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GMC 1982 Light Duty Truck, Service Manual

The 1982 GMC Light Duty Truck Service Manual is a comprehensive manual covering maintenance and repair instructions for all models. This invaluable resource is available for free download at manualshive.com. Get your hands on this manual to keep your truck running smoothly and efficiently.

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Summary of Contents for 1982 Light Duty Truck

Page 1: ......

Page 2: ...g of each major subject within the section Summaries of Special Tools when required and specifications are found at the end of major sections When reference is made in this manual to a brand name numb...

Page 3: ...e risk of personal injury to service personnel or the possibility that improper service methods will be followed which may damage the vehicle or render it unsafe It also is important to understand tha...

Page 4: ...7E ELECTRICAL BODY AND CHASSIS Lamps and Lighting 8A Electrical and Wiring 8B Instrument Panel Gages and 8C Wiring Diagrams ACCESSORIES 9 METRIC AND FASTENER INFORMATION 10 CAUTION These vehicles cont...

Page 5: ...tached to the left top of the instrument panel on CK and G truck and can be easily seen through the windshield from outside the vehicle Fig 0A 1 On P 10 20 30 models the plate is attached to the front...

Page 6: ...ORE V GMT C PONTIAC D GMAD D O R AVILLE z GMAD FREMONT F CHEVROLET FLIN T 1 GM OF CAN AD A OSHAWA J GMAD JANESVILLE 3 CHEVROLET DETROIT K GMAD LEEDS 4 GM OF CANADA SCARBOROUGH R GMAD ARLING TO N 7 GMA...

Page 7: ...by permits proper follow up of the plant involved to get corrections made when necessary Always include the prefix in the number S E R V I C E P AR T S I D E N T I F I C A T I O N V I N mu H i V1N VlM...

Page 8: ...O B PARMA 2 MODEL YEAR E MONTH A JAN B FEB 03 DAY D SHIFT D DAY SHIFT N NIGHT SHIFT H 7A 8 6 81 TRANSMISSION NAMEPLATE YPSILANTI PLANT MICHIGAN P z 82 PZ 86992 82 MODEL YEAR PZ MODEL 86992 SERIAL NO H...

Page 9: ...00 CID Located on Pad immediately forward of right hand cylinder head 8 Cylinder Gasoline Engine 454 CID Code is located on a pad of the front top center of the engine block immediately forward of the...

Page 10: ...LUBRICATION OB 1 SECTION OB MAINTENANCE AND LUBRICATION CONTENTS Maintenance Schedule OB 6 General Maintenance OB 6 Emission Control Maintenance OB 11 Recommended Fluids and Lubricants OB 13 Fluid Ca...

Page 11: ...Mile 48 000 km intervals Also check B 1 and B 4 at 45 000 Miles 72 000 km 0 B 2 Carburetor or Throttle Body Mounting 2 B 3 Engine Idle Speed See Explanation B 4 Vacuum Advance System B 5 Thermostatic...

Page 12: ...es and Distributor B 7 Spark Plugs Replace every 30 000 Miles 48 000 km 2 B 8 PCV System Check and Valve Replacement See Explanation for service intervals B 9 Engine Timing Adjust every 30 000 Miles 4...

Page 13: ...ON B EMISSION CONTROL MAINTENANCE B 1 Engine Idle Speed Adjustment At 1st 4 Months or 6 000 Miles 9 600 km then at 12 Month 12 000 Mile 19 2000 km intervals B 2 Idle Stop Solenoid Check B 3 Spark Plug...

Page 14: ...Axle See Explanation for service intervals A 15 Wheel Bearings Repack every 30 000 Miles 48 000 km A 16 Automatic Transmission See Explanation for service intervals SECTION B EMISSION CONTROL MAINTENA...

Page 15: ...ts and latch locking plate 3 Apply light engine oil to all pivot points in release mechanism as well as primary and secondary latch mechanisms 4 Lubricate hood hinges 5 Make hood hinge and latch mecha...

Page 16: ...lipping or loss of drive Automatic transmissions are sometimes overfilled because the fluid level is checked when the fluid is cold When cold the dipstick shows that fluid should be added However the...

Page 17: ...ter driving in a dust storm Also always use SF Quality oils of the proper viscosity See Owner s Manual for further details Engine Oil Additives The engine should not need these extra engine oil helper...

Page 18: ...r dusty or muddy conditions and in extensive off road use A 6 Exhaust System Inspect the complete exhaust system including the catalytic converter Inspect body areas near the exhaust system and also t...

Page 19: ...one should not be used in a vehicle at any time The cooling system should be serviced each year as follows 1 Wash radiator cap and filler neck with clean water 2 Check coolant level and test for freez...

Page 20: ...ion Fluid Refer to A 2 for checking automatic transmission Change the transmission fluid and service screen every 15 000 miles 24 000 km on light duty emissions or 12 000 miles 19 200 km on heavy duty...

Page 21: ...d purge valves work properly if equipped Remove canister check for cracks or damage Replace as needed B l4 Idle Stop Solenoid a n d o r Dashpot Check that parts work properly Replace them as needed B...

Page 22: ...rease H ood and D oor Hinges Engine Oil A utom atic Transm ission Shift Linkage Engine Oil Chassis Lubrication Chassis grease m eeting requirem ents of G M 6031 M Engine Oil Gasoline S F or S F C C or...

Page 23: ...e r Change 4 7 L 5 7L 5 qts 6 qts Code F H L M P 5 0 l V 8 Drain R efill 5 7 1 V 8 w F ilte r Change 3 8 L 4 7 L 4 qts 5 qts Code W 7 4 L V 8 Drain Refill w F ilte r Change 5 7L 6 6 L 6 qts 7 qts Code...

Page 24: ...sion Manual 14 Universal Joints Shaft PA10 Automatic 15 Rear Axle 5 Tie Rod Ends FOUR WHEEL DRIVE MODELS LUBRICATIO N POINTS 1 Air Cleaner 6 Master Cylinder 11 Front and Rear Axle 2 Control Linkage Po...

Page 25: ...rm Bushings and 5 Trans Control Shaft 8 Rear Axle Ball Joints 6 A ir Cleaner Element 9 Oil Filter 2 Tie Rod Ends 7 Transmission Manual 10 Brake Master Cylinder 3 Wheel Bearings Automatic 11 Parking Br...

Page 26: ...h the FAN switch and also the blower resistor assembly Located in the fuse block in series between the blower motor and the battery is a 25 amp fuse C K models a 20 amp fuse on G models HEATER DISTRIB...

Page 27: ...HEATER C O N T R O L VIEW A HEATER IN OFF P O S ITIO N HEATER A DEFROSTER A SM HEATER ASM D AS H PANEL C K MODELS HEATER A DEFROSTER A S M AIR FL O W LEGEND Q TEMPERATURE VALV E O U T S D Qjj DEFROST...

Page 28: ...HEATER 1A 3 Fig lA 2 Heater Control C K Models Fig lA 3 Heater Control G Models...

Page 29: ...as necessary 5 Check position o f bottom o f nozzle to heater locating tab Adjust 6 Check position o f defroster nozzle openings re la tiv e to in s tru ment panel openings Mounting tabs provide p o...

Page 30: ...ion Adjust if necessary j H E A TE R CO RE Feel temperatures of heater inlet and outlet hoses W A R M IN L E T A N D O U T L E T HOSES I I Check engine therm ostat I L IT T L E OR N O C H A N G E IN A...

Page 31: ...el FUSE OK I The following tests should be made with the ignition switch in RUN position the blower speed switch ON and the lever on heat position I Check blower motor ground X I POOR OR NO GROUND X G...

Page 32: ...4 ACC 2 5 A M P IN FUSE PANEL HEATER O P E R A T IO N LO BAT B LO SW RES Rl R2 BLO M T R G R D MED B AT BLO SW RES Rl BLO M T R G R D HI BAT BLO S W BLO M T R G R D JW V W r 7 IF 1 BLO MED BLOWER RESI...

Page 33: ...er wheel should rotate freely with no interference HEATER DISTRIBUTOR AND CORE ASSEMBLY C K Models Replacement Fig 1A 6 1 Disconnect the battery ground cable 2 Disconnect the heater hoses at the core...

Page 34: ...routed from the thermostat housing or inlet manifold and water pump radiator on some automatic transmission vehicles to the core inlet and outlet pipes as shown in Figures 1A 8 thru 1A 11 Hoses are a...

Page 35: ...t Fig 1A 15 1 Disconnect the battery ground cable 2 Remove I P bezel as outlined in Section 8C of this manual 3 Remove the control to instrument panel mounting screws 3 and carefully pull the control...

Page 36: ...required NOTICE Do not pinch the cable too tightly or damage to the cable could result 6 Install the cable reversing Steps 1 4 above Fig 1A l0 Heater Hose Routing V8 Adjustment G Van 1 Attach inner ca...

Page 37: ...Fig 1A 11 T E E V A L V E A S M TEE AND VALVE C36...

Page 38: ...HEATER 1A 13 Fig 1A l2 Distributor Ducts G Models Fig 1A l5 Control Assembly G Models...

Page 39: ...1A 14 HEATER V IE W A V IE W B Fig 1A l7 Control Cable Routing G Models...

Page 40: ...connected to the standard heater hoses with tees An on off vacuum operated water valve is installed in the heater core inlet line in the engine compartment The purpose of the valve is to cut off cool...

Page 41: ...luded with the auxiliary heater unit replacement procedures will not be repeated in this section On G Models When replacing heater hoses maintain a 1 2 in minimum clearance between hose clip and upper...

Page 42: ...HEATER 1A 19 Fig 1A 23 Auxiliary Heater Hose Routing...

Page 43: ...TER V olts Am ps Cold RPM Cold Blower Motor C K Models G Models 13 5 13 5 6 25 Max 7 1 Max 2550 Min 2950 Max 2850 Min 3250 Max Fuses C K Models G Models A U X IL IA R Y HEATER 20 Amp Blower Motor Volt...

Page 44: ...r Resistor 1B 40 Blower Motor Assembly 1B 41 Expansion Valve 1B 41 Evaporator Core 1B 41 Blower Motor Switch 1B 43 Fuse 1B 43 C60 System G Models 1B 43 Condenser 1B 43 A C Air Distributor D uct 1B 43...

Page 45: ...EVAPORATO R CORE SHROUD R H OUTLET BLOWER EVAPO RATO R A S M CONTROL R H OUTLET VIEW A CENTER OUTLET AIR CONDITIONING OVERHEAD SYSTEM L H OUTLET AIR INLET VALV E PLENUM VALV E HEATER CORE R H CENTER...

Page 46: ...ons only When heating above ambient temperatures is desired the vehicle heater must be used When air conditioning is desired the heater should be completely shut OFF This self contained unit is bracke...

Page 47: ...nsion tube is located in the evaporator inlet line Fig 1B 4 Thermostatic Switch Motor Home Chassis Units Only System temperature is controlled by running the compressor intermittently automatically tu...

Page 48: ...O PERATING POSITION W ITH O UTSIDE A IR D E L IV E R E D TH R U I P O U T LE T S A NON COMPRESSOR O PER ATIN G POSITION W ITH O U TSID E AIR D IS T R IB U T E D A B O U T 80 TO FLO O R 20 TO W SH LD C...

Page 49: ...n in Fig I B 7 System Operation G Models System operation is shown in Fig 1B 8 Vacuum Schematic G Models G Model vacuum schematic is shown in Fig 1B 9 OVERHEAD SYSTEM C K G SERIES This system operates...

Page 50: ...U T S ID E D A S H O U T L E T S H E A T E R A C Bl L E V O N A L L O U T S ID E D A S H O U T L E T S F L O O R O U T L E T S H E A T E R A C H E A T E R V E N T O F F A L L O U T S ID E D A S H O U...

Page 51: ...systems contain Refrigerant 12 This is a chemical mixture which requires special handling procedures to avoid personal injury Always wear goggles and wrap a clean cloth around fittings valves and conn...

Page 52: ...h the skin the injury should be treated the same as skin which has been frostbitten or frozen All Refrigerant 12 drums are shipped with a heavy metal screw cap The purpose of the cap is to protect the...

Page 53: ...h can cause internal compressor wear or plugged lines condenser and evaporator core expansion tubes orifice or compressor inlet screens The use of the proper wrenches when making connections on O ring...

Page 54: ...ere is sufficient refrigerant in the system for leak testing 2 Open control valve only until a low hiss of gas is heard then light gas at opening in chimney 3 Adjust flame until desired volume is obta...

Page 55: ...XPANSION O R IFIC E TUBE A CCUM ULATO R LOWER CASE C A S E IN L E T A ND D ISTR IB U TO R D R A IN COVER FLAPPER V A C U U M ACTU A TO R M ODE V A LV E M ODE V A LV E M O U N TIN G GASKET M O DU LE Ch...

Page 56: ...AIR CONDITIONING IB 13 Chart 1B 4 Pressure Cycling CCOT System Diagnosis...

Page 57: ...next step is to determine whether the cause is the vacuum harness or the vacuum valve Check the vacuum harness first 4 Vacuum Harness Circuit Check a Disconnect the vacuum harness at the control head...

Page 58: ...HIGH TORQUE COMPRESSOR SEIZED Check for proper air gap Correct if necessary 022 057 Check and correct belt tension REFRIGERATION CHARGE IS DEPLETED SYSTEM HAS SOME REFRIGERANT LEAKS REFRIGERANT DOES N...

Page 59: ...ANO EVACUATE THOROUGHLY RECHARGE SYSTEM CHECK COMPRESSOR DISCHARGE PRESSURE NORMAL EVAPORATOR PRESSURE T L LOW EVAPORATOR PRESSURE Check for malfunctioning expansion valve See Component Diagnosis 1 CH...

Page 60: ...otor Check wire connector on blower relay with 12 volt test light X With ignition switch in Run position and heater or A C on use 12 volt test lamp to check for voltage at resistor connector with blow...

Page 61: ...M IN L E T A N D O U T L E T HOSES Check engine therm ostat A dju st b y p a s s fo r no a ir flo w H IG H A IR FLOW A djust defroster door fo r low air flo w L IT T L E OR N O CH A N G E IN A IR FLO...

Page 62: ...ORATOR PRESSURE CONTROL SWITCH 8OK GRN 59 CsXl COMPRESSOR 297 3407 NOTE I W K N FAST IDLE SO LENO ID IS NOT USED EXTENSIO N WIRE WILL NOT BE INSTALLED ANO WIRE 66B WILL BE CUT OFF AT WIRE HARNESS BREA...

Page 63: ...72 2 Y E L L K B S I QRWLK A 30 N LK 852B 1 2BRN 50 2 BRN 50 r 3 BRfVWHT 850 1 2 0 0 4 9 3 2973427 e r a c r s REAR A C SWITCH 8917563 3 ORN LK 852 B 91738 2BRN 50 J83 v r V rroiryi I 8 9 1 7 3 8 0 5...

Page 64: ...Fig 1B 17 C60 System Vacuum Diagram C K Series...

Page 65: ......

Page 66: ...Fig 1B 19 C60 Motor Home Chassis Wiring Diagram SWITCH AIR CONDITIONING IB 2 3...

Page 67: ...IB 24 AIR CONDITIONING Fig IB 20 1 P A C Harness Wiring...

Page 68: ...AIR CONDITIONING IB 25 VIE W A Fig IB 21 A C Compressor wiring...

Page 69: ...iquid refrigerant comes into contact with the skin or eyes injury can result Before removing and replacing any of the air conditioning refrigeration lines or components the system must be completely d...

Page 70: ...A N T 1 2 3 F U L L Y OPEN G A U G E SE T V A C U U M V A L V E 4 C O N N E C T LOW SIDE G A U G E HOSE TO LOW SIDE P R E S S U R E S E R V IC E FITTIN G ON V E H IC L E S A C C U M U L A T O R ASM U...

Page 71: ...Evaporator Add 90ml 3 fl oz Condenser Add 30 ml 1 fl oz Accumulator Remove drain oil measure replace same amount of new oil plus 60ml 2 fl oz to compensate for that retained by the original accumulato...

Page 72: ...6 6mm 2 8 2 9 or more vacuum the system should be checked for leaks If no leaks are found the vacuum pump may require repair J 23500 01 CHARGING STATION METHOD Follow Charging instructions provided wi...

Page 73: ...ystem more rapidly 4 Shut off R efrigerant 12 source valve and run engine for 30 seconds to clear lines and gages 5 W ith the engine running remove the charging low side hose adapter from the Accumula...

Page 74: ...be caused by one of the following conditions valve stuck open valve stuck closed broken power element a restricted screen or an improperly located or installed power element bulb The first three condi...

Page 75: ...or on the mounting bracket and install all nuts bolts and lock washers 3 Install the connector assembly to the compressor rear head using new O rings coated with clean refrigeration oil 4 Connect the...

Page 76: ...AIR CONDITIONING IB 33 Fig 1B 26 Compressor Mounting...

Page 77: ...To install a new condenser reverse Steps 1 thru 9 above Add one fluid ounce of clean refrigeration oil to a new condenser Use new O rings coated with clean refrigeration oil when connecting all refri...

Page 78: ...tor assembly far enough to gain access to all vacuum and electrical harnesses 9 Disconnect the vacuum and electrical harness and remove the selector duct assembly 10 Remove the core mounting strap scr...

Page 79: ...IB 36 AIR CONDITIONING S K IR T GEN B RK T A C HOSE B ATT CABLE IN L E T HOSE 1 0 2 04 0 Fig 1B 29 Heater Hose Routings C K Series...

Page 80: ...a new switch reverse Steps 1 thru 4 above V A C U U M TANK The vacuum tank is mounted to the engine side of the dash panel above the blower assembly Fig 1B 33 Replacement 1 Disconnect the vacuum lines...

Page 81: ...1 IB 38 AIR CONDITIONING KICK PAD VALVE Fig 1B 31 Air Inlet Valves C K Models GRAY TO PLEN U M VALVE VIEW Fig 1B 34 Vacuum Line Routing C K Models...

Page 82: ...rporates four adjustable aii outlets Fig 1B 36 Replacement 1 Disconnect the battery ground cable 2 Disconnect the drain tube from the rear duct 3 Remove the screws securing the duct to the roof panel...

Page 83: ...strap 4 Disconnect the blower motor lead wire Front Wiring C K Models 5 Remove the lower to upper blower evaporator case screws and lower the lower case and motor assembly NOTICE Before removing the c...

Page 84: ...or 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 40 Removal 1 Disconnect the bat...

Page 85: ...nd center hood lock support as an assembly 4 Disconnect condenser inlet and outlet lines at condenser 5 Remove screws attaching left side condenser bracket to radiator 6 Remove screws attaching right...

Page 86: ...vacuum actuator Refer to Fig 1B 44 8 Disconnect temperature cable and vacuum hoses at distributor case 9 Remove heater distributor duct refer to Fig 1B 45 10 Remove 2 defroster duct to dash panel atta...

Page 87: ...ht hand marker lamp for access 7 Disconnect accumulator inlet and outlet lines and 2 brackets attaching accumulator to case 8 Disconnect evaporator inlet line 9 Remove three 3 nuts and one 1 screw att...

Page 88: ...MOTOR RELAY G SERIES Replacement Fig IB 49 1 Disconnect electrical harness at the relay 2 Remove the relay mounting screw and remove the relay 3 To install reverse Steps 1 thru 3 above Fig 1B 48 Contr...

Page 89: ...move steering column to I P attaching screw 4 Remove radio support bracket screw 5 Remove 1 P attaching screws 6 Pull right side of I P rearward 7 Remove duct distributor attaching screws 8 Remove cen...

Page 90: ...R ASSEMBLY RING HOSE TUBE ASSEMBLY C O N D OUTLET ACCUM DEHYDR ASSEMBLY OUTLET PIPE G MOD LE 3 ENG C60 HOSE TUBE ASSEMBLY E X T SIDE FRT RH RAIL V IEW G MOD V8 ENG C60 69 HOSE TUBE ASSEMBLY EVAP OUTLE...

Page 91: ...IB 48 AIR CONDITIONING Fig 1B 59 C K Models Refrigerant Lines L6...

Page 92: ...49 A C DUCTWORK Air Conditioning duct attachment is shown in Fig 1B 63 DEFROSTER DUCT Defroster duct mounting is shown in Fig 1B 64 TEMPERATURE DOOR CABLE Temperature cable attachment and routing is...

Page 93: ...mponents CONDENSER Replacement Fig IB 66 1 Disconnect the battery ground cable 2 Purge the system of refrigerant 3 Disconnect the condenser inlet and outlet lines and cap or plug all open connections...

Page 94: ...kit should be intalled The kit contains the sight glass seal and retainer Refer to Fig 1B 68 1 Purge system 2 Remove the sight glass retainer nut using a screwdriver and remove old glass and O ring se...

Page 95: ...____ CONNECTOR tang GROOVE A Insert screw driver in groove press tang toward terminal to release B Pry tang back out to insure locking when reinstalled into connector ___________________ Fig 1B 71 Bl...

Page 96: ...dial Displacement 6 Cylinder A x ia l 12 6Cu In 4 Cylinder R a d ia l 10 0Cu ln R o ta tio n Clockwise Amps RPM Volts Cold Cold Blower Motor C K Four Season 12 0 12 8 Max 3400 Min C K G Overhead G Flo...

Page 97: ...EAT O RING IN STA LLER PRESSURE TEST CONNECTOR CLUTCH HUB H O LD IN G TO O L n j 2 J 9553 01 p i J 9398 14 J 25008 j 5 J24092 p T s J 8433 T7 1 j 9393 18 1J 6083 fl9 J 24896 20 J 26271 p21 J 24895 22...

Page 98: ...No 21 Snap Ring Pliers No 26 Snap Ring Pliers Compressor Holding Fixtuie Compressing Fixture Clutch Hub Holding Tool 9 16 Thin W a ll Socket Hub and Drive Plate Assembly Remover Hub and Drive Plate A...

Page 99: ...sor connection areas and the Two types of drive systems are used on the R 4 Compressor exterior of the compressor should be cleaned off as much as V groove type and poly groove type The drive system a...

Page 100: ...g Tool J 25030 and tighten to 14 N m 10 lb ft torque using a 0 60 N m 0 25 lb ft torque wrench 7 If operation is performed with compressor on car connect drive belt tighten mounting brackets and adjus...

Page 101: ...T W ASHER K IT C Y L IN D E R A N D S H A F T A S S E M B LY R E T A IN E R R IN G T7 V A L V E PLATE T8 SHIPPING PLATE 1 9 SCREW 20 O R IN G S U C T IO N D IS C H A R G E PORTS 2T PRESSURE R E L IE...

Page 102: ...E P U L L E Y ROTOR T R E T A IN E R H I C LU T C H D R IV E A N D HUB ASSEM BLY 6 l S H A F T KEY T S H A F T N U T 2 1 0 7 2 9 shown in Fig 1C1 15 but do not stake too deeply to avoid distorting the...

Page 103: ...front head of the compressor 5 Install rotor and bearing assembly retainer ring using Snap Ring Pliers J 6083 see Fig 1C1 11 6 Apply sealer Loctite RC 75 Loctite 601 or equivalent to threads of pulle...

Page 104: ...g Fig 1C1 16 Installing Clutch Rotor Bearing special lock washers Fig 1C1 18 similar to original crimp and lock bends on washers 9 Reinstall Clutch Plate and Hub assembly as described in R 4 Compresso...

Page 105: ...wn 3 Using a center punch with a 45 angle point stake 1 1 1 4 mm 0 45 0 55 deep the bearing in three places 120 apart similar to that shown in Fig 1C1 15 Do Not stake too deeply to avoid distorting th...

Page 106: ...the locator holes in the Front Head 3 Install the rotor and bearing assembly retaining ring and reassemble the Clutch Plate and Hub assembly as described in R 4 Compressor Clutch Plate and Hub Asm Rep...

Page 107: ...ctite 601 or equivalent sealer to the screw threads of each mounting screw and threads of the mounting holes in the Clutch Rotor Wet the threads thoroughly to ensure complete thread coverage 7 Install...

Page 108: ...SOR Service repair procedures to the Compressor Shaft Seal Pressure Relief Valve or disassembly of the Internal Compressor Cylinder and Shaft Assembly are considered MAJOR SINCE THE REFRIGERATION SYST...

Page 109: ...Seat using Snap Ring Pliers J 5403 See Fig 1C1 29 Use the sleeve from Seal Seat Remover Installer J 9393 to press in on the seal seat retainer ring so that it snaps into its groove 7 For Leak Test pre...

Page 110: ...ings Check switch cavity and O ring groove in the rear head for dirt or foreign material and clean as necessary Install new O ring coated with clean 525 viscosity refrigerant oil into groove in switch...

Page 111: ...he Clutch Rotor and Bearing Clutch Coil and Pulley Rim as a total assembly Be careful not to drop the Puller Guide J 25031 when removing the assembly 3 Remove and discard the Shaft Seal parts as descr...

Page 112: ...cording to the directions in Section 1B1 R 4 COMPRESSOR THR UST AN D BELLEVILLE W ASHERS Remove and Replace 1 Discharge the Refrigerant System according to the directions in Section IB 1 2 Remove the...

Page 113: ...clean 525 viscosity refrigerant oil and install in the rear O ring groove of the cylinder Be careful in moving the O ring across the cylinder surface to prevent damaging the O ring 3 Dip the remainin...

Page 114: ...xture J 25008 1 in vise for access to the remaining two valve plates and retainers 4 Install Discharge Valve Plates and or Retainers as shown in Figs 1C1 43 and 1C1 44 Reposition compressor and Holdin...

Page 115: ...several turns to ensure piston assembly to cylinder wall lubrication 12 Connect the Charging Station high pressure line or a high pressure gage and Gage Adapter J 5420 to the Test Plate J 9625 high s...

Page 116: ...T C O N N E C T O R C L U T C H H U B H O L D IN G T O O L Hl r i J 9553 01 T31J 9398 1141 J 25008 15 J 24092 on J 8433 L jzJJ 9393 IjsJJ 6083 QUJ 24896 fan J 26271 1 1J 24895 12 2 J 25031 2 III o n...

Page 117: ...lacement ID 18 Assembly ID 18 Re Install 1D 21 A 6 Comp Leak Testing External and Internal ID 25 For all practical purposes all vehicles make use of the or reassembly of the compressor Clean tools and...

Page 118: ...thout removing the compressor from the vehicle but these operations are covered later in this section as Major Repair Procedures because the system must first be purged of Refrigerant 12 Illustrations...

Page 119: ...K N U T R E A R H E A D O U T E R O IL PUMP C O V E R q R E A R D IS C H A R G E V A L V E P L A T E A S S E M B L Y f R E A R S U C T IO N R E E D B U S H IN G N E E D L E B E A R IN G O R IN G R E A...

Page 120: ...ght curve for interference fit into hub keyway 2 Line up the key in the hub with keyway in the shaft Fig ID 6 3 Install the Drive Plate Installer J 9480 1 as illustrated This Installer has a left hand...

Page 121: ...Pliers J 6435 Fig ID 9 3 Pry out absorbent sleeve retainer and remove absorbent sleeve from compressor neck 4 Place Puller Pilot J 9395 over end of compressor shaft Inspection Check the appearance of...

Page 122: ...6435 6 Install absorbent sleeve retainer in neck of compressor Using sleeve from Seal Seat Remover Installer J 9393 install retainer so that outer edge is recessed 8mm 1 32 from compressor neck face...

Page 123: ...coil housing and scribe location on compressor front head casting 3 Remove coil housing retaining ring using Snap Ring Pliers J 6435 Fig ID 15 4 Lift Coil and Housing assembly off compressor front he...

Page 124: ...they are removed from the service package Piston shoe discs and shaft thrust races will be identified by number on the parts themselves for reference to determine their size and dimension see Fig ID 4...

Page 125: ...r prevent sealing Replace 1 Coat the new seal seat O ring in clean 525 viscosity refrigerant oil and assemble onto O Ring Installer J 21508 see Fig IB 20 2 Insert the O Ring Installer J 21508 complete...

Page 126: ...spread the sleeve until the ends of the sleeve butt at the top vertical centerline 10 Position the new metal sleeve retainer so that its flange face will be against the front end of the sleeve The sle...

Page 127: ...d with clean paper are of extreme importance An inspection should be made of the Internal Mechanism Cylinder and Shaft assembly to determine if any service operations should be performed A detailed in...

Page 128: ...on Front Head with a plastic hammer 16 Rest compressor shell on its side and push Front Head assembly through Compressor Shell being careful not to damage sealing areas on inner side of front head Dis...

Page 129: ...E U NDER NO CIRCUMSTANCES SHOULD SHAFT BE STRUCK AT EITH ER END in an effort to separate upper and lower cylinder halves because the shaft and the axial plate could be damaged 4 Carefully remove the R...

Page 130: ...earing in end of cylinder head 17 Wash all parts to be re used with trichloroethane naphtha Stoddard solvent kerosene or a similar solvent Air dry parts using a source of clean dry air A 6 compressor...

Page 131: ...e Piston and Ring Assembly particularly during assembly into and removal from the cylinder bores to prevent damage to the Teflon piston rings Shoe discs should not be installed on rear of piston durin...

Page 132: ...shaft is hard to rotate install shaft nut onto shaft and turn shaft with wrench Fig 1D 40 Gaging A 6 Rear Piston Ball 17 Rotate shaft another 12 P and again repeat Step 15 betw een these same parts a...

Page 133: ...0 2 1 0 2 1 0 2 2 21 200914 Fig 1D 42 Selection of Proper A 6 Shoe Disc 20B An alternate method of selecting a proper race is to use Gage Set J 9661 01 selecting a suitable feeler gage leaf until the...

Page 134: ...the Ring Installer J 24608 5 down over the Installer Guide J 24608 2 to install the Teflon ring in the piston ring groove Fig ID 47 If the Teflon ring is slightly off position in the ring groove it c...

Page 135: ...397 Install the shaft and axial plate threaded end down with its front bearing race pack ZERO race bearing ZERO race if this was not already done at the end of the Gaging Procedure Install rear bearin...

Page 136: ...for Pistons No 2 and No 3 Fig ID 52 5 W ithout installing any O rings or bushings assemble one end of the new Service Discharge Cross Over Tube into the hole in the front cylinder half Figs ID 53 and...

Page 137: ...nt cylinder half Align with dowel pins suction ports oil return slot and discharge cross over tube Fig ID 58 5 Install Front Discharge Valve Plate assembly it has a large diameter hole in the center a...

Page 138: ...BLY FRONT HEAD CASTING FRONT DISCHARGE VALVE PLATE ASSEMBLY SUPPORT BLOCK J 21352 204967 Fig 1D 61 Installing A 6 Front Head Casting 8 Generously lubricate new O ring and angled groove at lower edge o...

Page 139: ...gear with previously applied identification mark up and when standing facing oil sump position outer gear so that it meshes with inner gear at the 9 o clock position The resulting cavity between gear...

Page 140: ...ey and Bearing assembly as described in A 6 Compressor Pulley and Bearing Replacement procedure 29 Install compressor Clutch Plate and Hub assembly as described in A 6 Compressor Clutch Plate and Hub...

Page 141: ...on the crankshaft several turns to ensure piston assembly to cylinder wall lubrication 12 Connect the Charging Station high pressure line or a high pressure gage and Gage Adapter J 5420 to the Test Pl...

Page 142: ...98 J 8092 J 21352 22 J 51 39 No 21 Snap Ring Pliers No 26 Snap Ring Pliers Compressor Holding Fixture Compressing Fixture C lutch Hub H olding Tool 9 1 6 Thin Wall Socket Hub and Drive Plate A s s e m...

Page 143: ...so These holes can be opened by using a punch or drift The side panel drain holes are in the rear section of the rocker panels and in the lower rear quarter panels FRAME INSPECTION Raise the vehicle o...

Page 144: ...awn through the intersection of any two previously drawn pairs of equal intersecting diagonals Vertical Check Vertical dimensions are checked with a tramming bar from indicated points on the frame Fig...

Page 145: ...10 14 7 8 17 3 4 17 3 4 19 7 8 16 3 4 15 5 8 17 3 4 68 1 2 76 1 2 110 16 7 8 16 7 8 14 KA109 209 13 3 8 15 1 4 17 19 7 8 12 1 2 13 10 14 7 8 17 3 4 17 3 4 19 7 8 16 3 4 15 5 8 17 3 4 68 1 2 86 1 2 120...

Page 146: ...nts to be trammed 2 The vertical dimension from the datum line to the points to be trammed The tram bar should be on a parallel to that of the body plane The exception to this would be when one of the...

Page 147: ...NERAL DESCRIPTION All truck front and rear bumpers are of a single piece design Bumper attachments are the standard bracket and brace to frame mountings This section contains procedures for the remova...

Page 148: ...Remove bumper assembly 5 Remove bolts securing bumper brace to frame and bumper brackets and reinforcem ents to fram e if necessary Fig 2B 5 Front Bumper G Models Installation Install rear step bumper...

Page 149: ...e order of removal Fig 2B 7 Rear Bumper G Models SPECIFICATIONS TORQUE SPECIFICATIONS C P AND K Front Bumper 35 ft lbs Front Bumper Bracket and Brace 70 ft lbs Rear Bumper to Outer Bracket 35 ft lbs R...

Page 150: ......

Page 151: ...stment is allowed by oversize holes at the fender rear attaching point and chassis sheet metal mounts Special shims at the rear locations allow adjustment of the rear of the assembly The lower rear ed...

Page 152: ...Elongated holes in the bracket are provided for alignment purposes A separate secondary latch is mounted to the striker plate in the hood See Fig 2C 3 and 2C 4 Replacement 1 Open hood and remove the...

Page 153: ...as shown in Fig 2C 7 The lock bolt located on the hood dovetails with the mounted striker plate preventing upward or downward movement of the hood while the vehicle is in motion Integral with the str...

Page 154: ...g a suitable rod by pressing 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 Fig 2C 6 Ho...

Page 155: ...attaching cap screws at hinges firmly Close hood and check fit If necessary to align hood perform procedure as outlined under A lignm ent which follows Alignm ent 1 Loosen hood hinge bolts Note that t...

Page 156: ...Shims which are found at various locations should be recorded to ease installation of sheet metal assembly Removal 1 Remove bolts at hood hinge and link Remove hood assembly Fig 2C 12 Lower Radiator...

Page 157: ...erbody 6 Install bolts at steering column skirt reinforcement final torque 25 ft lb 33 N m 7 Tighten each radiator support mounting bolt 33 ft lb 44 N m 8 Torque bolts at fender to cowl 25 ft lb 33 N...

Page 158: ...crews attaching lower radiator grille panel 5 Remove screws attaching skirt to radiator support 6 Remove two 2 top rear fender bolts and shims 7 Remove bolt and shims at bottom of fender 8 Remove bolt...

Page 159: ...tal or primer The surface must be free of any imperfections that might high light through the film Remove dirt nibs and other foreign material in the paint by light sanding with 600 grit sandpaper The...

Page 160: ...re wrapping around or tucking ends 4 Remove about 6 00 in 152 4mm of the paper backing from stripe and align stripe on vehicle Fender stripe should bridge the gap at the fender extension be tucked in...

Page 161: ...ter a minimum of 72 hours aging For Large Decals 1 Prior to application of transer wet down the complete transfer surface with a solution of 0 25 oz of neutral detergent cleaner must not contain oils...

Page 162: ......

Page 163: ...On the following 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 Chassis Cabs Chassis cab models see fi...

Page 164: ...2D 2 BODY Fig 2D 4 Typical Utility Vehicle Model...

Page 165: ...BODY 2D 3 Fig 2D 5 Typical Vans and Sport Vans Models Fig 2D 6 Typical Commercial Cutaway Model Van...

Page 166: ...p See figure 2D 7 Fig 2D 7 Windshield Wipers WINDSHIELD WIPERS Windshield wiper units on all models are of the two speed electric type A single wiper motor unit mounted to the left side of the dash pa...

Page 167: ...y reaching into com partm ent opening with door partially open Adjustm ent Engagement of lock in striker may be adjusted by loosening striker retaining screws and moving the striker to desired positio...

Page 168: ...rtant that 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 aro...

Page 169: ...e assist the lip of the rubber weatherstrip channel over the pinchweld flange with a flat bladed tool See figures 2D 14 and 2D 15 4 With the aid of an assistant outside the cab remove the windshield f...

Page 170: ...weatherstrip that were cleaned in the previous step and are shown in View A Allow primer to cure for at least 30 minutes 30 day maximum Thoroughly clean surface of glass to which blackout primer will...

Page 171: ...enna pigtail to radio antenna lead 18 Install inside trim panels 19 Install rear view mirror to windshield STATIONARY BODY GLASS Replacement The method used to remove the windshield glass may be appli...

Page 172: ...the top and side edges and 25 inch clearance at the bottom The door should be adjusted in the opening so the edge of the door across the top and also at the lock side is parallel with the body opening...

Page 173: ...ecial Tool J 22585 remove 3 bolts securing front door 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 t...

Page 174: ...ck rod 3 Remove arm rest screws and trim panel See figure 2D 27 4 Remove screws attaching ventilator lower assembly to door panel 5 Remove three screws at the upper front of the door frame 6 Pull uppe...

Page 175: ...channel Glass should be installed so that rear edge is parallel to the division post Allow full cure before water testing Installation 1 Lower the ventilator assembly into the door frame 2 Make certai...

Page 176: ...ll up position and tape to door frame using cloth body tape 2 Disconnect battery ground cable 3 Remove door trim panel as previously outlined 4 Remove remote control bolts and lay control assembly asi...

Page 177: ...ure to replace all clips removed earlier Door Outside Handle Fig 2D 37 Replacement 1 Raise window to full up position 2 Remove trim panel as outlined 3 Remove clip from outside handle rod to lock 4 Re...

Page 178: ...all foreign material from door opening surface proceed as follows 1 Open door and block open 2 Remove sill plate retaining screws and remove sill plate 3 Remove side door inner weatherstrip seal 4 Sta...

Page 179: ...ow fore and aft adjustm ent Together this allows proper alignment of the glass to the rear glass run channel for full up and down travel W IN D O W GLASS FIG 2D 46 Replacement 1 Lower glass to full do...

Page 180: ...trol lower rod c Outside handle control rod 3 Remove screws retaining lock assembly to door panel then remove lock assembly 4 Install lock by reversing above procedure Be sure to replace all clips rem...

Page 181: ...tightening bolts See figure 2D 54 for hinge bolt location Rear door wedges and strikers should be adjusted as shown in figure 2D 55 Be sure that adjustments are as shown to insure proper latching of t...

Page 182: ...2D 20 BODY Fig 2D 51 Rear Door Controls Fig 2D 52 Rear Door Outside Handle and Lock Cylinder...

Page 183: ...f equipped with electric powered window disconnect wiring harness 5 Lift endgate to almost closed position and remove support cables 6 Remove endgate with torque rod 7 To install reverse removal proce...

