Chevrolet 10 1971 Series, Chassis Service Manual

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Page 2: ...e components are presented at the rear of the manual This manual should be kept in a handy place for ready reference If properly used it will enable the technician to better serve the owners of Chevrolet built vehicles All information illustrations and specifications con tained in this literature are based on the latest product information available at the time of publication approval The right is...

Page 3: ...GVW Range 0 All 1 3900 5800 2 5200 7500 3 6600 14000 Second and Third Numbers Cab To Axle Dimension Fourth and Fifth Numbers Body Styles 00 All 02 Flat Face Cowl 03 Cab m Stepside Pickup 06 Suburban Panel Rear Doors 14 Utility Blazer 16 Suburban Tail Liftgate 32 Motor Home Chassis 34 Fleetside Pickup 35 Forward Control Steel Step Van King 42 Forward Control Chassis 55 Forward Control Aluminum Step...

Page 4: ...at the Bottom Flange of Carrier Housing Series 20 30 Rear Axle Located at the Forward Upper Surface of Carrier Transmissions 3 Speed Transmission Unit Number Located on Lower Left Side of Case Adjacent to Rear of Cover 4 Speed Transmission Unit Number Stamped on Rear of Case Above Output Powerglide and Turbo Hydra Matic 350 Transmis sion Unit Number Located on Right Rear Vertical Surface of Oil Pa...

Page 5: ...MPH or dis tance of 50 miles will be exceeded CAUTION If a truck is towed on its front wheels only the steering wheel must be secured with the wheels in a straight ahead position Four Wheel Drive Trucks It is recommended that the truck be towed with the front wheels off the ground The truck can be towed however with the rear wheels off the ground if there is damage in the rear wheel area In this e...

Page 6: ...10904 KE20904 Fleetside Pickup 250 L 6 Gas 115 KS10734 127 KS10934 KS20934 307 V 8 Gas 115 KE 10734 127 KE 10934 KE20934 Suburban Carryall 250 L 6 Gas 127 KS10906 KS20906 127 KS10916 KS20916 307 V 8 Gas 127 KE 10906 KE20906 127 KE10916 KE20916 Utility K 5 Blazer 250 L 6 Gas 104 KS10514 307 V 8 Gas 104 KE 10514 Body Base Engine W B Series 10 Series 20 Series 30 Steel Step Van 7 250 L 6 Gas 102 PS10...

Page 7: ...by a number appears in these columns example RPO G50 the vehicle must be equipped with the extra cost equipment specified by the RPO to qualify the vehicle for the given GVW rating The ratings shown under the column identified Maxi mum Front End Weight At Ground Maximum Rear End Weight At Ground indicates the maximum permissible loading or weight at the ground regardless of spring or axle capacity...

Page 8: ...avy Duty with Dual Rear Wheels 133 157 11000 7 00 18 8 55 7 00 18 8 Dual 65 RPO H22 RPO H22 4000 RPO H22 RPO H22 9080 14000 8 19 5 8 50 8 19 5 10 Dual 80 RPO H22 RPO H22 4000 RPO H22 RPO H22 11000 KS KE10 04 34 Models 115 127 5200 G7815B 32 G78 15B 32 B E B E 2900 B E B E 2948 5600 H7815B 28 H78 15B 32 B E B E 2900 B E B E 3221 KS KE10 06 16 Models 127 5200 G78 15B 32 G78 15B 32 B E B E 2900 B E B...

Page 9: ...if knocking continues further check on the condition of the engine will be necessary In any case continuous or excessive knocking may result in engine damage and constitutes misuse of the engine for which the Chevrolet Division is not responsible under terms of the Manufacturer s New Vehicle Warranty Operation in a Foreign Country If it is planned to operate a truck outside the continen tal limits...

Page 10: ...Oil change intervals longer than those listed above will result in serious re ductions in engine life and may affect Chevrolet s obliga tion under the provisions of the new vehicle warranty A high quality MS oil meeting General Motors Standard GM 6041 M was installed in the engine at the factory It is not necessary to change this factory installed oil prior to the recommended normal change period ...

Page 11: ...e Controlled Combustion System is entirely separate from the Positive Crankcase Ventilation System and is designed to reduce pollutants in the exhaust by altering the combustion process CCS is a combination of design features including a special air cleaner which incorpo rates thermostatic control of heated air to the carbure tor a special calibrated carburetor and distributor and a modified combu...

Page 12: ...d getting battery fluid which is a sulfuric acid solution on skin on clothing or other fabrics or on painted surfaces Eye protection should be worn while working on the battery for any reason Battery Terminals The bolt on battery cable terminals must be clean and tight When corrosion appears on the terminals they should be cleaned in a solution of baking soda and water or ammonia and water Generat...

Page 13: ... the engine coolant outlet to main tain a satisfactory operating temperature of the engine This thermostat is designed for continuous use through both winter and summer and need not be changed sea sonally Radiator Pressure Cap The radiator cap a 15 lb pressure type must be in stalled tightly otherwise coolant may be lost and damage to engine may result from overheating Radiator pressure caps shoul...

Page 14: ...ra Matic will except for fluid capacity and filter change listed below follow the Powerglide transmission recommendations After check ing transmission fluid level it is important that the dipstick be pushed all the way into the fill tube Every 24 000 miles after removing fluid from the transmission sump add approximately 7 5 pints U S measure 6 25 pints Imperial measure for the Turbo Hydra Matic 4...

Page 15: ...nd 6 000 miles and every 6 000 miles thereafter Tighten to torque shown in the Specifications section WHEEL BEARINGS NOTE Use wheel bearing lubricant GM Part No 1051195 or equivalent This is a premium high melting point lubricant Front Due to the weight of the tire and wheel assembly it is recommended that they be removed from hub before lubricating bearings to prevent damage to oil seal Then remo...

Page 16: ...314 5 8 125 175 KA 100 9 16 105 130 KA 200 5 8 125 175 PA 200 5 8 125 175 PA 300 5 8 125 175 FOUR WHEEL DRIVE Most lubrication recommendations and procedures for 4 wheel drive equipped trucks are the same for corre sponding components of conventional drive trucks Only the front axle including the differential the transfer case which transmits power from the transmission to either front or rear axl...

Page 17: ... refill if necessary Paper Element 12 000 Miles Check If satisfactory reuse but recheck every 6 000 miles 9 Distributor L 6 12 000 Miles 1 2 turn of cam lubricator 10 Distributor V 8 12 000 Miles Rotate cam lubricator 11 Master Cylinder 6 000 Miles Delco Supreme No 11 or equivalent As required Check add fluid when necessary 12 Transmission Manual Automatic 6 000 Miles 6 000 Miles GL 5 Dexron or eq...

Page 18: ...equivalent As required Check add fluid when necessary 11 Transmission Manual Automatic 6 000 Miles 6 000 Miles GL 5 Dexron or equivalent As required As required Keep even w filler plug See Lubrication Section 12 Carburetor Linkage V 8 6 000 Miles Engine Oil As required 13 Universal Joints 6 000 Miles Chassis Lubricant As required See Lubrication Section 14 Propeller Shaft Slip Joints 6 000 Miles C...

Page 19: ...Control Assem bly 1A 4 JA 2 Control Cables 1A 4 i a Blower Sw itch 1A 4 Resistor U n it 1A 4 GENERAL DESCRIPTION Heater components attach to the right side of the fire wall The blower motor heater core and hose assembly mount on the engine side of the firewall while the distri butor ducting and controls are under the dash fig 1 The heater operates on outside air only when the blower receiving its ...

Page 20: ...ses through the core COMPONENT REPLACEMENT AND REPAIR BLOWER ASSEMBLY Removal 1 Disconnect battery ground cable 2 Support the right front of the hood in the fully raised position 3 Carefully scribe the hood and fender locations of the right hood hinge and remove the hinge 4 Unclip the blower wire at the blower flange terminal and note or mark the motor flange position in rela tion to the blower ca...

Page 21: ... Remove the screws attaching the core retainers to the case and remove the core Installation 1 Replace the core in the case using non hardening sealer Attach the core with the core retainers and screws 2 Remount the case to the firewall 3 Replace and tighten the fender skirt attaching screws and bolts 4 Reinstall the hood hinge bolts aligning it carefully with the scribe marks made at removal Chec...

Page 22: ...itch and wiring to the control unit 2 Place the unit in position in the dash and replace mounting screws CONTROL CABLES Remove the control assembly as outlined under CON TROL ASSEMBLY and replace the affected cable or cables Check cable adjustment before installing control BLOWER SWITCH Replacement Fig 7 1 Disconnect the battery ground cable 2 Disconnect the blower switch wiring harness connector ...

Page 23: ... to the standard heater hoses with tees An on off water valve is installed in the heater core inlet line in the en gine compartment This valve must be operated manually on for cold weather off in warm weather The purpose of the valve is to cut off coolant flow to the auxiliary core during warm weather and eliminate the radiant heat that would result CONTROLS Two methods of control are employed wit...

Page 24: ... auxiliary heater unit replacement pro cedures will not be repeated in this section CAUTION All Models When replacing heater hoses maintain a 1 1 8 minimum clearance between the auxiliary heater core outlet line and the exhaust pipe fig 12 Draw hoses tight to prevent sag or rub against other components 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 25: ...9 Expansion Valve 1A 29 Muffler Connector Block and Hose Assem bly 1A 29 POA V alv e 1A 30 Control Assembly 1A 31 Blower Motor S w itch 1A 31 Blower Motor R elay 1A 32 Anti Dieseling Relay 1A 32 Compressor Clutch S w itch 1A 32 Blower Resistor Unit 1A 32 Kick Panel Air Valve 1A 33 Plenum Air V alve 1A 33 Roof Mounted System 1A 34 Compressor Condenser Receiver Dehydrator and or Sight G lass 1A 34 C...

Page 26: ...arrel type outlet in the center of the dash will direct air up or down or if desired shut it off CONTROLS Full control of the Four Season System is obtained through the use of a single control panel fig 13 The control levers make use of bowden cables to activate the various doors and switches necessary for system opera tion Control adjustment is a matter of properly setting these bowden cables The...

Page 27: ...rtion of the airflow to the defroster ducts Full right position of the AIR knob as indicated on the panel is the DE ICE position which sends the total airflow to the defroster ducts Fan Switch The fan switch controls the operation of the three speed blower motor ROOF MOUNTED SYSTEM The Roof Mounted System is available for CK10 20 series Suburban Carryall Trucks This system is similar to the Four S...

Page 28: ...ition the system is totally inoperative In any of the other three positions LO MED or HI the compressor and the air conditioning blower motors are operative NOTE When operating the air conditioning system the heater controls should be in the OFF position to obtain maximum cooling GM CHEVROLET SYSTEM The GM Chevrolet System is available as a dealer installed accessory for CIO 30 and K10 20 series t...

Page 29: ...is attached to the instrument panel and to the right hand shroud side panel at five locations CONTROLS Fig 19 System controls are the AIR knob controlling the three speed blower motor switch and the TEMP knob which controls the setting of the thermostatic switch When operating this system the Heater must be fully off for maximum cooling Air Knob Turning the AIR knob clockwise operates the three sp...

Page 30: ... t depend on the safety valve many cylinders have burst when the safety valve failed Remember high pressure means that great forces are being exerted against the walls of the container A bucket of warm water not over 125 F or warm wet rags around the container is all the heat that is required Do not weld or steam clean on or near the system Welding or steam cleaning can result in a dangerous press...

Page 31: ...rigerant and time can be obtained by using this unit Since the refrigerant is metered into the system by volume the correct amount may be added to the system This coupled with the fact that the unit remains plumbed at all times and thus eliminates loss of refrigerant in purging of lines and hooking up com bines to enable the operator to get full use of all re frigerant purchased All evacuation and...

Page 32: ...sed Both valves will be open at the same time during purging evacuating and charging operations The charging station provides two flexible lines for connecting the gauge set to the system components VACUUM PUMP A vacuum pump should be used for evacuating air and moisture from the air conditioning system The vacuum pump fig 23 is a component part of Charging Station J 8393 described previously The ...

Page 33: ...rs may be present Operating Detector 1 Determine if there is sufficient refrigerant in the system for leak testing 2 Open control valve only until a low hiss of gas is heard then light gas at opening in chimney 3 Adjust flame until desired volume is obtained This is most satisfactory when blue flame is approxi mately 3 8 above reactor plate The reactor plate will quickly heat to a cherry red 4 Exp...

Page 34: ...e complete system 6 If there is evidence of an oil leak check the com pressor to see that the oil charge is satisfactory NOTE A slight amount of oil leakage at the compressor front seal is considered normal 7 Check the system controls for proper operation 6000 MILE INSPECTION 1 Check unit for any indication of a refrigerant leak 2 If there is an indication of an oil leak check the compressor for p...

Page 35: ...ced in front of the vehicle and blowing into the condenser will provide the extra circulation of air needed to bring the pressures to within the limits specified NOTE Higher temperatures and pressures will occur at higher ambient temperatures In areas of high humidity it is possible to have thermometer and gauge readings approach but not reach the figures listed in the performance tables and still...

Page 36: ...ft 32 0 psig 5000 ft 32 5 psig 6000 ft 33 0 psig 7000 ft 33 5 psig 8000 ft 34 0 psig 9000 ft 34 5 psig 10000 ft THERMOSTATIC SWITCH Roof Mounted and G M Chevrolet Systems These systems make use of a thermostatic switch with an air sensing capillary This capillary controls the switch by sensing the temperature of the air leaving the fins fig 27 Checking for Proper Operation 1 Install the gauge set ...

Page 37: ... temperature approximately 4 degrees 7 Reinstall switch end plate and install switch Rein stall ducts removed in Step 3 above Be sure that the air sensing capillary has been replaced properly if removed during disassembly 8 Check system performance If further adjustment is needed repeat Steps 3 through 7 until the pre scribed pressure is reached CAUTION Do not attempt to run a Perform ance Check w...

Page 38: ...to bend the bimetal strip or attempt any valve adjustment EVACUATING AND CHARGING PROCEDURES AIR CONDITIONING SYSTEM CAPACITY Refrigerant Charge Oil Charge Four Season System 3 lbs 4 oz 10 oz 525 Viscosity Roof Mounted 4 lbs 8 oz 13 oz 525 Viscosity GM Chevrolet 3 lbs 4 oz 10 oz 525 Viscosity PURGING THE SYSTEM In replacing any of the air conditioning components the system must be completely purge...

Page 39: ...HEATER AND AIR CONDITIONING 1A 21 Fig 30 Charging Schematic Four Season System Shown 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 40: ...cuum Control Valve 3 and shut off vacuum pump Open Refrigerant Control Valve 4 and allow 1 2 pound of R 12 to enter system Locate and repair all leaks Purge this 1 2 pound and re evacuate for 5 minutes 3 Only after evacuating as above is system ready for charging Note reading on sight glass of charging cylinder If it does not contain a sufficient amount for a full charge fill to the proper level 4...

Page 41: ...in the system it must be removed before restoring the system to opera tion In the case of compressor mechanical failure per form the following operations 1 Remove the compressor 2 Remove the receiver dehydrator and discard the unit 3 Flush the condenser to remove foreign material which has been pumped into it the system appears to have lost an excessive amount of oil add 6 fluid oz of clean refrig...

Page 42: ... replace if damaged in any way Coat the O ring with clean refrigeration oil and install carefully 4 Retorque the fitting using a backing wrench 5 Evacuate and charge the system Leaks at Hose Clamp Connection 1 Check the tightness of the clamp itself and tighten if necessary Recheck for leak 2 If leak has not been corrected discharge the system and loosen clamp and remove hose from connection Inspe...

Page 43: ...the hose protective grommets are badly muti lated they should be replaced 4 Evacuate charge and check the system GM Chevrolet System This system makes use of individual hoses attached at either end by hose clamps In case of a failed hose the entire hose should be replaced COMPRESSOR Removal Fig 32 1 Purge the refrigerant from the system 2 Remove connector attaching bolt and connector Seal connecto...

Page 44: ...ed Charge the system and check performance RECEIVER DEHYDRATOR The receiver dehydrator should be replaced if it has been damaged through an accident or if it leaks or be comes restricted or clogged Do not attempt to repair the receiver dehydrator The receiver dehydrator is merely a moisture collect ing device and a refrigerant storage area and is the least likely component of the system to cause a...

Page 45: ...od alignment 4 Connect battery ground cable EVAPORATOR CORE Removal 1 Disconnect battery ground cable and purge the system 2 Disconnect the evaporator core inlet line at the expansion valve Cap the open connections 3 Disconnect the evaporator oil bleed line at the POA valve Cap the open connections 4 Disconnect the evaporator outlet pipe at the POA valve Cap the open connections Remove the evap or...

Page 46: ...fig 36 6 Connect the blower motor wire to the motor flange terminal and connect the battery ground cable 7 Refill the cooling system and evacuate and charge the refrigeration system HEATER CASE Removal Fig 37 1 Drain the radiator Disconnect battery ground strap 2 Remove the heater hoses from the core tubes 3 Remove the sheet metal nuts from the heater case studs which project through the firewall ...

Page 47: ...rom the evaporator outlet pipe Disconnect the equalizer line from the POA Cap the POA connector 4 Disconnect the expansion valve inlet and outlet con nections and cap the lines 5 Remove expansion valve to bracket mounting screw and remove expansion valve Installation 1 Mount the expansion valve to the bracket 2 Connect the inlet and outlet connections Tighten the inlet pipe clamp 3 Connect the equ...

Page 48: ...s at the POA valve and condenser inlet pipes using new O ring seals coated with clean refrigeration oil 6 Evacuate charge and check system operation POA VALVE Removal 1 Disconnect battery ground cable andpurge the system 2 Remove evaporator oil bleed line and expansion valve equalizer line Cap the connections 3 Remove retaining clamp screw and loosen POA valve outlet pipe clamp mounting screw 4 Re...

Page 49: ...hem to the replacement control unit Checkthem for adjustment Installation 1 Attach the blower switch to the unit Connect the harness connector and illuminating lamps Attach the mounting bracket Install the vacuum switch and hoses 2 Lift the unit into position and attach it to the dash 3 Connect the battery ground cable BLOWER MOTOR SWITCH Fig 41 Removal 1 Disconnect battery ground cable 2 Disconne...

Page 50: ...e new relay in position tang in bole in instrument panel and install the mounting screw 4 Connect the wiring harness COMPRESSOR CLUTCH SWITCH Fig 44 Removal 1 Disconnect wiring harness at compressor clutch switch 2 Remove two mounting screws and remove switch Installation 1 Place switch in position and drive the two mounting screws 2 Connect wiring harness to switch BLOWER RESISTOR UNIT Removal Fi...

Page 51: ...ew attaching the connecting shaft to the tube extending forward from the valve 4 Remove the screws attaching the nylon bearing plate to the firewall and slide it forward 5 Pull the rear valve pivot pin forward against spring tension until it clears the rear bearing Lift the valve at the rear and withdraw the valve shaft from the firewall Installation 1 Insert the tube shaft on the valve into the f...

Page 52: ...the forward edge of the front air duct squeeze the sides of the duct together to remove the duct from the front roof cover and lower the duct enough to remove the switch connec tors 4 Remove the switch connectors from the switch 5 Remove the two switch mounting screws and remove the switch assembly Installation 1 Install the switch connectors to the switch assembly as noted in Figure 47 2 Place th...

Page 53: ...he rear duct as outlined previously NOTE It is not necessary to disconnect the drain tubes to gain access to these parts 3 Relay Disconnect the wiring harness remove the two mounting screws and remove the relay Resistor Remove the two mounting screws lower and disconnect the harness connector remove the resistor Thermostatic Switch Remove the two mounting screws Remove the sensing capillary from t...

Page 54: ...ll the rear duct as outlined previously 5 Connect the battery ground cable 6 Evacuate charge and performance test the system Removal Outer Valve 1 Disconnect the battery ground cable 2 Purge the system of refrigerant 3 Remove the rear duct as outlined previously 4 Disconnect the blower motor ground straps andleads relay and thermostatic switch wiring harness 5 Disconnect the refrigerant lines at t...

Page 55: ... of the core 4 Install the lower core case and blower assemblies 5 Install the blower evaporator to the roof panel first connecting the resistor wires 6 Connect the refrigerant lines to the blower evaporator unit using new O rings coated with clean refrigera tion oil 7 Connect the blower lead wires ground strap thermo static switch and relay harnesses 8 Install the rear duct as outlined previously...

Page 56: ...tic switches are located inside the duct assembly as shown in Figure 56 The coolant system need not be opened up to gain access to these switches However the entire unit must be lowered from its dash mounting Fig 55 Blower Motor Resistor Removal 1 Disconnect the battery ground cable 2 Remove the glove box and door assemblies 3 Remove the four dash to duct attachments and the bracket to kick pad sc...

Page 57: ...en the blower wheel set screws and remove the wheels from the motor shaft Expansion Valve Fig 58 Remove the evaporator core outlet line cover Remove the expansion valve capillary bulb clamps Remove the expansion valve clamp screw Disconnect the valve inlet and outlet lines and remove the expansion valve Cap or tape the open connections at once Fig 58 Blower Motor Installation Evaporator Core Fig 5...

Page 58: ...ect the inlet and outlet lines using new O rings coated with clean refriger ation oil Install the upper case half to the core and install the case to core screws Install the core outlet line and expansion valve clamps Install the expansion valve capillary bulb clamps making sure that the bulb makes good contact with the core outlet line Install the core outlet line cover making sure that the foam ...

