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Chevrolet 10 Series 1967, Service Manual

The Chevrolet 10 Series 1967 Service Manual is a comprehensive manual that covers all maintenance and repair procedures for this classic vehicle. Download it for free from manualshive.com to ensure your Chevrolet 10 Series 1967 is kept in top running condition with the help of this detailed manual.

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FRAME  2-7

10-30  SERIES  DIMENSIONS

Model

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

CA107 9-3/8 11-7/8 13-1/4 16 10-1/4 7-1/8 10

9

15-1/2 12

11-3/8 13-3/8 43

70

127-3/4 14

16-7/8 19-1/8 16-7/8

CA109 9-3/8 11-7/8 13-3/8 16 10-1/4 7-5/8 10

9

15-1/2 12

11-3/8 13-3/8 43

82

134

14

16-7/8 19-1/8 16-7/8

CA209 9-3/8 11-7/8 13-3/8 16 10-1/4 7-1/8 10

9

15-1/2 12

11-3/8 13-3/8 43

82

134

14

16-7/8 19-1/8 16-7/8

CA310 9-3/8 11-7/8 12-3/4 16

7-1/2

-

10 10

15-1/8

-

10-1/4 13-3/8 49

90-3/8 158-1/4 14

16-7/8 16-7/8 16-7/8

CA314 9-3/8 11-7/8 12-3/4 16

7-1/2 6-1/8 10

8-3/8 17-1/8 14-1/4 14-1/4 17-1/8 49

90

180-1/2 14

16-7/8 16-7/8 16-7/8

KA107 9-3/8 11-7/8 13-3/8 16 10-1/4 7-1/8 10

9

14-5/8 12

10-3/4 13-3/8 43

70

127-3/4 14

16-7/8 16-7/8 16-7/8

KA109

^ 2 0 9

9-3/8 11-7/8 13-3/8 16 10-1/4 7-1/8 10

9

15-1/2 12

10-3/4 13-3/8 43

82

139-3/4 14

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

9

15-1/2 12

10-3/4 13-3/8 43

57

114-5/8 14

16-7/8 19-1/8 16-7/8

PA209

309

6-1/2

8-5/8

8-1/4 10

6-3/8 6-5/8 10

8-3/4 12-1/2

7-7/8

7-7/8 10

42-5/8

89-1/8 115-1/8 16-7/8 16-7/8 16-7/8 16-7/8

PA213

313

6-1/2

8-5/8

8-1/4 10

6-3/8 6-5/8 10

8-3/4 12-1/2

7-7/8

7-7/8 10

43-3/4 110-1/8 161

16-7/8 16-7/8 16-7/8 16-7/8

PA215

315

6-1/2

8-5/8

8-1/4 10

6-3/8 6-5/8 10

8-3/4 12-1/2

7-7/8

7-7/8 10

42-5/8 122-1/8 148-1/8 16-7/8 16-7/8 16-7/8 16-7/8

40-60  SERIES  SINGLE  AXLE  DIMENSIONS

Model

A

B

C

D

E

F

G

H

I

J

K

L

M

N

Wheel­

base

CG5,  610

15-7/8

13-1/2

20

15-3/4

15-3/4

15-3/4

20

36

82-1/4

132

147-3/4

14-5/8

16-3/4

16-3/4

125-3/8

CG5,  612

15-7/8

13-1/2

20

15-3/4

15-3/4

17

20

36

94-1/4

144-1/2

169-7/8

14-5/8

16-3/4

16-3/4

137-3/8

CG5,  614

15-7/8

13-1/2

20

15-3/4

15-3/4

17

20

36

106-1/4

156

171-3/4

14-5/8

16-3/4

16-3/4

149-3/8

CG5,  617

15-7/8

13-1/2

20

15-3/4

15-3/4

17

20

36

127-1/4

177

218-1/4

14-5/8

16-3/4

16-3/4

167-3/8

CG5,  620

15-7/8

13-1/2

20

15-3/4

15-3/4

17

20

36

146-1/4

196

280-1/4

14-5/8

16-3/4

16-3/4

189-3/8

CG5,  623

15-7/8

13-1/2

20

15-3/4

15-3/4

17

20

36

160-1/4

210

285-1/4

14-5/8

16-3/4

16-3/4

203-3/8

SE520

15-7/8

13-1/2

20

15-3/4

15-3/4

17

20

36

146-1/4

196

280-1/4

14-5/8

16-3/4

16-3/4

189-3/8

SE525

15-7/8

13-1/2

20

15-3/4

15-3/4

17

20

36

174-3/4

224-1/2

299-3/4

14-5/8

16-3/4

16-3/4

217-7/8

SE5,  628

15-7/8

13-1/2

20

15-3/4

15-3/4

17

20

36

192-1/4

257-3/4

326-1/4

14-5/8

16-3/4

16-3/4

235-3/8

SE5,  631

15-7/8

13-1/2

20

15-3/4

15-3/4

17

20

36

210-3/4

260-1/2

344-3/4

14-5/8

16-3/4

16-3/4

253-7/8

SS414

15-7/8

13-1/2

20

15-3/4

15-3/4

17

20

36

106-1/4

156

171-3/4

14-5/8

16-3/4

16-3/4

149-3/8

PS414

15-3/4

13-1/2

20

15-3/4

15-3/4

17

20

45-1/2

106-1/2

156-1/4

185-1/2

16-1/4

16-3/4

16-3/4

157

PS421

15-3/4

13-1/2

20

15-3/4

15-3/4

17

20

45-1/2

124-1/2

174-1/4

215-1/2

16-1/4

16-3/4

16-3/4

175

CHEVROLET  TRUCK  SERVICE  M ANUAL

Summary of Contents for 10 Series 1967

Page 1: ...CHASSIS V3 a n s W U gw...

Page 2: ......

Page 3: ...uty Forward Control H Conventional Short Conventional Cab J Tandem Short Conventional Cab K Four Wheel Drive M Tandem Conventional Cab P Forward Control S School Bus T Conventional Tilt Cab W Tandem T...

Page 4: ...pical serial number is explained in the following chart c a b 2 STYLE MODELj YEAR ASSEMBLY3 PLANT UNIT4 NUMBER GS10705 7 P 100025 1 Last number of model year 1967 2 See Series and Model Identification...

Page 5: ...eed Auxiliary Transmission Number Stamped on Rear Face of Case Unit Number Stamped on Left Rear Unit Number to Left of Drain Plug Spicer 3000 Series of Case Near P T O Plate Above Plug Spicer 5000 Ser...

Page 6: ...fication Plate fig 23 is provided on all Truck models On most series it will be located on the inside of the glove box door on P series it will be located on an inner body panel The plate lists the ve...

Page 7: ...tten above the cutting or tumbler position indicates each different tumbler which is to be dropped into each tumbler slot of the lock In cases where a code book is not available the dia gram shown on...

Page 8: ...eaches 10 to 15 miles per hour Towing If a vehicle equipped with an automatic transmission becomes disabled and requires towing speed must not exceed 30 MPH Drive shaft must be disconnected if vehicle...

Page 9: ...6200 8 19 5 6 8 19 5 10 R P O G50 R ea r Springs 9000 8300 7 17 5 6 8 19 5 6 7 17 5 6D 8 19 5 6D R P O G60 R ea r Spring Equipm ent R P O F60 Fron t Springs 10000 3500 CS 314 CE 314 157 6700 3500 300...

Page 10: ...17000 18400 8 25 20 10 8 25 20 10D R P O G56 R e a r Springs 24000 20800 9 00 20 10 10 00 20 12D CE 60 149 167 189 27500 51000 9000 9000 18500 23000 10 00 20 12 10 00 20 12D R PO Z76 req u ires R P O...

Page 11: ...R e a r A x le includes 12 000 lb each R e a r Springs R P O F07 F ra m e R ein forcem en ts 65000 9000 9000 23000 24000 10 00 20 12 11 00 20 12D R P O F43 F ron t A x le R P O F94 Fron t Springs R P...

Page 12: ...F44 F ron t A x le includes 4500 lb each F ron t Springs R P O F08 F ra m e R e in fo rc e m ents R P O M61 A u x ilia ry Tran sm ission 65000 In addition to above equipm ent must o rd er R P O L29 4...

Page 13: ...6 Speedometer Adapter 0 16 Parking Brake Linkage 0 16 Tachometer M echanical 0 16 Body Lubrication 0 16 Diesel Oil Specifications 0 16 Lubrication D iagra m s 0 18 The 1967 Truck engine and chassis re...

Page 14: ...cold weather which promote accumulation of moisture condensation in the crankcase it becomes necessary to drain the oil more frequently For 10 30 Series vehicles in heavy duty operation involving cont...

Page 15: ...ngine running check for flow of air from air box drain tubes every 6 0 0 0 miles and if tubes are clogged remove clean and reinstall tubes Air box drain tubes should be cleaned at tune up intervals ev...

Page 16: ...normal operating temperature 2 Remove any dirt or gravel from area around indica tor in right side of engine compartment With engine running at 1 0 0 0 rpm remove indicator from case wipe clean reins...

Page 17: ...The bearings should be thoroughly cleaned before re packing with lubricant The front wheels are equipped with tapered roller bearings on all trucks except P 20 P 30 that are equipped with ball bearing...

Page 18: ...perations BRAKE AND CLUTCH PEDALS On Forward Control models the clutch pedal is lubri cated from a pressure gun lubrication fitting in the end of the shaft and the brake pedal is also equipped with a...

Page 19: ...rban operation Winter No 1 D 500 F 550 F 45 0 30 Summer No 1 D 550 F 600 F 40 0 50 Medium Load and speed Marine Pleasure Craft Tractors Industrial equipment Winter No 1 D 550 F 600 F 45 0 50 Summer No...

Page 20: ...Cleaner Oil Wetted Paper Element 12 000 Miles Check If satisfactory Reuse element Recheck every 6 000 miles until replaced Oil Bath 12 000 Miles Engine Oil SAE 50 Above Freezing Engine Oil SAE 20 Bel...

Page 21: ...Oil SAE 20 Below Freezing As required Check Clean and refill if necessary Check If satisfactory reuse but recheck every 6 0 0 0 miles 9 Distributor L 6 12 000 Miles 1 2 turn of cam lubricator 1 0 Dist...

Page 22: ...ne Oil SAE 50 Above Freezing Engine Oil SAE 20 Below Freezing As required Check Clean and refill if necessary Check If satisfactory reuse but recheck every 6 0 0 0 miles 1 0 Throttle Bell Crank 6 000...

Page 23: ...r L 6 12 000 Miles 1 2 turn of Lubricator 1 0 Distributor V 8 Cam Lubricator 12 000 Miles Rotate Cam Lubricator 1 1 Master Cylinder 6 000 Miles Delco Supreme No 11 As required Check add fluid when nec...

Page 24: ...to Top of Oiler Rotate Lubricator Replace Air Cleaner 8 Master Cylinder 6 000 Miles Delco Supreme No 11 As required Check add fluid when necessary 9 Transmission Synchromesh Allison Automatic Allison...

Page 25: ...Q ATF A See chart in Lubrication Section AQ ATF A As required As required 9 Quarts approx Keep even with filler See Lubrication Section Checking For off high way operation change after every 1 0 0 0 h...

Page 26: ...brication Section 9 Control Linkage Points 6 000 Miles Engine Oil As required Brush or Spray to apply 1 0 Wheel Bearings 30 000 Miles Wheel Bearing Grease 2 places as required 1 1 Steering Gear 36 000...

Page 27: ...echanism Check Link Every 6 000 miles a small amount of lubriplate or equivalent should be applied to the check link and roller 4 Tilt Cab Operating Controls The operating con trols and levers at the...

Page 28: ......

Page 29: ...wl vent plenum chamber Engine coolant constantly flows through the heater core during engine operation Heater output is adjusted by varying the airflow through the system A dash mounted three lever co...

Page 30: ...his lever is fully left no air passes through the system Moving the lever to the right about one third of its travel opens the air door in the air distributor duct Moving the lever further to the righ...

Page 31: ...U TLETS TEM PER A T U R E D O O R O U T SID E A IR IN LET D EFR O ST ER D O O R TO E B O A R D L FLO O R O U TLETS H EA TER C O R E B L O W E R A S S E M B L Y Fig 3 Chevy Van Heater Schematic Fig 5...

Page 32: ...bly Installation 1 Assemble the blower wheel to the motor with the open end of the blower away from the motor 2 Install the assembly to the blower case connect ground strap and connect the motor wire...

Page 33: ...ing 3 Connect the motor wire 4 Replace core case brace to cowl panel screw and the blower housing brace to cowl panel screw 5 Replace the floor mat and connect the battery ground cable BLOWER CORE CAS...

Page 34: ...lower by sliding core tubes further down through the toe pan When case is clear of the ash tray retainer and dash lower edge pull it toward the rear and withdraw the core tubes from the toe pan hole 1...

Page 35: ...ve assembly Installation 1 Assemble thermostatic valve assembly to core 2 Attach the thermostatic valve capillary tube to the core with the plastic pin Locate the pin 6 1 2 inches away from the edge o...

Page 36: ...AIR FAN control Connect the blower wire con nector to the control 4 Install the control to the steering column mounting plate with the escutcheon and nut Replace the knob 5 Check control operation Til...

Page 37: ...d remove the resistor unit mounting screws Remove resistor unit Installation 1 Place resistor unit in duct and drive in mounting screws 2 Connect the blower harness connector 3 Mount the heater assemb...

Page 38: ...ble refrigerant lines Both the heating and cooling functions are performed by this system Air entering the vehicle must pass either through the cooling unit evaporator or through the heating unit or t...

Page 39: ...HEATER AND AIR CONDITIONING 1A 11 EVAPORATOR OUTLET Fig 20 Airflow Schematic CHEVROLET TRUCK SERVICE MANUAL...

Page 40: ...ces and precautions of servicing refrigeration equipment will greatly reduce the possibilities of damage to the customers equipment as well as virtually eliminate the element of hazard to the servicem...

Page 41: ...least once a year for leaks or brittleness If found brittle or leaking they should be replaced with new lines Use only sealed lines from parts stock When disconnecting any fitting in the refrigeratio...

Page 42: ...ossible to make it Therefore it will quickly ab sorb any moisture with which it comes in contact For this same reason the oil container should not be opened until ready for use and then it should be c...

Page 43: ...igher quality work less chance of an over or undercharge or comeback The pump mount is such that the dealer may use his own vacuum pump The gauges and manifold are in com mon use Thus a current air co...

Page 44: ...air conditioning system Vacuum pump Tool J 5428 fig 26 is available for this purpose It is used as a component part of the Charging Station J 8393 described previously The fol lowing precautions shoul...

Page 45: ...other foreign material Check evaporator drain tubes regularly for dirt or restrictions system It is available in 1 quart graduated bottles through Parts Stock This oil is as free from moisture and co...

Page 46: ...tor fins re stricting airflow into the passenger area and resulting in insufficient or no cooling Four Season Systems Refrigerant Charge 3 Lbs 4 Oz Temperature of Air Entering Condenser 70 80 90 100 1...

Page 47: ...pletely purged or drained of re frigerant The purpose is to lower the pressure inside the system so that a component part can be safely removed 1 With engine stopped install high and low pressure line...

Page 48: ...e Vacuum Control Valve 3 and open freon con trol valve 4 Operating the heater and air con ditioner blower with the controls set for cooling will help complete the charging operation NOTE If the charge...

Page 49: ...HIGH PRESSURE G A G E VALVE VALVE REFRIGERANT SUPPLY HIGH PRESSURE G A U G E FITTING LOW PRESSURE G A U G E FITTING MUFFLER COMPRESSOR LOW PRESSURE G A G E VALVE VALVE T O VACUUM SUPPLY Fig 31 Chargi...

Page 50: ...em 7 Shut off the vacuum pump and connect the high pres sure line to the gauge set Open the high pressure valve and evacuate the system through the high and low pressure side of the system Complete th...

Page 51: ...been made If the system has been open to atmosphere for any pro longed period of time the receiver dehydrator should be replaced CONDITIONING SYSTEM FOR REPLACEMENT OF COMPONENT PARTS Air conditionin...

Page 52: ...cement condenser into position and replace mounting bolts Be certain shims are in stalled at lower condenser mount bolts 2 Move radiator into place and replace mounting bolts Replace shroud lower moun...

Page 53: ...d 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...

Page 54: ...valve Cap the open tubes 5 Remove clamp from P O A valve Installation 1 Assemble clamp on P O A valve and connect inlet and outlet connections 2 Secure P O A valve clamp and outlet line clamp 3 Connec...

Page 55: ...wall 8 Remove inboard case half and evaporator core Installation 1 Assemble evaporator core and inboard case half to the outboard case half Replace case to case case to back up plate and case to firew...

