Professional Documents
Culture Documents
FOREWORD
It is important to note that this manual contains various CAUTIONS, and NOTICES
which should be carefully read in order to minimize the risk o f personal injury to
service personnel or the possibility that improper service methods will be followed
which may damage the vehicle. It also is important to understand that these CAU
TIONS and NOTICES are not exhaustive. Chevrolet could not possibly know,
evaluate and advise the service trade of all conceivable ways in which service might
be done or o f the possible hazardous consequences of each way. Consequently, Chev
rolet has not undertaken any such broad evaluation. Accordingly, anyone who uses a
service procedure or tool which is not recommended by Chevrolet must first satisfy
himself thoroughly that neither his safety nor the vehicle will be jeopardized by the
service method he selects.
TABLE OF CONTENTS SECTION
GENERAL INFORMATION
General In fo rm a tio n OA
M a in te n a n ce and L u brication OB
CHASSIS SERVICE
Rear S uspension 3D
W h eel and Tires 3E
AXLE
ENGINE
Engine 6
In-Line 6 6A1
S m all Block 6A4
M ark IV 6A5
5.7L(Z) 350 Diesel 6A6
Engine Cooling 6B
Engine Fuel 6C
M o d e l 1ME 6C1
CAUTION M o d el 2SE 6C2
These vehicles contains some parts dimensioned in the metric M o d el M 2 M E 6C3
system as well as in the customary system. Some fasteners are M odel M 4M E 6C4
metric and are very close in dimension to familiar customary fast Fuel S ystem 6C5
eners in the inch system. It is important to note that, during any Engine Electrical 6D
vehicle maintenance procedures, replacement fasteners must Engine Emission Controls 6E
have the same measurements and strength as those removed, Engine Exhaust 6F
whether metric or customary. (Numbers on the heads of metric Engine P erform ance Specifications 6G
bofts and on surfaces of metric nuts indicate their strength.
Customary bolts use radial lines for this purpose, while most TRANSMISSION
customary nuts do not have strength markings.) Mismatched or A u to m a tic 7A
incorrect fasteners can result in vehicle damage or malfunction, or M a nual 7B
possibly personal injury. Therefore, fasteners removed from the C lutch 7C
vehicle should be saved for re-use in the same locations whenever T ra n s fe r Case 7E
possible. Where the fasteners are not satisfactory for re-use, care
should be taken to select a replacement that matches the original.
For information and assistance, see your dealer.
ELECTRICAL — BODY AND CHASSIS
Lam ps and L ig h tin g 8A
Electrical and Wiring 8B
In s tru m e n t Panel and Gages 8C
ACCESSORIES 9
SECTION OA
GENERAL INFORMATION
G e n e ra l.................................................................................................................... 0-1
Vehicle Identification N u m b e r......................................................................... 0-2
Service Parts Identification S tic k e r................................................................. 0-3
Vehicle L o a d in g .................................................................................................... 0-3
Engine Code N u m b e r......................................................................................... 0-3
U nit and Serial N um ber L ocations................................................................. 0-3
Q W A R R A N T Y V O ID E D IF L 0 A 0 E 0 IN E X C E S S OF R A T IN G S Q
SE E O W N E R S M A N U A L FO R O T H E R L O A D IN G A N D IN F L A T IO N D A T A
EXAMPLE ONL Y
and G) Fig. 0A-2--V.I.N. Rating Plate (P Model)
LIG H T T R U C K SERVICE M A N U A L
OA-2 GENERAL INFORMATION
GVWR/BRAKE SYSTEM
GVW R CHECK D IG lT ]
CODE ( IN P O U N D S ) BR A K E SYSTEM
ENGINE TYPE AND MAKE
B 3001 4000 TYPE M A K E (G M )
•c 4001 5000 CODE D IS P L A C E M E N T L IT R E S (C U IN ) E N G IN E S O U R C E M O D ELS R PO
D 5001 6000 D 4.1 L L 6 2 B B L (2 5 0 ) C H EVROLET G LE 3
E 6001 7000 H Y D R A U L IC O N L Y TRUCK SERIES F 5 .0 L V 8 4 B B L (3 0 5 I CHEVROLET C -K -G LF3
F 7001 8000 G 5 .0 L V 8 2 B B L (3 0 5 ) CHEVROLET C -K -G LG 9
■G 8001 9000 1 1 12 T O N H 5 .0 L V 8 4 B B L (3 0 5 ) CHEVROLET C -K -G LE 9
H 9001 10000 2 3 /4 T O N L 5 . 7 L V 8 4 B B L (3 5 0 ) C H EVROLET C -K -G LS 9
J 10001 14000 3 1 TO N M 5 .7 L V 8 4 B B L (3 5 0 ) CHEVRO LET C -K -G -P LT9
K 14001 16000 8 1 12 T O N P 5 .7 L V 8 2 B B L (3 5 0 I C HEVROLET CK LF5
( E L C A M IN O ) W 7 .4 L V 8 4 B B L (4 5 4 ) C HEVROLET C -K -P LE 8
T 4 . 8 L L 6 1 B B L (2 9 2 ) C HEVROLET C -K -P L25
In c lu d e s El C a m in o TRUCK BODY TYPE Z 5 .7 L V 8 D IE S E L (3 5 0 I O L D S M O B IL E CK LF9
In c lu d e s G V a n Bus.
S E D A N P IC K U P (F O R E L C A M IN O O N L Y )
1 H I C U B E /C U T A W A Y V A N V I . N. TYPE M A K E (G M )
LINE AND CHASSIS TYPE 2 FORW ARD CONTRO L CODE D IS P L A C E M E N T L IT R E S (C U IN ) E N G IN E S O U R C E M ODEL RPO
CODE L IN E M O D ELS C H A S S IS 3 FO U R DOOR CAB A 3 . 8 L V 6 2 B B L (2 3 1 ) B U IC K E L C A M IN O LD 5
TYPE 4 TW O D O O R C AB H 5 . 0 L V 8 4 B B L (3 0 5 ) C H EVROLET E L C A M IN O LG 4
C C O N V E N T IO N A L C A B (C l 4X 2 5 VAN J 4 4 L V 8 2 B B L (2 6 7 ) C H EVROLET E L C A M IN O L39
K C O N V E N T IO N A L C A B (K ) 4X 4 6 SUBURBAN K 3 . 8 L V 6 2 B B L (2 2 9 ) CHEVR O LET E L C A M IN O LC 3
P F O R W A R D C O N T R O L C H A S S IS (P) 4 X 2 7 M O TO R HOME
G V A N . SPORT V A N & C U T A W A Y V A N (G ) 4X 2 8 BLAZER
W E L C A M IN O (A P U ) 4X 2 S T A K E /P L A T F O R M
LIG H T T R U C K SE RV IC E M A N U A L
GENERAL INFORMATION OA-3
Fig. 0A-4--Service Parts Identification Plate Fig. 0A-5--Typical Vehicle Loading Condition
LIG H T T R U C K SERVICE M A N U A L
OA-4 GENERAL INFORMATION
OPTIONAL V .I.N .
LOCATION (M20)
V .I.N . LOCATION
V IE W (OPTIONAL) (M40)
V .I.N . LOCATION (M20)
MANUAL AUTOMATIC
LIG H T T R U C K SE RV IC E M A N U A L
GENERAL INFORMATION OA-5
E N G IN E V .I.N . # E N G IN E V .I.N . E N G IN E
DISTRIBUTOR PAD
L6 ENGINE ENGINE
E N G IN E V .I.N .
(OPTIO NAL)
V8 ENGINE — DIESEL
Fig. 0A-7-Engine V .I.N . Location
LIG H T T R U C K SERVICE M A N U A L
MAINTENANCE AND LUBRICATION OB-1
SECTION OB
MAINTENANCE AND LUBRICATION
CONTENTS
LIG H T T R U C K SE RV IC E M A N U A L
OB-2
MAINTENANCE AND LUBRICATION
VEHICLE MAINTENANCE SCHEDULE
OWNER'S SERVICE LOG (M iles) (km) lns#rt " on,h- 1 •I1- <*••• m -v 5/7.500) m column
Closest To Mileage (km) When Service Is Performed.
Item
7.500 15,000 22.500 30,000 37.500 45,000
(Mee*a tt MHw (k>l Wfcklmwr Ocean FW-»t> No. Services (12 000 km) (24 000 km) (36 000 km) (48 000 km) (60 000 km) (72 000 km)
S e c t io n A — L u b r ic a t io n a n d G e n e r a l M a in t e n a n c e
High Altitude Adiustment: Your 1981 General Motors vehicle has been certified to meet emission standards at low mental Vehicle Emission Control Information.” Information regarding adjustment of your vehicle, if permitted, can be
altitude Certain vehicles sold for high altitude use have been adjusted prior to delivery for improved driveability and obtained from the Consumer Relations Office shown in the Owner Assistance Section of your Owner's and Driver's
emission control at high altitude. These vehicles may be identified by additional underhood tune-up label, "Supple- Manual. Include your Vehicle Identification Number in your request.
VEHICLE MAINTENANCE SCHEDULE
OWNER'S SERVICE LOG ( M i l . , I ( M
When To Ptrform Services Item 30.000 37,500
7,500 15,000 22,500 45.000
(M l.— •> MHm (kali WMrtmr Occm n Rfst) No. Services (12 000 km) (24 000 km) (36 000 km) (48 000 km) (60 000 km) (72 000 km)
S e c t i o n A —L u b r ic a t io n a n d G e n t r a l M a in te n ance
A-1 ‘ Fluid Levels Check X X | ' X J L L ......... X X1
Every 1 2 M o n th s or 7 ,5 0 0 M iles C lutch Pedal Free Travel Check/Adjust X X X X X
A -2
A -3 *Engine Oil Change X X X * x X X . ..
X
Fig. OB-1 b--Maintenance Schedule, Gasoline, Light Duty Emissions, California
A -4 * 0 i l Filter Change X X
A -5 ‘ Chassis Lubrication
S e e Explanation A -6 F ront W h eel D rive
A -7 Tire Rotation
A -8 R ear A x le Lubrication
Every 1 2 M o n th s or 1 5 ,0 0 0 M iles
A -9 •C o o lin g System C h eck— See Explanation X X
( 2 4 0 0 0 km ) <
A -1 0 W heel Bearing Repack X
Every 3 0 ,0 0 0 M iles (4 8 0 0 0 km ) A -1 1 M anual Steering G ear Seals Check X
A -1 2 Clutch Cross S haft Lubrication X
Every 1 0 0 .0 0 0 M iles (1 6 0 0 0 0 km ) A -1 3 A uto. Trans. Fluid & Filter Change
S e c t i o n B — S a f e t y M a in t e n e n c e
B-1 O w n er Safety Checks X X X X X X
B -2 Tire, W heel and Disc Brake Check X X X X X X
Every 1 2 M o n th s or 7 ,5 0 0 M iles X X X X X
B -3 ‘ Exhaust System Check X
( 1 2 0 0 0 km )
B -4 Suspension and Steering Check X X X X X X
B -5 Brake and Power Steering Check X X X X X X
B -6 •D riv e B elt C h eck (2) X
B -7 Drum Brake and Parking Brake Check X X X
Every 1 2 M o n th s or 1 5 ,0 0 0 M iles X X X
B 8 Throttle Linkage Check
w U km j
B -9 Bumper Check X X X
B-10 *F u e l Cap, Tank and Lines Check X X X
Se ction C — Em ission Control Maintenance Schedule I
C-1 Therm o. Controlled Air Cleaner Check X
A t firs t 6 M o n th s o r 7,5 0 0 M iles
(12 0 0 0 km ) — T h e n 2 4 -M o n th /
C -2 C a rb u reto r Choke & Hoses Check X X (1) xt;
3 0 ,0 0 0 -M ile (48 000 km ) Intervals C -3 Engine Idle Speed A djustm ent X (1) X
C -7
PCV System Check xP X xT
E v ery 15,000 M ile s (24 000 km ) PC V Valve R e p la cem en t X
C -8 Spark Plug W ires Check X
C -9 Idle Stop Solenoid an d /o r Dashpot Check ---- X
C -1 0 Spark Plug Replacem ent X (1)
E v e ry 3 0 ,000 M ile s (48 000 km ) C -11 Engine Tim ing Adjust & Distrib. Check X
C -1 2 Air C le a n e r & PC V R e p la cem en t X (1)
* C -1 3 E G R System Check X
▲Also A Safety Service *AI»o An Emission Control Service (1) Only these emission control maintenance items are considered to be required maintenance as defined by the
California Air Resources Board (ARB) regulation and are, according to such regulation, the minimum maintenance an
Hioh Altitude Adjustment: Your 1961 General Motors vehicle has been certified to meet emission standards at low
owner in California must perform to fulfill the minimum requirements of the emission warranty. All other emission
altitude. Certain vehicles sold for high altitude use have been adjusted prior to delivery for improved driveability and
maintenance items are recommended maintenance as defined by such regulation. General Motors urges that all
emission control at high altitude. These vehicles may be identified by additional underhood tune-up label, "Supple
mental Vehicle Emission Control Information." Information regarding adjustment of your vehicle, if permitted, can be emission control maintenance items be performed.
obtained from the Consumer Relations Office shown in the Owner Assistance Section of your Owner's and Driver's (2) A separately driven air pump belt check is recommended but not required at 15,000 miles (24 000 km) and 45,000
Manual. Indud* your Vehicle MentMcation Number in your request. miles (72 000 km).
OB-3
OB-4
MAINTENANCE AND LUBRICATION
VEHICLE MAINTENANCE SCHEDULE
V-8 DIESEL FUELED ENGINE
Item
1200 km)
1200 km)
! 800 km)
! 400 km)
1000 km)
1800 km)
1200 km)
: 000 km)
1600 km)
Services
600 km)
800 km)
E
M.OOO
15,000
>7.000
12,000
18,000
13,000
19,000
15,000
30,000
(2,000
48,000
6,000
3,000
M a r t a m H H m /km . W W c k o m O ccan F t a ) No. (For D e ta ils , See Numbered Paragraphs) o
o o § 1
° . §
Fig. 0B-2--Maintenance Schedule-Gasoline - Heavy Duty Emissions
°-s to
at CM n w «*_ m m <e CO
—
S E C T IO N A — L u b ric a tio n an d G e n e ra l M a in te n a n c e
Every 3,0 0 0 Miles A-1 •Engine Oil Change X X X X X X X X X X X X X X X X
(4 8 0 0 km) A -2 *O il Filter Change X X X X X X X X X X X X X X X X
Every 6,0 0 0 Miles A -3 ‘ Chassis Lubrication X X X X X X X X
(9 6 0 0 km) A -4 ‘ Fluid Levels Check X X X X X X X X
A-5 •C rankcase V e ntilation System X X * X X X X X X
See Explanation A-6 Rear Axle Lubricant Check
A-7 Tire Rotation
Every 12 M onths or
1 2 ,0 0 0 Miles (1 9 2 0 0 km) ‘ Cooling System Check X X X X
A-8
Every 15,0 0 0 M iles (2 4 0 0 0 km) A-9 W heel Bearings Repack *! X
*!
Every 3 0 ,0 0 0 Miles (4 8 0 0 0 km) A-10 M anual Steering Gear Check X
Every 1 0 0 ,0 0 0 Miles A -11 Auto Trans. Fluid and
(1 6 0 0 0 0 km) Filter Change
S E C T IO N B — S a fe t y M a in te n a n c e
Every 12 M onths or B-1 O w ner Safety Checks X X X X X X X X
6 ,0 0 0 Miles (9 6 0 0 km) B -2 Tire, W heels and Disc Brake Check X X X X X X X X
B -3 Exhaust System Check X X X X X X X X
B -4 Suspension and Steering Check X X X X X X X X
B -5 Brakes and Power Steering Check X X X X X X X X
B -6 *D rive Belt Check X X X X X X X X
Every 1 2 M onths or B -7 Drum Brakes and Parking Brake Check X X X
1 5 ,0 0 0 M iles (2 4 0 0 0 km) B -8 Throttle Linkage Check X X X
B -9 Bumper Check X X X
S E C T IO N C — E m issio n C o n tr o l M a in te n a n c e
Every 15,0 0 0 M iles (2 4 0 0 0 km) C-1 Fuel Filter Replacement x| X
*1
A t First 3,0 0 0 M iles (4 8 0 0 km)
Then at 30,0 0 0 M ile (4 8 0 0 0 km) C-2 Engine Idle Speeds Adjust X X
Intervals
Every 3 0 ,0 0 0 M iles (4 8 0 0 0 km) C-3 Air Cleaner Element Replacement X
‘ Also A Safety Service *Also An Emission Control Service
High Altitude Adjustment: Your 1981 General Motors vehicle has been certified to meet emission standards at low mental Vehicle Emission Control Information." Information regarding adjustment of your vehicle, if permitted, can be
altitude. Certain vehicles sold for high altitude use have been adjusted prior to delivery for improved driveability and obtained from the Consumer Relations Office shown in the Owner Assistance Section of your Owner's and Driver's
emission control at high altitude. These vehicles may be identified by additional underhood tune-up label, "Supple Manual. Include your Vahid* Identification Number in your request.
MAINTENANCE AND LUBRICATION OB-5
S e c t io n A — L u b r ic a t io n a n d G e n e r a l M a in t e n a n c e
Every 4 m o n th s o r 6 ,0 0 0 m ile s A -1 •C h a s s is L u b ric a tio n X X X X X X X X
(9 6 0 0 k m ) A -2 • F lu id L e vels C he c k X X X X X X X X
A -3 F ro n t W h e e l D riv e X X X X X X X X
A -4 C lu tc h P e d a l F ree T ra v e l C h e c k /A d ju s t X X X X X X X X
A -5 ‘ E n g in e O il C h a n g e X X X X X X X X
A -6 *E n g in e O il F ilte r C h a n g e X X X X
(1 9 2 0 0 k m ) X X X X
A -1 0 C o o lin g S ystem C he c k
C -5 • A ir C lea ne r E le m e nt R ep lac e m e nt X X X X
C -8 • M a n if o ld H ea t V a lv e C he c k X X X X
C -9 C a rb u re to r F ue l F ilte r R e p la c e m e n t X X X X
C -1 0 T h ro ttle R e tu rn C o n tro l C h e c k X X X X
C -1 1 PC V S y s te m C h e c k X X X X
— PC V V a lv e & F ilter S e rvice X X
E very 2 4 m o n th s or C -1 2 ECS S ystem C he ck X X
2 4 ,0 0 0 m ile s ( 3 8 4 0 0 k m ) C -13 E n gin e Id le M ix tu r e A d ju s t (4 .8 L. L - 6 o n ly ) X X
C -14 EFE System C he c k X X
C -1 5 V a c u u m A d v a n c e S ystem C he ck X X
C -1 6 C a rb u re to r C h o k e C he ck X X
MAINTENANCE SCHEDULE
T his is an explanation o f th e service listed in the
Vehicle M aintenance Schedule.
SECTION A
N O R M A L V E H IC L E U S E -T h e m ain ten an ce in LUBE & GENERAL MAINTENANCE
structions contained in the m aintenance schedule are based
on the assum ption th a t the vehicle will be used as designed: A -l Fluid Levels
• To carry passengers and cargo within the lim itations Check battery and the following fluid levels:
indicated on the T ire Placard located on the edge of the Battery Care
driver’s door,
The original equipm ent battery (two batteries on diesel
• on reasonable road su rfaces w ithin legal o perating engine) needs no periodic m aintenance. Its top is perm a
limits, nently sealed (except for two small vent holes) and has no
• on a daily basis, as a general rule, for at least several filler caps. W ater will never have to be added.
miles (km ), and The h y drom eter (te st indicator) in the top of the
• O n unleaded gasoline (gasoline light duty emission battery provides inform ation for testing purposes only. See
only). Section 6D for battery test procedures.
• Always wear eye protection or shield your eyes when (Also a Safety Service)
working near any battery. Do not lean over a battery. Check the fluid level in the power steering pum p at
Remove all m etal jewelry. each oil change and add G M Power Steering FLuid (G M
• N ever expose a b a tte ry to open flames or electric 1050017) or equivalent as needed (Fig. OB-4):
sparks. Also, do not smoke near a battery. • If fluid is w arm ed up (about 150°F or 6 6 °C -h o t to the
• Do not allow b attery acid to contact eyes, skin, fabrics touch), it should be between " H o t" and "C old" marks
or painted surfaces. F L U S H A N Y C O N T A C T E D on the filler cap indcator.
A R E A W IT H W A T E R IM M E D IA T E L Y A N D • If cool (about 70°F or 21°C), fluid should be between
T H O R O U G H L Y . G E T M E D IC A L H E L P IF EY ES "A d d " and "C old" marks.
ARE A FFECTED .
Fluid does not need periodic changing.
• Be sure the ju m p er cables or clam ps to be used for jum p
starting do not have loose or missing insulation. Do not
proceed if suitable cables are not available. Rear Axle (Standard) Lubricant
• T his vehicle has a 12-volt b a tte ry and a negative Check lubricant level. Add lubricant, if necessary, to
ground electrical system. M ake sure th at the other fill to level of filler plug hole. Use SA E 80W GL-5 or SA E
vehicle also has a 12-volt b attery and th at it is the 80W -90 GL-5 or G M 1052271 /1052272 gear lubricant. For
negative (black te rm in a l w hich is grounded those vehicles driven in C anada, use SA E 80W GL-5 gear
(attached to the engine block). Its ow ner’s m anual may lubricant.
give you th a t inform ation. Do not try to jum p start if
you are unsure of the other vehicle’s voltage or ground Rear Axle (Limited-Slip) Lubricant
(or if the other vehicle’s voltage an d /o r ground are Check lubricant level. Add lubricant, if necessary, to
different from your vehicle). fill to level of filler plug hole. Use gear lubricant GM
• If either battery has filler caps, check the fluid level. 1052271/1052272 or equivalent.
(Do not check with an open flame.) If low, fill to the
proper level with clear drinking w ater. Replace all caps Automatic Transmission Fluid
before jum p starting. Use only auto m atic transm ission fluid labeled
• Do not allow m etal tools to contact both the positive D E X R O N ® -II or equivalent.
(red " + ") b attery term inal (or any m etal connected to Check the autom atic transmission fluid level at each
this term inal) and any other m etal on either vehicle at engine oil change period. Overfilling can cause foaming and
th e sam e tim e. M ake certain when a tta c h in g the loss of fluid. Transmission dam age can result. Low fluid
jum per cable clam ps to the positive .term inals of the level can cause slipping or loss of drive.
batteries th at neither clam p contacts any other m etal. A utom atic transmissions are often overfilled because
• Always make the final connection to ground (a solid, the fluid level is checked when the fluid is cold. W hen cold,
stationary, m etallic object) on the engine at least 450 the dipstick shows th at fluid should be added. However, the
m illim eters (18 inches) from the battery.
L IG H T T R U C K SE RV IC E M A N U A L
MAINTENANCE AND LUBRICATION OB-7
low reading is normal, the level will rise as the fluid gets • Use a fluid such as G M Optikleen or equivalent to help
warm. The fluid level will increase more than 3/4 inch prevent freezing dam age, and for better cleaning.
(19m m ) as fluid warm s up from 60°F to 180°F (16°C to • Do not use ra d ia to r an tifreeze in the w indshield
82°C). washer; it could cause paint dam age.
C heck th e transm ission fluid level w ith the engine • In cold weather, warm the windshield with the defrosters
running, the shift lever in " P a r k ", and the vehicle level. before using the washer--to help prevent icing that may
If the vehicle has ju st been driven for a long tim e at block the driver’s vision.
high speed or in city traffic in hot w eather, or if the vehicle
has been pulling a trailer, the correct fluid level cannot be Cooling System Care
read. W a it until th e fluid has cooled down (ab o u t 30 Do not remove radiator cap to check coolant level.
m inutes). Instead, check by looking at the "see through" coolant
Remove the dipstick. C arefully touch the wet end of the recovery tank. Level should be at the "F ull C old" m ark or
dipstick to find out if the fluid is cool, w arm or hot. W ipe it the recovery tank when the system is cold; and at the "Full
clean and push it back in until cap seats. Pull out the H ot" m ark during engine operation. Add a 50/50 mixture
dipstick and read the fluid level (fig. OB-5). of a good quality ethylene glycol antifreeze and w ater to the
• If it felt cool, about room tem perature, the level should recovery tank when more coolant is needed. If frequent
be 1/8 to 3/8 inch (3 to 10mm) below the "A d d " m ark. additions are needed, cooling system.
The dipstick has two dim ples below the "A d d " m ark to NOTICE: If the proper quality antifreeze is used, there is
show this range. no need to add extra inhibitors or additives th at claim
• If it felt warm , the level should be close to the "A d d " to improve the system. They may be harm ful to the
m ark (either above or below). proper operation of the system, and are an unnecessary
expense.
• If it was too hot to hold, the level should be at the
"F u ll" m ark. A-2 Manual Transmission Clutch Adjustment
• It takes only one pint (0.5 liter) to raise level from C lutch adjustm ent should be checked and adjusted as
"A d d " to "F u ll" with a hot transm ission. necessary to com pensate for clutch facing wear. To check,
depress pedal by hand until resistance is felt. Free travel
should be approxim ately one to one and a half inches; if very
M anual Transmission Lubricant little or no free travel is evident, clutch a d ju stm en t is
C heck lubricant level. A dd lubricant, if necessary, to required.
fill to level of filler plug hole.
A-3 and A-4 Engine Oil and Filter
U se SA E 80W G L-5 or S A E 80W -90 G L-5 gear
lubricant. For those vehicles driven in C anada, use SA E (Also an Emission Control Service)
80W G L-5 gear lubricant.
Engine Oil and Filter Recommendations
Windshield Washer Fluid
Gasoline Engine
(Also a Safety Service) • Engine oils are labeled on the containers with various
A PI (A m erican Petroleum Institute) designations of
Fill the w asher ja r only 3 /4 full during the w inter to quality.
allow for expansion if th e te m p e ra tu re should fall low • Use only S F q u ality engine oils (see m arkings on
enough to freeze the solution. containers).
• C heck the w asher fluid level re g u la rly -d o it often when • The oil and filter change intervals for the engine is
the w eather is bad. based on the use of SF-quality oils and high quality
filters. Using oils other than SF-quality oils, or oil
change intervals longer than listed, could reduce engine
life and m ight affect w arranty.
• The engine was filled with an S F quality engine oil
when it was built. You do not have to change this oil
before the suggested change period.
• Change oil each 7,500 miles (12 000 km) or once a year
for light duty emissions service, each 6,000 miles (9 600
km) or 4 m onths for heavy duty emissions service,
whichever occurs first.
LIG H T T R U C K SE RV IC E M A N U A L
OB-8 MAINTENANCE AND LUBRICATION
• Change oil filter: can, be sure not to confuse the S E designation with the
Light Duty Emissions- Replace at the first oil change letters " SA E ", which m ay also appear on the can.
and then every second oil change if mileage 7,500 • It is V ER Y IM P O R T A N T to change the oil and filter
miles (12 000 km) determines oil change. If time (12 every 3,000 miles (4 800 km ). Because of the way a
months) determines oil change, or you change the oil diesel engine operates, contam inants build up in the oil
at 3,000 miles (4 800 km) or 3 months, replace filter faster than in a gasoline engine which can cause engine
at each oil change. wear an d /o r dam age.
Heavy Duty Em issions- Replace at the first oil • Change the oil and filter soon after driving in a dust
change, and then every second oil change if mileage storm.
6,000 miles (9 600 km) determines oil change. If
• Single viscosity grade oils (such as SA E 30) are more
tim e (4 m onths) determines oil change, or you
satisfacto ry th an m ulti-viscosity oils (such as SA E
change the oil at 3,000 miles (4 800 km) or 2 months,
10W -30) for sustained high-speed driving.
replace filter at each oil change.
• Change oil and filter each 3,000 miles (4 800 km) or 3 The oil and filter change intervals for a diesel engine
months (light duty emissions) or 2 months (heavy duty are based on the use of " S F /C C " or " S F /C D " quality oils
emission service) if: and quality oil filters. Use of oils other than " S F /C C " or
• Driving in dusty areas " S F /C D " or oil and filter change intervals longer than
3,000 miles (4 800 km) could reduce engine life and may
• Pulling a trailer
affect w arranty.
• Frequent idling or idling for long periods
The diesel engine was filled with a quality engine oil
• Driving 4 miles (6 km) or less in freezing weather, or when it was built. You do not have to change the oil before
other short trips in cold weather, where the engine the recommended change interval. Keep in m ind the engine
does not thoroughly warm up. may use more oil when it is new. Check the oil level more
• After driving in a dust storm, change the oil and filter often when the engine is new.
as soon as possible. Engine Oil Additives - Do not use any supplem ental
additives. Using oil additives may cause engine dam age and
Engine Oil Additives - The engine should not need these may affect w arranty. If you think the engine has an oil
extra engine oil helpers or additives if SF quality engine oil related problem, see Section 6A.
is used and changed as suggested. If you think your engine
has an oil related problem, refer to Section 6A. RECOMMENDED SAE VISCOSITY GRADES
Diesel Engine
Use O N LY engine oils labeled with the A.P.I. (Ameri
can Petroleum Institute) designations "SF/C C " or "SF/
CD ". Do not use any other type of oil. The A.P.I. designa
tions are listed somewhere on the oil can, usually on the top
or label. The A.P.I. has several designations, such as: SC,
SD , SE, CB, CC, CD.
Several different designations may appear on the can.
Be sure the oil used has either the "SF/C C " or "SF/CD" 5W-20
designations, regardless of the order in which they appear on
the oil can. 20_ 40
_L_
100
--- r— —I— —r~ T
Using any type of oil other than "SF/C C " or "SF/ °C-30 -2 0 -1 0 10 .20
30 40
CD" may affect warranty. TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE
NOTICE: Do N O T use engine oils labeled only SE or NOTICE: Do not use SAE 5W -20 oils for continuous
high-speed driving.
only CC. These oils will not give the protection and
lubrication of diesel engine needs. When reading the Fig. OB-6--Oil Viscosity Chart (Gasoline)
LIG H T T R U C K SE RV IC E M A N U A L
MAINTENANCE AND LUBRICATION OB-9
LIG H T T R U C K SERVICE M A N U A L
OB-10 MAINTENANCE AND LUBRICATION
LUBRICATION POINTS
1 A ir Cleaner 6 Master Cylinder 11 Front and Rear Axle
2 C ontrol Linkage Points 7 Transmission - Manual 12 Drag L in k
3 Tie Rod Ends - A utom atic 13 Brake and Clutch
4 Wheel Bearings 8 Carburetor Linkage - V-8 Pedal Springs
5 Steering Gear 9 Universal Joints 14 Transfer Case
10 Propeller Shaft Slip Joints 15 T h ro ttle Bell Crank - L-6
LIG H T T R U C K SERVICE M A N U A L
MAINTENANCE AND LUBRICATION OB-11
LUBRICATION POINTS
1 Control Arm 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 - A u to m a tic 11 Parking Brake Linkage
4 Steering Gear
Clutch Cross-Shaft
Lubricate hood latch assem bly and hood hinge assem W ipe off d irt and apply a thin coat of engine oil. Open
bly as follows: and close door several times to insure th at the oil has worked
in effectively.
1. W ipe off any accum ulation of dirt or contam ination on
latch parts. Door Jam Switch
2. Apply L ubriplate or equivalent to latch pilot bolts and Apply a thin coat of lubriplate or equivalent to end of
latch locking plate. surface of switch plunger.
3. Apply light engine oil to all pivot points in release
Parking Brake Pulley, Cable and Linkage
m echanism , as well as prim ary and secondary latch
m echanisms.
(Also a Safety Service)
4. L ubricate hood hinges.
Apply w ater resistant EP chassis lubricant which meets
5. M ake hood hinge and latch m echanism functional G M specification 6 0 3 1M, to parking brake cable at cable
check to assure the assembly is working correctly. guides and at all operating links and levers.
LIG H T T R U C K SERVICE M A N U A L
OB-12 MAINTENANCE AND LUBRICATION
Accelerator Linkage Vehicle handling could be adversely affected and the tires
having the lower load rating could be overloaded.
(Also a Safety Service)
Lubricate carburetor stud and carburetor lever and
CAUTION:Before installing wheels, remove any
accelerator pedal lever at support with engine oil.
build up of corrosion on the wheel mounting
Body Lubrication surface and brake drum or disc mounting surface
See Body Service M anual for body lubrication. by scraping and wire brushing. Installing wheel
without good metal-to-m etal contact at the
A-6 Four Wheel Drive mounting surfaces can cause the wheel nuts to
loosen, which can later allow a wheel to come off
M ost lubrication recom m endations and procedures for
while the vehicle is moving, possibly causing loss
four wheel drive-equipped vehicles are the same for corre
of control.
sponding components of conventional drive vehicles.
In addition, the following item s require lubrication Dual Tire Operation
each 4 m onths or 6,000 miles (9 600 km).
The outer tire of a pair on dual wheel installations
Transfer Case generally wears faster than the inner tire, if this occurs,
reverse position of the tires to equalize wear and achieve
Check the transfer case level at the interval and if
optim um tire life.
necessary, add Dexron® II.
In addition, when trucks are driven continuously on
Front Axle high crown roads, an increase in air pressure of from 5 psi
The front axle should be checked at the interval and (35 kPa) to 10 psi (70 kPa) in the outside tire of each dual
refilled w ith S A E 80W -90 G L -5 gear lu b ric a n t when produces m axim um tire life. Be sure not to exceed the
necessary. W ith the differential at operating tem perature inflation pressure limits shown in the Load and Inflation
fill to the level of filler plug hole. If differential is cold, fill to C harts in Section 3E.
level of 1/2 inch below the filler plug hole.
Wheel Nut Torque (Fig. OB-12)
Propeller Shaft Slip Joints
Caution:
Propeller shaft slip joints should be lubricated at the
interval with w ater resistant E P Chassis lubricant which Trucks With Single Wheels:
m eets G eneral M otors Specification G M 6031M. As soon as possible after installing a wheel-and at the
Constant Velocity (C /V Joint) intervals shown on the chart in the Maintenance Schedule
have a mechanic tighten wheel nuts with a torque wrench to
A C /V joint is located a t the transfer case end of the the correct torque listed on the chart which follows.
front propshaft and must be lubricated at the interval with
G M lubricated part no. 1052497 or equivalent. See Fig. 0B- Trucks With Dual Wheels:
10 showing how the fitting m ay be lubricated from above the
Have a mechanic tighten wheel nuts with a torque
C /V joint, with a special ad ap ter on the end of a flex hose.
wrench as stated above for single wheels for both front and
rea r wheels. In addition, when the tru ck , or wheel, or
A-7 Tires fasteners are new, also have the torque set at the first 100,
1,000, and 6,000 miles (160, 1 600, and 9 600 km ). This
Inspection and Rotation precaution is necessary because the clam ping system used
Front and rear tires perform different jobs and can on this type of wheel in some cases needs to seat before the
wear differently depending on the types of roads driven, fasteners will hold a uniform clam p load and rem ain fully
driving habits, etc. To obtain m axim um tire life inspect and tightened.
rotate tires regularly. (Fig. 0 B -11) If the truck is equipped
with tires having different load ratings between the front For both single and dual wheels, wheel nuts should be
and the rear, the tires should not be rotated front to rear. tightened alternately and evenly to the correct torque in the
L IG H T T R U C K SE R V IC E M A N U A L
MAINTENANCE AND LUBRICATION OB-13
sequence shown in Section 3E. N ever use oil or grease on Bleeding serves to reduce "cold" inflation pressure and
studs or nuts. Im properly tig h ten ed wheel nuts could increase tire flexing which can result in tire dam age
eventually allow the wheel to come off while the vehicle is and failure.
moving, possibly causing loss of control.
Passenger-Car-Type tires:
CAUTION:This vehicle has some parts dimen
sioned in the metric system as well as in the For sustained driving at speeds of 75 mph of 85 mph
customary system. Some fasteners are metric and (120 km/h to 140 km/h), in countries where such speeds are
are very close in dimension to well-known custom permitted by law, cold inflation pressures must be increased
ary fasteners in the inch system. Mismatched or 4 psi (30 kPa) above the stated cold inflation pressures on
incorrect fasteners can result in damage to the the Certification Label. Sustained speeds of 75 mph to 85
vehicle or possibly personal injury. mph (120 km/h to 140 km/h) are not advised when the 4 psi
(30 kPa) adjustm ent would require pressures greater than
Inflation Pressure (Fig. OB-13) the maxim um pressures stated for each load range. Sus
tained driving at speeds over 85 mph (140 km/h), where such
The cold inflation pressures for the factory installed speeds are permitted by law, is not advised unless vehicle is
tires are on the label on the rear of the driver’s door. The equipped with special high speed.
tires m ust be inflated to these pressures to obtain the
G V W R (Gross Vehicle W eight R ating) or G A W R (Gross Truck-Type Tires:
Axle W eight R ating). Incorrect tire inflation pressures can
’ For sustained driving at speeds over 65 mph (100 km/h),
have adverse effects on tire life and vehicle perform ance.
where such speeds are permitted by law cold inflation
Too low an air pressure causes increased tire flexing and
pressures should be increased 10 psi (70 kPa) above those
h eat b uild-up. T his w eakens th e tire and increases the
stated in the Tire/W heel Load and Inflation Pressure Charts
chance of dam age or failure and can result in tire overload
for the load being carried. Do not exceed the wheel capacity
ing, ab n o rm al tire w ear, adverse vehicle handling, and
limit shown in Section 3E.
reduced fuel mileage. Too high an air pressure can result in
abnorm al wear, harsh ride, and also increase the chance of Sustained speeds over 65 mph (100 km/h) are not
dam age from road hazards. advised where the 10 psi (70 kPa) pressure increase would
exceed the wheel capacity limit.
For special operating conditions, such as carrying slide-
Lower inflation pressures can be used for light truck- in cam pers, cold inflation pressures may be increased up to
type tires with reduced vehicle loads. A fter finding the load 10 psi (70 kPa) above those shown in the table. The total
on each tire by weighing the vehicle on a scale, the minimum increase in cold inflation pressures, however, m ust not
cold inflation pressures can be found in Section 3E. exceed the wheel capacity limit shown in Section 3E.
T ire inflation pressures should be checked at least Passenger-car-type tires have a 15-inch (380 m illim e
m onthly (including the spare if so equipped). Always check ter) or sm aller wheel size and have no " L T " designation
tire inflation pressures when tires are " cold ". molded in the sidewall after the tire size. Light truck-type
1. The "co ld " tire inflation pressure applies to the tire tires have " L T " molded in the sidewall after the tire size
pressure when a vehicle has not been driven more than an d /o r are larger than 15 inches (380m m ) in wheel size.
one mile (1.6 km) after sitting for three hours or more.
Passenger-Car Type Snow Tires:
2. It is norm al for tire pressures to increase 4 to 8 pounds
per square inch (30 to 60 kilopascals) or more, when W hen using passenger-car-type snow tires, cold infla
the tires become hot from driving. Do not "bleed" or tion pressures should be increased 4 psi (30 kPa) above the
reduce tire inflation pressures after driving vehicle. stated cold inflation pressures on the Certification Label up
to the m axim um for each load range stated in the chart
above. Sustained speeds above 75 mph (120 km/h) are not
advised.
8. A dd enough ethylene glycol solution, m eeting G M gear housing should be refilled only with the proper Steering
Specification 1899-M, and w ater to provide the re G ear L ubricant as noted below.
quired cooling function as well as freezing and corro NOTICE: Use only 1052182 (13 oz. (.38L) container)
sion p rotection. Use a 50 percen t solution, -34°F Steering G ear L ubricant which meets G M Specifica
(-36°C), but no more than a 70 percent solution. Fill tion 4673M , or its equivalent.
radiator to the base of the radiator filler neck and raise
Do not use EP chassis lube, m eeting G M Specification
level of coolant in the recovery tank to the "F ull H o t"
6 0 3 1M, to lubricate the gear. DO N O T O V E R -F IL L
m ark. Reinstall recovery tank cap.
the gear housing.
9. Run engine, with radiator cap removed, until radiator
upper hose is hot. A -12 Clutch Cross-Shaft
10. W ith engine idling, add coolant to radiator until level Rem ove the plug, install a lubrication fitting and
reaches bottom of filler neck. Install cap, m aking sure lubricate with w ater resistant EP Chassis L ubricant which
arrows line up with overflow tube. meets G M Specification 6031M.
Radiator Pressure Cap A -13 Automatic Transmission Fluid
T he rad iato r cap, a 15 psi (105 kPa) pressure type, R efer to A-1 for checking au to m atic transm ission.
m ust be installed tightly, otherw ise coolant may be lost and C hange the transm ission fluid and service screen every
dam age to engine m ay result from overheating. R adiator 15,000 miles (24 000 km) on light duty emissions or 12,000
pressure cap should be checked periodically for proper miles (19 200 km) on heavy duty emission and diesel engine
operation. vehicles if the vehicle has been driven under one or more of
these hot conditions:
Thermostat
• In heavy city traffic where the outside tem perature
T he engine coolant te m p e ra tu re is controlled by a regularly reaches 90°F (32°C).
therm ostat. It stops coolant flow through the radiator until a
• In hill or m ountain areas.
pre-set tem perature is reached. This therm ostat is installed
on the engine block. The sam e therm ostat is used in both • Frequent trailer pulling.
w inter and sum m er. R efer to Section 6B-Engine Cooling for • Uses such as taxi, police or delivery service.
additional inform ation. If the vehicle was not used mainly under any of these
conditions, change the fluid and service screen each 100,000
A -10 Wheel Bearings miles (160 000 km) on light duty emissions and diesel engine
For norm al application, clean and repack front wheel vehicle or 24,000 miles (38 400 km) on heavy duty
bearings with a high m elting point wheel bearing lubricant emissions.
at each front brake lining replacem ent or 30,000 miles (48 It takes only one pint (0.5 liter) to raise level from
000 km) on light duty emissions 12,000 miles (19 200 km) "A d d " to "F u ll" with a hot transmission.
on heavy duty eymission or 15,000 miles (24 000 km) on
diesel engine vehicles which ever comes first. For heavy duty SECTION B
application such as police and taxi cabs, clean and repack
front wheel bearings at each front brake lining replacem ent SAFETY MAINTENANCE
or 15,000 miles (24 000 km ) which ever comes first.
B-l Owner or Driver Safety Checks -
Use W heel Bearing L ubricant G M P art N o. 1051344
(one pound), 1052356 (35 pounds) or Exxon Ronex M P The m aintenance Schedule in the glove box lists items
Grease or equivalent. This is a prem ium high m elting point to be checked by the owner or driver.
lubricant.
B-2 Tires, Wheels, and Disc Brakes
"Long fiber" or "viscous" type lubricant should not be
used. Do not mix wheel bearing lubricants. Be sure to During tire rotation, check disc brake pads for wear,
thoroughly clean bearings and hubs of all old lubricant and surface condition of rotors while wheels are removed
before repacking. (see Item A-7). Check tires for excessive or abnorm al wear,
or dam age. Also check tire inflation pressures and adjust as
NOTICE: T apered roller bearings used in this vehicle shown on Tim e P lacard (located on left front door). Be sure
have a slightly loose feel when properly adjusted. They wheels are not bent or cracked and that wheel nuts have
m ust never be over tightened (preloaded) or severe been tightened to the torque value shown Section 3E.
bearing dam age m ay result.
R efer to Section 3C for proper detailed adjustm ent B-3 Exhaust System
procedures and specifications. (Also an LD Emission Control Service)
C heck the com plete exhaust system , including the
A -1 1 Manual Steering Gear
catalytic converter. Check body areas near the exhaust
The steering gear is factory-filled with steering gear system and also the tailgate. Look for broken, dam aged,
lubricant. Seasonal change of this lubricant should not be missing, or out-of-position parts. Also, inspect for open
perform ed and the housing should not be drained-no seams, holes, loose connections, or other conditions which
lubrication is required for the life of the steering gear. could cause a heat buildup in the floor pan, or could let
Inspect for seal leakage (actual solid grease-not just exhaust fumes seep into the passenger com partm ent. D ust
oily film). If a seal is replaced or the gear is overhauled, the or w ater in the passenger com partm ent may indicate a leak
L IG H T T R U C K SE RV IC E M A N U A L
OB-16 MAINTENANCE AND LUBRICATION
in the area. N eeded repairs should be m ade at once. To help W hen adjusting a drive belt, it is im portant th at the proper
m aintain system integrity, replace the exhaust pipes and adjustm ent specification be used.
resonators rearw ard of the muffler whenever a new muffler is Refer to Section 6A for engine m echanical additional
put on. inform ation.
R efer to S ection 6F for ex h au st system repair A "U sed " belt is one th at has been rotated at least one
procedures. com plete revolution on engine pulleys. This begins the
"seating" of the belt and it should never be reset to "N ew "
B-4 Suspension and Steering belt specifications.
Check front and rear suspension, and steering system.
Look for dam aged, loose, or missing parts; also for parts B-7 Drum Brakes and Parking Brake
showing signs of w ear, or lack of lu b ricatio n . R eplace
(See Item B-2 for disc brake check.) Check drum brake
questionable parts at once.
linings for wear or cracks. Also inspect other brake parts at
R efer to Section 3B for steering and Section 3C and 3D each wheel, such as drum s, wheel cylinders, etc. Check
for suspension repair procedures. parking brake adjustm ent also when inspecting drum brake
linings.
B-5 Brakes and Power Steering Check brakes more often if conditions and habits result
Check lines and hoses for proper hook-up, binding, in frequent braking.
leaks, cracks, chafing, etc. Any questionable parts should be Refer to Section 5 for brake repair procedures.
replaced or repaired a t once. W hen rubbing or wear is noted
on lines or hoses, the cause m ust be corrected at once. B-8 Throttle Linkage
Refer to Section 5 for brakes and Section 3B for power
Check for dam aged or missing parts, interference or
steering repair procedures. binding. Fix any problems at once.
Refer to Section 6C for fuel system repair procedures.
B-6 Engine Drive Belts
C-4 Early Fuel Evaporation (EFE) System boot fit a t distributor cap and spark plugs. Replace wire if
dam aged or if corrosion cannot be cleaned.
C heck th a t valve works properly, correct any binding.
Check th a t therm al vacuum switch works properly. Check C-10 Idle Stop Solenoid
hoses for cracks, rubbing, or decay. R eplace parts as needed.
C heck th a t p arts work properly. R eplace them as
C-5 Carburetor Mounting needed.
Torque mounting bolts an d /o r nuts a t mileage shown C -11 Spark Plugs
on M aintenance Schedule.
Replace as shown on Schedule. Use the type listed in
C-6 Vacuum Advance System and Hoses O w ner’s and D river’s M anual.
C heck th at system works properly. Check hoses for
C-12 Engine Timing and Distributor Cap
proper hookup, cracks, rubbing or decay. R eplace parts as
needed. A djust tim ing to underhood label specifications. Check
the inside and outside of the cap and rotor for cracks, carbon
C-7 Fuel Filter tracking and corrosion. Clean or replace as needed.
R eplace at m ileage shown on M aintenance Schedule or
sooner if clogged.
C-13 Air Cleaner Element
Replace at m ileage showrr on Schedule. Replace more
C-8 PCV System often under dusty conditions.
Check th a t system works properly each 15,000 miles
(24 000 km ) - Light D uty Emission or 12,000 miles (19 200 C-14 Evaporation Control System (ECS)
km) - Heavy Duty Emissions. Check all fuel and vapor lines and hoses for proper
PCV Valve and Filter - Replace the valve, filter and hookup routing and condition. Check th at bowl vent and
worn or plugged hoses each 30,000 miles (48 000 km) - purge valves work properly, if equipped. Remove canister,
Light D uty Emissions or 24,000 miles (38 400 km) - Heavy check for cracks or dam age. Replace as needed. Replace
Duty Emissions. canister filter.
L IG H T T R U C K SERVICE M A N U A L
OB-18 MAINTENANCE AND LUBRICATION
SPECIFICATIONS
RECOMMENDED FLUIDS AND LUBRICANTS
USAGE FLUID/LUBRICANT
Pow er steerin g system and pum p reservoir GM p o w e r steering flu id Part No. 1050017 o r equivalent.
D iffe re n tia l — S tandard o r locking^M anual T ra n sm issio n , SAE-80W GL-5 o r SAE-80W-90 GL-5 gear lu b ric a n t
(SAE-80W — GL-5 in Canada)
L IG H T T R U C K SERVICE M A N U A L
MAINTENANCE AND LUBRICATION OB-19
CAPACITIES
IMPERIAL
S • r<,M U.S. MEASURE MEASURE
D ifferential
8% '' Ring Gear 1.9L 4% pts. 3Y2 pts.
8 -7 /8 ” Ring Gear 31/2 pts. 3 pts.
101/2 " Ring Gear (Chev.) 2.8L 6% pts. 5% pts.
10%'' Ring Gear (Dana) 3L 7.2 pts. 5% pts.
9% " Ring Gear (Dana) 2.6L 6.0 pts. 5 pts.
12%'' Ring Gear (Dana) 11.7L 26.8 pts. 21% pts.
Engine Crankcase
250 L6 — Drain & Refill 3 .8L 4 qts. 3% qts.
— w /F ilte r Change 4 .7L 5 qts. 4% qts.
292 L6 — Drain & Refill 4 .7L 5 qts. 414 qts.
— w /F ilte r Change 5.7L 6 qts. 5 qts.
305 V 8 ) _ . . _ ....
op-f. wc> ( - Drain & R efill 3.8L 4 qts. 31A qts.
400 V 8 i w/FM
- ,erChan9e
454 V 8 - Drain & Refill
4.7 L
5.7L
5 qts.
6 qts.
4% qts.
5 qts.
— w /F ilte r Change 6 .6L 7 qts. 5% qts.
350 V8 Diesel Including F ilte r 6 .6L 7 qts. 5% qts.
Transmission
A u to m a tic
350 — Total 9 .5 L 10 qts. 8% qts.
- Refill 2.8L 3 qts. 2% qts.
400 — Total 10.4L 11 qts. 9% qts.
- Refill 3.8L 3.5 qts. 3 qts.
Manual
4 Speed 1 17mm 3 .8L 4 qts. 3% qts.
3 Speed 76mm 1.4L 1.5 qts. VA qts.
3 Speed 77mm 1.4L 1.5 qts. VA qts.
Fuel Tank
Pickup — C10-35, K10-25 & Crew Cab
(Except 107 Models) 76 L 20 gal. 16.8 gal.
107 Models 60.5 L 16 gal. 13.3 gal.
A u x ilia ry Tank Same as Main Fuel Tank
Van — Standard 83 L 22 gal. 18% gal.
— Optional 125L 33 gal. 27% gal.
Suburban — Standard 95 L 25 gal. 20.8 gal.
— O ptional 117L 31 gal. 25.8 gal.
— O ptional 151 L 40 gal. 33.3 gal.
Blazer/Jim m y — Standard 95 L 25 qal. 20.8 gal.
— Optional 117L 31 gal. 25.8 gal.
P10, 15/20-35 117L 31 gal. 25.8 gal.
P30042 114L 30 gal. 25 gal.
P30032 151 L 40 gal. 33.5 gal.
LIG H T T R U C K SE RV IC E M A N U A L
0B-20 MAINTENANCE AND LUBRICATION
COOLING SYSTEM
L IG H T T R U C K SE R V IC E M A N U A L
HEATER 1A-1
SECTION 1A
HEATER
CONTENTS
STANDARD HEATER
INDEX
GENERAL DESCRIPTION
H eating com ponents are attach ed to the dash panel on The system consists basically of three parts: (1) the blower
th e rig h t side of th e vehicle. T h e blow er and air inlet and air inlet assem bly, (2) the heater distributor assembly
assem bly and w ater hoses are located on the forw ard side of and (3) the heater control assembly.
the dash panel while the heater core and distributor duct are
on the passenger side.
The heater system is an air mix type system in which HEATER AIR FLOW SCHEMATIC
outside air is heated and then mixed in varying am ounts C-K Series heater airflow is shown in Fig. 1A -1.
with cooler outside air to attain the desired air tem perature.
LIG H T T R U C K SERVICE M A N U A L
1A-2 HEATER
HE A T E R A D E F R O S T E R A S M
HEATER A
DEFROSTER A S M
AIR OUTLET
AIR OUTLET
VIEW A
STEERING VIEW B
COLUMN
DEFROSTER DUCT A S M
INST PANEL
HEATER C O N T R O L
&
V IE W A
AI R F L O W LEGEND
Q] TEMPERATURE V A L V E [ ] O U TS ID E AIR
L IG H T T R U C K SERVICE M A N U A L
HEATER 1A-3
BLOWER AND AIR INLET ASSEMBLY assembly, by the purge door. If the purge door is closed, then
air is directed through an d /o r around the heater core by the
The blower and air inlet assem bly draw s outside air tem perature door. A ir is then directed into the passenger
through the outside air inlet grille located forward of the com partm ent through the heater (floor) outlets an d /o r the
windshield reveal-m olding and channels the air into the defroster (dash) outlets by the defroster door. The tem pera
heater distributor assembly. The operation of the blower ture of the outlet air is dependent on the ratio of heated to
motor is controlled by the FA N switch on the heater control. unheated air (controlled by the tem perature door).
The m otor is connected in series with the FA N switch and
also the blower resistor assembly. Located in the fuse block,
in series between the blower motor and the battery, is a 25 G Models
amp. fuse C -K models, a 20 am p fuse on G models. A ir flow is controlled by doors in the d istrib u to r
assembly. The air door can be adjusted to vary airflow. If air
HEATER DISTRIBUTOR ASSEMBLY
is allowed to en ter the d istrib u to r assem bly, it is then
T he heater distributor assembly houses the heater core directed through an d /o r around the heater core by the
and the doors necessary to control mixing and channeling of tem perature door. Air is directed into the passenger com
the air. Since the unit has no w ater valve, w ater circulation partm ent through the heater (floor) and/or defroster (dash)
keeps the core hot a t all times. T h at portion of the air outlets by the defroster door. The tem perature of the outlet
passing through the core receives m axim um heat from the air is dependent of the ratio of heated to unheated air
core. A ir entering the distributor assembly is channeled as (controlled by the tem perature door).
follows:
LIG H T T R U C K SERVICE M A N U A L
1A-4 HEATER
DIAGNOSIS
Temperature o f heater a ir a t outlets too low to heat up pas 1. See " In s u ffic ie n t Heat Diagnostic Chart".
senger compartment.
Temperature o f heater a ir a t o utlets adequate but the vehicle Check fo r body leaks such as:
w ill not build up s u ffic ie n t heat. 1. Floor side kick pad v e n tila to rs p a r tia lly open.
2. Leaking grommets in dash.
3. Leaking welded seams along rocker panel and windshield.
4. Leaks through access holes and screw holes.
5. Leaking rubber molding around door and windows.
6. Leaks between sealing edge of blower and a ir in le t assembly
and dash, and between sealing edge o f heater d is trib u to r
assembly and dash.
Inadequate defrosting action. 1. Check that DEFROST lever completely opens defroster door
in DEF position - Adjust i f necessary.
Inadequate c irc u la tio n of heated a ir through vehicle. 1. Check heater a ir o u tle t fo r correct in s ta lla tio n - R e in s ta ll.
LIG H T T R U C K SE RV IC E M A N U A L
HEATER 1A-5
INSUFFICIENT HEAT D IA G N O S IS
NORMAL TEMPERATURE I
Check heater outlet for obstruction - re | CHECK FUSE |
move.
Remove all obstructions under front seat. I
FUSE BLOWN - replace fuse.
Check motor voltage at closest motor line
Car does not build up heat - operate vent
connection with a voltmeter. I = ;
AIR FLOW - system okay.
controls and see that the air vent doors
close completely, if not, adjust.
Check coolant level; if low, fill. Look for FUSE REMAINS OK - remove motor
or feel all radiator and heater hoses and Check wiring and connections for and check for obstruction in system
connections for leaks. Repair or replace. under 10 volts from motor to fan opening, if none, REPLACE MOTOR.
Check the radiator cap for damage and re switch. Repair or replace last point If obstruction, remove material and
place if required. of under 10 volt reading. re-install motor.
LIG H T T R U C K SERVICE M A N U A L
HEATER CIRCUIT D IA G N O S I S *
T
FUSE BLOWN FUSE OK
1........ " 1-----
With Ignition switch in The follow ing tests should be made w ith
"R U N " position and blower the ignition switch in "R U N ” position
speed switch "O N " use the blower speed switch "O N " and the
meter to locate short in one lever on heat position.
of the follow ing wires: _L
1. From fuse panel to blower Check blower motor ground
speed switch.
2. From blower speed switch I
to heater resistor.
X 1
POOR OR NO GROUND GROUND OK
3. From heater resistor to
blower. X T
Repair ground Check m otor connector
Note: Short circuit may be w ith 12 volt test light.
interm ittent. If meter does
not indicate a short circuit,
I
move harness around as -------------- J------------ 1
LAMP LIGHTS LAMP DOES NOT LIGHT
much as possible to re-create
short circuit. Watch and 1 I
listen fo r arcing. Replace Motor Check blower feed wire in connector
on resistor w ith 12 volt test light.
r
LAMP DOES NOT LIGHT LA M P L IG H T S 1
X .. 1 _
Use 12 volt test light and check feed Repair open in feed wire
terminal (brown) on blower speed switch. from resistor to blower motor. ‘ See heater circuit diagrams
HEATER 1A-7
LIG H T T R U C K SE RV IC E M A N U A L
1A-8 HEATER
ON VEHICLE SERVICE
BLOWER MOTOR bead of sealer to the entire circum ference of the
m ounting flange,
Removal (Fig. 1A-5) c. Check blower operations: blower wheel should rotate
freely with no interference.
1. Disconnect battery ground cable.
HEATER DISTRIBUTOR AND CORE ASSEMBLY
G Models - Remove the coolant recovery tank, and
power antenna as outlined in Sections 6 and 9. C-K Models
2. Disconnect the blower motor lead wire.
Replacement (Fig. 1A-6)
3. Remove the five blower motor m ounting screws and
remove the m otor and wheel assembly. Pry gently on
1. Disconnect the battery ground cable.
the blower flange if the sealer acts as an adhesive.
2. Disconnect the heater hoses at the core tubes and drain
4. Rem ove th e blow er wheel to m otor sh aft nut and engine coolant into a clean pan. Plug the core tubes to
separate the wheel and m otor assemblies. prevent coolant spillage at removal.
5. To install a new m otor, reverse Steps 1-4 above. 3. Remove the nuts from the d istrib u to r duct studs
The following steps should be taken to assure proper projecting into the engine com partm ent.
installation: 4. Remove the glove box and door assembly.
a. Assem ble the blower wheel to the motor with the 5. D isconnect the A ir-D efrost and T e m p eratu re door
open end of the wheel away from the blower motor. cables.
b. If the motor m ounting flange sealer has hardened, or 6. Remove the floor outlet and remove the defroster duct
is not intact, remove the old sealer and apply a new to heater distributor duct screw.
7. Remove the heater distributor to dash panel screws.
Pull the assembly rearw ard to gain access to wiring
harness and disconnect all harnesses attached to the
unit.
8. Remove the heater-distributor from the vehicle.
9. Remove the core retaining straps and remove the core.
10. To install, reverse Steps 1-9 above. Be sure core to case
and case to dash panel sealer is intact before assem
bling unit.
G Models
Replacement (Fig. 1A-7)
L IG H T T R U C K SERVIC E M A N U A L
HEATER 1A-9
VIEW A
HEATER HOSES
H eater hoses are routed from the therm ostat housing or
inlet m anifold and w ater pum p (radiator on some autom atic
transm ission vehicles) to the core inlet and outlet pipes as
shown in Figures 1A-8 thru 1A -1 1. Hoses are attached at
each end with screw type clamps.
LIG H T T R U C K SERVICE M A N U A L
1A-10 HEATER
L-6 V -8
C-K M O D E L S
TO WATER PUMP - f
^ 1v IEw [a 1 ^ C36
G M ODELS
L IG H T T R U C K SE RV IC E M A N U A L
HEATER 1A -1 1
Fig. 1A -1 1--Heater Hose Routing G Series
1A-12 HEATER
|vitwfA|
DEFROSTER DUCT
UPPER IP EXTENSION
D efroster assemblies attach m en t are shown in Fig. 1A - 13
CONTROL ASSEMBLY
G Models
Replacement (Fig. 1A-17)
H eater and defroster cable routing and attachm ent to
control and to distributor case is shown in Fig. 1A -17.
Fig. 1 A -14--C ontrol Assembly, C-K M odels
If cable adjustm ent is required, refer to A djustm ent,
G Models C-K Series.
Replacement (Fig. 1A-15)
Adjustment - C-K Series
1. Disconnect the b attery ground cable. 1. Disconnect the battery ground cable.
2. Remove I.P. bezel as outlined in Section 8C of this 2. Remove glove box and door as an assembly.
m anual.
3. Pry off the appropriate cable eyelet clip and disconnect
3. Rem ove th e control to in stru m e n t panel m ounting the cable from the door.
screws (3) and carefully pull the control rearw ard far
4. Remove the cable retaining screw.
enough to gain access to the bowden cable attachm ents.
C are should be taken to prevent kinking the bowden 5. W hile holding the cable with pliers, rotate the m ount
cables while lowering the control. ing tab on the cable to lengthen or shorten the cable,
whichever is required.
4. Disconnect the bowden cables, the control illum ination
bulb, the blower sw itch connector and rem ove the NOTICE: Do not pinch the cable too tightly or dam age
control from the vehicle. to the cable could result.
5. Rem ove th e blower sw itch screw s and rem ove the 6. Install the cable, reversing Steps 1-4 above.
blower switch.
6. To install, reverse Steps 1 thru 4. Adjustment - G Van
1. A ttach inner cable and sheath to I.P. Control.
CONTROL CABLES (Fig. 1A-16, 1A-17) 2. W ith I.P. installed, move tem perature cable to cold and
attach loop on inner cable to tem perature door on
C-K Models
heater case.
Replacement 3. A ttach cable sheath to heater case.
1. Disconnect the battery ground cable. 4. Move tem perature lever to full heat. This will require
2. Remove the instrum ent panel bezel. some effort due to force required to slide inner cable
clip to its proper position.
BLOWER SWITCH
C-K Models
Replacement (Fig. 1A-14)
1. Disconnect the battery ground cable.
2. Remove the instrum ent panel bezel.
3. Remove the control to instrum ent panel screws and
lower the control onto the radio.
4. Disconnect the switch electrical harness.
5. Remove the switch attaching screws and remove the
switch.
6. To install, reverse Steps 1-5 above.
LIG H T T R U C K SERVICE M A N U A L
1A-14 HEATER
V IE W A V IE W B
L IG H T T R U C K S fR V IC E M A N U A L
HEATER 1A-15
G Models
Replacement (Fig. 1A-15)
1. Disconnect the battery ground cable.
2. Disconnect the blower switch wiring harness connector
at the switch.
3. Remove the two switch attaching screws and remove
the switch assembly.
4. To install a new switch, reverse Steps 1 thru 3.
RESISTOR
Replacement (Figs. 1A-5 and 1A-18)
1. Disconnect the wiring harness at the resistor connector.
2. Remove the two resistor m ounting screws and remove
the resistor.
3. To install a new resistor, reverse Steps 1 and 2 above.
AUXILIARY HEATER
INDEX
GENERAL DESCRIPTION
An auxiliary heater is available as a dealer installed CONTROLS
accessory to provide additional heating capacity for the
rearm ost extrem ities of the G (05 and 06) models. Two methods of control are employed with this system:
This unit operates entirely independent of the standard Water Valve (Refer Fig. 1A -11)
heater and is regulated through its own controls at the W hen heat is desired, and the fan switch is any position
instrum ent panel. except off, a vacuum operated water valve controlled by the
This system consists of a separate core and fan unit switch, opens the w ater line to permit hot w ater circulation
m ounted as shown in Fig. 1A-23. through the heater core. In the O FF position the valve is
H eater hoses extend from the unit to the front of the closed to prevent unw anted heat during warm weather.
vehicle where they are connected to the standard heater
hoses with " te e s" . An "on-off" vacuum operated w ater Fan Switch (Fig. 1A-20)
valve is installed in the heater core inlet line in the engine
com partm ent. The purpose of the valve is to cut off coolant
flow to th e auxiliary core d uring w arm w eather and The three speed fan switch (L O W -M E D -H I) is located
elim inate the radiant heat th a t would result. in the instrum ent panel, to the right of the steering column.
LIG H T T R U C K SERVICE M A N U A L
1A-16 HEATER
DIAGNOSIS
R efer to the "S tan d ard H eater" section of this m anual
for diagnostic inform ation; R efer to Electrical D iagram Fig.
1A-21.
LIG H T T R U C K SE RV IC E M A N U A L
HEATER 1A-17
rjrrw77m n
rmarTTTuri
'iM n.f'g’m
m i r r u .iB i
2973781-
8905426
-3 BRN/WHT-50-
-3 BRN/WHT-50 — -3 WHT-952A-
•3 W H T-952A — ■2 WHT-952B-
■2984092 2984092
|3 W HT-952
3 BRN/WHT-5' REAR BLO.
2 TEL-51----- RESISTOR
■2 LT BLU-72 i!
8905426 8905426
LT BLU-72 —
■2 YE l-51 —
2984092
2 9 8 9 5 7 6 GROMMET-
G Series
FUSE PANEL
ON VEHICLE SERVICE
Since a detailed list o f installation instructions is
included with the auxiliary heater unit, replacement proce
dures will not be repeated in this section.
On G ModeIs--When replacing heater hoses, maintain
a 1/2 in. minimum clearance between hose clip and upper
control arm, a 1-1/2 in. minimum clearance between hoses
and propshaft and a 1-1/4 in. minimum clearance between
the auxiliary heater core lines and the exhaust pipe as shown
in Fig. 1A-24. All Models--Draw hoses tight to prevent sag
or rub against other components. Be sure to route hoses
through all clamps as originally installed.
LIG H T T R U C K SERVICE M A N U A L
1A-18 HEATER
LIG H T T R U C K SE RV IC E M A N U A L
HEATER 1A-19
SPECIFICATIONS
SECTION 1A
HEATER
Am ps. RPM
V olts (C old) (Cold)
Blower Motor
C-K Models 13.5 6.25 Max. 2550 Min.
2950 Max.
G Models 13.5 7.1 Max. 2850 Min.
3250 Max.
Fuses
C-K Models
G Models
A U XILIA R Y HEATER
Amps. RPM
Volts (Cold) (Cold)
Blower Motor . . . . 13.5 9.6 Max. 2700 Min.
. Kfei*!
;: ■. ^ r
\
J>
‘ kl ■
-i
SECTION IB
AIR CONDITIONING
NO TICE: W hen perform ing air conditioning diagnosis on Chevrolet
vehicles equipped with a catalytic converter, it will be necessary to warm the
engine to a norm al operating tem perature before attem pting to idle the
engine for periods g reater than five (5) minutes. Once the choke is open and
fast idle speed reduced to a norm al idle, diagnosis and adjustm ents can be
m ade.
CONTENTS
LIG H T T R U C K SERVICE M A N U A L
LIGHT
IB-2
TRUCK
EVAPORATOR CORE
AIR CONDITIONING
SERVICE
SHROUD.
M ANUAL
CONTROL
VIEW A
9
00
o
* AIR INLET VALVE
n3 "
Q PLENUM
=5.
VALVE
O
HEATER CORE
O
Q_
<D BLOWER &
EVAPORATOR A S M
(CK) MODELS
AIR CONDITIONING IB-3
GENERAL DESCRIPTION
C60 A /C SYSTEM System control is through the front system. The only
Both the heating and cooling functions are performed control on the overhead system is a three speed blower
by this system. Air entering the vehicle must pass through switch.
the cooling unit (evaporator) and through (or around) the MOTOR HOME CHASSIS SYSTEM
heating unit, in th at order, and the system is referred to as a
This system performs the cooling functions only. W hen
"re h e a t" system.
heating (above am bient tem peratures) is desired, the vehicle
The evaporator provides m axim um cooling of the air heater must be used. W hen air conditioning is desired, the
passing through the core when the air conditioning system is heater should be completely shut O FF.
calling for cooling.
This self-contained unit is bracket m ounted to the dash
On C-K and G Series, com pressor operation is control by the body m anufacturer. It operates on inside (recircu
led by a pressure sensing switch, located near the top of the lated) air only. A ir is drawn into the unit, passed through
accum ulator. The switch responds to pressure changes to the evaporator core (receiving maxim um cooling) and then
turn the com pressor O N or O FF, as required. directed into the vehicle through adjustable outlets.
System operation is as follows: A therm ostatic switch, located on the face plate is used
Air, either outside air or recirculated air, enters the to control compressor operation by sensing air tem perature
system and is forced through the system by the blower. As as it leaves the evaporator core.
the air passes th ro u g h th e ev ap o rato r core, it receives
m axim um cooling if the air conditioning controls are calling System Components
for cooling. A fter leaving the evaporator, the air enters the Receiver-Dehydrator (Motor Home Chassis
heater and air conditioner selector duct assembly where, by Models)
means of diverter doors, it is caused to pass through or to
bypass th e h eater core in th e proportions necessary to The receiver-dehydrator, serving as a reservoir for
provide the desired outlet tem perature. Then conditioned air storage of high pressure liquid produced in the condenser,
enters the vehicle through either the floor distributor duct or incorporates a screen sack filled with the dehydrating agent.
the dash outlets. D uring cooling operations, the air is cooled The receiver-dehydrator, used prim arily as a liquid
by the evaporator to below com fort level, it is then warmed storage tank, also functions to trap minute quantities of
by the heater to the desired tem perature. During "heating m oisture and foreign m aterial which may have rem ained in
only" operations, the evaporator will not be in operation and the system afte r installation or service operations. A
am bient air will be warm ed to the desired level in the same refrigerant sight glass is built into the receiver-dehydrator to
m anner. be used as a quick check of the state and condition of charge
of the entire system. The receiver-dehydrator is mounted
AIR DISTRIBUTION OUTLETS
near the condenser.
C-K Series
Sight Glass (Motor Home Chassis Models Only)
The dash outlets are rectangular in design. The outlets
can be rotated horizontally or vertically to direct air as W hile having no real function to perform in the system,
desired. U nder the left distributor duct is located a floor the sight glass is a valuable aid in determ ining w hether or
cooler which can be rotated to provide cooling air or shut off not the refrigerant charge is sufficient and for elim inating
completely. some guess work in diagnosing difficulties. The sight glass, is
built into the receiver-dehydrator outlet connection and is
G-Van designed and located so th a t a shortage of refrigerant at this
The dash outlets are rectangular in design and can be point will be indicated by the appearance of bubbles beneath
rotated horizontally or vertically to direct air as desired. the glass. The dust cap provided should be kept in place
Foot coolers are provided on both driver and passenger side. when the sight glass is not in use.
In th e h eater-d efro st m odes, th e air conditioning Thermostatic Expansion Valve (Fig. IB-2)
outside air door is closed. The heater air door is open and C-K and G overhead, and motor home chassis systems
outside air is allow ed to pass th ro u g h the h eater core use a therm ostatic expansion valve in place of a float system.
(receiving m axim um heating) and is then directed into the
The valve consists prim arily of the power element,
passenger com partm ent through the heater an d /o r defroster
body, actuating pins, seat and orifice. A t the high pressure
outlets.
liquid inlet, is a fine mesh screen which prevents dirt, filings
OVERHEAD SYSTEMS (C-K & G SERIES) or other foreign m atter from entering the valve orifice.
These systems (C69 on C-K & G Series) operate in
conjunction w ith the C 60 S y s te m -th e y do not operate W hen the valve is connected in the system , high
independently. However, control of rear blower motor speed pressure liquid refrigerant enters the valve through the
is possible even when the front system is O FF, thus, rear air screen from the receiver-dehydrator or condenser and passes
circulation without the refrigerant function m ay be had by on to the seat and orifice. Upon passing through the orifice
operating the rear blower control switch. the high pressure liquid becomes low pressure liquid. The
These units are self contained, operating on inside low pressure liquid leaves the valve and flows into the
(recirculated) air only. A ir is draw n into the unit, passed evaporator core where it absorbs heat from the evaporator
through the evaporator core and then directed into the core and changes to a low pressure vapor, and leaves the
passenger com partm ent through the air distributor duct. evaporator core as such. The power element bulb is clamped
LIG H T T R U C K SERVICE M A N U A L
IB-4 AIR CONDITIONING
LIG H T T R U C K SERVICE M A N U A L
AIR CONDITIONING IB-5
ui
i
•>/<
LIG H T T R U C K SERVICE M A N U A L
IB-6
AIR CONDITIONING
CONDITIONED AIR IS D IR E C T E D THRU W/SHLD,
I P. & FLOOR DISTRIBUTOR OUTLETS
A NON COMPRESSOR O P E R A T I N G POSITION,
CONDITIONED AIR IS D IR EC TED THRU I P. OUTLETS W IT H OUTSIDE AIR D E L I V E R E D T H R U I P. O U T L E T S
C O N D I T I O N E D AIR
D I S T R I B U T E D AB OU T
80% TO W /S H L D
& 20% TO FLOO R
Controls (C-K & G Series)
4 SPEED FAN
C O N T R O L LE VE R
V A C U U M O P E R A T E D SYSTEM T E M P E R A T U R E L E V E R POSITION R E G U L A T E S TE M P E R A T U R E
SELECTOR (MODE) L E VE R OF THE A I R E N T E R I N G THE PASSENGER C O M P A R T M E N T BY
CABLE O P E R A T I O N OF THE HEATER CORE TE M P E R A T U R E D O O R
AIR CONDITIONING IB-7
LIG H T T R U C K SERVICE M A N U A L
IB-8 AIR CONDITIONING
BLOW ER A IR H E A TE R H E A TE R
A IR D EFR O STER A /C
SPEEDS ENTERS
COMPRESSOR SOURCE
A V A IL V E H IC L E DOOR DOOR
OPEN TO OPEN TO
O FF OFF NONE O U T S ID E F LO O R O U T L E T S
HEATER H E A T E R -D E F
VACUUM RESER VO IR
(IN E N G I N E C O M P A R T M E N T )
T O VACUUM SORCE
GR AY
DASH P A N E L
P IN K
A /C
^ HEATER O U T S ID E
D ISTRIBUTOR A IR j
DUCT
H E A T E R AI R
DEFROST
CONTROL
DK B L U E
ORANGE S E L E C T VAL VE OPER A TIN G C HART
Air Knob
Turning the A IR knob clockwise operates a three speed
(L O W -M E D -H I) blower motor.
Temp Knob
This knob is used to control the degree of cooling
desired. Fully clockwise a t C IT Y provides m axim um
cooling, while tu rn in g th e knob to H IW A Y provided
adequate cooling for highway operation.
Reduced cooling could be encountered when operating
at highway speeds with the controls at the C IT Y setting.
The heater m ust be fully off to obtain maxim um cooling.
A C CUM U LA TO R
'L P L " - O R IF IC E M ETERS THE L IQ U ID R-12, IN T O EVAPO RA TO R, REDUCING ITS PRESSURE, AND
W ARM BLOWER A IR ACROSS EVAPO RA TO R CORE CAUSES B O ILIN G OFF OF L IQ U ID IN T O VAPOR.
'L P V " - LEAVES EVAPORATOR AS LOW PRESSURE VAPOR A N D RETURNS W ITH THE
SM A LL A M O U N T OF . . .
increase in pressure m ay cause the safety plug to release or CAUTION:Avoid breathing smoke and fumes
the drum to burst. produced by the burning of the Refrigerant-12.
Weeding or steam cleaning near any of the refrigerant Such fumes may be hazardous.
lines or com ponents of th e air conditioning system could
build up dangerous and dam aging pressures in the system.
One of the most im portant cautions concerns the eyes.
If the occasion arises to fill a small R-12 drum from a
Any liquid R-12 which may accidentally escape is approx
large one, never fill th e drum completely. Space should
imately 21°F (-6°C) below zero. If liquid R-12 should touch
always be allowed above the liquid for expansion. If the
the eyes, serious dam age could result. Always wear goggles
R-12 drum were com pletely full and the tem perature was
to protect the eyes when opening refrigerant connections.
increased, trem endous hydraulic force could be developed.
LIG H T T R U C K SE RV IC E M A N U A L
AIR CONDITIONING IB -11
disposable cans or R-12 drum s are also used. D IS C H A R G • Em pty R -12 container completely before disposing.
IN G , A D D IN G O IL , E V A C U A T IN G A N D C H A R G • See Disposable Can C H A R G IN G procedures later in
IN G P R O C E D U R E S F O R C C O T S Y S T E M S are de Service M anual.
scribed on following pages in the Service M anual.
With J-23500-01 Charging Station:
With R-12 Drum or 14 oz. Disposable Can Charging: • Follow m anufacturer’s directions carefully with three
• DO N O T charge while compressor system is hot. exceptions:
• A L W A Y S C H A R G E T H R O U G H L O W -S ID E O F • H I-P R E S S U R E V A LV E O F G A G E SE T SH O U L D
A /C S Y S T E M (low -side fitting is found on BE C L O S E D A T A L L T IM E S D U R IN G
accum ulator). C H A R G IN G
• N E V E R C O N N E C T O N H IG H -S ID E of A /C sys • DO N O T C O N N E C T H IG H P R E S S U R E L IN E TO
tem or to any system having a pressure higher than A /C SY ST E M
indicated on the R - 12 container. • A L L E V A C U A T IN G A N D C H A R G IN G O F A /C
« W hen opening valves designed for use with container, S Y S T E M M U S T BE P E R F O R M E D T H R O U G H
follow m an u factu rer’s directions carefully. LO W P R E S S U R E V A L V E /L IN E T O L O W -SID E
• Always use pressure gages before and during C harging. S E R V IC E F IT T IN G O N A C C U M U L A T O R
DIAGNOSIS
TESTING THE REFRIGERANT SYSTEM CAUTION:Do not use lighted detector in any place
where combustible or explosive gases, dusts or
If a m alfunction in the refrigerant system is suspected vapors may be present.
due to abnorm al system pressures, check the following:
1. C heck outer surfaces of radiator and condenser cores to Operating Detector
be sure they are not plugged with dirt, leaves or other
1. D eterm ine if there is sufficient refrigerant in the system
foreign m aterial. Be sure to check between the con
for leak testing.
denser and radiato r as well as the outer surfaces.
2. R estrictions or kinks in evaporator core or condenser 2. Open control valve only until a low hiss of gas is heard,
core, hoses, tubes, etc. then light gas at opening in chimney.
C irc u m s ta n c e s S h o u ld a S ig h t G la s s Be In s ta lle d
Feel L iq u id L in e B e fo re E x p a n s io n T u b e
R U N S C O N T IN U O U S L Y CYCLES H IGH OR LO W
W IT H IN L IM IT S C YC LES W IT H IN L IM IT S (O N AB O V E 51 PSI
T OR OFF BE LO W 20 PSD
D is c o n n e c t B lo w e r W ir e a n d C he c k For
C y c lin g O ff a t 13 8-1 93 kPa (20 -2 8 PSI)
--------- 1---------
D e fe c tiv e
P ressu re
S w itc h
PRESSU R E F A L LS C YC LES OFF A T 138 193 R ep lace
B E L O W 20 PSI kP a (20 -2 8 PSI) O R D O ES
*D o N o t D is c h a rg e
N O T P U L L D O W N TO
D e fe c tiv e P re s s u re PRESS
S w itc h
O U T LE T TE M P E R A T U R E O U T LE T TE M P E R A T U R E
W IT H IN LIM IT S HIGH A S PER C H AR T
S y s te m
C he ck C o m p re s s o r C y c lin g
(O .K .)
O N C O N T IN U O U S L Y CYCLE O N A N D OFF OR
R E M A IN S OFF FOR LO N G
••D is c h a rg e S y s te m a n d C he c k For PERIOD OF T IM E
M is s in g E x p a n s io n T u b e
D is c h a rg e S y s te m a n d
C he ck fo r P lu g g e d E x p a n s io n T ub e
| M IS S IN G | IN PLACE
R ep lace
T
In s ta ll E x p a n s io n T u b e C heck C o m p re s s o r In le t I
i
E v a c u a te fit C h a rg e
S cree n
_____________ i_____
E v a c u a te & C h a rg e
i
S y s te m C LE AN
S ys te m
(O .K.)
(O .K .)
R e p a ir o r R e p la ce S cree n
I
S y s te m O v e r C h a rg e d
I
E v a cu a te & C h a rg e E va cu a te & C h a rg e
i I
S ystem
S ystem
(O .K.) (O K .)
LIG H T T R U C K SE RV IC E M A N U A L
AIR CONDITIONING IB -15
T h is S y s te m D oe s N o t H ave a S ig h t G lass. U n d e r N o
C irc u m s ta n c e s S h o u ld a S ig h t G lass Be In s ta lle d
F eel L iq u id L in e B e fo re E x p a n s io n T u b e
R U N S C O N T IN U O U S L Y CYCLES H IG H OR LO W
W IT H IN L IM IT S | C YC LES W IT H IN L IM IT S | (ON A B O V E 51 PSI
T OR OFF B E LO W 20 PSI)
D is c o n n e c t B lo w e r W ir e a n d C he c k F or
C y c lin g O ff a t 13 8-1 93 kPa (20 -2 8 PSI) D e fe c tiv e
P re ssu re
S w itc h
I
R eplace. ’ D o N o t D is c h a rg e
In s ta ll T h e rm o m e te r in A/C O u tle t an d
C he ck P e rfo rm a n c e
S y s te m . T h e re is a S c h ra d e r
S yste m
V a lv e in th e F ittin g
1. SET T E M P LEVER TO F U LL C O LD (O .K.)
I
S ystem
2.
3.
SET SELECTOR LEVER TO M A X A/C
SET B LO W E R S W IT C H O N HI
(O .K.) 4. CLOSE D O O R S A N D W IN D O W S
5. R U N EN G IN E A T 2000 R .P.M
6. U SE A U X . F A N IN F R O N T OF G R ILL
O U T LE T TE M P E R A T U R E O U T LE T TE M P E R A T U R E
W IT H IN L IM IT S H IG H A S PER C H AR T
T
S y s te m
C he ck C o m p re s s o r C y c lin g
(O .K.)
O N C O N T IN U O U S L Y CYCLE O N A N D OFF OR
R E M A IN S OFF FOR LO N G
’ •D is c h a rg e S y s te m a n d C he ck For PERIOD OF T IM E
------------------------f -----------------------
M is s in g E x p a n s io n T u b e
D is c h a rg e S y s te m a n d
C heck fo r P lu g g e d E x p a n s io n T ub e
i
R ep lace
In s ta ll E x p a n s io n T u b e C he ck C o m p re s s o r In le t i
i
E v a c u a te & C h a rg e
S cree n E v a c u a te & C h a rg e
i
S yste m
S y s te m P LU G G E D (O .K.)
(O .K.)
R ep air o r R ep lace S cree n S y s te m O v e r C h a rg e d
I
E v a cu a te & C h a rg e
I
E v a cu a te & C h a rg e
i S ystem
S ystem
(O .K.) (O .K.)
L IG H T T R U C K SERVICE M A N U A L
IB-16 AIR CONDITIONING
LIG H T T R U C K SE RV IC E M A N U A L
COMPRESSOR DIAGNOSIS
AIR CONDITIONING
re-evaluate noise.
IB -1 7
MANUAL
LIGHT
IB -18
TRUCK
AIR CONDITIONING
1. Check for proper belt installation and tension with J-23600. 6. Check for proper air ducting hose connections.
2. Check for proper clutch coil terminal connector installation. 7. Check heater temperature door adjustment, adjust if incorrect.
3. Check for clutch air Gap (.022 • .057). 8. Check evaporator sealing for air leak, repair if leaking.
M ANUAL
4. Check for broken, burst, or cut hoses. Also check for loose fittings on all components. 9. Install pressure gages and thermometer and make performance test.
N O R M A L A IR FLO W C H E C K A IR FLO W NO O R LO W A I R F L O W
j CHECK D IS C H A R G E A I R T E M P E R A T U R E (S E E P E R F O R M A N C E D A T A ) |
B L O W E R N O T O P E R A T IN G
C H E C K B L O W E R O P E R A T IO N
N O R M A L B L O W E R O P E R A T IO N
I
D IS C H A R G E T E M P E R A T U R E H IG H O U T L E T A IR C H E C K F O R B L O W N F U S E , D E F E C T IV E B L O W E R SW IT C H , Check for loose or disconnected air distribution ducts,
A T O U T LET COLD TEM PERATU RE B R O K E N W IR E . L O O S E C O N N E C T IO N S , L O O S E B L O W E R M O T O R restricted or leaking air ducts, partially closed air out
G R O U N D W IR E O R I N O P E R A T IV E B L O W E R M O T O R . let valve or clogged evaporator core, if above check is
O K, check for ice blocking evaporator.
CHECK FOR A IR LE A K S TH R O U G H D ASH PA N E L.
C H E C K S IG H T G L A S S
DOORS, WINDOW S, OR FROM H EA TE R .
IC E B L O C K IN G
EVAPO RATOR
|'f o a m i n g | " NO F O A M IN G
C H EC K FO R LOW E V A P O R A T O R P R E SSU R E
SYSTEM IS P R O B A B L Y L O W O N R E F R IG E R A N T . 1. S Y S T E M M A Y B E E IT H E R F U L L Y C H A R G E D O R E M P T Y . 1. A L L O W S Y S T E M T O W A R M UP.
C H E C K F O R L E A K S . R E P A IR , A N D A D D F E E L H IG H A N D L O W P R E S S U R E P IP E S A T C O M P R E S S O R . 2. S T O P A N D R E S T A R T E N G IN E .
R E F R IG E R A N T . IF F O A M IN G S T I L L O C C U R S , H IG H P R E S S U R E P IP E S H O U L D B E W A R M . L O W P R E S S U R E 3. C H E C K E V A P O R A T O R P R E S S U R E
C H E C K F O R R E S T R IC T IO N IN R E F R I G E R A N T P IP E S S H O U L D B E C O L D . IM M E D IA T E L Y A F T E R R E S T A R T A N O
S Y S T E M B E T W E E N C O N D E N S E R A N O S IG H T 2. IF P IP E S A R E N O T IN D IC A T IN G P R O P E R T E M P E R A T U R E S , PU LL DOW N OF E V A P O R A T O R PR ESSU R E.
G LA SS. R E C H A R G E S Y S T E M A S R E C O M M E N D E D . IF N O Z Z L E A IR
T E M P E R A T U R E IS S T IL L H IG H . C H E C K E V A P O R A T O R NO RM AL EVAPO RATO R LOW E V A P O R A T O R
PRESSU RE. PRESSU RE * PR ESSU RE
X ~ I ----
LOW E V A P O R A T O R *C H E C K E V A P O R A T O R P R E S S U R E
S Y S T E M H A S E X C E S S M O IS T U R E . R E P L A C E R E C E I V E R
•PRESSU RE D E H Y D R A T O R AND EV A C U A T E TH O RO U G H LY . R E C H A R G E
SY STEM . Check for m alfunctioning
C H E C K E V A P O R A T O R O U T L E T L IN E H IG H E V A P O R A T O R expansion valve-See
Com ponent Diagnosis.
Z= 1 , ,
* P R ESSU RE
NORMAL
EV A PO RA T O R OUTLET
EVAPO RATO R PRESSU RE
L IN E W A R M C H E C K C O M P R E S S O R D IS C H A R G E P R E S S U R E
I
X | Check Compressor Discharge Pressure.
1. C H E C K F O R L IQ U ID L IN E R E S T R IC T IO N ,----- =3-------------------
( F R O S T S P O T O N L IN E ). IF NO T, | H IG H D IS C H A R G E P R E S S U R E L O W D IS C H A R G E P R E S S U R E ! N O R M A L D IS C H A R G E P R E S S U R E
2. C H E C K F O R P L U G G E D IN L E T S C R E E N IN I X JL
E X P A N S IO N V A L V E . IF N O T , 1. Check engine cooling system, fan clutch and check Check for restriction in liquid line, Refrigeration System is ok
3. C H E C K F O R D E F E C T IV E E X P A N S IO N V A L V E for restricted air flow thru condenser. partially plugged inlet screen at 1. Check for proper function of heater T E M P E R A T U R E door.
B Y R E M O V IN G V A L V E A N D B L O W IN G T H R O U G H 2. Check expansion valve bulb contact. Correct if expansion valve, or defective 2. Check for proper sealing of evaporator case.
V A L V E . IF U N A B L E T O B L O W T H R O U G H V A L V E , necessary.
expansion valve, replace valve if 3. Check for proper operation and seal around temperature door.
B U L B IS D IS C H A R G E D . R E P L A C E E X P A N S IO N 3. Check for refrigerant restriction in condenser.
defective. 4. N on-Foam ing sight glass does not always indicate a fully
VALVE. Return bends at equal elevation should be
charged system. A d d 1/2 lb. refrigerant and observe
approximately same temperature. If temperature
performance.
of bends is appreciably different, the cooler
5. Check for excess oil in system. A sym ptom of excess oil is a
bend indicates a restricted circuit, replace con
L O W D IS C H A R G E slipping clutch or belt or broken belt. T o remove excess oil
1------T
* PR ESSU RE
denser if restriction is found, If condenser is O K,
check for air in system. T o check observe outlet
air temperature and com pressor discharge
pressure while slowly discharging system at
in system see " C H E C K I N G CO M P RESSO R
D ash M o u n te d U n i t ( M o t o r H o m e C ha ssis)
O IL C H A R G E ".
1 F U SE B L O W N ! I fu se q k |
Disconnect resistor connectors, connect one lead
of a self powered test light to any one terminal
The following tests should be made
With ign. switch in " R u n " position and use the other lead to probe each of the
with the ignition switch in " R u n "
and heater or A /C on, locate short in other terminals.
one of the following wires: (see note) position, heater or A /C on and
blower switch on high.
---- I
Check blower motor ground
1. From fuse panel to master X
switch on control.
T E S T L IG H T D O E S N O T T E S T L IG H T L IG H T S ON
2. From master switch to compressor I poor or no g r o u n d | Iground ok I
clutch. L IG H T O N A L L T E R M I N A L S A L L T E R M IN A L S
3. Master switch to blower switch. Repair ground Check motor connector with X
4. From blower speed switch to 12 volt test light. Replace resistor With ignition switch in "R u n " position and heater
resistor.
or A/C on, use 12 volt test lamp to check for
5. From resistor to blower motor.
voltage at resistor connector w ith blower speed
| L A M P L IG H T S ! [ L A M P D O E S N O T L IG H T j switch in each position.
Replace relay
from resistor to X
Use 12 volt test light and check blower relay.
wire terminals at resistor. LAMP LIGHTS ON LAMP DOES NOT LIGH T
A L L WIRES ON A L L WIRES
AIR CONDITIONING
Check F E E D wire from Replace resistor
resistor to blower
speed switch.
LIGHT
|l a m p 0 n |
TRUCK
[L A M P 0 FFJ
T
Replace blower
SERVICE
IB -19
M ANUAL
IB-20 AIR CONDITIONING
NORMAL TEMPERATURE
Check heater outlet for obstruction - re | CHECK FUSE
move.
Remove all obstructions under fro n t seat.
FUSE BLOWN - replace fuse.
Check motor voltage at closest motor line
Car does not build up heat - operate vent connection with a voltmeter.
Al R FLOW - system okay.
controls and see that the air vent doors
close completely, if not, adjust.
Check coolant level; if low, fill. Look for FUSE REMAINS OK - remove motor
or feel all radiator and heater hoses and Check wiring and connections for and check for obstruction in system
connections for leaks. Repair or replace. under 10 volts from motor to fan opening, if none, REPLACE MOTOR.
Check the radiator cap for damage and re switch. Repair or replace last point If obstruction, remove material and
place if required. of under 10 volt reading. re-install motor.
Feel temperatures of heater inlet and outlet hoses. SAME AIR FLOW - remove motor and
check for obstruction in system open
ing. If none, REPLACE MOTOR. If FUSE OK - See Heater Circuit
obstruction, remove material and re Diagnostic Chart.
WARM INLET AND OUTLET HOSES install motor.
L IG H T T R U C K SE R V IC E M A N U A L
AIR CONDITIONING IB-21
S H E E T M E T A L « m _ .,
- BLK— H g \
Q
BLCWER
MOTOR
(2004627
SEE NOTE A
£ r\
S T
BLOWER RELAY •I LT GRN-6 6 B RESISTOR
I D K G R N -5 9 - ASM
■iCRD ---------1BRN/WHT-648,
■£ BLK-150---- '- I 0RN(WH>64A'^
[3 1 — 5 RED-2 -£ ORN-52-------- & ORN-52-
-1 TAN-63-------- -) TAN-63 —
(S I — I DK B L U -IO I -I BRI'VWHT-646-
- I LT BLU-72----- -I LT BLU-72-
| } - . 8 0 R N - 5 2 ------ -I LTGRN-66A— BLOWER SWfTCH
-5 PPL- 6 5
29649H
-5 RED-2 -
COMPRESSOR
12004268 - j
MOUNTNG
BLK-I50C
XSXLHSl!BRACKET ->5 LT G RN(SXU------- E S
GND i FAST ID L E
DK GRN-59$XL) SOLENOID -I BRN/WHT-64A-
1 LTGRN-66A-
NOTE: I BRN-50 -----
SELECTOR SWITCH
* l USE WITH 12010191 RETAINER
AIR CONDITIONING
R P 0C -60
i iLK-l50E(SXL)
S E [ S S — 2BRN-C
I \ A —6917585
' ---- §917580
1-------- 2 BRN VP HARN AIR CONDITIONING
ACC FUSED 2 0 A
RP.Q-C60
LIG H T T R U C K SERVICE M A N U A L
IB-22 AIR CONDITIONING
REAR BLOWER
WESISTgR
2 )t i
- w
m -12004752 GROMMET
•917542- 7541
•2 LT BLLVBLK-872 — i
2 LT BLIV6LK-872 -2LTBLIVBLK - 2 YEL^LK-851 —
>— 2 YEL/BLK-851- -2YEU/BLK---- [•Ml ( Ml - 2 QRN/BLK-852A
-2 0RI►/ blk - i8 5 2 - -2 OR^BLK— i-w- ii-r-i -30R IVB LK -852B -1
KO HO -2 B R N -5 0 — ■
MNI-C6Q-
W
MC. hi - 2 B R N -5 0 -
SEAR BLOWER
MOTOR
SHEET
3 BRfVW HT-850 METAL
GRD
REAR A/C SWITCH
8 9 I7683 •8917580*
L - 30RNfeLK-852B 5 ORH^BLK-852-
891758
-2 B R N -50
FUSE BLOCK
L IG H T T R U C K SE RV IC E M A N U A L
AIR CONDITIONING IB-23
Fig. 1B-17--C60 System Vacuum Diagram (C-K Series)
IB -24 AIR CONDITIONING
L IG H T T R U C K SE RV IC E M A N U A L
HI I TO FUSE PANEL
||l G RO U N D
COM PRESSOR
Fig. 1B-19--C60 Motor Home Chassis Wiring
RESISTOR. Z
ctr
O
BLOWER
1
I M OTOR I•
J
101 16 DK BLU ft
■52 16 DK BLU
■72 16 LT BLU'
BLOWER SWITCH
— 51 16 YEL
SET AT CONNECTIO N
OFF N TO N O N E
Diagram
LOW N TO 1 & 2
MED N TO 1 & 4
B LO W E R -E V A P O R A T O R HIGH N TO 1, 3 & 4
ASSEMBLY
AIR CONDITIONING
BLOWER
SWITCH
THERMOSTATIC
SWITCH
IB-25
IB-26 AIR CONDITIONING
L IG H T T R U C K SE RV IC E M A N U A L
AIR CONDITIONING IB-27
LIG H T T R U C K SERVICE M A N U A L
IB-28 AIR CONDITIONING
system head pressure by partially blocking the con Sight Glass Diagnosis (Motor Home Chassis Units)
denser. Disconnect the blower lead wire and repeat the
"perform ance check" to determ ine if the evaporator At tem peratures higher than 70°F (21°C), the sight
pressure can be obtained. glass may indicate wheter the refrigerant charge is suffi
cient. A shortage of liquid refrigerant is indicated after
3. The system will also indicate a low refrigerant charge
above five m inutes of compressor operation by the appear
by bubbles occurring in the sight glass (M otor Home
ance of slow-moving bubbles (vapor) or a broken column of
Chassis System s).
refrigerant under the glass. Continuous bubbles may appear
in a properly charged system on a cool day. This is a normal
EVAPORATOR
situation. If the sight glass is generally clear and perform
W hen the evaporator is defective, the trouble will show ance is satisfacto ry , occasional bubbles do not indicate
up as an inadequate supply of cool air. A partially plugged refrigerant shortage.
core due to dirt, a cracked case, or a leaking seal will
If th e sight glass consistently shows foam ing or a
generally be the cause. broken liquid column, it should be observed after partially
REFRIGERANT LINE RESTRICTIONS blocking the air to the condenser. If under this condition the
sight glass clears and the perform ance is otherwise satisfac
Restrictions in the refrigerant lines will be indicated as tory, the charge shall be considered adequate.
follows:
In all instances where the indications of refrigerant
1. Suction Line - A restricted suction line will cause low shortage continues, additional refrigerant should be added
suction pressu re a t th e com pressor, low discharge in 120 ml (1 /4 lb.) increm ents until the sight glass is clear.
pressure and little or no cooling. An additional charge of 240 ml (1 /2 lb.) should be added as
2. D ischarge Line - A restriction in the discharge line a reserve after the glass clears. In no case should the system
generally will cause the pressure relief valve to open. be overcharged.
3. Liquid Line - A liquid line restriction will be evidenced
by low discharge and suction pressure, and insufficient
cooling.
ON VEHICLE SERVICE
EVACUATING AND CHARGING PROCEDURES
PRECAUTIONARY SERVICE MEASURES M ake sure fittings are dry prior to reassembly. If dirt, grease
or moisture get inside pipes and cannot be removed, the pipe
Before any service is attem pted which requires opening should be replaced.
of refrigerant lines or com ponents, the person doing the
Sealing caps should be removed from subassemblies
work should be thoroughly fam iliar with the inform ation
ju st prior to making connections for final assembly. Use a
under P R E C A U T IO N S IN H A N D L IN G R E F R IG E R
small am ount of clean 525 viscosity refrigerant oil on all
A N T -12, P R E C A U T IO N S IN H A N D L IN G R E F R IG
tube and hose joints. Always use new "O " rings dipped in
E R A N T L IN E S A N D F IT T IN G S M A IN T A IN IN G
the clean refrigerant oil when assembling joints. The oil will
C H E M IC A L S T A B IL IT Y IN T H E R E F R IG E R A T IO N
aid in assembly and help provide a leak-proof joint. W hen
S Y S T E M , A N D R E F R IG E R A N T C H A R G IN G P R E
tightening joints, use a second wrench to hold stationary
C A U T IO N S and should follow very carefully the D IS
part of connection so th at a solid feel can be attained. This
C H A R G IN G , E V A C U A T IN G , O IL A D D IT IO N A N D
will indicate proper assembly.
C H A R G IN G T H E R E F R IG E R A N T S Y ST E M instruc
tions given on th e following pages for the unit being
serviced. NOTICE: Tighten all tubing connections as shown in
T he m ajor reasons behind these m easures are safety torque chart (C hart IB-9). Insufficient or excessive
and the prevention of d irt and m oisture in the system which torque when tightening can result in loose joints or
can restrict A /C system refrigerant flow. deformed joint parts. Either condition can result in
The presence of m oisture can also cause the form ation refrigerant leakage.
of hydrochloric or hydrofluoric acids in the system.
All subassem blies are dehydrated and sealed prior to CCOT REFRIGERANT OIL DISTRIBUTION
shipping. T hey are to rem ain sealed until ju st prior to A-6 C O M P R E S S O R SY STEM - requires 300 ml (10
making connections. All subassemblies should be at room oz.) of 525 viscosity oil.
tem perature before uncapping (this prevents condensation
R-4 C O M P R E S S O R SY ST E M - requires 180 ml (6
of m oisture from the air th a t enters the system ). If, for any
oz.) of 525 viscosity oil.
reason, caps are removed but the connections are not made,
parts should be resealed as soon as possible. New oil quantities m ust be added to the system during
All precautions should be taken to prevent dam age to Service component replacem ent and conditions stated as
fittings or connections. A ny fittings getting grease or dirt on follows:
them should be wiped clean with a cloth dam pened with A. W hen there are no signs of excessive oil leakage, for
Stoddard solvent, kerosene (or equivalent) m ay be used. the -
LIG H T T R U C K SERVICE M A N U A L
IB-30 AIR CONDITIONING
LIG H T T R U C K SERVICE M A N U A L
IB-32 AIR CONDITIONING
1 CLOSE A L L CO NTRO LS
J 23500-01
SE R V IC E C H A R G IN G
S T A T IO N
3 F U L L Y OPEN GAUGE
SET V A C U U M V A L V E
6 RE-CONNECT V A C U U M
HOSE TO PUMP A F T E R
DISCHARGE
DO NO T CONNECT
HIG H-SIDE HOSE
TO A /C SYSTEM
2 DISCO NNECT V A C U U M
HOSE A T V A C U U M PUMP
& PLACE IN T O CAN (SEE
“ N O T E " BELOW)
V A C U U M PUMP
L IG H T T R U C K SE R V IC E M A N U A L
AIR CONDITIONING IB-33
J5725-04
MANIFOLD
GAUGE SET TH,S HIGH PRESSURE VALVE IS
/ OPEN AND VACUUM PUMP LINE
USING J-5420 / DISCONNECTED ONLY DURING
ADAPTER OPEN DURING / EVACUATION
EVACUATION
AND CHARGING THIS HIGH PRESSURE
VALVE IS CLOSED AND
LINE DISCONNECTED
HIGH DURING DISCHARGING
SIDE AND CHARGING
VALVE VALVE
VACUUM PUMP
ACCUMULATOR CAUTJON: Make sure outlet valve on opener is closed 30 LB. DRUM HAS
(clockwise) before installing opener to R-12 container. OWN OPENER-VALVE
USING J23390
CLOSED D U R IN G / OPENER-VALVE
MULTI-CAN DISPENSING UNIT EVACUATION X FOR 12 LB. CAN
USING J6271-01 SINGLE CAN OPEN AND INVERTED
DURING CHARGING
OR
J6272-02 MULTI CAN
OPENER-VALVE
Fig. 1 B-24--Charging the CCOT A /C System with Disposable Can or Refrigerant Drum.
2. To begin evacuation, w ith M anifold G age Set and 3. W hen the system is fully Evacuated, close the high-side
V acuum Pum p as shown in Fig. 1B-24 slowly open high gage set valve and turn O F F the vacuum pump.
and low-side gage valves and begin vacuum pum p
4. W atch low-side gage to be sure vacuum holds for
operation. Pum p the system until low-side gage reaches five(5) m inutes at gage set and then proceed to
95-98 kPa (28 to 29 in.) vacuum or more. Charging.
In all Evacuation procedures, the specification of 95-98
5. If Vacuum Does N ot Hold For five(5) M inutes, charge
kPa (28 to 29 in.) of m ercury vacuum is used. This
system with 240 ml (1 /2 lb) R-12 and leak check.
specification can only be reached a t or near sea level.
Discharge system again then repair leak as necessary.
For each 304.8 m (1,000 ft) above sea level, specifica
Repeat Evacuation procedure.
tion should be lowered by one inch of m ercury vacuum.
A t 1524 m (5,000 feet) elevation only 78-81 kPa (23 to
24 in.) of vacuum is required. TO BEGIN CHARGING OF THE CCOT A /C
If prescribed vacuum cannot be reached, close vacuum SYSTEM
control valve, shut off pum p and look for a leak at 1. S tart engine, run with choke open and fast idle speed
connections or pump. reduced to normal idle, set A /C control lever on O FF.
LIG H T T R U C K SE RV IC E M A N U A L
AIR CONDITIONING IB-35
2. W ith the R efrig eran t-12 drum or 420 ml (14 oz.) 2. The expansion tube (orifice) screen is plugged.
can(s) inverted, open R-12 source valve(s) and allow 3. The compressor inlet screen is plugged.
480 ml (1 lb.) or 1 to 2, 420 ml (14 oz.) can(s) of liquid 4. An evaporator fails because of inside-out (internal)
R - 12 to flow into system through low-side service fitting corrosion.
on accum ulator (R efer to Fig. 1B -31).
DO N O T R E P L A C E the accum ulator assembly when:
3. As soon as 480 ml (1 lb.) or 1 to 2, 420 ml (14 oz.)
can (s) of liquid R -12 has been added to system , 1. If a sm all dent is found in the outer shell of the
im m ediately engage the com pressor, by setting the accum ulator.
A /C control lever to N O R M and blower speed on H I,
2. W hen a vehicle is involved in a collision and no physical
to draw in the rem ainder of the R - 12 charge.
perforation to the accu m u lato r is found. An open
The C harging operation can also be speeded up by
refrigerant line should be capped or have a plastic bag
using a large volume fan to pass air over the condenser.
tightly taped around it.
If condenser tem perature is m aintained below charging
cylinder tem perature, R efrig eran t-12 will enter system
more rapidly.
COMPRESSOR
4. Shut off R-12 source valve and run engine for 30
seconds to clear lines and gages. C-K SERIES
5. W ith the engine running, remove the charging low-side Removal (Fig. IB-33)
hose adap ter from the A ccum ulator Service fitting.
Unscrew rapidly to avoid excess R-12 escape from
system. 1. Discharge the system.
2. Remove connector attaching bolt and connector. Cap
CAUTION:Never remove a gage line from its
or plug open connections at once.
adapter when line is connected to A /C system.
Always remove the line adapter from the service 3. Disconnect electrical lead to clutch actuating coil.
fitting to disconnect a line. Do not remove charg 4. Loosen brace and pivot bolts and detach belt.
ing hose at set while attached to accumulator. 5. Remove the nuts and bolts attaching the compressor
This will result in complete discharge of system brackets to the m ounting brack et. Rem ove the
due to the depressed schrader valve in service compressor.
low-side fitting, and may cause personal injury 6. Before beginning any compressor disassembly, drain
due to escaping R-12. and m easure oil in the compressor. Check for evidence
6. R eplace protective cap on accum ulator fitting. of contam ination to determ ine if rem ainder of system
7. Leak check system with J-6084 leak detector. requires servicing. Com pressor servicing inform ation is
8. W ith system fully C harged and leak-checked, continue located in the U nit R epair M anual.
to operate system and test for proper system pressures
as outlin ed under P E R F O R M A N C E P R E S S U R E -
T E M P E R A T U R E D A T A C C O T A /C S Y S T E M
D IA G N O S T IC P R O C E D U R E .
ACCUMULATOR ASSEMBLY
T he accum ulator assembly for the C C O T system has a
service replacem ent which includes two " O " rings (for the
inlet and outlet connections). The dessicant within the shell
is N O T serviced sep arately - it is p a rt of the sealed
accum ulator assembly.
R efer C C O T R efrigerant oil distribution for presence
of refrigerant oil and service conditions when the accum ula
tor m ust be rem oved from the vehicle to m easure the
am ount of oil present inside the accum ulator.
T he accum ulator assembly should be replaced only
when:
1. A physical perforation to the accum ulator is found Fig. 1B-25--Checking Evaporator Inlet and
resulting in a leak. Acuumulator Outlet Temperatures
LIG H T T R U C K SE RV IC E M AN U AL
IB-36 AIR CONDITIONING
3 0 5 - 3 5 0 V -8 C-K M O D E L S
^ T l t r ^
3 0 5 - 3 5 0 V -8 G M O D E LS A N D M O T O R H O M E C H A SS IS
4 5 4 V -8 C- M O DELS 4 5 4 V -8 M O T O R H O M E C H A SS IS
L IG H T T R U C K SERVICE M A N U A L
AIR CONDITIONING IB-37
Installation
1. If th e oil d rain ed from th e com pressor showed no
evidence of contam ination replace the sam e am ount of
fresh refrig eratio n oil into th e com pressor before
LIG H T T R U C K SERVICE M A N U A L
IB -38 AIR CONDITIONING
L IG H T T R U C K SE RV IC E M A N U A L
AIR CONDITIONING IB-39
LIG H T T R U C K SERVICE M A N U A L
IB-40 AIR CONDITIONING
SELECTOR DUCT AND HEATER CORE ASSEMBLY- remove the selector duct assembly.
10. Remove the core m ounting strap screws and remove the
C-K core.
Replacement (Fig. IB-30) 11. To install, reverse Steps 1 thru 10 above.
12. Refill coolant system and connect the battery ground
1. Disconnect the b attery ground cable. strap. Check tem perature door cable adjustm ent.
2. D rain the radiator and remove the heater hoses from KICK PAD VALVE - C-K SERIES
the core tubes. Plug the core tubes to prevent coolant Replacement (Fig. IB-31)
spillage during removal. 1. Disconnect the vacuum hose a t the actuator.
3. Remove the glove box and door as an assembly. 2. Unhook the valve return spring at the actuator end.
4. Remove the center duct to selector duct and instrum ent 3. Remove the actuator bracket m ounting screws.
panel screws and remove the center lower and center 4. Remove the cam to actuator arm screw and separate
upper ducts. the actuator and bracket from the cam.
5. D isconnect the bowden cable at the tem perature door. 5. Remove the actuator to bracket nuts and separate the
actuator and bracket.
6. Rem ove the nuts from th e three selector duct studs
projecting through the dash panel. 6. To install reverse Steps 1 thru 5 above.
7. Remove the selector duct to dash panel screw (inside PLENUM VALVE - C-K SERIES
vehicle). Replacement (Fig. IB-31)
8. Pull the selector duct assembly rearw ard until the core 1. Raise the hood.
tubes clear the dash panel. Lower the selector assembly 2. Remove the cowl plastic grille.
far enough to gain access to all vacuum and electrical 3. Remove the three cowl to valve assembly screws and
harnesses. remove the valve assembly from the vehicle.
9. D isconnect th e vacuum and e lectrical harness and 4. Remove the actuator arm pushnut.
L IG H T T R U C K SE RV IC E M A N U A L
AIR CONDITIONING IB-41
LIG H T T R U C K SERVICE M A N U A L
IB-42 AIR CONDITIONING
ORANGE
CAM
LEVER
CABLE
RECIRC. AIR V IE W
ACTUA TO R
V IE W V IE W
BLOWER MOTOR RELAY - ALL This duct covers the blower-evaporator assembly, at
the rear of the vehicle, and incorporates four adjustable air
The blower m otor relay is located on the blower side of outlets (Fig. IB-36).
the blow er-evaporator case (Fig. 35).
Replacement
Replacement
1. Disconnect the battery ground cable.
1. Disconnect th e wiring harness at the relay.
2. Disconnect the drain tube from the rear duct.
2. Remove the relay to case attach in g screws and remove
the relay. 3. Remove the screws securing the duct to the roof panel
and rear header brackets.
3. Place the new relay in position and drive the m ounting
screws. 4. Remove the duct.
4. Connect the relay w iring harness. 5. To install, reverse Steps 1 thru 4 above.
L IG H T T R U C K SE RV IC E M A N U A L
AIR CONDITIONING IB-43
A /C HARNESS ASM
PRESSURE C Y C L IN G SWITCH
BLOW ER
RESISTOR
BLOW ER
R ELAY
ACC UM ULATO R
BLOW ER ASM G R O U N D
E V A P O R A TO R
BLOW ER ASM
V IE W A
Fig. 1 B-38--Blower-Evaporator (C-K Overhead Fig. 1B-39--Blower M otor (C-K Overhead System)
System) Removal
NOTICE: R o tate the blower wheels to m ake sure th at 1. Disconnect b attery ground cable.
they do not rub on the case.
2. Purge the system of refrigerant.
5. Install the center ground wire and connect the blower
lead wire. 3. Remove the rear duct as outlined previously.
6. Install the rear duct assem bly as described previously. 4. Disconnect the blower motor lead and ground wires.
7. Connect th e b attery ground cable. 5. Remove the lower to upper blower-evaporator case
screws and lower the lower case and motor assembly.
EXPANSION VALVE
This sytem incorporates an expansion valve which does NOTICE: Before removing the case screws, support the
not utilize and external equalizer line (Fig. IB-40). lower case and motor assemblies to prevent dam age to
the case or motor assemblies.
LIG H T T R U C K SE RV IC E M A N U A L
AIR CONDITIONING IB-45
7. Disconnect the valve inlet and outlet lines and remove Install the sensing bulb to the evaporator outlet line as
the expansion valve assembly. C ap or plug the open shown in Fig. IB-44; make sure the bulb has good
connections a t once. contact with the line.
Add 3 oz. clean refrigeration oil when installing a new
Installation core.
1. Remove caps or plugs from system connections and 3. Install the upper case and supports to the core.
install the new valve assembly using new " O " rings
4. Install the lower core case and blower assembly.
coated with clean refrigeration oil.
2. Install the sensing bulb, m aking sure th at the bulb 5. Install the blower-evaporator assembly to the roof and
m akes good contact with the core outlet line. install the support to roof rail screws.
3. Install the lower case and blower motor assemblies. 6. Connect the refrigerant lines to the blower-evaporator
Connect the blower motor lead and ground wires. unit using new " O " rings coated with clean refrigera
4. Install the rear duct as outlined previously. tion oil.
5. Connect the battery ground cable. 7. Connect the blower lead and ground wires.
6. Evacuate, charge and check the system.
8. Install the rear duct as outlined previously.
EVAPORATOR CORE (Fig. IB-40) 9. Connect the battery ground cable.
Removal 10. Evacuate, charge and check the system.
1. Disconnect the b attery ground cable.
2. Purge the system or refrigerant.
3. Remove the rear duct as outlined previously. BLOWER MOTOR SWITCH
4. Disconnect the blower m otor lead and ground wire The three-speed (L O -M E D -H I) blower motor switch is
connections. located in the instrum ent panel, just to the left of the ash
5. D isconnect the re frig e ra n t lines a t the re a r of the tray (Fig. IB-41).
b low er-evaporator assem bly. C ap or plug the open
connections at once. Replacement
6. Rem ove th e blow er-evaporator support to roof rail
1. Disconnect the battery ground cable.
screw s, lower th e blow er-evaporator assem bly and
place it on a work bench upside down. 2. Remove the switch retaining screws.
7. Remove the lower to upper case screws and remove the 3. Disconnect the wiring harness at the switch and remove
lower case assembly. Remove the support to upper case the switch.
screws and remove the upper case from the evaporator
core. 4. To install, reverse Steps 1 thru 3 above.
8. Remove the expansion valve inlet and outlet lines and
cap or plug the open connections at once. Remove the FUSE
expansion valve capillary bulb from the evaporator
The Four Season portion of this system is protected by
outlet line and remove the valve.
a 25 am p fuse in the junction block.
9. Remove the plastic pins holding the screen to the core
and remove the screen. The rear blower high speed circuit is protected by a 20
am p in-line fuse, located between the junction block and the
Installation rear blower motor switch.
1. Install the wire screen to the front of the core and insert
the plastic pins.
2. Install the expansion valve inlet and outlet lines using
new " O " rings coated with clean refrigeration oil.
E VA PO R A TO R B LO W E R -E V A P O R A TO R
SCREEN UPPER CASE
Fig. 1 B-40--Expansion Valve C69 System Fig. 1B-41--Blower Switch (C-K Overhead System)
LIG H T TR U C K SERVICE M A N U A L
IB-46 AIR CONDITIONING
Replacement
1. Disconnect battery ground cable.
G Series - Remove the coolant recovery tank, and
power antenna as outlined in Sections 6 and 9.
2. Disconnect the blower m otor lead wire.
3. Remove the five blower motor m ounting screws and
remove the motor and wheel assembly. Pry gently on
the blower flange if the sealer acts as an adhesive.
4. Rem ove the blower wheel to m otor shaft n u t and
separate the wheel and motor assemblies.
5. To install a new motor, reverse Steps 1 thru 4 above.
The following steps should be taken to assure proper
installation:
a. Assemble the blower wheel to the motor with the
open end of the wheel away from the blower motor.
b. If the motor mounting flange sealer has hardened, or
is not intact, remove the old sealer and apply a new
L IG H T T R U C K S E R V IC E M A N U A L
AIR CONDITIONING IB-47
Fig. 1B-44--Recirculating Air Door Vacuum Actuator Fig. 1B-45--Heater Distributor Duct
bead of sealer to the entire circum ference of the EVAPORATOR CORE
m ounting flange,
Replacement (Fig. IB-54)
c. C heck blower operations: blower wheel should rotate
freely with no interference. 1. Disconnect battery ground cable.
2. Purge system of refrigerant.
LIG H T T R U C K SERVICE M A N U A L
IB-48 AIR CONDITIONING
BLOWER SWITCH
Replacement (Fig. IB-48)
1. Disconnect the battery ground cable.
2. Remove the left foot cooler outlet assembly at the
instrum ent panel attachm ent.
3. Disconnect the switch electrical harness.
4. Remove the switch mounting screws and remove the
switch.
3. Remove coolant recovery tank and bracket as outlined 5. To install, reverse Steps 1 thru 4 above.
earlier.
4. D isconnect all e lectrical connectors from core case RESISTORS
assembly. Replacement (Fig. IB-49)
5. Remove bracket at evaporator case. 1. Disconnect electrical harness at the resistor.
6. Remove right hand m arker lam p for access. 2. Remove the resistor mounting screws and remove the
7. Disconnect accum ulator inlet and outlet lines and 2 resistor.
brackets attaching accum ulator to case. 3. To install, reverse Steps 1 thru 3 above.
8. Disconnect evaporator inlet line.
9. Remove three (3) nuts and one (1) screw attaching
module to dash panel. BLOWER MOTOR RELAY - G SERIES
10. Remove core case assem bly from vehicle. Replacement (Fig. IB-49)
11. Remove screws and separate case sections. 1. Disconnect electrical harness at the relay.
12. Remove evaporator core. 2. Remove the relay m ounting screw and remove the
13. To install new core, reverse Steps 3 thru 14 above. relay.
14. Add 90 ml (3 oz.) 525 viscosity refrigeration oil to a 3. To install, reverse Steps 1 thru 3 above.
new condenser.
CENTER A /C OUTLET - G SERIES
15. Evacuate charge and check the system.
Replacement
1. Disconnect negative battery cable.
TEMPERATURE DOOR CABLE - G SERIES
2. Remove engine cover (R efer to Section 6A).
Replacement 3. Remove steering column to I.P. attaching screw.
Follow Steps 1 thru 10 of "H e a te r A ir D istributor and 4. Remove radio support bracket screw.
Extension D uct R eplacem ent" procedure. 5. Remove I.P. attaching screws.
11. Disconnect tem perature door control cable at heater 6. Pull right side of I.P. rearw ard.
case.
7. Remove duct (distributor) attaching screws.
12. Disconnect tem perature door control cable at control. 8. Remove center deflector.
13. M ake up new cable.
9. To replace, reverse Steps 1 thru 8 above.
14. To reassemble, Reverse Steps 1 thru 13.
LIG H T T R U C K SE R V IC E M AN U AL
AIR CONDITIONING IB-49
L IG H T T R U C K SERVICE M A N U A L
IB-50 AIR CONDITIONING
L IG H T T R U C K SE R V IC E M A N U A L
AIR CONDITIONING IB-51
LIG H T TR U C K SERVICE M A N U A L
IB-52 AIR CONDITIONING
COMPRESSOR
COMPRESSOR
ASSEMBLY
R IN G
A C C U M DEHYDR
ASSEMBLY OUTLET
PIPE
G MOD. V8 ENG.
C60/69
HOSE & TUBE ASSEMBLY
EVAP. OUTLET REAR G MOD. LE 3 ENG.
C60
V IE W
LIG H T T R U C K SE RV IC E M A N U A L
AIR CONDITIONING IB-53
Replacement
1. Raise the hood.
CIRCUIT BREAKER
The entire air conditioning system is protected by a 45
am p circuit breaker located on the left side of the dash, in
the engine com partm ent.
A /C DUCTWORK
A ir C onditioning duct attachm ent is shown in Fig. 1B- OVERHEAD SYSTEM-G SERIES
63. This system is used in conjunction with the C60 system.
The G Van C69 system is almost identical to the C-K
DEFROSTER DUCT
M odels overhead system R efer to CK Series overhead
D efroster duct m ounting is shown in Fig. 1B-64. system service procedures.
LIG H T T R U C K SERVICE M A N U A L
IB-54 AIR CONDITIONING
LIG H T T R U C K SERVIC E M A N U A L
AIR CONDITIONING IB-55
LIG H T T R U C K SERVICE M A N U A L
IB-56 AIR CONDITIONING
LIG H T T R U C K SERVICE M A N U A L
IB-58 AIR CONDITIONING
TERMINAL
SCREW DRIVER
(NARROW BLADE)
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-69--Blower-Evaporator (Motor Home Chassis Fig. 1B-70--Terminal Removal
Units)
2. Remove blower assembly. Remove the wheels from the bracket. A tta ch the m ounting strap . Align blow er
m otor shaft. wheels so th at they do not contact case.
Installation 3. Assemble the case halves and attach the cover plate.
1. Install the blower wheels on the motor so th a t the lower 4. Reverse Steps 1-8 on the " Blower-Evaporator Assem
blades curve tow ard the dash panel side of the unit bly" removal procedure.
when the m otor is placed in the case as shown in Fig. 5. Evacuate, charge and check the system.
IB-85.
2. Place th e m otor in th e b ra c k e t w ith th e electrical
connector side of the m otor to the right side of the
L IG H T T R U C K SE RV IC E M A N U A L
AIR CONDITIONING IB-59
CORRECT
BLOWER
BLADE Fig. 1B-73--Thermostatic and Blower Switches
ANGLE
3. Remove evaporator core retaining screws and remove
core.
Fig. 1 B-71--Blower Assembly (M o to r Home Chassis 4. R e m o v e b lo w e r m o to r a n d h a rn e s s a s s e m b ly fr o m case.
Unit)
Installation
1. Reverse applicable steps in the removal procedure.
T HERM O STA TIC SW IT C H SCR EEN NOTICE: Use new " O " rings coated with clean refriger
CAPILLARY TUBE M E SH ation oil when connecting lines. Add 3 oz. of new
refrigeration oil to a new core.
2. Reverse steps 1 thru 8 of the "Blower Evaporator
Assem bly" removal procedure.
3. Evacuate, charge and check the system.
LIG H T T R U C K SERVICE M A N U A L
IB-60 AIR CONDITIONING
SPECIFICATIONS
A IR C O N D IT IO N IN G
Compressor
T y p e .........................................
4 Cylinder Radial
Displacement
6 Cylinder Axial • ........................1 2 .6 Cu. In.
4 Cylinder Radial • • • ....................... 1 0 .0 C u .ln .
R o t a t i o n .............................
Amps. RPM Torque Specifications
Volts (Cold) (Cold)
Compressor Suction and Discharge
Blower M otor Connector B o l t ...................................
C-K Four Season . . 12.0 12.8 Max. 3400 Min. Rear Head to Shell Stud Nuts ( 6 Cyl.) ............23 ft. lbs.
C-K-G Overhead, Shaft Mounting N u t (6 C y l . ) ............... ............ 20 ft. lbs.
G Floor and Shaft Mounting Nut (4 Cyl.) . . . . . . 8-12 ft. lbs.
M otor Home High Pressure Relief Valve (6 Cyl.) . . . 12 ft. lbs.
U n its .................... 12.0 13.7 M ax. 3400 M in. Oil Charge Screw (6 Cyl.) . . . .
Air Gapon Clutch (6 C y l.) . . . .
Compressor Mounting Bracket
Compressor Clutch Coil Compressor to Front Bracket Bolts . . . 25 ft. lbs.
Ohms (at 8 0 ° F ) ..................... ...................................... 3.70 Belt Tension ......................................... See Tune-Up Chart
Fuse Block—
Amps, (at 8 0 ° F ) ..................... ................. 3.33 @ 1 2 volts
C-K S y s te m s ...........................................
M o tor Home Chassis U n it..................... .... 20 Amp.
In -L in e -
C-K S y s te m s ........................................... . . . . 25 Amp.
M o tor Hom e Chassis U n i t .................... ............... None
Circuit Breaker
G Model Systems..................................... .... 45 Am p.
LIG H T T R U C K SE R V IC E M A N U A L
AIR CONDITIONING IB-61
SPECIAL TOOLS
LIG H T T R U C K SERVICE M A N U A L
IB-62 AIR CONDITIONING
SPECIAL TOOLS
1. J -8 3 9 3 C h a rg in g Station 11. J -5 4 2 1 -0 2 Pocket Thermometers (2) 22. J-93 9 8 Pulley B earing Remover
2. J -2 4 0 9 5 O il Inducer 12. J-54 0 3 N o. 21 S nap Ring Pliers 23. J-9481 Pulley a nd B earing In sta ller
3. J -54 5 3 G o ggles 13. J -64 3 5 N o. 26 S nap Ring Pliers 2 4. J-80 9 2 H a n d le
4. J -9 4 5 9 7 /1 6 " -2 0 9 0 ° G a u g e Line 14. J -9 3 9 6 Compressor H old ing 2 5. J -21 3 5 2 In tern a l Assembly
J -2 5 4 9 9 3 /8 " -2 4 A d a p te r Fixture Support Block
5. J -5 4 2 0 7 /1 6 " -2 0 S tra ig h t G a u g e Line 15. J -2 5 0 3 0 Compressing Fixture 2 6. J -51 3 9 O il Pickup Tube Remover
J -2 5 4 9 8 3 /8 " A d a p te r 16. J-94 0 3 Clutch H ub H old ing Tool 2 7. J-94 3 2 N e e d le B earing Installer
6. J -6 0 8 4 Leak Detector 17. J -9 3 9 9 9 /1 6 " Thin W a ll Socket 28. J-95 5 3 -01 Seal S eat " O " Ring
7. J -8 4 3 3 Puller 18. J-9401 H ub and Drive Plate Remover
8. J -9 3 9 5 Puller Pilot Assembly Remover 29. J -2 1508 S eal S eat " O " Ring
9. J -2 3 5 9 5 R efrig era n t C an V alve 19. J-94 8 0 -01 H ub and Drive Plate In staller
(S id e -T a p ) Assembly In staller 3 0. J -2 2 9 7 4 S haft Seal Protector
10. J -6271-01 R efrig era n t C an V alve 20. J -93 9 2 S eal Remover 3 1. J-96 2 5 Pressure Test C onnector
(To p-Tap) 21. J -2 3 1 2 8 S eal S eat Remover 32. J-94 0 2 Parts Tray
LIG H T T R U C K SE RV IC E M A N U A L
FRAME 2A-1
SECTION 2A
FRAME
CONTENTS
GENERAL DESCRIPTION
L ig h t d u ty 10-30 Series fram es are of th e ladder The G -Van fram e side rails, cross sills and outriggers
channel section riveted type. are part of the underbody assembly which is a welded unit.
Figure 2A-1 thru 2A-4 illustrates typical light duty M isalignm ent of the underbody can affect door opening
truck fram es with crossm embers, body mounts and suspen- fits and also influence the suspension system , causing
sion attaching brackets. This section also includes general suspension m isalignm ent. It is essential, th erefo re, th a t
instructions for checking fram e alignm ent and recommen- underbody alignm ent be exact to within - 1/16 in. (1.9m m )
dations on fram e repair. of the specified dimensions.
ON VEHICLE SERVICE
MAINTENANCE AND FRAME ALIGNMENT
INSPECTION Horizontal fram e checking can be made with tra m
ming gages applied directly to the fram e or by transferring
selected points of m easurem ent from the fram e to the floor
UNDERBODY INSPECTION
by means of a plum bob and using the floor layout for
Raise the vehicle on a hoist (preferably a twin-post measuring. Fig. 2A-2 or 2A-4 may be used as a general
type). guide in the selection of checking points; however, selection
of these points is a rb itrary depending on accessibility and
C heck for obvious floor pan deterioration. convenience. An im portant point to rem em ber is th at for
C heck for loose dirt and rust around the inside of the each point selected on one side of the frame, a corresponding
floor pan reinforcem ent m em ber access holes. This is the point on the opposite side of the frame m ust be used for
first indication th a t corrosion m ay exist in hidden areas, and vertical checks, opposite and alternate sides for horizontal
th at repairs m ight be required before the final cleaning and checks.
protective treatm en t is perform ed.
Vehicle Preparation
Using a chisel, ensure th at the drain provisions in the
floor pan reinforcem ent m em bers are open. Points to rem em ber when preparing vehicle for fram e
checking:
T here are drain holes in the body side panels also.
1. Place vehicle on a level surface.
These holes can be opened by using a punch or drift. The
side panel drain holes are in the rear section of the rocker 2. Inspect dam aged areas for obvious fram e misalignm ent
panels, and in the lower rear q u arter panels. to elim inate unnecessary measuring.
3. Support vehicle so th at fram e sidemembers are parallel
FRAME INSPECTION to the ground.
R aise the vehicle on a hoist (preferably a twin-post Tramming Sequence (Fig. 2A-1)
type).
1. Dimensions to bolts an d /o r holes in fram e extend to
Check for obvious floor pan deterioration. dead center of the hole or bolt.
Check for loose dirt and rust around the inside of the 2. Dimensions m ust be within 3/16 in. (4.7 mm).
fram e rails, on top and at the ends where corrosion m ay exist 3. If a tram bar is used, for horizontal alignm ent " X " -
in hidden areas. Check especially in the fram e box sections check from opposite and alternate reference points AA,
for accum ulation of debris. BB and CC, as illustrated by the lines in Fig. 2A-1.
2A-2 FRAME
Error will result if a tram b ar is not level and centered Vertical Check
at the reference points.
Vertical dimensions are checked with a tram m ing bar
4. O btain vertical dimensions and com pare the differences
from indicated points on the fram e (Figs. 2A-2 and 2A-4).
betw een these dim ensions w ith th e dim ensions as
For example, if the tram bar is set a t point B with a vertical
shown in Fig. 2A-3 or 2A-4.
pointer length of 8-1/4 in. (206 m m ), and a t point E with a
vertical pointer length of 5-1/4 in. (131 mm ) (a height
difference of 3 in. (75 m m ), the tram bar should be parallel
Horizontal Check with the fram e. If the area is tw isted or m isaligned in any
1. M easure fram e width at front and rear. If widths way, tram bar will not be parallel. Placing the tram bar
correspond to specifications, draw centerline full length vertical pointers on opposite sides of the fram e side rail is
of vehicle halfway between lines indicating front and preferable in th at fram e twist will show up during this
rear widths. If fram e widths are not correct, layout vertical check. Fig. 2A-2 and 2A-4 show typical checking
centerline as shown in Step 4. points, with dimensions for various fram es shown in Fig. 2A-
2. M easu re d istan ce from cen terlin e to corresponding 3.
points on each side of fram e layout over entire length.
Opposite side m easurem ent should correspond within Frame Repair
3/16 in. (4.7 mm).
3. M easure diagonals m arked A, B and C. If the lengths Welding
of intersecting diagonals are equal and these diagonals Before welding up a crack in fram e, a hole should be
intersect the centerline, fram e area included between
drilled at the starting point of the crack to prevent spread
these points of m easurem ent may be considered in
ing. W iden V groove crack to allow com plete weld
alignm ent.
penetration.
4. If front or rear end of fram e is dam aged and width is no
longer within limits, fram e centerline m ay be drawn NOTICE: Do not weld into corners of fram e or along
through the intersection of any two previously drawn edges of side rail flanges. W elding at these points will
pairs of equal, intersecting diagonals. tend to weaken the fram e and encourage new cracks.
■v Vjf*,
FRAME 2A-3
Model A B C D E F G H 1 J K L M N P R S T U V
CA107 13-3/8 15-1/4 16 19-7/8 12 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 76-1/2 110 16-7/8 16-7/8 14
CA109 13-3/8 15-1/4 16 19-7/8 12 13 10 14-7/8 17-3/4 17-3/4 19-7/8 16-3/4 15-5/8 17-3/4 69-5/8 86-1/2 120 16-7/8 16-7/8 14
CA209 13-3/8 15-1/4 17 19-7/8 12 13 10 14-7/8 17-3/4 17-3/4 19-7/8 16-3/4 15-5/8 17-3/4 69-5/8 86-1/2 120 16-7/8 16-7/8 14
CA210 13-3/4 15-1/4 16 18-1/2 10 13 10 14-1/4 17-3/4 17-3/4 19-7/8 15-5/8 17-3/4 68-3/4 105 131 16-7/8 16-7/8 14
310
CA314 13-3/8 14 7/8 16 18-1/2 10 13 10 14-1/4 17-3/4 17-3/4 19-7/8 15-5/8 17-3/4 69-7/8 129 155-1/2 16-7/8 16 7/8 14
KA107 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 76-1/2 110 16-7/8 16-7/8 14
KA109 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 16-7/8 16-7/8 14
209
PA 100 7-5/8 9-3/8 11 14-5/8 9-1/2 13 10 9-1/2 13 10-7/8 13 71-7/8 36 89 16-7/8 16-7/8 14
PA208 7-5/8 9-3/8 11-5/8 14-5/8 9-1/2 13 10 9-1/2 13 9-1/2 13 10-7/8 13 72-1/4 59 131 16-7/8 16-7/8 14
308
PA210 7-5/8 9-3/8 11-5/8 14-5/8 9-1/2 13 10 9-1/2 13 9-1/2 13 10-7/8 10-7/8 13 71-7/8 67 153 16-7/8 16-7/8 14
310
PA314 7-5/8 9-3/8 11-5/8 14-5/8 9-1/2 13 10 9-1/2 13 9-1/2 13 10-7/8 10-7/8 13 71-7/8 91 177 16-7/8 16-7/8 14
CA105 13-3/8 15-1/4 17 19-7/8 12 13 10 14-1/4 20 17-3/4 15-5/8 17-3/4 69-5/8 46 88 16-7/8 16-7/8 14
KA105 13-3/8 15-1/4 17 19-7/8 12-1/2 13 10 14-1/4 20 17 3/4 15-5/8 17 3/4 69-5/8 46 88 16-7/8 16-7/8 14
PE
31132 9-1/8 11-1/2 10-7/8 9-1/2 13 10 9-1/2 13 9-1/2 13 10-7/8 10-7/8 13 68-1/2 71 157 16-7/8 16-7/8 14
(137)
PE
31432 9-1/8 11-1/2 10-7/8 9-1/2 13 10 9-1/2 13 9-1/2 13 9-7/8 10-7/8 13 68-1/2 92-1/2 178-1/2 16-7/8 16-7/8 14
(157)
PE
9-1/8 11-1/2 10-7/8 9-1/2 13 10 9-1/2 13 9 1/2 13 10-7/8 10-7/8 13 68-1/2 112 240-3/16 16-7/8 16-7/8 14
31832
LIG H T T R U C K SERVICE M A N U A L
2A-4 FRAME
L IG H T T R U C K SERVICE M A N U A L
BUMPERS 2B-1
SECTION 2B
BUMPERS
NOTICE: Fasteners are im portant attaching parts in lesser quality or substitute design. Torque valves must
th a t they could affect the perform ance of vital compo be used as specified during reassembly to assure proper
nents and systems, an d /o r could result in m ajor repair retention of these parts. For prevailing torque nut(s)
expense. They m ust be replaced with one of the same and bolt(s), refer to the "R euse of Prevailing Torque
part num ber or with an equivalent part if replacem ent N ut(s) and B olt(s)" chart in Section 10.
becomes necessary. Do not use a replacem ent part of
CONTENTS
GENERAL DESCRIPTION
All truck front and rear bumpers are of a single piece design. Bumper
attachm ents are the standard bracket and brace to fram e mountings. This
section contains procedures for the removal and installation of face bar,
brackets, braces and license plate brackets.
LIG H T T R U C K SERVICE M AN U AL
2B-2 BUMPERS
L IG H T T R U C K SE RV IC E M A N U A L
BUMPERS 2B-3
SPECIFICATIONS
TORQUE SPECIFICATIONS G
Fig. 2B-ST--Specifications
LIG H T T R U C K SERVICE M A N U A L
CHASSIS SHEET METAL 2C-1
SECTION 2C
CHASSIS SHEET METAL
N O TIC E Fasteners are im portant attaching parts in th at they could
affect the perform ance of vital components and systems, an d /o r could result
in m ajor repair expense. They m ust be replaced with one of the same part
num ber or with an equivalent part if replacem ent becomes necessary. Do not
use a replacem ent part of lesser quality or substitute design. Torque valves
m ust be used as specified during reassembly to assure proper retention of
these parts. For prevailing torque nut(s) and bolt(s), refer to the "R euse of
Prevailing Torque N u t(s) and B olt(s)" chart in Section 10.
CONTENTS
GENERAL DESCRIPTION
CK MODELS these items are welded together as an integral part of the
body.
The chassis sheet metal assembly is attached to the
Front end sheet m etal includes the hood assembly, hood
fram e and body at adjustm ent points. The front of the
hinges, hood lock catch and support, a hood rod assembly
assembly is supported by two mounts located at the fram e
which supports the hood, a bolted radiator-upper tie bar,
side rails. Fore and aft and side adjustm ent is allowed by
and series designation plates and hoods emblems.
oversize holes at the fender rear attaching point and chassis
sheet m etal mounts. Special shims at the rear locations Anti-Corrosion Information
allow adjustm ent of the rear of the assembly. The lower rear
edge of the assembly is attached to the body at the rocker "Anti-corrosion m aterials have been applied to the
panel by bolts on each side. Shims are used at this location to interior surfaces of some m etal panels to provide rust
provide in and out adjustm ent at the rear of the fender. The resistance. W hen servicing these panels, areas on which this
bolts th a t retain the sheet m etal braces m ust be torqued to m aterial has been disturbed should be properly recoated
the required torques. If these bolts are loose, the braces will with service-type anti-corrosion m aterial."
not provide additional support for the sheet m etal assembly.
G MODELS
The front end sheet m etal design does not include the
radiator support and fenders as loose items inasmuch that
ON VEHICLE SERVICE
HOOD ASSEMBLY - CK MODELS 2. Open hood and remove two screws at each wiper nozzle
attachm ent.
Cowl Top Vent Panel (Fig. 2C-1) 3. Remove four screws at front of cowl panel.
Replacement 4. Pry the five plastic fasteners loose from windshield
1. Remove wiper arms. frame. Remove the panel.
5. Reverse the above listed procedure to replace.
LIG H T T R U C K SERVICE M A N U A L
2C-2 CHASSIS SHEET METAL
Replacement
1. Open hood and remove the two bolts holding the hood
latch to the bracket.
Hood Assembly
Removal
1. Open hood and prop in full open position.
If hood is to be reinstalled and present alignm ent is
satisfactory, m ark each hinge in relation to hood, to
assure original alignm ent.
Replacement
1. Prop the hood in the extrem e open position and place
protective covering over the cowl and fenders. Scribe
position of hinge attach m en t to hood.
2. Remove two bolts link assembly to hood and two bolts
at hinge to the hood.
3. Rem ove two bolts link assem bly to fender inner,
remove link.
4. Remove wiper arm s and a t the cowl cover panel remove
four screws and lift up w ithout removing for access.
L IG H T T R U C K SE RV IC E M A N U A L
CHASSIS SHEET METAL 2C-3
Replacement
1. Open hood and remove the four bolts holding the
com bination lock catch and lock bolt.
If original hood lock assembly is to be replaced, scribe a
line around lock for alignm ent on installation.
2. Place hood lock assembly in position.
3. A djust as outlined under A djustm ents.
Adjustment
Hood lock assembly to be adjusted fore and aft until
hood lock bolt enters center of elongated guide. Bending bolt
to accomplish this adjustm ent may seriously effect lock
2. Remove two (2) cap screws which attach each hinge operation and safety catch engagem ent and is, therefore not
and link to hood; then with a helper remove hood from recommended.
vehicle.
Installation 1. A djust lock bolt as shown in Fig. 2C-7.
1. If original hood is to be installed, position hood to 2. Open hood and adjust tightness of catch assembly so
hinges and links and install four cap screws snug which th at it is ju st "snug" enough to hold lock bolt in
attach hinges and links to hood. position.
If a new hood is to be installed, perform procedures as 3. Close hood in a normal manner.
outlined under Alignm ent, directly below. 4. Raise hood again; lock bolt assembly will have shifted
2. Shift hood on hinges to location m arks m ade before to operating position. T ighten bolts fully. F u rth e r
removal of hood, then tighten attaching cap screws at ad ju stm en t m ay be m ade a t lock bolt support, if
hinges firmly. Close hood and check fit. If necessary to necessary.
align hood perform p rocedure as outlined under 5. A djust lock bolt to obtain a secure hood closure and
"A lignm ent" which follows. reasonable lock release effort.
Alignment
1. Loosen hood hinge bolts.
N ote th at the rear most bolt holes in hinge are slotted to
allow hood to move back and forth.
2. A djust bracket at hood latch, as necessary. Slotted hole
in the bracket allow movement up or down a t the latch,
and right or left a t the radiator support.
3. A djust hood bum per as necessary in proportion to the
latch.
LIG H T T R U C K SERVICE M AN U AL
2C-4 CHASSIS SHEET METAL
Hood Bumper
Adjust hood bumpers so that hood top surface is flush
with the fender and grille top surfaces.
FENDER ASSEMBLY
Removal
, - /!- * , - ■
. ,, W* ; wr.SU"**lit-..'
Installation
1. With a helper place sheet metal assembly in position.
Install all bolts loosely to facilitate aligning after
complete installation.
2. Install fender bolts at cowl.
3. Install combination bolt and flat washer assembly into
each fender reinforcement while inserting shims re
quired between fender reinforcement and body (Refer
to Fig. 2C-16).
4. Install two bolts and shims required at each fender rear Radiator Support
lower edge to hinge pillar.
Removal
5. Install bolt in each fender skirt to underbody.
1. Drain radiator, saving coolant, loosen attachments and
6. Install bolts at steering column skirt reinforcement, remove radiator and coolant recovery tank.
final torque 25 ft. lb. (33 N-m).
2. Disconnect and remove battery.
7. Tighten each radiator support mounting bolt 33 ft. lb.
3. Remove wiring from radiator support.
(44 N-m).
4. Disconnect fan shroud and lay back on engine.
8. Torque bolts at fender to cowl 25 ft. lb. (33 N-m)
5. Remove both head lamp assemblies.
9. Install front bumper. 6. Remove grille assembly.
10. Connect wire connectors at dash and toe panel. Attach 7. Remove lower radiator grille panel. (Fig. 2 C -13).
generator and regulator wires. 8. Remove screws securing front fenders to radiator
11. Connect upper and lower radiator hoses. Connect oil support.
cooler lines to the radiator on models so equipped. 9. Remove screws securing fender skirts to rad iato r
12. Connect battery and fill radiator. S tart engine and support bottom. (Fig. 2 C - 15).
check for leaks. 10. Remove bolt securing center support to radiator
13. Install Hood. support.
11. Remove bolts securing hood latch assembly to radiator
support.
12. Remove radiator support bolts secured to frame.
13. Tilt radiator support rearward and lift up and off.
•! '•
Installation
1. Rotate radiator support into position and loosely install
attachments to frame.
2. Connect center support to radiator support.
3. Connect hood latch plate.
4. Connect radiator support brackets to fenders.
5. Connect support to fenders.
6. Connect screws from underside of fender skirts to
support bottom.
7. A ttach grille lower panel to fenders.
8. Tighten radiator support bolts.
9. Install radiator coolant recovery tank hoses and shroud.
10. Connect removed wiring to radiator support.
LIG H T T R U C K SERVICE M AN U AL
2C-8 CHASSIS SHEET METAL
Removal
1. Remove hood and hinge assembly.
2. Remove head lamp bezel, wiring and attachm ents from
fender.
3. Remove screws attaching lower radiator grille panel.
4. Remove screws attaching fender wheel opening flange
to skirt.
5. Remove skirt to fender bolts, located inboard on
underside of skirt.
6. Remove two (2) screws attaching support bracket to
fender.
7. Remove five (5) screws attaching radiator support to
front fender.
8. Remove bolt and shim attaching trailing edge of fender
to hinge pillar.
9. Remove two bolts and shims at top rear of fender Fender Skirt - P Model
attaching to cowl.
Refer to figure 2C-18 for removal and installation of
Installation fender skirt, brackets, rear supports and hangers.
12. Best results are obtained when metal temperature is 1. If the tape is ruined with no paint being removed, the
70°90°F (21°32°C). Use heat gun or allow cooling time surface should be wiped with a prep-sol to insure a
when metal is outside approximate temperature range. smooth and clean surface. Another section of tape
13. The maximum temperature that the tape should be would then be applied according to the application
subjected to is 175°F (79°C) (paint repair oven temper procedure.
ature). No tape stripe job should be left in a paint 2. If a section of paint is removed when the tape is pulled
repair oven as damage to the tape may occur. away, the area must be repainted and feathered into the
adjoining surfaces. Another section of tape should be
14. The tape will not be affected by any of the cleaning
applied according to the application procedure.
solvents, waxes or detergents now being used at the
assembly plants. Acrylic lacquer solvents will affect the REMOVAL
clear coating over the vinyl. Removal of decal should cause it to be permanently
15. This tape stripe highlights metal imperfections so that damaged. Test to be conducted at an ambient temperature
all dings and rough metal must be repaired before not to exceed 90°F (32°C) and after a minimum of 72 hours
applying the tape. aging.
16. If after application of stripes, there appears to be
For Large Decals
bubbles in the surface of the tape stripes, piercing them
with an ordinary safety pin will relieve the en- trapped 1. Prior to application of transer, wet down the complete
air so that the bubble can be smoothed out. transfer surface with a solution of 0.25 oz. of neutral
detergent cleaner (must not contain oils, perfumes, or
17. Shelf life of the vinyl tape is 90 days at a maximum bleaches) per gallon of clear water. It is essential that
temperature of 105°F (40°C). no substitute for this solution be used and that the
specified proportions be maintained.
REPAIR
2. While entire area is still wet with solution, remove
Repair is required when: paper backing from transfer, locate and press on
1. If the tape is damaged. lightly.
3. Start at center of transfer and squeegee outboard from
2. The paint is damaged as the tape is pulled back for
middle to edges, removing all air bubbles and wetting
realignment or releasing traped air.
solution to assure a satisfactory bond. Use teflon-
The following repair procedure is recommended: backed plastic squeegee only.
TORQUE SPECIFICATIONS
CK G
Lock to Bracket & Rad. Support 27 N- m ( 20 ft. lb s .)
Lock Support to Hood 17 N* m (150 i n .l b s . )
Lock Bolt Nut 54 N- m ( 40 ft. lb s.)
Bumper Bolt Nut 17 N- m (150 i n .l b s . )
Hood Hinge 24 N- m ( 18 ft. lb s.) 24 N- m ( 18 ft. lb s.)
Hood Lock Catch 27 N- m ( 20 ft. lb s .) 24 N- m ( 18 ft. lb s.)
Lock Support to Rad. Support 17 N. m (150 in .lb s .) 24 N- m ( 18 ft. lb s.)
Rad. Support to Frame 48 N- m ( 35 ft. lb s.)
Rad. Support to Fender 17 N- m (150 in .lb s .)
Fender Skirt to Fender 17 N- m (150 in . lb s .)
Fender to Cowl 48 N- m ( 35 ft. lb s.)
LIG H T T R U C K SERVICE M AN U AL
BODY 2D-1
SECTION 2D
CAB AND BODY
N OTICE Fasteners are important attaching parts in that they could
affect the performance of vital components and systems, and/or could result
in major repair expense. They must be replaced with one of the same part
number or with an equivalent part if replacement becomes necessary. Do not
use a replacement part of lesser quality or substitute design. Torque valves
must be used as specified during reassembly to assure 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.
General D escription............................................................................................2D-1
On Vehicle Service..............................................................................................2D-4
C-K M o dels........................................................................................................2D-4
G M odels.............................................................................................................2D-37
Specifications...................................................................................................... ..2D-62
Special Tools.........................................................................................................2D-64
GENERAL DESCRIPTION
On the following pages, service procedures will be given rear cargo doors. An optional endgate with moveable
for components on all 10-20-30 series trucks in C, K and G window is available.
models. Reference will be made, both in text and illustra
tions, to vehicle model lines and to individual model
numbers within these model lines. Utility
As an aid to identification of specific models, the Utility vehicle models see figure 2D-4. Are available
following general descriptions are given. with a removable roof or a convertible roof.
Chassis/Cabs
Chassis cab models see figure 2D-1. Two-wheel drive Vans
units come in CIO, C-20 and C-30 series. Four-wheel drive G-Series Vans are available in three models See figures
units may be either K -10 or K-20. Optional pickup boxes are 2D-5 and 2D-6. Vans without body windows and/or passen
available. ger seats, sport vans with body windows and passenger seats
and commercial cutaway vans as shown in figure 2D-6.
Crew Cab/Chassis
Crew cab/chassis models see figure 2D-2. Optional Anti-Corrosion Information
pickup boxes are available. "Anti-corrosion materials have been applied to the
interior surfaces of some metal panels to provide rust
resistance. When servicing these panels, areas on which this
Suburban material has been disturbed should be properly recoated
Suburban model see figure 2D-3. Base models have with service-type anti-corrosion material."
LIG H T T R U C K SERVICE M AN U AL
2D-2 BODY
LIG H T T R U C K SERVIC E M A N U A L
BODY 2D-3
LIG H T T R U C K SERVICE M AN U AL
2D-4 BODY
ON VEHICLE SERVICE
C-K MODELS
INDEX
FRONT END
WINDSHIELD WIPERS 4. Remove two screws from each transmission pivot shaft
assembly to windshield frame. Remove wiper linkage
Windshield wiper units on all models are of the two- and transmission from plenum.
speed electric type. A single wiper motor unit, mounted to
the left side of the dash panel inside the engine com part Installation
ment, powers both wiper arms. The wiper arm operating
1. Place wiper linkage and transmission into position.
link rods and pivot mountings on these models are located in
Secure assembly with two screws at each transmission.
the outside air inlet plenum chamber.
2. Attach end of cross rod to drive arm of motor assembly.
Arm Adjustment Secure rod.
3. Before installing wiper arms or cowl ventilator grille,
To adjust sweep of blades, turn on wipers and note
operate wiper motor momentarily which should rotate
sweep of arms. If necessary, remove one or both arms as
pivot shafts to park position. 4 .? Install arms, grille and
follows:
shafts.
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 holding arm in this position, pull
outward on cap section at base of arm to remove arm. Arm
can be reinstalled in any one of several positions due to
serrations on pivot shaft and in arm cap. See figure 2D-7.
Removal
1. Remove windshield wiper arm s from pivot shafts.
Procedure for removing arms is explained previously
under ‘A rm A d ju ste m n t".
2. Remove cowl ventilator grille.
3. Remove two nut and lock washer assemblies from the
connector link to motor drive arm via the plenum access
hole. Fig. 2D-7--Windshield Wipers
L IG H T T R U C K SE RV IC E M A N U A L
BODY 2D-5
Adjustment
Engagement of lock in striker may be adjusted by
loosening striker retaining screws and moving the striker to INSIDE REAR VIEW MIRROR - FIGURE 2D -11
desired position.
Replacement
1. Remove screw retaining mirror to its glass-mounted
OUTSIDE REAR VIEW MIRRORS bracket and remove mirror.
2. Install mirror into its mounting bracket. Torque screw
R ear view mirror installations are shown in figure 2D- to specifications.
9, 2D-10 and 2D-11. Occasional tightening of mounting and
assembly bolts and screws will sharply decrease occurrence COWL VENT VALVE - FIGURE 2D-12
i
of failure due to door slamming or road shock. Two styles are shown in Figure 2D-12. Removing the
C a m p e r m irror installation is similar to the below attaching screws allows removal of the valve from the side
eyeline mirror installation. panels.
L IG H T T R U C K SERVICE M A N U A L
2D-6 BODY
BODY GLASS
CAUTION:A!ways wear gloves and eye glasses To replace a window installed with urethane adhesive
when handling glass to avoid personal injury. requires replacement of the adhesive material. Adhesive
service kits No. 1052420 and No. 9631000 contain some of
the materials needed to remove and replace a urethane
adhesive installed glass. These kits and other materials that
CK TRUCK WINDSHIELD REPLACEMENT may be required can be obtained through the service parts
The windshield is a one-piece type and is retained in the system. The components of glass adhesive kits (urethane)
windshield opening by a urethane bonded rubber weather No. 1052420 and 9631000 are as follows:
strip. See figure 2D-13. 1. One tube of urethane adhesive material.
2. One dispensing nozzle.
W hen replacing a cracked windshield glass, it is very 3. Steel music wire.
important that the cause of the glass breakage be deter
4. Rubber cleaner.
mined and the condition corrected before a new glass is
installed. Otherwise, it is highly possible th a t a small 5. Rubber primer.
obstruction or high spot somewhere around the windshield 6. Pinch-weld primer.
opening will continue to crack or break the newly installed 7. Blackout primer.
windshield especially when the strain on the glass caused by
this obstruction is increased by such conditions as wind 8. Filler strip (for use on windshield installations on
pressures, extremes of temperature, motion of the vehicle, vehicles equipped with embedded windshield antenna).
etc. 9. Primer applicators.