Page 59: ...SOR ASM COMPRESSOR SWITCH Normally open contacts CONTROL SWITCH SET AT CONNECTS OFF B TO NONE LOW B TO L MED B TO L M HIGH B TO L H CONTROL SWITCH LOOSE CONNECTOR irnrv 7 d 120R______ 14 BRN CONNECTOR RECEPTACLE C IG REPLACE EXISTING HEATER FUSE WITH 25 AM P FUSE Fig 60 Four Season System W iring Diagram CHEVROLET TRUCK SERVICE MANUAL ...

Page 60: ... CONTROL SWITCH R H BLOWER MOTOR GROUND 12 P P L C D C 12 PPL Cd O RESISTOR PART OF INSTRUMENT PANEL W IRING HARNESS pS o kin aoc j c 3cay r rft f i r77 o C 3 A C RECEP Z TACLE czD 10 R 12 OR 14 DG 14 DG 1 4 DG ANTI DIESELING RELAY MED CONNECTOR L H BLOWER MOTOR GROUND RECEPTACLE Fig 61 Roof Mounted System Wiring Diagram CHEVROLET TRUCK SERVICE MANUAL ...

Page 61: ...CIGM FUSE PANEL CONNECTOR BODY 14 BRN f r p EXISTING 1 HEATER f HARNESS 14 YEL 14 OR 14 LB ANTI DIESELING RELAY ASM r1 14 BRN 12 OR MED 4 4 l m HI N RESISTOR 14 OR 14 PL CONNECTOR TO HEATER CONTROL SWITCH TEMP CONTROL SWITCH 14 TAN BLOWER CONTROL SWITCH EVAPORATOR BLCWER ASM Fig 62 G M Chevrolet System W iring Diagram CHEVROLET TRUCK SERVICE MANUAL ...

Page 62: ... Holding Fixture 13 J 9397 Compressing Fixture 14 J 9403 Clutch Hub Holding Tool 15 J 9399 9 16 Thin Wall Socket 16 J 9401 Hub and Drive Plate Assembly Remover 17 J 9480 Hub and Drive Plate Assembly Installer 18 J 9392 Seal Remover 19 J 23128 Seal Seat Remover 20 J 9398 Pulley Bearing Remover 21 J 9481 Pulley and Bearing Installer 22 J 8092 Handle 23 J 21352 Internal Assembly Support Block 24 J 51...

Page 63: ...lass R e p la c e m e n t IB 13 Door Window A ss e m b ly IB 14 Window Regulator R e p la c e m e n t IB 14 Door Opening W e a th e rs trip IB 14 Front Door L o c k IB 14 Front Door Lock C ylinder A s s e m b ly IB 15 Front Door Lock Rem ote Control and Connecting R o d IB 15 R ear Side D o o r IB 15 L o c k IB 15 Remote Controls and Connecting R o d s IB 16 Lock Striker A d ju s tm e n t IB 16 Fr...

Page 64: ...shield opening and sealed to the windshield glass When replacing a cracked windshield glass it is very important that the cause of the glass breakage be deter mined and the condition corrected before a new glass is installed Otherwise it is highly possible that a small obstruction or high spot somewhere around the wind shield opening will continue to crack or break the newly installed windshield e...

Page 65: ...break that the wind shield opening be thoroughly checked before installing a replacement windshield The replacement glass is used as a template 1 Check for the following conditions at the previous marked point of fracture a Chipped edges on glass b Irregularities in body opening c Irregularities in rubber channel weatherstrip 2 Remove all sealer from flange and body around windshield opening 3 Che...

Page 66: ...rners c Finish seating corners by simultaneously pull ing on both ends of the cord at each corner This will insure proper positioning of the critical upper corners d Apply sealer toupper corners as shown in Figure 6 OUTSIDE REAR VIEW MIRROR Rear view mirror installations are shown in Figure 11 Occasional tightening of mounting and assembly bolts and screws will sharply decrease occurrence of failu...

Page 67: ...the grille to the cowl 5 Remove the two larger size screws from each end STANDARD CUSTOM Fig 7 A Cross Section of Windshield Weatherstrip Typical Fig 8 Loosening Weatherstrip of the grille at the forward corners 6 Remove one 1 screw each side which is exposed when the door is opened 7 Inspect cowl hood ledge seal for fatigue or cuts and replace if necessary 8 Secure front edge of grille over lip o...

Page 68: ... end of arm away from glass which will trip lock spring at base of arm and release spring from undercut of pivot shaft While holding arm in this position pull outward on cap section at base of arm to remove arm Arm can be reinstalled in any one of Fig 13 Instrument Panel Cover Fig 11 Rear View Mirrors Fig 14 Cowl Ventilator G rille Intake Cab Models 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 69: ...evi ously under Arm Adjustments 2 Remove screws which attach outside air cowl venti lator grille to cowl Carefully remove grille forward fr 5m cowl 3 At center of cowl remove retainer fig 17 which attaches each link rod to motor drive linkage and arm assembly Disengage link rods from pins 4 Remove two screws which attach arm transmission NOTE TO INSTALL OR REMOVE DEPRESS PIN INSTALL CLIP BETWEEN T...

Page 70: ...ove endgate 4 Reverse procedure for installation Align slot in trunnion to coincide with hole in endgate to permit Fig 20 Liftgate Replacement using a tool to hold trunnion while tightening nut view A fig 18 LIFTGATE ASSEMBLY Fig 19 Removal and Installation 1 Remove one 1 of the two screws securing the lift gate strut supports on each side of the liftgate 2 Remove two 2 of the three hinge bolts fr...

Page 71: ...ss in this section ENDGATE ASSEMBLY Fig 22 Removal and Installation NOTE Scribe or mark hinges before removal 1 Remove hinge access covers from endgate assembly 2 Remove three 3 of the four hinge bolts and external tooth lock washers 3 Lift endgate to almost a closed position 4 Remove side endgate supports by removing pivot bolts and washers 5 While supporting the endgate in an up right position r...

Page 72: ...emote and Push Button Assembly Re moval procedures 2 Remove two nuts securing the escutcheon 3 Remove escutcheon and gasket 4 Reverse procedure to install Endgate Centerlock 1 Remove screws from endgate end 2 Remove centerlock assembly 3 Reverse above procedure to install Endgate Side Lock 1 Remove Remote and Push Button Assembly mechan ism access hole cover 2 Remove right or left side lock rod sp...

Page 73: ...llows a friction load to hold the door in any position between full open and closed The front door check hinge assembly is replaced as a complete unit as follows Removal 1 Remove windshield wiper blade assemblies 2 Remove cowl vent grille screws and lift off grille 3 Loosen front fender rear bolts 4 With special Tool J 22585 remove 3 bolts securing front door upper hinge to cowl pillar Refer to Fi...

Page 74: ...ner edge must beparallel to the striker mounting depression on the pillar Fig 32 Ventilator Assembly Removal DOOR VENTILATOR ASSEMBLY Removal NOTE The channel between the door window glass and door vent is removed as part of the vent assembly 1 Regulate the door window glass to the full down position 2 Remove one clip each from the door lock handle 3 Remove four 4 trim panel screws and trim panel ...

Page 75: ...ece to be installed two inches longer than necessary for the channel Place this piece of filler soapstoned side of filler away from glass evenly over the edge of the glass which will fit in the channel The extra filler extending beyond the rear edge of the glass should be pinched together to hold it in place during glass installation NOTE One side of this filler the outside of the roll is soapston...

Page 76: ...ch it is applied All rust road dirt and grease or oil must be completely removed as should all old cement and bits of old weatherstrip After removing all foreign ma terial from door opening surface wipe down with prepsol Fig 38 Remote Control and Side Door Lock or its equivalent Use only a good quality cement which is made specially for weatherstrip installation following the manufacturer s direct...

Page 77: ...nel out of engagement and remove lock cylinder fig 37 3 To install reverse removal procedure Front Door Lock Remote Control and Connecting Rod The remote control is secured to the door inner panel by the three attaching bolts Removal and Installation 1 Raise door window and remove door trim pad 2 Remove bolts securing remote to door inner panel 3 Pivot remote inboard slightly to disengage connect ...

Page 78: ...r the rear remote control assembly far enough Fig 42 Slide Rear Door Front Remote Control and Rod Removal for removal of the spring clip attachment through a door access hole See Figure 41 6 Remove rear remote control through large door ac cess hole 7 Guide the attaching rod with the front remote control assembly through the lock hole at the rear of door tilt upward to clear the regulator assembly...

Page 79: ...use replace ment parts of lesser quality or substitute design Torque values must be used as specified during reassembly to assure proper retention of these parts REAR DOOR Removal and Adjustment Follow procedures outlined for Front Door Removal and Adjustment Rear Doors Latch Controls Fig 46 Replacement 1 Remove latch access cover 2 Disconnect rods from latch and remove latch 3 Reinstall latch con...

Page 80: ...d the window opening Any irregularities must be corrected 4 Assemble the weatherstrip to the opening making sure the outer channel of weatherstrip is firmly seated on the edges of the panel all around the opening 5 Start one end of the glass into its channel in the weatherstrip Using a pointed tool follow around the rear lip of the glass channel so it bears against the rear surface of the glass fi...

Page 81: ... taken not to enlarge the soiled area It is sometimes more desirable to have a small stain than an enlarged stain as a result of careless cleaning Fig 48 Suburban Body Side Trim and Window Assembly CAUTION When cleaning interior soft trim such as upholstery or carpeting do not use volatile cleaning solvents such as acetone lacquer thin ners carbon tetrachloride enamel reducers nail polish removers...

Page 82: ...p Insert with J 2189 REMOVAL OF SPECIFIC STAINS Candy Chocolate use cloth soaked in lukewarm water other than chocolate use very hot water Dry If necessary clean lightly with fabric cleaning fluid Chewing Gum Harden gum with ice cube and scrape off with dull knife Moisten with fabric cleaning fluid and scrape again Fruit Stains Coffee Soft Drinks Ice Cream and Milk Wipe with cloth soaked in cold w...

Page 83: ... IB 21 Specific R e p a ir s IB 22 Scratched Panels Spot R e fin is h in g IB 22 Dents or Pits in Panels Cracks in Glaze C o a t IB 23 T o p IB 26 R e m o v a l IB 26 Page L iftg a te I B 26 Liftgate H in g e I B 26 Lock and H a n d le IB 26 D o o r s I B 28 S e a t s IB 28 D riv er s S e a t IB 28 R ear S e a t IB 28 Body and Pick Up Box M o u n tin g IB 28 GENERAL INFORMATION Fiber glass repairs...

Page 84: ...allow resin to enter hardener can or vice versa Fig 53 Finishing Plastic Solder Repair 7 Saturate layers of fiber glass fig 55 Place lami nate over damage area Smooth out wrinkles and make sure general contour of area is maintained Figure 56 8 Apply heat to repair area Heat lamps are recom mended used at least 12 away from repair Allow 15 to 20 minutes curing time Trim repair to shape at gel stage...

Page 85: ...acks in the glaze or finish coat of plastic and paint may also use this procedure NOTE This repair may be used wherever the damage is not extensive and the plastic is not pierced but the damage area does require a plastic build up Fig 56 Applying Laminate to Body Fig 57 Typical Scratched Panel 1 Remove paint dov n to the plastic from area sur rounding the damage 2 Scuff area surrounding damaged ar...

Page 86: ...ace 4 Remove all cracked and fractured material along the break Bevel the attaching edges of the panels at approximately a 30 angle with a file or grinder and scuff plastic surfaces along edges of break NOTE Mask surrounding panels using a non staining masking tape 5 Use C clamps to align panel portions allowing approximately 1 8 between the panels or as neces sary to provide proper alignment of p...

Page 87: ...ct adjacent panels by masking use non staining masking tape 6 Cut a strip of fiber glass cloth of sufficient size so the fracture will be lapped from 1 to 2 inches on all sides 7 Prepare plastic mixture in an unwaxed paper cup See Reinforced Plastic Repair Kit Epoxy Type procedure 8 Impregnate glass fiber cloth by brushing or dipping in plastic mixture Squeeze excess mixture from cloth NOTE Avoid ...

Page 88: ... holes 9 With assistance lift the top and move it rearward for removal Liftgate The Blazer liftgate is similar in appearance to the liftgate used on the Suburban truck models The Blazer liftgate however is constructed from fiber glass and latches to the side of the opening in the top instead of to the tail gate Removal 1 Open liftgate enough to remove the tail gate support screws from the tail gat...

Page 89: ...tgate and pull the latch and latch rod out as an assembly 4 Reverse Steps 1 3 to install the right hand rod and latch LEFT HAND LATCH AN D O R ROD Removal and Installation 1 Remove the control assembly access hole cover 2 Remove the handle assembly 3 Remove the screws which retain the control assem Fig 70 Passenger s Bucket Seat Mounting Provisions bly to the liftgate allowing the control assembly...

Page 90: ...The optional auxiliary seat fig 69 and the optional passenger bucket seat fig 70 are mounted differently due to mounting bracket design differences Torque all parts to specifications Rear Seat The optional rear seat is shown in Figure 71 NOTE After removing the rear seat reinstall the bolts into the anchor nuts to seal the open ings from dirt and foreign matter When re installing the seat torque a...

Page 91: ...ding nut Front Door and or Track Replacement 1 From inside vehicle remove top track access panel 2 Remove screws retaining door to upper track 3 Remove door by disengaging upper track and tilting door inward lifting off bottom track 4 Install by reversing steps 1 2 and 3 Drivers Window Weatherstrip and or Complete Window Assembly Removal Remove glass as outlined under Driver s Window Sliding Glass...

Page 92: ...ad of weatherstrip at rear of window opening Using the tool shown in Figure 77 or similar instrument work glass into the weatherstrip channel 5 Work top of stationary glass into weatherstrip chan nel in same manner as the bottom 6 Use rubber mallet to tap glass back to the weather strip Work into weatherstrip channel using paint scraper or similar tool and rubber mallet fig 78 Tap glass firmly int...

Page 93: ... bit start holes 1 2 inch below top edge of rubber and drill up through bottom side of run channel providing holes for water to drain out of channel 16 Place metal channel over leading edge of weather strip with the short leg of channel on the plush side of weatherstrip and tap on with rubber mallet In stall stationary glass retainer clips at top and bot tom of center weatherstrip Please note that...

Page 94: ...g edge of glass Fold the glazing strip over edge of glass apply No 30 weight motor oil on the outside of the glazing strip and press latch onto the glass If it is necessary to use mallet or hammer to position latch tap lightly Too hard a blow could chip or break glass or cause the clip to open up slightly thus re ducing the grip on glass The glazing strip should be allowed to setup a few hours bef...

Page 95: ...S Fig 79 Special Tools 1 J 2 189 Weatherstrip Tool Set 2 J 5742 01 and J 22577 Windshield Checking Block Typical 3 J 22585 Front Door Hinge Bolt Wrench 4 J 9316 Windshield Checking Blocks 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 96: ......

Page 97: ... damaged areas for obvious frame misalign ment to eliminate unnecessary measuring 3 Support vehicle so that frame sidemembers are parallel to the ground Tramming Sequence 1 Dimensions to bolts and or holes in frame extend to dead center of the hole or bolt 2 Dimensions must be within 3 16 3 If a tram bar is used for horizontal alignment X check from opposite and alternate reference points AA BB an...

Page 98: ...erable in that frame twist will show up during this vertical check Figures 3 and 4 show typical check ing points with dimensions for various frames shown in the chart below Frame Repair Welding Before welding up a crack in frame a hole should be drilled at the starting point of the crack to prevent spreading Widen and V groove crack to allow complete weld penetration NOTE Do not weld into corners ...

Page 99: ...16 7 8 16 7 8 16 7 8 PA100 9 3 8 11 7 8 13 3 8 16 10 1 4 7 1 8 10 13 3 8 15 1 2 12 10 3 4 13 3 8 43 79 114 5 8 14 16 7 8 19 1 8 16 7 8 PA208 308 9 3 8 11 7 8 12 3 4 16 13 1 2 7 1 2 10 10 15 1 8 11 5 8 11 1 4 13 3 8 31 5 8 99 3 4 175 3 4 16 7 8 16 7 8 16 7 8 16 7 8 PA210 310 9 3 8 11 3 8 12 3 4 16 13 1 2 7 1 2 10 10 15 1 8 11 5 8 11 1 4 13 3 8 31 1 2 107 3 4 183 3 4 16 7 8 16 7 8 16 7 8 16 7 8 PA31...

Page 100: ...10 30 CHEVROLET TRUCK SERVICE MANUAL Fig 4 10 30 Series Truck Frame FRAME 2 4 ...

Page 101: ...uspension crossmember fig 1 Double acting shock absorbers are attached to the lower control arm and to the frame at the upper end Front wheel bearings are the tapered roller type mounted within the hub and brake disc assembly MAINTENANCE AND ADJUSTMENTS WHEEL BEARINGS ADJUST 10 Series 1 Raise vehicle on hoist and remove wheel and tire assembly Remove dust cap from end of hub and withdraw spindle c...

Page 102: ... where necessary Caster and Camber Figure 2 Positive caster is the amount in degrees of the back ward tilt of the steering axis Positive camber is the amount in degrees that the front wheels are tilted out ward at the top from a vertical position Caster and camber adjustments are made by means of shims located between the upper control arm shaft and the mounting bracket attached to the suspension ...

Page 103: ...parts of lesser quality or substitute design Torque values must be used as specified during reassembly to assure proper retention of these parts WHEEL HUBS BEARINGS Removal Fig 6 1 Raise vehicle on hoist and remove wheel and tire assembly Remove dust cap from end of hub and withdraw cotter pin 2 Remove the brake caliper 3 Remove hub and disc assembly 4 Remove outer bearing from hub The inner beari...

Page 104: ... arms and remove stabilizer from vehicle Inspection Inspect rubber bushings for excessive wear or aging replace where necessary Use rubber lubricant when installing bushings over stabilizer bar Installation 1 Place stabilizer in position on frame and install frame brackets over bushings Install nuts and bolts loosely 2 Install brackets over bushings at lower control arm location Be sure brackets a...

Page 105: ...ems and or could result in major repair expense They must be replaced with parts of the same part numbers or equivalent parts if replacement becomes necessary Do not use replacement parts of lesser quality or substitute design Torque values must be used as specified during reassembly to assure proper retention of these parts Removal Fig 12 1 Raise vehicle on hoist and remove spring as outlined und...

Page 106: ...n on hex head screw until the ball joint is pushed out Installation 1 Start the replacement ball joint into the control arm using Tools J 9519 10 and J 9519 9 as shown NOTE Position bleed vent in rubber foot of the new ball joint facing inward 2 Turn down on hex head screw until ball joint is seated in the control arm 3 Install the ball stud to the steering knuckle secure in place by the nut and i...

Page 107: ...ay Typical J 23028 Fig 8 Shock Absorber C P Series Fig 11 Removing Coil Spring with Tool J 23028 REMOVE UPPER REMOVE LOWER HEAVY FLAT W ASHER l v A J 23742S1 Fig 9 Shock Absorber K Series Fig 12 Loosening Ball Joint Stud Typical 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 108: ... lower ball stud through steering knuckle and tighten nut Fig 15 Removing Control Arm Bushing 2 Install spring and control arm as outlined under spring installation 3 Torque lower control arm ball stud to specifications and install cotter pin 4 Remove vehicle from hoist UPPER CONTROL ARM ASSEMBLY NOTE All control arm attachments are impor tant attaching parts in that they could affect the performa...

Page 109: ...h a ft and c o n tr o l a r m R e m o v e s h a ft an d s e a ls 2 Slide new seal on each end of shaft and insert shaft into control arm 3 Start new bushings on shaft and into control arm Adjust shaft until it is centered in control arm then turn bushings in and torque Check shaft for free rotation Figure 17 shows correct final positioning of shaft Installation 1 Place control arm in position on b...

Page 110: ...Unit Component parts of the front suspension may be ser viced separately as outlined in the preceding service operations However if extensive service is to be per formed to crossmember frame etc the unit can be removed and installed as follows Removal Fig 18 1 Place vehicle on hoist and remove the shock absorber from the lower control arm 2 Remove idler arm and pitman arm 3 Support engine and remo...

Page 111: ...assembly Conventional truck service brakes are provided on all 4 wheel drive units STEERING KNUCKLE AND UNIVERSAL JOINT To permit the front wheels to be driven as well as turned the axle is equipped with steering knuckles and the axle shafts are equipped with yoke and trunnion type universal joints TRANSFER CASE Refer to Section 7 for service procedures ADAPTER ASSEMBLY Refer to Section 7 for serv...

Page 112: ...actuating cam body 4 Relieve pressure on the axle shaft snap ring and remove snap ring 5 Remove the axle shaft sleeve and clutch ring assem bly and inner clutch ring and bushing assembly 6 Remove pressure spring and spring retainer plate Disassembly 1 Remove actuator knob and O ring from retaining plate discard O ring and replace with a new O ring during assembly 2 Slide inner clutch ring and bush...

Page 113: ... internal snap ring 5 Install O ring on retaining plate and install ac tuating knob and retaining plate NOTE Install actuating knob with knob in LOCK position grooves in knob must fit into actuator cam body Fig 21 Hub Key Position Typical 6 Install six cover bolts and seals 7 Turn knob to FREE position to check for proper operation 8 Lower vehicle on hoist FREE WHEELING HUB K20 Series Removal 1 Pl...