Page 184: ...ift arms before removing the electric motor when the window glass has been removed or disengaged from the lift arms a Drill a 1 8 3 1mm inch hole through the sector gear and back plate as shown in fig...

Page 185: ...63 then grasping torque rod with one hand and pulling torque rod over gravel deflector as shown in figure 2D 64 5 Individual components may be removed from the endgate now or after reinstallation 6 T...

Page 186: ...al Window 1 Lower endgate and remove acess cover 2 Disconnect side latch remote control rods from center control by removing retaining clips See figure 2D 68 3 Remove four screws from each side latch...

Page 187: ...le motor mounted to the endgate inner panel This circuit also includes a block out switch to prevent operation of the window while the endgate is open fig 2D 75 Service procedures for endgate disassem...

Page 188: ...crew when the window glass has been removed or disengaged from the lift arms CAUTION Step 1 must be perform ed if the w indow is rem oved or disengaged from the regulator lift arms The lift arms are u...

Page 189: ...er the tailgate 3 Remove six top to roof mounting bolts 4 Remove ten top to side panel mounting bolts 5 on each side 5 Remove upper spare tire brace by removing brace bolt The spare tire brace must be...

Page 190: ...ust start with the rear vertical bolt 1 Now going forward install 2 LH side only 3 and 4 The RH side 2 bolt will be installed later 6 Loosen bolts 6 on both sides 7 Install and tighten bolts 5 on both...

Page 191: ...the retractor are not available as service replacement parts The shoulder belts and lap belts are attached to the front seat lap belt latch plate and connected to an inertia locking retractor installe...

Page 192: ...ube spacer should be in all bolt in body mounts and the insulator or metal washer positioned to prevent contact with the frame side rail Do not over torque the body mount or a stripped bolt may result...

Page 193: ...BODY 2D 31 BELTS 3RD SEAT Fig 2D 82 Seat Belt Installation Suburban Driver Seat Suburban...

Page 194: ...2D 32 BODY Fig 2D 85 Passenger s Bucket Seat Chassis Cab...

Page 195: ...BODY 2D 33 Fig 2D 88 Rear Bench Seats Suburban...

Page 196: ...2D 34 BODY Fig 2D 89 CK Utility Seat Attachments...

Page 197: ...BODY 2D 35 Fig 2D 90 Seat Separator Compartment and Door CK Models...

Page 198: ...2D 36 BODY MOUNT 1 V MOUNT 2 CK 10 j Fig 2D 91 Body Mounting Chassis Cab Fig 2D 92 Body Mounting Crew Cab...

Page 199: ...BODY 2D 37 Fig 2D 93 Body Mounting Suburban V M O U N T 2 M O U N T 1 M O U N T 1 L M O U N T 4 5 6 Fig 2D 94 Body Mounting Utility...

Page 200: ...te sweep of arms If necessary remove one or both arms as follows Pull outer end of arm away from glass which will trip lock spring at base of arm and release spring from undercut of pivot shaft While...

Page 201: ...bottom of valve Fig 2D 97 Cowl Ventilator Grille 3 Reverse the above steps for installation REAR VIEW MIRRORS Inside Rear View Mirror Replacement The inside mirror may be removed by removing screw ret...

Page 202: ...Otherwise it is possible that a small obstruction or high spot somewhere around the windshield opening will continue to crack or break the newly installed windshield especially when the strain on the...

Page 203: ...re fresh Urethane adhesive cartridge Essex SDC 551 2 or the equivalent are provided singularly Adhesive Kit No 9631000 urethane adhesive or equivalent contains some of the items needed to remove and r...

Page 204: ...ield opening Be sure to center the glass so that gaps on opposite sides and top to bottom are equalized Trim rubber blocks as necessary If the short method is used check reveal molding fit and cut awa...

Page 205: ...odel waterleaks can be corrected without the removal of the reveal moldings or glass from inside the vehicle Removal of the garnish and support molding will expose the urethane bond from the glass to...

Page 206: ...2 Remove screws retaining latch to body 3 Remove window by swinging glass out separating assembly at hinge 4 Remove latch from glass by twisting and pulling out 5 Reverse removal procedure to install...

Page 207: ...l must be completely removed as should all old cement and bits of old weatherstrip After removing all foreign material from door opening surface wipe down with prepsol or its equivalent Use only a goo...

Page 208: ...h will fit in the channel The extra filler extending beyond the rear edge of the glass should be pinched together to hold it in place during glass installation One side of this filler the outside of t...

Page 209: ...with lubriplate or equivalent WINDOW REGULATOR POWER In the case that window will not operate check electrical connections first Figure 2D 118 illustrates location of junctions switch relay and circu...

Page 210: ...de the door remove screws retaining lock to door edge and lower the lock assembly 6 Remove screws retaining remote control 7 Remove screws securing glass run guide channel 8 Remove lock push button ro...

Page 211: ...gh linkage fig 2D 120 See Figure 2D 117 for switches relay and wire routing Replacement 1 Disconnect battery ground cable 2 Remove door trim panel to gain access to power door lock motor 3 Disconnect...

Page 212: ...SWITCH ASSEMBLY DOOR LOCK SWITCH V I E W REAR DOOR MOTOR ACTUATOR DOOR LOCK VIEW MOTOR POWER WINDOW SWITCH CONTACT DOOR SWITCH CONTACT PILLAR Fig 2D 12 0 Power Door Lock Actuators Power Window Motor W...

Page 213: ...nt roller from its bracket 3 Loosen lower front roller bracket to arm bolts 4 Adjust front of door in or out then tighten bolts to specifications 5 Adjust door hold open catch bracket rear wedge assem...

Page 214: ...OLLER SECTION B B TOP VIEW UPPER LEVER LOWER LEVER UP AND DOWN ADJUSTMENT SLOTS STRIKER UPPER FRONTS 1in a n d o u t ROLLER ASSEMBLY adJustmenl FRONT LATCH STRIKER FACE VIEW GUIDE UP AND DOWN ADJUSTME...

Page 215: ...e Assembly Adjustment 1 Loosen screws attaching rear wedge assembly to the body pillar then close the door to the fully latched position 2 Center the wedge assembly on the door wedge as shown in figur...

Page 216: ...triker as outlined earlier under Adjustments UPPER REAR HINGE Removal 1 Remove the hinge cover and rear track cover See figures 2D 122 and 2D 127 2 Open the door 3 Disengage spring from bolt using a s...

Page 217: ...5 9 Plate 16 10 Upper lines 17 11 Spacer 18 12 Spring Upper Lever 19 13 Spring Lower Level 20 14 Lower Lever Screw 21 Guide Block 22 Hinge Body Half 23 Nut 24 Bushing 25 Bushing 26 Cam Bushing Hinge D...

Page 218: ...e 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 to compress seal...

Page 219: ...ct 2 Install handle and gaskets Torque screws to specifications 3 Install trim panel Fig 2D 132 Outside Handle and Lock Cylinder REAR DOOR LOCK CYLINDER Removal 1 Remove trim panel 2 Remove remote con...

Page 220: ...ig 2D 133 Rear Door Striker and Wedge Adjustment SEATS DRIVERS SEAT NOTICE See N O T IC E on page 1 of this section regarding fasteners used on seats and seat belts Seat Adjuster Replacement 1 Remove...

Page 221: ...d push seat rearward to clear anchor pins located beneath floor at front and rear of seat legs 3 Lift seat up and remove from van 4 To replace reverse steps 1 to 3 NOTICE When replacing seats make sur...

Page 222: ......

Page 223: ...BODY 2D 61 Fig 2D 139 Front Seat Belt Installation...

Page 224: ...ODY S H O U L D E R O F BO LT M U ST BO T TO M ON W ELD NUT SH O U L D E R OF BOLT M U ST B O T TO M ON W E LD NUT Fig 2D 141 2nd and 3rd Seat Lap Belt Installation Fig 2D 142 4th Seat Lap Belt Instal...

Page 225: ...Floor 2 5 ft lb 34 N m Rear Lower Bolt to Door lh 9 5 N m Passenger C hassis Cab Lock Lever to D o o r lb 9 5 N m Support to Seat 18 ft lb 24 N m Rear Door Support to Floor Lock Striker Suburban 19 ft...

Page 226: ...oor 25 ft lb 34 N m Upper Rear Hinge Body Half Door Hinges 40 N m Roller to Hinge 20 ft lb 27 N m Remote Control Retaining Screws 5 N m Guide Block to Hinge lb 5 N m Door Lock Striker lb 60 N m Lever...

Page 227: ...BODY 2D 65 SPECIAL TOOLS 1 J 22585 Front Door Hinge Bolt Wrench 2 J 22577 Windshield Checking Blocks 3 J 7797 Door Handle Clip Remover 4 J 23457 Door Striker Bolt Remover and Installer...

Page 228: ......

Page 229: ...ngle the lower 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 viewe...

Page 230: ...the vehicle it should remain in the vehicle during align ment checks 11 Consider the condition of the equipment being used to check alignment and follow the m anufacturer s instructions 12 Regardless...

Page 231: ...er control arm bumper then follow the same procedure as above Reinstall the upper control arm bumper when alignment is completed Caster All caster specifications are given assuming a frame angle of ze...

Page 232: ...or decreased by changing the length of the tie rods A threaded sleeve is provided for this purpose When the tie rods are mounted ahead of the steering knuckle they must be decreased in length in orde...

Page 233: ...f 0 3 mm 2 51 0 T A 57 1 2 A 63 5 2 69 8 3 76 2 3 A 82 5 3 A 89 0 3 95 2 4 102 0 4 A 107 9 4 A 114 3 4 3 4 120 6 P20 30 2 9 2 6 2 3 2 0 1 7 1 4 1 2 0 9 0 6 0 4 0 2 0 1 A D D 3 W IT H JB 8 OR JF9 S U...

Page 234: ......

Page 235: ...re proper retention of these parts For prevailing torque nut s and bolt s refer to the Reuse of Prevailing Torque Nut s and Bolt s chart in Section 10 CONTENTS General Description 3B1 1 Diagnosis 3B1...

Page 236: ...ssary Steering gear thrust bearings loosely adjusted Adjust preload to specification Excessive over center lash in steering gear Adjust preload to specification Worn intermediate rod or tie rod socket...

Page 237: ...salignment 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 correct as nec...

Page 238: ...they are properly and securely installed Tighten if loose Replace the damper assembly if the rubber bushings are badly worn 2 Inspecting Damper For Leaks Inspect the damper for evidence of fluid leak...

Page 239: ...must be installed in directions shown KNUCKLE STEERING GEAR PITMAN ARM ADJUSTABLE CONNECTING ROD STEERING ARM IDLER ARM ASSEMBLY RELAY ROD TIE ROD ASSEMBLY STEERING GEAR ASSEMBLY PITMAN ARM G SERIES S...

Page 240: ...the torque required to remove the nut from the bolt after breakaway Fig 3B1 7 Ball Stud Removal Typical exceed 7 pounds discard the nuts and bolts Apply penetrat ing oil between the clamp and tube and...

Page 241: ...nt of each joint Return the rod assembly to midposition of its travel This should result in the inner and outer ball studs being retained in a parallel relationship with the intermediate relay rod and...

Page 242: ...f the above mentioned conditions are met proper tie rod installation is assured RELAY ROD Removal 1 Raise vehicle on hoist 2 Remove inner ends of the tie rods from relay rod as described under Tie Rod...

Page 243: ...e PITM AN ARM Removal 1 Raise vehicle on hoist 2 Remove nut from pitman arm ball stud 3 Remove pitman arm or relay rod from ball stud by tapping on side of rod or arm in which the stud mounts with a h...

Page 244: ...P TO EACH OTHER AFTER ADJUSTMENT WITHIN 2 NOTE STEERING CONNECTING ROD MUST BE INSTALLED WITH LONG END FORWARD CAUTION CLAMPS MUST BE BETWEEN AND CLEAR OF DIMPLES BEFORE TORQUING NUT VIEW A NOTE SLOT...

Page 245: ...es must be used as specified during reassembly to assure proper retention of this part C O N T E N T S General Description 3B2 1 Diagnosis 3B2 1 Maintenance and Adjustments 3B2 4 On Vehicle Service 3B...

Page 246: ...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 normal and la...

Page 247: ...r 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 tire pres...

Page 248: ...ection Correct adjustment of steering gear is very important While there are but two adjustments to be made the following procedure must be followed step by step in the order given 1 Disconnect the ba...

Page 249: ...ls in straight ahead position This can 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 wheel...

Page 250: ...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 and torque to specifications If a clamp type pitman arm is used s...

Page 251: ...uster screw by reaching through the threaded hole in the side cover with a small screwdriver and turning the lash adjuster screw counter clockwise until it bottoms and turns back in 1 4 turn 10 Instal...

Page 252: ...3B2 8 MANUAL STEERING GEAR Fig 3B2 11 Manual Steering Gear Exploded View...

Page 253: ...enter steering gear 2 Remove parts as shown INSTALL 1 Before installing turn preload adjuster screw counter clockwise until it bottom s then back screw o ff one half turn 2 Install parts as shown PREL...

Page 254: ...ng re tainer out with screw driver R e m o ve c u p u s in g J 5822 puller and slide hammer W ORM BEARING ADJUSTER LOW ER W ORM BEARING CUP LOW ER W ORM BEARING ASSEMBLE 1 Press cup into adjuster usin...

Page 255: ...N W ORM SHAFT Worm B earing 0 6 1 0 N m 5 8 In Lbs Over Center P re lo a d 0 5 1 2 N m 4 10 In Lbs in excess of Worm Bearing Preload Total Steering Gear Preload 1 8 N m 16 In Lbs Maximum RECO M M ENDE...

Page 256: ......

Page 257: ...valent part if replacement becomes necessary Do not use a replacement part of lesser quality or substitute design Torque values must be used as specified during reassembly to assure proper retention o...

Page 258: ...f any major components should be attempted first Conditions such as hard or loose steering road shock or vibrations are not always due to the steering gear or pump but are often related instead to suc...

Page 259: ...pling will transmit hiss into passenger compartment Also check for proper sealing between steering column and toe pan Rattle Pressure hose touching other parts of car Loose pump pulley nut Pump vanes...

Page 260: ...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 damaged Tig...

Page 261: ...el 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 pump bel...

Page 262: ...nt 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 above checks...

Page 263: ...ressure plate Replace parts Hush 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 Ra...

Page 264: ...rn steering wheel from stop to stop several times Do not hold in corner for any length of time as this can damage the power steering pump It is easier if someone else operates the steering wheel while...

Page 265: ...N m 20 FT LB S IF LEAKAGE PERSISTS REPLACE 0 R ING SEAL 6 TORQUE FITTING T048 N m 35 FT LBS IF LEAKAGE PERSISTS REPLACE BOTH 0 RING SEALS 7 TORQUE NUT TO 27 N m 20 FT LBS REPLACE NUT IF LEAKAGE PERSIS...

Page 266: ...is can 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 posit...

Page 267: ...his test will result in readings indicating faulty hydraulic operation and will help to identify the faulty component Before performing hydraulic circuit test carefully check belt tension fluid level...

Page 268: ...osition ot prevent drainage of oil Cap or tape the ends of the hoses to prevent entrance of dirt 2 Install two plugs in gear fittings to prevent entrance of dirt 3 Remove the flexible coupling to stee...

Page 269: ...Engine PO W ER STEERING P U M P 3 B 3 1 5 T H R O U G H 3 B 3 2 6 Removal 1 Disconnect hoses at pump When hoses are discon nected secure ends in raised position to prevent drainage of oil Cap or tape...

Page 270: ...03 with CK300 LE4 LG9 LS9 LT9 Exc C60 JB8 I F9 Enaine Fig 3B3 18 P S Pump Mounting CK100 CK200 CK300 LE4 LG9 LT9 and C60 Fig 3B3 21 P S Pump Mounting G100 G200 G300 with LE3 Engine Fig 3B3 19 P S Pump...

Page 271: ...wn in Figs 3B3 27 through 3B3 42 It is important that the power steering hoses be installed correctly Hoses installed out of position may be subjected to chafing or other abuses during sharp turns Do...

Page 272: ...16 POWER STEERING SYSTEM Fig 3B3 27 P S Hose Routing CK100 CK200 03 with LE3 Engine with LE8 Engine L25 Engine JB8 Fig 3B3 29 P S Hose Routing CK100 CK 200 CK 300 LE4 LG9 LS9 LT9 Exc C60 JB8 LT9 and...

Page 273: ...POWER STEERING SYSTEM 3B3 17 with LE3 Engine Exc HC4 LE4 LG9 LF4 LS9 LT9 and JB7 HC4 and JB8...

Page 274: ...3B3 18 POWER STEERING SYSTEM L25 Engine and JB7 Fig 3B3 41 P S Hose Routing P300 32 with LT9 Engine LT9 Engine and JB7 Fig 3B3 42 P S Hose Routing P300 32 with LE8 Engine...

Page 275: ...RING GAP AT PO S iTiO N SHOWN END PLATE PRESSURE P L A T E SPRING P O S IT IO N IN G O F R E T A N IN G R IN G E N D PLATF RETAINING RING CONTROL VALVE ASSEMBLY FLOW CONTROL SPRING HOUSING ASSEMBLY N...

Page 276: ...TRG COUPLING SHIELD 3 B E A R IN G ASSY NEEDLE STUB SHAFT 4 SEAL STUB SHAFT 5 SEAL STUB SHAFT DUST 6 RING RETAINING STUB SHAFT SEAL 7 B E A R IN G ASSY NEEDLE PITM AN SHAFT 8 SEAL PITM AN SHAFT 9 W AS...

Page 277: ...install retaining ring DUST SEAL Screwdriver HOUSING ASSEMBLY J 29810 3 REMOVE AND INSTALL PITMAN SHAFT AND SIDE COVER REMOVE 1 If pitman shaft and side cover are to be separated remove preload adjus...

Page 278: ...ly C heck relation of stub shaft and rack piston a Screw worm and valve into rack piston until valve face and rack piston face are flush STUB SHAFT b With rack piston in position shown flats on stub s...

Page 279: ...p of seal with anhydrous calcium grease Install dust seal just deep enough to clear retaining ring groove then install retaining ring HO USING ASSEM BLY Inspect for burrs OIL SEAL W ASHER DUST SEAL HO...

Page 280: ...ust be firm ly seated against its retaining ring before any adjustment is attempted To seat the side cover tap on the end of the pitman shaft w ith a soft hammer Back o ff preload adjuster L E F T H A...

Page 281: ...ING SPOOL 10 BODY VALVE I I RING VALVE BODY 3 1 2 S E A L O RING VALVE BODY 3 1 3 R ETAINER BEARING ADJUSTER 1 4 SPAC ER THRUST BEARING 1 5 R A C E UPPER THRUST BEARING SMALL 1 6 B E A R IN G UPPER TH...

Page 282: ...U ID E BALL RETURN 2 3 6 C L A M P BALL RETURN GUIDE Kty No Pori Nome 3 7 S C R E W ASSY LOCKWASHER 2 3 8 P L U G RACK PISTON 3 9 S E A L O RING RACK PISTON 40 RING RACK PISTON 41 S E A L O RING HOUS...

Page 283: ...ing tabs around cover edges 2 Install parts as shown SIDE COVER BOLTS Torque to 60 Newton Meters 40 Ft Lbs PRELOAD ADJUSTER NUT SIDE COVER GASKET SEAL Separate pitman shaft and gasket seal from side c...

Page 284: ...se stub shaft seal protector J 29810 on stub shaft when installing stub shaft seal Screwdriver Pry bearing retainer at raised area VALVE BODY RING te flon SPOOL TO BODY O RING To ease assembly soak te...

Page 285: ...ing bearing L u b ricate balls w ith pow er steering fluid Install balls th rough ball return guide hole w hile rotatin g w orm co un te rclo ckw ise B efore assem bling rack in ho using ball retainer...

Page 286: ...on housing Turn a d ju ste r c o u n te rc lo ck w ise u n til m ark on face of a d ju ste r lines up w ith second m a rk o n h o u s in g Using pu nch in n o tch tig h te n lo ck nut securely H old a...

Page 287: ...ll as an improper gear over center adjustment it is necessary that the steering gear assembly be removed from the car and both thrust bearing and over center preload be checked and corrected as necess...

Page 288: ...ctor Used for Installing J 24319 01 Adjuster Plug J 22407 J 6278 Pitman Shaft Bearing Remover and Installer J 22616 J 6278 2 Adapter Used with J 6278 for Installing J 23600 Pitman Shaft Seals and Bear...

Page 289: ...olumn mounted lock the ignition steering and gearshifting operation can be locked to inhibit theft of the vehicle The function locking energy abosrbing column may be easily disassembled and reassemble...

Page 290: ...absolutely necessary to handle the column with care when performing any service operation Avoid hammering jarring dropping or leaning on any portion of the column When reassembling the column componen...

Page 291: ...umn components on C and K trucks is as follows Column Support Bracket Damage in this area will be indicated by separation of the mounting capsules from the bracket The bracket will have moved forward...

Page 292: ...ylinder D Burr or lock bolt or housing E Damaged housing F Transmission linkage adjustment incorrect G Damaged rack H Interference betw een bowl and coupling tilt I Ignition switch stuck J Actuator ro...

Page 293: ...ort section Cause Solution A Ignition switch is not set correctly B Defective lock cylinder LO CK C Y L IN D E R C A N BE R E M O V E D W IT H O U T D E P R E S S IN G R E T A IN E R A Readjust igniti...

Page 294: ...D Sheared intermediate shaft plastic joint E Horn contact ring not lubricated F Lhck of grease on bearings or bearing surfaces G Lower shaft bearing tight or frozen H Upper shaft tight or frozen I Sh...

Page 295: ...ission linkage adjustment C Loose lower shift lever D Improper gate plate E Sheared lower shift lever weld LA SH IN M O U N T E D C O L U M N A S S E M B L Y A Replace shift tube assembly B Readjust l...

Page 296: ...a ss em bly Cause S o lu tio n A C o l u m n not aligned co rr e c tl y in car B Lowe r b ow l be ari n g no t asse m bled correc tly C I m p r o p e r l y installed seal D Wave w a s h e r in lower b...

Page 297: ...ace either or both B Add spring or replace both C Replace both D Install seat F Tighten to 60 in lbs G Replace preload spring Cause Solution A Loose fit between shoe and shoe pivot pin N O IS E W H E...

Page 298: ...em There are 2 flashers in the signal switch system The hazard warning flasher and turn signal flasher are located on the fuse block 2 Check for secure connection at the chassis to switch connector Th...

Page 299: ...annot be depressed or released the switch must be replaced S w itc h V isu a l Inspection 1 With the upper part of the column disassembled so that the signal switch is visible Figure 3B4 12 check for...

Page 300: ...ced springs C Reposition or replace springs D Foreign parts and or m aterials D Remove foreign parts and or m aterial E Sw itch m ounted loosely E Tighten m ounting screws 2 5 in lbs Turn signal w ill...

Page 301: ...A B D Replace fuse and check operation Replace turn signal flasher Connect securely check operation Replace signal switch E Repair chassis wiring as required using manual as guide Turn indicator light...

Page 302: ...nds 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 B Conn...

Page 303: ...grounds at light sockets Connect securely and check operation Replace signal switch F Locate and repair as required Use manual as guide See Section 12 Hazard signal lights will not flash turn signal...

Page 304: ...2 Applying 50 lb force to the steering wheel end of the steering shaft adjust clamp to obtain clearances indicated in Figure 3B4 18 3 Tighten clamp bolt to specified torque SHIFTER TUBE A D JU ST M E...

Page 305: ...STEERING COLUMNS 3B4 17 Fig 3 B 4 1 9 S h ift T u b e A d ju s tm en t 3 S peed M an u al T ransm ission...

Page 306: ...round cable 2 Remove horn button cap 3 Remove snap ring and steering wheel nut 4 Using tool J 1859 03 thread puller anchor screws into holes provided on steering wheel See Fig 3B4 21 Turn center bolt...

Page 307: ...0 to 375 The coupling alignment pins should be centered in the flange slots INTERM EDIATE STEERING SHAFTS W IT H POT JO IN T COUPLINGS Removal Fig 3B4 23 1 Remove the lower shaft flange to flexible co...

Page 308: ...ame bolts and torque to specifications 4 Install the flexible coupling to steering shaft flange bolt lockwashers and nuts Check that the coupling alignment pins are centered in the flange slots and th...

Page 309: ...sing under impact 1 All except Tilt Be sure that the wiring harness is in the protector Feed the connector and cover down through the housing and under the mounting bracket column in vehicle Tilt Feed...

Page 310: ...t reasons the switch is located inside the channel section of the brake pedal support and is completely inaccessible without first lowering the steering column see steering column removal The switch i...

Page 311: ...ses where damage is evident or whenever the vehicle is being repaired due to a front end collision Whenever a force has been exerted on the steering wheel or steering column or its components inspecti...

Page 312: ...unting capsules 2 Place the column in a vise using both weld nuts of either Set A or B as shown in Figure 3B4 41 The vise jaws must clamp onto the sides of the weld nuts indicated by arrows shown on S...

Page 313: ...27 W A SH E R Spring Thrust 28 B O L T A SM Spring 29 SP R IN G Upper Shift Lever 30 BOW L Gearshift Lever 31 S H R O U D Shift Bowl 32 B E A R IN G Bowl Lower 33 J A C K E T A SM Steering Column 34 S...

Page 314: ...SCREW Pan Head Cross Recess 20 SHROUD Steering Column 21 WASHER Spring Thrust 22 BOLT ASSEMBLY Spring 23 SPRING Key Refuase 24 LEVER Key Release 25 WASHER Wave 26 SHAFT ASSEMBLY Steering 27 RING Reta...

Page 315: ...tooth on the sector with the 1st tooth on the rack if aligned properly the block teeth will line up when the rack assembly is pushed all the way in 5 Install the thrust cup on the bottom hub of the h...

Page 316: ...a d S p rin g 13 Install the neutral safety or back up switch as outlined in Section 8 of this manual 14 Slide the steering shaft into the column and install the upper bearing thrust washer 15 Install...

Page 317: ...HE SYSTEM IS LOOSE THEN S LID E THE SCREWS IN OPPOSITE D IR E C TIO N U N T IL A D E F IN IT E D R A G IS FELT AT THE 1ST REV S H IF T LEV E R 6 T IG H T E N THE C LA M P IN G SCREWS 7 REM O VE THE SH...

Page 318: ...ing SPRING Wheel T ilt GUIDE Spring SCREW Hex Washer Head RING Retaining SECTOR Switch Actuator HOUSING Steering Column SPRING Rack Preload RACK Switch Actuator LEVER Shoe Release ACTUATOR ASM Ignitio...

Page 319: ...Switch Actuator 36 PIN Pivot 37 HOUSING Steering Column 39 SPRING Rack Preload 40 RACK Switch Actuator 41 LEVER Shoe Release 42 ACTUATOR ASM Switch 43 SHROUD Column Housing 44 SPRING Key Release 45 L...

Page 320: ...he tube 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 i...

Page 321: ...prings lock shoes and shoe pin in the housing Use an approximate 180 rod to line up the shoes for pin installation c Install the shoe release lever spring and pin To relieve the load on the release le...

Page 322: ...t through the shift tube and bearing 11 Install the ignition switch actuator rod through the shift lever housing and insert in the slot in the bearing support Extend the rack downward from the bearing...

Page 323: ...S S T E E R IN G W H E E L Removal 1 Disconnect battery ground cable 2 Remove horn button or shroud receiving cup belleville spring and bushing and mark steering wheel to steering shaft relationship 3...

Page 324: ...isassembly 1 Mark cover to shaft relationship Pry off snap ring and slide cover from shaft 2 Remove bearing blocks and tension spring from pivot pin 3 Clean grease off pin and end of shaft Scribe loca...

Page 325: ...soft drift and hammer c Support the other side of the yoke and drive out the remaining bushing as in Step b above d Move the yoke on the trunnion as necessary to separate the upper and lower yokes e R...

Page 326: ...NOTICE See NOTICE not on page 1 of this section regarding fasteners referred to in step 2 1 Place the new bearing over the end of the steering shaft and press into position in the column 2 Install th...

Page 327: ...eload spring b Install the spheres into the upper short shaft and rotate 90 c Install the lower shaft 90 to the upper shaft and over the centering spheres Slowly straighten the shafts while compressin...

Page 328: ...Mark the location of each wire in the half moon connector and then remove each individual wire from the connector using Tool J 22727 Fig 3B4 69 Insert the tool into the lower end of the connector and...

Page 329: ...ly seated 3 Tilt Columns Only a Align the openings in the directional signal switch cover with the proper lever positions and tap the cover into place using a plastic hammer b Install the tilt release...

Page 330: ...ntain steering wheel clamping load and hub clearance STEERING SYSTEM M ANDATORY REQUIREMENTS Fig 3B4 72 Steering Column Attachment G Series 9 Remove the plastic thrust washer assembly and then remove...

Page 331: ...ushing from the upper end of the column 13 Remove the bolt and screws from the adjusting ring clamp and remove the clamp adjusting ring and lower bearing Press the lower bearing out of the adjusting r...

Page 332: ...he lock shoes and remove the bearing housing If it is necessary to disassemble the bearing housing proceed as follows a Press the upper and lower bearings out of the housing b Using Puller J 5822 and...

Page 333: ...IN G HOUS I NG ASSY BEARING s Z BUMPER 3 N SPRING 2 K SPRING RELEASE v ft PIN RELEASE o j X SHOE RELEASE BEARING ASSY 2 P N p VOT BOWL ASSY 5 JACKET SPHERE CENTERING 2 SHAFT PROTECTOR WIRE SUPPORT AS...

Page 334: ...e the tube when installing in the column or damage could occur to the components STEERING SHAFT TILT LEVER S P R IN G RETAINER 6 Pull up on the shift lever housing to compress the wave washer and inst...

Page 335: ...es have fully engaged the support Lubricate and install the bearing housing pivot pins Press the pins in flush with the housing Fig 3 B 4 8 2 R e v is e d S h ift T u b e R em oving Tool J 2 2 5 5 1 1...

Page 336: ...eering wheel as outlined under Steering Wheel Installation 11 Connect the transmission linkage 12 Connect the battery ground cable Mandatory Sequence P Series NOTICE See NOTICE note on page 1 of this...

Page 337: ...recom m ended torque 4 Threaded portion o f Steering S haft J must be co m pletely free o f lu b rican t a fte r M ast Jacket K j assem bly to m a in tain steering w heel clam p ing load an d hub cle...

Page 338: ...ue to give a com pressed spring dim ension C of 1 26 0 2 a fte r assem bly 2 A ll M ast Jacket attachm ents cT E must be tightened to recom m ended torque 3 Threaded portion o f Steering Shaft f must...

Page 339: ...20 30 24 1 29 4 1 to 36 3 1 16 1 to 13 1 17 2 1 to 20 6 1 K10 20 16 1 to 13 1 13 2 1 to 17 2 1 MANUAL STEERING GEAR POWER STEERING PUMP PRESSURES Vehicle Pressure C10 30 1200 1300 psi G 10 20 30 w o H...

Page 340: ...h e rm o m e te r 28 J 8524 1 T o rqu e W rench A d a p te r 29 J 8524 2 Pum p P ulley Rem over Stam per P ulley 30 J 6219 Steering Wheel Puller 31 J 22407 Sector S h a ft Bushing Rem over 32 J 8937...

Page 341: ...J 22708 12 J 1614 Sector Shaft Bushing Remover 30 J 22573 13 J 7539 Ball Retainer 31 J 22599 14 J 7624 Spanner Wrench 32 J 21854 15 J 4245 23 Internal Pliers 33 J 22551 16 J 23600 Belt Tension Gauge...

Page 342: ......

Page 343: ...ement becomes necessary Do not use a replacement part of lesser quality or substitute design Torque values must be used as specified during reassembly to assure proper retention of this part CONTENTS...

Page 344: ...trol arms are attached to the crossmember The upper control arms are attached to a frame bracket These control arms are connected to the steering knuckle through pivoting ball joints A coil spring is...

Page 345: ...ded 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 3 If b...

Page 346: ...3 Wheel Bearing Adjustment DIAGNOSIS SHOCK ABSORBER DIAGNOSIS O N VEHICLE CHECKS Follow the Procedures Outlined Below in the Order Indicated Preliminary Inspection and Ride Test Tire Pressure Check ti...

Page 347: ...ose shock absorbers h Broken stabilizer bar or missing link h Replace stabilizer or link FR O N T W HEEL S H IM M Y SMOOTH ROAD SHAKE a Tire and wheel out o f balance or out of round a Balance tires c...

Page 348: ...ct driver SCUFFED TIRES a Toe in incorrect a Adjust toe in to specifications b Excessive speed on turns b Advise driver c Tires improperly inflated c Inflate tires to proper recommended pressure d Sus...

Page 349: ...eels d 1lard Driving d Instruct driver c Over loaded vehicle e Instruct driver S C U F F E D T IR E S a Toe in incorrect a Adjust toe in to specifications b Lxcessive speed on turns b Advise driver c...

Page 350: ...ocks 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 on the shock until...

Page 351: ...ront shocks then compare the com pression resistance If a noticeable difference can be felt during either stroke usually the shock having the least resistance is at fault b If shock has an internal no...

Page 352: ...lag is noticed it means the gas filled cell has been ruptured and the shock should be replaced If no lag is noticed the remainder of the bench check is the same as given in the Spiral Groove Reservoir...

Page 353: ...drop to idle 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 sh...

Page 354: ...P A T TE R N ON R O L L E R ENDS C AUSED BY FIN E A B R A S IV E S C LE A N A L L PARTS A N D HOUSINGS CHECK SEALS A N D B E A R IN G S A N D R E P L A C E IF L E A K IN G ROU G H OR NOISY ETC H IN G...

Page 355: ...F TEM PER ON RACES OR R O L LE R S A SIM PLE F IL E TEST M A Y BE M A D E A FIL E D R A W N O V E R A TE M P E R E D PA R T W IL L G R A B A N D CUT M E T A W H ER EAS A F IL E D R A W N O V E R A H A...

Page 356: ...out all old grease Do not spin the bearing with compressed air while drying it or the bearing may be damaged 2 Use a GM approved high temperature front wheel bearing grease or equivalent Do not mix g...

Page 357: ...d s u n d e r fr a m e allowi ng control a r m s to h a n g free 2 D i s c o n n e c t s h o c k a b s o r b e r a t low er e n d a n d m o v e aside D isc o n n ect th e sta bil ize r b a r a t t a...

Page 358: ...Fi gu re 3 C 1 9 sh ow s c o r re c t final position ing o f sha ft C h e c k sh aft for free r o tatio n a n d install g r e as e fittings Installation N O TICE S e e N O T I C E on p a g e 1 of th...

Page 359: ...rque nuts at this time 4 Torque cross shaft end nuts The shaft should roate by hand after the nuts are torqued 5 Torque U bolt nuts 6 Remove safety chain 7 Lower vehicle to floor UPPER CONTROL ARM ASS...

Page 360: ...l Arm for Bushing Replacement 1 Place control a r m in position on b r a c k e t a n d install nuts Before t ig h te n in g nuts insert c a s te r a n d c a m b e r s h im s in th e s a m e o r d e r...

Page 361: ...on being sure to torque all fasteners to the proper specification Lower Control Arm Inner Pivot Shaft And Bushing Replacement G10 G20 Models Removal 1 Remove lower control arm as previously outlined 2...

Page 362: ...60 N m 45 ft lbs 2 Mate ball stud to steering knuckle and install stud nut 3 Torque the ball stud nut as follows A 10 Series 54 80 N m 40 60 ft lbs plus additional torque to align cotter pin not to ex...

Page 363: ...KNUCKLE It is recommended that vehicle be raised and supported as on a twin post hoist so that the front coil spring remains compressed yet the wheel and steering knuckle assembly remain accessible I...

Page 364: ...ckles Dis card cotter pins Refer to Section 3B 8 If equipped disconnect front stabilizer from lower control arms 9 Disconnect fron shock absorbers from lower control arms 10 Remove brake line clip bol...

Page 365: ...front brake hose to caliper using new special washers Refer to Section 5 13 Connect front brake hose clips to upper control arms Torque nuts to 17 N m 150 in lbs 14 Lubricate upper and lower ball join...

Page 366: ...RETAIN ER N O T 26 DRAG SLEEVE AND S H O W N D ETEN T 12 R ETA IN IN G RING 13 S P R IN G S U P P O R T W ASH ER 27 SPACER 40 D U ST SEAL 28 R ETAINING RING 41 D EFLECTO R 29 LOCK NUT 42 AXLE O U TER...

Page 367: ...ETA IN E R NOT SHOWN 12 R E TA IN IN G RING 13 SPRING SUPPORT W ASHER 14 SPRING R ETAIN ER 15 R ETURN SPRING 16 SPRING R ETAIN ER 17 C LUTCH GEAR 18 HUB SLEEVE 19 C TYPE R E TA IN IN G RING 20 C O N I...

Page 368: ...nditions the lubrication interval should be 12 000 miles off road use such as in mud or water will require shorter intervals The spindle bearings are accessible after removing the spindle as shown in...

Page 369: ...ng Before disassembling a unit for complaint of abnormal noise read the following To obtain all wheel drive the transfer case lever must be placed in 4L or 4H at which time the hub locks will automati...

Page 370: ...ainer K30 Assembly Aid Retainer 12 Retaining Ring 13 Spring Support Washer 14 Spring Retainer 15 Return Spring 16 Spring Retainer 17 Clutch Gear 18 Hub Sleeve 19 C Type Retaining Ring 20 Conical Sprin...

Page 371: ...tch housing 12 Assemble the steel inner cage 2 3 into the outer cage aligning the tab of the outer cage with the window of the inner cage 13 Assemble the retaining ring 2 4 into the groove of the oute...

Page 372: ...s w heel hu b T o r q u e t h e cover sc rew s to 4 5 5 6 N m 4 0 5 0 lb in A ssem ble a Rebuilt H ub to W h eel 30 S t e p s 1 17 in t h e a s s e m b l e p r o c e d u r e a r e u s u a l ly c o m p...

Page 373: ...icate the needle bearing and the spindle end with a high melting point type wheel bearing grease Installation 1 Install the thrust washer over the axle shaft with the chamfer toward the slinger and in...

Page 374: ...ed during knuckle removal J 23454 1 Fig 3 C 1 1K Removing Low er Ball Joint On the LH knuckle it is necessary to remove the steering arm before servicing the upper ball joint Remove the lower ball joi...

Page 375: ...on page 1 of this section regarding the fasteners in the following steps 1 Position the knuckle and sockets to the yoke Install new nuts finger tight to the upper the nut with the cotter pin slot and...

Page 376: ...t from the knuckle Check bronze spacer located Fig 3C 20K Removing Lower Bearing Cap between axle shaft joint assembly and bearing If wear is evident replace with a new one See Figure 3C 17K 2 Remove...