LIG H T T R U C K SE RV IC E M A N U A L
BODY 2D-7
Removal
Checking Windshield Opening
1. Before removing the windshield, mark the location of
the break on the windshield rubber channel and the Due to the expanse and contour of the windshield it is
body. Protect the paint finish inside of the cab. Mask imperative in the event of a stress crack that the windshield
around the windshield opening and outside, lay a opening be thoroughly checked before installing a replace
suitable covering across the hood and fenders. ment windshield. The replacement glass is used as a
template.
2. Remove windshield reveal molding (lock strip) and
1. Check for the following conditions at the previously
reveal molding cap.
marked point of fracture.
a. Chipped edges on glass.
3. To free windshield ru bb er channel of w eatherstrip
b. Irregularities in body opening.
loosen the lip of the windshield weatherstrip from the
pinchweld flange along the top and at the sides by c. Irregularities in rubber channel weatherstrip.
applying firm, controlled pressure to the edge of the 2. Check flange area for solder, weld high spots, or
glass. At the same time assist the lip of the rubber hardened spot-weld sealer. Remove all high spots.
weatherstrip channel over the pinchweld flange with a 3. Check windshield glass to opening, by supporting glass
flat bladed tool. See figures 2D-14 and 2D-15. with six spacers contained in packet J-22577. See figure
4. With the aid of an assistant outside the cab, remove the 2D-17.
windshield from the opening. See figure 2D-16. NOTICE: Do not strike glass against body metal.
5. Remove all excess urethane adhesive and any remain Chipped edges on the glass can lead to future breaks.
ing pieces of weatherstrip from pinch-weld flange.
6. If sheet metal and paint repairs are required, refer to 4. W ith the windshield supported and centered in its
"Repairing and Refinishing Pinchweld Flange" of this opening, check the relationship of the glass to the body
section. opening flange around the entire perimeter of the glass.
LIG H T T R U C K SERVICE M A N U A L
2D-8 BODY
LIG H T T R U C K SE RV IC E M AN U AL
2D-10 BODY
LIG H T T R U C K SERVIC E M A N U A L
BODY 2D-11
Hinge Adjustment
Door hinge bolt holes are oversized to make adjustment
possible. Alignment adjustments can be made by loosening
the proper hinge bolts, aligning door to proper position, and
tightening bolts securely (fig. 2D-22).
L IG H T T R U C K SERVICE M A N U A L
2D-12 BODY
3. Remove arm rest screws and trim panel. See figure 2D-
5. Remove (1) screw at door handle cover plate and (1)
27.
screw located under arm rest pad.
4. Remove screws attaching ventilator lower assembly to
6. If equipped assist strap, remove (2) screws retaining
door panel.
assist strap.
7. Remove trim panel by carefully prying out at trim
5. Remove three screws at the upper front of the door
retainers located around perimeter of panel.
frame.
Installation 6. Pull upper portion of vent assembly rearward and raise
upward while rotating counter clockwise.
Before installing door trim assembly, check that all
7. T urn vent assembly 90° and carefully remove by
trim retainers are securely installed to the assembly and are
not damaged. guiding up and out. See figure 2D-29.
1. To install door trim assembly, pull door inside handle Ventilator Glass Replacement
inward; then position trim assembly to inner panel,
inserting door handle through handle hole in panel. 1. Using an oil can or similar means, squirt prepsol or
2. Position trim assembly to door inner panel so trim equivalent on the glass filler all around the glass
retainers are aligned with attaching holes in panel and channel or frame to soften the old seal. When the seal
tap retainers into holes with a clean rubber mallet. has softened, remove the glass from the channel.
3. Install previously removed items. 2. Thoroughly clean the inside of the glass channel with
sandpaper, removing all rust, etc.
3. Using new glass channel filler, cut the piece to be
DOOR VENTILATOR ASSEMBLY-Fig. 2D-28 installed two inches longer than necessary for the
channel. Place this piece of filler (soapstoned side of
Removal filler away from glass) evenly over the edge of the glass
R E T A I N I N G SPR IN G
(D IS E N G A G E D ) PUSH T O O L IN
D m E C T I O N OF
IIN S ID E H A N D L E
\ ^ ^ ARROW
- -M
V ^ r Jj^
T O O L J-9886-01
LIG H T T R U C K SE RV IC E M A N U A L
BODY 2D-13
Fig. 2D-29--Removing Ventilator Assembly Fig. 2D-31--Bend Tabs Over Hex Nut
which will fit in the channel. The extra filler extending Adjustment
beyond the rear edge of the glass should be pinched 1. Adjust the ventilator by placing wrench on adjusting
together to hold it in place during glass installation. nut thru access hole and turning vent window to the
One side of this filler (the outside of the roll) is desired tension. See figure 2D-30.
soapstoned. This is the side which goes into the metal
2. After making adjustment bend tabs over the hex nut on
channel.
base of assembly. See figure 2 D -3 1.
4. Brush the inside of the metal glass channel freely with
3. Install arm rest screws and trim panel.
ordinary engine oil. This will enable the glass and filler
to slide freely into the channel. Push the glass with the 4. Install window regulator handle.
filler around it into the channel until it is firmly seated.
After the glass is firmly in place, the oil softens the DOOR WINDOW ASSEMBLY-FIG. 2D-32
filler, causing it to swell, thereby making a watertight
seal. Trim off the excess filler material around the Replacement
channel and at the ends of the channel. 1. Completely lower glass to bottom of door.
Glass should be installed so that rear edge is parallel to
2. Remove door arm rest and trim pad as outlined in this
the division post. Allow full cure before water testing.
section.
Installation 3. Mask or cover upper portion of door window frame.
Remove ventilator assembly as previously outlined.
1. Lower the ventilator assembly into the door frame.
2. M ake certain the rubber lip is positioned inside the 4. Slide glass forward until front roller is in line with
inner and outer panel before tightening screws. notch in sash channel. Disengage roller from channel.
3. Reinstall all screws and tighten. 5. Push window forward and tilt front portion of window
up until rear roller is disengaged. See figure 2D-33.
4. Install and tighten the three screws at the upper front
of the door. 6. Put window assembly in normal position (level) and
raise straight up and out.
7. Reverse above procedure for installation.
Replacement
1. Raise window and tape glass in full up position using
cloth body tape.
2. Remove trim panel as outlined previously.
3. Remove screws attaching regulator to door inner panel.
4. Remove regulator by sliding regulator rearward, disen
gaging rollers from sash channel.
A notch is provided in the sash channel to allow
disengagement of the forward roller on the window
regulator (Fig. 2D-32).
5. Install regulator by reversing above steps. Lubricate
Fig. 2D-30--Adjusting Tension regulator gear with lubriplate or equivalent.
LIG H T T R U C K SERVIC E M AN U AL
2D-14 BODY
NO TCH
SASH
CHANNEL;
N O TC H
ROLLER
sheet metal tapping screw (No. 10 - 12 x 3/4) in drilled Door Outside Handle—Fig. 2D-37
hole to lock sector gear in position.
10. Remove motor to regulator attaching screws. Replacement
11. Remove motor from regulator. 1. Raise window to full up position.
12. Prior to installation, lubricate the motor drive gear and 2. Remove trim panel as outlined.
regulator sector teeth. The lubrication used must be 3. Remove clip from outside handle rod-to-lock.
cold weather approved to a minimum of minus 20° 4. Remove screws which retain outside handle to door
Fahrenheit (-29°C). panel.
13. Install regulator motor to regulator. Make sure the 5. Remove handle and control rod.
motor pinion gear teeth mesh properly with the sector 6. Reverse above procedures to install outside handle.
gear teeth before installing the three motor attaching
screws.
14. Remove screw locking sector gear in a fixed position. Door Lock Cylinder -Fig 2D-37
15. Insert regulator into door in such a position that motor
Replacement
connector can be installed onto motor.
1. Raise door window.
16. Reinstall regulator into door.
2. Remove trim panel as outlined.
LOCKS, HANDLES AND RODS 3. Use a screwdriver or other suitable tool to slide the lock
cylinder retaining clip out of engagement with the lock
cylinder.
Door Lock Assembly—Fig. 2D-36
4. Remove lock cylinder.
Replacement 5. To install, reverse the above steps.
1.Raise window to full up position.
Door Inside Handle
2. Remove trim panel as outlined in this section.
3. Remove clip from inside handle rod-to-lock. Replacement
4. Remove clip from outside handle rod-to-lock. 1. Remove trim panel as outlined.
5. Remove screws which attach lock assembly to door 2. Disconnect control rod from inside handle, as shown in
panel. figure 2D-38.
6. Remove lock and remote control rod as an assembly. 3. Remove screws retaining inside handle to door.
7. To install lock assembly, reverse above steps. Be sure to 4. Remove inside handle.
replace all clips removed earlier. 5. Reverse above steps to install.
Replacement
1. Disconnect battery ground cable.
2. Remove door trim panel to gain access to power door
lock motor.
3. Disconnect electrical connector from motor.
LOCK'
Fig. 2D-36--Door Lock Assembly and Rods Fig. 2D-37--Outside Handle and Lock Cylinder
LIG H T T R U C K SERVIC E M A N U A L
2D-16 BODY
4. Remove screws attaching motor to door inner panel. 3. Remove side door inner weatherstrip seal.
5. Remove door lock lever from rubber mount at top of 4. Starting at the bottom center of the door opening,
motor actuator and remove motor through access hole. install seal on welded flange.
6. To install, reverse steps 1 through 5 above. 5. Trim inner weatherstrip with a notch and butt ends
together.
DOOR TO BODY OPENING WEATHERSTRIP-FIG. 6. Reinstall sill plate and sill plate retaining screws.
2D-40, 2D-41
REAR SIDE DOOR-CREW CAB AND SUBURBAN
Side door sealing incorporates an inner seal Fig. 2D-40 MODELS
and a secondary seal Fig. 2D-41. The inner seal is mounted
on the body opening welding flange and goes completely Adjustments and Hinge Replacement
around the periphery of the opening. The secondary seal is The procedures for hinge replacement, and for hinge
adhered to the upper portion of the door by adhesive and a and striker bolt adjustment are similar to those detailed in
screw at either end of the seal. The molded weatherstrip the front door adjustment procedure. Access to the hinges of
m aterial of the inner seal is snapped in place. A fter the rear door is shown in figure 2D-42.
removing all foreign material from door opening surface
proceed as follows:
1. Open door and block open. STATIONARY GLASS-REAR DOOR
2. Remove sill plate retaining screws and remove sill Replacement
plate. 1. Lower window to full down position.
2. Remove remote control knob and window regulator
handle.
LIG H T T R U C K SERVIC E M A N U A L
BODY 2D-17
Replacement
3. Remove screws retaining door trim pad, and remove
trim pad. See figure 2D-43. 1. Lower glass to full down position.
4. Remove glass run channel by removing screws retain 2. Remove remote control push botton knob, window
ing channel to door. See figure 2D-44. regulator handle and trim pad.
5. Remove stationary glass. 3. Remove stationary glass as previously outlined. Re
6. Replace glass by reversing above procedure. move screws from rear division channel, and slide
channel rearward in the opening.
4. Raise glass as far as possible, then slide glass until the
Glas Run Channel Adjustment
roller is in line with the notch in the sash channel. See
Figure 2D-45 illustrates the front run channel. At the figure 2D-46. Disengage roller from channel.
lower end, a slotted bracket provides for in-and-out adjust
5. Tilt window outboard and move until other roller can
ment. The screw and locknut at that bracket allow fore-and-
be removed from channel.
aft adjustment. Together, this allows proper alignment of
the glass to the rear glass run channel for full up and down 6. Raise window up and out.
travel.
7- Reverse above procedure for installation.
LIG H T TR U C K SERVICE M A N U A L
2D-18 BODY
Replacement
1. Remove regulator handle, remote control knob and
trim pad as outlined previously.
2. Disconnect control rod from inside handle by removing
clip as shown in figure 2D-47.
3. Remove inside handle by removing four screws which
secure handle to door panel.
4. Replace handle by reversing above procedure. Fig. 2D-48--Remote Control Assembly
L IG H T T R U C K SERVIC E M A N U A L
BODY 2D-19
LIG H T T R U C K SERVICE M A N U A L
2D-20 BODY
LIG H T T R U C K SE RV IC E M A N U A L
BODY 2D-21
-(Suburban)
LIG H T T R U C K SERVICE M A N U A L
BODY 2D-23
HINGE
Replacement
1. Lower endgate and disconnect hinge to be replaced by
removing hinge-to-body bolts. See figure 2D-62.
2. At the other hinge, loosen the hinge-to-body bolts.
3. On the hinge to be replaced, remove the hinge-to-
endgate bolts.
4. Pull the endgate away from the body several inches and
withdraw hinge from body. Then lift endgate slightly to
allow removal of hinge from endgate. See figure 2D-63.
5. To install hinge, reverse the above procedure. Be sure to
install hinge into endgate first, then into the body.
LIG H T T R U C K SERVICE M AN U AL
2D-24 BODY
Fig. 2D-65--Removing Access Cover (Utility) Fig. 2D-67--Removing Torque Rod (Utility)
TORQUE ROD 2. Disconnect side latch remote control rods from center
control by removing retaining clips. See figure 2D-68.
Replacement
3. Remove four screws from each side latch, and with
1. L o w e r e n d g a te a n d re m o v e a cc e ss cover, a s sh o w n in draw latch and control rod from endgate, as sown in
figure 2D-65. figure 2D-69.
2. Disconnect torque rod anchor plate. It is necessary to 4. Disconnect control rod from latch.
remove the lower bolt only, then let plate swing down.
5. Refer to figure 2D-70 for installation of latch control
See figure 2D-66.
and blockout rod.
3. Loosen four bolts retaining endgate hinge to body. 6. Disconnect blockout rod from control assembly by
4. Move endgate slightly away from body. detaching spring and removing two screws retaining
5. Remove torque rod retaining bracket on lower edge of rod to inner panel.
endgate. See figure 2D-66. 7. Disconnect inside handle control rod from control
6. Remove torque rod retaining clip on side edge of assembly, then remove screws which secure inside
endgate. handle to inner panel.
7. Lift torque rod up and slide from endgate as shown in 8. Remove three screws which retain remote control
figure 2D-67. assembly to inner panel.
8. Reverse the procedure above for installation. 9. Remove control assembly and inside handle as shown in
figure 2D-71.
10. Refer to figure 2D-72 for window and regulator
ENDGATE DISASSEMBLY-UTILITY MODELS ONLY installation.
11. Roll window to up position.
Manual Window
12. Disconnect sash from regulator as shown in figure 2D-
1. Lower endgate and remove acess cover. 73.
BRACKET
SILENCER
TORQUE
ROD
FRAME
LIG H T T R U C K SE RV IC E M A N U A L
BODY 2D-25
Fig. 2D-69--Removing Side Latch Fig. 2D-71 -Removing Control Assembly ancHnside
Handle
BLOCKOUT
INSIDE HANDLE ROD
BRACKET
CONTROL ROD
CONTROL
ASSEMBLY
Drive Cable
The drive cable can be replaced by disengaging the
cable from the motor and jackscrew assembly and removing
the cable. Reverse removal procedure to reinstall cable. Fig. 2D-73--Disconnecting Sash from Regulator
LIG H T T R U C K SERVICE M AN U AL
2D-26 BODY
L IG H T T R U C K SERVIC E M A N U A L
BODY 2D-27
3. Remove endgate.
4. Reverse procedure for installation. Align slot in tru n
nion to coincide with hole in endgate to permit using a
tool to hold trunnion while tightening nut.
Removal
1. Remove access and disconnect courtesy light.
2. Lower the tailgate window and lower 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 reinstalled after top is
removed.
6. Remove only the rear attaching screws for the side trim
panel (12 for LH panel and 11 for RH panel) so that
the rear of panel can be pulled away to gain access for
removal of hidden top bolt.
If rear roll bar equipment is present, it is necessary to
remove all the attaching screws, 20 on LH side and 19
on RH side, and the 1 bolt attaching the shoulder belt
retractor located behind the access plate on retractor.
Then the trim panel is raised and moved forward
approx. 2-1/2 inches so th at access can be gained
through the cut out in trim panel to remove hidden top
bolt.
7. With assistance, lift the top and move rearward for
removal. The top should be removed carefully to
prevent flexing of the sides and possible damage.
Fig. 2D-77--Tailgate
Mandatory Assembly Sequence (Fig. 2D-78)
TAILGATES-PICKUP AND UTILITY MODELS To prevent possible damage to the top and to ensure
proper weatherstrip sealing, the following procedure must
Fleetside be followed:
Handle Replacement (Fig. 2D-77)
1. Remove the upper spare tire brace by removing (2)
1. Open tailgate. bolts.
2. Remove screws attaching handle assembly to inner side 2. Remove the necessary side trim panel screws.
of tailgate.
3. Place top on box using the two rear guide pins as
3. Remove clips from handle assembly and remove locators.
handle.
4. Install bolts # 6 on both sides and tighten.
4. Remove screws from each latch assembly and lift off,
with actuating rods. 5. Bolting must start with the rear vertical bolt # 1. Now
going forward install # 2 LH side only, # 3 and # 4 .
Replacement of Trunnion Assembly The RH side # 2 bolt will be installed later.
1. Lower tailgate half way. 6. Loosen bolts # 6 on both sides.
2. Remove both retaining straps. 7. Install and tighten bolts # 5 on both sides.
3. Lift up tailgate at the right side and pull out at the left
8. Re-tighten bolts # 6 on both sides.
side to remove tailgate assembly.
9. Install and tighten remaining bolts to cab.
4. Remove two screws from trunnion and remove
trunnion. 10. Install and tighten the 2 rear hidden bolts.
11. Install the side trim panel screws that were removed
Stepside
including the shoulder belt retractor bolt if it had to be
Endgate Replacement (Fig. 2D-77) removed.
1. Unhook endgate chain assembly at each side. Finally, reconnect the courtesy light and reinstall the
2. Remove bolt and lock washer from each trunnion in upper spare tire brace using 2 bolts, with one of the
carrier box endgate. bolts being the # 2 R.H. top-to-side panel bolt.
L IG H T T R U C K SERVICE M AN U AL
2D-28 BODY
** V f>
UNSNAP AND REMOVE
COVER BOOT AND STORE
IN VEHICLE
L IG H T T R U C K SE RV IC E M A N U A L
i
BODY 2D-29
SEATS
SEAT BELTS
SERVICING LAP AND SHOULDER
SEAT MOUNTING
Typical Seat Mounting provisions are shown in figures
2D-83 through 2D-89.
NOTICE: See N O T I C E on page 1 of this section
regarding fasteners used on seats and seat belts.
L IG H T TR U C K SERVICE M A N U A L
2D-30 BODY
L IG H T T R U C K SERVICE M A N U A L
BODY 2D-31
LIG H T TR U C K SERVICE M A N U A L
2D-32 BODY
LIG H T T R U C K SERVIC E M A N U A L
BODY 2D-33
LIG H T T R U C K SERVICE M A N U A L
2D-34 BODY
BODY MOUNTING
The removal of anyone bodymount necessitates the
loosening of adjacent body mountings to permit the frame to
be separated from the body. Care should be exercised to
prevent breakage of plastic fan shroud, or damage to frame
attachments such as steering column, brake pipes, etc.,
during replacement of body mounts.
During installation of a body mount, caution should be
used to insure that the body mount is properly seated in the
frame mounting hole, otherwise a direct metal to metal
contact will result between the frame and body. The tube
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.
Do not use lubricants of any kind on the rubber parts of
the mounts. Proper clamping by the mount depends on clean
and dry surfaces. If the body mount bolt does not screw in
smoothly, it maybe necessary to run a tap through the cage
nut in the body to remove foreign material. Caution should
also be used to insure th at tap doesn’t punch through
underbody.
The sequence of mounting attachments is shown in
figures 2D-91 through 2D-94.
APPLIQUE PROCEDURES
Refer to Section 2C, Chassis Sheet Metal, for proce
dures relating to decal and woodgrain appliques.
L IG H T T R U C K SE RV IC E M A N U A L
BODY 2D-35
C-30 J
LIG H T T R U C K SERVICE M AN U AL
2D-36 BODY
LIG H T T R U C K SE RV IC E M A N U A L
BODY 2D-37
G MODELS
INDEX
FRONT END
WINDSHIELD WIPERS 4. Remove screws which attach each arm transmission
pivot shaft assembly to cowl. Remove pivot shaft
Windshield wiper units on all models are of the two- assembly with link rod from plenum chamber.
speed electric type. A single wiper motor unit, mounted to
dash panel at top and to left of engine cover inside cab, Installation
powers both wiper blades. The wiper blade operating link 1. Place pivot shaft assembly with link rod into position at
rods and pivot mountings on these models are located in the cowl bracket. Secure assembly to bracket with two
outside air inlet plenum chamber.
screws.
Arm Adjustment 2. Attach end of link rod to motor drive and arm. Secure
rod with the two attaching nuts.
To adjust sweep of blades turn on wipers, then note
3. Install outside air cowl ventilator grille to top of cowl.
sweep of arms. If necessary, remove one or both arms as
follows: 4. Before installing wiper arms, operate wiper motor
momentarily which should rotate pivot shafts to park
Pull outer end of arm away from glass which will trip
position. Install arms.
lock spring at base of arm and release spring from undercut
of pivot shaft. While holding arm in this position, pull
outward on cap section at base of arm to remove arm. Arm
can be reinstalled in any one of several positions due to
serrations on pivot shaft and in arm cap. See figure 2D-95.
Removal
1. Remove windshield wiper arm s from pivot shafts.
Procedure for removing arms is explained previously
under "A rm Adjustments."
2. Remove screws which attach outside air cowl ventilator
grille to cowl. Carefully remove grille from cowl.
3. At center of cowl, remove two attaching nuts which
attach link rod to motor drive. Disengage link rods from
pins. Fig. 2D-95--Wiper Pattern
LIG H T T R U C K SE RV IC E M AN U AL
2D-38 BODY
L IG H T T R U C K SE RV IC E M A N U A L
BODY 2D-39
BODY GLASS
CAUTION:Always wear gloves and eye glasses obstruction is increased by such conditions as wind pres-
when handling glass to avoid personal injury. sures, extremes of temperature, motion of the vehicle, etc.
Removal
WINDSHIELD GLASS
The windshield glass is retained to the body by ure There are two methods of windshield installation. The
thane adhesive. The windshield reveal moldings are vinyl windshield removal procedure is the same for both installa
tion methods with one exception. If the short method
and are retained by two strips of butyl adhesive on the
installation is to be used, more care must be used during
underside of the molding, attaching to the body on one side
removal to make certain that an even bead of adhesive
and the glass on the other and also by a retention lip in the
material remains on window opening to serve as a base for
urethane which retains the glass. The windshield rests upon
replacement glass, there should not be any loose pieces of
the support molding which is secured to the pinchweld by a
adhesive left in the opening. Cut away a sufficient amount of
bead of butyl adhesive.
material to allow for the installation of the reveal moldings.
W hen replacing a cracked windshield glass, it is very
1. Place protective coverings around the area where the
important that the cause of the glass breakage be deter
glass is being removed.
mined and the condition corrected before a new glass is
installed. Otherwise, it is possible that a small obstruction or 2. Remove windshield wiper arms, exterior reveal mold
high spot somewhere around the windshield opening will ings, interior garnish molding and support molding
continue to crack or break the newly installed windshield, from the pinchweld. Clean up any remaining adhesive
especially when the strain on the glass caused by this left on the body from the reveal molding.
LIG H T T R U C K SERVICE M AN U AL
2D-40 BODY
The reveal moldings can be removed from the urethane Adhesive Service Kit or Cartridge
adhesive by taking one end of the molding and pulling it
Material listed have a short shelf life. Be sure materials
away from the adhesive. The support molding is removed are fresh.
in the same manner from inside the vehicle , pry up one
end of the molding and pull it away from the pinchweld. Urethane adhesive cartridge Essex SDC 551.2 or the
These molding are to be removed prior to windshield equivalent are provided singularly. Adhesive Kit No.
removal. 9631000 (urethane adhesive) or equivalent contains some of
the items needed to remove and replace a urethane adhesive
3. Use a knife as shown in Fig. 2D-101 to cut the adhesive installed glass.
completely around the perimeter of the glass. Knife,
Additional items required:
J-24402-A or equivalent may be used. With help from
an assistant, carefully remove the glass. 1. Pinchweld primer for enamel painted surface Essex
SCD 435.34 or equivalent.
2. Clear glass primer, Essex SCD 435.18 or equivalent.
4. If original glass is to be reinstalled, place it on a
protected bench or holding fixture; remove old material 3. Black glass primer (included in kit 9631000) or Essex
using a razor blade or sharp scraper. Any remaining SCD 435.20 or equivalent.
traces of adhesive m aterial can be removed with 4. Solvent for cleaning edge of glass (preferably alcohol)
denatured alcohol or lacquer thinner dampened cloth. and adhesive dispensing gun No. J-2 4 8 1 1 or an equiv
When cleaning windshield glass, avoid contacting edge alent standard household cartridge type gun reworked
of plastic laminate material (on edge of glass) with as follows:
volatile cleaner. Contact may cause discoloration and a. Widen end slot to accept dispensing end of adhesive
deterioration of plastic laminate by wicking action. DO material tube.
N O T use a petroleum base solvent such as kerosene or b. Reduce diameter of plunger disc on rod so that disc
gasoline. The presence of oil will prevent adhesion of can enter large end of adhesive material tube.
new material.
5. Commercial type razor knife.
W hen replacing the windshield, u rethane adhesive 6. Urethane cutting knife No. J-24402-A or equivalent or
(part no. 9631000 or Essex SCD 551.2 or equivalent) must two pieces of wood for wire handles.
be used in order to maintain original installation integrity. 7. Two rubber support spacers.
The short method as described previously can be used
where original adhesive material left on window opening Installation
pinchweld flanges after glass removal serves as a base for the Steps 1 through 11 are to be used for installing glass
new adhesive to the glass. This method would be used in onto the original urethane adhesive left behind when the
cases of cracked windshields or removal of windows that are windshield was removed. In those instances where the
still intact. The amount of adhesive left in window opening adhesive was entirely removed, to make a metal repair or to
can be controlled during glass removal. perform a paint refinish operation, it is necessary to follow
However, in some instances all the material must be this extra step, before starting Step 1.
removed, to make a metal repair or to perform a paint- • Thoroughly clean the metal area surrounding the
refinishing operation. In these cases, an additional cleaning windshield opening by wiping with a clean alcohol-
and priming step is required before applying the urethane dampened cloth. Allow to air dry. Then apply primer
adhesive. See the instructions at the beginning of for enamel painted surface Essex SCD 435.34 or
"Installation". equivalent, to the same area, being careful not to
allow any spill over onto exposed paint surfaces as
this primer will damage the paint finish. The surface
should not exceed 38°C (100°F) at the time of the
application. Refer to Fig. 2D-102. Allow the primer
to dry for thirty minutes.
1. From inside the vehicle, install the support molding
onto the pinchweld flange, the joint is to be located at
bottom center of the opening. See Fig. 2D-103.
5. With the aid of a helper, lift the glass into the opening.
Carry the glass with one hand on the inside of glass, and
one hand on the outside. At the windshield opening, set
the glass in a horizontal position. While one partner
holds the glass in this position, the other can reach one
Fig. 2D-102 Windshield Installation Preparation
arm around the pillar and support the glass from the
inside, while the first person assumes the same position.
With the glass centered in the opening, place the glass
against the inside support molding, use small rubber
blocks to support the glass in the correct position. Use
the last screw on either side of the cowl grille cover as a
guide for the positioning of these blocks in the wind
shield 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 away additional
solidified urethane base as necessary. See Fig. 2D-104.
6. Cut the tip of the adhesive cartridge to make asmall
opening of approximately 3/16 inch. First, fill in behind
and around spacer blocks with urethane.
7. Then apply a smooth, continuous bead of urethane.
Direct the flow of urethane down into gap as shown in
Fig. 2D-105. The material should fill the gap between
the glass edge and the sheet metal. If necessary, use a
flat-bladed instrument to paddle material into position.
Be sure that adhesive contacts the entire edge of the
glass, and extends to fill the gap between the glass and
primed sheet metal or solidified urethane base from the
original installation.
^A D H E S IV E TO WEATHERSTRIP
AND PINCHWELD
FRONT DOOR
DOOR ADJUSTMENTS tightening bolts securely. See figure 2D-110, for typical
adjustments.
Doors can be adjusted for alignment of clearance in the
cab door opening, and for proper latching. Door alignment
adjustments are made at the striker bolt, and at door hinges.
T he door, when properly located in door opening, will have Striker Bolt Adjustment
equal clearance around its perimeter. The door should be With the use of J-23457, shown in figure 2 D -1 11, the
adjusted in the opening so the edge of the door across the top striker bolt can be adjusted in any of three ways. See figure
and also at the lock side is parallel with the body opening as 2D-112.
nearly as possible.
1. Up and dow n-To adjust striker up or down, loosen bolt,
adjust to center of lock entry, and tighten bolt securely.
Hinge Adjustment This adjustment is important to assure that the right
Door hinge bolt holes are oversized to make adjustment proportion of door’s weight will rest on striker bolt
possible. Alignment adjustments can be made by loosening when door is closed. If bolt is positioned too high on
the proper hinge bolts, aligning door to proper position, and pillar, rapid wear will occur to the lock cam; if too low,
L IG H T T R U C K SERVICE M AN U AL
2D-44 BODY
an extra load will be placed on door hinges as well as 4. Torque bolts to specifications.
pulling door downward and out of alignment. 5. Install hinge access hole covers.
2. In and Out-To adjust striker in and out, loosen bolt,
adjust horizontally to match the door surface to the DOOR WEATHERSTRIP
body surface, and tighten bolt securely.
Success of weatherstrip replacement depends entirely
3. Forward and Rearward-To m ake this adjustm ent, upon the quality of the cement used and the care with which
loosen striker bolt, shim to desired position, and tighten it is applied. All rust, road dirt and grease or oil must be
bolt securely. 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.
DOOR HINGE Use only a good quality cement which is made specially for
w eatherstrip installation, following the m a n u f a c tu re r ’s
Remove
directions. Proceed as follows:
1. Remove hinge access hole cover from door hinge pillar.
1. Open door and block open.
2. If removing one hinge, support door in such a manner
2. Remove side door weatherstrip.
that weight is taken off other hinge, and that the door
will not move. 3. Remove used adhesive from door with adhesive or
cement remover, and remove all plastic nails.
3. Remove hinge screws from both body and from door
and remove hinge. See figure 2D -110. 4. Apply adhesive to door.
5. Position weatherstrip by locating part number at top of
Installation vent window, making sure that plastic nails align with
1. Install hinge to door and body. Snug bolts. holes in door.
2. Remove door supports. 6. Install weatherstrip by pressing each nail into the door.
3. Adjust door as outlined under "Door A djustm ent".
TRIM PANEL, ARM REST AND HANDLES
Removal
1. Remove screws retaining arm rest to trim panel.
2. Remove door and window handles with Tool J-9886-01
and pull from shaft.
3. Remove trim panel screws and remove panel. If plastic
water shield seal is damaged, replace seal.
Installation
1. Install trim panel.
2. Install arm rest. Install door and window handle
washers and handles.
Removal
The channel between the door window glass and door
Fig. 2D-111--Loosening Striker Bolt vent is removed as part of the vent assembly.
LIG H T T R U C K SE R V IC E M A N U A L
BODY 2D-45
1. R egu late the door window glass to the full down Ventilator Glass Replacement
position. 1. Using an oil can or similar means, squirt prepsol on the
2. Remove door and window handles with Tool J-9886-01. glass filler all around the glass channel or frame to
3. Remove trim panel and water shields. soften the old seal. When the seal has softened, remove
4. Remove rear window run channel screws. the glass from the channel.
5. Slide door window glass rearw ard away from 2. Thoroughly clean the inside of the glass channel with
ventilator. sandpaper, removing all rust, etc.
6. Remove three screws at the upper front of the door and 3. Using new glass channel filler, cut the piece to be
lower forward channel screw, as shown in figure 2D- installed two inches longer than necessary for the
113. channel. Place this piece of filler (soapstoned side of
filler away from glass) evenly over the edge of the glass
7. Pull the upper portion of the ventilator rearward.
which will fit in the channel. The extra filler extending
8. Turn the vent assembly 90° and carefully remove by beyond the rear edge of the glass should be pinched
guiding up and out, as shown in figure 2D -114. together to hold it in place during glass installation.
One side of this filler (the outside of the roll) is
soapstoned. This is the side which goes into the metal
channel.
4. Brush the inside of the metal glass channel freely with
ordinary engine oil. This will enable the glass and filler
to slide freely into the channel.
Glass should be installed so that rear edge is parallel to
the division post. Allow full cure before water testing.
Installation
Replace the door window glass and regulate to the full
down position before installing the door ventilator assembly.
1. Lower the ventilator assembly into the door frame.
Center into position.
2. M ake certain the rubber lip is positioned before
tightening screws.
3. Slide door glass forward engaging glass in vent
channel.
4. Reinstall all screws and tighten.
5. Install and tighten the three screws at the upper front
of the door.
Adjustment
1. Adjust the ventilator adjusting nut by turning clock
wise to increase operating tension, as shown in figure
2D-115.
2. After making adjustment bend tabs over the hex nut.
3. Install trim panel.
4. Install door and window regulator handles.
Replacement
CAUTION:Electrical connectors must be removed
from window lift motor before performing any
operation on the regulator, or personal injury
could occur.
1. Disconnect battery ground cable.
Fig. 2D-115--Adjusting Ventilator Tension 2. Remove door trim panel.
9. Reverse above procedure for installation. 3. Disconnect harness from regulator.
4. Remove screws securing regulator to inner panel.
DOOR W INDOW ADJUSTMENT 5. Push regulator out of door opening while holding rear
of assembly, then slide assembly to the notches in the
To perform the adjustments listed, the door trim panels
must be removed. carrier channel and out through the door access hole.
CAUTION:Step 6 must be performed when reg
Glass Height (Fig. 2D -116) ulator is removed from door. The regulator lift
Loosen the bolt and adjust the stop assembly located arms are under tension from the counterbalance
above the regulator sprocket so that the glass height in the spring and can cause serious injury if the motor is
lowered position is flush with the top of the sill, then tighten removed without locking the sector gear in
stop assembly bolt. position.
6. Drill a hole through the regulator sector gear and back
Regulator Raising and Lowering Effort (Fig. 2D-109)
plate. DO N O T drill hole closer than 1/2" (12.7mm)
The lower bolt on the run channel assembly provides to edge of sector gear or back plate. Install a pan head
fore and aft movement to ease regulator effort. sheet metal tapping screw (No. 10 - 12 x 3/4) in drilled
hole to lock sector gear in position.
7. Remove motor to regulator attaching screws.
WINDOW REGULATOR - MANUAL 8. Remove motor from regulator.
Replacement 9. Prior to installation, lubricate the motor drive gear and
1. Wind window all the way up. regulator sector teeth.
The lubrication used must be cold weather approved to
2. Remove inside door handles with Tool J-7797.
a minimum of minus 20° fahrenheit (-29°C).
3. Remove door trim pad.
10. Install regulator motor to regulator. Make sure the
4. Remove screws securing regulator to inner panel. motor pinion gear teeth mesh properly with the sector
gear teeth before installing the three motor attaching
screws.
11. Remove screw locking sector gear in a fixed position.
12. Install regulator in reverse order of removal, lubricate
regulator gears and rollers with lubriplate or
equivalent.
ROD-Fig. 2D-118
Replacement
1. Raise door window and remove door trim pad.
2. Remove bolts securing remote control to door inner
panel.
3. Pivot remote inboard slightly, to disengage connecting
rod, and remove remote control from door.
Rod and c lip m ust be
to lo c k asm before
Connecting rod can be removed at this point by
lo ck asm is installed to door. disconnecting spring clip from lock.
4. To install, reverse removal procedure.
LIG H T T R U C K SERVICE M AN U AL
2D-48 BODY
Replacement
1. Disconnect battery ground cable.
2. Remove door trim panel to gain access to power door
lock motor.
3. Disconnect electrical connector from motor.
4. Remove screws attaching motor to door inner panel.
5. Remove door lock lever from rubber mount at top of
motor actuator and remove motor through access hole.
6. To install, reverse steps 1 through 5 above.
LIG H T TR UC K SE RV IC E M A N U A L
BODY 2D-49
W INDO W SWITCH
AS S E M B LY
DOOR LOCK
SW ITCH
REAR DOOR
M OTO R ACTUATOR
(DOOR LOCK)
MOTOR
(POWER W INDOW )
SW ITCH CONTACT
(DOOR)
SWITCH CO NTACT
(PILLAR )
Fig. 2D-120--Power Door Lock Actuators, Power Window Motor, Wiring and Switches
LIG H T T R U C K SERVICE M A N U A L
2D-50 BODY
STRIKER
F O R E - A N D -A F T A D J U S T M E N T S L O T S
C E N T E R ROLLER VERT ICA LLY
IN T R A C K S O IT D O E S N O T
CONTACT
THE T R A C K -------- ^
IN FULL O P E N
U P -A N D -D O W N O R FULL ... . .., .. J1
A D J U S T M E N T SLO T S CLOSED ^ 1
P O S IT IO N
STRIKER,
U PPER F R O N l Y N in -a n d -o u t
ROLLER ASSEMBLY) adJustment;
FRONT LATCH
FACE VIEW STRIKER
G U ID E
U P -A N D -D O W N
A DJU STM EN T
IN - A N D -O U T R U B B E R '"
ADJUSTM EN T C U S H IO N
LATCH
SECTION C-C
LOWER ROLLERS i
AND CATCH ASM
LIG H T T R U C K SERVICE M A N U A L
BODY 2D-51
LIG H T T R U C K S F R V irF M AN U AI
BODY 2D-53
LIG H T T R U C K SERVICE M A N U A L
2D-54 BODY
LIG H T T R U C K SERVICE M A N U A L
BODY 2D-55
STRIKERS
The front and rear strikers are shown in figure 2D-121.
The rear striker can be removed with J-23457 as in figure
2 D -1 11, and the front striker can be removed by removing
a tta ch in g screws. R efer to "A d ju stm en ts" when
reinstalling.
REAR DOORS
REAR DOOR HINGE STRAP 3. Remove hinge-to-door bolts and remove door assembly.
4. Remove hinge-to-body bolts and hinge.
Replacement
1. Remove strap release pin. See figure 2D-130. Installation
2. Remove screws retaining strap to door. 1. Install grom m et into door hinge opening (if removed).
3. Install stra p to door. T orque retain in g screws to 2. Install hinge into door. Snug bolts.
specifications. 3. Install seal and retainer on body half of hinge (if
removed).
4. Install hinge into body opening and install bolts.
REAR DOOR HINGE 5. Take care to compress seal between body and retainer
and snug bolts.
Removal
6. Install hinge strap and its retaining pin.
1. Open door. Support door so th a t when hinge screws are
removed door weight will be on support. 7. Adjust door and torque hinge bolts to specification.
2. Remove hinge strap release pin.
REAR DOOR REMOTE CONTROL
Removal
1. Remove trim panel.
2. Disengage upper and lower latch rods from control by
remmoving retaining clips. See figure 2D-131.
3. Remove rem ote control by rem oving its retaining
screws.
Installation
1. Install remote control screws loosely.
2. A ttach upper and lower control rods.
3. R otate remote control lever clockwise, and hold in this
position while torquing the screws to specifications.
4. Install the trim panel.
Removal
1. Remove trim panel.
2. D isengage rod from rem ote control assem bly. See
figure 2D-131.
LIG H T T R U C K SERVICE M A N U A L
2D-56 BODY
Installation
1. Install lock cylinder and retainer.
2. Install remote control. Torque screws to specifications.
3. Remove latch retaining screws and w ithdraw latch and
3. Install trim panel.
control rod.
4. Remove spring clip retaining rod to latch. REAR DOOR GLASS AND WEATHERSTRIP
Installation Removal and installation procedures are the same as
1. Install latch rod to latch. for the statio n ary body side windows. R efer to those
procedures for rear door glass and w eatherstrip
W hen reinstalling the lower latch rod to control, the
replacem ent.
short straight section attaches to the latch.
2. Install latch and rod assembly into door and connect
REAR DOOR ADJUSTMENTS
rod to remote control. Lube all moving parts.
3. Install latch re ta in in g screws and torque to Door adjustm ents are provided by slotted holes, at
specifications. hinge attachm ent, in body and door.
4. A djust latch to strikers. 1. Remove or loosen door strikers and wedges.
2. Loosen door hinge bolts and adjust door to provide
REAR DOOR OUTSIDE HANDLE equal clearances between body and door around perim
eter of door.
Removal
3. A djust door in and out so th at door panel is flush with
1. Remove trim panel. body.
2. Rem ove door handle retain in g screws, handle and 4. Install door strikers and wedges and adjust as outlined
gaskets. See figure 2D-132. under door striker adjustm ent.
Installation
REAR DOOR STRIKER AND WEDGE ADJUSTMENT
1. Apply grease to rem ote control where handle plunger
makes contact. NOTICE: See N O T IC E on page 1 of this section
regaring R ear Door Striker fasteners.
2. Install handle and gaskets. T orque screws to
specifications. 1. A djust striker by adding or deleting shims as necessary
to obtain dimension as shown in figure 2D-133. This
3. Install trim panel.
dimension can be checked by applying grease to the
latch and slowly closing door until striker fully engages
latch. T hen open door and m easure from grease
REAR DOOR LOCK CYLINDER im pression to bottom of latch slot. T orque to
specifications.
Removal
2. Adjust door wedge by adding or deleting shims as
1. Remove trim panel. necessary so that wedge contact ram p on body when
2. Remove rem ote control. door is closed. See figure 2D -133.
LIG H T T R U C K SERVICE M AN U AI
BODY 2D-57
SEATS
NOTICE: See N O T IC E on page 1 of this section
regarding fasteners used on seats and seat belts.
DRIVERS SEAT
Seat Adjuster
Replacement
1. Remove seat by removing nuts securing seat adjuster to
seat riser.
2. Remove adjuster from seat. See figure 2D-134.
3. Install seat a d ju ste r to seat. T orque bolts to
specifications.
4. Install seat onto seat riser, and torque nuts to
specifications.
SEAT RISER
Replacement
1. Remove seat and adjusters as an assembly by removing
nuts securing seat to riser.
2. Remove nuts securing seat riser to floor.
3. Install seat riser to floor. Torque nuts to specifications.
4. Install seat and torque nuts to specifications.
LIG H T T R U C K SERVICE M A N U A L
2D-58 BODY
Removal
1. Remove seat and brackets from seat riser. See figure
2D-135.
2. Remove brackets from seat.
Installation
1. Install brackets to seat. T orque to specifications.
2. Install seat to seat riser. Torque to specifications.
SEAT RISER
Removal
1. Remove seat and m ounting bracket as an assembly.
2. Remove riser from floor.
Installation
1. Install riser to floor. T orque nuts to specifications.
2. Install seat riser. Torque nuts to specifications.
LIG H T T R U C K SERVICE M A N U A L
2D-60 BODY
LIG H T T R U C K SERVICE M A N U A L
BODY 2D-61
LIG H T T R U C K SERVICE M A N U A L
2D-62 BODY
SPECIFICATIONS
DOORS TAILGATE-STEPSIDE
Window Regulator Assembly Trunnion Assembly..................................18 ft. lb. 24. N-m
to Door Panel............................................85 in. lb. 9.5 N 'm Chain Support Assembly..........................90 in. lb. 10. N-m
Remote Control Door Lock
to Door Panel........................................... 45 in. lb. 8. N 'm
Lock Striker to Body Pillar................... 45 ft. lb. 60. N 'm
Outside Door Handle................................ 85 in. lb. 9.5 N-m
Inside Door Handle.................................. 85 in. lb. 9.5 N-m
Hinges to Body and Do o r.........................31 ft. lb. 42. N- m
Front Door-Window Rear Channel
Upper Bolt Assem bly..................... 85 in. lb. 9.5 N-m
Lower Bolt Assembly..................... 85 in. lb. 9.5 N-m SEATS
Front Door-Ventilator and Glass Run Assembly
Top Vent Screw................................ 20 in. lb. 2.2 N 'm Front Bench Seat
Side Vent Screws and Spacers........22 in. lb. 2.5 N-m Adjuster-to-Seat.......................... 50 in. lb. 17. N-m
Lower Vent Channel Bolts............. 85 in. lb. 9.5 N-m Adjuster-to-Floor........................ 25 ft. lb. 34. N 'm
Side Rear Door-Run Channel Front Bucket Type
Front Upper Bolt to Door............... 85 in. lb. 9.5 N-m Driver
Rear Upper Screw to Door............. 20 in. lb. 2. N-m Adjuster-to-Seat................. 18 ft. lb. 24. N-m
Front Lower Nut to Door.............. 45 in. lb. 5. N- m Adjuster-to-Floor............... 25 ft. lb, 34. N-m
Rear Lower Bolt to Door............... 85 in. lb. 9.5 N-m Passenger Chassis Cab
Lock Lever to D o o r .......................85 in. lb. 9.5 N-m Support-to-Seat................... 18ft. lb. 24. N-m
Rear Door- Support-to-Floor
Lock Striker (Suburban).........................19 ft. lb. 26. N-m (Front)..................................25 ft. lb. 34. N-m
Rear Door-Latch LH and RH Support-to-Floor
to Door (Suburban)..................................85 in. lb. 9.5 N-m (Rear)....................................40ft. lb. 54. N-m
Rear Door-Latch Control Assembly to Door (Suburban) Passenger Suburban
Upper Assembly............................. 19 ft. lb. 26. N-m Latch Support
Lower Assembly............................ 85 in. lb. 9.5 N-m to Seat (Rear).......................18 ft. lb. 24. N 'm
Striker to Floor
(Rear)..................................25 ft. lb. 34. N-m
Support (Upper)
END GATE to Seat (Front).....................18 ft. lb. 24. N-m
Hinges-Body Half and Gate Half........... 35 ft. lb. 48. N-m Support (Lower)
Support Assembly-Cable Bolts............. 35 ft. lb. 48. N-m to Floor (Front)................... 25 ft. lb. 34. N-m
Torque Rod to Hinge Pocket................. 85 in. lb. 9.5 N-m Support (Upper)
Torque Rod to Body.......................... . 18 ft. lb. 2. N-m to Support (Lower)............. 30 ft. lb. 40. N-m
Latch Assembly to End Gate................. 33 ft. lb, 44. N 'm Rear Bench Utility, Suburban
Latch Control Assembly Support-Lo-Seat............................ 18 ft. lb. 24. N-m
to End Gate............................................. 45 in. lb. 5. N-m Support-to-Floor.......................... 50ft. lb. 70. N-m
Handle to Latch Control Assembly........45 in. lb. 5. N-m Rear Bench Crew Cab
Glass Channel (Suburban)......................45 in. lb. 5. N-m Support-to-Seat.......................... 150 in. lb. 17. N-m
Glass Channel (Utility).......................... 85 in. lb. 9.5 N-m Support-to-Floor.......................... 35 in. lb.
Outside Handle........................................55 in. lb. 6. N-m Folding Rear Seat Suburban
Cap Assembly to Channel Assembly... .24 in. lb. 2 .6 N-m Support Asm-to-Floor................. 150 in, lb. 17. N 'm
Striker-Body Mounted............................ 25 ft. lb. 34. N-m Seat-to-Support A s m .....................18 in. lb. 24. N-m
LIG H T T R U C K SERVICE M AN U AL
BODY 2D-63
G MODELS
Outside Rear View Mirror to Panel... .150 in. lb. 17. N-m Remote Control (front latch)
Sunshade Support to Header Panel-- lb. 1.6 N-m lb. 10. N* m
Rear Latch to Door.................................. lb. 10. N* m
Lower Front Roller and Roller Support
SIDE WINDOW (SWINGOUT) Support-to-Door................................ . .24 ft. lb. 32. N* m
Support to Roller Bracket............... ..2 4 ft. lb. 32. N ’ m
Latch to Body........................................ Lower Control Assembly................. lb. 10. N* m
lb 4 .6 N*m
Hinge to Body........................................ Upper Front Roller Bracket
lb. 6 .0 N-m
Bracket to Do o r................................ 24 ft. lb. 32. N 'm
Roller to Bracket.............................. 20 ft. lb. 27. N* m
SEATS
Hinge (to body and door)....................... . .40 ft. lb. 54. N 'm Seat Belt to S ea t...................................... ..3 7 ft. lb. 50. N* m
Remote Control RH Passenger and Drivers
Retaining Screws.................................. ..7 0 in.lb. 8. N- m Seat to Adjuster
Latch-to-Door Retaining (Mounting Bracket).......................... ..1 8 ft. lb. 24. N ‘ m
Screws Upper........................................ . . 19 ft. lb. 26. N-m Seat to Riser...................................... . .18 ft. lb. 24. N* m
Latch-to-Door Retaining Seat Riser-to-Floor......................... . .50 ft. lb. 70. N ‘ m
Screws Lower........................................ ..7 0 in. lb. 8. N-m Bench Seats
Door Strikers-to-Body......................... ..1 8 ft. lb. 24. N-m Seat to Seat Support........................ . .18 ft. lb. 24. N* m
Outside Door Handle............................ ..9 0 in. lb. 10. N-m Seat Support to Leg Assembly.......... .130 ft. lb. 170 N- m
LIG H T T R U C K SERVICE M A N U A L
2D-64 BODY
SPECIAL TOOLS
LIG H T T R U C K SE RV IC E M AN U AL
FRONT ALIGNMENT 3A-1
SECTION 3A
FRONT ALIGNMENT
CONTENTS
GENERAL DESCRIPTION
FRONT ALIGNMENT viewed from a side elevation. Caster is designed into the
front axle assembly on all K series vehicles (four-wheel
T he term "fro n t alig n m en t" refers to the ang ular drive), and is non-adjustable. See caster copy under
relationships between the front wheels, the front suspension A D JU S T M E N T S .
attaching parts and the ground.
The pointing in or "toe-in" of the front wheels, the tilt CAMBER
of the front wheels from vertical (when viewed from the Cam ber is the tilting of the front wheels from the
front of the vehicle) and the tilt of the suspension members vertical when viewed from the front of the vehicle. W hen the
from vertical (when viewed from the side of the vehicle), all wheels tilt outward at the top, the cam ber is said to be
these are involved in front alignm ent. The various factors positive ( + ). W hen the wheels tilt inward at the top, the
th at enter into front alignm ent are covered here each one cam ber is said to be negative (-). The am ount of tilt is
under its own heading. m easured in degrees from the vertical and this m easurem ent
is called the cam ber angle. C am ber is designed into the front
CASTER axle assembly of all K series vehicles and is non-adjustable.
C aster is the tilting of the front steering axis either See cam ber copy under A D JU ST M E N T S.
forward or backward from the vertical (when viewed from
the side of the vehicle). A backward tilt is said to be positive TOE-IN
( + ) and a forward tilt is said to be negative (-). Toe-in is the turning in of the front wheels. The actual
On the short and long arm type suspension you cannot am ount of toe-in is normally only a fraction of an inch. The
see a caster angle without a special instrum ent, but you can purpose of a toe specification is to ensure parallel rolling of
understand th at if you look straight down from the top of the the front wheels. (Excessive toe-in or toe-out will cause tire
upper control arm to the ground you would find that the ball wear). Toe-in also serves to offset the small deflections of the
joints do not line up (fore and aft) when a caster angle other wheel support system which occurs when the vehicle is
than 0° is present. If you had a positive caster angle the rolling forward. In other words, even when the wheels are set
lower ball joint would be slightly ahead (toward the front of to toe-in slightly when the vehicle is standing still, they tend
the vehicle) of the upper ball joint center line. In short then, to roll parallel on the road when the vehicle is moving. See
caster is the forward or backward tilt of the steering axis as toe-in copy under A D JU S T M E N T S .
L IG H T T R U C K SE RV IC E M AN U AL
3A-2 FRONT ALIGNMENT
(J. OF WHEEL
DIRECTION
CAMBER ANGLE CASTER ANGLE
FRONT V IE W SIDE V IE W
FORWARD
LIG H T T R U C K SE RV IC E M AN U AL
3A-4 FRONT ALIGNMENT
Toe-In
1. D eterm ine the wheel toe-in from the alignm ent
equipment.
"B ” IS LESS THAN “ A ” W H E N WHEELS TOE-IN
2. Change the length of both tie rod sleeves to affect a toe
change.
Toe-in can be increased or decreased by changing the
length of the tie rods. A threaded sleeve is provided for this
purpose.
W hen the tie rods are mounted ahead of the steering
knuckle they m ust be decreased in length in order to
increase toe-in. W hen the tie rods are mounted behind the
steering knuckle they m ust be lengthened in order to
increase toe-in.
See Section 3B for proper tie rod clam p orientation and
positioning.
CROSSMEMBER
LIG H T T R U C K SERVIC E M A N U A L
FRONT ALIGNMENT 3A-5
SPECIFICATIONS
D IM E N S IO N " A "
MODELS 2 1/2" 2% " 3" 3 %" 3 1/2" 3% " 4” 474" 4 1/2" 4% " 5"
(mm) 6 3 .5 69 .8 76.2 82.5 89.0 95.2 102.0 107.9 114.3 121.6 127.0
C10 2.4° 2.1° 1.8° 1.5° 1.2° 1.0° 0.7° 0.5° 0.2° 0.1° 0.3°
C20, 30 1.5° 1.2° 0.9° 0.6° 0.3° 0.1° 0° -0.1° -0.7° -1.0° -1.2°
K10,20,30 (8°) ( N O A D J U S T M E :N T P R O V I S O N )
r / 2" 1% " 2" 21/4" 21/2" 2%" 3" 3% " 3 1/2" 3% " 4" 4% "
(mm) 38 .0 44 .4 51.0 57.1 63 .5 69.8 76 .2 82.5 89.0 95.2 102.0 107.9
G10, 20 3.5° 3.3° 3.1° 2.9° 2.7° 2.4° 2.2C 2.1° 1.9C 1.8° 1.6°
G30 2.8C 2.5° 2:2° 1.9° 1.6° 1.0° .7° .5° .2° 0° -0.2°
2 1/2" 2% " 3" 3 1/4" 3 1/2" 3 3/4" 4" 474" 4 1/2" 4% " 5"
(mm) 63 .5 69.8 76 .2 82.5 89.6 95.2 102.0 107.9 114.3 120.6 127.0
P10 2.3° 2.0° 1.7° 1.5° 1.2° 0.9° 0.6° 0.4° 0.1° -0.1° -0 .3 *
2" 2 1/4" 21/2" 2 %" 3" 3V4" 3 1/2" 3 3/4" 4 " 4 1/4" 41/2" 4% "
(mm) 51.0 57.1 63 .5 6 9 .8 76.2 82.5 89.0 95.2 102.0 107.9 114.3 120.6
*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 J B 8 O R J F 9
S U B T R A C T .4° W IT H R 0 5
MOTOR HOME (32) 21/2" 2% " 3" 374" 3 1/2" 3% " 4" 4 1/4” 4 1/2" 4% " 5"
(mm) 63 .5 69.8 76.2 82.5 89.0 9 5.2 102.0 107.9 114.3 120.6 127.0
5.5° 5.3° 5.0° 4.7° 4.4° 4.1° 3.8° 3.6° 3.3° 3.1° 2.9°
C A M BER
MODEL
M O T O R HO M E (32) .2°
A L IG N M E N T T O L E R A N C E S T O E -IN
Specifications
L IG H T T R U C K SE RV IC E M A N U A L
STEERING LINKAGE 3B1-1
SECTION 3B1
STEERING LINKAGE
T he following notice applies to one or more steps in the assembly
procedure of components in this portion of the m anual as indicated at
appropriate locations by the terminology "See N otice on page 1 of this
Section ".
N O TICE: These fasteners are im portant attaching parts in th a t they
could affect the perform ance of vital components and systems, an d /o r could
result in m ajor repair expense. They must be replaced with one of the same
part num ber or with an equivalent part if replacem ent becomes necessary. Do
not use a replacem ent part of lesser quality or substitute design. Torque
values m ust be used as specified during reassembly to assure proper retention
of these parts. For prevailing torque nut(s) and bolt(s), refer to the " Reuse of
Prevailing Torque N u t(s) and B olt(s)" chart in Section 10.
CONTENTS
GENERAL DESCRIPTION
The steering linkage is located forward of the front
crossmember. Refer to Fig. 3B1-1, for a typical system.
Steering effort is transm itted to left and right hand adjusta
ble tie rods through a relay rod. T he relay rod is connected to
an idler arm on the right and to the pitm an arm on the left.
DIAGNOSIS
Reference should be m ade to the correct method of
disassembly, repair, adjustm ent and reassembly. Dam aged,
broken or deformed parts must be replaced with the correct
replacem ent.
L IG H T TR U C K SERVICE M A N U A L
3B1-2 STEERING LINKAGE
Excessive Play or Looseness in Front wheel bearings loosely Adjust bearings to obtain proper
Steering System. adjusted. end play.
Excessive looseness in tie rod Seal damage and leakage Replace damaged parts as
or intermediate rod pivots, or resulting in loss of lubricant, necessary. Properly position upon
excessive vertical lash in idler corrosion and excessive wear. reassembly.
support.
Excessive vertical lash Excessive end play in support Adjust end play.
in idler arm assembly.
(P Series Motorhome)
LIG H T T R U C K SERVICE M A N U A L
STEERING LINKAGE 3B1-3
Hard Steering - Excessive Effort Low or uneven tire pressure. Inflate to specified pressures.
Required at Steering Wheel.
LIG H T T R U C K SERVICE M A N U A L
3B1-4 STEERING LINKAGE
(Fig. 3B1-4)
This type of steering dam per is nonadjustable, nonre-
fillable and is not repairable. A t each lubrication interval
m ake check # 1 and # 2 on the steering dam per system.
1. Inspecting Damper Mountings: C heck th e dam per
attachm ents to be sure they are properly and securely
installed. (T ig h ten , if loose). R eplace th e d am per
assembly if the rubber bushings are badly worn.
2. Inspecting Damper For Leaks: Inspect the dam per for
evidence of fluid leakage. A light film of fluid is
MOTOR HOME
perm issible on the body of the dam per near the shaft
seal. A dripping d am per should be replaced.
Fig. 3Bl-4--Steering Dampers
If a Funtional or Noise C om plaint is R eported, M ake
the dam per for fluid leakage, effort and lag. Items from
the Following Inspections:
this check th at require dam per replacem ent are:
3. Inspecting Damper For Noise: Disconnect the fram e or
A.Any fluid leakage during this check.
axle end of the dam per. Extend and compress the
dam per using as much travel as possible. The dam per B. Seizing or binding condition during travel of damper.
action should be smooth throughout each stroke. C.A skip or lag at reversal near m id-stroke of dam per.
4. Inspecting Damper For Functioning: W hile checking 5. Reinstall Disconnected End of Damper Using Proper
the dam per in step (3) above, observe the operation of Torque.
LIG H T T R U C K SERVICE M A N U A L
STEERING LINKAGE 3B1-5
RELAY ROD
IDLER ARM
ASSEMBLY TIE ROD
ASSEMBLY l All clamps must be be tw ee n &
[ a ] [c a u t i o n
clear of dimples before torquing nut.
KNUCKLE |~B~| Exposed socket thread length must be
STEERING GEAR
equal within ± . 0 6 at each end of a d
PITMAN ARM justing sleeve on L.H. & R.H. tie rod asm
| C | All bolts must be installed in directions
shown -
ADJUSTABLE CONNECTING ROD
STEERING
IDLER ARM ARM
ASSEMBLY
RELAY ROD
TIE ROD
ASSEMBLY
CONNECTING,
ROD
SUPPORT ASSEMBLY
SUPPORT -
,LEFT IDLER
PITMAN ARM
ARM
RELAY ROD
P-SERIES
LIG H T T R U C K SERVICE M A N U A L
3B1-6 STEERING LINKAGE
ON-VEHICLE SERVICE
NOTICE: See N O T IC E on page 1 of this section
regarding all fasteners referred to in servicing steering
linkage components.
TIE RODS
Removal
1. Raise vehicle on hoist.
2. Remove nuts from ball studs. The inner tie rod ends use
crim p nuts, while the outer ends use castellated nuts
and cotter pins.
3. To remove outer ball stud, tap on steering arm at tie rod
end with a ham m er while using a heavy ham m er or
sim ilar tool as a backing (Fig. 3 B 1-7).
4. Remove inner ball stud from relay rod using same
procedure as described in Step 3.
5. To remove tie rod ends from tie rod, loosen clam p bolts
and unscrew end assemblies. Fig. 3B1 -7—Ball Stud Removal-Typical
Installation
NOTICE: See the N O T IC E on page 1 of this section exceed 7 pounds, discard the nuts and bolts. Apply penetrat
regarding the fasteners referred to in steps 4 and 6. ing oil between the clam p and tube and rotate the clamps
Tie rod adjuster com ponents often become rusted in until they move freely. Install new bolts and nuts having the
service. In such cases, it is recom m ended th at if the torque same part num ber to assure proper clam ping at the specified
required to remove the nut from the bolt after breakaw ay nut torque.
PRODUCTION NUT
IMPORTANT
WHENEVER ANY OF THE CRIMP NUTS OR STUDS AT THE (5) LOCATIONS SHOWN ARE LOOSENED OR
REMOVED, THE FOLLOWING STEPS MUST BE TAKEN:
A. WHEN RE-ATTACHING ANY TWO COMPONENTS BY MEANS OF A BALL STUD, CAREFULLY POSITION
THE TWO PARTS. THEN IN STALL A FREE-SPINNING NUT, AND DRAW THE ITEMS TOGETHER TO SEAT
THE TAPER, TORQUE NUT TO 54 N m (40 FT-LBS), THEN REMOVE NUT.
B. THEN USE A TORQUE PREVAILING SERVICE REPLACEMENT NUT (#351249) AND TORQUE TO
90 N-m (66 FT-LBS),
L IG H T T R U C K SERVICE M A N U A L
STEERING LINKAGE 3B1-7
T IE ROD - O UTER
A D JU S T E R RELAY
SLEEVE S T E E R IN G K N U C K L E
SLO T
REARW ARD-
R O T A T IO N
NOTE Equal w ith in th re e threads,
NOTE Locate clam ps m ust be visib le at inner and o u te r
w itn in to le ra n ce show n. ends o f ad ju ster sleeve when assembled
VIEW A to steering k n u ckle .
As a guide to correct orientation of the inner tie rod end 5. A djust toe-in as described in Section 3A.
relative to the outer tie rod end, rotate both ends to the Before tightening the tie rod adjusting sleeve clam p
extrem es of travel in the sam e direction before clamping. bolts, be sure th at the following conditions have been met:
The position of each tie rod end m ust be m aintained as the
a. The sleeve clam ps m ust be positioned between the
clam ps are tightened to ensure free movement of each joint. locating dimples at either end of the sleeve.
R eturn the rod assembly to midposition of its travel. This
b. The clam ps m ust be positioned within the angular
should result in the inner and outer ball studs being retained travel indicated in Figure 3B1-8.
in a parallel relationship with the interm ediate (relay) rod
and steering knuckle (arm ) respectively. T he following
procedure should be used when installing tie rods.
1. If the tie rod ends were removed, lubricate the tie rod
threads with EP Chassis lube and install ends on tie rod
m aking sure both ends are threaded an equal distance
from the tie rod.
2. M ake sure th at threads on ball studs and in ball stud
nuts are clean and smooth. If threads are not clean and
smooth, ball studs may turn in tie rod ends when
attem pting to tighten nut. Check condition of ball stud
seals; replace if necessary. Tool J-24434 may be used to
install ball stud seals.
3. Install ball studs in steering arm s and relay rod. F o r
the inner tie rod ends, use a free-spinning % - 1 8 nut to
seat the ta p e rs, p e r Fig. 3 B 1-6.
4. A t th e ou ter tie rod ends, install a ball stud n u t, tighten
to 70 N*m (50 lb. ft.), and install new c o tter pins.
L u b ricate tie rod ends.
Fig. 3B1 -9—Tie Rod Inspection
LIG H T TR U C K SERVICE M A N U A L
3B1-8 STEERING LINKAGE
c. The relationship of the clam p slot with the slit in the Installation
sleeve should be m aintained as shown in Figure 3B1-
NOTICE: See the N O T IC E on page 1 of this section
8.
regarding the fasteners referred to in steps 2 and 3.
d. R otate both inner and outer tie rod housing rearw ard
1. M ake sure th at threads on the ball studs and in the ball
to the lim it of ball jo in t travel before tightening stud nuts are clean and smooth. If threads are not clean
clam ps. Tighten clam ps to specifications. R eturn tie
and sm ooth, ball studs m ay tu rn in sockets when
rod assem bly to the center of travel.
attem pting to tighten nut. Check condition of ball stud
e. All procedures for alignm ent, adjustm ent and assem seals; replace if necessary.
bly of tie rods applies to each side.
f. Check each assem bly to be sure th at a total travel of 2. Install the relay rod to the idler arm and pitm an arm
at least 35° can be obtained using a bubble protractor ball studs, m aking certain th e seals are in place. U se a
and a pair of vise grips (Fig. 3B1-9). free-spinning nut to seat the ta p ers, p er Fig. 3 B 1 -6 .
RELAY ROD
Removal
1. Raise vehicle on hoist.
2. Remove inner ends of the tie rods from relay rod as
described under "T ie R od-R em oval".
3. Remove the nuts from the pitm an and idler arm ball
studs a t the relay rod.
4. Remove the relay rod from the pitm an and idler arm s
by tapping on the relay rod ball stud bosses with a
ham m er, while using a heavy ham m er as a backing
(Fig. 3B1-7).
5. Remove the relay rod from the vehicle. Fig. 3B1-10--Checking Idler Movement, Typical
LIG H T T R U C K SERVICE M A N U A L
STEERING LINKAGE 3B1-9
It is also necessary th a t a scale or ruler be rested tapping on side of rod or arm (in which the stud
against the fram e and used to determ ine the am ount of mounts) with a ham m er while using a heavy ham m er or
movement since observers tend to over-estim ate the sim ilar tool as a backing. Pull on linkage to remove
actual movement when a scale is not used. The idler from stud.
arm should always be replaced if it fails this test. 4. Remove pitm an arm nut from pitm an shaft or clam p
Jerking the right front wheel and tire assembly back bolt from pitm an arm , and m ark relation of arm
and forth, thus causing an up and down movement in the position to shaft.
idler arm is not an acceptable m ethod of checking since 5. Remove pitm an arm , using Tool J-6632 or J-5504.
there is no control on the am ount of force being applied.
Installation
C aution should be used in assum ing shimmy com
plaints are caused by loose idler arm s. Before suspecting NOTICE: See the N O T IC E on page 1 of this section
suspension or steering com ponents, techn icians should regarding the fasteners referred to in steps 3 and 4.
elim in ate shim m y excitation facto rs, such as dynam ic
1. Install pitm an arm on pitm an shaft, lining up the marks
im balance, run-out or force variation of wheel and tire
made upon removal.
assem blies and road surface irregularities.
NOTICE: If a clam p type pitm an arm is used, spread the
Removal pitm an arm ju st enough, with a wedge, to slip arm onto
1. Raise vehicle on a hoist. pitm an shaft. Do not spread pitm an arm more than
2. Remove the nut from ball stud at the relay rod. Remove required to slip over pitm an shaft with hand pressure.
the ball stud from the relay rod by tapping on the relay Do not ham m er or dam age to steering gear may result.
rod boss with a ham m er, while using a heavy ham m er Be sure to install the hardened steel washer before
as a backing (Fig. 3B1-7). installing the nut.
3. Remove the idler arm to fram e bolt and remove the 2. M ake sure th a t threads on ball studs and in ball stud
idler arm assembly. nuts are clean and smooth. If threads are not clean and
smooth, ball studs may turn in sockets when attem pting
Installation to tighten nut. C heck condition of ball stud seals;
NOTICE: See the N O T IC E on page 1 of this section replace if necessary.
regarding the fasteners referred to in steps 1 and 3. 3. Install pitm an shaft nut or pitm an arm clam p bolt and
1. Position the idler arm on the fram e and install the torque to specifications.
m ounting bolts (special plain w ashers under bolt 4. Position ball stud onto pitm an arm or relay rod. U se a
heads); torque the nuts to specifications. %-18 free-spinning nut to seat the tap ers, p er Fig.
2. M ake sure th at the threads on the ball stud and in the 3B1-6.
ball stud nut are clean and smooth. If threads are not
clean and smooth, ball stud m ay turn in the socket Lubricate ball studs.
when attem pting to tighten nut. Check condition of ball Lower the vehicle to the floor.
stud seal; replace if necessary.
STEERING CONNECTING ROD (K MODELS ONLY)
3. Install th e idler arm ball stud in th e relay rod, making
Removal
certain the seal is positioned properly. U se a %-18
free-spinning nut to seat th e tap ers, p er Fig. 3B1-6. 1. Remove cotter pins from ball studs, and then remove
the castellated nuts.
4. Lower the vehicle to the floor. 2. Remove ball studs from steering arm and pitm an arm
boss with a heavy ham m er and striking other side of
IDLER ARM — P SERIES MOTORHOME boss with lighter ham m er (sim ilar to method shown in
(Fig. 3B1-7).
T he fram e m ounted idler su p p o rt assem bly is adjusta
ble for su p p o rt shaft end play. C h eck for idler arm m ove
m ent at the relay rod end as indicated above. If the m ove
Installation
m ent at the end o f the arm ex ceed s ± 1/16 inch (1/8 inch NOTICE: See the N O T IC E on page 1 of this section
total m ovem ent), readjust the support shaft end-play as regarding the fasteners referred to in step 3.
follows: 1. M ake sure th a t threads on ball studs and in ball stud
1. L o o sen the su p p o rt assem bly ja m nut. nuts are clean and smooth. If threads are not clean and
2. Tighten the adjusting plug to m etal-to-m etal contact. smooth, ball studs may turn in connecting rod when
attem pting to tighten nut. Check condition of ball stud
3. B ack off the adjusting plug Vs o f a turn (Vi of a flat on
seals-replace if necessary.
the square nut, o r 45°).
2. Install ball studs in steering arm and pitm an arm . (Be
4. R etorque th e ja m nut to 25-35 ft. lb s., while taking care sure to install the long end of the connecting rod
th at the adjusting plug does not rotate. assembly to the pitm an arm , as shown in Fig. 3B1-5).
PITMAN ARM 3. Install ball stud nuts and torque to specifications.
Never back off nut to align cotter pin, always tighten
Removal nut to next slot th a t lines up with hole in stud.
1. Raise vehicle on hoist. 4. Install cotter pins and lubricate ball studs. For proper
2. Remove nut from pitm an arm ball stud. alignm ent and orientation of connecting rod clam ps see
3. Remove pitm an arm or relay rod from ball stud by Figure 3B 1-11.
LIG H T T R U C K SERVICE M A N U A L
3B1-10 STEERING LINKAGE
STEERING GEAR
ASSEMBLY .10
CLAMP
LIG H T T R U C K SERVICE M A N U A L
MANUAL STEERING GEAR 3B2-1
SECTION 3B2
MANUAL STEERING GEAR
The following notice applies to one or more steps in the assembly
procedure of com ponents in this portion of the m anual as indicated at
appropriate locations by the terminology "See N otice on page 1 of this
S ection".
N O TICE: This fastener is an im portant attaching part in th at it could
affect the perform ance of vital components and systems, an d /o r could result
in m ajor repair expense. It must be replaced with one of the same part
num ber or with an equivalent part if replacem ent becomes necessary. Do not
use a replacem ent part of lesser quality or substitute design. Torque values
m ust be used as specified during reassem bly to assure proper retention of this
part.
CONTENTS
G eneral D escription.....:.................................................................................3B2-1
D iagnosis.................................. ........................................................................3B2-1
M aintenance and A d ju stm e n ts................................................................. .3B2-4
On-V ehicle S erv ice....................................................................................... .3B2-5
M anual Steering G e a r............................................................................. .3B2-5
Pitm an S haft S eal......................................................................................3B2-6
S pecifications.................................................................................................. .3B2-7
Special T ools....................................................................................................3B2-7
GENERAL DESCRIPTION
The steering gear is of the recirculating ball type. This
gear provides for ease of handling by transm itting forces
from the w orm shaft to the pitm an shaft through the use of
ball bearings.
DIAGNOSIS
This section contains diagnostic inform ation to help
locate the cause of steering problems that may be related to
the m anual steering gear. Reference should be m ade to the
correct m ethod of disassem bly, repair, a d ju stm en t and
reassembly. D am aged, broken or deformed parts m ust be
replaced with the correct replacem ent.
LIG H T T R U C K SERVICE M A N U A L
3B2-2 MANUAL STEERING GEAR
C O N D IT IO N P O S S IB L E C A U SE C O R R E C T IO N
Rattle or Chuck in Steering Gear. Insufficient or improper lubricant Add lube specified.
in steering gear.
LIG H T T R U C K SERVICE M A N U A L
MANUAL STEERING GEAR 3B2-3
C O N D IT IO N P O S S IB L E C A U S E C O R R E C T IO N
Excessive Play or Looseness in Front wheel bearings loosely Adjust to obtain proper end play.
Steering System. adjusted.
LIG H T TR U C K SERVICE M A N U A L
3B2-4 MANUAL STEERING GEAR
LIG H T T R U C K SERVIC E M A N U A L
MANUAL STEERING GEAR 3B2-5
improper adjustm ent; the gear m ust be disassembled 11. Install the horn button cap or shroud and connect the
and inspected for replacem ent of dam aged parts. battery ground cable.
9. A djust "over-center preload" as follows: 12. Lower the vehicle to the floor.
a. T urn the steering wheel gently from one stop all the STEERING GEAR HIGH POINT CENTERING
way to the other carefully counting the total num ber
1. Set front wheels in straight ahead position. This can be
of turns. T urn the wheel back exactly half-way, to
checked by driving vehicle a short distance on a flat
center position.
surface to determ ine steering wheel position at which
b. T urn the lash adjuster screw clockwise to take out all vehicle follows a straight path.
lash between the ball nut and pitm an shaft sector 2. W ith front wheels set straight ahead, check position of
teeth and then tighten the locknut. m ark on w orm shaft designating steering gear high
c. C heck the torque at the steering wheel, taking the point. This m ark should be at the top side of the shaft at
highest reading as the wheel is turned through center 12 o’clock position and lined up with the m ark in the
position. See Specifications for proper over-center coupling lower clamp.
preload. 3. On C, G and P series, if the gear has been moved off
d. If necessary, loosen locknut and readjust lash ad high point when setting wheel in stra ig h t ahead
ju ster screw to obtain proper torque. Tighten the position, loosen adjusting sleeve clamps on both left and
locknut to specifications and again check torque right hand tie rods. Then turn both sleeves an equal
reading through center of travel. If m axim um speci num ber of turns in the same direction to bring gear
fication is exceeded, turn lash adjuster screw coun back on high point.
terclockwise, then come up on adjustm ent by turning Turning the sleeves an unequal num ber of turns or in
. the adjuster in a clockwise motion. different directions will disturb the toe-in setting of the
wheels.
10. Reassem ble the pitm an arm to the pitm an shaft, lining
up the m arks m ade during disassembly. Torque the 4. On K series, if the gear has been moved off' high point
pitm an shaft nut to specifications. when setting wheels in straight ahead position, loosen
adjusting sleeve clamps on the connecting rod. Then
If a clam p type pitm an arm is used, spread the pitm an
turn sleeve to bring gear back on high point.
arm ju st enough, with a wedge, to slip the arm onto the
pitm an shaft. Do not spread the clam p more than 5. R eadjust toe-in as outlined in Section 3A (if
required to slip over pitm an shaft with hand pressure. necessary).
Do not ham m er the pitm an arm onto the pitm an shaft. 6. Be sure to properly orient sleeves and clamps when
Be sure to install the hardened steel washer before fastening and torqueing clam ps to proper
installing the nut. specifications.
ON-VEHK 1 SERVICE
STEERING GEAR 2. Remove the flexible coupling to steering shaft flange
bolts (C-K models) or the lower universal joint pinch
bolt (P models). M ark the relationship of the universal
Removal yoke to the worm shaft.
1. S et the front wheels in s tra ig h t ahead position by 3. M ark the relationship of the pitm an arm to the pitm an
driving vehicle a short distance on a flat surface. shaft. Remove the pitm an shaft nut or pitm an arm
pinch bolt and then remove the pitm an arm from the
pitm an shaft using Puller J-6632 (Fig. 3B2-9).
L IG H T T R U C K SE RV IC E M A N U A L
3B2-6 MANUAL STEERING GEAR
4. Remove the steering gear to fram e bolts and remove 3. Install the pitm an arm onto the pitm an shaft, lining up
the gear assembly. the m arks made at removal. Install the pitm an shaft
5. C-K Models - Remove the flexible coupling pinch bolt nut or pitm an arm pinch bolt and torque to
and rem ove the coupling from the steering gear specifications.
worm shaft. If a clam p type pitm an arm is used, spread the pitman
arm just enough, with a wedge, to slip the arm onto the
Installation pitm an shaft. Do not spread the clam p more than
required to slip over pitm an arm onto the pitm an shaft.
NOTICE: See N O T IC E on page 1 o f this section Be sure to install the hardened steel washer before
regarding the fasteners referred to in steps la , lc, Id, installing the nut.
le, 2b, 2c and 3.
1. C-K Models
PITMAN SHAFT SEAL REPLACEMENT
a. Install the flexible coupling onto the steering gear
w orm shaft, aligning the flat in the coupling with the
flat on the shaft. Push the coupling onto the shaft A faulty seal may be replaced without removal of
until the w orm shaft bottom s on the coupling rein steering gear from C, G and P trucks by removing pitm an
forcem ent. In stall th e pinch bolt and torq u e to arm as outlined under M aintenance and A djustm ents -
specifications. The coupling bolt m ust pass through Steering G ear A djustm ents and proceed as follows:
the shaft undercut. On K series vehicles remove the gear from the vehicle
b. Place the steering g ear in position, guiding the first.
coupling bolt into the steering shaft flange. 1. R otate the steering wheel from stop to stop, counting
c. Install the steering gear to fram e bolts and torque to the total num ber of turns. Then turn back exactly half
specifications. way, placing the gear on center (the w orm shaft flat
d. If flexible coupling alignm ent pin plastic spacers should be at the 12 o’clock position).
were used, m ake sure they are bottom ed on the pins, 2. Remove the three self-locking bolts a tta ch in g side
torque the flange bolt nuts to specifications and then cover to the housing and lift the pitm an shaft and side
remove the plastic spacers. cover assembly from the housing.
e. If flexible coupling alignm ent pin plastic spacers 3. Pry the pitm an shaft seal from the gear housing using a
were not used, center the pins in the slots in the screw driver and being careful not to dam age the
steering shaft flange and then install and torque the housing bore. See Fig. 3B2-10.
flange bolt nuts to specifications.
NOTICE: Inspect the lubricant in the gear for contam i
2. P Models nation If the lubricant is contam inated in any way, the
a. Place the steering g ear in position, guiding the gear m ust be removed from the vehicle and completely
w orm shaft into th e universal jo in t assem bly and overhauled as outlined in the U nit R epair M anual, or
lining up the m arks m ade at removal. If a new gear dam age to the gear could result.
was installed, line up the m ark on the w orm shaft 4. Coat the new pitm an shaft seal with Steering G ear
with the slit in the universal joint yoke. Lubricant meeting GM Specification G M 4673M (or
b. Install the steering gear to fram e bolts and torque to equivalent). Position the seal in the pitm an shaft bore
specifications. and tap into position using a suitable size socket.
c. Install the universal joint pinch bolt and torque to 5. Remove the lash adjuster lock nut. Remove the side
specification. The pinch bolt m ust pass through the cover from the pitm an shaft assembly by turning the
shaft undercut. lash adjuster screw clockwise.
TOOL—J-5504
LIG H T T R U C K SERVICE M A N U A L
MANUAL STEERING GEAR 3B2-7
6. Place the pitm an shaft in the steering gear such th at the 10. Install the side cover bolts and torque to specifications.
center tooth of the pitm an shaft sector enters the center 11. Install the lash adjuster screw locknut, perform steerin
tooth space of the ball nut. gear adjustm ent and install the pitm an arm as outllined
7. Fill th e steering gear housing with S teerin g G ear under " M aintenance and A djustm ents".
L ubricant meeting G M Specification G M 4673M (or On K series install the gear into the vehicle using
equivalent). previously outlined procedure.
8. Install a new side cover gasket onto the gear housing.
9. Install the side cover onto the lash adjuster screw by SPECIFICATIONS AND SPECIAL TOOLS
reaching through the threaded hole in the side cover Refer to Specifications and Special Tools at end of
with a small screwdriver and turning the lash adjuster Section 3B4.
screw counter- clockwise until it bottom s and turns
back in 1/4 turn.
L IG H T TR UC K SE RV IC E M AN U AL
POWER STEERING SYSTEM 3B3-1
SECTION 3B3
POWER STEERING SYSTEM
The following notice applies to one or more steps in the assembly
procedure of com ponents in this portion of the m anual as indicated at
appropriate locations by the term inology "See N otice on page 1 of this
S ection".
N O TICE: This fastener is an im portant attaching part in th at it could
affect the perform ance of vital components and systems, an d /o r could result
in m ajor repair expense. It m ust be replaced with one of the same part
num ber or with an equivalent part if replacem ent becomes necessary. Do not
use a replacem ent part of lesser quality or substitute design. Torque values
m ust be used as specified during reassem bly to assure proper retention of this
part.
CONTENTS
G eneral D escription..........................................................................................3B3-1
D iagnosis............................................................................................................ .3B3-2
M aintenance and A d ju stm e n ts.....................................................................3B3-10
On-V ehicle S erv ice.............................................................................. ............3B3-12
Power Steering G e a r ...................................................................................3B3-12
Power Steering P u m p ................................................................................ .3B3-13
Power Steering H oses................................................................................ .3B3-15
S p ecifications.................................................................................................... .3B3-15
Special T o o ls..................................................................................................... .3B3-15
GENERAL DESCRIPTION
The steering gear is of the recirculating ball type. This
gear provides for ease of handling by transm itting forces
from the w orm shaft to the pitm an shaft through the use of
ball bearings.
L IG H T T R U C K SE RV IC E M AN U AL
3B3-2 POWER STEERING SYSTEM
LIG H T T R U C K SERVIC E M A N U A L
POWER STEERING SYSTEM 3B3-3
Gear noise (“ hissing” sound) There is some noise in all power steer Do not replace valve unless “ hiss” is
ing systems. One of the most common extremely objectionable. Slight “ hiss”
is a hissing sound most evident at is normal and in no way affects steer
standstill parking. There is no relation ing. A replacement valve will also exhi
ship between this noise and perfor bit slight noise and is not always a cure
mance of the steering. “ Hiss” may be for the objection, investigate clearance
expected when steering wheel is at end around flexible coupling rivets. Be
of travel or when slowly turning at sure steering shaft and gear are aligned
standstill. so flexible coupling rotates in a Hat
plane and is not distorted as shaft ro
tates. Any metal-to-metal contacts
through flexible coupling will transmit
“hiss” into passenger compartment.
Also, check for proper sealing between
steering column and toe pan.
Rattle. Pressure hose touching other parts of Adjust hose position.
car.
Rattle or chuckle. Steering linkage looseness. Check linkage pivot points for wear.
Replace if necessary.
Groan. Air in the oil. Poor pressure hose Bleed system by operating steering
connection. from right to left full turn.
Check connections, torque to specs.
Growl. Excessive back pressure caused by Locate restriction and correct. Replace
hoses or steering gear, (restriction) part if necessary.
LIG H T T R U C K SERVIC E M A N U A L
3B3-4 POWER STEERING SYSTEM
Pump growl Scored pump pressure plates, thrust Replace affected parts, flush system.
Note: Most noticeable at full plate or rotor.
wheel travel and stand still parking
Extreme wear of pump cam ring. Replace affected parts.
Whine in pump Pump shaft bearing scored. Replace housingand shaft, flush system
Squawk in gear (not belt) D am per “ 0 ” ring on valve spool cut Replace “0 ” ring.
SY STE M O P E R A T IO N
Excessive wheel kick-back or loose Backlash in steering linkage. Adjust parts affected or replace worn
steering. parts.
Steering gear flexible coupling too Tighten flange pinch bolts to 30 foot
loose on shaft or rubber disc mounting pounds, if serrations are not damaged.
screws loose. Tighten upper flange to coupling nuts
to 20 foot-pounds.
Front wheel bearings incorrectly ad Adjust bearings or replace with new
justed or worn. parts as necessary.
Lower coupling flange rubbing against Loosen pinch bolt and assemble prop
steering gear adjuster plug. erly.
Tie rod pivots not centralized. Adjust tie rod ends as required to
center pivots.
L IG H T T R U C K SERVICE M A N U A L
POWER STEERING SYSTEM 3B3-5
Poor return of steering. (Cont’d.) Steering gear adjustments over Check adjustment with pitman arm
specifications. disconnected. Readjust if necessary.
Car leads to one side or the other. Front suspension misaligned Adjust to specifications.
(Keep in mind road condition and
wind. Test car on flat road going in Steering shaft rubbing ID of shift tube. Align column.
both directions)
Unbalanced or badly worn steering Replace valve.
gear valve.
Steering wheel surges or jerks when Loose pump belt. Adjust tension to specification.
turning with engine running especially
during parking. Sticky flow control valve. Inspect for varnish or damage, replace
if necessary.
Hard steering or lack of assist. High internal leakage. (Gear or pump) Check pump pressure. (See pump
pressure test).
L IG H T T R U C K SERVIC E M AN U AL
3B3-6 POWER STEERING SYSTEM
Steering gear adjusted too tight. Test steering system for binding with
front wheels off floor. Adjust as neces
sary.
Excessive friction in steering linkage. Check tie rod pivot points for exces
sive friction. Replace the affected
pivot.
Lower coupling flange rnbbing Loosen pinch bolt and assemble
against steering gear adjuster plug. properly.
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 do not reveal cause of
hard steering, diagnose hydraulic
system to determine problem.
Low oil pressure due to restriction in Check for kinks in hoses. Remove kink.
hoses:
Foreign object stuck in hose. Remove hoses and remove restricting
object or replace hose.
Low oil pressure due to steering gear: Pressure loss in cylinder due to Remove gear from car for disassembly
worn piston ring or scored housing and inspection of ring and housing
bore. bore. Replace affected parts.
Leakage at valve rings, valve body Remove gear from car for disassembly
to worm seal. and replace seals.
(See pump pressure test)
Loose fit of spool in valve body or Replace valve.
leaky valve body.
Damaged poppet valve. Replace valve.
L IG H T T R U C K SERVICE M A N U A L
POWER STEERING SYSTEM 3B3-7
Low oil pressure due to steering Loose belt. Adjust tension to specification
pump:
Low oil level. Fill reservoir to proper level.
(See pump pressure test.)
Air in the oil. Locate source of leak and correct.
Bleed system.
Scored pressure plate, thrust plate or Replace parts. (If rotor, replace with
rotor. rotating group kit), flush system
Foaming rmlky power steering Air in the fluid, and loss of Check for leak and correct. Bleed
fluid, low level and possible fluid due to internal pump system. Extremely cold temperatures
low pressure. leakage causing overflow. will cause system aeriation should
the oil level be low. If oil level
is correct and pump still foams,
remove pump from vehicle and
separate reservoir from housing.
Check welsh plug and housing for
cracks. If plug is loose or housing
is cracked, replace housing.
LIG H T TR U C K SE RV IC E M AN U AL
3B3-8 POWER STEERING SYSTEM
L IG H T T R U C K SE RV IC E M A N U A L
POWER STEERING SYSTEM 3B3-9
1. C H E C K O IL L E V E L IF L E A K A G E P E R S I S T S W IT H THE LEVEL
C O R R E C T A N D THE C A P TIGHT. R E P L A C E C AP.
2. C R A C K E D O R BENT R E S E R V O IR . R E P L A C E R E S E R V O IR .
3. R E P L A C E R E S E R V O IR " 0 " R IN G .
4. R E P L A C E FR O N T S E A L M A K E C E R T A IN TH AT D R I V E SH A F T IS
C LE A N A N D FREE OF P IT T IN G IN S E A L R ID E AREA.
9. R E P L A C E A D J U S T E R PL U G " 0 " R IN G S E A L
11. R E P L A C E A D J U S T E R PLUG S E A L S.
12. SE A T B A L L F L U S H W IT H P U N C H A N D R E ST A K E . IF S E E P A G E
P E R S IS T S . R E P L A C E H O U SIN G .
13. R E P L A C E BOTH P IT M A N SH A F T S E A L S.
16. R E P L A C E D U S T S E A L A N D P IT M A N SH A F T S E A L
L IG H T TR UC K SE RV IC E M AN U AL
3B3-10 POWER STEERING SYSTEM
LIG H T TR UC K SE RV IC E M AN U AL
POWER STEERING SYSTEM 3B3-11
m aintained approxim ately 1/2 to 1 inch from top with HYDRAULIC SYSTEM CHECKS
wheels in full left turn position.
The following procedure outlines methods to identify
2. Fill, if necessary, to proper level w ith G M Power
and isolate power steering hydraulic circuit difficulties. The
Steering Fluid or equivalent.
test provides means of determ ining whether power steering
NOTICE: N ever use brake fluid in the power steering system hydraulic parts are actually faulty. This test will
pum p, or dam age may occur. result in readings indicating faulty hydraulic operation, and
will help to identify the faulty component.
BLEEDING HYDRAULIC SYSTEM Before perform ing hydraulic circuit test, carefully
1. Fill oil reservoir to proper level and let oil remain check belt tension, fluid level and condition of driving pulley.
undisturbed for at least two minutes.
2. S ta rt engine and run only for about two seconds. Power Steering System Test
3. Add oil if necessary.
4. R epeat above procedure until oil level rem ains constant Engine m ust be at norm al operating tem p e ra tu re.
after running engine. Inflate front tires to correct pressure. All tests are made with
5. Raise front end of vehicle so th at wheels are off the engine idling, check idle adjustm ent and if necessary adjust
ground. engine idle speed to correct specifications listed in Section
6. Increase engine speed to approxim ately 1500 rpm. 6C and proceed as follows:
7. T urn the wheels (off ground) right and left, lightly 1. W ith engine N O T runnning disconnect pressure hose
contacting the wheel stops. from pum p and install Tool J-5176 using a spare
8. A dd oil if necessary. pressure hose between gauge and pump. G auge must be
between shut-off valve and pump (Fig. 3B3-12), Open
9. Lower the vehicle and turn wheels right and left on the
ground. shut-off valve. *
10. C heck oil level and refill as required. 2. Remove filler cap from pump reservoir and check fluid
level. Fill pump reservoir to full m ark on dip stick. S tart
11. If oil is extrem ely foamy, allow vehicle to stand a few
engine and, m om entarily holding steering wheel
m inutes with engine off and repeat above procedure.
against stop, check connections at Tool J-5176 for
a. C heck belt tightness and check for a bent or loose leakage.
pulley. (Pulley should not wobble with engine
3. Bleed system as outlined under M aintenance and
running.)
A djustm ents.
b. Check to m ake sure hoses are not touching any other
4. Insert therm om eter (Tool J-5421) in reservoir filler
parts of the truck, particularly sheet m etal except
opening. Move steering wheel from stop to stop several
where design calls for a clam p.
times until therm om eter indicates that hydraulic fluid
c. Check oil level, filling to proper level if necessary, in reservoir has reached tem perature of 150° to 170°F.
following operations 1 through 10. This step and
Step " d " are extrem ely im portant as low oil level NOTICE: To prevent scrubbing flat spots on tires, do not
an d /o r air in the oil are the most frequent causes of turn steering wheel more than five times without rolling
objectional pump noise. vehicle to change tire-to-floor contact area.
d. C heck the presence of air in the oil. If air is present, 5. S ta rt engine and check fluid level adding any fluid if
attem p t to bleed system as described in operations 1 required. W hen engine is at norm al operating tem pera
through 10. If it becomes obvious th at the pum p will ture, the initial pressure read on the gage (valve open)
not bleed after a few trials, proceed as outlined under should be in the 80-125 PSI range. Should this pressure
H ydraulic System Checks. be in excess of 200 PSI - check the hoses for restrictions
and the poppet valve for proper assembly.
B E L T T E N S IO N
P R E SSU R E HOSE TO
NEW 350 N Max. 620 N Max. 750 N Max. P R E SSU R E HOSE
P /S G E A R
BELT 80 Lbs. Max. 140 Lbs. Max. 165 Lbs. Max. FRO M PU M P
L IG H T T R U C K SE RV IC E M AN U AL
3B3-12 POWER STEERING SYSTEM
6. Close gate valve fully 3 times. Record the highest c. If the pressures recorded are constant, but more than
pressures attained each time. 100 PSI, below the low listed spec., replace the flow
NOTICE: Do not leave valve fully closed for more than 5 control valve and recheck. If the pressures are still
seconds as the pump could be dam aged internally. low, replace the rotating group in the pump.
a. If the pressures recorded are within the listed specs 7. If the pump checks within specifications, leave the
and the range of readings are within 50 PSI, the valve open and turn (or have turned) the steering wheel
pump is functioning within specs. (Ex. Spec. 1250 - into both corners. Record the highest pressures and
1350 P S I-re a d in g s - 1270- 1275- 1280). com pare with the m axim um pum p pressures and
b. If the pressures recorded are high, but do not repeat com pare with the maximum pump pressure recorded.
within 50 PSI, the flow controlling valve is sticking. If this pressure cannot be built in either (or one) side of
Remove the valve, clean it and remove any burrs the gear, the gear is leaking internally and must be
using crocus cloth or fine hone. If the system contains disassembled and repaired. See the current Overhaul
some dirt, flush it. If it is exceptionally dirty, both the M anual.
pum p and the gear m ust be completely disassembled, 8. S hut off engine, remove testing gauge, spare hose,
cleaned, flushed and reassem bled before fu rth er reconnect pressure hose, check fluid level an d /o r make
usage. needed repairs.
ON-VEHICLE SERVICE
POWER STEERING GEAR Installation (Fig. 3B3-14)
NOTICE: See N O T IC E on page 1 of this section
Removal regarding the fasteners referred to in steps 1 ,3 ,4 and 5.
1. Install the flexible coupling onto the steering gear stub
1. D isconnect hoses at gear. W hen hoses are discon
shaft, aligning the flat in the coupling with the flat on
nected, secure ends in raised position ot prevent
the shaft. Push the coupling onto the shaft until the
drainage of oil. C ap or tape the ends of the hoses to
stub sh aft bottom s on the coupling reinforcem ent.
prevent entrance of dirt.
Install the pinch bolt and torque to specifications.
2. Install two plugs in gear fittings to prevent entrance of
dirt. NOTICE: The coupling bolt m ust pass through the shaft
undercut, or dam age to the components could occur.
3. Remove the flexible coupling to steering shaft flange
bolts (G, C and K models) or the lower universal joint 2. Place the steering gear in position, guiding the coupling
bolt into the steering shaft flange.
pinch bolt (P models). M ark the relationship of the
universal yoke to the stub shaft. 3. Install the steering gear to fram e bolts and torque to
4. M ark the relationship of the pitm an arm to the pitm an specifications.
shaft. Remove the pitm an shaft nut or pitm an arm 4. If flexible coupling alignm ent pin plastic spacers were
pinch bolt and then remove the pitm an arm from the used, make sure they are buttom ed on the pins, tighten
pitm an shaft using Puller J-6632 (Fig. 3B3-13). the flange bolt nuts to specifications and then remove
5. Remove the steering gear to fram e bolts and remove the plastic spacers.
the gear assembly. 5. If flexible coupling alignm ent pin plastic spacers were
6. G, C and K Models - Remove the flexible coupling not used, center the pins in the slots in the steering shaft
pinch bolt and remove the coupling from the steering flange and then install and torque the flange bolt nuts to
gear stub shaft. specifications.
TOOL—J-5504
TO OL—J-6632
L IG H T TR U C K SE RV IC E M A N U A L
POWER STEERING SYSTEM 3B3-13
LIG H T T R U C K SERVICE M AN U AL
3B3-14 POWER STEERING SYSTEM
Fig. 3 B 3 -1 7 --P /S Pump M o un tin g; C K 1 0 0 , C K 2 0 0 , Fig. 3 B 3 -2 0 --P /S Pump m ounting; C K 1 0 0 (03) with
C K 3 0 0 - LE4, LG 9, LS9, LT9 (Exc. C 60, JB8) I F9 Enaine
Fig. 3 B 3 -1 9 --P /S Pump M o u n tin g; C l 00, C 2 0 0 , C 3 0 0 Fig. 3 B 3 -2 2 --P /S Pump M oun tin g; G 1 0 0 , G 2 0 0 ,
with LE8 Engine G 3 0 0 - LE4, LF4, LG9, LS9, LT9
L IG H T T R U C K SE RV IC E M A N U A L
POWER STEERING SYSTEM 3B3-15
Fig. 3 B 3 -2 3 --P /S Pump M o u n tin g; P200, P300 (42) Fig. 3 B 3 -2 6 --P /S Pump M o un tin g; P300 (32) with LE8
with L25 Engine Engine
LIG H T T R U C K SE RV IC E M AN U AL
3B3-16 POWER STEERING SYSTEM
LIG H T TR U C K SE R V IC E M A N U A L
POWER STEERING SYSTEM 3B3-17
L IG H T T R U C K SERVICE M AN U AL
3B3-18 POWER STEERING SYSTEM
Fig. 3 B 3 - 3 9 - P / S Hose Routing; P200, P300 (42) with Fig. 3 B 3 -4 1 --P /S Hose Routing; P 300 (32) with LT9
L25 Engine an d JB7 Engine
Fig. 3 B 3 -4 0 --P /S H ose Routing; P200, P300 (42) with Fig. 3 B 3 -4 2 --P /S Hose Routing;P300 (32) with LE8
LT9 Engine an d JB7 Engine
L IG H T TR U C K SE R V IC E M A N U A L
STEERING C O L U M N S 3B4-1
SECTION 3B4
STEERING COLUMNS
The following notice applies to one or more steps in the assembly
procedure o f com ponents in this portion of the m anual as indicated at
appropriate locations by the term inology "See Notice on page 1 of this
Section".
NOTICE: This fastener is an im portant attaching part in th at it
could affect the perform ance of vital com ponents and systems, a n d /o r
could result in m ajor repair expense. It m ust be replaced w ith one of the
same part num ber or w ith an equivalent part if replacem ent becomes
necessary. D o not use a replacem ent part of lesser quality or substitute
design. T orque values m ust be used as specified during reassembly to
assure proper retention of this part.
CONTENTS
GENERAL DESCRIPTION
L IGHT T R U C K SE R V IC E M A N U A L
3B4-2 STEERING C O L U M N S
DIAGNOSIS
SU RFA CE “A’
Instrument Panel Bracket Capsule Damage
LIG H T T R U C K SE R V IC E M A N U A L
STEERING C O L U M N S 3B4-5
Cause Solution
H. D is to rte d c o u p lin g slo t in r a c k ( tilt) . H. Replace rack.
B. Any high effo rt condition. B. Check item s under high effo rt section.
Cause Solution
A. Defective fuse in “ accessory” circuit. A. Replace fuse.
LIGHT TRU C K SE R V IC E M A N U A L
3B4-6 STEERING C O L U M N S
NOISE IN COLUMN
Cause Solution
A. C oupling b o lts loose. A. T ighten pinch b o lts to specified torque.
B. C olum n n o t c o rrectly aligned. B. Realign colum n.
C. C oupling pulled apart. C. Replace coupling and realign colum n.
D. Sheared in term ed iate shaft plastic jo in t; D. Replace or repair steering shaft and realign colum n.
E. H orn c o n ta ct ring not lubricated. E. L ubricate w ith lubriplate.
LIGHT TR U C K SE R V IC E M A N U A L
STEERING C O L U M N S 3B4-7
Cause Solution
A. Colum n assem bly m isaligned in vehicle. A. Realign.
B. Im properly installed or deform ed dust seal. B. Remove and replace.
C. Tight or frozen upper or lower bearing. C. Replace affected bearing or bearings.
D. Flash on l.D. o f shift tube from plastic join t. D. Replace shift tube.
M ISCELLANEOUS
Cause Solution
A. Housing loose on jack et - will be noticed w ith ignition in A. Tighten four m ounting screws - (60 in. lbs.)
“ O ff-L ock” and a torque applied to the steering wheel.
B. Shroud loose on shift bowl. B. Bend tabs on shroud over lugs on bowl.
LIGHT T R U C K SER V IC E M A N U A L
3B4-8 STEERING C O L U M N S
M A N U A L T R A N S M IS S IO N COLUM NS
G E N E R A L INFORMATION
All of the preceding diagnosis information for autom atic transmission will apply to the manual transmission. The following
information is supplied in addition to and specifically for manual transmission columns.
D R I V E R C A N L O C K S T E E R IN G IN
SECO N D G EA R
Cause Solution
A. Defective upper shift lever. A. Replace shift lever.
B. Defective shift lever gate. B. Replace shift lever gate.
C. Loose relay lever on shift tube. C. Replace shift tube assembly.
LIGHT T R U C K SE R V IC E M A N U A L
STEERING C O L U M N S 3B4-9
TILT COLUMNS
GENERAL INFORMATION
All of the preceding diagnosis will generally apply to tilt columns. The following is supplied in
addition to and specifically for tilt columns.
HOUSING SCRAPING ON BOWL
Cause Solution
A. Bowl bent or not concentric with hub. A. Replace bowl.
Cause Solution
A. Excessive clearance betw een holes in support or housing A. Replace either or both .
and pivot pin diameters.
B. Defective or missing anti-lash spring in spheres. B. Add spring or replace both.
C. Upper bearing seat not seating in bearing. C. Replace both.
D. Upper bearing inner race seat missing. D. install seat.
F. Loose support screws. F. Tighten to 60 in. lbs.
A. Loose fit between shoe and shoe pivot pin. A. Replace both.
Cause Solution
A. Pivot pins are b ou n d up. A. Replace pivot pins.
B. Wheel tilt spring is defective. B. Replace tilt spring.
LIGHT T R U C K SE R V IC E M A N U A L
3B4-10 STEERING C O L U M N S
Electrical
Chassis Electrical
The most com m on tu rn signal system problems are
generally electrical and may easily, be fixed by the
replacem ent of fuses, bulbs, or flashers .
First m ake these checks and replace any non-operative
components.
1. Check fuses (Figure 3B4-9). Replace if blown. If
new fuse blows, replace flasher in system. (There are 2
flashers in the signal switch system. The hazard warning
flasher and tu rn signal flasher are located on the fuse block.
2. C heck for secure connection at the chassis to switch
connector. T his is the harm onica connector on the colum n
(Figure 3B4-10). Secure if loose. Check all individual wire
terminals for proper seating in the connector bodies.
Terminals should be locked in place.
3. Depress hazard w arning button and check all lights Fig. 3 B 4 -1 1 -C h e c k in g Hazard W arn ing Flasher
in signal switch system. Replace any which do not work.
LIGHT T R U C K SE R V IC E M A N U A L
STEERING C O L U M N S 3B4-11
LIGHT T R U C K SER V IC E M A N U A L
3B4-12 STEERING C O L U M N S
LIGHT TR U C K S E R V IC E M A N U A L
STEERING C O L U M N S 3B4-13
LIGHT T R U C K SE R V IC E M A N U A L
3B4-14 STEERING COLUMNS
Stop light not on when A. Burned out fuse A. Replace fuse and
turn indicated check operation
B. Loose column to B. Connect securely and
chassis connection check operation
C. Disconnect column to C. Replace signal switch
chassis connector.
Connect new switch
into system without
removing old. Operate
switch by hand.
If brake lights work
with switch in the
turn position, signal
switch is defective
D. If brake lights do not D. Repair connector to
work check connector stop light circuits
to stop light sockets using manual as guide.
for grounds, opens,
etc.
LIGHT TR U C K SE R V IC E M A N U A L
STEERING C O L U M N S 3B4-15
LIGHT TRU C K SE R V IC E M A N U A L
3B4-16 STEERING C O L U M N S
LIGHT T R U C K SE R V IC E M A N U A L
STEERING C O L U M N S 3B4-17
Fig. 3 B 4 -1 9 ~ S h ift Tube A djustm ent-3 Speed M an u al Fig. 3 B 4 -2 0 --S h ift Tube A d justm ent-A utom atic Transm ission
Transm ission
LIGHT TR U C K SER V IC E M A N U A L
3B4-18 STEERING C O L U M N S
ON-VEHICLE SERVICE
INDEX
CAPTURING
STRAP
COUPLING TO
STEERING SHAFT
FLANGE BOLTS
LIGHT T R U C K 8E RV ICE M A N U A L
STEERING C O L U M N S 3B4-19
BEARING
OW ER BLOCKS COVER BOLT
SNAP
RING
ft I
UPPER
SHAFT
CLAMP
TENSION NUT
QDD IKJn
LIGHT T R U C K SE R V IC E M A N U A L
STEERING C O L U M N S 3B4-21
Fig. 3B 4 -2 8 ~ R e m o v in g Directional Signal Sw itch Assem bly Fig. 3 B 4 -3 0 -ln s ta llin g Snap Ring
LOCK CYLINDER
The lock cylinder is located on the upper right hand
Fig. 3B4-29-lnstalling Switch Connector Onto Jacket Clips side of the column. The lock cylinder should be removed
in the "R U N " position only.
LIGHT T R U C K SER V IC E M A N U A L
3B4-22 STEERING C O L U M N S
DISASSEMBLE ASSEMBLE
1. Place lock in “run”. 1. Rotate as shown, align cylinder key with keyway in housing.
2. Remove lock plate, turn signal switch and buzzer switch (see 2. Push lock all the way in.
service manual.)
3. Install screw. Tighten to 4.5 N*m for regular columns-
3. Remove screw & lock cylinder. CAUTION: If screw is dropped 2.5 N*m for adjustable columns.
on removal, it could fall into the column, requiring complete
disassembly to retrieve the screw.
LOCK
CYLINDER To-assemble — Rotate to
SET stop while holding cylinder.
HOUSING
CYLINDER KEY
LIGHT T R U C K SE R V IC E M A N U A L
STEERING C OLU M NS 3B4-25
LIGHT TR U C K SE R V IC E M A N U A L
3B4-26 S TE E RI NG C O L U M N S
LIGHT T R U C K SE R V IC E M A N U A L
STEERING C O L U M N S 3B4-27
LIGHT T R U C K SE R V IC E M A N U A L
3B4-28 STEERING C O L U M N S
SHIFT GATE
RACK
LOCK BOLT
LOCK BOLT
SPRING
THRUST
CUP SECTOR
Fig. 3 B 4 -4 4 -R e m o v in g Ignition Sw itch A c tuator Sector Fig. 3 B 4 -4 6 -ln s ta llin g Rack Preload Spring
14. Slide the steering shaft into the colum n and install
the upper bearing thrust washer.
16. Install the shift lever and shift lever pivot pin.
LIGHT TR U C K SE R V IC E M A N U A L
STEERING C O L U M N S 3B4-29
_IVIAAOI I
A. TO REDUCE CLEARANCE .M A S T JACKET A. TO REDUCE CLEARANCE
SLIDE THE CLAMPING -2 -3 SHIFT LEVER
SLIDE THE CLAMPING
SC REW S AROUND THE .2 -3 SHIFT LEVER SC R EW S AROUND THE -PICK UP LEVER
M A S T JACKET IN THE .PICK UP LEVER M A ST JACKET IN THE
DIRECTION OF ARROW A. DIRECTION OF ARROW A.
1 ST-REV.
B. TO INCREASE CLEARANCE SHIFT LEVER B. TO INCREASE CLEARANCE
SLIDE THE CLAMPING SLIDE THE CLAMPING
SC R EW S AROUND THE SC R EW S AROUND THE ALIGNMENT
M A S T JACKET IN THE M A S T JAC KET IN THE LEVER
DIRECTION OF ARROW B. DIRECTION OF ARROW B.
“I ,-n . , -. < v
Disassembly-Tilt Columns (Fig. 3B4-49) 6. Install the tilt release lever and place the colum n in
the full "up" position. Remove the tilt lever spring retainer
Steps 3-14 m ay be perform ed w ith the steering colum n
using a # 3 phillips screwdriver that just fits into the slot
in the vehicle.
opening. Insert the phillips screwdriver in the slot, press in
1. Remove the four screws retaining the dash approxim ately 3 /1 6 ", turn approximately 1/8 tu rn
m ounting bracket to the colum n and set the bracket aside counterclockwise until the ears align with the grooves in the
to protect the breakaw ay capsules. housing and remove the retainer, spring and guide (Fig.
2. M ount the colum n in a vise using both weld nuts 3B4-50).
o f either Set A or B as shown in Figure 3B4-41. The vise 7. Remove the pot joint to steering shaft clam p bolt
jaw s m ust clamp onto the sides of the weld nuts indicated and remove the interm ediate shaft and pot joint assembly.
by arrow s shown on Set B.
Push the upper steering shaft in sufficiently to remove
the steering shaft upper bearing inner race and seat. Pry off
NOTICE: D o not place the colum n in a vise by the lower bearing retainer clip and remove the bearing
clam ping onto only one weld nut, by clam ping onto one reinforcement, bearing and bearing adapter assembly from
weld n u t of both Sets A and B or by clam ping onto the the lower end of the m ast jacket.
sides not indicated by arrows, since dam age to the
8. Remove the upper bearing housing pivot pins using
colum n could result.
Tool J-2 1854-1 (Fig. 3B4-51).
9. Install the tilt release lever and disengage the lock
3. Remove the directional signal switch, lock cylinder
shoes. Remove the bearing housing by pulling upward to
and ignition switch as outlined previously in this section.
extend the rack full down, and then moving the housing to
4. Remove the tilt release lever. Drive out the shift the left to disengage the ignition switch rack from the
lever pivot pin and remove the shift lever from the housing. actuator rod.
5. Rem ove the three tu rn signal housing screws and 10. Remove the steering shaft assembly from the upper
remove the housing. end of the column.
LIGHT T R U C K SE R V IC E M A N U A L
3B4-30 STEERING C O L U M N S
LIGHT T R U C K SE R V IC E M A N U A L
STEERING C O L U M N S 3B4-31
LIGHT T R U C K SE R V IC E M A N U A L
3B4-32 STEERING C O L U M N S
11. Disassemble the steering shaft by rem oving the 16. Remove the bearing housing support lock plate by
centering spheres and the anti-lash spring. sliding it out of the jacket notches, tipping it down tow ard
12. Rem ove the transm ission indicator wire, if so the housing hub at the 12 o’clock position and sliding it
equipped. under the jacket opening. Remove the wave washer.
13. Remove the four steering shaft bearing housing 17. All Columns - Remove the shift lever housing
support to gearshift housing screws and remove the bearing from the m ast jacket (transm ission control lock tube
housing support. Remove the ignition switch actuator rod. housing on floor shift models). Remove the shift lever spring
14. Remove the shift tube retaining ring w ith a by winding the spring up with pliers and pulling it out. On
screwdriver and then remove the th ru st washer. floor shift models, remove the spring plunger.
15. Install Tool J-23072 into the lock plate, m aking sure 18. Disassemble the bearing housing as follows:
that the tool screws have good thread engagement in the a. Remove the tilt lever opening shield.
lock plate. Then, turning the center screw clockwise, force b. Remove the lock bolt spring by removing the
the shift tube from the housing (Fig. 3B4-52). Remove the retaining screw and moving the spring clockwise to remove
shift tube (transm ission control lock tube on floor shift it from the bolt (Fig. 3B4-53).
models) from the lower end o f the m ast jacket. Remove Tool c. Remove the snap ring from the sector drive shaft.
J-23072. W ith a small punch, lightly tap the drive shaft from the
sector (Fig. 3B4-54). Remove the drive shaft, sector and
NOTICE: W hen rem oving the shift tube, be sure to lock bolt. Remove the rack and rack spring.
guide the lower end through the slotted opening in the d. Remove the tilt release lever pin with a punch and
m ast jacket. If the tube is allowed to interfere w ith the ham m er. Remove the lever and release lever spring. To
jacket in any way, dam age to the tube and jacket could relieve the load on the release lever, hold the shoes inward
result. and wedge a block between the top of the shoes (over slots)
Fig. 3B4-51--Removing Bearing Housing Pivot Pins Fig. 3B4-53--Replacing Lock Bolt Spring
LIGHT TR U C K SE R V IC E M A N U A L
STEERING C O L U M N S 3B4-33
SHIFT BOWL
J 2 3 0 7 3 -3
J 23073 4
LO C K
PLATE
W AVEn
J 23 07 3-1
W ASH ER
J 2 3 0 7 3 -2
FLAT
W ASHER
UPPER SHIFT TUBE
Fig. 3B4-55—Installing Lock Bolt and Rack Assemblies Fig. 3B4-57—Installing Shift Tube
LIGHT TRU C K SE R V IC E M A N U A L
3B4-34 STEERING C O L U M N S
LIGHT T R U C K SE R V IC E M A N U A L
3B4-36 STEERING C O L U M N S
BEARING
Installation
NOTICE: T he bolt m ust pass through the shaft may cause sticky or binding bearings when
undercut,or dam age m ay occur to the components. reassembled.
3. Place the steering gear into position, guiding the 5. Remove seal clamp and slide seal off end of shaft.
flexible coupling bolts into the proper holes in the steering
Assembly
shaft flange.
4. Install and tighten the steering gear to fram e bolts. 1. Be sure all parts are free of dirt. Slide seal onto
steering shaft. W ith lip of seal against step in shaft clamp
5. Install the coupling to flange bolt nuts and washers
seal.
and torque to specifications. Be sure to m aintain a coupling
to flange dim ension o f .250" to .375". The coupling 2. Press pin back into shaft from cham fered side.
alignm ent pins should be centered in the flange slots. Locate pin in shaft using scribe m ark as reference.
STEERING COLUMN UPPER BEARING-G AND 2. Pry out the lower bearing assembly.
P SERIES Installation
Standard Column
NOTICE: See N O T IC E not on page 1 of this section
Removal regarding fasteners referred to in step 2.
1. Remove steering wheel as outlined in this section.
2. Rem ove directional signal cancelling cam. 1. Place the new bearing over the end of the steering
shaft and press into position in the column.
3. Pry out upper bearing.
2. Install the preload spring and clam p and torque the
Installation clam p bolt nut to specifications. Refer to "Bearing
A djustm ent" in "M aintenance and A djustm ent Section.
NOTICE: See N O T IC E on page 1 o f this section Reinstall the interm ediate shaft and universal joint assembly
regarding the fasteners referred to in step 1. as outlined under "Interm ediate Steering Shaft with
Universal Joint Couplings - Installation".
1. Replace all com ponent parts in reverse order of TILT COLUMN BEARING HOUSING ASSEMBLY
rem oval m aking sure th at directional switch is in neutral
position before installing steering wheel. Torque steering
- G AND P SERIES
wheel nut to specifications. Removal (Column in Vehicle)
1. D isconnect the battery ground cable.
Tilt Column 2. Remove the steering wheel as outlined under
The upper bearings on the tilt colum n are spun into the "Steering Wheel - Removal".
bearing housing assembly. I f the bearings indicate need of 3. Remove the directional signal switch as outlined
replacement, the entire bearing housing m ust be replaced. under "D irectional Signal Switch - Rem oval".
See "Tilt Steering C olum n - D isassembly and Assembly" for 4. Column Shift Models - Using a suitable size
the correct replacem ent procedure. punch, drive out the shift lever pivot pin and remove the
STEERING COLUMN LOWER BEARING P shift lever.
SERIES 5. Install the tilt release lever and place the column in
the full "up" position. Remove the tilt lever spring and
Removal retainer using a screwdriver that just fits into the slot
1. Remove the interm ediate steering shaft and opening. Insert the screw driver into the slot, push in
universal jo in t assembly as outlined earlier in this section. approxim ately 3/16", rotate clockwise approxim ately 1/8
Remove the preload spring clam p and spring from the end tu rn until the retainer ears align with the grooves in the
o f the steering shaft. housing and remove the retainer and spring.
LIGHT T R U C K SE R V IC E M A N U A L
STEERING C O L U M N S 3B4-39
6. Remove the steering shaft bearing locknut using 4. Assemble the bearing housing as follows:
Socket J-22599. Rem ove the upper bearing race seat and a. Press the new upper and lower bearing races into
race. the bearing housing.
7. Remove the two bearing housing pivot pins using b. Lubricate and install the bearings into the bearing
Tool J -2 1854. races.
8. Pull up on the tilt release lever (to disengage the lock c. Place the lock shoe springs in position in the housing.
shoes) and remove the bearing housing. Install each shoe in place and compress the spring until a
If the bearing housing is being replaced or it is suitable size straight punch can be used to hold the shoe in
necessary to disassemble the bearing housing, proceed as position (it may be necessary to acquire assistance to install
follows: the shoes). Once the shoes are in place, drive in the shoe
retaining pin.
a. Press the upper and lower bearings out of the
housing. d. Install the shoe release lever and drive in the pivot
pin.
b. Using Puller J-5822 and Slide H am m er J-2619, pull
the bearing races from the housing. e. Install the tilt release lever.
c. Remove the tilt release lever. f. Lubricate the shoes and release lever.
d. Drive out the shoe release pivot pin using Tool J- 5. Install the bearing housing assembly to the support.
22635 or a suitable punch. Rem ove the lever spring and Hold the tilt release lever in the "up" position until the shoes
have fully engaged the support. Lubricate and install the
remove the wedge.
bearing housing pivot pins. Press the pins in flush with the
e. Using a suitable size punch, drive out the lock shoe housing.
retaining pin. Remove the shoes and shoe springs.
6. Place the housing in the full "up" position and then
If the upper steering shaft, lower steering shaft, or install tilt spring and retainer (tapered end of spring first).
centering spheres are being removed, proceed as follows: Push into the housing approxim ately 3/16" and rotate
9. To rem ove the steering shaft assembly through the counterclockwise 1/8 turn.
upper end of the colum n. If it is necessary to disassemble 7. Lubricate and install the upper bearing race, race
the shaft, proceed as follows: seat and locknut. Tighten the locknut (using Socket J-
a. To remove the lower steering shaft first disconnect 22599) to remove the lash and then carefully further tighten
the shaft at the pot jo in t coupling clamp. 1/16 to 1/8 of a turn (column m ust be in straight ahead
b. T u rn the upper shaft 90° to the lower shaft and slide position).
the upper shaft and centering spheres from the lower shaft. 8. Remove the tilt release lever.
c. R otate the centering spheres 90° and remove the 9. Install the directional signal switch as outlined
centering spheres and preload spring from the upper shaft. under "D irectional Signal Switch - Installation".
LIGHT T R U C K SE R V IC E M A N U A L
3B4-40 STEERING C O L U M N S
DIRECTIONAL
SIGNAL SWITCH
10. C olum n Shift M odels - Install the shift lever and 5. Pry the wiring harness protector out of the colum n
pivot pin. retaining slots as shown in Figure 3B4-68.
11. Install the steering wheel as outlined under 6. M ark the location of each wire in the half-moon
"Steering W heel - Installation". connector and then remove each individual wire from the
connector using Tool J-22727 (Fig. 3B4-69). Insert the tool
12. Check electrical and m echanical functioning of
column. into the lower end of the connector and push in until the
tool bottom s on the connector. Remove the tool and then
DIRECTIONAL SIGNAL SWITCH pull the wire from the connector.
7. Remove the directional signal lever screw and
If the directional signal switch m ust be replaced, the
remove the lever.
steering colum n does not have to be removed from the
vehicle. 8. Push in on the hazard w arning light knob and then
unscrew and remove the knob.
Removal 9. Tilt Columns Only
1. Remove the steering wheel as outlined under a. A utom atic Transm ission M odels - Remove the
"Steering W heel - Rem oval". P R N D L dial screws and remove the dial and indicator
needle. Remove the cap and dial illum ination bulb from the
2. Rem ove the directional signal switch cancelling cam
housing cover.
and spring.
b. Unscrew and remove the tilt release lever.
3. Rem ove the colum n to instrum ent panel trim plate c. Assemble Tool J-22708 inside the directional signal
(if so equipped). housing cover; push in until the tangs lock inside the cover
4. D isconnect the directional signal switch wiring flange (Fig. 3B4-70). T urn the tool center screw clockwise
harness at the half-m oon connector. to pull the cover from the housing.
J -2 2 7 0 8
Fig. 3B4-68--Removing Wiring Harness Protector Fig. 3B4-70--Removing Directional Signal Housing Cover
LIGHT T R U C K SE R V IC E M A N U A L
STEERING C O L U M N S 3B4-41
out the lower end of the shift lever housing and under the
dash seal.
2. Place the directional signal switch in position and
install the three m ounting screws; torque to 25 lbs. in. after
screw head has been firmly seated.
3. Tilt Columns Only-
a. Align the openings in the directional signal switch
cover with the proper lever positions and tap the cover into
place using a plastic ham m er.
b. Install the tilt release lever.
c. A utom atic Transm ission M odel - Install the
P R N D L dial, pointer, dial illum ination bulb and cap.
4. Install the directional signal switch lever and hazard
warning knob.
5. Bend the wire retaining tabs slightly outw ard on
each wire in the wiring harness as shown in Figure 3B4-71;
this will provide proper retention of the wire in the half
moon connector.
10. Remove the three directional signal switch 6. Install each wire in its m arked location in the half
m ounting screws and then carefully remove the switch moon connector. Push in until square p art of clip is flush
assembly from the colum n while guiding the wiring harness with the bottom side of the connector. Connect the
through the opening in the shift lever housing. directional signal switch wiring harness.
NOTICE: See N O T IC E on page 1 o f this section 8. Install the directional signal cancelling cam and
regarding the fasteners referred to in step 9. spring.
9. Install the steering wheel as outlined under
1. W rap the ends of the directional signal switch wires "Steering W heel - Installation".
w ith tape and then guide them through the opening at the 10. Install the colum n to instrum ent panel trim plate
lower left hand side o f the bearing housing (tilt colum ns) (if so equipped).
STEERING COLUMN G AND P SERIES 8. Remove the cap screws from the colum n support
bracket at the dash panel.
Removal 9. Carefully lower and then w ithdraw the colum n
1. D isconnect the battery ground cable. assembly, rotating so th at the shift levers clear the toe pan
2. Colum n Shift M odels - D isconnect transm ission opening.
shifter rods at the lower end o f the column. Disassembly of Standard Column (Fig. 3B4-74)
3. G Models - Rem ove the interm ediate steering F o r floor shift transm ission models, om it Steps 4, 14,
shaft flange to flexible coupling bolts. 15 and 16.
P Models - Rem ove the interm ediate steering shaft 1. Rem ove the steering wheel nut and lock w asher and
upper universal yoke to steering shaft pinch bolt. M ark the then slide the steering shaft assembly from the lower end
coupling to shaft relationship. of the column.
4. Remove colum n clam p screw(s) on engine side of 2. G M odels - Remove the lower bearing preload
firewall, if equipped, and remove or slide the clam p down spring and clam p from the steering shaft.
the column. P M odels - Rem ove the lower bearing preload spring
5. F rom inside the vehicle, remove the screws from the and clamp.
toe pan cover and slide the cover and seal up the column. 3. Rem ove the back-up lamp switch.
6. Remove the steering wheel as outlined under 4. D rive out the shift lever pivot pin and remove the
"Steering W heel-Rem oval", and reinstall the shaft n ut and shift lever.
washer. 5. Remove the directional signal cancelling cam.
7. All Colum ns - D isconnect the directional signal Remove the directional signal switch lever.
wiring harness. Standard Colum n with A utom atic 6. Remove the colum n wiring harness cover.
Transm ission - D isconnect the conductor tube (for 7. Remove the directional signal switch screws.
transm ission indicator) at the instrum ent panel. 8. R otate the directional signal switch housing
T ilt Colum n w ith A utom atic Transm ission counterclockwise and remove the housing from the column.
D isconnect the single w ire at the fuse block and unclip it The housing and switch cannot be fully removed from the
from the parking brake bracket. colum n until the shift lever housing is removed.
LIGHT T R U C K SE R V IC E M A N U A L
3B4-42 STEERING C O L U M N S
9. Remove the plastic th ru st w asher assembly and then remove the shift lever housing (or extension housing) from
LIG HT T R U C K SE R V IC E M A N U A L
STEERING C OLUM NS 3B4-43
1. Upper Steering Shaft 13. Shift Tube Felt Washer 25. Turn Sigial Sw itch Screw
2. Shiff Housing.Sushing 14. Shift Tube Assembly 26. Turn Signal Switch
3. Bushing Seat 15. Shift Lever Spacer 27. Steering Shaft Upper Bearing
4. Mast Jacket 16. lst-Reverse Shift Lever 28. Switch Contact Support
5. Column Cover 17. Adjusting Ring 29. Turn Signal Housing
6. B ack-Up Lamp Sw itch Screw 18. Shaft Lower Bearing 30. Turn Signal Switch Lever Screw
7. Back-Up Lamp Switch 19. Lower Bearing Preload Spring 31. Turn Signal Sw itch Lever
8 . Toe Pan Seal Retainer 20. Preload Spring Clam p 32. R u b b e rin g
9. Toe Pan Seal 21. N u t and Lockwasher 33. Plastic 'hrust Washer
10. Adjusting Ring Clam p Screws 22. Steering Shaft N u t 34. Shift Lever Housing
1 1. N u t and Lockwasher 23. Lockwasher 35. Shift Lever Pin
12. Adjusting Ring Clam p Bolt 24. Torn Signal C a n cellin g Cam 36. Shift Lever
A utom atic C olum ns - Remove the selector plate 2. Lubricate all bearing surfaces on the shift tube.
clam ping ring screws (3). 3. Place the felt seal onto the shift tube (next to spring)
15. Place the colum n upright on the floor, supporting and then place the shift tube in the jacket.
it with two pieces o f wood. Place a block of wood on the 4. 3-Speed C olum ns - Temporarily install spacer, 1st-
upper end o f the shift tube. Press down on the shift lever reverse shift lever and lower adjusting ring. Place a block
with foot while tapping on the wood block to w ithdraw the of wood on top of the adjusting ring and tap until the shift
tube from the colum n jacket. tube bottom s. Remove adjusting ring, shift lever and spacer.
LIGHT T R U C K SE R V IC E M A N U A L
3B4-44 S TEE RI NG C O L U M N S
A utom atic Colum is - Align the three holes in the a. Press the upper and lower bearings out of the
selector plate w ith the tlree holes in the jacket, position the housing.
clam ping ring and install the three screws. The shift tube b. Using Puller J-5822 and Slide H am m er J-2619 pull
spring retainer m ust be bottom ed against the jacket stops. the bearing races from the housing (Fig. 3B4-79).
5. 3-Speed C olum is-L ubricate and install the spacer c. Remove the tilt release lever.
and 1st-reverse shift le/er (tang of lever tow ards top of d. Drive out the shoe release lever pivot pin using Tool
column). J-22635 or a suitable punch (Fig. 3B4-80). Remove the lever
6. Install lower bearing in the adjusting ring and then spring and remove the wedge.
install the adjusting rinj, clam p and screws. e. Using a suitable size punch, drive out the lock shoe
7. Install the shift bver housing (or extension housing) retaining pin. Remove the shoes and shoe springs.
seat and bushing to upper end o f housing. 9. Remove the steering shaft assembly through the
8. T hread directiotial signal switch wiring harness upper end of the column. If it is necessary to disassemble
through the switch ard lever (or extension) housings, the shaft proceed as follows:
lubricate the inner diameter o f the shift housing, and then a. T urn the upper shaft 90° to the lower shaft and slide
place the shift lever (or extension) housing onto the upper the upper shaft and centering spheres from the lower shaft.
end of the column.
b. R otate the centering spheres 90° and remove the
9. Install the switch housing plastic w asher assembly. center spheres and preload spring from the upper shaft.
Press the upper bearing into the switch contact support.
10. Remove the four bearing housing support screws
10. Install the directional signal switch housing, contact and remove the support.
support, bearing and switch and torque the switch screws
Colum n Shift Models - If the shift tube index plate
to 25 lbs. in.
m ust be removed, remove the two retaining screws and
11. Install the column wiring harness cover and back remove the plate.
up lamp switch.
11. Remove the shift tube retaining ring with a
12. Install the directional signal and gearshift levers. screwdriver (Fig. 3B4-81). Remove the th ru st washer.
13. A djust the shift tube as outlined under "Shifter 12. Remove the neutral-safety or back-up lamp switch
Tube A djustm ent." screws and remove the switch.
14. Loosely install the lower bearing preload spring and 13. Rework Shift Tube Removing Tool J-22551 by
clamp. removing 1/2" from the pilot end of the tool (Fig. 3B4-82).
15. Slide the steering shaft assembly up through the This allows the shift tube to be pushed further out of the
colum n assembly. Install the directional signal cancelling housing and will not affect the use of the tool on other
cam, steering shaft nut and lock washer. columns.
Disassembly O f T ilt Column (Fig. 3B4-75) 14. Remove the shift tube assembly using Tool J-22551
1. If the colum n is removed from the vehicle, place the (Fig. 3B4-83). Insert the hooked end of the tool into the
colum n in a bench vise using H olding Fixtures J-22573 (Fig. notch in the shift tube just below the shift lever housing key.
3B4-76). Pilot the sleeve over the threaded end of the tool and into
the upper end of the shift tube. Force the shift tube out of
the housing by turning the n ut onto the tool. If the shift tube
NOTICE: Clamping the colum n directly in a vise,
is not completely free when the n u t is bottom ed on the
could result in a damaged column.
threads, complete the removal by hand.
2. Remove the directional signal switch as outlined
under "D irectional Signal Sw itch-Rem oval".
NOTICE: D o not ham m er or pull on the shift tube
during removal. On colum n shift models, guide the
3. Remove the lower steering shaft and pot joint
lower shift lever through the slotted opening in the
assembly and lower bearing and adapter assembly as
colum n to prevent dam age to the tube or column.
outlined under "Lower Bearing and A dapter-R em oval".
4. Colum n Shift Models - Using a suitable size punch,
15. Remove the lock plate by sliding out of the colum n
drive out the shift lever pivot pin and remove the shift lever.
notches, tipping the plate dow nw ard tow ard the housing (to
5. Install the tilt release lever and place the colum n in compress the wave washer) and then removing as shown in
the full "up" position. Remove the tilt lever spring and Figure 3B4-84. Remove the wave washer.
retainer using a screwdriver th a t ju st fits into the slot
16. Remove the shift lever housing.
opening (Fig. 3B4-77). Insert the screwdriver clockwise
17. Colum n Shift Models - Remove the shift lever
approxim ately 1/8 tu rn until the retainer ears align w ith the
spring by winding the spring up w ith pliers.
grooves in the housing and rem ove the retainer and spring.
18. If necessary, remove the dash panel seal, m ounting
6. Rem ove the steering shaft bearing locknut using
plate and the instrum ent panel seal from the colum n jacket.
socket J-22599. Remove the upper bearing race seat and
race. Assembly of T ilt Column
7. Remove the two bearing housing pivot pins using W hen lubricating com ponents during the following
Tool J-21854 (Fig. 3B4-78). installation sequence, use any general purpose lithium soap
8. Pull up on the tilt release lever (to disengage the lock grease.
shoes) and remove the bearing housing. If it is necessary to 1. Install the dash panel seal, m ounting plate and the
disassemble the bearing housing, proceed as follows: instrum ent panel seal on the column.
A
COVER SHAFT ASSY.
WEDGE ----- RACE INSTRU. PANEL
RACE SHAFT OPENING C O V E R -,
SCREW (3)
SPRING
SWITCH ASSY. —» JACKET
ASSY.-
YOKE
Fig. 3B4-75—Tilt Steering
ASSY. SHIFT
BOWL ASSY. SCREW
SCREW (4) DASH SEAL
SPRING
'-PLATE
\ RETAINER
& P
THRUST WASHER
\ PLATE LOCK
STEERING COLUMNS
WAVE WASHER
BOWL
"* LEVER
ADAPTER
RETAINER BEARING
3B4-45
3B4-46 STEERING C O L U M N S
2. C olum n Shift M odels - Press a new shift lever spring 6. Pull up on the shift lever housing (to compress the
into the shift lever housing. wave washer) and install the thrust washer and retaining
3. Slide the shift lever housing over the upper end of ring. Be sure the ring is seated in both slots of the shift tube.
the column. 7. Lubricate the I.D . of the bearing housing support
and install the support, aligning the bolt holes in the support
4. Place the wave w asher and lock plate in position.
w ith the bolt holes in the lock plate. Install the four support
W ork the lock plate into the notches by tipping the plate
screws and torque to 45 in. lbs.
tow ard the housing (com pressing the wave washer) at the
open side o f the colum n. L ubricate the lock plate and upper 8. Assemble the steering shaft as follows:
end of the shift tube. a. Lubricate and assemble the centering spheres and
5. Carefully install the shift tube into the lower end of preload spring.
the column (m ake sure the foam seal is at lower end of the b. Install the spheres into the upper (short) shaft and
shift tube). Align the keyway in the tube with the key in the rotate 90°.
shift lever housing and com plete installation o f the shift tube
using Tool J-22549 (Fig. 3B4-85). The shift lever housing c. Install the lower shaft 90° to the upper shaft and over
key m ust bottom in the shift tube slot to be fully installed. the centering spheres. Slowly straighten the shafts while
Remove Tool J-22549 from the colum n. Lubricate and push compressing the preload spring.
foam seal in flush with colum n housing. 9. Install the shaft assembly into the housing from the
upper end.
NOTICE: D o N ot ham m er or force the tube when 10. Install the lower bearing and adapter, bearing
installing in the colum n, or dam age could occur to the reinforcement, wire clip, pot joint coupling and lower shaft
components. as described under "Lower Bearing Installation".
STEERING SHAFT
BEARING LO CKNUT
TILT LEVER
SPR IN G RETAINER
LIGHT TR U C K SE R V IC E M A N U A L
STEERING C O L U M N S 3B4-47
1 /1 6 ” 4 5 ° CHA M FER
R E M O VE DOTTED
P O R T IO N
Fig. 3B 4 -8 0 ~ R e m o v in g Release Lever Pivot Pin Fig. 3 B 4 -8 2 -R e v is e d Shift Tube Removing Tool J -2 2 5 5 1
11. Assemble the bearing housing as follows: 13. Place the housing in the full "up" position and then
install tilt spring and retainer (tapered end of spring first).
a. Press the new upper and lower bearing races into
Push into the housing approxim ately 3/16" and rotate
the bearing housing.
counter clockwise 1/8 turn.
b. Lubricate and install the bearings into the bearing
races. 14. Lubricate and install the upper bearing upper race,
race seat and locknut. Tighten the locknut (using Socket
c. Place the lock shoe springs in position in the housing.
J-22549) to remove the lash and then further tighten 1/16
Install each shoe in place and com press the spring until a
to 1/8 of a turn (colum n m ust be in straight ahead position).
suitable size straight punch can be used to hold the shoes
in position (it m ay be necessary to acquire assistance to 15. Remove the tilt release lever.
install the shoes). Once the shoes are in place, drive in the
shoe retaining pin. 16. Install the directional signal switch as outlined
under "D irectional Signal Sw itch-Installation".
d. Install the shoe release lever and drive in the pivot
pin. 17. C olum n Shift M odels - Install the shift lever and
e. Install the tilt release lever. pivot pin.
f. Lubricate the shoes and release lever. 18. Install the neutral-safety or back-up lam p switch.
12. Install the bearing housing assembly to the support.
H old the tilt release lever in the "up" position until the shoes 19. Remove the colum n from the bench vise.
have fully engaged the support. Lubricate and install the
bearing housing pivot pins. Press the pins in flush w ith the
housing.
HOOK END-
OF TOOL
SLOT IN
SHIFT TUBE
Fig. 3B4-81~Removing Shift Tube Retaining Ring Fig. 3B4-83--Removing Shift Tube Assembly
LIGHT T R U C K SE R V IC E M A N U A L
3B4-48 STEERING C O L U M N S
LIGHT TR U C K SE R V IC E M A N U A L
A
3B4-50 STEERING C O L U M N S
LIGHT T R U C K SE R V IC E M A N U A L
STEERING C O L U M N S 3B4-51
SPECIFICATIONS
Manual Power
V e h icle
Ge a r O v e r a ll Ge a r O v e r a ll
R a tio R a tio R a tio R a tio
29.4:1 21.4:1
G 10-20 24:1 to 14:1 to
36.7:1 26.7:1
29.4:1 21.4:1
G30 24:1 to 14:1 to
36.4:1 26.5:1
21.2:1
P20-30 — — 17.5:1 to
25.7:1
16.0:1
M otor Home - - 14:1 to
21.9:1
16:1 13.2:1
K 10-20 — — to to
13:1 17.2:1
Over Center
25 lbs. ft.
Lock N ut
Fig. 3B4~Specs
LIGHT TR U C K SE R V IC E M A N U A L
3B4-52 STEERING C O L U M N S
SPECIAL TOOLS
LIGHT T R U C K S E R V IC E M A N U A L
STEERING C O L U M N S 3B4-53
LIGHT T R U C K SE R V IC E M A N U A L
„••; r ?
■’-f i W & K i ■
5 3 '
FRONT SUSPENSION 3C-1
SECTION 3C
FRONT SUSPENSION
The following notice applies to one or more steps in the assembly
procedure of components in this portion of the m anual as indicated at
appropriate locations by the terminology "See N otice on page 1 of this
section".
N O TIC E This fastener is an im portant attaching part in th at it could
affect the perform ance of vital components and systems, an d /o r could result
in m ajor repair expense. It must be replaced with one of the same part
num ber or with an equivalent part if replacem ent becomes necessary. Do not
use a replacem ent part of lesser quality or substitute design. Torque values
m ust be used as specified during reassembly to assure proper retention of this
part.
GENERAL DESCRIPTION
C-G-P Series
The C -G -P Series trucks incorporate an independent
coil spring front suspension system, as shown in Figures 3C-
1 and 3C-2. The control arm s are of unequal length (S.L.A .
Type).
This suspension system consists of upper and lower
control arm s pivoting on steel threaded or rubber bushings
on upper and lower control arm shafts. The lower control
arm s are attached to the crossm em ber. The upper control
arm s are attached to a fram e bracket. These control arm s
are connected to the steering knuckle through pivoting ball
joints.
A coil spring is located between the lower control arm
and a formed seat in the suspension crossmember, thus the
lower control arm is the load carrying member. Double
acting shock absorbers are also attached to the lower control
arm s and connect with the fram e to the rear on the upper
end. The front wheel bearings are tapered roller type and
are used on all models.
DIAGNOSIS
000 km), owner should be advised to have ride rechecked
SHOCK ABSORBER DIAGNOSIS after 7,000 to 8,000 miles (11 200 to 12 800 km).
..........
HARD STEERING
a. Ball jo ints and steering linkage ne ed lu bric ation a. Lubricate ball jo in ts and linkage
b. Low or uneven fron t tire pressure b. Inflate tires to the pro p e r re co m m e n d e d pressure
e. Incorr ect front wheel alig nm en t (m anu al steering) e. Check and align f ron t suspension
e. In correct front wheel alignm ent (caster) e. Check and align front suspension
a. Tire a nd wheel o u t o f bala nce, or o u t o f rou nd a. Balance tires, c hec k run -ou t
WHEEL TRAMP
a. Tire and wheel o u t 'of balance a. Balance wheels
b. Tire and wheel ou t o f round b. Replace tire
c. Blister o r b u m p on tire c. Replace tire
d. Im p ro p er sh ock a b so rb er action d. Replace shock absorber
SCUFFED TIRES
a. Toe-in incorrect a. Adjust toe-in to specifications
b. Excessive speed on turns b. Advise driver
e. Tires im p ro p e rly inflated c. Inflate tires to pro pe r r e c o m m e n d e d pressure
d. Suspension arm b e n t o r tw isted d. Replace arm
Bounce Test down motion stops very quickly. If up and down motion
continues longer at one corner when com pared to opposite
This is only a com parison type test to help locate the corner (example, both front shocks), the one having the
suspected shock or noise condition before proceeding. longer up and down m otion may be suspect. Do N ot
Test each front and rear shock by bouncing each corner com pare front to rear. If com plaint is noise, this test should
of the vehicle. This can usually be done by lifting up and help to locate the suspected area.
pushing down on the end of the bum per near each corner of
the vehicle u ntil m axim um m ovem ent up and down is
reached. Then let go of bum per and observe if the up and
LIGHT TRUCK SERVICE MANUAL
FRONT SUSPENSION 3C-7
f. Loose stab ili/er bar f. T ighten all sta b ili/e r bar a tta c h m e n ts
(T
P- Loose wheel nuts ti T ighten the wheel nuts to proper torqu e
h. Spring im properly p ositioned ll. R eposition
i. Loose suspension holts i. T orq ue to specificatio ns or replace
W HEEL TRAM P
a. Tire and wheel o u t o f balance a. Balance wheels
SCU FFED T IR E S
a. Toe-in incorrect a. Adjust toe-in to specifications
CUPPED T IR E S
a. Fro n t sh ock absorbers defective a. Replace shock absorbers
DIAGNOSIS
EXCESS NO ISE C O M P L A IN T
D IA G N O S T IC PRO CEDURE
Engine or 1. Drive slightly above speed where noise occurs, place transmission in neutral
2. Let engine speed drop to idle
Exhaust
3. Stop car
Noises
4. Run engine at various speeds
SURFACE IN DEN TAT IO NS IN RACEWAY WEAR A R O U N D OUTSIDE DIAM ETER OF PATTERN ON RACES AND RO LLERS
CAUSED BY RO LLERS EITHER U NDE R CAGE AND ROLLER POCKETS CAUSED CAUSED BY FINE AB RASIVES.
IMPACT L O A D IN G OR V I B R A T IO N W HIL E BY A B R A S IV E M A T E R IA L AND
THE BEARING IS NOT R O T A TIN G . IN E F F IC IE N T L U B R IC A TIO N . CHECK CLEAN A L L PARTS A N D HOUSINGS
SEALS A ND REPLACE BEARINGS. CHECK SEALS A N D BEARINGS AND
REPLACE BEARING IF ROUGH OR NOISY. REPLACE IF L E A K IN G , ROUGH OR
NOISY.
RACE CRACKED DUE TO IMPROPER FIT, SMEARING OF M E T A L DUE TO SLIPPAGE, CORROSION SET UP BY SMALL
COCKING, OR POOR BEARING SEATS. SLIPPAGE CAN BE CAUSED BY POOR R E L A T IV E M O VEM ENT OF PARTS WITH
F IT S , L U B R IC A T IO N , O V E R H E A T IN G , NO L U BR IC A TIO N .
O VE RLO ADS OR H A N D L IN G DA MAGE.
REPLACE BE ARIN G. CLEAN R E L A TE D
REPLACE BEARINGS, CLEA N R EL A TE D PARTS. CHECK SEALS A N D CHECK FOR
PARTS AND CHECK FOR PROPER FIT PROPER L U BR IC A TIO N .
AND LUBRICA TIO N.
i jo ht T r y o k m an u a }
FRONT SUSPENSION 3C-15
L IG H T T R U C K SERVICE M AN U AL
3C-16 FRONT SUSPENSION
UPPER CONTROL ARM INNER PIVOT SHAFT W hen installing the upper control arm be sure to
properly position the special aligning washers to the pivot
AND/OR BUSHING REPLACEMENT shaft with convex and concave sides together.
1. Install the shaft to the control arm and install end nuts.
C20-30, G30 and P20-30 (Steel Bushings) Do not torque nuts at this time.
2. Position cross shaft to frame bolts and start cross shaft
Pivot Shaft Removal
nuts.
1. Raise vehicle and remove tire and wheel assembly.
3. Torque the shaft end nuts. See Fig. 3C-19 for proper
2. Support the lower control arm with a floor jack. spacing. The shaft should rotate by hand after the nuts
Position jack under the ball joint assembly or as near as are torqued.
possible and still have good support.
4. Install caster and camber shim in their appropriate
3. Loosen the upper control arm shaft end nuts before places.
loosening the shaft to frame attaching nuts.
5. Torque the cross-shaft to frame nuts.
4. Loosen the shaft to frame nuts and remove the caster
6. Remove the safety chain and install the tire.
and camber shims. Tape the shims together as they are
removed and mark for position. 7. Lower vehicle to the floor.
5. Remove the pivot shaft to frame nuts but do not allow LOWER CONTROL ARM INNER PIVOT SHAFT
the arm to swing too far away from the frame.
AND/OR BUSHING REPLACEMENT
Use a safety chain to retain the arm in a close
C20-30, G30, P20-30 (Steel Bushings)
relationship to the frame. See Fig. 3 C -18.
6. Remove the shaft end nuts and remove shaft from arm. Lower-Removal (Fig. 3C-18)
1. Raise vehicle and support the frame so that control
Bushing Replacement (Steel Bushings) arms hang free.
1. Remove grease fittings from bushing outer ends and 2. Position an adjustable floor jack under the control arm
unscrew bushings from control arm and shaft. inboard of spring and into depression in lower arm.
2. Slide new seal on each end of shaft and insert shaft into 3. Install a chain over upper arm (Fig. 3C-18). Inboard of
control arm. stabilizer and outboard of shock absorber as a safety
3. Start new bushings on shaft and into control arm. measure.
Adjust shaft until it is centered in control arm, then 4. Disconnect shock absorber at lower control arm.
turn bushings in and torque to specifications. Figure 5. Loosen shaft end nuts.
3C-19 shows correct final positioning of shaft. Check
6. Remove " U " bolts.
shaft for free rotation and install grease fittings.
7. Lower jack just enough to get at shaft.
Installation 8. Remove shaft end nuts and remove shaft.
NOTICE: See N O T I C E on page 1 of this section
regarding the fasteners referred to in steps 3, 5 and 6. Bushing Replacement (Steel Bushings)
1. Remove grease fittings from ends of bushings and
unscrew bushings from shaft and control arm. Remove
shaft and seals.
Fig. 3C-18--Removing Inner Pivot Shaft Fig. 3C-19--Positioning U.C.A. Shaft (Steel Bushings)
LIG H T T R U C K SE RV IC E M AN U AL
FRONT SUSPENSION 3C-17
J—2 4 4 35 -7
J—24435-1
J —2 4 4 3 5 -7
J—2 4 4 3 5 -4
J— 2 4 4 3 5 -5
(HIDDEN)
Fig. 3C-21--Disconnecting Ball Joints from Knuckle Fig. 3C-23--U.C.A. Rubber Bushing Installation
L IG H T T R U C K SERVICE M AN U AL
3C-18 FRONT SUSPENSION
5. Remove nuts securing control arm shaft to frame. 1. Place control arm in position on bracket and install
W ithdraw control arm assembly. Tape shims together nuts. Before tightening nuts, insert caster and camber
and tag for proper relocation when control arm is shims in the same order as when removed. Torque the
reinstalled. nuts to specifications.
A normal shim pack will leave at least two (2) threads
Upper Control Arm Inner Pivot Shaft and/or of the bolt exposed beyond the nut. If two (2) threads
cannot be obtained: Check for damaged control arms
Bushing Replacement and related parts. Difference between front and rear
shim packs must not exceed 7.62 mm (.30 inches).
CIO, G10-20, P10 (Rubber Bushings)
Front shim pack must be at least 6.09 mm (.24 inches).
Removal (Fig. 3C-22) Always tighten the thinner shim packs’ nut first for
improved shaft to frame clamping force and torque
1. Remove the upper control arm using the preceding
retention.
procedure and mount the control arm in a vise.
2. Insert ball joint stud into steering knuckle and install
2. Install remover J-24435-1, receiver J-24435-3 and
nut. Torque stud nut to specifications and install cotter
" C " clamps J-24435-7 as shown in Figure 3C-22.
pin.
3. Tighten the clamp to draw out the old bushing. Discard
3. Install brake caliper assembly if removed (see section
old bushing.
5).
4. The pivot shaft may now be removed from the control
4. Remove adjustable support from under lower control
arm assembly.
arm. Install wheel and tire assembly.
5. Reposition the control arm in the vise and repeat the
5. Lower the vehicle to the floor.
removal procedure on the remaining bushing.
L IG H T T R U C K SE RV IC E M AN U AL
FRONT SUSPENSION 3C-19
Lower Control Arm Inner Pivot Shaft and/or 2. Remove pivot shaft nuts.
Bushing Replacement-On Vehicle 3. Place control arm in an arbor press, press front end of
pivot shaft to remove rear bushing, and pivot shaft
CIO (Rubber Bushings) assembly.
Removal (Figs. 3C-24, 3C-25) 4. Remove the stakes on the front bushing using Tool
J-2 2 7 17 or equivalent tool.
If just bushings or pivot shaft are to be replaced the
lower control arm does not have to be removed from the 5. Install " C " clamp J-24435-7 and receiver J-24435-3
vehicle. with remover J-24435-2 and spacer J-24435-6 as
shown in Figure 3C-25.
1. Raise vehicle on hoist and support the frame so that the
control arms hang free. 6. Tighten " C " clamp to remove the bushing.
2. Position an adjustable floor jack under the lower Installation
control arm inboard of spring and into depression of
NOTICE: See N O T I C E on page 1 of this section
control arm.
regarding the fasteners referred to in step 5.
3. Install a chain over the upper arm inboard of the
1. Install new bushings as shown in Figure 3C-26 using
stabilizer and outboard of shock absorber as a safety
spacer J-24435-6, installer J-24435-4 and " C " clamp
measure.
J-24435-7.
4. Disconnect shock and stabilizer bar attachments at
lower control arm. 2. Turn clamp in until bushing seats firmly.
Be sure outer tube hole is to the front or forwards to the
5. Loosen shaft end nuts.
staked bushing.
6. Remove " U " bolts that retain the inboard end of the
lower control arm. NOTICE: Be sure spacer J-24435-6 is in position as
shown in Figure 3C-26 to avoid collapsing control arm
7. Lower jack S L O W L Y to release spring compression
during assembly.
(Fig. 3C-24) and gain clearance to remove bushings.
Be sure all compression is released from coil springs. 3. Stake front bushing at least in two places when
installed.
8. Remove the stakes on the front bushing using tool
J-2 2 7 17 or equivalent tool. 4. Insert the pivot shaft and install second bushing.
9. Bushings may now be replaced. Install " C " clamps 5. Install the lower control arm to the vehicle as described
J-24435-7 and receiver J-24435-3 with remover under "Lower Control Arm - Installation", being sure
J-24435-2 and spacer J-24435-6 as shown in Figure to torque all fasteners to the proper specification.
3C-25. Lower Control Arm Installation
10. Tighten the " C " clamp to remove the bushing.
NOTICE: See N O T I C E on page 1 of this section
11. Remove tools and discard old bushing. regarding the fasteners referred to in steps 2 and 3.
12. Pivot shaft may now be removed if necessary.
1. Install lower ball stud through steering knuckle and
13. Remove second bushing (leave pivot shaft in to pilot tighten nut.
tool) by the same method as in steps 8-12.
2. Install spring and control arm as outlined under spring
installation.
Bushing Installation (Fig. 3C-26)
3. Torque lower control arm ball stud to specifications and
NOTICE: See N O T I C E on page 1 of this section install cotter pin.
regarding the fasteners referred to in step 5.
4. Install brake caliper assembly if removed (see section
1. Install new bushings as shown in Figure 3C-26 using
5).
spacer J-24435-6, installer J-24435-4 and " C " clamp
J-24435-7. 5. Lower the vehicle to the floor.
2. Turn clamp in until bushing seats firmly.
Installation
NOTICE: See N O T I C E on page 1 of this section
regarding the fasteners referred to in steps 1, 3 and 6.
LIG H T T R U C K SE RV IC E M A N U A L
FRONT SUSPENSION 3C-21
STEERING KNUCKLE
4. Install J-23742 between the ball studs as shown in
Figure 3C-27. It is recommended that vehicle be raised and supported
It may be necessary to remove the brake caliper as on a twin-post hoist so that the front coil spring remains
assembly and wire it to the frame to gain clearance for compressed, yet the wheel and steering knuckle assembly
tool J-23742. See section 5 for proper procedure. remain accessible. If a frame hoist is used, support lower
control arm with an adjustable jackstand to safely retain
5. Be sure lower control arm is supported as pointed out in spring in its curb height position.
Step 1. Extend bolt from Tool J-23742 to loosen ball
Removal
stud in steering knuckle. When stud is loosened, remove
tool and ball stud nut. 1. Raise vehicle on hoist and support lower control arm as
noted above.
6. Pull the brake disc and knuckle assembly up off the ball
stud and support the upper arm with a block of wood so 2. Remove wheel and tire assembly.
that assembly is out of working area. 3. Remove caliper as outlined under "Front Wheel Hub -
NOTICE: Do not put stress on the brake line flex hose or Removal".
damage to the brake line may result. 4. Remove disc splash shield bolts securing the shield to
7. Install Tools J - 9 5 19-10 and J-9519-2 and J-9519-29 as the steering knuckle. Remove Shield.
shown in Fig. 3C-30. 5. Refer to Section 3B-Steering for service removal
8. Turn hex head screw until ball joint is free of control operations.
arm. 6. Remove upper and lower ball stud cotter pins and
9. Remove tools and the ball joint. loosen ball stud nuts. Free steering knuckle from ball
studs by installing Special Tool J-23742. Remove ball
Installation (Fig. 3C-31) stud nuts and withdraw steering knuckle.
