in the housing so that the shaft splines enter the differential side gear.
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REAR A X L E 4 B 2 -3 D rum -N on -D em oun table-Type-Fig. 4 B 2 -2 R eplacem ent C onstruction of the nondem ountable-type hub and dru m assem bly is such th a t replacem ent c annot be accomplished with the hub assembly installed on the vehicle.
4 B 2 -4 R EAR A X LE Fig. 4B2-7~Wheel Bearing Adjusting Tool Fig. 4B2-6--Tightening Adjusting Nut-Typical 6. If adjusting nut slot in alignment with key way in axle 5. Install adjusting nut and complete the installation as spindle, insert square key into slot. If adjusting nut directed under "...
REAR A X LE 4 B 2 -5 Fig. 4B2-8-Cover Removed from Carrier Fig. 4B2-10-Differential Bearing Removal 6. W hen installing the second bearing, support case on 6. Loosen side bearing adjusting nuts, using J-24429 as pilot plug as shown in figure 4B2-11 to prevent damage shown in figure 4B2-9.
4 B 2 -6 R EA R A X L E 3. Back off the left adjusting nut approximately two slots. Install locking fingers into holes and fasten fingers to bearing cap. 4. Tighten right adjusting nut firmly to force the case into solid contact with the left adjusting nut.
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REAR A X L E 4 B 2 -7 Fig. 4B2-13--Removing Retainer Bolts Fig. 4B2-16--Pressing Drive Pinion from Bearing Retainer 4B2-16 and press out the drive pinion. Do not allow drive pinion to fall onto the floor. 6. S e p a ra te the pinion flange, the oil seal, the front bearing and the bearing retainer.
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4 B 2 -8 R EAR A X LE Fig. 4B2-18--Removing Straddle Bearing Fig. 4B2-20— Installing Straddle Bearing extreme pressure lubricant, and install the seal in the 4. Inspect the bearing retainer for cracks, imperfections, retainer bore. Use J-24434 with driver handle J-8092. corrosion, pits and grooves.
REAR A X LE 4 B 2 -9 3. Refer to the thickness of the shim recorded earlier in Pinion Removal procedures. Increase or decrease the shim dimension as indicated by the chart in figure 4B2-22. a. For example, if original shim measured .014 inch, CODE N U M B E R ON O R IG I N A L PIN ION original code was -1 and new code is + 2 , the correct shim would be .014 inch plus .003 = ,017inch.
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REAR A X LE 4 B 3 -1 SECTION 4B3 DANA 10-1/2 RING GEAR AXLE 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 ".
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4 B 3 -2 REAR A X LE D iffe re n tia l Spider Pinion Rear Bearing Pinion N ut D iffe re n tia l Side Gear Drive Pinion Washer Washer Ring Gear C om panion Flange Pinion Gear D iffe re n tia l Case Oil Seal Washer...
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REAR A X LE 4 B 3 -3 Position J-8 614 -11 on flange so that the four notches are toward the flange. 4. Remove pinion nut and washer. Discard pinion nut and use a new one upon reassembly. 5. Thread end of J - 8 6 14-3 into small O.D. end of J-8614- 2.
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4 B 3 -4 R EAR A X LE 9. Install bearing on opposite side in the same manner. Be sure to support differential case on pilot plug J - 8 107-3. S H IM REQUIREMENTS - G A G IN G PROCEDURES Side Bearing Shims 1.
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REAR A X LE 4 B 3 -5 DRIVE P IN IO N Assem bly a n d In sta lla tio n 1. Determine the correct pinion depth shim by using the chart in figure 4B3-9. 2. Install the pinion depth shim in rear cup bore. 3.
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4 B 3 -6 REAR A X LE J-8614-11, torque nut to 350 N-m (250 lbs. ft.). was .172 inch, the correct shim dimension would be .329-.172 = .157 + .006 = .163 inch. DIFFERENTIAL CASE 11. Spread the differential carrier as shown in figure 4B3- In sta lla tio n a n d A d ju s tm e n t 12.
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REAR A X LE 4 B 4 -1 SECTION 4B4 DANA 9-3/4" RING GEAR AXLE 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".