Page 377: ...ection regarding the fasteners in the following steps 1 Assemble new grease retainer and lower king pin bearing cup using J 7817 as shown in Figure 3C 24K 2 Fill the area in grease retainer with speci...

Page 378: ...r shock absorber eyes 3 Withdraw shock absorber and inspect rubber eye bushings If defective replace shock absorber Fig 3C 29K lnstalling Bearing Cap Steering Arm assembly Installation Place shock abs...

Page 379: ...hoist 2 Place adjustable lifting device under axle 3 Position axle so that all tension is relieved from spring 4 Remove shackle upper retaining bolt 5 Remove front spring eye bolt 6 Remove spring to a...

Page 380: ...e NOTICE on page one of this section regarding the fasteners referred to in steps 5 and 6 1 Install spring shackle bushings into spring and attach shackle Do not tighten bolt 2 Position spring upper c...

Page 381: ...140 65 75 Shock Absorber Low er End 60 60 65 75 Brake Splash Shield to Knuckle 120 in lbs 120 in lbs 120 in lbs 120 in lbs W heel Bearing A djustm ent Inner 35 O uter W heel Bearing End M ovem ent 001...

Page 382: ...Installer Bearing Race Installer Bearing Race Installer Bearing Race Installer Bushing Replacement C 10 G 10 20 6 7 8 9 10 11 1 1 J 8092 J 9519 9 J 9519 7 J 9519 10 J 23028 01 J 23742 1 Driver Handle...

Page 383: ...this part INDEX General Description 3D 1 Component Parts Replacement 3D 2 Shock Absorbers 3D 2 Stabilizer S h a ft 3D 3 Leaf Spring Assembly 3D 4 Specifications 3D 10 GENERAL DESCRIPTION All 10 30 se...

Page 384: ...olt on G models 3 At the lower mounting location remove nut washers and bolt as shown 4 Remove shock absorbers from vehicle 5 To install shock absorber place into position and reattach at upper mounti...

Page 385: ...t washers grommets and spacer Fig 3D 8 Shock Absorber P30 4 Remove brackets from anchor plates by removing attaching screws 5 Remove stabilizer shafts 6 Reverse above steps to install stabilizer shaft...

Page 386: ...Heavy Duty leaf springs on C20 CK30 and some P30 trucks use a staked in place flanged front eye bushing Before this bushing is pressed out of the spring the staked locations must be straightened with...

Page 387: ...assembly to axle Position spring to insure clearance to hangers The shackle assembly must be attached to the rear spring eye before installing shackle to rear hanger shackle must be positioned with ar...

Page 388: ...uts NOTICE See N O TIC E on page 1 of this section regarding U Bolt fasteners SHACKLE REPLACEMENT 1 Raise vehicle on hoist Place adjustable lifting device under axle 2 Remove load from spring by jacki...

Page 389: ...REAR SUSPENSION 3D 7 Fig 3D 17 Rear Spring Installation C K Models...

Page 390: ...3D 8 REAR SUSPENSION Fig 3D 20 Rear Spring lnstallation P10 20 Fig 3D 21 Rear Spring lnstallation P30...

Page 391: ...l four nuts to uniform en g ag em en t on U Bolts to retain and position anchor p la te in design position p e rp e n d ic u lar to axis of U Bolts 2 Torque a ll nuts in a d ia g o n a l sequence e g...

Page 392: ...90 135 G316 90 90 135 G316 90 110 110 Shock Absorber Upper Attachment 150 75 P10 25 P20 140 P30 50 Lower Attachment 115 75 115 Propeller Shaft To Rear Axle Strap To Rear Axle U Bolt Bearing Support to...

Page 393: ...rance and tire clearance to the body and chassis If replacing only a single tire it should be paired on the same axle with the least worn tire of the others All tires on four wheel drive vehicles must...

Page 394: ...ion width offset and mounting configurations to those origi nally installed on the vehicle A wheel of the wrong size or type may adversely affect load carrying capacity wheel and bearing life brake co...

Page 395: ...least wear whould be at the outside of each dual wheel In addition when trucks are operated continuously on high crown roads an increase in air pressure of from 5 to 10 PSI in the outside tire of each...

Page 396: ...86 BJ 15x8JJ 1910 866 40 276 BK 15x7 JJ 1670 757 40 276 BM 15x8 JJ 2030 921 40 276 Fig 3E 6 Tire Wheel Load and Inflation Pressure weighing the vehicle on a scale the correct cold inflation pressures...

Page 397: ...16 2350 1066 8 75 16 5 E 1570 712 1720 780 1850 839 1990 903 2110 957 2240 1016 2350 1066 2470 1120 2570 1166 2680 1216 BIAS TIRES USED AS DUALS 8 00 16 5 C 1195 542 1310 594 1415 642 1520 689 8 00 16...

Page 398: ...SINGLES 8R 19 5 D 2110 2270 2410 2540 2680 2800 957 1030 1093 1152 1216 1270 R A D IA L TIRES USED AS DUALS 8R 19 5 D 1850 1990 2110 2230 2350 2460 839 903 957 1012 1066 11161 BIAS TIRE SIZE AND LOAD...

Page 399: ...rolled flange rim on the outboard side of the wheel rims require special design weights to fit Dynamic balancing can be accomplished through use of these special balance weights which are designed on...

Page 400: ...rush or cloth swab apply a solution of neutral vegetable oil soap to the inside and outside of tire beads and also the the rim side of the tube Do not allow soap solution to run down into tire 5 When...

Page 401: ...ed air to seat beads and 2 rubber rings which seal between the tire bead and rim bead seat allowing the bead to move out and seat Lubrication is mandatory with both items 4 Check bead seating This che...

Page 402: ...sion coating following label directions This is a two step operation which will improve the adhesion of the primer 10 To ensure coverage in all areas an application of zinc chromate primer should be a...

Page 403: ...iving yoke rotates at a constant speed while the driven yoke speeds up and slows down twice per revolution This changing of velocity acceleration of the driven yoke increases as the angle between the...

Page 404: ...this Constant Velocity joint requires periodic lubrication A lubrication fitting is provided for this purpose and is illustrated later in this section Propeller Shafts The propeller shaft is a steel...

Page 405: ...yoke a Rough outside surface on splined yoke b Defective transmission rear oil seal a Replace seal if cut by burrs on yoke Minor burrs can be smoothed by careful use of crocus cloth or honing with a...

Page 406: ...fied replace shaft NOTE With tachometer installed in car determine whether propeller shaft is cause of complaint by driving through speed range and note the engine speed rpm at which vibration roughne...

Page 407: ...are marked prior to dissassembly for proper phasing Except for P models with disc brakes the universal joints are of the extended life design and do not require periodic inspection or lubrication how...

Page 408: ...Bearing Cup Injected Plastic Type Disassembly NOTICE Never clamp drive shaft tubing in a vise as the tube may be dented Always clamp on one of the yokes and support the shaft horizontally Avoid damagi...

Page 409: ...rs from the grooves in the yokes The sheared plastic may prevent the bearing cups from being pressed into place and this prevent the bearing retainers from being properly seated 2 Install one bearing...

Page 410: ...Assemble bearing support as follows a Jnstall inner deflector on propeller shaft if removed and prick punch deflector at two opposite points to make sure it is tight on shaft b Fill space between inn...

Page 411: ...an alignment key as shown in figure 4A 18 to obtain proper phasing The shafts can mate only in the correct position NOTICE G and K models with 16 splines must be phased as shown in figure 4A 19 1 For...

Page 412: ...to axle attachments Fig 4A 22 Cross Sectional View of CV Joint CONSTANT VELOCITY UNIVERSAL JOINT Inspection An inspection kit including two bearing caps and two snap rings is available to allow the re...

Page 413: ...ball on stud 5 Using Tool J 23996 drive ball onto stud as in Fig 4A 26 Removing Centering Ball figure 4A 27 until the ball can be seen to seat firmly against the shoulder at the base of the stud This...

Page 414: ...t with a special adapter J 25512 2 on the end of a flex hose Slip Spline Apply chassis lubricant at the fitting until grease begins to leave through the vent hole If the slip spline is dry or corroded...

Page 415: ...bore of the cast carrier Each tube is puddle welded to the carrier Welded on brackets provide attachment points for suspension componenets such as shock absorbers and leaf springs A welded flange is p...

Page 416: ...B 5a has a straddle mounted drive pinion which is supported at the rear by a straight roller bearing The pinion front bearing consists of a double row ball bearing The differential is a conventional f...

Page 417: ...ar The ring gear being bolted to the differential case rotates the case The differ ential pinion as it rotates with the case forces the pinion gears against the side gears When both wheels have equal...

Page 418: ...heel must turn faster than the inner wheel The inner wheel turning slower with respect to the outer wheel slows its rear axle side gear as the axle shaft is splined to the side gear and the rear axle...

Page 419: ...ifferential Case 24 Pinion Gear 5 Oil Slinger 15 Ring Gear Bolt 25 Washer 6 Pinion Front Bearing 16 Differential Side Bearing 26 Gasket 7 Front Bearing Cup 17 Side Bearing Cup 27 Cover 8 Preload Shim...

Page 420: ...ne and Roller 20 Shims Differential 27 Thrust Washer 6 Outer Pinion Oil Slinger Inner Pinion Adjusting Pinion 7 and 8 Cone and Roller 14 Ring and Pinion 21 Cone and Roller 28 Pinion Outer Pinion Beari...

Page 421: ...an automotive drive axle where engine torque multiplication occurs at a 90 turn in the drive line produces a certain amount of noise Therefore an interpretation must be made for each vehicle to determ...

Page 422: ...be confused with rear axle noises however front wheel bearing noise does not change when comparing pull and coast Light application of brake while holding vehicle speed steady will often cause wheel...

Page 423: ...acklash must be checked using a Gear Tooth Contact Pattern Check as outlined below Gear Tooth Contact Pattern Check Prior to final assembly of the differential a Gear Tooth Contact Pattern Check is ne...

Page 424: ...ller shaft at 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 turn...

Page 425: ...NDS CAUSED BY FINE ABRASIVES CLEAN A LL PARTS AND HOUSINGS CHECK SEALS AND BEARINGS AND REPLACE IF LEAKIN G ROUGH OR NOISY ETCHING BEARING SURFACES APPEAR GRAY OR GRAYISH BLACK IN COLOR WITH RELATED E...

Page 426: ...T OR M OISTURE RE USE B EAR IN G S IF S TAIN S CAN BE R EM O VED BY LIG H T PO LISHING OR IF NO EVIDENCE OF OVER H E A TIN G IS OBSERVED CHECK SEALS A N D R E LA T E D PARTS FOR D AM AG E HEAT DISCOL...

Page 427: ...arrier DANA AXLE EXAMPLE DANA P N 603560 1 MONTH CODE 29 T DAY CODE G Source Code C G K W 0 T MODEL YEAR Buffalo Gear Axle GM of Canada Warren B T SHIFT CODE 1 X Shift Code 1st Shift 4 T PRODUCTION LI...

Page 428: ...4 B 1 4 REAR AXLE Fig 4B 8 Gear Tooth Nomenclature Fig 4B 9 G ear Tooth Contact Pattern Check...

Page 429: ...ers Removal 1 Raise vehicle on hoist 2 Support rear axle assembly with suitable lifting device so that tension is relieved in springs and shock absorbers 3 Remove trunnion bearing U bolts from the axl...

Page 430: ...t Clearance which affects the removal of axle shafts as noted below 1 Raise the vehicle on a hoist Remove both rear wheel and tire assemblies and both rear brake drums 2 Remove the rear cover and drai...

Page 431: ...and remove bearing and seal On 9 1 2 inch ring gear axles use tool J 29712 Insert wobble plate into axle tube so that it grasps Fig 4Bl 7 Wheel Bearing Removal behind the bearing Center receiver on a...

Page 432: ...nents on flange and connect hydraulic line to wheel cylinder inlet See Section 5 for brake assembly bleeding and adjustment procedures Wheel Bolt Replacement 1 Raise vehicle on hoist allowing axle to...

Page 433: ...ve by tapping from flange clean up stake points install Fig 4B1 14 Drive Pinion Flange Removal new deflector and stake deflector at three new equally spaced positions Staking operation must be perform...

Page 434: ...er shaft and torque to specifications Reinstall brake drums and wheels NOTICE See N O TIC E on page 1 of this section regarding the fasteners referred to in step 7 8 Lower vehicle and remove from hois...

Page 435: ...ng the gear on the case 5 Insure that the gear is seated firmly against the case then torque the bolts to 145 N m 105 ft lbs for the 9 1 2 ring gear 80 N m 60 ft lbs for the 8 1 2 ring gear and 8 7 8...

Page 436: ...different equally spaced positions around the gear Variation in readings should not exceed 001 Position the dial indicator so that indicator button is perpendicular to tooth angle and in line with ge...

Page 437: ...C 265 010 240 TO MAINTAIN PROPER BACKLASH 005 008 ring gear is moved away from pinion by subtracting 010 shims from ring gear side and adding 010 shims to other side 010 275 004 TO OBTAIN PROPER PREL...

Page 438: ...shaking push pull the companion flange Looseness indicates the need for bearing replacement 3 Install Holder J 8614 11 on flange by using two bolts with flat washers as shown in figure 4B1 28 Positio...

Page 439: ...sure is applied Press bearing from pinion Record the thickness of shim removed from between bearing and pinion head 4 Inspect carrier pinion bearing bores and shoulders J 8614 3 while holding J 8614 1...

Page 440: ...the pinion during testing was found to have best tooth contact at a position varying from design or nominal depth In order to compensate for all of the allowable machining variables a procedure of gag...

Page 441: ...e 14 Check the rear face of the drive pinion being installed for a pinion code number This number indicates the necessary alteration of the pinion shim thickness as determined in step 13 a If the pini...

Page 442: ...T OF THE GAUGING SURFACE SWING THE PROBE OFF THE GAUGE PLATE THE INDICATOR NEEDLE WILL MOVE TOWARD THE PROPER NUMBER WHICH INDICATES THE REQUIRED SHIM FOR A NOMINAL PINION THIS NUMBER IS THE CORRECT S...

Page 443: ...5 inch pounds on reused bearings Use an inch pound torque wrench such as J 5853 as shown in figure 4B1 40 to measure the rotating torque After torque has been checked final tightening should be done v...

Page 444: ......

Page 445: ...is necessary only when housing replacement is required NOTICE All axle attachments are important attaching parts See NOTICE on page 1 of this section Removal 1 Raise vehicle place stand jacks under fr...

Page 446: ...ppropriate tool as specified in Step 2 to remove adjusting nut from housing tube Remove thrust washer from housing tube 5 Pull hub and drum assembly straight off axle housing 6 Remove oil seal and dis...

Page 447: ...ce until it seats against shoulder of hub bore 7 Install new oil seal with J 24428 Drum Non Demountable Type Fig 4B2 2 Replacement Construction of the nondemountable type hub and drum assembly is such...

Page 448: ...ing ring gear to pinion backlash as Fig 4B2 7 Wheel Bearing Adjusting Tool 6 If adjusting nut slot in alignment with key way in axle spindle insert square key into slot If adjusting nut slot is not al...

Page 449: ...ng in the same manner 4 Inspect bearings and hub for nicks burrs or evidence of abnormal wear 5 To install bearings place bearing onto hub and use driver handle J 8092 and bearing installer J 24430 to...

Page 450: ...new bearings are being installed 7 Install locking retainer into holes and attach fingers to bearing cap 8 Torque bearing cap bolts to specifications At this point the differential bearings are prope...

Page 451: ...on front and rear bearing cups from the bearing retainer using a drift 8 To remove the rear bearing use J 22912 as shown in figure 4B2 17 9 Drive the pinion straddle bearing from the carrier housing u...

Page 452: ...with a lithium base Fig 4B2 20 Installing Straddle Bearing extreme pressure lubricant and install the seal in the retainer bore Use J 24434 with driver handle J 8092 Press the seal into the bore until...

Page 453: ...riginal code was 1 and new code is 2 the correct shim would be 014 inch plus 003 017inch b If original shim was 012 inch original code 2 and new code is 2 the correct shim would be 012 minus 004 008 i...

Page 454: ......

Page 455: ...se the carrier must bespread The drive pinion assembly incorporates an inner and outer bearing shim The inner shim is used to maintain proper pinion depth The outer shim is used to maintain proper pre...

Page 456: ...3 Ring Gear 14 D ifferential Case 15 Ring Gear Bolt 16 D ifferential Side Bearing 17 Side Bearing Cup 18 Side Bearing Adjusting Shims 19 Bearing Cap 20 Bearing Cap Bolt 21 D ifferential Spider 22 Diff...

Page 457: ...n in figure 4B3 6 6 Remove drive pinion from carrier It may be necessary to tap on the pinion with a soft faced hammer 7 With a long drift tap on inner race of outer pinion bearing to remove pinion oi...

Page 458: ...caps just enough to keep the bearings in place 4 Mount a dial indicator on the carrier with the tip of the indicator on the back face of the ring gear 5 Position two screwdrivers between the bearing...

Page 459: ...up If a new gear set is being used notice the plus or minus etching on both the old and new pinion and adjust the thickn ss of the old shim pack to compensate for the difference of these two figures F...

Page 460: ...the size of the shim installed in step 9 above then add 006 inch for preload and backlash For example if the reading in step 8 was 329 inch and the shim just installed on the ring gear side of the ca...

Page 461: ...y incorporates an inner and outer bearing shim The inner shim is used to maintain proper pinion depth The outer shim is used to maintain proper preload on the pinion bearing DIFFERENTIAL CASE Removal...

Page 462: ...2 and 3 into holding bar as shown in figure 4B4 4 and remove flange from drive pinion Remove drive pinion from carrier 4 With a long drift tap on inner race of outer pinion bearing to remove pinion o...

Page 463: ...Check fit of differential side gears in case 6 Check fit of side gears and axle shaft splines 7 Inspect differential pinion shaft and spacer for scoring or evidence of excessive wear Fig 4B4 3 Removi...

Page 464: ...inion and ring gear before proceeding with assembly On the button end of each pinion there is etched a plus number a minus number or a zero 0 number which indicates the best running position for each...

Page 465: ...ents preload are not to specifications adjust shim pack as necessary Increase the outer shim pack to reduce rotation torque Decrease shim pack to increase rotating torque 11 Remove nut washer and flan...

Page 466: ...im will be 085 055 015 045 6 Install shims as indicated instep 5 which will give the proper bearing preload and backlash and install side bearing Installation 1 Spread differential carrier using sprea...

Page 467: ...tion 4B5 4 Unit Repair 4B5 4 Differential and Gear Assembly 4B5 4 Removal 4B5 4 Disassembly 4B5 5 Pinion and Cage Assembly 4B5 5 Removal 4B5 5 Disassembly 4B5 6 Cleaning and Inspection 4B5 6 Reassembl...

Page 468: ...4 B 5 2 REAR AXLE Fig 4B5 2 Rockwell Assembly...

Page 469: ...around carrier hole to insure fit of replacement vent Tap new vent into housing using a soft faced hammer Vent should be positioned in housing so that flat surface is toward centerline of differential...

Page 470: ...roller jack Start carrier into housing with four flat washers and nuts equally spaced NOTICE Do not drive carrier into housing with a hammer at the carrier stud flange The flange may easily be distor...

Page 471: ...2 Use drill 1 32 smaller than body of rivet to Fig 4B5 8 ldentification Mark drill completely through rivet 3 Press out rivets If necessary to replace differential bearings remove with a suitable pull...

Page 472: ...N Cleaning Steam cleaning assembled drive units after they have been removed from the housing is not recommended When this method of cleaning is used water is trapped in the cored passage of the casti...

Page 473: ...d approximately 1 8 diameter completely around one mating surface and all fastener holes to assure complete sealing and prevent leakage CAUTION M inor concentrations of acetic acid vapor m ay be produ...

Page 474: ...aced in a matched set 4 Pinion Cone Variation Number Each pinion has a Pinion Cone P C Variation Number which indicates variations in thousandths of an inch from the nominal mounting distance This Pin...

Page 475: ...essures and torque for checking pinion bearing preload are shown in specifications If rotating torque is not within 5 to 15 pound inches use thinner spacer to increase or thicker spacer to decrease pr...

Page 476: ...of the new shim pack to be used Refer to the following examples which cover all the possible combinations of or original and new PC variations After calculating the shim pack thickness assemble the n...

Page 477: ...ge between the gear and case thus resulting in gear runout Proper installation should therefore incorporate preheating the gear as described above to assure correct interference fit and to eliminate m...

Page 478: ...hand push fit in the bores otherwise the bores must be reworked with a Fig 4B5 24 Checking Torque scraper or some emery cloth until a hand push fit is obtained Use a blued bearing cup as a gage and ch...

Page 479: ...the established backlash recorded before disassembly For new gears the new backlash should be initially set at 010 Adjust backlash by moving the gear only This is done by backing off one adjusting ri...

Page 480: ...4 B 5 1 4 REAR AXLE...

Page 481: ...50 190 LB D IFF BEARING CAP TO CARRIER CAPSCREWS 9 16 12 115 140 LB FT GEAR TO D IFF CASE BOLT NUTS 11 2 2 0 85 115 LB FT ADJUSTING RING LOCK TO D IFF BEARING CAP CAPSCREWS 5 16 18 20 30 LB FT D IFF C...

Page 482: ...i...

Page 483: ...Disassembly 4B6 10 Inspection 4B6 10 Assembly 4B6 10 Testing Procedure 4B6 11 Eaton Positive Locking Differentials 1 2 Ton and 3 4 Ton Units 4B6 12 Description 4B6 12 Disassembly 4B6 15 Inspection 4B6...

Page 484: ...he axle shaft hole in the spring retainer then compress C clamp sufficiently to permit withdrawal of spring pack 4 Position spring pack in vise and remove 1 4 inch bolts Alternately relieve C clamp pr...

Page 485: ...l them over the side gear hub 5 Lubricate and assemble opposite side gear as above 6 Install one side gear clutch pack assembly and shim s in the differential case 7 Position pinion gears and thrust w...

Page 486: ...20 Install side bearings and ring gear to case using procedure outlined for the conventional differential 21 Place differential in carrier and adjust bearings and backlash as outlined for the convent...

Page 487: ...ch packs and shims Mark the gears clutch packs and shims for reinstallation in same positions Inspection Check the clutch plates and discs for wear and signs of overheating Check the condition of the...

Page 488: ...nstall the pinion shaft 10 Follow the procedure in steps 5 6 and 7 to determine the proper shim dimension 11 When the proper shims have been determined to achieve 005 to 008 backlash between both pini...

Page 489: ...rs and outer races 2 Place one outer race onto its matched inner race and roller assembly and turn slowly applying hand load 3 If bearing outer race turns smoothly and no visible damage is found beari...

Page 490: ...e changed 2 Place one spring block in position over gear face in alignment with pinion gear shaft grooves Install pinion shaft pinion gears and thrust washers into cap half or differential case in suc...

Page 491: ...wn in Fig 4B6 20 Then torque case bolts to 40 N m 30 ft lbs 7 If side bearings were removed lubricate outer bearing surfaces and press on bearings as shown in the Service Manual 8 After making sure th...

Page 492: ...s and dished Belleville friction plates on each side of differential side gears transmits drive from differential case to axle shafts Carefully observe the order in which the plates are used since the...

Page 493: ...rve if Power Lok components have been assembled properly Each pinion cross shaft can be tight on its ramp or if there is clearance it should be only a few thousandths and it should be equal at all fou...

Page 494: ...enever the wheel to wheel speed varies by approximately lOOjpm or more This action retards a cam which in turn compresses a multi disc clutch locking one side gear to the case At wheel to wheel differ...

Page 495: ...l to stop or both wheels to turn at the same speed The engine may stall if equipped with a manual transmission It may be necessary to accelerate engine until approximately 10 mph 16 km h is indicated...

Page 496: ...A Broken clutch plates B Broken reaction block C B roken d iffe re n tia l gears Correction A Replace governor assembly and latching bracket B Replace governor assembly and latching bracket C Replace...

Page 497: ...Remove cam gear disc pack assembly and disc pack guide clips 6 Remove plain side gear and shims Inspection 1 Clean all parts with solvent Inspect all bearing for chipping or evidence of excessive wear...

Page 498: ...m gear reshimming may be necessary Measure the overall length of the new cam gear assembly including the shim and compare to the dimension obtained in Step A of cam gear service section If the length...

Page 499: ...t be followed Failure to do so m ay disturb critical clearances and could result in differential complaints Disassem bly 1 Remove ring gear and side bearings following procedures established for the s...

Page 500: ...to keep the splined discs from becoming wedged between the thrust ring and gear shoulder while pressing the sub assembly together Completed sub assembly should be checked for proper disc sequence Als...

Page 501: ...their proper position 11 Install side gear in left side case half Rotate gear to engage spline with splines on discs 12 Being careful not to dislodge side gear assembly hold thumb on inside of side ge...

Page 502: ......

Page 503: ...iffe re n tia l Bearing Caps 55 55 65 85 135 BOLT TORQUES FT LB S A 00 IS 00 Os c o a O tf o IO V 2 C h e v ro le t 12 R ockw ell Filler Plugs 25 18 18 10 18 10 D iffe re n tia l Pinion Lock 20 20 Dr...

Page 504: ...20 Chevrolet Salisbu ry 3 500 8 1 2 E xcept C 30 Dual K 30 Wheel Cam per Chevrolet S a lisbury 75 00 10 1 2 C 30 Dual K 3o yyheei Cam per Dana S alisbury 75 00 10 1 2 P30 Chevrolet S alisb u ry 7 9 0...

Page 505: ...84 Pinion O il Seal Installer 6 J 1364 P inion Bearing Ring Drive 18 J 24385 Case Spreader Tool 7 J 1488 D iffe ren tia l Side Bearing Replacer 19 J 24430 Side Bearing Installer 8 J 8608 Drive Pinion...

Page 506: ...4 1 Pinion Seal Gauge Plate 21 J 8608 Outer Wheel Bearing Cup Installer 7 J 5748 Positraction Torque Measuring Adapter 22 J 24384 Pinion Oil Seal Installer Dana 8 J 6627 Wheel Bolt Remover 23 J 24428...

Page 507: ...s 4C 4 Unit Repair 4C 4 General Information 4C 4 Differential Case 4C 4 Removal 4C 4 Oil Seal Replacement 4C 5 Disassembly 4C 5 Drive Pinion 4C 5 Removal 4C 5 Inspection 4C 5 Differential Case 4C 8 Re...

Page 508: ...th road to minimize tire noises 4 Test at various speeds in drive float and coast 5 Rear pinion bearing noise may be louder on acceleration 6 Front pinion bearing noise may be louder on deceleration 7...

Page 509: ...front springs 4 Attach shock absorbers to axle brackets 5 Install caliper see Section 5 6 Attach connecting rod to steering arm 7 Remove jack stands and lower front of vehicle 8 Assemble propeller sha...

Page 510: ...om yoke 4 Support the other side of the yoke in the vise and drive the other bearing out by tapping on the end of the trunnion using a brass drift 5 Remove trunnion 6 Clean and inspect bearings Lubric...

Page 511: ...shown in Figure 4C 9 and remove flange from drive pinion Remove drive pinion from carrier 3 With a long drift tap on inner race of outer pinion bearing to remove pinion oil seal slinger gasket outer...

Page 512: ...ntial Bearing Cap 32 Differential Carrier 5 Drive Pinion Shims 23 Differential Bearing Cone 33 Inner Bearing Cone 6 Inner Bearing Shims 15 Differential Pinion 24 Differential Bearing Cup 34 Inner Bear...

Page 513: ...Pinion Shaft 5 Gasket 13 Cone and Roller 20 Shims Differential 27 Thrust Washer 6 Outer Pinion Oil Slinger Inner Pinion Adjusting Pinion 7 and 8 Cone and Roller 14 Ring and Pinion 21 Cone and Roller 2...

Page 514: ...10 Removing Inner Pinion Bearing Cone and Roller bearings onto case using Tool J 22175 Do not install shims at this time 6 Place differential case in carrier and install bearing caps Care should be t...

Page 515: ...ant to add 003 more shims than would be required if the pinions were etched 0 By adding 003 shims the mounting distance of the pinion was decreased 003 which is just what a 3 etching indicated If the...

Page 516: ...for preload and backlash Example If reading in step 10 of Differential Case Reassembly was 085 and the shims installed on ring gear side of case was 055 the correct amount of shim will be 085 055 015...

Page 517: ...d Toe end of tooth is smaller than heel end See Figure 4C 15 Test 1 Wipe oil out of carrier and carefully clean each tooth of ring gear 2 Use gear marking compound and apply this mixture sparingly to...

Page 518: ...ine of the ring gear Decreasing shim thickness will move pinion farther away from centerline of the ring gear Backlash is adjusted by means of the side bearing adjusting shims which moves the entire c...

Page 519: ...inion inner and 10 J 5341 Gauge Pinion Depth Consists outer bearing cone of Parts 5 J 6368 Installer Pinion outer 1 SE 1065 1 2 5 2 6 bearing cup use w ith J 8092 2 9SS 1 10 6 i 8092 Driver Handle use...

Page 520: ......

Page 521: ...5 36 Rotor Servicing 5 38 Brake Drum Shoe and Lining 5 39 Standard Drum Brake 5 39 Propeller Shaft Brake 5 42 Brake Drums 5 43 Wheel Cylinder 5 43 Power Brake Unit 5 44 Vacuum Booster 5 44 Hydro Boost...

Page 522: ...designed that the switch will latch in the warning position once a failure has occurred The only way the light can be turned off is to repair the failure and apply a pedal force as required to develo...

Page 523: ...aster cylinder should be disconnected from the booster Press in on spool plug insert a small screwdriver between snap ring and housing bore This unseats one side of the spool plug snap ring from its g...

Page 524: ...during brake applications as noted in the bleeding instructions CHECKING THE RESERVE SYSTEM 1 Start engine and charge accumulator by applying the brake pedal or by turning the steering wheel from sto...

Page 525: ...system Power steering pump belt slips Low fluid level in power steering pump reservoir Faulty spool operation caused by contamin ation in system Contamination in steering hydro boost system Internal...

Page 526: ...oe and lining in complete axle sets 7 Malfunctioning rear brakes 7 Check for inoperative auto adjusting mechanism defective lining grease or brake fluid on lining or defective wheel cylinders Repair a...

Page 527: ...alent Excessive Pedal Travel 1 Partial brake system failure 1 Check both front and rear system for a failure and repair Also check and repair warning light circuit It should have indicated a failure 2...

Page 528: ...due to improper clear ance or dirt 1 Remove caliper and correct as necessary 2 Uneven rotor wear causing a thickness variation between the two braking surfaces 2 Machine rotors as follows a Machine ro...

Page 529: ...X X XX X Out of Round or Vibrating Brake Drums X XX Out of Parallel Brake Rotors XX Excessive Rotor Run Out X Faulty Automatic Adjusters X X X X X Incorrect Wheel Cylinder Sizes X X X X Weak or Incor...

Page 530: ...assure that no audible click sounds remain Electrical contact should be made when the brake pedal is depressed 1 0 1 24 25 31 mm C K models 45 95 11 24 mm G P models from its fully released position B...

Page 531: ...systems use J 23518 Refer to Fig 5 4 special tool illustration and brake system description chart NO TICE It is very important that the correct master cylinder bleeder adapter be used to avoid possib...

Page 532: ...end pipe assembly to match old pipe using a tubing bender Clearance of 75 19 mm must be maintained to all moving or vibrating parts BRAKE HOSES Inspection The flexible hydraulic brake hose which trans...

Page 533: ...Fig 5 5 Front Brake Pipes and Hoses C K Models BRAKES 5 13...

Page 534: ...Fig 5 6 Front Brake Pipes and Hoses G M odels 5 14 B R A K E S...

Page 535: ...Fig 5 7 Front Brake Pipes and Hoses P Models BRAKES 5 15...

Page 536: ...5 16 BRAKES Fig 5 8 Rear Brake Hoses...

Page 537: ...e to specification again be careful not to bend bracket or pipe Check to see that hose installation did not loosen frame bracket re torque bracket if necessary 6 Bleed system 7 Lower vehicle from hois...

Page 538: ...5 18 BRAKES Fig 5 10 Parking Brake System Typical...

Page 539: ...BRAKES 5 19...

Page 540: ...ay lever This will assure freedom for full shoe release NOTICE It may be necessary to knock out lanced area in brake drum with punch and hammer to gain entry into adjusting screw through brake drum Be...

Page 541: ...wiring harness from valve switch terminal 2 Remove combination valve 3 Install combination valve by reversing removal steps 4 Bleed entire brake system Do not move vehicle until a firm brake pedal is...

Page 542: ...al and install lever assembly on valve shaft by pushing plastic bushing and clip assembly over serration on valve shaft 10 Install nut on shaft and tighten 11 Install brake line to lever assembly and...

Page 543: ...cate pedal pivot bushings and pivot pin bolt or sleeve with Delco Brake Lube or equivalent Adjust stoplamp switch NOTICE See Notice on Page 1of this section BRAKE PEDAL ROD P30 32 Models Replacement F...

Page 544: ...containers capped to prevent water contamination Except Bendix Mini Master Cylinder and Delco Quick Take Up Master Cylinder Removal 1 Disconnect brake pipes from master cylinder and tape end of pipes...

Page 545: ...ow pressure with initial brake application The low pressure fluid quickly provides the displacement requirements created by the seal retracting pistons into the front calipers and spring retraction of...

Page 546: ...all reservoir diaphragm in reservoir cover 2 Install assembly on reservoir 3 REMOVE AND INSTALL PRIMARY AND SECONDARY PISTONS REMOVE 1 Depress primary piston and remove lock ring 2 Direct compressed a...

Page 547: ...master cylinder body and use pry bar to remove reservoir PRY BAR RESERVOIR INSTALL 1 Lay reservoir on flat hard surface as shown Press on master cylinder body using rocking motion 5 REMOVE AND INSTALL...

Page 548: ...9 Install a new reservoir diaphragm in reservoir cover where needed and install cover on master cylinder Beaded side faces master cylinder casting to insure positive sealing The bail wire is now pushe...

Page 549: ...rt the secondary piston assembly actuator end first into the master cylinder bore and press assembly to the bottom of the bore 4 Lubricate the primary piston assembly with clean brake fluid Insert the...

Page 550: ...of brake pads Place inboard and outboard pad surfaces together and check for gap between pad surfaces If more than 0 13mm 005 gap is measured at middle of pad midway between attaching lugs pad must no...

Page 551: ...g If the bolts are corroded or damaged they should be replaced 2 Examine the inside of the caliper for evidence of fluid leakage If leakage is noted the caliper should be overhauled Wipe the inside of...

Page 552: ...5 32 BRAKES Fig 5 23 Caliper to Stop Clearance BOOT Fig 5 24 Boot Installation Fig 5 25 Sleeve Installation...

Page 553: ...gaged in the caliper cut out see fig 5 28 Be sure to note right and left brake shoes ROTOR 6 Postion the caliper over the rotor lining up the holes in the caliper ears with the holes in the mounting b...

Page 554: ...y looking down through the inspection hole in the top of the caliper see Brake Inspection portion of this section The inboard shoe is installed with the ends of the shoe resting in the steering knuckl...

Page 555: ...ition Be sure the clip remains in position 3 Postion the outboard shoe in the caliper with the ears at the top of the shoe over the caliper ears and the tab at the bottom of the shoe engaged in the ca...

Page 556: ...e a screwdriver to pry the boot out of the caliper Extend the screwdriver across the caliper bore under the boot and pry up Be careful not to scratch the caliper bore 5 Use a piece of wood or plastic...

Page 557: ...nnections to prevent dirt from entering the hose or caliper Discard the copper gaskets 2 Remove the caliper assembly as described under Shoe and Linings Removal Disassembly Fig 5 39 1 Clean the exteri...

Page 558: ...the boot large bead into the piston bore groove by reaching inside of Tool J 24548 and pressing the boot bead into the groove fig 5 41 Be sure boot is fully seated in the groove before proceeding 3 P...

Page 559: ...a refinish dimension Do not use a brake rotor that will not meet the specifications as shown below after refinishing Replace with a new brake rotor Wheel Bolt Replacement Disc Brakes NOTICE See Notic...

Page 560: ...oval of link pin Fluid coatings on piston within cylinder and on end of link pin removed from boot are normal as cylinder contains a porous PISTON WHICH IS IMPREGNATED WITH A CORROSION INHIBITING FLUI...

Page 561: ...tely 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 moderate use for several h...

Page 562: ...emove the cable from the lever 11 If necessary to remove the anchor pin straighten the washer from pin hex and reinforcement Remove reinforcement and washer with anchor pin 12 If necessary to remove t...

Page 563: ...ngs A grooved drum if used with new lining will not only wear the lining but will make it difficult if not impossible to obtain efficient brake performance An out of round drum makes accurate brake sh...

Page 564: ...accumulator contains compressed gas Always use proper tools and follow recommended procedures or personal injury may result Do not apply heat to accumulator Do not attem pt to repair an inoperative a...

Page 565: ...BRAKES 5 45 6 6L X 400 V 8 P MODELS 4 8L T 292 L 6 7 4L W 454 V 8 Fig 5 48 Power Brake Vacuum Hose Filter lnstallation C K P Trucks...

Page 566: ...and two nuts to booster NOTICE See Notice on Page 1of this section 4 Bleed system Refer to HYDRO BOOST BLEEDING PROCEDURE Tube Seat Replacement 1 Turn engine off and pump brake pedal 4 or 5 times to...

Page 567: ...on a hoist 3 Clean all dirt from the booster at the hydraulic line connections and master cylinder 4 Remove the nuts and lockwashers that secure the master cylinder to the booster and the support brac...

Page 568: ...nd remove the booster assembly Fig 5 54 Removing Tube Seat 7 P30 32 Models a Remove the cotter pin nut bolt and washers that secure the operating lever to the vertical brake rod b Remove the six nuts...

Page 569: ...c lines and attaching bolts to specifications Lubricate pedal rod and linkage pivot bolts pins sleeves and bushings with Delco Brake Lube or equivalent NOTICE See Notice on Page 1of this section 9 Fil...

Page 570: ...5 50 BRAKES Fig 5 57 Power Steering Hose Routing C K Models...

Page 571: ...BRAKES 5 51 Fig 5 58 Power Steering Hose Routing G Models...

Page 572: ...Fig 5 59 Power Steering H ose Routing P Models 5 52 BRAKES...

Page 573: ...uum suspended booster operates with vacuum on both sides of its diaphragms When the brakes are applied air at atmospheric pressure is admitted to one side of each diaphragm to provide the power assist...

Page 574: ...tains twelve 12 lances Four 4 of these lances one in each quadrant are deeper than the other lances The metal that forms the four 4 deep lances must be partially straightened so that the lances will c...

Page 575: ...turn counterclockwise to unlock housing BOOSTER 2 REMOVE AND INSTALL EXTERIOR COMPONENTS REMOVE INSTALL 1 Remove parts as shown 1 Lubricate inside and outside diam eters of grommet and front housing...

