Chevrolet 1977 light duty truck Page 563 Service Manual Download

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N O T E *: A N G L E G A U G E M E T H O D CAN BE USED

[L O O S E N T H R E E R E T A I N I N G S C R E W S A N D

R E M O V E T H E T H E R M O S T A T I C C O V E R A N D

C O I L A S S E M B L Y F R O M C H O K E H O U S IN G

C H O K E V A L V E

B E N D C H O K E R O D

A T T H I S P O IN T

T O A D J U S T

(S E E I N S E T )

I N S E R T S P E C I F I E D

P L U G G A U G E

( ^ 2 ^ P U S H U P O N T H E R M O S T A T I C

I V " ' C O I L T A N G ( C O U N T E R C L O C K W I S E )

------- U N T I L C H O K E V A L V E IS C L O S E D

L O W E R E D G E O F L E V E R S H O U L D

J U S T C O N T A C T S I D E O F P L U G

G A U G E

7 J IN S T A L L COVER A N D REFER

-— 'T O A U T O M A T IC CH O K E

A D J U S T M E N T

CHOKE COIL LEVER A D J U S T M E N T — M 4 M C /M 4 M E

C A R B . NO .

ALL

PLUG

GAUGE

120

1 I P O S IT IO N T R A N S M IS S IO N

IN PARK OR N E U T R A L

H O L D C A M

F O L L O W E R O N

H I G H E S T S T E P

O F F A S T I D L E C A M

3 J D IS C O N N E C T A N D PLUG

V A C U U M H O SE A T

EGR V A L V E

FAST ID L E A D JU S T M E N T

L IG H T D U T Y E M IS S IO N S

M A N U A L T R A N S M IS S IO N

1 3 0 0 RPM (N )

AUTOMATIC TRANSMISSION

1600 RPM (N )

H E A V Y D U T Y E M IS S IO N S

3 5 0 /4 0 0 C ID

1 6 0 0 RPM (N )

T U R N F A S T IDLE SC R E W
T O O B T A IN SPECIFIED

F A S T IDLE RPM

4 5 4

1700 RPM (N)

G A U G E B E T W E E N U P P E R

N O T E :

E D G E O F C H O K E V A L V E &

I N S I D E A I R H O R N W A L L (S E E N O T E * )

H O L D G A U G E

V E R T I C A L

C A R B . N O .

PLUG

GAUGE

) B E N D T A N G

O N F A S T I D L E C A M

T O A D J U S T

4 J C L O S E C H O K E B Y

P U S H IN G U P W A R D O N

C H O K E C O I L L E V E R

ALL WITH

LIGHT DUTY

EMISSIONS

P L A C E C A M F O L L O W E R

O N S E C O N D S T E P O F

C A M N E X T T O

H I G H S T E P

1M AK E F A S T IDLE A D J U S T M E N T

^ R E M O V E T H E R M O S T A T IC COVER

^ IN S T A L L COVER A N D REFER TO A U T O M A T IC C H O K E A D J U S T M E N T

CHOKE ROD (F A S T IDLE C A M ) A D J U S T M E N T — M 4 M C /M 4 M E

ALL WITH

HEAVY DUTY

EMISSIONS

ANGLE

GAUGE

. 3 2 5

.2 8 5

4 6 °

Summary of Contents for 1977 light duty truck

Page 1: ......

Page 2: ...At the beginning of each section containing more than one major subject is a Table of Contents which gives the page number on which each major subject begins An Index is placed at the beginning of eac...

Page 3: ...ize the risk of personal injury to service personnel or the possibility that im proper service methods w ill be follow ed which may dam age the vehicle or render it unsafe It is also im portant to und...

Page 4: ...an result in vehicle damage or malfunction or possibly per sonal injury Therefore fasteners removed from the vehicle should be saved for re use in the same locations whenever possible Where the fasten...

Page 5: ...ated These unit numbers and their prefix or suffix are necessary on these papers for various reasons such as accounting follow up on production etc The prefixes on certain units identify the plant in...

Page 6: ...42 Pickup Chassis Cab FC or M otor Home Chassis Step V an Valu e Van 5 6 S u b u rb a n Chassis Cab Pickup 60 FC Chassis Chevy V a n V a n d u ra Sportvan Rally W a g o n Chassis Cab S tep Van V a lu...

Page 7: ...Forward Control series it will be located on an inner body panel The plate lists the vehicle serial number Fig 0A 3 Service Parts Identification Plate wheelbase and all Production options or Special...

Page 8: ...E 50 M IL E S N O T E For speeds or distances greater than above both propshafts must be disconnected at the axle carrier end and secured in a safe position It is recommended that both propshafts be...

Page 9: ...three publications for a full understanding of vehicle maintenance requirements The time or mileage intervals for lubrication and maintenance services outlined in this section are intended as a genera...

Page 10: ...Capacity Does N ot Include Filter 292 L6 Engine 5 quarts U S measure 4 25 quarts Imperial measure All other engines 4 quarts U S measure 3 25 quarts Imperial measure Recom m ended Viscosity To help as...

Page 11: ...chever comes first except California 350 400 engines should be replaced every 24 months or 24 000 miles Accelerator Linkage Lubricate with engine oil every 15 000 miles 12 000 miles Heavy Duty Emissio...

Page 12: ...contacting faces with water resistant EP chassis lubricant which meets General Motors Specification GM6031 M Clutch The clutch pedal free travel should be checked at regular intervals Lubricate the c...

Page 13: ...TE Do not use EP Chassis Lube which meets G M Specification GM 6031 M to lubricate the gear DO NOT OVER FILL the gear housing Power Steering System Check the fluid level in the pump reservoir at each...

Page 14: ...a rubber lubricant UNDERBODY M AINTENANCE Corrosive materials used for ice and snow removal and dust control accumulate on the underbody If allowed to remain these materials can result in accelerated...

Page 15: ...Mile Intervals as Indicated in Log C 1 Thermo Controlled Air Cleaner Check C 2 Carburetor Choke Check C 3 Engine Idle Speed Adjustment C 4 EFE System Check C 5 Carburetor Mounting Torque C 6 Vacuum Ad...

Page 16: ...ths or 7 500 Miles Then at 24 Month 30 000 Mile Intervals as Indicated in Log C 2 Thermo Controlled Air Cleaner Check C 3 Engine Idle Speed Adjustment C 4 EFE System Check C 5 Carburetor Mounting Torq...

Page 17: ...5 000 miles thereafter Bias belted tires should be rotated every 7 500 miles A 6 REAR AXLE Change lubricant every 7 500 miles on all type rear axles or final drives when using vehicle to pull a traile...

Page 18: ...mps and hazard warning flashers Have headlamp aim checked every 12 months or 15 000 miles or more often if light beams seem to be aimed improperly r GLASS Check for broken scratched dirty or damaged g...

Page 19: ...distributor cap and spark plugs or other deterioration If corrosion cannot be removed or other conditions above are noted replace wire C 10 IDLE STOP SOLENOID Check for proper operation An inoperativ...

Page 20: ...r and exterior of the distributor cap and rotor for cracks carbon tracking and terminal corrosion Clean or replace as necessary C 13CARBURETOR VACUUM BREAK ADJUSTMENT In spect vacuum break linkage for...

Page 21: ...nkage 21 Underbody At 1st 4 months or 6 000 miles 22 Carburetor Choke and Hoses 1 then at 12 month 12 000 mile intervals 23 Engine Idle Speed Adjustment 1 24 Carburetor Mounting 1 Every 12 months or 1...

Page 22: ...at the first oil change and every other oil change thereafter if mileage 6 000 miles is the determining factor If time 4 months is the determining factor then change oil filter with every oil change...

Page 23: ...kup lamps and hazard warning flashers Have headlamp aim checked every 12 months or 15 000 miles or more often if light beams seem to be aimed improperly r GLASS Check for broken scratched dirty or dam...

Page 24: ...ioning switch must be replaced Check hoses for proper connection cracking abrasions or deterioration and re place as required 30 CARBURETOR FUEL INLET FILTER Replace filter at designated intervals or...

Page 25: ...ft linkage column shift Engine oil Shift linkage floor shift Engine oil Hood Latch assembly a Pivots and spring anchor b Release pawl Engine oil Chassis grease Hood and Door hinges Engine oil Automati...

Page 26: ...g 10 Transmission Manual 14 Universal Joints Shaft PA10 A utom atic 15 Rear Axle 5 Tie Rod Ends FOUR WHEEL DRIVE MODELS L U B R IC A T IO N P O IN T S 1 A ir Cleaner 6 Master Cylinder 11 Front and Rea...

Page 27: ...5 Trans Control Shaft 8 Rear A xle Ball Joints 6 A ir Cleaner Element 9 Oil Filter 2 Tie Rod Ends 7 Transmission Manual 10 Brake Master Cylinder 3 Wheel Bearings A utom atic 11 Parking Brake Linkage 4...

Page 28: ......

Page 29: ...ol Cables 1A 11 Blower M otor 1A 9 Blower Switch 1A 12 GENERAL DESCRIPTION Heating components are attached to the dash panel on the right side of the vehicle The blower and air inlet assembly and wate...

Page 30: ...O S ITIO N AIR OUTLET VIEW A AIR F L O W LEG E N D HEATER ASM DASH PANEL C K MODELS Q TEMPERATURE VALVE j j DEFROSTER VALVE GO PURGE VALVE OUTSIDE AIR M IX E D AIR HEATED AIR Fig 1A 2 Heater Air Flow...

Page 31: ...heater floor and or defroster dash outlets by the defroster door The temperature of the outlet air is dependent of the radio of heated to unheated air controlled by the temperature door CONTROLS C K...

Page 32: ...r assembly In the OFF position no air is allowed to enter the system Moving the lever to the right toward HEATER opens the air door with the AIR door being fully open at the HEATER position Incoming a...

Page 33: ...eal area as necessary 5 Check position of bottom of nozzle to heater locating tab Adjust 6 Check position of defroster nozzle openings relative to instru ment panel openings Mounting tabs provide posi...

Page 34: ...door fo r max heat po sition A djust if necessary HEATER CORE r Feel temperatures of heater inlet and o utle t hoses j WARM IN LE T AND O UTLET HOSES X i Check engine therm ostat HOT IN LE T AND WARM...

Page 35: ..._JL_ FUSE OK The fo llo w in g tests should be made w ith the ig n itio n sw itch in R U N p ositio n the b low er speed sw itch O N and the lever on heat p o sitio n X Check b lo w e r m o to r groun...

Page 36: ...PERATIO N LO BAT BLO SW RES Rl R2 BLO M TR G RD MED BAT BLO SW RES Rl BLO M TR G RD HI BAT BLO SW BLO M TR G RD IfVW W t l R I i j r S It B L O M ED BLOWER RESISTOR HI 0 MED LO 1 6 LBL BAT J C Q C S...

Page 37: ...mounting flange c Check blower operations blower wheel should rotate freely with no interference HEATER DISTRIBUTOR AND CORE ASSEMBLY C K Models Replacement Fig 1A 8 1 Disconnect the battery ground ca...

Page 38: ...not readily come off the tubes the hoses should be cut just forward of the core tubes The portion of the hose remaining on the core tube should then be split longitudinally Once the hoses have been s...

Page 39: ...to gain access to the bowden cable attachments CAUTION Care should be taken to prevent kinking the bowden cables while lowering the control 4 Disconnect the three bowden cables the control illuminatio...

Page 40: ...4 piece of wire 6 To install attach the new cable to the 4 piece of wire Tape the mounting tab and attached wire Carefully pull the new cable into position 7 Reverse Steps 1 4 NOTE If cable adjustmen...

Page 41: ...itch 6 To install reverse Steps 1 5 above G Models Replacement Fig 1A 14 1 Disconnect the battery ground cable 2 Disconnect the blower switch wiring harness connector at the switch 3 Remove the two sw...

Page 42: ...independent of the standard heater and is regulated through its own controls at the instrument panel This system consists of a separate core and fan unit mounted as shown in Figures 1A 16 and 1A 17 H...

Page 43: ...1A 19 The three speed fan switch LOW MED HI is located in the instrument panel to the right of the steering column Full down the blower is inoperative fully up the blower is on HI DIAGNOSIS Refer to t...

Page 44: ...RD HI BAT BLO SW BLO MTR GRD 14 ORN 1 4 YEL 14 LBL 12 BRN 50C 50A I15 AMP INLINE FUSE 16 BRN s OB CK IG N 3 3 0 0 UNFUSED G IGN ACC 4 FUSED FUSE PANEL v ZV Arf Rl v W i R2 b l c l L I m e d l o I 51 5...

Page 45: ...a 1 1 4 minimum clearance between the auxiliary heater core lines and the exhaust pipe as shown in Figure 1A 22 All M odels Draw hoses tight to prevent sag or rub against other components Be sure to...

Page 46: ...PM Volts Cold Cold Blower Motor C K Models 13 5 6 25 Max 2550 Min 2950 Max G M odels 13 5 7 1 Max 2850 Min 3250 Max Fuses C K Models 20 Amp G Models 20 Amp A U X IL IA R Y H E A T E R Amps RPM Volts C...

Page 47: ...e Pressure Switch IB 41 Fuse IB 42 Overhead System C K Models IB 42 Rear Duct IB 42 Blower Motor Resistor IB 42 Blower Motor Assembly IB 42 Expansion Valve IB 44 Evaporator C o re 1B 44 Blower Motor S...

Page 48: ...evaporator core As the core temperature increases the resistance of the thermister to 400 ohms the amplifier on the control furnishes current to energize the compressor clutch coil As the evaporator c...

Page 49: ...EVAPORATOR ASM FLOOR OUTLET L H L H OUTLET A IR J L O W LEGEND H ______ RECIRCULATED H i g B i COOLED AIR fe rS e l HEATED AIR CONTROL ASM VIEW A DASH PANEL BLOWER EVAPORATOR ASM EVAPORATOR CORE A C S...

Page 50: ...R EVAPORATOR ASM CONTROL R H OUTLET FOOT DEFLECTOR R H OUTLET VIEW A CENTER OUTLET AIR INLET VALVE PLENUM VALVE HEATER CORE R H CENTER OUTLET DIVERTER VALVE 7 A C OR HEATER 2 DASH PANEL BLOWER EVAPORA...

Page 51: ...from air entering vehicle vaporizes low pressure liquid 1 R efrigerant leaves compressor as a high pressure high tem perature vapor 16 Refrigerant returns to compressor as low pressure vapor 5 Liquid...

Page 52: ...ompressor and the condenser are the main working parts in any typical air conditioning system We have the evaporator where the refrigerant boils and changes into a vapor absorbing heat as it does so W...

Page 53: ...otor Home Chassis unit fittings are located on the inlet and outlet lines C K model gauge fittings are located on the accumulator and evaporator inlet line All fittings are equipped with a valve core...

Page 54: ...through driver springs riveted to both members The hub of the drive plate is pressed on the compressor shaft and keyed to the shaft by a square drive key A self locking nut threads on the end of the s...

Page 55: ...24 M a in B e a r i n g 2 5 F ro n t H e a d Assy 2 6 S cre w a n d W a s h e r Assy 2 7 O R in g 28 S h a f t S e a l 2 9 S e a l S e a t 3 0 R e ta in in g Ring Fig lB 5 Radial Four Cylinder Compre...

Page 56: ...lows into the evaporator core where it absorbs heat from the evaporator core and changes to a low pressure vapor Fig lB 7 Expansion Valve and leaves the evaporator core as such The power element bulb...

Page 57: ...e addition of entrained liquid and liquid flow through the oil bleed hole A bag of desiccant dehydrating agent is located in the base of the accumulator as a moisture collecting device NOTE There is n...

Page 58: ...vacuum valve will supply vacuum to or vent vacuum diaphragms which position the upper and lower mode and defroster air doors in the selector duct assembly The position of these air doors determines i...

Page 59: ...h of outside air is allowed Fig 1B11 System Operation CK Truck Fig 1B 12 Air Conditioning Vacuum Schematic CK Truck OVERHEAD SYSTEM C K MODELS This system operates in conjunction with the Four Season...

Page 60: ...Modes The temperature lever activates a potentiometer on the control assembly connected in series with the amplifier on the control and thermister on the evaporator to control compressor operation He...

Page 61: ...rom twisting and damaging the O ring Do not overtighten Correct torque specifications are as follows CAUTION Where steel to aluminum connec tions are being made use torque for aluminum tubing Hose Cla...

Page 62: ...nditions valve stuck open valve stuck closed broken power element a restricted screen or an improperly located or installed power element bult The first three conditions require valve replacement The...

Page 63: ...nstream b Vacuum Less Than Normal at Some Posi tion s If vacuum was low at one or several of the selector lever positions a leak is indicated in these circuits c Vacuum Normal at Alt Positions If vacu...

Page 64: ...N T If co il is s till in op e ra tive replace com pressor c o il If previous step does n ot co rre ct c lu tc h slippage repair com pressor A d d one pound re frig eran t Leak test co m p le te syst...

Page 65: ...harge System Check Inlet O utlet Pipe Temperatures N ot Engaged p A p p ly External G round to Com pressor if Clutch is Still not Engaged Replace Compresor Clutch See the O veraul Manual System O K En...

Page 66: ...EXCESS MOISTURE REPLACE RECEIVER UEHYDRATOR AND EVACUATE THOROUGHLY RECHARGE SYSTEM CHECK COMPRESSOR DISCHARGE PRESSURE NORMAL EVAPORATOR PRESSURE LOW EVAPORATOR PRESSURE Check for malfunctioning expa...

Page 67: ...eplace resistor L A M P L I G H T s l JL L A M P DOES N O T L I G H T l Replace m o to r Check wire connector on blo w er relay w it h 12 vo lt test light X With ignition switch in R u n position and...

Page 68: ...defective switch C K MODEL SYSTEMS 1 Wire from fuse panel to master switch on control 2 Master switch 3 Wire from master switch to thermostatic switch 4 Thermostatic switch 5 Wire from thermostatic s...

Page 69: ...0J o DISCHARGE CUT OU T SWITCH RESISTOR BLOWER MOTOR I I 40 16 DK GRN 10 ORN 16 YEL 16 DK G R N D B L WHT STR 18 ORN 16 LT GRN 16 LT BLU POS CIRCUIT OFF BATT TO NONE M ED 1 B A TT TO M l MED 2 B A TT...

Page 70: ...Fig IB 24 Four Season System Vacuum Diagram C K Models 1B 24 LIGHT TRUCK SERVICE M A N U A L...

Page 71: ...Fig lB 25 Overhead System Wiring Diagram C K Models AIR C O N D ITIO N IN G 1 B 2 5...

Page 72: ...Fig IB 26 C60 System Wiring Diagram G Models...

Page 73: ...E R T E M PE R A T U R E DOOR CABLE H E A T E R DISTRIBUTOR DUCT H E A T E R AIR ORANGE SE L E C T VALVE OPEItA TIN G CHART P O R T NO O F F MAX NORM H TR D EFO G DEF 9 H EAT VAC VAC VAC VAC V ENT VEN...

Page 74: ......

Page 75: ...Fig lB 29 Motor Home Chassis Wiring Diagram THERMOSTATIC SWITCH AIR C O N D ITIO N IN G IB 2 9...

Page 76: ...se Four Season Air Conditioning C K Models Refrigerant Charge 3 Lbs 1 2 o z Tem perature of Air Entering Condenser 70 80 90 100 110 Engine rpm 2000 Compressor Head Pressure 150 205 170 220 190 240 220...

Page 77: ...y the amount specified in Steps 3a and 3b above d If a field repaired compressor is being installed add one additional fluid oz to the compressor Dash Mounted Unit Motor Home Chassis Refrigerant Charg...

Page 78: ...k with leak detector Correct leak if any and fill sy stem to proper charge No bubbles Sight glass clear S ystem is either fully charged or empty Feel high and low p ressu re pipes at compressor High p...

Page 79: ...rpm The thermostatic switch should cycle the compressor off when the low limit of the outlet air temperature is reached see Peformance Data If it does not the switch points are fused which will lead...

Page 80: ...T BULB Normal Pressure Poor Cooling Check for Defective Valve C A PILLA RY BULB OUTLET The following procedure must be followed to determine if a malfunction is due to a defective expansion valve 1 Ch...

Page 81: ...dels 1 Purge the refrigerant from the system 2 Remove connector attaching bolt and connector Cap or plug open connections at once 3 Disconnect electrical lead to clutch actuating coil 4 Loosen brace a...

Page 82: ...ressor Check for evidence of contaimination to determine if remainder of system requires servicing Compressor Servicing infor mation is located in the Overhaul Manual Installation l If the oil drained...

Page 83: ...ator bracket screws and remove the accumulator from the vehicle 5 Drain any excess refrigerant oil from the accumulator into a clean container Measure and discard the oil 6 If a new accumulator is bei...

Page 84: ...over 9 Evacuate charge and check the system EXPANSION TUBE The expansion tube is located in the evaporator core inlet line Replacement Fig IB 37 l Purge the system of refrigerant 1 Disconnect the batt...

Page 85: ...ng at the actuator end 3 Remove the actuator bracket mounting screws 4 Remove the cam to actuator arm screw and separate the actuator and bracket from the cam 5 Remove the actuator to bracket nuts and...

Page 86: ...cable is installed in the bracket on the selector duct assembly 4 Place temperature lever in full COLD position and hold while tightening cable attaching screw MASTER SWITCH A N D O R BLOWER SWITCH Th...

Page 87: ...tached to the evaporator inlet pipe 1 2 O D with two clamps This end is covered with an insulation material Carefully remove the insulation and loosen clamps enough to pull the formed end of the capil...

Page 88: ...to the Overhead System will be covered in this section REAR DUCT This duct covers the blower evaporator assembly at the rear of the vehicle and incorporates four adjustable air outlets fig IB 46 Repla...

Page 89: ...e motor shaft Installation 1 Place the blower wheels onto the motor shaft making sure the wheel tension springs are installed on hub of wheels CAUTION Be sure that the blower wheels are installed as s...

Page 90: ...tor lead and ground wires 4 Install the rear duct as outlined previously 5 Connect the battery ground cable 6 Evacuate charge and check the system EVAPORATOR CORE Fig IB 50 Removal 1 Disconnect the ba...

Page 91: ...switch 4 To install reverse Steps 1 3 above FUSE The Four Season portion of this system is protected by a 25 amp fuse in the junction block The rear blower high speed circuit is protected by a 20 amp...

Page 92: ...il ready to fasten the inlet and outlet lines to the unit 9 Install receiver dehydrator by reversing Steps 1 6 above 10 Evacuate charge and check the system SIGHT GLASS REPLACEMENT If damage to the si...

Page 93: ...l up to gain access to the air distribution duct 9 Disconnect the blower resistor electrical harness 10 Remove the duct to instrument panel attaching screws and remove the duct assembly 11 If a new du...

