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Chevrolet 10 Series 1968, Service Manual

The Chevrolet 10 Series 1968 Service Manual is a must-have for classic car enthusiasts. Download this comprehensive manual for free from manualshive.com to learn how to properly maintain and repair your vintage vehicle. This manual provides detailed instructions and diagrams to help keep your 1968 Chevrolet 10 Series running smoothly.

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FRAME  2-7

10-30  SERIES  DIMENSIONS

M od el

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

K A 109

209

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

P A  100

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

OO 
0

0

o 

o

CM 
C

D

 

t

9-3/8

11-7/8

12-3/4

16-1/8

13-3/4

7-1/2

10

10

15-1/8

11-5/8

11-1/4

13-3/8

31-5/8

99-3/4

175-3/4

16-7/8

16-7/8

16-7/8

16-7/8

P A 210

310

9

11-3/8

12-3/4

16

13-1/2

7-1/2

10

10

15-1/8

11-5/8

11-1/4

13-3/8

31-3/4

107-3/4

183-3/4

16-7/8

16-7/8

16-7/8

16-7/8

PA314

9-3/8

11-7/8

12-3/4

16

13-1/2

7-1/2

10

10

15-1/8

11-5/8

11-1/4

13-3/8

31-5/8

131-3/4

207-3/4

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

40-60  SERIES  TANDEM  AXLE  DIMENSIONS

Model

A

B

C

D

E

F

G H

I

J

K

L

M

N

Wheelbase

MS 5,  614 15-7/8 13-1/2 20 15-3/4 15-3/4 15-3/4 20 36 107-1/4 137-1/4 192-1/4 14-5/8 16-3/4 16-3/4

238-5/8

MS 5,  617 15-7/8 13-1/2 20 15-3/4 15-3/4 15-3/4 20 36 107-1/4 192-1/4 222-1/4 14-5/8 16-3/4 16-3/4

268-5/8

MS 5,  620 15-7/8 13-1/2 20 15-3/4 15-3/4 15-3/4 20 — 137-1/4 192-1/4 252-1/4 14-5/8 16-3/4 16-3/4

298-5/8

CHEVROLET  TRUCK  SERVICE  MANUAL

Summary of Contents for 10 Series 1968

Page 1: ...ST 1 3 3 SB...

Page 2: ...the page number on which each major subject begins An Index is placed at the be ginning of each major subject within the section 6Y ENGINE ELECTRICAL Summaries of Special Tools when required are foun...

Page 3: ...w w...

Page 4: ...ries 20 and 30 Forward Control models the Round Front Step Van con figuration is discontinued Square Front Step Vans all have new bodies the 125 inch wheelbase is retained and the 137 inch wheelbase i...

Page 5: ...0 Conventional Conventional Cab Panel Suburban A All G Light Duty Forward Control D L 4 Diesel H Conventional Short Conventional Cab E V 8 Gasoline J Tandem Short Conventional Cab G V 6 Diesel GMC Tr...

Page 6: ...arter Serial Number and Production Date Stamped on Outer Case Toward Rear SERVICE PARTS IDENTIFICATION PLATE The Chevrolet Truck Service Parts Identification Plate fig 3 is provided on all Truck model...

Page 7: ...en towing a vehicle on its front wheels only the steering wheel should be secured to maintain a straight forward position Push Starts Trucks Equipped with Automatic Transmission Do not attempt to star...

Page 8: ...5 6 7 17 5 6 6200 8 00 16 5 6 8 00 16 5 8 6700 3000 RPO G50 6000 R PO G50 8 75 16 5 8 8 75 16 5 8 7500 9 50 16 5 6 9 50 16 5 8 KS KE 20 exc 05 06 16 m odels 127 5700 3500 3200 5200 3800 7 17 5 6 7 17...

Page 9: ...e J70 Power Brake Equip 16000 13500 RPO H07 15000 RPO H07 RPO J70 Power Brake Equipment 18000 17500 RPO G55 RPO Z85 GVW plate RPO J70 Power Brake Equipment SS 40 149 10500 14000 15000 5500 6000 11000...

Page 10: ...plate RPO F02 Frame Reinf RPO L43 427 engine 30000 7000 7000 149 167 185 36000 30000 34500 ME 60 39000 9000 RPO F43 9000 RPO F94 RPO Z82 GVW plate 41000 11000 RPO F44 11000 RPO F44 RPO Z78 GVW plate 4...

Page 11: ...000 RPO H82 22000 RPO H82 32000 65000 23000 RPO H82 22000 RPO H82 RPO L29 478M Engine for GVW rating 36000 45000 7000 7000 30000 151 39000 45000 9000 9000 RPO F06 Frame Reinforcements JM 70 169 43000...

Page 12: ...HD brake booster RPO J73 27500 9000 RPO F43 9000 RPO F94 HD brake booster RPO J73 Frame Reinforcement RPO F06 29000 7000 7000 22000 RPO H74 22000 RPO G49 31000 9000 RPO F43 9000 RPO F94 RPO F26 Hi Ten...

Page 13: ...31000 9000 RPO F43 9000 RPO F94 32000 23000 RPO H76 24000 RPO H76 6000 7000 7000 22000 RPO H75 22000 RPO H75 RPO L49 DH637 Engine This rating available on TJ 70 only JV 70 JJ 70 151 169 187 198 210 36...

Page 14: ...meter Adapter 19 Parking Brake Linkage 19 Tachometer M ech an ical 19 Body Lubrication 19 Engine Fuel Gas and D ie s e l 19 Lubrication D ia g ra m s 20 The 1968 Truck engine and chassis recommended l...

Page 15: ...s of the New Vehicle Warranty Certain atmospheric and or driving conditions in cluding prolonged operations at sub zero temperatures or under extremely dusty conditions frequent trailer hauling and ex...

Page 16: ...situtations oil change intervals should not exceed 2 months or 3 000 miles whichever occurs first or Engine Oil Supplement OIL FILTER REPLACEMENT Replace 1 quart filter at each oil change This recom m...

Page 17: ...l Wetted Paper Element with Polyurethane Wrap Every 12 000 miles inspect air cleaner Remove poly urethane wrap and wash in suitable solvent Check oil wetted element and replace if necessary Check ever...

Page 18: ...ssary This recommendation applies only to 10 Series Models For 20 30 Series Models drain period should be every 12 000 miles Use only General Motors Automatic Transmission Fluid or DEXRON Automatic Tr...

Page 19: ...h or spray engine oil on the lever pivot point and on all exposed control linkage every 6 000 miles WHEEL BEARINGS 10 30 SERIES NOTE Use high melting point wheel bearing lubricant which meets General...

Page 20: ...f operation disassemble actuator and clean all parts Install new diaphragm or any other rubber parts if they are worn or deteriorated Brake Valve Every Year or 50 000 Miles Disassemble brake valve and...

Page 21: ...as dust storms and frequent driving on dusty roads necessitate more frequent lubrication periods Lubricate front suspension kingpins tie rod ends etc every 1 000 miles Check spring U bolts kingpins s...

Page 22: ...d with a lubrication fitting Use water resistant EP chassis grease which meets General Motors Specifi cation GM 6031M SPEEDOMETER ADAPTER On trucks so equipped lubricate adapter at fitting with water...

Page 23: ...r allow open flames or sparks near the vehicle when refueling If gasoline fumes are noticed while driving the cause should be determined and corrected without delay DIESEL FUEL SPECIFICATIONS The qual...

Page 24: ...assis Lubricant As required 9 Air 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 Abo...

Page 25: ...s Engine 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 6 000 miles 9 Distributor L 6 12 000 M...

Page 26: ...ent 12 000 Miles 12 000 Miles Engine 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 6 000 mile...

Page 27: ...every 6 000 miles 9 Distributor L 6 12 000 Miles 1 2 turn of Lubricator 10 Distributor V 8 Cam Lubricator 12 000 Miles Rotate Cam Lubricator 11 Master Cylinder 6 000 Miles Delco Supreme No 11 As requi...

Page 28: ...00 Miles 12 000 Miles Engine Oil As required Fill 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 T...

Page 29: ...iles 12 000 Miles Multi Purpose Dexron See chart in Lubrication Section Dexron As required As required 9 Quarts approx Keep even with filler See Lubrication Section Checking For off high way operation...

Page 30: ...is Lubricant As required See Lubrication Section 9 Control Linkage Points 6 000 Miles Engine Oil As required Brush or Spray to apply 10 Wheel Bearings 30 000 Miles Wheel Bearing Grease 2 places as req...

Page 31: ...k 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 controls and levers at the rear of the cab sho...

Page 32: ...attach to the right side of the firewall The blower motor heater core and hose as sembly mount on the engine side of the firewall while the distributor ducting and controls are under the dash fig 1 Th...

Page 33: ...ow either through the heater core around CHEVY VAN HEATER the core or partially through and partially around the The Chevy Van heater assembly is mounted on the toe core board inside the van Outside a...

Page 34: ...y Van Heater Control Panel Fig 6 Tilt Cab Heater Control Panel air deflector in the distributor duct which channels the airflow partially or fully to the defroster air outlets AIR FAN Lever When this...

Page 35: ...ounting screws 6 Remove the blower assembly pry the flange away from the case carefully if the sealer acts as an ad hesive 40 60 Series turn the motor until its flange clears the hood hinge 7 Remove t...

Page 36: ...seal on the temperature door cable at the distributor duct adapter and dis connect the cable from the temperature door 6 10 30 Series In order to gain access to the lower outboard case attachments the...

Page 37: ...w the toe pan 11 Refill the Cooling System 12 Connect the battery ground cable Tilt Cab Removal Fig 11 1 Disconnect battery ground cable 2 Drain radiator 3 Remove exterior air intake grille panel belo...

Page 38: ...es and clamp securely 14 Replace air intake grille 15 Refill cooling system 16 Connect battery ground cable AIR DISTRIBUTOR DUCT ASSEMBLY All Models Figure 14 Deluxe Air Figure 15 Chevy Van and Figure...

Page 39: ...URE control Replace the heater as sembly and mount it to the firewall Replace the glove box assembly 3 AIR FAN control Connect the blower wire con nector to the control 4 Install the control to the st...

Page 40: ...ete control units covered under CONTROL ASSEMBLY Tilt Cab Remove the control assembly as outlined under CON TROL ASSEMBLY and replace the affected cable or cables When replacing the temperature cable...

Page 41: ...er case attach ing screws Fig 20 Chevy Van Heater Wiring 2 Disconnect the defroster ducts at the distributor and move the distributor away from the cowl until the resistor unit is accessible 3 Disconn...

Page 42: ...ine downstream of the con denser All cooling system components are connected by means of flexible refrigerant lines Both the heating and cooling functions are performed by this system Air entering the...

Page 43: ...ither the heater core the evaporator core or through both When the system is set for full cooling all air passes through the evaporator core When warmer out let air is desired the temperature door is...

Page 44: ...with a heavy metal screw cap The purpose of the cap is to protect the valve and safety plug from damage It is good prac tice to replace the cap after each use of the drum If it is ever necessary to t...

Page 45: ...m the system must first be discharged of all refrigerant However proceed very cautiously re gardless of gauge readings Open very slowly keep ing face and hands away so that no injury can occur if ther...

Page 46: ...e 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 conditioning dealer can use the equipment on hand and avoid duplication G...

Page 47: ...er a refrigerant leak is suspected in the system or a service operation performed which results in dis turbing lines or connections it is advisable to test for leaks Common sense should be the governi...

Page 48: ...less pale INSPECTION AND PRE DELIVERY INSPECTION 1 Check that engine exhaust is suitably ventilated 2 Check the belt for proper tension 3 With controls positioned for operation of the system operate t...

Page 49: ...ngine exhaust suitably ventilated 3 Vehicle in NEUTRAL with engine running at 2000 rpm 4 Air Conditioning controls set for Maximum cooling High blower speed 5 TEMPERATURE knob set at maximum cold and...

Page 50: ...cations of expansion valve trouble provided by the Performance Test are as follows VALVE STUCK OPEN Noisy Compressor No Cooling Freeze Up VALVE STUCK CLOSED PLUGGED SCREEN OR BROK EN POWER ELEMENT Ver...

Page 51: ...alve periodically to allow boiling to subside to check level in sight glass urge system as noted Refer to Figure 32 operation I line to the vacuum pump turn on pump and open Vacuum Control Valve 3 See...

Page 52: ...HEATER AND AIR CONDITIONING 1A 21 Fig 32 Charging Schematic CHEVROLET TRUCK SERVICE MANUAL...

Page 53: ...e compressor muffler 3 Disconnect the high pressure line from the gauge set make certain that the line is clean and place the end in a graduated oil container 4 Pour enough refrigerant oil in the cont...

Page 54: ...e the hose Removal 1 Carefully with a sharp knife make an angle cut in the hose as shown in Figure 33 This should loosen the hose so that it may be worked off the fitting 2 Cut off slit end of hose wh...

Page 55: ...lip of the dash which attach the control assembly bracket to the dash 3 Move the unit toward the front of the vehicle and lower it 4 Disconnect the blower harness connector and illumi nating lamp sock...

Page 56: ...ondenser out of the truck 9 Remove the upper brackets from the condenser frame if a new condenser will be installed Installation 1 Mount the upper condenser mounting brackets loose ly to the condenser...

Page 57: ...e sight glass should occur a new sight glass kit should be installed The kit contains the sight glass seal and retainer See Figure 36 1 Purge system 2 Remove the sight glass retainer nut using a screw...

Page 58: ...t the evaporator oil bleed line at the P O A valve Cap the open connections 4 Disconnect the evaporator outlet pipe at the P O A valve Cap the open connections Remove the evap orator outlet pipe clamp...

Page 59: ...e and vacuum hoses hose to engine vacuum source attaches to vacuum tank connection nearest the engine 4 Connect the refrigerant hoses to the expansion valve inlet and the P O A outlet using new O ring...

Page 60: ...ore straps and retaining screws 3 Replace the heater case in the vehicle as outlined under Heater Case BLOWER RESISTOR UNIT Removal Fig 40 1 Remove the screw attaching the floor outlet duct above the...

Page 61: ...nk from the connecting shaft arm 3 Remove the screw attaching the connecting shaft to the tube extending forward from the valve 4 Remove the screws attaching the nylon bearing plate to the firewall an...

Page 62: ...w it to extend into position 2 Attach valve return spring and nylon bushing 3 Assemble the connecting shaft to the valve and actuating diaphragm 4 Replace the cowl grille panel Fig 44 A ir Inlet Valve...

Page 63: ...idence of contamination replace a like amount of fresh refrigeration oil into the com pressor before reinstallation If it was necessary to service the entire system because of excessive contamination...

Page 64: ...NG 1A 33 L 6 ENGINE 366 427 V 8 ENGINE 307 327 V 8 ENGINE EXCEPT C K10 MODELS WITH STD TRANS 396 V 8 ENGINE 307 327 V 8 ENGINE C K10 MODELS WITH STD TRANS V 6 ENGINE Fig 47 Compressor Mountings CHEVRO...

Page 65: ...OF EQUIPMENT AIR CONDITION WIRING RELAY 16LBL 16Y DBL B S 14DBL RESISTOR m 20B 12PPL 120R1 E 14DBL 180R 16DG DBL WS COMPRESSOR 14Y v V SWITCH ON POS LIGHT HARNESS 14Y 16Y DBL B S 180R 14BRN y o POS N...

Page 66: ...and Bearing Installer 7 J 9395 Puller Pilot 22 J 8092 Handle 8 J 6271 Fitzall Valve Single Can 23 J 21352 Internal Assembly Support Block 9 J 5421 Pocket Thermometers 2 24 J 5139 O il Pickup Tube Rem...

Page 67: ......

Page 68: ...s servic ing of the cab and panel bodies on all models except Tilt Cab T Step Van P Chevy Van G vehicles which are covered under their own headings elsewhere in Section IB Service write ups which foll...

Page 69: ...placed with new models in the TG70 Series Other new features include side marker lights or re flectors for all models identification and clearance lights for Series 20 and 30 Step Vans and standard eq...

Page 70: ...Panel and Suburban Body Mounts 2 3 4 5 Remove the following trim from inside the cab Floor mats dash and toe panel pad and kick pads Dust leaks will be evident when these pads and mats are removed Lea...

Page 71: ...increased by such conditions as wind pressures extremes of temperature motion of the vehicle etc The procedure for removal of the windshield applies to the complete windshield assembly Removal 1 Befo...

Page 72: ...g check the relationship of the glass to the body opening flange around the entire perimeter of the glass 6 Check the relationship of glass to opening as follows a Inside edge of glass to body flange...

Page 73: ...chalk line from under rubber channel fig 12 7 Apply weatherstrip cement beneath outside lip of weatherstripping Fig 14 Rear View Mirrors Conv Trucks REAR VIEW MIRROR The standard equipment rear view...

Page 74: ...se removal procedure COWL VENTILATOR Fig 18 The cowl ventilator intake a louvered opening extends across the top of the cowl The opening permits outside air to enter into a plenum chamber which distri...

Page 75: ...otor unit mounted to center of cowl inside cab power both wiper blades The wiper blade operating link rods and pivot mountings on these models are located in the outside air inlet plenum chamber Fig 2...

Page 76: ...Remove screws attaching handle assembly to inner side of tailgate 3 Remove clips from handle assembly and remove handle 4 Remove 2 screws from each latch assembly and lift off with actuating rods Rep...

Page 77: ...val and Installation 1 Open liftgate and remove two 2 Phillip s head screws and two internal tooth lockwashers 2 Remove handle and rubber gasket 3 Reverse procedure to install Supports Upper Assembly...

Page 78: ...hers with a 1 4 Allen head wrench 5 While supporting the endgate in an up right position remove the remaining hinge bolt from each side See Figure 27 6 Remove endgate 7 Reverse procedure to install Ad...

Page 79: ...steps and pro ceed as follows 1 Secure the Remote and Push Button Control Assem bly and remove two screws from the back of the plate 2 Rotate the push button assembly to release the lock assembly and...

Page 80: ...door also can be moved in or 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 special door hinge bolt wrench Tool J 22585 Fi...

Page 81: ...in the body lock pillar to vertically position the striker so that the lock rotor and rotor cover assembly swing smoothly into the opening between the teeth and striker wedge block fig 37 Fig 37 Lock...

Page 82: ...nch clearance to the lock rotor cover Use special burred shims as required NOTE Under usual conditions shims are not required 5 As an aid to striker adjustment outline the striker in pencil or crayon...

Page 83: ...glass channel with sandpaper removing all rust etc 3 Using new glass channel filler cut the piece to be installed two inches longer than necessary for the channel Place this piece of filler soapstone...

Page 84: ...ear of assembly then slide assembly to the notches in the carrier channel and out through the door ac cess hole Installation Install regulator in reverse order of removal lubricate regulator gears wit...