Page 56: ...ase and move distributor away from case 8 Remove the heater case to firewall retaining screws 9 Pull the heater case away from the firewall and reach in and disconnect the resistor connector 10 Remove...

Page 57: ...stem 2 Remove hoses at the compressor inlet and muffler outlet pipes Cap the connections 3 Remove muffler outlet pipe clamp 4 Remove bolt retaining connector block to compressor and remove the connect...

Page 58: ...uator mounting bracket from kick panel Remove valve return spring Pull the top pivot pin downward against spring tension until it clears the upper pivot hole Pull valve in ward and withdraw lower pivo...

Page 59: ...AIR VALVE Removal 1 Remove cowl grille panel Refer to Section 11 2 Disconnect the diaphragm link from the connecting shaft arm 3 Remove the screw attaching the connecting shaft to the tube extending...

Page 60: ...mbly drain and measure oil in the compressor Check for evidence of contamination to determine if remainder of system requires servicing Compressor servic ing information is located in the Chassis Over...

Page 61: ...AIR CONDITION WIRING RELAY r 16LBL 16Y DBL B S 14DBL RESISTOR r nlnja 20B r FUSE 12OR 120R1 12PPL ED 14DBL 180R 16DG DBL WS 14Y LIGHT HARNESS COMPRESSOR SWITCH ON POS 14Y 16Y DBL B S 180R 14BRN o J P...

Page 62: ...etector 22 J 9298 Pulley Bearing Remover 6 J 8433 Puller 23 J 9481 Pulley and Bearing Installer 7 J 9395 Puller Pilot 24 J 8092 Handle 8 J 6272 No 3 M ulti Opener 3 Can 25 J 9521 Internal Assembly Sup...

Page 63: ...related position on the cab Figure 1 is not intended to accurately reflect the availability of serv ice repair parts It will be apparent upon reviewing the parts catalog which of the panels shown are...

Page 64: ...ntly used on 20 30 series and the M60 series Windshield cowl series are shown in Figure 4 The 2 mounts on heavy trucks are carryover except that a 2 spacer has been added which makes the clear ance be...

Page 65: ...provide water leaks When checking for water leaks a helper should be used on the inside of the cab or body to locate the entrance of water while it is applied on the outside NOTE Water does not always...

Page 66: ...nd the condition corrected before a new glass is installed Otherwise it is highly possible that a small obstruction or high spot somewhere around the windshield opening will continue to crack or break...

Page 67: ...ea for solder weld high spots or hardened spot weld sealer Remove all high spots 4 Check windshield glass to opening by supporting glass with six spacers contained in packet J 22577 fig 9 CAUTION Do n...

Page 68: ...ured to the instrument panel by studs nuts and screws The studs are an integral part of the cover assembly Removal and Installation 1 Loosen or remove any necessary instrument panel items glove box et...

Page 69: ...p of hood seal with seven retaining screws 4 Reinstall windshield wiper arms on pivot shafts COWL AIR VENTILATOR VALVE ASSEMBLY Replacement Entire outlet valve assembly may be removed from the vehicle...

Page 70: ...to motor drive linkage and arm assembly Disengage link rods from pins 4 Remove two screws which attach arm transmission pivot shaft assembly to cowl Remove pivot shaft assembly with link rod from ple...

Page 71: ...re aft up and down at the hinge pillar and the door also can be moved in and out at the hinge to door panel However in order to adjust the door assembly at the body hinge pillar it is necessary to use...

Page 72: ...n aid to striker adjustment outline the striker in pencil or crayon for use as a base for adjustment Horizontal slots are provided in the striker plate to position the striker assembly laterally so th...

Page 73: ...anism fig 24 5 Remove three sheet metal screws at the upper front of the door fig 25 6 Turn the vent assembly 90 and carefully remove by guiding up and out fig 25 Installation NOTE Replace the door wi...

Page 74: ...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...

Page 75: ...ng welding flange fig 30 and goes completely around the periphery of the opening The molded weatherstrip material is cemented fig 30 Success of weatherstrip replacement depends entirely upon the quali...

Page 76: ...ock assembly 6 Remove 3 screws retaining remote control 7 Remove lock push button rod and remote control rod as an assembly Installation 1 Transfer remote rod with clip to new lock 2 Connect remote do...

Page 77: ...ove weatherstrip merely pull it off the edges of the door panels On installation of new weatherstrip clean opening edge thoroughly then install with butt ends lightly coated with weatherstrip adhesive...

Page 78: ...abric and soil it 3 Place cloth on soiled spot do not rub apply slight tapping pressure several times This will pick up particles which are too embedded to be removed in the brushing operation This op...

Page 79: ...load on torsion bars by rotating adjuster lever assembly No 30 counter clockwise until ad juster assembly is disengaged from seat 3 Disengage back cushion from seat assembly by re moving bolts and loc...

Page 80: ...BODY IB 18 Fig 41 Exploded View of Level Ride Seat CHEVROLET TRUCK SERVICE MANUAL...

Page 81: ...corn Nut Self Locking 56 Pad Seat Cushion 16 Shock Lever Assy Kit 37 Pin Drive 57 Back Cushion Assy 17 Shock Lever Assy 38 Washer Plain Cover Assy Back Cushion 18 Hinge Shaft Shock 39 Thrust Ball Bear...

Page 82: ...IB CHEVY VAN BODY SPORTVAN INDEX Page General Description IB 20 Body and F r a m e IB 20 Front End Panel IB 20 Side Panels IB 21 Roof Panel IB 21 Underbody IB 21 Sealing IB 21 Service O perations IB 2...

Page 83: ...he engine cover to the underbody uses two different sealing compounds A special sealer is available for the tail lamp protector sealing SERVICE OPERATIONS WINDSHIELD GLASS The Conventional Cab Windshi...

Page 84: ...onnect the transmission and linkage assembly as a unit and install with screws under dash with gaskets in place 2 Connect the short link to the motor and install the nuts 3 Install the radio 4 Install...

Page 85: ...her bag bracket c Electrical harness from the quick disconnect under dash d Junction block e Speedo cable at instrument cluster f Loosen the metal electrical harness shield on the toe pan g Headlamps...

Page 86: ...od assembly attaching snap on clips with a screw driver located as shown in Figure 59 through the access hole New clips must be used on reassembly of the rod 2 Remove the rod assemblies and special sp...

Page 87: ...val Fig 64 1 Fully open forward side door extending step as sembly 2 Pull pin securing rod end to door and tape rod end to rod for reinstallation 3 Remove 4 screws securing rod cover to floor 4 Remove...

Page 88: ...to the floor with lock washers SEAT BACK ADJUSTMENT Fig 67 Replacement The seat back is adjustable forward or backward by loosening the top bolts right and left side at the lower side of the seat back...

Page 89: ...BODY IB 27 CHEVROLET TRUCK SERVICE MANUAL...

Page 90: ...ed forward or rearward Fig 68 Flip Swing Passenger Seat Fig 70 Center or Rear Seat Sportvan STEP VAN BODY INDEX Page General D escrip tion IB 29 Service Operations IB 30 Front End IB 30 Windshield and...

Page 91: ...ox B Access Door to Radiator Filler Cap C Tool Box D Battery Access Door for Servicing or Removing E Access Door to Hydraulic Band Adjusting Screws on Automatic Transmission Where Applicable F Removab...

Page 92: ...s are retained in body opening by wedge type weatherstrip such as that used on Conventional Cab rear window ACCESS DOORS AND COVERS The following information is intended as an accessi bility guide Com...

Page 93: ...ition of windshield wiper arms have them in park position Mark this position on glass with grease pencil 5 Remove the holding nut and lockwasher from the end of drive shaft 6 Lift off wiper arm and kn...

Page 94: ...Circuit breaker for wiper motor is located on fire wall directly above clutch pedal DOORS ADJUSTMENTS Bottom of Doors 1 The in and out adjustment for the bottom of sliding doors is controlled by two...

Page 95: ...ck striker is too low it will raise the rear roller off the track when door is in locked posi tion Raise striker slightly by striking it with ham mer to correct 8 Letting the door travel out farther a...

Page 96: ...as well as the other filler sec tions much easier to install 3 Set lower edge of sliding glass front section in run channel with upper edge of glass back of joint in weatherstrip rubber Place paint s...

Page 97: ...ight part of rubber Using 1 4 diameter drill 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 Plac...

Page 98: ...B 44 Windshield W ip e rs IB 45 Emblem Assembly and Front Access Panel IB 45 Instrument Panel Compartment IB 45 Doors IB 46 Adjustm ents IB 46 Door Assembly Removal and Installation IB 48 Window R egu...

Page 99: ...the full tilt position Check link must be released before cab can be returned to nor mal operation position Interconnected with the cab front mountings is a torsion bar which is under load when cab is...

Page 100: ...ed will distrub their alignment 7 Using two helpers and lifting device tilt cab approx imately 45 to the unloaded position of cab mounting torsion bar refer to preceding caution and suspend safely the...

Page 101: ...Fig 88 Bracket Bolt Locations 6 Insert a pry bar in between cab left support bracket and cab sill fig 87 7 Use two helpers one holding pry bar as shown in Figure 87 and the other helping to tilt cab f...

Page 102: ...right front mounting see inset view by pulling rearward on link release rod then pull cab back to operating position 2 Safety catch at rear of cab will automatically become engaged Pull downward on h...

Page 103: ...proceed as follows 1 Insert bar through left hand frame support bracket and into right hand body bracket 2 Install caps on right hand frame support bracket and left hand body bracket torque bolts to 5...

Page 104: ...e event repair such as welding is required to that part of cab covered with undercoating it is first neces sary to remove the undercoating from that area IMPORTANT Before spraying new undercoat ing cl...

Page 105: ...BODY IB 43 Fig 94 Check Link Assembly Typical CHEVROLET TRUCK SERVICE MANUAL...

Page 106: ...View A should be lubricated with machine or light motor oil whenever vehicle is lubricated Fig 95 Insert Type Seal that section of glass which is to be removed 3 With aid of an assistant to hold glass...

Page 107: ...ng shaft ferrule to body outer panel remove washers 5 From inside vehicle remove four screws retaining motor assembly to dash and remove assembly from vehicle Installation Install by following removal...

Page 108: ...per hinge NOTE Before making door adjustments al ways remove striker plate assembly View F fig 1 0 2 from the cab lock pillar In addition to the door lock striker rear of door is supported in cab open...

Page 109: ...el Use pointed tool to remove plug b After satisfactory adjustment has been obtained tighten hinge cap screws firmly Open and close door to check operation If necessary repeat adjustment Install hinge...

Page 110: ...door paneling c After adjustment has been made tighten hinge cap screws firmly Open and close door to check operation Readjust if necessary NOTE It may be necessary to reposition door striker plate on...

Page 111: ...lock and remote control units to disengage the connecting link Installation 1 Assemble connecting link between lock unit and re mote control unit 2 Through access opening at bottom of door place re m...

Page 112: ...sition glass assembly into opening at bottom of door fig 108 and engage edges of glass in door front and rear glass run channels 7 Engage regulator arm pin in glass channel with leather washer located...

Page 113: ...hannel to glass lower channel 6 Apply Prep Sol on vent glazing rubber to soften old rubber When rubber softens sufficiently separate upper and lower glass channels then remove old glass Installation 1...

Page 114: ...esive material which may have become bonded to door surface 3 Apply weatherstrip adhesive as directed by manu facturer of adhesive Directions for application are usually found on adhesive container 4...

Page 115: ...strip G LASS SEAL INSERT PA N EL TYPICAL Fig 113 Insert Type Seat Fig 114 Driver s Seat Assembly Fig 115 Driver s Seat Adjuster Assembly IN STA LLIN G G LA S S IN SEA L IN ST A LLIN G IN SERT IN SEAL...

Page 116: ...lubricant to rubber insert fig 113 Push tool and end of insert into groove at bottom center of window Feed in rubber insert while proceeding around window Use a hitching movement to avoid elongation o...

Page 117: ...BODY IB 55 Fig 116 A uxiliary Seat CHEVROLET TRUCK SERVICE MANUAL...

Page 118: ...mmm i l l l Fig 117 Special Tools 1 J 2189 Weatherstrip Tool Set 2 J 5742 01 and J 22577 Windshield Checking Blocks Typical 3 J 22585 Front Door Hinge Bolt Wrench 4 J 9316 Windshield Checking Blocks C...

Page 119: ...checking points however selection of these points is arbitrary depending on ac cessibility and convenience An important point to re member is that for each point selected on one side of the frame a co...

Page 120: ...ated points on the frame figs 4 8 For ex ample if the tram bar is set at point B with a vertical pointer length of 8 1 4 inches and at point E with a vertical pointer length of 5 1 4 inches a height d...

Page 121: ...Fig 4 1 0 3 0 Series Truck Frame...

Page 122: ...Fig 5 4 0 6 0 Single A xle Truck Frames Exc T ilt Cab FRAME 2 4...

Page 123: ...OF HOLE OR SLOT GAUGE HOLES ARE DIAMETER INDICATES THAT THE DIMENSION IS TO THE UNDERSIDE OF THE FRAME TOP SURFACE OR INSIDE OF THE FRAME OUTER SURFACE NOTE FRAME ILLUSTRATED IS TYPICAL FRAME DESIGN...

Page 124: ...CHEVROLET TRUCK SERVICE MANUAL 1 Ficu 7 4 0 6 0 Series T ilt Cab Truck Frames FRAME 2 6...

Page 125: ...1 2 7 7 8 7 7 8 10 42 5 8 122 1 8 148 1 8 16 7 8 16 7 8 16 7 8 16 7 8 40 60 SERIES SINGLE AXLE DIMENSIONS Model A B C D E F G H I J K L M N Wheel base CG5 610 15 7 8 13 1 2 20 15 3 4 15 3 4 15 3 4 20...

Page 126: ...7 20 15 3 8 62 1 2 112 1 4 141 1 2 33 1 2 26 3 8 16 3 4 16 3 4 97 TT _ TD 614 14 1 2 11 3 4 13 1 8 14 1 8 16 7 8 15 3 4 20 15 3 4 17 20 15 3 8 74 1 2 124 1 4 156 3 8 33 1 2 26 3 8 16 3 4 16 3 4 109 T...

Page 127: ...ions are required 1 The horizontal dimension between the two points to be trammed 2 The vertical dimension from the datum line to the points to be trammed The tram bar should be on a parallel to that...

Page 128: ...CHEVROLET TRUCK SERVICE MANUAL Fig 8 Underbody Reference Points and Dimensions Chevy Van G10 and 20 FRAME 2 10...

Page 129: ...ntrol Arm A ssem bly 3 11 R em oval 3 11 Repairs 3 11 B ushings 3 11 Ball J o in ts 3 11 Installation 3 11 Upper Control Arm A s se m b ly 3 12 R em oval 3 12 Repairs 3 12 B ushings 3 12 Ball Joint 3...

Page 130: ...e attached to the crossmember with U bolts These control arms are connected to the steering knuckle through pivoting ball joints A coil spring is located between the lower control arm and a formed sea...

Page 131: ...lly mounted semi elliptic springs with a transverse mounted stabilizer bar connected to the spring seat on the axle and ball front wheel bearings The Chevy Van front suspension fig 4 incorporates the...

Page 132: ...at this point there is no alignment between slots in nut and spindle holes fig 5 back off until slot lines up with the nearest hole in the spindle and insert new cotter pin Fig 5 Wheel Bearing Adjustm...

Page 133: ...10 30 Series caster and camber as follows refer to Figure 8 Caster 1 Measure frame angle ure 8 B at location shown in Fig Camber 1 Determine machine 2 Measure dimension A 3 Using dimension A and the c...

Page 134: ...ims 10 30 Series Fig 12 Tilting Tie Rod Sockets gear high point adjustment and place wheels in straight ahead position before checking toe in Adjustments are made by loosening clamp bolts at each end...

Page 135: ...it will be necessary to replace defective steering arm as outlined under Steering Knuckle Steering Arm later in this section Steering Axis or Kingpin Inclination Steering axis or kingpin inclination i...

Page 136: ...e cup installers for different vehicle series as listed in Special Tools illustration Figure 47 Wheel Hub and Brake Drum CP 10 and Chevy Van Figure 13 1 Brake drum is retained to hub by hub bolts and...

Page 137: ...nstall outer bearing pressing it firmly into position in hub 4 Adjust wheel bearings as outlined under Wheel Bear ings Adjust Shock Absorbers Figure 17 Removal 1 Remove nuts and eye bolts securing upp...

Page 138: ...ightly below end of stud b Loosen upper ball stud in steering knuckle using Tool J 8806 positioned as shown in Figure 19 Remove the nut from the ball stud c Swing the upper control arm up and away fro...

Page 139: ...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 to specifications Figure 22 shows correct f...