Page 94: ...teps 1 8 of Distributor Duct Replacement 3 Loosen the expansion valve sensing bulb clamps and remove the bulb from the evaporator core 4 Disconnect the expansion valve inlet and outlet lines and remov...

Page 95: ...connecting all refrigerant lines Transfer thermister to the new evaporator NOTE Make sure the expansion valve sensing bulb makes good contact with the core connector block 8 Evacuate charge and check...

Page 96: ...r motor resistor is mounted in the right hand plenum in the same position as without air conditioning The A C blower motor resistor is mounted in the forward face of the A C air distribution duct fig...

Page 97: ...liar to the Overhead system will be covered in this section BLOWER EVAPORATOR SHROUD This shroud covers the blower evaporator at the rear of the vehicle and incorporates four air outlets Replacement F...

Page 98: ...alve do not use and external equalizer line fig IB 65 Removal Inner Valve Fig IB 65 Expansion Valves G Overhead System 1 Disconnect the battery ground cable and compressor clutch connector 2 Purge the...

Page 99: ...ctor 2 Purge the system of refrigerant 3 Remove the blower evaporator shroud as outlined previously 4 Disconnect the blower motor leads and ground wire 5 Disconnect the refrigerant lines at the rear o...

Page 100: ...shield bracket to instrument panel reinforcement screws and remove the bracket 3 Remove the heater intermediate duct to A C distributor duct screw and remove the duct 4 Unsnap the engine cover latche...

Page 101: ...ect the battery ground cable 2 Purge the system of refrigerant 3 Disconnect the inlet and outlet lines at the receiver dehydrator and cap or plug the open lines at once 4 Remove the receiver dehydrato...

Page 102: ...he dash panel side of the unit when the motor is placed in the case as illustrated in Figure IB 73 2 Place the motor in the bracket with the electrical connector side of the motor to the right side of...

Page 103: ...t be removed to replace the resistor FUSE This Unit does not incorporate an in line fuse The lead wire is connected to the Heater Wiring Harness and operates off the 20 amp Heater Fuse SPECIFICATIONS...

Page 104: ...d Rotor Assy In staller 3 J 2 4 8 9 5 M a in B e a rin g Installer 4 J 2 4 8 9 6 M a i n B e a rin g Remover 5 J 2 5 0 3 1 2 Rotor a n d B e a rin g Puller 6 J 2 5 0 3 1 1 Rotor a n d B e a rin g Pull...

Page 105: ...o m p re ssin g F ixtu re 26 J 5 1 3 9 O il P icku p T ub e Rem over J 2 5 4 9 8 3 8 A d a p te r 16 J 9 4 0 3 C lu tc h H u b H o ld in g Tool 27 J 9 4 3 2 N e e d le B e a rin g In s ta lle r 6 J 6...

Page 106: ......

Page 107: ...rotective treatment is performed Using a chisel ensure that the drain provisions in the floor pan reinforcement members are open There are drain holes in the body side panels also These holes can be o...

Page 108: ...e length Opposite side measurement should correspond within 3 16 3 Measure diagonals marked A B and C If the lengths of intersecting diagonals are equal and these diagonals intersect the centerline fr...

Page 109: ...e quarters the length of the vehicle A good tramming tool is essential for analyzing and determining the extent of collision misalignment present in underbody construction MEASURING To measure the dis...

Page 110: ...6 1 2 120 16 7 8 16 7 8 14 PA 100 7 5 8 9 3 8 11 14 5 8 9 1 2 13 10 9 1 2 13 10 7 8 13 717 8 36 89 16 7 8 16 7 8 14 pA208 308 7 5 8 9 3 8 115 8 14 5 8 9 1 2 13 10 9 1 2 13 9 1 2 13 10 7 8 13 72 1 4 59...

Page 111: ...ove bolts securing two bumper brackets to frame 2 Remove bolts securing bumper face bar to frame and left and right bumper brackes and remove bumper from vehicle 3 If necessary disassemble bumper by r...

Page 112: ...o brackets and braces from left and right side Remove bumper 2 Remove the license plate support nut and bolts 3 If necessary to remove the braces and brackets remove screws securing brackets and brace...

Page 113: ...Fig 2B 7 Rear Bumper G Models Fig 2B 8 G Model Rear Step Bumper Installation NOTE The bumper may be removed with brackets and braces attached if necessary Instal1 in reverse order of removal...

Page 114: ...O uter Bracket and Brace 50 ft lbs License Plate B ra c k e t 18 ft lbs G ravel Deflector 85 in lbs Rear Step Bumper to Bracket or Frame 40 ft lbs TORQUE SPECIFICATIONS G Front Face Bar to Bracket 24...

Page 115: ...ued to the required torques If these bolts are loose the braces will not provide additional support for the sheet metal assembly G Series The front end sheet metal design does not include the radiator...

Page 116: ...he hood while the vehicle is in 1 Open hood and remove the four bolts holding the combination lock support and lock bolt Fig 2C 4 Hood Lock Bolt and Bumper CK Series motion Integral with the striker p...

Page 117: ...re removal of hood then tighten attaching cap screws at hinges firmly Close hood and check fit If necessary to align hood perform procedure as outlined under Alignment which follows Alignment Fig 2C 2...

Page 118: ...sing on the hood release tab at the right side of the lock assembly 2 Remove the cable at the lock assembly 3 Remove hood release handle to kickpad attaching screws 4 Remove hood release cable 5 To in...

Page 119: ...ow hood trailing edge to move up and down 2 Adjust hood bumpers so that hood and adjacent surfaces are flush 3 Perform hood lock adjustment as outlined in this section if necessary NOTE Hood Lock Asse...

Page 120: ...air conditioning and or power steering will require special handling Refer to appropriate sections of this manual for instructions Shims which are found at various locations should be recorded to eas...

Page 121: ...tal assembly with radiator battery horn and voltage regulator attached Installation 1 With a helper place sheet metal assembly in position NOTE Install all bolts loosely to facilitate aligning after c...

Page 122: ...rs 9 Tighten radiator support bolts 10 Place battery tray in position and fasten to radiator support 11 Install radiator coolant recovery tank hoses and shroud 12 Connect removed wiring to radiator su...

Page 123: ...o 2 screw attaching support bracket to fender 10 Remove five 5 screws attaching radiator support to front fender 11 Lift fender and skirt from truck Installation Install front fender and skirt assembl...

Page 124: ...the paint by light sanding with 600 grit sandpaper The temperature of the body must be maintained at a moderate level between approximately 70 and 90 degrees Too warm a body will cause the wood grain...

Page 125: ...e paper backing from transfer and align upper edge with pierced holes in fender and press on lightly 5 Start at center of transfer and squeeze outboard from middle to edges removing all air bubbles an...

Page 126: ...d Lock Catch Lock Support to Rad Support Rad Support to Frame Rad Support to Fender Fender Skirt to Fender Fender to Cowl Rad Grille Panel 150 in lbs 30 ft lbs 85 in lbs 35 ft lbs 150 in lbs 18 ft lbs...

Page 127: ...owing pages service procedures will be given for components on all 10 20 30 series trucks in C K and G models Reference will be made both in text and illustrations to vehicle model lines and to indivi...

Page 128: ......

Page 129: ...Fig 2D 5 Typical 05 and 0 6 Vans...

Page 130: ...Replacement 2D 12 Hinges 2D 12 Ventilator 2D 12 Window and Regulator 2D 14 Locks Handles R ods 2D 16 Weatherstrip 2D 17 Rear Side Doors 2D 17 Replacement 2D 17 Hinges 2D 17 Stationary Glass 2D 18 Wind...

Page 131: ...Shafts and Linkage Removal 1 Remove windshield wiper arms from pivot shafts Procedure for removing arms is explained previously under Arm Adjustemnt 2 Remove two nut and lock washer assemblies frfom t...

Page 132: ...tening of mounting and assembly bolts and screws will sharply decrease occurrence of failure due to door slamming or road shock NOTE Camper mirror installation is similar to the below eyeline mirror i...

Page 133: ...hat the cause of the glass breakage be determined and the condition corrected before a new glass is installed Otherwise it is highly possible that a small obstruction or high spot somewhere around the...

Page 134: ...move the windshield from the opening See figure 2D 16 Checking Windshield Opening Due to the expanse and contour of the windshield it is imperative in the event of a stress crack that the windshield o...

Page 135: ...osition lock the weatherstrip to the glass as follows a Base Weatherstrip Bend the locking strip over and use a thin bladed tool to lock weatherstrip tightly against windshield See figure 2D 18 for de...

Page 136: ......

Page 137: ...ents can be made by loosening the proper hinge bolts aligning door to proper position and tightening bolts securely See figure 2D 22 for typical adjustments Striker Bolt Adjustment With the use of J 2...

Page 138: ...or upper hinge to cowl pillar a Remove the door to upper hinge retaining bolts b With aid of an assistant to support weight of door remove the door to lower hinge retaining bolts and remove door Insta...

Page 139: ...2 Thoroughly clean the inside of the 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...

Page 140: ...ing adjustment bend tabs over the hex nut on base of assembly See figure 2D 30 3 Install arm rest screws and trim panel 4 Install window regulator handle DOOR W INDOW ASSEMBLY FIG 2D 31 Replacement 1...

Page 141: ...ontrol assembly aside for access 5 Remove glass outer seal 6 Remove rear glass run channel 7 Remove regulator to door panel attaching nuts and screws and pull rear of glass up as far as possible and r...

Page 142: ...el 8 Remove lock and remote control rod as an assembly 9 To install lock assembly reverse above steps Be sure to replace all clips removed earlier Door Outside Handle Fig 2D 36 Replacement 1 Raise win...

Page 143: ...l molded corner of inner weatherstrip starting at the bottom of the door opening 5 Trim inner weatherstrip with a notch and butt ends together 6 Reinstall sill plate and sill plate retaining screws RE...

Page 144: ...screw and locknut at that bracket allow fore and aft adjustment Together this allows proper alignment of the glass to the rear glass run channel for full up and down travel W INDOW GLASS FIG 2D 45 Rep...

Page 145: ...de handle control rod b Remote control lower rod c Outside handle control rod 4 Remove screws retaining lock assembly to door panel then remove lock assembly 5 Install lock by reversing above procedur...

Page 146: ...nge bolts and repositioning door then retightening bolts See figure 2D 53 for hinge bolt location Rear door wedges and strikers should be adjusted as shown in figure 2D 48 Glass Run Channel Adjustment...

Page 147: ...to insure proper latching of the rear doors CHECK ARM FIG 2D 53 Replacement 1 Remove bolts securing check arm bracket to body pillar 2 Remove check arm access cover 3 With one hand supporting housing...

Page 148: ...Fig 2D 51 Rear Door Controls...

Page 149: ...T M E N T 0 4 M A X C LEA R A N C E IN S E C O N D A R Y LA TCH ED P O S IT IO N OR 0 1 0 T O T 0 0 5 0 INTERFERENCE IN FULL LA TCH ED P O S IT IO N UPPER STRIKER A D JU S T M E N T 17 03 1 1 6 4 DRIL...

Page 150: ...ft endgate to almost closed position and remove support cables 6 Remove endgate with torque rod 7 To install reverse removal procedure HINGES Replacement If necessary to remove hinges remove endgate a...

Page 151: ...y if the motor is removed without locking the sector gears in position a Drill a 1 8 inch hole through the sector gear and back plate as shown in figure 2D 59 Install a sheet metal tapping screw into...

Page 152: ...l deflector as shown in figure 2D 63 5 Individual components may be removed from the endgate now or after reinstallation 6 To install endgate reverse the above procedure Fig 2D 61 Endgate Hinges and S...

Page 153: ...2D 65 Torque Rod Installation 14 7 Lift torque rod up and slide from endgate as shown in figure 2D 66 8 Reverse the procedure above for installation ENDGATE DISASSEMBLY 1 Lower endgate and remove aces...

Page 154: ...Remove outside handle by removing nuts from inside of outer panel See figure 2D 74 16 Reverse the above steps for reassembly Fig 2D 70 Removing Control Assembly and Inside Handle TAILGATES 03 63 and 1...

Page 155: ...ces 72 long from wood or square aluminum tubing Drill two 2 3 8 diameter holes 63 inches apart in the brace Fig 2D 74 Outside Handle b Attach one brace to the holes exposed in Step 7 c Slide top forwa...

Page 156: ...ble to have a small stain than an enlarged stain as a result of careless cleaning CAUTION When cleaning interior soft trim such as upholstery or carpeting do not use volatile cleaning solvents such as...

Page 157: ...move excess loose dirt Always clean at least a full trim panel or section of trim Mask adjacent trim along stitch or weld lines Mix detergent type foam cleaners in strict accordance with directions on...

Page 158: ...Fig 2D 79 Folding Top Assembly...

Page 159: ...Fig 2D 80 Folding Top Side Moldings and Header...

Page 160: ...aning fluid Tar Remove excess with dull knife moisten with fabric cleaning fluid scrape again rub lightly with additional cleaner Blood Wipe with clean cloth moistened with cold water Use no soap Urin...

Page 161: ...Fig 2D 85 Dnver s Bucket Seat 14 Fig 2D 86 Passenger s Bucket Seat 14...

Page 162: ...Fig 2D 89 Rear Folding Seat 06 Fig 2D 9 0 Rear Bench Seat 14...

Page 163: ......

Page 164: ......

Page 165: ......

Page 166: ...nary Glass 2D 45 Swingout Glass 2D 45 Front Door Adjustments 2D 45 Replacement 2D 4 Weatherstrip 2D 46 Hinges 2D 46 Ventilator 2D 47 Window and Regulator 2D 48 Locks Handles Rods 2D 48 Sliding Side Do...

Page 167: ...ld wiper arms from pivot shafts Procedure for removing arms is explained previously under Arm Adjustments 2 Remove screws which attach outside air cowl ventilator grille to cowl Carefully remove grill...

Page 168: ...MIRRORS Inside Rear View Mirror Replacement The inside mirror may be removed by removing screw retaining mirror to its glass mounted bracket and lifting mirror off bracket Outside Rear View Mirrors O...

Page 169: ...corrected before a new GLASS glass is installed Otherwise it is highly possible that a small obstruction or high spot somewhere around the windshield opening will continue to crack or break the newly...

Page 170: ...all sealer from flange and body around windshield opening 3 Check flange area for solder weld high spots or hardened spot weld sealer Remove all high spots 4 Check windshield glass to opening by supp...

Page 171: ...Remove screws retaining latch to body 3 Remove window hinge retaining screws and w indow 4 Remove latch from glass Installation 1 Install latch to glass using escutcheon spacer washer latch and screw...

Page 172: ...door in such a manner that weight is taken off other hinge and that the door will not move 3 Remove hinge screws from both body and from door and remove hinge See figure 2D 106 Installation 1 Install...

Page 173: ...channel or frame to soften the old seal When the seal has softened remove the glass from the channel 2 Thoroughly clean the inside of the glass channel with sandpaper removing all rust etc 3 Using ne...

Page 174: ...rear roller is disengaged 7 Put window assembly in normal position level and raise straight up and out 8 Reverse above procedure for installation W INDOW REGULATOR Replacement 1 W ind window all the...

Page 175: ...s securing remote control to door inner panel 3 Pivot remote inboard slightly to disengage connecting rod and remove remote control from door NOTE Connecting rod can be removed at this point by discon...

Page 176: ...RHINGE AND ROLLER SECTION B B TOP VIEW UPPER LEVER LOWER LEVER UP AND DOWN ADJUSTMENT SLOTS STRIKER U PPER FRONTSVN A N D U T R O L L E R ASSEM BLYJ adjustm ent FRONT LATCH ST R IK E R FACE VIEW GUIDE...

Page 177: ...rom the rear of the striker head to the impression The distance should be between 20 inch and 30 inch Refer to view E of figure 2D 115 8 Adjust position of striker by adding or deleting shims between...

Page 178: ...tating rod clear of latch See figure 2D 119 8 Remove latch assembly from door Fig 2D 11 9 Sliding Door Front Latch Fig 2D 120 Disconnecting Lower Latch Rod from Latch Installation 1 Install latch asse...

Page 179: ...r track cover See figures 2D 116 and 2D 122 2 Open the door Fig 2D 122 Rear Track Cover 3 Disengage spring from bolt using a spring removal tool 4 Close the door 5 Remove the hinge assembly Installati...

Page 180: ...e 10 Upper lines 11 Spacer 12 Spring Upper Lever 13 Spring Lower Level 14 Lower Lever 15 Screw 16 Guide Block 17 Hinge Body Half 18 Nut 19 Bushing 20 Bushing 21 Cam 22 Bushing 23 Hinge Door Half 24 Sp...

Page 181: ...met into door hinge opening if removed 2 Install hinge into door Snug bolts 3 Install seal and retainer on body half of hinge if removed 4 Install hinge into body opening and install bolts 5 Take care...

Page 182: ...emoval 1 Remove trim panel 2 Remove door handle retaining screws handle and gaskets See figure 2D 127 Installation 1 Apply grease to remote control where handle plunger makes contact 2 Install handle...

Page 183: ...sion to bottom of latch slot Torque to specifications 2 Adjust door wedge by adding or deleting shims as necessary so that wedge contact ramp on body when door is closed See figure 2D 128 Fig 2D 128 R...

Page 184: ...t onto anchor pins in floor anchor plates are used When the latch assemblies are depressed their cams and the hooks of the retainers are drawn tightly onto the anchor pins for secure seat attachment R...

Page 185: ......

Page 186: ......

Page 187: ...0 in lb End Support Bracket 90 in lb Latch Assembly to End G a te 20 ft lb Latch Remote Control Assembly to End Gate 40 in lb Access Cover 18 in lb Outside Handle 55 in lb Glass Channel 45 in lb TAILG...

Page 188: ...lb Door Strikers to Body 90 in lb Outside Door H and le 45 in lb Remote Control front latch to D o o r 90 in lb Rear Latch to D o o r 90 in lb Rear Plate to Door 90 in lb Lower Front Roller and Rolle...

Page 189: ...CIAL TOOLS 1 J 2189 Weatherstrip Tool Set 2 J 22585 F ront Door Hinge B olt Wrench 3 J 22577 Windshield Checking Blocks 4 J 7797 Door Handle Clip Remover 5 J 23457 Door Striker Bolt Remover and Instal...

Page 190: ......

Page 191: ...ower ball joint would be slightly ahead toward the front of the vehicle of the upper ball joint center line In short then caster is the forward or backward tilt of the steering axis as viewed from a s...

Page 192: ...the correction must be made before adjusting caster camber or toe in 6 Check for steering gear looseness at frame 7 Check for im properly operating shock absorbers 8 Check for loose control arms 9 Che...

Page 193: ...vehicle is in its normally loaded condition Trucks which are consistently operated with heavy loads should have toe in adjusted with the truck under heavy load This procedure should result in longer t...

Page 194: ...cifications for that dimension 7 Correct the actual caster angle as arrived at in Step 4 as necessary to keep within the specifications by adding or subtracting shims from the front or rear bolt on th...

Page 195: ...G 4 0 ACTUAL CORRECTED CASTER ANGLE 1 wnDi7r M TAi FRAME ANGLE HORIZONTAL D O W sj FRAME ANGLE V2 0 DOW N l 4 13 4 FRAME ANGLE VA UP ACTUAL CORRECTED CASTER ANGLE ANGLE READING ANGLE READING 2 ACTUAL...

Page 196: ...3 i CAMBER C10 C20 C30 1 4 K10 K20 K30 NO ADJUSTMENT PROVISION GI0 G2O G3O 1 4 Camber on P Truck is dependent on dimension A After measuring dimension A set camber as follows 2 1 2 2 3 4 3 3 1 4 3 1 2...

Page 197: ...31 Steering G ear High Point Centering 3B 32 Steering Wheel Alignment 3B 32 Steering Column Lower Bearing Adjustment 3B 32 Shifter Tube Adjustment 3B 32 Power Steering G e a r 3B 33 Belt Tension 3B 3...

Page 198: ...ible coupling This coupling incorporates a capturing strap which is designed to prevent column to coupling deflection from exceeding the length of the coupling alignment pins The trucks incorporate Fo...

Page 199: ...linkage ball studs Tighten to specified torque or replace if necessary Steering gear thrust bearings loosely adjusted Adjust preload to specification Excessive over center lash in steering gear Adjus...

Page 200: ...o column misalignment Align column Steering gear adjusted too tightly Adjust over center and thrust bearing preload to specification Front wheel alignment incorrect manual gear Check alignment and cor...

Page 201: ...teering gear to specified preloads NOTE On turns a slight rattle may occur due to the increased lash between ball nut and pitman shaft as gear moves off the center of high point position This is norma...

Page 202: ...r center preload to specifications Worm thrust bearings loosely adjusted Adjust worm thrust bearing preload to specifications Hard Steering Excessive Effort Required at Steering Wheel Low or uneven ti...

Page 203: ...f the column from compressing under impact COLLISION DIAGNOSIS To determine if the energy absorbing steering column components are functioning as designed or if repairs are required a close inspectio...

Page 204: ...Replace housing F Readjust see Sec 7 G Replace rack H Adjust or replace as necessary I Readjust or replace J Readjust or replace LOCK SYSTEM HIG H EFFO RT Cause Solution A Lock cylinder defective B Ig...

Page 205: ...s under high effort section Cause Solution A Ignition switch is not set correctly B Defective lock cylinder LOCK C Y LIN D E R CAN BE REM OVED W ITH O U T DEPRESSING R ETA IN ER A Readjust ignition sw...

Page 206: ...int E Horn contact ring not lubricated F Lack of grease on bearings or bearing surfaces G Lower shaft bearing tight or frozen H Upper shaft tight or frozen I Shaft lock plate cover loose J Lock plate...

Page 207: ...roper transmission linkage adjustment C Loose lower shift lever D Improper gate plate E Sheared lower shift lever weld LASH IN M O UN TED COLUM N ASSEMBLY A Replace shift tube assembly B Readjust link...

Page 208: ...correctly in car B Lower bowl bearing not assembled correctly C Improperly installed seal D Wave washer in lower bowl bearing defective E Improper adjustment of lower shift levers F Lack of grease on...

Page 209: ...d spring Cause Solution A Loose tit between shoe and shoe pivot pin NOISE WHEN T IL T IN G COLUMN A Replace both Cause Solution A Upper tilt bumper worn B Tilt spring rubbing in housing STEERING COLUM...

Page 210: ...ed or replaced If electrical J 23980 should be used to determine whether the switch or the chassis wiring is in need of repair or replacement This diagnostic procedure has been designed to guide the m...

Page 211: ...ed and then back to center Do this in both directions If the lever does not return to the neutral position disassemble the upper part of the column until the switch is visible 2 Check the return from...