Page 114: ... NOTE Final bearing adjusting should be from 001 to 010 end play 8 Install internal clutch gear collar and gear 9 Install lock ring at end of axle shaft Assembly of Locking Hub Cap Assembly a Use O ring lube and install the new O ring in the groove of the plastic hub key knob and insert into retainer cap b Install the lock ring securing the plastic key knob to the hub retainer cap NOTE Check to se...

Page 115: ...peller shaft to front axle differential 9 Lower vehicle on hoist Fig 26 Removing Steering Arm Nuts Disassembly NOTE Refer to K10 or K20 free wheeling hub for removal of 4 wheel drive units with a free wheeling hub assembly before starting the dis assembly of the front axle assembly 1 Securely mount the axle assembly in a suitable hold ing fixture 2 If the vehicle is not equipped with RPO F76 free ...

Page 116: ...mbly Repeat as required at the upper ball stud location Fig 28 Loosening Ball Stud Adjusting Sleeve CAUTION Do_ not remove the yoke upper ball stud adjusting sleeve unless new ball studs are being installed 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 28 The nonhardened threads in the yoke can be easil...

Page 117: ...nents on Page 3 16 and install in housing 10 Install the bronze thrust washer over the axle shaft and install the spindle as shown in Figure 30 Fig 30 Installing Spindle and Thrust Washer 11 Assemble spindle to knuckle NOTE Torque spindle nuts to 45 ft lbs Assemble Wheel Hub Components a Assemble the outer wheel bearing cup into the wheel hub using Installer J 6368 and Driver Handle J 8092 b Assem...

Page 118: ...ce Installer 2 J 8458 Bearing Race Installer 3 J 8849 Bearing Race Installer 4 J 9276 2 Bearing Race Installer 5 J 8092 Driver Handle 6 J 9519 9 Ball Joint Installer 7 J 9519 10 C Clamp 8 J 23742 1 Ball Joint Remover 9 J 23028 Spring Remover 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 119: ...ing Installer 3 J 8092 Driver Handle 4 J 9519 C Clamp 5 J 23445 Bearing Installer 6 J 23446 Bearing Adjuster Adapter 7 J 23447 Adjusting Sleeve Spanner 8 J 23448 Cup and Seal Installer 9 J 23454 1 Ball Joint Remover Installer 10 J 23454 2 Ball Joint Remover Installer 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 120: ......

Page 121: ...rlift shock absorber bleed air out of lines Disconnect line from shock absorber 3 Remove shock absorber pivot bolt nuts and washers pull bolts and remove from vehicle 4 Position eye at large end of shock absorber in frame bracket or crossmember install bolt washer and nut If equipped with airlift shocks install shock absorber with the air fitting pointed rearward 5 Align opposite end of shock abso...

Page 122: ...di tions exists such as looseness damage to or swell ing of rubber parts or general wear 3 Lower vehicle and remove from hoist BUSHING Replacement 1 Position end of rod on a suitable tube type support as shown in Figure 4 2 Press bushing from rod using Tool J 7079 2 3 Position new bushing over rod eye 4 Using Tool J 8518 on Series C P10 or Tool J 7574 6 on Series C20 place tool on bushing and pres...

Page 123: ...moval 1 Raise vehicle on hoist Allow axle to hang free 2 Support axle so that load is removed from springs Place adjustable lifting device under lower control arm 3 Remove spring clamp bolt from underside of control arm 4 Remove J bolt nuts and separate shock absorber bracket from control arm Separate control arm from U bolts and lower the rear of the arm fig 6 Fig 6 Removing Control Arm Spring Cl...

Page 124: ...d through holes in arm 4 Place shock absorber bracket on ends of U bolt install nuts and torque to specifications 5 Put full weight of unloaded vehicle on the front and rear suspension torque control arm pivot bolts to specifications 6 Lower vehicle and remove from hoist COIL SPRING AND AUXILIARY LEAF SPRING Series C PIOand C20 Removal Coil Spring 1 Raise vehicle on hoist Place adjustable lifting ...

Page 125: ...ket to underside of control arm install U bolt over axle and through auxiliary spring bracket control arm and shock absorber bracket install and alternately torque U bolt retaining nuts to specifications 2 Position auxiliary spring assembly in frame mounted bracket so that free end of spring is positioned above bumper and align spring to bracket bolt holeSo In stall bolt with washer through top si...

Page 126: ...le bolt and nut and again reposition spring if necessary to align front eye install front eye bolt and nut 5 Lower vehicle so that weight of vehicle is on suspen sion components and torque affected suspension parts to specifications 6 Lower vehicle and remove from hoist SHACKLE REPLACEMENT 1 Raise vehicle on hoist Place adjustable lifting de vice under axle 2 Remove load from spring by jacking fra...

Page 127: ...pension components such as spring seats shock absorbers and control arms A welded flange is provided for brake flange plate attachment An overhung hypoid drive pinion is supported by two preloaded tapered roller bearings The pinion shaft is sealed by means of a molded spring loaded rubber seal SHIM AND SERVICE SPACER Fig 1 Companion Flange 2 Deflector 3 Pinion O il Seal 4 Pinion Front Bearing 5 Pi...

Page 128: ...g construction enables easy removal of axle shafts without removing truck load and without jacking up the axle The differential carrier is heavily ribbed to provide rigid support for the differential assembly differential caps are doweled to the carrier to assure perfect alignment The straddle mounted drive pinion is supported at the front by two opposed tapered roller bearings The pinion rear bea...

Page 129: ... 13 Differential Side Gear 14 Differential Case Left Half 15 Axle Shaft 16 Differential Bearing 17 Differential Bearing Adjusting Nut 18 Adjusting Nut Lock 19 Differential Case Right Half Basically the two axle assemblies are identical with the exception of drive gear ratios and brake assemblies however some vehicles utilize a two pinion differential while others use a four pinion differential 11 ...

Page 130: ...ers are used between the side gears and case and also between differential pinions and the dif ferential case A thrust pad mounted on the end of an adjusting screw Differential Pinion Spider Gear Differential Side Gear Differential Case Left Half Axle Shaft 15 Differential Bearing 16 Differential Bearing Adjusting Nut 17 Adjusting Nut Lock 18 Differential Case Right Half threaded into the carrier ...

Page 131: ...bolts spacers and clamp plates 9 Lower axle assembly and remove from vehicle Installation 1 Position axle assembly under vehicle and align with springs or control arms as applicable 2 Install spacer clamp plate and bolts to axle as sembly loosely install retaining nuts to bolts 3 Position shock absorbers in lower attachment brack ets and loosely install nut to retain shock 4 Connect axle vent hose...

Page 132: ...lso lubricate new bearing with wheel bearing lubricant Fig 19 Sectional View of Housing at Wheel Bearing Fig 21 Axle Shaft Bearing Installation 5 To install bearing place on Tool J 23690 heavy duty axle or J 23765 light duty axle Bearing Installer and using J 8092 Drive Handle drive bearing in bore until tool bottoms against end of tube fig 21 This tool installs bearing to a depth of 550 from end ...

Page 133: ...sket Torque carrier bolts in a cross wise pattern to ensure uniform draw on cover gasket 5 Fill axle with lubricant to a level even with bottom of filler hole See Section 0 for proper lubricant 6 Install brake drum and wheel and tire assembly 7 Lower vehicle and remove from hoist WHEEL BOLT REPLACEMENT EXCEPT 5500 LB DANA AXLE Fig 22 Removal 1 Raise vehicle on hoist allowing axle to hang freely Fi...

Page 134: ...r bore 11 Using Tools J 21468 and J 9458 for light duty axle fig 26 and Tool J 21057 for heavy duty axle fig 27 press and seal into carrier bore until gauge plate is flush with the carrier shoulder and seal flange Turn gauge plate 180 from installed position seal must be square in carrier bore to seal properly against pinion flange 12 Position and align pinion flange on pinion shaft using Tools J ...

Page 135: ...he differential such as pinion shaft oil seal and companion flange and to Series 20 30 5200 7200 lb capacity axles service procedures for service on wheel hubs bearings and axle shafts Axle Assembly Service operations on these axle assemblies may be performed with the housing installed in the vehicle or with the housing installed in a holding fixture There may be occasions however when it will be ...

Page 136: ... bolt is installed and may destroy sealing effect of the flange to hub gasket AXLE SHAFT 11 000 LB AXLES AXLE VENT Replacement Service replacement axle housing assemblies are not equipped with an axle vent therefore always make sure that a new vent assembly is installed when replacing the housing If axle vent requires replacement pry old vent from housing being sure that entire vent is removed Pri...

Page 137: ...aring cone and roller assemblies in cleaning solvent Clean with stiff brush to remove old lubricant Blow bearings dry with compressed 1 Axle Shaft 9 Oil Deflector 2 Axle Shaft to Wheel Bolt 10 O il Seal 3 Adjusting Nut Locknut 11 Hub Inner Bearing 4 Hub Outer Bearing Assembly Assembly 5 Hub Outer Bearing Retainer 12 Thrust Washer 6 Wheel Bolt 13 Bearing Adjusting Nut 7 Drum 14 Adjusting Nut Lock 8...

Page 138: ...ress 3 Position bearing cup in hub thick edge of cup toward shoulder in hub then using applicable cup installer Fig 36 Removing Hub Inner Bearing Cup Fig 37 Installing Hub Inner Bearing Cup Typical as specified press cup into hub until it seats on hub shoulder fig 37 Make certain that cup is not cocked and that it is fully seated against shoulder a J 8114 Use with J 8092 driver handle 5200 5500 an...

Page 139: ...hich are easily removed with a screw driver DRUM NON DEMOUNTABLE TYPE Fig 33 Replacement Construction of the nondemountable type hub and drum assembly is such that replacement cannot be accom plished with the hub assembly installed on the vehicle 1 Separate the drum and hub by removing the drum to hub retaining bolts hub stud nuts or by pressing out the wheel studs as applicable 2 Position brake d...

Page 140: ...seated fig 42 1 J 22351 5200 and 7200 lb axles Seal should be installed flush with end of hub 2 J 22354 11 000 lb axle Seal should be installed flush with end of hub Installation 1 Using a high melting point EP bearing lubricant liberally pack bearings and apply a light coat on I D of hub bearing contact surface and O D of axle housing tube 2 Make sure inner bearing oil seal oil seal sleeve axle h...

Page 141: ...on seal on installer Tool J 22281 so that seal shoulders against installer drive surface 7 Press seal into retainer until it bottoms against shoulder 8 Carefully position seal retainer over pinion to pre vent damage to seal and torque retaining bolts to specifications 9 Reinstall pinion flange and propeller shaft as marked in step 1 NOTE This propeller shaft to pinion flange fastener is an importa...

Page 142: ...aft to companion flange and disconnect the rear uni versal joint by removing trunnion bearing V bolts or straps Tape bearing cups to trunnion to prevent dropping and loss of bearing rollers 2 For models with two piece shafts remove bolts re taining bearing support to frame crossmember 3 Slide propeller shaft forward disengaging trunnion from axle flange then slide assembly rearward disengaging fro...

Page 143: ...l other cup Align trunnion into cup and press cups into yoke 8 Install lock rings Center Support Bearing Fig 50 a Remove dust shield b Remove strap retaining rubber cushion from bearing support c Pull support bracket from rubber cushion and pull cushion from bearing d Pull bearing assembly from shaft 1 Assemble bearing support as follows a Install inner deflector on propeller shaft if re moved and...

Page 144: ...t and before installing align U joint trunnions in same vertical position as in step b at this point all U joint trunnions should be vertical fig 51 Then note rela tionship of front shaft and rear shaft spline po sition For all models except model CE31403 157 W B 307 CIO V 8 Engine Rotate rear shaft four splines toward left side of vehicle fig 42 and install rear shaft to front shaft For Model CE3...

Page 145: ... yoke half bearing cups Remove rear trunnion Gently pull rear yoke half from prop shaft Remove all loose needle bearings Remove spring seal 8 Remove front trunnion from center and front yoke in same manner as described in Steps 2 3 4 NOTE Before front trunnion can be removed all four 4 bearing caps must be removed Assembly 1 Clean and inspect all needle bearings cups seals fittings trunnions and y...

Page 146: ...all rear yoke half bearing caps on rear trunnion Install one rear trunnion bearing cap in center yoke and press into yoke until snap ring can be installed In stall remaining cap and snap ring 5 Grease universal as outlined in Section 0 at all three 3 fittings 2 conventional type and one in rear yoke half that requires a needle nose grease gun adapter 6 Install propeller shaft with constant velocit...

Page 147: ...J 21468 14 6 J 22813 3 Axle Shaft Bearing Remover 15 Light Duty Axle 7 J 23685 Axle Shaft Bearing Remover 16 Heavy Duty Axle 17 8 J 23690 Axle Shaft Bearing Installer 18 Heavy Duty Axle 9 J 21128 Axle Shaft Seal Instal ler Heavy Duty Axle J 21491 Rear Wheel Bearing and O il Seal Installer Light Duty Axle Used with J 8092 J 2619 Rear Wheel Bearing and Oil Seal Remover Slide Hammer J 22804 Pinion Se...

Page 148: ...il Seal Installer 7 3 J 22281 Pinion Flange O il Seal Installer 8 4 J 2223 Wheel Bearing Installer 9 5 J 2222 Wheel Bearing Nut Wrench 10 J 0879 Wheel Bearing Nut Wrench J 8093 Wheel Bearing Installer J 8114 Wheel Bearing Installer J 22380 Tru Arc Pliers J 2619 Slide Hammer with Adapter J 81 17 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 149: ...f the combination valve tends to hold off front hydraulic pressure until the rear brake system overcomes their pull back springs then pressure is allowed to flow with the result being a good distribution of braking effort The brake failure warning switch portion of the com bination valve senses a loss of hydraulic pressure if a failure should occur and turns on a red light in the dash to warn the ...

Page 150: ...cylinder and remove cylinder cover and rubber diaphragm 2 Reduce fluid level in main cylinder until reservoirs are approximately half full NOTE Make sure brake fluid in bleeder equip ment is at operating level and that the equipment is capable of exerting 20 to 30 lbs hydraulic pressure on the brake system 3 Install brake bleeder adapter J 23518 J 23339 for frame mounted boosters on main cylinder ...

Page 151: ...models is tilted When removing the bleeder adapter on these models place a clean dry cloth below the cylinder to absorb any fluid spillage as the cover is removed 11 Remove bleeder adpater Wipe all areas dry if fluid was spilled during adapter removal 12 Fill master cylinder reservoirs to within 1 4 of reservoir rims as shown in Figure 7 13 Install main cylinder diaphragm and cover 14 Test operati...

Page 152: ...y 6 Remove brake bleeder wrench and hose from the bleeder valve and repeat Steps 2 through 6 on the remaining wheel cylinders 7 Fill the main cylinder to the level shown in Figure 7 8 Install the main cylinder diaphragm and cover NOTE In order to have a good surge of fluid at the bleeder valve the brake pedal should be pumped up and pressure held before each open ing of the valve HYDRAULIC BRAKE L...

Page 153: ...r the compres sion couplings Unless the tubing is properly flared the couplings will leak and the brakes will become ineffective This safety steel tubing must be double lap flared at the ends in order to produce a strong leak proof joint The Tool J 2185 must be equipped with the proper size die block and upset flare punch for each size tubing to form the double lap flare The proper size die blocks...

Page 154: ...y to form a double lap flare LATCH PLATE f Pj UPSET FLARE PUNCH RAM GUIDE ir n i A i H L L D A kl DIE B L O C K TUBE STOP PLATE Fig 13 Flaring Operation 4 Slip the punch into the tool body with the gauge end toward the die blocks install the ram and tap lightly until the punch meets the die blocks and they are forced securely against the stop plate 5 Draw latch plate nuts down tight to prevent tub...

Page 155: ...maged or corroded they should be replaced 2 Examine the inside of the caliper for evidence of fluid leakage If leakage is noted the caliper should be overhauled 3 Wipe the inside of the caliper clean including the exterior of the dust boot Check the boot for cuts cracks or other damage NOTE Do not use compressed air to clean the inside of the caliper This may cause the dust boot to become unseated...

Page 156: ...gain 10 Remove the C clamp and position the caliper over the brake disc lining up the hole in the caliper ears with the holes in the mounting bracket NOTE Make sure that the brake hose is not twisted or kinked 11 Start the caliper to mounting bracket bolts through the sleeves in the inboard caliper ears and the mounting bracket making sure that the ends of the bolts pass under the retaining ears o...

Page 157: ...s to prevent dirt from entering the line or hoses U shaped 2 Remove the U shaped retainer from the hose fitting 3 Withdraw the hose from the frame support bracket and remove the caliper with the hose attached Disassembly Figs 17 and 22 1 Clean the exterior of the caliper using denatured alcohol or equivalent and place on a clean work surface 2 Remove the brake hose from the caliper and discard the...

Page 158: ...as it may damage the bore 7 Remove the bleeder valve from the caliper Fig 23 Installing Boot to Piston Fig 24 Installing Boot to Caliper Cleaning and Inspection NOTE The dust boot piston seal rubber bush ings and sleeves are to be replaced each time that the caliper is over hauled Discard these parts do not bother to clean and inspect them 1 Clean all parts other than those mentioned above in dena...

Page 159: ...stallation to make sure that the retaining ring moulded into the boot is not bent and that the boot is installed below the caliper face and evenly all around If the boot is not fully installed dirt and moisture may enter the bore and cause damage or corrosion 5 Install the brake hose in the caliper inlet using a new copper gasket Fig 27 Unhooking Pull Back Spring Installation NOTE Installation of ...

Page 160: ...rake pedal height results NOTE Frequent usage of an automatic trans mission forward range to halt reverse vehicle motion may prevent the automatic adjusters from functioning thereby inducing low pedal heights Retracting Self Adjusters Fig 26 A lanced knock out area is provided in the backing plate This hole is for service purposes in the event retracting of the brake shoes is required to remove th...

Page 161: ...13 Inspect backing plate for oil leakage past axle shaft oil seals Install new seals if necessary 14 Check all brake flange plate attaching bolts to make sure they are tight Clean all rust and dirt from shoe contact faces on flange plate using fine emery cloth Installation Figs 29 thru 34 CAUTION Make certain to install recommended shoe and lining assemblies Otherwise serious fade or permanent fai...

Page 162: ...in and then spring from secondary shoe over the wire link end Fig 34 Measuring Drum Diameter 14 Pry shoes away from the backing plate and lubricate shoe contact surfaces with a thin coating of brake lube CAUTION Be careful to keep lubricant off facings 15 After completing installation make certain the actu ator lever functions easily by hand operating the self adjusting feature 16 Follow the above...

Page 163: ...rface A brake drum must not be rebored more than 060 over the maximum standard diameter removal of more metal will effect dissipation of heat Cleaning New brake drums in parts stock are given a light coat ing of rust proofing oil to prevent the formation of rust on the critical braking surfaces during the time that the drums are in storage This rust proofing oil must be carefully removed before th...

Page 164: ...r Be sure cups are lint and dirt free before insertion Do not lubricate cups prior to assembly 3 Install new pistons into cylinder with flat surfaces toward center of cylinder Do not lubricate pistons before installation 4 Press new boots onto cylinder by hand Do not lubri cate boots prior to installation Installation 1 Position wheel cylinder to brake flange plate Install screws and tighten secur...

Page 165: ...pect the fluid reser voirs for foreign matter Check the bypass and compensating ports to the main cylinder bore to determine if they are unrestricted 5 Remove the primary seal primary seal protector and secondary seals from the secondary piston Cleaning Use denatured alcohol or clean brake fluid tothoroughly clean all reusable brake parts Immerse in the cleaning fluid and brush metal parts with ha...

Page 166: ...in the I D of the bore 7 Continue to hold the primary piston down This will also move the secondary piston forward and will insure that the secondary piston will be forward far enough to clear the stop screw hole which is in the bottom of the front fluid reservoir The stop screw is now positioned in its hole and tightened to a torque of 25 40 pound inches 8 Install the reservoir diaphragm in the r...

Page 167: ...rts do not remove easily examine bore carefully for extensive damage which may eliminate the possibility of reconditioning the master cylinder Cleaning and Inspection Clean all parts in denatured alcohol or brake fluid If reservoir housing is degreased finish clean to remove all trace of other solvents inspect cylinder bore for scratches or corrosion Minor blemishes can be removed with crocus clot...

Page 168: ...arts of lesser quality or substitute design Torque values must be used as specified during reassembly to assure proper retention of these parts NOTE The brake pedal is an integral design with the clutch pedal except automatic trans mission necessitating the removal of the clutch pedal before removing the brake pedal Removal 1 Remove the clutch pedal as outlined under Clutch Pedal in Section 7 2 Re...

Page 169: ...ctrical contact is made when pedal travel measures 38 to 64 Fig 42 Travel Switch Adjustment PARKING BRAKE REAR WHEEL Systems Figs 43 44 45 Refer to art Figures 43 44 and 45 for routing of cables and guides Brake Travel Warning Switch Adjustment Fig 42 Vehicles with frame mounted vacuum over hydraulic boosters have an electrical switch that senses pedal travel This switch will illuminate the lamp o...