Page 576: ...pact to dislodge diaphragm retainer 3 Remove parts as shown ASSEMBLE 1 Lubricate inside diameter of secondary diaphragm lip and fit in secondary support plate 2 Install secondary diaphragm and support...

Page 577: ...BRAKES 5 57 4 CONT A SECONDARY DIAPHRAGM B SECONDARY POWER 4 CONT C PRIMARY D Fig 5 5A Service...

Page 578: ...nd 15 Slowly release press to permit the two housings to separate 16 Continue to release press until diaphragm spring tension has been removed 17 Remove th front housing and return spring 18 Remove th...

Page 579: ...to seal in center plate then guide center plate seal first onto the front plate hub being careful not to damage center plate seal Remove Seal Protector J 22733 7 Apply a light coat of silicone lubrica...

Page 580: ...DIAPHRAGM PLATE REAR DIAPHRAGM REAR DIAPHRAGM RETAINER REAR SHELL VALVE POPPET POPPET RETAINER VALVE ROD SPRING SILENCER SILENCER RETAINER 0 VALVE OPERATING ROD FRONT SHELL SPRING REACTION DISC FRONT...

Page 581: ...hol and assemble with shoulder inside poppet Assemble retainer filters and silencer Fig 5 8B lnstalling Rear Bearing and Vacuum Seal over ridge on rod and return spring over ball end of operating valv...

Page 582: ...agm vacuum suspended unit In a normal operating mode with the service brakes in the released position a vacuum suspended booster operates with vacuum on both sides of its diaphragm When the brakes are...

Page 583: ...63 F R O N T H O U S IN G G A G E D PISTO N ROD F R O N T H O U S IN G SEA L D IA P H R A G M S U PPO R T G R O M M ET R EAR H O U S IN G P O W E R P IS TO N B E A R IN G Fig 5 1 C Booster Assembly E...

Page 584: ...and front housing seal 2 Install parts as shown FRONT HOUSING 3 UNLOCKING AND LOCKING BOOSTER DISASSEMBLE Unlock booster as shown in A and disassemble booster as shown POWER PISTON RETURN POWER SPRIN...

Page 585: ...Then remove reaction piston 3 Grasp assembly at outside edge of diaphragm support and diaphragm Hold with pushrod down against a hard surface Use a slight force or impact to dislodge diaphragm retain...

Page 586: ...ng assembly from the unit Rear Housing Group 1 Remove the air filter element from location within the diaphragm plate extension NOTICE To prevent chipping of the plastic diaphragm plate exercise extre...

Page 587: ...ped valve face 1 Replace Air Valve Push Rod Assembly 1 Air valve scratches dents distortion or corrosion of I D or O D All seats to be smooth and free of nicks and dents 1 Do not repair Replace 2 Push...

Page 588: ...Poppet Valve Spring 20 5 Diaphragm Plate 13 Poppet Retainer 21 6 Rear Housing 14 Dust Boot 22 7 Diaphragm Spring 15 Valve Push Rod 23 8 Reaction Disc 16 Filter and Silencers Valve Return Spring Mount...

Page 589: ...New parts will provide more satisfactory service even if the brake unit is allowed to go beyond the desired overhaul period Assembly Figs 5 ID and 5 2D 1 Be careful during the rebuild procedure that...

Page 590: ...ilter retainer Final Assembly 1 Attach base of Holding Fixture J 22805 to front housing with nuts and washers and draw down tight to eliminate bending or damage to studs Clamp base in bench vise with...

Page 591: ...ng seal and position seal in the depression in the housing BENDIX HYDRAULIC BRAKE gas Always use proper tools and follow recommended procedures or personal injury may result Do not apply heat to accum...

Page 592: ...ster cover in a vise equipped with soft jawed devices Remove the five screws that secure the booster housing to the cover 8 Remove the booster assembly from the vise and while holding the unit over a...

Page 593: ...umulator Valves shown in Figure 5 10E Cleaning and Inspection NOTICE Be sure to keep parts clean until reassembly Wash at reassembly if there are any parts dropped or left exposed for eight hours or l...

Page 594: ...ool valve plug in and install retaining ring 4 Coat the piston bore and the piston seal with clean power steering fluid and assemble the NEW seal in the bore The lip of the seal must be toward the rea...

Page 595: ...n in Figure 5 14E 16 Using clean power steering fluid lubricate accumulator seal Install seal and accumulator in housing and then place the retaining ring over the accumulator fig 5 7E Place Tool J 26...

Page 596: ...r housing Push on the end of the pedal rod to seat the grommet in the groove inside the housing When the grommet is fully seated the pedal rod will rotate freely with no binding 25 Slide the boot on t...

Page 597: ...REMOVE RETAINER WITH SM ALL SCREWDRIVER DO NOT DISCONNECT BRAKE LINES 2 Remove And Install Hydro Boost II REMOVE NOTICE Power steering fluid and brake fluid cannot be mixed If brake seals contact ste...

Page 598: ...Install Bracket REMOVE 1 Cut nut w ith chisel 2 Remove parts as shown IN S TA LL 1 Install parts as shown HOUSING COVER BOOT BRACKET 150 N m 1 10 FT LBS TORQUE WRENCH TORQUE NUT WITH TOOL J 29192 CUTT...

Page 599: ...27 N m 20 FT LBS POWER PISTON ACCUM ULATOR SPRING CLEAN GROOVE BOTTOM BEFORE IN S TA LLIN G SEAL SCREWDRIVER PISTON HOUSING SEAL 1 Remove parts as shown 2 If removing spool valve plug refer to Remove...

Page 600: ...m Shoe Gauge 7 J 21472 or J 22364 Bleeder Wrench 8 J 22904 Dust Boot Installer J 28735 Dust Boot installer JB7 9 J 24548 Dust Boot Installer 10 J 26889 Accumulation Piston Compressor 11 J 23709 Combin...

Page 601: ...Drum 11 00 x 2 00 Vacuum Single Diaphragm ALL MODELS JB5 Low Drag Disc 11 86 x 1 28 Drum 11 15 x 2 75 Vacuum Dual Diaphragm JB6 Low Drag Disc 12 50 x 1 28 Drum 11 15 x 2 75 Vacuum Dual Diaphragm JB7 C...

Page 602: ...Cable Clip to Trans Brkt 27 N m 20 ft lbs Flange Plate 40 N m 30 ft lbs Drum 110 N m 80 ft lbs Wheel Cylinder to Flange Plate Bolt 5 5 N m 50 in lbs 20 N m 180 in lbs on JB5 JB6 JB7 and JB8 Rear Brak...

Page 603: ...4 7 Height Gauge 16 J 2 4 5 53 6 J 2 2 6 7 7 Power Cylinder Seal Installer J 28485 7 J 2 2 7 3 3 Seal Installer and Protector J 28497 8 J 28458 Power Piston Seal Protector 17 J 24 554 9 J 228 0 5 Powe...

Page 604: ......

Page 605: ...mportant A liberal coating of engine oil should be applied to friction areas during assembly to pro tect and lubricate the surfaces on initial operation Throughout this section it should be understood...

Page 606: ...If doing the work prescribed does not correct the complaint then either the wrong Symptom was used or a more detailed analysis will have to be made All of the Symptoms can be caused by worn out or def...

Page 607: ...blems a Low coolant b Loose fan belt c Restricted air flow etc 2 Check ignition timing per emission control information label 3 For ESC see diagnosis Section 6 D 4 Perform EGR functional check see Sec...

Page 608: ...en If closed and engine is hot check temperature operation of sensor unit See air cleaner temperature test Section 6E 2 Visually check the following a Vacuum hoses for splits kinks and proper connecti...

Page 609: ...following a Vacuum hoses for splits kinks and proper connections See hose routing on the vehicle emission control information lable b Air leaks at carburetor mounting and intake manifold c Check igni...

Page 610: ...eturn to mark as throttle is closed 4 With engine off remove vacuum hose from distributor vacuum advance Connect vacuum pump and apply 15 vacuum Vacuum should hold steady for 15 seconds If vacuum drop...

Page 611: ...cuum pump and apply 15 vacuum Vacuum should hoid steady for 15 seconds If vacuum drops replace vacuum advance unit 7 Remove spark plugs Check for cracks wear improper gap burned eiectrodes heavy depos...

Page 612: ...ction 6C 8 Suggest owner fill tank and recheck mileage 1 Check ignition wires boots cap and coil for a Damage b Deterioration c Loose connections d Carbon tracking Clean tighten and or replace defecti...

Page 613: ...n tracking Repair or replace as necessary d Check choke and vacuum break operation and adjustment 2 Check ignition timing per emission control information label If timing is too early speed up engine...

Page 614: ...recheck timing 3 Check the following a Choke throttle linkage and fast idle cam for sticking b Carburetor flooding Clean and repair as necessary If repairs are necessary see carburetor cleaning and in...

Page 615: ...or repair as necessary Low Oil Pressure a Slow idle speed b Incorrect or malfunctioning oil pressure switch c Incorrect or malfunctioning oil pressure gage d Improper oil viscosity or diluted oil a Se...

Page 616: ...and continues for two to three minutes Knock increases with torque 1 EFE equipped engines may have valve knock 2 Flywheel contacting splash shield 3 Loose or broken balancer or drive pulleys 4 Excess...

Page 617: ...at 1 Loose or worn drive 1 Tension and or replace idle hot belts as necessary 2 Compressor or 2 Replace as necessary generator bearing 3 Fuel pump 3 Replace pump 4 Valve train 4 Replace parts as nece...

Page 618: ...AGNOSIS 3 Glow Plug Control System Inoperative Refer to ELECTRICAL DIAGNOSIS 4 No Fuel Into Cylinders Remove any one glow plug Depress the throttle part way and crank the engine for 5 seconds If no fu...

Page 619: ...jection pump lever in fast idle position If solenoid does not move refer to ELECTRICAL DIAGNOSIS 3 Restricted Fuel Return System Disconnect fuel return line at injection pump and route hose to a metal...

Page 620: ...stem Install a section of clear plastic tubing on the fuel return fitting from the engine Evidence of bubbles in fuel when cranking or running indicates the presence of an air leak in the suction fuel...

Page 621: ...ing Knock 1 Nozzle s Sticking Open or with very low Nozzle Opening Pressure Remove nozzle for test and replace as necessary 2 Mechanical Problem Refer to Mechanical Diagnosis Section 6 Excessive Black...

Page 622: ...ve assy 2 Loose tube on pump assy Hooting noise Valves not functioning properly Pump assy loose on drive assy Stripped threads Oil around end plug Loose plug Oil leaking out crimp Install hose and vac...

Page 623: ...______ IDLE SPEEDS OK IDLE SPEED INCORRECT I SET IDLE SPEED TO SPEC IF FAST IDLE WAS ADJUSTED ADJUST HIGH VACUUM SWITCH CALIF T Y P E I CHECK TIM IN G M AR K ON INJECTIO N PUMP AND FRO NT COVER FOR A...

Page 624: ...THE NOZZLE MOVE THE LINE SO THE INLET TO THE NOZZLE CAN BE OBSERVED REMOVE THE PINK WIRE TO THE PUMP AND CRANK THE ENGINE AND OBSERVE THE NOZZLE INLET FOR BUBBLES IF BUBBLES ARE EVIDENT REPLACE THE NO...

Page 625: ...NOTES ENGINE 6 21...

Page 626: ......

Page 627: ...ngs are also fed oil by intersect ing holes with main oil gallery The lifters are located in the main oil gallery A damper assembly on the forward end of the crank shaft dampens any engine torsional v...

Page 628: ...porization when the engine is cold An exhaust gas recirculation port is also cast into the manifold on 4 1 L D engines for the induction of a metered amount of exhaust gases into the air and fuel mixt...

Page 629: ...IN LINE 6 6A1 3 OIL PRESSURE SENDING UNIT Fig 6A1 1 In Line Engine Lubrication...

Page 630: ...6A1 4 IN LINE 6 Fig 6 A l 2 P Series Engine Front Mount...

Page 631: ...IN LINE 6 6A1 5 Fig 6Al 3 P Series Engine Rear Mount Fig 6 A l 4 C Series Engine Rear Mounts...

Page 632: ...CU IN ENGINE LEFT RIGHT MOUNT FRAME BRACKET 292 CU IN ENGINE LEFT MOUNT FRAME BRACKET ENGINE BRACKET ALL C SERIES WITH L 6 ENGINE 292 CU IN ENGINE RIGHT FRAME BRACKET MOUNT VIEW A Fig 6 A 1 5 C Series...

Page 633: ...Z 7 E N G IN E M O U N T BRACKET ALL K SERIES W IT H L 6 E N G IN E FWD V IE W A X 2 9 2 C U IN R SIDE L E N G IN E M O U N T FR A M E BRACKET ALL K SERIES W IT H L 6 E N G IN E...

Page 634: ...6A1 8 IN LINE 6 Fig 6Al 7 K Series Engine Rear Mount...

Page 635: ...If there is relative movement between a metal plate of the mount and its attaching points lower the engine on the mounts and tighten the screws or nuts attaching the mount to the engine frame or brack...

Page 636: ...ust be replaced 3 Assemble intake and exhaust manifolds using a new gasket by reinstalling the one bolt and two nuts at the center of the manifold to finger tight 4 Position a new gasket over manifold...

Page 637: ...ion interference 2 Place a continuous 1 8 3mm bead of RTV sealant 1052366 or equivalent all around the cover sealing surface Place cover on block while sealant is still wet 4 within 10 minutes Install...

Page 638: ...iver remove the push rod seat retainer 2 Remove the push rod seat and metering valve fig 6A 1 12 3 Remove the plunger ball check valve assembly and the plunger spring 4 Remove the ball check valve and...

Page 639: ...o position in plunger with the blade of a small screw driver fig 6A 1 14 3 Place the plunger spring over the ball retainer and slide the lifter body over the spring and plunger being careful to line u...

Page 640: ...heads on a buffing wheel 5 Clean carbon deposits from head gasket mating surface Inspection 1 Inspect the cylinder head for cracks in the exhaust ports combustion chambers or external cracks to the wa...

Page 641: ...e sending unit wires and install fuel and vacuum lines in clips 7 Fill cooling system 8 Install manifold assembly as previously outlined 9 Install and adjust valve mechanism as previously outlined 10...

Page 642: ...belt s and pulley if so equipped 3 Remove drive pulley from torsional damper 4 Install Tool J 23523 to damper and turn puller screw to remove damper fig 6A 1 21 Installation 1 Coat front cover oil see...

Page 643: ...lifter is on the heel of the cam lobe At this point the push rod will be in its lowest position 4 Set dial indicator on zero then rotate the crankshaft slowly or attach an auxiliary starter switch and...

Page 644: ...stall engine in vehicle Bearings Fig 6Al 25 Replacing Camshaft Front Bearing CAMSHAFT BEARINGS Removal 1 Remove camshaft as previously outlined 2 Remove oil pan and oil pump as described in this secti...

Page 645: ...rm the following steps before continuing a Disconnect clutch cross shaft from left front mount bracket b Remove transmission to bell housing upper bolt c Remove transmission rear mount bolts and insta...

Page 646: ...NG ROD BEARINGS Connecting rod bearings are of the precision insert type and do not utilize shims for adjustment DO NOT FILE RODS OR ROD CAPS If clearances are found to be excessive a new bearing will...

Page 647: ...specifications select a new correct size bearing and remeasure the clearance Be sure to check what size bearing is being removed in order to determine proper replacement size bearing Undersize is mark...

Page 648: ...the crankshaft must be supported upward to remove any clearance from the upper bearing The total clearance can then be measured between the lower bearing and journal To assure the proper seating of t...

Page 649: ...e and inspect the crankshaft 2 Remove the main bearings from the cylinder block and main bearing caps 3 Coat bearing surfaces of new correct size main bearings with oil and install in the cylinder blo...

Page 650: ...off seal mating ends 7 Position tip of tool between crankshaft and seal seat in cylinder case 8 Position seal between crankshaft and tip of tool so that seal bead contacts tip of tool Make sure iuit o...

Page 651: ...nkshaft slightly to disconnect some of the connecting rod and piston assemblies and push them out of the cylinder Fig 6Al 39 Removing Connecting Rod Piston Assembly Fig 6AT40 Removing Piston Pin Disas...

Page 652: ...uare with cylinder wall 3 Measure the space or gap between the ends of the ring with a feeler gage 4 If the gap between the ends of the ring is below specifications remove the ring and try another for...

Page 653: ...ront of engine fig 6A1 44 Use Tool J 8037 to compress the rings fig 6A1 45 Guide the connecting rod into place on the crankshaft journal with Tool J 6305 11 32 Use a hammer handle and light blows to i...

Page 654: ...turer s recommendations for the use of the hone and cleaning and lubrication during honing 2 Occasionally during the honing operation the cylinder bore should be thoroughly cleaned and the piston sele...

Page 655: ...l G Van Code D Engine 1 Disconnect battery negative cable at battery 2 Drain cooling system 3 Remove engine cover 4 Remove air cleaner 5 If equipped evacuate A C system and remove A C compressor 6 Dis...

Page 656: ...housing to engine retaining bolts Torque to specifications If equipped with automatic transmission install torque converter to flex plate attaching bolts Torque to specifications 4 Install engine mou...

Page 657: ...bearing caps with arrows pointing toward front of engine 7 Torque all except rear main bearing cap bolts to specifications Torque rear main bearing cap bolts to 10 12 lbs ft 14 16 N m then tap end of...

Page 658: ...R O D U C T IO N 015 055 SE R V IC E HI LIMIT 010 VIN Designation PISTON PIN L E 3 L25 D IA M E T E R 9270 9273 C L E A R A N C E P R O D U C TIO N 00015 00025 SE R V IC E 001 MAX F IT IN ROD 0008 001...

Page 659: ...Flyw heel Housing C over 80 lb in Oil Pan To Crankcase 1 4 20 80 lb in Oil Pan To Front C over 50 lb in Oil Pum p C o v e r 70 lb in Rocker A rm C over 45 lb in C onnecting Rod C a p 35 lb ft Clutch...

Page 660: ......

Page 661: ...R HEAD The cylinder heads are cast with individual intake and exhaust ports for each cylinder Valve guides are integral and rocker arms are retained on individual studs CRANKSHAFT AND BEARINGS The cra...

Page 662: ...the valve As the lifter body rides down the other side of the cam the plunger follows with it until the valve closes The lifter body continues to follow the cam to its low point but the plunger spring...

Page 663: ...SMALL BLOCK 6A4 3 Fig 6A4 T Engine Lubrication...

Page 664: ...6A4 4 SMALL BLOCK Fig 6A4 2 Engine Lubrication...

Page 665: ...Fig 6A4 3 P Series Engine Mount Bracket...

Page 666: ...ER SHAFT PARKING BRAKE ALL MANUAL TRANSMISSION ALL TURBO HYDRA MATIC 350 ALL MOBILE HOME CHASSIS WITHOUT PROPELLER SHAFT PARKING BRAKE M ANUAL TRANSMISSION WITH PROPELLER SHAFT PARKING BRAKE AUTOMATIC...

Page 667: ...SMALL BLOCK 6A4 7 Fig 6A 4 5 P Series Engine Front Mount...

Page 668: ...6A4 8 SMALL BLOCK...

Page 669: ...SMALL BLOCK 6A4 9 Fig 6A 4 7 K Series Engine Mounts...

Page 670: ...6A4 10 SMALL BLOCK Fig 6A 4 8 C Series Engine Mounts...

Page 671: ...olts then remove mount 5 On P Series with manual transmission and propeller shaft parking brake install new mounting cushions and bolts 6 Install new mount on transmission 7 While lowering transmissio...

Page 672: ...transferred from the old unit fig 6A4 10 1 Clean mating surfaces on manifold and head then install manifold in position and install bolts fingertight 2 Torque manifold bolts to specifications 3 Conne...

Page 673: ...ed in the same locations Installation and A djustm ent Whenever new rocker arms and or rocker arm balls are being installed coat bearing surfaces of rocker arms and rocker arm balls with Molykote or i...

Page 674: ...Grease may be used to hold the locks in place while releasing the compressor tool 4 Using tool J 23994 apply vacuum to the valve cap to make sure no air leaks past the seal 5 Install spark plug and t...

Page 675: ...ith oil and ready for installation Before installing lifters coat the bottom of the lifter with Molykote or its equivalent CYLINDER HEAD ASSEMBLY Removal 1 Remove intake manifold as previously outline...

Page 676: ...eads on a buffing wheel 5 Clean carbon deposits from head gasket mating surface Inspection 1 Inspect the cylinder head for cracks in the exhaust ports combustion chambers or external cracks to the coo...

Page 677: ...8062 c Install oil 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 prop...

Page 678: ...on both the head and the block must be clean of any foreign matter and free of nicks or heavy scratches Cylinder bolt threads in the block and threads on the cylinder head bolts must be clean as dirt...

Page 679: ...terial The installation procedures with proper tool must be followed or movement of the inertia weight section on the hub will destroy the tuning of the torsional damper 1 Coat front cover seal contac...

Page 680: ...ighten screws alternately and evenly while pressing downward on cover so that dowels in block are aligned with corresponding holes in cover Position cover so that dowels enter holes in cover without b...

Page 681: ...All camshaft journals are the same diameter and care must be used in removing camshaft to avoid damage to bearings Inspection The camshaft bearing journals should be measured with a micrometer for an...

Page 682: ...er and installer tool on puller screw with shoulder toward bearing Number one cam bearing oil hole must be positioned so that oil holes are equidistant from 6 o clock position Fig 6A4 36 Removing Cams...

Page 683: ...Figure 6A4 38 1 If the pickup screen and pipe assembly was removed it should be replaced with a new part Loss of press fit condition could result in an air leak and loss of oil pressure Mount the pum...

Page 684: ...c and false readings could occur if placed elsewhere b Install the bearing in the connecting rod and cap c Install the bearing cap and evenly torque nuts to specifications Do not turn the crankshaft w...

Page 685: ...own the crankshaft will rest on the upper bearings and the total clearance can be measured between the lower bearing and journal If the engine is to remain in the vehicle the crankshaft must be suppor...

Page 686: ...main bearing with a feeler gage fig 6A4 45 10 Install a new rear main bearing oil seal in the cylinder block and main bearing cap Replacement Main bearings may be replaced with or without removing the...

Page 687: ...Installation tool must remain in position until seal is properly positioned with both ends flush with block 10 Remove tool being careful not to withdraw seal 11 Install seal half in bearing cap again...

Page 688: ...installed in their original rod and cap 2 Remove piston rings by expanding and sliding them off the pistons Fig 6A4 51 Removing Connecting Rod Piston Assembly Fig 6A4 52 Removing Piston Pin 3 Place co...

Page 689: ...sion rings make sure the M ARKED SIDE IS TO W A RD T H E TOP OF TH E PISTON The top ring is chrome faced or treated with molybdenum for maximum life The second compression ring is a tapered face actin...

Page 690: ...This may be accomplished with a hot water and detergent wash or with a light honing as necessary After cleaning the bores should be swabbed several times with light engine oil and a clean dry cloth 1...

Page 691: ...iston to be fitted should be measured with a micrometer measuring at the center of the piston skirt and at right angles to the piston pin The cylinder should be bored to the same diameter as the pisto...

Page 692: ...ion G Van 1 Place engine transmission assembly into vehicle Sup port engine with blocks of wood between the oil pan and crossmembers 2 Raise vehicle and install engine mounts Retain by inserting engin...

Page 693: ...iator hoses to engine 21 Install water pump pulley and fan to water pump 22 Install accessory drive belts Adjust to specifications 23 Fill cooling system 24 Fill crankcase 25 Connect battery cables an...

Page 694: ...haft or seal 6 Install main bearing caps with arrows pointing toward front of engine 7 Torque all except rear main bearing cap bolts to specifications Torque rear main bearing cap bolts to 10 12 lbs f...

Page 695: ...C T IO N 01 5 055 S E R V IC E HI L IM IT P R O D U C T IO N 010 VIN Designation PISTON PIN L F 3 L G 9 L E 9 LS 9 LT9 D IA M E T E R 9270 9273 C L E A R A N C E P R O D U C T IO N 00025 00035 S E R...

Page 696: ...L F IL T E R B Y P A SS V A L V E 80 LB IN O IL PAN TO C R A N K C A S E 1 4 20 80 LB IN O IL PUM P C O V E R 80 LB IN R O C K E R A R M C O V E R 45 LB IN C A M S H A F T S P R O C K E T 20 LB FT O I...

Page 697: ...thrust bearing All main bearings are lubricated from oil holes that connect to the main oil gallery This runs along the left side of the cylinder case just above the oil pan rail Two additional galler...

Page 698: ...N U T B A L L C LA M P O U T L E T A R M S TU D G A S K E T G U ID E T H E R M O S T A T M A N IF O L D B O L T SPR IN G S E A L S H IM B O LT R O T A T O R PLU G G SKT H E A D G A S K E T B O L T M A...

Page 699: ...16 18 x 3 4 3 BOLT 3 16 LK WA PUMP GASKET GASKET BLOCK SEAL EXTENSION BOLT 3 8 16 x 1 3 4 C R AN KSH AFT WASHER 5 16 Jp PRO LOC M ADAPTER GASKET CONNECTOR COVER SEAL SHAFT FILTER DAMPER BOLT PUMP WAS...

Page 700: ...sign for efficient fuel distribution The carburetor pad is centrally located with a passage running underneath the pad E F E through which exhaust gases are forced to promote faster fuel vaporization...

Page 701: ...R FUEL PUMP PUSH ROD OILING VALVE MECHANISM OILING OIL COOLER BY PASS VALVE OIL FILTER BY PASS VALVE CAMSHAFT LOBE OILING OIL FILTER AND DISTRIBUTOR OILING CRANKCASE AND CRANKSHAFT OILING Fig 6A 5 3 M...

Page 702: ...SHAFT PARKING BRAKE ALL TURBO HYDRA MATIC 350 ALL MOBILE HOME CHASSIS WITHOUT PROPELLER SHAFT PARKING BRAKE MANUAL TRANSMISSION WITH PROPELLER SHAFT PARKING BRAKE AUTOMATIC TRANSMISSION WITH PROPELLER...

Page 703: ...MARK IV 6A5 7 Fig 6A 5 6 P Series Engine Front Mount...

Page 704: ...6A5 8 MARK IV Fig 6 A 5 7 C Series Engine Mounts...

Page 705: ...engine weight to relieve rear mounts 2 Remove crossmember to mount bolts 3 On P Series with manual transmission and propeller shaft parking brake remove mount attaching bolts from frame outrigger and...

Page 706: ...2 Disconnect crankcase ventilation hoses at rocker arm covers 3 Disconnect electrical wiring harness from rocker arm clips 4 Remove carburetor heat stove pipe from right exhaust manifold 5 If the veh...

Page 707: ...mined above the following valves may be adjusted Exhaust 1 3 4 8 Intake 1 2 5 7 c Back out adjusting nut until lash is felt at the push rod then turn in adjusting nut until all lash is removed This c...

Page 708: ...s outlined Disassembly 1 Hold the plunger down with a push rod and using the blade of a small screw driver remove the push rod seat retainer 2 Remove the push rod seat and metering valve fig 6A5 14 3...

Page 709: ...tall the push rod seat retainer press down on the push rod seat and remove the 1 16 drift pin from the oil holes The lifter is now completely assembled filled with oil and ready for installation Befor...

Page 710: ...aust ports combustion chambers or external cracks to the coolant chamber 2 Inspect the valves for burned heads cracked faces or damaged stems NOTICE Excessive valve stem to bore clearance will cause e...

Page 711: ...the locks seat properly in the groove of the valve stem Grease may be used to hold the locks in place while releasing the compressor tool 3 Install the remaining valves Fig 6A5 23 Valve Spring Instal...

Page 712: ...ilable for reseating valves seats The recommendations of the manu facturer of the equipment being used should be carefully followed to attain proper results Regardless of what type of equipment is use...

Page 713: ...g system start engine and check for leaks CRANKCASE FRONT COVER Removal 1 Remove torsional damper and water pump as outlined 2 Remove the two oil pan to front cover attaching screws 3 Remove the front...

Page 714: ...alve mechanism as previously outlined 2 Position indicator with ball socket adapter Tool J 8520 on push rod fig 6A5 35 Make sure push rod is in the lifter socket 3 Rotate the crankshaft slowly in the...

Page 715: ...ign dowel 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 ti...

Page 716: ...the camshaft rear bearing to install the rear intermediate bearing 6 Coat new rear plug O D with 1052080 sealant or equivalent and install flush to 1 32 80mm deep OIL PAN Removal 1 Disconnect battery...

Page 717: ...of extension shaft with drive tang on lower end of distributor drive shaft 2 Install pump to rear bearing cap bolt and torque to specifications 3 Install oil pan previously outlined CONNECTING ROD BE...

Page 718: ...020 undersize Fig 6A5 43 Measuring Connecting Rod Side Clearance Selective fitting of both rod and main bearing inserts is necessary in production in order to obtain close tolerances For this reason...

Page 719: ...the journal is out of round 001 interference between the bearing and journal will result in rapid bearing failure If the flattened gaging plastic tapers toward the middle or ends there is a differenc...

Page 720: ...ng cap 6 Install main bearing cap with arrows pointing toward front of engine 7 Torque all main bearing caps EXCEPT TH E REAR MAIN CAP to specifications Torque rear main bear ing cap to 10 12 lb ft 14...

Page 721: ...ome of the connecting rod and piston assemblies and push them out of the cylinder Disassembly 1 Remove connecting rod bearings from connecting rods and caps If bearings are being reused place them in...

Page 722: ...ed with a dial bore gage or an inside micrometer If clearance is in excess of the 001 wear limit the piston and piston pin assembly should be replaced Assembly 1 Lubricate piston pin holes in piston a...

Page 723: ...rly located c Install upper steel oil ring rail with gap properly located d Flex the oil ring assembly to make sure ring is free If binding occurs at any point the cause should be determined If bindin...

Page 724: ...en fitted to a high limit piston If it is desired to entirely clean up the bore in these cases it will be necessary to rebore for an oversize piston If more than 005 taper or wear they should be bored...

Page 725: ...hoist 10 Drain crankcase 11 Disconnect exhaust pipe at manifold and if so equipped converter bracket at transmission rear mount 12 Remove starter 13 Remove flywheel splash shield or converter housing...

Page 726: ...GEAR REPLACEMENT Remove crankshaft sprocket using Tool J1619 install using Tool J 21058 Installation 1 Install rear main bearing oil seal in cylinder block and rear main bearing cap grooves Install w...

Page 727: ...CTION 005 0065 O SERVICE HI L I M I T P R O D U C T I O N 001 1 L GAP PRODUCTION 015 055 SERVICE HI L I M I T P R O D U C T I O N 010 VIN D e sig n atio n PISTON PIN LE8 DIAM ETER 9895 9898 CLEARANCE...

Page 728: ...I L T E R B Y P A S S V A L V E 8 0 LB IN O I L P A N T O F R O N T C O V E R 5 5 L B IN O I L P U M P C O V E R 8 0 L B IN R O C K E R A R M C O V E R 5 0 LB IN C A M S H A F T S P R O C K E T 2 0 L...

Page 729: ...iesel operation The special alloy steel pre chamber inserts in the cylinder head combustion chambers are serviced separately from the head With the cylinder head removed they can be pushed out after r...

Page 730: ...ertical holes drilled from the cam bores to crank bores Oil flows onto the crankshaft main bearings and provides lubrication for the crankshaft to rotate freely in its bearings As the crankshaft rotat...

Page 731: ...6 2 DIESEL 6A7 3...

Page 732: ...KT TRANS SU PPO R T TRANS SU PPO R T RIGHT HAND ONLY N m FT LBS 45 N m 35 FT LBS 103046 4 FRT C MODELS 55 FT LBS RIGHT HAND TR A N SM ISSIO N ADAPTER TR AN SM ISSIO N SU PPO R T 103047 115 85 FT LBS 3...

Page 733: ...res Refer to figure 6A7 4 for proper bolt torque Removal and Installation Left Side 1 Disconnect battery 2 Remove dipstick tube nut 3 Remove dipstick tube 4 Disconnect glow plug wires 5 Remove glow pl...

Page 734: ...f installation reverse removal procedures ROCKER ARM COVER Fig 6A7 6 Rem oval 1 Remove intake manifold as previously outlined 2 Remove injection lines as outlined in Section 6C6 5 and 7 injection line...

Page 735: ...Remove rocker arm assemblies 2 Rotate engine so piston is at top dead center for each cylinder or install air line adapter to glow plug port and apply compressed air to hold valves in place 3 Install...

Page 736: ...valve springs figure 6A 7 10 and remove J 8 0 8 9 valve keys Release the compressing tool and remove rotators or spring caps springs and spring damper then remove oil seal and valve spring shims 2 Rem...

Page 737: ...ant because 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...

Page 738: ...aces are sealed when the gaskets are made using a newly developed method and material This sealer is accurately printed on the surface of the gasket in the exact quantity required and provides the des...

Page 739: ...al under the check valve will cause malfunctioning of the lifter Close inspection should be made for nicks burrs or scoring of parts If either the roller body or plunger is defective replace with a ne...

Page 740: ...or equivalent as shown in figure 6A7 21 Apply R T V sealer 1052366 to bottom portion of front cover which attaches to oil pan 2 Install front cover 3 Install baffle 4 Install injection pump making su...

Page 741: ...aside 19 Remove rocker arm covers as previously outlined 20 Remove rocker arm shaft assembly and push rods Place parts in a rack so they may be reinstalled in the same location 21 Remove thermostat ho...

Page 742: ...ring and install puller screw through pilot 3 Install remover and installer tool J 6098 11 for 2 3 4 bearing with shoulder toward bearing making sure a sufficient amount of threads are engaged 4 Using...

Page 743: ...orque bolts to specifications 3 Lower engine 4 Install engine mount through bolt 5 Install transmission dust cover 6 Lower vehicle 7 Refill oil 8 Connect battery OIL PUMP Rem oval 1 Remove oil pan as...

Page 744: ...od cap and bearing Before removal of connecting rod cap mark the side of the rod and cap with the cylinder number to assure matched reassembly of rod and cap 2 Inspect the bearing for evidence of wear...

Page 745: ...talled tap each rod lightly parallel to the crankpin to make sure they have clearance Fig 6 A 7 3 4 M e a s u rin g G a g in g Plastic 9 Measure all connecting rod side clearances see specifications b...

Page 746: ...earing or journal Be sure to measure the journal with a micrometer if the flattened gaging plastic indicates more than 001 difference 6 If the bearing clearance is within specifications 1 2 3 4 0018 0...

Page 747: ...11 Install the rear main bearing cap and torque to 95 N m 70 ft lbs 12 Remove the rear cap and check the plastic gage for bearing clearance If out of specification recheck the ends of the seal for fra...

Page 748: ...t checked the boring bar may be tilted which would result in the rebored cylinder wall not being at right angles to the crankshaft 2 The piston to be fitted should be measured with a micrometer measur...

Page 749: ...ter installing the piston pin retaining rings that the rings be rotated to make sure they are fully seated in their grooves RINGS The pistons have three rings two compression rings and one oil ring Th...

Page 750: ...handle and light blows to install the piston into the bore Hold the ring compressor firmly against the cylinder block until all piston rings have entered the cylinder bore 4 Install the bearing caps...

Page 751: ...N m 10 12 in lbs then tap end of crankshaft first rearward then forward with lead hammer This will line up rear main bearing and crankshaft thrust surface 5 Install connecting rod bearings 6 Reverse r...

Page 752: ...detent cable If fuel filters were removed they must be filled with 41 Remove engine support transmission clean diesel fuel to avoid long cranking Installation To install reverse the removal procedure...

Page 753: ...41 a r uiameter 5 74 912 74 936 1 n n a Taper 005 Max a l Out Of Round 005 Max Main Bearing Clearance 1 2 3 4 045 083 5 055 093 Crankshaft End Play 0 05 0 18 C Diameter 60 913 60 939 r a Taper 005 Max...

Page 754: ...a p B o lts 143 158 128 143 59 74 80 100 R o c k e r A r m S h a f t B o lt to H e a d 30 37 40 50 18 27 6 10 18 27 190 220 25 37 34 50 F a n D r iv e n P u lle y to H u b B o l t s 15 20 20 27 15 20...

Page 755: ...valve In this manner the radiator will keep itself full at all times COOLANT LEVEL The need for additional coolant can be detected by observing the level of coolant in the see through reservoir while...

Page 756: ...coolant outlet on small block and Mark Thermostats are designed to open and close at predetermined temperatures and if not operating properly should be removed and tested The thermostat for the 6 2L...

Page 757: ...DJUSTMENT BOLT P V0T C B O L T ADJUSTMENT BOLT PIVOT BOLT IN L IN E L 2 5 py ADJUSTMENT BOLT PIVOT BOLT ADJUSTMENT BOLT S M A L L B L O C K ADJUSTMENT BOLT PIVOT BOLT M K IV Iview fA 100998 Fig 6B 4 G...

Page 758: ...M E N T N U T P IV O T B O LT Vi A D JU S T M E N T BOLT j A D JU S TM E N T B O LT P IV O T B O LT A N D N U T SMALL BLOCK P G SMALL BLOCK EXCEPT P G ENGINE STUDS ADJUSTING NUT A D JU S T M E N T BO...

Page 759: ...E A D JU S T IN G BO LT SUPPORT A D JU S T M E N T B O LTS I P IV O T BOLT LOOSEN 4 A N D T U R N A D JU S T IN G B O LT ALL WITH SMALL BLOCK C 69 SMALL BLOCK EXCEPT G LS9 LT9 L69 VIEW SMALL BLOCK G M...

Page 760: ...6B 6 ENGINE COOLING Fig 6B 7 A C and A I R Adjustment...

Page 761: ...verheat and or cooling system noise may be caused by restrictions in the cooling system Components which may be prone to this condition are cylinder head water pump block thermostat housing and inlet...

Page 762: ...e is a rough grating feel as the fan is turned the clutch should be replaced 2 Looseness Under various temperature conditions there is a visible lateral movement that can be observed at the tip of the...

Page 763: ...T LIGHT OR TEMP GAGE FURTHER DIAGNOSTIC CHECKS SHOULD NOT BE REQUIRED 4 IS OVERHEATING OCCURRING AFTER PROLONGED DRIVING IN SLOW CITY TRAFFIC TRAFFIC JAMS PARADES ETC IF ANSWER IS YES INSTRUCT OWNER O...

Page 764: ...nary or of a major nature Listed on Sheet 3 are two groups of problem areas that should be checked in the order listed COOLANT LOSS CHECK PRESSURE CAP Use Pressure Cap Tester Per Chassis Service Manua...

Page 765: ...able at battery 2 Drain cooling system 3 Remove accessory drive belts 4 Remove fan to water pump hub or fan clutch to water pump hub attaching bolts or nuts and remove fan and pulley 5 Remove generato...

