1998 Gmt-98 Ck-2 Service Manual-Volume 2 of 4

1998 C/K Truck
Service Manual
Volume 2
This manual provides information on the diagnosis, the service procedures, the adjustments, and the
specifications for the 1998 C/K Truck.
Information on transmission unit repair (overhaul) can be found in the 1998 Transmission/Transaxle/Transfer Case
Unit Repair Manual (TURM), GMPT/98-TURM, available seperately. The TURM manual contains information on
automatic and manual transmissions and transaxles, and transfer cases for all GM passenger cars and light duty
trucks, including the fluid flow and circuit description information.
The technicians who understand the material in this manual and in the appropriate Dealer Service Bulletins better
service the vehicle owners.
When this manual refers to a brand name, a part number, or a specific tool, you may use an equivalent product in
place of the recommended item. All information, illustrations and specifications in this manual are based on the
latest product information available at the time of publication approval. General Motors reserves the right to make
changes at any time without notice.
Published by
NORTH AMERICAN OPERATIONS

General Motors Corporation
Warren, Michigan 48090
©1997 GENERAL MOTORS CORPORATION ALL RIGHTS RESERVED

The information cutoff date is 3/26/97. LITHO IN U.S.A.
No part of this manual may be reproduced, stored in any retrieval system, or transmitted in any form or by any means
(including but not limited to electronic, mechanical, photocopying, and recording) without the prior written permission of
General Motors Corporation. This applies to all text, illustrations, and tables.
Table of Contents
V o lu m e 1 Volume 2
P re fa c e Preface
Cautions and Notices................................................ 1 Cautions and Notices................................................ 1
G e n e ra l I n f o r m a t io n ........................................... 0-1 Steering ........................................................................ 2
General Information................................................0-3 Power Steering Gear and Pump.......................2B-1
Maintenance and Lubrication..............................0-41 Power Steering Gear Unit Repair..................2B1A-1
Vibration Diagnosis and Correction................... 0-85 Power Steering Pump Unit Repair............... 2B1B-1
H V A C ..............................................................................1 Steering Linkage.................................................2B3-1
Heater and Ventilation......................................... 1A-1 Speed Dependent Steering Electronic
Heater, Ventilation and Air Conditioning............ 1B-1 Variable Orifice (EVO )...................................2B5-1
HD6/HT6 Air Conditioning Compressor Steering Wheel and Column On Vehicle
Service or Unit Repair R-134a..................... 1D2-1 Service............................................................... 2F-1
E le c tr ic a l...................................................................... 8 Supplemental Inflatable Restraint (SIR)
Electrical Diagnosis............................................. 8A-1 Standard Steering Column Unit Repair...... 2F4-1
Lighting Systems................................................. 8B-1 Supplemental Inflatable Restraint (SIR)
Instrument Panel and Gauges........................... 8C-1 Tilt Steering Column Unit Repair................. 2F5-1
Chassis Electrical................................................ 8D-1 Suspension ............................................................. 3-1
Windshield Wiper/Washer System..................... 8E-1 Suspension General Diagnosis.............................S-3
Rear Window Wiper/Washer System.................8E-2 Wheel Alignment.................................................. 3-17
A c c e s s o r ie s ................................................................9 Front Suspension................................................. 3-35
Audio Systems......................................................9A-1 Rear Suspension.................................................. 3-93
Cruise Control.......................................................9B-1 Tires and W heels............................................... 3-113
Passlock System................................................. 9D-1 Driveline/Axle ......................................................... 4-1
Engine Coolant Heater........................................ 9E-1 Propeller Shaft........................................................ 4-5
Luggage Carrier....................................................9F-1 Wheel Drive S hafts..............................................4-29
Running Boards................................................... 9G-1 Front Drive A x le ................................................... 4-49
Restraints...............................................................9J-1 Rear Drive Axle.................................................. 4-103
Seat Belts.......................................................... 9J-1 Rear Drive Axle - Locking/Limited Slip
Supplemental Inflatable Restraints (SIR).... 9J-47 Rear A xle ........................................................ 4-169
Remote Keyless Entry......................................... 9K-1 Transfer Case..................................................... 4-181
B o d y .............................................................................10 B rakes ....................................................................... 5-1
Doors..................................................................10A1-1 Hydraulic Brakes.................................................... 5-5
Seats................................................................ 10A2-1 Disc Brakes...................... 5-89
Windows.............................................................10A3-1 Drum Brakes....................................................... 5-123
Interior Trim.......................................................10A4-1 Park Brake.......................................................... 5-145
Frame and Bumpers........................................ 10A5-1 Antilock Brake System...................................... 5r-163
Sheet Metal.......................................................10A6-1
Endgate............................................................. 10A7-1
Cab and Body Maintenance..............................10B-1
Table of Contents - Continued
Volume 3 Volume 4
Preface Preface
Cautions and Notices............................................... 1 Cautions and Notices................................................1
Engine............................................................ 6-1 Engine.............................................................6-1
Engine Mechanical - 4.3L.................................... 6-23 Engine Controls - 6.5L.................................... 6-2279
Engine Mechanical - 5.0L, 5.7L....................... 6-237 Engine Controls - 7.4 L ....................................6-2677
Engine Mechanical - 6.5L..................................6-455 Turbocharger.....................................................6-3239
Engine Mechanical - 7.4L..................................6-687 Vacuum Pump............................................... 6-3253
Engine Cooling....................................................6-927 Engine Exhaust................................................ 6-3259
Engine Electrical................................................ 6-991 Transmission/Transaxle .................................... 7-1
Engine Controls - 4 .3 L ....................................6-1089 Manual Transmission - New Venture................... 7-7
Engine Controls - 5.0, 5.7L............................ 6-1643 Automatic Transmission - 4L60-E...................... 7-39
Automatic Transmission - 4L80-E.................... 7-269
Clutch.................................................................. 7-593
REPORTING ERRORS AND SUGGESTIONS
If you find an error in a GM Service manual, or if you have a suggestion about a GM service manual, we
want to hear from you.
When calling, be prepared with the following information:

• Your name
• Your dealership’s name
• Your dealership’s phone number
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• The service manual section and page number(s)
• Any applicable electronic information element identification numbers
• A descriptive explanation of your concern
The GM service manual phone personnel will respond to your concerns in the follow ing ways:
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For paper manual users: The GM service manual phone personnel w ill also explain how to send in examples
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For electronic manual users: Be prepared to provide any applicable identification numbers pertaining to the
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The GM service manual comment telephone numbers do not provide technical assistance. For technical
assistance, contact your regular technical assistance source.
United States and Canada General Motors Dealer Employees

Please call the following number Monday through Friday with your comments: 1-800-828-6860,
fax number 810-265-9327, 8:00 a.m.-8:00 p.m. Eastern Time Zone.
Canada, French Speaking General Motors Dealer Employees

Please call the following number Monday through Friday with your comments: 1-800-503-3222,
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Please call the following number Monday through Friday with your comments: 810-265-0840,
United States and Canadian Vehicle Owner/Operator

Vehicle owners or operators are encouraged to address their comments and concerns to the applicable
Custom er Assistance Center. The phone number and address of the Custom er Assistance Centers are in the
Owner’s Manual.
Preface Table of Contents - 1
Preface
Cautions and Notices ............................................3 SIR Inflator Module Disposal Caution.................5

Definition of Caution, Notice, and Important..... 3 SIR Inflator Module Handling and
ABS Handling Caution......................................... 3 Storage Caution................................................5
Battery Disconnect Caution................................. 3 SIR Special Tool Caution..................................... 5
Brake Dust Caution...............................................3 Vehicle Lifting Caution......................................... 5
Brake Fluid Caution..............................................4 Window Removal C aution................................... 5
Clutch Dust Caution..............................................4 Window Retention Caution.................................. 6
Electric Coolant Fan Caution............................... 4 Work Stall Test Caution....................................... 6
Fuel and EVAP Pipe Caution.............................. 4 Defective Scan Tool Notice................................. 6
Fuel Pipe Fitting Caution..................................... 4 Fastener Notice..................................................... 6
Fuel Storage Caution............................................4 Fuel Pressure Notice............................................6
Gasoline/Gasoline Vapors Caution......................4 Handling ESD Sensitive Parts Notice................ 6
Lower O-Ring Removal Caution..........................4 Handling IAC Valve Notice.................................. 7
Moving Parts and Hot Surfaces Caution........... 4 Ignition OFF When Disconnecting Battery
Notice................................................................ 7
Relieving Fuel Pressure Caution.........................4
Latched DTC B1018, B1024 Notice
Road Test Caution................................................4 (SDM-RSD).......................................................7
Safety Glasses and Compressed Air Caution ...5 Nylon Fuel Lines Notice...................................... 7
Safety Goggles and Fuel Caution.......................5 OBDII System Description Notice...................... 7
Seat Belt Replacement Caution..................... :...5 PCM and ESD Notice...........................................7
Shop Towel Fuel Link Caution............................5 Servicing and Replacing Seat Belts Notice.......7
SIR Caution........................................................... 5 Single Cylinder Flooding Notice..........................7
SIR Handling Caution...........................................5
Preface
2 - Table of Contents
BLANK
Preface Cautions and Notices - 3
Cautions and Notices

Definition of Caution, Notice, and • Damage to fasteners, basic tools, or
Important special tools
• The leakage of coolant, lubricant, or other vital
Cautions, N otices, and Im portants in the fluids
Service Manual IMPORTANT Defined
The diagnosis and repair procedures in the GM IMPORTANT statements emphasize a necessary
Service Manual contain both general and specific characteristic of a diagnostic or repair procedure.
Cautions, Notices, and Importants. GM is dedicated IMPORTANT statements are designed to do the
to the presentation of service information that helps following:
the technician to diagnose and repair the systems • Clarify a procedure
necessary for the proper operation of the vehicle, • Present additional information for accomplishing
however, certain procedures may present a hazard a procedure
to the technician if they are not followed in the • Give insight into the reason or reasons for
recommended m anner. Cautions, Notices, and performing a procedure in the manner
Importants are elements designed to prevent these recommended
hazards, however, not all hazards can be foreseen.
• Present information that will help to accomplish
This information is placed at strategic locations within a procedure in a more effective manner
the service manual. This information is designed to
prevent the following from occurring: • Present information that gives the technician
the benefit of past experience in accomplishing
• Serious bodily injury to the technician a procedure with greater ease
• Damage to the vehicle
• Unnecessary vehicle repairs ABS Handling Caution
• Unnecessary component replacement Caution: Certain components In the Antilock
Brake System (ABS) are not intended to be
• Improper repair or replacement of vehicle
serviced individually. Attempting to remove or
components. Any caution or notice that appears
disconnect certain system components may
in general information is referenced from the result in personal Injury and/or Improper system
individual service categories. operation. Only those component with approved
CAUTION Defined removal and installation procedures should be
When encountering a CAUTION, you will be asked serviced.
to take a necessary action or not to take a
prohibited action. If a CAUTION is not heeded, the Battery Disconnect Caution
following consequences may occur:
Caution: Disconnect the negative battery cable
1. Serious bodily injury to the technician under the following circumstances:
2. Serious bodily injury to other technicians in the • When Installing an electrical unit.
workplace area • When a tool or equipment could easily come
3. Serious bodily injury to the driver and/or into contact with "live" exposed electrical
passenger(s) of the vehicle, if the vehicle has terminals.
been improperly repaired Failure to disconnect the negative battery
NOTICE Defined terminal may result in personal injury or damage
Notices call special attention to a necessary action to the vehicle’s components. Turn OFF the
or to a prohibited action. If a NOTICE is not heeded, vehicle ignition, unless instructed otherwise.
the following consequences may occur:
Brake Dust Caution
• Damage to the vehicle
Caution: Avoid taking the following actions when
• Unnecessary vehicle repairs you service wheel brake parts:
• Unnecessary component replacement • Do not grind brake linings.
• Improper operation or performance of the • Do not sand brake linings.
system or component under repair
• Do not clean wheel brake parts with a dry
• Damage to any systems or components which brush or with compressed air.
are dependent upon the proper operation of the Many earlier model or aftermarket brake parts
system or component under repair may contain asbestos fibers which can become
• Improper operation or performance of any airborne in dust. Breathing dust with asbestos
systems or components which are dependent fibers may cause serious bodily harm. Use a
upon the proper operation or performance of water-dampened cloth in order to remove any
the system or component under repair dust on brake parts. Equipment is available
4 - Cautions and Notices Preface
commercially in order to to perform this washing Fuel Pipe Fitting Caution

function. These wet methods prevent fibers from
Caution: Always apply a few drops of clean
becoming airborne.
engine oil to the male pipe ends before
Brake Fluid Caution connecting fuel pipe fittings In order to reduce
the risk of fire and personal injury.
Caution: Brake fluid may be Irritating to the skin
This will ensure proper reconnection and prevent
or eyes, in case o f contact, take the following
actions: a possible fuel leak.
During normal operation, the O-rings located In
• Eye contact - rinse eyes thoroughly with
the female connector will swell and may prevent
water.
proper reconnection if not lubricated.
• Skin contact - wash skin with soap and
water. Fuel Storage Caution
Clutch Dust Caution Caution: Do not drain the fuel into an open
container. Never store the fuel In an open
Caution: Avoid taking the following actions when container due to the possibility of a fire or an
you service wheel brake parts: explosion.
• Do not grind brake linings.
Gasoline/Gasoline Vapors Caution
• Do not sand brake linings.
• Do not clean wheel brake parts with a dry Caution: Gasoline or gasoline vapors are highly
brush or with compressed air. flammable. A fire could occur If an Ignition
source is present. Never drain or store gasoline
Many earlier model or aftermarket brake parts
or diesel fuel In an open container, due to the
may contain asbestos fibers which can become
possibility of fire or explosion. Have a dry
airborne in dust. Breathing dust with asbestos
chemical (Class B) fire extinguisher nearby.
fibers may cause serious bodily harm. Use a
water-dampened cloth In order to remove any Lower O-Ring Removal Caution
dust on brake parts. Equipment Is available
commercially in order to to perform this washing Caution: Verify that the lower (small) O-ring of
function. These wet methods prevent fibers from each Injector does not remain In the lower
becoming airborne. manifold in order to reduce the risk of fire and
personal injury.
Electric Coolant Fan Caution If the O-ring is not removed with the Injector, the
Caution: An electric fan under hood can start replacement Injector with new O-rings will not
even when the engine is not running and can seat properly in the Injector socket. Improper
injure you. Keep hands, clothing and tools away seating could cause a fuel leak.
from any underhood electrical fan.
Moving Parts and Hot Surfaces Caution
Fuel and EVAP Pipe Caution Caution: While working around a running engine,
Caution: In order to Reduce the Risk of Fire and avoid contact with moving parts and hot surfaces
Personal Injury observe the following items: to prevent possible bodily Injury.
• Replace all nylon fuel pipes that are nicked, Relieving Fuel Pressure Caution
scratched or damaged during Installation, Do
Not attempt to repair the sections of the Caution: Relieve the fuel system pressure before
nylon fuel pipes servicing fuel system components In order to
• Do Not hammer directly on the fuel harness reduce the risk of fire and personal Injury.
body clips when Installing new fuel pipes. After relieving the system pressure, a small
Damage to the nylon pipes may result in a amount of fuel may be released when servicing
fuel leak. the fuel lines or connections. In order to reduce
• Always cover nylon vapor pipes with a wet the chance of personal Injury, cover the regulator
towel before using a torch near them. Also, and the fuel line fittings with a shop towel before
never expose the vehicle to temperatures disconnecting. This will catch any fuel that may
higher than 115°C (239*F) for more than one leak out. Place the towel In an approved
hour, or more than 90eC (194*F) for any container when the disconnection Is complete.
extended period.
Road Test Caution
• Apply a few drops of clean engine oil to the
male pipe ends before connecting fuel pipe Caution: Road test a vehicle under safe
fittings. This will ensure proper reconnection conditions and while obeying all traffic laws. Do
and prevent a possible fuel leak. (During not attempt any maneuvers that could jeopardize
normal operation, the O-rings located In the vehicle control. Failure to adhere to these
female connector will swell and may prevent precautions could lead to serious personal injury.
proper reconnection if not lubricated.)
Safety Glasses and Compressed Air SIR Inflator Module Disposal Caution i
Caution Caution: In order to prevent accidental
Caution: Wear safety glasses when using deployment of the air bag which could cause
compressed air In order to prevent eye Injury. personal Injury, do not dispose of an undeployed
Inflator module as normal shop waste. The
Safety Goggles and Fuel Caution undeployed Inflator module contains substances
Caution: Always wear safety goggles when that could cause severe illness or personal Injury
working with fuel In order to protect the eyes If the sealed container Is damaged during
from fuel splash. disposal. Use the following deployment
procedures to safely dispose of an undeployed
Seat Belt Replacement Caution inflator module. Failure to dispose of an Inflator
module as instructed may be a violation of
Caution: Replace belts, retractors, and hardware federal, state, province, or local laws.
in use during all but a minor collision. Also,
restraint systems should be replaced and SIR Inflator Module Handling and Storage
anchorage’s properly repaired if they were in Caution
areas damaged by collision, whether the belt was
In use or not. If there Is any question, replace Caution: When you are carrying an undeployed
the belt system. Damage, whether visible or not, Inflator module:
could result in serious personal Injury in the • Do not carry the inflator module by the
event of an accident. wires or connector on the Inflator module
• Make sure the bag opening points away
Shop Towel Fuel Link Caution
from you
Caution: Wrap a shop towel around the fuel When you are storing an undeployed Inflator
pressure connection In order to reduce the risk module, make sure the bag opening points away
of fire and personal Injury. The towel will absorb from the surface on which the Inflator module
any fuel leakage that occurs during the rests. When you are storing a steering column,
connection of the fuel pressure gauge. Place the do not rest the column with the bag opening
towel In an approved container when the facing down and the column vertical. Provide free
connection of the fuel pressure gauge is space for the air bag to expand In case of an
complete. accidental deployment. Otherwise, personal injury
may result.
SIR Caution
Caution: This vehicle has a Supplemental SIR Special Tool Caution
Inflatable Restraint (SIR) System. Refer to SIR Caution: In order to avoid deploying the air bag
Component Location View in order to determine when troubleshooting the SIR system, use only
whether you are performing service on or near the equipment specified In this manual and the
the SIR components or the SIR wiring. When you Instructions given In this manual. Failure to use
are performing service on or near the SIR the specified equipment as Instructed could
components or the SIR wiring, refer to SIR cause air bag deployment, personal injury to you
On-Vehlcle Service Information. Failure to follow or someone else, or unnecessary SIR system
the CAUTIONS could cause air bag deployment, repairs.
personal Injury, or unnecessary SIR system
repairs. Vehicle Lifting Caution
SIR Handling Caution Caution: To help avoid personal Injury, when a
vehicle Is on a hoist, provide additional support
Caution: When you are carrying an undeployed for the vehicle at the opposite end from which
Inflator module: you are removing components. The additional
• Do not carry the Inflator module by the support will reduce the possibility o f the vehicle
wires or connector on the Inflator module falling off the hoist. When you are removing
• Make sure the bag opening points away major components from the vehicle while the
from you vehicle Is on a hoist, chain the vehicle frame to
the hoist pads at the same end from which you
When you are storing an undeployed Inflator
are removing the major components to prevent
module, make sure the bag opening points away
tip-off. If you fall to follow these precautionary
from the surface on which the Inflator module
measures, vehicle damage, serious personal
rests. When you are storing a steering column,
injury, or death may result.
do not rest the column with the bag opening
facing down and the column vertical. Provide free Window Removal Caution
space for the air bag to expand In case of an
accidental deployment. Otherwise, personal Injury Caution: When working with any type of glass,
may result. use approved safety glasses and gloves to
reduce the chance of personal Injury.
Window Retention Caution locking compound or sealant are identified in the

service procedure. Do not use paints, lubricants, or
Caution: When replacing stationary windows, corrosion inhibitors on fasteners or fastener joint
Urethane Adhesive Kit GM P/N 12346284, or a surfaces unless specified. These coatings affect
urethane adhesive system meeting GM fastener torque and joint clamping force and may
Specification GM3651M, must be used to damage the fastener. Use the correct tightening
maintain original installation integrity. Failure to sequence and specifications when installing fasteners
use the urethane adhesive kit will result in poor in order to avoid damage to parts and systems.
retention of the window which may allow
unrestrained occupants to be ejected from the Fuel Pressure Notice
vehicle resulting In personal Injury.
Notice: Do not allow the fuel pressure to exceed the
Work Stall Test Caution specified value because damage to the fuel pressure
regulator or the fuel pressure gauge may result.
Caution: One or more of the following guidelines
may apply when performing specific required Handling ESD Sensitive Parts Notice
tests in the work stall:
1. When a test requires spinning the drive
wheels with the vehicle Jacked up, adhere to
the following precautions:
NOTICE
• Do not exceed 56 km/h (35 mph) when
spinning one drive wheel with the other
drive wheel stopped. This limit Is
necessary because the speedometer
Indicates only one-half the actual vehicle
speed under these conditions. Personal
Injury may result from excessive wheel
spinning.
• If all of the drive wheels are spinning at
the same speed, do not exceed 112 km/h
(70 mph). Personal injury may result from
excessive wheel spinning. CONTENTS SENSITIVE
• All persons should stay clear of the TO
rotating components and the balance STATIC ELECTRICITY
weight areas in order to avoid possible
personal injury. 6392
• When running an engine in the repair stall
Electrostatic discharge (ESD) can damage many
for an extended period of time, use care
solid state electrical components. Not all components
not to overheat the engine and the
that are susceptible to damage from ESD are
transmission.
labeled with the ESD symbol. Exercise caution when
2. When a test requires Jacking up the vehicle handling all solid state electrical components.
and running with the wheels and brake
Avoid damaging solid state electrical components by
rotors removed, adhere to the following
taking the following precautions:
precautions:
• Discharge personal electricity by touching a
• Do not apply the brake with the brake
metal ground point after each of the following
rotors removed.
activities:
• Do not place the transmission in Park
- sliding across the vehicle seat
with the drive wheels still spinning.
- sitting or rising
• Turn Off the ignition In order to stop the
powertrain components from spinning. - walking
• Do not touch the exposed electric terminals on
Defective Scan Tool Notice a component with your finger or a tool. The
Notice: Do not use a scan tool that displays faulty connector that you are checking may be tied
data. Report the scan tool problem to the into a circuit that is susceptible to damage by
manufacturer. Use of a faulty scan tool can result in ESD.
misdiagnosis and unnecessary parts replacement. • Do not allow a screwdriver or a similar tool to
contact exposed terminals when disconnecting
Fastener Notice a connector.
Notice: Use the correct fastener in the correct • Do not remove the protective packing of the
location. Replacement fasteners must be the correct solid state component until you are ready to
part number for that application. Fasteners requiring install the solid state component.
replacement or fasteners requiring the use of thread
• Unless specified in a particular diagnostic OBDII System Description Notice
procedure, avoid the following activities:
Notice: The OBD II symbol is used on the circuit
- jumpering components or connectors diagrams in order to alert the technician that the
- grounding components or connectors circuit is essential for proper OBD II emission control
- using test equipment probes on components circuit operation. Any circuit which, if it fails causes
or connectors the Malfunction Indicator Lamp (MIL) to turn on, is
• When a diagnosis requires the use of test identified as an OBDII circuit.
equipment probes, connect the ground
lead first.
PCM and ESD Notice
• Touch the solid state component’s package to a Notice: Do not touch the connector pins or soldered
ground before opening. components on the circuit board in order to prevent
possible electrostatic discharge (ESD) damage to
• Do not lay the solid state component in any of
the following locations: the PCM.
- On a metal work bench Servicing and Replacing Seat Belts Notice
- On top of an electrically operating appliance
Notice: To prevent possible seat belt damage, refer
or piece of equipment, like a TV, radio or
to the following items before servicing or replacing
oscilloscope
lap and shoulder belts, including single loop belt
• Do not drop the solid state component. systems:
Handling IAC Valve Notice 1. Lap and shoulder belts will be serviced as
follows:
Notice: If the IAC valve has been in service: DO 1.1. Replace only the part in question.
NOT push or pull on the IAC valve pintle. The force
1.2. All belts need to be serviced as a set to
required to move the pintle may damage the threads
assure the belt components are from the
on the worm drive. Also, DO NOT soak the IAC
valve in any liquid cleaner or solvent, as damage same supplier.
may result. 1.3. Do not intermix standard and deluxe
belts on front or rear seats.
Ignition OFF When Disconnecting Battery 1.4. All attachment hardware must be
Notice replaced, not reused.
Notice: Always turn the ignition OFF when 2. Keep sharp edges and damaging objects away
connecting or disconnecting battery cables, battery from belts.
chargers, or jumper cables. Failing to do so may 3. Avoid bending or damaging any portion of the
damage the Powertrain Control Module (PCM) or belt buckle or latch plate.
other electronic components.
4. Do not bleach or dye belt or strap webbing.
Latched DTC B1018, B1024 Notice Clean with a mild soap solution and water.
(SDM-RSD) 5. When installing lap or shoulder belt anchor
bolts, start the bolts by hand to ensure that the
Notice: When DTC B1018 or B1024 has been set it bolts are threaded straight.
is necessary to replace the inflatable restraint
Sensing and Diagnostic Module (SDM). Setting DTC 6. Do not attempt repairs on lap or shoulder belt
B1018 or B1024 will also cause DTC B1071 to set. retractor mechanisms to lap belt retractor
When a scan tool clear codes command is issued covers. Replace defective assemblies with new
and the malfunction is no longer present, DTC service replacement parts.
B1018 or B1024 and DTC B1071 will remain current. 7. Do not attempt to remove the seat belt retractor
Make sure that the short to ground condition is cover. The cover and the long rivet securing the
repaired prior to installing a replacement SDM to cover to the retractor are not available as
avoid damaging the SDM. service replacement parts.
Nylon Fuel Lines Notice Single Cylinder Flooding Notice

Notice: Do not attempt to straighten the kinked Notice: In order to prevent flooding of a single
nylon fuel lines. Replace any kinked nylon fuel feed cylinder and possible engine damage, relieve the fuel
or return pipes in order to prevent damage to the pressure before performing the fuel injector coil test
vehicle. procedure.
BLANK
STEERING Table of Contents 1
— r — ■
SECTION 2
STEERING
Power Steering Gear and Pum p ............... 2B-1 Power Steering Pump Unit Repair.... 2B1B-1
General Description............................................2B-1 Specifications................................................. 2B1B-1
Power Steering G ear....................................... 2B-1 Fluid Capacities............................................ 2B1B-1
Hydraulic Pump.................................................2B-1 Fastener Tightening Specifications........... 2B1B-1
Diagnosis Of Power Steering System ..........2B-1 Power Steering Pump Assembly............... 2B1B-2
Locating Oil Leaks............................................2B-6 Power Steering Pump Service................... 2B1B-3
Power Steering System Test...........................2B-6 Drive Shaft Seal Replacement...................2B1B-3
On-Vehicle Service..............................................2B-8 Variable Assist Steering Actuator...............2B1B-3
Maintenance......................................................2B-8 Pump Reservoir Replacement....................2B1B-4
Fluid Level......................................................... 2B-8 End Plate and Rotating Group
Bleeding the Power Steering System........... 2B-8 Replacement............................................... 2B1B-5
Flushing the Power Steering System............2B-8 Special Tools...................................................2B1B-6
Steering Gear Replacement..........................2B-10 Steering Linkage .............................................. 2B3-1
Pitman Shaft Seal Replacement................... 2B-10 General Description.......................................... 2B3-1
Two Wheel D rive........................................ 2B-10 Diagnosis Of Steering Linkage......................2B3-1
On-Vehicle Service............................................2B3-1
Four Wheel Drive.........................................2B-11
Steering Linkage Inspection.......................... 2B3-1
Power Steering Pump Replacement............ 2B-11
Tie Rods........................................................2B3-1
Power Steering Hoses................................... 2B-12
Idler A rm ...................................................... 2B3-1
Specifications.................................................... 2B-20
Idler Arm Replacement..................................2B3-2
Fastener Tightening Specifications............... 2B-20
Relay Rod Replacement................................2B3-3
Power Steering System Pressures............... 2B-20
Drag Link Replacement.................................2B3-5
Special Tools..................................................... 2B-21
Pitman Arm Replacement..............................2B3-6
Power Steering Gear Unit R epair........ 2B1A-1
Two Wheel Drive........................................ 2B3-6
Specifications................................................. 2B1A-1
Four Wheel D rive....................................... 2B3-6
Fluid Capacities.......................... 2B1 A-1
I-Beam Front Axle (C3500HD Models).... 2B3-7
Fastener Tightening Specifications.............2B1 A-1 Tie Rod Replacement.................................... 2B3-7
Adjustment Tightening Specifications....... 2B1A-1 I-Beam Front Axle (C3500HD Models).... 2B3-8
Power Steering Gear Assembly..................2B1A-2 Tie Rod Clamp and Adjuster Tube
Steering Gear Adjustm ents......................... 2B1A-3 Positioning...................................................... 2B3-9
Worm Thrust Bearing Preload I-Beam Front Axle (C3500HD Models).... 2B3-9
Adjustment.......................................................... 2B1A-3 Steering Shock Absorber Inspection..........2B3-10
Pitman Shaft Over-Center Preload Steering Shock Absorber Replacement.... 2B3-10
Adjustment................................................... 2B1A-4 Four Wheel D rive..................................... 2B3-10
Steering Gear Service...................................2B1A-5 Specifications..................................................2B3-11
Pitman Shaft and Side Cover Fastener Tightening Specifications.............2B3-11
Replacement......................................................2B1A-5 Special Tools................................................... 2B3-12
Housing End Plug Replacement.................2B1A-6 Speed Dependent Steering Efectronic
Thrust Support Assembly Replacement....2B1A-6 Variable Orifice (EVO )..........................2B5-1
Valve Replacement.......................................2B1A-7 General Description......................................... 2B5-1
Rack Piston and Worm Shaft Handling Electrostatic Discharge (ESD)
Replacement............................................... 2B1A-8 Sensitive Parts...............................................2B5-1
Pitman Shaft Seal and Bearing EVO Component Operation and Location ...2B5-2
Replacement.............................................2B1 A-10 Steering Assist Control Solenoid................2B5-2
Check Valve Replacement.........................2B1A-11 Electronic Variable Orifice (EVO)/Passlock
Special Tools................................................2B1 A-12 Module....................................................... .2B5-2
2 Table of Contents STEERING
Steering Handwheel Speed (HWSS) S pe cifica tio ns................ 2F-16

Sensor...........................................................2B5-3 Fastener Tightening Specifications................2F-16
Diagnosis...................................... .................... 2B5-4 Special T o o ls............. 2F-17
On-Vehicle Service..........................................2B5-35 Supplemental Inflatable Restraint (SIR)
Steering Assist Control Solenoid, Standard Steering Column
Discharge Fitting, and Flow Control Unit Repair................................................. 2F4-1
Valve..................... 2B5-35 S pe cifica tio ns......... ..... .............................. 2F4-1
Electronic Variable Orifice (EVO)/Passlock Fastener Tightening Specification.......... .......2F4-1
. ” Module.......................................................... 2B5-35 Disabling the SIR System ............................... 2F4-4
Steering Handwheel Speed (HWSS) Enabling the SIR System ....... ..................... 2F4-4
Sensor....................................... ................. 2B5-36 Lower Shroud.................. 2F4-5
Specifications.................................................. 2B5-36 Steering Column Lock Cylinder Set..................2F4-5
Fastener Tightening Specifications..... ....... 2B5-36 Upper Shroud............................................... .......2F4-5
Special Tools............................... .............. ...2B5-37 Shift Lever Seal (C/S only)..... ................. 2F4-5
Steering Wheel and Column On Vehicle Inflatable Restraint Steering Wheel Middle
Service ............................................................ 2F-1 Coil Assembly................................................ 2F4-6
General Description............................................ 2F-1 T/S and Multifunction Switch Assembly........... 2F4-8
Brake Transmission ShiftInterlock (BTSI)......2F-1 Ignition and Key Alarm Switch Assembly....... 2F4-8
Supplemental Inflatable Restraint (SIR)........ 2F-1 Steering Column Lock Cylinder Set
Diagnosis.............................................................. 2F-1 (Lost Key)..................................................... 2F4-10
Ignition Lock System.........................................2F-1 Electrical (BTSI) Actuator (C/S only)............. 2F4-13
Repairs and Inspections Required After an Linear Shift Assembly Removal
Accident............................................................. 2F-1 (C/S only)..................................................... 2F4-15
Diagnosis of the Steering Column...................2F-1 Linear Shift Assem bly Disassembly
On-Vehicle Service.............................................. 2F-8 (C/S o n ly )........................... 2F4-17
Service Precautions - Supplemental Ball and Actuator Assembly........................ 2F4-17
Inflatable Restraint (S IR )................................ 2F-8 Shift Lever Clevis.......................................... 2F4-17
Disabling the SIR System ................... 2F-8 Park Lock Cable Assembly.......................... 2F4-17
Enabling the SIR System..........................»..2F-8 G/S Lever Assembly Support Bracket....... 2F4-17
Live (Undeployed) Inflator Module Upper Column Housing C om ponents........ 2F4-18
Handling............................................................ 2F-8 Shaft Lock Shield Assembly........................ 2F4-18
Deployed Inflator Module Handling............. 2F-9 Turn Signal Cancel Cam Assembly........... 2F4-18
Inflator Module Shipping Procedure............ 2F-9 Upper Bearing Spring...................................2F4-18
Inflator Module Scrapping Procedure........ 2F-9 Thrust Washer............................................... 2F4-18
Wiring Repairs................................................... 2F-9 Lock Module Assembly.....................................2F4-19
Ignition S w itch....................................................2F-9 Steering Column Housing Assem bly............. 2F4-20
Inflator Module Replacement........................... 2F-9 Steering Shaft Assembly..................................2F4-21
Horn Contact Replacement............................ 2F-10 Adapter and Bearing Assem bly...................... 2F4-21
Horn Pad Assembly Replacement.................2F-11 Steering Column Jacket Assembly.................2F4-21
Steering Wheel Replacement........................ 2F-11 Accident Damage.............................................. 2F4-23
Tilt Lever Replacement............................... ...2F-12 Special T o o ls....................................................2F4-24
Multifunction Turn Signal/Hazard Switch Supplemental Inflatable Restraint (SIR)
Replacement.................................................. 2F-12 Tilt Steering Column Unit Repair...2F5-1
Shift Lever Replacement................................. 2F-13 . S pe cifica tio ns.....................................................2F5-1
Shift Lever Seal Replacement.......................2F-13 Fastener Tightening Specifications................2F5-1
Intermediate Shaft Replacement...................2F-13 Disabling the SIR System ................................2F5-4
Steering Column Replacement......................2F-14 Enabling the SIR S ystem .................................2F5-4
Steering Column Seal Replacement Lower Shroud.......................................................2F5-5
(All Except C3500HD)....................................2F-16 Steering Column Lock Cylinder Set..................2F5-5
Steering Column Seal Replacement Upper Shroud.......................................................2F5-5
(C3500HD)..................................................... 2F-16 Shift Lever Seal (C/S only)................................2F5-5
Checking Steering Column for Accident Inflatable Restraint Steering Wheel Middle
Damage...........................................................2F-16 Coil Assembly.................................................2F5-7
STEERING Table of Contents 3
T/S and Mulitfunction Switch Assembly........... 2F5-8 Turn Signal Cancel Cam Assembly........... 2F5-19
Ignition and Key Alarm Switch Assembly........2F5-9 Upper Bearing Spring...................................2F5-19
Steering Column Lock Cylinder Set Upper Bearing Inner Race Seat..................2F5-19
(Lost Key)..................................................... 2F5-10 Inner Race..................................................... 2F5-19
Electrical (BTSI) Actuator................................ 2F5-13 Lock Module Assembly.....................................2F5-20
Linear Shift Assembly Removal (C/S only)...2F5-15 Steering Column Tilt Head Assembly............ 2F5-21
Linear Shift Assembly Disassembly Lower Steering Shaft Assem bly................. 2F5-22
(C/S o n ly).................................................... 2F5-17 Sphere........................................................... 2F5-22
Ball and Actuator Assembly.........................2F5-17 Joint Spring................................................... 2F5-22
Shift Lever Clevis..........................................2F5-17 Steering Column Support Assembly.............. 2F5-22
Park Lock Cable Assembly..........................2F5-17 Adapter and Bearing Assem bly......................2F5-22
G/S Lever Assembly Support Bracket.......2F5-17 Steering Column Jacket Assembly................ 2F5-22
Tilt Spring.......................................................... 2F5-18 Accident Damage..............................................2F5-25
Upper Tilt Head Components.......................2F5-19 Special Tools...................................................2F5-26
Shaft Lock Shield Assembly........................2F5-19
4 Table of Contents STEERING
BLANK
POWER STEERING GEAR AND PUMP 2B-1
SECTION 2B
POWER STEERING GEAR AND PUMP

GENERAL DESCRIPTION
The hydraulic power steering system consists of a mechanical force. If the steering system loses hydraulic
pump, fluid reservoir, steering gear, pressure hose, and pressure, the vehicle can be controlled manually.
a return hose.
HYDRAULIC PUMP
POWER STEERING GEAR The power steering pump is a vane-type design. The
The power steering gear has a recirculating ball sys submerged pump (Figure 1) has a housing and internal
tem which acts as a rolling thread between the worm parts that are inside the reservoir and operate sub
shaft and the rack piston. The worm shaft is supported merged in oil.
by a preloaded thrust bearing and two conical thrust The Electronic Variable Orifice (EVO) actuator assem
races at the lower end, and a bearing assembly in the bly is installed at the rear of the pump. This assembly
adjuster plug at the upper end. When the worm shaft is contains the electronic solenoid which controls fluid flow
turned right, the rack piston moves up in the gear. Turn to the steering gear. A pressure relief valve is installed
ing the worm shaft left moves the rack piston down in inside the pump. This valve limits the maximum pump
the gear. The rack piston teeth mesh with the sector, pressure. The pressure relief valve inside the flow con
which is part of the pitman shaft. Turning the worm trol valve limits the pump pressure. Vehicles that are
shaft turns the pitman shaft, which turns the wheels 15,000 GVW (RPO C5B) do not have an EVO actuator
through the steering linkage. assembly on the power steering pump. These pumps
The control valve in the steering gear directs the pow have a discharge fitting at the rear of the pump. A
er steering fluid to either side of the rack piston. The pressure relief valve is installed inside the pump. This
rack piston converts the hydraulic pressure into a valve limits the maximum pump pressure.
DIAGNOSIS OF POWER STEERING SYSTEM

PROBLEM POSSIBLE CAUSE CORRECTION
Objectionable Hiss Noisy relief valve in the hydraulic pump. 1. There is some noise in all power steer
ing systems. One of the most common
is a Hissing sound most evident at
standstill parking. Hiss is a high fre
quency noise. The noise is present in
every valve and results from high veloc
ity fluid passing valve orifice edges.
There is no relationship between this
noise and performance of the steering.
Hiss may be expected when the steer
ing wheel is at end of travel or when
slowly turning at standstill. Do not
replace valve unless hiss is extremely
objectionable. A replacement valve will
also exhibit slight noise and is not
always a cure for the objection.
2B-2 POWER STEERING GEAR AND PUMP
DIAGNOSIS OF POWER STEERING SYSTEM (cont’d)

Rattle Or Chuckle 1. Gear loose on the frame. 1. Check the gear mounting bolts. Torque
Noise In Steering the bolts to specifications. Refer to Fas
Gear tener Tightening Specifications in this
section.
2. Steering linkage looseness. 2. Check linkage pivot points for wear.
Replace if necessary. Refer to Steering
Linkage Inspection in Steering Linkage.
3. Pressure hose touching other parts of 3. Adjust the hose position. Do not bend
vehicle. tubing by hand.
4. Loose pitman arm. 4. Torque the pitman arm bolt.
5. Improper over-center adjustment. A 5. Adjust to specifications. Refer to Speci
slight rattle may occur on turns because fications in Power Steering Gear Unit
of increased clearance off the high Repair.
point. This is normal and clearance
must not be reduced below specified
limits to eliminate this slight rattle.
Excessive Wheel 1. Air in the system. 1. Add oil to the pump reservoir and bleed.
Kickback Or Loose Check hose connectors for proper
Steering torque.
2. Steering gear mounting loose. 2. Tighten attaching bolts to specifications.
Refer to Fastener Tightening Specifica
tions in this section.
3. Steering linkage joints worn. 3. Replace loose parts. Refer to Steering
Linkage Inspection in Steering Linkage.
4. Front wheel bearings incorrectly adjust 4. Adjust the bearings or replace with new
ed or worn. parts as necessary. Refer to Wheel
Bearing Adjustment in Front Suspen
sion.
5. Steering gear improperly adjusted. 5. Adjust to specifications. Refer to Steer
ing Gear Adjustment in Power Steering
Gear Unit Repair.
6. Damaged or worn steering gear. 6. Disassemble and repair the steering
gear as outlined in Steering Gear Ser
vice in Power Steering Gear Unit
Repair.
Vehicle Leads To One 1. Keep in mind the road and wind condi 1. Test the vehicle, going in both direc
Side Or The Other tions. tions, on a flat road.
2. Front wheels misaligned. 2. Adjust to specifications. Refer to Mea
suring Wheel Alignment in Wheel Align
ment.
3. Unbalanced steering gear valve. If this 3. Replace the gear valve.
is the cause, steering effort will be very
light in direction of lead and heavy in
opposite direction.
4. Steering shaft rubbing the ID of the 4. Align the column.
shaft tube.
5. Worn or bad tires. 5. Replace tires. Refer to Tire Mounting
and Dismounting in Wheels and Tires.
6. Low tire pressure. 6. Adjust tire pressure. Refer to Tire Infla
tion Pressure Specifications in General
Information.

Momentary Increase 1. Low oil level in the pump. 1. Add power steering fluid as required.
In Effort When Turn 2. Pump belt slipping. 2. Refer to Drive Belt Replacement in
ing The Wheel Quick- Engine Mechanical.
ly To The Right Or 3. High internal leakage (steering gear or 3. Refer to Power Steering System Test in
Left pump). this section.
4. Fluid flow actuator sticking closed. 4. Refer to Diagnostic System Checks in
Speed Dependent Steering.
Poor Return Of Steer 1. Tires under-inflated. 1. Inflate to specified pressure. Refer to
ing Tire Inflation Pressure Specifications in
Maintenance and Lubrication.
2. Lower coupling flange rubbing against 2. Loosen the pinch bolt and assemble
the steering gear adjuster plug. properly.
3. Steering wheel rubbing against direc 3. Adjust the steering jacket. Refer to
tional signal housing. Steering Column Jacket Assembly in
Steering Column Unit Repair.
4. Tight or frozen steering shaft bearings. 4. Replace the bearings. Refer to Adapter
and Bearing Assembly in Steering Col
umn Unit Repair.
5. Binding of steering linkage, steering 5. Replace the affected parts. Refer to
shock absorber or ball joints. Diagnosis of Front Suspension in Front
Suspension.
6. Steering gear to column misalignment. 6. Align the steering column.
7. Tie rod pivots not centralized. 7. Adjust tie rod ends as required to center
pivots. Refer to Steering Linkage
Inspection in Steering Linkage.
8. Lack of lubricant in the suspension ball 8. Lubricate. Refer to Steering Linkage
joints and the steering linkage. Inspections and Other Services in Gen
eral Information.
9. Stuck or plugged valve spool. 9. Remove and clean or replace the valve.
Refer to Valve Replacement in Power
Steering Gear Unit Repair.
10. Rubber spacer binding in the shift tube. 10. Make certain the spacer is properly
seated. Lubricate inside the diameter
with silicone lubricant.
11. Improper front wheel alignment. 11. Check and adjust to specifications.
Refer to Measuring Wheel Alignment in
Wheel Alignment.
12. Steering gear adjusted too tightly. 12. Adjust over-center and thrust bearing
preload to specifications. Refer to Pit
man Shaft Over-Center Preload Adjust
ment in Power Steering Gear Unit
Repair.
13. Kink in return hose. 13. Replace the hose.
14. Steering intermediate shaft stone shield 14. Eliminate side-load.
side-loaded against shaft assembly.
Steering Wheel Surg 1. Low oil level in pump. 1. Add power steering fluid as required.
es Or Jerks When Check for leaks.
Turning With Engine 2. Loose pump belt. 2. Refer to Drive Belt Replacement in
Running Especially Engine Mechanical.
During Parking 3. Sticky flow control valve. 3. Replace or clean the control valve.
Refer to Diagnosis System Check in
4. Insufficient pump pressure. 4. Refer to Power Steering System Test in
this section.
5. Faulty gear relief valve. 5. Replace the gear relief valve. Refer to
Check Valve Replacement in Power
DIAGNOSIS OF POWER STEERING SYSTEM tcont’d)

Hard Steering Effort in 1. Low tire pressure. 1. Adjust the tire pressure. Refer to Tire
Both Directions Inflation Pressure Specifications in Gen
eral Information.
2. Lack of lubricant in suspension or ball 2. Lubricate and relubricate at proper inter
joints (Worn/contaminated joints). vals or replace joints. Refer to Inspec
tions and Other Services in General
Information.
3. Binding of steering linkage, steering 3. Replace all affected parts. Refer to
shock absorber, or ball joints. Diagnosis of Front Suspension in Front
Suspension.
4. Steering gear to column misalignment. 4. Align the steering column.
5. Pump belt slipping. 5. Refer to Drive Belt Replacement in
Engine Mechanical.
6. Low fluid level in reservoir. 6. Fill to proper level. Inspect lines and
joints for external leakage.
7. High internal leakage (steering gear or 7. Refer to Power Steering System Test in
pump). this section.
8. Sticky flow control valve. 8. Replace or clean the valve. Refer to
Diagnosis System Check in Power
Steering Gear and Pump.
9. Lower coupling flange rubbing against 9. Loosen the pinch bolt and assembly
steering gear adjuster plug. properly.
10. Steering gear adjusted too tight. 10. Adjust over-center and thrust bearing
preload to specifications. Refer to Steer
ing Gear Adjustments in Power Steering
Gear Unit Repair.
11. Improper front wheel alignment. 11. Check and adjust to specifications.
Refer to Measuring Wheel Alignment in
Wheel Alignment.
12. Fluid flow actuator stuck. 12. Refer to Diagnostic System Check in
Easy Steering Effort 1. Stuck open fluid flow actuator. 1. Refer to Diagnostic System Check in
in both Directions Speed Dependent Steering.
Above 45 MPH
Foaming Milky Look 1. Air in the fluid and loss of fluid due to 1-2. Check for leak and correct. Bleed sys
ing Power Steering internal pump leakage causing overflow. tem. Extremely cold temperatures will
Fluid, Low Level And 2. Hose or air leakage in reservoir line. cause system aeriation should the oil
Possible Low Pres level be low. If oil level is correct and
sure pump still foams, remove pump from
vehicle and separate reservoir from
housing. Check welsh plug and hous
ing for cracks. If plug is loose or hous
ing is cracked, replace housing.
Low Oil Pressure Due 1. Check for kinks in the hose. 1. Remove the kinks or replace the hose.
To Restriction In The 2. Foreign object stuck in the hose. 2. Remove the foreign object or replace
Hose the hose.

Low Oil Pressure Due 1. Pressure loss in cylinder due to worn 1. Disassemble the steering gear as out
To Steering Gear. piston ring or scored housing bore. lined in Steering Gear Service in Power
Refer To Power Steer Steering Gear Unit Repair. Inspect the
ing System Test In ring and housing bore. Replace the
This Section affected parts.
2. Leakage at the valve rings and valve 2. Disassemble steering gear and replace
body to the worm seal. seals. Refer to Steering Gear Service in
Power Steering Gear Unit Repair.
3. Leakage at the valve body or a loose 3. Replace the valve. Refer to Valve
fitting spool. Replacement in Power Steering Gear
Unit Repair.
Low Oil Pressure Due 1. ,Flow control valve stuck or inoperative. 1. Replace or clean the valve. Refer to
To Steering Pump. Diagnostic System Check in Speed
Refer To Power Steer Dependent Steering.
ing System Test In 2. Pressure plate not flat against the cam 2. Replace the pressure plate. Refer to
This Section ring. Steering Gear Service in Power Steer
ing Gear Unit Repair.
3. Extreme wear of cam ring. 3. Replace and flush the system.
4. Scored pressure plate, thrust plate, or 4. Replace parts. If rotor, replace with
rotor. rotating group. Flush the system. Refer
to Steering Gear Service in Power
5. Vanes sticking in rotor slots. 5. Free up by removing burrs, varnish, or
dirt.
6. Vanes not installed properly. 6. Install properly. Radius edge to the out
side. Refer to Steering Gear Service in
Power Steering Gear Unit Repair.
7. Air in oil. 7. Locate source of leak and correct.
Bleed the system.
8. Low oil level. 8. Add power steering fluid as required.
9. Pump belt slipping. 9. Refer to Drive Belt Replacement in
Engine Mechanical.
10. Damaged hoses or steering gear. 10. Replace as necessary.
Chirp Noise In Steer 1. Pump belt slipping. 1. Refer to Drive Belt Replacement in
ing Pump Engine Mechanical.
Belt Squeal (Particu 1. Pump belt slipping. 1. Refer to Drive Belt Replacement in
larly Noticeable At Full Engine Mechanical.
Wheel Travel And
Standstill Parking)
Growl Noise In Steer 1. Excessive back pressure in hoses or 1. Locate restriction and correct.
ing Pump steering gear caused by restriction.
Growl Noise In Steer 1. Scored pressure plates, thrust plate, or 1. Replace parts and flush system. Refer
ing Pump (Particularly rotor. to Steering Gear Service in Power
Noticeable At Stand Steering Gear Unit Repair.
still Parking) 2. Extreme wear of cam ring. 2. Replace parts. Refer to Steering Gear
Service in Power Steering Gear Unit
Repair.
Groan Noise In Steer 1. Low oil level. 1. Add power steering fluid as required.
ing Pump Check for leaks.
2. Air in the oil. Poor pressure hose con 2. Torque the connector. Bleed the system.
nection.

Rattle Or Knock Noise 1. Loose pump pulley nut. 1. Torque nut.

In Steering Pump 2. Pump vanes sticking in rotor slots. 2. Free up by removing burrs, varnish, or
dirt.
3. Pressure hose touching other parts of 3. Adjust hose position.
vehicle.
Swish Noise In Steer 1. Faulty flow control valve. 1. Replace part. Refer to Diagnostic sys
ing Pump tem Check in Speed Dependent Steer
ing.
Whine Noise In Steer 1. Pump shaft bearing scored. 1. Replace the housing and shaft. Flush
ing Pump the system. Refer to Steering Gear Ser
vice in Power Steering Gear Unit
Repair. %
D0004
LOCATING OIL LEAKS POWER STEERING SYSTEM

1. With the ignition OFF, wipe the complete power TEST
steering system dry (gear, pump, hoses, and con
Tools Required:
nections). J 5176-D Power Steering Gauge
2. Check the fluid level in the pump reservoir. Refer to
J 5421-02 Thermometer
Fluid Level in this section.
The power steering system test is a method
3. Start the engine and turn the steering wheel from used to identify and isolate hydraulic circuit diffi
stop to stop several times. Do not hold the wheel culties. Prior to performing this test, the following
against the stops as this may damage the pump. inspection and necessary corrections must be
4. Locate the exact area of the leak (Figure 2). made (Figure 3).
A. Return Tube Fitting—Tighten hose clamp if
loose. If the fitting is deformed, replace it. Apply Inspect
LOCTITE ™ 75559 solvent and LOCTITE 290
adhesive (or equivalent) to the tube-housing • Pump reservoir for proper fluid level. Refer to Fluid
connection.
Level in this section.
B. Pressure Line Fitting—Tighten the fitting to • Pump belt for proper tension. Refer to Drive Belt
33 N.m (24 lb ft). If leakage persists, replace Replacement in Engine Mechanical.
the seal.
• Pump drive pulley condition. Refer to Drive Belt
C. Ball Seat Leak—Seat the ball in the housing
Idler Pulley in Engine Mechanical.
with a blunt punch. Following the manufactur
er’s directions, apply LOCTITE ™ 75559 sol | V | Important
vent and LOCTITE ™ 290 adhesive (or
equivalent) to the area. • All tests are made with the engine idling at nor
D. Drive Shaft Seal—Replace the drive shaft seal. mal operating temperature.
Make sure that the drive shaft is clean and free 1. Place a container under the steering gear or pump
of pitting in the seal area.
to catch the fluid when disconnecting or connecting
E. Housing Plug Seal—Seat the plug in the hous
the hoses.
ing. Following manufacturer’s directions, apply 2. With the ignition OFF, disconnect the pressure
LOCTITE™ 75559 solvent and LOCTITE™ hose at the steering gear or power steering pump
290 adhesive (or equivalent) to the plug-hous
and install J 5176-D to both hoses. The gauge
ing area.
must be between the shutoff valve and pump.
F. Housing Seal— Replace the seal.
Open the shutoff valve.
G. Side Cover Leak—Tighten side cover bolts to
3. Remove the filler cap from the pump reservoir and
60 N-m (45 lb ft). Replace the side cover seal if
check the fluid level. Fill the pump reservoir with
the leakage persists.
power steering fluid to the full mark on the dipstick.
H. Adjuster Plug Seal—Replace the adjuster plug
Start the engine and, momentarily holding steering
seals.
wheel against the stop, check the connections at
I. Pressure Line Fitting—-Tighten the line fitting nut
J 5176-D for leaks.
to 33 N.m (24 lb ft). If leakage persists, replace
4. Bleed the system. Refer to Bleed the Power Steer
the seal.
ing System in this section.
J. Pitman Shaft Seals—Replace the seals.
K. Top Cover Seal—Replace the seal.
5. Insert thermometer J 5421-02 in the reservoir filler 6. Start the engine and check the pump’s fluid level.
opening. Move the steering wheel from stop to stop Add power steering fluid if required. When the
several times until the thermometer indicates the engine is at normal operating temperature, the ini
power steering fluid in the reservoir has reached a tial pressure reading on the gauge (valve open)
temperature of 65 ’ to 77* C(150* to 170* F). should be in the 550-860 kPa (80-125 psi) range.
Should this pressure be in excess of 1380 kPa
Important (200 psi), check the hoses for restrictions and the
poppet valve for proper assembly.
• To prevent scrubbing flat spots on the tires, do
not turn the steering wheel more than five times NOTICE: Do not leave valve fully closed for
without rolling the vehicle to change the more than 5 seconds, since this could dam
tire-to-floor contact area. age the pump internally.
7. Fully close the gate valve three times. Record the
highest pressures attained each time.
• If the pressures recorded are within 9,308-9,
998 kPa (1 ,3 5 0 -1 ,4 5 0 p s i), C 3500H D
10,101-10,446 kPa (1,465-1,515 psi) and the
range of readings within 345 kPa (50 psi), the
pump is functioning within its specifications.
• If the pressures recorded are high, but do not
repeat within 345 kPa (50 psi), the flow control
ling valve is sticking. Remove the valve, clean it
and remove any burrs using crocus cloth or a
fine hone. If the system contains some dirt,
flush it. If it is exceptionally dirty, both the pump
and gear must be completely disassembled,
cleaned, flushed, and reassembled before fur
ther usage.
• If the pressures recorded are constant but
between 690 kPa (100 psi) and 9,308 kPa
(1,350 psi), replace the flow control valve and
recheck. If the pressures are still low, replace
the rotating group in the pump.
A. Return Tube Fitting

B. Pressure Line Fitting G. Side Cover Leak
G Ball Seat Leak H. Adjuster Plug Seal
D. Drive Shaft Seal I. Pressure Line Fitting
E. Housing Plug Seal J. Pitman Shaft Seals
F. Housing Seal K. Top Cover Seal
B8232
Figure 2—Fluid Leak Locations
8. If the pump pressures are within specifications, 9. Shut the engine OFF, remove the testing gauge,
leave the valve open and turn the steering wheel to reconnect the pressure hose, check the fluid level,
both stops. Record the highest pressures and com and/or make the needed repairs.
pare with the maximum pump pressure recorded. If 10. If the problem still exists, the steering and front
this pressure cannot be reached in at least one suspension must be thoroughly examined. Refer to
side of the gear, the gear is leaking internally and Diagnosis of Power Steering System in this section.
must be disassembled and repaired.
ON-VEHICLE SERVICE
MAINTENANCE • The fluid level should be between HOT/FULL
and COLD/FULL marks on the dipstick.
Keep the power steering system clean. The power 2. If the fluid level is being checked COLD, do the
steering pump’s fluid level should be checked at regular following:
intervals and fluid added when required. Refer to Main • Remove the reservoir cap and check the fluid
tenance and Lubrication in General Information for type level on the dipstick.
of fluid to be used and intervals for filling. • The fluid level should be between the bottom of
If the system contains some dirt, flush it. Refer to the COLD/FULL mark and the end of the
Flushing The Power Steering System in this section. If it dipstick.
is exceptionally dirty, both the pump and the gear must 3. If the fluid level is low, add power steering fluid to
be completely disassembled before further usage. the proper level and install the reservoir cap. Refer
All tubes, hoses, and fittings should be inspected for to Maintenance and Lubrication in General
leakage at regular intervals. Fittings must be tight. Make Information.
sure the clips, clamps, and supporting tubes and hoses 4. When checking the fluid level after the steering
are in place and properly secured. system has been serviced, air must be bled from
In s p e c t th e h o s e s w ith th e w h e e ls in th e the system. Refer to Bleeding The Power Steering
straight-ahead position. Then turn the wheels fully to the System in this section.
left and right while observing the movement of the hos
es. Correct any hose contact with other parts of the BLEEDING THE POWER
vehicle that could cause chafing or wear.
Power steering hoses and pipes must not be twisted, STEERING SYSTEM
kinked, or tightly bent. The hoses should have sufficient Refer to Figure 4 for the power steering bleeding
natural curvature in the routing to absorb movement and procedure.
hose shortening during vehicle operation.
Air in the system will cause spongy action and noisy FLUSHING THE POWER
operation. When a hose is disconnected or when fluid is
lost for any reason, the system must be bled after refill STEERING SYSTEM
ing. Refer to Bleeding The Power Steering System in 1. Raise the front end of the vehicle off the ground
this section. until the wheels are free to turn.
2. Remove the fluid return hose at the pump inlet
FLUID LEVEL connector and plug the connector port on the
1. The fluid level may be checked hot or cold. To pump. Position the hose toward a large container
check the fluid level when hot do the following: to catch the draining fluid.
• Run engine until the fluid reaches about 80* C 3. While an assistant is filling the reservoir with new
(170* F), then shut the engine OFF. power steering fluid, run the engine at idle. Turn
• Remove the reservoir cap and check the fluid the steering wheel from stop to stop. DO NOT con
level on the dipstick. tact wheel stops or hold the wheel in a corner or
fluid will stop and the pump will be in pressure
relief mode. A sudden overflow from the reservoir
may develop if the wheel is held at a stop.
4. Install all the pipes and hoses. Fill the system with
new power steering fluid and bleed the system as
described in Bleeding The Power Steering System
in this section. Operate the engine for about
15 minutes. Remove the pump return hose at the
pump inlet and plug the connection on the pump.
While refilling the reservoir, check the draining fluid
for contamination. If foreign material is still evident,
replace all hoses. Disassemble and clean or
replace the power steering system components. Do
not re-use any drained power steering fluid.
Figure 3—Checking Power Steering Pressure

Bleeding Air from Power Steering Systems

W hen to b le e d : Pow er S te e rin g F lu id
Before bleeding: Inspect steering system .
After any com ponent replacem ent Usa only d e a n , new pow er
Check, and correct as needed: After disconnecting flu id line steering flu id . F lu id m ust be:
In case o f steering system noise Conventional Climate:

Hoses must A ll hose GM # 1 0 5 2 8 8 4 - 16 ounce
not touch any connections W hy b le e d ? # 1 0 5 0 0 1 7 - 3 2 ounce
other part of m ust be To prevent pum p dam age Cold Climate:
vehicle. tig h t. To ensure proper system operation G M # 1 2 3 4 5 8 6 6 - 16 o u n ce
To stop steering system noise # 1 2 3 4 5 8 6 7 - 3 2 oun ce
•S te e rin g system noise cou ld • Loose connections m ig ht not
b e cau sed b y hose touching leak b u t co u ld allo w a ir in to
fra m e , bod y, o r eng ine. system .
How to bleed: Special Conditions:

© Switch
ignition off.
Start engine.
W ith engine
idling, maintain
Fluid
• Foam or bubbles in flu id
Fluid must be com pletsly free o I bubbles.
fluid level. In step S, be alert to periodic bubbles that
could Indicate e loose connection or leaky
Reinstall cap.
O - ring seal in either the return hose or
p ressure hose.
© Raise front
wheels off
ground
© r-\— i
Return wheels
to center.
Lower front
• Discolored fluid
(m ilky, opaque, or light tan color)
Switch ig nitio n off. W ait tw o m inutes. Recheck

1 ° "°1 wheels to hose connections. Repeat steps 7 -1 0 . If
ground condition s till exists, replace and check a
possible cause:
Turn steering
wheel fu l left. Keep engine 0 Return hose clam ps
running for two 0 Return hose O -rin g s
minutes. 0 Pressure hose O -rin g s
0 Gear cylinder line O - rings
FUl system and repeat bleed procedure fo r
FM fluid
each possible cause. Repeat steps 7 -1 0 to
reservoir to Turn steering verify w hether noise had been elim inated.
“ FULL COLD* wheel in both
level. Leave directions.
cap off. Nolee
•P um p w hine o r groan
© W ith assistant checking

fluid level and condition,
turn steering wheel lock -
Verfly:
0 Smooth power assist
W ith engine running, recheck
hoses fo r possible contact w ith
0 Nosieless operation fram e body o r engine. If no
to - lock at least 20 tim es.
contact is found, follow either
Engine remains off. 0 Proper fluid level m ethod below to cool down flu id
• O n systems w flh long return In e s o r fluid 0 No system leaks and repressurize system .
coo lers, turn steering w heel lo ck—to —lock a t 0 Proper fluid condition
least 4 0 tim es. Method 2:
• N o bubbles, no foam , no Method 1:
• Trapp ed a ir m ay cause fluid to overflow Normal Cool Down partial Fluid
Throughly d e a n an y spM ed fluid to a lo w Replacement
fo r leak check. Switch engine off.
• K eep fluid level a t "F U L L C O LD .’ @ N a fl proper conditions W ait fo r system Switch engine off.
apply, procedure is to cool. Use a suction device to
W hile turning complete. Install reservoir cap. remove fluid from reservoir.
wheel, check fluid RefiH with cool, dean fluid.
constantly. Install reservoir cap.
Q 2) If any problem remains, After either method of cooling, etert engine end allow engine to
see "S pecial Conditions.' com e up to operating tem perature. If nolee peraiata, rem ove and
* N o bubbiee a re slo w e d .
replace power ateering pum p. Repeat bleed procedure follow ing
F or an y aign o f bubblee, recheck pump replacem ent.
connections. R epeal step 5.
M -0 3 -M
YT0063B
Figure 4— Bleeding the Power Steering System

STEERING GEAR REPLACEMENT 6. Bleed the system. Refer to Bleeding The Power
Steering System in this section.
Remove or Disconnect (Figure 5)
PITMAN SHAFT SEAL
1. Place a drain pan below the steering gear. REPLACEMENT
2. Hoses from the steering gear. Raise the hose up to Tools Required:
prevent oil drainage. Cap or tape the ends of the J 4245 Internal Snap Ring Pliers
hose and gear fittings to prevent the entrance of J 6219 Seal Installer
dirt.
3. The intermediate shaft. Refer to Intermediate Shaft Two Wheel Drive
Replacement in Steering Wheel and Column
On-Vehicle Service. |*-»| Remove or Disconnect (Figure 6)
4. Pitman arm. Refer to Pitman Arm Replacement in
Steering Linkage. • Mark the position of the pitman arm to the pitman
5. The steering gear frame bolts and the steering shaft.
gear. 1. Pitman arm from pitman shaft. Refer to Pitman Arm
Replacement in Steering Linkage.
+◄- Install or Connect (Figure 5) 2. Pitman shaft boot.
3. Dust seal.
1. Place the steering gear in position. Guide the stub 4. Snap ring using J 4245.
shaft into the cardan joint assembly by lining up the • Loosely install pitman arm and nut on shaft.
marks made at removal. This is required to remove seal.
2. The steering gear to the frame bolts. • Position a drain pan under the steering gear.
• Start the engine.
NOTICE: Refer to Fastener Notice in Cau • Turn the steering wheel from stop to stop
tions and Notices. bouncing the wheel off the stops.
• Stop the engine.
Tighten 5. Remove nut and pitman arm.
6. Washer and seal.
• The bolts to 135 N-m (100 lb ft).
Inspect
3. The pitman arm. Refer to Pitman Arm Replacement
in Steering Linkage.
4. The intermediate shaft. Refer to Intermediate Shaft • Pitman shaft seal surfaces for roughness or pit
Replacement in Steering Wheel and Column ting. If pitted, replace the shaft.
On-Vehicle Service. • Housing for burrs. Remove the burrs before
• Remove the plugs and caps from the steering installing the new seals.
gear and hoses.
Clean
5. The hoses to the steering gear.
Tighten • Pitman shaft and seal areas using a crocus

cloth.
• Hose connection to 28 N-m (20 lb ft).
Install or Connect (Figure 6)
• Lubricate the new seals with power steering fluid.

• Apply a single layer of tape to the pitman arm shaft
to avoid damaging the seals.
1. Seal.
2. Washer using J 6219 to seat the seal.
• The seal should be in far enough to install the
snap ring.
3. Snap ring.
4. Center the steering wheel.
• Turn the wheel until it stops.
• Turn the wheel in the opposite direction until it
stops, while counting the number of turns.
• Turn the wheel back 1/2 the number of turns in
the previous step.
5. Dust seal.
6. Pitman shaft boot.
7. Pitman arm.
8. Bleed the system. Refer to Bleeding The Power
Figure 5—Steering Gear Assembly
POWER STEERINQ GEAR AND PUMP 2B-11
POWER STEERING PUMP
REPLACEMENT
Tools Required:
J 25034-B Power Steering Pump Pulley Remov
er
J 25033-B Power Steering Pump Pulley Installer
Remove or Disconnect (Figures 7 through 10)
• Place a drain pan below the pump.

1. Hoses. Cap the hoses.
2. Drive belt. Refer to Drive Belt Replacement in
Engine Mechanical.
3. Pulley.
• Install J 25034-B. Be sure the pilot bolt bottoms
in the pump shaft by turning the nut to the top
of the pilot bolt (Figure 7).
• Hold the pilot bolt.
• Turn the nut counterclockwise.
4. Front mounting bolts.
5. Rear mounting nuts from studs.
6. Electrical connector from EVO actuator.
7. Pump.
+ 4- Install or Connect (Figures 7 through 10)
1. Pump.
2. Front mounting bolts.
Legend NOTICE: Refer to Fastener Notice In Cau

(1) Pitman Shaft Boot tions and Notices.
(2) Dust Seal
(3) Snap Ring Tighten
(4) Washer
(5) Oil Seal . Bolts to 50 N.m (37 lb ft).
Figure 6—Pitman Seal Assembly 3. Rear mounting nuts to studs.
Four Wheel Drive Tighten
R Remove or Disconnect (Figures 5 and 6) • Nuts to 50 N.m (37 lb ft).

4. Pulley.
1. Power steering gear. Refer to Power Steering Gear • Place pulley on the end of the pump shaft.
Replacement in this section. • Install J 25033-B. Be sure the pilot bolt bottoms
2. Pitman arm. Refer to Pitman Arm Replacement in in the shaft by turning the nut to the top of the
Steering Linkage. pilot bolt (Figure 7).
3. Pitman shaft seal. Refer to Pitman Shaft Seals and • Hold the pilot bolt.
Bearing Replacement in Power Steering Gear Unit • Turn the nut clockwise.
Repair. • Install pulley flush ± 0.25 mm (0.010 in.) with
the end of the power steering pump shaft
-► 4- Install or Connect (Figures 5 and 6) (Figure 7).
1. Pitman shaft seal. NOTICE: Do not use arbor press or internal

2. Pitman arm. damage to the pump will result.
3. Power steering gear.
2B -12 POWER STEERING GEAR AND PUMP
Legend
(1) Pulley Hub (2) Pump Shaft
Figure 7—Replacing Steering Pump Pulley
5. Drive belt. • Route hoses smoothly; avoid sharp bends and

6. Hoses. kinking.
7. Electrical connector to EVO actuator. • After hoses are installed, check for leaks while the
• Fill and bleed the system.• system is being bled. Refer to Bleeding The Power
Inspect • Tighten the hose connections to 28 N-m (20 lb ft).
• Hoses and wiring for clearance. NOTICE: Do not start the engine with any
power steering hose disconnected, or dam-
POWER STEERING HOSES age to the components could occur.
When a hose is reinstalled or replaced, the following
points are essential:
• Route hoses in the same position they were in
before removal (Figures 11 through 16).
Figure 8—Power Steering Pump Mounting (4.3L, 5.0L, and 5.7L Engines)
Figure 9—Power Steering Pump Mounting (7.4L

Engines)
2B '14 POWER STEERING GEAR AND PUMP
Figure 10—Power Steering Pump Mounting (6.5L Diesel Engines)

Legend
(1) Pump (4) Seals
(2) Return Hose (5) Fluid Flow (EVO) Actuator and Fitting Assembly
(3) Feed Hose
Figure 11—Hose Routing (Vacuum Brakes without Power Steering Oil Cooler)
Legend
(1) Pump (4) Seals
(2) Return Hose (5) Fluid Flow (EVO) Actuator and Fitting Assembly
(3) Feed Hose (6) Frame Cooler
Figure 12—Hose Routing (Vacuum Brakes with Frame Cooler)
(1) Pump to Steering Gear Hose (3) Steering Gear to Power Steering Oil Cooler Hose
(2) Power Steering Oil Cooler to Pump Hose (4) Power Steering Oil Cooler
Figure 13— Hose Routing (Vacuum Brakes with Power Steering Oil Cooler)
(1) Pump to Hydraulic Booster Hose (3) Frame Cooler to Pump Hose
(2) Hydraulic Booster to Steering Gear Hose (4) Hydraulic Booster to Pump Hose
Figure 14— Hose Routing (Hydraulic Boost Brakes with Frame Cooler)
(1) Pump to Hydraulic Booster Hose (4) Power Steering Oil Cooler Outlet Hose
(2) Hydraulic Booster to Steering Gear Hose (5) Power Steering Oil Cooler
(3) Power Steering Oil Cooler Inlet Hose (6) Hydraulic Booster to Pump Hose
Figure 15— Hose Routing (Hydraulic Boost Brakes with Power Steering Oil Cooler)
(1) Pump to Hydraulic Booster Hose (4) Power Steering Oil Cooler
(2) Hydraulic Booster to Steering Gear Hose (5) Power Steering Oil Cooler Outlet Hose
(3) Power Steering Oil Cooler Inlet Hose (6) Hydraulic Booster to Pump Hose
Figure 16—Hose Routing (C3500HD I-Beam Front Axle)
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application N.m Lb ft Lb in
Coupler Clamp Bolt 30 22 —
Gear To Frame Bolts 135 100 —
Pressure Hose Connection (At Gear) 33 24 —
Gear Side Cover Bolts 60 45 —
Front Pump Mounting Bolts 50 37 —
Pressure Hose Connection (At Pump) 28 20 —
Rear Pump Mounting Nut 50 37 —
Pitman Shaft Nut 285 215 —
POWER STEERING SYSTEM PRESSURES

Application mPa PSI
C3500HD 10.1-10.45 1465-1515
All Other Applications 9.3-10.0 1350-1450
SPECIAL TOOLS
6 J 6219
J 5176-20 J 7624
J 25034-B
J 25033-B
5. J 29525
1. POWER STEERING PRESSURE TESTER

2. GAUGE ADAPTER 18MM POWER STEERING
3. THERMOMETER
4. POWER STEERING SYSTEM ANALYZER
5. POWER STEERING ANALYZER 18MM ADAPTER
6. PITMAN SHAFT SEAL INSTALLER
7. BEARING PRELOAD SPANNER WRENCH
8. POWER STEERING PUMP PULLEY REMOVER
9. POWER STEERING PUMP PULLEY INSTALLER
V0052
2B -22 POWER STEERING GEAR AMP PUMP
BLANK
POWER STEERING GEAR UNIT REPAIR 2B1A-1
SECTION 2B1A
POWER STEERING GEAR UNIT REPAIR
SPECIFICATIONS
FLUID CAPACITIES
Power Steering Fluid Requirement.................................................................................................. GM Power Steering Fluid

Part No. 1050017 or Equivalent meeting GM Specification 9985010.

(8) Steering Gear Adjuster Lock N ut................................................................................... 49 N*m (36 lb.ft.)
(21) Rack Piston Guide Clamp Screw.................................................................................... 58 N»m (43 lb.in.)
(27) Rack Piston Plug................................................................................................................. 150 N-m (111 lb. ft.)
(48) Coupling Shield Retainer and Lock Nut........................................................................ 109 N*m (80 lb.ft.)
ADJUSTMENT TIGHTENING SPECIFICATIONS
(40) Pitman Shaft Over-Center Preload*.............................................................................0.7-1.1 N*m (6-10 lb. in.)
(65) Steering Gear Adjuster Nut Assembly........................................................................... 30 N«m (22 lb.ft.)
*Figure is in addition to worm shaft thrust bearing preload and valve and seal drag.
2B1A-2 POWER STEERING GEAR UNIT REPAIR
Figure 1 Power Steering Gear

Key No. Part Name Key No. Part Name

1 - RING, RETAINING 27 - PLUG
2 - PLUG 28 - BEARING, NEEDLE
3 - SEAL, O-RING 31 - WASHER, BACKUP
5 - RING, TEFLON 35 - RING, RETAINING
6 - SEAL, O-RING 36 - WASHER, LOCK
7 - COVER, SIDE 37 - NUT
8 - NUT, ADJUSTER LOCK 38 - SEAL
10-BOLT 40 - SHAFT, STUB
11 - GASKET 41 - SPOOL, VALVE
12-SHAFT, PITMAN 42 - SEAL
13-SHAFT, WORM 43 - BODY, VALVE
15 - RACE, FLAT 45 - SEAL, O-RING VALVE BODY
16-BEARING, THRUST 46 - RING
1 8 -VALVE, CHECK 48 - NUT, COUPLING SHIELD RETAINER AND LOCK
20 - HOUSING 49 - THRUST SUPPORT ASSEMBLY
21 - SCREW 56 - SEAL, O-RING
22 - CLAMP 63 - SEAL, PITMAN SHAFT
23 - GUIDE, BALL 64 - SEAL, DUST
25 - BALLS 65 - ADJUSTER NUT ASSEMBLY
26 - PISTON, RACK
Figure 2 Power Steering Gear - Legend
STEERING GEAR ADJUSTMENTS WORM THRUST BEARING PRELOAD
ADJUSTMENT
Important Figures 1 thru 6
Tool Required:
• Before any adjustments are made on the steering J 42882 Adjuster Nut Socket
gear, refer to “Steering, Suspension, Tires and Wheels 1. Remove steering gear from vehicle. Refer to
Diagnosis” (Section 3) for reviewing the possible “Power Steering Gear Replacement” in section 2B.
steering system problems. Any steering gear adjust- 2. Rotate stub shaft (40) back and forth to drain power
ment is made only as a correction and not as a steering fluid.
periodic adjustment. 3. Remove coupling shield retainer and lock nut (48)
For proper adjustment, remove the steering gear from the from housing (20).
vehicle. Drain the power steering fluid from the gear. Notice: See “Fastener Tightening Notice.”
Mount the gear in a vise and make the following adjust-
ments. 4. Turn adjuster nut assembly (65) in (clockwise)
The steering gear requires two adjustments: using J 42882 until adjuster nut assembly (65) and
thrust support assembly (49) are firmly bottomed in
• The worm thrust bearing preload housing (20).
ment
The worm thrust bearing preload is controlled by the
amount of compression force exerted by the adjuster nut
assembly on the flat races.
The pitman shaft over-center preload is controlled by the
pitman shaft adjuster screw, which determines the clear
ance between the rack piston and the pitman shaft sector
teeth.
9 Important•
• Adjust the worm thrust bearing preload first, then

adjust the pitman shaft over-center preload.
40-SHAFT, STUB
48-NUT, COUPLING SHIELD RET. AND LOCK
Figure 3 Loosening Coupling Shield Ret. and Lock Nut
6. Starting at either stop, turn the stub shaft (40) back

Tighten 1/2 the total number of turns. This is the “center” of
the gear.
• Adjuster nut assembly (65) to 28-31 N»m • When the gear is centered, the flat on the stub
(20-23 lb. ft.). shaft (40) should face upward and be parallel
5. Place an index mark on housing (20) even with one with the side cover (7) and the master spline
of the holes in the adjuster nut assembly (65). on the pitman shaft should be in line with the
6 . Measure back counterclockwise 13 mm (1/2 inch) adjuster screw (see Figure 8).
and place a second mark on housing (20). 7. Place a torque wrench on the stub shaft (40) with the
7. Using J 42882 and a torque wrench, turn adjuster handle in the vertical position. Rotate the stub shaft
nut assembly (65) counterclockwise 15-20 degrees (40) 45 degrees each side of the center (see Figure
until hole in adjuster nut assembly (65) is aligned 9).
with the second mark on the housing (20) (see • Stub shaft must rotate smoothly and must not
Figure 6). stick or bind.
8. Install coupling shield retainer and lock nut (48). • Record the worm beling preload measured
on or near the center.
Tighten • Recorded bearing preload to be 0.7-1.7 N*m
• Coupling shield retainer and lock nut (48) to (6-15 lb. in.), with worm and ballnut
109 N*m (80 lb. ft.) using a drift in a notch. installed. If the torque is outside this range,
• Hold adjuster nut assembly (65) while tight the gear assembly should be readjusted or
ening the coupling shield retainer and lock repaired as required.
nut (48) to maintain alignment of the marks. Notice: See “Fastener Tightening Notice.”
9. Install steering gear. Refer to “Power Steering Gear
Replacement” in section 2B. Adjust
PITMAN SHAFT OVER-CENTER PRELOAD • Over-center torque by turning the pitman shaft ad
ADJUSTMENT juster screw clockwise until the correct preload
F ig u re s 7 th ru 9 torque is obtained.
• Add 0.7-1.1 N*m (6-10 lb. in.) torque to the previ
1. Remove steering gear from vehicle. Refer to “Power ously measured worm bearing preload torque.
Steering Gear Replacement” in section 2B.
2. Rotate stub shaft back and forth to drain power
steering fluid. Tighten
3,. Loosen the adjuster lock nut (8). • Adjuster lock nut (8) to 49 N»m (36 lb. ft.).
4. Turn the pitman shaft adjuster screw counterclock • Prevent adjuster screw from turning while
wise until fully extended, then turn clockwise 1 full tightening adjuster lock nut (8).
turn.
5. Rotate the stub shaft (40) from stop to stop, using a 8. Install steering gear. Refer to “Power Steering Gear
12-point socket, and count the number of turns. Replacement” in section 2B.
A-INDEX MARK
65-NUT, ADJUSTER
Figure 4 Marking Housing Even with Adjuster nut assembly Figure 5 Remarking the Housing
STEERING GEAR SERVICE

Disassemble
PITMAN SHAFT AND SIDE COVER
REPLACEMENT 1. Adjuster lock nut (8).
Figures 1 and 2 2. Bolts (10).
• Rotate stub shaft (40), using a 12-point socket,
44
to center gear.
Remove or Disconnect 3. Side cover (7), gasket (11), and pitman shaft (12) as
• Steering gear from vehicle. Refer to “Power Steer an assembly.
ing Gear Replacement” in section 2B. 4. Pitman shaft (12) from the side cover (7).
• Pitman arm from steering gear. Refer to “Steering
Linkage” in section 2B3. Assemble
• Rotate stub shaft back and forth to drain power
steering fluid. Notice: See “Fastener Tightening Notice.”
1. Pitman shaft (12) to side cover (7) by screwing
Clean pitman shaft (12) in until it fully seats to side cover
(7).
• Exposed end of pitman shaft and housing. 2. Adjuster lock nut (8).
• Use a wire brush to clean pitman shaft spline. • Do not tighten adjuster lock nut (8) until after
pitman shaft adjustment has been made.
Mark
Figure 7 Aligning the Stub Shaft Figure 9 Checking Over-Center Rotational Torque
3. Gasket (11) to side cover (7) and bend tabs around 1. Retaining ring (1) by using a punch inserted into the
edges of side cover (7). housing access hole to unseat it.
4. Pitman shaft assembly and side cover (7) to housing 2. Plug (2).
(20). 3. O-ring seal (3).
5. Bolts (10).
Assemble
Tighten
• Lubricate O-ring seal with power steering fluid.
• Bolts (10) to 60 N»m (44 lb. ft.).
1. O-ring seal (3) into housing (20).
2. Plug (2).
Adjust 3. Retaining Ring (1).
• Pitman shaft. Refer to “Pitman Shaft Over- • Install retaining ring (1) so that open end is
Center Sector Adjustment” in this section. approximately 25 mm (1 inch) from access
hole in housing (20).
Install or Connect
Install or Connect
• Steering gear. Refer to “Power Steering Gear Re • Steering gear. Refer to “Power Steering Gear Re
placement” in section 2B. placement” in section 2B.
HOUSING END PLUG REPLACEMENT
THRUST SUPPORT ASSEMBLY
Figure 10
Figures 1 ,2 ,3 , 11
|»+ | Remove or Disconnect Tools Required:

J 42882 Adjuster Nut Socket
• Steering gear from vehicle. Refer to “Power Steer J 6222-A Shaft Seal Protector
ing Gear Replacement” in section 2B.
Remove or Disconnect
kvM Disassemble
• Steering gear from vehicle. Refer to “Power Steer
• Rotate stub shaft back and forth to drain fluid. ing Gear Replacement” in section 2B.
Notice: Tool J 6222-A must be placed over the stub shaft
end before removing or replacing the adjuster nut assembly
and thrust support assemblies.
J 42882
20-HOUSING
48-NUT, COUPLING, SHIELD RETAINER AND LOCK
65-ADJUSTER NUT ASSEMBLY
Figure 10 Housing End Plug Figure 11 Removing Adjuster nut assembly
Disassemble Install or Connect

1. Coupling shield retainer and lock nut (48) from • Power steering gear. Refer to “Power Steering Gear
adjuster nut assembly (65). Replacement” in section 2B.
2. Adjuster nut assembly (65) from housing (20) using
J 42882. VALVE REPLACEMENT
3. Thrust support assembly (49) and O-ring seal (56). Figures 1 ,2 , 12 thru 15
Assemble Remove or Disconnect
Notice: Install a new O-ring (56) each time the thrust • Steering gear from vehicle. Refer to “Power Steer
support assembly is removed from the gear. ing Gear Replacement” in section 2B.
• Lubricate O-ring seal (56).
1. Install O-ring seal (56). Disassemble
2. Thrust support assembly (49). 1. Thrust support assembly (49). Refer to “Thrust
3. Adjuster nut assembly (65) to housing (20) using J Support Assembly Replacement” in this section.
42882. 2. Stub shaft (40) and valve assembly.
4. Coupling shield retainer and lock nut (48) to ad 3. Stub shaft (40) from valve assembly, if necessary.
juster nut assembly (65).
• Tap stub shaft (40) lightly on a wood block to
loosen shaft cap.
Adjust • Pull cap and valve spool (41) out from valve
body (43) 6 mm (1/4 inch) and disengage
• Thrust bearing preload. Refer to “Worm stub shaft pin from hole in valve spool (41).
Bearing Preload Adjustment” in this section. 4. Valve assembly, if necessary.
• Remove valve spool (41) by pulling and
5. Install coupling shield retainer and lock nut (48), rotating from valve body (43).
and using a drift in a notch, tighten securely. • Remove valve spool O-ring seal (42).
• Hold adjuster nut assembly (65) to maintain • Remove valve body teflon rings (46) and O-
alignment of the marks while tightening the ring seals (45).
coupling shield retainer and lock nut (48).
Assemble
Adjust
1. Valve assembly, if necessary.
• Pitman shaft over-center sector. Refer to • Install valve spool O-ring seal (42) to valve
“Pitman Shaft Over-Center Sector Adjust spool (41).
ment” in this section. • Lubricate valve spool (41) and O-ring seal
(42) with power steering fluid.
Figure 12 Bearing, Worm and Valve Assembly Figure 13 Remove and Install Stub Shaft
• Install valve spool (41) to valve body (43) by Hj+j Disassemble

pushing and rotating until hole in valve spool
(41) for stub shaft pin is accessible from Tool Required:
opposite end of valve body (43). J 21552 Rack Piston Arbor
2. Stub shaft (40) to valve spool, if necessary and insert 1. Pitman shaft and side cover. Refer to “ Pitman Shaft
pin. and Side Cover Replacement” in this section.
• Notch in stub shaft cap must fully engage 2. Housing end plug. Refer to “Housing End Plug
valve body pin and seat against valve body Replacement” in this section.
shoulder. • Turn stub shaft counterclockwise until the
• Install O-ring seals (45) and teflon rings (46) rack piston (26) begins to come out of the
to valve body (43). housing (20).
• Lubricate O-ring seals (45) and teflon rings 3. Rack piston plug (27).
(46) with power steering fluid. • Insert J 21552 into bore of rack piston (26).
3. Stub shaft (40) and valve assembly to worm shaft Hold J 21552 tightly against worm shaft
(13), fitting pin on worm shaft (13) to slot in the while turning the stub shaft counterclock
valve assembly. wise.
4. Thrust support assembly. Refer to “Thrust Support • The rack piston (26) will be forced onto J
Assembly Replacement” in this section. 21552 and hold the rack piston balls (25) in
Adjust 4. Rack piston (26), rack piston balls (25), and J 21552
£ together from housing (20).
• Thrust bearing preload and pitman shaft over- 5. Valve. Refer to “Valve Replacement” in this sec-
center sector. Refer to “Steering Gear Ad- tion.
justments” in this section. 6. Worm shaft (13).
7. Thrust bearing (16) and races (15).
8. J 21552 from rack piston (26).
|+ +l Install or Connect 9. Rack piston balls (25).
• Steering gear. Refer to “Power Steering Gear Re 10. Screws (21), clamp (22) and ball guide (23).
placement” in section 2B. 11. Teflon ring (5).
12. O-ring seal (6).
RACK PISTON AND WORM SHAFT TQi Clean
REPLACEMENT
Figures 1 ,2 , 16, 17, 18 a n d 19
All disassembled parts.
|<- +| Remove or Disconnect Inspect
• Steering gear from vehicle. Refer to “Power Steer All disassembled parts for wear. Replace if
ing Gear Replacement” in section 2B. necessary.
Figure 14 Remove and Install Spool Figure 15 Engage Stub Shaft

• Insert J 21552 into bore of rack piston (26)

Assemble while turning worm shaft (13) counterclock
Tools Required: wise. The rack piston (26) will be forced onto
J 8947 Rack Piston Teflon Ring Compressor J 21552 and will hold the rack piston balls
J 21332 Rack Piston Arbor (25) in place.
1. O-ring seal (6) and teflon ring (5) and lubricate with 7. Races (15 and 17) and thrust bearing (16) to worm
power steering fluid. shaft (13) (see Figure 19).
2. Worm shaft (13) to rack piston (26) outside of 8. Worm shaft (13) to housing (20).
housing (20). 9. Valve. Refer to “Valve Replacement” in this sec
• Fully seat worm shaft (13) to rack piston (26) tion.
and align worm shaft spiral groove with rack 10. Rack piston (26) to worm shaft (13) from J 21552,
piston ball return guide hole (see Figure 17). using J 8947 to compress seals.
• Hold J 21552 tightly against worm shaft and
|9 | Important turn stub shaft clockwise until rack piston
(26) is seated on worm shaft (13).
• Make sure that all rack piston balls (25) are
reinstalled in the rack piston. Improper rack 9 Important
piston ball installation may result in personal
injury. • Make sure that all rack piston balls (25) are
Notice: The black rack piston balls are smaller than the reinstalled in the rack piston. Improper rack
silver balls. The black and silver balls must be installed piston ball installation may result in personal
alternately into the rack piston and ball guide to maintain injury.
rack piston to worm shaft preload.
• Lubricate rack piston balls (25) with power 11. Rack piston plug (27).
steering fluid.
3. Rack piston balls (25) to rack piston (26) by insert Tighten
ing through ball return guide hole while turning
worm shaft (13) counterclockwise. • Rack piston plug (27) to 150N*m (llllb.ft.)
4. Remaining rack piston balls (25) to ball guide (23)
using grease at each end to retain balls (25) (see 12. Housing end plug. Refer to “Housing End Plug
Figure 18). Replacement” in this section.
5. Ball guide (23) to rack piston (26). 13. Pitman shaft and side cover. Refer to “Pitman Shaft
Notice: See “Fastener Tightening Notice.” and Side Cover Replacement” in this section.
6. Ball guide clamp (22) and screws (21).
Adjust
Tighten Steering gear. Refer to “Steering Gear Ad

justments” in section 2B.
• Screws (21) to 58 N»m (43 lb. in.).
A-INSTALL BALLS IN THIS HOLE WHILE SLOWLY

ROTATING WORM COUNTERCLOCKWISE
B-WORM FLANGE
Figure 16 Rack Piston Figure 17 Installing the Balls in the Rack Piston
fc d Install or Connect Inspect
• Steering gear. Refer to “Power Steering Gear • Housing (20) for burrs and remove if neces
Replacement” in this section. sary.
PITMAN SHAFT SEAL AND BEARING 4. Needle bearing (28).
REPLACEMENT • Insert J 6278 through the hole in the top of
Figures 1 a n d 2 the housing (20) and drive out bearing (28).
This procedure covers the seal and bearing replacement for
steering gears. The steering gear uses one double lip seal. Assemble
Seal may be replaced without removing the power steering • Coat double lip seal (63) and washer (31) with
gear. Refer to “Pitman Shaft Seal and Bearing Replace grease.
ment” under “On-Vehicle Service” in this section.
Tools Required: 1. Needle bearing (28) to housing (20) using J 6278.
J 6278 Pitman Shaft Bearing Remover and 2. Double lip seal (63).
Installer 3. Backup washer (31).
J 6219 Pitman Shaft Oil Seal Installer 4. Retaining ring (35) using J 4245.
J 4245 Internal Snap Ring Pliers 5. Pitman shaft and side cover. Refer to “Pitman Shaft
|» +| Remove or Disconnect and Side Cover Replacement” in this section.
• Pitman arm from steering gear. Refer to “Steering Install or Connect
Linkage” in section 2B3.
• Pitman arm to steering gear. Refer to “Steering
Clean Linkage” in section 2B3.
• Exposed end of pitman shaft (12) and
housing (20).
• Use a wire brush to clean pitman shaft splines.
Disassemble
1. Dust seal (64)
2. Retaining ring (35) using J 4245.
Notice: Use care not to score the housing bore when prying
out seals and washers.
3. Backup washer (31), and double lip seal (63) using
a screwdriver to pry them from the housing (20).
Figure 18 Placing Balls in the Ball Return Guide Figure 19 Worm Shaft and Bearing
CHECK VALVE REPLACEMENT
B Remove or Disconnect
• Steering gear from vehicle. Refer to “Power
Steering Gear Replacement” in section 2B.
Disassemble
Notice: Use care not to damage threads of housing when
removing check valve.
• Check valve (18) by prying from housing with a
small screwdriver.
Assemble
• Check valve (18) using a 3/8-inch diameter piece of
tubing 100 mm (4 inches) long to drive into housing.
[■»+| Install or Connect
• Steering gear. Refer to “Power Steering Gear

Replacement” in section 2B.
SPECIAL TOOLS
POWER STEERING PUMP UNIT REPAIR 2B1B-1
SECTION 2B1B
POWER STEERING PUMP UNIT REPAIR
SPECIFICATIONS
FLUID CAPACITIES
Power Steering Fluid Requirement..................................................................................................GM Power Steering Fluid

Part No. 1050017 or Equivalent meeting GM Specification 9985010.