Page 85: ...are of the free rotor type They include a safety interlock feature Where necessary striker spac ers should be used to insure satisfactory lock and striker engagement Fig 47 Installing Trim Panel Seal...

Page 86: ...NOTE Note position of rod end if disconnect ing for proper replacement 3 Unscrew door lock control button from door assem bly 4 Remove five 5 attaching screws and the upper trim molding two 2 forward...

Page 87: ...tationary glass with rubber seal attached and remove run by pulling through a glass opening if necessary 7 Reverse above procedures to install Fig 52 Side Rear Door Center Remote Assembly Replace Fig...

Page 88: ...SCREW Fig 55 Body Side Trim Window Assembly Suburban 5 Start one end of the glass into its channel in the weatherstrip Using a pointed tool follow around the rear lip of the glass channel so it bears...

Page 89: ...ly broadcloths 1 Carefully brush all loose particles of dirt and soil 2 Immerse small cloth in volatile type cleaning solu tion wring out thoroughly open cloth and allow med ium evaporation Do not use...

Page 90: ...from the optional level ride seat proper adjustment is of primary importance Back Rest Adjustment To adjust back rest angle depress top of seat back and move to desired position Fore and Aft Adjustmen...

Page 91: ...BODY IB 24 30 ADJUSTER SCREW AND l EVER ASSY Fig 60 Exploded View of Level Ride Seat CHEVROLET TRUCK SERVICE MANUAL...

Page 92: ...er seat in top position by using wood shim under tube located under front of seat cushion or by shim under tube located below back cushion 2 Remove preload on torsion bars by rotating adjuster lever a...

Page 93: ...ce hinge shaft No 19 at rear of shock Also see fig 63 2 Replace 2 roll pins No 20 in hinge shaft locking roll pin on right hand side in nibs in bent up ear 3 Replace hinge shaft No 18 at front of shoc...

Page 94: ...Panel extends from the body front side door lock pillar to the double rear door hinge pillar The right side or curbside panels are the Side Front Panel extending from the front side door lock pillar t...

Page 95: ...re located on the outside air inlet plenum cham ber Wiper motor is controlled by switch marked wiper on dash Wiper motor service operations are outlined in Section 12 Arm Adjustment To adjust sweep of...

Page 96: ...Remove three screws from the upper surface near the front of the compartment and the three screws located under the lower surface near the front of the compartment 4 Disengage the compartment by slid...

Page 97: ...er on shaft and with end of door inner handle pointing forward align serrations in both handles with shaft serrations and install set screws Window Glass The optional window glass in the rear and side...

Page 98: ...emblies and special spring clips not shown attached at the door rod opening in each end of the door 3 Remove the inside handle set screw handle and washer 4 Remove the lock assembly attaching screws r...

Page 99: ...el for removal 2 Remove handle and spring NOTE While handle is removed the escutch eon and gasket can be removed 3 Reverse procedure to install Fig 80 Rear Door Outside Handle Hinge Strap Fig 81 Repla...

Page 100: ...lancing step assembly by pivot rod start 2 inboard bolts Fasten 2 screws washers and nuts to rocker 3 L o w er veh icle and in stall 7 bolts in Van flo o r 4 Connect rod through step lever with remove...

Page 101: ...TURN TO LENGTHEN OR SHORTEN ROD Fig 83 Step Assembly Side Door Fig 84 Driver Seat Replacement CHEVROLET TRUCK SERVICE MANUAL...

Page 102: ...BODY IB 35 Fig 87 Positioning Passenger Seat Fig 86 Flip Swing Passenger Seat Fig 88 Center or Rear Seat Sportvan Typical STORED CHEVROLET TRUCK SERVICE MANUAL...

Page 103: ...g Door R ep la cem en t IB 40 IB 37 Window G la s s IB 42 IB 37 Special Tools IB 43 GENERAL DESCRIPTION The following information deals with servicing proce this section under Conventional Body Write...

Page 104: ...he conventional cabs WINDSHIELD AND FRONT QUARTER GLASS Both windshield and front quarter glass are retained in body opening by wedge type weatherstrip such as that used on Conventional Cab rear windo...

Page 105: ...is mounted in front end header ac cessible through left side opening A 4 Circuit breaker for wiper motor is located on fire wall directly above clutch pedal Windshield Wipers Adjustment 1 To adjust p...

Page 106: ...and down by means of elongated holes in the brackets fig 93 3 The door tracks can be adjusted back by the use of shims between the bracket on the front of each track and the body bracket or post to wh...

Page 107: ...t and lockwasher from the bolt that holds the upper door roller assembly to the bracket at front of door fig 93 4 Remove the nut and lockwasher from the bolt that acts as the axle for the upper door r...

Page 108: ...he weatherstrip channel 5 Work top of stationary glass into weatherstrip chan nel in same manner as the bottom 6 Use rubber mallet to tap glass back to the weather strip Work into weatherstrip channel...

Page 109: ...top and bottom clips It is important that they be in stalled correctly Without these clips the impact of closing door will drive the stationary glass forward and out of the rubber at rear of window D...

Page 110: ...IB 49 IB 60 Checking Windshield Body Opening IB 49 IB 60 Installation IB 49 IB 60 Rear View M i r r o r IB 49 IB 60 GENERAL DESCRIPTION The tilt cab bodies are of all steel welded construction fully...

Page 111: ...ased 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 in either the operat ing or full tilted posit...

Page 112: ...washer and nut A fig 107 Remove three bolts lock washers and nuts from right cab support to sill pivot bracket B fig 108 8 Remove cotter pin and clevis A fig 108 with at tached check link to right ca...

Page 113: ...ees While cab is in this po sition install the three remaining bolts lock washer and nuts B fig 106 in the right cab support and sill brackets Torque bolts 40 to 50 ft lbs Install front bolt lock wash...

Page 114: ...ng safety catch release rod to the right raise hold down release lever upward until hold down catch becomes disengaged and rear of cab raises from mount Tilt cab completely forward until check link at...

Page 115: ...emoval 1 Remove nut from adjusting lever clamping bolt and pull lever off end of torsion bar 2 Remove two bolts retaining cap to left body bracket 3 Remove clamp bolt from right hand body bracket 4 Re...

Page 116: ...ter seal with a pointed tool pull insert completely out of seal 2 In same manner remove insert from seal around that section of glass which is to be removed 3 With aid of an assistant to hold glass pu...

Page 117: ...STEERING CYLINDER ATTACHING HOLES ASSEMBLE SPRING IN PROPER HOLE AS SHOWN THIS IS A SAFETY ITEM TO INSURE CHECK LINK OPERATION WHEN TILTING CAB VIEW A Fig 113 Check Link Assembly Typical CHEVROLET TRU...

Page 118: ...WIPERS Two separate motors are used to power the wipers on Tilt Cab Trucks one switch controlling both Covered here will be removal and installation of the units on the vehicle only Repair of wiper mo...

Page 119: ...motor may be serv iced Removal 1 Remove positive cable from battery terminal 2 Remove nut retaining wiper onto shaft 3 Pull arm knurled driver and rain shield from shaft 4 Remove nut retaining shaft f...

Page 120: ...vide the proper clearance at top of door however shim can be removed or another added as desired a Loosen hinge to door cap screws slightly Re position door on hinges to provide equal clearance around...

Page 121: ...te Raised beads on the back of the striker plate and ser ations on both the front and back of the striker plate spacers coupled with movable anchor plates in the pillar allow for in and out or up and...

Page 122: ...23 Door Lock Striker Plate verse order When installation is completed check op eration of window and adjust if necessary as outlined in this section OUTSIDE HANDLE AND LOCK ASSEMBLY The servicing of t...

Page 123: ...m of door place re mote control mechanism into installed position Se cure remote control unit to door inner panel loosely with three screws 5 fig 124 Secure lock unit 16 fig 124 to door edge with thre...

Page 124: ...r is located so that smooth side of channel is located as shown in Figure 128 5 When installed bottom of glass must be centered in glass regulator channel fig 128 Press glass with filler into channel...

Page 125: ...hich attach glass upper channel to glass lower channel Fig 129 Cross Section of Window Assembly 6 Apply Prep Sol on vent glazing rubber to soften old rubber When rubber softens sufficiently separate u...

Page 126: ...Weatherstrip Fig 133 Driver s Seat Assembly Fig 134 Driver s Seat Adjuster Assembly Fig 132 Insert Type Seat GLASS INSERT PANEL TYPICAL SEAL INSTALLING INSERT IN SEAL INSTALLING GLASS IN SEAL CHEVROL...

Page 127: ...hen used are retained by means of rubber seal and seal in sert fig 132 Cement butt ends of insert 1 Pry end of seal insert out of seal with a pointed tool then remove rubber insert completely Push gla...

Page 128: ...BODY IB 61 Fig 135 A uxiliary Seat CHEVROLET TRUCK SERVICE MANUAL...

Page 129: ...S Fig 136 Special Tools 1 J 2189 W eatherstrip Tool Set 2 J 5742 01 and J 22577 W indshield Checking Blocks Typical 3 J 22585 Front Door Hinge Bolt Wrench 4 J 9316 W indshield Checking Blocks CHEVROLE...

Page 130: ...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 c...

Page 131: ...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 132: ...Fig 4 1 0 3 0 Series Truck Frame...

Page 133: ...Fig 5 4 0 6 0 Single A xle Truck Frame E x c Tilt Cab...

Page 134: ...HOLE OR SLOT GAUGE HOLES ARE Ve 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 135: ...Fig 7 4 0 6 0 Series Tilt Cab Truck Frames...

Page 136: ...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...

Page 137: ...determining the alignment of the under body is with a tram gauge which should be sufficiently flexible to obtain all necessary measurements up to three quarters the length of the vehicle A good trammi...

Page 138: ...CHEVROLET TRUCK SERVICE MANUAL Fig 8 Underbody Reference Points and Dimensions Chevy Van G10 and G20 J FRAME 2 9...

Page 139: ...w...

Page 140: ...o n 3 13 Crossmember and Suspension U n it 3 13 R em oval 3 13 In sta lla tion 3 13 I Beam Suspension A s s e m b ly 3 13 Chevy Van Stabilizer G 10 20 3 3 R em oval 3 13 In sta lla tio n 3 13 Shock A...

Page 141: ...ats forged integral with the I Beam Constant diameter solid kingpins are used with the full floating glass filled polycarbonate steering knuckle bushing Front wheel spindles are cast integral with the...

Page 142: ...g it around spin dle Install hub plate or cap wheel and tire assem bly and lower vehicle Steering Stop Screw Adjust I Beam Only Steering stop screws should be periodically checked and adjusted to stop...

Page 143: ...aft and the mounting bracket at tached to the suspension crossmember A series of concave and convex spacers with flat oppo site sides are used These spherical spacers allow a positive cross shaft to b...

Page 144: ...front of vehicle fig 9 Toe In Toe in is the amount in fractions of an inch that wheels are closer together in front than at rear Check steering gear high point adjustment and place wheels in straight...

Page 145: ...ked bearing cages worn or pitted rollers 2 Check bearing races for cracks or scoring check brake drums for out of round or scored condition and check bearing outer races for looseness in hubs Repairs...

Page 146: ...b on spindle and install outer bearing pressing it firmly into position in hub 4 Adjust wheel bearings as outlined under Wheel Bear ings Adjust SHOCK ABSORBERS Figure 15 Removal 1 Remove nuts and eye...

Page 147: ...s securing the cross shaft to the crossmember 8 Lower control arm by slowly releasing the jack until spring can be removed 9 Remove chain Remove spring Installation 1 Properly position spring on the c...

Page 148: ...e 70 lb ft on CP10 models 120 lb ft on CP20 30 models Lower Lower ball joints are a loose fit when not connected to the steering knuckle Wear may be checked without disassembling the ball stud as foll...

Page 149: ...er ball stud Extend bolt from Tool J 8806 to loosen lower ball stud in steering knuckle When stud is loosened remove tool and nut from lower stud 4 Remove control arm Fig 18 Tool Mounted to Cross Shaf...

Page 150: ...to specifications and install cotter pin Upper Control Arm Assembly Removal 1 Raise vehicle remove wheel and tire assembly and Fig 22 Positioning Lower Control Arm Shaft support lower control arm asse...

Page 151: ...ball joint seat Fig 26 Positioning Upper Control Arm Shaft 3 Install service ball joint assembly in arm using special hardened bolts only torquing bolts 45 lb ft Installation 1 Place control arm in po...

Page 152: ...Install new cotter pin dust cap and hub cap 9 Lower vehicle recheck and readjust wheel alignment where necessary Crossmember and Suspension Unit Figure 27 Component parts of the front suspension may b...

Page 153: ...mounting details Series G10 and G20 mounting details are shown in Figure 3 Spring G K10 and 20 Series Removal 1 Raise vehicle and place stand jacks under frame side rails Support axle so that tension...

Page 154: ...means of a drift and compress spring leaves in a vise 6 Remove drift from center hole and install a new cen ter bolt peen bolt to retain nut 7 Align spring leaves by tapping with hammer then bend spr...

Page 155: ...ss if available and adapters J 21978 1 2 to remove and reinstall bushing 7 0 0 0 Axles Removal and Installation procedures are the same as outlined for the 4 and 5000 axle except use adapter J 21979 f...

Page 156: ...3 Raise I beam with caster shims in position index spring center bolt into I beam spring seat and install XJ bolts spacers and nuts Torque bolt nuts 120 lb ft Connect shock absorber Steering Knuckle S...

Page 157: ...ll parts in solvent and air dry 2 Inspect steering knuckle for distortion cracks or breaks If equipment is available use magnetic penetrant method to check for minute fractures 3 Examine thrust bearin...

Page 158: ...000 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 front and tighten nut...

Page 159: ...6 Place hub and drum assemblies over spindles and adjust wheel bearings as outlined under Wheel Bear ings Adjust 7 Install wheel and tire assemblies and lower vehicle Check front end alignment and ad...

Page 160: ...J 21830 4 Spring Bushing Receiver 4 J 21979 7000 A xle Spring Bushing Remover Installer 5 J 21978 1 4 5000 A xle Spring Bushing Remover 6 J 21978 2 4 5000 A xle Spring Bushing Installer 7 J 21058 Nut...

Page 161: ...fer case from direct drive to low four wheel drive at a ratio of 1 94 to 1 thus eight for ward speeds and two in reverse as provided Front wheel drive may be engaged or disengaged at any time without...

Page 162: ...conditions where front wheel drive is not needed The engagement and disengagement of free wheeling hubs is a manual operation which must be performed at each front wheel The transfer case control lev...

Page 163: ...Seal Ring 11 Rubber Seal 12 Knuckle Bearing Upper 13 Bushing Woodruff Key H D 14 Knuckle Bushing H D K20 15 Axle Housing 16 Axle Shaft 17 Knuckle Bearing Lower 18 Bearing Retainer 23 19 Lower Adjusti...

Page 164: ...axle shaft snap ring and re move snap ring 5 Remove the axle shaft sleeve and clutch ring as sembly and inner clutch ring and bushing assembly 6 Remove pressure spring and spring retainer plate Disass...

Page 165: ...ring from end of axle shaft 4 Pull bushing and inner clutch ring assembly from shaft Disassembly 1 Turn key to engaged position to release pressure from springs 2 With suitable size drift punch remove...

Page 166: ...hub and drum as an assembly 7 Remove bolts and lock washers holding brake flange plate and spindle to steering knuckle 8 Remove flange plate from steering knuckle and sup port the plate so brake hose...

Page 167: ...ng knuckle over axle housing yoke and install bearing retainers Use same shims re moved or equivalent amount and tighten bearing retainer bolts or nuts to 25 ft lbs torque NOTE On K20 models position...

Page 168: ...Section 7 Muncie 3 Speed 2 Install control lever assembly Transfer Case Installation Lubricate adapter sleeve and transfer case splines with transmission lube during installation 1 Using chassis lubri...

Page 169: ...fit w...

Page 170: ...P 3 0 4 7 Shock Absorber Replacement 4 4 Series GK10 and 2 0 4 8 Tie Rod Series C P10 and C20 4 4 Series 40 50 and 6 0 4 8 Stabilizer Shaft Series P 3 0 4 5 Spring Replacement 4 9 Control Arm Series...

Page 171: ...on both the top and bottom of the spring mounting The front eye has a rubber insulated steel bushing through which the spring is bolted to the Fig 4 A uxiliary Rear Spring Series C10 C20 Fig 5 Series...

Page 172: ...eaf 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 stress plate below the control arm Two sla...

Page 173: ...using straight edge Minor defects may be re moved by bending A badly bent rod however should be replaced 2 Bushings should be replaced if any abnormal condi tions exists such as looseness damage to o...

Page 174: ...nchors to U bolts 3 Relieve tension on rear U bolts Then alternately and evenly tighten nuts to 120 ft lbs making sure that axle is properly positioned during nut tightening 4 Align stabilizer shaft s...

Page 175: ...l Spring 1 Place spring clamp inside spring Position 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 ha...

Page 176: ...ving bushing halves from frame and spring eye Fig 20 Series G10 and G20 Spring Shackle 5 Insert bushing halves in frame and spring eye 6 Position shackles to bushing halves and install re taining bolt...

Page 177: ...the vehicle fig 19 and 20 1 Raise and support rear of vehicle at frame side rail to relieve tension in springs 2 Remove nut washer and bolt from front bushing and hanger Continue to raise vehicle unti...

Page 178: ...del C314 install spacer assembly between axle housing Fig 26 Installing Spring Eye Bushing Series 40 50 and 60 and spring with thick edge forward Make sure spring is in position at rear shackle and at...

Page 179: ...pring and caster shim from spring seat and from beneath the vehicle 5 Inspect spring replace bushing repair or replace spring unit as outlined in this section Installation 1 Install spring caster shim...

Page 180: ...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 b...

Page 181: ...xle Mounting 1 Axle Bracket 2 Equalizer Beam 3 End Bushing 4 Adapter 5 Bolt 6 Nut 7 Washer Fig 31 Cross Tube to Spring Saddle Mounting 1 Center Bushing 2 Spring Saddle 3 Spring Assembly 4 Spring Saddl...

Page 182: ...in hanger 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 veh...

Page 183: ...er then compress leaves using C clamps or an arbor press Install cen ter bolt then install rebound clip bolts and spacers Tighten center bolt firmly tighten rebound clip bolts enough to hold leaves in...

Page 184: ...tube Repairs Bushing Replacem ent End and center bushings may be removed and new bushings installed using suitable tools Installation Refer to Figure 36 Fig 36 Equalizing Beam Details 1 Bolt 5 Nut 2 A...