Page 766: ...touch when bolts are torqued Fig 6B 9 G Van Radiator Mounting THERMOSTAT Rem oval All Engines 1 Disconnect battery negative cable at battery 2 Drain cooling system until radiator coolant level is belo...

Page 767: ...Installation 1 Place radiator in vehicle and install radiator to radiator support retainers 2 Install fan shroud 3 Connect overflow hose to radiator 4 Connect radiator hoses to radiator 5 Connect batt...

Page 768: ...dures Fig 6 B 1 4 G V a n Fan S h ro u d FAN SHROUD FIG 6B 14 THRU 6B 17 Rem oval CK Series 1 Disconnect battery negative cable 2 Remove fan shroud to radiator retainer attaching screws 3 Remove fan c...

Page 769: ...l windshield washer jar and bracket 7 If equipped with A C install vacuum reservoir 8 Connect battery cable FA N FA N CLUTCH Rem oval All 1 Remove battery negative cable at battery 2 Remove radiator f...

Page 770: ...move recovery bottle retaining fasteners and remove bottle from vehicle Installation When installing coolant recovery bottle make sure unit is clean and free from contamination If needed wash bottle w...

Page 771: ...ENGINE COOLING 6B 17 Fig 6B 20 Engine O il C o o le r 6 2L Diesel...

Page 772: ...APT ASM O IL C O O LER X ASM FR T C M E M B E R LW R M TG B R A C K E T LH SID Ev M EM BER A D A P T ASM R E TU R N HOSE R AD SUPPORT LWR R EIN F VIEW o i l f i l t e r A D A P T E R SUPPLY HOSE Iv i...

Page 773: ...FACTORY PROCEDURE FOR TEMPORARILY REMOVING PLUGS CAP ETC FOR PURPOSES OF SERVICING THE PRODUCT MUST BE STRICTLY FOLLOWED AND WHEREVER PRACTICABLE RETURNED TO THE ORIGINAL INTENT OF THE DESIGN GASOLINE...

Page 774: ...ned in the O wner s Manual A djust the choke th erm o static coil to specification Check the choke valve and or linkage as necessary Replace parts if defective If caused by foreign m aterial and gum c...

Page 775: ...s Check rou ting of all hot air parts Check con d itio n and routing of all vacuum hoses correct as necessary Check fo r free m ovem ent o f fast idle cam Clean an d or realign as necessary A djust bo...

Page 776: ...rect as necessary Check fuel pum p pressure and volum e Check fo r partially plugged fuel in let filte r Replace if d irty Check flo a t mechanism A djust as specified Check flo a t and needle and sea...

Page 777: ...arm If foreign m aterial is fo und in the carburetor clean the fuel system and carburetor Replace fuel filte r as necessary Replace as necessary Clean carburetor see Section 6C1 Readjust per specifie...

Page 778: ...uting Clogged or defective PCV system Choke sticking Clogged or inoperative power system Check the pum p discharge bail fo r proper seating and location Clean and blow o u t w ith compressed air Check...

Page 779: ...leaner system Refer to transm ission diagnosis Check ig nition system See Section 6D Refer to H E I diagnosis Check fo r restrictions Correct as required C orrect th ro ttle linkage to obtain w ide op...

Page 780: ...ed and cleaned Check fuel pum p pressure and volum e inspect lines fo r leaks and restrictions See F U E L SYSTEM D IA G N O S IS Section 6 Check fo r restrictions C orrect as required Check co n d it...

Page 781: ...and intake m anifold for leakage Check carburetor m ounting bolt torque Check vacuum and mechanical advance Check fuel tank fuel lines and fuel pump for any fuel leakage Check fuel inlet needle and se...

Page 782: ...ro l hoses 6 B o w l ve n t hose m is ro u te d 7 A ir clean er o r a ir cleaner gasket im p ro p e rly seated 8 L e a kin g o r in o p e ra tiv e ta n k pressure c o n tro l valve 1 T ig h te n fu e...

Page 783: ...k ne ck as re q u ire d C o lla p se d Fuel T a n k 1 Plugged o r p in c h e d v a p o r p ip e o r hoses d e fe c tiv e cap 2 C a n iste r filt e r p lug ged d e fe c tiv e cap C he ck all lin e s f...

Page 784: ......

Page 785: ...u t F ig 6 C 1 2 If re p la c in g th e float bow l follow th e m a n u f a c t u r e r s in s tru c tio n s c o n ta in e d in th e service p a c k a g e so t h a t th e id en tificatio n n u m b e...

Page 786: ...R EW POWER PISTON ACTUATING LINKAGE POWER PISTON V A C U U M Fig 6 C l 6 P o w e r E nrichm ent System T h e th ro ttle lever h a s a s p u n in plastic b u sh in g this is u se d as th e b e a rin g...

Page 787: ...v o ltag e is a p p ro x im a te ly 12 15 volts re p la c e th e e lectric ch o k e unit 9 I f th e v o lta g e is low o r z e ro c h e c k all w ire s a n d c o n n e c tio n s I f th e c o n n e c t...

Page 788: ...t be c o m p le te ly in stalled d u rin g a c tu a l setting R e fe r to F ig u re 6 C 1 9 for fast idle a n d idle speed a d ju s tm e n ts IDLE M IXTURE ADJUSTM ENT LEAN DROP 1 S e t p a rk in g b...

Page 789: ...ion It is good sh o p p ra c tic e to fill c a r b u r e to r bowl b efore in stallin g c a rb u re to r T h is re d u ce s s tra in on s ta rtin g m o to r a n d b a tte ry a n d re d u c e s th e po...

Page 790: ...ta in e r kit is re q u ire d to a tt a c h ch o k e cover to ch o k e hou sin g In sta ll p ro p e r re ta in e rs a n d riv ets c o n ta in e d in k it u s in g s u ita b le b lin d riv et in stalli...

Page 791: ...d p lac e on c le an b en ch A ir h o rn to float bow l g a sk e t c a n r e m a in on bow l for re m o v a l la te r F ig 6 C 1 16 Fig 6 C 1 1 6 A ir H orn Rem oval Disassembly 1 If re q u ire d th e...

Page 792: ...u ntil ta n g on rod slides o u t o f n o tch in lever 7 R e m o v e a c tu a to r lever fro m low er en d of a c c e le ra to r p u m p link in s a m e m a n n e r 8 P u sh d o w n on a c c e le r a...

Page 793: ...all p assag es in c a s tin g s w ith c o m p re ss ed air D o not pass drills th ro u g h je ts or p assag es 3 E x a m in e float n e e d le a n d s e a t a s s e m b ly for w e ar Install a new fa...

Page 794: ...to r lever to en d o f th ro ttle sh a ft hold p o w e r piston a sse m b ly d o w n a n d slid e u p p e r e n d o f c u r v e d p o w e r p isto n a c tu a to r link into low er e n d o f p o w e r...

Page 795: ...t t a c h i n g sc re w s for th e c h o k e v a c u u m b r e a k a s s e m b ly h a v e t a p e r e d h e a d s for lo c a tin g c h o k e d ia p h r a g m b ra c k e t M a k e su re to use th ese...

Page 796: ...E O P E N P U SH D O W N W A R D O N M E T E R IN G R O D A G A IN S T S P R IN G T E N S IO N T H E N S L ID E M E T E R IN G R O D O U T O F S L O T IN H O L D E R A N D R E M O V E F R O M M A IN M...

Page 797: ...H 1 S Q U A R E P IE C E O F M A S K IN G T A P E R E M O V E A F T E R A D J U S T M E N T H O L D G A U G E V E R T IC A L U S E O U T S ID E V A C U U M S O U R C E T O S E A T D IA P H R A G M P...

Page 798: ...mm Inches mm Inches mm Inches mm Inches m m Inches 1 7 0 8 1 0 0 9 M E 8 7 1 1 3 2 2 3 0 9 0 7 0 2 7 5 1 0 0 4 0 0 1 3 2 5 2 0 1 7 0 8 1 3 0 9 M E 8 7 1 1 3 2 2 3 0 9 0 7 0 2 7 5 1 0 0 4 0 0 1 3 2 5...

Page 799: ...e d A n a d ju s ta b le p a rt th ro ttle screw is used in th e float bow l to aid in re fin e m e n t o f fuel m ix tu re s for good em ission c o n tro l T h is screw is p re s et a t th e fa cto...

Page 800: ...ese o p e ra tin g p arts A lso the s e c o n d a ry th ro ttle b ore a n d valve a re c o ated w ith a special g r a p h ite c o m p o u n d for m in im u m a ir lea k ag e p ast th e valve for good...

Page 801: ...JUSTED SECONDARY M ETERING ROD SECONDARY METERING JET MAIN PRIM ARY METERING ROD P O W E R P IS T O N P O W E R P IS T O N S P R IN G V A C U U M C H A N N E L T O P O W E R P IS T O N FUEL WELL SECON...

Page 802: ...n g in e a n d d e te r m in e tim e for ch o k e b la d e to r e a c h full o p e n p o sitio n S t a r t tim e r w h e n e n g in e sta rts 5 If ch o k e b la d e fails to op en fully w ith in 3 1 2...

Page 803: ...ABEL SOLENO ID ENER G IZED A T IN DRIVE M T IN NEUTRAL r RECO NNECT SOLENO ID ELECTRICAL LEAD AFTER AD JUSTM EN T TURN SO LENO ID SCREW TO A DJUST CURB IDLE SPEED TO SPECIFIED RPM SOLENOID ENERG IZED...

Page 804: ...S MORE THAN 1 5mm FROM SPECIFICATIONS REMOVE AIR HORN AND ADJUST FLOAT LEVEL TO SPECIFI CATIONS FOLLOWING NORMAL ADJUSTMENT PROCEDURES T IF MECHANICAL SETTING IS FOUND TO BE WITHIN SPECIFIED TOLERANCE...

Page 805: ...s valu e given V ehicle E m ission C o n tro l In fo rm a tio n label 15 R e ch e ck e n ric h e d speed w ith p ro p a n e If not w ithin specification re p e a t a d ju s tm e n t b e g in n in g w...

Page 806: ...s fro m en d of a ir v a lv e ro d N e w r e ta in i n g clip is r e q u ir e d for re ass em b ly R e m o v e p lastic b u sh in g used on rods a n d re ta in for la te r re use 5 R e m o v e s e c o...

Page 807: ...CARBURETOR MODEL 2SE 6C2 9 Fig 6C2 6 Typical 2SE Carburetor Assembly...

Page 808: ...3 R e ta in e r In te rm e d ia te C h o k e S h a ft L in k 53 C lip C am S cre w 24 Vacuum Break and Bracket Assembly S e c o n d a ry 54 S cre w C am 25 C h o k e C o v e r an d C o il A s s e m b...

Page 809: ...rivet h ead a n d drill only e n o u g h to re m o v e rivet h ead F ig 6C 2 1 1 A fte r re m o v in g rivet h e ad s a n d re ta in e rs use a d rift a n d sm all h a m m e r to drive th e r e m a in...

Page 810: ...edle plug m a n ifo ld side w ith a h a c k saw T h e cu ts sh o u ld re ac h d o w n to th e steel plu g b u t sh o u ld not e x te n d m o re th a n 1 8 b ey o n d th e lo ca to r points T h e d ist...

Page 811: ...n g for p r o p e r in s ta lla tio n te n s io n a g a in s t a ir valve lever E Rough Idle 1 In s p e c t g a s k e t a n d g a s k e t m a t i n g s u r f a c e s on c as tin g s for d a m a g e to...

Page 812: ...tin g su rfa ce 9 U sin g a w id e b la d e s c rew d riv e r install m a in m e te rin g je t a n d th e float valve se a t w ith g a s k e t into b o tto m of float bowl T ig h te n je t a n d s e...

Page 813: ...m th e original stak in g s 2 Install fast idle c a m rod in low er hole o f v a c u u m b re a k a n d ch o k e lever a lig n in g s q u irt on rod w ith sm all slot in lever s q u irt e n d o f rod...

Page 814: ...se to p r im a r y side v a c u u m b re a k a s s e m b ly a n d th ro ttle b o d y tube 11 P e r f o r m c h o k e coil lev e r a d j u s t m e n t p r o c e d u r e as specified in c a r b u r e to...

Page 815: ...NERS H O LD IN G CH O K E COVER AND CO IL ASSEM BLY IN PLACE UNLESS NECESSARY TO C H EC K TH E CH O K E CO IL LEVER A D JU STM EN T IF RIVETS A N D COVER ARE REM O VED A CHO KE STAT COVER RETAINER KIT...

Page 816: ...E LIN G B U B B LE C E N T E R E D J r C H O K E V A LV E Z C L O S E D FA S T ID LE S C R E W M U S T BE ON HIG H STEP O F F A S T ID LE C A M M A G N E T F IG U R E 1 D U R IN G R E A D IN G O F A...

Page 817: ...SPECIFIED ANGLE SEE SPECS P U M P P L U N G E R C U P F O R S E A L F I G U R E 1 D U R IN G R E A D IN G O F A N G L E G A U G E L IG H T L Y P U S H C L O C K W IS E O N IN T E R M E D IA T E C H O...

Page 818: ...AND HOLD IN POSITION W ITH RUBBER BAND HO LD PRIMARY THRO TTLE VALVE W IDE OPEN 101444 Fig 6 C 2 2 5 U n lo a d e r A d ju stm e n t HOLD CHOKE VALVE WIDE OPEN BY PUSHING COUNTER CLOCKWISE ON IN T E...

Page 819: ...f t 1 15 30 37 o CN 100 17082342 4 5 f t 1 15 30 37 42 30 17082344 4 5 f t 1 15 o O CO 37 o CN 30 17082345 4 5 f t 1 15 o o CO 37 o CN 100 17082431 4 5 f t 1 15 24 o OO CO 42 70 17082433 4 5 f t 1 15...

Page 820: ......

Page 821: ...D u r in g off idle a n d p a r t t h r o tt l e o p e r a tio n fuel m e te rin g is a cc o m p lish e d by tw o ta p e re d p r im a r y m e te rin g ro d s o p e r a t in g in m e t e r i n g je ts...

Page 822: ...T R IC T IO N ID LE M IX T U R E NEED LE IDLE SYSTEM W LD EMISSION E G R E X H A U S T G A S R E C IR C U L A T IO N I FIX E D IDLE A IR BY P A S S PULL OVER ENRICHMENT P O E FUEL FEEDS 2 ID LE A IR B...

Page 823: ...V A C U U M S E C O N D A R Y L O C K O U T FA S T ID LE LEVER C A M FO LL O W E R FA S T ID LE A D J U S T IN G SC R E W PUMP SYSTEM W LD EMISSION CHOKE SYSTEM M4ME FEDERAL ELECTRIC CHOKE TYPE AIR V...

Page 824: ...u ld be o ff a n d all v a c u u m lines a n d all e le ctrica l leads c o n n ec te d S et p a rk in g b ra k e a n d block d riv e w heels A ir c le a n e r c a n be rem o v e d for se t u p a cces...

Page 825: ...id m a y not be stro n g e n o u g h to op en th e th ro ttle b u t th e p lu n g e r sh o u ld move 6 If p lu n g e r d o e s n o t m o v e in a n d o u t a s le a d is d isc o n n ec te d a n d c o...

Page 826: ...LLY EXTEND TURN IDLE SPEED SC R EW TO SET CURB IDLE SPEED TO S P EC IFIC A TIO N S A C OFF SEE EM ISSIO N LA BEL A C IDLE SPEED ADJUSTMENT ON VEHICLE 101362 Fig 6 C 4 6 ld le S peed A d ju stm e n t W...

Page 827: ...Enrichment d ro p s d u e to over richness N o te m a x im u m e n g in e speed e n ric h e d sp eed If rich sp eed d ro p c a n n o t be o b ta in e d c h ec k for e m p ty c a r tr id g e or p ro p...

Page 828: ...e a ir c lean er 2 C o n n e c t t a c h o m e te r a n d v a c u u m g a g e to engine 3 A s a p re lim in a ry a d ju s tm e n t tu r n idle m ix tu re needles in lightly to se a t a n d b a ck o u...

Page 829: ...b e fo re in stallin g c a r b u r e to r 3 Install c a r b u r e to r w ith new in su lato r a n d tig h te n bolts to c o rre c t to rq u e S e e C a r b u r e to r M o u n tin g T o r q u e 4 C o n...

Page 830: ...6C4 10 CARBURETOR MODEL M4ME M4MC 101368 Fig 6C4 12 M 4M C M 4M E Carburetor Exploded View...

Page 831: ...ring Id le S to p S crew 2 4 In t C hoke S h a ft Lever 66 Idle Speed S o le n o id B ra c k e t A sse m b ly 25 Cam Fast Idle 67 Idle Load C o m p e n s a to r B ra c k e t A sse m b ly 26 Seal C h o...

Page 832: ...o u ld be m a d e to c h a n g e th e a d ju s tm e n t in th e field If float bowl re p la c e m e n t is re q u ire d d u r in g se rv ice th e n e w b ow l a s s e m b ly will be s u p p lie d w i...

Page 833: ...on th e ch o k e cover h o t a ir ch o k e m o d el 4 R e m o v e ch o k e h o u sin g a s s e m b ly fro m float bow l by re m o v in g re ta in in g screw a n d w a s h e r inside th e ch o k e h o...

Page 834: ...u n d c o n d itio n s If w o rn lever sh o u ld be re p la ce d 4 In sp ect p lastic p a rts for c rac k s d a m a g e etc R e p la c e as n ecessary 5 C h e c k re p a ir or re p la c e th e follow...

Page 835: ...k e t a n d inlet n u t a n d tig h te n n u t to 24 N m 18 ft lbs W h e n in stallin g a service r e p la c e m e n t filter m a k e su re th e filter is th e ty p e th a t in clu d es th e c h e c k...

Page 836: ...e ta in e r is se a te d in recess in bowl a n d th e top is flush w ith th e to p of th e bow l castin g If n ecessary using a d rift p u n c h a n d sm a ll h a m m e r ta p r e ta in e r lightly in...

Page 837: ...a r o f the c a r b u r e t o r a n d th e n u m b e r on th e lev er will face o u tw a rd 8 Completion of Choke Assembly A fte r the inside ch o k e coil lever fast idle c a m c h o k e ro d a n d...

Page 838: ...R D O W N T O A D J U S T T O E G A U G IN G P O IN T 3 1 6 B A C K F R O M T O E f 5 J V IS U A L L Y C H E C K F L O A T A L IG N M E N T A F T E R A D J U S T IN G P U M P A D J U S T M E N T GAUG...

Page 839: ...PLUG G AU G E V IF N E C E S S A R Y DRILL OUT AND REMOVE R IVETS REM O VE THE T H E R M O S T A T IC C O V E R AND C O IL A SSEM BLY FROM C H O K E H O U SIN G P L A C E F A ST IDLE CAM F O L L O W E...

Page 840: ...E C H O K E C O IL LEVER AND FAST IDLE A D JU S T M E N T B E N C H OR O N T H E CAR S E TTIN G NOTE DO N O T REM O VE R IVETS AND C H O K E COVER TO PER FO R M TH IS A D JU S TM E N T USE RUBBER BAND...

Page 841: ...TER 6 S E A T C H O K E VACUUM DIAPHRAGM USIN G VACUUM SO U R C E ANY AIR B L E E D S IN DIAPHRAGM C O V ER M UST BE SEA LED A LSO ON FOUR B A R R E L C A R B U R E T O R S T H E AIR VALVE ROD M UST...

Page 842: ...OR VACUUM BREAK LEVER TANG HOLD IN POSITION WITH RUBBER BAND UNITS WITH BUCKING SPRING MUST HAVE THE PLUNGER EXTENDED TO MAXIMUM LENGTH BUCKING SPRING COMPRESSED WITH DIAPHRAGM SEATED 8 TO ADJUST TUR...

Page 843: ...ASSEMBLY IN HOUSING 8 CLOSE CHOKE VALVE BY PUSHING UP ON TANG ON V A C U U M BREAK LEVER HOLD IN POSITION W ITH RUBBER BAND 9 HOLD PR IM A R Y THROTTLE VALVES W IDE OPEN 10 TO AD JU ST BEND TANG ON F...

Page 844: ...U S T 01 5 M A X C L E A R A N C E S E C O N D A R Y L O C K O U T L E V E R T S ID E C L E A R A N C E S E C O N D A R Y C L O S IN G A D J U S T M E N T 3 L E V E R A G A IN S T T A N G 2 C H O K E...

Page 845: ...S T H E N T U R N A D J U S T IN G S C R E W C L O C K W IS E S P E C IF IE D N U M B E R O F T U R N S T IG H T E N LO C K S C R E W I L O O S E N L O C K S C R E W U S IN G S P E C IA L H E X W R E...

Page 846: ...7 9 32 4 6 0 6 025 24 34 22 7 8 39 17082223 10 13 32 IN N E R 7 9 32 46 0 6 025i 24 34 22 7 8 39 17082224 10 13 32 IN N E R 7 9 32 46 0 6 025 24 34 22 7 8 39 17082225 10 13 32 IN N E R 7 9 32 46 0 6...

Page 847: ...ARBURETOR PART NO PROPANE ENRICHMENT SPEED 17082221 150 RPM 17082230 20 RPM 17082293 100 RPM 17082222 50 RPM 17082231 100 RPM 17082506 50 RPM 17082223 100 RPM 17082234 20 RPM 17082508 50 RPM 17082224...

Page 848: ......

Page 849: ...eatly reduces any possibility of vapor lock by keeping cool fuel from the tank constantly circulating through the fuel pump DIAGNOSIS Complete diagnosis of all possible causes of the trouble prior to...

Page 850: ...d line is clogged or fuel pump is inoperative Before condemning the fuel pump disconnect feed line at both ends and blow through it with air hose to make certain that fuel pump is operating within spe...

Page 851: ...e and ground lead 3 Remove strap supports lines vent and clip 4 Loosen clamps from filler neck and vent line 5 Remove strap bolts and lock washers from tank front and rear locations on inside frame ra...

Page 852: ...antisqueak material 9 Lower vehicle and remove from hoist Frame Mounted Fuel Tank P Model Figs 6C5 15 and 16 1 Drain tank 2 Remove filler neck 3 Disconnect meter unit fuel line and wiring 4 Remove bol...

Page 853: ...it and inspect condition of filter If filter is contaminated a new filter should be installed upon reassembly 6 Complete draining of tank by rocking it and allowing fuel to run out of tank unit hole 7...

Page 854: ...nk unit wires and all fuel lines except pump to carburetor line see Removal of Tank for proper procedure 11 Connect a hose to fuel line at carburetor insert other end of hose into a one gallon fuel ca...

Page 855: ...secured to the underbody with clamp and screw assemblies Flexible hoses are located at fuel tank fuel vapor and return lines and fuel pump The pipes should be inspected occasionally for leaks kinks o...

Page 856: ...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 engine operation With this closed system it is...

Page 857: ...ne should exhibit a plugged condition 5 If the valve is not closed remove the control vacuum line and check for vacuum If no vacuum is present check hose for restriction or vacuum leak Repair or repla...

Page 858: ...ing accelerator pedal and if any binding is present check routing of cable ACCELERATOR CONTROL CABLE Refer to figures 6C5 18 through 6C5 21 for removal and installation of accelerator control cable AC...

Page 859: ...control cable thru slot in Rod Install retainer being sure it is seated i m m o w J Care must be used in pressing the retainer into hole in Rod to assure cable is nnt kinked or damaged in any way P3 V...

Page 860: ...slot in rod Install retainer being sure it is seated RETAINER CAUTION Care must be used in pressing the retainer into hole in rod to assure cable is not kinked or damaged in any Way REINFORCEMENT rod...

Page 861: ...LEANER BRIDGE 70 FAST IDLE CAM 50 THROTTLE BODY TO BOWL 180 CHOKE LEVER 25 NEEDLE SEAT 45 PUMP LEVER i G O 0 METERING JET 40 Loctite AVV or equivalent M 2M M 4M C A R B U R E TO R T O R Q U E SCREW IN...

Page 862: ...9 043 37 234 10 049 38 243 11 054 39 251 12 060 40 260 13 066 41 269 14 071 42 277 15 077 43 287 16 083 44 295 17 090 45 304 18 096 46 314 19 103 47 322 20 110 48 332 21 117 49 341 22 123 50 350 23 1...

Page 863: ...anifold Both filters remove foreign material which could damage the injection pump or clog the injector nozzle From the filter the fuel is pumped to the injection pump The 6 2 liter injection pump is...

Page 864: ...speeds are to be set within 25 RPM of specified value 2 Set parking brake and block drive wheels 3 Engine must be at normal operating temperature Air cleaner should be on and all accessories should be...

Page 865: ...otate the throttle switch clockwise facing throttle switch until continuity just occurs high meter reading across the IGN and EGR terminals or wires Hold switch body at this position and tighten mount...

Page 866: ...e pump This procedure is necessary only on a hot engine as the circuit will always be closed when the engine is cold INJECTIO N PUM P FUEL LINES Figs 6 C 6 6 and 6C 6 7 When lines are to be removed cl...

Page 867: ...injection pump and detent cable where applicable Fig 6C6 10 7 Disconnect necessary wires and hoses at injection pump 8 Disconnect fuel return line 9 Disconnect fuel line at pump 10 Remove A C hose ret...

Page 868: ...7 Install fuel line at pump torque to 25 N m 20 ft lbs 8 Install fuel return line 9 Connect necessary wires and hoses 10 Connect accelerator cable 11 Connect injection lines 12 Install intake manifol...

Page 869: ...old fixture flange nut to be finger tight 6 Torque large bolt 18mm head counterclockwise toward left bank to 50 ft lbs Tighten 10mm nut 7 Insure crankshaft has not rotated and fixture did not bind on...

Page 870: ...ress lever of manual test stand slowly until gage reads a pressure of 95 bar 1380 psi Observe tip of nozzle A drop may form but not drop off within a period of 10 seconds 5 Replace the nozzle holder a...

Page 871: ...cover should move the linkage If not the solenoid must be replaced Minimum voltage across solenoid terminals must be 12 0 16 Reinstall the cover and repeat Step 11 12 13 and 14 17 Reinstall the fuel...

Page 872: ...HEAD AND ROTOR ASSEMBLY CAM ADVANCE SCREW GUIDE STUD HEAD LOCKING SCREWS PISTON HOLE PLUG POWER SIDE ADVANCE SCREW HOLE PLUG PISTON HOLE PLUG TRIMMER SIDE HEAD LOCATING SCREW 103148 Fig 6C6 14a lnject...

Page 873: ...D HOUSING PRESSURE ADVANCE CAM COLD ADVANCE TER M INAL Fig 6C6 17 lnjection Pump Housing Right Side View Typical housing for any evidence of damage or unusual wear and leaks Remove the pump and send t...

Page 874: ...the pink wire With the ignition switch in the run position the solenoid in the cover should move the linkage If not the solenoid must be replaced Minimum voltage across solenoid terminals must be 12 0...

Page 875: ...rews and seal 7 Using a twisting motion remove the hydraulic head assembly Remove the O ring seal Installation 1 Install a new hydraulic head seal and lube it 2 Install the head assembly into the pump...

Page 876: ......

Page 877: ...se ELECTRIC CHOKE HEATER CHECKING PROCEDURE 1 Allow choke to cool so that when throttle is opened slightly choke blade fully closes This check must be performed with engine not running and at an ambie...

Page 878: ...Test Voltage Action 1 8 to G 7 volts or more If there are 7 volts or more at the starter solenoid terminal the starter is faulty If not the wire from connector terminal 8 to the solenoid is faulty Un...

Page 879: ...IN E S A N D B A T T E R IE S A T R O O M O R N O R M A L O P E R A T IN G T E M P E R A T U R E S IT A L S O A S S U M E S T H E R E A R E N O E N G IN E D E F E C T S W H IC H W O U L D C A U S E C...

Page 880: ...ery is completely sealed except for two small vent holes in the side These vent holes allows the small amount of gas produced in the battery to escape The battery has the following advantages over con...

Page 881: ...ssive or prolonged charging a broken case excessive tipping or normal battery wearout When finding a battery in this condition it may indicate high charging voltage caused by a faulty charging system...

Page 882: ...s and drops off to 10 amperes after 1 hour the average current for that hour was 20 amperes The actual boost charge was 20 ampere hours The sealed battery can be fast charged or slow charged with ordi...

Page 883: ...be observed 1 Hydrogen gas is produced by the battery A flame or spark near the battery may cause the gas to ignite 2 Battery fluid is highly acidic Avoid spilling on clothing or other fabric Any spil...

Page 884: ...ME BEARING BAT TERM INAL ROTOR STATOR ASSEMBLY 100148 Fig 6D 1C 10SI Generator r 2 IN D IC A T O R S W IT C H L A M P rsMMM l L 1rn R 2 D3i R 3 L rh _______________ TR1 R E G U L A T O R F IE L D IR O...

Page 885: ...he rectifier bridge as covered in the GENERATOR REPAIR Section This condition will cause an undercharged battery 2 Switch On Lamp Off Engine Stopped This condition can be caused by the defects listed...

Page 886: ...black lead to BAT terminal wires and red lead to BAT terminal 4 Connect battery ground strap 5 Turn on all accessories limits on high beam and blower on high speed 6 Run engine as required to obtain m...

Page 887: ...n 6 D 2 If an obvious overcharge condition exists as evidenced by excessive spewing of electrolyte proceed to Disassembly section of Generator Overhaul and check field windings for grounds and shorts...

Page 888: ...6D 12 ENGINE ELECTRICAL Fig 6D 6C Generator Mounting Fig 6D 7C Generator Mounting...

Page 889: ...except with a regulator tester CHECK FOR GROUNDS OHM METER TE S TIN G RO TO R 1 Make scribe marks on end frames to facilitate reassem bly 2 Remove four thru bolts and separate drive end frame as sembl...

Page 890: ...rom hous ing Remove retainer plate inside drive end frame and push bearing out Clean all parts with soft cloth Press against outer race to push bearing in Fill cavity between retainer plate and bearin...

Page 891: ...t glow plugs and a Glow Plugs lamp Other components which have no function in controlling glow plug operation but are part of the electrical system start and run operations are fuel solenoid fast idle...

Page 892: ...5 The thermal controller starts the glow plugs heating cycle Initially the glow plugs are activated continuously for a period of 7 1 2 to 9 seconds at 0 F The glow plugs then begin to pulse on and off...

Page 893: ...nd replace controller Repair open circuit in It blu wire from controller to glow plug relay f TEST L IG H T ON Replace relay Contacts burned TE S T L IG H T O FF Locate and repair open circuit in red...

Page 894: ...ne shorted switches within the controller Pin 3 Pin 2 40 to 75 12 Pin 5 Pin 1 130 12 10 Pin 4 Pin 5 27 12 3 12 Pin 2 Pin 6 C ontinuity 0 ohms GLOW PLUGS LAMP CYCLES ON AND OFF WARM ENGINE j This condi...

Page 895: ...ater element between pin 4 and 5 o f the controller w ill cause this condition Turn A C off ignition on and disconnect fast idle solenoid dark green wire 1 ___________________ SOLENOID RETRACTS Connec...

Page 896: ...by listening for click at relay I Re aV clicking Not clicking g oto With ignition switch OFF Engine does not Check continuity of BLK wire circuit 150A start c ld chart from bulb socket to fuse block...

Page 897: ...round and touch the disconnected light green wire at the solenoid connector TEST LIG HT OFF Touch test light to It green wire in connector on cold advance fast idle temp sw TEST LIGHT ON Check solenoi...

Page 898: ...order 1 8 3 26 5 7 3 8 With engine still idling probe each glow plug terminal and record the resistance values on each cylinder in firing sequence Most readings will be between 1 8 and 3 4 OHMS If th...

Page 899: ...LT GRN 24 B L K I5 0 B 8911027 SOCKET SPLICE 19 i 8 DK G R N I9 A 8 BRN 9 A 8 Y E L 18 LT GRN 24A SPLICE 34 L SPLICE 9 SK ICE 150 TAtL STOP DIR SIDE MKR8 tyU LAMP LIC LAM P A 8911027 SOCKET 8 B L K I...

Page 900: ...A D V A N C E TEMP SW OPENS A T 115 F 10 OHMS I v W V W G A U G E S y x GEN T E L L T A L E rowi i o G LO W PLUG R E L A Y G LO W PLUG C O N T R O L SW _ EPR ON 14 F CLOSED ISOL 1 j W 0 T EG R O N 21...

Page 901: ...ENGINE ELECTRICAL 6D 25 SHIM 1 0 MM OR 2 0 MM BRACKET STARTER Fig 6D 3D Diesel Starter Mounting 102084 Fig 6D 4D Generator Mounting Fig 6D 5D Generator Mounting with A C...

Page 902: ...CLIP CLAMP CABLE HARNESS HD LP WIRING RH CLIP BATTERY LOW COOLANT PROBE ASM BATTERY POSITIVE LEAD ROUTING BATTERY NEGATIVE LEADS BATTERY IviEwfBl C60 HARNESS FWD LAMP BATTERY CABLE POSITIVE HEADLAMP G...

Page 903: ...ENGINE ELECTRICAL 6D 27 CONNECTOR FUEL TERMINAL COLD ADVANCE FAST IDLE SOLENOID FILLER PIPE DETENT CABLE __________________102085 Fig 6D 7D Engine Compartment Wiring LH6...

Page 904: ...CABLE BRACKET WATER TEMP SENDER viEw Cl FUEL HEATER TERMINAL COLD ADVANCE CONNECTOR FUEL HEATER FAST IDLE Z53 SOLENOID SWITCH COLD FAST IDLE VIEW D ENG NUT GROUND STRAP ENG HARN GRD TERMINAL FUEL SOLE...

Page 905: ...ASM BAT CABLE FWD LAMP WIRING HARNESS ASM 102091 Fig 6D 9D Diesel Engine Wiring Relay INST CLUSTER CONNECTOR I n o t e IFor remainder of Harness routing see I P WIRING RM LAMP WITCH Fig 6D 10D I P W i...

Page 906: ...EL W IR IN G HARNESS BRAKE PEDAL SUPPORT CO O LANT LEVEL MODULE FUSE PANEL N O TE I INSTALL CONNECTOR INTO V A C A N T CAVITY M ARKED IG N G LO W PLUG LAMP VIEW A 102092 Fig 6D 11D Glow Plug Lamp Wiri...

Page 907: ...dio noisesupression The magnetic pick up assembly is mounted over the main bearing on the distributor housing and is made to rotate by the vacuum control unit thus providing vacuum advance The timer c...

Page 908: ...ed 1 2 turn before removing Care should also be exercised when connecting a timing light or other pick up equipment Do not force contacts between the boot and wiring or through the silicone jacket Con...

Page 909: ...ewtDl BATTERY CABLE SENSOR AFTER DETONATION SENSOR CONNECTOR IS INSTALLED APPLY A NOMINAL 3 LB 1 4 Kg REMOVAL FORCE TO THE CONNECTOR NOT TO THE WIRE TO ENSURE THAT IT IS LATCHED TO THE KNOCK SENSOR TH...

Page 910: ...detailed explanation of the electrical switching Fig 6D 18D Spark Plug Coding DIAGNOSIS H E I DISTRIBUTOR Use Figure 6D 19D and 20D for H E I Diagnosis SPARK PLUGS Worn or dirty plugs may give satisfa...

Page 911: ...s oil or moisture penetrates the fracture The fracture is usually just below thecrimped part of shell and may not bevisible Broken lower insulators usually result from carelessness when regapping and...

Page 912: ...INE ELECTRICAL ENGINE CRANKS BUT WILL NOT START NOTE IF A TACHOMETER IS CONNECTED TO THE TACHOMETER TERMINAL DISCONNECT IT BEFORE PROCEEDING WITH THE TEST NOTE VIEWS ARE IN PART 2 6741 Fig 6D 19D HEI...

Page 913: ...REMOVE GREEN AND WHITE LEADS FROM MODULE c a CUT A SPARK PLUG BOOT AS SHOWN DISCARD 7 16 11mm FROM TIP OF SPARK PLUG TO BAT TEST LIGHT CONNECT VOLTMETER TACH TERMINAL TO GROUND VIEW B INSERT BOOT OVER...

Page 914: ...are similar to the conventional ignition 6 The material used to construct the spark plug cables is very pliable and soft This cable will withstand more heat and carry ahigher voltage Due to the more...

Page 915: ...sion it will seldom need replacement Removal 1 Removedistributor cap and rotor 2 Remove capacitor attaching screw and unplug connector from module lt may help to loosen the module Installation 1 To in...

Page 916: ...N C A P D IS T R IB U T O R T E S T IN G IG N IT IO N C O IL COIL AND CAP ASSEMBLY TERMINALS B 1 A 6 cyl EST distributor with coil in cap is illustrated 2 Detach wiring connector from cap as shown 3 T...

Page 917: ...eplace unit if inoperative Observe ohmmeter throughout vacuum range flex leads by hand without vacuum to check for intermittent opens 16 Test 1 should read infinite at all times Test 2 should read ste...

Page 918: ...ect wiring harness from module 25 Check module with an approved module tester 26 Install module wiring harness and capacitor assembly Use silicone lubricant on housing under module IN S T A L L P IC K...

Page 919: ...ENGINE ELECTRICAL 6D 43...

Page 920: ...RETAINER Engine CTLH 9 CYL 7 CYL 5 CYL 3 CYL 1 fvtiwfAl REGULATOR ENG HARN SERVO BRKT CYL M TRANS OIL FILLER TUBE CYL H HEAT STOVE TUBE 4V8 ENGINE 4K35 CYL M TRANS OIL FILLER TUBE 7B CYL 8 ENG HARN R...

Page 921: ...ion switch is fed from the battery to the BAT terminal of the switch When the ignition switch is in the OFF position no current flows through the switch When the ignition switch is turned to the ACC p...

Page 922: ...N W 12 B RN M B ACC P l IH L w_____________ GRD 2 12 ORN h 2 0 D G I G N I T I O N S W I T C H P O S I T I O N S V I E W F R O M T E R M I N A L SI DE O F S WI TC H IG N 3 R U N P O S I T I O N I LOC...

Page 923: ...Fig 6D 28D Engine Wiring LE9 LF3 LG9 LS9 D IS T R W IR E ASM E S C CONNECTOR E N G IN E HARNESS...

Page 924: ...s s a s m b r a c k e t N41 c o n n e c t o r c100 200 POWER u n it K35 OIL PRESSURE SENCER o r SWITCH BOLT SCREW WASHER C U P H a rn e s s MOOULATOR PIPE O IL FILLER TUBE TRANS BOLT SCREW BATTERY CA...

Page 925: ...TH OR IM M ED IATELY AFTER ITEM a FAULTY IGNITION SYSTEM OF THE ENGINE DETONATION SECTION ON PAGE 6A 7 OF THE 1980 LIGHT DUTY TRUCK SERVICE MANUAL SOM E O CCASIO NAL TRACE TO LIGHT DETONATION IS ACCEP...