Page 170: ...tate switch bracket rearward until switch just opens light off b Hold switch bracket in this position and tighten bolt D Switch should close light on at 5 10 brake pedal pad movement from full back If Switch Circuit Is Open a Rotate switch bracket forward until switch just closes light on b Hold switch bracket in this position and tighten bolt D PARKING BRAKE PEDAL OR HANDLE Removal Figs 46 47 48 ...

Page 171: ...e brake drum to bring one of access holes into line with adjusting screw at bottom of shoes 4 Expand shoes by rotating adjusting screw with screw driver inserted through hole in drum Move outer end of screw driver away from drive shaft Continue adjustment until shoes are tight against drum and drum cannot be rotated by hand Back off adjustment ten notches and check drum for free rotation 5 Place p...

Page 172: ...on flange nut and transmission output flange Remove bolts holding the backing plate to bearing retainer and remove the backing plate Inspection Replace any worn or broken parts Installation 1 Place the backing plate in position on the rear bear ing retainer and fasten with four bolts Torque bolts to 24 foot pounds 2 Install transmission output flange on spline of main shaft and fasten with flange ...

Page 173: ...ument panel to warn the vehicle operator of a pres sure differential between the front or rear hydraulic sys tem Once the switch is activated on it will not reset until the defect in the hydraulic system has been repaired Hydraulic reset to the off position occurs with the application of equal front and rear pressures Proportioning Valve The function of this valve is to prevent premature rear whee...

Page 174: ...urn the star wheels and rotate the adjusting screws out ward from the anchor brackets This action adjusts the shoe until clearance between the lining and drum is with in proper limits Should low pedal heights be encountered it is recom mended that numerous forward and reverse stops be performed with a firm pedal effort until a satisfactory pedal height results Retracting Self Adjusters Access hole...

Page 175: ...s in the anchor brackets Installation 1 Put a light film of Lubriplate or equivalent on shoe bearing surfaces of brake flange plate and on threads of adjusting screw 2 Thread adjusting screw completely into anchor bracket without friction spring to be sure threads are clean and screw turns easily Then remove screw position a new friction spring on screw and reinstall in anchor bracket 3 Assemble s...

Page 176: ...m until the actuating lever and threaded area on the ad justing screw just touch the gauge figs 56and 57 11 Secure the adjusting cam cap screw and retract the adjusting screw 12 Install brake drums and wheels and remove vehicle from jack stands 13 Adjust the brakes by making several forward and reverse stops until a satisfactory brake pedal height results Fig 57 Plug Gage Positioning for Correct A...

Page 177: ...nd the vacuum reserve should be reduced to zero by applying the brake several times before starting the bleeding procedure Air Cleaner Service Servicing of the air cleaner is recommended and the element replaced when restriction becomes severe enough to affect power brake response At any other time if cleaning of the filter is felt necessary it should be shaken free of dirt or washed in soap and w...

Page 178: ...e Tool 6 J 22904 Dust Boot Installer 7 J 23518 or J 23339 Bleeder Adapter 8 J 23709 Combination Valve Bleeder 1 J 2185 Flaring Tool 2 J 8000 Tube Cutter 3 J 8049 Spring Remover Installer 4 J 21177 or J 22348 Brake Shoe Adjustment Gage 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 179: ...a tune upby correction of one or two items only Time will normally be saved and more lasting results assured if the technician will follow a definite and thorough procedure of analysis and correction of all items affecting power performance and economy The tune up will be performed in two parts The first part will consist of mechanical checks and adjustments the second part will consist of an inst...

Page 180: ... this defect NOTE If a weak cylinder cannot be located with the compression check see Cylinder Bal ance Test under Additional Checks and Ad justments in this section Service Install Spark Plugs Fig 2 1 Inspect each plug individually for badly worn elec trodes glazed broken or blistered porcelains and replace plugs where necessary 2 Clean serviceable spark plugs thoroughly using an abrasive type cl...

Page 181: ...g the rotor to see if the springs return it to their retarded position If the rotor does not return readily the distributor must be disassembled and the cause of the trouble corrected 2 Check to see that the vacuum control operates freely by turning the movable breaker plate counterclock wise to see if the spring returns to its retarded position Any stiffness in the operation of the vacu um contro...

Page 182: ... service they should be cleaned with a point file before adjusting with a feeler gauge Check distributor point spring tension contact point pressure with a spring gauge hooked to breaker lever at the contact and pull exerted at 90 degrees to the breaker lever The points should be closed cam follower between lobes and the read ing taken just as the points separate If not within limits replace Exces...

Page 183: ...ire brush If the battery has remained undercharged check for loose or defective fan belt defective Delcotron high resistance in the charging circuit oxidized regulator contact points or a low voltage setting If the battery has been using too much water the voltage output is too high Service Delcotron and Regulator The Delcotron and regulator tests during tune up con sist of the above battery tests...

Page 184: ...ooling system for leaks weak hoses loose hose clamps and correct coolant level and service as required NOTE A cooling system pressure test as de scribed in Additional Checks and Adjustments in this section may be performed to detect internal or external leaks within the cooling system Service Crankcase Ventilation Fig 11 All engines have a Closed Positive ventilation sys tem utilizing manifold vac...

Page 185: ...od move freely 2 Disconnect choke rod at choke lever 3 Hold choke valve and rod in position as shown in Figure 14 4 If necessary adjust rod length by bending rod at off set Bend must be such that rod enters choke lever hole freely and squarely and does not interfer with choke thermostat 5 Connect rod at choke lever and install air cleaner Fig 13 Crankcase Ventilation Filter INSTRUMENT CHECK OUT In...

Page 186: ...ng the distributor clamp and rotating the distributor body as required then tighten the clamp and recheck timing 5 Stop engine and remove timing light and reconnect the spark advance hose Fig 16 Ignition Timing Marks Adjust Idle Speed and Mixture Fig 17 10 Series Vehicles with Gasoline Engines 1 With engine running at operating temperature choke valve in fully open position parking brake on and dr...

Page 187: ...st idle cam follower on second step of fast idle cam turn air conditioning OFF and adjust fast idle to 1350 rpm with manual transmission in neutral 1500 rpm with automatic transmission in Park Reconnect Fuel Tank line to vapor canister and reconnect distributor spark advance hose 402 Cu In Four Barrel Carburetor Disconnect Fuel Tank line from Evaporation Emission vapor canister Disconnect the dist...

Page 188: ...ed and mixture as follows See Tune Up Decal Figure 18 250 and 292 Cu In L6 and 307 Cu In V8 Disconnect the distributor spark advance hose and plug the vacuum source opening Turn air conditioning ON Turn mixture screw s in until lightly contacting seat then back screw s out four turns Adjust carburetor speed screw to obtain 600 rpm with manual transmission in neutral 530 rpm with automatic transmis...

Page 189: ...h pair A variation of more than 1 inch of vacuum or 40 rpm between pairs of cylinders being tested indicates that the cylinders are off balance Battery The battery should be checked with special testing equipment and to the equipment manufacturers specifi cations See Section 6Y for complete information on battery tests Ignition The following additional ignition checks may be made with any of sever...

Page 190: ...rotor tip burned or an open secondary in coil If readings are higher than normal at two or more plugs adjacent in firing order cross firing is occur ring in distributor cap or between spark plug cables concerned If meter reads off scale to left the coil polarity is reversed Check for reversed coil primary wires wrong coil or reversed vehicle battery connections Ignition Output and Secondary Leakag...

Page 191: ...r mallet 2 With the engine running at idle back off valve rocker arm nut until the valve rocker arm starts to clatter 3 Turn rocker arm nut down slowly until the clatter just stops This is the zero lash position NOTE Oil deflector clips are commercially available fig 22 4 Turn nut down 1 4 additional turn and pause 10 seconds until engine runs smoothly Repeat ad ditional 1 4 turns pausing 10 secon...

Page 192: ...overs the removal and installation of en gine assemblies the removal installation and adjustment of some sub assemblies and replacement of some com ponents For service to all components and sub assemblies after removal and removal of some sub assemblies refer to Section 6 of the Chassis Over haul Manual Because of the interchangeability and similarity of many engine sub assemblies and parts regard...

Page 193: ...ipped a Lower engine secured by the hoist and sup port engine on blocks b Remove starter and converter housing under pan c Remove flywheel to converter attaching bolts do Support transmission on blocks e Disconnect throttle linkage and vacuum modula tor line f Remove transmission to engine mounting bolts g With the hoist attached remove blocks from the engine only and slowly guide the engine from ...

Page 194: ...ean gasket surfaces on cylinder head and manifolds 2 Position new gasket over manifold end studs on head and carefully install the manifold in position making sure the gaskets are in place 3 Install bolts and clamps while holding manifold in place with hand 4 Torque bolts to specifications NOTE Center bolt and end bolt torque differ 5 Connect exhaust pipe to manifold using a new packing 6 Connect ...

Page 195: ...end of the hose near the end of each intake and exhaust valve with the other end of the hose to the ear In this manner the sound is localized making it easy to determine which lifter is at fault Another method is to place a finger on the face of the valve spring retainer If the lifter is not functioning properly a distinct shock will be felt when the valve returns to its seat The general types of ...

Page 196: ...rocker arm cover as outlined 2 Remove spark plug rocker arm and push rod on the cylinder s to be serviced 3 Install air line adapter Tool J 23590 to spark plug port and apply compressed air to hold the valves in place 4 Using Tool J 5892 to compress the valve spring remove the valve locks valve cap valve shield and valve spring and damper fig 2L 5 Remove the valve stem oil seal 6 To replace set th...

Page 197: ... to insert 2 x 4 wood blocks between the engine mounts and frame brackets 3 Drain engine oil 4 Remove oil pan and discard gaskets and seals Installation 1 Thoroughly clean all gasket sealing surfaces 2 Install new rear seal in rear main bearing cap 5 Install oil pan and torque bolts to specifications 6 Complete installation as follows on CS 10 20 30 a Using a suitable jack with a flat piece of woo...

Page 198: ...flush with block 10 Remove tool being careful not to withdraw seal 11 Install seal half in bearing cap again using tool as a shoe horn feeding seal into cap using light pres sure with thumb and finger 12 Install bearing cap to case with sealant applied to the cap to case interface being careful to keep sealant off the seal split line fig 7L 13 Install the rear main bearing cap with new seal and to...

Page 199: ... cooling system and check for leaks Crankcase Front Cover Removal 1 Remove oil pan as outlined 2 Remove crankshaft pulley and hub or torsional damper as outlined 3 Remove crankshaft front cover attaching screws remove cover and gasket Installation 1 Clean gasket surfaces on block and crankcase front cover 2 Install centering Tool J 23042 in crankcase front cover seal fig 11L 3 Coat the gasket with...

Page 200: ...ol J 23042 fig 13L Camshaft Measuring Lobe Lift NOTE Procedure is similar to that used for checking valve timing If improper valve opera tion is indicated measure the lift of each push rod in consecutive order and record the readings 1 Remove valve mechanism as outlined 2 Position indicator with ball socket adapter Tool J 8520 on push rod fig 14L v 3 Rotate the crankshaft slowly in the direction o...

Page 201: ...r will have to be replaced 5 Check the backlash between the timing gear teeth with a dial indicator fig 17L The backlash should be not less than 004 nor more than 006 6 Install fuel pump as outlined in Section 6M 7 Install grille as outlined in Section 13 8 Install crankcase front cover as outlined 9 Install valve lifters as outlined Timing Gears Replacement With camshaft removed crankshaft gear m...

Page 202: ...ther mounts and drive line components Front Mount Replacement NOTE If only one mount appears to be damaged or deteriorated check opposite mount for future serviceability by raising engine sufficiently to produce a light strain on rubber portion of mount Observe mount for signs of separation and or deterioration 1 Remove frame bracket to mount bolt 2 Raise engine enough to clear mount 3 Remove moun...

Page 203: ...ENGINE 6 25 Fig 22L Engine Mounts 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 204: ...gines covered in this section are the 307 350 and 402 cu in engines used in 10 30 Series truck vehicles In order to avoid repetition and to identify the engines involved in a particular procedure the 307 and 250 cu in V8 engines are identified as Small V8 s The 402 cu in engine is identified as Mark IV V8 This section covers the removal and installation of engine assemblies the removal installatio...

Page 205: ...sion to engine mounting bolts g With the hoist attached remove blocks from the engine only and slowly guide the engine from the transmission ON ALL SERIES EXCEPT CE 10 20 30 Remove clutch housing Loosen clutch mounting bolts a turn at a time to prevent distortion of clutch cover until the spring pressure is released Remove all bolts clutch disc and pressure plate assembly 12 Mount engine in engine...

Page 206: ...chalk mark then install distributor cap 6 Connect Spark advance hose and governor line if so equipped at distributor Crankcase ventilation lines as required Fuel line and choke cable at carburetor Accelerator linkage at pedal lever Water pump by pass at water pump use new gasket Battery cables at battery 7 Adjust choke cable and accelerator linkage as outlined 8 Install air cleaner 9 Fill with coo...

Page 207: ...inter O mark and torsional damper mark are again in alignment This is number 6 firing position With the engine in this position the following valves may be adjusted Exhaust 2 5 6 7 Intake 3 4 6 8 4 Install rocker arm covers as outlined 5 Adjust carburetor idle speed and mixture on 20 30 series Valve Lifters Hydraulic valve lifters very seldom require attention The lifters are extremely simple in d...

Page 208: ...o hold the valves in place 4 Using Tool J 5892 to compress the valve spring remove the valve locks valve cap and valve spring and damper fig 3V 5 Remove the valve stem oil seal Fig 2V Valve Adjustment 6 Assemble as follows Small V8 Engines a Set the valve spring and damper valve shield and valve cap in place Compress the spring with Tool J 5892 and install oil seal in the lower groove of the stem ...

Page 209: ...wn in the torque sequence chart until the specified torque is reached 6 Install exhaust manifolds as outlined 7 Install intake manifold as outlined 8 Install and adjust valve mechanism as outlined Oil Pan Removal 1 Drain engine oil 2 Remove oil dip stick and tube 3 On vehicles so equipped remove exhaust crossover pipe 4 On vehicles equipped with automatic transmission remove converter housing unde...

Page 210: ...seal until it protrudes far enough to be removed with pliers fig 7V 4 Clean all sealant and foreign material from cylinder case bearing cap and crankshaft using anon abrasive cleaner 5 Inspect components for nicks scraches burrs and machining defects at all sealing surfaces case as sembly and crankshaft 6 Coat seal lips and seal bead with light engine oil keep oil off seal mating ends 7 Position t...

Page 211: ...er pump hub and tighten securely 7 Install fan belt and adjust to specifications using strand tension gauge 8 Fill cooling system start engine and check for leaks Crankcase Front Cover Removal 1 Remove oil pan as outlined 2 Remove torsional damper as outlined 3 Remove water pump as outlined in Section 6K 4 Remove crankcase front cover attaching screws and remove front cover and gasket then discard...

Page 212: ...t is a light press fit on camshaft If sprocket does not come off easily a light blow on the lower edge of the sprocket with a plastic mallet should dislodge the sprocket 5 If crankshaft sprocket is to be replaced on Small V8 engines remove sprocket using Tool J 5825 fig 14V Install new sprocket using bolt and nut from J 23523 fig 15V On Mark IV V8 engines remove sprocket using Tool J 1619 fig 16V ...

Page 213: ... 1 Remove the valve mechanism as outlined 2 Position indicator with ball socket adapter Tool J 8520 on push rod fig 18V NOTE Make sure push rod is in the lifter socket 3 Rotate the crankshaft slowly in the direction of Fig 17V Installing Timing Chain rotation until the lifter is on the heel of the cam lobe At this point the push rod will be in its lowest position 4 Set dial indicator on zero then ...

Page 214: ... 19V Removing Camshaft stall camshaft 2 Install timing chain on camshaft sprocket Hold the sprocket vertically with the chain hanging down and align marks on camshaft and crankshaft sprockets Refer to fig 13V and 17V 3 Align dowel in camshaft with dowel hole in cam shaft sprocket then install sprocket on camshaft 4 Draw the camshaft sprocket onto camshaft using the mounting bolts Torque to specifi...

Page 215: ...ENGINE 6 37 REAR M O U NT Fig 21V Engine Mounts 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 216: ...e enough to remove weight from cushions 3 Remove nut bolt spacer and cushions and reinstall with new cushions 4 Lower engine and torque bolt to specifications 5 Install cotter key Rear Mount Replacement 1 Support engine weight to relieve rear mounts 2 Remove mount attaching bolts from frame outrigger and clutch housing and remove rear mounting cushions 3 Install new mounting cushions and bolts 4 L...

Page 217: ...ide Reamer Set J 7049 3 8 14 J 8089 Carbon Removing Brush 15 J 5860 Cylinder Head Bolt Wrench 16 J 5715 003 Rocker Arm Stud Reamer J 6036 013 17 J 6880 Rocker Arm Stud Installer 18 J 5802 Rocker Arm Stud Remover 19 J 9534 Distributor Lower Bushing Remover 20 J 9535 Distributor Lower Bushing Installer 21 J 22144 O il Pick up Screen Installer 22 J 8369 O il Pick up Screen Installer 23 J 6098 Cam Bea...

Page 218: ......

Page 219: ... Pressure Cap mospheric pressure The higher pressure raises the boiling point of the coolant which increases the efficiency of the radiator The radiator filler cap contains a pressure relief valve and a vacuum relief valve The pressure relief valve is held against its seat by a spring which when compressed allows excessive pressure to be relieved out the radiator overflow The vacuum valve is also ...

Page 220: ...p NOTE A defective head gasket may allow ex haust gases to leak into the cooling system This is particularly damaging to the cooling system as the gases combine with the water to form acids which are harmful to both the radia tor and engine 3 To check for exhaust leaks into the cooling system drain the system until the water level stands just above the top of the cylinder head then disconnect the ...

Page 221: ...pressure replace the cap Cylinder Block and Cylinder Head 1 With the thermostat removed attach a lead away hose to the water pump inlet and a length of new hose to the water outlet connection at the top of the engine NOTE Disconnect the heater hose and cap connections at engine when reverse flushing engine 2 Insert the flushing gun in the new hose 3 Turn on the water and when the engine water jack...

Page 222: ...utches must be kept in an in car position When removed from the car the assembly should be supported so that the clutch disc remains in a vertical plane to prevent silicone fluid leakage 4 Remove pump to cylinder block bolts and remove pump and old gasket from engine NOTE On in line engines pull the pump straight out of the block first to avoid damage to impeller Installation 1 Install pump assemb...

Page 223: ...Carburetors 6M 1 Accelerators and Choke Controls 6M 2 Governors 6M 14 Air C le an e rs 6M 17 Fuel Pumps 6M 22 Special Tools 6M 24 CARBURETORS INDEX General Description 6M 1 Service Procedures 6M 1 Preliminary Checks 6M 1 External Adjustment also see below Additional External Settings and Adjustments 6M 2 Rochester Carburetors 6M 2 Holley Carburetors 6M 6 Removal 6M 9 Test Before Installation 6M 10...

Page 224: ...he fast idle cam and hold firmly against the rise to the high step 2 Rotate choke valve toward direction of closed choke by applying force to choke coil lever 3 Bend choke rod at point shown to give specified opening between the lower edge of choke valve at center of valve and inside air horn wall Manual choke models with smooth contour cam Use the same procedure as above except for Step 1 As ther...

Page 225: ...n a direction to close the choke blade 4 Slowly open accelerator until choke closes choke will not fully close due to the vacuum break link s reaction on it and idle is determined by high step of fast idle cam Release accelerator Fig 7C Vacuum Break Adjustment MV 5 With idle determined by fast idle cam and vacuum break link acting on the choke lever insert specified gauge hold vertical between the...

Page 226: ...ir horn wall 2GV Fig 11C With the throttle valves held wide open and the choke valve held toward the closed position with a rubber band bend the unloader tang on the throttle lever to obtain specified clearance between the upper edge of the choke valve and air horn wall CHOKE COIL ROD ADJUSTMENT M V Fig 12C 1 Hold choke valve closed Fig 11C Choke Unloader 2GV 2 Pull upward on coil rod to end of tr...

Page 227: ...of travel 3 The top of the rod should line up with the bottom of the hole 4 Bend choke coil rod at point shown to adjust 5 Connect coil rod to choke lever and install retaining clip 6 Ensure complete freedom of operation from full open to full closed choke C E C VALVE ADJUSTMENT Fig 15C MV 2GV and 4M V This adjustment is to be made only after 1 replace ment of the solenoid 2 major overhaul of the ...

Page 228: ...in the choke operating lever 2 Adjust to specified dimension by bending loop at the upper end of choke rod VACUUM BREAK ADJUSTMENT Fig H3 1 With air cleaner removed install rubber band on choke operating lever to hold in the closed choke position 2 With a flat tool depress the choke diaphragm stem until bottomed 3 Measure from choke plate edge to air horn wall on down stream side 4 Bend choke diap...

Page 229: ...ecified opening of throttle Fig H3 Vacuum Break Adjustment plates on idle transfer slot side of carb see specifi cations Bend fast idle lever to adjust SECONDARY THROTTLE VALVE STOP SCREW ADJUSTMENT Fig H7 1 Back off on adjustment screw until throttle plates are fully closed 2 Turn adjustment screw until it just touches the throttle lever and turn one half turn more to posi tion the valves in the ...