Page 212: ...misplaced springs C Reposition or replace springs D Foreign parts and or materials D Remove foreign parts and or material E Switch mounted loosely E Tighten mounting screws 2 5 in lbs Turn signal wil...

Page 213: ...nal switch is inoperative D Replace signal switch E If vehicle lights do not operate check chassis wiring for opens grounds etc E Repair chassis wiring as required using manual as guide Turn indicator...

Page 214: ...s grounds etc F Repair chassis wiring as required using manual as guide Stop light not on when turn indicated A Burned out fuse A Replace fuse and check operation B Loose column to chassis connection...

Page 215: ...r high resistance grounds at light sockets D Connect securely and check operation E Replace signal switch F Locate and repair as required Use manual as guide See Section 12 Hazard signal lights w ill...

Page 216: ...sly tensioned is considered to be a used belt and should be tightened to 75 pounds A belt that has never been tensioned is considered to be a new belt and should be tightened to 125 pounds Place belt...

Page 217: ...metal to metal contacts through flexible coupling will transmit hiss into passenger compartment Rattle Pressure hose touching other parts of car Loose pump pulley nut Pump vanes not installed properl...

Page 218: ...me Tighten attaching bolts to 70 foot pounds Steering gear flexible coupling too loose on shaft or rubber disc mounting screws loose Tighten flange pinch bolts to 30 foot pounds if serrations are not...

Page 219: ...not level Adjust to specifications Align column Replace valve Adjust as required Steering wheel surges or jerks when turning with engine running especially during parking Low oil level in pump Loose...

Page 220: ...per alignment or cracking Repair or replace as neces sary Front springs weak and sagging Check standing height Weak or sag ging springs should be replaced with new ones Insufficient oil pressure If ab...

Page 221: ...te Replace parts flush system Scored pressure plate thrust plate or rotor Replace parts If rotor replace with rotating group kit flush system Vanes not installed properly Install properly Radius edge...

Page 222: ...ft and adjuster seals are close together exact leakage point could be confused Example The point oil drips from is not necessarily the leakage point oil overflowing from reservoir for instance 6 When...

Page 223: ...RESERVOIR DEFECTS RESERVOIR CAP DRIVE SHAFT RETURN HOSE CLAMPS DEFECT PRESSURE HOSE BALL PLUG ADJUSTER PLUG O RING TORSION BAR 0 RING STUB SHAFT SEAL PRESSURE RETURN PORTS SIDE COVER 0 RING ADJUSTER...

Page 224: ...clean the surface of the shaft with crocus cloth Replace the shaft only if the leakage cannot be stopped by smoothing with crocus cloth first Housing or Cover Seepage Both the power steering gear and...

Page 225: ......

Page 226: ......

Page 227: ...on regarding the fastener referred to in step 10 Before any adjustments are made to the steering gear attempt to correct complaints of loose or hard steering or other wheel disturbances a careful chec...

Page 228: ...an be checked by driving vehicle a short distance on a flat surface to determine steering wheel position at which vehicle follows a straight path 2 With front wheels set straight ahead check position...

Page 229: ...ability complaint can be caused by improperly adjusted worm bearings as well as an improper gear over center adjustment it is necessary that the steering gear assembly be removed from the vehicle and...

Page 230: ...ely Hold or have held adjuster plug to maintain alignment of hole with mark Fig 3B 41 Fig 3B 38 Marking Housing Pump Belt Tension 1 Loosen pivot bolt and pump brace adjusting nuts CAUTION Do not move...

Page 231: ...aintained approximately 1 2 to 1 inch from top with wheels in full left turn position 2 Fill if necessary to proper level with GM Power Steering Fluid or equivalent Fig 3B 42 Checking Belt Tension wit...

Page 232: ...are pressure hose between gauge and pump Gauge must be between shut off valve and pump Fig 3B 43 Open shut off valve 2 Remove filler cap from pump reservoir and check fluid level Fill pump reservoir t...

Page 233: ...y 1 Place the steering wheel onto the steering shaft aligning the marks made at removal 2 Position into place and secure to proper torque with washer and nut Install snap ring 3 Install belleville spr...

Page 234: ...ins should be centered in the flange slots Interm ediate Steering Shafts With Pot Joint Couplings Removal Fig 3B 46 1 Remove the lower shaft flange to flexible coupling bolts 2 Remove upper shaft to i...

Page 235: ...in the flange slots and then torque the coupling bolts to specifications Fig 3B 49 Steering Gear Mounting Motor Home Typical Intermediate Steering Shaft With Universal Joint Couplings Removal Fig 3B 4...

Page 236: ...inch bolt must pass through the shaft undercut Steering Gear Removal 1 Set the front wheels in straight ahead position by driving vehicle a short distance on a flat surface 2 Remove the flexible coupl...

Page 237: ...ion the seal in the pitman shaft bore and tap into position using a suitable size socket 5 Remove the lash adjuster lock nut Remove the side cover from the pitman shaft assembly by turning the lash ad...

Page 238: ...ounting bracket column in vehicle Tilt Feed the connector down through the housing Fig 3B 54 lnstalling Switch Connector Onto Jacket Clips Fig 3B 53 Removing Directional Signal Switch Assembly upper b...

Page 239: ...er Exploded CAUTION Always use a new snap ring when reassembling 7 Place cover on the lock plate and snap into position 8 Install the steering wheel as outlined under Steering Wheel Installation ADAPT...

Page 240: ...f the cylinder so that the finger of the adapter is located at the step in the sleeve and the serrated edge of the adapter is visiblle after assembly to the cylinder and before staking fig 3B 60 The k...

Page 241: ...column mounted shift levers The shift tube within the outer column jacket includes two lower shift levers for connection to the transmission control linkage This column does not lock the transmission...

Page 242: ...ing Shaft If the steering shaft plastic pins have been sheared the shaft will rattle when struck lightly from the side and some lash may be felt when rotating the steering wheel while holding the rag...

Page 243: ...e two screws holding the back up switch or neutral safety switch to the column and remove the switch 14 Remove the lower bearing retainer clip fig 3B 71 15 Automatic and Floorshift Columns Remove the...

Page 244: ...y No Part Name 20 SWITCH ASM 21 PROTECTOR WIRE 22 HOUSING 23 CUP 24 BOLT ASM 25 WASHER 26 GATE 27 SCREW 2 28 JACKET ASM 29 SWITCH ASM IGNITION 30 SCREW 2 31 BOWL ASM 32 SPRING 33 BOWL 34 SHROUD 35 BEA...

Page 245: ...t and shift tube bearing Assemble the 1st Reverse lever and lower bearing and adapter assembly into the bottom of the jacket Holding the adapter in place install the bearing reinforcement and retainin...

Page 246: ...rrows since damage to the column could result 3 Remove the directional signal switch lock Fig 3B 74 Adjusting Lower Bearing Typical cylinder and ignition switch as outlined previously in this section...

Page 247: ...hoe Release Lever Pin 32 Shoe Release Lever 33 Lower Bearing 34 Ignition Switch Rack Spring 35 Ignition Switch Rack 3 6 Ig n itio n S w itch Rod 37 Upper Steering Shaft 38 Centering Spheres 39 Center...

Page 248: ...Fig 3B 77 Removing Bearing Housing Pivot Pins Fig 3B 79 Replacing Lock Bolt Spring...

Page 249: ...and jacket could result 16 Remove the bearing housing support lock plate by sliding it out of the jacket notches tipping it down toward the housing hub at the 12 o clock position and sliding it under...

Page 250: ...e plate end of Tool J 23073 into the upper end of the shift tube far enough to reach the enlarged portion of the tube Then install the adapter over the end of the tool seating it against the lock plat...

Page 251: ...g column COLUMN INSTALLATION MANDATORY SEQUENCE C and K SERIES VEHICLES Fig 3B 84 Mandatory Instructions 1 Assemble lower dash cover A and upper dash cover B to seal C with Carrots part of seal 2 Atta...

Page 252: ...r bearing assembly Installation CAUTION See CAUTION not on page I o f this section regarding fasteners referred to in step 2 1 Place the new bearing over the end of the steering shaft and press into p...

Page 253: ...hree mounting screws torque to 25 lbs in after screw head has been firmly seated 3 Tilt Columns Only a Align the openings in the directional signal switch cover with the proper lever positions and tap...

Page 254: ...ng bolt must pass through the shaft undercut 4 Assemble the bearing housing as follows a Press the new upper and lower bearing races into the bearing housing b Lubricate and install the bearings into...

Page 255: ...e the directional signal switch lever 6 Remove the column wiring harness cover 7 Remove the directional signal switch screws 8 Rotate the directional signal switch housing counterclockwise and remove...

Page 256: ...to use a press Be careful not to damage the tube or jacket 16 Remove the felt seal from the shift tube 17 Remove firewall clamp toe pan seal and dash panel seals from the jacket Assembly NOTE In the...

Page 257: ...emove the lever spring and remove the wedge e Using a suitable size punch drive out the lock shoe retaining pin Remove the shoes and shoe springs 9 Remove the steering shaft assembly through the upper...

Page 258: ...PRING RELEASE U PIN RELEASE o qg SHOE RELEASE BEARING ASSY 2 PIN PIVOT BOWL ASSY p r SCREW S P R IN G SPRING JACKET ASSY YOKE SHAFT ASSY STEERING JACKET SPHERE CENTERING 2 SHAFT PROTECTOR WIRE SUPPORT...

Page 259: ...be slot to be fully installed Remove Tool J 22549 from the column Lubricate and push foam seal in flush with column housing CAUTION Do Not hammer or force the tube when installing in the column Fig 3B...

Page 260: ...Fig 3ES 96 Removing Release Lever Pivot Pin Fig 3B 98 Revised Shift Tube Removing Tool J 22551 Fig 3B 97 Removing Shift Tube Retaining Ring...

Page 261: ...ion and then install tilt spring and retainer tapered end of spring first Push into the housing approximately 3 16 and rotate counter clockwise 1 8 turn 14 Lubricate and install the upper bearing uppe...

Page 262: ...wer end of the column through the toe pan opening guiding the steering shaft flange onto the flexible coupling Install and torque the glange to coupling bolts 4 Locate the index slot in the column jac...

Page 263: ...asm C All bolts must be installed in directions shown Figs 104 and 104B sO k iu X i ADJUSTABLE CONNECTING ROD IDLER ARM ASSEMBLY RELAY ROD STEERING ARM TIE ROD ASSEMBLY TIE ROD STEERING GEAR ASSEMBLY...

Page 264: ...e rod 2 Make sure that threads on ball studs and in ball stud nuts are perfectly clean and smooth Check condition of ball stud seals replace if necessary NOTE Tool J 24434 may be used to install ball...

Page 265: ...e Compare protractor readings obtained in Speps c and d Total rotation of tie rod assembly should measure at least 35 f If rotation is less than 35 loosen one tie rod sleeve clamp and rotate both tie...

Page 266: ...f wheel and tire assemblies and road surface irregularities Removal 1 Raise vehicle on a hoist 2 Remove the cotter pin and castellated nut from ball stud at the relay rod Remove the ball stud from the...

Page 267: ...STEERING SYSTEM Power Steering Gear Removal 1 Disconnect hoses at gear When hoses are disconnected secure ends in raised position ot prevent drainage of oil Cap or tape the ends of the hoses to preven...

Page 268: ...e pinch bolt must pass through the shaft undercut All Models 6 Install the pitman arm onto the pitman shaft lining up the marks made at removal Install the pitman shaft nut or pitman arm pinch bolt an...

Page 269: ...Series Power Steering Hoses When servicing the power steering hoses be sure to align the hoses in their correct position as shown in Figs 3B 118 3B 133 It is important that the power steering hoses b...

Page 270: ...d a few minutes with engine off and repead above procedure a Check belt tightness and check for a bent pulley Pulley should not wobble with engine running b Check to make sure hoses are not touching a...

Page 271: ...g Hose Routing Rotate hose assembly hydraboost housing as before tightening nut V IE W A B M l CLEARANCE Rotate hose assembly against steering gear housing before tightening nut 292 L 6 G 30 W H Y D R...

Page 272: ...e assembly against steering gear housing before tightening nut V IE W B 350 or 400 V 8 G 30 W H Y D R A B O O ST M INIM UM CLEARANCE Fig 3B 126 Power Steering Hose Routing Fig 3B 127 Power Steering Ho...

Page 273: ...31 Power Steering Hose Routing 90 INCH V IE W A 454 V 8 C 20 30 W V A C U U M POWER BRAKES A N D 4 56 A X L E Route pipe assembly inlet outboard 15 to parallel of steering gear VIEW Hose must be locat...

Page 274: ...Bearing Preload 6 to 11 lbs in 4 to 6 lbs in 9 to 12 lbs in Adjuster Plug Lock Nut 85 lbs ft Over Center Preload 5 to 11 lbs in 4 to 10 lbs in 9 to 13 lbs in Over Center Lock Nut 25 lbs ft Total Steer...

Page 275: ...28 J 8524T 5860 Torque Wrench Adapter 29 J 8524 2 21239 Pump Pulley Remover Stamper Pulley 30 J 6219 2927 Steering Wheel Puller 31 J 22407 1614 Sector Shaft Bushing Remover 32 J 8937 7539 Ball Retaine...

Page 276: ...Protector 25 J 6217 Connector Seat Installer 8 J 9226 Pitman Shaft Bushing Replacer 26 J 5421 Therm om eter 9 J 7576 Rack Piston Seal Compressor 27 J 22407 Pitman Shaft Bearing Installer 10 J 21239 P...

Page 277: ...Replacement 3C 15 Wheel Hubs Bearings 3C 15 Shock A bsorber 3C 15 Stabilizer 3C 16 Coil S pring 3C 16 Upper Control Arm Shaft 3C 17 Lower Control Arm Shaft 3C 17 Upper Control A r m 3C 18 Lower Contro...

Page 278: ...C 10 G 10 20 C 20 30 G 30 P 10 30 9 Fig 3C l Front Suspension C P Series...

Page 279: ...pre loaded Damage can result by the steady thrust on roller ends which comes from preloading 1 Raise vehicle and support at front lower control arm 2 Spin wheel to check for unusual noise or roughness...

Page 280: ...all dust cap on hub 10 Replace the wheel cover or hub cap 11 Lower vehicle to floor 12 Perform the same operation for each front wheel DIAGNOSIS SHOCK ABSORBER DIAGNOSIS ON VEHICLE CHECKS Follow the P...

Page 281: ...Incorrect front wheel alignment caster e Check and align front suspension f Broken springs f Replace springs g Malfunctioning sfiock absorber g Diagnose shock absorbers h Broken stabilizer bar or miss...

Page 282: ...tire c Blister or bump on tire c Replace tire d Improper shock absorber action d Replace shock absorber EXCESSIVE OR UNEVEN TIRE WEAR a Underinflated or overinflated tires a Inflate tire to proper re...

Page 283: ...ar adjustment d Adjust gear as outlined in Section3bof shop manual e Power steering gear valve spool binding e See Section3bin shop manual f Obstruction within power steering gear f See Section3bin sh...

Page 284: ...BALL JOINT DIAGNOSTIC PROCEDURE...

Page 285: ...calize defective shocks caused by internal noise in the shock weak leaking etc 1 Inspecting Shocks for Possible Loss of Hydraulic Fluid a Disconnect each shock lower mounting as required and pull down...

Page 286: ...EN COLLAPSE TOP END DOWN BOTTOM M 0 U N T INVERT THEN COLLAPSE POSITION FOR PURGING AIR FROM SHOCK ABSORBER Fig 3C 10 Position for Purging Air From Shocks Bench Test Procedure 1 This is a comparison t...

Page 287: ...ction 1 Bench Check Procedure BEARINGS AND RACES BENCH DIAGNOSTIC PROCEDURE This section describes common types of bearing distress and their causes Illustrations are included to help diagnose the cau...

Page 288: ...op car 4 Run engine at various speeds Test for Wheel Bearing Noise 1 Drive car at low speed on a smooth road 2 Turn car to develop left and right motions traffic permitting 3 Noise should change due t...

Page 289: ...ROLLER ENDS CAUSED BY FINE ABRASIVES CLEAN ALL PARTS AN D HOUSINGS CHECK SEALS A ND BEARINGS A ND REPLACE IF L E A K IN G ROUGH OR NO ISY E T C H I N G B E N T C A G E BEARING SURFACES APPEAR G R A Y...

Page 290: ...O RRECT LU B RICANT OR M O ISTURE RE USE BEARINGS IF STAINS CAN BE R EM O VED BY L IG H T POLISHING OR IF NO EVIDENCE OF OVER HEA TIN G IS OBSERVED CHECK SEALS A N D R ELA TED PARTS FOR DAM AGE HEAT D...

Page 291: ...the inner race in the same manner CAUTION Use care when installing new race to start it squarely into hub to avoid distortion and possible cracking Thoroughly lubricate bearing assemblies with new hig...

Page 292: ...o floor Fig 3C17 Removing Coil Spring with Tool J 23028 COIL SPRING Removal Fig 3C 17 1 Place vehicle on hoist and place jack stands under frame allowing control arms to hang free 2 Disconnect shock a...

Page 293: ...t final positioning of shaft Check shaft for free rotation and install grease fittings Installation CAUTION See CAUTION on page I o f this section regarding the fasteners referred to in steps 3 5 and...

Page 294: ...by hand after the nuts are torqued 5 Torque U bolt nuts 6 Remove safety chain 7 Lower vehicle to floor UPPER CONTROL ARM ASSEMBLY All Removal 1 Raise vehicle on hoist remove wheel and tire assembly a...

Page 295: ...ve and convex sides together 1 Place control arm in position on bracket and install nuts Before tightening nuts insert caster and camber shims in the same order as when removed Torque the nuts to spec...

Page 296: ...fety measure 4 Disconnect shock and stabilizer bar attachments at lower control arm 5 Loosen shaft end nuts 6 Remove U bolts that retain the inboard end of the lower control arm 7 Lower jack SLOWLY to...

Page 297: ...5 for the proper procedure CAUTION Before proceeding with Step 4 be sure lower control arm is supported as pointed out in Step I 4 Extend bolt from Tool J 23742 to loosen ball stud in steering knuckle...

Page 298: ...area CAUTION Do not put stress on the brake line flex hose 7 Install Tools J 9519 10 and J 9519 7 as shown in Fig 3C 29 NOTE It will be necessary to alter Tool J 9519 10 as illustrated in Fig 3C 30 an...

Page 299: ...nto knuckle bosses CAUTION Steering knuckle hole ball stud and nut should be free o f dirt and grease before tightening nut 2 Install ball stud nuts and tighten nut specifications See Specification Se...

Page 300: ...Bearing Lubrication 3C 28 Wheel Bearing Adjustment 3C 28 Component Replacement 3C 29 Hubs Free Wheeling Kid K20 3C 29 Hubs Locked KIO K20 K 30 3C 30 Spindle 3C 30 Steering Knuckle KIO K 20 3C 31 Stee...

Page 301: ...N U C K LE 4 SPRING 13 S P IN D LE BE A R IN G 22 A D JU S TIN G SLE EVE 5 LO C K N U T 14 S E A L 23 UPPER B A L L JO IN T 6 L O C K A D J N U T 15 H U B A N D D IS C ASM 24 Y O K E 7 P IN A D J N U...

Page 302: ...T O R KNOB R E T A IN IN G PLA TE BO LT A X L E S H A F T SNAP RING A C T U A T IN G CAM BODY IN T E R N A L SNAP RING O UTER C LU TC H R E T A IN IN G RING A X L E S H A F T SLE EVE A N D C LU TC H R...

Page 303: ...King Pins MAINTENANCE AND ADJUSTMENTS BALL JO IN T ADJUSTM ENT K10 K20 Front axle ball joint adjustment is generally necessary only when there is excessive play in steering irregular wear on tires or...

Page 304: ...the spindle 2 Torque the inner adjusting nut to 50 foot pounds while rotating the hub and disc to seat the bearings Use Tool J 6893 and Adapter J 23446 or J 6893 01 for K10 K20 use J 26878 for K30 Ba...

Page 305: ...ll parts for wear cracks or broken 4 teeth 5 6 Replace all O rings during assembly Place new O ring seal on actuator knob Apply Lubri plate or equivalent to O ring and place actuator knob in retaining...

Page 306: ...tallation 1 Assemble the outer wheel bearing cup into the wheel hub a Use installer J 6368 and Driver Handle J 8092 for KIO K20 b Use J 8608 for K 30 2 Assemble the inner wheel bearing cup into the wh...

Page 307: ...spindle components as outlined earlier 2 If the steering arm is to be removed disconnect the tie rod a Remove cotter pin b Loosen tie rod nuts and tap on nut with a soft hammer to break the studs loos...

Page 308: ...12K Installing Lower Ball Joint cotter pin hole in the stud end is straight Press the stud into the knuckle until properly seated using tools J 9519 10 J 23454 2 and J 6382 3 or equivalent as shown in...

Page 309: ...steering arm using the three stud adapters and three new self locking nuts Torque the nuts to 90 ft lbs b Assemble the tie rod to the knuckle arm Torque the tie rod nuts to 45 ft lbs and install cotte...

Page 310: ...Figure 3C 19K Discard gasket replace with new one at time of assembly 4 From the underside of the knuckle remove four cap screws from the lower king pin bearing cap Remove the bearing cap and lower k...

Page 311: ...ng pin bearing cup using J 7817 as shown in Figure 3C 24K 2 Fill the area in grease retainer with specified grease then grease the bearing cone and install Install Fig 3C 26K lnstalling Upper King Pin...

Page 312: ...ings If defective replace shock absorber assembly Installation Place shock absorber into position over mounting Fig 3C 30K Shock Absorber Attachment bolts or into mounting brackets Install eye bolts a...

Page 313: ...press out bushing using a suitable rod pipe or tool 2 Press in new bushing assure that tool presses on steel outer shell of bushing Install until bushing protrudes an equal amount on each side of spri...

Page 314: ...k Absorber Upper End 140 140 65 75 Shock Absorber Low er End 60 60 65 75 Brake Splash Shield to Knuckle 120 la Lbs 120 In Lbs 120 la Lbs 120 la Lbs Wheel Bearing Adjustm ent Inner 35 Outer 50 Wheel Be...

Page 315: ...ring Race Installer 7 J 9519 9 Ball Joint Installer 3 J 8849 Bearing Race Installer 8 J 9519 7 Ball Joint Remover 4 J 9276 2 Bearing Race Installer 9 J 9519 10 C Clamp 5 J 24435 1 Bushing Replacement...

Page 316: ......

Page 317: ...BE USED A S SPECIFIED DU RING R E A SSE M B L Y TO A SSU R E PROPER RE TEN TIO N OF THIS PART INDEX General Description 3D 1 Component Parts Replacement 3D 2 Shock A bsorbers 3D 2 Stabilizer Shaft 3D...