Page 185: ...e m b ly 4 25 R em ova l 4 25 In s ta lla tio n 4 26 Axle Vent Replacement 4 26 Axle Shaft Removal and In stallation 4 26 5200 and 7200 Lb Axles 4 26 11 000 13 500 and 15 000 Lb A x l e s 4 26 17 000...

Page 186: ...semblies are identical with the exception of drive gear ratios and brake assemblies however Series C K20 vehicles utilize a two pinion dif ferential while all other series are equipped with a four pin...

Page 187: ...al four pinion type Thrust washers are used between the side gears and case and also between differential pinions and the differential case A thrust pad mounted on the end of an adjusting screw Fig 38...

Page 188: ...able in spection cover 11 000 and 13 500 lb axles do not incor porate this feature the cover is an integral part of the axle housing Fig 39 11 000 lb Capacity A x le Cross Section 1 Universal Joint Yo...

Page 189: ...000 and 17 000 lb Capacity A xle Cross Section Pinion Spider 6 Drive Pinion 11 7 Rear Pinion Bearing 8 Ring Gear Thrust Pad 12 9 Ring Gear 13 10 Differential Spider 14 Differential Pinion Spider 15 Di...

Page 190: ...d will be very pronounced in the speed range at which it occurs appearing under either drive float or coast conditions Gear noise tends to peak in a narrow speed range or ranges while bearing noise wi...

Page 191: ...t The axle vent system consists of the vent connector vent hose and associated attaching parts When replacing vent hose make sure that it is routed along original path in such a manner that the hose i...

Page 192: ...s with a high melting point wheel bearing lubricant position seal in axle housing bore and tap seal into position so that it bot toms against bearing fig 45 To install seal use Tool J 2 1 4 9 1 for th...

Page 193: ...inion and flange for reassembly in the same relative position 5 Install Tool J 8614 1 on pinion flange and remove pinion flange nut fig 47 Position J 8614 1 on flange so that the four notches are towa...

Page 194: ...ck Fig 51 Pinion Flange Installation On the Vehicle Check If vehicle is equipped with a manual transmission shift transmission into neutral 1 Raise rear of vehicle until wheels are off the ground remo...

Page 195: ...rier hole to insure fit of replace ment vent Tap new vent into housing using a soft faced hammer Vent should be positioned in housing so that flat surface is toward centerline of differential carrier...

Page 196: ...semblies in cleaning solvent Clean with stiff brush to remove old lubricant Blow bearings dry with compressed Fig 55 Removing Axle Shaft 11 000 13 500 and 15 000 lb A xle air directing air stream acro...

Page 197: ...with J 8092 driver handle 17 000 lb axle inner bearing 9 Fig 56 Hub and Drum Details Nondemountable Type Drum 1 Axle Shaft 9 O il Deflector 15 Adjusting Nut Lock 20 O il Seal 2 Axle Shaft to W heel Bo...

Page 198: ...with J 8092 driver handle 17 000 lb axle outer bearing Replace outer bearing assembly all axles except 17 000 lb single speed as follows NOTE Inner bearing assembly must be re moved before attempting...

Page 199: ...o 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 15 000 lb with 15x4 inch brake and Tool J 22356 with J 8092 handle...

Page 200: ...installed on the vehicle 1 Separate the drum and hub by removing the drum to hub retaining bolts hub stud nuts or by pressing out the wheel studs as applicable 2 Position brake drum to hub assembly m...

Page 201: ...iate tool until seal is properly seated fig 68 5200 and 7200 lb axles Seal should be installed flush with end of hub 11 000 lb axle Seal should be installed flush with end of hub 13 500 lb axle Seal s...

Page 202: ...and 7200 lb axles b J 0870 for 11 000 and 13 500 lb axles c J 22343 for 15000 lb single and two speed axles M50 driving and trailing axles and 17000 lb two speed axle d J 7341 for 17000 lb single spe...

Page 203: ...olet two speed axle fig 72 is optionally available in both the 15 000 and 17 000 lb capacity In low gear torque is transmitted to the differential case through four planetary pinions to provide long l...

Page 204: ...ing Right 20 Axle Housing Cover 28 Shift Yoke 5 Pinion Adjusting Shim 13 A xle Shaft Welded 29 Shift Sleeve 6 Pinion Bearing Preload 14 A xle Housing 21 Differential Pinion 30 Anchor Bolt Lock Spacer...

Page 205: ...shift to axle low range the unit compensates for the increased pro peller shaft speed relative to vehicle forward speed en countered in axle low range When the axle is shifted to high range the speedo...

Page 206: ...Unit in High Range Position Operation The operation of the units in each speed range is ex plained in the following paragraphs High Speed Range When the control switch operating arm is moved to the up...

Page 207: ...em is to make sure that all wiring is in good condition with connections tight at terminals connectors and that the axle shift unit is filled with lubricant to proper level The shift unit should be fi...

Page 208: ...cessary to replace one of the parts If necessary to disassemble mount assembly in vise Turn spring winding lever clockwise and pull to separate Inspection and Test First clean all parts except motor i...

Page 209: ...wise direction until end of spring is past shift fork actuating lever then push lever inward until the spring is locked in place 8 Dip above assembly in SAE 10 engine oil With drive nut on drive scre...

Page 210: ...nd remove two nuts short spacer stop washer spring long spacer and stop washer from push rod bolt 5 Install stop washer long spacer new spring stop washer and short spacer 6 Install adjusting nut on p...

Page 211: ...with pin Secure switch housing rubber case to transmission shift lever as specified in Step 5 of Vacuum Shift Unit Control Switch Replacement 5 Test operation of shift system VACUUM SHIFT UNIT CONTRO...

Page 212: ...TION Fig 88 18 500 and 23 000 lb Eaton Single Speed Axle 18 500 lb Axle Shown 1 Flange Nut 8 Adjusting Spacer 16 Side Gear Thrust 22 Ring Gear Bolt 2 Pinion Flange 9 Bearing Cup Inner Washer 23 Bearin...

Page 213: ...rs 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 split tapered dowels The banjo type axle housing is one pi...

Page 214: ...at clearance exists between face of stud nuts and axle shaft flange If no clearance exists this indicates excessive wear at studs tapered dow els or flange holes replace worn part if necessary Hub and...

Page 215: ...on O D of axle housing tube 2 Make sure inner bearing oil seal oil seal sleeve axle housing oil deflector and inner bearing race and oil seal are properly positioned 3 Install hub and drum assembly o...

Page 216: ...olet Single Speed axle Refer to Rear Axle Chev axles are performed the same as those outlined for the rolet Single Speed COMPONENT PART REPLACEMENT Service operations on the axle may be performed with...

Page 217: ...shift unit on carrier and connect air line at cover 23 000 lb axle 5 Connect the hydraulic brake hose to the brake pipe on 16 Differential Pinion 17 Differential Support Case Right 18 Differential Thr...

Page 218: ...d connect test lamp from A to ground Turn on ignition switch and observe test lamp a If lamp lights and stays on circuit breaker and lead wire are satisfactory b If lamp does not light check for poor...

Page 219: ...r line opening in solenoid valve Apply voltage to solenoid valve terminal and observe pressure gauge reading If gauge indication is approximately that of reservoir pressure solenoid valve is satisfact...

Page 220: ...hers housing cover and gasket from shift unit housing Drain lubricant 2 Position housing in vise as shown in Figure 96 3 Remove nuts and bolts retaining piston housing cover to unit Remove piston hous...

Page 221: ...and actuator arm connection fig 97 6 Install housing cover and gasket Torque cover screws to 100 in lbs 7 Install new O ring in housing and install piston housing cover Torque piston housing cover nu...

Page 222: ...xle differential to provide positive drive to both axles when required Drive is transmitted from the transmission through a conventional propeller shaft to the power divider input shaft fig 101 The in...

Page 223: ...REAR SUSPENSION AND DRIVE LINE 4 54 Fig 101 Forward Rear Axle Assembly Exploded View CHEVROLET TRUCK SERVICE MANUAL...

Page 224: ...ew 86 Input Shaft Bearing 87 O il Seal 88 Bearing Cover Shims 89 Bearing Cover 90 Lock Washer 91 Cap Screw 92 Input Companion Flange 93 Flat Washer 94 Input Shaft Nut 95 Cotter Pin 96 Drain Hole Pipe...

Page 225: ...e to the lever pin and make note of the dimension At the end of ten minutes re 1 Differential Carrier Cover 2 Bracket 3 Push Rod Yoke 4 Boot 5 Locknut 6 Push Rod 7 Snap Ring 8 Dowel 9 Cylinder Inner H...

Page 226: ...all the boot nut and clevis yoke on the push rod 5 Make certain that the snap ring groove on the inner half of the cylinder is clean Position the cylinder in the bracket on the power divider with the...

Page 227: ...valve body to hold pin in place 4 Position new valve 7 and valve spring 8 in valve body 6 and install cap nut 10 Tighten nut firmly 5 Install tell tale lamp switch Installation 1 Position control val...

Page 228: ...iner Inner Deflector Dust Shield MAINTENANCE AND ADJUSTMENTS An extended life universal joint which does not require periodic inspection and lubrication has been incorporated in several applications o...

Page 229: ...from end of sleeve and pull seal and washer from retainer 3 Remove bearing support as follows a Remove dust shield or if equipped with flange remove cotter pin and nut and pull flange and de flector...

Page 230: ...nstallation to prevent seal distortion and to assure proper seating of seal on trunnion b On all other universal joints lubricate trunnion bearing rollers and install new seal rings c Insert trunnion...

Page 231: ...t Duty Axle Used with J 21468 6 J 21051 Rear Wheel Bearing and O il Seal Installer Heavy Duty Used with J 7079 2 7 J 21491 Rear Wheel Bearing and O il Seal Installer Light Duty Axle Used with J 8092 8...

Page 232: ...2357 Wheel Bearing Installer 23 J 22360 Wheel Bearing Remover 5 J 22354 Wheel O il Seal Installer 15 J 22349 Wheel Bearing Installer 24 J 7341 Wheel Bearing Nut Wrench 6 J 22281 Pinion Flange O il Sea...

Page 233: ...I...

Page 234: ...icle to a controlled stop The system is designed with separate hydraulic systems for the front and rear brake using a dual main cylinder fig 1 The main cylinder has two entirely separate reservoirs an...

Page 235: ...SWITCH MAIN CYLINDER LOWER SECONDARY PIPE i M A IN CYLINDER LOWER PIPE CA SA PA40 CD CG MA50 CD CG60 WELD NUT MA 60 FWD TA 40 50 60 INBOARD FORWARD GA 10 20 EXTENSION SIDE RAIL LEFT SIDE CE CS SA 50...

Page 236: ...is shaped to provide an anchor block for the brake shoe heeL Fig 4 Wagner Type F Front Left Brake The FR 3 brake is used on all Chevrolet 17 000 and 30 000 tandem equipped Eaton Rear Axles Each Fig 3...

Page 237: ...nk crank adjusters E On a reverse brake application the head of the shoe F moves away from its forward acting anchor G which cocks the link H crank system If lining clearance is sufficient the crank p...

Page 238: ...trically to the brake alarm indicator SWITCH ASSEMBLY light on the instrument panel In the event of fluid loss in NOTE The brake pressure differential warning either the front or rear brake system the...

Page 239: ...y or self adjusted brakes the adjustment is made through an opening in the flange plate or externally as outlined below Wagner Type F 1 Jack up axle Place wrench on one adjusting cam stud to adjust on...

Page 240: ...is capable of exerting 30 to 50 lbs hydraulic pressure on the brake system 3 Install brake bleeder adapter J 22489 fig 13 on main cylinder Connect hose from bleeder equipment to bleeder adapter and op...

Page 241: ...leeding tube J 0628 over end bleeding valve fig 16 5 Place other end of tube in transparent container holding sufficient fluid to cover end of tube 6 Open bleeder valve 3 4 turn and observe flow When...

Page 242: ...cables should be lubricated during a brake reline job or when adjusting brakes if cables feel sticky When lubricating the brake cables the rear brake drums must be removed on 1 2 and 3 4 ton vehicles...

Page 243: ...3 Tighten locknut on eccentric bol t and recheck movement BRAKE PEDAL ADJUSTMENT CA KA PA 10 20 CA PA 30 40 50 CD CG MA 60 SERIES Fig 19 1 Loosen locknut on adjustable push rod between the brake pedal...

Page 244: ...ake used on 1 2 3 4 and 1 ton models must be performed each time the service brakes are adjusted and can be accomplished only when service brakes are in adjustment The propeller shaft parking brake us...

Page 245: ...Install lock wire on anchor screw B 13 Recheck all points of facing for correct clearances T Models Figs 26 and 31 Tilt Cab vehicles are equipped with a compound type lever that applies the transmissi...

Page 246: ...0 015 clearance between inner shoe facing and brake drum Then hold nut B and tighten locknut C securely HYDRAULIC BRAKE LINES Hydraulic Brake Hose These hoses require no maintenance other than peri od...

Page 247: ...drum to bring one of access holes into line with adjusting screw at bottom of shoes 4 Expand shoes by rotating adjusting screw with screw driver inserted through hole in drum Move outer end of screw...

Page 248: ...BRAKES 5 15 TD 50 60 Fig 26 Parking Brake Cables T Models CHEVROLET TRUCK SERVICE MANUAL...

Page 249: ...The dual main cylinder used on 1968 light trucks is designed and built to satisfy individual brake system SERVICE OPERATIONS Fig 27 Internal Expanding Type Parking Brake b Turn the tool to the opposit...

Page 250: ...dentification The length of the secondary pistons in these main cyl inders is a critical factor in the displacement capabilities of a particular main cylinder These secondary pistons are coded using r...

Page 251: ...to keep it from turning and back out the tube nut This will re move the tube seat 8 Repeat Step 8 above on second tube seat 9 Remove the check valves and springs from the cavi ties beneath the tube s...

Page 252: ...cylinder in a vise with the open end of the bore up Coat the primary and secondary seal on the primary piston with clean brake fluid Push the primary piston assembly spring end first into the bore of...

Page 253: ...and vent in filler cap are clean and open NOTE Before washing parts hands must be clean Do not wash hands in gasoline or oil be fore cleaning parts Use soap and water to clean hands 2 Inspect cylinde...

Page 254: ...utch 4 Install cover on main cylinder Tilt Cab Fig 1 1 Align pedal push rods position cylinder against mounting flange and bolt in place 2 Slide end of rubber dust boots over cylinder tubes and connec...

Page 255: ...all tension from brake cable 3 Remove brake drums NOTE Since boots are recessed in grooves on wheel cylinders to prevent pistons from leaving cylinders it is not necessary to install wheel cylinder c...

Page 256: ...akes only lubricate fulcrum end of park ing brake lever and the bolt with brake lube then Fig 41 inspecting for Proper Lubrication attach lever to secondary shoe with bolt spring washer lock washer an...

Page 257: ...ator lever functions easily by hand operating the self adjusting feature Follow the above procedure for all brakes Adjust the service brakes as outlined below then adjust the parking brake Adjustment...

Page 258: ...cking up Applying the brakes moves actuators which turn the star wheels and rotate the adjusting screws out ward from the anchor brackets fig 47 This action adjusts the shoe until clearance between th...

Page 259: ...m Inspect drums for roughness scoring or out of round Replace or re condition drums as necessary NOTE If when reconditioning drums an un dercut of more than 045 is needed replace the drum 10 Carefully...

Page 260: ...Universal Carburetor Gauge Set at a 90 angle with the star wheel edge of the actuating lever Turn the adjusting cam until the actuating lever and threaded area on the adjusting screw just touch the ga...

Page 261: ...in wheel cylinder piston shoe guide and position shoe heel in slot in anchor block 3 Install flat washer and C washer on cam and shoe guide stud Crimp ends of C washer together 4 After installing both...

Page 262: ...justing screw in anchor support then turn adjusting wheel to thread adjusting screw into anchor support 2 Install brake shoes with cut away end of shoe web next to adjusting screw and with ends of sho...

Page 263: ...wedge guide slot aligned on lever pivot pin hole Insert contact plug from drum side of shoe guiding its shank through the hole in the shoe table and over wedge guide and wedge Insert adjuster lever pi...

Page 264: ...adjustment so much that starwheel is jammed against the friction ring on the adjuster screw as this may damage the ring 3 Remove rear brake drum as directed in Section 4 4 Unhook the two automatic ad...

Page 265: ...tandard drum diameter in order to provide a break in clearance at lining ends 9 Check to make sure that backing plate and anchor supports are clean and torqued to specifications Installation Fig 58 1...

Page 266: ...king plate so that they rotate freely while resting against retracting spring hooks Install and crimp the C washers At each crank assemble the short link small hook in to the short arm of the crank fr...

Page 267: ...cified in Chevrolet Parts Books should be used These linings may be purchased in replacement sets of four linings and sufficient rivets of correct specifications When replacing linings make sure that...

Page 268: ...auge fig 62 Clearance should be within 0 002 to 0 004 Replace cylinder if clearance exceeds 0 004 Assembly Before assembling wheel cylinder be sure each part has been cleaned in denatured alcohol CAUT...

Page 269: ...ening in the lower cylinder Install bleeder screw in upper opening of the upper cylinder Connect brake line at lower cylinder fitting 3 Install brake shoes as directed under Brake Shoe Installation Bl...

Page 270: ...d position Hold a 060 plug gauge from J 9789 01 Universal Carburetor Gauge Set at a 90 angle with the star wheel edge of the actuating lever Turn the adjusting cam until the actuating lever and thread...

Page 271: ...in wheel cylinder piston shoe guide and position shoe heel in slot in anchor block 3 Install flat washer and C washer on cam and shoe guide stud Crimp ends of C washer together 4 After installing bot...

Page 272: ...hor support insert threaded end of adjusting screw in anchor support then turn adjusting wheel to thread adjusting screw into anchor support 2 Install brake shoes with cut away end of shoe web next to...

Page 273: ...e wedge guide slot aligned on lever pivot pin hole Insert contact plug from drum side of shoe guiding its shank through the hole in the shoe table and over wedge guide and wedge Insert adjuster lever...

Page 274: ...adjustment so much that starwheel is jammed against the friction ring on the adjuster screw as this may damage the ring 3 Remove rear brake drum as directed in Section 4 4 Unhook the two automatic adj...

Page 275: ...dard drum diameter in order to provide a break in clearance at lining ends 9 Check to make sure that backing plate and anchor supports are clean and torqued to specifications Installation Fig 58 1 Whe...

Page 276: ...ing plate so that they rotate freely while resting against retracting spring hooks Install and crimp the C washers At each crank assemble the short link small hook in to the short arm of the crank fro...

Page 277: ...ified in Chevrolet Parts Books should be used These linings may be purchased in replacement sets of four linings and sufficient rivets of correct specifications When replacing linings make sure that s...