(33) Pump Fitting Assembly................................................................................................. 75 N#m (55 lb. ft.)
(36) Steering Pump Stud......................................................................................................... 35-80 N»m (29-59 lb. ft.)
(45) Variable Assist Steering Actuator.................................................................................. 50-75 N»m (37-55 lb. ft.)
2B1B-2 POWER STEERING PUMP UNIT REPAIR
Reservoir assembly
6.5L diesel
with Hydro-Boost
L -------------------------------------------------------------------- J
Figure 1 Power Steering Pump

K e y N o. P a rt N am e K e y N o. P a rt N am e
1 - SEAL, RECTANGULAR SECTION 1 8 -VANE, PUMP
2 - VALVE ASM, CONTROL 20- RING, PUMP
3 - SEAL, O-RING 21 - PLATE, PRESSURE
5 - SEAL, O-RING 22 - SPRING, PRESSURE PLATE
6 - SPRING, FLOW CONTROL 23 - PLATE, END
7 - MAGNET 25 - RING, END PLATE RETAINING
8 - HOUSING ASM, PUMP 33 - FITTING ASM (CONNECTOR &)
10 - SEAL, O-RING (HOUSING) 35 - SEAL, O-RING
11 - SEAL, DRIVE SHAFT 36 - STUD, PUMP MOUNTING
12- SHAFT, DRIVE 37 - RESERVOIR ASM
13- PIN, DOWEL 38 - ASM, RESERVOIR
15- PLATE, THRUST 40 - SEAL, RECTANGULAR SECTION
16- ROTOR, PUMP 45 - ACTUATOR & FITTING ASM, EVO
17 - RING, SHAFT RETAINING 46 - CLIP, RETAINING
Figure 2 Power Steering Pump - Legend
DRIVE SHAFT SEAL REPLACEMENT

Figures 1 ,2 an d 3
1. Negative (-) battery cable.
|++| Remove or Disconnect 2. Electrical connector from Variable Assist Steering
• Power steering pump from vehicle. Refer to “Power actuator (45).
Steering Pump Replacement” in section 2B. 3. Pump assembly from vehicle, if necessary for access.
4. Retaining clip (46) from Variable Assist Steering
actuator (45).
+1+1 Disassemble
• Protect drive shaft (12) with shim stock. Important
• Seal (11) by cutting with a chisel. • Note the position of the V ariable Assist Steer
ing actuator discharge fitting on the pump
Assemble reservoir. Marking the reservoir will assure
proper alignment during reassembly. See
Tool Required: Figure 4.
J 7728 Shaft Oil Seal Installer•
5. Variable Assist Steering actuator (45).
• Lubricate seal (11) with power steering fluid.
• Seal (11) using J 7728.
Install or Connect
• Power steering pump. Refer to “Power Steering

Pump Replacement” in section 2B.
VARIABLE ASSIST STEERING ACTUATOR
Figures 1 ,2 a n d 4
This vehicle may be equipped with a Variable Assist

Steering hydraulic control system. If the power steering
pump has a Variable Assist Steering actuator, service as
follows.
Figure 3 Drive Shaft Seal

Install or Connect Disassemble
| 9 | Important
• Drain power steering fluid from pump.
1. Studs (36).
• For correct orientation, align the Variable 2. Fitting (33) or actuator assembly (45), as equipped.
Assist Steering actuator discharge fitting with 3. O-ring seal (35).
the mark on the pump reservoir. 4. Control valve assembly (2) and flow control spring
(6) from housing (8) if replacement is required.
1. Variable Assist Steering actuator. 5. Reservoir (37) from housing (8).
2. Negative (-) battery cable. 6. O-ring seals (1,10 and 40).
7. Magnet (7).
Tighten
1 Clean
• Variable Assist Steering actuator (45) to
50-75 N*m (37-55 lb. ft.). • Magnet (7).
3. Electrical connector to Variable Assist Steering Inspect
actuator (45).
4. Retaining clip (46) to Variable Assist Steering • Welch plug in housing (8). Do not remove.
actuator (45). If plug is deformed or dislodged, replace
• If a new Variable Assist Steering actuator housing (8).
(45) is being installed, position electrical
connector before installing retaining clip (46). Important
5. Pump assembly to vehicle, if removed.
• Use new seals when assembling pump.
PUMP RESERVOIR REPLACEMENT
F ig u re 1
v l Assemble
E3 Remove or Disconnect • Lubricate O-ring seals (1,10,35 and 40) with power
steering fluid.
• Power steering pump from vehicle. Refer to “Power 1. Flow control spring (6) and control valve
Steering Pump Replacement” in section 2B. assembly (2) to housing (8). See Figure 1 for proper
orientation.
2. O-ring seals (1,10 and 40) to housing (8).
3. Magnet (7) to housing (8).
4. Reservoir (37) to housing (8).
5. O-ring seal (35)
6. Fitting (33) or actuator assembly (45), as equipped.
Notice: See “Fastener Tightening Notice.”
7. Studs (36).
Tighten
• Studs (36) to 35 to 80 N«m (29-59 lb. ft.).
• Fitting (33) to 75 N*m (55 lb. ft.) or
Variable assist actuator (45) to 50-75 N*m
(37-55 lb. ft.).
0 Install or Connect
• Power steering pump. Refer to “Power Steering
A-IDENTIFICATION ARROW Pump Replacement” in section 2B.
37-RESERVOIR ASM
45-ACTUATOR & FITTING ASM, EVO
Figure 4 Aligning the Variable Steering actuator
END PLATE AND ROTATING GROUP

Important
REPLACEMENT
Figures 1 ,2 a n d 5 • Use new seals and drive shaft retaining ring
when assembling pump.
Assemble
• Power steering pump from vehicle. Refer to
“Power Steering Pump Replacement” in section 2B. Lubricate O-ring seals (3 and 5) with power steering
fluid.
1. O-ring seals (3 and 5) to housing (8).
Disassemble
m
1. Pump reservoir. Refer to “Pump Reservoir 2. Dowel pins (13) to housing (8).
Replacement” in this section. 3. Thrust plate (15) and pump rotor (16) to drive shaft
2. Retaining ring (25). (12) and secure with retaining ring (17).
3. End plate (23) and spring (22). 4. Shaft, rotor and thrust plate assembly to housing
Notice: Examine exposed portion of pump drive shaft. If ( 8 ).
5. Pump vanes (18) to pump rotor (16).
it is corroded, clean with crocus cloth before removing. 6. Pump ring (20) to housing (8) with identification
This will prevent damage to the shaft bushing which may arrows on top edge of ring (20) facing outward.
require replacement of the entire housing. 7. Pressure plate (21).
4. Pressure plate (21) by using a rubber mallet to tap 8 . Spring (22) and end plate (23).
lightly on the drive shaft (12). 9. Retaining ring (25).
5. Pump ring (20). 10. Pump reservoir (37). Refer to “Pump Reservoir
6. Pump vanes (18). Replacement” in this section.
7. Shaft, rotor and thrust plate assembly.
8. Shaft retaining ring (17). Install or Connect
9. Pump rotor (16).
10. Thrust plate (15). • Power steering pump. Refer to “Power Steering
11. Drive shaft (12). Pump Replacement” in section 2B.
12. Dowel pins (13).
13. O-ring seals (3 and 5).
A-IDENTIFICATION ARROW
3-SEAL
5-SEAL
8-HOUSING
12- SHAFT, DRIVE
13- PINS
15- PLATE, THRUST
16- ROTOR
17- RING, RETAINING
18- VANES
20- RING
21- PLATE, PRESSURE
Figure 5 Rotating Group
SPECIAL TOOLS
STEERING LINKAGE 2B3-1
SECTION 2B3
STEERING LINKAGE
GENERAL DESCRIPTION
The steering linkage consists of a pitman arm, idler arm, tie rod assembly, and adjustable drag link.
arm, relay rod and two adjustable tie rods. On some In the heavy duty series, when the wheel is turned,
four wheel drive models, a steering shock absorber is the gear rotates the pitman arm which forces the adjust
attached to the relay rod. able drag link to one side. The tie rod then moves
When the steering wheel is turned, the gear rotates sideways, actuating the steering knuckles and turning
the pitman arm which forces the relay rod to one side. the wheels.
The tie rods, which are connected to the relay rod by The overall condition of the steering linkage affects
ball studs, transfer the steering force to the wheels. The steering performance. If parts are bent, damaged, worn
tie rods are adjustable and are used for toe-in adjust or poorly lubricated, improper and possibly dangerous
ments. The relay rod is supported by the pitman arm steering action will result.
and idler arm. The idler arm pivots on a support Whenever any steering linkage components are
attached to the frame rail. The steering shock absorber repaired or replaced, check the steering geometry and
is attached to the frame and relay arm. front end alignment. Refer to Measuring Wheel Align
The C3500HD steering linkage consists of a pitman ment in Wheel Alignment.
DIAGNOSIS OF STEERING LINKAGE

For diagnosis of steering system. Refer to Diagnosis
of Power Steering System in Power Steering Gear
and Pump.
ON-VEHICLE SERVICE
STEERING LINKAGE nents may be rusted. If the torque required to remove
the nut from the bolt exceeds 9 N m (80 lb in) discard
INSPECTION the nuts and bolts. Apply penetrating oil between the
clamp and tube and rotate the clamps until they move
m Important freely. Install all parts, with the correct part number, in
the proper position.
• Damaged or broken steering linkage components Idler Arm
must be replaced. Never attempt to repair these
parts by welding. Inspect (Figure 1)
Tie Rods
1. Raise the vehicle. Support the vehicle with jack
There are two tie rod assemblies. Each assembly is stands. Allow the front wheels to rotate freely and
made up of five pieces, consisting of a sleeve, two the steering mechanism freedom to turn. Position
clamps, and two tie rod ends. The ends are threaded the wheels in a straight ahead position.
into the sleeve and secured with the clamps. Right and • On four wheel drive (K Models), the front differ
left hand threads are used for toe-in adjustments and ential carrier shield must be removed to access
steering gear centering. For lubrication of tie rod idler arm and steering linkage. Refer to Shield
ends refer to Maintenance and Lubrication in General Replacement in Front Drive Axle.
Information. 2. Place a spring scale near the relay rod end of
Tie rod ends should be replaced when excessive the idler arm. Exert a 110 N (25 Lb) force upward
up-and-down motion is present, or when excessive end and then downward (the force is forward and
play or loss of motion at the ball stud exists. rearward) while measuring the total distance the
Before any service is performed, note the position of arm moves. The total allowable movement is
the tie rod adjuster tube, and the direction from which 2 mm (0.080 inch). Replace the idler arm if it
the bolts are installed. The tie rod adjuster tube compo exceeds this test.
2B3-2 STEERING LINKAGE
procedure. There is no control on the amount of
force being applied to the idler arm.
• Diagnose carefully whenever shimmy com
plaints are suspected of being caused by loose
idler arms. Before inspecting suspension or
steering components, technicians should con
sider areas such as dynamic imbalance, runout,
or force variation of wheel and tire assemblies,
and road surface irregularities. Refer to Vehicle
Leads/Pulls in Suspension General Diagnosis.
IDLER ARM REPLACEMENT

Tools Required:
J 24319-01 Steering Linkage Puller
J 29193 Steering Linkage Installer (12 mm)
NOTICE: Do not attempt to free the ball stud

by using a pickle fork or wedge type tool,
because seal or bushing dam age could
result. Use the proper tool to separate all
Joints.
Remove or Disconnect (Figures 2 through 4)
• Raise the vehicle. Support the vehicle with jack

stands.
1. Idler arm frame bolts and nuts.
2. Idler arm ball stud nut. Do not reuse the nut.
Figure 1—Idler Arm Movement Check 3. Idler arm from the relay rod. Use J 24319-01.
m Important |P | Inspect
• Jerking the right wheel and tire assembly back • Ball stud threads for damage.
and forth, causing an up and down movement • Ball stud seal for cuts or other damage.
of the idler arm, is NOT an acceptable testing
Legend
(1) Bolt (4) Idler Arm
(2) Washer (5) Steering Gear
(3) Nut
Figure 2—Idler Arm Installation
Legend
(1) Outer Tie Rod Nut (8) Pitman Arm Nut
(2) Pitman Arm (9) Inner Tie Rod Nut
(3) Steering Knuckle (10) Relay Rod
(4) Tie Rod Ball Stud (11) Idler Arm Nut
(5) Adjuster Sleeve Clamp (12) Idler Arm
(6) Adjuster Sleeve Nut (13) Inner Tie Rod
(7) Adjuster Sleeve
Figure 3—Steering Linkage (Two Wheel Drive)
Clean Tighten
• Threads on the ball stud. • Nut to 62 N-m (46 lb ft).

Lower the vehicle.
Install or Connect (Figures 2 through 4)
Adjust
• Position the idler arm mounting bracket on the
frame. Adjust front toe. Refer to Measuring Wheel
1. Frame bolts and nuts to the idler arm. Alignment in Wheel Alignment.
NOTICE: Refer to Fastener Notice In Cau RELAY ROD REPLACEMENT

tions and Notices. Tools Required:
Tighten J 29193 Steering Linkage Installer (12 mm)
1. Frame bolts to 99 N.m (73 lb ft).
2. Relay rod to the idler arm ball stud. Make sure Important
the seal is on the stud. Tighten tool J 29193 or
J 29194 to 54 N-m (40 lb ft) to seat the tapers. • Use the proper tool to separate all tie rod and ball
Remove the tool. joints.
3. New prevailing torque nut to the idler arm
ball stud
Legend
(1) Outer Tie Rod Nut (8) Pitman Arm Nut
(2) Pitman Arm (9) Inner Tie Rod Nut
(3) Steering Knuckle (10) Relay Rod
(4) Tie Rod Ball Stud (11) Idler Arm Nut
(5) Adjuster Sleeve Clamp (12) Idler Arm
(6) Adjuster Sleeve Nut (13) Inner Tie Rod
(7) Adjuster Sleeve
Figure 4— Steering Linkage (Four Wheel Drive)
[*"►! Remove or Disconnect (Figures 2 through 5) 3. Idler arm ball stud nut. Do not reuse.
4. Pitman arm nut. Do not reuse.
• Raise the vehicle. Support the vehicle with jack 5. Relay rod from the idler arm ball stud using
stands. J 24319-01.
1. Steering shock absorber from the relay rod (if 6. Relay rod from the pitman arm ball stud using
equipped). Refer to Steering Shock Absorber J 24319-01.
Replacement in this section. 7. Drag link from pitman shaft (if equipped). Refer to
2. Inner tie rod ball joint from the relay rod. Refer to Drag Link Replacement in this section.
Tie Rod Replacement in this section.
Legend
(1) Tie Rod Assembly (6) Nut
(2) Drag Link (7) Cotter Pin
(3) Drag Link Adjuster (8) Steering Gear
(4) Ball Stud (9) Nut
(5) Adjuster Clamp
Figure 5—Steering Linkage - I-Beam Front Axle (C3500HD Models)
Inspect Tighten
• Threads on the tie rod for damage. • Nuts to 62 N.m (46 lb ft).
• Ball stud threads for damage. 5. Tie rod inner ball joints to the relay rod.
• Ball stud seals for excessive wear. 6. S te e rin g shock a b so rb e r to the relay rod
(if equipped).
Ifii Clean
DRAG LINK REPLACEMENT
• Threads on the ball stud.
I-Beam Front Axle (C3500HD Models Only)
Install or Connect (Figures 3 through 5) Tools Required:
1. Relay rod to the idler arm ball stud. J 29194 Steering Linkage Installer (14 mm)
2. Relay rod to the pitman arm ball stud.
A. Make sure the seal is on the stud. Important
B. Install J 29193 or J 29194 to ball stud.
C. Tighten Steering Linkage Installer to 62 N.m • Use the proper tool to separate all ball joints.
(46 lb ft) to seat the tapers.
D. Remove the tool. Remove or Disconnect (Figure 5)
3. New idler arm prevailing torque nut.
4. New pitman arm prevailing torque nut. • Raise the vehicle. Support the vehicle with
jack stands.
NOTICE: Refer to Fastener Notice in Cau 1. Nuts from pitman arm ball stud and drag link
tions and Notices. ball stud.
2. Drag link from pitman arm using J 2419-01.
3. Drag link from tie rod assembly using J 2419-01. 4. Pitman arm. Use J 6632-01 or J 29107.
Inspect Inspect
- Threads on the tie rod for damage. • Ball stud threads for damage.
• Ball stud threads for damage. • Ball stud seals for excessive wear.
• Ball stud seals for excessive wear.
Clean
Clean
-►+ Install or Connect (Figure 3)
1. Pitman arm on the pitman shaft. Line up the marks
1. Drag link ball stud to tie rod assembly. made at removal.
2. Drag link to pitman arm ball stud. 2. Pitman arm washer and nut.
A. Make sure the seal is on the studs.
B. Install J 29194. NOTICE: Refer to Fastener Notice in Cau
C. Tighten to 62 N-m (48 lb ft) to seat the tapers. tions and Notices.
D. Remove the tool.
3. Nut to pitman arm ball stud. Tighten
NOTICE: Refer to Fastener Notice in Cau • Pitman arm nut to 250 N m (184 lb ft).
tions and Notices. 3. Relay rod to the pitman arm ball stud. Make sure
the seal is on the stud.
Tighten • Tighten J 29193 Steering Linkage Installer to
62 N-m (46 lb ft) to seat the tapers. Then
• Nut to 54 N-m (40 lb ft). remove the tool.
4. Nut to drag link ball stud. 4. New prevailing torque nut.
Tighten Tighten
. Nut to 105 N.m (77 lb ft). • Nut to 62 N-m (46 lb ft).

• Lower the vehicle. Lower the vehicle.
Four Wheel Drive
PITMAN ARM REPLACEMENT
Tools Required:
Two Wheel Drive J 24319-01 Steering Linkage Puller
Tools Required: J 29107 Pitman Arm Puller
J 24319-01 Steering Linkage Puller J 6632-01 Pitman Arm Remover
J 29107 Pitman Arm Puller J 29193 Steering Linkage Installer (12 mm)
J 6632-01 Pitman Arm Remover
J 29193 Steering Linkage Installer (12 mm) 0 Remove or Disconnect (Figure 3)
Important • Raise the vehicle. Support the vehicle with jack

stands.
• Use the proper tool to separate all ball joints. 1. Relay rod nut from the pitman arm ball stud. Do not
reuse the nut.
Remove or Disconnect (Figure 3) 2. Relay rod from the pitman arm ball stud using
J 24319-01.
• Raise the vehicle. Support the vehicle with jack 3. Power steering gear. Refer to Steering Gear
stands. Replacement in Power Steering Gear and Pump.
1. Relay rod nut from the pitman arm ball stud. Do not • Mark the pitman arm and the pitman shaft. This
reuse the nut. will permit proper alignment at assembly.
2. Relay rod from the pitman arm ball stud using
J 24319-01. NOTICE: Do not hammer on pitman arm, pit
3. Pitman arm nut and washer. man shaft, or puller. Damage to pitman arm
• Mark the pitman arm and the pitman shaft. This or steering gear may result.
will permit proper alignment at assembly.
4. Pitman arm from pitman shaft of steering gear.
NOTICE: Do not hammer on pitman arm, pit Use J 6632-01 or J 29107.
man shaft, or puller. Damage to pitman arm
or steering gear may result.
Inspect Install or Connect (Figure 5)
Ball stud threads for damage.

Ball stud seals for excessive wear. NOTICE: If a clamp type pitman arm is used,
spread the pitman arm just enough, with a
| Clean wedge, to slip the arm onto the pitman shaft.
Do not spread the pitman arm more than
Threads on the ball stud. required to slip over the pitman shaft with
hand pressure. Do not hammer, or damage to
++ Install or Connect (Figure 3) the steering gear may result.
1. Pitman arm on the pitman shaft. Line up the marks 1. Pitman arm on the pitman shaft. Line up the marks
made at removal. made at removal.
2. Pitman arm washer and nut. 2. Pitman arm washer and nut.
Tighten NOTICE: Refer to Fastener Notice in Cau

tions and Notices.
• Pitman arm nut to 250 N-m (184 lb ft).
3. Steering gear to frame of vehicle. Tighten
4. Relay rod to the pitman arm ball stud. Make sure
the seal is on the stud. • Pitman arm nut to 250 N-m (184 lb ft).
. Tighten J 29193 or J 29194 to 62 N-m (48 lb ft) 3. Drag link to the pitman arm ball stud. Make sure
to seat the tapers. Remove the tool. the seal is on the stud.
5. New prevailing torque nut. • Tighten J 29194 to 62 N-m (48 lb ft) to seat the
tapers. Remove the tool.
NOTICE: Refer to Fastener Notice in Cau 4. Pitman arm nut to the pitman arm ball stud.
tions and Notices.
Tighten
Tighten
• Nut to 47 N-m (35 lb ft).
• Nut to 62 N-m (46 lb ft). • Lower the vehicle.
• Lower the vehicle.
TIE ROD REPLACEMENT
I-Beam Front Axle (C3500HD Models)
Tools Required:
Tools Required: J 6627-A Wheel Stud Remover and Tie Rod
J 24319-01 Steering Linkage Puller Remover
J 29107 Pitman Arm Puller J 29193 Steering Linkage Installer (12 mm)
J 6632-01 Pitman Arm Remover There are two tie rod assemblies. Each assem
J 29194 Steering Linkage Installer (14 mm) bly consists of five pieces: an adjuster tube, two
clamps, and two tie rod ends. The ends are
Im portant
threaded into the sleeve and secured with the
clamps. Right and left hand threads are used for
• Use the proper tool to separate all ball joints. toe-in adjustments. The tie rod ends should be
replaced when excessive up and down motion is
present, or when excessive end play or loss of
motion at the ball stud exists.
• Raise the vehicle. Support the vehicle with jack Before servicing, note the position of the tie rod
stands. adjuster tube and the direction the clamp bolts are
1. Drag link from pitman arm ball stud. installed. The tie rod adjuster tube components
2. Pitman arm nut from steering gear shaft. may be rusted. If the torque required to remove
• Mark the pitman arm and the pitman shaft. This the nut from the bolt exceeds 9 N.m (80 lb in)
will permit proper alignment at assembly. discard the nuts and bolts. Apply penetrating oil
3. Pitman arm using J 6632-01 or J 29107. between the clamp and tube and rotate the
clamps until they move freely. Install all parts (with
Inspect
the correct part number) in the proper position.
• Ball stud threads for damage. Im portant
• Ball stud seals for excessive wear.
Use J 6627-A to separate all tie rods and ball
Clean
joints.
Threads on the ball stud.
2B 3-8 STEERING LINKAGE
3 Remove o r Disconnect (Figures 3 and 4) Tighten
• Raise the vehicle. Support the vehicle with jack . Nut to 62 N.m (46 lb ft).
stands.
1. Nut from the outer tie rod ball stud. Do not reuse 7 A djust
the nut.
2. Outer tie rod ball stud from the steering knuckle • Adjust front toe. Refer to Measuring Wheel
using J 6627-A. Alignment in Wheel Alignment.
3. Nut from the inner tie rod ball stud Do not reuse
the nut. I-Beam Front Axle (C3500HD Models)
4. Inner tie rod b a ll stud from the re la y rod The heavy duty suspension uses only one adjustable
using J 6627-A. tie rod end, connected to the left steering knuckle spin
5. Tie rod ends from the adjuster tube. dle. A ball socket is found at the end of the tie rod
A. Loosen the clamp nuts. assembly and attaches to the right steering knuckle
B. Spread the clamps. spindle. The tie rod assembly rod attaches to the steer
C. Unscrew the tie rods. ing gear by means of a drag link and ball socket with an
adjuster sleeve near the pitman arm stud hole.
Inspect
\n \ Remove o r Disconnect (Figure 5)
• Tie rod ends for damage.
• Tie rod end seals for excessive wear. 1. Cotter pin at ball stud.
• Ball stud threads for damage. 2. Nut from ball stud.
• Adjuster tubes for bending or damaged threads. 3. Loosen nut and adjuster clamp.
4. Ball stud and tie rod end from tie rod assembly.
idii Clean
■
Inspect
• The tapered surfaces.
• Threads on the ball stud and in the ball • Tie rod end for damage.
stud nut. • Tie rod end seals for excessive wear.
• Threads on the relay rod and tie rod end for
E Install or Connect (Figures 3 and 4) damage.
• Ball stud threads for damage.
• If the rod end was removed, lubricate the tie rod • Adjuster tubes for bending or damaged threads.
threads with chassis lubricant.
1. Tie rod end to the adjuster tube. The number of Clean
threads on both the inner and outer rod ends must
be equal within three threads. • The tapered surfaces.
2. Inner tie rod ball studs to the relay rod. The seal • Threads on the ball stud and in the ball
must be on the stud. stud nut.
NOTICE: Refer to Fastener Notice in Cau |-M-| Install o r Connect (Figure 5)

tions and Notices.•
1. Ball stud and tie rod end to tie rod assembly.
• Stud to 54 N.m (40 lb ft) to seat the tapers, 2. Ball stud into steering knuckle.
using J 29193. 3. Nut to ball stud and tie rod end.
3. New prevailing torque nut to the inner tie rod
Tighten
ball stud.
Tighten • Nut to 88 N.m (65 lb ft)

4. C otter pin, align co tte r pin s lo t in nut w ith
• Nut to 62 N.m (46 lb ft). hole through tie rod stud. DO NOT back off nut to
4. Outer tie rod ball studs to the steering knuckle. align slot.
Tighten 0 Adjust
• Stud to 54 N.m (40 lb ft) to seat the tapers, • Adjust front toe. Refer to Measuring Wheel
using J 29193. Alignment in Wheel Alignment.
5. New p re v a ilin g torque nut to the oute r rod 5. Adjuster clamp nuts.
ball studs.
Tighten
. Nut 104 N-m (77 lb ft).

TIE ROD CLAMP AND B. Adjuster clamp must be located between (and
not on) stamped adjuster tube dimples.
ADJUSTER TUBE POSITIONING C. Ears of the drag link adjuster clamps must be
rotationally positioned as in (Figure 6).
Adjust (Figure 6) D. Tighten the drag link to the recommended torque.
Refer to Specifications at the end of this section.
1. Position adjuster tube clamp bolts (Figure 6). E. The drag link assembly must be capable of
Before tightening the clamp bolts, be sure the fol rocking on the socket balls through a minimum
lowing conditions have been met: of 8 degrees total after the clamp nuts are
A. The clamps must be positioned between the tightened.
locating dimples at either end of the adjuster F. If tools are used to rotate the adjuster tube,
tube. special attention must be given to prevent dam
B. The clamps must be positioned within the angu age to the corrosion protection coating.
lar travel shown in Figure 6. 2. Align the left front wheel by using the tie rod adjust
C. Both inner and outer tie rod ends must rotate er tube assembly.
for their full travel. The position of each tie rod A. Position the tie rod adjuster clamps on the
end must be maintained as the clamps are adjuster tube so the edge of the clamp jaws do
tightened to ensure free movement of each not fall in the adjuster tube slot.
joint. B. Adjuster clamps must be located between (and
D. The clamp ends may touch when nuts are tight not on) the stamped adjuster tube dimples.
ened to specification, but the gap next to the C. Tie rod adjuster tube clamps must be positioned
adjuster tube must not be less than the mini as specified in Figure 6.
mum dimension shown in Figure 6. D. Tighten the tie rod adjuster tube clamp nut to
I-Beam Front Axle (C3500HD Models) the recommended torque. Refer to Specifica
tions at the end of this section.
Adjust (Figure 7) • If tools are used to rotate the adjuster tube,
special attention must be given to prevent
1. Align the front right wheel by using the drag link damage to the corrosion protection coating.
adjuster tube assembly.
A. Position the drag link adjuster clamps on the
adjuster tube so the edge of the clamp ears do
not fall in the adjuster tube slot.
D. SLOT IN ADJUSTER SLEEVE MUST NOT BE WITHIN VIEM

THIS AREA OF CLAMP JAWS
E. TIE ROD INNER
F. TIE ROD OUTER
Q. GAP
H. CLAMP ENDS MAY TOUCH WHEN NUTS ARE TORQUED TO SPECIFICATIONS
BUT GAP MUST BE VISIBLE ADJACENT TO ADJUSTER SLEEVE
J. EQUAL WITHIN THREE THREADS MUST BE VISIBLE AT INNER AND
OUTER ENDS OF THE ADJUSTER SLEEVE WHEN ASSEMBLED TO STEERING KNUCKLE
AFTER ADJUSTMENT, A MINIMUM OF 35.0 MM MUST BE ENGAGED FROM
EACH TIE ROD SLEEVE, SEE VIEW C
L CLAMP MUST BE BETWEEN AND CLEAR OF DIMPLES BEFORE TORQUING NUTS
Figure 6—-Tie Rod Clamp and Adjuster Tube Positioning

34. CLAMP, ADJUSTER TIE ROD
Figure 7—Tie Rod Clamp and Adjuster Tube Positioning - I-Beam Front Axle Models (C3500HD Models)
Tighten STEERING SHOCK ABSORBER

• Adjuster tube clamp bolt nuts to Specifications
REPLACEMENT
at the end of this section. Four Wheel Drive
STEERING SHOCK ABSORBER Remove or Disconnect (Figure 8)

INSPECTION
1. Relay rod cotter pin.
The steering shock absorber is a sealed assembly
2. Shock absorber lower ball stud nut.
and is non-repairable. Replace the complete assembly if
3. Shock absorber lower ball stud from the relay rod.
damaged.
4. Shock absorber mounting bolt nut.
Inspect (Figure 8) 5. Mounting bolt.
6. Shock absorber.
1. Shock absorber for fluid leakage. A slight film of fluid Inspect
is allowable near the shaft seal. If there is excessive
fluid leakage, be sure it is from the shock absorber
• Shock absorber for leaks and damage.
and then replace the shock absorber.
• M o u n tin g b o lts and n u ts fo r d a m a g e
2. Shock absorber bushing fo r excessive wear.
or corrosion.
Replace the shock absorber if necessary.
3. Test the shock absorber. *►4- Install or Connect (Figure 8)
A. Disconnect the shock absorber from the frame
or relay rod.
1. Shock absorber.
B. Extend and compress the shock absorber using
2. Mounting bolt.
as much travel as possible. Resistance should
3. Nut.
be smooth and constant for each stroking rate.
4. Lower ball stud to the relay rod. .
Replace the shock absorber if any binding or
unusual noises are present. 5. Nut.
C. Install the end of the shock absorber and tight
en to Specifications at the end of this section. NOTICE: Refer to Fastener Notice in Cau
tions and Notices.
(1) Relay Rod (4) Nut

(2) Nut (5) Cotter Pin
(3) Bolt (6) Shock Absorber
Figure 8—Steering Shock Absorber (K-Models)
Q Tighten

• Nut to 63 N m (46 lb ft). A maximum torque of
80 N-m (59 lb ft) is allowed in order to align the
cotter pin slot. Do not back off the nut to insert
the cotter pin.
6. Cotter pin.
SPECIFICATIONS
FASTENER TIGHTENING
SPECIFICATIONS
Application N-m Lb ft Lb in
C/K MODELS
Adjuster Tube Clamp Nut 25 18 —
Idler Arm to Frame Nut 99 73 —
Idler Arm to Relay Rod Nut 62 46 —

Pitman Arm to Relay Rod Nut 62 46 —
Pitman Arm to Steering Gear Nut 250 184 —
Relay Rod to Tie Rod Nut 47 35 —
Steering Shock Absorber to Frame Bracket Nut 40 30 —
Steering Shock Absorber to Relay Rod Nut 62 46 —
Tie Rod to Steering Knuckle Nut 62 46 —
C3500HD I-BEAM FRONT AXLE
Drag Link Adjuster Tube Nuts 68 50 —
Drag Link to Tie Rod 105 77 —
Pitman Arm to Drag Link 47 35 —
Pitman Arm to Steering Gear 250 184 —
Tie Rod Adjuster Tube Nuts 104 77 —
Tie Rod to Steering Knuckle 88 65 —
2B 3-12 STEERING LINKAGE______________
SPECIAL TOOLS
1. J-6627-A 5. J-29193
2. J-6632-01 6. J-29194
J-29107
1. Tie Rod Puller
2. Pitman Arm Puller
3. Pitman Arm Puller
4. Universal Steering Linkage Puller
5. Steering Linkage Installer (12 mm) GM
Torque Prevailing Nuts
6. Steering Linkage Installer (14 mm) GM
Torque Prevailing Nuts
F2539
SPEED DEPENDENT STEERING 2B5-1
SECTION 2B5
SPEED DEPENDENT STEERING

ELECTRONIC VARIABLE ORIFICE (EVO)
GENERAL DESCRIPTION 3. When using a screw driver or sim ilar tool to
The E le ctron ic V ariable O rifice (EVO) system disconnect a connector, never let the tool come in
increases or decreases the amount of fluid leaving the contact with or come between the exposed termi
power steering pump. This provides the driver with a nals.
comfortable balance of steering wheel feel and power 4. Never jumper, ground, or use test equipment
assist. probes on any components or connectors unless
At vehicle stand still or very low speeds, the system specified in diagnosis. When using test equipment,
allows full hydraulic fluid flow for maximum power assist always connect the ground lead first.
and reduced steering effort. As the vehicle gains speed, 5. Do not remove the solid state component from its
a variable orifice closes at the steering pump which protective packaging until you are ready to install
reduces the pump fluid flow. This action provides a stiff- the part.
er steering wheel response for improved road feel and 6. Always touch the solid state component package to
greater directional stability at highway speeds. a ground before opening. Solid state components
A sensor mounted on the steering column, detects the can also be damaged if:
steering wheel movements associated with defensive • They are bumped or dropped.
driving maneuvers. A control module uses this sensor • They are laid on any metal work benches or
input and vehicle speed to adjust the amount of current components that operate electrically, such as a
to the solenoid. Radio, TV or Oscilloscope.
The EVO S ystem c o n s is ts of th e fo llo w in g Not all parts that can be damaged by ESD have an
components: ESD label. Some components that can be damaged by
• The Steering Assist Control Solenoid is located on ESD are:
the power steering pump discharge fitting. • Chime Module.
• The EVO/Passlock Module is mounted on the • Cruise Control Module.
instrument panel carrier, to the right of the steering • Electronic Variable Orifice (EVO)/Passlock Module.
column. • Powertrain Control Module (PCM).
• The Steering Handwheel Speed Sensor is located • Vehicle Control Module (VCM).
in the lower bearing of the steering column. • Automatic Day/Night Mirror.
• The Vehicle Speed Sensor is located on the trans • Radio/Radio Control.
mission. • Anti-lock Brake System Electronic Brake Control
• The Vehicle Speed Sensor Buffer is located on the Module (EBCM).
bottom of the Powertrain Control Module (PCM) • Automatic Air Conditioning Control Assembly.
tray (Diesel Engines Only). • Twilight Sentinel Amplifier.
• The Vehicle Control Module (VCM) is located in the • Electronic Spark Control Module.
engine compartment on the left inner wheel well
panel (Gas Engines Only).
HANDLING ELECTROSTATIC
DISCHARGE (ESD) SENSITIVE
NOTICE
PARTS
Many solid state electrical components can be dam
aged by Electrostatic Discharge (ESD). Some will dis
play a label as shown in Figure 1, but many will not.
1. Body movement produces an electrostatic charge.
To discharge personal static electricity, touch a
ground point (metal) on the vehicle. This should be
done any time you:
• Slide across the vehicle seat.
• Sit down or get up. CONTENTS SENSITIVE
• Do any walking. TO
2. Do not touch exposed electric terminals on compo
nents or connectors with your finger or any tools. STATIC ELECTRICITY chnooioa
Remember, the connector you are checking might

be tied into a circuit that could be damaged by Figure 1— Electrostatic Discharge Sensitive
electrostatic discharge. Parts Label
2B5-2 SPEED DEPENDENT STEERING
• EEPROM (Electrically Erasable Programmable
Read Only Memory).
Solid state components also can be damaged if they
are bumped or dropped, or if they are laid on a metal
work bench or on an electrically operated item such as
a Radio, a TV or an Oscilloscope.
SPEED DEPENDENT STEERING

COMPONENTS AND OPERATION
Power Steering Hydraulic System
The Electronic Variable Orifice (EVO) power steering
pump is a conventional power steering pump with a
Steering Assist Control Solenoid mounted to the outlet
port. When driving conditions require less hydraulic
fluid, a flow control valve restricts the flow of fluid.
Steering Assist Control Solenoid

Legend
The Steering Assist Control Solenoid, mounted on the
(1) Discharge Fitting
power steering pump (Figures 2 and 3), contains a sole
(2) O Ring (Small) Seal
noid operated valve. Discharged fluid passes through (3) O Ring (Large) Seal
an orifice in the solenoid. As the vehicle speed increas (4) Flow Control Valve
es, the EVO/Passlock Module increases the PWM sig (5) Steering Assist Control Solenoid
nal to the Steering Assist Control Solenoid. Higher
Figure 3—Electronic Variable Orifice (EVO)
current gradually moves the valve further and further
Actuator Assembly
into the orifice. This action restricts the passage of fluid
flow through the orifice, reducing power assist in the Because the EVO/Passlock Module sends a variable
steering gear. For diagnosis of the steering system, signal, the Steering Assist Control Solenoid provides
refer to Diagnosis of Power Steering in Power Steering variable levels of power assist. The EVO system there
Gear and Pump. fore consistently adjusts power steering assist for
changing vehicle speeds and driving conditions. For
repair procedures, refer to Steering Assist Control Sole
noid. For diagnosis, refer to Diagnostic System Check.
Electronic Variable Orifice (EVO)/Passlock Module

The EVO/Passlock Module (Figure 4), mounted
behind the right side of the steering column to the IP
carrier, uses the Vehicle Speed Sensor and Steering
Handwheel Speed Sensor input to regulate electrical
current to the Steering Assist Control Solenoid.
The EVO/Passlock Module also detects faults with the
Steering Handwheel Speed Sensor, the Steering Assist
Control Solenoid, and associated circuits. Upon detect
ing a fault, the EVO/Passlock Module disables the EVO
system and the vehicle operates with maximum power
assist until the driver turns the ignition to the OFF posi
tion. When the vehicle is restarted, the EVO/Passlock
Module resets and enables EVO operation until it
detects another fault. The EVO/Passlock Module has
fault code memory and can pinpoint specific faults. For
repair procedure, refer to EVO/Passlock Module. For
diagnosis, refer to Diagnostic System Check.
Legend
(1) Power Steering Pump
(2) Steering Assist Control Solenoid
Figure 2—Steering Assist Control
Solenoid Location
Legend
(1) Instrument Panel Carrier
(2) Electronic Variable Orifice (EVO)/Passlock Module
Figure 4— Electronic Variable Orifice (EVO)/Passlock Module
Steering Handwheel Speed (HWSS) Sensor Vehicle Speed Sensor

This sensor is mounted in the lower bearing of the The Vehicle Speed Sensor (VSS) consists of a per
manent magnet generator on the transmission housing
steering column. It detects abrupt or evasive steering
or transfer case. The generator sends an electrical sig
maneuvers, and signals the EVO/Passlock Module to
nal to the VSS buffer (Diesel Engines Only) or to the
reduce steering effort. The faster the driver turns the VCM (Gas Engines Only). The VSS buffer or VCM then
steering wheel, the quicker the signal is generated by calculates vehicle speed and notifies the EVO/Passlock
the HWSS. For repair procedures, refer to Steering Module. For repair procedures, refer to Transmission
Handwheel Speed Sensor. For diagnosis, refer to Diag Controls. For diagnosis, refer to Diagnostic System
nostic System Check. Check.
DIAGNOSTIC SYSTEM CHECK

form normal acceleration, stopping, and turning
DIAGNOSTIC PROCESS maneuvers. If this does not reproduce the malfunc
When servicing the Speed Dependent Steering tion, refer to intermittent diagnosis.
Electronic Variable Orifice (EVO) system, the following 5. Once all system malfunctions have been corrected,
steps should be followed in order. Failure to follow clear the EVO DTC’s and test drive the vehicle.
these steps may result in the loss of important diagnos
tic data and may lead to difficult and time-consuming SELF DIAGNOSTICS
diagnostic procedures:
1. Perform a vehicle preliminary diagnostic inspection. The EVO/Passlock Module performs self-diagnostics
2. Perform a Power Steering System Test, refer to of the EVO system and can detect and isolate system
Power Steering System Test in Power Steering fa ilu re s . W hen a m a lfu n ctio n is d e te cte d , the
Gear and Pump. EVO/Passlock Module sets a corresponding Diagnostic
3. Perform the Diagnostic System Check. If any Trouble Code (DTC).
DTC’s are displayed, note the last malfunction that
occurred. Diagnose and repair this malfunction first. DISPLAYING DIAGNOSTIC
4. If no DTC’s or mechanical component malfunctions TROUBLE CODES (DTC’s)
are present, or if the failure is intermittent and not
reproducible, test drive the vehicle while using the DTC’s must be read using a scan tool. There are no
automatic snapshot feature of the scan tool. Per provisions for Flash Code DTC’s.
Diagnostic Trouble Code Description
coooo Vehicle Speed Information Circuit Malfunction
C0472 Steering Handwheel Speed Sensor (HWSS) Circuit Low
C0473 Steering Handwheel Speed Sensor (HWSS) Circuit High
C0495 EVO Tracking Error
C0498 Steering Assist Control Solenoid Feed Circuit Low
C0499 Steering Assist Control Solenoid Feed Circuit High
C0503 Steering Assist Control Solenoid Return Circuit Low
C0504 Steering Assist Control Solenoid Return Circuit High
C0559 EEPROM Checksum Error
CLEARING DIAGNOSTIC SCAN TOOL DIAGNOSTICS

TROUBLE CODES (DTC’s) Refer to the scan tool Owner’s Manual for information
about the scan tool and various modes.
The DTC’s in the memory can be erased using a
scan tool.
Be sure to ve rify proper system operation and CIRCUIT DESCRIPTION
absence of DTC’s when the clearing procedure is The EVO/Passlock Module supplies a 5.0 volt refer
completed. ence and a ground circuit to the Steering Handwheel
The EVO/Passlock Module will not permit DTC clear Speed (HWSS) Sensor. The HWSS returns a voltage
ing until all DTC’s have been displayed. Also, DTC’s signal to the EVO/Passlock Module indicating the steer
cannot be cleared by unplugging the EVO/Passlock ing wheel rate of steer. The HWSS returns a voltage
Module, disconnecting the battery cables, or turning the greater than 0.2 volts and no more than 4.9 volts when
ignition OFF.
the steering wheel has been turned one quarter revolu
tion (90 degrees). The EVO/Passlock Module uses the
INTERM ITTENT AND POOR sensor signal to control a PWM current (Percentage
CONNECTIONS Duty Cycle) to the Steering Assist Control Solenoid. The
Steering Assist Control Solenoid in turn regulates the
Most intermittent faults are caused by a faulty electri power steering pump output flow, thus increasing or
cal co n n e ctio n or w irin g , although a dam aged decreasing power steering assist.
EVO/Passlock Module can occasionally be at fault.
Refer to Interm ittent and Poor Connections for a
detailed explanation of how to locate and repair intermit
tent conditions.
DIAGNOSTIC AIDS not w ithin specifications, ve rify that the Steering
Handwheel Speed Sensor is not binding, grinding or
The scan tool reads steering wheel position in volts. damaged. For repair procedures refer to Supplemental
With the ignition switch in the ON position and as the Inflatable Restraint Steering Column Unit Repair.
steering wheel is rotated, the voltage should be
between 0.2 - 4.9 volts. Voltage should increase at a TEST DESCRIPTION
steady rate up to 4.9 volts when the wheel is turned in
either direction, one quarter revolution (90 degrees). The numbers below refer to the step numbers in the
• above 0.2 volts. Diagnostic System Check Table.
• below 4.9 volts when the steering wheel is • Step 1 verifies communication between the scan
rotated one quarter revolution (90 degrees). tool and the EVO/Passlock Module.
Using the scan tool, monitor the HWSS. • Step 2 verifies if the EVO System is operating.
• Turn the ignition ON. • Steps 3-11 verifies the power and ground to
• Turn the steering wheel. EVO/Passlock Module. Module.
The scan tool display should show voltages from • Steps 12-16 verifies the EVO system sensor input
0.2-4.9 volts as the steering wheel is turned one quarter and EVO/Passlock Module output.
revolution (90 degrees). If the steering wheel voltage is
DIAGNOSTIC SYSTEM CHECK TABLE

Step Action Value(s) Yes No
1 1. Connect the scan tool. Go to Step 2 Go to Step 7
2. Rotate the ignition switch to the ON position.
3. Using a scan tool try to communicate with the
EVO/Passlock Module.
Does the scan tool communicate with the EVO/Passlock

Module?
2 Monitor the EVO Data Display IGNITION 1. More than Go to Step 4 Go to Step 3
1 volt
Is voltage present?
3 INSPECT Fuse 21 (SECURITY/STRG). Go to Step 5 Go to Step 6
Was fuse open?

4 Check for any stored DTC’s. Go to Go to Step
appropriate 12
Are there any DTC’s stored? DTC Table
5 1. Disconnect the 16-way EVO/Passlock Module con Go to Step Go to Step
nector. Check for and REPAIR short to ground 14 15
between Fuse 21 (SECURITY/STRG) and terminal
B8 of the EVO/Passlock Module.
2. Inspect electrical terminals and connector for proper
fit. Repair as necessary.
Was there a repair made?

6 INSPECT for open in ORN (1740) wire between Fuse Go to Step Go to Step
21 and terminal B8 of EVO/Passlock Module. 14 15

7 INSPECT Fuse 4 (GAUGES). Go to Step 8 Go to Step 9
Was fuse open?

8 1. Disconnect the EVO/Passlock Module 16-way con Go to Step Go to Step
nector. Check for and REPAIR short to ground 14 15
between Fuse 4 (GAUGES) and terminal B3 of the

9 1. Disconnect EVO/Passlock Module 16-way connec Go to Step Go to Step
tor. Check for voltage at terminal B3 of 16-way con 11 10
nector and ground.
Is voltage present?
10 LOCATE and REPAIR open in PNK (39) wire between Go to Step Go to Step
Fuse 4 (GAUGES) and terminal B3 of EVO/Passlock 14 15
Module.

11 INSPECT for open in BLK/WHT (451) wire between ter Go to Step Go to Step
minal B1 of the 16-way EVO/Passlock Module connec 14 13
tor and ground.

12 1. With the scan tool still connected, monitor the 0.2-4.9 volts Go to Step Go to Step
Steering Handwheel Speed Sensor and Steering 16 14
Assist Control Solenoid parameters on the scan tool
in the EVO selection.
2. Rotate the steering wheel a half turn to the left then
slowly to the right.
Does the scan tool values change while rotating the

steering wheel?
13 INSPECT Serial Data Line PPL (1807) wire from termi Go to Go to Step
nal B4 of EVO/Passlock Module to terminal 11 of Con Diagnostic 15
nector C4 (Gas), terminal C8 of Connector C3 (Diesel) System
for open or short to ground. Check.

14 1. Using the scan tool clear DTC’s. Go to Go to Step
2. Start the engine and drive the vehicle until normal Applicable 16
operating temperature is reached. DTC Table
3. Using the scan tool check to see if any DTC’s are
recorded.
4. Perform Diagnostic System Check.
Are there any DTC’s stored?

15 REPLACE EVO/Passlock Module. Refer to ON-VEHI Go to Go to
CLE SERVICE. Applicable Diagnostic
DTC Table System
Are there any DTC’s stored? Check
16 System normal. Refer to Intermittent Procedures in —- — —
ELECTRICAL DIAGNOSIS.
2B 5-8 SPEED DEPENDENT STEERING
DTC COOOO - VEHICLE SPEED INFORMATION

CIRCUIT MALFUNCTION
CIRCUIT DESCRIPTION ACTION TAKEN WHEN THE

V ehicle speed in fo rm a tio n is provided to the DTC SETS
EVO/Passlock Module by the Vehicle Control Module
The EVO/Passlock Module will not send any current
(VCM) Gasoline Engines or by the Vehicle Speed Sen
sor (VSS) Buffer (Diesel Engines) and the class 2 data to the Steering Assist Control Solenoid. This will cause
fine. Once vehicle speed has been detected, the the Steering Assist Control Solenoid Valve to retract,
EVO/Passlock Module compares the vehicle speed sig providing maximum fluid flow and full power steering
nal received from the VSS with the vehicle speed data assist at all times.
received from the class 2 data line. The VSS is a per
manent magnet sensor producing an AC signal with CONDITIONS FOR CLEARING
varying frequency. The VSS is mounted in the transmis
sion or transfer case (4x4 models) and is driven off the THE DTC
output shaft. The VSS produces a pulsing AC voltage 1. A history DTC will clear after 100 consecutive
when vehicle speed is greater than 5 km/h (3 mph). The ignition cycles have occurred without a fault.
AC voltage and the number of pulses increase with
2. History and current DTC(s) can be cleared by using
vehicle speed. The VCM/VSS Buffer supplies the vehi
cle speed signal to the Instrument Cluster and to the the scan tool.
DIAGNOSTIC AIDS
CONDITIONS FOR SETTING
• Check for Powertrain DTC P0500 or any other
THE DTC vehicle speed related codes. If so, perform those
1. There is a difference of more than 10 km/h (6 mph) diagnostic tables first.
between the class 2 vehicle speed message for • A scan tool will show vehicle speed when the drive
10 seconds and the vehicle speed sensor is less wheels are turning faster than 5 km/h (3 mph). The
than 5 km/h (3 mph).
vehicle speed display should not be used if the
2. The above conditions have been met for 5 consec
utive class 2 samples. drive wheels are not turning.
• An Intermittent problem may be caused by a poor TEST DESCRIPTION
connection, break in the wire insulation exposing
The step numbers below refer to the same step
the internal wire, or a wire that is broken inside the
numbers in the Vehicle Speed Information Circuit
insulation.
Malfunction Diagnostic Table.
• The EVO/Passlock Module, the Vehicle Control • Step 1 ensures that the Diagnostic System Check
Module (VCM), and the Powertrain Control Module has been performed.
(PCM) should be thoroughly checked for terminals • Step 2 checks the vehicle speed signal to the VCM
that have backed out, broken locks, improperly (Gasoline Engines) or the PCM (Diesel Engines).
form ed or damaged term inals, weak term inal • Step 3 makes sure other systems on the same
retaining tension, or for proper routing. circuit are receiving a VSS signal.
DTC COOOO - VEHICLE SPEED INFORMATION CIRCUIT

MALFUNCTION DIAGNOSTIC TABLE
1 Was the Diagnostic System Check performed? Go to Step 2 Go to
Diagnostic
System
Check.
2 Does the speedometer operate correctly? — Go to Step 3 Go to Step 4
3 1. Connect the scan tool. Go to Step 4 Go to Step 5
2. CHECK for any stored DTC’s.
Are any (PCM) or (VCM) Vehicle Speed Sensor
(VSS) codes set?
4 1. Refer to ENGINE CONTROLS for diagnostic proce Go to Go to
dures. Applicable Diagnostic
2. Repair as necessary. DTC Table. System
Check.
Are there any DTC’s stored?
5 INSPECT for an open in DK GRN/WHT (817) wire. Go to Step 7 Go to Step 6
Refer to ELECTRICAL DIAGNOSIS.

6 REPLACE the EVO/Passlock Module. Refer to ON-VE Go to Go to
HICLE SERVICE. Applicable Diagnostic
DTC Table. System
Are there any DTC’s stored? Check.
7 1. Turn the ignition switch to the OFF position. Go to System
2. Install removed connectors and components. Diagnostic Normal
3. Clear DTC’s. System
4. Drive vehicle over 13 km/h (20 mph) for a minimum Check.
of 20 seconds.
Is DTC COOOO current?

■•EVO/
1Passlock
1Module
Steering I
nnW
I
S e n io r 5 V olt PoeMon
Return R ef 8ig n el
I
j
Steeling
Handwheel
Speed
Sensor
(HWSS)
DTC C0472 - STEERING HANDWHEEL SPEED (HWSS)

SENSOR—SIGNAL VOLTAGE LOW
CONDITIONS FOR CLEARING
C IRCU IT DESCRIPTION
THE DTC
The EVO /Passlock Module supplies a 5.0 volt
reference and a ground circuit to the Steering Hand- 1 . A history DTC will clear after 100 consecutive
wheel Speed (HWSS) Sensor. The HWSS returns a ignition cycles have occurred without the fault
voltage signal to the EVO/Passlock Module indicating reoccurring.
the steering wheel rate of steer. The HWSS returns a 2. History and current DTC(s) can be cleared using
voltage of 0.2 - 4.9 volts when the steering wheel has the Scan tool.
been turned one quarter revolution (90 degrees). The
EVO/Passlock Module monitors the HWSS signal volt DIAGNOSTIC AIDS
age to control a PWM current (Percentage Duty Cycle) The Scan tool will read steering wheel position in
to the Steering Assist Control Solenoid. volts. With the ignition switch in the ON position and as
the Steering Handwheel Speed Sensor is rotated, the
CONDITIONS FOR SETTING THE voltage reading should be 0.2 - 4.9 volts. Voltage
should increase at a steady rate up to 4.9 volts when
DTC the wheel is turned, one quarter revolution (90 degrees)
1 . The HWSS signal circuit voltage is less than in either direction.
0.2 volts. • Above 0.2 volts.
2. The above condition must be met for 1 second. • Below 4.9 volts when the steering wheel is
rotated one quarter revolution (90 degrees).
ACTION TAKEN WHEN THE Using the Scan tool, scan the HWSS.
DTC SETS • Above 0.2 volts.
The EVO/Passlock Module will not send any current • Turn the steering wheel.
to the Steering Assist Control Solenoid. This will cause • The Scan tool display should increase from
the Steering Assist Control Solenoid to retract, providing above 0.2 volts and below 4.9 volts as the
maximum fluid flow and full power steering assist at steering wheel is turned one quarter revolution
all times. (90 degrees).
TEST DESCRIPTION tionately to steering wheel rotational speed. If the
voltage is not within specifications, an appropriate
The step numbers below refer to the same step DTC will set. In addition to DTC diagnosis, check
numbers in the Steering Handwheel Speed (HWSS) for binding, grinding or damaged HWSS. Refer to
Sensor Signal Voltage Low Diagnostic Table. Supplemental Inflatable Restraint Steering Column
• Step 2 prompts the technician to complete some Unit Repair.
basic checks and store the Snapshot Data. This • Step 5 simulates a high voltage signal, which will
creates an electronic copy of the data taken when identify an open in the signal circuit.
the fault occurred. This stored information in the • Step 7 checks for voltage with the DMM while
scan tool can be referred to later. Step 2 also veri probing the HWSS signal circuit. The HWSS signal
fies when the voltage is between 0.2 and 4.9 volts, circuit is shorted to ground if voltage is present.
the EVO/Passlock Module will use this voltage to • Step 11 checks terminals for improper mating, bro
detect changes in tie rate of steering, and the system ken locks and physical damage to the wiring har
voltage should increase and decrease propor ness, before replacing the EVO/Passlock Module

SENSOR SIGNAL VOLTAGE LOW DIAGNOSTIC TABLE
Diagnostic
System
Check.
2 1. Turn the ignition switch ON, engine OFF. 0.2 - 4.9 Go to Go to Step 3
2. Connect scan tool. volts Diagnostic
3. Select from the CHASSIS MENU, ELECTRONIC System
VARIABLE ORIFICE, DATA DISPLAY. Check.
4. Check the scan tool while turning the steering
wheel one quarter revolution (90 degrees). Return
the steering wheel to the center position.
5. Record a Quick Snapshot while turning the steering
wheel.
6. Repeat Step 4 above twice.
Review the Snapshot. Does the HWSS value increase

and decrease steadily to the specified value when the
steering wheel is rotated?
3 Rotate the steering wheel one quarter revolution (90 0.2 volts Go to Step 4 Go to Step
degrees) and return. Record and review scan tool Snap 13
shot data.
Is the HWSS voltage less than the specified value?

4 1. Turn the ignition switch to OFF. 0.2 - 4.9 Go to Step Go to Step 5
2. Disconnect the HWSS electrical connector. volts 12
3. Jumper the 5.0 volt reference GRY (705) wire to the
signal LT BLU (1059) wire at the HWSS electrical
connector.
4. Monitor the scan tool values.
Is the HWSS voltage within the specified values?

5 Connect HWSS connector and using DMM connect neg 0.2 - 4.9 Go to Step 6 Go to Step
ative lead to ground and using positive lead, probe the volts 10
signal LT BLU (1059) wire at the HWSS harness con
nector.
Is the HWSS voltage within the specified value?

2BS-12 SPEED DEPENDENT STEERING
6 Using DMM connect negative lead to ground and using 0.2 - 4.9 Go to Step 8 Go to Step 7
positive lead, probe the sensor return at ORN/BLK volts
(1057) wire at the HWSS harness connector.
Is the HWSS voltage within the specified value?

7 CHECK the sensor return circuit ORN/BLK (1057) wire Go to Go to Step 8
for an open or short to ground. Diagnostic
System
Was there a repair made? Check.
8 CHECK the 5.0 volt reference circuit for an open or Go to Step Go to Step 9
short to ground in the HWSS signal GRY (705) wire. 14

9 CHECK the 5.0 volt reference GRY (705) wire for a Go to Step Go to Step
poor connection at the EVO/Passlock Module. Repair 14 13
and replace terminal(s) as necessary.

10 CHECK the HWSS signal LT BLU (1059) wire for an Go to Step Go to Step
open or short to ground. 14 11

11 CHECK HWSS signal LT BLU (1059) wire for a poor Go to Step Go to Step
connection at the EVO/Passlock Module. 14 12

12 REPLACE the HWSS. Go to Step Go to
14 Diagnostic
Was there a repair made? System
Check.
13 REPLACE the EVO/Passlock Module. Refer to ON-VE- Go to Step Go to
HICLE SERVICE. 14 Diagnostic
System
14 1. Using the scan tool clear DTC’s. Go to Step 2 Go to Step
2. Start the vehicle and drive until normal operating 15
temperature is reached.
3. Operate the vehicle for the conditions for setting
this DTC. Refer to Conditions for Setting the OTC’s.
Does the scan tool display DTC C0472?

15 Using the scan tool are there any DTC’s displayed that Go to System
have not been diagnosed? appropriate Normal
DTC table
BLANK
--------------------------------------- iB/O/
I 1Passlock
I * Module
I S i- rin g |
I W tw tl |
, 8m ar S V o lt PotM on .
1 RM um M ® fln « l J
Steering
Handwheel
Speed
Sensor
(HWSS)
DTC C 0473 - STEERING HANDWHEEL SPEED (HWSS)

SENSOR—SIGNAL VOLTAGE HIGH
ACTION TAKEN WHEN THE
C IR C U IT DESCRIPTION DTC SETS
The EVO/Passlock Module supplies a 5.0 volt refer
ence and a ground circuit to the Steering Handwheel
to the Steering Assist Control Solenoid. This will cause
Speed (HWSS) Sensor. The HWSS returns a voltage
the EVO Valve to retract, providing maximum fluid flow
signal to the EVO/Passlock Module indicating the steer
and full power steering assist at all times.
ing wheel position and rate of steer. The HWSS returns
a voltage 0.2 - 4.9 volts when the steering wheel has
been turned one quarter revolution (90 degrees). The CONDITIONS FOR CLEARING
EVO/Passlock Module monitors the HWSS signal volt THE DTC
age to control a PWM current (Percentage Duty Cycle)
to the Steering Assist Control Solenoid. 1. A history DTC will clear after 100 consecutive
ignition cycles have occurred without the fault
reoccurring.
CONDITIONS FOR SETTING 2. The history and current DTC(s) can be cleared
THE DTC using the Scan tool.
The HWSS signal circuit voltage is greater than
4.9 volts for one second or longer.
DIAGNOSTIC AIDS • Step 2 prompts the technician to complete some
basic checks and store the Snapshot Data. This
The Scan tool will read steering wheel position in
creates an electronic copy of the data taken when
volts. With the ignition switch in the ON position and as
the Steering Handwheel Speed Sensor is rotated, the the fault occurred. This stored information in the
voltage reading should be 0.2 - 4.9 volts. Voltage scan tool can be referred to later. When the voltage
should increase at a steady rate up to 4.9 volts when is 0.2 - 4.9 volts, the EVO/Passlock Module will use
the wheel is turned one quarter revolution (90 degrees) this voltage to detect changes steering wheel posi
in either direction. tion and the rate of steering. The system voltage
• Above 0.2 volts. should increase and decrease proportionately to
• Below 4.9 volts when the steering wheel is steering wheel rotational speed. If the voltage is not
rotated one quarter revolution (90 degrees). within specifications, an DTC will set. In addition to
Using the Scan tool, scan the HWSS. DTC diagnosis, check for binding, grinding or dam
• Above 0.2 volts. aged Steering Handwheel Speed Sensor. Refer to
• Turn the steering wheel. Supplemental Inflatable Restraint Steering Column
• The scan tool display should increase from Unit Repair.
above 0.2 volts and below 4.9 volts as the • Step 5 probes the ground circuit and checks the
steering wheel is turned one quarter revolution circuit for high resistance which will cause a DTC
(90 degrees). C0473 to set.
• Step 6 verifies a shorted 5.0 volt reference circuit
TEST DESCRIPTION may also set additional DTC’s.
The Step numbers below refer to the same step num
bers in the Steering Handwheel Speed Sensor Signal
Voltage High Diagnostic Table

SENSOR SIGNAL VOLTAGE HIGH DIAGNOSTIC TABLE
Diagnostic
System
Check.
2 1. Turn the ignition switch ON, engine OFF. 0.2 - 4.9 Go to Go to Step 3
2. Connect the scan tool. volts Diagnostic
3. Select from the Chassis Menu, Electronic Variable System
Orifice Data Display. Check.
4. Check the scan tool while turning the steering
wheel one quarter revolution (90 degrees). Slowly
return the steering wheel to center position.
5. Record a Quick Snapshot while turning the steering
wheel.
6. Review the Snapshot data.
Does the HWSS value increase and decrease steadily

to the specified value when the steering wheel is rotat
ed?
3 Operate the vehicle within the Snapshot conditions for 4.9 volts Go to Step 4 Go to Step
setting the DTC as noted. 13
Is the HWSS voltage greater than the specified value?

4 1. Turn the ignition OFF. 0.2 volts Go to Step Go to Step 6
2. Disconnect the HWSS electrical connector. 12
3. Monitor the values on the scan tool.
Is the HWSS voltage more than the specified values?

5 Using a DMM connect the negative lead to ground and 5 volts Go to Step 6 Go to Step 7
using positive lead probe sensor signal LT BLU (1059)
wire of HWSS harness connector.
Is voltage greater than specified?

2B5*16 SPEED DEPENDENT STEERING
6 LOCATE and REPAIR short to voltage In the HWSS sig Go to Step Go to Step
nal LT BLU (1059) wire. 13 12

7 Using a DMM connect the negative lead to ground and 5 volts Go to Step Go to Step 8
using positive lead probe sensor return ORN/BLK (1057) 10

8 Using a DMM connect the negative lead to ground and 5 volts Go to Step Go to Step 9
using positive lead probe 5 volt reference GRY (705) 12

9 CHECK for a short to voltage in the HWSS GRY (705) Go to Step Go to Step
wire. 13 12

10 CHECK for a short to voltage in the HWSS ORN/BLK Go to Step Go to Step
(1057) wire. 13 11

11 REPLACE the HWSS. Refer to ON-VEHICLE SERVICE. Go to Step
13
12 REPLACE the EVO/Passlock Module. Refer to ON-VE Go to Step
HICLE SERVICE. 13

13 1. Using the scan tool, clear DTC’s. Go to Step Go to Step 2
2. Start the vehicle and drive until normal operating 14
temperature is reached.
3. Select Specific, DTC, then enter the DTC number
which was set.
4. Operate the vehicle for the conditions for setting
this DTC. Refer to Conditions for Setting the DTC.
Does the scan tool display DTC C0473?

14 Using the scan tool, are any DTC’s displayed that have Go to System
not been diagnosed? Appropriate Normal
DTC table
SPEED DEPENDENT STEERING 285*17
BLANK
2B 5-18 SPEED DEPENDENT STEERING
r — —" ’ EV O /
I •Passlock
1 1Module
1 EVO \
, EVO Solenoid
1
1 FM d O utput
J
✓
A 3' Ar
0.35 WHT 1294

0.35 BRN 1295
B 3,
B2? Fr -------------- JC100
0.5 WHT 1294
0.5 BRN 1295
A- B /k
r -------- : >* Steering
■*
1 1Assist
1 1Control
1 1Solenoid
l i
L — — . J
DTC C0495 - EVO TRACKING ERROR

CIRCUIT DESCRIPTION THE DTC
The EVO/Passlock Module supplies a 0-850 milliam-
There is a open or short to ground, or short to voltage
peres PWM current (percent DUTY CYCLE) to the
in WHT (1294) or BRN (1295) w ires w hile the
Steering Assist Control Solenoid. This current is used to
EVO/Passlock Module is pulsing the current to the
extend or retract the actuator valve inside the solenoid.
Steering Assist Control Solenoid.
This in turn will regulate an orifice on the power steering
pump, causing the fluid flow output to modulate. This 1. When voltage is below 0 volts.
results in an increase or decrease in steering wheel 2. When voltage is at battery voltage.
effort. With 0 milliampere supplied to the Steering Assist
• The above conditions must be met for one sec
Control Solenoid, the valve will be fully retracted, pro
ond or longer.
viding maximum fluid flow and power steering assist.
With 850 milliamperes supplied to the Steering Assist
Control Solenoid, the valve will extend, decreasing fluid ACTION TAKEN WHEN THE
flow and m inim izing power steering assist. The DTC SETS
EVO/Passlock Module is constantly adjusting current
flow to the Steering Assist Control Solenoid based on The EVO/Passlock Module will not send any current
vehicle speed and steering wheel position rate of to the Steering Assist Control Solenoid. This will cause
change, thus providing vehicle speed related power the solenoid valve to retract, providing maximum fluid
steering assist. flow and full power steering assist at all times.
CONDITIONS FOR CLEARING TEST DESCRIPTION
THE DTC The Step numbers below refer to the same step
1. A history DTC will clear after 100 consecutivenumbers in the EVO Tracking Errors Diagnostic Table
ignition cycles have occurred without a fault.
2. History and current DTC(s) can be cleared by using • Step 1 ensures that the Diagnostic System Check
the scan tool. is performed.
• Step 2 checks for a short to voltage in WHT (1294)
or BRN (1295) wires with the EVO/Passlock Mod
DIAGNOSTIC AIDS ule disconnected.
. If DTC C0498, C0499, C0502 or DTC C0503 are
• Step 3 checks for commanded and actual duty
present, perform these code tests first.
cycle.
• An Intermittent problem may be caused by a poor
• Step 4 checks the Steering Assist Control Solenoid
harness for a short to voltage with the solenoid
disconnected on WHT (1294) or BRN (1295) wires.
insulation.
• Step 6 checks the Steering Assist Control Solenoid
• The EVO/Passlock Module and the Vehicle Control
harness for a short to ground or open with the
Module (VCM) should be thoroughly checked for
solenoid disconnected on WHT (1294) or BRN
term inals that have backed out, broken locks,
(1295) wires.
improperly formed or damaged terminals, weak ter
minal retaining tension, or for proper routing. — If voltage is indicated, there is a short to voltage
• The solenoid valve may be stuck, providing uncal on WHT (1294) or BRN (1295) wires.
culated power steering assist, refer to mechanical — If voltage is 0, there is a short to ground on
diagnosis in Power Steering Gear and Pump. WHT (1294) or BRN (1295) wires.
DTC C0495 - EVO TRACKING ERROR

DIAGNOSTIC TABLE
Diagnostic
System
Check.
2 1. Turn the ignition switch to the OFF position. Go to Go to Step 3
2. Connect the scan tool. Appropriate
3. Turn the ignition switch to the ON position. DTC Table
4. Select the Chassis Menu (EVO) and CHECK for
DTC C0498, C0499, C0502 or C0503.
Are any DTC(s) present?

3 1. Set the parking brake. Go to Go to Step 4
2. Block drive wheels. Diagnostic
3. Start the vehicle. System
4. Select the Chassis Menu, Electronic Variable Ori Check.
fice, Special Functions.
5. Command the solenoid to 0, 25, 50, 75, and 100%
ranges.
6. Monitor the commanded state of the solenoid.
Are the values equal?

4 1. Turn the ignition switch to the OFF position. Go to Step 5 Go to Step 6
2. Disconnect the 16-way EVO/Passlock Module con
nector.
3. Disconnect the Steering Assist Control Solenoid
connector.
4. Turn the ignition switch to the ON position.
5. Using a DMM, measure the voltage from terminal
A3 to ground, and then from terminal A1 to ground.
Is voltage present?
5 LOCATE and REPAIR the short to voltage in WHT Go to Go to Step 6
(1294) or BRN (1295) wires between the EVO/Passlock Diagnostic
Module and the Steering Assist Control Solenoid. System
Check.
6 1. Leave EVO/Passlock Module and Steering Assist Go to Step 7 Go to Step 8
Control Solenoid disconnected.
2. Using DMM measure for continuity from terminal A3
to ground and then from terminal A1 to ground.
Is continuity present?
7 LOCATE and REPAIR the short to ground in WHT Go to Step 9 Go to Step 8
(1294) or BRN (1295) wires between the EVO/Passlock
Module and the Steering Assist Control Solenoid.

8 Problem is intermittent. Refer to Intermittent Diagnosis
in ELECTRICAL DIAGNOSIS.
9 1. Turn the ignition switch to the OFF position. Go to

2. Reinstall removed connectors and components. Diagnostic
3. Clear DTC’s. Aids.

BLANK
r - “ - 1 EVO/
1 1Passlock
1 1Module
1 EVO 1
. EVO Solenoid I
1 Feed Output J
A3 ' f Arf
0.35 WHT 1294

0.35 BRN 1295
B 3,
B2 ' tf -------- JC100
0.5 WHT 1294
0.5 BRN 1295
A. B.
r ---- ; >* 1 Steering
1 1Assist
1 * Control
1 1Solenoid
1 i
L_ _ . J
DTC C0498 - STEERING ASSIST CONTROL SOLENOID

FEED CIRCUIT LOW
CIRCUIT DESCRIPTION DTC SETS
The EVO/Passlock Module supplies a 0-850 milliam- The EVO/Passlock Module will not send any current
peres PWM current (percent Duty Cycle) to the Steering to the Steering Assist Control Solenoid. This will cause
Assist Control Solenoid. This current is used to extend the Steering Assist Control Solenoid valve to retract,
or retract the actuator valve inside the solenoid. This in providing maximum fluid flow and full power steering
turn will regulate an orifice on the power steering pump assist at all times.
causing the fluid flow output to modulate. This results in CONDITIONS FOR CLEARING
an increase or decrease in steering wheel efforts. With
0 milliamperes supplied to the Steering Assist Control THE DTC
Solenoid, the valve will be fully retracted providing maxi 1. A history DTC will clear after 100 consecutive
mum fluid flow and power steering assist. With 850 ignition cycles have occurred without a fault.
milliamperes supplied to the Steering Assist Control 2. History and current DTC’s can be cleared by using
Solenoid the valve will extend decreasing fluid flow and the scan tool.
minimize power steering assist. The EVO/Passlock DIAGNOSTIC AIDS
Module is constantly adjusting current flow to the Steer
• An Intermittent problem may be caused by a poor
ing Assist Control Solenoid based on vehicle speed and
steering wheel position, thus providing vehicle speed
related power steering assist. the internal wire, or a wire that is broken inside the
insulation.
CONDITIONS FOR SETTING Module (VCM) or Powertrain Control Module (PCM)
THE DTC should be thoroughly checked for terminals that
have backed out, broken locks, improperly formed
1. There is a open or short to ground in WHT (1294) or damaged terminals, weak terminal retaining
wire. tension, or for proper routing.
2. When the ignition switch has been cycled to the • The Steering Assist Control Solenoid valve may be
OFF and then to the ON position. stuck, providing uncalculated power steering assist.
3. The above conditions must be met for one second For mechanical diagnosis, refer to Power Steering
or longer. Gear and Pump.
TEST DESCRIPTION • Step 2 will determine if the Steering Assist Control
Solenoid is open.
The step numbers below refer to the same step • Step 3 will determine if the Steering Assist Control
numbers in the Steering Assist Control Solenoid Feed Solenoid is shorted to ground.
Circuit Low Diagnostic Table. • Step 4 checks for a open or short to ground in
• Step 1 ensures that the Diagnostic System Check WHT (1294) wire.
is performed.
DTC C0498 ■ STEERING ASSIST CONTROL SOLENOID

FEED CIRCUIT LOW
Diagnostic
System
Check.
2 1. Turn ignition to OFF position. 7-15 ohms Go to Step 3 Go to Step 5
connector.
3. Using DMM measure the resistance at the Steering
Assist Control Solenoid between terminal, A and B.
Is the resistance within specifications?

3 1. D is c o n n e c t the 1 6-w ay c o n n e c to r at the Go to Step 6 Go to Step 4
2. Leave Steering Assist Control Solenoid disconnect
ed.
3. At the Steering Assist Control Solenoid, CHECK for
continuity in WHT (1294) wire from terminal A to
ground.
Does the DMM display continuity?

4 1. Reconnect the Steering Assist Control Solenoid. Go to Step 8 Go to Step 7
2. Leave the 16-way connector at the EVO/Passlock
Module disconnected.
3. Using DMM CHECK for continuity between the
16-way EVO/Passlock Module connector (harness
side) from terminal A1 to A3.
Is there continuity ?
5 Replace the Steering Assist Control Solenoid. Refer to Go to Step 9
ON-VEHICLE SERVICE.

6 1. LOCATE and REPAIR short to ground in WHT Go to
(1294) wire between the Steering Assist Control Diagnostic
Solenoid and the EVO/Passlock Module. System
2. Install connectors and components removed. Check.

7 LOCATE and REPAIR open in WHT (1294) wire. Go to Step 9
Was a problem found?

8 REPLACE EVO/Passlock Module. Refer to ON-VEHI- Go to Step 9
CLE SERVICE.

9 1. Install removed connectors and components. Go to
2. Clear DTC’s. Diagnostic
System.
r ~ - ’ EVO/
1 1Passlock
1 1Module
1 EVO 1
. EVO Solenoid
1
1 FMd Output
A 3' f
AT
0.35 WHT 1294

0.35 BRN 1295
B2 ' t
r ----------------- _______________ ?C100
0.5 WHT 1294
0.5 BRN 1295
A .t B,
p ---- ; / 1 Steering
1 1Assist
1 1Control
1 1Solenoid
1 l
L_ _ . j

FEED CIRCUIT HIGH
CIRCUIT DESCRIPTION DTC SETS
The EVO/Passlock Module supplies a 0-850 milliam- The EVO/Passlock Module will not send any current
peres PWM current (percent Duty Cycle) to the Steering to the Steering Assist Control Solenoid. This will cause
Assist Control Solenoid. This current is used to extend the Steering Assist Control Solenoid valve to retract,
or retract the actuator valve inside the solenoid. This in providing maximum fluid flow and full power steering
turn will regulate an orifice on the power steering pump, assist at all times.
causing the fluid flow output to modulate. This results in CONDITIONS FOR CLEARING
0 milliampere supplied to the Steering Assist Control
THE DTC
Solenoid, the valve will be fully retracted, providing 1. A history DTC will clear after 100 consecutive
maximum fluid flow and power steering assist. With
850 milliamperes supplied to the Steering Assist Control
the scan tool.
Solenoid, the valve will extend, decreasing fluid flow
and m in im iz in g p o w e r s t e e r in g a s s is t . The DIAGNOSTIC AIDS
EVO/Passlock Module is constantly adjusting current • An Intermittent problem may be caused by a poor
flow to the Steering Assist Control Solenoid based on connection, break in the wire insulation exposing
vehicle speed and steering wheel position, thus provid the internal wire, or a wire that is broken inside the
ing vehicle speed related power steering assist. insulation.
Module (VCM) or Powertrain Control Module (PCM)
CONDITIONS FOR SETTING should be thoroughly checked for terminals that
THE DTC have backed out, broken locks, improperly formed
or damaged terminals, weak terminal retaining ten
1. There is a short to voltage in WHT (1294) wire. sion, or proper routing.
2. The ignition switch has been cycled to the OFF and • The Steering Assist Control Solenoid valve may be
then to the ON position. stuck, providing uncalculated power steering assist.
3. The above conditions must be met for one second For mechanical diagnosis, refer to Power Steering
or longer. Gear and Pump.
TEST DESCRIPTION • Step 2 checks for short to voltage in WHT (1294)
wire with the EVO/Passlock Module disconnected.
The step numbers below refer to the same step num • Step 3 checks the Steering Assist Control Solenoid
bers in the Steering Assist Control Solenoid Feed Cir harness for a short to voltage with the actuator
cuit High Diagnostic Table. disconnected.
• Step 1 ensures that the Diagnostic System Check — If voltage is indicated, there is a short to voltage
is performed. on WHT (1294) wire.
FEED CIRCUIT HIGH
Diagnostic
System
Check.
2 1. Turn the ignition switch to the OFF position. Over 1.0 volt Go to Step 3 Go to Step 7
nector
4. Using DMM, measure voltage between the
EVO/Passlock Module connector (harness side) ter
minal A3 to ground.
Did the voltmeter display a voltage?

connector.
4. At the Steering Assist Control Solenoid connector
(harness side), measure the voltage between termi
nal A and ground.
Did the DMM display a voltage?