NOTICE: See N O T I C E on page 1 of this section
Installation
regarding the fasteners referred to in steps 4, 5 and 7.
1. S tart the new ball joint into the control arm and install NOTICE: See N O T I C E on page 1 of this section
J - 9 5 19-10 and J-9 5 19-16 as shown. Position bleed vent regarding the fasteners referred to in steps 2, 3 ,4 and 5.
in rubber boot facing inward. 1. Place steering knuckle in position and insert upper and
lower ball studs into knuckle bosses.
2. Turn hex head screw until ball joint is seated in control Steering knuckle hole, ball stud and nut should be free
arm. of dirt and grease before tightening nut.
3. Lower the upper arm and mate the steering knuckle to 2. Install ball stud nuts and tighten nut to specifications.
the lower ball stud. (See Specification Section.)
4. Install brake caliper assembly if removed (see Section If necessary, tighten one more notch to insert cotter
5). pins. Do not loosen nut to insert cotter pin. Refer to Ball
Joint text for proper nut installation sequence.
5. Install ball stud nut and torque as follows. All Series,
110 - 140 N-m (80-100 ft. lbs.) plus additional torque 3. Reverse rem aining removal procedure, and tighten
to align cotter pin hole not to exceed 175 N-m (130 ft. splash shield m ounting bolt. Tighten two caliper
lbs.) maximum. Never back off to align cotter pin. assembly mounting bolts to 48 N-m (35 ft. lbs.) torque.
6. Install a lube fitting and lube the joint. 4. Adjust wheel bearings as outlined under Front Wheel
7. Install tire and wheel assembly and lower vehicle to Bearing Adjustment.
floor. 5. Tighten wheel nuts to 100 N-m (75 ft. lbs.).
J-9519-2
(HIDDEN)
J-9519-29
J -9 5 19-16
J -9 5 19-1 0
J -9 5 19-10
BALL JOINT
REMOVAL BALL JOINT
INSTALLATION
Fig. 3C-30--Ball Joint Removal Fig. 3C-31—Installing Ball Joint
LIG H T T R U C K SE RV IC E M AN U AL
3C-22 FRONT SUSPENSION
CROSSMEMBER AND SUSPENSION UNIT 9. Disconnect fron shock absorbers from lower control
Com ponent parts of the front suspension may be arms.
serviced separately as outlined in the preceding service
operations. However, if extensive service is to be performed 10. Remove brake line clip bolts from front suspension
to crossmember, frame, etc., the unit can be removed and crossmember. On C-Models the clip is located under
installed as follows: right hand engine mount support bracket.
Removal (Fig. 3C-32) NOTICE: Failure to disconnect these clips from the front
1. Raise hood and disconnect negative battery cable from suspension unit will result in severe damage to the
battery. brake line when unit is lowered from vehicle.
2. Raise vehicle on hoist. 11. Remove engine mount support bracket to front suspen
sion crossmember bolts.
3. Remove front wheels.
4. Disconnect front brake hose clip from each upper 12. Remove crossmember to lower frame rail bolts.
control arm. 13. Raise hoist to support front suspension unit.
5. Support front of vehicle with jack stands at frame side 14. Support engine. Engine must be supported adequately
rails. Lower front hoist. before front suspension unit is lowered from vehicle.
6. Clean area adjacent to brake hose fittings. Disconnect 15. Remove upper control arm bracket to frame side rail
front brake hoses from calipers. Discard special wash bolts. Suspension unit is now disconnected from
ers (2 each hose). Cover disconnected end of each hose vehicle.
with suitable material. 16. Lower hoist to lower front suspension unit from vehicle.
7. Disconnect tie rod ends from steering knuckles. Dis
card cotter pins. Refer to Section 3B.
8. If equipped, disconnect front stabilizer from lower
control arms.
G-MODEL
LIG H T T R U C K SE RV IC E M A N U A L
FRONT SUSPENSION 3C-23
GENERAL DESCRIPTION
Front drive axles used on K10, K20, and K30 trucks Hub Design
have several styles of wheel-end construction.
An automatic locking hub is used on all K10 and K20
Knuckle Attachment models. This system, shown in Figs. 3C -lK (a ) and in 3C-
3K, automatically engages the hub whenever four-wheel
At the wheel ends of the axle tubes, two types of
drive is selected.
steering knuckle attachment are used. Figure 3 C -lK (a)
shows the K10 and K20 knuckle attached with ball joints. A free-wheeling hub is used on all K30 models. This
design is shown in Figs. 3 C -lK (b ) and in 3C-5K. This hub
Figure 3C -lK (b ) shows the king-pin attachment used in
K30. The tapered upper king pin fits in a tapered nylon allows the driver to manually engage or disengage the hub
from the axle shafts.
bushing. The lower king pin is part of the bearing cap, and
this king pin rides in a tapered roller bearing.
L IG H T T R U C K SERVICE M AN U AL
3C-24 FRONT SUSPENSION
Fig. 3C-1 K(a)--K10, K20 with Free-Wheeling Hub and Bbll Joints
LIG H T TR U C K SE RV IC E M A N U A L
FRONT SUSPENSION 3C-25
1. R E T A IN IN G P L A T E 13. L O C K -A D J . N U T 26. U P P E R B E A R IN G C A P
2. " 0 ” R IN G 14. P IN - A D J . N U T 27. P R E S S U R E S P R IN G
3. ACTU ATO R KNOB 15. A D J U S T IN G N U T 28. G ASKET
4. R E T A IN IN G P L A T E B O L T 16. O U T E R W H E E L B E A R IN G 29. B U S H IN G , K IN G - P IN
5. A X L E S H A F T S N A P R IN G 17. IN N E R W H E E L B E A R IN G 30. K IN G -P IN
6. A C T U A T IN G C A M B O D Y 18. SEAL 31. YOKE
7. IN T E R N A L S N A P R IN G 19. H U B -A N D - D IS C A S M 32. OUTER A XLE SHAFT
8. O U T E R C L U T C H R E T A I N I N G R IN G 20. S P IN D L E 33. G R E A S E R E T A IN E R
9. AXLE SH AFTSLEEVE AND 21. S P IN D L E B E A R IN G 34. L O W E R B E A R IN G
C L U T C H R IN G 22. SEAL 35. SEAL
10. I N N E R C L U T C H R IN G 23. DEFLECTOR 36. B E A R IN G C A P
11. S P R IN G 24. SPACER 37. L U B E F IT T IN G
12. LO CK NUT 25. L U B E F IT T IN G 38. S P IN D L E A T T A C H IN G N U T
39. S P IN D L E A T T A C H IN G B O L T
LIG H T T R U C K SERVICE M AN U AL
3C-26 FRONT SUSPENSION
LIG H T T R U C K SERVICE M A N U A L
FRONT SUSPENSION 3C-27
COMPONENT REPLACEMENT
plastic outer cage, causing the cage to rotate and move to the
HUB REPLACEMENT
disengaged condition. The release spring then moves the
NOTICE: See N O T I C E on page 1 of this section, clutch gear out of mesh with the outer clutch housing to
regarding the fasteners in the following procedures for disengage the wheel from the axle shaft.
H ub Replacement.
Preliminary Checking
AUTOMATIC LOCKING HUBS
Before disassembling a unit for complaint of abnormal
General Description noise, read the following:
The Automatic Locking Hub, shown in Fig. 3C-3K, • To obtain all-wheel drive, the transfer case lever must
engages or disengages to lock the front axle shaft to the hub be placed in (4L) o r (4H), at which time the hub locks
of the front wheel. Engagement occurs whenever the vehicle will automatically engage.
is operated in four-wheel drive. Disengagem ent occurs • To unlock (free wheel) the hubs, shift the transfer case
whenever two-wheel drive has been selected and the vehicle lever to (2H), th en slowly reverse vehicle direction a p
is moved rearward. Disengagement will not occur when the
proxim ately ten feet.
vehicle is moved rearward if four-wheel drive is selected and
• Incom plete shift from 2W D to 4WD, or disengagem ent
the hub has already been engaged.
o f only one hub lock may cause an abnorm al sound
The outer clutch housing is splined to the wheel. The
from the front axle. Shift to 4W D to stop the noise, then
hub sleeve is splined to the front axle shaft. The clutch gear
is splined to the hub sleeve. Engagement occurs when the unlock the hubs as described above.
clutch gear is moved on the splines of the hub sleeve to
engage the internal teeth of the outer clutch housing.
Removal of Hub from Wheel
1. Remove the five screws ( i t e m # l , Fig. 3C-3K) which
The cam surface of the steel inner cage forces the cam
retain the cover ( # 3 ) to the outer clutch housing
follower and clutch gear to move outward toward the cover
( # 10).
and into engagement with the clutch teeth of the outer
clutch housing. A lug on the inside of the drag sleeve 2. Remove the cover, seal ( # 4 ) , seal bridge ( # 1 1 ) , and
retainer washer keys the washer to the axle and two lock bearing components ( # 5 , 6 , 7, 8).
nuts retain this washer in position on the axle. Cutouts in the 3. Use needle-nose pliers to compress the wire retaining
drag sleeve engage the four tabs on the drag sleeve retainer ring ( # 9 ) , and pull the remaining components from
washer to hold the drag sleeve in a fixed position with the wheel.
respect to the axle shaft. The one way clutch spring (called a
brake band) is positioned over the serrated portion of the DISASSEMBLE HUB
drag sleeve. 1. Remove the snap ring ( # 2 8 ) from the groove of the
Engagement is accomplished (when four-wheel drive is hub sleeve ( # 1 8 ) .
selected) by the movement of the drag sleeve, causing one of 2. Turn the clutch gear ( # 1 7 ) until it drops into engage
the tangs of the brake band to engage the steel outer cage ment with the outer clutch housing ( # 1 0 ) . Lift and
and rotate the cage which will cause the cam ramp to move cock the drag sleeve ( # 2 6 ) to unlock the tangs of the
the clutch gear into mesh with the outer clutch housing. One brake band ( # 2 5 ) from the window of the inner cage
of the tangs of the brake band is used for engagement when ( # 2 3 ) and remove drag sleeve and brake assembly.
the vehicle is moving forward. The other tang is used to It is important that the brake band should never be
engage reverse when the vehicle is moving rearward. removed from the drag sleeve. The spring tension of the
Disengagement is accomplished (when two-wheel drive brake band can be changed if the coils are over-
has been selected) by the reverse movement of the wheel expanded and this could affect the operation of the hub.
causing the clutch gear, hub sleeve, and cam follower to 3. Remove the snap ring ( # 2 4 ) from the groove in the
rotate. The cam follower moves against the lugs of the outer clutch housing.
LIG H T T R U C K SERVICE M AN U AL
3C-28 FRONT SUSPENSION
LIG H T T R U C K SERVICE M A N U A L
FRONT SUSPENSION 3C-29
4. Use a small screwdriver to pry the plastic outer cage 8. The two " C " shaped clamps may be fabricated from
( # 2 2 ) free from the inner cage ( # 2 3 ) while the inner 3 /8 " (9.5mm) wide by 3 /3 2 " or 1/8" (2.4-3.2mm)
cage is being removed. thick stock. The distance between the two legs of the
5. Use a small screwdriver to pry the plastic outer cage clamps should be approximately 1-1/4" (31.8mm).
tabs free from the groove in the outer clutch housing. 9. Place the components assembled in steps 1 through 7
Remove outer cage. into the outer housing ( # 1 0 ) . The cam follower should
6. Remove the clutch sleeve ( # 1 8 ) and attached compo be positioned with the two legs directed outboard.
nents from the outer clutch housing. 10. Screw three of the cover screws ( # 1) into three holes of
7. Compress the return spring ( # 1 5 ) and hold the spring the outer clutch housing. These screws will support the
in the compressed condition with fabricated clamps as component to permit the clutch hub to drop down so
shown in Fig. 3C-4K. After the clamps are installed, that the tangs of brake band ( # 25) may be assembled.
position the entire assembly in a bench vise so that the 11. Carefully work the plastic outer cage ( # 2 2 ) into the
vise holds both ends of the clutch sleeve. Remove the outer clutch housing with the ramps facing toward the
retaining ring ( # 12). cam follower. The small external tabs of the plastic
8. With the clutch sleeve assembly still in the vise, remove cage should be located in the wide groove of the outer
the clamps holding the return spring. Slowly open the clutch housing.
vise to permit releasing of the retu rn spring in a 12. Assemble the steel inner cage ( # 2 3 ) into the outer
controlled manner. Remove the retainer seat, spring cage, aligning the tab of the outer cage with the
and spring support washers ( # 1 3 , 14) from the hub "window" of the inner cage.
sleeve.
9. Remove the C-type retaining ring ( # 1 9 ) from the
clutch sleeve. It is necessary to position the sleeve
assembly so that the C-ring ends are aligned with the
legs of the cam follower, allowing removal between the
two legs. "C "SHAPED
CLAMP
REASSEMBLE HUB
1. Snap the tangs of the cam follower ( # 2 1 ) over the flats
of the clutch gear ( # 1 7 ) .
2. Compress the conical spring ( # 2 0 ) and slide it into
position with the large diameter of the spring located
against the clutch gear.
3. Position the clutch gear assembly over the splines of the
hub sleeve ( ( # 1 8 ) . The teeth of the cam follower
should be located at the end of the hub sleeve which has
no splines. The clutch gear and spring should slide RETAINING RING
freely over the splines of the hub sleeve.
4. Assemble the " C " shaped retainer ring ( # 1 9 ) in the
groove of the hub sleeve.
5. Assemble a spring retainer ( # 1 4 , 16) over each end of
the return spring ( # 1 5 ) .
6. Position one end of the return spring with retainer
( # 1 6 ) against the shoulder of the clutch gear.
7. Place the spring support washer ( # 1 3 ) against the
retainer on the end of the return spring. Compress the
return spring and assemble the retainer ring ( # 1 2 ) in
the groove of the hub sleeve. Two " C " shaped clamps
may be used to retain the return spring while the Fig. 3C-4K--Using Clamp and Vise to Compress
retainer ring is being assembled. Refer to Fig. 3C-3K. Return Spring
3C-30 FRONT SUSPENSION
13. Assemble the retaining ring ( # 2 4 ) into the groove of over the axle shaft against the bearing adjustment nut.
the outer clutch housing above the outer cage. The tang on the inside diameter of this washer is
14. The brake band and drag sleeve are serviced as an assembled in the keyway of the axle shaft. Assemble
assembly. and tighten the outer lock nut to 217-310 N-m (160-
15. Assemble one of the two tangs of the brake band ( # 2 5 ) 205 lb-ft).
on each side of the lug of the outer cage which is located 29. Align the cut-outs in the drag sleeve with tabs on the
in the window of the steel inner cage. It will be drag sleeve washer as the splines of the outer clutch
necessary to cock these parts to engage the tangs in this housing are assembled into splines of the hub of the
position as the drag sleeve is positioned against the face wheel. Loosen the cover screws three or four turns and
of the cam follower. push in on these screws, to allow the retaining ring to
16. Remove the three screws and rest the end of the hub expand into groove in hub of wheel as the seal bridge is
sleeve on a suitable support. Assemble the washer forced from position over the retaining ring as the tang
( # 27) and snap ring ( # 28) above the drag sleeve. of seal bridge contacts wheel hub. Torque the cover
screws to 4.5-5.6 N-m (40-50 lb. in.)
The following steps may be completed as hub is
assembled to vehicle. Assemble a Rebuilt Hub to Wheel
17. Assemble the wire retaining ring ( # 9 ) in the groove in 30. Steps 1-17 in the assemble procedure are usually
the unsplined end of the outer clutch housing. The completed whenever the hub is rebuilt and then
tangs of the retainer ring should point away from the assembled to the wheel.
splined end of the clutch housing.
31. Hold the two tangs of the retaining ring in the clamped
18. Hold the tangs of the wire retainer together and condition as the assembled components are assembled
assemble the two bent down tabs of the seal bridge to the hub of the wheel. See step 29 for installation of
( # 1 1 ) over the tangs. The seal bridge holds the wire drag sleeve washer.
retainer ring in a clamped condition in the groove of the
32. Assemble the seal bridge in the cut-out of the outer
outer clutch housing. Assemble the " O " ring in the
clutch housing. Assemble the sealing ring over the
groove of the outer clutch housing and over seal bridge.
outer clutch housing.
19. Assemble the bearing ( # 7 ) over the inner race ( # 6 ) .
33. Assemble the bearing and retainer assembly into the
Lubricate the bearing as it is assembled with light
hub sleeve.
wheel bearing grease. The steel balls should be visible
when bearing is properly assembled. 34. Assemble the bearing race spring to the cover.
20. Snap the bearing retainer clip ( # 8 ) into the hole in the 35. Assemble the cover and cover bolts. Tighten cover
outer race. screws to 4.5-5.6 N-m (40-50 lb. in.).
21. Assemble the bearing and retainer assembly in the end FREE-WHEELING HUBS
of the hub sleeve. Assemble the seal ring ( # 4 ) over the
outer clutch housing. K30 (Fig. 3C-5K)
22. Assemble the bearing race spring ( # 5 ) into the bore in Hub Removal
the cover.
1. Turn actuator lever to set hub to "L O C K " position
23. Assemble the cover and spring assembly. Align the hole (Fig. 3C-5K) and raise vehicle on hoist. Rotate tire to
in the cover to the holes in the outer clutch housing and assure that hub lock is engaged.
assemble the five screws.
2. Remove six retaining plate bolts and remove retaining
24. Assemble the O-ring over the seal bridge to prevent it plate, actuating knob, and " O " ring.
from jumping out of position during handling prior to
3. Remove internal snap ring, outer clutch retaining ring,
the hub bearing assembled to the vehicle. This " O "
a c tuating cam body, outer clutch gear, and clutch
ring may be left on but is not required.
spring.
25. The hub sleeve and attached parts should turn freely
4. Relieve pressure on the axle shaft snap ring and remove
after the unit has been completely assembled.
snap ring.
26. The five cover screws must be loosened to assemble the
5. Remove the inner clutch gear.
hub to the vehicle. Torque these screws after hub is
installed to 4.5-5.6 N-m (40-50 in-lbs.). 6. Remove spring retainer plate.
7. Remove the wheel bearing outer lock nut, lock ring,
and wheel bearing inner adjusting nut using Tool
Assemble New Hub to Wheel
J-6893 and Adapter J-23446 or Tool J-6893-01.
27. A drag sleeve retainer washer ( # 3 0 ) is supplied with
each new assembly. Assemble this washer between the 8. Remove the hub-and-disc assembly, outer wheel bear
wheel bearing adjustment nut and the lock nut. Adjust ing and the spring retainer plate.
the inner nut to give proper bearing adjustment. a. Remove the oil seal and inner bearing cone from the
28. Use J-6893 to torque adjusting nut ( # 3 1 ) to 60 N-m hub using a brass drift and tapping with a hammer.
(50 ft. lbs.), to seat the bearings; then, back off the nut Discard the oil seal.
and torque to 47 N-m (35 ft. lbs.) while the hub is being b. Remove the inner and outer bearing cups using a
rotated. Finally, back the adjusting nut off a maximum brass drift and hammer.
of 3/8 turn. Assemble the drag sleeve retainer washer c. Clean, inspect and lubricate all parts as required.
LIG H T T R U C K SERVIC E M AN U AL
FRONT SUSPENSION 3C-31
SPINDLE
Removal
1. Remove the hub-and-disc assembly as outlined earlier.
2. Remove the spindle retaining bolts.
3. Remove the spindle and bronze thrust washer by
tapping the end of the spindle lightly with a soft
hammer to break it loose from the knuckle as shown in
Figure 3C-6K. Replace the thrust washer if excessive
wear has occurred. Fig. 3C-6K~Removing Spindle and Thrust Washer
L IG H T T R U C K SERVICE M AN U AL
FRONT SUSPENSION 3C-33
KNUCKLE b. Loosen tie rod nuts and tap on nut with a soft
ham mer to break the studs loose from the knuckle
K10, K20, (WITH BALL JOINTS) arm.
c. Remove nuts and disconnect the tie rod. If it is
Removal necessary to remove the steering arm, discard the
1. Remove hub and spindle components as outlined self-locking nuts (Fig. 3C-9K) and replace with new
earlier. nuts at assembly.
2. If the steering arm is to be removed, disconnect the tie 3. Remove the cotter pin from the upper ball socket nut.
rod. 4. Remove the retaining nuts from the upper and lower
a. Remove cotter pin. ball sockets as shown in Figure 3C-10K.
L IG H T T R U C K SERVIC E M AN U AL
3C-34 FRONT SUSPENSION
J-23454-1
Fig. 3C-8K--lnstalling Spindle and Thrust Washer Fig. 3C-11 K--Removing Lower Ball Joint
LIG H T T R U C K SE RV IC E M A N U A L
FRONT SUSPENSION 3C-35
J -6 3 8 2 -3 OR
J -2 3 4 5 4 -3
J-2 3 4 4 7
BALL J O IN T J -2 3 4 5 4 -2
Fig. 3C-13K—Installing Lower Ball Joint Fig. 3C-15K--Ball Stud Adjusting Sleeve
2. Remove Lhe upper ball joint using tools J-9519-10, 3. Torque the yoke upper ball stud adjusting sleeve to 70
J-23454-1, and sleeve J-23454-4 or equivalent as shown N-m (50 ft. lbs.) using Spanner J-23447. See Figure
in Figure 3C-12K. 3C-15K.
3. Install the lower ball joint into the knuckle. Make sure
that the lower ball joint (the joint without cotter pin
hole in the stud end) is straight. Press the stud into the
knuckle until properly seated using tools J-9519-10,
J-23454-2, and J-23454-4 or equivalent as shown in
Figure 3C-13K and install snap ring.
4. Install the upper ball joint into the knuckle. Press the
stud into the knuckle until properly seated using Tools
J-9519-10, J-23454-2, and J-23454-4 or equivalent as
shown in Figure 3C-14K.
Installation
NOTICE: See N O T I C E 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 lower ball socket studs.
2. Push up on the knuckle (to keep the ball socket from
turning in the knuckle) while tightening the lower
socket retaining nut. Torque lower nut to 95 N-m (70 Fig. 3C-16K--Torquing U p per Ball Socket Nut
ft. lbs.).
BALL JO IN T
J -2 3 4 5 4 -2
J-6382-3
OR
J-23454-3
J-9519-10
L IG H T T R U C K SE RV IC E M AN U AL
3C-36 FRONT SUSPENSION
4. Torque the upper ball socket nut to 100 ft. lbs. as shown 2. Remove four nuts from upper king pin cap. Remove
in Figure 3 C -16K. After torquing the nut, do not loosen nuts alternately as compression spring will force cap
to install cotter pin, apply additional torque, if neces up. Refer to Figure 3C-18K.
sary, to line up hole in stud with slot in nut. 3. Remove cap, compression spring, and gasket, as shown
5. If the tie rod and steering arm were removed: in Figure 3C-19K. Discard gasket, replace with new
a. Assemble the steering arm using the three stud one at time of assembly.
adapters and three new self-locking nuts. Torque the 4. From the underside of the knuckle, remove four cap
nuts to 120 N-m (90 ft. lbs.). screws from the lower king pin bearing cap. Remove
b. Assemble the tie rod to the knuckle arm. Torque the the bearing cap-and-lower king pin. See Figure 3C-
tie rod nuts to 60 N-m (45 ft. lbs.) and install cotter 20K.
pin. 5. Remove upper king pin tapered bushing and knuckle
from yoke. Remove king-pin felt seal. See Figure 3C-
KNUCKLE 21K. Remove knuckle.
6. Remove upper king-pin from yoke with large breaker
K30 (WITH KING PINS) bar and J-2 6 8 7 1, as seen in Figure 3C-22K.
Torque specification is 677.50-813.00 N-m (500-600 ft.
Removal lbs.).
1. Remove the hub and spindle as outlined earlier. If 7. Remove lower king pin bearing cup, cone, grease
necessary, tap lightly with a rawhide ham mer to free it retainer, and seal all at the same time, as shown in
from the knuckle. Check bronze spacer located Figure 3C-23K. Discard seal and replace with new one
between axle shaft joint assembly and bearing. If wear at time of assembly. If grease retainer is damaged,
is evident, replace with a new one. See Figure 3C-17K. replace with new one at time of assembly.
Fig. 3C-19K--Removing Cap, Spring and Gasket Fig. 3C-21 K--Removing Tapered Bushing
L IG H T T R U C K SERVIC E MANUAL
FRONT SUSPENSION 3C-37
Installation
NOTICE: See the N O T I C E on page 1 of this section
regarding the fasteners in the following steps.
1. Assemble new grease retainer and lower king pin
bearing cup, using J - 7 8 17, as shown in Figure 3C-24K.
Fig. 3C-23K--Removing Cup, Cone and Seal Fig. 3C-26K--lnstalling Upper King-Pin
LIG H T T R U C K SE RV IC E M ANUAL
3C-38 FRONT SUSPENSION
SHOCK ABSORBER
Removal (Fig. 3C-30K)
1. Raise vehicle on hoist.
2. Remove nuts and eye bolts securing upper and lower
shock absorber eyes.
3. W ith draw shock absorber and inspect rubber eye
bushings. If defective, replace shock absorber
assembly.
Installation
Place shock absorber into position over mounting bolts
or into mounting brackets. Install eye bolts and nuts and
torque as shown in Specifications Section. Lower vehicle to
floor.
STABILIZER BAR-TYPICAL
Removal (Fig. 3C-31K)
1. Raise vehicle on hoist and remove nuts and bolts
Fig. 3C-28K--lnstalling Lower Bearing Cap-and-King
attaching stabilizer brackets and bushings at frame
Pin
location.
2. Remove brackets and bushings at lower spring anchor
plates and remove stabilizer from vehicle.
TYPICAL L.&R.H.
VIEW A
SPRING
PLATE
TYPICAL L &R.H.
VIEW B
Fig. 3C-29K--lnstalling Bearing Cap/Steering Arm Fig. 3C-31 K--Stabilizer Bar Attachment
LIG H T T R U C K SERVICE M A N U A L
FRONT SUSPENSION 3C-39
Inspection
Inspect rubber rushings for excessive wear or aging- 2. Press in new bushing; assure that tool presses on steel
replace where necessary. Use rubber lubricant when install outer shell of bushing. Install until bushing protrudes
ing bushings over stabilizer bar. an equal am ount on each side of spring.
LEAF SPRING AND BUSHINGS (Figs. 3C-32K and 1. Install spring shackle bushings into spring and attach
3C-33K) shackle. Do not tighten bolt.
2. Position spring upper cushion on spring.
Removal
3. Insert front of spring into frame and install bolt. Do not
1. Raise vehicle on hoist. tighten.
2. Place adjustable lifting device under axle. 4. Install shackle bushings into frame and attach rear
3. Position axle so that all tension is relieved from spring. shackle. Do not tighten bolt.
4. Remove shackle upper retaining bolt. 5. Install lower spring pad and spring retainer plate.
5. Remove front spring eye bolt. Torque bolts to specifications, Fig. 3C-35.
6. Remove spring-to-axle u-bolt nuts and remove spring, 6. Torque front and rear spring eye and shackle bolts to
lower plate and spring pads. specifications.
7. Remove shackle to spring bolt and remove bushings 7. Remove stands and lower vehicle to floor.
and shackle.
Bushing Replacement
1. Place spring on press and press out bushing using a
suitable rod, pipe, or tool.
TIG H TE N IN G SEQUENCE
1. Install all four nuts to uniform engagement
on 'U ' Bolts to retain and position anchor
plate in design position (perpendicular to
axis of 'U ' Bolts).
2. Torque nuts in positions 1 and 3 to
10-25 ft. lbs. (14-34 N-m).
3. Torque all nuts to full torque in follow ing
sequence: 2-4-1-3.
LIG H T T R U C K SE RV IC E M AN U AL
3C-40 FRONT SUSPENSION
SPECIFICATIONS
* Plus additional torque to align cotter pin. Not to exceed 90 ft. lbs. maximum.
** Plus additional torque to align cotter pin. Not to exceed 130 ft. lbs. maximum.
*** Plus additional torque to align cotter pin.
t All specifications are given in foot pounds of Torque unless indicated otherwise,
tt C10, G10-20 Rubber Bushings; C20-30, P10-30 Steel Bushings.
• P300 (32), P300 (42) and JF9 — 100 ft. lbs.
•• P300 (32) — 215 ft. lbs., P300 (42) and JF9 — 130 ft. lbs.
••• (K10-20) 205 ft. lbs., (K30) 65 ft. lbs.
Specs Page
LIG H T TR U C K SE R V IC E M AN U AL
FRONT SUSPENSION 3C-41
SPECIAL TOOLS
SECTION 3D
REAR SUSPENSION
The following notice applies to one or more steps in the assembly
procedure of components in this portion of the manual as indicated at the
appropriate locations by the terminology "See Notice on page 1 of this
Section ".
N OTICE This fastener is an important attaching part in that it could
affect the performance of vital components and systems, and /o r could result
in major repair expense. It must be replaced with one of the same part
number or with an equivalent 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 of this
part.
INDEX
GENERAL DESCRIPTION
All 10-30 series vehicles use a leaf spring/solid rear
axle suspension system. Typical systems are illustrated in
Fig. 3D-1, 3D-2 and 3D-3.
LIG H T T R U C K SE R V IC E M AN U AL
3D-2 REAR SUSPENSION
Fig. 3D-2--Typical G-Truck Rear Suspension Fig. 3D-3--Typical P-30 H.D. Truck Rear Suspension
Fig. 3D-4--Shock Absorber-CK-10, CK-20 (03, 06) Fig. 3D-5~Shock Absorber-CK-20 (43), CK30
LIG H T TR U C K SE RV IC E M A N U A L
REAR SUSPENSION 3D-3
SPACER
GROMMET
SHAFT
P300(32)
LINK BOLT
ANCHOR
PLATE NOTE T orqu e by running nut to
unthreaded portion of bolt.
1. Place spring on press and press out bushing using a 4. Wire brush and clean spring leaves. Inspect spring
suitable rod, pipe or tool as shown in Fig. 3D-21. leaves to determine if replacement is required; also
replace defective spring leaf liners at this time.
2. Press in new bushing; assure that tool presses on steel
outer shell of bushing. 5. Align center holes in spring leaves by means of a long
R ear Spring, Front Eye-Heavy Duty leaf springs on drift and compress spring leaves in a vise.
C20, CK30, and some P30 trucks use a staked- in-place 6. Remove drift from center hole and install a new center
flanged front eye bushing. Before this bushing is bolt. Tighten nut and peen bolt to retain nut.
pressed out of the spring, the staked locations must be 7. Align spring leaves by tapping with hammer, then
straightened with a chisel or drift. After a new bushing reinstall alignment clips. Spring clips should be bent
is installed, it must be staked in three equally spaced sufficiently to maintain alignment, but not tight enough
locations. to bind spring action.
LIG H T T R U C K SERVICE M A N U A L
REAR SUSPENSION 3D-5
G 1 0 0 + 2 0 0 ( 0 5 + 0 6 ) ALL
G 3 0 0 ( 0 5 + 0 6 ) ex c G 50
C 3 0 0 (0 5 + 0 6 ) & G 50
Fig. 3D-13~Rear Spring Installation - G Models Fig. 3D-14--Rear Spring Hangers - G Models
(Cutaway Vans) (Cutaway Vans)
L IG H T T R U C K SE RV IC E M AN U AL
3D-6 REAR SUSPENSION
SHACKLE REPLACEMENT
1. Raise vehicle on hoist. Place adjustable lifting device
under axle.
2. Remove load from spring by jacking frame.
3. Loosen spring-to-shackle retaining bolt, but do not
remove.
4. Remove shackle-to-frame bracket retaining bolt then
remove shackle bolt from spring eye.
5. Position shackle to spring eye and loosely install
retaining bolt. Do not torque retaining bolt at this time.
6. Position shackle to frame bracket and install retaining
bolt. Arrow stamped on shackle must point forward.
7. Rest vehicle weight on suspension components and
torque both shackle bolt retaining nuts to
specifications.
LIG H T T R U C K SERVICE M A N U A L
REAR SUSPENSION 3D-7
LIG H T T R U C K SE RV IC E M A N U A L
REAR SUSPENSION 3D-9
L IG H T T R U C K SERVICE M A N U A L
3D-10 REAR SUSPENSION
SPECIFICATIONS
TORQUE SPECIFICATION
C-K G P
Spring-to-Axle "U " Bolt Nuts 140 G10 120 P10 140
Leaf Spring
(G316 . . .90)
(G316 . . .90)
Shock Absorber
P20 140
P30 50
Propeller Shaft
Hanger-to-Frame 40-50 — —
Rear Stabilizer-to-Anchor Plate 20-30 — 20-30
--Specifications
SECTION 3E
WHEELS AND TIRES
NOTICE: The Wheel bolt and nut fasteners are an important attaching
part in that they could affect the performance of vital components and
systems, and /o r could result in major repair expense. They must be replaced
with one of the same part number or with an equivalent 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 of this part.
INDEX
General Description.............................................................3E-1
Replacement T ire s.............................................................3E-1
Metric T ir e s ....................................................................... .3E-2
Replacement W h e e ls....................................................... .3E-2
Certification L ab el.............................................................3E-3
Service O perations.............................................................. .3E-3
Tire Inspection and R o ta tio n ........................................ .3E-3
Tire Inflation Pressure......................................................3E-4
Correcting Irregular Tire W e a r .....................................3E-7
Wheel Installation .............................................................3E-8
Tire Mounting and D em ounting.................................. .3E-9
Tire R epair......................................................................... .3E-10
Wheel N u t T orqu es......................................................... .3E-10
GENERAL DESCRIPTION
The factory installed tires and wheels are designed to affect load carrying capacity, ride, handling, speedometer/
operate satisfactorily with loads up to and including the full odometer calibration, vehicle ground clearance, and tire
rated load capacity when inflated to the recommedned clearance to the body and chassis. If replacing only a single
inflation pressures. tire, it should be paired on the same axle with the least worn
Correct tire pressures and driving techniques have an tire of the others.
important influence on tire life. Heavy cornering, exces All tires on four-wheel drive vehicles must be of equal
sively rapid acceleration, and unnecessary sharp braking size (but not necessarily ply rating) and of same tread
increase tire wear.
configuration.
kPa psi kPa psi The wheels originally equipped on the vehicle will
provide optimum life up to the maximum load and inflation
140 20 215 31 pressures shown in the Wheel Code and Limits Chart.
145 21 220 32 M axim um loads, m axim um inflation pressures, wheel
155 22 230 33 identification codes, and wheel sizes are stamped on each
160 23 235 34 wheel. Service tested and approved wheels are available
165 24 240 35 from service. When obtaining wheels for any reason from
170 25 250 36 any other source, the replacement wheels should be equal in
180 26 275 40 load capacity, inflation pressure capacity, diameter, width,
185 27 310 45 offset and mounting configurations to those originally
190 28 345 50 installed on the vehicle.
200 29 380 55
A wheel of the wrong size or type may adversely affect
205 30 415 60
load carrying capacity, wheel and bearing life, brake
cooling, speedometer/odometer calibration, stopping abil
C onve rsion: 6.9 kPa = 1 psi
ity, headlight aim, bumper height, vehicle ground clearance,
and tire clearance to the body and chassis. Replacement
Fig. 3E-2--lnflation Pressure Conversion with "used" wheels is not advised: they may have been
subjected to harsh treatm ent or very high mileage and could
REPLACEMENT WHEELS fail without warning.
Wheels must be replaced if they become damaged (for
example: bent, heavily rusted, leak air) or if wheel nuts often The use of wheels a n d /o r tires with higher load
carrying limits than originally equipped on the vehicle does
not in itself increase the G A W R or the G V W R of the
vehicle.
LIG H T T R U C K SERVIC E M A N U A L
WHEELS AND TIRES 3E-3
r.
□ 0 8 /7 8
GVW R
MFD. BY GENERAL MOTORS CORP
Cj A W R F R T G AW R RR
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T IR E S 10 5X16 5D 10 5 X16 51
R IM S 16 5 X 9 /5 16 6 X 9 75
P S l/k P . C O LD DUAL 3 6 /2 4 8 4 2 290
l HIS VI MU. | | C !)\ I IIRMS 10 A| I U U tH A l MIMUH U HiC i f SAM Tv
f ON TH> E DATE M ANUF AC TU R E SHO W N A B O V E
I c G Q I 691100001 B U S - N O T S C H O O L BU S
SE E O W NERS M A N U AL F OH A D D IT IO N A L IN FO R M A TIO N
E XAMPL E ONLY
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4 WHEEL 5 WHEEL 4 WHEEL 5 WHEEL
ROTATION ROTATION ROTATION ROTATION
SERVICE OPERATIONS
CAUTION:Servicing of tires mounted on multi uneven wear corrected. Be certain to check wheel nut
piece rims requires proper tools, safety equipment tightness and to adjust the tire pressures, front and rear,
and specialized training. Severe injuries can result after rotation to agree with those recommended in the tire
from improper servicing techniques. It is recom inflation charts.
mended that tires on multi-piece rims be serviced
only by competent personnel with proper equip The outer tire on a dual wheel will skid or drag on a
ment or by competent truck tire repair shops. turn because of the difference in the turning radii of the
inner and outer tires. This results in faster wear of the outer
TIRE INSPECTION AND ROTATION (Figs. 3E-4, tire. In general, the tire with the largest diameter or least
wear whould be at the outside of each dual wheel. In
3E-5) addition, when trucks are operated continuously on high
Front and rear tires perform different jobs and can crown roads an increase in air pressure of from 5 to 10 PSI
wear differently depending on the type of roads driven, in the outside tire of each dual produces maximum tire life.
individual driving habits, etc. To obtain maximum tire life,
tires should be inspected at intervals shown in Section OB. As shown in Fig. 3E-5, the X method of rotation is
For the longest tire life, any time irregular wear is noticed, allowed with radial tires if necessary. Due to their design,
the tires should be inspected and rotated and the cause of the radial tires tend to wear faster in the shoulder area
LIG H T TR U C K SE RV IC E M A N U A L
3E-4 WHEELS AND TIRES
particularly in the front positions. This makes regular Too low an air pressure can result in tire overloading,
rotation especially necessary. abnormal tire wear, adverse vehicle handling, and reduced
fuel economy. The tire flexes more and can build up
INFLATION PRESSURE excessive heat, weakening the tire and increasing suscepti
The maximum cold inflation pressures for the factory bility to damage or failure. Too high an air pressure can
installed tires are listed on the Certification Label. Tires result in abnormal wear, harsh vehicle ride, and increased
must be inflated to these pressures when the G V W R or an susceptibility to damage from road hazards. Lower inflation
axle G A W R is reached. Improper tire inflation pressures for pressures should be used only with reduced vehicle loads and
the load the vehicle is carrying can adversely affect tire life the rear tire pressure should be equal to or greater than the
and vehicle performance. front pressure on single wheel application. After determin
For improved ride comfort in vehicles rated at 8600 ing the load on each tire by weighing the vehicle on a scale,
G V W R , it is permissible to use the lower tire pressure valves the correct cold inflation pressures for the actual tire loads
shown on the label located on the rear edge of the driver’s can be obtained from the Tire/W heel Load and Inflation
door provided there is a m aximum of 200 lbs. cargo, no slide Pressure Charts shown in this section. Refer to Section OB
in camper, and there are three or less occupants. The lower for additional information on inflation pressure.
G V W R and G A W R (rear) reflect the m axim um load
carrying capacity of the tires at lower pressure.
T IR E S U SED AS S IN G L E S
YF 9.50-16.5 D 1860 2030 2190 2350 2500 2650 2780
YF 9.50-16.5 E 1860 2030 2190 2350 2500 2650 2780 2920 3050 3170
T IR E S U SED AS D U A L S
ZX 7.00-16 C 1260 1365 1475 1580
ZX 7.50-16 C 1430 1565 1690 1815
ZX 7.50-16 D 1430 1565 1690 1815 1930 2040 2140
YD 8.75-16.5 C 1380 1515 1630 1750
YD 8.75-16.5 D 1380 1515 1630 1750 1855 1970 2070
L IG H T T R U C K SERVICE M A N U A L
WHEELS AND TIRES 3E-5
• Wheel Code
• Wheel Size Stamps
WHEEL USAGE AND TIRE LOAD LIM ITS AT VARIOUS INFLATION PRESSURES*
BIAS TIRES FOR LIG H T TRUCKS
USED AS SINGLES
Wheel Code Tire Load Ply Tire Load Limits at Various Inflation Pressures (PSI)
Regular O p tio n a l Size Range Rating 30 35 40 45 50 55 60 65 70 75
Wheel load limits are shown below. Vehicle loading must be limited such that neither the wheel or tire load limits are exceeded.
W H E E L C O D E A N D L IM IT S
Wheel Limits
Code Size of Wheel Max. Load Max. Press.
(Lbs.) (PSI)
YH 15 x 6 JJ 1585 40
YD, YH 16.5 x 6.00 2680 85
YJ 16.5 x 6.75 2680 85
CD 15 x 6V2 JJ 1690 40
XW 15 x 6 Jj 1916 70
BX 15 x 7 JJ 1690 40
A LU M . 15 x 6 'A JJ 1690 40 • Wheel Code
LIG H T T R U C K SERVICE M A N U A L
3E-6 WHEELS AND TIRES
W H E EL CODE AN D L IM IT S
W HE EL L IM IT S
S IZ E OF M AX. M A X.
STAMPING LOCATION CODE W HEEL LOAD PRESS.
(L B S .) (P S I)
I FOR RIM SIZE
Y D , YJ 1 6 .5 x 6 .0 2680 85
YC 1 6 .5 x 6 .0 2350 70
YF 1 6 .5 x 6 .7 5 3170 85
BF 16 x 6 .5 0 L 2780 85
(#) 2 7 8 0 lb s . a t 8 0 lb s . p re s s u re .
LIG H T T R U C K SE RV IC E M A N U A L
WHEELS AND TIRES 3E-7
CORRECTING IRREGULAR TIRE WEAR resulting in excessive wear on the outside half of the tire,
producing a type of wear like that caused by excessive
Heel and Toe Wear positive camber.
This is a saw-toothed effect where one end of each tread Cornering wear can be most easily distinguished from
block is worn more than the other. The end that wears is the abnorm al cam ber wear by the rounding of the outside
one that first grips the road when the brakes are applied. shoulder or edge of the tire and by the roughening of the
Heel and toe wear is less noticeable on rear tires than tread surface which denotes abrasion.
on front tires, because the propelling action of the rear Cornering wear often produces a fin or raised portion
wheels creates a force which tends to wear the opposite end along the inside edge of each row in the tread pattern. In
of the tread blocks. The two forces, propelling and braking, some cases this fin is almost as pronounced as a toe-in fin,
make for more even wear of the rear tires, whereas only the and in others, it tapers into a row of tread blocks to such an
braking forces act on the front wheels, and the saw-tooth extent that the tire has a definite "step wear" appearance.
effect is more noticeable. The only remedy for cornering wear is proper instruc
A certain amount of heel and toe wear is normal. tion of operators. Driving more slowly on curves and turns
Excessive wear is usually due to high speed driving and will avoid grinding rub ber off tires. To offset normal
excessive use of brakes. The best remedy, in addition to cornering wear as much as possible tires should be inter
cautioning the owner on his driving habits, is to interchange changed at regular intervals.
tires regularly.
Wheel and Tire Balancing
Side Wear
It is desirable from the standpoints of tire wear and
This may be caused by incorrect wheel camber, un vehicle ride and handling ease to maintain proper balance of
derinflation, high cambered roads or by taking corners at too wheel and tire assemblies on all models. This m ay be
high a rate of speed. The first two causes are the most accomplished by either of the two types of balancing
common. Camber wear can be radily identified because it systems in currect use which balance wheels either on the
occurs only on one side of the treads, whereas underinflation vehicle or off. The "on the vehicle" type, however, is the
causes wear on both sides. Cam ber wear requires correction more desirable in that all rolling components (brake drums,
of the camber first and then interchanging tires. There is, of bearings, seals, etc.) are included in the balancing procedure
course, no correction for high cambered roads. Cornering and thereby have any existing unbalance corrected.
wear is discussed further on.
• Bent wheels that have runout over 1/16" should be mounting surfaces can cause wheel nuts to loosen
replaced. which can later allow a wheel to come off while
• Inspect tire and wheel assembly to determine if an the vehicle is moving, possibly causing loss of
eccentric or out-of-round condition exists. Note that control.
this condition, if severe, cannot be "balanced ou t". An
assembly which has an out-of-round condition exceed Dual Wheels
ing 3/16 " on tire sizes through 19.5" is not suitable for W hen installing wheels on vehicles with dual rear
use on the front of the vehicle. Its use on the rear should wheels:
be governed by its general condition and whether the
1. Install inner and outer wheel and clamp ring on rear, or
roundness defect seriously detracts from overall ride
wheel and clamp ring on front (be sure pins on clamp
quality.
ring face outboard).
• When balancing wheels and tires, it is recommended
2. Install and snug nuts finger tight.
that the instructions covering the operation of the wheel
balancer being used be closely followed. 3. Torque nuts to specified torque in sequence shown in
Fig. 3E-12.
• When balancing truck type nylon tires, tires must be
hot (run for several miles) before raising vehicle to Lateral runout should not exceed 1/8" on front wheel
balance so that flat spot is elimated. A tire which is flat or 3 /1 6" on rear wheel.
spotted will be incorrectly balanced.
• On 10 and 20 series trucks, do not attem pt to externally Attachment of Dual Wheels On P300 Models
drive the wheels with the transfer case in the neutral To assure secure attachm ent of the dual disc wheels, it
position. Although, the transfer case will be uncoupled is important that all dirt or rust scale be removed from the
from the transmission, the front and rear drive trains mating surface of the wheels, hub, and clamp ring as well as
will be coupled through the transfer case. For example, the stud and nut. P O W E R D R IV E N U T S T H E N M A N U
attempting to balance a rear wheel on the vehicle will A L L Y IN S P E C T T O R Q U E A T 130-180 FT. LBS. M A N
cause one or both of the front wheels to also be driven. U A L T O R Q U E O N L Y : 150-200 FT. LB.
T he wheels may be dynam ically balanced on the
vehicle with the transfer case in the 2H position. The Side and Lock Rings
transfer case neutral position should only be used when
Side and lock rings of different rim types are not
it becomes necessary to uncouple the transmission from
interchangeable. Some may appear to be, but they do not fit
the transfer case.
peoperly on the rim base. Serious accidents have resulted
from the use of mismatched rings. Rim base and rings must
WHEEL INSTALLATION
be matched according to manufacturer, size and type. This
information is stamped on each part.
Single Wheels
Inspection for Leaks
When installing the tire and wheel on the vehicle, the
1. With wheel assembly removed from vehicle, inflate the
following procedure should be followed:
tire to recommended operating pressure.
After wheel nuts are put on loosely, turn the wheel until
2. Check for leaks at rim bead by placing wheel and tire
one nut is at the top of the bolt circle; tighten the nut just
horizontal and allowing w ater to stand in groove
snug. Snug up the remaining nuts criss-cross to minimize
between rim and tire. Check for other leaks by lowering
runout, then tighten the nuts to the recommended torque
assembly into water tank or running water over tire.
alternately and evenly to avoid excessive runout.
CAUTION:Before re-installing wheels, remove any Installing Synthetic Tubes
build up of corrosion of the wheel mounting NOTICE: When tube and flap are not properly lubri
surface and brake drum or disc mounting surface cated and mounted, they will stretch thin in the tire
by scraping and wire brushing. Installing wheels bead and rim region. This will cause prem ature failure.
without good metal-to-metal contact at the
1. Before installing tube in tire, clean inside of casing
thoroughly.
2. Insert tube in tire and inflate until it is nearly rounded
out.
3. Inspect rim for rust scale and bent flanges-clean rust
scale and straighten flanges where necessary.
4. Using a brush 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 mounting tire and tube on a drop center rim,
follow the standard procedure. Be sure tire is centered
on rim so that beads are out of rim well before inflating.
Do not allow tire to hang loosely on wheel while
inflating.
LIGHT TRUCK SERVICE MANUAL
WHEELS AND TIRES 3E-9
6. Center valve and pull it firmly against the rim. Hold in RADIAL TIRES
this position and inflate until tire beads are firmly
Recommended truck tire mounting and inflation proce
seated on rim against flanges.
dures are especially im p ortant with radial truck tires.
7. Completely deflate tire by removing valve core. Failure to follow these recommendations can cause bead
8. Reinflate tire to recommended pressure. deformation in both tube type and tubeless tires due to
incorrect bead seating. Bead deformation may lead to
TUBELESS TIRES chafing, lower sidewall and bead area cracking, demounting
difficulties, eccentric wear, ride vibration and non-retread-
Tubeless tires mounted on one piece full drop center
able casing.
rims are standard on some trucks. These tires have a safety
inner liner which if punctured, tends to cling to the Mounting
penetrating object forming a partial seal until the object is
To insure correct mounting and bead seating and to
removed from the tire.
prevent bead deform ation, the following steps must be
taken:
Mounting and Demounting A. Tube Type Tires
Use a tire changing machine to mount or demount tires. 1. Only use rims approved for radial tire usage by rim
Follow the equipment m anufacturer’s instructions. Do not manufacturer. Thoroughly clean rim parts, removing
use hand tools or tire irons alone to change tire as they may all rust and other foreign material. Make sure rim
damage the tire beads or wheel rim. parts match and are not sprung or broken.
Rim bead seats should be cleaned with a wire brush or 2. Thoroughly lubricate tire beads, portion of tube
coarse steel wool to remove lubricants, old rubber, and light between beads, and flaps with an approved rubber
rust. Before mounting or demounting a tire, the bead area lubricant. Radial tubes are identifiable by the letter
should be well lubricated with an approved tire lubricant. " R " in the size designation. Example 100R20. Also,
After mounting, inflate to 40 psi so that beads are to further identify the radial tube, a red band on the
completely seated. valve stem has been required since March, 1975.
Radial flaps are also identified by the letter " R " .
CAUTION:Do not stand over tire when inflating. Example - 20R8.
Bead may break when beads snaps over safety NOTICE: Do not use silicone base lubricants - this could
hump and cause serious personal injury. cause the tire to slip on the wheel.
Do not exceed 275 kPa (40 psi) pressure when 3. Double inflate. Inflate to operating pressure, deflate
inflating. If 275 kPa (40 psi) pressure will not seat completely and reinflate to operating pressure. This
beads, deflate, re-lubricate and reinflate. Overin allows tube, flap and tire to fit together properly.
flation may cause the bead to break and cause
4. Check bead seating. Visually check slot and side ring
serious personal injury. gap (on two piece rim) to make sure bead is seated.
Install valve core and inflate to proper pressure. Check The flange and one of the three lower sidewall rim
the locating rings of the tire to be sure they show around the line rings while the tire is laying flat (measurements
rim flanges on both sides (Fig. 3 E - 14). should be taken each 90° around the circumference
of the rim flange). If spacing is uneven around bead
from side to side, repeat Step 1 through 3, and
recheck.
B. Tubeless Tires.
1. Only use rims approved for radial tire usage by rim
manufacturer. Thoroughly clean rim, removing all
rust and other foreign material.
2. Thoroughly lubricate tire beads and rim bead seats
with an approved rubber lubricant.
NOTICE: Do not use silicone base lubricants - this could
cause the tire to slip on the wheel.
3. Inflation. Inflate tire to operating pressure. Due to
the construction of radial truck tires, particularly in
the lower sidewall and bead area, it may be difficult
to get the tire to take air. An inflation aid may be
necessary to help seat the bead of tubeless radial
tires. Two types of inflation aids are commercially
available, (1) metal rings which use compressed air
to seat beads, and (2) rub ber rings which seal
between the tirebead and rim bead seat allowing the
bead to move out and seat. Lubrication is mandatory
with both items.
4. Check bead seating. This check is made by measur
ing the space between the rim flange and one of the
L IG H T T R U C K SERVICE M A N U A L
3E-10 WHEELS AND TIRES
LIG H T T R U C K SE RV IC E M A N U A L
PROPELLER SHAFT 4A-1
SECTION 4A
PROPELLER SHAFT
The following notice applies to one or more steps in the assembly
procedure of components in this portion of the manual as indicated at
appropriate locations by the terminology "See Notice on page 1 of this
Section".
N O T IC E : This fastener is an important attaching part in that it could
affect the performance of vital components and systems, a nd/or could result
in major repair expense. It must be replaced with one of the same part
number or with an equivalent 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 of this
part.
CONTENTS
General D escription...........................................................................................4A-1
Universal Jo in ts............................................................................................... .4A-1
Propeller S h a f t ................................................................................................ ..4A-2
Diagnosis.............................................................................................................. ..4A-2
On C ar Service....................................................................................................4A-5
GENERAL DESCRIPTION
Universal Joints greater than three to four degrees. At four degrees, for
example the change of velocity is .5%. At ten degrees it is
The simple universal joint is basically two Y-shaped 3%. If the universal joint were set at 30 degrees and the
yokes connected by a crossmember called a spider. The driving yoke were turning at 1000 RPM the velocity of the
spider is shaped like an X and arms that extend from it are driven yoke would change from 856 RPM to 1155 R PM in
called trunnions. See figure 4 A - 1. one q u a rte r of a revolution. In the rem aining q u a rte r
revolution the velocity would change from 1155 R PM to 866
The spider allows the two yoke shafts to operate at an RPM .
angle to each other. When torque is transmitted at an angle, On a one-piece drive shaft this problem can be elimi
through this type of joint, the driving yoke rotates at a nated by arranging two simple universal joints so that the
constant speed while the driven yoke speeds up and slows two driving yokes are rotated 90 degrees to each other.
down twice per revolution. This changing of velocity However the angle between the drive and driven yokes must
(acceleration) of the driven yoke increases as the angle be very nearly the same on both joints for this to work. Refer
between the two yoke shafts increases. This is the prime to figure 4A-2. This allows the alternate acceleration and
reason why single universal joints are not used for angles deceleration of one joint to be offset by the a lte rn a te
deceleration and acceleration of the second joint. When the
two joints do not run at approximately the same angle,
operation can be rough and an objectionable vibration can
be produced.
LIG H T T R U C K SERVICE M AN U AL
4A-2 PROPELLER SHAFT
Propeller Shafts
The propeller shaft is a steel tube which is used to
transmit power from the transmission output shaft to the
differential. To accommodate various model, wheelbase and
transmission combinations, drive shafts differ in length,
diameter and the type of splined yoke. Each shaft is installed
Universal joints are designed to consider the effects of in the same manner. A universal joint and splined slip yoke
various loadings and rear axle windup, during acceleration. are located at the transmission end of the shaft, where they
Within the design angle variations the universal joints will are held in alignment by a bushing in the transmission rear
operate safely and efficiently. However, when the design extension. The slip yoke permits fore and aft movement of
angles are exceeded the operational life of the joints may the drive shaft as the differential assembly moves up and
decrease. down. The spline is lubricated internally by transmission
The bearings used in universal joints are the needle lubricant or grease. An oil seal at the transmission prevents
roller type. The needle rollers are held in place on the leakage and protects the slip yoke from dust, dirt and other
trunnion by round bearing cups. The bearing cups are held harmful material.
in the yoke by either (depending on the manufacturer) snap Since the drive shaft is a balanced unit, it should be
rings or plastic injection. These joints usually are lubricated kept completely free of undercoating and other foreign
for life and cannot be lubricated while on the vehicle. material which would upset shaft balance.
Both one piece and two piece propeller shafts are used
Constant Velocity Joint-Double Cardan Joint depending on the model. All are tubular and use needle
As mentioned previously, the simple universal joint will bearing type universal joints.
operate efficiently through small angles only. Also, two On models that use a two piece shaft, the shaft is
simple universal joints phased properly and operating supported near its splined end in a rubber cushioned ball
through the same angle will transmit constant velocity. bearing which is mounted in a bracket attached to a frame
When a large angle is encountered in a driveline, a simple crossmember. The ball bearing is permanently lubricated
universal joint will introduce two vibrations in each revolu and sealed.
tion. It is in this situation that a constant velocity joint is Four wheel drive models use a front propeller shaft
used. incorporating a constant velocity joint.
D IA G N O STIC CH ART
K n o ck in drive line, clu n k in g a. W orn o r dam aged universal a. D isassem ble universal jo in ts , in sp e ct
noise w hen car is o p e ra te d jo in ts. an d replace w o rn or d am ag ed p a rts.
u n d e r flo atin g c o n d itio n at
10 m p h in high gear or b. Side gear h u b c o u n te rb o re in b. R eplace d iffere n tia l case a n d /o r side
d iffe re n tia l w o rn oversize. gears as re q u ire d .
n e u tra l.
C O M P L A IN T POSSIBLE CAUSE C O R R E C T IO N
If vibration decreased, or h. Drive shaft or companion h. Check for missing balance weights
is eliminated, in a flange unbalance. on drive shaft. Remove and
different gear range but reassemble drive shaft to companion
at the same engine speed flange, 180° from original position.
(rpm), check the
possible causes: i. Excessive looseness at slip i. Replace necessary parts.
yoke spline.
j. Check drive shaft runout at front and
j. Drive shaft runout (50-80 mph rear. Should be less than specified. If
throttle conscious) above, rotate shaft 180° and recheck.
If still above specified, replace shaft.
Roughness usually at low speeds, a. U-bolt clamp nuts excessively a. Check and correct torque to that
light load, 15-35 mph. tight. specified. If torque was excessive
or if brenelled pattern on trunnions
is evident, replace joints.
Roughness on heavy a. Double cardan joint ball seats a. Replace joint and shaft assembly.
acceleration (short duration.) worn. Ball seat spring may be
broken.
UNIT REPAIR
PROPELLER SHAFT Due to length of the propeller shaft it may be more
convenient to use a bench vise, for removal and
The rear universal joint to propshaft bolt on some CK 1
installation, instead of an arbor press. In this case,
ton dual wheel models requires a # 10 "Six Lobed Socket"
proceed with disassembly and assembly procedure as
(J-25085), for proper removal and installation. 34 N-m,
with an arbor press Fig. 4A-8 and 4A-9.
(Torque to 25 lbs. ft.).
3. Using a suitable socket or rod, press on trunnion until
bearing cup is almost out. Grasp cup in vise and work
Removal cup out of yoke. See figures 4A-8 and 4A-9. The
1. Raise vehicle on hoist. M ark relationship of shaft to bearing cup cannot be fully pressed out.
companion flange and disconnect the rear universal
joint by removing trummion bearing " U " bolts or
straps. Tape bearing cups to trunnion to prevent 4. Press trunnion in opposite direction and remove other
dropping and loss of bearing rollers. cup as in Step 3.
2. For models with two-piece shafts remove bolts retain 5. Clean and inspect dust seals, bearing rollers, and
ing bearing support to hanger. trunnion. Relubricate bearings as indicated in Section
3. Slide propeller shaft forward disengaging trunnion 0.
from axle flange, then slide assembly rearward disen
gaging from transmission.
For models using strap or U-bolt atta ch m e n ts to
transmission or transfer case use same removal proce
dure as above.
Universal Joints
On models with between center slip propshaft it is
important that components are marked prior to dissassem-
bly for proper phasing.
Reassembly Fig. 4 A -1 0
1. Position trunnion into yoke. Paritally install one
bearing cup into yoke. Start trunnion into bearing cup.
Partially install other cup. Align trunnion into cup, and
press cups into yoke.
2. Install lock rings.
6. If the front universal joint is being serviced, remove the 4. Install opposite bearing cup part way. Make sure that
pair of bearing cups from the slip yoke in the same both trunnions are started straight and true into both
manner. bearing cups.
5. Press against opposite bearing cups, working the cross
Reassem bly all of the time to check for free movement of the
A universal joint service kit is used when reassembling trunnions in the bearings. If there seems to be a hang
this joint. See figure 4 A - 13. This kit includes one pregreased up, stop pressing and recheck needle rollers, to deter
cross assembly, four service bearing cup assemblies with mine if one or more of them has been tipped under the
seals, needle rollers, washers, grease and four bearing end of the trunnion.
retainers. 6. As soon as one bearing retainer groove clears the inside
of the yoke, stop pressing and snap the bearing retainer
Make sure that the seals are in place on the service into place as shown in figure 4A-15.
bearing cups to hold the needle rollers in place for handling.
ROLLER BEARINGS
BEARING RETAINER
Fig. 4 A -1 3 -R e p a ir Kit
STRIKE TUBE YOKE
EAR IN THIS AREA
LIG H T T R U C K SERVICE M A N U A L
4A-8 PROPELLER SHAFT
9. Check the freedom of rotation of both sets of trunnions length of pipe over splined end of shaft, press bearing
of the cross. If too tight, again rap the yoke ears as and inner slinger against shoulder on shaft.
described above. This will loosen the bearings and help
d. Install dust shield over shaft, small diameter (Dana
seat the bearing retainers.
Style). Install bearing retainer (GM Style).
LIG H T T R U C K SERVICE M A N U A L
PROPELLER SHAFT 4A-9
3. For G-K models with two piece shafts, install front half
into transmission and bolt support to crossmember.
a. Slide grease cap and gasket onto rear splines.
b. Rotate shaft so front U-joint trunnion is in correct
position. See figure 4 A - 19.
c. Take rear propeller shaft and before installing, align
U-joint trunnions as shown in figure 4A-19. Attach
rear U-joint to axle. Tighten grease cap.
d. Torque bearing support to crossmember and U-joint
to axle attachments.
L IG H T T R U C K SERVIC E M A N U A L
4A-10 PROPELLER SHAFT
WASHER
SEAL
TUBE
BALL STUD
YOKE COUPLING YOKE
FLANGE YOKE
FLANGE YOKE
COUPLING YOKE BALL SUPPORT
TUBE YOKE
Fig. 4A-21--Reassembling Coupling Yoke Fig. 4A-24-lnstalling Tool J-23996 Over Ball
Fig. 4A-25--lnstalling Outer Cylinder of Tool J-23996 Fig. 4A-27--lnstalling Centering Ball
Over Ball 7. Lubricate seal lip and press seal flush with Tool
Centering Ball Replacement J-23694, as shown in figure 4A-28. Sealing lip should
1. Place fingers of inner part of Tool J-23996 under ball as tip inward.
shown in figure 4A-24. 8. Fill cavity with grease provided in kit.
2. Place outer cylinder of Tool J-23996 over outside of 9. Install flange yoke to centering ball as shown in figure
ball as shown in figure 4A-25. 4A-29, making sure alignment marks are correctly
3. Thread nut on Tool J-23996 and draw ball off stud, positioned. Install trunnion and bearing caps as pre
using wrench as shown in figure 4A-27. viously outlined.
4. Place the replacement ball on stud.
5. Using Tool J-23996, drive ball onto stud as in figure
4A-27, until the ball can be seen to seat firmly against LUBRICATION
the shoulder at the base of the stud. This is important as The front axle propshaft found on all four-wheel drive
the center of the double C ardan joint is determined by trucks requires special lubrication procedures at two loca
the ball seating tightly in the proper location. tions: The C /V joint, and the slip yoke.
6. Using grease provided in the ball seat kit, lubricate all
parts and insert them into the clean ball seat cavity in
Constant Velocity Joints (C/V)
the following order: spring, w asher (smallest O D ), T he constant velocity ( C /V ) joint, located at the
three ball seats (with largest opening outw ard to transfer case end of the front propshaft, must be lubricated
receive ball), washer (largest OD) and seal. periodically (see Section 0) with special lubricant,
# 1050679, or equivalent. If the fitting cannot be seen from
beneath the vehicle Figure 4A-30 shows how the fitting may
be lubricated from above the C /V joint, with a special
adapter J -2 5 5 12-2 on the end of a flex hose.
L IG H T TR U C K SE R V IC E M AN U AL
4A-12 PROPELLER SHAFT
Slip Spline
to disconnect the propshaft from the truck, remove the slip
yoke, and wire brush the affected areas. Wipe clean before
Apply chassis lubricant at the fitting until grease begins reinstallation. When installing the propshaft to transfer case
to leave through the vent hole. front output flange attaching bolts, torque to specification
If the slip spline is dry or corroded, it may be necessary 95-110 N-m (70-80 ft. lbs.).
SPECIFICATIONS
PROPELLER SHAFT
CK G P
P ro p e lle r S h a ft
To R ear A x le (S tra p ) 1 2 -1 7 1 2 -1 7 1 2 -1 7
B e a rin g S u p p o rt-to -H a n g e r 2 0 -3 0 2 0 -3 0 2 0 -3 0
H a n g e r-to -F ra m e 4 0 -5 0 — —
To T ra n s fe r Case
D a n a Style 2 0 -3 0
G M Style 7 0 -8 0
SECTION 4B
REAR AXLE
The following notice applies to one or more steps in the assembly
procedure of components in this portion of the manual as indicated at
appropriate locations by the terminology "See Notice on Page 1 of this
Section ".
N O T IC E : This fastener is an important attaching part in that it could
affect the performance of vital components and systems, a nd/or could result
in major repair expense. It must be replaced with one of the same part
number or with an equivalent 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 of this
part.
CONTENTS
GENERAL DESCRIPTION
A differential is an arrangement of gears that divides If a vehicle were always driven in a straight line, the
the torque between the axle shafts and allows them to rotate ring and pinion gears would be sufficient. The axle shaft
at different speeds. A basic differential consists of a set of could then be solidly attached to the ring gear and both
four gears. Two of these gears are called differential side driving wheels would turn at equal speeds.
gears, and the other two are differential pinion gears. Some
differentials have more than two pinion gears. Each side However, if it became necessary to turn a corner, the
gear is splined to an axle shaft. Consequently, each axle tires would scuff and slide because the outer wheel would
shaft must turn when its side gear rotates. travel further than the inner wheel To prevent tire scuffing
The differential pinion gears are mounted on a differ
ential pinion shaft, and the gears are free to rotate on this
shaft. The pinion shaft is fitted into a bore in the differential
case and is at right angles to the axle shafts.
Power flow through the differential is as follows: The
drive pinion roates the ring gear. The ring gear, being bolted
to the differential case, rotates the case. The differential
pinion, as it rotates with the case, forces the pinion gears
against the side gears. W hen both wheels have equal
traction, the pinion gears do not rotate on the pinion shaft
because the input force on the pinion gear is equally divided
between the two side gears. See figure 4B-1. Consequently,
the pinion gears revolve with the pinion shaft, but do not
rotate around the shaft itself. The side gears, being splined
to the axle shafts and in mesh with the pinion gears, rotate
the axle shafts.
LIG H T T R U C K SE R V IC E M AN U AL
4B-2 REAR AXLE
1. C om panion Flange 7. D iffe r e n tia l Case 13. C over 19. Thrust W asher
2. D e fle c to r 8. Shim 14. P inion S haft 2 0 . D iffe r e n tia l Pinion
3. Pinion O il Seal 9. G a sket 15. Ring G e a r 2 1 . Shim
4. Pinion Front Bearing 10. D iffe r e n tia l Bearing 16. Side G e a r 2 2 . Pinion Rear Bearing
5. Pinion Bearing Spacer 11. " C " Lock 17. Bearing C a p 2 3 . D riv e Pinion
6. D iffe r e n tia l C a rr ie r 12. Pinion Shaft Lock Screw 18. A x le Shaft
Fig. 4B-3--8-1 /2 " and 8 -7 /8 " Ring Gear Axle Cross-Section Typical
4B-4 REAR AXLE
•J9HT U&mg W i
REAR AXLE 4B-5
1. Nut 11. Shims (Inner Pinion 17. Cover and Plug 24. Bolt (Differential
2. Washer Bearing) 18. Lock Pin (Pinion Bearing Cap)
3. Companion Flange 12. Cup (Inner Pinion Shaft) 25. Bolt (Ring Gear)
4. Pinion Oil Seal Bearing) 19. Differential Case 26. 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 28. Pinion
(Outer Pinion Bearing) 15. Gasket (Housing (Differential Bearing) 29. Side Gear
9. Shims (Outer Pinion Cover) 22. Cup (Differential 30. Thrust Washer (Side
Bearing) 16. Screw and Washer Bearing) Gear)
10. Inner Pinion Oil Slinger (Cover) 23. Cap (Differential
Bearing)
DIFFERENTIAL DIAGNOSIS
STANDARD DIFFERENTIAL vehicle to determ ine w hether the noise is normal or if a
problem actually exists. A norm al am ount of noise must be
expected and cannot be elim inated by conventional repairs
Noise
or adjustm ent. See figure 4B-9.
The most essential part of rear axle service, as with any
mechanical repair, is proper diagnosis of the problem, and,
in axle work one of the most difficult areas to diagnosis is A cceptable noise can be defined as a slight noise heard
noise. Locating a broken axle shaft, or broken differential only at a certain speed or under unusual or rem ote condi
gear, presents little or no problem , but, locating and tions. For example, this noise tends to reach a "p eak " at
isolating axle noise can be an entirely different m atter. speeds from 40 to 60 miles per hour (60 to 100 km /h)
depending on road and load conditions, or on gear ratio and
Degree of Noise tire size. This slight noise is in no way indicative of trouble in
Any gear driven unit, and especially an automotive the axle assembly.
drive axle where engine torque m ultiplication occurs at a Drive line noises may baffle even the best diagnostician.
90° turn in the drive line, produces a certain am ount of Vehicle noises coming from tires, transm ission, propeller
noise. Therefore, an interpretation m ust be m ade for each shaft, universal joints, and front or rear wheel bearings, are
LIGHT TRUCK SERVICE MANUAL
REAR AXLE 4B-9
Problem Cause
9. Drive noise, coast noise or float noise 9. Ring and pinion gear
10. Clunk on acceleration or deceleration 10. Worn differential cross shaft in case
14. Clunk or knock on rough road operation 14. Excessive end play of axle shafts to differential
cross shaft
Fig. 4B-11--Diagnosis of Noise Problems
U il &
PATTERN ON RACES AND ROLLERS CAUSED BY METAL SMEARS ON ROLLER ENDS DUE TO OVERHEAT, CAGE DAMAGE DUE TO IMPROPER HANDLING
FINE ABRASIVES. LUBRICANT FAILURE OR OVERLOAD (WAGON'S) OR TOOL USAGE.
CLEAN ALL PARTS AND HOUSINGS. CHECK SEALS REPLACE BEARING CHECK SEALS AND CHECK REPLACE BEARING.
AND BEARINGS AND REPLACE IF LEAKING, ROUGH FOR PROPER LUBRICATION.
OR NOISY.
..
mm m m m ML -
//Ill w
INDENTATIONS CAGE WEAR M ISALIG N M EN T
SURFACE DEPRESSIONS ON RACE AND ROLLERS WEAR AROUND OUTSIDE DIAMETER OF CAGE AND OUTER RACE MISALIGNMENT DUE TO FOREIGN
CAUSED BY HARD PARTICLES OF FOREIGN MATERIAL. ROLLER POCKETS CAUSED BY ABRASIVE MATERIAL OBJECT.
AND INEFFICIENT LUBRICATION.
CLEAN ALL PARTS AND HOUSINGS. CHECK SEALS CLEAN RELATED PARTS AND REPLACE BEARING.
AND REPLACE BEARINGS IF ROUGH OR NOISY. CLEAN RELATED PARTS AND HOUSINGS. MAKE SURE RACES ARE PROPERLY SEATED.
CHECK SEALS AND REPLACE BEARINGS.
«r
Fig. 4B-12-Differential and Axle Bearing Diagnosis Chart A
RACE CRACKED DUE TO IMPROPER FIT, FLAKING OF SURFACE METAL RESULTING FROM SURFACE INDENTATIONS IN RACEWAY CAUSED BY
COCKING, OR POOR BEARING SEATS. FATIGUE. ROLLERS EITHER UNDER IMPACT LOADING OR
VIB RATIO N WHILE THE BEARING IS NOT ROTATING.
REPLACE BEARING AND CORRECT BEARING REPLACE BEARING - CLEAN ALL RELATED PARTS.
SEATS.
REPLACE BEARING IF ROUGH OR NOISY.
SMEARS
SMEARING OF METAL DUE TO SLIPPAGE.
SLIPPAGE CAN BE CAUSED BY POOR FITS.
LUBRICATION, OVERHEATING, OVERLOADS
OR HANDLING DAMAGE.
ON-VEHICLE SERVICE
8-1 /2 , 8 -7 /8 and 9-1 /2 RING AXLE SHAFT
GEAR AXLE Removal
1. Raise vehicle on hoist. Remove wheel and tire assembly
AXLE ASSEMBLY and brake drums.
C onstruction of the axle assembly is such th at service 2. Clean all dirt from area of carrier cover.
operations may be perform ed with the housing installed in 3. D rain lubricant from carrier by removing cover.
the vehicle or with the housing installed in a holding fixture.
4. Remove the differential pinion shaft lock screw and the
The following removal and installation procedure is neces
differential pinion shaft as shown in figure 4 B -14.
sary only when the housing requires replacem ent.
5. Push flanged end of axle shaft tow ard center of vehicle
NOTICE: See N O T IC E on page 1 of this section, and remove " C " lock from button end of shaft.
regarding Axle Assembly fasteners.
6. Remove axle shaft from housing, being careful not to
Removal dam age oil seal.
W hen removing the axle shaft on the 9 1/2" ring gear
1. Raise vehicle on hoist.
axle, be sure the thrust washer in the differential case
2. Support rear axle assem bly with suitable lifting device, do es n o t slip out.
so th a t tension is relieved in springs and shock
absorbers.
Axles equipped with 8 -7 /8 " ring gears and E aton
3. Remove trunnion bearing " U " bolts from the axle
Locking differentials use a thrust block on the pinion shaft
com panion flange, se p a ra te trunnion from flange,
which affects the removal of axle shafts as noted below.
position propeller shaft to one side and tie it to fram e
side rail.
Secure trunnion bearing caps to trunnion, using m ask
ing tape or a large rubber band, to prevent loss of
bearings.
4. Disconnect shock absorbers at lower attachm ent points
and position out of the way.
5. Disconnect axle vent hose from vent connector and
position vent hose to one side.
6. Disconnect hydraulic brake hose at connector on axle
housing. Rem ove brak e dru m , disconnect parking
brake cable at actuating levers and at flange plate.
Refer to Section 5 for cable removal and brake details.
Remove axle " U " bolt nuts, " U " bolts, spacers and
clam p plates.
7. Lower axle assembly and remove from vehicle.
Installation
1. Position axle assembly under vehicle and align with
springs.
2. Install spacer, clam p plate and " U " bolts to axle
assembly, loosely install retaining nuts to " U " bolts.
3. Position shock absorbers in lower attachm ent brackets
and loosely install nut to retain shock.
4. Connect axle vent hose to vent connector at carrier.
5. Connect hydraulic brake hose to connector on axle
housing, connect park in g brak e cable to a c tu atin g
levers. Install brake drum and wheel and tire assembly-
bleed brakes and adjust parking brake as outlined in
applicable portion of Section 5.
6. Reassem ble the propeller shaft to companion flange,
m aking sure th at bearing caps are indexed in flange
seat. T orque b earin g cap retaining nuts to
specifications.
7. Position vehicle so th at weight is placed on suspension
components and torque affected parts to specifications.
Fig. 4B-15--Removing Lock Screw
8. Lower vehicle and remove from hoist.
LIGHT TRUCK SERVICE MANUAL
REAR AXLE 4B-15
Fig. 4B-18--Push Axle Shaft Inward Fig. 4B-19—Oil Seal and Wheel Bearing
Fig. 4B-24--Measuring Pinion Rotating Torque Fig. 4B-27~Drive Pinion Flange Removal
Inspection
1. Inspect pinion flange for smooth oil seal surface, worn
drive splines, dam aged ears, and for smoothness of
bearing contact surface. Replace if necessary.
2. If deflector requires replacem ent, remove by tapping
from flange, clean up stake points; install new deflector,
and stake deflector at three new equally spaced posi
tions. Staking operation m ust be perform ed in such a
m anner th at the seal operating surface is not dam aged.
Installation
1. Lubricate cavity between the seal lips of the pinion
flange oil seal with a lithium -base extrem e pressure
lubricant.
2. Position seal in bore and place gauge plate J-22804-1
over seal and against seal flange. The gauge plate
assures proper seating of seal in carrier bore.
3. Use J-21057 or J-22388 for the 9 1/2 inch ring gear, as Fig. 4B-29--lnstalling Pinion Flange
shown in figure 4B-28, to press seal into carrier bore 7. R eattach propeller shaft and torque to specifications.
until gauge plate is flush with the carrier shoulder and Reinstall brake drum s and wheels.
seal flange. T u rn gauge plate 180° from installed
position; seal m ust be square in carrier bore to seal NOTICE: See N O T IC E on page 1 of this section
properly against pinion flange. regarding the fasteners referred to in step 7.
8. Lower vehicle and remove from hoist.
4. Pack the cavity between end of pinion splines and
pinion flange with a non-hardening sealer (such as CHEVROLET 1 0 -1/2 RING
Perm atex Type A or equivalent) prior to installing GEAR AXLES
washer and nut on pinion.
5. U sing J-8614-11 as shown in figure 4B-29, install AXLE ASSEMBLY
flange oi\to pinion. Install washer and nut, and tighten Service operations on these axle assemblies may be
nut to original position. Refer to scribe m arks and perform ed with the housing installed in the vehicle or with
num ber of exposed threads, recorded earlier. the housing installed in a holding fixture. There may be
NOTICE: Do not attem p t to ham m er the flange onto occasions, however, when it will be necessary to remove the
pinion shaft. To do so may dam age the ring gear and complete housing assembly. The following axle assembly
pinion. removal and installation procedure, therefore, is necessary
only when housing replacem ent is required.
6. M easure rotating torque of pinion and com pare with NOTICE: All axle attachm ents are im portant attaching
torque recorded before removal. Tighten pinion nut in parts. See N O T IC E on page 1 of this section.
additional small increm ents until the torque necessary
Removal
to rotate the pinion exceeds the original figure by 1 to 5
inch pounds. Do not exceed the original torque by more 1. Raise vehicle, place stand jacks under fram e side rails,
than 5 inch pounds. and remove rear wheels.
2. Remove two trunnion bearing " U " bolts from the rear
yoke, split rear universal joint, position propeller shaft
J-22804-1 to one side, and tie it to the fram e side rail.
The bearings can be left on the trunnion and held in
place with tape.
J-21057 3. Remove hub and drum assembly and disconnect park
ing brake cable at lever and at flange plate. See Section
5 for cable removal.
4. Disconnect hydraulic brake hose at connector on rear
axle housing. Refer to Section 5.
5. Disconnect shock absorbers at axle brackets.
6. Support axle assembly with hydraulic jack, remove
spring " U " bolts, and lower axle assembly to the floor.
Installation
1. Place axle assembly under vehicle, raise into position,
install spring " U " bolts, anchor plates and nuts, and
tighten securely.
Fig. 4B-28--Pinion Oil Seal Installation 2. Connect and secure shock absorbers to axle brackets.
UGHT TRUCK SERVICE MANUAL
REAR AXLE 4B-19
AXLE SHAFT
Replacement
1. Remove bolts th at attach the axle shaft flange to the
wheel hub. See figure 4B-30.
Bearing /Cup-Removal
1. Use a ham m er and long d rift to knock the inner
bearing, cup and oil seal from the hub assembly.
Fig. 4B-30--Removing Flange-to-Hub Bolts 2. Remove outer bearing snap ring with a pair of pliers.
LIGHT TRUCK SERVICE MANUAL
4B-20 REAR AXLE
3. W ith J-24426 on H andle J-8092, as shown in figure 4B- 6. To install inner bearing cup, use J-24427 on H andle
33, drive outer bearing and cup from the hub assembly. J-8092. D rive cup into place until it seats against
shoulder of hub bore.
7. Install new oil seal with J-24428.
Inspection and Cleaning o f Bearings
1. Inspect bearin g rollers for excessive w ear, chipped
edges, and other dam age. Slowly move rollers around
Drum-Non-Demountable-Type-Fig. 4B-31
cone to detect any flat or rough spots on rollers or cone.
Replacement
2. Exam ine bearing cups in hub for pits, cracks, and other
damage. C onstruction of the nondem ountable-type hub and
drum assembly is such th at replacem ent cannot be accom
3. Exam ine axle sh a ft flange studs, wheel studs, hub
plished with the hub assembly installed on the vehicle.
splines, hub bore, and tapped holes for evidence of
dam age. C lean up th read s or replace p arts w here 1. Separate the drum and hub by removing the drum -to-
required. hub retaining bolts, hub stud nuts, or by pressing out
the wheel studs, as applicable.
4. E xam ine oil seal sleeve for evidence of w ear or
roughness, check axle housing oil deflector and brake 2. Position brake drum to hub assembly, making certain
drum oil deflector for evidence of dam age. Replace th a t all drain holes are in alignm ent.
parts where required. 3. Apply a light, even coating of sealing compound to the
5. Exam ine brake drum for excessive scoring and other hub oil deflector contact surface, and position deflector
dam age. To replace brake drum refer to "B rake D rum to drum .
R eplacem ent." 4. Install drum -to-hub retaining bolts, hub stud nuts, or
6. Im m erse bearing cone and roller assemblies in cleaning press wheel studs into drum , as applicable.
solvent. Clean with stiff brush to remove old lubricant.
Blow bearings dry with compressed air, directing air Wheel Bolt
stream across b earing. Do not spin bearings while
blowing them dry. Replacement
7. Thoroughly remove all lubricant from axle housing W heel bolts are serrated and m ay also be swaged in
tube and from inside the hub, wipe dry. M ake sure all place; however, replacem ent procedure rem ains the same
particles of gasket are removed from outer end of hub, for both types of installation.
axle shaft, and hub cap. Press bolts out of hub flange and press new bolts into
8. Scrape old sealing com pound out of oil seal bore in the place, m aking sure they are a tight fit. If all bolts are
hub. removed, be sure th at hub oil deflector is in position under
bolt heads. See figure 4B-34.
Bearing / Cup-lnstallation
1. Place outer bearing into hub.
2. Install cup of outer bearing into hub by using H andle Installation of Hub and Drum Assembly
J-8092 and J-8 60 8 , installed upside-down. Be sure 1. U sing a high m elting point E P bearing lu bricant,
J-8608 is upside down on driver handle, so th a t cham fer liberally pack bearings and apply a light coat on I.D. of
does not contact bearing cup. hub bearing contact surface and O.D. of axle housing
3. Drive cup beyond the snap ring groove. tube.
4. Using a pair of pliers, install snap ring into its groove. 2. M ake sure inner bearing, oil seal, axle housing oil
5. Drive cup back against snap ring by using J-24426, as deflector, and inner bearing race and oil seal are
shown in figure 4B-33. properly positioned.
REMOVAI INSTALLATION
Fig. 4B-33--Removing Outer Bearing and Cup Fig. 4B-34--Wheel Bolt Replacement
BEARING ADJUSTMENT
Before checking bearing adjustm ent, m ake sure brakes
are fully released and do not drag.
C heck bearing play by grasping tire at top and pulling
back and forth, or by using a pry bar under tire. If bearings
are properly adjusted, m ovem ent of brake drum in relation
to brake flange plate will be barely noticeable and wheel will
turn freely. If movement is excessive, adjust bearing as
follows:
1. Remove axle shaft and raise vehicle until wheel is free
to rotate.
2. Keyways and threads on tube and nut m ust be clean DRIVE PINION OIL SEAL
and free from chips, burrs and shavings.
Replacement
3. Disengage tang of retainer and remove retainer from
axle housing tube. The pinion oil seal m ay be replaced with the carrier
assembly installed in the vehicle.
4. T orque adjusting nut to 50 ft. lbs., at the sam e tim e
1. Disconnect propeller shaft.
rotating the hub assem bly and m aking sure bearing
cones are seated and in co n ta c t w ith the spindle 2. Scribe a line down the pinion stem, pinion nut and
shoulder. companion flange.
Proper wheel bearing adjustm ent can be m ade using 3. Use J - 8 6 14-11 to rem ove the pinion n ut and the
tool J-2222-02 with some modification or tool J-2222-L companion flange.
(Fig. 4B-36). 4. Pry the oil seal from the bore, using care not to dam age
5. Back off nut until loose. the m achined surfaces. Thoroughly clean all foreign
m aterial from contact area.
6. If adjusting nut slot is in alignm ent with key way in axle
5. Lubricate the cavity between the seal lips with a high
spindle, insert square key into slot. If adjusting nut slot
melting point bearing lubricant.
is not aligned, back off nut a slight am ount and insert
square key into slot. Do not back off nut more than one 6. In stall a new pinion oil seal into the bore, using
slot to align key. J-24434.
7. Assemble snap ring at end of spindle to retain key in 7. R einstall the com panion flange, pinion nut and propel
position. ler shaft.
NOTICE: See N O T IC E on page 1 of this section,
regarding the above fasteners.
Bearing Cup-lnstallation
Replacement
1. To install outer bearing, place axle shaft spacer in hub,
1. Remove hub cap, and install Tool J -8 117 in tapped hole
followed by the outer bearing. The larger O.D. of the
on shaft flange.
bearing goes toward the outer end of the hub.
2. Install slide ham m er, Tool J-2619, and remove axle
2. Position outer bearing cup in hub with the thin edge of
shaft.
the cup tow ard the outer end of the hub.
3. Thoroughly remove old gasket m aterial from hub and
3. Press the cup into the hub, using J - 8 114 and H andle
hub cap. Clean shaft flange and m ating surfaces in the
J-8092.
wheel hub.
4. Install axle shaft so th a t the flange splines index into
hub splines. T ap shaft into position, using J -8 117 and
J-2619.
5. Install new gasket, position flange to hub and install
attaching bolts. T orque bolts to specifications.
BEARING ADJUSTMENT
Before checking bearing adjustm ent, make sure brakes
are fully released and do not drag.
Check bearing play by grasping tire at top and pulling
back and forth, or by using a pry bar under tire. If bearings
are properly adjusted, movement of brake drum in relation
Fig. 4B-40--lnstalling Hub Inner Bearing Cup to brake flange plate will be barely noticeable and wheel will
LIGHT TRUCK SERVICE MANUAL
4B-24 REAR AXLE
SPECIFICATIONS
DIFFERENTIAL SPECIFICATIONS
Chevrolet
Chevrolet
0 0
c c
0 0
O a
IOV 2 "
>< »
lO W '
£ i
£
£ O ri' (X £ O rf' CN
00 00 05 ■— Ov BOLT TORQUES 00 oo o. — o-
(FT.-LBS.)A
G ear Backlash .005"- .005"- .005"- .004"- .005"- .005"-
Preferred .008" .008" .008"- .009" .008" .008" Filler Plugs 25 18 18 10 18 10
.003"- .003"- .003*'- .004"- .003"- .003"- Differential Pinion
Min. and Max. 2 0"# 2 0"# — — — —
.010" .010" .010"- .009" .012" .012" Lock
Pinion Bearing Drive Pinion Nut — * * * 220
Preload (In.-Lbs.) Differential Carrier
— New 15-30 15-30 20-25 20-40 25-35 — — — — 85
to Axle Housing
— Used 5-10 5-10 5-15 10-20 5-15 Differential Bearing
— 20 — 20 15
Adjusting Lock
Pinion Bearing Cage
— — — 65 165
To Carrier
Carrier Cover 20 20 20 35 30 — Thrust Pad Lock Nut — — — — 135
Ring G ear 80 60 110 110 120 105 Brake Backing Plate 35 35 105 105 105 155
Differential Axle Shaft To
55 55 65 85 135 205 — — 115 115 15
Bearing Caps Hub Bolts
AExcept where noted otherwise. *T orque as necessary to obtain correct preload.
RING GEAR
MODEL SOURCE TYPE/CAPACITY
SIZE
K10 C h e v ro le t S a lis b u ry / 3 7 5 0 # 8 -1 /2 ”
K10 C h e v ro le t S a lis b u r y /3 7 5 0 # 8 - 7 /8 ”
K10 C h e v ro le t S a lis b u r y /4 0 0 0 # 8 - 7 /8 ”
(Except
C20 Crew C h e v ro le t S a lis b u r y /6 0 0 0 # 9 -1 /2 ”
Cab)
P20 C h e v ro le t S a lis b u r y /6 0 0 0 # 9 -1 /2 ”
(Except
C30 Dual
K30 Wheel C h e v ro le t S a lis b u r y /7 5 0 0 # 1 0 - 1 /2 "
Camper)
C30 *Dual
K 3o yyheel . Dana S a lis b u r y /7 5 0 0 # 1 0 - 1 /2 "
Camper)
RING GEAR BEARING ADJUSTING ADJUSTING NUT OUTER LOCKNUT RESULTING TYPE OF
SIZE NUT TORQUE* BACK-OFF* TORQUE BEARING ADJUSTMENT BEARING
10-1/2” 50 FT. LBS. .001 TO .010 TAPERED
9-3/4” 50 FT. LBS. ** 65 FT. LBS. END PLAY ROLLER
SLIGHT BARREL
12-1/4” 90 FT. LBS. 1/8 * 250 FT. LBS.
PRELOADED ROLLER
**B a ck-o ff n ut and retighten to 35 Ft. Lbs. then, back-off nut 1/4 turn.
*W ith wheel rotating.
SPECIAL TOOLS
*§>
10
11
13
H* m
16 17
° I
w
19 20 21
22
1. J-2 15 4 8 T ru n n io n Seal In sta lle r 16. J-2 44 3 0 D iffe re n tia l Side Bearing In s ta lle r
2. J-2 36 9 0 A x le S h a ft Bearing In sta lle r 17. J-2 3 3 2 2 P in io n S tra d d le B earing In s ta lle r
3. J-2 36 8 9 A x le S h a ft Bearing R em over 18. J-2 44 2 6 O u te r W heel B earing C up Tool
4. J-21128 A x le S h a ft Seal In sta lle r 19. J-2 4 4 3 2 P in io n Rear Bearing C up In s ta lle r
5. J-21057 P in io n O il Seal In sta lle r 20. J-24427 In n e r W heel Bearing C up In s ta lle r
6. J-22804-1 P inio n Seal Gauge Plate 21. J-8 60 8 O u te r W heel Bearing C up In s ta lle r
7. J-5 74 8 P o s itra c tio n T o rq u e Measuring A d a p te r 22. J-2 43 8 4 P in io n O il Seal In s ta lle r - Dana
8. J-6 62 7 Wheel B o lt R em over 23. J-2 44 2 8 Wheel H u b O il Seal In sta lle r
9. J-8 09 2 D rive r H andle 24. J-2 4 4 3 4 P in io n O il Seal In s ta lle r - C h e v ro le t
10. J -5 8 5 3 T o rq u e W rench - In ch /P o u n d 25. J-870 W heel B earing N u t W rench
11. J-8 61 4 -II C om p a n io n Flange H o ld e r 26. J-2 23 8 0 T ru -A rc Pliers
12. J-2 61 9 S lid e H am m er 27. J -2 2 3 5 4 W heel O il Seal In s ta lle r
13. J-2 22 2 Wheel Bearing N u t W rench 28. J-22281 P in io n O il Seal In sta lle r
14. J-2 44 2 9 A d ju s tin g N u t W rench 29. J-8 11 4 Wheel Bearing O u te r C up In s ta lle r
15. J-2 44 3 3 P inio n Rear Bearing In sta lle r 30. J-8 09 3 Wheel Bearing In n e r C up In s ta lle r
: ;
m ##■
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-• Vr.
SECTION 4C
CONTENTS
GENERAL DESCRIPTION
The front axle is a hypoid gear axle unit equipped with 1. Install seal and thru st w asher on axle shaft.
steering knuckles. Axle assembly num ber and production 2. Install axle shaft into axle housing.
date are stam ped on left tube of assembly. 3. Install spindle.
K 10-20 M odels use a C hevrolet front axle, both
4. Install splash shield. Torque nuts to specifications.
incorporate a 8-1/2" ring gear. A 4500 lb. capacity unit is
used on the K-30 Model. The K-30 axle assembly is a Dana 5. Install rotor and adjust wheel bearings.
(60 Series) which incorporates a 9 -3 /4 " ring gear. 6. Install gears and snap rings.
7. Install hub lock mechanism.
8. Install caliper.
Axle Shaft
9. Install tire and wheel.
Removal 10. Lower vehicle.
1. Syp h on m aster cylinder.
11. Add fluid and check brake operation.
2. Raise vehicle.
3. Remove wheel and tire. FRONT AXLE ASSEMBLY (Refer to Fig. 4C-2)
4. Remove caliper.
Removal
5. Remove hub lock mechanism.
1. Raise front of vehicle on hoist until weight is removed
6. Remove gears and snap rings.
from front springs. Support truck with jack stands
7. Remove rotor. behind front springs.
8. Remove inner bearing and seal.
2. Disconnect propeller shaft from front axle differential.
9. Remove spindle and backing plate.
3. Disconnect connecting rod from steering arm .
10. Remove axle shaft.
4. Remove and support caliper.
Installation 5. Disconnect shock absorbers from axle brackets.
Prior to installation, the following items should be 6. D isconnect axle vent tube clip a t the differential
checked. housing (see fig. 4C-3).
a. Lube spindle bearing.
7. Dismount " U " bolts from axle to separate axle from
b. Clean, inspect and repack inner and outer wheel truck springs.
bearing.
8. Raise truck to clear axle assembly and roll front axle
c. Clean hub and spindle and lube spindle. out from under the truck.
LIGHT TRUCK SERVICE MANUAL
4C-2 FRONT WHEEL DRIVE
FRONT WHEEL, PINION, DIFFERENTIAL SIDE AND REAR WHEEL ROLLER BEARINGS
DIAGNOSIS
Engine or 1. Drive slightly above speed where noise occurs, place transmission in neutral
2. Let engine speed drop to idle
Exhaust
3. Stop car
Noises
4. Run engine at various speeds
SPECIFICATIONS
CHEVROLET
DANA
Bolt Torques Bolt Torques
Axle Axle
(Ft.-Lbs.) (Ft.-Lbs.)
Gear Backlash Preferred .004"-. 009" Carrier Cover 35
Min. and Max. .004"-.009" Ring Gear* — K-30 110
New Pinion Bearing Preload 20-40 in.-lbs. Differential Bearing Caps 85
Used Pinion Bearing Preload 10-20 in.-lbs. Filler Plugs 10
Drive Pinion Nut** — K-30 270
SECTION 5
BRAKES
T he following notice applies to one or more steps in the assembly
procedure of com ponents in this portion of the m anual as indicated at
appropriate locations by the term inology "See N otice on page 1 of this
section ".
N O TICE: This fastener is an im portant attaching p art in th a t it could
affect the perform ance of vital components and systems, an d /o r could result
in m ajor repair expense. It m ust be replaced with one of the same part
num ber or with an equivalent p art if replacem ent becomes necessary. Do not
use a replacem ent p art of lesser quality or substitute design. Torque values
m ust be used as specified during reassem bly to assure proper retention of this
part.
C A U TIO N : W hen servicing wheel brake parts, do not create dust by
grinding or sanding brake linings or by cleaning wheel brake parts with a dry
brush or with compressed air. (A w ater dam pened cloth should be used.)
M any wheel brake parts contain asbestos fibers which can become airborne if
dust is created during servicing. Breathing dust containing asbestos fibers
m ay cause serious bodily h a rm ."
CONTENTS
G eneral D escrip tio n ............................................................ 5-1 Delco Disc Brake Shoe and Lining..............................5-29
Diagnosis................................................................................ 5-2 Bendix Disc Brake Shoe and Lining.......................... .5-34
On-V ehicle Service.............................................................. 5-10 C aliper O v erh au l..............................................................5-36
Pedal T ravel...................................................................... 5-10 Rotor Servicing................................................................ .5-39
Stop L ight S w itc h ........................................................... 5-10 Brake D rum Shoe and L ining...................................... .5-39
Bleeding and Flushing B ra k e s..................................... 5-10 Standard D rum B rake............................................... .5-39
Hydro-Boost Bleeding P ro c e d u re ............................... 5-12 Propeller Shaft B rake................................................ .5-42
Brake P ip es....................................................................... 5-17 Brake D ru m s .....................................................................5-43
Brake H oses.......................................................... ........... 5-17 W heel C y lin d e r............................................................... .5-43
Parking Brake Pedal or H a n d le .................................. 5-21 Power Brake U n it.............................................................5-46
Parking Brake (Propshaft) Internal E xpanding...... 5-21 Vacuum B ooster......................................................... .5-46
Parking Brake C a b le ...................................................... 5-22 Hydro-Boost U n it....................................................... .5-46
C om bination V a lu e ........................................................ 5-22 Specifications........................................................................ .5-53
Brake P e d a l...................................................................... 5-22 Brake System D escription............................................ .5-53
Brake Pedal R o d ............................................................. 5-23 Torque Specifications......................................................5-54
M aster C y lin d er.............................................................. 5-24 Special Tools........................................................................ ..5-55
GENERAL DESCRIPTION
OPERATION OF MASTER CYLINDER brake re tra c to r springs to re tra c t the shoe and lining
assemblies from contact with the drum which forces brake
W hen the brake pedal is depressed, force is transferred fluid out of the wheel cylinder assemblies and back into the
through the push rod to the m aster cylinder prim ary piston, m aster cylinder assembly. The reduction in fluid pressure
which moves forw ard. U nder norm al conditions, the com also allows the caliper pistons to retract slightly by action of
bination of hydraulic pressure and the force of the prim ary the piston seal.
piston spring move the secondary piston forw ard a t the same M aster cylinders designed for use w ith a system
time. W hen th e pistons have moved forw ard so th at their
incorporating low drag calipers. In addition to the standard
prim ary cups cover the bypass holes, hydraulic pressure is
m aster cylinder functions, a quick take-up fea tu re is
b u ilt up and tra n sm itte d to the fro n t and re a r brake included. This provides a large volume of fluid to the wheel
assemblies. H ydraulic pressure behind the wheel cylinder brakes at low pressure with initial brake application. The
cups forces the pistons outw ard, causing the brakes to be low pressure fluid quickly provides the displacem ent re
applied. quirem ents created by the seal retracting pistons into the
As brake pedal force is reduced, brake fluid pressure in front calipers and spring retraction of the rear drum brake
the m aster cylinder is also reduced. This allows the drum shoes.
LIGHT TRUCK SERVICE MANUAL
5-2 BRAKES
OPERATION OF DISC BRAKE the pressure to overcome the rear shoe and lining retractor
springs. There is no restriction a t inlet pressures below 21
Upon application of the brakes, fluid pressure behind
kPa (3 psi) to allow for pressure equalization during non
the caliper piston increases. Pressure is exerted equally
apply periods.
against the bottom of the piston and also against the bottom
of the piston bore. The pressure applied to the piston is The proportioning section of the combination valve
transm itted to the inner shoe and lining, forcing the lining proportions outlet pressure to the rear brakes after a pre
against the inner rotor surface. The pressure applied to the determ ined rear input pressure has been reached. This is
bottom of the piston bore forces the caliper to slide or move done to prevent rear wheel lock-up on vehicles with light
on the mounting bolts tow ard the inner side, or toward the rear wheel loads. C ertain models having high rear wheel
vehicle. Since the caliper is one piece, this movement toward loads do not have the proportioning feature.
the vehicle causes the outer section of the caliper to apply
The valve is designed to have a "B y-Pass" feature
pressure against the back of the outer shoe and lining
assembly, forcing the lining against the outer rotor surface. which assures full system pressure to the rear brakes in the
As line pressure builds up, the shoe and lining assemblies are event of a front brake system failure. Full front pressure is
pressed against the rotor surfaces with increased force, retained in the event of rear failure.
bringing the vehicle to a stop. The pressure differential w arning switch is designed to
Lining wear is autom atically com pensated for by the constantly com pare front and rear brake pressure from the
outw ard movement of the caliper and piston. Brake fluid fills m aster cylinder and energize the warning light on the dash
this void as lining wears. in the event of a front or rear system failure. The valve and
switch are so designed th at the switch will latch in the
OPERATION OF COMBINATION VALVE "w arning" position once a failure has occurred. The only
The m etering or hold off section of the com bination way the light can be turned off is to repair the failure and
valve limits pressure to the front disc brakes until a pre apply a pedal force as required to develop up to 3100 kPa
determ ined front input pressure is reached, approxim ating (450 psi) line pressure.
DIAGNOSIS
INSPECTION AND TESTING BRAKES 4. Front End Alignment—M isalignm ent of the front end,
particularly in regard to limits on cam ber and theoreti
Testing Brakes cal king pin inclination, will cause the brakes to pull to
one side.
New linings m ust be protected from severe use for
several hundred miles. HYDRO-BOOST
Brakes should be tested on dry, clean, reasonably Prior to perform ing the Booster Function Tests, or the
smooth and level roadway. A tru e test of brake perform ance A ccum ulator L eakdow n T est, th e following prelim inary
cannot be m ade if roadw ay is wet, greasy or covered with checks m ust be made:
loose dirt so th a t all tires do not grip the road equally. NOTICE: Power steering fluid and brake fluid cannot be
Testing will also be adversely affected if roadway is crowned mixed. If brake seals contact steering fluid or steering
so as to throw weight of vehicle tow ard wheels on one side or seals contact brake fluid, seal dam age will result.
if roadway is so rough th a t wheels tend to bounce. 1. Check all power steering and brake lines and connec
Test brakes at different vehicle speeds with both light tions for leaks and/or restrictions.
and heavy pedal pressure; however, avoid locking the wheels 2. Check and fill brake m aster cylinder with B R A K E
and sliding the tires on roadway. Locked wheels and sliding FL U ID .
tires do not indicate brake efficiency since heavily braked 3. Check and fill power steering pum p reservoir with
but turning wheels will stop vehicle in less distance than P O W E R S T E E R IN G FL U ID . Be sure fluid is not
locked wheels. M ore tire-to-road friction is present with a aerated (air mixed with fluid).
heavily braked turning tire th an with a sliding tire. 4. Check power steering pum p belt for tension an d /o r
dam age. A djust if necessary.
External Conditions that Affect Brake Performance
5. Check engine idle speed and adjust if necessary.
1. T ires—Tires having unequal contact and grip on road 6. Check steering pump pressure; R efer to Section 3B.
will cause unequal b raking. T ires m ust be equally
inflated and tread p attern of right and left tires m ust be
approxim ately equal. SEAL LEAK DIAGNOSIS (FIG. 5-1)
2. Vehicle Loading—W hen vehicle has unequal loading, 1. IN P U T R O D SEAL: A dam aged seal will show up as a
the most heavily loaded wheels require more braking fluid leak from the m ounting bracket vent hole. The
power th an others. A heavily loaded vehicle requires booster m ust be removed from the vehicle and disas
sembled. The input rod bore should be checked for any
more braking effort.
scratches th at may cause the leak. If scratches are
3. Front W heel Bearings—A loose front wheel bearing present, housing cover m ust be replaced. If no excessive
perm its the drum to tilt and have spotty contact with scratches are present, then the booster seal kit can be
the brake shoe linings causing e rratic action. used to replace the appropriate seals.
LIGHT TRU CK SERVICE MANUAL
BRAKES 5-3
4. A fter the accu m u lato r has been em ptied, and the booster m ust be disassembled and the accum ulator
engine is started again, another hissing sound m ay be valves replaced.
heard during the first brake application or the first 3. If the accum ulator can be heard charging and dis
steering m aneuver. This is caused by the fluid rushing charging, but it does not hold a charge, disassem ble the
through the accum ulator charging orifice. It is normal booster and replace the accum ulator valves.
and will only be heard once after the accum ulator is 4. Deplete the accum ulator by pressing the brake pedal 4
emptied. However, if this sound continues, even though or 5 times. If the accum ulator can has lost its gas
no apparent accum ulator pressure assist was m ade, it charge, it is possible to rotate or wobble the accum ula
could be an indication th a t the accum ulator is not tor can w ith respect to the housing. R eplace the
holding pressure and should be checked using the accum ulator assembly.
procedure for " A C C U M U L A T O R L E A K D O W N
T E S T ".
BOOSTER FUNCTIONAL TEST
5. A fter bleeding, a "gu lp in g " sound m ay be present
W ith the engine off", apply the brake pedal several times
during brak e ap p licatio n s as noted in the bleeding
until the accum ulator is completely depleted. Depress the
instructions.
brake pedal (approxim ately 40 p o u n d s/180 N pedal force)
and sta rt the engine. The pedal should fall and then push
CHECKING THE RESERVE SYSTEM back against driver’s foot.
1. S tart engine and charge accum ulator by applying the
brake pedal or by turning the steering wheel from stop ACCUMULATOR LEAKDOWN TEST
to stop. Turn off engine and let vehicle sit for one hour. S ta rt engine and charge accum ulator by either apply
A fter one hour there should be at least two power ing the brake pedal (approxim ately 100 pounds/450 N
assisted applications with the engine off. force) or by turning the steering wheel from stop to stop.
2. If the reserve system will not retain a charge for one Turn off engine and let vehicle sit for one hour. A fter one
hour, but functions norm ally im m ediately following hour there should be two power assisted applies w ith engine
charging, the accum ulator valves are at fault and the stopped.
Excessive Brake Pedal Loose or broken power steering pump belt. Tighten or replace the belt.
Effort
No fluid in power steering reservoir. Fill reservoir and check for external leaks.
Faulty booster piston seal causing leakage at Overhaul with new seal or input rod and
booster flange vent. piston assembly.
Faulty booster input rod seal with leakage at Overhaul with new seal kit.
input rod end.
Faulty booster cover seal with leakage Overhaul with new seal kit.
between housing and cover.
Faulty booster spool plug seal. Overhaul with spool plug seal kit.
Slow Brake Pedal Excessive seal friction in booster. Overhaul with new seal kit.
Return
Faulty spool action. Flush steering system while pumping brake
pedal.
Damaged input rod end. Replace input rod and piston assembly.
Crabby Brakes Faulty spool action caused by contamina Flush steering system while pumping brake
tion in system. pedal.
Faulty spool operation caused by contamin Flush steering system while pumping brake
ation in system. pedal.
Accumulator Leak Contamination in steering hydro-boost Flush steering system while pumping brake
Down-System does system pedal
not hold charge
Internal leakage in accumulator system Overhaul unit using accumulator rebuild kit
and seal kit.
Noise (high pitched squeak 1. Front linings worn out. 1. Replace linings.
without brake applied).
Brake roughness or chatter 1. Excessive lateral runout. 1. Check per instructions and
(Pedal Pulsates) replace or machine rotor,
if not within specifications.
Brake roughness or chatter 5. Shoe reversed (steel 5. Replace shoe and lining and
(Pedal Pulsates) — Continued against iron). machine rotor within
specifications.
Excessive Pedal Effort 1. Malfunctioning power 1. Check power brake and repair
brake. if necessary.
Excessive Pedal Travel 1. Partial brake system 1. Check both front and rear
failure. system for a failure and
repair. Also check and
repair warning light circuit.
It should have indicated
a failure.
Pulsation (roughness) 1. Uneven pad wear caused 1. Remove caliper and correct
Felt during normal by caliper not sliding as necessary.
brake application. due to improper clear
ance or dirt.
A ir In Brake System XX X XX
Improperly Assembled
X X X X XX
Power Head Valvinq
Worn Out Brake Lining - Replace X X X X X X X X
X - Indicates causes
5-10 BRAKES
ON-VEHICLE SERVICE
PEDAL TRAVEL Electrical contact should be m ade when the brake
pedal is depressed 1.0-1.24" (25-31 mm) (C -K m od
A t reasonably frequent intervals, the brakes should be els), .45-.95'1 (11-24 mm) (G -P models) from its fully
inspected for pedal travel, which is the distance the pedal released position.
moves tow ard th e floor from a fully-released position.
Inspection should be m ade with the brake pedal firmly
BLEEDING AND FLUSHING BRAKE SYSTEM
depressed (approxim ately 90 lbs.) while the brakes are cold.
C-K -G M a n u a l......... 4.5" (115 mm) Bleeding Brake Hydraulic System
C-K -G P o w e r.......... 3.5" (90 mm)
A bleeding operation is necessary to remove air w hen
P (Except J F 9 ) ....... 3.5 " (90 m m) ever it is introduced into the hydraulic brake system.
P ( J F 9 ) ...............6.0" (1 5 0 m m ) It may be necessary to bleed the hydraulic system at all
On power brake-equipped vehicles, pum p the pedal a four wheel cylinders if air has been introduced through low
minimum of 3 tim es with the engine off before m aking pedal fluid level or by disconnecting b ra k e pipes at m aster
travel checks. This exhausts all vacuum from the power cylinder. If brake pipe is disconnected at any wheel cylinder,
booster. then th a t wheel cylinder only need be bled. If pipes are
disconnected at any fitting located between m aster cylinder
and wheel cylinders, then all wheel cylinders served by the
STOP LIGHT SWITCH disconnected pipe m ust be bled.
Time required to bleed the hydraulic system when the
master cylinder is removed can be reduced if the master
Adjustment (Fig. 5-3) cylinder is filled with fluid and as much as as possible is
The design of the switch and valve m ounting provides expelled before the cylinder is installed on the vehicle.
for autom atic adjustm ent when the brake pedal is m anually
returned to its m echanical stop as follows: Manual Bleeding
1. Fill the m aster cylinder reservoirs with brake fluid and and other c o n taim in an ts from en tering the h y d rau lic
keep at least one-half full of fluid during the bleeding system.
operation.
1. Install the correct pressure bleeding adapter to the
2. If the m aster cylinder is known or suspected to have air m aster cylinder. Brake System s JB1 throught JB6 gas
in the bore, then it m ust be bled before any wheel engine vehicles req u ire a d a p te r J-26819, extension
cylinder or caliper in the following manner: J-2 6 8 19-30 and clam p J-2 6 8 19-25. All other systems
a. D isconnect th e forw ard (blind end) brak e pipe use J-23518. R efer to Fig. 5-4, special tool illustration
connection at the m aster cylinder. and brake system description chart.
b. Allow brake fluid to fill the m aster cylinder bore until NOTICE: It is very im portant th at the correct m aster
it begins to flow from the forw ard pipe connector cylinder bleeder a d a p te r be used to avoid possible
port. dam age to the m aster cylinder reservoir (fig. 5-4).
c. C onnect the forw ard b rak e pipe to the m aster 2. M ake sure the pressure tank is at least 1/3 full of
cylinder and tighten. Suprem e # 11 brake fluid or its equivalent.
The bleeder ball m ust be re-bled each tim e fluid is
d. Depress the brake pedal slowly one tim e and hold.
added.
Loosen the forward brake pipe connection at the
m aster cylinder to purge air from the bore. Tighten 3. C harge the bleeder ball to between 140-170 kPa (20
the connection and then release the brake pedal and 25 psi)
slowly. W ait 15 seconds. R ep eat the sequence, 4. W hen ready to begin bleeding, connect hose to m aster
including the 15 second w ait, until all air is removed cylinder bleeder adapter and open the tank valve.
from the bore. C are m ust be taken to prevent brake 5. Disc brakes require a m anual override of the front
fluid from contacting any painted surface. brake m etering or com bination valve to perm it flow to
e. A fter all air has been rem oved a t the forw ard the front wheels. Therefore, it will be necessary to hold
connection, bleed the m aster cylinder at the rear the valve stem open m anually pressure bleeding.
(cowl) connection in the sam e m anner as the front in To hold the m etering valve open to bleed the front
step " d " above. brakes, the valve stem m ust be either pushed in or
pulled out. Install m etering valve actuator J-23709.
f. If it is known th at the calipers and wheel cylinders do
6. Bleed the brakes in the following sequence: right rear,
not contain any air, then it will not be necessary to
left front, left rear and right front.
bleed them.
7. W ith the proper size wrench over the bleeder valve
3. Individual wheel cylinder or calipers are bled only after
attach bleeder tube. The discharge end m ust hang
all air is removed from m aster cylinder.
subm erged in a clean container partially filled with
a. Place a proper size box end wrench or Tool J - 2 1472 brake fluid.
over the bleeder valve. A ttach transparent tube over 8. Open the bleeder valve a t least 3 /4 turn and allow flow
valve and allow tube to be hand subm erged in brake to continue until no air is seen in the fluid.
fluid in a transparent container. Depress the brake
9. Close the bleed valve; Be sure it seals.
pedal slowly one tim e and hold. Loosen the bleeder
valve to purge the air from the cylinder. Tighten 10. R epeat Steps 7-9 for the rem aining bleeder valves (see
bleeder screw and slowly release pedal. W ait 15 Step 6 for sequence).
seconds. R ep eat th e sequence, including the 15 11. Check the pedal feel for "sponginess" and repeat the
second w ait u n til all air is rem oved. It m ay be entire procedure if necessary.
necessary to repeat the sequence 10 or more times to 12. Dispose of all removed brake fluid.
remove all the air. 13. Remove Tool J-23709 from the com bination valve and
JB1 thru JB6 gas engine vehicles — Rapid pumping of tighten the m ounting bolt.
the brake pedal pushes the master cylinder secondary 14. Disconnect bleeder equipm ent from the brake bleeder
piston down the bore in a manner that makes it difficult to adapter.
bleed the rear side of the system.. 15. Remove bleeder adapter. W ipe all areas dry if fluid was
4. If it is necessary to bleed all of the wheel cylinders and spilled during adapter removal.
calipers, the following sequence should be followed: 1) 16. Fill m aster cylinder reservoir(s) to proper level and
R ight rear wheel cylinder; 2) L eft rear wheel cylinder; install m aster cylinder diaphragm and cover.
3) R ight front caliper; 4) Left front caliper.
5. Check the brake pedal for "sponginess" and the brake Flushing Brake Hydraulic System
warning light for indication of unbalanced pressure. It is recom m ended th a t the entire hydraulic system be
Repeat entire bleeding procedure to correct either of thoroughly flushed with clean brake fluid whenever new
these two conditions. parts are installed in the hydraulic system.
Flushing is also recommended if there is any doubt as to
Pressure Bleeding
the grade of fluid in the system. If fluid has been used which
Pressure bleeding equipm ent m ust be of the diaphragm contains the slightest trace of m ineral oil, all rubber parts
type. T h a t is, it m ust have a rubber diaphragm between the th at have been subjected to the contam inated fluid should be
air supply and the brake fluid to prevent air, m oisture, oil replaced.
HYDRO-BOOST BLEEDING PROCEDURE 11. Check oil level and refill as required.
W henever the booster is removed and reinstalled, the 12. If oil is extrem ely foamy, allow vehicle to stand a few
steering system should be bled as outlined below. m inutes w ith engine off and repeat above procedure.
NOTICE: Power steering fluid and brake fluid cannot be a. Check belt tightness and check for a bent pulley.
mixed. If brake seals contact steering fluid or steering (Pulley should not wobble w ith engine running.)
seals contact brake fluid, seal dam age will result. b. Check to m ake sure hoses are not touching any other
1. Fill oil reservoir to proper level and let oil rem ain parts of the vehicle, particularly sheet m etal.
undisturbed for a t least two m inutes. c. Check oil level, filling to proper level if necessary,
2. S tart engine and run m om entarily. following operations 1 through 10. This step and
Step " d " are extrem ely im portant as low oil level
3. Add oil, if necessary.
an d /o r air in the oil are the most frequent causes of
4. R epeat above procedure until oil level rem ains constant objectionable pum p noises.
after running engine.
d. Check the presence of air in the oil. A ir will show up
5. Raise front end of vehicle so th a t wheels are off the as milky appearing oil. If air is present, attem p t to
ground. bleed system as described in operations 1 through 10.
6. Turn the wheels (off ground) right and left, lightly If it becomes obvious th a t the pum p will not bleed
contacting the wheel stops. after a few trials, proceed as outlined under Power
7. Add oil if necessary. Steering System Test Procedure in the "S teerin g "
8. Lower the vehicle. section of this m anual.
9. S ta rt engine and depress the brake pedal several times 13. T he presence of trapped air in the system will cause the
while rotating the steering wheel from stop to stop. fluid level in the pum p to rise when the engine is turned
10. T urn engine off and then pum p brake pedal 4-5 times to off. C ontinue to bleed system until this condition no
deplete accum ulator pressure. longer occurs.
BRAKES 5-13
G MODELS
VIEW
CK MODELS
CK10-20
(EXCEPT C20-43)
C20 (43) CK30
VIEW VIEW
VIEW
CK10
P MODELS
Installation
BRAKE PIPES
1. Use new copper gaskets on both sides of fitting block,
Replacement (Figs. 5-5 thru 5-7) wet bolt threads with brake fluid, then with fitting
NOTICE: N ever use copper tubing because copper is orientation flange engaged with the caliper orientation
subject to fatgue cracking and corrosion which could ledge on JB8 and JF 9 (hose located in caliper gate on
result in brake failure. all except JB8 and JF 9 ), fasten hose to caliper; torque
to specifications.
1. Procure the recom m ended tubing and steel fitting nuts
of the correct size. (O utside diam eter of tubing is used 2. W ith w eight of vehicle on suspension, pass fem ale
to specify size.) fitting through fram e or fram e bracket. Fitting fits the
2. C ut tubing to length. C orrect length may be deter bracket in only one position. W ith least am ount of twist
mined by measuring old pipe using a cord and adding in hose, install fitting in this position. There should be
1/8 " (3 m m) for each double flare. no kinks in hose.
3. Double flare tubing ends using a suitable flaring tool 3. Install " U " clip to fem ale fitting at fram e bracket.
such as J-23530. Follow instructions included in tool 4. A ttach brake pipe to hose fitting using a backup wrench
set. on fitting; torque to specifications.
M ake sure fittings are installed before starting second 5. Inspect to see th a t hose doesn’t m ake contact with any
flare. part of suspension. Check in extrem e right hand and
NOTICE: Double flaring tool m ust be used as single extrem e left hand turn conditions. If hose m akes any
flaring tools cannot produce a flare strong enough to contact, remove and correct.
hold the necessary pressure. 6. Bleed brake system.
4. Bend pipe assembly to m atch old pipe using a tubing 7. Lower vehicle from hoist.
bender. C learance of .75" (19 m m ) m ust be m ain
tained to all moving or vibrating parts. Rear Hose
Removal (Fig. 5-8)
BRAKE HOSES
1. Raise vehicle on hoist.
Inspection 2. Remove all three brake pipes from hose, two at junction
T he flexible h y d rau lic b rak e hose w hich tran sm its block and, with the use of a back-up wrench, one on the
hydraulic pressure from the steel brake pipe on the fram e to female fitting at bracket. Be careful not to bend bracket
the rear axle and to the calipers should be inspected every 4 or pipes; use penetrating oil if necessary.
m onths or 6,000 miles (9 600 km ) (heavy duty emission 3. Rem ove " U " clip and tak e fem ale fitting out of
vehicles), every 12 m onths or 7,500 miles (12 000 km) (light bracket.
duty emission vehicles). T he brake hose assembly should be 4. Observe position at which junction block is m ounted to
checked for road hazard dam age, for cracks and chafing of the axle. W hen installing new hose be sure this junction
the outer cover, and for leaks and blisters. A light and block is in the sam e position.
m irror m ay be needed for an adequate inspection. If any of
5. Remove bolt attaching junction block to axle.
the above conditions are observed on the brake hose, it will
be necessary to replace it. Installation
1. Thread both rear axle pipes into junction block.
Front Hose
2. Bolt junction block to axle and then torque rear pipes
Removal (figs. 5-5 thru 5-7) into block.
1. Raise vehicle on hoist. 3. Pass fem ale end of hose through bracket; fem ale fitting
2. C lean dirt and foreign m aterial from both hose end will fit bracket in only 1 position (except G models), 2
fittings. positions (G models). W ithout twisting hose, position
3. Disconnect brake pipe from hose fitting using a back-up female end in bracket.
wrench on fitting. Be careful not to bend fram e bracket 4. I n s ta ll" U " clip.
or brake pipe. It m ay be necessary to soak the connec 5. A ttach pipe to female fitting using a back-up wrench on
tions with penetrating oil. fitting; torque to specification, again be careful not to
4. Remove " U " clip from fem ale fitting a t bracket and bend bracket or pipe. Check to see th at hose installation
remove hose from bracket. did not loosen fram e b racket, re-to rq u e b rack et if
5. Remove bolt from caliper end of hose. Remove hose necessary.
from caliper, and discard the two copper gaskets on 6. Bleed system.
either side of fitting block. 7. Lower vehicle from hoist.
Removal (Fig. 5-9) NOTICE: See "N o tic e" on Page 1 of this section.
5. Fully release parking brake and rotate the rear wheels.
1. Place parking brake pedal or handle in the released
position. N o drag should be present.
2. Remove nuts from the engine com partm ent on C, K 6. Remove vehicle from hoist.
and G models or bolts from m ounting bracket on P
Adjustment-Orscheln Lever Type
models.
T ake notice of th e spacers on P m odels for 1. T urn adjusting knob on parking brake lever counter
reinstallation. clockwise to stop.
3. Disconnect the release handle rod at the parking brake 2. Apply parking brake.
assem bly end (C-K models). 3. Raise vehicle on a hoist.
4. Remove the bolts from the underside of the dash and 4. Loosen nut at interm ediate cable equalizer and then
lower the brake assembly (C -K -G M odels). adjust nut to give light drag at rear wheels.
5. C-K-G Models- Disconnect the cable ball from the NOTICE: See "N o tic e" on Page 1 of this section.
parking brake clevis and remove the assembly. 5. R eadjust parking brake lever knob to give a definite
P Models- Remove the clevis pin and disconnect the snap-over-center feel.
cable from the brake assembly; remove the assembly.
PARKING BRAKE (PROPELLER SHAFT)-
Installation
INTERNAL EXPANDING
Reverse the removal procedure. Torque all bolts and
nuts. A fter installing the clevis-pin, use a new cotter pin to Adjustment-Drum On
secure the clevis pin. A d ju st th e cable if necessary as 1. Jack up at least one rear wheel. Block wheels and
outlined below. release hand brake.
NOTICE: See "N o tice" on Page 1 of this section. 2. Remove cotter pin and clevis pin connecting pull rod
and relay lever. This will assure freedom for full shoe
ADJUSTMENT release.
A djustm ent of parking brake cable is necessary when NOTICE: It m ay be necessary to knock out lanced area
ever holding ability is not adequate or whenever the center in brake drum with punch and ham m er to gain entry
brake cables have been disconnected. into adjusting screw through brake drum . Be sure all
The service brake m ust be properly adjusted as a base m etal has been rem oved from parking brake
for parking brake adjustm ent; conversely the parking brake com partm ent.
m ust be properly adjusted for the service brake to function 3. R otate brake drum to bring one of access holes into line
as intended. w ith adju stin g screw a t bottom of shoes (m an u al
transm ission), top of shoes (autom atic transm ission).
Inspection 4. Expand shoes by rotating adjusting screws with screw
If com plete release of the parking brake is not obtained, driver inserted through hole in drum . Move outer end
unless it is forcibly returned to its released position, or if of screwdriver away from drive shaft. Continue ad ju st
application effort is high, check parking brake assembly for m ent until shoes are tight against drum and drum
free operation. If operation is sticky or a bind is experienced, cannot be rotated by hand. Back off adjustm ent ten
correct as follows: notches and check drum for free rotation.
1. Clean and lubricate brake cables and equalizer with 5. Place parking brake lever in fully released position.
Delco Brake Lube (or equivalent). Take up slack in brake linkage by pulling back on cable
ju st enough to overcome spring tension. A djust clevis of
2. Inspect brake assembly for straightness and alignm ent
pull rod or front cable to line up with hole in relay
(replace if necessary).
levers.
3. C lean and lubricate parking brake assem bly with Delco
a. Insert clevis pin and cotter pin, then tighten clevis
Brake Lube (or equivalent).
locknut.
4. C hecking routing of cables for kinks or binding.
b. Install a new metal hole cover in drum to prevent
contam ination of brake.
Adjustment—Foot Pedal Type
c. Lower rear wheels. Remove jack and wheel blocks.
Before adjusting parking brake, check service brake
condition and adjustm ent. NOTICE: See "N o tice" on Page 1 of this section.
1. Raise vehicle on hoist. Adjustment-Drum Off
2. Loosen the equalizer adjusting nut. 1. W ith parking brake drum off, use special Tool J -2 1177
3. Apply parking brake 4 notches from fully released or J-22364, D rum to Brake Shoe Clearance G auge, to
position. check diam eter of drum clearance surface.
2. Turn the tool to the opposite side and fit over brake hose in a container partially filled with clean brake
shoes by turning the star wheel until the gauge just fluid. Be sure m aster cylinder reservoir is full.
slides over the linings. 2. Turn ignition switch to "O n "; open bleeder screw while
3. R otate the gauge around the brake shoe lining surface a helper applies m oderate pressure to the brake pedal;
to insure proper clearance. warning lamp should light. Close bleeder screw before
4. Install propeller shaft flange at m ainshaft as outlined in helper releases brake pedal. Reapply brake pedal with
transm ission section. m oderate-to-heavy pressure; light should go out.
5. Lower rear wheels. Remove jack and wheel blocks. 3. A ttach the bleeder hose to a front brake bleeder screw
and repeat above test. W arning lam p action should be
PARKING BRAKE CABLES (Fig. 5-10) the same as in Step No. 2. T urn ignition switch off.
4. If warning lamp does not light during Steps 2 and 3 but
Front Cable Replacement does light when a jum per is connected to ground, the
1. Raise vehicle on hoist. warning light switch portion of the com bination valve is
2. Remove adjusting nut from equalizer. defective. Do not attem pt to disassem ble the com bina
tion valve. If any portion of the com bination valve is
3. Remove retainer clip from rear portion of front cable at
fram e and from lever arm . defective, it must be replaced with a new com bination
valve.
4. Disconnect front brake cable from parking brake pedal
or lever assemblies. Remove front brake cable. On 5. Lower vehicle to floor. Check and refill m aster cylinder
to proper level.
some models it m ay assist installation of new cable if a
heavy cord is tied to other end of cable in order to guide Replacement
new cable through proper routing.
The com bination valve is not repairable and m ust be
5. Install cable by reversing removal procedure.
serviced as a complete assembly.
6. A djust parking brake.
1. Disconnect hydraulic lines a t com bination valve. Plug
Center Cable Replacement lines to prevent loss of fluid and en tran ce of dirt.
Disconnect warning switch wiring harness from valve
1. Raise vehicle on hoist.
switch term inal.
2. Remove adjusting nut from equalizer.
2. Remove com bination valve.
3. Unhook connector a t each end and disengage hooks and
3. Install com bination valve by reversing removal steps.
guides.
4. Bleed entire brake system. Do not move vehicle until a
4. Install new cable by reversing removal procedure.
firm brake pedal is obtained.
5. A djust parking brake.
6. Apply parking brake 3 tim es with heavy pressure and
repeat adjustm ent. BRAKE PEDAL
The brake pedal mounting is an integral design with the
Rear Parking Brake Cable Replacement
cluth pedal (except autom atic transm ission), necessitating
1. Raise vehicle on hoist. the removal of the clutch pedal before removing the brake
2. Remove rear wheel and brake drum . pedal.
3. Loosen adjusting nut at equalizer.
Removal (Fig. 5*12)
4. Disengage rear cable at connector.
1. Remove the pull back spring from the body or brake
5. Bend retainer fingers.
pedal support bracket.
6. Disengage cable a t brake shoe operating lever.
2. Manual Transmission Vehicles-- Remove the clutch
7. Install new cable by reversing removal procedure. pedal as outlined under "C lutch P edal" in Section 7C.
8. A djust parking brake. Automatic Transmission Vehicles— Remove pedal pivot
bolt nut or pivot pin retainer and remove bolts or pin
COMBINATION VALVE and bushings.
3. P Models-- Remove the sleeve assembly screw a tta c h
Electrical Circuit Test m ent and remove sleeve.
1. Disconnect wire from switch term inal and use a jum per 4. Disengage the push rod from the m aster cylinder and
to connect wire to a good ground. remove the pedal.
2. Turn ignition key on "O n " - warning lam p should
light. If lam p does not light, bulb is burned out or Inspection
electrical circuit is defective. R eplace bulb or repair Clean all parts and inspect for wear, cracks or any other
electrical circuit as necessary. dam age th at m ight im pair operation; replace if required.
3. W hen w arning lamp lights, turn ignition switch off.
D isconnect ju m p er and reconnect w ire to switch Installation
term inal. Reverse the above procedure and m ake certain the
brake pedal is secure and adjusted properly before operating
Warning Light Switch Test the vehicle. L ubricate pedal pivot bushings and pivot pin,
1. Raise vehicle on hoist. A ttach a bleeder hose to a rear bolt or sleeve with Delco Brake Lube (or equivalent). A djust
brake bleed screw and im m erse the other end of the stoplam p switch.
LIGHT TRUCK SERVICE MANUAL
BRAKES 5-23
P30(32) Models
Replacement (Fig. 5-13)
1. Remove the cotter pin, nut, special washers and bolt at
the brake pedal lever end of rod; discard the cotter pin.
2. Remove the boot to floorpan screws.
3. Raise the vehicle on a hoist.
4. Remove the cotter pin, nut, special washers and bolt at
the lower end of the rod and remove the pedal rod
assembly. Discard the cotter pin.
5. To install a new rod, adjust the rod length to 31.00"
(790 mm ) (center of upper attachm ent to center of
lower attachm ent).
6. L ubricate the pedal rod bolts and special washers with
Delco Brake Lube (or equivalent).
7. Install the rod up through the floorpan opening and
install the lower pivot bolt, special washers and nut.
Tighten the nut to 22-30 lb. ft. (30-40 N -m ) and install
a N E W cotter pin.
8. Push the boot up to the floorpan.
9. Lower the vehicle from the hoist.
10. Install the rod upper pivot bolt, special washers and
nut. Tighten the nut to 22-30 lb. ft. (30-40 N-m ) and
install a N E W cotter pin.
11. Fasten the boot to the floorpan and compress the boot to
2.54" (65 mm ) installed height; tighten the boot to
2.54" (65 mm) installed height; tighten the boot screws
to 13-18 lb. in. (1.5 - 2.0 N-m ). (R efer to Figure 5-13).
12. A djust brake pedal and stoplam p switch as outlined
previously.
RESERVOIR COVER
1. REMOVE AND INSTALL MASTER CYLINDER. 3. REMOVE AND INSTALL PRIMARY AND
SECONDARY PISTONS.
REMOVE INSTALL REMOVE INSTALL
1. Disconnect two hydraulic SEE NOTICE ON PAGE 5-1 1. Depress primary piston and SEE NOTICE ON PAGE 5-1
lines. OF THIS SECTION remove lock ring. OF THIS SECTION.
2. Remove two attaching 1. Install master cylinder 2. Direct compressed air into 1. Assemble secondary piston
nuts. as shown and torque the outlet at the blind end of as shown in A, following.
3. Remove master cylinder as attaching nuts to 30-45 N-m the bore and plug the other 2. Install spring and secondary
shown. (22-30 ft-lb). outlet to remove primary piston assembly in cylinder.
2. Attach two hydraulic lines. and secondary pistons.
3. Install primary piston, de
Torque tube nuts to 3. Disassemble secondary press, and install lock ring.
13.6-20.3 N-m (120-180 in-lb). piston as shown in A,
following.
MASTER CYLINDER 4. Inspect master cylinder bore
for corrosion. If bore is
corroded, replace master
cylinder. No abrasives shall
be used on bore.
NUTS
TUBE
NUTS
SPRING
REMOVE INSTALL
1. Remove reservoir cover and SEE NOTICE ON PAGE 5-1
diaphragm as shown. OF THIS SECTION
2. Discard any brake fluid in 1. Install reservoir diaphragm
reservoir. in reservoir cover.
3. Inspect reservoir cover and 2. Install assembly on
diaphragm for cuts, cracks reservoir.
or deformation. Replace
damaged or defective parts.
SECONDARY
PISTON
ASSEMBLY
PRIMARY
PISTON
ASSEMBLY
A.
REMOVE INSTALL
1. Remove seals as shown. 1. Install new seals, posi
tioning as shown.
SPRING RETAINER
SECONDARY
PISTON
SECONDARY
SEAL
REMOVE INSTALL
REMOVE INSTALL
1. Remove reservoir as shown 1. Install reservoir as shown in
in A, following. B, following. 1. Remove reservoir grommets. 1. Lubricate new reservoir
grommets with silicone
brake lube.
A.
REMOVE
2. Press grommets into master
cylinder body. Make sure
1. Clamp master cylinder in grommets are properly
vise as shown—do not seated.
clamp on master cylinder
body—and use pry bar to
remove reservoir.
GROMMET
PRY
BAR
RESERVOIR
B.
INSTALL
1. Lay reservoir on flat, hard
surface as shown. Press on
master cylinder body using
rocking motion.
Assembly Disassembly
1. Place brass tube fitting insert (new parts) in outlet 1. Remove the reservoir cover and diaphragm , and drain
holes so th a t it is in a position to be pressed into outlet the fluid from the reservoir.
hole. T he recom m ended m ethod of in serting tube 2. Remove the four bolts th a t secure the body to the
fitting insert is to thread a spare brake line tube nut into reservoir using Socket J-25085.
outlet hole and turn nut down until tube fitting insert 3. Remove the small " O " ring and the two com pensating
bottoms. Remove tube nut and check outlet hole for valve seals from the recessed areas on the bottom side
loose burrs, which m ight have been turned up when of the reservoir.
tube fitting insert was pressed down. Do not remove the two small filters from the inside of
2. Put new secondary seal in groove in end of secondary the reservoir unless they are dam aged and are to be
piston (fig. 5-15). replaced.
3. Assem ble a new prim ary seal over end of secondary 4. Depress the prim ary piston using a tool with a smooth
piston, so th at flat side of the seal seats against flange of rounded end. Then remove the com pensating valve
piston (fig. 5-15). poppets and the com pensating valve springs from the
4. Assem ble new secondary seal into groove on end of the com pensating valve ports in the m aster cylinder body.
secondary piston. 5. Using a small screwdriver, remove the snap ring at the
5. In order to insure correct assem bly of the prim ary end of the m aster cylinder bore. Then release the piston
assem bly, a com plete p rim ary piston assem bly is and remove the prim ary and secondary piston assem
included in the repair kits. blies from the cylinder bore. It may be necessary to
plug the front outlet port and to apply low air pressure
6. C oat bore of m aster cylinder with clean brake fluid.
C oat prim ary and secondary seals on secondary piston to the front com pensating valve port to remove the
with clean brake fluid. Insert the secondary piston secondary piston assembly.
spring re ta in e r into secondary piston spring. Place Assembly
retainer and spring over end of secondary piston, so th at
1. L u b ricate th e secondary piston assem bly and the
retainer locates inside lip of prim ary cup.
m aster cylinder bore with clean brake fluid.
7. Hold m aster cylinder with open end of bore down, push
2. Assemble the secondary spring (shorter of the two
secondary piston into bore, so th a t spring will seat
springs) in the open end of the secondary piston
against closed end of bore. actuator, and assem ble the piston return spring (longer
8. Place m aster cylinder in a vise with open end of bore spring) on the projection at the rear of the secondary
up. C oat prim ary and secondary seal on prim ary piston piston.
with clean brake fluid. Push prim ary piston assembly, 3. Insert the secondary piston assembly, actuator end
spring end first, into bore of m aster cylinder. Hold the first, into the m aster cylinder bore, and press assembly
piston down and snap lock ring into position in groove to the bottom of the bore.
in inside diam eter of bore.
4. L u b ric ate th e prim ary piston assem bly w ith clean
9. Install a new reservoir diaphragm in reservoir cover brake fluid. Insert the prim ary piston assembly, ac tu a
where needed, and install cover on m aster cylinder. tor end first, into the bore.
Beaded side faces m aster cylinder casting to insure
5. Place the snap ring over a smooth round ended tool and
positive sealing. T he bail w ire is now pushed into
depress the pistons in the bore.
position to hold reservoir cover.
6. A ssem ble the retain in g ring in th e groove in the
10. Manual brake o n ly -A ssem ble push rod through push
cylinder bore.
rod retainer, if it has been disassem bled. Push retainer
over end of m aster cylinder. A ssem ble new boot over 7. Assemble the com pensating valve seals and the small
push rod and press it down over the push rod retainer. " O " ring seal in the recesses on the bottom of the
reservoir. Be sure th at all seals are fully seated.
Installation 8. W hile holding the pistons depressed, assem ble the
com pensating valve springs and the com pensating valve
NOTICE: Refer to "N o tic e " on Page 1 of this section
poppets in the com pensating valve ports.
regarding fasteners referred to in Steps 1 and 2 below.
9. Holding the pistons compressed, position the reservoir
1. Manual brake only—Connect push rod to brake pedal
on the m aster cylinder body and secure with the four
pin and install retainer while holding m aster cylinder in
m ounting bolts. Tighten the bolts to 12-15 lb. ft. (16-20
place.
N -m ).
2. In stall m aster cylinder on dash or pow er cylinder;
torque nuts to specifications. DELCO DISC BRAKE SHOE AND LINING
3. Connect brake pipes to m aster cylinder.
Lining Inspection
4. Bleed hydraulic system.
5. Road test vehicle for proper brake perform ance.
Inspect the brake linings per m aintenance schedule and
anytim e th at the wheels are removed (tire rotation, etc.)
Bendix Mini-Master Cylinder Check both ends of the outer shoe by looking in a t each end
Removal, Inspection and Installation procedures are of the caliper (see figure 5-18). Check the lining thickness
the same as described for "E xcept Bendix M ini-M aster on the inner shoe by looking down through the inspection
C ylinder". hole in the top of the caliper housing. W henever the lining is
LIGHT TRUCK SERVICE MANUAL
5-30 BRAKES
COVER
DIAPHRAGM
FILTER
RESERVOIR
VALVE POPPET
SPRING
SECONDARY SPRING
SECONDARY PISTON
PRIMARY PISTON
SNAP RING
Caliper Installation
1. Install rubber bushings in all four caliper ears.
LIG H T T R U C K SERVICE M AN U AL
5-34 BRAKES
Clamp
Installation
If original disc pads are being reinstalled, they m ust be
installed in original positions (as m arked at removal).
1. Lubricate the caliper and steering knuckle (or support)
sliding surfaces and the support spring with Delco
Silicone Lube (or equivalent).
NOTICE: Do not support the weight of the caliper on the 2. Install a N E W inboard shoe clip in the steering knuckle
brake hose as dam age to the brake hose could result. or re ar support. Be sure the tabs are positioned
6. Remove the inboard shoe from the steering knuckle or correctly and the loop-type spring positioned aw ay
rear caliper support (fig. 5-32). Remove and discard from the rotor. Install the lower end of the inboard shoe
the inboard shoe clip. Remove the outboard shoe from into the groove provided in the steering knuckle or
the caliper. It may be necessary to tap the shoe to support (against the spring clip). Slide the upper end of
loosen it in the caliper housing. the shoe into position. Be sure the clip rem ains in
M ark disc pad positions if pads are to be reinstalled. position.
Cleaning and Inspection 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 shoes should be replaced when the lining is worn to
the bottom of the shoe engaged in the caliper cutout. If
approxim ately 1 /3 2 " (0.80 m m) thickness over the rivet
assembly is difficult, a "C " clam p may be used. Be
heads. Replace shoes in axle sets. careful not to m ar the lining.
1. Exam ine the inside of the caliper for evidence of fluid
leakage. If leakage is noted, the caliper should be 4. W ith both shoes installed, lift up the caliper and rest
overhauled. the bottom edge of the outboard lining on the outer
edge of the brake disc to m ake sure th ere is no
clearance between the tab at the bottom of the out
board shoe and the caliper abutm ent. T he outboard
LIG H T T R U C K SERVICE M A N U A L
5-36 BRAKES
6. Place the spring over the caliper support key, install the
assembly between the steering knuckle (or rear sup
port) and lower caliper groove. T ap into place (until the
key retaining screw can be installed) using a brass
punch and a light ham m er (fig. 5-36).
7. Install the screw and torque to 12 to 18 lb. ft. (18-24
N -m ). The bolt boss m ust fit fully into the circular
cutout in the key.
Fig. 5-37--Removing Piston
NOTICE: See "N o tic e " on Page 1 of this section. bracket and remove the caliper - with hose attached —
8. Reinstall the front wheel and tire assembly. to a work bench for overhaul.
9. A dd brake fluid to the m aster cylinder reservoir to
bring the fluid level up to within 1 /4 " (6 m m ) of the Disassembly
top. 1. Before beginning disassembly, thoroughly clean the
NOTICE: Before moving the vehicle, pum p the brake exterior of the caliper using brake cleaner. Place the
pedal several tim es to m ake sure th at it is firm. Do not caliper on a clean work surface.
move vehicle until a firm pedal is obtained. Check 2. Remove the brake hose from the caliper, discarding the
m aster cylinder fluid level again after pum ping the copper gasket. Check the hose for worn spots, cracks or
brake pedal. other signs of deterioration, discard the hose, if dam
aged, to be replaced with a new hose a t reassembly.
CALIPER OVERHAUL D rain brake fluid from the caliper.
3. Use clean shop towels to pad the interior of the caliper.
Delco Remove the piston by directing compressed air into the
Removal caliper inlet hole (fig. 5-37).
ru b b er p arts w hen they com e in co n tact a fte r 3. Install the brake hose in the caliper inlet using a new
reassembly. copper gasket.
3. C heck the m ounting for corrosion, breaks in the plating Installation
or other dam age. Do not use abrasives in an attem pt to 1. Installation of the caliper and m ounting parts (rubber
clean the pins -- replace them. bushing, sleeves, shoe and lining assemblies and pins) is
4. C arefu lly exam ine th e piston outside d iam eter for the sam e as for lining replacem ent except for the
scoring, nicks, corrosion and worn or dam aged chrom e following:
plating. If any surface defects are detected, replace the a. The brake hose m ust be connected to the brake pipe
piston. a t the fram e or fram e bracket.
5. Check the bore in the caliper for the sam e defects as the Use extrem e care to orient the hose so th at the keyed
piston with the exception of plating dam age. The piston hose end fitting aligns with the slot in the bracket
bore is not plated and stains or minor corrosion can be without twisting or kinking the hose.
polished with crocus cloth. Do not use em ery cloth. b. A fter overhaul -- or any tim e that the brake hose or
Thoroughly clean the caliper after the use of crocus line is disconnected -- the calipers m ust be bled.
cloth. If the bore cannot be cleaned up in this m anner,
replace the caliper.
Bendix
Reassembly Removal
C lean d irt from hose to caliper connection before
1. L ubricate the bore in the caliper and the new piston proceeding with removal.
seal with clean brake fluid. Position the seal in the 1. Remove the hose to caliper bolt and cap or tape the
caliper bore groove. L ubricate the piston with clean open connections to prevent dirt from entering the hose
brake fluid and assemble a new boot into the groove in or caliper. D iscard the copper gaskets.
the piston so th at the fold faces the open end of the
2. Remove the caliper assembly as described under "Shoe
piston. Insert the piston into the caliper bore, using care
and L inings-R em oval".
not to unseat the seal and force down to the bottom in
the bore. This will require a force of 50 to 100 pounds
(220 to 440 N ). Position the outside diam eter of the CALIPER
boot in the caliper counterbore and seat with Tool
J-22904 (fig. 5-38). PISTON
BOOT
2. C heck th e boot in stallatio n to m ake sure th a t the SQUARE
retaining ring molded into the boot is not bent and th at RING SEAL
the boot is installed fully, below the caliper face, and
evenly all around. O therw ise d irt or m oisture m ay enter SCREW
the bore and cause dam age or corrosion.
SUPPORT
INBOARD SHOE KEY
CALIPER SPRING
OUTBOARD SHOE
ANfl-RATTLE SPRING
BOOT INSTALLER
(EXCEPT JB7) J -2 2 9 0 4
(JB7) J -2 8 7 3 5
DUST
BOOT
L IG H T T R U C K SERVICE M AN U AL
5-38 BRAKES
handle or " C " clam p (fig. 5-42); remove Tool J-24548. of the rotor. All m easurem ents m ust be made at the
Check to be sure the boot was not unseated at piston same distance in from the edge of the rotor.
installation. M ake sure the outer bead of the boot is 2. A rotor th at varies over .0005" (0.013 mm) causes
seated in the piston outer groove.1 pedal vibration, as well as front end vibration during
brake applications. A rotor th at does not meet these
Installation
specifications m ay be refinished to specifications if
Installation of the caliper and m ounting parts is the precision equipm ent is available.
sam e for: "Shoe and Lining-Disc B rake" except for steps
given below: Tolerance and Surface Finish
1. C onnect the brake hose to the caliper using N E W In m anufacturing the brake rotor, tolerances of the
copper gaskets. rubbing surfaces for flatness, for parallelism and for lateral
NOTICE: Hose m ust be properly positioned to prevent runout are held very closely. The m aintenance of these close
hose twist or m isalignm ent or hose dam age m ay result. controls on the shape of the rubbing surfaces is necessary to
prevent brake roughness.
2. Bleed the caliper assemblies as outlined earlier in this
section. In addition to these tolerences, the surface finish must
be held to a specified range. The control of the rubbing
ROTOR SERVICING surface finish is necessary to avoid pulls and e rratic
perform ance and to extend lining life.
Light scoring of the rotor surfaces not exceeding .015"
Lateral Runout (0.38 mm) in depth, which may result from norm al use, is
1. L ateral runout is the movement of the rotor from side not detrim ental to brake operation.
to side as it rotates on the steering knuckle spindle. This
Machining
could be described as " rotor wobble ".
2. The movement of the rotor from side to side in the Since accurate control of the rotor tolerances is neces
lateral plane causes the brake shoe and lining and sary for proper perform ance of the disc brakes, m achining of
pistons to be knocked back into their bores. This results the rotor should be done only with precision equipm ent.
in additional pedal travel required and a vibration All brake rotors have a minimum thickness dimension
during the braking action. cast into them. This dimension is the minimum wear
3. To check lateral runout, first tighten the wheel bearings dimension and not a refinish dimension. Do not use a brake
until all of the play is out of the bearings. Fasten a dial rotor that will not meet the specifications, as shown below,
indicator to some portion of the suspension so th a t the after refinishing. Replace with a new brake rotor.
point of the stylus contacts the rotor face approx
im ately 1" (25 mm) from the rotor edge (fig. 5-43). Set
the dial at zero. Move the rotor one complete rotation, ROTOR THICKNESS
checking the indicator as the rotor moves. REPLACEMENT
MINIMUM
4. L ateral runout should not be over .004" (0.10 mm) AFTER REFINISHING (DISCARD)
total indicator reading.
1.480 1.465
Parallelism 1.230 1.215
1. Parallelism is the m easurem ent of the thickness of the .980 .965
rotor at four or more points around the circum ference
Adjustment
1. Using a punch, knock out lanced area in brake drum . If
this is done with the drum installed on the vehicle, the
LIG H T T R U C K SERVICE M AN U AL
5-40 BRAKES
SHOE GUIDE
PARKING BRAKE STRUT
STRUT SPRING
ADJUSTER LEVER
HOLD DO W N PINS
HOLD DO W N SPRING
SPRING & CUP ADJUSTING SCREW SPRING
-A D JU S T IN G SCREW
BRAKE SHOE RETURN SPRING ____ R RETURN SPRINGS
11. Check all backing plate attaching bolts to m ake sure S paringly apply sam e lu b ric an t w here brake cable
they are tight. Using fine em ery cloth, clean all rust and contacts backing plate.
dirt from shoe contact surfaces on plate. 4. Place brake shoes on backing plate, at the same tim e
engaging shoes with wheel cylinder links. The prim ary
Installation and Adjustment shoe (short lining) goes tow ard front of vehicle.
Connect cable to parking brake lever and install strut
1. L ubricate fulcrum end of parking brake lever with and spring between lever and prim ary shoe.
Delco Brake L ubricant or equivalent, then attach lever 5. Install acutator, actuator return spring and actuating
to secondary shoe. M ake sure th a t lever is free moving. link. If old brake shoe re tu rn springs are nicked,
distorted or of doubtful strength (discolored from
2. Connect brake shoes together with adjusting screw
heat), it is advisable to install new parts.
spring, then place adjusting screw in position. W hen
in stallin g th e adju stin g screw spring and adjusting 6. Install shoe hold down springs.
screw, m ake sure the spring does not touch the star- 7. Install the prim ary and secondary shoe return springs
wheel portion of the adjusting screw; and, also, when using large pliers. Be careful not to distort springs.
installing adjusting screw, m ake sure right hand thread 8. M easure brake drum I.D. using inside caliper portion
adjusting screw is on left side of vehicle and left hand of Tool J-21177 (fig. 5-45). A djust brake shoes to
thread adjusting screw is on right side of vehicle. M ake dimension obtained on outside caliper portion of Tool
certain starw heel lines up w ith ad ju stin g hole in J-21177 (fig. 5-46).
backing plate. 9. Install brake drum s and wheels.
3. L ubricate shoe contact surfaces on backing plate with a 10. If any h y draulic connections were distu rb ed , bleed
thin coating of Delco Brake L ubricant or equivalent. hydraulic system.
11. A djust parking brake.
12. Inspect all brake pipes, hoses and connections for
evidence of fluid leakage. Tighten any leaking connec
tion. Then apply heavy pedal pressure to brake pedal
and recheck connections.
13. Check fluid level in m aster cylinder and add fluid if
necessary.
14. C heck brake pedal for proper feel and for proper
return.
15. Remove vehicle from hoist and road test for proper
brake action. Brakes m ust not be severely applied
im m ediately after installation of new brake shoes or
linings. Severe application may perm anently dam age
new linings and m ay score brake drums. W hen linings
are new, they m ust be given m oderate use for several
hundred miles of burnishing.
im bedded particles from surfaces and rivet counter 6. Pull brake shoe and lining assem blies aw ay from
bores of linings. anchor pin and remove the stru t and spring.
8. Check all backing plate bolts to m ake sure they are 7. Lift the brake shoes and linings with the adjusting nut
tight. (R efer to Section 4B for wheel stud replacem ent and bolt and connecting spring off the flange plate.
procedure.)
8. Move the shoes toward each other until the adjusting
9. M easure brake drum I.D. using inside caliper portion bolt and connecting spring drop off.
of Tool J - 2 1 177. A d ju st brak e shoes to dim ension
obtained on outside caliper portion of Tool J-2 1 177 9. Remove the clip holding the brake lever to the prim ary
(figs. 5-45 and 5-46). shoe (shoe with short lining).
10. Install drum and wheel and tire assemblies. 10. Compress the spring on the brake cable and remove the
11. Remove vehicle from hoist and road test for proper cable from the lever.
b rak e action. B rakes m ust not be severely applied 11. If necessary to remove the anchor pin, straighten the
im m ediately after installation. Severe application may w asher from pin hex and reinforcem ent. Rem ove
perm anently dam age new linings and may score brake reinforcem ent and washer with anchor pin.
drum s. W hen linings are new, they m ust be given
12. If necessary to remove the cable, compress tangs on
m oderate use for several hundred miles of burnishing.
cable and pull assembly out of the hole in the flange
plate.
Propeller Shaft Brake
13. If necessary to remove the flange plate, remove the
Removal (Fig. 5-47) transm ission flange nut and transm ission output flange.
Rem ove bolts holding th e flange p late to bearing
retainer and remove the flange plate.
1. Remove the propeller shaft; see Section 4A.
2. Remove the brake drum . It may be necessary to back Inspection
off the shoe adjustm ent before removing the drum .
On autom atic transm ission models, the exhaust cross Replace any worn or broken parts.
over pipe m ay be in the way. If so, loosen the transm is
sion rear m ounting bolts and jack the transmission Installation
sufficiently for brake drum to clear the pipe. NOTICE: Refer to "N o tice " on Page 1 of this section
3. Remove the two pull back springs. when installing fasteners in steps 1, 2 and 4 below.
4. Remove the guide plate from anchor pin. 1. Place the flange plate in position on the rear bearing
5. Remove shoe hold down cups, springs, and washers retainer and fasten with four bolts. Torque bolts to 24
from hold down p ins-rem ove pins. lb. ft. (33 N-m ).
RETURN
SPRINGS
W AVE
WASHER FLANGE
BRAKE LOCK
LEVER
ANCHOR
PIN
HOLD STRUT ^
DOW N GUIDE
PIN STRUT PLATE
SPRING
DRUM
HOLD D O W N
SPRING WASHER, SPRING , CUP
SOCKET
A D JU STIN G SCREW
BACKING BRAKE
PLATE CABLE
I IG H T t r u c k s e r v i c e m a n u a l
BRAKES 5-43
2. Install transm ission output flange on spline of main- m etal, while if left alone, the grooves and lining ridges
shaft and fasten with flange nut. Torque nut to 100 lb. m atch and satisfactory service can be obtained.
ft. (136 N-m). If brake linings are to be replaced, a grooved drum
3. Install cable assembly from back of flange plate. Push should be turned for use with new linings. A grooved drum ,
retainer through hole in flange plate until tangs se if used with new lining, will not only wear the lining, but will
curely grip the inner side of the plate. m ake it difficult, if not impossible to obtain efficient brake
4. Place washer and reinforcem ent over the threaded end perform ance.
of anchor pin. Hold anchor pin nut (flat side against An out-of-round drum m akes ac cu rate brake shoe
flange on flange plate) in position behind flange plate adjustm ent impossible and is likely to cause excessive wear
and insert threaded end of anchor pin from front side. of other parts of brake m echanism due to its eccentric
T hread the anchor pin into nut and tighten securely action. An out-of-round drum can also cause severe and
(140 lb. f t . - 190 N -m ). Bend tan g of w asher over irregular tire tread wear as well as pulsating brake pedal.
reinforcem ent and side of w asher over hex of anchor W hen the braking surface of a brake drum exceeds the
pin. factory specification limits in taper (and/or) being out-of-
5. In stall lever on cable by com pressing spring and round, the drum should be turned to true up the braking
inserting cable in channel of lever. Release spring. surface. O ut-of-round as well as taper and wear can be
6. Install prim ary shoe (short lining) to lever as follows: accurately m easured with an inside m icrom eter fitted with
Place pin in lever, place w asher on pin and push pin proper extension rods.
through hole in prim ary shoe. Fasten parts together by W hen m easuring a drum for out-of-round, taper and
installing the clip in groove of pin. wear, take m easurem ents at the open and closed edges of
7. Fasten two brake shoes and linings together by install m achined surface and at right angles to each other.
ing connecting spring. Move the shoes toward each Turning Brake Drums
other and install adjusting screw.