Page 318: ...axle 2 If equipped with air lift shock absorbers bleed air from lines Disconnect line from shock absorber 3 At the upper mounting location disconnect shock absorber by removing nut and washers shown a...

Page 319: ...section regarding shock absorber fasteners 9 If equipped with airlift shock absorbers inflate to 10 15 pounds minimum air pressure Fig 3D 8 Shock Absorber P30 10 Lower vehicle and remove from hoist S...

Page 320: ...leaf spring fasteners Removal 1 Raise vehicle on hoist so that tension in spring is relieved 2 Loosen but do not remove spring to shackle retaining nut 3 Remove nut and bolt securing shackle to sprin...

Page 321: ...Fig 3D 12 Rear Spring Installation G Models...

Page 322: ......

Page 323: ...stall shackle bolt and nut and again reposition spring if necessary to align front eye Install front eye bolt and nut Torque hanger and shackle fasteners to specifications NOTE Make certain that the b...

Page 324: ...0 Rear Shackle Bolt 110 90 1 35 G 3 1 6 90 110 Shock Absorber Upper Attachment 140 75 PIO 25 P20 140 P30 50 Lower Attachment 115 75 115 Propeller Shaft To Rear Axle Strap 12 17 12 17 12 17 To Rear Axl...

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Page 326: ......

Page 327: ...of tire may seriously affect ride handling ground clearance tire clearance and speedometer calibration Similarly use of wheels with offsets other than recommended or use of what are commonly referred...

Page 328: ...16 inch through 19 5 inch diameter range without the radial identification stamp are not to be used with radial tires WHEEL N U T TORQUES On a new vehicle or after the wheel has been changed the wheel...

Page 329: ...omy The tire flexes more and can build up excessive heat weakening the tire and increasing susceptibility to damage or failure Too high an air pressure can result in abnormal wear harsh vehicle ride a...

Page 330: ...3 9 0 1 5 0 0 1 6 1 0 A X F T 7 0 0 1 5 C 1 3 5 0 1 4 8 0 1 6 1 0 1 7 2 0 A X F T 7 0 0 1 5 D 1 3 5 0 1 4 8 0 1 6 1 0 1 7 2 0 1 8 3 0 1 9 4 0 2 0 4 0 X L B R 7 0 0 1 6 C 1 4 3 0 1 5 6 0 1 6 8 0 1 8 0...

Page 331: ...tire pressures to increase 4 8 PSI or more when the tires become h ot from driving Do not bleed or reduce tire in flation pressures after driving your vehicle Bleeding serves to reduce cold inflation...

Page 332: ...ompetent truck tire repair shops CORRECTING IRREGULAR TIRE WEAR Heel and Toe Wear This is a saw toothed effect where one end of each tread block is worn more than the other The end that wears is the o...

Page 333: ...which balance wheels either on the vehicle or off The on the vehicle type however is the more desirable in that all rolling components brake drums bearings seals etc are included in the balancing pro...

Page 334: ...ire to hang loosely on wheel while inflating 6 Center valve and pull it firmly against the rim Hold in this position and inflate until tire beads are firmly seated on rim against flanges 7 Completely...

Page 335: ...e iron with stop toward rim work progressively around bead using small bites until bead slips over flange onto rim base If necessary insert second tire iron and lubricate last 6 of bead before complet...

Page 336: ......

Page 337: ...s the angle between the two yoke shafts increases This is the prime reason why single universal joints are not used for angles greater than three to four degrees At four degrees for example the change...

Page 338: ...The ball socket on this Constant Velocity joint requires periodic lubrication A lubrication fitting is provided for this purpose and is illustrated later in this section Fig 4A 3 Ball Socket Location...

Page 339: ...An occasional drop o f lubricant leaking from splined yoke is normal and requires no attention a Rough outside surface on splined yoke b Defective transmission rear oil seal a Replace seal if cut by b...

Page 340: ...ss at slip yoke spline j Drive shaft runout 50 80 mph throttle conscious a Replace b Clean drive shaft c Balance or replace as required d Check and correct to specified torque e Impact yokes with a ha...

Page 341: ...dure as above Universal Joints On models with between center slip propshaft it is important that components are marked prior to dissassembly for proper phasing Arrows are stamped on assemblies as show...

Page 342: ...e Paritally install one bearing cup into yoke Start trunnion into bearing cup Fig 4A ll U niversal Joint Repair Kit Partially install other cup Align trunnion into cup and press cups into yoke 2 Insta...

Page 343: ...in place for handling 1 Remove all of the remains of the sheared plastic bearing retainers from the grooves in the yokes The sheared plastic may prevent the bearing cups from being pressed into place...

Page 344: ...ng propshafts it is necessary to place the shafts into particular positions to assure proper operation This is called phasing All models with 32 splines use an alignment key as shown in figure 4A 19 t...

Page 345: ...ve been removed remove rear yoke half bearing cups Remove rear trunnion 7 Gently pull rear yoke half from prop shaft Remove all loose needle bearings Remove spring seal 8 Remove front trunnion from ce...

Page 346: ...to Center Line of Prop Shaft as shown PROP SHAFT SPLINE SETTING K300 00 WITH 2 PIECE PROP SHAFT 2 Piece prop shaft must be assembled as follows to prevent excessive drive line excitation 1 Transmissi...

Page 347: ...own in figure 4A 23 DOUBLE CARDAN TYPE CV JOINT Inspection An inspection kit including two bearing caps and two snap rings is available to allow the removal of the two trunnion caps shown at location...

Page 348: ...t the base of the stud This is important as the center of the double Cardan joint is Fig 4A 28 lnstalling Tool J 23996 Over Ball Fig 4 A 29 Installing Outer Cylinder of Tool J 23996 Over Ball determin...

Page 349: ...shaft First loosen the screw on grease cap shown in Figure 4A 35 and slide the collar back to reveal the sealing area Apply chassis lubricant Fig 4A 33 Reassembling Flange Yoke at the fitting until gr...

Page 350: ...ion truck remove the slip yoke and wire brush the affected areas Wipe clean before reinstallation When installing the propshaft to transfer case front output flange attaching bolts torque to specifica...

Page 351: ...7 To Rear A xle U Bolt 18 22 18 22 Bearing Support to H anger 20 30 20 30 20 30 H anger to Fram e 40 50 To Transfer Case Dana Style G M Style 20 30 70 80 Torque Specifications Ft Lbs UNIVERSAL JO IN T...

Page 352: ......

Page 353: ...side gear is splined to an axle shaft Consequently each axle shaft must turn when its side gear rotates The differential pinion gears are mounted on a differential pinion shaft and the gears are free...

Page 354: ...olded spring loaded rubber seal The seal is mounted on the pinion flange which is splined and bolted to the hypoid pinion shaft The hypoid ring gear is bolted to a one piece differential case which is...

Page 355: ...tial side bearing shims are located between the case and the side bearings Chevrolet 1 2 1 4 Ring Gear Axle 11 000 Pound Capacity The 11 000 lb capacity single speed hypoid axle illustrated in figure...

Page 356: ...ive Pinion 10 Straddle Bearing 11 Ring Gear 12 D ifferential Spider 13 Differential Case 14 D ifferential Pinion 15 Differential Side Gear 16 Side Bearing 17 Side Bearing Adjusting N ut 18 Adjusting N...

Page 357: ...Pim on Gear 5 O il Slinger 15 Ring Gear B o lt 25 Washer 6 P inio n F ro n t Bearing 16 D iffe re n tia l Side Bearing 26 Gasket 7 F ro n t Bearing Cup 17 Side Bearing Cup 27 Cover 8 Preload S him Pa...

Page 358: ...ms Outer Pinion Cover Bearing 16 Screw and Washer 0 Inner Pinion Oil Slinger Cover 17 Cover and Plug 24 Bolt Differential 18 Lock Pin Pinion Bearing Cap Shaft 25 Bolt Ring Gear 19 Differential Case 26...

Page 359: ...Axle 11 000 Capacity DIFFERENTIAL DIAGNOSIS STANDARD DIFFERENTIAL Noise The most essential part of rear axle service as with any mechanical repair is proper diagnosis of the problem and in axle work o...

Page 360: ...o approximately 50 pounds pressure for test purposes only will materially alter noise caused by tires but will not affect noise caused by the rear axle Rear axle noise usually ceases when coasting at...

Page 361: ...Charts appear later in this section Gear Noise There are two basic types of gear noise The first type is produced by broken bent or forcibly damaged gear teeth and is usually quite audible over the e...

Page 362: ...t companion flange f Companion flange runout too great 6 A knock or click approximately every two revolutions of rear wheel 6 A brinelled rear wheel bearing 7 Noise most pronounced on turns 7 Differen...

Page 363: ...BEARING ABRASIVE ROLLER WEAR PATTERN ON RACES AND ROLLERS CAUSED BY FINE ABRASIVES CLEAN ALL PARTS AND HOUSINGS CHECK SEALS AND BEARINGS AND REPLACE IF LEAKING ROUGH OR NOISY G A L L I N G METAL SMEAR...

Page 364: ...BY INCORRECT LU B R IC A N T OR M O ISTURE RE USE BEARINGS IF STAINS CAN BE R EM O VED BY LIG H T PO LISHING OR IF NO EVIDENCE OF OVER H EA TIN G IS OBSERVED CHECK SEALS A ND R ELA TED PARTS FOR DAM...

Page 365: ...at carrier 5 Connect hydraulic brake hose to connector on axle housing connect parking brake cable to actuating levers Install brake drum and wheel and tire assem bly bleed brakes and adjust parking...

Page 366: ...t Fig 4B 19 1 Remove oil seal by using button end of axle shaft Insert button end behind the steel case of the oil seal then pry seal out of bore being careful not to Fig 4B 18 Push Axle Shaft Inward...

Page 367: ...cise care that splines on end o f Fig 4B 21 Wheel Bearing Installation Fig 4B 22 Seal Installation shaft do not damage oil seal and that they engage with splines o f differential side gear 2 Install a...

Page 368: ...lation Make sure lines show the relationship of components accurately Count the number of exposed threads on pinion stem and record for later reference See figure 4B 25 6 Install Tool J 8614 11 on pin...

Page 369: ...with a non hardening sealer such as Permatex Type A or equivalent prior to installing washer and nut on pinion Fig 4B 28 Pinion Oil Seal Installation 5 Using J 8614 11 as shown in figure 4B 29 instal...

Page 370: ...system and adjust parking brake NOTE Before reinstalling wheel hub and drum assembly replace hub oil seal 5 Reassemble the rear universal joint making sure that U bolts are drawn up tight and locked...

Page 371: ...compressed air directing air stream across bearing Do not spin bearings while blowing them dry 7 Thoroughly remove all lubricant from axle housing tube and from inside the hub wipe dry Make sure all p...

Page 372: ...contact surface and O D of axle housing tube 2 Make sure inner bearing oil seal axle housing oil deflector and inner bearing race and oil seal are properly positioned 3 Install hub and drum assembly o...

Page 373: ...ement axle housing assemblies are not equipped with an axle vent therefore always make sure that a new vent assembly is installed when replacing the housing If axle vent requires replacement pry old v...

Page 374: ...iner ring as shown in figure 4B 38 NOTE The bearing cup to retainer ring seating procedure is essential to assure that an accurate wheel bearing adjustment will be obtained and that the adjustment wil...

Page 375: ...ghten inner adjusting nut at the Fig 4B 41 Pinion Oil Seal 12 1 4 Axle same time rotating hub to make sure all bearing surfaces are in contact Then back off inner nut to specified amount of turn back...

Page 376: ...V 2 C h e v ro le t CN G e a r Backlash 0 0 5 0 0 5 004 0 0 5 005 Preferred 0 0 8 0 0 8 009 008 008 0 0 3 0 0 3 004 003 0 0 3 M in and M ax 0 1 0 0 1 0 009 0 1 2 012 Pinion Bearing Preload In Lbs New...

Page 377: ...ller 6 J 22804 1 Pinion Seal Gauge Plate 21 J 8608 O u ter W heel Bearing Cup Installer 7 J 5748 Positraction T orq u e Measuring Adapter 22 J 24384 Pinion O il Seal Installer Dana 8 J 6627 W heel B o...

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Page 379: ...E P LA C E M E N T P A R T OF L E SSE R Q U A LITY OR SU B STITU TE D ISIGN TORQUE VALU ES M U ST BE USED A S SPECIFIED DURING R E A SSE M B L Y TO A SSU R E PROPER R ETEN TIO N OF TH IS PART CONTENT...

Page 380: ...3 Stop car 4 Run engine at various speeds Test for Wheel Bearing Noise 1 Drive car at low speed on a smooth road 2 Turn car to develop left and right motions traffic permitting 3 Noise should change d...

Page 381: ...i l y ABRASIVE STEP WEAR ETCHING BENT CAGE PATTERN ON ROLLER ENDS CAUSED BY FINE ABRASIVES BEARING SURFACES APPEAR GRAY OR GRAYISH BLACK IN COLOR WITH RELATED ETCHING AWAY CAGE DAMAGE DUE TO IMPROPER...

Page 382: ...INCORRECT LUBRICANT OR MOISTURE RE USE BEARINGS IF STAINS CAN BE REMOVED BY LIGHT POLISHING OR IF NO EVIDENCE OF OVER HEATING IS OBSERVED HEAT DISCOLORATION CAN RANGE FROM FAINT YELLOW TO DARK BLUE R...

Page 383: ...e to separate axle from truck springs 8 Raise truck to clear axle assembly and roll front axle out from under the truck Installation CAUTION See CA U TIO N on page I of this section regarding the fast...

Page 384: ...ass drift and a soft hammer drive on end of one trunnion bearing just far enough to drive opposite bearing from yoke 4 Support the other side of the yoke in the vise and drive the other bearing out by...

Page 385: ...dro Boost Power Steering System 5 15 Parking Brake Pedal or H andle 5 15 Parking Brake Adjustment 5 15 Parking Brake Propshaft Internal Expanding 5 22 Parking Brake Cable 5 22 Combination Value 5 22 B...

Page 386: ...lace when the brakes are applied with a firm pedal effort while the vehicle is backing up Applying the brakes moves the actuator which turns the star wheel and lengthens the adjuster screw assembly Th...

Page 387: ...ining in complete axle sets 7 M alfunctioning rear brakes 7 Check for inoperative auto adjusting mechanism defective lining grease or brake fluid on lining or defective wheel cylinders Repair as neces...

Page 388: ...e Pedal Travel 1 P artial brake system fa ilu re 1 Check both front and rear system for a failu re and re p a ir Also check and re p a ir warning light circuit It should have indicated a failu re 2 In...

Page 389: ...roper clear ance or dirt 1 Remove calip er and correct as necessary 2 Uneven rotor w ear causing a thickness variation between the two braking surfaces 2 M achine rotors as follows a M achine rotors t...

Page 390: ...ra lle l Brake Rotors X X Excessive R otor R u n O u t X F a ulty A uto m a tic A d ju ste rs X X X X X In c o rre c t W heel C y lin d e r Sizes X X X X Weak or In c o rre c t Brake Shoe R etention...

Page 391: ...e unit is operating correctly the brake pedal will fall slightly and then push back against the driver s foot remaining at about the same position If the booster is not operating correctly the trouble...

Page 392: ...used by c o n ta m in a tio n in sy s te m 2 In s p e c t c le a n and r e p la c e a l l b o o ste r s e a l s 3 No cargo body on c h a s s i s 3 Normal c o n d it io n BOOSTER CHATTERS PEDAL VIBRATE...

Page 393: ...the engine Depress and release the brake pedal There should be a minimum of three power assisted brake applications before a hard pedal is obtained Re start the engine and turn the steering wheel unt...

Page 394: ...located between master cylinder and wheel cylinders then all wheel cylinders served by the disconnected pipe must be bled Manual Bleed If the vehicle is equipped with power brakes deplete the vacuum...

Page 395: ...Fig 5 2 Front Brake Pipes and Hoses C K Models...

Page 396: ......

Page 397: ...Fig 5 4 Front Brake Pipes and Hoses P Models BRAKES 5 1 3...

Page 398: ...th penetrating oil 4 Remove U clip from female fitting at bracket and remove hose from bracket 5 Remove bolt from caliper end of hose Remove hose from caliper and discard the two copper gaskets on eit...

Page 399: ...rvoir cap 13 Remove vehicle from hoist PARKING BRAKE PEDAL OR HANDLE Removal Fig 5 9 1 Place parking brake pedal or handle in the released position 2 Remove nuts from the engine compartment on C K and...

Page 400: ......

Page 401: ...V 8 N 4 0 L 6 N 4 0...

Page 402: ......

Page 403: ...fryIvtcwfA POOO 4 2 MODELS lVIEW C K MODELS P 3 0 0 3 2 MODELS G MODELS Fig 5 9 Parking Brake Assembly Typical...

Page 404: ......

Page 405: ...P300 42 M40 JB9...

Page 406: ...22364 Drum to Brake Shoe Clearance Gauge to check diameter of drum clearance surface 2 Turn the tool to the opposite side and fit over brake shoes by turning the star wheel until the gauge just slides...

Page 407: ...pairable and must be serviced as a complete assembly 1 Disconnect hydraulic lines at combination valve Plug lines to prevent loss of fluid and entrance of dirt Disconnect warning switch wiring harness...

Page 408: ...er the vehicle from the hoist 10 Install the rod upper pivot bolt special washers and nut Tighten the nut to 22 30 ft lbs and install a NEW cotter pin Fig 5 13 Brake Pedal and Stop Lamp Adjustment P30...

Page 409: ...Remove lock ring and primary piston assembly Remove secondary piston secondary piston spring and retainer by blowing air through the outlet port 5 Place master cylinder in vise so that outlet holes ar...

Page 410: ...compensating valve poppets and the compensating valve springs from the compensating valve ports in the master cylinder body 5 Using a small screwdriver remove the snap ring at the end of the master cy...

Page 411: ...the metal part of the outboard shoe fig 5 20 Tighten the C clamp until the caliper moves away from the vehicle far enough to push the piston to the bottom of the piston bore This will allow the shoes...

Page 412: ...s noted the caliper should be overhauled Wipe the inside of the caliper clean including the exterior of the dust boot Check the boot for cuts cracks or other damage Make sure that the boot is properly...

Page 413: ...hined surface of the ear 3 Install the shoe support spring by replacing the single tang end of the spring over the notch in the center of the edge of the shoe Then press the two tangs at the spring en...

Page 414: ...es in the caliper ears with the holes in the mounting bracket CAUTION When reinstalling caliper be sure you haven t turned it over end over end This would cause a severe twist in the brake hose After...

Page 415: ...ds of the outboard shoe by looking in at each end of the caliper fig 5 31 This is the point at which the highest rate of wear normally occurs At the same time check the lining thickness on the inboard...

Page 416: ...placed when the lining is worn to approximately 1 32 thickness over the rivet heads Replace shoes in axle sets 1 Examine the inside of the caliper for evidence of fluid leakage If leakage is noted the...

Page 417: ...fit fully into the circular cutout in the key See Caution on Page 1 o f this section 8 Reinstall the front wheel and tire assembly 9 Add brake fluid to the master cylinder reservoir to bring the fluid...

Page 418: ...oth If the bore cannot be cleaned up in this manner replace the caliper Reassembly 1 Lubricate the bore in the caliper and the new piston seal with clean brake fluid Position the seal in the caliper b...

Page 419: ...ll leave a film o f mineral oil on the metal parts This may damage rubber parts when they come in contact after reassembly 2 Check the sliding surfaces of the caliper steering knuckle and support spri...

Page 420: ...ide as it rotates on the steering knuckle spindle This could be described as rotor wobble 2 The movement of the rotor from side to side in the lateral plane causes the brake shoe and lining and piston...

Page 421: ...al hole cover and install it in the drum after adjustment to prevent dirt and water from getting into the brakes Use J 6166 to turn brake adjusting screw expand brake shoes at each wheel until the whe...

Page 422: ...hing rivets out will distort shoe rim Thoroughly clean surface of shoe rim and file off any burrs or high spots 2 Use GM brake lining or equivalent and the rivets included in lining package which are...

Page 423: ...e severely applied immediately after installation of new brake shoes or linings Severe application may permanently damage new linings and may score brake drums When linings are new they must be given...

Page 424: ...ing the brake lever to the primary shoe shoe with short lining 10 Compress the spring on the brake cable and remove the cable from the lever 11 If necessary to remove the anchor pin straighten the was...

Page 425: ...11 Install hold down pins washers springs and cups from flange plate to shoes 12 Place guide plate on anchor pin 13 Install pull back springs 14 Remove the knock out plug if necessary and install a n...

Page 426: ...ight 150 ft lbs torque Clean all dirt and rust from shoe contact faces on flange plate using emery cloth 13 Thoroughly clean adjusting screws and threads in the anchor brackets Installation 1 Put a li...

Page 427: ...ning the cap screw and turning the adjusting cam NOTE To determine 020 to 039 turn the adjusting screw 2 full turns out from the fully retracted position Hold a 060 plug gage from J 9789 01 Universal...

Page 428: ...um that will not meet the specifications as shown below after refinishing O R IG IN AL DRUM DIAMETERS M AXIM UM REFINISH REPLACEM EN T D ISC AR D 11 000 11 060 11 090 12 000 12 060 12 090 13 000 13 06...

Page 429: ...s and the booster ports to prevent loss of fluid and to keep out foreign material 6 P30 42 and C K G Models a Remove booster pedal push rod cotter pin and washer and disconnect the push rod from the b...

Page 430: ...P M O D E L S E X C E P T M O T O R H O M E M O T O R H O M E C H A S S IS M O D E L S G M O D E L S Fig 5 55 Booster Installation Hydroboost...

Page 431: ...1 86 x 1 28 D rum 11 00 x 2 00 V acuum Single Diaphragm JB5 Disc 11 86 x 1 28 D rum 11 15 x 2 75 Vacuum Dual Diaphragm JB6 Disc 12 50 x 1 28 D rum 11 15 x 2 75 Vacuum Dual Diaphragm JB7 Disc 12 50 x 1...

Page 432: ...0 5 0 7 0 0 0 Base JB5 C 2 0903 3 4 131 5 6 4 0 0 7 1 0 0 Base JB6 6 4 0 0 7 1 0 0 J 5 5 JB 7 7 5 0 0 8 2 0 0 J55 JB7 C 2 0 9 06 129 5 7 1 0 0 Base JB6 7 1 0 0 J 5 5 JB 7 7 5 0 0 8 2 0 0 J55 JB7 C 20...

Page 433: ...131 5 6 2 0 0 Base JB5 K 10906 129 5 6 2 0 0 7 3 0 0 Base JB5 K 2 0 9 0 3 3 4 131 5 680 0 Base JB6 6 8 0 0 J 5 5 JB 7 7 5 0 0 8 4 0 0 J55 JB7 K 2 0 9 0 6 129 5 6 8 0 0 Base JB6 6 8 0 0 J 5 5 JB 7 7 5...

