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Chevrolet 1981 Light Duty Truck Service Manual

Chevrolet 1981 light duty truck (series 10-35) service manual

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William Normoyle

June 6, 2025

1981 ing. firing order 5.7 L

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Summary of Contents for Chevrolet 1981 Light Duty Truck

Page 1 CHEVROLET...
Page 2 1981 Chevrolet Passenger Car and Light D uty T ruck U n it Repair (Overhaul) Manual. W iring diagrams fo r 1981 trucks are contained in a separate Wiring Diagram Booklet.
Page 3 Accordingly, anyone who uses a service procedure or tool which is not recommended by Chevrolet must first satisfy himself thoroughly that neither his safety nor the vehicle will be jeopardized by the...
Page 4 TABLE OF CONTENTS SECTION GENERAL INFORMATION General In fo rm a tio n M a in te n a n ce and Lu brication HEATING AND AIR CONDITIONING H eating and V e n tila tio n A ir C o n d itio n in g 1981 FRAME AND BUMPERS Fram e and Body M ounts...
Page 5: General Information
GENERAL INFORMATION OA-1 SECTION OA GENERAL INFORMATION CONTENTS OF THIS SECTION G e n e ra 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 ....................0-3 Engine Code N u m b e r..................
Page 6 OA-2 GENERAL INFORMATION VEHICLE IDENTIFICATION NUMBER 1GCEC14 0 9BF123456 NA TIO N OF ORIGIN PLANT SEQUENTIAL NUMBER U .S .A . MODEL YEAR ASSEMBLY PLANT C A N A D A C O D E A S S E M B L Y P L A N T C O D E A S S E M B L Y P L A N T 1981...
Page 7 The Service P arts Identification Sticker (Fig. OA-6) is provided on all Truck models. On C and K models, the Chevrolet Built identification sticker be located on the inside of the glove box • On 10 Series, the Code is stam ped on Top of Right door or on G model, the sticker will be located on an inner R ear Axle Tube.
Page 8 OA-4 GENERAL INFORMATION PRIMARY V .I.N . SECONDARY V .I.N . LOCATION LOCATION ( M l 5) To be used only when .suitable for stamping PRIMARY V .I.N . LOCATION (MV4 or M38) SECONDARY V .I.N . LOCATION To be used only when primary locationis not suitable for stamping PRIMARY V .I.N .
Page 9 GENERAL INFORMATION OA-5 E N G IN E V .I.N . E N G IN E E N G IN E V .I.N . CASE PAD (O PTIO N AL) E N G IN E V .I.N . DISTRIBUTOR PAD ENGINE L6 ENGINE E N G IN E V .I.N .
Page 10: Table Of Contents
MAINTENANCE AND LUBRICATION OB-1 SECTION OB MAINTENANCE AND LUBRICATION CONTENTS M aintenance S c h e d u le .................. OB-2 Lubrication and G eneral M aintenance............ 0B-5 Safety M aintenance..................OB-15 Emission Control M aintenance............. OB-16 Specifications....................0B-18 Recom m ended Fluids and L u b ric a n ts............. OB-18 Fluid C ap acities.....................
Page 11 VEHICLE MAINTENANCE SCHEDULE OWNER'S SERVICE LOG (M iles) (km) lns#rt " on,h- 1 •I1- <*••• 5/7.500) m m -v column Closest To Mileage (km) When Service Is Performed. Item 7.500 15,000 22.500 30,000 37.500 45,000 (Mee*a MHw (k>l Wfcklmwr F W -» t> Ocean Services (12 000 km)
Page 12 VEHICLE MAINTENANCE SCHEDULE OWNER'S SERVICE LOG ( M i l . , I ( M When To Ptrform Services Item 30.000 37,500 15,000 22,500 45.000 7,500 Services (M l.— •> MHm (kali WMrtmr Occm n Rfst) (12 000 km) (24 000 km) (36 000 km) (48 000 km) (60 000 km)
Page 13 VEHICLE MAINTENANCE SCHEDULE V-8 DIESEL FUELED ENGINE OWNER'S SERVICE LOG (Miles/km) M rTth' .D?V' u l - c‘*' ■"*? 5 / '5°0> '!! Column Closest To Mileage When Service Is Performed Item When To Perforin Services Services M a r t a m H H m /km . W W c k o m O ccan F t a ) (For D e ta ils , See Numbered Paragraphs) §...
Page 14: Maintenance Schedule
MAINTENANCE AND LUBRICATION OB-5 VEHICLE MAINTENANCE SCHEDULE Insert Montk. Day and Mileage (i.e. M ay 5 /8 ,9 0 0 ) la OWNER'S SERVICE LOG (Miles/km) Colamn Closest te Mileage When Service ia Performed. To Perform Services W h a n Item Services 6.000...
Page 15 OB-6 MAINTENANCE AND LUBRICATION Jump Starting fluid. See section on power steering system when checking fluid level or adding fluid. CAUTION:Batteries produce explosive gases, cor rosive acid and levels of electrical current high NOTICE: Power steering fluid and brake fluid cannot be enough to cause burns.
Page 16 MAINTENANCE AND LUBRICATION OB-7 low reading is normal, the level will rise as the fluid gets • Use a fluid such as G M Optikleen or equivalent to help warm. The fluid level will increase more than 3/4 inch prevent freezing dam age, and for better cleaning. (19m m ) as fluid warm s up from 60°F to 180°F (16°C to •...
Page 17 OB-8 MAINTENANCE AND LUBRICATION can, be sure not to confuse the S E designation with the • Change oil filter: letters " SA E ", which m ay also appear on the can. Light Duty Emissions- Replace at the first oil change and then every second oil change if mileage 7,500 •...
Page 18 MAINTENANCE AND LUBRICATION OB-9 a. On C20, G 30 and P20, lubricate every 4 m onths or Oil Viscosity (Figs. OB-6 and 7) 6,000 miles (9 600 km). Engine oil viscosity (thickness) has an effect on fuel b. On all other vehicles, lubricate every 12 m onths or economy.
Page 19 OB-10 MAINTENANCE AND LUBRICATION Lower C ontrol Arms Wheel Bearings T h ro ttle Bell Crank - L-6 Upper C ontrol Arms Steering Gear Carburetor Linkage - V-8 Upper and Lower Control A ir Cleaner - Element Brake and Clutch Pedal Arm Ball Joints Master C ylinder Springs...
Page 20 MAINTENANCE AND LUBRICATION OB-11 LUBRICATION POINTS Trans. Control Shaft Rear Axle Control Arm Bushings and Oil Filter Ball Joints A ir Cleaner - Element Brake Master Cylinder Tie Rod Ends Transmission - Manual Parking Brake Linkage Wheel Bearings - A u to m a tic Steering Gear Clutch Cross-Shaft Fig.
Page 21 OB-12 MAINTENANCE AND LUBRICATION Accelerator Linkage Vehicle handling could be adversely affected and the tires having the lower load rating could be overloaded. (Also a Safety Service) Lubricate carburetor stud and carburetor lever and CAUTION:Before installing wheels, remove any accelerator pedal lever at support with engine oil. build up of corrosion on the wheel mounting Body Lubrication surface and brake drum or disc mounting surface...
Page 22 MAINTENANCE AND LUBRICATION OB-13 sequence shown in Section 3E. N ever use oil or grease on Bleeding serves to reduce "cold" inflation pressure and studs or nuts. Im properly tightened wheel nuts could increase tire flexing which can result in tire dam age eventually allow the wheel to come off while the vehicle is and failure.
Page 23 OB-14 MAINTENANCE AND LUBRICATION out and/or catch fire, possibly resulting in dam Service age to the vehicle and its contents and/or per • M aintain cooling system freeze protection at -34°F sonal injury to its occupants and persons in the (-37°C) to ensure protection against corrosion and loss area.
Page 24: Safety Maintenance
MAINTENANCE AND LUBRICATION OB-15 8. A dd enough ethylene glycol solution, m eeting G M gear housing should be refilled only with the proper Steering G ear L ubricant as noted below. Specification 1899-M, and w ater to provide the re quired cooling function as well as freezing and corro...
Page 25: Emission Control Maintenance
OB-16 MAINTENANCE AND LUBRICATION W hen adjusting a drive belt, it is im portant th at the proper in the area. N eeded repairs should be m ade at once. To help adjustm ent specification be used. m aintain system integrity, replace the exhaust pipes and resonators rearw ard of the muffler whenever a new muffler is Refer to Section 6A for engine m echanical additional put on.
Page 26 MAINTENANCE AND LUBRICATION OB-17 boot fit a t distributor cap and spark plugs. Replace wire if C-4 Early Fuel Evaporation (EFE) System dam aged or if corrosion cannot be cleaned. C heck th a t valve works properly, correct any binding. Check th a t therm al vacuum switch works properly.
Page 27: Specifications
OB-18 MAINTENANCE AND LUBRICATION SPECIFICATIONS RECOMMENDED FLUIDS AND LUBRICANTS USAGE FLUID/LUBRICANT Pow er steerin g system and pum p reservoir GM pow er steering flu id Part No. 1050017 o r equivalent. C o n ve ntiona l tra n sfe r case DEXRON®-ll A u to m a tic T ransm ission Fluid M anual ste erin g gear L u b ric a n t GM Part No.
Page 28 MAINTENANCE AND LUBRICATION OB-19 CAPACITIES IMPERIAL r< ,M • MEASURE U.S. MEASURE D ifferential pts. 1.9L pts. 8% '' Ring Gear 31 /2 pts. 3 pts. 8 -7 /8 ” Ring Gear 5% pts. 2.8L 6% pts. 101 /2 " Ring Gear (Chev.) 5% pts.
Page 29 0B-20 MAINTENANCE AND LUBRICATION COOLING SYSTEM Capacity H.D. Transmission (Qts./Liters) Radiator Cond. U.S. Imperial Engine Series Measure Measure Man. Auto Man. Man. Auto Auto C K10-15 15 (14L) 121 / 2 15% (14.5L) C 20-25 15 (14L) 250 CID 15!4 (14.5L) G 10-30, 15-35 C 20-25...
Page 30 HEATER 1A-1 SECTION 1A HEATER CONTENTS S tan d ard H e a te r....................1A-1 A uxiliary H e a te r ....................1A-15 Specifications...................... 1A-19 STANDARD HEATER INDEX H eater H o ses..............1A-9 G eneral D escription............1A-1 C enter D istributor D uct - G M odels......
Page 31 1A-2 HEATER HE A T E R A D E F R O S T E R A S M H E A T E R A D E F R O S T E R A S M AIR OUTLET AIR OUTLET VIEW A VIEW...
Page 32 HEATER 1A-3 assembly, by the purge door. If the purge door is closed, then BLOWER AND AIR INLET ASSEMBLY air is directed through an d /o r around the heater core by the The blower and air inlet assembly draw s outside air tem perature door.
Page 33 1A-4 HEATER DIAGNOSIS CAUSE AND CORRECTION TROUBLE Temperature o f heater a ir a t outlets too low to heat up pas See " In s u ffic ie n t Heat Diagnostic Chart". senger compartment. Temperature o f heater a ir a t o utlets adequate but the vehicle Check fo r body leaks such as: w ill not build up s u ffic ie n t heat.
Page 34 HEATER 1A-5 INSUFFICIENT HEAT D IA G N O S IS Position the controls so that the: Temperature lever is on full heat. Selector or heater lever is on Heater. Fan switch is on Hi. •CHECK DUMP DOOR OUTLET FOR AIR FLOW AIR FLOW NO AIR FLOW A d ju st d u m p d o o r fo r n o air flo w .
Page 35 HEATER CIRCUIT D IA G N O S I S * BLOWER MOTOR INOPERATIVE (AN Y SPEED) Check fuse in fuse panel. FUSE BLOWN FUSE OK 1.." 1----- The follow ing tests should be made w ith With Ignition switch in the ignition switch in "R U N ”...
Page 36 HEATER 1A-7 Fig. lA-4--Heater Wiring Diagrams LIG H T T R U C K SE RV IC E M A N U A L...
Page 37: On Vehicle Service
1A-8 HEATER ON VEHICLE SERVICE bead of sealer to the entire circum ference of the BLOWER MOTOR m ounting flange, c. Check blower operations: blower wheel should rotate Removal (Fig. 1A-5) freely with no interference. 1. Disconnect battery ground cable. HEATER DISTRIBUTOR AND CORE ASSEMBLY G Models - Remove the coolant recovery tank, and power antenna as outlined in Sections 6 and 9.
Page 38: Heater Hoses
HEATER 1A-9 VIEW A Fig. lA-7--Heater Distributor - G Models Replacement connections (see "H e a te r H oses-R eplacem ent" later in this section). Quickly plug the heater hoses and support The heater core can be easily dam aged in the area of them in a raised position.
Page 39 1A-10 HEATER AUTOMATIC TRANSMISSION MODELS1 ( EXCEPT C-K 10 350 V8 W / O VOI OR C60 ) V -8 C-K M O D E L S TO WATER PUMP - f 1 ^ C36 G M O D E L S Fig.
Page 41: Defroster D U C
1A-12 HEATER |vitwfA| Fig. 1 A-12--Distributor Ducts--G Models DISTRIBUTOR DUCTS - G Models Replacement (Fig. 1A-12) 1. Disconnect the battery ground cable. 2. R aise I.P. at rig h t side as outlined und er heater distributor removal. 3. U nsnap the engine cover front latches. Remove the two cover to floorpan screws and remove the cover.
Page 42: Control C Ab Les
HEATER 1A-13 3. Remove the control to instrum ent panel screws. 4. Raise or lower control as necessary to remove cable push nuts and tab attaching screws. 5. Remove glove box and door as an assembly. 6. Remove cable push nut and tab attaching screw at door end of cable.
Page 43 1A-14 HEATER Fig. 1 A-16--Control Cables, C-K Series V IE W A V IE W B Fig. 1 A-17--Control Cable Routing, G Models L IG H T T R U C K S fR V IC E M A N U A L...
Page 44 HEATER 1A-15 G Models Replacement (Fig. 1A-15) 1. Disconnect the battery ground cable. 2. Disconnect the blower switch wiring harness connector at the switch. 3. Remove the two switch attaching screws and remove the switch assembly. 4. To install a new switch, reverse Steps 1 thru 3. RESISTOR Replacement (Figs.
Page 45 1A-16 HEATER DIAGNOSIS R efer to the "S tan d ard H eater" section of this m anual for diagnostic inform ation; R efer to Electrical D iagram Fig. 1A-21. LIG H T T R U C K SE RV IC E M A N U A L...
Page 46 HEATER 1A-17 rjrrw77m n rmarTTTuri ' i M n.f'g’m i r r u . i B i 2 9 7 3 7 8 1 - 8 9 0 5 4 2 6 BRN/WHT-50- BRN/WHT-50 — WHT-952A- ■ 2 WHT-952B- •3 W H T-952A —...
Page 47 1 A-18 HEATER LIG H T T R U C K SE RV IC E M A N U A L...
Page 48 HEATER 1A-19 SPECIFICATIONS SECTION 1A HEATER A m ps. (Cold) V olts (C old) Blower Motor C-K Models 13.5 6.25 Max. 2550 Min. 2950 Max. G Models 13.5 7.1 Max. 2850 Min. 3250 Max. Fuses C-K Models G Models A U XILIA R Y HEATER Amps.