4 1. Turn the ignition switch to the OFF position. 7-15 ohms Go to Step 7 Go to Step 6
2. Using DMM, measure the resistance between termi
nals A and B.
Does the DMM display correct resistance values?

5 LOCATE and REPAIR short to voltage in WHT (1294) Go to Step 9
wire.

6 REPLACE the Steering Assist Control Solenoid. Refer Go to Step 9
to ON-VEHICLE SERVICE.

7 1. CHECK the Steering Assist Control Solenoid con Go to Step 5 Go to Step 8
nector and harness for intermittent short to voltage.
2. CHECK for intermittent short to voltage on WHT
(1294) wire.

8 REPLACE the EVO/Passlock Module. Refer to ON-VE Go to
HICLE SERVICE. Diagnostic
System
2. Install removed connectors or components. Diagnostic

r —— - ■•EVO/
1 1Passlock
1 1Module
l EVO 1
. EVO Solenoid
1 FM d Output 1
A 3' / AV /
0.35 WHT 1294

0.35 BRN 1295
B 3,
B2 ' r ------- ------ JC100
0.5 WHT 1294
0.5 BRN 1295
A- B, L
r ---- : > ■•Steering
1 1Assist
1 1Control
1 I Solenoid
1 1
L_ _ . j

RETURN CIRCUIT LOW
C IRCU IT DESCRIPTION THE DTC
1. There is a open or short to ground in BRN (1295)
peres PWM current (percent Duty Cycle) to the Steering
wire.
Assist Control Solenoid. This current is used to extend
2. The ignition switch has been cycled to the OFF and
or retract the actuator valve inside the solenoid. This in
then to the ON position.
turn will regulate an orifice on the power steering pump,
3. The above conditions must be met for one second
causing the fluid flow output to modulate. This results in
or longer.
0 milliamperes supplied to the Steering Assist Control
Solenoid, the valve will be fully retracted, providing ACTION TAKEN WHEN THE
maximum fluid flow and power steering assist. With 850 DTC SETS
milliamperes supplied to the Steering Assist Control
Solenoid, the valve will extend decreasing fluid flow and The EVO/Passlock Module will not send any current
minimizing power steering assist. The EVO/Passlock to the Steering Assist Control Solenoid. This will cause
Module is constantly adjusting current flow to the Steer the Steering Assist Control Solenoid valve to retract
ing Assist Control Solenoid based on vehicle speed and providing maximum fluid flow and full power steering
steering wheel position, thus providing vehicle speed assist at all times.
related power steering assist.
THE DTC
1. A history DTC will clear after 100 consecutive
2. History and current DTC’s can be cleared by using
the scan tool.
DIAGNOSTIC AIDS TEST DESCRIPTION
• An Intermittent problem may be caused by a poor The step numbers below refer to the same step
numbers in the Steering Assist Control Solenoid Return
Circuit Low Diagnostic Table.
• Step 1 ensures that the Diagnostic System Check
insulation.
is performed.
• The EVO/Passlock Module and the Vehicle Control • Step 2 will determine if the Steering Assist Control
Module (VCM) or Powertrain Control Module (PCM) Solenoid is open.
should be thoroughly checked for terminals that • Step 3 will determine if the Steering Assist Control
have backed out, broken locks, improperly formed Solenoid is shorted to ground.
or damaged terminals, weak terminal retaining • Step 4 checks for a short or open to ground in BRN
tension, or for proper routing. (1295) wire.
• The Steering Assist Control Solenoid valve may be
stuck providing uncalculated power steering assist.
For mechanical diagnosis, refer to Power Steering
Gear and Pump.

RETURN CIRCUIT LOW
Diagnostic
System
Check.
2 1. Turn ignition to OFF position. 7-15 ohms Go to Step 3 Go to Step 5
connector.
3. Using DMM, measure the resistance at the Steering
Assist Control Solenoid between terminals A and B.
Is the resistance within specifications?

3 1. D is c o n n e c t the 16 - w a y . c o n n e c to r at the Go to Step 6 Go to Step 4
2. Leave Steering Assist Control Solenoid disconnect
ed.
3. At the Steering Assist Control Solenoid, CHECK for
continuity in BRN (1295) wire terminal B to ground.
Does the DMM display continuity?

4 1. Connect the Steering Assist Control Solenoid. Go to Step 8 Go to Step 7
2. Leave the 16-way connector at the EVO/Passlock
Module disconnected.
3. Using DMM, CHECK for continuity between the
16-way EVO/Passlock Module connector (harness
side) terminals A1 to A3.
Is there continuity?
5 Replace the Steering Assist Control Solenoid. Refer to Go to Step 9
ON-VEHICLE SERVICE.

6 1. LOCATE and REPAIR short to ground In BRN Go to
(1295) wire between the Steering Assist Control Diagnostic
Solenoid and the EVO/Passlock Module. System
2. Install connectors and components removed. Check.

7 LOCATE and REPAIR open in BRN (1295) wire. Go to Step 9

8 REPLACE EVO/Passlock Module. Refer to ON-VEHI- Go to Step 9
CLE SERVICE.

9 1. Install removed connectors and components. Go to
2. Clear DTC’s. Diagnostic
System
p — “ ”
1 1Passlock
1 1Module
1 EVO |
. EVO Solenoid .
1 Feed O utput |
A3' t Ar/
0.35 WHT 1294

0.35 BRN 1295
B3,
B2! ; -------------- JC100
0.5 WHT 1294
0.5 BRN 1295
A, B.
p -------- ; > i steering
1 1Assist
1 1Control
1 1Solenoid
1 1
L _ _ .

CIRCUIT HIGH
CIRCUIT DESCRIPTION
DTC SETS
peres PWM current (percent Duty Cycle) to the Steering The EVO/Passlock Module will not send any current
Assist Control Solenoid. This current is used to extend to the Steering Assist Control Solenoid. This will result
or retract the actuator valve inside the solenoid. This in in the Steering Assist Control Solenoid valve to retract
turn will regulate an orifice on the power steering pump, providing maximum fluid flow and full power steering
causing the fluid flow out-put to modulate. This results assist at all times.
in an increase or decrease in steering wheel effort. With
0 milliampere supplied to the Steering Assist Control CONDITIONS FOR CLEARING
Solenoid, the valve will be fully retracted, providing THE DTC
maximum fluid flow and power steering assist. With 850
1. A history DTC will dear after 100 consecutive igni
milliamperes supplied to the Steering Assist Control
tion cycles have occurred without a fault.
Solenoid, the valve will extend decreasing fluid flow and
minimize power steering assist. The EVO/Passlock
the scan tool.
Module is constantly adjusting current flow to the Steer
ing Assist Control Solenoid based on vehicle speed and
steering wheel position, thus providing vehicle speed DIAGNOSTIC AIDS
related power steering assist. • An Intermittent problem may be caused by a poor
CONDITIONS FOR SETTING the internal wire, or a wire that is broken inside the
insulation.
THE DTC • The EVO/Passlock Module and the Vehicle Control
1. There is a short to voltage in BRN (1295) wire. Module (VCM) or Powertrain Control Module (PCM)
2. The ignition switch has been cycled to the OFF and should be thoroughly checked for terminals that
then to the ON position. have backed out, broken locks, improperly formed
3. The above conditions must be met for one second or damaged terminals, weak terminal retaining ten
or longer. sion, or for proper routing.
• The Steering Assist Control Solenoid valve may be • Step 2 checks for short to voltage in BRN (1295)
stuck, providing uncalculated power steering assist. wire with the EVO/Passlock Module disconnected.
For mechanical diagnosis, refer to Power Steering • Step 3 checks the Steering Assist Control Solenoid
Gear and Pump. harness for a short to voltage with the actuator
disconnected.
TEST DESCRIPTION — If voltage is indicated, there is a short to voltage
The step numbers below refer to the same step num on BRN (1295) wire.
bers in the Steering Assist Control Solenoid Circuit High
Diagnostic Table.
• Step 1 ensures that the Diagnostic System Check
is performed.

CIRCUIT HIGH
Diagnostic
System
Check.
nector.
4. Using a DMM, measure voltage between the
EVO/Passlock Module connector (harness side) ter
minal A1 to ground.
Did the voltmeter display a voltage?

connector.
4. At the Steering Assist Control Solenoid connector
(harness side), measure the voltage between termi
nal B to ground.
Did the DMM display a voltage?

4 1. Turn the ignition switch to the OFF position. Between Go to Step 7 Go to Step 6
2. Using DMM measure the resistance from terminal A 7-15 ohms
to terminal B.
Does the DMM display correct resistance values?

5 LOCATE and REPAIR short to voltage in BRN (1295) Go to Step 9
wire.

6 REPLACE the Steering Assist Control Solenoid. Refer Go to Step 9
to ON-VEHICLE SERVICE.

7 1. CHECK the Steering Assist Control Solenoid con Go to Step 5 Go to Step 8
nector and harness for intermittent short to voltage.
2. CHECK for intermittent short to voltage on WHT
(1294) wire.

8 REPLACE the EVO/Passlock Module. Refer to ON-VE Go to
HICLE SERVICE. Diagnostic
System
2. Install removed connectors or components. Diagnostic

BLANK
I H ot In Run O r Start I I H ot At All Tim es] ABS

-IP Controls
2 Fuse
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Fuse 4
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20 A
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1807 B7 1807
0.8 PNK 39 Distribution - —i
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Fuse Block
^ 0.35 ORN 1740 S215 0.5 PPL 1807
Details
Ce> 11
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1 BLK/WHT 451 0.5
0.35 PNK 39
EVO/
B3 k B8 J B4JL B1
PPL 1807 0.5 PPL 1807
I Q as|
Ignition Battery Serial G round
Passlock Feed D ata
Module Claes 2
D ata
Unk
C onnector
0.5 PPL 1807
1 BLK/WHT 451 0.5 PPL 1807
<Qas) F
(D iesel) K l C200
11 C4 C8_ C3
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1 BLK/WHT 451 1Da? 'Control 1olta 'train
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1 BLK/WHT 451
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D istribution S103
C ell 14
1 BLK/WHT 451
1 BLK/WHT 451
(Diesel)
G103 (G as) LG104 (G as)
DTC C0559 - EEPROM CHECKSUM ERROR

CIRCUIT DESCRIPTION THE DTC
The EVO/Passlock Module calibrations are stored in After the ignition is cycled no internal calibration faults
the EEPROM (Electrically Erasable Programmable (checksum errors) are indicated by the EVO/Passlock
Read Only Memory). The EVO/Passlock Module per Module, or when the EVO/Passlock Module is properly
forms internal tests on the EEPROM and will indicate if programmed.
any calibration faults (checksum errors) are current.
DIAGNOSTIC AIDS
CONDITIONS FOR SETTING T h e E E P R O M is n o t re m o v a b le fro m th e
EVO/Passlock Module. If service is required, the mod
THE DTC ule must be replaced. Refer to ON-VEHICLE SERVICE.
When an internal calibration failure (checksum error)
is detected by the EVO/Passlock Module, a code TEST DESCRIPTION
will set. The numbers below refer to the step numbers on the
EEPROM Checksum Error Diagnostic Table.
ACTION TAKEN WHEN THE • Step 1 makes sure the Diagnostic System Check is
completed.
DTC SETS • Step 2 checks if the EVO/Passlock Module was
previously replaced.
to the Steering Assist Control Solenoid. This will cause
the Steering Assist Control Solenoid valve to retract
providing maximum fluid flow at all times.
DTC C0559 - EEPROM CHECKSUM ERROR

DIAGHOSTIC TABLE
1 Was the Diagnostic System Check performed? Go to Step 2 Go to Diag
nostic
System
Check.
2 1. Cycle the ignition OFF then ON. Go to Step 3 Go to Diag
2. Clear DTC’s. nostic
System
Is DTC C0559 set? Check.
3 1. REPLACE the EVO/Passlock Module. Refer to Go to Diag
ON-VEHICLE SERVICE. nostic
System
ON-VEHICLE SERVICE
STEERING ASSIST CONTROL variable orifice solenoid to the pump.
SOLENOID, DISCHARGE Tighten
FITTING , AND FLOW CONTROL • Steering Assist Control Solenoid to 62 N.m
VALVE (46 Lb ft).
2. Power steering pump to vehicle. Refer to Power
Remove or Disconnect Steering Pump Replacement in Power Steering
Gear and Pump.
1. Power steering pump from vehicle. Refer to Power
Steering Gear and Pump. ELECTRONIC VARIABLE
2. Power steering Steering Assist Control Solenoid,
discharge fitting, and flow control valve. Refer to ORIFICE (EVO)/PASSLOCK
Power Steering Pump Service in Power Steering MODULE
Pump Unit Repair.
■M- Install or Connect
1. Negative battery cable. Refer to Battery Disconnect
1. Flow control valve, discharge fitting, and electronic Caution in General Information.
2. Knee bolster. Refer to Knee Bolster Replacement
in Instrument Panel and Gauges.
3. IP auxiliary storage compartment. Refer to Instru
ment Panel and Gauges.
4. Ashtray. Refer to Ashtray Replacement in Instru
5. Electrical connector.
• Pull down on module to release.
1. Electrical connector.
• Slide in rear tabs and push up to engage mod
ule.
2. Ashtray. Refer to Ashtray Replacement in Instru
3. IP auxiliary storage compartment. Refer to Instru
4. Knee bolster. Refer to Knee Bolster Replacement
in Instrument Panel and Gauges.
Caution in General Information.
Figure 6—Position Sensor Removal

STEERING HANDWHEEL SPEED 6. Position sensor from clips in bearing assembly.
(HWSS) SENSOR -►4- Install or Connect

El Remove or Disconnect 1. Position sensor into bearing assembly.
• Set front wheels in the straight-ahead position and 2. Bearing into steering column jacket. Align notches
the steering wheel in the LOCKED position. on bearing and column jacket and seat bearing
1. Negative battery cable. Refer to Battery Disconnect fully into jacket. Use care not to apply force to
Caution in General Information. sensor and bearing in a sideways direction.
2. Disable the (SIR). Refer to Disabling the SIR 3. Position sensor connector.
System in Restraints. 4. Bolt and nut to upper end of shaft.
3. Nut and bolt from upper to lower steering shaft
connection. Slide lower shaft down. Tighten
4. Position sensor connector by using suitable tool to
pull connector down around the right side of steer • Nut to 62 N.m (46 Lb ft).
ing column for accessibility.
5. Position sensor and bearing assembly from steer 5. Negative battery cable.
ing column jacket by pulling straight out (Figure 6). 6. Enable the SIR system. Refer to Enabling the SIR
Use care not to apply force to sensor and bearing System in Restraints.
in a sideways direction.
SPECIFICATIONS
Application N.m Lb ft Lb in
Inlet Power Steering Pipe to the Steering Assist Control 62 46 —
Solenoid
Steering Assist Control Solenoid to the Power Steering 28 21 —
Pump
Upper to Lower Steering Shaft Bolt 62 46 —
SPECIAL TOOLS
1. TECH 2 SCAN TOOL

2. J 39200 DIGITAL MULTIMETER (DMM)
BLANK
STEERING WHEEL AND COLUMN ON-VEHICLE SERVICE 2F-1
SECTION 2F
STEERING WHEEL AND COLUMN

ON-VEHICLE SERVICE
GENERAL DESCRIPTION
The steering wheel and column components include a BRAKE TRANSMISSION SHIFT
steering wheel, horn pad or inflator module, steering
column, and brackets. INTERLOCK (BTSI)
The locking, energy-absorbing, steering column
includes three important features in addition to the The brake transmission shift interlock (BTSI) system
steering function. prevents the automatic transmission from being shifted
1. The column is energy-absorbing, designed to com out of PARK unless the brake pedal is depressed.
press in a front-end collision to minimize the possi When the brake pedal is depressed, the BTSI solenoid
bility of injury to the driver of the vehicle. releases a lock paw, enabling the shift linkage to move
2. The ignition switch and lock are mounted conve and the shift lever to operate.
niently on the column. When service operations are required, the BTSI sys
3. With the column mounted lock, the ignition, steer tem can be overridden. This is done by turning the
ing, and gearshifting operation can be locked to ignition switch to OFF (not locked) and removing battery
inhibit theft of the vehicle. voltage from the solenoid.
The column may be disassembled and reassembled.
To ensure the energy absorbing action, it is important SUPPLEMENTAL INFLATABLE
that the specified screws, bolts, and nuts be used only
as designated and they are tightened to the specified RESTRAINT (SIR)
torque. The supplemental inflatable restraint (SIR) system
NOTICE: When the column is removed from supplements the normal restraint of the driver’s seat
the vehicle, actions such as a sharp blow on belt by deploying an air bag from the center of the
the end o f the steering shaft or shift lever, steering wheel during an accident. The air bag deploys
leaning on the column assembly, or dropping when the vehicle is involved in a front end collision of
the assem bly could shear or loosen the plas sufficient force. Refer to Supplemental Inflatable
tic fasteners that maintain column rigidity. Restraint (SIR) System Operation in SIR.
DIAGNOSIS
IG NITIO N LOCK SYSTEM REPAIRS and INSPECTIONS
Refer to Diagnosis of the Steering Column in REQUIRED AFTER an ACCIDENT
this section.
Refer to Repairs and Inspections Required After an
Accident in SIR.
DIAGNOSIS OF THE STEERING COLUMN

Lock System Will Not Unlock
STEP CAUSE/ACTION YES NO
1 Damaged Shaft Assembly? Go to Step 2. Go to Step 3.
2 Repair or replace shaft as needed. Go to Unit Repair.
3 Damaged shear bolts? Go to Step 4. Go to Step 5.
4 Replace shear bolts. Go to Unit Repair.
5 Damaged housing assembly? Go to Step 6. Go to Step 7.
6 Replace housing assembly. Go to Unit Repair.
2F-2 STEERING WHEEL AND COLUMN ON-VEHICLE SERVICE
7 Damaged BTSI system? Go to Step 8. Go to Step 9.
8 Repair or replace as needed. Go to Unit Repair.
9 Damaged ignition switch assembly? Go to Step 10. Go to Step 11.
10 Replace ignition switch assembly. Go to Unit Repair.
11 Park lock cable misadjusted? Go to Step 12. Go to Step 13.
12 Adjust park lock cable. Go to Unit Repair.
13 Shift lever not in “ PARK” . Go to Step 14. Go to Step 15.
14 Place gear shifter in “ PARK” position. Go to Unit Repair.
15 Incorrect, bent or twisted key? Go to Step 16.
16 Replace key. Go to Unit Repair.
Lock System Will Not Lock

1 Damaged shear bolts? Go to Step 2. Go to Step 3.
2 Replace shear bolts. Go to Unit Repair.
5 Improper shift linkage adjustment? Go to Step 6 Go to Step 7
6 Adjust shift linkage adjustment. Go to Unit Repair.
9 Damaged shaft assembly? Go to Step 10. Go to Step 11.
10 Replace as needed. Go to Unit Repair.
- 12 Replace ignition switch assembly. Go to Unit Repair.
13 Incorrect, bent or twisted key? Go to Step 14. Go to Step 15.
14 Replace key. Go to Unit Repair.
17 Shift lever not in “ PARK” ? Go to Step 18.
18 Place gear shifter in “ PARK” position. Go to Unit Repair.
Lock System-High Effort

3 Damaged lock cylinder housing assembly? Go to Step 4. Go to Step 5.
4 Replace lock cylinder housing. Go to Unit Repair.
6 Replace shaft assembly. Go to Unit Repair.
9 Improper shaft linkage adjustment? Go to Step 10. Go to Step 11.
10 Adjust shift linkage adjustment. Go to Unit Repair.
11 Broken or weak rack preload spring? Go to Step 12. Go to Step 13.
12 Replace rack preload spring. Go to Unit Repair.
16 Replace key. Exit.
17 Bent or broken rack? Go to Step 18.
18 Replace rack. Go to Unit Repair.
Lock Cylinder High Effort Between the “OFF” and “OFF-LOCK”
Positions
1 Distorted rack? Go to Step 2.
2 Repair or replace as required. Go to Unit Repair.
Lock Cylinder-Sticks in “START” Position

2 Repair or replace as required. Go to Unit Repair.
6 Replace shaft assembly. Exit.
7 Park lock cable misadjusted? Go to Step 8.
Key Cannot Be Removed in the “OFF-LOCK” Position

1 Damaged shaft system? Go to Step 2. Go to Step 3.
2 Replace shaft assembly. Go to Unit Repair.
3 Damaged housing assembly? Go to Step 4. Go to Step 5."
6 Repair or Replace as required. Go to Unit Repair.
8 Replace key. Exit.
9 Park lock cable misadjusted? Go to Step 10.
Steering Vibrates, (Shudders), During Low Speed or S tatic Steering

1 Air in system? Go to Step 2. Go to Step 3.
2 Bleed air from power steering system. Exit.
3 Loose power steering belt? Go to Step 4.
4 Tighten power steering belt. Exit.
Noise in the Column

1 Worn or broken lower or upper steering column Go to Step 2. Go to Step 3.
jacket bushing assembly.
2 Replace bushing. Go to Unit Repair.
3 Column not correctly aligned? Go to Step 4. Go to Step 5.
4 Align column correctly. Go to Unit Repair.
5 Horn contact ring not lubricated? Go to Step 6. Go to Step 7.
6 Lubricate horn contact ring. Go to Unit Repair.
7 Lack of grease on bearing or bearing surface? Go to Step 8. Go to Step 9.
8 Lubricate bearings and surfaces. Go to Unit Repair.
9 Retaining ring not sealed? Go to Step 10. Go to Step 11.
10 Seat retaining ring. Go to Unit Repair.
11 Sheared intermediate shaft plastic joint? Go to Step 12. Go to Step 13.
12 Replace intermediate shaft. Go to Unit Repair.
13 Loose column components? Go to Step 14. Go to Step 15.
14 Replace loose components. Exit.
15 Unlubricated spherical joints? Go to Step 16. Go to Step 17.
16 Lubricate spherical joints. Exit.
17 Loose steering coupling? Go to Step 18. Go to Step 19.
18 Tighten steering coupling. Go to Unit Repair.
19 Joints from column to gear loose? Go to Step 20. Go to Step 21.
20 Tighten all connectors. Go to Unit Repair.
21 Loose intermediate shaft pinch bolt? Go to Step 22.
22 Tighten pinch bolt to specified torque. Go to Unit Repair.
High Steering Shaft Effort

1 Column assembly is misaligned? Go to Step 2. Go to Step 3.
2 Align column correctly. Go to Unit Repair.
3 Worn or broken lower or upper steering column Go to Step 4.
jacket bushing assembly?
4 Replace bushing assembly. Go to Unit Repair.
Lash in Mounted Column

1 Column mounting bracket bolts loose? Go to Step 2. Go to Step 3.
2 Tighten connection. Go to Unit Repair.
3 Broken weld nut on jacket? Go to Step 4. Go to Step 5.
4 Replace jacket assembly. Go to Unit Repair.
5 Column bracket capsule sheared? Go to Step 4. Go to Step 6.
6 Loose tilt head pivot pins? Go to Step 4. Go to Step 7.
7 Loose shoe lock pin in support? Go to Step 4. Go to Step 8.
8 Loose support screws? Go to Step 9. Go to Step 10.
9 Tighten support screws. Go to Unit Repair.
10 Loose column upper and lower bracket to jacket Go to Step 11. Go to Step 12.
bolts?
11 Tighten bolts to specified torque. Go to Unit Repair.
12 Loose lower bracket to adapter and bearing Go to Step 13. Go to Step 14.
assembly, mounting bolts?
13 Tighten mounting screws to specified torque. Go to Unit Repair.
14 Loose I.P. to jacket mounting bolts? Go to Step 15.
15 Tighten mounting bolts to specified torque. Go to Unit Repair.
Steering W heel Loose

1 Excessive clearance between holes in support or Go to Step 2. Go to Step 3.
housing and pivot pin diameter?
2 Inspect A. Is support out of round? B. Is housing Go to Unit Repair. Go to Step 3.
damaged? C. Is the pivot pin seated correctly?
3 Broken or missing joint preload spring? Go to Step 4. Go to Step 5.
4 Replace joint preload spring. Go to Unit Repair. Go to Step 5.
5 Upper bearing not seated in housing? Go to Step 6. Go to Step 7.
6 Seat bearing in housing. Go to Unit Repair.
7 Missing upper bearing inner race seal? Go to Step 8. Go to Step 9.
8 Replace inner race seal. Go to Unit Repair.
9 Loose support screws? Go to Step 10.
10 Tighten screws to specified torque. Go to Unit Repair.
Steering Wheel Loose in every other Tilt Position

1 Loose fit between shoe and show pivot/dowel Go to Step 2. Go to Step 3.
pin?
2 Replace pivot/dowel pin. Go to Unit Repair.
3 Shoe not in free slot (both shoes engaged on pin Go to Step 4.
at the same time)?
4 Check for proper shoes and replace if necessary. Go to Unit Repair.
Steering Wheel not Locking in any T ilt Position

1 Shoe seized on pivot pin? Go to Step 2. Go to Step 3.
2 Replace the shoes and pivot pin. Go to Unit Repair.
3 Burrs or dirt in shoe grooves? Go to Step 4. Go to Step 5.
4 Remove burrs and dirt from grooves. Exit.
5 Weak or broken shoe lock spring? Go to Step 6.
6 Replace shoe lock spring. Go to Unit Repair.
Steering W heel Fails to Return to Top T ilt Position

1 Binding pivot pins? Go to Step 2. Go to Step 3.
2 Lubricate end of pivot pin. Go to Unit Repair.
3 Broken or weak wheel tilt spring? Go to Step 4. Go to Step 5.
4 Replace tilt spring. Go to Unit Repair.
5 Binding wire harness. Go to Step 6.
6 Loosen screws, reposition wires. Exit.
Noise when Tilting Column

1 Worn upper tilt bumpers? Go to Step 2. Go to Step 3.
2 Replace support assembly. Go to Unit Repair.
3 Unlubricated tilt spheres? Go to Step 4.
4 Lubricate tilt spheres. Go to Unit Repair.
Pivot and Sw itch Assembly Inoperative: No “LOW,” “HIGH”

and/or “WASH”
1 Loose body to switch connector? Go to Step 2. Go to Step 3.
2 Tighten connection, check operation. Exit.
3 Internally damaged or worn switch? Go to Step 4.
4 Replace switch. Go to Unit Repair.
Ignition Sw itch: E lectrical System w ill not Function
1 Damaged ignition switch? Go to Step 2. Go to Step 3.
3 Loose connection at the ignition switch or column Go to Step 4.
connectors?
4 Connect securely, check operation. Go to Unit Repair.
Ignition Sw itch w ill not Turn

1 Damaged ignition switch? Go to Step 2.
H im Signal Sw itch w ill not Cancel

1 Broken, missing, or out of position detent, return Go to Step 2. Go to Step 3.
or canceling spring?
2 Replace turn signal switch. Go to Unit Repair.
3 Loose switch mounting screws? Go to Step 4. Go to Step 5.
4 Tighten screws to specified torque. Go to Unit Repair.
5 Broken switch? Go to Step 6. Go to Step 7.
7 Uneven or canceling cam to canceling spring Go to Step 8.
interference?
8 Inspect canceling cam & switch (replace Go to Unit Repair.
damaged parts).
Tkirn Signal Difficult to O perate

Broken switch? Go to Step 2. Go to Step 3.
2 Replace turn signal switch. . Go to Unit Repair.
3 Switch mounted loosely? Go to Step 4. Go to Step 5.
4 Install switch correctly. Go to Unit Repair.
5 Foreign material? Go to Step 6.
6 Remove foreign material. Exit.
H im Signal w ill not Indicate Lane Change

1 Broken switch? Go to Step 2. Go to Step 3.
3 Broken lane change pressure pad or spring Go to Step 4. Go to Step 5.
hanger?
5 Jammed base wires? Go to Step 6.
6 Reposition wire harness. Go to Unit Repair.
ttirn Signal w ill not Stay in TUrn Position

Broken switch? Go to Step 2. Go to Step 3.
3 Foreign material or loose parts impeding move Go to Step 4. Go to Step 5.
ment of the switch?
5 Broken or missing detent? Go to Step 6.
Hazard Sw itch cannot be Tlirned Off

1 Damaged turn signal switch? Go to Step 2. Go to Step 3.
3 Foreign material? Go to Step 4.
Hazard Sw itch w ill not Stay On or Difficult to Turn Off

1 Loose turn signal switch? Go to Step 2. Go to Step 3.
2 Tighten turn signal switch to correct torque. Go to Unit Repair.
3 Interference with other components? Go to Step 4. Go to Step 5.
4 Reposition components. Exit.
5 Foreign material? Go to Step 6. Go to Step 7.
7 Damaged or broken turn signal switch? Go to Step 8.
No Turn Signal Lights

1 Damaged turn signal lights? Go to Step 2. Go to Step 3.
2 Replace bulbs. Exit.
3 Electrical failure in wiring harness? Go to Step 4. Go to Step 5.
4 Replace turn signal switch if damage is on Go to Unit Repair.
column side of connection.
5 Inoperative turn signal flasher? Go to Step 6. Go to Step 7.
6 Replace turn signal flasher. Go to Unit Repair.
7 Loose turn signal switch connector? Go to Step 8. Go to Step 9.
8 Tighten all wiring connectors. Go to Unit Repair.
9 Blown fuse? Go to Step 10.
10 Replace fuse. Exit.
T u rn Indicator Light On, But Not Flashing

1 Inoperative turn signal flasher? Go to Step 2. Go to Step 3.
2 Replace turn signal flashers. Exit.
3 Inoperative turn signal switch? Go to Step 4. Go to Step 5.
5 High resistance connection? Go to Step 6.
6 Inspect and repair connections. Go to Unit Repair.
Front or Rear Turn Signal Lights Not Flashing
1 Burned-out or damaged turn signal bulb? Go to Step 2. Go to Step 3.
3 High resistance connection to ground at bulb Go to Step 4. Go to Step 5.
socket?
4 Check for shorts to ground. Exit.
5 Loose turn signal switch connection? Go to Step 6.
6 Reconnect turn signal switch. Go to Unit Repair.
Turn Indicator Panel Lights

1 Burned-out or damaged bulbs? Go to Step 2. Go to Step 3.
3 Opens or grounds in wiring harness? Go to Step 4.
4 Inspect for broken wires or damaged terminals Exit.
and repair if necessary.
Hazard Signal Lights W ill Not Flash - Turn Signal Norm al Operation
1 Blown fuse? Go to Step 2. Go to Step 3.
2 Replace fuse. Exit.
3 Inoperative hazard warning flasher? Go to Step 4. Go to Step 5.
4 Replace multifunction switch. Go to Unit Repair.
5 Loose turn signal switch connection? Go to Step 6.
6 Check wire harness connection. Go to Unit Repair.
Turn Signal Lights Flash Very Slow

1 Loose turn signal connection? Go to Step 2.
2 Check wire harness connection. Exit.
ON-VEHICLE SERVICE
SERVICE PRECAUTIONS - Disabling the SIR System
For procedure to disable the SIR system, refer to
SUPPLEMENTAL INFLATABLE Disabling the SIR System in SIR.
RESTRAINT Enabling the SIR System
CAUTION: When perform ing service on or For procedure to enable the SIR system, refer to
around SIR components or wiring, follow the Enabling the SIR System in SIR.
procedures listed in SIR Service Precautions Live (Undeployed) Inflator Module Handling
in SIR to temporarily disable the SIR system. Special care is necessary when handling and storing
Failure to follow procedures could result in a live (undeployed) inflator module. The rapid gas gen
possible air bag deployment, personal injury eration produced during deployment of the air bag could
or otherwise unneeded SIR repairs. cause the inflator module, or another object placed in
front of the inflator module, to be thrown through the air
in the unlikely event of an accidental deployment.
CAUTION: When carrying a live inflator mod IGNITION SWITCH
ule, make sure the bag opening cover is
pointed away from you. In case of accidental Refer to Ignition and Key Alarm Switch in Standard
deployment, the bag will then deploy with a Steering Column Unit Repair or Tilt Steering Column
minimal chance of injury. Never carry the Unit Repair.
inflator module by the wires or connectors on
the underside of the module. When placing a INFLATOR MODULE
live inflator module on a bench or other sur REPLACEMENT
face, always face the bag and trim cover up,
away from the surface. This is necessary so CAUTION: When perform ing service on or
that a free space is provided to allow the air around SIR components or wiring, follow the
bag to expand in the unlikely event of acci procedures listed below to temporarily dis
dental deployment. Never rest a steering col able the SIR system. Failure to follow proce
umn assembly on the steering wheel with the dures could resu lt in p o ssib le a ir bag
inflator m odule face down and the column deploym ent, personal injury, or otherwise
vertic a l. O therw ise, personal injury may unneeded SIR system repairs.
result.
Deployed Inflator Module Handling Remove or Disconnect (Figures 1 through 3)

After an inflator module has been deployed, the sur
face of the air bag may contain a powdery residue. This 1. Disable the SIR system. Refer to Disabling the SIR
powder consists primarily of cornstarch (used to lubri System in SIR.
cate the bag as it inflates) and by- products of the 2. Negative battery cable. Refer to Battery Disconnect
chemical reaction. Sodium hydroxide dust (similar to lye Caution in General Information.
soap) is produced as a by-product of the deployment 3. Turn steering wheel 90 degrees to access rear
reaction. The sodium hydroxide then quickly reacts with shroud holes to inflator module.
atmospheric moisture and is converted to sodium car 4. Insert screw driver and push leaf spring to
bonate and sodium bicarbonate (baking soda). There release pin.
fore, it is unlikely that sodium hydroxide will be present 5. Turn steering wheel 180 degrees to access remain
after deployment. However as a precaution, wear ing rear shroud holes.
gloves and safety glasses to prevent any possible irrita 6. Insert screw driver and push leaf spring to
tion of the skin or eyes. release pin.
7. Inflator module (tilt rearward from the top to access
Inflator Module Shipping Procedure
SIR wiring).
Refer to Inflator Module Handling, Shipping, and 8. Tethered Connector Position Assurance (CPA)
Scrapping in SIR. retainer from SIR connection.
Inflator Module Scrapping Procedure 9. SIR connector from inflator module.
CAUTION: Failure to follow proper Supple

mental Inflatable Restraint (SIR) inflator mod
ule disposal procedures can result in air bag
deployment which may cause personal injury.
Undeployed inflator modules must not be dis
posed of through normal refuse channels.
The undeployed inflator m odule contains
substances that can cause severe illness or
personal injury if the sealed container is dam
aged during disposal. Disposal in any manner
inconsistent with proper procedures may be
a violation of federal, state and/or local laws.
Refer to Inflator Module Handling, Shipping, and

Scrapping in SIR.
WIRING REPAIRS
NOTICE: Do not repair or splice the wire
harness on the column side o f the connector,
if wiring within the column requires repair,
replace the component with a new replace
m ent part. Failure to follow these instructions Figure 1— Releasing the SIR Module
could cause a short circuit and malfunction
o f the steering column controls.
Install or Connect (Figures 2 and 4)
1. SIR connector to the inflator module.

2. Tethered Connector Position Assurance (CPA) to
the SIR connector.
3. Inflator module by pressing it firmly into steering
wheel enough to engage and latch the two notched
pins in the leaf spring. Do not pinch the wires.
4. Negative battery cable.
5. Enable the SIR system. Refer to Enabling the SIR
System in SIR.
HORN CONTACT REPLACEMENT

(Plunger Sw itch)

Figure 3—SIR Module Connection Location
CAUTION: When carrying a live inflator mod

ule, make sure the bag opening is pointed
away from you. in case of accidental deploy
ment, the bag will then deploy with a minimal
chance of personal injury. Never carry the
inflator module by the wires or connectors on
the underside of the module. When placing a
live inflator module on a bench or other sur
face, always face the bag and trim cover up,
away from the surface. This is necessary so
that a free space is provided to allow the air
bag to expand in the unlikely event of acci
dental deployment. Never rest a steering col
umn assem bly on the steering wheel with the
in fla to r m odule face down and the colum n
v e rtic a l. O therw ise, personal injury may
result.
Figure 5— Horn Contact Replacement

2. Disable the SIR system. Refer to Disabling the SIR STEERING WHEEL
System in SIR.
3. Inflator module. Refer to Inflator Module Replace REPLACEMENT
ment in this section. Tools Required:
4. The horn contact from the steering column. J 1859-A Steering Wheel Puller
5. The four TORX® head screws from the two contact J 42578 Steering Wheel Puller Legs
plates.
6. The two contact plates from the steering column. Remove or Disconnect (Figures 7 and 8)
-►4- Install or Connect (Figure 5) 1. Negative battery cable. Refer to Battery Disconnect
1. The two contact plates to the steering column. 2. Disable the SIR system (if equipped). Refer to Dis
2. The four TORX® head screws securing the two abling the SIR System in SIR.
contact plates to the steering column. 3. Inflator module. Refer to Inflator Module Replace
3. The horn contact to the steering column. ment in this section.
4. Inflator module to the steeing wheel. 4. Horn pad assembly (if not equipped with SIR).
5. Negative battery cable. Refer to Horn Pad Assembly Replacement in this
6. Enable the SIR system. section.
5. Horn contact. Refer to Horn Contact Replacement
HORN PAD ASSEMBLY in this section.
REPLACEMENT 6. Steering wheel nut.
• Notice the alignment mark and its relationship
to the steering wheel and steering shaft.
Remove or Disconnect (Figure 6) 7. Steering wheel using J 1859-A and J 42578, if
equipped with SIR. If vehicle is not equipped with
1. Negative battery cable. Refer to Battery Disconnect SIR, use J 1859-A.
2. Pull four corners of horn pad from steering wheel. +4- Install or Connect (Figures 7 and 8)
3. Ground wire.
4. Horn wire assembly. 1. The steering wheel onto the steering shaft.
• Align the marks on the steering shaft and steer
+4- Install or Connect (Figure 6) ing wheel made during removal.
2. The steering wheel nut to the steering shaft.
1. Horn wire assembly.
2. Ground wire. N O T IC E : R e fe r to F a s te n e r N o tic e in
3. Push horn pad assembly on steering wheel. Cautions and Notices.
4. Negative battery cable.
Tighten

3. Horn contact.
4. Horn pad assembly (if not equipped with SIR).
Figure 6—Horn Pad Assembly Replacement
Figure 7—Steering Wheel Assembly

Figure 9—Multifunction Lever
5. Inflator module. 10. Knee bolster. Refer to Instrument Panel Assembly

6. Enable the SIR system (if equipped). Refer to Replacement in Instrument Panel and Gages.
Enabling the SIR System in SIR. 11. Loosen steering column bracket nuts.
7. Negative battery cable. 12. Two TORX® head screws from lower column
cover.
TILT WHEEL LEVER 13. Lower column cover.
• Tilt cover down and slide back to disengage
REPLACEMENT locking tabs.
14. Two TORX® head screws from upper column
0 Remove or Disconnect cover.
15. Steering column lock set. Refer to Steering Column
1. Pull the lever out of the steering column. Lock Cylinder Set in Standard Steering Column
Unit Repair or Tilt Steering Column Unit Repair.
16. Upper column cover.
17. Two wire harness straps from steering column
1. Align and push the lever into steering column. wire harness.
18. Retainer (CPA) and connector from BTSI.
MULTIFUNCTION TURN 19. Steering column bulkhead connector from vehicle
SIGNAL/HAZARD SWITCH wire harness.
20. Gray and black connectors of switch from column
REPLACEMENT bulkhead connector.
21. Two TORX® head screws on switch.
0 Remove or Disconnect (Figure 9) 22. Multifunction turn signal/hazard switch.
1. M a ke s u re th e le v e r is in th e c e n te r or Install or Connect (Figure 9)

OFF position.
2. Negative battery cable. Refer to Battery Disconnect 1. Multifunction turn signal/hazard switch.
Caution in General Information. • Use small blade screwdriver to compress
3. Disable the SIR system. Refer to Disabling the SIR electrical contact and move multifunction switch
System in SIR. into position.
4. Inflator module. Refer to Inflator Module Replace- • Electrical contact must rest on canceling cam
ment-SIR in this section. assembly.
5. Horn pad assembly (if not equipped with SIR). 2. Two TORX® head screws on switch.
Refer to Horn Pad Assembly Replacement in
this section. Tighten
6. Horn contact. Refer to Horn Contact Replacement
in this section. • Screws to 6 N-m (53 lb in).
7. Tilt wheel lever. Refer to Tilt Wheel Lever Replace 3. Gray and black connectors of switch to column
ment in this section. bulkhead connector.
8. Steering wheel nut. 4. Steering column bulkhead connector to vehicle
9. Steering wheel using J 1859-A. Refer to Steering wire harness.
Wheel Replacement in this section. 5. Connector and retainer (CPA) to BTSI.
6. Two wire straps on steering column wire harness. 2. R oll seal back until TO R X ® head screw
7. Upper column cover. is exposed.
8. Steering column bracket nuts. 3. TORX® head screw from shift lever.
4. Shift lever.
Tighten 5. Shift lever seal.
• Nuts to 30 N-m (22 lb ft). install or Connect

9. Knee bolster.
10. Steering column cylinder lock set. 1. Shift lever seal.
11. Two TORX® head screws to upper column cover. 2. Shift lever.
3. TORX® head screw to shift lever.
Tighten • Screw to 22 N-m (16 lb ft).
4. Roll seal up lever until TORX® head screw is
• Screws to 1.4 N-m (12 lb in). covered.
12. Lower column cover. 5. TORX® head screws to lower column cover.
13. Two TORX® head screws to lower column cover. • Screws to 6 N-m (53 lb in).
Tighten INTERMEDIATE SHAFT

• Screws to 6 N-m (53 lb in).
REPLACEMENT
14. M ake su re th e le v e r is in the c e n te r or
OFF position. Remove or Disconnect (Figure 10)
15. Steering wheel onto the steering shaft.
16. Steering wheel nut. • Set the front wheels in the straight-ahead position
and the steering wheel in the LOCKED position.
Tighten 1. Shield from steering gear.
• Mark the upper to lower intermediate shaft
• Nut to 40 N-m (29 lb ft). and the lower shaft coupler to the steering
17. Horn pad assembly (if not equipped with SIR). gear inputshaft relationship to be sure of
18. Horn contact (if equipped with SIR). proper installation.
19. Inflator module. 2. Nut and bolt from upper to lower shaft
20. Tilt wheel lever. connection.
21. Negative battery cable. 3. Bolt from lower shaft coupler.
22. Enable the SIR system (if equipped). Refer to 4. Intermediate shaft assembly by sliding shaft up
Enabling the SIR System in SIR. (towards dash) to get lower shaft coupler to
clear steering gear input shaft.
SHIFT LEVER REPLACEMENT 5. Slide intermediate shaft down out of the upper
shaft.
Remove or Disconnect ■M- Install or Connect (Figure 10)
1. Roll seal back until TORX® head screw is
1. Upper end of intermediate shaft into upper shaft.
exposed.
2. Lower end of intermediate shaft coupler onto steer
2. TORX® head screw.
ing gear wormshaft. Align marks made at removal
3. Shift lever.
only if putting the same shaft back in.
■M- Install or Connect 3. Bolt to lower shaft coupler.
4. Bolt and nut to upper end of shaft.
1. Shift lever.
2. TORX® head screw. N O TIC E : R e fe r to F a s te n e r N o tic e in
• Screw to 22 N-m (29 lb ft). Cautions and Notices.
3. Roll seal over TORX® head screw.
Tighten
SHIFT LEVER SEAL
• Upper nut to 62 N m (46 lb ft).
REPLACEMENT • Coupler pinch bolt to 30 N-m (22 lb ft).
5. Shield on to steering gear.
1. TORX® head screws from lower column cover. Do

not remove cover, let the lower column cover pivot
on upper column cover.
Figure 10—Intermediate Shaft installation
STEERING COLUMN 10. Steering column assembly.

• Rotate the column so the shift lever clears the
REPLACEMENT dash panel opening.
B Remove or Disconnect (Figures 10 through 12) -M- Install or Connect (Figures 10 through 12)
1. Lower the end of the steering column through the

NOTICE: When the column Is removed from dash panel opening.
the vehicle, a sharp blow on the end of the 2. Harness to connectors on the steering column.
steering shaft or shift lever, leaning on the 3. Raise the steering column into place.
column assembly, or dropping of the assem • Rotate column up over two upper studs and
bly could shear or loosen the plastic fasten loosely assemble two nuts.
ers that maintain column rigidity.• 4. Lower column nuts.
5. Upper column nuts.
• Set front wheels in the straight-ahead position and
the steering wheel in the LOCKED position. N O T IC E : R e fe r to F a s te n e r N o tic e In
1. Negative battery cable. Refer to Battery Discon Cautions and Notices.
nect Caution in General Information.
2. Disable the (SIR). Refer to Disabling the SIR
Q Tighten
System in SIR.
3. Screws and steering column trim panels. Refer
to Instrument Panel Assembly Replacement in • Nuts to 30 N m (22 lb ft).
Instrument Panel and Gages. 6. Bolt and nut to upper end of shaft.
4. Transmission control cable from the column.
Q Tighten
5. S teering wheel. Refer to Steering Wheel
Replacement in this section.
6. Harness at the connectors. • Nut to 62 N.m (46 lb ft).
7. Nut and bolt from upper to low er shaft 7. Transmission control cable.
connection. 8. Steering column trim panel and screws.
8. Nuts from upper and lower support brackets. 9. Steering wheel.
9. Lower the steering column. 10. Negative battery cable.
11. Enable the SIR system. Refer to Enabling the SIR
System in SIR.
DASH PANEL
DASH PANEL
ALL C/K EXCEPT

C3500HD
C3500HD
Figure 12—Steering Column Seal

STEERING COLUMN STEERING COLUMN SEAL
SEAL REPLACEMENT REPLACEMENT (C3500HD)
(ALL EXCEPT C3500HD) Remove or Disconnect (Figures 11 and 12)
Remove or Disconnect (Figures 11 and 12)
1. Steering column. Refer to Steering Column
Replacement in this section.
• Set the front wheels in the straight-ahead position
2. Push locking ring tabs inward one at a time until
and the steering wheel in the LOCKED position.
seal separates from the dash panel. Note position
• Mark the upper to lower intermediate shaft to be
of locating tab directly at bottom of the locking ring
sure of proper installation.
and dash panel opening (Figure 12).
1. Shield from steering gear.
2. Nut and bolt from upper to lower shaft ■M* install or Connect (Figures 11 and 12)
connection.
3. Pull lower shaft out of upper shaft.
1. Align locating tab groove on seal directly at bottom
4. Seal by grasping and compressing it while pull
of dash panel opening so sheet metal fits into the
ing away from dash panel.
tabs groove. Force the seal upward and inward
0 Install or Connect (Figures 11 and 12) until seal snaps into place.
2. Steering column.
1. Slide seal up steering column.
2. Align locating tab on seal with notch at the bottom CHECKING STEERING COLUMN
of dash panel opening. FOR ACCIDENT DAMAGE
3. Slightly compress seal while forcing it inward until Refer to Accident Damage in Standard Steering Col
retaining collar snaps open inside cab. umn Unit Repair or Tilt Steering Column Unit Repair.
4. Pull lower shaft up into upper shaft.
• Verify retaining collar has opened inside cab
360 degrees.
5. Nut and bolt to upper end of shaft.
NOTICE: Refer to Fastener Notice in Cau

tions and Notices.
Tighten
• Nut and bolt to 62 N m (46 lb ft).

6. Shield to intermediate shaft.
SPECIFICATIONS
FASTENER TIGHTENING
SPECIFICATIONS
Application N-m Lb Ft Lb In
Intermediate Shaft Coupling Pinch Bolt 30 22 —
Intermediate Shaft Upper Pinch Nut 62 46 —

Steering Column Bracket Nuts 30 22 —
Steering Wheel Nut 40 29 —
Support Bracket Bolts 30 22 —
Upper Column Cover Screws 1.4 — 12
Lower Column Cover Screws 6 — 53
Multifunction Turn Signal/Hazard Switch Screws 6 — 53
Shift Lever Screw 22 16 —
SPECIAL TOOLS
1. 2.
J 1 8 5 9 -A J 42578
1. J1859 STEERING WHEEL PULLER

2. J42578 STEERING WHEEL PULLER LEGS
BLANK
STD STRG COL UNIT REPAIR (SIR) 2F4-1
SECTION 2F4
SUPPLEMENTAL INFLATABLE RESTRAINT

(SIR) STANDARD STEERING COLUMN
UNIT REPAIR
FASTENER SPECIFICATIONS
Specif cation
Aoolication Metric Enalish
G/S Lever S uddoiI Bracket Screws 10 N-m 89 lb in
Hex Hd Nut 62 N-m 46 lb ft
Housina Assem blv-to-Jacket Screws 17 N-m 13.5 lb ft
lanition & Kev Alarm Switch Screws 1.5 N-m 13 lb in
Lock Cvlinder Module Screws 7 N-m 62 lb in
Lower Shroud Screws 3.5 N-m 31 lb in
Pinch Bolt 62 N-m 46 lb ft
Shift Lever Clevis and Cable Shift Cam Screws 18 N-m 141b ft
Shift Lever Gate Screws 6.5 N-m 57.5 lb in
Shift Lever Screw 20 N-m 161b ft
Steerina W heel-to-Shaft Nut 41 N-m 30 lb ft
Turn Signal & Multifunction Switch Screws 7 N-m 62 lb in
Upper Shroud Screws 1.5 N-m 13 lb in
2F4-2 STD STRG COL UNIT REPAIR (SIR)
Figure 1 - Standard Steering Column

STD STRG GOL UNIT REPAIR (SIR) 2F4-3
1- NUT, HEXAGON LOCKING (M14x1.5)

2- C O IL ASM INFLATABLE RESTRAINT
STEERING W HEEL MODULE,
3- W ASHER, W AVE
4- RING, RETAINING
5- SHIELD ASM, SH AFT LOCK
6- CAM ASM, T/SIG CANCEL
7- SPRING, UPPER BEARING
8- W ASHER, TH RUST
9 - SCREW , TO R X HEAD
10- SHROUD, UPPER
1 1 - BO LT ASM, LOCK
12- SPRING, LOCK BOLT
13- SCREW, PAN HD TAPPING
1 4 - SCREW, TO RX HEAD
15- MODULE ASM, LOCK
16- SEAL, SHIFT LEVER
17- LOCK CYL SET, STRG COLUMN
18- SCREW , TAPPING
19- SW ITCH ASM, IGN & KEY ALARM
22- STRAP, W IRE HARNESS
23- CO NNECTOR, A X IA L POSN ASSUR
24- SW ITCH ASM, T/S & MULTIFUNC
26- HOUSING ASM, STRG COLUMN
2 7 - PROTECTOR, SHROUD
2 8 - SHROUD, LOWER
29- STUD, SHROUD MOUNTING
30- RING, RETAINING
31- RING, RETAINING
32- SHAFT ASM, STEERING
33- SCREW, SHIFT LEVER
34- LEVER ASM, AUTO TRANS CONTROL
40- SHIFT ASM, LINEAR
4 1 - CLEVIS, SHIFT LEVER
43- SCREW , FLAT HD 6-LOBED SOC TAP
44- CAM ASM, CABLE SHIFT
45- ACTUATO R ASM, BALL &
46- BOLT, HEX FLANGE HEAD
47- SCREW , OVAL HD 6-LO BED SOC TAP
48- CABLE ASM, PA RK LOCK
49- BRACKET, G/S LEVER ASM SUPPORT
58- JAC KET ASM, STRG COL
60- BEARING ASM, ADAPTER &
6 1 - ACTUATO R, ELECTRICAL (BTSI)
62- SENSOR ASM, EVO
63- BUSHING, CAM
Figure 2 - Standard Steering Column - Legend

CAUTION: The procedures in this section must pl+| Remove or Disconnect

be followed in the order listed to temporarily
disable the Supplemental Inflatable Restraint
(SIR) System and prevent false diagnostic codes
• Turn the steering wheel so that the vehicle's wheels
from setting. Failure to follow procedures could are pointing straight ahead.
result in possible air bag deployment, personal • Turn the ignition switch to “LOCK” and remove
injury, or otherwise unneeded SIR system key.
repairs.
1. “AIR BAG” fuse from I/P fuse block.
CAUTION: Before removing or installing any 2. Steering column filler panel. Refer to section 10A4.
electrical unit or when a tool or equipment could 3. Connector position assurance (CPA) retainer and
easily come in contact with "live" exposed yellow 2-way SIR connector at base of steering
electrical terminals, disconnect the negative column.
battery cable to help prevent personal injury
and/or damage to the vehicle or components.
Unless instructed otherwise, the ignition switch [T[ Important
must be in the "off" or "lock" position. • With the "AIR BAG" fuse removed and ignition
switch "ON", the "AIR BAG" warning lamp will be
NOTICE: Once steering column is removed from vehicle, "ON". This is normal operation and does not indicate
the column is extremely susceptible to damage. Dropping an SIR system malfunction.
steering column assembly on its end could collapse steering
shaft or loosen plastic injections which maintain column
rigidity. Leaning on steering column assembly could cause ENABLING THE SIR SYSTEM
jacket to bend or deform. Any of the above damage could
impair steering column's collapsible design. If it is necessary
to remove steering wheel, use only the specified steering |+7| Install or Connect
wheel puller and holding fixture. Never place column
directly into a vise. Under no conditions should the end of • Turn the ignition switch to “LOCK” and remove
shaft be hammered on as hammering could loosen plastic key.
injections which maintain steering column rigidity. 1. Yellow 2-way SIR connector and CPA retainer at
base of steering column.
2. “AIR BAG” fuse to I/P fuse block.
DISABLING THE SIR SYSTEM 3. Steering column filler panel. Refer to section 10A4.
• Turn ignition switch to “RUN” and verify that
SERVICE PRECAUTIONS the "AIR BAG" warning lamp flashes 7 times
and then turns “OFF”. If it does not operate as
CAUTION: When performing service on or described, perform the “SIR Diagnostic System
around SIR components or SIR wiring, follow Check” in section 9J-A of the Service Manual
the procedures listed below to temporarily Supplement.
disable the SIR system. Failure to follow
procedures could result in possible air bag
deployment, personal injury, or otherwise
unneeded SIR system repairs.
The DERM can maintain sufficient voltage to

cause a deployment for up to 2 minutes after the
ignition switch is turned "OFF" or the battery is
disconnected. Many of the service procedures require
disconnection of the "AIR BAG" fuse and the inflator
module circuits from the deployment loops to avoid an
accidental deployment.
STD STRG COL UNIT REPAIR (SIR) 2F4*5
UNIT REPAIR [ffl| Inspect
LOWER SHROUD • Steering shaft assembly for accident damage.

STRG COLUMN LOCK CYL SET (See Figure 27).
UPPER SHROUD
SHIFT LEVER SEAL (c/s only) 5. Two pan head tapping screws (13) from lower
Figure 1, 3, through 5 shroud (28).
6. Lower shroud (28).
Tools Required: • Tilt shroud (28) down and slide back to
J 41352 Modular Column Holding Fixture disengage locking tabs.
7. Two torx head screws (14) from
0 Remove or Disconnect upper shroud (10).
2. Disable the SIR system; refer to DISABLING THE
SIR SYSTEM in this Section.
3. Cplg & Strg shaft assembly (68) or Yoke & Inter Strg
shaft assembly (64) (Depending on Model) from
shaft assembly.
• Remove bolt
NOTICE: Once steering column is removed from vehicle,
the column is extremely susceptible to damage. See
NOTICE on page 2F5-1 in this section.
4. Lower or remove steering column from vehicle;
refer to section 2F.
• Secure steering column to modular col. holding 8. Lift upper shroud (10) to gain access to lock cylinder
fixture J 41352. hole.
• Place holding fixture into vise. (See Fig.3) A. Hold key in "START" position.
B. Using 1/16-inch alien wrench push on lock
cylinder retaining pin.
C. Release key to "RUN" position and pull steering
column lock cylinder set (17) from lock
module assembly (15).
D. Remove upper shroud (10).
9. Shift lever; refer to section 2F.
10. Shift lever seal (16).
11. Shroud protector (27) from lower shroud (28).
Figure 3 - Modular Column Holding Fixture

0 Install or Connect 8. Two pan head tapping screws (13) to lower

shroud (28).
NOTICE: Refer to the fastener NOTICE in the caution
and fastener section. Failure to do so may result in component Tighten
damage or malfunction of steering column.
• Tighten screws (13) to 3.5 N-m (31 lb.in.).
1. Shift lever seal (16).
2. Shift lever; refer to section 2F. 9. Shift lever seal (16) and multifunction lever seal into
3. Shroud protector (27) to lower shroud (28). position.
4. Move shift lever seal (16) and multifunction lever 10. Raise or install steering column to vehicle; refer to
seal to ease in installation of upper and section 2F.
lower shrouds. 11. Cplg & strg shaft assembly (68) of yoke & inter strg
shaft (64) to shaft assembly (32).
[^ T ig h te n
• Tighten nut and bolt to 62 N-m (46 lb.ft.).
[$j] Tighten
• Tighten hex hd nut to 62 N-m (46 lb.ft.).

12. If all service operations are completed, enable the
SIR system; refer to "ENABLING THE SIR
SYSTEM" in this section.
COIL ASM, INFL RST STRG WHL MDL

5. Upper shroud (10) and steering column lock Figures 1 through 7
cylinder set (17).
A. Key installed in lock cylinder (17) and in Tools Required:
"RUN" position. J 41352 Modular Column Holding Fixture
B. Ensure sector in lock module assembly (15) is
in "RUN" position. (See Figure 5)
C. Lock cylinder (17) to upper shroud (10). |7+| Remove or Disconnect
D. Line up locking tab and positioning tab with
slots in lock module assembly (15) and push 1. Negative (-) battery cable.
cylinder (17) into position. 2. Do steps 1 through 7, "Remove or Disconnect",
LOWER SHROUD, UPPER SHROUD, in this
6. Two torx head screws (14) to upper shroud (10). section.
3. Air bag module and steering wheel; refer to service
Tighten procedures in section 2F.
• Tighten screws (14) to 1.5 N-m (13 lb.in.). NOTICE: Coil assembly (2) will become uncentered if:
1) Steering column is separated from steering
7. Lower shroud (28). gear and allowed to rotate.
• Ensure that slots on lower shroud (28) engage 2) Centering spring is pushed down, letting
with tabs on upper shroud (10). hub rotate while coil (2) is removed from
• Tilt lower shroud up and snap shrouds together. steering column. (If this occurs, refer to
Figure 7 to center coil)
PERFORM THE FOLLOWING STEPS TO CENTER COIL ASSEMBLY
A. WHEELS STRAIGHT AHEAD.

B. REMOVE COIL ASSEMBLY.
C. HOLD COIL ASSEMBLY WITH BOTTOM UP.
D. WHILE HOLDING COIL ASSEMBLY, DEPRESS SPRING LOCK TO
ROTATE HUB IN DIRECTION OF ARROW UNTIL IT STOPS.
E. THE COIL RIBBON SHOULD BE WOUND UP SNUG AGAINST
4. Retaining ring (30). CENTER HUB.
5. Coil assembly (2). (See Figure 6) F. ROTATE COIL HUB IN OPPOSITE DIRECTION APPROXIMATELY
6. Wave washer (3). TWO AND A HALF (2-1/2) TURNS. RELEASE SPRING LOCK
BETWEEN LOCKING TABS._______________________________
7. Two wire harness straps (22) from steering column Figure 7 - Centering Coil Assembly
wire harness.
3. Coil assembly (2).
■ M- Install or Connect A. Ensure shaft (32) and coil (2) are centered.
B. Align coil (2) with horn tower and slide onto
shaft (32).
and fastener section. Failure to do so may result in component 4. Retaining ring (30) must seat securely in groove on
damage or malfunction of steering column. shaft (32).
1. Center steering shaft assembly (32) and Coil 5. Route lower coil wire along steering column jacket
assembly(2). assembly (58).
A. Wheels straight ahead. 6. Two wire harness straps (22) to steering column wire
• Block tooth and centering mark on steering harness.
shaft assembly (32) at 12 o'clock position. 7. Do steps 4 through 10, "Install or Connect", LOWER
SHROUD, UPPER SHROUD, in this Section.
B. Ignition switch to "LOCK" position. 8. Steering wheel and air bag module; refer to service
C. Ensure coil (2) is centered; refer to figure (6). procedures in section 2F.
2. Wave washer (3). SIR system; refer to ENABLING THE SIR SYSTEM
in this section.
NOTICE: New Coil assembly (2) will be pre-centered. 10. Negative (-) battery cable.
Install new coil, remove and dispose of centering tab.
T/S & MULTIFUNCTION SWITCH ASM |7»| Install or Connect

Figures 1 through 8
Tools Required: and fastener section. Failure to do so may result in component
J 41352 Modular Column Holding Fixture damage or malfunction of steering column.
p+| Remove o r Disconnect 1. Turn signal & multifunction switch assembly (24)
to column.
1. Do steps 1 through 7, "Remove or Disconnect", • With small blade screwdriver compress
LOWER SHROUD, UPPER SHROUD, in this electrical contact and move multifunction switch
section. (24) into position.
• Electrical contact must rest on cancelling cam
assembly (6).
2. Two pan head tapping screws (13).
f$Q Tighten
• Tighten screws (13) to 7 N*m (62 lb.in.).

3. Grey and black connectors of multifunction switch
(24) to column bulkhead connector.
4. Electrical connector to electrical (BTSI) actuator
(61). (Column shift only)
• Axial position assurance connector (23).
5. Steering column bulkhead connector to vehicle wire
harness.
6. Two wire harness straps (22) to steering column wire
harness.
Figure 8 - Removing T/S & Multifunction Switch 7. Do steps 4 through 10, "Install or Connect", LOWER
SHROUD, UPPER SHROUD, in this section.
2. Two wire harness straps (22) from steering column
wire harness.
3. Steering column bulkhead connector from vehicle IGN & KEY ALARM SWITCH ASM
wire harness. Figures 1 through 10
4. Axial position assurance connector (23) from
electrical (BTSI) actuator (61). (Column shift only) Tools Required:
e Electrical connector from (BTSI) actuator (61). J 41352 Modular Column Holding Fixture
5. Grey and black connectors of turn signal & |7+| Remove or Disconnect
multifunction switch (24) from column bulkhead
connector. 1. Do steps 1 through 7, "Remove or Disconnect",
6. Two pan head tapping screws (13). LOWER SHROUD, UPPER SHROUD, in this
7. Turn signal & multifunction switch assembly (24) section.
from column.
5. Ignition & key alarm switch assembly (19).

• Wire harness from slot in steering column
housing assembly (26).
p7| Install or Connect

and fastener section. Failure to do so may result in component
• Route wire harness through slot in steering
column housing assembly (26). Secure wire
harness with a wire harness strap (22) through
hole located in the bottom of housing
assembly (26).
2. Two tapping screws (18).
[$[] Tighten
2. Alarm switch from lock module assembly (15).
• Gently pry retaining clip on alarm switch with • Tighten screws (18) to 1.5 N’m (13 lb.in.).
small blade screwdriver.
• Rotate alarm switch 1/4 turn and remove. 3. Alarm switch to lock module assembly (15).
A. Switch with retaining clip parallel to lock
3. Remove pass key connector (19) from lock module cylinder (17).
asm (15). B. Rotate switch 1/4 turn until locked into piece.
4. Install pass key connector from switch asm, ign &
key alarm (19) to lock module asm (15).
5. Doallsteps, "Install or Connect", LOWER SHROUD,
UPPER SHROUD, in this section.
Figure 10 - Removing Ignition & Key Alarm Switch

STRG COLUMN LOCK CYL SET 10. Key alarm switch from module assembly (15).
(Replacement - Lost Key) (See Figure 9)
Figure 3, 7 and 11-14,19 through 21 • Gently pry retaining clip on alarm switch with
Tools Required: • Rotate alarm switch 1/4 turn and remove.
J 23653-SIR Lock Plate Compressor
J 41352 Modular Column Holding Fixture 11. Pass key connector from switch asm, ign & key (19)
J 41396 Park Lock Cable Pliers from module assembly (15).
|++| Remove or Disconnect • Let switch (19) hang freely.
NOTICE: Lock bolt assembly (11) is under slight spring
1. Do steps 1 through 7, "Remove or Disconnect", tension from lock bolt spring (12). Hold lock bolt (11) in
LOWER SHROUD, UPPER SHROUD, in this place while removing lock module assembly (15).
section if you "DO NOT" have the "Key" to match
the cylinder. The upper shroud (10) will remain with 14. Three pan head tapping screws (13).
the lock module assembly (15). 15. Lock module assembly (15) with upper shroud (10).
NOTICE: If you "DO" have the "Key" that matches the
lock cylinder, then do steps 1 through 8, "Remove or
Disconnect", LOWER SHROUD, UPPER SHROUD, in
this section.
2. Air bag module and steering wheel; refer to service
procedures in section 2F.
NOTICE: Coil assembly (2) will become uncentered if:
gear and allowed to rotate.
2) Centering spring is pushed down, letting
hub rotate while coil (2) is removed from
steering column. (If this occurs, refer to
Figure 7 to center coil).
3. Retaining ring (30).
5. Wave washer (3).
6. Shaft lock retaining ring (4) using J 23653-SIR to Figure 11 - Sector Gear Timing Position (OFF-LOCK)
push down shaft lock shield assembly (5).
• Dispose of ring (4). 16. Backing plate from lock module assembly (15).
7. Shaft lock shield assembly (5). [T| Important
8. Turn signal cancel cam assembly (6).
9. Park lock cable assembly (48) from lock module
assembly (15). • Mark two sector gears at "OFF-LOCK" position to
• Lock cylinder should be in "OFF-LOCK" ensure proper reassembly. Failure to assemble sector
position and gear shift in "PARK" position. gears properly will cause lock cylinder (17) and
• Insert small blade screwdriver into slot in ignition switch (19) to improperly timed.
module assembly (15). Push against locking (See Figure 11 for proper timing)
tab on end of cable assembly (48) and remove.
17. Remove both sector gears (See Figure 11)
|ffi| Clean
• All debris and metal shavings from inside
• Remove all burrs.
■ M- Install or Connect

1. Align marks made on sector gears and install sector

gears and backing plate to lock module assembly
(15). (See Figure 11 for proper timing of gears)
2. Steering column lock cylinder set (17) to lock
18. Remove positioning tab on end of lock cylinder (17) A. Ensure sector in lock module assembly (15) is
using an 1/8-inch burring tool. (See Figure 12) in "OFF-LOCK" position. (See Figure 11)
• Remove all burrs in and around lock module B. Key installed in lock cylinder (17) and in "OFF-
assembly (15) and lock cylinder (17). LOCK" position.
C. Line up locking tab positioning with slots in
19. From inside module assembly (15) push on locking lock module assembly (15) and push
tab and pull lock cylinder (17) from lock module cylinder (17) into position.
assembly (15) and upper shroud (10). D. Rotate lock cylinder to "ACC" position and
check alignment of "ARROWS"on sector gears.
Arrows should be pointing towards each other.
E. Rotate lock cylinder to "LOCK" position.
KEY CODE SIDE VIEW
3. Lock module assembly (15).
• Push lock bolt (11) into steering column housing
assembly (26) until flush.
• Align lock module assembly (15) with housing
assembly (26) and install.
4. Three pan head tapping screws (13).
[^ T ig h te n
• Tighten screws (13) to 7 N-m (62 lb.in.)

Figure 13- Location of Key Code 5. Ignition & key alarm switch assembly (19).
20. Record "Key Code "from old lock cylinder.
(See Figure 13)
• Build up "New" lock cylinder.
• Cut "New" key.
• Discard "Old" lock cylinder.
6. Two tapping screws (18) for ignition and key alarm

switch (19)
Tighten

7. Key alarm switch to module assembly (15).
A. Key alarm switch with retaining clip parallel to
lock cylinder (17).
B. Rotate key alarm switch 1/4 turn until locked
into place.
8. Pass key connector to module assembly (15).
(See Figure 10).
• Lubricate lower brass surface with grease,
synthetic (service kit).
10. Shaft lock shield assembly (5).
• Align inner block tooth of lock plate to block 18. Park lock cable assembly (48) to module
tooth of race & upper shaft assembly (34). assembly (15).
• Lock cylinder should be in "OFF - LOCK"
11. New shaft lock retaining ring (4) using J 23653-SIR position and gear shift in "PARK" position.
to push down shaft lock shield assembly (5). • Locking tab on end of cable (48) to slot in
• Ring (4) must be firmly seated in groove module assembly (15)
on shaft.
12. Center steering shaft assembly (32). Adjust
A. Wheels straight ahead.
• Block tooth and centering mark on shaft • Park lock cable assembly (48). (See Figure 17)
assembly (32) at 12 o'clock position.
A. Gear shift lever installed and in "PARK"
B. Ignition switch to "LOCK" position. position.
C. Ensure coil (2) is centered; refer to figure (7). B. Ignition in "OFF LOCK" position and
remove key.
13. Wave washer (3). C. Unlock adjuster ring on cable assembly
(48) with tool J 41396. (See Figure 18)
NOTICE: New coil assembly (2) will be pre-centered. D. Pull on cable until park lock latch contacts
Install new coil, remove and dispose of centering tab. gear shift lever.
• Release the cable.
A. Ensure shaft (32) and coil (2) are centered. E. Lock adjuster ring securely in place on
B. Align coil (2) with horn tower and slide onto cable assembly (48) with tool J 41396.
shaft (32). (See Figure 19)
15. Retaining ring (30) must seat securely in groove on
shaft (32).
16. Route lower coil wire along steering column jacket
assembly (58).
harness.
[ffl| Inspect 26. Raise or install steering column to vehicle; refer to

section 2F.
27. Steering wheel.
• Park lock cable assembly (48). (See Figure 17) 28. If all service operations are completed, enable the
A. With lock cylinder in "OFF-LOCK" SIR system; refer to "ENABLING THE SIR
position, gear shift lever should not SYSTEM" in this section.
be able to shift out of "PARK" position. 29. Negative (-) battery cable.
B. Insert key and turn to "RUN" position.
C. Shifter in "NEUTRAL" position.
D. With gear shift in NEUTRAL" position
lock cylinder should not be able to go into ELECTRICAL (BTSI) ACTUATOR
"OFF-LOCK" position. (c/s only)
E. Shifter in "PARK" position. Figures 1,15,16 and 17
F. Lock cylinder in "OFF-LOCK" position
and remove key.
p+| Remove or Disconnect
19. Remove steering column lock cylinder (17) from
lock module assembly (15). 1. Negative (-) battery cable.
20. Upper shroud (10). 2. Disable the SIR system; refer to DISABLING THE
21. Two torx head screws (14) to upper shroud (10). SIR SYSTEM, in this section.
[^ T ig h te n

• Ensure that slots on lower shroud (28) engage
with tabs on upper shroud (10).
• Tilt lower shroud up and snap shrouds together.
23. Two pan head tapping screws (13) to lower
shroud (28).
Tighten
• Tighten screws (13) to 7 N-m (62 lb.in.).

Figure 15 - Removing Electrical (BTSI) Actuator
24. Shift lever seal (16) and multifunction lever seal into
position. 3. Electrical (BTSI) actuator (61) from column.
25. Steering column lock cylinder set (17) to lock module A. Column in "NEUTRAL" position.
assembly (15). B. Pry (BTSI) actuator (61) from mounting pin on
A Ensure sector in lock module assembly (15) is steering column jacket assembly (58) and outer
in "RUN" position. (See Figure 11) shift cable ball stud on cable shift cam
B. Key installed in lock cylinder (17) and in "RUN" assembly (44).
position. C. Axial position assurance connector (23) from
C. Line up locking tab and positioning tab with electrical connector.
slots in lock module assembly (15) and push • Electrical connector from (BTSI)
cylinder (17) into position. actuator (61).

SIR system; refer to ENABLING THE SIR
SYSTEM, in this section.
A. MOVE ACTUATOR ROD TO ADJUSTER BLOCK SIDE

FOR LEVERAGE.
B. PRESS ON ADJUSTER BLOCK TO COMPRESS
INTERNAL ADJUSTER SPRING AND DISENGAGE
ADJUSTER TEETH.
C. SLIDE ADJUSTER BLOCK AS FAR AWAY FROM
SOLENOID AS POSSIBLE.
D. REPLACE ACTUATOR ROD TO SOLENOID
ACTUATOR TEETH LOCK
SIDE. ROD WILL BE VISIBLE IN HOLE IN
ADJUSTER BLOCK.
Figure 16 - Adjusting Electrical (BTSI) Actuator A. SHIFTER MUST BE IN NEUTRAL POSITION.
B. BTSI ASM MUST BE SNAPPED SECURELY
TO MOUNTIG STUDS.
0 Adjust C. SHIFT INTO PARK.

D. SEAT ADJUSTER LOCK FIRMLY BY PUSHING
LOCK TOWARD THE SOLENOID.
• Electrical (BTSI) Actuator (61). Figure 17 - (BTSI) Adjuster Lock
(See Figures 16,17)
A. Move actuator rod to adjuster block side for
leverage. |ffi| Inspect
B. Press on adjuster block to compress internal
adjuster spring and disengage the adjuster teeth. • Function check Electrical (BTSI) actuator (61)
C. Slide the adjuster block as far away from the for proper operation.
solenoid as possible. • Actuator (61) must lock gearshift lever when
D. Replace actuator rod to solenoid side. ever steering column is in "PARK" position
and when trying to shift from "PARK" position
without pressing brake pedal.
|+7| Install or Connect (Solenoid is energized)
• Actuator (61) must release gearshift lever when
pressure is applied to brake pedal.
NOTICE: Refer to the fastener NOTICE in the caution (Solenoid is de-energized)
and fastener section. Failure to do so may result in component • Readjust if needed.
1. Electrical (BTSI) actuator (61) to column.

A. Column in "Neutral" position.
B. (BTSI) actuator (61) to mounting pin on steering
column jacket assembly (58) and outer shift
cable ball stud on cable shift cam
assembly (44).
C. Electrical connector to (BTSI) actuator (61).
• Axial position assurance connector (23) to
electrical connector.
LINEAR SHIFT ASM (REMOVAL) 5. Three flat head 6 -lobed socket tap screws (43).
(c/s only) • Shift column to "NEUTRAL" position to gain
Figures 1,3,15 through 21 access to lower socket tap screw (43).
Tools Required: 6. Linear shift assembly (40) from column.
J 41352 Modular Column Holding Fixture
J 41396 Park Lock Cable Pliers CZI Install or Connect
NOTICE: Linear shift assembly (40) may be removed as an

assembly or certain components may be disassembled as and fastener section. Failure to do so may result in component
necessary to do repairs. Remove or disassemble only those damage or malfunction of steering column.
components necessary to do repairs.
1. Linear shift assembly (40) to column.
Q Remove or Disconnect 2. Three flat head 6-lobed socket tap screws (43).
• Linear shift assembly (40) must be out of
"PARK" position to install lower socket tap
1. Do all steps, "Remove or Disconnect", LOWER screw (43).
2. Park lock cable assembly (48) from lock module [^ T ig h te n
assembly (15).
• Lock cylinder should be in "OFF-LOCK" position • Tighten screws (43) to 10 N-m (89 lb.in.).
and gear shift in "PARK" position.
• Insert small blade screwdriver into slot in module 3. Transaxle cable to inner shift cable ball stud on cable
assembly (15). Push against locking tab on end shift cam assembly (44).
of cable assembly (48) and remove. 4. Park lock cable assembly (48) to lock module assembly
3. Pry actuator arm of electrical (BTSI) actuator (61) (15).
from outer shift cable ball stud on cable shift cam • Lock cylinder should be in "OFF-LOCK"
assembly (44) and mounting pin on jacket (58). position and gear shift in "PARK" position.
4. Transaxle cable from inner shift cable ball stud on • Locking tab on end of cable (48) to slot in
cable shift cam assembly (44). module assembly (15).
5. Actuator arm of electrical (BTSI) actuator (61) to
outer shift cable ball stud on cable shift cam
assembly (44).
6. Do Adjust and Inspect, "Install or Connect",
ELECTRICAL (BTSI) ACTUATOR, in this section.
Figure 18 - Removing Linear Shift Assembly

D. Pull on cable until park lock latch contacts

gear shift lever.
£. Lock adjuster ring securely in place on
cable assembly (48) with tool J 41396.
(See Figure 21)
A. SHIFTER IN "PARK" POSITION.

B. IGNITION IN "OFF-LOCK" POSITION.
C. UNLOCK ADJUSTER RING.
D. PULL LOWER CABLE SECTION TO REMOVE LASH.
E. LOCK ADJUSTER RING SECURELY IN PLACE.
Figure 19 - Adjusting Park Lock Cable
[jy| Inspect
• Park lock cable assembly (48). (See Figure 19)

A. With lock cylinder in "OFF-LOCK"
position, gear shift lever should not be
able to shift out of "PARK" position.
Figure 20 - Unlocking Adjuster Ring on Park Lock Cable B. Insert key and turn to "RUN" position.
D. With gear shift in "NEUTRAL" position,
0 A d ju st
lock cylinder should not be able to go into
"OFF-LOCK" position.
• Park lock cable assembly (48). (See Figure 9) E. Shifter in "PARK" position.
A. Gear shift lever installed and in F. Lock cylinder in "OFF-LOCK" position'
"PARK" position. and remove key.
B. Ignition in "OFF LOCK" position and
remove key. 7. Do all steps "Install or Connect", LOWER SHROUD,
C. Unlock adjuster ring on cable assembly UPPER SHROUD, in this section.
(48) with tool J 41396. (See Figure 20)
LINEAR SHIFT ASM (DISASSEMBLY) 7. Park lock cable assembly (48) from support
BALL & ACTUATOR ASM bracket (49). Insert retaining clip.
SHIFT LEVER CLEVIS 8. Pry actuator arm of electrical (BTSI) actuator (61)
PARK LOCK CABLE ASM from outer shift cable ball stud on cable shift cam
G/S LEVER ASM SUPPORT BRKT assembly (44).
(c/s only)
9. Pry transaxle shift cable from inner ball stud on
Figures 1,3,15 through 22
cable shift cam assembly (44).
10. Hexagon flange head bolt (46).
Tools Required: 11. Cable shift cam assembly (44).
J 41352 Modular Column Holding Fixture 12. Cam bushing (63) from cable shift cam
J 41396 Park Lock Cable Pliers assembly (44).
13. Three flat head 6-lobed socket tap screws (43).
14. Gearshift lever assembly support bracket (49).
Disassemble
1. Do all steps "Remove or Disconnect", LOWER Assemble

1. Lubricate all moving parts of assembly with synthetic
grease.
[^ T ig h te n

41 CLEVIS, SHIFT LEVER
43 SCREW, FLAT HD 6-LOBED SOC TAP 4. Insert cam bushing (63) into cable shift cam
44 CAM ASM, CABLE SHIFT assembly (44).
45 ACTUATOR ASM, BALL &
46 BOLT, HEX FLANGE HEAD
5. Cable shift cam assembly (44).
47 SCREW, OVAL HD 6-LOBED SOC TAP 6. Hexagon flange head bolt (46).
48 CABLE ASM, PARK LOCK
49 BRACKET, G/S LEVER ASM SUPPORT
63 BUSHING, CAM [$(] Tighten
Figure 22 - Disassembling Linear Shift Assembly
• Tighten bolt (46) to 18 N*m (14 lb.ft.).
2. Hexagon flanged head bolt (46).
3. Ball & actuator assembly (45). 7. Transaxle shift cable to inner ball stud on cable shift
4. Pop off locking ring on park lock cable, cam assembly (44).
assembly (48). (See Figure 19,20) 8. Actuator arm of electrical (BTSI) actuator (61) to
• Move park lock latch to gain access to lower outer shift cable ball stud on cable shift cam
oval head 6-lobed socket tap screw (47). assembly (44).
9. Park lock cable assembly (48) to support
5. Two oval head 6-lobed socket tap screws (47) from bracket (49). Remove retaining clip.
shift gate. 10. Shift lever clevis (41) and shift gate to support
6. Shift lever clevis (41). bracket (49).
A. Lift up on shift gate and rotate shift lever A. Position shift gate to end of clevis (41) lever.
clevis (41). B. Rotate clevis (41) and shift gate into position.
B. Clevis (41) from gearshift lever assembly support C. Push against shift lever spring tension to align
bracket (49). shift gate holes with support bracket (49) holes.
11. Two oval head 6-lobed socket tap screws (47).
|$fl Tighten
• Tighten screws (47) to 6.5 N-m (57.5 lb.in.).

12. Ball & actuator assembly (45).
Jgfl Tighten
Figure 23 - Removing Shaft Lock Retaining Ring
• Tighten bolt (46) to 18 N-m (14 lb.ft.).
2. Shaft lock retaining ring (4) using J 23653-SIR to
14. Parklock cable assembly (48) to lockmodule assembly push down shaft lock shield assembly (5).
(15). • Dispose of ring (4).
• Lock cylinder should be in "OFF-LOCK"
position and gear shift in "PARK" position.
• Locking tab on end of cable (48) to slot in
LINEAR SHIFT ASM (REMOVAL), in this section.
16. Do all steps, "Install or Connect", LOWER SHROUD,
UPPER SHROUD, in this section.
UPPER COLUMN HOUSING COMPONENTS

SHAFT LOCK SHIELD ASM
TURN SIGNAL CANCEL CAM ASM
UPPER BEARING SPRING
THRUST WASHER Figure 24 - Removing Upper Shaft Components
Figures 1, 3, 5, 9, 21 and 22
Tools Required: 4. Turn signal cancel cam assembly (6).
J 23653-SIR Lock Plate Compressor 5. Upper bearing spring (7).
6. Thrust washer (8).
I++] Remove or Disconnect
1. Do steps 1 through 6, "Remove or Disconnect", [77| Install or Connect

COIL ASSEMBLY, in this section.
# Let coil assembly (2) hang freely. NOTICE: Refer to the fastener NOTICE in the caution
1. Thrust washer (8).
2. Upper bearing spring (7).
4. Shaft lock shield assembly (5). 9. Lock bolt assembly (11) with lock bolt spring (12).
• Align inner block tooth of lock plate to block • Spring (12) from lock bolt (11).
tooth of steering shaft assembly (32).
10. Steering column lock cylinder set (17).
5. New shaft lock retaining ring (4) using J 23653-SIR • Turn lock cylinder (17) to "RUN" position.
to push down shaft lock shield assembly (5). • Insert small blade screwdriver into hole on top
• Ring (4) must be firmly seated in groove on of module assembly (15). Push against locking
shaft. button and remove lock cylinder (17).
6. Do steps 1 through 4 and 7 through 10, "Install or
Connect", COIL ASSEMBLY, in this section.
LOCK MODULE ASM

Figures 1, 4, 5, 7 through 21 and 25
Tools Required:
J 41396 Park Lock Cable Pliers
|7+| Remove or Disconnect
1. Do steps 1 through 4, "Remove or Disconnect",

UPPER COLUMN HOUSING COMPONENTS,
in this section.
assembly (15).
position and gear shift in "PARK" position. 11 BOLT ASM, LOCK
• Insert small blade screwdriver into slot in module 12 SPRING, LOCK BOLT
assembly (15). Push against locking tab on end 13 SCREW, PAN HD TAPPING
15 MODULE ASM, LOCK
of cable assembly (48) and remove. 17 LOCK CYL SET, STRG COLUMN
Figure 25 - Removing Lock Module Assembly

3. Key alarm switch from module assembly (15).
(See Figures 9 and 10)
• Gently pry retaining clip on alarm switch with 0 Install or Connect
• Rotate alarm switch 1/4 turn and remove. NOTICE: Refer to the fastener NOTICE in the caution
4. Pass key connector from module assembly(15). damage or malfunction of steering column.
6. Ignition & key alarm switch assembly (19). 1. Steering column lock cylinder set (17).
• Let switch (19) hang freely. • Key installed in lock cylinder (17).
• Ensure sector is in "RUN" position.
NOTICE: Lock bolt assembly (11) is under slight spring (See Figure 5,14).
tension from lock bolt spring (12). Hold lock bolt (11) in • Line up locking tab with slot in lock module
place while removing lock module assembly (15). assembly (15) and push into position.
• Turn lock cylinder (17) to "LOCK" position.
8. Lock module assembly (15). 2. Lock bolt assembly (11) with lock bolt spring (12).
• Ensure cutout in lock bolt (11) is in the 6 o'clock
position. (See Figure 25)
3. Lock module assembly (15). [jy| Inspect

• Push lock bolt (11) into steering column housing
assembly (26) until flush.
• Align lock module assembly (15) with housing • Park lock cable assembly (48). (See Figure 19)
assembly (26) and install. A. With lock cylinder in "OFF-LOCK"
position, gear shift lever should not be
4. Three pan head tapping screws (13). able to shift out of "PARK" position.
[^Tighten D. With gear shift in "NEUTRAL" position,
• Tighten screws (13) to 7 N-m (62 lb.in.) "OFF-LOCK" position.
E. Shifter in "PARK" position.
5. Ignition & key alarm switch assembly (19). F. Lock cylinder in "OFF-LOCK" position'
6. Two tapping screws (18). and remove key.
[^ T ig h te n 9. Do steps 3 through 6, "Install or Connect", UPPER

COLUMN HOUSING COMPONENTS, in this
section.
7. Alarm switch to module assembly (15). STRG COL HOUSING ASM
(See Figures 9 and 10). Figures 1, 4 through 25
cylinder (17). Tools Required:
B. Rotate switch 1/4 turn until locked into place. J 23653-SIR Lock Plate Compressor
9. Pass key connector to module assembly (15).
10. Park lock cable assembly (48) to module
assembly (15). (See Figure 18) p»| Remove or Disconnect
position and gear shift in "PARK" position. 1. Do all steps, "Remove or Disconnect", COIL
• Locking tab on end of cable (48) to slot in ASSEMBLY, in this section.
module assembly (15). 2. Do steps 2 through 7, "Remove or Disconnect", T/S
& MULTIFUNCTION SWITCH ASM, in this
[^[A djust section.
• Park lock cable assembly (48). (See Figure 18,19) LINEAR SHIFT ASM (REMOVAL), in this section.
A. Gear shift lever installed and in 4. Do steps 2 through 6, "Remove or Disconnect",
"PARK" position. UPPER COLUMN HOUSING COMPONENTS,
B. Ignition in "OFF LOCK" position and in this section.
remove key. 5. Do steps 2 through 9, "Remove or Disconnect",
C. Unlock adjuster ring on cable LOCK MODULE ASM, in this section.
assembly (48) with tool J 41396. 6. Four torx head screws (9).
(See Figure 20) 7. Steering column housing assembly (26).
gear shift lever.
E. Lock adjuster ring securely in place on
(See Figure 21)
Install or Connect 5. Cplg & strg shaft assembly (68) or yoke & inter strg
-► 4 -
shaft assembly (32).
NOTICE: Refer to the fastener NOTICE in the caution • Remove bolt
damage or malfunction of steering column. 6. Adapter & bearing assembly (60), and steering shaft
assembly (32) from bottom ofjacket assembly (58).
1. Steering column housing assembly (26). 7. Evo sensor asm (62) and adapter & bearing assembly
2. Four torx head screws (9). (60) from shaft assembly (32).
• Retaining ring (31) from shaft assembly (32).
[^ T ig h te n
• Tighten screws (9) to 17 N-m (13.5 lb.ft.)