Page 434: ...3 0 6 5 6 0 0 Base JB3 G 2 1 0 0 5 3 4 110 6 4 0 0 Base JB5 G 2 1 0 0 6 6 4 0 0 Base JB5 G 2 1 3 0 5 125 6 4 0 0 Base JB5 G 2 1 3 0 6 6 4 0 0 Base JB5 G 3 1 0 0 5 1 110 6 4 0 0 7 1 0 0 6 4 0 0 7 1 0...

Page 435: ...0 0 Base JB7 7 6 0 0 8 2 0 0 J 5 5 JB 8 9 0 0 0 1 0 0 0 0 J55 JB8 1 2 0 0 0 1 4 0 0 0 H 2 2 or H 23 JF9 P 30832 1 0 5 0 0 1 2 5 0 0 Base JB8 P 31042 133 7 6 0 0 8 2 0 0 Base JB7 7 6 0 0 8 2 0 0 J 5 5...

Page 436: ...Brkt _ 20 ft lbs Flanqe Plate 30 ft lbs Drum 80 ft lbs Wheel Cylinder to Flanqe Plate Bolt 50 in lbs 180 in lbs on JB5 JB6 JB7 and JB8 Rear Brake Anchor Pin 140 ft lbs 230 ft lbs JB7 and JB8 Front Bra...

Page 437: ...nch 2 J 23530 Flaring Tool 8 J 22904 Dust Boot Installer 3 J 23533 Tubing Cutter 9 J 23518 Bleeder Adapter 4 J 25085 Socket 10 J 23709 Combination Valve Pin Retainer 5 J 8049 or J 22348 Spring Remover...

Page 438: ......

Page 439: ...terminal connections a nd or weak battery g Broken or loose ignition wires and or faulty ignition switch h Excessive moisture on plugs caps or ignition system i Damaged distributor rotor or cracked di...

Page 440: ...E N G IN E I D C O D E V IE W B O P T IO N A L z V I N LO C ATIO N D IS T R IB U T O R P A D V IE W A V IE W A O P T IO N A L E N G IN E...

Page 441: ...etor for incorrect and or misad justed idle speed float level leaking needle and seat air valve sticking choke or enrichment system and secondary vacuum break operation Adjust repair or replace as nec...

Page 442: ...ndition of cylinders for uneven compression a n d o r blown head gasket Repair as necessary valve k Check power steering flow control operation Repair or replace as necessary 1 Check for clutch slippa...

Page 443: ...ain back holes in head missing or loose Repair or replace as necessary Correct as necessary b Check for worn valve stems or guides Repair as d Inspect PCV system operation Correct as necessary necessa...

Page 444: ...as necessary e Inspect for excessive clearance between and grooves Repair or replace as necessary f Check for broken piston rings Replace necessary rings as BROKEN PISTONS AND OR RINGS a Check for und...

Page 445: ...Seats 6A 23 Valves 6A 24 Torsional D am per 6A 24 Crankcase Front Cover 6A 25 Oil Seal Front Cover 6A 26 C am shaft 6A 27 Camshaft Bearings 6A 29 Oil P a n 6A 30 Oil Pump 6A 30 Connecting Rod Bearings...

Page 446: ...oses The lifter body continues to follow the cam to its low point but the plunger spring keeps the plunger in contact with the push rod The ball check valve will then move off its seat and the lifter...

Page 447: ...SPLASH R OILING FILTER BY PASS SYSTEM OIL PRESSURE SENDING UNIT DISTRIBUTOR SHAFT OILING TIM ING GEAR OIL NOZZLE FULL FLOW OIL FILTER z z z z z z z z z z z...

Page 448: ...Fig 6A 4 P Series Engine Rear Mount...

Page 449: ...ENGINE BRACKET ALL P SERIES W ITH L 6 ENGINE 2 5 0 CU IN ENGINE 4 l LEFT RIGHT M OUNT FRAME BRACKET 292 CU IN ENGINE LEFT MOUNT 0 FRAME BRACKEET...

Page 450: ...250 CU IN ENGINE LEFT RIGHT M OUNT FRAME BRACKET 292 CU IN ENGINE LEFT M OUNT FRAME BRACKET V I E W ENGINE BRACKET ALL C SERIES WITH L 6 ENGINE 292 CU IN ENGINE RIGHT FRAME BRACKET M OUNT V I E W...

Page 451: ...Fig 6A 8 K Series Engine Rear Mount...

Page 452: ...ENGINE M O U N T BRACKET ALL K SERIES W ITH L 6 ENGINE 6A14 LIGHT TRUCK SERVICE M A N U A L...

Page 453: ...ne mount exhibits a Hard rubber surface covered with heat check cracks b Rubber separated from a metal plate of the mount or c Rubber split through center Replace the mount If there is relative moveme...

Page 454: ...a gap of 030 or more exists it is likely that the manifold has distorted to a point where it will not seat properly If a good exhaust seal is to be expected the exhaust manifold must be replaced 3 Rei...

Page 455: ...nuts rocker arm balls rocker arms and push rods NOTE Place rocker arms rocker arm balls and push rods in a rack so that they may be reinstalled in the same location Installation and Adjustment NOTE Wh...

Page 456: ...Locating Noisy Lifters Locate a noisy valve lifter by using a piece of garden hose approximately four feet in length Place one end of the hose near the end of each intake and exhaust valve with the ot...

Page 457: ...g by prying the ball retainer loose from the plunger with the blade of a small screw driver fig 6A 15 Cleaning and Inspection Thoroughly clean all parts in cleaning solvent and inspect them carefully...

Page 458: ...ming and carburetor idle speed CYLINDER HEAD ASSEMBLY Removal 1 Remove manifold assembly as previosuly outlined 2 Remove rocker arm cover and valve mechanism as previously outlined 3 Drain cooling sys...

Page 459: ...and may cause valve breakage Insufficient clearance will result in Fig 6A 21 Measuring Valve Stem Clearance Typical noisy and sticky functioning of the valve and disturb engine smoothness 3 Measure v...

Page 460: ...ealer or composition steel asbestos gasket 1 Place the gasket in position over the dowel pins with the bead up 2 Carefully guide cylinder head into place over dowel pins and gasket 3 Coat threads of c...

Page 461: ...important factor is the cooling of the valve heads Good contact between each valve and its seat in Fig 6A 26 lnstalling Rocker Arm Stud Typical Fig 6A 27 Reaming Valve Guide Typical the head is impera...

Page 462: ...3 Start the grinder and move the valve head in line with the grinder wheel 4 Turn the feed screw until the valve head just contacts wheel Move valve back and forth across the wheel and regulate the fe...

Page 463: ...t rem oving oil pan 1 Remove torsional damper as outlined 2 Remove the two oil pan to front cover attach ing screws Fig 6A 31 Cutting Tabs on Oil Pan Front Seal 3 Remove the front cover to block attac...

Page 464: ...positioned evenly around balancer 7 Install crankcase front cover to block Install and partially tighten the two oil pan to front cover screws 8 Install the front cover to block attaching screws 9 Re...

Page 465: ...indicator reading 7 If camshaft readings for all lobes are within specifications remove dial indicator assembly 8 Install and adjust valve mechanism as outlined Removal 1 Remove engine following proce...

Page 466: ...nd clearance of the thrust plate should be 001 to 005 fig 6A 40 Installation Fig 6A 41 Removing Camshaft Gear 1 Install the camshaft and gear assembly in the engine block being careful not to damage c...

Page 467: ...re is based on removal of the bearings nearest center of the engine first With this method a minimum amount of turns are necessary to remove all bearings 4 Using Tool Set J 6098 with nut and thrust wa...

Page 468: ...and be parallel with rear surface of cylinder block OIL PAN Removal 1 Disconnect battery negative cable 2 Raise vehicle on hoist and drain engine oil 3 Remove starter 4 Remove flywheel splash shield...

Page 469: ...ipe while installing in pump Pickup screen must be parallel to bottom o f oil pan when oil pump is installed 2 Install the pressure regulator valve and related parts 3 Install the drive gear and shaft...

Page 470: ...lightly parallel to the crankpin to make sure they have clearance 9 Measure all connecting rod side clearances between the connecting rod cap and side of crankpin fig 6A 50 CRANKSHAFT MAIN BEARINGS M...

Page 471: ...results with Plasti gage or its equivalent a wax like plastic material which will compress evenly between the bearing and journal surfaces without damaging either surface certain precautions should b...

Page 472: ...pper and lower insert as a unit NOTE If a new bearing cap is being installed and clearance is less tha 001 inspect for burrs or nicks if none are found then install shims as required 7 A standard 001...

Page 473: ...Rotate the bearing into place and remove tool from oil hole in crankshaft journal 4 Oil new lower bearing and install in bearing cap 5 Install main bearing cap with arrows pointing toward front of eng...

Page 474: ...ap to case interface being careful to keep sealant off the seal split line fig 6A 59 13 Install the rear main bearing cap with new seal and torque to specifications PISTON AND CONNECTING ROD ASSEMBLIE...

Page 475: ...must be free of varnish or scuffing when being measured The piston pin should be measured with a micrometer and the piston pin bore should be measured with a dial bore gauge or an inside micrometer I...

Page 476: ...n 4 1 Litre Violet G 8 927 292 cu in 4 8 Litre J 24086 7 8 Small Block 283 302 305 307 350 400 Violet J 24086 7 G 8 927 Mark IV 366 396 402 427 454 Gray J 24086 3 G 7 990 Fig 6A 63 Piston Pin Tool Spe...

Page 477: ...ig 6A 66 to make sure that the ring is free If binding occurs at any point the cause should be determined and if caused by ring groove remove by dressing with a fine cut file If the binding is caused...

Page 478: ...37 to compress the rings fig 6A 70 Guide the connecting rod into place on the crankshaft journal with Tool J 5239 3 8 or J 6305 11 32 Use a hammer handle and light blows to install the piston into the...

Page 479: ...pped 14 Connect Accelerator linkage at inlet manifold Fuel line from tank at fuel pump Hoses at fuel vapor storage canister Vacuum line to power brake unit at manifold if equipped 15 Connect wires at...

Page 480: ...except rear main bearing cap bolts to specifications Torque rear main bearing cap bolts to 10 12 ft lbs then tap end of crankshaft first rearward then forward with a lead hammer This will line up rear...

Page 481: ...y the main oil gallery which is rifle drilled down the center of the block above the camshaft Two additional oil gallerys are on either side of the main oil gallery to provide an oil supply for the hy...

Page 482: ...HAMBERS Combustion Chambers are cast to insure uniform shape for all cylinders Spark plugs are located between the intake and exhaust valves The contoured wedge shape of the combustion chamber minimiz...

Page 483: ...FUEL PUMP PUSH ROD OILING OIL F LTER AND BY PASS VALVE...

Page 484: ...FUEL PUMP PUSH ROD OILING CRANKCASE AND CRANKSHAFT OILING VALVE MECHANISM OILING...

Page 485: ...engine and cowl panel 3 Replace mount to engine and lower engine into place 4 Install retaining bolt and torque all bolts to specifications Rear Mount Replacement 1 Support engine weight to relieve re...

Page 486: ...E CHASSIS WITHOUT PROPELLER SHAFT PARKING BRAKE ALL MANUAL TRANSMISSION ALL TURBO HYDRA MATIC 350 ALL MOBILE HOME CHASSIS WITHOUT PROPELLER SHAFT PARKING BRAKE AUTOMATIC TRANSMISSION WITH PROPELLER SH...

Page 487: ......

Page 488: ...MOUNT VIEW A V AUTOMATIC TRANSMISSION FRONT MANUAL TRANSMISSION...

Page 489: ......

Page 490: ......

Page 491: ...n 1 Clean gasket and seal surfaces on manifold block and cylinder heads 2 Install manifold seals on block and gaskets on cylinder heads fig 6A 9V Use sealer at water passages and where seals butt to g...

Page 492: ...isconnect electrical wiring harness from rocker arm clips 4 Remove carburetor heat stove pipe from right exhaust manifold 5 If the vehicle is equipped with air conditioning remove the A C compressor r...

Page 493: ...side of the holes Install cover and torque bolts to specification while RTV is wet within 10 min 2 On A C equipped vehicles install the A C compressor upper brace Adjust pulley belt to specification...

Page 494: ...engine and adjust carburetor idle speed VALVE STEM OIL SEAL and or VALVE SPRING Removal 1 Remove rocker arm cover as previously outlined 2 Remove spark plug rocker arm and push rod on the cylinder s...

Page 495: ...ore of lifter body usually caused by an abrasive piece of dirt or metal wedging between plunger and lifter body 2 Moderate Rapping Noise Probable causes are a Excessively high leakdown rate b Leaky ch...

Page 496: ...hat spring rests on the ball Carefully press the retainer into position in plunger with the blade of a small screw driver fig 6A 19V 3 Place the plunger spring over the ball retainer and slide the lif...

Page 497: ...pped springs and spring damper then remove oil seals and valve spring shims 3 Remove valves from cylinder head and place them in a rack in their proper sequence so that they can be assembled in their...

Page 498: ...ressure to obtain a clearance reading If clearance exceeds specifications it will be necessary to ream valve guides for oversize valves as outlined 4 Check valve spring tension with Tool J 8056 spring...

Page 499: ...il seal in the lower groove of the stem making sure that the seal is flat and not twisted d Install the valve locks and release the compressor tool making sure that the locks seat properly in the uppe...

Page 500: ...a new gasket with a good sealer Spread the GRIND OUT THIS PORTION i i II i j 111j I p 111 I l l l l 1 r l r rj I 1 1 2 3 4 5 6 Fig 6A 30V Cutaway Scale sealer thin and even One method of applying the...

Page 501: ...ecause the seating of the valves must be perfect for the engine to deliver the power and performance built into it Another important factor is the cooling of the valve heads Good contact between each...

Page 502: ...rt the grinder and move the valve head in line with the grinder wheel 4 Turn the feed screw until the valve head just contacts wheel Move valve back and forth across the wheel and regulate the feed sc...

Page 503: ...pecifications 4 Install accessory drive pulley 5 Install radiator shroud as outlined in Section 6B 6 Install fan and pulley to water pump hub and tighten securely 7 Install fan belt and adjust to spec...

Page 504: ...cover 2 Cut tabs from the new oil pan front seal fig 6A 40V use a sharp instrument to ensure a clean cut 3 Install seal to front cover pressing tips into holes provided in cover 4 Coat the gasket with...

Page 505: ...4V NOTE Make sure push rod is in the lifter socket 3 Rotate the crankshaft slowly in the direction of rotation until the lifter is on the heel of the cam lobe At this point the push rod will be in its...

Page 506: ...in camshaft with dowel hole in camshaft sprocket then install sprocket on camshaft 4 Draw the camshaft sprocket onto camshaft using the mounting bolts Torque to specifications 5 Lubricate timing chain...

Page 507: ...and install puller screw through pilot 3 Index camshaft bearing in bore with oil hole aligned as outlined below then install remover and installer tool on puller screw with shoulder toward bearing a...

Page 508: ...ith ends butting side gaskets fig 6A 51V 3 Install oil pan and torque bolts to specifications 4 Install starter brace and attaching bolts Torque bolts to specifications 5 Install converter housing und...

Page 509: ...y is necessary Assembly Figures 6A 52V and 6A 53V Fig 6A 55V Installing Screen Mark IV 2 Install the pressure regulator valve and related parts 3 Install the drive gear and shaft in the pump body 4 In...

Page 510: ...kpin If the bearing is fitted to the minimum diameter and the crankpin is out of round 001 interference between the bearing and crankpin will result in rapid bearing failure a Place a piece of gauging...

Page 511: ...ced Never replace one half without replacing the other half Checking Clearance To obtain the most accurate results with Plasti gage or its equivalent a wax like plastic material which will compress ev...

Page 512: ...shims as required 7 A standard 001 or 002 undersize bearing may produce the proper clearance If not it will be necessary to regrind the crankshaft journal for use with the next undersize bearing 8 Pro...

Page 513: ...lows 1 With the oil pan and oil pump removed remove the rear main bearing cap 2 Remove oil seal from the bearing cap by prying from the bottom with a small screw driver fig 6A 63V 3 To remove the uppe...

Page 514: ...onnecting rod cap and install Tool J 5239 3 8 or J 6305 11 32 on studs Push connecting rod and piston assembly out of top of cylinder block fig 6A 67V NOTE It will be necessary to turn the crankshaft...

Page 515: ...e piston pin holes in piston and connecting rod to facilitate installation of pin 2 Place connecting rod in piston and hold in place Fig 6A 69V Piston Pin Ready for Installation with piston pin guide...

Page 516: ...3 Measure the space or gap between the ends of the ring with a feeler gauge fig 6A 72V 4 If the gap between the ends of the ring is below specifications remove the ring and try another for fit 5 Fit...

Page 517: ...ring groove is very important to provide proper ring action and reduce wear Therefore when fitting new rings the clearances between the surfaces of the ring and groove should be measured fig 6A 75V Se...

Page 518: ...he numbers on the connecting rod and bearing cap must be on the same side when installed in the cylinder bore If a connecting rod is ever transposed from one block or cylinder to another new bearings...

Page 519: ...gine removed from the vehicle and the transmission and or clutch housing removed from the engine mount engine in stand and clamp securely 2 Remove the oil dip stick and oil dip stick tube if applicabl...

Page 520: ...main bearing cap bolts to specifications Torque rear main bearing cap bolts to 10 12 ft lbs then tap end of crankshaft first rearward then forward with a lead hammer This will line up rear main bearin...

Page 521: ...0026 0036 0007 0017 0007 0017 0014 0024 0024 Service 0025 Max 0045 Max 0027 Max 0035 Max PISTON RING C 0 M P R E S S I 0 N Clear ance Groove Produc tion Top 0012 0027 0020 0040 0012 0032 0017 0032 2n...

Page 522: ...0008 0020 1 2 3 4 Main Bearing Clearanc Production 0003 0008 2 3 4 0013 0025 e 0011 0023 5 0024 0040 0029 0034 5 0017 0032 Service 1 002 Max A ll Others 0035 Max Crankshaft End Play 002 006 006 010 D...

Page 523: ...h 46 Seat Runout Int Exh 002 Max Seat Width Intake 1 32 1 16 Exhaust 1 16 3 32 Stem Clearance Produc tion Int 0010 0027 Exh 0015 0032 0010 0027 0012 0029 Service Hi Limit Production 001 Intake 002 Exh...

Page 524: ...uide Ream er Set 3 8 C arbon R em oving Brush C y lin d e r Head B o lt W rench 16 J 5715 003 Rocker A rm Stud Reamer J 6036 013 17 J 6880 Rocker A rm Stud Installer 18 J 5802 Rocker A rm Stud Remover...

Page 525: ...ng system at higher than atmospheric pressure The higher pressure raises the boiling point of the coolant which increases the efficiency of the radiator The radiator filler cap contains a pressure rel...

Page 526: ...vel stands just above the top of the cylinder head then disconnect the radiator upper hose and remove the thermostat and fan belt Start the engine and quickly accelerate several times At the same time...

Page 527: ...aph 1 B If the fan and clutch assembly free wheels with no drag revolves over 5 times when spun by hand the clutch should be replaced If clutch performs properly with a slight drag go to step C NOTE T...

Page 528: ...e radiator The radiator should be hot along the left side and warm along the right side with an even temperature rise from right to left Cold spots in the radiator indicate clogged sections 2 Water pu...

Page 529: ...the radiator and run the engine at moderate speed until engine coolant temperature reaches 180 degrees 6 Remove cover from radiator and continue to run the engine for 20 minutes Avoid boiling 7 While...

Page 530: ...and gasket from thermostat housing fig 6B 5 3 Inspect thermostat valve to make sure it is in good condition 4 Place thermostat in a 33 glycol solution 25 above the temperature stamped on the thermost...

Page 531: ...or run out to verify that run out is within 006 inch Install fan belt and adjust Water Pump Removal WARNING If you siphon coolant from the radiator do not use mouth to start siphoning action The coola...

Page 532: ...p pulley and fan on pump hub and tighten bolts to specifications NOTE A guide stud 5 16 24 bolt with the head removed installed in one hole of the fan hub will aid in aligning hub pulley and fan Remov...

Page 533: ...bination fuel pickup filter and fuel gage tank unit The tank unit can be removed by removing a cam ring which retains the unit The fuel feed pipes are coated welded steel tubing Connections from the t...

Page 534: ...lly balanced venting through a vent hole in the air horn which leads from the float bowl into the bore beneath the air cleaner The carburetor model identification is stamped on a vertical portion of t...

Page 535: ...IN W ELL A IR BLEED POWER PISTON M E TE R IN G ROD POWER PISTON SPRING 3 TH R O TTL E V A LV E M A IN M E TE R IN G C A L IB R A TIO N SCREW POWER PISTON A C T U A TIN G LIN K A G E LOWER ID LE A IR...

Page 536: ...cted and there are no signs of damage 2 If choke or linkage binds sticks or works sluggishly clean with Choke Cleaner X 20 A or equivalent Use cleaner as directed on can Refer to disassembly instructi...

Page 537: ...L D E R A N D R E M O V E F R O M M A I N M E T E R I N G JE T M ETERING ROD ADJUSTMENT B E N D H E R E T O A D J U S T CARB IMO PLUG GAUGE 17057001 17057002 17057004 17057005 17057010 17057302 008 i...

Page 538: ...SCREWS PLACE C A M FOLLOWER ON HIGH STEP OF CAM IN S E T AUTO M ATIC CHOKE ADJUSTMENT CARB NO N D E X M A R K ALL INDEX 6 G G A U G E B E T W E E N U P P E R E D G E O F C H O K E V A L V E A T C E N...

Page 539: ...M 8 CARB NO PLUG G AUG E N O T E H O L D G A U G E V E R T IC A L iM H O L D I N G D O W N O N C H O K E V A L V E G A U G E B E T W E E N U P P E R E D G E O F C H O K E V A L V E A N D IN S ID E A...

Page 540: ...ark plugs and wires Check air cleaner evaporative emission system EFE System PCV system EGR valve and engine compression Also inspect intake manifold vacuum hoses and connections for leaks and check t...

Page 541: ...tor insulator 3 Install carburetor over manifold studs 4 Install vacuum and fuel lines at carburetor 5 Install attaching nuts and tighten alternately to 16 pounds feet 21 Nm 6 Tighten fuel line 7 Conn...

Page 542: ...0 RPM D 250 CID A U T O M A T IC TRANS HIGH A L T IT U D E 620 RPM D 600 RPM D 250 CID M A N U A L TRANS C A L IF O R N IA 1100 RPM N 850 RPM N ID LE M IX T U R E LE A N DROP H E A V Y D U T Y EM ISSI...