If a drum is to be turned, only enough m etal should be
8. L ubricate the flange plate contact surfaces with a very
removed to obtain a true, smooth braking surface. If a drum
light coat of Delco Brake Lube (or equivalent).
does not clean-up when turned to a m axim um diam eter as
9. Place shoe and linings in position on flange plate. shown in the general specification, it m ust be replaced.
W hen facing the brake assembly, the shoe with the Removal of more m etal will affect dissipation of heat and
short lining should be to th e left w ith the lever may cause distortion of the drum .
assem bled to it (autom atic transm ission), to the right
All brake drums have a maximum diameter cast into
(m anual transmission).
them. This diameter is the maximum wear diameter and not a
10. Pull brake shoes ap art and install stru t lever and spring refinish diameter. Do not refinish a brake drum that will not
between them . The loop on the stru t spring should be in meet the specifications, as shown below, after refinishing.
the " u p " position.
11. Install hold down pins, washers, springs and cups from
flange plate to shoes.
12. Place guide plate on anchor pin. DRUM D IA M E TE R S
R E PL A C E M E N T
13. Install pull back springs. O R IG IN A L MAXIMUM R E F IN IS H (D ISC A R D )
14. Remove the "knock o u t" plug (if necessary) and install
11.000 11.060 11.090
a new m etal plug in the brake drum adjusting hole. 11.150 11.210 11.240
15. Install the brake drum . 12.000 12.060 12.090
13.000 13.060 13.090
16. Install the propeller shaft.
BRAKE DRUMS
Brake Drum Balance
Inspection and Reconditioning D uring m anufacture, brake drum s are balanced. Any
NOTICE: See "N o tice" on Page 1 of this section. balance weights m ust not be removed.
W henever brake drum s are removed, they should be WHEEL CYLINDER
thoroughly cleaned and inspected for cracks, scores, deep
grooves and out-of-round. Removal
A cracked drum is unsafe for fu rther service and must 1. Remove wheel, drum and brake shoes. Be careful not to
be replaced. Do not attem pt to weld a cracked drum . get grease or dirt on brake lining.
Sm ooth up any slight scores. H eavy or extensive 2. Remove wheel cylinder from backing plate.
scoring will cause excessive brake lining wear, and it will
probably be necessary to rebore in order to true up the
Disassembly
braking surface. 1. Inspect cylinder bore for scoring or corrosion. It is best
to replace a corroded cylinder.
If the brake linings are slightly worn and the drum is
grooved, the drum should be polished with fine emery cloth 2. Polish any discolored or stained area with crocus cloth
but should not be turned. A t this stage, elim inating the by revolving cylinder on cloth supported by a finger.
grooves in drum would necessitate removal of too much 3. Rinse cylinder in clean brake fluid.
LIG H T T R U C K SERVICE M AN U AL
5-44 BRAKES
4. Shake excessive rinsing fluid from cylinder. Do not use pipe to wheel cylinder to specifications.
a rag to dry cylinder, as lint from the rag cannot be kept 2. Install brake shoes, drum and wheel; then flush and
from cylinder bore surfaces. bleed hydraulic system.
Assembly
POWER BRAKE VACUUM HOSE FILTER
1. L ubricate cylinder bore and counterbore with clean
brake fluid and insert spring-expander assembly. Removal
2. Install new cups. (Be sure cups are lint and dirt free.) 1. Use a pair of pliers to move the hose clam p approx
Do not lubricate cups prior to assembly. im ately 2" (50 mm).
3. Install new pistons. 2. Twist the filter in the hose to break the seal and remove
4. Press new boots into cylinder counterbores by hand. Do the filter.
not lubricate boots prior to assembly.
Installation
Installation 1. Install the filter. Be sure the vacuum check valve on the
NOTICE: See "N o tic e " on page 1 of this section. power brake unit is positioned from vertical as shown in
1. Install wheel cy linder on brak e backing plate and figure(s) 5-48 and 5-49.
connect brake pipe to hose. Torque rear wheel brake 2. Position hose clam p to retain filter.
C-K MODELS
P MODELS
LIG H T T R U C K SERVICE M A N U A L
5-46 BRAKES
POWER BRAKE UNIT 9. Connect m aster cylinder to power cylinder and torque
nuts to specifications.
Vacuum Booster
HYDRO-BOOST BRAKE SYSTEM
Replacement (Fig. 5-50) NOTICE: Power steering fluid and brake fluid cannot be
mixed. If brake seals contact steering fluid or steering
NOTICE: See "N o tic e " on page 1 of this section when seals contact brake fluid, seal dam age will result.
installing fasteners referred to in steps 6, 7 and 9 below.
T he following operations can be perform ed with the
1. Remove two nuts holding m aster cylinder to power
booster installed in the vehicle; exceptions to this statem ent
cylinder and position it away from power cylinder.
m ay exist where Body M anufacturers sheet m etal ( " P "
Do not disconnect hydraulic brake lines; be careful not Models) would require removal of the booster from the
to bend or kink pipes. vehicle.
2. Disconnect the vacuum hose from the vacuum check Pneumatic Accumulator
valve on the front housing of the power head. Plug
vacuum hose to prevent dust and dirt from entering CAUTION:The accumulator contains compressed
hose. gas. Always use proper tools and follow recom
3. Disconnect the power brake push rod from the brake mended procedures or personal injury may result.
Do not apply heat to accumulator. Do not attempt
pedal.
to repair an inoperative accumulator, always
4. Remove the four nuts from the m ounting studs which replace with a new accumulator. Dispose of an
hold the power brake to the cowl. inoperative accumulator by drilling a 1/16" (1.6
5. C arry the power brake to a clean work area and clean mm) diameter hole through the end of the accu
the exterior of the power brake prior to disassembly. mulator can opposite the "O " ring.
6. M ount power brake assembly to cowl and torque nuts Removal
to specified torque.
1. T urn engine off and pum p brake pedal 4 or 5 times to
7. Connect power brake push rod to brake pedal. deplete accum ulator.
8. C onnect vacuum hose to vacuum check valve. 2. Disconnect the high pressure hose.
LIG H T TR U C K SE RV IC E M A N U A L
BRAKES 5-47
Installation
1. Install " O " ring and spool valve plug (fig. 5-53).
2. Push spool valve plug in and install retaining ring.
3. Install m aster cylinder and two nuts to booster.
NOTICE: See "N o tic e " on Page 1 of this section.
L IG H T T R U C K SERVICE M A N U A L
BRAKES 5-49
^ G MODELS
LIG H T T R U C K SERVICE M AN U AL
5-50 BRAKES
LIG H T T R U C K SERVIC E M A N U A L
BRAKES 5-51
LIG H T T R U C K SERVICE M A N U A L
5-52 BRAKES
LIG H T T R U C K SERVICE M A N U A L
BRAKES 5-53
Hydro-Boost Unit b. Remove the lower dash trim , then lower the steering
column on C and K models. Remove support braces
Replacement (fig. 5-56 thru 5-59) on P30 (42) models.
1. D epress and release th e b rak e pedal several tim es c. Remove the booster bracket to dash panel or support
(engine not running) to be sure th at all pressure is bracket nuts and remove the booster assembly.
discharged from the accum ulator prior to disconnec- 7. P30(32) Models-
tiong the hoses from the booster. a. Remove the cotter pin, nut, bolt and washers th at
2. P30(32) Models- Raise the vehicle on a hoist. secure the operating lever to the vertical brake rod.
3. Clean all dirt from the booster at the hydraulic line b. Remove the six nuts, lock w asher and bolts th at
connections and m aster cylinder. secure the booster linkage bracket to the front and
rear support brackets, and remove the booster from
4. Rem ove th e nuts and lockw ashers th a t secure the
the vehicle by sliding the booster off the rear support
m aster cylinder to the booster and the support bracket.
studs.
S upport the m aster cylinder, being careful to avoid
kinking or bending the hydraulic lines attached to the c. Remove the cotter pin, nut, washer and bolt th at
m aster cylinder. Cover the end of the m aster cylinder secures the operating lever to the pedal rod.
with a clean cloth. d. Remove the brake pedal rod lever nut and bolt and
It should not be necessary to disconnect the hydraulic then remove the lever, sleeve and bushings.
lines from the m aster cylinder. 8. To install, reverse Steps 1-7 above. Torque all hydraul-
5. Disconnect the hydraulic lines from the booster ports. lic lines and attaching bolts to specifications.
Plug all lines and the booster ports to prevent loss of L u b ricate pedal rod and linkage pivot bolts, pins,
fluid and to keep out foreign m aterial. sleeves and bushings w ith Delco B rake L ube (or
equivalent).
6 . P30(42) and C-K-G Models-
NOTICE: See "N o tice " on Page 1 of this section.
a. Rem ove booster pedal push rod co tter pin and
w asher and disconnect the push rod from the brake 9. Fill and bleed system. R efer to "H ydro-Boost bleeding
pedal (C and K models) or booster bracket pivot procedure."
lever (G and P models). 10. Check brake pedal and stoplam p switch adjustm ent.
SPECIFICATIONS
LIG H T T R U C K SERVICE M A N U A L
5-54 BRAKES
SPECIFICATIONS
c K G P
M aster C y lin d e r — to Dash o r B o o ste r **3 4 N .m (25 ft. lbs.) **3 4 N .m (25 ft. lbs.) 34 N .m (25 ft. lbs.) 34 N .m (25 ft. lbs.)
B o o ste r to Dash o r Fram e **3 4 N .m (25 ft. lbs.) **3 4 N .m (25 ft.lb s.) 34 N .m (25 ft. lbs.) 34 N«m (25 ft. lbs.)
C o m b in a tio n Valve — M o u n tin g B o lts 17 N*m (150 in.lbs.) 17 N .m (150 in. lbs.) 23 N .m (17 ft. lbs.) 23 N«m (17 ft. lbs.)
— B ra cke t _ _ 34 N«m 125 ft. lb s .l 34 N .m (25 (t. lbs.I
C a liper — M o u n tin g B o lt 48 N .m (35 ft. lbs.)
— S u p p o rt Plate to K n u ckle 16 N*m (140 in. lbs.)
Brake Pedal — B ra c k e t to Dash 34 N .m (25 ft. lbs.) 34 N .m (25 ft. lbs.) 17 N .m (150 in. lbs.) 34 N .m (25 ft. lbs.)
— B ra c k e t to I.P. 34 N .m (25 ft. lbs.) 34 N .m (25 ft. lbs.) — —
L IG H T T R U C K SE RV IC E M AN U AL
BRAKES 5-55
SPECIAL TOOLS
L IG H T T R U C K SERVICE M A N U A L
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SECTION 6
ENGINE
CONTENTS
GENERAL INFORMATION
STATEMENT ON CLEANLINESS GENERAL INFORMATION ON
AND CARE ENGINE SERVICE
T H E F O L L O W IN G IN F O R M A T IO N ON E N
An autom obile engine is a com bination of m any
G IN E S E R V IC E S H O U L D BE N O T E D C A R E FU L L Y ,
m achined, honed, polished and lapped surfaces with toler
AS IT IS IM P O R T A N T IN P R E V E N T IN G D AM AGE,
ances th at are measured in the ten thousands of an inch.
A N D IN C O N T R IB U T IN G TO R ELIA B LE E N G IN E
W hen any internal engine parts are serviced, care and PERFO RM A N CE.
cleanliness are im portant. A liberal coating of engine oil
should be applied to friction a reas d uring assem bly to W hen raising or supporting the engine for any reason,
p rotect and lu b ricate the su rfaces on initial operation. do not use a jack under the oil pan. Due to the small
T hroughout this section, it should be understood that proper clearance between the oil pan and the oil pump screen,
cleaning and protection of machined surfaces and friction jacking against the oil pan may cause it to be bent against
areas is part of the repair procedure. This is considered the pump screen resulting in a dam aged oil pick-up unit.
standard shop practice even if not specifically stated. It should be kept in mind, while working on the engine,
W henever valve train com ponents are removed for that the 12-volt electrical system is capable of violent and
dam aging short circuits. W hen perform ing any work where
service, they should be retained in order. At the tim e of
electrical term inals could possibly be grounded, the ground
installation, they should be installed in the same locations cable of the battery should be disconnected at the battery
and with the sam e m ating surfaces as when removed. Any tim e the carburetor or air cleaner is removed, the
Battery cables should be disconnected before any major intake opening should be covered. This will protect against
work is performed on the engine. Failure to disconnect accidental entrance of foreign m aterial which could follow
cables may result in dam age to wire harness or other the intake passage into the cylinder and cause extensive
electrical parts. dam age when the engine is started.
LIG H T T R U C K SERVICE M AN U AL
6-2 ENGINE
SYMPTOM DEFINITION
A. Dieseling Engine continues to run after the switch is turned off. It runs unevenly
and makes knocking noises.
B. D etonation A mild to severe ping, usually worse under acceleration. The engine makes sharp
metallic knocks that change with throttle opening. Sounds like pop corn popping.
C. & D. Stalls, The engine quits running. It may be at idle or while driving.
Cold or H ot
C. & D. Rough Idle, The engine runs unevenly at idle. If bad enough, it may make the car shake.
Cold or Hot
E. Miss Steady pulsation or jerking that follows engine speed, usually more
pronounced as engine load increases. N ot normally felt above 1500 rpm
or 30 mph. The exhaust has a steady spitting sound at idle or low speed.
G. Surges Engine power variation under steady throttle or cruise. Feels like the
car speeds up and slows down with no change in the accelerator pedal.
H. Sluggish Engine delivers limited power under load or at high speed. W on’t accelerate
as fast as normal; loses too much speed going up hills, or has less top speed
than normal.
I. Spongy Less than the anticipated response to increased throttle opening. Little
or no increase in speed when the accelerato r pedal is pushed down a little
LIG H T T R U C K SERVICE M AN U AL
ENGINE 6-3
to increase cruising speed. C ontinuing to push the pedal down will finally
give an increase in speed.
3. Check and reset ignition timing and idle speed settings. Refer to emission la
2. For “ non-EST” check ignition timing per emission control inform ation label.
C. Stalls or Rough 1. W ith engine running, remove air cleaner cover and filter. D am per door
Idle - Cold in air cleaner snorkel should be closed when engine is cold. It may be
necessary to place cold wet rag over sensor to close it if engine is too warm.
If dam per door does not close, apply vacuum directly to vacuum motor. If
door closes, replace sensor. If door stays open, replace vacuum motor.
LIG H T T R U C K SERVICE M A N U A L
6-4 ENGINE
4. W ith engine running, visually check vacuum break linkage for movement while
removing and reinstalling vacuum hose. If the linkage does not move and vacuum
is at hose, replace vacuum break assembly.
5. W ith engine off, check all choke adjustments. See Section 6C.
6. Check engine timing and idle speed. See Emission Control Inform ation Label.
7. Remove vacuum hose from E.G .R. valve and connect an extra hose from any
manifold vacuum source to valve. If rpm doesn’t drop, valve is leaking.
See E.G .R. Section 6E for further functional tests, cleaning, a n d /o r replacement.
D. Stalls or Rough 1. W ith engine running, remove air cleaner cover and filter. D am per door in
Idle - Hot air cleaner snorkel should be open. If closed and engine is hot, check
tem perature operation of sensor unit. See air cleaner tem perature test,
Section 6E.
3. Check engine tim ing and idle speed. See emission control inform ation label.
4. Check P.C.V. valve for proper operation by placing finger over inlet hole
in valve end several times. Valve should snap back. If not, replace valve.
5. Remove vacuum hose from E.G .R. valve and connect an extra hose from any
manifold source to valve. If rpm doesn’t drop, valve is leaking. See E.G.R.
Section 6E for further functional tests, cleaning a n d /o r replacement.
LIG H T T R U C K SERVICE M A N U A L
ENGINE 6-5
replace as necessary.
2. Disconnect air cleaner and E.G .R. vacuum hoses and cap both vacuum sources.
3. Remove one spark plug wire at a time with insulated pliers. If there is
an rpm drop on all cylinders, go to rough idle (hot) diagnosis charts.
5. Check spark plug wires by connecting ohm m eter to ends of each wire in question.
If m eter reads over 50,000 ohms, replace wire(s).
: ' '
6. Visually check distributor cap and rotor for moisture, dust, cracks,
burns, etc. Clean a n d /o r repair as necessary.
8. Remove rocker covers. Check for bent push rods, worn rocker arms, broken
valve springs, worn cam shaft lobes. Repair as necessary.
3. Check carburetor accelerator pum p operation. W ith air cleaner removed and
engine off, hold choke valve open and look for gas squirt in carburetor bore
while moving throttle.
4. If weak or no pump squirt, remove carburetor air horn and repair pum p system as
necessary. See air horn removal, cleaning and inspection, Section 6C for
proper procedures. Check float level adjustm ent before replacing air horn
and pum p rod adjustm ent after assembly. See Float Adjustm ent, Section 6C.
6. W ith engine running, remove air cleaner cover and filter. D am per door in
LIG H T T R U C K SERVICE M A N U A L
6-6 ENGINE
air cleaner snorkel should be closed when engine is cold. It may be necessary
to place cold wet rag over sensor to close if engine is too warm.
If dam per door does not close, apply vacuum directly to vacuum motor. If
door closes, replace sensor. If door stays open, replace vacuum motor.
G. Surges 1. W ith engine running, remove air cleaner cover and filter. D am per door in
air cleaner snorkel should be closed when engine is cold. It may be necessary
to place cold wet rag over sensor to close if engine is too warm.
3. “ Non EST” check ignition timing per emission control inform ation label.
To check m echanical advance, observe timing marks. It should advance
as throttle is opened and return to m ark as throttle is closed.
Check EST operation if applicable.
4. “ Non EST” with engine off, remove vacuum hose from distributor vacuum advance
Connect vacuum pum p and apply 15" vacuum. Vacuum should hold steady for 15
seconds. If vacuum drops, replace vacuum advance unit.
6. Test fuel pum p by connecting hose from carburetor fuel feed line to a suitable
container. Start engine and let idle for 15 seconds.
a. M echanical pum p should supply 1/2 pint or more. If not, go to step 7.
If O K, go to step 9.
8. Check fuel lines and hoses for splits, leaks or kinks by disconnecting each
section of line and connect vacuum gage. Crank or run engine until vacuum
gage peaks. Vacuum should be at least 12 inches. If less, repair or replace
defective line or hose.
9. If fuel lines and pum p check O K , remove tank unit, replace strainer and
clean fuel tank, if necessary.
10. Remove spark plugs, Check for cracks, wear, im proper gap, burned electrodes,
heavy deposits. R epair or replace as necessary.
LIG H T T R U C K SERVICE M A N U A L
ENGINE 6-7
H. Sluggish or Spongy 1. Rem ove air cleaner and check air filter for dirt or being plugged.
Replace as necessary.
2. W ith engine running, dam per door in air cleaner snorkel should be closed when
engine is cold. It may be necessary to place cold wet rag over sensor to close
if engine is too warm.
If dam per door does not close, apply vacuum directly to vacuum m otor. If
door closes, replace sensor. If door stays open, replace vacuum m otor.
4. Remove air cleaner and check for full throttle valve opening in carburetor
by depressing accelerator pedal to floor; also check for full choke valve
opening and free operating air valve (if equipped). R epair as necessary.
See carburetor cleaning and inspection, Section 6C.
5. Rem ove vacuum hose from E.G .R . valve and connect an extra hose from any
m anifold vacuum source to valve. If rpm doesn’t drop, valve is leaking.
See E .G .R . Section 6E for further functional tests, cleaning, a n d /o r replacem ent.
6. “ N on EST” with engine off, remove vacuum hose from distributor vacuum advance
vacuum pum p and apply 15" vacuum. Vacuum should hold steady for 15 seconds.
If vacuum drops, replace vacuum advance unit.
7. Remove spark plugs. Check for cracks, wear, im proper gap, burned electrodes,
heavy deposits. Repair or replace as necessary.
I. Poor Gasoline 1. W ith engine running, remove air cleaner cover and filter. Check
Mileage filter for dirt or being plugged. Replace as necessary. D am per door in air
cleaner snorkel should be closed when engine is cold. It may be necessary
to place cold wet rag over sensor to close it if engine is too warm.
If dam per door does not close, apply vacuum directly to vacuum motor.
If door closes, replace sensor. If door stays open, replace vacuum motor.
LIG H T TR U C K SERVICE M A N U A L
6-8 ENGINE
4. Check carburetor choke linkage and settings. Clean and repair as necessary.
See carburetor choke adjustments, cleaning and inspection, Section 6C.
5. “N O N EST” with engine off, remove vacuum hose from distributor vacuum advance
vacuum pum p and apply 15" vacuum. Vacuum should hold steady for 15 seconds.
If vacuum drops, replace vacuum advance unit.
6. Remove spark plugs, check for cracks, wear, im proper gap, burned electrodes,
heavy deposits. Repair or replace as necessary.
7. I f in p re v io u s c h eck s, a d ju s tm e n ts have n o t b e e n m ad e th a t c o u ld
im p ro v e m ileag e, rem o v e c a rb u re to r air h o rn an d c h e ck th e fo llow ing:
3. Remove spark plugs. Check for cracks, wear, im proper gap, burned electrodes,
heavy deposits. R epair or replace as necessary.
5. Test fuel pum p by connecting hose from carburetor fuel feed line to a
suitable container. Start engine and let idle for 15 seconds.
a. F u e l pump should supply 1/2 pint or more. If not, go to step 7.
6. To check m echanical fuel pum p, disconnect inlet hose at pum p and connect
a vacuum gage. C rank or run engine until m axim um vacuum is reached. If
less than 12 inches, replace pump. If vacuum reading is 12 inches or more,
go to step 8.
LIG H T T R U C K SERVIC E M A N U A L
ENGINE 6-9
7. Check fuel lines and hoses for splits, leaks or kinks by disconnecting
each section of line and connecting a vacuum gage. Crank or run engine until
vacuum gage peaks. Vacuum should be at least 12 inches. If less, repair or
replace defective line or hose as necessary.
8. If fuel pum p and fuel lines check O K , remove tank unit, replace strainer
and clean fuel tank, if necessary.
If carburetor is suspected, remove the air horn and check the
following:
a. Power Piston(s) or main fuel piston for freeness.
b. D irt in jets and m etering passages.
c. M etering rods.
d. Power valve(s) or main fuel valve(s).
e. Float adjustment.
See C arburetor Cleaning Inspection and A djustm ent, Section 6C.
5. Remove spark plugs. Check for cracks, wear, im proper gap, burned electrodes,
heavy deposits. Repair or replace as necessary.
6. Test fuel pump by connecting hose from carburetor fuel feed line to a
suitable container.
Start engine and let idle for 15 seconds. Pum p should supply 1/2 pint or more.
If m ore than 1/2 pint, check filter in carburetor. Replace if necessary.
If less than 1/2 pint, for mechanical pum p go to step 7.
7. Disconnect inlet hose at pum p and connect a vacuum gage. C rank or run engine
LIG H T T R U C K SERVICE M A N U A L
6-10 ENGINE
8. Check fuel lines and hoses for splits, leaks or kinks by disconnecting each
section of line and connect vacuum gage. C rank or run engine until vacuum gage
peaks. Vacuum should be at least 12 inches. If less, repair or replace
defective line or hose.
9. If fuel lines and pump check O K, remove tank unit, replace strainer and clean
fuel tank, if necessary.
5. Remove spark plugs. Check for cracks, wear, im proper gap, burned electrodes,
heavy deposits. Repair or replace as necessary.
LIG H T T R U C K SERVICE M A N U A L
ENGINE 6-11
Low Oil Pressure a. Slow idle speed 1. Set idle speed to spec.
LIG H T TR U C K SERVICE M A N U A L
6-12 ENGINE
Valve Train Noise a. Low oil pressure. 1. Repair as necessary. (See diagnosis
for low oil pressure.)
LIG H T T R U C K SERVIC E M A N U A L
ENGINE 6-13
‘Cold engine piston knock usually disappears when the cylinder is grounded out. Cold engine piston knock which
disappears in 1.5 minutes should be considered acceptable.
2W hen the engine is stopped, some valves will be open. Spring pressure against lifters will tend to bleed lifter down.
A ttem pts to repair should be m ade only if the problem is consistent and appears each time engine is started.
L IG H T T R U C K SERVICE M A N U A L
6-14 ENGINE
Diesel Engine Mechanical Diagnosis such as noisy lifters, rod bearings, main bearings, valves, rings and pistons is the same as for a
gasoline engine. This diagnosis covers only those conditions that are different for the diesel engine.
Engine Will Not Crank 1. Loose or Corroded Check connections at batteries, engine block and starter
Battery Cables solenoid.
2. Discharged Batteries Check generator output and generator belt adjustm ent.
3. Starter Inoperative Check voltage to starter and starter solenoid. If OK, remove
starter for repair. (Use diagnostic connector term inals shown
on circuit drawing in ELECTRICAL DIAGNOSIS).
Engine Cranks Slowly - 1. Battery Cable Check connections at batteries, engine block and starter.
Will Not Start Connections Loose
(Minimum Engine or Corroded
Cranking Speed -
100 RPM COLD,
240 RPM HOT) 2. Batteries Undercharged Check charging system.
3. Wrong Engine Oil Drain and refill with oil o f recom m ended viscosity.
Engine Cranks Normally — 1. Incorrect Starting Use recom m ended starting procedure.
Will Not Start Procedure
4. No Fuel Into Cylinders Remove any one glow plug. Depress the th ro ttle part way
and crank the engine for 5 seconds. If no fuel vapors come
out o f the glow plug hole, go to step 5. If fuel vapors are
4 noticed remove the rem ainder o f the glow plugs and see if
fuel vapors come out o f each hole when the engine is
cranked. If fuel comes out o f one glow plug hole only
replace the injection nozzle in that cylinder. Crank the
engine and check to see that fuel vapors are coming out o f
all glow plug holes. If fuel is coming from each cylinder,
go to step 11.
5. No Fuel To Injection Loosen the line coming out o f the filter. Crank the engine,
Pump the fuel should spray out o f the fitting, use care to direct
fuel away from sources o f ignition. If fuel sprays from the
fitting go to step 10.
6. Restricted Fuel Filter Loosen the line going to the filter, if fuel sprays from the
fitting, the filter is plugged and should be replaced. Use care
to direct the fuel away from sources o f ignition.
7. Fuel Pump Inoperative Remove inlet hose to fuel pum p. Connect a hose to the
pum p from a separate container that contains fuel. Loosen
the line going to the filter. If fuel does not spray from the
fitting, replace the pum p. Use care to direct the fuel away
from source o f ignition.
8. Restricted Fuel Tank Remove fuel tank and check filter. (Filter for diesel fuel is
Filter blue).
Diesel Diagnosis 1
LIG H T T R U C K SERVIC E M A N U A L
ENGINE 6-15
9. Plugged Fuel Return Disconnect fuel return line at injection pum p and route hose
System to a metal container. Connect a hose to the injection pum p
connection, route it to the m etal container. Crank the
engine. If it starts and runs, correct restriction in fuel return
lines. If it does not start, remove the ball check connector
from the top o f the injection pum p and make sure that
it is not plugged.
10. No Voltage To Connect a volt m eter to the wire at the injection pum p
Fuel Solenoid solenoid and ground. The voltage should be a m inimum o f
9 volts. If there is inadequate voltage, refer to the
ELECTRICAL DIAGNOSIS for more inform ation.
Engine Cranks Normally - 11. Incorrect or Flush fuel system and install correct fuel.
Will Not Start (C ontd) Contam inated Fuel
12. Pum p Timing Incorrect Make certain that pum p timing m ark is aligned with mark on
adapter.
Engine Starts But 1. Slow Idle Incorrectly Adjust idle screw to specification.
Will Not Continue Adjusted
To Run At Idle
2. Fast Idle Solenoid With engine cold, start engine;solenoid should move to hold
Inoperative injection pum p lever in “ fast idle position". If solenoid does
not move, refer to ELECTRICAL DIAGNOSIS.
3. Restricted Fuel Disconnect fuel return line at injection pum p and route hose
R eturn System to a metal container. Connect a hose to the injection pum p
connection; route it to the metal container. Crank the engine
and allow it to idle. If engine idles norm ally, correct
restriction in fuel return line. If engine does not idle
norm ally, remove the return line check valve fitting from
the top o f the pum p and make sure it is not plugged.
5. Pum p Timing Incorrect Make certain that tim ing m ark on injection pum p is aligned
with m ark on adapter.
6. Limited Fuel To Test the engine fuel pum p, check for plugged filters; check
Injection Pump fuel lines. Replace or repair as necessary.
9. Fuel Solenoid Closes Ignition switch out o f adjustm ent. If OK, refer to
In Run Position ELECTRICAL DIAGNOSIS.
Engine Starts, Idles 1. Slow Idle Incorrectly Adjust slow idle screw to specification.
Rough, WITHOUT Abnormal Adjusted
Noise or Smoke
2. Injection lin e Leaks Wipe o ff injection lines and connections. Run engine and
check for leaks. Correct leaks.
Diesel Diagnosis 2
LIG H T TR U C K SERVICE M AN U AL
6-16 ENGINE
3. Restricted Fuel Return Disconnect fuel return line at injection pum p and route hose
System to a metal container. Connect a hose to the injection pump
connection; route it to the metal container. Start the engine
and allow it to idle; if engine idles norm ally, correct
restriction in fuel return lines. If engine does not idle
norm ally, remove the return line check valve fitting from
the top o f the pum p and make sure it is not plugged.
4. Air In System Install a section o f clear plastic tubing on the fuel return
j .".m ! r r j fitting from the engine. Evidence o f bubbles in fuel when
cranking or running indicates the presence of an air leak in
the suction fuel line. Locate and correct.
Engine Cold Starts and 1. Injection Pump Be sure timing mark on injection pum p is aligned with mark
Idles Rough WITH Timing Incorrect on adapter.
Excessive Noise and/or
Smoke But G ears Up 2. Insufficient Engine Break-in engine 2000 or more miles.
After Warmup Break-in Time
3. Air in System Install a section o f clear plastic tubing on the fuel return
fitting from the engine. Evidence o f bubbles in fuel when
cranking or running indicates the presence o f an air leak in
the suction fuel line. Locate and correct.
Engine Will Not 1. External Linkage Binding Free up linkage. Adjust or replace as required.
Return To Idle Or Misadjusted
Fuel Leaks On G round — 1. Loose or Broken Fuel Examine complete fuel system , including tank,
No Engine Malfunction Line or Connection and injection lines. Determine source and cause o f
leak and repair.
Noticeable Loss 1. Restricted Air Intake Check air cleaner elem ent.
Of Power
2. EGR Malfunction Refer to Section 6E.
Diesel Diagnosis 3
LIG H T T R U C K SERVIC E M A N U A L
ENGINE 6-17
5. Plugged Fuel Tank Remove fuel cap. If loud “hissing” noise is heard, vacuum
V acuum Vent In vent in fuel cap is plugged. Replace cap. (Slight hissing sound
Fuel Cap is norm al).
6. R estricted Fuel Supply Examine fuel supply system to determ ine cause o f
From Fuel Tank To restriction. Repair as required.
Injection Pump
7. Restricted Fuel Remove fuel tank and check filter. (Filter for diesel fuel is
Tank Filter blue).
10. External Compression Check for com pression leaks at all nozzles and glow plugs,
Leaks using “ Leak-Tec” or equivalent. If leak is found, tighten
nozzle or glow plug.
11. Plugged Nozzle(s) Remove nozzles. Have them checked for plugging and repair or
replace.
Noise - “Rap” From 1. Nozzle(s) Sticking Open Remove nozzle for test and replace as necessary.
One or More Cylinders or with very low Nozzle
(Sounds Like Rod Opening Pressure
Bearing Knock)
Excessive Black Smoke 1. Timing Not Set To Make certain that tim ing m ark on injection pum p is aligned
and/or Objectionable Specification with m ark on adapter.
Overall Combustion
Noise 2. EGR Malfunction Refer to Emission Diagnosis. (Section 6E)
Engine Noise - 1. Engine Fuel Pump, Repair or replace as necessary. If noise is internal, see
Internal Or G enerator, Water Pum p, Diagnosis For Noise - Rap From One or More Cylinders and
External Valve Train, Vacuum Engine Starts and Idles Rough With Excessive Noise and/or
Pum p, Bearings, Etc. Smoke.
Engine Overheats 1. Coolant System Leak, Check for leaks and correct as required. Check coolant
Oil Cooler System Leak recovery jar, hose and radiator cap.
or Coolant Recovery
System Not Operating
Diesel Diagnosis 4
LIG H T T R U C K SERVICE M A N U A L
6-18 ENGINE
Oil Warning Lamp 1. Oil Cooler or Oil or Remove restriction in cooler or cooler line.
“ ON” at Idle Cooler Line Restricted
2. Oil Pum p Pressure Low See Section 6A5 for oil pum p repair procedures.
Engine Will Not Shut 1. Injection Pump Fuel Refer to ELECTRICAL DIAGNOSIS.
O ff With Key Solenoid Does Not
Return Fuel Valve To
NOTE With engine at “ O F F ” Position
idle, pinch the fuel
return line at the
flexible hose to
shut o ff engine.
V A C U U M PU M P D IA G N O S IS
Excessive noise or clattering 1. Loose screws between pump 1. A - Tighten screws to spec.
noise. assy, and drive assy. B -R eplace “ 0 ” ring.
C -R eplace pum p assy.
Pump assy, loose on drive assy. Stripped threads. Replace pum p assy.
Install hose and vacuum gage 1. Defective valves. Replace pum p assy.
to pum p, engine running, gage
should have reading o f 20 2. Defective diaphragm.
inches vacuum m inim um . With
engine off, vacuum level loss 3. Worn push rod seal.
should not drop from 20
inches to 19 inches in less than 4. Loose tube.
1-1/2 seconds.
Diesel Diagnosis 5
LIG H T T R U C K SERVIC E M A N U A L
ENGINE 6-19
DIESEL ENGINE
ROUGHNESS AT IDLE
REMOVE A IR CLEANER
INSTALL COVER J-26996-1
T IM IN G OK T IM IN G OFF
I
ALIGN M A R K S
I
NO LEAKS LEAKS
CORRECT
I
NO LEAKS LEAKS
CORRECT
Diesel Diagnosis 6
L IG H T T R U C K SERVIC E M AN U AL
6-20 ENGINE
F IN D C A U SE IN FUEL SU P PLY
LOOSEN THE LINE AT THE NOZZLES TO BLEED A SM ALL AMOUNT OF FUEL FROM THE
L IN E IF S O L ID FUEL APPEARS, GO ON TO THE NEXT NOZZLE. IF FOAM A P P E A R S
SHUT THE ENGINE OFF AND DISCONNECT THE LINE FROM THE N O Z ZLE MOVE THE
LINE SO THE INLET TO THE NOZZLE CAN BE OBSERVED. REMOVE THE P IN K W IRE
TO THE PU M P AND CRANK THE ENGINE AND O BSERVE THE NOZZLE INLET FOR
BUBBLES. IF BUBBLES ARE EVIDENT, REPLACE THE N O Z ZLE S Q U IR T SOME
O IL OR FUEL IN THE NEW NOZZLE INLET AND RECHECK FOR BUBBLES. IF BU BBLES
ARE NOT EVIDENT RECONNECT THE LINE AND P IN K W IR E AND GO ON TO THE
NEXT NOZZLE AND REPEAT THE PROCESS. CHECK THE REMOVED NOZZLE ON A
TESTER TO DETERMINE IF IT IS INOPERATIVE OR IF IT IS IN C O M PA T IB LE WITH
THE C YLIN D ER HEAD.
Diesel Diagnosis 7
LIG H T T R U C K SERVIC E M A N U A L
IN-LINE 6 6A1-1
Section 6A1
Contents
GENERAL DESCRIPTION
CYLINDER BLOCK coupled with a spherical face on the lifters, causes the valve
lifters to rotate.
The cylinder block is m ade of cast iron and has 6
cylinders arranged "In -L in e". Seven main bearings support
the crankshaft which is retained by recessed bearing caps
PISTONS AND CONNECTING RODS
th at are m achined with the block for proper alignm ent and The pistons are m ade of a cast alum inum alloy using
clearances. Cylinders are completely encircled by coolant two compression rings and one oil control ring.
jackets. Piston pins in the 4.1 L (D) engine are offset .060"
(1.5m m ) toward the th ru st side (right hand side) to provide
CYLINDER HEAD a gradual change in th ru st pressure against the cylinder wall
The cast iron cylinder head has individual intake and as the piston travels its path. This also provides for quieter
exhaust ports for each cylinder. Valve guides are integral operation. 4.8 L (T ) engine piston pins are on piston
and rocker arm s are retained on individual threaded studs centerline for best durability and reduced friction. Pins are
pressed into head. The 4.1 L(D ) heads have integrated inlet chrom ium steel and have a floating fit in the pistons. They
manifolds. The 4.8 L(T) uses separate inlet manifolds. are retained in the connecting rods by a press fit.
Connecting rods are made of forged steel. Full pressure
CRANKSHAFT AND BEARINGS lubrication is directed to the connecting rods by drilled oil
The crankshaft is cast nodular iron and is supported by passages from the adjacent main bearing journal. Oil holes
seven main bearings. N um ber seven bearing is the end at the connecting rod journals are located so that oil is
thrust bearing. M ain bearings are lubricated from oil holes supplied to give m axim um lubrication just prior to full
which intersect the main oil gallery located on the right side bearing load.
of the block. The cam bearings are also fed oil by intersect
ing holes with main oil gallery. The lifters are located in the VALVE TRAIN
m ain oil gallery.
A very simple ball pivot-type train is used. M otion is
A dam per assembly, on the forward end of the crank
transm itted from the cam shaft through the hydraulic lifters
shaft, dampens any engine torsional vibrations. The outer
and push rods to the rocker arms. The rocker arm pivots on
ring of the dam per is grooved for the accessory drive belts.
its ball and transm its the cam shaft motion to the valve. The
CAMSHAFT AND DRIVE rocker arm ball is retained by a self locking nut.
The hydraulic lifter assembly consists of: the lifter INTAKE MANIFOLD
body, which rides in the cylinder block boss, a plunger, a
The intake manifold is of cast iron, single level design
push rod seat, a m etering valve, a plunger spring, a check
for efficient fuel distribution. The 4.1 L (D) manifold is an
ball and spring, a check ball retainer and a push rod seat integral unit with the head on all vehicles. 4.8 L (T) engines
retainer. use separate components. The carburetor pad is centrally
W hen the lifter is riding on the low point (base circle) located w ith an early fuel evaporation (E F E ) passage
of the cam , the plunger spring keeps the plunger and push running underneath the pad, through which exhaust gases
rod seat in contact with the push rod. are forced, to promote faster fuel vaporization when the
engine is cold. An exhaust gas recirculation port is also cast
W hen the lifter body begins to ride up the cam lobe, the into the manifold on 4.1 L (D ) engines, for the induction of a
check ball traps the oil in the reservoir below the plunger. m etered am ount of exhaust gases into the air and fuel
The plunger and lifter body then rise as a unit, pushing up m ixture which has entered through the carburetor.
the push rod and opening the valve. A very small am ount of
oil will leak out between the plunger and the body. EXHAUST MANIFOLD
On 4.8 L (T) engines a single four port, underslung,
As the lifter body rides down the other side of the cam,
center take down manifold of cast ironl is used to direct
the plunger follows with it until the valve closes. The lifter
exhaust gases from the com bustion cham bers. On 4.1 L (D)
body continues to follow the cam to its low point, but the engines a single four port, underslung, dual center take
plunger spring keeps the plunger in contact with the push down manifold of cast iron is used. A heat shield is m ounted
rod. The ball check valve will then move off its seat and the to the manifold th a t is used to route heated air to the air
lifter reservoir will be refilled with oil. cleaner for better fuel vaporization.
Engine Lubrication
Full pressure lubrication, through a full flow oil filter is The connecting rod bearings are supplied oil from the
furnished by a gear-type oil pump. The distributor, driven c ran k sh a ft m ain bearings by m eans of cross drilled
by a helical gear on the cam shaft, drives the oil pump. passages.
Oil draw n by the pick-up screen and pipe is pressurized
in the pum p and routed to the oil filter. If excessive The valve train is supplied its lubrication from the valve
backpressure is encountered at the filter, a bypass valve lifters. Oil within the lifters is pum ped up through the top of
allows oil flow to the m ain oil gallery, located along the right the lifters through the hollow push rods to the rocker arms.
side of the block. This rifle drilled gallery supplies oil to the From the head, oil is drained back to the crankcase through
cam shaft bearings, the hydraulic lifters and the crankshaft oil drain back holes and the push rod holes. (Fig. 6A1-1).
main bearings.
LIG H T T R U C K SERVICE M A N U A L
IN-LINE 6 6A1-3
OIL PRESSURE
SENDING UNIT
LIG H T T R U C K SERVIC E M AN U AL
6A1-4 IN-LINE 6
LIG H T T R U C K SERVIC E M A N U A L
IN-LINE 6 6A1-5
L IG H T TR U C K SERVIC E M AN U AL
6A1-6 IN-LINE 6
VIEW
ENGINE BRACKET
ALL C SERIES
WITH L-6 ENGINE
VIEW A
LIG H T T R U C K SERVICE M A N U A L
L ENGINE M O U N T FRAME BRACKET
ALL K SERIES WITH L-6 ENGINE
Z........... 7
ALL K SERIES WITH L-6 ENGINE
VIEW A \
FWD X
292 CU. IN. R. SIDE
6A1-8 IN-LINE 6
LIG H T T R U C K SERVICE M A N U A L
IN-LINE 6 6A1-9
ON VEHICLE SERVICE
ENGINE MOUNTS lower the engine on the m ounts and tighten the screws or
nuts attaching the m ount to the engine, frame, or bracket.
Engine mounts (Fig. 6A1-2 - 6A 1-8) are the non-
ad ju sta b le type and seldom req u ire service. Broken or Rear Mount
d e te rio ra ted m ounts should be replaced im m ediately,
because of the added strain placed on other m ounts and Raise the vehicle on a hoist. Push up and pull down on
drive line components. the transm ission tailshaft while observing the transm ission
m ount. If the rubber separates from the metal plate of the
Checking Engine Mounts m ount or if the tailsahft moves up but not down (m ount
bottom ed out) replace the m ount. If there is relative
Front Mount movement between a m etal plate of the m ount and its
attaching point, tighten the screws or nuts attaching the
Raise the engine to remove weight from the m ounts and
m ount to the transm ission or crossmember.
to place a slight tension in the rubber. Observe both mounts
while raising engine. If an engine m ount exhibits:
Front Mount Replacement
a. H ard rubber surface covered with heat check cracks;
1. Remove engine m ount through bolt.
b. R ubber separated from a m etal plate of the mount;
2. R aise engine and remove m ount to fram e bracket
c. R ubber split through center,
atta c h in g bolts. Remove m ount. R aise engine only
replace the m ount. If th e re is relative m ovem ent enough for sufficient clearance. Check for interference
between a m etal plate of the m ount and its attaching points, between rear of engine and cowl panel.
LIG H T T R U C K SERVICE M A N U A L
6A 1-10 IN-LINE 6
3. Install new engine m ount to fram e bracket and torque 6. Clean, oil and torque all manifold assembly to cylinder
attaching bolts to specifications. head bolts and nuts to 40 lbs. ft. (55 N-m).
4. Install engine m ount through bolt and torque to 30 lb. 7. Com plete torquing the inlet to exhaust manifold bolt
ft. (40 N-m) specifications. and two nuts at the center of the manifold to 45 lb. ft.
(61 N-m).
Rear Mount Replacement
8. Connect exhaust pipe to manifold using a new packing.
1. Support engine weight to relieve rear mounts.
9. C onnect crankcase ventilation hose at rocker arm
2. Remove crossm em ber-to-m ount bolts. cover.
3. On " P " Series with m anual transm ission and propeller 10. Connect vapor hoses at canister.
shaft parking brake, remove mount attaching bolts
11. Connect fuel and vacuum lines a carburetor.
from fram e outrigger and clutch housing and remove
rear mounting cushions. 12. C onnect th ro ttle controls at bellcrank and install
throttle return spring.
4. Rem ove m ount-to-tran sm issio n bolts, then remove
mount. 13. Install air cleaner, start engine, check for leaks and
adjust carburetor idle speed.
5. On "P " Series with m anual transm ission and propeller
shaft parking brake, install new mounting cushions and
bolts.
EXHAUST MANIFOLD ASSEMBLY - INTEGRATED
6. Install new m ount on transm ission. HEAD
7. W hile lowering transm ission, align and sta rt cross- Removal
m em ber-to-m ount bolts. 1. Disconnect negative battery cable.
8. Torque bolts to 45 lb. ft. (60 N-m ) then bend lock tabs 2. Remove air cleaner.
to bolt head as applicable.
3. Remove power steering pum p a n d /o r A .I.R . pum p
brackets, if so equipped.
MANIFOLD ASSEMBLY - NON-INTEGRATED
4. Remove P A IR pipes as outlined in Section 6E.
HEAD
5. Raise vehicle on hoist and disconnect exhaust pipe at
Removal manifold and converter bracket at transmission mount.
1. Disconnect battery negative cable at battery. 6. Lower vehicle.
2. Remove air cleaner. 7. Remove exhaust manifold bolts.
3. D isconnect both th ro ttle controls at bellcrank and 8. Remove exhaust manifold, check EFE Valve to see if
remove throttle retu rn spring. free and check manifold for cracks.
4. Disconnect fuel and vacuum lines at carburetor.
Installation
5. Disconnect crankcase ventilation hose at rocker arm
cover. If a new exhaust manifold is being installed, the E.F.E.
valve and actuator and rod assembly m ust be transferred
6. Disconnect vapor hose at canister.
from the old component.
7. Disconnect exhaust pipe at m anifold flange.
1. C lean gasket surface and position new gasket on
8. Remove m anifold a tta c h in g bolts and clam ps then exhaust manifold.
remove m anifold assembly.
2. Install manifold bolts, while holding manifold assembly
9. Check for cracks in manifold castings. in place.
10. Separate manifolds by removing one bolt and two nuts 3. Torque all manifold to cylinder head bolts in sequence
at center of assembly. to torques shown in figure 6 A 1-9.
11. Observe gaskets and packing if necessary to diagnose a
leakage problem. 4. Raise vehicle on hoist.
Installation 5. Connect exhaust pipe at manifold flange and converter
bracket at transm ission mount. A ttach exhaust pipe
1. Clean gasket surfaces on cylinder head and manifolds.
and align exhaust system. Torque attaching bolts to
2. Lay a straight edge along the full length of the exhaust specification.
port faces and m easure any gaps between the straight
edge and the port faces. If at any point a gap of .030"
(.80m m) or more exists, it is likely th at the m anifold / 12W 1 8 -2 5 — ( 5 } 18~ 25
w ft. lbs w _ 4 0 _ 45 w f t . | bs. w
has distorted to a point where it will not seat properly.
If a good exhaust seal is to be expected, the exhaust
manifold must be replaced. ^ & ex. 3 5 -4 0
Ix d —
<3 &
3. Assem ble intake and exhaust manifolds using a new
<ET
ft.lb s .
LIG H T T R U C K SERVIC E M A N U A L
IN-LINE 6 6A1-11
6. Lower vehicle. surface. Place cover on block while sealant is still wet
7. Install P A IR pipes as outlined in Section 6E. (within 10 m inutes). Install retaining bolts and torque
8. Install power steering pum p an d /o r A .I.R . pum p and to 50 lb. in. (5.6 N-m ).
brackets, if so equipped. Tighten drive belt using strand 3. "C K " Models - Clean dipstick tube and apply sealant
tension gage. # 1052080 or equivalent around tube 1/2" below bead.
Install dipstick tube.
9. Install air cleaner.
4. Connect battery negative cable.
10. Connect negative b attery cable.
11. S ta rt engine and check for leaks.
VALVE MECHANISM
ROCKER ARM COVER Removal
Removal 1. Remove rocker arm cover as previously outlined.
1. Disconnect crankcase ventilation hose(s) at rocker arm 2. Remove rocker arm nuts, rocker arm balls, rocker arm s
cover. and push rods. Place rocker arm s, rocker arm balls and
push rods in a rack so th a t they may be reinstalled in
2. Remove air cleaner.
the same location.
3. D isconnect all w ires, fuel and vacuum pipes from
rocker arm cover clips. Installation and Adjustment
4. On LE3 engines, remove pulse air pipes (as outlined in W henever new rocker arm s and/or rocker arm balls are
Section 6E) and disconnect accelerator linkage and being installed, coat bearing surfaces of rocker arm s and
springs from bracket. rocker arm balls with " M olykote " or its equivalent.
5. Remove rocker arm cover bolts and remove cover. 1. Install push rods. Be sure push rods seat in lifter socket.
NOTICE: If cover adheres to cylinder head, try bum ping 2. Install rocker arm s, rocker arm balls and rocker arm
end of rocker arm cover with a rubber m allet. If cover nuts. T ighten rocker arm nuts until all lash is
still will not come loose, C A R E F U L L Y pry until loose. elim inated.
DO N O T D IS T O R T S E A L IN G FL A N G E . 3. A djust valves when lifter is on base circle of cam shaft
lobe as follows:
Installation
a. M ark distributor housing, with chalk, at # 1 and # 6
1. Clean sealing surfaces on cylinder head and rocker arm
positions (plug wire). Remove distrubutor cap and
cover with degreaser. Remove all loose pieces of RTV
lay aside.
or pieces that will cause installation interference.
b. Crank engine until distributor rotor points to # 1
2. Place a 3/16 " (5m m ) bead of RTV sealant, # 1052366
cylinder position. The following valves can be ad
or equivalent, all around the rocker arm cover sealing
justed with engine in # 1 firing position:
surface of the cylinder head. W hen going around the
# 1 cylinder-Exhaust and Intake.
a tta c h in g bolt holes, alw ays flow the RTV on the
# 2 cylinder-Intake
inboard side of the holes.
# 3 cylinder-Exhaust
3. Place cover on head while RTV is still wet, install # 4 cylinder-Intake
retaining bolts and torque to 45 lb. in. (5N -m ). # 5 cylinder-Exhaust
4. C onnect wires, fuel and vacuum pipes at rocker arm c. Back out adjusting nut until lash is felt at the push
cover clips. rod then tu rn in adju stin g nut until all lash is
5. Install pulse air pipes (as outlined in Section 6E), and removed. This can be determ ined by rotating the
accelerator linkage and springs where removed. push rod while turning adjusting nut (Fig. 6A 1-10).
6. Install air cleaner. W hen play has been removed, turn adjusting nut in
7. C onnect cran k case v en tilatio n hoses (w here so one full additional turn (to center lifter plunger).
equipped). d. C rank engine until distributor rotor points to # 6
position. The following valves can be adjusted with
PUSH ROD SIDE COVER engine in # 6 firing position:
Removal # 2 cylinder-Exhaust
1. Disconnect battery negative cable. # 3 cylinder-Intake
2. "C K " M odels-Remove dipstick tube (rear cover). # 4 cylinder-Exhuast
3. Remove cover bolts. # 5 cylinder -Intake
# 6 cylinder-Intake and Exhuast
4. Remove cover. If cover sticks to block, a heated knife
blade, or sim ilar device, used to pry at the sealing 4. Install distributor cap.
surfaces will aid in removal. 5. Install rocker arm cover as outlined.
6. A djust carburetor idle speed (if necessary).
Installation (Front Cover)
1. Clean sealing surfaces of both the cover and block with VALVE STEM OIL SEAL AND/OR VALVE SPRING
d eg reaser. Remove loose R T V , or pieces causing
installation interference. Replacement
2. Place a continuous 1 /8 " (3m m ) bead of RTV sealant,
# 1 0 5 2 3 6 6 or equivalent, all around the cover sealing 1. Remove rocker arm cover as previously outlined.
LIG H T T R U C K SERVICE M A N U A L
6AM 2 IN-LINE 6
VALVE LIFTERS
H ydraulic valve lifters very seldom require attention.
The lifters are extrem ely simple in design. Readjustm ents
are not necessary, and servicing of the lifters requires only
th at care and cleanliness be exercised in the handling of
parts.
Rem oval
1. Rem ove rocker arm cover and loosen rocker arm s
sufficiently to remove the push rods. Place push rods in
a rack so th at they may be returned to their original
location.
2. M ark distributor housing, with chalk, at # 1 and # 6
positions. Remove distributor cap and lay aside.
Fig. 6A1-10--Valve Adjustment
3. Remove push rod covers as outlined.
4. Remove valve lifters. Place valve lifters in a rack so that
they may be installed in the sam e location.
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 m etering valve (fig. 6A1-
12).
3. Remove the plunger, ball check valve assembly and the
plunger spring.
4. Remove the ball check valve and spring by prying the
ball retainer loose from the plunger with the blade of a
small screw driver (fig. 6A 1-13).
LIG H T T R U C K SERVICE M A N U A L
IN-LINE 6 6A1-13
Fig. 6Al-13--Removing Ball Check Valve Fig. 6 A 1-14—Installing Ball Check Valve
Cleaning and Inspection
Thoroughly clean all parts in cleaning solvent, and
inspect them carefully. If any parts are dam aged or worn,
the entire lifter assembly should be replaced. If the lifter
body wall is scuffed or worn, inspect the cylinder block lifter
bore, if the bottom of the lifter is scuffed or worn inspect the
cam shaft lobe, if the push rod seat is scuffed or worn inspect
the push rod. V s" DRIFT PIN
An additive containing E P lube, such as EOS, should
always be added to crankcase oil for run-in when any new
cam shaft or lifters are installed. All dam aged or worn lifters
O IL FEED HO LE
should be replaced.
For proper lifter rotation during engine operation, lifter
foot m ust be convex.
W henever a new cam shaft is installed, replace oil, oil
filter and all valve lifters. Install G M E.O .S. or equivalent
over the cam and lifter feet after the parts are installed.
Assembly
LIG H T T R U C K SERVICE M A N U A L
IN-LINE 6 6A1-15
LIG H T T R U C K SE RV IC E M AN U AL
6A 1-16 IN-LINE 6
CUT THIS P O R T IO N
FR OM N E W SEAL
LIG H T T R U C K SERVIC E M A N U A L
IN-LINE 6 6A1-17
OIL SEAL (FRONT COVER) Fig. 6Al-23--M easuring Camshaft Lobe Lift
Replacement 7. If cam shaft readings for all lobes are within specifica
tions, remove dial indicator assembly.
With Cover Installed
8. Install and adjust valve mechanism as outlined.
1. W ith torsional dam per removed, pry old seal out of
cover from the front with a large screw driver, being Rem oval
careful not to dam age the seal surface on the cover.
1. Remove engine following procedure in this section.
2. Install new seal so th a t open end of seal is tow ard the
2. Remove lifters as previously outlined.
inside of cover and drive it into position with Tool
J-23042. 3. Remove crankcase front cover as previously outlined.
4. Remove fuel pump.
With Cover Removed
5. Align tim ing gear m arks then remove the two cam shaft
1. W ith cover removed, pry old seal out of cover from the thrust plate bolts by working through holes in cam shaft
front with screw driver, being careful not to distort gear.
cover.
6. Remove the cam shaft and gear assembly by pulling it
2. Install new seal so th at open end of the seal is toward out through the front of the block. Support cam shaft
the inside of cover and drive it into position with Tool carefully when rem oving so as not to dam age the
J-23042. cam shaft bearings.
CAMSHAFT Inspection
M easu ring Lobe Lift The cam shaft bearing journals should be m easured
with a m icrom eter for an out-of-round condition. If the
1. Remove valve m echanism as previously outlined. journals exceed .001 " out-of-round, the cam shaft should be
2. Position indicator w ith ball socket a d a p te r (Tool replaced.
J-8520) on push rod (fig. 6A 1-23). Inspect the cam shaft gear and thrust plate for wear or
3. R otate the cranksahft slowly in the direction of rotation dam age. M easure the cam shaft end play. This should be
until the lifter is on the heel of the cam lobe. A t this .001" to .005".
point, the push rod will be in its lowest position.
G e a r R eplacem ent
4. Set dial indicator on zero, then rotate the crankshaft
slowly, or a tta c h an au x iliary s ta rte r switch and 1. If the inspection indicated th at the cam shaft, gear or
"b u m p " the engine over, until the push rod is in the th ru st p late should be replaced, the gear m ust be
fully raised position. Disconnect the coil prim ary lead removed from the cam shaft. This operation requires
before cranking. the use of cam shaft gear remover J -9 7 1.
5. C om pare the total lift recorded from the dial indicator 2. Place the cam shaft through the gear remover, place
with specifications. end of remover on table of a press and press shaft out of
gear.
6. C ontinue to rotate the crankshaft until the indicator
reads zero. This will be a check on the accuracy of the NO TIC E: T h ru st p late m ust be positioned so th a t
original indicator reading. woodruff key in shaft does not dam age it when the shaft
LIG H T T R U C K SE RV IC E M AN U AL
6 A 1-18 IN-LINE 6
Installation
The cam sh aft front and re a r bearings should be
installed first. These bearings will act as guides for the pilot
and center the rem aining bearings being pulled into place.
1. Assemble remover and installer tool on driver handle
and install cam shaft front and rear bearings by driving
towards center of cylinder block (fig. 6 A 1-25).
2. Using Tool Set J-6098, with nut and thrust washer
installed to end of threads, index pilot in cam shaft front
bearings and install puller screw through pilot.
3. Index cam shaft bearing in bore, then install remover
and installer tool on puller screw with shoulder tow ard
bearing.
NOTICE: All cam bearing oil holes m ust be aligned with
Fig. 6Al-24--Replacing Camshaft Intermediate oil holes in cam bore to prevent oil starvation and
Bearings subsequent failure.
LIGHT TRUCK SERVICE MANUAL
IN-LINE 6 6A1-19
4. Using two wrenches, hold puller screw while turning b. Remove transm ission to bell housing upper bolt.
nut. A fter bearing has been pulled into bore, remove c. Remove transm ission rear mount bolts and install
the remover and installer tool from puller screw and two 7 /1 6 " x 3" bolts.
check alignm ent of oil hole in cam shaft bearing. d. Raise transm ission using jack and install 2" (51 mm)
5. Install rem aining bearings in the same m anner. It will block between m ount and crossmember.
be necessary to index pilot in the cam shaft rear bearing 7. Remove starter and lay aside.
to install the rear interm ediate bearing.
8. Drain crankcase.
6. In stall a new cam sh aft re a r plug flush to 1 /3 2 "
9. Remove m ount "th ro u g h " bolts.
(.80m m ) deep and parallel with rear surface of cylinder
block. 10. R aise engine sufficiently to insert wooden blocks
between engine m ounts and cross member brackets.
OIL PAN 11. Remove flywheel splash shield or converter cover, as
applicable.
All except 'G' Van 12. Remove oil pan bolts.
Removal 13. Remove oil pan and clean gasket surfaces.
1. Disconnect battery negative cable.
Installation
2. Raise vehicle and drain engine oil.
1. Install new gasket on cleaned gasket surface.
3. Remove starter.
2. Install oil pan and retain in g bolts and torque to
4. Remove flywheel splash shield or converter housing
specifications.
underpan, as applicable.
3. Install flywheel splash shield or converter cover, as
5. Remove " through " bolts from engine front mounts.
applicable.
6. R aise front of engine, reinstall m ount "th ro u g h " bolts
4. Raise engine sufficiently to remove wooden blocks,
and lower engine.
lower engine and install mount ’through’ bolts. Torque
7. Remove oil pan bolts. bolts to specification.
8. Remove oil pan. 5. Install starter.
Installation • If vehicle is equipped with a standard transm ission,
1. Thoroughly clean all gasket sealing surfaces. perform the following steps.
2. Using a new gasket, install rear seal in rear main a. Raise transm ission using jack and rem ove 2"
bearing cap. (51m m ) block from betw een m ount and cross
3. Install front seal on crankcase front cover, pressing tips member.
into holes provided in cover. b. Lower transm ission on cross member, remove two
4. Install side gaskets to engine block, using a gasket 7 /1 6 " x 3 " bolts, install rear m ount bolts and torque
sealant with sufficient body to act as a retainer. to specifications.
5. Install oil pan, torquing the retaining bolts to 80 lb. in. c. Install transm ission to bell housing upper bolt.
(9N -m ). d. C onnect clutch cross shaft to left front m ount
6. Raise engine sufficiently to allow removal of " through " bracket.
bolts - lower engine and install m ount "th ro u g h " bolts. 6. Lower vehicle on hoist.
Torque bolts to 75 lb. ft. (100 N-m ). 7. Install radiator upper support brackets.
7. Install flywheel splash shield or converter housing 8. Install fan finger guard.
underpan, as applicable. 9. Install air cleaner studs and air cleaner.
8. Install starter. 10. Install engine cover.
9. Lower vehicle and fill crankcase with oil. (See O w ner’s 11. Fill crankcase with oil. (See O w ner’s M anual).
M anual) 12. Connect battery negative cable, start engine and check
10. Connect battery negative cable, sta rt engine and check for leaks.
for leaks.
OIL PUMP
"G" Van
Removal Removal
1. Disconnect battery negative cable. 1. Remove oil pan as previously outlined.
2. Remove engine cover. 2. Remove two flange mounting bolts, pickup pipe bolt,
3. Remove air cleaner and studs. then remove pump and screen as an assembly.
4. Remove fan finger guard. Disassembly
5. Remove radiator upper support brackets.
6. R aise vehicle. 1. Remove the pump cover attaching screws, the pump
• If vehicle is equipped with a standard transmission, cover and the pump cover gasket (fig. 6 A 1-26).
perform the following steps before continuing, 2. M ark gear teeth so they may be reassembled with the
a. Disconnect clutch cross shaft from left front m ount same teeth indexing. Remove the idler gear and the
bracket. drive gear and shaft from the pump body.
LIGHT TRUCK SERVICE MANUAL
6A1-20 IN-LINE 6
Assembly
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. M ount the pump in a soft-jawed vice, apply
sealer to the end of pipe and tap the pipe in place with a
plastic ham m er using Tool J-8369.
NOTICE: Be careful of twisting, shearing or collapsing
pipe while installing in pump. Pickup screen m ust be
parallel to bottom of oil pan when oil pump is installed.
2. Install the pressure regulator valve and related parts.
3. Install the drive gear and shaft in the pump body.
4. Install the idler gear in the pum p body with the smooth
side of gear towards pum p cover opening.
5. Install the pump cover, with new gasket, and torque
attaching screws to 70 lb. in. (8N -m ).
6. Turn drive shaft by hand to check for smooth operation.
Inspection
Checking Clearance
To obtain the most accurate results with "P lastig ag e",
or its equivalent, a wax-like plastic m aterial which will
compress evenly between the bearing and journal surfaces
without dam aging either surface, certain precautions should
be observed. If the engine is out of the vehicle and upside
down, the crankshaft will rest on the upper bearings and the
total clearance can be m easured between the lower bearing
and journal. If the engine is to rem ain in the vehicle, the
c ran k sh a ft m ust be supported upw ard to rem ove any
clearance from the upper bearing. The total clearance can
then be m easured between the lower bearing and journal.
Fig. 6A l-30--G aging Plastic on Journal - Typical To assure the proper seating of the c ran k sh a ft all
bearing cap bolts must be at their specified torque. In
addition, preparatory to checking fit of bearings, the surface
of the crankshaft journal and bearing m ust be wiped clean
of oil.
1. W ith the oil pan and oil pum p removed, and starting
with the rear main bearing, remove bearing cap and
wipe oil from journal, both bearing shells and bearing
cap.
2. Place a piece of gaging plastic the full width of the
bearing (parallel to the crankshaft) on the journal (fig.
6A1-30).
Do not rotate the crankshaft while the gaging plastic is
between the bearing and journal.
3. Install the bearing cap and evenly torque the retaining
bolts to 65 lb. ft. (88N -m ). Bearing cap M U ST be
torqued to specification in o rder to assure proper
reading. V ariations in torque affect the compression of
the plastic gage.
4. Remove bearing cap. The flattened gaging plastic will
be found adhering to either the bearing shell or journal.
5. On the edge of gaging plastic envelope th e re is a
graduated scale which is correlated in thousandths of
Fig. 6 A 1-31--Measuring Gaging Plastic - Typcial an inch. W ithout removing the gaging plastic, m easure
its compressed width, at the widest point, with the
LIGHT TRUCK SERVICE MANUAL
IN-LINE 6 6A1-23
.0 0 4 S H IM STOCK
1 1 /6 4
APPLY
SEALANT
TO SHADED
AREAS ONLY
The rear main bearing oil seal can be replaced (both 8. Position seal between crankshaft and tip of tool so that
halves) w ithout removal of the crankshaft. Always replace seal bead contacts tip of tool. M ake sure *hat oil-seal lip
the upper and lower seal as a unit. Install seal with lip facing is positioned toward front of engine (fig. 6 A 1-37).
front of engine. Extrem e care should be exercised when 9. Roll seal around crankshaft using tool as a "shoe
installing this seal to protect the sealing bead located in the horn" to protect seal bead from sharp corner of seal
channel on the outside diam eter of the seal. An installation seat surface in cylinder case. Installation tool must
tool (fig. 6A1-34) can be used to protect the seal bead when remain in position until seal is properly positioned with
positioning seal as follows: both ends flush with block.
IN-LINE 6 6A1-25
Removal
FIXTURE &
SUPPORT
1. Remove oil pan, oil pump and cylinder head as pre ASSEMBLY
viously outlined. J -2 4 0 8 6 -2 0
The piston pin clearan ce is designed to m aintain All compression rings are m arked on the upper side of
adequate clearance under all engine operating conditions. the ring. W hen installing compression rings, make sure the
Because of this, the piston and piston pin are a m atched set m arked side is toward the top of the piston. The top ring is
and not serviced separately. chrom e faced, or treated with molybdenum for m axim um
life.
Inspect piston pin bores and piston pins for wear. Piston
The oil control rings are of three piece type, consisting
pin bores and piston pins m ust be free of varnish or scuffing
of two segments (rails) and a spacer.
when being m easured. The piston pin should be measured
with a m icrom eter and th e piston pin bore should be 1. Select rings com parable in size to the piston being used.
measured with a dial bore gage or an inside m icrom eter. If 2. Slip the compression ring in the cylinder bore; then
clearance is in excess of the .001 " wear limit, the piston and press the ring down into the cylinder bore about 1/4"
piston pin assembly should be replaced. (6.5m m ) (above ring travel). Be sure ring is square
with cylinder wall.
ASSEMBLY 3. M easure the space or gap between the ends of the ring
1. Lubricate piston pin holes in piston and connecting rod with a feeler gage.
to facilitate installation of pin. 4. If the gap betw een th e ends of the ring is below
specifications, remove the ring and try another for fit.
2. Place connecting rod in piston and hold in place with
5. Fit each compression ring to the cylinder in which it is
piston pin guide and piston pin. Place connecting rod
going to be used.
and piston assem bly on fixture and support assembly.
6. If the pistons have not been cleaned and inspected as
3. Using piston pin installer, J-24086-9, press the piston previously outlined, do so.
pin into the piston and connecting rod (Fig. 6A1-41).
7. Slip the outer surface of the top and second com pres
M ake sure in staller is set properly (see tool
sion ring into the respective piston ring groove and roll
instructions).
the ring entirely around the groove to make sure that
the ring is free. If binding occurs at any point the cause
should be determ ined, and if caused by ring groove,
NOTICE: A fter installer hub bottoms on support assem
remove by dressing with a fine cut file. If the binding is
bly, do not exceed 5000 psi pressure, as this could cause
caused by a distorted ring, check a new ring.
structural dam age to the tool.
8. Install piston rings as follows (fig. 6A1-42):
4. Remove piston and connecting rod assembly from tool
a. Install oil ring spacer in groove and insert an ti
and check piston for freedom of movement on piston
rotation tang in oil hole.
pin.
b. Hold spacer ends butted and install lower steel oil
ring rail with gap properly located.
PRESS c. Install upper steel oil ring rail with gap properly
located.
d. Flex the oil ring assembly to m ake sure ring is free. If
binding occurs at any point, the cause should be
determ ined, and if caused by ring groove, remove by
dressing groove with a fine cut file. If binding is
PISTON PIN
caused by a distorted ring, check a new ring.
INSTALLER e. Install second compression ring expander then ring
J -2 4 0 8 6 -9 with gaps properly located.
f. Install top com pression ring w ith gap properly
located.
Installation
C ylinder bores must be clean before piston installation.
This may be accomplished with a hot w ater and detergent
wash or with a light honing as necessary. A fter cleaning, the
bores should be swabbed several tim es with light engine oil
and a clean dry cloth.
1. L ubricate connecting rod bearings and install in rods
Fig. 6 A 1-41--Installing Piston Pin and rod caps.
LIGHT TRUCK SERVICE MANUAL
IN-LINE 6 6A1-27
FRONT OF
ENGINE
A " O IL R IN G SPACER G A P
B" O IL R IN G RAIL G A P S
“C" 2N D C O M P R E S S IO N R IN G GAP
2. Remove oil gallery plugs and clean all oil passages. to obtain very fine uniform surface finish m arks in a
3. Clean and inspect w ater passages in the cylinder block. cross-hatch pattern of approxim ately 45 to 65° in
4. Inspect the cylinder block for cracks in the cylinder cluded angle. The finish m arks should be clean but not
walls, w ater jacket, valve lifter bores and main bearing sharp, free from imbedded particles and torn or folded
webs. m etal.
5. M easure the cylinder walls for taper, out-of-round or 4. Perm anently m ark the piston for the cylinder to which
excessive ridge at top of ring travel. This should be done it has been fitted and proceed to hone cylinders and fit
with a dial indicator. Set the gage so th at the thrust pin the rem aining pistons.
must be forced in about 1/4" (6.5m m ) to enter gage in NOTICE: H andle the pistons with care and do not
cylinder bore. C enter gage in cylinder and turn dial to attem pt to force them through the cylinder until the
" O " . Carefully work gage up and down cylinder to cylinder has been honed to correct size as this type
determ ine taper and turn it to different points around piston can be distorted through careless handling.
cylinder wall to determ ine the out-of-round condition. 5. Thoroughly clean the bores with hot w ater and deter
If cylinders were found to exceed specifications, honing gent. Scrub well with a stiff bristle brush and rinse
or boring will be necessary. thoroughly with hot w ater. It is extrem ely essential that
Conditioning a good cleaning operation be perform ed. If any of the
abrasive m aterial is allowed to rem ain in the cylinder
The perform ance of the following operation is contin bores, it will rapidly wear the new rings and cylinder
gent upon engine condition at tim e of repair. bores in addition to the bearings lubricated by the
If the cylinder block inspection indicated th at the block contam inated oil. The bores should be swabbed several
was suitable for continued use except for out-of-round or times with light engine oil and a clean cloth and then
tapered cylinders, they can be conditioned by honing or wiped with a clean dry cloth. Cylinders should not be
boring. cleaned with kerosene or gasoline. Clean the rem ainder
If the cylinders were found to have less than .005" of the cylinder block to remove the excess m aterial
taper or wear they can be conditioned with a hone and fitted spread during the honing operation.
with the high limit standard size piston. A cylinder bore of
less then .005 " wear or taper may not entirely clean up when PISTON SELECTION
fitted to a high limit piston. If it is desired to entirely clean 1. C heck U SE D piston to cylinder bore clearance as
up the bore in these cases, it will be necessary to rebore for follows:
an oversize piston. If m ore than .005" taper or wear, they a. M easure the "C y lin d er Bore D iam eter" w ith a
should be bored and honed to the sm allest oversize th at will telescope gage (2 -1 /2 " (64m m ) from top of cylinder
perm it complete resurfacing of all cylinders. bore).
W hen pistons are being fitted and honing is not b. M easure the "P iston D ia m e te r" (a t skirt across
necessary, cylinder bores may be cleaned with a hot water center line of piston pin).
and d eterg en t w ash. A fter cleaning, the cylinder bores
c. S ubtract piston diam eter from cylinder bore diam e
should be swabbed several times with light engine oil and a
ter to determ ine " Piston to Bore C learance ".
clean cloth and then wiped with a clean dry cloth.
d. D eterm ine if piston to bore clearance is in the
Boring acceptable range.
1. Before using any type boring b ar, th e top of the 2. If used piston is not acceptable, determ ine if a new
cylinder block should be filed to remove any dirt or piston can be fitted to the cylinder bore.
burrs. This is very im portant. If not checked, the boring 3. If cylinder bore must be reconditioned, m easure new
bar may be tilted which would result in the rebored piston diam eter (across center line of piston pin) then
cylinder wall not being a t rig h t angles to the hone cylinder bore to correct clearance.
crankshaft. 4. M ark the piston to identify the cylinder for which it
2. The piston to be fitted should be m easured with a was fitted.
m icrom eter, m easuring at the center of the piston skirt
and at right angles to the piston pin. The cylinder FLYWHEEL
should be bored to the sam e diam eter as the piston and
honed to give the specified clearance. Removal
3. The instructions furnished by the m anufacturer of the
All Except L25 Engines
equipm ent being used should be carefully followed.
1. Remove transmission an d /o r clutch housing and clutch
Honing from engine.
1. W hen cylinders are to be honed follow the hone 2. Remove flywheel retaining bolts and remove flywheel.
m anufacturer’s recom m endations for the use of the
hone and cleaning and lubrication during honing. L25 Engines
2. Occasionally during the honing operation, the cylinder 1. Remove transmission an d /o r clutch housing and clutch
bore should be th oroughly cleaned and th e piston from engine.
selected for the individual cylinder checked for correct 2. M ark relationship of flywheel and crankshaft so th at
fit. dowel holes can be aligned in their original positions on
3. W hen finish honing a cylinder bore to fit a piston, the assembly.
hone should be moved up and down at a sufficient speed 3. Remove engine oil pan and rear main bearing cap.
LIGHT TRUCK SERVICE MANUAL
IN-LINE 6 6A1-29
4. Remove flywheel retaining bolts and drive crankshaft 7. Remove grille and grille cross brace.
dowels out of flywheel and crankshaft. R otate crank 8. Remove windshield washer ja r and, if equipped, A /C
shaft as necessary so dowels clear cylinder block. vacuum reservoir.
5. Remove flywheel and discard used dowel pins. 9. Disconnect radiator hoses from radiator.
Repair 10. Remove radiator to radiator support attaching brackets
and remove radiator.
Only repair recom m ended at flywheel used with con
ventional clutch is replacem ent of starter gear in event gear • If equipped with autom atic transm ission, remove
cooler lines from rad iato r before a ttem p tin g
is worn or otherwise dam aged.
removal.
Use torch to heat the gear around entire circum ference,
• If equipped with A /C , remove condenser to radiator
then drive the gear off flywheel, using care not to dam age
support attaching bolts and swing condenser to the
the flywheel.
side, out of the way.
U niform ly heat the flywheel gear to tem perature which
11 . Remove heater hoses from engine.
will expand gear to perm it installation. [T em perature must
not exceed 400°F (204° C )|. 12. Disconnect all necessary wiring from engine:
As soon as gear has been heated, install on flywheel. • G enerator
• D istributor
NOTICE: NEVER HEAT STARTER GEAR TO RED
HEAT AS TH IS W ILL CHANGE METAL • All sending switches
STRUCTURE. • S tarte r
13. Raise vehicle.
Installation
14. Remove fuel line hose from suction side of fuel pump.
All Except L25 Engines 15. Drain crankcase.
1. Clean the mating surfaces of flywheel and crankshaft 16. Remove propshaft and plug end of transmission.
to m ake certain there are no burrs.
17. Remove exhaust pipe from manifold flange.
2. Install flywheel on crankshaft and position to align
18. Remove linkage from transm ission and disconnect
dowel hole of crankshaft flange and flywheel.
speedometer cable.
3. Install flywheel retain in g bolts and torque to
19. Remove transm ission m ount bolts.
specifications.
• If equipped with m anual transm ission, disconnect
L25 Engine clutch linkage and remove clutch cross shaft.
1. Clean the mating surfaces of flywheel and crankshaft 20. Remove engine m ount "th ro u g h " bolts.
to m ake certain there are no burrs. 21. Lower vehicle.
2. Install flywheel on crankshaft and position to align 22. A ttach lifting devise to engine.
dowel holes of crankshaft flange and flywheel.
23. Raise engine slightly and remove right hand m ount
3. In stall flywheel retain in g bolts and torque to assembly from engine.
specifications.
24. Remove engine/transm ission assembly.
• The interference fit dowel pins used on 4.8 L (T)
engines must be replaced with an oversize dowel pin Installation ("G " Van/Code D Engine)
when installing the flywheel. 1. Place engine/transm ission assembly into vehicle.
4. W hen installing the original flywheel, ream the dowel 2. Install right hand engine m ount assembly and lower
pin holes with Tool J-22808-2. W hen installing a new engine onto m ounts.
flywheel, first ream the dowel pin holes w ith Tool
3. Remove lifting tool.
J-22808-2 and then finish ream ing them with Tool
J-22808-1. 4. R aise vehicle and install engine m ount " th ro u g h "
bolts. Torque to specifications.
5. Install oversize dowel pins flush with flywheel retaining
bolt surface. 5. Install transm ission m ount bolts. T orque to
specifications.
6. In stall rear m ain b earing cap and torque bolts to
specifications. Install oil pan with new gaskets and 6. Connect transm ission shift linkage and speedom eter
seals. Torque oil pan retaining screws to specifications. cable.
• If equipped w ith m anual transm ission, connect
ENGINE ASSEMBLY clutch linkage and install clutch cross shaft.
Removal ("G " Van/Code D Engine) 7. A ttach exhaust pipe to manifold flange.
1. Disconnect battery negative cable a t battery. 8. Install propshaft.
2. D rain cooling system. 9. Connect fuel tank line to fuel pump.
3. Remove engine cover. 10. Lower vehicle.
4. Remove air cleaner. 11 . Connect all wiring to engine components:
5. If equipped, evacuate A /C system and remove A /C • G enerator
compressor. • D istributor
6. D isconnect accelerato r linkage a t c a rb u reto r and • All sending units
remove carburetor from manifold. • S tarter
LIGHT TRUCK SERVICE MANUAL
6A1-30 IN-LINE 6
12. Connect heater hoses to engine. • If equipped with au to m a tic transm ission, install
13. Install radiator and hold in place with radiator to torque converter to flex plate attaching bolts. Torque
support attaching brackets. to specifications.
• If equipped with A utom atic Transm ission, connect 4. Install engine mount to fram e retaining bolts. Torque
cooler lines to radiator. to specifications.
• If equipped with A /C , install condenser in front of 5. Connect exhaust pipe to exhaust manifold flange.
radiator. Bolt to radiator support. 6. Install flywheel or torque converter splash shield, as
14. Connect radiator hoses to radiator. applicable.
15. Install windshield washer ja r and, if equipped, A /C 7. Install starter. Torque bolts to specifications.
vacuum reservoir. 8. Lower vehicle.
16. Install grille cross brace and grille. 9. A ttach fuel line to fuel pump.
17. Using a new pad gasket, install carburetor. Connect 10. Install w ater pump pulley and fan. Torque bolts to
accelerator linkage. specifications.
18. If equipped, m ount A /C compressor. 11. Install radiator.
19. Fill crankcase with oil. 12. Connect heater hoses to engine.
20. Fill cooling system. 13. Connect radiator hoses to radiator.
21. Connect battery negative cable and start engine. Check 14. Connect all wiring to engine.
ignition tim ing and adjust carburetor if necessary. 15. Connect accelerator cable to carburetor throttle lever.
22. Install air cleaner and engine cover. • If equipped with autom atic transmission, connect
detent cable to throttle lever.
Removal (CK Series/Code D & T Engines) 16. Fill cooling system.
1. Disconnect b attery cables at battery. 17. Fill crankcase with oil.
2. Remove air cleaner. 18. Install vehicle hood.
3. Drain cooling system. 19. Connect battery cables, start engine. Check tim ing and
4. Disconnect accelerator cable from carburetor throttle carburetor adjustm ent. A djust if necessary.
lever. 20. Install air cleaner.
• If equipped with autom atic transm ission, remove
detent cable from carburetor throttle lever. CRANKSHAFT
5. Disconnect all wiring from engine.
Removal
6. Remove radiator hoses from radiator.
7. Remove heater hoses from engine. 1. Remove engine as previously outlined. Remove clutch,
if applicable, and flywheel and m ount engine on stand.
8. Remove radiator.
2. Remove the oil dipstick and oil dipstick tube.
9. Remove fan and w ater pump pulley.
3. Remove the spark plugs.
10. Disconnect fuel line from fuel pump.
4. Remove crankshaft pulley and torsional dam per.
11. Remove vehicle hood.
5. Remove oil pan and oil pump.
12. Raise vehicle.
6. Remove crankcase front cover.
13. Remove starter.
7. Remove the connecting rod caps and push the pistons to
14. Remove flywheel or torque converter splash shield, as the top of bores.
applicable. 8. Remove main bearing caps and lift cranksahft out of
15. Disconnect exhaust pipe from exhaust m anifold flange. cylinder block.
W ire up and out of way. 9. Remove rear main bearing oil seal and main bearings
16. Remove engine m ount ’through’ bolts. from cylinder block and m ain bearing caps.
• If equipped with autom atic transm ission, remove
converter to flex plate bolts. Cleaning and Inspection
• If ’K’ model, remove strut rods at motor mounts. 1. W ash crankshaft in solvent and dry with compressed
17. Remove bell housing to engine retaining bolts. Support air.
transm ission with chain. 2. M easure dim ensions of m ain bearing jo u rn als and
crankpins with a m icrom eter for out-of-round, taper or
18. Lower vehicle.
undersize. (See Specifications.)
19. A ttach engine lifting device.
3. Check crankshaft for run-out by supporting the front
20. Remove engine. and rear main bearing journals in "V " blocks and
check at the front and rear interm ediate journals with a
Installation (CK Series/Code D & T Engines)
dial indicator. (See Specifications.)
1. Place engine in vehicle.
4. R eplace or recondition th e cra n k sh aft if out of
2. Raise vehicle. specifications.
3. Install bell housing to engine retaining bolts. Torque to
specifications. Installation
REMOVAL
IN
PRODUCTION .00015-.00025
IN-LINE 6
DISPLACEMENT LITRE (*) 4.1 (D) 4.8 (T) CLEARANCE
.001 M A X .
M AN U AL
SERVICE
THRUST
.0005 M AX.
SIDE # 1 -6 .0010-.0024
PRODUC MAIN PRODUCTION
TAPER TION RELIEF BEARING # 7 .0016-.0035
.0005 M AX.
SIDE CLEARANCE
* VIN Designation
TORQUE SPECIFICATIONS
C a m sha ft T h ru s t P la te ......................................... 80 lb. in.
C ra n ksh aft F ron t C o v e r ....................................... 80 lb. in.
VALVE SYSTEM_______________ LE 3 | L25
F lyw heel H o using C over ................................... 80 lb. in.
L IF T E R H YD RAULIC Oil Pan (To Crankcase) (1/4-20) .......................80 lb. in.
RO CKER A R M R A T IO
Oil Pan (To F ront Cover) ................................... 50 lb. in.
1.75:1
Oil P um p C o v e r......................................................70 lb. in.
VALVE IN T A K E Rocker A rm C over ............................................... 45 lb. in.
LASH ONE TURN D O W N FROM ZERO LASH C o n n e ctin g Rod C a p ............ .............................. 35 lb. ft.*
EXHAUST
C lutch Pressure P la t e ......................................... 20 lb. ft.*
FACE A N G L E ( IN T . & EXH.) 45° 46° Oil Pan (To C rankcase) 5 /1 6 -1 8 ).......................75 lb. in.
SE AT A N G L E ( IN T. & EXH.) 46°
Oil P u m p ................................................................ 115 lb. in.
Push Rod C over ....................................................50 lb. in.
SEAT R U N O U T .002 M A X . W a te r P u m p ............................................................15 lb. in.
C lutch Pressure P la t e ....................................... 30 lb. ft.@
SE AT IN T A K E 1/32-1/16
D is trib u to r C la m p ..................................................25 lb. ft.
W ID T H
EXHAUST 1/16-3/32 F lyw heel H o usin g ..................................................30 lb. ft.
INT. .0010-.0027 M a n ifo ld (E xhaust) ........................................... 30 lb. ft. 2
STEM P R O D U C TIO N M a n ifo ld (E xhaust To Inlet) .............................45 lb. ft.
CLEARANCE EXH. .0015-.0032
M a n ifo ld To H e a d ................................................40 lb. f t . 2
SE RVIC E HI I IM IT INTAKE
MIU[V111 + .002 EXHAUST T h e rm o s ta t H o u s in g ............................................. 30 lb. ft.
FREE LENG TH 2.08 W a te r O u t le t ................................... .....................30 lb. ft.
C o n necting Rod C a p ......................................... 40 lb. ft.@
PRESSURE CLOSED 7 8 -8 6 @ 1.66
VALVE M a in B earing C a p ..................................................65 lb. ft.
LBS. @ IN.
SPRING OPEN 1 7 0 -1 8 0 @ 1.26 F ly w h e e l.................................................................. 60 lb. ft.*
( O U TE R ) T o rsio n a l D a m p e r ............................................. 60 lb. ft.@
I N S T A L L E D H E IG H T C y lin d e r H e a d ..........................................................95 lb. f t . 1
1.66
± 1 /3 2 " T e m p e ra tu re S e nd ing U n i t ................................. 20 lb. ft.
Oil F ilte r .............................................................. Hand T ig h t
FREE L E N G TH 1.94
D AM PER
Oil Pan D rain P lu g ................................................. 20 lb. ft.
APPROX. # OF COILS 4 F ly w h e e l.............................................................. 110 1b. ft.@
S park P lu g ..........................................................17-27 lb. ft.
* 4.1 (D) o n ly
@ 4.8 (T) o n ly
1 Except LH Front Bolt 85 lb. ft.
2 Non-Integral Head
SMALL BLOCK 6A4-1
SECTION 6A4
5.0L (G) V-8 - RPO LG9
5.0L (F) V-8 - RPO LF3
5.0L (H) V-8 - RPO LE9
5.7L (L) V-8 - RPO LS9
5.7L (M) V-8 - RPO LT9
Contents
GENERAL DESCRIPTION
CYLINDER BLOCK gallerys are on either side of the main oil gallery to provide
an oil supply for the hydraulic lifters.
The cylinder block is made of cast iron and has 8
A torsional dam per on the forward end of the crank
cylinders arranged in a "V " shape with 4 cylinders in each
shaft dampens any engine torsional vibrations.
bank. Five main bearings support the crankshaft which is
retained by bearing caps th at are m achined with the block CAMSHAFT AND DRIVE
for proper alignment and clearnances. Cylinders are com
pletely encircled by coolant jackets. The cast iron cam shaft is supported by five bearings
and is chain driven. A steel or sintered iron crankshaft gear
drives the timing chain which in turn drives the cam shaft
CYLINDER HEAD
through either a nylon/alum inum or cast iron gear depend
The cylinder heads are cast with individual intake and ing on application.
exhaust ports for each cylinder. Valve guides are integral, Cam lobes are ground, hardened and tapered with the
and rocker arm s are retained on individual studs. high side toward the rear. This, coupled with a spherical
face on the lifter, causes the valve lifters to rotate.
CRANKSHAFT AND BEARINGS C am shaft bearings are lubricated through oil holes
The crankshaft is cast nodular iron, and is supported by which intersect the main oil gallery. The main oil gallery is
five main bearings. N um ber five bearing is the end thrust rifle drilled down the center of the block, above the
bearing. cam shaft.
M ain bearings are lubricated from oil holes which
intersect the cam shaft bearings. The cam shaft bearings are PISTONS AND CONNECTING RODS
fed oil by the main oil gallery which is rifle drilled down the The pistons are made of cast alum inum alloy using two
center of the block, above the cam shaft. Two additional oil compression rings and one oil control ring. Piston pins are
L IG H T T R U C K SERVICE M ANUAL
6A4-2 SMALL BLOCK
offset 1/16" (1.6m m ) tow ard the thrust side (right hand below the plunger. The plunger and lifter body then rise as a
side) to provide a gradual change in thrust pressure against unit, pushing up the push rod and opening the valve.
the cylinder wall as the piston travels its path. Pins are As the lifter body rides down the other side of the cam,
Chrom ium steel and have a floating fit in the pistons They the plunger follows with it until the valve closes. The lifter
are retained in the connecting rods by a press fit. body continues to follow the cam to its low point, but the
Connecting rods are m ade of forged steel. Full pressure plunger spring keeps the plunger in contact with the push
lubrication is directed to the connecting rods by drilled oil rod. The ball check valve will then move off its seat and the
passages from the adjacent main bearing journal. Oil holes lifter reservoir will rem ain full.
at the connecting rod journals are located so th at oil is
supplied to give m axim um lubrication just prior to full INTAKE MANIFOLD
bearing load. The intake manifold is of cast iron double level design
for efficient fuel distribution. The carburetor pad is centrally
VALVE TRAIN located with a passage running underneath the pad (E .F.E .)
through which exhaust gases are forced to promote faster
A very simple ball pivot-type train is used. Motion is
fuel vaporization when the engine is cold. An EG R port is
transm itted from the cam shaft through the hydraulic lifter
also cast into the manifold for the m ixture of exhaust gases
and push rod to the rocker arm . The rocker arm pivots on its
with the fuel air mixture.
ball and transm its the cam shaft motion to the valve. The
rocker-arm ball is retained by a nut. EXHAUST MANIFOLDS
Two cast iron exhaust manifolds are used to direct
HYDRAULIC VALVE LIFTERS
exhaust gases from the combustion cham bers to the exhaust
H ydraulic Valve Lifters are used to keep all parts of the system. The right hand side m anifold receives a heat shield
valve train in constant contact. th at is used to route heated air to the air cleaner for better
The hydraulic lifter assembly consists of: the lifter fuel vaporization.
body, which rides in the cylinder block boss, a plunger, a
push rod seat, a m etering valve, a plunger spring, a check COMBUSTION CHAMBERS
ball and spring, a check ball retainer and a push rod seat C om bustion C ham bers are cast to insure uniform
retainer. shape for all cylinders. Spark plugs are located between the
W hen the lifter is riding on the low point of the cam, intake and exhaust valves.
the plunger spring keeps the plunger and push rod seat in The contoured wedge shape of the combustion cham ber
contact with the push rod. minimizes the possibility of detonation, facilitates breath
W hen the lifter body begins to ride up the cam lobe, the ing, and provides swirling turbulence for smooth, complete
check ball cuts off the transfer of oil from the reservoir combustion.
ENGINE LUBRICATION
Full pressure lubrication through a full flow oil filter, is cam shaft and crankshaft to lubricate the bearings. The
furnished by a gear-type oil pump. The distributor, driven valve lifter oil gallery feeds the valve lifters which, through
by a helical gear on the cam shaft, drives the oil pump. The hollow push rods, feed the individually mounted rocker arms
main oil gallery feeds oil, through drilled passages, to the (fig. 6A4-1 and 6A4-2).
L IG H T TR U C K SERVICE M AN U AL
SMALL BLOCK 6A4-5
LIG H T T R U C K SERVICE M A N U A L
6A4-6 SMALL BLOCK
L IG H T T R U C K SERVICE M A N U A L
SMALL BLOCK 6A4-7
LIGHT T R U C K SERVICE M A N U A L
6A4-8 SMALL BLOCK
LIG H T T R U C K SERVIC E M A N U A L
SMALL BLOCK 6A4-9
L IG H T TR U C K SERVICE M AN U AL
6A4-10 SMALL BLOCK
L IG H T T R U C K SERVIC E M A N U A L
SMALL BLOCK 6A4-11
ON VEHICLE SERVICE
ENGINE MOUNTS INTAKE MANIFOLD
E ngine m ounts (fig. 6 A 4 -3 - 6 A 4 -8 ) are the non- Removal
ad ju sta b le type and seldom req u ire service. Broken or 1. D rain radiator and remove air cleaner.
d e te rio ra ted m ounts should be replaced im m ediately, 2. Disconnect:
because of the added strain placed on other m ounts and
• B attery negative cable at battery.
drive line components.
• R adiator upper hose and heater hose at manifold.
Checking Engine Mounts • A ccelerator linkage a t carburetor.
Front Mount
• Fuel line at carburetor.
Raise the engine to remove weight from the mounts and • Crankcase ventilation lines.
to place a slight tension in the rubber. Observe both mounts
• Spark advance hose at distributor.
while raising engine. If an engine m ount exhibits:
3. Remove distributor cap and m ark rotor position with
a. H ard rubber surface covered with heat check cracks;
chalk, then remove distributor.
b. R ubber separated from a metal plate of the mount;
4. Remove air conditioning compressor and bracket (if
c. R ubber split through center
equipped), accelerator return spring and bracket, and
replace the m ount. If th e re is relative m ovem ent accelerator bellcrank.
between a m etal plate of the m ount and its attaching points, 5. Remove generator upper mounting bracket.
lower the engine on the m ounts and tighten the screws or
6. Remove manifold attaching bolts, then remove m ani
nuts attaching the mount to the engine, fram e, or bracket.
fold and carburetor as an assembly. Discard gaskets.
Rear Mount 7. Remove A .I.R . crossover.
R aise the vehicle on a hoist. Push up and pull down on 8. If manifold is being replaced, transfer:
the transm ission tailshaft while observing the transm ission • C arburetor and carburetor attaching bolts.
m ount. If the rubber separates from the m etal plate of the • T em perature sending unit.
m ount or if the tailshaft moves up but not down (m ount • T herm ostat with housing (use new gasket).
bottom ed out) replace th e m ount. If th ere is relative
movement between a m etal plate of the m ount and its • H eater hose adapter.
attaching point, tighten the screws or nuts attaching the • E G R Valve (use new gasket).
m ount to the transm ission or crossm em ber. • TVS switch.
Front Mount Replacement • Vacuum fitting(s).
1. Rem ove m ount retain in g bolt from below fram e • Choke spring assembly (where applicable).
m ounting bracket.
Installation
2. R aise front of engine and rem ove m ount-to-engine
bolts and remove mount. 1. Clean gasket and seal surfaces on manifold, block, and
NOTICE: Raise engine only enough for sufficient clear cylinder heads with degreaser. Remove all RTV th at is
ance. Check for interference between rear of engine loose or will cause installation interference.
and cowl panel which could cause distributor dam age. 2. Install gaskets on cylinder heads and place a 3 /1 6 "
3. Replace mount to engine and lower engine into place. (5m m ) bead of RTV , # 1 0 5 2 3 6 6 or equivalent, on the
4. Install retain in g bolt and torque all bolts to front and rear ridges of the cylinder case. Extend the
specifications. bead 1/2" (13m m ) up each cylinder head to seal and
retain the manifold side gaskets.
Rear Mount Replacement 3. Install manifold and torque bolts to specifications in the
1. Support engine weight to relieve rear mounts. sequence outlined in fig. 6A4-9.
2. Remove crossm em ber-to-m ount bolts. 4. Install (if rem oved) air com pressor and brack et,
3. On " P " Series with m anual transm ission and propeller accelerator bellcrank.
shaft parking brake, remove m ount attaching bolts 5. Install distributor, positioning rotor at chalk m ark,
from fram e outrigger and clutch housing and remove then install distributor cap.
rear m ounting cushions. 6. Connect:
4. Rem ove m ount-to-transm ission bolts, then rem ove • Spark advance hose a t distributor.
mount.
• Crankcase ventilation lines.
5. On " P " Series with m anual transm ission and propeller
• Fuel line at carburetor.
shaft parking brake, install new m ounting cushions and
bolts. • A ccelerator linkage at carburetor.
6. Install new mount on transm ission. • B attery negative cable at battery.
7. W hile lowering transm ission, align and start cross 7. Install air cleaner.
m em ber-to-m ount bolts. 8. Fill w ith coolant (refer to section 6B for proper
8. Torque bolts to specifications then bend lock tabs to procedure), start engine, adjust ignition timing and
bolt head as applicable. carburetor idle speed (if necessary) and check for leaks.
LIG H T T R U C K SERVICE M A N U A L
6A4-12 SMALL BLOCK
W IN G NUT
LOWER STOVE
NOTE: Inboard flange
of lower stove must be
installed on top of rib
of exhaust manifold.
3 5 0 /4 0 0 V8 4Bbl
IvSwfBl
UPPER STOVE
LOWER STOVE
EXHAUST MANIFOLD
Removal
1. Remove carburetor heat stove pipe.
2. Remove the spark plug wiring heatshields.
3. D isconnect exhaust pipe from m anifold and hang
exhaust pipe from fram e with wire.
4. Remove end bolts then remove center bolts and remove
manifold.
Installation
• If installing a new right side manifold, the carburetor
heat stove m ust be transferred from the old unit (fig.
6A4-10).
1. Clean m ating surfaces on m anifold and head, then
install m anifold in position and install bolts
(fingertight).
2. Torque manifold bolts to specifications.
3. Connect exhaust pipe to manifold.
4. Install carburetor heat stove pipe.
5. Install spark plug wiring heatshields.
6. S tart engine and check for leaks.
Removal
1. Disconnect battery negative cable.
2. Remove air cleaner.
3. Disconnect crankcase ventilation hoses at rocker arm
covers.
4. Disconnect electrical wiring harness from rocker arm
clips.
5. Remove carburetor heat stove pipe from right exhaust
manifold.
6. If the vehicle is equipped with air conditioning, remove
the A /C compressor rear brace (fig. 6 A 4 -11).
L IG H T T R U C K SERVIC E M A N U A L
SMALL BLOCK 6A4-13
VALVE MECHANISM
Removal
1. Remove rocker arm covers as previously outlined.
2. Remove rocker arm nuts, rocker arm balls, rocker arm s
and push rods. Place rocker arm s, rocker arm balls and
LIG H T T R U C K SERVICE M AN U AL
6A4-14 SMALL BLOCK
Installation
1. Install valve stem seal over valve stem and seat against
head.
2. Set the valve spring and dam per, oil shedder and valve
cap in place. Compress the spring with Tool J-5892 and
install oil seal in the lower groove of the stem , making
sure the seal is flat and not twisted. A light coat of oil on
the seal will help prevent twisting.
3. Install the valve locks and release the compressor tool
m aking sure the locks seat properly in the upper groove
of the valve stem. G rease 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
Fig. 6A4-12--Valve Adjustment
m ake sure no air leaks past the seal.
-- Exhaust--2, 5 ,6 , 7 5. Install spark plug, and torque to 22 lb. ft. (30 N-m).
- I n ta k e - 3 ,4 ,6 , 8 6. Install and ad ju st valve m echanism as previously
outlined.
4. Install rocker arm covers as previously outlined.
5. S ta rt engine and a d ju st c a rb u re to r idle speed, if
VALVE LIFTERS
needed.
H ydraulic valve lifters very seldom require attention.
VALVE STEM OIL SEAL and/or VALVE SPRING The lifters are extrem ely simple in design, readjustm ents
are not necessary, and servicing of the lifters requires only
(Fig. 6A 4-11A) th at care and cleanliness be exercised in the handling of
parts.
Removal
Removal
1. Remove rocker arm cover as previously outlined. 1. Remove intake manifold as previously outlined.
2. Remove valve mechanism as previously outlined.
3. Remove valve lifters. Place valve lifters in a rack so that
they may be reinstalled in the sam e location.
Installation
1. C oat foot of valve lifters w ith "M o ly k o te" or its
equivalent and install valve lifters. M ake sure lifter foot
is convex.
2. Install intake manifold as previously outlined.
3. Install and adjust valve m echanism as 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 m etering valve (fig. 6A4-
14).
3. Remove the plunger, ball check valve assembly and the
J-2 3 5 9 0 plunger spring.
ADAPTER 4. Remove the ball check valve and spring by prying the
ball retainer loose from the plunger with the blade of a
Fig. 6A4-13--Compressing Valve Spring small screw driver (fig. 6A 4-15).
L IG H T T R U C K SERVIC E M A N U A L
SMALL BLOCK 6A4-15
Assembly
LIG H T T R U C K SERVICE M A N U A L
6A4-16 SMALL BLOCK
Cleaning
1. Clean all carbon from com bustion cham bers and valve
ports using Tool J-8089 (fig. 6 A 4 -19).
2. Thoroughly clean the valve guides using Tool J - 8 101.
3. Clean all carbon and sludge from push rods, rocker
arm s and push rod guides.
4. Clean valve stems and heads on a buffing wheel.
5. C lean carbon deposits from head gasket m ating
surface.
Inspection
1. Inspect the cylinder head for cracks in the exhaust
ports, combustion cham bers, or external cracks to the
coolant cham ber.
2. Inspect the valves for burned heads, cracked faces or
dam aged stems.
Fig. 6A4-17--Assenbling Hydraulic Lifter NOTICE: Excessive valve stem to bore clearance will
4. Drain cylinder block of coolant. cause excessive oil consumption and may cause valve
breakage. Insufficient clearance will result in noisy and
5. If vehicle is equipped wi.h A /C , remove A /C com pres sticky functioning of the valve and d isturb engine
sor and forw ard mounting bracket. Lay unit aside. smoothness.
6. Remove valve push rods as previously outlined.
7. Remove cylinder head belts, cylinder head and gasket. 3. M easure valve stem clearance (fig. 6A4-20) as follows:
Place cylinder head on two blocks of wood to prevent a. Clam p a dial indicator on one side of the cylinder
damage. head rocker arm cover gasket rail.
b. Locate the indicator so th at movement of the valve
Disassembly
stem from side to side (crosswise to the head) will
cause a direct movement of the indicator stem. The
1. With cylinder head removed, remove valve rocker arm indicator stem m ust contact the side of the valve
nul.s, balls and rocker arm s (if not previously done). stem ju st above the valve guide.
2. U sng Tool J-8062, compress the valve springs (fig. c. Drop the valve head about 1/16" (1.6m m ) off the
6 A M 8) and remove valve keys. Release the compres valve seat.
sor ool and remove rotators or spring caps, oil shed- d. Move the stem of the valve from side to side using
ders springs and spring dam per, then remove oil seals light pressure to obtain a clearance reading. If
and ialve spring shims. clearance exceeds specifications, it will be necessary
to ream valve guides for oversize valves as outlined.
4. Check valve spring tension with Tool J-8056 spring
tester (fig. 6A 4-21). Springs should be compressed to
LIG H T T R U C K SERVIC E M A N U A L
SMALL BLOCK 6A4-17
SEAL
SHIELD
DAMPER
Assembly
5. Check the installed height of the valve springs, using a
1. Insert a valve in the proper port.
narrow thin scale. A cutaw ay scale will help (fig. 6A4-
2. Assemble the valve spring and related parts as follows: 24). M easure from the top of the shim or the spring seat
to the top of the oil shedder (fig. 6A 4-25). If this is
a. Set the valve spring shim, valve spring, oil shedder found to exceed the specified height, install a valve
and valve cap or rotator in place (fig. 6A4-22). spring seat shim approxim ately 1/16" (1.6mm) thick.
LIG H T T R U C K SERVICE M A N U A L
6A4-18 SMALL BLOCK
Replacement
, GRIND OUT THIS PORTION
n-rp-rn l|i l|l|IM|l|> 1| 1| 1| 1J1| 1| 1| 1J1| 1| 1| 1| I| >| 1| 1| 1| 1| 1| 1| 1| 1| 1| 1 M'| Mfj'irpt'
Rocker arm studs th at have dam aged threads or are
3 4 / f 6
loose in cylinder heads should be replaced with new studs
available in .003" and .013" oversize. S tuds m ay be
installed after ream ing the holes as follows:
Fig. 6A4-24--Cutaway Scale
Installation
• The gasket surfaces on both the head and the block
m ust be clean of any foreign m atter and free of nicks
or heavy scratches. Cylinder bolt threads in the block
and threads on the cylinder head bolts m ust be clean
as d irt will affect bolt torque.
1. If using a ST E E L gasket, coat both sides of a new
gasket with a good sealer. Spread the sealer thin and
even. O ne m ethod of applying the sealer th a t will Fi9- 6A4-26--Removing Rocker Arm Stud
assure the proper coat is with the use of a paint roller.
Too m uch sealer may hold the gasket away from the
head or block.
• Use no sealer if using a composition ST E E L A S
BESTO S gasket.
2. Place the gasket in position over the dowel pins with the
bead up.
3. Carefully guide the cylinder head into place over the OVERSIZE
dowel pins and gasket.
4. C oat th read s of cylinder head bolts w ith sealing
compound, # 1 0 5 2 0 8 0 or equivalent, and install bolts
finger tight.
5. Tighten each cylinder head bolt a little at a tim e in the
sequence shown in the torque sequence chart until the
specified torque is reached.
6. Install exhaust manifolds as previously outlined.
7. Install intake manifold as previously outlined.
8. Install and ad ju st valve m echanism as previously
outlined. Fig. 6A4-27--Reaming Rocker Arm Stud Bore
LIG H T T R U C K SERVIC E M A N U A L
SMALL BLOCK 6A4-19
TORSIONAL DAMPER
Removal
Installation
NOTICE: The inertial weight section of the torsional
dam per is assembled to the hub with a rubber type
Fig. 6A4-28--lnstalling Rocker Arm Stud m aterial. The installation procedures (with proper tool)
m ust be followed or movement of the inertia weight
3. C oat press-fit area of stud with hypoid axle lubricant.
section on the hub will destroy the tuning of the
Install new stud, using Tool J-6880 as a guide. Gage
torsional dam per.
should bottom on head (fig. 6A4-28).
1. Coat front cover seal contact area (on dam per) with
engine oil.
VALVE GUIDE BORES
2. Place dam per in position over key on crankshaft.
Valves with oversize stems are available (see specifica 3. Pull dam per onto crankshaft as follows:
tions). To ream the valve guide bores for oversize valves use
a. Install appropriate threaded end of Tool J-23523
Tool Set J-5830. into crankshaft. Install tool in crankshaft so th at at
least 1 /2 " (13m m ) of th re ad engagem ent is
VALVE SEATS obtained.
R econditioning the valve seats is very im p o rtan t,
because the seating of the valves m ust be perfect for the b. Install plate, th rust bearing and nut to complete tool
engine to deliver the power and perform ance built into it. installation.
A nother im portant factor is the cooling of the valve c. Pull dam per into position as shown in Figure 6A4-
heads. Good contact between each valve and its seat in the 31.
head is im perative to insure th a t the heat in the valve head d. Remove tool from crankshaft then install dam per
will be properly carried away. retaining bolt and torque to specifications.
Several different types of equipm ent are available for 4. Install accessory drive pulley.
reseating valves seats. The recom m endations of the m anu 5. Install fan shroud.
facturer of the equipm ent being used should be carefully 6. Install fan and pulley to w ater pum p hub and tighten
followed to attain proper results. securely.
Regardless of what type of equipm ent is used, however, 7. Install fan belt and adjust (see section 6B).
it is essential th a t valve guide bores be free from carbon or 8. Fill cooling system (see section 6B) and check for leaks.
dirt to ensure proper centering of pilot in the guide.
VALVES
Valves th at are pitted can be refaced to the proper
angle, insuring correct relation between the head and stem
on a valve refacing mechanism. Valve stems which show
excessive wear, or valves th at are warped excessively should
be replaced. W hen a valve head which is warped excessively
is refaced, a knife edge will be ground on part or all of the
valve head due to the am ount of metal th at must be removed
to completely reface. Knife edges lead to breakage, burning
or pre-ignition due to heat localizing on this knife edge. If
the edge of the valve head is less than 1/32" (.80m m ) thick
after grinding, replace the valve.
Several different types of equipm ent are available for
refacing valves. The recom m endation of the m anufacturer
of the equipm ent being used should be carefully followed to
attain proper results. Fig. 6A4-30--Removing Torsional Damper - Typical
LIG H T T R U C K SERVICE M A N U A L
6A4-20 SMALL BLOCK
Removal
1. Remove torsional dam per as previously outlined.
2. Remove w ater pump (see section 6B).
3. Remove crankcase front cover attaching screws and
remove front cover and gasket, then discard gasket.
Installation
1. Clean gasket surface on block and crankcase front
cover.
2. Use a sharp knife or other suitable cutting tool to
remove any excess oil pan gasket m aterial th at may be
protruding at the oil to engine block junction.
3. Apply a 1/8" (3m m ) bead of RTV, # 1 0 5 2 3 6 6 or
equivalent, to th e jo in t form ed at the oil pan and
cylinder block. Fig. 6A4-32--lnstalling Oil Seal
4. Coat the cover gasket with gasket sealant and place in
position on cover.
5. Install cover-to-oil pan seal, lightly coat bottom of seal
with engine oil, and position cover over crankshaft end.
6. Loosely install the cover-to-block upper atta c h in g
screws.
7. Tighten screws alternately and evenly while pressing
downward on cover so th a t dowels in block are aligned
with corresponding holes in cover. Position cover so that
dowels enter holes in cover without binding. Do not
force cover over dowels so th a t cover flange or holes are
distorted.
8. Install rem aining cover screws and torque to
specifications.
9. Install torsional dam per and w ater pum p as previously
outlined.
Replacement
LIG H T T R U C K SERVICE M A N U A L
SMALL BLOCK 6A4-21
CAMSHAFT Inspection
The cam shaft bearing journals should be m easured
Measuring Lobe Lift with a m icrom eter for an out-of-round condition. If the
1. Remove the valve m echanism as previously outlined. journals exceed .001" (,025m m ) out-of-round, the cam shaft
should be replaced.
2. Position in d icato r w ith ball socket ad ap te r (Tool
J-8520) on push rod (fig. 6A 4-33). M ake sure push rod
is in the lifter socket.
Installation
3. R otate the crankshaft slowly in the direction of rotation
W henever a new cam shaft is installed coat cam shaft
until the lifter is on the heel of the cam lobe. A t this
lobes with "M olykote" or its equivalent.
point, the push rod will be in its lowest position.
W henever a new cam shaft is installed, replacem ent of
4. Set dial indicator on zero, then rotate the crankshaft all valve lifters oil filter, and new oil is recom m ended to
slowly, or a tta c h an au x iliary s ta rte r sw itch and
insure durability of the cam shaft lobes and lifter feet.
"b u m p " the engine over, until the push rod is fully
1. L ubricate cam shaft journals with engine oil and install
raised position.
cam shaft.
• W henever the engine is cranked remotely at the
2. Install tim ing chain on cam shaft sprocket (fig. 6A4-
starter, with a special jum per cable or other means,
35). Hold the sprocket vertically w ith the chain
the distributor prim ary lead should be disconnected
hanging down and align m arks on c am sh aft and
from the distributor (coil).
crankshaft sprockets.
5. C om pare the total lift recorded from the dial indicator 3. Align dowel in cam shaft with dowel hole in cam shaft
with specifications. sprocket then install sprocket on cam shaft.
6. If cam shaft readings for all lobes are within specifica 4. Draw the cam shaft sprocket onto cam shaft using the
tions, remove dial indicator assembly. m ounting bolts. Torque to specifications.
7. Install and adjust valve m echanism as outlined. 5. Lubricate tim ing chain with engine oil.
6. Install fuel pump push rod and fuel pump (see section
Removal 6C).
7. Install grille.
1. Remove valve lifters as previously outlined. 8. Install crankcase front cover as previously outlined.
2. Remove crankcase front cover as previously outlined. 9. Install valve lifters as previously outlined.
3. Remove grille.
4. Remove fuel pump and push rod (see section 6C). CAMSHAFT BEARINGS
5. Com plete cam shaft removal as follows:
Removal
• Sprocket is a light fit on cam shaft. If sprocket does
C am shaft bearings can be replaced with engine com
not come off easily a light blow on the lower edge of
pletely or p artially disassem bled. To replace bearings
the sprocket (with a plastic m allet) should dislodge
without complete disassembly, remove the cam shaft and
the sprocket.
crankshaft leaving cylinder heads attached and pistons in
6. Install two 5 /1 6 " - 18 x 4" bolts in cam shaft bolt holes place. Before removing crankshaft, tape threads of connect
then remove cam shaft (fig. 6A4-34). ing rod bolts to prevent dam age to cran k sh aft. Fasten
NOTICE: All cam shaft journals are the same diam eter
and care m ust be used in removing cam shaft to avoid
dam age to bearings.
LIG H T T R U C K SERVICE M A N U A L
6A4-22 SMALL BLOCK
Installation
1. Thoroughly clean all gasket and seal surfaces on oil
pan, cylinder block, crankcase front cover and rear
main bearing cap.
2. Install new oil pan side gaskets on cylinder block using
gasket sealant as a retainer. Install new oil pan rear seal
in rear main bearing cap groove, with ends butting side
gaskets. Install new oil pan front seal in groove in
crankcase front cover with ends butting side gaskets.
3. Install oil pan and torque bolts to specifications.
4. If ’K ’ model, replace strut rods.
Fig. 6A4-36--Removing Camshaft Bearings 5. Install converter housing under pan.
LIG H T T R U C K SERVIC E M A N U A L
SMALL BLOCK 6A4-23
6. Install exhaust crossover pipe. 4. Check the drive gear shaft for looseness in the pump
7. Fill with oil, start engine and check for leaks. body.
5. Inspect inside of pum p cover for w ear th a t would
OIL PUMP perm it oil to leak past the ends of the gears.
6. Inspect the pickup screen and pipe assem bly for
Removal dam age to screen, pipe or relief grom m et.
1. Remove oil pan as previously outlined. 7. Check the pressure regulator valve for fit.
2. Rem ove pum p to re a r m ain bearing cap bolt and
remove pum p and extension shaft. Assembly (Figure 6A4-38)
LIG H T TR U C K SERVICE M A N U A L
6A4-24 SMALL BLOCK
and in .010" and .020" undersize for use with reconditioned b. Install the bearing in the connecting rod and cap.
crankshafts. c. Install the bearing cap and evenly torque nuts to
On removing a connecting rod cap, it is possible to find specifications.
a .009" undersize bearing. These are used in m anufacturing Do not turn the crankshaft with the gaging plastic
for selective fitting. installed.
d. Remove the bearing cap and using the scale on the
Inspection and Replacement gaging plastic envelope, m easure the gaging plastic
width at the widest point (fig.6A4-41).
1. W ith oil pan and oil pum p rem oved, rem ove the
connecting rod cap and bearing. 6. If the clearance exceeds specifications, select a new,
Before removal of connecting rod cap, m ark the side of correct size, bearing and rem easure the clearance.
the rod and cap with the cylinder num ber to assure Be sure to check w hat size bearing is being removed in
m atched reassembly of rod and cap. order to determ ine proper replacem ent size bearing. If
2. Inspect the bearing for evidence of wear or dam age. clearance cannot be brought to within specifications,
(Bearings showing the above should not be installed.) the crankpin will have to be ground undersize. If the
crankpin is already at m axim um undersize, replace
3. W ipe both upper and lower bearing shells and crankpin
crankshaft.
clean of oil.
7. Coat the bearing surface with oil, install the rod cap
4. M easure the crankpin for out-of-round or taper with a
and torque nuts to specifications.
m icrom eter. If not w ithin specifications replace or
recondition the crankshaft. If within specifications and 8. W hen all connecting rod bearings have been installed
a new bearing is to be installed, m easure the maxim um tap each rod lightly (parallel to the crankpin) to make
diam eter of the crankpin to determ ine new bearing size sure they have clearance.
required. 9. M easure all connecting rod side clearances (see speci
5. If within specifications m easure new or used bearing fications) between connecting rod caps (fig. 6A 4-42).
clearances with Plastigage or its equivalent.
If a bearing is being fitted to an out-of-round crankpin,
be sure to fit to the m axim um diam eter of the crankpin. M AIN BEARINGS
If the bearing is fitted to the m inim um diam eter and M ain bearings are of the precision insert type and do
the cran k p in is o u t-of-round .001" interference not utilize shims for adjustm ent. If clearances are found to
between the bearing and crankpin will result in rapid be excessive, a new bearing, both upper and lower halves,
bearing failure. will be required. Service bearings are available in standard
a. Place a piece of gaging plastic, the length of the size and .001", .002 ", .009 " ,.0 1 0 " and .020 " undersize.
bearing (parallel to the crankshaft), on the crankpin Selective fitting of both rod and m ain bearing inserts is
or bearing surface (fig. 6A 4-40). Plastic gage should necessary in production in order to obtain close tolerances.
be positioned in the middle of upper or lower bearing For this reason you may find one half of a standard insert
shell. (B earings are eccen tric and false readings with one half of a .001" undersize insert which will decrease
could occur if placed elsewhere). the clearance .0005 " from using a full standard bearing.
LIG H T T R U C K SERVICE M A N U A L
S/ALL BLOCK 6A4-25
1. W ith the oil pan and oil pum p removei and starting
with the rear main bearing, remove bering cap and
wipe oil from journal and bearing cap.
2. Place a piece of gaging plastic the full vidth of the
bearing (parallel to the crankshaft) on theournal (fig.
6A4-43).
Do not rotate the crankshaft while the gagig plastic is
between the bearing and journal.
Inspection
In general, the lower half of the bearing (except # 1
bearing) shows a g reater wear and the most distress from
fatigue. If upon inspection the lower half is suitable for use,
it can be assumed th a t the upper half is also satisfactory. If
the lower half shows evidence of wear or dam age, both upper
and lower halves should be replaced. N E V E R R E PL A C E
O N E H A L F W IT H O U T R E P L A C IN G T H E O T H E R
H A L F.
Checking Clearance
To obtain the most accurate results with "P lastigage"
(or its equivalent) a wax-like plastic m aterial which will
compress evenly between the bearing and journal surfaces
w ithout dam aging either surface, certain precautions should
be observed.
If the engine is out of the vehicle and upside down, the
crankshaft will rest on the upper bearings and the total Fig. 6A4-43--Gaging Plastic on Journal
LIG H T T R U C K SERVICE M A N U A L
6A4-26 SMALL BLOC
Replacement
M ain bearings m ay be replaced w ith or w ithout
removing the crankshaft.
1
I
— 1 / 2 —►
/ cleaner.
5. Inspect com ponents for nicks, scratches, burrs and
machining defects at all sealing surfaces, case assembly
and crankshaft.
t — h I - .............. '
6. Coat seal lips and seal bead with light engine oil - keep
11/64
oil off seal m ating ends.
7. Position tip of tool between crankshaft and seal seat in
cylinder case.
Fig. 6A4-46--Oil Seal Installation Tool
8. Position seal between crankshaft and tip of tool so that
seal bead contacts tip of tool. M ake sure th at oil-seal lip
is positioned tow ard front of engine (fig. 6A4-49).
APPLY
SEALANT
Fig. 6A4-48--Removing Oil Seal - Upper Half TO SHADED
The rear main bearing oil seal can be replaced (both AREAS ONLY
halves) w ithout removal of the crankshaft. Extrem e care
should be exercised when installing this seal to protect the
sealing bead located in the channel on the outside diam eter
of the seal. An installation tool (fig. 6A4-46) m ust be used to
protect the seal bead when positioning seal as follows:
1. W ith the oil pan and oil pum p removed, remove the
rear m ain bearing cap.
2. Remove oil seal from the bearing cap by prying from
the bottom with a small screw driver (fig. 6A4-47).
3. To remove the upper half of the seal, use a small
ham m er to tap a brass pin punch on one end of seal Fig. 6A4-50--Sealing Bearing Cap
LIGHT T R U C K SERVICE M A N U A L
6A4-28 SMALL BLOCK
Disassembly
Fig. 6A4-52--Removing Piston Pin
1. Remove connecting rod bearings from connecting rods 3. Place connecting rod and piston assem bly on Tool
and caps. If bearings are being reused, place them in a J-24086-20. U sing an arb o r press and piston pin
rack so they m ay be reinstalled in their original rod and remover, J-24086-8, press the piston pin out of connect
cap. ing rod and piston (fig. 6A4-52).
2. Remove piston rings by expanding and sliding them off
the pistons. Cleaning and Inspection
Connecting Rods
W ash connecting rods in cleaning solvent and dry with
compressed air. Check for twisted or bent rods and inspect
for nicks or cracks. R eplace connecting rods th a t are
dam aged.
Pistons
C lean varnish from piston skirts and pins w ith a
cleaning solvent. DO N O T W IR E B R U SH A N Y PA R T
O F T H E P IS T O N . Clean the ring grooves with a groove
cleaner and make sure oil ring holes and slots are clean.
Inspect the piston for cracked ring lands, skirts or pin
bosses, wavy or worn ring lands, scuffed or dam aged skirts,
eroded areas at top of the piston. Replace pistons th at are
dam aged or show signs of excessive wear.
Inspect the grooves for nicks or burrs th at might cause
the rings to hang up.
M easure piston skirt (across center line of piston pin)
and check clearance.
w
Piston Pins
The piston pin clearance is designed to m aintain
adequate clearance under all engine operating conditions.
Fig. 6A4-51--Removing Connecting Rod & Piston Because of this, the piston and piston pin are a m atched set
Assembly and not serviced separately.
LIG H T T R U C K SERVICE M A N U A L
i
SMALL BLOCK 6A4-29
Inspect piston pin bores and piston pins for wear. Piston ring is a tapered face acting as both a compression and oil
pin bores and piston pins m ust be free of varnish or scuffing control ring.
when being m easured. The piston pin should be m easured The oil control rings are of three piece type, consisting
w ith a m icrom eter and th e piston pin bore should be of two segments (rails) and a spacer.
m easured with a dial bore gage or an inside m icrom eter. If
clearance is in excess of the .001" wear limit, the piston and
1. Select rings com parable in size to the piston being used.
piston pin assembly should be replaced.
2. Slip the compression ring in the cylinder bore; then
Assembly press the ring down into the cylinder bore about 1/4"
(6.5m m ) (above ring travel). Be sure ring is square
with cylinder wall.
1. L ubricate piston pin holes in piston and connecting rod
3. M easure the space or gap between the ends of the ring
to facilitate installation of pin.
with a feeler gage (fig. 6A4-54).
2. Place connecting rod in piston and hold in place with
4. If the gap betw een the ends of the ring is below
piston pin guide and piston pin. Place assembly on
specifications, remove the ring and try another for fit.
fixture and support assembly.
5. Fit each compression ring to the cylinder in which it is
3. Using piston pin installer, J-24086-9, press the piston
going to be used.
pin into the piston and connecting rod (fig. 6A4-53).
6. If the pistons have not been cleaned and inspected as
NOTICE: A fter installer hub bottom s on support assem previously outlined, do so.
bly, do not exceed 5000 psi pressure, as this could cause 7. Slip the outer surface of the top and second com pres
structural dam age to the tool. sion ring into the respective piston ring groove and roll
4. Remove piston and connecting rod assembly from tool the ring entirely around the groove (fig. 6A4-55) to
and check piston for freedom of movement on piston make sure th at the ring is free. If binding occurs at any
pin. point, the cause should be determ ined. If binding is
Piston Rings
All compression rings are m arked on the upper side of
the ring. W hen installing compression rings, make sure the
M A R K E D S ID E IS T O W A R D T H E T O P O F T H E
P IS T O N . The top ring is chrom e faced, or treated with
molybdenum for m axim um life. The second compression
LIG H T T R U C K SERVICE M A N U A L
6A4-30 SMALL BLOCK
bearing cap m ust be on the sam e side when installed in the 3. The instructions furnished by the m anufacturer of the
cylinder bore. If a connecting rod is ever transposed from equipm ent being used should be carefully followed.
one block or cylinder to another, new bearings should be
fitted and th e connecting rod should be num bered to Honing
correspond with the new cylinder num ber. 1. W hen cylinders are to be honed, follow the hone
m anufacturer’s recom m endations for the use of the
CYLINDER BLOCK hone and cleaning and lubrication during honing.
Cleaning and Inspection 2. Occasionally during the honing operation, the cylinder
1. W ash cylinder block thoroughly in cleaning solvent and bore should be thoroughly cleaned and the piston
clean all gasket surfaces. selected for the individual cylinder checked for correct
2. Remove oil gallery plugs and clean all oil passages. fit.
3. Clean and inspect coolant passages in the cylinder 3. W hen finish honing a cylinder bore to fit a piston, the
block. hone should be moved up and down at a sufficient speed
4. Inspect the cylinder block for cracks in the cylinder to obtain very fine uniform surface finish m arks in a
w alls, coolant ja c k e t, valve lifter bores and m ain cross-hatch pattern of approxim ately 45° to 65° in
bearing webs. cluded angle. The finish m arks should be clean but not
5. M easure the cylinder walls for taper, out-of-round or sharp, free from imbedded particles and torn or folded
excessive ridge at top of ring travel. This should be done metal.
with a dial indicator. Set the gage so th a t the thrust pin 4. Perm anently m ark the piston for the cylinder to which
m ust be forced in about 1/4" (6.5m m ) to enter gage in it has been fitted and proceed to hone cylinders and fit
cylinder bore. C enter gage in cylinder and turn dial to the rem aining pistons.
" 0 " . Carefully work gage up and down cylinder to
determ ine taper and turn it to different points around NOTICE: H andle th e pistons with care and do not
cylinder wall to determ ine the out-of-round condition. attem pt to force them through the cylinder until the
If cylinders were found to exceed specifications, honing cylinder has been honed to correct size as this type
or boring will be necessary. piston can be distorted through careless handling.
5. Thoroughly clean the bores with hot water and deter
Conditioning
gent. Scrub well with a stiff bristle brush and rinse
The perform ance of the following operation is contin thoroughly with hot w ater. It is extremely essential th at
gent upon engine condition at tim e of repair. a good cleaning operation be performed. If any of the
If the cylinder block inspection indicated th at the block abrasive m aterial is allowed to rem ain in the cylinder
was suitable for continued use except for out-of-round or bores, it will rapidly wear the new rings and cylinder
tapered cylinders, they can be conditioned by honing or bores in addition to the bearings lubricated by the
boring. contam inated oil, the bores should be swabbed and then
If the cylinders were found to have less than .005" wiped with a clean dry cloth. C ylinder should not be
(. 13mm) taper or wear, they can be conditioned with a hone cleaned with kerosene or gasoline. Clean the rem ainder
and fitted w ith the high lim it sta n d a rd size piston. A of the cylinder block to remove the excess m aterial
cylinder bore of less then .005" (.13m m ) w ear or taper may spread during the honing operation.
not entirely clean up when fitted to a high lim it piston. If it is
desired to entirely clean up the bore in these cases, it will be Piston Selection
necessary to rebore for an oversize piston. If more than 1. C heck U S E D piston to cylinder bore clearan ce as
.005" (.13m m ) taper or wear, they should be bored and follows:
honed to the sm allest oversize th at will perm it complete
a. M easure the "C y lin d er Bore D ia m e te r" w ith a
resurfacing of all cylinders.
telescope gage |2 - l / 2 " (64m m ) from top of cylinder
W hen pistons are being fitted and honing is not
bore]).
necessary, cylinder bores m ay be cleaned with a hot w ater
and d eterg en t wash. A fte r cleaning, th e cylinder bores b. M easure the "P iston D iam eter" (a t sk irt across
should be swabbed several tim es with light engine oil and a center line of piston pin).
clean cloth and then wiped with a clean dry cloth. c. S ubtract piston diam eter from cylinder bore diam e
ter to determ ine " Piston to Bore C learance ".
Boring
1. Before using any type boring b ar, th e top of the d. Locate piston to bore clearance on Piston Selection
cylinder block should be filed to remove any dirt or C hart and determ ine if piston to bore clearance is in
burrs. This is very im portant. If not checked, the boring the acceptable range.
bar m ay be tilted which would result in the rebored 2. If used piston is not acceptable, determ ine if a new
cylinder wall not being a t rig h t angles to the piston can fit cylinder bore.
crankshaft.
3. If cylinder bore m ust be reconditioned, m easure new
2. The piston to be fitted should be m easured with a
piston diam eter (across center line of piston pin) then
m icrom eter, m easuring at the center of the piston skirt
hone cylinder bore to correct clearance.
and at right angles to the piston pin. The cylinder
should be bored to the sam e diam eter as the piston and 4. M ark the piston to identify the cylinder for which it
honed to give the specified clearance. was fitted.
LIG H T T R U C K SERVICE M A N U A L
6A4-32 SMALL BLOCK
OIL FILTER BYPASS VALVE 2. Raise vehicle and install engine m ounts. R etain by
inserting engine mount "th ro u g h " bolts.
Inspection and Replacement
3. Raise engine slightly, remove wooden blocks and lower
W ith the oil filter removed, check the spring and fibre engine onto mounts.
valve for operation. Inspect for a cracked or broken valve. If 4. Install engine mount bracket to fram e bolts. Torque to
replacem ent is necessary, the oil filter adapter and bypass specifications.
valve assembly m ust be replaced as an assembly. Clean
5. Install transm ission m ount bolts. T orque to
valve cham ber in cylinder block thoroughly. Torque retain
specifications.
ing screws to specifications.
6. Connect fuel tank line and return line to fuel pump.
ENGINE ASSEMBLY 7. Connect transmission shift linkage and speedom eter
cable.
Removal ("G " V an ) 8. Install propshaft.
1. Disconnect battery cables at battery. 9. Connect exhaust pipe to exhaust manifold flanges.
2. D rain cooling system. 10. Lower vehicle.
3. Remove coolant reservoir bottle. 11. Connect heater hoses.
4. Remove grille, upper radiator support and lower grille 12. Connect engine wiring harness.
valance. 13. Using a new gasket, install carburetor. Connect accel
5. Disconnect radiator hoses at radiator. erator cable.
• If equipped with autom atic transm ission, remove 14. Install radiator. Install radiator to radiator support
cooler lines from radiator. attaching brackets.
• If equipped with A /C , evacuate system and remove • If equipped with autom atic transm ission, connect
condenser. Remove A /C vacuum reservoir. cooler lines to radiator.
6. Remove w asher ja r and bracket. • If equipped with A /C , install condenser to radiator
7. Remove radiator to rad iato r support attaching brackets support.
and remove radiato r and shroud. 15. Connect radiator hoses to radiator.
8. If equipped with P /S , remove pum p and lay aside. 16. Install grille cross brace and grille.
9. Remove engine cover. 17. Fill cooling system.
10. Remove air cleaner air stove pipe. 18. Fill crankcase with oil.
11. Remove accelerator cable from carburetor and remove • If equipped with A /C , m ount compressor, connect
carburetor. hosing and charge system.
12. Disconnect engine wiring harness from connection on 19. Connect battery cables and start engine. Check ignition
firewall. tim ing and adjust carburetor if necessary.
13. Disconnect heater hoses a t engine. 20. Install air cleaner and engine cover.
14. Remove therm ostat housing.
15. Remove oil fill pipe. Removal (CK Series)
16. If equipped w ith cruise control, rem ove servo and 1. Disconnect battery cables at battery.
bracket and transducer. 2. D rain cooling system.
17. Raise vehicle. 3. Remove air cleaner.
18. D isconnect ex h au st pipe from exhaust m anifold 4. Remove all accessory drive belts.
flanges.
5. Remove fan and w ater pum p pulley.
19. Remove propshaft; plug transm ission end.
6. Disconnect upper and lower radiator hoses at engine.
20. Disconnect transm ission shift linkage and speedometer
7. Disconnect heater hoses at engine.
cable.
• If equipped with autom atic transm ission, disconnect
21. Disconnect fuel hose from fuel pump.
cooler lines a t radiator.
22. Remove transm ission m ount bolts.
8. Remove radiator and shroud.
23. Remove engine m ount bracket to fram e bolts.
9. Disconnect accelerator linkage and detent linkage, if so
24. Drain crankcase. equipped, from carburetor.
25. Remove engine m ount "th ro u g h " bolts.
10. If A /C equipped, remove com pressor from engine and
26. Raise engine slightly and remove engine m ounts. Block lay aside.
up engine with wood between oil pan and crossm ember.
11. If power steering equipped, remove pum p from engine
27. Lower vehicle and install lifting tool. and lay aside.
28. Remove engine/transm ission assembly. 12. Remove engine wiring harness from engine.
13. Disconnect fuel line at fuel pump.
Installation ("G " Van)
14. Disconnect all vacuum lines from intake manifold.
1. Place engine/transm ission assembly into vehicle. Sup
port engine with blocks of wood between the oil pan and 15. Raise vehicle.
crossmembers. 16. D rain crankcase.
LIG H T T R U C K SERVIC E M A N U A L
SMALL BLOCK 6A4-33
LIG H T T R U C K SERVICE M A N U A L
6A4-34 SMALL BLOCK
SPROCKET OR GEAR REPLACEMENT (REFER TO surfaces. R etorque all m ain bearing cap bolts to
specifications.
FIG. 6A4-59)
8. M easure crankshaft end play with a feeler gage. Force
• Rem ove c ra n k sh a ft sprocket using Tool J-5825, crankshaft forward and m easure clearance between the
install using Tool J-5590. front of the rear main bearing and the crankshaft
thrust surface.
Installation
9. Install flywheel and torque to specifications. A wood
block placed between the crankshaft and cylinder block
1. Install rear m ain bearing oil seal in cylinder block and will prevent crankshaft from rotating.
rear main bearing cap grooves. Install with lip of seal
• Align dowel hole in flywheel with dowel hole in
toward front of engine. W here seal has two lips install
crankshaft. On vehicles equipped with autom atic
lip with helix tow ards front of engine.
transm issions, install flywheel with the converter
2. Lubricate lips of seal with engine oil. Keep oil off attaching pads towards transm ission.
parting line surface.
3. Install m ain b earings in cylinder block and m ain
bearing caps then lubricate bearing surface with engine
oil. APPLY
4. Install crankshaft, being careful not to dam age bearing SEALANT
TO SHADED
surfaces.
AREAS ONLY
5. Apply a thin coat of brush-on type oil sealing com
pound to block m ating su rface and corresponding
surface of cap only (fig. 6A4-60). Do not allow sealant
on crankshaft or seal.
6. Install main bearing caps with arrows pointing toward
front of engine.
7. T orque all except re a r m ain bearing cap bolts to
specifications. Torque rear m ain bearing cap bolts to
10-12 lbs. ft. (14-16 N -m ) then tap end of crankshaft,
first rearw ard then forw ard with a lead ham m er. This
will line up rear main bearing and crankshaft thrust Fig. 6A4-60--Sealing Bearing Cap
LIG H T T R U C K SERVICE M A N U A L
GENERAL DATA: PISTON PIN LF3.LG9,LE9, LS9/LT9
TYPE 90° V-8 G A S O LIN E D IA M E T E R .9270-.9273
5.0 (F) P R O D U C T IO N •00025-.00035
5.7 (L) CLEARANCE
D IS P L A C E M E N T L ITR E (* ) 5.0 (G) 5.7 (M) S E R V IC E .001 M A X .
5.0 (H)
RPO LF3 LG9 LE9 LS9 /L T 9 F IT IN R O D .0008-.001 6 IN T E R F E R E N C E
F IR IN G O R D E R 1-8-4-3-6-5-7-2 #5 2.4479 -2 .4 4 88
M A IN
C YLINDER BORE: JO UR NAL P R O D U C T IO N .0002 M A X .
1A r t H
D IA M E T E R 3.7350-3.7385 3.9995-4.0025 S E R V IC E .001 M A X .
O U T OF P R O D U C T IO N .001 M A X . O UT OF
P R O D U C T IO N .0002 M A X .
ROUND ROUND
S E R V IC E .002 M A X . S E R V IC E .001 M A X .
THRUST #1 .0 0 8 .0 0 2 0
S ID E
.0005 M A X .
PRODUC M A IN P R O D U C T IO N #2-3-4 .0011-.0023
TAPER T IO N R E L IE F B E A R IN G
.001 M A X . C L E A R A N I: e #5 .001 7-.0032
S ID E
S E R V IC E .001 M A X . S E R V IC E #1 .0 0 1 .0 0 1 5 # 2 -4 .0 0 1 .0 0 2 5 # 5 .0 0 2 5 .0035
P R O D U C T IO N .0007-.0017 D IA M E T E R 2.0988-2.0998
CLEARANCE
S E R V IC E .0027 M A X . P R O D U C T IO N .0005
SMALL BLOCK
O ANCE S E R V IC E HI L IM IT P R O D U C TIO N + .001 EXHAUST .2667 .2733
I
L P R O D U C T IO N .01 5-.055 J O U R N A L D IA M E T E R 1.8682-1.8692
GAP
S E R V IC E HI L IM IT PR O D U C TIO N + .010 CAM SHAFT END PLAY .0 0 4.0 1 2
* VIN D esignation
6A4-35
LIGHT
6A4-36
TRUCK
SERVICE
SMALL BLOCK
MANUAL
T O R Q U E S P E C IF IC A T IO N S
VA LV E SYSTEM LF3. LG9L J L LE9 LS9; LT9
L IF T E R H Y D R A U LIC CRANKCASE FRONT C O V E R ........................... 80 LB. IN.
FLYW H EEL HOUSING C O V E R ........................ 80 LB. IN.
ROCKER A R M R A T IO 1.50:1 O IL FILTE R BYPASS V A L V E ........................... 80 LB. IN.
IN T A K E ONE TURN DOWN O IL PAN (TO CRANKCASE) (1 /4 -2 0 ).............. 80 LB. IN.
VALVE
O IL PUMP C O V E R ................................................ 80 LB. IN.
LASH
EXHAUST FROM ZERO LASH
ROCKER ARM C O V E R ........................................ 45 LB. IN.
FACE A N G L E (IN T . & EXH.) 45 CAM SHAFT S P R O C K E T ...................................... 20 LB. FT.
O IL PAN TO CRANKCASE (5 /1 6 -1 8 )..............165 LB. IN.
SEAT A N G L E (INT. & EX H.) 46 CLUTCH PRESSURE P L A T E .............................. 30 LB. FT.
SEAT R U N O U T .002 M AX. DISTR IBU TO R CLAMP . . . ................................. 25 LB. FT.
FLYW H EEL H O U S IN G ........................................ 30 LB. FT.
SEAT IN T A K E 1/32-1/16 M A N IF O LD (E X H A U S T )......................................20 LB. F T .i
W ID T H M A N IF O LD (IN L E T ).............................................. 30 LB. FT.
EXHAUST 1/1 6-3/32
WATER O U T L E T ................................................... 30 LB. FT.
IN T . .0010-.0027
n STEM P R O D U C T IO N WATER P U M P ......................................................... 30 LB. FT.
3I EX H .0010-.0027 CONNECTING ROD CAP...................................... 45 LB. FT.
CL E A R A N C E
n SERVICE C Y LIN D E R H E A D ................................................ 65 LB. FT.
> HI L IM IT + .001 IN T A K E + .002 EXHAUST
M AIN BEAR IN G C A P ................................ .. 80 LB. FT.2
O
z FREE L E N G T H 2.03 O IL P U M P ................................................................ 65 LB. FT.
CO
F L Y W H E E L .............................................................. 60 LB. FT.
PRESSURE CLOSED 76-84 @ 1.70 INT. @ 1.61 EXH. T O R S IO N A L D A M P E R ........................................ 60 LB. FT.
VALVE
LBS. @ IN. TEM PER ATU RE SENDING U N IT ...................... 20 LB. FT.
SPRING OPEN 194-206 @ 1.25 INT. @ 1.16 EXH.
(O UTE R) O IL F I L T E R ........................................................... 25 LB. FT.
IN S T A L L E D H E IG H T O IL PAN D R A IN PLUG ........................................ 20 LB. FT.
1-23/32 INT. 1-19/32 EXH.
± 1/32" SPARK P L U G ........................................................ 17-27 LB. FT.
SECTION 6A5
7.4 L (W) V-8 - RPO LE8
Contents
LIG H T T R U C K SERVICE M A N U A L
6A5-2 MARK IV
CO VER
DISTRIBUTO R
STUD
NUT
BALL
CLAMP
OUTLET ARM
STUD
GASKE T
G U ID E
THERMOSTAT
M A N IFO L D
BO L T
SPRING
SEAL
SHIM BOLT
ROTATOR
PLUG
GSKT
HEAD
G ASKE T
BOLT
M A N IFO L D
VALVE
L IF T E R
VALVE
LIG H T T R U C K SERVIC E M A N U A L
MARK IV 6A5-3
PISTON
BOLT
BEARING SET
CAMSHAFT
FLYWHEEL
CHAIN
GEAR
PLUG
WASHER
PUMP GASKET
GASKET
BLOCK SEAL
EXTENSION
SHAFT
FILTER
DAMPER
BOLT
PUMP
WASHER
BOLT
BOLT
SCREEN
BOLT
GASKET
SEAL
GASKET
BOLT
BOLT PLUG
LIG H T TR U C K SERVICE M A N U A L
6A5-4 MARK IV
ENGINE LUBRICATION
Full pressure lubrication through a full flow oil filter, is cam shaft and crankshaft to lubricate the bearings. The
furnished by a gear-type oil pump. The distributor, driven valve lifter oil gallery feeds the valveiifters which, through
by a helical gear on the cam shaft, drives the oil pump. The hollow push rods, feed the individually mounted rocker arm s
main oil gallery feeds oil, through drilled passages, to the (fig. 6A5-3).
ON VEHICLE SERVICE
LIG H T T R U C K SERVICE M A N U A L
MARK IV 6A5-5
LIG H T T R U C K SERVICE M A N U A L
6A5-6 MARK IV
MANUAL TRANSMISSION
LIG H T T R U C K SERVIC E M A N U A L
MARK IV 6A5-7
LIG H T T R U C K SERVICE M A N U A L
6A5-8 MARK IV
LIG H T T R U C K SERVIC E M A N U A L
MARK IV 6A 5-9
EXHAUST MANIFOLD
Removal
1. Remove carburetor air cleaner and heat stove pipe.
2. Remove spark plugs.
3. D isconnect exh au st pipe from m anifold and hang Fig. 6A5-10--A/C Compressor Mounting
exhaust pipe from fram e with wire.
ROCKER ARM COVER
4. Remove end bolts then remove center bolts and remove
manifold.
Removal
Installation
1. Remove air cleaner.
If installing a new right side manifold, the carburetor 2. Disconnect crankcase ventilation hoses at rocker arm
heat stove m ust be transferred from the old unit (fig. 6A5- covers.
9). 3. Disconnect electrical wiring harness from rocker arm
1. Clean m ating surfaces on manifold and head, then clips.
install m anifold in position and install bolts.
4. Remove carburetor heat stove pipe from right exhaust
2. Torque manifold bolts to specifications. manifold.
3. Connect exhaust pipe to manifold. 5. If the vehicle is equipped with air conditioning, remove
4. Install spark plugs and torque to 22 lb. ft. (30 N-m). the A /C compressor upper brace (fig. 6A5-10).
5. Install carburetor heat stove pipe. 6. Remove rocker arm cover to head attaching bolts and
remove rocker arm cover.
6. S ta rt engine and check for leaks.
NOTICE: If cover adheres to cylinder head, shear off by
bum ping end of rocker arm cover with a rubber m allet.
If cover will not come loose, C A REFU LLY pry until
loose. DO N O T D IST O R T S E A L IN G FL A N G E .
Installation
1. Clean sealing surface on cylinder head and rocker arm
cover with degreaser. Using a 3 /1 6 " (5m m ) bead of
RTV, # 1052366 or equivalent, place rocker arm cover
on the head, install retain in g bolts and torque to
specification. Loose RTV sealant, or pieces causing
installation interference, m ust be removed from both
cylinder head and cover seal surfaces prior to applying
new sealant.
• W hen going around the attaching bolt holes, always
flow the RTV on the inboard side of the holes.
2. On A /C equipped vehicles, install the A /C compressor
upper brace. A djust pulley belt to specification.
STUD
3. Install carburetor heat stove pipe.
DUCT 4. Connect electrical wiring harness at clips on rocker arm
ASSEMBLY cover.
5. Connect crankcase ventilation hoses.
Fig. 6A5-9--Carburetor Heat Stove Assembly 6. Install air cleaner, start engine and check for leaks.
LIGHT TRUCK SERVICE MANUAL
MARK IV 6 A 5 -1 1
J-23590
VALVE LIFTERS
H ydraulic valve lifters very seldom require attention.
The lifters are extrem ely simple in design, readjustm ents
are not necessary, and servicing of the lifters requires only
that care and cleanliness be exercised in the handling of
parts.
Removal
1. Remove intake m anifold as previously outlined.
2. Remove valve m echanism as previously outlined.
3. Remove valve lifters. Place valve lifters in a rack so that
they m ay be reinstalled in the sam e location.
Installation
1. C oat foot of valve lifters w ith "M o ly k o te" or its i
equivalent and install valve lifters. M ake sure lifter foot Fig. 6A5-15--Removing Ball Check Valve
is convex, Cleaning and Inspection
2. Install intake manifold as previously outlined.
3. Install and adjust valve m echanism as outlined.
Thoroughly clean all parts in cleaning solvent, and
Disassembly inspect them carefully. If any parts are dam aged or worn,
the entire lifter assembly should be replaced. If the lifter
1. Hold the plunger down with a push rod, and using the body wall is scuffed or worn, inspect the cylinder block lifter
blade of a small screw driver, remove the push rod seat bore. If the bottom of the lifter is scuffed or worn, inspect the
retainer. cam shaft lobe. If the push rod seat is scuffed or worn,
2. Remove the push rod seat and m etering valve (fig. 6A5- inspect the push rod. An additive containing EP lube, such
14). as EOS, should always be added to crankcase oil for run-in
3. Remove the plunger, ball check valve assembly and the when any new cam shaft or lifters are installed. All dam aged
plunger spring. or worn lifters should be replaced.
4. Remove the ball check valve and spring by prying the
ball retainer loose from the plunger with the blade of a • For proper lifter rotation during engine operation,
small screw driver (fig. 6A5-15). lifter foot m ust be convex.
LIGHT TRUCK SERVICE MANUAL
MARK IV 6A 5-13
Fig. 6A5-17--Assem bling Hydraulic Lifter Fig. 6A5-18--C om pressing Valve Spring
3. Remove valves from cylinder head and place them in a NOTICE: Excessive valve stem to bore clearance will
rack in their proper sequence so th at they can be cause excessive oil consumption and may cause valve
assembled in their original positions. breakage. Insufficient clearance will result in noisy and
sticky functioning of the valve and distu rb engine
Cleaning
smoothness.
J- 8101
Fig. 6A 5-20--C lean ing Valve Guides Fig. 6A 5-22--C hecking Valve Spring Tension
Assembly
Fig. 6A5-25--Measuring Valve Spring Installed Height
1. Insert a valve in the proper port.
4. Check the installed height of the valve springs, using a
2. A ssem ble the valve spring and related parts as follows:
narrow thin scale. A cutaw ay scale will help (fig. 6A5-
24). M easure from the top of the shim or the spring seat
a. Install valve spring shim on valve spring seat then to the top of the valve spring or valve spring shield (fig.
install a new valve stem oil seal over valve and valve 6A5-25). If this is found to exceed the specified height,
guide. install a valve spring seat shim approxim ately 1/16"
b. Set the valve spring (w ith dam per); and valve cap in (1.6m m ) thick. A t no tim e should the spring be
place (fig. 6A5-23). shimmed to give an installed height under the mini
mum specified.
c. Com press the spring with Tool J-8062.
d. Install the valve locks and release the compressor Installation
tool, m aking sure th e locks seat properly in the
groove of the valve stem. G rease may be used to hold
the locks in place while releasing the compressor tool. • The gasket surfaces on both the head and the block
must be clean of any foreign m atter and free of nicks
3. Install the rem aining valves.
or heavy scratches. Cylinder bolt threads in the block
and threads on the cylinder head bolts m ust be clean
as dirt will affect bolt torque.
1. On engines using a ST E E L gasket, coat both sides of a
new gasket with a good sealer. Spread the sealer thin
and even. One method of applying the sealer th at will
assure the proper coat is with the use of a paint roller.
Too much sealer may hold the gasket away from the
head or block.
G R IN D O U T THIS P O R T IO N
<1»| rr 1j n 7] 1
T j T T T ] T | l | ' | l | T F j ' l ' | U lj TP | rTTj r^ ry n y T T j 1
! ' ] 1111 11' | 1 11 | 1111T 1'
\
'2 3 4 5 6
L '
• Use no sealer on engines using a composition ST EEL head is im perative to insure th at the heat in the valve head
A SB E ST O S gasket. will be properly carried away.
2. Place the gasket in position over the dowel pins with the Several different types of equipm ent are available for
bead up. reseating valves seats. The recom m endations of the m anu
3. Carefully guide the cylinder head into place over the facturer of the equipm ent being used should be carefully
dowel pins and gasket. followed to attain proper results.
4. C oat th read s of cylinder head bolts with sealing Regardless of what type of equipm ent is used, however,
compound, # 1 0 5 2 0 8 0 or equivalent, and install bolts it is essential th at valve guide bores be free from carbon or
finger tight. dirt to ensure proper centering of pilot in the guide.
5. Tighten each cylinder head bolt a little at a tim e in the
sequence shown in figure 6A5-26 until the specified VALVES
torque is reached.
6. Install exhaust m anifolds as previously outlined.
7. Install intake manifold as previously outlined. Valves th at are pitted can be refaced to the proper
angle, insuring correct relation between the head and stem
8. Install and a d ju st valve m echanism as previously
on a valve refacing m echanism. Valve stems which show
outlined.
excessive wear, or valves th at are w arped excessively should
be replaced. W hen a valve head which is warped excessively
ROCKER ARM STUDS is refaced, a knife edge will be ground on part or all of the
valve head due to the am ount of m etal th at must be removed
Replacement
to completely reface. Knife edges lead to breakage, burning
The push rod guides are attached to the cylinder head or pre-ignition due to heat localizing on this knife edge. If
by the rocker arm studs (fig. 6A 5-27). R eplace where the edge of the valve head is less than 1/3 2 " (.80m m ) thick
necessary and torque rocker arm studs to specifications. after grinding, replace the valve (fig. 6A 5-29).
Several different types of equipm ent are available for
refacing valves. The recom m endation of the m anufacturer
VALVE GUIDE BORES of the equipm ent being used should be carefully followed to
Valves with oversize stems are available (see specifica attain proper results.
tions). To ream the valve guide bores for oversize valves use
Tool Set J-7049. TORSIONAL DAMPER
VALVE SEATS Removal
R econditioning the valve seats is very im p ortant, 1. Remove fan belt, fan and pulley.
because the seating of the valves must be perfect for the 2. Remove the fan shroud assembly as outlined in Section
engine to deliver the power and perform ance built into it. 6B.
A nother im portant factor is the cooling of the valve • If additional operations (such as cam shaft removal)
heads. Good contact between each valve and its seat in the are not being perform ed, the radiator removal will
not be necessary.
3. Remove accessory drive pulley then remove dam per
retaining bolt.
4. Install Tool J-23523 on dam per then, turning puller
screw, remove dam per.
Fig. 6A5-27--R ocker Arm Stud & Push Rod G uide Fig. 6A 5-29--M easuring Valve Head
Installation
NOTICE: The inertial weight section of the torsional
dam per is assembled to the hub with a rubber type
m aterial. The installation procedures (with proper tool)
m ust be followed or movement of the inertia weight
section on th e hub will destroy the tuning of the
torsional dam per.
1. C oat front cover seal contact area (on dam per) with
engine oil.
2. Place dam per in position over key on crankshaft.
3. Pull dam per onto crankshaft as follows:
a. Install appropriate threaded end of Tool J-23523
into crankshaft. Install tool in crankshaft so th at at
least 1 /2 " (6.5m m ) of th re a d engagem ent is
obtained.
CRANKCASE FRONT COVER 1. Clean gasket surface on block and crankcase front
cover.
Removal
2. C ut tabs from the new oil pan front seal (fig. 6A5-32).
Use a sharp instrum ent to ensure a clean cut.
1. Remove torsional dam per and w ater pum p as outlined.
3. Install seal to front cover, pressing tips into holes
2. Rem ove the two, oil p an -to -fro n t cover attach in g
provided in cover.
screws.
4. Coat the gasket with gasket sealer and place in position
3. Remove the front cover-to-block attaching screws.
on cover.
4. Pull the cover slightly forward only enough to perm it
5. Apply a 1/8" (3m m ) bead of RTV sealer, # 1052366
cutting of oil pan front seal.
or equivalent, to the joint formed at the oil pan and
cylinder block (fig. 6A 5-33).
6. Position crankcase front cover over crankshaft.
7. Press cover downward against oil pan until cover is
aligned and installed over dowel pins on block.
#6 C Y LIN D ER
AT T.D.C.