Page 278: ...auge fig 62 Clearance should be within 0 002 to 0 004 Replace cylinder if clearance exceeds 0 004 Assembly Before assembling wheel cylinder be sure each part has been cleaned in denatured alcohol CAUT...

Page 279: ...ening in the lower cylinder Install bleeder screw in upper opening of the upper cylinder Connect brake line at lower cylinder fitting 3 Install brake shoes as directed under Brake Shoe Installation Bl...

Page 280: ...racket assembly and remove assembly from channel 7 Withdraw lower pedal arm from channel Cleaning and Inspection 1 Wash all metal parts with an approved cleaning solvent 2 Inspect Installation 1 Posit...

Page 281: ...0 CA KA PA20 CA PA30 CA PA40 CD CG MA50 60 ALL EXCEPT FLAT FACE COWLS FLAT FACE COWLS CA KA MAOO PA10 40 SAOO VIEW B SA50 60 TA40 50 60 MAIN BRAKE CYLINDER Fig 63 Brake Pedal C K P M S and T Models CH...

Page 282: ...cable to equalizer by removing check nut at rear of cable 3 Engage parking brake handle until ball on front end of cable can be slipped out of handle assembly 4 Remove two handle attaching screws wash...

Page 283: ...from rear cables at connectors Installation 1 Feed cable ends through holes in frame cross member and install cable ends into rear cable connectors 2 Place cable through equalizer and install equalize...

Page 284: ...r shaft at transmission Remove bolts attaching center bearing bracket to cross member then lower center bearing and front propeller shaft to floor if necessary 3 Remove bolt from transmission output s...

Page 285: ...clears clevis pin in brake cam 5 Cut lock wire back off anchor adjusting screw until clear of anchor 6 Slide band assembly off drum removing anchor screw spring as band is removed Inspection 1 Examin...

Page 286: ...rt lower release spring and band lower bracket Install flat washer adjusting nut lock washer and lock nut on adjusting bolt NOTE On remote control parking brake no tension spring is used 5 Turn up anc...

Page 287: ...en rod is connected NOTE On floor mounted installations attach cable to bottom hole On dash mounted installa tions attach cable to top hole of cam Brake Drum Removal 1 Remove brake band and lining ass...

Page 288: ...shaft center bearing hanger bracket to crossmember 3 On some vehicles brake drum is mounted on for ward side of transmission output shaft flange and on other vehicles it is mounted on rear side of the...

Page 289: ...bracket to crossmember Replace all lock washers and nuts and tighten securely 5 Install brake band and adjust brake as directed in Brake Band Installation PARKING BRAKE PROPELLER SHAFT INTERNAL EXPAND...

Page 290: ...ounting bolts Install yoke flange and eight nuts and lock washers Tighten nuts alternately and evenly 2 Adjust brake as directed under Parking Brake Adjustment 3 Connect propeller shaft universal join...

Page 291: ...ntenance and Adjustments in this section ANCHOR PIN REPLACEMENT CHEVY VAN 1 Raise vehicle and place on jack stand 2 Remove wheel and drum as outlined in this section 3 Remove brake shoe pull back spri...

Page 292: ...ing the brakes On 1 2 ton models brake tubing of 3 16 diameter is used for all hydraulic brake pipes except the line between main cylinder and tee fitting on frame right hand side rail which is 1 4 Ex...

Page 293: ...blocks and they are forced securely against the stop plate fig 78 5 Draw latch plate nuts down tight to prevent tube from slipping Draw nuts down alternately beginning with nut on closed side to prev...

Page 294: ...etainer 21 Rear Diaphragm Retainer Control Valve Body GENERAL DESCRIPTION The Master Vac fig 82 is a self contained hydraulic and vacuum unit for power braking utilizing manifold vacuum and atmospheri...

Page 295: ...he air cleaner filter used with the power brake unit should be cleaned at least twice a year To clean re move air cleaner element and wash thoroughly in cleaning solvent allow element to dry before re...

Page 296: ...um base cleaning agent Coat new seals and rubber parts with hydraulic brake fluid Assembly 1 Place spring 1 and check valve 4 into end of cyl inder body 2 Place O ring seal 2 over check valve retainer...

Page 297: ...ers are now equipped with a boss or plug for connection of trailing axle or trailer brake if owner so desires simply by re moving plug and replacing with proper fitting Frame mounted vacuum powered cy...

Page 298: ...allowing pedal to travel only 3 4 stroke Close power cyl inder valve 3 Repeat above operations until clear fluid comes from this valve 4 Bleed wheel cylinders in same sequence followed in pressure ble...

Page 299: ...BRAKES 5 56 Fig 88 Frame Mounted Vacuum Single Diaphragm Power Brake Installation CHEVROLET TRUCK SERVICE MANUAL I...

Page 300: ...ES 5 57 Fig 89 Vacuum Booster Unit FRONT BRAKE CYLINDERS MAIN CYLINDER REAR BRAKE CYLINDERS WARNING SWITCH AIR CLEANER CHECK VALVE MANIFOLD Fig 90 Vacuum Power Brake System CHEVROLET TRUCK SERVICE MAN...

Page 301: ...r presence of excessive carbon deposits Also check the discharge line for carbon If excessive carbon is found in either check the cylinder head or discharge line should be cleaned or replaced 100 000...

Page 302: ...bject to wear should be replaced if worn or damaged Strainers at relay diaphragm bleeder passage and exhaust port should be cleaned or replaced QUICK RELEASE VALVE Every Year or 50 000 Miles Disassemb...

Page 303: ...nal precautions must be taken 1 Drain air brake system 2 If water cooled type compressor drain engine cool ing system compressor cylinder head and block 3 Disconnect all air lines water and oil lines...

Page 304: ...from air brake system 3 Disconnect air lines from relay valve 4 Remove mounting bolts and remove relay valve Disassembly 1 Remove actuator adapter and its gasket 2 Remove cover diaphragm diaphragm ri...

Page 305: ...at the non pressure plate with vise or vise grip pliers If necessary use air pressure to move the push rod out Grips of vise or vise grip pliers should be covered or taped to prevent damage to push ro...

Page 306: ...t stem and its spring from the top of the piston 8 With the body in the inverted position tap it lightly to remove the piston 9 Remove the inlet and exhaust valve spring and the valve from the piston...

Page 307: ...Exhaust all air from system 2 Remove all lines running to brake valve 3 Remove pedal push rod clevis pin 4 Remove mounting bolts and remove valve Disassembly Fig 98 1 Remove boot 18 from plunger 17 an...

Page 308: ...hree seconds 4 No leakage is permissible at any other point on the brake valve with the pedal in the depressed position Adjustments If the brake valve does not release promptly or does not fully relea...

Page 309: ...ew 1 Lock Sleeve 2 Spring 3 DoweI 4 Lever 5 6 7 Worm Worm Shaft Gear Cover Plate Fig 101 Lapping Exhaust Port Seat Spring Seat If the spring seat is worn or damaged replace with new spring seat Repair...

Page 310: ...ce from small end of shaft to edge of body A fig 102 is 0 625 Install new welch plug in worm shaft bore 4 Position cover plates on body and attach with new rivets Covers must be flat and in good conta...

Page 311: ...brake shoe pull back springs 5 Remove cam rollers 6 Remove C washers flat washers and wave washers from each hold down stud 7 Remove brake shoe hold down nuts washers and anchor pin horseshoe clips 8...

Page 312: ...ng nuts 6 Install inner rim and tire assembly make certain valve points toward the outside rim spacer and outer rim and tire assembly making certain tire valve is 180 away from inner tire valve 7 Inst...

Page 313: ...compound Before the key is again put in place it should be given a light application of a good grade of cup grease Assembly 1 Insert key in body 2 Place spring and spring washer over key 3 Push down o...

Page 314: ...he adjusting screw clock wise raises the pressure setting Turning the ad justing screw counter clockwise lowers the pressure setting The setting of the adjusting screw should be locked by lightening t...

Page 315: ...g plate using original screws or equivalent Fig 110 Pressure Protection Valve Cross Section 2 Mount backing plate gauge assembly in instrument panel 3 Replace lamp socket and gauge line 4 Thoroughly c...

Page 316: ...7 Valve Spring Retainer 13 Cam Shaft 19 Operating Lever 2 Seal 8 Piston Return Spring 14 Cam Housing 20 Name Plate 3 Nut 9 Piston Cup 15 Adjusting Bearing 21 Lock Washer 4 Valve Disc 10 Piston 16 Col...

Page 317: ...e Then pull knob out test gauge should drop to zero 3 Again build up air pressure in system to operating range then stop engine Push emergency air valve knob in Make a series of brake applications unt...

Page 318: ...ion or deterioration and re place as necessary Make sure shuttle valve will slide freely back and forth in valve guide Assembly Apply a thin coating of Lubriplate or equivalent to in side of valve gui...

Page 319: ...rvoirs charged as above and with the control valve plunger in pull the valve plunger out The brake actuators should apply 4 Push control valve plunger in The brake actua tors should release with a ser...

Page 320: ...brake applications and note that ac tuators apply and release properly 2 Operate parking control valve and observe that ac tuators apply While actuators are in a parking po sition drain air supply to...

Page 321: ...BRAKES 5 78 RESERVOIR ATMOSPHERIC AIR SUPPLY SOURCE Fig 114A Schematic Diagram of DD3 Brake Actuator System CHEVROLET TRUCK SERVICE MANUAL...

Page 322: ...BRAKES 5 79 Exhaust Port Plunger DRY ROAD POSITION SLIPPERY ROAD POSITION Fig 114B Front Brake Limiting and Two Way Control Valve Operation CHEVROLET TRUCK SERVICE MANUAL...

Page 323: ...nting nut then control valve Disassembly Fig 115 1 Insert a punch or rod in the plunger pin hole to keep the plunger from turning while removing the nut at the bottom of the valve 2 Remove the plunger...

Page 324: ...rely 7 Connect air line and electrical connections to the switch 8 Build up the air in the system and check to switch for leaks 9 Check operation of switch as outlined under Oper ating Test in this se...

Page 325: ...mets on piston 2o Install piston with grommets in valve body 3 Position piston springs cover plate and retainer ring in the piston in that order Press the cover and retainer down and with a pair of Tr...

Page 326: ...OTE Clean actuator exterior of all road grime then mark it in such a way so it can be assembled in the same manner 1 Remove yoke and yoke locknuts 2 Remove boot splash guard and felt breather 3 Remove...

Page 327: ...ramp 5 Place roller spring seat washer on top rollers 6 Position cone shaped roller spring on washer with small end to washer 7 Position cap on roller spring Press cap down and hold while installing c...

Page 328: ...c Adjuster Components automatic adjuster components are given in the following paragraphs Any time the adjuster assemblies are removed for service they should be lubricated as directed in the followin...

Page 329: ...embly 18 Guide Screw 4 Adjusting Bolt Assembly 19 Gasket 5 Identification Ring 20 Plunger Seal and Retainer 6 Spanner Nut 21 Roller Retaining Cage 7 Plunger Seal and Retainer 22 Wedge Spring 8 Adjusti...

Page 330: ...ove wheels 2 Remove hub and brake drum assembly Refer to REAR SUSPENSION under HUBS AND BEARINGS SEC 4C of this manual 3 Remove brake shoe return springs from both shoes 4 Lift brake shoe web out of s...

Page 331: ...BRAKES 5 88 Fig 126 Stopmaster Brake Components Automatic Adjuster with Fail Safe CHEVROLET TRUCK SERVICE MANUAL...

Page 332: ...panner nut then unscrew nonpressure hous ing from brake spider This leaves wedge roller and spring assembly exposed 3 Remove wedge roller and spring assembly from actuation housing by pulling straight...

Page 333: ...corrosion are too deep to be polished out spider must be replaced 5 Inspect plungers for scoring scratches or corrosion Light scratches may be polished out with crocus cloth If scratches or corrosion...

Page 334: ...nal brake chamber Movement of diaphragm plate rod is transmitted to the brake shoes through the mechanical actuating components as described later The outer chamber contains a spring loaded piston whi...

Page 335: ...ides 2 Parking Brakes Apply parking brakes by pulling knob of control valve to release air from chamber Brakes should apply promptly and should hold on any grade on which vehicle is expected to operat...

Page 336: ...Diaphragm plate rod and boot will remain in the non pressure housing Mount pressure housing in vise NOTE Do not tighten vise jaws enough to dis tort pressure housing Using a wrench on hex end of cap...

Page 337: ...or deterioration or rust In spect release bolt for signs of rust on threaded por tion Unless spring or bolt is in very bad condition replacement should not be necessary See Caution in step 10 of Remov...

Page 338: ...year All valves are now located in the cab or engine compart ment fig 139 There are two air tanks used on base installations a primary and secondary The secondary tank is a split tank a dry and wet si...

Page 339: ...ting hours or after 200 000 miles or every two years disassemble brake valve clean and in spect all parts Install new parts where they are found to be worn or damaged MANUAL AND EMERGENCY CONTROL VALV...

Page 340: ...T AT 80 PSI FOR AIR OPERATED ACCESSORIES LOW PRESSURE INDICATOR SWITCH SET AT 70 PSI PRIMARY SYSTEM QUICK RELEASE VALVE PRIMARY SYSTEM PRIMARY DRY TANK DD2 SAFETY ACTUATORS STOP LAMP SWITCH PRIMARY SY...

Page 341: ...nlet Valve 29 Front End Cover Gasket 17 Governor 41 Piston Rings 6 Cylinder Head Body 30 Ball Bearing 18 Cap Screw 42 Cylinder Head Gasket 7 Inlet Valve Seat 31 Front End Cover 19 Lock Washer 43 Inlet...

Page 342: ...unction in one of the circuits Leakage Tests 1 Fully charge air brake system 2 Make several service brake applications and check for prompt application and release at all wheels 3 With service brakes...

Page 343: ...ry pressure the Double Check Valves are functioning correctly If one of the modes is not correct all other valves operating correctly the shuttle of the affected valve is stuck If all modes operate co...

Page 344: ...h gauge make and hold a hand valve application and observe that no air escapes at the open trailer service hose coupling 5 When system pressure reaches approximately 60 psi the Trailer Emergency Contr...

Page 345: ...be above 60 psi at this stage so that the handle will stay in Next open tractor primary reservoir drain cock and slowly drain down air at about 40 psi the handle should pop out and the emer gency line...

Page 346: ...r Cylinder Spanner Wrench 9 J 22364 Drum to Brake Shoe Clearance Gauge 10 J 21601 Power Brake Retainer Installer 11 J 22839 Front Plate Holding Fixture 12 J 21524 Power Piston Remover and Installer 13...

Page 347: ......

Page 348: ...power 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 technicia...

Page 349: ...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 diagnosis info...

Page 350: ...ts 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 or dirty Ne...

Page 351: ...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 tight en...

Page 352: ...ld Heat Control Valve V8 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 important function...

Page 353: ...ew window and insert an Allen wrench in the socket of the adjusting screw fig 11 Turn the adjusting screw as required until a dwell reading of 30 is obtained A 2 variation is allow able for wear Close...

Page 354: ...ditioning ON 3 Adjust idle mixture screw to obtain highest steady idle speed Adjust idle speed screw to recommended rpm on DECAL NOTE Idle speed adjustment for L 6 engines and Powerglide transmissions...

Page 355: ...balance Battery The battery should be checked with special testing equipment and to the equipment manufacturers specifi cations See Section 6Y for complete information on battery tests Ignition The f...

Page 356: ...stem Pressure Test Fig 18 O il Deflector Clips Installed Ignition Output and Secondary Leakage Use equipment as directed by manufacturer GOOD readings indicate both ignition output and secondary insul...

Page 357: ...se 10 seconds until engine runs smoothly Repeat ad ditional 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 adjus...

Page 358: ...me sub assemblies and replacement of some com ponents For service to all components and sub assemblies after removal and r e m o v a l of some sub assemblies refer to Section 6 of the Truck Chassis Ov...

Page 359: ...ap 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 fig 1L then take engine weight off mount...

Page 360: ...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 361: ...Disconnect exhaust pipe at manifold flange and dis card packing 6 Remove manifold attaching bolts and clamps then re move manifold assembly and discard gaskets 7 Check for cracks in manifold castings...

Page 362: ...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 363: ...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 364: ...t 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 suitabl...

Page 365: ...ed Oil Seal Rear Main Replacement The rear main bearing oil seal can be replaced both halves without removal of the crankshaft NOTE Always replace the upper and lower seal as a unit Install with the l...

Page 366: ...r onto crankshaft CAUTION Install bolt in crankshaft with suf ficient thread engagement min 1 2 b Remove bolt nut and washer and install retaining bolt and torque to specifications 3 Install fan belt...

Page 367: ...Camshaft Measuring Lobe Lift NOTE Procedure is similar to that used for checking valve timing If improper valve opera tion is indicated measure the lift of each push rod in consecutive order and reco...

Page 368: ...gs Installation 1 Install the camshaft and gear assembly in the engine block being careful not to damage camshaft bearings or camshaft 2 Turn crankshaft and camshaft so that the valve tim ing marks on...

Page 369: ...lywheel on crankshaft and position to align dowel hole of crankshaft flange and flywheel fig 20L 3 Install flywheel retaining bolts and torque to specifications Fig 20L Flywheel installation Typical 2...

Page 370: ...models using a propeller shaft brake of any type it is necessary to remove screws from transmission hole cover to allow the engine to raise because of the limited clearance be tween the brake and tra...

Page 371: ...the jack until the rear support is clear of the frame 5 Remove both halves of the rear support 6 Install a new rear support both halves 7 Raise the jack until the rear support hole lines up and insta...

Page 372: ...moval and installation of engine assemblies the removal installation and adjust ment of some sub assemblies and replacement of some components For service to all components and sub assemblies after re...

Page 373: ...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 374: ...kage and 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 fo...

Page 375: ...asket and seal surfaces on manifold block 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 Inst...

Page 376: ...justment rocker arm balls are being installed coat bear ing surfaces of rocker arms and rocker arm balls with Molykote or its equivalent 1 Install push rods Be sure push rods seat in lifter socket 2 I...

Page 377: ...have a flat spot c Improper adjustment In most cases where noise exists in one or more lifters all lifter units should be removed disassembled cleaned in a solvent reassembled and reinstalled in the...

Page 378: ...de the cylinder head into place over the dowel pins and gasket 4 Coat threads of cylinder head bolts with sealing compound and install bolts finger tight 5 Tighten each cylinder head bolt a little at...

Page 379: ...removal 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 and oil pump removed remove the rear main...

Page 380: ...and 427 cu in engines Installation CAUTION The inertia weight section of the torsional damper is assembled to the hub with a rubber type material The installation pro cedures with proper tool must be...