3. Do steps 1 through 8, "Install or Connect", LOCK
MODULE ASM, in this section.
4. Do steps 1 through 5, "Install or Connect", UPPER
section.
5. Do steps 1 through 5," Install or Connect", LINEAR
SHIFT ASM (REMOVAL), andA^just andlnspect,
in this section.
6. Do steps lthrough 6, "Install or Connect", T/S &
MULTIFUNCTION SWITCH ASM, in this section.
7. Do all steps /'Install or Connect", COIL ASSEMBLY,
in this section.
STEERING SHAFT ASM

ADAPTER & BEARING ASM
STRG COL JACKET ASM
Figures 1 , 3 , 4 , 5, 19, through 24, 26 and 27
Tools Required:
J 23653-SIR Lock Plate Compressor Figure 26 - Removing Steering Shaft Assembly

2. Disable the SIR System; refer to DISABLING THE
SIR SYSTEM, in this section.
section.
4. Do all steps "Remove or Disconnect", UPPER
section.
|-m -[ Install or Connect

1. Retaining ring (31) to steering shaft assembly (32).
2. Shaft assembly (32) through bottom of jacket
assembly (58).
3. Evo sensor asm (62) and adapter & bearing assembly
(60) to steering column jacket assembly (58).
(See Figure 26).
• Position tab on adapter & bearing assembly
(60) with slot in steering column j acket assembly
(58) and push together.
4. Cplg & strg shaft assembly (68) or yoke & inter strg
shaft assembly (64) to shaft assembly (32).
[^ T ig h te n
• Tighten bolt and nut to 62 N m (46 lb.ft.),
j ^ j Tighten
• Tighten Hex Hd Nut and Locking Bolt (65) and

(67) to 62 N m (46 lb.ft.).
section.
6. Do steps 1 through 7, "Install or Connect", COIL
ASSEMBLY, in this section.
7. Steering column assembly to vehicle, refer to
section 2F.
SIR system; refer to ENABLING THE SIR SYSTEM
in this section.
CHECKING STEERING COLUMN FOR ACCIDENT DAMAGE
NOTICE: Vehicles involved in accidents resulting in frame damage,

m ajor body or sheet metal damage, or where the steering column
has been impacted, or where supplemental inflatable restraints
systems deployed may also have a damaged or misaligned steering
column.
CHECKING PROCEDURE
JACKET ASM, STEERING COLUMN

• Check capsules on steering column bracket assembly; all must be
securely seated in bracket slots and checked for any loose conditions CHECK FOR ANY LOOSE CONDITION WHEN
when pushed or pulled by hand (View A). If not, bracket should be PUSHED OR PULLED BY HAND.
replaced if bolted to jacket assembly. If bracket is welded to jacket
replace jacket assembly.
• Check for jacket assembly collapse by measuring the distance from
h-
the lower edge of upper jacket to a defined point on the lower jacket
(View C). If measured dimensions are not within specifications, a
new jacket must be installed.
NOTICE: Inflatable restraint coil assembly must be removed from

steering column and allowed to hang freely before shaft is rotated.
Failure to do so could damage coil assembly.
STEERING SHAFT ASM

( -------------- 131.00 MM --------- >
• Visually inspect steering shaft for sheared injected plastic (View B).
If steering shaft shows sheared plastic, a new steering shaft must be
installed.
• Any frame damage that could cause a bent steering shaft must have
steering shaft runout checked in the following manner; Using a dial
indicator at lower end of steering shaft, have steering wheel rotated.
Runout must not exceed 1.59mm.
VIEW C (METHOD TO DETERMINE COLUMN COLLAPSE)

WITH LOWER BEARING REMOVED
MEASURE DISTANCE BETWEEN ARROWS.
Figure 27 - Checking for Accident Damage

1 MODULAR COL HOLDING FIXURE

2 PARK LOCK CABLE PLIERS
3 LOCK PLATE COMPRESSOR
4 PIVOT PIN REMOVER
Figure 28 - Special Tools

TILT STRG COL UNIT REPAIR (SIR) 2F5-1
SECTION 2F5
SUPPLEMENTAL INFLATABLE RESTRAINT

(SIR) TILT STEERING COLUMN
UNIT REPAIR
FASTENER SPECIFICATIONS
Specif cation
Application Metric Enalish
G/S Lever S uddoiI Bracket Screws 10 N-m 89 lb in
Ignition & Kev Alarm Switch Screws 1.5 N-m 131b in
Lock Module Assem bly Screws 7 N-m 62 lb in
Lower Shroud Screws 3.5 N-m 31 lb in
Pinch Bolt & Nut 62 N-m 46 lb ft
Round Hd Lockino Bolt & Hex Hd Nut 62 N-m 46 lb ft
Shift Lever Clevis and Cable Shift Cam Screws 18 N-m 14 lb ft
Shift Lever Gate Screws 6.5 N-m 57.5 lb in
Shift Lever Screw 20 N-m 161b ft
Steering Column Support Screws 17 N-m 13.5 lb ft
Steering W heel-to-Shaft Nut 41 N-m 30 lb ft
Turn Signal & Multifunction Switch Screws 7 N-m 62 lb in
Upper Shroud Screws 1.5 N-m 131b in
2F5-2 TILT STRG COL UNIT REPAIR (SIR)
Figure 1 - Tilt Steering Column

1- NUT, HEXAGON LOCKING (M14x1.5)

2 - lNFLATABLE RESTRAINT STRG W H L
MODULE CO IL ASM
3- W ASHER, W AVE
4- RING, RETAINING
5- SHIELD ASM , SHAFT LO CK
6- CAM ASM, T/SIG CANCEL
7- SPRING, UPPER BEARING
8- SEAT, UPPER BEARING INNER RACE
9 - RACE, INNER
10- SHRO UD, UPPER
11- BOLT ASM , LOCK
12- SPRING, LO C K BOLT
13- SCREW , PAN HD TAPPING
14- SCREW , TO R X HEAD
15- ASM, LO CK MODULE
16- SEAL, SH IFT LEVER
17- LOCK CYL SET, STRG COLUMN
18- SCREW , TAPPING
19- SW ITCH ASM, IGN & KEY ALARM
20- SPRING, TILT
21- GUIDE, SPRING
22- STRAP, W IRE HARNESS
23- CO NNECTOR, AX IA L POSN ASSUR
24- SW ITCH ASM, T/S & M ULTIFUNCTION
26- TILT HEAD ASM, STRG COL
2 7- PROTECTOR, SHROUD
28- SHROUD, LOW ER
29- STUD, SHRO UD MOUNTING
30- RING, RETAINING
31- SCREW, SHIFT LEVER
32- LEVER ASM, A/TR NS CO NTRO L
3 3- LEVER ASM, TILT
34- SHAFT ASM, RACE & UPPER
35- SPHERE, CENTERING
36- SPRING, JO IN T PRELOAD
37- SHAFT ASM, LOW ER STRG
40- SHIFT ASM, LINEAR
41- CLEVIS, SHIFT LEVER
43- SCREW, FLAT HD 6-LO BED SOC TAP
44- CAM ASM, CABLE SHIFT
45- ACTUATO R ASM, BALL &
4 6- BOLT, HEX FLANGE HEAD
47- SCREW, O VAL HD 6-LO BED SOC TAP
48- CABLE ASM, PARK LOCK
4 9 - BRACKET, G/S LEVER ASM SUPPORT
55- SCREW, TO R X HEAD
5 6 - PIN, PIVOT
57- SUPPORT ASM, STRG COL
58- JAC KET ASM, STRG COL
6 0- BEARING ASM, ADAPTER &
61- AC TUATO R, ELECTRICAL (BTSI)
62- SENSO R ASM, EVO
63- BUSHING, CAM
Figure 2 - Tilt Steering Column - Legend

CAUTION: The procedures in this section must Remove or Disconnect

be followed in the order listed to temporarily
disable the Supplemental Inflatable Restraint
(SIR) System and prevent false diagnostic codes
• Turn the steering wheel so that the vehicle's wheels
from setting. Failure to follow procedures could are pointing straight ahead.
result in possible air bag deployment, personal • Turn the ignition switch to “LOCK” and
injury, or otherwise unneeded SIR system remove key.
repairs.
1. “AIR BAG” fuse from I/P fuse block.
C A U TIO N :Before removing or installing any 2. Steering column filler panel. Refer to section 10A4.
electrical unit or when a tool or equipment could 3. Connector position assurance (CPA) retainer and
easily come in contact with "live" exposed yellow 2-way SIR connector at base of steering
electrical terminals, disconnect the negative column.
battery cable to help prevent personal injury
and/or damage to the vehicle or components.
Unless instructed otherwise, the ignition switch 9 Important
must be in the "off11or "lock" position. • With the "AIR BAG" fuse removed and ignition
switch "ON", the "AIR BAG" warning lamp will be
NOTICE: Once steering column is removed from vehicle, "ON". This is normal operation and does not indicate
the column is extremely susceptible to damage. Dropping an SIR system malfunction.
steering column assembly on its end could collapse steering
shaft or loosen plastic injections which maintain column
rigidity. Leaning on steering column assembly could cause
jacket to bend or deform. Any of the above damage could ENABLING THE SIR SYSTEM
impair steering column's collapsible design. If it is necessary
to remove steering wheel, use only the specified steering Install or Connect
wheel puller and holding fixture. Never place column
directly into a vise. Under no conditions should the end of • Turn the ignition switch to “LOCK” and remove
shaft be hammered on as hammering could loosen plastic key.
injections which maintain steering column rigidity.
1. Yellow 2-way SIR connector and CPA retainer at
base of steering column.
DISABLING THE SIR SYSTEM 2. “AIR BAG” fuse to I/P fuse block.
3. Steering column filler panel. Refer to section 10A4.
• Turn ignition switch to “RUN” and verify that
SERVICE PRECAUTIONS the "AIR BAG" warning lamp flashes 7 times
CAUTION: When performing service on or and then turns “OFF”. If it does not operate as
SIR components or SIR wiring, follow
a ro u n d
described, perform the “SIR Diagnostic System
the procedures listed below to temporarily Check” in section 9J-A of the Service Manual
disable the SIR system. Failure to follow Supplement.
procedures could result in possible air bag
deployment, personal Injury, or otherwise
unneeded SIR system repairs.
The DERM can maintain sufficient voltage to

cause a deployment for up to 2 minutes after the
ignition switch is turned "OFF" or the battery is
disconnected. Many of the service procedures require
disconnection of the "AIR BAG" fuse and the inflator
module circuits from the deployment loops to avoid an
accidental deployment.
UNIT REPAIR
LOWER SHROUD
STRG COLUMN LOCK CYL SET
UPPER SHROUD
SHIFT LEVER SEAL (c/s only)
Figure 1, 3 through 5, 14, and 29
Tools Required:
Q Remove or Disconnect

SIR SYSTEM in this Section.
3. Cplg & strg shaft assembly (64) or yoke & inter strg
shaft assembly (65) (Depending on Model) from Figure 3 - Modular Column Holding Fixture
shaft assembly (37).
e Remove bolt
5. Tilt lever; refer to section 2F.
6. Two pan head tapping screws (13) from lower
the column is extremely susceptible to damage. See shroud (28).
NOTICE on page 2F5-1 in this section. 7. Lower shroud (28).
• Tilt shroud (28) down and slide back to
4. Lower or remove steering column from vehicle; disengage locking tabs.
refer to section 2F. 8. Two torx head screws (14) from
• Secure steering column to modular col. holding upper shroud (10).
fixture J 41352.
• Place holding fixture into vise. (See Fig.3)
|ffll Inspect
• Steering shaft assembly for accident damage.

(See Figure 31).
Figure 4 - Removing Lock Cylinder and Upper Shroud

9. Lift upper shroud (10) to gain access to lock
cylinder hole.
A. Hold key in "START" position.
B. Using 1/16-inch alien wrench push on lock
cylinder retaining pin.
4. Retaining ring (30). 2. Two wire harness straps (22) from steering column
• Ring (30) must seat securely in groove on wire harness.
shaft (34). 3. Steering column bulkhead connector from vehicle
wire harness.
5. Route lower coil wire along steering column j acket 4. Axial position assurance connector (23) from
assembly (58). electrical (BTSI) actuator (61). (Column shift only)
6. Two wire harness straps (22) to steering column wire • Electrical connector from (BTSI) actuator (61).
harness.
7. Do steps 4 through 11, "Install or Connect", LOWER 5. Grey and black connectors of turn signal &
SHROUD, UPPER SHROUD, in this Section. multifunction switch (24) from column bulkhead
8. Steering wheel and air bag module; refer to service connector.
procedures in section 2F. 6. Two pan head tapping screws (13).
9. If all service operations are completed, enable the 7. Turn signal & multifunction switch assembly (24)
SIR system; refer to ENABLING THE SIR SYSTEM from column.
in this section.
10. Negative (-) battery cable. -►+ Install or Connect

T/S & MULTIFUNCTION SWITCH ASM
Figures 1 through 8
Tools Required: 1. Turn signal & multifunction switch assembly (24)

J 41352 Modular Column Holding Fixture to column.
• With small blade screwdriver compress
electrical contact and move multifunction switch
|*+| Remove or Disconnect (24) into position.
• Electrical contact must rest on cancelling cam
1. Do steps 1 through 8, "Remove or Disconnect", assembly (6).
section. 2. Two pan head tapping screws (13).
[^ T ig h te n

3. Grey and black connectors of multifunction switch
(24) to column bulkhead connector.
4. Electrical connector to electrical (BTSI) actuator
(61). (Column shift only)
• Axial position assurance connector (23).
5. Steering column bulkhead connector to vehicle wire
harness.
6. Two wire harness straps (22) to steering column
wire harness.
7. Do steps 4 through 11, "Install or Connect", LOWER
13 SCREW, PAN HD TAPPING SHROUD, UPPER SHROUD, in this section.
22 STRAP, WIRE HARNESS
23 CONNECTOR, AXIAL POSN ASSUR
24 SWITCH ASM, T/S & MULTIFUNC
Figure 8 - Removing T/S & Multifunction Switch

IGN & KEY ALARM SWITCH ASM

Figures 1 through 10 KEY ALARM CONNECTOR
KEY CONNECTOR
Tools Required:
|•* * | Remove or Disconnect

section.
18 SCREW, TAPPING
19 SWITCH ASM, IGN & KEY ALARM
22 STRAP, WIRE HARNESS
26 HOUSING ASM, STRG COLUMN
Figure 10 -Remove Ignition & Key Alarm Switch

• Wire harness from slot in steering column tilt
head assembly (26).
♦« - Install or Connect

• Route wire harness through slot in steering
2. Key alarm switch from lock module assembly (15). column tilt head assembly (26). Secure wire
• Gently pry retaining clip on alarm switch with harness with a wire harness strap (22) through
small blade screwdriver. hole located in the bottom of housing
• Rotate alarm switch 1/4 turn and remove. assembly (26).
3. Pass key connector from module asm (15). 2. Two tapping screws (18).
(See Figure 10).
[^ T ig h te n

3. Key alarm switch to lock module assembly (15).
A. Switch with retaining clip parallel to lock cylinder
(17).
B. Rotate switch 1/4 turn until locked into place.
4. Pass key connector to lock module asm (15). 10. Key alarm switch from lock module assembly (15).
5. Do all steps, "Install or Connect", LOWER SHROUD, (See Figure 9)
UPPER SHROUD, in this section. • Gently pry retaining clip on alarm switch with
STRG COLUMN LOCK CYL SET • Rotate alarm switch 1/4 turn and remove.
(Replacement-Lost Key)
Figure 3-5, 6, 7, 9 through 21, 28, 30 11. Pass key connector from lock module assembly (15).
(See Figures 9 and 10).
Tools Required: 12. Two tapping screws (18).
J 23653-SIR Lock Plate Compressor 13. Ignition & key alarm switch assembly (19).
J 41352 Modular Column Holding Fixture • Let switch (19) hang freely.
NOTICE: Lock bolt assembly (11) is under slight spring
tension from lock bolt spring (12). Hold lock bolt (11) in
I++I Remove or Disconnect place while removing lock module assembly (15).
1. Do steps 1 through 7, "Remove or Disconnect", 14. Three pan head tapping screws (13).
LOWER SHROUD, UPPER SHROUD, in this 15. Lock module assembly (15) with upper shroud (10).
section if you "DO NOT" have the "Key" to match
the lock cylinder. The upper shroud (10) will remain
with the lock module assembly (15).
NOTICE: If you "DO" have the "Key" that matches the
lock cylinder, then do steps 1 through 9, "Remove or
Disconnect", LOWER SHROUD, UPPER SHROUD, in
this section.
2. Air bag module and steering wheel; refer to^ervice
procedures in section 2F.
NOTICE: Coil assembly (2) will become uncentered if:
gear and allowed to rotate.
2) Centering spring is pushed down, letting
hub rotate while coil (2) is removed from
steering column. (If this occurs, refer to
Figure 7 to center coil)
3. Retaining ring (30). Figure 11 - Sector Gear Timing Position (OFF-LOCK)
5. Wave washer (3). 16. Backing plate from lock module assembly (15).
6. Shaft lock retaining ring (4) using J 23653-SIR to
push down shaft lock shield assembly (5). 9 Important
• Dispose of ring (4).
7. Shaft lock shield assembly (5). • Mark two sector gears at "OFF-LOCK" position
8. Turn signal cancel cam assembly (6). to ensure proper reassembly. Failure to assemble
9. Park lock cable assembly (48) from lock module sector gears properly will cause lock cylinder (17)
assembly (15). and ignition switch (19) to be improperly timed. (See
• Insert small blade screwdriver into slot in lock Figure 11 for proper timing)
module assembly (15). Push against locking tab
on end of cable assembly (48) and remove. 17. Remove both sector gears.
Clean
• All debris and metal shavings from inside lock
• Remove all burrs.
Install or Connect

1. Align marks made on sector gears and install sector
gears and backing plate to lock module assembly
(15). (See Figure 11 for proper timing of gears)
2. Steering column lock cylinder set (17) to lock
A. Ensure sector in lock module assembly (15) is in
"OFF-LOCK" position. (See Figure 11)
18. Remove positioning tab on end of lock cylinder (17) B. Key installed in lock cylinder (17) and in
using an 1/8-inch burring tool. (See Figure 12) "OFF-LOCK" position.
• Remove all burrs in and around lock module C. Line up locking tab and positioning tab with slots
assembly (15) and lock cylinder (17). in lock module assembly (15) and push cylinder
(17) into position.
19. From inside lock module assembly (15) push on D. Rotate lock cylinder to "ACC" position and
locking tab and pull lock cylinder (17) from lock check alignment of "ARROWS" on sector
module assembly (15) and upper shroud (10). gears. Arrows should be pointing towards
each other.
E. Rotate lock cylinder to "LOCK" position.
3. Lock module assembly (15).
KEY CODE SIDE VIEW
• Push lock bolt (11) into steering column tilt
head assembly (26) until flush.
• Align lock module assembly (15) with tilt head
assembly (26) and install.
P& | Tighten
• Tighten screws (13) to 3.5 N-m (31 lb.in.)

Figure 13 - Location of Key Code 6. Two tapping screws (18) for ignition & key
alarm switch (19).
20. Record "Key Code" from old lock cylinder.
(See Figure 13) [^ T ig h ten
• Build up "New" lock cylinder.
• Cut "New" key.
• Discard "Old" lock cylinder. • Tighten screws (18) to 1.5 N-m (13 lb.in.).
7. Key alarm switch to lock module assembly (15).

cylinder (17).
8. Pass key connecter to lock module assembly (15).
• Align inner block tooth of lock plate to block
tooth of race & upper shaft assembly (34).
11. New shaft lock retaining ring (4) using J 23653-SIR
to push down shaft lock shield assembly (5).
• Ring (4) must be firmly seated in groove on
shaft.
12. Center race & upper shaft assembly (34).
A. Wheels straight ahead. 18. Park lock cable assembly (48) to lock module
• Block tooth and centering mark on shaft assembly (15).
assembly (34) at 12 o'clock position. • Lock cylinder should be in "OFF-LOCK"
(See Figure 30) position and gear shift in "PARK" position.
• Locking tab on end of cable (48) to slot
B. Ignition switch to "LOCK" position. in lock module assembly (15).
C. Ensure coil (2) is centered; refer to figure (7).
13. Wave washer (3). |^ 1 Adjust
NOTICE: New coil assembly (2) will be pre-centered. • Park lock cable assembly (48). (See Figure 19)
Install new coil, remove and dispose of centering tab.
A. Gear shift lever installed and in "PARK"
14. assembly (2).
C o il
position.
A. Ensure shaft (34) and coil asm (2) are centered. B. Ignition in "OFF-LOCK" position and
• If steering shaft assembly (34) needs to be remove key.
centered (See Figure 28). C. Unlock adjuster ring on cable assembly
• If coil needs to be centered (48) with tool J 41396. (See Figure 20)
(See Figure 7). D. Pull on cable until park lock latch contacts
gear shift lever.
B. Align coil (2) with hom tower and slide onto • Release the cable.
shaft (34).
15. Retaining ring (30) must seat securely in groove cable assembly (48) with tool J 41396. (See
on shaft (32). Figure 21)
16. Route lower coil wire along steering column jacket
assembly (58).
harness.
|ffl| Inspect 27. Wheels straight ahead and column at 12 o'clock

position.
28. Raise or install steering column to vehicle; refer to
• Park lock cable assembly (48). (See Figure 19) section 2F.
A. With lock cylinder in "OFF-LOCK" 29. Steering wheel.
position, gear shift lever should not be able 30. If all service operations are completed, enable the
to shift out of "PARK" position. SIR system; refer to "ENABLING THE SIR
B. Insert key and turn to "RUN" position. SYSTEM" in this section.
C. Shifter in "NEUTRAL" position. 31. Negative (-) battery cable.
E. Shifter in "PARK" position. ELECTRICAL (BTSI) ACTUATOR
F. Lock cylinder in "OFF-LOCK" position (c/s only)
and remove key. Figures 1,15 through 17
19. Remove steering column lock cylinder (17) from
lock module assembly (15). |*+] Remove or Disconnect
20. Upper shroud (10).
21. Two torx head screws (14) to upper shroud (10). 1. Negative (-) battery cable.
[^ T ig h te n SIR SYSTEM, in this section.
3. Tilt column to "CENTER" position.
• Ensure that slots on lower shroud (28) engage
with tabs on upper shroud (10).
23. Two pan head tapping screws (13) to lower
shroud (28).
[^Tighten

24. Shift lever seal (16) and multifunctional lever Figure 15 - Removing Electrical (BTSI) Actuator
seal into position.
25. Steering column lock cylinder set (17) to
lock module assembly (15). 4. Electrical (BTSI) actuator (61) from column.
A. Ensure sector in lock module assembly (15) is in A. Column in "NEUTRAL" position.
"RUN" position. (See Figure 11) B. Pry (BTSI) actuator (61) from mounting pin on
B. Key installed in lock cylinder (17) and in "RUN" steering column jacket assembly (58) and outer
position. shift cable ball stud on cable shift cam
C. Line up locking tab and positioning tab with assembly (44).
slots in lock module assembly (15) and push C. Axial position assurance connector (23) from
cylinder (17) into position. electrical connector.
• Electrical connector from (BTSI)
26. Tilt lever; refer to section 2F. actuator (61).

SIR system; refer toENABLING THE SIR SYSTEM,
in this section.
A. MOVE ACTUATOR ROD TO ADJUSTER BLOCK SIDE

FOR LEVERAGE.
B. PRESS ON ADJUSTER BLOCK TO COMPRESS
INTERNAL ADJUSTER SPRING AND DISENGAGE
ADJUSTER TEETH.
C. SLIDE ADJUSTER BLOCK AS FAR AWAY FROM
SOLENOID AS POSSIBLE.
D. REPLACE ACTUATOR ROD TO SOLENOID
SIDE. ROD WILL BE VISIBLE IN HOLE IN
ADJUSTER BLOCK.
Figure 16 - Adjusting Electrical (BTSI) Actuator
2 1 Adjust
• Electrical (BTSI) Actuator (61) (See Figures Figure 17 - (BTSI) Adjuster Lock
16,17)
A. Move actuator rod to adjuster block side
for leverage.
B. Press on adj uster block to compress internal [ffl| Inspect
adjuster spring and disengage the adjuster
teeth. • Function check Electrical (BTSI) actuator (61)
C. Slide the adjuster block as far away from for proper operation.
the solenoid as possible. • Actuator (61) must lock gearshift lever when
D. Replace actuator rod to solenoid side. ever steering column is in "PARK" position
and when trying to shift from "PARK" position
without pressing brake pedal.
Install or Connect (Solenoid is energized)
• Actuator (61) must release gearshift lever when
pressure is applied to brake pedal.
and fastener section. Failure to do so may result in component (Solenoid is de-energized)
damage or malfunction of steering column. • Readjust if needed.
1. Electrical (BTSI) actuator (61) to column.

A. Column in "Neutral" position.
B. (BTSI) actuator (61) to mounting pin on steering
column jacket assembly (58) and outer shift
cable ball stud on cable shift cam
assembly (44).
C. Electrical connector to (BTSI) actuator (61).
• Axial position assurance connector (23) to
LINEAR SHIFT ASM (REMOVAL) 5. Three flat head 6 -lobed socket tap screws (43).
(c/s only) • Shift column to "NEUTRAL" position to gain
Figures 1, 3, 15 through 21 access to lower socket tap screw (43).
Tools Required: 6. Linear shift assembly (40) from column.
Install or Connect
NOTICE: Linear shift assembly (40) may be removed as an
assembly or certain components may be disassembled as NOTICE: Refer to the fastener NOTICE in the caution
necessary to do repairs. Remove or disassemble only those and fastener section. Failure to do so may result in component
components necessary to do repairs. damage or malfunction of steering column.
Q Remove or Disconnect 1. Linear shift assembly (40) to column.

1. Do all steps, "Remove or Disconnect", LOWER • Linear shift assembly (40) must be out of
SHROUD, UPPER SHROUD, in this section. "PARK" position to install lower socket tap
2. Park lock cable assembly (48) from lock module screw (43).
assembly (15).
• Lock cylinder should be in "OFF-LOCK" position [^ T ig h te n
and gear shift in "PARK" position.
# Insert small blade screwdriver into slot in lock • Tighten screws (43) to 10 N-m (89 lb.in.).
module assembly (15). Push against locking tab
on end of cable assembly (48) and remove. 3. Transaxle cable to inner shift cable ball stud on cable
3. Pry actuator arm of electrical (BTSI) actuator (61) shift cam assembly (44).
from outer shift cable ball stud on cable shift cam 4. Park lock cable assembly (48) to lock module assembly
assembly (44) and mounting pin on jacket (58). (15).
4. Transaxle cable from inner shift cable ball stud on • Lock cylinder should be in "OFF-LOCK"
cable shift cam assembly (44). position and gear shift in "PARK" position.
• Locking tab on end of cable (48) to slot in lock
5. Actuator arm of electrical (BTSI) actuator (61) to
outer shift cable ball stud on cable shift cam
assembly (44).
ELECTRICAL (BTSI) ACTUATOR, in this section.
Figure 18 - Removing Linear Shift Assembly

C. Unlock adjuster ring on cable

assembly (48) with tool J 41396.
(See Figure 20)
gear shift lever.
(See Figure 21)
A. SHIFTER IN "PARK" POSITION.
B. IGNITION IN "OFF-LOCK" POSITION.
C. UNLOCK ADJUSTER RING.
D. PULL LOWER CABLE SECTION TO REMOVE LASH.
E. LOCK ADJUSTER RING SECURELY IN PLACE.
Figure 19 - Adjusting Park Lock Cable
{9 Inspect
• Park lock cable assembly (48). (See Figure 19)

Figure 20 - Unlocking Adjuster Ring on Park Lock Cable position, gear shift lever should not be
0 Adjust
• Park lock cable assembly (48). (See Figure 19) "OFF-LOCK" position.
A. Gear shift lever installed and in E. Shifter in "PARK" position.
"PARK" position. F. Lock cylinder in "OFF-LOCK" position'
B. Ignition in "OFF LOCK" position and and remove key.
remove key.
7. Do all steps "Install or Connect", LOWER SHROUD, 6. Shift lever clevis (41).
UPPER SHROUD, in this section. A. Lift up on shift gate and rotate shift lever
clevis (41).
B. Clevis (41) from gearshift lever assembly support
LINEAR SHIFT ASM (DISASSEMBLY) bracket (49).
BALL & ACTUATOR ASM
SHIFT LEVER CLEVIS 7. Park lock cable assembly (48) from support
PARK LOCK CABLE ASM bracket (49). Remove retaining clip.
G/S LEVER ASM SUPPORT BRKT
8. Pry actuator arm of electrical (BTSI) actuator (61)
(c/s only)
from outer shift cable ball stud on cable shift cam
assembly (44).
Figures 1,3,15 through 22 9. Pry transaxle shift cable from inner ball stud on cable
shift cam assembly (44).
Tools Required: 10. Hexagon flange head bolt (46).
J 41352 Modular Column Holding Fixture 11. Cable shift cam assembly (44).
J 41396 Park Lock Cable Pliers 12. Cam bushing (63) from cable shift cam
assembly (44).
Disassemble 14. Gearshift lever assembly support bracket (49).
1. Do all steps "Remove or Disconnect", LOWER
SHROUD, UPPER SHROUD, in this section. |^|h| Assemble
1. Lubricate all moving parts of assembly with

synthetic grease.
[§j] Tighten
41 CLEVIS, S H IR LEVER
43 SCREW, FLAT HD 6-LOBED SOC TAP
44 CAM ASM, CABLE S H IR 4. Insert cam bushing (63) into cable shift cam
45 ACTUATOR ASM, BALL & assembly (44).
46 BOLT, HEX FLANGE HEAD
47 SCREW, OVAL HD 6-LOBED SOC TAP 5. Cable shift cam assembly (44).
48 CABLE ASM, PARK LOCK 6. Hexagon flange head bolt (46).
49 BRACKET, G/S LEVER ASM SUPPORT
63 BUSHING,CAM
Figure 22 - Disassembling Linear Shift Assembly | ^ | Tighten
• Tighten bolt (46) to 18 N-m (14 lb.ft.).

3. Ball & actuator assembly (45). 7. Transaxle shift cable to inner ball stud on cable shift
4. Pry off locking ring on park lock cable cam assembly (44).
assembly (48). (See Figures 19,20) 8. Actuator arm of electrical (BTSI) actuator (61) to
• Move park lock latch to gain access to lower outer shift cable ball stud on cable shift cam
oval head 6-lobed socket tap screw (47). assembly (44).
9. Park lock cable assembly (48) to support
5. Two oval head 6-lobed socket tap screws (47) from bracket (49). Insert retaining clip.
shift gate.
10. Shift lever clevis (41) and shift gate to support

bracket (49).
A. Position shift gate to end of clevis (41) lever.
B. Rotate clevis (41) and shift gate into position.
C. Push against shift lever spring tension to align
shift gate holes with support bracket (49) holes
11. Two oval head 6-lobed socket tap screws (47).
[^ T ig h te n

12. Ball & actuator assembly (45).
13. Hexagon flanged head bolt (46). Figure 23 - Removing Tilt Spring
[^ T ig h te n
CAUTION: The tilt spring (20) and spring guide (21) are
• Tighten bolt (46) to 18 N-m (14 lb.ft.). under pressure and could become a projectile. During
removal and installation secure spring with locking pliers.
14. Park lock cable assembly (48) to lock module Exercise caution when removing or installing spring and
assembly (15). guide, as bodily injury may result.
• Lock cylinder should be in "OFF-LOCK" 5. Tilt spring (20).
position and gear shift in "PARK" position. A. Pry spring (20) up until a bulge occurs and most
• Locking tab on end of cable (48) to slot in lock spring tension is removed.
module assembly (15). B. Secure spring (20) with locking pliers and
15. Do Adjust and Inspect, "Install or Connect", continue prying until spring disengages from
LINEAR SHIFT ASM (REMOVAL), in this section. post on steering column support assembly (57)
16. Doallsteps, "Install or Connect", LOWER SHROUD, and steering column tilt head assembly (26).
UPPER SHROUD, in this section. 6. Spring guide (21) from tilt spring (20).
TILT SPRING
Figures 1 and 23 ■+4* Install or Connect
Remove or Disconnect NOTICE: Refer to the fastener NOTICE in the caution

1. Disable the SIR System; refer to DISABLING THE
SIR SYSTEM, in this section. 1. Spring guide (21) to tilt spring (20).
2. Two pan head tapping screws (13) from lower 2. Tilt spring (20) with guide (21).
shroud (28). A. Spring (20) to post on steering column support
3. Lower shroud (28). assembly (57).
• Tilt shroud (28) down and slide back to disengage B. Secure spring (20) with locking pliers.
locking tabs. C. With end of spring (20) on post pull on center of
spring (20) while pushing guide end to post on
4. Tilt column to "UP" position. steering column tilt head assembly (26).
D. With both ends installed to post, push spring
(20) into position.
3. Lower shroud (28). 2. Shaft lock retaining ring (4) using J 23653-SIR to
• Ensure that slots on lower shroud (28) engage push down shaft lock shield assembly (5).
with tabs on upper shroud (10). • Dispose of ring (4).
4. Two pan head tapping screws (13) to lower 4. Turn signal cancel cam assembly (6).
shroud (28). 5. Upper bearing spring (7).
6. Upper bearing inner race seat (8).
[^ T ig h te n 7. Inner race (9).

SIR system; refer to ENABLING THE SIR
SYSTEM, in this section.
UPPER TILT HEAD COMPONENTS

SHAFT LOCK SHIELD ASM
TURN SIGNAL CANCEL CAM ASM
UPPER BEARING SPRING
UPPER BEARING INNER RACE SEAT
INNER RACE 4 RING, RETAINING
5 SHIELD ASM, SHAFT LOCK
Figures 1, 6, 7, 24, and 25 6 CAM ASM, T/SIG CANCEL
7 SPRING, UPPER BEARING
Tools Required: 8
9
SEAT, UPPER BEARING INNER RACE
RACE, INNER
Figure 25 - Removing Upper Shaft Components
p»| Remove or Disconnect
-► - Install or Connect
1. Do steps 1 through 4, "Remove or Disconnect",COIL
4
ASSEMBLY, in this section.

• Let coil assembly (2) hang freely. NOTICE: Refer to the fastener NOTICE in the caution
1. Inner race (9).
2. Upper bearing inner race seat (8).
3. Upper bearing spring (7).
• Align inner block tooth of lock plate to block
tooth of race & upper shaft assembly (34).
• Lubricate with grease, synthetic (service kit).
6. New shaft lock retaining ring (4) using J 23653-SIR
Figure 24 - Removing Shaft Lock Retaining Ring to push down shaft lock shield assembly (5).
• Ring (4) must be firmly seated in groove on
shaft.
7. Do steps 1 through 3 and 6 through 9, "Install or

Connect", COIL ASSEMBLY, in this section.
LOCK MODULE ASM

Figures 1,6,7, 9,10,19,20,21 and 24 through 26
J
Tools Required:
Rem ove or Disconnect

UPPER TILT HEAD COMPONENTS,
in this section.
assembly (15).
e Lock cylinder should be in "OFF-LOCK"
position and gear shift in "PARK" position. 11 BOLT ASM, LOCK
• Insert small blade screwdriver into slot in lock 12 SPRING, LOCK BOLT
module assembly (15). Push against locking

13 SCREW, PAN HD TAPPING
15 MODULE ASM, LOCK
tab on end of cable assembly (48) and remove. 17 LOCK CYL SET, STRG COLUMN
Figure 26 - Removing Lock Module Assembly

3. Key alarm switch from lock module assembly (15).
(See Figure 9)
• Gently pry retaining clip on alarm switch with Install or Connect
• Rotate alarm switch 1/4 turn and remove.
4. Pass key connector from lock module assembly (15). and fastener section. Failure to do so may result in component
(See Figures 9 and 10). damage or malfunction of steering column.
6. Ignition & key alarm switch assembly (19). 1. Steering column lock cylinder set (17).
• Let switch (19) hang freely. • Key installed in lock cylinder (17).
• Ensure sector is in "RUN" position.
NOTICE: Lock bolt assembly (11) is under slight spring (See Figure 5,14).
tension from lock bolt spring (12). Hold lock bolt (11) in • Line up locking tab with slot in lock module
place while removing lock module assembly (15). assembly (15) and push into position.
• Turn lock cylinder (17) to "LOCK" position.
8. Lock module assembly (15). 2. Lock bolt assembly (11) with lock bolt spring (12).
9. Lock bolt assembly (11) with lock bolt spring (12). • Ensure cutout in lock bolt (11) is in the 6 o'clock
• Spring (12) from lock bolt (11). position. (See Figure 26)
10. Steering column lock cylinder set (17). 3. Lock module assembly (15). (See Figure 26)
• Turn lock cylinder (17) to "RUN" position. • Push lock bolt (11) into steering column housing
• Insert small blade screwdriver into hole on top of assembly (26) until flush.
module assembly (15). Push against locking • Align lock module assembly (15) with tilt head
button and remove lock cylinder (17). assembly (26) and install.
4. Three pan head tapping screws (13). |f f | Inspect
| ^ | Tighten • Park lock cable assembly (48). (See Figure 19)

• Tighten screws (13) to 3.5 N-m (31 lb.in.) position, gear shift lever should not be
5. Ignition & key alarm switch assembly (19). B. Insert key and turn to "RUN" position.
6. Two tapping screws (18). C. Shifter in "NEUTRAL" position.
[gX] Tighten lock cylinder should not be able to go into
E. Shifter in "PARK" position.
• Tighten screws (18) to 1.5 N-m (13 lb.in.). F. Lock cylinder in "OFF-LOCK" positions
and remove key.
7. Alarm switch to lock module assembly (15).
A. Switch with retaining clip parallel to lock 10. Do steps 4 through 7, "Install or Connect", UPPER
cylinder (17). TILT HEAD COMPONENTS, in this section.
8. Pass key connector to lock module assembly (15).
9. Park lock cable assembly (48) to lock module STRG COL TILT HEAD ASM
assembly (15). (See Figure 18)
• Lock cylinder should be in "OFF-LOCK" Figures 1 through 27
position and gear shift in "PARK" position.
• Locking tab on end of cable (48) to slot in lock Tools Required:
module assembly (15). J 23653-SIR Lock Plate Compressor
J 21854-01 Pivot Pin Remover
Adjust Remove or Disconnect
• Park lock cable assembly (48). 1. Do all steps, "Remove or Disconnect", COIL
(See Figure 18,19) ASSEMBLY, in this section.
A. Gear shift lever installed and in 2. Do steps 2 through 7," Remove or Disconnect", T/S
"PARK" position. & MULTIFUNCTION SWITCH ASM, in this
B. Ignition in "OFF LOCK" position and section.
remove key. 3. Do steps 2 through 6, "Remove or Disconnect",
C. Unlock adjuster ring on cable assembly LINEAR SHIFT ASM (REMOVAL), in this section.
(48) with tool J 41396. (Column shift only)
(See Figure 20) 4. Do steps 2 through 7, "Remove or Disconnect",
D. Pull on cable until park lock latch contacts UPPER TILT HEAD COMPONENTS, in this
gear shift lever. section.
• Release the cable. 5. Do steps 6 through 8, "Remove or Disconnect",
LOCK MODULE ASM, in this section.
E. Lock adjuster ring securely in place on 6. Do steps 4 and 5, "Remove or Disconnect", TILT
cable assembly (48) with tool J 41396. SPRING, in this section.
(See Figure 21)
8. Do all steps, "Install or Connect", COIL

ASSEMBLY.
LOWER STEERING SHAFT ASM

SPHERE
JOINT SPRING
STRG COL SUPPORT ASM
ADAPTER & BEARING ASM
STRG COL JACKET ASM
Figures 1,3,6through8,15through23,27through31
Tools Required:
J 21854-01 Pivot Pin Remover
7. Two pivot pins (56) using J 21854-01. J 41352 Modular Column Holding Fixture
8. Steering column tilt head assembly (26).
• Pull tilt arm to disengage steering wheel lock Remove or Disconnect
shoes from dowel pins in steering column support
assembly (57).
the column is extremely susceptible to damage. See NOTICE
on page 2F5-1 in this section.
Install or Connect
1. Steering column guide assemblies (53) and (54) from
NOTICE: Refer to the fastener NOTICE in the caution steering column jacket assembly (58).
and fastener section. Failure to do so may result in component 2. Do steps 1 through 8, "Remove or Disconnect",
damage or malfunction of steering column. LOWER SHROUD, UPPER SHROUD, in
this section.
1. Steering column tilt head assembly (26). 3. Two pan head tapping screws (13).
• Using tilt lever position lock shoes to dowel 4. Turn signal & multifunction switch assembly (24).
pins. 5. Linear shift assembly (40).
• Rotate head assembly (26) until holes for • Do steps 2 through 6 "Remove or Disconnect",
pivot pins (56) line up. LINEAR SHIFT ASM (REMOVAL), in this
section. (Column shift only)
2. Two pivot pins (56).
A. Lubricate with lithium grease. 6. Refer to CAUTION and do steps 5 and 6, "Remove
B. Press pins until firmly seated two places. or Disconnect", TILT SPRING, in this section.
C. Stake pins (56) three locations two places. 7. Cplg & strg shaft assembly (64) or yoke & inter strg
3. Do step 2, "Install or Connect", TILT SPRING, in shaft assembly (37).
this section. • Remove bolt
4. Do steps 2 through 4, "Install or Connect", LOCK
MODULE ASM, in this section. 8. Evo sensor (62) and adapter & bearing assembly (60)
5. Do steps 1 through 6, "Install or Connect", T/S & from jacket assembly (58).
MULTIFUNCTION SWITCH ASM, in this section.
TILT HEAD COMPONENTS, in this section.
7. Do steps 1 through 6,"Install or Connect", LINEAR
SHIFT ASM (REMOVAL), in this section.
(Column shift only) and adjust and inspect in
this section.
TILT STRQ COL UNIT REPAIR (SIR) 2F5-23
26 TILT HEAD ASM, STRG COL

58 JACKET ASM, STRG COL
60 BEARING ASM, ADAPTER &
62 SENSOR ASM, EVO
Figure 28 - Removing Tilt Head Assembly Figure 29 - Disassembling Steering Shaft Assembly
with Steering Shaft
9. Two pivot pins (56) using J 21854-01. p|»| Disassemble
10. Steering column tilt head assembly (26) with steering
shaft assembly.
• Install and pull tilt arm to disengage steering • Lower steering shaft assembly (37) from race &
wheel lock shoes from dowel pins in steering upper shaft assembly (34) and steering column
column support assembly (57). tilt head assembly (26).
A. Race & upper shaft assembly (34) from lower
steering shaft assembly (37).
[T| Important e Tilt 90 degrees to each other and disengage.
• Mark race & upper shaft assembly (34) and lower B. Centering sphere (35) from upper shaft
steering shaft assembly (37) to ensure proper assembly (34).
assembly. Failure to assemble properly will • Rotate sphere 90 degrees and slip out.
causesteering wheel to be turned 180 degrees.
(See Figures 28 and 29). C. Shaft preload spring (36) from centering
sphere (35).
1. Steering column support assembly (57).
2. Four torx head screws (55).
[^ T ig h te n
• Tighten screws (55) to 17 N-m (13.5 lb.ft.)

3. Do steps 1 through 4,6, and 7, "Install or Connect",
STRG COL TILT HEAD ASM, in this section.
4. Evo sensor asm and adapter & bearing assembly (60)
to steering column jacket assembly (58).
• Position tab on adapter & bearing assembly
Figure 30 - Correct Upper to Lower Shaft Orientation (60) with slot in steering column jacket assembly
(58) and push together. (See Figure 28).
Assemble 5. Cplg & strg shaft assembly (64) or yoke & inter strg
shaft assembly (65) (Depending on Model) to shaft
e Lower steering shaft assembly (37) to race & upper assembly (37).
shaft assembly (34) and steering column tilt head
assembly (26). [§ ([Tighten
A. Shaft preload spring (36) to centering
sphere (35). • Tighten bolt to 47 N-m (35 lb.ft.)
B. Centering sphere (35).
• Lubricate with lithium grease. Slip into
upper shaft assembly (34) and rotate sphere [$(| Tighten
90 degrees.
• Tighten Hex Hd Nut (68) to 62 N-m (46 lb.ft.)
C. Lower steering shaft assembly (37) to race &
upper shaft assembly (34). 6. Turn signal & multifunction switch assembly (24) to
• Line up marks and tilt assemblies 90 column.
degrees to each other. • With small blade screwdriver compress
electrical contact and move multifunction
10. Four torx head screws (55). switch (24) into position.
11. Steering column support assembly (57). • Electrical contact must rest on cancelling cam
assembly (6).
7. Two pan head tapping screws (13).
[^ T ig h te n

8. Do steps 4 throughl3, "Install or Connect", LOWER
CHECKING STEERING COLUMN FOR ACCIDENT DAMAGE
NOTICE: Vehicles involved in accidents resulting in frame damage,

major body or sheet metal damage, or where the steering column
has been impacted, or where supplemental inflatable restraints
systems deployed may also have a damaged or misaligned steering
column.
CHECKING PROCEDURE
JACKET ASM, STEERING COLUMN

• Check capsules on steering column bracket assembly; all must be
securely seated in bracket slots and checked for any loose conditions CHECK FOR ANY LOOSE CONDITION WHEN
when pushed or pulled by hand (View A). If not, bracket should be PUSHED OR PULLED BY HAND.
replaced if bolted to jacket assembly. If bracket is welded to jacket
replace jacket assembly.
• Check for jacket assembly collapse by measuring the distance from
b -
the lower edge of upper jacket to a defined point on the lower jacket
(View C). If measured dimensions are not within specifications, a
new jacket must be installed.
NOTICE: Inflatable restraint coil assembly must be removed from

steering column and allowed to hang freely before shaft is rotated.
Failure to do so could damage coil assembly.
STEERING SHAFT ASM

<-------------- 131.00 MM --------- >
• Visually inspect steering shaft for sheared injected plastic (View B).
If steering shaft shows sheared plastic, a new steering shaft must be
installed.
• Any frame damage that could cause a bent steering shaft must have
steering shaft runout checked in the following manner: Using a dial
indicator at lower end of steering shaft, have steering wheel rotated.
Runout must not exceed 1.59mm.
VIEW C (METHOD TO DETERMINE COLUMN COLLAPSE)

WITH LOWER BEARING REMOVED
MEASURE DISTANCE BETWEEN ARROWS.
Figure 31 - Checking for Accident Damage

1 MODULAR COL HOLDING FIXURE

2 PARK LOCK CABLE PLIERS
3 LOCK PLATE COMPRESSOR
4 PIVOT PIN REMOVER
Figure 32 - Special Tools

Suspension Table of Contents 3-1
Section 3
Suspension
Suspension General Diagnosis .....................3-3 D iagnostic Inform ation and P rocedures....... 3-21
D iagnostic Inform ation and P ro ced u re s.........3-3 Preliminary Alignment Inspection
Vehicle Leads/Pulls (Leads to Either Side) ....3-3 (C M odel).....................................................3-21
Vehicle Leads/Pulls (Pulls to One Preliminary Alignment Inspection
Side-No Braking)............................................3-3 (K 1, 2 Model)..............................................3-21
Abnormal or Excessive Tire Wear Preliminary Alignment Inspection
(Center of Tread)........ ..................................3-3 (K M odel)..................................................... 3-22
Abnormal or Excessive Tire Wear Repair In s tru c tio n s ............................................. 3-23
(G eneral)........................................................ 3-3 Measuring Wheel Alignment (C M odel)........ 3-23
Abnormal or Excessive Tire Wear Measuring Wheel Alignment (K M odel)........ 3-23
(Heel and Toe W ear).................................... 3-4 Frame Bracket Knock Out Removal
Abnormal or Excessive Tire Wear (C M odel)..................................................... 3-25
(Tire Edges Wear)..........................................3-4 Frame Bracket Knock Out Removal
Abnormal or Excessive Tire Wear (K M odel)..................................................... 3-27
(Uneven)......................................................... 3-4 D escription and O peration............................... 3-30
Abnormal or Excessive Tire Wear General Description (2WD)............................. 3-30
(Excessive or Uneven).................................. 3-4 General Description (4WD)............................. 3-31
Abnormal or Excessive Tire Wear S pecial Tools and Equipm ent.......................... 3-33
(Scuffed Tires)................................................3-5 Special Tools.................................................... 3-33
Abnormal or Excessive Tire Wear
Front Suspension ..............................................3-35
(Cupped Tires)...............................................3-5
Trim Height......................................................... 3-5 S p e cifica tio n s...................................................... 3-35
Fastener Tightening Specifications................ 3-35
Wheel Tramp...................................................... 3-7
GM SPO Group Numbers.............................. 3-35
Noisy Front Suspension.................................... 3-7
Com ponent Locator............................................3-37
Poor Directional Stability................................... 3-7
Front Suspension Components......................3-37
Tire Hop or Poor Handling
(Radial Tire W addle)..................................... 3-8 D iagnostic Inform ation and P ro ced u re s....... 3-42
Noise in the Front E nd..................................... 3-8 Ball Joint Wear Check.....................................3-42
Excessive Road Shock..................................... 3-9 Repair In s tru c tio n s .............................................3-43
Struts or Shock Absorbers Weak (Front)........3-9 Wheel Hub Bolt Replacement (2W D )........... 3-43
Struts or Shock Absorbers Noisy (Front)........3-9 Wheel Hub Bolt Replacement (4W D )........... 3-44
Struts or Shock Absorbers Leak (Front).........3-9 Wheel Hub Bolt Replacement (C3500HD) ...3-45
Struts or Shock Absorbers Bench Test Stabilizer Shaft Replacement (2WD)............. 3-45
(Non-Spiral G roove-Pliacell).......................3-10 Stabilizer Shaft Replacement (4WD)............. 3-46
Front Wheel Shim m y...................................... 3-10 Stabilizer Shaft Replacement (C3500HD).....3-47
Hard S teering................................................... 3-10 Upper Ball Joint Replacement (2W D)...........3-48
Wheel Bearings Diagnosis.............................. 3-11 Upper Ball Joint Replacement (4W D)........... 3-50
Low or Uneven Trim H eight...........................3-15 Lower Ball Joint Replacement (2W D)........... 3-53
Wheel Alignm ent................................................3-17 Lower Ball Joint Replacement (4W D)........... 3-55
S p e cifica tio n s...................................................... 3-17 Steering Knuckle Replacement (2WD)..........3-57
Wheel Alignment Specifications Steering Knuckle Replacement (C3500HD) ....3-60
(C M odel)..................................................... 3-17 Upper Control Arm Replacement (2W D )......3-60
Wheel Alignment Specifications Upper Control Arm Replacement (4W D )......3-62
(K Model)...................................................... 3-18 Lower Control Arm Replacement (2W D )......3-63
Fastener Tightening Specifications................ 3-19 Lower Control Arm Replacement (4W D )......3-64
GM SPO Group Numbers............................... 3-20
3-2 Table of Contents Suspension
Front Coil Springs Replacement.................... 3-67 T ire s a n d W h e e ls ............................................. 3-113

Leaf Springs Replacement (C3500HD).........3-69 S p e cifica tio n s.....................................................3-113
Wheel Hub, Bearing, and Fastener Tightening Specifications.............. 3-113
Seal Replacement (2W D)...........................3-72 GM SPO Group Numbers............................. 3-113
Wheel Hub, Bearing, and Seal D iagnostic inform ation and
Replacement (4W D).................................... 3-74 P rocedures.................................................... 3-114
Wheel Hub, Bearing, and Seal Wheel Mounting Surface Check...................3-114
Replacement (C3500HD)............................3-76 Radial Tire Lead/Pull Correction...................3-115
Torsion Bar and Support Assembly Repair In s tru c tio n s ...........................................3-117
Replacement (All except 4 Door U tility)...3-77
Aluminum Wheel Hub Cap
Torsion Bar and Support Assembly Replacement...............................................3-117
Replacement (4 Door U tility )..................... 3-79
Aluminum Wheel Porosity Repair................ 3-117
Wheel Bearing Adjustment (2W D)................. 3-81
Aluminum Wheel Refinishing....................... 3-117
Wheel Bearing Adjustment (C3500HD).........3-82
Clearcoat Damage to Aluminum
Shock Absorber Replacement (2WD)............3-83
W heels........................................................ 3-118
Shock Absorber Replacement (4WD)............3-84 Aluminum Wheel Recoating Procedure...... 3-118
Shock Absorber Replacement Wheel Removal (Single W heels).................3-118
(C3500HD)....................................................3-84
Wheel Removal (Dual Rear W heels)......... 3-119
Front Axle Replacement (C3500HD).............3-85
Wheel Installation
D escription and O p e ra tio n ...............................3-88 (Single Wheels-Front or R ear)................3-120
General Description......................................... 3-88 Wheel Installation (Dual Rear W heels)..... 3-120
S pecial Tools and E quipm ent......................... 3-90
Tire Repair......................................................3-121
Special Tools..................................................... 3-90
Tire Mounting and Dismounting...................3-121
Rear Suspension ................................................3-93 Tire Rotation...................................................3-122
S p e cifica tio n s...................................................... 3-93 Spare Tire Carrier Replacement
Fastener Tightening Specifications................ 3-93 (Suburban Models)....................................3-123
GM SPO Group Numbers...............................3-93 Spare Tire Carrier Replacement
Com ponent L o c a to r............................................3-94 (2 Door Utility M odels)............................. 3-124
Rear Suspension Com ponents...................... 3-94 Tire Hoist and Shaft Replacement
R epair In s tru c tio n s .............................................3-97 (All Pickup M odels)...................................3-126
Stabilizer Shaft Replacement (C M odel)..... 3-97 Tire Hoist and Shaft Replacement
(4 Door U tility)........................................... 3-127
Stabilizer Shaft Replacement (K M odel)..... 3-98
D escription and O p e ra tio n ............................ 3-129
Stabilizer Shaft Link Bracket Replacement
(All Models Except C/K 3 )......................... 3-98 General Description.......................................3-129
Stabilizer Shaft Link Bracket Metric Wheel Nuts and Bolts
Replacement (C/K 3 M odels).................... 3-98 Description................................................. 3-129
Shock Absorber Replacement (C Model).... 3-99 Tire Inflation Description............................... 3-129
Shock Absorber Replacement (K Model)......3-100 Tire Chain Usage Description......................3-130
Wheel Bolt Replacement...............................3-101 Replacement Tires Description................... 3-130
Spring Bushing Replacement....................... 3-101 All Seasons Tires Description......................3-131
Leaf Spring Replacement P-Metric Sized Tires D escription................ 3-131
(Single Wheel Spring Assem bly).............3-101 Tire Placard Description............................... 3-131
Leaf Spring Replacement Wheels Description........................................3-131
(Dual Wheel Spring Assembly)................ 3-103 Wheel Repair D escription............................3-131
Leaf Spring Replacement (HD Chassis) ....3-105 Aluminum Wheels D escription.................... 3-131
Spring Shackle Replacement S pecial Tools and E qu ip m e n t...................... 3-132
(CK M odel).................................................3-107
Spring Shackle Replacement
(Heavy Duty C hassis)...............................3-108
Wheel Stud Replacement
(Semi-Floating A xle).................................. 3-109
(Full-Floating A xle ).................................... 3-110
D escrip tio n and O peration.............................. 3-111
General D escription........................................3-111
Suspension Suspension General Diagnosis 3-3
Suspension General Diagnosis

Diagnostic Information and
Procedures
Vehicle Leads/Pulls (Leads to Either Side)

Checks Action
Keep in mind the wind and the road Test the vehicle, going in both directions, on a flat road.
conditions
Front end misaligned Adjust to specifications. Refer to Measuring Wheel Alignment (C Model) or
Measuring Wheel Alignment (K Model) in Wheel Alignment.
Unbalanced steering gear valve (if Replace the gear valve. Refer to Valve Replacement in Power Steering System.
this is the cause, steering effort will
be very light in direction of lead and
heavy in the opposite direction)
Steering shaft rubbing the inside Align or replace the steering column. Refer to Steering Column Replacement in
diameter of the shaft tube Steering Wheel and Column.
Vehicle Leads/Pulls (Pulls to One Side-No Braking)

Checks Action
Low or uneven tire pressure Inflate the tires to the recommended pressure. Refer to Tire Inflation Description in
Tires and Wheels.
Front or rear brakes dragging Adjust the brakes.
Broken or sagging front spring Replace the spring. Refer to Front Coil Springs Replacement or Leaf Springs
Replacement (C3500HD) in Front Suspension.
Incorrect front wheel alignment Check and align the front suspension. Refer to Measuring Wheel Alignm ent
(camber) (C Model) or Measuring Wheel Alignment (K Model) in Wheel Alignment.
Abnormal or Excessive Tire Wear (Center of Tread)

Problem Action
The tires are overinflated. Deflate the tire to the recommended pressure. Refer to Tire Inflation Description in
Tires and Wheels.
The vehicle is overloaded. Refer to Vehicle Certification Label in General Information.
The operator is using hard driving Inform the operator about proper driving techniques.
techniques such as rapid acceleration
or excessive braking.
Abnormal or Excessive Tire Wear (General)

Checks Action
Failure to rotate the tires Refer to Tire Rotation in Tires and Wheels.
Damaged shock absorbers Replace the shock absorber.
• For 2WD, refer to Shock Absorber Replacement (2WD) in Front Suspension.
• For C3500HD, refer to Shock Absorber Replacement (C3500HD) in Front
Suspension.
Improper tire pressure Refer to Tire Inflation Description in Tires and Wheels.
Incorrect wheel alignment Align the wheels. Refer to Measuring Wheel Alignment (C Model) or Measuring
Wheel Alignment (K Mode!) in Wheel Alignment.
3-4 Suspension General Diagnosis_______________________________________ Suspension
Abnormal or Excessive Tire Wear (General) (cont’d)
Checks Action
Overloaded or improperly loaded Avoid overloading the vehicle. Refer to Vehicle Certification Label in General
vehicle Information.
Broken or sagging springs Replace the springs.
• For 2WD, refer to Front Coil Springs Replacement in Front Suspension.
• For C3500HD, refer to Leaf Springs Replacement (C3500HD) in Front
Suspension.
Loose or worn stabilizer bushings Tighten the stabilizer bushing brackets or replace the stabilizer bushings.
• For 2WD, refer to Stabilizer Shaft Replacement (2WD) in Front Suspension.
• For C3500HD, refer to Stabilizer Shaft Replacement (C3500HD) in Front
Suspension.
Abnormal or Excessive Tire Wear (Heel and Toe Wear)

Checks Action
Hard cornering Inform the operator of proper driving techniques.
Incorrect alignment (excessive toe) Set to the correct specifications. Refer to Measuring Wheel Alignm ent (C Model) or
Abnormal or Excessive Tire Wear (Tire Edges Wear)

Checks Action
Underinflated tires Inflate the tires to the recommended pressure. Refer to Tire Inflation Description in
Tires and Wheels.
Vehicle overloaded Refer to Vehicle Certification Label in General Information.
Hard cornering Inform the driver about proper driving techniques.
Incorrect toe setting Set to the correct specifications. Refer to Measuring Wheel Alignm ent (C Model) or
Measuring Wheel Alignm ent (K Model) in Wheel Alignment.
Abnormal or Excessive Tire Wear (Uneven)

Checks Action
Improper tire pressure Inflate the tires to the recommended pressure. Refer to Tire Inflation Description in
Tires and Wheels.
Incorrect tire and wheel usage Install the correct tire and wheel combination.
Front end out of alignment Align the front end. Refer to Measuring Wheel Alignm ent (C Model) or Measuring
Wheel Alignment (K Model) in Wheel Alignment.
Loose, worn, or damaged steering Inspect, repair, or replace the components as required.
linkage, joints, or suspension
components, bushings, or ball joints
Abnormal or Excessive Tire Wear (Excessive or Uneven)

Checks Action
Underinflated or overinflated tires Inflate the tires to the recommended pressure. Refer to Tire Inflation Description in
Tires and Wheels.
Improper toe-in Adjust the toe-in setting. Refer to Measuring Wheel Alignm ent (C Model) or
Measuring Wheel Alignm ent (K Model) in Wheel Alignment.
Wheels are out of balance Balance the wheels. Refer to Balancing Tires and Wheels in Vibration Diagnosis
and Correction.
Abnormal or Excessive Tire Wear (Excessive or Uneven) (cont’d)
Checks Action
Hard driving Instruct driver about proper driving techniques.
Overloading the vehicle Do not exceed the maximum recommended payload rating. Refer to Vehicle
Certification Label in General Information.
Abnormal or Excessive Tire Wear (Scuffed Tires)

Checks Action
Incorrect toe-in Adjust the toe-in setting. Refer to Measuring Wheel Alignm ent (C Model) or
Excessive speed on turns Instruct operator about proper driver techniques.
Improper inflation of the tires Inflate the tires to the recommended pressure. Refer to Tire Inflation Description in
Tires and Wheels.
Suspension arm is bent or twisted Replace the suspension arm.
Abnormal or Excessive Tire Wear (Cupped Tires)

Checks Action
Front shock absorbers are worn Replace the shock absorbers.
Suspension.
Worn ball joints Replace the ball joints.
• For the upper ball joint, refer to Upper Ball Joint Replacement (2WD) or Upper
Ball Joint Replacement (4WD) in Front Suspension.
• For the lower ball joint, refer to Upper Ball Joint Replacement (2WD) or Lower
Ball Joint Replacement (4WD) in Front Suspension.
Incorrectly adjusted or worn wheel Adjust or replace the wheel bearings.
bearings • For 2WD, refer to Wheel Hub, Bearing, and Seal Replacement (2WD) in Front
Suspension.
• For 4WD, refer to Wheel Hub, Bearing, and Seal Replacement (4WD) in Front
Suspension.
• For C3500HD, refer to Wheel Hub, Bearing, and Seal Replacement
(C3500HD) in Front Suspension.
Wheel and tire is out of balance Balance the wheel and tire. Refer to Balancing Tires and Wheels in Vibration
Diagnosis and Correction.
Excessive tire or wheel runout Check and compensate for runout. Refer to Wheel Runout Measurement in Vibration
Trim Height 2. Gently remove your hands. Let the vehicle

7 U«UU« settle.
a m ca o u icu re m 3. Repeat this operation for a total of three times.
1. Lift the front bumper of the vehicle up about
38 mm (1.5 in).
3-6 Suspension General Diagnosis Suspension
8. Allow the vehicle to rise.
9. Repeat the operation twice for a total of
three times.
10. Measure the Z dimension.
11. The true Z dimension number is the average of
the high and low measurements.
• For C1, 2, and 3 vehicles, the Z
measurement should be between 89-101 mm
(3.5-4.0 in).
• For K models, use the following Z
measurements:
- K1,2 models (except K10906 + L65 and
K20906 + C6P)— 151-163 mm (5.9-6.4 in)
- K models (10906 + L65 and 20906 +
C6P + 3)— 139-151 mm (5.5-5.9 in)
- K3 models— 139-151 mm (5.5-5.9 in)
D Height Measurement
4. For 2WD vehicles, measure from the pivot bolt 1

center line (2) down to the lower ball joint
extrusion (4) in order to obtain the Z height
dimension (3).
156342
1. Lift the rear bumper of the vehicle

38 mm (1.5 in).
2. Gently remove your hands. Let the vehicle
settle.
156339
3. Repeat this operation for a total of three times.
5. For 4WD vehicles, measure from the pivot bolt
center line (2) down to the lower corner (5) of 4. Measure the D dimension (2). Measure from
the steering knuckle (1) in order to obtain the the bottom surface of jounce bracket (6) to the
Z height measurement (4). For torsion bar top of the axle jounce pad (3).
adjustment, refer to Torsion Bar and Support 5. Push the rear bumper of the vehicle downward
Assembly Replacement (All except 4 Door 38 mm (1.5 in).
Utility) or Torsion Bar and Support Assembly 6. Gently remove your hands. Let the vehicle rise.
Replacement (4 Door Utility) in Front
Suspension. 7. Repeat this operation for a total of three times.
6. Push the front bumper of the vehicle down 8. Measure the D dimension.
about 38 mm (1.5 in). 9. The true D dimension is the average of the
7. Gently remove your hands. high and the low measurements.
Wheel Tramp
Checks Action
DEFINITION: Abnormal bounce or hop of the wheel under normal driving conditions
Tire and wheel are out of balance Balance the wheels. Refer to Balancing Tires and Wheels in Vibration Diagnosis
and Correction.
Tire and wheel are out of round Replace the tire. Refer to Replacement Tires Description in Tires and Wheels.
Blister or bump on the tire Replace the tire. Refer to Replacement Tires Description in Tires and Wheels.
Improper shock absorber action Replace the shock absorber.
Suspension.
Excessive wheel or tire runout Refer to Wheel Runout Measurement in Vibration Diagnosis and Correction.
Tire lead Use any of the following tables:
• Refer to Vehicle Leads/Pulls (Leads to Either Side).
• Refer to Vehicle Leads/Pulls (Pulls to One Side-No Braking).
• Refer to Radial Tire Lead/Pull Correction in Tires and Wheels.
Noisy Front Suspension

Checks Action
Worn tie rod ends Replace the tie rod ends. Refer to Tie Rod Replacement in Steering linkage.
Loose suspension bolts Refer to Fastener Tightening Specifications in Front Suspension.
Lack of proper lubrication Refer to Recommended Fluids and Lubricants in Maintenance and Lubrication.
Loose shock absorbers Tighten the bolts. Refer to Fastener Tightening Specifications in Front Suspension.
Worn shock absorber bushings Replace the bushings.
Suspension.
Loose stabilizer shaft Tighten the bolts. Refer to Fastener Tightening Specifications in Front Suspension.
Worn stabilizer shaft insulators Replace the insulators.
Suspension.
Poor Directional Stability

Checks Action
Lack of lubrication of the steering Lubricate the linkage. Refer to Recommended Fluids and Lubricants in Maintenance
linkage and Lubrication.
Low or uneven tire pressure Inflate the tires to the recommended pressure. Refer to Tire Inflation Description in
Tires and Wheels.
Loose wheel bearings Adjust or replace the wheel bearings.
Suspension. •
Suspension.
Poor Directional Stability (cont’d)

Checks Action
Incorrect front wheel alignment Check and align the front suspension. Refer to Measuring Wheel Alignm ent
(caster) (C Model) or Measuring Wheel Alignment (K Model) in Wheel Alignment.
Broken springs Replace the springs.
Suspension.
Malfunctioning shock absorber Check and replace the shock absorber.
Suspension.
Broken stabilizer shaft or a Replace the stabilizer shaft or link.
missing link • For 2WD, refer to Stabilizer Shaft Replacement (2WD) in Front Suspension.
Suspension.
Tire Hop or Poor Handling (Radial Tire Waddle)

Problem Action
DEFINITION: Side to side movement at speeds between 8-24 km/h (5-15 MPH)
The wheel has excessive lateral Replace the wheel. Refer to Wheel Removal (Single Wheels) or Wheel Removal
runout. (Dual Rear Wheels) and Wheel Installation (Single Wheels-Front or Rear) or Wheel
Installation (Dual Rear Wheels) in Tires and Wheels.
The tire has excessive lateral runout. Replace the tire. Refer to Tire Mounting and Dismounting in Tires and Wheels.
Noise in the Front End

Checks Action
Steering linkage needs lubrication Lubricate at the recommended intervals. Refer to Recommended Fluids and
Lubricants in Maintenance and Lubrication.
Loose shock absorber Tighten the bolts. Refer to Fastener Tightening Specifications in Front Suspension.
Worn shock absorber bushings Replace the shock absorber.
Suspension.
Worn control arm bushings Replace the bushings or the control arm.
• For the upper control arm, refer to Upper Control Arm Replacement (2WD) or
Upper Control Arm Replacement (4WD) in Front Suspension.
• For the lower control arm, refer to Lower Control Arm Replacement (2WD) or
Lower Control Arm Replacement (4WD) in Front Suspension.
Worn or loose wheel bearings Adjust or replace the wheel bearing.
Suspension.
Suspension.
Suspension ____________________________________ Suspension General Diagnosis 3-9
Noise in the Front End (cont’d)
Checks Action
Loose wheel nuts Tighten the wheel nuts. Refer to Fastener Tightening Specifications in Tires and
Wheels.
Spring is improperly positioned Reposition the spring. Refer to Front Coil Springs Replacement or Leaf Springs
Loose suspension bolts Tighten to specifications or replace. Refer to Fastener Tightening Specifications in
Front Suspension.
Worn king pins and bushings Replace the bushings and the king pins. Refer to Steering Knuckle Replacement
Excessive Road Shock
Checks Action
DEFINITION: Vehicle ride unsteady and harsh.
Tire air pressure is too high Deflate the tire to the correct pressure. Refer to Tire Inflation Description in Tires
and Wheels.
Loose wheel bearings Adjust the bearings. Refer to Wheel Bearing Adjustment (2WD) or Wheel Bearing
Adjustment (C3500HD) in Front Suspension.
Camber adjustment incorrect Adjust camber. Refer to Measuring Wheel Alignment (C Model) or Measuring Wheel
(Negative camber contributes to Alignment (K Model) in Wheel Alignment.
road shock)
Weak or broken front spring Replace the spring. Refer to Front Coil Springs Replacement or Leaf Springs
Loose suspension components Inspect, repair, and adjust the components as necessary. Refer to Fastener
Tightening Specifications in Front Suspension.
Struts or Shock Absorbers Weak (Front)

Checks Action
Worn out shocks Replace the shock absorbers.
Suspension.
Loss of shock fluid Replace the shock absorbers.
• For C3500HD, refer to Shock Absorber Replacement (C3500HD ) in Front
Suspension.
Struts or Shock Absorbers Noisy (Front)

Checks Action
Loose mountings Check all mounting torques (bolt and nut). Refer to Fastener Tightening
Specifications in Front Suspension.
Struts or Shock Absorbers Leak (Front)

Checks Action
Worn out seals Replace the shock absorber.
Suspension.
3-10 Suspension General Diagnosis_____ _________________________ Suspension
Struts or Shock Absorbers Bench Test 3. Pump the shock at various rates of speed.
(Non-Spiral Groove-Pliacell) Observe the rebound force.
• The rebound force normally is stronger than
Testing Procedure the compression force (approximately two
It is not necessary to purge air from non-spiral to one).
groove shock absorbers. These shock absorbers • The rebound force should be smooth and
contain a gas filled cell within the shocks reservoir. constant for each stroke rate.
These shocks differ from spiral groove shocks. Spiral 4. Compare this shock with a good shock
groove shocks contain an air filled cell within the absorber.
reservoir.
5. If you observe any of the following conditions,
1. Remove the shock absorber from the vehicle. replace the shock absorber:
• For 2WD vehicles, refer to Shock Absorber • A skip, or a lag, at reversal near mid-stroke
Replacement (2WD) in Front Suspension.
• A seizing (except at the extreme ends of
• For 4WD vehicles, refer to Shock Absorber travel)
• A noise, a grunt or a squeal, after
• For the C3500HD, refer to Shock Absorber completing one full stroke in both directions
Replacement (C3500HD) in Front
Suspension. • A clicking noise at fast reversal
Im portant: Do not clamp the vise jaws on the

shock upper stem threads or the reservoir.
2. Place the shock absorber in a vise.
• Clamp the jaws on the top mounting stud of
the shock.
• Hold the shock vertically in the vise with the
bottom end up.
Front Wheel Shimmy

Checks Action
DEFINITION: Vehicle front wheel shimmy or shake while driving on a smooth road
Tire and wheel are out of balance Balance the tires. Refer to Balancing Tires and Wheels in Vibration Diagnosis and
Correction.
Tire and wheel are out of round Check runout. Refer to Wheel Runout Measurement in Vibration Diagnosis and
Correction.
Worn or loose wheel bearings Adjust the wheel bearings. Refer to Wheel Bearing Adjustm ent (2WD) or Wheel
Bearing Adjustment (C3500HD) in Front Suspension.
Worn or loose king pin or king pin Replace the worn parts or adjust the king pin bearing. Refer to Steering Knuckle
bearing Replacement (C3500HD) in Front Suspension.
Worn bail joints Replace the ball joints.
• For the upper ball joint, refer to Upper B all Joint Replacement (2WD) or Upper
B all Joint Replacement (4WD) in Front Suspension.
• For the lower ball joint, refer to Lower B all Joint Replacement (2WD) or Lower
B all Joint Replacement (4WD) in Front Suspension.
Malfunctioning shock absorber Check and replace the shock absorber.
Suspension.
Hard Steering
Checks Action
Ball joints and steering linkage need Lubricate the ball joints and the steering linkage. Refer to Recommended Fluids and
lubrication Lubricants in Maintenance and Lubrication.
Low or uneven front tire pressure Inflate the tires to the recommended pressure. Refer to Tire Inflation Description in
Tires and Wheels.
Incorrect front wheel alignment Check and align the front suspension. Refer to Measuring Wheel Alignment
(C Model) or Measuring Wheel Alignment (K Model) in Wheel Alignment.
Worn ball joints Check ball joint free play.
Worn or loose king pin or king pin Replace any worn parts or adjust the king pin bearing. Refer to Steering Knuckle
bearing Replacement (C3500HD) in Front Suspension.
Wheel Bearings Diagnosis Abrasive Step Wear

Tapered Roller Bearing Diagnosis
Consider the following factors when diagnosing
bearing condition:
• General condition of all parts during
disassembly and inspection.
• Classify the failure with the aid of the
illustrations.
• Determine the cause.
• Make all repairs following recommended
procedures.
Abrasive Roller Wear
1453
The pattern on the roller ends is caused by fine

abrasives.
1. Clean all of the parts and the housings.
2 . Check the seals and the bearings.
3. Replace any leaky, rough, or noisy bearings.
1452
The pattern on the races and the rollers is caused

by fine abrasives.
2 . Check the seals and the bearings.
Galling Bent Cage
The metal smears on the roller ends are due to When a cage is damaged due to improper handling
overheating, lubricant failure, or lubricant overload. or improper tool usage.
1. Replace the bearing. Replace the bearing.
2 . Check the seals. Cage Wear
3. Check for proper lubrication.
Etching
1457
The wear around the outside diameter of the cage

1455 and the roller pockets is caused by abrasive material
or inefficient lubrication.
The bearing surfaces appear gray or grayish black in
color, with related etching away of material usually at 1. Clean the related parts and the housings.
roller spacing. 2. Check the seals.
1. Replace the bearings. 3. Replace the bearings.
2. Check the seals.
Suspension______________________________________ Suspension General Diagnosis 3-13
Indentations Smears
1456 1460
The surface depressions on the race and the rollers The smearing of the metal is due to slippage.
are caused by hard particles of foreign matter. Slippage can be caused by the following factors:
1. Clean all the parts and the housings. • Poor fits
2. Check the seals. • Lubrication
3. Replace rough or noisy bearings. • Overheating
Frettage • Overloads
• Handling damage
If this condition occurs, perform the following:
1. Replace the bearings.
2. Clean the related parts.
3. Check for proper fit and lubrication.
1459
The corrosion caused by small relative movement of

parts with no lubrication.
1. Replace the bearing.
3. Check the seals.
Stain Discoloration Misalignment
1461 1463
The discoloration on the bearings is caused by The outer race is misaligned due to a foreign object.
incorrect lubrication or moisture and ranges in color 1. Clean the related parts.
from light brown to black. Reuse the bearing if you
can remove the stains with light polishing and there 2. Replace the bearing.
is no evidence of overheating. Check the seals and 3. Ensure the races are properly sealed.
the related parts for damage.
Cracked Inner Race
Heat Discoloration
1464
1462
The race is cracked due to improper fit, cocking, or
The discoloration on the bearings ranges from faint poor bearing seats.
yellow to dark blue and results from overload or an
incorrect lubricant. Excessive heat causes softening
of the races or the rollers. In order to check for loss 2. Correct bearing seats.
of temper on the races and the rollers, perform a file
test. A file drawn over a tempered part will grab and
cut the metal and fail the file test. A file drawn over
a hard part w ill glide readily with no metal cutting.
If overheating damage is indicated, perform the
following:
2. Check the seals and the other related parts.
Fatigue Spalling Brineliing
1465 1466
The surface is flaked with metal due to bearing The surface indentations in the race way are caused
fatigue. by the rollers under impact loading or from vibration
1. Replace the bearing. while the bearing is not rotating. Replace a rough or
noisy bearing.
2. Clean all related parts.
Low or Uneven Trim Height

Checks Action
Broken or sagging springs Replace the springs.
Suspension.
Overloaded or improperly loaded Avoid overloading the vehicle. Refer to Vehicle Certification Label in General
vehicle Information.
BLANK
Suspension_______________________________________; ______ Wheel Alignment 3-17
Wheel Alignment
Specifications An up-in-rear frame angle must be added to a
positive caster reading.
Wheel Alignment Specifications (C Model)
Important: The vehicle must be jounced 3 times
before checking the alignment in order to eliminate
false geometry readings.
Important: The caster angle must be corrected to
m
the level frame angle. 1
90*
C Model
Service Setting
Application C 100 200 300
Caster (Degrees) 3.75* ±1.0* (2)
H *— 3 2
Camber (Degrees) .5* ± .5* (2)
(Sum Toe Degrees) .24- ± .2- (4) 4^ 7
I-Beam Front Suspension

Service Setting
Application I-Beam Front Suspension 156353
Caster (Degrees) +5 (E) • Horizontal (1)
Camber (Degrees) +1.25 ± .5 (E) • The frame angle is 1 degree up (2).
Sum Toe-In (Inches) .06 in ± .06 in • The caster angle reading is + (2 degrees) (3).
Sum Toe-In (Degrees) .12* ± .1 2 ‘ • The actual corrected caster angle is
(E) Nominal: Reference only, no means of adjustment + (3 degrees) (4).
provided. A down-in-rear frame angle must be added to a
negative caster reading.
A down-in-rear frame angle must be subtracted from
a positive caster reading.
90* 1
m ■W
1 L f l L
90*
=*£Tj I W - a
2
3
< *-3 2
156355
• Horizontal (1)
156353
• The frame angle is 1/2 degrees down (2).
• Horizontal (1)
• The caster angle reading is
• The frame angle is 1 1/4 degree down (2). - (1 1/4 degrees) (3).
• The caster Angle Reading is • The actual corrected caster angle is
- (2 1/4 degrees) (3). + - (1 3/4 degrees) (4).
• The actual corrected caster angle is
+ (1 degrees) (4).
3-18 Wheel Alignment Suspension
An up-in-rear frame angle must be subtracted from a Wheel Alignment Specifications (K Model)
Im portant: The vehicle must be jounced 3 times
before checking the alignment in order to eliminate
false geometry readings.
im portant: The caster angle must be corrected to
the level frame angle.
K M odel
Service Setting Service Setting
K100, K200, K200, K300,
Application 7200 lbs GVW 8600 lbs GVW
3.0 degrees ± 1.0 3.0 degrees ± 1.0
Caster (Degrees) degrees (2)
degrees (2)
0.65 degrees ± 0.5 0.65 degrees ± 0.5
Camber (Degrees) degrees (2)
degrees (2)
(Sum Toe 0.24 degrees ± 0.2 0.24 degrees ±
Degrees) degrees (4) 0.2 degrees (4)
A down-in-rear frame angle must be subtracted from

a positive caster reading.
• Horizontal (1)
• The frame angle is 1 1/4 degrees up (2).
• The caster angle reading is - (1/4 degrees) (3).
+ (1 degrees) (4).
• Horizontal (1)
• The frame angle is 1 1/4 degree down (2).
• The caster angle reading is + (2 1/4 degrees)
(3).
+ (1 degrees) (4).
• The front suspension Z dimension (3) is held as
indicated.
• The left side and the right side are to be equal
within .50 degrees.
• The left side and the right side are to be equal
within 1.0 degrees.
• The to e -in left side and the right side are to be
equal per wheel and the steering wheel, must
be held in a straight ahead position within
± 5.0 degrees.
Suspension Wheel Alignment 3-19
An up-in-rear frame angle must be added to a An up-in-rear frame angle must be subtracted from a
positive caster reading. negative caster reading.
n
1 1
90* 90*
- ^ f n j
1 e
'
i .
CO
■^— 3 2
C l
156353 156353
• Horizontal (1) • Horizontal (1)
• The frame angle is 1 degree up (2). • The frame angle is 1 1/4 degrees up (2).
• The caster angle reading is+ (2 degrees) (3). • The caster angle reading is - (1/4 degrees) (3).
• The actual corrected caster angle is • The actual corrected caster angle is
+ (3 degrees) (4). + (1 degrees) (4).
A down-in-rear frame angle must be added to a
m
1
90*
- fn1 *S
\ 2
156339
• The front suspension Z dimension (4) is held as
156355 indicated.
• Horizontal (1) • The left side and the right side are to be equal
• The frame angle is 1/2 degrees down (2). within 0.50 degrees.
• The caster angle reading is • The left side and the right side are to be equal
- (1 1/4 degrees) (3). within 1.0 degrees.
• The actual corrected caster angle is • The toe-in left side and the right side to be
± (1 3/4 degrees) (4). equally per the wheel and the steering wheel,
must be held in a straight ahead position within
± 5.0 degrees.
Fastener Tightening Specifications

Upper Control Arm Nuts 190 140 —
Tie Rod Adjuster Sleeve Nuts 19 14 —
GM SPO Group Numbers

Application GM SPO Group Number
Steering Knuckle Upper Control Arm Bolt and Cam Kit 6.172
Diagnostic Information and 11. Inspect the level of the vehicle.