Fig. 6A 5-37--Tim ing Sprocket Alignment M arks Fig. 6A5-38--R em oving Cam shaft Bearings
4. Using two wrenches, hold puller screw while turning 6. C oat new rear plug O.D. with # 1052080 sealant, or
nut. W hen bearing has been pulled from bore, remove equivalent, and install flush to 1/32" (.80m m ) deep.
remover and installer tool and bearing from puller
screw (fig. 6A 5-38). OIL PAN
5. Remove rem aining bearings (except front and rear) in
the same m anner. It will be necessary to index pilot in Removal
cam shaft rear bearing to remove the rear interm ediate 1. Disconnect battery negative cable.
bearing. 2. Loosen fan shroud.
6. Assemble remover and installer tool on driver handle 3. Remove air cleaner.
and rem ove c a m sh a ft front and re a r bearings by
4. Remove distributor cap.
driving towards center of cylinder block (fig. 6A5-39).
5. Raise vehicle and drain oil pan.
• If equipped with m anual transm ission, rem ove
Installation starter.
6. Rem ove torque converter cover or clutch cover as
T he cam sh aft fro n t and re a r bearings should be
applicable.
installed first. These bearings will act as guides for the pilot
and center the rem aining bearings being pulled into place. 7. Remove oil filter.
1. Assemble remover and installer tool on driver handle 8. On gage equipped vehicles, remove oil pressure line
and install cam shaft front and rear bearings by driving from side of block.
towards center of cylinder block (fig. 6A5-39). NOTICE: Rem oval of pressure line is im p o rtan t to
2. Using Tool Set J-6098 with nut then thrust washer prevent crushing of line when raising engine.
installed to end of threads, index pilot in cam shaft front 9. Remove m ount "th ro u g h " bolts and raise engine.
bearing and install puller screw through pilot. 10. Remove oil pan bolts and drop pan.
3. Index cam shaft bearing in bore (with oil hole aligned as
outlined below), then install remover and installer tool Installation
on puller screw with shoulder toward bearing. If installing new oil pan, transfer dipstick tube from old
• N um ber one through num ber four cam bearing oil unit.
hole m ust be aligned with oil holes in cam bearing 1. W ith clean sealing surfaces on pan and block, place oil
bore. pan on block and install oil pan bolts. Torque to 135 lb.
• The num ber five bearing bore is annulus, and cam in. (15N-m ).
bearing m ust be positioned at or near the 6 o’clock 2. Lower engine on mounts and install m ount through
position. bolts. Torque to 75 lb. ft. (100 N-m).
4. Using two wrenches, hold puller screw while turning 3. Install oil pressure line, if applicable, and install oil
nut. A fter bearing has been pulled into bore, remove filter.
the remover and installer tool from puller screw, and 4. Install torque converter cover or clutch cover, as
check alignm ent of oil hole in cam shaft bearing. applicable.
5. Install rem aining bearings in the same m anner. It will • If equipped with m anual transm ission, install starter.
be necessary to index pilot in the cam shaft rear bearing 5. Lower vehicle.
to install the rear interm ediate bearing. 6. Install distributor cap and tighten fan shroud.
7. Fill crankcase with oil; see owners m anual.
8. Install air cleaner and connect battery negative cable.
9. S ta rt engine and check for leaks.
OIL PUMP
Removal
1. Remove oil pan as previously outlined.
2. Rem ove pum p to rea r m ain bearing cap bolt and
remove pump and extension shaft.
Installation
1. A ssem ble pum p and extension sh aft to rear m ain
bearing cap, aligning slot on top end of extension shaft
with drive tang on lower end of distributor drive shaft.
2. Install pum p to rear bearing cap bolt and torque to
specifications. Fig. 6A5-41--Gaging Plastic On Crankpin
M ain bearings are of the precision insert type and do In general, the lower half of the bearing (except # 1
not utilize shims for adjustm ent. If clearances are found to bearing) shows a greater wear and the most distress from
be excessive, a new bearing, both upper and lower halves, fatigue. If upon inspection the lower half is suitable for use,
will be required. Service bearings are available in standard it can be assum ed th a t the upper half is also satisfactory. If
size and .0 0 1 ", .0 0 2 ", .0 0 9 ", .010" and .020" undersize. the lower half shows evidence of w ear or dam age, both upper
and lower halves should be replaced. Never replace one half
w ithout replacing the other half.
Checking Clearance
To obtain the most accurate results with "P lastig ag e",
(or its equivalent) a wax-like plastic m aterial which will
compress evenly between the bearing and journal surfaces
w ithout dam aging either surface, certain precautions should
be observed.
If the engine is out of the vehicle and upside down, the
crankshaft will rest on the upper bearings and the total
clearance can be m easured between the lower bearing and
jo u rn al. If the engine is to rem ain in th e vehicle, the
cran k sh a ft m ust be supported upw ard to rem ove the
clearance from the upper bearing. The total clearance can
then be m easured between the lower bearing and journal.
To assure the proper seating of the crankshaft, all
bearing cap bolts should be at their specified torque. In
addition, preparatory to checking fit of bearings, the surface
of the crankshaft journal and bearing should be wiped clean
of oil.
1. W ith the oil pan and oil pum p removed, and starting
with the rear main bearing, remove bearing cap and
Fig. 6 A 5 -4 2 -M e a s u rin g G agin g Plastic wipe oil from journal and bearing cap.
LIGHT TRUCK SERVICE MANUAL
MARK IV 6A 5-23
Fig. 6A 5-45--M easuring G agin g Plastic Fig. 6A 5-46--M easuring Crankshaft End Play
10. Install a new rear m ain bearing oil seal in the cylinder
block and m ain bearing cap.
Replacement
M ain bearings m ay be replaced w ith or w ithout
removing the crankshaft. 11/64
7. Position tip of tool between crankshaft and seal seat in CONNECTING ROD AND PISTON ASSEMBLIES
cylinder case.
Removal
8. Position seal between crankshaft and tip of tool so that
1. Remove oil pan, oil pum p and cylinder head as pre
seal bead contacts tip of tool. M ake sure th at oil-seal lip
viously outlined.
is positioned toward front of engine (fig. 6A5-50).
2. For the cylinder being serviced, turn crankshaft until
piston is at the bottom of the stroke. Place a cloth on top
9. Roll seal around crankshaft using tool as a "shoe of the piston.
horn" to protect seal bead from sharp corner of seal 3. Use a ridge ream er to remove any ridge an d /o r deposits
seat surface in cylinder case. Installation tool must from the upper end of the cylinder bore.
rem ain in position until seal is properly positioned with 4. Turn crankshaft until piston is at top of stroke and
both ends flush with block. remove cloth and cuttings.
10. Remove tool, being careful not to w ithdraw seal. 5. Remove connecting rod cap and install Tool J-5329 (3/
8 " ) on studs. Push connecting rod and piston assembly
11. Install seal half in bearing cap, again using tool as a out of top of cylinder block. It will be necessary to turn
"shoe-horn", feeding seal into cap using light pressure the c ra n k sh aft slightly to disconnect some of the
with thum b and finger. connecting rod and piston assemblies and push them
out of the cylinder.
12. Install bearing cap to case with sealant applied to the
cap-to-case interface being careful to keep sealant off Disassembly
the seal split line (fig. 6A 5 -5 1).
13. Install the rear m ain bearing cap (with new seal) and 1. Remove connecting rod bearings from connecting rods
torque to 10-12 lb. ft. (14-16N -m ). T ap end of crank and caps. If bearings are being reused, place them in a
shaft first rearw ard then forw ard with lead ham m er. rack so they may be reinstalled in their original rod and
This will line up thru st surfaces. R etorque bearing cap cap.
to specifications. 2. Remove piston rings by expanding and sliding them off
the pistons.
3. Place connecting rod and piston assem bly on Tool
J-24086-20. U sing an arb o r press and piston pin
remover, J-24086-8, press the piston pin out of connect
ing rod and piston (fig. 6A5-52).
DU ST SEAL
PRESS
-PISTON PIN
REMOVER
J-24086-8
Fig. 6A5-50--Crankshaft Oil Seal - Rear Main
APPLY
SEALANT
TO SHADED
AREAS ONLY
FIXTURE &
SUPPORT
ASSEMBLY
J-24086-20
Pistons
PISTON PIN— ^
C lean varnish from piston skirts and pins w ith a INSTALLER
cleaning solvent. DO N O T W IR E B R U SH A N Y PA R T J-24086-9
O F T H E PIST O N . Clean the ring grooves with a groove
cleaner and m ake sure oil ring holes and slots are clean.
Inspect the piston for cracked ring lands, skirts or pin
bosses, wavy or worn ring lands, scuffed or dam aged skirts,
eroded areas at top of the piston. Replace pistons th at are
dam aged or show signs of excessive wear.
Inspect the grooves for nicks or burrs th at m ight cause
the rings to hang up. PISTON PIN
M easure piston skirt (across center line of piston pin)
and check clearance.
Piston Pins
T he piston pin c learan ce is designed to m aintain
adequate clearance under all engine operating conditions.
Because of this, the piston and piston pin are a m atched set
and not serviced separately.
Inspect piston pin bores and piston pins for wear. Piston
pin bores and piston pins m ust be free of varnish or scuffing
when being m easured. The piston pin should be m easured Fig. 6A5-53--lnstalling Piston Pin
with a m icrom eter and the piston pin bore should be
measured with a dial bore gage or an inside m icrom eter. If
clearance is in excess of the .001" wear limit, the piston and
piston pin assembly should be replaced.
Assembly
Piston Rings
All compression rings are m arked on the upper side of
the ring. W hen installing compression rings, make sure the Fig. 6A5-54--Measuring Ring Gap
m arked side is tow ard the top of the piston. The top ring is
2. Slip the compression ring in the cylinder bore; then
chrome faced, or treated with molybdenum for m aximum
press the ring down into the cylinder bore about 1/4"
life.
(6.5m m ) (above ring travel). Be sure ring is square
The oil control rings are of three piece type, consisting with cylinder wall.
of two segments (rails) and a spacer.
3. M easure the space or gap between the ends of the ring
with a feeler gage (fig. 6A 5-54).
1. Select rings com parable in size to the piston being used.
LIGHT TRUCK SERVICE MANUAL
MARK IV 6A 5-27
Installation
C ylinder bores m ust be clean before piston installation.
This may be accomplished with a hot water and detergent
wash or with a light honing as necessary. A fter cleaning, the
bores should be swabbed several times with light engine oil
and a clean dry cloth.
1. Lubricate connecting rod bearings and install in rods
and rod caps.
2. Lightly coat pistons, rings and cylinder walls with light an oversize piston. If more than .005" taper or wear, they
engine oil. should be bored and honed to the sm allest oversize that will
3. W ith bearing caps removed, install Tool J-5329 (3 /8 " ) perm it complete resurfacing of all cylinders.
on connecting rod bolts. W hen pistons are being fitted and honing is not
4. Install each connecting rod and piston assembly in its necessary, cylinder bores may be cleaned with a hot w ater
respective bore. Install with connecting rod bearing and deterg en t wash. A fter cleaning, the cylinder bores
tang slots on side opposite cam shaft. Use Tool J-8037 should be swabbed several times with light engine oil and a
to compress the rings. G uide the connecting rod into clean cloth and then wiped with a clean dry cloth.
place on the crankshaft journal with Tool J-6305 (11/
3 2 "). Use a ham m er handle and light blows to install Boring
the piston into the bore. Hold the ring compressor 1. Before using any type boring b ar, the top of the
firmly against the cylinder block until all piston rings cylinder block should be filed off to remove any dirt or
have entered the cylinder bore. burrs. This is very im portant. If not checked, the boring
5. Remove Tool J-5329. bar may be tilted which would result in the rebored
6. Install the b earin g caps and to rq u e nuts to cylinder wall not being a t rig h t angles to the
specifications. crankshaft.
2. The piston to be fitted should be m easured with a
Be sure to install new pistons in the cylinders for which
microm eter, m easuring at the center of the piston skirt
they were fitted, and used pistons in the cylinder from which
and at right angles to the piston pin. The cylinder
they were removed. Each connecting rod and bearing cap
should be bored to the same diam eter as the piston and
should be m arked, beginning at the front of the engine.
honed to give the specified clearance.
Cylinders 1,3,5 and 7 in the left bank and, 2 4, 6 and 8 in the
right bank. The num bers on the connecting rod and bearing 3. The instructions furnished by the m anufacturer of the
cap must be on the sam e side when installed in the cylinder equipm ent being used should be carefully followed.
bore. If a connecting rod is ever transposed from one block
Honing
or cylinder to another, new bearings should be fitted and the
connecting rod should be num bered to correspond with the 1. W hen cylinders are to be honed, follow the hone
new cylinder num ber. m anufacturer’s recom m endations for the use of the
hone and cleaning and lubrication during honing.
CYLINDER BLOCK 2. Occasionally during the honing operation, the cylinder
bore should be thoroughly cleaned and the piston
Cleaning and Inspection selected for the individual cylinder checked for correct
1. W ash cylinder block thoroughly in cleaning solvent and fit.
clean all gasket surfaces. 3. W hen finish honing a cylinder bore to fit a piston, the
2. Remove oil gallery plugs and clean all oil passages. hone should be moved up and down at a sufficient speed
3. Clean and inspect w ater passages in the cylinder block. to obtain very fine uniform surface finish marks, in a
4. Inspect the cylinder block for cracks in the cylinder cross-hatch pattern of approxim ately 45° to 65° in
walls, w ater jacket, valve lifter bores and main bearing cluded angle. The finish m arks should be clean but not
webs. sharp, free from imbedded particles and torn or folded
metal.
5. M easure the cylinder walls for taper, out-of-round or
excessive ridge at top of ring travel. This should be done 4. Perm anently m ark the piston for the cylinder to which
with a dial indicator. Set the gage so th a t the thrust pin it has been fitted and proceed to hone cylinders and fit
must be forced in about 1/4" (6.5m m ) to enter gage in the rem aining pistons.
cylinder bore. C enter gage in cylinder and turn dial to NOTICE: H andle th e pistons w ith care and do not
" 0 " . C arefully work gage up and down cylinder to attem pt to force them through the cylinder until the
determ ine taper and turn it to different points around cylinder has been honed to correct size as this type
cylinder wall to determ ine the out-of-round condition. piston can be distorted through careless handling.
If cylinders were found to exceed specifications, honing 5. Thoroughly clean the bores with hot w ater and deter
or boring will be necessary. gent. Scrub well with a stiff bristle brush and rinse
Conditioning thoroughly with hot w ater. It is extrem ely essential that
a good cleaning operation be perform ed. If any of the
The perform ance of the following operation is contin abrasive m aterial is allowed to rem ain in the cylinder
gent upon engine condition a t tim e of repair. bores, it will rapidly wear the new rings and cylinder
If the cylinder block inspection indicated th at the block bores in addition to the bearings lubricated by the
was suitable for continued use except for out-of-round or contam inated oil, the bores should be swabbed and then
tapered cylinders, they can be conditioned by honing or wiped with a clean dry cloth. C ylinder should not be
boring. cleaned with kerosene or gasoline. Clean the rem ainder
If the cylinders were found to have less than .005" of the cylinder block to remove the excess m aterial
taper or wear, they can be conditioned with a hone and fitted spread during the honing operation.
with the high limit standard size piston. A cylinder bore of
less then .005 " wear or taper m ay not entirely clean up when Piston Selection
fitted to a high limit piston. If it is desired to entirely clean 1. C heck U SE D piston to cylinder bore clearance as
up the bore in these cases, it will be necessary to rebore for follows:
LIGHT TRUCK SERVICE MANUAL
MARK IV 6A 5-29
a. M easure th e "C y lin d er Bore D ia m e ter" w ith a 13. Remove flywheel splash shield or converter housing
telescope gage |2 - 1/2" (64m m ) from top of cylinder cover as applicable.
bore|. 14. On vehicles with au to m atic transm ission, remove
b. M easu re th e "P isto n D ia m e te r" (a t skirt across converter to flywheel attaching bolt.
center line of piston pin). 15. Remove m ount "th ro u g h " bolts.
c. S u b tract piston diam eter from cylinder bore diam e 16. Remove bell housing bolts.
ter to determ ine " Piston to Bore C learance ". 17. Lower vehicle on hoist.
d. Locate piston to bore clearance on Piston Selection 18. Raise transm ission using floor jack.
C h art and determ ine if piston to bore clearance is in
19. A ttach engine lifting devices, raise engine.
the acceptable range.
20. Remove motor m ount to engine brackets.
2. If used piston is not acceptable,-determ ine if a new
piston can fit cylinder bore. 21. Remove engine assembly.
3. If cylinder bore m ust be reconditioned, m easure new Installation
piston diam eter (across center line of piston pin) then 1. Position engine assembly in vehicle.
hone cylinder bore to correct clearance. 2. A ttach motor m ount to engine brackets and lower
4. M ark the piston to identify the cylinder for which it engine in place.
was fitted. 3. Remove engine lifting device.
4. Remove transm ission floor jack.
OIL FILTER BYPASS VALVE
5. Raise vehicle on hoist.
Inspection and Replacement 6. Install m ount " th ro u g h " bolts. T orque to
W ith the oil filter removed, check the spring and fibre specifications.
valve for operation. Inspect for a cracked or broken valve. If 7. Install bell housing bolts. Torque to specifications.
replacem ent is necessary, the oil filter adapter and bypass 8. On vehicles w ith au to m atic transm issions, install
valve assembly must be replaced as an assembly. Clean converter to flywheel attach in g bolts. T orque to
valve cham ber in cylinder block thoroughly. Torque retain specifications.
ing screws to specifications. 9. Install flywheel splash shield of converter housing cover
as applicable. Torque attaching bolts to specifications.
ENGINE ASSEMBLY 10. Install starter.
Removal 11. C onnect exhaust pipe at m anifold and converter
1. Remove hood. bracket at transm ission rear mount.
2. Disconnect battery cables at battery. 12. Lower vehicle on hoist.
3. Remove air cleaner. 13. Reinstall power steering pum p and A /C compressor, if
so equipped.
4. D rain radiator and block.
5. D isconnect ra d ia to r and h eater hoses and remove 14. Connect:
radiator and fan shroud. • A ccelerator linkage at inlet manifold.
6. Disconnect wires at: • Fuel line, from tank, at fuel pump.
• S ta rte r Solenoid • Hoses at fuel vapor storage canister.
• G enerator • Vacuum line to power brake unit at manifold, if
equipped.
• T R C Speed Switch
• T R C Solenoid 15. Connect wires at:
• T em perature switch • S tarter Solenoid
• G enerator
• Oil Pressure Switch
• ?T R C Speed Switch
• D istributor
• T R C Solenoid
7. Disconnect:
• A ccelerator linkage a t inlet manifold. • T em perature Switch
• Fuel line, from tank, at fuel pump. • Oil Pressure Switch
• Hoses at fuel vapor storage canister (if applicable). • D istribotor
• Vacuum line to power brake unit a t manifold, if so 16. Install radiator and fanshroud and reconnect radiator
and heater hoses.
equipped.
8. Remove power steering pump and A /C compressor and 17. Fill cooling system.
lay aside, if so equipped. 18. Fill crankcase w ith oil. See Section OB for
specifications.
9. Raise vehicle on hoist.
19. Install air cleaner.
10. D rain crankcase.
11. D isconnect exhaust pipe at m anifold and, if so 20. Install hood.
equipped, converter b rack et a t transm ission rear 21. Connect battery cables.
m ount. NOTICE: To avoid possible arcing of battery, connect
12. Remove starter. positive battery cable first.
LIGHT TRUCK SERVICE MANUAL
6A 5-30 MARK IV
CRANKSAHFT APPLY
The crankshaft can be removed while the engine is SEALANT
TO SHADED
disassembled for overhaul, as previously outlined or without
AREAS ONLY
complete disassem bly as outlined below.
Removal
1. W ith the engine removed from the vehicle and the
transm ission an d /o r clutch housing removed from the
engine, m ount engine in stand and clam p securely.
2. Remove the oil dip stick and oil dip stick tube, (if
applicable).
3. Rem ove the sta rtin g m otor, clutch assem bly (if
equipped) and flywheel.
4. Remove the spark plugs.
Fig. 6A5-58--Sealing Bearing Cap
5. Remove crankshaft pulley and torsional dam per.
tow ard front of engine. W here seal has two lips install
6. Remove oil pan and oil pump. lip with helix towards front of engine.
7. Remove crankcase front cover, and if so equipped, 2. Lubricate lips of seal with engine oil. Keep oil off
remove tim ing chain and cam shaft sprocket. parting line surface.
8. Check the connecting rod caps for cylinder num ber 3. Install m ain bearings in cylinder block and m ain
identification. If necessary, m ark them. bearing caps then lubricate bearing surface with engine
9. Remove the connecting rod caps and push the pistons to oil.
top of bores. 4. Install crankshaft, being careful not to dam age bearing
10. Remove m ain bearing caps and lift crankshaft out of surfaces.
cylinder block. 5. Apply a thin coat of brush-on type oil sealing com
11. Remove rear main bearing oil seal and m ain bearings pound to block m ating su rface and corresponding
from cylinder block and main bearing caps. surface of cap only (fig. 6A 5-58). Do not allow sealant
Cleaning and Inspection on crankshaft or seal.
1. W ash crankshaft in solvent and dry with compressed 6. Install main bearing caps with arrows pointing toward
air. front of engine.
2. M easure dim ensions of m ain bearing jo u rn als and 7. T orque all except rea r m ain bearing cap bolts to
crankpins with a m icrom eter for out-of-round, taper or specifications. Torque rear m ain bearing cap bolts to
undersize. (See Specifications.) 10-12 lbs. ft. (14-16 N-m) then tap end of crankshaft,
first rearw ard then forward with a lead ham m er. This
3. Check crankshaft for run-out by supporting at the front
will line up rear main bearing and crankshaft thrust
and rear m ain bearings journals in "V " blocks and
surfaces. R etorque all m ain bearing cap bolts to
check a t the front and rear interm ediate journals with a
specifications.
dial indicator. (See Specifications.)
8. M easure crankshaft end play with a feeler gage. Force
4. R eplace or recondition the cra n k sh a ft if out of
crankshaft forward and m easure clearance between the
specifications.
front of the rear main bearing and the crankshaft
SPROCKET OR GEAR REPLACEMENT thrust surface.
9. Install flywheel and torque to specifications. A wood
Remove crankshaft sprocket using Tool J 1619, install
block placed between the crankshaft and cylinder block
using Tool J -2 1058.
will prevent crankshaft from rotating.
Installation • Align dowel hole in flywheel with dowel hole in
crankshaft. On vehicles equipped with autom atic
1. Install rear m ain bearing oil seal in cylinder block and transm issions, install flywheel w ith th e converter
rear main bearing cap grooves. Install with lip of seal attaching pads towards transm ission.
F IR IN G ORDER 1-8-4-3-6-5-7-2 #5 2 .7 4 7 6 -2 .7 4 8 6
M AIN
C Y L IN D E R BORE: J O URNAL PRODUCTIO N .0 0 0 2 M A X .
TAPER
DIAM ET ER 4.2495-4.2525 SERVICE .001 M A X .
THRUST
.0005 M A X . # 1 -2 -3 -4 .001 3 -.0 0 2 5
SIDE
1
O
D
PF
C
M AIN
0
PRODUCTION
TAPER TION RELIEF BEARING
.001 M A X . #■5 .0 0 2 4 .0 0 4 0
SIDE CLEARANCE
n . . .0 0 1 - +U- .0 0 2 5 -
SERVICE .001 M A X . SERVICE m 4 .0 0 2 5 '*0 .0 0 3 5
P IS T O N : C R A N K S H A F T END P L A Y .006-.010
IN T . .0010-.0027 M A N IF O L D ( I N L E T ) ........................................ 30 LB . F T.
STEM P R O D U C T IO N W A T E R O U T L E T ............................................. 30 LB . FT.
CLEARANCE EXH. .001 2-’. 0029
W A T E R P U M P .................................................. 30 LB. FT.
S E R V IC E C O N N E C T IN G R O D C A P ............................... 50 LB. FT.
HI L IM IT + .001 IN . + .0 0 2 E X .
C Y L IN D E R H E A D ........................................... 8 0 LB . FT.
FREE L E N G T H 2.12 O I L P U M P ......................................................... 6 5 LB . FT.
R O C K E R A R M S T U D ...................................... 5 0 LB . FT.
PRESSURE CLOSED 8 4 -9 6 @ 1.80
VALVE FLYW HEEL .................................................... 6 5 LB . FT.
LBS. @ IN.
SPRING OPEN 2 1 0 -2 3 0 @1.40 M A IN B E A R I N G C A P ...................................... 110 LB . FT.
(OUTER) T E M P E R A T U R E S E N D I N G U N I T ................... 20 LB . FT.
IN S T A L L E D H E I G H T T O R S I O N A L D A M P E R .................................... 8 5 LB . FT.
1-51/64
± 1/32" O I L F I L T E R ............................................. .. 25 LB . FT.
O IL PA N D R A IN PLUG ................................. 20 LB . F T.
FREE L E N G T H 1.86
DAM PE R SPA R K PLUG ................................................17-27 LB . FT.
APPROX. # O F COILS 4
V8-D IE SE L 6A6-1
SECTION 6A6
5.7 L (N) 350 Diesel
Contents
GENERAL DESCRIPTION
ENGINE CONSTRUCTION spring loaded and calibrated to open at a specified fuel
pressure, and are not adjustable.
T he engine is a 5.7 L iter V-8 four cycle diesel fuel
engine. C ylinder num bers 1, 3, 5 and 7 are on the left bank.
C ylinder num bers 2, 4, 6 and 8 are on the right bank. The
firing order is 1-8-4-3-6-5-7-2. T he m ajor difference
between a gasoline engine and the diesel is in the cylinder
heads, com bustion cham ber, fuel distribution system, air
intake m anifold and m ethod of ignition. The cylinder block,
crankshaft, main bearings, rods, pistons and pins are of a
heavier construction because of the high compression ratio
required to ignite diesel fuel. Diesel ignition occurs because
of h eat developed in the com bustion ch am b er during
compression. This elim inates the need for spark plugs and
high voltage ignition.
Intake and exhaust valves in the cylinder heads operate
the sam e as in a gasoline engine, but are of a special design
and m aterial for diesel operation. The stainless steel pre
cham ber inserts in the cylinder head com bustion cham bers
are serviced separately from the head. W ith the cylinder
head removed they can be pushed out after removing the
glow plugs and injection nozzles. Glow plugs and nozzles are
threaded into the cylinder head. The injection nozzles are Fi9* 6A6-1--Injection Pump-Cutaway
DELIVERY
TRANSFER PUMP
FILTER PU R PO SE :
HIGH PRESSURE DISCHARGE CIRCUIT 1. Emission Control device.
NOZZLE
■ TRANSFER PUMP PRESSURE CIRCUIT
M HOUSING PRESSURE CIRCUIT 2. B etter cold starts.
E Z 3 INLET PRESSURE AND RETURN OIL CIRCUIT
3. Improves idle and noise when cold.
Fig. 6A6-3--Pump Fuel Circuit
W hen changing the fuel filter or when the car has run
FUEL SYSTEM (Figs. 6A6-1, 2, 2a, 3&4) out of fuel, disconnect the connector from the tem pera
ture switch and jum per connector term inals. This will
The diesel fuel injection pum p is m ounted on top of the
aid in purging air from the pump. (This procedure is
engine. It is gear driven off the cam shaft and turns at
necessary only on a hot engine, as the circuit will
cam shaft speed. It is a high pressure rotary pum p that
always be closed when the engine is cold.)
LIGHT TRUCK SERVICE MANUAL
V 8 - DIESEL 6A 6-3
ELECTRICAL
Eight glow plugs are used to heat the pre-cham ber to
aid in starting. They are 6 volt heaters th at pulse when the
ON VEHICLE SERVICE
INJECTION PUMP ON VEHICLE SERVICE Reinstall the guide stud with a new washer making
certain th a t the upper extension of the m etering valve
There are three areas on the injection pum p where spring rides on top of the guide stud. Torque the guide
leaks can be corrected w ithout removing the pum p from the stud to 9.5 N-m (85 in. lbs.) O vertorquing the guide
engine. These are cover seal, guide stud seal and throttle stud may strip the alum inum threads in the housing
shaft seal. (Figs. 6A6-5 and 6A6-8).
9. Hold the throttle in the idle position.
Pump Cover Seal and/or Guide Stud Seal
10 . Install new pum p cover seal. M ake sure the screws are
Replacement not in the cover and position the cover about 1/4 inch
1. Disconnect the negative cables from both batteries. forw ard (tow ard shaft end) and about 1/8 inch above
2. Rem ove th e a ir clean er and air crossover. Install the pum p (Fig. 6A 6 -10).
screens J-26996-2 (C alif.) or J-26996-10 (Excl. Calif.) 11 Move the cover rearw ard and downward into position,
in the intake m anifold. being careful not to cut the seal and reinstall the cover
3. D isconnect the injection pum p fuel solenoid and screws. Be careful not to drop or lose flat washer and
(housing pressure cold advance if equipped) wires and internal lock w asher with each screw. Flat washer must
the fuel return pipe. be against pum p cover. T orque to 3.7 N-m (33 in. lbs.)
4. Clean the injection pum p cover, upper portion of the 12. Reconnect the negative cables to both batteries.
pum p and the guide stud area (Fig. 6A 6-5). Place
M I N - M A X GOVERNOR
several rags in engine valley to catch fuel.
ASSEM BLY IDLE GOVERNOR
5. Remove injection pum p cover and remove screws from S P R IN G
the cover.
13. T urn the ignition switch to the run position and touch a. Install tool J-29601 over the throttle shaft with slots
the pink solenoid wire to the solenoid. A clicking noise of tool engaging pin. Put the spring clip over the
should be heard as the wire is connected and discon throttle shaft advance cam and tighten the wing nut.
nected. If this clicking is not observed, the linkage may W ithout loosening the wing nut, pull the tool off the
be jam m ed in a wide open throttle position and the shaft. (This provides the proper alignm ent on reas
engine M U ST N O T be started. If clicking is observed, sembly, Fig. 6A6-9).
connect the pum p solenoid and (housing pressure cold b. Drive the pin from the throttle shaft and remove the
advance if equipped) wires (Fig. 6A 6-5), then proceed throttle shaft advance cam and fiber washer. Remove
to step 16. any burrs from the shaft th at may have resulted from
14. Remove the cover. G round the solenoid lead (opposite pin removal (Fig. 6A6-5).
the hot lead) and connect the pink wire. W ith the If the injection pump does not have an Advance Cam
ignition switch in the run position, the solenoid in the A ctuating Arm:
cover should move the linkage. If not, the solenoid must a. Drive the throttle shaft drive pin out of shaft and
be replaced. M inim um voltage across solenoid term i remove the throttle retaining ring and fiber washer.
nals m ust be 12.0. Remove any burrs from the shaft th at may have
15. Reinstall the cover and repeat Step 10. resulted from pin removal.
16. R einstall the fuel return pipe and the throttle cable and 8. Clean the injection pum p cover, upper portion of the
return springs. pump, the throttle shaft and the guide stud area.
17. S ta rt the engine and check for leaks. (Fig. 6A6-5). Place several rags in the engine valley
to catch fuel.
18. Idle roughness may be observed due to the air in the
9. Remove injection pum p cover and remove screws
pump, give it plenty of tim e to purge which it will do by
from the cover.
allowing the engine to idle. It m ay be necessary to shut
the engine down for several m inutes to allow air bubble NOTICE: E xtrem e care m ust be exercised to keep
to rise to the top of the pum p where they will be purged. foreign m aterial out of the pump when the cover is off.
19. Remove the intake m anifold screens, then reinstall the If any objects are dropped into the pump, they must be
air crossover and air cleaner. removed before the engine is started or injection pump
dam age or engine dam age could occur.
10. Observe position at m etering valve spring over the top
of the guide stud. T his position m ust be exactly
Throttle Shaft Seal Replacement
duplicated during reassembly. (Fig. 6A6-8).
1. Disconnect the negative cables from both batteries.
11. Remove the guide stud and washer. N ote location of
2. Rem ove the air cleaner and air crossover. Install parts prior to removal. (Fig. 6A6-5)
screens J-26996-2 (Calif.) or J-2 6 9 9 6 -10 (Exc. Calif.)
12. R otate the m in-m ax governor assembly up to provide
in the intake manifold.
clearance and remove from the throttle shaft. (Fig.
3. D isconnect the injection pum p fuel solenoid and 6A6-8). If idle governor spring becomes disengaged
(housing pressure cold advance if equipped) wires and from throttle block, it m ust be reinstalled with tightly
the fuel return pipe (Fig. 6A6-5). wound coils toward throttle block.
4. Remove the vacuum regulator valve, the throttle rod 13. Remove the throttle shaft assembly and exam ine the
and return springs. shaft for unusual wear or dam age, replace if required.
5. Remove the throttle cable bracket. It may be necessary to loosen the nuts at the injection
6. If injection pump is equipped with an Advance Cam pump m ounting flange and rotate the pum p slightly to
A ctuating Arm: allow the throttle shaft assembly to clear the intake
manifold.
14. E xam ine th e th ro ttle sh aft bushings in the pum p
housing for any evidence of dam age or unusual wear.
THROTTLE SHAFT .005" CLEARANCE Remove the pum p and send to the local Roosa M aster
ADVANCE CAM dealer if bushing replacem ent is necessary.
THROTTLE J-29601
15. Remove the throttle shaft seals. Do not attem pt to cut
SHAFT the seals to remove, as nicks in the seal seat will cause
PIN leakage.
16. Install new shaft seals using care not to cut the seals on
the sharp edges of the shaft. Apply a light coating of
clean chassis grease on the seals.
17. C arefully slide the throttle shaft back into the pump to
the point where the m in-m ax governor assembly will
slide back onto the throttle shaft. (Fig. 6A6-8)
ADVANCE CAM
ACTUATING ARM 18. R o ta te the m in-m ax governor assem bly dow nw ard,
hold in position and slide the th ro ttle shaft and
governor into position.
Fig. 6A6-9--lnjection Pump W ith Tool J-29601
19. Install a new fiber washer, the throttle shaft advance
Installed cam, (do not tighten cam screw at this tim e), and a new
LIGHT TRUCK SERVICE MANUAL
6A 6-6 V8 - DIESEL
EXHAUST MANIFOLD
Removal and Installation (Left Side)
1. Remove air cleaner and install air crossover screened
cover J-26996-1.
2. Remove lower generator bracket.
3. Hoist vehicle.
4. Remove crossover pipe.
5. Lower vehicle.
6. Remove exhaust manifold from above.
To install, reverse removal procedure. R efer to Fig.
6A 6 -13 for proper bolt torque.
COMPRESSION TEST
To determ ine if the valves or rings are the cause of low
com pression, a test should be m ade to determ in e the
cylinder compression pressure.
W hen checking compression, the batteries should be at
or near full charge. The lowest reading cylinder should not
be less than 70% of the highest and no cylinder reading
should be less than 275 p.s.i. (1900 kPa).
1. Remove air cleaner then install air crossover cover
J-26996-1.
2. Disconnect the wire from the fuel solenoid term inal of
the injection pump.
3. Disconnect wires from glow plugs then remove all glow
plugs.
4. Screw the compression gage J-26999 into the glow plug
hole of the cylinder th at is being checked.
5. C rank engine.
This should be done with six "puffs" per cylinder.
• N orm al-Com pression builds up quickly and evenly
to specified compression on each cylinder.
• Piston R ings Leaking-C om pression low on first
stroke tends to build up on following strokes but does
not reach normal.
NOTICE: Do not add oil to any cylinder to compression
test as extensive dam age may result.
Throttle Linkage
1. Check timing, adjust if needed.
2. If equipped with cruise control, remove clip from cruise
control throttle rod and disconnect the rod from the
throttle lever assembly.
CHECKING OR ADJUSTING TIMING
3. Disconnect the transm ission T.V. (or detent) cable
Checking (Fig. 6A6-14, 14a) from the throttle assembly.
For the engine to be properly timed, the m arks on the 4. Loosen the lock nut on the pum p rod and shorten
top of the injection pum p adapter and the flange of the several turns.
injection pump m ust be aligned. The engine m ust be off
when the timing is reset.
FUEL RETURN H O U S IN G P R E S S U R E
FUEL ELB0W
Adjusting SHUT-OFF
L IN E CONNECTOR COLD A D V A N C E
T ER M IN A L
If the marks are not aligned, adjustm ent is necessary. SO LE N O ID
(H ID D EN ) (H ID D EN )
1. Loosen the th re e pum p retain in g nuts w ith tool
SLOW IDLE
J-26987. A DJU ST M EN T
P R E-SET
DO NOT A D J U S T
2. Align the m ark on the injection pum p with the m arks SCREW
on the adapter and tighten nuts. Torque to 35 lbs. ft. P R E S S U R E TAP
(47N-m ). PLUG & SEA L
3. Put the seal from the pressure tap plug on the pressure
tap adapter J-29382, then screw the adapter into the
pump housing.
4. Screw pressure tap adapter J-28526 into pressure tap
adapter J-29382 then attach a low pressure gage to the
adapter.
5. Install m agnetic pick-up tachom eter J-26925.
6. Check the pressure with the engine running at 1000
R PM (P A R K ), parking brak e on, drive wheels
blocked. The pressure should be 8-12 PSI (55-83 kPa)
with not more than 2 PSI (14 kPa) fluctuation.
7. If equipped with H PC A and the pressure is zero, check
the operation of the houing pressure cold advance as
follows:
a. Remove the electrical connector from the housing
pressure cold advance term inal, Fig. 6A6-5. If the
pressure rem ains zero, remove the injection pump
cover and check the operation of advance solenoid. If
it is binding, free up or replace parts as needed.
b. If the pressure becam e norm al with lead off, check
the operation of the te m p e ra tu re switch on the
cylinder head bolt. See "D iesel E lectrical".
8. If the pressure is still incorrect, replace the fuel return
line connector assembly. If the pressure is too high, the
fuel retu rn system m ay be restricted . Remove the
return line at the injection pump. Install a fitting and
short piece of hose to allow the return flow to em pty into
a small container.
9. If th e pressure is lower th an before, correct the
restriction in the fuel line.
10. If still to high, replace the fuel return line connector
assembly.
11. If it rem ains too high, remove the injection pump for
repair.
12. Remove the tachom eter, pressure gage, and adapters.
13. Put a new pressure tap plug screw seal on the pressure
tap plug, then screw in the tap plug.
14. Remove screened covers, then install air crossover.
BREATHER CAP
AND VALVE ASSY.
Removal
All lines may be removed w ithout removing injection
pump. It is not necessary to use a back-up wrench when
removing the lines from pump.
1. Remove air cleaner. (Fig. 6A6-20 and 6A6-21).
2. Remove filters and pipes from valve covers and air
crossover.
3. Remove air crossover (Fig. 6A6-22, 6A6-23) and cap
intake manifold with J-26996-2 (Calif) and J-26996-
10 (exc. Calif) screened covers.
4. Remove injection pum p line clamps. C ap open lines,
nozzles, and pum p fittings. Use a back-up wrench on
the nozzle upper hex to prevent a fuel leak.
Installation
1. In stall new injection pum p line, install loose then
torque both ends. T orque pum p end to 35 lbs. ft.
(47N-m ) and nozzle end to 25 lbs. ft. (34 N-m ). Use a
back-up wrench on the nozzle upper hex to prevent
INJECTION PUMP FUEL LINES (Fig. 6A6-14,14a) nozzle dam age. Then install clamps.
W hen lines are to be removed, clean all line fittings • If several lines are to be replaced, sta rt with the
thoroughly before loosening. Im m ed iately cap all lines, bottom lines.
nozzles and pum p fittings to m aintain cleanliness.
2. S tart engine and check for fuel leaks.
LIGHT TRUCK SERVICE MANUAL
6A 6-12 V8-D IE SE L
Removal
1. Remove air cleaner.
2. Remove filters and pipes from valve covers and air
crossover.
3. Remove air crossover and cap intake m anifold with
J-26996-2 (C alif) or J-26996-10 (Exc. Calif.) screened
covers.
4. Disconnect throttle rod and return spring. (Fig. 6A6-16
and 6A6-26).
5. Remove bellcrank.
6. Remove throttle and T.V. cables from intake manifold
brackets. Position cable away from engine.
Installation
1. C oat both sides of gasket sealing surface th at seal the
intake manifold to the head with # 1 0 5 0 8 0 5 sealer, or
equivalent, and position intake manifold gasket. (Fig. Fig. 6A6-37--lntake Manifold Drain Tube
6A6-35).
2. Install end seals, m aking sure th a t ends are positioned
under cylinder heads.
3. Position intake manifold on engine and connect th er
m ostat bypass hose to w ater pump.
ADAPTER
SEAL
ADAPTER
LUBRICATE SEAL TOOL ADAPTER & MANIFOLD
''C ^
Fig. 6A6-38--lnstalling A dapter Seal
VACUUM PUMP
(OIL PUMP DRIVE)
ENGINE ENGINE
V IE W A
VALVE CLOSED VALVE OPEN
Removal
Cleaning and Inspection
Valve lifters and push-rods should be kept in order so
they can be reinstalled in their original position. The push A fter lifters are disassem bled, all p arts should be
rods have a "w ing" at the upper end so the push rod can cleaned in clean solvent. A small particle of foreign m aterial
only be installed one way. This is necessary as the ball under the check valve will cause m alfunctioning of the lifter.
hardness is not the sam e on both ends. Some engines will Close inspection should be made for nicks, burrs or scoring
have both standard and .010" oversize valve lifters. The of parts. If either the roller body or plunger is defective,
.010" oversize lifter is etched " 0 " on the side of the lifter. replace with a new lifter assembly.
W henever lifters are removed, check as follows: NOTICE: Do not rotate the engine until the valve lifters
1. Roller should rotate freely, but without excessive play. have been bled down, or dam age to the engine will
occur.
2. Check for missing or broken needle bearing.
3. Roller should be free of pits or roughness. If present,
check cam sh aft for sim ilar condition. If pits or
roughness are evident, replace lifter and cam shaft.
Valve Lifter Diagnosis
1. M om entarily Noisy W hen Vehicle Is Started:
Assembly This condition is normal. Oil drains from the lifters
which are holding the valves open when the engine is
1. C oat all lifter parts with a light coating of clean engine
not running. It will take a few seconds for the lifters to
oil.
fill after the engine is started.
2. Assem ble valve disc spring and retainer into plunger.
2. In te rm itte n tly N oisy On Idle O nly, D isappearing
(Fig. 6A6-45). M ake sure retainer flange is pressed
W hen Engine Speed Is Increased:
tight against bottom of recess in plunger.
Interm ittent clicking may be an indication of a pitted
3. Install plunger spring over check retainer. check valve disc, or it may be caused by dirt.
4. Hold plunger with spring up and insert into lifter body. Correction: Clean the lifter and inspect. If check valve
Hold plunger vertically to prevent cocking spring. disc is defective, replace lifter.
5. Install oil m etering valve and push rod seat into lifter 3. Noisy A t Slow Idle O r W ith H ot Oil, Q uiet W ith Cold
and install retaining ring. Oil O r As Engine Speed Is Increased:
Leak check the suspected lifters and replace any lifters
VALVE LIFTER BLEED DOWN th at do not meet specifications.
If the intake m anifold has been removed and if any 4. Noisy A t High C ar Speeds A nd Q uiet A t Low Speeds:
rocker arm s have been loosened or removed; it will be a. High oil level-Oil level above the " F u ll" m ark allows
necessary to remove those valve lifters, dissassemble, drain crankshaft counterw eights to churn the oil into foam.
the engine oil then reassem ble the lifters. See "V A LV E W hen foam is pumped into the lifters, they will
L IF T E R D IS A S S E M B L Y ". become noisy since a solid colum n of oil is required
If the intake m anifold has not been removed but rocker for proper operation.
arm s have been loosened or removed, valve lifters can be Correction: D rain oil until proper level is obtained.
bled down by the following procedure: See P E R IO D IC M A IN T E N A N C E Section.
1. Before installing any removed rocker arm s, rotate the b. Low oil level - Oil level below the "A d d " m ark
engine crankshaft to a position of No. 1 cylinder being allows air to the pump at high speeds which results in
32° before top dead cen ter. T his is 13mm ( 1 /2 " ) noisy lifters.
beyond the end of the tim ing indicator. It may be Correction: Fill until proper oil level is obtained. See
necessary to remove No. 1 cylinder’s glow plug to P E R IO D IC M A IN T E N A N C E Section.
determ ine if the position of the piston is the correct one. c. Oil pan bent on bottom or pump screen cocked,
The compression pressure will tell you th a t you are in replace or repair as necessary.
the right position. 5. Noisy A t Idle Becoming Louder As Engine Speed Is
NOTICE: Use only hand wrenches to torque the rocker Increased To 1500 rpm:
arm pivot bolt to avoid engine dam age. This noise is not connected with lifter m alfunction. It
becomes most noticeable in the vehicle at 10 to 15 mph
2. If removed, install the N o. 5 cylinder pivot and rocker
(16 to 24 k m /h ) " L " range, or 30 to 35 mph (48 to 56
arm s. Torque the bolts alternately between the intake km /h) "D " range and is best described as a hashy
and exhaust valves until the exhaust valve begins to sound. A t slow idle, it may be entirely gone or appear as
open, then stop.
3. Install rem aining rocker arm s but w atch No. 3 intake
and N o. 8 intake valves (if these rocker arm s were
removed) as the pivot bolts are being torque.
4. Do not torque No. 3 and No. 8 intake valve pivots
beyond the point th a t the valve would be fully open.
This is indicated by strong resistance while still turning
the pivot retaining bolts. Going beyond this would bend
the push rod. T orque the bolts S L O W L Y allowing the
lifter to bleed down.
5. Finish torquing N o. 5 cylinder rocker arm pivot bolt
SL O W L Y . Do not go beyond the point th a t the valve
would be fully open. T his is in d icated by strong
resistance while still turning the pivot retaining bolts.
Going beyond this would bend the push rod.
6. DO N O T turn the engine crankshaft for at least 45
minutes.
7. Finish reassem bling the engine as the lifters are being
bled. Fig. 6A6-46--C hecking Valve Spring
a light ticking noise in one or more valves. It is caused possible valve to piston in terference, due to close
by one or m ore of the following: tolerances, could exist.
a. Badly worn or scuffed valve tip and rocker arm pad. 2. Install lifters and push-rods into original position in
b. Excessive valve stem to guide clearance. cylinder block. See note under Removal.
c. Excessive valve seat runout. 3. Install manifold gaskets and manifold.
d. Off square valve spring. 4. Position rocker arm s, pivots and bolts on cylinder head
e. Excessive valve face runout. as shown in Fig. 6A6-40.
f. Valve spring dam per clicking on rotator. 5. Install valve covers.
To check valve spring and valve guide clearance, 6. Install intake m anifold assembly.
remove the valve covers:
a. Occasionally this noise can be elim inated by rotating
the valve spring and valve. C rank engine until noisy GLOW PLUG
valve is off its seat. R otate spring. This will also
rotate valve. R epeat until valve becomes quiet. If A burned out FA ST G LO W glow plug tip may bulge
correction is obtained, check for an off square valve then break off and drop into the pre-cham ber when the glow
spring. If spring is off square m ore th an 1 /1 6 " plug is removed. W hen this occurs, the cylinder head must
(1.6m m ) in free position, replace spring. (Fig. 6A6- be removed and the pre-cham ber removed from the head to
46). remove the broken tip.
b. C heck for excessive valve stem to guide clearance. If
necessary, correct as required. DIESEL INJECTION NOZZLE TESTING
6. Valves N oisy R egardless O f E ngine Speed: This W hen a m alfunction occurs where the injection nozzles
condition can be caused by foreign particles or exces are suspected as the cause, they may be tested as follows:
sive valve lash.
Check for valve lash by turning engine so the piston in
th a t cylinder is on top dead center of firing stroke. If
valve lash is present, the push-rod can be freely moved
up and down a certain am ount with rocker arm held
against valve. If OK, clean suspected valve lifters.
Valve lash indicates one of the following:
a. W orn push-rod.
b. W orn rocker arm .
c. L ifter plunger stuck in down position due to dirt or
carbon.
d. Defective lifter.
Checking of the above four items:
1. Look at the upper end of push-rod. Excessive wear of
the spherical surface indicates one of the following
conditions.
a. Im proper hardness of the push-rod ball. T he push-
rod and rocker arm m ust be replaced.
b. Im proper lubrication of the push-rod. The push-rod
and rocker arm m ust be replaced. The oiling system
to the push-rod should be checked.
2. If push-rod appears in good condition and has been
properly lubricated, replace rocker arm and recheck
valve lash.
3. If valve lash exists and push-rod and rocker arm are
okay, trouble is in the lifter. L ifter should be replaced.
Installation
C oat the roller and bearings of lifter with # 1052365
lubricant or equivalent.
P rim e new lifters by w orking lifter plunger while
subm erged in new kerosene or diesel fuel. Lifter could be
dam aged if dry when starting engine
1. W hen a rocker arm is loosened or removed, valve lifter
bleed down is required. R efer to "V A L V E L IF T E R
B L E E D D O W N ". L ifters m ust be bled down as
LIGHT TRUCK SERVICE MANUAL
6A 6-20 V 8 - DIESEL
Test Preparation
To ensure correct preparation of the nozzle for testing,
the following procedure should be performed.
1. Clean the carbon from the tip of the nozzles with a
brass wire brush. Do not use motorzed brush or a steel
wire brush as they could dam age the nozzle tip.
Diesel fuel should never be used as a test fluid. It is
recom m ended th at SA E J967D or equivalent be used.
M ake sure th at the tester reservoir has a sufficient
am ount of fluid to complete test.
A t this point the proper connecting adapter to be used
from th e nozzle to the te ste r should be selected
(adapters are available from the tester m anufacturer).
Connect the nozzle to the tester (available tool) with
the tip pointing down.
Testing Procedure
CAUTION:When testing nozzles, do not place your
hands or arms near the tip of the nozzle. The high
pressure atomized fuel spray from a nozzle has
sufficient penetrating power to puncture flesh and
may result in blood poisonging and/or damaged
tissue. The nozzle tip should always be enclosed in
12 FT. LBS.
a receptacle, preferably transparent, to contain
(16 N-m) the spray.
To test the perform ance of the nozzle, the following
items should be checked as described.
25 FT. LBS. 1. Opening pressure test
(34 N-m) Close the pressure gage valve and flush the nozzle by
operating the test pump rapidly. Open the gage valve
NOZZLE and raise the pressure slowly until the nozzle opens.
(TORQUE MUST BE (The gage reading will drop sharply at this point.) The
APPLIED TO LARGEST nozzle opening pressure will be the m axim um gage
NOZZLE HEX) pressure observed and should be within the following
limit: 1750 PSI to 1900 PSI.
2. Spray pattern test
Fig. 6A6-48a~lnjection Nozzle Installation Close the pressure gage valve. O perate the tester at
Injection Nozzle Removal (With Lines Removed) approxim ately 30 strokes per m inute (one strke every
two seconds) and observe spray pattern.
Roosa-Master CAUTION:Test fuel spray is flam mable. Keep
vapor aw ay from open flames or personal injury
Removal could result.
1. Remove the fuel retu rn line clam ps from all nozzles on When testing nozzles, do not place your hands or
the bank where a nozzle is to be removed then remove arms near the tip of the nozzle. The high pressure
th a t fuel return line. atomized fuel spray from a nozzle has sufficient
penetrating power to puncture flesh and destroy
2. Remove nozzle spring clam p and spacer; then remove
tissue and may result in blood poisoning. The
nozzle using tool J-29082.
nozzle tip should always be enclosed in a recepta
3. Cap the nozzle inlet line and the tip of the nozzle. cle, preferably transparent, to contain the spray.
The nozzle should have a finely atom ized cloud-like
Installation pattern. The pattern should not be streaky with tester
1. If a nozzle is to be reinstalled after removal, a new fluid. Refer to Figure 6A6-49.
compression seal and carbon stop seal m ust be installed 3. Seat tightness test
after removal of the used seals. See Figure 6A6-47 for W ith the nozzle top pointed downward and the gage
seal installation. valve closed, operate the tester rapidly to firmly seat the
2. Remove protective caps then install injection nozzle valve. Dry the nozzle tip thoroughly. Open the gage
and spring clam p and spacer. T orque bolt to 25 lb. ft. valve and raise the pressure to 1300-1400 P S I/ W hile
(34 N -m ) (Fig. 6A 6-48). holding this pressure, a drop of tester fluid should not
form on the tip within ten seconds.
3. Install fuel return line. Slight dam pness, however, is perm issable with a used
4. Start engine and check for leaks. nozzle.
LIGHT TRUCK SERVICE MANUAL
V8-D IE SE L 6A6-21
T ~
IN T A K E V A L V E
V
FACE A N G LE IN T A K E V A L V E
SEAT A N G LE
E XH AUST V A L V E
EXH AUST V A L V E
FACE A N G LE
SEAT A N G LE
Reaming
3. Install Tool J-5892-1 (Fig. 6A6-61) and compress the
Before attem pting to ream the valve guide bores they valve spring until valve keys are accessible; then remove
should be cleaned using Tool J-8101 as shown in Fig. 6A6- keys, valve rotators and springs. If valve spring does not
59. compress, tap tool with a m allet to break bind at rotator
This procedure to ream valve guide bores is shown in and keys.
Fig. 6A6-60. Use care to hold ream er straight in valve guide
bore.
Checking Rotators
VALVE SPRING (HEAD ON ENGINE)
T he ro tato rs cannot be disassem bled and require
To replace a worn or broken valve spring w ithout
removing the cylinder head proceed as follows: replacem ent only when they fail to rotate the valve.
R otator action can be checked by applying a daub of
paint across the top of the body and down the collar. Run
Removal engine approxim ately 1500 rpm. There should appear to be
1. Remove rocker arm assemblies. motion between the body and collar; the body will appear to
2. R otate engine so piston is at top dead center for each "w alk" around the collar. R otator action can be either
cylinder. clockwise or counterclockwise. Sometimes on removal and
LIGHT TRUCK SERVICE MANUAL
6A 6-26 V8 - DIESEL
OIL PUMP
Removal
1. Remove oil pan.
2. Remove the oil pum p to rear main bearing cap a tta c h
ing bolts, then remove pum p and drive shaft extension.
Installation
1. Install valve spring and rotator. Using Tool J-5892-1,
compress the valve spring until the valve keys can be
installed.
2. Install rocker arm assemblies.
3. Bleed valve lifters w here rocker arm pivots were
loosened. R efer to "V A L V E L IF T E R B L E E D
D O W N ".
OIL PAN
Removal
1. Remove oil pum p drive and vacuum pump.
2. Disconnect b attery cables. Remove dipstick.
3. Remove upper radiato support and fan shroud a ttac h
ing screws.
4. H oist the car and drain oil.
5. Remove flywheel cover.
LIGHT TRUCK SERVICE MANUAL
V 8 - DIESEL 6A 6-2 7
1. Remove the oil pump drive shaft extension. 1. Insert the drive shaft extension through the opening in
the main bearing cap and block until the shaft m ates
2. Position thum b over pressure regulator bore before into the vacuum pum p driven gear.
removing cotter pin, as the spring is under pressure. 2. Position pum p onto the rear main bearing cap and
Then remove the cotter pin, spring and the pressure install attaching bolts. Torque bolts to 35 lb. ft. (47
regulator valve. N-m) (Fig. 6A 6-65).
3. R em ove th e oil pum p cover a tta c h in g screws and 3. Install the oil pan. R efer to O IL PAN Installation.
remove the oil pump cover and gasket.
4. Remove the drive gear and idler gear from the pump
body.
CONNECTING ROD AND PISTON
Removal
Inspection
1. Remove intake m anifold, head or heads.
Check the gears for scoring or other dam age. If they 2. Remove oil pan.
are dam aged, new gears should be installed. D uring assem
3. Remove oil pum p assembly.
bly, the gear end clearance should be gaged. Proper end
4. S tam p cylinder num ber on the m achined surfaces of
clearance is .0005" to .0075". Also check the pressure
the bolt bosses of the connecting rod and cap for
regulator valve, valve spring and bore for dam age. Proper identification when reinstalling. If the pistons are to be
valve to bore clearance is .0025 " to .0050". The checking of rem oved from the connecting rod, m ark cylinder
gear end clearance will be covered in "A ssem bly". Check num ber on piston with a silver pencil or quick drying
the extension shaft at each end for abnorm al wear. The shaft paint for proper cylinder identification and cap to rod
is h ard en ed a t both ends and identified by a red dye location. The right bank is num bered 2-4-6-8, left bank
m arking. 1-6-5-7.
5. Exam ine the cylinder bore above ring travel. If ridge
Assembly exists, remove ridge with ridge ream er before a ttem p t
1. Install the gears and shaft in the oil pump body and ing to remove the piston and rod assembly.
check the gear end clearance by placing a straight edge 6. Remove rod bearing cap and bearing.
over the gears and m easure the clearance between the 7. Install guide hose over threads of rod bolts. This to
straight edge and the gasket surface. The clearance prevent dam age to bearing jo u rn al and rod bolt
should be betw een .0 0 0 5 " to .0 0 7 5 ". If the end threads. (Fig. 6A 6-66).
clearance is to the high lim it, check for scores in the 8. Remove rod and piston assembly through the top of the
cover th a t would bring the total clearance over the cylinder bore.
specified am ount. 9. Remove other rod and piston assemblies in the same
m anner.
2. Install the cover screws and tighten alternately and
evenly. The torque is 8 lbs. ft. (1 lN -m ).
3. Position the pressure regulator valve into the pump ROD BEARINGS
cover, closed end first, then install th e spring and
The connecting rod bearings are designed to have a
retaining pin.
slight projection above the rod and cap faces to insure a
4. Assemble the drive shaft extension to the drive shaft. positive contact.
Honing
1. W hen cylinders are being honed, follow the m anufac
tu re r’s recom m endations for the use of the hone.
2. Occasionally during the honing operation, the cylinder
bore should be thoroughly cleaned and the selected
piston checked for correct fit.
3. W hen finish honing a cylinder bore, the hone should be
moved up and down at a sufficient speed to obtain very
fine uniform surface finish m arks in a cross hatch
pattern of approxim ately 45 to 65 degrees included
angle. The finish m arks should be clean but not sharp,
free from imbedded particles and torn or folded metal.
4. Perm anently m ark the piston for the cylinder to which
it has been fitted and proceed to hone the rem aining
cylinders.
NOTICE: H andle pistons with care. Do not attem pt to
force pistons through cylinders until the cylinders have
been honed to correct size. Pistons can be distorted
through careless handling.
5. Thoroughly clean the bores with hot w ater and deter
gent. Scrub well with a stiff bristle brush and rinse
thoroughly with hot w ater. It is extrem ely essential that
a good cleaning operation be performed. If any of the
abrasive m aterial is allowed to remain in the cylinder
bores, it will rapidly wear the new rings and cylinder
bores. The bores should be swabbed several tim es with
light engine oil and a clean cloth and then wiped with a
clean dry cloth. C Y L IN D E R S S H O U L D N O T BE
C L E A N E D W IT H K E R O S E N E O R G A S O L IN E .
Clean the rem ainder of the cylinder block to remove the
excess m aterial spread during the honing operation.
Side Clearance
Each ring m ust be checked for side clearance in its
respective piston groove by inserting a feeler gage between
the ring and its upper land. (Fig. 6A6-74). The piston
grooves m ust be cleaned before checking ring for side
clearance. See Piston Ring C learance C hart. To check oil
ring side clearance, the oil rings m ust be installed on the
piston.
Ring Installation
For service ring specifications and detailed installation
instructions, refer to the instructions furnished with the
parts package.
Ring Tolerances
W hen installing new rings, ring gap and side clearance
should be checked as follows:
W hen m ore than one rod and piston is being installed, Fig. 6A6-79--Connecting Rod Side Clearance
the connecting rod cap a tta c h in g nuts should only be
tightened enough to keep each rod in position until all have PISTON PINS
been installed. This will facilitate installation of rem aining The piston pin is free floating and the correct fit in the
piston assemblies. piston is .0003 " to .0005 " and rod is .0003 " to .0013 " loose.
T he cle a ra n ce betw een th e a d ja c e n t rods, when If the pin to piston clearance is to the high lim it (.0005"
checked with a feeler gage on each crankpin, should be from piston or .0013" rod)., the pin can be inserted in the piston
.006" to .020 " .(F ig . 6A6-79). or rod with very little hand pressure and will fall through the
piston or rod by its own weight. If the clearance is .0003",
5. Torque rod bolt nuts to 42 lbs. ft. (57 N-m ).
LIGHT TRUCK SERVICE MANUAL
6A 6-32 V8 - DIESEL
the pin will not fall through. It is im portant th a t the piston BALANCER
and rod pin hole be clean and free of oil when checking pin
fit. Removal
The rod may be installed in the piston with either side 1. Remove belts and crankshaft pulley.
facing up. 2. Remove balancer hub bolt and washer.
W henever the replacem ent of a piston pin is necessary, 3. Using balancer puller, remove balancer as shown in
remove the snap ring retaining the pin. Then remove the pin. Fig. 6A6-80.
NOTICE: Use of any o th er type puller such as a
It is very im portant th a t after installing the piston pin
retaining snap rings th at the rings be rotated to make sure universal claw type which pulls on the outside of the
they are fully seated in their grooves. hub can destroy the harm onic balancer. The outside
ring of the balancer is bonded in rubber to the hub; by
pulling on the outside, rath er than the hub, it is possible
CRANKSHAFT PULLEY to break the bond. The T .D .C . slot is on the outside ring
of the balancer; if the bond between the hub and the
Removal
outside ring is broken, the outside ring could slip which
1. Remove belt(s). would change the location of the slot mark. If it is
suspected th at the bond between the sections of the
2. Hoist vehicle.
harm onic b alancer has been broken and the slot
3. Remove pulley bolts and pulley. changed, it can be visually checked as shown in Fig.
6A6-81 The center of the keyway should be approx
Installation imately 16° from the center of the tim ing slot. In
1. Install pulley, and bolts. Torque to 20 lbs. ft. (27 N-m). addition, there are chisel aligning m arks between the
weight and hub, m arks should be together.
2. Install belt(s). A djust belts using Tool J-23600.
Installation
1. A pply sealer # 1 0 5 0 8 0 5 , or equivalent, to inside
diam eter of pulley hub and to crankshaft key to prevent
possible oil leakage. C oat outside area of crankshaft
pulley hub w hich enters seal w ith seal lu b rican t
# 1050169, or equivalent.
2. Install balancer on crankshaft. Balancer to crankshaft
fit is .001 " tight to .007 " loose.
3. Install washer and bolt. Torque 200-310 lb. ft. (271 -
420 N -m ).
4. Install pulley and belts. A djust belts using belt adjust
ing gage J-23600. Torque pulley bolts to 10 lb. ft.
(14N-m).
FRONT COVER
Removal
1. D rain cooling system. Disconnect radiator hoses and
bypass hose.
2. Remove all belts, fan and fan pulley, crankshaft pulley
and harm onic balancer, and accessory brackets.
3. Remove cover to block attaching bolts and remove
cover, tim ing indicator and w ater pum p assembly.
4. Remove front cover and both dowel pins. It may be
necessary to grind a flat on the pins to get a rough
surface for gripping.
Installation
1. G rind a cham fer on one end of each dowel pin as shown
in Fig. 6A6-82.
2. C ut excess m aterial from front end of oil pan gasket on
each side of engine block.
3. Clean block, oil pan and front cover m ating surfaces
with solvent.
4. Trim about 1/8" (3m m ) from each end of new front
pan seal, using a sharp tool as shown in Fig. 6A6-83.
LIGHT TRUCK SERVICE MANUAL
V8 - DIESEL 6A 6-33
Downward
INJECTION P U M P D R IV E
GEAR - P U SH CAM
A G A IN S T REAR CUP
PLUG
KEY
CRANKSHAFT SPROCKET
35 FT. LBS. CAM SH A FT SPROCKET
GASKET
(47 N-m I T IM IN G C H A IN
1 FT. LBS.
CRANKSHAFT O IL SLINGER
(30 N-m)
(SEAL TWO LOWER
5. Install new front cover gasket on engine block and new WATER P UM P BOLTS)
front seal on front cover. Apply 1050805 or equivalent
sealer to gasket around coolant holes and place on
block.
Fig. 6A6-86--E ngine Front Cover Bolts
11. Install tim ing in d icato r and w ater pum p assem bly.
Then torque bolts evenly as shown in Fig. 6A6-86.
12. Apply lubricant # 1 0 5 0 1 6 9 or equivalent on balancer
seal surface.
13. Install balancer and balancer bolt. Torque from 200-
3101b. ft. (271-420N -m ).
14. Install necessary brackets.
15. Connect bypass hose and radiator hoses.
16. In stall c ra n k sh a ft pulley and four a tta c h in g bolts.
Torque to 20 lbs. ft. (27 N -m ).
17. Install fan pulley, fan and four attaching bolts. Torque
bolts to 20 lbs. ft. (27 N-m ).
18. Install belts and adjust, using Tool J-23600.
19. Fill radiator.
20. Road test vehicle and check for leaks. Use of spray foot
powder or equivalent m ay aid in detecting leaks.
OIL SEAL
Removal (Front Cover Installed)
1. Rem ove th e c ra n k sh a ft balan cer, See "B alan cer
R em oval."
2. Remove oil seal.
PO SIT IO N AT
20. If necessary to rem ove pum p driven gear, rem ove
'3 O'CLOCK
injection pump adapter, then remove snap ring and 'S '
selective washer. Remove the driven gear and spring.
21. Remove cam shaft by carefully sliding it out the front of
CRANKSHAFT AND
the engine. Do not force shaft as dam age can occur to CAMSHAFT SPROCKET
cam shaft bearings. R efer to Fig. 6A6-86 for cam shaft T IM IN G CH A IN
identification. GASKET
35 FT. LBS.
CRANKSHAFT O IL SLINGER
22. If cam bearings are being replaced, it is necessary to
22 FT. LBS.
remove oil pan. Refer to "O IL P A N R E M O V A L ".
ENGINE T IM IN G INDICATOR
UNIT REPAIR
ENGINE
Removal
1. D rain cooling system.
THREAD
2. Remove air cleaner and install screened cover J-26996-
PROTECTORS
1.
3. Remove hood from hinges, m ark hood for reassembly.
4. Disconnect battery negative cables at batteries and
ground wires at inner fender panel. Disconnect engine
ground strap.
5. Disconnect radiator hoses, cooler lines, heater hoses,
vacuum hoses, power steering pum p hoses at power
/ RUBBER
steering gear, air conditioning com pressor with brack " 'V B A N D S
ets and hoses attached, fuel hose from fuel pump and
wiring. NOTE O VERLA P
6. Remove hairpin clip at bellcrank. OF ADJACENT RODS
Installation R.H. O IL
P ASSAG E PLUG
1. Measure the crankshaft journals and crankpins with a
micrometer to determine the correct size rod and main
bearings to be used.
.^ .p .p f M Q .O - O llP A S S A C E
• W henever a new or reconditioned crankshaft is
installed, new connecting rod bearings and main L H . O IL / y
i \
\ C U P P lU G
L H. O IL
MAIN BEARINGS
Main bearing clearance must not exceed .0035" on all
bearings. The .0035" clearance is permissible only if the
LIG H T T R U C K SE RV IC E M A N U A L
V8 - DIESEL 6A6-39
8. Install lower flex plate cover. Fig. 6A6-103--Engine Oil Dipstick Identification
LIG H T T R U C K SERVICE M A N U A L
DRIVE AND VACUUM PUMPS
GENERAL DESCRIPTION
The vacuum pump is used to provide vacuum The vacuum pump is driven two ways, gear driven
required for some accessories. It is a diaphragm and belt driven. The gear driven pump has a drive
pump which needs no periodic maintenance. It is gear on the lower end which meshes with the cam
driven by a cam inside the drive assembly to which it shaft gear in the engine. This drive gear causes the
mounts. The pump’s diaphragm moves back and cam in the drive housing to rotate. The drive gear
forth causing air to flow into the inlet tube, through also powers the engine oil lubricating pump. The
the pump, and exhaust out the rear port. belt driven pump has a pulley attached to the shaft
at the lower end of the housing assembly. The
pump pulley is driven off the belt cluster at the front
of the engine.
CAUTION: Do not operate engine
Fig. 6A6-104--Vacuum
K ey N o. P a rt N a m e
D R IV E G EAR 1 — PU M P ASSY, V A C U U M
2 — SCREW , HEX.H E A D T A P P IN G Key No. Part Name
3 — SEAL, “O" RING 1 — PU M P AS SY , V A C U U M
4 — DR IVE ASSY, V A C U U M PU M P 2 — SC REW , HE X H E A D T A P P IN G
3 — SEAL, “O ” R IN G
4 — D R IV E AS SY , V A C U U M PU M P
5 — B O LT AS SY , SE AL &
O ” R IN G S E A L
D RIVE & V A C U U M
PU M P A S S E M B LY
BO LT
Install Seal “O" Ring
S c re w s s h o u ld be
tig h te n e d e v e n ly a n d to a
to rq u e o f 12 N *m
(9 Ft. L bs.) j
T h e b e a rin g a s s e m b ly in th e b e lt
d riv e n p u m p n e e d s lu b ric a n t.
T h is s h o u ld be c h e c k e d a n d k e p t fille d
a t a ll tim e s (see b e lo w ).
Seal a n d b o lt a s s e m b ly
tig h te n to 4 to 6 N «m
(4 Ft. Lbs.)
T h e s h a ft s h o u ld
be fre e to tu rn w h e n
in s ta llin g th e
s c re w s to th e p u m p
a s s e m b ly .
LIG H T TR U C K SE R V IC E M AN U AL
6A6-44
GENERAL DATA: PISTON PIN LF9
TYPE V -8 D IE S E L DIAMETER 1 .0 9 4 9 -1 .0 9 5 3
V8 - DIESEL
DISPLACEMENT 5 .7 (N ) PRODUCTION .0 0 0 3 -.0 0 0 5
LITRE {*) CLEARANCE
SERVICE N .A .
BORE 4 .0 5 7
CRANKSHAFT
STROKE 3 .3 8 5
DIAMETER i A rtH
4 .0 5 6 -4 .0 5 8 SERVICE N .A .
THRUST # 1 -2 -3 -4
N .A .
PRODUC SIDE .0 0 0 5 -.0 0 2 1
MAIN
TAPER TION RELIEF BEARING #5
N .A .
SIDE CLEARANCE .0 0 1 5 -.0 0 3 1
SERVICE N .A . SERVICE N .A .
* V IN D e s ig n a tio n
TORQUE SPECIFICATIONS
Ib. ft. N-m
Injection Pump A tta ch ing Nuts ...................... .......... 19. .___ 26
Injection Line Nut To Pum p .................. ..........25. ■ . . . 34
Injection Pum p A da pter B o lts .................... .......... 25- • . . . 34
Injection Line Nut To N o z z le ............ .......... 25- . . . . 34
Injection Pum p Fuel Filter Inlet L in e .............. ..........20. . . . . 27
V A L V E SYSTEM LF9 Injection Pum p Fuel Filter O utlet L i n e .......... ..........18. . . . . 24
Injection Pum p Fuel Inlet Line ........................ ..........20. . . . . 27
LIFTER HYDRAULIC
Injection Nozzle H old-D ow n C la m p ................ ..........25. . . . . 34
ROCKER ARM RATIO N.A. G lo w P lu g .............................................................. ..........12. . . . . 16
Crankshaft Bearing Cap B o lts .......................... ........120. . , . 163
VALVE INTAKE NON- Flywheel To C o n v e rte r...................................... ..........40. . . . . 54
LASH ADJUSTABLE
EXHAUST Flywheel To C rankshaft .................................... ..........60. . . . . 81
Oil Pum p To Bearing Cap B o lt s ...................... ..........35. . . . . 47
FACE ANGLE (INT. & EXH.) @
Oil Pum p Cover To Pum p B o lt s ...................... ............8. . . . . 11
SEAT ANGLE (INT. & EXH.) * Rocker A rm Pivot B olt To H e a d ...................... ..........28 . . . . 38
SEAT RUNOUT .003 Valve Cover Bolts Fully Driven, Seated, Not Stripped
Oil Pan Bolts ........................................................ ..........10. . . . . 14
</> SEAT INTAKE .075.098 Oil Pan Drain Plug .............................................. ..........30. . . . . 41
T5
WIDTH EXHAUST .037-.075 Crankshaft Balancer To C rankshaft Bolt . . . . .200-310. . 2 7 1 -4 ;
Oil Filter Elem ent To B a s e ................................ ..........20 - . . . . 27
INT. .0010-.0027
PRODUCTION Oil Filter A ssem bly To C ylinder Block Bolts . ..........35- • . . . 47
STEM
EXH. .0015-.0032 Oil C ooler Lines To Oil Filter Base ................ ..........12- ■ . . . 16
CLEARANCE
SERVICE N.A. Oil C ooler Lines To R a d ia to r............................ ..........25- • . . . 34
S upport/F ront Cover To C ylinder Block
FREE LENGTH 2.09
Bolts 3/8" .............................................................. ..........35- • . . . 34
PRESSURE CLOSED 85-95 @ 1.670 Fan Driven Pulley To Hub B o lt s ...................... ..........20 . . . . . 27
VALVE
LBS. e IN. Fan D riving Pulley To Balancer B o lt s ............ ..........20. . . . . 27
SPRING OPEN 203-207 @ 1.300
W ater Pum p To Front Cover Bolts ................ ..........13. - . . . 18
(OUTER)
INSTALLED HEIGHT W ater O utlet To M anifold B o lt s ...................... ..........20. . . . . 27
N.A.
*lntake M a n ifold To C ylinder Head Bolts . . . ..........40. . . . . 54
± 1/32"
Exhaust M a n ifold To C ylinder Head Bolts .. ..........25. . . . . 34
FREE LENGTH N.A. Engine M o u n t To C ylinder Block Bolts ........ ..........75. . . . 102
DAMPER Engine M o u n t To Frame M o u n t...................... ..........50. . . . . 68
APPROX. # OF COILS N.A.
Starter To C ylinder Block Bolts ...................... ..........35. . . . . 47
@ — 44° INTAKE — 30° EXHAUST Starter Brace To C ylinder Block Bolts .......... ..........25. . . . . 34
* — 45° INTAKE — 31° EXHAUST S tarter Brace To Starter B o lt............................ ..........15. . . . . 20
Vaccum Pum p C lam p To C ylinder Block Bolt ........ 17. . . . . 23
*C ylin d e r Head B o lts .......................................... ........130. . . . 176
LIGHT
SECTION 6B
ENGINE COOLING
CONTENTS
General Description......................................................... .6B-1 On Vehicle S ervice........................................................... 6 B -1 1
Coolant Level.................................................................. ..6 B -1 Water Pump..................................................................... 6B-11
Thermostat................. ..................................................... ..6B-2 Thermostat....................................................................... 6B-11
Drive B elts....................................................................... .6B-7 Radiator............................................................................ 6B-12
Diagnosis...............................................................................6B-7 Fan Shroud...................................................................... 6B-12
System C hecks................................................................ .6B-7 Fan/Fan C lutch.............................................................. 6B-12
O verheat/N oise............................................................... ..6B-7 Coolant Recovery Bottle............................................... 6B-13
Fan C lu tch....................................................................... .6B-8 Engine Oil C ooler........................................................... 6B-14
GENERAL DESCRIPTION
All Chevrolet Light Duty Trucks have pressure type while the engine is at normal operating temperature. The
engine cooling systems with thermostatic control of coolant radiator cap need not normally be removed.
circulation. The cooling system is sealed by a pressure type The coolant level should be at the "Full Cold" mark
radiator filler cap which causes the system to operate at when the system is cool or at ambient temperature. After
higher than atmospheric pressure. The higher pressure the vehicle has been driven sufficiently to obtain normal
raises the boiling point of the coolant which increases the operating temperatures, the level should be above the "Full
cooling efficiency of the radiator. The 15 pound (103 kPa) Cold" mark.
pressure cap used raises the boiling point of coolant to
approximately 258° F (125°C) at sea level. Periodically, the radiator cap should be removed to
observe coolant level in the radiator.
The radiator cap should be washed with clean water
and pressure checked every 12 months. CAUTION:The radiator coolant level should only
All models have a closed cooling system using a round be checked when the engine is cool. If the radiator
pressure cap (Fig. 6B-1) and a coolant reservoir. Coolant cap is removed from a hot cooling system, serious
can be added without removing the radiator cap. personal injury may result.
A pressure-vacuum valve radiator cap is used which Coolant levels in crossflow radiators with coolant
allows the coolant to expand through the pressure valve in recovery bottles should be maintained to the top of the filler
the center of the cap without building unnecessary pressure. neck.
The expanding coolant flows into the coolant reservoir. The The recovery bottle should be at its appropriate mark
vent valve closes due to expansion and coolant flow. The when checked.
nominal 15 pound (103 kPa) pressure will not be reached
Regardless of whether freezing temperatures are
until the system is working at maximum capacity.
expected or not, cooling system protection should be
Any air or vapor in the cooling system will be forced to maintained at least to -34°F (-37°C), to provide adequate
the coolant reservoir under the liquid level and leave corrosion protection and loss of coolant from boiling. With
through the vent tube at the top of the reservoir. As the glycol content less than requirement for -34°F (-37°C )
system cools, the extra coolant in the reservoir will be drawn protection, coolant boiling point is less than the temperature
back to the radiator through the vent valve. In this manner, indicating light setting. When adding solution due to loss of
the radiator will keep itself full at all times. coolant for any reason or in areas where temperatures lower
than -34°F (-37°C) may occur, a sufficient amount of an
COOLANT LEVEL ethylene glycol base anti-freeze that meets GM Specifica
tion 1899-M should be used.
The need for additional coolant can be detected by
observing the level of coolant in the "see through" reservoir NOTICE: Alcohol or methanol base anti-freeze, or plain
water, are not recommended for your engine at any
time. They will not provide proper protection against
corrosion.
THERMOSTAT
The thermostat consists of a restriction valve actuated
by a thermostatic element. This is mounted in the housing at
the cylinder head coolant outlet above the water pump on
ALL L6 ENGINES AND ALL V8 ENGINES EXCEPT DIESEL
L-6, and in the forward part of the intake manifold, under
GENERATOR 50 LB. ADJUST TO 75 + 5 LBS. USED
the coolant outlet on "small block" and "Mark". Thermo (334 ± 22 N)
stats are designed to open and close at predetermined A.I.R. PUMP (222 N)
P/S PUMP MIN. ADJUST TO 125 ± 5 LBS. NEW
temperatures and if not operating properly should be (556 + 22 N)
removed and tested. 65 LB. ADJUST TO 95 ± 5 LBS. USED
A/C (423 + 22 N)
(289 N)
COMPRESSOR ADJUST TO 140 ± 5 LBS. NEW
MIN.
(623 ± 22 N)
5.7L — V8 DIESEL
GENERATOR ADJUST TO 75 ± 5 LBS. USED
P/S PUMP 70 LB. (334 ± 22 N)
A.I.R. PUMP (311 N) ADJUST TO 110-140 LBS. NEW
(NON A/C) MIN. (480-623 N)
A/C 80 LB. ADJUST TO 90 ± 5 LBS. USED
COMPRESSOR (356 N) (400 ± 22 N)
A.I.R. PUMP MIN. ADJUST TO 135-165 LBS. USED
(600-734 N)
Fig. 6B-2--Drive Belt Tension Specifications
LIG H T T R U C K SE RV IC E M A N U A L
ENGINE COOLING 6B-3
ADJU STM EN T
DJUSTM ENT BOLT
BOLT
PIVOT PIVOT
BOLT BOLT
IN LIN E IN L IN E /L 2 5 VIEW
ADJU STM EN T BO LT
PIVO T BOLT
S M A L L BLOCK
DIESEL - EXCEPT A /C
PIVO T
ADJU STM EN T BOLT BOLT
PIV O T BOLT
ADJU STM EN T
BOLTS
[ v i ew] A D IE S E L -A /C EQUIPPED
ADJUSTMENT NUT
A D JUSTM EN^^
SMALL BLOCK-EXCEPT 'P' & 'G' SMALL BLOCK - *P' & 'G'
ADJUSTMENT
MK IV DIESEL
PIVOT BOLT
& NUT
ADJUSTMENT BOLT
PIVOT BOLT
ADJUSTMENT
'I BOLT
ADJUSTMENT BOLT
IN LINE-'G' MODEL
■BRACE
.SUPPORT ADJUSTING
BOLT
ADJUSTMENT
BOLTS.! V
PIVOT BOLT
.BRACE
ADJUSTMENT
BOLT \
SUPPORT,
.SUPPORT
TAPPED HOLE
■PIVOT BOLT
PIVOT
BOLT
.ADJUSTMENT/
BOLTS
LIG H T T R U C K SERVICE M AN U AL
6B-6 ENGINE COOLING
L IG H T T R U C K SE RV IC E M A N U A L
ENGINE COOLING 6B-7
DIAGNOSIS
If the cooling system requires frequent addition of Thermostat
coolant in order to maintain the proper level, check all units An operational check of the thermostat can be made by
and connections in the cooling system for evidence of hanging the thermostat on a hook in a 33% glycol solution
leakage. Inspection should be made with cooling system 25°F (4°C) above the temperature stamped on the thermo
cold. Small leaks which may show dampness or dripping can stat valve. Submerge the valve completely and agitate the
easily escape detection when the engine is hot, due to the solution thoroughly. Under this condition the valve should
rapid evaporation of coolant. Tell-tale stains of grayish open. Remove the thermostat and place in a 33% glycol
white or rusty color, or dye stains from anti-freeze, at joints solution 10°F (-12°C) below temperature indicated on the
in cooling system are almost always sure signs of small leaks valve. With valve com pletely submerged and coolant
even though there appears to be no damage. agitated thoroughly, the valve should close completely.
Air may be drawn into the cooling system through
leakage at the water pump seal or through leaks in the Overheat and/or Noise
coolant recovery system. Gas may be forced into the cooling Engine overheat and/or cooling system noise may be
system through leakage at the cylinder head gasket(s) even caused by restrictions in the cooling system.
though the leakage is not sufficient to allow coolant to enter Components which may be prone to this condition are
the combustion chamber. cylinder head, water pump, block, thermostat housing and
inlet manifold. Symptoms of this condition are as follows:
SYSTEM CHECKS • Engine may make snapping/cracking noises.
• Heater core may gurgle or surge.
Exhaust Leaks
• Radiator hoses may collapse and expand.
To check for exhaust leaks into the cooling system, • Heater hoses may vibrate and thump.
drain the system until the coolant level stands just above the • Overheat light may or may not come on.
top of the cylinder head(s), then disconnect the radiator
upper hose and remove the thermostat and fan belt(s). Start Symptoms are the result of coolant boiling at some
localized area and may be noticed after extending idling
the engine and quickly accelerate several times. At the same
and/or while being driven. Determine which side of the
time note any appreciable coolant rise or the appearance of
engine is involved and whether it is more at the front or rear
bubbles which are indicative of exhaust gases leaking into
of engine.
the cooling system.
NOTICE: A defective head gasket may allow exhaust Diagnosis & Inspection
gases to leak into the cooling system. This is particu 1. Isolate area of engine the localized boiling is originat
larly damaging to the cooling system as the gases ing from. This can be done by probing engine with a
combine with the water to form acids which are sounding bar (large screw driver).
harmful to the radiator and engine. 2. With radiator cap removed, observe water being
circulated in radiator. Feel the front area of radiator
Water Pump for cold spots which indicate blockage. Blocked radia
tors generally occur on units that have accrued miles
Water pump operation may be checked by running the
and not on new vehicles.
engine while squeezing the radiator upper hose (engine
warm). A pressure surge should be felt. Check for a plugged CAUTION:The radiator cap should be removed
venthole in pump. from a cool engine only. If the radiator cap is
removed from a hot cooling system, serious per
Radiator sonal injury may result.
Test for restriction in the radiator, by warming the 3. Inspect thermostat to see if it opens completely.
engine up and then turning the engine off and feeling the 4. Inspect thermostat housing to make sure it is com
radiator. The radiator should be hot along the left side and pletely free of obstructions.
warm along the right side, with an even temperature rise 5. Remove water pump from vehicle and remove the back
from right to left. Cold spots in the radiator indicate clogged cover on the pump. All internal passages can be
sections. inspected using a flash light.
L IG H T T R U C K SERVICE M AN U AL
6B-8 ENGINE COOLING
6. Inspect cross over at the front of the inlet manifold. • When clutch is engaged for maximum cooling.
This entire passage can be seen with only the thermo • During first few minutes after start-up until the
stat removed. clutch can re-distribute the silicone fluid back to its
7. Remove heads, but lay them aside for now and check normal disengaged operating condition after over
the block first because the heads are the most complex night settling.
pieces as far as coolant passages are concerned.
8. With water pump and heads removed, ALL coolant Fan noise or an excessive roar will generally occur
passages C A N be inspected by using a pen light flash continuously, however, under all high engine speed condi
light. All water jacket areas can be seen directly and a tions (2500 r.p.m. and up) if the clutch assembly is locked
block should never be replaced as being suspect unless up due to an internal failure. If the fan cannot be rotated by
the restricted area can be DIRECTLY SEEN . hand or there is a rough grating feel as the fan is turned, the
9. If none of the above inspections reveal the problem clutch should be replaced.
area, the heads must be considered prime suspect.
Heads with blocked coolant passages generally have
more than one area that is blocked. Inspect the heads 2. - Looseness
for signs of overheat discoloration (a dark blue or black Under various temperature conditions, there is a visible
area). If none are found look in the coolant passages for lateral movement that can be observed at the tip of the fan
blockage and probe all passages that are accessible. blade. This is a normal condition due to the type of bearing
The head is very intricate and all passages cannot be used. Approximately 1/4" (6.5m m ) maximum lateral
reached. Use a probe that is fairly substantial as a tag movement measured at the fan tip is allowable. This is not
wire may go through or around a partially blocked cause for replacement.
area. If nothing is found by visual inspection and
probing, inspect the passages for a rough ragged
3. - Silicone Fluid Leak
appearance. The roughest internal passages are proba
bly the ones that are blocked. The operation of the unit is generally not affected by
Replace a blocked or suspect head and inspect the small fluid leaks which may occur in the area around the
replacement head in the same manner before installing bearing assembly. If the degree of leakage appears exces
it. sive, however, proceed to item 4.
FAN CLUTCH
4. - Engine Overheating
1 Noise If the fan and clutch assembly free-wheels with no drag
Fan noise is sometimes evident under the following (revolves over 5 times when spun by hand), the clutch should
normal conditions: be replaced.
LIG H T T R U C K SE RV IC E M A N U A L
ENGINE COOLING 6B-9
TO AVO ID NEEDLESS TIME AND COST IN DIAGNOSING COOLING SYSTEM COMPLAINTS, THE CUSTOMER
SHOULD BE QUESTIONED ABOUT D R IVIN G CONDITIONS THAT PLACE ABNORM AL LOADS ON THE COOLING
SYSTEM.
4. IS O VERHEATING OCCURRING AFTER PROLONGED D RIVING IN SLOW CITY TRAFFIC, TRAFFIC JAMS.
PARADES. ETC.?
IF ANSWER IS "Y E S " - INSTRUCT OWNER ON DRIVING TECHNIQUES THAT WOULD AVO ID OVERHEATING - SAME AS
FOR PROLONGED IDLES - NO. 3. FURTHER DIAGNOSTIC CHECKS SHOULD NOT BE REQUIRED.
TO EFFECTIVELY USE THIS CHART, QUESTION THE OWNER TO DETERMINE WHICH OF THE FOLLOWING
[3] CATEGORIES APPLIES TO THE COMPLAINT:
1. HOT LIGHT OR HOT INDICATION ON TEMPERATURE GAGE
2. BOILING
3. COOLANT LOSS
2. IF COMPLAINT IS BOILING - GO TO B O IL IN G ON C H AR T
NOTICE: AN Y TIM E COOLING SYSTEM IS OBVIOUSLY CONTAM INATED, THE SYSTEM SHOULD BE
D RAIN ED AND FLUSHED. \> / . y • j S ( CJ X
CAUTION - THE COOLING SYSTEM IS DESIGNED TO OPERATE AT 15 P.S.I. PRESSURE & TEMPERATURES
EXCEEDING 200° F. CAUTION SHOULD BE EXERCISED WHEN REMOVING PRESSURE CAP OR
SERVICING THE SYSTEM.
. 1316
L IG H T T R U C K SERVICE M A N U A L
6B-10
DIAGNOSIS CHART
ENGINE COOLING
H O T L IG H T
B O IL IN G C O O L A N T LOSS
(or Tem p. Gage)
•'ON” OR
HOT TEMP C H E C K P R E S S U R E CA P C H EC K PRESSURE CAP
Use Pressure Cap Tester Per Use Pressure Cap Tester Per
C H E C K BULB
Chassis Service M anual REPLACE Chassis Service M anual
OK
C H E C K S E N D IN G U N IT OK O.K. REPLACE
A N T I FREEZE
P R O T E C T IO N CHECK C O O LA N T LE V E L
i_fdE
REPLACE V IS U A L S Y S T E M C H E C K
T O SPEC.
YES
ADD
H O T L IG H T 1. L E A K S Check Hoses, R a d ia to r, Clamps,
G O TO " B O IL IN G ”
W ater Pum p, Therm ostat Housing, Rad.
ON C H A R T OR LOW (or Tem p. Gage)
D ra in , S o ft or Core Plugs, Heater W ater
TEMP?
CH E C K S E N D IN G U N IT ■’O N” OR Valves, Heater Core.
HOT TEMP
2. F O A M IN G C O O L A N T Observe in fille r
ON CAR TH E R M O S TA T CHECK J
_____________________________________ * SEE T H E R M O S T A T neck after engine w arm up.
D IA G N O S T IC C H A R T
3. O V E R F L O W S Y S T E M (Sem i-Sealed System)
A . Check fo r Gasket in Pressure Cap.
T IG H T E N TO SPEC. F A N B E L T T E N S IO N REPLACE B. Check fo r Leaks • Hoses, Clam ps. O ver
flo w B o ttle , F ille r Neck N ipple.
C. Check fo r O bstructions or Plugging in
Hose Betw een R adiator and B o ttle.
NO / SYSTEM \
C O L L A P S E D UPPER OR
I O .K . J
LO W ER R A D IA T O R HOSE?
R E P A IR OR
REPLA CE D E FEC TS
YES D IR T , BU GS, B E N T F IN S . E T C . |
C L E A N OR
B L O C K IN G R A D IA T O R OR PRESSURE CHECK SYSTEM
S T R A IG H T E N
A /C C O N D E N S E R ? 1 Install Pressure Cap Checker on
I R a dia tor F ille r Neck and Pressurize
R E P A IR
1
1
1 NO
System to Rated Pressure.
I f System Does not H o ld Pressure,
L po k fo r Leak Location.
A N Y F IX E S A B O V E ?
NO
ON VEHICLE SERVICE
WATER PUMP Installation - V8
If installing new water pump, transfer heater hose
Removal - L6 fitting from old unit. On 7.4 liter engine, also transfer by
1. Disconnect battery negative cable at battery. pass fitting.
2. Drain cooling system. 1. With clean sealing surfaces on both water pump and
3. Remove accessory drive belts. block, place a 1/8 " (3mm) bead of RTV, # 1052366 or
4. Remove fan to water pump hub (or fan clutch to water equivalent, along the sealing edge of each water pump
pump hub) attaching bolts (or nuts) and remove fan leg. Place pump against block and retain with attaching
and pulley. bolts. Torque bolts to 20 N-m.
5. Remove lower radiator hose and heater hose from 2. Attach lower radiator hose and heater hose to water
water pump. pump. On 7.4 liter engine, install by-pass hose.
6. Remove water pump to block attaching bolts and 3. Attach generator upper and lower braces to water
remove water pump. pump. Torque bolts to 35 N-m.
• On some vehicles, the generator adjusting brace is 4. Install water pump pulley and fan (or fan clutch) to
retained by one of the water pump to block bolts. If water pump hub. Torque fasteners to 30 N-m.
necessary, loosen generator adjusting bolt to allow 5. Install accessory drive belts. Adjust to specifications.
this brace to be moved away from pump to prevent 6. Connect battery negative cable.
removal interference. 7. Fill cooling system with an ethylene glycol anti-freeze
and water mixture of 50/50%.
Installation - L6
8. Start engine and run, with radiator cap removed, until
1. With clean sealing surfaces on both water pump and radiator upper hose becomes hot (thermostat open).
block, place new gasket on water pump, mount on block
9. With engine idling, add coolant to radiator until level
and retain with attaching bolts. Torque bolts to 15 lb.
reaches bottom of filler neck.
ft. (20 N-m).
10. Install cap, making sure arrows line up with overflow
• If generator adjusting brace was moved, move to
tube.
original position before torquing water pump bolts.
2. Install lower radiator hose and heater hose to pump. Removal - Diesel
3. Install water pump pulley and fan (or fan clutch 1. Drain radiator.
assem bly) on water pump hub. Torque retaining
2. Disconnect lower radiator hose at water pump.
fasteners to 30 N-m (25 N-m if engine has fan clutch
assembly). 3. Disconnect heater hose and by-pass hose at water
pump.
4. Install accessory drive belts and adjust to specifications.
4. Remove fan assembly.
5. Connect battery negative cable.
5. Remove all pulley belts.
6. Fill cooling system with an ethylene glycol anti-freeze
and water mixture of 50/50%. 6. Remove water pump pulley.
7. Start engine and run, with radiator cap removed, until 7. Disconnect generator, P /S pump bracket and, if
radiator upper hose becomes hot (thermostat open). equipped, A /C compressor bracket.
8. With engine idling, add coolant taradiator until level 8. Remove water pump attaching bolts and water pump.
reaches bottom of filler neck.
Installation - Diesel
9. Install cap, making sure arrows line up with overflow
tube. 1. Transfer studs to new water pump, if applicable.
2. Clean gasket material from engine block.
Removal - V8 3. Apply a thin coat of # 1050026 sealer, or equivalent, to
1. Disconnect battery negative cable at battery. the water pump housing to retain gasket, then position
2. Drain cooling system. new gasket on housing.
3. Remove accessory drive belts. 4. Reverse removal procedure.
4. Remov^fan to water pump hub (or fan clutch to water 5. Adjust belts to specifications.
pump hub) attaching bolts (or nuts) and remove fan 6. Refill cooling system.
and pulley.
5. Remove generator lower brace to water pump attach THERMOSTAT
ing bolts and swing brace down and out of way.
6. Remove generator upper brace to water pump attach Removal (All Engines)
ing bolts. 1. Disconnect battery negative cable at battery.
7. Remove lower radiator hose and heater hose from 2. Drain cooling system until radiator coolant level is
water pump. On 7.4 liter engine, remove by-pass hose. below thermostat.
8. Remove water pump to block attaching bolts and 3. Remove water outlet attaching bolts and remove outlet.
remove pump. Remove thermostat.
LIG H T T R U C K SERVICE M AN U AL
6B-12 ENGINE COOLING
FAN/FAN CLUTCH
Removal (All)
1. Remove battery negative cable at battery.
2. Remove radiator fan shroud as required.
LIG H T T R U C K SE RV IC E M AN U AL
ENGINE COOLING 6B-13
CK 2 0 0 -3 0 0 5.7 AUTO-ALL
CK-100 5 .0 -5 .7 AUTO W / A / C 5 .0 -5 .7-M AN.-ALL
OR H.D. COO LING CK-100 5 .0 -5 .7-AUTO W / O A /C
6.6-7.4-ALL OR H.D. COOLING
5.7-DIESEL-ALL 4.1-4.8-ALL W / A / C 4.1-4.8-ALL W / O A /C
RADIATOR.
SUPPORT RADIATOR SUPPORT
BRACE
P000(42)
RADIATOR ASM
EXC. LF8 W /L F 8
STUD
B R AKE C YL
SUPPORT
VIEW
LIG H T TR U C K SE RV IC E M AN U AL
ENGINE COOLING 6B-15
RADIATOR M O U N T IN G PANEL
RADIATOR SUPPORT 5 .0 /5 .7
RADIATOR SUPPORT WITH
7 .4 OR 5.7 DIESEL
jV IE W
|VIEW A
&LE3 OR L25
Fig. 6B-11--"CK" Series Fan Shroud
M O T O R H O M E C H A S S IS
P (3 2 )
LIG H T T R U C K SERVICE M AN U AL
6B-16 ENGINE COOLING
LIG H T TR U C K SE RV IC E M A N U A L
S T R U T ROD
ENG INE MTG B R K T / R ETU R N HOSE
CO O LER / / / SUPPLY HOSE
A D A P T ASM
Fig. 6B-16--Engine Oil Coolers Except LF9
ENGINE COOLING
'G ' V A N
6B-17
ENGINE FUEL 6C-1
SECTION 6C
ENGINE FUEL
CONTENTS
GENERAL
ALL N EW GM VEHICLES ARE CERTIFIED BY THE U N ITED
ST A T E S E N V IR O N M E N T A L PRO TECTIO N A G E N C Y A S C O N
FO RM ING TO THE R EQ U IR EM EN TS OF THE REG U LATIO NS
FOR THE CONTROL OF AIR POLLUTION FROM N EW MOTOR
VEHICLES. THIS CERTIFICATION IS C O N T IN G E N T O N CER
T A IN A D JU ST M E N T S BEING SET TO FACTORY ST A N D A R D S. IN
M OST C A SE S, TH ESE A D JU ST M E N T PO IN T S EITH ER HAVE
BEEN PE R M A N E N T L Y SEALED A N D /O R MADE INA CCESSIBLE
TO PREVENT IN D ISC R IM IN A T E OR ROUTINE A D JU ST M E N T IN
THE FIELD. FOR THIS REA SO N , THE FACTORY PROCEDURE
FOR TEM PORARILY REM OVING PLUGS, CAP, ETC., FOR PU R
POSES OF SE R V IC IN G THE PR O D U C T, M U ST BE STR IC TLY
FOLLOW ED A N D , W HEREVER PRACTICABLE, R E T U R N E D TO
THE O R IG IN A L IN TEN T OF THE DESIGN.
This section, divided into sub-sections by carburetor NOTICE: All engines require the use of unleaded fuel
model, covers the repair and adjustment procedure for fuel only. Use of leaded and/or low lead fuel can result in
system components. Typical illustrations and procedures are engine damage and reduce the effectiveness of the
used except where specific illustrations or procedures are Emission Control Systems.
necessary to clarify the operation.
LIG H T T R U C K SERVICE M A N U A L
6C-2 ENGINE FUEL
CARBURETOR DIAGNOSIS
T h e fo llo w in g d ia g n o s tic p ro c e d u re s are f o r c a r b u re to r re la te d p ro b le m s a n d th e ir e ffe c ts o n c a r p e rfo rm a n c e . O th e r syste m s o f th e c a r can
also cause s im ila r p ro b le m s a n d s h o u ld be c h e c k e d w h e n lis te d o n th e c h a r t. T h e p r o b le m areas d e s c rib e d are:
1. E n g in e c ra n k s n o r m a lly . W ill n o t s ta rt.
2. E n g in e s ta rts a n d sta lls .
3. E n g in e s ta rts h a rd .
4. E n g in e id le s a b n o rm a lly a n d / o r sta lls.
5. In c o n s is te n t e n g in e id le speeds.
6. E n g in e die se ls (a fte r- ru n ) u p o n s h u t o f f .
7. E n g in e h e sita te s o n a c c e le ra tio n .
8. E n g in e has less th a n n o rm a l p o w e r a t lo w speeds.
9. E n g in e has less th a n n o rm a l p o w e r o n h e a vy a c c e le ra tio n o r a t h ig h speed.
10. E n g in e surges.
11. P o o r gas m ile a ge .
C O N D I T IO N P O S S IB L E C A U S E C O R R E C T IO N
N o fu e l in c a rb u re to r . R e m o v e fu e l lin e a t c a r b u r e to r . C o n n e c t
hose to fu e l lin e a n d ru n in t o m e ta l
c o n ta in e r . R e m o v e th e w ir e fr o m th e " b a t "
te r m in a l o f th e d is t r ib u t o r . C ra n k
o v e r e n g in e — i f th e re is n o fu e l d is
ch arg e f r o m th e fu e l lin e , te s t fu e l
p u m p as o u t lin e d in S e c tio n 6 . I f fu e l
s u p p ly is o k a y , c h e c k th e f o llo w in g :
a. In s p e c t fu e l in le t f il t e r . I f
p lu g g e d , re p la c e .
b . I f fu e l f i l t e r is o k a y , re m o v e a ir
h o rn a nd c h e c k f o r a b in d in th e
f lo a t m e c h a n is m o r a s tic k in g in le t
n e e d le . I f o k a y , a d ju s t f lo a t as s p e c ifie d .
E n g in e flo o d e d . T o c h e c k R e m o v e th e a ir h o r n .
f o r flo o d in g , re m o v e th e a ir
cle a n e r w it h th e e n g in e C h e c k fu e l in le t n e e d le a n d seat f o r
im m e d ia te ly s h u t o f f a nd p r o p e r seal. I f a n e e d le a n d seat
lo o k in t o th e c a rb u r e to r te s te r is n o t a v a ila b le , a p p ly v a c u u m
b ore s. F uel w il l be d r ip p in g to th e n e e d le seat w it h n e e d le in s ta lle d .
o f f n o zzle s. I f th e n e e d le is le a k in g , re p la c e .
C h e c k f lo a t f o r fre e m o v e m e n t,
b e n t f lo a t h a n g e r o r b in d s in th e
f lo a t a rm .
I f fo r e ig n m a te ria l is in fu e l s y s te m , cle a n
th e s y s te m a nd re p la c e fu e l filt e r s as
n ece ssa ry. I f e xcessive fo r e ig n m a te ria l is
fo u n d , c o m p le te ly d is a s s e m b le a n d c le a n .
Fig. 6C-1--Diagnosis 1 of 8
LIG H T T R U C K SERVICE M A N U A L
ENGINE FUEL 6C-3
C h o k e h e a te r s y s te m m a l C h e c k v a c u u m s u p p ly a t h o t a ir in le t
f u n c tio n in g (m a y cause t o c h o k e h o u s in g . S h o u ld be n o t less
lo a d in g ). th a n m a n ifo ld v a c u u m m in u s 3 " H g. w it h
e n g in e r u n n in g a t id le . (E x c . IM V )
C h e c k w ir in g .
C h e c k f o r p lu g g e d , r e s tr ic te d , o r b ro k e n
h e a t tu b e s .
C h e c k r o u t in g o f a ll h o t a ir p a rts .
L o o s e , b ro k e n o r in c o r r e c t C h e c k c o n d itio n a n d r o u t in g o f all
v a c u u m hose r o u tin g . v a c u u m hoses — c o r r e c t as necessary.
T o c h e c k th e v a c u u m b re a k u n its , a p p ly
a c o n s ta n t v a c u u m s o u rc e o f a t least
1 0 " H g ., p lu n g e rs s h o u ld s lo w ly m o ve
in w a rd a n d h o ld v a c u u m . I f n o t , re pla ce
th e u n it .
A lw a y s c h e c k th e fa s t id le ca m a d ju s tm e n t
w h e n a d ju s tin g v a c u u m b re a k u n its .
I n s u ffic ie n t fu e l in C h e c k fu e l p u m p p ressure a nd v o lu m e .
C a rb u re to r.
C h e c k f o r p a r t ia lly p lu g g e d fu e l
in le t f il t e r . R e p la c e if c o n ta m in a te d .
C h e c k th e f l o a t level a d ju s tm e n t
f o r b in d in g c o n d itio n . A d ju s t as
s p e c ifie d .
Fig. 6C-2--Diagnosis 2 of 8
LIG H T T R U C K SERVICE M A N U A L
6C-4 ENGINE FUEL
E n g in e S ta rts H a rd M a lf u n c t io n in a c c e le ra to r C h e c k a c c e le ra to r p u m p a d ju s tm e n t
(C ra n k s N o r m a lly ) p u m p s y s te m . an d o p e r a tio n .
(C o n tin u e d )
C h e c k p u m p d is c h a rg e b a ll f o r s tic k in g
o r leakage.
C h o k e v a lv e n o t c lo s in g . A d ju s t c h o k e th e r m o s ta tic c o il. C h e c k
c h o k e v a lv e a nd lin k a g e f o r b in d s a n d
a lig n m e n t. C le a n a nd re p a ir o r re p la c e
as necessary.
V a c u u m b re a k s m is a d ju s te d C h e c k f o r a d ju s tm e n t a n d fu n c tio n o f
o r m a lfu n c tio n in g . v a c u u m b re a k s . C o r r e c t as necessary.
In s u ffic ie n t fu e l in b o w l. C h e c k fu e l p u m p p ressu re a n d v o lu m e .
C h e c k f o r p a r t ia lly p lu g g e d fu e l
in le t f il t e r . R e p la c e i f d ir t y . C h e c k
f lo a t m e c h a n is m . A d ju s t as s p e c ifie d .
F lo o d in g . C h e c k f lo a t a nd n e e d le a n d seat
f o r p r o p e r o p e r a tio n .
S lo w e n g in e c ra n k in g speed. R e fe r to s ta r tin g c ir c u it d ia g n o s is .
S e c tio n 6 D .
A i r leaks in t o c a rb u r e to r C h e c k a ll v a c u u m hoses a nd re s tr ic to r s
b o re s b e n e a th t h r o t t le valve s, le a d in g in t o th e m a n ifo ld o r c a r b u r e to r
m a n ifo ld lea ks, o r v a c u u m base f o r leaks o r b e in g d is c o n n e c te d .
hoses d is c o n n e c te d o r in In s ta ll o r re pla ce as nece ssa ry.
s ta lle d im p r o p e r ly .
T o r q u e c a r b u r e to r to m a n ifo ld b o lts
to 10 f t . lbs. U s in g a p re ssu re o il c a n ,
s p ra y lig h t o il o r ke ro s e n e a ro u n d
m a n ifo ld to head su rfa ce s a n d c a r b u r e to r
t h r o t t le b o d y .
N O T E : D o n o t s p ra y a t t h r o t t l e s h a ft
end s.
I f e n g in e R P M ch an g e s, tig h te n o r re
p la ce th e c a r b u r e to r o r m a n ifo ld gas
k e ts as necessary.
C lo g g e d o r m a lf u n c t io n in g C h e c k P C V s y s te m . C le a n a n d / o r re p la c e
P C V syste m . as necessary.
C a rb u r e to r flo o d in g . R e m o v e a ir h o rn a n d c h e c k f lo a t
a d ju s tm e n ts .
C h e c k b y u s in g p ro c e d u re
o u t lin e d u n d e r " E n g in e C h e c k f lo a t n e e d le a n d seat f o r p r o p e r
Flooded". seal. I f a n ee d le a n d seat te s te r is n o t
a v a ila b le , a p p ly v a c u u m t o th e n e e d le
seat w it h n ee d le in s ta lle d . I f th e
n e e d le is le a k in g o r d a m a g e d , re p la c e .
Fig. 6C-3--Diagnosis 3 of 8
LIG H T T R U C K SERVIC E M A N U A L
ENGINE FUEL 6C-5
E n g in e Id le s A b n o r m a lly C h e c k f lo a t f o r fre e m o v e m e n t.
(T o o fa s t o r to o s lo w ) C h e c k f o r b e n t f l o a t h a n g e r o r b in d s
( C o n tin u e d ) in th e f l o a t a rm .
I f fo r e ig n m a te r ia l is fo u n d in
th e c a r b u r e to r , c le a n th e fu e l s y s te m
a nd c a r b u r e to r . R e p la c e fu e l f i l t e r
as n e ce ssa ry.
Id le s y s te m p lu g g e d C le a n c a r b u r e to r , see S e c tio n 6 C 1 .
o r re s tric te d .
In c o r r e c t id le m ix tu r e R e a d ju s t p e r s p e c ifie d p ro c e d u re . See
a d ju s tm e n t. S e c tio n 6 C 1 .
D e fe c tiv e id le s to p s o le n o id , C h e c k s o le n o id a n d w ir in g .
id le sp e e d -u p s o le n o id o r
w ir in g .
T h r o t t le b la d e s o r lin k a g e C h e c k t h r o t t l e lin k a g e a n d t h r o t t le
s tic k in g a n d / o r b in d in g . b la d e s ( p r im a r y a n d s e c o n d a ry ) f o r
s m o o th a n d fre e o p e r a tio n . C o r r e c t
p r o b le m areas.
M a lf u n c t io n o f id le s to p C h e c k f o r c o r r e c t o p e r a tio n o f id le
s o le n o id , id le s p e e d -u p s o le n o id . C h e c k f o r s tic k y o r b in d in g
s o le n o id o r d a s h p o t. s o le n o id .
F a st id le ca m n o t f u l ly o f f . C h e c k fa s t id le c a m f o r fr e e d o m o f
o p e r a tio n . C le a n , re p a ir, o r a d ju s t
as r e q u ir e d . C h e c k c h o k e h e a te d a ir
tu b e s f o r r o u t in g , f it t in g s b e in g
t ig h t o r tu b e s p lu g g e d . C h e c k c h o k e
lin k a g e f o r b in d in g . C le a n a nd c o r r e c t
as nece ssa ry.
E x c e s s iv e ly lean c o n d itio n A d ju s t c a r b u r e to r id le m ix tu r e as
caused b y m a la d ju s te d c a r d e s c rib e d in S e c tio n 6 C 1 .
b u r e t o r id le m ix tu r e .
A c c e le r a to r p u m p n o t a d ju s te d A d ju s t a c c e le ra to r p u m p , re p la c e .
t o s p e c ific a tio n o r in o p e r a tiv e .
In o p e r a tiv e a c c e le ra to r p u m p R e m o v e a ir h o r n a nd c h e c k p u m p c u p .
sy s te m . I f c ra c k e d , s c o re d o r d is t o r t e d , re
p la c e th e p u m p p lu n g e r.
Fig. 6C-4--Diagnosis 4 of 8
L IG H T T R U C K SERVICE M AN U AL
6C-6 ENGINE FUEL
E n g in e H e s ita te s O n N O T E : A q u ic k c h e c k o f th e C h e c k th e p u m p d is c h a rg e b a ll f o r
A c c e le ra tio n p u m p sy s te m can be m a de as p ro p e r s e a tin g a n d lo c a tio n .
( C o n tin u e d ) fo llo w s : W ith th e e n g in e
o f f , lo o k in t o th e c a r b u r e to r
b o re s a n d o b se rve p u m p n o z z le s
w h ile q u ic k ly o p e n in g t h r o t t le
le ve r. A f u ll s tre a m o f fu e l
s h o u ld e m it f r o m each p u m p
n o z z le .
F o re ig n m a tte r in p u m p passages. C le a n a n d b lo w o u t w it h c o m p re s s e d
a ir.
F lo a t leve l to o lo w . C h e c k a nd re set f l o a t le v e l to
s p e c ific a tio n .
F r o n t v a c u u m b re a k d ia p h ra g m C h e c k a d ju s tm e n t a n d o p e r a tio n o f
n o t f u n c tio n in g p r o p e r ly . v a c u u m b re a k d ia p h ra g m .
P o w e r e n r ic h m e n t s y s te m n o t C h e c k f o r b in d in g o r s tu c k p o w e r
o p e ra tin g c o r r e c t ly . p is to n (s ) — c o r r e c t as nece ssa ry.
F u e l f i l t e r d ir t y o r p lu g g e d . R e p la c e f i l t e r a nd clea n fu e l s y s te m as
necessary.
D is t r ib u t o r v a c u u m o r m e c h a n ic a l C h e c k f o r p r o p e r o p e r a tio n .
ad va n ce m a lfu n c tio n in g .
C h o k e c o il m is a d ju s te d (c o ld A d ju s t t o s p e c ific a tio n s .
o p e ra tio n .)
E G R v a lve s tu c k o p e n . In s p e c t a nd cle a n E G R v a lv e .
C h o k e s tic k in g . C h e c k c o m p le te c h o k e s y s te m f o r s tic k in g
o r b in d in g . C le a n a n d re a lig n as
n ece ssa ry. C h e c k a d ju s tm e n t o f c h o k e
th e r m o s ta tic c o il.
C h e c k c o n n e c tio n s a n d o p e r a tio n o f
c h o k e h o t a ir s y s te m .
C h e c k je ts a n d c h a n n e ls f o r p lu g g in g ;
c le a n a n d b lo w o u t passages.
C lo g g e d o r in o p e ra tiv e p o w e r R e m o v e a ir h o rn a nd c h e c k f o r fre e
syste m . o p e r a tio n o f p o w e r p is to n s .
Fig. 6C-5-Diagnosis 5 of 8
L IG H T T R U C K SERVICE M A N U A L
ENGINE FUEL 6C-7
E x h a u s t s y s te m . C h e c k f o r r e s tr ic tio n s . C o r r e c t as
re q u ire d .
S e c o n d a ry t h r o t t le lo c k o u t C h e c k f o r b in d in g o r s tic k in g lo c k o u t
n o t a llo w in g s e c o n d a rie s to le v e r.
open.
C h e c k f o r fre e m o v e m e n t o f fa s t id le
ca m .
C h e c k c h o k e h e a te d a ir s y s te m f o r p ro p e r
a n d t i g h t c o n n e c tio n s p lu s f lo w th r o u g h
s y s te m .
C h e c k a d ju s tm e n t o f c h o k e th e r m o s ta tic
c o il.
S p a rk p lu g s fo u le d , in c o r r e c t C le a n , re g a p , o r re p la c e p lu g s.
gap.
P lug g e d a ir c le a n e r e le m e n t. R e p la c e e le m e n t.
P lu g g e d fu e l in le t f ilt e r . R e p la c e w it h a n e w f i l t e r e le m e n t.
In s u ffic ie n t fu e l to c a r b u r e to r . C h e c k fu e l p u m p a nd s y s te m , ru n p ressu re
a nd v o lu m e te s t. See F U E L S Y S T E M
D IA G N O S IS , S e c tio n 6 .
P o w e r e n r ic h m e n t s y s te m R e m o v e th e a ir h o r n a n d c h e c k f o r fre e
n o t o p e ra tin g c o r r e c t ly . o p e r a tio n o f b o th p o w e r p is to n ( s ) , clea n
a n d c o r r e c t as n ece ssa ry.
C h e c k f o r lo o se je ts .
Fig. 6C-6--Diagnosis 6 of 8
LIG H T T R U C K SERVICE M A N U A L
6C-8 ENGINE FUEL
Less T h a n N o rm a l P o w e r T ra n s m is s io n m a lf u n c t io n . R e fe r to tra n s m is s io n d ia g n o s is .
O n H e a v y A c c e le ra tio n
O r A t H ig h Speed I g n it io n s y s te m m a lf u n c t io n . C h e c k ig n itio n s y s te m . See S e c tio n 6 D .
(C o n tin u e d )
F u e l m e te rin g je ts re s tric te d . I f th e fu e l m e te rin g je ts are r e s tric te d
and an excessive amount of foreign material
is found in th e fu e l b o w l, th e c a r b u r e to r
s h o u ld be c o m p le te ly d is a s s e m b le d a nd
c le a n e d .
Fuel p u m p . C h e c k fu e l p u m p p ressu re a n d v o lu m e , in s p e c t
lin e s f o r leaks a nd r e s tr ic tio n s . See
F U E L S Y S T E M D IA G N O S IS , S e c tio n 6.
E x h a u s t s y s te m . C h e c k f o r r e s tr ic tio n s . C o r r e c t as
required.
P C V s y s te m clo g g e d o r C h e c k P C V s y s te m . C le a n o r re p la c e
m a lf u n c t io n in g . as necessary.
Lo o se c a r b u r e to r , E G R o r in ta k e T o r q u e c a r b u r e to r to m a n ifo ld b o lts
m a n ifo ld b o lts a n d /o r le a k in g t o 10 f t . lbs. U s in g a p re ssu re o il
gaskets. c a n , s p ra y lig h t o il o r ke ro s e n e
a ro u n d m a n ifo ld t o hea d m o u n tin g s u r
fa c e a nd c a r b u r e to r base. I f e n g in e R P M
changes, tig h te n o r re p la c e th e c a r
b u r e t o r o r m a n ifo ld g aske ts as necessary.
C h e c k E G R m o u n tin g b o l t to r q u e .
C o n ta m in a te d fu e l. C h e c k f o r c o n ta m in a n ts in fu e l. C lean
s y s te m i f necessary.
M a lf u n c t io n in g f lo a t a n d /o r C h e c k o p e r a tio n o f s y s te m . R e p a ir o r
n e e d le a n d seat. re p la c e as necessary.
P o w e r p is to n s tu c k o r b in d in g . C h e c k f o r fre e m o v e m e n t o f p o w e r
p is to n ( s ) . C le a n a n d c o r r e c t as necessary.
F u e l je ts o r passages p lu g g e d C le a n a n d b lo w o u t w it h c o m p re s s e d
o r re s tric te d . a ir.
E x h a u s t s y s te m . C h e c k f o r r e s tr ic tio n s . C o r r e c t as
necessary.
Fig. 6C-7--Diagnosis 7 of 8
L IG H T T R U C K SERVICE M A N U A L
ENGINE FUEL 6C-9
E n g in e in need o f s e rvice . C h e c k e n g in e c o m p re s s io n , e x a m in e s p a rk
p lu g s ; if fo u le d o r im p r o p e r ly g a p p e d ,
c le a n a n d re ga p o r re p la c e . C h e c k ig n itio n
w ir e c o n d itio n a n d c h e c k a n d re s e t ig
n it io n t im in g . R e p la c e a ir c le a n e r e le m e n t
i f d ir t y . C h e c k f o r r e s tr ic te d e x h a u s t
s y s te m a n d in ta k e m a n ifo ld f o r leakage.
C h e c k c a r b u r e to r m o u n tin g b o lt to r q u e . C h e c k
v a c u u m a n d m e c h a n ic a l adva n ce .
C h e c k f o r lo a d e d f lo a t . R ese t f lo a t
level to s p e c ific a tio n .
I f e xcessive fo r e ig n m a te ria l is p re s e n t
in th e c a r b u r e to r b o w l, th e c a r b u r e to r
s h o u ld be c le a n e d .
P o w e r s y s te m in c a r b u r e to r R e m o v e a ir h o rn a n d c h e c k f o r fre e
n o t fu n c tio n in g p r o p e r ly . m o v e m e n t o f p o w e r p is to n (s ). C le a n
P o w e r p is to n (s ) s tic k in g o r a n d c o r r e c t as n ece ssa ry.
m e te rin g ro d s o u t o f je ts .
C h o k e s y s te m . C h e c k c h o k e h e a te d a ir tu b e s f o r r o u tin g
a n d /o r p lu g g in g w h ic h w o u ld r e s tr ic t
h o t a ir f l o w to c h o k e h o u s in g . C h e c k c h o k e
lin k a g e f o r b in d in g . C le a n o r re p a ir
as r e q u ire d . C h e c k a d ju s tm e n t o f th e r m o
s ta tic c o il. R e a d ju s t t o s p e c ific a tio n
as r e q u ir e d . C h e c k e le c tr ic c h o k e
w ir in g .
P lu g g e d a ir c le a n e r e le m e n t. R e p la c e e le m e n t.
E x h a u s t sy s te m . C h e c k f o r r e s tr ic tio n s . C o r r e c t as re q u ire d .
F o re ig n m a te ria l in fu e l s y s te m o r In s p e c t p ip e s ,a n d hoses f o r k in k s a nd
k in k e d fu e l p ip e s o r hoses. b e n d s , b lo w o u t to c h e c k f o r p lu g g in g .
R e m o v e a n d re p la c e as re q u ire d .
Fig. 6C-8--Diagnosis 8 of 8
L IG H T T R U C K SE RV IC E M A N U A L
6C-10 ENGINE FUEL
C O N D IT IO N P O S S IB L E CAUSE C O R R E C T IO N
A) From area o f fue l ta n k o r fuel 1. Leaking or plugged fuel 1. Repair o r replace hoses as
cap - Perform pressure check or EVAP hoses necessary
to determ ine possible causes
2. Leaking fuel cap 2. Repair o r replace cap as
necessary
3. Leaking fuel fille r neck 3. Repair o r replace as necessary
4. Fuel fille r neck gasket surface 4. Repair o r replace as necessary
nicked, burred, o r dented
5. Leaking sending u n it o r gasket 5. Repair o r replace as necessary
6. Leaking ta n k sw itch u n it 6. Replace u n it
(Dual ta n k system)
7. Inoperative ta n k switch u n it 7. Replace u n it
(Dual ta n k system)
8. Plugged or inoperative ta n k 8. Repair or replace as necessary
pressure co n tro l valve
B) From under hood - Perform 1. L iq u id fuel leaking fro m fuel 1. T ighten fuel lines, repair or
pressure check to determ ine lines, fuel pum p or carburetor replace fue l pum p or carburetor
possible causes as necessary
2. Cracked or damaged canisters 2. Repair o r replace canisters as
necessary
3. Inoperative bowl vent valve 3. Repair or replace hoses
(see Bowl V en t Check Pro Replace canister
cedures)
4. Inoperative purge valve 4. Repair o r replace hoses
(see Purge Valve Check Pro Replace canister
cedures)
DIAGNOSIS
FUEL TANK
6. F a u lty f ill cap or tan k neck. Install new cap o r tank neck as required.
1. Plugged o r pinched vapor pipe or hoses, Check all lines fro m tank to canister and
& defective cap. replace cap.
Collapsed Fuel Tank
2. Canister filte r plugged & de fective cap. Replace filte r in canister & cap.
LIG H T T R U C K SERVICE M A N U A L
w - V
CARBURETOR MODEL 1ME 6C1-1
SECTION 6C1
CARBURETOR MODEL 1ME
CONTENTS
GENERAL DESCRIPTION
The Monojet, carburetor (Fig. 6C1-1) is a single bore emissions is used in the filter inlet to prevent fuel draining
downdraft carburetor using a triple venture in conjunction from the fuel system after roll-over.
with a plain tube nozzle. To improve hot engine starting and meet evaporative
Fuel flow through the main metering system is control emission requirements, fuel vapors from the carburetor bowl
led by a main well air bleed and a variable orifice jet. A are vented to the vapor canister on some models. A tube
power enrichment system is used to provide good perform (location F) is added to the air horn to connect air horn and
ance during moderate to heavy acceleration and at higher canister.
engine speeds. Other features of the Monojet carburetor include an
The model 1ME incorporates an integral automatic aluminum throttle body for decreased weight and improved
choke system which uses and electrically heated choke coil. heat distribution and a thick throttle body to bowl insulator
The vacuum diaphragm unit is mounted externally on the gasket to keep excessive engine heat from the float bowl.
air horn and connects to the thermostatic coil lever through On California models seals have been added in the float
a connecting line. bowl to seal the power piston drive rod and the pump lever to
prevent escape of fuel vapors to atmosphere. During unit
The electric choke coil is contained in a choke housing
repair, the seals and retainer, where used, must be removed
mounted on a bracket attached to the float bowl. Special
prior to immersion of the float bowl in carburetor cleaner.
rivets are installed to retain the factory setting of the choke
coil and provide a non-adjustable design. The carburetor model identification is stamped on a
vertical portion of the float bowl, adjacent to the fuel inlet
An integral, pleated-paper fuel inlet filter is mounted in
nut (Fig. 6C1-2).
the fuel bowl behind the fuel inlet nut to give maximum
filtraton of incoming fuel. A check valve on light duty
If replacing the float bowl, follow the manufacturer’s
T H R O T T L E LEVER A C T U A T O R instructions contained in the service package so that the
(V A C U U M O PER A TED ) identification number can be transferred to the new float
VACUUM bowl.
BR EAK
An electrically operated idle stop solenoid is used on all
models.
E L E C T R IC A L
CONNECTO R
(TO E LE C T R IC
CHOKE)
LIG H T T R U C K SERVICE M AN U AL
6C 1-2 CARBURETOR MODEL 1ME
IDLE C H A N N E L
R E S T R IC T IO N
FLOAT
CHECK VALVE
SEAT
T H R O TTLE
VALVE
IDLE D IS C H A R G E
HOLE
Dual throttle return springs are used on all carburetors. •FACTORY ADJUSTED
M A IN WELL A IR BLEED TUBE
The throttle lever has a spun-in plastic bushing, this is METERING ROD HANGER
used as the bearing surface for the dual throttle return POWER PISTON
springs. METERING ROD
M A IN DISCHARGE
The spun-in plastic return spring bushing will with DRIVE ROD
NOZZLE
stand normal cleaning time in an approved cold immersion BOOST VENTURI POWER PISTON
type carburetor cleaner. The bushing is not serviced sepa: SPRING
M A IN VENTURI
rately and should not be removed from the carburetor M A IN METERING
JET
throttle lever.
Six basic systems of operation are used: float, idle, main -P L U G
L IG H T T R U C K SERVICE M A N U A L
CARBURETOR MODEL 1ME 6C 1-3
•F A C T O R Y ADJUSTED
"T" DISCHARGE
, SPRING RETAINER
,PUMP PLUNGER
ft DURATION
SPRING
M A IN M E TE R IN G -AS PLUNGER
JET 'MOVES UP.
FUEL FLOWS
PLUG PAST CUP INTO
PUMP WELL
PARTTHROTTLE
AD JU STM EN T SC REW 1 PUMP ACTUATING LINK
PO W ER PIS TO N PUMP CUP OPERATION
A C T U A T IN G LIN K A G E
TH R O TTLE V A L V E PO W ER P IS TO N V A C U U M
CHOKE COIL VA CU UM
LINK BREAK LINK
VA CU UM
FAST IDLE INLET
CAM FOLLOWER RESTRICTIOr
INSIDE
COIL LEVER
MANIFOLD J )
VACUUM r
HOSE .jJ
CHOKE SYSTEM
Fig. 6CT8--Choke System
LIG H T T R U C K SERVICE M AN U AL
6C1-4 CARBURETOR MODEL 1ME
F L O A T LEVEL A D J U S T M E N T
G A U G E FROM TO P O F
C A S T IN G TO TO P O F
IN D E X P O IN T A T TO E
O F FLOAT
1 )H O L D F L O A T R E T A IN IN G
( T ) B E N D H E R E TO ' ^ P I N F IR M L Y IN P L A C E -
A D JU S T F L O A T PUSH D O W N ON EN D O F
UP O R DOW N F L O A T A R M , A G A IN S T
TO P O F F L O A T N E E D L E
M E T E R IN G R O D A D J U S T M E N T
( 3 )H O L D POWER
( 5 ) BEN D HERE
PISTO N D O W N A N D SW ING
M E T E R IN G R O D H O L D E R T O A D JU S T
OVER F LA T SURFACE
(G A S K E T R E M O V E D )
O F BO W L C A S T IN G N E X T
T O C A R B U R E T O R BORE
(7),
1 ) R E M O V E M E T E R IN G RO D
B Y H O L D IN G T H R O T T L E
V A L V E W ID E O PEN . PUSH ^ 4 J S P E C IF IE D P LU G
D O W N W A R D ON M E T E R IN G G A U G E - S L ID E F IT
R O D A G A IN S T SPR IN G
T E N S IO N , T H E N S L ID E B A C K O U T ID L E
M E T E R IN G ROD O U T OF STOP S O L E N O ID —
S L O T IN H O L D E R A N D HO LD TH R O TT LE
R E M O V E FR O M M A IN V A LV E C OM PLETELY
M E T E R IN G JE T. C LO S E D
F A S T ID LE A D J U S T M E N T
NOTE: M A N U A L C H O K E
SUPPORT LEVER WITH
M ODELS W ITH SM O O TH
PLIERS-BENDTANGIN
CONTOUR C A M SURFACE
OR OUT TO OBTAIN SPECIFIED
ROTATE FAST IDLE C A M
FAST IDLE R.P.M. (SEE INSET).
CLOCKWISE TO ITS
FARTHEST UP PO SITIO N.
SECOND jC
HIGH
L IG H T T R U C K SERVICE M A N U A L
CARBURETOR MODEL 1ME 6C1-5
C H O K E C O IL LEVER A D J U S T M E N T - 1M E
o PLACE FAST
IDLE CAM
FOLLOWER ON
H IG H EST STEP
OF FAST IDLE
CAM
C H O K E R O D (F A S T ID LE C A M ) A D J U S T M E N T (2N D STEP)
© HOLD DOW N
ON CHOKE V A L V E -
ROD IN END OFSLO
LIG H T TR U C K SERVICE M AN U AL
6C1-6 CARBURETOR MODEL 1ME
V A C U U M BREAK A D J U S T M E N T - 1M E (B O W L S ID E )
NOTE:
v HOLD GAUGE
PLACE FAST
NOTE: ON DELAY FEATURE IDLE CAM
M O D ELS, COVER PLUG AND FOLLOWER ON
PURGE BLEED HOLE W ITH 1" HIGHEST STEP
SQ U A R E PIECE OF M A S K IN G OF C A M .
TA PE. REMOVE AFTER
ADJUSTMENT.
ID LE SP EE D A D J U S T M E N T
TO ADJUST BASE
IDLE TURN 1/8”
HEX SCREW
(SOLENOID NOT
ENERGIZED)
© NOTE: ENGINE M U ST BE
W A R M -C H O K E WIDE OPEN -
FAST IDLE CAM FOLLOWER OFF
STEPS OF C A M (SEE EM ISSIO N
LABEL)
LIG H T T R U C K SERVIC E M A N U A L
CARBURETOR MODEL 1ME 6C 1-7
ON-VEHICLE SERVICE
1ME CARBURETOR ADJUSTMENTS 7. If plunger did not move in step 5 insert test lamp (1893
bulb or smaller) between solenoid feed wire and
Refer to figure 6C1-9 through 6C1-11 for adjustment ground.
specifications and procedures. 8. If lamp lights, replace solenoid.
Choke Checking Procedure 9. If lamp does not light, locate cause of open circuit in
1. Remove air cleaner. With engine off, hold throttle half solenoid feed wire.
open. Open and close choke several times. Watch IDLE MIXTURE ADJUSTMENT (LEAN DROP)
linkage to be certain all links are connected and there
are no signs of damage. For Heavy Duty Emission Vehicles Without 4 Barrel
2. If choke or linkage binds, sticks, or works sluggishly, 1. Set parking brake and block drive wheels.
clean with Choke Cleaner X -20-A or equivalent. Use 2. Remove air cleaner for access to carburetor, but keep
cleaner as directed on can. Refer to disassembly vacuum hoses connected.
instructions for additional direction if cleaning does not 3. Disconnect and plug other hoses, as directed on Emis
correct. sion Control information Label under the hood.
3. Visually inspect carburetor to be certain all vacuum 4. Start engine and bring to normal operating tempera
hoses are connected. Inspects hoses for cracks, abra ture, choke open, air conditioning off.
sions, hardness or other signs of deterioration. Replace 5. Connect an A C CURA TE tachometer to engine.
or correct as necessary.
6. Disconnect vacuum advance and plug hose. Check
4. Make sure vacuum break diaphragm shaft is fully ignition timing. If necessary, adjust to specification
extended when engine is off. If shaft is not fully shown on Emission Control Information Label. Recon
extended, replace vacuum break assembly. Start engine nect vacuum advance.
- vacuum break diaphragm shaft should fully retract
7. Carefully remove cap from idle mixture screw. Be
within 10 seconds. If unit fails to retract, replace
careful not to bend screw. Lightly seat screw, then back
vacuum break assembly.
out just enough so engine will run.
5. Allow choke to cool so that when throttle is opened
8. Place transmission in Neutral.
slightly choke blade fully closes. This check must be
performed at an ambient temperature of 60°F to 80°F. 9. Back screw out (richen) 1/8 turn at a tim e until
maximum idle speed is obtained. Then set idle speed to
6. Start engine and determine time for choke blade to
value shown on Engine Emission Control Information
reach full open position. (Start timer when engine
Label. Repeat step 9 to be certain you have maximum
starts).
idle speed.
7. If the choke blade fails to open fully within 3-1/2 10. Turn screw in (lean) with 1/8 turn increments until idle
minutes proceed with steps 8-9-10 below. speed reaches value shown on Engine Emission Control
8. Check voltage at the choke heater connection. (Engine Information Label.
must be running). If the voltage is approximately 12-15 11. Reset idle speed to specification shown on Engine
volts, replace the electric choke unit. Emission Control Information Label.
9. If the voltage is low or zero, check all wires and 12. Check and adjust fast idle as described on the Engine
connections. If the connections at the oil pressure Emission Control Information Label.
switch are faulty, the oil warning light will be off with
13. Reconnect vacuum hoses. Install air cleaner.
the key "on" and engine off. If the fuse is blown, the
radio or turn signal indicator will be inoperative. 14. Recheck idle speed. If necessary, reset to specification.
Repair wires or replace fuses as required.
CARBURETOR MOUNTING TORQUE
10. If step 9 is good, replace oil pressure switch.
When torquing carburetor after removed, overhaul,
N o gasket is used between the choke cover and the replacement or when installing a new heat insulator, torque
choke housing due to grounding requirements. mounting bolts, in a clockwise direction to 23 N-m (198 in.
lbs.).
Checking Solenoid
When retorquing carburetor at recommended mainte
1. Turn on ignition, but do not start engine. nance intervals, retorque to 16 N-m (144 in. lbs.) maximum.
2. Open throttle to allow solenoid plunger to extend.
3. Hold throttle lever wide open, feel end of plunger and CARBURETOR REPLACEMENT (FIG. 6C1-12)
disconnect wire at solenoid. Removal
4. Plunger should move. Some spring tension should be Flooding, stumble on acceleration and other perform
felt. ance complaints are, in many instances, caused by presence
5. If plunger did not move, back out 1/8 hex screw of dirt, water, or other foreign matter in carburetor. To aid
(counterclockwise) one full turn and repeat steps 3 and in diagnosing cause, carburetor should be carefully removed
4. from engine without draining fuel from bowl. Contents of
6. If plunger moves in step 5, connect wire to solenoid and fuel bowl may then be examined for contamination as
adjust idle speed. carburetor is disassembled. Check filter.
LIG H T T R U C K SERVICE M A N U A L
6C1-8 CARBURETOR MODEL 1ME
Installation
.V gff
It is good shop practice to fill carburetor bowl before
installing carburetor. This reduces strain on starting motor
and battery and reduces the possibility of backfiring while
attempting to start engine. A small supply of fuel will enable Fig. 6C l-12 a--C hoke Coil
carburetor to be filled and the operation of float and intake
needle and seat to be checked. Operate throttle lever several
times and check discharge from pump jets before installing
carburetor.
1. Be certain throttle body and intake manifold sealing
surface are clean.
2. Install carburetor insulator.
3. Install carburetor over manifold studs.
4. Install vacuum and fuel lines at carburetor
5. Install attaching nuts and tighten alternately to 21 N-m
(16 ft. lbs.).
6. Tighten fuel line.
7. Connect accelerator linkage.
8. Connect choke and solenoid electrical connectors.
9. Install air cleaner.
10. Check and adjust idle speed.
SOLENOID REPLACEMENT
An inoperative solenoid should be replaced.
Removal
1. Remove carburetor air cleaner. Fig. 6 C 1-12b—Installing Choke
LIG H T T R U C K SERVICE M A N U A L
CARBURETOR MODEL 1ME 6 C 1-9
3 / 16 ’
Fig. 6 C M 2 d -T R C
UNIT REPAIR
DISASSEMBLY Remove choke rod from choke coil lever on end of
choke shaft.
Place carburetor on a holding fixture to prevent
damage to throttle valve. 4. R em ove choke coil assem bly as follows; Align a#21
drill (.159 ") on rivet head and drill only enough to
Air Horn rem ove rivet head. Drill the tw o remaining rivet
heads and then use a drift and small hammer to drive
Removal the remainder o f the rivets out o f the choke housing.
R em ove the three retainers and choke cover assem
1. Remove choke vacuum break diaphragm hose. bly from choke housing.
2. Remove vacuum break diaphragm assembly from air 5. Choke coil housing need not be removed from float
horn by removing two attaching screws. These screws bowl unless replacement is necessary. To remove choke
have a tapered head and do not use lockwashers. housing, remove three attaching screws from float
Remove diaphragm plunger stem from diaphragm to bowl. Two screws have lockwashers and the one facing
choke lever link. (Fig. 6 C 1-13). the choke housing has a tapered head for locating choke
housing.
NOTICE: Screw that retains vacuum break lever to 6. Remove four remaining air horn to bowl attaching
choke shaft is installed with thread torque retaining screws and lockwashers (three long and one short
compound. It is not necessary to remove this screw and screw).
lever unless choke shaft replacement is required.
7. Remove air horn by lifting and twisting back towards
3. Remove fast idle cam attaching screw; then remove fast choke housing so that the choke coil lever link will
idle cam (Fig. 6C1-14). disengage from the choke coil lever at the choke
LIG H T T R U C K SERVIC E M A N U A L
CARBURETOR MODEL 1ME 6C 1-11
Disassembly
1. If required, the choke valve and choke shaft can be
removed from air horn by removing the screw that
retains the vacuum break lever to the choke shaft. Care
should be exercised when removing this screw because
it is retained in place by thread torque retaining
compound. Remove the two attaching screws from the
choke valve, then, remove the choke valve and choke
shaft from air horn.
The choke valve screws are staked in place so it will be
necessary to file off staking and re-stake during assem
bly. Do not bend choke shaft when restaking.
2. N o further disassembly of the air horn is necessary.
Fig. 6C1-15--Air Horn Removal Fig. 6CT17--Pump and Power Piston Actuator Lever
LIG H T T R U C K SERVICE M A N U A L
6C 1-12 CARBURETOR MODEL 1ME
Fig. 6Cl-18--Float Bowl Assembly Fig. 6Cl-20--Pump Discharge " T " Retainer
14. Remove float needle seat and gasket using Tool Throttle Body (Fig. 6C1-22)
J-22769.
15. The idle stop solenoid can be removed at this time if
desired. 1. Invert carburetor bowl on bench and remove two
throttle body to bowl attaching screws. Throttle body
16. Remove the fuel inlet nut, filter and spring (Fig. 6C1- and insulator gasket may now be removed.
2 1 ).
2. N o further disassembly of the throttle body is neces
N o further disassembly of the float bowl is required. sary unless the idle mixture needle is damaged or the
idle channels need cleaning. If necessary to remove the
idle mixture needle, cut the tang from the plastic
limiter cap. Do not install a replacement cap as a bare
mixture screw is sufficient to indicate that the mixture
has been readjusted.
SPRING
CHECK VALVE
FUEL FILTER
GASKET
INLET NUT
Fig. 6C1-19--Metering Rod and Accelerator Pump Fig. 6C1-21-Fuel Filter and Check Valve
LIG H T T R U C K SERVIC E M A N U A L
CARBURETOR MODEL 1ME 6C 1-13
Float Bowl
1. Install fuel filter spring, filter, and check valve assem
bly, (if used), inlet nut and gasket rubber seal on check
valve faces fuel inlet nut.
The fuel inlet check valve must be installed (where
required) in the filter to meet Motor Vehicle Safety
Standards (M .V .S.S.) for roll-over. New service re
placement filter include the check valve, where
required.
1. If removed, install idle mixture needle and spring into -AS PLUNGER
MOVES UP.
throttle body until lightly seated. Back out two turns as FUEL FLOWS
PAST CUP INTO
a preliminary adjustment. Final idle mixture adjust PUMP WELL
ment will be made on vehicle.
2. Invert float bowl and install new throttle body to bowl PUMP CUP OPERATION
insulator gasket.
3. Install throttle body on bowl gasket so all holes in
throttle body are aligned with holes in gasket. Fig. 6Cl-23--Pump Drive Link
LIG H T T R U C K SERVICE M A N U A L
6C1-14 CARBURETOR MODEL 1ME
enter hole in bowl and end of metering rod into jet. H O L D POW ER
P IS TO N D O W N ©
15. Before fastening power piston and pump actuator lever /P L U G GAUGE
Float Level Adjustment (Fig. 6C1-24) 4. Holding downward pressure on power piston, swing
metering rod holder over flat surface of bowl casting
next to carburetor bore.
1. Hold float retaining pin firmly in place push down on
5. Insert gage between bowl casting and lower surface of
float arm at outer end against top of float needle, as metering rod holder. Gage should have a slide fit
shown.
between both surfaces, as shown.
2. Use adjustable "T" scale and measure distance from 6. To adjust, carefully bend metering rod holder up or
top of float at index point on toe to float bowl gasket down.
surface (gasket removed).
7. Install air horn gasket on float bowl by carefully sliding
3. To adjust, bend float pontoon up or down at float arm slit portion of gasket over metering rod holder. Then
junction. align gasket with dowels provided on top of bowl
casting and press gasket firmly in place.
Metering Rod Adjustment (Fig. 6C1-25)
Air Horn
1. Open throttle valve, slide metering rod out of holder
and remove from main metering jet.
2. To check adjustment, back out 1/8" hex screw on idle
stop solenoid and rotate fast idle cam so that cam
follower is not contacting steps on cam.
3. With throttle valve completely closed, apply pressure to
top of power piston and hold piston down against stop.
LIG H T T R U C K SERVIC E M A N U A L
CARBURETOR MODEL 1ME 6C 1-15
L IG H T T R U C K SERVICE M A N U A L
6C 1-16 CARBURETOR MODEL 1ME
LIG H T T R U C K SERVIC E M A N U A L
CARBURETOR MODEL 2SE 6C2-1
SECTION 6C2
GENERAL DESCRIPTION
The Model 2SE is a two barrel, two stage carburetor of maneuvers. A single pontoon float, brass needle seat, and a
down-draft design for use on the 4.1 litre engine. To reduce rubber tipped float valve with pull clip are used to control
carburetor weight, aluminum die castings are used for the fuel level in the float chamber. The float chamber is
air horn, float bowl, throttle body and choke housing. A heat internally vented through a vertical vent cavity in the air
insulator gasket is used between the throttle body and float horn. Above this vent cavity is a removable vent stack
bowl to reduce heat transfer to the float bowl. assembly that has a small meshed screen as its top portion.
This vent stack provides the correct height for the internal
The primary stage has a triple venturi, with a small vent and the screen offers necessary backfire protection to
35mm bore that results in good fuel control during idle and the float chamber.
part throttle operation.
The secondary stage has a large 46mm bore that The Model 2SE float chamber also is externally vented
provides sufficient air capacity for engine power require through a tube in the air horn. A hose connects this tube
ments. An air valve is used in the secondary stage with a directly to a vacuum operated vapor vent valve. When the
single tapered metering rod. engine is not running, the canister vapor vent valve is open
allowing fuel vapors from the float chamber to pass into the
On the 2SE models, an integral 2" pleated paper fuel canister where they are stored until normally purged. The
filter with check valve is mounted in the front of the float venting of fuel vapors from the carburetor float bowl to the
bowl behind the fuel inlet nut to give maximum filtration of canister meets evaporative emission requirements and
incoming fuel. The check valve is used to shut off fuel flow to improves hot engine starting.
the carburetor and prevent fuel leaks if a vehicle roll-over
should occur. An adjustable part throttle screw is used in the float
The float chamber is located adjacent to the primary bowl to aid in refinement of fuel mixtures for good emission
and secondary bores. This feature assures adequate fuel control. This screw is pre-set at the factory and a plug is
supply to both carburetor bores during all vehicle normal installed to prevent tampering and to seal against any fuel
L IG H T T R U C K SERVICE M A N U A L
6C2-2 CARBURETOR MODEL 2SE
leaks. No attempt should be made to adjust this screw in the The 2SE carburetor has a separate screw located in the
field. If it becomes necessary to replace the float bowl, the primary throttle lever for fast idle speed adjustment. A
new service float bowl will include an adjustable part separate screw, located in the throttle body, is used to make
throttle (A.P.T.) screw which has been pre-set at the factory the base speed setting (solenoid de-energized).
and plugged as required. The carburetor model identification is stamped verti
A hot idle compensator assembly (when used) is cally on the float bowl in a flat area adjacent to the vacuum
located in the air horn casting. The opening and closing of tube Figure 6C2-2). If replacing the float bowl, follow the
the hot idle compensator valve is controlled by a bi-metal manufacturer’s instructions contained in the service pack
strip that is calibrated to a specific temperature. When the age so that the identification number can be transferred to
valve opens, additional air is allowed to by-pass the throttle the new float bowl. Refer to the carburetor part number on
valves and enters the intake manifold to prevent rough idle the bowl when servicing the carburetor.
during periods of hot engine operation. An exhaust gas recirculation system (E.G.R.) is used
The idle mixture needle is recessed in the throttle body on all applications to help control oxides of nitrogen. The
casting and sealed with a hardened steel plug to discourage vacuum supply ports necessary to operate the recirculation
tampering with the factory adjusted mixture setting in the valve are located in the throttle body and connect through a
field which could upset exhaust emissions. The plug must channel to a tube (location C) in the float bowl. This tube is
not be removed and idle mixture screw re-adjusted unless connected by a rubber hose to the E.G.R. valve. California
required due to major carburetor overhaul or throttle body models use a fixed idle air by-pass system to reduce the
replacement in which case special service procedures must amount of air flowing through the carburetor primary
be carefully followed. venturi to prevent the main nozzle from feeding fuel at idle.
The choke system of the 2SE carburetor uses a dual On the 2SE carburetor, the primary and secondary
vacuum break system. The front (primary side) vacuum throttle shafts, the secondary actuating lever and lock-out
break unit with bracket is mounted on the air horn and the lever are coated with a special coating to reduce friction and
rear unit is mounted on the idle speed solenoid bracket wear in these operating parts. Also, the secondary throttle
located on the secondary side of the carburetor. An electri bore and valve are coated with a special graphite compound
cally heated thermostatic choke coil is mounted in the choke for minimum air leakage past the valve for good idle air
housing located on the secondary side of the carburetor. To control. Care should be taken during carburetor service to
provide a non-adjustable design to discourage field readjust not disturb or damage these coatings.
ment of factory settings, the 2SE carburetor usues vacuum A throttle body mounted idle speed solenoid is used to
break rods of a non-bendable design, a special cap over the position the primary throttle valve to obtain idle speed
vacuum break unit adjustment screw, a special notch in requirements of the engine.
choke cover which must be indexed with a raised boss cast in
cover mounting flange on the choke housing, and special Carburetor Operation
rivets (with retainers) to retain choke thermostatic cover
and coil assembly in choke housing. The m odel 2SE carburetor has six basic system s.
T hey are float, idle, main metering, power, pump and
choke (Fig. 6C2-3).
VENTSTACK
HOT IDLE COMPENSATOR
SECONDARY AIR VALVE
SECONDARY AIR
CHOKE VALVE
VALVE LEVER
PUMP LEVER
CHOKE HOUSING
/P R IM A R Y SIDE
SECONDARY SIDE ♦/V A C U U M BREAK
VACUUM BREAK
SLOW IDLE
SPEED SCREW
Sr ■ FAST IDLE
ADJUSTING SCREW
LIG H T T R U C K SERVIC E M A N U A L
CARBURETOR MODEL 2SE 6C2-3
HOT IDLE
COMPENSATOR
FLOAT HINGE •EXHAUST GAS IDLE CROSS-OVER
PLASTIC RECIRCULATION PASSAGE
INSERT
UPPER
PULL CLIP IDLE AIR BLEED
IDLE CHANNEL
VENT TUBE
RESTRICTION
TO CANISTER
FLOAT VALVE
TIMED VACUUM
PORT FOR E.G.R.*
LOWER IDLE
AIR BLEED
THROTTLE VALVE
(DOTTED LINE - OFF
IDLE POSITION)
OFF IDLE
PORT
_ — PLUG
METERING ROD
HANGER MAIN DISCHARGE
NOZZLE
SECONDARY
MAIN METERING AIR VALVE
ROD (OPEN)
■
FUEL PICKUP
TUBE
MAIN METERING
■
FUEL WELL
POWER PISTON
JET (SECONDARY
POWER PISTON
SPRING
PLUG
SECONDARY
PART THROTTLE THROTTLE VACUUM CHANNEL
VALVE (TO POWER PISTON)
CALIBRATION SCREW VACUUM CHANNEL
(FACTORY ADJUSTED) (TO POWER PISTON)
LIG H T T R U C K SERVICE M A N U A L
6C2-4 CARBURETOR MODEL 2SE
ON-VEHICLE SERVICE
MODEL 2SE ADJUSTMENTS 5. If plunger does not move in and out as lead is discon
Before checking or resetting the carburetor as the cause nected and connected, insert test lamp (1893 bult or
of poor engine performance or rough idle, check ignition smaller) between the solenoid feed wire and ground.
system including distributor, timing, spark plugs and wires. 6. If light lights, replace solenoid.
Check air cleaner, evaporative emission system, EFE 7. If light does not light, locate cause of open circuit in
system, PCV system, EGR valve and engine compression. solenoid feed wire.
Also inspect intake manifold vacuum hose gaskets and
connections for leaks and check torques of carburetor IDLE SOLENOID REPLACEMENT
mounting bolts/nuts.
An inoperative solenoid should be replaced.
Refer to Figures 6C2-A through 6C2-I for carburetor
adjustment procedures and specifications. Removal
1. Remove carburetor air cleaner.
2. Disconnect electrical connector at solenoid.
Checking Idle Solenoid 3. Unscrew and remove solenoid from float bowl
1. Turn on ignition, but do not start engine. assembly.
2. Open throttle to allow solenoid plunger to extend, close
Installation
throttle.
1. Hold choke valve wide open so that fast idle cam
3. Disconnect lead at solenoid. Solenoid plunger should
follower clears fast idle cam.
drop away from throttle lever.
2. Install solenoid and turn in until it contacts lever tang.
4. Connect solenoid lead. Plunger should move out and
contact the throttle lever. Solenoid may not be strong 3. Connect electrical connector.
enough to open the throttle, but the plunger should 4. Install air cleaner.
move. 5. Check and adjust idle speed.
LIG H T T R U C K SERVIC E M A N U A L
CARBURETOR MODEL 2SE 6C2-5
FLOAT ADJUSTMENT
PUMP ADJUSTMENT
NON-ADJUSTABLE
LIG H T TR U C K SERVIC E M AN U AL
6C2-6 CARBURETOR MODEL 2SE
PUSH ON IN T E R
INSERT .0 8 5 M EDIATE CHOKE
PLUG G AG E INTO LEVER U N TIL
EDGE OF LEVER SHO ULD HOLE PROVIDED CHOKE VALVE
JUST C O N T A C T SIDE OF
IS CLOSED
PLUG G AG E AS SHOW N
LIG H T T R U C K SERVICE M A N U A L
CARBURETOR MODEL 2SE 6C2-7
FIGURE 1
1. CHOKE COIL LEVER ADJUSTMENT MUST BE CORRECT AND FAST IDLE
ADJUSTMENT MUST BE MADE BEFORE PROCEEDING.
2. USE CHOKE VALVE MEASURING GAUGE J-26701. TOOL MAY
BE USED WITH CARBURETOR ON OR OFF ENGINE. IF OFF ENGINE,
PLACE CARBURETOR ON HOLDING FIXTURE SO THAT IT WILL REMAIN
IN SAME POSITION WHEN GAUGE IS IN PLACE.
3. ROTATE DEGREE SCALE UNTIL ZERO (0) IS OPPOSITE POINTER.
4. WITH CHOKE VALVE COMPLETELY CLOSED (NECESSARY FOR FAST
IDLE SCREW TO BE ON HIGH STEP OF FAST IDLE CAM FOR INITIAL ZERO
SETTING OF GAUGE). PLACE MAGNET SQUARELY ON TOP OF CHOKE VALVE.
5. ROTATE BUBBLE UNTIL IT IS CENTERED.
FIGURE 2
6. ROTATE SCALE SO THAT DEGREE SPECIFIED FOR ADJUSTMENT IS
OPPOSITE POINTER.
7. PLACE FAST IDLE SCREW ON SECOND STEP OF CAM AGAINST RISE OF
HIGH STEP.
8. HOLD CHOKE VALVE TOWARD CLOSED POSITION BY LIGHTLY PUSHING
ON INTERMEDIATE CHOKE LEVER.
9. TO ADJUST, BEND FAST IDLE CAM ROD UNTIL BUBBLE IS CENTERF.D.
10. REMOVE GAUGE.
^ LEVE LIN G S P E C IF IE D A N G L E
BUBBLE
©DEGREE SEE SP EC S .)
(C E N T E R E D )
SCA LF
/ B EN D RO D T O A D J U S T
P O IN T E R
MAGNET
FIG U R E 1
HOLD C H O K E VALVE
TOW ARD C L O S E D
PO S ITIO N BY LIG H TLY
PU S H IN G ON IN T E R
M E D IA T E C H O K E LEVER
FIG U R E 2
2 S E CARBURETO R A D J U S T M E N T S
NOTE: PRIOR TO A D JUSTM ENT, REMOVE PRIMARY VAC UUM BREAK FROM
CARBURETOR. PLACE BRACKET IN A VISE AND, USING SAFETY PRECAUTIO N S,
G R IN D OFF A D JU S TM EN T SCREW CAP. REINSTALL VACUUM BREAK.
FIGURE 1
1. USE CHOKE VALVE M EASURING GAUGE J-26701 . TO O L MAY
BE USED W ITH CARBURETOR ON OR OFF ENGINE. IF OFF ENGINE, PLACE
CARBURETOR ON HO LD IN G FIXTURE SO TH A T IT WILL REMAIN IN SAME
PO SITIO N WHEN G AUGE IS IN PLACE.