Page 230: ...tment clockwise to lower or counterclockwise to raise fuel level then tighten lock screw NOTE 1 6 turn of adjusting nut equals ap proximately 1 16 fuel level change 5 Allow a minute for fuel level to stabilize and re check the level at sight plug 6 Readjust if necessary until proper level is obtained and install sight plug and air cleaner NOTE To assure proper secondary float level setting it is a...

Page 231: ...ter completing instruction on tune up sticker With engine running and transmission in Neutral for manual and in Drive for automatics with air condition ing off distributor vacuum hose removed and plugged and fuel tank hose from vapor canister disconnected perform the following 1 Manually extend the C E C valve plunger to contact throttle lever 2 Adjust plunger length to obtain idle speeds see Othe...

Page 232: ... and battery and reduces the possi bility of backfiring while attempting to start the engine A fuel pump clamped to the bench a small supply of fuel and the necessary fittings enable the carburetor to be filled and the operation of the float and intake needle and seat to be checked Operate the throttle lever several times and check the discharge from the pump jets before installing the carburetor ...

Page 233: ...sure the locator sets properly in locating hole and install mounting screw 4 Complete installation as follows WITH ROCHESTER 4MV 2GV and HOLLEY CAR BURETORS Install the choke rod and adjust as necessary without choke coil shield installed Disconnect choke rod upper end and lower choke coil shield over choke rod and install over choke coil Move shield to best fit along manifold and connect upper pn...

Page 234: ... Check torque references Check for correct open ing and closing positions by operating accelerator pedal in vehicle NOTE If any binding is present check for correct routing of cable or pedal interference with carpets Also check for proper return spring and its proper installation THROTTLE ROD KICKDOWN LINKAGE ADJUSTMENT 1 Disconnect throttle rod swivel at throttle lever on carburetor or at dash le...

Page 235: ...ION Care must be taken during installation of Retainer onto Accelerator Cable and the proper attention must be made to press the Retainer into hole on Rod to assure the Cable is not KINKED or D A M A G ED in any way VIEW A FWD Fig K6 Accelerator Controls P Series Typical Fig K7 Accelerator Pedal and Controls C K and P 10 thru 30 Series 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 236: ...ll be determined by vacuum on the diaphragm and the tension of the governor or spring acting on the gov ernor lever Vacuum is applied to the diaphragm through a system of vacuum passages and restrictions in the throttle body and governor housing A speed sensitive centrifugal valve in the distributor acts as a vacuum break so that there is no vacuum applied to the diaphragm until the desired govern...

Page 237: ...d CAUTION Since the idle ports in the throttle body were drilled after the throttle body was assembled the throttle valves were nicked dur ing the drilling operation No attempt should be made to remove the throttle valve or to further disassemble the throttle body since any slight change in positioning of the throttle valves with relation to the idle ports would seriously disrupt carburetor operat...

Page 238: ... diaphragm cover and distribu tor and install lockwire in attaching nuts TROUBLE SHOOTING 2G VACUUM SPINNER TYPE 1 Loss of speed control Check for vacuum leaks and operation of bleed valves in distributor Also for proper seal of diaphragm cover and condition of diaphragm itself Vacuum in the governor housing can be checked by removing the connection to the distributor and attaching a vacuum line I...

Page 239: ...parts d If tampering is suspected visually check parts with the governing parts of an engine that is gov erning properly AIR CLEANERS INDEX Page Page General Description 6M 17 Inspecting Paper Element 6M 18 Maintenance Procedures 6M 18 Cleaning Oil Bath Cleaner 6M 18 Element Replacement 6M 18 GENERAL DESCRIPTION Air cleaners on all models operate primarily to re move dust and dirt from air before ...

Page 240: ...Empty oil out of cleaner and clean out all oil and accumulated dirt 4 Wash body with cleaning solvent and wipe dry 5 Wash filter element by sloshing up and down in cleaning solvent 6 Dry filter unit with an air hose or let stand until dry 7 Fill body of cleaner to full mark with SAE 50 engine oil If expected temperatures are to be consistently below freezing use SAE 20 engine oil 8 Assemble filter...

Page 241: ...t this time immerse the cover far enough to cover the ther mostat pellet in water of less than 80 F The valve should remain closed Gradually raise temperature of the water The valve should begin to open at a water temperature of 83 F and be fully open at a temperature of 120 F Thermostat Replacement Fig 5A 1 Remove sheet metal to air cleaner hose from the air cleaner cover Fig 5A Thermostatic A ir...

Page 242: ...m fig 6A and 7A is designed to improve carburetor operation and engine warm up character istics It achieves this by keeping the air entering the carburetor at a temperature of at least 100 F or more The thermostatic air cleaner system includes a tem perature sensor a vacuum motor and control damper assembly mounted in the air cleaner vacuum control hoses manifold heat stove and connecting pipes Th...

Page 243: ...d satisfactory replace sensor unit TEMPERATURE SENSOR REPLACEMENT Removal 1 Remove air cleaner from engine and disconnect vacuum hoses at sensor 2 Pry up tabs of sensor retaining clip fig 11a NOTE Observe position of sensor new sensor must be installed in this same position 3 Remove clip and sensor from air cleaner Replacement 1 Install sensor and gasket assembly in air cleaner in position as note...

Page 244: ...al is the diaphragm type The pump is actuated by an eccentric locatedon the engine camshaft On in line engine the eccentric actuates the rocker arm On V 8 engines a push rod located be tween the camshaft eccentric and fuel pump actuates the pump rocker arm Because of design this pump is serviced as an assembly only GASKET GAS PIPE ASSEMBLY GASKET PUMP ASSEMBLY Fig IP Fuel Pump and Pipe L 6 Fig 2P ...

Page 245: ...n the ON position Failure to do this will result in a damaged grounding circuit in the ignition switch 3 If fuel flows from pump in good volume from pipe at carburetor check fuel delivery pressure to be cer tain that pump is operating within specified limits as follows a Attach a fuel pump pressure test gauge to dis connect end of pipe b Run engine at approximately 450 1 000 rpm on gasoline in car...

Page 246: ...Special Tools J 1137 Choke Rod Bending J 4552 Choke Rod Bending 1 and 2 bbl J 5197 Unloader Bending J 8328 Carburetor Holding Tool J 9789 Universal Carburetor Kit J 10176 Fast Idle Wrench J 22973 Ther Mac Thermometer 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 247: ...on throttle blade setting will be performed with the solenoid in the non energized position With the vacuum line removed at the distributor and plugged and with the electrical connec tion also removed the curb idle speed is set with the carburetor screw The throttle stop adjustment screw is then pulled out to its most extended position and adjusted to a specified RPM to provide the desired high ge...

Page 248: ...onnections resulting in failure of the solenoid to function will result in no vac uum advance and no high gear deceleration throttle po sition The valve will be serviced as a unit replacement only HIGH GEAR DECELERATION POSITION MANIFOLD VACUUM HOT LIGHT BATTERY TIME DELAY RELAY u i r I ___ R E V E R S I N G RELAY IGNITION SWITCH EN ERG IZED WATER TEMP SWITCH APPROX 15 SEC TRANSMISSION SWITCH CLOS...

Page 249: ......

Page 250: ...EMISSION CONTROL SYSTEMS 6T 4 Fig 3 Combination Emission Control System Routing V8 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 251: ...furic acid Plate straps located on the top of each element connect all the positive plates and all the negative plates into groups The elements are connected in series electrically by connectors that pass directly through the case partitions between cells The top is a one piece cover The cell connectors by passing through the cell partitions connect the elements along the short est practical path ...

Page 252: ...to keep the Battery top clean cable ends clean and tight and improper addition of water to the cells LEVEL INDICATOR The Battery features an electrolyte level indicator which is a specially designed vent plug with a transparent rod extending through the center fig 3b When the electrolyte is at the proper level the lopwer tip of the rod is immersed and the exposed top of the rod will appear very da...

Page 253: ...Battery securely and keep it level To prevent the Battery from shaking in its carrier the hold down bolts should be tight 60 80 in lbs However the bolts should not be tightened to the point where the Battery case or cover will be placed under a severe strain SAFETY PRECAUTIONS When Batteries are being charged an explosive gas mixture forms in each cell Part of this gas escapes through the holes in...

Page 254: ... due to age or over filling in which case the specific gravity reading will be lower For the most satisfactory charging the lower charging rates in amperes are recommended If after prolonged charging a specific gravity of at least 1 230 on all cells cannot be reached the battery is not in an optimum condition and will not provide optimum performance however it may continue to pro vide additional s...

Page 255: ...nutes that will determine the condition of the Battery with a high degree of accuracy When using these testers the procedure recommended by the tester manufacturer should be fol lowed Batteries should not be charged prior to testing or doing so may alter the test results If a tester is not available for testing the Specific Gravity Cell Com parison Test may be used or an alternate method but with ...

Page 256: ...ing battery fluid on car or clothing as it is extremely corrosive Any fluid that drops should be washed off immediately with baking soda solution The specific gravity of the electrolyte varies not only with the percentage of acid in the liquid but also with temperature As temperature increases the electrolyte expands so that the specific gravity is reduced As temperature drops the electrolyte cont...

Page 257: ... n t 6Y 13 GENERAL DESCRIPTION The charging system includes the battery generator regulator telltale light and necessary wiring to connect these components The Delcotron is offered as standard equipment although there are various capacities available on all models The Delcotron continuous output A C generator fig lc consists of two major parts a stator and a rotor The stator is composed of a large...

Page 258: ...yed insulation Check mounting bolts for tightness Check the drive belt for alignment proper tension and wear Because of the higher inertia and load capacity of the rotor used in A C generators PROPER BELT TENSION is more critical than on D C generators Since the Delcotron and its companion regulator are designed for use on negative polarity systems only the following precautions must be observed F...

Page 259: ...ition and check indicator lamp If lamp fails to glow perform appropriate tests and corrections Indicator Lamp Circuit Tests before continuing Models equipped with Ammeter Turn ignition switch to ACC with an accessory on and check ammeter If ammeter fails to read discharge check ammeter circuit before continuing 5 Models equipped with Indicator Lamp If lamp glows start the engine and run it at 1500...

Page 260: ...s disconnected when removing or install ing cover This is to prevent regulator damage by short circuits SYSTEM COMPONENT TESTS Delcotron Output Test Ammeter Method Fig 5c 1 Disconnect the battery ground cable at the battery 2 Disconnect the red wire at Delcotron battery ter minal and connect an ammeter in series between the wire and terminal 3 Connect a voltmeter from battery terminal to a good gr...

Page 261: ... sides of bulb bulb goes out The indicator light should glow when ignition switch is ON and go out almost immediately when engine starts Ammeter equipped vehicles use the same initial field excitation and control circuits as the indicator lamp ex cept the lamp is omitted The continuity tests on both type vehicles can be made as follows If Lamp Fails to Glow or Ammeter Fails to Function the Possibl...

Page 262: ...ONNECTOR it must be spliced with a crimp type connector It is rated at 10 ohms 6 25 watts minimum The check for an open resistor or field excitation wire connected to the ignition switch A terminal is as follows 1 Connect a test lamp from the wiring harness con nector terminal 4 to ground as shown in Figure 9c Step 1 2 Turn the ignition switch to the ACC position and note test bulb a Test lamp glo...

Page 263: ...ining nut and insert 5 16 alien wrench into shaft to hold shaft while removing nut fig 11c 2 Remove washer and slide pulley fan and spacer from shaft 3 Reverse Steps 1 and 2 to install use a torque wrench with a craw foot adapter instead of box wrench and torque the nut to 50 ft lbs fig 12c Double Groove Pulley 1 Place a 15 16 socket with wrench flats on the drive end or use Adapter J 21501 and a ...

Page 264: ...der Tune up Section 6 DOUBLE CONTACT REGULATOR REPLACEMENT NOTE Voltage regulating contacts should never be cleaned as they are made of special material that may be destroyed by cleaning with any abra sive material A sooty or discolored condition of the contacts is normal after a relatively short period of operation To remove the regulator assembly disconnect the battery ground cable and the wirin...

Page 265: ...iring of the engine Connections should be clean and tight SERVICE OPERATIONS Replacement DISTRIBUTOR CONTACT POINTS Cleaning Dirty contact points should be dressed with a few strokes of a clean fine cut contact file The file should not be used for other metals and should not be allowed to become greasy or dirty Never use emery cloth to clean contact points Contact surfaces after considerable use m...

Page 266: ...eads as shown in Figure 3i Improper installa tion will cause lead interference between the cap weight base and breaker advance plate 6 If vehicle has 20 000 to 25 000 miles or sooner if desired the cam lubricator wick fig 4i should be changed Using long nosed pliers squeeze assembly together at base and lift out Remove all old lubri cant from cam surface Replace in same manner NOTE End of cam lubr...

Page 267: ...ures normalized the dwell is adjusted by first raising the window provided in the cap and inserting a Hex type wrench into the adjusting screw head fig 8i 1 Preferred Method Turn the adjusting screw until the specified dwell andle is obtained as measured in degrees 29 to 31 30 preferred by a dwell angle meter 2 Alternate Method Turn adjusting screw in clock wise until the engine begins to misfire ...

Page 268: ...lements and the insulating and impreg nating materials For a complete check of the condenser use a tester which will check for all of the above conditions Follow the instructions given by the manufacturer of the test equipment Condenser capacity should be 18 23 micro farads Replacement Six Cylinder Engine Distributor Fig 1i 1 Release distributor cap hold down screws remove cap and place it out of ...

Page 269: ...and condition of contacts This test will give valuable information on distributor condition and indicate parts replacement which may be necessary Check the area on the breaker plate just beneath the contact points A smudgy line indicates that oil or crankcase vapors have been present between the points Six Cylinder Engines Refer to Figure 9i 1 Remove the rotor and dust shield 2 Remove the vacuum c...

Page 270: ...r lever spring tension which should be 19 23 ounces See contact point replacement 10 Install dust shield and rotor V 8 Engines Fig lOi 1 a Fill housing lubricating cavity with proper com pound press in new plastic seal and install felt washer b Replace the vacuum advance unit c Install the breaker plate in housing and the spring retainer on the upper bushing NOTE Spring should seat on the flat ma ...

Page 271: ...y until points just open and tighten distributor clamp bolt 6 Place distributor cap in position and check to see that rotor lines up with terminal for No 1 spark plug 7 Install cap check all high tension wire connections and connect spark plug wires if they have been re moved It is important that the wires be installed in their location in the supports NOTE The brackets are numbered to show the co...

Page 272: ...brittle cracked or loose insulation Defective insula tion will permit missing or cross firing of engine therefore defective wires should be replaced 5 If the wires are in good condition clean any terminals that are corroded and replace any terminals that are broken or distorted Replace any borken or deterio rated cable nipples or spark plug boots Spark Plug Cleaning Spark plugs which have carbon o...

Page 273: ...r cap tower after the adjusting window moving in the direc tion of rotation V 8 or in the foremost tower L 6 The other wires are then installed in a clockwise direction according to the firing order figs 14i and 15i STARTING SYSTEM INDEX Page General D e s c r ip tio n 6Y 23 M aintenance and A d ju s tm e n ts 6Y 24 L u b ric a tio n 6Y 24 Resistance C h e c k s 6Y 24 Page Starting M otor and Sole...

Page 274: ...sure the voltage drop between the BATTERY ter minal of the solenoid and the SWITCH S terminal of the solenoid 1 If this voltage drop exceeds 3 5 volts excessive re sistance in the solenoid control circuit is indicated and should be corrected 2 If the voltage drop does not exceed 3 5 volts and the solenoid does not pull in measure the voltage available at the SWITCH terminal of the solenoid 3 If th...

Page 275: ...Installation Fig 2s The following procedure ia a general guide for all vehicles and will vary slightly depending on the truck series and model 1 Disconnect battery ground cable at the battery 2 Disconnect engine wiring harness and battery leads at solenoid terminals 3 Remove starter mounting bolts and retaining nuts and disengage starter assembly from the flywheel housing 4 Position starter motor ...

Page 276: ...ENGINE ELECTRICAL 6Y 26 SPECIAL TOOLS J 9717 2 SUPPORT TOOL J 5184 CHECKING SCALE J 21501 PULLY ADAPTER J 9600 2 SHOULDERED INSTALLER Fig 3s Special Tools 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 277: ... 350 7 4 Turbo Hydra Matic 400 7 7 Special T ools 7 13 Page 7 20 7 29 7 39 CLUTCH CONTROLS INDEX General Description Maintenance and Adjustments Clutch Free Pedal Travel Adjustment 7 1 7 2 7 2 Insufficient Clutch Release 7 2 Clutch Pedal Replacement 7 2 Clutch Cross Shaft Replacement 7 4 GENERAL DESCRIPTION I 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 278: ...intervals to provide sufficient free pedal travel fig 4 to permit full engagement of the clutch 1 Disconnect clutch fork return spring at fork 2 Loosen nut A fig 3 and back off from swivel ap proximately 1 2 inch 3 Hold clutch fork push rod against fork to move throwout bearing against clutch fingers push rod will slide through swivel at cross shaft 4 Adjust nut B to obtain approximately 3 16 to 1...

Page 279: ...llation NOTE Use new shaft bushing if needed and lubricate with Lubriplate or petrolatum 1 Slide one pedal shaft bushing over shaft install shaft in support enough to still clear pedal bumper stop hook pedal return or overcenter spring to pedal then rotate pedal forward of bumper stop slide shaft into position in support and release pedal against bumper stop 2 Install clutch pedal shaft bushing ov...

Page 280: ... linkage 4 Tighten all front and rear engine mounting bolts Should the mountings be oil soaked it will be neces sary to replace them CLUTCH RETRACTING SPRING REPLACEMENT A rattle in the clutch assembly at idling speeds with the clutch released or failure of the clutch to release prop erly may be caused by insufficient tension on the pres sure plate retracting springs These troubles can easily be c...

Page 281: ...port the clutch assembly during removal 6 Loosen the clutch attaching bolts one turn at a time to prevent distortion of clutch cover until dia phragm spring is released 7 Remove clutch pilot tool and remove clutch assembly from vehicle Installation to Vehicle 1 Install the pressure plate in the cover assembly lin ing up the notch mark on pressure plate with notch mark on flange of cover 2 Install ...

Page 282: ...dge contact between the outer end of the lever and the lug The outer ends of the eyebolts extend through holes in the stamped cover 4 and are fitted with adjusting nuts 5 to correctly position the levers 2 Eyebolt 4 Cover 5 Adjusting Nut Fig 9 Release Lever SERVICE OPERATIONS CLUTCH ASSEMBLY Removal From Vehicle Before removing clutch from flywheel mark with a punch the flywheel clutch cover and o...

Page 283: ...checked as outlined in the procedure in Section 9 of this manual Page Rear Oil Seal Replacement Speedometer Driven Gear Replacement Side Cover Replacement Repair Transfer Case Replacement Fig 11 Removing Transmission Gearshift Lever TRANSMISSION SHIFT CONTROL LEVER REPLACEMENT FLOOR SHIFT 1 On K Series models remove transfer case shift lever boot retainer attaching screws and retainer from compart...

Page 284: ...n com panion flange or output yoke Move the transmission forward guiding the main drive gear shaft into the clutch disc splines IMPORTANT Avoid springing the clutch when the transmission is being installed to the engine Do not force the transmission into the clutch disc hub Do not let the transmission hang un supported in the splined portion of the clutch disc Install flywheel housing to transmiss...

Page 285: ...n guide pins J 1126 Use of the guide pins will prevent damage to the clutch assembly 17 Slide transmission rearward until main drive gear clears the clutch assembly and lower assembly from vehicle 4 Speed Transmission Installation 1 Position transmission with transfer case attached to the flywheel housing Install bolts attaching trans mission to flywheel housing 2 Install flywheel housing cover an...

Page 286: ... If the maximum indicator reading is at the 12 o clock position put shims on the two bottom bolts 6 After the position and quantity of shims has been determined and recorded the transmission case may be removed NOTE The clutch housing should then be stamped showing the position where shims are to be installed and the thickness of shims at each location 7 Inspect the external clutching teeth of the...

Page 287: ...riven gear shaft with transmission lubricant and insert shaft Hold the assembly so slot in fitting is toward lock plate boss on housing and install in housing Push fitting into housing until lock plate can be inserted in groove and attached to housing TRANSMISSION SIDE COVER REPLACEMENT REPAIR Saginaw and Muncie 3 Speed Fig 14 1 Disconnect control rods from levers back up lamp wiring and TCS switc...

Page 288: ...attaching transfer case to transmission adapter 8 Move transfer case to rear until input shaft clears adapter and lower assembly from vehicle Installation 1 Support transfer case in suitable stand and position case to transmission adapter Install bolts attaching case to adapter and torque to 45 ft lbs 2 Remove stand as required and install bolts attach ing transfer case to frame rail Bend tabs aft...

Page 289: ...cessible for service by removing the oil pan assembly The valve body consists of an upper and lower body lo cated on either side of a transfer plate The vacuum modulator is located on the left rear face of the trans mission case The modulator valve bore is located in the upper valve body MAINTENANCE AND ADJUSTMENTS OIL LEVEL CHECK The transmission oil level should be checked periodi cally as recom...