Page 926: ...3 CHEVROLET LIGHT TRUCK ESC SYSTEM DIAGNOSIS THIS DIAGNOSIS SHOULD BE INSERTED IMMEDIATELY AFTER ITEM b IGNITION TIMING OF THE ENGINE HAS LOW POWER SECTION ON PAGE 6A 3 OF THE 1980 LIGHT DUTY TRUCK SE...

Page 927: ...SYSTEM DIAGNOSIS THIS DIAGNOSIS SHOULD BE INSERTED WITH OR IMMEDIATELY AFTER ITEM g IGNITION PROBLEMS OF THE ENGINE FAILS TO START SECTION ON PAGE 6A 2 OF THE 1980 LIGHT DUTYTRUCK SERVICE MANUAL 10108...

Page 928: ...C B SENSOR A SHIELD BROWN BLACK WHITE GREEN LT PINK BLK Y E L L O W H G n c a v BLUE SENSOR SHIELD DETONATION SENSOR C B A u D BROWN BLACK WHITE GREEN LT HEI DISTRIBUTOR VACUUM SWITCH AUTO ONLY BROWN...

Page 929: ...es used on diesel equipped engines is shown in Fig 6D 3E The main difference is that the 27MT has a center bearing Fig 6D 4E shows an exploded view of the 27MT series Differences in service procedures...

Page 930: ...DER TO RISER BARS RISER BARS T 0 ARMATURE SWITCH TERMINAL SOLENOID GROMMET Fig 6D 2E Cross Section of 10MT Starting M otor INSULATED BRUSH HOLDER SWITCH TERMINAL SOLENOID PLUNGER RETURN I SPRING GROMV...

Page 931: ...motor solenoid ignition switch and battery including all ground connections Clean and tighten all connections asrequired Solenoid and Ignition Switch Inspect all switches to determine their condition...

Page 932: ...isturned off Turn engine off and rotate flywheel so that the marked teeth are in the area of the starter pinion gear c Disconnect negative battery cable to prevent inadvertent cranking ofengine Insert...

Page 933: ...ecified in the figure as an accurate interpretation can be made by recognizing that if the voltage is slightly higher the RPM will be proportionately higher with the current remaining essentially unch...

Page 934: ...Fig 6D 8E Starter M otor Mounting...

Page 935: ...eral Electric CG321 Dow Corning 33 Medium or equivalent on the shaft underneath the overrunning clutch assembly REMOVE AN D REPLACE Starter Fig 6D 8E Use the following procedure to remove the starter...

Page 936: ...aw indicates Too much friction tight dirty or worn bearings bent armature shaft allowing armature to drag Shorted armature This can be further checked on a growler after disassembly Grounded armature...

Page 937: ...IBER SHAFT W A S H E R RETAINER THRUST WASHER RETURN SPRING SNAP RING SHIFT LEVER CENTER BEARING CLUTCH AND DRIVE ASSEMBLY 12 If necessary to remove overrunning clutch from armature shaft proceed as f...

Page 938: ...commutator shaft and bushings over running clutch pinion brushes and springs for discoloration damage or wear Replace as required 17 Check fit of armature shaft in bushing in drive housing Shaft shou...

Page 939: ...minal on the solenoid before making these tests Com plete tests in a minimum of time to prevent overheating of the solenoid To check hold in winding connect an ammeter in series with 12 volt battery a...

Page 940: ...ushing with lubricant 1960954 or equivalent 22 Engage shift lever yoke with clutch and slide complete assembly into drive gear housing On non diesel starters the shift lever may be installed in drive...

Page 941: ...Connect one 12 volt battery lead to the solenoid switch terminal and the other to the starter frame 33 Flash a jumper lead momentarily from the solenoid motor terminal to the starter frame This will s...

Page 942: ...37 1102485 1102841 1102887 292 L 6 L25 Base G 20 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 or V 8 with RPO K76 454 V 8...

Page 943: ...9 400 V 8 LF4 350 Amps 170 80 89 5 454 V 8 LF8 RPO UA1 465 Amps 230 125 87 5 RPO TP2 430 Amps 210 100 STARTING MOTOR MODEL NO APPLICATION SPEC NO VOLTS FREE SPEED AMPERES RPM 1108778 250 L 6 LD4 C K 1...

Page 944: ...i m 1 jry V pvh i HQdVOfcW 0 t V c i v 5 1 J A oh yj Vlk op a j A K j A fmJO Y A u e v c ii gty V AA...

Page 945: ...service procedures for the PCV system can befound in this section 1 F B imnfr COMBUSTIBLE MIXTURE EGR System 6E 5 Belt Driver Air Pump 6E 6 Emission Failure 6E 8 On Vehicle Service 6E 9 Positive Crank...

Page 946: ...ir supply line A deceleration valve is used on all L6 and automatic V8 models to prevent backfiring in the exhaust system during decleration When deceleration causes a sudden vacuum increase in the va...

Page 947: ...fuel economy and exhaust emission control Carburetor adjustments and service must be performed using the recommended procedures to insure engine exhaust emission levels remain within offical limits S...

Page 948: ...off paint Also rubber grommets and hose will deteriorate Failure could also be indicated by a hissing noise Repair rocker cover plenum seals and replace grommets and hose asrequired b If rubber hose t...

Page 949: ...locked or air flow restricted Restriction in EGR vacuum line or vacuum signal tube Sticking or binding EGR valve Check transducer control valve operation See Checking Back Pressure EGR Valve Check EGR...

Page 950: ...ed pump 2 Replace pum p 3 Excessively tight belt Excessive pum p noise Chirping Insufficient break in Run vehicle 10 15 miles 16 24 kilom eters at turnpike speeds recheck Excessive pum p noise chirpin...

Page 951: ...ler w ith vehicle at idle replace diverter valve 5 Diverter valve inoperative Usually accom panied by backfire during deceleration 5 Replace diverter valve 6 Check valve inoperative 6 Blow air through...

Page 952: ...ination of catalytic converter check for absence of filler neck restrictor Im proper operation of A I R or Pulsair system Leaking carburetor fuel passages or gaskets Carburetor flo at level Stuck car...

Page 953: ...el Engine A Crankcase Depression Regulator Valve Fig 6E 12 is used to regulate meter the flow of crankcase gases back into the engine The Crankcase Depression Regulator Valve C D R V is designed to li...

Page 954: ...erature 90 C approx 195 F 4 Remove vacuum hose from EGR signal tube and check for diaphragm plate to movedownward valve closed 5 Replace vacuum hose and check for diaphragm plate tomove upward valve o...

Page 955: ...ENGINE EMISSION CONTROLS 6E 11 P O S IT IV E B A C K PR E S S U R E EG R V A L V E D IA P H R A G M PL AT E A S SE M BL Y Fig 6E 15 Positive EGR Identification...

Page 956: ...external vacuum 34 kPa 10 or moresupply to EGR vacuum signal tube c Valve should not open If it does transducer control valve is stuck closed and EGR valve must be replaced d With the vacuum supply s...

Page 957: ...Remove Carb to switch hose from switch and connect hoseto vacuum gage Repeat Step 2 5 If vacuum gage responds to throttle opening then switch is defective Remove switch and replace with newpart If ga...

Page 958: ...and closed at wide open throttle A Response Vacuum Reducer Valve is used between the VRV and the EGR valve to allow the EGR valve to change position quickly asthrottle position ischanged EPR V alve F...

Page 959: ...r gage bar Federal California manual or automatic transmission between the gage boss on the injection pump and the wide open stop screw on the throttle shaft 4 Rotate and hold the throttle shaft again...

Page 960: ...If there is novacuum replace actuator Coolant Tem perature Thermal Vacuum Switch TVS V 8 Replacement 1 Drain coolant below level of engine coolant outlet housing 2 Disconnect hosesat TVS ports 3 Remov...

Page 961: ...lt of the system operate the engine with the pump drive belt removed If excessive noise does not exist with the belt removed proceed as follows 2 Check for a seized Air Injection Pump Do not oil pump...

Page 962: ...acuum and electrical connections from diverter valve 5 Remove air pump mounting bolts and remove pump assembly 6 If pump is being replaced transfer diverter valve to new pump Install 1 Install air pum...

Page 963: ...nd pipe connections 4 Check pipe and hose routing Interference may cause wear 5 If a leak is suspected on the pressure side of the system or any pipe and or hose has been disconnected on the pressure...

Page 964: ...6E 20 ENGINE EMISSION CONTROLS CHECK V A LV E PIPE ASSY EX TE N S IO N PIPE ASSY E X TEN SIO N Fig 6E 34 Air Injection Pipes L 6 C H EC K V A L V E Fig 6E 35 Air infection Pipes V8...

Page 965: ...ICE Vacuum drop must be a result of a leaking valve not a leaking hose or connection Replacement of Pulse Air Valve Fig 6E 39 1 Remove air cleaner and disconnect rubber hose from plenum connecting pip...

Page 966: ...PIPE HOSE ATRCLEANER PLENUM CHECK VALVE ASM TORQUE TO 23 N m 17 FT LBS B PIPE ASM GROMMETv A PIPE ASM EXTENSION TUBES B PIPE ASM A PIPE ASM TORQUE TO 38 N m 28 FT LBS PLENUM CONNECTING PIPE VIEW Fig 6...

Page 967: ...r snorkel When engine is first started damper door should close As air cleaner warms up damper door should open slowly 6 If dam per door does not close when the engine is started remove air cleaner 7...

Page 968: ...rt and idle engine Damper door should move to close the snorkel passage immediately if engine is cool enough When damper door starts to open the snorkel passage in a few minutes remove air cleaner cov...

Page 969: ...solvent from the element 7 Dip band into light engine oil and squeeze out excess oil 8 Install band around outer surface of new paper element 9 Install element in bottom section of air cleaner with e...

Page 970: ...ottle lever actuator should be retracted at this speed 4 If the throttle lever actuator operates outside of the 1700 to 1890 RPM limits the speed switch is out of calibration and should be replaced 5...

Page 971: ...e terminal at the speed switch If it does not extend repair the wire connecting the speed switch and solenoid If it does extend check the speed switch ground wire for ground it should read 0 volts whe...

Page 972: ...be replaced g If the engine rpm noted in step 3 is not within the specified TRC speed range the TRC actuator must be adjusted See Throttle Lever Actuator Adjusting Procedure in section 6C V A C U U M...

Page 973: ...ANISTER P rAST IDLE SPEED SCREW RPM MANUAL 4 6 00 N 0 0 4 5 6 00 N 750 N 1 3 0 0 N jlTION t f TO ASSURE RECONNECT COM u TLE ON HIGH STEP OF FAST IDLE cGR VALVE CANISTER PURGE HOSE AND START ENGINE WIT...

Page 974: ......

Page 975: ...jacking or lifting vehicle from frame side rails be certain lift pads do not contact catalytic converter as damage to converter will result CATALYTIC CONVERTER The catalytic converter is an emission c...

Page 976: ...nifold or pipe connections Tighten clamps at leaking connections to specified torque Replace gasket or packing as required Burned or blown out muffler Replace muffler assembly Burned or rusted out exh...

Page 977: ...ct inner shell of the converter for damage If there is damage in the inner shell the converter assembly must be replaced 4 Place new insulation in the replacement cover Fig 6F 4 Apply sealing compound...

Page 978: ...NE EXHAUST CATALYTIC CON VER TER IN N E R SHELL Fig 6F 5 Catalytic Converter Inner Shell Fig 6F 6 Installing Bottom Cover Replacement SEALING C O M P O U N D 1 0 1 6 7 6 Fig 6F 8 lnstalling Bottom Cov...

Page 979: ...in the oil imparts a milky pink cast to the oil and can cause spewing W ater in the oil can also cause swelling of nylon parts General Description 7A 8 Torque C onverter 7A 8 Torque Converter C lutch...

Page 980: ...V must be installed on the high portion of the surface not in the groove Refer to Fig 7A 3 MAINTENANCE SCHEDULE The fluid level should be checked at each oil change see below W hen adding or changing...

Page 981: ...ssion at Room Temperature 65 to 85 F 18 to 2 9 C A utom atic transmission are frequently overfilled because the fluid level is checked when the fluid is cold and the dipstick indicates fluid should be...

Page 982: ...shaft while observing transmission mount If rubber separates from metal plate of mount or if tailshaft moves up but not down mount bottomed out replace mount If there is relative movement between a me...

Page 983: ...by rerouting the cable or replace it if required 2 Sharp end or burr on the T V link dragging in the T V cable housing Correct by making end smooth using a file or stone DO NOT SHORTEN LINK 3 Bent T...

Page 984: ...ed 2 Be sure engine is operating properly and brakes are not dragging 3 Check for correct cable according to the parts catalog 4 Check that the cable is connected at both ends 5 Adjust the cable as fo...

Page 985: ...odulator must be checked Vacuum Diaphragm Check Turn modulator so vacuum line stem points downward If transmission oil comes out the vacuum diaphragm is bad Gasoline and or water vapor may settle in t...

Page 986: ...ne f Grease in pipe delayed or no upshift cold GENERAL DESCRIPTION Torque Converter The torque converter is filled with oil and is attached to the engine crankshaft by a flex plate and always rotates...

Page 987: ...onverters a Install dial indicator J 8001 Fig 7A 19 and set it at zero while its plungers rests on the converter b Lift up the arm on the tool handle Converter end clearance should be 0 1 2mm 0 050 If...

Page 988: ...the best balanced position Install longer flywheel to converter bolts adding and removing washers until the best balance is achieved Be sure the bolts are not bottoming in the holes Always rotate the...

Page 989: ...minimal and most times can be corrected by following Converter Vibration Procedure A secondary balance procedure is to balance flywheel If the original balance weights have broken loose and the proced...

Page 990: ...rocedures 1 Road test and bring the transmission to operating temperature approximately 93 C 200 F 2 Raise vehicle on a hoist or jack stand engine running and locate source of oil leak Check for leak...

Page 991: ...ssion 2 Place a hose over the end of the cooler inlet line from the bottom of the cooler and insert the hose into an empty container 3 Flush clean oleum solvent or equivalent through the return line f...

Page 992: ...r is damaged it must be replaced 3 Remove governor 4 Refer to the Overhaul Section for inspection procedure 5 Install governor 6 Apply anaerobic sealant such as Loctite Cup Plug Sealant II or equivale...

Page 993: ...X 17 Throttle Lever and Bracket Assembly X 18 TV Detent Cable and O Ring X X 19 TV Boost Valve and Bushing 20 Parking Pawl Actuator Rod X X X 21 Parking Pawl Bracket X X X 22 Parking Pawl X X X 23 Man...

Page 994: ...gear must be performed with care in the following manner 1 Drive out governor gear retaining split pin using Fig 7A 29 Check Valve Opening Exhaust small punch or 1 8 drill rod 2 Support governor on 7...

Page 995: ...isconnect electrical connectors at valve body 3 Remove detent spring and roller assembly from valve body and remove valve body to case bolts 4 Remove valve body assembly while disconnecting manual con...

Page 996: ...A C U U M MODULATOR 350C 400 Removal and Installation 1 Disconnect vacuum hose from vacuum modulator stem and remove vacuum modulator attaching screw and retainer 2 Remove modulator assembly and its O...

Page 997: ...R E TO R LEVER U N TIL SLIDER S TO P S A G A IN S T FITTIN G 3 RELEASE M ETA L LO CK TAB 4 R E P E A T S T E P S 2 3 4 O F A D J U S T M E N T P R O C E D U R E LINK TR A N S M IS S IO N I VIEW A Fig...

Page 998: ...the vehicle Removal K Model 1 Open hood and place protectors on both fenders 2 Remove air cleaner 3 Disconnect T V detent cable at its upper end 4 Remove transfer case shift lever knob and boot 5 Rais...

Page 999: ...nsmission Support Brace Attachments 90 N m 65 ft lbs Control Rod Linkage Adjustment Bolt 30 N m 20 ft lbs TV Detent Cable to Case 10 N m 7 ft lbs Converter Housing Cover Except K Series 10 N m 7 ft lb...

Page 1000: ...ITCH CLOSED AT IDLE b PART THROTTLE SW ITCH OPEN AT H EAVY FULL THROTTLE CH ECK FOR O PEN S IN H A RN E SS CH ECK OPERATION OF VRV CLOSED AT IDLE A N D PA RT THROTTLE OPEN AT HEAVY FULL THROTTLE D ISC...

Page 1001: ...gear sets Four multiple disc clutches two roller clutches and an intermediate overrun band provide the friction elements required to obtain the desired function of the two planetary gear sets Inspect...

Page 1002: ...Transmission 1 2 PR ES SU R E LIN E PRESSURE M U L T I L IP S E A L W8F ID LE SPEED T R A N S M IS S IO N LINE PR ES SU R E C H EC K S 1200 RPM W IT H TH E P N I2 R M O D U L A T O R V A C U U M PIPE...

Page 1003: ...ings low leaking b Vacuum modulator c Modulator valve d Pressure regulator e Oil pump 2 Low oil pressure 2a Vacuum line or fittings obstructed b Vacuum modulator c Modulator valve d Pressure regulator...

Page 1004: ...utral 1 Manual linkage 1 Misadjusted 2 Forward clutch 2 Clutch does not release this condition will also cause No Reverse No motion in Reverse 1 Low oil level 1 Add oil or slips in Reverse install pre...

Page 1005: ...hift 1 Oil level low 1 Add oil install pressure gage 2 Oil pressure 2a Vacuum modulator as sembly inoperative b Modulator valve sticking c Pump pressure regulator valve 3 2 3 accumulator 3 Oil ring da...

Page 1006: ...Pressure regulator and or boost valve stuck No engine braking L l 1st gear 1 Manual low control valve assembly 2 Oil pressure low 3 Low and reverse clutch 1 Stuck 2 Pressure regulator and or boost va...

Page 1007: ...Wrong number of clutch plates or wrong piston Locks up in reverse usually hot only 1 Forward clutch 2 Direct clutch 1 Bore undersize or piston oversize 2 Direct clutch feeding forward clutch thru sta...

Page 1008: ...1 2 accumulator la Piston or spring b Accumulator feed hole in valve body plate Slow reverse hot 1 Valve body la Leaking valve body only support plate 2 Shift selector 2a Bent or S hook hole lever of...

Page 1009: ...sket 2 Remove filter assembly and filter gasket Removal of Valve Body 1 Remove detent roller and spring assembly from valve body See Figure 350C 35A 2 Remove actuator pin from detent control link and...

Page 1010: ...IN G S P O R O U S C R O S S L E A K G A S K E T S C R E E N P R E S S U R E B A N D I N T E R M O R C A S E P O R O U S X L E A K 1 2 A C C U M U L A T O R I N T E R M E D S E R V O F O R W A R D C...

Page 1011: ...Figure 350C 25A Neutral Engine Running AUTOMATIC TRANSMISSION 350C 11...

Page 1012: ...rter Holding Fixture V A C U U M M O DULATO R Figure 350C 31 Vacuum Modulator Figure 350C 30 Removal of Modulator Retainer V A C U U M M O D U LA TO R 6B7C81 TORQUE CONVERTER ASSEMBLY 7C 79 EXTENSION...

Page 1013: ...his is due to a plastic grooved piston that is not serviceable Piston and Seal are one assembly REMOVAL OF PUMP ASSEMBLY Removal of Oil Pump Assembly 1 Remove eight 8 pump attaching bolts with washer...

Page 1014: ...emoval of Sun Gear Drive Shell Assembly 1 Remove sun gear drive shell assembly See Figure 350C 53 Removal of Low and Reverse Clutch Support Assembly 1 Remove low and reverse roller clutch support to c...

Page 1015: ...Feed Screen Figure 350C 38 Valve Body and Spacer Plate Gasket Figure 350C 41A Check Ball Locations CHECK BALLS OIL P U M P H H H PRESSURE SCREEN OIL P U M P _ PRESSURE HOLE 8B7A33 M A N U A L SHAFT C...

Page 1016: ...JAM NUTf Figure 350C 47 Pump Removal PARK PAWL Figure 350C 45 Park Pawl d is e n g a g in g spring j g PARK 2 pawl S i SHAFT PARKING PAWL SHAFT RETAINING PLUG 7C 96 Figure 350C 48 Intermediate Clutch...

Page 1017: ...350C 52 Removing Input Carrier Figure 350C 55 Lo and Reverse Clutch Removal V IE W A LOW A N D R E V E R S E R O L L E R C L U T C H SU P P O R T T O C A S E R E T A IN E R SP R IN G T R A N SM IS SI...

Page 1018: ...spring retainer and remove piston retaining ring and spring retainer with springs See Figure 350C 60 Figure 350C 60 Remove Low and Reverse Piston Snap Ring 2 Remove low and reverse clutch piston asse...

Page 1019: ...Figure 350C 64 3 Install J 23069 tool and compress intermediate clutch 1 2 accumulator cover and install retaining ring See Figure 350C 63 DISASSEMBLY AND REASSEMBLY OF OIL PUMP ASSEMBLY Disassembly...

Page 1020: ...ure 350C 69 Figure 350C 67 Intermediate Clutch Piston Seals 9 Remove pump body to converter hub lip seal if necessary See Figure 350C 72 10 Place pump on wood blocks so surface finish is not damaged a...

Page 1021: ...C o n v e rte r S eal R em oval V A L V COOLER B Y PASS 2 3 1 3 4 7C 148 P U M P BO D Y PUMP BO DY W O O D BLOCKS 7C 151 PUM P TO CONVERTER HUB LIP SEAL J 21 35 9 F igure 3 5 0 C 7 0 C o o le r By Pa...

Page 1022: ...ing seat retaining ring and spring seat by using Tools J 2590 3 J 2590 5 and snap ring pliers See Figure 350C 82 9 Remove spring retainer springs and piston See Figure 350C 83 10 Inspect the return sp...

Page 1023: ...T C LU T C H C LU T C H D R IV E C O N V E R T E R C LU T C H APPLY P U M P PRESSURE LIP SEAL D R A IN IN T E R M E D IA T E C LU T C H REVERSE D IR E C T C LU T C H O U T E R S U C T IO N C O N V E R...

Page 1024: ...and springs by compressing with a ram press See Figure 350C 92 5 Inspect the return springs Evidence of extreme heat or burning in the area of the clutch may have caused the springs to take a heat set...

Page 1025: ...ARD CLUTCH H O U SIN G NEEDLE ROLLER BEARING F ig u re 3 5 0 C 7 9 N e e d le B e a rin g A s se m b ly Figure 350C 80 Disassembly of Direct Clutch 7C 165 R E T A IN IN G R IN G PRESSURE P LA T E D I...

Page 1026: ...t three times before final assembly 8 Check that the seal has not been cut and is free in the groove NOTICE All service input shafts will be provided with the seal design incorporated therefore when r...

Page 1027: ...E S S U R E P L A T E R E T A IN IN G C A U T IO N IF ROLLER FALLS OUT D U R IN G ASSEM BLY OPERATION REINSTALL ROLLER FROM INSIDE TO OUTSIDE CAGE DIR EC TIO N TO A V O ID BEND IN G SPRING INTERMEDIAT...

Page 1028: ...g and install into drive shell See Figure 350C 104 Use a new ring and do not overstress when installing 2 Install sun gear to drive shell flat thrust washer See Figure 350C 103 3 Install sun gear to s...

Page 1029: ...e 3 5 0 C 9 5 P iston S eal R em oval 1 Position valve body assembly with cored face up 2 Remove manual valve from lower left hand bore J 4 From the next bore B remove the 2 3 shift valve train retain...

Page 1030: ...retaining pin plug manual low control valve spring and the manual low control valve 7 From the next bore F remove the retaining pin spring seat and the detent regulator valve 8 Install Tool J 22269 on...

Page 1031: ...ks scored bores interconnected oil passages and flatness of mounting face Reassembly of Valve Body 1 Install direct clutch accumulator piston spring and piston into valve body 2 Install J 22269 and J...

Page 1032: ...h piston center and inner seal See Figure 350C 113 3 Install low and reverse clutch piston assembly with notch in piston installed adjacent to parking pawl See Figure 350C 114 4 Position piston return...

Page 1033: ...LVE SLEEVE 7 RETAINING PIN 8 2 3 s h i f t V a l v e 9 2 3 SHIFT VALVE SPRING 10 2 3 SHIFT CONTROL VALVE 11 2 3 SHIFT CONTROL VALVE SPRING 12 2 3 SHIFT CONTROL VALVE SLEEVE U 3 RETAINING PIN p rnrnn I...

Page 1034: ...vin g 2 3 A c c u m u la to r F igure 3 5 0 C 1 14 In s ta lla tio n o f L o w an d R everse P iston F ig u re 3 5 0 C 1 12 In s ta lla tio n o f O u te r S eal F ig ure 3 5 0 C 1 15 L o w an d R eve...

Page 1035: ...W A F ig u re 3 5 0 C 1 2 0 In s ta llin g L o w and R everse C lu tch P lates LOW AND REVERSE CLUTCH PACK 5B7C119 RE TAIN ER SPRING TRANSMISSION CASE 3 1 FOR ILLUSTRATION PURPOSES THE TRANSMISSION HA...

Page 1036: ...re installed into slots on the sun gear drive shell See Figure 350C 128 Installing Intermediate Clutch Overrun Brake Band 1 Install intermediate clutch overrun brake band See Figure 350C 129 Installin...

Page 1037: ...alling Oil Pump Assembly 1 Install original amount of 017 shims and needle thrust bearing lip side face down on pump cover hub Before installation apply petrolatum to both sides of shim and bearing Se...

Page 1038: ...ve shaft rearward Install Dial Indicator Set J 8001 on rod and O dial indicator on end of input shaft Push on end of output shaft to move shaft forward the reading obtained should be between 010 and 0...

Page 1039: ...in g P um p 7C 83 EXTENSION HOUSING TO CASE OIL SEAL F ig ure 3 5 0 C 1 3 6 C h e ck in g E nd P lay O u tp u t S h a ft S le eve 0 Ring Installing Parking Pawl and Actuating Rod If internal linkage w...

Page 1040: ...4 1 In sta ll R e ta in in g Plug 4 Install park lock bracket torque bolts to 29 ft lbs 39 N m See Figure 350C 142 5 Install actuating rod under the park lock bracket and parking pawl See Figure 350C...

Page 1041: ...body Connect manual control valve link to range selector inner lever Install manual shaft retaining clip Torque bolts in random sequence to 13 ft lbs leaving bolt loose for detent roller and spring as...

Page 1042: ...N OF BUSHINGS GOVERNOR BUSHING 1 Remove transmission from car 2 Remove the output shaft valve body support plate and governor from the case 3 Assemble transmission case in fixture J 8763 and mount in...

Page 1043: ...12 Install the bushing using the following procedure a Note the two 2 notches at one end of the bushing b Position the notches so that one notch is toward the front of the case and the other is toward...

Page 1044: ...E BODY AUXILIARY VALVE BODY J c O N T R O L V A L V E S LINK DETENT ROLLER SPRING ASSY CASE ELECTRICAL CONNECTOR PARK LOCK BRACKET SPECIAL BOLTS TORQUE WRENCH DETENT SPRING A N D ROLLER ASSEMBLY F ig...

Page 1045: ...a circular one way direction only Removal of Extension Housing Bushing Installation of Extension Housing Bushing T O R Q U E C O N V E R TE R A S S E M B LY F igure 3 5 0 C 1 6 1 In sta ll T o rq u e...

Page 1046: ...re 3 5 0 C 1 6 6 J 2 2976 9 TRANSM ISSIO N O l 7C 247 F igure 3 5 0 C 1 6 8 B u s h in g In sta lle r F ig u re 3 5 0 C 1 6 9 B u sh in g P ro p e rly S e a te d B R A S S H A M M E R Replacing Input...

Page 1047: ...G GEAR 7C 111 Replacing Reaction Carrier Bushing J 8092 REACTION CARRIER J 23062 3 7C 121 1 Inspect reaction carrier bushing for wear or galling If replacement is necessary proceed as follows a Thread...

Page 1048: ...to vise Grasp stator shaft and remove bushing See Figure 350C 177 2 Install front stator shaft bushing as follows Support pump assembly on J 21424 17 before installing bushing Install bushing into the...

Page 1049: ...clutch bushing using Tool J 23062 14 Drive Handle J 8092 and install 010 below slot in retainer hub See Figure 350C 182 2 Install sun gear bushings using Tool J 23062 13 and Drive Handle J 8092 and i...

Page 1050: ...hannel Support Plate to Case 5 16 18 13 Pump Body to Pump Cover 5 16 18 15 Parking Lock Bracket to Case 5 16 18 29 Extension Housing to Case 3 8 16 35 Inside Shift Nut 3 8 16 30 External Test Plugs to...

Page 1051: ...S NO OF FACED PLATES NO OF STEEL PLATES CLUTCH PISTON THICKNESS 9WD 9W A 9WH 9WC 9WP 9TX 9VN 9VL 9TS 9VJ 9VC 10 PURPLE 3 3 992 4 4 833 4 4 1 405 4 4 3 106 9WT 9W X 9VW 10 PURPLE 3 3 992 4 4 833 5 5 1...

Page 1052: ...staller J 23062 01 Bushing Service Tool Set use w ith J 8092 J 21426 Extension Housing Seal Installer J 21424 7 Stator Shaft Bushing Installer Front use w ith J 8098 J 21366 Converter Holding Strap J...

Page 1053: ...7A 25 Direct Clutch and Intermediate Roller Service 7A 31 Center Support Service 7A 35 Reaction Carrier Roller Clutch and Output Carrier Assembly 7A 40 Pinion Replacement 7A40 Output Shaft Rear Intern...

Page 1054: ...Fig 7A 1C 400 Autom atic Transmission Side Cross Section Typical...

Page 1055: ...nstall fixture and transmission into holding Tool Base J 3289 14 with bottom pan facing up Fig 7A 2C Fig 7 A 4 C R e m o v in g V a c u u m M o d u la to r an d V a lve 4 Remove modulator assembly att...

Page 1056: ...7A 7C 7 Remove filter and intake pipe assembly from case Fig 7A 8C and discard filter 8 Remove intake pipe to case O ring seal from intake pipe or case and discard Removal of Control Valve Assembly So...

Page 1057: ...sconnect solenoid lead wire from connector terminal Fig 7A 12C Removal of Rear Servo Valve Body Spacer Gasket and Front Servo 1 Remove rear servo cover attaching screws servo cover and gasket Discard...

Page 1058: ...ly Pin M odels CD and CL d If the gage surface is between the steps the medium pin identified by 2 rings should be used e If both steps are above the gage surface the short pin identified by 1 ring sh...

Page 1059: ...e transmission is in the vehicle be careful when the detent solenoid is removed as it prevents the spacer plate and gasket and check balls from dropping down 5 Remove detent solenoid attaching screws...

Page 1060: ...6 Remove parking pawl return spring Fig 7A 24C The following steps are to be completed only if 1 or more of the parts involved require replacement 7 Remove parking pawl shaft retainer Fig 7A 25C 8 Rem...

Page 1061: ...ft rearward e Push output shaft forward f Set dial indicator to Zero g Pull turbine shaft forward Read resulting travel or end play Should be 003 024 Selective washer controlling this end play is the...

Page 1062: ...J 9539 with weights J 6585 01 into bolt holes in pump body and remove pump assembly from case Fig 7A 32C See illustration for location of threaded holes 4 Remove and discard pump to case seal and gask...

Page 1063: ...Install J 9539 or a 3 8 16 threaded bolt into an extension housing attaching bolt hole Fig 7A 37C b Mount a dial indicator on bolt and index with end of output shaft c Move output shaft in and out to...

Page 1064: ...three 3 steel clutch plates 14 Remove center support to case retaining snap ring Fig 7A 41C Fig 7A 4 1C Rem oving Center Support to Case Retaining Snap Ring Fig 7A 42C R em oving Center S u p p o rt a...

Page 1065: ...r Unit Assembly CL Model spur gears disassembly procedure is identical as illustrated 1 Remove center support assembly Fig 7A 46C Fig 7A 46C Rem oving Center S upport Assem bly 2 Remove center support...

Page 1066: ...ig 7A 49C 7 Remove reaction carrier to output carrier thrust washer 8 Turn assembly over and place main shaft through hole in work bench 9 Remove O ring from output shaft of models that use an O ring...

Page 1067: ...ft Fig 7A 53C 2 To install place clip square end toward flange of shaft into hole in output shaft Fig 7A 54C Align slot in speedometer drive gear with clip and install gear The nylon speedometer drive...

Page 1068: ...r thrust cap governor weights and springs Governor weights are interchangeable from side to side and need not be identified Fig 7A 57C 2 Remove governor valve from governor sleeve Be careful not to da...

Page 1069: ...place in arbor press and with a long punch press gear out of sleeve 3 Carefully clean governor sleeve of chips that remain from original gear installation 4 Support governor on 7 64 inch plates insta...

Page 1070: ...flon oil seal ring from the front servo piston unless the oil seal ring requires replacement For service the oil seal ring is aluminum 1 Inspect servo pin for damage 2 Inspect piston and oil ring for...

Page 1071: ...reedom of accumulator rings in piston grooves 2 Inspect fit of servo pin in servo piston in case bore 3 Inspect servo pin for scores or cracks 4 Inspect accumulator and servo pistons for scoring crack...

Page 1072: ...cumulator piston and oil seal ring for damage Reassembly 1 Install front accumulator spring and piston into valve body 2 Install Special Tools J 22269 and J 24675 and compress spring and piston and se...

Page 1073: ...r Bushing Spring 28 Retaining Pin Valve Spring 13 Retaining Pin 20 2 3 Modulator Valve 29 1 2 Accumulator 8 1 2 Shift Valve 14 Retaining Pin 21 2 3 Shift Valve Spring Valve Sec Spring L A T E R DESIGN...

Page 1074: ...ssure regulator spring 5 Remove regulator valve spring retainer and spacer s if present Fig 7A 70C 6 Remove pump cover to body attaching bolts Fig 7A 7 1C Installing Pressure R egulator R etaining Pin...

Page 1075: ...ttaching threads 6 Check for overall flatness of pump body face Fig 7A 75C Pum p Body Oil Passages 7 Check bushing for scores or nicks If replacement is necessary proceed as follows a Using Tool J 214...

Page 1076: ...ive replacement bushing into place until tool bottoms Rear c With pump and stator shaft properly supported using Tool J 21465 15 with slide hammer Tool J 2619 and adapter tool J 2619 4 remove bushing...

Page 1077: ...seal rings 10 Assemble pump cover to pump body with attaching bolts Fig 7A 78C Leave bolts one turn loose at this time 11 To align the pump body and cover place the pump assembly less rubber seal ring...

Page 1078: ...L PLATES NO OF W AVED STEEL PLATES NO OF COMPOSI TION PLATES NO OF FLA T STEEL PLATES NO OF W AVED STEEL PLATES NO OF COMPOSI TION PLATES NO THICKNESS FM FA FJ FP FN FH FY FF FW FB FD FX FZ FK FT 4 07...

Page 1079: ...es and waved steel plate Models FL and FS do not use a waved steel plate Fig 7A 82C Rem oving T urbine Shaft from Forward Clutch Housing 5 If necessary place forward clutch and turbine shaft in arbor...

Page 1080: ...re care should be exercised to make certain the proper piston be installed in the clutch assemblies as shown in Figure 7A 102C 1 Place new inner and outer oil seals on clutch piston lips face away fro...

Page 1081: ...tch A s s e m b ly E x p lo d e d V ie w NOTICE Do not confuse the flat steel clutch plate plate with V notch with the waved steel clutch plate plate with U notch or damage may occur J 2 13 62 FORW AR...

Page 1082: ...G INTERMEDIATE CLUTCH RETAINER INTERM EDIATE CLUTCH OUTER RACE IN T E R M E D IA T E ROLLER C LU TC H DIRECT CLUTCH H O U SIN G A N D RACE ASSEMBLY DIRECT CLUTCH CENTER SEAL DIRECT CLUTCH OUTER SEAL D...

Page 1083: ...te to direct clutch housing snap ring Fig 7A 93C 4 Remove direct clutch backing plate composition plates and steel clutch plates 5 Using clutch compressor Tool J 4670 and J 21664 compress spring retai...

Page 1084: ...tons during reassembly therefore care should be exercised to make certain the proper piston be installed in the clutch assemblies as shown in Figure 7A 102C 1 Install a new inner clutch piston seal on...

Page 1085: ...with the service piston which has a check ball EITHER THE DIRECT CLUTCH HOUS ING AND OR THE PISTON MUST CONTAIN A CHECK BALL S 4 Place seal protectors Tools J 21362 Inner J 21409 Outer over hub and c...

Page 1086: ...inserting the roller from the outer side Fig 7 A 1 0 6 C ln s ta llin g In te rm e d ia te C lu tc h R oller A s s e m b ly 11 Turn unit over and install the intermediate clutch roller assembly onto t...

Page 1087: ...age left oil feed hole This is considered normal Apply air through left oil feed hole to actuate piston and move direct clutch plates DISASSEM B LY INSPECTION AND RE ASSEM BLY OF CENTER SUPPO RT Disas...

Page 1088: ...ove snap ring 7A 113C 3 Remove spring retainer Fig 7A 114C and three 3 clutch release springs Fig 7A 115C 4 Remove intermediate clutch spring guide Fig 7A 116C 5 Remove intermediate clutch piston Fig...

Page 1089: ...ushing is flush to 010 below top of oil delivery sleeve 3 Check oil ring grooves and oil rings for damage 4 Air check oil passages to be sure they are not inter connected 5 Inspect piston sealing surf...

Page 1090: ...of the center support Fig 7A 121C 3 Install intermediate clutch spring guide Fig 7A 122C Assembly 1 Lubricate and install new inner and outer seals on piston with lip of seal facing away from spring p...

Page 1091: ...ompress springs and install snap ring Fig 7A 124C 7 Install four 4 oil seal rings on the center support When installing teflon oil seal rings make sure slit ends are assembled in same relation as cut...

Page 1092: ...ers 9 Inspect roller clutch cage and springs for damage 10 Inspect front internal gear output carrier for damaged teeth 11 Inspect output carrier pinions for damage rough bearings or excessive tilt 12...

Page 1093: ...r damage or wear 2 Inspect splines for damage 3 Be sure oil lubrication hole is open Inspection of Sun Gear Shaft 1 Inspect shaft for cracks or splits 2 Inspect splines for damage 3 Inspect bushings f...

Page 1094: ...e used if tool to press bearing out is located on outer race of bearing DO NOT locate against inner race or balls d Install ball bearing assembly and spacer bearing first e Install ball bearing assemb...

Page 1095: ...and P arkin g L in k a g e E x p lo d e d V ie w REVERSE LINE v DRIVE MODULATOR OR INTERMEDIATE TO COOLER PUMP INTAKE COOLER RETURN INTERMEDIATE CLUTCH CUP PLUG VENT DRIVE ETENT EXHAUST REVERSE INTERM...