Page 49 Kfei*! ;: ■ . ^ r \ J > ‘ k l ■ - i < ,Kr '...
Page 50 SECTION IB AIR CONDITIONING NO TICE: W hen perform ing air conditioning diagnosis on Chevrolet vehicles equipped with a catalytic converter, it will be necessary to warm the engine to a norm al operating tem perature before attem pting to idle the engine for periods g reater than five (5) minutes.
Page 51 EVAPORATOR CORE SHROUD. CONTROL VIEW A AIR INLET VALVE 3 " PLENUM VALVE HEATER CORE BLOWER & < D EVAPORATOR A S M (CK) MODELS...
Page 52: General Description
AIR CONDITIONING IB-3 GENERAL DESCRIPTION C60 A /C SYSTEM System control is through the front system. The only control on the overhead system is a three speed blower Both the heating and cooling functions are performed switch. by this system. Air entering the vehicle must pass through the cooling unit (evaporator) and through (or around) the MOTOR HOME CHASSIS SYSTEM heating unit, in th at order, and the system is referred to as a...
Page 53 IB-4 AIR CONDITIONING The accum ulator is located at the evaporator outlet. Its most im portant function is not to "accum u late" although this too is im portant. Its prim ary function is to separate liquid retained from vapor, retain the liquid and release the vapor to the compressor.
Page 54: Pressure Cycling S W Itch
AIR CONDITIONING IB-5 As soon as the compressor starts running, the tem pera tu re begins to go down. As the air being cooled gets colder, th e gas in th e th e rm o sta tic tu b e begins to reduce the pressure on th e sw itch bellows.
Page 55 CONDITIONED AIR IS D IR E C T E D THRU W/SHLD, I P. & FLOOR DISTRIBUTOR OUTLETS A NON COMPRESSOR O P E R A T I N G POSITION, CONDITIONED AIR IS D IR EC TED THRU I P. OUTLETS W IT H OUTSIDE AI R D E L I V E R E D T H R U I P.
Page 56: System C O N Tro L
AIR CONDITIONING IB-7 Vacuum Schematic - G Models SYSTEM CONTROLS G Model vacuum schem atic is shown in Fig. 1B-9. C60 SYSTEM (C-K & G SERIES) - FIG. IB-5 System Operation - C-K Truck OVERHEAD SYSTEM (C-K & G SERIES) T his system operates in conjunction w ith th e C60 System operation is shown in Fig.
Page 57 IB-8 AIR CONDITIONING BLOW ER A IR H E A TE R H E A TE R A IR D EFR O STER A /C SPEEDS ENTERS COMPRESSOR SOURCE A V A IL DOOR DOOR V E H IC L E OPEN TO OPEN TO O FF...
Page 58 AIR CONDITIONING IB-9 This system is self contained and is mounted below the dash by the body m anufacturer. System controls consist of an A IR knob and T E M P knob located in the center of the unit face plate (Fig. 1B -12). Air Knob Turning the A IR knob clockwise operates a three speed (L O W -M E D -H I) blower m otor.
Page 59 IB -10 AIR CONDITIONING A C CUM U LA TO R PRESSURE CYCLING SYSTEM 'H P V " H IG H PRESSURE VAPOR L E A V IN G COMPRESSOR. 'H P L " VAPOR IS COOLED DOWN BY CONDENSER A IR FLOW A N D LEAVES AS HIG H PRESSURE L IQ U ID . 'L P L "...
Page 60 AIR CONDITIONING IB -11 nut, as well as the coupling to which it is attached, be held at the sam e tim e using three different wrenches to prevent turning the fitting and dam aging the ground seat. • "O " rings and seats m ust be in perfect condition. A burr or piece of dirt may cause a refrigerant leak.
Page 61: Diagnosis
IB -12 AIR CONDITIONING disposable cans or R-12 drum s are also used. D IS C H A R G • Em pty R - 12 container com pletely before disposing. 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 •...
Page 62 PRESSURE CYCLING CCOT SYSTEM C60, C-K and G MODELS C om pressor clutch cycling on C -K & G Series C60 C C O T A /C System s is accomplished through the use of a pressure sensing switch, (R efer to Fig. IB-21 &1B-22) located n ear the top of th e accu m u lato r.
Page 63 IB -14 AIR CONDITIONING SERVICE DIAGNOSTIC PROCEDURE INSUFFICIENT COOLING A/C SYSTEMS WITH CYCLING CLUTCH — EXPANSION TUBE (PRESSURE SENSING) M O V E T E M P LEVER R APID LY BA C K A N D FORTH FR O M H O T TO C O LD . LIS T E N FOR DOOR H IT T IN G A T EACH END C irc u m s ta n c e s S h o u ld a S ig h t G la s s Be In s ta lle d Feel L iq u id L in e B e fo re E x p a n s io n T u b e...
Page 64 AIR CONDITIONING IB -15 SERVICE DIAGNOSTIC PROCEDURE INSUFFICIENT COOLING A/C SYSTEMS WITH CYCLING CLUTCH — EXPANSION TUBE (PRESSURE SENSING) M O V E T E M P LEVER R APID LY B A C K A N D FORTH FR O M H O T T O C O L D . LIS T E N FOR D O O R H IT T IN G A T EACH END T h is S y s te m D oe s N o t H ave a S ig h t G lass.
Page 65 IB-16 AIR CONDITIONING ELECTRICAL/VACUUM TROUBLE DIAGNOSIS W hen diagnosing problem s in the electrical and vac 1. O peration of the air conditioning blower at all four uum systems of the air conditioning system, consult electri speeds and engagem ent of the compressor clutch would indicate th a t electrical circu its are functioning cal wiring diagram s and vacuum diagram s.
Page 66: Compressor Diagnosis
COMPRESSOR DIAGNOSIS If previous step does not Check for proper air gap. CLUTCH SLIPPING. correct clutch slippage, Correct if necessary. (.022- .057) repair compressor. C O M P R E S S O R E N G A G E D B U T N O T O P E R A T IO N A L BELT SLIPPING.
Page 67 INSUFFICIEN T COOLING D IA G N O S IS CHART DASH MOUNTED UNIT (MOTOR HOME CHASSIS UNITS) The follow ing procedures should be applied before performance testing an A/C System. 5. Check for condenser air blockage due to foreign material. 1.
Page 68 ELECTRICAL SYSTEM DIAGNOSTIC CHART BLOWER MOTOR INOPERATIVE B L O W E R M O T O R IN O P E R A T IV E (CERTAIN SPEEDS-EXCEPT HIGH (A N Y S P E E D ) ON C-K FOUR-SEASON) Check for proper fuse 1 F U SE B L O W N !
Page 69 IB-20 AIR CONDITIONING CHANGE IN AIR FLOW LITTLE OR NO CHANGE IN AIR FLOW ..NORMAL AIR FLOW | LOW OR NO AIR FLOW | Check heater outlet temperature Check shutoff door position for full w ith 220° F range thermometer. system air flow.
Page 70 AIR CONDITIONING IB-21 S H E E T M E T A L « m _ ., - BLK— H g \ BLCWER MOTOR (2004627 SEE NOTE A £ r \ RESISTOR BLOWER RELAY •I LT G RN-6 6 B I D K G R N -5 9 - ---------1BRN/WHT-648, ■...
Page 71 IB-22 AIR CONDITIONING REAR BLOWER W ESISTgR 2 ) t i -12004752 GROMMET 7541 •917542- •2 LT BLLVBLK-872 — -2LTBLIVBLK 2 LT BLIV6LK-872 - 2 YEL^LK-851 — -2YEU/BLK---- [•Ml ( Ml > — 2 YEL/BLK-851- - 2 QRN/BLK-852A -2 OR^BLK— i-w- ii-r-i -2 0RI ►...
Page 73 IB -24 AIR CONDITIONING Fig. 1B-18--C60 System Vacuum Diagram (G Series) L IG H T T R U C K SE RV IC E M A N U A L...
Page 74 TO FUSE PANEL ||l G RO U N D COM PRESSOR RESISTOR. BLOWER M O T O R • 101 16 DK BLU ■52 16 DK BLU ■72 16 LT BLU' BLOWER SWITCH — 51 16 YEL SET AT CONNECTIO N N TO N O N E N TO 1 &...
Page 75 IB-26 AIR CONDITIONING Fig. 1B-20--I.P. A /C Harness Wiring L IG H T T R U C K SE RV IC E M A N U A L...
Page 76 AIR CONDITIONING IB-27 LIG H T T R U C K SERVICE M A N U A L...
Page 77: Insufficient Cooling
IB-28 AIR CONDITIONING in the system. These possibilities should be checked INSUFFICIENT COOLING "QUICK-CHECK" prior to servicing the compressor. If the compressor is PROCEDURE inoperative, but is not seized, check to see if current is being supplied to the m agnetic clutch coil term inals. The following C C O T "H an d -F eel"...
Page 78: Evacuating And Charging Procedures
AIR CONDITIONING IB-29 system head pressure by partially blocking the con Sight Glass Diagnosis (Motor Home Chassis Units) denser. Disconnect the blower lead wire and repeat the At tem peratures higher than 70°F (21°C), the sight "perform ance check" to determ ine if the evaporator glass may indicate w heter the refrigerant charge is suffi...
Page 79 IB-30 AIR CONDITIONING For A-6 & R-4 Com pressor System s - Condenser - 30 ml (1 oz.). For R -4 C om pressor S ystem only - A ccu m u lato r (D rain oil, m easure, replace sam e am ount plus 30 ml- 1 oz.).
Page 80 AIR CONDITIONING IB-31 A L W A Y S D IS C H A R G E SY ST E M AT LO W SID E C harging Station or the J-5725-04 M anifold and Gage Set S E R V IC E F IT T IN G . and 420 ml (14 oz.) disposable cans of R - 12.
Page 81 IB-32 AIR CONDITIONING CLOSE A L L CO NTRO LS J 23500-01 S E R V IC E C H A R G IN G S T A T IO N F U L L Y OPEN GAUGE SET V A C U U M V A L V E CONNECT LOW-SIDE GAUGE HOSE TO LOW-SIDE PRESSURE S ERVICE F IT T IN G ON V E H IC L E 'S...
Page 82 AIR CONDITIONING IB-33 Prior to Evacuation, check the low pressure gage for proper calibration. W ith the gage disconnected from the refrigeration system, be sure th at the pointer indicates to the center of " O " . Lightly tap gage a few tim es to be sure pointer is not sticking.
Page 83 IB-34 AIR CONDITIONING J5725-04 MANIFOLD GAUGE SET TH,S HIGH PRESSURE VALVE IS OPEN AND VACUUM PUMP LINE USING J-5420 DISCONNECTED ONLY DURING OPEN DURING EVACUATION ADAPTER EVACUATION AND CHARGING THIS HIGH PRESSURE VALVE IS CLOSED AND LINE DISCONNECTED HIGH DURING DISCHARGING SIDE AND CHARGING VALVE...
Page 84: Compressor
AIR CONDITIONING IB-35 2. The expansion tube (orifice) screen is plugged. 2. W ith the R efrig eran t-12 drum or 420 ml (14 oz.) can(s) inverted, open R-12 source valve(s) and allow 3. The compressor inlet screen is plugged. 480 ml (1 lb.) or 1 to 2, 420 ml (14 oz.) can(s) of liquid 4.
Page 85 IB-36 AIR CONDITIONING 3 0 5 - 3 5 0 V -8 C-K M O D E L S l t r ^ 3 0 5 - 3 5 0 V -8 M O D E L S A N D M O T O R H O M E C H A SS IS 4 5 4 V -8 C- M O D E L S 4 5 4 V - 8...
Page 86 AIR CONDITIONING IB-37 Installation reinstallation. If it is necessary to service the entire 1. If oil previously drained from the compressor upon system because of excessive contam ination in the oil removal shows no evidence of contam ination, replace a removed, install a full charge of fresh refrigeration oil like am ount of fresh refrigeration oil into the com pres...
Page 87: Accumulator - All
IB -38 AIR CONDITIONING C60 SYSTEM--C-K SERIES CONDENSER - C-K SERIES (FIG. IB-27) Replacement (Fig. IB-27) 1. Disconnect battery ground cable. 2. D ischarge system. 3. Remove the grille assembly. 4. Remove the rad iato r grille center support. 5. Remove the left grille support to upper fender support (2) screws.
Page 88 AIR CONDITIONING IB-39 LIG H T T R U C K SERVICE M A N U A L...
Page 89: Selector D Uct And H Eater C O Re
IB-40 AIR CONDITIONING UPPER CENTER DISTRIBUTOR DUCT RIGHT HAND OUTLETS LEFT DISTRIBUTOR DUCT AND FOOT COOLER LOWER CENTER DISTRIBUTOR DUCT Fig. lB-30--Air Selector and Ducts (C-K Series) remove the selector duct assembly. SELECTOR DUCT AND HEATER CORE ASSEMBLY- 10. Remove the core m ounting strap screws and remove the core.
Page 90: Control Assembly
AIR CONDITIONING IB-41 4. Remove the control to instrum ent panel screws and lower the control far enough to gain access to the control assembly. Be careful not to kink the bowden cable. 5. Disconnect the bowden cable, vacuum harness and electrical harness at the control.
Page 91: V A C U U M Tank
IB-42 AIR CONDITIONING GR A Y-TO PLENUM VALVE V A C U U M TANK O R A N G E C A M LEVER CABLE V IE W RECIRC. AIR DEFROSTER BLUE HEATER ASSEMBLY A CTUA TO R C O N TR O L N O COLOR STRIPE ACTUA TO R V IE W...
Page 92: Blower Motor Resistor
AIR CONDITIONING IB-43 A /C HARNESS ASM PRESSURE C Y C L IN G SWITCH BLOW ER RESISTOR BLOW ER R E L A Y A C C U M U LA T O R BLOW ER ASM G R O U N D E V A P O R A TO R BLOW ER ASM V IE W A...
Page 93: Expansion Valve
IB-44 AIR CONDITIONING Fig. 1 B-37--Overhead System Front W iring (C-K Models) Fig. 1 B-38--Blower-Evaporator (C-K Overhead Fig. 1 B-39--Blower M otor (C-K Overhead System) System) Removal NOTICE: R o tate the blower wheels to m ake sure th at 1.
Page 94: Evaporator C Ore
AIR CONDITIONING IB-45 Install the sensing bulb to the evaporator outlet line as 7. Disconnect the valve inlet and outlet lines and remove shown in Fig. IB-44; m ake sure the bulb has good the expansion valve assembly. C ap or plug the open contact with the line.
Page 95: Condenser
IB-46 AIR CONDITIONING 5. Remove left floor outlet deflector and bracket. C60 SYSTEM-G SERIES 6. Loosen steering column to instrum ent panel reinforce CONDENSER - G Series m ent screws. Remove one screw. T orque both screws on installation. Replacement (Fig. IB-42) 7.
