7A-12
A UTO M ATIC T R A N SM ISSIO N S
3. R eplace the com position-faced clutch plate assemblies.
(T he facing m aterial m ay becom e separated from the
steel center portion).
4. R eplace the nylon w ashers, speedom eters gears and
governor g ear. (T h e nylon can swell and becom e
dam aged.)
5. Flush the converter, including T .C .C . types.
6. T horoughly clean and rebuild transm ission, using new
gaskets and oil filter.
7. Flush the cooler lines afte r the transm ission cooler has
been properly repaired or replaced.
Clutch P late Diagnosis
1. Com positioned Plates.
a. Dry plates and inspect for pitting, flaking, wear,
glazin g , c rack in g , c h a rrin g and chips or m etal
particles im bedded in lining.
b. If a com positioned plate shows any of the above
conditions, replacem ent is required.
2. Steel Plates.
a. W ipe plates dry and check for discoloration. If the
surface is sm ooth and even color sm ear is indicated,
th e p late should be reused. If severe h e a t spot
discoloration or surface scuffing is indicated, the
p late m ust be replaced.
3. C lutch Release Spring.
a. Evidence of extrem e heat or burning in the area of
the clutch m ay have caused the springs to take a heat
set and would require replacem ent of the springs.
Causes of Burned Clutch Plates
1. Forw ard C lutch
a. C heck ball in clutch housing dam aged, stuck or
missing.
b. C lutch piston cracked, seals dam aged or missing.
c. Low line pressure.
d. Pum p cover oil seal rings m issing, broken or
undersize, ring groove oversize.
e. C ase valve body face not flat or porosity between
channels.
2. Interm ed iate C lutch
a. Interm ed iate clutch piston seals dam aged or missing.
b. Low line pressure.
c. C ase valve body face not flat or porosity between
channels.
3. D irect C lutch
a. C lutch piston seals dam aged or missing.
b. C ase valve body face not flat or porosity between
channels.
Burned clutch plates can be caused by incorrect usuage
of clutch plates. Also, engine coolant in transm ission fluid
can cause severe d a m ag e , such as larg e pieces of
composition clutch plate m aterial peeling off.
On 350C, an inoperative E xhaust G as R ecirculation
System
will
raise engine vacuum , c au sin g
lower
transm ission oil pressure which will result in burned clutch
plates.
Case Porosity Repair
E x te rn a l leaks caused by case p o rosity have
successfully been re p a ire d w ith th e tran sm issio n in the
vehicle by using the following recom m ended procedures:
1. R o ad te st an d brin g th e tran sm issio n to o p e ra tin g
tem p eratu re, approxim ately 93°C (200°F).
2. Raise vehicle on a hoist or ja c k stand, engine running
and locate source of oil leak. C heck for leak in all
operating positions. A m irror m ay be helpful in finding
leaks.
3. S h u t engine off and th o ro u g h ly clean a re a to be
repaired with a cleaning solvent and air dry.
4. Using instructions of the m an u factu rer, mix a sufficient
am ount of epoxy, No. 1052533, or equivalent to m ake
repair. Observe cautions of m an u factu rer in handling.
5. W hile the transm ission case is still H O T, apply the
epoxy to the area to be repaired. A clean, dry soldering
acid brush can be used to clean the area and also to
apply the epoxy cem ent. M ake certain the area to be
repaired is fully covered.
6. Allow cem ent to cure for three hours before startin g
engine.
7. Road test and check for leaks.
Service M ethods
W hen servicing the transm ission, it is recom m ended
th a t upon disassem bly of a unit, all parts should be cleaned
and in spected as o u tlined u n d e r C L E A N IN G A N D
IN S P E C T IO N . The unit should be reassem bled before
disassem bly of o th er u nits to avoid confusion and
interchanging of parts.
1. Before disassem bly of the unit, thoroughly clean the
exterior.
2. D isassem bly and reassem b ly of the u n it an d the
subassem blies m ust be m ade on a clean bench. As in
repairing any hydraulically operated unit, cleanliness is
of the utm ost im portance; therefore, the bench, tools,
and parts m ust be kept clean a t all times.
3. Before in stallin g cap screw s into a lu m in u m p a rts,
A L W A Y S D IP S C R E W S IN T O T R A N S M IS S IO N
O IL to prevent cap screws from galling the alum inum
threads and also to prevent the screws from seizing.
4. Always use a torque w rench when installing cap screws
into alu m in u m p a rts to prev en t the possibility of
stripping the threads.
5. If tapped, threads in alum inum parts are stripped or
dam aged, the p art can be m ade serviceable by the use
of Heli-Coils or equivalent.
6. Seal protecting tools m ust be used when assem bling the
units to prevent dam age to the seals. The slightest flaw
in the sealing surface of the seal can cause an oil leak.
7. T he alum inum castings and the valve parts are very
susceptible to nicks, burrs, etc., and care should be
exercised when handling them .
8. The internal snap rings should be expanded and the
external snap rings com pressed if they are to be reused.
This will insure proper seating when installed.
9. R eplace all " O " rings, gaskets and oil seals th a t are
rem oved.
O il
seal
rings
should
not
be
Summary of Contents for 1982 Light Duty Truck
Page 1: ......