Page 140: ...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 to...

Page 141: ...s into knuckle bosses 2 Install ball stud nuts and tighten as follows Upper nuts 70 lb ft CP10 120 lb ft C20 30 lower nuts 120 lb ft CP10 215 lb ft C20 30 3 Place brake backing plate and wheel cylinde...

Page 142: ...spacer re tainer and rubber bushing over bolt and thread bolt through eye on stabilizer bar 4 Install rubber bushing and retainer over bolt and in stall nut tightening it to limit of bolt threads 5 W...

Page 143: ...g to axle U bolts 3 Remove spring front and rear eye bolts and withdraw spring from vehicle Inspection Inspect bushings for excessive wear check spring leaves for breaks and inspect spring clips for t...

Page 144: ...hen bend spring clips into place IMOTE Spring clips should be tightened suffi ciently to maintain alignment but not tight enough to bind spring action Installation 1 Position spring assembly under veh...

Page 145: ...bent sufficiently to maintain alignment but not tight enough to bind spring action Installation 1 Assemble fixed end of spring to spring hanger and install spring hanger bolt 2 Install nut and tighte...

Page 146: ...bushing is replaced with spring off vehicle use a press if available and adapters J 21978 1 2 to remove and reinstall bushing Fig 41 Installed Position of Offset Bushing 7000 Axles Removal and Install...

Page 147: ...ings Steering knuckle bushings are split type floating Delrin bushings and can be removed by sliding them out of knuckle bores without the use of special tools After re moval clean up bushing bores us...

Page 148: ...hole in axle end On 9000 11 000 models install kingpin from bot tom and install kingpin upper nut Torque nut 250 lb ft and insert new cotter pin 4 Insert threaded end of lockpin through axle end from...

Page 149: ...e wheel and tire assembly 2 Disconnect shock absorber lower mount from U bolt spacer bracket or spring seat bracket Disconnect stabilizer lower link on P20 30 models 3 Remove wheel hub and drum assemb...

Page 150: ...ct shock absorber lower eye and stabilizer link on P20 30 models 4 Install brake backing plate assembly to steering knuckle as outlined in Section 5 Brakes 5 Install steering arm and the rod assembly...

Page 151: ...3 J 21830 4 Spring Bushing Receiver 4 J 21979 7000 A xle Spring Bushing Remover Installer 5 J 21978 1 4 5000 Axle Spring Bushing Remover 6 J 21978 2 4 5000 Axle Spring Bushing Installer 7 J 21058 N u...

Page 152: ...flow to each front wheel regardless of the turning angle Provisions for Power Take off have been incorporated in the transfer case FRONT AXLE The front axle is a Spicer hypoid gear axle unit equipped...

Page 153: ...ke shoes in the rear wheels through a pistol grip type parking brake lever mounted under the left side of the instrument panel ADAPTER1 ITRANSFER ICASE Fig 1 Control Lever Fig 2 Transfer Case and Adap...

Page 154: ...ing assembly from shaft Disassembly Refer to Figures 4 and 5 1 Turn key to engaged position fig 3 to release pres sure from springs 2 With suitable size drift punch remove key knob re taining pin thro...

Page 155: ...oke Support the other side of yoke in bench vise and drive other bearing out using brass drift on end of trunnion On other joints remove trunnions from yokes in similar manner Remove trunnion Clean an...

Page 156: ...ap Ring 8 Steering Arm 14 Axle Shaft 20 Wheel Bearing Seal 3 Lock Nut 9 Seal Retainer 15 Bearing Cup 21 Wheel Bearing Inner 4 Lock Ring 10 Sea 1 Ri ng 16 Bearing Cone 22 Wheel Hub 5 Adjusting Nut 11 R...

Page 157: ...knuckle should turn with 1 1 2 0 lbs pull Add shim to decrease preload remove shim to increase preload b On 44 5HDF models use a torque wrench posi tioned on upper bearing retainer nut knuckle should...

Page 158: ...is lubricant install new gaskets to adapter case Fig 9 Four Wheel Drive Special Tools 2 With transfer case on suitable cradle line up the output spline on the adapter and input spline on the transfer...

Page 159: ...1 and C20 fig 2 trucks use a two link suspension with a control arm attached between each end of the axle housing and the central area of the frame A single U bolt attaches each control arm to the axl...

Page 160: ...rear hangers Series P20 C P30 fig 7 trucks use a conventional leaf spring with tension mounted clevis type shackles at the rear hangers Shock absorbers are installed between brackets welded to the ax...

Page 161: ...ing pile a spacer separates the last leaf from the control arm radius leaf which is a half leaf formed with an eye and bushed for attachment to the front hanger The spring assembly makes use of a stre...

Page 162: ...ing A badly bent rod however should be replaced 2 Bushings should be replaced if any abnormal condi tions exists such as looseness damage to or swell ing of rubber parts or general wear Bushing Replac...

Page 163: ...rly positioned during nut tightening 4 Align stabilizer shaft so that both ends protrude equally from the anchors Alternately torque frame bracket retaining nuts to 25 ft lbs Control Arm Series C P10...

Page 164: ...ition clamp so that the end of the spring coil is within the area of the notch as shown in Figure 16 so that it seats freely on spring end without any hang up and locate over bolt hole in control arm...

Page 165: ...front Fig 20 Series G10 and G20 Spring Shackle eye with the spring installed on the vehicle to replace the rear spring eye bushing remove spring from vehicle before attempting to replace bushing 1 Re...

Page 166: ...Installing Spring Eye Bushing Series P20 and C P30 Bushing Replacement Series G Kf 10 and 20 NOTE Only the front bushings are the same on both the G and K series truck Both front and rear bushings on...

Page 167: ...4 Remove U bolt retaining nuts withdraw U bolts and remove spring assembly from the vehicle 5 Inspect spring replace bushings repair or replace spring unit as outlined in this section Installation 1...

Page 168: ...icle 5 Inspect spring replace bushing repair or replace spring unit as outlined in this section Installation 1 Install spring camber shim making sure shim is po sitioned so that it corresponds to shim...

Page 169: ...e by a lock bolt The rear end of the spring rides free in a spring hanger Each spring is mounted at its center on a saddle sup ported on the end of a cross tube which passes through the two equalizing...

Page 170: ...5 Bolt 6 Nut 7 Washer T 699 Fig 30 Beam to Axle Mounting Axle Bracket Equalizer Beam End Bushing 5 Bolt 6 Nut 7 Washer 4 Adapter Fig 31 Cross Tube to Spring Saddle Mounting 1 Center Bushing 6 Lock Nu...

Page 171: ...er install pin so slot in pin lines up with lock bolt holes in hanger and install lock bolt so wedge mates with slot in pin Install lock bolt washer and nut 9 Install wheels and tires Lower vehicle to...

Page 172: ...oat spring leaves with a light film of graphite grease Stack spring leaves in correct order then compress leaves using C clamps or an arbor press Install cen ter bolt then install rebound clip bolts a...

Page 173: ...ION Keep cross tube level so beams do not slide off tube 4 Lower the beams and tube from vehicle and pull beams off tube Repairs A D A PT ER Fig 35 Adapter and Retaining Bolt at Axle Bracket Fig 36 Eq...

Page 174: ...Salisbury Type Axles 4 17 5200 and 7200 Lb Capacity A x le s 4 17 11 000 13 500 15 000 and 17 000 Lb Capacity A x le s 4 17 Maintenance and Adjustments 4 17 Lubricant 4 17 U Bolt and Hub N uts 4 17 Re...

Page 175: ...speed hypoid axles illustrated in Figures 39 and 40 respectively have a straddle mounted drive pinion which is supported at the rear by a straight roller bear ing The pinion front bearing consists of...

Page 176: ...ector 8 Shim A with Service Shim 14 Pinion Shaft 20 Differential Pinion 3 Pinion O il Seal 9 Gasket 15 Ring G ear 21 Shim 4 Pinion Front Bearing 10 Differential Bearing 16 Side G ear 22 Pinion Rear 5...

Page 177: ...Pinion Spider 15 2 Pinion Bearing Retainer and 7 Pinion Bearing Shim G ear 16 O il Seal 8 Rear Pinion Bearing 12 Differential Side G ear 3 O il Seal Packing 9 Ring Gear 13 Differential Case Left Half...

Page 178: ...rive Pinion 7 Rear Pinion Bearing 8 Ring G ear Thrust Pad 9 Ring G ear 10 Differential Spider Capacity Axle Cross Section 11 Differential Pinion Spider G ear 12 Differential Side G ear 13 Differential...

Page 179: ...y Axle Cross Section 6 Drive Pinion 11 7 Rear Pinion Bearing 8 Ring G ear Thrust Pad 12 9 Ring G ear 13 10 Differential Spider 14 Differential Pinion Spider G ear Differential Side G ear Differential...

Page 180: ...nnect shock absorbers at lower attachment points and position out of the way 6 Disconnect axle vent hose from vent connector and ing of the ring gear and pinion teeth as a result of insuf ficient or i...

Page 181: ...EAL AND OR BEARING REPLACEMENT 1 Remove the oil seal by using the button end of the axle shaft insert the button end of the shaft behind the steel case of the oil seal then pry seal out of bore being...

Page 182: ...rsal joint tape trunnion bearings to joint position propeller shaft to one side and tie it to frame side rail 4 Using Tool J 5853 with Adapter J 5810 and a suitable socket on the pinion flange nut rot...

Page 183: ...t seats against internal shoulder at this point there should be a gap of approximately 1 8 between seal flange and carrier fig 51 Do not apply unnecessary pressure after seal is seated to do so will d...

Page 184: ...to floor and road test for leaks POSITRACTION DIFFERENTIAL UNIT The optionally available Positraction differential unit is installed in the conventional carrier to replace the stand ard differential...

Page 185: ...vent into housing using a soft faced hammer Vent should be positioned in housing so that flat surface is toward centerline of differential carrier fig 54 Axle Shaft Removal and Installation 5200 and 7...

Page 186: ...nge and install a new gasket over hub studs and against hub 5 Install axle shaft so that splines are aligned with dif Fig 57 Hub and Drum Details Nondemountable Type Drum 1 Axle Shaft 7 Drum 2 Axle Sh...

Page 187: ...r assembly NOTE The hub oil seal should be replaced whenever the hub is removed for any reason 6 Remove oil seal 1 Remove wheel assembly and axle shaft as specified in applicable Axle Shaft Removal pr...

Page 188: ...cannot be replaced with inner bearings in position therefore replace outer bearings if required before proceeding 3 Position bearing cup in hub thick edge of cup toward shoulder in hub then using app...

Page 189: ...p in hub thin edge of cup toward outer end of hub press cup into hub using Tool J 2223 for 5200 and 7200 lb axles Tool J 8114 with J 8092 drive handle for 11 000 and 13 500 lb axle Tool J 5698 for 15...

Page 190: ...sition de flector to drum 4 Install drum to hub retaining bolts hub stud nuts or press wheel studs into drum as applicable Wheel Bolt Replacement Wheel bolts are serrated and may also be swaged in pla...

Page 191: ...al Replacement Pry old seal from its location in the hub bore using care so as not to damage bore surface Thoroughly clean all oil and foreign matter from seal contact area in hub bore Pack the cavity...

Page 192: ...2343 15 000 lb axle with 15 x 5 inch brake M50 trailing axle single speed M50 trailing axle two speed 15 000 lb two speed axle 17 000 lb two speed axle Tighten adjusting nut to approximately 50 ft lbs...

Page 193: ...ve and inspect the No Spin DRIVE LINE REAR AXLE CHEVROLET TWO SPEED INDEX Page General D escrip tion 4 35 Maintenance and Adjustm ent 4 37 Component Parts Replacement 4 37 Electric Shift S y s te m 4...

Page 194: ...ting 7 Pinion Intermediate Bearing Nut Right 8 Pinion 16 O il Baffle 9 Differential Carrier 17 Adjusting Nut Lock Right 18 Thrust Washers 26 Planet Gears 4 19 Differential and Planet 27 Differential a...

Page 195: ...nge the speedometer drive is straight thru the adapter The inner mechanism is prelubricated and sealed by the manufacturer In the event of failure the adapter is replaced as a unit AXLE SHIFT UNIT The...

Page 196: ...winds the torsion spring Thus the tension of the spring is increased and in this position the axle is ready to shift into the high speed ratio as soon as the load on the axle gears is relieved The tor...

Page 197: ...shift unit should be filled with lubricant to the filler opening on the front cover using SAE 10 engine oil At ambient temperatures below 0 F use SAE 5W The oil level should be checked every 10 000 mi...

Page 198: ...mbly can then be lifted out of housing 8 Remove the two lock nuts fig 83 from terminals on switch 27 and pull off motor wires 9 Remove three screws and lock washers 1 which at tach motor cover to hous...

Page 199: ...snap ring assembly Pack bearing assembly with chassis lubricant Check torsion spring 17 for breaks or wear at lever contact points Observe condition of fiber contact bumper 24 if broken or excessively...

Page 200: ...open end wrenches one to hold the push rod inner nuts and the other to remove the outer nut from the push rod remove the diaphragm plates and diaphragm CAUTION Be careful not to transpose hose connect...

Page 201: ...m Replacement VACUUM SHIFT UNIT CONTROL SWITCH REPLACEMENT The manually operated control switch mounted on the transmission shift lever fig 8 6 is an electromechanical two position switch which contro...

Page 202: ...ve the transmission shift lever knob then re move the two screws retaining switch housing case to transmission lever Transfer conduit and speedom eter adapter switch to new housing 5 Loosely install t...

Page 203: ...fts are full floating type splined to differential side gears at inner ends and attached at flanged outer ends to hubs by studs and nuts Stud holes in each shaft flange are taper reamed to accommodate...

Page 204: ...e the rear spring U bolts and roll the axle assembly out from under the truck Raise the axle clear of the floor and remove the wheels Installation 1 Install the wheels then roll the axle assembly into...

Page 205: ...n on electrical system The Axle Shafts Housing Wheels and Hubs used on the 17201 and 17221 Model axles are the same as those out lined in 17 000 lb Chevrolet Single Speed An improved lubrication syste...

Page 206: ...the axle assembly into position under the truck 2 Attach axle to the rear springs with the U bolts Tighten the bolt nuts to 300 320 foot pounds torque 3 Connect propeller shaft to the axle drawing U b...

Page 207: ...REAR SUSPENSION AND DRIVE LINE 4 49 Fig 91 Tandem Rear Axles and Power Divider CHEVROLET TRUCK SERVICE MANUAL...

Page 208: ...ement with the input shaft helical gear A light installed on the dash warns when differen tial is locked out NOTE Use lockout only in slippery going When differential is to be locked out vehicle must...

Page 209: ...solenoid valve is positioned at the frame left side rail by the vacuum pipe clips and may be removed by dis connecting the three fittings at the valve LOCKING CYLINDER When leakage tests indicate the...

Page 210: ...k shift cylinder mounted on forward rear axle torque divider case cover and interconnecting air lines and fittings With lock control lever fig 96 in UNLOCK position there is no air pressure in differe...

Page 211: ...each shaft except the rear is supported near its splined end in a rubber cushioned ball bearing which is mounted in a bracket attached to a frame cross member The ball bearing is a permanently sealed...

Page 212: ...ear Propeller Shaft and Sleeve Assy 14 Retainer 23 Grease Retainer 5 Frame Cross member 15 Washer 24 Inner Deflector 6 Guard 16 Cork Packing 25 Dust Shield 7 U Clamp Intermediate or Rear Intermediate...

Page 213: ...nge and de flector assembly as follows 1 Install deflector on flange if removed and prick punch at two opposite points to make sure it is tight on flange 2 Align centerline of flange yoke with center...

Page 214: ...hange the speedometer gears or to use a speedometer adapter with the present gears In certain combination changes of both rear axle and tires it may be necessary to change the speedometer gears and us...

Page 215: ...eal Installer Light Duty A x le Used with J 21468 6 J 21051 Rear W heel Bearing and O il Seal Installer Heavy Duty Used with J 7079 2 7 J 21491 Rear Wheel Bearing and O il Sebl Installer Light Duty A...

Page 216: ...l Bearing Nut Wrench 19 10 J 22359 Wheel Bearing Installer 20 J 8092 Driver Handle J 8093 Wheel Bearing Installer J 21108 Wheel Bearing Installer J 22357 Wheel Bearing Installer J 22349 Wheel Bearing...

Page 217: ...cylinder Fig 1 The main cylinder has two entirely separate reservoirs and outlets in a common body pasting The front reservoir and outlet is connected to the front wheel brakes and the rear reservoir...

Page 218: ...RAKES 5 2 PA 20 30 PA 40 CA SA 40 CD CG MA 50 CD CG 60 TA 40 50 60 EXTENSION SIDE RAIL LEFT SIDE INBOARD FORWARD GA 10 20 CE CS SA 50 60 Fig 1 Main Cylinders A ll Models CHEVROLET TRUCK SERVICE MANUAL...