Page 381: ...ching screws and remove front cover and gasket then discard gasket Installation 307 and 3 2 7 cu in Engines 1 Make certain that cover mounting face and cylinder block front end face are clean and flat...

Page 382: ...crew driver 2 Install new seal so that open end of the seal is toward the inside of cover and drive it into position with Tool J 995 on 307 and 327 cu in engines fig 13V or Tool J 22102 on 366 396 and...

Page 383: ...sing the three mounting bolts Torque to specifications 8 Lubricate timing chain with engine oil 9 Install crankcase front cover and torsional damper as outlined Camshaft Measuring Lobe Lift NOTE Proce...

Page 384: ...t holes then remove camshaft fig 22V On 366 and 427 cu in Engines Align the timing gear marks then remove the two camshaft thrust plate screws through holes in the camshaft gear fig 23V Remove camshaf...

Page 385: ...th engine oil 7 Install fuel pump push rod as outlined in Section 6M 8 Install grille as outlined in Section 13 9 Install crankcase front cover as outlined 10 Install valve lifters as outlined Timing...

Page 386: ...engine and cowl panel 4 Replace mount to engine and lower engine into place 5 Install retaining bolt and torque all bolts to specifications With 366 cu in Engine 1 Remove cotter keys then loosen front...

Page 387: ...remove the rear support nut 3 Place a jack or jack stand under the transmission extension and raise until the pressure is off the rear support 4 Remove the rear support bolt and lower the jack until t...

Page 388: ...Cam Bearing Tool J 8032 4 24 J 0971 Camshaft Gear 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 Damp...

Page 389: ......

Page 390: ...cold Coolant level in cross flow radiators should be maintained three inches below the bottom of the filler neck when the system is cold It is very important that the correct fluid level be maintained...

Page 391: ...when this type cleaner is used 1 Drain the cooling system including the cylinder block and then close both drain plugs 2 Remove thermostat and replace thermostat housing 3 Add the liquid portion No 1...

Page 392: ...ose completely 8 If thermostat checks satisfactorily re install using a new housing gasket 9 Refill cooling system Water Pump Removal 1 Drain radiator and break loose the fan pulley bolts 2 Disconnect...

Page 393: ......

Page 394: ...specifications Carburetors for engines with the Air Injection Reactor System are designed particularly for these engines therefore they should not be inter changed with or replaced by a carburetor des...

Page 395: ...ons with idle solenoid is as follows adjust idle speed to 500 rpm by adjusting solenoid plunger hex only Disconnect wire at solenoid and observe idle speed De energizing the solenoid allows the thrott...

Page 396: ...econdary Throttle Lockout Secondary Opening Secondary Closing Holley 4150G Float Idle Vent Choke Rod Accelerator Pump Removal Flooding stumble on acceleration and other perform ance complaints are in...

Page 397: ...Adjust swivel on accelerator control rod until it freely enters hole in accelerator control lever M odels TE TE 4 0 5 0 6 0 1 Depress accelerator pedal to floor 2 Hold carburetor throttle lever in wi...

Page 398: ...ENGINE FUEL 6M 5 Fig 7 C Throttle Linkage GS100 200 Fig 8C Throttle Linkage GE100 200 CHEVROLET TRUCK SERVICE MANUAL...

Page 399: ...mounted a throttle plate or throttle valve The valve is slightly offset on the shaft and in its wide open position is about 10 degrees from the vertical fig 1G The gas mixture rushing from the carbure...

Page 400: ...ent pattern for shift control for automatic type transmissions The governor is comprised of two basic units the cen trifugal control valve housed in the distributor see En gine Distributors in Section...

Page 401: ...y can be re moved by detaching the fast idle cam and pump rod and removing the four attaching screws No attempt should be made to service the throttle lever bearing If the action is sticky or binding...

Page 402: ...e connection to the distributor and attaching a vacuum line If there is no vacuum reading check the dia phragm for holes and be sure the vacuum passage is clear 2 Erratic operation under load Check fo...

Page 403: ...into the carburetor and engine The air cleaner also helps to reduce engine noise and quenches any flame that may be caused by engine backfire through the carburetor Three types of air cleaners are us...

Page 404: ...hrough the element towards a light bulb 4 Tap element on smooth flat surface to dislodge dirt particles being careful not to damage element Com pressed air can be used to clean element if done very ge...

Page 405: ...ature of the water The valve should begin to open at a water temperature of 83 F and be fully open at a temperature of 120 F Thermostat Replacement 1 Remove sheet metal to air cleaner hose from the ai...

Page 406: ...control damper should close the cold air passage as long as vacuum is applied the hot air pipe will be open 8 If the vacuum motor fails to operate the control damper assembly with the direct applicat...

Page 407: ...installed in this same position 3 Remove clip and sensor from air cleaner Replacement 1 Install sensor and gasket assembly in air cleaner in position as noted above 2 Press retaining clip on sensor S...

Page 408: ...IN IN G STRAP INSTALL REPLACEM ENT SEN SO R ASSM IN SAME PO SITIO N AS O R IG IN A L ASSM A SPOTWELDS M OT O R ASSM Fig 9A Component Replacement Fig 10A 6 C yl Typical Fig 1 1 A C E 100 200 300 CHEVRO...

Page 409: ...ENGINE FUEL 6M 16 Fig 12A CM KM 250 CM350 Fig 13A CM KM 250 CM350 CHEVROLET TRUCK SERVICE MANUAL...

Page 410: ...ENGINE FUEL 6M 17 Fig 14A PE200 300 TE400 500 600 Fig 15A PT200 300 CHEVROLET TRUCK SERVICE MANUAL...

Page 411: ...ENGINE FUEL 6M 18 Fig 18A V 8 Typical CHEVROLET TRUCK SERVICE MANUAL...

Page 412: ...ENGINE FUEL 6M 20 ENGINE FUEL 6M 19 Fig 21 A CE100 200 With Heat Stove CHEVROLET TRUCK SERVICE MANUAL...

Page 413: ...ENGINE FUEL 6M 20 Fig 2 2 A C S K A 1 00 200 CS300 With Heat Stove CHEVROLET TRUCK SERVICE MANUAL...

Page 414: ...ENGINE FUEL 6M 21 Fig 25A CS PS SS400 CS M S SS500 CS600 TSOOO With Heat Stove CHEVROLET TRUCK SERVICE MANUAL...

Page 415: ...fuel pump actuates the rocker arm OUTLET INLET Fig IP Fuel Pump Non Serviceable Fig 2P Step Van Fuel and Vacuum Pump 1 Outlet Valve 10 Pulsator Diaphragm 2 Fuel Cover 11 Fuel Inlet Valve Assembly 3 Fu...

Page 416: ...um pump and join them with a piece of tubing Slowly operate engine from idle to about 1000 rpm the wiper should run at full speed operat ing on engine vacuum only If it does not it can be assumed that...

Page 417: ...pes in vacuum cover are bent or loose the pump should be replaced 3 Inspect rocker arm for wear or scoring at camshaft pad at point of contact with links and at pivot hole Inspect bushing for wear Ass...

Page 418: ...ke fuel link into 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 tensio...

Page 419: ...inch 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 ri...

Page 420: ...manifold assemblies tubes and hoses necessary to connect the various components Carburetors and distributors for engines with the A I R System are designed particularly for these engines therefore the...

Page 421: ...stment 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 mounting bolt a...

Page 422: ...t tension and adjust if required PUMP FILTER Replacement Remove drive belt and pump pulley as previously outlined Pry loose outer disc of filter fan Pull remaining portion of filter off with pliers fi...

Page 423: ...ER VALVE Inspection Check condition and routing of all lines especially the signal line All lines must be secure without crimps and not leaking Disconnect signal line at valve A vacuum signal must be...

Page 424: ...connect the hoses at the pump Remove pump pulley as outlined Fig 9 lnstalling Pressure Relief Valve Remove pump mounting bolts and remove pump Install pump with mounting bolts loose Install pump pulle...

Page 425: ...d tap in place using a plate to pro Fig 11 lnstalling Exhaust Tube tect end of tube Tap down until approximately 7 8 of tube extends above cover NOTE Support pump as shown in Figure 11 do not clamp wh...

Page 426: ...n an electrolyte composed of dilute sulfuric acid Plate straps located on the top of each element connect all the positive plates and all the negative plates into groups The elements are con nected in...

Page 427: ...ould oxidize the negative active materials and reduce the freshness of the battery fig 3b The integral hard rubber seals and the sealing compound between the case and one piece cell cover make possibl...

Page 428: ...p pear very dark when the level falls below the tip of the rod the top will glow The Indicator reveals at a glance if water is needed without the necessity of removing the vent plugs fig 6b The Level...

Page 429: ...arged or which have been very recently charged 2 Do not break live circuits at the terminals of Bat teries because a spark usually occurs at the point where a live circuit is broken Care must always b...

Page 430: ...vailable for testing the Specific Gravity Cell Comparison Test may be used or an alternate method but with a sacrifice in testing accuracy NOTE New energizers which have become completely discharged o...

Page 431: ...I TURN TAB BATTERY SHIELD GA10 20 PANEL BODY VIEW A RPO T60 ONLY NOTE WHEN RPO K67 IS USED CUT OFF ANTI TURN TAB STARTER MOTOR BATTERY BOX FLOOR PANEL GAT0 20 SUBURBAN RPO T60 VIEW B NEG CABLE GROUND...

Page 432: ...odel and series To install a Battery properly it is important to observe the following precautions Connect grounded terminal of Battery last to avoid short circuits which may damage the electrical sys...

Page 433: ...d rectifier as used in other types of application The diodes change the Delcotron A C current to D C current Three regulators are available on truck models A double contact two unit type a transistor...

Page 434: ...a capacitor and a thermistor to form a com pletely static voltage regulating unit in combination with a conventional vibrating type field relay The transistor is an electrical device which limits the...

Page 435: ...inals on the generator or regulator 6 Do not attempt to polarize the generator 7 Do not disconnect lead at generator without first disconnecting battery ground cable Trouble in the A C charging system...

Page 436: ...en repeat Step 6 2 Delcotron tests good disconnect regulator connector remove regulator cover and re Voltage Setting connect the connector Then repeat Step 6 and turn voltage adjusting screw fig 5c to...

Page 437: ...y posts 8 Start the engine and slowly bring the speed to 1500 rpm and at the same time adjust the carbon pile load to hold the voltage at 14 volts 9 Read the amperage and compare with a specifications...

Page 438: ...gulator An open circuit in regulator or relay is stuck closed See Service Operations for repair b Fails to glow problem is in wire between F terminals on generator and regulator or in field windings G...

Page 439: ...s faulty Refer to specifications Check and adjust regulator as follows Closing Voltage Adjustment 1 Make connections as shown 50 ohm variable resistor in Figure 11c using a NOTE This gives us a variab...

Page 440: ...relay points stuck closed or relay damaged 3 Turn the switch on and read the voltmeter a Voltmeter reads battery voltage relay O K b Voltmeter reads zero relay winding bad or open circuit in wiring to...

Page 441: ...adings total more than 3 volt check for excessive resistance in field circuit leads If these leads are satisfactory the field relay contacts may have excessive resistance In this case replace the rela...

Page 442: ...the drive end or use Adapter J 21501 and a box wrench on retaining nut insert a 5 16 alien wrench through socket and adapter into hex on shaft to hold the shaft while removing the nut 2 Remove washer...

Page 443: ...er be cleaned as they are made of special material that may be destroyed by cleaning with any abrasive material Fig 20c Lead Arrangement After Assembly Fig 21c Checking Field Relay Point Opening NOTE...

Page 444: ...t and is by passed at cranking The other units in the system the ignition switch spark plugs and battery are of standard design The distributor and control unit ignition pulse amplifier are shown in F...

Page 445: ...n the ignition amplifier unit Ignition Coil Check Breakerless The ignition coil primary can be checked for an open condition by connecting an ohmmeter with car battery disconnected across the two prim...

Page 446: ...breaker plate install attaching screw Cleaning Dirty contact points should be dressed with a few strokes of a clean fine cut contact file The file should not be used for other metals and should not be...

Page 447: ...oid excessive spring distortion 9 Set point opening 019 for new points 10 Reinstall rotor position and lock distributor cap to housing 11 Start engine and test dwell and ignition timing Eight Cylinder...

Page 448: ...adjusting if they have been in service To adjust the contact point opening 1 If necessary align points fig 9i by bending the fixed contact support Do not bend the breaker lever Do not attempt to align...

Page 449: ...e condenser circuit due to broken strands in the condenser leak or to a defective connection This will cause burned points and ignition failure upon initial starts and at high speeds 4 Capacity Capaci...

Page 450: ...s detach the unit from the distributor housing 3 Disconnect the primary and condenser leads from the contact point quick disconnect terminal remove the contact point set attaching screw condenser at t...

Page 451: ...r 9o Drive Gear Pin 10 Drive Gear 11 Cap 12 Rotor 13 Weight Springs 14 Mainshaft 15 Advance Weights 16 Cam Weight Base Assembly denser breaker plate assembly and vacuum control unit Degreasing compoun...

Page 452: ...opening and alignment See setting and alignment of points 9 Check breaker lever spring tension which should be 19 23 ounces See contact point replacement V 8 Engine Fig 13i 14i 1 On distributor withou...

Page 453: ...he hose adjust vacuum so that gauge reads 5 0 inches Replace hose then repeat adjustment until reading returns to 5 0 each time the hose is pinched 4 Attach vacuum hose to the adapter on the distribut...

Page 454: ...Continue cranking until timing mark on crankshaft pulley lines up with timing tab attached to engine front cover b Remove rocker cover left bank on V 8 engines and crank engine until No 1 intake valv...

Page 455: ...engine so rotor is in position to fire No 1 cylinder and timing mark on harmonic balancer is indexed with pointer 4 Disconnect air intake and governor vacuum lines from distributor 5 Remove distributo...

Page 456: ...ce wire for No 1 cylinder in tower marked on old cap during disassembly then install remaining wires clockwise around the cap according to the firing order 1 8 4 3 6 5 7 2 6 Attach distributor to coil...

Page 457: ...Internal circuitry of the amplifier is shown in Figure 26i 1 Transistors TRl and TR2 Check each transistor by referring to Figure 27i If both readings in Step 1 are zero the transistor is shorted If...

Page 458: ...in off position and inserting wire in small hole in cylinder Fig 28i Setting Spark Plug Gap face Push in on wire to depress plunger and con tinue to turn key counter clockwise until lock cylin der can...

Page 459: ...acuum Spinner Type described in Section 6M 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 460: ...nected with the armature The aluminum drive end hous ing is extended to enclose the entire shift lever and plunger mechanism protecting them from dirt splash and icing The flange mounted solenoid swit...

Page 461: ...MUTATOR POLE SHOE Fig 2s Cross Sectional View of Intermediate Starter BRUSH CABLE COVER O RINGS BAND GASKETS HEAVY DUTY SOLENOID SWITCH LINKAGE SEAL COMMUTATOR BASKET END FRAME OIL RESERVOIR LINKAGE S...

Page 462: ...t the SWITCH terminal of the solenoid 3 If the solenoid does not feel warm it should pull in whenever the voltage available at the SWITCH ter minal is 7 7 volts or more When the solenoid feels warm it...

Page 463: ...NGINE ELECTRICAL 6Y 38 SPECIAL TOOLS J 9717 2 SUPPORT TOOL CHECKING SCALE J 21600 HARNESS ADAPTER J 21501 PULLY ADAPTER J 9600 2 SHOULDERED INSTALLER Fig 5s Special Tools CHEVROLET TRUCK SERVICE MANUA...

Page 464: ...st the clutch release fingers and releasing the clutch The Step Van uses mechanical linkage activated by a floor pedal mounted through a pivot shaft on a frame bracket fig 2 A pull rod connects the pe...

Page 465: ...CLUTCHES AND TRANSMISSIONS 7 2 PS 40 PA 20 30 VIEW C VI W C VIEW B PE 20 30 VIEW B VIEW A Fig 2 Clutch Linkage Step Van CHEVROLET TRUCK SERVICE MANUAL...

Page 466: ...k to move throwout bearing against clutch fingers push rod will slide through swivel at cross shaft 4 Adjust nut B to obtain approximately 3 16 to 1 4 clearance between nut B and swivel 5 Release push...

Page 467: ...dal push rod lever then remove lever from pedal shaft 3 Hold pedal pad with one hand and slide pedal and shaft assembly outboard enough to clear pedal stop then allow return spring or overcenter sprin...

Page 468: ...ve cylinder and re move slave cylinder Disassembly Refer to Figure 10 1 Remove slave cylinder push rod push rod boot and fulcrum as a unit 2 Remove snap ring from slave cylinder using a small screw dr...

Page 469: ...n in Fig ure 12 4 Install boot over push rod fig 13 and install push rod and boot to slave cylinder Installation 1 Bolt slave cylinder assembly to engine clutch housing fig 3 2 Adjust slave cylinder p...

Page 470: ...CLUTCHES AND TRANSMISSIONS 7 7 Fig 14 Clutch Linkage Exploded View CHEVROLET TRUCK SERVICE MANUAL...

Page 471: ...the shaft or loose mountings 3 Lubricate the pedal linkage 4 Tighten all front and rear engine mounting bolts Should the mountings be oil soaked it will be neces sary to replace them CLUTCH RETRACTIN...

Page 472: ...fork 3 Remove clutch throwout bearing from the fork 4 Remove clutch fork by pressing it away from its ball mounting with a screwdriver until the fork snaps loose from the ball or remove ball stud from...

Page 473: ...release lever engages the pressure plate lug by means of a strut 3 which provides knife edge contact between the outer end of the lever and the lug The outer ends of the eye bolts extend through holes...

Page 474: ...gh hubs of driven discs into pilot bearing and place a wood or metal spacer ap proximately 1 x 1 x 3 8 thick between each re lease lever and clutch cover fig 19 to facilitate removal and installation...

Page 475: ...er opening 7 Disconnect propeller shaft from transmission as described in PROPELLER SHAFTS SEC 4 of this manual 8 Position a suitable dolly or jack under the vehicle and adjust to carry the weight of...

Page 476: ...ans mission reconnect shift levers to transmission side cover firmly and rotate clockwise to install gearshift lever Install transmission floor pan cover and floor mat 11 If other equipment exhaust pi...

Page 477: ...sem blies Remove both shifter shaft assemblies from cover O ring seals around shifter shaft may now be pried out if replacement is required because of damage 5 Remove detent cam spring and pivot retai...

Page 478: ...d plate assembly NOTE Installation is easiest if shifter shaft and plate assembly passes over ball in its neu tral position 10 Check clearance between end of interlock sleeve and shifter shaft and pla...

Page 479: ...ipped with Apron type flywheel housing position a suitable dolly jack under the flywheel housing and adjust to carry the weight of the engine Remove rear engine mounts NOTE On conventional cab models...