Page 28: ...HEATER 1A 3 Fig lA 2 Heater Control C K Models Fig lA 3 Heater Control G Models...
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 42: ...HEATER 1A 19 Fig 1A 23 Auxiliary Heater Hose Routing...
Page 56: ...AIR CONDITIONING IB 13 Chart 1B 4 Pressure Cycling CCOT System Diagnosis...
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 76: ...AIR CONDITIONING IB 33 Fig 1B 26 Compressor Mounting...
Page 91: ...IB 48 AIR CONDITIONING Fig 1B 59 C K Models Refrigerant Lines L6...
Page 150: ......
Page 162: ......
Page 164: ...2D 2 BODY Fig 2D 4 Typical Utility Vehicle Model...
Page 182: ...2D 20 BODY Fig 2D 51 Rear Door Controls Fig 2D 52 Rear Door Outside Handle and Lock Cylinder...
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 222: ......
Page 223: ...BODY 2D 61 Fig 2D 139 Front Seat Belt Installation...
Page 228: ......
Page 234: ......
Page 252: ...3B2 8 MANUAL STEERING GEAR Fig 3B2 11 Manual Steering Gear Exploded View...
Page 256: ......
Page 273: ...POWER STEERING SYSTEM 3B3 17 with LE3 Engine Exc HC4 LE4 LG9 LF4 LS9 LT9 and JB7 HC4 and JB8...
Page 342: ......
Page 389: ...REAR SUSPENSION 3D 7 Fig 3D 17 Rear Spring Installation C K Models...
Page 428: ...4 B 1 4 REAR AXLE Fig 4B 8 Gear Tooth Nomenclature Fig 4B 9 G ear Tooth Contact Pattern Check...
Page 444: ......
Page 454: ......
Page 468: ...4 B 5 2 REAR AXLE Fig 4B5 2 Rockwell Assembly...
Page 480: ...4 B 5 1 4 REAR AXLE...
Page 482: ...i...
Page 502: ......
Page 520: ......
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 538: ...5 18 BRAKES Fig 5 10 Parking Brake System Typical...
Page 539: ...BRAKES 5 19...
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 577: ...BRAKES 5 57 4 CONT A SECONDARY DIAPHRAGM B SECONDARY POWER 4 CONT C PRIMARY D Fig 5 5A Service...
Page 604: ......
Page 625: ...NOTES ENGINE 6 21...
Page 626: ......
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 634: ...6A1 8 IN LINE 6 Fig 6Al 7 K Series Engine Rear Mount...
Page 660: ......
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 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 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 731: ...6 2 DIESEL 6A7 3...
Page 760: ...6B 6 ENGINE COOLING Fig 6B 7 A C and A I R Adjustment...
Page 771: ...ENGINE COOLING 6B 17 Fig 6B 20 Engine O il C o o le r 6 2L Diesel...
Page 784: ......
Page 807: ...CARBURETOR MODEL 2SE 6C2 9 Fig 6C2 6 Typical 2SE Carburetor Assembly...
Page 820: ......
Page 830: ...6C4 10 CARBURETOR MODEL M4ME M4MC 101368 Fig 6C4 12 M 4M C M 4M E Carburetor Exploded View...
Page 848: ......
Page 876: ......
Page 888: ...6D 12 ENGINE ELECTRICAL Fig 6D 6C Generator Mounting Fig 6D 7C Generator Mounting...
Page 919: ...ENGINE ELECTRICAL 6D 43...
Page 934: ...Fig 6D 8E Starter M otor Mounting...
Page 974: ......
Page 1011: ...Figure 350C 25A Neutral Engine Running AUTOMATIC TRANSMISSION 350C 11...
Page 1054: ...Fig 7A 1C 400 Autom atic Transmission Side Cross Section Typical...
Page 1152: ...700 R4 40 AUTOMATIC TRANSMISSION Figure 700 R4 76 Transmission Assembly Exploded View...
Page 1162: ......
Page 1189: ...89MM MANUAL TRANSMISSION 7B3 5 Fig 7 3 4 4 Speed 89mm Exploded View...
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 1234: ...7E 2 TRANSFER CASE Fig 7E 1 Model 208 Transfer Case Cross Section...
Page 1252: ...7E 20 TRANSFER CASE Fig 7E 39 Transfer Case Attachment Typical...
Page 1278: ...8A 16 ELECTRICAL BODY AND CHASSIS Fig 8A 11 License Plate Lamps C K Series...
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 1290: ...8B 8 ELECTRICAL AND WIRING Fig 8B 13 Seat Belt Reminder System Schematic...
Page 1292: ......
Page 1346: ...8C 54 INSTRUMENT PANEL AND GAGES Fig 8C 46 CK Series W iring 3 of 29...
Page 1351: ...INSTRUMENT PANEL AND GAGES 8C 59 SUBURBAN Fig 8C 51 CK Series W iring 8 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 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 1379: ...INSTRUMENT PANEL AND GAGES 8C 87 Fig 8C 79 G Series W iring 7 of 19...
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 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 1396: ...8C 104 INSTRUMENT PANEL AND GAGES Fig 8C 96 P Series W iring 5 of 11...
Page 1399: ...INSTRUMENT PANEL AND GAGES 8C 107 Fig 8C 99 P Series W iring 8 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 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 1435: ...t f l i t 1...