Procedures The vehicle must be on a level surface fore
and aft and side to side.
Preliminary Alignment Inspection 12. Inspect for excess drag or poor return of the
(C Model) steering wheel due to stiff or rusty suspension
1. Before making any adjustments affecting the or linkage components.
caster, the camber, or the toe-in, inspect the Preliminary Alignment Inspection
front end.
(K 1, 2 Model)
2. Inspect the tires for the proper inflation
pressure. Refer to Tire Inflation Description in Important: Before making any adjustments affecting
Tires and Wheels. the caster, the camber, or the toe-in, inspect the
front end.
3. Inspect the front wheel bearing for proper
adjustment. Refer to Wheel Bearing Adjustment 1. Inspect the tires for the proper inflation
(2WD) in Front Suspension. pressure. Refer to Tire Inflation Description in
4. Correct any excessive looseness before Tires and Wheels.
adjusting the ball joints, the tie rod ends, and 2. Inspect the front wheel bearing for proper
the relay rods. Refer to Steering Linkage adjustment. Refer to Wheel Bearing Adjustment
Inspection in Steering Linkage. (C3500HD) Front Suspension.
5. Inspect the wheels and tires for runout. Refer to 3. Correct any excessive looseness before
Measuring Wheel and Tire Runout in Vibration adjusting the following parts:
Diagnosis and Correction. • The ball joints
• The tie rod ends
• The relay rods.
Refer to Steering Linkage Inspection in
Steering Linkage.
4. Inspect the wheels and tires for runout. Refer to
Measuring Wheel and Tire Runout in Vibration
6. The correct specification is 95.0 ± 6.0 mm. If

not within specifications, make the correction
before adjusting the caster.
7. Inspect the steering gear for looseness at
the frame.
8. Inspect the shock absorbers for leaks or
noticeable noise. Refer to Shock Absorber 156339
5. The correct specification is 157.0 ± 6.00 mm. H
9. Inspect the control arms or the stabilizer shaft not within specifications, make the correction
attachments for looseness. Refer to Stabilizer before adjusting the caster.
Shaft Replacement (2WD) in Front Suspension
and Axle. 6. Inspect the steering gear for looseness at
the frame.
10. Inspect the alignment equipment.
Follow the manufacturer’s instructions. noticeable noise. Refer to Shock Absorber
8. Inspect the control arms or the stabilizer shaft

attachments for looseness. Refer to Stabilizer
Shaft Replacement (4WD) in Front Suspension.
9. Inspect the alignment equipment.
Follow the manufacturer’s instructions.
10. Inspect the level of the vehicle.
The vehicle must be on a level surface fore
11. Inspect for excess drag or poor return of the
steering wheel due to stiff or rusty suspension
or linkage components.
Preliminary Alignment Inspection
(K Model)
Important: Before making any adjustments affecting
the caster, the camber, or the toe-in, inspect the
front end.
1. Inspect the tires for the proper inflation
156339
pressure. Refer to Tire Inflation Description in
Tires and Wheels. 5. The correct specification is 10906 ± L65 and
20906 ± C6P ± 3 145.0 ± 6.0 mm. If not within
2. Inspect the front wheel bearing for proper
specifications, make the correction before
adjustment. Refer to Wheel Bearing Adjustment
adjusting the caster.
(2WD) in Front Suspension.
6. Inspect the steering gear for looseness at
3. Correct any excessive looseness before
the frame.
adjusting the following parts:
• The ball joints
noticeable noise. Refer to Shock Absorber
• The tie rod ends Replacement (4WD) in Front Suspension.
• The relay rods 8. Inspect the control arms or the stabilizer shaft
Refer to Steering Linkage Inspection in attachments for looseness. Refer to Stabilizer
Steering Linkage. Shaft Replacement (4WD) in Front Suspension.
4. Inspect the wheels and tires for runout. Refer to 9. Inspect the alignment equipment.
Measuring Wheel and Tire Runout in Vibration Follow the manufacturer’s instructions.
10. Inspect the level of the vehicle.
The vehicle must be on a level surface fore
11. Inspect for excess drag or poor return of the
steering wheel due to stiff or rusty suspension
or linkage components.
Repair Instructions 12. Correct the caster as follows:

12.1. A down-in-the-rear frame angle must be
Measuring Wheel Alignment (C Model) subtracted from a positive caster reading.
1. Satisfactory vehicle operation may occur over a 12.2. An up-in-the-rear frame angle must be
wide range of front wheel alignment settings. If added to a positive caster reading.
the settings vary beyond the tolerances, 12.3. A down-in-the-rear frame angle must be
adjustments are needed. Refer to Wheel added to a negative caster reading.
Alignment Specifications (C Model).
12.4. An up-in-the-rear frame angle must be
As originally installed, the upper control arm subtracted from a negative caster
cannot be adjusted for the camber or the reading.
caster. However, if the camber or the caster is
out of tolerance, the alignment can be reset to 13. If the caster angle is wrong, remove the frame
specifications by removing the knockouts in the bracket knockouts. Refer to Frame Bracket
upper control arm frame brackets. Refer to Knock Out Removal (C Model).
Frame Bracket Knock Out Removal (C Model). 14. Reset the caster angle by turning the cam
Upon removal of the control arm, remove the bolts. Refer to Wheel Alignment Specifications
inserts outboard from the inside of the bracket (C Model).
with the J 38794. Refer to Frame Bracket Important: In order to make the caster or the
Knock Out Removal (C Model). camber adjustments, remove the frame bracket
Important: Set the front wheel alignment to the knockouts. Refer to Frame Bracket Knock Out
specifications while the vehicle is in its normally Removal (C Model).
loaded condition. For vehicles which are 15. Determine the camber from the alignment
consistently operated with heavy loads, adjust equipment.
the toe-in with the vehicle under heavy load. 16. If the camber angle is wrong, remove the frame
Following this procedure prolongs the life of bracket knockouts. Refer to Frame Bracket
the tires. Knock Out Removal (C Model).
2. Measure the front alignment angles. 17. Reset the camber angle by turning the cam
3. Install the alignment equipment according to the bolts. Refer to Wheel Alignment Specifications
manufacturer’s instructions. (C Model).
4. Measure the alignment angles and record the 18. Determine the toe-in from the alignment
readings. equipment.
5. Make any required adjustments in the 19. Change the length of both tie rod sleeves in
following order: order to affect a toe-in change. The toe-in can
5.1. Caster be increased or decreased by changing the
length of the tie rod ends. A threaded sleeve is
5.2. Camber
provided for this purpose. When the tie rod
5.3. Toe-in ends are mounted ahead of the steering
Important: All of the caster specifications are knuckle they must be decreased in length in
given with the vehicle frame level (zero angle). order to increase the toe-in. When the tie rod
ends are mounted behind the steering knuckle
In order to make the caster or the camber they must be lengthened in order to increase
adjustments, the frame bracket knockouts must the toe-in. Refer to Tie Rod Clamp and
be removed. Refer to Frame Bracket Knock Out Adjuster Tube Positioning in Steering Linkage.
Removal (C Model).
6. Position the vehicle on a smooth, level surface. Measuring Wheel Alignment (K Model)
7. Correct the Z dimension specification. Refer to 1. Satisfactory vehicle operation may occur over a
Trim Height in Suspension General Diagnosis. wide range of front wheel alignment settings. If
8. Measure the frame angle, using a bubble the settings vary beyond the tolerances,
protractor or inclinometer. adjustments are needed. Refer to Wheel
Alignment Specifications (K Model).
The frame angle is the tilt (in degrees) of the
frame from the level position. As originally installed, the upper control arm
cannot be adjusted for the camber or the
9. Note the frame angle as being either up in the caster. However, if the camber or the caster is
rear or down in the rear. out of tolerance, the alignment can be reset to
10. Determine the caster angle from the alignment specifications by removing the knockouts in the
equipment. upper control arm frame brackets. Refer to
11. Determine the caster reading. Refer to Wheel Frame Bracket Knock Out Removal (K Model).
Alignment Specifications (C Model). Upon removal of the control arm, remove the
inserts outboard from the inside of the bracket
with the J 38794. Refer to Frame Bracket
Knock Out Removal (K Model).
Important: Set the front wheel alignment to the 13. If the caster angle is wrong, remove the frame
specifications while the vehicle is in its normally bracket knockouts. Refer to Frame Bracket
loaded condition. For vehicles which are Knock Out Removal (K Model).
consistently operated with heavy loads, adjust 14. Reset the caster angle by turning the cam
the toe-in with the vehicle under heavy load. bolts. Refer to Wheel Alignment Specifications
Following this procedure prolongs the life of (K Model).
the tires.
Important: In order to make the caster or the
2. Measure the front alignment angles. camber adjustments, remove the frame bracket
3. Install the alignment equipment according to the knockouts. Refer to Frame Bracket Knock Out
manufacturer’s instructions. Removal (K Model).
4. Measure the alignment angles and record the 15. Determine the camber from the alignment
readings. equipment.
5. Make any required adjustments in the following 16. If the camber angle is wrong, remove the frame
order: bracket knockouts. Refer to Frame Bracket
5.1. Caster Knock Out Removal (K Model).
5.2. Camber 17. Reset the camber angle by turning the cam
5.3. Toe-in bolts. Refer to Wheel Alignment Specifications
(K Model).
Important: All of the caster specifications are 18. Determine the toe-in from the alignment
given with the vehicle frame level (zero angle). equipment.
In order to make the caster or the camber 19. Change the length of both tie rod sleeves in
adjustments, the frame bracket knockouts must order to affect a toe-in change. The toe-in can
be removed. Refer to Frame Bracket Knock Out be increased or decreased by changing the
Removal (K Model). length of the tie rod ends. A threaded sleeve is
6. Position the vehicle on a smooth, level surface. provided for this purpose. When the tie rod
7. Correct the Z dimension specification. Refer to ends are mounted ahead of the steering
Trim Height in Suspension General Diagnosis. knuckle they must be decreased in length in
8. Measure the frame angle, using a bubble order to increase the toe-in. When the tie rod
protractor or inclinometer. ends are mounted behind the steering knuckle
they must be lengthened in order to increase
The frame angle is the tilt (in degrees) of the the toe-in. Refer to Tie Rod Clamp and
frame from the level position. Adjuster Tube Positioning in Steering Linkage.
9. Note the frame angle as being either up in the
rear or down in the rear.
10. Determine the caster angle from the alignment
equipment.
11. Determine the caster reading. Refer to Wheel
Alignment Specifications (K Model).
12. Correct the caster as follows:
subtracted from a positive caster reading.
added to a positive caster reading.
added to a negative caster reading.
subtracted from a negative caster
reading.
Frame Bracket Knock Out Removal

(C Model)
Removal Procedure
Tools Required
J 38794 Knockout Removal Tool
Important: As originally installed, the upper control
arm cannot be adjusted for the caster or the camber.
However, if the caster or the camber is measured
and is out of tolerance, the caster and the camber
can be set to the proper specifications.
1. Raise the vehicle.
2. Suitably support the vehicle. Refer to General
Vehicle Lifting and Jacking in General
Information.
Important: The jack or the jack stand must
remain under the lower control arm during the
removal and the installation procedure in order
to retain the lower control arm position.
3. Support the lower control arms with a jack or
the jack stands.
4. Remove the tire and the wheel assembly.
5. Remove the following parts from the upper
control arm bracket (4):
• The nuts (6)
• The cams (5)
• The bolts (1)
6. Lift the upper control arm (3) up and to the
side in order to gain access to the inner portion
of the frame bracket.
7. Use the J 38794 in order to remove the frame
bracket knockout as follows:
• Do not distort the frame bracket when
removing the knockout.
• Apply extreme pressure lubricant to the
threads of the T-bolt.
• Insert the bolt through the knockout hole in
the bracket support.
• Install the bridge onto the T-bolt.
The forward bracket requires the bridge to be
installed between the legs of the bracket due
to access problems.
Notice: Do not subject the tool to more than
100 N-m (75 lb ft) torque. Exceeding the
recommended torque may damage the tool
and/or the bracket.
• Assemble the following parts in order:
7.5.1. The bridge
7.5.2. The bearing with the chamfered
side out
7.5.3. The washer
7.5.4. The nut
3-26 Wheel Alignment _____________________________Suspension
• The T-bolt head and the bridge must line up
horizontally with the knockout.
The bridge should span the knockout without
interfering with the knockout procedure.
• Tighten the T-bolt head against the knockout
by turning the nut at the opposite end using
a socket and torque wrench.
• An open end wrench or adjustable wrench
may be needed in order to prevent the
T-bolt from losing the horizontal alignment
with the knockout.
• If the torque limit on the T-bolt is met and
the knockout does not break free, use a die
grinder of appropriate size.
Using the stamped outline as a guide,
remove the knockout.
Remove the wax coating in the knockout
area in order to make the perforation lines
more visible.
• If the outline is not visible, use the T-bolt
head installed horizontally, as a template,
and scribe the frame bracket.
• Repeat the procedure on the other upper
control arm frame bracket.
Installation Procedure
1. Install the upper control arm (3) into the frame
brackets (2).
2. Install the bolts (1) and the cams (6) through
the frame brackets (2) and through the control
arm (3).
3. Install the cams (6) and the nuts (4).
Install the cams with the radius toward the
frame brackets.
4. Partially tighten the nut (4).
5. Install the front wheel assemblies.
6. Install the alignment machine heads.
Important: Verify alignment specifications
before proceeding. Refer to Fastener Tightening
Specifications.
Notice: Refer to Fastener Notice in Cautions
and Notices.
7. Adjust the caster and the camber to the correct
specifications by rotating the bolt head installed
through the adjuster cam.
Tighten
7.1. Tighten the front upper control arm nuts
(4) to 190 N.m (140 lb ft).
7.2. Tighten the rear upper control arm nuts
to 190 N.m (140 lb ft).
8. Set the steering wheel on center with the
wheels straight.
9. Loosen the adjuster sleeve nuts.
Suspension Wheel Aiignment 3-27
10. Adjust the toe-in. Refer to Fastener Tightening
Specifications.
Tighten
Tighten the tie rod adjuster sleeve nuts to
19 N.m (141b ft).
11. Ensure that the clamps are properly positioned.
Refer to Tie Rod Clamp and Adjuster Tube
Positioning in Steering Linkage.
12. Recheck the alignment specifications.
13. Lower the vehicle.
Frame Bracket Knock Out Removal
(K Model)
Removal Procedure
Tools Required
J 38794 Knockout Removal Tool
2. Suitably support the vehicle. Refer to General
Information.
important: The jack or the jack stand must
remain under the lower control arm during the
removal and the installation procedure in order
to retain the lower control arm position.
3. Support the lower control arms with a jack or
the jack stands.
5. Remove the following parts from the upper
control arm bracket (2): 156347
• The nuts
• The cams (4)
• The bolts (3)
6. Lift the upper control arm (2) up and to the
side in order to gain access to the inner portion
of the frame bracket.
7. Use the J 38794 in order to remove the frame
bracket knockout as follows:
• Do not distort the frame bracket when
removing the knockout.
• Apply extreme pressure lubricant to the
threads of the T-bolt.
• Insert the bolt through the knockout hole in
the bracket support.
• Install the bridge onto the T-bolt.
The forward bracket requires the bridge to be
installed between the legs of the bracket due
to access problems.
Notice: Do not subject the tool to more than
100 N-m (75 lb ft) torque. Exceeding the
recommended torque may damage the tool
and/or the bracket.
Description and Operation

General Description (2WD)
1. The front wheel alignment refers to the angular
relationship between the front wheels, the front
suspension attaching parts, and the ground.
Proper front wheel alignment must be
maintained in order to ensure efficient steering,
good directional stability, and prevent abnormal
tire wear. Following are the most important
factors of the front wheel alignment:
• The wheel toe-in
• The wheel camber
• The axle caster
3. The camber is the inward or outward tilting of

the front wheels from the vertical (2). When the
wheels tilt outward at the top, the camber is
positive (3). When the wheels tilt inward at the
top, the camber is negative. The amount of tilt
measured in the degrees from the vertical is
called the camber angle. The camber is
designed into the front axle assembly of all the
vehicles and is intended to be non-adjustable.
However, if the camber is measured and found
to be out of tolerance, the camber can be set
to proper specifications.
If the camber is extreme or unequal between
the wheels, improper steering and excessive
tire wear will result. The negative camber
causes wear of the inboard side of the tire,
2. The caster is the tilting of the steering axis
while the positive camber causes wear to the
either forward or backward from vertical (1)
when viewed from the side of the vehicle. A outboard side.
backward tilt is measured in positive degrees
(3) and a forward tilt in negative degrees (2).
On the short and long arm type suspension,
you cannot see a caster angle without a special
instrument. However, if you look straight down
from the top of the upper control arm to the
ground, the ball joints do not line up (fore and
aft) when a caster angle other than 0 degrees
is present. With a positive angle, the lower ball
joint center line would be slightly ahead (toward
the front of the vehicle) of the upper ball joint
center line. The caster is designed into the front
axle assembly on all vehicles, and is intended
to be non-adjustable. However, if the caster is
measured and found to be out of tolerance, the
caster can be set to proper specifications.
156652
4. The linear sum toe-in results when the distance On the short and long arm type suspension,
between the front wheels is less at the front of you cannot see a caster angle without a special
the axle than at the rear of the axle. instrument. However, if you look straight down
Angular toe-in (3) is the angle of the front from the top of the upper control arm to the
wheel centerlines (1), relative to the intersection ground, the ball joints do not line up (fore and
of the forward projected vehicle center line (2). aft) when a caster angle other than 0 degrees
is present. With a positive angle, the lower ball
The actual amount of the toe-in is normally a
joint center line would be slightly ahead (toward
fraction of a degree. Toe-in is measured from
the front of the vehicle) of the upper ball joint
the center of the tire treads or from the inboard
center line. The caster is designed into the front
side of the tires. The purpose of toe-in is to
axle assembly on all vehicles, and is intended
ensure parallel rolling of the front wheels and to
to be non-adjustable. However, if the caster is
offset any small deflections of the wheel
measured and found to be out of tolerance, the
support system which occur when the vehicle is
caster can be set to proper specifications.
rolling forward. Incorrect toe-in can cause
unstable steering and front tire wear. The toe-in
is the last angle to be set in the front wheel
alignment procedure.
General Description (4WD)
1. The front wheel alignment refers to the angular
relationship between the front wheels, the front
suspension attaching parts, and the ground.
Proper front wheel alignment must be
maintained in order to ensure efficient steering,
good directional stability, and prevent abnormal
tire wear. Following are the most important
factors of the front wheel alignment:
• The wheel toe-in
• The wheel camber
• The axle caster
3. The camber is the inward or outward tilting of

the front wheels from the vertical (2). When the
wheels tilt outward at the top, the camber is
positive (3). When the wheels tilt inward at the
top, the camber is negative. The amount of tilt
measured in the degrees from the vertical is
called the camber angle. The camber is
designed into the front axle assembly of all the
vehicles and is intended to be non-adjustable.
However, if the camber is measured and found
to be out of tolerance, the camber can be set
to proper specifications.
If the camber is extreme or unequal between
the wheels, improper steering and excessive
tire wear will result. The negative camber
causes wear of the inboard side of the tire,
while the positive camber causes wear to the
2. The caster is the tilting of the steering axis outboard side.
either forward or backward from vertical (1)
when viewed from the side of the vehicle. A
backward tilt is measured in positive degrees
(3) and a forward tilt in negative degrees (2).
4. The linear sum toe-in results when the distance

between the front wheels is less at the front of
the axle than at the rear of the axle.
Angular toe-in is the angle of the front wheel
centerlines (1), relative to the intersection of the
forward projected vehicle center line.
The actual amount of the toe-in is normally a
fraction of a degree. Toe-in is measured from
the center of the tire treads or from the inboard
side of the tires. The purpose of toe-in is to
ensure parallel rolling of the front wheels and to
offset any small deflections of the wheel
support system which occur when the vehicle is
rolling forward. Incorrect toe-in can cause
unstable steering and front tire wear. The toe-in
is the last angle to be set in the front wheel
alignment procedure.
Suspension____________________ Wheel Alignment 3-33
Special Tools and Equipment

BLANK
Suspension Front Suspension 3-35
Front Suspension
Specifications

Axle Shaft Nut (K Models) 225 165 —
Brake Hose Bracket Nuts (C Models) 18 13 —

Caps to Steering Knuckle (C3500HD) 17 12 —
Hub and Bearing Assembly to Steering Knuckle Bolts 180 133 —
(K Models)
Lock Pin to Steering Knuckle Nut (C3500HD) 40 29 —
Lower Ball Joint to Steering Knuckle Nut (C and K Models) 128 94 —
Lower Control Arm Bumper (C Models) 32 23 —
Lower Control Arm to Frame Nuts and Bolts 165 121 —

(C and K Models)
Lower Shock Absorber Nut (C3500HD) 185 136 —
Outer Tie Rod Nut (C and K Models) 62 46 —
Shackle to Frame Nut and Bolt (C3500HD) 95 70 —
Shock Absorber Nuts (K Models) 90 66 —
Shock Absorber to Control Arm Bolts (C Models) 27 20 —
Shock Absorber Upper Nut (C Models) 11 — 100

Splash Shield to Anchor Plate Bolts (C3500HD) 16 12 —
Splash Shield to Steering Knuckle Bolts (C and K Models) 26 19 —
Spring Eye Bolts and Nuts (C3500HD) 95 70 —
Spring to Axle U-Bolts (C3500HD) 125 92 —
Stabilizer Bar Bracket to Frame Nuts and Bolts 33 24 —

(C and K Models)
Stabilizer Bracket Bolts (C3500HD) 7 — 60
Stabilizer Clamp Bolts (C3500HD) 29 21 —
Stabilizer Link Nuts (C and K Models) 18 13 —

Stabilizer to Link Nuts (C3500HD) 68 50 —
Steering Arm to Knuckle Nut (C3500HD) 285 210 —
Steering Knuckle Nuts (C3500HD) 312 230 —

Suspension Bumper (C3500HD) 34 25 —
Torsion Bar Support Link Nuts (4 Door Utility K Models) 125 92 —
Torsion Bar Support Center Nuts (K Models) 24 18 —
Torsion Bar Support Outside Nuts (K Models) 62 46 —

Upper Ball Joint Nuts (C Models) 24 18 —
Upper Ball Joint to Steering Knuckle Nut (C and K Models) 100 74 —
Upper Control Arm to Frame Nuts and Bolts 190 140 —

(C and K Models)
Upper Shock Absorber Bolt and Nut (C3500HD) 50 37 I____ =____
3-36 Front Suspension__________________________________________________ Suspension

Steering Knuckle 6.020
Steering Knuckle Spindle Nut 6.022
Steering Knuckle Upper Control Arm Bushing and Ball Joint Stud Kit 6.164
Steering Knuckle Upper and Lower Control and Arm Kit 6.168
Steering Knuckle Lower Control Arm Bushing 6.170
Steering Knuckle Lower control Arm Bolt and Cam Kit 6.172
Steering Knuckle Lower Control Arm Pivot Nut and Ball Joint Stud Kit and Washer 6.174
Steering Knuckle Upper and Lower Control Arm Bumper 6.176
Front Wheel Inner Bearing and Cup 6.311
Front Wheel Outer Bearing 6.313
Front Wheel Bearing Cone 6.135
Steering Knuckle Spindle Washer 6.321
Front Wheel Bearing Retainer Seal 6.326
Front Wheel Hub Grease Cap 6.330
Stabilizer Shaft Link 7.240
Stabilizer Shaft 7.241
Stabilizer Shaft Clamp 7.243
Stabilizer Shaft Insulator 7.243
Suspension Absorber 7.345
Shock Absorber Bolt Nut 7.347
Shock Absorber Bracket 7.380
Shock Absorber Insulator 7.388
Shock Absorber Retainer 7.389
Front Chassis Spring 7.412
Front Spring Insulator 7.420
Front Spring Bumper Bolt Stop 7.421
Component Locator
Front Suspension Components
__________ Shock Absorber, Axle Tie Rod, and Components (C3500HD)
34
157092
Legend
(1) Shock Absorber Upper Mounting Bolt (13) Spring Hanger to Frame Nut
(2) Shock Absorber Upper Mounting Bolt (14) Spring Hanger to Frame Washer
Washer (15) Axle Tie Rod
(3) Shock Absorber Upper Mounting Nut (16) Axle Tie Rod Lower Mounting Bolt
(4) Front Spring Mounting Bolt (17) Axle Tie Rod Lower Mounting Washer
(5) Front Spring Mounting Washer (18) Stabilizer Link Lower Mounting Washer
(6) Front Spring Mounting Nut (19) Stabilizer Link Lower Mounting Nut
(7) Shock Absorber Assembly (20) Stabilizer Shaft Clamp
(8) Shock Absorber Lower Mounting Washer (21) Stabilizer Shaft U-bolt
(9) Shock Absorber Lower Mounting Nut (22) Stabilizer Shaft Insulator
(10) Axle Tie Rod Upper Mounting Bolt (23) Front Stabilizer Bracket Mounting Bolt
(11) Axle Tie Rod Lower Mounting Washer (24) Stabilizer Shaft
(12) Axle Tie Rod Upper Mounting Nut (25) Axle Tie Rod Lower Mounting Washer
3-38 Front Suspension Suspension
(26) Axle Tie Rod Lower Mounting Nut (32) Stabilizer Link Retainers
(27) Front Axle (33) Stabilizer Link Insulator
(28) Front Stabilizer Bracket (34) Stabilizer Link Mounting Nut
(29) Front Stabilizer Mounting Bracket Washer (35) Spring Hanger to Frame Bolt
(30) Front Stabilizer Mounting Bracket Nut (36) Spring Hanger to Frame Washer
(31) Stabilizer Link
Control Arm and Components (2WD)
157091
Legend
(1) Cam (14) Lower Ball Joint Cotter Pin
(2) Upper Control Arm Bushing (15) Lower Ball Joint
(3) Upper Control Arm (16) Lower Ball Joint Nut
(4) Nut (17) Lower Control Arm
(5) Upper Ball Joint (18) Lower Control Arm Bushing
(6) Brake Hose Bracket (19) Front Coil Spring
(7) Upper Control Arm to Frame Nut (20) Front Coil Spring Upper Insulator
(8) Upper Ball Joint Nut (21) Lower Control Arm to Frame Bolts
(9) Brake Hose Bracket Screw (22) Lower Control Arm to Frame Nut
(10) Upper Control Arm (23) Upper Control Arm to Frame Nut
(11) Lower Control Arm Bushing (24) Cams
(12) Lower Control Arm Bumper (25) Upper Control Arm to Frame Bolts
(13) Lower Control ArmBumper Nut
Front Spring and Components (C3500HD)
157093
Legend
(1) Front Spring Spacer Cushion (16) Splash Shield
(2) Front Spring U-bolt (17) Anchor Plate
(3) Front Spring (18) Splash shield Bolt
(4) Spring Spacer (19) Wheel Hub Rotor Bolt Washer
(5) Front Stabilizer Bracket Nut (20) Bearing Seal
(6) Front Stabilizer Bracket Washer (21) Wheel Hub Bolt
(7) Front Stabilizer Bracket (22) Wheel Hub
(8) Steering Knuckle Nut (23) Hub Outer Bearing
(9) Steering Knuckle Washer (24) Washer
(10) Steering Knuckle (25) Retainer Cap Cotter Pin
(11) Steering Knuckle Nut (26) Retainer Cap
(12) Front Spring U-bolt Nut (27) Wheel Bearing Nut
(13) Front Spring U-bolt Washer (28) Inner Bearing
(14) Front Stabilizer Bracket Bolt (29) Hub Rotor
(15) Brake Caliper (30) Wheel Hub Rotor Bolt
(31) Bearing Seal Shield (35) Spring Hanger
(32) Front Stabilizer Bracket Bolt (36) Spring Hanger to Front Spring Nut
(33) Spring Hanger Washers (37) Cushion Nut
(34) Spring Hanger to Front Spring Bolt (38) Spacer

Procedures
Ball Joint W ear Check
2009
4. Check the ball joints for vertical looseness. With

the vehicle on the jack stands, place a dial
indicator (1) against the spindle to show vertical
movement.
2006
Important:
• The vehicle must rest on a level surface.
• The vehicle must be stable. Do not rock the
vehicle on the floor stands.
• The upper control arm bumper must not contact
the frame.
1. Raise the vehicle. Support the vehicle with
safety stands. Support the lower control arm
with a floor stand or jack, as far outboard as
possible, under the stabilizer shaft bracket.
Important: If a seal is cut or torn, replace the
ball joint.
2. Wipe the ball joints clean. Check the seals for
cuts or tears.
3. Adjust the wheel bearings. Refer to Wheel
Bearing Adjustment (2WD).
Notice: Do not pry between the lower arm and

the drive axle (halfshaft) boot or in such a
manner that the ball joint seal is contacted.
Damage to the drive axle (halfshaft) boot will
result (4WD).
5. Pry between the lower control arm and the
outer race (2) while reading the dial indicator.
This shows vertical looseness in the ball joints.
5.1. The indicator reading should be no more
than 2 mm (0.08 in).
5.2. If the reading is too high, replace the
ball joint.
Repair Instructions
Wheel Hub Bolt Replacement (2WD)
Removal Procedure
Tools Required
J 9746-02 Wheel Stud Remover
safety stands.
2. Remove the tire and wheel assembly. Refer to
Wheel Removal (Single Wheels) in Tires and
Wheels.
Notice: Support the caliper with a piece of wire
to prevent damage to the brake line.
3. Remove the brake caliper. Refer to Brake
Caliper Replacement (Front Delco) or Brake
Caliper Replacement (Front Bendix) in Disc
Brakes.
4. Remove the hub/rotor. Refer to Wheel Hub,
Bearing, and Seal Replacement (2WD).
5. Remove the wheel hub bolts with a press.
• Support the hub/rotor using the J 9746-02
and the press bars.
• Do not damage the wheel mounting surface
on the hub/rotor flange.
1. Install the wheel hub bolts into the hub/rotor.
1.1. Place four washers and a nut on
the bolt.
1.2. Tighten until the bolt is fully seated in the
hub/rotor.
2. Install the hub/rotor. Refer to Wheel Hub,
Bearing, and Seal Replacement (2WD).
3. Install the brake caliper. Refer to Brake Caliper
Replacement (Front Delco) or Brake Caliper
Replacement (Front Bendix) in Disc Brakes.
4. Install the wheel assembly. Refer to Wheel
Installation (Single Wheels-Front or Rear) in
Tires and Wheels.
156969
Important: Place the bushings on the stabilizer shaft
with the slits facing toward the front of the vehicle.
1. Install the rubber bushings to the
stabilizer shaft.
2. Install the stabilizer shaft.
3. Install the brackets over the bushings and the
stabilizer shaft.
4. Install the bolts to the brackets and the frame.
Tighten
Tighten the bolts to 33 N-m (24 lb ft).
and Notices.
5. Install the spacer assembly.
6. Install the link bolt assembly.
7. Install the nuts.
Tighten
7.1. Tighten until the nut meets the end of
the bolt threads for torque value.
7.2. Tighten the nut to 18 N-m (13 lb ft).
Stabilizer Shaft Replacement (4WD)
Removal Procedure
safety stands.
Important: Remove the parts from the right
front and the left front of the vehicle. Keep the
parts separated.
2. Remove the nuts.
3. Remove the bolts.
4. Remove the spacers.
6. Remove the clamp.
7. Remove the stabilizer shaft.
8. Remove the insulators.
9. Inspect all of the parts for wear and damage.
157041
Suspension ___________ Front Suspension 3-47
1. Unload the torsion bar. Refer to Torsion Bar
and Support Assembly Replacement (All except
4 Door Utility) or Torsion Bar and Support
Assembly Replacement (4 Door Utility).
2. Install the insulators to the stabilizer shaft. Face
the slit in the insulator forward.
3. Install the stabilizer shaft to the frame and to
the lower control arm.
4. Install the clamp to the insulator.
5. Install the bolts to the frame.
Tighten
and Notices.
6. Install the spacer assembly.
7. Install the link bolts.
Tighten
Tighten the nuts to 18 N-m (13 lb ft).
Important: Adjust the trim height of the vehicle.
Refer to Measuring Wheel Alignment (K Model)
in Wheel Alignment.
Stabilizer Shaft Replacement (C3500HD)
Removal Procedure
Tools Required
J 6627-A Wheel Stud and Tie Rod Remover
suitable safety stands.
Wheels.
3. Remove the nut and the washer.
4. Remove the stabilizer shaft from the stabilizer
link. Using the J 6627-A, separate the stabilizer
link from the stabilizer end.
5. Remove the nuts, the washers, the clamp bolts,
and the clamps.
6. Remove the stabilizer shaft from the axle.
7. Remove the insulator from the stabilizer shaft.
8. Remove the nut, the retainer, and the insulator.
9. Remove the stabilizer link from the frame
bracket.
• Pull the link from the bracket.
• Another insulator and retainer will come off
of the link.
1. Install the stabilizer link to the frame bracket.
1.1. Slide a retainer and an insulator onto
the link.
1.2. Insert the link into the proper hole in the
frame bracket.
2. Install the insulator, the retainer, and the nut.
Tighten
Tighten the nut until the distance between each
retainer is 38 mm (1.5 in).
and Notices.
3. Install the stabilizer shaft to the front axle.
4. Install the insulators onto the stabilizer shaft.
5. Install the clamps, the clamp bolts, the
washers, and the nuts.
Tighten
6. Install the stabilizer shaft to the stabilizer link.
7. Install the washer and the nut.
Tighten
8. Install the tire and wheel assembly. Refer to
Wheel Installation (Single Wheels-Front or
Rear) in Tires and Wheels.
Upper Ball Joint Replacement (2WD)
Removal Procedure
For control arms and components, refer to Control
Arms and Components (2WD).
Tools Required
J 23742 Ball Joint Separator
Caution: Floor jack must remain under the
control arm spring seat during removal and
Installation to retain the spring and control arm
In position. Failure to do so could result in
personal injury.
1. Raise the vehicle. Support the lower control
arm with floor stands.
Wheels.
Brakes.
4. Remove the rivets from the upper ball joint.
5. Use a 3.175 mm (1/8 in) drill in order to cut a
6.35 mm (V4 in) deep hole in the center of
each rivet.
Suspension_________________ Front Suspension 3-49
6. Drill away the rivet heads. Use a
12.75 mm (1/2 in) drill.
7. Punch the rivets out. Use a small pin punch.

8. Remove the cotter pin.
9. Remove the stud nut from the upper ball joint.
Important: Support the knuckle assembly so that the

knuckle weight does not damage the brake hose.
10. Use the J 23742 as shown.
11. Apply pressure on the tool until the stud
breaks loose.
12. Remove the J 23742.
13. Pull the stud away from the knuckle.
14. Remove the ball joint.
130902
1. Install a new upper ball joint to the upper
control arm.
2. Position four attaching bolts and nuts.
Tighten
and Notices.
3. Remove the support from the knuckle assembly.
4. Install the upper ball joint to the steering
knuckle.
5. Install the stud nut.
Tighten
• Tighten the nut to 100 N.m (74 lb ft).
• Tighten the stud nut in order to align
the slot in the stud nut with the hole in
the stud.
6. Install a new cotter pin.
Important:
• Check the running clearance at all
suspension components.
• Check the front wheel alignment. Refer to
Measuring Wheel Alignment (C Model) in
Wheel Alignment.
Upper Ball Joint Replacement (4WD)
Removal Procedure
Tools Required
Wheels.
3. Remove the brake hose and the bracket (upper
control arm only).
4. Using a 3.17 mm (1/8 in) drill, cut a 6.35 mm
(V4 in) deep hole in the center of each rivet.
157004
5. Using a 12.7 mm (1/2 in) drill bit, drill away the
rivet heads.
6. Using a pin punch, remove the rivets.

8 . Remove the stud nut from the upper ball joint.
9. Using the J 36607, remove the ball joint from
the knuckle. Support the knuckle.
10. Remove the ball joint.
157043
1. Install the ball joint to the control arm.
2. Install the bolts and the nuts to the ball joint.
Tighten
• For K1 and K2, tighten the nuts to
23 N-m (17 1b ft).
• For K3, tighten the nuts to 70 N-m (52 lb ft).
and Notices.
3. Install the ball joint to the knuckle.

4. Install the ball joint stud nut.
Tighten
• Tighten the nut to 100 N-m (74 lb ft).
• Tighten the nut with the control arm at the
proper Z height. Refer to Measuring Wheel
Alignment (K Model) in Wheel Alignment.
• Tighten the nut in order to align the cotter
pin. Do not tighten more than V6 turn.
5. Install the new cotter pin. Bend the pin ends
against the nut.
6. Install the brake hose and the bracket (upper
control arm only).
9. Check the front wheel alignment. Refer to
Measuring Wheel Alignment (K Model) in Wheel
Alignment.
Suspension_____________________________ Front Suspension 3*53
Lower Ball Joint Replacement (2WD)

Removal Procedure
Tools Required
• J 9519-D Ball Joint Remover and Installer Set
• J 23742 Ball Joint Separator
1. Raise the vehicle. Support the frame with safety
stands.
Wheels.
Caution: Floor Jack m ust remain under the
Installation to retain the spring and control
arm In position. Failure to do so could result
In personal Injury.
3. Place a floor jack under the control arm spring
seat. Raise the jack in order to support the
control arm.
Brakes.
5. Remove the cotter pin and the nut.
6 . Break the ball joint loose from the knuckle
using the J 23742.
Important: Place a wooden block between the frame
and the upper control arm in order to block the
knuckle assembly out of the way.
7. Remove the lower control arm from the knuckle.
Guide the lower control arm out of the splash
shield with a screwdriver while lifting the upper
control arm with a pry bar.
1827
3*56 Front Suspension Suspension
1. Using Loctite Cleaning Solvent 755, or
equivalent, clean the mounting surfaces of the
lower control arm ball joint and the new ball
joint prior to installation. Do not apply solvent to
the ball joint seal.
2. Install the new ball joint into the lower
control arm.
2.1. Apply a 6 mm (1/4 in) bead of Loctite 680
evenly to the serrations on the ball joint
prior to installation.
2.2. Position the ball joint in the control arm
with the grease fitting toward the rear of
the vehicle.
2.3. Press in the ball joint using the tools
as shown.
• The ball joint will bottom on the
control arm.
• When installing the ball joint with the
J 41435, make sure the notch in the
tool aligns with the grease fitting.
3. Install the ball joint into the steering knuckle.
4. Install the stud nut onto the stud.
Tighten
Tighten the nut to 128 N.m (94 lb ft). Tighten in
order to align the slot in the stud nut with the
hole in the stud.
and Notices.
5. Install a new cotter pin to the stud.
6. Install the drive axle (halfshaft). Refer to Front
Drive Axle Assembly Replacement in Front
Drive Axle.
157043
Important: Check the front wheel alignment.
Refer to Measuring Wheel Alignment (K Model)
in Wheel Alignment.
Suspension_________________________________________________ Front Suspension 3-57
Steering Knuckle Replacement (2WD)

Removal Procedure
Tools Required
1. Raise the front of the vehicle.
• Place safety stands under the front lift points.
• Do not place floor stands under the lower
control arms because spring tension is
needed to assist in breaking loose the ball
joint studs.
Wheels.
Caliper Replacement (Front Bendix) in Disc 1645
Brakes.
4. Remove the hub/rotor assembly. Refer to Wheel
Hub, Bearing, and Seal Replacement (2WD).
5. Remove the three bolts that attach the splash
shield to the knuckle.
6. Remove the knuckle seal if the knuckle is to be
replaced. Do not damage the knuckle seal.
1842
3-58 Front Suspension _________ _________________ Suspension
7. Remove the lower ball joint stud from the
knuckle using the J 23742.
8. Remove the upper ball joint stud from the

knuckle using the J 23742.
Caution: Floor jack must remain under the
installation to retain the spring and control
arm in position. Failure to do so could result
In personal injury.
9. Position a floor jack under the lower control
arm near the spring seat.
• Raise the jack until the jack just supports the
lower control arm.
• Raise the upper control arm. Disengage the
ball joint stud from the knuckle.
10. Remove the knuckle from the lower ball
joint stud.
10.1. Clean the steering knuckle.
10.2. Inspect the steering knuckle tapered
hole. If this tapered hole is out-of-round,
deformed, or damaged, replace the
knuckle.
1. Install the upper ball joint into the knuckle.
Refer to Upper Ball Joint Replacement (2WD).
2. Install the lower ball joint into the knuckle.
Refer to Lower Ball Joint Replacement (2WD).
3. Install the knuckle seal.
4. Install the splash shield to the knuckle.

5. Install the bolts to the splash shield.
Tighten
Tighten the bolts to 26 N.m (19 lb ft).
and Notices.
6. Install the tie rod end into the knuckle.
7. Install the hub/rotor assembly. Refer to Wheel
Bearing Adjustment (2WD).
10. Remove the floor stands.
Measuring Wheel Alignment (K Model) in Wheel
Alignment.
3-60 Front Suspension ____________________________ Suspension
Steering Knuckle Replacement (C3500HD) 4. Install the king pin and the lock pin.
4.1. Prelube the king pin.
Removal Procedure
4.2. Insert the spacers in the correct order.
For steering arm, knuckle, and components, refer to
Shock Absorber, Axle Tie Rod, and Components
(C3500HD) or Front Spring and Components Tighten
(C3500HD). Tighten the nut to 40 N-m (29 lb ft).
1. Raise the vehicle. Support the vehicle with Notice: Refer to Fastener Notice in Cautions
suitable safety stands. and Notices.
2. Remove the tire and wheel assembly. Refer to 6. Install the gaskets.
Wheel Removal (Single Wheels) in Tires and 7. Install the caps to the steering knuckle.
Wheels.
8. Install the stabilizer bracket and the bolts.
Tighten
Caliper Replacement (Front Bendix) in Disc Tighten the bolts to 7 N-m (60 lb in).
Brakes. 9. Install the steering arm, the splash shield, and
4. Remove the hub/rotor assembly. Refer to Wheel the anchor plate.
Hub, Bearing, and Seal Replacement (C3500HD). 10. Install the bolts and the washers that attach the
5. Remove the bolts, the washers, and the nuts. splash shield to the anchor plate.
6. Remove the anchor plate, the splash shield, 11. Install the bolts, the washers, and the nuts that
and the steering arm. attach the anchor plate and the steering arm to
the steering knuckle.
6.1. Pull the anchor plate and the splash
shield off of the knuckle. The steering Tighten
arm hangs by the rods. • Tighten the bolts to 16 N-m (12 lb ft).
6.2. Remove the bolts and the washers in • Tighten the nuts to 312 N-m (230 lb ft).
order to separate the anchor plate from 12. Install the steering arm to the steering linkage.
the splash shield. 13. Install the hub/rotor assembly. Refer to Wheel
6.3. Refer to Tie Rod Replacement and Hub, Bearing, and Seal Replacement
Pitman Arm Repiacement in Steering (C3500HD).
Linkage in order to separate the steering 14. Adjust the wheel bearings. Refer to Wheel
arm from the tie rod and the pitman arm. Bearing Adjustment (C3500HD).
7. Remove the bolts and the washers. 15. Install the brake caliper. Refer to Brake Caliper
6. Remove the stabilizer bracket. Replacement (Front Delco) or Brake Caliper
9. Remove the gaskets. Replacement (Front Bendix) in Disc Brakes.
10. Remove the caps from the steering knuckle. 16. Install the tire and wheel assembly. Refer to
11. Remove the nut and the washer. Rear) in Tires and Wheels.
12. Remove the lock pin. 17. Lower the vehicle.
13. Remove the king pin from the steering knuckle. 18. Check the front wheel alignment. Adjust as
• Using a drift, drive out the king pin. necessary. Refer to Measuring Wheel Alignment
• The spacers and the bushings will also (C Model) in Wheel Alignment.
come out. Upper Control Arm Replacement (2WD)
14. Remove the steering knuckle from the axle.
Removal Procedure
15. Remove the dust seal, the shim, and the thrust
bearing. For control arms and components, refer to Control
Installation Procedure Caution: Floor jack must remain under the control
For steering arm, knuckle, and components, refer to arm spring seat during removal and installation to
Shock Absorber, Axle Tie Rod, and Components retain the spring and control arm In position.
(C3500HD) or Front Spring and Components Failure to do so could result In personal Injury.
(C3500HD).
1. Raise the front of the vehicle.
1. Install the bushings. Ream the new bushings to
• Support the lower control arm with floor
between 29.982-30.022 mm (1.1804-1.1820 in)
stands.
after installation.
• Because the weight of the vehicle is used to
2. Install the steering knuckle.
relieve the spring tension on the upper
3. Install the thrust bearing shim and the dust control arm, position the floor stands
seal. Prelube the thrust bearing. Refer to between the spring seats and the ball joints
Recommended Fluids and Lubricants in of the lower control arms in order to maintain
Maintenance and Lubrication. maximum leverage.
2. Remove the tire and wheel assembly. Refer to 3. Install the bolts and new nuts.
Wheel Removal (Single Wheels) in Tires and Tighten v
Wheels.
• Tighten the nuts with the control arm at
3. Remove the air cleaner extension, if necessary.
Z height. Refer to Measuring Wheel
4. Remove the brake hose bracket from the upper Alignment (C Model) in Wheel Alignment.
control arm.
• Tighten the nuts to 190 N-m (140 lb ft).
4.1. Remove the nuts and the screws.
4. Install the upper ball joint to the steering
4.2. Tie the hose out of the way.
knuckle. Refer to Upper Ball Joint
5. Remove the upper ball joint from the steering Replacement (2WD).
knuckle. Refer to Steering Knuckle
Replacement (2WD). 5. Install the brake hose bracket to the upper
control arm.
6. Remove the attaching bolts and nuts of the
upper control arm. . 6. Install the bracket screws and the nuts.
7. Remove the upper control arm. Tighten
8. Remove the bushings. Tighten the nuts to 18 N-m (13 lb ft).
9. Inspect all of the parts for wear and damage. 7. Install the brake hose to the bracket.
installation Procedure 8. Install the air cleaner extension, if necessary.
1. Install the bushings. 9. Install the tire and wheel assembly. Refer to
2. Install the upper control arm to the frame. Wheel Installation (Single Wheels-Front or
Important:
• The pivot bolts must be installed in the 10. Check the front wheel alignment. Refer to
proper direction. Measuring Wheel Alignment (C Model) in Wheel
Alignment.
• Tighten the front nut prior to tightening the
rear nut.
and Notices.
Upper Control Arm Replacement (4WD)

Removal Procedure
Wheels.
3. Remove the air cleaner extension, if necessary.
4. Remove the brake hose.
4.1. Remove the nut and the screw.
4.2. Remove the bracket and the hose.
4.3. Tie the hose out of the way.
6. Remove the nut.
7. Disconnect the upper control arm from the
knuckle.
157036 8. Remove the nuts.
10. Remove the upper control arm.
11. Remove the bushings.
1. install the bushings.
2. Install the upper control arm to the frame.
157043
3. Install the bolts and the washers. Make sure
the bolt heads are opposed inside the bracket.
4. Install the new nuts.
Tighten
rear nut.
Z height. Refer to Measuring Wheel
• Tighten the nuts to 190 N.m (140 lb ft).
and Notices.
5. Install the upper ball joint stud to the knuckle.

6. Install the nut to the upper ball joint stud.
Tighten
• Tighten the nut to 100 N.m (94 lb ft).
• Tighten the nut in order to align the cotter
pin. Do not tighten more than V6 turn.
7. Install the new cotter pin. Bend the pin ends
against the nut flats.
8. Remove the support from the knuckle.
9. Install the brake hose.
9.1. Install the bracket and the hose.
9.2. Install the screw and the nut.
10. Install the air cleaner extension, if necessary.
Lower Control Arm Replacement (2WD)

Removal Procedure
Tools Required
2. Support the vehicle with safety stands.
Wheels.
4. Remove the hub and the rotor. Refer to Wheel
5. Remove the cotter pin and the nut.
6. Separate the ball joint using the J 23742.
7. Disconnect the control arm from the knuckle.
156979
3-64 Front Suspension__________________________________________________ Suspension
8. Remove the coil spring. Refer to Front Coil
Springs Replacement
9. Remove the nuts from the pivot bolts.
10. Remove the pivot bolts from the lower
control arm.
11. Remove the lower control arm.
1. Install the control arm bushings.
2. Install the control arm to the frame.
Important: The pivot bolts must be installed in
the proper direction.
3. Install the pivot bolts and the nuts.
4. Install the coil spring. Refer to Front Coil
Springs Replacement
5. Install the control arm to the steering knuckle.
6. Install the ball joint stud nut.
Tighten
• Tighten the nuts of the control arm at the
proper Z height. Refer to Measuring Wheei
Alignment (C Model) in Wheel Alignment.
• Tighten the ball joint stud nut to
128 N-m (94 lb ft). Tighten the nut by
aligning the slot in the stud nut with
the hole in the stud.
and Notices.
8. Install the hub and the rotor. Refer to Wheel
10. Remove the safety stands.
Lower Control Arm Replacement (4WD)
Removal Procedure
Tools Required
• J 24319-B Steering Linkage Puller
• J 36202 Torsion Bar Loading/Unloading Tool
• J 36618 Lower Control Arm Bushing Service
Set (Series 30)
• J 9519-23 Ball Joint C-Clamp
Wheels.
156607
3. Unload the torsion bar using the J 36202.
3.1. Mark the adjuster bolt for installation.
3.2. Slide the bar forward in order to remove
the adjuster arm.
3.3. Remove the adjuster arm.
• Refer to Torsion Bar and Support
Assembly Replacement (All except
4 Door Utility).
• For the 4 Door Utility models, refer to
Torsion Bar and Support Assembly
Replacement (4 Door Utility).
4. Remove the outer axle shaft nut (2) and the
washer (3) from the hub assembly (4).
Brakes.
6. Remove the brake rotor. Refer to Brake Rotor
Replacement (K Models Below 8600 GVW) or
Brake Rotor Replacement (K Models Above
8600 GVW) in Disc Brakes.
7. Remove the lower shock absorber bolt from the
control arm. Compress the shock. Refer to
Shock Absorber Replacement (4WD).
8. Using the J24319-B, disconnect the inner tie
rod end from the relay rod.
9. Support the lower control arm with a jack.
10. Remove the stabilizer link from the control arm.
Refer to Stabilizer Shaft Replacement (4WD).
11. Remove the drive axle (halfshaft) (5) from the
hub. Refer to Front Drive Axle Assembly
Replacement in Front Drive Axle.
12. Remove the cotter pin and the nut from the
upper ball joint.
13. Using the J 36607, disconnect the upper ball
joint from the knuckle.
157043
3-66 Front Suspension ___________________ ________ Suspension
14. Remove the lower control arm nuts and the
washers.
16. Remove the lower control arm and the knuckle
as a unit.
17. Remove the front bushing.
17.1. Using a punch, unbend the crimps.
17.2. Remove the bushing using J 36618-2,
J 9519-23, J 36618-4, and J 36618-1.
18. Remove the rear bushing (no crimp).
18.1. Removing the bushing using J 36618-5,
J 36618-3, J 36618-2, and J 9519-23.
18.2. If the bushings on the K1 and
K2 vehicles are worn or damaged,
replace the lower control arm.
156934
1. Using the J 36618 and the J 9519-23, install
the front bushing.
• This applies to the K3 vehicle only.
• After installing the bushing, crimp the
bushing in place.
2. Using the J 36618 and the J 9519-23, install
the rear bushing.
3. Install the lower control arm and the knuckle
assembly to the crossmember and the frame
bracket. Install the front leg of the lower control
arm into the crossmember before installing the
rear leg into the frame bracket.
4. Install the bolts in the direction shown.
5. Install the new nuts.
Tighten
rear nut.
the proper Z height. Refer to Measuring
Wheel Alignment (K Model) in Wheel
Alignment.
and Notices.
6. Prelube the steering knuckle seal.
7. Start the drive axle through the hub.
156934
8. Connect the ball joint to the knuckle.
9. Install the ball joint nut.
Tighten
Tighten the nut to 128 N-m (94 lb ft).
10. Install the cotter pin. Bend the pin ends against
the side of the nut.
11. Install the torsion bar adjuster arm.
11.1. Slide the bar rearward in order to install
the sides of the nut.
11.2. Using the J 36202, load the torsion bar.
11.3. Install the adjuster bolt and screw the
bolt down to the installation mark.
• Refer to Torsion Bar and Support
Assembly Replacement (All except
4 Door Utility).
• For the 4 Door Utility models, refer to
Replacement (4 Door Utility).
12. Install the outer axle shaft washer (3) and the
nut (2) to the hub assembly (4).
Tighten
Tighten the nut to 225 N.m (165 lb ft).
13. Install the lower shock absorber bolt. Refer to
Shock Absorber Replacement (4WD).
14. Install the stabilizer link. Refer to Stabilizer
Shaft Replacement (4WD).
Front Coil Springs Replacement

Removal Procedure
Tools Required
J 23028-01 Coil Spring Remover and Installer
1. Raise the vehicle on a hoist so that the control
arms hang free.
Wheels.
3. Remove the shock absorber. Refer to Shock
Absorber Replacement (2WD).
4. Cradle the lower control arm. Use the
J 23028-01, secured to the end of a
suitable jack.
130891
3*68 Front Suspension Suspension
5. Remove the stabilizer shaft from the lower
control arm. Refer to Stabilizer Shaft
Replacement (2WD).
5.1. Raise the jack in order to relieve tension
on the lower control arm pivot bolts.
5.2. Secure the spring with a chain through
the spring and the control arm.
6. Remove the pivot bolts and nuts.
6.1. Take the rear pivot bolt out first.
6.2. Lower the control arm by lowering
the jack.
6.3. When compression is removed from the
coil spring, take the chain away.
Important: While removing the coil spring,
do not force to the lower control arm and the
ball joint.
7. Remove the coil spring and the insulator.
8. Position the coil spring properly for easy
removal.
1. Install the coil spring and the insulator on the
lower control arm.
• The coil spring is installed with the tape at
the lowest position, and a gripper notch at
the top (2).
• Inspection drain holes (3). One hole must be
covered by the end of the spring, and one
hole must be open.
• Secure the spring with a chain through
spring and the control arm.
• Make sure the spring insulator (1) is on top.
2. Support the control arm using the J 23028-01.

3. Install the lower control arm in place on the
frame. Guide the control arm into place with a
pry bar.
130B91
Important: The pivot bolts must be installed in the
proper direction.
Notice: Refer to Fastener Notice in Cautions and
Notices.
4. Install the pivot bolts and the new nuts.
4.1. Insert and tighten the front bolt first.
4.2. Remove the chain and the jack.
Tighten
• The front nut must be tightened
before the rear nut.
• The nuts must be tightened with the
control arm at Z height. Refer to
Measuring Wheel Alignment
(C Model) in Wheel Alignment.
• Tighten the nuts to 137 N-m
(101 lb ft).
5. Install the stabilizer shaft. Refer to Stabilizer
Shaft Replacement (2WD).
6. Install the shock absorber. Refer to Shock
Absorber Replacement (2WD).
Leaf Springs Replacement (C3500HD)
Removal Procedure
Tools Required
1. Raise the vehicle. Support the axle separately
in order to eliminate any load on the springs.
Wheels.
4. Remove the shock absorber from the axle.
157010
3-72 Front Suspension ____________________________ Suspension
9. Install the shock absorber to the axle.
Tighten
Wheel Installation (Single Wheeis-Front or
13. Check the front wheel alignment. Adjust as
necessary. Refer to Measuring Wheel Alignment
(C Model) in Wheel Alignment.
157010
Wheel Hub, Bearing, and Seal
Replacement (2WD)
Removal Procedure
Notice: Support the caliper with a piece of wire to
prevent damage to the brake line.
Brakes.
2. Remove the cap from the hub/rotor.
3. Remove the cotter pin, the nut, and the washer.
important: Do not damage the outer bearing
and the spindle threads.
4. Remove the hub/rotor from the spindle.
5. Remove the outer bearing.
6. Remove the seal. Pry the seal out and discard
130890 the seal.
7. Remove the inner bearing.
Notice: Do not spin the wheel bearings with
compressed air to dry them -the wheel bearings
may be damaged.
8. Clean all of the parts in a solvent, then air dry.
Do not spin the bearings with compressed air.
9. Inspect the hub/rotor. Refer to Brake Rotor
Thickness Variation Check or Brake Rotor
Lateral Runout Check or Brake Rotor Tolerance
in Disc Brakes.
10. Inspect the bearings and the races for wear or
damage. Replace the parts as necessary. Refer
to Wheel Bearings Diagnosis in Suspension
General Diagnosis.
Suspension__________________________________________________ Front Suspension 3-73
Important:
• Make sure all of the parts are clean and free of
grease.
• Apply an approved high-temperature front
wheel bearing grease to the spindle at the
inner and outer bearing seat, the shoulder, and
the seal seat.
• Also, finger apply a small amount of grease
inboard of each bearing cup in the hub/rotor.
• Pressure pack the bearings with a greasing
machine, or hand pack the bearings. Make sure
the grease is worked thoroughly into the rollers,
the cone, and the cage.
1. Install the inner bearing to the hub/rotor.
2. Apply an additional quantity of grease outboard
of the inner bearing.
3. Install the seal. 130880
3.1. Lubricate the seal lip.
3.2. Use a seal installation tool or a flat block
in order to press the seal down flush
with the hub.
3.3. Seat the outer bearing and the cup.
Important: Do not scuff the spindle threads.
4. Install the hub/rotor to the spindle.
5. Install the outer bearing to the hub/rotor.
6. Install the washer.
Important: Adjust the wheel bearings. Refer to
Wheel Bearing Adjustment (2WD).
and Notices.
7. Install the nut.
Tighten
7.1. Tighten the nut to 16 N-m (12 lb ft),
while turning the wheel assembly forward
by hand.
7.2. Apply grease to the outboard side of the
outer bearing.
Wheel Hub, Bearing, and Seal

Replacement (4WD)
Rem oval Procedure
Tools Required
• J 36605 Steering Knuckle Seal Installer
Wheels.
Important: Wrap shop towels around the inner
and the outer CN joint boots in order to avoid
damage to the boots during removal and
installation.
157043
Brakes.
4. Remove the brake rotor. Refer to Brake Rotor
5. Remove the drive axle nut.
6. Remove the washer.
7. Remove the tie rod nut.
8. Disconnect the tie rod end from the knuckle.
Refer to Tie Rod Replacement in Steering
Linkage.
Important: Lay the hub and bearing assembly
on the hub bolt (outboard) side. This will
prevent damage or contamination of the
bearing seal.
9. Using a puller, remove the hub and bearing
assembly.
10. Remove the drive axle (halfshaft). Refer to
Front Drive Axle Assembly Replacement in
Front Drive Axle.
11. Remove the splash shield bolts.
12. Remove the splash shield.
13. Support the lower control arm with a jack stand.
14. Remove the upper ball joint nut.
15. Using the J 36607, remove the upper ball joint
from the knuckle. Refer to Upper Ball Joint
Replacement (4WD).
16. Remove the lower ball joint nut.
17. Using the J 36607, remove the lower ball joint
from the knuckle. Refer to Lower Ball Joint
Replacement (4WD).
18. Remove the knuckle.
19. Remove the seal from the knuckle.
Suspension_____________________________ Front Suspension 3-75
1. Using the J 36605, install the seal into the
knuckle.
2. Connect the knuckle to the upper and the lower
ball joint.
3. Install the ball joint stud nuts.
Tighten
3.1. Tighten the lower stud nut to
128 N.m (94 lb ft).
3.2. Tighten the upper stud nut to
100 N.m (74 lb ft).
3.3. Tighten the nuts in order to align the
cotter pin. Do not tighten more than
1/6 turn.
and Notices.
4. Install new cotter pins. Bend the pin ends
against the nut. 157043
5. Install the splash shield. Properly align the
splash shield.
6. Install the splash shield bolts.
Tighten
7. Prelube the steering knuckle seal.
Drive Axle Assembly Replacement in Front
Drive Axle.
9. Install the hub and bearing assembly. Align the
threaded holes.
10. Install the bolts.
Tighten
11. Connect the tie rod end to the knuckle. Refer
to Tie Rod Replacement in Steering Linkage.
12. Install the tie rod nut.
Tighten
14. Install the drive axle nut.
Tighten
15. Install the brake rotor. Refer to Brake Rotor
18. Remove the jack stand.
20. Check the vehicle trim height. Adjust if
necessary. Refer to Measuring Wheel Alignment
(K Model) in Wheel Alignment.
Wheel Hub, Bearing, and Seal Installation Procedure

Replacement (C3500HD) For Front Spring and Components refer to Front
Spring and Components (C3500HD).
Removal Procedure Notice: Start the races squarely inside the hub/rotor
For front spring and components, refer to Front to avoid distortion and possible cracking.
Spring and Components (C3500HD). 1. Install the races into the hub/rotor.
Tools Required 1.1. Place the hub/rotor on the J 9746-02.
J 9746-02 Wheel Stud Remover Rest this assembly on the press bars.
1. Raise the vehicle. Support the vehicle with 1.2. Using a 7.6 cm (3 in) diameter bar, or
suitable safety stands. equivalent, press the outer bearing race
2. Remove the tire and wheel assembly. Refer to into position.
Wheel Removal (Single Wheels) in Tires and 1.3. Remove the J 9746-02 and use a
Wheels. 7.6 cm (3 in) diameter bar, or equivalent,
in order to press the inner bearing race
Notice: Support the caliper with a piece of wire into position. If the bar is larger than
to prevent damage to the brake line. 7.6 cm (3 in), the bar may damage the
3. Remove the brake caliper. Refer to Brake bearing seal seat.
Caliper Replacement (Front Delco) or Brake Important:
• Use an approved, high-temperature front
Brakes. wheel bearing grease in order to lubricate
4. Remove the retainer/cap. the bearings. Refer to Recommended
5. Remove the cotter pin, the nut, and the washer. Fluids and Lubricants in Maintenance and
Lubrication.
6. Remove the wheel hub/rotor.
• Do not mix different greases because
• Pull the hub/rotor free from the spindle. Make mixing may change the grease properties,
sure the outer wheel bearing comes free. resulting in poor performance.
• Do not damage the steering knuckle spindle 2. Apply a thin film of grease to the steering
threads. knuckle spindle at the outer wheel bearing seat
and at the inner wheel bearing seat, the
7. Remove the inner wheel bearing. Pry out
shoulder, and the seal seat.
the seal.
3. Apply a small amount of grease inboard of
8. Remove the races. Using a brass drift, drive each wheel bearing retainer/cap.
out each race.
Notice: Failure to completely pack the wheel
9. Clean any grease from the hub/rotor and the bearing (cones, rollers, and cage) with grease
steering knuckle spindle. Clean any grease from will result in premature wheel bearing damage
inside the hub. and/or wear.
Notice: Do not spin the wheel bearings with 4. Fill each wheel bearing (cone and roller
compressed air to dry them -the wheel bearings assembly) full of grease.
may be damaged. • Use a cone-type grease machine that forces
10. Using clean solvent and a small brush with no grease into the bearing.
loose bristles, clean any grease from the wheel • If a cone-type grease machine is not
bearings and the races. available, pack the wheel bearing by hand.
When packing the wheel bearing by hand,
11. Inspect the wheel bearings and the races for work the grease into the bearings between
damage or wear. the rollers, the cones, and the cage.
• Refer to Wheel Bearings Diagnosis in 5. Install the inner wheel bearing into the
Suspension General Diagnosis. hub/rotor. Put an additional quantity of grease
• If a bearing or the race is damaged, replace outboard of this bearing.
both of these. 6. Install the new seal.
12. Inspect the hub/rotor for damage or wear. 6.1. Using a seal installer or a block, install
• Check for out of round or scored conditions. the seal in order to ensure that the seal
is flush with the hub/rotor flange.
• Check for pitting or cracks.
6.2. Lubricate the seal lip with a thin layer of
• If necessary, repair or replace the hub/rotor. grease.
7. Install the hub/rotor. Do not damage the
steering knuckle spindle threads.
8. Install the outer wheel bearing. Slide the
bearing over the spindle until the wheel bearing
fully seats against the hub/rotor outer race.
9. Install the washer, the nut, and the cotter pin.
Do not place the cotter pin through the hole in
the spindle until the wheel bearings are
adjusted.
Tighten
Tighten the nut to 16 N-m (12 lb ft), while
turning the hub/rotor assembly by hand.
and Notices.
9.1. Apply an additional amount of grease
outboard of the wheel bearing.
9.2. Adjust the wheel bearings. Refer to
Wheel Bearing Adjustment (C3500HD).
10. Install the cotter pin.
11. Install the retainer/cap in place.
Replacement (All except 4 Door Utility)
Rem oval Procedure
Tools Required
J 36202 Torsion Bar Unloading/Loading Tool
2. Remove the adjustment assemblies on both
torsion bars.
2.1. Mark the adjustment bolt setting.
2.2. Using the J 36202, increase the tension
on the adjustment arm.
2.3. Remove the adjustment bolt and the
retaining plate.
2.4. Move the tool aside.
2.5. Slide the torsion bars forward.
2.6. Remove the adjustment arms.
3. Remove the nuts and the bolts from the torsion
bar support crossmember. Slide the support
crossmember rearward.
4. Remove the torsion bars. Note the location and
the front ends of the torsion bars. The left side
and the right side torsion bars are different.
5. Remove the support crossmember.
6. Remove the retainer, the spacer, and the
insulator from the support crossmember.
157033
1. Install the insulator, the spacer, and the retainer
on the support crossmember.
2. Install the support crossmember assembly on
the frame, rearward of the mounting holes.
3. Install the torsion bars.
3.1. Make sure the bars are installed on the
proper sides.
3.2. Slide the support crossmember forward
until the torsion bars are supported.
4. Install the adjustment arms on the torsion bars.
5. Install the bolts and the nuts into the torsion
bar support crossmember.
Tighten
5.1. Tighten the center nut to 24 N-m
(18 1b ft).
5.2. Tighten the edge nuts to 62 N.m
(46 lb ft).
and Notices.
6. Install the adjustment retainer plate and the bolt
on both torsion bars.
7. Using the J 36202, increase the tension on the
torsion bar.
8. Install the retaining plate and the adjustment bolt.
9. Set the adjustment bolt to 34 mm (1.3 in).

10. Release the tension on the torsion bar until the
load is taken up by the adjustment bolt.
13. Check the Z height, refer to Measuring Wheel

Replacement (4 Door Utility)
Rem oval Procedure
Tools Required
J 36202 Torsion Bar Unloading/Loading Tool
2. Remove the adjustment assemblies on both
torsion bars.
2.1. Mark the adjustment bolt setting.
2.2. Using the J 36202, increase the tension
2.3. Remove the adjustment bolt and the
retaining plate.
2.4. Using the J 36202, decrease the tension
2.5. Move the tool aside.
2.6. Slide the torsion bars forward.
2.7. Remove the adjustment arms.
3. Remove the nuts and the bolts from the torsion
bar support crossmember link assembly.
4. Remove the torsion bars. Note the location and
the front ends of the torsion bars. The left side
and the right side torsion bars are different.
5. Remove the support crossmember.
6 . Remove the link assembly from the support
crossmember.
1. Install the link assembly on the support
crossmember.
2. Install the support crossmember assembly to
the frame, rearward of the mounting holes.
3. Install the torsion bars.
3.1. Make sure the bars are installed on the
proper sides.
3.2. Slide the support crossmember forward
until the torsion bars are supported.
4. Install the adjustment arms on the torsion bars.
5. Install the bolts and the nuts into the torsion
bar support crossmember link assembly.
Tighten
Tighten the link assembly nuts to
125 N-m (92 lb ft).
and Notices.
6. Install the adjustment retainer plate and the bolt
on both torsion bars.
7. Using the J 36202, increase the tension on the
torsion bar.
8. Install the retaining plate and the
adjustment bolt.
9. Set the adjustment bolt to 34 mm (1.3 in).
10. Release the tension on the torsion bar until the
load is taken up by the adjustment bolt.
13. Check the Z height, refer to Measuring Wheel
157031
Suspension_____________________________ Front Suspension 3-81
Wheel Bearing Adjustment (2WD)
A djustm ent Procedure
Notice: Never preload the front wheel bearings.
Damage can result by the steady load on the roller
ends that comes from preloading.
Important:
• Adjust the front wheel bearings correctly in
order to ensure the front suspension functions
properly.
• The bearings must be a slip fit on the spindle.
• Lubricate the bearings in order to ensure that
the roller bearings will roll and not skid.
• The spindle nut must have a free-running fit on
the spindle threads.
safety stands.
2. Remove the wheel cover, if used. 130890
3. Remove the dust cap from the hub.
Tighten
Tighten the hub/rotor bearing nut to 16 N-m
(12 lb ft), while turning the wheel forward by
hand. This will seat the bearings.
and Notices.
Important: Do not back the nut off more than
1/4 turn.
5. Adjust the nut to so that it is just loose. Then,
back the nut off until the hole in the spindle
aligns with a slot in the nut.
6.1. Make sure the cotter pin ends do not
interfere with the cap.
6.2. Bend the ends of the cotter pin against
the nut.
6.3. Cut off any extra pin length.
7. Measure the endplay in the hub/rotor assembly.
Proper endplay is 0.03-0.20 mm (0.001-0.008 in).
8. Install the cap to the hub/rotor.
9. Install the wheel cover, if used.
156959
Wheel Bearing Adjustment (C3500HD)
A djustm ent Procedure
Notice: Never preload the front wheel bearings.
Damage can result by the steady load on the roller
ends that comes from preloading.
Important:
• In order to maintain the continuous, smooth
functioning of the front suspension, the front
wheel bearings must be correctly adjusted.
• The bearings must be a slip fit on the spindle
and the wheel bearings must be lubricated in
order to ensure that the roller bearings will roll
and not skid.
• The spindle nut must have a free-running fit on
the spindle threads.
suitable safety stands under the lower
control arm.
2. Remove the retainer cap.
Tighten
Tighten the nut to 16 N-m (12 lb ft), while
rotating the wheel and tire assembly, or the
hub/rotor. This will seat the bearings.
and Notices.
4. Back off the nut one flat.
• If the hole in the spindle lines up with the
slot in the nut, insert the cotter pin.
• If these do not line up, back off the nut until
the hole and the slot line up. Do not back off
the nut more than one additional flat.
5. Measure the endplay in the hub/rotor. This
measurement should be between
0.013-0.20 mm (0.0005-0.008 in) when
properly adjusted.
6. Install the retainer cap.
Suspension Front Suspension 3*83
Shock Absorber Replacement (2WD)

Removal Procedure
Notice: The front shock absorbers of the vehicle are
multifunctional. In addition to contributing to a
smooth ride they also provide the only stop to the
front suspension when fully extended. Therefore,
when servicing the shock absorber, service
replacement shock absorbers must be equivalent to
original shock absorbers in both extended length and
strength. Use of shocks not complying to original
equipment or strength could result in suspension
over-travel or shock breakage. Suspension
over-travel may result in suspension component
breakage.
safety stands.
2. Remove the nut. Hold the shock absorber stem
with a wrench while backing the nut off.
3. Remove the retainer.
4. Remove the grommet.
5.1. Pull the shock absorber out of the spring
from below.
5.2. The lower grommet and the retainer are
on the stem.
1. Install the retainer and the grommet on the
stem. Fully extend the stem.
2. Install the shock absorber up through the lower
control arm and the spring. Insert the stem end
through the hole in the upper control arm frame
bracket.
3. Install the grommet to the stem.
4. Install the retainer to the stem.
5. Install the nut.
Tighten
Tighten the nut to 11 N.m (100 lb in), while
holding the stem with a wrench.
and Notices.
6. Install the bolts through the pivot holes to the
lower control arm holes.
Tighten
3-84 Front Suspension____________________________________________ Suspension
Shock Absorber Replacement (4WD)
Removal Procedure
Notice: Original equipment shock absorbers serve
additionally as suspension drop cutoffs. Replacement
shock absorbers must have a built in suspension
cutoff feature and must not be longer than original
shocks when they are fully extended or serious
vehicle or component damage could result.
1. Raise the vehicle on a hoist.
2. Remove the lower nut, the washer, and the
bolt. Collapse the shock absorber.
3. Remove the upper nut, the washer, and
the bolt.
4. Remove the shock absorber.
1. Install the shock absorber to the bracket.
2. Install the bolts. Fit the bolts in the
direction shown.
3. Install the new nuts and the washers to
the bolts.
Tighten
Tighten the upper and the lower nut to
90 N.m (66 lb ft).
and Notices.
157039
Shock Absorber Replacement (C3500HD)
Removal Procedure
Wheels.
4. Remove the shock absorber from the leaf
spring spacer.
5. Remove the nut, the washer, and the bolt.
6. Remove the shock absorber from the frame.
7. Inspect the shock absorbers for damage and
leakage.
8. Test the shock absorbers. Refer to Struts or
Shock Absorbers Bench Test (Non-Spiral
Groove-Pliacell) in Suspension General
Diagnosis.
1. Install the shock absorber to the frame. Insert
the bolt through the upper shock bracket and
the shock absorber.
2. Install the washer and the nut. Do not tighten.
3. Install the shock absorber to the leaf spring
spacer. Position the lower shock mount onto
the stud.
Tighten
• Tighten the upper nut to 185 N.m (136 lb ft).
• Tighten the lower nut to 50 N-m (37 lb ft).
and Notices.
Front Axle Replacement (C3500HD)
Removal Procedure
Tools Required
suitable safety stands on the frame.
Wheels.
3. Support the axle with a floor jack in order to
eliminate any load on the springs.
4. Remove the steering arm, the knuckle, and the
spindle. Refer to Steering Knuckle Replacement
(C3500HD).
6. Remove the shock absorber from the axle.
Refer to Shock Absorber Replacement
(C3500HD).
8. Remove the stabilizer link from the stabilizes
shaft. Using the J 6627-A, separate the
stabilizer shaft from the stabilizer link.
9. Remove the nut, the retainer, and the insulator.
10. Remove the stabilizer link from the axle. Pull
the link free from the axle. Do not lose the
other insulator and retainer.
157007
11. Remove the nuts, the washers, and the U-bolts.
12. Remove the spacer and the spring spacer.
13. Remove the leaf spring from the axle. Refer to
Leaf Springs Replacement (C3500HD).
14. Remove the steering damper from the axle.
Refer to Steering Linkage.
15. Lower the floor jack and pull the axle clear of
the vehicle.
1. Line up the axle under the leaf springs.
2. Using a floor jack, raise the axle into position.
3. Install the steering damper to the axle. Refer to
Steering Linkage.
4. Install the axle to the leaf springs.
5. Install the stabilizer link to the axle.

6. Install the link into the hole on the spring
spacer and the axle.
157007
Suspension____________________________ Front Suspension 3-87
7. Install the insulator, the retainer, and the nut. /: —
Tighten
Tighten the nut until the distance between each
retainer is 38.0 mm (1.5 in).
Notice: Refer to Fastener Notice in General
Information.
8. Install the stabilizer link to the stabilizer shaft.

Tighten
10. Install the shock absorber to the axle.

Tighten
12. Install the steering arm, the knuckle, and the
spindle. Refer to Steering Knuckle Replacement
(C3500HD).
Bearing Adjustment (C3500HD).
Measuring Wheel Alignment (C Model) in Wheel
Alignment.
157010
The front suspension allows each wheel to A spring steel stabilizer shaft controls the side roll of
compensate for changes in the road surface without the front suspension on some models. This shaft is
affecting the opposite wheel. Each wheel, except mounted in rubber bushings that are held by
C3500HD, independently connects to the frame with brackets to the frame side rails. The ends of the
a steering knuckle, ball joint assemblies, and upper stabilizer shaft connect to the lower control arms with
and lower control arms. link bolts. Rubber grommets isolate these link bolts.
Two tie rods connect to steering arms on the knuckles A ball joint assembly is riveted to the outer end of
and to a relay rod. These operate the front wheels. the upper control arm. A castellated nut and a cotter
Two-wheel drive C Series models (1), except pin join the steering knuckle to the upper ball joint.
C3500HD, have coil chassis springs. These springs The inner ends of the lower control arm have
are mounted between the spring housings on the pressed-in bushings. The bolts pass through the
frame and the lower control arms. Shock absorbers bushings and join the arm to the frame. The lower
mount inside the coil springs. The coil springs attach ball joint assembly is a press fit in the lower control
to the lower control arms with bolts and nuts. arm and attaches to the steering knuckle with a
The upper part of each shock absorber extends castellated nut and a cotter pin.
through a frame bracket. Two grommets, two
grommet retainers, and a nut secure the upper part
of the shock to the frame.
Ball socket assemblies have rubber grease seals. K Series models have sealed front wheel bearings.
These seals prevent entry of moisture and dirt, These bearings are pre-adjusted and need no
preventing damage to the bearing surfaces. And, all lubrication. Heat treatment may create darkened
ball joints have grease fittings for routine maintenance. areas on the bearing assembly. This discoloration
Four-wheel drive (2) K Series models have a front does not signal a need for replacement.
suspension that consists of the following components: A heavy-duty front suspension (3) is standard on the
• Control arms C3500HD model. This suspension is centered around
a solid I-beam axle that includes taper leaf springs,
• Stabilizer shaft
shock absorbers, and a stabilizer shaft.
• Shock absorber
• Torsion bar (right and left side)
Torsion bars replace the conventional coil springs. The
front end of the torsion bar attaches to the lower
control arm. The rear of the torsion bar mounts into an
adjustable arm at the torsion bar crossmember. This
arm adjustment controls the vehicle trim height.
3-90 Front Suspension_________ Suspension

Illustration Tool Number/ Description Illustration Tool Number/ Description
J 6627-A J 9519-30
Wheel Stud and Tie Rod Ball Joint Remover/lnstaller
Remover
l j 0
130 156882
J 8092 J 9746-02
Driver Handle Wheel Bearing Remover
2015 36479
J 9519-D J 21474-5
Ball Joint Receiver
Remover/lnstaller Set
2016 3288
I
J 9519-E J 21474-8
C P ( f o lmi1IIHfprnm Lower Control Arm Bushing Lower Control Arm Bushing
Remover Remover
3266 156915
Illustration Tool Number/ Description
J 21474-12
Lower Control Arm Bushing
Installer Spacer
156905
J 21474-13
Installer
3289
J 21474-18
Special Nut
2018
J 21474-19
Special Bolt
2019
J 21747-20
Installer
2020
J 29117
Front Outer Race Remover
2025
J 29193
Steering Linkage Installer
136
J 36202
SiP
Torsion Bar Unloading Tool
2028
J 36605
Steering Knuckle Seal
Installer
156695
Suspension___________________________________________________Rear Suspension 3-93
Rear Suspension
Specifications

Leaf Spring to Bracket Nuts 95 70 —
Leaf Spring to Bracket Nuts (C3500HD) 415 306 —
Leaf Spring to Shackle Nuts 95 70 —
Leaf Spring to Shackle Nuts (C3500HD) 213 157 —

Shackle to Bracket Nuts 95 70 —
Shackle to Bracket Nuts (C3500HD) 213 157 —
Shock Absorber Lower Nuts 100 74 —
Shock Absorber Lower Nuts (C3500HD) 70 52 —

Shock Absorber Upper Nuts 17 13 —
Shock Absorber Upper Nuts (C3500HD) 15 11 —
Stabilizer Clamp U-Bolt Nuts 30 22 —
Stabilizer Kit Nut 23 17 —
Stabilizer Link Bracket to Frame Nut 45 33 —
Stabilizer Link Nut 45 33 —
U-Bolt Nuts (C/K 1,2) 110 81 —
U-Bolt Nuts (C/K 3 without Dual Rear Wheels or —
7.4L Engine) 110 81
U-Bolt Nuts (C/K 3 with Dual Rear Wheels or 7.4L Engine —
without Dual Rear Wheels) 148 109
U-Bolts (C3500HD) 253 187 —

Rear Stabilizer Shaft 7.241
Rear Stabilizer Shaft Insulator and Support 7.243
Rear Shock Absorber 7.345
Rear Leaf Spring Insert 7.495
Rear Spring Auxiliary 7.503
Rear Spring Bushing 7.504
Leaf Spring 7.505
Spring Center Bolt 7.506
Spring Rebound Clip and Spacer 7.513
Rear Spring U Bolt, Nut and Washer 7.516
Rear Spring U Bolt, Plate and Spacer 7.518
Rear Spring Bolt, Nut, Shackle and Washer 7.523
Auxiliary Spring Hanger 7.526
Rear Spring and Axle Washer 7.529
Rear Spring Eye Nut 7.530
3-94 Rear Suspension Suspension
Component Locator
Rear Suspension Components
Axle Attaching Components (C 3500HD)
156234
Legend
(1) U-bolt (10) Washer
(2) Bolt (11) Anchor Plate
(3) Washer (12) Spacer
(4) Shackle (13) Bolt
(5) Washer (14) Washer
(6) Nut (15) Front Bracket
(7) Spring Assembly (16) Washer
(8) Washer (17) Nut
(9) Nut (18) Spring Pad
Suspension Rear Suspension 3-95
Stabilizer Shaft and Components (C 3500HD)
156275
Legend
(1) U-Bolt (7) Stabilizer Kit Bolt
(2) Clamp (8) Insulator
(3) Insulator (9) Spacer
(4) Stabilizer Shaft (10) Insulator
(5) Nut (11) Nut
(6) Insulator
Stabilizer Shaft and Components (C/K 3)
Legend
0) Bracket (13) Insulator
(2) Nut (14) Bolt/Screw
(3) Bolt/Screw (15) Bolt/Screw
(4) Stabilizer Shaft (16) Insulator
(5) Bolt/Screw (17) Clamp
(6) Bracket (18) Bolt/Screw
(7) Nut (19) Washer
(8) Nut (20) Nut
(9) Washer (21) Nut
(10) Stabilizer Link (22) Washer
(11) Bolt/Screw (23) Bolt/Screw
(12) Clamp
Repair Instructions
Stabilizer Shaft Replacement (C Model)
Removal Procedure
For stabilizer shaft and components, refer to
Stabilizer Shaft Components (C 3500 HD Models).
2. Remove the following part from the
stabilizer links:
• The lower nuts
• The washers
• The bolts
3. Remove the bolt/screws from the clamp.
4. Remove the clamps and the insulators.
For stabilizer shaft and components, refer to
1. Install the stabilizer shaft to the rear axle.
2. Install the insulators.
3. Install the clamps.
4. Install the bolt to the clamp.
5. Install the lower bolts through the following
components:
• The washer
• The stabilizer link
• The washer
Tighten
• Tighten the bolts to 34 N-m (25 lb ft).
Notice: Refer to Fastener Notice in
Cautions and Notices.
3-98 Rear Suspension__________________ Suspension
Stabilizer Shaft Replacement (K Model) Tighten

Tighten the nuts to 45 N.m (33 lb ft).
Removal Procedure
For stabilizer shaft components, refer to Stabilizer Notice: Refer to Fastener Notice in Cautions
Shaft Components (C/K 3 Models). and Notices.
1. Raise the vehicle on a hoist. 2. Install the bolts to the insulators and the
clamps.
2. Remove the following part from the
stabilizer links: Tighten
• The lower nuts Tighten the bolts to 34 N.m (25 lb ft).
• The washers 3. Install the nuts, the washers, and the bolts to
• The bolts the stabilizer links.
3. Remove the bolt/screws from the clamp. Tighten
4. Remove the clamps and the insulators. Tighten the nuts to 45 N.m (33 lb ft).
5. Remove the stabilizer shaft. Stabilizer Shaft Link Bracket Replacement
Installation Procedure (C/K 3 Models)
For stabilizer shaft components, refer to Stabilizer Removal Procedure
Shaft Components (C/K 3 Models).
For stabilizer shaft link bracket components, refer to
1. Install the stabilizer shaft to the rear axle. Stabilizer Shaft Components (C/K 3 Models).
2. Install the insulators. 1. Raise the vehicle on a hoist.
3. Install the clamps.
2. Remove the nuts.
4. Install the bolt to the clamp.
3. Remove the insulators.
5. Install the lower bolts through the following
4. Remove the bolts from the spacer and the
components:
stabilizer shaft.
• The washer
5. Remove the nuts from the U-bolts.
• The stabilizer link
6. Remove the following parts:
• The washer
• The U-bolts
• The clamps
Tighten
• The insulators
• Tighten the bolts to 34 N.m (25 lb ft).
Notice: Refer to Fastener Notice in Installation Procedure
Cautions and Notices. 1. Install the stabilizer shaft to the rear axle.
Stabilizer Shaft Link Bracket Replacement 2. Install the following parts:

(All Models Except C/K 3) • The insulators
• The clamps
Removal Procedure • The U-bolt
For stabilizer shaft link bracket components, refer to
3. Install the nuts to the U-bolt.
Tighten
2. Remove the following parts from the
stabilizer links: Notice: Refer to Fastener Notice in Cautions
• The upper nuts and Notices.
• The washers 4. Install the bolts through the following parts:
• The bolts • The insulators
3. Remove the bolts from the clamp insulators. • The stabilizer shaft
4. Remove the nuts and bolts from the stabilizer • The spacers
bracket to the frame. 5. Install the nuts.
Installation Procedure Tighten
1. Install the nuts and the bolts to the stabilizer Tighten the nuts to 23 N.m (17 lb ft)
bracket and the frame.
Shock Absorber Replacement (C Model)

Removal Procedure
2. Remove the following parts from the frame
bracket:
• The upper shock nut (3)
• The bolt (1)
3. Remove the following parts from the axle
bracket:
• The lower shock nut (6)
• The washer (5)
• The bolt (2)
4. Remove the shock absorber (4) from the
vehicle.
1. Install the shock absorber (4) to the vehicle.
2. Install the following parts:
2.1. The upper shock bolt (2)
2.2. The washer (5)
2.3. The lower nut (6)
Tighten
Tighten the lower nut to 70 N-m (52 lb ft).
2.5. The upper nut (3)
Tighten
Tighten the upper nut to 15 N-m
(11 lb ft).
156191
3-100 Rear Suspension _____________________________Suspension
Shock Absorber Replacement (K Model)

Removal Procedure
2. Remove the following parts from the frame
bracket:
• The upper shock nut (5)
• The bolt (6)
3. Remove the following parts from the axle
bracket:
• The lower shock nut (1)
• The washer (2)
• The bolt (3)
4. Remove the shock absorber (4) from the
vehicle.
1. Install the shock absorber (4) to the vehicle.
2.1. The lower shock bolt (3)
2.2. The washer (2)
2.3. The lower nut (1)
Tighten
Tighten the lower nut to
100 N.m (74 lb ft).
2.5. The upper nut (5)
Tighten
Tighten the upper nut to
17 N.m (131b ft).
156196
Wheel Bolt Replacement

Wheel bolts are serrated and may also be swaged in
place; however, the replacement procedure remains
the same for both types of installation.
1. Press the wheel bolts out of the hub flange.
2. Press the new wheel bolts into place.
• Make sure of a tight fit.
• When replacing all of the wheel bolts, make
sure that the hub oil deflector is in position
under the wheel bolt heads.
Spring Bushing Replacement
Removal Procedure
1. Remove the spring assembly. Refer to Leaf
Spring Replacement (Single Wheel Spring
Assembly) or Leaf Spring Replacement (Dual
Wheel Spring Assembly) or Leaf Spring
Replacement (HD Chassis).
2. Remove the bushing from the leaf spring as
follows:
2.1. Place the leaf spring in a press.
Press the bushing out.
2.2. Clean the spring bushing bore of any
foreign material or old bushing.
1. Install the bushing to the leaf spring.
Place the leaf spring in a press.
Press the bushing in.
2. Install the spring assembly. Refer to Leaf Spring
Replacement (Single Wheel Spring Assembly)
or Leaf Spring Replacement (Dual Wheel
Spring Assembly) or Leaf Spring Replacement
(HD Chassis).
Leaf Spring Replacement (Single Wheel
Spring Assembly)
Removal Procedure
Support the rear axle independently in order to
relieve the tension on the leaf springs.
2. Remove the U-bolt nuts (6).
3. Remove the washers (5).
4. Remove the anchor plate (7).
5. Remove the U-bolts (1),(4).
6. Remove the spacer (8).
Loosen the shackle to spring nut.
• The shackle (3)
• The shackle to rear bracket nut 156215
• The washers
• The bolt
8. Remove the spring to front bracket.
9. Remove the following spring to front
bracket parts:
• The nut
• The washers
• The bolt
10. Remove the spring assembly from the vehicle.
1. Install the spring assembly to the vehicle.
156206
2. Install the following spring to front bracket parts:
• The bolt
• The washers
• The nut
Do not tighten the nut.
• The shackle (3)
• The shackle to rear bracket bolt
• The washers
• The nut
4. Install the spacer (8).
Important: Do not use old U-bolts.
5. Install the new U-bolts (1, 4) to the top of the
spring.
6. Install the anchor plate (7).
7. Install the washers (5).
8. Install the nuts (6).
Tighten
8.1. Tighten the U-bolt nuts in the
sequence shown.
8.2. Tighten the U-bolt nuts to
110 N.m (81 lb ft).
8.3. Adjust the spring height between the top
surface of the axle jounce pad and the
bottom surface of the frame jounce
bracket.
8.4. Tighten the leaf spring to bracket nuts to
95 N.m (70 lb ft).
8.5. Tighten the leaf spring to shackle nut to
95 N.m (70 lb ft).
8.6. Tighten the shackle to bracket nuts to
95 N.m (70 lb ft).
Leaf Spring Replacement (Dual Wheel
Spring Assembly)
Removal Procedure
2. Remove the U-bolt nuts (6).
3. Remove the washers (5).
4. Remove the anchor plate (7).
5. Remove the U-bolts (1),(4).
6. Remove the spacer (8).
156215
• The shackle (3)
• The shackle to rear bracket nut
• The washers
• The bolt
bracket parts:
• The nut
• The washers
• The bolt
156207
• The bolt
• The washers
• The nut
• The shackle (3)
• The washers
• The nut
4. Install the spacer (8).
5. Install the new U-bolts (1, 4) to the top of the
spring.
6. Install the anchor plate (7). 156215
7. Install the washers (5).
8. Install the nuts (6).
Tighten
sequence shown.
110 N.m (81 lb ft).
bracket.
95 N.m (70 lb ft).
95 N.m (70 lb ft).
95 N.m (70 lb ft).
Leaf Spring Replacement (HD Chassis)
Removal Procedure
For Heavy Duty Chassis leaf spring components,
refer to Axle Attaching Components
(C 3500 HD Models).
2. Remove the U-bolt nuts.
3. Remove the washers.
4. Remove the anchor plate.
5. Remove the U-bolts.
6. Remove the spacer.
156210
• The shackle
• The shackle to rear bracket nut
• The washers
• The bolt
bracket parts:
• The nut
• The washers
• The bolt
For Heavy Duty Chassis leaf spring components,
refer to Axle Attaching Components
(C 3500 HD Models).
• The bolt
• The washers
• The nut
• The shackle
• The washers
• The nut
4. Install the spacer.
5. Install the new U-bolts to the top of the spring.
6. Install the anchor plate.
7. Install the washers.
Tighten
sequence shown.
148 N-m (109 lb ft).
bracket.
415 N.m (306 lb ft).
213 N-m (157 lb ft).
213 N.m (157 lb ft).
156238
Suspension__________________________________________________Rear Suspension 3-107
Spring Shackle Replacement (CK Model)

Removal Procedure
For spring shackle components, refer to Stabilizer
Shaft Components (C/K 3 Models).
2. Loosen the shackle to spring nut.
3. Remove the shackle from the following parts:
• The rear bracket bolt
• The nut
• The washers
• The spring nut
• The washers
• The bolt
5. Remove the shackle from the vehicle.
1. Install the shackle to the vehicle.
2. Install the shackle to the following parts:
• The spring bolt
• The washers
• The nut
Do not tighten.
• The washers.
• The nut. Do not tighten.
Tighten
• Tighten the leaf spring to bracket nuts
to 95 N.m (70 lb ft).
• Tighten the leaf spring to shackle nut to
95 N.m (70 lb ft).
• Tighten the shackle to bracket nuts
95 N.m (70 lb ft).
4. Adjust the spring height between the top
surface of the axle jounce pad (3) and the
bottom surface of the frame jounce bracket (6).
156342
Spring Shackle Replacement
(Heavy Duty Chassis)
Removal Procedure
Shaft Components (C 3500 HD Models).
2. Loosen the shackle to spring nut.
• The nut
• The washers
• The spring nut
• The washers
• The bolt
5. Remove the shackle from the vehicle.
Shaft Components (C 3500 HD Models).
1. Install the shackle to the vehicle.
• The spring bolt
• The washers
• The nut
Do not tighten.
• The washers
Do not tighten.
• The nut
Tighten
• Tighten the leaf spring to bracket nuts
to 415 N.m (306 lb ft).
• Tighten the leaf spring to shackle nut to
213 N-m (157 lb ft).
• Tighten the shackle to bracket nuts
213 N-m (157 lb ft).
4. Adjust the spring height between the top
surface of the axle jounce pad (3) and the
bottom surface of the frame jounce bracket (6).