Page 480: ...ry cable sup port clip if attached to transmission or clutch housing 12 Connect propeller shaft to transmission as de scribed in PROPELLER SHAFTS Section 4 of this manual 13 Connect parking brake leve...

Page 481: ...have the position of the air valve inverted from that shown Constant regulated air is supplied to the bottom port of the air valve and to the IN port of the control valve With the control button down...

Page 482: ...1 Place control valve and mounting clamp on gearshift lever 2 Install the gearshift lever knob 3 Position the control valve and mounting clamp so that the control button is at least 6 inches below th...

Page 483: ...ing a slight pressure against the body and end cap Fig IOC Regulator Valve 2 Loosen large lock ring which attaches end cap to body 3 Slowly loosen vise releasing the pressure exerted by the pressure s...

Page 484: ...ng air pressure to remove piston do not stand in front of range shift cylinder during removal 5 Remove seals A and B fig 11C from piston and replace with new seals NOTE Remove snap ring washer and rep...

Page 485: ...at the seal Inspect and replace diaphragm if necessary Clean regulator 2 Cut off the vehicle air pressure and install air gauge into the air system at the output port of the regulator valve Bring the...

Page 486: ...ow or high range steady leak out air valve breather in both ranges 2 Leakage at seal C results in failure to shift into low range pressurizing of transmission TRANSMISSION OVERDRIVE INDEX Page General...

Page 487: ...haft and new O ring seals into housing and install tapered pin Connect control wire to lever SPEEDOMETER DRIVEN GEAR Disconnect speedometer cable remove lock plate to housing bolt and lock washer and...

Page 488: ...The pawl rod should move in 3 8 under a load of not less than 8 lbs nor more than 12 Pawl should move out to extended position when load is removed Ignition Grounding Contact Place a test lamp between...

Page 489: ...throttle lever touches its stop Occasionally the large nuts which clamp the OVERDRIVE switch through the switch bracket are tightened sufficiently to bend the switch shank thus pre venting free motion...

Page 490: ...Does not release a Remove the connection to the KD terminal of the relay If this releases overdrive look for a grounded control circuit between the relay and governor switch b If the overdrive is not...

Page 491: ...t the two shift rods at the gearshift lever by removing the cotter pin and clevis pin 2 Remove four nuts and lockwashers to remove gear shift from cab then remove two gaskets and stop plate 3 Install...

Page 492: ...ift rods refer to Shift Rod Adjustment Fig 20C Transmission Mounting 7 Connect input and output prop shafts Shift Cover and Forks Refer to Figure 21C Disassembly 1 Mount cover in vise and remove lock...

Page 493: ...teering Column Gearshift island or transmission end of the selector and shift rods 8 Tighten lock nuts securely 3 Check adjustment by moving gearshift lever through the shift pattern There must be no...

Page 494: ...ntrol rods from shift levers at transmission NOTE On models with New Process trans mission remove selector lever belle rank snap ring 2 Remove remote control assembly to transmission cover attaching p...

Page 495: ...nd lock washer 11 retaining shift rail selector 12 to ball joint assembly 13 Re move selector from the assembly 13 8 Remove nut and lock washer retaining bell crank 17 to ball joint assembly 13 Turn b...

Page 496: ...attaching parts holding shifter shaft collar 4 to shifter shaft 5 then remove shifter shaft collar 3 Loosen locknut 13 and remove selector lever 12 4 Remove snap ring 9 and washer 8 from selector arm...

Page 497: ...her 21 and retaining screw 22 Tighten screw firmly 2 Position selector arm and shaft assembly 15 and bushing 14 in control housing 7 then install washer 8 and snap ring 9 3 Position selector finger 16...

Page 498: ...lection cam and stud assembly 6 from end cover 19 8 Remove attaching parts holding reverse shift finger 23 to control housing 3 then remove reverse shift finger Cleaning and Inspection Use same proced...

Page 499: ...rings The valve body assembly is bolted to the bottom of the transmission case and is ac cessible for service by removing the oil pan assembly The valve body consists of an upper and lower body lo cat...

Page 500: ...jacket See Section 9 for alignment of steering column assembly if necessary 2 To check for proper shift linkage adjustment lift the transmission selector lever towards the steering wheel Allow the sel...

Page 501: ...PRESSURE TO CAUSE APPARENT NORMAL OPERATION OF THE VEHICLE WILL RESULT IN FAILURE OF THE CLUTCHES OR OTHER INTERNAL PARTS AFTER ONLY A FEW MILES OF OPERATION Throttle Valve Linkage Adjustment L 6 Mode...

Page 502: ...verter holding Tool J 9549 immediately or a similar tool constructed as shown in Figure 4PG or in an emergency a length of strong wire may be used after removal from the engine Installation NOTE The l...

Page 503: ...to engine 2 Set parking brake tight and start engine 3 Place selector lever in D drive range 4 Adjust carburetor idle speed adjusting screw to run engine at approximately 750 rpm and operate in this m...

Page 504: ...e made at the low servo apply main line test point fig 5PG Run the gauge line into the driving compartment by pushing aside the mast jacket seal Tie line out of the way of the drivers feet and connect...

Page 505: ...ire V307 Base 4 57 Axle 8 00 17 5 T ire V327 L30 4 57 Axle 8 00 17 5 T ire Throttle Position Up Down Up Down Up Down Up Down Up Down Up Down Up Down Closed 10 8 13 4 10 0 12 7 10 5 13 3 9 8 12 5 10 6...

Page 506: ...iply engine torque As turbine speed increases the direction of the oil leaving the turbine changes and flows against the rear side of the stator vanes in a clockwise direction Since the stator is now...

Page 507: ...is an indication of transmission fluid at normal operating temperature of 180 F This tempera ture is only obtained after at least 15 miles of expressway driving or equivalent of city driving 1 With m...

Page 508: ...d which occurs as transmission tempera tures rise to normal operating temperature of 180 F FLUID LEVEL INDICATOR The fluid level indicator is located in the filler pipe at the right rear corner of the...

Page 509: ...nly on 30 Series models but will not start in the other positions For replacement refer to Section 12 of this manual DRAINING AND REFILLING TRANSMISSION Drain oil immediately after operation before it...

Page 510: ...emoval 1 Remove modulator assembly attaching screw and retainer 2 Remove modulator assembly from case Discard 0 ring seal 3 Remove modulator valve from case Installation Installation of the modulator...

Page 511: ...o its normal position support engine with jack and slide transmission rearward from engine and lower it away from vehicle CAUTION Use converter holding Tool J 5384 when lowering transmission or keep r...

Page 512: ...ng bolts not correctly torqued b Improperly installed or damaged pan gasket c Oil pan gasket mounting face not flat 2 REAR EXTENSION LEAK a Attaching bolts not correctly torqued b Rear seal assembly d...

Page 513: ...ut the presence of oil the modulator should not be changed 2 Atmospheric Leak Check Apply a liberal coating of soap bubble solution to the vacuum connector pipe seam the crimped upper to lower housing...

Page 514: ...5 Tire CE 200 L47 3 54 Axle 7 00 17 5 Tire Throttle Position 1 2 up 2 1 dn 2 3 up 3 2 dn 1 2 up 2 1 dn 2 3 up 3 2 dn Closed 5 0 7 5 6 9 4 5 11 4 14 7 12 3 9 3 6 5 9 6 8 9 5 3 14 7 19 0 15 9 12 1 Thru...

Page 515: ...Bearing Installer 2 J 1048 Gauge Plate 8 J 21169 Pilot Arbor Alignment Stud 3 J 1522 Pilot Bearing Driver 2 Plate Clutch 4 J 5824 Clutch Pilot Tool 9 J 7126 Release Lever Adjusting Tool 5 J 1448 Pilot...

Page 516: ...eal Installer 5 J 22246 Countergear Loading Tool 13 J 0936 Clutch Gear Bearing Remover 6 J 5778 Extension Housing Bushing Remover and Installer 14 J 0937 Clutch Gear Bearing Retainer Wrench 7 J 5154 E...

Page 517: ...r Bearing Remover Installer 9 4 J 22833 Front Bearing Retainer Seal Installer 10 5 J 22873 2nd Speed Bushing Installer 11 6 J 22875 3rd Speed Bushing Installer J 22830 Snap Ring Installer J 22874 1 Be...

Page 518: ...J 1614 Reverse Idler Gear Bushing Remover and Replacer 4 J 8107 TR 278 R Countershaft Rear Bearing Remover 12 J 1488 Rear Bearing Retainer O il Seal Driver 5 J 1126 Transmission Guide Pin Set 2 13 J...

Page 519: ...g Remover Plate Fig 5ST 5 Speed New Process 3 J 8108 K 342 Clutch Gear Bearing 6 Replacer 7 4 J 0358 Press Plate Holder 8 5 J 6382 Reverse Idler Shaft Remover J 6416 Rear Bearing Retainer Seal Install...

Page 520: ...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 6 419 Bearing Installer 6 J 0996 J 996 Bearing...

Page 521: ...CLUTCHES AND TRANSMISSIONS 7 58 Fig 7ST 5 Speed Clark 1 J 161 9 Mainshaft Bearing Remover 2 J 6382 Reverse Idler Gear Shaft Remover 3 J 6419 Bearing Installer Set CHEVROLET TRUCK SERVICE MANUAL...

Page 522: ...utch Drum Bushing Remover and Installer J 8001 10 J 7782 Clutch Spring Compressor Adapter Plate J 5492 11 J 5133 Clutch Spring Compressor J 6585 12 J 4599 Planet Pinion Assembly Tool Set 13 J 9542 Rev...

Page 523: ...r Bolts 3 8 16 Threads 24 J 2 1 465 6 9 J 5590 Speedo Gear Installer 25 J 2 1 465 15 10 J 21867 Pressure Gauge and Hose 26 J 2 1 465 16 11 J 2 1 370 6 Rear Band Apply Fixture 27 J 2 1 465 9 12 J 21370...

Page 524: ...ear Remover 11 J 21664 Clutch Spring Compressor Adapter Ring 4 J 9539 Slide Hammer Bolts 3 8 16 Threads 12 J 4670 Clutch Spring Compressor 5 J 8105 Speedo Gear Remover Puller 13 J 8059 Snap Ring Plier...

Page 525: ......

Page 526: ...6 Fuel tank filler caps and neck assemblies conform to the latest SAE Standards for filler caps and related filler neck cams These units are interchangeable with 1967 models for service replacement U...

Page 527: ...ean strainer with compressed air as required 5 Install gauge unit using reverse of removal procedure FUEL TANK Cab Mounted Tanks Fig 2 Removal and Installation 1 Remove seat back hinge hold down wing...

Page 528: ...1 Ton Chassis Frame Mounted Tanks Fig 4 Removal and Installation 1 Drain tank 2 Remove filler neck 3 Disconnect gauge unit fuel line and wiring Ignition switch must be in OFF position 4 Remove bolts a...

Page 529: ...neck assemblies Remove the filler neck from the vehicle Installation 1 Position the filler neck to the body panel and connect the filler neck and vent hoses to the filler neck and tank assemblies 2 Ti...

Page 530: ...series vehicles The fuel filter element should be replaced at the recom mended mileage intervals outlined in Section 0 this manual Typical installation is shown in Figures 7 and 8 FUEL LINE RETAINER...

Page 531: ...FUEL TANK AND EXHAUST SYSTEMS 8 6 Fig 8 Single Fuel Filter System CD 50 60 Shown as Typical CHEVROLET TRUCK SERVICE MANUAL...

Page 532: ...e exhaust gases All 1968 1 2 tons plus people carrying 3 4 tons incorporate stain less steel exhaust systems Always use the correct replacement parts when servicing these systems When installing a new...

Page 533: ...FUEL TANK AND EXHAUST SYSTEMS 8 8 SPECIAL TOOLS 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 534: ...0 30 series units have an adjustable tie rod connected to the steering arm at each wheel Steering effort is trans mitted to the tie rods through a relay rod connected to the pitman arm on the left and...

Page 535: ...ber of turns Then turn wheel back exactly half way to center position Turn lash adjuster screw clockwise to take out all lash in gear teeth and tighten locknut Check torque at steering Fig 2 Removing...

Page 536: ...0 3 0 Lower Bearing Adjustment NOTE On 10 20 and 30 Series trucks check distance from top edge of washer to lower edge of bearing fig 6 3 Tighten clamp bolt Shifter Tube Adjustment 3 Speed Transmissi...

Page 537: ...directional signal switch attaching screws 5 Guide directional wiring while pulling out directional signal switch and bearing assembly 6 Remove bearing Installation 1 Replace all component parts in r...

Page 538: ...haft Models with Splined Slip Joint Fig 10 Removal and Installation Remove and install as outlined under Steering Coupling Universal Joint Type Disassembly 1 With shaft on bench straighten tangs on du...

Page 539: ...ip mast jacket over steering shaft and attach mast jacket clamp and transmission lever housing to steering gear 2 Position steering gear in frame rail and attach mast jacket bracket to support leaving...

Page 540: ...ver support housing drive out selector lever pivot pin and re move shift lever Fig 14 Light Duty Mast Jacket Mounting 2 Remove steering wheel retaining nut and washer from shaft 3 Slide steering shaft...

Page 541: ...ing 11 Install directional signal switch and housing assem bly feeding wires through gear shift lever support housing Secure with three attaching screws 12 Adjust shifter tube as outlined under Shifte...

Page 542: ...d using same procedure as described in Step 2 To remove tie rod ends from tie rod loosen clamp bolts and unscrew end assemblies Installation 1 If the tie rod ends were removed lubricate the tie rod th...

Page 543: ...n frame and install mounting bolts with special plain washers under heads tight ening nuts to specifications 2 Install relay rod to idler arm making certain seal is on stud and install and tighten nut...

Page 544: ...If through collision or other damage it becomes Fig 22 Ball Stud Removal Typical necessary to remove and replace either steering arm proceed as follows Removal 1 Remove tie rod and on models so equipp...

Page 545: ...d 60 Series Fig 23 Sector lash adjustment is the only power steering gear adjustment that can be made on the vehicle However in order to make this adjustment it is also necessary to check the combined...

Page 546: ...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 indicated by Tool J 7316 fig 24 3 Tighten pump brace...

Page 547: ...oses are discon nected secure ends in raised position to prevent drainage of oil Cap or tape the ends of the hoses to prevent entrance of dirt 2 Install two caps at pump fittings to prevent drainage o...

Page 548: ...rom bracket if replacement parts are required b Remove cotter pin nut and ball stud at relay rod 40 50 60 Series Except 9 000 lb and 11 000 lb Front Axles a Loosen dust covers from ball joints at each...

Page 549: ...STEERING 9 16 KA 10 20 CE ME SE 50 CE SE 60 Fig 29 Typical Power Steering Hose Routing CHEVROLET TRUCK SERVICE MANUAL...

Page 550: ...nap Ring Remover 12 J 2927 A Steering Wheel Puller 13 J 5178 Puller Gauge 14 J 6632 Pitman Arm Puller 15 J 5176 Checking Gauge with J 5900 Adapter Kit 16 J 2619 Slide Hammer 17 J 2619 4 Slide Hammer A...

Page 551: ......

Page 552: ...esl 16 inch or less as indicated by the bands there is a significant decrease in traction and anti skid properties also the majority of tire troubles will occur in the last 10 of tire life TREAD TREAD...

Page 553: ...1610 1720 1830 1940 2040 7 00 16 6 1560 1680 1800 7 00 16 8 1560 1680 1800 1910 2030 2130 7 10 15 6 1440 1560 1670 7 50 15 8 1710 1840 1980 2100 2220 2330 7 50 16 6 1770 1930 2060 7 50 16 8 1770 1930...

Page 554: ...r light trucks shall be based on meeting the requirements of tire load conditions NOTE 2 Underscoring denotes maximum permissible loads Minimum recommended cold inflation pressures for various loads m...

Page 555: ...1195 1310 1415 1520 8 00 16 5 8 1195 1310 1415 1520 1620 1710 1800 8 00 16 5 10 1195 1310 1415 1520 1620 1710 1800 1885 1970 2050 8 75 16 5 4 1380 8 75 16 5 6 1380 1515 1630 1750 8 75 16 5 8 1380 1515...

Page 556: ...1 00 20 12 4630 4900 5150 5400 5640 5870 11 00 20 14 4630 4900 5150 5400 5640 5870 6090 6320 6530 11 00 22 12 4920 5220 5480 5760 6010 6250 11 00 22 14 4920 5220 5480 5760 6010 6250 6480 6730 6950 11...

Page 557: ...of tire sizes for trucks and busses shall be based on meeting the requirements of tire load conditions Note 2 Underscoring denotes maximum permissible loads Minimum recommended cold inflation pressure...

Page 558: ...0 1760 1870 1980 2080 2180 8 19 5 6 1830 1960 2090 8 19 5 8 1830 1960 2090 2220 2330 2440 2550 2650 2750 8 22 5 8 2060 2210 2350 2490 2620 2740 8 22 5 10 2060 2210 2350 2490 2620 2740 2860 2980 3090 9...

Page 559: ...hours or more or driven less than one 1 mile Hot tire inflation pressure after vehicle has been driven ten 10 miles or more at 60 70 MPH 4 Vehicles with luggage racks do not have a vehicle load limit...

Page 560: ...h case consists of locating the mechanical defect and correcting it Cornering Wear When a truck makes an extremely fast turn the weight is shifted from an even loading on all wheels to an abnormal loa...

Page 561: ...a heavy side like this is statically out of balance Static unbalance of a wheel causes a hopping or pounding action up and down which frequently leads to wheel flutter and quite often to wheel tramp D...

Page 562: ...lean Remove any oxidized rubber dried soap solution rust heavy paint etc with a wire brush or in extreme cases a file 2 Lubricate tire beads rim flanges and bead ledge areas with a liberal amount of t...

Page 563: ...tter with the tire iron moving pro gressively around the rim fig 7 4 Drive the curved end of the tire iron in between the side ring and the tire bead fig 8 Then pry down on the opposite end of tire ir...

Page 564: ...im of the spare or new wheel for tire installation stand the wheel up with the operating notch in the side ring at the top The straight end of a tire iron is inserted and driven into the operating not...

Page 565: ...ide ring are positioned so as to span the rim gutter 7 At point C opposite valve force ring into rim gut ter as far as possible 8 Insert straight end of tire iron into operating notch B fig 18 Then pu...

Page 566: ...rim flanges Ru Glyde or equivalent in addition to materially assisting in mounting and demounting also prevents rust ing at the tire sealing area and thus prevents tires from adhering to the wheel De...