Page 96: Evaporator Core
AIR CONDITIONING IB-47 Fig. 1 B-43--Heater Distributor Duct-G Series Fig. 1 B-45--Heater Distributor Duct Fig. 1 B-44--Recirculating Air Door Vacuum Actuator bead of sealer to the entire circum ference of the EVAPORATOR CORE m ounting flange, Replacement (Fig. IB-54) c. C heck blower operations: blower wheel should rotate 1.
Page 97: T Em Perature Door C Able
IB-48 AIR CONDITIONING 2. Remove the headlam p switch control knob. 3. Remove the instrum ent panel bezel. 4. Remove the control to in stru m en t panel attach in g screws. 5. Remove the tem perature cable eyelet clip and m ount ing tab screw.
Page 98 AIR CONDITIONING IB-49 Fig. lB-47--Air Deflector Outlets (G Series-C60 System) L IG H T T R U C K SERVICE M A N U A L...
Page 99 IB-50 AIR CONDITIONING Fig. 1 B-52--Vacuum Harness (G Series) Fig. 1 B-53--Condenser Installation-G Series L IG H T T R U C K SE R V IC E M A N U A L...
Page 100 AIR CONDITIONING IB-51 Fig. 1 B-54--Evaporator Blower Assembly-G Series LIG H T TR U C K SERVICE M A N U A L...
Page 101 IB-52 AIR CONDITIONING COMPRESSOR COMPRESSOR ASSEMBLY R IN G HOSE & TUBE ASSEMBLY C O N D . OUTLET A C C U M DEHYDR ASSEMBLY OUTLET PIPE G MOD. V8 ENG. C60/69 HOSE & TUBE ASSEMBLY G MOD. LE 3 ENG. EVAP.
Page 102: Circuit Breaker
AIR CONDITIONING IB-53 Fig. 1 B-56--Refrigerant Lines-Condenser Inlet 6 Cyl Engine TEMPERATURE DOOR CABLE Tem perature cable attachm ent and routing is shown in Fig. IB-65. VACUUM TANK - G SERIES (Fig. IB -60 & IB-61) Replacement 1. Raise the hood. 2.
Page 103 IB-54 AIR CONDITIONING LIG H T T R U C K SERVIC E M A N U A L...
Page 104 AIR CONDITIONING IB-55 LIG H T T R U C K SERVICE M A N U A L...
Page 105: Condenser
IB-56 AIR CONDITIONING Fig. 1 B-64--Defroster Duct-G Series DASH MOUNTED SYSTEM-MOTOR HOME CHASSIS This system is installed on the vehicle and checked at CONDENSER assembly. The blow er-evaporator is then disconnected and shipped with the chassis unit to the body supplier. For this Replacement (Fig.
Page 106: Receiver-Dehydrator
AIR CONDITIONING IB-57 Fig. 1 B-66--Condenser (Motor Home Chasis Unit) Unit) 3. Disconnect the condenser inlet and outlet lines and cap 2. Remove the sight glass retainer nut using a screwdriver or plug all open connections at once. and remove old glass and " O " ring seal. 4.
Page 107 IB-58 AIR CONDITIONING Fig. lB-68--Sight Glass Replacement TERMINAL SCREW DRIVER (NARROW BLADE) CONNECTOR TANG GROOVE A. Insert screw driver in groove & press tang toward terminal to release. B. Pry tang back out to insure locking when reinstalled into connector. Fig.
Page 108: Thermostatic And/Or Blower Switches
AIR CONDITIONING IB-59 THERMOSTATIC SWITCH AIR SENSING CAPILLARY CORRECT BLOWER Fig. 1 B-73--Thermostatic and Blower Switches BLADE ANGLE 3. Remove evaporator core retaining screws and remove core. 4. R e m o v e b lo w e r m o to r a n d h a rn e s s a s s e m b ly fr o m case. Fig.
Page 109: Specifications
IB-60 AIR CONDITIONING SPECIFICATIONS A IR C O N D IT IO N IN G Compressor T y p e ......... 4 Cylinder Radial Displacement ......1 2 .6 Cu. In. 6 Cylinder Axial • ....... 1 0 .0 C u .ln . 4 Cylinder Radial •...
Page 110: Special Tools
AIR CONDITIONING IB-61 SPECIAL TOOLS 1. J-25030 Clutch Hub Holding Tool 2. J-25029 Rotor Bearing Remover and Rotor Assy. Installer 3. J-24895 M ain Bearing Installer 4. J-24896 M ain Bearing Remover 5. J-25031-2 Rotor and Bearing Puller 6. J-25031-1 Rotor and Bearing Puller G uide 7.
Page 111 IB-62 AIR CONDITIONING SPECIAL TOOLS Pulley B earing Remover 11. J -5 4 2 1 -0 2 Pocket Thermometers (2) 22. J-93 9 8 1. J -8 3 9 3 C h a rg in g Station Pulley a nd B earing In sta ller 23.
Page 112 FRAME 2A-1 SECTION 2A FRAME CONTENTS G eneral Description ..................2A-1 On Vehicle S ervice................... .2A-1 M aintenance and Inspection................ .2A-1 U nderbody In sp ectio n................. .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................
Page 113 2A-2 FRAME Error will result if a tram bar is not level and centered Vertical Check at the reference points. Vertical 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.
Page 114 FRAME 2A-3 Model CA107 13-3/8 15-1/4 19-7/8 14-7/8 17-3/4 17-3/4 19-7/8 16-3/4 15-5/8 17 3/4 68-1/2 76-1/2 16-7/8 16-7/8 CA109 13-3/8 15-1/4 19-7/8 12 14-7/8 17-3/4 17-3/4 19-7/8 16-3/4 15-5/8 17-3/4 69-5/8 86-1/2 16-7/8 16-7/8 CA209 13-3/8 15-1/4 19-7/8 12 17-3/4 14-7/8 17-3/4...
Page 115 2A-4 FRAME Fig. 2A-4--G Van Truck Reference Dimensions 2. The vertical dimension from the datum line to the Bolting 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 m ust be as near the O.D.
Page 116 BUMPERS 2B-1 SECTION 2B BUMPERS NOTICE: Fasteners are im portant attaching parts in lesser quality or substitute design. Torque valves must th a t they could affect the perform ance of vital compo be used as specified during reassembly to assure proper nents and systems, an d /o r could result in m ajor repair retention of these parts.
Page 117 2B-2 BUMPERS 4. If necessary, replace body splash shield. Removal Fig. 2B-5, 2B-6 1. Remove nuts securing bum pers to brackets and braces Installation from left and right side. Remove bum per. 2. If necessary to remove the braces and brackets, remove Install rear bum per following removal procedure in screws securing brackets and braces to sheet metal.
Page 118 BUMPERS 2B-3 SPECIFICATIONS TORQUE SPECIFICATIONS C, P AND K Front Bumper ............35 ft.-lbs. Front Bumper Bracket and Brace ......70 ft.-lbs. Rear Bumper to Outer Bracket ......35 ft.-lbs. Rear Bumper Outer Bracket and Brace ....50 ft.-lbs. License Plate Bracket..........18 ft.-lbs. Gravel Deflector ...........85 in.-lbs.
Page 120 CHASSIS SHEET METAL 2C-1 SECTION 2C CHASSIS SHEET METAL N O TIC E Fasteners are im portant attaching parts in th at they could affect the perform ance of vital components and systems, an d /o r could result in m ajor repair expense. They m ust be replaced with one of the same part num ber or with an equivalent part if replacem ent becomes necessary.
Page 121: Hood H In G
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 Mechanism The hood latch assembly and bracket are mounted to the R adiator Support. Elongated holes in the bracket are provided for alignm ent purposes.
Page 122 CHASSIS SHEET METAL 2C-3 m ounted strik er plate, preventing upw ard or dow nw ard m ovem ent of the hood while the vehicle is in m otion. Integral with the strik er plate is the com bination lock release lever and safety catch.
Page 123: Hood Bumper
2C-4 CHASSIS SHEET METAL HOOD EMBLEM - CK MODELS (FIG. 2C-9) Hood Bumper Adjust hood bumpers so that hood top surface is flush with the fender and grille top surfaces. Hood Assembly-G Model (Fig. 2C-7) Removal 1. Lay a fender cover along cowl top to prevent hood from scratching painted surfaces.
Page 124 CHASSIS SHEET METAL 2C-5 FENDER ASSEMBLY TIE BAR ASSEMBLY Fig. 2C-10--Hood Rod Support - G Model GRILLE MOLDING - CK, G MODELS (FIG. 2C-14) FRONT SHEET METAL ASSEMBLY-CK SERIES LOWER RADIATOR GRILLE - G MODEL (FIG. 2C- Removal of entire front sheet metal assembly including rad iato r involves disassembly of mounts, disconnecting ra d iato r hoses and removal of front bumper.
Page 125 2C-6 CHASSIS SHEET METAL Fig. 2C-11--Typical Carburetor Air Inlet Snorkel - CK Model Fig. 2C-13--Grille Panel or Brackets Refer to ap prop riate sections of this m anual for instructions. Shims which are found at various locations should be recorded to ease installation of sheet metal assembly. Removal - /!- * , ■...
Page 126: Radiator Support
CHASSIS SHEET METAL 2C-7 6. Remove bolts attaching fender upper edge to cowl door frame. 7. Remove fan shroud. 8. W orking from u n de rne a th rear of fender, remove attachm ent from each fender at the hinge pillar. 9.
Page 127: Front Fender
2C-8 CHASSIS SHEET METAL 11. Install both head lamp assemblies. 12. Tighten all previously installed bolts and screws. 13. Install battery and connect leads and wires. 14. Install grille assembly. 15. Fill radiator with coolant as specified in Section 13. FRONT FENDER (FIG.
Page 128: Wood G Rain Applique Installation Procedure
CHASSIS SHEET METAL 2C-9 Although adhesive cures enought to retain molding Molding Completely Removed after 15 minutes, total cure time is 24 hours. C ar should This method is valid only for moldings attached with not be exposed to high pressure car washes, etc., for a adhesive foam tape.
Page 129 2C-10 CHASSIS SHEET METAL 4. While entire area is still wet with solution, remove paper backing from transfer and align upper edge with pierced holes in fender and press on lightly. 5. Start at center of transfer and squeeze outboard from middle to edges removing all air bubbles and wetting solution to assure a satisfactory bond.
Page 130 CHASSIS SHEET METAL 2C -11 12. Best results are obtained when metal temperature is 1. If the tape is ruined with no paint being removed, the 70°90°F (21°32°C). Use heat gun or allow cooling time surface should be wiped with a prep-sol to insure a when metal is outside approximate temperature range.
Page 132 BODY 2D-1 SECTION 2D CAB AND BODY N OTICE Fasteners are important attaching parts in that they could affect the performance of vital components and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary.
Page 133 2D-2 BODY Fig. 2D-3--Typical Suburban Model LIG H T T R U C K SERVIC E M A N U A L...
Page 134 BODY 2D-3 Fig. 2D-5--Typical Vans and Sport Vans Models LIG H T T R U C K SERVICE M AN U AL...
Page 135 2D-4 BODY ON VEHICLE SERVICE C-K MODELS INDEX Front End H inges................2D-16 Windshield W ip e rs............2D-4 Stationary G la s s ............2D-16 Glove B o x ................ .2D-5 Window and R egu lato r..........2D-17 Rear View M irro rs............2D-5 Locks, Handles, Rods..........
Page 136 BODY 2D-5 INSTRUMENT PANEL COMPARTMENT AND LOCK Replacement Removal of the entire assembly including door may be accomplished by removing four screws which attach hinge just below box. See figure 2D-8. The outer door panel may be removed, leaving the compartment intact, by removal of four screws.
Page 137 2D-6 BODY BODY GLASS CAUTION:A!ways wear gloves and eye glasses To replace a window installed with urethane adhesive when handling glass to avoid personal injury. requires replacement of the adhesive material. Adhesive service kits No. 1052420 and No. 9631000 contain some of the materials needed to remove and replace a urethane adhesive installed glass.
Page 138 BODY 2D-7 Additional Material Required: 1. Rubber lubricant No. 1051717 (available through the service parts system). 2. Alcohol for cleaning edge of glass. 3. Adhesive dispensing gun No. J-24811 or a standard household cartridge type gun reworked as follows: a. Widen end slot to accept dispensing end of adhesive material tube.
Page 139 2D-8 BODY maximum), then wipe both channels with a clean dry cloth. 4. Apply rubber primer to both channels of rubber weatherstrip that were cleaned in the previous step and are shown in View A. Allow primer to cure for at least 30 minutes (30 day maximum).
Page 140 BODY 2D-9 Fig. 2D-18--Windshield Installation-CK Truck LIG H T T R U C K SE RV IC E M AN U AL...
Page 141 2D-10 BODY Fig. 2D-19— Installing Reveal Molding Fig. 2D-20--Back Window Glass BODY SIDE DOORS .19 inch clearance at the top and side edges, and .25 inch DOOR ADJUSTMENTS clearance at the bottom. The door should be adjusted in the Doors can be adjusted for alignment of clearance in the opening so the edge of the door across the top and also at the cab door opening, and for proper latching.
Page 142 BODY 2D-11 Hinge Adjustment Door hinge bolt holes are oversized to make adjustment possible. Alignment adjustments can be made by loosening the proper hinge bolts, aligning door to proper position, and tightening bolts securely (fig. 2D-22). Striker Bolt Adjustment W ith the use of J-23457, shown in figure 2D-23, the striker bolt can be adjusted in any of three ways.
Page 143 2D-12 BODY 3. Remove arm rest screws and trim panel. See figure 2D- 5. Remove (1) screw at door handle cover plate and (1) screw located under arm rest pad. 4. Remove screws attaching ventilator lower assembly to 6. If equipped assist strap, remove (2) screws retaining door panel.
Page 144 BODY 2D-13 BEND TAB OVER HEX NUT Fig. 2D-29--Removing Ventilator Assembly Fig. 2D-31--Bend Tabs Over Hex Nut Adjustment which will fit in the channel. The extra filler extending beyond the rear edge of the glass should be pinched 1. Adjust the ventilator by placing wrench on adjusting together to hold it in place during glass installation.
Page 145 2D-14 BODY NO TCH SASH CHANNEL; Fig. 2D-32--Door W indow and Regulator WINDOW REGULATOR - POWER - CK MODELS Fig. 2D-34--Power W indow Switch, Relay and In the case th a t window will not operate, check Breaker Assembly electrical connections first. Figure 2D-34 illustrates location A notch is provided in the sash channel to allow of junctions, switch, relay and circuit breaker.
Page 146 BODY 2D-15 sheet metal tapping screw (No. 10 - 12 x 3/4) in drilled Door Outside Handle— Fig. 2D-37 hole to lock sector gear in position. Replacement 10. Remove motor to regulator attaching screws. 1. Raise window to full up position. 11.
Page 147 2D-16 BODY 4. Remove screws attaching motor to door inner panel. 3. Remove side door inner weatherstrip seal. 4. Starting at the bottom center of the door opening, 5. Remove door lock lever from rubber mount at top of install seal on welded flange. motor actuator and remove motor through access hole.
Page 148 BODY 2D-17 WINDOW GLASS-FIG. 2D-46 Replacement 3. Remove screws retaining door trim pad, and remove 1. Lower glass to full down position. trim pad. See figure 2D-43. 2. Remove remote control push botton knob, window 4. Remove glass run channel by removing screws retain regulator handle and trim pad.