Page 219: ...Shoe 5 Brake Shoe Return Spring 6 Brake Shoe Hold Down Bolt 7 Brake Shoe Return Spring 8 Adjusting Screw Spur W heel 9 Brake Line 10 Wheel Cylinder 11 Brake Shoe Anchors Fig 2 Self Adjusting Brake op...

Page 220: ...cylinders are identified with type of brake with which they are used figs 6 and 7 On Duo Servo Fig 7 Wheel Cylinders Used with Types F and FR 3 Brakes 1 Boot 2 Brake Shoe Guide 3 Piston 4 Piston Cup 5...

Page 221: ...n a brake lining will cause that brake to grab first on brake application and fade out on heavy brake application BRAKE SHOE ADJUSTMENT The duo servo and Twinplex brakes used on all 10 thru 50 series...

Page 222: ...l J 7647 on bleeder valve at wheel cylinder and install one end of bleeder 5 Pour a sufficient amount of brake fluid into a trans parent container to insure that end of bleeder hose will remain submer...

Page 223: ...hose and no bubbles are present then close bleeder valve tightly 6 Remove brake bleeder wrench and bleeder tube from wheel cylinder bleeder valve 7 Repeat Steps 2 through 7 on the remaining wheel cyli...

Page 224: ...emerges from the bleeder tube Close bleeder valve as brake pedal is on down stroke 5 Replace reservoir cover then readjust all brake shoes 6 Apply approximately 75 pounds pressure on the brake pedal...

Page 225: ...ten nut to 40 50 ft lbs torque Then to obtain the correct clearance between the push rod and the master cylinder adjust the push rod so that the free pedal travel measured at the center of the pedal p...

Page 226: ...er and rear end of slot in guide fig 22 Tighten lock nuts 4 Pull parking brake lever to the applied position 5 Check drag on each rear wheel An equal amount of drag should be present at each wheel If...

Page 227: ...Oil all moving parts Propeller Shaft Parking Brake Single Shoe Type Fig 25 1 Set hand brake lever in the fully release notch of the ratchet sector 2 Loosen lock nut D and draw up adjusting bolt A to...

Page 228: ...BRAKES 5 12 TD 50 60 Fig 23 Parking Brake Cables T Models CHEVROLET TRUCK SERVICE MANUAL...

Page 229: ...SYSTEM NOTE This model cylinder is installed on CA KA PA10 20 and CA PA30 series vehi cles When service procedures for CE CS SA50 60 series models are required refer to Main Cylinder Single Reservoir...

Page 230: ...Seal 13 Cup 19 Spring 2 Cover 8 Piston 14 Seal 20 Stop Screw 3 Diaphragm Seal 9 Cup 15 Piston 21 Seal 4 Body 10 Seal 16 Washer 22 Spring 5 V alve 11 Ring 17 V alve Seat 23 Check V alve 6 Spring 12 Re...

Page 231: ...Remove the spring retainer primary seal primary seal protector and secondary seal from the primary piston Cleaning and Inspection 1 Remove main cylinder casting from vice and inspect the bore for corr...

Page 232: ...5 Connect the brake lines to the main cylinder 6 Fill the main cylinder reservoirs to the levels shown in Figure 13 Bleed the brake system as outlined in this section 7 If necessary adjust the brake p...

Page 233: ...ort To check this clearance proceed as follows 11 12 13 14 15 Lock Ring Housing Seal Check Valve Return Spring 16 Retainer 17 Primary Cup 18 Piston 19 Piston Seal 20 Snap Ring a Place spring assembly...

Page 234: ...in this section 5 Install cover on main cylinder BRAKE COMPONENTS SELF ADJUSTING FRONT AND REAR BRAKES Brake shoe adjustment takes place when brakes are applied with a firm pedal effort while vehicle...

Page 235: ...ly 11 Clean dirt out of brake drum using care to avoid getting dirt into front wheel bearings Inspect drums for roughness scoring or out of round Replace or recondition drums as necessary 12 Inspect w...

Page 236: ...down pin and spring using a pair of needle nose pliers Engage shoes with the wheel cylinder connecting links 8 Install and secure the actuator assembly and second ary brake shoe with the hold down pin...

Page 237: ...tor lever functions easily by hand operating the self adjusting feature 16 Follow the above procedure for all brakes 17 Adjust the service brakes as outlined below then adjust the parking brake Adjust...

Page 238: ...CAM ACTUATING LEVER LINK OVER RIDE LEVER HOLD DOWN PIN SPRING ACTUATING STAR LEver WHEEL Fig 42 Twinplex Self Adjusting Rear Brake 40 and 50 Series Brake shoe adjustment takes place when brakes are a...

Page 239: ...of fluid is nearly al ways present and acts as a lubricant for the piston 11 Inspect flange plate for oil leakage past axle shaft oil seals Install seals if necessary 12 Check all flange plate attach...

Page 240: ...upper or lower end of the shoes with a plastic mallet until the distances at each end become equal 10 Locate the adjusting lever 020 to 039 above the outside diameter of the adjusting screw thread by...

Page 241: ...complaints denoting actual brake lining or shoe failure the brake drums should be re moved and before disassembly of the shoes from the flange plate all linings should be inspected for wear improper...

Page 242: ...ake shoe assemblies 5 Remove screws attaching adjusting wheel lock springs to anchor supports Thread each adjusting screw from the shoe side of its anchor support by turning adjusting wheels then lift...

Page 243: ...ached to brake shoes by a special bonding process When lining becomes worn to the extent that replacement is necessary it is recommended that factory bonded shoe and lining assemblies be used for repl...

Page 244: ...and remove DUO SERVO TWINPLEX Fig 53 Duo Servo and Twinplex Cylinders Fig 54 W heel Cylinders Used with Types F and FR 3 Brakes bolt attaching connecting tube fitting to lower cylin der Remove connect...

Page 245: ...der valve in upper opening in cylinder housing 3 At rear connect metal brake tube to wheel cylinder or to connector At front thread brake hose fitting into wheel cylinder housing or connector using a...

Page 246: ...ssible and is likely to cause excessive wear of other parts of brake mechanism due to its eccentric action A drum that is more than 010 out of round on the diameter is unfit for service and should be...

Page 247: ...CE MANUAL __________________ ALL EXCEPT FLAT FACE COWLS FLAT FACE COWLS VIEW A CA KA PA10 CA KA20 CA30 CA PA40 CD CG MA50 60 VIEW B SA40 HYDROVAC ASSEMBLY JJr VIEW A CE CS50 60 CA KA MAOO PA10 40 SAOO...

Page 248: ...t shaft s 6 Remove two screws from pivot sleeve and bracket assembly and remove assembly from channel 7 Withdraw lower pedal arm from channel Cleaning and Inspection 1 Wash all metal parts with an app...

Page 249: ...on 12 4 Grease fitting until grease passes thru bushing and comes out both sides of pivot bore Adjustment 1 Loosen check nut on the eccentric bolt attachment gpween the brake pedal and main cylinder p...

Page 250: ...e on top of lever Install adjusting nut on link Connect return spring to outer shoe 4 Adjust lining to drum clearance as previously directed under Parking Brake Adjustment Brake Drum Removal 1 Remove...

Page 251: ...Remove four nuts lock washers and bolts attaching oil deflector to inner side of brake drum 5 Press four serrated bolts from flange and drum assembly to separate drum from flange Brake Drum Installati...

Page 252: ...s onto output shaft 4 Place lock washer and special serrated flat washer on flange retaining bolt and install bolt in output shaft Tighten bolt to 68 73 ft lbs torque 5 Connect propeller shaft at tran...

Page 253: ...ket upper release spring brake support lower release spring and band lower bracket Install tension spring flat washer adjusting nut lock washer and lock nut on adjusting bolt NOTE On remote control pa...

Page 254: ...uire no service other than periodic inspection for damage from road hazards or other like sources Should damage occur and replacement become necessary the following procedure is to be followed Removal...

Page 255: ...lap flare A and the other with a double lap flare B It will be noted that the single lap flare splits the tubing while the double lap flare shown in B is a heavy well formed joint The following proced...

Page 256: ...ydraulic brake lines and connect lines to switch If neces sary tighten brake line connections at main cylinder 4 Connect switch electrical lead 5 Connect battery cable 6 Bleed the brake systems as out...

Page 257: ...ng manifold vacuum and atmospheric pressure for its power The Master Vac power brake unit permits the use of a low brake pedal as well as less pedal effort than is re quired with the conventional nonp...

Page 258: ...f clevis on rod 2 Disconnect vacuum hose from check valve in front shell of power section 3 Disconnect hydraulic lines at main cylinder Cover main cylinder outlet ports and ends of brake tubes to prev...

Page 259: ...Slide bushing 15 off push rod 11 and discard O ring seal 16 7 Discard piston cup 26 8 Remove retainer 17 and washer 18 9 Disengage snap ring 25 from piston 10 Slide piston 20 off push rod 11 Discard p...

Page 260: ...cuum power booster brake units a single and a tandem diaphragm are used in 1967 Both types are installed between the master cylinder and the wheel cylinders in series in the hydraulic circuit and use...

Page 261: ...st pedal height is obtained and maintain foot pressure 3 Bleed power cylinder and wheel cylinders in same sequence followed in pressure bleeding Fig 77 Vacuum Booster Brake System SERVICE OPERATIONS T...

Page 262: ...alve diaphragm off its seat and permit air to pass to the accessories Should the air pressure drop below 80 psi the diaphragm closes off all air to the accessories and all remaining air pressure is re...

Page 263: ...ning solvent that is known to have no detrimental effect on metal nylon or rubber material BRAKE VALVE Every Year or 50 000 Miles Disassemble brake valve and clean all parts Install new inlet valves a...

Page 264: ...or gear and associated parts for wear or damage They must be a neat fit on compressor crankshaft Replace pulley or gear if worn or damaged 6 Install pulley or gear on compressor crankshaft making sure...

Page 265: ...ge in body diaphragm ring and cover and clear any restrictions noted 7 Clean or replace strainer and filter elements 8 Replace any parts which are no longer serviceable by these inspections Assembly P...

Page 266: ...it in such a way that it can be assembled the same way If the brake chamber is to be dismantled on the vehicle for example to change the diaphragm or spring first back off the slack adjuster to relie...

Page 267: ...rnor Disassembly Fig 84 1 Remove all dirt or grease from exterior of governor using cleaning solvent and a brush 2 Unscrew the top cover 3 Remove the spring assembly retaining ring 4 Remove the adjust...

Page 268: ...3 Connect air lines to governor 4 Test governor for proper operation FOOT OPERATED AIR BRAKE CONTROL VALVE Removal 1 Exhaust all air from system 2 Remove all lines running to brake valve 3 Remove peda...

Page 269: ...dal in the depressed position Adjustments If the brake valve does not release promptly or does not fully release it indicates that the exhaust valve is not operating sufficiently This can be caused by...

Page 270: ...by washing in a suitable cleaning fluid Fig 89 Slack Adjuster Cutaway V iew 1 Lock Sleeve 2 Spring 3 Dowel 4 Lever 5 Worm 6 Worm Shaft 7 G ear 8 Cover Plate Fig 88 Lapping Exhaust Port Seat 2 Cut off...

Page 271: ...rotate freely and without binding Release brakes and make sure all slack adjusters return to released position freely without binding With brakes released make sure the angle formed by slack adjuster...

Page 272: ...dle nut Tighten spindle nut to 55 foot pounds torque and insert cotter pin The nut may have to be backed off slightly to allow entrance of cotter pin 6 Install rim and tire assembly rim locks and whee...

Page 273: ...means of the slack adjuster which is incorporated in the camshaft lever With brakes released the angle formed by the push rod and camshaft lever must be greater than 90 and all units should be set at...

Page 274: ...ion of Parts Wash all metal parts in cleaning solvent If the key or body is badly scored the complete drain cock should be replaced Do not attempt to fit a new key in an old body or vice versa Repairs...

Page 275: ...isc valve and seat for corrosion Inspect body and cap nut for cracks or damage If any damage is present replace entire valve assembly Assembly 1 Position valve stop bushing spring and disc valve in bo...

Page 276: ...same pressure within 5 pounds as registered on the dash air gauge 2 Move the handle to several positions between fully released and fully applied and note that pressure registered on the test gauge va...

Page 277: ...air pressure in system to operating range then stop engine Push emergency air valve knob in Make a series of brake applications until low air buzzer sounds Slightly open drain cock in the dry air tank...

Page 278: ...nstall end cap in body 5 Install piston return spring in body 6 Install new piston cup on piston and install piston in valve body 7 Install piston spring in valve body 8 Install adjusting bearing in c...

Page 279: ...eeding Tube 7 J 7647 Brake Bleeding Wrench Fig 101 Special Tools 8 J 4705 W heel Cylinder Piston Cup Installer 9 J 22364 Drum to Brake Shoe Clearance Gauge 10 J 21601 Power Brake Retainer Installer 11...

Page 280: ......

Page 281: ...performance and fuel consumption It is seldom advisable to attempt a tune up by correction of one or two items only Time will normally be saved and more lasting results assured if the technician will...

Page 282: ...n 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 Refer to spark plug...

Page 283: ...Dirty points should be cleaned with a clean point file Use only a few strokes of a clean fine cut con tact file The file should not be used on other metals and should not be allowed to become greasy...

Page 284: ...soda solution to neutralize any acid present and then flush off with clean water Keep vent plugs tight so that the neutralizing solution does not enter the cell The hold down bolts should be kept tigh...

Page 285: ...ystems utilizing manifold vacuum to draw fumes and contaminating vapors into the combustion chamber where they are burned Since it affects every part of the engine crankcase ventilation is an importan...

Page 286: ...ES With engine running at idle raise the adjustment screw window and insert an Allen wrench in the socket of the adjusting screw fig 1 1 Turn the adjusting screw as required until a dwell reading of 3...

Page 287: ...ure screw to obtain highest steady idle speed 1 4 turn out from lean roll 4 Repeat Steps 2 and 3 as needed for final adjustment 5 Shut down the engine remove gauges and install air cleaner 2 3 IDLE MI...

Page 288: ...Order 1 8 4 3 6 5 7 2 1 8 4 3 1 6 8 5 4 7 3 2 6 5 7 2 4 Operate engine on each pair of cylinders in turn and note engine rpm and manifold vacuum for each pair A variation of more than 1 inch of vacuum...

Page 289: ...n it io n O u t p u ta n d S e c o n d a r yL e a k a g e Use equipment as directed by manufacturer GOOD readings indicate both ignition output and secondary insulation are good If all readings are B...

Page 290: ...tional 1 4 turns pausing 10 seconds each time until nut has been turned down 1 full turn from the zero lash position NOTE This 1 turn preload adjustment must be done slowly to allow the lifter to adju...

Page 291: ...emblies after removal and r e m o v a l of some sub assemblies refer to Section 6 of the Truck Chassis Overhaul Manual Because of the interchangeability and similarity of many engine sub assemblies an...

Page 292: ...ire harness clip and engine ground strap Disconnect Powerglide cooler lines at both ends then remove cooler lines Place a suitable jack with the engine cradle Tool J 21741 attached under the engine fi...

Page 293: ...rter d Connect throttle linkage and vacuum modulator line ON ALL SERIES EXCEPT CS 10 20 30 GS 10 20 Install clutch assembly and clutch housing as out lined in Section 7 ON GS 10 20 SERIES Mount engine...

Page 294: ...ps then re move manifold assembly and discard gaskets 7 Check for cracks in manifold castings 8 If necessary to replace either intake or exhaust manifolds separate them by removing one bolt and two nu...

Page 295: ...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 va...

Page 296: ...will help prevent twisting 7 Install the valve locks and release the compressor tool making sure the locks seat properly in the upper groove of the valve stem NOTE Grease may be used to hold the locks...

Page 297: ...at the radiator 7 Remove accessory drive pulley if so equipped 8 Remove the shroud 9 Install Tool J 6978 1 on the torsional damper Place the shoulder of the tool toward damper fig 5L 10 Place a suita...

Page 298: ...of the crankshaft NOTE Always replace the upper and lower seal as a unit Install with the lip facing toward the front of the engine 1 With the oil pan removed remove the rear main bearing cap 2 Remov...

Page 299: ...Centering Tool in Cover CHEVROLET TRUCK SERVICE MANUAL Fig 8L Removing O il Seal Upper Half 1 Coat front seal contact area on damper with engine oil 2 Install torsional damper as follows DRIVE ON TYP...

Page 300: ...nd to position seal to seal evenly around the damper or hub surface 5 Install crankshaft hub and or damper as outlined 6 Install oil pan as outlined Oil Seal Front Cover Replacement W it h C o v e rR...