Page 567: ...ry second bead off fig 23 Mounting all except 7 75 15 and 6 50 16 tires All tubeless tires except the 7 75 15 and 6 50 16 sizes will be mounted as follows 1 Inspect rim to insure bead seats are clean...

Page 568: ...Fig 26 Working Second Bead onto Rim 3 Start tire beads into the rim bead seats as follows If a tire mounting machine is being used lift the tire high in the rim forcing the top tire bead against the t...

Page 569: ...side of the ring is fitting into the rim gutter Do not bend the ring 3 Now a second tool can be inserted and used with the first to walk the tools in a counterclockwise direction from the tool notch...

Page 570: ...during inflation Fig 31 Applying Second Bead Fig 32 Forcing Ring into Gutter Insure that tire is completely deflated prior to removal of rings Mounting 1 Place tire on rim so that valve is in line wi...

Page 571: ...fig 33 Progress around rim using 2 tools as shown To remove ring insert tool in notch and force ring opposite of notch into gutter then pry off fig 34 Pry out and up on side ring carefully but firmly...

Page 572: ...Assembly Hood Hinge Spring Replacem ent Hood Hinge Hood Lock Assembly A d ju stm en t Hood Assembly Removal and Installation INDEX Page 11 3 11 3 11 3 11 3 11 3 11 3 11 4 Hood Assembly Alignment Front...

Page 573: ...odels have been redesigned for 1968 to provide engine access from either the front or from inside of the vehicle See Section IB The following pages contain servicing information for removal assembly a...

Page 574: ...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 explained in preceding write up...

Page 575: ...ow 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 as out...

Page 576: ...l exten sion mounting 12 With a helper remove front sheet metal assembly with radiator battery horn and voltage regulator Installation 1 With a helper place sheet metal assembly in position NOTE Insta...

Page 577: ...heet metal assembly 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 combi...

Page 578: ...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 14...

Page 579: ...n 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 and attach loosely 13 Att...

Page 580: ...ecure cowl grille 30 Install windshield wiper arm assemblies FRONT FENDER 10 thru 30 Series 9 Remove bolt and shim attaching to trailing edge of fender to hinge pillar 10 Remove two bolts and shims at...

Page 581: ...ment 11 Remove 3 bolts fastening gusset to fender and grille fig 13 12 Remove two bolts fastening gusset to fender 13 Remove all electrical connections Installation To install reverse the removal proc...

Page 582: ...5 Remove 6 screws holding skirt to fender opening flange 6 Remove screw attaching skirt to radiator grille 7 Underneath the skirt inboard remove a large bolt fastened through the fender skirt to the...

Page 583: ...CHASSIS SHEET METAL 11 12 Fig 20 Designation and Name Plate CHEVROLET TRUCK SERVICE MANUAL...

Page 584: ...torqued sufficiently to eliminate rattles or wind vibration ENGINE COMPARTMENT COVER ASSEMBLY Fig 23 Removal 1 Disengage the clamp at the front of the cover and re move the nut washers and bolt from t...

Page 585: ...CHASSIS SHEET METAL 11 14 SPECIAL TOOLS Fig 24 J 5544 1 Hood Spring Remover CHEVROLET TRUCK SERVICE MANUAL...

Page 586: ...ng diagrams are included at the end of this section The standardized color code is common to all wiring harnesses The wire covering color designates a particular circuit usage MAINTENANCE AND ADJUSTME...

Page 587: ...ELECTRICAL BODY AND CHASSIS 12 2 Fig 1 Fuse Panel CHEVROLET TRUCK SERVICE MANUAL...

Page 588: ...crossarms HORIZONTAL ADJUSTMENT 7 a Turn horizontal aiming screw Figure 4 on left hand lamp until the string is positioned over the crossarm centerline Turn the screw clockwise in making the final adj...

Page 589: ...the tires are in the spots made on the floor before the car was moved 5 If the bubbles are still within the two outside black marks on the vials the floor is level enough to use the Aimer as it comes...

Page 590: ...s and disengage assembly from grille or panel opening 3 Disconnect parking lamp wiring from forward wiring harness 4 Connect wiring of new unit to vehicle harness 5 Position lamp housing in grille or...

Page 591: ...ELECTRICAL BODY AND CHASSIS 12 6 CA SA MA 50 60 CHEVY VAN Fig 9 Front Lighting Assemblies CHEVROLET TRUCK SERVICE MANUAL...

Page 592: ...ELECTRICAL BODY AND CHASSIS 12 7 V I E W A S U B U R B A N A N D PANELS ALL OTHERS Fig 10 Clearance and Identification Lamps CHEVROLET TRUCK SERVICE MANUAL...

Page 593: ...ELECTRICAL BODY AND CHASSIS 12 8 CHEVY VAN SUBURBAN CA KA 10 20 CA 31 04 34 CA 30 03 12 MARKER LAMP CA 20 30 40 09 F F COWLS Fig 11 Rear Lighting Composite CHEVROLET TRUCK SERVICE MANUAL...

Page 594: ...g 12 Light Switch Chevy Van Fig 13 Stop Lamp Switch Chevy Van tact should be made when pedal is depressed 3 8 to 5 8 from fully released position DIMMER SWITCH REPLACEMENT 1 Fold back upper left corne...

Page 595: ...tch Located on Mast Jacket 1 Disconect wiring at switch terminals 2 Remove switch attaching screws and switch from mast jacket 3 Position replacement switch to mast jacket install retaining screws and...

Page 596: ...ELECTRICAL BODY AND CHASSIS 12 11 Fig 15 Electrical Components Conv Cab CHEVROLET TRUCK SERVICE MANUAL...

Page 597: ...Unit Replacement 12 16 Oil Pressure Indicator L ig h t 12 16 Oil Pressure Gauge Replacement 12 16 Oil Pressure Sender Unit Replacement 12 17 Generator Indicator 12 17 Ammeter Gauge Replacement 12 17...

Page 598: ...0 30 Conventional Cab Models Fig 18 1 Disconnect battery ground cable 2 Remove choke control knob 3 Remove windshield wiper knob and bezel nut 4 Remove light switch rod and bezel 5 Disconnect speedome...

Page 599: ...Disconnect all indicator and illuminating bulb sock ets carefully noting their location for proper re installation Remove cluster 5 To install reverse removal procedure Tilt Cab Models Fig 20 1 Disco...

Page 600: ...Cowl Models 1 Disconnect battery ground cable 2 Disconnect speedometer cable and all indicator and illuminating sockets 3 Remove three screws attaching speedometer housing to dash panel 4 Pull speedom...

Page 601: ...uge unit 3 Remove three attaching screws cover and gauge as sembly from cluster housing 4 Remove terminal attaching nuts and gauge unit from cover plate 5 To install reverse removal procedure and chec...

Page 602: ...ls Ignition on engine not running and telltale light off 1 Indicator bulb burned out replace bulb 2 Open circuit or loose connection in the telltale light circuit Telltale light stays on after engine...

Page 603: ...ay 9 To Backing Lamp Switch 3 To Light Switch 10 To Stop Lamp Switch 4 To Wiper Switch 11 To Dome Lamp Conn 5 To Directional Switch 12 Dimmer Switch 6 To Wiper Motor 13 To Instrument Cluster Conn 7 Ig...

Page 604: ...To Ignition Switch 2 Horn Relay 9 Bulkhead Connector 3 To Light Switch 10 To Stop Lamp Switch 4 To Wiper Switch 11 Air Brake Buzzer 5 To Directional Switch 12 Dome Lamp Conn 6 Instr Cluster Connector...

Page 605: ...p Lamp Switch 3 Hi Beam Lamp 4 Cluster Lamp 5 Brake Warning Lamp 6 Bulkhead Conn 7 Directional Signal Conn 8 Fuel Gauge Conn 9 Ignition Switch 10 To Temp Gauge 11 R H Turn Ind 12 To Ammeter 13 L H Tur...

Page 606: ...il Pressure Ind 8 L H Turn Ind 2 Temperature Ind 9 R H Turn Ind 3 Cluster Lamp 10 Generator Ind 4 Wiper Switch 11 Ignition Switch 5 Light Switch Conn 12 To Directional Signal Switch 6 To Heater Switc...

Page 607: ...ted Circuit 3 Instr Cluster Lamp 4 Temperature Ind 5 Brake Warning Ind 6 Generator Ind 7 R H Directional 8 L H Directional 9 O il Pressure Ind 10 High Beam Ind 11 Overspeed Warning Low Vacuum 12 Gener...

Page 608: ...pin and shift lever if ap plicable 4 Remove directional signal lever retaining screw and lever 5 Push in hazard warning knob NOTE Hazard switch knob must be pushed in to prevent damage to switch when...

Page 609: ...g Screw 3 S w itch M o unting Screw 4 Sw itch 9 2 6 D re c tio n a l S ig n a l A sse m b ly C o n v e n tio n a l C a b and P Series 5 U pper Bearing 6 B earing Support 7 Sw itch C o v e r 8 Leve r...

Page 610: ...SSIS 12 25 Fig 27 Directional Signal Assembly Chevy Van 1 Cancelling Cam 3 Switch Mounting Screw 6 Switch Cover 2 Lever Screw 4 Directional Switch 7 Directional Lever 5 Upper Bearing Assembly CHEVROLE...

Page 611: ...r ELECTRICAL BODY AND CHASSIS 12 26 9 CHEVROLET TRUCK SERVICE MANUAL...

Page 612: ...s when the wiper is operated this with three or four terminals For service replacement rotor is always turning with the gear Programming is a four terminal assembly is used servicing both the accompli...

Page 613: ...grease before reassembly 5 Drill out gear box cover retaining rivets remove cover from gear train Fig 31 Windshield Wiper Assy Tilt Cab 1 Crown Nut 2 Lock Washer 3 Wiper Arm Assembly 4 Knurled Driver...

Page 614: ...t Plug 17 Frame and Field 18 End Plate 19 Tie Bolts Two Required 4 Remove end play adjusting washers from armature noting arrangement for proper reinstallation WIPER MOTOR INSPECTION Check and inspect...

Page 615: ...l crank arm on output shaft rotate crank so alignment marks line up with those on cover fig 34 3 Replace retaining nut place crank arm in vise tighten retaining nut WINDSHIELD WASHER PUMP Removal and...

Page 616: ...llows a To remove bellows first remove valve assembly b Manually operate pump clockwise to release pump from lock out position fig 38 c Hold bellows plunger arm from moving then push in against bottom...

Page 617: ...R RESISTOR 12 DG BRAKE FLUID WARNING SWITCH 12 R 18 T L H PARK DIR SIG LP 18 W 18 OR STOP LP SW 18 W 20 DBL 12 DG 18 T 18 OR 16 LG 18 T 18 BRN 18 BRN 20 LBL 20 LG 14 LB L 16 LG 18 T 12 R 12 DG 20 B 14...

Page 618: ...BODY A N D CHASSIS 12 33 18 W 20 DBL 12 DG 18 T J S gc OBJm o o m 18 DG 12 PPL 20 DG 16 BRN 20 DBL 12 R 12 P 18 LG 10BRN 18 W 18 DG 18 Y 14 LBL 14 LBL Fig 40 Fuse Panel G A 10 20 CHEVROLET TRUCK SERV...

Page 619: ...ELECTRICAL BODY A N D CHASSIS 12 34 18 DG 18 DG HQ CLSTR LGT y C Q GEN LGT G 0 RH TURN IND C Q BRK WRN LGT CLSTR LGT 18 Y 0 Fig 41 Instrument Panel G A 10 20 CHEVROLET TRUCK SERVICE MANUAL...

Page 620: ...2 R 20 W OR P P L CR TR 12 P GS ONLY 18 LG FUSIBLE LINK 16 BLK JUNCTION BLOCK NEU SAF BACK UP LP SW RPO M35 18 DG V 12 PPL t 18 DG DBL W J 12 PPL t f 20BR 20DG R H TAIL STOP DIR SIG LAMP 20LG R H BACK...

Page 621: ...La V PPL N E U SF T SW R P O M35 L r wriM j E X C E P T R PO M35 W ITH R P O M35 1 2 P P L 12PPL 20W OR PP 18B W H FU SE b 1 p 12R S H U N T l8 B A M M E T E R RESISTOR FUSE T E M P GAGE A M M E T E...

Page 622: ...ELECTRICAL BODY A N D CHASSIS 12 37 IGNITION SWITCH Fig 44 Engine Compartment PA20 30 CHEVROLET TRUCK SERVICE MANUAL...

Page 623: ...ELECTRICAL BODY A N D CHASSIS 12 38 Fig 45 Engine Compartment PS40 CHEVROLET TRUCK SERVICE MANUAL...

Page 624: ...ELECTRICAL BODY A N D CHASSIS 12 39 JUNCTION BLOCK LEFT FRONT MARKER LP iiim iii jiilliiiirirl 300 09 ONLY Fig 46 Eng ne Compartment C S K S 10 20 CS30 CHEVROLET TRUCK SERVICE MANUAL...

Page 625: ...STOP LP HARN CONN 12PPL 4 5 L 6 EMG 20DG TEMP SW 2QW OR PPL CR TR BACKING LP SW CS 300 CS 100 200 W RPO M20 28 P 18DG 1 8 L G 12PPL O A C Ik GEN i 12B 1S TI 12R 18B 12R 12B 118B GEN FWD LP HARN CONN 2...

Page 626: ...ELECTRICAL BODY A N D CHASSIS 12 41 JUNCTION BLOCK RIGHT FRONT MARKER LP 300 09 ONLY Fig 48 Engine Compartment CE K E10 20 CE30 Exc 02 CHEVROLET TRUCK SERVICE MANUAL...

Page 627: ...PANEL TAIL STOP LP HARN CONN 2QW OR PPL CR TR BACKING LAMP SW CE 300 CE 100 200 W RPO M20 28 18DG 18LG OP 12B A C S mI p GEN 0S J Id n _ _ _ 3 12R 12B GEN FWD LP HARN CONN 12PPL 20DG 18B 16LG J 20DBL...

Page 628: ...ELECTRICAL BODY A N D CHASSIS 12 43 FOR WIRE GAGE SEE CHASSIS TAIL LAMP WIRING SHEET Fig 50 Engine Compartment CS40 50 60 MS50 02 03 09 CHEVROLET TRUCK SERVICE MANUAL...

Page 629: ...ICAL BODY A N D CHASSIS 12 44 JUNCTION BLOCK FOR WIRE GAGE SEE CHASSIS TAIL LAMP WIRING SHEET DIFF LKOUT W1RE ME 600 03 Fig 51 Engine Compartment CE40 50 60 M E50 60 02 03 09 CHEVROLET TRUCK SERVICE M...

Page 630: ...ELECTRICAL BODY A N D CHASSIS 12 45 A a Z U 18B C V V V C T I O JUNCTION BLOCK FOR WIRE GAGE SEE CHASSIS TAIL LAMP WIRING SHEET Fig 52 Engine Compartment CS60 13 CHEVROLET TRUCK SERVICE MANUAL...

Page 631: ...ArC M R Jla ____3 10R 20W OR PPL y OVER SPEED VACUUM SW 327 366 427 ENG DIFF LKOUT LP SW 18B 12PPL j 12 PP L 4 NEU SFTY SW CONN RPO M45 18LG 18DG BACKING LP SW 12PPL 20DBL N GEN FWD LP 2 DG HARN CONN...

Page 632: ...ELECTRICAL BODY A N D CHASSIS 12 47 JU N C T IO N B L O C K A FOR WIRE GAGE SEE CHASSIS TAIL LAMP WIRING SHEET Fig 54 Engine Compartment SS40 50 CHEVROLET TRUCK SERVICE MANUAL...

Page 633: ...ELECTRICAi BODY A N D CHASSIS 12 48 Fig 55 Engine Compartment SE50 60 02 62 CHEVROLET TRUCK SERVICE MANUAL...

Page 634: ...YJ ELECTRICAL CHASi V 49 4 Fig 56 Engine Compartment C D C G CD60 CHEVROLET TRUCK SERVICE MANUAL...

Page 635: ...fc ELECTft CAL BODY J d V jHASSIS 12 50 M6BRN M y 16BRN 18BRN 1 TAIL STOP DIRECTION LP CONN Fig 57 Chassis Engine Harnesses TS40 50 60 CHEVROLET TRUCK SERVICE MANUAL...

Page 636: ...ELECTRICA L B O D Y A N D CHASSIS 12 51 O S SW 327 366 427 ENG TAIL STOP DIRECTION LP CONN 20DG Fig 58 Chassis Engine Harnesses TE40 50 60 CHEVROLET TRUCK SERVICE MANUAL...

Page 637: ...FRAME 00 STRAP DIESEL ENG V 03 MODELS ONLY aoB LA C GEN 1 B 16DBL lew 10R SOB 10BRN V A C 8 W 03 MOD y O N LY 16DG 16Y 16BRN 1 6 L G 03 MODELS ONLY 20DG BACKING L P SW 00B 09 MODELS ONLY BATTERY FRAM...

Page 638: ...ELECTRICAL BODY A N D CHASSIS 12 53 NTROL 18BRN FRONT MARKER LPS 300 09 ONLY DOME L P CONN 18BRN Fig 60 Instrument Panel C A K A 10 20 CA30 03 04 09 34 CHEVROLET TRUCK SERVICE MANUAL...

Page 639: ...R N 20T b l k h d CONN T 18B 20DG 20T JOT 20DI m j 20P 20BRN 20LG 20LBL 20DBL 20GY S CLUSTER CONN 18LBL 18DBL 18B 16BRN FRONT MARKER L P CONN 300 09 ONLY ROOF MARKER L P CONN 300 09 ONLY 18BRN 18G Y 1...

Page 640: ...W 18DG V 12DG 12R 20LG 1 6 L G 18BRN iOLBL 20DBL 18BRN 18G Y 18DG 18LG 18T VOUTSIDE F U E L TANK I E 20 T 12BRN 12P 12PPL 12R 20B 18DG 12P 12P j 12P i 18DG 16BRN 18T 16GY 20Ts 16DG 160R 2OP f lBPPlr...

Page 641: ...0GY V 20GY 20P 20T 20P 160R 18BRN 18BRN 16DG 12R BLKHD CONN 20GY 20LG 20DBL 20GY 20GY Ifeo 20B W 20B 20LBL 20P 20T 20P 20DG 20GY FWD CLUSTER L P HIGH BEAM IND LP R H DIR SIG L P CLUSTER LP HYD BRK W A...

Page 642: ...ELECTRICAL BODY A N D CHASSIS 12 57 TAIL STOP LAM P HARNESS CONNECTOR Fig 64 lnsfrumenf Panel C A K A 10 20 05 06 16 CHEVROLET TRUCK SERVICE MANUAL...