Page 149 2D-18 BODY WINDOW REGULATOR ASSEMBLY-FIG. 2D-46 Remote Control— Fig. 2D-48 Replacement Replacement 1. Remove regulator handle, remote control knob and 1. Remove trim pad, stationary glass, and window glass as trim pad. outlined earlier. 2. Disconnect remote control lower rod from door lock 2.
Page 150 BODY 2D-19 5. Replace by reversing above procedure. LOCKS, HANDLES AND RODS The rear door lock, outside handle, lock cylinder, control rods and latch are shown in figures 2D-51 and 2D- WEATHERSTRIP-FIG. 2D-50 52. The rods can be disconnected from the lock, latch or The procedure outlined in Front Door Weatherstrip handle by disengaging the retaining clips, as shown.
Page 151 2D-20 BODY Fig. 2D-52--Rear Door Outside Handle and Lock Cylinder Fig. 2D-53--Rear Door Check Strap LIG H T T R U C K SE RV IC E M A N U A L...
Page 152 BODY 2D-21 Fig. 2D-54--Wedge and Striker Adjustments -(Suburban) AND UTILITY MODELS ENDGATES SUBURBAN 5. Lift endgate to almost closed position and remove Suburban and utility models use endgates of similar, support cables. yet distinct design. Separate procedures follow for service on each of these endgates.
Page 153 2D-22 BODY CAUTION:Step 10 must be performed if the window is removed or disengaged from the regulator lift arms. The lift arms are under tension from the counter-balance spring, and can cause injury if the motor is removed without locking the sector gears in position.
Page 154 BODY 2D-23 Fig. 2D-63--Pulling Hinge Away From Body (Utility) HINGE Replacement 1. Lower endgate and disconnect hinge to be replaced by removing hinge-to-body bolts. See figure 2D-62. 2. At the other hinge, loosen the hinge-to-body bolts. 3. On the hinge to be replaced, remove the hinge-to- endgate bolts.
Page 155 2D-24 BODY Fig. 2D-65--Removing Access Cover (Utility) Fig. 2D-67--Removing Torque Rod (Utility) TORQUE ROD 2. Disconnect side latch remote control rods from center control by removing retaining clips. See figure 2D-68. Replacement 3. Remove four screws from each side latch, and with 1.
Page 156 BODY 2D-25 Fig. 2D-69--Removing Side Latch Fig. 2D-71 -Removing Control Assembly ancHnside Handle BLOCKOUT INSIDE HANDLE BRACKET CONTROL ROD CONTROL ASSEMBLY Fig. 2D-70--Control Assembly and Blockout Rod Fig. 2D-72--Window and Regulator 13. Remove glass from endgate. 14. Remove four regulator attaching screws and withdraw regulator from endgate as shown in figure 2D-74.
Page 157 2D-26 BODY Fig. 2D-74--Removing Regulator Motor (Fig. 2D-76) Removal 1. D is c o n n e c t d riv e c a b le fr o m m o tor. 2. Disconnect wiring harness from motor. 3. Remove (3) motor attaching screws and remove motor. 4.
Page 158 BODY 2D-27 Remove endgate. 4. Reverse procedure for installation. Align slot in tru n nion to coincide with hole in endgate to permit using a tool to hold trunnion while tightening nut. REMOVABLE TOP-FOLDING TOP-UTILITY MODELS Removal 1. Remove access and disconnect courtesy light. 2.
Page 159 2D-28 BODY ** V f> UNSNAP AND REMOVE COVER BOOT AND STORE IN VEHICLE Fig. 2D-79--Folding Top Assembly L IG H T T R U C K SE RV IC E M A N U A L...
Page 160: Seat Belts
BODY 2D-29 SEATS SEAT BELTS SERVICING LAP AND SHOULDER BELTS - ALL MODELS Before servicing or replacing lap and shoulder belts, including single loop belt systems, refer to the following precautionary items: 1. Lap and shoulder belts will be serviced as follows: a.
Page 161 2D-30 BODY Fig. 2D-82--Seat Belt Installation (Suburban) Passenger and Driver Seat (Suburban) L IG H T T R U C K SERVICE M A N U A L...
Page 162 BODY 2D-31 Fig. 2D-85--Passenger's Bucket Seat (Chassis Cab) LIG H T TR U C K SERVICE M A N U A L...
Page 163 2D-32 BODY Fig. 2D-88--Rear Bench Seats (Suburban) LIG H T T R U C K SERVIC E M A N U A L...
Page 164 BODY 2D-33 Fig. 2D-89--CK Utility Seat Attachments LIG H T T R U C K SERVICE M A N U A L...
Page 165 2D-34 BODY BODY MOUNTING 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 attachments such as steering column, brake pipes, etc., during replacement of body mounts.
Page 166 BODY 2D-35 C-30 Fig. 2D-91--Body Mounting (Chassis Cab) Fig. 2D-92--Body Mounting (Crew Cab) LIG H T T R U C K SERVICE M AN U AL...
Page 167 2D-36 BODY Fig. 2D-94--Body Mounting (Utility) LIG H T T R U C K SE RV IC E M A N U A L...
Page 168 BODY 2D-37 G MODELS INDEX Description............... 2D-48 Front End A djustm ents..............2D-48 Windshield W ipers............2D-37 Front L atch ..............2D-52 Cowl Ventilator Grille........... 2D-38 Rear L a tc h ..............2D-53 Side Ventilator V alve............ 2D-38 Upper Rear Hinge............2D-53 R ear View M i r r o r ............
Page 169 2D-38 BODY Fig. 2D-96--Windshield W iper Linkage Fig. 2D-97~Cowl Ventilator Grille COWL VENTILATOR GRILLE REAR VIEW MIRRORS Replacement Inside R ear V ie w M irro r 1. Remove windshield wiper arms. 2. Remove screws retaining grille, figure 2D-97. Replacement 3.
Page 170 BODY 2D-39 Fig. 2D-l(X)--Outside Rear View Mirrors BODY GLASS CAUTION:Always wear gloves and eye glasses obstruction is increased by such conditions as wind pres- when handling glass to avoid personal injury. sures, extremes of temperature, motion of the vehicle, etc. Removal WINDSHIELD GLASS There are two methods of windshield installation.
Page 171 2D-40 BODY The reveal moldings can be removed from the urethane Adhesive Service Kit or Cartridge adhesive by taking one end of the molding and pulling it Material listed have a short shelf life. Be sure materials away from the adhesive. The support molding is removed are fresh.
Page 172 BODY 2D-41 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. At the windshield opening, set the glass in a horizontal position. While one partner holds the glass in this position, the other can reach one Fig.
Page 173 2D-42 BODY Fig. 2D-105 Adhesive Material Application fully contacts the adhesive all around and that the gap is entirely covered by the crown of the molding. Slide molding caps into position between moldings connect ing them. Use tape to hold the molding down in the correct position against the body and glass until the adhesive cures.
Page 174 BODY 2D-43 ^A D H E S IV E TO WEATHERSTRIP AND PINCHWELD LATCH SWINGOUT WINDOW Replacement 1. Swing out the window. 2. Remove latch to body attaching screws. 3. Twist and pull latch to remove from glass. 4. Reverse above steps for installation. FRONT DOOR tightening bolts securely.
Page 175 2D-44 BODY an extra load will be placed on door hinges as well as 4. Torque bolts to specifications. pulling door downward and out of alignment. 5. Install hinge access hole covers. 2. In and Out-To adjust striker in and out, loosen bolt, adjust horizontally to match the door surface to the DOOR WEATHERSTRIP body surface, and tighten bolt securely.
Page 176 BODY 2D-45 1. R egu late the door window glass to the full down Ventilator Glass Replacement position. 1. Using an oil can or similar means, squirt prepsol on the 2. Remove door and window handles with Tool J-9886-01. glass filler all around the glass channel or frame to soften the old seal.
Page 177 2D-46 BODY 5. Push regulator out of door opening while holding rear of assembly, then slide assembly to the notches in the carrier channel and out through the door access hole. 6. Install regulator in reverse order of removal, lubricate regulator gears with lubriplate or equivalent.
Page 178 BODY 2D-47 Fig. 2D-117--Power W indow and Power Door Lock Wiring 8. Remove lock, push button rod and remote control rod as an assembly. R EM O TE Installation 1. Transfer remote rod with clip to new lock. 2. Connect remote door handle rod to lock after lock is positioned.
Page 179 2D-48 BODY POWER DOOR LOCKS The power door lock system incorporates a motor a c tu a to r in each door which actuates the lock through linkage (fig. 2D-120). See Figure 2D-117 for switches, relay and wire routing. Replacement 1.
Page 180 BODY 2D-49 W INDO W SWITCH AS S E M B LY DOOR LOCK SW ITCH REAR DOOR M OTO R ACTUATOR (DOOR LOCK) MOTOR (POWER W INDOW ) SW ITCH CONTACT (DOOR) SWITCH CO NTACT (PILLAR ) Fig. 2D-120--Power Door Lock Actuators, Power Window Motor, Wiring and Switches LIG H T T R U C K SERVIC E M A N U A L...
Page 181 2D-50 BODY STRIKER F O R E - A N D -A F T A D J U S T M E N T S L O T S C E N T E R ROLLER VERT ICA LLY IN T R A C K S O IT D O E S N O T C O N T A C T THE T R A C K -------- ^...
Page 182 BODY 2D-51 Up and Down Fore and Aft Up and down adjustments are provided by means of Fore and aft adjustment is provided at the upper rear slotted holes located at the upper front roller, view B of hinge striker by means of a slotted bracket mounted to the figure 2D-121;...
Page 183 2D-52 BODY 2. The lower lever must extend at least .10 inch (2.5mm) outb oard of the striker tang. Add or delete shims between the striker and the body as necessary. 3. If necessary to shim roller away from guide, shims are added between the nylon block and hinge and between roller and hinge.
Page 184 BODY 2D-53 Fig. 2D-127~Rear Track Cover A djust re ar latch strik er as outlined earlier under Fig. 2D-126--Sliding Door Rear Latch "A d justm ents". 6. A d ju st door front strik e r as outlined earlier under UPPER REAR HINGE "A d ju stm en ts".
Page 185 2D-54 BODY Screw Bolt Roller Bushing Guide Block Plate Lockwashers Hinge (Door Half) Hinge (Body Half) Upper lines Spring 11. Spacer Spring retainer Spring (Upper Lever) 19. Bushing 5. Washer Hinge liner Spring (Lower Level) 20. Bushing Bushing Lower Lever Bushing Fig.
Page 186 BODY 2D-55 STRIKERS The front and rear strikers are shown in figure 2D-121. The rear striker can be removed with J-23457 as in figure 2 D -1 11, and the front striker can be removed by removing a tta ch in g screws.
Page 187 2D-56 BODY 3. Remove lock cylinder retainer and lock cylinder. Installation 1. Install lock cylinder and retainer. 2. Install remote control. Torque screws to specifications. 3. Remove latch retaining screws and w ithdraw latch and 3. Install trim panel. control rod. 4.
Page 188 BODY 2D-57 Fig. 2D-133--Reor Door Striker and W edge Adjustment SEATS NOTICE: See N O T IC E on page 1 of this section regarding fasteners used on seats and seat belts. DRIVERS SEAT Seat Adjuster Replacement 1. Remove seat by removing nuts securing seat adjuster to seat riser.
Page 189 2D-58 BODY PASSENGER SEAT-MOUNTING BRACKETS Removal 1. Remove seat and brackets from seat riser. See figure 2D-135. 2. Remove brackets from seat. Installation 1. Install brackets to seat. T orque to specifications. 2. Install seat to seat riser. Torque to specifications. SEAT RISER Removal 1.
Page 191: Decal Applique Procedure (All V Ehicles)
2D-60 BODY REAR BENCH SEATS All models equipped with 2nd, 3rd and 4th bench seat assemblies feature a quick release m echanism which facili tates removal of the seats for added cargo space. Instead of the conventional clam p and bolt m ethod of seat reten tio n , cam type latch assem blies and hooked retainers, which fit onto anchor pins in floor anchor plates are used.
Page 192 BODY 2D-61 LIG H T T R U C K SERVICE M A N U A L...
Page 193: Specifications
2D-62 BODY SPECIFICATIONS FRONT END TAILGATE-FLEETSIDE Sunshade Support........18 in. lb. 2. N* m Trunnion Assembly........ 18 ft. lb. 24. N 'm Outside Rear View Mirror lo Door Panel Linkage and Striker Assembly- Base M irror........18 in. lb. 2. N 'm Support............
Page 194 BODY 2D-63 BODY MOUNTING (C-K MODELS) M O D E L 55 ft. lb. 55 ft. lb. CHASSIS C A B 75 N- m 75 N- m 55 ft. lb. 35 ft. lb. 55 ft. lb. C R E W CAB 75 N- m 48 N- m 75 N- m...
Page 195 2D-64 BODY SPECIAL TOOLS 1. J-2 25 85 Front Door Hinge, Bolt Wrench 2. J-22577 Windshield Checking Blocks 3. J-7797 Door Handle Clip Remover 4. J-23457 Door Striker Bolt Remover and Installer Fig. 2D-143--Special Tools LIG H T T R U C K SE RV IC E M AN U AL...
Page 196: General Description
FRONT ALIGNMENT 3A-1 SECTION 3A FRONT ALIGNMENT CONTENTS G eneral D escription....3A-1 M aintenance and A djustm ents 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 T he term "fro n t alig n m en t"...
Page 197 3A-2 FRONT ALIGNMENT (J. OF WHEEL DIRECTION CAMBER ANGLE CASTER ANGLE FRONT V IE W SIDE V IE W Fig. 3A-1--Caster - Camber - Toe-In MAINTENANCE AND ADJUSTMENTS 11. Consider the condition of the equipm ent being used to PRELIMINARY CHECKS PRIOR TO ADJUSTING check alignm ent and follow the m a n u fa c tu re r’s FRONT ALIGNMENT instructions.
Page 198 FRONT ALIGNMENT 3A-3 Caster G overnm ental Periodic M otor V ehicle Inspection program s usually include wheel alignm ent among items that All caster specifications are given assum ing a frame are inspected. To provide useful inform ation for such angle of zero.
Page 199 3A-4 FRONT ALIGNMENT Toe-In 1. D eterm ine the wheel toe-in from the alignm ent equipment. "B ” IS LESS THAN “ A ” W H E N WHEELS TOE-IN 2. Change the length of both tie rod sleeves to affect a toe change.
Page 200 FRONT ALIGNMENT 3A-5 SPECIFICATIONS WHEEL ALIGNMENT SPECIFICATIONS CASTER D IM E N S IO N " A " MODELS 2 1 / 2" 3 " 3 %" 3 1 / 2" 4 ” 4 1 / 2" 4% " 5 " 474"...
Page 202 STEERING LINKAGE 3B1-1 SECTION 3B1 STEERING LINKAGE T he following notice applies to one or more steps in the assembly procedure of components in this portion of the m anual as indicated at appropriate locations by the terminology "See N otice on page 1 of this Section ".