Page 1096: ...rooves for damage 7 Inspect bore for governor assembly for scratches or scoring 8 Inspect modulator valve bore for scoring or damage 9 Inspect cup plug inside case for good staking and sealing 10 Insp...

Page 1097: ...p nut of Tool J 21371 8 5 Loosen hex nut while holding cap nut stationary With the hex nut loosened and holding Tool J 21371 3 firmly against the converter hub the reading obtained on the dial indicat...

Page 1098: ...r flange facing up b Place bearing on race c Place second race on bearing with outer flange cupped over bearing 7 Install output shaft into output carrier assembly Fig 7A 145C 8 Install output shaft t...

Page 1099: ...eing installed and if the front internal gear ring prevents assembly of the carriers replace the front internal gear ring with the SERVICE ring 16 Install center support to sun gear thrust races and b...

Page 1100: ...r check of roller clutch 21 Install J 21795 on gear unit assembly to hold units in place 22 Install output shaft to case thrust washer tabs in pockets Fig 7A 152C and retain with petrolatum This must...

Page 1101: ...t the shoulder at the bottom of case splines and the gap located adjacent to the band anchor pin Fig 7A 157C Do not confuse this spacer 040 thick and both sides flat with either the center support to...

Page 1102: ...d C lu tc h P la tes b Models FL and FS Lubricate with transmission oil three 3 flat steel and three 3 composition faced intermediate clutch plates and install starting with flat steel and alternatin...

Page 1103: ...ual shaft Rotate transmission to vertical position and remove J 21795 17 With converter end of transmission up carefully install direct clutch and intermediate roller assembly It will be necessary to...

Page 1104: ...washer may tend to discolor It will be necessary to measure washer for its actual thickness 24 Install remaining front pump attaching bolt and seal Torque 18 ft lbs CASE EXTENSION ASSEM B LY 1 Install...

Page 1105: ...ta lla tio n Installation of Check Balls Control Valve Spacer Plate and Gasket Detent Solenoid Front Servo Assembly and Electrical Connector 1 Install two control valve assembly attaching bolts with...

Page 1106: ...llows the front servo piston to slide very freely in the case The free fit of the ring in the bore is a normal characteristic and does not indicate leakage Fig 7A 1 7 7 C F ro n t S e rvo G r o u p ln...

Page 1107: ...lective apply pin bears identification in the form of one two or three rings There are three selective pins identified as follows 1 If both steps are below the gage surface the long pin identified by...

Page 1108: ...vernor pipes on transmission while carefully aligning the governor feed pipe over the governor screen Fig 7A 184C Make certain gasket and spacer do not become mispositioned Check manual valve to make...

Page 1109: ...ing bolts Torque bolts to 18 ft lbs INSTALLATIO N OF SPEEDOMETER DRIVEN GEAR ASSEM BLY 1 Install speedometer driven gear assembly Fig 7A 188C 2 Install speedometer driven gear retainer and attaching b...

Page 1110: ...to Manual Shaft N u t 8 ft lbs Manual Shaft to Inside Detent Lever 18 ft lbs Linkage Swivel Clamp N ut 43 ft lbs Converter Dust Shield Screws 93 ft lbs Transmission to Engine Mounting B olts 35 ft lb...

Page 1111: ...r Tools J 2 1465 01 21 J 21465 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 W eights 23 J 2 1465 13 Part of Bushing To...

Page 1112: ...r R em over P uller 15 J 5 4 0 3 Snap R ing Pliers 6 J 22269 01 A c c u m u la to r Piston R em over and Installer 16 J 1313 T o rq u e W re n ch 0 1 4 0 F t Lbs 7 J 2 1 3 6 9 C o n ve rte r Pressure...

Page 1113: ...DR4 3RD DRo 2ND DR2 1ST LO 2 4 BAND REV INPUT CLUTCH OVERRUN CLUTCH FORWARD CLUTCH ON FORWARD ROLLER CLUTCH 3 4 CLUTCH LO ROLLER CLUTCH LO REV CLUTCH STATOR SHAFT REVERE INPUT CLUTCH STATOR ROLLER CL...

Page 1114: ...b ra ke s a p p lie d ta k e th e lin e pressure rea din gs in th e ranges a n d a t th e e n g in e r p m s in d ic a te d in th e c h a r t b e lo w NOTICE T o ta l ru n n in g tim e f o r th is c o...

Page 1115: ...PRESSURE REGULATOR VALVE 2 ICL PRESSURE TAP PRESSURE RELIEF VALVE LINE BOOST 4 th ACCUMULATOR PRESSURES I 1iNTAKE DECREASE CONVERTER LUBE I 1MAINLINE I I T V FEED I 1TV t l g i j MODULATED T V M T V...

Page 1116: ...sembly A Sticking Governor Valve B Governor Driven Gear 1 Damaged 2 Missing Retaining Pin CHECK OIL LEVEL T V CABLE OIL PRESSURE 3 Nicks or Burrs on Output Shaft 4 Correct Governor Retaining Pin in Ca...

Page 1117: ...4 Piston Exhaust Ball Open F Restricted Apply Passages G Check Ball 7 Capsule Damaged or Misassembled C h eck O ilL evel T V C a b le O ilP ressu re 3 4 SLIP OR ROUGH 1 3 4 Accumulator A Missing Accum...

Page 1118: ...in Pump 5 Restricted Converter Clutch Apply Passage 6 Low Oil or Oil Pressure 7 Engine Not Tuned Properly NO CONVERTER RELEASE 1 Converter Clutch ApplyValve Stuck inthe Open Position 2 0 Ring or Check...

Page 1119: ...ERNOR AND EXTERNAL PARTS Removal 1 Remove the governor and governor cover Do Not Damage Governor Cover 2 If the rear seal requires replacement replace at this time by removing with a screwdriver and i...

Page 1120: ...A N U A L D E T E N T R O L L E R 8 V A L V E B O D Y 9 T V L E V E R A N D B R A C K E T 10 P A R K I N G L O C K B R A C K E T 11 V A L V E B O D Y S P A C E R G A S K E T 12 V A L V E B O D Y S P A...

Page 1121: ...s required 2 4 BAND AND INPUT GEAR SET Removal 1 Remove the 2 4 band assembly from the case 2 Remove the band anchor pin from the case 3 Remove the input sun gear Fig ure 7 0 0 R 4 4 In sta llin g o r...

Page 1122: ...assemblies composition and 5 low and reverse clutch plates steel 7 Remove the reaction internal gear output shaft if not removed and bearing assembly 8 Remove the support bearing assembly from the cas...

Page 1123: ...eturn spring for distortion or damage 3 Inspect the parking lock shaft for damage and freeness of fit with the pawl Assembly 1 Position the return spring on the parking lock pawl so the long end of th...

Page 1124: ...b Support the governor assembly on plates installed in the exhaust slots of the governor sleeve Place in a arbor press and with a long punch press the gear out of the sleeve c Clean the governor sleev...

Page 1125: ...ion gear damage excessive wear incorrect number of pinion pin washers and proper staking of the pinion pins 2 Inspect the captive bearings of the carrier for excessive heat damage flatness and roller...

Page 1126: ...S T S P R IN G 2 R E M O V E T H E R E T A I N I N G N U T F R O M T H E P IN 3 R E M O V E T H E P IN T O R S I O N L E V E R S P R IN G L I N E B O O S T L E V E R T H R O T T L E L E V E R A N D B...

Page 1127: ...iston if removed Large aluminum 3 Install the low reverse clutch piston in the transmission case indexing the piston with the notch at the bottom of the case with the hub facing downward making certai...

Page 1128: ...T S H E L L T H R U S T W A S H E R 23 O U T P U T S H A F T S L E E V E 8 R E A C T I O N S U N G E A R S H E L L 2 4 O U T P U T S H A F T S E A L 9 R E A C T I O N S U N G E A R S N A P R IN G 2 5...

Page 1129: ...S Assembly 1 Install the snap ring on the reaction sun gear if removed and install into the reaction carrier indexing the pinions 2 Install the nylon low reverse thrust washer with 4 locating ears on...

Page 1130: ...ut housing with the hub upwards using an 8mm feeler gage to position the seal 3 Install the reverse input clutch spring assembly with the large opening first 4 Install tools J 23327 and J 25018 A on t...

Page 1131: ...om the input housing assembly 27 Inspect the 4 four teflon oil seal rings on the turbine shaft for damage or distortion Remove and Replace only if necessary FORWARD CLUTCH CAM ASSEMBLY Fig 35 Disassem...

Page 1132: ...etainer and check valve assembly until it is 3mm 1 8 below the top surface of the turbine shaft f Inspect the 3 4 check ball in the input housing for free operation 2 Overrun Forward 3 4 Gear Pistons...

Page 1133: ...8 F O R W A R D C L U T C H P IS T O N 18 F O R W A R D C L U T C H B A C K I N G P L A T E 9 O V E R R U N C L U T C H P IS T O N 19 F O R W A R D C L U T C H B A C K I N G P L A T E S N A P R IN G...

Page 1134: ...overrun clutch piston locating the release springs on the piston tabs 14 Position tools J 23456 and J 25018 overrun on the ovrrun spring assembly and compress the spring retainer Fig 40 Do not over co...

Page 1135: ...H H U B 10 F O R W A R D C L U T C H O U T E R S E A L 29 O V E R R U N C L U T C H S P R IN G A S S Y 11 F O R W A R D C L U T C H I N N E R S E A L 3 0 O V E R R U N C L U T C H H U B S N A P R I N...

Page 1136: ...y A r T r t I J I n H 700R4 9 21 Install the forward clutch spacer thick steel into the input clutch housing indexing the lug on the spacer with the large slot in the input housing A five clutch plate...

Page 1137: ...nto the input housing assembly 3 4 Clutch Piston Travel Check Fig 48 Using feeler gages measure the end clearance between the backing plate and the first composition plate If the end clearance is not...

Page 1138: ...0 3 m m 0 7 9 1 3 3 0 m m 1 2 8 1 S E L E C T IV E 1 9 4 1 3 3 7 1 Figure 7 0 0 R 4 4 6 3 4 C lutch Plate C ha rt H 700R4 55 3 4 B A C K I N G P L A T E S E L E C T I O N M O D E L B A C K I N G P L...

Page 1139: ...h apply valve and spring 2 Pressure Relief Ball a Remove the pressure relief spring retaining rivet with a small punch Rivet is under very strong spring pressure b Remove the pressure relief spring an...

Page 1140: ...S E R V O A P P L Y P IN S E A L DISASSEM BLY 1 R e m o v e th e 4 t h a p p ly p is to n an d h o u s in g f r o m th e 2 n d a p p ly p is to n a sse m b ly 2 R e m o v e th e servo release s p rin...

Page 1141: ...pocket 4 Install the pump slide seal and support into the slide adjacent to the rotor The pump slide seal composition must be positioned against the other diameter of the pump pocket 5 Install a vane...

Page 1142: ...3 T O C O O L E R 14 C O N V C L U R E L 15 L U B E 16 C O N V F E E D H 700R4 15 Figure 700 R4 55 Pump Cover Passage I D 1 C O N V F E E D 2 V E N T 3 L U B E 4 E X H A U S T 5 C O N V C L U R E L 6...

Page 1143: ...Assemble the pump cover to pump body with the attaching bolts finger tight 3 Position the pump cover and pump body using J 25015 and place a holding bolt or screwdriver through a pump to case bolt hol...

Page 1144: ...H 700R4 64 n F igure 7 0 0 R 4 5 9 P ressu re R e g u la to r and C o n v e rte r V alves 2 5 0 1 5 4 With the dial indicator set at zero pull upwards The end play should be 0 13 0 92 mm 005 036 The...

Page 1145: ...o spacer gasket identified with a V on the spacer plate g Install the 3 exhaust balls and check valve into the valve body and retain with petrolatum Fig 70 h Install the valve body and connect the lin...

Page 1146: ...u g h th e e x p o s e d h o le S o m e o f th e ro ll p in s have a p p lie d pressure a g a in st th e m W hen re m o v in g care s h o u ld be ta k e n to p re v e n t th e p o ssib le loss o f p a...

Page 1147: ...s p rin g an d sleeve 11 Line Bias Valve F ro m b o re N o 11 u sin g ne edle nose p lie rs co m p re ss th e lin e bias valve s p rin g re ta in e r a n d re m o v e th e p lu g lin e bias a n d sp...

Page 1148: ...7 D E T L O 2 8 3 4 C L U T C H 3 2 E X C H E C K B A L L S 2 9 R N D 4 3 H 700R4 1 F igure 7 0 0 R 4 6 8 Case C heck B alls and Oil Passages 1 L IN E 2 D 4 3 D 2 4 LO 5 R E V E R S E 6 G O V E R N O...

Page 1149: ...tioning the gasket on top D Install the housing spring and piston on the transmission case and secure with 3 three attaching bolts torquing to 11 N m 8 ft lbs 13 Install the speedo gear and retaining...

Page 1150: ...ar and C lip 20 Install all remaining outside connectors such as driven speedo gear and adaptor outside manual lever and nut F igure 7 0 0 R 4 7 5 In s ta llin g O u tp u t S h a ft S leeve 21 Remove...

Page 1151: ...E A L T O R Q U E S P E C IF IC A T IO N S L O C A T IO N Q T Y S IZ E T O R Q U E L O C A T IO N Q T Y S IZ E T O R Q U E A C C U M U L A T O R C O V E R T O C A S E 2 1 0 X 3 0 3 11 N m 8 F T L B P...

Page 1152: ...700 R4 40 AUTOMATIC TRANSMISSION Figure 700 R4 76 Transmission Assembly Exploded View...

Page 1153: ...L T H R U S T W A S H E R 25 3 4 C L U T C H A P P L Y R IN G 73 L O R E V E R S E R O L L E R R A C E 26 3 4 C L U T C H S P R IN G A S S Y 74 L O R E V E R S E S U P P O R T S N A P R IN G 2 7 F O...

Page 1154: ...C L U T C H S P R IN G C O M P R E S S O R P R ES S o J 8 7 6 3 0 2 H O L D IN G F IX T U R E A N D B A S E J 2 2 2 6 9 0 1 P IS T O N C O M P R E S S O R J 2 4 7 7 3 A O IL P U M P R E M O V E R A N...

Page 1155: ...rotate at the time the clutch is 89mm center distance and is designed to combine normal engaged The countergear is carried on roller bearings at performance in the city with improved fuel economy on...

Page 1156: ...ccomplished and the following checks and adjustments performed in the presented sequence before removing the clutch or transmission for repairs CLUTCH ADJUSTMENT Clutch Free Pedal Travel 1 The clutch...

Page 1157: ...s have been checked and the problem still exists the transmission will have to be removed and disassembled for further diagnosis There are three basic type of transmission internal problems reflected...

Page 1158: ...possible to obtain ignition L O C K position in N E U T R A L or any gear other than R E V E R S E 102706 Fig 7B 2 C Truck C o lum n S h ift Linkage clash is slight the load will build up on the shif...

Page 1159: ...of the clutch housing and transmission as any foreign material on these faces will change alignment also check carefully for dings or burrs on these mating surfaces and remove carefully as necessary...

Page 1160: ...ll to correct level b 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...

Page 1161: ...ear 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 seals leak...

Page 1162: ......

Page 1163: ...r from the flywheel housing This will prevent the release bearing from NOTICE When removing the transmission do not allow the weight of the transmission to hang on the clutch disc hub as the disc may...

Page 1164: ...riven gear shaft with transmission lubricant and insert shaft 2 Hold the assembly so slot in fitting is toward lock plate boss on housing and install in housing Push fitting into housing until lock pl...

Page 1165: ...ch Snap Ring 20 M ainshaft 33 2 3 S ynch Sleeve 7 2 3 Synch H ub 21 Rear O il Seal 34 C ountergear 8 2nd Speed B lo cker Ring 22 R etainer O il Seal 35 C oun ter S h a ft 9 2nd Speed Gear 23 Snap R in...

Page 1166: ...rive Gear Bearing 29 2nd Speed Gear 16 Case 30 Mainshaft 17 Drive Gear 31 1st Speed Gear 18 Pilot Bearings 32 1st Speed Blocker Ring 33 1 2 Synchronizer Hub 47 Gasket Assembly 48 2 3 Shift Fork 34 1 2...

Page 1167: ...a screwdriver or other suitable tool can be inserted between bearing large snap ring and case to complete removal Fig 7B1 5 The clutch gear bearing is a slip fit on the gear and into the case bore Th...

Page 1168: ...of mainshaft See Fig 7B1 10 2 Depress speedometer retaining clip and slide or tap gear from mainshaft 3 Remove rear bearing snap ring from mainshaft groove See Fig 7B1 11 4 Support reverse gear with p...

Page 1169: ...proper meshing of the gears Because of the high degree of accuracy to which these parts are machined the bushing is not serviced separately REPAIRS Clutch Keys and Springs Replacement The clutch hubs...

Page 1170: ...T h ru s t W a s h e r S p rin g W a s h e r R e ar B earin g S n a p Ring S p e e d o D rive G e a r a nd C lip M a in s h a ft Fig 7 B 1 1 8 D rive G e a r A n d M a in s h a ft A ssem b ly Drive Be...

Page 1171: ...19 2 Place countergear assembly through case rear opening along with a tanged thrust washer tang away from gear at each end and install countergear shaft and woodruff key from rear of case Be sure cou...

Page 1172: ...m e m b e r to M o u n t B o lts 5 4 N m 4 0 f t lb 2 3 Cross O v e r S h a ft B ra c k e t R e ta in in g N u t 2 4 N m 1 8 f t lb 1 R ev S w iv e l A tta c h in g B o lts 2 7 N m 2 0 f t lb M o u n...

Page 1173: ...s removed NOTICE When removing the transmission do not allow the weight of the transmission to hand on the clutch disc hub as the disc may become distorted seriously affecting clutch operation 9 Move...

Page 1174: ...on 4A 4 Pry seal out of extension housing Installation 1 Coat outer diameter of new oil seal with sealing cement Install oil seal using extension housing oil seal install J 21359 2 Reconnect propeller...

Page 1175: ...U G 32 F I L L E R P L U G 33 T R A N S M IS S IO N C A S E M A G N E T 34 C A S E 35 E X T E N S IO N H O U S IN G T O C A S E G A S K E T 36 S P E E D O M E T E R D R IV E R G E A R R E T A IN IN G...

Page 1176: ...asket from case 3 Remove long spring that retains the detent plug in the case Fig 7B2 5 Remove the detent plug with a small magnet 4 Remove extension housing and gasket 5 Press down on speedometer gea...

Page 1177: ...ng from rear bearing and smaller retaining snap ring from output shaft It may be necessary to place a screwdriver or a piece of bar stock between the case and the first reverse sleeve and gear assembl...

Page 1178: ...shaft with hammer until end of idler gear shaft end with roll pin clears counterbore in rear of case and remove shaft Fig 7B2 13 24 From the bottom of the case retrieve clutch shaft 102728 roller bear...

Page 1179: ...e wear chips or cracks and replace any that are worn or damaged 2 Check both clutch sleeves to see that they slide freely on their hubs REPAIRS Synchronizer Keys and Spring Replacement 1 Mark hub and...

Page 1180: ...th marks made during disassembly S E C O N D 3 Install spring in First Reverse hub Make sure spring is bottomed in hub and covers all three key slots Position three synchronizer keys in hub with small...

Page 1181: ...st washer from being displaced when the countergear is installed 7 Align bore in countergear with countershaft and front thrust washer then start countershaft into countergear Before countershaft is c...

Page 1182: ...bearing on clutch gear shaft by hand drive bearing on clutch gear shaft using tool J 24433 Fig 7B2 23 25 Install smaller snap ring on clutch gear shaft Fig 7 B 2 2 5 ln sta llin g S p e e d o m e te r...

Page 1183: ...m 2 5 f t lb L u b ric a tio n F ille r P lug 2 0 N m 15 f t lb T ra n s m is s io n to C lu tc h H o u s in g B o lts 101 N m 75 f t lb C ro ssm e m b e r to F ra m e N u ts 8 5 N m 6 5 f t lb C ro s...

Page 1184: ...le r 5 J 8 0 5 9 S nap R in g P liers 6 J 2 5 2 3 3 D riv e G ear B rg R e ta in e r Seal In s ta lle r 7 J 2 1 4 6 5 1 5 E x te n s io n B u sh in g R e m o v e r and In s ta lle r 8 J 2 5 2 3 2 C o...

Page 1185: ...y during removal of the transmission main drive gear from the flywheel housing This will prevent the release bearing from NOTICE When removing the transmission do not allow the weight of the transmiss...

Page 1186: ...essive amount of grease in the above areas as under normal operation this grease could be thrown onto clutch facings resulting in clutch problems 2 Shift the transmission into high gear Mount transmis...

Page 1187: ...ng 7 Remove E ring from interlock lever pivot pin and remove interlock levers and spring from cover Installation 1 Install interlock levers on pivot pin and fasten with E ring Use pliers to install sp...

Page 1188: ...sy 13 Stop Ring 14 First Gear 15 Rear Main Bearing 16 Extension Housing 17 Vent Plug 18 M ainshaft 19 Retainer Clip 20 Speedometer Gear 21 Rear Oil Sea 22 Reverse Idler Gear 23 Reverse Idler Gear Bush...

Page 1189: ...89MM MANUAL TRANSMISSION 7B3 5 Fig 7 3 4 4 Speed 89mm Exploded View...

Page 1190: ...O N IZ E R A S M T R A N S 3 R D 4 T H 15 F O R K S H IF T 3 R D 4 T H 4 8 S P R IN G F O R W A R D C L U T C H K E Y 16 F O R K S H IF T 1 S T 2 N D 4 9 K E Y F O R W A R D S Y N C L U T C H 17 S H A...

Page 1191: ...VER Fig 7 B 3 8 E xte n sio n H ousing a n d M a in s h a ft A ssem b ly 4 Remove extension housing bolts and rotate the extension on the output shaft to expose the rear of the countershaft Clearance...

Page 1192: ...m transmission case To remove the shaft use a 3 8 x 3 1 2 bolt with a free spinning nut and a 7 16 deep socket 3 8 inch drive Place the bolt and socket in the case with the socket against the shaft an...

Page 1193: ...nner snap ring and 16 bearing rollers from cavity of drive gear CLEANING AND INSPECTION Transmission Case 1 Wash the transmission thoroughly inside and outside using a suitable solvent then inspect th...

Page 1194: ...be kept together as originally Fig 7 B 3 1 8 ln sta llin g Rear Extension Bushing assembled but the keys and springs may be replaced if worn or broken 1 If relation of hub and sleeve are not already m...

Page 1195: ...and push each shaft into its proper bore followed by greased O ring and retainer 7 Install operating levers and torque retaining nuts to specifications Be sure 3rd 0 D operating levers point downward...

Page 1196: ...from moving rearward Refer to Fig 7B3 7 6 Install drive gear assembly through the front of the case and position it in the front bore Install outer snap ring in bearing groove Tap lightly into place...

Page 1197: ...onizer in neutral position Slight motion of the 1 2 shift lever toward low gear is normal during shifting into reverse gear 24 Install backup light switch and torque to specifications SPECIFICATIONS S...

Page 1198: ...n s ta lle r 3 J 2 1 4 2 6 R ear E x te n s io n Seal In s ta lle r 4 J 2 3 0 9 6 D riv e G e a r R e ta in e r Seal In s ta lle r 5 J 8 0 9 2 D riv e r H a n d le 6 J 2 9 7 9 3 C o u n te rg e a r L...

Page 1199: ...n lock tabs and remove transmission mount to crossmember bolts 8 Support transmission with a suitable floor stand Remove frame to crossmember bolts and remove crossmember from vehicle 9 Remove transmi...

Page 1200: ...ransmission has been removed If the clutch requires repair refer to Section 7C before transmission is reinstalled in the vehicle Installation 1 Apply a light coating of high temperature grease to the...

Page 1201: ...nd remove lock plate Insert screwdriver in lock plate slot in fitting and pry fitting gear and shaft from housing Pry O ring from groove in fitting Installation 1 Install new O ring in groove in fitti...

Page 1202: ...Rear 4 1 Pilot Bearing Rollers Synchronizer Collar 17 Thrust Washer Bearing 42 Clutch Gear Oil 6 3rd and 4th Shift 18 Bearing Snap Ring 29 Bearing Snap Ring Slinger Fork 19 Speedometer Drive 30 Revers...

Page 1203: ...ug 6 Oil Slinger 18 1st Gear 31 Synchronizer Spring 42 Snap Ring 54 Reverse Idler Gear 7 Drive Gear and Pilot 19 Thrust Washer 32 Synchronizer Keys 43 3rd Speed 55 Case Bearings 20 Rear Main Bearing 3...

Page 1204: ...ear bearing retainers and gasket 7 Remove countergear front bearing cap and gasket 8 Pry countergear front bearing out by inserting a two pronged puller J 28509 through the cast slots in case 9 Remove...

Page 1205: ...and chisel and remove bushing from shaft Exercise care not to damage mainshaft COUNTERSHAFT Disassem bly 1 Remove front countergear retaining ring and thrust washer Discard snap ring 2 Install Tool J...

Page 1206: ...peed G ear 7 Thrust Washer 8 3 rd Speed B u sh in g 9 3 rd Speed G ear 102882 10 11 12 13 14 15 16 3 rd S peed B lo c k e r R in g 3 rd 4 th S peed S y n c h ro n iz e r H u b A s s e m b ly 3 rd 4 t...

Page 1207: ...eal out of retainer 3 Install new seal on Tool J 22833 with lip of seal toward flange of tool 4 Support front surface of retainer in press start seal and tool in retainer bore and drive seal into reta...

Page 1208: ...ke Install split pin in fork and shaft then push fork in neutral position 4 Hold 3rd and 4th fork in position and push shaft through yoke but not through front support bore 5 Place two interlock balls...

Page 1209: ...ing or damage may occur 4 Position clutch countergear and spacer on shaft and press countergear onto shaft against snap ring using t Fig 7 B 4 19 C lu tch C o u n te rg e a r Tool J 22873 Fig 7B4 19 C...

Page 1210: ...mission assembly is pushed forward into recess by mainshaft pilot MAINSHAFT Assem bly 1 Using Tool J 22873 press 2nd speed bushing onto mainshaft until it bottoms against shoulder Fig 7B4 23 Lubricate...

Page 1211: ...ynchronizer blocker ring and 3rd speed gear onto mainshaft against 3rd speed gear thrust washer 8 Index synchronizer ring key slots with synchronizer assembly keys and press 3rd and 4th synchronizer a...

Page 1212: ...uter race with plastic tip hammer 7 Install drive gear bearing retainer using a new gasket install bolts and torque to specifications 8 9 12 13 14 15 Install appropriate tool in countergear front bear...

Page 1213: ...n an d R e ta in e r to Case B o lts U p p e r 2 7 N m 2 0 f t lb E x te n s io n an d R e ta in e r to Case B o lts L o w e r 4 0 N m 3 0 f t lb L u b ric a tio n F ille r P lug 4 0 N m 3 0 f t lb S...

Page 1214: ...rin g In s ta lle r 7 J 2 2 8 7 4 1 0 C o u n te rg e a r F r o n t S u p p o rt 8 J 8 4 3 3 B e a rin g P u lle r 9 J 2 2 8 3 2 0 1 C o u n te rg e a r R ear B e a rin g R e m o v e r 10 J 2 3 0 7 0...

Page 1215: ...Inspection 7C 15 Assembly 7C 15 Adjusting Levers 7C 16 Special Tools 7C 18 GENERAL DESCRIPTION DRIVEN PLATE ASSY CLUTCH H O U SIN G COVER PRESSURE PLATE A N D COVER ASSY CLUTCH FORK RELEASE BEARING CL...

Page 1216: ...strength In order to make clutch engagement as smooth as possible and eliminate chatter the steel segments attached to the splined hub are slightly waved which causes the contact pressure on the faci...

Page 1217: ...sure plate and is pivoted on rings approximately 25mm 1 in in from the outer edge so that the application of the pressure at the inner section will cause the outer rim to move away from the flywheel a...

Page 1218: ...ng and collar rotate with the flywheel when the clutch is engaged When the clutch is disengaged the release bearing rotates with the flywheel but the driven plate and the clutch shaft rotate as dictat...

Page 1219: ...CLUTCH 7C 5 Fig 7C 6 C K Truck Clutch Controls...

Page 1220: ...Fig 7C 7 G Truck Clutch Controls...

Page 1221: ...CLUTCH 7C 7 Fig 7C 8 P Truck Clutch Controls...

Page 1222: ...e fingers or to prevent the bearing from running continually A clutch that has been slipping prior to free play adjustment may still slip right after the new adjustment due to previous heat damage C K...

Page 1223: ...ce at pedal 31 to 37mm 11 4 to 1 1 2 in is proper clearance Readjust if necessary INSUFFICIENT CLUTCH RELEASE Where complaints of first or reverse gear clash due to insufficient clutch release are enc...

Page 1224: ...e Burned or smeared resin on flywheel or pressure plate a Install new disc and correct leak b Replace transmission clutch gear c Tighten or replace mountings d Replace pressure plate or flywheel e Sa...

Page 1225: ...tion 1 Install the pressure plate in the cover assembly lining up the notch mark on pressure plate with notch mark on flange of cover 2 Install pressure plate retracting springs lockwashers and drive...

Page 1226: ...phite grease as shown in Fig 7C 13 8 Install release bearing assembly to the clutch fork Install clutch and flywheel housing to engine 9 Assemble transmission as outlined in Section 7B 10 Align push r...

Page 1227: ...pring to pedal then rotate pedal forward of bumper stop slide shaft into position in support and release pedal against bumper stop 2 Install clutch pedal shaft bushing over pedal shaft end and into pl...

Page 1228: ...transmission clutch shaft If splines are worn the clutch disc or clutch gear should be replaced as necessary 7 Inspect clutch fork ball socket and fingers for wear and ball retaining spring for damage...

Page 1229: ...other hand grasp strut as shown in Fig 7C 22 3 Insert strut in the slots in the pressure plate lug drop slightly and tilt the lower edge until it touches vertical milled surface of lug 4 Insert lower...

Page 1230: ...th the tops of the eyebolts Slowly release pressure of spindle and remove cover assembly from press Adjusting Levers While no wear adjustment is needed because of the coil spring design it is imperati...

Page 1231: ...7C 29 to eyebolt with a dull punch to lock adjustment 6 Loosen the cover to flywheel bolts a turn or two at a time and in rotation until spring pressure is relieved to allow clutch and gauge plate to...

Page 1232: ...7C 18 CLUTCH i i 1 J 6456 01 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 Fig 7C S T C lutch S pecial Tools...

Page 1233: ...ission gearshift lever Furthermore the transfer case shift pattern is not in a straight line for 208 models the range positions are shown in Fig 7E 2 Four Wheel Drive Indicator Lamp An indicator lamp...

Page 1234: ...7E 2 TRANSFER CASE Fig 7E 1 Model 208 Transfer Case Cross Section...

Page 1235: ...onary and does not rotate This causes the planetary pinions to rotate about the annulus gear internal teeth producing a gear reduction ratio of 2 61 1 SERVICE DIAGNOSIS GENERAL Before attempting to re...

Page 1236: ...3 In s ta ll R o d S w ive l in S h ift L e ver H o le 4 H ang 2 0 0 th ic k Gage C o ve r R o d b e h in d S w iv e l 5 R u n Rear R o d N u t A a g ainst Gage w ith S h ifte r a g a in st 4 H I s t...

Page 1237: ...M J TRANSFER CASE 7E 5 STRUT ROD SKID PLATES 102757 AUTOMATIC Fig 7E 5 Transfer Case Shifter Skid Plates and Strut Rods...

Page 1238: ...7E 6 TRANSFER CASE WITH AUTOMATIC TRANSMISSION WITH MANUAL TRANSMISSION Fig 7E 6 Transfer Case Attachments...

Page 1239: ...ON II only Check for leaks and repair if necessary Note If unit is still noisy after drain and refill disassembly and inspection may be required to locate source of noise NOISY IN OR JUMPS OUT OF FOUR...

Page 1240: ...l transmission to transfer case gasket on transmission 2 Shift transfer case to 4H position if not done previously 3 Rotate transfer case output shaft by turning yoke until transmission output shaft g...

Page 1241: ...G R A C E T H IC K 68 LO C K M O D E IN D IC A T O R S W IT C H 15 D R IV E S P R O C K E T S N A P R IN G 45 CA SE M A G N E T A N D W A S H E R 16 D R IV E S P R O C K E T 46 F R O N T O U T P U T S...

Page 1242: ...s assembly Fig 7E 15 Lift evenly on both sprockets to REPAIR remove assembly Mainshaft roller bearings may drop out of driven sprocket 16 Remove front output shaft and front thrust bearing assembly Fi...

Page 1243: ...amage and check all gear splines for burrs nicks wear or damage Remove minor nicks or scratches on oil stone Replace any part exhibiting excessive wear or damage Inspect all snap rings and thrust wash...

Page 1244: ...ct the condition of all needle roller and thrust bearings in the front and rear case halves and the input gear Also check the condition of the bearing bores in both cases and in the input gear rear ou...

Page 1245: ...nd tighten lock plate attaching bolts to 41 N m 30 ft lb Bearing and Bushing Replacement All of the bearings used in the transfer case must be correctly positioned to avoid covering the bearing oil fe...

Page 1246: ...u tp u t S h a ft F ro n t B earing R ep lacem en t 1 Remove bearing using Tools J 8092 and J 29168 Fig 7E 26 2 Install new bearing using Tools J 8092 and J 29167 Fig 7E 27 3 Remove installer tools a...

Page 1247: ...oles are not covered Also be sure bearings are flush with case bore surfaces M a in s h a ft Pilot B earing R ep lacem en t 1 If bearing cannot be removed by hand remove it using Slide Hammer J 2619 0...

Page 1248: ...ork as assembly 15 Install synchronizer blocker ring 16 Coat mainshaft with liberal amount of petroleum jelly and position bearing retainer Install two rows of 60 needle bearings on mainshaft separate...

Page 1249: ...ten fill plug to 24 N m 18 ft lb MODEL 205 TRANSFER CASE 30 SERIES GENERAL DESCRIPTION A transfer case mounts behind the transmission and allows drive torque to be transmitted in a proportional split...

Page 1250: ...C over and G asket 50 W asher 9 R o lle r Bearings 25 B earing 36 T h ru s t W asher 51 L o c k n u t 10 Spacer 26 S pe e d o m e te r G ear 37 Snap R ing 52 O u tp u t Y o k e 11 T h ru s t W asher 2...

Page 1251: ...nt 2 Replace from Position 3 Missing detent ball or spring 3 Replace Lubricant 1 E xcessive lubricant in case 1 Adjust level Leaking 2 Leaking seals or gaskets 2 Replace 3 Loose bolts 3 Tighten 4 Scor...

Page 1252: ...7E 20 TRANSFER CASE Fig 7E 39 Transfer Case Attachment Typical...

Page 1253: ...7E 39 40 and 41 Refer to these figures when removing or replacing these components 102825 W IT H T H M 4 0 0 102827 W IT H M A N U A L 4 S P E E D Fig 7E 40 Skid Plates Fig 7E 42 A dapter Assembles UN...

Page 1254: ...both shift rails in neutral and using a long narrow punch drive shift fork pins through shift rails into the case Fig 7E 48 4 Remove clevis pins and shift rail link 5 Remove shift rails Fig 7E 49 uppe...

Page 1255: ...e cto r Link 6 0 N ee d le B e aring s 12 S na p Ring 35 Front W h e e l Drive S hift Rail 6 1 S pa ce r 13 T h ru s t W a s h e r 36 In te rlo ck Pins 62 N ee d le B ea rin g 14 T h ru s t W a s h e...

Page 1256: ...for further service Bearings are nonadjustable and if worn or damaged must be replaced with new parts Inspect shaft splines and gears If any indication of failure such as chipped teeth or excessive w...

Page 1257: ...Start range rail into case from front with poppet notches up 7 Install sliding clutch onto fork place over input shaft in case Position to receive range rail and push rail through to neutral position...

Page 1258: ...t low gear onto shaft with clutch teeth facing down 3 Install thrust washer over gear with tab pointing up and away from gear Install washer pin and also large thrust washer over shaft and pin Rotate...

Page 1259: ...TRANSFER CASE 7E 27 102837 Fig 7E 59 Installing Rear Output Shaft Spacer and Speedometer Gear Fig 7E 60 lnstalling Rear Bearing Retainer Seal...

Page 1260: ...BOLT SUPPORT STRUT ROD TRANSMISSION END 40 54 40 54 TRANSFER CASE END 150 200 150 200 MODEL NO 205 PART TIME 208 PART TIME AVAILABILITY ALL K30 SERIES ALL K10 20 SERIES RATIOS HI RANGE LO RANGE 1 00 T...

Page 1261: ...J 29170 Input Gear Bearing Remover J 29163 Ft Output Shaft Rear Bearing Installer J 29169 Input Gear Bearing Installer J 29168 Ft Output Shaft Ft Bearing Remover J 29174 Mainshaft Bearing Installer J...

Page 1262: ...t Bearing Retainer Seal Installer 6 J 21359 Rear O utput Shaft Bearing Retainer Seal Installer 7 J 23431 Rear O utput Shaft Housing Bearing Remover and Installer 8 J 8611 01 Adapter Seal Installer 9 J...

Page 1263: ...er and backing lamp switches head and parking lamps stop tail side marker clearance and identification lamps instrument illumination directional signal and indicator lamps and the necessary wiring to...

Page 1264: ...RCUIT BREAKER a FUSE WINDSHIELD WIPER j Bj RECEPTACLE IGN ACC ltADIO AUX B A l j_Cj FUSE STOP TRAF HAZARD LPS d POWEH ACCESSORY e j RECEPTACLE POWER DOOR LOCK j F j FUSE INST PANEL LAMPS j G RECEPTACL...

Page 1265: ...1 Check and secure connections at dimmer switch and light 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 Chec...

Page 1266: ...dark blue white 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...

Page 1267: ...e If new fuse 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...

Page 1268: ...rear lamps operate 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...

Page 1269: ...e lamp inoperative or intermittent 1 Loose or burnt out bulb 2 Loose connection 3 Open ground connections 1 Secure or replace bulb 2 Tighten connectors 3 Repair bulb ground circuit Both lamps inoperat...

Page 1270: ...2 Defective directional 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 cance...

Page 1271: ...diagrams use metric wire size designations a chart showing metric to AWG size conversions is provided in the manual HEADLAMP ADJUSTMENT Fig 8A 2 The headlamps must be properly aimed to obtain maximum...

Page 1272: ...LECTRICAL BODY AND CHASSIS RADIATOR SUPPORT VIEW A FRONT FENDER ASSEMBLY FORWARD LAMP HARNESS BULB RADIATOR GRILLE LOWER PANEL RADIATOR SUPPORT RADIATOR GRILLE LOWER PANEL Fig 8A 3 Front Lighting C K...