(Semi-Floating Axle)
Tools Required
J 6627-A Wheel Stud Remover
Removal Procedure
1. Raise the vehicle on a hoist and allow the axle
to hang free.
2. Remove the wheel, tire and brake drum.
3. Use the J 6627-A in order to remove the stud
from the axle flange.
156430
1. Start the new stud into the axle flange hole by
pressing firmly with your hand.
2. Thread the lug nut on the stud with the flat side
of the lug nut to the vehicle.
3. Tighten the lug nut in order to draw the stud
into the rear of the flange.
4. Thread the lug nut off the stud.
5. Install the wheel, tire and brake drum.

(Full-Floating Axle)
Wheel studs are serrated and may also be swaged
in place; however, the replacement procedure
remains the same for both types of installation.
1. Press the wheel studs out of the hub flange.
156480
2. Press the new wheel studs into place.
• Make sure of a tight fit.
• When replacing all of the wheel studs, make
sure that the hub oil deflector (if equipped) is
in position under the wheel bolt heads.
156483
Suspension ____ _____________ Rear Suspension 3-111
Description and Operation bushings. The rear ends of the springs are attached
to the frame with the shackles that allow the springs
General Description in order to change their length while the vehicle is in
All of the C/K series vehicles use a leaf spring and a motion.
solid rear axle suspension system. The rear axle The ride control is provided by two identical direct
assembly is attached to the multi-leaf springs by the double-acting shock absorbers angle-mounted
U-bolts. The front ends of the springs are attached between the frame and the brackets attached to the
to the frame at the front hangers through the rubber axle tubes.
BLANK
Suspension Tires and Wheels 3-113
Tires and Wheels

Specifications

Hoist to Crossmember Nuts (All Pickup Models) 25 18 —
Hoist to Wheel Carrier Nuts (4 Door Utility Models) 47 35 —
Support Bolts (Suburban Models) 5 — 44
Support Bolts (2 Door Utility Models) 44 32 —
Wheel Nut Stud (C1) (5 Studs) 190 140 —
Wheel Nut Stud (CK1, 2) (6 Studs) 190 140 —

Wheel Nut Stud (CK2, 3) (Single Wheel) (8 Studs) 190 140 —
Wheel Nut Stud (CK3) (Dual Wheel) (8 Studs) 190 140 —
Wheel Nut Stud (C3500HD) (Dual Wheel) (10 Studs) 240 177 —

Wheel Front or Rear 5.803
Wheel Balance Weight 5.805
Hub or Drum Wheel Bolt and Stud 5.812
Wheel Cap 5.858
Wheel Cover Appearance Insert Ring 5.871
Tire Valve and Cover Lock Cap and Stem 5.875
Spare Wheel Guide, Hoist, Pin, Retainer and Shaft 7.629
Wheel Carrier Adapter and Stud 7.632
3-114 Tires and Wheels Suspension
Diagnostic Information and 2. Repeat this procedure on at least three or four

different positions on the inboard mounting
Procedures surface.
Wheel Mounting Surface Check • The outer ring of the mounting surface
normally is raised above everything inside
If is necessary to replace any wheels which are the mounting surface.
bent, dented, or which have excessive lateral or
radial runout. Also, wheels with runout greater than • The mounting surface will be raised above
specified may cause objectionable vibrations. the outer ring if the wheel mounting surface
has been bent on a tire changer.
979
981
1. Use a straight edge 203-229 mm (8-9 in) long.
3. Inspect the mounting wheel/nut holes for
Place the straight edge on the wheel inboard
damage caused from over-torquing the wheel
mounting surface. Try to rock the straight edge
nuts. Inspect for collapsed wheel/nut bosses.
up and down within the mounting surface.
Inspect for cracked wheel bosses.
980
Notice: The use of aftermarket reverse-type • A wheel of incorrect size or type may
wheels, designed to extend the wheel away effect the following conditions:
from the body, will increase the scrub radius. - Wheel and hub-bearing life
An increased scrub radius may greatly increase
steering effort and reduce hub bearing life. - Brake cooling
- Speedometer/odometer calibration
Important:
- Vehicle ground clearance
• Replacement wheels must be equivalent to
the original equipment wheels in the - Tire clearance to the body and the
following ways: chassis
- Load capacity 4. Replace the wheel if the wheel is bent. Replace
the wheel if the wheel/nut boss area is cracked.
- Wheel diameter
Identify steel wheels with a 2 or 3 letter code
- Rim width stamped into the rim near the valve stem. Aluminum
- Wheel offset wheels have the code, the part number, and the
- Mounting configuration manufacturer identification cast into the back side of
the wheel.
Radial Tire Lead/Pull Correction

Step Action Value Yes No
DEFINITION: Vehicle leads or pulls to either side while driving straight ahead.
1. Adjust the tire pressure to specifications. Refer to
Tire Inflation Description in Tires and Wheels.
2. Check for proper trim heights. Refer to Measuring
Wheel Alignm ent (C Model) or Measuring Wheel
1 Alignment (K Model) in Wheel Alignment. —
3. Check the brakes for drag.
4. Road test the vehicle.
Does the vehicle lead or pull to one side? Go to Step 2 System OK
1. Interchange the front tire and wheel assemblies.
2 2. Road test the vehicle. —
Does the vehicle still pull to one side? Go to Step 3 System OK

3 Check to see if the vehicle pulls in the same direction.
Does the vehicle pull in the same direction?
—
Go to Step 4 Go to Step 5
Check the caster, camber, toe and the cross caster/cross
camber alignment settings. Refer to Measuring Wheel
4 Alignm ent (C Model) or Measuring Wheel Alignment —
(K Model) in Wheel Alignment.
Are the alignment settings within specifications? Go to Step 6 Go to Step 7
1. Check the tires.
2. Interchange the left front tire and wheel assembly
5 with the left rear tire and wheel assembly. —
3. Road test the vehicle. Replace the left
Does the vehicle still pull to one side? Go to Step 10 rear tire
Change the caster setting.
6 —
Does the vehicle lead to the left? Go to Step 8 Go to Step 9
Adjust the front wheel alignment to specifications. Refer to
M easuring Wheel Alignment (C Model) or Measuring
7 Wheel Alignm ent (K Model) in Wheel Alignment. — —
Is the adjustment complete? Go to Step 13
Set the left caster at the top specification, and set the right
8 caster at one degree less. — —
Radial Tire Lead/Pull Correction (cont’d)

Step Action Value Yes No
Set right caster at the top specification, and set the left
9 caster at one degree less. — —
1. Interchange the right front tire and wheel assembly
with the right rear tire and wheel assembly.
10 —
2. Road test the vehicle. Replace the right
Does the vehicle still pull to one side? Go to Step 6 rear tire
Continue decreasing the right caster setting until the pull is
11 eliminated. Do not exceed 2 degrees cross caster. —
Is the pull eliminated? System OK Go to Step 12
Continue decreasing the left caster setting until the pull is
12 eliminated. Do not exceed 2 degrees cross caster. — —
Is the pull eliminated? System OK
Road test the vehicle.
13 —
Does the vehicle still pull to one side? Go to Step 14 System OK
14 Does the vehicle pull to the left? — Go to Step 11 System OK
Repair Instructions Caution: To avoid serious personal Injury,

do not stand over tire when Inflating. The
Aluminum Wheel Hub Cap Replacement bead may break when the bead snaps over
the safety hump. Do not exceed 275 kPa
Removal Procedure (40 psi) pressure when Inflating any tire If
1. Remove the tire and wheel assembly. beads are not seated. If 275 kPa (40 psi)
• For single wheels, front or rear, refer to pressure will not seat the beads, deflate,
Wheel Removal (Single Wheels). relubricate the beads and relnflate.
Overinflation m ay cause the bead to break
• For dual rear wheels, refer to Wheel and cause serious personal Injury.
Removal (Dual Rear Wheels).
7. Adjust the tire pressure in order to meet
2. Against the back surface of the cap, place a specifications.
block of wood approximately 50 mm (2 in) in
diameter with a squared off end. Remove the 8. Balance the tire and wheel assembly.
cap with a sharp hammer blow on the block 9. Install the tire and wheel assembly.
of wood. • For single wheels, front or rear, refer to
Wheel Installation (Single Wheels-Front
Installation Procedure or Rear).
Notice: Failure to hit the cap squarely without the • For dual rear wheels, refer to Wheel
load distributed evenly could result in permanent Installation (Dual Rear Wheels).
damage to the cap.
1. Place the cap into position at the wheel
Aluminum Wheel Refinishing
opening. Place a block of wood at least 75 mm A protective clear coating covers the surface of
(3 in) in diameter against the cap face. Install original equipment cast aluminum wheels. A surface
the cap by striking the block of wood with a degradation develops if frequent automatic car wash
hammer. cleaning wears off the factory applied protective clear
coating. This can happen at some automatic car
2. Install the tire and wheel assembly.
wash facilities that use aggressive silicon
• For single wheels, front or rear, refer to carbide-tipped air brushes to clean whitewalls and
Wheel Installation (Single Wheels-Front tires. Once you damage the protective clear coating,
or Rear). exposure to caustic cleaners and road salt can
• For dual rear wheels, refer to Wheel cause further surface deterioration. The following
Installation (Dual Rear Wheels). procedure details how to strip, clean, and re-coat
aluminum wheels affected by these conditions:
Aluminum Wheel Porosity Repair
Important: You do not need to remove the tire from
1. Remove the tire and wheel assembly. the wheel in order to perform this procedure. If you
• For single wheels, front or rear, refer to remove the tire, mark the tire position to the wheel.
Wheel Removal (Single Wheels). Use the valve stem as an index. When remounting,
• For dual rear wheels, refer to Wheel return the tire to the original position on the wheel.
Removal (Dual Rear Wheels). 1. Mark the wheel and the tire for position on the
2. Locate the leaking areas by inflating the tire to vehicle.
345 kPa (50 psi), and by dipping the tire and 2. Remove the tire and wheel assembly.
wheel assembly into a water bath.
• For single wheels, front or rear, refer to
3. Mark the leak areas. Remove the tire from Wheel Removal (Single Wheels).
the wheel.
• For dual rear wheels, refer to Wheel
4. Scuff the inside surface at the leak area with Removal (Dual Rear Wheels).
80 grit sandpaper. Clean the area with general
3. Mark the position of the wheel weights.
purpose cleaner such as 3M #08984, or
Remove the wheel weights.
equivalent.
5. Apply a 3 mm (Vs in) thick layer of
4. Wash the wheel inside and out with a water
base, all-purpose cleaner. Remove the grease
adhesive/sealant P/N 1052366, or equivalent, to
and oil with a solvent cleaner.
the leak area. Allow 12 hours to dry.
6. Mount the tire on the wheel. Inflate the tire to Accent Color Preparation
345 kPa (50 psi). Check the tire for leaks. Sand the painted areas that will not require
recoloring with 400 grit, wet or dry, in order to
promote adhesion of the clear coat.
Clearcoat Damage to Aluminum Wheels Aluminum Wheel Recoating Procedure

Important: Do not use abrasives coarser than 1. Remove the original clear coating.
80 grit. 1.1. Apply a chemical stripper to the wheel
• Sand with 80 grit sandpaper. surface. Allow the chemical to penetrate
the coating.
• Sand with 150 grit sandpaper.
1.2. Remove the stripper. Follow the
• Sand with 240 grit sandpaper. manufacturer’s recommendations.
Mount the wheel on a brake lathe and spin slowly. 1.3. Thoroughly rinse the wheel surface with
Sand the wheel with a backing block or a pad. Hold
clean water.
the abrasive flat against the surface of the wheel.
Move slowly back and forth from the center to the Caution: Use of eye goggles is necessary to
outer edge of the wheel in order to remove prevent personal injury.
imperfections. 2. Remove the surface oxidation.
Slight Clear Coat Damage on Unpainted Caution: Do not use vehicle power to rotate
Wheels the wheel while sanding to avoid personal
injury.
Caution: Use o f eye goggles is necessary to
prevent personal injury. 3. Sand the wheel with 240 grit, wet or dry, while
rotating the wheel on a slow spinning brake
1. Remove the original clear coating. lathe. Or mount the wheel on the vehicle and
1.1. Apply a chemical stripper to the wheel spin the wheel by hand. This should restore the
surface and allow the chemical to machined appearance and promote adhesion.
penetrate the coating. 4. Re-coat the wheels.
Remove the stripper following the 4.1. Clean the surface of any contaminants
manufacturer’s recommendations. by washing with soap and water.
1.2. Rinse the wheel surface thoroughly with 4.2. Spray the wheel with Amchem #33, or
clean water. equivalent. Let this soak 1-3 minutes.
2. Remove the surface oxidation. Sand the wheel 4.3. Rinse with water and blow dry.
with 240 grit (wet or dry) while rotating the 4.4. Mask the tire off.
wheel on a slow spinning brake lathe, or by
mounting it on the vehicle and spinning the 4.5. Finish with Ditzler Delclear™ acrylic
wheel by hand. This should restore the urethane and Ditzler Ultra™ urethane
machined appearance and promote adhesion. additive, or equivalent. Use the following
three coats:
Caution: Do not use vehicle power to rotate
• 1st coat — Light mist coat, let flash
the wheel while sanding to avoid personal
injury. • 2nd coat — Light, let flash
3. Recoat the wheels. • 3rd coat — Heavy, double wet coat
3.1. Clean any contaminants from the surface 4.6. Let dry for 24 hours or, if necessary,
by washing with soap and water. flash for 30 minutes. Force dry at 60 * C
(140' F) for 30 minutes. Allow to cool for
3.2. Spray the wheel with Amchem® #33 or
30 minutes before mounting.
the equivalent and let soak 1-3 minutes.
4.7. Balance the tire and wheel assembly.
3.3. Rinse with water and blow dry.
Replace the original balance weights with
3.4. Mask-off the tire. nylon coated weights.
3.5. Finish with Ditzler Delclear® acrylic 4.8. Mount the weights in the marked
urethane and Ditzler Ultra® urethane positions. Remove the masking from
additive or the equivalent. Apply the the tire.
following three coats:
3.5.1. A light mist coat (let flash). Wheel Removal (Single Wheels)
3.5.2. A light coat (let flash). Caution: If penetrating oil gets on the vertical
3.5.3. A heavy double wet coat. surfaces between the wheel and the rotor or
drum it could cause the wheel to work loose as
4. Let the finish dry for 24 hours. If it is
the vehicle is driven, resulting in loss of control
necessary, flash the finish for 30 minutes, force
and an injury accident.
it dry at 6 0 ' C (140' F) for 30 minutes, and
allow it to cool for 30 minutes before mounting. Notice: Never use heat to loosen a tight wheel. It
5. Re-balance the tire and wheel assembly by can shorten the life of the wheel, studs, or hub and
replacing the original balance weights with bearing assemblies. Wheel nuts must be tightened in
nylon coated weights. sequence and to the specified torque to avoid
bending the wheel or rotor.
6. Mount the weights in the marked positions and
remove the masking from the tire.
Penetrating oil effectively removes tight wheels. Notice: Never use heat to loosen a tight wheel. It
Apply the oil sparingly to the hub surface, if oil can shorten the life of the wheel, studs, or hub and
is used. bearing assemblies. Wheel nuts must be tightened in
Removing wheels can be difficult, because of foreign sequence and to the specified torque to avoid
material or a tight fit between the wheel center hole bending the wheel or rotor.
and the hub or the rotor. Excessive force, such as Penetrating oil effectively removes tight wheels.
hammering on the wheel or the tire, can cause Apply the oil sparingly to the hub surface, if oil
damage. Slightly tapping the tire side wall with a is used.
rubber mallet is acceptable. Wheel removal should
Removing wheels can be difficult, because of foreign
be done in the following way:
material or a tight fit between the wheel center hole
1. Tighten all wheel nuts on the affected wheel. and the hub or the rotor. Excessive force, such as
Do not torque the wheel nuts. hammering on the wheel or the tire, can cause
2. Loosen each wheel nut two turns. damage. Slightly tapping the tire side wall with a
3. Rock the vehicle from side to side in order to rubber mallet is acceptable. Wheel removal should
loosen the wheel. be done in the following way:
You also can rock the vehicle from front to 1. Tighten all wheel nuts on the affected wheel.
back, allowing the vehicle several feet of Do not torque the wheel nuts.
movement in each direction. 2. Loosen each wheel nut two turns.
4. Apply quick, hard jabs to the brake pedal in 3. Rock the vehicle from side to side in order to
order to loosen the wheel. If this does not loosen the wheel.
loosen the wheel, rock the vehicle from side to You also can rock the vehicle from front to
side, using the body weight of one or more back, allowing the vehicle several feet of
persons. movement in each direction.
5. Repeat this procedure if the wheel is still tight. 4. Apply quick, hard jabs to the brake pedal in
order to loosen the wheel. If this does not
Removal Procedure loosen the wheel, rock the vehicle from side to
Tools Required side, using the body weight of one or more
Torque Wrench or J 39544 Wheel Nut Torque persons.
Adapters (use with pneumatic impact)
5. Repeat this procedure if the wheel is sffli tight.
safety stands. Removal Procedure
2. Remove the hub cap, if required. Tools Required
3. Remove the wheel nuts. Mark the location of Torque Wrench or J 39544 Wheel Nut Torque
the tire and wheel assembly to the hub Adapters (use with pneumatic impact)
assembly. 1. Raise the vehicle. Support the vehicle with
4. Remove the tire and wheel assembly. safety stands.
5. Clean the wheel nuts, the bolts, and the wheel 2. Remove the hub cap, if required.
and rotor mounting surfaces. 3. Remove the wheel nuts. Mark the location of
the tire and wheel assembly to the hub
Wheel Removal (Dual Rear Wheels) assembly.
Caution: If penetrating oil gets on the vertical 4. Remove the clamp ring and the outer and
surfaces between the wheel and the rotor or inner wheel.
drum it could cause the wheel to work loose as
the vehicle is driven, resulting in loss o f control
and an injury accident.
Wheel Installation (Single Wheels-Front

or Rear)
Caution: Before installing the wheels, remove any
buildup o f corrosion on the wheel mounting
surface and brake drum or disc mounting surface
by scraping and wire brushing. Installing wheels
with poor metai-to-metai contact at the mounting
surfaces can cause wheel nuts to loosen. This
can cause a wheel to come off when the vehicle
is moving, causing loss o f control and possibly
personal injury.
1. Install the tire and wheel assembly. Align the
locating mark of the tire and wheel to the hub
assembly.
Notice: A torque wrench or J 39544 must be
used to ensure that wheel nuts are tightened to
specification. Never use lubricants or
penetrating fluids on wheel stud, nuts, or
mounting surfaces, as this can raise the actual
torque on the nut without a corresponding
torque reading on the torque wrench. Wheel
nuts, studs, and mounting surfaces must be
clean and dry. Failure to follow these
instructions could result in wheel, nut, and/or
stud damage.
and Notices.
2. Install the wheel nuts.
Tighten
• Tighten the wheel nuts to specifications.
Refer to Fastener Tightening
Specifications.
• Tighten the wheel nuts evenly and
alternately in order to avoid excessive
runout.
3. Install the hub cap, if required.
Wheel Installation (Dual Rear Wheels)
1. Install the inner and outer wheel and the clamp
ring. Make sure the pins on the clamp ring face
outward.
Notice: A torque wrench or J 39544 must be
used to ensure that wheel nuts are tightened to
specification. Never use lubricants or
penetrating fluids on wheel stud, nuts, or
mounting surfaces, as this can raise the actual
torque on the nut without a corresponding
torque reading on the torque wrench. Wheel
nuts, studs, and mounting surfaces must be
clean and dry. Failure to follow these
instructions could result in wheel, nut, and/or
stud damage.
and Notices.
156809
2. Install the wheel nuts.
Tighten
• Tighten the wheel nuts to specifications.
Refer to Fastener Tightening
Specifications.
• Tighten the wheel nuts evenly and
alternately in order to avoid excessive
runout.
3. Install the hub cap, if required.
Tire Repair
Many different materials and techniques are on the
market to repair tires. These work only on some
types of tires. Tire manufacturers publish detailed
instructions on how and when to repair tires. Read
these instructions.
Tire Mounting and Dismounting
Notice: It is important to note that damage to either
the tire mounting surface or the wheel mounting
holes can result from the use of improper wheel
attachment or tire mounting techniques. It takes
70 seconds for all the air to completely exhaust from
a large tire. Failure to follow proper procedures could
cause the tire changer to put enough force on the
tire to bend the wheel at the mounting surface. Such
damage may result in vibration and/or shimmy and
under severe usage lead to cracking.
Use a tire changing machine to mount or dismount
the tires. Follow the manufacturer’s instructions. Do
not use hand tools or tire irons to change a tire.
These may damage the tire beads or the wheel rim
flanges.
Notice: Do not scratch the clear coating on
aluminum wheels with the tire changer attachments,
wheel mounting techniques, or tire changing tools.
Failure to follow proper procedures could cause the
aluminum wheel to corrode and the clear coating to
peel from the wheel.
1. Clean the rim bead seats with a wire brush or
coarse steel wool in order to remove old rubber
and light rust or corrosion. Before you mount or
dismount a tire, clean the bead area. Lubricate
the bead area well.
2. Install the valve core.
Caution: To avoid serious personal injury,
do not stand over tire when inflating. The
bead may break when the bead snaps over
the safety hump. Do not exceed 275 kPa
(40 psi) pressure when inflating any tire if
beads are not seated. If 275 kPa (40 psi)
pressure will not seat the beads, deflate,
relubricate the beads and reinflate.
Overinflation may cause the bead to break
and cause serious personal injury.
3. Inflate the tire to the proper air pressure.
4. Check the locating rings to ensure these rings
show around the rim flanges on both sides of
the wheel.
Tire Rotation
In order to equalize wear, rotate the tires at the
specified intervals. Refer to Maintenance Schedule in
Maintenance and Lubrication. In addition to
scheduled rotation, rotate the tire and wheel
3
assembly whenever you notice uneven tire wear.
Radial tires tend to wear faster in the shoulder area,
particularly in front positions, due to design. Radial
tires in non-drive locations may develop an irregular
XI wear pattern that can generate tire noise. This

especially makes regular tire rotation necessary.
• For vehicles with single rear wheels (four tires),
rotate the tires as shown.
1014
rl
• For vehicles with single rear wheels (five tires),
rotate the tires as shown.
o0
/t
13
156806
• For vehicles with dual rear wheels (same tire
□0
sizes and load ranges), rotate the tires
h
as shown.
<\
T_» tir 156825
• For vehicles with dual rear wheels (different tire
sizes and load ranges), rotate the tires
as shown.
Spare Tire Carrier Replacement

(Suburban Models)
Rem oval Procedure
The spare tire mounting for the Suburban is at the
left rear wheel well. The Suburban uses a mount
that is part of the body.
1. Remove the spare tire.
1.1. Remove the nut.
1.2. Remove the adapter.
1.3. Remove the spare tire.
2. Remove the bolts from the support.

3. Remove the support from the vehicle.
156780
1. Install the support.
Tighten
Tighten the bolts to 5 N-m (44 lb in).
and Notices.
156780
3. Install the spare tire.
3.1. Install the spare tire.
3.2. Install the adapter.
3.3. Install the nut.
Spare Tire Carrier Replacement

(2 Door Utility Models)
Rem oval Procedure
The spare tire mounting for the 2 Door U tility models
is at the left rear wheel well. A bracket retains the
spare tire.
1.1. Remove the nut from the bolt.
1.2. Remove the adapter from the bolt.
156785
2. Remove the bolts from the carrier.
3. Remove the carrier.
1. install the carrier.
Tighten
and Notices.

3.1. Install the spare tire.
3.2. Install the adapter.
3.3. Install the nut.
156785
3-126 Tires and Wheels _____________________________Suspension
Tire Hoist and Shaft Replacement

(All Pickup Models)
Rem oval Procedure
The pickup models use a winch/cable hoist system
for tire stowage. The hoist is behind the rear axle
and forward of the rear bumper.
1.1. Attach a ratchet to the wheel with the
DOWN mark facing you.
1.2. Put the end of the wheel wrench through
the rear bumper access hole until the
wrench connects into the hoist shaft.
1.3. Turn the ratchet counterclockwise in
order to lower the tire.
1.4. Turn the ratchet until the spare tire can
be pulled out from under the vehicle.
1.5. Once the tire has been lowered, tilt the
156811 retainer at the end of the cable and pull
the retainer through the wheel opening.
2. Remove the pin and the retainer from the shaft.
3. Remove the bolts and the nuts.
4. Remove the hoist from the crossmember.
1. Install the hoist to the crossmember.
2. Install the bolts and the nuts.
Tighten
and Notices.
3. Install the pin and the retainer to the shaft.
156814
4.1. Place the tire on the ground, with the
valve stem pointed down, at the rear of
the vehicle.
4.2. Pull the wheel retainer through the wheel
opening.
4.3. Attach the ratchet to the wheel with the
UP mark facing you.
4.4. Place the end of the wheel wrench
through the rear bumper access hole
until the wrench connects into the
hoist shaft.
4.5. Turn the ratchet clockwise in order to
raise the tire.
4.6. When two clicks are heard, stop turning
the wrench.
Tire Hoist and Shaft Replacement

(4 Door Utility)
Rem oval Procedure
The 4 Door Utility models use a winch/cable hoist
system for tire stowage. The hoist is behind the rear
axle and forward of the rear bumper.
1.1. Attach a ratchet to the wheel with the
DOWN mark facing you.
hoist shaft.
1.3. Turn the ratchet counterclockwise in
order to lower the tire.
1.4. Turn the ratchet until the spare tire can
be pulled out from under the vehicle. 156774
1.5. Once the tire has been lowered, tilt the
retainer at the end of the cable and pull
the retainer through the wheel opening.
2. Remove the pin and the retainer that attaches
the shaft to the hoist assembly.
3. Remove the shaft from the hoist assembly.
4. Remove the two bolts that attach the hoist
assembly to the wheel carrier.
5. Remove the hoist assembly from the wheel
carrier.
1. Install the hoist assembly to the wheel carrier.
2. Install the bolts and the nuts that attach the
hoist assembly to the wheel carrier.
Tighten
and Notices.
3. Install the shaft to the hoist assembly.
4. Install the pin and the retainer that attaches the
shaft to the hoist assembly.
5.1. Place the tire on the ground, with the
valve stem pointed down, at the rear of
the vehicle.
5.2. Pull the wheel retainer through the wheel
opening.
5.3. Attach the ratchet to the wheel with the
UP mark facing you.
hoist shaft.
5.5. Turn the ratchet clockwise in order to
raise the tire.
5.6. When two clicks are heard, stop turning
the wrench.
Suspension____________________________ Tires and Wheels 3-129
Description and Operation Inflation Pressure Conversion C hart

(K ilopascals to PSI)
General Description kPa psi kPa psi
The factory installed tires are designed to operate 140 20 215 31
satisfactorily with loads up to and including the full
rated load capacity when these tires are inflated to 145 21 220 32
the recommended pressures. 155 22 230 33
Correct tire pressures, wheel alignment, and driving 160 23 235 34
techniques have an important influence on tire life. 165 24 240 35
Heavy cornering, excessive rapid acceleration, and 170 25 250 36
heavy braking increase tire wear.
180 26 275 40
Metric Wheel Nuts and Bolts Description 185 27 310 45
Metric wheel nuts and bolts are identified in the 190 28 345 50
following way: 200 29 380 55
• The wheel nut has the word Metric stamped on 205 30 415 60
the face.
Conversion: 6.9 kPa = 1 psi
• The letter M is stamped on the end of the
wheel bolt.
Tires with a higher than recommended pressure can
The thread sizes of metric wheel nuts and bolts are
cause the following conditions:
indicated by the following example: M14 x 1.5.
• A hard ride
• M = Metric
• Tire bruising
• 14 = Diameter in millimeters
• Rapid tread wear at the center of the tire
• 1.5 = Millimeters per thread (gap between)
Tires with a lower than recommended pressure can
Tire Inflation Description cause the following conditions:
When you inflate the tires to the recommended • A tire squeal on turns
inflation pressures, the factory-installed wheels and • Hard steering
tires are designed to handle loads to the tire’s rated • Rapid wear and uneven wear on the edge of
load capacity. Incorrect tire pressures, or the tread
under-inflated tires, can cause the following
• Tire rim bruises and tire rim rupture
conditions:
• Tire cord breakage
• Vehicle handling problems
• High tire temperatures
• Poor fuel economy
• Reduced vehicle handling
• Shortened tire life
• High fuel consumption
• Tire overloading
Check the tire pressure when the following apply: • Soft riding
Unequal pressure on the same axle can cause the
• The tires are cool.
following conditions:
• The vehicle has not been driven for more than
• Uneven braking
3 hours.
• Steering lead
• The vehicle has been driven less than
1.6 km (1 mi). • Reduced vehicle handling
Check the tires monthly or before any extended trip. For specific tire and wheel application and tire
Adjust the tire pressure to the specifications on the pressures, refer to Tire Placard in General
tire label. Install the valve caps or extensions on the Information.
valves. These keep out dust and water.
The kilopascal (kPa) is the metric term for pressure.
The tire pressure may be printed in both kilopascal
(kPa) and psi. One psi equals 6.9 kPa.
Tire Chain Usage Description • Drive in a restrained manner. Avoid large

bumps, potholes, severe turns, and other
When you use tire chains, most current vehicles
maneuvers that could cause the tires to bounce
require the following chain types:
up and down.
• Follow any other instructions from the chain
manufacturer that do not disagree with
the above.
1 Replacement Tires Description

Caution: Do not mix different types of tires on
the same vehicie such as radial, bias, and
bias-belted tires except in emergencies because
vehicle handling may be seriously affected and
m ay result in loss of control and possible
serious injury.
Important: Install new tires in pairs on the same
axle. If you need to replace only one tire, this should
3 be paired with the tire that has the most tread.
A Tire Performance Criteria (TPC) specification
number is molded in the sidewall near the tire size
of all original equipment tires. This number ensures
that the tire meets GM’s performance standards for
1012
traction, endurance, dimension, noise, handling,
• SAE Class S or 1100 Series, Type PL tire rolling resistance, and others. A specific TPC number
chains (1). usually is assigned to each tire size.
• SAE Class U or 1200 Series, Type P tire C3500HD models do not use TPC tires. Refer to the
chains (2). tire manufacturer for assistance.
• 1800 Series Lug Reinforced tire chains (3). Replacement tires should be the same size, load
These chains are specially designed to limit the range, and construction as the original tires. Replace
"'fly off"' effect that occurs when the wheel rotates. the original tires with tires that have the same TPC
specification number.
Manufacturers of tire chains have a specific chain
size for each tire size. These ensure a proper fit Use of any other tire size or type may seriously
when the chains are installed. For this reason, affect the following items:
purchase the correct chains for the tires on which • Vehicle ride
the chains will be used. Do not use rubber adjusters • Vehicle handling
to take up slack in chains that are loose due to
• Speedometer/odometer calibration
incorrect size. Always follow the chain manufacturer’s
installation instructions. • Vehicle ground clearance
Use of chains may adversely affect handling. When • Tire clearance to the body and chassis
using chains, remember the following information: Inspect the tires. Replace tires when you find the
• Ensure that the vehicle is designed for chain
clearance. 1. The tires are worn to a point where 1.6 mm
(1/16 in) or less tread remains, or, the cord or
• Adjust vehicle speed to road conditions.
fabric shows. The tires may have built-in tread
• Avoid sharp turns. wear indicators that appear between the tread
• Avoid locked-wheel braking in order to help grooves when the tread is 1.6 mm (1/16 in) or
prevent chain damage to the vehicle. less. When the indicators appear in two or
• Install the chains as tightly as possible on the more adjacent grooves at three spots around
drive tires. Tighten the chains again after the tire, replace the tire.
driving 0.4-0.8 km (1/4 - V2 mi). Use of chains 2. The tread or sidewall is cracked, cut, or
on the non-drive tires is not recommended. snagged deep enough to expose the cord or
These chains may contact and damage the the fabric.
vehicle. If you must use chains on the 3. The tire has a bump, bulge, or a split. Slight
non-drive tires, make sure that there is enough sidewall indentations are normal and this should
clearance. not affect ride.
• Do not exceed 70 km/h (45 mph) or the chain 4. The tire has a puncture, a cut, or other damage
manufacturer’s speed lim it, if lower. that cannot be repaired correctly because of the
size or location of the damage.
All Seasons Tires Description
Some vehicles are equipped with all-season radial
tires as standard equipment.
These tires have a 37 percent higher average rating
for snow traction than non all-season radial tires
previously used. For this reason, these qualify as
snow tires. You can identify these tires by an M+S
molded in the tire sidewall after the size.
P-Metric Sized Tires Description

Most P-metric and LT-metric tires do not have
exactly corresponding alpha/numeric tire sizes. For
example, a P205/75R15 is not equal in size and
load carrying capacity to an FR78-15. Because of
this, replacement tires should be of the same TPC
specification number (size, load range, and
construction) as those originally on the vehicle. If you
must replace P-metric or LT-metric tires with other
sizes, consult a tire dealer. Tire companies can best
recommend the closest match. 156797
Use the following table for tire code designations:
P-M etric Tire Sizes Inform ation

Aspect Ratio—Section
Height (2) Section Rim Diameter Section Width
Tire Type W idth (1) (Inches) (M illim eters) Construction Type
P = Passenger 70 14 205 R = Radial
T = Temporary 75 15 225 B = Bias Belted
LT = Light Truck 80 16 235 D = Diagonal (Bias)
Tire Placard Description • Elongated bolt holes

The tire information label is on the rear face of the • The wheel nuts will not stay tight
driver’s door. Refer to this label for tire information. Wheels with runout greater than specified may cause
The label lists the following items: objectionable vibrations.
• Maximum vehicle load
• Tire size
Wheel Repair Description
• Cold inflation pressure Do not use heating, welding, or peening to repair
wheels. These methods are not approved. Do not
Wheels Description use inner tubes to repair leaky wheels or tires. You
Replace any wheel when the following conditions can repair porosity in aluminum wheels. Refer to
apply: Aluminum Wheel Porosity Repair. If leaks are found
in a steel wheel, replace the wheel with a wheel of
• A bent wheel original equipment quality.
• A dented wheel
• Wheels with excessive lateral or radial runout Aluminum Wheels Description
• The welds leak air Clean aluminum wheels and wax aluminum wheels
regularly. Do not use abrasive cleaners. These could
damage the protective coating of the wheel.

Illustration Tool No. and Description
J 39544-GM
Wheel Nut Torque Adapters
(Use with pneumatic impact
wrench that does not
exceed 250 lb ft). Includes:
J 39544-12, J 39544-13,
J 39544-14, J 39544-CSE
1015
Driveline/Axle Table of Contents 4-1
Section 4
Driveline/Axle
Propeller S haft...................................................... 4-5 Repair In stru ctio n s............................................ 4-32

S p e cifica tio n s........................................................ 4-5 Deflector Ring Replacement........................... 4-32
Fastener TighteningSpecifications.................... 4-5 Drive Axle Inner Joint and Seal
Propeller Shaft RunoutSpecifications...............4-5 Replacem ent............................................... 4-33
GM SPO Group Numbers................................. 4-5 Drive Axle Outer Joint and Seal
Replacem ent............................................... 4-38
D iagnostic Inform ation and P ro ced u re s........ 4-6
Wheel Drive Shafts Boot Cover
Leak at Front Slip Yoke.................................... 4-6 Replacement (Wheel Drive
Roughness or Vibration (Norm al).................... 4-6 Shaft Boot Cover R )....................................4-43
Roughness or Vibration (Above 56 km/h Special Tools and E quipm ent..........................4-48
35 M PH)......................................................... 4-6 Special Tools (Special tools for
Ping, Snap, or Click N oise...............................4-6 C/K Truck).................................................... 4-48
Knock or Clunk Noise....................................... 4-7 F ro n t D riv e A x le ................................................. 4-49
Scraping Noise...................................................4-7 S p e cifica tio n s...................................................... 4-49
Squeak N oise.....................................................4-7 Fastener Tightening Specifications................ 4-49
Shudder on Acceleration at Low Speed........ 4-7 Lubrication Specifications...............................4-49
Repair In s tru c tio n s ...............................................4-8 GM SPO Group Num bers..............................4-49
Propeller Shaft Replacement D iagnostic Inform ation and
(Front D rive)...................................................4-8 P rocedures.......................................................4-50
Propeller Shaft Replacement Noise Diagnosis (Causes of Noise).............. 4-50
(System Balanced Assembly)...................... 4-9
Noise Diagnosis
One-Piece Propeller Shaft (Determining Type of N oise)......................4-50
Replacem ent................................................4-10
Front Drive Axle Diagnosis
Two-Piece Propeller Shaft (Clicking Noise in Turns)............................ 4-51
Replacement................................................4-12
Three-Piece Propeller Shaft (Clunk Acc. from Coast)............................. 4-51
Replacement................................................4-14
Center Bearing Replacement..........................4-17 (Shudder or Vibration)................................ 4-51
Universal Joints Replacement Front Drive Axle Diagnosis (Vibration
(Nylon Injected Ring Type).........................4-18 at Highway Speeds)....................................4-51
Universal Joints Replacement Front Drive Axle Diagnosis
(External Snap Ring Type).........................4-20 (Front Drive Axle Leaks)............................ 4-51
D escription and O pe ra tio n ............................... 4-23 Four-Wheel-Drive Diagnosis
Propeller Shaft Description.............................4-23 (4WD Will Not Engage).............................. 4-52
Propeller Shaft Phasing Description.............. 4-24 Four-Wheel-Drive Diagnosis
Universal Joint D escription.............................4-25 (4WD Does Not Disengage)....................... 4-52
Center Bearing Description.............................4-26 Four-Wheel-Drive Diagnosis
Special Tools and E quipm ent..........................4-27 (Indicator Light Not O ff)...............................4-52
Special Tools.................................................... 4-27 Four-Wheel-Drive Diagnosis
(Indicator Light Not O n).............................. 4-52
Wheel Drive Shafts ........................................... 4-29
Electric Motor Actuator Check........................4-52
S p e cifica tio n s...................................................... 4-29
Repair In s tru c tio n s .............................................4-53
(Fastener Tightening Specificat)................ 4-29 Lubricant Change.............................................4-53
V isual id e n tific a tio n ............................................4-29 Shield Replacement.........................................4-54
Disassembled Views ...................................... 4-29
4-2 Table of Contents Driveline/Axle
Indicator Switch Replacement........................ 4-55 D iagnostic Inform ation and P rocedures.... 4-106
Electric Motor Actuator Replacement............4-55 Determining Type of N oise...........................4-106
Vent Hose Replacement.................................4-56 Rear Axle Wheel Bearing W ear.................. 4-108
Shift Fork Replacement................................... 4-57 Repair In s tru c tio n s .......................................... 4-113
Shift Mechanism Inspection........................... 4-58 Oil Seal and/or Bearing Replacement........ 4-113
Output Shaft, Bearing, and Tube Pinion Oil Seal Replacement
Replacement (Right S ide).......................... 4-58 (Semi-Floating Axle)..................................4-118
Axle Shaft and Seal Replacem ent................4-60 Pinion Oil Seal Replacement
Differential Pilot Bearing Replacement..........4-61 (10 1/2 Inch Ring G ear).......................... 4-121
Pinion, Flange, and Dust Deflector Pinion Oil Seal Replacement
Replacement........................................... 4-62 (11 Inch Ring G ear).................................. 4-125
Differential Carrier Bushing Vent Hose Replacement............................. 4-126
Replacement................................................ 4-64 Inspection Before Disassembly....................4-129
Differential Carrier Assembly Drive Axle Disassemble............................... 4-129
Replacement................................................ 4-65 Axle Housing Inspection............................... 4-134
Front Drive Axle Assembly Differential Inspection................................... 4-134
Replacement................................................ 4-67 Pinion and Ring Gear Inspection............... 4-134
Differential Carrier Overhaul........................... 4-72 Bearings Inspection...................................... 4-134
Differential Assembly Installation................... 4-80 Shims Inspection...........................................4-134
Cleaning Carrier Components........................ 4-82 Pinion Depth Adjustment..............................4-135
Ring and Pinion Gear Inspection.................. 4-82 Differential Case Assem bly..........................4-137
Bearings Inspection......................................... 4-82 Determining Total Shim Pack S ize.............. 4-138
Thrust Washers, Shims, and Pinion Installation......................... 4-139
Adjuster Sleeves......................................... 4-82 Differential to Axle Housing Assem ble...... 4-141
Pinion Bearing Cup Installation...................... 4-83 Backlash Adjustm ent.................................... 4-143
Pinion Depth Adjustment................................. 4-84 Gear Tooth Contact Pattern C heck............4-144
Pinion Installation............................................. 4-85 Drive Axle Final Assem bly...........................4-147
Differential Case Assembly Assem ble...........4-87
Axle Replacement
Carrier Case Assem bly................................... 4-88 (10 1/2 In Ring G ear)............................... 4-147
Backlash Inspection and Adjustment.............4-90 Axle Replacement
Gear Tooth Contact Pattern C heck...............4-92 (11 Inch Ring G ear).................................. 4-148
Axle Tube Assem bly........................................ 4-93 Axle Replacement
Differential Carrier Final Assem bly................4-96 (Rear Axle Assem bly)............................... 4-148
D escrip tio n and O p e ra tio n ...............................4-97 Axle Replacement
Front Drive Axle Description.......................... 4-97 (Assembly Replacement 11 Inch)............ 4-150
S pecial T ools and E qu ip m e n t......................... 4-98 Hub and Drum Assembly
Replacement............................................... 4-151
Special Tools..................................................... 4-98
Hub and Rotor Assembly
Rear Drive A xle .................................................4-103 Replacement...............................................4-153
S p e c ific a tio n s .................................................... 4-103 Bearing Cup Replacement
Fastener Tightening Specifications (10 1/2 Inch Ring G ear)........................... 4-154
(8 1/2 and 8 5/8)....................................... 4-103 Bearing Cup Replacement
Fastener Tightening Specifications (11 Inch Ring G ear).................................. 4-156
(9 1/2 In Ring G ear).................................4-103 Wheel Bearing Adjustment
Fastener Tightening Specifications (10 1/2 Inch Ring G ear)........................... 4-158
(10 1/2 In Ring G ear)...............................4-103 Wheel Bearing Adjustment
Fastener Tightening Specifications (11 Inch Ring Gear Axle).......................... 4-159
(11 Inch Ring G ear).................................. 4-103 C om ponent L o ca to r..........................................4-161
Spacer and Shim Specifications.................. 4-103 Rear Axle Disassembled View......................4-161
Pinion Bearing and Differential D escription and O p e ra tio n ............................. 4-164
Bearing Preload......................................... 4-104
Rear Axle Description................................... 4-164
Lubrication Specifications..............................4-104
S pecial Tools and E quipm ent........................4-166
GM SPO Group Numbers.............................4-104
Special Tools.................................................. 4-166
Driveline/Axle Table of Contents 4-3
Rear Drive Axle - Locking/Limited Slip Diagnostic Information and Procedures .....4-209
Rear A xle ........................................................ 4-169 Troubleshooting Hints (Selectable 4WD) ....4-209
S p e cifica tio n s....................................................4-169 Troubleshooting Hints (Automatic 4W D).... 4-209
Fastener Tightening Specifications.............. 4-169 System Diagnosis (Automatic 4W D).......... 4-210
Thrust Block Sizes (Locking)........................4-169 Diagnostic Trouble Codes
Right Side Gear Thrust Washer (Selectable 4WD)......................................4-212
(Locking)..................................................... 4-169 Obtaining Diagnostic Trouble Codes
Reaction Block, 10 1/2 Inch Axle................ 4-169 (Selectable 4WD)...................................... 4-212
Lubrication Specifications..............................4-169 Clearing Memory (Selectable 4WD)............ 4-212
Repair In s tru c tio n s .......................................... 4-170 Transfer Case Functional Test
(Selectable 4WD).......................................4-212
Locking Differential Disassemble
(10 1/2 Case)............................................ 4-170 Functional Test Failed
(Selectable 4WD).......................................4-213
(8 1/2 and 9 1/2 C ase)............................4-176 All Shift Select Buttons Do Not Light
(Selectable 4WD).......................................4-214
Locking Differential Cam Unit
Disassemble (10 1/2 Assembly).............. 4-177 One or Two Shift Select Buttons
Do Not Light (Selectable 4W D ).............. 4-216
Locking Differential Cam Unit Disassemble
(8 1/2 and 9 1/2 Assem bly).................... 4-177 All Shift Select Buttons Remain Lit
(Selectable 4WD).......................................4-217
Locking Differential Cleaning
and Inspection........................................... 4-178 More Than One Shift Select Button
Remains Lit (Selectable 4W D)................ 4-218
Locking Differential Cam Unit Assemble.... 4-178
No Shift Select Buttons Remain Lit
Locking Differential Adjustm ent................... 4-178 (Selectable 4W D).......................................4-219
Locking Differential Assemble.......................4-179 Reduced or No Mode and Range Shift
Special Tools and E quipm ent........................4-180 Operation (Selectable 4WD).....................4-219
Special Tools.................................................. 4-180 Perform a Diagnostic On the TCCM
Transfer C ase .................................................... 4-181 (Selectable 4WD)...................................... 4-220
S p e cifica tio n s.................................................... 4-181 Four-Wheel Drive Does Not Disengage
Fastener Tightening Specifications (Selectable 4W D)...................................... 4-220
(Manual Shift Transfer Case).................. 4-181 Four-Wheel Drive Does Not Engage
Fastener Tightening Specifications (Selectable 4W D).......................................4-220
(Auto and Select Transfer Case)............ 4-181 Four-Wheel Drive Indicator Does
Approximate Fluid Capacities.......................4-181 Not Light (Selectable 4W D ).....................4-221
Schem atic and Routing D ia g ra m s............... 4-182 Four-Wheel Drive Indicator Does
Not Turn Off (Selectable 4W D)............... 4-221
Transfer Case Control Schematic
References.................................................4-182 Transfer Case Electronic Shift System
Diagnosis (Selectable 4WD).....................4-222
Transfer Case Control
Schematic Icons........................................ 4-182 Transfer Case Diagnosis
(Selectable 4W D).......................................4-222
Transfer Case Control Schematics
(Selectable 4W D)...................................... 4-182 DTC B0768 Service Indicator
Circuit H ig h ................................................4-223
Transfer Case Control Schematics
(Automatic 4WD)....................................... 4-182 DTC B2725 Mode Switch Circuit
M alfunction................................................. 4-225
C om ponent Locator......................................... 4-190
DTC C0300 Rear Speed Sensor
Transfer Case Control Components............ 4-190
M alfunction................................................. 4-228
Transfer Case Control Component
DTC C0305 Front Speed Sensor
Views (Selectable 4W D)...........................4-193
M alfunction................................................. 4-231
Transfer Case Control Component
DTC C0308 Motor A/B Circuit Low...........4-234
Views (Automatic 4W D)............................4-203
DTC C0309 Motor A/B Circuit H igh..........4-236
Transfer Case Control Connector
End Views (Selectable 4W D).................. 4-205 DTC C0310 Motor A/B Circuit O p e n ....... 4-238
Transfer Case Control Connector DTC C0315 Motor Ground Circuit Open....4-241
End Views (Automatic 4W D)................... 4-206 DTC C0323 T-Case Lock Circuit L o w ....... 4-243
4-4 Table of Contents Driveline/Axle
DTC C0324 T-Case Lock Circuit H igh....... 4-245 Motor/Encoder Replacement

DTC C0327 Encoder Circuit M alfunction... 4-247 (Selectable 4W D).......................................4-291
DTC C0357 Park Switch Circuit H ig h .........4-253 Motor/Encoder Replacement
(Automatic 4W D)....................................... 4-293
DTC C0362 4LO Discrete Output
Circuit H igh.................................................4-255 Shift Select Switch Replacement
(Selectable 4W D)...................................... 4-294
DTC C0367 Front Axle Control
Circuit H igh................................................ 4-257 Shift Select Switch Replacement
(Automatic 4W D)....................................... 4-295
DTC C0374 General System
M alfunction................................. 4-259 Transfer Case Control Module
Replacement (Selectable 4W D ).............. 4-295
DTC C0376 Front/Rear Shaft
Speed Mismatch........................................ 4-260 Transfer Case Control Module
Replacement (Automatic 4W D )............... 4-296
DTC C0550 ECU Malfunction...................... 4-262
AFWD Speed Sensor Replacement
DTC C0611 VIN Information Error............... 4-263
(Front Speed Sensor)...... ........................ 4-297
DTC C0895 Device Voltage M alfunction....4-264
Front Axle Will Not Engage (Rear Speed Sensor)................................ 4-297
(Automatic 4W D)............... 4-265
Transfer Case Electrical Connector
Front Axle Will Not Disengage Replacement (Selectable 4W D ).............. 4-298
(Automatic 4W D)....................................... 4-267
D escription and O p e ra tio n .............................4-299
Range/Mode Switch Inoperative
Transfer Case Description
(Automatic 4 WD)...................................... 4-268
(Selectable 4W D )...................................... 4-299
No Correction for Slip in AWD Mode
Transfer Case System Description
(Automatic 4W D)....................................... 4-270
(Automatic 4W D)....................................... 4-300
Two or More Indicator Lamps Remain
Transfer Case System Description
ON (Automatic 4W D)................................ 4-271
(Selectable 4W D)...................................... 4-301
Service 4WD Lamp Stays ON when
Mode Shifts (Selectable 4WD)......................4-301
Key is ON (Automatic 4WD).................... 4-271
Range Shifts (Selectable 4W D)................... 4-301
T-Case w ill Shift Ranges When
Trans is in Park (Automatic 4W D )..........4-272 Transfer Case Control Module
Description (Selectable 4W D).................. 4-302
R epair In s tru c tio n s .......................................... 4-274
RAM/ROM Check (Selectable 4W D)........... 4-302
Fluid Drain and F ill........................................ 4-274
Data Memory Retention Check
Shield Replacement..... ................................. 4-274
(Selectable 4W D)...................................... 4-302
Shift Cable Replacem ent..............................4-275
Encoder Signal Check
S hift Lever Replacement...............................4-276 (Selectable 4W D )...................................... 4-303
Transfer Case Output Shaft Seal Encoder Switch Monitor Check
Replacement (New Venture)............... ....4-278 (Selectable 4W D )...................................... 4-303
Transfer Case Output Shaft Seal Motor and Relay Voltage Checks
Replacement (Borg-W arner).................... 4-279 (Selectable 4W D )...................................... 4-303
Rear Extension Housing Replacement........4-281 Motor/Encoder Circuit Operation
Transfer Case Replacement (Selectable 4W D )...................................... 4-303
(Selectable Four Wheel D rive)................ 4-282 Control Module Data Information
Transfer Case Replacement (Automatic 4W D)............... 4-304
(Manual S h ift)............................................ 4-285 Scan Tool Data Definitions
Transfer Case Replacement (Automatic 4W D)....................................... 4-304
(Auto Four-Wheel-Drive 2-S peed)...........4-288 S pecial Tools and E quipm ent........................4-305
Adapter Replacement.................................... 4-291 Special T ools....................... 4-305
Driveline/Axle Propeller Shaft 4-5
Propeller Shaft
Specifications

Application N>m Lb Ft Lb In
Center Bearing Mounting Bolt 35 26 —
Front Axle Yoke Retainer Bolt 20 15 —

Rear Axle Yoke Retainer Bolt C/K 1,2,3 Except C3500HD 20 15 —
Rear Axle Yoke Retainer Bolt C3500HD 37 27 —
Transmission Parking Brake Drum Flange Bolt 37 27 —
Transfer Case Yoke Retainer Bolt 20 15 —
Transmission Yoke Retainer Bolt 20 15 —

Propeller Shaft Runout Specifications
Propeller Center
Shaft Front Check Check Rear Check
One Piece 0.025 in 0.050 in 0.025 in
Two Piece Driveshaft:
Front Piece 0.025 in 0.005 in* —
Rear Piece — 0.030 in“ 0.030 in

‘ NOTE: This measurement must be taken on the ground
surface near the spline with the rear propeller shaft
removed.
“ NOTE: This measurement must be taken with the rear
propeller shaft mounted on the front shaft which is
within specifications.

Propeller Shaft 5.544
Propeller Shaft Pinion Deflector, Flange and Yoke 5.545
Propeller Shaft Universal Joint, Joint Kit 5.548
Universal Joint and Power Divider Deflector and Yoke 5.555
Universal Joint Sleeve Yoke Bushing, Cap, Nut and Washer 5.556
Propeller Shaft Universal Joint Trunnion Ring and Seal 5.560
Universal Joint Yoke Trunnion Bearing 5.566
Universal Joint Trunnion and Yoke Bolt, Boot Kit, Clamp, Nut and Retainer 5.586
Propeller Shaft Bolt, Bracket, Hanger, Nut, Reinforcement, Support and Washer 5.598
Center Bearing, Bearing, Cushion and Retainer 5.600
Propeller Shaft Bearing Shields, Slinger and Washer 5.601
Propeller Shaft Internal Cam and Shoe Brake Bolt, Drum, Nut, Plate, Shield, Shoe 5.605
Kit, Spring and Washer
4-6 Propeller Shaft_______________________ Driveline/Axle
Diagnostic Information and Procedures

Leak at Front Slip Yoke
Checks Action
DEFINITION-. An occasional drop of lubricant leaking from the splined yoke is normal and requires no attention.
The slip yoke barrel is burred, nicked, • Replace the seal.
corroded, or worn. • Smooth minor burrs by careful use of crocus cloth or fine stone honing.
• Replace a badly burred yoke.
A defective transmission rear oil seal. Replace the transmission rear oil seal and replenish the transmission oil.
Roughness or Vibration (Normal)

Checks Action
DEFINITION: The roughness or vibration occurs while driving the vehicle at various speeds.
A bent or dented propeller shaft. Replace the propeller shaft. Refer to One-Piece Propeller Shaft Replacement or
Two-Piece Propeller Shaft Replacement.
Undercoating is on the propeller shaft. Clean the propeller shaft.
The tires are unbalanced at Balance or replace the tires.
48-80 km/h (30-50 mph).
The universal joints are tight. On snap ring retainer U-joints, tap the yokes with a hammer in order to free up the
U-joints. If you are unable to free up the U-joints, or if the joint feels rough, replace
the joint.
The universal joints are worn. Replace the worn universal joints.
The companion flange is bent or has Refer to Vibration Diagnosis in General Information.
excessive runout.
Burrs or gouges are on the • Inspect the snap ring locating surfaces on the flange yoke.
companion flange. • Deburr or replace the companion flange.
The propeller shaft, parking brake • Check for a missing balance weight on all three components.
drum, or the companion flange • Rotate the propeller shaft in the companion flange 180 degrees.
is unbalanced.
Incorrect rear joint angle usually as • Inspect and correct the trim height at curb weight.
result of the angle being too large. • Inspect and correct the joint angle. Refer to Vibration Diagnosis in General
Information.
Excessive looseness at the Replace the necessary parts.
slip spline.
Distorted or damaged yokes Install new yokes or flanges.
or flanges.
The yokes are out of phase on Re-index the propeller shaft.
two-piece propeller shaft system.
The driveline vibration is at 80 km/h Inspect the propeller shaft for runout and for missing balance weights. Refer to
(50 mph). Vibration Diagnosis in General Information.
The propeller shaft and axle flange Align the paint marks as close as possible.
paint marks are misaligned by more
than 90 degrees.
Roughness or Vibration (Above 56 km/h 35 MPH)

Checks Action
DEFINITION: One hears or feels a roughness when driving the vehicle above 56 km/h (35 mph).
The tires are unbalanced or worn. Balance or replace the tires.
Ping, Snap, or Click Noise
Checks Action
DEFINITION: A ping, snap or click is usually heard on initial load after the transmission is in gear, either forward
or reverse.
The rear springs or upper and Tighten the bolts to specified torque refer to Fastener Tightening Specifications.
lower control arms have loose
bushing bolts.
A loose fixed yoke or Tighten the bolts and pinion nut to specified torque refer to Fastener
companion flange. Tightening Specifications.
Worn or damaged universal joints. Replace the universal joints. Refer to Universal Joints Replacement (Nylon Injected
Ring Type) or Universal Joints Replacement (External Snap Ring Type).
Knock or Clunk Noise

Checks Action
DEFINITION: Knocking or clunking noise occurs when operating the vehicle in high gear or coasting in neutral at
16 km/h (10 mph).
A worn or damaged universal joint. Replace the worn or damaged universal joint. Refer to Universal Joints
Replacement (Nylon Injected Ring Type) and Universal Joints Replacement
(External Snap Ring Type).
The side gear hub counterbore in the Replace the differential case and/or the side gears.
differential is worn oversize.
Scraping Noise
Checks Action
DEFINITION: A scraping noise occurs when driving the vehicle at various speeds.
The pinion flange, or center bearing Correct the interference.
is nibbing.
Squeak Noise
Checks Action
DEFINITION: When driving the vehicle at various speeds a squeaking sound occurs.
Lack of lubricant Replace the universal joints as required. Refer to Universal Joints Replacement
(Nylon Injected Ring Type) and Universal Joints Replacement (External Snap
Ring Type).
Shudder on Acceleration at Low Speed

Checks Action
DEFINITION: When accelerating the vehicle at low speed a shudder occurs.
Bolts are loose or missing at Replace or tighten the bolts to specified torque. Refer to Fastener
the flanges. Tightening Specifications.
The joint angle is excessive or Shim under the transmission support mount in order to change the joint angle. Use
incorrectly set. the standard shim P/N 1254001, or shim the axle pinion down.
The universal joint is worn. Replace the universal joint. Refer to Universal Joints Replacement (Nylon Injected
Ring Type) or Universal Joints Replacement (External Snap Ring Type).
4-8 Propeller Shaft Driveline/Axle
Repair Instructions 9. Clean all parts with an approved solvent.

10. Inspect the splines for damage, wear, burrs,
Propeller Shaft Replacement (Front Drive) and twisting.
Removal Procedure 11. Inspect the universal joint bearings for wear.
1. Raise the vehicle on a hoist. 12. Inspect the propeller shaft for any evidence
of damage.
2. Remove the front differential carrier shield, if
used. Refer to Shield Replacement. Installation Procedure
Important: Observe and accurately reference 1. Extend the propeller shaft to its full length, then
mark all driveline components relative to the compress it about half its stroke.
propeller shaft and axles before disassembly. 2. Install the propeller shaft to the front axle by
These components include the propeller shafts, lining up the reference marks made previously.
drive axles, pinion flanges, output shafts, etc. 3. Install the retainers and bolts.
All components must be reassembled in the
exact relationship to each other as they were Tighten
when removed. In addition, published Tighten the retainer bolts to 20 N.m (15 lb ft).
specifications and torque values, as well as any Notice: Refer to Fastener Notice in Cautions
measurements made prior to disassembly must and Notices.
be followed.
4. Install the propeller shaft to the transfer case.
3. Reference mark the relationship of the
propeller shaft to the front axle and the transfer 4.1. Line up the reference marks
case flange. made previously.
4. Remove the bolts and the retainers from the 4.2. Adjust the propeller shaft length.
front axle. 4.3. Support the propeller shaft.
5. Remove the bolts and retainers from the 5. Install the retainers and bolts.
transfer case. Tighten
Important: Do not pound on the propeller shaft Tighten the retainer bolts to 20 N.m (15 lb ft).
when trying to disconnect the propeller shaft. 6. Install the front differential carrier shield, if
6. Remove the propeller shaft. equipped. Refer to Shield Replacement
7. Compress the propeller shaft forward enough Important: If the slip spline is dry or corroded,
to disengage, then move the propeller it may be necessary to disconnect the propeller
shaft rearward. shaft from the vehicle. Wipe the spline clean
8. Avoid dropping the bearing cap assemblies before installation.
from the yoke ends. 7. Apply chassis lubricant at the slip spline grease
fitting until the grease begins to leave through
the vent hole.
Propeller Shaft Replacement (System

Balanced Assembly)
Rem oval Procedure
Important: If one propeller shaft of a system
balanced assembly is replaced, the mating shaft
must be rebalanced with the replaced shaft.
Important: Center slip yokes to spline shafts,
end yokes, companion flanges, etc. must not
be rotated from their original position
during reassembly.
2. Reference mark all propeller shaft related
components for reassembly including flanges
and yokes.
3. Remove the bolts and retainers.
4. Remove the propeller shaft.
5. Clean the propeller shaft, universal joints, and
attachments with an approved solvent.
1. Install the propeller shaft.
2. Install the bolts and retainers.
Tighten
• Tighten the bolts to 20 N.m (15 lb ft).
• Tighten the bolts 37 N.m (27 lb ft).
and Notices.
1236
One-Piece Propeller Shaft Replacement
Removal Procedure
Im portant: Observe and accurately reference mark
all driveline components relative to the propeller
shaft and axles before disassembly. These
components include the propeller shafts, drive axles,
pinion flanges, output shafts, etc. Ail components
must be reassembled in the exact relationship to
each other as they were when removed. In addition,
published specifications and torque values, as well
as any measurements made prior to disassembly
must be followed.
1. Reference mark the propeller shaft to pinion
flange connection.
2. Reference mark the slip yoke to the
transmission for proper reassembly.
3. For two-piece American Axle and Manufacturing
propeller shafts, unscrew the threaded cap on
the center slip yoke.
4. For two-piece Dana propeller shafts, pull the
stub shaft (2) out of the slip yoke (1).
5. When servicing driveshafts with the pop on
seal, do not remove the seal from the sleeve.
Removal of the seal causes damage to the seal
lip where it contacts the sleeve yoke. If removal
of the seal is necessary, replace the seal with a
new unit.
used. Refer to Shield Replacement in Front
Driving Axle.
9. Remove the retainers.
156961
Important: Do not pound on the propeller shaft yoke
ears. The injection joints may fracture. Never pry or
place any tool between a yoke and a universal joint.
10. Remove the yoke (4) and cross assembly by
taping the bearing cups in order to prevent the
loss of bearing rollers.
• Slide the propeller shaft forward.
• Lower the propeller shaft and remove the
propeller shaft.
• Do not allow the universal joint to incline
greatly. The joint may fracture.
12. Remove the center bearing support bolts.
13. Remove the center support bearing nuts
and washers.
14. Remove the center bearing support (3).
15. Use the following procedure in order to remove

the front propeller shaft:
15.1. Always support the propeller shaft.
15.2. Do not allow the universal joint to
bend deeply as the universal joint
could fracture.
15.3. Remove the propeller shaft with a
rearward movement.
16. Clean all parts with an approved solvent.
17. Inspect the outer diameter of the transmission
yoke for burrs. Burring damages the
transmission seal.
18. Inspect the slip yoke splines for wear.
19. Inspect for twisted slip yoke splines or possibly
the wrong universal joint.
20. Inspect the universal joint bearings for wear.
Replace as necessary.
1. Install the propeller shaft into the transmission.
2. Lubricate the slip joint spline with
chassis grease.
3. Align the reference marks on the pinion flange
and the propeller shaft rear yoke.
4. Install the yoke and cross assembly onto the
fixed yoke.
5. Install the retainers.
Tighten
• Tighten the bolt to 20 N-m (15 lb ft)
• Tighten the bolt to 37 N-m (27 lb ft)
and Notices.
156961
TWo-Piece Propeller Shaft Replacement

Removal Procedure
Im portant: Observe and accurately reference mark
shaft and axles before disassembly. These
components include the propeller shafts, drive axles,
pinion flanges, output shafts, etc. All components
must be reassembled in the exact relationship to
each other as they were when removed. In addition,
published specifications and torque values, as well
as any measurements made prior to disassembly
must be followed.
1. Reference mark the propeller shaft to pinion
flange connection.
2. Reference mark the slip yoke to the
transmission for proper reassembly.
3. For two-piece American Axle and Manufacturing
propeller shafts, unscrew the threaded cap on
the center slip yoke.
4. For two-piece Dana propeller shafts, pull the
stub shaft (2) out of the slip yoke (1).
5. When servicing driveshafts with the pop on
seal, do not remove the seal from the sleeve.
Removal of the seal causes damage to the seal
lip where it contacts the sleeve yoke. If removal
of the seal is necessary, replace the seal with a
new unit.
used. Refer to Shield Replacement in Front
Driving Axle.
156961
Important: Do not pound on the propeller shaft yoke
ears. The injection joints may fracture. Never pry or
place any tool between a yoke and a universal joint.
10. Remove the yoke (4) and cross assembly by
taping the bearing cups in order to prevent the
loss of bearing rollers.
• Slide the propeller shaft forward.
• Lower the propeller shaft and remove the
propeller shaft.
• Do not allow the universal joint to incline
greatly. The joint may fracture.
12. Remove the center bearing support bolts.
13. Remove the center support bearing nuts
and washers.
14. Remove the center bearing support (3).
15. Use the following procedure in order to remove

the front propeller shaft:
15.1. Always support the propeller shaft.
15.2. Do not allow the universal joint to
bend deeply as the universal joint
could fracture.
15.3. Remove the propeller shaft with a
rearward movement.
17. Inspect the outer diameter of the transmission
yoke for burrs. Burring damages the
transmission seal.
18. Inspect the slip yoke splines for wear.
19. Inspect for twisted slip yoke splines or possibly
the wrong universal joint.
20. Inspect the universal joint bearings for wear.
Replace as necessary.
1. Install the propeller shaft into the transmission.
2. Ensure that the slip joint splines are lubricated.
3. Bottom the propeller shaft yoke in
the transmission.
4. Install the center bearing support.
5. Align the center bearing support 90 degrees to
the propeller shaft center lines.
6. Install the center bearing support bolts.
Tighten
Tighten the center bearing support bolts to
35 N.m (26 lb ft).
and Notices.
1236
7. Install the slip yoke (4) onto the splined shaft.
8. Mate the missing tooth (5) in the yoke (4) with
the bridged tooth (6) on the splined shaft (1).
9. Support the propeller shaft.
10. Be sure the slip yoke ears are horizontal.
12. Align the reference marks.
13. Align the reference marks.
14. Install the retainers.
Tighten
16. Install the front differential carrier shield if used.
17. Inspect for proper joint fit.
18. Lubricate the slip yoke.
19. Lubricate the center slip joint on
two-piece shaft.
Three-Piece Propeller Shaft Replacement
Removal Procedure
Important: Observe and accurately reference
mark all driveline components relative to the
propeller shaft and axles before disassembly.
These components include the propeller shafts,
drive axles, pinion flanges, output shafts, etc.
All components must be reassembled in the
exact relationship to each other as they were
when removed. In addition, published
specifications and torque values, as well as any
measurements made prior to disassembly must
be followed.
2. Reference mark the rear propeller shaft to the
pinion flange connection.
3. Support the rear propeller shaft.
4. Remove the bolts from the pinion flange.
Important: Do not pound on the original
propeller shaft yoke ears. The plastic injection
joints may fracture. Never pry or place any tool
between a yoke and a universal joint. Tape the
bearing cups onto the yoke in order to prevent
the loss of bearing rollers.
6. Remove the yoke and the universal joint
assembly from the pinion flange.
7. Remove the rear propeller shaft.
• Slide the rear propeller shaft forward.
• Lower the rear propeller shaft and withdraw
under the rear axle.
• Do not allow the universal joint assembly to
incline greatly. The joint may fracture.
• Reference mark the intermediate propeller
shaft to front propeller shaft yoke.
. Support the intermediate propeller shaft.
8. Remove the bolts from the front propeller shaft
yoke at the front center bearing support.
10. Remove the nuts from the intermediate shaft
center bearing support.
11. Remove the bolts and washers.
12. Remove the intermediate propeller shaft center
bearing support from the hanger.
13. Remove the yoke and the universal joint
assembly from the front propeller shaft
rear yoke.
14. Remove the intermediate propeller shaft.
156865
• Reference mark the front the propeller shaft
to the yoke or to the parking break drum.
• Support the front propeller shaft.
15. Remove the bolts and the retainers from
the yoke.
16. Remove the nuts from the front propeller shaft
center bearing support.
17. Remove the bolts and washers.
18. Remove the front propeller shaft center bearing
support from the hanger.
19. Remove the front propeller shaft.
21. Inspect for proper installation and uniform
seating of all universal joint bearing cups.
22. Inspect the intermediate propeller shaft to rear
propeller shaft slip yoke splines for twisting
or wear.
23. Inspect the inside of the rear propeller shaft slip
yoke for spline twisting or wear.
24. Inspect the front and rear center bearing
support rubber insulators for deterioration or
separation from the support frame work.
25. Inspect the propeller shaft assemblies
for damage.
1. Install the front propeller shaft to the yoke.
• Make sure the reference marks are aligned.
• Support the front propeller shaft.
2. Install the bolts and retainers to the yoke.
Maintain alignment.
Tighten
General Information.
3. Install the intermediate propeller shaft to the
front propeller shaft yoke while maintaining
alignment and supporting the propeller shaft.
Tighten
• Tighten the bolts to 35 N.m (26 lb ft)
• Tighten the nuts to 35 N-m (26 lb ft)
5. Install the rear center bearing support to

the hanger.
6. Align the center bearing support 90 degrees to
both the front and intermediate propeller shaft
center lines.
7. Inspect for proper installation and uniform
seating of all universal joint bearing cups.
8. Inspect the intermediate propeller shaft to rear
propeller shaft slip yoke splines for twisting
or wear.
9. Inspect the inside of the rear propeller shaft slip
yoke for spline twisting or wear.
10. Inspect the front and rear center bearing
support rubber insulators for deterioration or
separation from the support frame work.
11. Inspect the propeller shaft assemblies
for damage.
12. Install the bolts and washers.
13. Install the nuts while supporting the rear
propeller shaft.
Tighten
14. Install the rear propeller shaft to the rear axle
pinion flange while making sure the reference
marks are aligned.
Tighten
Center Bearing Replacement

Removal Procedure
1. Raise and suitably support the vehicle.
2. Remove the rear propeller shaft. Refer to
One-Piece Propeller Shaft Replacement or
Two-Piece Propeller Shaft Replacement
3. Remove the front or intermediate
propeller shaft.
4. Remove the center bearing.
• Stand the propeller shaft on end in press
with the center bearing supported by
press bars.
• Press the propeller shaft down and off the
center bearing.
1. Install the center bearing onto the propeller
shaft by pressing the center bearing onto the
shaft using a press.
Important: The center bearing must be aligned
in order to prevent damage to the propeller
shaft assembly. When bolting the center bearing
in place, be sure to keep it perpendicular (90
degrees plus or minus 1 degree) to the
propeller shaft.
2. Install the front or intermediate propeller shaft.
3. Install rear the propeller shaft. Refer to
Tighten
and Notices.
4. Remove the safety stands and lower
the vehicle.
Universal Joints Replacement (Nylon
Injected Ring Type)
Disassem bly Procedure
Tools Required
• J 9522-3 Universal Joint Bearing Separator
• J 9522-5 Universal Joint Bearing
Spacer Remover
Notice: Never clamp propeller shaft tubing in a vise.
Clamping could dent or deform the tube causing an
imbalance or unsafe condition. Always clamp on one
of the yokes and support the shaft horizontally. Avoid
damaging the slip yoke sealing surface. Nicks may
damage the bushing or cut the lip seal.
1. Support the propeller shaft in a line horizontal
with the table of a press.
2. Mark the propeller shaft as to which end is the
transmission end and which end goes to the
1222 rear axle.
3. Place the universal joint so that the lower
ear of the yoke is supported on a
30 mm (1 1 /8 in) socket.
4. In order to shear the plastic retaining ring on
the bearing cup, place J 9522-3 on the open
horizontal bearing cups and press the lower
bearing cup out of the yoke ear.
5. If the bearing cup is not completely removed,
lift the cross and insert J 9522-5 between the
seal and bearing cup being removed and
continue to press it out of the yoke.
6. Rotate the propeller shaft and press the
opposite bearing cup out of the yoke.
7. Mark the orientation of the slip yoke to the tube
for proper reassembly.
8. Remove the cross from the yoke.
9. Remove the remaining universal joint parts from
the yoke. If you are replacing the front universal
joint, remove the bearing cups in the slip yoke
in the same manner.
10. Inspect the retaining ring grooves for plastic.
11. Inspect the bearing cup bores in the yoke ears
for burrs or imperfections.
12. Clean the remains of the sheared plastic
bearing retainers from the grooves in the yoke.
13. The sheared plastic may prevent the bearing
cups from being pressed into place and thus
prevent the bearing retainers from being
properly seated.
Assem bly Procedure
1. Remove the bearing cups from the
universal joint.
2. Use you finger in order to coat the needle
bearings in the bearing cup with a thin layer of
chassis grease.
3. Assemble one bearing cup part way into one
side of the yoke.
4. Turn the yoke ear toward the bottom.
5. Assemble the cross into the yoke so the
trunnion seats freely into the bearing cup.
6. With the trunnion seated in the bearing cup
press the bearing cup into the yoke until it is
flush with the yoke ear.
1223
7. Assemble the opposite bearing cup part way
into the yoke ear.
8. Make sure that the trunnions are started
straight and true into both bearing cups.
9. Press the opposite bearing cup into the yoke
ear while working the cross all the time in order
to check for free unbinding movement of the
trunnions in the bearing cups.
Im portant: If there seems to be a hangup or
binding, stop pressing, and check the needle
bearings for misalignment in the bearing cup.
10. Press the bearing cup into the yoke until the
bearing retainer groove clears the inside of
the yoke.
11. Assemble the bearing retainer in the

retainer groove.
12. Continue pressing until both retainers can be
snapped into place.
1225
13. If seating the retainer is difficult, spring the
yoke slightly with a firm blow from a dead
blow hammer.
14. It may be necessary to lubricate the snap ring
with a slight amount of chassis grease so it
seats in the bearing cup groove.
Universal Joints Replacement (External

Snap Ring Type)
Tools Required
• J 9522-3 Universal Joint Bearing Separator
• J 9522-5 Universal Joint Bearing
Spacer Remover
Notice: Never clamp propeller shaft tubing in a vise.
Clamping could dent or deform the tube causing an
imbalance or unsafe condition. Always clamp on one
of the yokes and support the shaft horizontally. Avoid
damaging the slip yoke sealing surface. Nicks may
damage the bushing or cut the lip seal.
1. Support the propeller shaft in a line horizontal
with the table of a press.
2. Mark the propeller shaft in order to show which
end connects to the transmission and which
1222 end goes to the rear axle.
3. Disassemble the snap rings by pinching the
ends together with a pair of pliers.
4. If the ring does not readily snap out of the
groove in the yoke, tap the end of the cup
lightly in order to relieve the pressure from
the ring.
5. Place the universal joint so that the lower
ear of the yoke is supported on a
30 mm (1 1/8 in) socket.
6. Place J 9522-3 on the open horizontal bearing
cups and press the lower bearing cup out of
the yoke ear.
7. If the bearing cup is not completely removed,
lift the cross and insert J 9522-5 between the
seal and bearing cup being removed and
continue pressing it out of the yoke.
8. Rotate the propeller shaft and press the
opposite bearing cup out of the yoke.
9. Mark the orientation of the slip yoke to the tube
for proper reassembly.
10. Remove the cross from the yoke.
11. Remove the remaining the universal joint parts
from the yoke.
12. If the front universal joint is being replaced,
remove the bearing cups in the slip yoke in the
same manner.
13. Inspect the retaining ring grooves for dirt,
corrosion, or pieces of the old ring.
14. Inspect the bearing cup bores for burrs
or imperfections.
15. Clean the retaining ring grooves. Corrosion, dirt,
rust, or pieces of the old retaining ring may
prevent the bearing cups from being pressed
into place or prevent the bearing retainers from
being properly seated.
Assembly Procedure
1. Remove the bearing cups from the
universal joint.
2. Use your finger in order to coat the needle
bearings in the bearing cup with a thin layer of
chassis grease.
3. Assemble one bearing cup part way into one
side of the yoke. Turn the yoke ear toward
the bottom.
4. Assemble the cross into the yoke so that the
trunnion seats freely into the bearing cup.
1223
5. With the trunnion seated in the bearing cup,
press the bearing cup into the yoke until it is
flush with the yoke ear.
6. Install the opposite bearing cup part way into
the yoke ear.
7. Make sure that the trunnions are started
straight and true into both bearing cups.
8. Press the opposite bearing cup into the yoke
ear while working the cross all the time in order
to check for free unbinding movement of the
trunnions in the bearing cups.
Important: If there seems to be a hang up or
binding, stop pressing, and check the needle
bearings for misalignment in the bearing cup.
9. Press the bearing cup into the yoke until the
bearing cup retainer groove is visible over the
top of the bearing cup.
1224
10. Assemble the bearing retainer in the

retainer groove.
11. Continue pressing until both retainers can be
snapped into place.
12. If the retainer is difficult to seat, the yoke can

be sprung slightly with a firm blow from a dead
blow hammer.
13. It may be necessary to lubricate the snap ring
with a slight amount of chassis grease so that
the snap ring seats in the bearing cup groove.
1226

Propeller Shaft Description
Two Piece Propeller Shaft

Propeller shafts transmit torque from the transmission
to the rear axle. The number of propeller shafts
varies with the vehicle wheel base combination of
transmission, transfer case, (front drive), and rear
axle equipment.
Propeller shafts have universal joints at each end in
order to accommodate angle variations between the
transmission and rear axle, and the rear axle
position caused by suspension motion. All propeller
shafts are the balanced tubular type.
3649
One Piece Propeller Shaft
156961
For a one-piece propeller shaft, a splined slip joint
connects the driveline to the transmission.
156362
For two-piece and three-piece propeller shafts, a

fixed yoke connects the driveline to the transmission.
Vehicles with two or more propeller shafts use a
center bearing. The center bearing is usually near
the rear of the front propeller shaft. The slip joint is
at the forward end of the rear propeller shaft.
Propeller Shaft Phasing Description
t
Universal Joint Description
1236
The propeller shaft is designed and built with the
yoke lugs (ears) in line with each other which
produces the smoothest running shaft possible. A Universal joints are designed to handle the effects of
propeller shaft designed with built in yoke lugs in line various loadings and rear axle windup during
is known as in-phase. acceleration and braking. Within the designed angle
variations, the universal joint operates efficiently and
An out of phase propeller shaft often causes safely. When the design angle changes or is
vibration. The propeller shaft generates vibration from exceeded, the operational life of the joint
speeding up and slowing down each time the may decrease.
universal joint goes around. The vibration is the
same as a person snapping a rope and watching the The trunnion bearings used in universal joints are
wave reaction flow to the end. An in phase propeller the needle roller type. Round bearing cups hold the
shaft is similar to two persons snapping a rope at needle rollers in place on the trunnions. Either snap
the same time and watching the waves meet and rings or injected plastic hold the bearing cups in
cancel each other out. A total cancellation of the yokes.
vibration produces a smooth flow of power in the The Original Equipment Manufacturer (OEM)
drive line. Since phasing of a propeller shaft is universal joints are lubricated for life and cannot be
between the front and center universal joints, you lubricated on the vehicle. A service kit which consists
must reference mark the front and rear propeller of a spider with bearing assemblies and snap rings
shafts before removal in order to ensure proper may be installed if a universal joint becomes worn or
phasing upon reinstailation. Some splined shaft slip noisy. If it is necessary to repair a universal joint,
yokes are keyed in order to ensure proper phasing. you must remove the propeller shaft from the
vehicle. Avoid jamming, bending, or over-angulating
any parts of the propeller shaft assembly. Avoid
damaging the propeller weld yokes and slip yoke
ears upon installation or removal of U-joints.
4-26 Propeller Shaft _______ ______________________________ Driveline/Axle
Center Bearing Description
Center bearings support the driveline when using two

or more propeller shafts. The center bearing is a ball
bearing mounted in a rubber cushion that attaches to
a frame crossmember. The manufacturer
prelubricates and seals the bearing. The cushion
allows vertical motion at the driveline and helps
isolate the vehicle from vibration.