Page 203 3B1-2 STEERING LINKAGE CO N D ITIO N POSSIBLE C A U SE CO RRECTIO N Excessive Play or Looseness in Front wheel bearings loosely Adjust bearings to obtain proper Steering System. adjusted. end play. Worn steering shaft couplings. Replace part. Worn upper ball joints.
Page 204 STEERING LINKAGE 3B1-3 CO RRECTIO N CONDITIO N PO SSIBLE C A U SE Inflate to specified pressures. Low or uneven tire pressure. Hard Steering - Excessive Effort Required at Steering Wheel. Lube with specified lubricant. Steering linkage or bolt joints need lubrication.
Page 205: Maintenance And Adjustments
3B1-4 STEERING LINKAGE MAINTENANCE AND ADJUSTMENTS LUBRICATION LUBRICATION OF STEERING LINKAGE K-SERIES The steering linkage under norm al conditions should be E R I N G D A M P E R lubricated with any w ater resistant EP type chassis lubri cant every 7,500 miles (12 000 km) or six m onths, whichever occurs first.
Page 206 STEERING LINKAGE 3B1-5 RELAY ROD IDLER ARM TIE ROD ASSEMBLY ASSEMBLY l All clamps must be be tw ee n & c a u t i o n clear of dimples before torquing nut. KNUCKLE |~ B ~ | Exposed socket thread length must be STEERING GEAR equal within ±...
Page 207: On-Vehicle Service
3B1-6 STEERING LINKAGE ON-VEHICLE SERVICE NOTICE: See N O T IC E on page 1 of this section regarding all fasteners referred to in servicing steering linkage components. TIE RODS Removal 1. Raise vehicle on hoist. 2. Remove nuts from ball studs. The inner tie rod ends use crim p nuts, while the outer ends use castellated nuts and cotter pins.
Page 208 STEERING LINKAGE 3B1-7 NOTE S lo t in adjuster C A U TIO N Clam ps m ust be between sleeve m ust n o t be & clear o f d im ples before to rq u in g n u t. w itn in th is area o f cla m p jaws.
Page 209: Relay Rod
3B1-8 STEERING LINKAGE c. The relationship of the clam p slot with the slit in the Installation sleeve should be m aintained as shown in Figure 3B1- NOTICE: See the N O T IC E on page 1 of this section regarding the fasteners referred to in steps 2 and 3.
Page 210: Pitman Arm
STEERING LINKAGE 3B1-9 tapping on side of rod or arm (in which the stud It is also necessary th a t a scale or ruler be rested mounts) with a ham m er while using a heavy ham m er or against the fram e and used to determ ine the am ount of sim ilar tool as a backing.
Page 211 3B1-10 STEERING LINKAGE SPECIFICATIONS AND SPECIAL TOOLS R efer 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...
Page 212 MANUAL STEERING GEAR 3B2-1 SECTION 3B2 MANUAL STEERING GEAR The following notice applies to one or more steps in the assembly procedure of com ponents in this portion of the m anual as indicated at appropriate locations by the terminology "See N otice on page 1 of this S ection".
Page 213 3B2-2 MANUAL STEERING GEAR C O N D IT IO N P O S S IB L E C A U SE C O R R E C T IO N Rattle or Chuck in Steering Gear. Insufficient or improper lubricant Add lube specified.
Page 214 MANUAL STEERING GEAR 3B2-3 C O N D IT IO N P O S S IB L E C A U S E C O R R E C T IO N Front wheel bearings loosely Excessive Play or Looseness in Adjust to obtain proper end play.
Page 215: Maintenance And Adjustments
3B2-4 MANUAL STEERING GEAR MAINTENANCE AND ADJUSTMENTS 6. Turn the steering wheel gently in one direction until LUBRICATION OF MANUAL STEERING GEAR stopped by the gear; then turn back one-half turn. The m anual steering gear is factory-filled with steering gear lubricant.
Page 216 MANUAL STEERING GEAR 3B2-5 improper adjustm ent; the gear m ust be disassembled 11. Install the horn button cap or shroud and connect the battery ground cable. and inspected for replacem ent of dam aged parts. 12. Lower the vehicle to the floor. 9.
Page 217 3B2-6 MANUAL STEERING GEAR 4. Remove the steering gear to fram e bolts and remove 3. Install the pitm an arm onto the pitm an shaft, lining up the gear assembly. the m arks made at removal. Install the pitm an shaft nut or pitm an pinch bolt and torque to...
Page 218 MANUAL STEERING GEAR 3B2-7 10. Install the side cover bolts and torque to specifications. 6. Place the pitm an shaft in the steering gear such th at the center tooth of the pitm an shaft sector enters the center 11. Install the lash adjuster screw locknut, perform steerin tooth space of the ball nut.
Page 220: Power Steering System
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 m anual as indicated at appropriate locations by the term inology "See N otice on page 1 of this S ection".
Page 221 3B3-2 POWER STEERING SYSTEM POWER STEERING PUMP 1. DRIVE SHAFT 13. RING, Shaft Retainer 2 SEAL 14. VANE KIT, Rotor 3 SEAL, Reservoir "O " Ring 15. RING KIT, Pump Rotor 4. HOUSING ASSEM BLY 16. PLATE, Pressure 5 . SEAL 17.
Page 222 POWER STEERING SYSTEM 3B3-3 CONDITION POSSIBLE CAUSE CORRECTION S Y 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. Adjust belt tension to specification.
Page 223 3B3-4 POWER STEERING SYSTEM CONDITION POSSIBLE CAUSE CORRECTION Pump growl Scored pump pressure plates, thrust Replace affected parts, flush system. Note: Most noticeable at full plate or rotor. wheel travel and stand still parking Extreme wear of pump cam ring. Replace affected parts.
Page 224 POWER STEERING SYSTEM 3B3-5 CONDITION POSSIBLE CAUSE CORRECTION Poor return of steering. (Cont’d.) Steering gear adjustments over Check adjustment with pitman arm specifications. disconnected. Readjust if necessary. Sticky or plugged valve spool. Remove and clean or replace valve. ■ Rubber spacer binding in shift tube. Make certain spacer is properly seated.
Page 225 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 jo in ts. intervals. Tires not properly inflated. Inflate to recommended pressure. Steering gear to column misalignment. Align steering column.
Page 226 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.
Page 227 3B3-8 POWER STEERING SYSTEM A. W ith the vehicle’s engine off, wipe the com plete power POWER STEERING SYSTEM EXTERNAL LEAKAGE steering system (g ear, pum p, hoses, G en eral Procedure connections). 1. W ipe suspected area dry. B. Check oil level in p u m p ’s reservoir and ad ju st as directed in m aintenance section.
Page 228 POWER STEERING SYSTEM 3B3-9 GEAR A N D PUMP LEAK DIAGNOSIS ST A R T E N G IN E A N D TU RN S T E E R IN G WHEEL F R O M S T O P TO ST O P S E V E R A L T IM E S .
Page 229: D Iagnosis
3B3-10 POWER STEERING SYSTEM MAINTENANCE AND ADJUSTMENTS 2. W ith front wheels set straight ahead, check position of LUBRICATION OF POWER STEERING PUMP m ark on w orm shaft designating steering gear high point. This m ark should be at the top side of the shaft at Check the fluid level in the pump reservoir according to 12 o’clock position and lined up with the m ark in the the intervals listed in Section OB.
Page 230 POWER STEERING SYSTEM 3B3-11 m aintained approxim ately 1/2 to 1 inch from top with HYDRAULIC SYSTEM CHECKS wheels in full left turn position. The following procedure outlines methods to identify 2. Fill, if necessary, to proper level w ith G M Power and isolate power steering hydraulic circuit difficulties.
Page 231: On-Vehicle Service
3B3-12 POWER STEERING SYSTEM 6. Close gate valve fully 3 times. Record the highest c. If the pressures recorded are constant, but more than pressures attained each time. 100 PSI, below the low listed spec., replace the flow 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.
Page 232: Power Steering Pump
POWER STEERING SYSTEM 3B3-13 POWER STEERING PUMP (3B3-15 THROUGH P Models 3B3-26) a. Place the steering gear in position, guiding the stub shaft into the universal joint assembly and lining up Removal the m arks m ade at removal. If a new gear was 1.
Page 233 3B3-14 POWER STEERING SYSTEM Fig. 3 B 3 -1 7 --P /S Pump M o un tin g; C K 1 0 0 , C K 2 0 0 , Fig. 3 B 3 -2 0 --P /S Pump m ounting; C K 1 0 0 (03) with C K 3 0 0 - LE4, LG 9, LS9, LT9 (Exc.
Page 234: Power Steering Hoses
POWER STEERING SYSTEM 3B3-15 Fig. 3 B 3 -2 3 --P /S Pump M o u n tin g; P200, P300 (42) Fig. 3 B 3 -2 6 --P /S Pump M o un tin g; P300 (32) with LE8 with L25 Engine Engine POWER STEERING HOSES...
Page 235 3B3-16 POWER STEERING SYSTEM Fig. 3 B 3 - 2 7 - P / S Hose Routing; C K 1 0 0, C K 2 0 0 (03) with LE3 Engine with LE8 Engine L25 Engine Fig. 3 B 3 - 2 9 - P / S Hose Routing; C K 1 0 0 , C K 200, C K 300 - LE4, LG9, LS9, LT9 (Exc.
Page 236 POWER STEERING SYSTEM 3B3-17 Fig. 3 B 3 -3 3 --P /S Hose Routing; C K 100 (03) with LF9 with LE3 Engine Engine, a n d JB3, JB5 LE4, LG9, LF4, LS9, LT9 and JB7 (Exc. H C 4 ) and JB8 L IG H T T R U C K SERVICE M AN U AL...
Page 237 3B3-18 POWER STEERING SYSTEM Fig. 3 B 3 - 3 9 - P / S Hose Routing; P200, P300 (42) with Fig. 3 B 3 -4 1 --P /S Hose Routing; P 300 (32) with LT9 L25 Engine an d JB7 Engine Fig.
Page 238 S T E E R I N G C O L U M N S 3 B 4 - 1 SECTION 3B4 STEERING COLUMNS The following notice applies to one or m ore steps in the assembly procedure o f com ponents in this portion o f the m anual as indicated at appropriate locations by the term inology "See N otice on page 1 of this Section".
Page 239 3 B 4 - 2 S T E E R I N G C O L U M N S Fig. 3 B 4 -1 ~ Ste e rin g Colu m n DIAGNOSIS GENERAL INFORMATION STEERING COLUMN ELECTRICAL ANALYZER J-23980 This section contains diagnostic inform ation to help locate the cause of the problem in the colum n.
Page 240 S T E E R I N G C O L U M N S 3 B 4 - 3 COLUMN JACKET T U R N ", "R IG H T T U R N ", "K E Y B U Z Z E R ", and "H A Z A R D ".
Page 241 3 B 4 - 4 S T E E R I N G C O L U M N S SU RFA CE “A’ Instrument Panel Bracket Capsule Damage NO TE: The bolt head m ust not co n tact surface “ A” . If co n tact is m ade, the capsule shear load will be increased.
Page 242 S T E E R I N G C O L U M N S 3 B 4 - 5 LOCK SYSTEM HIGH EFFORT (CONT'D.) Cause Solution Replace rack. H. D is to r te d c o u p lin g slo t in r a c k ( tilt) . Bent or restricted actu ato r rod.
Page 243 3 B 4 - 6 S T E E R I N G C O L U M N S IGNITION SYSTEM - ELECTRICAL SYSTEM - WILL NOT FUNCTION (CONT'D.) Cause Solution D. Replace ignition sw itch. D. Defective ignition sw itch. E.
Page 244 S T E E R I N G C O L U M N S 3 B 4 - 7 HIGH STEERING SHAFT EFFORT Cause Solution A. Colum n assem bly m isaligned in vehicle. A. Realign. B. Im properly installed or deform ed dust seal. B.
Page 245 3 B 4 - 8 S T E E R I N G C O L U M N S M A N U A L T R A N S M IS S IO N C O L U M N S G E N E R A L INFORMATION All of the preceding diagnosis information for autom atic transmission will apply to the manual transmission.
Page 246 S T E E R I N G C O L U M N S 3 B 4 - 9 TILT COLUMNS GENERAL INFORMATION All of the preceding diagnosis will generally apply to tilt columns. The following is supplied in addition to and specifically for tilt columns.
Page 247 3 B 4 - 1 0 S T E E R I N G C O L U M N S Fig. 3 B 4 -1 0 -C h e c k in g H arm onica Connector on Column lamps light when hazard w arning is depressed, but flashing does not occur, replace h azard warning flasher.
Page 248 S T E E R I N G C O L U M N S 3 B 4 - 1 1 2. Check the retu rn from lane change by holding the lever in lane change and releasing (both left and right). If the lever does not return to neutral, disassemble the upper part of the column.
Page 249 3 B 4 - 1 2 S T E E R I N G C O L U M N S SIGNAL SWITCH DIAGNOSIS CORRECTION CONDITION POSSIBLE CAUSE Loose switch Tighten to specified Turn signal will not cancel mounting screws torque (25 in-lbs) Switch or anchor Replace switch...
Page 250 S T E E R I N G C O L U M N S 3 B 4 - 1 3 SIGNAL SWITCH DIAGNOSIS CONDITION POSSIBLE CAUSE CORRECTION Hazard switch will not Loose switch Tighten mounting stay on or difficult mounting screws screws (25 in-lbs) to turn off...
Page 251 3B4-14 STEERING COLUMNS SIGNAL SWITCH DIAGNOSIS CORRECTION CONDITION POSSIBLE CAUSE Replace fuse and Front or rear turn signal Burned out fuse check operation lights not flashing Replace bulb Burned out or damaged turn signal bulb Remove or repair High resistance defective connection connection to ground and check operation...
Page 252 S T E E R I N G C O L U M N S 3 B 4 - 1 5 SIGNAL SWITCH DIAGNOSIS CONDITION POSSIBLE CAUSE CORRECTION Inoperative turn Turn signal lights flash Replace turn signal signal flasher very slowly flasher System charging I ncrease voltage to...
Page 253 3 B 4 - 1 6 S T E E R I N G C O L U M N S MAINTENANCE AND ADJUSTMENTS STEERING WHEEL ALIGNMENT SHIFTER TUBE ADJUSTMENT On all series vehicles, check steering gear for high point G and P Series Only centering as shown in Sections 3B2 and 3B3 before checking steering wheel alignment.
Page 254 S T E E R I N G C O L U M N S 3 B 4 - 1 7 Fig. 3 B 4 -1 9 ~ S h ift Tube A djustm ent-3 Speed M an u al Fig.
Page 255: Steering Wheel
3 B 4 - 1 8 S T E E R I N G C O L U M N S ON-VEHICLE SERVICE INDEX Steering W h eel............... 3B4-35 C-Series and K -S eries............3B4-18 Flexible C oupling............3B4-35 Steering W h ee l..............3B4-18 Interm ediate Shaft............
Page 256: Pitm An Shaft S Eal
S T E E R I N G C O L U M N S 3 B 4 - 1 9 BEARING BOLT BLOCKS COVER O W E R SNAP RING ft I UPPER SHAFT CLAMP TENSION Q D D I K J n Fig.