3. W ITH CHOKE VALVE COM PLETELY CLOSED (FAST IDLE SCREW M UST
BE ON H IG H STEP OF FAST IDLE CAM ), PLACE M AG NET SQUARELY
ON TOP OF CHOKE VALVE.
FIGURE 2
5. ROTATE SCALE SO TH A T DEGREE SPECIFIED FOR AD JU S TM EN T IS
O PPOSITE PO INTER.
6. SEAT CHOKE VAC UUM DIAPHRAGM USING VAC UUM SOURCE. OVER 5"
HG. VACUUM M UST BE APPLIED TO VACUUM BREAK. ALSO, AIR VALVE
ROD M UST N O T BE RESTRICTING VACUUM DIAPHRAG M FROM SEATING.
IT MAY BE NECESSARY TO BEND AIR VALVE ROD TO O BTAIN A SLIG HT
CLEARANCE BETWEEN ROD AND END OF SLOT IN AIR VALVE LEVER.
PROCEED TO AIR VALVE ROD AD JU S TM EN T AFTER PRIMARY VACUUM
BREAK ADJUSTM ENT.
ODEGREE © L E V E L IN G
SPECIFIED ANGLE BUBBLE
(SEE SPECS.) SCALE
(CENTERED)
® AIR VALVE
CLOSED
© MAGNET
\ POINTER
ROTATE Al« VALVE
IN THE DIRECTION
OF OPEN AIR VALVE FIGURE 1
BY APPLYING ALIGHT
PRESSURE TO THE
AIR VALVE SHAFT. TO ADJUST,
BEND AIR
VALVE ROD
UNTIL BUBBLE
IS CENTERED.
SEAT VACUUM
DIAPHRAGM USING
VACUUM SOURCE
2 S E CARBURETOR A D J U S T M E N T S
FIG URE 1
1. REMOVE VACUUM BREAK FROM CARBURETOR. PLACE BRACKET IN A
VISE AND, USING SAFETY PRECAUTIONS, G RIND OFF ADJUSTM ENT
SCREW CAP.
FIG UR E 2
3. USE CHOKE VALVE M EASURING GAUGE J-26701 . TO O L MAY
BE USED W ITH CARBURETOR ON OR OFF ENG INE. IF OFF ENGINE,
PLACE CARBURETOR ON HO LDING FIXTURE SO TH A T IT WILL REMAIN
IN SAME PO S ITIO N WHEN GAUGE IS IN PLACE.
5. W ITH CHOKE VALVE COM PLETELY CLOSED (FAST IDLE SCREW M UST BE ON
HIG H STEP OF FAST IDLE CAM), PLACE M AGNET SQUARELY ON TOP OF
CHOKE VALVE.
10. TO ADJUST, USING 1/8" HEX W RENCH, TURN SCREW IN REAR COVER U N T IL
BUBBLE IS CENTERED. REMOVE CUP INSTALLED IN STEP 2 (FIG URE 1)
AFTER ADJUSTM ENT. APPLY SEALER (SUCH AS SILICO NE SEALANT RTV
RUBBER OR EQ UIVALENT) OVER SCREW HEAD TO SEAL SETTING .
11. REMOVE GAUGE.
© S E A T D IA P H R A G M U S IN G V A C U U M S O U R C E .
(A IR B L E E D S E A L E D A N D O V E R SPECIFIED ANGLE
5 ” H g V A C U U M ). (SEE SPECS.)
© ADJUSTMENT
SCREW ACCESS
© LEVELING
bubble
(C ENTERED )
(CAP REMOVED)
© Ii PUMP
PLUNGER CUP ' ©CHOKE
©
;9 )
DURING READING OF ANGLE
^ FIGURE 1 / VALVE
CLOSED
^ . ( F A S T IDLE
GAUGE, LIGHTLY PUSH SCREW
CLOCKW ISE ON IN T E R MUST BE ON
MEDIATE CHOKE w HIGH STEP OF
LEVER (IN DIRECTION T FAST IDLE
OF CLOSED CHOKE CAM)
VALVE) AND HOLD rj
IN POSITION WITH
RUBBER BAND. ®
TO ADJUST, USING 1 /8 ”
HEX WRENCH, TURN
SCREW IN REAR COVER
UNTIL BUBBLE IS CENTERED.
REMOVECUP INSTALLED IN STEP 2
(FIGURE 1) AFTER ADJUSTMENT.
APPLY SEALER (SUCH AS SILICONE
'SEALANT RTV RUBBER OR EQUIVALENT) OVER
FIGURE 3
SCREW HEAD TO SEAL SETTING.
FIGURE 2
5. ROTATE SCALE SO THAT DEGREE SPECIFIED FOR ADJUSTMENT IS
OPPOSITE POINTER.
6. HOLD PRIMARY THROTTLE VALVE WIDE OPEN.
7. DURING READING OF ANGLE GAUGE:
LIGHTLY PUSH CLOCKWISE ON INTERMEDIATE CHOKE LEVER (IN
DIRECTION OF CLOSED CHOKE VALVE) AND HOLD IN POSITION WITH
RUBBER BAND.
8. TO ADJUST, BEND TANG ON THROTTLE LEVER UNTIL BUBBLE IS CENTERED.
9. REMOVE GAUGE.
10. AT THIS POINT REINSTALL CHOKE COVER AND COIL ASSEMBLY (IF
PREVIOUSLY REMOVED AND NOT REINSTALLED) FOLLOWING
INSTRUCTIONS IN CHOKE STAT COVER RETAINER KIT (INCLUDES
REPLACEMENT ATTACHING RIVETS).
© L E V E L IN G
V -T B U B B LE © S P E C IF IE D A N G L E
/ J (C E N T E R E D ) (S E E S P E C S .)
"
CHOKE
V A LV E BEND TANG TO
CLOSED A D J U S T U N T IL
B U B B L E IS
CENTERED.
© D U R I N 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 ON
IN T E R M E D IA T E C H O K E LEVER (IN
D IR E C T IO N O F C L O S E D C H O K E
V A L V E ) A N D H O L D IN P O S IT IO N
W IT H R U B B ER B A N D .
©V H O L D P R IM A R Y T H R O T T L E
V A LV E W ID E O P E N
2S E CARBURETO R A D J U S T M E N T S
© RECONNECT
SOLENOID
ELECTRICAL
LEAD AFTER
ADJUSTMENT
© TURN SOLENOID
SCREW TO ADJUST
OPEN THROTTLE
SLIGHTLY TO
CURB IDLE SPEED ALLOW SOLENOID
TO SPECIFIED RPM PLUNGER TO
(SOLENOID ENERGIZED) FULLY EXTEND
Fig. 6 C 2 -H —C a rb u re to r Adjustments
( 5) IF THE MECHANICAL
SETTING (STEP 4) VARIES
MORE THAN ±1.5mm FROM
SPECIFICATIONS, REMOVE SELECT
AIR HORN AND ADJUST GAUGE
FLOAT LEVEL TO SPECIFI TO MATCH
CATIONS FOLLOWING CARBURETOR
NORMAL ADJUSTMENT SERIES BEING
PROCEDURES. CHECKED
TOOL J-9789-135
© I F MECHANICAL SETTING IS FOUND TO BE WITHIN BLUE - 1979-81 2SE
SPECIFIED TOLERANCE - REPLACE AIR HORN SCREW, RED - 1979 1/2-80 E2SE
VENT STACK AND VENT STACK SCREWS. WHITE - 1981 E2SE
FLOAT GAUGE - EXTERNAL CHECKING PROCEDURE
(2SE - E2SE TYPICAL)
6C2-14 CARBURETOR MODEL 2SE
CHECKING ELECTRIC CHOKE heads and retainers, use a draft and small ham m er to
1. Remove air cleaner. W ith engine off, hold throttle half drive the rem ainder of the rivets out of the choke
open. O pen and close choke several tim es. W atch housing. Use care in drilling to prevent dam age to the
linkage to be certain all links are connected and there choke cover or housing. Remove the three retainers and
are no signs of dam age or binding. choke cover assembly from choke housing.
2. If choke or linkage binds, sticks or works sluggishly due 3. Remove choke coil from housing.
to petroleum gum form ation, clean with choke cleaner 4. Install the choke cover and coil assembly in choke
or equivalent. Use cleaner as directed on can. housing as follows:
3. Allow choke to cool so th at when throttle is opened a. Install the choke cover and coil assembly in the choke
slightly, choke blade fully closes. This check should be housing, aligning notch in cover with raised casting
m ade at an am bient tem perature of 15° to 27°C (59° to projection on housing cover flange. M ake sure coil
80°F). pick-up tang engages the inside choke coil lever.
4. S ta rt engine and determ ine tim e for choke blade to A choke cover retainer kit is required to attach the
reach full open position. (S ta rt tim er when engine choke cover to the choke housing. Install proper
starts.) retainers and rivets contained in kit using a suitable
5. If choke blade fails to open fully within 3-1/2 minutes, blind rivet installing tool. It may be necessary to use
open throttle about 1/3. If choke still fails to open fully, an adapter (tube) if installing tool interferes with
proceed with steps 6 and 7. electrical connector tower on choke cover.
6. Check voltage at the choke heater connection: (Engine 5. Connect choke electrical connector.
m ust be running). 6. S ta rt engine, check operation of choke and then install
a. If the voltage is approxim ately 12-15 volts, replace air cleaner.
the electric choke unit.
b. If the voltage is low or zero, check all wires and Idle Mixture Check and Adjustment (Propane
connections. If any connections in the oil pressure Enrichment)
sw itch c irc u itry are faulty or if the oil pressure
switch is failed open, the oil pressure w arning light Idle m ixture screws have been present at the factory
and sealed. Idle m ixture should be adjusted only in the case
will be on with engine running. R epair wires or
of m ajor carburetor overhaul, th rottle body replacem ent or
connections as required.
high emissions as determ ined by offical inspections. A djust
7. If steps 4a and 4b do not correct problem, replace oil ing m ixture by other than the following method may violate
pressure switch. Federal an d /o r California or other state or provincial laws.
No gasket is used between the choke cover and the
Because of the sealed idle m ixture screws, the idle
choke housing due to grounding requirem ents.
m ixture checking procedure requires artificial enrichm ent
8. Reinstall air cleaner. by adding propane.
1. Set parking brake and block drive wheels. On cars
CHOKE COIL REPLACEMENT equipped with vacuum parking brake release, discon
Choke m echanism should be checked for free opera nect and plug hose at brake. Engine must be at normal
tion. A binding condition may have developed from petro operating tem perature and air conditioning off.
leum gum form ation on the choke shaft or from dam age. 2. Disconnect and plug hoses as directed on the Emission
Choke shafts can usually be cleaned without disassembly. Control Inform ation Label under the hood.
1. Remove air cleaner and disconnect choke electrical 3. Connect an accurate tachom eter to engine.
connector. 4. Disconnect vacuum advance and set tim ing to specifi
2. Align a # 2 1 drill (.1 5 9 ") on rivet head and drill only cation shown on the Emission Control Inform ation
enough to remove rivet head. A fter removing rivet Label. Re-connect vacuum advance.
UNIT REPAIR
The procedures below apply to the com plete overhaul engine (refer to On-Car Service). A complete carburetor
with the carburetor removed from the engine. However, in overhaul includes disassembly, thorough cleaning, inspec
m any cases service adjustm ents of individual systems may tion, and replacement of all gaskets - diaphragms - seals -
be com pleted without removing the carburetor from the
LIGHT TRUCK SERVICE MANUAL
6C2-16 CARBURETOR MODEL 2SE
worn or dam aged parts, and service adjustm ent of individual reassembly. Remove plastic bushing used on rods and
systems. retain for later re-use.
5. Remove secondary side idle speed solenoid-vacuum
CARBURETOR DISASSEMBLY break b racket a ttac h in g screws from th ro ttle body
Before perform ing any service on the carburetor, it is (Fig. 6C2-3b). Then, rotate bracket to remove second
essential th at the carburetor be placed on a holding fixture ary side vacuum break link from slot in break and
such as tool J-9 7 8 9 -1 18 or equivalent. W ithout the use of choke lever.
the holding fixture, it is possible to dam age throttle valves. 6. Remove and discard retaining clip from interm ediate
choke rod at choke lever (Fig. 6C2-4). A new retaining
Idle Speed Solenoid clip is required for reassembly. Remove choke rod and
plastic bushing from choke lever, and save the bushing
Removal for later re-use.
1. Bend back retaining tabs on lockwasher; then remove 7. Remove (2) sm all screws th a t retain the hot idle
large solenoid retaining nut using suitable wrench. Use com pensator valve (Fig. 6C2-5). Remove valve and seal
care in removing nut with wrench to avoid bending or from air horn. Discard seal. Hot idle com pensator valve
dam ag in g choke linkage, solenoid b rack et, vacuum m ust be removed to gain access to short air horn to bowl
break unit or throttle lever. attaching screw.
2. Remove lockwasher and solenoid unit from bracket. 8. Remove the seven (7) air horn to bowl attaching screws
NOTICE: T he solenoid should not be imm ersed in any and lockwashers (Fig. 6C 2-6). Remove vent and screen
type of c a rb u re to r cleaner and should alw ays be assembly.
removed before com plete carburetor overhaul. Im m er 9. R otate fast idle cam to the full U P position and remove
sion in cleaner will dam age solenoid. air horn assembly by tilting to disengage fast idle cam
and pum p rod from hole in pump lever (Fig. 6C2-7). If
pum p plunger came out of float bowl with air horn
Air Horn removal, remove pump plunger from air horn. The air
1. Remove clip from hole in pump lever. Do not remove horn gasket should rem ain on the float bowl for removal
pump lever retaining screw or pum p lever from air horn later.
assembly. Do not remove fast idle cam screw and cam from float
2. Rem ove hose from prim ary side vacuum break bowl. These parts are not serviced separately and are to
assembly. rem ain perm anently in place as installed by the factory.
The new service replacem ent float bowl will include the
3. Rem ove (2) screws securing p rim ary side vacuum
secondary lock-out lever, fast idle cam and screw
break bracket to air horn (Fig. 6C2-3b); then, rotate
installed as required.
vacuum break and b rack et assem bly to disengage
vacuum break link from slot in vacuum break and 10. Remove fast idle cam rod from choke lever by rotating
choke lever and air valve rod from slot in air valve lever. rod to align squirt on rod with small slot in lever.
N O TIC E: Do not place vacuum break assem bly in
carburetor cleaner. Immersion in cleaner will dam age
vacuum break diaphragm . Air Horn Disassembly
4. If necessary to replace the vacuum break rod or air 1. Remove pump plunger stem seal by inverting air horn
valve rod, remove and discard retaining clips from end and use a small screwdriver to remove staking holding
of air valve rods. New retaining clip is required for the seal retainer in place. Remove and discard retainer
and seal.
LO CATING LUG
VALVE BRACKET AT TAC H IN G
LEVER SCREWS
SECONDARY SIDE
VACUUM
PR IM AR Y SIDE
V A C U U M BREAK
Fig. 6C2-3b--Vacuum Break and Idle Speed Solenoid Fig. 6C2-4--Choke Rod and Choke Lever
H O T IDLE
2. F urth er disassembly of the air horn is not required for pressing the piston down and releasing it with a snap.
cleaning purposes or air horn replacem ent. The new This will cause the power piston spring to snap the
service a ir horn assem bly includes the secondary piston up against the plastic retainer. This procedure
m etering rod-air valve assembly and is pre-set at the may have to be repeated several times. Do not remove
factory. N o attem pt should be m ade to change this power piston by using pliers on m etering rod holder.
adjustm ent in the field. The air valve and choke valve 7. Remove the power piston spring from the piston bore. If
screws are perm anently staked in place and should not necessary, m etering rod may be removed from power
be removed. piston hanger by compressing spring on top of m etering
rod and aligning groove on rod with slot in holder. Use
Float Bowl Disassembly extrem e care in handling the m etering rod to prevent
1. Remove air horn gasket. G asket is pre-cut for easy dam age to m etering rod tip.
removal around m etering rod and hanger assembly. 8. Remove the m ain m etering jet using a wide blade
2. Remove pump plunger from pum p well. screwdriver th at fully fits the slot in top of the jet (Fig.
6C2-8).
3. Remove pump return spring from pum p well.
9. Using a small slide ham m er or equivalent, remove
4. Remove plastic filler block over float valve.
plastic retainer holding pump discharge spring and
5. Remove float assembly and float valve by pulling up on check ball in place (Fig. 6C 2-10). D iscard plastic
retaining pin. Remove float valve seat and gasket, using retainer (a new retainer is required for reassem bly).
a wide blade screwdriver th a t fully fits the slots on top T urn bowl upside down catching pum p discharge
of the float valve seat. spring and check ball in palm of hand.
6. Remove power piston and m etering rod assembly by
NOTICE: Do not attem pt to remove plastic retainer by
depressing piston stem and allowing it to snap free (Fig.
prying out with a tool such as a punch or screwdriver -
6C2-8). The power piston can be easily removed by
this will dam age the sealing beads on the bowl casting
surface requiring com plete float bowl replacem ent.
A IR H O R N S C R E W S - a id lio d k i c r o c u /c
Choke Disassembly
1. Support float bow and throttle body as an assembly on a
suitable holding fixture such as Tool J-9789-1 18. Align
a # 2 1 drill (.1 5 9 ") on rivet head and drill only enough
to remove rivet head (Fig. 6C 2-11). D rill the two
rem aining rivet heads and then use a drift and small
ham m er to drive the rem ainder of the rivets out of the
choke housing. Use care to prevent dam age to choke
cover or housing.
2. Remove the choke cover assembly from choke housing.
3. Remove screw from end of interm ediate choke shaft
inside choke housing. Remove choke coil lever from
shaft.
4. Remove interm ediate choke shaft and lever assembly
from float bowl by sliding rearw ard out throttle lever
Fig. 6C2-6--Air Horn Screws side (Fig. 6C2-12).
LIGHT TRUCK SERVICE MANUAL
6C2-18 CARBURETOR MODEL 2SE
RETAINER
MAIN METERING
ROD
MAIN METERING
JET
Rivets
and
Disassembly of Rem aining Float Bowl Parts
Retainers
1. Remove/fuel inlet nut, gasket, check valve filter assem
bly, and spring.
2. Remove (4) throttle body to bowl attaching screws and
lockwashers and remove throttle body assembly (Fig.
6C2-14).
3. Remove throttle body to bowl insulator gasket.
Throttle Body
Disassem bly
Place throttle body assembly on carburetor holding
fixture to avoid damaging throttle valves.
HOLDER
GROD
R E T A IN E R
PO W ER P IS T O N
INTERMEDIATE CHOKE
SHAFT AND LEVER
ASSEMBLY
Fig. 6C2-9~Power Piston Assembly Fig. 6C2-12--Choke Shaft and Lever Assembly
FLAT PUNCH
CENTER PUNCH
STEP#2
LOCATOR
STEP #1 p 0 |N T
\HACKSAW
RECESSED IDLE MIXTURE
NEEDLE AND PLUG LOCATION
Fig. 6C2-15—Idle Mixture Needle
1. Inspect pump plunger and cup for cracks, scores, 4. Check air valve and secondary metering rod for
or cup excessive wear. A used pum p cup will binding conditions.
shrink when dry. If dried out, soak in fuel for 8 If air valve or m etering rod is dam aged, the air
hours before testing. horn assembly must be replaced. Also, check air
2. Inspect pum p d u ratio n and retu rn springs for valve spring for proper installation (tension
being weak or distorted. against air valve lever)
3. Check all pum p passages and je t for dirt, im proper E.Rough Idle
seating of discharge check ball and scores in pump 1. Inspect gasket and gasket m ating surfaces on
well. Check condition of pump discharge check castings for dam age to sealing beads, nicks, burrs
ball spring. and other dam age.
4. Check pump linkage for excessive wear; repair or 2. Clean all idle fuel passages.
replaceas necessary. 3. If removed, inspect idle m ixture needle for ridges,
C .H ard S tarting - Poor Cold O peration burrs, or being bent.
1. Check choke valve and linkage for excessive wear, 4. Check throttle lever and valves for bind, nicks and
binds or distortion. other dam age.
2. Inspect choke vacuum diaphragm s for leaks. 5. C heck all d iaphragm s for possible ru p tu res or
3. Clean or replace carburetor fuel filter. leaks.
4. Inspect float valve for sticking, dirt, etc. 6. C lean plastic p arts only in S to d d ard solvent -
5. Also check items under " Flooding". never in gasoline.
D.Poor Perform ance - Poor Gas Mileage
1. Clean all fuel and vacuum passages in castings. CARBU RETO R A SSEM B LY
2. Check choke valve for freedom of movement.
3. Check power piston, m etering rod, and jet for dirt, Throttle Body
sticking, binding, d am aged p arts or excessive 1. Holding prim ary throttle lever wide open, install lower
wear. end of pump rod in throttle lever by aligning squirt on
C A U TIO N : DO N O T
HO O K PULL CLIP
IN THESE HOLES
FLOAT AND
LEVER ASSEMBLY
(18 ft. lbs.). Tightening beyond specified torque can 16. Install power piston and m etering rod assembly into the
dam age nylon gasket and cause fuel leak. float bowl and main m etering jet. Use care installing
W hen installing a service replacem ent filter, make sure the m etering rod into the jet to prevent dam aging the
the filter is the type th at includes the check valve to m etering rod tip. Press down firmly on plastic power
m eet U .S. M otor V ehicle S afety S ta n d ard s piston retainer to make sure the retainer is seated in
(M .V .S.S.). W hen properly installed,hole in filter faces recess in bowl and the top is flush with the top of the
toward inlet nut. Ribs on closed end of filter element bowl casting. If necessary, tap retainer lightly in place
prevent filter from being installed incorrectly unless using a drift and small ham m er.
forced. 17. Install plastic filler block over float valve, pressing
5. Install choke housing on throttle body, m aking sure dow nw ard until properly seated (flush w ith bowl
raised boss and locating lug on rear of housing fit into casting surface).
recesses in float bowl casting (Fig. 6C 2-13). Install (2) 18. Install air horn gasket on float bowl by carefully sliding
choke housing attaching screws and lockwashers in slit portion of gasket over the two dowel locating pins on
throttle body and tighten screws evenly and securely. the float bowl.
6. Install interm ediate choke shaft and lever assembly in 19. Install pump return spring in pum p well.
float bowl by pushing through from throttle lever side 20. Install pump plunger assembly in pump well.
(Fig. 6C2-12).
7. W ith interm ediate choke lever in the U P (12 o’clock) Air Horn
position, install therm ostatic coil lever inside choke
housing onto flats on interm ediate choke shaft. Coil is Assembly
properly aligned when the coil pick-up tang is at the top 1. Install new pum p plunger stem seal and retainer in air
(12 o’clock) position. Install inside lever retaining horn casting. Lightly stake seal retainer in three places,
screw into end of interm ediate choke shaft and tighten choosing locations different from the original stakings.
securely.
2. Install fast idle cam rod in lower hole of vacuum break
Do not install th e rm o sta tic choke cover and coil
and choke lever, aligning squirt on rod with small slot in
assembly in housing until inside coil lever is adjusted
lever (squirt end of rod points inward toward air horn).
(see A djustm ents).
8. Install pum p discharge steel check ball and spring in
Air Horn To Bowl
passage next to float cham ber (Fig. 6C2-10). Insert end
of new plastic retainer into end of spring and install Installation
retainer in float bowl, tapping lightly in place until top
1. R otate fast idle cam to the full U P position and tilt the
of retainer is flush with bowl casting surface.
air horn assembly to engage lower end of fast idle cam
9. Using a wide-blade screwdriver th a t fully fits the slot in rod in slot in fast idle cam and install pump rod end into
the top, install m ain m etering je t and the float valve hole in pump lever (Fig. 6C2-24). Then, holding down
seat (with gasket) into bottom of float bowl. Tighten jet on the pump plunger assembly, carefully lower air horn
and seat securely (Fig. 6C2-26). assembly onto float bowl, guiding pump plunger stem
10. To m ake adjustm ent easier, carefully bend float arm through hole in air horn casting. Do not force air horn
upward at notch in arm before assembly. assembly onto bowl, but rath er lightly lower in place.
11. Install float valve onto float arm by sliding float lever 2. Install vent and screen assembly over vent stack in air
under pull clip. C orrect installation of the pull clip is to horn Then, install (7) air horn to bowl attaching screws
hook the clip over the edge of the float on the float arm and lockwashers. following proper installation location
(Fig. 6C2-16). and tightening sequence. All air horn screws must be
12. Install float retaining pin into float arm with end of loop tightened evenly and securely. See Fig. 6C2-18 for
of pin facing pum p well. Then, install float assembly by proper tightening sequence.
aligning valve in the seat and float retaining pin into
locating channels in float bowl. 3. Install new retainer clip through hole in end of pump
13. A djust float level as follows: rod extending through pum p lever, making sure clip is
a. Hold float retaining pin firmly in place and push securely locked in place.
down lightly on float arm at outer end against top of 4. Install new seal in recess of air horn, then install hot
float needle. idle com pensator valve and retain w ith (2) sm all
b. Using adjustable " T " scale, m easure from top of attaching screws. Tighten screws securely (Fig. 6C2-
float bowl casting surface (air horn gasket removed) 11).
to top of float at toe (See inset, Float A djustm ent 5. Install plastic bushing in upper hole in vacuum break
Fig. 6C 2-A ). and choke lever, m aking sure small end of bushing
faces retaining clip when installed. W ith inner coil
c. Bend float arm as necessary for proper adjustm ent by
lever and interm ediate choke lever at the 12 o’clock
pushing on pontoon (see specifications).
position, install interm ediate choke rod in bushing.
d. Visually check float alignm ent after adjustm ent. R etain rod with new clip, pressing clip securely in place
14. Install power piston spring into piston bore. with needlenose pliers (Fig. 6C2-10). M ake sure clip
15. If removed, assemble m etering rod to holder on power has full contact on rod but is not seated tightly against
piston. Spring m ust be on top of arm when assembled bushing. Rod to bushing clearance should be ,8mm
correctly (Fig. 6C2-9). (.030").
CARBURETOR MODEL 2SE 6C2-23
"TRAPPED S T A T ”
COIL
3 /1 6 ”
ADAPTER (P ro c u re s te e l tu b in g lo c a lly )
CARBURETOR
MODEL 2SE
CD
1
cX
o
3<
o
6 C 2 -2 5
2
CARBURETOR MODEL M2ME 6C3-1
SECTION 6C3
CARBURETOR MODEL M2ME
CONTENTS
GENERAL DESCRIPTION
The M 2M E carburetors (Fig. 6C3-2) for light duty rivets are installed at the factory to retain the setting of the
emission vehicles are basically carryover for the 1981 model therm ostatic coil in the housing.
except a new electric choke carburetor is used replacing the A special cut-out is notched in the choke cover which
hot air choke model (M 2M C ) previously used. All models m ust be aligned with an extended tab on one of the choke
include ta m p e r-re sista n t featu res such as rivets, plugs, retainers which is located in the 2 o’clock position. The other
covers, etc. to discourage readjustm ent of facotory settings two retainers are of the conventional design (no tab).
which could affect eith er or both em ission control and
The choke therm ostatic cover and coil assembly m ust
driveability. For example, as a carryover feature, blind
not be removed unless required during major carburetor
overhaul, or replacem ent of the cover and coil assembly or
choke housing in which case special service procedures are
necessary. An integral 2" pleated paper fuel filter, with
^ VAPOR VENTTUBE
j- & . (TO CANISTER) check valve, is m ounted in the front of the float bowl behind
the fuel inlet nut to give m axim um filtration of incoming
fuel. The check valve is used to shut off fuel flow to the
ca rb u re to r and prevent fuel leaks if a vehicle roll-over
should occur.
A single pontoon float, brass needle seat, and a rubber
tipped float valve with pull clip are used to control fuel level
in the float cham ber. The aneroid cavity insert, used on past
models, is deleted. This change was m ade to improve fuel
IDLE SPEED
SOLENOID handling during vehicle m aneuvers. A plastic filler block is
used above the float cham ber to reduce fuel slosh in the float
FRONT VACUUM PLUG (IDLE
bowl.
BREAK MIXTURE NEEDLE) To reduce the possibility of fuel vapor losses, the
following c a rb u re to r changes have been m ade to m eet
evaporative emission requirem ents.
Fig. 6C3-1-M odel M2ME
• Pum p plunger stem seal and retainer added to the air
horn on all models.
• Raised beads added to the air horn and float bowl
gasket m ating surfaces, and air horn gasket, for good
air horn to bowl sealing.
• The new model M 2M E carburetor uses two (2) addi
tional air horn to bowl a tta ch in g screws and
lockwashers.
• Four (4) throttle body to bowl screws used for improved
sealing as a carryover feature.
• Idle m ixture needle plugs vapor sealed.
T he c a rb u re to r has internally balanced venting
through a vent tube, pressed into the air horn casting,
located adjacent to the air intake, and by a vent slot located
directly over the float cham ber. In addition, vent baffles
located strategically in the float bowl provide efficient fuel
LIGHT TRUCK SERVICE MANUAL
6C3-2 CARBURETOR MODEL M2ME
handling during severe vehicle m aneuvers and hot engine O ther features include an alum inum throttle body for
operation. decreased weight and improved heat distribution, plus a
All m odels are ex tern ally vented th ro u g h a tube thick throttle body to bowl insulator gasket to keep excessive
(Location T) in the float bowl. A hose connects this tube heat from the float bowl. A new special coated throttle body
directly to a vacuum operated vapor vent valve located in the to bowl gasket reduces fuel vapor losses.
vapor canister. W hen the engine is not running, the canister For ease of service, alp h a b etic al code le tte rs are
vapor vent valve is open allowing fuel vapors from the float included on the air horn, float bowl and throttle body casting
cham ber to pass into the canister where they are storeed at external tube locations to identify air and vacuum hose
until norm ally purged. T he venting of fuel vapors from the connections.
ca rb u re to r float bowl to th e can ister m eets evaporative The carburetor part num ber is stam ped vertically on
emission requirem ents and improves hot engine starting. the left rear corner of the float bowl (Fig. 6C3-2). R efer to
the part num ber on the bowl when servicing the carburetor.
Adjustable Part Throttle W hen replacing the float bowl assembly, follow the instruc
In order to provide a close tolerance adjustm ent in the tions contained in the service package. Stam p or engrave the
main m etering system , an adjustm ent is provided to very model num ber on the new float bowl.
accurately set the depth of the m etering rods in the main As a carryover item , th e idle m ixture needles are
m etering jets. recessed in the throttle body casting and sealed with a
The ad justm ent feature consists of a pin pressed in the hardened steel plug to discourage tam pering in the field
side of the power piston which extends through a slot in the which could upset exhaust emissions. The plugs m ust not be
side of the piston well. W hen the power piston is down removed and idle m ixture needles readjusted unless required
(economy position), the side of the pin stops on top of a flat due to m ajor carburetor overhaul in which case special
surface on the ad justm ent screw located in the cavity next to procedures must be followed carefully.
the power piston. T he adjustm ent screw is held from turning An E xhaust G as R ecirculation System (E .G .R .) is used
by a tension spring beneath the head of the adjustm ent on Light Duty vehicles to control oxides of nitrogen (N O x).
screw. D uring production flow test, this adjustm ent screw is The vacuum ports necessary to operate the recirculation
turned up or down which, in turn, raises or lowers the power valve are located in the throttle body and connect through a
piston and m etering rod assembly. This very accurately channel to a tube in the throttle body. This tube is connected
controls the fuel flow between the rods and jets to meet by a hose to the E.G .R . valve (See Idle System for port
emission requirem ents. location).
N o a tte m p t should be m ade to change the A P T On models used with air conditioning, an electrically
adjustm ent. If float bowl replacem ent is required, the new operated A /C idle speed solenoid is used to m aintain proper
bowl assem bly will include an adjustm ent screw pre-set by idle speed when the air conditioning is in operation.
the factory.
All models use a bowl m ounted choke housing with a Carburetor Operation
n on -ad ju stab le electrically operated th e rm o sta tic choke Incorporated in the Model M 2M C carburetors are six
control assembly. A single front vacuum break is used for basic systems. They are float, idle, main metering, power,
control of choke valve opening after initial engine start. pump, and choke (Figs. 6C3-3 and 4).
ON-VEHICLE SERVICE
CARBURETOR ADJUSTMENTS
Before checking or resetting the carburetor as the cause
of poor engine perform ance or rough idle, check ignition
system including distributor, timing, spark plugs and wires.
C heck air cleaner, evaporative em ission system , E F E
system, PCV system, E G R valve and engine compression.
Also inspect in tak e m anifold vacuum hose gaskets and
connections for leaks and check torques of c arb u reto r
m ounting bolts/nuts.
Refer to Figures 6C3-A through 6C 3-F for carburetor
adjustm ent procedures.
CARBURETOR MODEL M2ME 6C3-3
FLOAT NEI
/
FLOAT NEEDLE
SEAT
VE NTTUBE
TO CANISTER
INLET FILTER
FUEL I
CHECK VALVE
SEAT
FLOAT SYSTEM
‘ EXHAUST GAS RECIRCULATION
IDLE SYSTEM
r M A IN D IS C H A R G E
N O ZZLE
M A IN VE N TU R I
M A IN M E TE R IN G RO DS ( 2 )'
R IC H M IX TU R E SCREW RIVETED
(FA C TO R Y A D JU S TE D ) S COVER IDLE AIR BLEED VALVE
(FA C TO R Y A D JU S TE D )
LEAN M IX TU R E SCREW
(FA C TO R Y A D JU S TE D )
SO LE N O ID
PLUNG ER
(SH O W N U P ).
M A IN D IS C H A R G E
N O ZZL E
D IS C H A R G E
PASSAGE
D IS C H A R G E
B A L L R E T A IN E R
CUP SEAL D IS C H A R G E
C H E C K BALL
! PUM P PLUNG ER
PUMP SYSTEM
CHOKE
CHOKE
INSET
VA CU UM BREAK
W IT H LE AF-TYP E
BUCKING SPRING
(S E E IN S E T)
UNLOADER
FAST TANG
IDLE
ADJUSTING
SCREW
CHOKE SYSTEM
(ELECTRIC CHOKE TYPE)
FLOAT ADJUSTMENT
(M EC H A N IC AL SETTIN G )
G A U G E F R O M T O P O F C A S T I N G TO T O P
OF F L O A T — G A U G I N G P O I N T 3 1 6 " B A C K
F R O M E N D OF F L O A T A T T O E (SEE IN S E T )
G A U G IN G PO INT
(3 1 6 BACK
F R O M TO E )
PUMP ADJUSTMENT
© GAUGE FROM TO P OF C H O K E
V A L V E W A L L , N E X T TO V E N T
S T A C K , TO TO P
OF P U M P S T E M
A S S P E C IF IE D
m u
5JB E N D PUMP-
LEVER TO
ADJUST
^ © ROD IN S P E C IF I E D HOLE
OF P U M P L E V E R
S U P P O R T LEVER W IT H
S C R E W D R IV E R W H IL E
B E N D IN G LEVER
© THROTTLE VALVES
C O M PLETELY CLOSED
N O T E : M A K E S U R E F A S T ID L E
CAM FO LLOW ER LEVER IS OFF
S T E P S O N F A S T ID L E C A M
N O T E : IF A D J U S T M E N T
B E N D C H O K E R O D A T T H IS ,s N E C E S S A R Y , D R IL L
P O IN T T O A D J U S T (SEE IN S E T ) 0 UT R IV E T S A N D R E M O V E
i l ------1 C H O KE C O V ER . USE S TA T
n C H O KE VALVE
C LO SED
C O V E R R E T A IN E R K IT .
INSET 3 ) P U S H U P O N T H E R M O S T A T IC
C O IL T A N G (C O U N T E R C L O C K W IS E )
U N T IL C H O K E V A L V E IS C L O S E D .
LO W E R E D G E O F LE V E R S H O U L D
J U S T C O N T A C T S ID E O F P L U G
GAUGE. UJ \
4 ; IN S E R T 1 2 0 ”
PLUG G A U G E
IF N E C E S S A R Y , D R IL L OUT A N D R EM O V E
R IV E T S . R E M O V E T H E T H E R M O S T A T IC P L A C E F A S T ID L E C A M
C O V E R A N D C O IL A S S E M B L Y F R O M C H O K E F O L L O W E R O N H IG H S TE P
H O U S IN G OF F A S T ID L E C A M .
H O LD CAM
FO LLO W ER ON
H IG H EST S T E P -----
OF FAST ID L E CA M
Sl/C HO KE
VALVE
SPECIFIED
CLOSED ANGLE (SEE SPECS.)
©
CLOSE CHOKE BY
PUSHING UPWARD
ON CHOKE COIL FAST IDLE CAM
LEVER OR
VACUUM BREAK
LEVER TANG (HOLD
IN POSITION WITH
RUBBER BAND).
PLACE CAM FOLLOWER
ON SECOND STEP OF
REMOVE GAUGE. CAM AGAINST RISE OF
HIGH STEP.
FIGURE 1
1. USE CHOKE VALVE M EASU RIN G GAUGE J-26701 . TOOL M AY
BE USED WITH CARBURETOR ON OR OFF ENGINE. IF OFF ENGINE, PLACE
CARBURETOR ON HOLDING FIXTURE SO THAT IT WILL REM AIN IN
S A M E POSITION WHEN GAUGE IS IN PLACE.
2. ROTATE DEGREE SCALE UNTIL ZERO (0) IS OPPOSITE POINTER.
3. PLACE M AGNET SQUARELY ON TOP OF CHOKE VALVE.
4. CHOKE VALVE COMPLETELY CLOSED.
5. ROTATE BUBBLE UNTIL IT IS CENTERED.
FIGURE 2
6. ROTATE SCALE SO THAT DEGREE SPECIFIED FOR ADJUST MENT IS
OPPOSITE POINTER.
7. SEAT CHOKE VACUUM DIAPHRAGM USING VACUU M SOURCE.
8. HOLD CHO KE VALVE TOWARD CLO SED POSITION, PUSH IN G UPW ARD
ON CHOKE COIL LEVER OR VACUUM BREAK LEVER TANG (HOLD IN
POSITION WITH RUBBER BAND).
9. TO ADJUST, TURN SCREW IN OR OUT UNTIL BUBBLE IS CENTERED.
10. REMOVE GAUGE.
O MAKE CHOKE COIL LEVER AND FAST IDLE ADJUSTMENT (BENCH OR ON-THE-CAR
SETTING).
NOTE: DO NO T REMOVE RIVETS AND CHOKE COVER TO PERFORM THIS ADJUSTMENT.
USE RUBBER BAND ON VACUUM BREAK LEVER TANG TO HOLD CHOKE VALVE
CLOSED (STEP 9 ).
( 6 ) SPECIFIED
®
HOLD PRIMARY
THROTTLE VALVES
V J ANGLE (SEE SPECS.)
FIGURE 1
6 C 3 -10
© WITH ENGINE RUNNING AT IDLE,
SERVICE M AN U AL
CARBURETOR
INSERT GAUGE IN VENT SLOT
OR VENT HOLE (NEXT TO AIR
CLEANER MOUNTING STUD) IN
AIR HORN. RELEASE GAUGE AND
MODEL M 2 M E
ALLOW IT TO FLOAT FREELY.
© R E A D IN G AT EYE LEVEL, OBSERVE
MARK ON GAUGE THAT LINES UP CAUTION: DO NOT PRESS DOWN
WITH TOP OF CASTING AT THE ON GAUGE TO CAUSE FLOODING
VENT SLOT OR VENT HOLE. OR DAMAGE TO FLOAT.
SETTING SHOULD BE WITHIN
±1/16" FROM SPECIFIED FLOAT
LEVEL SETTING.
REMOVE FLOAT GAUGE
FROM AIR HORN.
UNIT REPAIR
DISASSEMBLY 4. Remove seven air horn to bowl attaching screws; then
remove the two countersunk screws located next to the
Before doing any service on the carburetor place it on a venture (Fig. 6C3-8).
holding fixture. W ithout the use of the holding fixture, it is
5. Remove air horn from float bowl by lifting straight up.
possible dam age to th ro ttle valves.
The air horn gasket should rem ain on the float bowl for
removal later (Fig. 6C3-9).
Solenoid (If Equipped)
Removal Air Horn - Disasembly
1. Remove front vacuum break hose. Then remove two
Remove screws holding the solenoid and bracket to
atta ch in g screws and rem ove vacuum break and
float bowl and remove solenoid and bracket assembly. The
solenoid should not be imm ersed in any type of carburetor
cleaner and should always be removed before complete
carburetor overhaul. UPPER
CHOKE LEVER
LEVER RETAINING SCREW
Air Horn
Removal
1. Remove upper choke lever trom the end of choke shaft
by removing retaining screw (Fig. 6C3-6). Then rotate
upper choke lever to remove choke rod from slot in
lever.
2. Remove choke rod from lower lever inside the float
bowl casting. Rem ove rod by holding lower lever
outw ard w ith sm all screw driver and tw isting rod
counterclockwise.
3. W ith Tool J-25322 drive roll pin (pum p lever pivot pin)
inward ju st until pum p lever can be removed from air
horn. Then remove pum p lever from pum p rod (Fig.
6C3-7). N ote location of accelerator pum p rod for
Fig. 6C3-6--Removing Upper Choke Lever
reassembly.
LIGHT TRUCK SFRVICF M'NIIAI
CARBURETOR MODEL M2ME 6C 3-13
Float Bowl
ATTACHING
SCREWS
Fig. 6C3-9--Removing A ir Horn
bracket assembly. (Fig. 6C3-10). Do not place vacuum
break assembly in carburetor cleaner.
FR O N T V A C U U M
Remove pum p plunger stem seal by inverting air horn BREAK
and use a small screwdriver to remove staking holding
the seal retainer in place (Fig. 6C3-11). Remove and Fig. 6C3-10--Removing Front Vacuum Break
SEAL STAKE
PUMP
PLUNGER
SEAL
Fig. 6C3-13--Power Piston and Metering Rods
SCREWDRIVER
NEEDLE SEAT
REMOVER TOOL
MAIN METERING
JETS
Fig. 6C3-12--Float Bowl
Choke Disassembly
Removal of Choke Cover (Fig. 6C3-17)
1. Support float bowl and throttle body as an assembly on
a suitable holding fixture such as Tool J-9789-118.
2. Align a #21 drill (.159") on rivet head and drill only enough
to remove rivet head. Drill the two (2) remaining rivet
heads and then use a drift and small hammer to drive the
remainder of the rivets out of the choke housing.
P U M P D IS C H A R G E
C H E C K BALL RE T A IN E R
PLASTIC INSE 1
W ITH CUP SEAL
FAST IDLE
CAM
INTERMEDIATE
CHOKE SHAFT
Fig. 6C3-16--Pump Discharge Retainer and Check Ball
Throttle Body
Disassembly
1. Remove pump rod from throttle lever by rotating rod
until tang on rod aligns with slot in lever.
2. Do not remove the plugs covering idle m ixture needles
during normal carburetor cleaning and servicing unless
Fig. 6C3-17--Choke Cover diagnosis (Section 6C) indicates the carburetor is the
LIGHT TRUCK SERVICE MANUAL
6C3-16 CARBURETOR MODEL M2ME
Air Horn
Assembly PIN REMOVING
TOOL
1. If used, install new pum p plunger stem seal in air horn
casting (Fig. 6C3-11). Lightly stake seal retainer in
PUMP LEVER
three places, choosing locations different from original
staking.
CARBURETOR FLOAT PUMP PUMP ROD FAST IDLE VACUUM VACUUM UNLOADER
NUMBER LEVEL ROD LOCATION CAM BREAK BREAK
(CHOKE ROD) FRONT REAR
0
00
00
o
INNER —
NJ
on
17081101 13/32 5/16 38°
0
—
00
00
17081103 13/32 5/16 INNER 38° 25°
0
—
00
00
17081142 13/32 5/16 INNER 38° 25°
o
—
0
5/16
CO
00
CM
LO
17081143 13/32 INNER 38°
0
00
38°
ro
17081144 13/32 5/16 INNER 25° —
0
INNER —
00
00
17081145 13/32 5/16 38° 25°
18Y2 HAN
G SERIES A U T O M A T IC 50 RPM*
5 .0 L (305 CID)
RPO LG9 M ANUAL 150 RPM*
ENG INE F A M IL Y
18Y2 HAN
C SERIES A U T O M A T IC 50 RPM*
SECTION 6C4
CARBURETOR MODEL M4M
CONTENTS
GENERAL DESCRIPTION
The model M 4M C carburetor is used on Heavy D uty feature, blind rivets are installed at the factory to retain the
Emissions vehicles. In addition, a new electric choke model setting of the therm ostatic coil in the housing.
M 4M E carburetor is used on Light D uty Emissions vehicles A special cut-out is notched in the choke cover which
replacing th e hot air choke m odel previously used. All m ust be aligned with an extended tab on one of the choke
models (Fig. 6C4-1,2 and 3) tam per - resistant features such retainers which is located in the 2 o’clock position. The other
as rivets, plugs, covers, etc., to discourage readjustm ent of two retainers are of the conventional design (no tab).
factory settings which could affect either or both emission
control and driveability. For exam ple, as a carryover The choke therm ostatic cover and coil assembly must
not be removed unless required during m ajor carburetor
overhaul, or replacem ent of the cover and coil assembly or
choke housing in which case special service procedures are
necessary.
VACUUM BREAK
VAPOR VENT
(AIR VALVE DASHPOT)
TUBE An integral 2" pleated paper fuel filter, with check
(TO CANISTER) valve on light duty vehicles, is m ounted in the front of the
float bowl behind the fuel inlet nut to give m axim um
filtration of incoming fuel. The check valve is used to shut off
fuel flow to the carburetor and prevent fuel leaks if a vehicle
roll-over should occur.
ELECTRIC CHOKE f JP A single pontoon float, brass needle seat, and a rubber
tipped float valve with pull clip are used to control fuel level
■ K jr
PLUG (IDLE in the float cham ber. On M 4M C models, the aneroid cavity
MIXTURE NEEDLE) insert is revised; on M 4M E models, the aneriod cavity insert
is deleted. T hese changes w ere m ade to im prove fuel
handling during vehicle maneuvers.
Fig. 6C4-1--Model M4ME with L.D. Emissions To reduce the possibility of fuel vapor losses, the
following c a rb u re to r changes have been m ade to m eet
evaporative emission requirem ents:
REAR V A C U U M BREAK
ELECTRIC CHOKE
VAPO R VE N TT U B E
{TO CANISTER! RIVETS
RIVETS
PLUG (IDLE
FRONT V A C U U M BREAK M IX TU R E NEEDLE)
HO T AIR
CHOKE
Fig. 6C4-2--M4ME W /C alif. Emissions Fig. 6C4-3--Model M4MC With H.D. Emissions
• Pum p plunger stem seal and retainer added to the air For ease of service, alp h ab etical code lette rs are
horn on M 4M E models. included on the air horn, float bowl and throttle body casting
• Raised beads added to the air horn and float bowl at external tube locations to identify air and vacuum hose
gasket m ating surfaces, and air horn gasket, for good connections.
air horn to bowl sealing on M 4M E models. The carburetor part num ber is stam ped on a vertical
• Sim ilar to past model C alifornia Heavy D uty Emis section of the float bowl, near the secondary throttle lever
sions vehicles with M 4M C carburetor, the new model (Fig. 6C4-4). R efer to the part num ber on the bowl when
M 4M E carburetor uses four (4) additional air horn to servicing the carburetor. W hen replacing the float bowl
bowl attaching screws and lockwashers. assembly, follow the instructions contained in the service
• T hree (3) th ro ttle body to bowl screws used for package. Stam p or engrave the model num ber on the new
improved sealing as a carryover feature. float bowl.
• Idle m ixture needle plugs vapor sealed. As a carryover item , the idle m ixture needles are
recessed in the throttle body casting and sealed with a
T he c a rb u re to r has in tern ally balanced venting hardened steel plug to discourage tam pering in the field
through a vent tube, pressed into the air horn casting, which could upset exhaust emissions. The plugs m ust not be
located adjacent to the prim ary air intake, and by a vent slot removed and idle m ixture needles readjusted unless required
located directly over the float cham ber. In addition, vent due to m ajor carburetor overhaul in which case special
baffles located strategically in the float bowl provide efficient procedures m ust be followed carefully.
fuel handling durin g severe vehicle m aneuvers and hot
An Exhaust Gas Recirculation system (E.G .R .) is used
engine operation.
on Light Duty vehicles to control oxides of nitrogen (N O x).
M 4M E models are externally vented through a tube The vacuum ports necessary to operate the recirculation
(Location T) in the float bowl. A hose connects this tube valve are located in the throttle body and connect through a
directly to a vacuum operated vapor vent valve located in the channel to a tube in the throttle body. This tube is connected
vapor canister. W hen the engine is not running, the canister by a hose to the E.G .R . valve. (See Idle System for port
vapor vent valve is open allowing fuel vapors from the float location).
cham ber to pass into the canister where they are stored until
norm ally purged. T h e venting of fuel vapors from the Carburetor Operation
c arb u re to r float bowl to th e can ister m eets evaporative
The carburetor has six systems of operation. They are
emission requirem ents and improves hot engine starting.
float, idle, main m etering, power, pump, and choke (Figs.
ADJUSTABLE Part Throttle 6C4-4 and 4a).
In order to provide a close tolerance adjustm ent in the
main m etering system, an adjustm ent is providedto very
accurately set the depth of the m etering rods in the main
m etering jets.
The adjustm ent feature consists of a pin pressed in the
side of the power piston which extends through a slot in the
side of the piston well. W hen the power piston is down
(economy position), the side of the pin stops on top of a flat
surface on the adjustm ent screw located in the cavity next to
the power piston. The adjustm ent screw is held from turning
by a tension spring beneath the head of the adjustm ent
screw. During production flow test, this adjustm ent screw is
turned up or down which, in turn, raises or lowers the power
piston and m etering rod assembly. This very accurately
controls the fuel flow between the rods and jets to meet
emission requirem ents.
N o attem p should be m ade to change the A PT adjust Fig. 6C4-4--Carburetor Identification
ment. If float bowl replacem ent is required, the new bowl
assembly will include an adjustm ent screw pre-set by the
factory.
All models use a bowl mounted choke housing with a
non-adjustable therom static choke control assembly. Light
D uty Em issions C alifo rn ia vehicles (M 4 M E ) and all
M 4M C models use two vacuum breaks for control of choke
valve opening after initial engine start. A single rear vacuum
break is used on M 4M E non-California models.
O ther features include an alum inum throttle body for
decreased weight and improved heat distribution, plus a
thick th ro ttle body to bowl insulator gasket to keep excessive
heat from the float bowl. A new special coated throttle body
to bowl gasket, used on M 4M E models, reduces fuel vapor
losses.
INLET FILTER
E.G.R
CHECK VALVE IDLE MIXTURE NEEDLE
SEAT
PULL-OVER ENRICHMENT
•E.G.R. (EXHAUST GAS (PO E.) FUEL FEEDS (2)*
FIXED IDLE
RECIRCULATION) AIR BY PASS
IDLE AIR
BLEED
ADJUSTS
IDLE CHANNEL
RESTRICTION
/
NOTE:
SIDE FUEL ENTRY
MAIN
METERING
POWER PISTON
SPRING VACUUM MAJN
PASSAGE METERING
IDLE MIXTURE NEEDLE JETS
* (USED ON SOME MODELS)
SECONDARY
METERING RODS
BOOST
VENTURI ACCELERATOR AJR VALVES
WELLS ft TUBES (0PEN)
MAIN WELL A
FACTORY METERING BLEEDS ac c ele r a tin g / m e t e r in g
ADJUSTMENT SCREW WELL P O R T S / ROD LEVER
(UPI
L I
:|
SECONDARY
THROTTLE
CUP SEAL
PUMP PLUNGER
POWER PISTON / m a in
EXPANDER SPRING
SPRING 'METERING
VACUUM ICTe
PASSAGE
PUMP SYSTEM
POWER SYSTEM W/LD EMISSION
RETAINER
ELECTRIC
CHOKE COIL
PUMP RETURN
SPRING REAR VACUUM
EXPANDER SPRING
CHOKE SYSTEM
PUMP SYSTEM M4ME (FEDERAL)
W/HD EMISSION (ELECTRIC CHOKE TYPE)
RETAINER
(WITH TAB)
UNLOADER
VACUUM BREAK TANG
FAST IDLE ROD
SECONDARY LOCKOUT FAST IDLE ADJUSTING SCREW FAST IDLE
LEVER CAM FOLLOWER SECONDARY LOCKOUT FAST IDLE ADJUSTING SCREW
LEVER CAM FOLLOWER
ON-VEHICLE SERVICE
Adjustments 3. Visually inspect carburetor to be certain all vacuum
Before checking or resetting the carburetor as the cause hoses are connected. Inspect hoses for cracks, a b ra
of poor engine perform ance or rough idle; check ignition sions, hardness or other signs of deterioration. Replace
system including distributor, tim ing, spark plugs and wires. or correct as necessary.
C heck air clean er, evaporative em ission system , E F E 4. M ake sure vacuum break diaphragm shaft is fully
System , PCV system, EGR valve and engine compression. extended when engine is off. If sh aft is not fully
Also inspect intake manifold, vacuum hoses and connections extended, replace vacuum break assem bly. S h aft
for leaks and check torque of carburetor mounting bolts/ should fully retract within 10 seconds after starting
nuts. engine. If unit fails to retract, replace vacuum break
M ake all adjustm ents with engine at normal operating assembly.
tem perature, choke full open, air cleaner installed. Except
as noted air conditioning should be "off" and all vacuum
lines and all electrical leads connected. Set parking brake Checking Solenoid
and block drive wheels. A ir cleaner can be removed for set 1. Turn on ignition, but do not start engine.
up accessibility but m ust be com pletely installed during 2. Turn A /C to "o n " position.
actual setting.
3. Open throttle to allow solenoid to extend, close throttle.
R efer to Figure 6C4-A through 6C 4-J for carburetor
4. Disconnect lead at solenoid. Solenoid plunger should
adjustm ent procedures.
drop away from throttle lever.
Checking Carburetor Choke 5. Connect solenoid lead. Plunger should move out and
1. Remove air cleaner. W ith engine off, hold throttle half contact the throttle lever. Solenoid may not be strong
enough to open the throttle, but the plunger should
open. O pen and close choke several tim es. W atch
linkage to be certain all links are connected and there move.
are no signs of dam age. 6. If plunger does not move in and out as lead is discon
nected and connected, insert test light (1893 bulb or
2. If choke or linkage binds, sticks or works sluggishy,
sm aller) between the solenoid feed wire and ground.
clean with choke cleaner X-20-A or equivalent. Use
cleaner as directed on can. R efer to U nit R epair 7. If light lights, replace solenoid.
instructions for additional direction if cleaning does not 8. If light does not light, locate cause of open circuit in
correct. solenoid feed wire.
© HO LD RETA IN ER
F IR M L Y IN PLACE
TOE
©
PUSH FLOAT DOWN
L IG H T L Y AGAINST NEEDLE
G AUG ING PO INT
(3/1 6 " BACK
FROM TOE)
©
REM OVE FLOAT AND
BEND FLO AT ARM
UP OR DOWN TO
ADJUST
© V IS U A L L Y CHECK FLO AT A L IG N M E N T
AFTER ADJUSTING
PUMP ADJUSTMENT
G A U G E F R O M T O P OF C H O K E
V A L V E W A L L . N E X T TO V E N T
S T A C K , TO T O P
OF P U M P S T E M
A S S P E C IF IE D
BEND P U M P
LE VER TO
AD JUST
3^=0 R O D IN S P E C IF IE D H O L E
O F P U M P LE VER
'S U P P O R T LE VER W IT H
S C R E W D R IV E R W H IL E
B E N D IN G LE VER
>T H R O T T L E V A L V E S
CO M PLETELY CLOSED
NO TE M A K E S U R E F A S T ID LE
C A M F O L L O W E R L E V E R IS OFF
S T E P S O N F A S T ID L E C A M
B E N D S E C O N D A R Y C L O S IN G T A N G
A W A Y T O C L O S E P R IM A R Y V A L V E S ,
T H E N RE A D J U S T
NO TE: IF A D JU S T M E N T
BEND C H O K E R O D A T T H IS IS N E C E S S A R Y , DRILL
P O IN T TO A D JU S T (SEE IN S E T) O UT R IV E TS AND REM O VE
11 I C H O K E CO VER . USE S T A T
C H O K E VALVE CO VER RETAINER KIT.
C LO SED
■\
PUSH UP ON T H E R M O S T A T IC
C O IL T A N G (C O U N T E R C L O C K W IS E )
U N T IL C H O K E VALVE IS CLOSED.
W
LOW ER ED G E OF LEVER S H O U L D
JU ST C O N T A C T S ID E OF PLUG
G A U G E.
43 IN S E R T .1 2 0
PLUG G AUG E.
N O T E : R E C H E C K FA ST
ID L E A D J U S T M E N T O N
T H E V E H IC L E S E T T IN G
T O S P E C IF IC A T IO N S .
cx
( 7 ) H O LD CAM
FOLLOW ER ON
H IG H E S T STEP
O F FAST ID L E C A M
0 T U R N SCREW IN T O
CO NTACT LEVER THEN
T U R N F A S T ID L E SCREW
O U T U N T IL P R IM A R Y
T U R N SC R EW IN S P E C IF IE D
T H R O T TL E V A L V E S ARE
N U M B E R O F T U R N S (N O T E )
CLOSED.
{ § ) SPECIFIED
ANGLE (SEE SPECS.)
© AIR VALVE
COMPLETELY
SEAT CHOKE VACUUM
DIAPHRAGM USING
OUTSIDE VACUUM
SOURCE
©
BEND HERE FOR SPECIFIED
CLEARANCE BETWEEN ROD
AND END OF SLOT IN LEVER
AIR VALVE
COMPLETELY CLOSED
© PLACE GAUGE BETWEEN
ROD AND END OF SLOT
IN LEVER
4. CH OK E VA LV E CO M PLETELY CLOSED.
5. RO TA TE BUBBLE UN TIL IT IS CENTERED.
FIGURE 2
LEVELING
BUBBLE
(CENTERED)
CHOKE
% , VA LVE
CLOSED
N O T E 2:
LEAF B U C K IN G
S P R IN G M U S T BE
SE A TE D A G A IN S T ; » ^ S E A T D IA P H R A G M
LEVER _____ _ ' \ / \ /} U S IN G V A C U U M S O U R C E
(W H ER E U S E D ) / /X J ? N O T E : O N D E LA Y M O D E L S W IT H AIR
BA ND - c /A m o, r e m o v e R U BB ER C O V E R O VER
E L E M E N T A N D P LU G SM A LL
BLEED HO LE IN V A C U U M T U B E W IT H
TA PE. R E M O VE TA PE A FTER A D J U S T
M ENT.
L IG H T L Y C L O S E C H O K E REMOVE V A C U U M BREAK FROM C A RB UR
BY P U S H IN G UP W A R D ETOR. PLACE BRACKET IN A VISE AN D .
O N C H O K E C O IL LEVER OR V A C U U M USING SAFETY PR ECAUTIO NS, G RIND OFF
BREAK LEVER T A N G (H O L D IN P O S IT IO N W ELD HOLDING A D JU S T M E N T SCREW
W IT H R U BB ER B A N D ). COVER. REMOVE COVER A N D REINSTALL
V A C U U M BREAK.
PLUNGER FIG U R E 3
BUCKING LIGHTLY CLOSE CHOKE BY PUS H IN G
SPRING UPWARD ON CHOKE CO IL LEVER
OR VACUUM BREAK LEVER TA N G
® SEAT DIAPHRAGM (HO LD IN PO S ITIO N W ITH
USIN G VAC UUM SOURCE RUBBER BAND). MAKE SURE
(S E E NOTE 2) PLUNGER BUCKING SPRING (IF
USED) IS COMPRESSED A ND S E A T E D .
NOTE 2: ON DELAY M O DELS, PLUG END COVER USING AN ACCELERATOR PUMP PLUNG ER CUP • 2G
TYPE (FIG U R E 3 ) OR EQUIVALENT. SE A T VACUUM DIAPHRAGM M AKING SURE VAC UUM IS
ABOVE 5 " Hg WHEN READING GAUGE (STEP 9 ). REMOVE CUP AFTER A D JUSTM ENT.
© MAKE CHOKE COIL LEVER AND FAST IDLE ADJUSTMENT (BENCH OR ON-THE-CAR
SETTING).
NOTE: DO NOT REMOVE RIVETS AND CHOKE COVER TO PERFORM THIS ADJUSTMENT.
USE RUBBER BAND ON VACUUM BREAK LEVER TANG TO HOLD CHOKE VALVE
CLOSED (STEP 8).
6) SPECIFIED
HOLD PRIM ARY ANGLE (SEE SPECS.)
THROTTLE VALVES
LEVELING W ,DE0PEN
BUBBLE
(CENTERED)
\ VACUUM BREAK
CHOKE LEVER TANG
RUBBER
VALVE
BAND
CLOSED
FIGURE 1
© THERMOSTATIC
IF REMOVED, INSTALL CHOKE
COVER AND COIL BEND TANG TO
ASSEMBLY IN HOUSING. A D JU ST UNTIL
BUBBLE IS CENTERED.
PUSH DOWN
ON T A IL OF
CAM
(STEP 2)
H O L D C H O K E V A L V E W ID E
CHOKE VALVE O P E N BY P U S H IN G D O W N O N
CLOSED THROTTLE T A IL OF F A S T ID L E C A M
VALVES
C H E C K L O C K O U T P IN
CLOSED
FO R C L E A R A N C E
^GAUGE
FILE E N D OF P IN
B E N D P IN
x
x
^ 5 '
----- --- FOR C L E A R A N C E
TO A D J U S T 015 MAX (C H E C K FO R N O
CLEARANCE B U R R S AFTER
F IL IN G )
S E C O N D A R Y L O C K O U T LEVER SECO ND ARY LO CKOUT
© S ID E C L E A R A N C E
©2 ) O P E N IN G C L E A R A N C E
(7 ) .020"
^ -" C L E A R A N C E
CARBURETOR ADJUSTMENTS
2 J T U R N TENSIO N ADJUSTING
V " S C R E W COUNTERCLOCKWISE
U N T IL A IR V A L V E
OPENS PART WAY
® PREPARE V E H I C L E FOR A D J U S T M E N T S -
SEE EMISSION L A B E L ON V E H IC L E .
N OTE : I G N I T I O N T I M I N G SET PER L A B E L .
1T U R N ID L E SPEED SCREW TO
SET C UR B I D L E SPEED TO
S P E C IF IC A T IO N S - A / C OF F
(SEE EMISSION L A B E L )
J”
WITH ENGINE SET AT SPECIFIED IDLE SPEED, USING OUTSIDE VACUUM SOURCE
APPLY SUFFICIENT VACUUM TO THE ACTUATOR TO EXTEND THE PLUNGER FULLY.
© P O SITIO N T R A N S M IS S IO N
IN P A R K OR N EU TRAL I T
y- 09
® HOLD C A M FOLLOWER ON
P RO P ER STEP OF FAST IDLE
C A M PER E M IS S IO N LABEL
S____t
® D IS C O N N E C T A N D PLUG
V A C U U M H O SE AT EGR
VALV E TU RN FAST IDLE SC R E W
TO O B T A IN SP EC IF IED R P M
ON E M IS S IO N LABEL
IDLE MIXTURE CHECK AND ADJUSTMENT 11. Lightly seat screws, then back out equally, just enough
so engine will run.
(PROPANE ENRICHMENT)
12. Place transmission in Drive (autom atics) or N eutral
Light Duty Emission Vehicles Only (m anuals).
Idle m ixture screws have been preset at the factory and 13. Back each screw out (richen 1/8 turn a t a time until
sealed. Idle m ixture should be adjusted only in the case of m axim um idle speed is obtained). Then set idle speed to
major carburetor overhaul, throttle body replacem ent or the enriched idle specification.
high emissions as determ ined by offical inspections. A djust 14. T urn each m ixture screw in (clockwise) 1/8 turn at a
ing m ixture by other than the following method may violate tim e until idle speed reaches value given on Emission
Federal an d /o r California or other state or Provincial laws. Control Inform ation Label.
Because of the sealed idle m ixture screws, the idle 15. Re-check enriched speed with propane. If not within
m ixture checking procedure requires artificial enrichm ent specification, repeat adjustm ent beginning with Step
by adding propane. 12 .
1. Set parking brake and block drive wheels. On cars
16. Check and adjust fast idle as described on Emission
equipped with vacuum parking brake release, discon
Control Inform ation Label.
nect and plug hose at brake. Engine m ust be at normal
operating tem perature and air conditioning off. 17. Turn off engine. Remove propane tool, connect crank
2. Disconnect and plug hoses as directed on the Emission case ventilation tube. Re-connect vacuum hoses.
Control Inform ation Label under the hood.
3. Connect an accurate tachom eter to engine. IDLE MIXTURE ADJUSTMENT - BEST IDLE
4. Disconnect vacuum advance and set tim ing to specifi METHOD
cation shown on the Emission Control Inform ation
Label. Re-connect vacuum advance. (For Heavy Duty Emission Vehicles With 4-Barrel)
5. Set carburetor idle speed to specification as shown on Perform this ad ju stm en t w ith engine at o perating
Emission Control Inform ation Label. tem perature, parking brake applied and transmission in
6. Disconnect crankcase ventilation tube from air cleaner. park or neutral.
7. Using tool J-2691 1, insert hose with rubber stopper, 1. Remove air cleaner.
from propane valve into crankcase ventilation tube 2. Connect tachom eter and vacuum gage to engine.
opening in air cleaner. Propane c a rtrid g e m ust be 3. As a prelim inary adjustm ent, turn idle m ixture screws
vertical. in lightly to seat and back out 2 turns.
8. W ith engine idling in drive (neutral for m anual shifts)
NOTICE: Do not turn idle m ixture screw tightly against
slowly open propane control valve while pressing
seat or dam age may result.
button. Continue to add propane until speed drops due
to over richness. N ote m axim um engine speed (en 4. W ith engine running (choke wide open and transm is
riched speed). sion in neutral) adjust idle speed screw to idle speed
If rich speed drop cannot be obtained check for empty specified on Engine Em ission C ontrol Inform ation
cartridge or propane system leaks. Label.
9. If the enriched idle speed is within the enriched idle 5. A djust idle m ixture screw to obtain highest R PM .
specification the m ixture is correct. Go to step 17. 6. R epeat steps 4 and 5 until "b e st" idle is obtained.
10. If the enriched idle speed is not within specifications, 7. Shut down the engine, remove gages and install air
remove m ixture screw plugs following procedures. cleaner.
CARBURETOR REPLACEMENT
Installation
1. C lean sealing surfaces on intake m anifold and
CARBURETOR MOUNTING TORQUE carburetor.
W hen torquing c a rb u re to r a fte r rem oval overhaul, 2. Fill carburetor bowl before installing carburetor.
replacem ent or when installing a new heat insulator, torque 3. Install carburetor with new insulator and tighten bolts
m ounting bolts, in a clockwise direction, to 16 N-m (144 in. to correct torque (See C arburetor M ounting Torque).
lbs.). 4. Connect downshift cable as required.
W hen retorquing carburetor a t recom m ended m ainte
5. Connect cruise control cable as required.
nance intervals, check in clockwise direction. If less than 7
6. Connect accelerator linkage.
N-m (60 in. lbs.), retorque to 11 N-m (96 in. lbs.); if greater
than 7 N-m (60 in. lbs.), do not retorque. 7. Connect choke system.
8. Connect fuel pipe and vacuum hoses.
9. Connect solenoid as required.
10. Install air cleaner.
11. Check and adjust idle speed.
UNIT REPAIR
DISASSEMBLY
Place c a rb u re to r on a holding fixture to prevent
dam age to throttle plates.
Air Horn
1. Remove upper choke lever from the end of choke shaft
by removing retaining screw (Fig. 6C4-8). Then rotate
upper choke lever to remove choke rod from slot in
lever.
LO NG
LO NG
and the dashpot rod from the air valve lever. Do not Float Bowl
place vacuum break assembly in carburetor cleaner.
1. Remove air horn gasket by lifting out of dowel locating
pins and lifting tab of gasket from beneath the power
2. If used, remove pum p plunger stem seal by inverting air piston hanger, being careful not to disto rt springs
horn and using a small screwdriverto remove staking holding the main m etering rods (Fig. 6C4-15).
holding the seal re ta in e r in place (Fig. 6C 4-14).
2. Remove pum p plunger, and pump plunger stem seal
Remove and discard retainer and seal.
(Fig. 6 C 4 -14) if used, from pump well.
F urth er disassembly of the air horn is not required for 3. Remove pum p return spring from pump well.
cleaning purposes. If part replacem ent is required, proceed
as follows:
4. Remove power piston and m etering rods by depressing
T he air valves and air valve sh aft should not be
piston stem and allowing it to snap free (Fig. 6C4-16).
removed. If it is necessary to replace the air valve closing
The power piston can be easily removed by pressing the
spring or center plastic eccen tric cam , a rep air kit is
piston down and releasing it with a snap. This will cause
available. Instructions for assem bly are included in the
the power piston spring to snap the piston up against
repair kit.
the retainer. This procedure may have to be repeated
several times.
Do not remove power piston by using pliers on m etering
rod hanger.
Remove the power piston spring from the well.
The A.P.T. m etering rod adjustm ent screw is pre-set at
the factory and no attem pt should be m ade to change
this adjustm ent in the field. If float bowl replacem ent is
required during service, the new bowl assem bly will be
supplied with an A .P.T. m etering rod screw which will
be pre-set as required.
5. Remove m etering rods from power piston by discon
necting tension spring from top of each rod, then rotate
rod to remove from hanger.
Use care when disassem bling rods to prevent distortion
of tension spring an d /o r m etering rods. N ote carefully
position of tension spring for later reassembly.
FLO AT BOWL
RETAINING
SPRING
METERING
ROD
POWER
PISTON
POWER A N E R O ID
PISTON C A VITY
SPRING
INSERT
Fig. 6 C 4-16--P o w er Piston and M etering Rods Fig. 6C4-18--R em oving A neroid Cavity Insert
PUMP DISCHARGE
CHECK BALL RETAINER
AND CHECK BALL
NEEDLE SEAT
■ R E M O V IN G TO O L
NOTICE: N o attempt should be made to remove the the assembly to remove vacuum break rod from slot in
secondary metering jet (metering orifice plates). These plunger head (Fig. 6C4-20). The non-adjustable vac
jets are fixed and, if damaged, bowl replacement is uum break rod, riveted to the intermediate choke lever,
required. is not removed at this tim e, but is removed after
removal of the choke assembly from the float bowl.
10. Remove pump discharge check ball retainer and check
ball.
Choke
11. Remove secondary air baffle, if replacement is
required. Disassembly
12. Remove pump well fill slot baffle only if necessary. The non-adjustable choke cover design is used to
13. Remove rear vacuum break control and bracket assem discourage readjustment of the choke thermostatic cover
bly by removing (2) screws from bracket and rotating and coil assembly in the field. However, it is necessary to
LIGHT TRUCK SERVICE MANUAL
CARBURETOR MODEL M 4M 6C 4-21
ATTACHING
SCREWS
C H O K E COVER
RETAINERS
VACUUM BREAK ROD
(NON —ADJUSTABLE)
Fig. 6 C 4 -20--R ear Vacuum Break-Typical Fig. 6C 4 -2 1 --C h o ke Rivets
INTERMEDIATE
CHOKE SHAFT SEAi
PLASTIC
TUBE SEAL
(HOT AIR CHOKE
MODELS ONLY)
INSULATOR
•HROTTLE VALVE GASKET
LOCKOUT LEVER ST IDLE
CAM
FLAT PUNCH
STEP #2
LOCATOR
POINTS
STEP #1
HACKSAW
RECESSED IDLE MIXTURE
NEEDLE AND PLUG LOCATIONS
Fig. 6 C 4 -2 6 a ~ ld le M ixture N eedle
1. Thoroughly clean all metal parts and blow dry with 1. Check choke valve and linkage for excessive wear,
compressed air. M ake sure all fuel passages and binds or distortion.
metering parts are free of burrs and dirt. 2. Inspect choke vacuum diaphragm for leaks.
2. Check, repair or replace the following parts if the 3. Clean or replace carburetor filter.
following problems were encountered. 4. Inspect needle for sticking, dirt etc.
5. Examine fast idle cam for wear or damage.
a. Flooding
6. Also check items under "flooding ".
1. Inspect float needle seat for dirt, deep wear
grooves, scores and proper seating. d. Poor Performance - Poor Gas Mileage
1. Power Piston, power valve, metering rods for dirt,
2. Inspect float, float arm and hinge pin for distor
sticking, binding, damaged parts or excessive
tion, binds and burrs. Check float for leaks and/or
wear.
being loaded (heavier than normal).
2. Check air valve for binds and damage. If air valve
b. Hesitation is damaged, the air horn assembly must be re
1. Inspect pump plunger for cracks, scores or cup, placed. A torsion spring kit is available for repairs
excessive wear. A used pump cup will shrink when to air valve closing spring. A new plastic secondary
dry. Soak in fuel for 8 hours before testing if dried metering rod cam is included in the kit.
out. e. Rough Idle
2. Inspect pump duration and return spring for being 1. Inspect gasket and gasket mating surfaces on
weak or distorted. castings for damage to sealing beads, nicks, burrs
3. Check all pump passages and jets for dirt, im and other damage.
proper seating inlet or discharge balls, scores in 2. Clean all idle fuel passages.
pump well. 3. If removed, inspect idle mixture meedles for
4. Check pump linkage for excessive wear, repair or ridges, burrs, or being bent.
replace as necessary. 4. Check throttle lever and valves for binds, nicks,
c. Hard Starting - Poor Cold Operation and other damage.
LIGHT TRUCK SERVICE MANUAL
6C4-24 CARBURETOR MODEL M 4M
5. Check all diaphragms for possible ruptures or The intermediate choke shaft lever and fast idle cam
leaks. are in correct relation when the tang on lever is beneath
6. Clean plastic parts only in cleaning solvent - never the fast idle cam. Do not install choke cover and coil
in gasoline. assembly until inside coil lever is adjusted.
ASSEMBLY
1. If removed, install idle mixture needle, washer, and Float Bowl
spring using Idle Mixture Adjusting Tool J-29030. 1. Install end of vacuum break rod in slot in rear vacuum
Lightly seat needle and then back out 4-1/2 turns as a break plunger (Fig. 6C4-20). Then, install rear vacuum
preliminary idle mixture adjustment. Final idle mix break and bracket assembly on float bowl using two
ture adjustment must be made on car using the large countersunk attaching screws. Tighten secure
procedures described under Idle Mixture Adjustment. ly.If vacuum break adjustment is necessary, see
2. Install lower end of pump rod in throttle lever by adjustments.
aligning tang on rod with slot in lever. End of rod
2. If removed, install air baffle in secondary side of float
should point outward toward throttle lever. bowl with notches toward the top. Top edge of baffle
must be flush with bowl casting.
Float Bowl Assembly 3. If removed, install baffle in pump well fill slot.
1. Install new throttle body to bowl gasket over two
locating dowels on bowl. 4. Install pump discharge check ball and retainer in
passage next to pump well. Tighten retainer securely.
2. Install throttle body making certain throttle body is
properly located over dowels on float bowl, then install 5. Install primary main metering jets (if removed).
throttle body to bowl screws and tighten evenly and 6. Install aneroid cavity insert into float bowl.
securely (Fig. 6C4-25).
7. Install new needle seat assembly, with gasket.
3. Place carburetor on proper holding fixture J-8328.
8. To make adjustment easier, bend float arm upward at
4. Install fuel inlet filter spring, filter, new gasket and inlet notch in arm before assembly.
nut and tighten nut to 24 N-m (18 ft. lbs.) (Fig. 6C4-
Install needle by sliding float lever under needle pull
24).
clip-correct installation of the needle pull clip is to
The fuel inlet check valve on a vehicle with light duty
hook the clip over the edge of the flat on the float arm
emissions must be installed in the filter to meet Motor
facing the float pontoon (Fig. 6C4-28). With float lever
Vehicle Safety Standards (M .V .S .S .) for roll-over.
in pull clip, hold float assem bly at toe and install
New service replacement filter includes the check
retaining pin from aneroid cavity side (ends of retain
valve.
ing pin face the accelerating pump well).
Ribs on closed end of filter element prevent filter from
being installed incorrectly unless forced. Do not install float needle pull clip into holes in float
Tightening beyond specified torque can damage nylon arm.
gasket. 9. Adjust float level as follow s:
Choke
1. Install new cup seal into plastic insert on side of float CHOKE
bowl for intermediate choke shaft. Lip on cup seal faces ROD
J23417 lever
outward.
2. Install secondary throttle valve lock-out lever on boss
on float bowl with recess in hole in lever facing inward.
3. Install new cup seal into inside choke housing shaft
hole. Lips on seal face inward, towards inside of
housing.
4. Install fast idle cam onto the intermediate choke shaft
(steps on fast idle cam face downward) (Fig. 6C4-23).
5. Carefully install fast idle cam and intermediate choke
shaft assembly through seal in choke housing; then
install thermostatic coil lever onto flats on intermediate
choke shaft. Inside thermostatic choke coil lever is
properly aligned when both inside and outside levers
face towards fuel inlet. Install inside lever retaining
screw into end of intermediate choke shaft. Tighten
securely.
6. Using Tool J-23417, install lower choke rod lever into
cavity in float bowl. Install plastic tube seal into cavity
on choke housing before assembling choke housing to
bowl. Install choke housing to bowl sliding intermedi
ate choke shaft into lower choke lever (Fig. 6C4-27). Fig. 6C4-27--lnstalling Choke Rod Lever
Air Horn
AIR HORN SCREW T IG H T E N IN G
1. If used, install new pump plunger stem seal in air horn
casting (Fig. 6C4-32a). Lightly stake seal retainer in S EQ U E N C E - QUADRAJET
three places, choosing locations diferent from the
original stakings. Fig. 6 C 4 -2 9 --A ir Horn Screw Tightening Sequence
CARBURETOR PUMP PUMP FAST IDLE AIR VACUUM VAC UUM AIR
FLOAT
PART NUM BER ROD ROD CAM VALVE BREAK BREAK VALVE UNLOADER
LEVEL
LOCATION SETTING (CHO KE ROD) ROD FRONT REAR W INDUP
17080212 3/8" INNER 9/32" 46° .025" 24° 30° 3/4 40°
17080213 3/8" INNER 9/32" 37° .025" 23° 30° 1 40°
17080215 3/8" INNER 9/32" 37° .025" 23° 30° 1 40°
17080298 3/8" INNER 9/32" 37° .025" 23° 30° 1 40°
17080507 3/8" INNER 9/32" 37° .025" 23° 30° 1 40°
17080512 3/8" INNER 9/32" 46° .025" 24° 30° 3/4 40°
17080513 3/8" INNER 9/32" 37° .025" 23° 30° 3/4 40°
17081200 15/32" INNER 9/32" 46° .025" 24° 23° 7/8 42°
17081201 15/32" INNER 9/32" 46° .025" 23° 23° 7/8 42°
17081205 15/32" INNER 9/32" 46° .025" 23° 23° 7/8 42°
17081206 15/32" INNER 9/32" 46° .025" 23° 23° 7/8 42°
17081220 15/32" INNER 9/32" 46° .025" 23° 23° 7/8 42°
17081226 15/32" INNER 9/32" 46° .025" 24° 23° 7/8 42°
17081227 15/32" INNER 9/32" 46° .025" 24° 23° 7/8 42°
17081290 13/32" INNER 9/32" 46° .025" 23° 24° 7/8 42°
17081291 13/32" INNER 9/32" 46° .025" 23° 24° 7/8 42°
17081292 13/32" INNER 9/32" 46° .025" 23° 24° 7/8 42°
17081506 13/32" INNER 9/32" 46° .025" 23° 36° 7/8 36°
17081508 13/32" INNER 9/32" 46° .025" 23° 36° 7/8 36°
17081524 13/32" OUTER 5/16" 46° .025" 25° 36° 7/8 38°
17081526 13/32" OUTER 5/16" 46° .025" 25° 36° 7/8 38°
5 .0 L (3 0 5 C I D )
E N G IN E F A M IL Y A U T O M A T IC 20 R P M
18L4 H H N A
RPO LF3
C A N D G S E R IE S
A U T O M A T IC 40 R PM
MANUAL
5 .0 L (3 0 5 C I D ) E X C . C S E R IE S 100 R P M
E N G IN E F A M IL Y W /4 S P E E D
18L4 H A N A O V E R D R IV E
RPO LE9
C, K A N D G S E R IE S MANUAL
C S E R IE S 150 R P M
W /4 S P E E D
O V E R D R IV E
5 .0 L (3 0 5 C I D )
E N G IN E F A M IL Y A U T O M A T IC 50 RPM
18Y4 H G N
RPO LE9 MANUAL 150 R P M
C S E R IE S
5 .7 L (3 5 0 C I D ) A U T O M A T IC 2 0 -5 0 R P M
E N G IN E F A M IL Y
18L4 H A N A A N D
18L4 H H N A MANUAL 100 R P M
RPO LS9
C, K A N D G S E R I E S
* R P M A B O V E ID L E S P E E D S H O W N O N E M IS S IO N L A B E L
SECTION 6C5
FUEL SYSTEM
CONTENTS
Fuel Filter.......................................................................... ..6C5-1 Evaporative Control System .......................................... ..6C5-10
Fuel Pump.......................................................................... ..6C5-1 Accelerator C ontrols....................................................... ..6C5-12
Fuel Tank..............................................................................6C5-4 Specifications.......................................................................6C5-15
Cleaning Fuel S y stem .......................................................6C5-8 Angle to Decimal Conversion....................................... ..6C5-16
Fuel Feed and Vapor Pipes..............................................6C5-9 Special Tools...................................................................... ..6C5-17
FUEL FILTER
GENERAL DESCRIPTION abnormal amount of sediment or water; the tank should
therefore be removed and thoroughly cleaned.
All engine fuel filters are located in the carburetor fuel
inlet. These fuel filter elem ents are of pleated paper. Fuel Filter Replacement
Elements are placed in the inlet hole with the gasket surface 1. Disconnect fuel line connection at fuel inlet filter nut.
outward. A spring holds the element outward, sealing it by
2. Remove fuel inlet filter nut from carburetor.
compressing a gasket surface against the inlet fitting.
3. Remove filter and spring.
ON-VEHICLE SERVICE 4. If removed, install check valve in fuel inlet filter.
The fuel inlet check valve must be installed in the filter
The carburetor inlet fuel filter should be replaced at
to meet Motor Vehicle Safety Standards (M .V .S.S.)
intervals shown in Section OB. A plugged filter and/or check
for roll-over. N ew service replacement filter must
valve will restrict fuel flow.
include the check valve.
After assembling any filter element in the carburetor,
5. Install fuel inlet filter spring, filter, and check valve
always start the engine and check for leaks in the fuel line
assembly in carburetor. Check valve end of filter faces
and fittings before installing the air cleaner.
toward fuel line. Ribs on closed end of filter element
O th e r Filters or Strainers prevent filter from being installed incorrectly unless
forced.
A woven plastic filter is located on the lower end of the
fuel pickup pipe in the gas tank. This filter prevents dirt 6. Install new gasket on fuel inlet filter nut and install nut
from entering the fuel line and also stops water unless the in carburetor. Tighten nut to 24 N-m (18 ft. lbs.).
filter becomes completely submerged in water. This filter is Tightening beyond specified torque can damage gasket.
self cleaning and normally required no maintenance. Fuel 7. Install fuel line and tighten connection.
stoppage at this point indicates that the gas tank contains an 8. Start engine and check for leaks.
FUEL PUMP
GENERAL DESCRIPTION Low Pressure Complaint
The fuel pump (Figs. 6C5-1 through 6C 5-5) is a The only way to check fuel pump pressure is by
diaphragm type pump and is actuated by the rocker arm connecting an accurate pressure gage to the fuel line at
carburetor level. Never replace a fuel pump without first
through a link and a push rod.
making that simple check.
Some vehicles have a fuel pump with an outlet for a
vapor return system. Any vapor which forms is returned to Not Enough Fuel Flow Complaint
the fuel tank along with hot fuel through a separate line. When an engine has a "starving-out"- condition, many
This greatly reduces any possibility of vapor lock by keeping mechanics jump to the conclusion that the fuel pump is not
cool fuel from the tank constantly circulating through the pumping enough fuel. Many times the "starving-out"
fuel pump. condition is actually due to a weakness in the ignition
system, since these two troubles are very hard to separate.
Even when an engine is starving for fuel, the cause is more
DIAGNOSIS
likely to be a plugged fuel filter or a restricted fuel line than
Complete diagnosis of all possible causes of the trouble a malfunctioning fuel pump.
prior to replacement of the fuel pump will save time, expense
and possible causes of the trouble prior to replacement of the
fuel pump will save time, expense and possibly prevent a
repeat complaint.
LIGHT TRUCK SERVICE MANUAL
6C5-2 FUEL SYSTEM
ON-VEHICLE SERVICE
Rem oval
30 N.m
(22 F T .-L B S .)
BO TH E N D S
O F P IP E
G ASKET
37 N.m
(27 F T .-L B S .)
PUSH ROD
PLUG
7.4L (LE-8)
FUEL TANK
ON-VEHICLE SERVICE 5. Remove strap bolts and lock washers from tank front
and rear locations on inside frame rail.
O utside Fram e Rail Fuel T an k-
6. Remove tank from frame simultaneously disengaging
Cab a n d C rew ca b (Figs. 6 C 5 -6 an d 8) filler neck hose from filler neck (Fig. 6C5-8 and 6C5-
9).
1. Drain tank. 7. Remove meter assembly from fuel tank using Tool
2. Disconnect fuel lines, meter wire and ground lead. J-24187 (Fig. 6C5-10).
3. Remove strap supports (lines, vent) and clip. 8. Reverse removal procedure to install fuel tank.
4. Loosen clamps from filler neck and vent line.
H O S E -V E N T
STRAP
BRACKET
CLAM P
HOSE-FILLER
1. Drain tank.
2. Raise vehicle on hoist.
3. Unclamp upper filler neck and vent tube hose (Fig.
6C5-8 and 9).
4. Unclamp gage unit hoses at frame end.
5. Support tank and remove support straps.
6. Lower tank and disconnect meter wire.
7. Remove tank.
8. Install in the reverse order, using new antisqueak
material.
9. Lower vehicle and remove from hoist.
ON-CAR SERVICE 5. In repairable areas, cut a piece of fuel hose 4" (100
mm) longer than portion of the line removed.
Fuel Line Repair If more than a 6 inch (152 mm) length of pipe is
removed, use a combination of steel pipe and hose so
Replacem ent that hose lengths will not be more than 10 inches (254
mm).
1. If replacement of a fuel feed, fuel return or emission Follow the same routing as the original pipe.
pipe is required use welded steel tubing meeting GM
6. Cut ends of pipe remaining on car square with a tube
Specification 124-M or its equivalent.
cutter. Using the first step of a double flaring tool, form
2. Do not use copper or aluminum tubing to replace steel a bead on the end of both pipe sections. If pipe is too
tubing. Those m aterials do not have satisfactory corroded to withstand bead operation without damage,
durability to withstand normal vehicle vibrations. the pipe should be replaced. If a new section of pipe is
3. When rubber hose is used to replace pipe, use only used, form a bead on both ends of it also.
reinforced fuel resistant hose which meets GM Speci 7. Use screw type hose clamp, Part Number 2494772, or
fication 6165-M . Hose inside diameter must match equivalent. Slide clamps onto pipe and push hose 2"
pipe outside diameter. (51 mm) onto each portion of fuel pipe. Tighten clamps
4. Do not use rubber hose within 4" (100 mm) of any part on each side of repair.
of the exhaust system or within 10" (254 mm) of the 8. Pipes must be properly secured to the frame to prevent
catalytic converter. chafing.
1. A fuel tank overfill protector is provided on all series to Canister Purge Valve
assure adequate room for expansion of liquid fuel
volume with temperature changes. Disassembly
2. A one point fuel tank venting system is provided on all 1. Disconnect lines at valve.
series to assure that the tank will be vented under any 2. Snap off valve cap (slowly remove cap as diaphragm is
conceivable vehicle attitude. under spring tension). Remove diaphragm, spring
retainer and spring.
3. To protect the tank from mechanical damage in the
3. Replace parts as necessary. Check orifice openings.
event of excessive internal or external pressures result
ing from the operation of this closed system, a pressure- Assembly
vacuum relief valve, located in the gas cap, will control 1. Install spring, spring retainer, diaphragm and cap.
the tank internal pressure. 2. Connect lines to valve.
3. If the valve will not hold vacuum, replace canister. Pressure Checking E vaporative Control System
4. If valve holds vacuum, remove purge line and check for 1. Stabilize vehicle by operating until warmed up.
vacuum. If no vacuum, check PCV hoses and system. 2. Remove tank line at canister and observe for liquid in
Repair ir replace as necessary. the line. Hook-up pressure device.
3. Apply 15 " H 20 pressure to the fuel vapor line.
A.Observe for excessive loss of pressure.
Checking Bowl V e n t V a lv e
B .If negligible pressure loss occurs observe for fuel
1. Remove the bowl vent vapor hose from the carburetor. vapor smell or fuel loss at points listed in Diagnostics
under Possible Cause.
2. Check the open condition of the valve by connecting to
a manual vacuum pump. It should not be possible to C.Remove fuel filler cap(s) and observe for pressure in
obtain .5 inch Hg if the valve is open. tank(s).
3. If a high resistance or plugged system is found, check 4. Remove fuel cap (LH on duel tank units) and blow on
for a plugged or restricted hose. Hose may be cleared vent line to check for obstructions. (Install LH cap on
with compressed air. If the hose is clear, remove the dual tank units and remove RH cap. Repeat above.)
canister filler. If the restriction persists, replace the
Fuel Tank Selector Valve
canister.
4. A simple check of the valve closed condition can be R eplacem ent (Fig. 6 C 5 -1 7 a )
obtained with the same procedure as in Step 2, but with 1. Disconnect battery.
the engine operating at operating temperature. M ani 2. Remove hose shield and brace.
fold vacuum will be applied to the valve through the 3. Remove fuel and vapor hoses noting their position for
control line. The bowl vent line should exhibit a later installation.
plugged condition.
4. Remove two screws holding valve to frame and remove
5. If the valve is not closed, remove the control vacuum valve.
line and check for vacuum. If no vacuum is present,
5. Install valve and tighten screws.
check hose for restriction or vacuum leak. Repair or
replace as required. If vacuum is present, replace 6. Install fuel and vapor hoses in same positions noted at
canister. removal.
7. Install brace and hose shield.
8. Connect battery.
ACCELERATOR CONTROLS
GENERAL
The accelerator control system is cable type. There are
no linkage adjustments. A reference between the bottom of
accelerator pedal and floor pan should be used only as a
check for bent bracket assembly. Check torque references.
Check for correct opening and closing positions by
operating accelerator pedal and if any binding is present,
check routing of cable.
ACCELERATOR PEDAL
SEALER
OUTER SPRING
SPRING OUTER
CARBURETOR STUD l± _____
QF
SPRING INNER NOTE | With Inner Spring inside Outer Spring,
FASTENER anchor both Springs thru hole in Carburetor
Lever and holes in Support and Bracket.
I NOTE I Slip accelerator control cable thru slot in Rod. CAUTION: Care must be used in pressing
Retainer into hole in Rod to assure Cable
Install retainer, being sure it is seated. is not kinked or damaged in any way.
I CAUTION! Care must be used in pressing the retainer
into hole in Rod to assure cable is not kinked or LE ASSEMBLY
damaged in any way
SUPPORT,
SPRING REINFORCEMENT
PEDAL*— 1T ill'll j1
/ — L N U I U Retainer must
bear against pedal rib.
NOTE I Having secured all components ot tne accelerator
linkage as specified, linkage must operate freely without TIGHTEN TO
bind between full closed throttle and full wide open throttle. 27 IN. LBS.
SUPPORT
SPRING' REINFORCEMENT
ACCELERATOR T IG H T E N T O
CO NTRO L CABLE
5 0 IN . LBS.
TIGHTEN TO
42 IN. LBS.
PEDAL
SUPPORT
Fig. 6 C 5 -24--A ccelerato r Pedal-P42
SPECIFICATIONS
V8 (LF8) 71
/2-9
WITH VAPOR RETURN LINE
TORQUE
SPECIFICATIONS
IM E C A R B U R E TO R
TORQUE TORQUE
SCREW (IN. LBS.) SCREW (IN. LBS.)
AIR HORN TO BOWL 45 FUEL INLET NUT 400
AIR CLEANER BRIDGE 70 FAST IDLE CAM 50
THROTTLE BODY TO BOWL 180 CHOKE LEVER 25
NEEDLE SEAT 45 PUMP LEVER 30*
METERING JET 40
TORQUE
SCREW (IN. LBS.)
THROTTLE BODY
THROTTLE BODY TO BOWL 46
CHOKE HOUSING
CHOKE LEVER 14
CHOKE HOUSING ATTACHING 46
CHOKE HOUSING COVER 26
AIR HORN
AIR HORN TO BOWL 10-32 46
AIR HORN TO BOWL 8-32 26
AIR HORN TO THROTTLE BODY 46
CHOKE LEVER 14
VACUUM BREAK UNIT 26
FUEL INLET NUT 400
NEEDLE SEAT 45
METERING JET 40
SOLENOID BRACKET 71
Fig. 6C5-26--Specifications
THE RELATION BETWEEN DECIMAL AND ANGLE READINGS IS NOT EXACT DUE TO MANUFACTURING
TOLERANCES OF THE COMPONENT PARTS. THIS CHART IS SUPPLIED FOR USE BY THE MECHANIC
WHO HAS ACCESS TO PLUG GAUGES ONLY. THE RECOMMENDED TOOL IS AN ANGLE GAUGE FOR
ACCURACY AND BEST OVERALL PERFORMANCE AND EMISSIONS.
D E C IM A L E Q U IV . D E C IM A L E Q U IV .
ANGLE DEG REES TOP OF V A L V E ANGLE DEG REES TOP OF V A L V E
5 .023 33 .203
6 .028 34 .211
7 .033 35 .220
8 .038 36 .227
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 .129 51 .360
24 .136 52 .370
25 .142 53 .379
26 .149 54 .388
27 .157 55 .400
28 .164 56 .408
29 .171 57 .418
30 .179 58 .428
31 .187 59 .439
32 .195 60 .449
SPECIAL TOOLS
Idle Mixture Socket................................................................................ J-29030-B
Adjustable Float G age........................................................................... J-9789-90
Bending T ool.......................................................................................... J-9789-111
Needle Valve Seat Remover..................................................................... J-22769
Carburetor S tand.................................................................................. J-9789-1 18
Float Level G age.................................................................................... J-9789-130
Float Level G age................................................................................... J-9789-135
Carburetor Choke Angle Gage............................................................. J-26701-4
Hand Vacuum D evice................................................................................ J-23738
Thermae Thermometer.............................................................................. J-22973
Carburetor Gage S e t................................................................................ J-9789-C
Fuel Tank Sending Unit Remover.......................................................... J-24187
.. .... I S.iiix:?.’
SECTION 6D
ENGINE ELECTRICAL
CONTENTS
'OIL" LIGHT
FUSIBLE
LINK ! 1 "GAUGE' ELECTRIC CHOKE HEATER CHECKING
j —cTVo— FUSE CARB. CHOKE
HEATER PROCEDURE
1*3
ir — ■((— ||l-
IGNITION 1. Allow choke to cool so that when throttle is opened
I SWITCH
01L PRESSURE
slightly, choke blade fully closes. This check must be
performed with engine not running and at an ambient
SWITCH
temperature of (60°C to 27°C).
2. Start engine and determine time for choke blade to
Fig. 6D-1 A--Electric C hoke Heater D iag ra m reach full open position. (Start timer when engine
starts).
All engines have a two-terminal oil pressure switch
(sending unit) for controlling current to the electric choke 3. If the choke blade fails to open fully within 3.5 minutes,
proceed with steps 4-5-6 below.
heater. This switch and its associated circuitry provide for
the illumination of the "Oil" tell tale lamp in the event of 4. Check voltage at the choke heater connection. (Engine
loss of oil pressure or loss of voltage at the choke heater. must be running). If the voltage is approximately 12-15
The diagram in Figure 6D-1A shows how the dual volts, replace the electrical choke unit.
function is accomplished. The "Bulb Check" feature is 5. If the voltage is low or zero, check all wires and
same as present system. That is, with ignition switch in connections. If any connections in the oil pressure
"Run" position with engine off. This circuit will also switch circuitry are faulty or if the oil pressure switch is
indicate continuity in the choke heater and its connector. failed open, the oil warning light will be on with the
engine running. Repair wires or connections as
If "Oil" tell tale lamp illuminates with engine running,
required.
it could indicate one or more of the following:
1. Loss of oil pressure. 6. If all wiring and connections are good, replace oil
pressure switch. No gasket is used between the choke
2. Loss of choke heater voltage. cover and the choke housing because of grounding
3. Blown GAGE fuse. requirements.
3634
Wiring
JUNCTION BLOCK
TEMPERATUR
POWER UNIT GAGE SENDER
W/S WIPER
OIL PRESS MOTOR
SWITCH
exc Z53
TAIL COMBINATION
VIEW A
EXTENSION WIRE
|THROTTLE
/KICKER . ENDER ASM
W/GAGE PACK
CONNECTOR
CK 100+200
■SPEED
SWITCH
BATTERY
General Description......................................................... .. 6 D -1 Built In H ydrom eter..................................................... 6D-6
General Information....................................................... 6D-1 Diagnosis............................................................................... 6D-6
Common Causes of Failure........................................ .6 D -1
On-Vehicle Service............................................................. 6D-7
Electrolyte F reezing..................................................... 6 D -1
Charging Procedure ......................................................... 6D-7
Carrier and Hold D ow n...............................................6D-1
Ratings..............................................................................6D-6 Jump Starting................................................................... 6D-7
Remove and Replace....................................................... 6D-8
GENERAL DESCRIPTION
The sealed battery (see Fig. 6D-1B) is standard on all
vehicle lines (see Specifications for specific applications).
There are no vent plugs in the cover. The battery is
B U ILT-IN
H YD RO M ETER
completely sealed, except for two small vent holes in the
side. These vent holes allow the small amount of gas
produced in the battery to escape. The battery has the
following advantages over conventional batteries:
1. N o water addition for the life of the battery. This
improvement makes the sealed battery possible.
2. Overcharge protection. If too high a level voltage is
applied to the battery, it will not accept as much
current as a conventional battery, the excess voltage
will cause gassing, which leads to liquid loss.
3. Reduced self-discharge compared to a conventional
battery. This is important when a battery is left
standing for long periods of time.
4. Comparable power available in a lighter and smaller
case.
The battery has three major functions in the electrical
system.
First, it is a source of electrical energy for cranking the
engine. Second it acts as a voltage stabilizer for the
electrical system. And third, it can, for a limited time,
provide energy when the electrical load exceeds the output
Fig. 6D-1 B~Sealed Top Battery of the generator.
GENERAL INFORMATION
COMMON CAUSES OF FAILURE Electrolyte Freezing
A battery is not designed to last indefinitely; however, The freezing point of electrolyte depends on its specific
with proper care, it will provide many years of service. If the gravity. Since freezing may ruin a battery, it should be
battery tests good but fails to perform satisfactorily in protected against freezing by keeping it in a fully charged
service, the following are some of the more important factors condition.
that may point to the cause of the trouble.
1. Accessories left on overnight. Carrier and Hold-Down
2. Slow average driving speeds for short periods.
The battery carrier and hold-down should be clean and
3. The cars electrical load is more than the generator free from rust before installing the battery. The carrier
output particularly with the addition of after market
should be in good condition so that it will support the battery
equipment such as radio equipment, air conditioning,
securely and keep it level.
window defoggers or light systems.
4. Defects in the charging system such as electrical shorts Make certain there are no parts in carrier before
slipping fan belt, faulty generator or voltage regulator. installing the battery.
5. Battery abuse, including failure to keep the battery To prevent the battery from shaking in its carrier, the
cable terminals clean and tight or loose battery hold h old -d ow n bolts sh ou ld be tight. S ee On V eh icle Serv
down. See On Vehicle Service for torque specifications. ic e for torq u e sp ecifica tio n s.
LIGHT TRUCK SERVICE MANUAL
6D-6 ENGINE ELECTRICAL
Visual Inspection
The external condition of the battery should be checked
periodically for damage such as cracked cover or case.
RATINGS
A battery has two ratings: (1) a reserve capacity rating
at 80°F (27°C) which is the time a fully charged battery will
operate the car with no generator operation, (2) a cold crank
rating at 0°F (18°C) which indicates the cranking load
capacity. (See Specifications for specific battery ratings).
The Ampere/Hour rating formerly found on batteries was
based on the reserve capacity rating and is no longer used.
Built-In Hydrometer
The sealed battery has a built-in temperature compen
sated hydrometer in the top of the battery. This hydrometer
is to be used with the following diagnostic procedure. When
observing the hydrometer, make sure that the battery has a
clean top. A light may be required in some poorly-lit areas to
see the right indication.
Under normal operation, two indications can be ob
served (see Figure 6D-2B):
1. G REEN DOT VISIBLE
Any green appearance is interpreted as a green dot and
condition, it may indicate high charging voltage caused by a
the battery is ready for testing.
faulty charging system and therefore, the charging and
2. DARK; G REEN DOT N O T VISIBLE
electrical system may need to be checked. If a cranking
If there is a cranking complaint, the battery should be complaint exists and is caused by the battery, it should be
tested as described in the Diagnosis section. The charging replaced.
and electrical systems should also be checked at this time.
Replace battery. Do not charge, test or jump-start.
Occasionally, a third condition may appear:
3. CLEAR OR LIGHT YELLOW C A U T IO N :D o not charge, test or jum p start b a tte ry
This means the fluid level is below the bottom of the w h e n th e h ydrom eter is clear or lig h t ye llo w . N ot
hydrometer. This may have been caused by excessive or fo llo w in g this ca u tio n could result in serious
prolonged charging, a broken case, excessive tipping or personal injury (p articu larly to eyes) or property
normal battery wearout. When finding a battery in this d a m a g e from b a tte ry explosion or b attery acid.
DIAGNOSIS
The following procedure should be used for testing
batteries:
INSULATOR STRAP
PREVENTS TOOL SEPARATION
1. VISUAL INSPECTION A ND LOSS WHEN NOT IN USE
Check for obvious damage, such as cracked or broken
case or cover, that could permit loss of electrolyte. If obvious
damage is noted, replace the battery. Determine cause of
damage and correct as needed. If not, go to step 2.
3. LOAD TEST
Load testing may require use of battery side terminal ADAPTER CHARGING
adapters to insure good connections (see Fig. 6D-3B). TOOL ATTACHED
TO TERMINALS
a. Connect a voltmeter and a battery load tester across
Fig. 6D-3B--Side Terminal Battery Adapters
the battery terminals.
LIGHT TRUCK SERVICE MANUAL
ENGINE ELECTRICAL 6D-7
9.6 70 21
9.5 60 *16
9.4 50 10
9.3 40 4
B A TTER Y TEST LOAD
9.1 30 - 1
8.9 20 - 7
8.7 10 -1 2
Y 85-4 130 AMPS 8,5 0 -1 8
R85-5 170 AMPS
R87-5 Fig. 6D-5B--M inim um V o lta ge D rop
210 AMPS
R89-5 230 AMPS c. Wait 15 seconds to let battery recover and apply
specified load from load test chart. Read voltage
2996
after 15 seconds, then remove load.
ON-VEHICLE SERVICE
CHARGING PROCEDURES C A U T IO N :D ep artu res from these conditions or the
procedure b elo w could result in:
When it is necessary to charge the battery, the follow
1.Serious personal injury (particularly to eyes) or
ing safety precautions must be followed:
property d a m a g e from such causes as b a tte ry
1. DO NOT CHARGE battery if hydrometer is clear or explosion, b a tte ry acid, or electrical burns; a n d / or
light yellow. Replace battery.
2 . D a m a g e to electronic com ponents of e ith e r
2. If the battery feels hot 125°F (52°C), or if violent vehicle.
gassing or spewing of electrolyte through the vent hole
N ever expose b a tte ry to open fla m e or electric
occurs, discontinue charging or reduce charging rate.
spark - batteries g e n e ra te a gas w hich is fla m
Charge the battery until the green ball appears.
m ab le a n d explosive. Remove rings, w atches, a n d
Tipping or shaking the battery may be necessary to
other jew elry . W e a r ap p ro ved eye protection. Do
make the green ball appear.
not a llo w b a tte ry flu id to contact eyes, skin,
Temperature of the battery will effect the charging fabrics, or p a in te d surfaces - it is a corrosive acid.
rate, and most charging equipment will not charge at a Flush a n y contacted a re a w ith w a te r im m e d ia te ly
constant rate. For example, if the charger starts at 30 an d thoroughly. Be careful th a t m e tal tools or
amperes and drops off to 10 amperes after 1 hour, the jum per cables do not contact th e positive b a tte ry
average current for that hour was 20 amperes. The term in a l (or m e ta l in contact w ith it) an d a n y other
actual boost charge was 20 ampere-hours. The sealed m e ta l on th e car, because a short circuit could
battery can be fast charged or slow charged with occur. Batteries should a lw a y s be kept out of the
ordinary chargers in the same manner as conventional reach of children.
batteries. Either method will restore the battery to full
charge. 1. Set parking brake and place automatic transmission in
Many chargers have special settings for sealed batter PARK (N E U T R A L for manual transmission.) Turn
off lights, heater, and other electrical loads.
ies. These settings reduce the charge voltage and limit
the current. It is not necessary to use these settings with 2. Check the built-in hydrometer. If it is clear or light
this sealed battery. yellow, replace the battery, do not attempt to jump
start.
JUMP STARTING IN CASE OF EMERGENCY WITH 3. Only 12 volt batteries can be used to start this engine.
AUXILIARY (BOOSTER) BATTERY 4. Hook up one end of the positive jumper cable to the
positive terminal of the booster battery and the other
N O TIC E: Do not push or tow this vehicle to start. end to the positive terminal of the discharged battery.
Damage to the emission system and/or to other parts of DO NOT PERMIT vehicles to touch each other as this
the vehicle may result. could cause a ground connection and counteract the
Both booster and discharged battery should be treated benefits of this procedure.
carefully when using jumper cables. Follow the procedure 5. Hook up one end of the negative jumper cable to the
outlined below, being careful not to cause sparks: negative terminal of the booster battery, and the other
LIGHT TRUCK SERVICE MANUAL
6D-8 ENGINE ELECTRICAL
end to a solid engine ground (such as A /C compresser 1. Hydrogen gas is produced by the battery. A flame or
or generator mounting bracket) at least 450 mm (18 spark near the battery may cause the gas to ignite.
inches) from the battery of the vehicle being started 2. Battery fluid is highly acidic. Avoid spilling on clothing
(DO NO T C O N N E C T DIRECTLY TO THE N EG or other fabric. Any spilled electrolyte should be
ATIVE T E R M IN A L OF THE DEAD BATTERY). flushed with large quantities of water and cleaned
6. Start the engine of the vehicle that is providing the immediately. To remove or replace a battery, always
jump start and turn off electrical accessories. Then disconnect the negative cable first, then the positive
start the engine in the car with the discharged battery. cable. Torque battery cables at battery to 12 Nm (9 lb.
7. Reverse these directions exactly when removing the ft.). Two types of battery hold-downs are used. The
jumper cables. The negative cable must be removed hold-down rod going across the battery top should be
from the engine that was jump started first. torqued to 3.0 N-m (25 lb. in.), and the clamp which
holds the bottom of the battery should be torqued to
REMOVE AND REPLACE 16.0 N-m (12 lb. ft.).
When handling a battery, the following safety precau
tions should be observed:
CHARGING SYSTEM
General Description............................................................ 6D-8 Stator C hecks................................................................... 6D-14
Diagnosis............................................................................... 6D-10 Rotor Field Winding C hecks........................................ 6D-14
Faulty Indicator Lamp Operation............................... 6D-12 Diode Trio C heck............................................................ 6 D -15
Undercharged Battery..................................................... 6D-12 Rectifier Bridge Check.................................................... 6D-15
Overcharged Battery............................................... ....... 6D-13 Brush Holder and Regulator Replacem ent............... 6D-15
On-Vehicle Service............................................................. 6D-13 Slip Ring Servicing......................................................... 6D-16
Unit Repair.......................................................................... 6D-14 Bearing Replacement and Lubrication....................... 6D-16
Disassembly....................................................................... 6D-14 Reassembly.......................................................... ............. 6D-16
GENERAL DESCRIPTION
The basic charging system is the SI integral regulator the slip ring end frame. The regulator voltage setting never
charging system (Fig. 6D -1C ). The internal components are needs adjusting, and no means for adjustment is provided.
connected electrically as shown in Fig. 6D-2C. The genera The generator rotor bearings contain a supply of
tor is connected to the vehicle electrically as shown in Fig. lubricant sufficiently adequate to eliminate the need for
6D-3C. periodic lubrication. Two brushes carry current through the
The 15-SI generator is similar to the 10-SI except that: two slip rings to the field coil mounted on the rotor, and
under normal conditions will provide long periods of
1. It is slightly larger physically.
attention-free service.
2. It produces 70 amps output at full speed.
The stator windings are assembled on the inside of a
3. It uses different drive end and slip ring end bearings. laminated core that forms part of the generator frame. A
4. The stator uses delta windings, which cannot be recitifier bridge connected to the stator windings contains
checked for opens. six diodes, and electrically changes the stator a.c. voltages to
a d.c. voltage which appears at the generator output
terminal. Generator field current is supplied through a diode
The brown field wire to the generator is used to initially trio which also is connected to the stator windings. A
activate the generator. The 10 ohm resistance, provided by capacitor or condenser, mounted in the end frame protects
either the generator warning lamp or the resistance wire the rectifier bridge and diode trio from high voltages, and
with optional gages, is needed to protect the diode trio. suppresses radio noise.
Although several models of generators are available N o periodic adjustments or maintenance of any kind
with different outputs at idle and different maximum are required on the entire generator assembly.
outputs, their basic operating principles are the same.
The generator features a solid state regulator that is NOISY GENERATOR
mounted inside the generator slip ring end frame. All Noise from a generator may be caused by a loose drive
regulator components are enclosed into a solid mold, and pulley, loose mounting bolts, worn or dirty bearings,
this unit along with the brush holder assembly is attached to defective diode, or defective stator.
VOLTMETER
(R A L L Y GAUGE
ONLY)
GENERATOR WARNING
LAMP (EXC. R ALLY GAUGE)
SWITCH
BATTERY 10 ohms
10 ohms RESISTANCE'
WIRE (R A LLY GAUGE
BROWN (FIELD) ONLY) [U - ..............
RED (SENSING)
BULKHEAD
CONNECTOR
GENERATOR
DIAGNOSIS
Most charging system troubles show up as a faulty • When connecting a charger or a booster battery to the
indicator lamp, an undercharged or an overcharged battery. vehicle battery, see Battery Charging Section.
Since the battery itself may be defective, it should be • In some circuits (Gage option), a voltmeter may be
checked first to determine its condition. Also, in the case of used instead of an indicator lamp. In this case, Section
an undercharged battery, check for battery drain caused by "A" pertaining to faulty indicator lamp operation
grounds or by accessories being left on. should be omitted from the troubleshooting procedure.
A basic wiring diagram showing lead connections is
shown in Figure 6D-3C. To avoid damage to the electrical Trouble in the charging system will show up as one or
equipment, always observe the following precautions: more of the following conditions:
• Do not polarize the generator. A. Faulty indicator lamp operation.
• Do not short across or ground any of the terminals in
. the charging circuit except as specifically instructed. B. An undercharged battery as evidenced by slow crank
ing or test indicator dark.
• Never operate the generator with the output terminal
open circuited. C. An overcharged battery as evidenced by excessive
• Make sure the generator and battery are of the same spewing of electrolyte from the vent holes.
ground polarity.
Lam p O ff Lam p O n La m p O n L am p O ff L a m p O ff
NORMAL La m p On La m p O n
NORMAL D IM NORMAL
See Test 2 See Test 3
If th e in d ic a to r lam p o p e ratio n
is norm al fo r all th re e tests,
C onnect v o ltm e te r to B A T . Check 10 am p. Check drive b e lt and refer to SI g enerator Diagnosis
te rm in al on generator and "G A U G E S " w irin g connections at
chassis ground. T u rn " T R A N S ." fuse generator and batte ry cables. D isconnect N o . 1 and 2 C onn e c to r Disconnect N o . 1 and 2
ignition key on. in fuse block. at generator, G ro u n d N o . 1 w ire. Do C o n n e c to r a t ge n era to r.
N O T ground N o . 2 w ire .
r
Fig. 6D-4C--CHarging
La m p On Lam p O ff
B a tte ry V oltag e Zero V o lta g e Check 10 am p.
"G A U G E S "
I J " T R A N S ." fuse L a m p O ff L a m p On
Disconnect N o . 1 and N o . 2 Connector Repair open c irc u it betw een in fuse b lo c k.
at generator. C onnect v o ltm e te r fro m B A T . term inal on generator
N o . 1 c onnec tor to chassis ground. and junction b lo c k or R e pa ir short betw een Replace R e c tifie r
battery. N o . 1 and N o . 2 Bridge in g e n era to r.
A p p ro x im a te ly 1. La m p b urned o u t. w ires in harness.
2 to 4 V o lts Install N o . 1 and 2 C o n n e c to r.
O pen in N o . 1 w ire fro m
System
ENGINE
N O R M A *. 1. M a k e sure N o . 1 w ire
co n n ec to r is m aking
O u tp u t N O T w ith in 1 0 am ps o f rated Replace R egulator good co n ta ct on te rm in a l.
C heck b a tte ry connections and b a ttery output stam p ed on generator fra m e.
c o n d itio n 2. Disassemble generator
ELECTRICAL
and check brushes, slip
Insert screw driver in to test hole. rings and ro to r w inding
End of screw driver m ust to u c h ta b and side fo r open.
O u tp u t w ith in 1 0 am ps o f rated o u t o f screwdriver gro u n d against end fra m e.
p u t stam ped on generator fram e. Run engine as b e fo re and recheck o u tp u t.
6D -11
o u tp u t stam p ed o n generator fra m e.
2427
6D-12 ENGINE ELECTRICAL
j. If output is within 10 amperes of rated output, check 2. Connect a voltmeter from generator No. 2 terminal to
field winding as covered in Generator Repair section, ground. If reading is zero, No. 2 lead circuit is open.
and test regulator with an approved regulator tester, 3. If battery and No. 2 lead circuit check good, but an
k. If output is not within 10 amperes of rated output, obvious overcharge condition exists as evidenced by
check the field winding, diode trio, rectifier bridge, excessive spewing of electrolyte, proceed to disassembly
and stator as covered in the Generator Repair section of Generator Overhaul and check field windings
Section. for grounds and shorts. If defective, replace rotor, and
7. If test hole is not accessible, disassemble generator and test regulator with an approved regulator tester.
make tests listed in Unit Repair section. Generator Tester - many testers are available to check
the generator. They provide a quick on-vehicle test, and can
OVERCHARGED BATTERY save time over conventional diagnostic methods. Consult
1. To determine battery condition refer to Battery section. manufacturer’s instructions for usage.
ON-VEHICLE SERVICE
The generator does not require periodic lubrication. 4. Remove generator drive belt.
The rotor shaft is mounted on ball bearings at the drive end 5. Remove thru bolt which retains generator.
and roller bearings at the slip ring end, and each contains a
permanent grease supply. A t periodic intervals, check 6. Remove generator from vehicle.
mounting bolts for tightness and adjust belt tension (see Sec.
Install In Vehicle
6B).
When adjusting belt tension, apply pressure at center 1. If removed from vehicle, install generator to mounting
of generator, never against either end frame. bracket with bolts, washers and nuts. Do not tighten.
2. Install generator drive belt.
Rem ove From Vehicle
1. Disconnect negative battery terminal at battery. 3. Tighten belt to the specified belt tension. See Engine
Cooling Section for proper belt tensioning procedures.
C A U T IO N :F ailure to observe this step m a y result in
an injury from hot b a tte ry lea d a t g en erator. 4. Tighten bolts to 41 N-m (30 lb. ft.), except bolt at
sliding slots on brackets which is 27 N-m (20 lb. ft.).
2. Remove two terminal plug and battery leads on back of
generator. 5. Install generator terminal plug and battery leads to
3. Loosen adjusting bolts (see Fig. 6D-6 through 6D-8 for generator.
generator mounting). 6. Connect negative battery terminal.
UNIT REPAIR
THRU-BOLT
TEST HOLE
(CHECK FOR T E S T IN G RO TO R
GROUNDS) (OHMMETER)
RECTIFIER
BRIDGE _ __
DIODE
CAPACITOR ■«> .«v,n.n.vi TR|0
OHMMETER
NUTS
3. Remove three attaching nuts and regulator attaching CHECK FOR OPENS
screws. 7. Check rotor for grounds with ohmmeter. Reading should
4. Separate stator, diode trio and regulator from end frame. be very high (infinite). If not, replace rotor.
NOTE: The regulator cannot be tested on the work bench 8. Check rotor for opens. Should read 2.4-3.5 ohms, If not,
except with a regulator tester. replace rotor.
BRUSHES
SINGLE CONNECTOR
P AR TIA L W
R EC TIFIER END FRAME
15S1/100
20. Push slip ring end bearing out from outside toward inside
of end frame.
21. On 10SI and 27SI, place flat plate over new bearing, press
from outside toward inside until bearing is flush with end
frame.
22. On 15SI, see illustration.
23. Assemble brush holder, regulator, resistor, diode trio,
rectifier bridge and stator to slip ring end frame.
24. Assemble end frames together with thru-bolts. Remove
brush retainer wire.
BRUSH HOLDER AND REGULATOR The continuity test accessory cable is used in conjunc
tion with the meter on the Tester. A high meter reading
REPLACEMENT indicates an open circuit (no continuity) while a zero meter
To determine if the regulator is defective, an approved reading indicates continuity.
regulator tester must be used. After removing the three When you make a continuity test, keep the following
attaching nuts, the stator, and diode trio screw, the brush points in mind:
holder and regulator may be replaced by removing the two 1. Make sure a regulator is not installed in the holder.
remaining screws. Note the two insulators located over the
2. The knob is turned clockwise only until it clicks.
top of the brush clips and that these two screws have special
insulating sleeves over the screw body above the threads. 3. All components must be isolated for testing.
The third mounting screw may or may not have an insulat 4. Make sure voltage is not applied to the component
ing sleeve. If not, this screw must not be interchanged with being tested.
either one of the other two screws, as a ground may result,
causing no output or uncontrolled generator output. Regula SLIP RING SERVICING
tors may vary in appearance but are com pletely inter If the slip rings are dirty, they may be cleaned and
changeable in these generators. finished with 400 grain or finer polishing cloth. Spin the
Using voltage regulator tester CTW -1170 or equiv rotor, and hold the polishing cloth against the slip rings until
alent (Fig. 6D-10C), it is possible to check the voltage they are clean.
regulator both on the vehicle and on the bench. Use the
NOTICE: The rotor must be rotated in order to clean the
instructions on the tester cover for testing the regulator on
slip rings evenly. Cleaning the slip rings by hand
the bench and use the following instructions for the on
without spinning the rotor may result in flat spots on
vehicle test and the continuity test.
the slip rings, causing brush noise.
Slip rings which are rough or out of round should be
O n -V eh icle Test trued in a lathe to .002 inch maximum indicator reading.
This on-vehicle test procedure helps to quickly deter Remove only enough material to make the rings smooth and
mine if a problem exists in the generator/regulator circuit. round. Finish with 400 grain or finer polishing cloth and
If you do not obtain the proper results in this test, the blow away all dust.
SPECIAL TOOLS
J-2150 1
PULLY
AD AP TER
.8 YEL-508 (HW)
.8 PNK-30(HW)
PRODUCTION
TANK SENOER
MODULE CIRCUITS
A - Blank
B - Blank
C - 502 - Probe 506 Glow Plug Relay Coil Feed (-)
D - Blank 505 Glow Plug Relay Coil Feed (+)
E - 503 Right Bank Glow Plugs (Monitor) Glow Plug Feed (Power)
F - 505 Glow Plug Relay Coil Feed (+)
G - 3 - Ignition
H - 150 Ground (Power)
J 506 - Glow Plug Relay Coil Feed (-)
K - B la n k
L - 501 - Probe
M - 5 0 0 Module Logic Ground
N - Generator Output (Monitor)
1 2
Ignition Switch-Off Ignition Switch - "Run"
Don't Start/Glow Plugs Lamp-Off Don't Start/Glow Plugs Lp - On
3 4
Ignition Switch "Start" Ign Sw Run
Don't Start/Glow Plugs Lp - Don't Start/Glow Plugs Lp -
Pulsing on/off Pulsing on/off*
ASM
B R A K E LAM P IN S T R U M E N T P A N E L
S W IT C H W IR IN G H A R N E S S
BRAKE PEDAL
BRACKET BEZEL
O P E N IN G
W A R N IN G
LAM P
IN S T R U M E N T
CLU STER
VIEW A
GROUND
BUS BAR
A u to m a tic
transm ission clutch
test connection.
VIEW B
________ _ Install C on ne ctor into
vacant cavity m arked " i G N 1 .
Fig. 6D-6D--Diesel Engine - A ccelerator Control and Fig. 6D-7D--Diesel Starter M ou n tin g
Sole noid Assem bly
CKT 2
RED
Fig. 6D-10D--C-10
PRINTED CIRCUIT
BOARD RELAY
GEN 25 CKT BRN
C K T 505 YEL
CKT 501 PPI TIM IN G
A © LATCHING GLOW
EN G IN E TRANSISTOR
CKT 502 GRA
TEM P C
PROBE E CKT 500 B © AND LEVEL
DETECTION
SWITCH
PLUG
RELAY
B D BJ_K/WHT CKT 506 LT BLU
Series Diesel Electrical System
500 CIRCUIT
LOGIC LOGIC.
GROUND
CKT 509
C K T 150 BLK
POWER — ■“DO N 'T ST A RT/G LOW-
© GROUND PLUGS LAMP
ELECTRONIC MODULE
CKT 503 B ORN _________ BUS BAR GRD
<►
juuub^jTnnni' >
D iagn osis
W IT H IG N IT IO N SW IN " R U N "
Listen for G low Plug Relay clicking with cold engine.
Relay should come on for approxim ately 6 seconds.
(Varies with engine temperature) Then turn off and
then pulse O N /O F F .
G LO W PLU G R E L A Y N O T C L IC K IN G O N /O F F R E L A Y C L IC K S O N /O F F
I
Connect 12 volt test light to
I
Connect 12 volt test light to ground.
ground. Touch Yel wire (C K T 5 0 5 ) Touch glow plug relay terminal with 2
at G lo w Plug Relay connector red wires. Test light should turn
light should pulse on and off as O N / O F F as relay clicks on/off.
above with engine cold.
T E S T L IG H T P U L S E S O N / O F F T E S T L IG H T D O E S N O T T E S T L IG H T N O T L IG H T P U L S E S O N / O F F
P U LSE O N /O F F T U R N IN G O N / O F F
I '----1
GLO W PLUG R E L A Y O P E R A T E S DOES NOT O PERATE
1 T Ir/,
Check 506 circuit from relay to module. Replace relay
ON
1 1
OFF
1
ON ST E A D Y
I
0 VOLTS 12 VOLTS OR MORE
I I
Repair open in pink wire (C K T 3) Check the voltage at cavity C
from module to Ign. Switch. (C K T 502 Gray) of the module
-------------------- ,
I
12 VOLTS OR MORE LESS THAN 6 VOLTS
I I
Turn ignition O F F , remove probe connector, Measure voltage at module
measure resistance between probe terminals C and D. connectors F and J
I 1
OPEN CIRCUIT LESS THAN 20 OHMS 2 TO 8 VOLTS (F)
I 2 TO 8 VOLTS (J)
Replace the probe Reconnect bulkhead connector, remove module. With
Ign. ON check voltage at module connector cavity C
I
Measure voltage at
......... * -NO C O NTINUITY module connector cavity M
r J___________
502 circ. (G R A ) open --------1
READS CO N TIN U ITY from probe to module LESS THAN 1 VOLT 0 VOLTS
I I
Reconnect probe. Disconnect 12 terminal bulkhead connector and measure 500 circuit is open Replace
resistance to ground of the 502 circuit (Gray) in the engine harness. in module jumper module
I or engine harness
LESS THAN 10 OHMS
I
12 VOLTS OR M ORE' ■Reconnect bulkhead connector,1 — 0 VOLTS
I remove module. With Ign. ON I
502 circuit is shorted Replace the module
check voltage at module
to batt circuit in connector cavity C
harness
I----------------- I ----------------------------- 1
12 VOLTS (F)/12 VOLTS (J) LESS THAN 1 VOLT, BOTH 12 VOLTS (F) 1 VO LT (J)
OR I I
Disconnect probe and measure resistance Measure voltage to ground at Glow Plug Relay coil
2 VOLTS (F)/2 VOLTS (J)
between probe terminals E to D with Ign. OFF terminal 2 way connector (Y e ll/L t Blu)
I ___ I__ ______________ I____________
Measure Glow Plug
Relay coil resistance
I I I 1 •
OPEN CIRCUIT LESS THAN 30 OHMS 1 VOLT/1 VOLT 12 VO LTS/2 VOLTS
_________ L _ I I I
I Replace probe I 505 circuit open 506 circuit
0 - OHMS 3 OHMS Check continuity open
Repair
I I from cavity D of probe Repair
Replace relay Remove module harness to ground
and module check terminal _________ I_________ 12 VOLTS/1 VO LT
in cavity J for
damage
r
NO C O NTINUITY
-------------1
C O NTINUITY
I
Replace relay
____ L I I
I 1 Repair open in 503 circuit Remove module, check for deformed
DAMAGED NORMAL from probe to module terminals in cavities C, G and H
I I
Repair connector Replace module
I------------------ 1--------------------
iFO R M ED NORMAL
I I
Repair the connector Replace the module
I
1 I
11
C O N T IN U IT Y
11
N O C O N T IN U IT Y
1I
Replace lamp Check lamp
ground continuity
N O C O N T IN U IT Y
11 11
C O N T IN U IT Y
NO CONTINUITY
Replace probe
CONTINUITY
I
Measure the resistance
between probe terminals
C and E.
r
12 VOLTS
I
LESS THAN 1 VOLT
I I
Turn ignition O F F , Check continuity of cavity D
remove the module. to ground of the probe harness
Turn ignition O N , connector. I
Check voltage at cavity
F of the connector
Brown wire from alternator Observe alternator lamp CONTINUITY
to module open, repair I
as necessary. 12 VOLTS Turn ignition O F F .
I Remove the module.
505 circuit is
Check continuity from
shorted to batt. plus
module connector
in the harness.
cavity C to ground.
LAMP OFF LAMP ON Repair as necessary
I
Bad alternator Disconnect the tw o
lamp or circuit 25 terminal connector from NO CONTINUITY
open from lamp the alternator and check J I
Replace the module
to alternator the voltage of the 25 circuit
in the connector.
_________ L—
r ---------- I
0 VOLTS 12 VOLTS CONTINUITY NO CONTINUITY
I I I I
25 circuit is shorted Repair alternator 502 circuit is short 503 circuit is open
to ground in the harness. to ground in the harness. between the probe and
Repair short. the glow plugs.
Repair as necessary.
at m odule cavity L.
r J_______
LESS THAN 20 OHMS
I Turn ignition O F F . Rem ove
CONTINUITY NO CO N TINU ITY
the module. Turn ignition O N .
I.
501 circuit is shorted to Check voltage at m odule
ground in the harness. cavity L
Repair as necessary 12 VOLTS 12 VOLTS
I
Turn Ignition off. 501 circuit is shorted
Measure the resustance to batt + in the harness
between these probe
terminals is it:
Check cont. from AtoE 4 to 10 O H M S
M od. term L to A to B 10 to 20 O H M S 0 VOLTS
probe term A Turn Ign. off.
NO
Reconnect the probe. Check
Replace probe resistance to ground from
m odule connector cavity L
OPEN CONTINUITY YES
I I I LESS THAN 20 OHM
Repair Replace Turn ignition O F F . Rem ove \
501 circuit the module. Check con tinu ity Replace the m odule
M odule OPEN CIRCUIT
to ground from m odule
connector cavity J 501 circuit is open
in the harness
CONTINUITY NO CONTINUITY
I
Repair short to Replace the module
ground in 506 circuit
harness
JUNCTION
BLOCK ASM
,W /S WIPER
MOTOR ASM
TEMP SENDER
Engine
I NOTE 1 For remainder of harness
routing see sheet 12H-17.
T A IL COMB
LP EXT ASM
BATTERY BRACE
CABLE
FW D LA M P
HARNESS ASM
SENDER OR
/!°J
SWITCH
GENERATOR
ASM &C60 GLOW
PLUG
VIEW B VIEW C
TRANSMISSION STARTER
ASM Engine
ENGINE W IRING
HARNESS ASM
SOLENOID
Engine
TEMP CONTROL
SWITCH-Engine
GLOW PLUG W IR IN G
HARNESS ASM
SOLENOID
GENERATOR
ASM exc C60
VIEW E
GENERAL DESCRIPTION
The ignition circuit consists of the battery, the distrib also features a longer spark duration, made possible by the
utor, the ignition switch, the spark plugs, and the primary higher amount of energy stored in the coil primary. This is
and secondary wiring. Refer to the Battery portion of this desirable for firing lean mixtures.
section for battery information.
When making compression checks, disconnect ignition
H.E.l. DISTRIBUTOR
switch connector (pink wire) from HEI system.
The High Energy Ignition distributor used on all
No periodic lubrication is required. Engine oil lubri-
engines combines all ignition components in one unit (Fig.
ca .es the lower bushing and an oil-filled reservoir provides
6D -17D and 6D-18D). The external electrical connections
lubrication for the upper bushing.
are the ignition switch feed wire, the tachometer pickup, and
the four, six or eight spark plug leads. The ignition switch
feed connector to the distributor has full battery voltage IGNITION TIMING
when the ignition switch is in the "R U N " and "START" Timing specifications for each engine are listed in
positions. There is NO RESISTOR W IRE FROM THE Section 6E and on the Vehicle Emissions Control Informa
IG N IT IO N SW ITCH TO TH E D IST R IB U T O R . The tion label on the radiator support. When using a timing
ignition coil is in the distributor cap and connects through a light, connect an adapter between the No. 1 spark plug and
resistance brush to the rotor. The High Energy Ignition
System is basically identical in operation to conventional
ignition except the module and pick-up coil replace the GROUND
BAT. TERMINAL
contact points. TERMINAL
(CONNECTED TO
The High Energy Ignition is a magnetic pulse trig IGNITION SWITCH)
gered, transistor controlled, inductive discharge ignition
system. The magnetic pick-up assembly located inside the
distributor contains a permanent magnet, a pole piece with
internal teeth, and a pick-up coil. When the teeth of the
timer core rotating inside the pole piece line up with the
teeth of the pole piece, an induced voltage in the pick-up coil
signals the electronic module to trigger the coil primary
circuit. The primary current decreases and a high voltage is
induced in the ignition coil secondary winding which is /
LATCH (4)
directed through the rotor and secondary leads to fire the CONNECTOR CONNECT TACHOMETER
spark plugs. The capacitor in the distributor is for radio FROM THIS TERMINAL
C-TERMINAL TO GROUND.
noise supression.
TACH TERMINAL
The magnetic pick-up assembly is mounted over the
main bearing on the distributor housing, and is made to (SOME TACHOMETERS
rotate by the vacuum control unit, thus providing vacuum MUST CONNECT FROM
THIS TERMINAL TO
advance. The timer core is made to rotate about the shaft by ENERGIZER POSITIVE ( + ).
conventional advance weights, thus providing centrifugal CONSULT TACHOMETER
MANUFACTURER.)
advance.
The module automatically controls the dwell period,
stretching it with increasing engine speed. The HEI system Fig. 6D-17D-HEI Distributor Assembly
o . *
IGNITION SWITCH
1 2 3 4 5
The m echanical switch is located in the steering
R T V T S X~
column on the right hand side just below the steering wheel.
1 - R--INDICATES RESISTOR-TYPE PLUG.
The electrical switching portion of the assembly is separate
2 - "4 " INDICATES 14 mm THREADS. from the key and lock cylinder. However, both are synchro
3 - HEAT RANGE nized and work in conjunction with each other through the
4 - TS-TAPERED SEAT. action of the actuator rod assembly.
S -E X T E N D E D T IP
5 - SPECIAL GAP For a complete explanation of the key and lock
6221 cylinder, and the actuator rod assembly, see S T E E R I N G ,
Section 3B. See Section 8 for the detailed explanation of the
Fig. 6D-20D--Spark Plug Coding electrical switching.
DIAGNOSIS
H.E.I. DISTRIBUTOR result of plug overheating, caused by combustion gases
Use Figure 6D-21D and 22D for H.E.I. Diagnosis. leaking past the threads, due to insufficient torquing of the
spark plug. Excessively lean carburetion will also result in
SPARK PLUGS excessive electrode wear.
Worn or dirty plugs may give satisfactory operation at
idling speed, but under operating conditions they frequently Broken insulators are usually the result of improper
fail. Faulty plugs are indicated in a number of ways: poor installation or carelessness when regapping the plug. Broken
fuel economy, power loss, loss of speed, hard starting and upper insulators usually result from a poor fitting wrench or
general poor engine performance. an outside blow. The cracked insulator may not make itself
Spark plug failure, in addition to normal wear, may be evident immediately, but will as soon as oil or moisture
due to carbon fouled plugs, excessive gap or broken penetrates the fracture. The fracture is usually just below
insulator. the crimped part of shell and may not be visible.
Fouled plugs may be indicated by checking for black
carbon deposits. The black deposits are usually the result of Broken lower insulators usually result from careless
slow-speed driving and short runs where sufficient engine ness when regapping and generally are visible. In fairly rare
operating temperature is seldom reached. Worn pistons, instances, this type of break may result from the plug
rings, faulty ignition, over-rich carburetion and spark plugs operating too " h o t" , encountered in sustained periods of
which are too cold will also result in carbon deposits. high-speed operation or under extremely heavy loads. When
Excessive gap wear, on plugs of low mileage, usually regapping a spark plug, to avoid lower insulator breakage,
indicates the engine is operating at high speeds or loads that always make the gap adjustment by bending the ground
are consistently greater than normal or that a plug which is (side) electrode. Spark plugs with broken insulators should
too hot is being used. In addition, electrode wear may be the always be replaced.
IN T E R M IT T E N T OPERATION OR MISS
REM O VE GREEN
AN D W H ITE LEADS
FRO M M O DULE
TEST LIG H T
0 DISCARD
CONNECT V O LT M E T E R ,
"T A C H " T E R M IN A L
7 /1 6 " (11mm)
TO G RO UND VIEW B
FROM TIP OF
SPARK PLUG
INSERT BOOT
OVER
PORCELAIN
END OF ST-125
6742
DETACH
LEADS
FROM
MODULE
OHMMETER OHMMETER
ON-VEHICLE SERVICE
H.E.I. DISTRIBUTOR Some service tachometers and electronic diagnostic
equipment currently in use may N O T be compatible
Service Precautions with the High Energy Ignition System. It is recom
mended that you consult your representative of such
1. W hen making compression checks, disconnect the
equipment as to the necessary updating of your equip
ignition switch feed wire at the distributor. W hen
ment for compatibility with the HEI System.
disconnecting this connector do not use a screwdriver or
tool to release the locking tab as it may break. 4. There is no dwell adjustment as this is controlled by the
module.
2. No periodic lubrication is required. Engine oil lubri
cates the lower bushing and an oil-filled reservoir 5. The centrifugal advance and vacuum advance are
provides lubrication for the upper bushing. similar to the conventional ignition.
6. The material used to construct the spark plug cables is
3. The tach om eter (T A C H ) term inal is next to the
very pliable and soft. This cable will withstand more
ignition switch (BAT) connector on the distributor cap.
heat and carry a higher voltage. Due to the more pliable
NOTICE: The tachometer terminal must N E V E R be cable, scuffing and cutting become easier. It is therefore
allowed to touch ground, as damage to the module and/ extremely important that the spark plug cables be
or ignition coil can result.. routed correctly to prevent chaffing or cutting. See
2. Remove distributor cap by turning four latches coun Vacuum Advance Unit (Refer to Fig. 6D-25D)
terclockwise. Move cap out of the way.
If necessary to remove secondary wires from cap, REMOVAL
release wiring harness latches and remove wiring 1. Remove distributor cap and rotor.
harness retainer. The spark plug wire numbers are 2. Remove module.
indicated on the retainer. 3. Remove two vacuum advance attaching screws.
3. Remove vacuum hose from vacuum advance unit. 4. Turn the pick-up coil clockwise and push the rod end of
the vacuum advance down so that it will disengage and
4. Remove distributor clamp screw and hold-down clamp. clear the pick-up coil plate.
5. Note position of rotor, then pull distributor up until
rotor just stops turning counterclockwise and again INSTALLATION
note position of rotor. To install, reverse removal procedure.
UNIT REPAIR
DISTRIBUTOR DISASSEMBLY
TEST AND REASSEMBLY
(COIL IN CAP)
TESTING IGNITION COIL
"COIL IN C A P ” D ISTRI BUTOR
OHMMETER OHMMETER
4. Connect ohmmeter, Test 1.
5. Reading should be zero, or nearly zero. If not, replace
coil, Step 8.
4 -TE RM IN AL 6. Connect ohmmeter both ways, Test 2. Use high scale.
CONNECTOR Replace coil only if both readings are infinite. Step 8.
7. If coil is good, go to Step 13.
CONNECTOR
(DISCONNECTED IGNITION COIL ATTACHING SCREWS
COIL A T T A C H I N G ^ ^ ^ _ asBa^ ^ IG NITIO N
FROM CAP)
SCREW (4) / COIL
GROUND
LEAD
C- GRD. B+
COIL
T ER MINA LS
SECONDARY
SEAL IG NITIO N
GROUND COIL
CONNECTOR
4-T E R M IN A L THREE
CONNECTOR ATTA CH IN G
SCREWS
M AGNETIC
IELD
MODULE
PICKUP COIL
ASSEMBLY
T E R M IN A L
MODULE
C Y L #1
_^CYL #2
Sfer CYL #7
j P ' ^ ' C Y L #5
F I L T E R ASM
r~POWER U N IT
V IE W -A F I L T E R ASM
POWER U N I T
V IE W
IGNITION SWITCH
GENERAL DESCRIPTION
The electrical switching portion of the assembly is terminal is connected to the ACC. terminal. This permits
separate from the key and lock cylinder. However, both are operation of accessories when the engine is not running.
synchronized and work in conjunction with each other
When the ignition switch is turned to the S T A R T
through the action of the actuator rod assembly. For a
position, the BAT. terminal is connected to the SOL. and
complete explanation of the key and lock cylinder, and the
IGN. terminals. When the clutch or automatic transmission
actuator rod assembly, refer to the Steering section of this
neutral start switches are closed, current flows to the starter
manual.
solenoid. This energizes the solenoid windings. The solenoid
The ignition switch is key operated through the actua has two sets of windings: a "pull-in" winding and a "hold-
tor rod assembly to close the ignition primary circuit and to in" winding. Both windings are used to create the magnetic
energize the starting motor solenoid for cranking. The field to actuate the the solenoid plunger and move the starter
ignition switch used on all cars have five positions: OFF, pinion into engagement with the flywheel. As the solenoid
LOCK, A C C E S S O R Y , R U N and ST A R T . O F F is the plunger reaches the end of its travel, it closes a switch which
center position of the key-lock cylinder, and LOCK is the connects battery voltage to the starter motor. With battery
next position to the left. A C C E S S O R Y is located one more voltage applied to both terminals of the "pull-in" windings,
detent to the left of LOCK. Turning the key to the right of the "pull-in" winding is no longer energized, so that only
the O F F position until spring pressure is felt will put the the "hold-in" winding keeps the starter solenoid engaged.
ignition switch in the R U N position, and when turned fully
to the right against spring pressure, the switch will be in the The instrument panel warning lights are fed from the
S T A R T position. ignition terminal of the ignition switch and have battery
All ignition switches have five terminals which are voltage applied to them when the ignition switch is in the
connected in different combinations for each of the three S T A R T and R U N position. These circuits are explained in
operating positions. A brass plate, inside the switch, has the Chassis Electrical Section.
three contacts which connect these terminals. Figure 6D-
31D shows the positions of the contacts in all positions as
viewed from the key side of the switch. There is also a When the ignition switch is released from the S T A R T
ground pin in the switch which contacts the "ground" to the RU N position, the IGN. terminal is still connected to
terminal when the ignition switch is in the S T A R T position. the BAT. terminal With the ignition switch in the RU N
This pin contacts the IG N. terminal when in the O F F position, the BAT. term inal is connected to the IG N .
position. terminal and the ACC. terminal. This permits operation of
all accessories and the ignition system.
Ignition S tart a n d Run Circuit
12 R
12P P L / W
I r\ 12 ORN
SOL ■
1 5
L
1 BAT 1 BAT 2
2
C
I »
IGN 1
---------
12 P
1 J
24 B R N / W
12 B R N
_GRD-1
20 D G
|0 » D -2 l.g ^ 3 |
IG N ITIO N SWITCH POSITIONS—
(VIEW FROM TERMINAL SIDE OF SWITCH)
OFF POSITION ACC
IGN-3 IGN-3
□ BAT-3 L .
so l D
BAT-1 J
fORD-2\
IGN-3
SOL Q
BAT-2
UIGNU
RUN POSITION
A .I.R . ELBOW
Fig. 6D -32D --Engine
Wiring
CK-LE9, LF3, LG9, LS9
H .E .I DISTRIBUTOR
Engine
ENGINE
E.S.C. CONNECTOR
ENGINE HARNESS
ELECTRICAL
6 D -4 7
6D-48 ENGINE ELECTRICAL
ENGINE
ELECTRICAL
© TH IS DIAG NO SIS SHOULD BE INSERTED W ITH OR IM M E D IA TE LY AFTER ITEM a. (FAULTY IGNITION SYSTEM )
OF THE “ ENGINE DETO NATIO N” SECTION ON PAGE 6A-7 OF THE 1980 LIGHT D U TY T R U C K SERVICE MANUAL
6 D -4 9
© SO M E O C C ASIO N AL TRACE-TO-LIGHT DETO NATIO N IS AC C EPTAB LE.
6D-50
ENGINE
CHEVROLET LIGHT TRUCK
ESC SYSTEM DIAGNOSIS
ELECTRICAL
Fig. 6D-35D --Engine
Wiring
G Series
LE3
© T H IS DIAG NO SIS SHO ULD BE INSERTED IM M EDIATELY AFTER ITEM b. (IGNITION TIM IN G ) OF THE “ ENGINE
HAS LO W PO W ER ” SECTION ON PAGE 6A-3 OF THE 1980 LIG HT DUTY TRUCK SERVICE M ANUAL.
CHEVROLET LIGHT TRUCK
ESC SYSTEM DIAGNOSIS
Fig. 6D-36D--Engine Wiring
CK Series - LE3, L25
ENGINE
ELECTRICAL
© T H IS DIAG NO SIS SHO ULD BE INSERTED WITH OR IM M E D IA TE LY AFTER ITEM g. (IGNITION P R O B LE M S ) OF
THE “ ENG INE FAILS TO START” SECTION ON PAGE 6A-2 OF THE 1980 LIG HT D U TY T R U C K SERVICE M ANU AL.
6D -51
6D-52 ENGINE ELECTRICAL
K GRND BROWN
J DELAY BLACK
H LO WHITE
G HI GREEN
ESC F BAT. PINK/BLK
CO NTROLLER E
D
C
B SENSOR
- A SHIELD
PINK
BROWN
BLACK
WHITE
GREEN
CRANKING SYSTEM
General Description.............................................................6D-53 Solen oid............................................................................ 6D-60
Cranking C i r c u i t...............................................................6D-53 O v e rh a u l............................................................................... 6D-61
Starter M o t o r ................................................................... .6D-53
Disassembly....................................................................... 6D-61
Diagnosis............................................................................... .6D-56
Component Inspection..................................................... 6D-62
On-Vehicle Service............................................................ .6D-60
Remove and Replace........................................................6D-60 Reassembly.......... ................................................... .......... 6D-64
S ta r te r ................................ .............................................. .6D-60 Specifications....................................................................... 6D-67
GENERAL DESCRIPTION
CRANKING CIRCUIT Enclosed shift lever cranking motors have the shift
lever mechanism and the solenoid plunger enclosed in the
The cranking circuit consists of the battery, staring drive housing protecting them from exposure to dirt, icing
motor, ignition switch, and related electrical wiring. These conditions and splash.
components are connected electrically as shown in Figure
In the basic circuit shown in Figure 6D-1E, the solenoid
6D-1E. Only the starting motor will be covered in this
windings are energized when the switch is closed. The
portion.
resulting plunger and shift lever movement causes the pinion
STARTING MOTOR to engage the engine flywheel ring gear and the solenoid
main contacts to close, and cranking takes place. When the
Two types of starter motors are used. The first, referred engine starts, pinion overrun protects the arm ature from
to as the 10MT series, is shown in Fig. 6D-2E. The second excessive speed until the switch is opened, at which time the
type, referred to as the 20MT series used on diesel equipped return spring causes the pinion to disengage. To prevent
engines, is shown in Fig. 6D-3E. The main difference is that excessive overrun, the switch should be opened immediately
the 2 0 M T has a center bearing. Fig. 6D -4E shows an when the engine starts.
exploded view of the 20M T series. Differences in service
procedures will be pointed out as they occur.
SHIFT
LEVER
BUSHING
PINION
STOP
INSULATED
BRUSH
HOLDER BRUSH TO RISER BARS OVERRUNNING
RISER BARS TO ARMATURE CLUTCH
SHIFT
LEVER
BUSHING
PINION
STOP
INSULATED
BRUSH CONDUCTORS
HOLDER BRUSH TO RISER BARS OVERRUNNING
RISER BARS TO ARMATURE CLUTCH
RETURN SO LENOID
D R IV E GEAR PLUNGER
SPRING
HOUSING
COM M UTATO R
END FRAME
T U P I I QT FIBER
F IE LD FRAME
WASHER RETA IN ER WASHER
SNAP
RING WASHER
CLUTCH AND CENTER
D R IV E ASM. BEARING AR M A TU R E
DIAGNOSIS
Before removing any unit in a cranking circuit for above, correction can be achieved by proper "shim
repair, the following checks should be mad?: ming" as follows:
a. Remove lower flywheel housing cover and examine
Battery:
for visual proelbmes - bent flywheel, unusual wear,
To determine the condition of the battery, follow the etc.
testing procedure outlined in the Battery Section.
b. Start engine and carefully touch outside diameter of
W iring: rotating flywheel ring gear with chalk or crayon to
show high point of tooth runout after engine is turned
Inspect the wiring for damage. Inspect all connections
off. Turn engine off and rotate flywheel so that the
to the cranking motor, solenoid, ignition switch, and battery,
marked teeth are in the area of the starter pinion
including all ground connections. Clean and tighten all
gear.
connections as required.
c. Disconnect negative battery cable to prevent inad
Solenoid a n d Ignition Switch: vertent cranking of engine.
Inspect all switches to determine their condition. Insert screwdriver in small hole in bottom of starter
Starter M otor Noise: shown by arrow in Fig. 6D-6E and move starter
pinion and clutch assembly so that pinion teeth and
To correct starter motor noise during starting, use the
flywheel teeth are meshed. If necessary, rotate the
following procedure:
flywheel so that a pinion tooth is directly in the center
1. Refer to Fig. 6D-5E to determine the problem. of two flywheel teeth and on the centerline of the two
2. If the complaint is smiliar to problem categories 1 or 2 gears, as shown in Fig. 6D-7E.
ENGINE ELECTRICAL 6D-57
PROBLEM CAUSE
1. HIGH PITCHED WHINE DURING CRANKING (BEFORE DISTANCE TOO GREAT BETWEEN STARTER PINION AND
ENGINE FIRES) BUT ENGINE CRANKS AND FIRES FLYWHEEL.
OKAY.
2. HIGH PITCHED "W HINE" AFTER ENGINE FIRES, AS DISTANCE TOO SMALL BETWEEN STARTER PINION AND
KEY IS BEING RELEASED. ENGINE CRANKS AND FLYWHEEL. FLYWHEEL RUNOUT CONTRIBUTES TO THE
FIRES OKAY. THIS INTERMITTENT COMPLAINT IS INTERMITTENT NATURE.
OFTEN DIAGNOSED AS "STARTER HANG-IN" OR
"SOLENOID WEAK."
3. A LOUD "WHOOP" AFTER THE ENGINE FIRES BUT MOST PROBABLE CAUSE IS A DEFECTIVE CLUTCH. A NEW
WHILE THE STARTER IS STILL HELD ENGAGED. CLUTCH WILL OFTEN CORRECT THIS PROBLEM.
SOUNDS LIKE A SIREN IF THE ENGINE IS REVVED
WHILE STARTER IS ENGAGED.
4. A "RUM BLE", "GROW L" OR (IN SEVERE CASES) A MOST PROBABLE CAUSE IS A BENT OR UNBALANCED
"KNO C K" AS THE STARTER IS COASTING DOWN TO STARTER ARMATURE. A NEW ARMATURE WILL OFTEN
A STOP AFTER STARTING THE ENGINE. CORRECT THIS PROBLEM. r/lon
5488
V8 ENGINE
SHIELD
BRACE
LF9 ENGINE
STARTER MOTOR
SOLENOID
S" TERMINAL
GROUND
1 2-VOLT
BATTERY
ON-VEHICLE SERVICE
Starting motors do not require lubrication except 1. Disconnect negative battery lead at battery.
during overhaul. 2. Raise vehicle.
W hen the motor is disassembled for any reason, 3. Remove starter braces, shields, etc., that may be in the
lubricate as follows: way.
1. The arm ature shaft and drive end and commutator end 4. Remove two starter motor to engine bolts, and allow
bushings should be coated with no. 1960954 lubricant starter to drop down.
or equivalent.
5. Remove solenoid wires and battery cable and remove
2. The roll type overrunning clutch requires no lubrica starter.
tion. However, the drive assembly should be wiped
clean. Do not clean in any degreasing tank or with 6. To replace, reverse the above procedure. Insure that
grease dissolving solvents; this will dissolve the lubri any shims removed are replaced.
cant in the clutch mechanism. Use silicon grease
Solenoid
General Electric CG321, Dow Corning 33 Medium or
equivalent, on the shaft underneath the overrunning Use the following procedure to remove the solenoid
clutch assembly. from the starter:
1. Disconnect field strap.
REMOVE AND REPLACE
2. Remove solenoid to drive housing attaching screws,
Starter (Fig. 6D-8E) motor terminal bolt, and remove solenoid by twisting.
Use the following procedure to remove the starter: 3. Replace by reversing above procedures.
UNIT REPAIR
5MT, 10MT, 25MT AND 27MT STARTER MOTORS
DISASSEMBLY, TEST AND REASSEMBLY
(STARTER REMOVED FROM ENGINE)
NO- LOA D TEST
With the starter motor removed from the engine, the pinion
should be checked for freedom of operation by turning it on the 3. Failure to operate with high current draw indicates:
screw shaft. The armature should be checked for freedom of • A direct ground in the terminal or fields.
rotation by prying the pinion with a screwdriver. If the armature • “ Frozen” bearings (this should have been determined by
does not turn freely, the motor should be disassembled im turning the armature by hand).
mediately. However, if the armature does rotate freely, the 4. Failure to operate with no current draw indicates:
motor should be given a no-load test before disassembly. • Open field circuit. This can be checked after disassembly
Make connections as shown. Close the switch and compare by inspecting internal connections and tracing circuit with a
the RPM, current, and voltage readings with the specifications test lamp.
. If the specified current draw does not include • Open armature coils. Inspect the commutator for badly
the solenoid, deduct from the ammeter reading the specified burned bars after disassembly.
current draw of the solenoid hold-in winding. Make disconnec • Broken brush springs, worn brushes, high insulation be
tions only with the switch open. Use the test results as follows: tween the commutator bars or other causes which would pre
1. Rated current draw and no-load speed indicates normal vent good contact between the brushes and commutator.
condition of the starter motor. 5. Low no-load speed and low current draw indicates:
2. Low free speed and high current draw indicates: • High internal resistance due to poor connections, defec
• Too much friction — tight, dirty, or worn bearings, bent tive leads, dirty commutator and causes listed under Number
armature shaft allowing armature to drag. 4.
• Shorted armature. This can be further checked on a 6. High free speed and high current draw usually indicate
growler after disassembly. shorted fields. If shorted fields are suspected, replace the field
• Grounded armature or fields. Check further after disas coil assembly. Also check for shorted arm ature, using a
sembly. growler.