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4 B 4 -2 REAR A X LE 24. Bolt (Differential 17. Cover and Plug 11. Shims (Inner Pinion 1. Nut Bearing Cap) 18. Lock Pin (Pinion Bearing) 2. Washer 25. Bolt (Ring Gear) Shaft) 12. Cup (Inner Pinion 3. Companion Flange 26.
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REAR A X LE 4 B 4 -3 J -8 6 1 4-1 J-86 1 4 - 2 & 3 Fig. 4B4-4--Removing Pinion Flange Fig. 4B4-2--Tool J-24385 Mounted on Carrier 4. Inspect differential case for carcks or scores. Inspect side gears, thrust washers, and pinion thrust faces. 5.
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4 B 4 -4 REAR A X LE total amount of shims needed (less preload) for setting backlash later during assembly. 11. Remove differential from carrier. DRIVE P IN IO N In s ta lla tio n a n d A d ju s tm e n t o f D epth a n d Preload Ring gears and pinions are supplied in matched sets only.
Page 465
REAR A X LE 4 B 4 -5 New Pinion Marking Old Pinion Marking + 0.008 + 0.007 + 0.006 + 0.005 + 0.004 + 0.003 + 0.002 + 0.001 + 0.004 + 0.002 + 0.001 - 0.001 + 0.007 + 0.006 + 0.005 + 0.003...
4 B 4 -6 REAR A X LE recoreded step Differential Case- Reassembly. b. To this figure, add an additional .015" shims to com pensate for preload and backlash. E xam ple: If reading in step 10 of Differential Case-Reassem bly was .085", and the shims in stalled on ring gear side of case was .055”, the correct amount of shim will be .085"...
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REAR A X LE 4 B 5 -1 SECTION 4B5 ROCKWELL 12 RING GEAR AXLE All rear axle a tta c h in g fasteners are an equivalent part if replacement becomes necessary. Do NOTICE: important attaching part in that it could affect the not use a replacem ent part of lesser quality or performance of vital components and systems, an d /o r substitute design.
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4 B 5 -2 REAR A X LE Fig. 4B5-2--Rockwell Assembly...
REAR A X LE 4 B 5 -3 ON-VEHICLE SERVICE WHEEL BOLT REPLACEMENT Refer to procedure listed under "Chevrolet 10-1/2" Ring G ear Axle (Section 4B2). BEARING A D JU STM ENT Before checking bearing adjustment, make sure brakes are fully released and do not drag. Check bearing play by grasping tire at top and pulling back and forth, or by using a pry bar under tire.
4 B 5 -4 R EAR A X LE 6. Remove top nuts and washers and work carrier free. A small pinch bar may be used to straighten the carrier in the housing bore. However, the end must be rounded to prevent indenting the carrier flange.
REAR A X LE 4 B 5 -5 101918 Fig. 4B5-6--Punching Carrier Leg Fig. 4B5-8--ldentification Mark drill completely through rivet. 4. Remove bearing cap, capscrews, bearing caps and adjusting nuts. 3. Press out rivets. If necessary to replace differential bearings, remove 5.
4 B 5 -6 R EAR A X LE The use of a pinch bar will damage the shims. NOTICE: Driving pinion from inner end with a drift will damage Fig. 4B5-1 2--Removing Flange the bearing lock ring groove. 6. Wire shim pack together to facilitate adjustment on C LE A N IN G A N D INSPECTIO N reassembling.
REAR A X LE 4 B 5 -7 2. Dry both surfaces. 3. Apply thin bead, approxim ately 1/8" d iam eter completely around one mating surface and all fastener holes to assure complete sealing and prevent leakage. C AU T IO N : M in o r co n c e n tra tio n s o f acetic acid va p o r m a y be p rod u ce d d u rin g a p p lic a tio n .
Page 474
4 B 5 -8 REAR A X LE A gear and pinion which do not have the same m atching numbers must together. Therefore, if either a pinion or a ring gear should require replacem ent, both m ust be replaced in a matched set.
Page 475
REAR A X LE 4 B 5 -9 P IN IO N A N D CA G E Reassembly 8. While in press under pressure, check bearing preload 1. If new cups are to be installed, press firmly against pinion bearing cage shoulders (Fig. 4 B 5 -16). torque.