Page 290: ...t lift the transmission selector lever towards the steering wheel Allow the selector lever to be positioned in drive D by the transmission detent NOTE Do not use the indicator pointer as a reference to position the selector lever When performing linkage adjustment pointer is ad justed last 3 Release the selector lever The lever should be in hibited from engaging low range unless the lever is lifte...

Page 291: ...n carburetor to wide open throttle position Carbure tor must reach wide open throttle position at the same time the ball stud contacts end of slot in upper T V rod 5 Adjust swivel on end of upper T V rod to obtain set ting described in Step 4 Allowable tolerance is ap proximately 1 32 6 Connect and adjust accelerator linkage as described in Section 6 7 Check for throttle linkage freedom Neutral Sa...

Page 292: ...diately or a similar tool constructed as shown in Figure 4PG or in an emergency a length of strong wire may be used after removal from the engine Installation 1 Mount transmission on transmission lifting equip ment installed on jack or other lifting device 2 Remove converter holding tool CAUTION Do not permit converter to move forward after removal of holding tool 3 Raise transmission into place a...

Page 293: ...least 15 miles the fluid level should be between the FULL mark and 1 4 inch below FULL The vehicle should be level with the engine idling and the trans mission in PARK Transmission at Room Temperature 80 F If the vehicle has not been driven sufficiently to bring the transmission up to operating temperature the fluid level should be checked as follows 1 Apply the parking brake put the selector leve...

Page 294: ...ure Drive Range Overrun Coast Pressure It is not recommended that stall tests be conducted which would result in engine vacuum falling below 10 Hg Pressure gauge hose connections should be made at the low servo apply main line test point fig 5PG Run the gauge line into the driving compartment by pushing aside the mast jacket seal Tie line out of the way of the drivers feet and connect to Pressure ...

Page 295: ...Base 3 36 Axle C78 14 Tire Closed Throttle 17 24 21 16 Detent Touch 39 49 37 25 Wide Open Throttle 46 54 51 43 Engine Throttle Position MPH in Drive Upshift Downshift Min Max Max Min CE 200 V 8 307 Base 4 57 Axle 8 75 16 5Tire Closed Throttle 15 21 18 14 Detent Touch 34 43 32 22 Wide Open Throttle 40 47 44 37 GS 200 L 6 250 Base 4 11 Axle G78 15 Tire Closed Throttle 15 22 19 14 Detent Touch 35 44 ...

Page 296: ...ed operating range Engine Vacuum To operate the vacuum modulator Detent Cable To operate Detent System The Turbo Hydra Matic 350 transmission features three forward driving ranges which can be selected with the shift lever Approximate gear ratios of the transmission are as follows FIRST 2 5 1 INTERMEDIATE 1 5 1 DIRECT 1 00 1 REVERSE 2 00 1 The selector quadrant has six selector positions P R N D L...

Page 297: ...thoroughly into a pan or can 4 Replace drain plug and refill with approximately two and one half quarts of oil specified in Section 0 NOTE To refill the transmission remove dip stick from oil filler tube and refill transmission Fig 1 Turbo Hydra Matic 350 Control Rod Link P Mod els with oil specified in Section 0 Then after shift ing into all ranges at idle speed to fill all oil passages the engin...

Page 298: ...meter drive cable fitting at the transmission Tie lines out of the way 3 Disconnect manual control lever rod and detent cable from transmission 4 Disconnect prop shaft from transmission 5 Install suitable transmission lift equipment to jack or other lifting device and attach on transmission 6 Disconnect engine rear mount on transmission exten sion then remove the transmission support cross member ...

Page 299: ...ine 8 Remove the transmission support rear crossmember 9 Remove converter under pan scribe flywheel to converter relationship for assembly then remove flywheel to converter attaching bolts 10 Support engine at the oil pan rail with a jack or other suitable brace capable of supporting the engine weight when the transmission is removed 11 Lower rear of the transmission slightly so that the upper tra...

Page 300: ... and for leakage Check and if necessary adjust linkage OPERATIONS without removing the Turbo Hydra Matic 350 their service procedure is covered in the Overhaul Manual and is not repeated here Refer to the Turbo Hydra Matic 350 Section of the Overhaul Manual for all other service operations not covered here DIAGNOSIS PROCEDURE The following sequence based on field experience pro vides the desired i...

Page 301: ...ent pipe refer to Item 5 i Porous case 4 FRONT END LEAK a Front seal damaged check converter neck for nicks etc also for pump bushing moved forward b Pump attaching bolts and seals damaged miss ing bolts loose c Converter leak in weld d Pump O ring seal damaged Also check pump groove and case bore e Porous casting pump or case 5 OIL COMES OUT VENT PIPE a Transmission over filled b Water in oil c P...

Page 302: ... into the tube and observe for leak bubbles If bubbles appear replace the modulator NOTE Do not use any method other than human lung power for applying air pressure as pres sures over 6 psi may damage the modulator Fig 7 Bellows Comparison Gauge 3 Bellows Comparison Check Using a comparison gauge as shown in Fig 7 com pare the load of a know good Turbo Hydra Matic 350 mod ulator with the assembly ...

Page 303: ...73 Axle F78 14 Tire GS 100 3 36 Axle C78 14 Tire Throttle Position 1 2 up 2 1 dn 2 3 up 3 2 dn 1 2 up 2 1 dn 2 3 up 3 2 dn Closed Throttle 5 12 10 3 17 31 29 14 6 13 10 3 16 31 28 14 Detent Tho Touch 28 36 8 0 41 52 57 38 30 38 9 0 43 54 59 39 Wide Open Throttle 24 40 27 14 50 63 63 49 25 42 29 14 52 66 66 51 Model Engine GE 100 V 8 307 3 36 Axle C78 14 Tire GS 200 4 11 Axle G78 15 Tire Throttle P...

Page 304: ...0 3 18 32 31 14 5 12 10 3 17 31 29 14 Detent Tho Touch 30 37 8 0 43 54 60 40 29 36 8 0 42 52 57 39 Wide Open Throttle 25 42 28 14 52 66 66 52 24 40 27 14 50 64 64 50 TURBO HYDRA MATIC 350 TRUCK P MODEL Model Engine PA 200 4 57 Axle 8 75 16 5 Tire PS 100 3 73 Axle G78 15 Tire Throttle Position 1 2 up 2 1 dn 2 3 up 3 2 dn 1 2 up 2 1 dn 2 3 up 3 2 dn Closed Throttle 5 11 9 3 16 28 27 13 6 13 10 3 18 ...

Page 305: ... that it actually assists the converter pump to deliver power or multiply engine torque As turbine speed increases the direction of the oil leaving the turbine changes and flows against the rear side of the stator vanes in a clockwise direction Since the stator is now impeding the smooth flow of oil its roller clutch releases and it revolves freely on its shaft Once the stator becomes inactive the...

Page 306: ... should be level with the engine idling and the trans mission in PARK Transmission at Room Temperature 80 F If the vehicle has not been driven sufficiently to bring the transmission up to operating temperature the fluid level should be checked as follows 1 Apply the parking brake put the selector lever in PARK and start the engine Note Do Not Race the Engine Move the selector lever through each ra...

Page 307: ...be and lever assembly must be free in the mast jacket See Section 9 for alignment of steering column assembly if necessary 2 To check for proper shift linkage adjustment lift the transmission selector lever towards the steering wheel Allow the selector lever to be positioned in drive D by the transmission detent NOTE Do not use indicator pointer as a reference to position the selector lever When p...

Page 308: ... the swivel and recheck the adjustment See Steps 2 and 6 10 Readjust indicator needle if necessary to agree with the transmission detent positions See Section 9 11 Readjust neutral safety switch if necessary to pro vide the correct relationship to the transmission de tent positions See Section 12 12 When properly adjusted the following conditions must be met by manual operation of the steering col...

Page 309: ...solid style valve must only be used in the pump cover with the squared off pressure regulator boss Pressure boost bushing end See Fig 5T The previous pressure regulator valve with the oil holes and orifice cup plug will be used to service either type pump cover Removal 1 Remove bottom pan and filter 2 o Compress regulator boost valve bushing against pressure regulator spring and remove snap ring u...

Page 310: ...ut with screw driver Installation All Models Except CM 1 a Use a non hardening sealer on outside of seal body and using ToolJ 21359 drive seal in place M odel CM b Use a non hardening sealer on outside of seal body and using Tool J 21464 drive seal in place 2 Re install propeller shaft OTHER SERVICE WITH TRANSMISSION IN VEHICLE The following operations when done as single opera tions and not as pa...

Page 311: ...gine running and the vehicle on level pavement Fluid level should be to the FULL mark with the trans mission at normal operating temperature 180 F With warm fluid room temperature 80 F the level should be at or 1 4 inch below the ADD mark See checking procedure If oil level was low refer to Oil Leaks The condition of the oil is often an indication of whether the transmission should be removed from...

Page 312: ...ressures should check as follows Approximate Altitude of Check Ft above seal level Drive Neutral Park LI or L2 Reverse 0 150 150 244 2 000 150 150 233 4 000 145 150 222 6 000 138 150 212 8 000 132 150 203 10 000 126 150 194 12 000 121 150 186 14 000 116 150 178 Minimum Maximum L2 2nd Gear Steady road load at approximately 25 mph 145 psi 155 psi Gear Selector Lever Position Minimum Maximum 1st Driv...

Page 313: ...n question a Install the modulator that is known to be acceptable on either end of the gauge b Install the modulator in question on the opposite end of the gauge c Holding the modulators in a horizontal position bring them together under pressure until either modulator sleeve end just touches the line in the center of the gauge The gap between the opposite modulator sleeve end and the gauge line s...

Page 314: ...itch circuit the transmission bottom pan must be re moved to service the pressure switch or lead wire assembly TURBO HYDRA MATIC 400 SHIFT POINTS CONV TRUCK MODELS MPH Engine CE 100 V 8 402 CJ 3 07 Axle G78 15 Tire CE 200 V 8 402 CJ 3 54 Axle 8 75 16 5 Tire Throttle Position 1 2 up 2 1 dn 2 3 up 3 2 dn 1 2 up 2 1 dn 2 3 up 3 2 dn Closed 8 14 13 7 20 31 27 16 7 13 12 6 19 29 25 15 Thru Detent W O T...

Page 315: ...SSIONS 7 39 SPECIAL TOOLS Fig 1ST C lutch Special Tools 1 J 6456 Height Gauge 2 J 1048 Gauge Plate 3 J 1522 Pilot Bearing Drive 4 J 5824 Clutch Pilot Tool 5 J 1448 Pilot Bearing Puller 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 316: ...l J 358 1 and Press Plate Holder 4 J 5778 Extension Bushing Remover 8 J 2228 Rear Bearing Press Plates and Installer 9 J 5590 Clutch Gear Bearing Installer 5 J 5154 Extension Seal Installer 10 J 9772 Clutch Gear Bearing Installer 6 J 5814 01 Speedometer Drive Gear Remover 11 J 23096 Clutch Gear Retainer Seal J 5814 15 and Adapter Installer 12 J 5752 Transmission Holding Fixture 10 30 CHEVROLET TRU...

Page 317: ...port Tool 3 J 22872 Clutch Gear Bearing Remover and Installer 10 J 22874 2 Countershaft Support Tool 4 J 22833 Front Bearing Retainer Seal Installer 11 J 22834 2 Rear Bearing Retainer Seal Installer 5 J 22873 2nd Speed Bushing Installer 12 J 23070 Mainshaft Rear Bearing Lock Nut 6 J 22875 3rd Speed Bushing Installer Insta Her 7 J 22830 Snap Rina Installer 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 318: ...ller 3 J 8092 Handle 8 J 7137 Adapter Seal Installer 4 J 23429 Intermediate Shaft Remover and Installer 9 J 9276 2 Intermediate Gear Bearing Cup Installer 5 J 22836 Front Output Shaft Bearing Retainer Seal Installer 10 J 22875 Rear Output Shaft Rear Bearing Installer 6 J 21359 Rear Output Shaft Bearing Retainer Seal Installer 11 J 22303 Adapter Seal Installer 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 319: ...Shaft Front Bearing Cup Installer 4 J 23423 Rear Output Shaft Rear Bearing Cup Installer 5 J 5590 Bearing Installer 6 J 23 419 Intermediate Shaft Remove and Installer 7 J 22833 Output Shaft Housing Seal Installer 8 J 23420 Pilot Bearing Installer 9 J 7137 Adapter Seal Installer 10 J 6219 Front Output Shaft Bearing Installer 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 320: ...lanet Pinion Assembly Tool Set 13 J 9542 Reverse Piston Spring Compressor 14 J 9557 Transmission Case Rear Bushing Remover and Installer and Governor Support Bushing Remover 15 J 7079 16 J 6582 17 J 9543 18 J 5778 19 J 5154 20 J 5403 21 J 5853 22 J 8039 23 J 21848 J 8001 J 5492 J 6585 J 6585 3 J 9534 Handle Governor Support Bushing Installer Vacuum Modulator Wrench Extension Bushing Remover and In...

Page 321: ...ver Handle Extension 18 J 21359 Pump Seal Installer 6 J 23062 3 Sun Gear and Reaction Carrier Bushing Installer 19 J 6585 Slide Hammer Weights 7 J 23062 7 Output Shaft Bushing Installer 19A J 9539 Slide Hammer Screw 8 J 21465 15 Stator Shaft Front Bushing Remover 20 J 21885 2 3 Accumulator Piston Compressing Tool 9 J 23329 Direct Clutch Bushing Installer 21 J 23071 Intermediate Band Apply Pin Gaug...

Page 322: ...1 J 21465 17 Part of Bushing Tool Set 6 J 5154 Extension O il Seal Installer 22 J 2 1465 8 Part of Bushing Tool Set 7 J 6585 Slide Hammer Weights 23 J 2 1465 13 Part of Bushing Tool Set 8 J 9539 Slide Hammer Bolts 3 8 16 Threads 24 J 2 1465 6 Part of Bushing Tool Set 9 J 5590 Speedo Gear Installer 25 J 2 1465 15 Part of Bushing Tool Set 10 J 21867 Pressure Gauge and Hose 26 J 2 1465 16 Par6 of Bus...

Page 323: ...ar Remover 11 J 21664 Clutch Spring Compressor Adapter Ring 4 J 9539 Slide Hammer Bolts 3 8 16 Threads 12 J 4670 Clutch Spring Compressor 5 J 8105 Speedo Gear Remover Puller 13 J 8059 Snap Ring Pliers 6 J 21885 Accumulator Piston Installer 14 J 5586 Snap Ring Pliers 7 J 21369 Converter Pressure Check Fixture 15 J 5403 Snap Ring Pliers 8 J 21362 Seal Protector Forward and Direct Clutch Inner 16 J 1...

Page 324: ......

Page 325: ... system Lower filler necks are first bolted or riveted to the tank except on cab models and then sweat soldered in place to eliminate any possibility of leakage at this point All tanks 10 series are equipped with a pressure vacuum filler neckcaps The fuel pickup pipe is built integrally with the tank gauge unit located at the top of the tank A large area fine mesh screen is located on the bottom o...

Page 326: ...s heard to strike the bottom of the tank 4 With the opposite end of the hose in a suitable con tainer insert an air hose in the downward direction in the flap type slit and trigger the flow of fuel CAUTION Before draining be sure that the fuel tank gauge unit wire or battery negative cable is disconnected Always drain gasoline from complete fuel sys tem including carburetor fuel pump all fuel line...

Page 327: ...rder by part number FUEL TANKS NOTE The optional auxiliary fuel tank installs in the same manner as center mounted tanks It is connected to the cab mounted tank as shown in Figure 3 CAB MOUNTED TANKS Fig 2 Removal and Installation 1 Remove seat back hold down bolts and tilt seat back forward 2 Remove tank cover if so equipped 3 Drain tank 4 Disconnect fuel line meter wire and ground lead 5 Remove ...

Page 328: ...igs 6 and 7 Rem oval and Installation 1 Drain tank 2 Remove filler neck 3 Disconnect gauge unit fuel line and wiring Ignition switch must be in OFF position 4 Remove bolts attaching tank supports to frame 5 Remove tank complete with mounting brackets and support straps 6 Remove tank from brackets and support straps if necessary 7 To install reverse the removal procedures Re place all anti squeak m...

Page 329: ...hole Rock tank to assure complete removal of water IMPORTANT This procedure will not remove fuel vapor Do not attempt any repair on tank or filler neck where heat or flame is required 8 Disconnect inlet fuel line at pump and use air pressure to clean fuel line and fuel return line if equipped Apply air pressure in the direction fuel normally flows through line 9 Use low air pressure to clean pipes...

Page 330: ...FUEL TANK AND EXHAUST SYSTEMS 8 6 C A 10 BLAZER SERIES PIPE V 8 ENGINE M fwd GROMMET CA 10 20 EXCEPT BLAZER SERIES Fig 9a Fuel Lines C A 10 and 20 Series 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 331: ...SE BRAKE PIPE CLIP UPC5 BRAKE PIPE UPC5 FWD PA 200 250 300 350 L 6 ENGINE FUEL FEED FRONT PIPE V 8 ENGINE HOSE REAR PIPE REAR FUEL METER PIPE REAR PIPE ASSEMBLY REAR FUEL FEED FRONT PIPE FUEL TANK VENT FRONT PIPE UNION INTER PIPE M f w d PA 200 250 300 350 FUEL FEED INTER AND REAR PIPE AND HOSE REAR PIPE HOSE Fig 9b Fuel Lines P 10 30 Series 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 332: ...orating this system GASOLINE TANK The gasoline tanks incorporate special extended filler necks and vents and also external hose connections LIQUID VAPOR SEPARATOR The separator mounts to the right or left hand side of the gasoline tank If service is necessary the entire assembly must be replaced CANISTER The canister is mounted on the left side of the engine compartment A filter is mounted in the ...

Page 333: ...FUEL TANK AND EXHAUST SYSTEMS 8 9 Fig 11 Canisters Hoses and Front Vent Pipes C K and P 10 Series Fig 12 Upper Vent and Intermediate Hoses and Pipe C K 10 Series 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 334: ...ap 2 Reinstall canister as previously outlined connect lines to valve SEPARATOR Removal 1 Raise vehicle on hoist 2 Disconnect lines from separator 3 Remove retaining screw and remove separator Installation 1 Install separator and its retaining screw 2 Connect lines to separator 3 Lower vehicle and remove from hoist FUEL TANK Removal and installation procedures are the same as Fig 14 Fuel Vapor Sti...

Page 335: ...ts when servicing these systems When installing a new exhaust pipe or muffler and tail pipe on any model care should be taken to have the cor rect alignment and relationship of the components to each other Particular care should be given to the installa tion of the exhaust pipe and crossover pipe assembly on V 8 engine single exhaust systems Incorrectly assem bled parts of the exhaust system are f...

Page 336: ... sure that exhaust system components have at least 3 4 inch clearance from the floor pan to avoid possible overheating of the floor pan and possible damage to the passenger compartment carpets Fig 17 Exhaust System C 10 and 20 Series Except Fleetside Pickup 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 337: ...FLER TAIL PIPE CA314 TAIL PIPE FRAME BRKT C A 310 02 03 7 b r a c k e t CS MODELS RETAINER NOTE Tail Pipe t o be rotated outboard approx 30 Z RETAINER IB R A C K E T CE MODELS SEE 8C 1 BRACKET A N D INSULATOR VIEW V A ft LOWER CLAM P J v VIEW D V VIEW Fig 18 Exhaust System C 20 Fleetside Pickup and C 30 Series Trucks Fig 19 Crossover Pipe Assembly C K 10 thru 30 V 8 Series 10 30 CHEVROLET TRUCK SE...

Page 338: ...A N D TAIL PIPE ASSEMBLY EXHAUST PIPE V VIEW D V VIEW B Fig 20 Muffler and Tailpipe P 10 30 Series Typical BRACKET RING MUFFLER TAIL PIPE ASSEMBLY EXTENSION VIEW B V VIEW A MUFFLER TAIL PIPE ASSEMBLY C O VER PIPE BRACKET BRACKET A N D IN SU LA T O R ASSEMBLY EXHAUST PIPE ASSEMBLY v VIEW D v VIEW C T LOWER CLAM P J Fig 21 Exhaust System K 10 Series 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 339: ...FUEL TANK AND EXHAUST SYSTEMS 8 15 SPECIAL TOOLS Fig 22 Special Tools 1 J 23346 Fuel Tank Gauge Remover and Installer ...

Page 340: ......

Page 341: ...nected to the pitman arm on the left and an idler arm on the right K10 20 models use a single adjustable tie rod connecting the left and right steering arms Steering effort is re layed to the left steering arm from the pitman arm by a non adjustable connecting rod MAINTENANCE AND ADJUSTMENTS ADJUSTMENTS LUBRICATION The steering gear is factory filled with steering gear lubricant Seasonal change of...

Page 342: ...a maximum torque reading of more than 50 inch pounds 7 Adjust thrust bearing preload by tightening the adjuster plug until the proper thrust loading pre load is obtained See specifications section at rear of this manual When the proper preload has been obtained tighten the adjuster plug locknut to speci fications and recheck torque If the gear feels lumpy after adjustment there is probably damage ...

Page 343: ...f high point when setting wheels in straight ahead position loosen adjusting sleeve clamps on both left and right hand tie rods then turn both sleeves an equal number of turns in the same direction to bring gear back on high point CAUTION Turning the sleeves an unequal number of turns or in different directions will disturb the toe in setting of the wheels 4 Readjust toe in as outlined in Section ...