BLANK
Driveline/Axle Wheel Drive Shafts 4-29
Wheel Drive Shafts

Specifications
Fastener Tightening Specifications (Fastener Tightening Specificat)

Specification
Application Metric English
Small Seal Retaining Clamp 136 N.m 1001b. ft.
4-30 Wheel Drive Shafts Driveline/Axle
Visual Identification
Disassembled Views
Legend
(1) Tripot Housing Assembly (9) CV Joint Seal
(2) Spacer Ring (10) Race Retaining Ring
(3) Tripot Joint Spider Assembly (11) Ball
(4) Swage Ring (12) CV Joint Inner Race
(5) Tripot Joint Seal (13) CV Joint Cage
(6) Small Seal Retaining Clamp (14) CV Joint Outer Race
(7) Drive Axle Seal Cover (Optional) (15) Deflector Ring
(8) Drive Axle Shaft
Repair Instructions
Deflector Ring Replacement
Disassembly Procedure
1. Inspect the deflector ring (1).
1.1. Replace the deflector ring (1) if the
deflector ring (1) is damaged.
1.2. Use a hammer and a brass drift to tap
the damaged deflector ring (1) off of the
C/V joint.
1.3. Discard the deflector ring (1).
211904
Assembly Procedure
Tools Required
• 3 inch or 4 inch pipe coupling
• 12 mm x 12 mm steel plate with a 28 mm hole
drilled in the center. The plate must be at least
3 mm thick.
• M24 x 2.0 nut
1. Put the new deflector ring (1) into position on
the C/V joint.
2. Put the 3 inch or 4 inch pipe coupling against
the deflector ring (1). Put the 12 mm x 12 mm
steel plate over the pipe. The axle shaft (2)
will protrude through the 28 mm hole in the
steel plate.
3. Install the M24 x 2.0 nut on the axle shaft.

Tighten the M24 x 2.0 nut until the deflector
ring (1) bottoms against the C/V joint.
Important: If the tripot end of the drive axle
(halfshaft) assembly does not require service,
follow the directions for the installation of the
drive axle seal cover found at the end of this
section.
4. Remove the nut, the steel plate and the pipe
coupling.
212015
Drive Axle Inner Joint and

Seal Replacement
Tools Required
J 8059: Snap Ring Pliers.
Notice: With removal of the halfshaft for any reason,
the transmission sealing surface (the tripot
male/female shank of the halfshaft) should be
inspected for corrosion. If corrosion is evident, the
surface should be cleaned with 320 grit cloth or
equivalent. Transmission fluid may be used to clean
off any remaining debris. The surface should be
wiped dry and the halfshaft reinstalled free of
any buildup.
1. Use a hand grinder in order to cut through the
swage ring (2). Do not damage the tripot
212024 housing (1).
2. Remove the tripot housing (1) from the
drive axle.
3. Wipe the grease off of the tripot assembly roller
bearings and the tripot housing (1).
4. Thoroughly degrease the tripot housing (1).
5. Allow the tripot housing (1) to dry prior to
assembly.
Important: Handle the tripot spider assembly (1) with
care. Tripot balls and needle rollers may separate
from the spider trunnion if the tripot balls and needle
rollers are not handled carefully.
6. Use side cutters to cut away the small seal
clamp (3).
7. Slide the tripot seal (2) up the drive axle shaft
(4), away from the tripot spider assembly (1)
toward the outboard (CN joint assembly) end
of the drive axle (4).
212028
8. Spread the spider spacer ring (2) with tool
J 8059: Snap Ring Pliers, (or equivalent).
221915
9. Remove the following items:
9.1. The spacer ring (1)
9.2. The spider assembly (2)
9.3. The tripot seal (3)
10. Clean the drive axle (4). Use a wire brush in
order to remove any rust in the seal mounting
area (grooves).
11. Inspect the needle rollers, needle bearings, and
trunnion. Check the tripot housing for unusual
wear, cracks, or other damage. Replace any
damaged parts.
Assembly Procedure
Tools Required
• J 35910: Earless Clamp Tool.
• J 36652 Large Clamp Swage Tool
1. Place the new small seal clamp (2) onto the
small end of the joint seal (1). Slide the joint
seal (1) and small seal clamp (2) onto the
axle shaft.
2. Position the small end of the joint seal (1) into
the joint seal groove (3) on the axle shaft.
214024
3. Secure the small seal clamp (1) with J 35910
Earless Clamp Tool (or equivalent), a breaker
bar, and a torque wrench.
Tighten
Tighten the small seal clamp (1) to 136 N-m
(100 lb ft).
4. Check the gap dimension on the clamp ear.
214026
Notice: You must assemble the joint with the
convolute retainer in the correct position, as
illustrated. The joint seal will be damaged if the joint
assembly does not meet the specified dimension.
5. Install the convolute retainer over the inboard
joint seal, being sure to capture three
convolutions.
214938
6. Install tripot spider assembly (3) onto the axle
shaft (2) with the counterbore towards the end
of the axle shaft (2).
7. Install the spacer ring (1) in the groove at the
end of the axle shaft (2).
212035
8. Push the spider assembly (1) back toward the
end of the axle shaft (2) until the spacer ring is
covered by the spider assembly (1)
counterbore.
212043
9. Pack the tripot seal (4) and the tripot housing
(1) with the grease supplied in the kit. The
amount of grease supplied in this kit has been
pre-measured for this application.
212048
10. Reassemble the tripot housing (3) and the tripot
seal (1) using the following procedure:
10.1. Pinch the swage ring (2) slightly by hand
in order to distort it into an oval shape.
10.2. Slide the distorted swage ring (2) over
the large diameter of the seal (1).
10.3. Place the housing (3) over the spider
assembly.
10.4. Install the seal (1) onto the housing (3).
10.5. Align the tripot seal (1), with the swage
ring (2) in place, over the flat area on
the tripot housing (3).
214957
11. Mount J 36652 Large Clamp Swage
Tool in a vise.
12. Install the bottom half of the split-plate
swage clamp. For K10 models, use
J 36652 Large Clamp Swage Tool.
13. For K20/K30 models, use J 36652
Large Clamp Swage Tool.
14. Check the inboard stroke position.

• Use measurement A for the K10 models.
• Use measurement B for the K20 and
K30 models.
15. Position the inboard end (tripot end) of the

drive axle (halfshaft) assembly in the J 36652
Large Clamp Swage Tool.
16. Install the top half of the proper size tool on
the lower half of the tool. For K10 models,
use J 36652 Large Clamp Swage Tool.
17. For K20/K30 models, use J 36652 Large
Clamp Swage Tool.
17.1. Align the swage ring (2) and the
swage ring clamp.
17.2. Insert the bolts and hand tighten
until snug.
Important: Align the following during
this procedure:
• The tripot seal (3)
• The housing (1)
• The swage ring (2)
212054
18. Tighten
Tighten each bolt 180 degrees at a time.
Alternate between the bolts until both sides of the
top half of J 36652 Large Clamp Swage Tool
touch the bottom half of the tool.
Tighten each bolt 180* at a time. Tighten each
bolt alternately until both sides touch the bottom
half of the tool.
19. Loosen bolts and remove halfshaft assembly
from the tool.
20. Remove the convolute retainer from the seal.
Drive Axle Outer Joint and

Seal Replacement
D isassem bly Procedure
Tools Required
J 8059: Snap Ring Pliers.
1. Place protective covers over the vise jaws.
Place the drive axle in the vise.
2. Use a hand grinder to cut through the swage
ring (2). Do not damage the outer race.
3. Use side cutters to cut off the small seal
clamp (4).
211906
4. Slide the seal (5) down the axle shaft (4) and
away from the C/V joint outer race (1). Wipe all
grease away from the face of the C/V joint.
5. Find the axle shaft retaining snap ring (3),
which is located in the inner race (2). Spread
the snap ring ears apart using J 8059: Snap
Ring Pliers (or equivalent).
6. Pull the C/V joint (1) and the C/V joint seal (5)
from the axle shaft (4). Discard the old C/V
joint seal (5).
1. Place a brass drift against the C/V joint
cage (1).
1 2. Tap gently on the brass drift with a hammer in
order to tilt the cage (1).
3. Remove the first chrome alloy ball (2) when the
C/V joint cage (1) tilts.
4. Tilt the C/V joint cage (1) in the opposite
direction to remove the opposing chrome alloy
ball (2).
5. Repeat this process to remove all six of
the balls.
211933
6. Pivot the C/V joint cage (4) and the inner race
90 degrees to the center line of the outer race
(1). At the same time, align the cage windows
1 (3) with the lands of the outer race (2).
7. Lift out the cage (4) and the inner race.
214946
8. Remove the inner race (1) from the cage (2) by
rotating the inner race (1) upward.
9. Clean the inner and outer race assemblies, the
C/V joint cage and the chrome alloy balls
thoroughly with cleaning solvent. Remove all
traces of old grease and any contaminates.
10. Dry all the parts.
11. Check the C/V joint assembly for unusual wear,
cracks, or other damage.
12. Replace any damaged parts.
13. Clean the axle shaft (8). Use a wire brush to
remove any rust in the seal mounting area
(grooves).
214947
Assembly Procedure
Tools Required
• J 35910: Earless Clamp Tool. Seal Clamp Tool
• J 36652 Large Clamp Swage Tool (K10 models)
(K20/K30 models)
1. Inspect all of the parts for unusual wear,
cracks, or other damage. Replace the joint
assembly if necessary.
2. Put a light coat of the recommended grease on
the inner (6) and the outer race (8) grooves.
3. Insert the inner race (1) into the cage (2) by

rotating the inner race (1) downward:
3.1. Hold the inner race (1) at 90 degrees to
the centerline of the cage (2).
3.2. Align the lands of the inner race (1) with
the windows of the cage (2).
3.3. Insert the inner race (1) into the cage
(2), by rotating the inner race (1)
downward.
214947
4. Insert the cage (4) and inner race into the
outer race (1).
214946
5. Place a brass drift against the C/V joint
cage (1).
6. Tap gently on the brass drift with a hammer in
1 order to tilt the cage (1).
7. Install the first chrome alloy ball (2) when the
C/V joint cage (1) tilts.
8. Tilt the C/V joint cage (1) in the opposite
direction to install the opposing chrome alloy
ball (2).
9. Repeat this process to install all six of the balls.
211933
Assembly Procedure
1. Pack the C/V joint seal (1) and the C/V joint
assembly with the grease supplied in the kit.
The amount of grease supplied in this kit has
been pre-measured for this application.
2. Place the new small seal clamp (2) onto the
C/V joint seal (1).
3. Slide the C/V joint seal (1) onto the axle shaft.
4. Position the small end of the C/V joint seal (1)
into the joint seal groove (3) on the axle shaft.
214024
5. Secure the small seal clamp (6) with J 35910:
Earless Clamp Tool (or equivalent), a breaker
bar, and a torque wrench.
Tighten
Tighten the small clamp (1) to 136 N-m
(100 lb ft). Check the gap dimension on the
clamp ear.
6. Pinch the new swage ring (2) slightly by hand

to distort it into an oval shape.
7. Slide the distorted swage ring (2) over the large
diameter of the seal (1).
Important: Be sure that the retaining ring side
of the C/V joint inner race faces the axle shaft
(3) before installation.
8. Slide the C N joint (4) onto the axle shaft (3).
The retaining snap ring inside of the inner race
engages in the axle shaft groove with a click
when the C N joint (4) is in the proper position.
9. Pull on the C N joint (4) to verify engagement.
10. Slide the large diameter of the C/V joint seal
(1), with the large swage ring (2) in place, over
the outside edge of the C/V joint outer race (4).
212006
11. Clamp the C/V joint seal (2) tightly to the

C/V joint outer race (1) with the large swage
ring (4), using the following procedure:
11.1. Mount J 36652 Large Clamp Swage Tool
in a vise.
11.2. Install the bottom half of the split-plate
swage clamp. For K10 models, use
J 36652 Large Clamp Swage Tool.
11.3. For K20/K30 models, use J 36652 Large
Clamp Swage Tool.
11.4. Position the C/V joint end (outboard end)
of the drive axle (halfshaft) assembly in
the bottom half of J 36652 Large Clamp
Swage Tool.
214030
12. Align the following during this procedure:
• The C N joint seal (3)
• The C N joint assembly (1)
• The swage ring (2)
12.1. Install the top half of J 36652 Large
Clamp Swage Tool - K- trucks, onto the
lower half of the tool, over the C N joint
seal (3) and the C N joint assembly (1).
12.2. Align the swage ring (2) and the swage
ring clamp.
12.3. Insert the bolts into the tool J 36652
Large Clamp Swage Tool - K- trucks.
Hand tighten the bolts until the bolts
are snug.
Tighten
Tighten each bolt 180 degrees at a time.
Alternate between the bolts until both
sides of the top half of J 36652 Large
Clamp Swage Tool touch the bottom half
of the tool.
12.4. Loosen the bolts and remove halfshaft
assembly from J 36652 Large Clamp
Swage Tool.
Wheel Drive Shafts Boot Cover
Replacement (Wheel Drive Shaft
Boot Cover R)
• J 8059: Snap Ring Pliers. Snap Ring Pliers
• J 35910: Earless Clamp Tool. Earless Seal
Clamp Tool
Notice: If the drive axle seal cover (3) will be
reused, do not damage the drive axle seal cover (3)
while removing the clamps (2).
1. Use side cutters to cut the drive axle seal cover
clamps (2) and the nylon strap (1).
212151
2. Slide the drive axle seal cover (1) off of the
drive axle, over the C/V joint end.
3. Check the drive axle seal cover (1) for rips,
tears, worn spots or other damage. Reuse
the drive axle seal cover (1) if there is no
damage visible.
Assembly Procedure
Tools Required
J 41187 Bandit Tool for Seal Cover.
1. Insert new clamps (3) into the original drive
axle seal cover (1) (if you are reusing the
original drive axle seal cover).
2. Slide the drive axle seal cover (1) onto the
drive axle halfshaft assembly (2), starting at
the outboard (C/V joint) end.
3. Align the inboard clamp (2) on the inboard joint

(1). Align the seal cover seam so the seam is
straight.
212079
Important: Tighten the seal cover clamp (1) as tight
as possible without deforming the retaining clip.
Clamps that are not tight enough allow the cover
to slide upon the joint. This causes shortened
service life.
4. Use J 41187 Bandit tool for Seal Cover in order
to tighten the inboard seal cover clamp (1).
5. Rotate the tool toward the clip in order to bend

the band onto the clip.
6. Pull on the tool’s cutting handle in order to cut
off the excess band.
7. Pound the band flat between the latch tabs.

Peen the latch tabs over in order to lock the
band into position.
212084
8. Twist the drive axle seal cover (1):
• K10 = 180 degrees
• K20/K30 = 90 degrees
Important: Be sure that the inboard tab of the
drive axle seal cover (1) is 180 degrees
opposite the outboard tab of the drive axle seal
cover (1) before proceeding.
9. Position the outboard end of the drive axle seal
cover (1) over the C/V joint (2) flat.
Important: Tighten the seal cover clamp (1) as tight

as possible without deforming the retaining clip.
Clamps that are not tight enough allow the cover to
slide upon the joint. This causes shortened service life.
10. Use J 41187 Bandit tool for Seal Cover in
order to tighten the outboard cover clamp (1).
11. Rotate the tool toward the clip in order to bend

the band onto the clip.
12. Pull the tool’s cutting handle in order to cut off
excess band.
214984
13. Pound the band flat between the latch tabs.
Peen the latch tabs over in order to lock the
band into position.
14. Gather the drive axle seal cover material at the

center. Wrap the drive axle seal cover (1) tightly
with the nylon strap (2) provided in the kit.
212099

J 8059
Snap Ring Pliers
&
221884
4T J 35910
Eared Seal Clamp
221882
BLANK
Driveline/Axle Front Drive Axle 4-49
Front Drive Axle

Specifications

Application N.m Lb Ft Lb In
Axle Shaft Tube to Carrier Bolts 40 30 —
Brake Pipe Support Bracket Nut 18 13 —

Carrier Frame Screws 22 16 —
Carrier Mounting Bolts and Nuts 110 80 —
Drive Axle (Halfshaft) Nut at Front Hub 225 165 —
Drive Axle (Halfshaft) Bolts 78 58 —
Electric Motor Actuator 20 15 —
Engagement Switch 20 15 —
Front Differential Carrier Shield Bolts 34 25 —
Lower Shock Absorber Mounting Nut 73 54 —
Outer Tie Rod Nut 62 46 —

Plug, Drain and Fill 33 24 —
RH Axle Tube to Frame Nuts-K1 and K2 100 75 —
RH Axle Tube to Frame Nuts-K3 145 106 —
Stabilizer Bar Clamp to Frame Bolts 33 24 —
Universal Joint Clamp Bolts 20 15 —

Upper Control Arm Stud Nut 100 75 —
Lubrication Specifications
Application Liters Pints Quarts
K1 and K2 Models-Fill to Level of the Filler Plug Hole 1.66 3.5 —
K3 Models-Fill to Level of the Filler Plug Hole 1.85 3.9 —
Type Recommended SAE 80W-90 GL5 Gear Lubricant (SAE 80W GL5 in Canada)

Front Axle, Axle Kit, Shaft and Shaft Kit 6.055
Front Axle Bearing, Bolt, Cover, Deflector, Nut, Ring, Seal, Shim, Sleeve, Spacer 6.056
and Washer
Front Drive Axle Shifter/Lock Actuator, Clip, Connector, Fork, Ring, Rivet, Shaft, 6.058
Spring and Washer
4-50 Front Drive Axle Driveline/Axle
Diagnostic Information and Wheel Bearing Noise

Procedures A brinelled wheel bearing causes a knock or click
approximately every two revolutions of the wheel,
Noise Diagnosis (Causes of Noise) since the bearing rollers do not travel at the same
speed as the axle and wheel. With the wheels
Any gear-driven unit produces a certain amount of
jacked up, spin the wheels by hand while listening at
noise that is normal and that conventional repairs or
the hubs for evidence of a rough or brinelled wheel
adjustment cannot eliminate. Slight noise that is
bearing or loose bearings.
heard only at a certain speed or under unusual or
remote conditions is acceptable. For example, this Gear Noise
noise tends to reach a peak at speeds from 60 to
100 km/h (40 to 60 mph) depending upon road and
load conditions, or upon gear ratio and tire size.
Noise of this kind does not indicate trouble in the
axle assembly.
When an axle is suspected of being noisy, make a
thorough test in order to determine whether the
noise originates in the tires, road surface, wheel
bearings, engine, transmission, propeller shaft, or
axle assembly. The following procedures will help
locate the source of the noise: Raising tire pressure
in order to eliminate tire noise (although this will not
silence tread noise of mud and snow tires), listening
for the noise on varying road surfaces, and listening
for noise at varying speeds such as drive, float, and
coast conditions.
Noise Diagnosis (Determining Type

of Noise)
Road Noise 156406
Driving on certain road surfaces, such as brick or
rough-surfaced concrete, causes noise which may be There are two basic types of gear noise. The first
mistaken for tire or rear axle noise. Driving on a type is produced by broken, bent, or forcibly
different type of road, such as smooth asphalt or dirt, damaged gear teeth (1), which is usually quite
will quickly show whether the road surface is the audible over the entire speed range, and presents
cause of noise. Road noise usually is the same in no difficulty in diagnosis. For example, hypoid gear
drive as in coast. tooth scoring generally results from the following:
insufficient lubricant, improper break-in, wrong
Tire Noise lubricant, insufficient gear backlash, improper ring
Tire noise may easily be mistaken for axle noise. and pinion alignment, or loss of drive pinion nut
Tire noise changes with different road surfaces; axle torque. The scoring progressively leads to complete
noise does not. Temporarily inflating all tires to erosion of the gear tooth or gear tooth pitting and
345 kPa (50 psi) pressure, for test purposes alters then eventual fracture if the initial scoring is
the noise caused by tires only materially, but does not corrected.
not affect noise caused by the axle. Axle noise Another cause of hypoid gear fracture is extended
usually stops when coasting at speeds under overloading of the gear set, which produces fatigue
30 miles per hour. Tire noise still continues with fracture, or shock loading, and can result in
lower tone as the vehicle speed reduces. sudden failure.
Engine and Transmission Noises

In order to determine which unit causes the noise,
take note of approximate vehicle speeds and
conditions under which the noise is most
pronounced. Then stop the vehicle in a quiet place
in order to stop interfering noises. With the
transmission in neutral, run the engine slowly up and
down the engine speeds corresponding to the
vehicle speed at which the noise was most
pronounced. If a similar noise is produced with the
vehicle standing stjJJ, the engine or transmission is
the cause, not the axle.
The second type of gear noise pertains to the mesh
pattern of the gear teeth (2). This form of abnormal
gear noise is recognizable because it produces a
cycling pitch (whine) and is pronounced in the speed
range at which it occurs, appearing under either
drive, float, or coast conditions. Gear noise tends to
peak in a narrow speed range or ranges and will
tend to remain constant in pitch. Bearing noise
varies in pitch with vehicle speeds.
156776
Front Drive Axle Diagnosis (Clicking Noise in Turns)

Checks Action
DEFINITION: A clicking noise occurs when driving the vehicle at varying speeds.
Worn out or damaged CV joint Replace the CV joint.
Front Drive Axle Diagnosis (Clunk Acc. from Coast)

Checks Action
DEFINITION: A clunking noise occurs when accelerating the vehicle from coast.
Loose CV joint to output shaft bolts Tighten the output shaft bolts.
A damaged inner CV joint Replace the inner CV joint.
Front Drive Axle Diagnosis (Shudder or Vibration)

Checks Action
DEFINITION: A shudder or vibration occurs when accelerating the vehicle.
An excessive CV joint angle Repair the CV joint angle.
Worn or damaged CV joints Replace the CV joints.
Sticking spider assembly Lubricate or replace the inner CV joint.
(inner CV joint)
Sticking joint assembly Lubricate or replace the outer CV joint.
(outer CV joint)
Front Drive Axle Diagnosis (Vibration at Highway Speeds)

Checks Action
DEFINITION: Vibration occurs while driving the vehicle at highway speeds.
Out of balance or out of round tires Balance or replace the tires.
Front end out of alignment Align the front end.
Front Drive Axle Diagnosis (Front Drive Axle Leaks)

Checks Action
DEFINITION: Fluid leaks from the front drive axle.
Worn differential output seals Repair the seals.
Inspect the mating area between the Reseal the differential housing mating area with RTV sealant.
axle tube and the differential housing.
Inspect the vent hose connector. Replace the vent hose connector.
Four-Wheel-Drive Diagnosis (4WD Will Not Engage)

Checks Action
DEFINITION: Four wheel drive will not engage.
A blown fuse (A/C-HTR fuse) Replace the fuse.
Feed wire to transfer case Repair the open wire.
switch open
The transfer case switch is faulty. Replace the transfer case switch.
The wires to the front axle actuator Repair the open wiring.
are open.
The front axle actuator is faulty. Replace the axle actuator.
The axle is damaged internally. Repair the axle as necessary. Refer to Drive Axle Unit Repair in Driveline/Axle.
Four-Wheel-Drive Diagnosis (4WD Does Not Disengage)

Checks Action
DEFINITION: The four-wheel drive will not disengage.
The transfer case switch is faulty. Replace the transfer case switch.
The front axle actuator is faulty. Replace the actuator.
The internal axle is damaged. Repair the internal axle as necessary. Refer to Drive Axle Unit Repair in
Driveline/Axle.
Four-Wheel-Drive Diagnosis (Indicator Light Not Off)

Checks Action
DEFINITION: The four-wheel drive indicator light will not turn off.
The fr o n t a x le switch is faulty. Replace the front axle switch.
Four-Wheel-Drive Diagnosis (Indicator Light Not On)

Checks Action
DEFINITION: Four-wheel drive engages but the indicator light will not come on.
The bulb is burned out. Replace the bulb.
The front axle switch is faulty. Replace the front axle switch.
Electric Motor Actuator Check 2. Disconnect the actuator from the power source.
1. Apply 12-volt battery voltage to the actuator The plunger should retract within several
terminals. seconds.
The plunger should extend within several 3. If the actuator does not operate as specified,
seconds. replace the actuator.
Repair Instructions
Lubricant Change
Removal Procedure
equipped. Refer to Shield Replacement
2. Remove the fill plug (25).

3. Remove the drain plug (23) and the
washer (24).
4. Drain the fluid from the differential.
1. Install the washer (24) and the drain plug (23).
Tighten
Tighten the plug (27) to 33 N-m (24 lb ft).
and Notices.
2. Fill the differential. Refer to
Lubrication Specifications.
3. Install the fill plug (25).
Tighten
Tighten the plug (25) to 33 N-m (24 lb ft).
156568
4. Install the front differential carrier shield. Refer
to Shield Replacement
156585
Shield Replacement
Removal Procedure
2. Remove the front differential carrier shield.
1. Install the front differential carrier shield.
Tighten
and Notices.
156585
Indicator Switch Replacement

Removal Procedure
1. Remove the front differential carrier shield
(if equipped). Refer to Shield Replacement
2. Remove the electrical connector from the
indicator switch located on the upper right side
of the differential.
3. Remove the indicator switch.
1. Coat the indicator switch threads with sealer
GM P/N 1052942.
2. Install the indicator switch.
3. Install the electrical connector.
4. Install the front differential carrier shield
(if equipped). Refer to Shield Replacement.
Electric Motor Actuator Replacement

Removal Procedure
2. Remove the electrical connector from
the actuator.
3. Remove the electric motor actuator (10)
by unthreading.
156SB8
1. Coat the threads of the electric motor
actuator (10) with sealant GM P/N 1052942.
2. Install the electric motor actuator (10).
Tighten
Tighten the actuator to 20 N-m (15 lb ft)
Notice: Refer to Fastener Notice In Cautions
and Notices.
3. Install the electrical connector.
Vent Hose Replacement

Removal Procedure
2. Remove the clamp (3).
Important: Make note of the routing in order to
aid in reassembly.
3. Remove the vent hose (4) from the axle.
4. Remove the bolt (1).
5. Remove the clip (6).
6. Remove the vent hose (7).
1. Install the vent hose (4) to the vehicle.
• Route the same way as when removed.
• Make sure the hose is free of kinks and is
routed clear of sharp components.
• Make sure the vent is not plugged.
2. Install the clip (6).
3. Install the bolt (1) and the clamp (2).
4. Install the vent hose (4) to the axle fitting.
5. Install the clamp (3).
156604
Shift Fork Replacement

Removal Procedure
1. Remove the axle shaft (output shaft) and tube
assembly. Refer to Output Shaft, Bearing, and
Tube Replacement (Right Side).
2. Remove the shift shaft (12), damper spring
(13), fork (14) and clip (15) assembly.
3. Remove the spring (16) from the carrier case.
Take care not to dislodge the shim (20) from
the axle shaft (output shaft).
156588
1. Install the spring (16) into the carrier case.
2. Install the shift shaft (12), damper spring (13),
fork (14), and clip (15) assembly into the axle
tube. Make sure that the clip fully seats into the
groove on the shift lever.
3. Install the axle shaft (output shaft) and tube
156588
Shift Mechanism Inspection

1. Inspect the carrier connector for damaged
splines and teeth. Replace as required.
2. Inspect the shift fork for wear, scoring, and
damage to the thrust surfaces. Replace
as required.
3. Inspect the differential sleeve and the inner
output shaft for damaged splines and teeth.
Replace as required.
4. Inspect the damper spring for breakage.
5. Inspect the differential actuator and the
engagement switch for damage and
frayed wiring.
Output Shaft, Bearing, and Tube

Replacement (Right Side)
Rem oval Procedure
1. Raise the vehicle and support it using
safety stands.
Front Drive Axle Assembly Replacement
3. Drain the front axle. Refer to Lubricant Change.
4. Remove the electrical connectors (5).
5. Remove the axle shaft (output shaft) nut (6)
and washers (2).
6. Remove the axle shaft output shaft bolts (19)

from the carrier.
Im portant: Keep the open end of the tube up.
7. Remove the axle shaft (output shaft) tube from
the carrier.
156588
Tools Required
• J 29369-1 Bearing Remover (K2 models)
• J 29369-2 Bearing Remover (K3 models)
1. In a vise, hold the axle shaft (output shaft) tube
by the mounting flange.
2. Remove the sleeve (9).
3. Remove the gear (7).
4. Remove the thrust washer (6).
5. Remove the axle shaft (output shaft) (1). Tap
out the axle shaft with a soft mallet.
6. Remove the deflector (2). Pry out the deflector
with a screwdriver.
7. Remove the seal (3). Pry out the seal with
a screwdriver.
8. Remove the bearing (4). Use the J 29369-1 or
the J 29369-2 and a slide hammer.
9. Clean the parts in a suitable solvent.
10. Clean the gasket surfaces on the axle shaft
(output s h a ft) tube and carrier housing.
Assem bly Procedure
• J 36609 Bearing Installer
• J 36600 Axle Seal Installer (K2 Models)
• J 22833 Seal Installer (K3 Models)
1. Assemble the new bearing (4). Use
the J 36609.
2. Apply axle lubricant to the bearing.
3. Install the new seal (3). Use the J 36600 Axle
or the J 22833.
4. Coat the seal lips with grease.
5. Install the deflector (2).
6. Install the axle shaft (output shaft) (1).
7. Install the thrush washer (6).
8. Use grease in order to hold the thrust washer
in place.
9. Make sure the tabs on the washer align with
the slot in the axle shaft (output shaft) tube.
10. Install the gear (7).
11. Install the sleeve (9).
1. Apply sealant GM P/N 12345739 or equivalent
to the carrier sealing surface.
2. Install the axle shaft (output shaft) tube (5) to
the carrier.
3. Install the bolts (19).
Tighten
and Notices.
4. Install axle shaft (output shaft) tube washers (2)

and the nuts (6) to the frame.
Tighten
• Tighten the nuts of K2 models to
100 N-m (75 lb ft).
• Tighten the nuts of K3 models to
145 N.m (106 lb ft).
Drive Axle Assembly Replacement
6. Install electrical connectors (5).
7. Fill the front axle. Refer to Lubricant Change.
Axle Shaft and Seal Replacement

Rem oval Procedure
Tools Required
• J 23907 Puller/Slide Hammer/Clutch Pilot
Bearing Remover.
2. Support the vehicle with jack stands.
Front Drive Axle Assembly Replacement.
5. Remove the axle shaft (output shaft) (19).
Important: Do not damage the case.
6. Attach a slide hammer with adapter to the axle
shaft (output shaft) and pull the axle shaft from
the case.
7. Remove the deflector (28).
8. Remove the seal (26).
9. Remove the bearing (21). Use the J 23907.
Tools Required
• J 23907 Puller/Slide Hammer/Clutch Pilot
Bearing Remover.
• J 22761 Differential Side Bearing Installer
Important: You may need to attach 1/2 inch by
13 inch long extension handle onto the slide hammer
for easier pulling of the bearing.
1. Install the bearing with the square shoulder in.
Use the J 22761.
2. Lubricate the new seal (26) lips with grease.
3. Install the new seal (26). Use the J 36600
or J 22833.
4. Install the deflector (28).
5. Install the axle shaft (output shaft) (19).
6. Carefully tap the axle shaft (output shaft) (19)
into place with a soft mallet.
Drive Axle Assembly Replacement.
Differential Pilot Bearing Replacement
Rem oval Procedure
Tools Required
• J 340011 Differential Pilot Bearing Remover
Pilot Bearing Remover
• J 33842 Pilot Bearing Installer
1. Remove the axle shaft (output shaft) and tube
2. Remove the shim (20).
3. Remove differential pilot bearing (21). Use the
J 340011 Differential Pilot Bearing Remover.
156588
1. Install the shim (20).
2. Install the differential pilot bearing (21). Use
the J 33842.
3. Lubricate the bearing with axle lubricant.
4. Install the axle shaft (output shaft) and tube
156588
Pinion, Flange, and Dust Deflector

Replacement
Rem oval Procedure
Tools Required
• J 8614-01 Companion Flange Holder and
Remover
• J 36366 Seal Installer
2. Remove the propeller shaft from the axle. Refer
to Propeller Shaft Replacement (Front Drive).
3. Tie the propeller shaft to a frame rail
or crossmember.
4. Measure the torque required to rotate the
pinion. Record the torque value for reassembly.
5. Scribe a line (1) on the pinion stem, pinion nut

and the companion flange (2) and record the
number of exposed threads on the pinion stem.
156435
6. Remove the nut. Use the J 8614-01.
7. Position the J 8614-01 on the flange so that the
four notches on the tool face the flange.
9225
8. Remove the flange. Use the J 8614-01. Use the

special nut and forcing screw.
Important: Carefully pry the seal from the bore.
Do not distort or scratch the aluminum case.
9. Remove the oil seal.
10. Inspect the pinion flange for a smooth oil
seal surface.
11. Inspect the pinion flange for worn drive splines.
12. Replace the pinion flange if necessary.
13. Remove the dust deflector.
• Tap the deflector from the flange.
• Clean up the stake points on the flange.
157175
Tools Required J 36366
• J 8614-01 Companion Flange Holder and
Remover
Important: Stake the new deflector at three new
equally spaced positions. You must stake the new
deflector in such a way that you do not damage the
seal operating surface.
1. Install the dust deflector on the flange.
Important: Position the oil seal in the bore,
then place the J 36366 over the oil seal. Strike
the J 36366 with a hammer until the seal flange
seats on the axle housing surface. Drive the
seal in straight, not at an angle, as this will
damage the aluminum housing.
2. Install the oil seal. Use the J 36366.
156671
Notice: Do not hammer the pinion flange onto the
pinion shaft or the pinion flange may be damaged.
3. Install the flange onto the pinion using
the J 8614-01.
4. Place the washer and a new nut on the pinion
threads and tighten the nut to the original
scribed position using the scribe marks and
exposed threads as reference.
5. Measure the rotating torque of the pinion and
compare this with the rotating torque
recorded earlier.
Tighten
Tighten the pinion nut by small increments until
the torque required to rotate the pinion is
0.35 N.m (3 lb in) greater than the original torque.
and Notices.
6. Install the propeller shaft. Refer to Propeller
Shaft Replacement (Front Drive).
Differential Carrier Bushing Replacement
Rem oval Procedure
Tools Required
J 36616 Bushing Remover and Installer
1. Remove the carrier. Refer to Differential Carrier
Assembly Replacement
2. Remove the carrier bushing. Use the J 36616.
156679
1. Install the carrier bushing. Use the J 36616.
2. Install the carrier. Refer to Differential Carrier
Differential Carrier Assembly Replacement

Removal Procedure
1. Raise the vehicle and support with jack stands.
3. Remove the front propeller shaft at the carrier
yoke. Refer to Propeller Shaft Replacement
(Front Drive).
4. Wire the propeller shaft out of the way.
5. Remove the left and right drive axle
(halfshaft). Refer to Front Drive Axle
Assembly Replacement.
6. Remove the screws (1), nuts (6), and
washers (2).
7. Remove the wiring at the axle (5).
8. Remove the vent hose at the axle. Refer to
9. Remove the carrier lower mounting bolt.
10. Remove the right side inner tie rod end from
the relay rod. Refer to Steering Linkage in
Steering, Suspension, Tires and Wheels.
11. For some models, remove the engine oil filter.
12. Attach a transmission jack to the carrier (5).
13. Remove the upper carrier mounting bolt (6).
14. Remove the carrier from the vehicle.
installation Procedure
1. Install the carrier to the vehicle.
2. Install the carrier mounting bolts (6), nuts (2)
and washers (3).
Tighten
and Notices.
3. Remove the transmission jack.
4. Install the new engine oil filte r if your model
required that you remove the engine oil filter.
5. Install the tie rod. Refer to Steering Linkage in
Steering Suspension Tires and Wheels.
6. Install the axle tube bolts (1), nuts (6), and

washers (2).
Tighten
• For K2 models tighten the nuts to
100 N-m (75 lb ft).
• For K3 models tighten the nuts to
145 N-m (106 lb ft).
7. Install the vent hose. Refer to Vent
Hose Replacement.
8. Install the wiring.
9. Install the left and right drive axle
(halfshaft). Refer to Front Drive Axle
10. Install the front propeller shaft to the
carrier yoke.
Tighten
Tighten the universal joint clamp bolts to
20 N.m (15 lb ft).
12. Add engine oil as necessary. Refer to
Maintenance and Lubrication in
Front Drive Axle Assembly Replacement
Rem oval Procedure
Tools Required
• J 24319-01 Steering Linkage Puller
• J 36605 Front Knuckle Seal Installer
• J 36607 Upper Bail Joint Separator
• J 29193 Steering Linkage Installer (12 mm)
1. Raise the vehicle and support it with
safety stands.
2. Insert a drift or large screwdriver through the
brake caliper into one of the brake rotor vanes
in order to prevent the drive axle (halfshaft)
from turning.
3. Remove the wheel and tire assembly.
1932
4. Remove the drive axle (halfshaft) hub nut (2)

and washer (3).
5. Loosen, but do not remove, the 6 bolts (1)
securing the inboard C/V joint drive flange to
the output shaft companion flange.
6. Wrap shop towels around both the inner and
outer C/V joint boots in order to avoid damage
to the boots during removal and installation.
156607
7. Remove the wheel speed sensor wire support
bracket (2) from the upper control arm (1) in
order to allow extra travel of the knuckle
(all K-models).
156608
8. Remove the wire and the brake line support

brackets (2) from the knuckle on 8600# and
heavier GVWR.
Important: Do not reuse the nut.
9. Remove the prevailing torque nut from the
outer tie rod.
Notice: Do not disengage the joint by driving a

wedge-type tool between the joint and the knuckle.
This may cause seal damage.
10. Separate the outer tie rod ball stud from the
steering knuckle. Use the J 24319-01.
11. Push the linkage to the opposite side of the
vehicle and secure the outer tie rod up and out
of the way which will provide the needed
clearance in order to remove the drive
axle (halfshaft).
8996
12. Remove the lower shock mounting nut,
washers, and bolt.
13. Collapse the shock absorber and secure
if necessary.
14. Remove the stabilizer shaft components

as follows:
14.1. Remove the stabilizer shaft bushing
and bracket.
14.2. Remove the stabilizer shaft bolt,
spacer, and nut assembly at the lower
control arm.
Notice: This is required on K vehicles
with 8050 lb and below GVW rating in
order to provide needed clearance for
drive axle (halfshaft) removal.
Caution: The floor jack or stand must
remain under the control arm while servicing
the drive axle (halfshaft) In order to maintain
torsion bar and control arm position. Failure
to do so could result In personal Injury.
15. Position the floor jack or stand behind the
steering knuckle.
16. Remove the cotter pin from the upper control

arm ball joint stud.
17. Loosen (do not remove at this time) the stud
nut on the upper ball joint stud.
18. Loosen the stud from the knuckle using
the J 36607.
19. Remove the nut.
20. Remove the stud from the knuckle.
Important: Cover the shock mounting bracket
and the ball stud on the lower control arm with
a shop towel in order to prevent possible drive
axle (halfshaft) boot damage during removal
and installation.
21. Remove the knuckle assembly using a hammer
and brass drift or equivalent in order to
separate the outer CN joint splined shank from
the knuckle hub.
1943
22. Remove the six bolts (1) from the inboard
joint flange.
• Support the inboard end of the drive
axle (halfshaft).
• Move the knuckle and hub assembly outward
in order to free the splined shank from
the hub.
23. Remove the drive axle (halfshaft) from
the vehicle.
24. For unit repair of the drive axle (halfshaft), refer
to Drive Axle Unit Repair in Driveline/Axle.
Important: Wipe the wheel bearing seal area
on the knuckle clean.
25. Inspect the seal for cuts or tears.
26. Lubricate the seal lip.
27. If the seal is cut or torn, inspect the wheel
bearing for damage and replace the seal.
28. Do the following in order to replace the seal:
• Pry the old seal from the knuckle.
• Discard the old seal.
• Lubricate the new seal lip.
• Use the J 36605 in order to install the seal
into the knuckle.
1. Prior to drive axle (halfshaft installation, cover
the shock mounting bracket, lower control arm
ball stud, and all other sharp edges with shop
towels so that the drive axle (halfshaft) boot is
not damaged during assembly.
Important: Do not lubricate the drive axle
(halfshaft) splines and knuckle with grease.
2. Insert the outer C/V joint splined shank into the
knuckle hub and secure the inboard C/V joint
flange to companion flange with bolts. Do
not tighten.
3. Install the upper ball joint to the
steering knuckle.
4. Install the stud nut.
Tighten
Tighten the stud nut to 100 N-m (75 lb ft).
and Notices.
5. Install the cotter pin.
6. Lubricate the upper ball joint until grease
appears at the seal.
7. Install the stabilizer shaft bushing, bracket,
and bolts.
Tighten
Tighten the bolts (5) to 33 N.m (24 lb ft).
8. Install the stabilizer shaft link bolt assembly,
spacer, and nut assembly.
Tighten
Obtain torque by running the nut assembly to
the unthreaded portion of the bolt, then tighten
to 18 N.m (13 lb ft).
9. Remove the floor jack or stand from the
beneath the lower control arm.
10. Install the shock absorber to the lower shock
mounting bracket.
11. Install the shock mounting bolt, washer,
and nut.
Tighten
12. Install the outer tie rod to the steering knuckle
using the J 29193.
Tighten
Tighten the tool to 54 N.m (40 lb ft).
13. Install the new outer tie rod prevailing
torque nut.
Tighten
14. Install the brake pipe support bracket to the
upper control arm.
Tighten
Important: Make sure that the brake hose is
not twisted or kinked, or damage to the hose
could result.
15. Install the brake pipe support bracket to the
upper control arm.
Tighten
16. Install the hub nut washer (3) and the nut (2).
17. Seat the shank splines in the hub.
18. Insert a drift through the brake caliper in order
to prevent the drive axle from turning.
Tighten
Tighten the inboard flange bolts to 78 N.m
(58 lb ft).
19. Install the hub nut.
Tighten
Tighten the hub nut to 225 N.m (165 lb ft).
20. Remove the drift.
21. Install the wheels.
Differential Carrier Overhaul

Inspection Procedure
Perform the following checks before disassembling
the axle:
1. Remove the drain plug from the axle.
Drain the axle lubricant.
2. Check the ring gear backlash. Refer to
Backlash Inspection and Adjustment.
This information can be used to determine the
cause of the axle problem. The information will
also help when setting up the shim packs for
locating and preloading the differential case.
3. Inspect the case for metal chips.
Determine the source of the metal chips, such
as a broken gear or bearing cage.
4. Determine the cause of the axle problem before
disassembly, if possible.
206820
Tools Required
• J 29369-1 Bearing Remover (T, K1 and
K2 Models)
• J 29369-2 Bearing Remover (K3 Models)
• J 29307 Slide Hammer
• J 34011 Pilot Bearing Remover
• J 36699 Adjusting Sleeve Wrench
• J 36615 Adjuster Plug Wrench (K3 Models)
• J 6614-01 Pinion Remover
• J 36598 Holding Fixture and Pinion Service Tool
• J 8612-B Pinion Bearing Remover (T, K1 and
K2 Models)
• J 36606 Inner Pinion Bearing Remover Pinion
Bearing Remover (K3 Models)
• J 22888 Side Bearing Puller
• J 8107-2 Side Bearing Puller Pilot (T, K1 and
K2 Models)
• J 36597 Side Bearing Puller Pilot ( K 3 ) Side
Bearing Puller Pilot (K3 Models)
• J 36616 Bushing Replacer
• J 2619-01 Slide Hammer
• J 36598 Holding Fixture Holding Fixture
1. Remove the differential actuator.
2. Remove the engagement switch.
4. Remove the axle tube with the right output
shaft.
5. Remove the differential sleeve.
• The shift shaft
• The damper spring
• The shift fork
• The shifter shaft ring
7. Remove the spring.
8. Remove the shim.
9. For the T, K1, and K2 models, remove the
carrier connector with the retainer ring.
9.1. Clamp the axle tube in a vise.
Clamp only on the mounting flange.
9.2. Strike the inside of the shaft flange with
a brass hammer in order to dislodge the
carrier connector.
10. For the K3 models, remove the following parts:
• The snap ring
• The washer
• The thrust washer
11. Remove the right output shaft.
205896
12. Remove the seal and the output shaft bearing.
• For the T, K1, and K2 models, use
the J 29369-1.
• For the K3 model, use the J 29369-2 or
the J 29307.
13. Remove the output shaft.
14. Use the J 34011 in order to remove the

differential pilot bearing.
9106
15. Use the J 2619-01 in order to remove the left

output shaft.
16. Remove the seal.
Pry the seal out with a removal tool.
9107
17. Remove the bearings.
• For the T, K1, and K2 models, use
the J 29369-1.
• For the K3 model, use the J 29369-2 or
the J 29307.
19. Remove the right side carrier half.

Tap on the cast lugs provided.
20. Remove the differential assembly.

Pry up on the locks.
Pry the right side only on the K3 model.
21. For the K3 model, remove the bolt and
the lock.
205918
22. Remove the sleeve(s) and the side
bearing cups.
• Turn the sleeve(s) in order to push the
bearing cup(s) out of the bore(s).
• Use the J 36599.
• For the K3 model, remove the sleeve(s) and
side bearing cups only from the right side.
23. For the K3 model, use the J 36615 in order to

remove the adjuster plug with the side bearing
cup and the O-ring seal.
205912
24. Remove the nut.

Use the J 8614-01 in order to hold the
pinion flange.
26. Use the J 8614-01 in order to remove the
pinion flange with the deflector.
9225
27. Mount the left carrier case in the J 36598.

For the T, K1, and K2 models, use the adapter
plate J 36598.
28. Use the J 36598 in order to remove the ring
and pinion with the following parts:
• The shim
• The bearing cone
• The spacer
29. Remove the spacer from the pinion.
30. Remove the pinion bearing.

• For the T, K1, and K2 models, use the
J 8612-B.
• For the K3 model, use the J 36598 Holding
Fixture and a press.
31. Remove the shim.

following parts: J 36598 - 6
• The seal
• The bearing cup
• The cone
206863
bearing cup.
34. Remove the side bearings.

J 22888 and the J 8107-2.
• For the K3 model, use the J 36597 Side
Bearing Puller Pilot ( K3 ) and a press.
Notice: Do not pry the ring gear from the case.
This will damage the ring gear and the
differential case.
35. Remove the ring gear bolts.
The ring gear bolts have left-handed threads.
36. Remove the ring gear from the differential case.

Drive the ring gear off with a brass drift.
206947
37. For the T, K1, and the K2 models, remove
the pin.
Use a drift and a hammer in order to drive out
the pin.
/ ( ^ ✓ ] r^vvJ
wI
168052
38. For the K3 model, remove the bolt.

39. Remove the shaft. =l
40. Remove the differential pinion gears and the

side gears.
40.1. Roll the pinion gears out of the case with
the pinion thrust washers.
40.2. Remove the side gears and the side
gear thrust washers.
Mark the gears and the differential case
as left and right.
40.3. For the K3 model, remove the spacer.
41. Remove the vent plug.
Use a 6-point deep socket.
206945
42. Use the J 36616 in order to remove

the bushings.
Thoroughly and carefully inspect all of the drive units
before assembly. Thorough inspection of the parts
for wear or stress and replacement of worn parts will
help prevent costly drive component repair after
the reassembly.
Axle Housing Inspection
1. Inspect the axle housing bore for nicks or burrs
that would prevent the outer diameter of the
pinion seal from sealing. Remove any burrs.
2. Inspect the bearing cup surfaces for nicks or
burrs. Remove any burrs.
3. Replace the housing if any cracks are found.
4. Inspect the housing for the following materials:
• Metal chips
• Dirt
• Rust
5. If the above materials are found, refer to
Cleaning Carrier Components.
D ifferential Inspection
1. Inspect the pinion gear shaft for unusual wear.
2. Inspect the pinion gear and the side gear teeth
for the following conditions:
• Wear
• Cracks
• Scoring
• Spalling
3. Inspect the thrust washers for wear.
4. Inspect the fit of the differential side gears in
the differential case.
5. Inspect the fit of the side gears on the
axle shafts.
6. Inspect the differential case for cracks
and scoring.
7. Inspect all the parts for wear. Replace
as necessary.
Differential Assembly Installation
Tools Required
• J 36612 Bearing Installer (T, K1, and
K2 models)
• J 36613 Bearing Installer Bearing Installer
(K3 model)
• J 36513 Driver Handle
• J 36599 Sleeve Adjusting Wrench
• J 36615 Adjuster Plug Wrench (K3 model)
• J 36603 Side Bearing Cup Installer
1. For the T, K1, and K2 models, use the J 36513
and the J 36612 in order to install the bearings
to the sleeves.
2. For the K3 model, use the J 36613 Bearing
Installer in order to install the adjuster plug.
3. For the K3 model, install the new O -ring seal
210226 to the adjuster plug.
4. For the T, K1, and K2 models, use the and the
J 36599 in order to install the sleeves to the
carrier case.
install the right sleeve to the carrier case.
Use the J 36599 in order to install the
adjuster plug.
6. Use the J 36603 with the J 36513 in order to
install the side bearing cups.
7. Install the differential assembly to the carrier

case half.
• Place the differential assembly into the
carrier case half which contains the
pinion gear.
• For T, K1, and K2 models, use the J 36599
in order to turn the left sleeve in until the
backlash is felt between the ring and
the pinion.

turn the adjuster plug in until the backlash is
felt between the ring and the pinion.
9. Remove the carrier case from the J 36599
10. Install the carrier case halves.
Do not use sealer at this time.
If the carrier halves do not make complete
contact, use the J 36599 in order to back out
the right sleeve.
Tighten
205912
Cleaning Carrier Components 6. Inspect the sealing surface of the pinion flange
for nicks, burrs, or rough tool marks which will
Cleaning Procedure damage the inside diameter of the pinion seal
1. Do not steam-clean the drive parts having and result in an oil leak.
found and polished the following surfaces: 7. Inspect all of the parts for wear and replace
• The gears as necessary.
• The bearings Bearings Inspection
• The shafts
Important:
2. Disassemble all of the parts before cleaning.
• When replacing the worn or cracked bearings
3. Clean the parts in a suitable solvent. and the cups, replace the bearings in sets.
4. Dry the parts immediately after cleaning. • The low mileage bearings may have very small
• Use soft, clean, lintless rags. scratches and pits on the rollers and the
• Parts may be dried with compressed air. bearing cups from the initial preload.
• Do not allow the bearings to spin while Do not replace a bearing for this reason.
drying them with compressed air. 1. Inspect the bearings for smooth rotation
after oiling.
Ring and Pinion Gear Inspection
2. Inspect the bearing rollers for wear.
1. The ring and pinion gears are matched sets
and must be replaced any time a replacement 3. Inspect the bearing cups for the
of either is necessary. following conditions:
2. Inspect the pinion and the ring gear teeth for • Wear
the following conditions: • Cracks
• Cracking • Brinefling
• Chipping • Scoring
• Scoring Thrust Washers, Shims, and Adjuster
• Excessive wear Sleeves
3. Inspect the pinion gear splines for wear. 1. Inspect the shims and the thrust washers for
4. Inspect the pinion flange splines for wear. cracks and chips.
5. Inspect the fit of the pinion flange on the The damaged shims should be replaced with
pinion gear. an equally sized service shim.
2. Inspect the adjuster sleeves for damaged
threads. Replace if required.
Pinion Bearing Cup Installation

Tools Required
• J 36698 Holding Fixture and Pinion Service Tool
• J 36598 Holding Fixture Adapter Plate (T, K1,
K2 models)
Important: At assembly, apply axle lubricant to all of
the following parts:
• The bearings
• The seal lips
• The gears
• The thrust washers
• The bearing surfaces
1. Mount the left carrier case in the J 36698.
For the T, K1, and K2 models, use the J 36598
adapter plate.
2. Tighten the attaching bolts securely.
3. Install the outer bearing cup.
forcing screw and the J 36598
Holding Fixture.
• For the K3 model, use the J 36598
Holding Fixture.
4. Install the inner bearing cup.
4.1. Remove the J 36598 Holding Fixture or
the J 36598 Holding Fixture from the
forcing screw.
4.2. Place the pilot J 36598 Holding Fixture in
the pinion seal bore.
4.3. Extend the forcing screw through the
pinion bore.
4.4. For the T, K1, and K2 models, install
the J 36598 Holding Fixture on the
forcing screw.
For the K3 model, install the J 36598
Holding Fixture on the forcing screw.
4.5. Rotate the forcing screw until the installer
is snug against the bearing cup.
4.6. Rotate the tool several times in order to
ensure the bearing cup is not cocked in
the bore.
206943
5. Pull the bearing cup into place with the
forcing screw.
Pinion Depth Adjustment

• J 36601 Pinion Depth Setting Gauge
• J 29763 Dial Indicator
• J 21777-40 Pinion Setting Gauge Set
1. The pinion depth is adjusted by selecting a
shim of the proper thickness.
2. Lubricate the pinion bearings liberally with
axle lubricant.
3. For the T, K1, and K2 models, assemble the
J 29763 to the proper gauging arm.
4. For the K3 model, assemble the J 29763 to the
proper gauging arm.
5. Install the pinion bearings and hold them
in place.
6. For the T, K1, and K2 models, insert the
threaded rod of the J 36601 through the
pinion bearings.
206851 7. Install the proper pilot, washer, and nut.
8. Tighten the nut while holding the threaded
rod with a wrench in order to adjust
bearing preload.
8.1. Adjust the nut in order to obtain a
preload of 1.0-1.6 N.m (10-15 lb in)
using an inch pound torque wrench.
8.2. Rotate the shaft several times in order to
ensure that the bearings are seated.
8.3. Take another measurement.
9. Push the dial indicator downward until the
needle rotates about 3/4 turns.
10. Tighten the dial indicator in this position.
11. Set the button of the J 36601 on the differential
bearing bore.
12. Rotate the tool slowly back and forth until the
dial indicator reads the lowest point of the bore.
12.1. Set the dial indicator to ZERO.
12.2. Repeat the rocking action to the tool in
order to verify the ZERO setting.
206853
13. After the ZERO setting is obtained and verified,
grasp the gauging arm by the flats and move
the tool button out of the differential side
bearing bore.
14. Record the dial indicator reading.
Notice: Proper pinion depth setting is a tw o-step

procedure. Both procedures must be performed to
ensure the proper axle performance and prevent
system damage.
15.1. Setup dimension arrived at with the
indicator is to be considered a
starting point.
15.2. Gear tooth pattern check is necessary to
fine tune the pinion depth and may
indicate addditional shim changes to the
pinion stem.
15.3. The dial indicator reading is equal to the
required shim size.
16. Remove the tool and the bearing cones.
Pinion Installation
• J 35512 Bearing Installer (T, K1, and
K2 Models)
• J 36614 Bearing Installer (K3 Models)
• J 8614-01 Pinion Flange Remover
1. Install the shim to the pinion gear.
Use the proper size shim.
in order to install the bearing onto the
pinion gear.
install the bearing onto the piston gear.
4. Install the new spacer onto the pinion gear.
210203
5. Install the bearing into the case.
J 36366 6. Install the seal into the case using the J 36366.
7. Install the pinion gear, with the bearing and the
spacer, to the case.
156671
8. Install the deflector, the flange, the washer and

the nut using the following procedure:
• Apply PST Sealant GM P/N 1052080 or the
equivalent, to the pinion gear threads and on
both sides of the washer.
• Tighten the nut until no end play is
detectable while holding the flange with
the J 8614-01.
• No further tightening should be attempted
until the bearing preload has been checked.
9225
9. Measure the pinion bearing preload.

9.1. Use an inch-pound torque wrench.
The correct preload is 1.7-2.8 N-m
(15-25 lb in).
9.2. Rotate the pinion witht he torque wrench
and note the reading.
9.3. If the preload torque is below
specifications, continue torquing the
pinion nut in small increments. Check the
preload after each tightening.
Each tightening will increase the bearing
preload by several inch pounds.
If the bearing preload is exceeded, the
pinion will have to be removed, and a
new collapsible spacer installed.
9.4. Once the preload has been obtained,
rotate the pinion several times in order to
ensure the bearings are seated.
9.5. Recheck the preload, and adjust
as necessary.
Differential Case Assembly Assemble

Tools Required
• J 22761 Side Bearing Installer (T, K1, and
K2 models)
• J 29710 Side Bearing Installer (K3 model)
1. Install the thrust washers and the side gears
into the differential case.
If the same gears and the washers are being
used, install the gears and washers to the
original locations.
2. Install the pinion gears.
• Position one pinion gear between the
side gears.
• Rotate the gears until the pinion gear is
directly opposite the opening in the case.
• Place the other pinion gear between the
206945
side gears.
Line up the hole in both pinion gears.
3. Install the thrust washers.
Rotate the pinion gears toward the opening
in order to permit the sliding in of the
thrust washers.
4. For the T, K1, and K2 models, install the shaft
and pin.
5. For the K3 models, install the bolt.
6. Install the ring gear onto the differential case.
Important: Install new bolts. Do not reuse the
old bolts.
The bolts have left hand threads.
Tighten
Tighten the bolts alternating in progressive
steps to 120 N.m (88 lb ft).
in order to install the side bearings.
install the side bearings.
210219
Carrier Case Assembly

1. Bend the lock over the sleeves.
For the K3 model, bend the lock over the
sleeves on the right side.
2. For the K3 model, install the bolt and the lock.
Removal Procedure
2. Remove the right carrier case half.
3. Clean the carrier case and the axle tube
sealing surfaces.
Remove all the grease and the oil.
205917
• J 36600 Axle Output Shaft Seal Installer
(K1, K2 models)
• J 22833 Output Shaft Seal Installer (K3)
• J 33842 Pilot Bearing Installer
• J 36616
Bushing Replacer Set
1. Apply a bead of sealer GM P/N 105942 or
the equivalent to one carrier case half
sealing surface.
2. install the right carrier case half.
Tighten

Axle in order to install the left seal. Drive the J 36600
seal into place with a soft faced hammer. J 22833
install the left seal. Drive the seal into place
with a soft faced hammer.
6. Install the shaft.
Drive in place with a brass hammer.
210234
7. Use the J 33842 in order to install the bearing

to the output shaft.
8. Install the output shaft to the carrier.
7796
9. Install the vent plug.
Use a small amount of sealer GM P/N 105942
or the equivalent on the threads.
10. Use the J 36616 in order to install

the bushings.
Backlash Inspection and Adjustment

Tools Required
J 8001 Dial Indicator Set
1. Use the J 36599 in order to tighten the
right sleeve.
Tighten
Tighten the right sleeve to 140 N.m (100 lb ft).
and Notices.
205910
in order to tighten the left sleeve.
Tighten
Tighten the left sleeve to 140 N-m (100 lb ft).
tighten the adjuster plug.
Tighten
Tighten the adjuster plug to 140 N-m (100 lb ft).
4. Mark the location of the adjusting sleeves in
relation to the carrier halves.
Ensure that the notches in the adjusting
sleeves can be counted when turned.
5. Turn the right sleeve OUT two notches.
6. For the T, K1, and K2 models, turn the left
sleeve in one notch.
7. For the K3 model, turn the adjuster plug in
one notch.
8. Rotate the pinion several times in order to seat
the bearings.
Measuring Backlash
1. Install a dial indicator so the button contacts
the outer edge of the pinion flange.
Ensure that the plunger is at a right angle to
the pinion flange.
2. Move the pinion flange through the pinion
flange’s free play while holding the
differential carrier.
Record the dial indicator reading.
3. Divide the dial indicator reading by 2 in order
to obtain the actual backlash when using
this method.
A dial indicator reading of 0.16 mm means that
there is actually 0.08 mm backlash.
4. In order to adjust the backlash, use the
following procedure:
• The gear backlash should be between
0.08-0.25 mm (0.0003-0.010 in) with a
7833
preferred specification of 0.13-0.18 mm
(0.005-0.007 in).
• If the backlash is incorrect, adjust the
sleeves as necessary. Always maintain the
one notch preload on the side bearings.
Example: If necessary to turn the right sleeve
in one notch, then turn the left sleeve out
one notch.
• In order to increase the backlash, turn the
left sleeve in and turn the right sleeve out an
identical amount.
• In order to decrease the backlash, turn the
right sleeve in and turn the left sleeve out an
identical amount.
• Changing the sleeves one notch changes the
backlash about 0.08 mm (0.003 in).
Gear Tooth Contact Pattern Check 3. Using a torque wrench, apply a load until a
torque of 62 N-m (45 lb ft) is required to turn
Before the final assembly of the differential, a gear
the pinion.
tooth contact pattern check should be performed.
• A test that is made without loading the gears
A gear tooth contact pattern check is NOT a
will not give a satisfactory pattern.
substitute for adjusting the pinion depth and the
backlash. The gear tooth contact pattern check is a • Turn the companion flange with a wrench so
final check in order to verify the correct running that the ring gear rotates one full revolution.
position of the ring gear and the drive pinion. Any • Then reverse the rotation so that the ring
gear sets which are not aligned properly may be gear rotates one revolution in the
noisy and have a short life. With a pattern check, opposite direction.
the best contact between the ring gear and the • Excessive turning of the ring gear is
drive pinion for low noise level and long life can not recommended.
be ensured.
4. Observe the pattern on the ring gear teeth.
Gear Tooth Terms Refer to Gear Tooth Contact Pattern Check in
Rear Drive Axle.
Adjustments Affecting Tooth Contact
There are two adjustments, backlash and pinion
depth, which will affect the tooth contact pattern. The
effects of the bearing preloads are not easily seen
on hand loaded teeth pattern tests. Make the
adjustments within specifications before proceeding
with the backlash and the drive pinion adjustments.
Adjust the pinion depth and the backlash as
necessary, in order to obtain the correct pattern.
The pinion depth is adjusted by increasing or
decreasing the shim thickness between the pinion
head and the inner race of the rear bearing. The
shim is used in the differential in order to
compensate for the manufacturing tolerances.
Increasing the shim thickness will move the pinion
closer to the centerline of the ring gear.
The backlash is adjusted by means of the side
bearing adjusting sleeves which move the entire
case and the ring gear assembly closer to, or farther
The side of the ring gear tooth which curves from the drive pinion. The adjusting sleeves are also
outward, or is convex, is the DRIVE side (4). The used in order to set side the bearing preload. In
concave side is the COAST side (3). The end of the order to increase the backlash, turn the left sleeve in
tooth nearest center of the ring gear is the TOE and turn the right sleeve out an identical amount. In
end (2). The end of the tooth farthest away from the order to decrease the backlash, turn the right sleeve
center is the HEEL end (1). The toe end of the tooth in and turn the left sleeve out an identical amount.
is smaller than the heel end. The contact pattern must be centrally located up and
Test down on the face of the ring gear teeth.
1. Wipe the oil out of the carrier.
Carefully clean each tooth of the ring gear.
2. Apply gear making compound sparingly to all
ring gear teeth using a medium stiff brush.
When properly used, the area of pinion
tooth contact will be visible when hand load
is applied.
Axle Tube Assembly

Assembly
Tools Required
• J 36609 Bearing Installer
• J 36600 Seal Installer (T, K1, and K2 models)
• J 36609 Seal Installer (K3 model)
1. Use the J 36609 in order to install the bearing.
Drive into place with a hammer.
in order to install the seal.
3. For the K3 models, use the J 36609 in order to

install the seal.
4. Install the shaft to the axle tube.

5. Install the washer. Align the tabs with the slots
in the tube.
6. For the T, K1, and K2 models, install the gear
with the retaining ring.
Drive the gear into place with a plastic hammer.
206820
7. For the K3 model, install the washer and the
new snap ring.
Ensure the snap ring is properly seated in
the groove.
Output Shaft Shim Selection

Tools Required
J 34672 Depth Gauge
1. Select the proper size output shaft shim if any
of the following parts were replaced:
• The shaft
• The axle tube
• The output shaft
• The carrier case
• The ring and pinion gears
• The differential case
• The bearings
• For T, K1, and K2 models, the carrier
connector
2. Push on the inner end of the shaft, and move
the shaft outboard as far as it will go. The shaft
206848 must be in this position when measuring
dimension A.
3. Use the J 34672 in order to measure
dimension A.
• For the T, K1, and K2, install the tube flange
machined surface to the inner surface of
the connector.
• For the K3, install the tube flange machined
surface to the inner surface of the axle
shaft shoulder.
206836
4. Measure the dimension B.
Install the carrier machined surface to the outer
surface of the output shaft.
5. Subtract the dimension A from the dimension B.
6. The correct shim size will be one size smaller
than the figure obtained in the previous step.
Note the following examples:
• If the figure obtained in step 5 was 3.53 mm,
use a 3.30 mm shim.
• For the T, K1, and K2 models, if the figure
obtained in step 5 was 3.30 mm, use a
2.70 mm shim.
• For the K3 model, if the figure obtained in
step 5 was 3.30 mm, use a 2.80 mm shim.
7. For the T, K1, and K2 models, shims are
available in the following sizes:
• 1.27 mm
• 1.78 mm
• 2.29 mm
• 2.70 mm
• 3.30 mm
• 3.81 mm
8. For the K3 models, shims are available in the
following sizes:
• 1.80 mm
• 2.30 mm
• 2.80 mm
• 3.30 mm
• 3.80 mm
• 4.30 mm
• 4.80 mm
Alternate Method
Tools Required
J 8001 Dial Indicator
Important: Use this method only if the proper tools
for calculating the shim size are unavailable.
1. Install the original shim to the shaft.
Use the chassis grease in order to hold the
shim in place.
2. Install the assembled axle tube and the shaft to
the carrier.
Do not use sealer at this time.
Tighten
4. Measure the shaft end play using the
4.1. Install the J 8001 or the equivalent on
the axle tube end.
The plunger of the indicator must be at a
right angle to the axle flange.
4.2. Move the shaft back and forth and read
the end play.
The correct end play is 0.03-0.51 mm
(0.001-0.020 in).
4.3. If the end play is incorrect, install a
thicker or thinner shim as needed in
order to bring the end play into the
specified range.
4.4. Install the bolts.
4.5. Install the axle tube assembly.
Differential Carrier Final Assembly
1. Clean the sealing surfaces of the tube and the
carrier assembly.
Remove all the oil and the grease.
2. Install the shim to the output shaft.
Hold the shim in place with grease.
3. Install the sleeve.
4. Install the spring.
5. Install the following parts to the carrier case:
• The shift shaft
• The damper spring
The damper spring fits into the shift
fork indentation.
• The shift fork
• The clip assembly
Ensure that the clip is seated in the groove
of the shift shaft.
6. Apply a bead of sealer GM P/N 1052942 or the
equivalent to the tube sealing surface.
7. Install the assembled tube to the
carrier assembly.
Tighten
9. Inspect the shift mechanism operation.
9.1. Insert a drift into the actuator hole in the
axle tube.
9.2. Rotate the axle flange while moving the
shift fork with the drift.
9.3. The shift mechanism should work
smoothly, without binding.
10. Install the actuator.
Apply the sealer GM P/N 1052942 or the
equivalent to the threads.
11. Install the switch.
Apply the sealer GM P/N 1052942 or the
equivalent to the threads.
12. Install the axle lubricant, as specified.
13. Install the drain and fill plugs with
sealing washers.
Tighten
206832 • Tighten the actuator bolts to
22 N-m (16 lb ft).
• Tighten the switch bolts to
5 N-m (45 lb in).
• Tighten the drain and fill plug to
33 N-m (24 lb in).
Description and Operation wheels to turn at different rates of speed while the
axle continues to transmit the driving force. This
Front Drive Axle Description prevents tire scuffing when going around comers and
premature wear on internal axle parts. The ring and
The Front Axle on four-wheel drive model vehicles
pinion set and the differential are contained within an
has a central disconnect feature that, under most
aluminum carrier. You can find the axle identification
conditions, allows shifting into and out of four-wheel
number on a tag attached to the right axle tube.
drive when the vehicle is in motion. An electric motor
actuator engages the central disconnect feature. The drive axles (halfshafts) are completely flexible
assemblies consisting of inner and outer constant
The axle uses a conventional ring and pinion gear
velocity CV joints protected by thermoplastic boots
set in order to transmit the driving force of the
and connected by an axle shaft (output shaft).
engine to the wheels. The differential allows the

J 3612
Pinion Bearing Installer
(K15-K25 Models)
156584
J 3660
Axle Seal Installer
(K15-K25 Models)
156805
J 8001
Dial Indicator Set
2014
J 8059
Snap Ring Pliers
5616
J 22888
Differential Side
Bearing Puller
162966
J 23907
Slide Hammer
163061
J 29193
Steering Linkage
Installer-12 mm
136
( ( (o) J 29710
Differential Side Bearing
Installer (K35)
5325
J 36366 J 36601
Pinion Seal Installer Pinion Depth Setting Gauge
157993 156597
J 36578 J 36603
Holding Fixture and Pinion Side Bearing Cup Installer
Service Tool
156592 156605
J 36597 J 36605
Side Bearing Puller Pilot Knuckle Seal Installer
(K35)
5322 156895
J 36599 J 36606
Side Bearing Adjuster Pinion Bearing Installer
Wrench (K35 Models)
156594 156586
J 36600 J 36607
Axle Tube Seal Installer Ball Joint Separator
(K2 Models)
156805 2032
J 36609 J 29369-1
Axle Tube Bearing Installer Axle Tube Bearing and Seal
Remover (K15-25)
156807 57531
J 36612 J 29369-2
Output Shaft Bearing Axle Tube Bearing and Seal
Installer (K15-25) Remover (K35)
156578 57540
J 36616 J 8107-2
Case Bushing Replacer Side Bearing Puller
Pilot (K15-25)
156810 5322
^ --------- — --------------- U
J 36652 J 8614-01
Clamp Swage Tool Set Pinion Flange Holder
5725 1507
J24319-B
Steering Linkage Puller
133
BLANK
Driveline/Axle Rear Drive Axle 4-103
Rear Drive Axle

Specifications
Fastener Tightening Specifications (8 1/2 and 8 5/8)

Brake Backing Plate 47 35 —
Carrier Cover 27 20 —
Filler Plug 34 25 —
Pinion Shaft Lock Screw 34 25 —
Fastener Tightening Specifications (9 1/2 In Ring Gear)

Pinion Shaft Lock Screw 34 25 —
Fastener Tightening Specifications (10 1/2 In Ring Gear)

Axle Flange Bolt 150 110 —
Fastener Tightening Specifications (11 Inch Ring Gear)

Axle Shaft Cap 21 15 —
Bearing Cap Bolts 115 85 —
Driving Pinion Nut 637 470 —
Filler Plug 33 24 — •
Outer Wheel Bearing Locknut 88 65 —
Ring Gear Bolts 298 220 —
Spacer and Shim Specifications

Shim Type mm inch
Differential Bearing Adjusting Shim 0.0726 0.003
Outer Pinion Bearing Preload Shim 0.3556 0.014
4-104 Rear Drive Axle_________________________________________________ Driveline/Axle
Spacer and Shim Specifications (cont’d)
Shim Type mm inch
Inner Pinion Bearing Preload Shim 0.0762 0.003
Outboard Shim 5.18 0.204
Outboard Shim (Non-Selective) 4.98 0.196
Outboard Shim (Non-Selective) 4.88 0.192
Inboard Shim 0.84 0.330
Inboard Shim 0.69 0.270
Pinion Bearing and Differential Bearing Preload

New Drive Pinion Bearing Preload 47 35 —
New Drive Pinion Bearings Final Tightening 57 42 —
Existing Differential Case Bearing Preload Tightening 57 42 —
Existing Differential Case Bearing Final Tightening 68 50 —
Application Liters Gallons Quarts
American Axle 81/2 and 85/8 Inch Ring Gear 2.0 0.52 2.1
American Axle 91/2 Inch Ring Gear 2.6 0.67 2.7
American Axle 101/2 Inch Ring Gear 3.08 0.81 3.25
Dana 11 Inch Ring Gear 4.0 1.05 4.2
C3500HD models in applications requiring extreme overioad/trailer tow conditions at high speeds (above 45 MPH) for
extended periods of time should have lubricant changed every 3,000 miles or 3 months, whichever comes first. If synthetic
lubricant (GM P/N 12346140 or equivalent) is used, the change interval may be extended to 30,000 miles.

Rear Axle 5.386
Rear Axle Bolt, Clip, Connector, Housing, Stud and Vent 5.387
Front and Rear Axle Bumper 5.395
Rear Axle Housing Bolt and Cover 5.398
Rear Axle Housing Cover Gasket 5.399
Rear Axle Shaft 5.420
Rear Axle Shaft Bolt, Cap, Gasket and Lock 5.422
Pinion Shaft Front Bearing, Cone and Cup 5.447
Differential Drive Pinion Front and Center Bearing Bolt and Spacer 5.453
Differential Pinion Cage Shim 5.458
Differential Rear Pinion Bearing Shim and Shim Kit 5.460
Differential Drive Pinion Seal 5.469
Pinion Bearing and Oil Seal Retainer 5.476
Drive Pinion Rear and Intermediate Baffle, Bearing, Cone and Cup 5.484
Final Drive Bracket, Shield and Washer 5.500
Differential Carrier 5.505
Differential Carrier Bolt, Bushing, Pin and Washer 5.506
Differential Carrier Housing Magnet 5.508
Differential and Planet Case, Cover and Differential 5.510
Differential Locking Bushing, Cam, Disc Set, Governor and Guide 5.511
Differential Locking Shaft 5.517
Pinion Shaft Lock Bolt and Pin 5.518
Differential Pinion Spider 5.520
Differential Pinion Gear 5.526
Differential Side with Pinion Gear Kit 5.527
Differential Side Gear 5.528
Ring and Pinion Gear Kit and Gear Set 5.529
Ring Gear Bolt 5.531
Differential Side Bearing 5.536
Differential Bearing Adjusting Adjuster, Lock, Nut, Ring, Shim, Shim Kit, Sleeve 5.537
and Spacer
Differential Bearing Adjusting Nut Lock 5.539
Differential Pinion Thrust Block and Washer 5.542
Differential Side Gear Thrust Shim, Sleeve and Washer 5.543
4-106 Rear Drive Axle Driveline/Axle
Diagnostic Information Tire Noise

and Procedures Tire noise can easily be mistaken for rear axle noise,
even though noisy tires may be located on the front
wheels. Tires worn unevenly, or having surfaces on
Determining Type of Noise
non-skid divisions worn in sawtooth fashion, are
Rear Axle Noise usually noisy and may produce vibrations which
seem to originate elsewhere in the vehicle. This is
The proper diagnosis is an important part of rear particularly true with low tire pressure.
axle repair. In axle work, one of the most difficult
conditions to diagnose is noise. Locating a broken Tire Noise Test
axle shaft or broken differential gear presents little or Tire noise changes with different road surfaces, but
no problem, but locating and isolating axle noise can rear axle noise does not. Temporarily inflating tires to
be an entirely different matter. 345 kPa (50 psi) pressure, for test purposes only, will
materially alter noise caused by tires but will not
Any gear driven unit, especially an automotive drive affect noise caused by the rear axle. Rear axle noise
axle where the engine torque multiplication occurs at usually stops when coasting at speeds under
a 90 degree turn in the driveline, produces a certain 30 mph; however, tire noise continues but with lower
amount of noise. Therefore, an interpretation must tone as the vehicle speed is reduced. Rear axle
be made for each vehicle to determine where the noise usually changes when the tire pulls in a
noise is normal or if a problem actually exists. A forward direction or when the vehicle coasts down
certain amount of noise must be expected and the road and tire noise remains about the same.
cannot be eliminated by conventional repairs
Engine and Transmission Noises
or adjustment.
Sometimes a noise which seems to originate in the
Normal axle noise can be described as a slight noise rear axle is actually caused by the engine or
heard only at a certain speed or under unusual or transmission. To determine which unit is actually
remote conditions. For example, the noise tends to causing the noise, observe approximate vehicle
reach a peak at speeds from 60 to 100 km/h (40 to speeds and conditions under which the noise is the
60 mph) depending on road and load conditions, or most pronounced; then stop the vehicle in a quiet
on gear ratio and tire size. This slight noise is in no place to avoid interfering noises. With the
way indicative of trouble in the axle assembly. transmission in neutral, run the engine slowly up and
down through the engine speeds corresponding to
Driveline noises may confuse even the best
the vehicle speed at which the noise was most
technician. Vehicle noises coming from tires, pronounced. If a similar noise is produced with the
transmission, propeller shaft, universal joints, and vehicle standing, it is caused by the engine or
front or rear wheel bearings are often mistaken for transmission and not the rear axle.
axle noise. Such practices as raising tire pressure to
eliminate tire noise (although this will not silence Front Wheel Bearing Noise
tread noise of mud and snow tires), or listening for Loose or rough front wheel bearings will cause noise
the noise at varying speeds and road surfaces which may be confused with rear axle noise;
(drive, float, and coast conditions), will aid in locating however, front wheel bearing noise does not change
the source of alleged axle noises. Every effort should when comparing pull and coast conditions. Light
be made to isolate the noise to a specific driveline application of the brake, while holding the vehicle
component instead of a making random guess that speed steady, will often cause the wheel bearing
noise to diminish, since this takes some weight off
could be a costly waste of time.
the bearing. Front wheel bearings may be easily
External Noise checked for noise by jacking up the wheels and
spinning them, and also by shaking the wheels to
Noise which seems to be coming from the rear axle determine if the bearings are excessively loose.
may actually be produced somewhere else.
Determine whether the noise might originate in the Body Boom Noise or Vibration
tires, road surface, front wheel bearings, engine, Objectionable body boom noise or vibration at
or transmission. 55-65 mph (90-100 km/h) can be caused by an
unbalanced propeller shaft. Excessive looseness at
Road Noise the spline can contribute to this unbalance.
Driving on certain road surfaces, such as brick or Other items that may also contribute to the noise
rough-surfaced concrete, causes noise which may be problem are as follows:
mistaken for tire or rear axle noise. Driving on a • Undercoating or mud on the shaft,
different type of road, such as smooth asphalt or dirt, causing unbalance
will quickly show whether the road surface is the • Shaft or companion flange balance
cause of noise. Road noise usually is the same in weights missing
drive as in coast. • Shaft damage, such as bends, dents, or nicks
• Rough tires (Switch tires from a known good
vehicle in order to determine a tire fault.)
If after making a comprehensive check of the
vehicle, all indications point to the rear axle, further
diagnostic steps are necessary to determine the axle
components at fault. True rear axle noise generally
falls into two categories: gear noise and
bearing noise.
Rear Axle Noise
If a careful test of the vehicle shows that the noise
is not caused by external items, it is then reasonable
to assume that noise is caused by the rear axle
assembly. Test the rear axle on a smooth level road
to avoid road noise. It is not advisable to test the
rear axle for noise by running with the rear wheels
jacked up.
Noise in the rear axle assembly may be caused by a
faulty propeller shaft, faulty wheel bearings, fault
differential or pinion shaft bearings, misalignment
between two U-joints, or worn differential side gears
and pinions. Noise may be caused by a mismatched,
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improperly adjusted, or scored ring and pinion
gear set. The first type is produced by broken, bent, or forcibly
damaged gear teeth (1) and is usually quite audible
Rear Wheel Bearing Noise over the entire speed range and presents no
A rough rear wheel produces a vibration or growl particular problem in diagnosis. For example, hypoid
which continues with the vehicle coasting and the gear tooth scoring generally results from the
transmission in neutral. A brinelled rear wheel following: insufficient lubricant, improper break-in,
bearing causes a knock or click, approximately every incorrect lubricant, insufficient gear backlash,
two revolutions of the rear wheel, since the bearing improper ring and pinion gear alignment, or loss of
rollers do not travel at the same speed as the rear drive pinion nut toque. The scoring will progressively
axle and wheel. With the rear wheels jacked up, spin lead to complete erosion of the gear tooth, or gear
the rear wheels by hand while listening at the hubs tooth pitting and then eventual fracture if the initial
for evidence of a rough or brinelled wheel bearing. scoring condition is not corrected.
Other causes of hypoid tooth fracture are extended
Differential Side Gear and Pinion Noise overloading of the gear set which will produce
Differential side gears and pinions seldom cause fatigue fracture, or shock loading which will result in
noise since their movement is relatively slight on sudden malfunction.
straight ahead driving. Noise produced by these
gears will be most pronounced on turns.
Pinion bearing failures can be determined by how
the bearings rotate at higher speeds as opposed to
differential side bearings and axle shaft bearings.
Rough or brinelled pinion bearings produce a
continuous low-pitched whirring or scraping noise
starting at a low speed.
Side bearings produce a constant rough noise
pitched lower than pinion bearing noise. Side bearing
noise may also fluctuate in the previous rear wheel
bearing test.
Gear Noise
There are two basic types of gear noise.
156776
Differential pinion and side gears rarely give trouble. Abrasive Step Wear
Common causes of differential malfunction are shock
loading, and seizure of the differential pinions to the
cross shaft resulting from excessive wheel spin and
consequent lubrication breakdown (2). The second
type of gear noise pertains to the mesh pattern of
the gear teeth. This form of abnormal gear noise can
be recognized because it produces a cycling pitch
(whine) and will be very pronounced in the speed
range at which it occurs, appearing under either
drive, float or coast conditions. Drive is acceleration
or heavy pullout. Coast is allowing the vehicle to roll
down the road without accelerating and float is lightly
stepping on the accelerator pedal to keep the vehicle
from driving the engine; the vehicle slows down
gradually but the engine still pulls slightly. Gear noise
tends to peak in a narrow speed range or ranges
and will tend to remain constant in pitch. Bearing
noise will vary in pitch with vehicle speeds.
Refer to Rear Axle Wheel Bearing Wear for
bearing diagnoses.
1453
Rear Axle Wheel Bearing Wear
The pattern on the roller ends is caused by
Tapered Roller Bearing Diagnosis fine abrasives.
Consider the following factors when diagnosing 1. Clean all of the parts and the housings.
bearing condition: 2. Check the seals and the bearings.
• General condition of all parts during 3. Replace any leaky, rough, or noisy bearings.
disassembly and inspection.
• Classify the failure with the aid of Galling
the illustrations.
• Determine the cause.
• Make all repairs following
recommended procedures.
Abrasive Roller Wear
The metal smears on the roller ends are due to

overheating, lubricant failure, or lubricant overload.
2. Check the seals.
The pattern on the races and the rollers is caused

by fine abrasives.
2. Check the seals and the bearings.
Etching Cage Wear
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The bearing surfaces appear gray or grayish black in The wear around the outside diameter of the cage
color, with related etching away of material usually at and the roller pockets is caused by abrasive material
roller spacing. or inefficient lubrication.
1. Replace the bearings. 1. Clean the related parts and the housings.
2. Check the seals. 2. Check the seals.
3. Check for proper lubrication. 3. Replace the bearings.
Bent Cage Indentations
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When a cage is damaged due to improper handling The surface depressions on the race and the rollers
or improper tool usage. are caused by hard particles of foreign matter.
Replace the bearing. 1. Clean all the parts and the housings.
2. Check the seals.
3. Replace rough or noisy bearings.
Frettage If this condition occurs, perform the following:
3. Check for proper fit and lubrication.
Stain Discoloration
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The corrosion caused by small relative movement of

parts with no lubrication.
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3. Check the seals.
The discoloration on the bearings is caused by
4. Check for proper lubrication. incorrect lubrication or moisture and ranges in color
Smears from light brown to black. Reuse the bearing if you
can remove the stains with light polishing and there
is no evidence of overheating. Check the seals and
the related parts for damage.
1460
The smearing of the metal is due to slippage.
Slippage can be caused by the following factors:
• Poor fits
• Lubrication
• Overheating
• Overloads
• Handling damage
Driveiine/Axle Rear Drive Axle 4-111
Heat Discoloration Cracked Inner Race
1462 1464
The discoloration on the bearings ranges from faint The race is cracked due to improper fit, cocking, or
yellow to dark blue and results from overload or an poor bearing seats.
incorrect lubricant. Excessive heat causes softening 1. Replace the bearing.
of the races or the rollers. In order to check for loss
2 . Correct bearing seats.
of temper on the races and the rollers, perform a file
test. A file drawn over a tempered part will grab and Fatigue S palling
cut the metal and fail the file test. A file drawn over
a hard part will glide readily with no metal cutting.
If overheating damage is indicated, perform
the following:
2 . Check the seals and the other related parts.
M isalignm ent
1465
The surface is flaked with metal due to

bearing fatigue.
1 . Replace the bearing.
2 . Clean all related parts.
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The outer race is misaligned due to a foreign object.