Page 301: ...in Section 13 4 Remove fuel pump as outlined in Section 6 M 5 Align timing gear marks then remove the two cam shaft thrust plates screws by working through holes in the camshaft gear fig 15L 6 Remove...

Page 302: ...haft and position to align dowel hole of crankshaft flange and flywheel fig 20L NOTE The interference fit dowel pins used on 292 cu in engines must be replaced with an oversize dowel pin when installi...

Page 303: ...0 S e r ie s The two piece rear support in transmission case ex tension may be removed without removing the transmis sion from the vehicle Replace both halves as a unit 1 Position the fan blade with...

Page 304: ...allation and adjust ment of some sub assemblies and replacement of some components For service to all components and sub assemblies after removal and removal of some sub assemblies refer to Section 6...

Page 305: ...emove engine mount bolts exc GE 10 20 ON GE 10 20 SERIES Remove the flywheel housing bolt retaining starter wire harness clip and engine ground strap Disconnect Powerglide cooler lines at both ends th...

Page 306: ...vacuum modulator line ON ALL SERIES EXCEPT CE 10 20 30 GE 10 20 Install clutch assembly and clutch housing as out lined in Section 7 ON GE 10 20 SERIES Mount engine in engine cradle so the forward le...

Page 307: ...and cylinder heads 2 Install manifold seals on block and gaskets on cyl inder heads fig 2V Use sealer at water passages and where seals butt to gaskets 3 Install manifold and torque bolts to specific...

Page 308: ...same locations Fig 3V V alve Adjustment Installation and Adjustment NOTE Whenever new rocker arms and or rocker arm balls are being installed coat bear ing surfaces of rocker arms and rocker arm ball...

Page 309: ...ntermittent Clicking Probable causes are a A miscroscopic piece of dirt momentarily caught between ball seat and check valve ball b In rare cases the ball itself may be out of round or have a flat spo...

Page 310: ...a paint roller Too much sealer may hold the gasket away from the head or block CAUTION Use no sealer on engines using a composition STEEL ASBESTOS gasket Place the gasket in position over the dowel pi...

Page 311: ...l as a unit Install with the lip facing toward the front of the engine Fig 7V Removing O il Seal Lower Half 1 With the oil pan and oil pump removed remove the rear main bearing cap 2 Remove oil seal f...

Page 312: ...on pro cedures with proper tool must be followed or movement of the inertia weight section on the hub will destroy the tuning of the torsional Fig 9V Removing Torsional Damper Fig 10V Installing Torsi...

Page 313: ...oil pan as outlined 366 cu in Engines 1 Make certain that cover mounting face and cylinder block front end face are clean and flat 2 Coat the oil seal with engine oil and install Aligning Tool J 22102...

Page 314: ...nment fig 17V 3 Remove camshaft sprocket to camshaft bolts 4 Remove camshaft sprocket and timing chain together Sprocket is a light press fit on camshaft If sprocket does not come off easily a light b...

Page 315: ...proper valve opera tion is indicated measure the lift of each push rod in consecutive order and record the readings 1 Remove the valve mechanism as outlined 2 Position indicator with ball socket adapt...

Page 316: ...rust plate screws through holes in the camshaft gear fig 23V Remove camshaft and gear assembly Installation NOTE Whenever a new camshaft is installed coat camshaft lobes with Molykote or its equivalen...

Page 317: ...ousing and clutch removed from engine remove the flywheel Installation 1 Clean the mating surfaces of flywheel and crankshaft to make certain there are no burrs 2 Install flywheel on crankshaft and po...

Page 318: ...k tabs to bolt head GE 10 20 Series The two piece rear support in transmission case ex tension may be removed without removing the transmis sion from the vehicle Replace both halves as a unit 1 Positi...

Page 319: ...ENGINE 6 39 CYLINDER HEAD TORQUE SEQUENCE L6 L4 V8 283 327 350 V8 396 427 INTAKE MANIFOLD TORQUE SEQUENCE FRONT V8 283 327 FRONT V8 396 427 Fig IT Torque Sequence...

Page 320: ...aring Tool J 8032 4 24 J 0971 Camshaft G ear Support J 22249 3 15 16 25 J 6987 Torsional Damper Puller J 22147 4 3 32 26 J 22197 Torsional Damper Installer J 22250 4 1 4 27 J 21058 Torsional Damper an...

Page 321: ...when the cooling level is too high All passenger car cooling systems are pressurized with a pressure cap which permits safe engine operation at cooling temperatures of up to 247 F When the radiator c...

Page 322: ...te to the normal flow This action causes the water to get behind the corrosion deposits and force them out Radiator 1 Remove the upper and lower radiator hoses and re place the radiator cap 2 Attach a...

Page 323: ...fan belt then remove fan bolts fan and pulley 4 Remove pump to cylinder block bolts and remove pump from engine NOTE On in line engines pull the pump straight out of the block first to avoid damage t...

Page 324: ...I I...

Page 325: ...are not al ways interchangeable Refer to carburetor part number and or specifications Carburetors for engines with the Air Injection Reactor System are designed particularly for these engines therefo...

Page 326: ...ll point is a 20 to 30 rpm drop in en gine speed obtained by leaning the idle mixture 6 Repeat Steps 4 and 5 as needed for final adjustment NOTE If necessary final adjustment of the carburetor may be...

Page 327: ...ility 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...

Page 328: ...l Description 6M 4 Maintenance and Adjustments 6M 5 Adjustments 6M 5 Vacuum Spinner Type 2G C arbu retors 6M 5 Page General D escription 6M 5 Major Service O perations 6M 6 Control V a lv e 6M 6 Gover...

Page 329: ...to the left 1 4 turn at a time until desired regulation is obtained 2 When adjustment is completed tap lightly on end of hollow wrench so that nut A will seat properly 2G ENGINE GOVERNOR VACUUM SPINN...

Page 330: ...aching screws and then th diaphragm cover Hold the throttle lever to avoid damage to the throttle valves and loosen the nut attaching the governor lever and pin assembly to the throttle shaft Remove t...

Page 331: ...haft for free rotation in the seal then tighten the housing screws The throttle valves must be held in a closed position while tightening the screws Recheck for free rotation and repeat as sembly proc...

Page 332: ...M 8 Maintenance P ro c e d u re s 6M 9 Element Replacem ent 6M 9 Testing Paper E le m e n t 6M 9 Page Tool J 7825 6M 10 Cleaning Polyurethane B a n d 6M 10 Cleaning Oil Bath C le a n e r 6M 11 GENERAL...

Page 333: ...leaner element condition NOTE Before testing inspect for holes or breaks in the element as these defects require immediate replacement If no holes or breaks exist proceed as follows 1 Remove all hoses...

Page 334: ...es fig 6 A Refill whenever the level falls below the lower FILL line Storing Tool When the tool is not in use fully depress the inner tube This seals off the oil reservoir from the vent hole to preven...

Page 335: ...ment The air valve thermostatic element may be easily checked for proper operation whenever the cover is re moved for regularly scheduled element cleaning At this time immerse the cover far enough to...

Page 336: ...ENGINE FUEL 6M 12 CHEVROLET TRUCK SERVICE MANUAL...

Page 337: ...pump actuates the rocker arm INLET OUTLET Fig 2P Step Van Fuel and Vacuum Pump Fig IP Fuel Pump Non Serviceable 1 Outlet Valve 10 Pulsator Diaphragm 2 Fuel Cover 11 Fuel Inlet V alve Assembly 3 Fuel D...

Page 338: ...at vacuum pump and join them with a piece of tubing Slowly operate engine from idle to about 1 0 0 0 rpm the wiper should run at full speed operat ing on engine vacuum only If it does not it can be as...

Page 339: ...pump should be replaced 3 Inspect rocker arm for wear or scoring at camshaft pad at point of contact with links and at pivot hole0 Inspect bushing for wear Assembly 1 Install seals by placing seal and...

Page 340: ...position to engage with pull rod 18 Position diaphragm in palm of hand so that flat of pull rod is parallel with fuel link fig 7P Push pull rod through oil seal against spring tension Turn diaphragm 9...

Page 341: ...ch piece of metal between rocker arm stop and body This tool can be made from a piece of steel 3 16 x 3 32 x 6 Bend one end to form a right angle 3 8 from bend to end 26 Place spring retainer on rivet...

Page 342: ......

Page 343: ...onnect the various components Carburetors and distributors for engines with the A I R System are designed particularly for these en gines therefore they should not be interchanged with or replaced by...

Page 344: ...hten adjustment bracket bolt and mounting bolt CAUTION Do not pry on the pump housing Distortion of the housing will result in extensive damage to the Air Injection Pump Replacement Loosen pump mounti...

Page 345: ...valve from air manifold being careful not to bend or twist air manifold Mixture Control Valve Inspection Check condition and routing of all lines especially the signal line A defective signal or outl...

Page 346: ...o deter mine if excessive noise is the fault of the Air Injection Reactor System operate the engine with the pump drive belt removed If excessive Fig 6 Removing Pressure Relief Valve Fig 7 Installing...

Page 347: ...face of relief valve with a small screw driver To install the pressure setting plug carefully push into relief valve until legs lock If a pressure setting plug is to be reused be sure leg angles are s...

Page 348: ......

Page 349: ...n the top of each element connect all the positive plates and all the negative plates into groups The elements are con nected in series electrically by connectors that pass directly through the case p...

Page 350: ...ushing the Delco Eye down into each vent well The seals drop into the cells and can remain there since they are not chemically active and will cause ho harm The Delco Eye is a special type of vent plu...

Page 351: ...discharged condition 2 Slow speed driving of short duration to cause an undercharged condition 3 A vehicle electrical load exceeding the generator capacity 4 Defect in the charging system such as hig...

Page 352: ...and free from corrosion before installing the Battery The carrier should be in a sound mechanical condition so that it will support the Battery securely and keep it level To prevent the Battery from...

Page 353: ...have approved testing equipment available These testers have a programmed test proce dure consisting of a series of timed discharge and charge events requiring approximately 2 to 3 minutes that will d...

Page 354: ...ry 10 above 80 F add four specific gravity points 004 to the hydrometer reading Example A hydrometer reading of 1 260 at 110 F would be 1 272 corrected to 80 F indicating a fully charged Battery For e...

Page 355: ...ents The Delcotron is offered as standard equipment although there are various capacities available on all models The Delcotron continuous output A C generator figs lc and 14c consists of two major pa...

Page 356: ...regulator when used with the special 63 amp air conditioning model generator 4 ohm field coil uses a field discharge diode internally in the field circuit fig 2c The added diode adapts the regulator t...

Page 357: ...tion block On tilt cab models TE 40 50 60 TT 40 TD TG 50 60 this link is a 14 gauge red wire School bus models have an additional link 16 gauge red wire located in the battery feed circuitry between t...

Page 358: ...rpm or above Check indicator lamp If lamp fails to go out perform appropriate test and corrections see Indicator Lamp Circuit tests before continuing test NOTE At this point a field circuit has been e...

Page 359: ...RON OUTPUT TEST Ammeter Method 1 Disconnect the battery ground cable at the battery 2 Disconnect the red wire at Delcotron battery terminal and connect an ammeter in series between the wire and termin...

Page 360: ...should read 7 to 20 ohms b If meter reads zero or excessively high resis tance the Delcotron is faulty 5 If above tests indicate a defective Delcotron remove and completely check Delcotron as outlined...

Page 361: ...st NOTE This test lamp procedure may be used on lamp type circuits and on ammeter circuits If Lamp Fails to Go Out or if Ammeter Shows Dis charge the Possible Causes are 1 Loose drive belt adjust as n...

Page 362: ...oil 2 Turn resistor to open position 3 Turn ignition switch off 4 Slowly decrease resistance and note closing voltage of the relay Adjust by bending heel iron in the manner illustrated in Figure 13c O...

Page 363: ...defective generator field Check the field as follows before installing the new regulator 1 Turn the switch off and disconnect the battery ground strap 2 Disconnect the adapter from the regulator 3 Co...

Page 364: ...the regulator SERVICE OPERATIONS Service Operations described in the following section are for the 5 5 Series ID aluminum Delcotron 6 2 Series 2D Type 100 Delcotron and the 6 6 Series 4D Type 150 Del...

Page 365: ...move two screws retaining the capacitor and brush holder to rear end frame Remove brush holder NOTE Capacitor lead is connected inside the generator Allow capacitor to remain with the generator to avo...

Page 366: ...ition systems available on 1967 vehicles The breaker point type which is continued as the regular production system and the optional transis tor controlled breakless ignition system magnetic pulse typ...

Page 367: ...hing contains a supply of lubricant which will last between overhaul periods At time of overhaul the upper bushing may be lubricated by removing the plastic seal and then adding SAE 20 oil to the pack...

Page 368: ...come greasy or dirty Never use emery cloth to clean contact points Contact surfaces after considerable use may not appear bright and smooth but this is not neces Fig 4 i Breaker Plate and Attaching Pa...

Page 369: ...d point alignment are factory set 2 Remove the distributor cap by placing a screw driver in the slot head of the latch press down and turn 1 4 turn in either direction 3 Remove the two attaching screw...

Page 370: ...mpt to align used points replace them where serious misalignment is observed Use an aligning tool if available 2 Turn or crank the distributor shaft until the breaker arm rubbing block is on the high...

Page 371: ...connection This will cause burned points and ignition failure upon initial starts and at high speeds 4 Capacity Capacity is determined by the area of the metallic elements and the insulating and impr...

Page 372: ...i 1 Remove the rotor 2 Remove the vacuum control assembly retaining screws detach the unit from the distributor housing 3 Disconnect the primary and condenser leads from the contact point quick discon...

Page 373: ...the special punch shown in Figure 17i to push out seal 8 Shim Washer 9 Drive G ear Pin 10 Drive G ear 11 Cap 12 Rotor CLEANING AND INSPECTION 13 Weight Springs 14 Mainshaft 15 Advance Weights 16 Cam...

Page 374: ...e in breaker plate Connect primary and condenser leads to contact set quick disconnect terminal Attach vacuum control assembly to distributor housing Check and adjust contact point opening and alignme...

Page 375: ...move shims as necessary 6 Install contact point set and condenser to breaker plate Connect leads as shown in Figure 4i NOTE Contact point spring tension is factory set above specifications to assure e...

Page 376: ...probably be above 3 8 hg 5 After this maximum reading has been reached slowly decrease the distributor speed until the vac uum gauge hand falls back 1 hg The speed at which this 1 hg drop occurs will...

Page 377: ...e supports NOTE The brackets are numbered to show the correct installation Wires must be installed as indicated to prevent cross firing 8 Connect vacuum line to distributor and distributor primary wir...

Page 378: ...ing position for No 1 cylinder timing mark on harmonic balancer indexed with pointer 2 Position a new distributor to block gasket on the block 3 Before installing distributor index rotor with hous ing...

Page 379: ...new epoxy which is commercially available Fig 26i Pulse Am plifier Internal Circuitry In order to check the panel board assembly it is nec essary to unsolder at the locations indicated in Figure 5i th...

Page 380: ...ce Push in on wire to depress plunger and continue Fig 28i Setting Spark Plug Gap to turn key counter clockwise until lock cylinder can be removed 3 Remove the metal ignition switch nut using tool J 7...

Page 381: ...cuum Spinner Type described in Section 6 M of this Shop Manual In operation when the engine reaches its governed speed 4000 rpm with standard transmission or with Powermatic transmissions maximum unde...

Page 382: ...starting system composed of the starting motor solenoid and battery is to crank the engine The battery supplies the electrical energy the solenoid completes the circuit to the starting motor and the m...

Page 383: ...having four pole shoes and four fields con nected with the armature The aluminum drive end housing is extended to enclose the entire shift lever and plunger mechanism protecting them from dirt splash...

Page 384: ...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...

Page 385: ...OOLS J 9717 2 SUPPORT TOOL J 5184 CHECKING SCALE J 9600 2 SHOULDERED INSTALLER J 21501 PULLY ADAPTER J 21 600 HARNESS ADAPTER J 7607 IGNITION SWITCH NUT REMOVER J 9717 1 PRESS TOOL Fig 5s Special Tool...

Page 386: ......

Page 387: ...n to the cross shaft lever When the clutch pedal is depressed the pedal pull or push rod moves upward rotating the cross shaft pushing the fork push rod rearward and pivoting the clutch fork to move t...

Page 388: ...ill slide through swivel at cross shaft 4 Adjust nut B to obtain approximately 3 16 to 1 4 clearance between nut B and swivel 5 Release push rod connect return spring and tighten nut A to lock swivel...

Page 389: ...32 E U 80 only 3 16 All Hydraulic except above NOTE This clearance can be checked with the shank of appropriate diameter drill Clutch Pedal Free Travel Adjustment Adjust clutch master cylinder adjust...