Page 257 3 B 4 - 2 0 S T E E R I N G C O L U M N S Fig. 3B 4-26--R em ovin g Lock Plate R etaining Ring Removal (Fig. 3B4-25) 1. Remove the steering wheel as outlined under "Steering W heel - Removal".
Page 258 S T E E R I N G C O L U M N S 3 B 4 - 2 1 Fig. 3B 4 -2 8 ~ R e m o v in g Directional Signal Sw itch Assem bly Fig.
Page 259: Ignition Switch
3 B 4 - 2 2 S T E E R I N G C O L U M N S LOCK CYLINDER INSTALLATION DISASSEMBLE ASSEMBLE Place lock in “run”. Rotate as shown, align cylinder key with keyway in housing. Remove lock plate, turn signal switch and buzzer switch (see Push lock all the way in.
Page 260 S T E E R I N G C O L U M N S 3 B 4 - 2 3 CAUTION: Use only the specified screws since over-length screws could prevent a portion assembly from compressing under impact, which could result in personal injury.
Page 261 3 B 4 - 2 4 S T E E R I N G C O L U M N S Removal 10. Remove the two colum n bracket-to-instrum ent panel nuts and carefull remove from vehicle. A dditional F ro n t o f dash m ounting plates m ust be loosened help should be obtained to guide the lower shift levers whenever the steering colum n is to be lowered from the through the firewall opening.
Page 262 S T E E R I N G C O L U M N S 3 B 4 - 2 5 30. BOWL, Gearshift Lever STEERING COLUMN 31. SHROUD, Shift Bowl RETAINER 32. BEARING, Bowl Lower NUT, Hexagon Jam 33. JACKET ASM, Steering Column COVER, Shaft Lock 34.
Page 263 3 B 4 - 2 6 S TE E RI NG C O L U M N S 1. ROD, Switch Actuator SPRING, Key Release LEVER, Key Release 2. RACK, Switch Actuator WASHER, Wave 3. SPRING, Rack Preload SHAFT ASSEMBLY, Steering 4.
Page 264 S T E E R I N G C O L U M N S 3 B 4 - 2 7 6. Install the gearshift housing lower bearing. Insert the bearing from the very end of the jacket. Aligning the indentations in the bearing with the projections on the jacket (Fig.
Page 265 3 B 4 - 2 8 S T E E R I N G C O L U M N S SHIFT GATE RACK LOCK BOLT LOCK BOLT SPRING THRUST SECTOR Fig. 3 B 4 -4 3 ~ T u rn S ig nal Housing Assem bly Fig.
Page 266 S T E E R I N G C O L U M N S 3 B 4 - 2 9 I V I A A O I . M A S T J A C K E T A. TO REDUCE CLEARANCE A.
Page 267 3 B 4 - 3 0 S T E E R I N G C O L U M N S 51. SCREW, Support 1. S T E E R IN G C O L U M N S P R IN G , Upper Bearing 52.
Page 268 S T E E R I N G C O L U M N S 3 B 4 - 3 1 1. B E A R IN G ASM 26. R E T A IN E R 51. PIN , Dowel 27.
Page 269 3 B 4 - 3 2 S T E E R I N G C O L U M N S Fig. 3 B 4 -5 0 ~ R e m o v in g T ilt Lever Spring R etainer Fig.
Page 270 S T E E R I N G C O L U M N S 3 B 4 - 3 3 Fig. 3 B 4 -5 6 ~ ln s ta llin g Bearing Housing Fig. 3B 4 -5 4 ~ R e m o v in g Sector Drive Shaft and bearing housing.
Page 271 3 B 4 - 3 4 S T E E R I N G C O L U M N S 3. Install the bearing support lock plate wave washer. 4. Install the bearing support lock plate. W ork it into the notches in the jacket by tipping it tow ard the housing hub at the 12 o’clock position and sliding it under the jacket opening.
Page 272 S T E E R I N G C O L U M N S 3 B 4 - 3 5 Mandatory Installation Sequence 1. Position colum n in body and position flange to rag join t and install lock washers and nuts (F) (M ay be tightened to specified torque at this time).
Page 273 3 B 4 - 3 6 S T E E R I N G C O L U M N S BEARING Fig. 3 B 4 -6 1 -S te e rin g S h aft In term ed iate Coupling Installation NOTICE: See N O T IC E on page 1 of this section...
Page 274 S T E E R I N G C O L U M N S 3 B 4 - 3 7 b. Remove the felt washer, plastic washer and dust cap. D iscard the felt washer. If the trunnion assemblies are to be replaced, proceed as follows: a.
Page 275 3 B 4 - 3 8 S T E E R I N G C O L U M N S STEERING COLUMN UPPER BEARING-G AND 2. Pry out the lower bearing assembly. P SERIES Installation Standard Column NOTICE: See N O T IC E not on page 1 of this section Removal regarding fasteners referred to in step 2.
Page 276 S T E E R I N G C O L U M N S 3 B 4 - 3 9 If the bearing housing support is being replaced, proceed as follows: Remove the four bearing housing support screws and remove the support. Assembly NOTICE: See N O T IC E on page 1 of this section...
Page 277 3 B 4 - 4 0 S T E E R I N G C O L U M N S DIRECTIONAL SIGNAL SWITCH Fig. 3B4-67~Directional Signal Switch Fig. 3B4-69~Removing Wires from Connector 10. C olum n Shift M odels - Install the shift lever and 5.
Page 278 S T E E R I N G C O L U M N S 3 B 4 - 4 1 out the lower end o f the shift lever housing and under the dash seal. 2. Place the directional signal switch in position and install the three m ounting screws;...
Page 279 3 B 4 - 4 2 S T E E R I N G C O L U M N S STEERING SYSTEM M A N D A T O R Y REQ UIREM EN TS Using a 50 lb. force applied to the steering wheel end of Shaft Lower Clamp Nut [ F ] must be tightened to the specified torque to give a compressed...
Page 280 S T E E R I N G C O L U M N S 3 B 4 - 4 3 Upper Steering Shaft 13. Shift Tube Felt Washer Turn Sigial Sw itch Screw 14. Shift Tube Assembly Turn Signal Switch 2 .
Page 281 3 B 4 - 4 4 S TEE RI NG C O L U M N S a. Press the upper and lower bearings out of the A utom atic Colum is - Align the three holes in the selector plate w ith the tlree holes in the jacket, position the housing.
Page 282 COVER SHAFT ASSY. WEDGE ----- RACE INSTRU. PANEL SHAFT RACE OPENING C O V E R -, SCREW (3) SPRING JACKET SWITCH ASSY. — » ASSY.- YOKE PIN DOWEL SHAFT ASSY. STEERING BEARING ASSY S H O E - RETAINER _ H O U S IN G ----- HO USING JACKET SPHERE...
Page 283 3 B 4 - 4 6 S T E E R I N G C O L U M N S Fig. 3 B 4 -7 6 -S e c u rin g Colum n w ith J -2 2 5 7 3 2.
Page 284 S T E E R I N G C O L U M N S 3 B 4 - 4 7 1 /1 6 ” 4 5 ° CHA M FER R E M O VE DOTTED P O R T IO N Fig.
Page 285 3 B 4 - 4 8 S T E E R I N G C O L U M N S 5. Loosely install the colum n dash bracket and screws. 6. Push the column down until the steering shaft flange bottom s on the plastic spacers on the flexible coupling and then torque the dash bracket screws.
Page 286 S T E E R I N G C O L U M N S 3 B 4 - 4 9 STEERING SYSTEM M A N D A T O R Y REQUIREMENTS Using 50 lb. force app lie d to the steering w heel | ~B~] end of Shaft A | , Lower Clam p Nut...
Page 287 3 B 4 - 5 0 S T E E R I N G C O L U M N S STEERING SYSTEM M A N D A T O R Y REQUIREMENTS Using a 50 lb. force app lie d to the steering w heel end of Shaft | A | Low er Clam p Nut | ~ B ~ |...
Page 288: Specifications
S T E E R I N G C O L U M N S 3 B 4 - 5 1 SPECIFICATIONS STEERING GEAR RATIOS M a n u a l P o w e r V e h i c l e Ge a r Ge a r O v e r a ll...
Page 289: Special Tools
3 B 4 - 5 2 S T E E R I N G C O L U M N S SPECIAL TOOLS 1. J-6632 Pitman A rm Puller J-6222 Shaft Seal Protector J-5504 Pitman A rm Puller J-23600 Belt Tension Gauge J-23073 Shift Tube Installer Rack-Piston Seal Compressor...
Page 290 S T E E R I N G C O L U M N S 3 B 4 - 5 3 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.
Page 291 „••; r ? ■ i W & K ’-f i ■ 5 3 '...
Page 292 3C-1 FRONT SUSPENSION SECTION 3C FRONT SUSPENSION The following notice applies to one or more steps in the assembly procedure of components in this portion of the m anual as indicated at appropriate locations by the terminology "See N otice on page 1 of this section".
Page 293: General Description
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 arm s are of unequal length (S.L.A . Type). This suspension system consists of upper and lower control arm s pivoting on steel threaded or rubber bushings on upper and lower control arm shafts.
Page 294: M Aintenance And A D Ju Stm E N
FRONT SUSPENSION 3C-3 Fig. 3C-2--Front Suspension - G-Typical MAINTENANCE AND ADJUSTMENTS 2. Spin wheel to check for unusual noise or roughness. NOTICE: See N O T IC E on page 1 of this section regarding the fasteners referred to in the m aintenance 3.
Page 295: Diagnosis
3C-4 FRONT SUSPENSION ADJUSTMENT OF WHEEL BEARINGS (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. Tighten the spindle nut to 16 N-m (12 ft. lbs.) while turning the wheel assembly forward by hand to fully seat the bearings.
Page 296 FRONT SUSPENSION 3C-5 ..HARD STEERING Probable Remedy Probable Cause Ball jo ints and steering linkage ne ed lu bric ation Lubricate ball jo in ts and linkage Inflate tires to the pro p e r re co m m e n d e d pressure Low or uneven fron t tire pressure Check p o w e r steering c o m p o n e n t s for pro p e r o p e ratio n Pow er steering partially or n o t operativ e...
Page 297 3C-6 FRONT SUSPENSION NOISE IN FRONT END Probable Cause Probable Remedy Ball joints a nd steering linkage need lubrication Lubricate at r e c o m m e n d e d intervals Shock a b sorb er loose or bushings worn T ighten bolts a n d /o r replace bushings Worn co n tro l arm bushings Replace bushings...
Page 298 FRONT SUSPENSION 3C-7 NOISE IN FRONT END Probable Cause Probable Remedy Ball joints and steering linkage need lubrication Lubricate at re co m m e n d e d intervals S l u v k a bso rber loose or bushings worn T ig hten bolts a n d /o r replace bushings Replace bushings Worn c ontrol arm bushings...
Page 299 3C-8 FRONT SUSPENSION BALL JOINT DIAGNOSTIC PROCEDURE Fig. 3C-7--Ball Joint Diagnostic Procedure M anually O perating 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.
Page 300 FRONT SUSPENSION 3C-9 C ertain precautions should be observed when in specting shocks for leaks: • shocks m ay 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 replacem ent.
Page 301 3C-10 FRONT SUSPENSION AIR ADJUSTABLE SHOCKS TYPICAL FRONT SH O C K TYPICAL REAR SH O C K This type of shock contains an air cham ber like the spiral groove reservoir type, and must have the air purged from the working cham ber. See Section 1, Spiral Groove BOTTO M ' MO UNT Reservoir.
Page 302 FRONT SUSPENSION 3C-11 BEARINGS AND RACES FRONT WHEEL, PIN IO N , DIFFERENTIAL SIDE A N D REAR WHEEL ROLLER BEARINGS DIAGNOSIS EXCESS NO ISE C O M P L A IN T D IA G N O S T IC PRO CED URE Check tires for irregular wear Check tire pressure Road Test...
Page 303 3C-12 FRONT SUSPENSION FRONT WHEEL BEARING DIAGNOSIS CONSIDER THE FOLLOWING FAC T O R SW H E N DIAGNO SING BE AR ING CO NDIT ION: 1. G E N E R A L CONDITION OF A L L PARTS DURING DISASSEMBLY AN D INSPECTION. 2.
Page 304 FRONT SUSPENSION 3C-13 FRONT WHEEL BEARING DIAGNOSIS (CONT’D) B R INELLING CAGE WEAR ABRASIVE ROLLER WEAR SURFACE IN DEN TAT IO NS IN RACEWAY WEAR A R O U N D OUTSIDE DIAM ETER OF PATTERN RACES RO LLERS CAUSED BY RO LLERS EITHER U NDE R CAGE AND ROLLER POCKETS CAUSED...
Page 305: Component Parts Replacement
3C-14 FRONT SUSPENSION COMPONENT PARTS REPLACEMENT WHEEL HUBS, BEARINGS (Fig. 3C-14) cleaning solvent. Use a sm all brush w ith no loose bristles to clean out all old grease. Do not spin the Rem oval C, G an d P Series bearing with compressed air while drying it or the 1.
Page 306: Front Suspension (K -S Eries)
FRONT SUSPENSION 3C-15 COIL SPRING SHOCK ABSORBER Removal (Fig. 3C-17) Removal (Fig. 3C-15) 1. Raise vehicle on hoist. 1. Place vehicle on hoist and place jack stands under 2. Remove nuts and eye bolts securing upper and lower frame, allowing control arms to hang free. shock absorber eyes.
Page 307 3C-16 FRONT SUSPENSION W hen installing the upper control arm be sure to UPPER CONTROL ARM INNER PIVOT SHAFT properly position the special aligning washers to the pivot AND/OR BUSHING REPLACEMENT shaft with convex and concave sides together. 1. Install the shaft to the control arm and install end nuts. C20-30, G30 and P20-30 (Steel Bushings) Do not torque nuts at this time.
Page 308 FRONT SUSPENSION 3C-17 J—2 4 4 35 -7 J—24435-1 Fig. 3 C -2 2 -U .C .A . Rubber Bushing Rem oval 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.
Page 309 3C-18 FRONT SUSPENSION 1. Place control arm in position on bracket and install 5. Remove nuts securing control arm shaft to frame. nuts. Before tightening nuts, insert caster and camber W ithdraw control arm assembly. Tape shims together shims in the same order as when removed. Torque the and tag for proper relocation when control arm is nuts to specifications.
Page 310: Lower Control Arm
FRONT SUSPENSION 3C-19 2. Remove pivot shaft nuts. Lower Control Arm Inner Pivot Shaft and/or 3. Place control arm in an arbor press, press front end of Bushing Replacement-On Vehicle pivot shaft to remove rear bushing, and pivot shaft CIO (Rubber Bushings) assembly.
Page 311 3C-20 FRONT SUSPENSION 1. Install new service ball joint, using bolts and nuts supplied with joint, to upper arm. Torque nuts to 60 R E M O VE R EM O VE N-m (45 ft. lbs.). UPPER LO W ER 2.
Page 312: Ball Joint
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.
Page 313 3C-22 FRONT SUSPENSION CROSSMEMBER AND SUSPENSION UNIT 9. Disconnect fron shock absorbers from lower control arms. Com ponent parts of the front suspension may be serviced separately as outlined in the preceding service operations. However, if extensive service is to be performed 10.