Page 543: ...dels equipped with automatic transmission and air conditioning The solenoid is used to maintain proper idle speed when the air conditioning is in operation Fuel for the pump system is obtained through...

Page 544: ...L E o FF ID L E pu se T E R idle 0F FIDLE TUBE DISCHARGE DISCHARGE THROTTLE HOLE PORTS VALVE Fig 6C 19 Idle System California FUEL IN LE T F IT T IN G FILTER RELIEF FILTER S P R IN G LARGE IN TER N A...

Page 545: ...diaphragm shaft should fully retract within 10 seconds If unit fails to retract replace vacuum break assembly Refer to figure 6C 26 for the following adjustments Choke Rod Fast Idle Cam Vacuum Break U...

Page 546: ...UGE B E N D F L O A T T A N G TO A D J U S T FO R P R O P E R S E T T IN G M E A S U R E S P E C IF IE D D IS T A N C E F R O M G A S K E T S U R F A C E TO N O T C H A T TO E OF F LO A T ALL 1 9 3 2...

Page 547: ...T IL C HO KE V A L V E CLOSES SET M A R K O N CO V ER TO S PE C IFIE D P O IN T ON C H O K E H O U S IN G N O TE ON M O D E LS W ITH S L O T T E D C O IL PICK UP L E V E R M A K E SURE C O IL TAN G I...

Page 548: ...F FAST ID L E C A M V A C U U M D IA P H R A G M S E A T E D S j B E N D R O D T O A D J U S T N O T E P L U G E N D C O V E R j W IT H A P IE C E O F M A S K IN G T A P E M A K IN G S U R E T O C O...

Page 549: ...O L E N O ID EN ER G IZED A C COMPRESSOR LE AD DISC ON NECTED A T A C COMPRESSOR A C ON A T TR A N S M IS S IO N IN D R IV E E LE C T R IC A L C O N N EC TIO N L IG H T D U T Y E M IS S IO N S M A N...

Page 550: ...ew in lean with 1 8 turn increments until idle speed reaches value shown in Chart Column B of specifications 11 Reset idle speed to specification shown on Emission Control Information Label 12 Check a...

Page 551: ...AIR HORN TIGHTENING SEQUENCE Refer to figure 6C 29 for air horn tightening sequence Fig 6C 29 Air Horn Tightening Sequence...

Page 552: ...T Y EM ISSIONS ENGINE COLUMN A SPEED BEFORE LEAN DROP COLUMN B SPEED AFTER LEAN DROP 305 CID 800 RPM N 700 RPM N T O R Q U E S P E C IF IC A T IO N S 2GC C A R B U R E TO R SCREW TORQUE IN LBS TH R O...

Page 553: ...en the air conditioning is in operation as when it is off The float assembly is used along with a windowless type needle seat for better fuel handling in the float bowl Also a plastic filler block is...

Page 554: ...cup on the accelerator pump assembly improves pump fuel delivery All M 4MC M4ME models use the bowl mounted choke housing with thermostatic control assembly The choke shaft and some other parts of the...

Page 555: ...PULL CLIP FUEL INLET FILTER INLET NUT S ID E ENTRY INTERNAL VENT TUBE INTERNAL VENT SLOT FLOAT HINGE PIN FLOAT ASSEM BLY c FLOAT BOWL Fig 6C 34 Float System...

Page 556: ...ENTURI A u r M A IN POWER PISTON D O W N POWER PISTON SPRING M A IN VENTURI THROTTLE VALVE M A IN m a i m METERING VACUUM f NR NG RODS 2 PASSAGE METERING JETS 2 Fig 6C 36 Main Metering System M4MC M4M...

Page 557: ...T M E N T SC R EW AIR VALVE M ETERING ROD LEVER M A IN POWER PISTON UP P O W E R P IS T O N S P R IN G V A C U U M PASSAGE M A IN M E T E R IN G J E T S 2 M ETERING DISC M A IN M E T E R IN G RODS 2 S...

Page 558: ...Fig 6C 41 Air Valve Dashpot 4MV PUMP LEVER EXPANDER SPRING Fig 6C 43 Accelerating Pump System 4MV Fig 6C 42 Accelerating Pump System M4MC IVI4ME...

Page 559: ...CUP BAFFLE S E C O N D A R Y LO CKO UT LEVER V A C U U M BREAK A D J U S T IN G SCREW V A C U U M BREAK D IA P H R A G M FAST IDLE C A M FOLLOWER FAST IDLE A D J U S T IN G SCREW U NLO AD ER T A N G C...

Page 560: ...M O S T A TIC COIL FAST IDLE C A M FOLLOWER INSET CHOKE SYSTEM ELECTRIC CHOKE TY P E PLUNGER B U CK IN G SPR IN G S E C O N D A R Y LO CKO UT LEVER UNLO ADER TA N G FAST IDLE A D JU S T IN G SCREW EL...

Page 561: ...nition but do not start engine 2 Turn A C to on position 3 Open throttle to allow solenoid to extend close throttle 4 Disconnect lead at solenoid Solenoid plunger should drop away from throttle lever...

Page 562: ...15 32 17057209 17057218 17057222 17057518 17057522 17057586 17057588 17057219 17057519 17057512 17057517 7 16 17056212 17057221 17056217 3 8 17057213 17057215 17057216 17057525 17057514 17057529 1705...

Page 563: ...P O F F A S T ID L E C A M L 3 JDISCONNECT A N D PLUG V A C U U M HOSE A T EGR VALVE FAST IDLE ADJUSTMENT L IG H T D U T Y EMISSIONS M A N U A L TR A N SM ISSIO N 1300 RPM N AUTOMATIC TRANSMISSION 16...

Page 564: ...D H E R E F O R S P E C IF IE D C L E A R A N C E B E T W E E N R O D A N D E N D O F S L O T IN L E V E R N O T E P L U G P U R G E B L E E D H O L E W IT H T A P E W H E R E U S E D R E M O V E A F...

Page 565: ...U S T G A U G E B E T W E E N A IR H O R N W A L L U P P E R E D fiF O F C H O K E V A L V E S E E N O T E CARB NO N O T E P L U G P U R G E B L E E D H O L E W IT H A P IE C E O F M A S K IN G T A P...

Page 566: ...STEP OF CAM INSET 1 AUTOMATIC CHOKE COILADJUSTMENT M4MC CARB NO 1 7 0 5 7 5 0 3 1 70 E 7519 17057202 17057204 17057218 17057222 17057502 17057504 17057518 17057522 17057582 17057584 17057586 17057588...

Page 567: ...O R N W A L L A N D U PPE R EDGE OF C H O K E V A LV E SEE NOTE UNLOADER ADJUSTMENT 4MV CARB NO PLUG GAUGE ANGLE GAUGE 17057213 17057215 17057216 17057529 17057229 205 40 17057525 17057514 225 4 3 170...

Page 568: ......

Page 569: ...E V E H IC LE FOR ADJUSTMENTS SEE EMISSION LA B E L ON VEHICLE NOTE IG N ITIO N TIMING SET PER LABEL TURN SCREW TO ADJUST TO SPECIFIED RPM RECONNECT A C COMPRESSOR LE A D AF TER O J AD JUSTMENT O P E...

Page 570: ...Information Label 12 Check and adjust fast idle as described on the Emission Control Inforamtion Label 13 Reconnect vacuum hoses Install air cleaner 14 Recheck idle speed If necessary reset to specifi...

Page 571: ...and insulator Installation 1 Clean sealing surfaces on intake manifold and carburetor 2 Fill carburetor bowl before installing carburetor 3 Install carburetor and new insulator with attaching bolts Ti...

Page 572: ...with attaching bolts Tighten bolts alternately to 144 pound inches 4 Connect downshift cable as required 5 Connect accelerator linkage 6 Connect choke linkage and install clip 7 Connect solenoid as re...

Page 573: ...400 CID 770 RPM N 700 RPM N 454 CID EXCEPT C A L IF O R N IA 800 RPM N 454 CID C A L IF O R N IA 750 RPM N T O R Q U E S P E C IF IC A T IO N S M 4M C M 4M E C A R B U R ETO R 4M V C A R B U R ETO R S...

Page 574: ...t filter from being installed incorrectly unless forced 6 Install new gasket on fuel inlet filter nut and install nut in carburetor Tighten nut to 18 pound feet CAUTION Tightening beyond specified tor...

Page 575: ...prior to replacement of the fuel pum p will save time expense and possibly prevent a repeat complaint Low Pressure Complaint The only way to check fuel pump pressure is by connecting an accurate press...

Page 576: ...nd vent line 5 Remove strap bolts and lock washers from tank front and rear locations on inside fram e rail 6 Remove tank from fram e sim ultaneously disengaging filler neck hose from filler neck Fig...

Page 577: ...ontamination If filter is plugged replace leave fuel line disconnected 5 Locate tank away from heat flame or other source of ignition Remove fuel gauge tank unit and inspect condition of filter If fil...

Page 578: ...al of Tank for proper procedure 11 Connect a hose to fuel line at carburetor insert other end of hose into a one gallon fuel can Fig 6C 66 Fuel Tank CK 10 20 06 16 12 Connect battery cable Make sure d...

Page 579: ...O S E G A S K E T S C R E W Fig 6C 68 Filler Neck CK10 20 06 16 BRACKET FUEL TANK ASSEMBLY VIEW A REAR CROSS SILL CEMENT TORQUE AT 45 IN LBS ANTI SQ UEAK FUEL TANK ASSEMBLY VIEW B upper nut jw e r nut...

Page 580: ...ASM ANTI SQUEAK CEMENT SPACER STRAP ASSEMBLY SPACER TORQUE A T 10 FT LBS ASSEMBLY Cement anti squeak to upper surface of tank flange with 1 00 wide coverage before installation of tank assembly Tighte...

Page 581: ...F W P J I BRACKET ASSEMBLY REAR SPRING FRONT HANGER STRAP ASSEMBLY FUEL TANK ANTI SQUEAK Fig 6C 71 Fuel Tank and Mounting P20 30 Fig 6C 72 Fuel Tank 50 Gal Meter and Filler Neck P30...

Page 582: ...ssion line stores any vapor generated for consumption during the next period of operation The amount of vapor drawn into the engine at any time is too small to have any effect on fuel economy or engin...

Page 583: ...RATOR CONTROL CABLE Refer to figures 6C 73 through 76 for removal and installation of accelerator control cable ACCELERATOR PEDAL Refer to figures 6C 77 through 80 for removal and installation of acce...

Page 584: ...ring anchor both Springs thru hole in Carburetor Lever and holes in Support and Bracket Fig 6C 75 Accelerator Controls V8 2Bbl I CAUTION 1 Flexible components hoses wires conduits etc must not be rout...

Page 585: ...be used in pressing the retainer into hole in rod to assure cable is not kinked or damaged in any way R E IN F O R C E M E N T ROD sV LUBRICATE SUPPORT SPRING ACCELERATOR CONTROL CABLE TIGHTEN TO 42...

Page 586: ...L TOOLS J9789 02 UNIVERSAL CARBURETOR GAUGE SET J9789 118 CARBURETOR HOLDING STAND J9789 111 BENDING TOOL J25322 PUMP LEVER PIN DRIVE PUNCH J23417 CHOKE LEVER INSTALLING TOOL J26701 CHOKE VALVE ANGLE...

Page 587: ...6D43 Starter M otor 6D 43 Solenoid 6D 46 Diagnosis 6D 48 No Cranking A ction 6D 48 Cranking Speed Abnormally Low 6D 48 Voltage T est 6D48 Amperage Test 6D49 On Vehicle Service 6D 50 Component Part Re...

Page 588: ...s into groups The elements are connected in series electrically by connectors that pass directly through the case partitions between cells The battery top is a one piece cover The cell connectors by p...

Page 589: ...energy for the cranking motor and for the ignition system as the engine is started 2 It supplies current for the lights radio heater and other accessories when the electrical demands of these devices...

Page 590: ...d in an area at 60 F 16 C for the same length of time To minimize self discharge a wet battery should be stored in as cool a place as possible provided the electrolyte does not freeze A wet battery wh...

Page 591: ...nd early failure Figure 6D 8B shows how battery power shrinks while the need for engine cranking power increases with falling temperatures Sub zero temperatures reduce capacity of a fully charged batt...

Page 592: ...arging period of sufficient duration to restore the battery to a satisfactory state of charge Refer to the charging guide in this section When out of the vehicle the sealed side terminal battery will...

Page 593: ...des visual information only for battery testing On rare occasions the state of charge indicator will turn light yellow Normally a battery with this condition is capable of further service but the indi...

Page 594: ...ot 52 C 125 F or if violent gassing or spewing of electrolyte through the vent holes occur After charging in accordance with the tables the green dot may appear in the state of charge indicator after...

Page 595: ...of the indicator lamp current and is shown in figure 6D 2C With the generator operating a c voltage is generated in the stator windings and the stator supplies d c field current through the diode tri...

Page 596: ...of the terminals in the charging circuit except as specifically instructed in these procedures Never operate the generator with the output terminal open circuited Make sure the generator and battery a...

Page 597: ...ercharged condition has not been caused by accessories having been left on for extended Fig 6D 4C Generator End View periods 2 Check the drive belt for proper tension 3 Check battery Test is not valid...

Page 598: ...sion of insulating washer Fig 6D 5C omission of insulating sleeve over screw or damaged insulating sleeve Remove screw to inspect sleeve If satisfactory replace regulator as covered in the Chassis Ove...

Page 599: ...CARBON c 5 PILE L VOLTMETER f m s K K K V v D BATTERY RESISTOR TEST AMMETER s S S 5 S V GENERATOR D C...

Page 600: ...N G IN E OFF I G N I T IO N ON IF A L L L IG H T S O F F VCHECK FO R CAUSE S T A R T E N G IN E A N D REPLACE G A U G E S FUSE G E N E R A T O R L I G H T ON C O N N E C T T EST L I G H T T O NO 1 T E...

Page 601: ...S REPAIR IF N E C E S S A R Y G E N E R A T O R L IG H T ON REPLACE G A U G E S FUSE G E N E R A T O R L I G H T O F F V i GO TO STEP 3 G E N E R A T O R L IG H T ON RE P A IR OPEN IN NO 18 P IN K W...

Page 602: ......

Page 603: ...Y G E N E R A T O R B E L T SEQUENCE RESULT C O N N E C T V O L T M E T E R T E R M I N A L A N D G R O U N D C O N N E C T JUMPER T E R M I N A L A N D G R O U N D R E C O N N E C T N E G A T I V E...

Page 604: ...H A N P R E V IO U S R E A D I N G GO TO STEP 8 T U R N O F F ACCESSORIES W A IT U N T IL UPPER R A D IA T O R I N L E T A N D IS H O T V O L T M E T E R N E E D L E STOPS IF M E T E R RE A D S U N D...

Page 605: ......

Page 606: ...procedure to install then adjust drive belt s as outlined in Section 6A of this manual GENERATOR PULLEY Replacement 1 Place 15 16 box wrench on retaining nut and insert a 5 16 alien wrench into shaft...

Page 607: ...6D 8C b Double groove pulley place a 15 16 socket with wrench flats on the drive end or use adapter J 21501 and a box wrench on the pulley retaining nut insert a 5 16 alien wrench through the socket...

Page 608: ...t and to one of the three connectors Observe the reading then reverse the ohmmeter leads to the same connectors A good diode trio will give one high and one low reading If both readings are the same r...

Page 609: ...e rings smooth and round Finish with 400 grain or finer polishing cloth and blow away all dust Drive End Frame Bearing Replacement Lubrication 1 The drive end frame bearing can be removed by detaching...

Page 610: ...ce an induced voltage in the pick up coil signals the all electronic module to open the coil primary circuit The primary current decreases and a high voltage is induced in the ignition coil secondary...

Page 611: ...ion coil Each time the timer core teeth align with the pole piece teeth the pick up coil magnetic field is changed creating a different voltage The pick up coil sends this different voltage signal the...

Page 612: ...Fig 6D 3i High Energy Ignition Basic W iring...

Page 613: ...L IG H T REPAIR TEST LIG H T O FF LE A D OR ON CONNECTOR STARTS I___ IN S E R T TE ST L IG H T IN RED B W IRE NO S TAR T TEST LIG H T ON IG N IT IO N SW Q 0 D REPAIR OR REPLACE AS NECESSARY TEST LIG...

Page 614: ...VE GREEN W HITE LE A D S FROM M OD ULE STARTS M_ESS T H A N IN F IN IT Y X 1000 SCALE REPLACE C O IL PICK UP f CONNECT O H M M E TER FROM G R O UN D TO EITHER LE AD NO S TA R T READS IN F IN IT E X 1...

Page 615: ...C T O H M M E T E R C 0 K BOTH TESTS READ IN F IN IT Y REPLACE COIL REM O VE G REEN WHITE LEADS FROM MODULE RUNS SMOOTH LESS THAN IN FIN IT Y X 1000 SCALE REPLACE COIL PICK UP RUNS ROUGH f CONNECT OHM...

Page 616: ...LIGHT OFF IGNITION SW 0 R EPA IR OR TEST LIGHT REPLACE AS ON N ECESSARY STARTS NO START REM O VE A SPARK PLUG WIRE INSERT EXTEN SIO N AND PERFO RM SPARK TEST USING IN SULA TED PLIERS HOLD SPA RK PLUG...

Page 617: ...O S T A R T READS IN F IN IT E X 1000 SCALE REMOVE GREEN W HITE LE AD S FROM M O D ULE STARTS REPLACE CO IL PICK UP _tc X X T H AN IN F IN IT Y X 1000 SCALE f CONNECT s O H M M E TER FROM V V _ G RQ...

Page 618: ...CT OHMMETER ACROSS 2 LEADS READS 500 TO 1500 OHMS REPEA T STEPS 4 AND 5 W HILE MOVING VAC ADVANCE WITH SCREW D RIV ER IF READING IS S T ILL OK DOES NOT READ 500 TO 1500 OHMS RUNS SMOOTH REPLACE COIL P...

Page 619: ...the distributor cap connector is a tach terminal Connect the tachometer to this terminal and to ground Some tachometers must connect from the tach terminal to the battery positive terminal Follow tach...

Page 620: ...caused by removal of pin 8 Remove distributor shaft from housing 9 Remove washer from upper end of distributor housing 10 Remove lock ring at top of housing and remove pole piece and plate assembly a...

Page 621: ...y Replacement Figs 6D 7i 6D 9i The pole piece and plate assembly is serviced by complete replacement only The three screws securing stationary pole piece and permanent magnet should not be disturbed e...

Page 622: ...follows black ground in center brown next to vacuum advance unit pink opposite vacuum advance unit 3 Secure ignition coil with four screws Place ground wire under coil mounting screw 4 Install coil c...

Page 623: ...thousandths of a second The effect is that the ignition wiring acts like a radio transmitting antenna the surges of high voltage send out impulses that causes radio and television interference Howeve...

Page 624: ...s of useful life from a spark plug However operating conditions are an important factor and life expectany of the spark plug will vary with the type of service in which the engine is used The same typ...

Page 625: ...te However under certain conditions of operation these deposits melt and form a shiny yellow glaze coating on the insulator which when hot acts as a good electrical conductor This allows the current t...

Page 626: ...LED IN ACCORDANCE WITH AC INSTALLATION INSTRUCTIONS Insufficient Installation Torque PRE IGNITION Pre ignition causing burned or blistered insulator tip and badly eroded elec trodes indicates excessiv...

Page 627: ...t on the 5 8 hex tapered plugs Use care in this operation to avoid cracking spark plug insulators 2 Carefully inspect the insulator and electrodes of all spark plugs Replace any spark plug which has a...

Page 628: ...t these terminals Figure 12i shows the positions of the contacts in all positions as viewed from the key side of the switch There is also a ground pin in the switch which contacts the ground terminal...

Page 629: ...e the entire shift lever and plunger mechanism protecting them from dirt splash and icing The drive end frame also includes a grease reservoir to provide improved lubrication of the drive end bearing...

Page 630: ...oles of the horseshoe magnet will be upward as shown The current carrying conductor will produce a magnet field shown as circles around the wire The net result is more magnetic lines on the left hand...

Page 631: ...the other side of the conductor S T R O N G FIELD W E A K FIELD Fig 6D 5s Basic M otor Construction A cross sectional view of a typical starter motor with a solenoid is shown in figure 6D ls The start...

Page 632: ...e and the rolls move away from the taper allowing the pinion to overrun the shell The start switch should be opened immediately when the engine starts to avoid prolonged overrun When the shift lever i...

Page 633: ...ugh the contact disc cranking takes place The pull in winding operates to assist the hold in winding in pulling the plunger into the core Once the plunger movement has been completed much less magneti...

Page 634: ...okay test cranking motor and solenoid switch 3 If starter motor and solenoid switch test okay the trouble is due to an internal condition of engine This may be due to use of engine oil which is too h...

Page 635: ...d S terminal Connect a heavy jumper wire from solenoid base to ground post of battery 3 Connect a voltmeter between base of solenoid and small solenoid S terminal 4 Slowly adjust resistance until volt...

Page 636: ...motor terminal to ground 2 After energizing the solenoid push the pinion away from the stop retainer as far as possible and use feeler gauge to check clearance between pinion and retainer Fig 6D 15s 3...

Page 637: ...forcing the collar toward the clutch and removing lock ring from end of tube 3 Check brush holders to see that they are not deformed or bent but will properly hold brushes against the commutator test...

Page 638: ...rming this test when applicable Place one lead on the connector bar and the other on the grounded brush fig 2 IS If the lamp lights the field coils are grounded Field Coil Replacement Field coils may...

Page 639: ...bars o f the molded commutator Fig 6D 19S Armature Ground Test 2 Undercut insulation between commutator bars 1 32 This undercut must be the full width of insulation and flat at the bottom a triangula...

Page 640: ...ure shaft with silicone lubricant b Slide clutch assembly onto armature shaft with pinion outward c Slide retainer onto shaft with cupped suraface facing end of shaft away from pinion d Stand armature...

Page 641: ...ge shift lever yoke buttons or improper assembly of the shift lever mechanism Worn or defective parts should be replaced STARTING SOLENOID Removal 1 Remove the outer screw and washer from the motor co...

Page 642: ...L25 Base G 2 0 30 P Truck A ll P Truck Base V 8 Except P31832 4521 4 4 5 38 42 1102480 1102486 1102886 1102888 P31832 Truck Base A ll L 6 o r V 8 w ith RPO K76 454 V 8 FL8 Base K31303 G 30003 Truck B...

Page 643: ...400 V 8 LF4 350 Am ps 170 80 89 5 454 V 8 LF8 RPO UA1 465 Amps 230 125 87 5 RPO TP2 430 Am ps 210 100 STARTING MOTOR MODEL N O APPLICATIO N SPEC N O VOLTS FREE SPEED AMPERES RPM 1108778 250 L 6 LD4 C...