Page 390: ...EDAL Refer to Figure 9 Removal 1 Remove upper to lower clutch pedal arm nut and remove upper arm from lower arm 2 Disconnect clutch return spring and pedal to cross shaft pull rod 3 Remove snap ring r...

Page 391: ...ylinder bore 4 Wash all parts in clean alcohol NOTE Since the clutch hydraulic system on vehicles equipped with a dual master cylinder use the same hydraulic fluid and reservoir as the brake system it...

Page 392: ...is section under Clutch Pedal Total Travel 3 Attach hydraulic line to slave cylinder and bleed air from system at slave cylinder bleed fitting CLUTCH CROSS SHAFT Fig 15 Removal 1 Disconnect clutch for...

Page 393: ...CHEVROLET TRUCK SERVICE MANUAL CLUTCHES AND TRANSMISSIONS 7 7...

Page 394: ...ace 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 tent...

Page 395: ...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 CAUTION bricant Be careful not to use to...

Page 396: ...to correctly position the levers Fig 19 Release Lever 1 Release Lever 2 Eyebolt 3 Strut 4 Cover 5 Adjusting Nut SERVICE OPERATIONS CLUTCH ASSEMBLY Removal From Vehicle Before removing clutch from flyw...

Page 397: ...work clutch discs as needed to slide arbor pilot into pilot bearing 4 Install three bolts loosely then remove alignment stud and install last bolt loosely 5 Thread alignment stud in arbor to act as a...

Page 398: ...cation during the life of the bearing The pilot bearing pressed into engine flywheel carries the forward end of the transmission main drive gear This bearing requires lubrication only at time of clutc...

Page 399: ...g Column Gearshift tion The shifter gate for selection between first and reverse and second and high is contained in the shifter housing mounted on the lower portion of the steering col umn mast jacke...

Page 400: ...pull levers from shafts 4 Remove nuts and locks and remove shifter interlock retainer This will allow removal of shifter shaft and fork assembly poppets and springs or interlock from cover 5 Replace...

Page 401: ...Sun Gear Solenoid Oil Seal Control Cable Bracket 7 16 Case Rear Oil S eal 7 16 Control Shaft Lever and or O Ring Oil Seals 7 16 Speedometer Driven G e a r 7 16 Electrical Unit Checks 7 16 Overdrive R...

Page 402: ...slot in fitting and pry fit ting gear and shaft from housing Pry O ring from groove in guide Install new 0 ring in groove in fitting and insert shaft Hold the assembly so slot in fitting is toward lo...

Page 403: ...verdrive wire at governor and connect test lamp between governor overdrive terminal and positive terminal of battery Drive car on road or raise on jacks The lamp should light at a car speed of between...

Page 404: ...d more than 1 4 it indicates that misalignment probably exists To correct this loosen the capscrews between the overdrive hous ing and transmission case and tap the adapter plate and overdrive housing...

Page 405: ...If the solenoid clicks when one terminal is grounded but not the other replace the switch If the solenoid does not click when either of the terminals is grounded check the wiring between the relay an...

Page 406: ...t service in every type of truck operation The transmission incorporates synchromesh action in second third and fourth gears All gears are helical except first and reverse The clutch gear is supported...

Page 407: ...ter shafts one half turn to raise yoke detent balls out of the notches in the shifter shafts and drive shafts out of cover and shifter yokes Shifter shafts will push expansion plugs out ahead of them...

Page 408: ...in retainer fig 5J until seal is flush with outside of retainer 5 To replace speedometer gear press speedometer drive gear off hub of universal joint flange and press new gear into position using Too...

Page 409: ...take off opening 4 Shift the transmission into reverse and check for clearance between reverse idler gear and transmis sion case at the rear If necessary rotate the ec centric an additional amount in...

Page 410: ...escribed in PROPELLER SHAFT SEC 4 3 Remove propeller shaft brake parts if used from transmission as described in HAND BRAKE SEC 5 4 Remove speedometer driven gear from rear bearing retainer 5 Remove o...

Page 411: ...ransmission straight away from the clutch housing until main drive gear shaft clears clutch disc splines 8 Lower transmission and remove it from the vehicle Installation NOTE Before installing transmi...

Page 412: ...r 11 Retaining Ring 17 3rd and 4th Shift Rail 24 Lock Pin 4 Cap Screw 12 Reverse Shift Lug 18 Shift Rail Interlock 25 Lock Pin 5 Lock Pin 13 Detent Ball Plunger 26 1st and 2nd Shift Lug 6 1st and 2nd...

Page 413: ...With 2 easy out fig 3K remove roll pin 5 from 1 st and 2 nd shift fork 6 6 Using hammer and drift drive 1st and 2nd shift rail 27 out of cover 2 forcing out welch plug Remove shift rail 27 1st and 2n...

Page 414: ...m remote control shift rail 2 Remove shift yoke 9 and selector 12 from shift rail 2 2 Remove rubber shift rail boot 8 and O ring boot retainer 21 Discard boot and retainer 3 Remove O ring seal 20 from...

Page 415: ...ng seal 2 0 on shift rail against the snap ring 6 Install new shift rail boot 8 with new retaining ring 2 1 on shift rail 2 7 Position shift rail yoke 9 and rail selector 12 with offset toward front o...

Page 416: ...e syn chronizer assembly used for 2nd and 3rd speeds consists of two inner synchronizer rings or cones and one outer synchronizing ring or plate The synchronizer for 4th and 5th speeds consists of two...

Page 417: ...te mainshaft by turning clutch gear until the teeth on the 1 st speed sliding gear will butt against the low speed teeth on the countershaft as the sliding gear is pushed rearward This will prevent th...

Page 418: ...ake 7 If not installed with cover assembly install trans mission gearshift lever as outlined under Mainte nance and Adjustments 8 Connect speedometer cable to the driven gear fitting in the transmissi...

Page 419: ...ove lock wire from set screws in shifter forks fig 5S 6 Remove set screws from fourth and fifth speed shifter fork and tap shaft out through hole in front of cover Remove fork Remove interlock poppet...

Page 420: ...shown in Figure 9S Install set screw and lock with wire 9 Install plugs in front of cover fig 5S using a small amount of Permatex or equivalent around plugs to seal 10 Place cover right side up on ben...

Page 421: ...mission and remove mounting bolts Move transmission to rear until the clutch gear is free of the splines in the clutch disc and lower the transmission away from vehicle Installation in Vehicle 1 Slide...

Page 422: ...e two transmission shift rods in the neutral center detent position Adjust the length of the shift control rods by loosening the jam nuts then turning the clevises to lengthen or shorten the rods as r...

Page 423: ...ift Rod 3 Lock W ire 7 Direct and Overdrive 4 Shift Fork Screw Shift Fork 3 Remove shift rods 1 and 6 from cover stripping off forks 5 and 7 as shift rods are removed Tip cover on one side and jar int...

Page 424: ...nd is ac 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 lef...

Page 425: ...ustment 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 refe...

Page 426: ...removal while the transmission rear end is being lowered 10 Remove remainder of transmission housing to en gine attaching bolts 11 Remove the transmission by moving it slightly to the rear and downwar...

Page 427: ...wing the recommended procedure provided earlier in this section 13 Check transmission for proper operation and for leakage Check and if necessary adjust linkage OPERATIONS vehicle without removing the...

Page 428: ...transmission case and transmission case eJrtension should be carefully examined for signs of leakage The vacuum modulator must also be checked to insure that the diaphragm has not ruptured as this wo...

Page 429: ...tion screen 2 Broken or damaged ring low servo 3 Pressure regulator valve stuck 4 Leak at valve body to case gasket 5 Leak between valve body gaskets 6 Leak at servo center 7 Front pump clearances Dri...

Page 430: ...Tire L250 L22 4 11 Axle 8 15 15 Tier L250 Base 4 57 Axle 7 17 5 Tire L292 L25 4 57 Axle 7 17 5 Tire L230 Base 3 36 Axle 6 95 14 Tire L250 L22 3 36 Axle 6 95 14 Tire Throttle Position Up Down Up Down...

Page 431: ...against the rear side of the stator vanes in a clockwise direction Since the stator is now impeding the smooth flow of oil its rol ler clutch releases and it revolves freely on its shaft Once the sta...

Page 432: ...smis sion at normal operating temperature With cold fluid the level should be at the add mark or slightly below SHIFT CONTROL LINKAGE ADJUSTMENT Adjust linkage as described below COLUMN SHIFT 1 The sh...

Page 433: ...if necessary to pro vide the correct relationship to the transmission detent positions See Section 12 12 When properly adjusted the following conditions must be met by manual operation of the steerin...

Page 434: ...inal 3 Remove control valve body attaching screws and de tent roller spring assembly NOTE Do not remove solenoid attaching screws 4 Remove control valve body assembly and governor pipes If care is tak...

Page 435: ...m can be isolated and investigated further Analytical diagnosis will pro tect the technician from come backs and certainly will improve owner satisfaction An important and often overlooked aspect of d...

Page 436: ...k 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 Pump to case gasket mispos...

Page 437: ...PECIAL TOOLS Fig 1ST Clutch Special Tools 1 J 6456 Height Gauge 2 J 1048 Gauge Plate 3 J 1522 Pilot Bearing Driver 4 J 5824 Clutch Pilot Tool 5 J 1448 Pilot Bearing Puller 6 J 5822 Ball Type Pilot Bea...

Page 438: ...utch G ear Bearing Retainer Wrench 3 J 0937 J 937 Clutch G ear and Bearing Puller 4 J 5750 Transmission Holding Fixture 5 J 5778 Extension Housing Bushing Remover and Installer 6 J 5154A J 5154 Rear B...

Page 439: ...eedometer G ear Remover and Replacer Set 5 J 5589 Countershaft Assembly Tool 2 J 1126 Transmission G uide Pins 6 J 8039 K M O 410 Snap Ring Pliers 3 J 5590 Transmission Front Bearing Installer 7 J 575...

Page 440: ...et 2 6 J 2671 Third Speed G ear Bushing Installer 7 J 7785 O il Seal Installer 8 J 2667 Mainshaft and Bearing Assembly Remover and Replacer 10 30 Models 9 J 1453 Clutch G ear Bearing Replacer 10 J 222...

Page 441: ...ver and Replacer 2 J 2228 Clutch G ear Bearing Remover Plate 3 J 8108 K 342 Clutch G ear Bearing Replacer 4 J 0358 Press Plate Holder 5 J 6382 Reverse Idler Shaft Remover 6 J 6416 Rear Bearing Retaine...

Page 442: ...l Tools 1 J 1619 Mainshaft Bearing Remover 2 J 4761 Reverse Idler Shaft Remover 3 J 8107 TR 278 R Differential Side Bearing Remover 4 J 6418 Synchronizer Hub Remover 5 J 6419 Bearing Installer 6 J 099...

Page 443: ...TRANSMISSIONS 7 57 Fig 7ST Five Speed Clark Transmission Special Tools 1 J 1619 Mainshaft Bearing Remover 2 J 6382 Reverse Idler G ear Shaft Remover 3 J 6419 Bearing Installer Set CHEVROLET TRUCK SER...

Page 444: ...ts 21 J 5814 Speedometer Drive G ear Remover and Installer from Slide Hammers J 6585 22 J 5853 Torque Wrench 8 J 6839 Front Pump Seal Driver 23 J 8039 Snap Ring Pliers 9 J 9546 Clutch Drum Bushing Rem...

Page 445: ...465 17 Part of Bushing Too Set 6 J 5154 Extension O il Seal Installer 22 J 2 1465 8 Part of Bushing Too Set 7 J 6585 Slide Hammer Weights 23 J 21465 13 Part of Bushing Too Set 8 J 9539 Slide Hammer Bo...

Page 446: ...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 G ear Remover Puller 13 J 8059 Snap Ring Plier...

Page 447: ...SAE Standards for filler caps and related filler neck cams These units are not directly interchangeable with past models for service replacement Upper and lower filler necks vary as to size length and...

Page 448: ...uge unit mounting loca tion or if unit is inaccessible remove fuel tank 2 Disconnect fuel feed line and wiring from gauge unit 3 Unlock gauge cam ring using Tool J 8950 and remove gauge unit from tank...

Page 449: ...unit wiring can be removed 6 Remove fuel tank 7 Install in the reverse order being sure that the anti squeak material is replaced Removal and Installation P Models and 1 Ton Chassis Frame Mounted Tan...

Page 450: ...FILLER NECK ASSEMBLY CHEVY VAN Removal Fig 6 1 Remove screws securing upper filler neck flange to body panel 2 Raise and support vehicle 3 Loosen the screw clamps securing the filler neck and vent hos...

Page 451: ...letely drain gasoline from fuel tank and all fuel lines if vehicle is to be stored for any appreciable length of time This precaution will prevent gum formation and resultant improper engine performan...

Page 452: ...FUEL TANK AND EXHAUST SYSTEMS 8 6 Fig 7 Fuel Lines and Filter CD50 60 CHEVROLET TRUCK SERVICE MANUAL...

Page 453: ...rate special ma terials such as stainless steel and heavier gauge metals These materials are necessary because of the increased heat generated by the burning of the exhaust gases Always use the correc...

Page 454: ...FUEL TANK AND EXHAUST SYSTEMS 8 8 SPECIAL TOOLS I TAPER TO 1 2 Fig 10 Special Tools 1 J 8950 Fuel Tank Gauge Unit Spanner 2 J 7777 Fuel Line C lip Installer CHEVROLET TRUCK SERVICE MANUAL...

Page 455: ...30 series units have an adjustable tie rod connected to the steering arm at each wheel Steering effort is transmitted to the tie rods through a relay rod connected to the pitman arm on the left and a...

Page 456: ...d for replacement of damaged parts 6 After proper adjustment of worm is obtained and all mounting bolts securely tightened adjust lash ad Fig 2 Removing Pitman Arm Fig 3 Steering G ear Adjustment Poin...

Page 457: ...10 20 30 Lower Bearing Adjustment from center figs 4 5 remove steering wheel and reposition Mast Jacket Lower Bearing Adjustment 1 Loosen clamp on steering shaft 2 Adjust clamp to allow steering shaft...

Page 458: ...washer and nut 3 Install belleville spring receiving cup bushings and attaching screws 4 Install horn button 5 Connect directional signal switch wiring harness to chassis wiring harness Fig 8 Steering...

Page 459: ...the vehicle 6 Disassemble lower portion of coupling on bench by repeating Steps 3 and 4 Installation 1 Position center cross in lower yoke of coupling 2 Position bushing and new cork washer on center...

Page 460: ...floor pan 3 Remove floor pan from around mast jacket 4 Remove pitman arm from steering gear 5 Remove steering gear to frame mounting bolts 6 Remove mast jacket to dash panel support 7 Lift steering g...

Page 461: ...ch to lower brake pedal assembly Line up in dexing marks Torque to 40 ft lbs 6 Tighten support bracket bolts 7 Torque steering gear attaching nuts 8 Install pitman arm to sector shaft and tighten nut...

Page 462: ...tomatic transmission models con nect transmission shift linkage 5 On 10 20 and 30 series trucks install parking brake support and lever assembly and trim plate at dash panel Fig 16 Medium and Heavy Du...

Page 463: ...all bearing surfaces on shift tube 3 Place felt seal on shifter tube Push in place up to spring 4 Insert shifter tube into mast jacket 5 On 3 speed models Temporarily install spacer low and reverse sh...

Page 464: ...d 60 series Installation 1 With mast jacket completely assembled and inter mediate steering shaft yoke tube assembled to upper steering shaft place assembly in vehicle and assem ble intermediate shaft...

Page 465: ...od to idler arm making certain idler stud seal is in place then install and tighten nut to specifications Advance nut just enough to align castellation with cotter pin hole and install pin 2 Raise end...

Page 466: ...eering arm and pitman arm 3 Install ball stud nuts and torque to specifications Continue to tighten nuts enough to align castellations with holes in studs 4 Install cotter pins and lubricate STEERING...

Page 467: ...n the same manner as the manual steering gear 40 50 and 60 Series Fig 24 Sector lash adjustment is the only power steering gear adjustment that can be made on the vehicle However in order to make this...

Page 468: ...bolt and pump brace adjusting nut CAUTION Do not move pump by prying against reservoir or by pulling on filler neck 2 Move pump with belt in place until belt is tensioned to specifications as indicate...

Page 469: ...ape the ends of the hoses to prevent entrance of dirt 2 Install two caps at pump fittings to prevent drainage of oil from pump 3 Loosen bracket to pump mounting nuts 4 Remove pump belt 5 Remove bracke...

Page 470: ...d to the power cylinder and drain fluid into a container Do not reuse Fig 30 Side Mounted P S Cylinder C l0 2 0 3 0 S e r ie s a Remove cotter pin nut retainer and grommet from power cylinder rod atta...