Page 314 FRONT SUSPENSION 3C-23 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.
Page 315 3C-24 FRONT SUSPENSION 14. S P R I N G R E T A IN E R 27. S P A C E R 40. D U S T S E A L 1. R E T A IN IN G S C R E W 15.
Page 316 FRONT SUSPENSION 3C-25 R E T A I N I N G P L A T E L O C K - A D J . N U T U P P E R B E A R I N G C A P "...
Page 317 3C-26 FRONT SUSPENSION MAINTENANCE AND ADJUSTMENTS bearings are accessible after removing the spindle, as shown BALL JOINT ADJUSTMENT (K10, K20) in Figure 3C-6K. Front axle ball joint adjustment is generally necessary WHEEL BEARING ADJUSTMENT only when there is excessive play in steering, irregular wear on tires or persistent loosening of the tie rod is observed.
Page 318 FRONT SUSPENSION 3C-27 COMPONENT REPLACEMENT plastic outer cage, causing the cage to rotate and move to the HUB REPLACEMENT disengaged condition. The release spring then moves the NOTICE: See N O T I C E on page 1 of this section, clutch gear out of mesh with the outer clutch housing to regarding the fasteners in the following procedures for disengage the wheel from the axle shaft.
Page 319 3C-28 FRONT SUSPENSION 1. M achine Screw 12. Retaining Ring 23. Inner Cage 2. Cover Plate 13. Spring Support W asher 24. Snap Ring 3. Cover 14. Spring Retainer 25. Brake Band 4. Sealing Ring 1 5. Return Spring 26. Drag Sleeve and Detent 5.
Page 320 FRONT SUSPENSION 3C-29 8. The two " C " shaped clamps may be fabricated from 4. Use a small screwdriver to pry the plastic outer cage ( # 2 2 ) free from the inner cage ( # 2 3 ) while the inner 3 /8 "...
Page 321 3C-30 FRONT SUSPENSION 13. Assemble the retaining ring ( # 2 4 ) into the groove of over the axle shaft against the bearing adjustment nut. the outer clutch housing above the outer cage. The tang on the inside diameter of this washer is 14.
Page 322 FRONT SUSPENSION 3C-31 RETAINING PLATE BOLTS OUTER CLUTCH RETAINING RING WASHER ACTUATING CAM BODY HUB RING RETAINING KNOB AXLE SHAFT SNAP RING ACTUATOR KNOB " 0 " RING AXLE SHAFT SLEEVE AND RING ACTUATOR KNOB INNER CLUTCH RING " 0 " RING PRESSURE SPRING INTERNAL SNAP RING SPRING RETAINER PLATE...
Page 323 3C-32 FRONT SUSPENSION Installation of Hub Servicing Spindle Components NOTICE: All parts should be lubricated for normal When servicing the spindle check the spindle grease operation during assembly with an ample amount of seals (Fig. 7K). high speed grease. Lubrication M U S T be applied to prevent deterioration before the unit is placed in 1.
Page 324 FRONT SUSPENSION 3C-33 Fig. 3C-7K--Front Spindle Grease Seals b. Loosen tie rod nuts and tap on nut with a soft KNUCKLE ham mer to break the studs loose from the knuckle K10, K20, (WITH BALL JOINTS) arm. c. Remove nuts and disconnect the tie rod. If it is Removal necessary to remove the steering arm, discard the 1.
Page 325 3C-34 FRONT SUSPENSION J-23454-1 Fig. 3C-8K--lnstalling Spindle and Thrust Washer Fig. 3C-11 K--Removing Lower Ball Joint Ball Joint Service NOTICE: Do not remove the yoke upper ball stud adjusting sleeve unless new ball studs are being in stalled. If it is necessary to loosen the sleeve to remove the knuckle, do not loosen it more than two threads using Spanner J-23447 as shown in Figure 3C-15K.
Page 326 FRONT SUSPENSION 3C-35 J - 6 3 8 2 - 3 O R J - 2 3 4 5 4 - 3 J-2 3 4 4 7 BALL J O IN T J - 2 3 4 5 4 - 2 Fig.
Page 327 3C-36 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 2. Remove four nuts from upper king pin cap. Remove in Figure 3 C -16K. After torquing the nut, do not loosen nuts alternately as compression spring will force cap to install cotter pin, apply additional torque, if neces...
Page 328 FRONT SUSPENSION 3C-37 Fig. 3C-24K--lnstalling Grease Retainer Fig. 3C-22K--Removing Upper King Pin Installation See the N O T I C E on page 1 of this section NOTICE: regarding the fasteners in the following steps. 1. Assemble new grease retainer and lower king pin bearing cup, using J - 7 8 17, as shown in Figure 3C-24K.
Page 329 3C-38 FRONT SUSPENSION Fig. 3C-27K--lnstalling Knuckle to Yoke Fig. 3C-30K--Shock Absorber Attachment SHOCK ABSORBER Removal (Fig. 3C-30K) 1. Raise vehicle on hoist. 2. Remove nuts and eye bolts securing upper and lower shock absorber eyes. 3. W ith draw shock absorber and inspect rubber eye bushings.
Page 330 FRONT SUSPENSION 3C-39 Inspection Inspect rubber rushings for excessive wear or aging- 2. Press in new bushing; assure that tool presses on steel replace where necessary. Use rubber lubricant when install outer shell of bushing. Install until bushing protrudes ing bushings over stabilizer bar. an equal am ount on each side of spring.
Page 331 3C-40 FRONT SUSPENSION SPECIFICATIONS FRONT SUSPENSION BOLT TORQUE (ft. lbs.) * CP-10 K-AII G-10-20 G-30 CP-20-30 Lower Control Arm Shaft U-Bolt — Upper Control Arm Shaft Nuts — Control Arm Rubber Bushings — — — N ew — — Upper Control Arm Bushing Steel Used 115 Used N ew...
Page 332 FRONT SUSPENSION 3C-41 SPECIAL TOOLS J-8457 Bearing Race Installer J-8092 Driver Handle J-8458 Bearing Race Installer J-9519-9 Ball Joint Installer J-8849 Bearing Race Installer J-9519-7 Ball Joint Remover J-9276-2 Bearing Race Installer J-9519-10 " C " Clamp Bushing Replacement Spring Remover J-24435-1 J-23028-01 thru 7...
Page 334 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 ".
Page 335 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 SHOCK ABSORBERS 5. To install shock absorber, place into position and reattach at upper mounting location. Be sure to install nuts and washers as shown. Replacement 6.
Page 336 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. 6. Reverse above steps to install stabilizer shaft. On Refer to Fig. 3D-9, 3D-10 and 3D -11 for specific rear installation, position shaft so parking brake cable is stabilizer shaft mounting on C and P models.
Page 337 3D-4 REAR SUSPENSION SPACER GROMMET SHAFT P300(32) LINK BOLT ANCHOR PLATE NOTE T orqu e 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.
Page 338 REAR SUSPENSION 3D-5 G 1 0 0 + 2 0 0 ( 0 5 + 0 6 ) ALL G 3 0 0 ( 0 5 + 0 6 ) ex c G 50 C 3 0 0 ( 0 5 + 0 6 ) & G 5 0 Fig.
Page 339 3D-6 REAR SUSPENSION 3. Jack frame as required to align spring and shackle with spring hangers. 4. Install shackle bolt and nut and again reposition spring, if necessary to align front eye. Install front eye bolt and nut. Torque hanger and shackle nuts to specifications. Make certain that the bolts are free-turning in their bushings prior to torquing.
Page 340 REAR SUSPENSION 3D-7 Fig. 3D-17--Rear Spring Installation-C-K Models LIGHT TRUCK SERVICE MANUAL...
Page 341 3D-8 REAR SUSPENSION Fig. 3D-20--Rear Spring Installation-P 10,20 Fig. 3D-21--Rear Spring lnstallation-P30 LIG H T T R U C K SE RV IC E M A N U A L...
Page 342 REAR SUSPENSION 3D-9 1. Install all four nuts to uniform engagement on 'U' Bolts to retain and position anchor plate in design position (perpendicular to axis of 'U ' Bolts). 2. Torque all nuts in a diagonal sequence (e.g . 1-3-2-4) to 14-35 N.m.
Page 343 3D-10 REAR SUSPENSION SPECIFICATIONS TORQUE SPECIFICATION Spring-to-Axle "U " Bolt Nuts G10 120 P10 140 G20 120 P20 140 G30 150 P30 170 (Exc. W /3 /4 " Bolt) 200 (W /3 /4 " Bolt) Leaf Spring — Front Bushing Bolt 1 1 0 90/135* 1 1 0...
Page 344 WHEELS AND 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, and /o r could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary.
Page 345 3E-2 WHEELS AND TIRES METRIC TIRES METRIC TIRE SIZES Metric tires are available in two load ranges, Standard P 205 load and Extra load. Figure 3E-1 shows the meaning of the RIM DIAMETER TIRE TYPE X ... metric tire format. Most metric tire sizes do not have exact ASPECT RATIO P - PASSENGER (INCHES)
Page 346 WHEELS AND TIRES 3E-3 □ MFD. BY GENERAL MOTORS CORP 0 8 /7 8 GVW R A W R F R T G A W R R R L B /'k i) 1 4 0 0 0 /6 3 5 0 4 0 0 0 /1 8 1 4 1 0 0 0 0 4 5 3 6 T IR E S...
Page 347 3E-4 WHEELS AND TIRES particularly in the front positions. This makes regular Too low an air pressure can result in tire overloading, rotation especially necessary. abnormal tire wear, adverse vehicle handling, and reduced fuel economy. The tire flexes more and can build up INFLATION PRESSURE excessive heat, weakening the tire and increasing suscepti...
Page 348 WHEELS AND TIRES 3E-5 W HEEL USAGE A N D T IR E L O A D L IM IT S (LBS) A T V A R IO U S I N F L A T I O N PRESSURES B IA S L IG H T T R U C K (L T ) T IR E S Inflation Pressures (PSI) Tire...
Page 349 3E-6 WHEELS AND TIRES MINIMUM TIRE INFLATION PRESSURE AT GROSS VEHICLE WEIGHT RATING GVWR LBS. W H E EL CODE AN D L IM IT S W HE EL L IM IT S S IZ E OF M A X . M A X.
Page 350 WHEELS AND TIRES 3E-7 resulting in excessive wear on the outside half of the tire, CORRECTING IRREGULAR TIRE WEAR producing a type of wear like that caused by excessive Heel and Toe Wear positive camber. Cornering wear can be most easily distinguished from This is a saw-toothed effect where one end of each tread abnorm al cam ber wear by the rounding of the outside block is worn more than the other.
Page 351 3E-8 WHEELS AND TIRES mounting surfaces can cause wheel nuts to loosen • Bent wheels that have runout over 1/16" should be which can later allow a wheel to come off while replaced. the vehicle is moving, possibly causing loss of •...
Page 352 WHEELS AND TIRES 3E-9 6. Center valve and pull it firmly against the rim. Hold in RADIAL TIRES this position and inflate until tire beads are firmly Recommended truck tire mounting and inflation proce seated on rim against flanges. dures are especially im p ortant with radial truck tires. 7.
Page 353 3E-10 WHEELS AND TIRES three lower sidewall rim line rings while the tire is Series Description Torque laying flat (measurements should be taken each 90° around the circum ference of the rim flange. If 7 / 1 6 " B o lts (6) 70-9 0 Ft.
Page 354 PROPELLER SHAFT 4A-1 SECTION 4A PROPELLER SHAFT The following notice applies to one or more steps in the assembly procedure of components in this portion of the manual as indicated at appropriate locations by the terminology "See Notice on page 1 of this Section".
Page 355 4A-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.
Page 356 PROPELLER SHAFT 4A-3 D IA G N O STIC CH ART CO M PLAINT POSSIBLE CAUSE CO RRECTIO N R o u g h o u tsid e surface o n splined R eplace seal if c u t by b u rrs on y o k e . L eak a t fro n t slip y o k e .
Page 357 4A-4 PROPELLER SHAFT C O M P L A IN T POSSIBLE CAUSE C O R R E C T IO N Roughness, Vibration or a. Bent or dented drive shaft. a. Replace. Body Boom at any speed. b. Undercoating on drive shaft. b.
Page 358 PROPELLER SHAFT 4A-5 UNIT REPAIR Due to length of the propeller shaft it may be more PROPELLER SHAFT convenient to use a bench vise, for removal and The rear universal joint to propshaft bolt on some CK 1 installation, instead of an arbor press. In this case, ton dual wheel models requires a # 10 "Six Lobed Socket"...
Page 359 4A-6 PROPELLER SHAFT J-9522-3, on the open horizontal bearing cups, and press the lower bearing cup out of the yoke ear as shown in figure 4 A - 11. This will shear the plastic retaining the lower bearing cup. 2. If the bearing cup is not completely removed, lift the cross and insert Spacer J-9522-5 between the seal and bearing cup being removed, as shown in figure 4A-12.
Page 360 PROPELLER SHAFT 4A-7 4. Install opposite bearing cup part way. Make sure that 6. If the front universal joint is being serviced, remove the both trunnions are started straight and true into both pair of bearing cups from the slip yoke in the same bearing cups.
Page 361 4A-8 PROPELLER SHAFT 9. Check the freedom of rotation of both sets of trunnions length of pipe over splined end of shaft, press bearing of the cross. If too tight, again rap the yoke ears as and inner slinger against shoulder on shaft. described above.
Page 362 PROPELLER SHAFT 4A-9 3. For G-K models with two piece shafts, install front half into transmission and bolt support to crossmember. a. Slide grease cap and gasket onto rear splines. b. Rotate shaft so front U-joint trunnion is in correct position.
Page 363 4A-10 PROPELLER SHAFT WASHER SEAL TUBE BALL STUD YOKE COUPLING YOKE FLANGE YOKE Fig. 4A-20--Bearing Cap Removal Sequence socket is part of the flange yoke assembly, while the Fig. 4A-22--Cross Sectional View of CV Joint centering ball is pressed onto a stud and is part of the ball stud yoke.
Page 364 PROPELLER SHAFT 4 A -11 Fig. 4A-25--lnstalling Outer Cylinder of Tool J-23996 Fig. 4A-27--lnstalling Centering Ball Over Ball 7. Lubricate seal lip and press seal flush with Tool Centering Ball Replacement J-23694, as shown in figure 4A-28. Sealing lip should tip inward.
Page 365 4A-12 PROPELLER SHAFT Fig. 4A-29--Reassembling Flange Yoke to disconnect the propshaft from the truck, remove the slip Slip Spline yoke, and wire brush the affected areas. Wipe clean before Apply chassis lubricant at the fitting until grease begins reinstallation. When installing the propshaft to transfer case to leave through the vent hole.
Page 366: Rear Axle
On Vehicle Serv ice.................... 4B-14 8-1 /2 ", 8 -7 /8 ", and 9-1/2" Ring G e a r............. 4B-14 Chevrolet 10-1/2" Ring G e a r ..............4B-18 Dana 10-1/2" Ring G e a r ................4B-21 Dana 9 - 3 /4 "R ing G e a r .................. 4B-21 Chevrolet 12-1/4"...