Page 644: ......

Page 645: ...ases the revised Thermostatic Air Cleaner TAC Federal and California regualtions make it necessary to Evaporation Control System ECS have specific engines and emission control systems for The emission...

Page 646: ...ator valve periodically NOTE If an engine is idling too slow or rough this may be caused by a clogged ventilator valve or plugged hose therefore never adjust the car buretor idle without first checkin...

Page 647: ...Fig 6E 1 Vacuum Hose Schematic L6 250 CID LD Emissions DISTRIBUTOR PCV VALVE MANIFOLD VAC FITTING...

Page 648: ...DISTRIBUTOR VALVE Fig 6E 3 Vacuum Hose Schematic L6 292 CID Calif HD Emissions...

Page 649: ...V A LV E Fig 6E 5 Vacuum Hose Schematic V8 305 CID HD Emissions...

Page 650: ...Fig 6E 7 Vacuum Hose Schematic V8 350 CID High Altitude Calif LD Emissions...

Page 651: ...VALVE Fig 6E 9 Vacuum Hose Schematic V8 350 400 CID Except Calif HD Emissions...

Page 652: ...CANISTER...

Page 653: ...PCV V AL VE Fig 6E 13 Vacuum Hose Schematic V8 454 CID Except Calif HD Emissions...

Page 654: ...make knocking noises Detonation A mild to severe ping usually worse under acceleration The engine makes sharp metallic knocks that change with throttle opening Stalls The engine quits running It may...

Page 655: ...1100 7 2300 16 4200 H A L T IT U D E A T TB B C IO TB H G 10 12 600 600 D 010 17050492 DD 18 1 2 Hg C A L IF O R N IA M T TB I C10 TBJ G 10 6 850 850 D 303 7044383 CH 692 517 0 4 Hg 18 1 2 Hg 0 1100 7...

Page 656: ...584 A C ECS UFC EFE 3139 WS OR CR 246 517 0 4 Hg 0 1200 1 2 2000 2 2 4200 H A L T IT U D E A T TJS G 10 588 NO A C 586 A C A IR C A L IF O R N IA 1 8 1 2 Hg C A L IF O R N IA M T TWJ C10 700 N 1300 50...

Page 657: ...C A R B U R E T O R R P O L 2 5 49 S T A T E S M T T H H CKP T U B G 009 679 520 0 1100 14 2300 49 S T A TE S A T T H K CKP T H L C30 P30 T U A G 8 600 R 44T 600 N 450 N 2400 008 PCV TAC 0 1 0 Hg 24 4...

Page 658: ...30 8 700 R44T 045 700 N 1600 213 CT 1103274 1973482 0 6 Hg 15 12 Hg 0 1200 15 2700 20 4200 49 STATES A T TX T P 20 30 TW T P30 216 49 STATES A T TX U P30 MOTOR HOME 215 PCV TAC C A LIF O R N IA M T TX...

Page 659: ...R K 1 0 2 0 T L L K 20 30 7529 TRC C A L IFO R N IA ECS C A L IF O R N IA 454 CID V 8 ENGINE 4MV M4MC M4MC CARBURETOR RPO LF8 49 STATES M T TSC C 20 30 6212 49 STATES A T TSD C 20 30 TSK C10 20 T R A...

Page 660: ...linder the exhaust heat valve should move to its open position 5 If valve does not move disconnect hose at actuator and check for vacuum If there is vacuum replace TVS If there is no vacuum replace ac...

Page 661: ...HEAT VALVE V8 Replacement 1 Remove crossover exhaust pipe Refer to Section 6F for removal and installation Fig 6E18 Actuator and Rod 454 V8 2 Disconnect rod from valve 3 Remove valve 4 Install valve...

Page 662: ...ssful function test must meet the following EGR diaphragm must move Speed must drop when diaphragm moves FUNCTIONAL TEST OF INDIVIDUAL EGR SYSTEM COMPONENT PARTS 1 EGR VALVE Valve can be left on or re...

Page 663: ...ff vacuum decreasing the signal trying to open the EGR valve Therefore if back pressure does not close the control valve sealing off the air flow there will not be any vacuum built up to open the EGR...

Page 664: ...to signal tube A constant vacuum supply must be used 4 Valve should not open If it does control valve is stuck closed Clean the valve See EGR valve cleaning 5 W ith the vacuum still applied direct a s...

Page 665: ...check the vacuum out of the EGR thermal control valve to EGR valve If the two vacuum readings are not equal w ithin 1 2 in Hg 1 7 kPa then proceed to EGR vacuum control diagnoses Check vacuum from car...

Page 666: ...al control valve function per service procedure Check EGR valve hose routing Check EGR valve operation Repair or re place as required Check EGR thermal control valve and or EGR TVS as listed in Engine...

Page 667: ...mintues at idle to warm up a cold engine If coolant is below 75 F 24 C greater time may be required 3 If operation is satisfactory remove gage and reconnect hose to EGR valve If gage does not respond...

Page 668: ...he passage Finish cleaning with a small screwdriver CAUTION Do not use a power drill or file 3 Brush any small particles down the EGR port and blow compressed air through the port NOTE Do not use solv...

Page 669: ...door should start to allow outside air and heated air to enter the carburetor inlet 5 The system is operating normally as described above If the air cleaner fails to operate as above or if correct ope...

Page 670: ...Polyurethane Band must wrap over both end seals of paper element as shown POLYWRAP A IRfc CLEANER ELEMENT BAN D SHO W N AIR CLEANER ELEMENT _ PAPER FILTER PORTION n o t e Polyurethane Band must comple...

Page 671: ...etaining strap 5 Lift up motor cocking it to one side to unhook the motor linkage at the control dam per assembly Installation 1 Drill a 7 64 hole in snorkel tube at center of vacuum motor retaining s...

Page 672: ...Fig 6E 29 Air Cleaner 305 350 400 V8 CK...

Page 673: ...N G N U T LOW ER S T O VE N O TE Inboard flange o f lo w er stove m ust be installed on to p o f rib o f exhaust m a nifold OP UPPER S T O VE LOW ER S T O VE W IN G NUT STOVE GASKET POSITION RED SURFA...

Page 674: ...i AIR INTAKE DUCT AIR INLET V8 ENGINE Fig 6E 33 Carburetor Air lntake L6 Fig 6E 34 Carburetor Air lntake V8 DRILL 7 6 4 HOLE IN CENTER POSITION OF STRAP VACUUM RETAINING STRAP INSTALL REPLACEMENT SENS...

Page 675: ...e air and injects it through the air manifolds into the exhaust system in the area of the exhaust valves The fresh air helps burn the unburned portion of the exhaust gases in the exhaust system thus m...

Page 676: ...hub Fig 6F 41 NOTE Care should be taken to prevent fragments from entering the air intake hole Do not insert a screwdriver between pump and filter It is seldom possible to remove the filter without de...

Page 677: ...and blow through hose tow ard check valve If air passes fu n c tio n is norm al If air can be sucked fro m check valve replace check valve 6 Pump failure 6 Replace pum p Excessive pum p noise chirp in...

Page 678: ...does not increase or is not present proceed as follows 1 Check for proper drive belt tension 2 Check for a leaky pressure relief valve Air may be heard leaking with the pump running NOTE The AIR Syst...

Page 679: ...the system Check hoses for cracking abrasion or deterioration and replace as necessary Check system function for proper operation and adjust as as necessary CHECKING AND ADJUSTING SYSTEM Control Valve...

Page 680: ...e vacuum gage reading drops then the actuator is leaking and must be replaced 3 To check the actuator for proper operation a Check the throttle lever shaft and linkage to be sure that they operate fre...

Page 681: ...engine coolant tem perature and a delay valve is between manifold vacuum distributor and thermal vacuum switch W hen engine tem perature is below specified valve the manifold vacuum signal is routed...

Page 682: ......

Page 683: ...ion control device added to the exhaust system to reduce hydrocarbon and carbon monoxide pollutants from the exhaust gas stream The converter contains beads which are coated with a catalytic material...

Page 684: ...anifold or pipe connections Tighten clamps at leaking connections to specified torque Replace gasket or packing as required Burned or blown out muffler Replace m uffler assembly Burned or rusted out e...

Page 685: ...t NOTE When reinstalling exhaust pipe to m ani fold always use new packings and nuts Be sure to clean manil old stud threads with a wire brush when installing the new nuts CONVERTER HEAT SHIELD C 10 S...

Page 686: ...yst has been removed from the converter disconnect air supply to vibrator and remove container from the converter 7 Discard used catalyst Catalyst Replacement 1 Fill container with approved replacem e...

Page 687: ...heck that catalyst has filled converter flush with fill plug hole Add catalyst if required 7 Apply an anti seize compound to the fill plug install and tighten to 60 pound feet If built with a pressed...

Page 688: ...lowed to seat against the converter before installing bolt the threaded hole in the bridge will fill with beads and it will be very difficult to start the bolt Fig 6F 12 Installing Fill Plug 10 After...

Page 689: ...amage If there is damage in the inner shell the converter assembly must be replaced Fig 6F 17 4 Place new insulation in the replacement cover Apply sealing compound all around the cover after the insu...

Page 690: ...c Converter Inner Shell Fig 6F 19 Installing Eiottom Cover Retaining Channels RETAINING CHANNEL INSULATION SEALING COMPOUND CLAMP Fig 6F 18 lnstalling Bottom Cover Replacement Fig 6F 20 lnstalling Bot...

Page 691: ...SPECIAL TOOLS n 1 J 25077 1 Vibrator Include Catalyst Container and Fill Tube Extension 2 J 25077 2 Aspirator...

Page 692: ......

Page 693: ...ction elements required to obtain the desired function of the two planetary gear sets The 3 element torque converter consists of a pump turbine and a stator assembly The stator is mounted on a one way...

Page 694: ...odulator is used to automatically sense any change in the torque input to the transmission The vacuum modulator transmits this signal to the pressure regulator which controls line pressure so that all...

Page 695: ...SSEMBLY CLUTCH OVERRUN BAND CLUTCH SUN GEAR OUTPUT SHAFT INPUT SHAFT INTERMEDIATE OVERRUN ROLLER CLUTCH REACTION CARRIER PARKING PAWL OUTPUT CARRIER MANUAL SHAFT LOW AND REVERSE CLUTCH STATOR SHAFT GO...

Page 696: ...ic transmission fluid or its equivalent to F mark on indicator If the vehicle cannot be driven sufficiently to bring the transmission to operating temperature and it becomes necessary to check the flu...

Page 697: ...m DO NOT RACE ENGINE Move manual control lever through each range 3 Immediately check fluid level with selector lever in park P engine running and vehicle on LEVEL surface and add additional fluid to...

Page 698: ...be removed that steering CAUTION Any inaccuracies in the above adjustments may result in premature failure of the transmission due to operation without controls in fu ll detent Such operation results...

Page 699: ...release lock and detent downshift cable 2 Disconnect cable from carburetor lever 3 Compress locking tabs and disconnect snap lock assembly from bracket 4 Remove clamp around filler tube remove screw...

Page 700: ...Fig 7A 6B Detent Downshift Cable C K and P Series...

Page 701: ...pancies in operation or oil pressure occur c Attempt to isolate the unit or circuit involved in the malfunction d If engine performances indicates an engine tune up is required this should be performe...

Page 702: ...se or between pump cover and body d Case porous near converter bosses Front pump cover or housing oil channels shy or stock near breather See Subparagraph C e Pump to case gasket mis positioned OIL PR...

Page 703: ...he sleeve for concentricity to the cam If the sleeve is concentric and the plunger is free the modulator is acceptable Once the modulator assembly passes all of the above tests it is an acceptable par...

Page 704: ...event the vehicle from rolling The pointer on the indicator quadrant should line up properly with the range indicators in all ranges ROAD TEST Drive Range Position selector lever in DRIVE RANGE and ac...

Page 705: ...ainer Assembly a Blocked or restricted b Gasket omitted or damaged Oil Pump a Gear clearance damaged worn gear installed backwards b Pump to case gasket mispositioned c Defective pump body and or cove...

Page 706: ...lease will cause DRIVE in NEUTRAL Slips in All Ranges or Slips on Start Install pressure gauge Low Oil Level add oil Low Oil Pressure refer to LOW LINE PRESSURE above Forward clutch a Clutch plates bu...

Page 707: ...ly a 1 2 shift valve train sticking b 2 3 shift valve train sticking Case refer to case porosity repair W on t Hold in Park Manual Linkage misadjusted correct align ment in manual lever shift quadrant...

Page 708: ...E 2 3 A C C U M U L A T O R ________________ M A N U A L V A L V E L I N K A G E P O R O S I T Y C R O S S L E A K __________ P U M P G E A R S _______________________ P R I M I N G V A L V E S H Y __...

Page 709: ...Fig 7 A 12B CBC 350 Hydraulic Circuit A U TO M A T IC T R A N S M IS S IO N 7 A 1 7...

Page 710: ...and tighten finger tight before torqueing to specification This will insure proper converter alignment After installation of transmission lower vehicle and remove vehicle from hoist Check linkage for...

Page 711: ...to case retainer and unthread jam nut holding rnage selector inner lever to manual shaft 4 Remove jam nut and remove manual shaft from range selector inner lever and case NOTE Do not remove manual sha...

Page 712: ...to strainer and oil pan and adjust the fluid level 1 2 ACCUMULATOR Rem ove 1 Remove two transmission oil pan bolts below the 1 2 accumulator cover Install J 23069 in place of bolts removed 2 Press in...

Page 713: ...n such a direction that if it were not re directed by the stator it would hit the rear of the converter pump blades and impede its pumping action So at low turbine speeds the oil is re directed by the...

Page 714: ...ed and the transmission will shift to second gear and remain in second until vehicle is reduced to approx imately 40 MPH depending on axle ratio LI Range position prevents the transmission from shifti...

Page 715: ...ke and start engine DO NOT RACE ENGINE Move selector lever through each range 2 Immediately check fluid level with selector lever in Park engine running and vehicle on LEVEL surface Fluid level on ind...

Page 716: ...nt NOTE Do not use indicator pointer as a reference to position the selector lever When performing linkage adjustment pointer is adjusted last 3 Release the selector lever The lever should be inhibite...

Page 717: ...of this manual DIAGNOSIS SEQUENCE FOR DIAGNOSIS 1 Check and correct oil level 2 Check detent switch 3 Check and correct vacuum line and fittings 4 Check and correct manual linkage 5 Install oil press...

Page 718: ...missing c Front p um p housing O ring d a m ag ed or cut d C on verte r leak in w eld area e Porous casting pum p 5 Oil C o m e s O ut V ent Pipe a T ransm ission over filled b W ater in oil c Foreign...

Page 719: ...0 1 2 1 1 5 0 18 6 14 0 0 0 1 1 6 1 5 0 1 7 8 R o a d or N o rm a l O p e ra tin g C o n d itio n s side o f the modulator If this is found w ithout the presence o f oil the m odulator should not be c...

Page 720: ...dulator B e llo w s G o o d W ith the selector lever in the Park position the p ark in g pawl should freely e ng ag e and prevent the vehicle from rolling The pointer on the indicator quadrant should...

Page 721: ...C h eck forw ard clutch seals b D irect clutch leak pressure low in Reverse pressure norm al in all other ranges 1 C h eck center support oil seal rings 2 C h eck direct clutch outer seal 3 C h eck r...

Page 722: ...al rings or grooves d a m a g e d or worn Slips in all Ranges Slips on Start Install pressure gauge L ow fluid level O il pressure refer to L O W L IN E P R E S S U R E above C a se cross leaks porosi...

Page 723: ...a V a lv e sticking b F e e d holes restricted or leakin g pipes d a m a g ed or m ispositioned c F eed line screen plugged Detent switch D etent solenoid stuck open loose etc will cause late shifts C...

Page 724: ...mbly d Interm ediate clutch piston seals d a m ag ed or missing e Center support bolt loose f Low line pressure see L O W L IN E P R E S S U R E above g Interm ediate clutch cup plug in case missing h...

Page 725: ...yd rau lic C ir c u it MAINLINE PRESSURE INTAKE PRESSURE CONVERTER PRESSURE GOVERNOR PRESSURE MODULATOR PRESSURE DETENT PRESSURE 1 2 ACCUMULATOR PRESSURE re v er se GOVERNOR ASHMI1V REVERSE AUTOMATIC...

Page 726: ...verter as flush with the flex plate and the converter rotates freely by hand in this position T h en hand start all bolts and tighten finger tight before torquing to sp ecification T h is will insure...

Page 727: ...TION o not drop manual valve 6 R em ove the governor pipes and m anual valve from control valve body Installation Installation o f control valve body is in reverse o f rem oval See O verh aul M anual...

Page 728: ...R e fe r to the T ransm ission D isassem bly and R e assem b ly section o f the O verhaul M anu al for service procedures 1 O il filler pipe and O rin g seal 2 Oil pan and gasket 3 D o w n shift solen...

Page 729: ...t B o l t 23 ft lbs Pump to Case Attaching B o l t s 18 ft lbs Extension Housing to Case Attaching B o lts 23 ft lbs Rear Servo Cover B o l t s 18 ft lbs Detent Solenoid Bolts 7 ft lbs Control Valve B...

Page 730: ...J 23062 7 Output Shaft Bushing Installer Pump Body removal 3 8 x 16 tread 7 J 21465 15 Stator Shaft Front Bushing Remover Used with J 8092 19 J 21885 2 3 Accumulator Piston Compressor 8 J 23329 Direc...

Page 731: ...emover Tools J 2 1465 01 21 J 2 1465 17 Part of Bushing Tool Set 6 J 5154 Extension Oil Seal Installer 22 J 2 1465 8 Part of Bushing Tool Set 7 J 6585 Slide Hammer Weights 23 J 2 1465 13 Part of Bushi...

Page 732: ...Pliers 5 J 8105 Speedo Gear Remover Puller 15 J 5403 Snap Ring Pliers 6 J 22269 01 Accumulator Piston Remover and Installer 16 J 1313 Torque Wrench 0 140 Ft Lbs 7 J 21369 Converter Pressure Check Fixt...

Page 733: ...otate or com e to rest independently o f the input shaft It is carried at the rear by a ball bearing m ounted in the front face o f the extension housing Helical gears are incorporated throughout incl...

Page 734: ...taneous e n g ag e m ent o f two gears A s one rod is m oved it pushes a ball out that eng ag es the other two rods to prevent their m ovem ent G ea rsh ift levers on m anual transmissions are located...

Page 735: ...e Gear Thrust and Spring Washers 28 Snap Ring Bearing to Mainshaft 29 Extension 30 Vent 31 Speedometer Drive Gear and Clip 32 Mainshaft 33 Rear Oil Seal 34 Retainer Oil Seal 35 Snap Ring Bearing to Ge...

Page 736: ...Bearing 29 2nd S p e e d G e a r 16 C a se 30 M a in s h a ft 17 D rive G ear 31 1st S p e e d G e a r 18 P ilo t B e a rin g s 32 1st S p e e d B lo c k e r Ring 33 1 2 S y n c h ro n iz e r H ub 47...

Page 737: ...CHRONIZER HUB 49 COUNTERGEAR SHAFT 16 1ST REVERSE SYNCHRONIZER RETAINING RING 50 COUNTERGEAR SPRING PIN 17 REAR BEARING RETAINING RING 51 COUNTERGEAR 18 TRANSMISSION MAINSHAFT 52 2ND 3RD SHIFTER FORK...

Page 738: ...and Clip 13 Rear Extension Seal 14 Rear Extension 15 Rear Bearing to Shaft Snap Ring 16 Rear Bearing to extension Snap Ring 17 C ountergear W o o d r u ff Key 18 T h ru s t Washer 19 Reverse I dler S...

Page 739: ...Blocker 15 Thrust Washer Ring 16 Bearing Washer 34 Syncrhonizer Key 17 Needle Bearings Spring 35 Synchronizer Keys 50 Gasket 36 1st and Reverse 51 2nd and 3rd Shifter Synchronizer Hub Fork Assembly 52...

Page 740: ...Nut 9 2nd Speed Gear 22 Rear Bearing 10 1st and 2nd Retainer Oil Seal Synchronizer 23 Rear Bearing Assembly Retainer 24 Mainshaft Rear 37 Thrust Washer Bearing 38 Snap Ring 25 Rear Bearing Snap 39 Fro...

Page 741: ...Ring 29 Selective Fit Snap 48 Reverse Shifter Shaft Speed Gear Shifter 11 Third and Fourth Ring Ball Detent Spring Shaft and Detent Speed Clutch Sliding 30 Reverse Gear 49 Speedometer Driven Plate Sl...

Page 742: ...sure clam ps are properly adjusted so that tube levers and transm ission shifter levers rem ain in their neutral positions w hile tightening 4 R em ove gau g e and m ove selector lever through all po...

Page 743: ...VIEW B FLAT IvEwfDl l6 G tO 2 GAGE...

Page 744: ......

Page 745: ...on Arms F G in a straight down 6 o clock neutral position 3 With Swivel E Lock Nuts D loosely assembled to Rod C rotate Swivel E u ntil ends o f Rod C w ill simultaneously enter Lever B Arm F 4 Lock i...

Page 746: ...control lever tangs should line up with the slot in the m ain control lever Floor Shift Control A ll swivels rods and m ountings should be checked fo r lost m otion and repaired or replaced as necess...

Page 747: ...nd the radii indicated should be very small A n y ch ip p ing will require synchronizer replacem ent Check the synchronizer load W h e n the keys are installed the spring ends on one side o f the hub...

Page 748: ...Replace countergear bearings and shaft c Replace worn or damaged gears d Replace damaged bearings or main drive gear e Replace countergear Noisy in High Gear a Damaged main drive gear bearing b Damag...

Page 749: ...rive gear bearing retainer c Main drive gear bearing retainer gasket damaged d Side cover loose or gasket damaged e Rear bearing retainer oil seal leaks f Countershaft loose in case g Shift lever seal...

Page 750: ...is grease could be thrown onto clutch facings resulting in clutch problems 2 S h ift the transmission into high gear M ount transmission on dolly or jac k and m ove into position under the vehicle CAU...

Page 751: ...and transm ission assemblies 9 D isconnect speedom eter cable from transfer case D isconnect back up lam p switch w irin g and T C S switch 10 D isconnect prop shaft at rear o f transfer case and tie...

Page 752: ...9 and 12 o clock readings in rotation 5 Install tem porary slotted shims between the transm ission case and the clutch housing in the quantities and at the bolt locations as necessary to bring m isal...

Page 753: ...lock plate can be inserted in groove and attached to housing TRANSMISSION SIDE COVER Replacement Repair Fig 7B 20 1 D isconnect control rods from levers back up lam p w iring and T C S switch 2 Shift...