Page 471: ...Install hoses with the wheels in the straight ahead position then turn the wheels to the right and left while observing movement of the hoses Note and correct any hose contact with other parts of the...

Page 472: ...STEERING 9 18 Fig 31 Typical Power Steering Hose Routing CHEVROLET TRUCK SERVICE MANUAL...

Page 473: ...7 V alve Connector Seat 26 J 5853 Inch Pound Torque Wrench 4 J 8523 1 Steering G ear and Idler Arm Instal ler 27 J 8359 Sector Bearing Remover Support Bushing Installer 13 J 7624 Spanner Wrench 28 J 5...

Page 474: ...w j...

Page 475: ...t as an air seal Puncture Inspection and Repair At each lubrication tires should be checked for for eign objects in the tread or breaks in the tread or side wall If tire is punctured or otherwise dama...

Page 476: ...owner on his driving habits is to inter change tires regularly Side Wear This may be caused by incorrect wheel camber underinflation high cambered roads or by taking corners at too high a rate of spee...

Page 477: ...anged at regular intervals FRONT WHEELS Wheel and Tire Balancing It is desirable from the standpoints of tire wear and vehicle handling ease to maintain proper balance of front wheel and tire assembli...

Page 478: ...n the front of the vehicle Its use on the rear should be governed by its general condition and whether the roundness defect seriously detracts from overall ride quality When balancing wheels and tires...

Page 479: ...rims are available as optional equipment Tires and tubes may be demounted and mounted as outlined in this section Mounting and Demounting T h r e eS e c t io n R im s D e m o u n t in g T ir e 1 Compl...

Page 480: ...de opposite the ring If no solid wall is avail able place tire and wheel on floor with clamp ring down and inflate from above 6 Inflate tire slowly with tires lightly inflated tap gently around ring w...

Page 481: ...round side ring prying ring from rim gutter until free 5 To free opposite tire bead from wheel rim turn tire over and repeat bead loosening operation fig 14 NOTE It is not necessary to remove side rin...

Page 482: ...g 17 Then pull in direction indicated 9 Retain pressure with tool and strike side ring down ward at a point between operating notch and cutaway section thereby engaging side ring over rim gutter at th...

Page 483: ...nts tires from adhering to the wheel Demounting and Mounting All tubeless tires used on Chevrolet trucks with the exception of the 7 75 15 and 6 50 16 sizes should be de mounted and mounted as describ...

Page 484: ...h Then place rim on floor with wide side down and lubricate first bead of tire and upper bead seat of rim fig 23 2 Push first bead into well of rim and onto rim as far as possible Using straight end o...

Page 485: ...g Second Bead Onto Rim 2 With tire beads still unseated rotate tire on wheel so that balance mark on tire lines up with the valve stem 3 Start tire beads into the rim bead seats as follows If a tire m...

Page 486: ......

Page 487: ...ns 11 3 Front Sheet Metal Assembly 1 1 4 Hood A s se m b ly 11 3 Flat Face Cowl M o d e ls 11 6 Hood Hinge Spring Replacement 11 3 Radiator Support 11 6 Hood H inge 11 3 Hood Lock Assembly 11 3 Adjust...

Page 488: ...piece fan shroud elimination of the radiator support on 40 thru 60 series trucks and other design improvements of individual assemblies The following pages contain servicing information for removal as...

Page 489: ...xtreme open position and place protective covering over the cowl and fenders 2 Scribe position of hinge attachment on hood rear reinforcement and remove two bolts 3 Remove hood hinge spring as explain...

Page 490: ...y below 2 Shift hood on hinges to location marks made before removal of hood then tighten attaching cap screws at hinges firmly Close hood and check fit If neces sary to align hood perform procedure a...

Page 491: ...fender skirt at steer ing column 5 Remove front bumper bolts and remove bumper 6 Remove wiper arm assemblies and cowl grille 7 Remove bolts attaching fender upper edge to plenum and hinge pillar 8 Rem...

Page 492: ...mbly in position NOTE Install all bolts loosely to facilitate alignment after complete installation 3 Install two bolts and shims required at each fender rear upper edge 4 Install combination bolt and...

Page 493: ...2 Connect center grille support to radiator support 13 Remove bolts securing hood catch assembly to radia 3 Connect hood latch plate tor support 4 Connect left radiator support gusset to left fender 1...

Page 494: ...wer limited access between radiator sup port outer face and grille inner face 11 Install radiator support to fender 12 Using drift line up right fender skirt rearmost bot tom screw with fender flange...

Page 495: ...fender 8 Remove four bolts attaching radiator grille to fender 9 Remove bolt and shim attaching to trailing edge of fender to hinge pillar Fig 13 Front Fender and Skirt Attachment 10 thru 30 Series 10...

Page 496: ...d skirt assembly 2 Install bolts loosely 3 Install shims and secure all parts in reverse order of removal 4 Tighten shimmed bolts FRONT FENDER SKIRT Replacement To replace the skirt alone remove requi...

Page 497: ...th external tooth washers bolts and nuts Tape is used before installation The surge tank access door is retained with screws and a stud as shown ENGINE SPLASH SHIELD Refer to Figure 18 Removal and Ins...

Page 498: ...plash shields and then removing the deflec tor attaching screw and plain washers Upon installation make certain that all screws are installed and torqued sufficiently to eliminate rattles or wind vibr...

Page 499: ...CHASSIS SHEET METAL 11 13 Fig 23 Engine Compartment Cover Assembly SPECIAL TOOLS Fig 24 J 5544 1 Hood Spring Remover CHEVROLET TRUCK SERVICE MANUAL...

Page 500: ...1...

Page 501: ...appropriate circuits The engine wiring harness and forward lamp harness connectors are bolted to the fuse panel All wiring systems incorporate a fusible link which provides increased overload protecti...

Page 502: ...l c t r iC al 12 2...

Page 503: ...or supports in this area will hinder proper aiming of headlamps When aiming headlamps vehicle should be filled to ca pacity with gas oil and water but no load Tires should be uniformly inflated to rec...

Page 504: ...To install Aimer press firmly on the knob extending out from the center of the Aimer base This forces the suction cup into place on the Sealed Beam unit 3 Loosen the slider knob beneath the aimer arm...

Page 505: ...aining ring spring and attach wiring har ness connector to unit then check operation of unit and install bezel PARKING LAMP HOUSING REPLACEMENT Fig 9 1 Remove retaining screws and lens from housing 2...

Page 506: ...ELECTRICAL BODY AND CHASSIS 12 6 VIEW C Fig 9 Front Lighting Assemblies CHEVROLET TRUCK SERVICE MANUAL...

Page 507: ...ELECTRICAL BODY AND CHASSIS 12 7 CA 31 04 CA 20 30 40 09 F F COWLS 34 CA 30 03 12 Fig 10 Rear Lighting Composite CHEVROLET TRUCK SERVICE MANUAL...

Page 508: ...h which is located under the toe pan adjacent to the brake lever arm 4 Remove two screws attaching the switch to the underside of the toe pan and remove switch 5 Install new switch with the switch lev...

Page 509: ...drive tang and tighten screws Remove clamp and pin 6 Connect wiring harness to terminals and check op eration of switch Column Shift Switch Located on Transmission Fig 15 1 Raise and support vehicle...

Page 510: ...tch attaching screws and switch from mast jacket 3 Position replacement switch to mast jacket install retaining screws and connect wiring to switch terminals NOTE Position gear shift in neutral before...

Page 511: ...All instruments and gauges of the 1967 Trucks are in stalled in the instrument cluster The entire cluster may be removed from the vehicle for servicing of the instruments and gauges Illuminating and i...

Page 512: ...ng their location for proper rein stallation Remove cluster 5 To install reverse removal procedure Tilt Cab Models Fig 19 1 Disconnect battery ground cable 2 From under dash disconnect speedometer cab...

Page 513: ...cluster lamp assemblies 3 Remove laminated circuit retaining screws NOTE These screws serve as a ground for the circuit and must be reinstalled to provide the proper ground connections for the laminat...

Page 514: ...head remove old cable by pulling it out from speed ometer end of conduit NOTE If old cable is broken it will be neces sary to remove lower piece from transmission end of conduit 2 Lubricate the lower...

Page 515: ...use Panel 8 Bulkhead Conn 2 Horn Relay 9 To Backing Lamp Switch 3 To Light Switch 10 To Stop Lamp Switch 4 To W iper Switch 11 To Dome Lamp Conn 5 To Directional Switch 12 Dimmer Switch 6 To W iper Mo...

Page 516: ...Fuse Panel 8 To Ignition Switch 2 Horn Relay 9 Bulkhead Connector 3 To Light Switch 10 To Stop Lamp Switch 4 To W iper Switch 11 A ir Brake Buzzer 5 To Directional Switch 12 Dome Lamp Conn 6 Instr Cl...

Page 517: ...Lamp Switch 10 To Temp Gauge 3 Hi Beam Lamp 11 R H Turn Ind 4 Cluster Lamp 12 To Ammeter 5 Brake Warning Lamp 13 L H Turn Ind 6 Bulkhead Conn 14 Light Switch Conn 7 Directional Signal Conn 15 A ir Bra...

Page 518: ...Chevy Van 1 O il Pressure Ind 8 2 Temperature Ind 9 3 Cluster Lamp 10 4 W iper Switch 11 5 Light Switch Conn 12 6 To Heater Switch 13 7 Hi Beam Ind 14 L H Turn Ind R H Turn Ind Generator lnd Ignition...

Page 519: ...aminated Circuit 3 Instr Cluster Lamp 4 Temperature Ind Brake Warning Ind Generator Ind R H Directional L H Directional 9 O il Pressure Ind 10 H igh Beam Ind 11 Overspeed Warning Low Vacuum 12 Generat...

Page 520: ...nventional Cab Models Chevy Van Tilt Cab Models If the light does not come on when the ignition switch is turned on or if the light comes on and remains on after the engine is started one or more of t...

Page 521: ...the directional signal switch but there is a separate hazard warning switch on the instru ment panel DIRECTIONAL SIGNAL SWITCH REPLACEMENT 10 60 Conventional Cab Chevy Van and P 10 Fig 25 1 Disconnect...

Page 522: ...Assembly Conventional Cab and P10 Series 1 Cancel ling Cam 5 Upper Bearing 9 W iring Connector 2 Directional Lever Retaining Screw 6 Bearing Housing 10 Wiring Cover 3 Switch Mounting Screw 7 Switch Co...

Page 523: ...SSIS 12 23 Fig 26 Directional Signal Assembly Chevy Van 1 Cancel ling Cam 3 Switch Mounting Screw 6 Switch Cover 2 Lever Screw 4 Directional Switch 7 Directional Lever 5 Upper Bearing Assembly CHEVROL...

Page 524: ...P20 30 Series WINDSHIELD WIPER AND WASHER INDEX Page Page General Description 12 28 Service Operations Windshield Washer Pump 12 28 Wiper Motor R em oval 12 28 Removal Installation 12 28 Installation...

Page 525: ...the wiper motor fig 37 Thus when the wiper is operated this rotor is always turning with the gear Programming is accomplished electrically and mechanically by a relay assembly and ratchet wheel arrang...

Page 526: ...e 32 1 Remove the two washer pump mounting screws fig 36 and lift pump off washer 2 Remove washer pump drive cam as required fig 37 The cam is pressed on the shaft but can be wedged off by using two s...

Page 527: ...assembly then slide intermediate gear and pinion assembly off shaft 7 If necessary remove terminal board and park switch assembly as follows a Unsolder motor leads from terminals Coding of motor leads...

Page 528: ...rs See Figure 34 for proper assem bly of end play washers Lubricate armature shaft bushings with light machine oil Gear Box 1 Assemble gear box using reverse of disassembly procedure NOTE Lubricate ge...

Page 529: ...embly a To remove valve assembly remove screws that secure valve assembly to bellows housing CAUTION It may be necessary to carefully pry bellows lip out of the valve body groove 7 Bellows a To remove...

Page 530: ...ELECTRICAL BODY AND CHASSIS 12 30 IGNITION SW 12R SHUNT 18b AMMETER RESISTOR V V TO CLUTCH HOUSING AMMETER GAGE Fig 40 Engine Compartment PA10 CHEVROLET TRUCK SERVICE MANUAL...

Page 531: ...1 I i 111 mmm TEMP SW 18D G EXCEPT RPO M35 M49 12PPL 12PPL NEU SFT SW 12P 12PPL 12P 12R 18D G TEMP GAGE D 16B 16B W BAT _ f f 4B 4B PS 20 30 6B PS 40 1 TOTRANS WITH RPO M35 OR M49 EXCEPT PS 40 WITH R...

Page 532: ...ELECTRICAL BODY AND CHASSIS 12 32 Fig 42 Engine Compartment PT 20 30 CHEVROLET TRUCK SERVICE MANUAL...

Page 533: ...SIBLE LIN K DASH PAN EL T A IL STOP L P HARN CONN 20T FOR WIRE GAGE SEE CHASSIS T A IL LA M P WIRING SHEET BRN Y DG 18LG 20T OUTSIDE FUEL I TAN K _ _ 2 0 T o c j BRAKE WARNING SW Fig 43 Engine Compart...

Page 534: ...E 20 30 W RPO E57 12PPL s 20DBL GEN FWD L P 20DS HARN CONN 16LG s 20DG TEM P sw m 3 A C U h GEN 20PPL 20PPL 16BRN 12R 16W 16DBL 16BRN 20LBL 20LBL ENG HARN CONN 20PPL L H PARKING DIR SIGNAL L P BRN Y D...

Page 535: ...ELECTRICAL BODY AND CHASSIS 12 35 Fig 45 Engine Compartment CS40 50 60 MS60 CHEVROLET TRUCK SERVICE MANUAL...

Page 536: ...ELECTRICAL BODY AND CHASSIS 12 36 JUNCTION BLOCK 12R C fl l t s W i TA IL STOP L P HARN CONN V BRW Y DG 18LG Fig 46 Engine Compartment CE40 50 60 ME50 60 CHEVROLET TRUCK SERVICE MANUAL...

Page 537: ...R N C O N N JO f PL R H PA RK IN Gfc DIR SIG N A LLP L H PA RK IN G D IR SIG N A L LP TEMP SENDER PPG FUSE A C Q ENJ B i 12R G EN FW DLP H A R NC O N N 14LG JOPPI 16BRN 20LBL 20DBL 12R V 18B W 18B 1ST...

Page 538: ...ELECTRICAL BODY AND CHASSIS 12 38 FUEL G A G E C O N K TAIL STO P D IRECTIO N LP C O N N 20D G Fig 48 Chassis Wiring Harness and Engine Wiring Harness TS 40 50 60 CHEVROLET TRUCK SERVICE MANUAL...

Page 539: ...20W OK 4 283 ENG 327 366 ENG 20Y k r 0 s sw 327 366 ENG O N LY 2 4 9 9 6 8 g V 8EH Sr Do l y 6 1 3 5 7 OIL PRESS SW TA IL STOP DIRECTION LP CONN 20DG Fig 49 Chassis Wiring Harness and Engine Wiring H...

Page 540: ...ELECTRICAL BODY AND CHASSIS 12 40 TAIL STO P D IRECTIO N LP C O N N Fig 50 Chassis Wiring Harness and Engine Wiring Harness TT40 TD TG 50 60 CHEVROLET TRUCK SERVICE MANUAL...

Page 541: ...ELECTRICAL BODY AND CHASSIS 12 41 FOR WIRE GAGE SEE CHASSIS T A IL LA M P WIRING SHEET V 14LBL 16LG Fig 51 Instrument Panel C A K A 10 20 CA30 Exc 02 CHEVROLET TRUCK SERVICE MANUAL...

Page 542: ...L OUTSIDE FUEL T A N K n 2 0 P 20BRN I39 2 0 L G EH 12 20LBL N 2 0 T G p 20DBL 120GY CLUSTER LA M P TEM P GAGE LA M P BRAKE WARNING LA M P 20DBL CLUSTER CONN 18LBL 18DBL 18B V IS J w s WASHER W IPER S...

Page 543: ...ELECTRICAL BODY AND CHASSIS 12 43 FOR WIRE GAGE SEE CHASSIS T A IL LA M P WIRING v SHEET Fig 53 Instrument Panel CE C S40 CE CS M S50 CE ME60 Exc 02 13 CHEVROLET TRUCK SERVICE MANUAL...

Page 544: ...ELECTRICAL BODY AND CHASSIS 12 44 180R Fig 54 Instrument Panel CE CS40 CE CS M S M E50 CE CS M E60 Exc 02 13 62 CHEVROLET TRUCK SERVICE MANUAL...