S TA R T E R DI SASSEMBLY
THRUST FIBER
WASHER RETAINER WASHER FIELD FRAME
7. Remove screw from field coil connector and solenoid 8. Remove 2 through b o lt, then remove commutator end
mounting screws. Rotate solenoid 90? and remove along with frame (diesel only, remove insulator) and washer.
plunger return spring. Solenoid may now be serviced without 9. Remove field frame assembly from drive gear housing
further starter disassembly at this time. (On diesel starter, armature remains in drive end frame.)
RETURN
SPRING r snap
SHIFT
CENTER/ CLUTCH AND D R IV E RING
LEVER
BEARING ASSEMBLY
REPLACE BR US H HOLDER
( S T A N D A R D S T AR TE R ) (SMALL 5MT S T A R TE R )
PIVOT P I N - ^ O
BRUSH INTEGRAL
BRUSH HOLDER FIELD FRAME
(INSULATED) ASSEMBLY
BRUSH V
SUPPORT
BRUSH H O L D E R V V
(G R O U N D E D )W \ ROUTE WIRE
J BRUSH HOLDER BRUSH HOLDER
AS SHOWN
SPRING SUPPORT
CLEANING INSPECTION
AND TESTS
15. Clean all starting m otor p arts, but DO NOT USE
TESTING S H U N T COIL FOR OPEN GREASE DISSOLVING SOLVENTS FOR CLEANING THE
OVERRUNNING CLUTCH, ARMATURE, AND FIELD
COILS, solvent would dissolve the grease packed in the clutch
and would damage armature and field coil insulation.
16. Inspect armature commutator, shaft and bushings, over
TO TEST running clutch pinion, brushes and springs for discoloration,
LIG HT
damage or wear. Replace as required.
17. Check fit of armature shaft in bushing in drive housing.
Shaft should fit snugly in the bushing. If the bushing is worn, it
should be replaced.
18. Inspect armature commutator. If commutator is rough, it
should be turned down. Do not undercut or turn to less than
1.65(T O.D. Do not turn out-of-round commutators. Inspect the
points where the armature conductors join the commutator bars
to make sure they have a good connection. A burned com
mutator bar is usually evidence of a poor connection.
19. If test equipment is available:
a. Check the armature for short circuits by placing on
growler and holding hack saw blade over armature core
while armature is rotated. If saw blade vibrates, armature is
GROUNDED shorted. Recheck after cleaning between the commutator
BRUSH bars. If saw blade still vibrates, replace the armature.
b. Using a test lamp, place one lead on the shunt coil ter
minal and connect the other lead to a ground brush. This test
should be made from both ground brushes to insure con
tinuity through both brushes and leads. If the lamp fails to
light, the field coil is open and will require replacement.
Fig. 6 D -1 1 E -S ta rte r Unit Repair 3 of 6
SERIES COIL
CONNECTION
IN SULATED
BRUSH
c. Using a test lamp, place one lead on the series coil ter
minal and the other lead on the insulated brush. If the lamp
fails to light, the series coil is open and will require repair or
replacement. This test should be made from each insulated
brush to check brush and lead continuity.
TESTING SE RI ES COIL FOR G R O U N D
THESE TWO T ER M IN A L S
MUST BE SEPARATED
AND NOT TOUCHIN G A
GROUND D URIN G TEST e. Check the current draw of the solenoid winding as fol
lows:
If solenoid is not removed from starting motor, the connec
tor strap terminals must be removed from the terminal on the
solenoid before making these tests. Complete 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 and the “ switch” terminal on the solenoid.
Connect a voltmeter to the “ switch” terminal and to ground.
Connect carbon pile across battery. Adjust the voltage to 10
volts and note the ammeter reading. It should be 14.5 to 16.5
amperes for all starting motors.
To check both windings, connect as for previous test
Ground the solenoid motor terminal. Adjust the voltage to 10
volts and note the ammeter reading. It should be 41 to 47 am
INSULATED peres for all starting motors.
BRUSH GROUNDED NOTE: Current will decrease as windings heat up.
BRUSH HOLDER Current draw readings that are over specifications indicate
shorted turns or a ground in the windings of the solenoid and the
solenoid should be replaced. Current draw readings that are
under specifications indicate excessive resistance. No reading
indicates an open circuit. Check connections then replace sole
noid if necessary.
d. On starters with shunt coil, separtate series and shunt
coil strap terminals during this test. Do not let strap terminals
touch case or other ground. Using a test lamp place one lead
on the grounded brush holder and the other lead on either
insulated brush. If the lamp lights, a grounded series coil is
indicated and must be repaired or replaced.
Fig. 6D -12E --Starter Unit Repair 4 of 6
STARTER ASSEMBLY
CHECKING PINION C LE A R AN CE
PRESS ON C L U T C H TO
R E M O V E S LA C K
P IN IO N
\v ,
R E T A IN E R
010 to .1 4 0 '
P IN IO N
CLEARAN CE
FEELER^
G AG E J
When the starter motor has been disassembled or the sole
noid has been replaced, it is necessary to check the pinion
clearance. Pinion clearance must be correct to prevent the but
tons on the shift lever yoke from rubbing on the clutch collar
during cranking.
31. Disconnect the motor field coil connector from the sole
noid motor terminal and insulate it carefully.
32. 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 shift the pinion into
cranking position and it will remain so until the battery is dis
connected.
34. Push the pinion back as far as possible to take up any
movement, and check the clearance with a feeler gage. The
clearance should be .010" to .140".
Means for adjusting pinion clearance is not provided on the
starter motor. If the clearance does not fall within limits, check
for improper installation and replace all worn parts.
SPECIFICATIONS
GENERATOR
FIELD CURRENT COLD OUTPUT*
DELCO REMY RATED HOT
MODEL N O . APPLICATION AMPS 27°C (80°F) AMPS @
SPEC. N O . O U T P U T ** AMPS
@ 12 VOLTS 5000 RMP
SPECIFICATIONS
DISTRIBUTOR & SPARK PLUGS
Distributor and spark plug specifications are shown in the Emission Control Chart in Section 6E Specifications.
BATTERY
COLD CRANK RATE AMPS FOR 25 AMP. RESERVE
MODEL N O . APPLICATION
@ 0°F (-18°C) LOAD TEST CAPACITY (MINUTES)
STARTING MOTOR
FREE SPEED
MODEL N O . APPLICATION SPEC. N O .
VOLTS AMPERES RPM
^Includes Solenoid
SECTION 6E
ENGINE EMISSION CONTROLS
CONTENTS
GENERAL DESCRIPTION evaporation and more uniform fuel distribution to aid cold
driveability. It also reduces the length of time carburetor
POSITIVE CRANKCASE VENTILATION (PCV) choking is required making reductions in exhaust emission
levels possible.
SYSTEM
EFE systems may use a valve which increases the
All engines have closed Positive Crankcase Ventilation exhaust gas flow under the intake manifold during cold
System to provide more complete scavenging of crankcase engine operation. The valve is vacuum operated and is
vapors (Fig. 6E-1). controlled by a thermal vacuum switch (TVS) which applies
Ventilation air is drawn from the dirty air side of the air vacuum when the coolant temperature is below the calibra
cleaner, through a hose, down into the crankcase, up tion value.
through the ventilator valve, through a hose and into the Diagnosis and service procedures of the EFE system
intake manifold. Intake manifold vacuum draws any fumes can be found in this section.
from the crankcase to be burned in the engine.
Diagnosis and service procedures for the PCV system
can be found in this section.
AIR MANAGEMENT SYSTEM Valve" provides quick balancing of chamber pressure when
a sudden decrease in vacuum is caused by accleration rather
Two different types of air management systems are
than deceleration.
used on light duty trucks.
An air injection reactor (A IR ) (Fig. 6E-3) is used on THERMOSTATIC AIR CLEANER (THERMAC)
some engines to provide additional oxygen to continue the
The Thermostatic Air Cleaner (T H E R M A C ) is on all
combustion process after the exhaust gases leave the
engines. The TAC uses a damper door in the air cleaner
combustion cham ber. A belt driven air pump provides
inlet, controlled by a vacuum diaphragm motor to mix pre
pressurized air which is injected into the exhaust port of the heated and non pre-heated air entering the air cleaner to
cylinder head or exhaust pipe and then into the exhaust maintain a controlled air temperature into the carburetor.
system. The A IR system operates at all times and will The vacuum motor is modulated by a temperature sensor in
bypass air only for a short duration of time during decelera the air cleaner. The pre-heating of the air cleaner inlet air
tion and at high speeds. A diverter valve performs a bypass allows leaner carburetor and choke calibrations resulting in
function, and the check valve protects the air pump from lower emission levels, while maintaining good driveability.
damage by preventing a back flow of exhaust gas. The pre-heated air is obtained by drawing inlet air through
Diagnosis and service procedures for air injection stove attached to the exhaust manifold. Diagnostics and
reactor systems are is in this section. service procedures for the thermostatic air cleaner can be
The Pulse Air Injection Reactor System consists of four found in this section.
pulse air check valves. The check valves are connected by
tubes to the exhaust ports. The firing of the engine creates a
pulsating flow of exhaust gases which are positive or
negative pressure. A negative pressure at the pulse air valves
results in the flow of fresh air into the exhaust system. If
pressure is positive the check valve is forced closed and no
exhaust gas will flow past the valve into the fresh air supply
line.
A deceleration valve is used on some L6 and California
V8 models to prevent backfiring in the exhaust system
during decleration. W hen deceleration causes a sudden
vacuum increase in the vacuum signal line, the pressure
differential on the diaphragm will overcome the closing
force of the spring, opening the valve and bleeding air into
the intake manifold.
Air trapped in the chamber above the vacuum dia
phragm will bleed at a calibrated rate through the delay
valve portion of the integral "Check and Delay Valve,
reducing the vacuum acting on the diaphragm. When the
vacuum load on the diaphragm and the spring load become
equal, the valve assembly will close, shutting off the air flow
into the intake manifold.
The check valve portion of the "Check and Delay
LIGHT TRUCK SERVICE MANUAL
ENGINE EMISSION CONTROLS 6E-3
N O R M A L F LO W SHOW N B Y B L A C K A R R O W S :
BY-PASS C O N D IT IO N S SHOW N BY CROSS H A T C H E D A R R O W S
TUBE ASSEM BLY
HOSE
CHECK V A L V E
A IR IN
IN JE C T IO N
TUBE
H IG H SPEED
BY-PASS
A IR PUMP
E X H A U S T PO RT
D E C E L E R A T IO N
D IV E R T E R
BY-PASS
VALVE
M A N IF O L D V A C U U M
SO URCE
DIAGNOSIS
EGR DIAGNOSIS
CONDITION POSSIBLE CAUSE CORRECTION
Engine idles abnormally rough EGR valve vacuum hoses Check EGR valve vacuum hose
and/or stalls. misrouted. routing. Correct as required.
Leaking EGR valve. Check EGR valve for correct
operation.
EGR valve gasket failed or loose Check EGR attaching bolts for
EGR attaching bolts. tightness. Tighten as required.
If not loose, remove EGR valve
and inspect gasket. Replace as
required.
EGR-TVS. Perform EGR-TVS functional check.
Improper vacuum to EGR valve Check vacuum from carburetor
at idle. EGR port with engine at stabilized
operating temperature and at
curb idle speed. (See checking EGR
valve.)
Engine runs rough on light EGR valve vacuum hose Check EGR valve vacuum hose
throttle acceleration and has misrouted. routing. Correct as required.
poor part load performance.
Check for loose valve. Torque valve.
Failed EGR-TVS Same as listing in "Engine Idles
(TVS open below 130°F.) Abnormally Rough and/or
Stalls” condition.
Clean EGR passage deposits.
Sticky or binding EGR valve. Perform EGR System check.
Wrong or no EGR gasket(s) Install new gasket(s), install spacer
and/or Spacer. (if used), torque attaching parts.
Engine stalls on decelerations. Transducer control valve blocked Check transducer control valve
or air flow restricted. operation (See Checking Back
Pressure EGR Valve).
Restriction in EGR vacuum line or Check EGR vacuum lines for kinks,
vacuum signal tube. bends, etc. Remove or replace
hoses as required. (See Checking
EGR Valve).
Check EGR valve for excessive
deposits causing sticky or binding
operation.
Sticking or binding EGR valve. Perform EGR System Check.
Part throttle engine detonation. Transducer control valve blocked Check internal control valve
or air flow restricted. operation (See Checking EGR
Valve).
(NOTICE: Non-Functioning EGR Insufficient exhaust gas Check EGR valve hose routing.
valve could contribute to part recirculation flow during part Check EGR valve operation. Repair
throttle detonation. Detonation throttle accelerations. or replace as required. Check EGR-
can also be caused by several TVS as listed in "Engine Idles
other engine variables. Perform Abnormally Rough and/or
ignition and carburetor related Stalls" section. Replace valve as
diagnosis.) required. Check EGR passages and
valve for excessive deposit.
Clean as required.
Control valve blocked or flow Check EGR per service procedure.
restricted.
Engine starts but immediately EGR valve hoses misrouted. Check EGR valve hose routings.
stalls when cold.
(NOTICE: Stalls after start can EGR-TVS system malfunctioning Perform EGR-TVS functional check.
also be caused by carburetor when engine is cold.
problems.)
Fig. 6E-6--EGR Diagnosis
EXCESSIVE
EMISSIONS EXPLANATION POSSIBLE CAUSES
Hydrocarbons Excessive hydrocarbons • Engine not at normal operating temperature.
(HC) * are caused by an air • Disconnected, obstructed, leaking, or mis-
fuel m ixture that is routed vacuum hoses.
not burning completely. • Vacuum leaks.
• Maladjusted idle speed.
• Maladjusted idle m ixture - if plugs are
removed.
• Maladjusted initial spark tim ing.
• Spark plugs, wires or d istrib u to r cap.
• Improper operation of A l R or Pulsair
system.
• Lead contamination o f catalytic converter
(check fo r absence o f fille r neck
restrictor).
Carbon m onox Excessive carbon m onox • Engine not at normal operating temperature.
ide (CO) * ide emissions are due • Maladjusted idle m ixture if plugs are
to a m ixture that is removed.
rich. • Im properly adjusted/sticking choke.
• Stuck PCV valve or obstructed PCV hose.
• Lead contam ination o f catalytic converter
(check fo r absence o f fille r neck
restrictor).
• Improper operation o f A l R or Pulsair
system.
• Leaking carburetor fuel passages or
gaskets.
• Carburetor flo a t level.
• Stuck carburetor power piston.
• Restricted air cleaner element.
* Excessive emissions o f both hydrocarbons and carbon monoxide are related to an extrem ely rich air/fuel
m ixture. A rich air/fuel m ixture increases CO emissions, but if the m ixture is too rich, it w ill not burn
completely. This unburned fuel contributes to high hydrocarbon emissions. Check fo r possible causes
as stated in the HC and CO section. Check co-related causes first.
P.A.I.R. FAILURE DIAGNOSIS plenum, indicated by burned off paint. Also, rubber
grommets and hose will deteriorate. Failure could
1. A hissing noise may indicate a defective pulse air valve
or improper torque at manifold. Inspect pulse air valve. also be indicated by a hissing noise. Repair rocker
cover plenum seals and replace grommets and hose
2. If one or more check valves have failed, exhaust gas will
as required.
enter the carburetor through the air cleaner and cause
poor driveability indicated by a surge or poor perform b. If rubber hose to air cleaner deteriorates, particles
ance. Check pulse air valves. Be sure pulse air pipe may enter carburetor causing poor driveability. It
extension tubes are installed in exhaust manifold. will be necessary to clean carburetor, and remove
a. If exhaust gases pass through the pulse air valve, particles from pulse air plenums and connecting
excessive heat is transmitted to the rocker cover pipe.
ON-VEHICLE SERVICE
POSITIVE CRANKCASE VENTILATION plugged hoses or valve. Replace plugged and/or deteri
orated hoses.
An engine which is operated without any crankcase
ventilation can be dam ag ed seriously. Therefore, it is 4. Shut off the engine and remove PCV valve. Shake valve
important to replace the PCV valve at intervals shown in and listen for the rattle of check needle inside the valve
Section OB. (Fig. 6E-11). If valve does not rattle, replace valve
(Fig. 6E-10).
NOTICE: If an engine is idling too slow or rough, this
5. After installing a new PCV valve, readjust engine idle
may be caused by a clogged ventilator valve or plugged
if necessary.
hose; therefore, never adjust the carburetor idle with
out first checking the PCV valve and hose.
EXHAUST GAS RECIRCULATION (EGR)
With this system, any blow-by in excess of the system
capacity (from a badly-worn engine, sustained heavy load, A backpressure EG R valve is used on Light Duty
etc.) is exhausted into the air cleaner and is drawn into the Emission class engines. The valve opening is determined by
the amount of vacuum received from a ported source on the
engine.
carburetor and the amount of backpressure in the exhaust
Proper operation of the PCV System is dependent upon
system.
a sealed engine. If oil sludging or dilution is noted, and the
PCV System is functioning properly, check engine for Two different types of backpressure EGR valves are
possible cause and correct to ensure th a t system will used. A positive tra nsdu c e r valve (Fig. 6E-12) and a
negative tran sdu ce r valve (Fig. 6E-13). The negative
function as intended.
transduced backpressure valve is used on engines with a
relatively low backpressure to provide the desired opening
Removal point and flow rate.
1. Remove PCV valve from intake manifold or rocker arm The EGR system requires the use of unleaded fuel.
shaft cover.
2. Run the engine at idle. EGR Valve Identification
3. Place your th u m b over end of valve to check for Refer to figures 6E-14 and 6E-15 for identification of
vacuum. If there is no vacuum at valve, check for the different EG R valves.
CO N TR O L V A LVE
OPEN
ORIFICE O P E N IN G .0 3 0
(SEE O P T IO N A L C O N S T R U C T IO N )
TRANSDUCER
V A C U U M S IG N A L TUBE
D IA P H R A G M PLATE
O P T IO N A L C O N S T R U C T IO N
ORIFICE O P E N IN G
EXHAUST .020
G A S (IN )
I I EXHAUST GAS
NOTE: ID E N T IF Y P O S IT IV E EGR V A L V E
B Y D IA P H R A G M P L A T E D ESIG N
D IA P H R A G M P L A T E A S S E M B L Y
N E G A TI V E BACK P R ES SU R E EGR V A L V E
NOTE: ID E N T IF Y N E G A T IV E EGR V A L V E
B Y D IA P H R A G M P L A T E D E S IG N
D IA P H R A G M P L A T E A S S E M B L Y
clogging the EGR valve or from being ingested into the NOTICE: Leakage of up to 2 in. hg. ( - 7 kPa) of vacuum
engine. in 2 minutes is allowable and does not mean a defective
switch.
EGR Thermal Vacuum Switch (EGR - TVS) 7 . If operation is satisfactory, reinstall switch. If switch is
defective, replace with a new part.
R eplacem ent 8. Replace coolant and check level.
1. Drain engine coolant.
2. Disconnect vacuum lines from the thermal vacuum
switch.
EARLY FUEL EVAPORATION (EFE)
3. Remove switch. Inspection (except 4.8L - 292 CID)
4. Apply an approved sealer to threaded portion of switch. • Visually inspect exhaust heat valve for d am age or
5. Install switch and torque to 20 N-m (15 lbs. ft.). binding linkage.
6. Rotate switch head as required to align for proper hose • Check that linkage is connected and vacuum hoses are
routing. properly routed and connected.
7. Install vacuum hoses to switch. • Move exhaust heat valve by hand. If binding or stuck,
8. Replace engine coolant and check level. free with manifold heat valve lubricant, G M Part No.
1050422 or equivalent. If valve cannot be freed, replace
valve.
EGR-TVS Functional Check - Hot
The EG R Thermal Vacuum Delay Switch opens as Manifold Heat Valve Inspection (with 4.8L - 292
coolant temperature increases, permitting the ported vac CID)
uum signal to reach the EG R valve. Check as follows:
• Visually inspect manifold heat valve for damage or
1. Remove EGR valve vacuum hose at EGR valve and binding.
connect hose to a vacuum gage.
• Move valve by hand. If binding or stuck, free with
2. S ta rt engine. W ith transmission seelector lever in manifold heat valve lubricant, G M Part No. 1050422
N e u tra l or Park open throttle partially. (Do not or equivalent. If valve cannot be freed, replace valve.
overspeed engine.) as throttle is opened, the vacuum
gage should respond with an increase in vacuum Checking EFE System
reading. 1. With engine cold, position transmission in neutral or
3. If operation is satisfactory, remove gage and reconnect park and apply parking brake.
hose to EG R valve. 2. Start engine and observe movement of actuator rod and
If gage does not respond to throttle opening, proceed to exhaust heat valve. Valve should move to its closed
Step 4. position.
4. Remove Carb-to-switch hose from switch and connect 3 . If valve does not close, disconnect hose at actuator and
hose to vacuum gage. Repeat Step 2. check for vacuum.
5. If vacuum gage responds to throttle opening, then • If there is vacuum, replace actuator.
switch is defective. Remove switch and replace with
• If there is no vacuum, disconnect hose at TVS-to-
new part.
vacuum source.
If gage does not respond to throttle opening, then check
for plugged hose or defective carburetor. • If there is vacuum at hose, replace TVS.
• If there is no vacuum, check for deteriorated hose
and vacuum source to determine lack of vacuum.
EGR-TVS Functional Check - Cold
4. W hen coolant reaches 180°F (82°C) (V8), or oil
This check can be used to diagnosis a stall after cold reaches 150°F (66°C) (six cylinder), the exhaust heat
start or poor driveability immediately after cold start. valve should move to its open position.
The EGR thermal vacuum delay switch should be 5. If valve does not move, disconnect hose at actuator and
closed below a coolant temperature of 85°F (29°C) thereby check for vacuum.
blocking the ported vacuum signal from reaching the EGR
• If there is vacuum, replace TVS.
valve below that temperature. Check as follows:
• If there is no vacuum, replace actuator.
1. Drain coolant to below level of switch.
2. Disconnect vacuum lines and remove switch. Coolant Temperature Thermal Vacuum Switch
3. Inspect switch to make sure it is in good condition. (TVS) - V8
4. Connect a vacuum hose to lower nipple of switch,
R eplacem ent
marked " C " or " C A R B " . Connect a vacuum gage to
upper nipple, marked " E " or " E G R " . 1. Drain coolant below level of engine coolant outlet
5. Place switch in water at 75°F (24°C) and submerge housing.
completely for 2 m inutes while agitating water 2. Disconnect hoses at TVS ports.
thoroughly. 3 . Remove TVS.
6. Apply 12 in. hg. (-41 kPa) vacuum to hose on lower 4. Apply a soft setting sealant uniformly on replacement
nipple of switch. Under this condition, the switch TVS male threads. No sealant should be applied to
should be closed. sensor end of TVS.
LIGHT TRUCK SERVICE MANUAL
6E-14 ENGINE EMISSION CONTROLS
5. Install TVS, tighten to 120 pound inches (14N-m) and 2. Remove TVS switch.
then hand torque clockwise as required to align TVS to 3. Install TVS switch.
accomodate hoses. 4. Connect hoses to TVS ports.
6. Connect hoses to TVS ports.
7. Add coolant as required.
Actuator Assembly (Fig. 6E-18, 19, 20)
Oil Temperature Thermal Vacuum Switch (TVS) -
L6 The actuator assembly is located on a bracket attached
to right exhaust manifold or mounted directly to the right or
Replacem ent left exhaust manifold. Actuators which are remotely located
1. Disconnect hoses at TVS ports. on bracket are connected to the heat valve by a rod.
Replacem ent
1. Disconnect vacuum hose from actuator.
2. Remove fasteners holding a c tu a to r to mainifold or
bracket.
3. If used, disconnect rod from actuator and remove.
4. Remove actuator. Exhaust Heat Valve - 4.1L
5. Install actuator and rod (if used) reversing steps 1
R eplacem ent
through 4. Tighten nuts to 3 N-m (25 in. lbs.).
1. Remove 2 nuts attaching actuator bracket-to-valve and
exhaust manifold.
Exhaust Heat Valve - V8
2. Remove bracket and disconnect rod from valve.
R eplacem ent 3. Remove 2 additional nuts from valve and remove valve.
1. Remove crossover exhaust pipe. 4. Install valve reversing Steps 1 through 3.
2. Disconnect rod from valve.
3. Remove valve. Manifold Heat Valve - 4.8 L
4. Install valve and connect rod. R eplacem ent
5. Install crossover exhaust pipe. 1. Remove exhaust pipe to manifold nuts and lower
exhaust pipe.
2. Remove heat valve and packings.
3. Reverse above steps to install.
Inspection
Accelerate engine to approximately 1500 R P M and
observe air flow from hose(s). If air flow increases as engine
is accelerated, pump is operating satisfactorily. If air flow
does not increase or is not present, proceed as follows:
1. Check for proper drive belt tension.
The A IR system is not completely noiseless. Under
normal conditions, noise rises in pitch as engine speed
increases. To determine if excessive noise is the fault 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.
LIGHT TRUCK SERVICE MANUAL
6E-16 ENGINE EMISSION CONTROLS
Air Hoses and Injection Pipes pressure side, the connection should be checked fo leaks
with a soapy water solution.
Inspection a n d R eplacem ent (Fig. 6E -25 an d 26) 6. If hose a n d /o r pipe replacem ent is required, note
1. I nspect all hoses for deterioration or holes. routing, then remove hose a nd/or those as required.
2. Inspect all air injection pipes for cracks or holes. 7. Install new hose and /o r pipe, routing them as when
removed. -
3. Check all hose and pipe connections.
8. Tighten hose and pipe connections. Use an anti-seize
4. Check pipe and hose routing. Interference may cause
compound on threads of the air pipe fitting when re
wear.
assembling.
5. If a leak is suspected on the pressure side of the system
or any pipe and/or hose has been disconnected on the
s i, .
PIPE ASSY
CHECK VALV
EXTENSION
PIPE ASSY
EXTENSION
NOTICE: Vacuum drop must be a result of a leaking THERMOSTATIC AIR CLEANER (THERMAC)
valve not a leaking hose or connection.
Checking Thermae Air Cleaner
1. Inspect system to be sure all hoses and charts are
Replacement of Pulse Air Valve (Fig. 6E-30) connected (Fig. 6E-34 and 35). Check for kinked,
1. Remove air cleaner and disconnect rubber hose from plugged or deteriorated hoses.
plenum connecting pipe. 2. If engine is warm above 27°C (80°F), remove air
2. Disconnect four pipe check valve fittings at cylinder cleaner. Allow it to cool to room temperature, below
head and remove check valve pipes from plenum 27°C (80°F). Placing a cool wet rag on the temperature
grommets. sensor will aid in cooling.
3. Install cooled air cleaner with cold air intake discon
3. Disconnect check valve from check valve pipe.
nected from snorkel (if equipped).
4. Bench assemble check valves to check valve pipe. 4. Observe damper door before starting the engine. It
5. Install pipe check valve assemblies to cylinder head as should be in the open snorkel position (hot air duct
shown in fig. 6E-34 and finger tighten the fittings. covered).
5. S ta r t engine. W atch d am p e r door in air cleaner
6. Using a 1 " open end wrench or similar tool as a lever,
snorkel. When engine is first started, damper door
align check valve on pipe " A " (fig. 6E-31) to the
should close. As air cleaner warms up, damper door
plenum grommet. Then using palm of your left hand
should open slowly.
install check valve into the grommet. Use rubber
lubricant on grommets to ease assembly. 6. If d am per door does not close when the engine is
started, remove air cleaner.
7. Repeat procedure in step 6 on pipe "B " (fig. 6E-32)
7. Apply at least 23 kPa (7 in. Hg.) of vacuum to the
but use your left hand on the tool for alignment of
vacuum diaphragm motor through hose disconnected
check valve and install valve with the palm of your right
at the temperature sensor. Damper door should com
hand.
pletely block off snorkel passage when vacuum is
8. Tighten fittings to specified torque and reinstall air applied. If not check to see if linkage is hooked up
cleaner and hose. correctly.
LIGHT TRUCK SERVICE MANUAL
ENGINE EMISSION CONTROLS 6E-21
CHECK V A L V E ASM.
PLENUM TORQUE TO 23 N-m (17 FT. LBS.)
8. With vacuum still applied, trap vacuum in vacuum Thermometer Check of Sensor
diap hrag m motor by bending hose. D am per door 1. S tart test with air cleaner temperature below 80°F
should remain closed; if not, replace vacuum dia (27°C). If engine has been run recently, remove air
phragm motor assembly. (Failure of th vacuum dia cleaner and place a cool wet rag on sensor. Remove air
phragm motor assembly is more likely to be caused cleaner cover and place T h e rm o m e te r as close as
from binding linkage or a corroded snorkel than from a possible to the sensor. Let air cleaner cool until
failed diaphragm. This should be checked first, before thermometer reads below 79°F (26°C) about 5 to 10
replacing the diaphragm.) minutes. Reinstall air cleaner on engine and continue to
9. Reinstall air cleaner. As the engine warms up, the step 2 below.
dam p er door should s ta rt to allow outside air and 2. S tart and idle engine. Damper door should move to
heated air toenter the carburetor. close the snorkel passage immediately if engine is cool
10. If the air cleaner fails to operate as described above or enough. When damper door starts to open the snorkel
if correct operation of the air cleaner is still in doubt, passage (in a few minutes), remove air cleaner cover
perform thermometer check of sensor. and reaethermometer. It must read 100°F.-(-20oF. (38°C
7°C).
3. If the damper door does not start to open up the snorkel
passage at temperature indicated, tem perature sensor
if malfunctioning and must be replaced.
10. Install air cleaner cover. Do not over-torque wing 1. Remove air cleaner.
nut(s). 2. Detach hoses at sensor.
LIGHT TRUCK SERVICE MANUAL
6E-24 ENGINE EMISSION CONTROLS
TEMPERATURE SENSOR*
AIR BLEED VALVE
DIAPHRAGM
VACUUM DIAPHRAGM CLOSED
MOTOR
SNORKEL
HOT AIR DELIVERY
MODE VACUUM HOSES
INLET-
DIAPHRAGM
DAMPER DOOR
HOT AIR DUCT
HOT AIR
TEMPERATURE SENSOR
B
MOTOR
REGULATING MOD E
c. If voltage is not present at either device, check the Throttle Lever Actuator - Checking Procedure
engine harness connections at the distributor a nd/or 1. Disconnect valve to actuator hose at valve and connect
bulkhead connector. Repair as required. to an external vacuum source equipped with a vacuum
d. If the proper voltage exists at each device, to check gage.
for proper solenoid valve operation "ground" the 2. Apply 20 in. Hg vacuum to the actuator and seal off the
solenoid-to-switch connecting wire terminal at the vacuum source. If the vacuum gage reading drops, then
solenoid connector using a jum per wire. The throttle the actuator is leaking and must be replaced.
lever actuator should extend (engine running).
3. To check the actuator for proper operation:
e. If it does not extend, remove the hose from the
a. Check the throttle lever, shaft, and linkage to be sure
solenoid side port that connects to the actuator hose.
that they operate freely without binding or sticking.
Visually check the orifice in this port for plugging.
Clear the orifice as required. If not plugged, replace b. S tart engine and run until warmed up and idle is
the solenoid. stable. Note idle rpm.
c. Apply 20 in. Hg vacuum to the actuator. Manually
open the throttle slightly and allow to close against
the extended actuator plunger. Note the engine rpm.
DRILL 7 /6 4 " HOLE
IN CENTER POSITION d. Release and reapply 20 in. Hg vacuum to the
OF STRAP actuator and note the rpm to which the engine speed
increases (do not assist the actuator).
SPOTWELDS e. If the rpm obtained in step D is not within 150 rpm of
VACUUM that obtained in step C, then the actuator plunger
DIAPHRAGM may be binding due to dirt, corrosion, varnish, etc.,
MOTOR or the actuator diaphragm may be too weak. If
binding is not indicated or cannot be corrected then
the actuator must be replaced.
f. Release the vacuum from the a c tu a to r and the
engine speed should return to within 50 rpm of the
idle speed noted in step 2. If it does not, the plunger
may be binding due to dirt, corrosion, varnish, etc. If
the problem cannot be corrected, the actuator must
INSTALL REPLACEMENT be replaced.
RETAINING SENSOR ASSM. IN SAME g. If the engine rpm noted in step 3 is not within the
STRAP POSITION AS ORIGINAL ASSMJ specified T R C speed range, the T R C actuator must
be adjusted. See Throttle Lever A ctuator Adjusting
Fig. 6E-37--Vacuum M o to r Procedure in section 6C.
LIGHT TRUCK SERVICE MANUAL
6E-26 ENGINE EMISSION CONTROLS
P R IM A R Y T H R O T T L E
T H R O T T L E LEVER LEVER
ACTUATOR
M A N IF O L D V A C U U M
/ (V A L V E OPEN O N L Y )
ELECTRONIC
SPEED SENSO V E N T TO ATM OSPHERE
\ SO LE N O ID
VACUUM
E N G INE SPEED— C O N TR O L
S IG N A L FROM VALVE
D IS T R IB U T O R
VACUUM ADVANCE CONTROL When engine temperature is below specified value, the
manifold vacuum signal is routed through the check valve to
Trapped Vacuum Spark the distributor. Ports on TVS are blocked. The check valve
Trapped vacuum spark is on all engines. A thermal will keep the vacuum to the distributor at vacuum levels
vacuum switch (T V S) is used to sense engine coolant higher than manifold depression during vehicle accelera
temperature. A check valve is between manifold vacuum, tion. A small sintered iron bleed orifice is provided in the
distributor and thermal vacuum switch. check valve to allow for a leak-down to enable restarts in
case of engine stalls.
T R C S O L E N O ID T H R O T T L E LE V E R A C T U A T O R
HOSE
CONTROL
V A L V E ASM.
THRO TTLE V A LV E TRC S O LE N O ID
ACTUATOR CO NTRO L
V A L V E ASM.
A C C E LE R A T O R
SUPPORT VACUUM
F IT T IN G
HOSE
I
ENGINE EMISSION CONTROLS 6E-27
When engine temperature is above specified value, the Electronic Spark Control system. It mounts on the right
ports on TVS will be open to allow manifold vacuum to the hand side of engine in block drain hole.
distributor. The check valve in this mode of operation acts as Upon replacement, avoid the use of impact type tools
a connector. and excessive torque.
• Minimum torque 16.3 N-m (12.02 ft. lbs.)
SPARK VACUUM DELAY
• Maximum torque 21.7 N-m (16.01 ft. lbs.)
General Description
On heavy duty emission engines a check valve with an VEHICLE EMISSION CONTROL INFORMATION
internal beed is installed between the Trapped Vacuum LABEL
S park check valve and the distributor. W hen manifold
vacuum increases it opens the check valve which allows the The Vehicle Emission Control Information Label (Fig.
distributor vacuum to increase to the same level. Decreasing 6E-42) is located in the engine compartment (fan shroud,
manifold vacuum, as during vehicle acceleration; closes the radiator support, hood underside, etc.) of every vehicle
check valve and the distributor vacuum will decrease at a produced by General Motors Corporation. The label con
rate controlled by the internal bleed. tains important emission specifications and setting proce
dures, as well as a vacuum hose schematic with emission
DETONATION SENSOR components identified.
When servicing the engine or emission systems, the
Replacement Vehicle Emission Control Inform ation Label should be
The Detonation Sensor is an integral part of the checked for up-to-date information.
CONTROLS
Fig. 6E-42--Vehicle
r W HERE
R O U T IN S
A IR CLEANER
1040 8 IO W AlTITUOE ( ERIIFKATION 1 EQUIPPE
TIMING (“BTC (a> R P M I ?• 700 (N)
S IT P A R K IN G B K A K l A N D H O C K D K IV t W M fflS
M * * ( A l l ADJUSTMENTS WITH ENGINE AT NORMAL OPERATING TEMPERATURE CHOKE FULL OPEN. AM CLEANER SPARK PlUG GAP (IN )
HSTALLED. AMO A M CONDITIONING OH . EXCEPT WHIRS NOTiD
IDLE SPEED SCREW IR P M )
(SOLENOIO INACTIVE)
Emission Control Information
I DISTRIBUTOR DISC ON NIC T AND PlUG VACUUM HOSE AT DISTRIBUTOR SIT IGNITION TIM ING AT
SPECIFIED ENGINI SP IE D UNPLUG ANO RICONNICT VACUUM HOSi TO DISTRIBUTOR IDLE SPEED SOLENOID (R PM )
(SOLENOID ACTIVE)
? O i l SP IE D SCREW DISCONNECT ELECTRICAL IEAD (ROM KHE SOLENOIO * EQUIPPED ADJUST
CARBURETOR IDIE SPEED SCREW TO S P K I M D SPIED RECONNICT IEAD TO SOEENOIO FAST IDEE S P IE D SCREW (R P M i
FAST IDEE SPEED SCREW WITH ENGINE O ff. PLACE THROTTLE ON HIGH STEP OE FAST IDEE C A M SEE SERVICE M ANUAL. MAMTENANCE SCHEDULE I ANO
DISCONNfCT ANO P lU G V AC U UM HOSE AT EGR VALVE START ENGINE WITHOUT TOUCHING EM ISSIO N HOSE ROUTING DIAG RA M FOR ADDITIONAL
THROTTLE ADJUST TO SPICIFIED SPEED OPEN THROTTLE TO RELEASE FAST IDEE C A M STOP ENGINE. INFORMATION
UNPLUG ANO RECONNECT VACU UM HOSE TO EGR V A lV f
THIS V IH IC ll CONFORMS TO U S EPA REGULATIONS APPLICABLE TO 1911 MODEL YEAR NEW LIGHT DUTY TRUCKS P I NO 14076117
Label
LABEL E M IS S IO N C O M P O N E N T
PART NUMBER A N D V A C U U M H O S E S C H E M A T IC
ENGINE EXHAUST SYSTEM 6F-1
SECTION 6F
ENGINE E X H A U S T S Y S T E M
G E N E R A L D E SC R IP T IO N
CO NVERT ER SHELL
CONVERTER SHELL
MONOLITH
LIGHT TR U C K SER V IC E M A N U A L
6F-2 ENGINE EXHAUST SYSTEM
Loss o f engine pow er and/or Dislodge d turn in g tubes and or Replace m uffler.
internal rattles in m uffler. baffles in m uffler.
LIGHT T R U C K SE R V IC E M A N U A L
ENGINE EXHAUST SYSTEM 6F-3
ON-VEHICLE S E R V IC E
CATALYST (Figs. 6F-3 & 6F-4) NOTICE: Do not pry fill plug from converter as damage
to fill plug sealing surface could result.
Removal (Off Vehicle)
4. Holding converter over a container, empty catalyst
1. Raise vehicle. from converter by shaking until all beads are removed.
2. Remove converter.
3. Remove converter pressed fill plug by driving a small
chisel between the converter shell and the fill plug (Fig. 6F-5). Installation (Off Vehicle)
Continue to deform fill plug until it can be removed with pliers
(Fig. 6F-6). 1. Raise front of converter to approximately 45° and fill
with approved new catalyst. Filling can be accomplished by
tapping on converter belt (Fig. 6F-7) with a hammer, 90° to the
converter, while pouring beads into the converter thru the fill
plug hole. Continue tapping and pouring until converter is full.
Not all beads will be able to be installed.
2. Install service fill plug (Fig. 6F-8) as follows: Install
the bolt into the bridge and put the bridge into the converter
opening. Move bolt back and forth to loosen catalyst beads
until bridge is positioned as shown in Fig. 6F-9.
3. Remove bolt from bridge then put the washer and fill
plug, dished side out, over the bolt.
4. While holding the fill plug and washer against the bolt
head (Fig. 6F-10), thread the bolt 4 or 5 turns into the bridge.
LIGHT TR U C K SE R V IC E M A N U A L
6F-4 ENGINE EXHAUST SYSTEM
BRIDGE
LIGHT TR U C K SE R V IC E M A N U A L
ENGINE EXHAUST SYSTEM 6F-5
LIGHT TR U C K SE R V IC E M A N U A L
6F-6 ENGINE EXHAUST SYSTEM
LIGHT T R U C K SE R V IC E M A N U A L
ENGINE PERFORMANCE SPECIFICATIONS 6G-1
SECTION 6G
ENGINE PERFORMANCE SPECIFICATIONS
T H E F O L L O W IN G C H A R T R E P R E S E N T S T H E L A T E ST C E R
T IF IE D IN F O R M A T IO N A V A IL A B L E AT T IM E O F P R IN T IN G .
A L W A Y S R E F E R TO T H E V E H IC L E E M IS S IO N C O N T R O L IN
F O R M A T IO N LABEL FO R THE M O ST U P -T O -D A T E
IN F O R M A T IO N .
4.1 L (250 C.I.D.) LE3 ACR 10° R45TS 4501N) 750(N) 2000(N) 17081621 1110589 644 0° @3" 0° @ 1100
FAMILY 18F2HANQR ACS (.035) 16° @ 6.5" 14° @ 2300
MANUAL TRANS. 17081629 ‘ ill 1388 691 0“ @ 3" 24° @ 4100
FEDERAL SALES 20° @ 7.5"
C-10
4.1 L (250 C.I.D.) LE3 ACR 10° R46TS 450 (N) 750 (N) 2000 (N) 17081625 1110590 665 0° @ 4" 0° @ 1100
FAMILY 18F2HANQR ACS (.035) 15° @ 10" 14° @ 2300
MANUAL TRANS. 17081633 1110753 626 1 24° @ 4100
FEDERAL SALES
K-10
4.1L (250 C.I.D.) LE3 ACS 10° R46TS 450 (N) 750 (N) 2000 (N) 17081623 1110589 644 0° @ 3" 0°@ 1100
FAMILY 18F2HANQR ADA (.035) LABEL 800 (N) ADA 17081627 16° @ 6.5" 14° @ 2300
MANUAL TRANS. 24° @ 4100
FEDERAL SALES
G10.20
4.1 L (250 C.I.D.) LE3 ACW 10° R46TS 450 (N) 750 (N) 2000 (N) 17081721 1110749 626 0° @ 4" 0° @ 1100
FAMILY 18F2HHNR AWA (.035) 10° @ 8" 7° @ 2300
MANUAL TRANS ACK 16° @ 4200
CALIF. SALES AWB
C-10
4.1L (250 C.I.D.) LE3 ACX 10° R46TS 450 (N| 750 (N) 2000 (N) 17081727 G10 1110749 626 0° @ 4" 0° @ 1100
FAMILY 18F2HHNR ADB (035) 17081725 G20, 30 10° @ 8" 7° @ 2300
MANUAL TRANS. AFA 16° @ 4200
CALIF. & FED. SALES
G-10, G20, G30
4.1 L (250 C.I.D.) LE3 ACT 10° R46TS 450 (D) 650 (D) 2200 17081622 1110589 644 0° @ 3" 0° @ 1100
FAMILY 18F2HANQR AUU (.035) (P or N) 16° @ 6.5" 14° @ 2300
AUTO TRANS. ACU 24° @ 4100
FEDERAL SALES
C-10, 20 K-10
4.1 L (250 C.I.D.) LE3 ADC 8° R46TS 450(D) 650 ID) 2200 17081624 1110589 644 0° @ 3" 0° @ 1100
FAMILY 18F2HANQR AAC (.035) 700 (D) AAC (P or N) 17081626 16° @ 6.5" 14° @ 2300
AUTO TRANS. 24° @ 4100
FEDERAL SALES
G-10, 20
4.1 L (250 C.I.D.) LE3 R46TS 450 (D| 650 (D) 2200 17081720 1110749 626 0° @ 4" 0° @ 1100
ACY 10°
FAMILY 18F2HHNR (.035) (P or N) 10° @ 8" 7° @ 2300
AWC
AUTO TRANS. 16° @ 4200
ACZ
CALIF. SALES
C-10 AWD
4.1 L (250 C.I.D.) LE3 ACZ 10° R46TS 450 (D) 650 (0) 2200 17081726 1110749 626 0° @ 4" 0° @ 1100
FAMILY 18F2HHNR ADD (.035) IP or N) 10° @ 8" 7° @ 2300
AUTO TRANS. AFB 16° @ 4200
CALIF. & FED. SALES
G10, 20, 30
4.8 L (292 C.I.D.) L25 ADF 8° R44T 4501N) 7001N) 2400(N) 17081309 1110753 626 0° @ 4" 0° @ 1100
FAMILY GM 112 ADM (.035) 17081680 10° @ 8" 14° @ 2300
MANUAL TRANS. ADH 24° @4100
NATION WIDE
CK20, 30; P20, 30
LIG H T T R U C K SERVICE M A N U A L
6G-2 ENGINE PERFORMANCE SPECIFICATIONS
4.8L 1292 C I D.) L25 ADF 8° R44T 450 (N) 700 (N) 2400 (N) 17081309 1110753 626 0° @ 4" 0C @ 1100
FAMILY GM112 ADM . (.035) 17081680 10° @ 8" 14c @ 2300
AUTO TRANS ADH 24° @ 4100
NATION WIDE SALES
CKP20, 30
5.0L (305 C I D.) LG9 AAA 'r 8° R45TS 700 (N) 600 (N) 1300 (N) 17081143 1103381 691 0° @ 3" 0° @ 1200
FAMILY 18Y2HAN (.045) 17081145 w/AC 1 0 ° 7 .5 " 8° @ 2000
MANUAL TRANS. 20° @ 4200
FEDERAL SALES
C-10
5 0L (305 C I D.) LG9 AAA 8C R45TS 700 (N) 600 (N) 1300 (N) 17081101 1103369 644 0° @ 3*' 0° @ 1200
FAMILY 18Y2HAN (.045) 17081103 w/AC 16° @ 6.5" 8° @ 2000
MANUAL TRANS 20° @ 4200
FEDERAL SALES
G10, 20
5.0L (305 C.I.D.) LG9 AAB 8° R45TS 600 (D) 500 (D) 1600 17081142 1103381 691 0° @ 3" 0° @ 1200
FAMILY 18Y2HAN (.045) (P or N) 17081144 w/AC 10° @ 7.5" 8° @ 2000
AUTO TRANS 20° @ 4200
FEDERAL SALES
CIO; G10, 20
5.0L (305 C.I.D.) LE9 AAF 4° R45TS 700 (N) 1300 INI 17081201 1103464 Elect
FAMILY 18Y4HAN (0.45) Spark
MANUAL TRANS Control
FEDERAL SALES
C-10
5.0L (305 C.I.D.) LE9 AAM 4C R45TS 700 (N) 1300 (N) 17081220 1103464 Elect
FAMILY 18L4HANA AAR (0.45) Spark
MANUAL TRANS. Control
FEDERAL SALES
CIO. 20; K10 026
5.0L (305 C.I.D.) LE9 AUS 4° . R45TS 600 (N) , 1500 (N) 17081200 1103465 Elect
FAMILY 18L4HANA (.045) Spark
MANUAL TRANS. Control
FEDERAL SALES
C-10
5.0L (305 C.I.D.) LE9 AAJ 6C R45TS 700 (N) 1300 (N) 17081220 1103464 Elect
FAMILY 18L4HANA (.045) Spark
MANUAL TRANS. Control
FEDERAL SALES '
G10, 20
5.0L (305 C.I.D.) LE9 AAH 4C R45TS 500 (D) 1600 17081206 w/AC 1103464 Elect
FAMILY 18Y4HANA (045) (PI or (N) 17081205 Spark
AUTO TRANS. Control
FEDERAL SALES
C-10
5.0L (3.05 C.I.D.) LE9 AAN , 6° R45TS 500 (D) 1600 17081227 1103464 Elect
FAMILY 18Y4HANA (.045) (P) or <N> 17081226 w/AC Spark
AUTO TRANS. Control
FEDERAL SALES AAS 2°
C-10. 20: K-10
5.0L (305 C.I.D.) LF3 ACC 8° R45TS 650 (D) 550(D) 1800 17081526 w/AC 1103432 620 0° @ 4" 0° @ 1000
FAMILY 18L4HHNA AWF (.045) (P) or (N) 17081524 15° @ 12" 10° @ 2000
AUTO TRANS. ACD 14° @ 4000
CALIF. SALES ACF
C-10
5.7L (350 C.I.D.) LS9 AAT 8° R45TS 700 (N) 1300(N) 17081291 1103353 624 0° @ 4" 0° @ 1100
FAMILY 18L4HANA (.045) 20° @ 10 12° @ 1600
MANUAL TRANS. 16° @ 2400
FEDERAL SALES 22° @ 4600
C-10; K-10, 20
5.7L (350 C.I.D.) LS9 AAW 8° R45TS 700 (N) 1300(N) 17081291 1103353 624 0° @ 4" 0° @ 1100
FAMILY 18L4HANA (.045) 20° @ 10 12° @ 1600
MANUAL TRANS. 16° @ 2400
FEDERAL SALES 22° @ 4600
G-10, 20
5.7L (350 C.I.D.) LS9 AAU 8° R45TS 600 (D) 500 (D) 1600' 17081290 1103353 624 0° @ 4"
(© © © ©
I i i i
5.7L (350 C.I.D.) LS9 AAK 8° R45TS 600 (D) 500 (D) 1600 17081290 1103353 624 0° @ 4" 0” @ 1100
FAMILY 18L4HANA (.045) (P) or (N) 17081292 w/AC 20° @ 10" 12” @ 1600
AUTO TRANS. 16° @ 2400
FEDERAL SALES 22° @ 4600
G-10, 20
5.7L (350 C.I.D.) LS9 AAZ 6° R45TS 650 (D) 550 (D) 1800 17081506 1103433 620 0° @ 4" 0” @ 1100
FAMILY 18L4HHNA AAD (.045) (P) or (N) 17081508 w/AC 15° @ 12" 12“ @ 1600
AUTO TRANS. 16° @ 2400
CALIF. SALES 22” @ 4600
CK-10
5.7L (350 C.I.D.) LS9 AAZ 6° R45TS 650 (D) 550 (D) 1600 17081506 0° @ 4" 0°@ 1100
FAMILY 18L4HHNA (.045) (P or N) 17081508 w/AC 1103433 620 15° @ 12" 12” @ 1600
AUTO TRANS. AAD 8° 16° @ 2400
CALIF. SALES 0° @ 4" 22° @ 4600
CK-20 1103339 626
10° @ 8"
5.7L (350 C.I.D.) LS9 ACA 8° R45TS 650 (D) 550 (D) 1800 17081506 1103433 620 0° @ 4" 0° @ 1100
FAMILY 18L4HHNA ACB (.045) (P or N) 17081508 w/AC 15° @ 12" 12° @ 1600
CALIF. SALES 16” @ 2400
G10, 20 22° @ 4600
LIG H T T R U C K SERVIC E M A N U A L
ENGINE PERFORMANCE SPECIFICATIONS 6G -3
VACUUM 8. MECHANICAL
DISTRIBUTOR
ADVANCE
SPARK MECHANICAL VACUUM
IGNITION ADVANCE
ADVANCE
EMISSION TIMING PLUG SOLENOID CURB FAST
ENGINE AND LABEL B.T.D.C. TYPE SCREW IDLE IDLE CARBURETOR DIST. VACUUM (Crank (In Crank
EMISSION FAMILY CODE DEGREES & GAP (RPM) (RPM) (RPM) PART NUMBER MODEL MODEL Degrees @ Degrees @
Engine RPM) Inches of
Vacuum)
5.7L (350 C.I.D.) LT9 ACJ 4° R44T *1600 700 (N) 1900 (N) 17080213 1103375 620 0° @ 4" 0 ° @ 1150
FAMILY GM113 (.045) 10° @ 8" 17° @ 2900
MANUAL TRANS. 22° @ 4200
FEDERAL SALES
CK-20
5.7L (350 C.I.D.) LT9 ACJ 4° R44T *1600 700 (N) 1900 (N) 17080298 1103375 620 0° @ 4” 0 ° @ 1150
FAMILY GM113 ACM (.045) 14° @ 8" 17° @ 2900
MANUAL TRANS. 0°@ 3" 22° @ 4200
FEDERAL SALES 16° @ 6.5"
G-30
5.7L (350 C.I.D.) LT9 ACK 6° R44T *1500 700 (N) 1900 (N) 17080507 1103420 681 0° @ 10 0° @ 1800
FAMILY GM113 (.045) 10° @ 13" 24° @ 4000
MANUAL TRANS.
CALIF. SALES
CK-20, 30
5.7L (350 C.I.D.) LT9 ACK 6° R44T *1500 700 (N) 1900 (N) 17080507 1103420 681 0° @ 10" 0° @ 1800
FAMILY GM113 (.045) 10° @ 13" 24° @ 4000
MANUAL TRANS.
CALIF. SALES
G-30
5.7L (350 C.I.D.) LT9 ACJ 4° R44T *1600 700 (N) 1900 (N) 17080213 1103375 626 0° @ 4" 0 ° @ 1150
FAMILY GM113 ACM (.045) 10° @ 8" 17° @ 2900
MANUAL TRANS. 22° @ 4200
FEDERAL SALES
P-20, 30
5.7L (350 C.I.D.) LT9 ACK 6° R44T *1500 700 (N) 1900 (N) 17080513 1103420 681 0 ° @ 10" 0° @ 1800
FAMILY GM113 (.045) 10° @ 13" 24° @ 4000
MANUAL TRANS.
CALIF. SALES
P-30
5.7L (350 C.I.D.) LT9 ACJ 4° R44T *1600 700 (N) 1900 (N) 17080213 1103375 626 0° @ 4" 0 ° @ 1150
FAMILY GM113 (.045) 10° @ 8" 17° @ 2900
AUTO TRANS. 22° @ 4200
FEDERAL SALES
CK-20, 30
5.7L (350 C.I.D.) LT9 R44T *1600 700 (N) 1900 (N) 17080298 1103375 681 0° @ 4" 0° @ 1150
ACJ 4°
FAMILY GM113 10° @ 8" 17° @ 2900
ACM (.045)
AUTO TRANS. 22° @ 4200
FEDERAL SALES
G-30
5.7L (350 C.I.D.) LT9 ACK 6° R44T *1500 700 (N) 1900 (N) 17080513 1103420 681 0° @ 4" 0 ° @ 1000
FAMILY GM113 (.045) 15° @ 10" 17° @ 1600
AUTO TRANS. 22° @ 4200
CALIF. SALES
CK-20, 30
•THROTTLE RETURN CONTROL SPEED
5.7L (350 C.I.O.) LT9 AC K 6° R44T *1500 700 (N) 1900 (N) 17080507 1103420 681 0° @ 4 " 0° @ 1000
FA M IL Y G M113 (.045) 15° @ 10" 17° @ 1600
AU TO T R AN S. 22° @ 4200
CALIF. S A L E S
G-30
5.7L (350 C.I.D.) LT9 AC J 4° R44T *1600 700 (N) 1900 (N) 17080213 1103375 626 0° @ 4 " 0° @ 1000
F A M IL Y G M113 ACM (.045) 17080215 14° @ 8 8° @ 1600
AU TO T R AN S. 19° @ 3450
FED ERAL S A L E S
P-30
5.7L (350 C.I.D.) LT9 AC K 6° R44T *1500 700 (N) 1900 (N) 17080513 1103420 681 0° @ 4 " 0° @ 1000
F A M IL Y G M113 (.045) 15° @ 10" 17° @ 1600
AU TO T R A N S 22° @ 4200
CA LIF S A L E S
P-30
7.4L (454 C.I.D.) LE8 ADJ 4° R44T *1500 700 (N) 1900 (N) 17080212 1103376 682 0° @ 8 " 0° @ 1100
F A M IL Y G M115 AD K (.045) 17080512 10° @ 13 14° @ 2800
M A N U A L T R AN S. 20° @ 4200
N A T IO N W ID E
C-20, 30; K-30
7.4L (454 C.I.D.) LE8 ADJ 4° R44T *1500 700 (N) 1900 (N) 17080212 1103376 682 0° @ 8 " 0° @ 1100
F A M IL Y G M115 AD K (.045) 17080512 10° @ 13" 14° @ 2800
AUTO T R A N S. 20° @ 4200
N A T IO N W ID E
P-30
5.7L (350 C.I.D.) LF9 O JD 8° G LO W 575 ID) 650 (D) Mechanical Injector
FA M IL Y 19J9ZZ PLUG Fuel Injection Pump
AU TO T R AN S.
FED ER AL S A L E S
C-10
5.7L (350 C.I.D.) LF9 HKD 5° GLO W 600 (D) 750 (D) Mechanical Injector
FA M IL Y 19J9ZZP OHD PLUG Fuel Injection Pum p
AU TO T R AN S.
CALIF. S A L E S
C-10
u. ,;>■
'■ ■ .• tv ■! < . f. •
A U T O M A T IC TRAN SM IS S IO N 7A-1
SECTION 7 A
AUTOMATIC TRANSMISSION
CONTENTS
T O R Q U E CO N V ER T ER CLUTCH (TCC)
INDEX
G eneral D escription.......................................................... 7A-1 External Controls C h e c k ............................................... 7A-6
C onverter Clutch D iagnosis............................................ 7A-4 Vacuum Switch C heck................................................. 7A-6
Com plaints and Possible C auses............................... 7A-4 Low A nd High Vacuum Switch Check (Diesel)... 7A-6
Converter Clutch Applied In All Ranges............... 7A-4 High Vacuum Switch A d ju stm en t........................... 7A-6
Converter Clutch Applies E rratically ...................... 7A-5 Therm al Vacuum Valve C h e ck ................................. 7A-7
Converter Clutch Applies At All T im e s................ 7A-5 Brake Release Switch C h e ck ...................................... 7A-7
Internal C ontrols C h eck ................................................ 7A-5 Solenoid Diode C h e c k ................................................. 7A-7
Internal H ydraulic/M echanical Controls Check... 7A -5
G EN ER A L D E SC R IP T IO N
The torque converter clutch (as shown in Fig. 7A -la) of the converter clutch apply valve controls which direction
is an internal mechanism (with a friction material attached converter feed oil flows to the converter.
to the front plate) splined to the turbine assembly, and when
A spring loaded dam per assembly is splined to the
operated applies against the converter cover. This provides
converter turbine assembly. The converter clutch pressure
a mechanical direct drive coupling of the engine to the
plate is attached to the pivoting mechanism of the dam per
planetary gears. By applying the converter clutch, slippage
assembly. This pivoting action allows the pressure plate to
is eliminated, resulting in improved fuel economy and
rotate independent of the dam per assembly, up to
reduced fluid operating tem peratures.
approximately 45 degrees. The rate of independent rotation
The operation of the converter clutch is determined by is controlled by the pivoting mechanism acting on the
a series of controls, and by drive range selection (as shown springs in the dam per assembly. The spring cushioning
in Fig. 7A-2a and 2b). The converter clutch is applied in effect of the dam per assembly aids in reducing converter
direct drive and above a m inimum preset vehicle speed. At clutch apply "feel."
wider throttle openings, where the 2-3 upshift occurs above
To further aid the apply and release of the converter
converter clutch apply, the apply o f the converter clutch will
clutch during various driving situations, controls have been
occur immediately after the 2-3 shift. W hen vehicle speed
incorporated in the electrical system. The converter clutch
decreases or the transmission shifts out of direct drive, the
is applied when all of the following conditions exist:
fluid pressure is released, the converter clutch is released,
and the converter operates in a conventional manner. • Transmission in 3rd gear
• Vehicle exceeds 24 to 30 m ph (38 to 48 k m /h )
The apply or release of the converter clutch is
determ ined by the direction that converter feed oil is fed to • Engine coolant is above 130° F (54°C)
the converter. Converter feed oil from the pressure regulator • Engine vacuum is above 2.5 in. hg.(8 kPa)
valve flows to the converter clutch apply valve. The position • B rake pedal is released
LIGHT T R U C K SE R V IC E M A N U A L
7A-2 A U TO M A TIC TRAN SM ISSIO N
TURBINE
THRUST
SPACER
LIGHT TR U C K SE R V IC E M A N U A L
A U T O M A T IC T R A N SM IS S IO N 7A-3
ENGINE
TRANSMISSION
CONVERTER CLUTCH
SOLENOID
(CLUTCH IS
ENGAGED IN
GOVERNOR OIL 3RD GEAR AND
PRESSURE SOLENOID IS
SWITCH ENERGIZED)
(CLOSES WHEN
VEHICLE SPEED
EXCEEDS 24 TO 30 MPH)
LIGHT T R U C K SE R V IC E M A N U A L
7A-4 A U TO M A TIC TRAN SM ISSIO N
C O N V ER T ER CLUTCH D IA G N O S IS
If engine perform ance indicates an engine tune-up is 3. R oad test vehicle to verify com plaint at norm al
required, this should be performed, before road testing or operating tem perature.
attem pting to diagnose the transmission. Poor engine
perform ance can result in rough shifting or other
Converter Clutch Applied In All Ranges, Engine
malfunctions.
On 4 wheel drive vehicles equipped with a Torque Stalls When Transmission Is Put In Gear
Converter C lutch (TCC). W hen the driver shifts from 2H
1. Converter clutch valve is stuck in the A PPL Y
to 4L or 4H, the circuit to the TCC system is opened. A position.
light is provided on the instrum ent panel to indicate when
the vehicle is in 4 wheel drive. In this position (4L or 4H)
converter clutch will not apply. W hen the driver shifts back If Converter Clutch Does Not Apply, Applies
to 2H, the TCC system should operate in a norm al manner.
IF the vehicle does not shift out of 4 wheel drive, the light
Erratically Or At Wrong Speed During Road
on the instrum ent panel (IP) will stay lit. The converter Test
clutch will not apply. Use the diagnosis listed below to
determ ine the problem. 1. Disconnect electrical connector at transm ission case
and test female connector for 12 volts using v olt/ohm meter
COMPLAINTS AND POSSIBLE CAUSES (2000 rpm in N eutral).
Before faulting any com ponent parts of the TCC a. If 12 volts are present at connector, problem is
system first: internal (Refer to Internal C ontrols Check).
1. Check transm ission oil level, correct as needed. b. N o voltage or low voltage present at connector,
problem is external (Refer to External C ontrols Check).
2. Check m anual linkage adjustm ent, correct as
required.
LIGHT TR U C K SE R V IC E M A N U A L
A U T O M A T IC TRAN SM IS S IO N 7A-5
• D irect clutch oil passages in pum p blocked, restricted 2. A ttach one lead of a test light to either term inal of
or interconnected. the vacuum switch (low or high).
• Converter M alfunction. 3. G round the remaining terminal of the vacuum
13. A fter test, remove test governor and replace with switch (low or high).
original governor. If the original governor was used for the 4. A ttach the remaining lead of the test light to the hot
test, ensure that the weight springs are in the correct 5. A ttach a hand vacuum pum p with a gage (J-23738
position, before reinstalling in the vehicle. or equivalent) to the vacuum port of the vacuum switch (low
or high).
EXTERNAL CONTROLS CHECK 6. T urn car ignition ON.
1. T urn car ignition "O N ".
7. If using a self-powered test light, connect one lead
2. Check vacuum switch connector for 12 volts and of the test light to either term inal of the vacuum switch (low
check vacuum switch for proper operation. (Refer to or high) and connect the rem aining lead of the test light to
Vacuum Switch Check). the other term inal of the low or high vacuum switch. Car
a. If no voltage is present at switch: ignition does not have to be turned O N when using this type
1. Check fuse. of test light.
2. Check brake switch (Refer to Brake Switch Check). 8. A ctuate hand vacuum pump.
3. Check wiring to vacuum switch. a. F or LOW vacuum test light should be O FF, and
b. If 12 volts are present at switch, and switch check remain O FF, until vacuum gage reads approximately 5.5 in.
OK, continue to Step 3. (18 kPa) of vacuum.
3. Reconnect electrical connector to vacuum switch b. F or H IG H vacuum test light should be ON, and
and using a hand held vacuum pum p with a gage (J-23738 remain ON, until vacuum gage reads approximately 12.5 in.
or equivalent) apply 2.5 to 7 in. (18 to 23 kPa) of vacuum (41 kPa) of vacuum. Test light should be O F F with vacuum
above 12.5 in. (41 kPa).
to vacuum switch.
9. Decrease vacuum slowly.
4. W ith the ignition switch in the "O N " position,
check for 12 volts at female end of transm ission connector. a. F or LOW vacuum test, light should remain O N
until vacuum drops to approxim ately 4 in. (13 kPa).
a. If "N O " or low voltage is present, check and repair
the wire between vacuum switch and transmission. b. F or H IG H vacuum test, light should come back ON
at 12.5 in. (41 kPa) high vacuum.
b. if 12 volts are present at transm ission, check
10. If the LOW vacuum switch does not turn the test
Therm al Vacuum Valve for proper operation (Refer to
light "O N " at approxim ately 5.5 in. (18 kPa) of vacuum and
Therm al Vacuum Valve Check) if operation checks OK
"O FF" at approxim ately 4 in. (13 kPa) of vacuum, the low
return vehicle to owner.
vacuum switch is malfunctioning.
VACUUM SWITCH CHECK 11. If the H IG H vacuum does not turn O F F and O N
1. D isconnect vacuum hose and electrical connector at approxim ately 12.5 in. (41 kPa) of vacuum, the high
from vacuum switch. vacuum switch is malfunctioning.
2. A ttach one lead of a test light to either term inal of HIGH VACUUM SWITCH ADJUSTMENT
the vacuum switch. (DIESEL)
3. G round rem aining term inal of vacuum switch. The high vacuum switch m ust be adjusted anytime the
4. Apply 12 volts to rem aining test light lead. throttle rod, transmission vacuum valve and high idle speed
5. A ttach a hand vacuum pum p with a gage (J-23738 adjustm ents are changed.
or equivalent) to vacuum port of switch. 1. Disconnect high vacuum switch electrical
6. T urn ignition "O N ". connector.
7. A ctuate hand vacuum pump. Test light should be 2. Using self-powered test light, connect one lead to
"O FF" and rem ain O F F until hand vacuum pum p gage either term inal of the high vacuum switch and connect the
reads between 2.5 and 7 in. (8 to 23 kPa) of vacuum. Test probe of the test light to the other vacuum switch terminal.
light should come "O N ". 3. Start engine and run at high idle speed. Energize fast
8. Decrease vacuum slow ly-light should remain idle solenoid by disconnecting pink and green wire
"O N " until vacuum drops to between 1.5 and 2.5 in. (5 to connector from coolant switch located on the left rear of the
8 kPa) of vacuum. engine on the intake manifold.
9. If the vacuum switch does not turn the test light 4. Remove seal cap on back of high vacuum switch.
"O N " and "O F F " between the values specified, the switch 5. High vacuum switch contacts m ust be closed (test
is defective. light O N ) before m aking adjustm ent. If contacts are open
10. (test light O FF), turn switch adjustm ent screw clockwise
The high vacuum limit, (the point at which the test
until contacts close (test light ON).
light goes "O U T ") and the low vacuum limit, (the point at
which the test light comes back "O N ") must have at least 6. A djust vacuum switch by slowly turning the
4 in. (13 kPa) of vacuum difference. adjustm ent screw counterclockwise until switch contacts
just open (test light O FF). T urn adjustm ent screw slowly
LOW AND HIGH VACUUM SWITCH CHECK to prevent adjusting past this position.
(DIESEL) 7. Reinstall seal cap on back of switch, reconnect high
1. Disconnect vacuum hose and electrical connector vacuum switch electrical connector, and reconnect coolant
from vacuum switch (low or high). switch connector.
LIGHT TR U C K SE R V IC E M A N U A L
A U TO M A TIC TR A N SM IS S IO N 7A-7
Fig. 7A-4a— High Vacuum Switch Adjustment Diode used in solenoids may be checked using O N LY
a M E T E R R E A D IN G or SCA LE-TY PE ohm meter, set
on the X I SCALE. Electronic or digital-type meters,
THERM AL V A C U U M VALVE CHECK C A N N O T be used because a false defective indication can
1. D isconnect vacuum hose at vacuum switch. be obtained.
2. A ttach vacuum gage to hose. Proper procedure is as follows:
3. Start car and check vacuum in Park(P). 1. Set the SC A LE-TY PE or M E T E R -R E A D IN G
a. W ith engine cold, engine coolant tem perature below ohm m eter on the X I SCA LE and zero the needle.
130° F (54°C), vacuum at idle and at 2000 rpm should read 2. A ttach the PO SITIV E SO LEN O ID LEA D (R ED ,
zero(O). marked with +) to the POSITIVE METER LEAD and the
NEGATIVE SOLENOID LEAD (black, marked - ) to the
b. W ith engine warm (approxim ately five minutes
NEGATIVE METER LEAD.
running time at fast idle), engine coolant tem perature above
130° F (54°C), vacuum at idle should be zero(O), while a. A m eter reading of 20 to 40 ohms (depending on
vacuum at 2000 rpm should be 10 in. (33 kPa) minimum. solenoid tem perature), diode or coil is nor shorted.
BRAKE SW ITC H CHECK b. A m eter reading of 0 ohms, diode or coil is shorted.
1. D isconnect electrical connector from rear of brake c. Open circuit reading, coil is open.
switch. These are the cruise co ntrol/converter clutch release 3. Reverse the solenoid lead attachm ent.
terminals. a. Lower reading than in Step 2 (usually 2 to 15 ohms),
2. T urn ignition switch on the "O N " position. solenoid is OK.
3. Now ground one of the term inals of the brake b. Same reading as in Step 2, diode is open.
release switch.
LIGHT TRU CK SE R V IC E M A N U A L
7A-8 A U TO M A TIC TRAN SM ISSIO N
350 A U T O M A T IC T R A N S M IS S IO N
INDEX
G EN ER A L D E SC R IP T IO N
The 350 transmission is a fully autom atic unit impeding the sm ooth flow of oil, its roller clutch releases
consisting prim arily of a 3-element hydraulic torque and it revolves freely on its shaft. Once the stator becomes
converter and two planetary gear sets. Four multiple-disc inactive, there is no further m ultiplication of engine torque
clutches, two roller clutches, and an interm ediate overrun within the converter.
band provide the friction elements required to obtain the
A t this point, the converter is merely acting as a fluid
desired function of the two planetary gear sets.
coupling as both the converter pum p and turbine are being
The 3-element torque converter consists of a pump, driven at approximately the same speed.
turbine and a stator assembly, with the addition of a
converter clutch. The stator is m ounted on a one way roller A hydraulic system pressurized by a gear type pum p
clutch which will allow the stator to turn clockwise, but not provides the working pressure required to operate the
counterclockwise. References to clockwise and friction elements and autom atic controls.
counterclockwise are determ ined by looking toward rear of External control connections to the transmission are:
vehicle.
• M anual Linkage - To select the desired operating
The torque converter is of welded construction and is
range.
serviced as a complete assembly. The unit is filled with oil
and is attached to the engine crankshaft by a flywheel, thus • Engine Vacuum - To operate the vacuum m odulator.
always rotates at engine speed. The converter pum p is an
• Cable Control - To operate the detent valve.
integral part of the converter housing, therefore, the pump
blades, rotating at engine speed, set the oil within the A vacuum m odulator is used to autom atically sense
converter into m otion and direct it to the turbine, causing any change in the torque input to the transmission. The
the turbine to rotate. vacuum m odulator transm its this signal to the pressure
As the oil passes throughout the turbine it is traveling regulator, which controls line pressure, so that all torque
in such a direction th at if it were not redirected by the stator requirements of the transm ission are met and sm ooth shifts
it would hit the rear of the converter pum p blades and are obtained at all throttle openings.
impede its pumping action. So at low turbine speeds, oil is The detent valve is activated by a cable that is
redirected by the stator to the converter pum p in such a connected to the accelerator lever assembly. W hen the
m anner that it actually assists the converter pum p to deliver throttle is half open, the valve is actuated causing throttle
power, or multiply engine torque. downshift at speeds below 50 m ph, (80 km /h). W hen the
As turbine speed increases, the direction of oil leaving throttle is fully open the detent valve is actuated causing the
the turbine changes and flows against the rear side of the transm ission to downshift from 3-1 at speeds below 40 mph
stator vanes in a clockwise direction. Since the stator is now (65 k m /h ) and 3-2 below 75 m ph (120 km /h).
LIGHT T R U C K SE R V IC E M A N U A L
AU TO M A TIC TRAN SM ISSIO N 7A-9
LOW AND
REVERSE SUN OUTPUT
CLUTCH GEAR SHAFT
REACTION
CARRIER
GOVERNOR
AND REVERSE
OVERRUN ROLLER
INPUT
SHAFT PARKING
PAWL
OUTPUT
CARRIER
M A IN T E N A N C E A N D A D J U S T M E N T S
LIGHT TR U C K SE R V IC E M A N U A L
A U T O M A T IC TRAN SM IS S IO N 7 A -1 3
LINK —
TRANSMISSION
I VIEW A
B RA CK ET-
ENGINE
LEVER - VIEW B
CARBURETOR
LIGHT TRU C K SE R V IC E M A N U A L
7A-14 AUTOMATIC TRANSMISSION
VIEW A
LOCK TAB
T.V./DETENT
CABLE
BRACKET
TERMINAL
VIEW B
LEVER ASSEMBLY
1. Remove pump rod from lever assembly. In case re-adjustment is necessary because of inadver
tent adjustment before or during assembly, perform the
2. After installation to transmission, install cable fitting into following.
cable bracket. CAUTION Slider must not be ad
justed before or during assembly to bracket. 1. Remove pump rod from lever assembly, depress and
hold metal lock tab.
3. Install cable terminal to lever assembly.
2. Move slider through fitting in direction away from lever
4. Rotate the lever assembly to its full throttle stop position assembly until slider stops against fitting.
to automatically adjust slider on cable to correct setting.
3. Release metal lock tab.
5. Release lever assembly & reconnect the pump rod to
lever assembly. 4. Repeat steps 4 & 5 of adjustment procedure.
LIGHT T R U C K SE R V IC E M A N U A L
A U T O M A T IC TR A N SM IS S IO N 7 A -1 5
2. IN S T A L L CABLE T E R M IN A L TO CARBURETOR
LEVER.
3. O P E N C A R B U R E T O R L E V E R T O “FU LL T H R O T T LE
S T O P ” P O S IT IO N TO A U T O M A T IC A L L Y A D JU S T
S L ID E R O N C A B L E TO C O R R E C T SET T IN G .
CAUTION L O C K T A B M U S T NO T B E D E
P R E S S E D D U R IN G T H IS O P E R A T IO N .
4. R E L E A S E C A R B U R E T O R LE V E R .
D IA G N O S IS
Oil leaks around the engine and transm ission are FLUID PRESSURE CHECK
generally carried tow ard the rear of the vehicle by air W hile vehicle is stationary (service brake ON), engine
stream. F or example, a transm ission oil filler tube to case speed set to 1200 rpm, transm ission oil pressure gage
leak will sometimes appear as a leak at the rear of the attached as shown in Fig. 7A-10B, and vacuum m odulator
transmission. In determ ining the source of a leak, proceed tube disconnected , the transm ission line pressure tap
as follows: should read 167 psi (1152 kPa) in Drive(D), 166 psi (1145
1. Degrease underside of transmission. kPa) in LI or L2, and 254 psi (1752 kPa) in reverse.
2. Road test to get unit at operating tem perature. While vehicle is stationary (service brake ON), engine
3. Inspect for leak with engine running. speed set to m aintain 12 in. hg. (39 kPa) absolute manifold
pressure, transm ission oil pressure gage attached, and
4. W ith engine O F F, check for oil leaks due to the
vacuum m odulator tube connected , the transmission line
raised oil level caused by drain back.
pressure tap should read 85 psi (586 kPa) in D R IV E (D),
Possible Points of Oil Leak 105 psi (724 kPa) in LI or L2, and 129 psi (890 kPa) in
1. Transmission Oil Pan Leak. reverse.
a. A ttaching bolts not correctly torqued. CASE POROSITY REPAIR
b. Im properly installed or damaged pan gasket. External oil leaks caused by case porosity can be
c. Oil pan gasket m ounting face not flat. successfully repaired with the transm ission in the vehicle by
using the following recom m ended procedures:
2. Extension Housing.
1. Road test and bring the transm ission to operating
a. A ttaching bolts not correctly torqued. tem perature, approxim ately 180°F (82°C).
b. R ear seal assembly damaged or im properly installed. 2. Raise vehicle on a hoist or jack stand, engine
c. Square seal, extension to case, damaged or running, and locate source of oil leak. Check for oil leaks
improperly installed. in Low(L), D rive(D ), and Reverse(R).
d. Porous casting. Refer to Subparagraph C. 3. Shut engine off and thoroughly clean area to be
3. Case Leak. repaired with a suitable cleaning solvent and a brush and
a. Filler pipe seal dam aged or missing; misposition of air dry.
filler pipe bracket to engine. A clean, dry soldering acid brush can be used to clean
b. M odulator assembly "O" ring seal damaged or the area and also to apply the epoxy cement.
im properly installed. 4. Using instructions of the m anufacturer, mix a
c. D etent cable connector seal dam aged or improperly sufficient am ount of epoxy to m ake the repair. M ake certain
installed. the area to be repaired is fully covered.
5. Allow cement to cure for 3 hours before starting
d. G overnor cover not tight.
engine.
e. Speedometer gear "O" ring damaged.
6. R oad test and check for leaks.
f. M anual shaft seal dam aged or im properly installed.
g. Line pressure tap plug loose. VACUUM MODULATOR DIAGNOSIS
A defective vacuum m odulator can cause one or more
h. Vent pipe (refer to item 5).
of the following complaints.
i. Porous casting. Refer to Subparagraph C.
1. H arsh upshifts and downshifts.
4. Leak at F ro n t of Transmission. 2. Delayed upshifts.
a. F ront pum p seal leaks. 3. Soft upshifts and downshifts.
1. Seal lip cut. Check converter hub, etc. 4. Slips in Low(L), D rive(D ) and Reverse(R).
2. Bushing moved and damaged, Oil return hole 5. Transmission overheating.
plugged. 6. Engine burning transm ission oil.
3. No oil return hole. If any one of the above com plaints are encountered, the
b. F ront pum p attaching bolts loose or bolt washer m odulator must be checked.
type seals dam aged or missing.
Vacuum Diaphragm Leak Check
c. F ront pum p housing "O" ring damaged or cut.
Insert a pipe cleaner into the vacuum connector pipe
d. Converter leak in weld area.
as far as possible and check for the presence of transmission
e. Porous casting (pump). oil. If oil is found, replace the m odulator.
5. Oil Comes O ut Vent Pipe. Gasoline or w ater vapor may settle in the vacuum side
a. Transm ission overfilled. of the m odulator. If this is found w ithout the presence of
b. W ater in oil. oil, the m odulator is serviceable and should not be changed.
c. Foreign m aterial between pum p and case or between Atmospheric Leak Check
pump cover and body.
Apply a liberal coating of soap bubble solution to the
d. Case - porous near converter bosses. F ront pum p vacuum connector pipe seam, the crim ped upper to lower
cover or housing oil channels shy or stock near breather. housing seam (Fig. 7A-8). Using a short piece of rubber
See Subparagraph C. tubing, apply air pressure to the vacuum pipe by blowing
e. Pum p to case gasket mispositioned. into the tube and observe for leak bubbles. If bubbles appear,
replace the m odulator.
LIGHT T R U C K SE R V IC E M A N U A L
AU TO M A TIC TRAN SM ISSIO N 7A -17
Low L1 Range
Position the selector lever in LI range and accelerate
the vehicle from 0 mph (0 k m /h). No upshift should occur
in this range.
COOLER O il TO
2ND Gear - Overrun Braking: (L2)
RADIATOR
Position the selector lever in D R IV E R A N G E , and
with the vehicle speed at approxim ately 35 m ph (56 k m /h ),
1-2 CLUTCH COOLER OIL FROM
(INTERMEDIATE) RADIATOR
move the selector lever to L2 R A N G E. The transmission
PRESSURE TAP should downshift to 2nd. An increase in engine R PM and
an engine braking effect should be noticed. Line pressure
should change from approxim ately 100 psi (690 kPa) to
DETENT CONTROL approxim ately 125 psi (875 kPa) in 2nd.
VALVE WIRE HOLE
LIGHT T R U C K SE R V IC E M A N U A L
A U TO M A TIC TRAN SM IS S IO N 7A-19
L2 ON Locked ON O FF ON O FF F r e e - W h e e lin g
LIG HT T R U C K SE R V IC E M A N U A L
PROBLEM
CAR R O A D TEST
LEGEND
X -P R O B LE M AREA VS CA US E
* —@ " O " VACUUM ONLY
O -B A L L S / #2/3/4 ONLY
L-LO C K E D
S-STUCK
PO SS IB LE CA US E
L O W O I L L E V E L / W A T E R IN O IL
VACUUM LEAK
M O D ULA TO R & /O R VALVE
S T R A IN E R & /O R GASKET
G O V E R N O R - V A LV E /S C R E E N
V A L V E B O D Y -G A S K E T /PLAT E
PRES R E G . & / O R BOOS T V A L V E
BALL (# 1 ) SHY
1-2 S H I F T V A L V E
2 -3 S H I F T V A L V E
M A N U A L LOW C O N T 'L VALVE
D E TE N T V A L V E & LIN K AG E
D E T E N T REG. V A L V E
2-3 A C C U M U L A T O R _________
M A N U A L V A L V E /L IN K A G E
AUTOMATIC TRANSMISSION
PO RO SITY/CROSS LEAK
P U M P —G E A R S
P R I M I N G V A L V E SH Y
COOLER V A LVE LEAK
C L U T C H S E A L R IN G S
PO RO U S /C R O S S L E A K
G A S K E T SCREEN-PRESSURE
B A N D - I N T E R M . O.R.
C A S E -P O R O U S /X LEAK
1 2 ACCUMULATOR
IN T E R M E D . SERVO
F O R W A R D C L U T C H ASS Y
D I R E C T C L U T C H ASS Y
I N T E R M E D . C L . A S S 'Y
L & R E V . C L . A S S 'Y
I N T . R O L L E R C L . ASS Y
L. & R. R O L L E R C L . AS S' Y
PA RK P A W L /L IN K A G E
C O N V E R T E R A S S' Y
G E A R SE T & B E A R I N G S
7A-23
7A-24
AUTOMATIC TRANSMISSION
[COOLER IN;
[COOLER OUT;
COOLER
CONV APPLY!
INTERM EDIATE CLUTCH
LUBE ACCUMULATOR
Fig. 7 A -13 -3 5 0
PUMP PRESSURE!
conv r e l:
CONV F D l MOD
zn 23 c l :
REVZ
d r iv e ;
Circuit - TCC
DRIVE
GOVERNOR
M ANUAL VALVE ;MOD OR DET
SWITCH ASM SCREEN
SUMP PRESSURE
Applied
DRIVE
2 3 SHIFT VALVE
d r iv e ;
MODULATOR
1 2 SERVO:
A U T O M A T IC TRAN SM IS S IO N 7A-25
ON V EH IC LE S E R V IC E
TRANSMISSION REPLACEMENT 12. Remove transm ission to engine mounting bolts and
remove oil filler tube at transmission.
(All Except K Model) 13. Raise transmission to its norm al position, support
If necessary, the catalytic converter may have to be engine with jack and slide transmission rearw ard from
disconnected to provide adequate clearance for transmission engine and lower it away from vehicle.
removal. This procedure will include removal of the Use suitable converter holding tool when lowering
converter support bracket. transm ission or keep rear of transmission lower than front
1. Before raising the vehicle, disconnect the negative so as not to lose converter.
battery cable detent downshift cable at carburetor and
The installation of the transmission is the reverse of the
release the parking brake.
removal with the following added step. Before installing the
2. Raise vehicle on hoist. flexplate-to-converter bolts, make certain that the attaching
3. Remove propeller shaft. lugs on the converter are flush with the flex plate and the
4. D isconnect speedometer cable, detent downshift converter rotates freely by hand in this position. Refer to
cable, m odulator vacuum line and oil cooler pipes at Fig. 7A-14 for instructions on attaching the converter-to-
transm ission. flexplate. This will insure proper converter alignment.
5. Disconnect shift control linkage. After installation of transmission, lower vehicle and
remove vehicle from hoist. Check linkage for proper
6. Support transm ission with suitable transmission
adjustm ent.
jack.
Check transmission fluid level.
7. Disconnect rear m ount from frame crossmember.
8. Remove two bolts at each end of frame TRANSMISSION REPLACEMENT (K MODEL)
crossmember. Remove crossmember.
1. Disconnect battery cable.
9. Remove converter under pan.
2. Remove transm ission dipstick.
10. Remove converter-to-flexplate bolts, as shown in
Fig. 7A-14. 3. Disconnect detent downshift cable at carburetor.
11. Lower transmission until jack is barely supporting 4. Remove transfer case shift lever knob and boot.
it. 5. Raise vehicle on hoist.
LIG HT TRU CK SE R V IC E M A N U A L
7A-26 A U T O M A T IC TRAN SM IS S IO N
6. Remove flexplate cover. Fig. 7A-1 6—In stallin g Oil Se a l into Extension H o u sin g
7. Remove torque converter to flexplate attaching
bolts. Refer to Fig. 7A-14. Secure the converter.
8. D isconnect transm ission shift linkage and 29. Refill transfer case. Reverse removal procedure to
speedometer cable. install.
9. Remove engine crossunder pipe to m anifold bolts. E X T E N S IO N H O U S IN G O IL S E A L
10. Disconnect vacuum m odulator line, line to filler Removal
tube clip and detent downshift cable to filler tube strap. 1. Remove propeller shaft.
11. Disconnect detent downshift cable at the 2. Pry out lip oil seal with screwdriver or small chisel.
transmission.
Installation
12. D isconnect transm ission oil cooler lines at the 1. Drive a new oil seal into place with Installer J-
transmission. 21426, as shown in Fig. 7A-16.
13. Remove transfer case adapter to crossm em ber bolts. 2. Install propeller shaft and adjust fluid level.
W hen applicable, disconnect engine-to-transmission
support strut rod from transmission. Refer to Fig. 7A-22. S P E E D O M E T E R D R IV E N G E A R
14. Raise engine as necessary. Removal
15. Remove crossm em ber bolts and remove 1. D isconnect speedometer cable.
crossmember. 2. Remove retainer bolt, retainer, speedometer driven
16. Remove exhaust system hanger bolts. gear and O-ring seal.
17. D isconnect rear propeller shaft at transfer case. Installation
Installation of speedometer driven gear is the reverse
18. D isconnect parking brake cable.
of REM O V A L. Install new O-ring seal (if required) and
19. Disconnect exhaust system. (Tie aside.) adjust the fluid level.
20. Disconnect front propeller shaft at front axle. (Tie
S P E E D O M E T E R D R IV E G E A R
aside.)
21. Support transm ission and transfer case w ith jack Removal
(use safety chains). 1. Raise vehicle and support transm ission with
22. Remove transfer case to fram e bracket bolts. suitable transm ission jack.
2. Remove propeller shaft.
23. Remove transm ission to engine bolts, remove
3. D isconnect speedometer cable.
transm ission and transfer case.
4. D isconnect transm ission rear m ount from frame
24. D isconnect transfer case-to-transm ission strut rod.
crossmember.
Remove transfer case from transm ission (includes: new "O"
5. Remove two bolts at each end of frame cross
ring seal). Refer to Fig. 7A-15.
member and remove crossmember.
25. Move transm ission to bench fixture.
6. Remove extension housing.
26. D rain transmission. 7. Install Special Tools J-2 1427-01 and J-8105 on
27. Remove torque converter. output shaft and remove speedom eter drive gear. Remove
28. Remove and discard front pum p seal. retaining clip.
LIGHT T R U C K SE R V IC E M A N U A L
A U T O M A T IC TRAN SM IS S IO N 7A-27
MANUAL SHAFT TO
CASE RETAINER
SCREWDRIVER
LEVER AND PARKING LINKAGE ASSEMBLIES 1. Raise vehicle and disconnect speedometer cable at
transmission.
Removal
2. Remove governor cover, as shown in Fig. 7A-18.
1. Refering to draining procedures, drain transmission
fluid from oil pan.
NOTICE: Be careful not to damage cover.
2. A fter oil pan and strainer have been removed,
remove valve body assembly. D iscard gaskets.
3. Remove governor. Inspect weights and valve for
3. Remove manual shaft-to-case retainer and unthread
freeness.
jam nut holding range selector inner lever to m anual shaft.
Refer to Fig. 7A-17. In s ta lla tio n
4. Remove jam nut and remove m anual shaft from 1. Install governor.
range selector inner lever and case. 2. Apply anerobic sealant to cover, then install
Do not remove m anual shaft lip oil seal unless governor cover using a brass drift around the outside flange
replacem ent is required. of the cover.
5. Remove parking pawl actuating rod and range
selector inner lever from case. NOTICE: Do not distort cover on installation.
6. Remove bolts and parking lock bracket.
7. Remove parking pawl disengaging spring and, if 3. Install a retainer wire.
necessary to replace parking pawl or shaft, clean up bore
in case and remove parking pawl shaft retaining plug, park NOTICE: Be sure to install a bail wire retainer, to
pawl shaft and pawl. prevent loss of cover, which could result in damage to
the transmission.
LIG HT TRU CK SE R V IC E M A N U A L
7A-28 A U T O M A T IC TRAN SM IS S IO N
GOVERNOR
PRESSURE
SWITCH SERVO
TORQUE
n * CONVERTER
O ” R IN G SEAL
SOLENOID
SWITCH
iX B £ J A
VA C U U M MODULATO R AUXILIARY VALVE BODY
MAIN 'ELECTRICAL
VALVE
CONNECTOR
BODY
Fig. 7 A -1 9 ~ R e m o v in g V a cu u m M o d u la to r
Fig. 7A -2 0 ~ D e te n t S p r in g /V a lv e B o d y
Removal
1. Refering to draining procedures, drain transm ission
fluid from oil pan.
2. A fter oil pan and strainer, have been removed,
discard gaskets.
3. Remove detent spring and roller assembly from
valve body and remove valve body-to-case bolts. Refer to
Fig. 7A-20.
4. Remove valve body assembly while disconnecting
m anual control valve link from range selector inner lever
and removing detent control valve link from the detent
actuating lever.
5. Remove m anual valve and link assembly from valve
body assembly. Fig. 7 A -2 1 -In te rm e d ia te Clutch A ccu m u la to r Com ponents
L IGHT T R U C K SE R V IC E M A N U A L
A U T O M A T IC TRAN SM IS S IO N 7A-29
4 0 0 A U T O M A T IC T R A N S M IS S IO N
INDEX
G E N E R A L D E S C R IP T IO N
The 400 autom atic transm ission is a fully autom atic gear set produces three forward speeds and reverse.
unit consisting prim arily of a 3-element hydraulic torque The 3-element torque converter consists of a pum p or
converter and a com pound planetary gear set. Three driving member, a turbine or driven member, and a stator
m ultiple-disc clutches, one gear unit, one roller clutch, and assembly. The stator is m ounted on a one-way roller clutch
two bands provide the friction elements required to obtain which will allow the stator to turn clockwise but not
the desired function of the com pound planetary gear set. counter-clockwise.
The torque converter couples the engine to the The torque converter housing is filled with oil and is
planetary gears through oil and provides hydraulic torque attached to the engine crankshaft by a flexplate and always
m ultiplication when required. The com pound planetary rotates at engine speed. The converter pum p is an integral
LIGHT T R U C K SE R V IC E M A N U A L
7A-30 A U T O M A T IC TRAN SM IS S IO N
part of the converter housing, therefore the pum p blades, 12 Volt Electrical - To operate an electrical detent
rotating at engine speed, set the oil within the converter into solenoid.
motion and direct it to the turbine, causing the turbine to A vacuum m odulator is used to automatically sense
rotate. any change in the torque input to the transmission. The
As the oil passes through the turbine it is traveling in vacuum m odulator transm its this signal to the pressure
such a direction that if it were not redirected by the stator regulator for line pressure control, to the 1-2 accum ulator
it would hit the rear o f the converter pum p blades and valve, and to the shift valves so th at all torque requirem ents
impede its pum ping action. So at low turbine speeds, the oil of the transm ission are met and sm ooth shifts are obtained
is redirected by the stator to the converter pum p in such a at all throttle openings.
m anner th at it actually assists the converter pum p to deliver The detent solenoid is activated by an electric switch
power or m ultiply engine torque. on the carburetor. W hen the throttle is fully opened, the
As turbine speed increases, the direction of the oil switch on the carburetor is closed, activating the detent
leaving the turbine changes and flows against the rear side solenoid and causing the transm ission to downshift for
of the stator vanes in a clockwise direction. Since the stator passing speeds.
is now impeding the sm ooth flow of oil, its roller clutch The selector quadrant has six selector positions: P, R,
releases and it revolves freely on its shaft. Once the stator N, D, L2, L I.
becomes inactive, there is no further m ultiplication of P. P A R K position positively locks the output shaft to
engine torque w ithin the converter. A t this point, the the transm ission case by means of a locking pawl to prevent
converter is merely acting as a fluid coupling as both the the vehicle from rolling in either direction (not on CL
converter pum p and turbine are being driven at model). The engine may be started in Park position.
approxim ately the same speed or at one-to-one ratio. R. REV ERSE enables the vehicle to be operated in a
A hydraulic system pressurized by a gear type pum p reverse direction.
provides the working pressure required to operate the N. N eutral postion enables the engine to be started and
friction elements and autom atic controls. run w ithout driving the vehicle.
External control connections to transm ission are: D. D R IV E Range is used for all norm al driving
conditions and maxim um economy. Drive Range has three
M anual Linkage - To select the desired operating
gear ratios, from the starting ratio to direct drive. Detent
range.
downshifts are available by depressing the accelerator to the
Engine Vacuum - To operate a vacuum m odulator unit. floor.
LIGHT TR U C K SER VIC E M A N U A L
A U T O M A T IC T R A N SM IS S IO N 7A-31
L2. L2 Range has the same starting ration as Drive L I. L I Range can be selected at any vehicle speed, and
Range, but prevents the transm ission from shifting ration the transm ission will shift to second gear and rem ain in
when extra perform ance is desired. L2 Range can also be second until vehicle is reduced to approxim ately 40 M PH
used for engine braking. L2 Range can be selected at any (60 km /h ), depending on axle ratio. L I Range position
vehicle speed, and the transmission will shift to second gear prevents the transm ission from shifting out of first gear.
and remain in second until the vehicle speed or the throttle
are changed to obtain first gear operation in the same NOTICE: It is very im portant that any
m anner as in D Range. com m unication concerning the transm ission always
contain the transm ission code and vehicle
identification number.
M A IN T E N A N C E A N D A D J U S T M E N T S
Fig. 7A-3 1~Dipstick M arkings If fluid is too low, especially when cold, complete loss
of drive may result which can cause transm ission failure.
LIGHT TR U C K SE R V IC E M A N U A L
7A-32 A U T O M A T IC TRAN SM ISSIO N
PLUNGER
PLUNGER
TRANSMISSION
CONTROL
SWITCH
P30 ( 42 ) SERIES
PLUNGER
CK SERIES P30
D IA G N O S IS
M inim um M axim um
1st D rive
2nd
3rd ( “ Z e ro ” th r o ttle to fu ll th r o t t l e .................................. ................ 60 150
Drive, N eutral,
Park Li or L2 Reverse Drive, N eutral, Park LI or L2 Reverse
Fig. 7 A -3 6 ~ F lu id Pressure C h e c k - V eh icle Stationary, Fig. 7A-37--Fluid Pressure C h eck - V e iic le Stationary,
V a cu u m T ub e D iscon n e cted V a c u u m T ub e Connected
LIGHT T R U C K SE R V IC E M A N U A L
7A-36 A U TO M A TIC TRAN SM ISSIO N
COMPARISON
GAUGE
1 RYv
\
J
i j -j
o r i u
HOLD MODULATORS IN A HORIZONTAL POSITION,
AS SHOWN,
BRING THEM SLOWLY TOGETHER UNDER PRESSURE
MANUAL LINKAGE • Low oil level - check for external leaks or defective
vacuum m odulator (leaking diaphragm will evacuate oil
M anual linkage adjustm ent and the associated neutral
from unit).
safety switch are im portant from a safety standpoint. The
neutral safety switch should be adjusted so th at the engine • M anual linkage m aladjusted (correct alignment in
will start in the Park (P) and N eutral (N) positions only. m anual lever shift quadrant is essential); m anual valve
W ith the selector lever in the P ark position, the parking disconnected from m anual lever pin.
pawl should freely engage and prevent the vehicle from • Low oil pressure - refer to LOW L IN E PRESSU RE
rolling. The pointer on the indicator quadrant should line below.
up properly with the range indicators in all ranges.
Fig. 7A-39--Bellows Com parison Gage Fig. 7A-4 1--M odulator B ellow s - Bad
LIGHT TR U C K SE R V IC E M A N U A L
A U T O M A T IC TR A N SM IS S IO N 7A-37
First and Second Speeds Only, No 2-3 Shift Slips in all Ranges, Slips on Start
• D etent solenoid - stuck open (detent shifts only - the (Install pressure gage)
2-3 shift would occur at very high speeds, being interpreted • Low fluid level.
as no 2-3 shift). • Oil pressure - Refer to LOW L IN E PRESSURE.
• D etent switch. • Case - cross leaks, porosity.
• Control valve: • Forw ard and direct clutches slipping (if burnt, Refer
a. 2-3 valve train stuck. to B U R N E D C LU TC H PLA TE); oil seal rings on pum p
b. Valve body gaskets leaking, damaged, incorrectly cover broken or worn.
installed. Slips 1-2 Shift
• D irect clutch:
(Install pressure gage)
a. Center support oil rings missing, broken, defective.
• Low fluid level.
b. C lutch piston seals missing, im properly assembled,
• Oil pressure - Refer to LOW L IN E PRESSU RE.
cut; piston ball check stuck or missing.
• F ront accum ulator piston oil ring dam aged or
Drive in Neutral missing.
• M anual linkage m aladjusted. • C ontrol valve:
• Internal Linkage: a. 1-2 accum ulator valve train sticking.
a. M anual valve disconnected or end broken. b. Porosity in valve body or case.
b. Inside detent lever pin broken. c. Valve body attaching bolts not properly torqued.
• Pum p Assembly - transm ission lube pressure leaking • R ear accum ulator oil ring missing or damaged; case
into forward clutch apply passage. bore damaged.
• Forw ard Clutch: • Pum p-to-case gasket mispositioned.
a. Burned plates - check cause. • Case:
b. C lutch doesn’t release - will also cause no drive in a. Interm ediate clutch cup plug leaks excessively.
Reverse. b. Porosity between channels.
No Drive in Reverse or Slips in Reverse c. Raised ridge around case center support bolt (does
not allow control valve assembly to seat properly).
(Install pressure gage)
• Interm ediate clutch:
• Low fluid level.
a. Piston seals missing or damaged; clutch plates burnt
• M anual linkage m aladjusted. (Refer to B U R N E D C L U T C H PLATES).
• Oil pressure - refer to LOW L IN E PR E SSU R E b. Center support - leak in feed circuit (oil rings
above. damaged or grooves defective), excessive leak between tower
• Control valve: and bushing, orifice bleed plug hole (0.020 dia.) blocked,
a. Valve body gaskets leaking, damaged, incorrectly center support bolt not seated properly in case.
installed (O ther m alfunctions may also be indicated).
Rough 1-2 Shift
b. Low reverse ball check missing from case (this will
also cause no overrun braking in L I Range). (Install pressure gage)
c. 2-3 valve train stuck open (this will also cause 1-3 • Oil pressure - Refer to H IG H L IN E PRESSURE.
upshift in Drive range). • Control valve:
d. Reverse feed passage restricted; also check case a. 1-2 accum ulator valve train.
passages. b. Valve body-to-case bolts loose.
• R ear servo and accum ulator: c. W rong gaskets or off location, damaged.
LIGHT T R U C K SE R V IC E M A N U A L
A U T O M A T IC TR A N SM IS S IO N 7A-39
a. G ears dam aged or defective; driving gear installed • Interm ediate Clutch:
backwards. a. C onstant bleed orifice in center support missing.
b. Crescent interference. b. R ear accum ulator piston oil ring damaged or
c. Oil seal rings dam aged or worn. missing.
• Converter: c. 1-2 accum ulator valve stuck in control valve
a. Loose flexplate-to-converter bolts. assembly.
b. Dam aged converter. d. Interm ediate clutch piston seals damaged or missing.
e. Center support bolt loose.
F irs t, S ec o n d a n d /o r R e v e rs e G e a rs
f. Low line pressure (Refer to LOW L IN E
Planetary G ear Set: PRESSURE).
a. G ears or th ru st bearings damaged. g. Interm ediate clutch cup plug in case missing.
b. F ront internal gear ring damaged. h. Transm ission case valve body face not flat or
D u rin g A c c e le ra tio n - A n y G e a r porosity between channels.
• Transm ission or cooler lines grounded to underbody. i. M anual valve bent and center land not ground
properly.
• M otor m ounts loose or broken.
• D irect Clutch:
S q u e a l a t L o w V e h ic le S p ee d a. R estricted orifice in vacuum line to m odulator (poor
Speedometer driven gear shaft seal - requires vacuum response).
lubrication or replacement. b. Check ball in clutch piston damaged, stuck or
missing.
Burned Clutch Plates
c. Defective m odulator bellows.
• Forw ard clutch:
d. C enter support bolt loose (bolt may be tight in
a. Check ball in clutch drum damaged, stuck or support but not holding support tight to the case).
missing. e. Center support oil rings or grooves damaged or
b. C lutch piston cracked, seals dam aged or missing. missing.
c. Low line pressure (Refer to LOW L IN E f. C lutch piston cracked, seals damaged or missing.
PRESSU RE). g. F ront and rear servo pistons a n d /o r seals damaged.
d. M anual valve mispositioned (may also cause front h. 3-2 valve, 3-2 valve spring or 3-2 spacer pin installed
band failure). in wrong location in 3-2 valve train bore.
e. R estricted oil feed to forward clutch (clutch housing i. M anual valve bent and center land not ground
to inner and outer areas not drilled, restricted, porosity in properly.
pump, etc.). j. Transm ission case valve body not flat or porosity
f. Transm ission case valve body face not flat or porosity between channels.
between channels. k. Interm ediate roller clutch installed backwards.
g. M anual valve bent and center land not ground • In addition, burned clutch plates can be caused by
properly. incorrect usage of clutch plates. Also, anti-freeze in
h. Pum p cover oil seal rings missing, broken or transmission fluid can cause severe damaged, such as large
undersize, ring groove oversize. pieces of clutch plate material peeling off.
LIGHT T R U C K SE R V IC E M A N U A L
A U T O M A T IC TRAN SM IS S IO N 7A-41
LIGHT T R U C K SE R V IC E M A N U A L
7A-42
AUTOMATIC TRANSMISSION
M A IN L IN E PRESSURE
INTAKE PRESSURE
CONVERTER PRESSURE I 1
G O VE R N O R PRESSURE I 1
M O D U LA TO R PRESSURE [Z ^ l
DETENT PRESSURE CZZI
1 -2 A C C UM ULA TO R PRESSURE 1 1
Fig. 7A-44--400
Hydraulic
Circuit
A U T O M A T IC TR A N SM IS S IO N 7A-43
ON V EH IC LE S E R V IC E
TRANSMISSION REPLACEMENT 11. Remove transm ission to engine m ounting bolts and
If necessary, the catalytic converter may have to be remove oil filler tube at transmission.
disconnected to provide adequate clearance for transm ission 12. Raise transm ission to its norm al position, support
removal. This procedure will include removal of the engine with jack and slide transmission rearw ard from
converter support bracket. engine and lower it away from vehicle.
LIGHT T R U C K SER V IC E M A N U A L
7A-44 A U T O M A T IC TRAN SM ISSIO N
GOVERNOR C O N T R O L VALVE
PIPES A SS Y .
G O V E R N O R SCREEN
A SSY.
G O V E R N O R FEED
PIPE H O L E
The following steps should be com pleted unless part PRESSURE REGULATOR VALVE
replacem ent is required.
Rem oval
8. Remove parking pawl shaft retainer.
1. Remove bottom pan and filter.
9. Remove parking pawl shaft, cup plug parking pawl 2. Compress regulator boost valve bushing against
shaft, and parking pawl.
pressure regulator spring and remove snap ring, using J-
In s ta lla tio n 5403 pliers.
Installation of the parking linkage is the reverse of the 3. Remove regulator boost valve bushing and valve.
removal. Use new seal and cup plug, if removed, and new 4. Remove pressure regulator spring.
bottom pan gasket. 5. Remove spring retainer, washer spacer(s) if present,
CONTROL VALVE BODY and regulator valve.
In s ta lla tio n
Rem oval
A solid type pressure regulator valve m ust only be used
1. Remove bottom pan and filter.
in a pum p cover with a squared-off pressure regulator boss
2. Disconnect lead wire from pressure switch (Refer to Figure 7A-51). A pressure regulator valve with oil
assembly. holes and orifice cup plug may be used to service either type
3. Remove control valve body attaching screws and pump.
detent roller spring assembly. Installation of the pressure regulator valve is the
Do not remove solenoid attaching screws. reverse of the removal. Install new gasket on oil pan and
adjust fluid level.
NOTICE: If the transm ission is in the vehicle, the front
servo parts may drop out as the control valve assembly
is removed.
LIGHT TR U C K SE R V IC E M A N U A L
A U T O M A T IC TR A N SM IS S IO N 7A-47
SPECIFICATIONS
350 C (MV4)
P u m p C o v e r to P u m p B o d y .............................................. ____23 N- m . . . .1 7 f t. lb .
P u m p A sse m b ly to C a s e .................................................. . . . . 24 N- m . .1 8 .5 f t. lb .
V alv e Body and A u x ilia ry V alve Body . . . . 14 N- m . ..1 3 0 in . lb .
P a rk in g L o c k B r a c k e t „. .................................................. ____39 N- m . . . .2 9 f t. lb .
..........4 N- m . ...4 0 in . lb .
O il P a n to C a s e ..................................................................... . . . . 14 N- m . ..1 3 0 in . lb .
E x te n sio n to C a s e ............ ................................................. . . . . 33 N- m . ...2 5 ft. lb .
M o d u la to r R e ta in e r to C a s e ........................................... . . . . 14 N* m . ...3 0 in . lb .
In n e r S e le c to r L e v e r to S h a ft............ ............................ ....3 3 N- m . ...2 5 ft. lb .
D e te n t V alv e A ctu atin g B r a c k e t .................................... ..........6 N- m . ...5 2 in . lb .
C o n v e r te r to F ly w h e e l B o lts ......................................... . . . . 47 N- m . ...3 5 f t. lb .
U n d er P a n to T r a n s m is s io n C a s e ............................... ___ 12 N- m . . .1 1 0 in . lb .
T r a n s m i s s i o n C a s e to E n g in e ......................................... ....4 7 N- m . ...3 5 ft. lb .
O il C o o le r P ip e C o n n e c to rs to T r a n s m is s io n
C a s e o r R a d i a t o r ............................................................ ____14 N- m . ..1 2 5 in . lb .
O il C o o le r P ip e to C o n n e c to r s ...................................... ..........13 N- m . ...1 0 f t. lb .
D e te n t C ab le to T r a n s m i s s i o n ................... .................. ..........8 N* m . ...7 5 in . lb .
D e te n t C a b le to C a r b ......................................................... . . . . 12 N- m . ..1 1 2 in . lb .
S o len o id A s s e m b l y .............................................................. ..........4 N* ____3 f t. lb .
G o v e rn o r P r e s s u r e S w itc h .............................................. . . . . 10 N- ___ 8 ft. lb .
400 (AMO)
........ 24 N- m . . . . 1 8 f t. lb .
..........24 N- m . . . .1 8 ft. lb .
____29 N- m . . . . 2 3 f t. lb .
P u m p to C a s e A tta c h in g B o l t s ...................................... ..........24 N* m . . . .1 8 f t. lb .
E x te n s io n H o u sin g to C a s e A ttac h in g B o lts ............ . . .23 f t. lb .
..........24 N- m . . . . 1 8 f t. lb .
............ 9 N. ____7 ft. lb .
C o n tro l V a lv e Body B o l t s ................................................ ..........10 N- ____8 f t. lb .
B o tto m P a n A tta c h in g S c r e w s ....................................... ..........14 N- m . . . . 1 2 f t. lb .
..........24 N* m . . . . 1 8 f t. lb .
..........24 N- m . . . . 1 8 ft. lb .
M an u al L e v e r to M an u al S haft N u t ............................. ..........10 N- 8 ft. lb .
M an u al S h aft to In s id e D e te n t L e v e r ........................... ..........24 N- m . . . . 1 8 ft. lb .
L in k a g e S w iv el C la m p N u t .............................................. ..........57 N- m . . . .4 3 ft. lb .
C o n v e r te r D u s t S h ield S c r e w s ...................................... ___ 124 N* m . . . . 9 3 ft. lb .
T r a n s m i s s i o n to E n g in e M ounting B o l t s ................. ..........47 N- m . . . . 3 5 ft. lb .
C o n v e r te r to F ly w h e e l B o l t s ......................................... ..........47 N* m . . . .3 5 ft. lb .
R e a r M ount to T r a n s m i s s io n B o l t s ............................. ..........54 N- m . . . . 4 0 ft. lb .
R e a r M ount to C r o s s m e m b e r B o lt . ........................... ..........54 N- m . . . . 4 0 ft. lb .
C r o s s m e m b e r M o u n tin g B o l t s ....................................... ..........32 N- m . . . . 2 5 ft. lb .
O il C o o le r L i n e ..................................................................... ..........13 N* m . . . . 1 0 ft. lb .
L in e P r e s s u r e T a k e -O ff P l u g ....................................... ..........17 N* m . . . . 1 3 ft. lb .
S t r a i n e r R e ta in e r B o l t ..................................................... ..........13 N- m . . . . 1 0 ft. lb .
O il C o o le r P ip e C o n n e c to rs to T r a n s m is s io n
C a s e o r R a d ia to r .............................................................. .......... 14 N* m . ..1 2 5 in. lb .
O il C o o le r P ip e to C o n n e c to r ......................................... .......... 1 N* m . . . . 1 0 in . lb .
D o w n sh ift S w itch to B r a c k e t........................................... ............ 2 N- m . . . . 2 2 in . lb .
LIGHT TR U C K SE R V IC E M A N U A L
7A-48 A U T O M A T IC TRAN SM IS S IO N
S P E C IA L T O O LS
1. J-8763-02 Transmission Holding Fixture 14. J-21424-7 Stator Shaft Front Bushing
(Used with J-3289-20 Base) Installer (Used with J-8092)
2. J-3289-20 Transmission Holding Fixture 15. J-23062-5 Input Ring Gear Bushing
Base Remover and Installer
3. J-8092 Driver Handle (Threaded type) 16. J-5154 or Extension Housing Oil Seal
4. J-21465-13 Driver Handle Extension (Used with J-8092) J-21426 Installer
5. J-23062-3 Sun Gear and Reaction Carrier 17. J-21359 Pump Oil Seal Installer
Bushing 18. J-7004 Slide Hammers (Pair) (Ear
6. J-23062-7 Output Shaft Bushing Installer Pump Body removal) (3 /8 " x 16 tread)
7. J-21465-15 Stator Shaft Front Bushing 19. J-21885 2-3 Accum ulator Piston
Remover (Used with J-8092) Compressor
8. J-23329 Direct Clutch Bushing Installer 20. J-23069 Intermediate Accum ulator Cover
9. J-9534-01 Output Shaft Bushing Remover * Remover and Installer
10. J-23327 Clutch Spring Compressor 21. J-2619-01 Slide Hammer (5 /8 " x 18
11. J-23062-2 Stator Shaft Rear Bushing with 1/2" x 13 Adapter)
Installer (Both Rear) Not Illustrated
12. J-23062-1 Case Bushing Remover and Installer
J-21369 Converter Pressure Check
13. J-21424-9 Extension Housing Bushing Remover and
Fixture
Installer (Used with J-8092)
J-8001 Dial Indicator Set
(.001" Increments, .001" Travel)
1. J-8763 Transm ission H old in g Fixture 11. J-21664 C lu tch S p rin g C om pressor
2 . J-3289-14 H o ld in g Fixture Base A dapter R in g
3. J-21427-1 Speedo Gear Rem over 12. J-4670 C lu tch S p rin g C om pressor
4. J-9539 Sid e H am m er B o lts (3 /8 " - 16 13. J-8059 Sn a p R in g Pliers
Threads) 14. J-5586 S n a p R in g Pliers
5. J-8105 Speedo Gear Rem over Puller 15. J-5403 Sn a p R in g Pliers
6 . J-22269-01 A cc u m u la to r Piston Rem over and Installer 16. J 1313 T orqu e W rench 0-140 Ft. Lbs.
7. J-21369 Converter Pressure Check Fixture Not Illustrated
8 . J-21362 Seal Protector - Forw ard and J-24684 Pressure Regulator
Direct Clu tch - Inner Valve C om pressor
9. J-21363 Seal Protector - Interm ediate J-24675 A c c u m u la to r Piston A dapter
C lu tch - Inner (Used w ith J-22269-01)
10. J-21409 Seal Protector - Forw ard Clu tch - Outer
SECTION 7B
MANUAL TRANSMISSION
CONTENTS
GENERAL DESCRIPTION
THREE-SPEED TRANSMISSIONS synchronizer keys. The synchronizer hubs are splined to the
m ainshaft and retained by snap rings. These assemblies
perm it gears to be selected w ithout clashing,by synchroniz
3-Speed 76mm ing the speeds of m ating parts before they engage.
In the 76mm unit, the driven gear, second speed gear,
3-Speed 77mm first speed gear and reverse gear are rigidly connected to the
M anual transmissions are designated according to: (A) countergear. In the 77mm transm ission, only the driven
the num ber of forward gears, and (B) the m easured distance gear, second speed gear and first speed gear are rigidly
between centerlines of the m ainshaft and the countergear. connected to the countergear. The engine driven clutch gear
The three speed synchrom esh transm issions (Figs. 7B-1 drives the countergear through a constant mesh counter
through 7B-3) are representative of a constant-m esh tran s shaft driven gear. The countergear rotates in a direction
mission design. Fundam ental components of these units are opposite, or counter, to the rotation of the clutch gear.
the case, which houses the gears and shaft; the shift control Forward speed gears on the countergear rem ain in constant
mechanism and the various shafts and gears. The input mesh with two nonsliding m ainshaft gears giving first and
shaft has an integral main drive gear and rotates with the second speed. T hird speed is a direct drive with the clutch
clutch driven plate; th at is, the shaft rotates all the tim e the gear engaged directly to the m ainshaft. Forward gears are
clutch is engaged and the engine is running. The input shaft engaged through two sliding synchronizer sleeves m ounted
is supported in the case by a ball bearing and at the front end on the m ainshaft. E ngagem ent of the co n stant mesh
by an oil im pregnated bushing m ounted in the engine m ainshaft gears to the m ainshaft is accomplished through
crankshaft. The drive gear is in constant mesh with the blocker ring-type synchronizers.
countershaft drive gear. Since all gears in the countershaft
cluster are integral to the shaft, they also rotate at the time FOUR-SPEED TRANSMISSION
the clutch is engaged. The countergear is carried on roller
bearings at both ends and thrust is absorbed by thrust 4-Speed 89mm
washers located between the countergear and thrust bosses The four speed transm ission with overdrive has an
in the case. The transm ission m ainshaft is held in line with 89mm center distance and is designed to combine normal
the input shaft by a pilot bearing at its front end, which perform ance in the city with improved fuel economy on the
allows it to rotate or come to rest independently of the input highway. G ear ratios are: first 3.09 to 1; second 1.67 to 1;
shaft. In the 76mm unit, the m ainshaft is carried at the rear third 1.00 to 1; fourth (overdrive) 0.73 to 1. All forward
by a ball bearing m ounted in the front face of the extension gears are fully synchronized. The synchronizer assemblies
housing. In the 77mm unit, the m ainshaft is carried at the consist of a hub, sleeve, two key springs and three synchro
rear by a ball bearing m ounted in the rear face of the case. nizer keys. T he synchronizer hubs are splined to the
Helical gears are incorporated throughout, except for m ainshaft and retained by snap rings. These assemblies
reverse gear in the 77 mm transm ission. The m ainshaft perm it gears to be selected w ithout clashing, by synchroniz
gears are free to rotate independently on the m ainshaft and ing the speeds of m ating parts before they engage.
are in co n stan t mesh w ith the c o u n te rsh a ft gears. The The drive pinion (input shaft) is supported by a ball
reverse idler gear is carried on a bushing, finish bored in bearing in the transm ission case and an oil im pregnated
place, and thrust is taken on the thru st bosses of the case. bushing pressed in the end of the crankshaft.
The transm issions are fully synchronized in all forward The m ainshaft front end is supported by roller bearings
speeds; how ever, reverse gear is not. T he synchronizer in the end of the main drive pinion and a ball bearing in the
assemblies consist of a hub, sleeve, two key springs and three front of the extension housing. T he o u tput end of the
LIGHT T R U C K SE R V IC E M A N U A L
7B-2 MANUAL TRANSMISSIONS
m ainshaft is splined to the sliding universal joint yoke, with the second speed synchronizer sleeve. Second, third and
which is supported by a bushing in the extension housing. fourth gears are synchronized. The clutch gear is supported
The countershaft gear is supported by a double row of by a heavy duty ball bearing. T he forward end of the
needle type roller bearings at each end and the thrust is m ainshaft is supported by a loose collar-type bearing inside
taken on thrust washers between the ends of the gear and the the clutch gear, while the rear is carried on a ball bearing in
transmission case. The alignm ent of the needle type roller the case. End play is taken up by the rear flange retaining
bearings within the gear is m aintained by a tubular spacer in nut. The countergear is supported at the rear by a single row
the center and four thrust washers (one being used between ball bearing which takes the thrust load, and by a roller
the rows of roller bearings and one at each end). The bearing at the front. Incorporated in the cover is a ball pin
countershaft is not a press fit in the case bores, but has .005 type interlock which prevents sim ultaneous engagem ent of
inch diam eter clearance. An expansion plug is pressed into a two gears. As one rod is moved, it pushes a ball out that
counter bore at the front of the case to prevent oil leakage engages the other two rods to prevent their movement.
around the countershaft.
G earshift levers on m anual transm issions are located
The reverse idler gear is supported on a bronze bushing, either on the steering column or on the floorboard. R egard
pressed into the gear. A m agnetic disc is attached to bottom, less of location, the lever perform s two operations: It selects
near rear of case under countershaft gear. This m agnet the gear assembly to be moved, and moves it either forward
collects and prevents circulation of chips in transm ission oil. or backw ard into the desired gear position. The transmission
action is the same w hether a floor-type shift lever or a
4-Speed 117mm steering column shift lever is used. W hen the shift lever is
The 117mm, Model C H 465 truck transm ission (Fig. moved, the m ovem ent is carried by linkage to the
7B-4 and 7B-5) uses a constant mesh first gear th at engages transmission.
LIGHT T R U C K S E R V IC E M A N U A L
MANUAL TRANSMISSIONS 7B-3
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
30 31 32 33 34 35 36 37 38 39 40
1. Clutch Gear 15. Reverse Gear Thrust and Spring Washers 28. Snap R in g— Bearing to Extension
2. Bearing Retainer 16. Snap R ing— Bearing to Mainshaft 29. Rear Bearing
3. Pilot Bearings 17. Extension 30. Countegear Roller Bearings
4. Case 18. Vent 31. Anti-Lash Plate Assembly
5. 3rd Speed Blocker Ring 19. Speedometer Drive Gear and Clip 32. Magnet
6. 2-3 Synch. Snap Ring 20. Mainshaft 33. 2-3 Synch. Sleeve
7. 2-3 Synch. Hub 21. Rear Oil Seal 34. Countergear
8. 2nd Speed Blocker Ring 22. Retainer Oil Seal 35. Counter Shaft
9. 2nd Speed Gear 23. Snap R in g— Bearing to Gear 36. Reverse Idler Shaft
10. 1st Speed Gear 24. Clutch Gear Bearing 37. 1st Speed Synch. Sleeve
11. 1st Speed Blocker Ring 25. Snap R ing— Bearing to Case 38. " E ” Ring
12. 1st Speed Synch. Hub 26. Thrust Washer— Front 39. Reverse Idler Gear
13. 1st Speed Synch. Snap Ring 27. Thrust Washer— Rear 40. W oodruff Key
14. Reverse Gear
LIGH T T R U C K SE R V IC E M A N U A L
7B-4 MANUAL TRANSMISSIONS
1. Thrust W asher - Front 19. 3rd Speed Blocker 33. 1-2 Synchronizer Hub 47. Gasket
2 Bearing W asher Ring Assembly 48. 2-3 S hift Fork
3. Needle Bearings 20 "E " Ring 34. 1-2 Synchronizer 49 1st and Reverse Shift
4. Countergear 21. Reverse Idler Gear Sleeve Fork
5. Needle Bearings 22 Reverse Idler Shaft 35 Snap Ring - Hub to 50. 2-3 S hifter Shaft
6 Bearing W ahser 23. W oodruff Key Shaft Assembly
7 Thrust W asher - Rear 24. Snap Ring - Hub to 36 Reverse Gear 51 1st and Reverse
8 Counter Shaft Shaft 37. Thrust Washer Shifter Shaft
9 W o o d ru ff Key 25 2-3 Synchronizer 38 Spring Washer Assembly
10 Bearing Retainer Sleeve 39 Rear Bearing 52 ” 0 " Ring Seal
11. Gasket 26 Synchronizer Key 40. Snap Ring - Bearing 53 "E " Ring
12. Oil Seal Spring to Shaft 54 Spring
13 Snap Ring - Bearing 27. 2-3 Synchronizer Hub 41. Speedometer Drive 55 2nd and 3rd Detent
to Case Assembly Gear Cam
14. Snap Ring - Bearing 28 2nd Speed Blocker 42. Retaining Clip 56 1st and Reverse
to Gear Ring 43 Gasket Detent Cam
15. Drive Gear Bearing 29 2nd Speed Gear 44. Snap Ring - Rear 57. Side Cover
16 Case 30. Mainshaft Bearing to Extension 58 TCS Switch and
17. Drive Gear 31. 1st Speed Gear 45. Extension Gasket
18 Pilot Bearings 32 1st Speed Blocker 46. Oil Seal 59 Lip Seal
Ring
LIGHT T R U C K S E R V IC E M A N U A L
MANUAL TRANSMISSIONS 7B-5
LIG H T T R U C K S E R V IC E M ANU AL
1. D riv e G e a r B earin g Retainer 12. 1st & 2n d S peed Clutch Assy 23 . Reverse Id le r G e a r Bushing
2. Seal 13. Stop Ring 24. Reverse Id le r S h a ft
3. S n ap Ring 14. First G e a r 25. S n ap Ring
4. D riv e G e a r B earing 15. R ear M a in B earin g 26. W o o d ru ff Key
5. D riv e G e a r 16. Extension Housing 27. Thrust W a s h e r
6. Stop Ring 17. V e n t Plug 28. C o u n te rs h a ft Roller B earings
7. 3 rd & O / D Speed Clutch Assy 1 8. M a in s h a ft 29. C o u n te rs h a ft
8. Stop Ring 1 9. R e tain e r C lip 30. C o u n te rs h a ft G e a r
9. O v e rd riv e G e a r 20. S p e e d o m e te r G e a r 31. C o u n te rs h a ft S leeve
10. Second G e a r 21. R ear O il Seal 32. Expansion Plug
1 1. Stop Ring 22. Reverse Id le r G e a r 33. S n ap Ring
34 . D riv e G e a r Roller B earings
MANUAL TRANSMISSIONS 7B-7
34 33 32 31 30
1. Main Drive Gear 1 1. Reverse Driven Gear 24 M ainsh a ft Rear 37. Front C ountershaft
2 Drive Gear Bearing 12. Poppet Spring Bearing Bearing
Retainer 13. Poppet Ball 25 Rear Bearing Snap 38, C ountergear Front
3 Snap Ring-Outer 14 S h ift Rail Ring Cover
4. 3rd and 4th 15. 1st and 2nd S hift 26. Snap Ring 39 Pilot Bearing Rollers
Synchronizer Ring Fork 27. C ountershaft 40. Clutch Gear Oil
5. 3rd and 4th 16. 1st Speed Gear 28. C ountershaft Rear Slinger
Synchronizer Collar 17. T hrust W asher Bearing 41. Snap Ring
6. 3rd and 4th S hift 18. Bearing Snap Ring 29. Bearing Snap Ring 42. 3rd Speed Gear
Fork 19. Speedom eter Drive 30. Reverse Idler Gear Bushing
7. 3rd and 4th Speed Gear 31. Reverse id le r Shaft 43. T hrust W asher
S ynchronizer Ring 20. O utput Yoke 32, Case M agnet 44. 2nd Speed Gear
8. 3rd Speed Gear 21. Flange Nut 33 Spacer Bushing
9, 2nd Speed Gear 22. Rear Bearing 34. C ountergear 45. 1st Speed Gear
10. 1st and 2nd Retainer Oil Seal 35. T hrust W asher Bushing
Synchronizer 23. Rear Bearing 36. Snap Ring
Assem bly Retainer
LIG H T T R U C K S E R V IC E M AN U AL
7B-8
1
MANUAL TRANSMISSIONS
Fig. 7B-6--4-Speed
117mm, Exploded
View
1. Drive Gear Bearing 13. 1st-2nd Speed 26. 2nd Speed Gear 37. Snap Ring 48. Rear Retainer
Retainer Synchronizer Hub 27. 3rd Gear Bushing 38. Snap Ring 49. Retainer Bolts
2. Retainer Gasket 14. Synchronizer Keys 28. Thrust Washer 39. Thrust Washer 50. Retainer Lip Seal
3. Lip Seal 15. Synchronizer Spring 29. 3rd Speed Gear 40. Clutch Countergear 51. Reverse Idler Shaft
4. Snap Ring 16. Reverse Driven Gear 30. 3rd Speed Blocker 41. Spacer 52. Drain Plug
5. Drive Gear Bearing 17. 1st Gear Bushing Ring 42. 3rd Speed 53. Reverse Idler Gear
6. O il SI in ger 18. 1st Gear 31. Synchronizer Spring Countergear 54. Case
7. Drive Gear and Pilot 19. Thrust Washer 32, Synchronizer Keys 43. Countergear Shaft 55. Fill Plug
Bearings 20. Rear Main Bearing 33. 3rd-4th Synchronizer 44. Countergear Rear 56. Countergear Front
8. Power Take-O ff Cover 21. Bearing Snap Ring Hub Bearing Bearing
Gasket 22. Speedometer Gear 34 Synchronizer Spring 45. Snap Ring 57. Gasket
9. Power Take-O ff Cover 23. Rear Mainshaft Lock 35. 3rd-4th Speed 46. Bearing Outer Snap 58. Front Cover
10. Retaining Screws N ut Blocker Ring Ring 59. Cover Screws
11. 1st-2nd Speed 24. 2nd Speed Bushing 36. 3rd-4th Speed 47. Rear Retainer Gasket
Blocker Rmg (On Shaft) Synchronizer Sleeve
12. Synchronizer Spring 25. Mainshaft
MANUAL TRANSMISSIONS 7B-9
LIGH T T R U C K S E R V IC E M AN U AL
7B-10
MANUAL TRANSMISSIONS
S H IF T L E V E R H
S H IF T LEVER J RELA Y LEVER K
ROD F
COLUM N CONTROL
R E T A IN E R LEVER A
ROD G
G A G E P IN
S H IF T L E V E R H TRANS LEVER B
Fig. 7B-8--C
ROD F
BO LT C
and
S W IV E L D
K-Truck
Column
Set Levers (A ) and (B ) in " R E V E R S E " p o sitio n a n d tu rn ign itio n sw itch to " L O C K " p o sitio n . NOTE O b ta in
R E V E R S E " p o sitio n by m o vin g T ra n s Lever (B ) c lo c k w ise to fo rw a rd detent.
2. A tta c h R o d (G ) to S h ift Lever (J) w ith retainer. See V ie w A . S lid e sw ivel (D ) o n to R o d (G ). Insert Sw iv e l (D )
into Lever (B ) and lo ose ly asse m bly w ith b o lt (C ) a n d w asher at th is tim e.
3. R e m o ve c o lu m n " L A S H " by rotatin g Lever (J) in a d o w n w a r d d ire c tio n and c o m p le te a tta c h m e n t o f R o d (G ) to
Lever (B ) by tig h te n in g B o lt (C) u sin g re c o m m e n d e d torque.
4. T u rn ign itio n key to " U N L O C K " p o sitio n an d p o sitio n Levers (A ), (B ) an d (E ) in " N E U T R A L " . NOTE O b ta in
" N E U T R A L " p o sitio n by m o vin g Levers (B ) and (E ) c lo c k w ise to fo rw a rd detent then c o u n te r-c lo ck w ise o n e detent.
5. A lig n gage holes in Levers (H), (J) an d (K ) and insert G a ge Pin (L ).
NOTE W ith sh ift lever in " R E V E R S E " the ign itio n key m u st m ove freely to " L O C K " p o sitio n . It m u st n ot be p ossib le
to o b ta in ig n itio n " L O C K " p o sitio n in " N E U T R A L " or a n y gear o th e r tha n " R E V E R S E " .
MANUAL TRANSMISSIONS 7 B -1 1
DIAGNOSIS
Preliminary Inspection 2. Disengage the clutch, wait nine seconds and shift the
transmission to reverse. No grinding noise should be
Before attempting to repair the clutch, transmission or heard. A grinding noise indicates incorrect clutch
related linkages for any reason other than an obvious adjustment, lost motion clutch misalignment, or inter
failure, the problem and probable cause should be identified. nal problems such as failed dampers, facings, cushion
A large percentage of clutch and m anual transmission springs, diaphragm spring fingers, pressure plate drive
problems are manifested by shifting difficulties such as high straps, etc.
shift effort, gear clash and grinding or transmission block-
out. When any of these problems occur a careful analysis of
these difficulties should be accomplished, and the following SHIFT LINKAGE ADJUSTMENT
checks and adjustments performed in the presented se
quence before removing the clutch or transmission for Steering Column Shift Control
repairs. 1. Remove the shift control rods from the column levers.
2. Check shift effort at the shift control lever knob. (Effort
CLUTCH ADJUSTMENT should not exceed 2 lb. with transmission linkage
removed.)
Clutch Free Pedal Travel
1. The clutch free pedal travel adjustment should be made 3. If binding is felt, refer to the adjustment procedure for
the steering column lower bearing in Section 3B.
as outlined in Section 7C.
2. Check clutch linkage for lost motion caused by loose or 4. Lubricate all rod and swivel connections and recheck
worn swivels, deflection of mounting brackets or shift effort after installation.
damaged cordon shaft. 5. If shift linkage is free from binding, the column levers
should be checked for end play. A .005" feeler gauge
Clutch Spin Down Time should fit between the levers and control lever.
1. Run the engine at a normal idle with transmission in 6. Connect control rods and check steering column control
neutral and clutch engaged. levers for alignment. In neutral, the column control
LIG H T T R U C K S E R V IC E M AN U AL
7B-12 MANUAL TRANSMISSIONS
S H IFT T O R Q U E 3 -S P D — 76m m
In ch -P oun ds 50
LIGHT T R U C K SER V IC E M A N U A L
MANUAL TRANSMISSIONS 7B-13
High Shift Effort-Column Shift Binding of column levers Adjust column mechanism per Section 3B
(Effort exceeds 2 ft. lbs. at Steering of the Chassis Service Manual
lever knob with transmission
linkage disconnected.) Clean and lubricate all rod and swivel
connections.
Gear Clash and binding Improper linkage Adjustment Adjust Shift linkage
Lost motion Loose or worn swivels and grommets. Replace defective parts
Deflection of Mounting Brackets.
Loose shift levers.
Damaged Cordon Shaft
LIGH T T R U C K S E R V IC E M A N U A L
7B-14 MANUAL TRANSMISSIONS
Slips out of High Gear a. Transmission loose on clutch housing a. Tighten mounting bolts
b. Shift rods interfere with engine b. Replace or bend levers and rods to
mounts or clutch throw-out lever eliminate interference
c. Shift linkage does not work freely; c. Adjust and free up shift linkage
binds
d. Damaged mainshaft pilot bearing d. Replace pilot bearing
e. Main drive gear retainer broken or e. Tighten or replace main drive gear
loose
f. Dirt between transmission case and f. Clean mating surfaces
and clutch housing
g. Misalignment of transmission g. Refer to TRANSMISSION
ALIGNMENT
h. Stiff shift lever seal h. Replace seal
i. Pilot bearing loose in crankshaft i. See Section 6 for brg. fits
j. Worn or improperly adjusted linkage j. Adjust or replace linkage as required
Noisy in High Gear a. Damaged main drive gear bearing a. Replace damaged bearing
b. Damaged mainshaft bearing b. Replace damaged bearing
c. Damaged high speed gear synchronizer c. Replace synchronizer
Noisy in Neutral with Engine a. Damaged main drive gear bearing a. Replace damaged bearing
Running b. Damaged or loose mainshaft pilot b. Replace pilot bearings. See Section 6
bearing for bearing fits
c. Worn or damaged countergear anti c. Replace countergear
lash plate
d. Worn countergear bearings d. Replace countergear bearings and shaft
Noisy in Third Only (Four a. Damaged or worn third-speed constant a. Replace damaged gears
Speed) mesh gears
b. Worn or damaged countergear bearings b. Replace damaged countergear bearings
and shaft
Fig. 7 B -1 2 -M a n u a l Transmission D iagn osis C hart A
LIGH T T R U C K SER V IC E M AN U AL
MANUAL TRANSMISSIONS 7B-15
Main Drive Gear Bearing a. Loose or damaged mainshaft pilot a. Replace b taring. See Section 6 for
Retainer Burned or Scored bearing bearing fit
by Input Shaft b. Misalignment of transmission b. Align transmission
COMPONENT REPLACEMENT
TRANSMISSION REPLACEMENT On vehicle equipped with 4-Speed ( 1 17mm) transm is
sion, remove the gearshift lever using Tool J-8109 as
3-Speed and 4-Speed Transmission Removal shown in Fig. 7B-15. Press down firmly and rotate tool
counterclockwise to release gearshift lever.
(Except K Series) Place clean lint-free cloth or other suitable covering
over opening on transm ission to prevent entry of dirt of
1. Raise vehicle on suitable hoist and drain lubricant from foreign m aterial.
transm ission.
2. Disconnect speedom eter cable. 4. Disconnect parking brake lever and controls (when
3. Remove shift controls from transm ission. used) and back up lam p switch wire.
LIGH T T R U C K SE R V IC E M ANU AL
7B-16 MANUAL TRANSMISSIONS
5. Disconnect propeller shaft from transmission as de 8. R econnect speedom eter cable to a d a p te r at
scribed in Section 4A. transmission.
6. Position a suitable dolly or jack under the vehicle and 9. Reinstall shift controls on transmission.
adjust to carry the weight of the transmission. On vehicles equipped with a 3-speed transmission and 4
7. Visually inspect to determine if other equipment, lines speed 89mm reconnect shift levers to transmission side
or brackets must be removed to permit removal of the cover. On vehicles equipped with a 4-Speed, 117mm
transmission. Remove crossmember. transm ission, install gearshift lever using Tool J-8109
as shown in Fig. 7B-15. Press down firmly and rotate
NOTICE: Be sure to support the clutch release bearing
clockwise to install gearshift lever. Install transmission
and support assembly during removal of the transmis
floor pan cover and floor mat.
sion main drive gear from the flywheel housing. This
will prevent the release bearing from falling out of the 10. If other equipm ent (exhaust pipe, support brackets,
flywheel housing when the transmission is removed. etc.) was removed, reinstall these parts.
8. Remove transm ission-to-clutch housing mounting 11. Refill transm ission with lu b ric an t recom m ended in
bolts. Section 0-B of this m anual.
12. If necessary, ad just clutch or transm ission control
C A U T IO N rW h en rem oving the transmission, do
linkage to achieve proper transm ission operation.
not a llo w th e w e ig h t of th e transmission to hang
on the clutch disc hub, as th e disc m a y become
distorted, seriously affecting clutch o peration.
3-Speed Transmission - "K" Series
9. Move the transmission assembly straight away from Removal and Installation
the engine, using care to keep the transmission main 1. Raise vehicle on hoist.
drive gear shaft in alignment with the clutch disc hub. 2. Drain transfer case and transm ission. Disconnect the
Refer to Fig. 7B-14. speedom eter cable from speedom eter driven gear
10. When the transmission is free from the engine, lower fitting.
the transmission and move from under the vehicle. 3. Disconnect propeller shaft front U-joint yoke a t case,
11. If desired, a careful check of clutch components should and tie up out of way.
be made after the transmission has been removed. If 4. Remove bolt holding the shift lever control assembly to
the clutch requires repair, refer to Section 7C before the adapter assembly. Remove shift lever rod from
transmission is reinstalled in the vehicle. transfer case shift rail connector link. Push assembly to
one side and tie up out of way.
3-Speed and 4-Speed Transmission Installation
5. Remove the bolts attaching the strut to the right-hand
(Except K Series) side of the transfer case and also to the engine rear face.
1. Apply a light coating of high temperature grease to the Remove the strut.
main drive gear bearing retainer and splined portion of 6. Support transfer case in a suitable cradle. Remove bolts
transmission main drive gear shaft to assure free attaching transfer case to adapter, and remove the
movement of clutch and transmission components transfer case.
during assembly. 7. Disconnect shift control rods from the shifter levers at
NOTICE: Do not apply an excessive amount of grease in
the transmission.
the above areas, as under normal operation this grease 8. Support rear portion of engine. Remove two (2)
could be thrown onto clutch facings resulting in clutch adapter m ount bolts.
problems. 9. Remove the 2 top transm ission to clutch housing cap
2. Shift the transmission into high gear. Mount transmis screws and insert 2 transm ission guide pins, Tool
sion on dolly or jack and move into position under the J -l 126 in these holes.
vehicle. 10. Remove the 2 lower transm ission-to-clutch housing cap
Avoid springing the clutch when the transmission is screws.
being installed to the engine. Do not force the transmis 11. Slide the transmission and adapter assembly straight
sion into the clutch disc hub. Do not let the transmis back on guide pins until the clutch gear is free of splines
sion hang unsupported in the splined portion of the in the clutch disc.
clutch disc. The use of the 2 guide pins during this operation will
3. Align the transmission main drive gear shaft with the support the transmission and prevent dam age to the
clutch disc hub by rotating the transmission companion clutch disc through springing.
flange or output yoke. Move the transmission forward, 12. Remove the transm ission and adapter as an assembly
guiding the main drive gear shaft into the clutch disc from under the body.
splines. 13. Remove adapter from transm ission.
4. Install transmission-to-clutch housing mounting bolts 14. To install, reverse removal procedure.
and washers. Tighten bolts to specifications.
5. Install crossmember. 4-Speed Transmission Removal
6. Connect propeller shaft to transmission as described in
Section 4A. Remove transmission jack. K Series
7. Connect parking brake lever and control (if used). 1. Remove attaching screws from transfer case shift lever
Adjust brakes as outlined in Section 5. boot retainer and remove retainer.
LIGHT T R U C K SER V IC E M A N U A L
MANUAL TRANSMISSIONS 7B-17
2. Remove attaching screws from transm ission shift lever 10. Install heater distributor duct center outlet.
boot retainer. Slide boot and retainer up lever and On models with center console, install console and
remove transm ission shift lever using Tool J-8109 as retaining bolts.
shown in Fig. 7B-15.
11. Install floor mat, transfer case shift lever retainer and
3. Remove floor m at or carpeting from com partm ent. attaching screws.
4. If necessary, remove center floor outlet from heater
12. Install transmission shift lever, boot and retainer.
distributor duct. If equipped with a center console,
remove console before proceeding to next step.
5. Remove transmission floor cover attaching screws and
TRANSMISSION ALIGNMENT
cover. R otate cover approxim ately 90° to clear transfer In some instances where excessive gear whine or high
case shift lever while lifting cover from vehicle. gear hop out, particularly at 50 mph (80 km/h) and up, are
6. Disconnect shift lever rod assembly from transfer case encountered, and after all other probable causes have been
shift rail connecting link. checked, an alignment check of the transmission and clutch
7. Remove shift lever attaching bolt and shift lever control housing may be helpful.
from adapter. A special tool, on which a dial indicator is mounted, is
8. Raise and support vehicle on hoist. Support engine with necessary to check the transmission case rear bore align
suitable floor stand. Drain transfer case and transm is ment. This tool may be made from a new or good used clutch
sion assemblies. gear which has a good bearing surface on the crankshaft
9. Disconnect speedom eter cable from transfer case. pilot end and at the front main bearing location.
10. Disconnect prop shaft at rear of transfer case and tie up The splines on the clutch gear shaft and the teeth on the
away from work area. clutch gear should be ground off so the shaft may be rotated
in a clutch disc hub without interference when assembled in
11. Disconnect front prop shaft from transfer case and tie
the car. Weld a piece of 1/4 in. (6.3m m) rod in the
up away from work area.
mainshaft pilot bore long enough to extend out the case rear
12. Open lock tabs and remove transm ission m ount-to- bore. Assemble a good bearing on the clutch gear shaft and
fram e crossmem ber bolts. secure it with the clutch gear bearing snap ring. Attach a
13. Support transm ission and transfer case assembly with suitable dial indicator to the rod.
suitable floor stand.
1. Remove the transmission from the vehicle and com
14. Remove fram e to crossm em ber bolts and remove pletely disassemble, except for the reverse idler gear.
crossm em ber from vehicle. R o tate crossm em ber to
In any case where the clutch gear pilot or pilot bearing
clear fram e rails.
is excessively loose or worn, the pilot bearing should be
15. On V-8 engine models, remove exhaust crossover pipe. replaced before checking the transmission case rear
16. Remove transm ission to clutch housing attaching bolts. bore alignment by the dial indicator method.
Remove upper bolts first and install transm ission guide
2. Carefully install the special tool with the dial indicator
pins J -l 126. Use of the guide pins will prevent dam age
in the transmission case with the face of the indicator to
to the clutch assembly.
the rear of the case and with the tracing finger
17. Slide transm ission rearw ard until m ain drive gear contacting the I.D. of the case rear bore. Secure in
clears the clutch assembly and lower assembly from place with a clutch gear bearing retainer.
vehicle.
3. Assemble the transmission case to the clutch housing
4-Speed Transmission Installation and tighten the four transm ission mounting bolts
securely.
K Series Be sure to clean off any paint or other foreign material
1. Position transm ission, with transfer case attached, to on the mating faces of the clutch housing and transmis
the clutch housing. Install bolts attaching transmission sion as any foreign material on these faces will change
to clutch housing. alignment; also, check carefully for dings or burrs on
these m ating surfaces and remove carefully as
2. On V-8 models, install exhaust crossover pipe.
necessary.
3. Position fram e crossm em ber and install retaining bolts.
Install bolts retaining adapter assem bly to crossm em 4. Dial indicate the transmission case rear bore and
ber and transfer case to fram e rail bracket. Torque all record the indicator readings in the 12, 3, 6 and 9
bolts to specification. o'clock positions.
4. Torque front and rear transfer case yoke lock nuts to It is best to start the reading at the 3, 6, 9 or 12 o’clock
specifications. position closest to the point where the indicator plunger
reaches its m axim um outward travel. Set the dial
5. Install front and rear propshafts to transfer case output
indicator at " 0 " at this location and then record the 3,
yokes.
6, 9 and 12 o’clock readings in rotation.
6. Connect the speedom eter cable.
5. Install temporary slotted shims between the transmis
7. Fill transmission and transfer case to proper level with sion case and the clutch housing in the quantities and at
lubricant specified in Section OB.
the bolt locations as necessary to bring misalignment at
8. Install transfer case shift lever assem bly and attaching the transmission case rear bore to a miximum of 0.005
bolt. C onnect shift lever rod to shift rail connector link. in. indicator reading in either the vertical or horizontal
9. Install transm ission floor cover and attaching bolts. direction.
LIGH T T R U C K SE R V IC E M ANU AL
7B -18 MANUAL TRANSMISSIONS
E X A M PL E: If the maximum indicator reading is at b. Disconnect speedometer cable and remove speedom
the 12 o’clock position, put shims on the two bottom eter driven gear from m ainshaft rear bearing
bolts. retainer.
6. After the position and quanity of shims has been c. Using flange or yoke holding tool, remove the output
determined and recorded the transmission case may be yoke or companion flange nut. Pull output yoke or
removed. companion flange nut off the mainshaft.
NOTICE: The clutch housing should then be stamped, d. Support transmission while removing mounting bolts
showing the position where shims are to be installed and bearing retainer. Remove mainshaft rear bear
and the thickness of shims at each location. ing retainer and gasket. Discard gasket.
7. Inspect the external clutching teeth of the clutch gear e. Remove oil seal from rear bearing cap. Discard oil
and second speed gear. Inspect the second and third seal.
speed clutch internal clutching teeth. If the teeth are f. Coat outer diameter of new oil seal with sealing
worn or tapered, even slightly, the gears should be cement. Install oil seal in rear bearing cup using a
replaced. Reassemble the transmission. suitable installer. Drive seal flush with outside of rear
8. Install the transmission assembly to the clutch housing, bearing cap, being careful not to damage seal. Use
using the correct num ber of shims at the proper Installer J-22834 with A d a p te r J-22834-1 as re
locations as previously determined. Shims are available quired, as shown in Fig. 7B-16.
by unit part number with each unit consisting of the
following shims: g. Clean all gasket surfaces, then install the rear
4 - .0 0 2 " shims Identification-two corners cut off. bearing cap with a new gasket on the transmission.
2--.005" shims Identification-one corner cut off. Tighten cap screws firmly.
1- .0 1 0 " shims Identification-all corners square. h. Install output yoke or companion flange on main
These special shims have a tab on one end for ease of shaft. Using a flange or yoke holding tool install
installation. Do not slot the shims for the permanent retaining nut. Torque the retaining nut to
installation. specification.
i. Install speedometer driven gear, then connect speed
REAR OIL SEAL REPLACEMENT ometer cable.
1. Drain lubricant from transmission. 5. Reconnect propeller shaft to transmission as described
2. Disconnect propeller shaft from transmission as de in Section 4A.
scribed in Section 4A. 6. Refill transmission with lubricant recom mended in
3. On 3-speed transmissions and 4-speed 89mm, perform Section 0B. *
the following replacement procedures:
a. Remove slip joint yoke from rear of transmission SPEEDOMETER DRIVEN GEAR REPLACEMENT
mainshaft. 1. Disconnect speedometer cable, then remove lock plate
to housing bolt and lock washer and remove lock plate.
b. Pry seal out of extension housing or remove oil seal
Insert screw driver in lock plate slot in fitting and pry
using oil seal remover (J-5859) and slide hammer (J-
fitting, gear and shaft from housing. Pry " O " ring from
2619) as shown in Fig. 7B-16.
groove in fitting.
c. Coat outer diameter of new oil seal with sealing
2. Install new " O " ring in groove in fitting, coat " O " ring
cement. Install new oil seal using extension housing
and driven gear shaft with transmission lubricant and
oil seal installer (J-5154).
insert shaft.
d. Install slip joint yoke on rear of transmission
3. Hold the assembly so slot in fitting is toward lock plate
mainshaft.
boss on housing and install in housing. Push fitting into
J-22834-1
NOTE PARKING
BRAKE M O U N T IN G
FLANGE
J- 22834-2
ONLY
LIGHT T R U C K S E R V IC E M ANU AL
MANUAL TRANSMISSIONS 7B-19
5. Remove detent cam spring and pivot retainer " C " ring.
Remove both detent cams.
DETENT C A M
DETENT SP R IN G
6. With detent spring tang projecting up over the 2nd and
CAM
3rd shifter shaft cover opening, install the first and
reverse detent cam onto the detent cam pivot pin. With
the detent spring tang projecting up over the first and
reverse shifter shaft cover hole install the 2nd and 3rd
detent cam.
7. Install detent cam retaining " C " ring to pivot shaft,
and hook spring into detent cam notches.
8. Install both shifter shaft assemblies in cover being
2 -3 SHIFT careful not to damage seals. Install both shift forks to
FORK
shifter shaft assemblies, lifting up on detent cam to
allow forks to fully seat into position.
9. Install outer shifter levers, flat washers, lock washers
and bolts.
1ST & REV. 2 -3 SHIFTER SHAFT
SHIFT FORK 10. Shift shifter levers into neutral detent (center) position
SHIFTER SHAFT
DETENT C A M
and slide cover into place making sure the shift forks
RETAINER R IN G are aligned with their respective m ainshaft clutch
sliding sleeves.
Fig. 7 B - 1 8--Transmission Sid e Cover Assem bly 11. Install cover a tta c hing bolts and tighten evenly to
housing until lock plate can be inserted in groove and specified torque, then connect wiring.
attached to housing. 12. Remove filler plug and add lubricant specified in
Section OB to level of filler plug hole.
TRANSMISSION SIDE COVER
Replacement/Repair (Fig. 7B-17) TRANSMISSION FLOOR SHIFT CONTROL LEVER
REPLACEMENT (4 SPEED) 1 17mm
1. Disconnect control rods from levers and back-up lamp 1. On K-Series models, remove transfer case shift lever
wiring. boot retainer atta c h in g screws and retainer from
2. Shift transmission into neutral detent positions before compartment floor.
removing cover. Remove cover assembly from trans 2. Remove floor covering from vehicle.
mission case carefully and allow oil to drain. 3. Remove transmission shift lever boot retainer attaching
3. Remove the outer shifter levers. screws.
4. Remove both shift forks from shifter shaft assemblies. 4. Slide boot and retainer up on shift lever and remove the
Remove both shifter shaft assemblies from cover. Seals transmission shift lever using Tool J-8109 as shown in
around shifter shaft may now be pried out if replace Fig. 7B-14.
ment is required because of damage. 5. To install, reverse removal procedure Steps 1-4.
L IG H T T R U C K S E R V IC E M AN U AL
7B-20 MANUAL TRANSMISSIONS
SPECIFICATIONS
THREE-SPEED 76mm
THREE-SPEED 77mm
C lu tc h G e a r R e ta in e r to C a s e B o l t s .......................................47 N* m . . . . 35 ft. lb .
T op C o v e r to C a s e B o l t s .............................................................. 40 N *m . . . . 3 0 ft. lb .
E x te n s io n to C a s e B o l t s .................................................................61 N* m . . . . 45 ft. lb .
S h ift L e v e r to S h ifte r Sh aft B o lts ..............................................32 N* m . . . . 25 ft. lb .
L u b r ic a tio n F i l l e r P lu g . . . . . . ...................................................20 N • m . . . . 15 ft. lb .
T r a n s m i s s i o n C a s e to C lu tc h H o u sin g B o l t s ................... 101 N- m . . . . 75 ft. lb .
C r o s s m e m b e r to F r a m e N u ts ..................................................... 32 N - m . . . .25 ft. lb .
C r o s s m e m b e r to M ount B o l ts ..................................................... 54 N* m . . . . 4 0 ft. lb .
2 -3 C r o s s O v e r Sh aft B r a c k e t R e ta in in g N u t......................24 N- m . . . . 18 ft. lb .
1 -R e v . S w ivel A ttach in g B o l t ..................................................... 27 N- m . . . . 20 ft. lb .
M ount to T r a n s m i s s i o n B o l t ....................................................... 68 N* m . . . . 50 ft. lb.
LIGHT T R U C K S E R V IC E M ANU AL
MANUAL TRANSMISSIONS 7B-21
SPECIAL TOOLS
14-16
LIGHT T R U C K S E R V IC E M ANU AL
MANUAL TRANSMISSIONS 7B-23
L IG H T T R U C K S E R V IC E M AN U AL
: .ic. j rr
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S E C T IO N 7 C
CLUTCH
INDEX
G E N ER A L D E SC R IP T IO N
D R IV E N PLATE A S S Y .
PRESSURE PLATE
C LUTCH H O U S IN G A N D COVER ASSY.