Page 754: ...up shaft aw ay fro m w ork area 6 Disconnect shift lever rod from shift rail link On full time 4 w heel drive models disconnect shift levers at transfer case 7 Support transfer case and rem ove bolts...

Page 755: ...V I E W B WITH AUTOMATIC TRANSMISSION WITH MANUAL TRANSMISSION V I E W A...

Page 756: ...bs Crossmember to Mount Bolts 40 ft lbs 2 3 Cross Over Shaft Bracket Retaining Nut 18 ft lbs 1 Rev Swivel Attaching B o l t 20 ft lbs Mount to Transmission B o l t 50 ft lbs THREE SPEED MUNCIE 83mm Cl...

Page 757: ...p R ing Pliers 7 C o u n te rg e a r L o a d in g T o o l 8 E x te n s io n B u sh in g R em o v e r and In sta lle r 9 E x te n s io n Seal Installer J 2 2 2 8 Rear B earing Press Plates J 5 5 9 0 C...

Page 758: ...r Seal Installer 5 J 22873 2nd Speed Bushing Installer 6 J 22875 3rd Speed Bushing Installer 7 J 22830 Snap Ring Installer 11 A 8 J 22874 1 Bearing Installer 9 J 22874 5 M ainshaft Support Tool 10 J 2...

Page 759: ...In s ta lle r 9 10 10 J 23431 Rear O u t p u t Shaft Housing Bearing Remover and In s ta lle r J 7 1 3 7 A d a p te r Seal In sta lle r J 9 2 7 6 2 In te rm e d ia te G e a r Bearing C u p In s ta ll...

Page 760: ...r...

Page 761: ...and pressure plate Suitable frictional facings are attached to each side o f the clutch disc by m eans o f brass rivets These facings must be heat resistant since friction produces heat T he most com...

Page 762: ...lutch will cause inability to obtain proper freeped al travel resulting in slippage and rapid wear Clutch Spring Operation In d iaph ragm spring type clutches a d iaph ragm spring is used instead o f...

Page 763: ...FLAT FINGER B E N T F IN G E R 1 Flywheel 3 Pilot Bushing 5 Pressure Plate 7 Cover 9 Fork 2 Dowel hole 4 Driven Disc 6 Diaphragm Spring 8 Throwout Bearing 10 Retracting Spring...

Page 764: ...hem on their pivot pins T h e outer ends o f the release levers being fastened to the cover m ove the pressure plate to the rear com pressing the clutch springs and allow ing drivin g m em bers to rot...

Page 765: ...er pull rod connected from the clutch pedal shaft to a bell crank and a lower pulll rod from the bell crank to the cross shaft W h en the pedal is depressed the pull rods are m oved rotating the cross...

Page 766: ......

Page 767: ...V I E W D 1 6 ENGINE VIEW V 8 ENGINE...

Page 768: ......

Page 769: ...owout bearing engages the clutch diaphragm spring or levers Lash is required to prevent clutch slippage which would occur if the bearing was held against the fingers or to prevent the bearing from run...

Page 770: ...en nut B and swivel 5 Release push rod connect return spring and tighten nut A to lock swivel against nut B 6 Check free pedal clearance at pedal l 1 4 to 1 1 2 is proper clearance Readjust if necessa...

Page 771: ...flywheel e Burned or sm eared resin on flywheel or pressure plate a Install new disc and correct leak b Replace transm ission clutch gear c Tighten or replace m ountings d Replace pressure plate or f...

Page 772: ...er until diaphragm spring is released 7 Remove clutch pilot tool and remove clutch assembly from vehicle NOTE The flywheel should be inspected for cracks heat checking flatness and other defects Insta...

Page 773: ...ng screws 3 Tighten holding screws a turn at a time before removing dummy shaft 4 Remove clutch pilot tool 5 Pack clutch fork ball seat with a small amount of high melting point grease and install a n...

Page 774: ...Allow return spring or center spring to pull pedal up high enough to unhook spring from pedal arm 4 Remove pedal and shaft assembly from support bracket Inspection 1 Check clutch pedal bushings for e...

Page 775: ......

Page 776: ...SPECIAL TOOLS 1 J 6456 Height Gauge 2 J 1048 Gauge Plate 3 J 1522 Pilot Bearing Driver 4 J 23720 Clutch Pilot Tool 5 J 1448 Pilot Bearing Puller...

Page 777: ...ponent Part Replacement 8 39 Wiper M otor 8 39 Unit Repair 8 39 W iper W asher Disassembly 8 39 Motor Disassembly 8 40 Motor Assembly 8 43 Wiper Adjustments 8 43 Washer P u m p 8 43 Windshield Wiper a...

Page 778: ...M E LAMPS 0F U S E T R A F F IC HAZARD E lO U T LE T TRAFFIC H A ZAR D FLASHER GDRECEPTACLE CIG LIGHTER ____ _______ _____ G SERIES TRAFFIC HA ZAR D FLASHER A FUSE HE ATE R AIR C O N D B FUSE ACCESSO...

Page 779: ...d ground circuit 6 Defective light switch switch 2 Check voltage at dimmer switch with test lamp If test lamp bulb lights only at light blue wire terminal replace dimmer switch 3 Check light blue wire...

Page 780: ...hite strip wires 2 Replace bulb 3 Loose connection or open in wiring 3 Usiftg test lamp check brown wire terminal at bulb socket If test lamp lights repair open ground circuit If lamp does not light r...

Page 781: ...e blows repair short to ground in brown wire circuit between fuse panel through light switch to lamps 2 Loose connection 2 Secure connector at light switch 3 Open wiring 3 Using test light check circu...

Page 782: ...erate check for improper bulb 1034 instead of 1157 If bulbs are OK replace defective turn signal switch 4 Short to ground Flasher can be heard no bulbs operate 4 Locate and repair short to ground by d...

Page 783: ...ve or intermittent 1 Loose or burnt out bulb 1 Secure or replace bulb 2 Loose connection 2 Tighten connectors 3 Open ground connections 3 Repair bulb ground circuit Both lamps inoperative or intermitt...

Page 784: ...tional signal switch or cancelling cam 2 If lamp will operate by turning directional signal on the switch is not centering properly during cancelling operation Replace defective cancelling cam or dire...

Page 785: ...d wire must be held securely in place by clips or other holding devices to prevent chafing or wearing away the insulation due to vibration By referring to the wiring diagram manual circuits may be tes...

Page 786: ...at connector 6 Remove housing stud nuts and remove housing with pigtail 7 To install reverse removal steps Left Side 1 Remove two screws and parking lamp lens 2 Disconnect wiring harness at connector...

Page 787: ...res 8 7 through 8 10 for clearance license plate and identification lamp installations LIGHT SWITCH C K Models Fig 8 11 Replacement 1 Disconnect battery ground cable 2 Reaching up behind instrument cl...

Page 788: ......

Page 789: ...SSEMBLY TAIL STOP LAMP ASSEMBLY SIDE MARKER LAMP REAR LICENSE LAMP ASSEMBLY SIDE MARKER LAMP TAIL STOP LAMP HARNESS C209 03 WITH OPTION E56 C310 03 WITH OPTION E56 Fig 8 7 Rear Lighting C K Platform a...

Page 790: ...STOPLAMP SWITCH See Section 5 Brakes of this manual for adjustment and replacement procedures G MODELS...

Page 791: ...e for servicing of the instruments and gauges G Models Illuminating and indicator lamps may be replaced without removing the cluster from the vehicle Bulbs are installed in plastic holders which lock...

Page 792: ...3 Low oil pressure 3 Locate cause of low oil pressure and correct COOLANT TEMPERATURE INDICATOR C on d itio n Possible C ause C o rrection H O T indicator light not lit when cranking engine 1 Bulb bu...

Page 793: ...rn relay or horn circuit Check and tighten connections Defective horn switch Replace switch Defective relay Replace relay Defects w ithin horn Replace horn H O R N S B LO W C O N S T A N T L Y Cause C...

Page 794: ...G A S G A U G E...

Page 795: ...E M any fuel gauge tank units and dash units are replaced because of poor diagnosis or lack of j knowledge of the variables in the system F or exam ple som e ow ners com plain that w hen their gauge r...

Page 796: ...auge pin to depth of 3 8 inch into switch gauge hole switch assembly is lixed in neutral position with internal plastic shear pin 6 Assemble the switch to column by inserting the switch carrier tang i...

Page 797: ...h Manual Transmission Replacement 1 Disconnect battery ground cable 2 Disconnect switch wiring harness 3 Remove column mounting screws and remove switch 4 Assemble the switch to the column Fasten in p...

Page 798: ...ressure gauge 8 Remove cluster to bench for further disassembly laminated printed circuit speedometer head gauges 9 Install cluster in reverse order of removal G Models Replacement Fig 8 15 1 Disconne...

Page 799: ...INE TEMP IND E BRAKE WARNING IND F GEN TELL TALE G FUEL GAGE CLIPPING H AMP GAGE CLIPPING J BRAKE WARN EXC U35 K CLOCK U35 L TEMP GAGE CLIPPING M BRAKE WARN U35 N FUEL GAGE CLIPPING 16 P TURN SIGNAL I...

Page 800: ...round cable 2 Remove headlamp switch control knob 3 Remove radio control knobs and clock adjuster stem 4 Remove instrument cluster bezel and steering column cover 5 Remove instrument cluster lens 6 Re...

Page 801: ...a plain washer on each of two studs holding laminated circuit and finally a nut on back of the studs that have a washer and laminated circuit TEMPERATURE GAUGE C K Models Replacement 1 Perform Steps...

Page 802: ...uster assembly as pre viously described in this section 2 Remove terminal nuts retaining laminated circuit to meter 3 Lay back laminated circuit portion after removing grounding screws and bulb holder...

Page 803: ...black with pink stripe lead to the series field coils Larger diameter wire where it divides and flows as follows 1 The shunt field coils to wiper terminal No 3 through the wiring harness to the dash s...

Page 804: ...circuits completed to ground via the parking switch the wiper motor continues to operate until the wiper gear cam opens the park switch contact Figure 8 17 stopping the wiper See Figure 8 21 for Wipe...

Page 805: ......

Page 806: ...AND ARMATURE CIRCUIT SHUNT FIELD CIRCUIT Fig 8 2 0 PA R K IN G C ircu it OFF LO HI DASH X SWITCH BLACK WITH PINK STRIPE WIPER O F F SERIES FIELD SHUNT FIELD c 12 VOLTS BATTERY FUSE WIPER TERMINAL BOA...

Page 807: ...ody Refer to Figure 8 22 for 2 terminal location B To determine if wiper is cause of trouble disconnect existing harness from wiper and connect jumper leads to wiper terminals as shown in Figure 8 22...

Page 808: ...wiper housing N O T E To r echeck park posi ti on of gear r ec on nect lumper wire to Hsg Grd momentar i ly Wiper gear shoul d cont inue to rotate unt il it stops in the p osi ti on shown P O W E R S...

Page 809: ...erminal No 1 to dash switch open 2 Wiper would not shut off but had fa Both LO and HI speeds b LO speed only c HI speed only a Wire from wiper terminaM to dash switch grounded b Wire from wiper termin...

Page 810: ...ic Insulation ITEM 3 1 Circuit breaker Contacts clean and closed 2 Solder Connections to Circuit breaker Terminals ITEM 4 Splice Connections Brush pigtail to Field Coil leads ITEM 6 Brushes slide free...

Page 811: ...and check Items 1 2 b 4 and 5 4 Wiper has L O Speed Only See Trouble Description 2 b 5 Wiper Gear and or crank arm does not park correctly Wiper gear and or crank arm stops ro ta tin g immediately wh...

Page 812: ...ld testing the armature and continuity of field coils consists of using a test light similar to that shown in Figure A Disassemble Motor as required to gain access to the field and armature assemblies...

Page 813: ...and 5 in Trouble Chart opposite wiper inoperative Series Field Brush lead A and No 2 terminal on wiper terminal board Figure C If lamp fails to light check splice joints Items 2 4 and 5 in Trouble Ch...

Page 814: ...ective F Replace wiper switch G Pum p solenoid coil defective G Replace solenoid H W asher nozzles plugged H Clean washer nozzles I Ratchet wheel tooth missing I Replace ratchet wheel J Ratchet pawl s...

Page 815: ...to engine cover shroud and slip heater duct down and out 9 Protect carpet then remove windshiled washer hoses from washer pump 10 Remove three screws securing wiper motor to cowl and lift wiper motor...

Page 816: ...y to remove the armature end play adjusting screw and insert a rod through the opening in order to apply pressure against the end of the armature 4 Unsolder black cotton covered lead from circuit brea...

Page 817: ...emove brush plate and armature 2 The end case and field assembly is serviced as a unit To free the field and case assembly cut the solid black plastic insulation and black with pink stripe leads in a...

Page 818: ...G R O M M E T Fig 8 31 Circuit B re a k e r BRUSH PLATE ASSEMBLY RETAINER TAB 4 BLACK LEAD TO CIRCUIT BREAKER U BRUSH RETAINER CLIP f m CUT MOTOR LEADS IN THIS GENERAL AREA FOR SPLICING SPLICE NOTES...

Page 819: ...nsure proper alignment of the new Fig 8 34 Brush P la te A s s e m b ly case with the scribed line made on the housing Step 1 under Brush Plate Removal 9 Position armature worm shaft inside housing an...

Page 820: ...access 3 Disconnect washer hoses and electrical connec tions from assembly 4 Remove three screws securing washer pump and cover to wiper assembly Remove pump from wiper gear box 5 To install reverse S...

Page 821: ...f a motor armature helical gearshaft which drives an intermediate gear and pinion assembly The pinion gear of the intermediate gear and pinion drives an output gear and shaft assembly Turning the wipe...

Page 822: ...ch contacts are still closed The wiper will continue to operate until the wiper output gear is turned to a position where its cam opens the park switch Referring to Figure 8 39 it can be seen that the...

Page 823: ...park position If wiper fails to operate correctly proceed to Step 3 3 Disconnect wiring harness from wiper and try operating wiper as shown in Figure 8 40 a If wiper operates correctly independently...

Page 824: ...al on wiper motor to wiper switch A Locate short circuit and repair B W iper has Lo speed only A Defective wiper switch A Replace wiper switch B G rounded wire No 3 terminal on wiper motor to wiper sw...

Page 825: ...l not shut off A W iper has normal Hi and Lo speed A Defective park switch A Replace terminal board assembly B G rounded red lead wire B Repair short circuit in red wire B Wiper has Lo speed only A G...

Page 826: ...T IT FROM GRD STR AP W IPER SHOULD STOP W ITH GEAR SHAFT FLATS AS SHOWN W IPER GROUND STRAP TEST LIGHT PROBES FOR GROUND CHECK IF LAMP LIGHTS ARMATURE IS CHECK FOR TEST LIGHT PROBES POOR WELD BAR TO B...

Page 827: ...ch defective F Replace wiper switch G Ratchet relay coil defective G Replace ratchet relay H W asher nozzles plugged H Clean washer nozzles I Ratchet wheel tooth missing I Replace ratchet wheel J Ratc...

Page 828: ...ars 4 Remove crank arm seal cap retaining ring and end play washers NOTE Seal cap should be cleaned and repacked with a waterproof grease before reassembly 5 Drill out gear box cover retaining rivets...

Page 829: ...cover and terminal board rivets Assembly Refer to Figure 8 43 for exploded view of motor and gear train Motor Reassemble motor using reverse of disassembly procedure NOTE Armature end play is control...

Page 830: ...p D rive C a m a n d A c tu a to r connector will result in direct ground and destroy wiper motor fuse Disassembly Assembly Figures 8 49 8 52 1 Remove washer pump cover by squeezing 2 Solenoid assemb...

Page 831: ...chet wheel off its shaft 5 Pump and actuator plate assembly a Remove solenoid assembly ratchet pawl and ratchet wheel as outlined in their respective procedures b To separate pump and pump actuator pl...

Page 832: ...U IT BREAKER Fig 8 53 A circuit breaker is a protective device designed to open the circuit when a current load is in excess of rated breaker capacity If there is a short or other type of overload co...

Page 833: ...a new 20 gauge wire DIAGNOSIS Failures in a circuit are usually caused by short or open circuits Open circuits are usually caused by breaks in the wiring faulty connections or mechanical failure in a...

Page 834: ...AMPS W ARNING BUZZER Replacement Fig 8 56 1 Disconnect electrical connector from LPS Lamps socket of fuse panel 2 Disconnect electrical connector from IGN Ignition socket of fuse panel Fig 8 5 6 H e a...

Page 835: ...MPER G R O U N D 3 CON N EC T SH O R T TESTER TO TIM ER FEED C IR C U IT P IN K A T T IM E R C O N N EC TO R A N D TO B O D Y G R O U N D TEST L IG H T ON CON N EC T SH O R T TESTER TO T IM E R O U IP...

Page 836: ...Fig 8 58 Seat Belt Reminder System Schematic...

Page 837: ...e fuses o f h ig h e r a m p e ra g e th a n those recom m ended a bo ve The fo llo w in g w irin g harnesses a re pro te cte d by a fu s ib le lin k w hich is a sp e cia l w ire in c o rp o ra te d i...

Page 838: ...7 10 1895 2 CP U n d e rh o o d lam p 1 93 15 CP S eat b e lt w a rn in g 1 168 3 CP C a rgo d o m e lam p 2 211 2 12 CP Four w heel d riv e in d ic a to r 1 168 3 CP 1 O n CA KA 10 35 instrum ent clu...

Page 839: ...urn the throttle to idle position The purpose of the Cruise Master system is to allow the driver to maintain a constant highway speed without the necessity of continually applying foot pressure to the...

Page 840: ...N O R M A L A N D IS A V O I D E D B Y A S L O W E R M O R E D E L I B E R A T E R E L E A S E O F T H E S W I T C H F R O M T H E T R I M D O W N P O S I T I O N N O T E A S P E E D S W I T C H B U I...

Page 841: ...o the chassis The ohmmeter should read between 42 and 49 ohms If a resistance either above or below the value indicated is shown then disconnect the connector from the Regulator and measure the resist...

Page 842: ...EG U L A T O R F U SE IG N IT IO N SW ITCH DIRECTION OF RO TATIO N WITH SPEED INCREASE I HO LD CLUTCH CLUTCH SPR IN G B O W D E N C A B L E TO C A R B U R ET O R L IN K A G E EN G A G E PO SITIO N V...

Page 843: ...OO SHARP A TURNING RADIUS NOT LESS THAN 6 RADIUS CHECK DRIVE CABLE FOR DISTORTED OR BENT TIPS FERRULES MUST BE SNUG 4 CHECK FOR A BINDING THROTTLE LINKAGE CONDITION 5 CHECK ADJUSTMENT OF BRAKE RELEASE...

Page 844: ...C H E C K n...

Page 845: ...the hoses which connect to the Regulator and replace any which are cracked or deteriorated SERVO U N IT FIG 9 7C Before adjusting the Servo Cable make sure the carburetor is set at its lowest idle thr...

Page 846: ...cover Disconnect ball chain from cable retainer 4 Remove servo to bracket screw s and remove servo 5 To install reverse Steps 1 4 above 6 Adjust the servo cable as outlined in Figure 9 7C COLUMN M OU...

Page 847: ...3 8 T O 6 4 IN S T A L L A T IO N O F S E L F A D J U S T IN G V A C U U M R E L E A S E V A L V E 1 Install m ou nting clip into bracket 2 Depress brake pedal push valve in to clip u n til shoulder...

Page 848: ...by substituting a known good speaker Radio does not play even with a known good substitute speaker Defective receiver Remove for servicing Radio plays with substitute speaker Replace speaker Thump He...

Page 849: ...at all times to avoid scratching windshield a If a shrill sound is emitted through the speaker when both antenna wires are tested antenna is operational b If no sound is emitted through one or both an...

Page 850: ...tors and antenna lead Remove radio 9 Reverse Steps 1 8 for installation of radio FRONT SPEAKER C K Models Replacement Fig 9 5R 1 Disconnect battery ground cable 2 Remove instrument cluster bezel upper...

Page 851: ...cable assembly from turning by using two separate wrenches Remove rod and mast assembly 2 To install insert rod and mast assembly into cable assembly and tighten mast nut Prevent cable assembly from...

Page 852: ......

Page 853: ...SPECIAL TOOLS J 2 3 5 2 0...

Page 854: ...ME Inchesof mercury Pounds sq in 3 38 6 895 kilopascals kPa kilopascals Inch3 16 387 16 387 mm3 cm3 ENERGY OR WORK Quart Gallon Yard3 0 016 4 0 946 4 3 785 4 0 764 6 litres 1 litres litres metres3 m3...

Page 855: ...1 031 60 70 21 336 21 641 21 946 22 250 22 555 22 860 23 165 23 470 23 774 24 079 70 80 24 384 24 689 24 994 25 298 25 603 25 908 26 213 26 518 26 822 27 127 80 90 27 432 27 737 28 042 28 346 28 651 2...

Page 856: ...2 311 32 933 33 554 34 175 34 797 35 417 36 040 36 660 50 60 37 282 37 904 38 525 39 147 39 768 40 389 41 011 41 631 42 254 42 874 60 70 43 497 44 118 44 739 45 361 45 982 46 603 47 225 47 845 48 468...

Page 857: ...44 190 9303 195 4763 200 0222 204 5682 209 1142 213 6601 218 2061 222 7520 40 50 227 2980 231 8440 236 3899 240 9359 245 4818 250 0278 254 5738 259 1197 263 6657 268 2116 50 60 272 7576 277 3036 281 8...

Page 858: ...130 07 50 60 132 28 134 48 136 69 138 89 141 10 143 30 145 51 147 71 149 91 152 12 60 70 154 32 156 53 158 73 160 94 163 14 165 35 167 55 169 76 171 96 174 17 70 80 176 37 178 57 180 78 182 98 185 19...

Page 859: ...6560 61 0118 62 3676 63 7234 65 0793 66 4351 40 50 67 7909 69 1467 70 5025 71 8584 73 2142 74 5700 75 9258 77 2816 78 6374 79 9933 50 60 81 3491 82 7049 84 0607 85 4165 86 7724 88 1282 89 4840 90 389...

Page 860: ...37 4 5 6 4 703125 17 85937 7 32 21875 5 55625 23 32 71875 18 25625 15 64 234375 5 95312 47 64 734375 18 65312 1 4 250 6 35000 3 4 750 19 05000 17 64 265625 6 74687 4 9 6 4 765625 19 44687 9 32 ____ 28...

Page 861: ...0 c L m s L H r t v W8S 8R X _ v A B H V S v N jifa l v CHEVROLET SERVICE J u w s M V f r i ir w v i V _ v V i 3 f liP iT vV a i 3 r x r t f c 1 1 a 4...

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Chevrolet 1977 light duty truck, Service Manual

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Summary of Contents for 1977 light duty truck

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