Page 545: ...ELECTRICAL BODY AND CHASSIS 12 45 FOR WIRE GAGE SEE CHASSIS T A IL LA M P WIRING SHEET DIMMER SW Fig 55 Instrument Panel CD CG50 CD CG M G 60 CHEVROLET TRUCK SERVICE MANUAL...

Page 546: ...ELECTRICAL BODY AND CHASSIS 12 46 BRN Y D G 20T BRN Y DG 200R 18W 200R 18W Fig 56 Instrument Panel CD CG50 C D CG M G 60 CHEVROLET TRUCK SERVICE MANUAL...

Page 547: ...ELECTRICAL BODY AND CHASSIS 12 47 FOR WIRE GAGE SEE CHASSIS T A IL LA M P WIRING SHEET Fig 57 Instrument Panel CA SA 000 02 12 CHEVROLET TRUCK SERVICE MANUAL...

Page 548: ...PNL 16D G 160R 10P 18P TEMP G A CLUSTER LP AIRG ALP O VERSPEED IN D LP CE SE 50 60 LIG H TS W 18T 18T BRN Y D G 18LG FORW IRE G AG E SEE C H A SSIS TAIL LAM PW IR IN GSHEET Fig 58 Instrument Panel CA...

Page 549: ...CTRICAL BODY AND CHASSIS 12 49 16U K V 160R l a 180R 18W fl j S9 18W_____ FO RW IRE G A G E SEE C H A SSIS TAIL LAM PW IR IN GSHEET Fig 5 9 Instrument Panel CE CS M E60 13 CHEVROLET TRUCK SERVICE MANU...

Page 550: ...2R 20DBL 20DBL FUSE PN L TO DIRECTION SIGNAL SW IN L HORN CONTACT IGNITION SW INSIDE FUEL TA N K INSTRUMENT CLUSTER CIRCUIT fiPin 3 0 20DG 20DBL t e l 20T 20P 4 20B C S Ip 18B 2OGY 20DBL 20LBL 20 LG 1...

Page 551: ...ECTRICAL BODY AND CHASSIS 12 51 R H DIRECTION SIGNAL vv J j A M r r i8 Fp L L H DIRECTION SIGNAL Fig 61 Instrument Panel and Forward Lamp Wiring Harness TE TS 40 50 Exc 13 CHEVROLET TRUCK SERVICE MANU...

Page 552: ...cf H R H w s U U TOTTR 18LBL 18B W IPER SW L H W S WASHER W IPER SW OVER SPEED IND L P FUEL GA DIRECTION SIG L P OIL PRESS IND L P CLUSTER L P CLUSTER L P HI BEAM IND L P Fig 62 Instrument Panel TE TS...

Page 553: ...ELECTRICAL BODY AND CHASSIS 12 53 R H DIRECTION SIGNAL S T lnp L H DIRECTION SIGNAL Fig 63 Instrument Panel and Forward Lamp TT40 TD TG 50 60 CHEVROLET TRUCK SERVICE MANUAL...

Page 554: ...S WASHER W IPER SW VAC W ARN L P 20P FUEL 2ot JeT 20DBL 20LBL DI RECTI ON SIG LP 20GY 7 C O A IR PRESS GA L P 18B 2QGY CLUSTER L P 20GY 1Q p f CLUSTER L P 18Bi 2QLC r HI BEAM IND L P 12DG 20DG Fig 64...

Page 555: ...ELECTRICAL BODY AND CHASSIS 12 55 R H DIRECTION SIGNAL L H DIRECTION SIGNAL Fig 65 Instrument Panel and Forward Lamp TE60 13 CHEVROLET TRUCK SERVICE MANUAL...

Page 556: ...6 18LBL t 1 1 1 R H W S WIPER S W c f t r l L H W S WASHER WIPER SW OVERSPEED IND LP DIRECTION SIGNAL LP OIL PRESSURE LP CLUSTER LP CLUSTER LP HIGH BEAM IND LP 10DG 20DG Fig 66 Instrument Panel TE60 1...

Page 557: ...05 06 12 16 45 62 MDLS 18B li 20T 180R 18W i 1 Qaffll DOME LA M P INSIDE FUEL GAGE 03 04 09 13 34 MDLS R H DIRECTION T A IL LA M P 16LG R H BACKING LAM P 04 09 34 MODELS O N LY r I d 16BRN LICENSE LAM...

Page 558: ...EL GAGE CONN 18T 18Y 18DG DOME L P FUEL GAGE 18B HI 18T R H DIRECTION T A IL STOP L P Jo 18BRN LICENSE L P FUSE 18BRN 1 8 Y 18BRN L H DIRECTION T A IL STOP L P DIRECTION T A IL STOP L P CONN Fig 68 Ta...

Page 559: ...LB L 12 DG BRAKE FLUID W ARNING SWITCH V 18 T 18 W 18 OR L H PA R K DIR SIG L P STOP L P SW VJ 18 W 20 DBL 12 DG 18 T 18 OR 16 LG 18 T 20 P P L 20 P P L 20 LB L 20 LG 14 L B L 16 LG 18 T 12 R 12 DG 20...

Page 560: ...18 W 20 DBL o o d SmQ0SjS m 18 DG 12 PPL 20 DG 16 BRN 20 DBL 12 R 12 P 18 LG 18 W 14 OR 14 Y 14 LBL LEGEND CHEVROLET WRG FISHER BODY WRG CHEVROLET RPO WRG I 14 OR 14 Y 14 LBL Fig 70 Fuse Panel G A 10...

Page 561: ...ELECTRICAL BODY AND CHASSIS 12 61 18 DG 18 DG Fig 71 Instrument Panel G A 10 20 CHEVROLET TRUCK SERVICE MANUAL...

Page 562: ...ELECTRICAL BODY AND CHASSIS 12 62 Fig 72 Engine and Tail Lamps G A 10 20 CHEVROLET TRUCK SERVICE MANUAL...

Page 563: ...Y AND CHASSIS 12 63 SPECIAL TOOLS JUNCTION BLOCK HORN FOR WIRE GAGE SEE CHASSIS TAIL LAMP WIRING SHEET OUTSIDE FUEL TANK 18T BRAKE WARN SWITCH Fig 73 Engine Compartment CS 10 20 30 02 CHEVROLET TRUCK...

Page 564: ...ELECTRICAL BODY AND CHASSIS 12 64 JUNCTION BLOCK HORN FOR WIRE GAGE SEE CHASSIS TAIL LAMP WIRING SHEET Fig 74 Engine Compartment CE 10 20 30 02 CHEVROLET TRUCK SERVICE MANUAL...

Page 565: ...ELECTRICAL BODY AND CHASSIS 12 65 FOR WIRE GAGE SEE CHASSIS TAIL LAMP WIRING SHEET Fig 75 Engine Compartment SS40 50 02 62 CHEVROLET TRUCK SERVICE MANUAL...

Page 566: ...ELECTRICAL BODY AND CHASSIS 12 66 Fig 76 Engine Compartment SE50 60 CHEVROLET TRUCK SERVICE MANUAL...

Page 567: ...SPECIAL TOOLS ELECTRICAL BODY AND CHASSIS 12 67 J 21 932 BEZEL NUT REM O VER Fig 77 Special Tools CHEVROLET TRUCK SERVICE MANUAL...

Page 568: ......

Page 569: ...or removal 3 Remove screws attaching two retainers to radiator and support and remove retainers 4 Lift radiator up out of lower mounts Lift shroud out of vehicle if applicable 5 Inspect lower pads and...

Page 570: ...nnect radiator hoses and transmission coolant line if so equipped 5 Remove lower shroud screws Fig 3 Radiator and Shroud Mounting P20 and P30 Models 6 Remove bolts securing radiator support to frame a...

Page 571: ...check for leaks If no leaks are present install air deflector and splash shields Fig 5 Radiator and Shroud Mounting G E Models Fig 6 Radiator and Shroud Mounting G S Models SERVICE OPERATIONS 40 THRU...

Page 572: ...CS SA60 Models difference is that the radiator is turned around in its vehicle position as illustrated by a comparison of Figures 8 and 9 Continue to refer to Figure 7 for trucks equipped with fan sh...

Page 573: ...60 and TG 50 60 are equipped with the extended fan shroud shown in Figure 12 All other T models are equipped with the shroud shown in Figure 13 Fig 13 Fan Shroud Mounting TS40 50 60 and TE40 50 60 Mod...

Page 574: ...6 13 6 13 7 T3 7 13 7 SERVICE OPERATIONS 10 THRU 30 SERIES Fig 15 G rille Mounting CA KA 10 20 CA 30 Models C A KA 10 20 CA 30 MODELS GRILLE REPLACEMENT Fig 15 Removal 1 Disconnect battery ground cab...

Page 575: ...om vehicle Remove three lower panels and retainer from ve hicle CA SA 40 50 60 M A 50 60 Models 11 Replace mouldings catch plate and other grille and mounting components as required Installation Assem...

Page 576: ......

Page 577: ...ecessary disassemble bumper by removing bolts attaching brackets and braces to bumper face bar Installation Assemble and install front bumper following the re moval procedure in reverse order Refer to...

Page 578: ...lation Assemble and install front bumper following the re moval procedure in reverse order Refer to torque specifications in rear of manual for correct torque values FRONT BUMPER G MODELS Fig 5 Remova...

Page 579: ...essary to remove bumper brack ets from frame drive out rivets and remove brackets Install brackets using bolts washers and nuts Installation Install bumper following the removal procedure in re verse...

Page 580: ...1...

Page 581: ...Cold 20 Max RPM Cold 4000 System Capacities Refrigerant 1 2 3 lbs 4 oz 525 Viscosity Compressor Oil 10 fluid oz Torque Specifications Compressor Suction and Discharge Connector Bolt 20 ft lbs Rear Hea...

Page 582: ...4 7 1 4 7 1 4 7 1 4 5 1 4 LH 6 1 4 RH 5 5 3 4 LH 6 1 4 RH Camber See Chart Fig 9 Sec 3 See Chart Fig 9 Sec 3 l l 2 l 4 1 1 2 1 1 2 1 4 1 1 2 1 1 2 1 1 2 1 1 2 1 1 2 1 4 LH 1 4 RH 1 1 4 LH 1 4 RH Curo...

Page 583: ...t Studs Upper 70 1 2 0 Ball Joint Studs Lower 1 2 0 215 Stabilizer Bar Link 2 0 Stabilizer Bar Bracket 25 2 0 Suspension Cross member 65 1 0 0 Shock Absorber Upper Eye 140 140 30 75 75 80 80 80 Shock...

Page 584: ...175 90 90 75 2 0 1 1 0 0 0 CO o 250 15 155 350 13 000 90 250 15 150 350 15 000 with 15 x 4 inch Brakes 90 250 15 150 350 15 000 with 15 x 5 inch Brakes 55 135 2 0 150 350 17 000 Single Speed 18 500 Si...

Page 585: ...Bolt 65 65 155 155 1 0 70 70 155 1 0 Spring Rear Shackel Bolts 50 50 155 155 5 5 Shock Absorber Attaching Bolts 75 75 75 75 65 65 65 1 2 0 Universal Joint Rear 15 15 15 2 0 15 2 0 2 0 2 0 2 0 2 0 2 0...

Page 586: ...Bolt Torques Ft Lbs Carrier Cover 2 0 2 0 2 0 2 0 2 0 45 45 80 80 Ring Gear 50 1 1 0 1 1 0 105 1 1 0 160 160 90 140 140 90 90 Differential Bearing Caps 55 1 0 0 1 0 0 205 205 205 205 LH 230 RH 160 2...

Page 587: ...SPECIFICATIONS 7 ENGINE SECTION 6 8 25 1 on CE TE400 Series CHEVROLET TRUCK SERVICE MANUAL...

Page 588: ...2993 1 2 2987 2 2997 l 2 3 4 2 7482 2 7492 5 2 7478 2 7488 2 3 4 2 2983 2 2993 5 2 2978 2 2998 Taper Production 0002 Max Service 001 Max Out of Round Production 0002 Max Service 001 Max Main Bearing C...

Page 589: ...Int Exh 46 Seat Runout Int Exh 002 Max Seat Width Intake l 3 2 l l6 Exhaust l 16 3 32 3 32 l 8 Stem Clearance Production Int 0010 0027 0 0 1 0 0025 Exh 0015 0032 0010 0027 0 0 1 2 0029 Service Hi Limi...

Page 590: ...SPECIFICATIONS 10 ENGINE TORQUES CHEVROLET TRUCK SERVICE MANUAL...

Page 591: ...cover PAPER ELEMENT Service at 12 000 miles initially Check every 6 000 miles thereafter until replaced POLYURETHANE BAND Service every 12 000 miles OIL BATH Change oil at regular engine oil change in...

Page 592: ...Injection Reactor 3908465 4369S 230 250 Syr All with Air Injection Reactor 3908466 4370S 230 250 Auto All with Air Injection Reactor 3908467 437 IS 230 250 292 w Gov Syn All with Air Injection Reactor...

Page 593: ...jection Reactor 7020109 283 All All exc with Air Injection Reactor 7027106 283 Gov Syn All exc with Air Injection Reactor 7037105 283 All Exc O D All with Air Injection Reactor 7037100 283 Overdrive A...

Page 594: ...Van 230 250 L 6 283 V 8 292L 6 327 366 V 8 School Bus Optional G 10 Optional P Models 4 53 D 478 Diesel 6V 53 Diesel Ground Neg Neg Neg Neg Neg Neg Neg Neg No of Plates 54 54 54 6 6 6 6 6 6 114 162 C...

Page 595: ...40 4000 RPM C 3036 0 8 Hg 15 15 5 Hg 6 ATDC Manual 700 AC 44 V8 327 Cu In Truck 4 bbl 220 HP All Exc with RPO K19 1111249 C 4633 0 900 RPM 11 1500 RPM 26 4100 RPM C 3036 0 8 Hg 15 15 5 Hg Pass 8 BTDC...

Page 596: ...V 8 Auto Trans Optional Optional G 10 Optional Brush Spring Tension Oz 35 35 35 35 35 35 35 80 80 80 80 35 40 40 40 Free Speed Volts 10 6 10 6 10 6 10 6 10i6 10 6 10 6 11 5 11 5 11 11 5 10 6 11 8 11...

Page 597: ...ngines V 8 Engines V 8 w Transistor Ignition Primary Resistance Ohms 1 41 1 65 1 24 1 46 38 51 Secondary Resistance Ohms 5 400 7 100 7 200 9 500 8 200 12 400 Type In Wiring Harness In Wiring Harness I...

Page 598: ...l t s 22 ft lbs Side Cover to Case B o lts 22 ft lbs Extension to Case Bolts except overdrive 45 ft lbs Overdrive Attaching Lower Left Hand Bolt Marked X 30 ft lbs Shift Lever to Shifter Shaft B o lt...

Page 599: ...lugs at Transmission C a s e 5 ft lbs Pressure Test Point P lu g s 5 ft lbs Low Band Adjustment Locknut 15 ft lbs Converter to Engine B o lts 35 ft lbs Under Pan to Transmission C ase 7 1 2 ft lbs Oil...

Page 600: ...50 lb ft 1 0 0 lb ft 1 0 0 lb ft Steering Wheel Nut 35 lb ft 35 lb ft 35 lb ft 35 lb ft 35 lb ft 35 lb ft 35 lb ft Lower Mast Jacket Bearing Adj 7 8 7 8 7 8 005 to 030 1 2 to 15 Power Steering Belt T...

Page 601: ...P License Lamp Roof Lights Front Directional Signal 1156 32CP Back Up Lamps Parking and Directional Signal 1157 4 32CP Tail Stop and Directional Signal 1157 4 32CP Cigarette Lighter Differential Locko...

Page 602: ...2 Reqd 3 3AG AGC Application Trade Number Rating Dome Lights 2 1 1 12CP License Plate Lamp 67 4CP Parking and Direction Signal 1157 4 32CP Tail Stop and Direction Signal Turn Signal Indicator 1895 2C...

Page 603: ...lash Shields to Underbody B o lts 90 lb in CE CS SA00 CD ME MS50 CT40 CD MD ME60 Models Radiator Shroud Attaching S cre w s 43 lb in CE CS00 ME MS50 SA40 60 SE SS50 Models Radiator Radiator Drain Plug...

Page 604: ...e Grille Extension to Grille Nuts Center Support to Grille Screws Grille Bumper Jam N uts CA SA 40 50 60 MA 50 60 Models Grille Hood Catch to Grille Screw s Lower Retainer to Lower Center Panel Screws...

Page 605: ...Bar Nuts 35 lb ft P20 and 30 Models Front Bumper Face Bar to Upper Bracket Lock Nuts 36 lb ft G10 and 20 Models Front Bumper Face Bar to Frame and Brace N uts 17 lb ft Bumper Brace to Frame Screw s 1...

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