Page 367 These six, categorized by ring gear diam eter, are a) 8-1/2" and b) 8 -7 /8 " Ring G ear, c) Chevrolet 9 -1 /2 " 10-1/2" Ring G ear, d) D ana 10-1/2" Ring G ear, e) D ana 9 -3/4 "...
Page 368 REAR AXLE 4B-3 13. C o v e r 19. Thrust W asher 1. C om panion Flange D iffe r e n tia l Case D e fle c to r P inion S haft 2 0 . D iffe r e n tia l Pinion Shim Ring G e a r 2 1 .
Page 369 4B-4 REAR AXLE U&mg •J9HT...
Page 370 REAR AXLE 4B-5 10. S t r a d d le Be arin g R e ta in e r S c r e w 1. C o m p a n i o n F la n g e 11.
Page 371 4B-6 REAR AXLE D iffe re n tia l Spider Pinion Rear Bearing P inion N ut D iffe re n tia l Side Gear Drive Pinion Washer Washer Ring Gear Com panion Flange P inion Gear D iffe re n tia l Case O il Seal Washer Ring Gear B o lt...
Page 372 REAR AXLE 4B-7 11. Shims (Inner Pinion Cover and Plug Bolt (Differential Bearing) 2. Washer Lock Pin (Pinion Bearing Cap) 3. Companion Flange Cup (Inner Pinion Bolt (Ring Gear) Shaft) Bearing) Pinion Shaft Pinion Oil Seal Differential Case Gasket Cone and Roller Shims (Differential Thrust Washer 6.
Page 373: Differential Diagnosis
D iffe re n tia l C a s e -L e ft D rive Pinion H alf R ear Pinion Bearing Fig. 4B-8--Chevrolet 1 2 -1 /4 " Ring Gear A xle-11,000# Capacity DIFFERENTIAL DIAGNOSIS vehicle to determ ine w hether the noise is normal or if a STANDARD DIFFERENTIAL problem actually exists.
Page 374 REAR AXLE 4B-9 actually causing the noise, observe approxim ate car speeds and conditions under which the noise is most pronounced; then stop vehicle in a quiet place to avoid interfering noises. SOME A/O/SE / S \ W ith transmission in neutral, run engine slowly up and \<C ACCEPTABLE down through engine speeds corresponding to vehicle speed...
Page 375 4B-10 REAR AXLE Gear Noise Noise produced by these gears will be most pronounced on turns. T here are two basic types of gear noise. The first type is produced by broken, bent, or forcibly dam aged gear teeth Pinion Bearing failures can be distinguished because and is usually quite audible over the entire speed range and they rotate at higher speeds than differential side bearings presents no p articular problem in diagnosis.
Page 376 REAR AXLE 4B-11 A G EN ER AL D IAG N O STIC PROCEDURE FOR IS O LA T IN G REAR A X L E NOISE PROBLEMS Problem Cause 1. a) Road noise Noise is the same in drive or coast Tire noise Front wheel bearing noise 2.
Page 377: Differential And Rear Axle Bearing Diagnosis
4B-12 REAR AXLE DIFFERENTIAL A N D REAR AXLE BEARING DIAGNOSIS CONSIDER THE FOLLOWING FACTORS WHEN DIAGNOSING BEARING CONDITION: 1. GENERAL CONDITION OF ALL PARTS DURING DISASSEMBLY AND INSPECTION. 2. CLASSIFY THE FAILURE WITH THE AID OF THE ILLUSTRATIONS. 3. DETERMINE THE CAUSE. 4.
Page 378 REAR AXLE 4B-13 DIFFERENTIAL A N D REAR A X LE BEA R IN G D IA G N O SIS (CO NT’D) CRACKED INNER RACE F A T I G U E S P A L L I B R I N E L L I N G RACE CRACKED DUE TO IMPROPER FIT, FLAKING OF SURFACE METAL RESULTING FROM SURFACE INDENTATIONS IN RACEWAY CAUSED BY...
Page 379: On-Vehicle Service
4B-14 REAR AXLE ON-VEHICLE SERVICE AXLE SHAFT 8-1 /2 , 8 -7 /8 and 9-1 /2 RING GEAR AXLE Removal 1. Raise vehicle on hoist. Remove wheel and tire assembly AXLE ASSEMBLY and brake drums. C onstruction of the axle assembly is such that service 2.
Page 380 REAR AXLE 4B-15 1. Raise the vehicle on a hoist. Remove both rear wheel and tire assemblies and both rear brake drums. 2. Remove the rear cover and drain the lubricant. 3. R otate the case to the position shown in figure 4B-15. Support the pinion shaft so that it cannot fall into the case, then remove the lock screw.
Page 381 4B-16 REAR AXLE Fig. 4B-20--Wheel Bearing Removal Fig. 4B-22--Seal Installation 4. Lubricate cavity between seal lips with wheel bearing Axle Shaft-lnstallation lubricant and also lubricate new bearing with wheel 1. Slide axle shaft into place. Exercise care th at splines on bearing lubricant.
Page 382 REAR AXLE 4B-17 Fig. 4B-23--Pressing Out Wheel Stud Fig. 4B-25-Scribe Marks 2. Disconnect propeller shaft from axle. 3. Position propeller shaft to one side and tie it to fram e side rail. 4. M easure the torque required to rotate the pinion, as shown in figure 4B-24.
Page 383 8. Lower vehicle and remove from hoist. 4. Pack the cavity between end of pinion splines and CHEVROLET 1 0 -1/2 RING pinion flange with a non-hardening sealer (such as Perm atex Type A or equivalent) prior to installing GEAR AXLES washer and nut on pinion.
Page 384 REAR AXLE 4B-19 3. Connect brake hose at connector on rear axle housing. 4. Connect parking brake cable at lever and flange plate. Install hub and drum assembly. Bleed brake hydraulic system and adjust parking brake. Before rein stallin g wheel hub and drum assem bly replace hub oil seal.
Page 385 4B-20 REAR AXLE 3. W ith J-24426 on H andle J-8092, as shown in figure 4B- 6. To install inner bearing cup, use J-24427 on H andle J-8092. D rive cup into place u n til it seats against 33, drive outer bearing and cup from the hub assembly. shoulder of hub bore.
Page 386 REAR AXLE 4B-21 3. Install hub and d ru m assem bly on axle housing, exercising care so as not to dam age oil seal or dislocate other internal components. 4. Install th ru st washer so th a t tang on I.D. of washer is in keyway on axle housing.
Page 387 4B-22 REAR AXLE HUB AND DRUM ASSEMBLY 12-1/4" RING GEAR AXLE Removal AXLE ASSEMBLY Use the procedure given for "C hevrolet 10-1/2" Ring The axle assembly removal and installation is identical G ear A x le", and use J-0870 to remove the adjusting nut. to the procedure given earlier for "C hevrolet 10-1/2"...
Page 388 REAR AXLE 4B-23 Fig. 4B-41--Installing Hub Oil Seal DRUM-DEMOUNTABLE-TYPE Fig. 4B-39--Removing Hub Outer Bearing 4. W ithdraw cup installer, then install retainer ring, using Replacement J-22380 as shown in figure 4B-37. Press the cup into The dem ountable-type drum may be separated from contact with the retainer ring as shown in figure 4B-39.
Page 389 4B-24 REAR AXLE turn freely. If movement is excessive, adjust bearing as follows: 1. Remove axle shaft and raise vehicle until wheel is free to rotate. 2. Disengage tang of retainer from locknut and remove both locknut and retain er from axle housing tube. 3.
Page 390: Specifications
Lubricant Capacity " 4.2 Pints 8 % " 3.5 Pints Chevrolet 10'/j" 5.4 Pints " Dana 1 7.2 Pints Dana 9 % " 6.0 Pints 12>/4" 14.0 Pints Chevrolet 9 V i" 5.5 Pints Specifications Chart 4B-A LIGHT TRUCK SERVICE MANUAL...
Page 391 4B-26 REAR AXLE RING GEAR MODEL SOURCE TYPE/CAPACITY SIZE 8 - 7 / 8 " C h e v ro le t S a lis b u r y /3 7 5 0 # -1/2" C h e v ro le t S a lis b u ry /3 7 5 0 # C h e v ro le t S a lis b u ry / 3 7 5 0 #...
Page 392: Special Tools
REAR AXLE 4B-27 SPECIAL TOOLS * § > ’ -"■v >•p ■ .Avfi:', ° I " R.G. A X L E O N L Y T ru n n io n Seal In s ta lle r 16. J-2 44 3 0 D iffe re n tia l Side Bearing In s ta lle r 1.
Page 393 : « v «KI # # ■ ----------- . fiOieM 3 '"f.girji" .• ■ I*.,. H'9& - f 1? ■ j -as? jV-iit .,•■ . w v^-S pic I* . .'V - ■ . .-I no;h m u .:> o ■ 0 f .r , j.i:S .
Page 394: Front Wheel Drive
FRONT WHEEL DRIVE 4C-1 SECTION 4C FRONT WHEEL DRIVE The following notice applies to one or more steps in the assembly procedure of com ponents in this portion of the m anual as indicated at appropriate locations by the term inology "S ee N otice on page 1 of this S ection".
Page 395 4C-2 FRONT WHEEL DRIVE BEARINGS AND RACES FRONT WHEEL, PINION, DIFFERENTIAL SIDE AND REAR WHEEL ROLLER BEARINGS DIAGNOSIS EXCESS NOISE C O M PLA IN T DIAG N O STIC PROCEDURE Check tires for irregular wear Check tire pressure Road Test Check lubricant level D rive to w a rm -u p f r o n t ax le Test at various speeds in drive, float, coast and cornering...
Page 396 FRONT WHEEL DRIVE 4C-3 Fig. 4C-2~Front Drive Axle Typical 2. Support the shaft yoke in a bench vise or on a short Disassembly length of pipe. R efer to Section 3C for hub, spindle and knuckle 3. Using a brass drift and a soft ham m er, drive on end of removal and installation procedures.
Page 397 4C-4 FRONT WHEEL DRIVE SPECIFICATIONS CHEVROLET Bolt Torques Bolt Torques Axle Axle (Ft.-Lbs.) (Ft.-Lbs.) G ear and Backlash Preferred .005-.008 C arrier Cover .003-.010 Ring G ear Min. and Max. Differential Bearing Caps 15-30 in.-lbs. New Pinion Bearing Preload 5-10 in.-lbs.
Page 398 BRAKES SECTION 5 BRAKES The following notice applies to one or more steps in the assembly procedure of components in this portion of the m anual as indicated at appropriate locations by the term inology "See N otice on page 1 of this section ".
Page 399 BRAKES the pressure to overcome the rear shoe and lining retractor OPERATION OF DISC BRAKE springs. T here is no restriction a t inlet pressures below 21 Upon application of the brakes, fluid pressure behind kPa (3 psi) to allow for pressure equalization during non the caliper piston increases.
Page 400 BRAKES HYDRO— BOOST SEAL LEAKAGE A. INPUT SEAL LEAK — Fluid leakage from housing cover end of booster near reaction bore. Replace seal(s). B. PISTO N SEAL LEAK — Fluid leakage from vent at front e# unit near master cylinder. Replace seal. C.
Page 401 BRAKES booster m ust be disassembled and the accum ulator 4. A fter the accu m u lato r has been em ptied, and the valves replaced. engine is started again, another hissing sound m ay be 3. If the accum ulator can be heard charging and dis heard during the first brake application or the first charging, but it does not hold a charge, disassemble the steering m aneuver.
Page 402 BRAKES HYDRO — BOOST DIAGNOSIS CONDITION CAUSE CORRECTION Excessive Brake Pedal Loose or broken power steering pump belt. Tighten or replace the belt. Effort No fluid in power steering reservoir. Fill reservoir and check for external leaks. Leaks in Hydro-Boost Replace faulty parts.
Page 403 BRAKES CONDITION POSSIBLE CAUSE CORRECTION 1. Inflate evenly on both sides to Pulls 1. Incorrect tire pressures. the recommended pressures. 2. Front end out of line. 2. Check and align to manufacturer's specifications. 3. Unmatched tires on same 3. Tires with approximately the axle.
Page 404 BRAKES 5-7 CORRECTION CONDITION POSSIBLE CAUSE 5. Replace shoe and lining and Brake roughness or chatter 5. Shoe reversed (steel (Pedal Pulsates) — Continued machine rotor within against iron). specifications. 1. Check power brake and repair 1. Malfunctioning power Excessive Pedal Effort if necessary.
Page 405 BRAKES CONDITION POSSIBLE CAUSE CORRECTION 3. Incorrect parking brake Dragging Brakes 3. Check and readjust to (A very light drag adjustment on rear brakes. correct specifications. present In all disc 4. Incorrect installation of inboard 4. Refer to caliper installation in brakes immediately after shoe and lining.
Page 406 BRAKES < 5 - < 0 . < £ . < £ \ <£. \ < ^ \ „ < £ \ Leaking Brake Line or Connection Leaking Wheel Cylinder or Piston Seal Leaking Master Cylinder A ir In Brake System Contaminated or Improper Brake Fluid Leaking Vacuum System Restricted A ir Passage...
Page 407 5-10 BRAKES ON-VEHICLE SERVICE PEDAL TRAVEL Electrical contact should be m ade when the brake pedal is depressed 1.0-1.24" (25-31 mm) (C -K m od A t reasonably frequent intervals, the brakes should be els), .45-.95'1 (11-24 mm) (G -P models) from its fully inspected for pedal travel, which is the distance the pedal released position.
Page 408 BRAKES 5-11 and other c o n taim in an ts from en tering the h y d rau lic 1. Fill the m aster cylinder reservoirs with brake fluid and system. keep at least one-half full of fluid during the bleeding operation.
Page 409 5-12 BRAKES HYDRO-BOOST BLEEDING PROCEDURE 11. Check oil level and refill as required. 12. If oil is extrem ely foamy, allow vehicle to stand a few W henever the booster is removed and reinstalled, the steering system should be bled as outlined below. m inutes w ith engine off and repeat above procedure.
Page 410 BRAKES 5-13 Fig. 5-5--Front Brake Pipes and Hoses--C-K Models LIGHT TRUCK SERVICE MANUAL...
Page 413 5-16 BRAKES G MODELS VIEW CK MODELS CK10-20 (EXCEPT C20-43) C20 (43) CK30 VIEW VIEW VIEW CK10 P MODELS Fig. 5-8--Rear Brake Hoses LIGHT TRU CK SERVICE MANUAL...
Page 414 BRAKES 5-17 Installation BRAKE PIPES 1. Use new copper gaskets on both sides of fitting block, Replacement (Figs. 5-5 thru 5-7) wet bolt threads with brake fluid, then with fitting orientation flange engaged with the caliper orientation NOTICE: N ever use copper tubing because copper is ledge on JB8 and JF 9 (hose located in caliper gate on subject to fatgue cracking and corrosion which could all except JB8 and JF 9 ), fasten hose to caliper;...
Page 415 5-18 BRAKES P300 (32) MODELS v i e w Fig. 5-9--Parking Brake Assembly-Typical LIGHT TRUCK SERVICE MANUAL...
Page 416 BRAKES 5-19 Fig. 5-10--Parking Brake System-Typical LIGHT TRUCK SERVICE MANUAL...

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1979 light duty truck

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