4 B 5 - 1 0 REAR A X LE Pinion and C ag e Assembly Selecting Pinion C ag e Shim Pack Thickness In sta lla tio n A means of accurately installing a new pinion and cage assembly into the carrier is to mathematically calculate the 1.
Page 477
REAR AXLE 4B 5-11 For correct installation, heat the ring gear in water to approxim ately 160°-180° for about ten m inutes before assembly. This will allow an easier fit of the gear over the differential case pilot, w ithout the use of a press, and without damaging the case and ring gear mating surfaces.
4 B 5 - 1 2 R EAR A X L E Fig. 4B5-22--Align Marks Fig. 4B5-24~Checking Torque scraper or some emery cloth until a hand push fit is 2. Insert checking tool (m ade from splined axle shaft end) obtained.
REAR A X L E 4 B 5 - 1 3 Fig. 4B5-26-Fitting Bearing Cups Checking Backlash 5. Install flat washers and capscrews. Tighten stud nuts or If the drive gear is not going to be replaced, use the capscrews to correct torque. established backlash recorded before disassembly.
4B6-2 REAR AXLE EATON LIMITED SLIP - FIGURE 4B6-1 Fig. 4B6-2--Removing Preload Spring Pack (Typical) D isa sse m b ly 1. Remove ring gear and side bearings following the procedures established for the conventional differential unit. Fig. 4B6-3--lnstalling Bolts to Retain Springs 2.
REAR AXLE 4B6-3 AXLE SHAFT Fig. 4B6-8--Assembling Clutch Pack reinstall them over the side gear hub. 5. Lubricate and assemble opposite side gear as above. 6. Install one side gear, clutch pack assembly and shim(s) in the differential case. Fig. 4B6-6--Removing Differential Pinion Gears 7.
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4B6-4 REAR AXLE Fig. 4B6-10--Spring Pack Compressed for Installation Fig. 4B6-12—Installing Spring Pack assembly in vise. Install "C" clamp and bar stock on c. With wheel and tire assembly still on vehicle held spring retainer then install a 1/4 inch bolt and nut in firmly to prevent turning, measure torque required to each front spring.
REAR AXLE 4B6-5 CHEVROLET LIMITED SLIP - FIGURE 4B6-14 SHIM BOLT (PINION SHAFT) SPLINED DISC (3) PINION FIXED SHAFT DISC (4) THRUST WASHER BOLT PINION (RING GEAR) GEAR RELOAD SIDE SPRING BEARING Fig. 4B6-14~Chevrolet Limited Slip - Exploded Check the gear teeth for signs of wear. Replace parts as D isa sse m b ly needed.
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4B6-6 REAR AXLE the face of the side gear. Force the screwdriver in until 11. When the proper shims have been determined to achieve .005" to .008" backlash between both pinion the clutch pack is compressed. gears and both side gears, install shims, clutch packs 7.
REAR AXLE 4B6-7 BORG WARNER (CONE TYPE) M A IN T E N A N C E A N D LU BR ICA T IO N Refer to Section OB for maintenance and lubrication 20 FT. LBS. requirements. SER V IC E P RO CED U RES CASE Rear axle service procedures are the same for the limited slip as for the conventional differential, except for...
4B6-8 REAR AXLE 2. Place one spring block in position over gear face, in alignment with pinion gear shaft grooves. Install pinion shaft, pinion gears and thrust washers into cap half or differential case in such a manner that pinion shaft retaining dowel can be inserted through pinion gear shaft into differential case.
Page 491
REAR AXLE 4B6-9 3. Insert five springs into spring block that is already installed into case, then place second spring block over springs (Fig. 4B6-18). 4. Install second cone/gear assembly face down on spring block so that gear will mesh with pinion gears. 5.
4B6-10 REAR AXLE POWER-LOK DIFFERENTIAL ’ Friction P late-T abbed Differential C a se Bolt Friction Plate-T abbed S id e G ear Ring Differential (Belleville) (Flat) S id e Gear C a se -P la in Half Friction D isc-T o o th ed Friction D isc-T o o th e d Pinion G ears Differential...