Page 1273: ...rotating bulb socket counterclockwise 4 Connect wiring harness to new housing by inserting bulb socket into housing and rotating clockwise 5 Install bulb if removed during disassembly Install lens an...

Page 1274: ...nt Same as Right Front Side Marker Lamp Bulb and or Housing Replacement All Vehicles Bulb on G Models without interior trim may be removed from inside the vehicle C K 16 03 and 63 with E63 and 06 Mode...

Page 1275: ...ELECTRICAL BODY AND CHASSIS 8A 13 LICENSE PLATE BRACKET VIEW A LICENSE PLATE BRACKET HARNESS ASSEMBLY Fig 8A 6 Rear Lighting C K Models Except with E56 or E62...

Page 1276: ...e switch knob and rod 3 Remove instrument cluster bezel screws on left end Pull out on bezel and hold switch nut with a wrench 4 Disconnect multiple wiring connectors at switch terminals 5 Remove swit...

Page 1277: ...C O M B IN A T IO N LAM P GRAY 0 3 6 3 M O D E L S W IT H O P T I O N E 6 3 TAIL C O M B IN A T IO N LAMP G RAY BACK UP LAMP W HITE MARKER LAMP CREAM BACK UP L A M P H fvTTwfA WHITE TYPICAL 0 6 1 4 M...

Page 1278: ...8A 16 ELECTRICAL BODY AND CHASSIS Fig 8A 11 License Plate Lamps C K Series...

Page 1279: ...LY VIEW A NUT B ATTERY G R O U N D H O RN A S S E M B LY E N G IN E H A R N E S S VIEW B VIEW C PARKING BRAKE CABLE PA RK ING BRAKE NUT VIEW D Fig 8A 13 G Series Forward Lamp Wiring FUSE PANEL fw d P...

Page 1280: ...8A 18 ELECTRICAL BODY AND CHASSIS VIEW A VIEW B Fig 8A 15 CK Series Rear Lamp W iring...

Page 1281: ...ELECTRICAL BODY AND CHASSIS 8A 19 Fig 8A 16 CK Series Auxiliary W iring...

Page 1282: ...1 161 1 CP Choke heater Ind 1 168 3 CP 1 On CA KA 10 35 instrum ent clusters only 2 3 lamps used on instrum ent cluster on P models or C K w o gauges 3 Double filam ent sealed beam 60W high beam 50W l...

Page 1283: ...ect battery ground cable 2 Pull off radio control knobs and remove knob bezels Remove nuts and washers from control shafts using a deep well socket 3 AM Radio Remove the radio support bracket stud nut...

Page 1284: ...A M Radio 1 Slide radio dial lens upward approximately 1 8 inch 2 Tip bottom edge of lens outward toward technician and remove lens 3 Pull out bulb section and remove bulb 4 Install new bulb into soc...

Page 1285: ...aker attaching screws disconnect speaker wiring harness and remove speaker 7 To install reverse Steps 1 6 above 8 Check operation REAR SPEAKER C K Series Replacement Fig 8B 5 1 Remove four screws secu...

Page 1286: ...RCUIT BREAKER Fig 8B 8 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 1287: ...n locating and correcting a failure in the body wiring electrical system 1 If a major portion of the electrical circuit becomes inoperative simultaneously the failure may be due to improper connection...

Page 1288: ...pe light duty trucks have a non sequential timer controlled seat belt warning system This system has an instrument panel warning light that will illuminate every time the ignition switch is turned on...

Page 1289: ...Fig 8B 12 Seat Belt Reminder System Diagnosis SEAT BELT REMINDER LIGHT BUZZER DIAGNOSIS ELECTRICAL AND WIRING 8B 7...

Page 1290: ...8B 8 ELECTRICAL AND WIRING Fig 8B 13 Seat Belt Reminder System Schematic...

Page 1291: ...Directional Signal Lamp Time Delay Relay Emission Control Solenoid Transmission Downshift M 40 10 Amp In line fuses are located in the auxiliary heater circuits C K P models and underhood lamp front...

Page 1292: ......

Page 1293: ...On Vehicle Service 8C 29 Component Part Replacement 8C 29 Wiper Motor 8C 29 Unit Repair 8C 29 Wiper Washer Disassembly 8C 29 Motor Disassembly 8C 29 Motor Assembly 8C 29 Washer Pump 8C 34 Windshield W...

Page 1294: ...R C O N N E C T J 24538 A T E S T E R TO LE A D T H A T G O E S TO TH E G A G E G A G E R E S P O N D S TO T E S T E R A C C U R A T E L Y G A G E D O E S NOT R E S P O N D C H E C K W IR IN G B E T W...

Page 1295: ...y replace and recheck for noise Whine Oversize driven gear stem in transmission binds with adapter Replace driven gear and stem Buzzing sound with manual transmission Shift linkage vibration Adjust tr...

Page 1296: ...E G A G E R E S P O N D S TO T E S T E R A C C U R A T E L Y G A G E D O E S N O T R E S P O N D C H E C K W I R I N G B E T W E E N S E N D E R C O N N E C T O R E N G I N E H A R N E S S C O N N E...

Page 1297: ...on Loose or intermittent connections in horn relay or horn circuit Check and tighten connections Defective horn switch Replace switch Defective relay Replace relay Defects within horn Replace horn HOR...

Page 1298: ...R C O N N E C T O R OR LOOSE N U T S AT G AG E T E R M IN A L S C H E C K FOR LOOSE N U T S A T G AG E T E R M IN A L S OR LA C K OF G R O U N D C O N N E C T IO N TO G AG E GO O D C O N N E C T IO N...

Page 1299: ...B A C K IN G LA M P SW ITC H See Neutral Start Switch for automatic transmission models C olum n M o u n te d S w itch M a n u a l Transm ission Replacement 1 Disconnect battery ground cable 2 Discon...

Page 1300: ...cement bulb in holder press inward to lock in place 4 Insert holder into housing with lugs on holder entering notches in case and turn clockwise to lock holder against printed circuit LAMINATED PRINTE...

Page 1301: ...C OIL PRESSURE IN D D E N G IN E TEMP IND E BRAKE W A R N IN G IND F G E N TELL TALE G FUEL G A G E CLIPPING H AM P G A G E CLIPPING J BRAKE W A R N EXC U 35 K CLOCK U 35 L TEMP G A G E CLIPPING M BR...

Page 1302: ...edometer Replacement 2 Remove fuel gage attaching screws and remove the gage 3 To install reverse Steps 1 2 above Check gage operation G Models Replacement 1 Remove instrument cluster assembly as prev...

Page 1303: ...1 Perform Steps 1 of Speedometer Replacement procedure 2 Remove gage to cluster attaching screws and remove gage 3 To install reverse Steps 1 3 above and check gage operation G Models Replacement 1 Re...

Page 1304: ...8C 12 INSTRUMENT PANEL AND GAGES INSTRUMENT CLUSTER KOOO OO K30 TRANSFER CASE I 6 Chart 8C F2 Speedometer Cable Routing...

Page 1305: ...INSTRUMENT PANEL AND GAGES 8C 13 ACCELERATOR CABLE DASH PANEL f NOT 1Push on ferrule to speedom eter INSTRUMENT CLUSTER SPLG WIRES TRANS ASM VIEW Chart 8C G2 Speedometer Cable Routing...

Page 1306: ...ull switch which is located on the right side of the steering column opposite the directional signal lever The switch knob must be pulled to cancel circuit The lane changing circuit is activated by ho...

Page 1307: ...TRUMENT PANEL AND GAGES 8C 15 102093 Fig 8C 6 lnstrument Panel Wiring L H G Models C IG LIGHTER C O N N BRACKET BOLTS D IRECTIONAL S IG N A L FLASHER A S M Fig 8C 7 lnstrument Panel W iring R H CK Mod...

Page 1308: ...r motor assembly The wiper motor is protected by an automatic reset type circuit breaker located on the motor brush holder assembly A fuse located in the fuse block protects the vehicle wiring The wip...

Page 1309: ...P OPERATION Pumping Mechanism The basic pump consists of a spring loaded piston enclosed in a plastic cylinder housing Attached to the piston and extending out of cylinder housing is an actuator plate...

Page 1310: ...and valve assembly This pressure build up forces the two exhaust valves open compelling the washer solution to flow to the nozzles See Fig 8C 14 For purposes of explanation only one exhaust valve open...

Page 1311: ...Position DIAGNOSIS WIPER O N VEHICLE Troubleshooting with wiper installed on the vehicle consists of two basic steps A Preliminary inspection and B Operating wiper independent of vehicle wiring and da...

Page 1312: ...ALS 1 2 V NO LOAD CURRENT DRAW 12V Lo Speed 2 5 Amps Max HI Speed 5 0 Amps Max Crank Arm Rotation CCW Looking at Arm 4 LO SPEED Connections to operate wipers Independently of vehicle wiring and dash s...

Page 1313: ...m e in both Lo and Hi 4 5 B lades stop at random positions w hen w ip er is tu rned off Do Not R eturn to Park Position 5 6 W iper w ill not shut off 6 7 In term itten t op eratio n 7 8 W iper m oto r...

Page 1314: ...heck system Locate and repair shorted or grounded condition in wiring Problem is in motor refer to wiper repair page Check dash switch ground wire connection If OK replace dash switch Problem is in mo...

Page 1315: ...n Lo Problem is on open wire from wiper terminal no 2 to dash switch or The Dash Switch Wiper Inop Repair wiper motor Look for Lo speed hung brush PROCEDURE 4 One speed same in both Lo and Hi Problem...

Page 1316: ...Wiper has both speeds STEP 1 Remove wiper fuse from fuse block and connect an ammeter 0 30 amp across the fuse block terminals where the fuse was Turn ignition switch ON and run wiper in H i speed wi...

Page 1317: ...p Inoperative Go To STEP 2 M ake necessary repair or correction and check system If system still inoperative Go To STEP 2 Go To STEP 3 Go To STEP 4 Look for open in B circuit to pum p Replace relay co...

Page 1318: ...ay coil a rm atu re leg dro ps dow n on g e ar ram p and ratch et paw l starts rotatin g ra tc h et gear R efer to view in S T E P 4 R elay a rm atu re o p erates co rrectly but ratch et g ear d o e s...

Page 1319: ...ch or a defective dash sw Disconnect wiring from wiper unit remove washer pump cover and re connect wiring to wiper washer Turn on wiper and check the following items _________ a Ratchet gear dog spri...

Page 1320: ...d will only remain activated as long as the knob is held in position Upon releasing the control knob it will automatically return to OFF position By positioning the control knob in the first detent ri...

Page 1321: ...ch as the crank arm spacer seal plastic and output shaft seal PARK SWITCH This is part of the washer pump relay coil assembly Refer to figure 8C 19 Rem oval 1 Disconnect wiring from wiper assembly and...

Page 1322: ...When re assembling the crank arm be sure wiper motor is in park refer to figure 8C 25 and assemble crank arm on shaft in position shown in Figure 8C 25 Motor G Series W ASHER PUMP Relay Coil This is...

Page 1323: ...2 but read note In order to push gear on shaft until it bottoms move ratchet pawl shaft in a direction away from the gear This will allow gear collar to slide past the tab on the piston actuator plat...

Page 1324: ...A S E D P O S IT IO N 3 S P R IN G S B E S U R E B R U S H L E A D S A R E R O U T E D C O R R E C T L Y A N D A R E N O T T O U C H IN G E A C H O T H E R B R U S H S P R IN G L E G IN C O R R E C T...

Page 1325: ...STIC ARMATURE END PLAY ADJUSTING SCREW Fig 8C 24 Crank Arm Spacer Seal T R U C K C R A N K A R M P A R K P O S IT IO N A X ID E N T IF IC A T IO N C O D E G V A N C R A N K A R M P A R K P O S IT IO N...

Page 1326: ...TRUMENT PANEL AND GAGES P A W L S P R IN G E R E T A IN E R R IN G R A T C H E T G E A R L E G O F R E T A IN E R IN R A T C H E T G E A R S H A F T G R O O V E D O G S P R IN G Fig 8C 26 Washer Pump...

Page 1327: ...The gear train consists of 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...

Page 1328: ...the wiper blades have not reached the park position When the wiper blades are not in the normal park position the parking switch contacts are still closed The wiper will continue to operate until the...

Page 1329: ...operate correctly proceed to Step 3 3 Disconnect wiring harness from wiper and try operating wiper as shown in Figure 8C 31 a If wiper operates correctly independently of switch and vehicle wiring ref...

Page 1330: ...re No 1 terminal on wiper motor to wiper switch A Locate short circuit and repair B Wiper has Lo speed only A Defective wiper switch A Replace wiper switch B Grounded wire No 3 terminal on wiper motor...

Page 1331: ...ure 2 Wiper will not shut off A Wiper has normal Hi and Lo speed A Defective park switch A Replace terminal board assembly B Grounded red lead wire B Repair short circuit in red wire B Wiper has Lo sp...

Page 1332: ...T FROM GRD STRAP WIPER SHOULD STOP WITH GEAR SHAFT FLATS AS SHOWN AMMETER 3 0 AM PS TEST LIGHT PROBES FOR GROUND CHECK IF LAMP LIGHTS ARMATURE IS GROUNDED COMMUTATOR HOOK CHECK FOR POOR WELD JOINTS TE...

Page 1333: ...ir F Wiper switch defective F Replace wiper switch G Ratchet relay coil defective G Replace ratchet relay H Washer nozzles plugged H Clean washer nozzles I Ratchet wheel tooth missing I Replace ratche...

Page 1334: ...rm in a vise and remove crank arm retaining nut NOTICE Failure to clamp crank arm may result in stripping of wiper gears 4 Remove crank arm seal cap retaining ring and end play washers Seal cap should...

Page 1335: ...ushings with light machine oil Fig 8C 37 Washer Pump Attaching Screws G ear Box 1 Assemble gear box using reverse of disassembly procedure Lubricate gear teeth with Delco Cam and Ball Bearing lubrican...

Page 1336: ...e pump and pump actuator plate from frame pull pump housing in direction of the arrow until grooves in housing clear the frame Then remove actuator plate from ratchet wheel and cam follower shafts 6 V...

Page 1337: ...S T R O K E Fig 8C 43 Cross Section of Windshield Washer Pump Valve WIRING DIAGRAMS Body and Chassis Wiring Diagrams and circuit identification charts are shown on the pages which follow W IR E SIZE C...

Page 1338: ...round Eng Temp Sw Controlled Cold 37 Light Green Ground Eng Metal Temp Sw Controlled Hot 38 Dark Blue Flasher Fused Feed Circuit Number Circuit Color Circuit Name 39 Pink Black Feed Ign Sw On and Cran...

Page 1339: ...r Brkr Protected 154 Black Ground Circuit Direct 91 Gray Windshield Wiper Low 155 Black Ground Circuit Direct 92 Purple Windshield Wiper Hi 156 White Ground Circuit Sw Controlled 93 White Windshield W...

Page 1340: ...Sensor Detector Hi Feed Lo 192 Purple Defogger Hi or Single Speed Level IR 193 Purple White Defogger Low Speed 0 38 230 Pink Recorder Power Feed Ohms per foot 231 Orange Driver Initiator Feed IR 194...

Page 1341: ...ight Blue Theft Deterrent Alarm 300 Orange Feed Ign Sw O n Controlled 264 Dark Green Theft Deterrent Arm Indication Unfused 265 Black White Theft Deterrent Alarm Output 318 Yellow Black Relay Activate...

Page 1342: ...IMC Set Timing 463 Black Orange IMC to Trip Computer Signal Fuel Flow Data Injector on Time 464 Tan Black MPG Reset Signal Circuit Number Circuit Color Circuit Name 465 Dark Green White Feed Electric...

Page 1343: ...ed Fused Temp Sensor Output Con 808 Dark Blue Feed EFI Module Fast Idle Valve trolled Output and 3 Circuit Con 822 Dark Blue Ground Resistive Coolant trolled Fused Temp Sensor Controlled 810 Tan Feed...

Page 1344: ...SXL I OK GRN 290 SXL 1 DK GRN 29AISXL _ 0RN9e J4 V r5 LT B LIH 4B SD MRK LP LEFT SPUCE SHEET METAL GROUND ENG BLOCK GAD 8 PNK B LK 39 S X L t DK GRN 29ACSXL 18 0R N 9A 5 CKBULH5A I LTG RW IA 5LTBLU 14...

Page 1345: ...M 8 N nxsic xwd c n x S V 6 C 1 9 M N d 0 H i C D D III SiSt a M 2 i j S i ii SSSbbi a tr i e g X1N0 S 390V9 H U M 0 3 S n n x s iC 6 m g K 8 O xg iC N V i 9 O x g o iH M x N d 9 03t xM dt O x s 9 N...

Page 1346: ...8C 54 INSTRUMENT PANEL AND GAGES Fig 8C 46 CK Series W iring 3 of 29...

Page 1347: ...C SPLICE 39 Vuu 1 th r o tt le lin ked 12004267 INST CLUSTER CJNN I50G TRANSMISSION KICKDOWN SW 5 P N K 3 0 30A GUAGES 3 R E 0 2 A 3 P PL 6 3PNK 3A 3 PNK 3B r8 PNK WH1 350 NOT USEDGUAGES w C choke 5 3...

Page 1348: ...BLU 15B BULK HD CONN 15 5 IT B L U I4 B BULK HO CONN 14 8 BLK 150G SPLICE 150 8 DKBLU 7 5 8 IT GRN 24 TAN WHT 33B 6 DK GRN 35A _ s LT G R N 24 _ 0 DK BLU 75 J3 PNK 94 8 B LK I50E 8 PPL 9 2 8 GRY 91 8...

Page 1349: ...PPL 6 CLUTCH START INTERLOCK MAN TRANS I _ J 3 BRN 4 3 P N K 3 A 0 GRN I4QA 3 RED 2F 8 DK GRN 19 8 YEL 18 8 PPL 16 8 BRN 2 7 5 DK BLU I5A 5 LT BLU I4 A 5 DK G RN 35A 5 TAN WHT 3 3 B I l t g r n i i a...

Page 1350: ...RGO LAMP DO LAMP CONTACTORS PLUG fTO DOOR JAMB SW HARN CONNECTOR X DOME LP 1 SAT FEED _ 2 PNL LP W 3 TAIL LP 4 TAIL LP 5 TAIL LP FEED FUSED I 5 6 HEAD LP l HD Lp qh l PRK ON OFF LIGHT SW 8 W HT 1568 t...

Page 1351: ...INSTRUMENT PANEL AND GAGES 8C 59 SUBURBAN Fig 8C 51 CK Series W iring 8 of 29...

Page 1352: ...4 0 RADIATOR LOW COOLANT LEVEL SENSOR IBR N 25B IS XL 3 P E D 2 C S X D LEFT HAND BATTERY 6 9 50l BOOT P T r r i I y f 2 RE 0 09A THERM O H M r 5 O R N 0 LK 5 0 9 6 L BOOT FU 5 Lt Lm J 0 3 V l r t GLO...

Page 1353: ...T PANEL AND GAGES 8C 61 3 3i n M w i l t I otO O 0 T 0 YEL aoe HW 0 PNK 30 H W REF V C f T I L1BRN256 SXU I BRN25ACSXl 3PNK BLK J9KSXL FRAME GROUND psoo uction TANK SENDER Fig 8C 53 CK Series W iring...

Page 1354: ...8C 62 INSTRUMENT PANEL AND GAGES automatic transmission RPO M06 WO EGHBLEED K TRUCK W D M D t T M N M N U aO N AUTOMATIC TRANSM6SCN RPO M06 W O E6R bleed c truck Fig 8C 54 CK Series W iring 11 of 29...

Page 1355: ...INSTRUMENT PANEL AND GAGES 8C 63 R P OM 0 6 TOANSM fcSON AUTOMATIC TRANSMISSION RPO M 0 6 W ITH EGA BLEED C TRUCK Fig 8C 55 CK Series W iring 12 of 29...

Page 1356: ...w 8 LT BLU BLK 382 8 LT BLU 363 8 LT GRN 364A FRONT OF DASH l 8 L T GRN 3 6 4 C S X D J 0 LT 8LU BLK 3 6 2 0 S X L V 200503 asm RPO M 0 6 TRANSMISSION 8 LT BLU BLK 382 WWT I56A 8 W H T 5 6 6 j8 BRN 1...

Page 1357: ...0 JUNCTION BLOCK WITH TP2 AUX BAT TAIL STOP LAMP REAR wine ASM 5 RED 26 8 LT GRN back 8 B R N t a il 8 YEL l h s t o I D SIG l a D K G N H S T to P iD lR SIG LAMP 5 w h t enou D LICENSE LAMP TO CAMPE...

Page 1358: ...ANEL AND GAGES a u to m a tic tra n s m is s io n RPO M 0 6w ith e g r b le e d k t r u c k DP NEUT ma S TRANSFER CASE l e v e r u g h t MANUAL TRANSMISSION HPT RPQ M2Q MY6 K TRUCK Fig 8C 58 CK Series...

Page 1359: ...0 4 3 7 9 ASM tt BRAKE SWITCH S T O PL A M P CONTACTS TEST ORANGE MX FUSCO n amp E ir 1 n C O M V C L U T C H MM P FUSE BLOCK RPO M V4 T R A N S M ftS C N AUTOMATIC TRANSMISSION RPO MV4 UNJM 5 PPL 2...

Page 1360: ...8C 68 INSTRUMENT PANEL AND GAGES POWCR WINDOWS RPO A 31 FOUR DR Fig 8C 60 C K Series W iring 17 of 29...

Page 1361: ...5 r 8 9 1 7 5 4 6 Q D LT lUJ 383 sa 1 ra S f S I 8 LT 3 K l lZ J reT T U H JB LT BLU 383 S X L 3 8 3 O B A l t L U 3 8 3 6 r C D LT BLU h a J S rs 8 LT GRN 384A SXL C B 8 3 8 LT 0 N 3 6 W S t Z J 8 LT...

Page 1362: ...U LAMP 4 B U LAMP FLEETSOE PICKUP RPQ E 6 3 6 2 M S 6 6 REAR CONN TAJL 1 STOP LP FRONT EXT WWC TAL 4 STOP 4 DtR StG SI MKR 4 B U LAMP TAL 4 STOP 4 DtR SIG SI MKR 4 B U LAMP STEPSO E PICKUP R P 0 E 6 2...

Page 1363: ...INSTRUMENT PANEL AND GAGES 8C 71 ELECTRONIC SPARK CONTROL W ITH RPO L E 9 A U T 0 TRANS Fig 8C 63 CK Series W iring 20 of 29...

Page 1364: ...8C 72 INSTRUMENT PANEL AND GAGES Fig 8C 64 CK Series W iring 21 of 29...

Page 1365: ...INSTRUMENT PANEL AND GAGES 8C 73 CAB CRFW CAB CHASSIS Fig 8C 65 CK Series W iring 22 of 29...

Page 1366: ...8C 74 INSTRUMENT PANEL AND GAGES Fig 8C 66 CK Series W iring 23 of 29...

Page 1367: ...INSTRUMENT PANEL AND GAGES 8C 75 BLOWER MOTOR REAR AIR CONDITIONING RPO C 69 AIR CONOITIQNING RPO C 60 Fig 8C 67 CK Series W iring 24 of 29...

Page 1368: ...BLU 92 5 BLK W HT 91 5 BLK LT BLU 5 G R A 0 9 7 PULSE WIPER ONTROLMODULE L i i 8 P N K 9 4 1 i l l 8 B L K I 50 I 8 P P L 9 2 i 6 G R A 91 J 8 B LK LT BLU 97 5 G R A 8 INST PNL WRG HARN PULSE W IP E...

Page 1369: ...INSTRUMENT PANEL AND GAGES 8C 77 FRONT IDENTIFICATION LIGHTS LEFT LIGHT RIGHT MARKER LIGHT ROOF MARKER LAMP RPO UOI Fig 8C 69 CK Series W iring 26 of 29...

Page 1370: ...OR LOCK SW 8911670 GROVMET D K B L U W H T 1 6 ll l tib l PhjK 7 6 7 1 5 IV t fcLK I t OK BLU WHT 166 s I I s s j OJ P O ft iN C G u P M LH WINDOW MOTOR LH W INDfW SW o JKC i RH WINDOW MOTOR POWER WIN...

Page 1371: ...0 0905425 h 3 0R N B L K 6 0 3 LT BLU 183A 120151 2 3TAN W HT 184 r 3 PNK 76 3 LTBLU 183 3 TAN WHT 184 SPLICE 2004727 TAILGATE 1 QE H E I2 0 0 4 W 0 M 2 0 0 4 S 9 9 E F A K A 3 IM E WOASSftuXD WITH W...

Page 1372: ...8C 80 INSTRUMENT PANEL AND GAGES RT SIDE MARKER L W LT SIOE MARKER FORWARD LAMP RPO V 22 Fig 8C 72 CK Series W iring 29 of 29...

Page 1373: ...506 8 BLK I50A LT HIGH LOW BEAM SHEET METAL GRD S M C t 14 5LT BLU I4B J5BHN 96 LT SOE MARKFR PRO Z62 6 CYL 2 50 CID ENG 3 PINK 3 SXL 8917644 j j l gag 4 GRD STRAP j LWHO l l 7Q77 ENG TO OOY G D OIL P...

Page 1374: ...8C 82 INSTRUMENT PANEL AND GAGES Fig 8C 74 G Series W iring 2 of 19...

Page 1375: ...INSTRUMENT PANEL AND GAGES 8C 83 Fig 8C 75 G Series W iring 3 of 19...

Page 1376: ...8C 84 INSTRUMENT PANEL AND GAGES Fig 8C 76 G Series W iring 4 of 19...

Page 1377: ...B R N 9 A 8 LT GRN 24A 8 VEL 18 8 WHT 1566 8O W N406 PRINTED C IR C U IT B A S E IDENTIFICATION 8 ILLUMINATION 11 HIGH B EA M 14 LT TURN SIGNAL 15 RT TURN SIGNAL 25 GENERATOR LP 2 37 SEAT BELT 30 FUE...

Page 1378: ...31 I BULK HP COHM GAL Cf51 S T CLUSTER CONTfGAUGES P t w r t r c ir c u it c Ajjcts MLLUMINATION ll HIG H BEAM M LT TURN SIGNAL 15 RT TURN SIGNAL 391 VOLT METER iGN 3 0 f u e l j AUGE I50 GR0UND 31 OI...

Page 1379: ...INSTRUMENT PANEL AND GAGES 8C 87 Fig 8C 79 G Series W iring 7 of 19...

Page 1380: ...REST FUSE BLOCK 12015792 ASM 8 LT BLU 383 8 LT G RN 384B 8 LT GW 384A B M 1 S p 8 LT GRN 364A SXL 8917583 1 1 9917580 8 LT GRN 384B SXL ORN 387 SXL RPO MV4 TRANSMISSION TEST 12004275 TRANS PRESSURE SW...

Page 1381: ...O BATTERY 3 8BRN WHT I4I AUX 3ATTERY 2 RED 2A r y 5 RED 2B SXL S P L IC E 2 T H E R M O HW F U S tB L E L IN K c FUSED 10 AMP ef FUSE BLOCK AUXILIARY BATTERY RP0 TP2 CRUISE CONTROL EQUIPMENT P P 0 K 3...

Page 1382: ...STRUMENT PANEL AND GAGES TO MST L VFNT DANEl WIRING LEFT SIDE MARKER BACK UP LAMP 2 DOOR CAB VAN G 30003 R P0 E3I E 34E 6 38 E39 RADIO EQUIPMENT R PO U63 U694 ACCY RR SPKF Fig 8C 82 G Series W iring 1...

Page 1383: ...INSTRUMENT PANEL AND GAGES 8C 91 Fig 8C 83 G Series W iring 11 o f 19...

Page 1384: ...8C 92 INSTRUMENT PANEL AND GAGES BUS BARGWO Fig 8C 84 G Series W iring 12 of 19...

Page 1385: ...OTOR SHEET METAL GRO 8 9 1 7 5 8 0 5 0RNI BLK 852 1 2BRN INST P N l HARN FUSED 2 5 AMP FUSE BLOCK f EF SELECTOR CONTROL 2 BRN 5QH 50 RP0 C60 991737 r 4 4 M 4 891 7580 L 2 BRN l P HARN ACC FUSED 2 0 A...

Page 1386: ...8C 94 INSTRUMENT PANEL AND GAGES 2P IN K 7 h B INSTRUMENT PANEL HARNESS DOME LP S W WIRE Fig 8C 86 G Series W iring 14 of 19...

Page 1387: ...INSTRUMENT PANEL AND GAGES 8C 95 UNLOCK UP l e f t frt SPKR CHANNEL A Fig 8C 87 G Series W iring 15 of 19...

Page 1388: ...AMP wire a s m TO t r a i l e r REF BODY I WIRING HARNESS I LFF T SIDE B R N 9 C 8 YEL 18 8 LT G RN 24 2 9 8 4 6 7 8 y cr g i 24 8 YFI I8A 8 LT GRN 24 8 BRN 9 5 BRN 9A 5 DK GRN 19 5 LT GRN 24 PF F RE...

Page 1389: ...INSTRUMENT PANEL AND GAGES 8C 97 L H STFPWELl LAMP R H STEPWEIL LAMP AUX LIGHTING R RO TR9 STEPWELL 4 READING LAMP Fig 8C 89 G Series W iring 17 of 19...

Page 1390: ...8C 98 INSTRUMENT PANEL AND GAGES Fig 8C 90 G Series W iring 18 of 19...

Page 1391: ...INSTRUMENT PANEL AND GAGES 8C 99 Fig 8C 91 G Series W iring 19 of 19...

Page 1392: ...8C 100 INSTRUMENT PANEL AND GAGES Fig 8C 92 P Series W iring 1 of 11...

Page 1393: ...INSTRUMENT PANEL AND GAGES 8C 101 Fig 8C 93 P Series W iring 2 of 11...

Page 1394: ...18 GPT 20K G fm 9fiP T 2 LTGRN 24 GPT n 6 BRN 9A HDT 8 0RN 9A GPT P1OO r 8 BRN 9B H0T 8 BRN 9K GPT P100 76 LTGRN BfHOT 1 3 LTGRN 248 GPT P 00j 8 LTGRN WUHDT i LTGRN AIGPT PI00 8 DK GRN 19IHDT 8 DK GRN...

Page 1395: ...INSTRUMENT PANEL AND GAGES 8C 103 RADIATOR LOW COOLANT LEVEL SENSOR 0 YEL BLK 60 SXL Fig 8C 95 P Series W iring 4 of 11...

Page 1396: ...8C 104 INSTRUMENT PANEL AND GAGES Fig 8C 96 P Series W iring 5 of 11...

Page 1397: ...TCHING MODULE 8 2 i f i i a SI NOTE THE GROUND LEADS PROVIDED INAlL ELECTRICAL WIRING MUST 8E TERMINATED INA MANNER TO INSURE A COMPLETE UNIFORM A CONTINUOUS VEHICIE ELECTRICAL GROUNDCIRCUIT DIESEL EN...

Page 1398: ...8C 106 INSTRUMENT PANEL AND GAGES PROVISIONS FOR SIDE MARKER LP HIGH LOW SEAM Fig 8C 98 P Series W iring 7 of 11...

Page 1399: ...INSTRUMENT PANEL AND GAGES 8C 107 Fig 8C 99 P Series W iring 8 of 11...

Page 1400: ...8C 108 INSTRUMENT PANEL AND GAGES PROVISIONS FOR SIDE MARKER LP Fig 8C 100 P Series W iring 9 of 11...

Page 1401: ...INSTRUMENT PANEL AND GAGES 8C 109 START RUN OF LOCK ACC Fig 8C 101 P Series W iring 10 of 11...

Page 1402: ...8C 110 INSTRUMENT PANEL AND GAGES IGN SW START OFF LOCK P 3 0 0 3 2 D RIVE Fig 8C 102 P Series W iring 11 of 11...

Page 1403: ...SET COAST button DRIVER OPERATION Engaging the Cruise System The driver accelerates to the desired cruise speed above 30 mph 50 km h and moves the on off resume slider to the on position located on di...

Page 1404: ...ower Speed Disengage the system by depressing the Set Coast button fully and holding it there until the vehicle has decelerated to the new desired speed then release the button slowly The system re en...

Page 1405: ...depressed On manual transmission models the Cruise Clutch Release Valve is mounted on the clutch pedal bracket and disengages the system pneumatically when the clutch pedal is depressed The Cable and...

Page 1406: ...G A G E POSITIO N Lb I s mimt i L q _ H PUSH I r HOLD EN G A G E f t HOLD l B RELEASING MOTION HOLD H O L D ENGAGE Fig 9 6C Cruise Control Switch Operation SW ITCH FUNCTIO N TABLE Sw itch Condition x...

Page 1407: ...N K A G E OR C R U IS E C O N TR O L B EA D C H A IN O N B O W D E N CABLE R E P A IR A S R E Q U IR E D A N D R O A D TEST P E R FO R M G E N E R A L P R E L IM IN A R Y D IA G N O S T IC S Y S T E M...

Page 1408: ...ch can be tested in the same manner Leakage from 15 Hg should not exceed one inch in one minute Harness Test 1 Disconnect engage switch wire harness connector from the main harness connector red brown...

Page 1409: ...ES Check for open circuit in brn wire from engagement switch connector to brake or clutch switch Check brake and clutch switch should have voltage on both terminals when ignition key is in run positio...

Page 1410: ...Control Actuating Engagement Switch 1 Place shift lever in low and remove horn actuator and steering wheel 2 Remove cover plate three screws 3 Remove turn signal lever and conduit from wire assembly 4...

Page 1411: ...can frequently be avoided if the diagnosis chart is used to eliminate problems which can be easily fixed or which are not caused by a faulty player In diagnosing radio tape problems the main point to...

Page 1412: ...suspected the following checks should be made before replacing the windshield 1 Check Tester J 23520 for operation on any vehicle radio antenna that is operating normally to test for a weak or dead b...

Page 1413: ...ACCESSORIES 9 11 Fig 9 3R Radio Static Suppression Typical BRAIDED GROUND BLOWER MOTOR CAPACITOR AM FM HO O D GROUND BRAIDED GROUND Fig 9 4R Testing Windshield Antenna Typical...

Page 1414: ...9 12 ACCESSORIES R A D IO N O IS E D IA G N O S IS IM PRO PERLY O PERA TIN G IGNITION SY STEM HEI Fig 9 5R Radio Diagnosis Chart A...

Page 1415: ...ACCESSORIES 9 13 RADIO NOISE BLOWER MOTOR Fig 9 6R Radio Diagnosis Chart B...

Page 1416: ...9 14 ACCESSORIES D E A D R A D IO A M R A D IO I Fig 9 7R Radio Diagnosis Chart C...

Page 1417: ...ACCESSORIES 9 15 DEAD RADIO AM FM RADIO Fig 9 8R Radio Diagnosis Chart D...

Page 1418: ...THAT ANTENNA IS PLUGGED IN TO RADIO MAKE SURE PLUG ISN T COCKED CHECK AT THE RADIO FOR FAULTY POWER CONNECTION OR SPEAKER CONNECTIONS UNPLUG RADIO POWER LEAD REPLACE FUSE FAULTY C O N N E C T IO N FU...

Page 1419: ...rive cable for broken hook I f OK replace gear and spool assembly BINDING Free up sections or replace mast and support tube LIGHT OFF Replace Relay LIGHT ON Check relay connections ground wire black a...

Page 1420: ...a motor fo r repair Disconnect 3 wire connector with pink wire at antenna relay Install new radio fuse FUSE BLOWS Check yellow wire from fuse panel to radio and pink wire from radio to relay connector...

Page 1421: ...no on car service of the AM FM antenna other than cleaning of the mast sections On the Tri Band antenna the load coil and tip are servicable in the event of damage or loss The load coil has an adjust...

Page 1422: ...CABLE s L O A D C O IL A D J U S T M E N T S T U R N O N L Y 1 8th T U R N A T A T IM E P O S S IB L E SW R R E A D IN G S 1 Initial readings taken on Channel 1 20 40 a SWR of 2 1 or lower on Channel...

Page 1423: ...then adjusted for the most pleasant stereo listening The tape player is equipped with a cartridge locking arm to hold the cartridge in a rigid position against the capstan drive for minimum wow and f...

Page 1424: ...rough the dash panel from the forward side 7 Reverse Steps 1 5 above to complete installation Be sure cable grommet is properly positioned in dash panel POWER AN TEN N A DESCRIPTION AND OPERATION The...

Page 1425: ...nect electrical leads and remove antenna and motor assembly 6 To install reverse steps 1 5 above POW ER AN TEN N A RELAY The power antenna relay is bracket mounted to the parking brake assembly as ill...

Page 1426: ...AISE TO LOWER MOTOR AND GEAR HOUSING GREEN GREY Disengage cable from gear by rotating cable 90 POWER A N T EN N A D IS A S SE M B L Y SL IM L IN E N O TIC E W ith the exception of load coil on the tri...

Page 1427: ...BLY ARM ATURE Position switch levers between thrust blocks MOTOR AND GEAR HOUSING 4 R E M O V E A N D IN S T A L L A R M A T U R E A N D M A G N E T A S S E M B L Y R E M O V A L 1 Remove parts as sho...

Page 1428: ...AR AND SPOOL ASSEMBLY CABLE HOOK REMOVE AND IN STALL CB LOAD COIL AND OR TIP R E M O V A L 1 Disconnect Neg Battery Cable 2 Turn on ignition and radio then connect battery long enough to raise antenna...

Page 1429: ...eme International This was done to reduce the number of sizes used and yet retain the best strength characteristics in each thread size For example the customary I 4 20 and I 4 28 screws are replaced...

Page 1430: ...V E C O A TIN G NYLON PATCH N Y L O N W ASHER IN S E R T c p eJ N Y LO N STRIP OR PATCH O U T OF R O U N D T H R E A D A R E A T H R E A D P R O F IL E D E FO R M E D RECOMMENDATIONS FOR REUSE A CLEAN...

Page 1431: ...ic nuts will be marked with single digit strength identification numbers on the nut face The following figure illustrates the different strength markings GRADE 2 GRADE 5 GRADE 7 GRADE 8 GM 200 M GM 28...

Page 1432: ...87 cm Pounds sq in 6 895 kilo paseaIs 0 016 4 liters 1 Quart 0 946 4 liters ENERGY OR WORK Gallon 3 785 4 liters Yard 0 764 6 meters3 m3 BTU 1 055 joules J Foot pound 1 355 8 joules MASS Kilowatt hour...

Page 1433: ...937 45 64 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 49 64 765625...

Page 1434: ...trolle d C ata lytic HVM H eater V ent M odule Sol Solenoid Converter CB Citizens Band Radio IAC Id le A ir Control T T urbocharger CCOT C ycling Clutch O rifice Tube 1C Inte g ra te d C ircuit TAC Th...

Page 1435: ...t f l i t 1...

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