Page 344: ...eutral position when assembling steering wheel to prevent damage to cancelling cam and control assembly 1 Place the steering wheel onto the steering shaft aligning the marks made at removal 2 Tap whee1 gently into place and secure with washer and nut NOTE The steering wheel to steering shaft fastener is an important attaching part in that it could affect the performance of vital components and sys...

Page 345: ...rmshaft until the coupling reinforcement bottoms against the end of the worm 2 Install the special bolt into the split clamp and torque to specifications NOTE The bolt must pass through the shaft undercut 3 Place the steering gear into position guiding the flexible coupling bolts into the proper holes in the steering shaft flange Install and tighten the steering gear to frame bolts Install the cou...

Page 346: ...etainer Installation NOTE All steering gear to frame and all steering coupling fasteners are important at taching parts in that they could affect the per formance 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 Do not use a replacement part of lesser qualit...

Page 347: ...made at removal and assemble the intermediate shaft lower yoke onto the steering gear wormshaft Install the pinch bolt and torque to specifications NOTE The pinch bolt must pass through the shaft undercut If a new yoke was installed the slit in the yoke should be up 12o clock position 2 Raise the steering gear into position while guiding the upper yoke assembly onto the steering shaft NO TE The ma...

Page 348: ... in neutral position before installing steering wheel NO TE The steering wheel to steering shaft fastener is an important attaching part in that it could affect the performance of vital components and systems and or could result in major re pair expense It must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary Do not use a replacement part of ...

Page 349: ... lower end of the connector and push in until the tool bottoms on the connector Remove the tool and then pull the wire from the connector 7 Remove the directional signal lever screw and re move the lever 8 Push in on the hazard warning light knob and then unscrew and remove the knob 9 Tilt Columns O nly a Automatic Transmission Models Remove the PRNDL dial screws and remove the dial and in dicator...

Page 350: ...umn Shift Models Disconnect transmission shifter rods at the lower end of the column 3 C K Models Remove the intermediate steering shaft flange to flexible coupling bolts P Models Remove the intermediate steering shaft upper universal yoke to steering shaft pinch bolt Mark the coupling to shaft relationship 4 Remove column clamp screw s on engine side of firewall and remove or slide the clamp down...

Page 351: ... Shift Lever 14 Shift Tube Assembly 29 Steering Shaft Nut 15 Shift Lever Spacer 30 Lockwasher toe pan cover and slide the cover and seal up the column 6 Remove the steering wheel as outlined under Steer ing Wheel Removal and reinstall the shaft nut and washer 7 All Columns Disconnect the directional signal wir ing harness Standard Column with Automatic Transmission Dis connect the conductor tube f...

Page 352: ...IN STRU PA N EL OPENING COVER HOUSING ASSY PIN RELEA SE 0 SHOE R E LE A SE BEARING ASSY RET A IN ER Fig 20 Tilt Steering Column Explode ...

Page 353: ... the shift tube in the jacket 4 3 Speed Columns Temporarily install spacer 1st reverse shift lever and lower adjusting ring Place a block of wood on top of the adjusting ring and tap until the shift tube bottoms Remove adjusting ring shift lever and spacer NO TE The shift tube spring retainer must be bottomed against the jacket stops Automatic Columns Align the three holes in the se lector plate w...

Page 354: ...ft bearing locknut using socket J 22599 Remove the upper bearing race seat and race 7 Remove the two bearing housing pivot pins using Tool J 21854 fig 23 8 Pull up on the tilt release lever to disengage the lock shoes and remove the bearing housing If it is Fig 24 Removing Bearing Race necessary to disassemble the bearing housing pro ceed as follows a Press the upper and lower bearings out of the ...

Page 355: ...51 fig 28 Insert the hooked end of the tool into the notch in the shift tube just below the shift lever housing key Pilot the sleeve over the threaded end of the tool and into the upper end of the shift tube Force the shift tube out of the housing by turning the nut onto the tool If the shift tube is not com pletely free when the nut is bottomed on the threads complete the removal by hand CAUTION ...

Page 356: ...llows a Lubricate and assemble the centering spheres and preload spring Fig 30 Installing Shift Pin Tube b Install the spheres into the upper short shaft and rotate 90 c Install the lower shaft 90 to the upper shaft and over the centering spheres Slowly straighten the shafts while compressing the preload spring 9 Install the shaft assembly into the housing from the upper end 10 Install the lower b...

Page 357: ...cations 5 C K Models After the assembly is completed and all bolts are properly torqued the dimension be tween the steering shaft lower tube and intermediate coupling must be maintained at 6 38 to 6 78 inches The rag joint to steering shaft flange clearance should be 250 to 375 NOTE If plastic spacers were used on the flexible coupling alignment pins fig 10 re move the spacers after all bolts have...

Page 358: ...relay rod 4 Install ball stud nut tighten and install new cotter pins see Specifications Section at rear of manual Lubricate tie rod ends 5 Remove vehicle from hoist 6 Adjust toe in as described in Section 3 C A U T IO N Before tightening the tie rod ad justing sleeve clamp bolts be sure that the fol lowing conditions have been met a The sleeve clamps must be positioned between the locating dimple...

Page 359: ...fications section at the rear of this manual 4 Remove the vehicle from the hoist Pitman Arm Removal 1 Place vehicle on hoist 2 Remove cotter pin from pitman arm ball stud and re move nut 3 Remove pitman arm or relay rod from ball stud by tapping on side of rod or arm in which the stud mounts with a hammer while using a heavy hammer or similar tool as a backing fig 35 Pull on linkage to remove from...

Page 360: ...o made in the rack piston teeth Hydraulic pressure is provided by an engine driven vane type pump which is bracket mounted to the left side Fig 37 Pitman Shaft Sector Teeth of the engine Pressure is deliveredfrom thepump through two hoses to the variable ratio steering gear MAINTENANCE AND ADJUSTMENTS ADJUSTMENTS Power Steering Gear The over center adjustment fig 38 is the only power steering gear...

Page 361: ...l remains con stant after running engine Fig 39 Checking Belt Tension with Tool J 23600 5 Raise front end of vehicle so that wheels are off the ground 6 Increase engine speed to approximately 1500 rpm 7 Turn the wheels off ground right and left lightly contacting the wheel stops 8 Add oil if necessary 9 Lower the vehicle and turn wheels right and left on the ground 10 Check oil level and refill as...

Page 362: ...ng wheel against a stop momentarily and read pressure gauge If the maximum pres sure is below specifications a faulty hydraulic circuit is indicated To determine which part is faulty proceed with test number two Test Number Two Oil Circuit Closed a Slowly turn shut off valve on J 5176 to closed position and read pressure indicated on gauge Quickly reopen valve to avoid pump damage If indicated pre...

Page 363: ...If a new gear was installed line up the mark on the stub shaft with the slit in the universal yoke b Install the steering gear to frame bolts and torque to specifications c Install the universal joint pinch bolt and torque to specification NOTE The pinch bolt must pass through the shaft undercut 3 Install the pitman arm onto the pitman shaft lining up the marks made at removal Install the pitman s...

Page 364: ...eering right and left while observing movement of the hoses equipment should include a thorough inspection of the Note and correct any hose contact with other parts of hydraulic line system the vehicle that could cause chafing or wear Figure 44 illustrates typical installations 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 365: ...10 30 CHEVROLET TRUCK SERVICE MANUAL Fig 43 Power Steering Pump M ounting STEERING 9 25 ...

Page 366: ...CPK L 6 v i E W _ A _ _ y CPK 10 30 ALL V 8 EXC 400 V VIEW B VIEW A C K 10 30 400 V 8 Fig 44 Typical Power Steering Hose Routings ...

Page 367: ...0 Belt Tension G auge 17 J 5755 Wormshaft Bearing Cup Installer 18 J 2619 Slide Hammer 19 J 6278 Pitman Shaft Bearing Remover 20 J 6278 2 Pitman Shaft Bearing Installer 21 J 7079 2 Drive Handle 22 J 8524 1 Adjuster Plug Bearing Installer 23 J 8524 2 Adjuster Plug Bearing Remover 24 J 6219 Pitman Shaft Seal Installer 25 J 6217 Connector Seat Installer 26 J 5421 Therm ometer 27 J 22407 Pitman Shaft ...

Page 368: ......

Page 369: ...RES These tires have an inner liner which if punctured tends to cling to the penetrating object forming a partial seal until the object is removed from the tire It is es sential to conduct a periodic pressure check according to the tire inflation tables on the following pages plus a visual tire inspection to detect imbedded objects which might otherwise go unnoticed and cause serious casing damage...

Page 370: ...ife To equalize wear it is recommended that the tires be rotated every 6 000 miles Upon rotation tire pressure must be adjusted front and rear in accordance with the recommendations in the Tire Load and Inflation Pres sure table Inflation Pressure Standard inflation pressures for tires are listed in the Load Capacity Chart in the Section 0 General Infor mation in this manual These are the minimum ...

Page 371: ... Load Range Ply Rating Tire Load Lim its at Various Inflation Pressures 30 35 40 45 50 55 60 65 70 75 8 00 16 5 C 6 1195 1310 1415 1520 8 00 16 5 D 8 1195 1310 1415 1520 1620 1710 1800 8 75 16 5 C 6 1380 1515 1630 1750 8 75 16 5 D 8 1380 1515 1630 1750 1855 1970 2070 Tire Load and Inflation Pressure Table Notes 1 Tire inflation pressure may increase as much as 6 pounds per square inch psi when hot...

Page 372: ...sults First the rear tire on the inside of the curve may be relieved of so much load that it is no longer geared to the road and it slips grinding off the tread on the inside half of the tire at the excessive rate This type of tire shows much the same appearance of tread wear as tire wear caused by negative camber Second the transfer of weight may also overload the outside tires so much that they ...

Page 373: ...inflate until it is nearly rounded out 3 Inspect rim for rust scale and bent flanges clean rust scale and straighten flanges where necessary 4 Using a brush or cloth swab apply a solution of neutral vegetable oil soap to the inside and outside of tire beads and also to the rim side of the tube Do not allow soap solution to run down into tire 5 When mounting tire and tube on a drop center rim follo...

Page 374: ...re Iron in Second Bead 1 Inspect rim to insure bead seats are clean and smooth Then place rim on floor with wide side down and lubricate first bead of tire and upper bead seat of rim fig 8 2 Push first bead into well of rim and onto rim as far as possible Using straight end of tire iron and with stop resting on rim flange work remaining section of first bead over rim fig 9 3 Hold second bead in we...

Page 375: ...used lift the tire high in the rim forcing the top tire bead against the top rim flange seating the top bead The lower bead will be seated by the tire weight When a tire mounting machine is not being used beads may be seated by holding the tire and wheel assembly in Fig 9 Working Bead onto Rim Fig 10 Working Second Bead onto Rim a vertical position and bouncing on the floor at various points about...

Page 376: ...ad fig 12 Progress around rim using 2 tools as shown 4 The side ring is ready to demount if it is loose and turns easily in the rim gutter 5 Locate the tool notch in the side ring and insert the rim tool or a long husky screwdriver and pry up fig 13 making sure the opposite side of the ring is fitting into the rim gutter Do not bend the ring Fig 13 Removing Ring 6 Now a second tool can be inserted...

Page 377: ...tter and push until the ring is half on and the crescent shaped cutouts straddle the rim gutter per illustration fig 19 7 Insert rim tool or large screwdriver in the tool notch and pull the ring on and down toward the rim gutter 8 While pulling on the rim tool or screwdriver hit the side ring a sharp blow with a mallet in the area be tween the tool notch and the nearest cutout The second half of t...

Page 378: ... CUT OUTS STRADDLE THE RIM 4 CONTINUE TAPPING RING WITH MALLET W ORKING IN THIS DIRECTION TOWARDS FARTHEST CUT OUT 3 WHILE PRYING WITH RIM TOOL GIVE RING A SHARP BLOW WITH MALLET IN THIS AREA WHICH WILL START SECOND HALF OF RING INTO POSITION Fig 20 Forcing Ring into Gutter Fig 19 Assembling Side Ring 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 379: ...eplacement 11 2 Hood H inge 11 2 Hood Lock Assembly 11 2 A djustm ent 11 2 Hood Assembly Removal and Installation 11 3 Page Hood A lignm ent 11 3 Front Sheet Metal Assem bly 11 3 Radiator Support 11 5 Fender 11 6 Skirt ll 7 Running Board 11 7 Fig 1 Front End Sheet Metal 10 30 Series 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 380: ... Installation 1 Install hinge assembly to fender and align within scribe marks Install bolts 2 Install hood hinge spring 3 Install bolts and align hood See Hood Alignment in this section HOOD LOCK ASSEMBLY A bolt type hood lock is used as shown in Figure 4 The lock bolt located on the hood dovetails with the mounted striker plate preventing upward or downward movement of the hood while the vehicle...

Page 381: ...talled and present alignment is satisfactory mark each hinge in relation to hood to assure original alignment 3 Remove two cap screws which attach each hinge to hood then with a helper remove hood from vehicle Fig 5 1 0 3 0 Series Typical Fig 6 Hood and Lock Adjustment Installation 1 If original hood is to be installed position hood to hinges and install four cap screws snug which attach hinges to...

Page 382: ...ement on left fender skirt at steer ing column 5 Remove front bumper bolts and remove bumper 6 Remove wiper arm assemblies and cowl grille Refer to appropriate sections of this manual for instructions Shims which are found at various locations should be recorded to ease installation of sheet metal assembly Proceed as follows 10 THROUGH 30 SERIES Except Step Vans Removal 1 Drain radiator and remove...

Page 383: ...t metal assembly in position NOTE Install all bolts loosely to facilitate aligning after complete installation 2 Install fender bolts at cowl 3 Install combination bolt and flat washer assembly into each fender reinforcement while inserting shims required between fender reinforcement and body See Figure 9 4 Install two bolts and shims required at each fender rear lower edge to hinge pillar 5 Insta...

Page 384: ...ch loosely 12 Attach right fender skirt inner top bolts to fender underside 13 Install screw from underside of skirt to center of fender flange 14 Tighten rearmost bottom screw offender skirt pre viously installed loosely 15 Install remainder of skirt to right fender screws snugly 16 Tighten right fender skirt front 3 bolts from under side to radiator support 17 Place battery tray in position and ...

Page 385: ...olumn left skirt only 5 Remove 2 top rear fender bolts and shims 6 Remove bolt and shims at bottom of fender 7 Remove bolt and shim s attaching skirt to sill extension 8 Remove 4 screws attaching head light door to fender and grille 9 Remove screws attaching gusset to radiator support 10 Remove 3 screws attaching skirt to radiator support 11 Remove 2 screws securing fender to radiator support 12 R...

Page 386: ......

Page 387: ... section The standardized color code is common to all wiring harnesses The wire covering color designates a particular circuit usage MAINTENANCE AND ADJUSTMENTS Maintenance of the lighting units and wiring system consists of an occasional check to see that all wiring connections are tight and clean that the lighting units are tightly mounted to provide good ground and that the head lamps are prope...

Page 388: ...s set for focus during manufacturing assembly SERVICE OPERATIONS SEALED BEAM UNIT REPLACEMENT Fig 3 1 Remove bezel retaining screws and bezel 2 Disengage spring from retaining ring 3 Turn headlamp unit to disen9age assembly from headlamp adjusting screws 4 Disconnect wiring harness connector located at rear of unit in engine compartment NOTE Do not disturb adjusting screw setting 5 Remove retainin...

Page 389: ...ve from behind instrument cluster 5 Disconnect wiring at switch terminals 6 To install reverse removal procedure and check operation of unit LIGHT SWITCH REPLACEMENT Fig 8 1 Disconnect battery ground cable 2 Reaching up behind instrument cluster depress shaft retaining button and remove switch knob and rod 3 Remove bezel and retaining nut 4 Push switch from panel opening and remove from behind ins...

Page 390: ...ELECTRICAL BODY AND CHASSIS 12 4 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 391: ......

Page 392: ...ELECTRICAL BODY AND CHASSIS 12 6 Fig 5 Rear Lighting Composite 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 393: ...tion attach switch rod to switch 6 Tighten transmission lever extension bolt to 12 16 ft lbs torque and remove pin 7 Connect switch wiring to engine wiring harness and install wiring retaining clip bolt 8 Check operation of switch and lower vehicle BACKING LAMP SWITCH REPLACEMENT Switch Located on Mast Jacket 1 Disconnect wiring at switch terminals 2 Remove switch attaching screws and switch from ...

Page 394: ...essure Sender U nit Replacem ent 12 13 Generator Indicator 12 15 Am m eter G auge Replacem ent 12 16 Fig 8 Instrument Cluster Assembly Conventional Cab GENERAL DESCRIPTION All instruments and gauges are installed in the instru ment cluster The entire cluster may be removed from vehicle for servicing of the instruments and gauges Illuminating and indicator lamps may be replaced without removing the...

Page 395: ...connector from their position on the switch Unplug the connector 6 Snap the connector into place on a new ignition switch 7 Place the switch into position from behind the dash and install the metal ignition switch nut 8 Install the lock cylinder 9 Install the battery cable to the battery and lower the hood INSTRUMENT CLUSTER REMOVAL AND INSTALLATION 10 30 Conventional Cab Models Fig 8 1 Disconnect...

Page 396: ...atface Cowl Models Fig 10 1 Disconnect battery ground cable 2 Disconnect electrical connectors and oil pressure pipe NOTE Oil pressure line connector may leak oil when opened wrap with cloth 3 Remove three screws attaching cluster housing to dash panel 4 Pull cluster from opening in dash panel 5 To install reverse removal procedure INDICATOR AND ILLUMINATING BULB REPLACEMENT 10 30 Conventional Cab...

Page 397: ...onn 2 Laminated Circuit 3 Instr Cluster Lamp 4 Temperature Ind 5 Brake Warning Ind 6 Generator Ind 7 R H Directional 8 L H Directional 9 O il Pressure Ind 10 H igh Beam Ind 12 Generator Ammeter 13 Battery Ammeter 14 Ignition Terminal 15 Temperature Gauge 16 Fuel Gauge 10 30 CHEVROLET TRUCK SERVICE MANUAL 1 ...

Page 398: ...is section 2 Remove retaining screws and cluster rear cover 3 Remove front cover from face of cluster 4 Remove two retaining screws and speedometer from cluster 5 To install reverse removal procedure and check operation of unit DO NOT KINK CABLE CASING Flatface Cowl Models 1 Disconnect battery ground cable 2 Disconnect speedometer cable and all indicator and illuminating sockets 3 Remove three scr...

Page 399: ...stall reverse removal procedure and check operation of unit Flatface Cowl Models Fig 10 1 Remove instrument cluster assembly as previously described in this section 2 Uncrimp bezel 7 places and remove bezel 3 Remove 2 nuts securing temperature gauge to cluster case and remove gauge 4 To install reverse removal procedure and check operation of unit TEMPERATURE SENDER UNIT REPLACEMENT All Models 1 R...

Page 400: ...witch 11 To Dome Lamp Conn 12 Dimmer Switch 13 To Instrument Cluster Conn 14 Ground Wire Cluster Conn 15 Fuel Tank Meter 16 Heater Control 1 Disconnect wiring harness connector from sender unit terminal located in block above starter on L 6 engines and at left front of distributor on V 8 engines 2 Remove sender unit using Tool J 21757 replace with new unit and check operation 10 30 CHEVROLET TRUCK...

Page 401: ...INDICATOR 10 30 Conventional Cab Models Ignition on engine not running and telltale light off 9 Ignition Switch 10 To Temp Gauge 11 R H Turn Ind 12 To Ammeter 13 L H Turn Ind 14 Light Switch Conn 15 Fuel Tank Meter 16 Dimmer Switch 1 Indicator bulb burned out replace bulb 2 Open circuit or loose connection in the telltale light circuit Telltale light stays on after engine is started refer to 10 30...

Page 402: ...is located on the right side of the mast jacket opposite the directional signal lever The switch knob must be pulled to cancel circuit The lane changing circuit is activated by holding the directional signal lever in the first detent position there is no lock in or cancelling device in this position DIRECTIONAL SIGNAL SWITCH REPLACEMENT Fig 15 1 Disconnect battery ground cable 2 Remove steering wh...

Page 403: ...30 Conventional Cab Models Fig 16 1 Disconnect battery ground cable 2 Remove wiper arms and blades from transmission shaft 3 Remove plenum chamber grille 4 Disconnect wiper drive rods from crank arm re move crank arm nut and arm from motor shaft 5 Working under instrument console disconnect wiper motor and washer wiring connectors NOTE If vehicle is equipped with a parking brake assembly located o...

Page 404: ...arrangement for proper reinstallation WIPER MOTOR INSPECTION Check and inspect all parts for wear replace as neces sary All parts can be replaced individually except motor frame and field which is serviced as an assembly Service kits also provide screws nuts and washers to replace gear cover and terminal board rivets WIPER MOTOR ASSEMBLY Refer to Figure 17 for exploded view of motor and gear train...

Page 405: ...g and valve arrangement driven by a 4 lobe cam and follower assembly fig 22 The cam is attached to one shaft of the wiper motor output gear fig 21 Pro gramming is accomplished electrically and mechanically by a relay assembly and ratchet wheel arrangement SERVICE OPERATIONS from the wiper motor Removal and Installation Removal of the washer pump consists of 1 Disconnect battery ground cable 2 Disc...