Page 643: ...ED 20P TEM P GA LP 20DG BRAKE W ARN LP 20T R H DIR SIG L P 20DBL OIL PRESS L P 20DBL L H DIR SIG L P 20LBL C L U S T E R LP 20GY H L BEAM IND LP 20LG C L U S T E R LP 20GY LIGHT SW INSTRUMENT CLUSTER...

Page 644: ...SIS 12 59 OVERSPEED VACUUM SW 327 366 427 ENG I W S WASHER W IPER MTR FOR WIRE GAGE SEE CHASSIS TA IL L A M P WIRING SHEET Fig 66 Instrument Panel CE CS40 CE CS M E M S50 CE CS M E60 Exc 02 J3 62 CHEV...

Page 645: ...HASSIS 12 60 B R N Y DG 18LG 160R 18W 18T BRN Y DG 18LG 160R 1 8 W FOR WIRE GAGE SEE CHASSIS TAIL LA M P WIRING SHEET Fig 67 lnstTumenl Panel CE C S40 CE CS M E M S50 CE C S M E60 Exc 02 13 62 CHEVROL...

Page 646: ...CHASSIS 12 61 R ELAY f 1 AIR BRld I EMER ___ 20T 14W SA MODELS ONLY 18LG CA MODELS O N LY FOR WIRE GAGE SEE CHASSIS TAIL LA M P WIRING SHEET Fig 68 Instrument Panel CA SA 40 50 60 02 SE60 62 CHEVROLET...

Page 647: ...L P AIR GA L P SE 600 62 OVER SPEED IND L P C E 8 E 5 0 0 600 INSTRUMENT CLUSTER LAM PS LIGHT SW 16BRN BRN Y DG 14LG 18T 18T BRN Y DG 14LG 14W SA MODELS O NLY 18LG CA MODELS O N LY FOR WIRE GAGE SEE...

Page 648: ...ELECTRICAL BODY A N D CHASSIS 12 63 FOR WIRE GAGE SEE CHASSIS TAIL LAM P WIRING SHEET Fig 70 Instrument Panel CE CS M E60 13 CHEVROLET TRUCK SERVICE MANUAL...

Page 649: ...m 20LBI 18B 18DG r 20B W EB f 20LG 20B CLUSTER CONN FWD CLUSTER LP 20G Y __FUEL GA 20T FUEL GA FEED 20P OVERSPEED WARN LP 20DBL 327 326 427 ENG DIFF LKOUT WARN LP ME 600 18DG CLUSTER LP 20GY R H DIR...

Page 650: ...ELECTRICAL BODY A N D CHASSIS 12 65 FOR WIRE GAGE SEE CHASSIS TAIL LA M P WIRING SHEET DIMMER SW Fig 72 lnstTument Panel C D C G 5 0 CD60 CHEVROLET TRUCK SERVICE MANUAL...

Page 651: ...G L G 180R 18W 20DG ig jir ji 18B E8I 20GY 81 20DBL 20LBL 20LG 20B INSTRUMENT CLUSTER CONN W S WASHER W IPER SW 18LBL 18DBL 18B FWD CLUSTER LP 20GY FUEL GA 20T F UE L GA FEED 0P LOW VAC W ARN L P 20B...

Page 652: ...ELECTRICAL BODY A N D CHASSIS 12 67 L H DIRECTION SIGNAL Fig 74 Instrument Panel TE TS40 50 60 Exc 13 CHEVROLET TRUCK SERVICE MANUAL...

Page 653: ...n R H W S U WIPER SW L H W S WASHER WIPER SW OVER SPEED IND LP TE MODELS ONLY FUEL GA DIRECTION SIG LP OIL PRESS IND LP CLUSTER LP CLUSTER LP HI BEAM IND LP 10DG Fig 75 Instrument Panel TE TS40 50 60...

Page 654: ...ELECTRICAL BODY A N D CHASSIS 12 69 R H DIRECTION SIGNAL L H DIRECTION SIGNAL 14LBL 10BRN 18DG 10P 10DG Fig 7 6 Instrument Panel TE60 13 CHEVROLET TRUCK SERVICE MANUAL...

Page 655: ...S 12 70 cf f f R H W S WIPER SW c fl T I l H W S WASHER U WIPER SW OVERSPEED IND LP FUEL a DIRECTION SIGNAL LP OIL PRESSURE LP CLUSTER LP CLUSTER LP HIGH BEAM IND LP Fig 77 Instrument Panel TE60 13 CH...

Page 656: ...ELECTRICAL BODY A N D CHASSIS 12 71 R H FRONT R H DIRECTION SIGNAL L H DIRECTION SIGNAL rid f L H 0NT U MARKER LP Fig 78 Instrument Panel TD50 60 TG50 CHEVROLET TRUCK SERVICE MANUAL...

Page 657: ...D CHASSIS 12 72 18LBL 18B 18LBL 18B R H W S WASHER 1 J W IPER SW L H W S WASHER b W IPER SW VAC WARN L P DIRECTION SIG LP OIL PRESS GA L P 10DG 20DG Fig 79 lnstrumenJ Panel TD50 60 TG50 03 CHEVROLET T...

Page 658: ...ICAL BODY A N D CHASSIS 12 73 R H W S WASHER WIPER SW L H W S WASHER WIPER SW OIL PRESS GA LP DIRECTION SIG LP GEN LP TELL TALE AIR PRESS GA LP Fig 80 Instrument Panel TD60 13 CHEVROLET TRUCK SERVICE...

Page 659: ...200 CA 300 R H DIRECTION b TA IL LAM P OUTSIDE FUE L TAN K M IT E R 02 62 MDL6 18GA 100 200 300 16GA 400 500 600 F O R WIRE GAGE SEE CHART ABOVE SA 000_ ONLY 180R 18W 1 19288 X Z DOME LA M P EXC 01 IN...

Page 660: ...IL STOP DIR SIG LAM P R H BKNG LAM P IOOR 10W DOME LA M P 18 OR 180R 18BRN 18T 18Y 18DG 18W 18LG 1 W FLO O R GROMMET L H BKNG LAM P L H TAIL STOP D R SIG LAM P 18BRN Fig 82 Tail Stop Lamp C A K A I0 2...

Page 661: ...16 CA 400 09 18 CA 300 09 R H SIDE MARKER L P CENTER MARKER LP FOR WIRE GAGE SEE CHART ABOVE 1flARK Cs I L H DIRECTION TAIL LP I L H CORNER MARKER LP V 18BRN 18B fli L H SIDE MARKER LP Fig 83 Tail St...

Page 662: ...L GAGE CONN 18T 18Y 16BRN 18BRN 18LG 16LG 18DG DIRECTION TAIL STOP LP CONN 18BRN 16DG R H DIRECTION TAIL t 8TOP LP 18LG R H BACKING LAMP 18BRN LICENSE LP FUSE 1 LG 18BRN L H BACKING LAMP 18BRN L H DIR...

Page 663: ......

Page 664: ...35 13 4 Page Service Operations 40 thru 60 S e r ie s 13 4 CA40 CE CS MA SA50 60 M o d e ls 13 4 CD CG50 CD60 M o d e ls 13 4 PA40 M o d e ls 13 4 TA M o d e ls 13 5 SERVICE OPERATIONS 10 THRU 30 SER...

Page 665: ...olant line fill cooling system and check for leaks 5 Refer to torque specifications in rear of manual for correct torque values PT20 30 MODELS Fig 4 Radiator Replacement 1 Drain radiator and disconnec...

Page 666: ...ission coolant line if so equipped 5 Remove lower shroud screws 6 Remove bolts securing radiator support to frame and lower radiator and support from vehicle Fig 5 A ir Deflector and Engine Splash Shi...

Page 667: ...mission coolant line if so equipped 2 If vehicle is equipped with a fan shroud remove shroud attaching screws fig 8 and carefully hang shroud over engine fan assembly to provide clearance for radiato...

Page 668: ...tor and Shroud Mounting PA40 Models and transmission coolant line fill cooling system and check for leaks 6 Refer to torque specifications in rear of manual for correct torque values TA MODELS Figs 13...

Page 669: ...5 Remove radiator and support assembly from the vehicle as a unit Remove fan shroud 6 Replace radiator supports and mounting components as necessary 7 Install shroud and radiator following the remova...

Page 670: ...bottom of center support to radiator support 6 Unplug parking lamps from receptacles at radiator support 7 Remove screws four from each side securing grille assembly to fenders and frame and remove g...

Page 671: ...mouldings catch plate and other grille and mounting components as required Installation Assemble and install grille and related components following the removal procedure in reverse order Refer to to...

Page 672: ...s and braces to bumper face bar Installation Assemble and install front bumper following the re moval procedure in reverse order Refer to torque specifications in rear of manual for correct torque val...

Page 673: ...for correct torque values REAR BUMPER G MODELS Fig 5 Removal 1 Remove screws attaching left and right bumper Fig 5 Rear Bumper G Models braces to frame extensions 2 Remove bolts securing face bar to...

Page 674: ...ications in rear of manual for correct torque values FRONT BUMPER T MODELS Fig 7 Removal NOTE On tilt cab models equipped with air brakes the air reservoir tank mounted inside the front bumper must be...

Page 675: ...RIPTION The Cruise Master is a speed control system which adjustment is necessary by receiving a varying amount employs engine manifold vacuum to power the throttle of bleed air from the Regulator uni...

Page 676: ...located at the end of the turn signal lever Brake and clutch release switches are provided Electric switches disengage the Regulator unit The operation of each unit of the system and the op eration of...

Page 677: ...other is connected to a variable air bleed in the Regulator Unit The vacuum port is located at the center of the unit and the air bleed port is near the outer wall When vacuum is applied to the center...

Page 678: ...is a device which has two primary functions First it is a vacuum switch which when en gaged by the driver supplies engine manifold vacuum to the Servo Second it meters a small variable quantity of ai...

Page 679: ...the rubber drum is a U shaped spring clip which is held spread away from the drum by the nose or cam of the solenoid when the solenoid is in the relaxed position The rubber drum and this clip com pri...

Page 680: ...al wire to the solenoid coil This current is not sufficient to pull in the solenoid 3 Driver partially presses Engagement Switch full voltage flows through the solenoid to pull it into operation Solen...

Page 681: ...at the time of engagement BRAKE RELEASE SWITCHES ELECTRIC Service An inoperative switch must be replaced Switch sembly then rotates to a new position because of the higher car speed When the solenoid...

Page 682: ...switch Figure 7 ENGAGEMENT SWITCH Service The engagement is serviced only by replacement Removal 1 Disconnect battery ground cable 2 Pry the engagement button out of the turn signal knob with a small...

Page 683: ...ed During replacement check the hoses which connect to the regu lator and replace any which are cracked or deteriorated Air Filter The air filter located in the solenoid cover should be replaced every...

Page 684: ...nce of the brown white stripe wire from point C to D It should measure 40 ohms 2 ohms If a resistance either above or below the value indicated is shown the main wiring harness should be replaced Note...

Page 685: ...Vacuum Switch mis adjusted or defective Adjust or replace as required Refer to Servo and Vacuum System Check Out and Electrical Check Out Red wires which should be connected to the pedal switch es con...

Page 686: ...w...

Page 687: ...Volts 14 Amps Cold 20 Max RPM C old 4000 Refrigerant 1 2 3 lbs 4 oz 525 Viscosity Compressor O il 10 fluid oz Torque Specifications Compressor Suction and Discharge Connector Bolt 20 ft lbs Rear Head...

Page 688: ...0 C30 3500 P20 30 4000 G10 2200 G20 3000 K10 3300 K20 3500 C40 4000 P40 4000 S40 4500 5000 or 5500 5000 7000 9000 1100 King Pin Inclination 7 1 4 5 3 4 Camber See Chart Fig 9 Sec 3 1 1 2 Curb Caster 3...

Page 689: ...int Studs Upper 70 120 Ball Joint Studs Lower 120 215 Stabilizer Bar Control Arm Bracket 25 25 Stabilizer Bar Bracket 25 25 20 Suspension Crossmember 65 100 Shock Absorber Upper Eye 140 140 75 75 80 8...

Page 690: ...s Ft Slight Preloaded Barrel Roller 11 000 and 13 500 75 100 Lbs Ft 1 8 250 Lbs Ft Slight Preloaded Barrel Roller 15 000 and 28 000 Single Speed With 15x4 Brakes 75 100 Lbs Ft 1 8 250 Lbs Ft Slight Pr...

Page 691: ...5 65 155 155 10 70 70 155 10 Spring Rear Shackel Bolts 50 50 155 155 5 5 Shock Absorber Attaching Bolts 75 75 75 75 65 65 65 120 Universal Joint Rear 15 15 15 20 15 20 20 20 20 20 20 Intermediant Shaf...

Page 692: ...olt Torques Ft Lbs Carrier Cover 20 20 20 20 20 20 45 45 80 80 Ring Gear 50 110 n o 110 105 110 160 160 90 140 140 90 90 Differential Bearing Caps 55 80 100 100 205 205 205 205 LH 230 RH 160 210 LH 35...

Page 693: ...12 3 25 3 76 Compression Ratio 8 5 1 8 1 8 25 1 9 0 1 8 1 8 5 1 8 1 9 1 8 1 F irin g Order 1 5 3 6 2 4 1 8 4 3 6 5 7 2 CYLINDER BORE Diam eter 3 8745 3 8775 3 9995 4 0025 3 9365 3 9395 4 0925 4 0995...

Page 694: ...030 Service Hi Limit Production 001 Gap Production Top 010 020 2nd 010 020 013 025 010 020 010 020 010 020 3rd 010 020 010 020 010 020 Service Hi Limit Production 01 0 1 L Groove Clearance Production...

Page 695: ...02 Max Service 001 Max Main Bearing Clearance Production All 0003 0029 All 0008 0034 l 2 3 4 0008 0024 l 2 3 4 0013 0025 1 2 0010 0022 3 4 0009 0025 H 2 3 4 0013 0025 5 0010 0026 5 0015 0031 5 0013 00...

Page 696: ...497 Camshaft Runout 0015 Max VALVE SYSTEM Lifter Hydraulic Rocker Arm Ratio 1 75 1 1 50 1 1 70 1 Valve Lash Int Exh One turn Down from Zero Lash Face Angle Intake 45 Exhaust 45 46 45 46 Seat Angle Int...

Page 697: ...sed 56 64 1 66 85 93 1 69 78 86 1 66 84 96 1 80 94 106 1 88 84 96 1 80 Open 170 184 1 33 180 192 1 27 174 184 1 30 170 178 1 26 210 230 1 40 303 327 1 38 210 230 1 40 Installed Height 1 32 Intake 1 21...

Page 698: ...SPECIFICATIONS 12 ENGINE TORQUES CHEVROLET TRUCK SERVICE MANUAL...

Page 699: ...at 12 000 m ile s in itia lly Check e v e ry 6 000 m ile s th e rea fter until re p laced P O L U R E T H A N E B A N D S e r v ic e e v e ry 12 000 m ile s O IL B A T H Change o il at re gu la r engi...

Page 700: ...0 150 150 100 100 Choke Vacuum Break 245 245 Choke Unloader 300 300 Thermostat Choke Rod 1 Rod Dia Interference A ir Valve Spring 3 8 7 8 Secondary Closing 020 020 Secondary Opening 070 070 Secondary...

Page 701: ...te Ampere Hour 45 53 61 70 150 205 GENERATOR Generator Application G 10 20 P 10 CK 10 thru 30 Except w RPO R 05 and E 57 Base on PS PE 20 30 40 CA and KA 20 30 w RPO R 05 and E 57 CMT 40 50 60 PT 20 3...

Page 702: ...0 R P M 23 2000 R P M 32 4200 R P M C 3912 0 7 Hg 23 16 Hg 3 1 3 4 TDC Manual 700 AC C44N 5611031 V 8 307 Cu In 200 H P 10 30 1111257 C 4680 0 1000 R P M 10 1600 R P M 28 4300 R P M C 3064 0 6 Hg 15 1...

Page 703: ...8 11 8 11 8 11 8 Am peres 49 87 49 87 49 87 65 100 65 100 55 95 75 100 57 70 57 70 105 155 90 130 70 99 72 72 72 65 100 65 100 72 72 72 72 rpm 6200 10 700 6200 10 700 6200 10 700 3600 5100 3600 5100...

Page 704: ...on Transistor V 8 w Transistor Ignition Primary Resistance Ohms 1 41 1 65 1 77 2 05 41 51 Secondary Resistance Ohms 3 000 20 000 3 000 20 000 3 000 20 000 Ignition Resistor Type In Wiring Harness In W...

Page 705: ...rdrive 45 ft lbs Overdrive Attaching Lower Left Hand Bolt Marked X 30 ft lbs Shift Lever to Shifter Shaft B olts 20 ft lbs Lubrication Filler P l u g 15 ft lbs Transmission Case to Clutch Housing B o...

Page 706: ...on Case 7 1 2 ft lbs Oil Cooler Pipe Connectors to Transmission Case or Radiator 10 ft lbs Oil Cooler Pipe to Connectors 10 ft lbs Vacuum Modulator to Transmission C a s e 15 ft lbs Oil Pan Drain Plug...

Page 707: ...teering Wheel Nut 40 lb ft 40 lb ft 40 lb ft 40 lb ft 40 lb ft 40 lb ft 40 lb ft Lower Mast Jacket Bearing Adj 7 8 7 8 7 8 005 to 030 12 to 15 Power Steering Belt Tension 125 lb New 75 lb Used Steerin...

Page 708: ...Tail Stop and Direction Signal Turn Signal Indicator 1895 2CP Upper Beam Indicator Radio Dial Lamp 1893 2CP Instrument Illumination 1895 2CP Temperature Tell Tale Oil Pressure Tell Tale Generator Tell...

Page 709: ...EAKER USAGE Applicability Location Amps Type Instrument Cluster 3 3AG AGC Windshield Wiper Motor Air Conditioning 20 SFE SAE Heater Motor Backup Lamps Fuse block in driver s compartment 10 3AG AGC Tai...

Page 710: ...0 60 Models Radiator Retainer to Radiator Support S c re w s 150 lb in Radiator Drain C o c k 118 lb in Shroud Attaching S crew s 43 lb in PA40 Models Radiator Shroud to Radiator Support S c re w s 25...

Page 711: ...er Bracket Lock Nuts 36 lb ft G10 and 20 Models Front Bumper Face Bar to Frame and Brace N u ts 17 lb ft Bumper Brace to Frame Screws 17 lb ft Face Bar to License Plate Bracket Screw s 43 lb in G10 an...

Page 712: ...ON 15 CRUISE MASTER Solenoid Resistance 5 0hms 1 4 ohm Solenoid Wire R esistan ce 40 ohms Maximum allowable Vacuum Leakage Rate for Servo U n it 5 inches of Vacuum Per Minute Operational Test Speed 50...

Page 713: ...9...

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