COVER
C L U T C H RELEASE B E A R IN G
C LU TC H FORK
C LUTCH H O U S IN G
C LU TC H FO RK
JALL S TU D
attached to the front of the transmission case. The release thus engaging the clutch.
bearing is moved by the clutch fork to contact the release
levers and move the pressure plate to the rear, thus
COIL SPRING CLUTCH
separating the clutch driving members from the driven The coil spring single plate clutch (Fig. 7C-4) is a dry
member when the clutch pedal is depressed by the driver. disc type and no adjustm ent for wear is provided in the
A return spring preloads clutch linkage, removing looseness clutch itself. An individual adjustm ent is provided for
due to wear, keeping the bearing clear of the spring fingers. locating each lever in m anufacturing but the adjusting nut
The clutch free pedal travel, therefore, will increase with is locked in place and should never be disturbed, unless the
linkage wear and decrease with driven disc wear. The free clutch assembly is dism antled for replacement of parts.
travel felt at the clutchpedal is release bearing lash. W hen the clutch pedal is depressed the release bearing
is moved tow ard the flywheel and contacts the inner ends
of the release levers, (item 1 in Fig. 7C-5). Each release lever
Clutch Spring Operation is pivoted on a floating pin which rem ains stationary in the
In diaphragm spring type clutches, a diaphragm spring lever and rolls across a short flat portion of the enlarged hole
is used instead of coil springs. It is a conical piece of spring in the eyebolt (item 2). The outer end of each release lever
steel punched to give it greater flexibility. The diaphragm engages the pressure plate lug by means of a strut (3), which
is positioned between the cover and the pressure plate so provides knife-edge contact between the outer end of the
that the diaphragm spring is nearly flat when the clutch is lever and the lug. The outer ends of the eyebolts extend
in the engaged position. The action of this type of spring through holes in the stam ped cover (4), and are fitted with
is similar to that of the bottom of an ordinary oil can. The adjusting nuts (5) to correctly position the levers.
pressure of the outer rim of the spring on the pressure plate W hen the clutch system is fully engaged, the clutch
decreases as the flat position is passed. The outer rim of the disc is firmly clamped between the flywheel and the pressure
diaphragm is secured to the pressure plate and is pivoted plate by the pressure of the springs. W hen the driver
on rings approxim ately 1 inch in from the outer edge so that disengages the clutch by depressing the pedal, the release
the application of the pressure at the inner section will cause fork is moved on its pivot, and the pressure is applied to the
the outer rim to move away from the flywheel and draw the release bearing. The rotating race of the release bearing
pressure plate away from the clutch disc, releasing or presses against the clutch release levers and moves them on
disengaging the clutch. W hen the pressure is released from their pivot pins. The outer ends of the release levers, being
the inner section, the oil-can action of the diaphragm causes fastened to the cover, move the pressure plate to the rear,
the inner section to move out, and the movement of the compressing the clutch springs and allowing driving
outer rim forces the pressure plate against the clutch disc, members to rotate independently of the driven member. The
LIGHT TRUCK SER V IC E M A N U A L
CLUTCH 7C-3
Fi g. 7 C - 2 - - C r o s s - S e c t i o n V i e w o f D i a p h r a g m - T y p e
release fork moves only on its pivot, which contacts the CLUTCH CONTROLS
clutch fork ball stud. All parts of the clutch system, except
the clutch release bearing and collar, rotate with the The clutch operating controls for C-K trucks (Fig. 7C-
flywheel when the clutch is engaged. 6) are a mechanical type consisting of a pendant type pedal,
return spring, pedal push rod, cross-shaft, fork push rod,
W hen the clutch is disengaged, the release bearing routed vertically, inside the cab, from the pedal lever down
rotates with the flywheel, but the driven plate and the clutch through two boots on the toe pan, to the cross-shaft lever.
shaft rotate as dictated by the transm ission gear range and W hen the clutch pedal is depressed, the pedal push rod
vehicle speed. moves rotating the cross-shaft, pushing the fork push rod
rearward, and pivoting the clutch fork to move the release
bearing against the clutch release fingers and releasing the
clutch.
The clutch operating controls for "G " and "P" models
are a mechanical type similar to the C-K models. On "G "
models (Fig. 7C-7) a pedal pull rod is routed vertically from
the clutch pedal lever down through the toe-panel to the
cross shaft. W hen the pedal is depressed, the pedal pull rod
moves, rotating the cross shaft, pushing the clutch fork rod
rearw ard and pivoting the clutch fork. This action moves
the release bearing against the clutch release fingers,
releasing the clutch.
LIGHT TRUCK SE R V IC E M AN U AL
7C-4 CLUTCH
Fi g. 7 C - 4 ~ C r o s s - S e c t i o n V i e w o f C o il S p r i n g T y p e
U G H T TRU C K SE R V IC E M AN U AL
CLUTCH 7C-5
LIGHT TRUCK SE R V IC E M A N U A L
7C-6 CLUTCH
LIGHT TR U C K SE R V IC E M A N U A L
CLUTCH 7C-7
LIGHT TRUCK SE R V IC E M A N U A L
7C-8 CLUTCH
M A IN T E N A N C E A N D A D J U S T M E N T S
LIGHT T R U C K SE R V IC E M A N U A L
CLUTCH 7C-9
Fi g. 7 C - 1 0 - - P - T r u c k F r e e P e d a l T r a v e l Fi g. 7 C - 1 1 - - G - T r u c k F r e e P e d a l T r a v e l
D IA G N O S IS
CONDITION PROBABLE CAUSE CORRECTION
Fails to Release (Pedal pressed a. Improper linkage Adjustment a. Adjust Linkage
to floor-shift lever does not b. Improper pedal travel b. Trim bumper stop and adjust linkage
move freely in and out of c. Loose linkage c. Replace as necessary
reverse gear d. Faulty pilot bearing d. Replace bearing
e. Faulty driven disc e. Replace disc
f. Fork off ball stud f. Install properly and* lubricate fingers
at release bearing with wheel bearing
grease.
g. Clutch disc hub binding on clutch g. Repair or replace clutch gear and/or
gear spline disc.
h. Clutch disc warped or bent h. Replace disc (run-out should not
exceed .020").
*Very lightly lubricate fingers
Slipping a. Improper Adjustment (no lash) a. Adjust linkage to spec.
b. Oil Soaked driven disc b. Install new disc and correct leak at its
source
c. Worn facing or facing torn from disc. c. Replace disc
d. Warped pressure plate or flywheel d. Replace pressure plate or flywheel
e. Weak diaphragm spring e. Replace pressure plate (Be sure lash is
checked before replacing plate.)
f. Driven plate not seated in f. Make 30 to 40 normal starts
CAUTION: Do Not Overheat
g. Driven plate overheated g. Allow to cool —check lash
Grabbing (Chattering) a. Oil on facing. Burned or glazed a. Install new disc and correct leak.
facings.
b. Worn splines on clutch gear. b. Replace transmission clutch gear.
c. Loose engine mountings. c. Tighten or replace mountings.
d. Warped pressure plate or flywheel. d. Replace pressure plate or flywheel.
e. Burned or smeared resin on flywheel e. Sand off if superficial, replace burned
or pressure plate. or heat checked parts.
Rattling-Transmission Click a. Weak retracting springs. a. Replace pressure plate.
b . Clutch fork loose on ball stud or in bear b. Check ball stud and retaining.
ing groove.
c. Oil in driven plate damper. c. Replace driven disc.
d. Driven plate damper spring failure. d. Replace driven disc.
Release Bearing Noise with a. Improper adjustment. No Lash. a. Adjust linkage.
Clutch Fully Engaged b. Release bearing binding on trans b. Clean, relubricate, check for burrs,
mission bearing retainer. nicks,etc.
c. Insufficient tension between clutch c. Replace fork.
fork spring and ball stud.
d. Fork improperly installed. d. Install properly.
e. Weak linkage return spring. e. Replace spring.
Noisy a. Worn release bearing. a. Replace bearing.
b. Fork off ball stud (heavy clicking). b. Install properly and lubricate fork
fingers at bearing.
c. Pilot Bearing loose in crankshaft. c. See Section 6 for bearing fits.
Pedal Stays on Floor When a. Bind in linkage or release bearing. a. Lubricate and free up linkage and
Disengaged release bearing.
b. Springs weak in pressure plate. b. Replace pressure plate.
c. Springs being over traveled. c. Adjust linkage to get proper lash, be
sure proper pedal stop (bumper) is
installed.
Hard Pedal Effort a. Bind in linkage. a. Lubricate and free up linkage.
b. Driven plate worn. b. Replace driven plate.
Fig. 7C-1 2--Clutch Diagnosis Chart
LIGHT TRU C K SE R V IC E M A N U A L
CLUTCH 7 C -1 1
PRELIMINARY INSPECTION 4. Install clutch disc, pressure plate and cover assembly
There are m any things which affect good clutch and support them with Tool J-5824 or a used clutch drive
operation. Therefore, it is necessary, before performing any gear.
major clutch operations, to m ake a prelim inary inspection 5. T urn clutch assembly until "X" mark or painted
to determ ine w hether or not the trouble is actually in the white letter on clutch cover flange lines up with "X" mark
clutch. on flywheel.
1. Check the clutch pedal and m ake sure that the pedal 6. Install attaching bolts and tighten each one a turn
has proper free travel, as described in "M aintenance and at a time to prevent distorting the cover as the spring
A djustm ents". pressure is taken up.
2. Check the clutch pedal bushing for wear and for 7. Remove clutch pilot tool.
sticking on the shaft or loose mountings. 8. Pack clutch fork ball seat with a small am ount of
3. Lubricate the pedal linkage. high melting point grease. On "P" models with J76, install
4. Tighten all front and rear engine m ounting bolts. a new retainer in the groove of the clutch fork if the old
retainer is worn or damaged.
CLUTCH DISC AND PRESSURE PLATE
(DIAPHRAGM TYPE) NOTICE: Install retainer with high side up, away from
bottom of the ball socket and with open end of retainer
Removal from Vehicle on the horizontal.
1. Remove transmission as outlined in Section 7B.
2. Disconnect clutch fork push rod and pull back
spring. CAUTION: Be careful not to use too much
3. Remove clutch and flywheel housing. lubricant. Excessive lubricant may get on
4. Remove clutch fork by pressing it away from its ball clutch fingers and cause slippage.
m ounting with a screwdriver, until the fork snaps loose from
the ball or remove ball stud from rear of clutch housing. 9. Replace clutch fork ball if removed from the clutch
Remove release bearing from clutch fork. housing and snap clutch fork onto the ball.
10. Pack lubricant in the recess on the inside of the
NOTICE: The retainer may be removed from the fork release bearing collar and coat the clutch fork groove with
by prying out with a small screwdriver.
a small am ount of graphite grease, as shown in Figure 7C- NOTICE: Install retainer with high side up, away from
13. bottom of the ball socket and with open end of retainer
11. Install release bearing assembly to the clutch fork. on the horizontal.
Install clutch and flywheel housing to engine.
12. Assemble transm ission as outlined in Section 7B.
13. Align push rod to clutch fork and attach return CAUTION: Be careful not to use too much
spring to clutch fork. lubricant. Excessive lubricant may get on
14. Adjust clutch linkage as described in "M aintenance clutch fingers and cause slippage.
and A djustm ents."
6. Replace clutch fork ball if removed from the clutch
CLUTCH DISC AND PRESSURE PLATE housing and snap clutch fork onto the ball.
(COIL SPRING TYPE) 7. Pack lubricant in the recess on the insde of the
release bearing collar and coat the clutch fork groove with
Removal From Vehicle
a small am ount of graphite grease, as shown in Figure 7C-
1. Remove transm ission as outlined in Section 7B.
13.
2. Disconnect clutch fork push rod and pull back
8. Install release bearing assembly to the clutch fork.
spring.
Install clutch and flywheel housing to engine.
3. Remove clutch and flywheel housing.
9. Assemble transmission as outlined in Section 7B.
4. Remove clutch fork by pressing it away from its ball
10. Align push rod to clutch fork and attach return
mounting with a screwdriver, until the fork snaps loose from
spring to clutch fork.
the ball or remove ball stud from rear of clutch housing.
Remove release bearing from clutch fork. 11. A djust clutch linkage as described in "M aintenance
and A djustm ents."
NOTICE: The retainer may be removed from the fork CLUTCH PEDAL ARM, PUSH ROD OR
by prying out with a small screwdriver. BUSHING REPLACEMENT (Fig. 7C-14)
5. Install Tool J-5824 or a used clutch drive gear to C-K Models
support the clutch assembly during removal. Removal
1. Disconnect battery negative ground cable at the
NOTICE: Before removing clutch from flywheel, battery terminal.
m ark the flywheel, clutch cover and one pressure plate
2. D isconnect clutch push rod at the cross shaft under
lug, so that these parts may be assembled in their same
the vehicle.
relative positions, as they were balanced as an
3. Remove steering colum n covers. Remove screws
assembly.
retaining push rod boots to bulkhead.
4. Remove air conditioning duct from lower left side
6. Loosen the holding screws a turn or two at a time
of instrum ent cluster is so equipped. (Refer to Section 1A).
to avoid bending rim of cover. It is advantageous to place
wood or metal spacers (approxim ately 3/8 thick) between
the clutch levers and the cover to hold the levers down as CAUTION: Maintain pressure on lower
the holding screws are removed or when clutch is removed arm. When lower attaching bolt is
from engine. W hen removing driven plate be sure to m ark removed upper section will snap upward.
flywheel side.
7. Remove clutch pilot tool and remove clutch 5. Disconnect clutch neutral start switch from pedal
assembly from vehicle. arm.
6. Remove bolts attaching lower section of clutch pedal
NOTICE: Inspect flywheel for heat defects, cracks, arm to the upper arm.
flatness, or other defects. 7. Remove lower arm and push rod from vehicle.
8. Remove pedal return spring.
Installation To Vehicle 9. Remove pedal pivot shaft retaining nut and pivot
1. Assemble driven plate and clutch cover assembly to shaft. Insert a dum m y shaft or rod through the support to
flywheel in accordance with marking on driven plate for hold the brake pedal com ponents in place.
flywheel side. Use Tool J-5824 or a dum m y shaft to support
10. Remove the clutch pedal assembly from the support
assembly.
assembly.
2. Line up the clutch assembly with "X" m ark or
11. Remove pedal bushings and spacer from pedal arm.
painted white letter with "X" m ark on flywheel, before
Check pedal bum per for wear and replace as required.
tightening cover holding screws.
3. Tighten holding screws, a turn at a time, before Installation
removing dum m y shaft. 1. Install new bushings and spacer in pedal arm.
4. Remove clutch pilot tool. Com ponents should be lubricated prior to assembly.
5. Pack clutch fork ball seat with a small am ount of 2. Position clutch pedal upper arm in support bracket
high melting point grease and install a new retainer in the and install pivot bolt through support and pedal arms.
groove of the clutch fork if the old retainer is worn or
damaged. NOTICE: Bolt must be installed in direction shown in
L IG HT TRU C K SE R V IC E M A N U A L
CLUTCH 7C-13
Inspection
1. Check clutch pedal bushings for excessive wear and
replace as necessary.
2. Check clutch pedal shaft for wear and alignment.
Straighten or replace as necessary.
Installation
LIG HT TRUCK SE R V IC E M A N U A L
7C-14 CLUTCH
S P E C IA L T O O LS
Fi g. 7 C - S T ~ C l u t c h S p e c i a l T o o l s
LIG HT TR U C K SE R V IC E M A N U A L
TRANSFER CASE 7E-1
SECTION 7E
TRANSFER CASE
CONTENTS
GENERAL DESCRIPTION
MODEL 208,PART TIME (ALUMINUM CASE)
The Model 208 transfer case (as shown in Fig. 7E-1) is
an alum inum case, chain drive, four position unit providing
four-wheel drive high and low ranges, a two-wheel high
range, and a neutral position. The model 208 is a part-tim e
four-wheel drive unit. Torque input in four-wheel high and
low ranges is undifferentiated. The range positions on the
Model 208 are selected by a floor m ounted gearshift lever.
LIGH T T R U C K S E R V IC E M ANU AL
7E-2 TRANSFER CASE
1. INPUT GEAR THRUST WASHER 33. MODE FORK BRACKET 57. WASHER AND LOCKNUT
2. INPUT GEAR THRUST BEARING 34. REAR CASE 58. RANGE SECTOR SHAFT SEAL
3. INPUT GEAR 35. SEAL RETAINER
4. MAINSHAFT PILOT BEARING 36. PUMP HOUSING 59. RANGE SECTOR SHAFT SEAL
5. PLANETARY ASSEMBLY 37. REAR RETAINER 60. DETENT BALL, SPRING AND
6. PLANETARY THRUST WASHER 38. BEARING SNAP RING RETAINER BOLT
7. ANNULUS GEAR 39. REAR OUTPUT BEARING 61. FRONT SEAL
8. ANNULUS GEAR THRUST WASHER 40. VENT TUBE 62. FRONT YOKE
9. NEEDLE BEARING SPACERS 41. REAR SEAL 63. YOKE SEAL WASHER
10. MAINSHAFT NEEDLE BEARINGS (120) 42. DRAIN AND FILL PLUGS 64. YOKE NUT
11. NEEDLE BEARING SPACER 43. FRONT OUTPUT SHAFT REAR 65. INPUT GEAR OIL SEAL
12. SPACER WASHER BEARING 66. INPUT GEAR FRONT BEARING
13. OIL PUMP GEAR 44. FRONT OUTPUT SHAFT REAR THRUST 67. FRONT CASE
14. SPEEDOMETER GEAR BEARING RACE (THICK) 68. LOCK MODE INDICATOR SWITCH
15. DRIVE SPROCKET SNAP RING 45. CASE MAGNET AND WASHER
16. DRIVE SPROCKET 46. FRONT OUTPUT SHAFT REAR THRUST 69. INPUT GEAR REAR BEARING
17. BLOCKER RING BEARING 70. LOCKPLATE
18. SYNCHRONIZER SLEEVE 47. FRONT OUTPUT SHAFT REAR THRUST 71. SHIFTER FORK SHAFT
19. SYNCHRONIZER SPRING BEARING RACE (THIN) 72. LOCKPLATE BOLTS
20. SYNCHRONIZER KEY 48. DRIVEN SPROCKET RETAINING RING 73. CASE ALIGNMENT DOWELS
21. SYNCHRONIZER HUB 49. DRIVE CHAIN
22. SYNCHRONIZER HUB SNAP RING 50. DRIVEN SPROCKET
23. MAINSHAFT 51. FRONT OUTPUT SHAFT
24. MAINSHAFT THRUST BEARING 52. FRONT OUTPUT SHAFT FRONT
25. INTERNAL GEAR SNAP RING THRUST BEARING RACE (THIN)
26. MODE FORK 53. FRONT OUTPUT SHAFT FRONT
27. BUSHING(SHIFT ROD THRUST BEARING RACE (THICK)
28. SPRING 54. FRONT OUTPUT SHAFT FRONT
29. SPRING RETAINER BEARING
30. RANGE FORK PADS 55. FRONT OUTPUT SHAFT FRONT
31. RANGE FORK THRUST BEARING
32. RANGE SECTOR 56. OPERATING LEVER
LIGH T T S U C K s e r v i c e m a n u a l
TRANSFER CASE 7E-3
Shift Pattern
A floor m ounted shift lever is used to select the various REAR
operating ranges on the 208 model. The shift lever is located YOKE IDENTIFICATION
on the floorpan transm ission tunnel adjacent to the tran s TAG
mission gearshift lever. Furtherm ore, the transfer case shift DRAIN
pattern is not in a straight line for 208 models, the range
positions are shown in Fig. 7E-2. FILL
PLUG
Identification INDICATOR
An identification tag is attached to the rear half of the SWITCH
transfer case (Fig. 7E-3). This tag provides the transfer case
model num ber, low range reduction ratio, and assembly
num ber. The inform ation on this tag is necessary for
Fig. 7E-3 M o d e l 208 Indicator Switch, Identification
servicing inform ation. If the tag is removed or becomes
Tag, an d Drain an d Fill Plug Location
dislodged during service operations, it should be reattached
using an adhesive sealant such as Loctite 312, or equivalent. and adjustm ents section for lubricant change procedures
and fill level.
Power Flow
In all drive range positions input torque is transm itted
to the transfer case gear train through the transfer case
input gear.
In 2H range, torque flows from the input gear to the
planetary assembly and annulus gear which rotate as a unit.
Torque is transferred to the m ainshaft through the plane
tary carrier which is splined to the m ainshaft. Torque flow
continues through the m ainshaft and rear yoke which is
splined to the m ainshaft, and finally to the rear propeller
shaft and axle. In 2H range, the sliding clutch rem ains in a
neutral position and does not lock the drive sprocket to the
m ainshaft. As a result, torque is not transferred to the
driven sprocket.
In 4H range, input torque from the input gear is
transm itted through the planetary and annulus gear and
through the m ainshaft in exactly the same fashion as in 2H
range. However, in 4H position, the sliding clutch is shifted
forward and into engagem ent with the m ainshaft clutch
gear. This locks the drive sprocket to the m ainshaft through
the sliding clutch. Torque is now transm itted through the
drive sprocket to the driven sprocket by the connecting
drived chain. Since the front output shaft is splined to the
Lubrication driven sprocket, torque now flows through the front output
The M odel 208 tran sfer case lu b rican t should be shaft to the front propeller shaft and axle resulting in high
changed at the intervals specified in the M aintenance range four-wheel drive.
Schedule. W hen adding lubricant to or refilling the transfer In 4L range, the path of torque through the transfer
case after service, use Dexron® II. Refer to the m aintenance case is exactly the same as in 4H range but with one major
difference. In 4L range, the annulus gear is shifted forward and does not rotate. This causes the planetary pinions to
and into engagem ent with the lock plate. Since the lock rotate about the annulus gear internal teeth producing a
plate is fixed in the case, the annulus gear is held stationary gear reduction ratio of 2.61:1.
SERVICE DIAGNOSIS
GENERAL the front hubs, axles, propeller shafts, wheels and tires,
transm ission, or clutch instead. If all other driveline
Before attem pting to repair a suspected transfer case components are in good condition and operating properly,
m alfunction, check all o th er driveline com ponents. The refer to the Service Diagnosis C h art for further inform ation.
actual cause of a problem may be related to such items as
LIGH T T R U C K S E R V IC E M AN U AL
TRANSFER CASE 7E-5
Fig. 7E-4 Transfer Case Linkage Skid Plates and Strut Rods
LIGH T T R U C K S E R V IC E M AN U AL
7E-6 TRANSFER CASE
LIGH T T R U C K S E R V IC E M ANU AL
TRANSFER CASE 7E-7
Service Diagnosis
Condition Possible Cause Correction
.awn* u# vo *
T R A N S FE R CASE (1) Vehicle speed to o great to perm it (1) S top vehicle and shift into desired
D IFF IC U L T TO SH IFT shifting. range. Or reduce speed to 2-3 m ph
O R WILL NOT SH IFT . (3-4 k m /h) before attem p tin g to
INTO D ESIRED cniilj Off) t?flfegri shift.
RANGE
bnjd n ft! 10 usihob ? icy, (2) If vehicle was o perated for extended (2) Stop vehicle, shift transm ission to
period in 4H m ode on dry paved n eutral, shift transfer case to 2H
^ i^ J n p jrfg iT
surface, driveline to rq u e load may m ode and o p erate vehicle in 2H on
cause difficult shifting. dry paved surfaces.
roforisi'i '4'i.a'jg novi 1*11.**•ft)0 h 0 1 r:’i;K >
(3) T ransfer case external shift linkage (3) L ubricate or repair or replace link
na:,- 1 * ;1 V, pj feJiBila iai[: qO’iC binding. age, or tighten loose com ponents as
, i ,'i/fs uz " 4j i grti^ij as A? / -u. necessary.
- m r i c / . " . ;T i t t/m -"i grtr, - i
(4) Insufficient or incorrect lubricant. (4) Drain and refill to edge of fill hole
w ith DEXRON®-II only.
isb n u iTTO* 1 br ^j/ l7oqc5c-a*:vcni.v.>i
(5) Internal com ponents binding, (5) Disassemble un it and replace w orn or
w orn, or damaged. dam aged com ponents as necessary.
>l*nivU;i no a$i& ishnuii o. Ju’}j •> i)f
T R A N SFE R CASE (1) Insufficient or incorrect lubricant. (1) D rain and refill to edge of fill hole
NOISY IN ALL DRIVE w ith DEXRON®-II only. Check
MODES for leaks and repair if necessary.
N ote: If u n it is still noisy after drain
and refill, disassem bly and inspection
m ay be required to locate source of
noise.
NOISY I N - O R JUMPS (1) T ransfer case n o t com pletely (1) S top vehicle, shift.transfer case in
OUT O F FOUR WHEEL engaged in 4L position. N eutral, th en shift back into 4L
D RIV E LOW RANGE position.
(2) S hift linkage loose or binding. (2) T ighten, lubricate, or repair linkage
as necessary.
(3) Range fork cracked, inserts w orn, (3) D isassemble u n it and repair as
or fork is binding on shift rail. necessary.
LUBRICANT LEAKING (1) Transfer case overfilled. (1) Drain to correct level.
FROM OUTPUT SHAFT
SEALS OR FROM (2) V ent closed or restricted. (2) Clear or replace vent if necessary.
VENT
(3) O u tp u t shaft seals dam aged or (3) Replace seals. Be sure seal lip faces
installed incorrectly. interior o f case when installed. Also
be sure yoke seal surfaces are n o t
scored or nicked. Rem ove scores,
nicks w ith fine sandpaper or replace
yoke(s) if necessary.
ABNORMAL TIR E (1) E xtended o peration on dry hard (1) O perate in 2H on hard surface
WEAR surface (paved) roads in 4H range. (paved) roads.
LIGHT T R U C K S E R V IC E M A N U A L
7E-8 TRANSFER CASE
ON VEHICLE SERVICE
TRANSFER CASE REMOVAL 2. Shift transfer case to 4H position if not done previously.
1. Place transfer case in 4H. 3. R otate transfer case output shaft (by turning yoke)
2. Raise vehicle. until transm ission output shaft gear engages transfer
3. D rain lubricant from transfer case. case input shaft. Move transfer case forward until case
seats against transmission. Be sure the transfer case is
4. Remove cotter pin from shift lever swivel.
flush against the transm ission. Severe dam age to the
5. M ark transfer case front and rear output shaft yokes tran sfer case will result if the atta ch in g bolts are
and propeller shafts for assembly alignm ent reference. tightened while the transfer case is cocked or in a bind.
6. D isconnect speedom eter cable and indicator sw itch
wires. 4. Install transfer case attaching bolts. Tighten bolts to 30
ft.lb. (41 N-m).
7. Disconnect front propeller shaft at transfer case yoke.
8. D isconnect p arking brak e cable guide from pivot 5. Connect speedometer driven gear to transfer case.
located on right fram e rail, if necessary. 6. Connect front and rear propeller shafts to transfer case.
9. Remove engine stru t rod from transfer case on auto Be sure to align shafts-to-yokes using reference m arks
m atic transm ission models. m ade duri ng rem oval. T ighten shaft-to-yoke clam p
10. Place support under transfer case and remove transfer strap nuts to 15 ft.lb. (20 N-m ).
case-to-transm ission adapter bolts. 7. Remove support stand from under transfer case.
11. Move transfer case assembly rearw ard until free of
8. Connect parking brake cable if disconnected.
transm ission output shaft and remove assembly.
12. Remove all gasket m aterial from rear of transmission 9. A ttach cotter pin to shift lever swivel.
adapter housing. 10. Connect engine strut to transfer case on autom atic
models.
TRANSFER CASE INSTALLATION ®
1. Install tran sm issio n -to -tran sfer case gasket on 11. Fill transfer case with Dexron II.
transm ission. 12. Lower vehicle.
LIGH T T R U C K SE R V IC E M A N U A L
TRANSFER CASE 7E-9
GENERAL DESCRIPTION
MODEL 205 TRANSFER CASE (30 SERIES)
A transfer case mounts behind the transmission and
allows drive torque to be transm itted in a proportional split
to both the front axle and the rear axle, resulting in four-
wheel drive. The shift control lever for the transfer case is
floor-mounted in the passenger com partm ent. Depending on
the type of transfer case and the shift lever position, various
com binations of rear wheel drive, four wheel drive, high
traction (gear reduction) or direct drive may be selected.
The model 205 transfer case shown in Fig. 7E-7 is a
two-speed unit which can be used for either two-wheel or
four-wheel drive. Direct drive (1:1 ratio) is available in two
modes, 2H for two-wheel drive, or 4H for four-wheel drive.
G ear reduction (1.96:1 ratio) is used in the 4L position. This
unit uses constant mesh helical gears to connect the input
shaft, idler gear and two output gears, thus allowing gear
selection to m atch driving conditions. The front input shaft
gear (Item # 2 7 ) is in constant mesh with the idler gear
( # 4 4 ) and, through the idler gear, with the front output
gears ( # 5 9 and # 6 7 ) and the rear output gear ( # 1 7 ) .
S liding clutches ( # 2 6 , # 6 4 ) allow for selective gear
engagem ent resulting in High or Lo range, and two-wheel or
four-wheel drive. Ball bearings support the input shaft, rear
output shaft and front output shaft. Tapered roller bearings
are used on the idler shaft. W hen driving in a four-wheel
mode (4L or 4H ) the hubs on the front wheels must be
turned to the "L ocked" position.
LIG H T T R U C K S E R V IC E M ANU AL
7E-10 TRANSFER CASE
LIGHT T R U C K SE R V IC E M ANU AL
TRANSFER CASE 7E -11
DIAGNOSIS
LIGHT T R U C K SE R V IC E M A N U A L
7E-12 TRANSFER CASE
ON VEHICLE SERVICE
TRANSFER CASE REPLACEMENT 3. Install connecting rod to shift rail link or connect shift
levers to transfer case, as applicable.
Removal (Fig. 7E-10) 4. Connect front prop shaft to transfer case front output
1. Raise and support vehicle on hoist. Drain transfer case. flange or yoke.
2. Disconnect speedom eter cable. 5. Connect rear prop shaft to transfer case rear output
3. Rem ove skid p late and crossm em ber supports as yoke.
necessary. 6. Install crossm em ber support and skid plate, if removed.
4. Disconnect rear prop shaft from transfer case and tie 7. Connect speedometer cable.
up away from work area.
8. Fill transfer case to proper level with lubricant specified
5. Disconnect front prop shaft from transfer case and tie in Section 0-B.
up shaft away from work area.
9. Lower and remove vehicle from hoist.
6. Disconnect shift lever rod from shift rail link. Check and tighten all bolts to specified torques.
7. S upport tra n sfe r case and rem ove bolts attach in g Before connecting prop shafts to companion flanges, be
transfer case to transm ission adapter. sure locknuts are torqued to specifications.
8. Move transfer case to rear until input shaft clears
adapter and lower assembly from vehicle.
SKID PLATE, STRUT ROD
Installation
1. Support transfer case in suitable stand and position ADAPTER ASSEMBLIES
case to transm ission adapter. Install bolts attaching A ttachm ent of the above items is shown in Fig. 7E-10,
case to adapter and torque to 45 ft. lb. (61 N-m). 11 and 12. R efer to these figures when rem oving or
2. Remove stand. replacing these components.
LIGHT T R U C K SE R V IC E M ANU AL
TRANSFER CASE 7E-13
LIGH T T R U C K SE R V IC E M AN U AL
7E-14 TRANSFER CASE
A U T O M A T IC
Fig. 7 E -1 1 -S k id Plates
LIGH T T R U C K S E R V IC E M AN U AL
TRANSFER CASE 7E-15
SPECIFICATIONS
N*m N«m
MODEL 205 MODEL 208
NUT, SHIFT LEVER-TO-SHIFTER ASSEMBLY — 19-27
NUT, KNOB ASSEMBLY-TO-SHIFT LEVER 26-40 26-40
BOLT, SHIFTER ASSEMBLY-TO-TRANSFER CASE 120-150 120-140
NUT, SHIFT ARMS-TO-CASE 14-20 14-20
SCREW, SHIFT LEVER BOOT RETAINER 2.2-3.2 2.2-3.2
BOLT, DETENT RETAINER — 27-34
SWITCH, INDICATOR — 122-176
BOLT, ADAPTER-TO-TRANSMISSION 26-40 26-40
BOLT, ADAPTER-TO-TRANSFER CASE 26-40 26-40
FILLER PLUG 40-48 40-54
BOLTS P.T.O. COVER 20-24 —
NUT, SKID PLATE-TO-CROSSMEMBER 55-70 55-70
BOLT, SUPPORT STRUT ROD
— TRANSMISSION END 40-54 40-54
— TRANSFER CASE END 150-200 150-200
LEVER POSITIONS 4-LO (ALL WHEEL UNDERDRIVE) 4-LO (ALL WHEEL UNDERDRIVE)
N (NEUTRAL) N (NEUTRAL)
2-HI (REAR WHEEL DRIVE) 2-HI (REAR WHEEL DRIVE)
4-HI (ALL WHEEL DIRECT DRIVE) 4-HI (ALL WHEEL DIRECT DRIVE)
LEVER LOCATION REAR OF TRANS. SHIFT LEVER REAR OF TRANS. SHIFT LEVER
LUBRICANTS:
OIL CAPACITY 5.2 PINTS* 8 PINTS*
TYPE, GRADE SEE OWNER’S MANUAL SEE OWNER’S MANUAL
LIGHT T R U C K SER V IC E M A N U A L
Fig. 7E-ST1
SPECIAL TOOLS
208--Special Tools
10
1. J —23432 —1 Snap Ring Picks 7. J -23 4 3 1 Rear O u t p u t Shaft Housing Bearing
2. J-23432 Snap Ring Pliers Remover and In s ta l le r
3. J-8092 Han dl e J —713 7 A d a p t e r Seal I n s ta l le r
4. J-23429 In te r m e d ia te Sh aft Remover and In s ta lle r 9. J -9276-2 In te r m e d ia te G e a r Bearing C up In s ta l le r
5. J —22836 Front O u t p u t Shaft Bearing Ret ainer Seal I n s ta l le r 10 . J —22875 Rear O u t p u t Shaft Rear Bearing I n s ta i le r
6. J —21359 Rear O u t p u t Sha ft Be aring Ret aine r Seal In s ta l le r
LIG H T T R U C K SE R V IC E M AN U AL
ELECTRICAL - BODY AND CHASSIS 8A-1
SECTION 8A
ELECTRICAL - BODY AND CHASSIS
LIG H TIN G SYSTEM
CONTENTS
The lighting system includes the main light switch; stop All wiring systems not protected by a fuse or circuit
light, dim m er and backing lam p switches; head and parking breaker incorporate a fusible link which provides increased
lamps; stop, tail, side m arker, clearance and identification overload protection. T he sta rtin g m otor circu it is the
lam ps; in strum ent illum ination, d irectional signal and exception.
indicator lamps and the necessary wiring to complete the Composite wiring diagram s are available in Section
various circuits. 8C. The standardized color code is common to all wiring
A bulkhead fuse panel (fig. 8A-1) provides convenient harnesses. The wire covering color designates a particular
power taps and fuse clips for the appropriate circuits. The circuit usage. W ire size designations are m etric, conversions
engine wiring harness and forward lam p harness connectors to AW G sizes are provided.
are bolted to the fuse panel.
LIGHT T R U C K SER V IC E M A N U A L
8A-2 ELECTRICAL - BODY AND CHASSIS
Q] C U IT BREAKER
0 -CHOKE
0 -RADIO
0 PTACLE 4C69
□ PTACLE-POWER ACCESSORY
0 -WINDSHIELD WIPER
0 PTACLE IAU3/A33
□ PTACLE &T63/UF2/U35
0 PTACLE-IT63
□ PTACI.f
(TJ CIRCUIT B R E A K E R
[_Aj FUSE-WINDSHIELD W IP E R
| b ] RECEPTACLE-IGN ACC-RADIO & AUX BAT.
j C~j FUSE-STOP & TRAF H A ZA R D LPS
[d ] P O W E R ACCESSORY
[jfj R E C E PT A C L E- PO W ER D OOR LOCK>
|_Fj FUSE-INST PA N EL LAM PS
[g ] RECEPTACLE-DIR SIG LP F LA SH ER
|H| FUSE-HEATER & A./C
IT] REC EPTACLE- BAT, L TR , RDO CAP AC.
CLOCK, H /L WARNING
[ k] RECEPTACLE-PNL LPS, RAD DIAL,
TRANS IND LP & TILT WHEEL.
[Y] FUSE-HORN D M
1~M| FUSE-DIR SIG & BACK-UP LAM PS
m RECEPTACLE-IGN-AUTO TRANS.
CRUISE C O N T R O L , PU LSE W IPER ,
TRANS IND LP
[p ] FUSE-GAUGES
IqJ FUSE-TAIL LAM PS
[R~| R EC EPTACLE- TRAFFIC H A ZA R D F LA SH E R
[sl REC EPTACLE- IGN /AC C REA R AIR C ON D
" AUX H E A T E R
j_Tj FUSE-AUX H E A T E R & A C
[u ’| FUSE-RADIO
LIGHT T R U C K SER V IC E M A N U A L
ELECTRICAL - BODY AND CHASSIS 8A-3
D IA G N O S IS
HEADLAMP DIAGNOSIS
One or more headlights 1. Open ground connection 1. Repair black wire connection
are dim. at headlight between sealed beam and body
ground.
2. Black ground wire 2. Relocate black wire in connector
mislocated in headlight
connector (type 2
sealed beam)
LIGH T T R U C K SER V IC E M A N U A L
8A-4 ELECTRICAL - BODY AND CHASSIS
One lamp inoperative 1. Turn signal bulb burnt 1. Sw itch turn signals on. If signal
out (Front lamp) bulb does not light, replace bulb.
(Bulb filam ent provides ground
path for marker lam p bulb
through the light blue or dark
b lu e/w h ite strip wires).
LIGHT T R U C K S E R V IC E M A N U A L
ELECTRICAL - BODY AND CHASSIS 8A-5
LIGH T T R U C K SE R V IC E M A N U A L
8A-6 ELECTRICAL - BODY AND CHASSIS
H azard warning lamps 1. Blown stop-hazard 1. Switch turn signals on. If lamps
inoperative fuse operate, replace stop-hazard
fuse if blown. If new fuse blows,
repair short to ground. (Could be
in stop light circuit).
2. Defective hazard 2. If stop-hazard fuse is OK,
warning flasher. (Located switch turn signals on. If
on fuse panel). lamps operate, replace
defective hazard flasher.
3. Open in wiring or 3. Using test lamp, check brown
defective turn signal wire in turn signal steering
switch. colum n connector. If lamp
does not light on either side of
connector, repair open circuit
between flasher and connector.
If lamp lights only on feed side
o f connector, clean connector
contacts. If lamp lights on both
sides of connector, replace
defective turn signal switch
assembly.
BACK-UP LAMP
Both lamps inoperative 1. N eutral start switch 1. Readjust neutral start switch.
or intermittent. misadjusted (Open when
shift lever is in reverse
position)
2. Loose connection or 2. Secure all connectors. If O K ,
open circuit check continuity of circuit from
fuse to lamps with test lamp. If
lamp does not light on either side
of fuse, correct open circuit from
battery to fuse.
3. Blown fuse 3. Replace fuse. If new fuse blows,
repair short to ground in circuit
from fuse through neutral start
switch to back-up lamps.
Defective neutral 4. W ith ignition on, check switch
start switch terminals in back-up position with
test lamp. If lamp lights at pink
wire terminal but not at light
green wire terminal, replace
neutral start switch.
5. Defective ignition 5. If test lamp lights at ignition
switch switch battery terminal but not
at outpu t terminal, replace
ignition switch.
STOP LIGHTS
ON-VEHICLE SERVICE
Maintenance of the lighting units and wiring system The headlam ps must be checked for proper aim
consists of an occasional check to see that all wiring whenever a sealed beam unit is replaced and after repairs of
connections are tight and clean, that the lighting units are the front end sheet metal assembly.
securely mounted to provide good ground and that the Regardless of the method used for checking headlamp
headlamps are properly adjusted. Loose or corroded connec aim, the truck must be at normal weight, that is with gas, oil,
tions may cause a discharged battery, difficult starting, dim water and spare tire. Tires must be inflated to specified
lights, and possible damage to the generator. Wire harnesses pressures.
must be replaced if insulation becomes burned, cracked, or Some states have special requirements for headlamp
deteriorated. Whenever it is necessary to splice a wire or aiming adjustment and these requirements must be known
repair one that is broken, always use solder to bond the and followed.
splice. Always use rosin flux solder on electrical connections.
Horizontal and vertical aiming of each sealed beam is
Use insulating tape to cover all splices or bare wires.
proveded by two adjusting screws visible through the bezel
When replacing wires, it is important that the correct which move the mounting ring against the tension of the coil
size be used. Never replace a wire with one of a smaller size. spring (fig. 8A-2).
Fusible links in the wiring are four gage sizes smaller than
There is no adjustment for focus since the sealed beam
the cable it is designed to protect. The links are marked on
unit is set for focus during manufacturing assembly.
the insulation with wire gage size because of the heavy
insulation which makes the link appear a heavier gage than
it actually is.
Each harness and wire must be held securely in place
by clips or other holding devices to prevent chafing or
wearing away the insulation due to vibration.
By referring to the wiring diagram manual, circuits
may be tested for continuous circuit or shorts with a
conventional test lamp or low reading voltmeter. These
wiring diagrams use metric wire size designations, a chart
showing metric to A W G size conversions is provided in the
manual.
FORW ARD
RADIATOR FRO NT FEN D ER LAMP
VIEW A
RADIATOR
SUPPO R T
RADIATOR GRILLE
LOWER PANEL
FRONT LAMP
FRONT
MARKER
HARNESS ASSEMBLY
LAMP
VIEW A
E94 O R Z80
SEALED BEAM UNIT 6. Install retaining ring then check operation of unit and
install bezel.
Replacement (Figs. 8A-3 and 8A-4)
PARKING LAMP BULB
1. Remove bezel retaining screws and bezel.
2. Remove retaining ring. Replacement (Figs. 8A-3 and 8A-4)
Do not disturb adjusting screw setting. 1. Remove lens retaining screws and remove lens from the
3. Disconnect wiring harness connector located at rear of housing.
unit in engine compartment and remove sealed beam 2. Replace bulb and check lamp operation.
unit. 3. Install lens and retaining screws.
4. A ttach wiring harness connector to unit.
5. Position new sealed beam unit in mounting ring and
install retaining ring.
The number molded into lens face must be at top.
LIGHT TRUCK SERVICE MANUAL
8A -12 ELECTRICAL - BODY AND CHASSIS
DARK GREEN
BROW N
MARKER LAMP
LIGHT GRFEN
LIGHT GREEN
BROW N
LICENSE ' I
LAMP WIRE jfc
ASSEMBLY & FUEL TA NK
METER ASSEMBLY
BROW N
( L H SIDE O NLY) RIGHT SIDE
FRONT MARKER
VIE W 1
LAMP HARNESS | v ie w ]
FRONT WIRE
TAIL & STOP ~ ASSEMBLY
LAMP ASSEMBLY
REAR LICENSE ^ SIDE MARKER
LAMP ASSEMBLY LAMP \
C209 (03) WITH OPTION E56 C310 (03) WITH OPTION E56
Fig. 8A-7--Rear Lighting (C-K Platform and Stake Rack Models)
C 3 0 ( 0 3 ) W IT H O P T IO N E56 CK 1 0 - 2 0 A N D C 3 0 9 ( 0 3 ) W IT H O P T IO N E62
Fig. 8AA-8A--Rear Lighting (C30 03 Models with E56 and C-K Models with E62)
C 3 0 9 W ITH O P T IO N E63
MARKER LAMP
(CREAM)
FRO NT LAMP
4 $*
BRAKE DIST.
& SW. ASSEMBLY HORN A SSEM BLY
ENGINE HARNESS
HORN
ASSEMBLY
NUT
PARKING
BRAKE
PARKING NUT
BATTERY BRAKE
GROUND VIEW C CABLE
VIEW B VIEW D
Fig. 8A-13--G Series Forward Lamp W iring
FUSE PANEL
REINFORCEMENT
GROUND
WIRE
GROUND WIRE
SIDE MARKER
LAMP
PARKING LAMP
BRACKET
VIEW B
VIEW A
CR O SSM EM BER
2-9.00
S P E C IF IC A T IO N S
SECTION 8B
ELECTRICAL AND WIRING
CONTENTS
RADIO RECEIVER
REMOVAL AND INSTALLATION 3. AM Radio -Remove the radio support bracket stud nut
and lockwasher.
A M /F M Radio -Remove radio support bracket to
C-K Series
instrument panel screws.
Replacement (Fig. 8B-1) 4. Lift up on the rear edge of radio. Then push radio
forward until control shafts clear instrument panel.
1. Disconnect battery ground cable. Lower control far enough to disconnect electrical
harness.
2. Pull off radio control knobs and remove knob bezels.
Remove nuts and washers from control shafts using a 5. Disconnect power feed, speaker and antenna lead wires
deep well socket. and remove radio.
G Models AM Radio
1. Slide radio dial lens upward, approximately 1/8 inch.
Replacement (Fig. 8B-2)
2. Tip bottom edge of lens outward (toward technician)
and remove lens.
1 Disconnect battery ground cable.
3. Pull out bulb section and remove bulb.
2. Remove engine cover.
4. Install new bulb into socket and then reinstall bulb
3. Remove air cleaner cover and element.
section.
4. Remove radio control knobs and retaining nuts.
5. Reinstall dial lens.
5. Remove rear mounting bracket.
6. Push radio forward in vehicle and then lower assembly AM-FM And Stero Radio
and disconnect electrical harnesses and antenna lead. 1. Slide radio dial lens upward approximately 1/8 inch.
7. Remove radio receiver from vehicle.
2. Tip bottom edge of lens outward (toward technician)
8. To install, reverse Steps 1-7 above. and remove lens.
9. Check operation. 3. Remove rear dial plate screw. Place dial pointer at 16
CAUTION:Always attach speaker wiring harness and remove plate.
before applying power to the radio to prevent 4. Remove bulb.
receiver damage.
5. To install, reverse steps 1-4 above.
C Models—Right Side
1. Disconnect battery ground cable.
2. Remove engine cover.
3. Remove steering column brace bolts.
4. Remove radio support bracket bolt and instrument
panel upper and lower attaching screws.
5. Pull instrument panel assembly rearward to gain access
to speaker.
6. Remove speaker attaching screws, disconnect speaker
wiring harness and remove speaker.
AM /FM
7. To install, reverse Steps 1-6 above.
8. Check operation.
CK 1 0 5 (0 0 ) & Z 8 4
.0 9 + 2 0 9 (0 6 )
REINFORCEMENT
SPEAKER SPEAKER
GRILLE
[v ie w [ a 1
SPEAKER
CIRCUIT PROTECTION
GENERAL DESCRIPTION
All electrical circuits are protected against excessive CIRCUIT BREAKER (Fiq 8B-8)
loads which might occur due to shorts or overloads in the . .
wiring system. Such protection is provided by either a A circuit breaker is a protective device designed to open
circuit breaker, fuse or fusible link. Each of these protective circu^ when a current load is in excess of rated breaker
devices are explained below. capacity. If there is a short or other type of overload
condition in the circuit, the excess current willl open the
circuit breaker and cause it to cycle if it automatically
resets, thus, indicating there is something wrong in the
BREAKER TO JUNCTION
BLOCK
DIAGNOSIS
FUSE (Fig. 8B-8) Failures in a circuit are usually caused by short or open
circuits. Open circuits are usually caused by breaks in the
A common method of protection is to use a fuse in the
wiring, faulty connections or mechanical failure in a
circuit. Whenever there is an excessive current through the
component such as a switch or curcuit breaker. Short
circuit, the fusible element will melt and open the circuit.
circuits are usually caused by wires from different compo
The disadvantage of using a fuse instead of a circuit breaker
nents of the circuit contacting one anothe or by a wire or
is the fuse in a one-time protection and replacement is
component grounding to the metal of the body due to a
required.
screw driven through the wires, insulation cut through by a
sharp metal edge, etc.
FUSIBLE LINK (FIG. 8B-9) The following information may aid in locating and
correcting a failure in the body wiring electrical system.
In addition to circuit breakers and fuses, the wiring
1. If a major portion of the electrical circuit becomes
harness incorporates fusible links to protect the wiring.
inoperative simultaneously, the failure may be due to
Links are used rather than a fuse in wiring circuits that are
im proper connections between the front and rear
not normally fused, such as the ignition circuit. Fusible links
harness, or between the front harness and the chassis
are color coded red in the charging and load circuits to
wiring connector on top of fuse block.
match color coding of the circuit they protect. Each link is
four gage sizes smaller than the cable it is designed to 2. If only one of the circuits is inoperative, the failure is
protect and are marked on the insulation with wire gage size due to and open circuit or short in the affected circuit.
because the heavy insulation makes the link appear a Short circuits usually result in blown fuses or in the
heavier gage than it actually is. case of power equipment circuits, in the circuit breaker
opening the circuit. If the fuse is not blown and the
Engine com partm ent wiring harnesses incorporate circuit affected is a lamp circuit, check the bulb before
several fusible links. The same size wire with special proceeding with any checking procedures.
hypalon insulation must be used when replacing a fusible
3. The dome lamp and courtesy lamp circuits are designed
link.
so that the switches are in the "ground" side of the
The links are: circuit. If a condition is encountered where the lamps
1. A molded splice at the starter solenoid " B a t" terminal, remain "on" even though the jam b or courtesy lamp
14 gage red wire. Servicing requires splicing in a new switches are not actuated, the failure is probably due to
link. defective switches, or to the wire leading to the switches
being grounded to the metal body.
ON-VEHICLE SERVICE
Fusible Link R eplacem ent (Fig. 8B -10) HEADLAMPS WARNING BUZZER
R eplacem ent (Fig. 8 B -1 1)
A new fusible link can be installed, after the short
circuit is located and repaired, as follows:
1. Disconnect electrical connector from LPS (Lam ps)
1. Disconnect battery ground cable. socket of fuse panel.
2. Disconnect fusible link from junction block or starter 2. Disconnect electrical connector from IGN (Ignition)
solenoid. socket of fuse panel.
3. C ut harness directly behind connector to remove 3. Disconnect electrical connector to instrument panel
damaged fusible link (fig. 8B-9). harness.
4. Strip harness wire approximately 1/2". 4. Remove strap securing buzzer to instrum ent panel
5. Position clip around new fusible link and harness wire, harness.
crimp so that all wires are securely fastened. 5. Install replacement headlamp warning buzzer in re
6. Solder connection using rosin core solder. Use sufficient verse wequence of removal.
heat to obtain a good solder joint.
7. Tape all exposed wires with plastic electrical tape to SEAT BELT WARNING SYSTEM
prevent corrosion and shorting. All C-K type light duty trucks have a non-sequential
8. Connect fusible link to junction block or starter timer controlled seat belt warning system. This system has
solenoid. an instrument panel warning light that will illuminate every
9. Connect battery ground cable. time the ignition switch is turned on, whether or not the
driver’s seat belt is buckled, but will automatically go off
after 4-8 seconds. The buzzer is also controlled by the 4-8
second timer, but will operate only if the driver has not
buckled-up prior to turning on the ignition. If no attem pt is
made to buckle-up after turning on the ignition, the buzzer
will also shut-off automatically after 4-8 seconds.
CONNECTOR
A trouble shooting diagnostic chart and wiring sche
F U SIB LE LIN K matic are shown in Figures 8B-12 and 8B-13.
CONNECTOR C R IM P E D
AND SOLDERED
involved in this actuation of the alarm, and the key switch Component attachm ent and locations are illustrated in
will not stop the alarm. To stop the alarm, the plunger of the Figures 8B-15 thru 8B-18.
anti-tamper switch must be depressed, or power removed
from the system (Relay B disconnected).
SPECIFICATIONS
The headlam p circuits are protected by a circuit breaker in the In-line fuses are located in the au xilia ry heater circuits (C-K-P
models) and underhood lamp, front and rear A/C circuits (C-K
light switch. An electrical overload on the breaker will cause
the lamps to go on and off, or in some cases to remain off. models)
tW h e n incorporated by body builder
In addition to a fuse, the windshield w iper motor is also pro Do not use fuses of higher amperage than those recommended above
tected by a circuit breaker. If the motor overheats, due to
The following wiring harnesses are protected by a "fusible link" which is a
overloading caused by heavy snow, etc., the wipers will remain
special wire incorporated in the circuit headlamp hi-beam indicator, horn, air
stopped until the motor cools.
conditioning high blower, ignition circuits (C-K-P models) starter solenoid
(pull-in and hold) circuit(C-K models). Should an electrical overload occur, this
Fuses located in the Junction Block beneath the dash on the wire will fail and prevent damage to the major harness.
drivers side are:
G TRUCK
C-K TRUCK H eater, A / C ................................................................. 25 Amp
Idle Stop Solenoid, Cruise Control,
Heater, Front A/C, G enerator W arning Directional Signal Lamp, Directional
Lam p ........................................................................... 20 Amp Signal Indicator Lamp, Transmission
Idle Stop Solenoid, Aux. Battery, Radio, Downshift ( M - 4 0 ) ................................................... 10 Amp
Time D elay Relay, Emission Control Solenoid, C igarette Lighter, Dome Lamp, Spot Lamp . . . 15 Amp
Transmission Downshift ( M 4 0 ) .......................... 15 Amp Fuel G au ge, Brake W arning Lamp,
Cigarette Lighter, Clock, Dome Lamp, Temperature W arning Lamp, G enerator
Cargo L a m p ............................................................ 20 Amp W arning Lamp, O il Pressure W arning Lamp 3 Amp
Fuel G au g e , Brake W arning Lamp, Stop Lamp, Traffic H a z a r d .................................... 15 Amp
Temperature W arning Lamp, O il A uxiliary Battery, Backing Lamp, Radio
Pressure W arn ing Lamp .................................... 4 Amp Dial Lamp, Radio ................................................ 15 Amp
Courtesy Lamp, Roof M arker Lamp, Instrument Cluster Lamp, H eater Dial Lamp,
License Plate Lamp, Parking Lamp, Transmission Control Lamp with Tilt W h e el,
Side M arker Lamp, Tail Lamp, Cruise Control Lamp, W /S W ip e r
Clearance Lamp .................................................. 20 Amp Switch Lamp, H ead lam p B u z z e r...................... 3 Amp
Directional Signal Indicator Lamp, Stop Lamp, License Lamp, Parking Lamp, Sid e
Traffic H a z a r d ....................................................... 15 Amp M arker Lamp, Tail L a m p .................................... 15 Amp
Instrument Cluster Lamp, H eater Dial Lamp, W indshield W i p e r ..................................................... 25 Amp
Radio Dial Lamp, Cruise Control Lamp,
An in-line fuse is located in the Ammeter and the auxiliary
W indshield W ip e r Switch L a m p ...................... 4 Amp
heater circuits.
W indshield W ip e r /W a s h e r .................................... 25 Amp
Cruise Control, Rear W indow Aux., Fuel Tank, Do not use fuses of higher amperage rating than those recommended above
Tachometer, Back-up Lamp, Directional The following wiring harnesses are protected by a "fusible link" which is a
Signal Indicator Lamp, Directional special wire incorporated in the circuit, ignition, horn and headlamp hi-beam
Signal Lamp, H ead lam p Buzzer ........................ 15 Amp indicator circuits, air conditioning high blower. Should an electrical overload
occur, this wire will fail and prevent damage to the major harness.
P TRUCK
SECTION 8C
INSTRUMENT PANEL AND GAGES
CONTENTS
Instrument Panel and G ages........................................... 8C-1 Windshield Wiper and W asher (C-K and G Models) .8C-18
General Description......................................................... 8C-1 General Description......................................................... 8C-18
Diagnosis............................................................................ 8C-2 Electrical Circuits.......................................................... 8C-18
On-Vehicle Service.......................................................... 8C-7 Diagnosis............................................................................. 8C-21
Component Part Replacem ent................................... 8C-7 Wiper - On V ehicle....................................................... 8C-21
N eutral Start Sw itch.................................................. 8C-7 Wiper - Off Vehicle....................................................... 8C-21
Backing Lamp S w itc h ................................................ 8C-7 On Vehicle Service.......................................................... 8C-32
Windshield W iper/W iper/W asher S w itc h ........... 8C-7 Component Part Replacem ent................................... 8C-32
Ignition S w itc h ............................................................ 8C-7 Wiper M o to r................................................................. 8C-32
Instrument C lu s te r...................................................... 8C-10 Unit R epair........................................................................ 8C-32
W iper/W asher Disassembly........................................ 8C-32
Indicator and Illuminating Bulbs............................. 8C-10
Motor Disassembly........................................................ 8C-32
Laminated (Printed) C irc u it.................................... 8C-11
Motor A ssem bly............................................................ 8C-32
S p ee d o m e te r................................................................. 8C-11
Wiper A d ju s tm e n ts ....................................................... 8C-33
Speedometer Cable C o re ........................................... 8C-11
Washer P u m p ................................................................. 8C-33
Fuel G a u g e ................................................................... 8C-11
Windshield Wiper and Washer (P M odels)................ 8C-38
Temperature G a u g e .................................................... 8C-11
General Description......................................................... 8C-38
Temperature Sending U n i t ...................................... 8C-12
Diagnosis............................................................................ 8C-40
Oil Pressure G auge...................................................... 8C-12 Wiper - On Vehicle....................................................... 8C-40
Oil Pressure Sending U n i t ........................................ 8C-15 Unit Repair.......................... ............................................. 8C-45
V oltm eter...................................................................... 8C-15 Wiper M o to r................................................................... 8C-45
Directional Signal S w itc h ......................................... 8C-I5 Windshield W a s h e r....................................................... 8C-46
Instrument Panel Wiring Harnesses.............................. 8C-15 Wiring D i a g r a m s ............................................................. 8C-56
GENERAL DESCRIPTION
All instruments and gages are installed in the instru Bulbs are installed in plastic holders which lock into the
ment cluster. Instruments and gages can be serviced in the cluster housing.
vehicle (C-K Series); however, the entire cluster must be Regular maintenance is not required on the instrument
removed from the vehicle for servicing of the instruments cluster or its components other than maintaining clean, tight
and gages (G Series). Illuminating and indicator lamps may electrical connections, replacing defective parts and keeping
be replaced without removing the cluster from the vehicle. the speedometer cable properly lubricated.
8C-2 INSTRUMENT PANEL AND GAGES
D IA G N O S IS
4. C o o la n t te m p e ra tu re 4. L o c a te a n d c o rre c t cause
above 258 degrees F. o f high c o o la n t te m p e ra tu re.
Cause Correction
Cause Correction
Cause Correction
Cause Correction
SPEEDOMETER
Cause Correction
GAS GAUGE
D A S H U N IT N E V E R R E A D S F U L L
1. C o n n e c t G a s G a u g e T e ste r J-2 2 3 4 4 to ta n k u n it
feed w ire an d o b se rv e dash unit.
3. N o te d ash u n it p o in te r w ith en g in e ru n n in g .
1. C h e ck c lu ste r fuse.
j
4. R em o v e d ash u n it a n d c h e c k .
3 . Open in f i e l d . 3. R e p la c e rotor.
098 DIA.
SWITCH LEVER
M O U N T IN G
BRACKET
COLUM N
ON-VEHICLE SERVICE
NEUTRAL START SWITCH Column Mounted Switch (Manual Transmission)
Replacement
C-K Models (Fig. 8C-1) 1. Disconnect battery ground cable.
2. Disconnect switch wiring harness.
Replacement and Adjustment
3. Remove column mounting screws and remove switch.
1. Disconnect battery ground cable. 4. Assemble the switch to the column. Fasten in position
by installing mounting screws.
2. Disconnect electrical harness at switch.
5. Install battery ground cable.
3. Remove switch mounting screws and remove switch. 6. Check operation to make sure back-up lights come on
4. Position shift lever in neutral gate notch. in reverse gear only.
5. Insert .096" (2.4mm) gage pin to depth of 3/8 inch Transmission Mounted Switch
(9.5mm) into switch gage hole, switch assembly is fixed Replacement
in neutral position with internal plastic shear pin. 1. Raise vehicle on a hoist.
6. Assemble the switch to column by inserting the switch 2. Disconnect switch wiring harness.
carrier tang in the shift tube slot and fasten in position 3. Remove switch from transmission.
by assembling mounting screws to retainers. If retainer 4. To install a new switch, reverse Steps 1-3 above.
strips out it must be replaced.
WINDSHIELD WASHER/WIPER SWITCH
7. Remove .096" gage pin.
C-K Models
8. Move shift lever out of neutral gate notch to park gate Replacement
position to shear switch internal plastic pin.
1. Disconnect battery ground cable.
9. Return shift lever to neutral gate notch.
2. Remove instrument panel bezel screws and bezel.
10. Switch (2.0mm) gage hole will freely admit .080" gage
3. Remove switch attaching screws.
pin to a depth of 3/8 inch (9.5mm).
4. Pull out on switch assembly and disconnect electrical
11. If pin will not freely enter gage hole, switch must be
harness - remove switch.
reset as below.
5. To install, reverse Steps 1-4 above. Check switch
12. Connect battery ground cable and electrical harness.
operation before reinstalling instrument panel bezel.
Reset Installation Procedure G Models
1. Place shift lever in neutral gate notch. Replacement
2. Loosen attaching screws. 1. Disconnect battery ground cable.
3. Rotate switch on column and insert .096" (2.4mm) 2. Reach up behind left side of instrument panel, and:
gage pin to depth of 3/8 inch (9.5mm). a. Remove plug connector from rear of switch.
4. Tighten attaching screws. b. Remove (3) mounting screws securing bezel and
5. R epeat installation procedure Steps 7 through 12 ground wires to switch.
above. 3. Replace switch, installing ground wire and connector.
Check operation of switch, first observing washer
G-P Series solvent level.
Replacement (Fig. 8C-1)
IGNITION SWITCH
1. Raise vehicle on a hoist. C-K Series
2. Disconnect the switch harness from the switch.
See Section 3B - Steering, for ignition switch replace
3. Remove switch mounting bolts and remove switch. ment procedure.
4. Assemble new switch loosely to mounting bracket.
G Series
5. Align .093/.097" (2.3/2.4mm) hole in Lever (B) with Replacement (Fig. 8C-2)
hole in Switch Assembly. Insert Pin (A) to hold in
1. Disconnect battery ground cable.
N E U T R A L position.
2. Remove lock cylinder by positioning switch in " A C C "
6. Set Transmission Lever (C) in N E U T R A L position by
position and inserting stiff wire in small hole in cylinder
the following method.
face. Push in on wire to depress plunger and continue to
Obtain N E U T R A L by moving Transmission Lever
turn key counterclockwise until lock cylinder can be
counterclockwise to LI detent, then clockwise three
removed.
detents to the N E U T R A L detent position.
3. Remove metallic ignition switch nut.
7. Install Rod into Transmission Lever and Switch Lever.
Secure with clips. 4. Pull ignition switch out from behind instrument panel
and remove "theft resistant" connector. Use a screw
8. Tighten switch attaching screws.
driver to unsnap locking tangs on connector from their
9. Lower vehicle from hoist and carefully check switch position on switch.
operation.
5. Snap connector into place on new ignition switch.
BACKING LAMP SWITCH 6. Place switch into position from behind instrum ent
See "N eutral Start Switch" for automatic transmis panel, first adding grounding ring then install ignition
sion models. switch nut.
LIGHT TRUCK SERVICF MANUAI
8C-8 INSTRUMENT PANEL AND GAGES
BEZEL
(TYPICAL)
INSTRUMENT BEZEL
CLUSTER
INSTRUMENT
PRINTED CIRCUIT CLUSTER INSTRUMENT CLUSTER
HI BEAM IN D .
INSTR. CLUSTER
OIL PRESSURE IN D
INSTRUMENT
E N G IN E TEMP IN D .
CLUSTER
BRAKE W A R N IN G IN D .
G E N . TELL TALE
FUEL G A G E CLIPPING
AMP G A G E CLIPPING
BRAKE W A R N (EXC U 35)
CLOCK & U35
TEMP GAGE CLIPPING
BRAKE W A R N & U 35
FUEL GA G E CLIPPING & 16
TURN SIGNAL IN D .
VIEW B
PRINTED CIRCUIT
7. Install lock cylinder, key inserted. speedometer head, then pulling cable free from head as
8. Install battery ground cable. tang is depressed.
3. Remove clock set stem knob.
INSTRUMENT CLUSTER 4. Remove screws attaching instrument cluster bezel to
C-K Series instrument panel and remove bezel.
Replacement (Fig. 8C-3) 5. Remove two lower cluster attachm ent screws.
1. Disconnect battery ground cable. 6. Pull top of cluster away from instrument panel and lift
2. Remove headlamp switch control knob. out bottom of cluster.
3. Remove radio control knobs. 7. Unplug instrum ent panel harness connector from
printed circuit.
4. Remove four screws and remove steering column cover.
8. Remove cluster to bench for further disassembly
5. Remove eight screws and remove instrument bezel.
(laminated printed circuit, speedometer head, gages).
6. Reach up under instrum ent cluster and disconnect
speedometer by first depressing tang on rear of speed INDICATOR AND ILLUMINATING BULBS
ometer head, then pulling cable free from head as tang
is depressed.
All Models
Replacement (Figs. 8C-3 and 8C-4)
7. Remove cluster to bench for further disassembly
(laminated printed circuit, speedometer head, gages). 1. Reach up under instrument panel and turn bulb holder
counterclockwise to remove from cluster housing.
8. Install cluster in reverse order of removal.
2. Pull bulb straight out to remove from holder.
G Series . 3. Install replacement bulb in holder, press inward to lock
Replacement (Fig. 8C-4) in place.
1. Disconnect battery ground cable. 4. Insert holder into housing, with lugs on holder entering
2. Reach up under instrum ent cluster and disconnect notches in case, and turn clockwise to lock holder
speedometer cable by first depressing tang on rear of against printed circuit.
LIGHT TRUCK SERVICE MANUAL
INSTRUMENT PANEL AND GAGES 8C-11
G Models
Replacem ent
1. Remove instrument cluster as previously described in
this section.
2. Remove and replace volt-temp-oil gage assembly as
previously described.
INSTRUMENT
CLUSTER
TRANSFER
CASE
TRANS COVER
TRANS
-HARN
INSTRUMENT CL U ST ER
SPLG WIRES
TRANS. ASM.
ACCELERATOR
CABLE
DASH PANEL
V IE W
OIL PRESSURE SENDING UNIT 2. Remove gage to instrument panel screws and remove
meter.
All Models 3. To install, reverse Steps 1 and 2 above and check meter
operation.
Replacement
Be sure meter studs engage clips holding printed circuit
1. Disconnect wiring harness connector from sending unit to back of cluster housing.
terminal located in block above starter on L-6 engines,
at left front of distributor on V-8 (except 454 V-8) or G Models
rear left side of block (454 V-8) engines.
Replacement
2. Remove sending unit using Tool J21757. Replace with
new unit and check operation. 1. Remove instrum ent cluster assembly as previously
described in this section.
VOLTMETER 2. Remove and replace volt-temp-oil gage assembly as
previously described.
C-K Series
Replacement
1. Perform Steps 1-6 of "Speedometer - Replacement"
procedure.
L IG H T SW IT C H
CONN
IN S T P A N EL
H A R N E SS
L IG H T SW IT C H
CONN
R E C E IV E R IN S T P A N E L
R E C E IV E R HARN
H AR N ESS
HARN
IN S T P A N E L FU S E
H A R N E SS PANEL
FU SE
P A N EL
VIEW B
Fig. 8C-5--lnstrument Panel W iring - R.H. - G Models
IG N SW
BLOWER LIGHT SW C O N N
MOTOR
LEAD \
W S W & W A SWITCH CONN
l/P HARN
GRD WIRE
BODY W IR IN G ,
HARN & C O N N
V IE W
GROUNDINC W/0
BRACKET
BUS BAR
PARKING
BRAKE DIM M ER SWITCH
A .C IG LIGHTER C O N N ^
r - HEATER CONTROL LP (INSTALLED)
— HEATER SW C O N N • BRACKET
BOLTS
C IG LIGHTER
STOP LP
CONN
SWITCH
■NEUTRAL
IG N IT IO N ■ START
SW C O N N
SWITCH
BRAKE^
PEDAL
BRACKET
DIRECTIONAL
B A C K IN G SIGNAL
LAMP FLASHER
CONN ASM
l/P HARNESS
IN S T CLU STCH
CO N N ECTO R.
U)/U) SW CONN
LAMP3WITCH-
CONNECTOR
LPMPSO)
■RELfi
HORNy GROUNDWIRE P/MMEZ.
SWITCH
-PARK. BRAKE
BRACKET
V IE W
-DIM
CONMERTSOW
NEC RITCH
SEATBELT
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.
Attached to the end of the cylinder housing is a valve
assembly consisting of two exhaust check valves and one
Jj STAKING
intake check valve. Figure 8 C - 11.
^ ( 1 0 PLACES) Note the cam follower pin that extends through an
elongated opening in the piston actuator plate. When the
wiper motor is running, a 4 lobe cam, which is part of the
Fig. 8C-9~Wiper M otor Housing wiper gear, moves the cam follower back and forth.
LIGHT TRUCK SERVICE MANUAL
INSTRUMENT PANEL AND GAGES 8C-19
PARK SWITCH
(Normally Closed)
I GEAR
i CAM i
r
WASHER
RELAY COIL
I
WIPER/WASHER PUMP ASS’Y |
ELONGATED
SLOT n
TANG
SPRING
PISTON
COMPRESSED
INTAKE
VALVE
OPEN
FROM DIRECTION OF TRAVEL
WASHER
JAR ■'/ / / i
ACTUATOR PLATE
EXHAUST
VALVES
CLOSED
INTAKE STROKE
LEG IN SLOT
ON RIM OF GEAR
DIAGNOSIS
WIPER - ON 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 dash
switch.
12V( + ^ ^ H I SPEECH
12V( + )
DIAGNOSIS CHART
SYMPTOM PROCEDURE
NO.
7) Intermittent operation 7
Go To STEP 5 Go To STEP 2
Procedure 1 (cont.)
PROCEDURE 5
(Wiper shuts off but blades don’t return to park position)
STEP 2 Remove w iring from w iper term inals 1, 2,3. Connect 12v+ to wiper terminal 1 only.
STEP 3 Disconnect wiper linkage from wiper crank arm and repeat Step 1.
P r o b le m is in w ip e r
Check w iper linkage
m o to r. C h e c k fo r
fo r a binding condition
a r m a t u r e e n d p la y ,
and repair or replace s h o r te d o r g r o u n d e d
as req’d. a r m a tu r e .
Go To STEP 3 Go To STEP 4
Remove washer pump cover and re-connect wiring to wiper motor terminals 1, 2 and
STEP 4
3. Turn on wiper motor and observe if ratchet pawl is moving back and forth.
SPRING
leg\ i>
awi Moves back
Not moving
and forth
Check the following: Leave wiper running
1) Pawl spring properly and Go To STEP 5
connected.
2) Cam-follower not
binding.
STEP 5 Connect 12(+) volts to one of washer pump terminals (6 or 7) and ground the other for
approx. 2 seconds. Observe it relay armature is pulled toward the relay coil; armature
leg drops down on gear ramp and ratchet pawl starts rotating ratchet gear.
Refer to view in STEP 4.
STEP 6
Disconnect wiring from wiper unit; remove washer pump cover and re-connect
w iring to wiper-washer. Turn on wiper and check the follow ing items.__________
-------
icifeni 6 • !J- / . I T 1 0 TO M l
CHECK W IPER OPERATIONS
B n tiV iU
o nwtt>
M l v :--v hr xJ*':
i *’I
W IP ER S DO W IPER OPERATE
ru inun N O R M A LLY
NOT OPERATE
iO fl j!c: j i r m i s . tri iw<: j r i ! oi •:* rim
N ORM ALLY
, *j*?.sq j&i,] y j
lliiM umuo fe’fix (u?!>b .j', ' D ETERM IN E
CONTROLLER IS
REFER TO
P R O P ER LY CONNECTED
W IND SHIELD
H Dum ? w *
W IPER DIAGNOSIS
)p iTfki 8) -in '■ CONTROLLER CONNECTED
^ I -3 8 S jSjSIi GJ T .b
RELAY DOES
CHECK W IPER SY S T E M IS
NOT FUNCTION
SW ITCH .n? RESTORED
(SEE PRO CEDU RE) h . ,T >•'* ’>
:GfT '
K! m A:r • •j REPLACE
=L RELAY
•c v ia ;.! SW ITCH
SWITCH OK
DEFECTIVE
S Y S T E M IS
REPLACE
REPLACE R ESTO RED
CONTROLLER
SWITCH
" ..... 1 " r~
S YST EM SYST EM
RESTORED RESTORED
01 O'
Control
full clock w ise)
—
in on
uq bns : t'.; /joa i ;q#jo-,brf* bh-i
(Oft Mode
control)
(Rotate
Delay
:>u:
Delay
W ash
press
Mist
s= o
o -J z
Selector Switch Checking Procedure
Dark Blue X
If the w iper/w asher selecto r sw itch is su sp ected o f being
faulty, it can be ch eck ed with an ohm meter as indicated in Light Blue X X X X
table below . Before perform ing any continuity ch eck on
Green X X X X X
selector sw itch , d iscon n ect both harness con n ectors from
sw itch to controller. N e x t, place selecto r sw itch in m ode Black X X X X X X
desired and perform a continuity ch eck betw een the indi
Black Wht Str X X X X X
vidual leads as indicated in table b elow , Figure 15. If there is
a meter reading at each ch eck but no indication o f shorts,
Orange X
sw itch can be assum ed to be good.
.■ i if- *J*
White X
.Hjfunfi'M- ■■ •
:B /Gig 3fii oi )» rt..
ON-VEHICLE SERVICE
WIPER MOTOR 10. Remove three screws securing wiper motor to cowl and
lift wiper motor out from under dash for further
disassembly on bench.
C-K Models
11. To install, reverse Steps 1-10 above.
Replacement (Fig. 8C-17) NOTICE: Install wiper in the PARK position. Lube
wiper motor crank arm pivot prior to installation.
1. Make sure wiper motor is in Park position.
2. Open hood and disconnect ground cable from battery. UNIT REPAIR
3. Disconnect electrical harness at wiper motor and hoses
at washer pump. WIPER MOTOR
4. Reach down through access hole in plenum and loosen Repairs to the motor/gear box section of the wiper are
wiper drive rod attaching screws. Remove drive rod limited to the switch, armature, and cap and brush holder
from wiper motor crank arm. assy., plus the external parts such as the crank arm, spacer/
5. Remove wiper motor to dash panel attaching screws seal (plastic) and output shaft seal.
and remove the motor assembly.
PARK SWITCH
6. To install, reverse Steps 1-5 above.
Lubricate wiper motor crank arm pivot prior to This is part of the washer pump relay coil assembly.
reinstallation. Refer to figui e 8 C -19.
Removal
G Series
1. Disconnect wiring from wiper assembly and remove
Replacement (Fig. 8C-18) washer pump cover.
2. Remove pawl spring.
1. Make sure wiper motor is in Park position. 3. Push in retainer tab to release relay coil-park switch
2. Open hood and disconnect battery ground cable. assembly from washer frame.
3. Remove wiper arms from wiper transmission linkage. 4. To re-assemble, reverse steps 1 thru 3 and check wiper
operation, figure 8C-19.
4. Remove remaining screws securing cowl panel cover
and lift off.
5. Loosen nuts holding transmission linkage to wiper ARMATURE ASSEMBLY END CAP-BRUSH HOLDER
motor crank arm and lift linkage off arm.
ASSEMBLY
6. Disconnect power feed to wiper motor at multiple
connector. Replacement
7. Remove left dash defroster outlet from flex hose and 1. Bend retainer tabs as required to provide clearance for
push hose aside for access to wiper motor screws. removing end cap assembly. Figure 8C-20.
8. Remove one screw securing left hand heater duct to 2. To assist in pushing the end of the motor housing,
engine cover shroud and slip heater duct down and out. rotate crank arm clock-wise (looking at crankarm).
9. Protect carpet, then remove windshield washer hoses 3. Pull end cap assembly off the arm ature shaft and pull
from washer pump. arm ature out of wiper housing.
Replace
1. Release brush spring tension figure 8C-21 and slide
brushes back in their respective brush holders.
2. Assemble a r m a tu re in end cap assembly and re
position brush spring legs behind their respective tabs,
figure 8C-22.
3. To maintain the end cap in its assembled position on
arm ature shaft during re-assembly of arm ature in the
wiper housing proceed as follows: Using small wire
such as tag wire, tie arm ature to end cap assembly as
shown in figure 8C-23.
4. Guide a rm a tu re worm shaft through the housing
bearing.
The strong magnetic field will pull arm ature toward
one of the magnets. It will be necessary to overcome the
magnetic force to start shaft into the bearing.
5. Guide terminal housing of end cap into the slot area of
Fig. 8C-17--Wiper M otor (C-K Series) the wiper housing.
LIGHT TRUCK SERVICE MANUAL
INSTRUMENT PANEL AND GAGES 8C-33
6. Remove wire used to attach arm ature to end cap. This WASHER PUMP
should be done before end cap enters the housing.
7. After wire is removed, rotate crank arm slightly to Relay Coil
permit armature worm shaft to engage gear teeth. The This is part of park switch assembly. Refer to "P ark
end cap assembly can then be pushed into the housing switch" for disassembly-assembly procedure.
until it bottoms against the end of the housing.
Ratchet Paw l
8. Bend the 4 tabs as required to secure the end cap in
position figure 8-11. Refer to Figure 8C-26.
9. Check wiper operation. 1. Disconnect pawl spring.
2. Rem ove"e" type retainer ring and slip pawl off of
CRANK ARM, SPACER, SEAL Refer to Figure SC- shaft.
24 Dog Spring: Refer to Figure 8C-26
Replacement 1. Remove screw th a t atta c h e s dog spring to washer
1. Remove crank arm retaining nut, crank arm, shaft seal frame.
and spacer in the order indicated.
When re-assembling the shaft seal, be sure flat side is Ratchet Gear: Refer to Figure 8C-26
toward crank arm. 1. Remove dog spring and ratchet pawl.
2. When re-assembling the crank arm, be sure wiper 2. Move leg of retainer spring out of shaft groove and slide
motor is in park (refer to figure 8C-25), and assemble ratchet gear off shaft. Be careful not to lose retainer
crank arm on shaft in position shown in Figure 8C-25. spring.
3. To re-assemble gear, reverse steps 1 and 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.
LIGHT TRUCK SERVICE MANUAL
8C-34 INSTRUMENT PANEL AND GAGES
C O N N E C T IO N S TO O P E R A T E W IP E R S IN D E P E N D E N T L Y OF V E H IC L E W I R I N G A N D D A S H S W ITC H.
LO SPEED
12V(
PARK
B E SU RE BRUSH L E A D S
ARE ROUTED CO RR EC T LY
A N D A R E N O T T O U C H IN G
E A C H OTHER
B R U S H S P R IN G L E G
IN C O R R E C T P O S IT IO N
F O R R E - A S S E M B L Y IN
M O T O R (3 S P R IN G S )
S P E E D BRUSH
LEA D ROUTED
CO RRECTLY
NOTE: B E SU R E LO W ER
B R U S H S P R IN G L E G S A R E
IN B R U S H H O L D E R S L O T S
B R U S H S P R IN G IN R E L G A S E D
P O S IT IO N (3 S P R IN G S )
R O T A T E BRUSH
SP R IN G IN D IR E C T IO N
B R U S H S P R IN G LEG OF AR R O W TO RE
RELEASED FROM RE P O SITIO N IT B E H IN D
T A IN E R NOTCH R E T A IN E R NOTCH
R E T A IN E R
NOTCH
SHAFT SEA L
(RUBBER)
SP A CER
(PLASTIC)
ARMATURE
END PLAY
ADJUSTING
SCREW
“A X ” - I D E N T I F 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 I T IO N
A Y - ID E N T IF IC A T IO N
CODE
P A W L S P R IN G
“E ” R E T A IN E R
R IN G
L E G O F R E T A IN E R
IN R A T C H E T G E A R
SH AFT GROOVE
D O G S P R IN G
RATCHET G EA R
M O U N T IN G G R O O V E
(Both Sides)
PER GEAR
TRAIN
WIPER DA S H
TERMINAL S WI TC H
BOARD
PARK I
S WI TC H
TOTX
GRAY
ig n it io n /
SHUNT F - NAT. W I R E S WI TC H
wiper will continue to operate until the wiper output gear is switch to ground. The series field and arm ature circuit is
turned to a position where its cam opens the park switch. also completed from terminal No. 1 through the parking
Referring to Figure 8C-30, it can be seen that the wiper switch to ground.
motor circuits are completed to ground through the parking The shunt field is connected direct to ground, by
switch. passing the resistor. This results in LO speed operation
I■ 1Jji 51"*j.i during the parking operation.
The wiper motor must be securely grounded to body W hen the o utput gear cam opens the park switch
metal. contacts, the wiper is OFF.
The shunt field circuit is completed from terminal No.
3 via the switch to terminal No. 1 through the parking
DASH
SWITCH
PARK OFF-LO-Hl
SWITCH
Fig. 8 C - 3 0 - P A R K IN G C ircuit
DIAGNOSIS
WIPER - ON VEHICLE a. If wiper operates correctly independently of switch
1. Inspect for the following items: and vehicle wiring, refer to the D IA G N O S I S
a. Wiring harness is securely connected to wiper and C H A R T - W IP E R O N V E H IC L E .
switch. b. If wiper still fails to operate correctly in Step 3,
b. Wiper motor is securely grounded to body. disconnect wiper linkage from motor crankarm and
c. Wiper switch is securely mounted and grounded. try operating wiper again. If wiper opeates correctly
d. Check fuse. independently of linkage, check linkage for cause of
wiper malfunction.
2. If items in Step 1 check out, try operating wiper in both
" L O " and " H I " speeds, then turn wiper off (blades c. If wiper fails to operate correctly independently of
should return to park position). If wiper fails to operate linkage, remove wiper motor from vehicle and refer
correctly, proceed to Step 3. to D IA G N O IS C H A R T -W IP E R O F F V E H IC L E .
3. Disconnect wiring harness from wiper and try operat
ing wiper as shown in Figure 8C -3 1.
C O N D IT IO N A PPA R E N T CAUSE C O R R E C T IO N
B. W ip e r has "L o" speed only A. Defective w iper switch A. R e p la c e w iper switch
C. W ip er has "H i" speed only A. Defective w iper switch A. R e p la c e w iper switch
3. W iper has "H i" speed only A. O p en circuit in wire (N o. 3 A. L o c ate b ro ken wire
te rm in a l on wiper m o to r) to a n d rep air
w iper switch
4. W ip e r has "L o" speed only A. G r o u n d e d wire (N o. 3 A. L ocate short circuit and
term inal on wiper m o to r) to rep air
w iper switch
C O N D IT IO N A PP A R E N T CAUSE C O R R E C T IO N
E. O p e n circuit in a r m a tu r e E. R eplace a r m a t u r e
C. W ip e r has " H i" speed only A. O p en circuit in sh u n t field A. R e pla c e fra m e a n d field
coil assem bly
LO SPEED - AS SHOWN
WIPER
GROUND STRAP
C O N D IT IO N A PPA R E N T CAUSE C O R R E C T IO N
D. R a tc h e t wheel dog D. R e p la c e o f re p a ir
b roken o r not c on ta c tin g ra tc h e t wheel do g
ratchet wheel teeth
ON-VEHICLE SERVICE
WIPER MOTOR manufacturers; however, disassembly of the unit will be
covered.
Wiper motor replacement procedures are not included
here since installation is performed by the individual body
UNIT REPAIR
5. Drill out gear box cover retaining rivets, remove cover
WIPER MOTOR
from gear train.
Disassembly (Fig. 8C-34) Screws, nuts and lockwashers for reassembling cover to
wiper are contained in the service repair package.
6. Remove output gear and shaft assembly, then slide
Gear Box intermediate gear and pinion assembly off shaft.
1. Remove the two washer pump mounting screws and lift 7. If necessary, remove terminal board and park switch
pump off washer. assembly as follows:
2. Remove washer pump drive cam as required (figs. SC- a. Unsolder motor leads from terminals. Code motor
33 and 8C-34). The cam is pressed on the shaft but can leads.
be wedged off by using two screwdrivers between cam b. Drill out rivets securing terminal board and park
and plate. switch ground strap to mounting plate. Screws, nuts
3. Clamp crank arm in a vise and remove crank arm and washers for attaching a replacement terminal
retaining nut. board park switch assembly are included with the
NOTICE: Failure to clamp crank arm may result in replacement assembly.
stripping of wiper gears.
Motor
4. Remove crank arm, seal cap, retaining ring, and end-
play washers. 1. Follow Steps 1 through 7b under gear box disassembly.
Seal cap should be cleaned and repacked with a 2. Remove motor through bolts, tap motor frame lightly,
waterproof grease before reassembly. and remove motor from mounting plate.
1. Nut 7. O u tp u t Gear and 11. Brush Plate Assembly and 15. Armature
2. Crank Arm Shaft Assembly M ounting Brackets 16. Thrust Plug
3. Seal Cap 8. Interm ediate G ear 12. Brushes 17. Frame and Field
4. Retaining Cap 9. W ave Washer 13. W ave Washers 18. End Plate
5. Washer 10. G e a r Box Housing 14. Flat Washers 19. Tie Bolts (Two Required)
6. G e a r Box Cover
3. Remove brush spring tension (fig. 8C-34), slide a rm a 2. Place wiper in park position and install crank arm on
ture and end plate from motor frame. Pull end plate output shaft, rotate crank so alignment marks line up
from armature. with those on cover (fig. 8C-36).
Thrust plug located between arm ature shaft and end 3. Replace retaining nut, place crank arm in vise, tighten
plate. retaining nut.
4. Remove end play adjusting washers from armature,
noting arrangement for proper reinstallation.
WINDSHIELD WASHER
Inspection
The positive displacement washer pump used on the
Check and inspect all parts for wear; replace as two-speed non-depressed park wipers (fig. 8C-37) use a
necessary. All parts can be replaced individually except pump mechanism consisting of a piston, piston spring and
motor frame and field, which is serviced as an assembly. valve arrangement driven by a (4) lobe cam, and follower
Service kits also provide screws, nuts and washers to replace assembly (fig. 8C-39). The cam is attached to one shaft of
gear cover and terminal board rivets.
Assembly ------G E A R C A S E G R O O V E S
Refer to Figure 8C-34 for exploded view of motor and — CRANK ARM GROOVES
gear train.
Motor
Gear Box
1. Assemble gear box using reverse of disassembly
procedure.
Lubricate gear teeth with Delco Cam and Ball Bearing
lubricant (or equivalent). Be sure cover is properly
located over dowel pins and be sure to reinstall ground
strap.
Fig. 8C -36 --W ip er M o t o r C ra n k A rm in Park Position
SO L EN O ID COIL
VALVE \ SO LEN OID
ASSEM BLY _ \ PLUNGER
RATCHET
PAWL
SPRIN G
C A M FOLLOW ER
UPPER PIN
4 LOBE C A M
(PRESS FIT
"E” R IN G
O N SHAFT)
CAM
FOLLOW ER
RATCHET
PAWL
RATCHET D O G SOLENO ID
R ETAINING ASSEMBLY
SCREW
RATCHET
PAWL
SPRING
VA LVE ASSEMBLY
M O U N T IN G SCREW
FRAME
ft RATCHET
\ PAW L
RATCHET
G R O O V ES WHEEL J.
BOTH SIDES
Fig. 8C-39--Washer Pump Drive Cam and Actuator Fig. 8C-41--Washer Pump-Exploded View
WIRING DIAGRAMS
Body and Chassis Wiring Diagrams and circuit identi
fication charts are shown on the pages which follow.
FROM
WASHER
JAR
N U K E STROKE
INTAKE
VA L V E
CLO SED
EXHAUST STR O K E
W IRE S IZ E C O N V E R S IO N T A B L E
M E T R IC S IZ E
(mm)2 AWG S IZ E
.22 24
.5 20
.8 18
1 16
2 14
3 12
5 10
8 8
13 6
19 4
32 2
E L E C T R IC A L C IR C U IT ID E N T IF IC A T IO N
2 Red Feed, Batt ery - U n fu se d 39 Pin k - B la c k Feed, Ign. S w . " O n and C r a n k "
3 Pink Feed, Ign. Sw. " O n & C r a n k " C o n tr o lle d - Fused
Con trolled, U nfu sed 40 Orange Feed, Battery - Fused
4 Brown Feed, Ign. Sw. " A c c s y & O n " 41 Br o w n -W h ite Feed, Ign. Sw. " A c c s y and
Controll ed, Unfu se d O n " C o n tr o ll e d - Fused
5 Y e l lo w Neutral Safety Start Sw. or 42 Yellow Feed, A / C A u t o Rela y C o n t r o ll e d
Start Relay Feed 43 Yellow R a d i o Feed
6 Purple Starter S o le n o i d Feed 44 D a r k Green I.P. and Lights Feed (U sually
7 Y ellow Prim ary Ign ition Resistance L ight S w . to Fuse)
By-Pass 45 B lack M a rke r and Clearance L a m p s
8 Gray In str u m ent and Panel Lights (Trailers)
(Fused No. 44 Cir.) 46 D a r k Blue Rear Seat S pe ak er Feed F r o m
9 Brown Tail, License, Park and Side S in gle R a d i o or R ig h t Stereo
M a r k e r L a m p Feed 47 D a r k Blue A u x il i a r y C ir c u it (Trailer)
10 Y ellow D i m m e r Sw. Feed 48 Gray Tail Lp. - H e a d la m p Sw. " O n " -
11 Light Green H e a d la m p Feed, H i-B e am
or Dir. S ig na l and S t o p -
12 Tan H e a d la m p Feed, L o -B e a m
H e a d la m p Sw. " O f f " Rear L.H.
13 Purple F r o n t Parking L a m p s
49 D a r k Blue Tail Lp. - H e a d la m p Sw. " O n " -
14 Light Blue L.H. Indicato r and Front
or Dir. S ig na l and S t o p -
Directional La m p s
H e a d la m p Sw. " O f f " Rear R.H .
15 D a r k Blue R.H . Indicato r and F ront
50 Brown Feed, Ign. Sw. " O n " C o n tr o lle d -
Direction al La m p s
Fused
16 Purple Direction al Signal Sw., Feed
51 Yellow Blo w e r Resistor Feed - L o w
F r o m Flasher
52 Orange Feed, B l o w S w . " H i " or
17 White Direction al Sig nal Sw., Feed
Selector Sw. " M a x C o l d "
F r o m S t o p Sw.
C o n tr o lle d
18 Y e l lo w S t o p and Directional L a m p 53 L ight Green Valve Release S o le n o i d to
or Direction al L a m p
C o n tr o l B o x
O n l y - Rear L.H. 54 D a r k Green C o n tr o l to Shie ld
19 D a r k Green S t o p and Directional L a m p or 55 Orange K i c k D o w n S o le n o i d Feed
Directional L a m p O n l y - 56 Tan A m p li f i e r to Tra n sdu c er
Rear R.H . 57 Orange L.H. C o r n e r in g L a m p Feed
20 Lig h t Blue S t o p L a m p (O nly) 58 Black R.H . C o r n e r in g L a m p Feed
21 Pink S p o t Light 59 D a r k Green C o m p r e s s o r Feed
22 White Direct G r o u n d - Trailer 60 Or a n g e -B la c k Feed, Battery, C ir c u it Breaker
24 Light Green B a c k U p L a m p Feed Protected
25 Brown Feed, V o lta g e R egula to r 61 Y e l lo w G r o u n d , Resistive, A u t o A / C
C on trolled A m b . S e n so r C o n tr o lle d
26 D a r k Blue Field Cir cu it (F ) (G e n /R eg.) 62 Light Green G r o u n d , Resistive, A u t o A / C
27 Brown T ra f f ic Hazard Sw., Feed F r o m Feed B a c k Pot C o n tr o lle d
Hazard Flasher 63 Tan Feed, B lo w e r Sw. " M e d i u m 1 "
28 B lac k G r o u n d , H o r n Sw. C o n troll ed
C o n tr o lle d
29 D a r k Green H o r n Feed 64 Brown B lo w e r Sw. Feed F r o m A / C
30 Pi nk Fuel G a u g e to T a n k Unit
Sele ctor Sw.
31 T an Oil Pressure, Engine 65 Purple Blo w e r M o t o r Feed
32 Y e l lo w M a p L igh t Feed
66 L ight Green Feed, A / C S ele ctor Sw. C o n tr o lle d
33 T an -W h ite W a r n in g L igh t - Brake
(C o m p . Ct.)
34 Purple F o g or Drive L a m p 67 L ight Blue Feed, A / C F reon Press, C u t - O u t
35 D a rk Green G r o u n d , Eng. C o o la n t Temp.
Sw. C o n t r o ll e d
Sw. or E C M C o n troll ed (H ot)
68 Y e l lo w - B la c k G r o u n d , Resistive, L o w C o o la n t
36 Light Green G r o u n d , Eng. Tem p . Sw.
Probe C o n tr o lle d
C o n tr o lle d (Cold)
69 Gray G r o u n d L o w C o o la n t M o d u l e
37 L ight Green G r o u n d , Eng. Metal T em p.
C o n tr o lle d
Sw. C o n tr o lle d (H ot) 70 Pin k Feed, R e la y C on trolled , Ign.
38 D a rk Blue Flasher Fused Feed
Sw. C o n tr o ll e d
E L E C T R IC A L C IR C U IT ID E N T IF IC A T IO N (Cont'd)
C ir cu it Cir cu it Circuit C ir cu it
C ir c u it N a m e C ir cu it N a m e
Number C o lo r Number C o lo r
- '
71 B la c k G r o u n d , A / C Selector Sw. " D e f " 131 B la c k -P in k G en e ra to r (A lt ern ator) Ext.
C o n tr o lle d Resist. 1 O h m / F o o t
72 L ight Blue Feed, Blo w e r Sw. " M e d i u m 2 " 132 W hite G r o u n d , Fuel E c o n o m y Sw.
C o n tr o lle d Con troll ed, A m b e r Telltale
73 Purple-White Feed, B lo w e r Sw. " M e d i u m 3 " 133 Y ellow G r o u n d , Fuel E c o n o m y Sw.
C o n tr o lle d Con troll ed, Grn. Telltale
74 L ight Green Feed to T h ro tt le S w it c h 135 D a r k Green
75 D a r k Blue Feed, Ign. Sw. " O n and C r a n k " W hite G r o u n d , Resistive, Tem p . G a uge
C o n tr o lle d - Fused S e n so r C o n tr o lle d
76 P in k Feed, Ign. Sw. C o n tr o lle d 139 P in k - B la c k Feed, Ign. Sw. " O n and C r a n k "
78 L ight Blue Electric C h o k e Feed C o n tr o lle d - Fused
80 L ight Green G r o u n d K e y W ar n in g Buzzer 140 Orange Feed, Batt ery - Fused
81 Nat. White Electric R e m o t e Mirror, R ig h t 141 B r o w n -W h ite Feed, Ign. Sw., " A c c s y and O n "
82 L ig h t Blue Electric R e m o t e Mirror , Left C o n tr o lle d
83 D a r k Green Feed, Cruise E ngage Sw. 142 B lac k R r C o m p a r t m e n t Lid L o c k
" R e t a r d " C o n tr o lle d Release
84 D a r k Blue Feed, Cruise E ngage Sw. 143 P in k Feed R a d i o Sw. " O n " C o n tr o lle d
" E n g a g e " C o n tr o lle d 144 Y ellow Feed to Pw r A n t Sw.
85 W hite G r o u n d , Cruise In dicator 145 D a r k Green Feed, Pw r A n t Up, R ela y C o n
R e gu la to r C o n tr o lle d trolled
86 Brown Feed, Cruise Brake Release Sw. 146 D a r k Green G r o u n d , T r u n k Release Tell-Tale
C o n tr o lle d 150 B lac k G r o u n d C ir c u it - Direct
E L E C T R IC A L C IR C U IT ID E N T IF IC A T IO N (Cont'd)
E L E C T R IC A L C IR C U IT ID E N T IF IC A T IO N (Cont'd)
E LE C T R IC A L C IR C U IT ID E N T IF IC A T IO N (Cont'd)
E L E C T R IC A L C IR C U IT ID E N T IF IC A T IO N (Cont'd)
801 Brown Feed, E F I Batt ery Controll ed, 81 8 Ligh t Green A cc elera tor E n r ic h m e n t Sw.
Fusible L i n k Protected S u p p l y V o lta ge
80 4 Purple Feed, E F I , Ign. Sw. " C r a n k " 819 Black-W hite Clo ss ed T h ro tt le Sw.
C on troll ed, Fusible L i n k 820 Orang e W id e O p e n T h ro ttle S w itch
Protected 821 D a r k Green G r o u n d , E F I M o d u le C o o la n t
80 7 Purple Feed, E F I Batt ery Con troll ed, Fused T e m p . Sen sor O u t p u t C o n
80 8 D a r k Blue Feed, E F I M o d u le Fast Idle Valv e trolled
O u t p u t and 3 C ir c u it C o n 822 D a r k Blue G r o u n d Resistive, C o o la n t
trolled - Fused T em p . Sen so r C o n troll ed
-- I DK GRN - 29A----
-------------- 8 BRN 9A----------------
----- 5 DK BUU I5A -----
---------- I LT GRN-I1A------------
------5 LT BLU-I4A------------
pimk-3CkH x O -
5 PNK/BLK-39G - - - SPLICE 39
5 TAN-31 — -BULK HD CONN-31
0 PNK/BLK-39E- — SPLICE 39
BLK- 150H----- SPLICE 150
5 PNK-30B-------------------------------------- -
5 PNK-30A----- BULK HD CONN-30
5 TAN/WHT -33A-----BULK HD CONN-33
5 TAN/WHT-33C — PARK BK WARN SW
.5 PNK/BLK-39F----- SPLICE 39
-----------------------.8 DK BLU-931 — BULK HD CONN-931
-5 TAN WHT-33B
- 5 DK GRN - 35A
LT G RN-24 —
- g DK BLU-75
- 8 P N K -94-----------
-.8 BLK-150E---------
-.8 PPL-9 2 ------------
- 8 GRY-91-------------
-.8 BLK/LT BLU-97-
-.8 LT GRN-2 4 -------
-2984369 TERM
628 8585
-8 BR N -9
-8 LT GRN-24
- 6 DK GRN-19
- 6 YEL-18
CAB.CREW-CAB CHASSIS
-£ BLK-I50D-
SPLICE 150 SHEET METAL GRO
6294015 SOCKET-
BRN -96
TAIL STOP DIR
-8 BLK-I50C
SPLCE 9- 9
BRN- A —
SIDE M K R t
tytl LAMP
-.8 YEL-18 -
-.8 8LK-I50A
-.8 LT G RN -24
-.8 BLK-I50B -
8 9 1 1 0 2 7 SOCKET-
/''BLU OR A
- J PPL OR V -
LT GRN SPLICE-19-i r - 2977720
FRAME -SPLICE-9 \
GRD - 8 DK GRN-l9iA->
- 8 BRN-9A -.8 BRN-9C---- ( x ) ( l }-|
"8 YEL-18
.8 BU
L
r -.8 PNK-30(HDT)
-SPLICED
S ) LIC LAMP
EXT WIRE
WHEN USED
FUEL METER
TANK UNIT
8911027 SOCKET
- 8 B L K - I5 0 B -
- 8 LT GRN- 24 TAIL STOP DIR
S ID E MKR&
LAMP
— .8 BLK-I50A
*-^8
t8 YEL-18
YEL-
SPLICE 9- -8 BRN-9A -
— :8 B L K -I5 0C
8 B R N -9 B —
6294015 SOCKET
SUBURBAN
R EF BODY H AR N ESS- LT G R N 3 8 4 B — -1
RPO M V4
top89l7583
m<
00 00
rO rO
Z2
cc
o cr
o
RPO M V4
CE N G IN E )
TRA N SM ISSIO N
RPO MV4 TRANSM ISSION
FOR RPO N A 5 /L G 9 /L S9
j— 8900444
CHANNEL-A FOR 06 S 16
2989557 -
GROMMET RIGHT RR SPKR
06 ONLY 8900444-
CHANNEL-B
FOR 03
RIGHT RR SPKR
1 2 0 0 4 5 4 5 —7
.8DK B L U - 4 6 ---------- 1/
;8 L T B L L H ' '
8 Y E L - 1 16
8 B R IM -1 9 9
s; -1 2 0 0 4 5 4 5
-.8 DK BLU -4 6 J
-.8TAN-2 01 - 8 L T BLU -115-
.8 GRA-118 — rTO
.80KGRN-I 17-HT
-8L.T GRN-200— /
12004544 M
e
-.8YEL-43- ___ F (jr
-.8BLK-I50 —
-.8GRA-8------------
8900444-
')
U80
R E A R SPEAKER
LEFT SIDE (16)
---.5 YEL-43-H43lKh
U --fi B L K -1 5 0 - - J V
12004543 -----4
- B G R A H ie -
- .8 T A N -201-
F R O N T SP K R .
("r a d i o e q u i p m e n t RPO.
U 63-U693U80
i IP 'jrr , S F R W .S MANUAL
INSTRUMENT PANEL AND GAGES 8C-67
-.8 Y E L - 5 0 8 ( H W ) -
- . 8 P N K - 3 0 IH W )
FUEL TANKS RPO NL2
WITH RPO LF9
8917102
(ATTACHES TO FUSE BLOC
---------- .8 PNK/BLK-39C
INST CLUSTER CONN-237----------- .8 Y E L -2 3 7 --------------------
(SEAT BELT WARNING LAMP) ®
SPLICE 150---------------— • ---------------- .8 B L K -I5 0 J --------
(GROUNO;
EXTENDED
12004962
-120 0 4 6 9 0
FUSE BLOCK
HEADLAMPWARNING BUZZER
RPO T 63
S ID E M A R K E R L A M P
R E A R -S T O P &
.D IR E C T IO A L L A M P
BACK U P LA M P
BACK U P LAM P
R E A R -ST O P &
D IR E C T IO A L L A M P
S ID E M A R K E R L A M P
----------- BCSTER
T AIL,ST O P, + D IR SIG N A L L IG H T S
8900444
46
i DK B L U -4 6 ^ "
i L T B L U -1 1 5 % .
11 5
J
7J R IG H T REAR SPK R .
1
-.8 LT B L U - II5 - K H R P O U .8 0
-.8 D K B L U -4 6 -
-B T A N -2 0 1 -
-.8 G R A - I 18 D p I°H
jC! •cr'
-------- .8 G R A - 8 ----
12004545
- . 8 T A N - 2 0 IB
- . 8 G R A -I I S B L J
K H
I
£ T A N -2 0 1 A - - S T A N -201 A -
:0 G R A -I I 8 A - - . 8 G R A -I I 8 A -
s ji'" !
------------. 8 Y E L - 4 3 -
-----------.8 B L K - 1 5 0 -
P
M
y M d
CB R A D I O E Q U IP M E N T
RPO U P 5 - U 8 0
BLOWER MOTOR
(REAR)
AIR CONDITIONING
RPO C-69
EVAPORATOR
PRESSURE
CONTROL SW Li
__«
»■
I■
T U --T V
AIR CONDITIONING
R P 0 C -6 0
J U N C T IO N B L O C K
C A M P E R E Q U IP M E N T
R P O -U Y I
FLEETStDE PICKUP
RPO. E63
TAIL & STOP & DIR SIG-SI MKR TAIL & STOP 4 DIR SIG-SI MKR
i. B/U LAMP & B/U LAMP
STEPSIDE PICKUP
RPO E62
H E A V Y D U T Y T R A IL E R
R P O UY7
R X . DOOR
L.H. D O O R LOCK SW
6394742
r— 2 B L K - I5 0 A -
166Q /
■O
FU U T H
r *-----1—1b=i 1 R|,’h' R H WINDOW
SWITCH
a y i
BU S BAR G RD
L H WINDOW
SWITCH
2 B L K - I5 0 B
MTR BKT G RD
g )— 2 B L K -1 5 0 M T R BKT G R D
L— 2 B L K -1 5 0 — ®
— 2 D K B L U / W H T -1 6 6 -
2 T A N - 167 — 3 PNK-70 — — -------
3 P N K -7 0 - 2 T W -I6 7 A ------------
2 D K B L U / W H T - I6 6 A -
L-2 TANH67B(HDT|
L - 2 D K BLU W H T-66B-
AUTO BESET
(HDT)
8917486
FUSE BLOCK
M
L H MOTOR
- W E P W IN D O W
(■/ ^O O R R.P.O. A 3
LOCK
LH DOOR
1 9 I LOCK SW
M
--- £^*“12004155
I2 c"CUT*» — ^
R H W IN D O W M O T O R
LH W IN D O W M O T O R
POWER WINDOW & LOCKS
RPO A3I & AU3 (2 DOOR)
RT SIDE M ARKER
6294015 SOC
.5 DK 8 L U -I5 B
.5 BRN-9F -----
.8 B LK-I5IC -
I LT G R N -IIG
.8 TAN-I2C —
.8 DK BLU H 5C -
.8 B R N -9 G ------
.8 B L K - I5 IF -
.8 B L K - I5 IE -
7
I LT G R N -IIF -
12004267
RT HAND HIGH BEAM
TO RT HAND HORN i
(J UJ
C\J CTI
i
p
a
CD
CO 00
12004267
TO LT HAND HORN
LT HAND HIGH BEAM
.8 B L K -I5 0 A —
.8 B LK-I50C -
I LT GRN-I IB
.8 L T B L U -I4 C
.8 B R N - 9 C ----
.8 B L K -I5 0 E
1 I DK G R N -2 9 A
•5DK B L U -I5 A -
.5 LT B L U - I4 A —
I LT G R N - I I A -
.8 B L K -I5 0 B -
.8 B R N -9 A ----- 4 II 12 1 14 15
I LT G R N -1 1C
<Z 33 29
2977976 .8 T A N / W H T -33 (HOT)
BRAKE WARNING SW EXTENSION
.8 TAN-I2B ------------------------------ .8 TAN-12 A ---------------
LT HAND HIGH & LOW BEAM BULK HEAD CONN
.5 LT B L U - I4 B
.5 B R N -9 B —
JTTU—6294015 SOC
LT SIDE M ARKER
FORWARD LAMP
RPO V 2 2
h Sf.AL 12010391
V / 8 -E N G IN E
H E A V Y DUTY TRUCK
- I DK G R N -2 9 -
I LT G R N -IIA
.8 TAN -12 A —
.5 DK B L U -I5 A
.5 LT B L U -I4 A
.5 B R N -9 A —
[ FWD- LR WRGJHm]
/-89I754S
-8917540
B
URK m \— .8 BLK/LT 8LU-97 8917539
Sw 1911— .8 GRA-9IB ------ -
» » sh
SOL [ M V - .8 PNK-94------ 1
co— .8BLK/LT BLU-97
Q J r— .8 WHT-93B— |
<->j-.8 PNK-94---------
-.8WHT-39A oJ-,8 W H T -9 3 -----------
-3PNK-3A
-.8 PPL-92 - W - .8 P P L - 9 2 -------------
■8917544
i W iPER MOTOR 1
I 0RN-240A
I 0RN-240B
-I DKGRN-29-
— .5 BLK-28-
•3 BRNMB - 3 BRN-4A-
2984164 ■3RED-2A------
HORN R ELAY
,5 TAM/WHT-33A
.5 B R N -2 5 ------
.5 OK GRN-35A-
2 LT 6LU-72 —
-2 ORN-52------
-2 YEL 51------
-1 0RN-I40----
-.5 DKBLU-I5B
2973407 -.5 TAN-3 1-----
-3 RED-2F-----
BACK UP 9W
M AN U AL
TRANS
.5 BLK-28----
.5 LT BLUH4A-
-5LT BLU-I4B
-5DK BLU-I5A -
-.5DKBLU I5B- — .8 OK BLU
8911921 .8BRN-27----- — .8 BRN----
.8 PPL-16----- - . 8 PPL —
.8YEL-I8----- — .8 Y E L ----
NEUT START i .8 DKGRN-19- — .8 DK GRN
BACK UP SW .8 WHT-17-----
AU T O -TR AN S — .8 WHT----
1200414 7- * -12004148
REf GAUGE
CIRCUIT
lBULK'HD.CONN.1
2904SM TERM-7
- £ TAN/W HT-3JC- -dT ' NOTE: THE WIRE ASSEMBLY WITH C H J WIRES 156A.I56B « 156C
-----1— IS NOT USED WHEN THE POWER WINOOW OR POWER DOOR
,—
3 WHT*-<Ta
LOCK,OR COMBINED POWER WINOOW » DOOR LOCK HARNESS
IS USED AS THEY ARE PART OF THESE HARNESSES
REF RPO AU3-A3I COMBINED [tiR. JAMB S W
3 B L K - I5 0 F -
------------------------------------ ( W -- n
L. -.5 GRA-8C —
B L K -I5 0 H
-•8 8 L K -I5 0 E
r
i
----- — s 5 LT GRN-II
5 4
---------- s LTBLU-I I
______ i
TO S P L IC E 3 3 ------ .5TA/VWHT-33B
— 0WHT-I56B — -8 W H T - I5 6 B -
— 80RN -40B---- - 8 0 R N -4 0 B -
-» 8 DK GRN -19 — -.8 DK GRN -19 -
—8 T A N - 3 0 -------
—5 P N K -3 0 --------
-* 8 B R N -9 A -----
- ^ L T G R N -2 4 A - -=8 LT GRN-24A ■
- . 8 Y E L -I-----------
I P R .S ID E M A R K E R -R lT l
8917548
Zl— .8 BLK/LT B L U - 9 7 -
.8 BLK/WHT-9IB— -
■i !
-.8 DK 8 L U -9 4 — ,
8 Y E L -9 3 B — -i [
8 905205
2004 6 2 2 i____
- . 5 GRN-901
— .5 WKT-902
8 YEL-93 A-------- 1 - .5 RED-903
.8 LT BLU-92 >L - .5 DK BLU-9 4
.5 BIK-I50
— .8 B L K /W H T - 9 IA - J / -------.5 LT BLU-92
-.5 BLK/WHT- 91
8917544 8917540'— '
-.5 BLK/LTBLU-9/
WIPER MOTOR -.5 GRA-8
T
PULSE WIPER/WASHER
CONTROL
PULSE WIPER
CONTROL MODULE
MOM
REF l/P B+ACC FUSED-------- .8 WHT-93J L j3 PNK— -
GROUND--------------- .8 BLKH50C—t
HARNESS IP S DIM CKT--------.5 GRA-8E = ;^ L
PK
Lz z r T i i i
-------------J | I
| 1--------- .8 BLK/LT BLU-------- -1 I
L------------ .5 G RA-8B---------------- 1
8 BLK-I50(HW>
89 0 5426
3BRIVW HT-50
3 WHT-952A
890 5 4 2 6
2 LT BLU-72
2 rEL-51
2984092
2989576 GROMMET
AUXILIARY HEATER
EQUIPTMENT RRO.C-36
KEY
SWITCH
ASM
•1 PINK-76B — —
-2 P N K - 7 6 ---------------
k
■ I T A N - 167 ------------- 167176 -1 TAN* 167-------------
' 1 DK BLU/W HT-166 isjj- 166 -1 DK BLU/WHT-166-
---- 2 B L K - 1 5 0 -------------- -2 BLK- 150-------------
12004267
1252240 CIRCUIT BKR
30 AMP AUTO RESET
2 - PLACES
A *
\ , /-I20 0 40 29
r
“1 fa5! fs
X2o
CIRCUIT
i ^ 12 0 0 4 8 8 9
"—0+\
— T~° ' u BAT - . BUS BAR
LEFT CIRCUIT ' S■ b GROUND
INDOW i___ u
LH WINDOW SW
FUSE BLOCK
12004155
UP
£ DN-LOCK
667
T "1
1 *uro«»tT
:h
RH DOOR LOCK SW
POS, 2NEG=UP pfyj
LH WINDOW
MOTOR
___ _ , | COCUIT •*«
_ T M L c D-I »UTO KCSET
BODY HARNESS
DOME LP WIRE CONTACT SW
NOTE:
PM = PERMANENT MAGNET
-.8 W HT-156B-
INSTRUMENT PANEL RT DOOR
HARNESS JAMB SW POWER WINDOWS R.RO. A31 9
DOME LP SW WIRE POWER DOOR LOCKS R.R0.AU3
CONTROL
/—120
r
MODIFIER CONTROL
2973324 TERM
BODY HARN
FOREWARD
BODY~_I~_7
W R G _______,
HARN---------- / I
8905206
— >PL--------(RFAR RETURN!
.8DKGRN-I17- -01^ 116 - . 8 YEL-H6
(" I E ) ggg y —£LT GRN200
L FOR 03 4 32
CUTAWAY V AN
G 300(03) (32)
RIGHT FRT SPKR.
:8 DK BLU-4
120045457 n 8 L T BLU-II
.8 DK BLU-46——
.8 LT BLUH I5~ p _L RIGHT RR.SPKR.
— .8 YEL-II6—MJ<
— .8 BRN-199-
— .8TAN-20T
— .8GRA-118—r .
.8 DK GRN-117—1
3 LT GRN-200-
-----.8 GRA-8
- .8 YEL-43 M.
-.8 BLK-150 RADIO RCVR.
12004543
T
* 8 9 117 7 3 ^ ^—8911772
REF
BODY 5 BRN-9------------- r e f r ig h t
WIRING .
HARNESS - REAR LAMP
.5 DK GRN-19-----
RIGHT WIRE ASM
SIDE 5 LT GRN-24------
TO
TRAILER
REF RIGHT
REAR LAMP
WIRE ASM
BATTERY CIRCUIT
PROVISIONS FOR
SIDE MARKER LP
DASH
HIGH - LOW
BEAM
PROVISIONS FOR
SIDE MARKER LP
.22 24
.5 20 PROVISIONS FOR
.8 18 BACK UP LP
1 16
2 14
3 12
5 10
8 8
13 6
19 4
32 2
40 1
PROVISIONS FOR
TAIL-STOP&DIR LP
trim
03 CD
0 BRN-9E(HOT)
c D
SPLICE 9
PROVISIONS FOR
LIC PLT LP
10RN-240B------- §5 PROVISIONS FOR TWO PLACES
, 8W HT. 1 5 6 ^ , DOME LAMP
2965901 .8 BRN-9C (HOT)
(K SPLICE 9
111
OQtpCD
PROVISIONS FOR
TAIL-STOP 8 DIR LP
-.8 BRN-9B(HDTI-
-.8 BRN-9AIHDT) -
.6 LT GRN-2481HDTI
LTGRN-24AIH0T) PROVISIONS FOR
jW —.6 DKGRN-191HDT) BACK UP LP
PROVISIONS FOR
SIDE MARKER LP
TO SHEET METAL
-2 BR N -9 —
-2 YEL-18 —
-2 DK GRN-19 -
-2 LT GRN-24
FRAME GRD
(S>-50GRD STRAP
FPAME GRD
V W ’' neut
\-Z '/ START
NEUT START
C BACK UP SW
START OfF-LOCK
/F R O N T \
VOF DASH/
NOTE
rHE GROUND LEADS PROVIDED IN Al I
ELECTRICAL WIRING MUST BE
TERMINATED IN A MANNER TO
INSURE A COMPLETE UNIFORM A.
ONTINUOUSVEHICIE ELECTRICA1
GROUND CIRCUIT.
START O FF-LO CK
13RED-2B(GPT)---------------------------------------
RPO B3K
TEMP
SENDER
YS
2962965
SEE
NOTE 1
HIGH - LOW — 2 BRN-9(GPT) —
BEAM SIDE MARKER LAMP •2YEL-18(GPT) —
RPO E32 AND E33 ----- 2 DK GRN-I9(GPT) -
ONLY 2LT GRN-24CGPT) -
8905381 SOCKET
-2984164
HORN
RELAY
STOP LPSW \
2984235
8911781
G RO MM ET
0911781 G R O M M E T
"T2004962 12010094
■3 RED-2C - FUSE BLOCK
5PLICE-4-
.8 DK BLU- 3 8 J L.8 DK BLU-75
.8 P N K /B L K -1 3 9 -------— ------------
SPLICE 3 - ^
-.5 DKBLU-15A
1 BRN-9A —
1 LT GRN - 24
8900855
DIMMER
SW
100 AMP
JUNCTION BLOCK
PROVISIONS FOR
DOME LAMP
NOTE I
WIRES 9 ,1 8 ,1 9 +2 4 IN TAIL LT
EXTENTION ARE FOR P 1 0 0 .
-2BRN -9(t3PT)-------
-2Y EL-I8(G P T)------ -
-2DKGRN-*9(GPT)-
-2 LT GRN-24(GPT)-
B/U LAMP
RPO E32
AND E33 ONLY
^rSPLICE-9 2977107
- . 8 P N K -3 0 (H X L )—
(EjOQ
B R N -9A (H D T)-
B R N -9A (G P T)-P 100
-.8 BRN- 9 B (H D T)-
.8 B R N -9 K (G P T )-P 1 0 0
8 LT G RN-24B(HD T)—1
1.8 LT GRN - 24B(GPT )-P)OOj B/U LAMP
:8 LT GRN-24A(HOT) *B L K RPO E32
8 LT GRN-24A<GPT)-P100 AND E 33 ONLY
8 DK GRN-)9(H0T)
.8 DK G R N -19(G P T)-P I00
-.8 Y E L-18(H 0T)
.8 Y E L-18(G P T)-P 100 -.8 B R N -9K (G P T)
.8 B R N -9D (H 0T)-P H
)BLK(GPT)
NOTE 2 S
WIRE 130 ISA 10
RESISTANCE WIRE. TO SHEET METAL
' MSRRE r l a m p
RPO E32 AND
E 33 ONLY
12004267-
tp tp rh
LAMP
CHECK
RELAY
SPLICE-150
TEST CONN
H 2 0 I0 9 9 7 (ORANGE)
12004826. ■12010649
ASM
C-TRUCK
.6 LT G RN-384—
8 PNK/BLK-39B ■t STOP LP
CONTACTS
.8 LT BLU/BLK-383
8905581
TO LAMP CHECK SOCKET GLOW PLUGS
RELAY
12010973-
TO WATER
.8 Y E L -5 0 B A ----------- IN FUEL LAMP
12004215 SOCKET
.8 LT B LU /BLK-383A
.6 PNK/BLK- 39E------
.8 LT B LU /BLK-363B-
.8 P N K /B L K -39 F -------
.8 W H T -1 5 6 A -------------- 120*0015 4WD RELAY
.8 W H T -I5 6 B ------------
4 W DRIVE
IND LIGHT
I 0 R N -5 0 3 A
8905381
SOCKET
WATER
IN « ■NORMAL TO
FUEL GLOW
PLUGS
.8 YEL- 506 (HW) LAMP
.8 PNK-30(HW) - 4 WD SHIFT
LEVER LIGHT
" -----9905426
8 BLK-I50A<HW>
.0 BLK-I50BHW)- DIESEL ENGINE
PRODUCTION (RPO LF9) FOR RPO
FRAME GROUND TANK SENOER
■■Aj '
ACCESSORIES 9-1
SECTION 9
ACCESSORIES
CONTENTS
Cruise Master.......................................................................................................9-1
General Description................................................................................ .........9-1
Diagnosis.............................................................................................................9-4
On-Vehicle Service................................................... ...................................... .9-8
Specifications......................................................................................................9-8
R a d io ................................................. .................................................................. .9-8
General Description........................................................................................ .9-8
Diagnosis................................... ........................................... ............................ .9-9
On-Vehicle Service.......................................................................................... .9-21
CRUISE MASTER
GENERAL DESCRIPTION
The Cruise Master is a speed control system which ON - The cruise switch must be in the ON position and
employs engine manifold vacuum to control the throttle the vehicle speed above 30 mph (50 km/h) before the system
power unit. The power unit moves the throttle, when speed can be engaged.
adjustment is necessary, by receiving a varying amount of SET-COAST - This is a dual function switch that
controlled vacuum from the transducer. The speedometer operates in the following manner.
cable (from the transmission) drives the transducer, and a • SET - Depress the "SET" button completely when
cable (from the transducer) drives the instrument panel vehicle reaches desired speed, and release the button
speedometer. The engagement of the transducer unit is slowly to engage system. Use of the brakes will
controlled by an engagement switch located at the end of the disengage the system but pre-set speed will be retained
turn signal or multi-function lever. Two brake release in memory.
switches are provided: an electric switch disengages the
• COAST - Cruise speed may be reduced by depressing
transducer and a vacuum valve decreases the vacuum in the
"COAST" button until desired speed is reached, then
power unit to quickly return the throttle to idle position.
releasing slowly to re-engage. Higher speeds are set by
The purpose of the Cruise Master system is to allow the accelerating vehicle to desired speed and depressing
driver to maintain a constant highway speed without the "SET-COAST" button.
necessity of continually applying foot pressure to the
accelerator pedal. Speed changes are easily made and RESUM E - Slide cruise switch to "RESUME" and
override features allow the vehicle to be stopped, slowed or release, vehicle will accelerate to previously set cruise speed.
accelerated as described below. It is advisable not to use "RESUME" in city traffic or in
suitations where the previously set speed is faster than the
immediate traffic flow. Do not use "RESUME" or cruise
SWITCH FUNCTIONS control features on slippery conditions.
D ISEN G A G EM EN T - The system is disengaged by
The switch functions of the cruise control lever (Fig.
applying the brakes. Under normal operation, it is not
9-1C) are as follows:
necessary to use the "OFF" position. Sliding the cruise
switch to "OFF" or turning off the ignition will erase the
memory and disengage the system. System can be momen
tarily disengaged by holding in the "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 directional signal handle. The
operator then fully depresses and slowly releases the cruise
"set coast" button. A speed switch built into the transducer
assembly prevents engaging the system below approx
Fig. 9-lC -R esum e Cruise Control Lever imately 30 mph (50 km/h). The cruise system takes over
LIGHT TRUCK SERVICE MANUAL
9-2 ACCESSORIES
■PORT "C"
ENGAGE
HOLD
PORT "B"
P O R T"A '
RESUME-
SOLENOID
RESUME'
CONNECTOR
M ou n tin g
DIAGNOSIS
ELECTRICAL SYSTEM TROUBLESHOOTING Resume Cruise Control Quick Checks
1. Check fuse and connector. Refer to Figure 9-7C for cruise control quick checks.
2. Check brake electric switch as follows:
Servo and Vacuum System Test
a. Unplug connector at switch.
To determine the condition of the Servo diaphragm,
b. Connect ohmmeter across cruise master contacts on
remove hose from the Power Unit and apply 15 inches of
brake switch. The ohm m eter must indicate no
vacuum to the tube opening and hold in for one minute. The
continuity when the pedal is depressed and continu
vacuum shall not leak down more than 5 inches of vacuum in
ity when pedal is released. The cruise release brake
one minute. If leakage is detected, replace the Power Unit.
switch (electric) is adjusted as is the standard stop
light brake switch. The cruise release brake valve (vacuum), resume valve
and connecting hoses can be checked by applying 15" of
c. Replace brake electric switch if needed.
vacuum to each component, then sealing them off. The
vacuum leakage from 15" Hg should not excess 5 inches, in
a one second interval.
Electrical Test
The cruise vacuum switch can be tested in the same
Refer to wiring diagram in Figure 9-5C to perform any manner. Leakage from 15" Hg should not exceed one inch
electrical test. in one minute.
Harness Test
Engagement Switch Test 1. Disconnect engage switch wire harness connector from
Refer to Figures 9-6C and 9-7C to perform engage the main harness connector (red, brown/white, and
ment switch test. white wires).
PUSH PUSH
BUTTON i BUTTON | m o ti |
IN REST l
m iK iuttoh ~ | IN REST
1 tH O LD POSITION HOLD
p o s it io n !
I— B+-------
!3 1} y2 v v v
BRN BLKBLU -H O L D -
HOLD ENGAGE
SLIDER IN j SMUTTLI
SLIDER IN r~ ENGAGE "ON" POSITION
"OFF" SHUTTLE PUSH ---PUSHIUTTMI |
U r u BUTTON
PUSH BUTTON i n I tuTTI>11 IN "COAST" Z HOLD
REST POSITION t HOLD POSITION B+ —
(DEPRESSING
-B+- MOTION) HOLD------
— ENGAGE
SLIDER IN I SHUTTLE
HOLD "ON" POSITION
PUSH
MIL
----^ PUSHHITTOW I
SLIDER IN ENGAGE BUTTON
IN "COAST" t C lO L D
"RESUME" l B + -----------
POSITION POSITION
--------- SHOE! (FULLY DEPRESSED)r -H O L D —
PUSH BUTTON IN ENGAGE
REST POSITION T hold SLIDER IN
"ON" POSITION [s jilli1
B+ PUSH BUTTON I—P -
IN "ENGAGE"-*H pmhmttw
POSITION I
(RELEASING HOLD
MOTION) Lb +
O ff Released O ff 0 0 0
Cruise Released On C 0 0
1 C o ilt H alf On 0 0 0
Depressed
2 Coast Fully On 0 0 C
Depressed
3 Set Releasing On c C c
O = Open C = Continuity
x These test are continuity tests b etw een the term inals show n in figures of
resum s cruise control lever and lever electrical operation,
xx The slider m ust have a detent in the "o n " and " o ff" positions and must
return to the "o n " detent w hen released from the resum e position.
OK NO T OK
RO A D TEST
NOTE: 1 /4 OF A T U R N EQ UALS A P P R O X IM A T E L Y
1 M PH.
CRUISE CONTROL D IA G N O S IS
(ALL SERIES)
PRFI I M IN A R Y CHECKS
1. Check S e r v o C h a in o r rod adjustm ent. M u s t have m in im u m slack. 5. C he ck adjustm ent of brake release sw itch and v a c u u m release
2. Check v a cu u m hoses. M u s t be in good co n d itio n - no re stric tio n s valve.
o r leaks. 6. C h e ck engagem ent sw itch operation.
3. C heck d rive cable ro u tin gs. No k in k s o r s h a r p bends. 7. If steps 1 t h ro u g h 6 do not solve the problem, c o n tin u e with
4. C heck throttle linkage o r cable fo r binding._____________________ diag n osis.
C R U IS E C O NTRO L
IN O P E R A T IV E
J------
1. Check gages fuse. If blown check w ir in g fo r s h o rt circu it.
2. If fu se and p r e lim in a r y ch e ck s ok. t u r n ig n itio n to r u n position
and c r u is e con trol sw itch on.
3. D isc o n n e c t 2 w ire c o n n e cto r at tra n sd u c e r.
4. C onne ct 12 volt test ligh t to g ro u n d and to engage w ire in
connector. P u s h e ngagem ent button in part way.
5. Repeat test on hold w ire in connector.
\
Test engagem ent switch. C h e ck for poor g ro u n d C h e ck fo r open c ir c u it in
(See test procedure) at tra n sd u c e r. If ok. b rn w ire from engagem ent
C heck for open c irc u it remove tra n sd u c e r sw itch c o n n e cto r to brake
in w ire if test light fo r repair. switch.
did not lig h t C h e ck brake sw itch (sh o u ld , ENGAGED ENGINE
SV / ° SOLENOID y VACUUM
R epair o r replace part have voltage on both te rm in a ls 4 V ALVE ^ / SOURCE
that ch eck s bad. w hen ig n itio n key is in r u n SERVO i MB W* RESUME
SOLENOID
po sition and on/off sw itch on). ■■4 - J k a ^ °^°
sVALVE
v
C h e ck for open in w ire TO BRAKE
•*RELEASE
from brake release switch VALVE
NOT
to on/off sw itch to fu se panel ENGAGED
TRANSDUCER
p lu g -in . If ok. ch e ck engagem ent WITH SET
SPEED IN ENGINE
sw itch operation and replace if MEMORY jv S'"*'
VACUUM
SOURCE
nece ssary. RESUME
SOLENOID
VALVE
TO BRAKE
RELEASE
ENGAGEMENT VALVE
SWITCH
E N G A G E M E N T S W IT C H T E S T P R O C E D U R E
USE AS S E L F POW ERED T EST LIGH T. LIG H T
W ILL BE ON FOR EA CH T EST IF SW ITCH IS
GOOD. CO N N ECTO R TER M IN A LS AND COLOR
1 - BROWN, 2 - BLUE, 3 - B LACK.
SW IT C H P O S IT IO N S T E R M IN A L S
ENGAGE R ESU M E
BUTTON SW IT C H 1 to 2 1 to 3 2 to 3
2. Connect ohm m eter between point C (brow n/w hite should be exercised so as not to damage the blade
stripe wire in main wire harness) and ground. Make connectors or the wiring harness. The disconnect may
sure the Transducer is well grounded to the chassis. be facilitated by prying carefully on the plastic connec
The ohmmeter should read between 42 and 49 ohms. If tor with a small screwdriver.
a resistance either above or below the value indicated is
4. Measuring the solenoid coil circuit resistance between
shown, then disconnect the connector from the T rans
point E (Hold Terminal) and ground, the ideal resist
ducer and measure the resistance of the brown/white
ance should be between 5 and 6 ohms. A reading of less
stripe wire from point C to D. It should measure 40
than 4 ohms indicates shorting in the coil circuit. A
ohms ± 2 ohms.
reading of more than 7 ohms indicates excessive
3. If a resistance either above or below the value indicated
resistance in the coil circuit. Either extremity indicates
is shown, the main wiring harness should be replaced.
replacement of the Transducer assembly. The main
NOTICE: When disconnecting or reconnecting the main harness wiring from point F to G (white wire) should
wiring harness connector from the Transducer, care also be checked for continuity.
ON CAR SERVICE
Power Unit Bead Chain Adjustment change cruise speed approximately one mph. Snug-up
lock nut after each adjustment before testing.
1. With air conditioning off, adjust engine curb hot idle
speed, with the idle stop solenoid disconnected (if Removal of Cruise Control Actuating Engagement
equipped), to 500 rpm, then shut off engine.
Switch
2. Check bead chain slack by unsnapping swivel from ball 1. Place shift lever in low and remove horn actuator and
stud and holding chain taut at ball stud; center of swivel steering wheel.
should extend 1/8 inch beyond center of ball stud.
2. Remove cover plate (three screws).
3. Adjust bead chain slack if necessary, by removing the 3. Remove turn signal lever and conduit from wire
retainer from the swivel and chain assembly. Place assembly.
chain into swivel cavities which permits chain to have
4. Attach fine pliable wire through hole in connector.
slight slack. Place retainer over swivel and chain
Tape end of wire and connector.
assembly.
5. Pull switch and wire assembly through column.
(Threading pliable wire).
Brake Release Switch and Valve Adjustment 6. Attach and tape wire to new connector.
With brake pedal fully depressed, push switch and 7. Pull cofmector and wire through column.
valve forward until they stop against bracket or arm, pull 8. Replace conduit on wire assembly.
pedal rearward with 15-20 lbs. force to properly adjust
9. Install turn signal lever screw.
switch and valve.
10. Install cover plate.
11. Install steering wheel and horn actuator.
Cruise Speed Adjustment
If the car cruises at a speed above or below the TRANSDUCER
engagement speed, this error can be corrected with a simple Replacement
adjustment of the orifice tube in the transducer.
1. Disconnect battery ground cable.
1. To check cruise speed error, engage Cruise Control at 2. Disconnect speedometer cables at transducer.
exactly 50 mph.
3. Disconnect vacuum and wiring harness at transducer
2. If care cruise below engagement speed, screw orifice body.
tube outward. 4. Remove transd ucer to bracket screws and remove
3. If car cruises above engagement speed, screw orifice transducer.
tube inward. Each 1/4 turn of the orifice tube will 5. To install, reverse Steps 1-4 above.
RADIO
GENERAL DESCRIPTION
Six types of radios are available: A M Pushbutton, A M / On models equipped with auxiliary speakers, a variable
Stereo 8-Track Tape, A M /F M , A M /F M Stereo, A M /F M control located behind the manual tuning knob adjusts the
Stereo/Stereo tape, and A M /F M Stereo Cassette Tape. volume of the front and rear speakers. Turn the control
The left knob operates the on-off switch and volumne clockwise to increase rear speaker volume and decrease
control, the left ring operates the tone control. The right front speaker volume. Turn the control counterclockwise
hand knob controls manual tuning. All A M /F M radios have and the rear speaker volume decreases and the front speaker
five push buttons (10 station selections) five on A M and five volume increases. Both speakers are controlled toegether by
on FM. the volume control knob.
LIGHT TRUCK SERVICE MANUAL
ACCESSORIES 9-9
DIAGNOSIS
CASSETTE TAPE PLAYER DIAGNOSIS In diagnosing radio/tape problems the main point to
remember is that you now have both a radio and a tape
Diagnosis of radio portion of c a s s e tte - A M /F M is player to diagnose as part of the stereo system. By inserting
shown on the diagnosis charts. For cassette diagnosis, refer test tape, J-22683-01, you can quickly determine whether
to Fig. 9-1R. If unit must be removed, it must be repaired by the tape speed is proper. Since only the pre-amps and audio
an authorized service station. See Section 8 for removal are common to both radio and tape, by listening for
procedures and connections for speaker and power wiring. distortion with the tape playing and comparing it to the
radio signal, you can further isolate the problem to either
radio or tape; See the Diagnosis Chart.
EIGHT-TRACK STEREO TAPE DIAGNOSIS STATIC AND NOISE DIAGNOSIS
The tape player trouble diagnosis guide is intended as Refer to figure 9-3R for radio static suppression on the
an aid in locating minor faults which can be corrected vehicle. Ground strap connections must be clean and tight,
without a specialized knowledge of electronics and without spark plug cables must be T V R S type and in good condition
special test equipment. If the suggestions given here do not and resistance type spark plugs used. Extra electrical
effect a correction, further testing should be done only be a equipment added to the car could cause static if not properly
trained radio technician having proper test equipment. It grounded or wiring was improperly routed. Radio and
should first be determined if the owner’s tape and not the antenna lead-in grounding must be clean and tight. An
player is at fault. Substituting a known good tape cartridge improperly trimmed antenna adjusting screw could result in
for the owner’s is a simple check. poor sensitivity and static/noise on AM stations only.
Because tape player service problems are generally W eak FM station reception will be affected by near-by
corrected by a radio repair shop, there is a tendency for buildings, car speed, direction and windshield wiper opera
many technicians to remove a set when a problem is tion. These "flutter," "swish" and "fading" conditions are
reported. Removal of the tape player can frequently be characteristics of weak FM signals.
avoided if the diagnosis chart is used to eliminate problems
which can be easily fixed or which are not caused by a faulty
player.
TAPE ONLY
NO O B S T R U C T IO N O B S T R U C T IO N
NOT OK OK
TR Y A KNOW N REMOVE
GOOD TAPE O B S T R U C T IO N
C A R T R ID G E R EM OVE R A D IO A D V IS E C U ST O M E R
FOR R E P A IR TAPE IS W ORN OR
r
DEAD
♦
W ORKS
DEFECTIVE
REMOVE R A D IO U N IT A D V IS E C U S T O M E R
FOR R E P A IR TAPE IS W O RN OR
DEFECTIVE
Irregular channel stepping & Cable connections Remove radio for repair
unit not coordinated with display
Channel display won’t change Selector switch Remove radio for repair
Channel display indicates only “0 ” Power connector Remove radio for repair
POPPING NOISE DIAGNOSIS a. If a shrill sound is emitted through the speaker when
both a ntenna wires are tested, a ntenna is
Operating switches such as turn signal, pushing in
operational.
cigarette lighter, operating stop lights, etc., may cause a
popping noise on distant A M (weak) signals. Adjusting the If no sound is emitted through one or both antenna
antenna trimmer, if it is out of adjustment, will minimize wires, move tester along the wire toward center of
the noise. windshield and down toward radio.
If a shrill sound is picked up, find exact location
where the noise begins, this is the area of the defect.
TESTING WINDSHIELD ANTENNA (Fig. 9-4R) Replace windshield.
If no noise is heard over entire length of antenna,
unplug antenna lead at radio and touch tester to
All C-K model trucks with factory installed radios are
antenna socket in radio.
equipped with windshield antennas. To positively identify
antenna failure and eliminate the possibility of unnecessary If radio now makes a shrill sound, check connectors
windshield replacem ent, Windshield A ntenna Tester and antenna lead for possible defect before replacing
J-23520 should be used to determine continuity of the thin windshield.
antenna wire. f. If no noise is emitted, radio, speaker, or fuse is
W hen antenna failure is suspected, the following defective.
checks should be made before replacing the windshield. Make sure that antenna tester is turned off after
completing antenna test.
1. Check Tester J-23520 for operation on any vehicle
radio antenna that is operating normally to test for a
weak or dead battery.
2. Check all antenna connectings to insure that antenna is
electrically coupled to the radio.
3. Turn ignition switch to accessory position, turn radio
"O N ", select A M band if receiver is A M /F M and tune
radio to an off station position.
4. Hold tester to antenna beginning at the upper corner of
antenna:
NOTICE: The plastic shield must be on tester at all
times to avoid scratching windshield.
BRAIDED
GROUND
BLOWER MOTOR
CAPACITOR
AM/FM
FUSE PANEL
[v i e w
HOOD GROUND
CAPACITOR
BODY
BRAIDED
GROUND
FRAME
CHECK ALL
ACCESSORIES ON FUSE
FOR PROBLEM. (SEE
SERVICE MANUAL/TEST
DRIVE IF NECESSARY.)
CO RRECT PROBLEM.
C H E C K IF A L L S P E A K E R S A R E D E A D
( U S E F A D E R T O C H E C K .)
NO YES
S U B S T IT U T E B A D S P E A K E R ( S ) . FM O N LY D EAD A M A N D FM D E A D |A M O N L Y D E A D
R E M O V E R A D IO
R E P L A C E M A L F U N C T IO N IN G R E M O V E R A D IO .
S P E A K E R / W IR IN G A S S E M B L Y
A N D R E M O V E R A D IO .
*FADER D EA D SPOT:
A S FADER IS ROTATED, A
P O SIT IO N IS FO UND AT
WHICH O N E O R TWO S P E A K E R S S U B ST IT U T E S P E A K E R W O R K S
S U D D E N L Y GO DEAD. A N D NO D E A D SP O T ON FA D ER*
R E P L A C E M A L F U N C T IO N IN G
S P E A K E R / W IR IN G A S S E M B L Y .
CHECK FU SE] C H E C K T H A T A N T E N N A IS
FUSE OK FU SE BLOW N P L U G G E D IN T O R A D IO . M A K E
S U R E P L U G I S N ’T C O C K E D
C H E C K A T T H E R A D IO F O R U N P L U G R A D IO P O W E R L E A D ,
F A U L T Y P O W E R C O N N E C T IO N R E P L A C E F U SE.
O R S P E A K E R C O N N E C T IO N S .
GO O D C O N N E C T IO N B A D C O N N E C T IO N
C H E C K A N T E N N A A N D L E A D IN R E P A IR
W IT H S U B S T IT U T E A N T E N N A . C O N N E C T IO N
T R IM ( S E E P R O C E D U R E )
S T IL L NO R E C E P T IO N R A D IO W O R K S
R E M O V E R A D IO l R E P L A C E M A L F U N C T IO N IN G
A N T E N N A O R L E A D IN.
FU SE B L O W S A G A IN FU SE D O E S N ’T BLO W
C H E C K A L L A C C E S S O R IE S O N
F U S E F O R P R O B L E M (S E E
S E R V I C E M A N U A L / T E S T D R IV E IF
NECESSARY)
CORRECT PROBLEM
r P L U G R A D IO
PO W ER LEAD
FAULTY B A C K IN.
C O N N E C T IO N R A D IO W O R K S
I
E FU SE B L O W S
R E P A IR C O N N E C T IO N S U B S T IT U T E S P E A K E R ( U S E 1S T O P | R E M O V E R A D IO " !
F A D E R IF S O E Q U IP P E D . )
NO R E C E P T IO N R A D IO W O R K S
REM O VE R E P L A C E M A L F U N C T IO N IN G
R A D IO S P E A K E R / W IR IN G A S S E M B L Y .
r
FU SE BLOW N
“1
FUSE O K
NOT B R O K E N BROKEN
D R IV E C A B L E L IG H T O N N O L IG H T
1 t
R e p a ir s h o r t in D is c o n n e c t o t h e r
o r a n g e w ire . co n n e cto r. C o n n e ct
o r n w ire c o n n e c t o r,
R em ove m ast a n d Replace m ast a nd U se a 12 v o lt test Locate a n d re p a ir re c h e c k f u se .
Power Antenna
L IG H T OFF L IG H T ON
Diagnosis, Chart F
L IG H T ON NO L IG H T
A C C E S S O R IE S
C h e c k re la y c o n n e c t io n s ; C h e c k dk. g r e e n w ire
g r o u n d w ir e (black) a n d re la y to c o n n e c t o r a nd
g r o u n d scre w . If OK. c o n n e c t o r to a n t e n n a
replace relay. fo r loose c o n n e c t io n o r
open c ir c u it. If O K re p a ir
9 -1 7
m otor asse m b ly.
9-18
SLIMLINE POWER ANTENNA DIAGNOSIS (CONT’D)
ACCESSORIES
A N T tN N A W IL L NOT GO U P
IG N IT IO N A N D R A D IO
S W IT C H E S ON
(M O T O R D O E S NO T RUN)
C h e c k F u se s
(Radio a nd C ig - C lk - D m )
----------}
Fig. 9-11R—Slimline
F U S E S BLOW N FU SES OK
I
T u r n ig n itio n off.
Use a 12 volt test light
C L K -C IG R A D IO
and probe the o ra n g e
FU SE F U SE jjeii
w ire at the relay connector.
D isc o n n e c t 3 w ire
Power Antenna
F U SE B L O W S FU SE OK C L IC K S NO C L IC K
FU SE O K FUSE
(R E L A Y E N E R G IZ E D )
B LO W S C h e ck f o r :
f C h e ck yellow w ire from Replace 1. Open relay gro u n d .
D isc o n n e c t 3 w ire Locate and repair sh o rt 2. Open pin k w ire from radio.
fu se panel to radio and a n te n n a
co n n e cto r w ith w hite c ir c u it in orange w ire 3. Bad radio switch. C heck
pin k w ire from radio relay. Probe Dk. Green w ire
w ire and in sta ll co n n e cto r from fu se panel to with test light at pin k wire
to relay c o n n e cto r for in relay con nector.
w ith o ra n ge w ire at a n te n n a con nector. term inal. If OK replace
sh o rt c ir c u iL If OK
relay. Recheck fuse. relay.
rem ove radio fo r repair.
kL0P6 U iu3e M1L6 i
L IG H T ON L IG H T OFF
t
Replace C h e ck g ra y and dk. green
L IG H T ON LIG H T OFF
relay. w ire s from relay to an te n n a
motor co n n e cto r and to the I \
a n te n n a assem bly for sh o rt C h e c k co n n e cto r te rm in a ls C h e ck for open in w ire s or co n n e ctio n s:
c irc u il If O K remove an te n n a for good contact to relay. If gray to a n te n n a motor and dk. g r n from
OK. replace relay. a n te n n a motor to relay. If O K remove
motor fo r repair.
a n te n n a motor for repair.
ACCESSORIES 9-19
POWER A N T E N N A
C IR C U IT
B R EA K ER
LIM IT
BRUSHES SW ITCHES
G EA R AND SPOOL
A SSEM BLY
MOTOR AND GEAR
BEAR IN G
HOUSING
TH R U ST
BLO CKS
ARM ATURE
F IE L D M AGNET ASSEM BLY
ASSEM BLY
MAST AND /
TUBE ASSEM BLY STUB LEA D CABLE
CONNECTION
DRAIN TUBE
SWR (S T A N D IN G W A V E R A T IO ) C H E C K
1. With Ignition and Radio off install an SWR meter as shown 2. Turn on Ignition and Radio,
following meter manufacturers instructions.
3. Check Antenna height - Must be fully extended.
NO TICE: Operation of transmitter requires FC C CB Operators 914 mm (36”) from fender to tip
License. 286 mm (11-1 /A") top of load coil to tip.
When making this check, car should be at least 20 feet away from any
building, hood closed and no one should be standing close to the 4 After adjustment is complete apply a small amount of thread
antenna. cement to adjusting band.
LEAD IN CABLE
FROM A N TE N N A LE A D IN CA BLE
TO AM-FM RAD IO
SWR M ETER
RF JUMPER CA B LE
CB
R AD IO
IN -LIN E
S P LITTE R BOX
T R A N SM ITT ER SO CK ET
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 /8 th T U R N A T A T IM E
/ SWR
/
CH A N N EL 40
H IGH ER
PO SSIBLE SWR R E A D IN G S
MOVE B A N D — ^
A N Y R E A D IN G IN T H E R E D B A N D (A B O V E 3:1 SW R) C H E C K F O R :
— Antenna mounting screws tight making a good ground connection — Lead in cable connections to radio, splitter and antenna are tight,
between antenna mounting surface and car sheet metal.
L e a d in c a b le s n o t p in c h e d a n d c u t t i n g t h e i n s u la t i o n .
ON VEHICLE SERVICE
MAINTENANCE AND ANTENNA TRIMMER ADJUSTMENT-ALL RADIOS
(Fig. 9-16R)
ADJUSTMENTS
The antenna trimmer adjustment must be made any
time the radio is removed and installed, a new windshield or
TAPE PLAYER MAINTENANCE lead-in is installed or if weak, AM reception is noted. (Fig.
9-6R).
The only required m aintenance on tape players is
periodic cleaning of the tape player head and capstan. This COMPONENT PART
service should be performed every 100 hours of operation.
Since you can reach them through the tape door, you can REPLACEMENT
leave the tape player in the truck.
RADIO OR RADIO TAPE REMOVAL
To clean the head and capstan, use a cotton swab
dipped in ordinary rubbing alcohol. Wipe the head and (Refer to Section 8).
capstan as shown in Figure 9-15R .
No lubricants should be used since they will cause the RADIO DIAL LAMP REMOVAL
player to operate improperly, especially at extreme (Refer to Section 8).
temperatures.
Do not bring any magnetized tools near the tape head. RADIO SPEAKER REMOVAL
If the head becomes magnetized, every cartridge played in
the player will be degraded. (Refer to Section 8).
To operate the tape player, completely insert a car
tridge into the unit. This turns the tape player on, autom ati ANTENNA
cally removes power from the radio, and switches the
speakers from the radio to the tape player. This feature C-K Models
prevents accidental damage to the radio should the owner
attempt to operate it while the tape player is in use.
After the tape player is in operation, the front panel 1. T U R N R A D IO O N A N D TU N E R A D IO FOR
W EAK S T A T IO N A T OR N E AR 1400 KC.
controls of the player are then adjusted for the most pleasant
stereo listening. 2. RE M O V E R IG H T H A N D KNOBS.
other side of the cartridge is not completely disengaged N O TE: O N CARS W IT H POWER A N T E N N A ,
when the cartridge lock arm reaches a detent point on the T R IM W IT H MAST F U L L Y E X T E N D E D
Antenna Replacement
Refer to Section 2 of this manual "Windshield Re
placement" procedure.
Cable Replacement (Fig. 9 -1 7R)
1. Disconnect battery ground cable.
2. Unsnap antenna cable from windshield.
3. Remove bracket to dash panel screws.
4. Disconnect cable at rear of radio receiver and remove
cable assembly.
G Models
Antenna Replacement (Fig. 9 -1 8R)
1. Unscrew mast nut. Prevent the cable assembly from
turning by using two separate wrenches. Remove rod
and mast assembly.
2. To install, insert rod and mast assembly into cable
assembly and tighten mast nut. Prevent cable assembly Fig. 9-19 R--G M o d e l Power Antenna
from turning by using a second wrench.
Cable Assembly Replacement (Fig. 9 -1 8R) drive cable when the mast is in the retracted position, plus
two limit switches and a gear operated cam system to
1. Disconnect battery ground cable.
actuate the switches. The limit switches are used to open the
2. Remove antenna assembly as described above. motor circuits when the mast reaches the full up or down
3. Remove cable body nut and then remove seal, bezel, positions.
gasket and ring ground.
When the motor circuit is completed by the radio or
4. Perform Steps 2-8 of "R ad io Receiver Rem oval". ignition switch, the motor drives the gear and pulley to
Refer to Section 8. extend the drive cable and antenna.
5. Disconnect cable at rear of receiver. The gear is coupled to the drive pulley by a torque
6. Insert new cable through the dash panel (from the limiting clutch that permits continued gear rotation when
forward side). the mast reaches the limit of travel. The antenna mast fully
7. Reverse Steps 1-5 above to complete installation. retracts into the fender or extends 3 1 - 1 / 4 " and has no
Be sure cable grommet is properly positioned in dash intermediate position.
panel.
PO W ER
ANTENNA
RELAY "
R EM O V A L INSTALL
MAST A N D TUBE SC RE W D R I V E R
ASSEMBLY NOTCHES
CLIPS
REMOVAL IN S TA LL
1. Remove parts as shown 1. Reassemble as shown with mast extended to reduce length of
cable.
2. Run motor to lower mast into support tube. Reseal housing and
MOTOR AN D GEAR
support tube.
H O U S IN G C OVER
GREEN
CONNECT B A TT E R Y LEADS
CABLE HOOK
TO RAISE TO LOWER
MOTOR AN D GEAR
H O U S IN G
REMOVAL INSTALL
S W IT C H A N D H A R N E S S
ASSEMBLY
be tw e e n th r u s t b lo c ks
REMOVAL IN S TA LL
REMOVAL IN STA LL
SWITCH A N D HARNESS
MOTOR A N D GEAR
H OUSING C OVER
MAST AND
TUBE ASSEMBLY
GEAR A N D SPOOL
ASSEMBLY
MOTOR AN D GEAR
H OUSING
CABLE
1 X
CABLE HOOK
REMOVAL IMSTALL
TIP
LOAD COIL
(USED ON AM FM CB
TR I BAND A N T E N N A O N LY )
\
SECTION 10
Some of the 1981 model cars present special service requirements to the technician due to the use of both
metric and customary (inch) type nuts, bolts and screws on the same car. Many are metric and some are
very close in dimension to customary nuts, bolts and screws in the inch system. Mismatched or incorrect
nuts, bolts and screws can result in damage, malfunction or possible personal injury. Nuts, bolts and screws
removed from the car should be saved for re-use whenever possible. If they are not re-usable, care should be
taken to select a replacement that matches the original.
( /X;i
General Motors Engineering Standards have adopted a portion of the standard metric fastener sizes defined
by SI (Systeme 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 1/4-20 and 1/4-28 screws are
replaced by the metric M6.3 x 1 screw which has nearly the same diameter and 25.4 threads per inch. The
thread pitch is in between the customary coarse and fine thread pitches.
Metric and customary thread notation differ slightly. The difference is illustrated below.
CUSTOMARY METRIC
1/4 M6.3
20 1
Number of Distance
Threads Between Threads
per Inch in Millimeters
Care should be taken when servicing the car to guard against cross threading or improper retention due to
interchanged metric and inch nuts and bolts.
When obtaining metric or customary nuts, bolts, and screws locally for servicing the car, care must be
exercised in selecting parts that are equivalent to the original parts in dimensions, strength, and pitch of
threads.
10-2 METRIC AND FASTENER INFO RM A TIO N
(I ° I )
TOP LO CK M AN Y CEN TER
TYPES LO CK
D R Y A D H E S IV E C O A T IN G O U T OF R O U N D T H R E A D A R E A
I® GSD
N Y LO N NYLON
IN S E R T P A TCH
Q
N Y LO N
W ASH ER N Y LO N S T R IP OR P A TCH T H R E A D P R O F IL E D E F O R M E D
IN S E R T
R E C O M M E N D A T I O N S FOR REUSE
1. C L E A N D IR T A N D O T H l R FO R E I G N M A T E R I A L OL E NI T A N D BOLT
2. INSPECT B O L T A N D N I T TO ASSURE T i l l Rl A R L NO ( RAC KS. E L O N G A T I O N OR
O T H E R SIGNS Of ABUSE OR O V E R T I G H T E N I N G . L IG H T L V L U B R I C A T E T H R E A D S . ( I F
A N Y D O U B T . RE PL A CE WI TH NEW P R E V A I L I N G TO RQ UE F A S T E N E R OF E Q U A L OR
G R E A T E R S T R E N G T H .)
3. ASSEMBLE PARTS A N D S T A R T B O L T OR N UT .
4 OBSERVE T H A T BEFORE F A S T E N E R SEATS. IT DE VE L OP S P R E V A I L I N G TO RQ UE PER
C H A R T Bl LOW ( IF A N Y D O U B T . I N S T A L L NEW P R E V A I L I N G T O R Q U I FA S T E N E R OF
E Q U A L OR G R E A T E R S T R E N G T H ) .
5. T I G H T E N TO TO RQ UE SPE C IF IE D IN S E R V K I M A N U A L .
METRI r s izes
6 & 6.3 8 10 i: 14 16 20
N • in
0.4 0.6 12 1.6 2.4 3.4 5.6
A D H E S I V E OR N Y L O N
C O A T E D BOLTS
In. I hs.
4.0 5.0 10 14 20 28 46
INCH SIZES
N •m 1.8 3.4
0.4 0.6 1.0 1.4 2.6 5.2
A D H E S I V E OR N Y L O N
C O A T E D BOLTS
In. Lbs. 11
4.0 5.0 9.0 12 15 28 43
METRIC AND FASTENER INFO RM A TIO N 10-3
Common metric fastener strength property classes are 9.8 and 10.9 with the class identification
embossed on the head of each bolt. Customary (inch) strength classes range from grade 2 to 8 with
line identification embossed on each bolt head. Markings correspond to two lines less than the
actual grade (i.e. grade 7 bolt will exhibit 5 embossed lines on the bolt head). Some metric nuts will
be marked with single digit strength identification numbers on the nut face. The following figure
illustrates the different strength markings.
ID E N T IF IC A T IO N MARKS (4)
10-4
SI METRIC-CUSTOMARY CONVERSION TABLE
LENGTH ACCELERATION
TEMPERATURE VELOCITY
Degree Fahrenheit (°F-32) v 1.8 degree Celsius (C) Miles/hour r 609 3 kilometers/hr. (km/h)
°F °F
32 98.6 212
-40 0 1 40 80 120 160 200 ,
1 i i i i i
1 i i t
1 1 ..i..i -
i l l
i . i ;
1 i t
i i i i i i i il
i t
-40 20 0 20 40 60 80 100
°C 37 °c
I
METRIC AND FASTENER INFO RM A TIO N 10-5