Page 406: ...a Remove the ratchet dog retaining screw Hold the spring loaded solenoid plunger in position and carefully lift the solenoid assembly and ratchet dog off the frame of the pump b Separate the ratchet dog from solenoid mounting plate as required 3 Ratchet pawl fig 23 24 a Disconnect ratchet pawl spring b Remove ratchet pawl retaining ring and slide ratchet pawl off cam follower shaft 4 Ratchet wheel...

Page 407: ...atchet wheel and cam follower shafts 6 Valve assembly fig 26 a Remove the four 4 screws that attach the valve assembly to the pump housing CAUTION During re assembly be sure gasket between housing and valve plate is properly positioned in the housing and valve plate grooves Also be sure triple O ring is properly in stalled between valve body and pipe assembly 7 To assemble washer unit reverse abov...

Page 408: ...ELECTRICAL BODY AND CHASSIS 12 22 FROM WASHER JAR w I N T A K E S T R O K E E X H A U S T S T R O K E Fig 26 Cross Section of Windshield Washer Pump Valve 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 409: ...ELECTRICAL BODY AND CHASSIS 12 23 Fig 27 Engine Compartment CA30 02 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 410: ...ELECTRICAL BODY AND CHASSIS 12 24 18DK GRN 19 Fig 28 Instrument Panel CA30 02 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 411: ...ELECTRICAL BODY AND CHASSIS 12 25 Fig 29 Instrument Panel CA30 02 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 412: ...ELECTRICAL BODY AND CHASSIS 12 26 fh Ar r kk 4 Fig 30 Engine Compartment C A K A 10 20 CA30 03 z _ ...

Page 413: ...ELECTRICAL BODY AND CHASSIS 12 27 20WHT2I 18 BRIM 9B YEL 18 14LT BLU 10 DK GRNI9 1 8lt grn 2 4 Fig 31 Instrument Panel C A K A 10 20 CA30 03 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 414: ...ELECTRICAL BODY AND CHASSIS 12 28 Fig 32 Instrument Panel CA KA10 2O CA30 03 10 30 CHEVROLET TRUCK SERVICE MANUAL I4BRN50 I4 B R N 5 0 ...

Page 415: ...ELECTRICAL BODY AND CHASSIS 12 29 LP ASM SI MRK REFLEX Fig 33 Rear Lamps CA1 KA10 20 CA30 03 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 416: ...ELECTRICAL BODY AND CHASSIS 12 30 Fig 34 Engine Compartment CA KA10 20 CA30 04 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 417: ...ELECTRICAL BODY AND CHASSIS 12 31 20 WHT 21 8BRN9B YEL 18 14IT BLU 18DKGRNI9 18LT GRN 2 4 Fig 35 Instrument Panel C A K A 10 20 CA30 04 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 418: ...5 0 20 ORN 4 0 20W HT2I 18 BRN 9 B 18 Y E L I3 14 LT BLU10 18 DKGRN 19 18 LT GRN 24 i r BATTERY A rDOME LP 60RN40B 16 DKGRN 44 RHEOSTAT LT SWITCH ASM 20 ORN 40 20WHT 2I 18 BRN9B 18 YEL 18 18 DKGRN 19 18 LT GRN 24 Fig 36 Instrument Panel CA KA10 20 CA30 04 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 419: ...ELECTRICAL BODY AND CHASSIS 12 33 18 YEL 18 I88RN 9 I8LT GRN 24 I8DKGRN I9 Fig 37 Rear Lamps C A K A 10 2 0 CA30 04 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 420: ...ELECTRICAL BODY AND CHASSIS 12 34 Fig 38 Engine Compartment C A K A 1 0 20 06 16 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 421: ...ELECTRICAL BODY AND CHASSIS 12 35 16LT GRN IIA 20 ORN 40 20 WHT 21 BRN 9 B YEL 18 14LT BIU 10 DKGRNI9 I8LT CRN 2 4 Fig 39 Instrument Panel C A K A 10 20 06 16 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 422: ...ELECTRICAL BODY AND CHASSIS 12 36 Fig 40 Instrument Panel C A K A 10 20 06 16 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 423: ...ELECTRICAL BODY AND CHASSIS 12 37 Fig 41 R ear Lamps C A K A 1 0 20 06 16 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 424: ...ELECTRICAL BODY AND CHASSIS 12 38 Fig 42 Engine Compartment CA KA10 20 CAl30 14 34 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 425: ...ELECTRICAL BODY AND CHASSIS 12 39 16LT GRN IIA 18 YEl 1 8 14LT BLU O 18DK GRIM19 18LT GRN 2 4 Fig 43 Instalment Panel CA KA10 20 CA30 14 34 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 426: ...ELECTRICAL BODY AND CHASSIS 12 40 Fig 44 Instrument Panel CA KA10 20 CA30 14 34 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 427: ...ELECTRICAL BODY AND CHASSIS 12 41 LP ASM 51 MRK REFLEX 18 YEL 18 I8BRN 9 8LT GRN 24 I8DKGRN I9 Fig 45 Rear Lamps CA KA10 20 CA30 14 34 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 428: ......

Page 429: ...SCRIPTION P10 trucks are equipped with down flow type radiators All other models are equipped with cross flow type ra diators The cross flow radiator is similar to the con ventional down flow radiator except it is mounted sideways in the vehicle and attached in the conventional manner Two retainers one on each side at the top secure the radiator in position The radiators are of copper brass constr...

Page 430: ... at top of radiator and shroud with six screws 9 Connect radiator hoses and transmission coolant line fill cooling system and check for leaks 10 Refer to torque specifications in rear of manual for correct torque values PA 10 MODELS Fig 2 Radiator Replacement 1 Drain radiator and disconnect water hoses and Pow erglide coolant line if applicable 2 Remove mounting screws attaching radiator to sup po...

Page 431: ...e can be removed separately if need be by removing center brace and hood lock plate Disconnect parking lamps and lift inner grille free Assembly Assemble parts removed in the disassembly procedure tighten all screws and bolts Installation 1 Position grille and install bolts at fender 2 Install bolts at center brace and lock plate 3 Connect parking lamps 4 Connect battery 10 30 CHEVROLET TRUCK SERV...

Page 432: ......

Page 433: ... Fig 1 Removal 1 Remove parking lamp assemblies See Section 12 2 Remove bolts securing left and right bumper braces to frame 3 Remove bolts securing two bumper brackets to frame 4 Remove bolts securing bumper face bar to frame and remove bumper from vehicle 5 If necessary disassemble bumper by removing bolts attaching brackets and braces to bumper face bar Installation Assemble and install front b...

Page 434: ... order Connect license lamp wiring on suburban panel and pickup models FRONT BUMPER P20 AND P30 MODELS Fig 3 Removal Remove nuts washers and bolts securing front bumper to forward frame horns and remove bumper from vehicle Installation Place bumper in mounted position and secure to frame with bolts washers and nuts 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 435: ...ocated at the end of the directional signal lever or bottom of the instrument panel The cruise system takes over speed control and within engine limitation maintains this speed regardless of changes in terrain The Engagement Switch button performs these functions 1 When partially depressed it engages the system 2 When depressed fully and held there it disengages the system 3 When released complete...

Page 436: ...ND CASING ASSEMBLIES These assemblies drive the regulator and the speedo meter SERVICE OPERATIONS The components of the Cruise Master System are designed to be replaced should they become inoperative The Regulator is calibrated in such a manner during manufacturing that overhaul operations are impractical However one adjustment may be made to the Regulator to correct speed drop or increase at the ...

Page 437: ...e 2 Disconnect cruise master engagement switch wiring harness plug on steering column 3 Remove plastic protector from cruise master wiring harness on column 4 Remove turn signal lever see Sec 9 Turn Signal Steps 1 through 5 5 Connect a 15 piece of piano wire to cruise master wiring harness plug for installation before easing turn signal lever assembly up and out of the column INSTALLATION 1 Attach...

Page 438: ...k nut after each adjustment before testing CAUTION Do not remove orifice tube from casting ELECTRICAL SYSTEM CHECK Fig 6 1 Check fuse and connector 2 Check electric brake switch as follows a Unplug connector at switch b Connect ohmmeter at points A and B on brake switch The ohmmeter must indicate no continuity when the pedal is depressed and continuity when pendal is released The cruise release br...

Page 439: ...ONFIGURATION WHITE BRO W N W H ITE STRIPE f BRAKE SWITCH RED _yr CLUTCH SWITCH RED BROW N W HITE STRIPE RESISTANCE WIRE 40S2 I WHITE WHITE REGULATOR CONNECTOR i I SO LENO ID COIL j o 512 RESISTANCE i g 1 7 7 B R O W N WHITE STRIPE REGULATOR Fig 6 Cruise Master Wiring Diagram CLUTCH CRUISE ENGAGEMENT SWITCH RELEASE SWITCH WHITE REGULATOR Fig 7 Vacuum and Electrical Diagram 10 30 CHEVROLET TRUCK SER...

Page 440: ...es excessive resistance in the coil circuit Either extremity indicates replacement of the Regulator assembly The white main harness wiring from Point F to G should also be checked for continuity SERVO A N D V A C U U M SYSTEM CHECK To determine the condition of the diaphragm remove hose from the Servo Unit and apply 14 inches of vacuum to the tube opening and hold in for one minute The vacuum shal...

Page 441: ...d 12 13 7 Max 3400 Min Compressor Clutch Coil Ohms at 80 F 3 70 Amps at 80 F 3 22 12 volts System Capacities Refrigerant 12 Four Season and GM Chevrolet Roof Mounted 525 Viscosity Compressor Oil Four Season and GM Chevrolet Roof Mounted Torque Specifications Compressor Suction and Discharge Connector B o lt 25 ft lbs Rear Head to Shell Stud N uts 23 ft lbs Shaft Mounting N u t 15 ft lbs Belt Tensi...

Page 442: ...h Control 85 in lb Rear Door Latch 85 in lb LIFTGATE Hinge B olts 25 ft lb Liftgate Support 40 in lb Handle 40 in lb Striker 95 in lb ENDGATE EXCEPT SUBURBAN Handle 95 in lb Tailgate to Pickup Box Support 17 ft lb Latch 150 in lb Trunnion 17 ft lb ENDGATE SUBURBAN Latch 85 in lb Latch Remote Control 40 in lb Endgate to Body Support 45 ft lb Striker Body Mounted 90 in lb H inges 30 ft lb Bumpers 10...

Page 443: ...o 5 16 1 8 to 1 4 K 10 20 Camber Caster Toe In Total 1 16 to 5 16 1 8 to 1 4 See Chart Figure 4 Section 3 Toe setting must always be made after camber and caster Any change in cam ber and caster will effect toe Camber and caster must not vary more than 1 20 from side to side Camber Designed to be 1 1 2 at curb weight with no provision for resetting Caster Designed to be 4 at curb weight with no pr...

Page 444: ...40 65 Shock Absorber Lower End 75 75 65 Brake Splash Shield to Knuckle 140 In Lbs 140 In Lbs Wheel Bearing Adjustment 15 40 Inner 35 Outer 50 Wheel Bearing Preload Zero Zero Zero Wheel Bearing End Movement 001 008 001 010 001 010 Caliper Mounting Bolt 35 35 35 Spring Front Eye Bolt 90 Spring Rear Eye Bolt 50 Spring To Rear Shackle Bolt 50 Spring To Axle U Bolt 120 Spring Front Hanger to Frame 30 S...

Page 445: ... Lbs U Bolt Attachment 20 Ft Lbs DIFFERENTIAL SPECIFICATIONS 3300 3600 Lb Capacity 5500 Dana 5200 7200 Lb Capacity 11 000 Lb Capacity Gear Backlash Preferred 005 004 005 005 008 009 008 008 Min and Max 003 004 003 003 010 009 012 012 Pinion Bearing Preload In Lbs New 20 25 20 40 Used 5 10 10 20 Bolt Torques Ft Lbs Carrier Cover 23 35 18 Ring Gear 50 110 110 105 Differential Bearing Caps 55 85 100 ...

Page 446: ... Attaching Bolts 145 145 Coil Spring Attaching Bolt Lower 55 55 Coil Spring Attaching Bolt Upper 50 50 Spring Front Bushing Bolt 90 90 90 90 Spring Rear Shackle Bolts 90 90 90 90 Shock Absorber Attaching Bolts 75 75 65 65 Propshaft Bearing Support Hanger 20 35 35 Rear Stabilizer 25 C P10 Models 135 Ft Lbs Models CE CS 25903 04 34 250 Ft Lbs All others 135 Ft Lbs C20 Except 133 W B Models 20 Ft Lbs...

Page 447: ... Rear Pipe to Wheel Cylinder 100 In Lbs Rear Pipe to Connector 100 In Lbs Flex Hose to Connector 115 In Lbs Flex Hose to Pipe 115 In Lbs Push Rod to Pedal 1 28 Ft Lbs Push Rod to Clevis N u t 25 Ft Lbs Pedal Bracket to Dash 25 Ft Lbs Pedal Support to Bracket 150 In Lbs Parking Brake Assembly to Dash 100 In Lbs Parking Brake Assembly to Instrument P an e l 100 In Lbs Parking Brake Cable to Assembly...

Page 448: ...n into the engine through the carburetor the air cleaner also acts as a flame arrestor in the event the engine backfires Because backfiring may cause fire in the engine compartment the air cleaner should be installed at all times unless its removal is necessary for repair or main tenance services Paper Element Type First 12 000 miles inspect element for dust leaks holes or other damage and replace...

Page 449: ...SPECIFICATIONS 9 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 450: ...utor Clamp 20 lb ft Flywheel Housing 30 lb ft Manifold Exhaust 20 lb ft D Manifold Exhaust to Inlet 25 lb ft Manifold Inlet 30 lb ft Manifold Clamp L6 Outer 20 lb ft Manifold Clamp All Others 30 lb ft Thermostat Housing 30 lb ft Water Outlet 30 lb ft Water Pump 30 lb ft 3 8 24 Connecting Rod Cap 40 lb ft 45 lb ft 50 lb ft 7 16 14 Cylinder Head 65 lb ft 80 lb ft Main Bearing Cap 65 lb ft 70 lb ft O...

Page 451: ... 7041025 7041025 10 10 292 L 6 L 25 170 1 7041022 7041022 20 30 20 20 30 292 L 6 L 25 170 1 7041026 7041026 10 10 307 V 8 Base 200 2 7041105 7041125 10 307 V 8 Base 200 2 7041111 7041126 20 30 20 20 30 307 V 8 Base 215 2 7041139 7041138 20 30 350 V 8 Base 250 4QJ 7041208 7041208 10 10 350 V 8 LS 9 250 4QJ 7041211 7041211 20 30 20 20 30 350 V 8 LS 9 250 4QJ 7041208 7041208 10 402 M 4 L 47 300 4QJ 7...

Page 452: ...1025 A M 1 4 070 100 180 260 350 MV 7041026 A M 1 4 070 100 275 350 350 2GV 7041105 M 21 32 1 3 4 1 3 64 040 080 215 2GV 7041125 A 21 32 1 3 4 1 3 64 040 080 215 2GV 7041111 M 21 32 1 3 4 1 3 64 040 080 215 2GV 7041126 A 21 32 1 3 4 1 3 64 040 080 215 2GV 7041138 A 23 32 1 1 4 1 5 32 100 170 325 2GV 7041139 M 23 32 1 1 4 1 5 32 100 180 325 4MV 7041206 M 1 4 100 020 260 4MV 7041208 A M 1 4 100 020 ...

Page 453: ...47 675 600 850 Automatic L 6 250 C I D L 6 292 C I D L 25 530 500 750 V 8 307 C I D V 8 350 C I D LS 9 580 550 650 MK IV 402 C I D L 47 630 600 650 CAUTION If the C E C valve solenoid on the carburetor is used to set engine idle or is adjusted out of limits specified in the Service Manual decrease in engine braking may result ENGINE ELECTRICAL SECTION 6Y BATTERY MODEL NO APPLICATION NO OF PLATES P...

Page 454: ...ls 3396 2 2 2 6 14 28 40 42 Generator temperature approximately 800F Ambient temperature 80 F VOLTAGE REGULATOR MODEL NO FIELD RELAY VOLTAGE REGULATOR APPLICATION AIR GAP POINT OPENING CLOSING VOLTAGE AIR GAP POINT OPENING VOLTAGE SETTING 1119515 ALL 015 030 2 3 3 7 067 014 13 8 14 8 85 F STARTING MOTOR MODEL NO SEC NO BRUSH SPRING TENSION OZ FREE SPEED VOLTS AMPERES RPM 1108365 1108367 1108368 35...

Page 455: ...00 RPM 24 4300 RPM C 3954 0 8 Hg 20 17 Hg 31 34 4 600 RPM Manual AC R45TS 307 Cu In V 8 215 HP 20 30 Series 1112043 C 4824 00 800 RPM 2 1200 RPM 11 2100 RPM 20 4200 RPM C 3036 0 8 Hg 15 15 5 Hg 31 34 4 600 RPM 8 550 RPM Manual Automatic AC R45TS 350 Cu In V 8 250 255 HP RPO LS 9 1112047 C 4818 0 865 RPM 2 1335 RPM 11 2400 RPM 18 4200 RPM C 3036 0 8 Hg 15 15 5 Hg 31 34 8 550 RPM Automatic AC R44TS ...

Page 456: ... ft lbs Extension to Case Bolts 45 ft lbs Shift Lever to Shifter Shaft Bolts 20 ft lbs Lubrication Filler P lu g 15 ft lbs Transmission Case to Clutch Housing B olts 55 ft lbs Crossmember to Frame N uts 25 ft lbs Crossmember to Mount and Mount to Extension B o lts 40 ft lbs Transmission Drain P lu g 30 ft lbs FOUR SPEED MUNCIE Rear Bearing Retainer 18 ft lbs Cover Bolts 25 ft lbs Filler P lu g 35 ...

Page 457: ...r Mount B olts 75 ft lbs Transfer Case Bracket to Frame Nuts Upper 30 ft lbs Transfer Case Bracket to Frame Nuts Lower 65 ft lbs Adapter to Transmission Bolts Manual Transmission 22 ft lbs Automatic Transmission 35 ft lbs DANA TRANSFER CASE MODEL 20 Shift Rail Set Screws 15ft lbs Front Output Shaft Rear Cover Bolts 30 ft lbs Front Output Shaft Front Bearing Retainer 30 ft lbs Front Output Shaft Yo...

Page 458: ... ft lbs 40 ft lbs 40 ft lbs Lower M ast Jacket B earing Adj P10 1 26 02 CIO 50 02 50 i 02 50 02 1 26 i 02 Power Steering Belt Tension 125 lb New 75 lb Used Pum p P ressure 850 1 000 p si Lower M ast Jacket B earing C lam p or Interm ediate Coupling C lam p Bolt 120 in lbs P10 32 ft lbs CIO 32 ft lbs 32 ft lbs 120 in lbs Lower Coupling to W orm shaft C lam p Bolt C10 30 ft lbs P10 75 ft lbs 30 ft l...

Page 459: ... worm bearing preload In excess of valve assembly drag POWER STEERING GEAR C P10 C20 30 K10 20 P20 30 Steering Gear Ball Drag 3 in lbs Max 3 in lbs Max 3 in lbs Max 3 in lbs Max Thrust Bearing Preload 1 2 to 2 in lbs 1 2 to 2 in lbs 1 2 to 2 in lbs 1 2 to 2 in lbs Adjuster Plug Locknut 80 ft lbs 80 ft lbs 80 ft lbs 80 ft lbs Over Center Preload 3 6 in lbs 3 6 in lbs 3 6 in lbs 3 6 in lbs Over Cent...

Page 460: ... 16 Bolts 8 90 120 ft lbs C30 Heavy Duty Wheels 1 2 Bolts 10 200 250 ft lbs TIRES See Load Capacity Charts in Section 0 and Tire Load and Inflation Pressure tables in Section 10 of this manual SHEET METAL SECTION 11 Hood Safety P late 20 ft lbs Hood Lock Bolt 30 ft lbs Hood Lock Bolt Plate 150 in lbs Hood H inge 25 ft lbs Hood Bumper 85 in lbs 10 30 CHEVROLET TRUCK SERVICE MANUAL ...

Page 461: ...il Resistance ohms 6 1 Use Trade No Rating Oil Pressure Gauge 1895 2CP Tachometer 194 2CP Heater Control 1895 2CP Dome Lamp 211 12CP License Lamp 67 4CP Back Up Lamps 1156 32CP Parking and Directional Signal 1157 4 32CP Tail Stop and Rear Directional Signal 1157 4 32CP Headlamp 6014 60W High Beam 50W Low Beam Side Marker Lamps 194 2CP Roof Clearance and Identification Lamps All Exc P Suburban 194 ...

Page 462: ...bs 45 ft lbs Front Bum per Front Bumper Bracket and Brace Rear Bumper to Outer Bracket Rear Bumper Outer Bracket and Brace ACCESSORIES SECTION 15 CRUISE MASTER Solenoid Resistance 5 ohms 1 4 ohm Solenoid Wire Resistance 40 ohms Maximum allowable Vacuum Leakage rate for Servo u n it 5 inches of Vacuum Per Minute Not Greater than 1 inch of Vacuum per 10 seconds Operational Test Speed 60 MPH 10 30 CH...

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