Chevrolet 10 Series 1968, Service Manual

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CHASSIS SHEET M ETAL 11 -6
12. Connect battery and fill radiator. Start engine and
check for leaks.
40 THROUGH 60 SERIES
Removal
1. Remove windshield wiper arms and cowl grille.
2. Drain radiator and remove radiator hoses.
3. Disconnect transmission cooler lines; and disconnect
air cleaner intake hose at fender skirt, if so
equipped.
4. Disconnect wire connectors at dash and toe panel.
Disconnect the battery, generator and regulator wire
leads.
5. Disconnect power steering fluid reservoir from in­
side grille.
6. Remove front bumper bolts and remove bumper,
a. Remove two bolts from underneath front frame
crossmember and attachments securing sheet
metal. (See Figure
8 a.)
7. Remove one screw, each side attaching cowl bracket
to fender (plastic plug covers) access from inside
cab, on cowl (fig. 9). DO NOT remove cowl bracket.
8
. Remove two bolts attaching fender upper edge to
plenum and hinge pillar (fig. 9).
9. Tape shims in their respective positions for reas­
sembly ease.
10. Remove two screws (each side) attaching fender gus­
set to cowl (fig. 10 ).
11. Working from underneath rear of fender, remove
bolts which attach each fender skirt to the fender
extension flange.
12. Remove two bolts from radiator support mount.
13. Remove bolt attaching each fender skirt to cab sill
extension.
14. With a helper, remove front sheet metal assembly
with radiator, battery, horn and voltage regulator.
Installation
1. Tape washers and cushions to frame and fender
brackets with masking tape.
NOTE:
If sheet metal mounting cushions on
frame brackets are worn or deteriorated, re­
place before installing front sheet metal.
2. With a helper place sheet 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 combination bolt and flat washer assembly
into each cowl bracket to fender.
5. Tighten the sheet metal mounting bolt 35 to 55 ft. lbs.
torque. (See Figure
8
a.)
6 . Install spacer, washer and bolt in each fender skirt
to cab sill extension.
7. Install skirt attaching bolts to fender extension.
8 . Tighten all bolts.
9. Install front bumper bolts and bumper as outlined in
this section.
10. Connect upper and lower radiator hoses.
11. Install transmission cooler lines.
12. Connect power steering fluid reservoir hose to pump.
See Section 9.
13. Connect air cleaner intake hose to fender skirt.
14. Connect wire connectors at dash and toe panel. Con­
nect battery, generator and regulator leads.
15. Fill radiator, start engine and check for leaks.
FLAT FACE COWL
Removal and installation operations for front sheet
metal of flat face cowl models, are the same as Conven­
tional Cab 40 thru 60 series, except as follows:
• Remove two bolts from inside of cab at the top of
each fender.
o Remove bolt and plug at lower rear fender location.
• For installation, reverse the above added procedure.
RADIATOR SUPPORT
10-30 Series
Removal
1. Remove hood as described in this section.
2. Drain radiator, saving coolant, loosen attachments
and remove.
3. Remove right front fender as described in this
section.
4. Disconnect battery and remove.
5. Remove battery tray, 1 bolt under skirt.
6 . Remove wiring from radiator support.
7. Disconnect fan shroud and lay back on engine.
8
. Remove
6
screws retaining lower grille baffle to
radiator support.
9. Remove both head lamp assemblies. Complete.
10. Remove left fender gusset (5 screws).
CHEVROLET TRUCK SERVICE MANUAL