Page 493
REAR AXLE 4B6-11 9. Observe Power-Lok components have been 2. Assemble remaining plates and discs to splines of side assembled properly. Each pinion cross shaft can be gear ring, being sure they are assembled in the same tight on its ramp or if there is clearance it should be order of removal.
4B6-12 REAR AXLE EATON POSITIVE LOCKING DIFFERENTIAL B U S H IN G ^ BUSHING LOCKSCREW LOCK WASHER EARED DISC (3) SPLINED DISC(2) PINION SHAFT CAMFORM SIDE GEAR GUIDE CLIP(4) CAM PLATE ___________ THRUST BLOCK WAVE SPRING PINION GEAR{2) SHIM r THRUST RING PINION THRUST —^ WASHER (2)
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REAR AXLE 4B6-13 SCREW (3) CASE HALF — L.H SHIM GUIDE CLIP (6) DISC PACK S/A THRUST WASHER (3) CASE H A L F — R .H GUIDE CLIP (6) PINION ‘GEAR (3) GOVERNOR ASSEMBLY SHIM SIDE GEAR EARED DISC (3) SPLINED DISC (2) PINION YOKE LATCHING...
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4B6-14 REAR AXLE D IF F E R E N T IA L D IA G N O S IS Complaint Possible Cause Correction Does n o t lo c k : L ittle o r n o s p rin g R eplace g o v e rn o r assem bly p re lo a d on th e la tc h in g and la tc h in g b ra c k e t.
REAR AXLE 4B6-15 2. Inspect all differential components for excessive wear and breakage. Replace parts as needed The following are serviceable components for this differential: • Governor assembly and latching bracket with spring and stop pin. • Cam plate. • Clutch disc pack with guides and guide clip. •...
4B6-16 REAR AXLE 5. Locate cam gear assembly in arbor press with hub end up. Place thrust ring on gear hub and press to shoulder making sure that ring is square with hub. a. Compress disc pack by pushing down on the discs to keep the splined discs from becoming wedged between the thrust ring and gear shoulder while pressing the sub-assembly together.
Page 499
REAR AXLE 4B6-17 D isa sse m b ly 1. Remove ring gear and side bearings following procedures established for the standard differential. 2. Remove (3) screws on front face of ring gear flange. 3. Set unit on right side case half and gently pry apart at yoke hole locations Fig.
Page 500
4B6-18 REAR AXLE 2. Assemble cam plate with cam form down to mate with cam form on gear. 3. Assemble onto cam plate (2) eared discs, (1) splined disc, and (1) wave spring alternately as shown Fig. 4B6-9H. 4. Assemble onto gear hub: (4) eared discs and (3) splined discs alternately as shown.
Page 501
REAR AXLE 4B6-19 their respective locations. Place straight end of latching 12. Being careful not to dislodge side gear assembly (hold bracket spring over and to the outside of the governor thumb on inside of side gear spline), lower the left hand shaft to preload the latching bracket against the case assembly onto the right hand case.
Page 503
REAR AXLE 4B10-1 SECTION 4B10 SPECIFICATIONS AND SPECIAL TOOLS D IFFE R E N TIA L S P E C IF IC A T IO N S □ >■ > fO- £ O (O' £ — O' — o- BOLT T O R Q U E S (F T .-L B S .)A .0 0 5 "...
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4B10-2 REAR AXLE R IN G G E A R M O D E L S O U R C E T Y P E /C A P A C IT Y S IZ E C 1 0 C he vrolet S a l i s b u r y / 3 7 5 0 # 8 - 7 / 8 "...
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REAR AXLE 4B10-3 f * 1 J-2 2 9 1 2 Press Plate 13. J-8001 D ia l In d ic a to r Set . J-1 4 5 3 P in io n B earing Press P late 14. J-0 9 7 2 D iffe re n tia l N u t W rench 3.
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4B10-4 REAR AXLE SPECIAL TOOLS Q ffl i\ £ . A h 1 ' ■ A w — 8 7 / s " R.G. A X L E O N L Y 10'/2" R.G. A X LE O N L Y .
FRONT AXLE 4C-1 SECTION 4C FRONT AXLE 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 N otice on page 1 of this Section".
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