3. Ensure the races are properly sealed.
B rinelling
1466
The surface indentations in the race way are caused

by the rollers under impact loading or from vibration
while the bearing is not rotating. Replace a rough or
noisy bearing.
Driveline/Axle Rear Drive Axle .4-113
Repair Instructions
Oil Seal and/or Bearing Replacement
Rem oval Procedure
Tools Required
• J 2619-01 Driver Handle.
• J 23690 Axle Shaft Bearing Installer.
• J 29709 Axle Shaft Bearing Installer
• J 21128 Axle Shaft and Pinion Seal Installer.
• J 29713 Axle Shaft Bearing Installer
(91/2 in ring gear)
2. Remove the wheel and tire assembly.
3. Remove the brake drum (6).
4. Clean the dirt from the carrier cover (4) and
surrounding area.
5. Remove the carrier cover bolts (3) and clips.
6 . Remove the carrier cover (4) from the
housing (2).
• Catch the oil in a drain pan
• Remove any gasket material
7. Remove the screw.
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8. On axles without a locking differential, remove
the pinion shaft.
9. On axles with a locking differential, remove the

shaft part way, and rotate the case until the
pinion shaft touches the housing.
156411
10. On axles with a locking differential, use a

screwdriver or similar tool to enter the
differential case and rotate the lock (1) until it
aligns with the thrust block (2).
156412
11. Push the flange of the axle shaft toward
the differential.
Notice: Refer to Shaft Damage in Cautions
and Notices.
12. Remove the lock from the button end of the
axle shaft.
Important: Carefully slide the axle shaft (7) out in

order not to damage the seal (9).
13. Remove the axle shaft (7) from the housing (2).
14. Use the J 23689 to remove the seal (9).
15. Use the J 23689 for 81/2 and 85/8 inch ring
gear axles or the J 29712 for 91/2 inch ring
gear axles to pull the bearing (1) from the
housing (2).
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16. Insert the tool into the axle bore so that it

grasps behind the bearing.
17. Tighten the nut and washer against the face of J 22813-01
the bearing.
18. Pull the bearing out using the J 2619-01.
19. Inspect all parts. Replace as necessary.
1477
1. Lubricate the axle cavity between the seal lips
and the bearing with wheel bearing lubricant.
Refer to Maintenance and Lubrication in
2. Install the bearing using the J 23690 for
81/2 and 85/8 in ring gear axles and the
J 29709 for 91/2 in ring gear axles.
3. Drive the bearing into the axle housing until the
tool bottoms against the tube.
156575
4. Install the seal using the J 21128 for 8V2 and

85/8 in ring gear axles and the J 29713 for
9V2 in ring gear axles.
5. Drive the tool into the bore until the seal
bottoms flush with the tube.
Important: Carefully insert the axle shaft (7) in order

not to damage the seal (9).
6. Install the axle shaft (7) into the housing (2).
7. Slide the axle shaft (7) into place allowing the
splines to engage the differential side gear.
8 . On axles without a locking differential, place the
lock (8) on the button end of the axle shaft (7).
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9. On axles with a locking differential, keep the
pinion shaft partially withdrawn.
10. On axles with a locking differential, place the

lock (1) on the axle shaft (3) so that the ends
are flush with the thrust block (2).
11. Pull the shaft flange outward in order to seat
the lock in the differential side gear.
Important: Anytime a differential pinion shaft locking

screw is removed, coat the screw threads with
Loctite 242 before reinstalling. The screw has an
adhesive coating in order to prevent the screw from
loosening in the case. Removing the screw removes
the adhesive on the screw.
12. Align the hole in the pinion shaft with the screw
hole in the differential case.
156410
13. Install the screw
Tighten
Tighten the screw to 3.4 N.m (25 lb ft).
and Notices.
14. Install the carrier cover gasket or RTV (if used).

15. Install the carrier cover (4).
16. Install the carrier cover bolts (3) and clips.
Tighten
Tighten the bolts (3) in a crosswise pattern to
27 N.m (20 lb ft).
17. Install the brake drum (6).
18. Install the wheel and tire assembly.
20. Fill the housing with axle lubricant to the filler
plug hole level. Refer to Maintenance and
Lubrication in General Information.
4
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Pinion Oil Seal Replacement

(Semi-Floating Axle)
Rem oval Procedure
Tools Required
• J 5853-B Torque Wrench
• J 8614-01 Companion Flange Holder/Remover
• J 22388 Pinion Oil Seal Installer (91/2 in ring
gear axle)
• J 22836 Pinion Oil Seal Installer (81/2 and
85/8 in ring gear axles)
• J 22804-1 Pinion Oil Seal Spacer
The pinion oil seal and the companion flange may
be replaced with the carrier assembly installed in
the vehicle.
1. Raise the vehicle on a hoist and support the
vehicle with safety stands.
2. Remove the rear wheels and brake drums.
Im portant: Observe and accurately mark the
positions of all driveline components relative to
the propeller shaft and axles prior to
disassembly. These components include the
propeller shaft, drive axles, pinion flanges,
output shafts, etc. Reassemble all components
in the exact relationship the components had to
each other during removal. Follow specifications
and torque values. Follow any measurements
made prior to disassembly.
3. Accurately marked the installed position of the
rear propeller shaft.
4. Remove the propeller shaft. Refer to One-Piece
Propeller Shaft Replacement or Two-Piece
Propeller Shaft Replacement
• Use a piece of tape in order to hold the
bearing caps
• Secure the propeller shaft so that the
propeller shaft is out of the way
• Do not put unnecessary stress on the
universal joints in securing the propeller shaft
5. Use a J 5863-B in order to measure the torque
required to turn the pinion.
6. Record the torque measurement, which gives
the combined pinion bearing, seal, carrier
bearing, axle bearing and seal preload.
7. Make an accurate alignment mark (1) on the
pinion stem, pinion flange nut, and pinion
flange (2).
8. Record the number of exposed threads on the
pinion stem.
156435
9. Hold the pinion flange with the J 8614-01.
10. Remove the pinion flange nut and washer.
11. Use a container to catch any lubricant.
12. Remove the pinion flange using the J 8614-01
with the remover attachment.
Important: Avoid damaging the
machined surfaces.
13. Pry the oil seal from the bore.
14. Thoroughly clean any foreign material from the
contact area.
15. Replace any parts as necessary.
1496
1. Install the oil seal into the bore using the
J 22804-1 and either the J 22388 (91/2 in ring
gear axles) or the J 22836 (81/2 and 85/s in ring
gear axles).
2. Turn the J 22804-1 from the installed position
180 degrees to ensure proper installation
against the pinion flange.
3. Lubricate the cavity between the new seal lips
with a high melting point lubricant for bearings.
156579
Important: Do not hammer the pinion flange onto

the pinion stem.
4. Install the pinion flange using the J 8614-01.
156437
5. Use the alignment marks (1) in the installation
of the pinion flange (2).
6. Install a washer and a new nut.
Tighten
Tighten the nut on the pinion stem as close as
possible to the alignment marks without going
past the mark.
and Notices.
• Use the record of the alignment marks and
the thread count as a reference.
• Tighten the nut a little at a time and turn the
pinion flange several times after each
tightening in order to set the rollers.
Important: If the preload torque value recorded

earlier was less than 3 lb in, reset the torque
specification to 3 -5 lb in.
7. Measure the torque required to rotate the pinion
using the J 5853-B.
8. Compare the measurement of the torque
with the measurement made during the
removal procedure.
9. Continue tightening and measuring a little at a
time until the preload is achieved.
10. Install the propeller shaft. Refer to One-Piece
11. Install the retainers and bolts.
Tighten
12. Install the rear wheels and brake drums.
13. Lubricate the rear axle as necessary.
(10 1/2 Inch Ring Gear)
Removal Procedure
Tools Required
• J 24384 Pinion Oil Seal Installer
The pinion oil seal and the companion flange may
be replaced with the carrier assembly installed in
the vehicle.
1. Raise the vehicle on a hoist and support with
safety stands.
1497
2. Remove the axle shafts. Refer to Axle
Replacement (10 1/2 In Ring Gear).
Important: Observe and mark the positions of
shaft and axles prior to disassembly. These
components include the propeller shafts, drive
axles, pinion flanges, output shafts, etc. All
components must be reassembled in the exact
relationship to each as the components had
prior to disassembly. Follow all specifications
and torque values, as well as any
measurements made prior to disassembly.
3. Mark the installed position of the rear propeller
shaft.
4. Disconnect the propeller shaft. Refer to
• Use a piece to tape in order to hold the
bearing caps
• Secure the propeller shaft up and out of the
way in a manner that does not put
unnecessary stress on the universal joints
5. Measure the amount of torque required to turn
the pinion using the J 5853-B.
• Record the torque measurement
for reassembly
• The measurement give the combined pinion
bearing, seal, and carrier bearing preload.
6. Make an alignment mark (1) on the pinion
stem, pinion flange (2), and pinion flange nut.
7. Record the number of exposed threads on the
pinion stem for a reference.
15643S
8. Hold the pinion flange with the J 8614-01.
9. Remove the pinion flange nut and washer.
10. Remove the pinion flange using the J 8614-01.

11. Use a container to catch any lubricant.
Important: Do not damage the
machined surfaces.
13. Thoroughly clean foreign material from the
contact area.
14. Replace parts as necessary.
Tools Required
Notice: Use the correct fastener in the correct
location. Replacement fasteners must be the correct
part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread
locking compound or sealant are identified in the
service procedure. Do not use paints, lubricants, or
corrosion inhibitors on fasteners or fastener joint
surfaces unless specified. These coatings affect
fastener torque and joint clamping force and may
damage the fastener. Use the correct tightening
sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
1. Lubricate the cavity between the lips of the new 156435
seal with a high melting point lubricant.
2. Install the oil seal into the bore using
the J 24384.
Important: Do not hammer the pinion flange (2)
onto the pinion stem.
3. Install the pinion flange using the alignment
marks (1) as a reference
4. Install the washer and a new pinion nut.
• Tighten the pinion nut on the pinion stem as
close to the alignment mark (1) as possible
without going past the mark
• Use the alignment mark and the thread
count as a reference
• Tighten the nut a little at a time and turn the
pinion flange (2) several times after each
tightening in order to set the rollers
Important: If the recorded preload torque value was
less than 3 lb in, reset the torque specification
to 3 -5 lb in.
5. Measure the torque required to rotate
the pinion.
• Compare the rotating torque with the
recorded value
• Continue tightening the pinion nut and
measuring the torque until the recorded value
is achieved
6. Align the propeller shaft with the
alignment marks.
7. Connect the propeller shaft. Refer to One-Piece
Propeller Shaft Replacement.
8. Install the retainers and bolts.
Tighten
1497
and Notices.
9. Install the Axle Shafts. Refer to Axle
10. Add lubricant to the rear axle as necessary.
Refer to Maintenance and Lubrication in

(11 Inch Ring Gear)
Removal Procedure
Tools Required
• J 8614-01 Pinion Flange Holder/Remover
The pinion oil seal and the pinion flange may be
replaced with the carrier assembly installed in
the vehicle.
3. Make an alignment mark (1) on the pinion
stem, pinion nut and pinion flange (2) for use
as an installation guide.
156435
4. Remove the pinion nut using J 8614-01.
5. Remove the flange using J 8614-01 with the

special nut and forcing screw.
• Do not damage the machined surfaces
• Clean any foreign material from the contact
area
7. Inspect the following
• The oil seal mating surfaces for any burrs
which may cause seal failure
• Flange deflector for any abnormality such as
cracking or distortion
1494
Tools Required
• J 8614-01 Pinion Flange Holder/Remover
1. Lubricate the inside diameter of the new oil
seal with extreme pressure lubricant such as
GM P/N 9985038.
2. Install the oil seal into the bore using
the J 24384.
Im portant: Do not coat the bearing.
3. Pack the cavity between the pinion stem, pinion
flange and pinion nut with a non-hardening
sealer such as Permatex® Type A or
the equivalent.
156490
4. Install the pinion flange using the J 8614-01

and use the alignment marks as a guide.
5. Install the pinion nut using the J 8614-01 and
use the alignment marks as a guide.
Tighten
Tighten the pinion nut to 596-678 N-m
(440-550 lb ft).
and Notices.
6. Install the propeller shaft. Refer to One-Piece
Propeller Shaft Replacement.
156437

Removal Procedure
The axle vent hose is located on the axle carrier on
8V2, 85/s, and 91/2 in ring gear axles.
156407
1. Remove the vent clamp bolt from the

brake bracket.
2. Remove the vent clamp from the brake bracket.
3. Remove the vent assembly from the vent hose.
4. Remove the vent clamp from the vent hose.
157127
5. Remove the vent clamp bolt from the vent hose

clamp and brake junction block.
6. Remove the vent hose clamps and vent hose

from the axle nipples.
7. Remove the vent hose clamps from the
vent hose.
157129
1. Connect vent hose clamps to the vent hose.
2. Connect the vent hose clamps and the vent
hose to the axle nipples.
3. Install the vent hose clamp bolt to the vent

hose clamp and the brake junction block.
4. Connect the vent hose clamp to the vent hose.

5. Install the vent assembly to the vent hose.
6. Connect the vent hose clamp to the
brake bracket.
7. Install the vent hose clamp bolt to the vent
hose clamp and the brake bracket.
157127
Inspection Before Disassembly

1. Remove the cover and drain the oil.
Important: Use this information in the diagnosis
of an axle problem. Information on ring gear
backlash also helps in setting shim packs for
locating and preloading the differential case.
2. Check the ring gear backlash. Refer to
Backlash Adjustment
Important: If possible, determine the cause the
axle problem before disassembly of the axle.
3. Inspect the case for metal chips and shavings.
Determine where the chips and shavings came
from, such as a broken gear or bearing cage.
Drive Axle Disassemble

Rem oval Procedure
Tools Required
• J 8107-2 Side Bearing Puller Plug
• J 8614-01 Pinion Flange Holder
• J 24385-01 Differential Housing Spreader
• J 29721 Differential Side Bearing Remover
• J 29721-70 Side Bearing Adapters
• J 39330 Bearing Race Remover
• J 39331 Outer Bearing Race Remover
• J 39709 Universal Handle
1. Place the axle in a suitable support.
2. Remove the bolts from the cover and the cover.
This will drain the oil.
3. Pull the axle shafts out of the axle housing to 168044
the point where the axle shafts are clear of the
differential case.
4. Remove the bearing cap bolts.
Im portant: Corresponding letters are stamped on
the bearing caps and axle housing. The bearing
caps must be reassembled exactly as removed.
5. Remove the bearing caps.
6. Assemble the J 24385-01 to the
differential housing.
Notice: You may use the older style gage set if
you already have them. The new style gages
use the bearings as part of the gage system,
while the older style uses a master block that
acts as a master bearing.
7. Assemble the J 39704.
8. Preset the gage to a minimum of 5 mm
(0.200 inch). Rotate the indicator housing to
zero on the dial.
Notice: Do not spread the axle housing more
than 0.38 mm (0.015 inch). Overspreading the
housing can damage or distort it.
9. Spread the housing while examining the J 39704.
10. Remove the case from the housing using two
pry bars.
11. Remove the J 24385-01 from the housing.
Important: Mark the bearing cups left and right
and place each bearing cup with the
corresponding proper bearing cap.
12. Remove the bearing caps.
168049
Important: Mark the bearings left and right and

place each bearings with the corresponding set of
bearing cap and cup.
13. Remove the bearings using the J 8107-2,
J 29721, and J 29721-70.
Important: Mark the shims left or right.
14. Remove the shims.
15. Check the outboard spacers for damage such
as bends or deep groves caused by worn
bearings. Replace any damaged spacers at the
time of assembly.
16. Place towels over the jaws of the vice. Place
the differential case in the vice
Important: Replace the ring gear bolts with
new ones at the time of assembly.
17. Remove the ring gear bolts. Discard the ring
gear bolts.
Notice: Do not pry the ring gear from the case. This
will damage the ring gear and differential case.
18. Remove the lock pin screw.
168052
19. Remove the pinion shaft using a hammer and
brass drift.
20. Rotate the side gears until the pinion gears are
in the opening of the case. Remove the pinion
gears and thrust washers.
Important: Mark the side gears and thrust
washers left and right.
21. Remove the side gears and thrust washers.
22. Replace the cover using two bolts in order to
keep the pinion from falling.
23. Measure the drive pinion rotating torque.

Record the measurement.
24. Check for looseness of the pinion assembly by
moving the assembly back and forth.
Looseness indicates excessive bearing or
pinion wear.
1497
25. Remove the pinion nut and washer using the
J 8614-01 in order to hold the pinion.
1496
26. Remove the pinion flange using the J 8614-01.

27. Use a soft-faced hammer to tap the pinion in
order to remove the pinion from the
pinion bore.
28. Remove the cover and the pinion from
the vehicle.
Important: Keep the shims together
29. Remove the pinion preload shims.
30. Remove the pinion seal.
31. Remove the outer bearing and oil slinger.
32. Remove the pinion outer bearing cups from the
axle using J 39330.
Important: Keep the shims together.
33. Remove the pinion outer adjusting shims and
baffle, if used.
1495
34. Remove the pinion inner bearing cup using

the J 39331.
Important: Keep the shims together
35. Remove the pinion outer adjusting shims and
baffle, if used.
168083
168059
Axle Housing Inspection Important: Ring and pinion gears are matched sets
and both are replaced any time a replacement of
Carefully and thoroughly inspect all drive unit parts
either is necessary.
before assembly. Thorough inspection of the drive
parts for w ear or stress with subsequent replacement • Inspect the pinion and ring gear teeth for
of worn parts eliminates costly drive component cracking, chipping, scoring, and excessive wear.
repair after assembly. • Inspect the pinion gear splines for wear.
• Inspect for nicks or burrs that could prevent the • Inspect the pinion flange splines for wear.
outer diameter of the pinion seal from sealing.
• Inspect the fit of the pinion gear splines on the
Remove any burrs.
pinion flange.
• Inspect the bearing cup bores for nicks or
• Inspect the sealing surface of the pinion flange
burrs. Remove any burrs that are found.
for nicks, burrs, or rough tool marks that could
• Inspect the housing for cracks. Replace the cause damage to the inside diameter of the
housing if any cracks are found. seal and result in an oil leak.
• Inspect the housing for foreign material such as • Replace all worn or broken parts.
metal chips, dirt, or rust.
Bearings Inspection
Differential Inspection
Carefully and thoroughly inspect all drive unit parts
Carefully and thoroughly inspect all drive unit parts before assembly. Thorough inspection of the drive
before assembly. Thorough inspection of the drive parts for wear or stress with subsequent replacement
parts for wear or stress with subsequent replacement of worn parts eliminates costly drive component
of worn parts eliminates costly drive component repair after assembly.
repair after assembly.
Important: Bearings and cups are matched sets.
• Inspect the pinion gear shaft for unusual wear. Replace both bearing and cup when either part
• Inspect the pinion gear and side gear teeth for requires replacement.
wear, cracks, scoring, and spalling.
• Oil the bearings. Inspect the bearings for
• Inspect the thrust washers for wear. smooth rotation.
• Inspect the fit of the side gears in the • Inspect the bearing rollers for wear.
differential case.
• Inspect the bearing cups for wear, cracks,
• Inspect the fit of the side gears on the brinelling, and scoring.
axle shafts.
• Inspect the differential case for cracks Shims Inspection
and scoring. Carefully and thoroughly inspect all drive unit parts
• Inspect all parts for wear. Replace parts before assembly. Thorough inspection of the drive
as necessary. parts for wear or stress with subsequent replacement
of worn parts eliminates costly drive component
Pinion and Ring Gear Inspection repair after assembly.
Carefully and thoroughly inspect all drive unit parts Inspect shims for cracks and chips. Replace
before assembly. Thorough inspection of the drive damaged shims with a service shim of an equal size.
parts for wear or stress with subsequent replacement
of worn parts eliminates costly drive component
repair after assembly.

Tools Required
• J 7818 Rear Pinion Bearing Cup Installer
• J 39701 Master Discs
. J 39702 Arbor
• J 39707 Cup Installer
. J 39708 Handle
• J 41689 Pinion Height Block
• J 41690 Master Pinion Block
• J 41691 Adapter Cone
• J 41692 Threaded Rod
1. Clean the carrier bores and all tools. Make sure
the pinion bore is free of nicks and dirt.
important: Make sure the cup is seated.
2. Drive the inner bearing cup into the axle
168086
assembly using the J 39708 and J 39707.
3. Drive the outer bearing cup into the axle
assembly using the J 7818 and J 8092.
4. Install the inner bearing cone into the inner
bearing cup.
Notice: You may use the older style gage set if you
already have them. The new style gages use the
bearings as part of the gage system, while the
older style uses a master block that acts as a
master bearing.
Important: Install the outer bearing cone with
the J 41691.
5. Assemble the J 41690 and J 41689 into the
carrier housing using the J 41691 and J 41692.
6. Tighten the cone by hand until all end play is
removed from the gage assembly.
7. Assemble the J 39702 and J 39701 into the
carrier housing.
168083
8. Place the J 39704 on the upper step of
the J 41689.
• Apply pressure to the block of the J 39704,
pushing down on the J 41689.
• While applying pressure, set the J 39704
at zero.
J 39704 9. Slide the J 39704 over the J 39702.

10. Record the reading at the point of greatest
deflection, when the needle of the J 39704 is
centered between movement to the left
and right.
• This reading determines the amount of shims
needed for a nominal pinion setting.
• The pinion marking may change the pinion
depth by adding or deleting shims.
• Refer to the pinion marking table.
11. After determining the pinion marking, remove
the J 39704, J 39702, J 41689, J 41692,
J 41691, and J 41690.
Important: If a baffle or oil siinger is used,
J 39701 j 39702 measure the baffle or oil siinger. Include this
measurement in the shim pack.
12. Measure with a micrometer each shim
168401
separately. Add the dimensions in order to
obtain the total shim pack thickness.

Distance
Between Ring
Gear Marking
Pinion Marking And Pinion Head Shim Pack
Positive (+) Must Increase Decrease
Negative (-) Must Decrease Increase
Use Nominal
Zero (0) OK
Setting
Differential Case Assembly

Tools Required
• J 24385-01 Differential Case Spreader
• J 39705 Master Differential Bearings
1. Lubricate all parts with an axle lubricant.
2. Install new thrust washers to the side gears.
Important: Install the side gears to the
same side that the side gears were on
when removed.
3. Install the side gears to the differential case.
4. Install the pinion gears to the differential without
the thrust washers.
4.1. Install the pinion gears to the side gears
so that the holes in the pinion gears are
180 degrees apart.
4.2. Rotate the pinion gears into place. Verify
168067
that the pinion gears line up with the
pinion shaft holes.
5. Rotate the pinion gears toward the differential
opening in order to allow enough space for the
pinion thrust washers to slide in.
6. Install the pinion shaft.
7. Align the roll pin holes in the differential case
and the pinion shaft.
8. Install the roll pin.
8.1. Peen metal from the case over the
lock pin in two places that are
180 degrees apart.
8.2. Make sure the mating surfaces of the
differential case and the ring gear are
clean and free of burrs.
9. Align the holes in the differential case and the
holes in the ring gear. Press the ring gear onto
the case.
Important: Tighten the ring gear bolt in stages
in order to gradually pull the ring gear onto the
differential case.
and Notices.
10. Install new ring gear bolts.
Tighten
Tighten the ring gear bolts in sequence to
298 N.m (220 lb ft).
11. Install the J 39705 to the differential.
• Refer to Determining Total Shim Pack Size in
this section.
• Put the outboard spacers in place, if
outboard spacers are used.
Determining Total Shim Pack Size

Tools Required
J 39704 Dial Indicator
Notice: Both methods for setting differential bearing
preload and gear backlash are described. All Model
80 axle assemblies can be serviced by using the
outboard selective shim method.
Notice: If the original axle assembly has the
outboard selective shims, it should not be serviced
using the inboard shims for preload/backlash
adjustment. In other words, if you have outboard
selective shims, you must stay with that method. If
the axle assembly uses in board shims and outboard
spacers (non-selective), you may use the outboard
selective shim method for service.
Notice: If your axle assembly has selective outboard
spacers and one 0.76 mm (0.030 inch) shim (each
side) between the differential case and bearing cone.
Make your measurements with the outboard spacers
removed, but with the 0.76 mm (0.030 inch) shim
assembled on the differential case trunion placed
between the case and the master differential
bearings. The selective outboard spacers are
available in sizes (thickness) from
5.18 mm (0.2040 inch) to 6.10 mm (0.2400 inch), in
0.08 mm (0.003 inch) increments. The dial indicator
should have the capability of making measurements
up to 12.7 mm (0.500 inch).
Notice: If your axle assembly has outboard spacers,
but controls the preload and backlash by using
selective shims (each side) between the differential
case and bearing cone. Make the measurements
with the outboard spacers installed in the housing,
but do not place any shims on the differential case
hubs between the case and master differential
bearings. The selective shims placed between the
bearing cone and differential case are available in
0.08, 0.13, 0.25, 0.76 mm (0.003, 0.005, 0.010,
0.030 inch) sizes. The dial indicator should have the
capability of making measurements up to 3.81 mm
(0.150 inch).
1. Assemble the case to the axle housing. The
pinion must not be installed.
2. Mount the J 39704 on the ring gear bolt side of
the differential housing.
3. Force the differential assembly as far as
possible in the direction of the J 39704.
4. Preload the J 39704 one half of its travel.
5. Place the tip of the J 39704 on a flat surface of
the differential next to a ring gear bolt.
6. Mark with chalk the location of the tip of
the J 39704.
7. Zero the dial indicator.
8. Force the differential case as far as possible in
the direction away from the J 39704. Repeat
this step until the same reading is obtained.
9. Record the number of thousandths that the dial
indicator traveled, not the reading on the dial.
This is the measurement of the shim pack
without the bearing preload, which will be
added later.
11. Important
Do not remove the J 39704 from
the differential.
Remove the differential from the housing.
Important: Removal of the spacers prevents
the spacers from falling out during the
installation of the pinion gear. Mark the spacers
and indicate from which side you removed the
spacers. Reassemble the spacers as removed
in order to ensure that the shim pack
measurement is correct.
12. Remove any spacers used in the procedure
from the housing.
Pinion Installation
Tools Required
• J 5590 Rear Pinion Bearing Cone Installer
• J 8614-01 Pinion Flange Remover
• J 39707 Rear Pinion Bearing Cup Installer
• J 39708 Handle
• J 41696 Pinion Seal Installer
1. Place the required amount of shims in the inner
bearing bore. Include the baffle, if used.
2. Drive the inner bearing cup into the axle
assembly using the J 39708 and J 39707. Make
sure the cup is seated on the shims.
168086
3. Install the inner bearing cone on the pinion.
Drive the inner bearing cone onto the pinion
shaft using the J 5590.
4. Apply a light coat of axle lubricant to the lip of
the pinion seal.
5. Install the outer bearing cone, slinger, and oil
seal using the J 41689.
6. Install the preload shims onto the pinion gear.
7. Install the pinion into the axle housing.
8. Install the washer and old pinion nut.

Tighten
Tighten the pinion nut to 637 N-m (470 lb ft)
while holding the pinion with the J 8614-01.
and Notices.
9. Tighten the nut until the pinion end play is just
taken up. Rotate the pinion while tightening the
nut in order to seat the bearings.
10. Once there is no end play, check the
preload torque.
11. Remove the J 8614-01.
important: The pinion preload should be at or blow

4 N-m (35 lb in) on new bearings, or 1.2 N.m
(10 lb in) on old bearings.
12. Check the pinion preload by rotating the pinion
with a torque wrench.
13. Once the specified preload has been obtained,
make sure the bearings are seated by rotating
the pinion several times.
14. Recheck the pinion preload. Adjust the pinion
preload as necessary.
1497
Differential to Axle Housing Assemble

Assembling The Differential Into the Axle
• J 8001 Dial Indicator Set
• J 23690 Differential Side Bearing Installer
• J 24385-01 Differential Housing Spreader
• J 39704 Master Differential Bearings
Notice: If your axle assembly has selective outboard
spacers and one 0.76 mm (0.030 inch) shim (each
side) between the differential case and bearing cone.
Make your measurements with the outboard spacers
removed, but with the 0.76 mm (0.030 inch) shim
assembled on the differential case trunion placed
between the case and the master differential
bearings. The selective outboard spacers are
available in sizes (thickness) from 5.18 mm
(0.2040 inch) to 6.10 mm (0.2400 inch), in 0.08 mm
(0.003 inch) increments. The dial indicator should
have the capability of making measurements up to
12.7 mm (0.500 inch).
Notice: If your axle assembly has outboard spacers,
but controls the preload and backlash by using
selective shims (each side) between the differential
case and bearing cone. Make the measurements
with the outboard spacers installed in the housing,
but do not place any shims on the differential case
hubs between the case and master differential
bearings. The selective shims placed between the
bearing cone and differential case are available in
0.08, 0.13, 0.25, 0.76 mm (0.003, 0.005, 0.010,
0.030 inch) sizes. The dial indicator should have the
capability of making measurements up to 3.81 mm
(0.150 inch).
1. Force the ring gear to mesh with the pinion.
Rock the ring gear in order to allow the gear
teeth to mesh.
Important: The pinion must be installed
2. Assemble the differential with the master
bearings installed to the axle.
3. Mount a J 8001 with a magnetic base on the
ring gear bolt side of the housing.
4. Place the indicator tip of the J 8001 on the
chalk mark made earlier.
5. With force still applied to the differential case,
set the J 8001 to zero.
6. Force the differential case away from the
pinion gear in order to obtain a reading from
the J8001.
7. Repeat the last step until a consistent reading
is obtained. Record the reading.
8. Remove the J 8001 and the differential case
from the axle housing.
9. Remove the J 39705 from the differential case.
10. Subtract the reading taken of the differential
movement from the total shim pack size
determined earlier. Refer to Determining Total
Shim Pack Size.
• Use the reading taken of the differential
movement for the shim size on the ring
gear side.
• Use the remainder from the equation in the
last step for the shim size on the side
opposite of the ring gear.
• Add an additional 0.25 mm (0.010) in) of
shims to the side opposite of the ring gear in
order to preload the bearings.
Important: If the axle assembly uses the outboard
selective spacers, place the 0.76 mm (0.030 in) shim
on the hub that was used along with the master
bearings to make the measurement. Then select the
appropriate outboard selective spacer and assemble
the outboard selective spacer into the housing.
11. Place the proper shims on the differential side
of the bearing hub (ring gear side) and drive
the differential bearing onto the hub using the
J 8092 and J 23690.
Important: If the axle assembly uses the
outboard selective spacers, place the 0.76 mm
(0.030 in) shim on the hub that was used along
with the master bearings to make the
measurement. Then select the appropriate
outboard selective spacer and assemble the
outboard selective spacer into the housing.
12. Place the proper shims on the differential side
of the bearing hub (opposite of the ring gear)
and drive the differential bearing onto the hub
using J 8092 and J 23690.
13. Assemble the J 24385-01 to the axle housing.
14. Assemble the J 8001.
15. Preset the J 39704 to at least
0.05 mm (0.020 in).
16. Rotate the indicator housing in order to zero
the dial.
Notice: Do not spread the axle housing more
than 0.38 mm (0.015 inch). Overspreading the
housing can damage or distort it.
17. Spread the housing while watching the J 8001.
19. Place the bearing cups onto the bearings.
20. Install the differential assembly into the carrier.
21. Seat the differential assembly into the axle
using a soft-faced hammer.
22. Remove the J 24385-01.
Important: Install the bearing caps into the
exact positions from which each had prior
to removal.
23. Install the bearing caps.
24. Install the bearing cap bolts.
Tighten
Tighten the bearing cap bolts to
115 N.m (85 lb ft).
and Notices.
Backlash Adjustment
Checking Backlash
1. Mount a J 39704 with a magnetic base to the
axle housing.
2. Place the indicator tip of the J 39704 on the

heel end (1) of the ring gear tooth.
Important: The measurement must not vary
more than 0.05 mm (0.002 in) between the
points checked.
3. Check the backlash at three equally spaced
points.
Important: The reduction in the shim pack on
one side must be equal to the increase in the
shim pack on the other side.
4. If the backlash needs adjustment, remove the
differential case from the housing.
5. If the backlash is correct, change the preload
on each side by an equal amount.
6. Make a final gear pattern check. Refer to Gear
Tooth Contact Pattern Check.
Backlash Adjustment
7558
Less Than Greater Than
0.13 mm 0.13-0.23 mm 0.23 mm
(0.005 inch) (0.005-0.009 inch) (0.009 inch)
Move shims from
Move shims from
the ring gear side
the side opposite
to the side No change
of the ring to the
opposite of the
ring gear side.
ring gear
4-144 Rear Drive Axle Drivel ine/Axle
Gear Tooth Contact Pattern Check

Before final assembly of the differential, perform a
gear tooth pattern check.
This contact patter check is not a substitute for
adjusting the pinion depth and backlash. Use this
method in order to verify the correct running position
of the ring gear and drive pinion. Gear sets which
are not positioned properly may be noisy, have a
short life, or both. A pattern check ensures the best
contact between the ring gear and the drive pinion
for low noise and long life.
Gear Tooth Nomenclature
The side of the ring gear tooth which curves
outward, or is convex, is the drive side (4). The
concave side is the coast side (3). The end of the
tooth nearest the center of the ring gear is the toe
end (2). The end of the tooth farthest away from the
center is the heel end (1).
7558
Testing Procedure
1. Wipe the oil out of the axle housing. Carefully
clean each tooth of the ring gear.
2. Use a medium stiff brush in order to sparingly
apply gear marking compound to all of the ring
gear teeth.
Important: A test made without loading the
gears does not give a satisfactory pattern.
3. Use the parking brake in order to apply a load
until a torque of 61 N m (45 lb ft) is required in
order to turn the pinion.
Important: Avoid excessive turning of the
ring gear.
4. Turn the companion flange with a wrench so
that the ring gear rotates one full revolution.
5. Reverse the rotation so that the ring gear
rotates one revolution in the opposite direction.
6. Observe the pattern on the ring gear teeth.
Compare the pattern with the following
illustrations. Use the legend below:
6.1. (1) Toe
6.2. (2) Heel
6.3. (3) Coast side (Concave)
6.4. (4) Drive side (Convex)
Condition
• The backlash is correct.
• The pinion depth is incorrect. The pinion gear is
too far away from the ring gear.
Correction
Increase the thickness of the pinion shim. Refer to
Service Hints
How to check the pattern:
1. Brush gear marking compound on the ring
gear teeth.
2. Rotate the pinion clockwise six times.
3. Rotate the pinion counterclockwise six times.
4. Observe the tooth contact pattern. Make any
necessary corrections.
Condition
• The backlash is correct. 1
• The pinion depth is correct.
Correction
Correction may not be necessary.
Service Hints
Loose bearings on the pinion or in the differential
case may cause patterns that vary. Check the
following preload settings:
• Total assembly
• Differential case
• Pinion
If these settings are correct, look for damage or
incorrectly assembled parts. 4 3
7566
Condition
• The backlash is correct.
• The pinion depth is incorrect.
Correction
Decrease the thickness of the pinion shim. Refer to
Pinion Depth Adjustment.
Service Hints
The shims which adjust the pinion depth are located:
• Between the inner pinion bearing cone and the
hear of the pinion gear
• Between the inner pinion bearing cup and the
rear axle housing
7579
4-146 Rear Drive Axie Driveline/Axle
Adjustments Affecting Tooth Contact
There are two adjustments that affect the tooth
contact pattern: backlash and drive pinion depth. The
effects of bearing preloads are not readily apparent
on hand loaded tooth contact pattern tests. However,
bearing preloads should be within specifications
before proceeding with backlash and drive
pinion adjustments.
Adjust the position of the drive pinion by increasing
or decreasing the distance between the pinion head
and the centerline of the ring gear. Decreasing the
distance moves the pinion closer to the centerline of
the ring gear. Increasing the distance moves the
pinion farther away from the centerline of the
ring gear.
Adjust the backlash by means of the side bearing
adjusting shims which move the case and ring gear
assembly closer to, or farther from, the drive pinion.
Also use the adjusting shims to set the side
bearing preload.
If the thickness of the right shim is increased, along
with an equal decrease in the thickness of the left
shim, backlash will increase.
If the thickness of the left shim is increased, along
with an equal decrease in the thickness of the right
shim, the backlash will decrease.
Drive Axle Final Assembly

1. Apply a thin layer of sealant to the axle cover.
2. Install the axle cover to the axle with the bolts.
Tighten
Tighten the axle cover bolts to 47 N.m (35 lb ft).
and Notices.
3. Fill the axle with oil. Refer to
4. Install the fill plug to the case.
Tighten
Tighten the fill plug to 33 N.m (24 lb ft).
Axle Replacement (10 1/2 In Ring Gear)

Removal Procedure
1. Remove the bolts (6).
2. Lightly rap the axle shaft flange with a
soft-faced hammer in order to loosen the shaft.
3. Grip with a locking plier the rib on the axle
shaft flange and twist in order to start the axle
shaft (5) removal.
4. Remove the axle shaft (1) from the tube.
5. Clean the axle shaft flange.
6. Remove the gasket (4) and RTV.
7. Clean the outside face of the hub assembly (3).
8. Inspect all parts and replace as necessary.
1. Install the axle shaft (5) with a gasket (4) or
RTV applied.
• Be sure the shaft splines mesh into the
differential side gear.
• Align the holes in the axle shaft flange with
the holes in the hub (3).
Tighten
Tight the bolts (6) to 150 N.m (110 lb ft).
and Notices.
160066
Axle Replacement (11 Inch Ring Gear)

Removal Procedure
For Full-Floating Axle Wheel End Components refer
to Rear Axle Disassembled View.
1. Remove the axle cap bolts.
2. Tap the axle cap lightly with a soft-faced
hammer to loosen the gasket.
3. Grip the rib on the axle shaft with a locking
plier and twist to start the axle shaft removal.
4. Remove the axle shaft from the tube.
5. Remove the old RTV or gasket.
6 . Clean the hub assembly.
7. Inspect the shaft to see if it is bent.
8. Inspect the shaft spline for chips, burrs,
cracking, or excessive wear.
9. Replace any damaged components.
1. Install the axle shaft with RTV or the gasket,
being sure that the shaft splines mesh into the
differential side gear.
2. Install the axle cap and the bolts.
Tighten
Tighten the cap bolts to 20 N-m (15 lb ft).
and Notices.
Axle Replacement (Rear Axle Assembly)
Removal Procedure
2. Support the axle assembly with a suitable
lifting device.
3. Drain the lubricant from the axle housing.
• Tie the propeller shaft to a side rail
or crossmember
• Tape the bearing cups to prevent loss of the
needle bearings
5. Remove the wheel and brake drum or hub and
drum assembly. Refer to Linings Replacement
and Wheel Cylinder Replacement in
Leading/Trailing Drum Brakes or Linings
Replacement and Wheel Cylinder Replacement
in Duo-Servo Drum Brakes.
6. Disconnect the parking brake cable from the
lever and at the brake backing plate. Refer to
Park Brake Cable Replacement (Front Cable) or
Park Brake Cable Replacement (Rear Cable -
1Ton) or Park Brake Cable Replacement
(Parking Brake Cable) or Park Brake Cable
Replacement (Rear Cable - 1/2 and 3/4 Ton) in
Parking Brake.
7. Disconnect the hydraulic brake pipes from the
connectors. Refer to Pipe Replacement in
Hydraulic Brakes.
8. Disconnect the shock absorbers from the axle
brackets. Refer to Shock Absorber Replacement
(C Model) or Shock Absorber Replacement (K
Model) in Rear Suspension.
9. Remove the vent hose from the axle vent
fitting. Refer to Vent Hose Replacement
10. Remove the nuts and washers from the U-bolts.
11. Remove the U-bolts, spring plates, and spacers
from the axle assembly.
12. Lower the axle assembly.
1. Place the axle assembly under the vehicle.
2. Align the axle assembly with the springs.
3. Connect the spacers, spring plates, and U-bolts
to the axle assembly.
4. Raise the axle assembly.
5. Install the washers and nuts to the U-bolts.
6. Install the vent hose to the axle vent fitting (if
used). Refer to Vent Hose Replacement
7. Connect the shock absorbers to the axle
brackets. Refer to Shock Absorber Replacement
(C Model) or Shock Absorber Replacement
(K Model) in Rear Suspension.
8. Connect the hydraulic brake pipes to the
connectors. Refer to Pipe Replacement in
Hydraulic Brakes.
156407
9. Connect the parking brake cable to the lever
and the brake backing plate. Refer to Park
Brake Cable Replacement (Front Cable) or Park
Brake Cable Replacement (Rear Cable - 1 Ton)
or Park Brake Cable Replacement (Parking
Brake Cable) or Park Brake Cable
Parking Brake.
10. Install the wheel and brake drum or hub and
drum assembly. Refer to Linings Replacement
Leading/Trailing Drum Brakes or Linings
Replacement and Wheel Cylinder Replacement
in Duo-Servo Drum Brakes.
11. Connect the propeller shaft. Refer to One-Piece
11.1. Check axle lubricant level at the filter
plug hole.
11.2. Lubricate as necessary. Refer to
Maintenance and Lubrication in General
Information.
11.3 Bleed the brake system, check brake
operation, and adjust if necessary. Refer
to Hydraulic Brake System Bleeding in
Hydraulic Brakes.
11.4. Check for fluid leaks.
11.5. Road test the vehicle.
Axle Replacement (Assembly 4. Raise the axle assembly.

Replacement 11 Inch) 5. Install the washers and nuts to the U-bolts.
• Firmly thread the nuts.
Removal Procedure
• Adjust the alignment of the axle assembly.
1. Raise the vehicle and place jack stands under
the frame side rails for support. 6. Connect the vent hose to the axle vent fitting.
2. Drain the lubricant from the axle housing. 7. Connect the shock absorbers to the
axle brackets.
One-Piece Propeller Shaft Replacement or 8. Connect the hydraulic brake lines to the
Two-Piece Propeller Shaft Replacement. connectors. Refer to Pipe Replacement in
Hydraulic Brakes.
4. Remove the tire and wheel assembly.
9. Connect the parking brake cable to the level
5. Remove the brake drum or hub and drum. and the flange plate. Refer to Park Brake Cable
6. Disconnect the parking brake cable from the Replacement (Front Cable) or Park Brake Cable
lever and at the brake flange plate. Refer to Replacement (Rear Cable - 1Ton) or Park
Park Brake Cable Replacement (Front Cable) or Brake Cable Replacement (Parking Brake
Park Brake Cable Replacement (Rear Cable - Cable) or Park Brake Cable Replacement (Rear
1Ton) or Park Brake Cable Replacement Cable - 1/2 and 3/4 Ton) in Parking Brake.
(Parking Brake Cable) or Park Brake Cable 10. Install the brake drum or hub and drum.
Parking Brake. 11. Install the tire and wheel assembly.
7. Disconnect hydraulic brake pipes from the 12. Connect the propeller shaft. Refer to One-Piece
connectors. Refer to Pipe Replacement in Propeller Shaft Replacement or Two-Piece
Hydraulic Brakes. Propeller Shaft Replacement
8. Disconnect the shock absorbers from the 13. Fill the axle assembly with axle lubricant to
axle brackets. the filler plug hole level. Refer to
9. Disconnect the vent hose from the axle
vent fitting. 14. Bleed the brake system, check brake operation
and adjust if necessary. Refer to Hydraulic
10. Support the axle assembly with a hydraulic Brake System Bleeding in Hydraulic Brakes.
floor jack.
15. Remove the jack stands and lower the vehicle.
11. Remove the nuts and washers from the U-bolts.
16. Check axle operation.
12. Remove the U-bolts, spring plates, and spacers
from the axle assembly. 17. Check for fluid leaks.
13. Lower the axle assembly. 18. Road test the vehicle.
1. Place the axle assembly under the vehicle.
2. Align the axle assembly with the springs.
3. Connect the spacers, spring plates, and U-bolts
to the axle assembly.
Hub and Drum Assembly Replacement

Removal Procedure
Tools Required
J 2222-C Wheel Bearing Nut Wrench
1. Raise the vehicle until the wheel is free
to rotate.
2. Remove the wheel and tire.
3. Remove the axle shaft (5). Refer to Axle
Replacement (11 Inch Ring Gear).
4. Remove the retaining ring (10).
5. Remove the key (9).
6. Remove the adjusting nut using the J 2222-C.

160066
4-152 Rear Drive Axle Drivel ine/Axle
1. Install the hub and drum (3) on the axle tube.
• Be sure the bearings and the oil seal are
positioned properly.
• Apply a light coat of high melting point EP
bearing lubricant to the contact surfaces and
the outside of the axle tube.
3. Place the tang into the keyway.
4. Install the adjusting nut.

5. Adjust the bearing preload. Refer to Axle
Replacement (11 Inch Ring Gear)
6. Install the key (9).

7. Install the retaining ring (10).
8. Install the axle shaft. Refer to Axle
9. Install the wheel and tire.
160066
Hub and Rotor Assembly Replacement

Removal Procedure
For Full-Floating Axle Wheel End Components Refer
to Rear Axle Disassembled View.
Tool Required
1. Raise the vehicle until the wheel is free
to rotate.
3. Remove the axle shaft. Refer to Axle
4. Remove the nut using J 2222-C.
5. Remove the retaining ring.
6. Remove the lock or the key.
7. Remove the adjusting nut.
9. Remove the hub and the rotor.
Inspect for any worn or damaged parts.
Replace any defective parts.
1. Connect the hub and rotor to the tube being
sure that the bearings and the oil seal are
positioned properly.
2. Apply a light coat of high melting point EP
bearing lubricant to the contact surfaces and on
the outside of the axle tube.
3. Install the washer and engage the tang in
the keyway.
4. Install the adjusting nut.
Tighten
• Tighten the adjusting nut to 68 N.m
(50 lb ft) while turning the hub.
• Back-off the locknut and re-tighten it to
41 to 54 N.m (30 to 40 lb ft) while rotating
the hub.
• Back-off the nut 135 degrees to
150 degrees. 156458
• The final bearing adjustment is 0.025 to

0.25 mm (0.001 to 0.010 inch).
and Notices.
5. Install the lockwasher and the outer locknut.
6. Bend on of the ears of the lockwasher over the
inner nut to a minimum of 30 degrees.
7. Bend one of the ears of the lockwasher over
the outer nut to a minimum of 60 degrees.
Tighten
9. Install the tire and the wheel assembly.
Bearing Cup Replacement

Removal Procedure
Tools Required
• J 8608 Pinion Bearing Cup Installer
• J 24426 Outer Bearing Cup Installer
• J 24427 Inner Wheel Bearing Cup Installer
• Axle Shaft Seal Installer
1. Raise the vehicle until the wheels are free
to rotate.
2. Remove the hub and drum. Refer to Hub and
Drum Assembly Replacement.
3. Remove the oil seal (2).
4. Use a drill to remove the inner bearing and
the cup (1).
160066 5. Use snap ring pliers to remove the retaining
ring (11).
6. Remove the outer bearing ring using J 24426
and J 8092.
7. Drive the bearing and the cup (8) from the

hub (3).
8. Clean the old oil sealing compound from the oil
seal bore in the hub.
9. Clean the bearing assemblies in a solvent
using a stiff brush in order to remove the
old lubricant.
• Dry the bearings with compressed air.
• Do not spin the bearings.
10. Clean the lubricant from the axle housing and
from inside the hub.
11. Remove the gasket material from the hub and
the axle shaft.
12. Inspect the bearings for wear, chipped edges or
other damage.
13. Check for flat or rough spots on the rollers.
14. Inspect the cups for pits and cracks.
160066 15. Replace parts as necessary.
Tools Required
. J 8608 Pinion Bearing Cup Installer
• J 24426 Outer Bearing Cup Installer
• J 24427 Inner Wheel Bearing Cup Installer
• Axle Shaft Seal Installer
1. Install the outer bearing cup (8) into the
hub (3).
Important: Install the J 8608 upside down on the

J 8092 so that the chamfer does not contact the
bearing cup.
2. Drive the outer bearing cup into hub using the
J 8608 and the J 8092.
156462
3. Drive the outer bearing cup (7) beyond the

retaining ring groove.
4. Install the retaining ring (11) in the groove.
5. Drive the outer bearing cup onto the retaining
ring (11) using the J 24426.
6. Install the inner bearing cup using the J 24427
and the J 8092.
7. Drive the inner bearing cup until it is seated
against the hub shoulder.
8. Install the inner bearing (1).
9. Install a new oil seal (2) using the Axle Shaft
Seal Installer.
10. Install the hub and drum assembly (3). Refer to
Hub and Drum Assembly Replacement.
11. Install the wheel bearing adjusting nut (8).
12. Adjust the bearing preload. Refer to Wheel
Bearing Adjustment (10 1/2 Inch Ring Gear).
13. Install the axle shaft (5). Refer to Axle

(11 Inch Ring Gear)
Rem oval Procedure
Tools Required
• J 8092 Drive Handle
• J 8608 Outer Pinion Bearing Cup Installer
• J 24426 Outer Wheel Bearing Cup Installer
• J 24427 Inner Wheel Cup Bearing Installer
• J 39114-A Axle Shaft Seal Installer
1. Raise the vehicle until the wheels are free
to rotate.
3. Remove the hub and drum assembly. Refer to
Hub and Drum Assembly Replacement
4. Remove the inner bearing and the oil seal.
156462
• Lay the drum on a flat surface using a
shop towel in order to catch the bearing and
the seal.
• Use a drift to remove the bearing cup and
the seal.
5. Remove the retaining ring using snap
ring pliers.
6. Remove the outer bearing using J 8092
with J 24426.
7. Drive the bearing and the cup from the hub.
8. Clean the old sealing compound from the oil
seal bore in the hub.
9. Clean the bearing assemblies in a solvent using
a stiff brush to remove the old lubricant. Dry
the bearings with compressed air. Do not spin
the bearings.
10. Clean the lubricant from the axle tube and from
inside the hub.
11. Clean the gasket material, if used, from the hub
and the axle shaft.
12. Inspect the bearings for any wear, chipped
edges or other damage.
13. Check for any flat or rough spots on the rollers.
14. Check the cups for any pits or cracks.
15. Replace and discard the old oil seal.
16. Pack the inner and the outer bearing with
wheel bearing lubricant GM P/N 1051344. Refer
to Lubrication Specifications.
1452
Tools Required
• J 8092 Drive Handle
• J 8608 Outer Pinion Bearing Cup Installer
• J 24426 Outer Wheel Bearing Cup Installer
• J 24427 Inner Wheel Cup Bearing Installer
• J 39114-A Axle Shaft Seal Installer
1. Install the outer bearing cup into the hub using
J 8092 and J 8608. Drive the cup beyond the
retaining ring groove.
Important: Be sure to install J 8608 Upside
down on J 8092 so that the chamfer does not
contact the bearing cup.
2. Install the retaining ring into the groove.

Drive the cup back onto the retaining ring
using J 24426.
156462
3. Install the inner bearing cup using J 8092 and

J 24426. Drive the cup into place until it sits
against the hub shoulder.
4. Install the inner bearing.
5. Install the new oil seal using J 39114-A.
6. Install the outer bearing.
7. Install the hub and drum.
33870
Wheel Bearing Adjustment

Rem oval Procedure
Tools Required
1. Make sure the brakes are fully released and do
not drag.
2. Pull or push the tire at the top back and forth
in order to check the wheel bearing play.
• Use a pry bar under the tire as
an alternative.
• If the wheel bearing adjustment is correct,
movement of the brake drum in relation to
the brake backing plate will be
barely noticeable.
• If the movement of the brake drum in
relation to the brake backing plate is
excessive, adjust the bearings.
3. Raise the vehicle until the wheel is free to spin.
5. Clean the following from the keyway, the
threads, and the adjusting nut (8).
7. Remove the key (9).
and Notices.
8. Tighten the wheel bearing adjusting nut.
Tighten
Tighten the adjusting nut to 68 N-m (50 lb ft)
using the J 2222-C.
• Rotate the drum in the opposite direction as
the adjusting nut turns.
• Make sure the inner bearing roller assembly
is seated against the spindle shoulder.
9. Adjust the adjusting nut as follows:
9.1. Back off the adjusting nut one
quarter turn.
9.2. Retighten the adjusting nut to
17 N m (13 lb ft).
9.3. Align the closest adjusting nut slot with
156468 the keyway in the axle spindle.
1. Install the key (9) into the keyway and adjusting
nut slot.
3. Make sure the retaining ring is seated.
Wheel Bearing Adjustment

(11 Inch Ring Gear Axle)
D iagnostic Procedure
Tools Required
1. Make sure the brakes are fully released and do
not drag.
2. Pull or push the tire at the top back and forth
in order to check the wheel bearing play.
• Use a pry bar under the tire as
an alternative.
• If the wheel bearing adjustment is correct,
movement of the brake drum in relation to
the brake backing plate will be
barely noticeable.
• If the movement of the brake drum in
relation to the brake backing plate is
excessive, adjust the bearings.
Rem oval Procedure

1. Raise the vehicle until the wheel spins freely.
3. Remove the retaining ring.
4. Remove the rear wheel bearing axle adjusting
nut key.
5. Adjust the adjusting nut.
Tighten
Tighten the adjusting nut to 68 N-m (50 lb ft)
with the J 2222-C while rotating the
hub assembly.
6. Make sure the bearing cones are seated and in
contact with the spindle shoulder.
7. Back off the adjusting nut and retighten the
adjusting nut while rotating the hub.
8. Back off the adjusting nut.
9. Retighten the adjusting nut while rotating the
hub assembly.
Tighten
Tighten the adjusting nut to 47 N-m (35 lb ft).
10. Back off the adjusting nut 135-150 degrees.
1. Install the lock washer
2. Bend one tang of the retaining washer over a
flat of the adjusting nut to a minimum of
30 degrees.
3. Install the outer retaining nut.
Tighten
Tighten the outer retaining nut to a minimum of
88 N-m (65 lb ft)
and Notices.
4. Make the final bearing adjustment
0.025-0.25 mm (0.001-0.010 in).
5. Bend one tang of the retaining washer over a
flat of the outer nut to a minimum of
60 degrees.
6. Add wheel bearing grease in the bearings.
Component Locator
Rear Axle Disassembled View
Full-Floating Axle Wheel End Components
Legend
(1) Wheel Hub Bolt (12) Outer Bearing
(2) Caliper Mounting Plate Bolt (13) Wheel Bearing Spacer
(3) Dust Shield (14) Rear Wheel Hub
(4) Caliper Mount Bracket (15) Wheel Bearing Washer
(5) Washer (16) Adjuster Nut
(6) Nut (17) Lock Washer
(7) Wheel Bearing Oil Deflector (18) Outer Locknut
(8) Oil Seal (19) Rear Axle Shaft Bolt
(9) Inner Bearing (20) Axle Shaft Cap
(10) Rear Brake Rotor (21) Axle Shaft Gasket
(11) Retaining Ring (22) Rear Axle Shaft
Legend
(1) Pinion Nut (8) Preload Shims
(2) Washer (9) Axle Housing
(3) Pinion Flange/Yoke (10) Shims
(4) Pinion Oil Seal (11) Inner Pinion Bearing Cup
(5) Slinger (12) Inner Pinion Bearing Cone
(6) Outer Pinion Bearing Cone (13) Pinion
(7) Outer Pinion Bearing Cup
168037
Legend
(1) Axle Housing (10) Shim
(2) Ring Gear (11) Bearing Cup
(3) Roll Pin (12) Bearing Cone
(4) Differential Case (13) Ring Gear Bolt
(5) Shim (14) Pinion Shaft
(6) Cover (15) Pinion Gear
(7) Cover Bolt (16) Pinion Thrust Washer
(8) Bearing Cap Bolts (17) Side Gear
(9) Bearing Cap (18) Side Gear Thrust Washer
Description and Operation Under light loads, the clutch plates alone tend to
lock axle shafts to the differential case, and
Rear Axle Description therefore, locking each other. This is due primarily to
the gear separating load developed on the right
General Description clutch pack. This induced clutch torque capacity
These trucks use various rear axles. The axles can resists motion between the side gear and the rear
be identified by the ring gear size in inches, by axle differential case. The differential allows the
manufacturer (American Axle Manufacturing or Dana) wheels to turn at different speeds while the axle
and by the type of axle shaft used (semi-floating or shafts continue to transmit the driving force. Also,
full-floating). American Axle Manufacturing axles heavier throttle application will cause an axle speed
include the 81/2, 85/8, 91/2, and 101/2 inch ring gear differential, but this starts the full-lock feature of
axle. Dana supplies an 11 inch ring gear axle. The the unit.
locking differential is supplied by Eaton. Full locking is accomplished through the use of a
Rear Axle Operation heavyweight governor mechanism, cam system, and
A basic differential has a set of four gears. Two are multi-disc clutch packs. The flyweights on the
side gears and two are pinion gears. Some governor mechanism move outward to engage a
differentials have more than two pinion gears. Each latching bracket whenever the wheel-to-wheel speed
side gear is splined to an axle shaft; so each axle varies by approximately 100 RPM or more. This
shaft turns when its side gear rotates. action retards a cam which, in turn, compresses the
multi-disc clutch packs locking both side gears to the
The pinion gears are mounted on a differential pinion case. The 100 RPM wheel-to-wheel speed allows for
shaft, and the gears are free to rotate on this shaft. cornering without differential lockup.
The pinion shaft is fitted into a bore in the differential At vehicle speeds above approximately 32 km/h
case and is at right angles to the axle shafts. (20 mph), the latching bracket overcomes a spring
Power is transmitted through the differential as preload and swings away from the flyweights. At this
follows: the drive pinion rotates the ring gear. The vehicle speed or greater, the differential is designed
gear, being bolted to the differential case, rotates the not to lock, since added traction is generally
case. The differential pinion, as it rotates with the not needed.
case, forces the pinion gears against the side gears. All axle parts of vehicles equipped with the locking
When both wheels have equal traction, the pinion rear axle are interchangeable with those equipped
gears do not rotate on the pinion shaft because the with the conventional rear axle, except for the
input force on the pinion gear is equally divided case assembly.
between the two side gears. Therefore, the pinion Dana Model 80 (11 Inch Ring Gear)
gears revolve with the pinion shaft, but do not rotate The Dana 11 inch ring gear axle uses a conventional
around the shaft itself. The side gears, being splined ring and pinion gear set to transmit the driving force
to the axle shafts and in mesh with the pinion gears, of the engine to the rear wheels. The gear set
rotate the axle shafts. transfers the driving force at a 90 degree angle from
If a vehicle were always driven in a straight line, the the propeller shaft to the axle shafts.
ring and pinion gears would be sufficient. The axle This axle is full-floating. The wheel hubs support the
shaft could then be solidly attached to the ring gear axle shaft at the wheel ends. The shaft at the wheel
and both driving wheels would turn at equal speed. end is supported and splined to the hub
inner-diameter. The differential supports the other
However, if it became necessary to turn a corner, the
splined end of the shaft.
tires would scuff and slide because the outside
wheel would travel further than the inside wheel. To Two tapered roller bearings support the pinion gear.
prevent tire scuffing and sliding, the differential A shim pack between the inner pinion bearing cup
allows the axle shafts to rotate at different speeds. and the axle housing sets the pinion depth. A shim
pack at the front of the axle housing between the
When the vehicle turns a comer, the inner wheel bearing cone and pinion gear sets the pinion
turns slower than the out wheel and slows its rear bearing preload.
axle side gear (as the shaft is splined to the side
The ring gear bolts to the differential case.
gear), the rear axle pinion gears will roll around the
slowed rear axle side gear, driving the rear axle side Two tapered rolling bearings support the differential
gear and wheel faster. case. Two methods are in use in order to control the
differential bearing preload and drive gear to pinion
Locking Rear Axle
gear backlash.
The locking rear differential allows for normal
differential function as indicated in the standard rear One method uses a 0.76 mm (0.030 inch) hardened
axle description. Additionally, the locking rear shim and a selective outboard spacer shim. The
differential uses multi-disc clutch packs and a speed location of the hardened shim is between each
sensitive engagement mechanism that locks both differential bearing cone and the differential case.
The location of the selective outboard spacer shim is
wheels together if one wheel should spin excessively
between each differential bearing cup and
during slow vehicle operation.
the housing.
Driveline/Axle Rear Drive Axle 4*165
The other method uses selective shims between
each differential bearing cone and the differential
case, with outboard spacers between each
differential bearing cup and the housing.
When moving the ring gear with outboard
selective shims, choose shims of different thickness
in order to accommodate the change. For example: if
a change requires a shim on the ring gear side that
is 0.13 mm (0.005 inch) thinner, then the opposite
side will require a shim that is 0.13 mm (0.005 inch)
thinner.
On axles built using the other method, accomplish
gear movement by moving shims from one side of
the differential case to the other. If the differential
preload needs to be changed, equal amounts must
be added or subtracted from each side.
Spread the axle housing in order to remove the
differential from the housing. When the spreader is
removed, the housing sets the bearing preload. Two
bearing caps hold the differential in the axle housing. 168032
A pinion seal, hub seal, and RTV between the cover A part number (2) and manufacturing date (1) on the
and the housing seals the axle. right axle tube, cover plate side, identifies all Dana
axles. The model number (3) is cast on the carrier.
Tags attached to the differential cover plate carry
information on limited slip lubrication (4) and the axle
ratio (5). The carrier does not have a drain plug.

Illustration Tool Number/Description
!^ J J2222C
< c
Wheel Bearing Nut Wrench
N = S
156470
o H -------------------- - J 5853-B
==C D
Torque Wrench
156497
J 6627-A
Wheel Stud Remover
130
(q ..- ,. M ) J 8092
Driver Handle
2015
J 24426
Outer Wheel Bearing Cup
Installer
36475
f o) J 24427
Inner Wheel Bearing Cup
W 36474
Installer
J 29709
Axle Shaft Bearing Installer
156531
J 29712
Axle Shaft Bearing Remover
(91/2 in)
156545
J 29713
Axle Shaft Bearing Installer
(91/2 in)
156537
J 39114-A
Axle Shaft Seal Installer
36472
Driveline/Axle Rear Drive Axle - Locking/Limited Slip Rear Axle 4-169
Rear Drive Axle - Locking/Limited Slip Rear Axle

Specifications

Specification
Application Metric English
7 5/8, 8 1/2, and 8 5/8" Differential Lockscrew 36 N-m 27 lb ft
9 1/2" Differential Lockscrew 50 N.m 37 lb ft
Thrust Block Sizes (Locking)

8 1/2" and
Color Code 7 5/8" 8 5/8" 9 1/2"
Purple 1.260" 1.322" 1.598"
White 1.264“ 1.326" 1.602"
Brown 1.268" 1.330" 1.606"
Yellow 1.272" 1.334" 1.610"
Orange 1.276" 1.338" 1.614"
Pink 1.280" 1.342" 1.618"
Green 1.284" 1.346" 1.622"
Blue 1.288" 1.350" 1.626"
Black — — 1.630"
Reaction Block, 10 1/2 Inch Axle

Gear Size Reaction Block Size
10 1/2" 0.787"
Application Type of Material GM Part Number
GL-5 80W90 Lubricant —
4-170 Rear Drive Axle - Locking/Limited Slip Rear Axle Driveline/Axle
Repair Instructions
(10 1/2 Case)
Removal Procedure
Tools Required
J 22912-01 Bearing Remover
1. Remove the ring gear and the differential side
bearings. Refer to Drive Axle Disassemble in
Rear Drive Axle.
2. Remove the case screws.
Set the unit on the right side case half.
3. Remove the case halves.
3.1. Pry the halves apart at the yoke
hole location.
3.2. Hold the side gear in the left side
case half.
4. Remove the governor assembly.
5. Remove the latching bracket assembly.
6. Remove the left side gear.
7. Remove the left side clutch plates and the
guide clips.
8. Remove the left side gear thrust washer.
• The reaction blocks
• The pinion yoke
• The pinion gears
• The pinion thrust washers
10. Remove the right cam unit from the differential.
11. Remove the right side gear thrust washer.
Measure and record the overall length of the
gear assembly from the front of the gear to the
back of the thrust sleeve including the side
gear thrust washer.
12. 206983
Remove the thrust sleeve using the J 22912-01.
Press the sleeve from the side gear.
13. Remove the clutch plates.
14. Remove the guide clips.
15. Remove the wave washer.
16. Remove the cam plate.
17. Remove the side cam gear.
CP
&
_ )
206994
Cleaning and Inspection Procedure

1. Clean all the parts with an approved solvent.
2. Inspect the following parts:
• The pinion gear and the side gear for wear,
cracks, scoring, and spalling
• The thrust washers for wear
• The fit of the side gears on the axle shafts
• The differential case for cracks and scoring
• The thrust sleeve for excessive wear
Do not replace the thrust sleeve unless
necessary.
• All the parts for excessive wear CP
and breakage &
Important: If any damage to the differential
case is found, the differential must be replaced.
4. Inspect the side gear bore for scoring. 206994
If scoring is present, replace the differential.
Cam Unit Assembly
1. Install a cam plate to the side cam gear.
2. Install a wave washer.
3. Install the clutch plates.
Alternate the plates and position the wave
washer as shown.
4. Install the thrust sleeve.
Press the thrust sleeve flush with the side gear
disc spline.
5. Install the guide clips to the plates.
5.1. Use a chassis grease in the clips in
order to hold the clips in place on
the plates.
5.2. If the side gear or the thrust sleeve has
been replaced, measure and record the
overall length of the gear to the back of
the thrust sleeve including the side gear
thrust washer.
5.3. Compare the reading with the reading
obtained earlier.
5.4. If the new reading is more than
0.0762 mm (0.003 in) higher or lower
than the original, select a side gear
thrust washer that will return the reading
closest to the original reading.
Adjustment of the Differential
1. If it is necessary to replace the cam gear, the
right hand side gear, or the reaction blocks, the
entire differential must be adjusted. The
differential is adjusted using selective thickness
thrust washers behind each side gear, and the
selective thickness thrust washers between the
reaction blocks.
2. Build up the differential properly.
The proper clearance between parts is critical
to the operation of the unit.
3. Note the three adjustments necessary as follow:
• The left side gear backlash
• The right side gear backlash
• The thrust block clearance
Right Side Gear Backlash Adjustment
1. Install the cam unit and the side gear thrust
washer to the right case half.
2. Clamp the cam unit in place using a set of
washers, nut, and a bolt long enough to hold
the cam unit in place.
3. Place the pinion gears and the pinion thrust
washers on the pinion yoke.
4. Install the yoke firmly to the differential
case half.
5. Loosen the nut.
6. Index one pinion gear tooth to point downward,
perpendicular to the case half face.
Tighten the nut.
206998
7. Mount a dial indicator on the case half face
using a magnetic base.
8. Place the stem of the dial indicator on the
pinion gear tooth.
9. Pull the pinion gear firmly into the seat.
• Rotate the gear back and forth while reading
the dial indicator.
• Record the reading.
• Do not unseat the pinion yoke.
This will make the backlash
reading inaccurate.
10. Repeat steps 5 through 9 on the remaining
two pinions.
11. The backlash should be between 0.254 and
0.457 mm (0.010 and 0.018 in).
12. If the backlash is too high, use a thicker side
gear thrust washer.
13. If the backlash is too low, use a thinner side 206996
gear thrust washer.
Left Side Gear Backlash Adjustment
1. Assemble the clutch plates.
Alternate the plates as shown.
2. Assemble the guide clips to the plates.
Use grease in the clips in order to hold them in
place on the plates.
3. Install the following parts to the differential:
• The side gear thrust washer
• The clutch plate assembly
• The left side gear
CP
&
4. Install the clamp the side gear in place using a

set of washers, a nut, and a bolt long enough
to hold the side gear in place.
5. Place the pinion gears and the pinion thrust
washers on the pinion yoke.
206997
6. Install the yoke firmly to the differential
case half.
7. Loosen the nut and the index one pinion gear
tooth to point downward, perpendicular to the
case half face.
Tighten the nut.
8. Mount a dial indicator on the case half face

using a magnetic base.
9. Place the stem of the dial indicator on the
pinion gear tooth.
10. Pull the pinion gear firmly into the seat.
• Rotate the gear back and forth while reading
the dial indicator.
• Record the reading.
• Do not unseat the pinion yoke. This will
make the backlash reading inaccurate.
11. Repeat steps 7 through 10 on the other
two pinions.
12. The backlash should be between 0.051 and
0.254 mm (0.002 and 0.010 in).
13. If the backlash is too high, use a thicker pinion
thrust washer.
14. If the backlash is too low, use at a thinner
position thrust washer.
Reaction Block Clearance Adjustment

1. Install the left side gear thrust washer, the
clutch plates, and the side gear.
Bolt the parts into position. Refer to Left Side
Gear Backlash Adjustment.
2. Install the right side gear thrust washer and
cam assembly.
Bolt the parts into position. Refer to Right Side
Gear Backlash Adjustment.
3. Measure the distance from the side gear face
to the case half face.
3.1. The thickness of the straight edge must
be subtracted from the reading.
3.2. Add the measurement of both sides
together. This is the side gear spread.
206999
4. Measure the thickness of the original
reaction blocks and the reaction block thrust
washers together.
5. If the combined reaction block and the thrust
washer thickness is not 0.000 to 0.1524 mm
(0.000 to 0.006 in) less than the side gear
spread, adjust the clearance using the
• Select a new reaction block thrust washer of
the correct thickness in order to obtain 0.000
to 0.1524 mm (0.000 to 0.006 in) clearance.
• Reshim the left and/or the right clutch
disc pack.
Maintain the side gear backlash. Refer to
Right Side or Left Side Gear Backlash
Adjustment in this section.
• Some of the older locking differentials had
select fit reaction blocks without a between
thrust washer. These models require
replacing the reaction blocks with the correct
thickness reaction block.
Assembly of the Differential
1. Install the right thrust washer.
2. Install the right cam unit. Refer to Cam
Unit Assembly.
• The reaction blocks
• The reaction block thrust washer
• The pinion yoke
• The pinion gears
• The pinion thrust washers
4. Install the left thrust washer.
Assemble the plates as shown.
&
5. Install the left side gear.
6. Install the latching bracket assembly.
7. Install the governor assembly.
The straight end of the latching bracket spring
must be over and outside the governor 206994
assembly shaft.
8. Install the case halves together.
Hold the side gear in the left side case half.
9. Install the case screws.
10. Install the ring gear and the differential side
bearings. Refer to Assembly of the Rear Axle in
10 1/2 Inch Ring Gear.

(8 1/2 and 9 1/2 Case)
Removal Procedure
Tools Required
J 26252 Governor Remover
Refer to Differential Components
1. Remove the governor bushing (2)
using J 26252.
2. Remove the E-clips that hold the latching

bracket on the shaft. Move the bracket down
the shaft.
3. Remove the latching bracket bushing (3) using
J 26252.
4. Remove the latching bracket, the shaft, and the
spring from the case.
5. Remove the governor assembly (14) from
the case.
6. Remove the lock screw (4).
7. Remove the pinion shaft (23).
8. Remove the differential pinion gear (6) and
pinion thrust washer (5).
Rotate one of the side gears and roll the gears
out of the case.
9. Remove the thrust block (22) and the right
side gear (11).
10. Remove the right clutch plates (7) and the side
thrust washer (8).
11. Remove the left side gear, the cam plate, and
the clutch plates as an assembly (cam unit).
12. Remove the side gear thrust washer.
Driveline/Axle Rear Drive Axle - Locking/Limited Slip Rear Axle 4*177

(10 1/2 Assembly)
Cam Unit Disassembly
Tools Required
J 22912-01 Bearing Remover
1. Measure and record the overall length of the
gear assembly from the front of the gear to the
back of the side thrust sleeve, including the
side gear thrust washer.
2. Remove the guide clips.
3. Remove the side thrust sleeve using
the J 22912-01.
Press the sleeve from the side gear.
4. Remove the clutch plates.
5. Remove the wave washer.
6. Remove the cam plate.
7. Remove the side cam gear.

(8 1/2 and 9 1/2 Assembly)
Removal Procedure
1. Remove the retaining ring using snap ring
pliers.
2. Remove the clutch plates and the guide clips.
1. Install the cam plate to the side cam gear.
2. Install the wave washer.
3. Install the clutch plates (75/8 ring gear = 8
plates, 81/2 ring gear = 10 plates). Alternate the
plates.
5. Install the guide clips (13) and (16) to the
clutch plates. Use grease in the clips in order
to hold the clips in place on the plates.
6343
Locking Differential Cleaning 2. Assemble the guide clips (10) and (13) to the
and Inspection plates. Use grease in order to hold the clips in
place on the plates.
Cleaning and Inspection Procedure 3. Install the side gear thrust washer (8), the
1. Clean all the parts with an. approved solvent. clutch plate assembly (7) and the right side
2. Visually inspect all the parts for excessive wear gear (11) to the differential.
or breakage. Replace the parts if necessary. 4. Place the pinion gears (6) and the thrust
3. Check the pinion gear and the side gear teeth washers (5) into the differential.
for any the following conditions: 5. Align the gears and the washers with the pinion
• Wear shaft hole.
• Cracks 6 . Press down on the side gear. Install the pinion
shaft (23) and the lock screw (4). Use a thinner
• Scoring side gear thrust washer if you can not press
• Spalling the side gear down far enough to install the
4. Check the thrust washer for wear. pinion shaft.
5. Check the fit of the side gears on the 7. Rotate the pinion gear closest to the lock screw
axle shafts. so that one of the teeth is pointing downward
(perpendicular to the ring gear flange).
6. Check the differential case for cracks
and scoring. 8 . Insert a large tapered tool, such as a
screwdriver, firmly between the side gear and
Important: Do not replace the thrust sleeve the pinion shaft.
unless this is necessary.
7. Check the thrust sleeve for excessive wear.
8. Check the side gear bore for scoring, if scoring
is present, replace the entire differential.
9. Replace the differential if you find any damage
to the case.
Locking Differential Cam Unit Assemble
1. Install the cam plate to the side cam gear.
2. Install the wave washer.
3. install the clutch plates.
Alternate the plates as shown.
4. Install the thrust sleeve.
Press the thrust sleeve flush with the side gear
disc splines.
5. Install the guide clips to the clutch plates.
5.1. Use grease in the clips in order to hold
the clips in place on the plates.
7531
5.2. If the side cam gear or the side thrust
sleeve has been replaced, measure and 9. Mount and zero in a dial indicator to the ring
record the overall length of the gear gear flange. Place the stem of the indicator on
assembly from the front of the gear to one of the teeth of the pinion gear closest to
the back of the side thrust sleeve, the lock screw (3).
including the side gear thrust washer. 10. Pull the pinion gear firmly into the gear’s seat.
5.3. Compare the reading with the reading Rotate the gear back and forth while reading
obtained earlier in this section. the dial indicator. Record the reading.
5.4. If the new reading is more than 11. Repeat steps 7 through 9 for the opposite
0.0762 mm (0.003 in) higher or lower pinion gear.
than the original, select a thrust washer 12. The backlash should be between
that will return the reading closest to the 0.051-0.243 mm (0.002-0.010 in).
original reading. 13. Use a thicker side gear thrust washer if the
backlash is too high. Use a thinner washer if
Locking Differential Adjustment
the backlash is too low.
Adjustment Procedure
Refer to Differential Components.
1. Assemble the clutch plates. Alternate the plates
as shown.
Driveline/Axle Rear Drive Axle - Locking/Limited Slip Rear Axle 4*179
Locking Differential Assemble

Assembly Procedure
Refer to Differential Components.
1. Install the left side gear thrust washer (17).
2. Install the cam unit. Refer to Locking
Differential Cam Unit Disassemble.
3. Install the right side gear thrust washer (8).
4. Install the right clutch plates with the guide clips
(9) and (10). Assemble the unit as shown.
5. Install the right side gear (11).
6. Install the thrust block (22), the pinion thrust
washer (5), and the pinion gear (6).
6.1. Place the pinion gears into the differential
180 degrees apart.
6.2. Rotate the gears and the thrust block
into position.
6.3. The open side of the thrust block must
face the small window opening.
Important: Install a new lock screw (4),
finger tight.
7. Install the pinion shaft (23).
8. Tighten to specifications after installation in the
vehicle. Refer to Fastener Tightening
Specifications (8 1/2 and 8 5/8) in Rear
Drive Axle.
Important: The straight end of the latching
bracket spring must be over and outside the
governor assembly shaft.
9. Install the governor assembly (14) and the
latching bracket bushing (3).
10. Install the governor bushing (2).
10.1. Use the bushing with a straight hole,
not tapered.
10.2. Press the bushing in far enough to give
0.1016-0.508 mm (0.004-0.020 in) shaft
end play.
11. Install the latching bracket bushing (3).
Press the bushing in far enough to eliminate all
of the end play.
4-182 Transfer Case Driveline/Axle
Schematic and Routing Diagrams
T ran s fer C a s e Control Schematic References

Section Number
Reference on Schematic Subsection Name
Fuse Block Details Cell 11 8A-11
Ground Distribution Cell 14 8A-14
Instrument Panel Cell 81 8A-81
Power Distribution Cell 10 8A-10
Transfer Case Control Schematic Icons

Icon Icon Definition
Notice: Refer to E S D N o tic e in Cautions and Notices.
>
19384
Notice: Refer to O B D I I S y m b o l D e s c rip tio n N o tic e .
A
JOBDnV
19385
Driveline/Axle Transfer Case 4-183
Transfer Case Control Schematics (Selectable 4WD) (Transfer Case Encoder)
4-184
Transfer Case
Driveline/Axle
187317
Transfer Case Control Schematics (Selectable 4WD) (Transfer Case Switch and Front Axle Actuator)
Driveline/Axle
Transfer Case 4-185
187320
Transfer Case Control Schematics (Selectable 4WD) (Transfer Case Switch and Front Axle Actuator)
4-186 Transfer Case

VEW CLE CO NTRO L M ODULE
h CO NN EC TO R IDEN TIFIC ATIO N
IP
]l. Transfer Case /I
.A
4WD
Cl - BUI
C 2 - RED
C 3 -C L R
-
-
-
3 2 W AY
3 2 W AY
3 2 W AY
’ Fuse
’ Block C:
vd
i ) Mode Selector { i
Illumination Lamp ^
) Indicator C 4 -B L K
C 5 - BLK
-
-
2 4 W AY
5 W AY
fB DIESEL PO W ER TRA N
j
0.5 BLK 150 S259 1 BLK 150
CO NN EC TO R ID EN TIFIC ATIO N
C l - BRN
C 2 - BRN
- 3 2 W AY
- 2 4 W AY
0
1 BRN Fuse B lock
Deteas
11
5 BLK 150
C 3 - LTB U J - 3 2 W AY
0
A
G et
G round
0.5 GRY D istribution ±G 202
O IIH
* Cross Body
AuxMary
Ground
H eater And
A /C C ontrols
C ell 63
Transfer
Case
C enter)
0.8 BRN 241 1 Fuse B lock Synchronizer
D iesel | B e te ls
O nly 1 C e l 11
S326 0.8 BLK/WHT
0.8 BRN
241
0.8
LT
BLU 1296 0.8 BLK/WHT
0.8 0.8 1695
GRY/BLK C l 20
BRN 241 —« —
1694 A
0.5 GRY/BLK 1694
P101S SP101
Cl B3 C 2 (D iesel)
D iesel
2SL 23 X - - A9X C4 (Oas)
--------------- -- Vehicle Control
(M an) I I Module (VCM)
I I (GAS)
u -------------- J Powertrain Control
Driveline/Axle
_ B jL (Auto) Module (PCM)
Transfer (D iesel)
Case
/ -/ Switch
Auto
Trans Engine
i O nly G105 Ground
187323
Transfer Case Control Schematics (Selectable 4WD) (Power, GND and DLC)
Driveline/Axle
I Hot In RUN I | H ot WWh HEAD LIG HT SW ITC H In PARK O r HEADLIG HT |
ILLUM
l;Fuse
'P
M2 E3
4W D
Fuse 14
20 A
D4 10 A
Block
V
0.8 BRN 241

a 0.35 QRY
Fuse B lock
Fuse Block
1 BRN 241 S217< Details
S235 < D etails
0
C e l 11
0.8 BRN 241

C ell 11
C120
0.5 GRY 8
F3
- ...... «
r “ ^ Spare Power 1694 E C298
A 0.8 BLK/ 1695 *
1 * Source
I I (C onvenience 0.5 GRY/BLK 1694 WHT 0.5 GRY 8 To Auxiliary
l. _ j C enter) 0.8 GRY/BLK
SP101 € P101 S253
H eater And
E5, A /C Controls
D iesel/B ase
R 96 C ab Diesel
/ Suburban
O nly
Section 8 A - 63
O nly
Pickup B
Transfer Case
A
(Auto)
B3 C2
23
Transfer r
Jl
D2 Cl
191
(Diesel)
■* Vehicle
© Av
Mode Selector
Illumination Lamp
Case * •Control
Switch * I Module S259
------------------------------ J (VC M ) (G as)
5 BLK 150
Powertrain
4WD
9
- . G202
5 BLK 150 ’ Cross
0.8 BLK/WHT C l20

—« —
Control
Module
0.8 BLK/WHT (PCM) <Die8e,)
® bT
Indicator
w Lamp
1
G round
Distribution
C e l 14
Body
Ground
S111
S302 n 1695 1695
\ 1 BLK/ 1695
0.8 BLK 150 WHT
C a Cl 20
A C210
S162 (G as) r ■
' ‘1 Convenience
S107 (D iesel) !di • Center
I
Transfer Case 4-187

G round . j
Distribution
1 BLK 150 C ell 14 0.8 BLK/ 1695
WHT
S147 D6 Cl00
3 BLK 150 0.5 BLK 150
1 BLK/ 1695
WHT
G105
Engine Ground
205842
Transfer Case Control Schematics (Automatic 4WD) (Power, GND and DLC)
4-188
Transfer Case
Driveline/Axle
183198
Driveline/Axle
Transfer Case Control Schematics (Automatic 4WD) (Active Transfer Case Select Switch Controls)
Transfer Case
4-189
232516
Component Locator
Transfer Case Control Com ponents

Name Location Locator View Connector End View
Automatic Transfer Case Under LH side of IP, near Convenience Transfer Case Control Transfer Case Control
Control Module Center Component Views Connector End Views
Convenience Center Under LH of IP, on Bulkhead — —
Cruise Control Module LR of Engine Compartment, near Bulkhead — —
Selectable Four-Wheel Center floor console Transfer Case Control Transfer Case Control
Drive Indicator Component Views Connector End Views
Front Axle Actuator RH rear side of the front drive axle Transfer Case Control Transfer Case Control
Component Views Connector End Views
IP Fuse Block LH of IP, near LF Door Jamb Switch Transfer Case Control
Component Views —
Instrument Cluster Upper LH of IP, near Steering Column Transfer Case Control —
Component Views
Park/Neutral Position At LH Center of Transmission —
Switch —
Powertrain Control Under RH end of IP, above Blower Motor,

Module behind IP Compartment Box
Radio Center of IP — —
Stoplamp Switch Top of Brake Pedal — —
Transfer Case Control Transfer Case Control
Transfer Case Control Under the l/P on the steering column Component Views Connector End Views
Module (TCCM) support bracket (Selectable 4WD) (Selectable 4WD)
Transfer Case Encoder RH side, center of the transfer case Component Views —
Motor (Selectable 4WD)
Transfer Case Mode
Selector Illumination In the Switch — —
Lamp
Transfer Case Relay RH rear of the engine compartment, near Component Views Connector End Views
the center of the cowl (Selectable 4WD) (Selectable 4WD)
Transfer Case On the l/P Component Views Connector End Views
Select Switch (Selectable 4WD) (Selectable 4WD)
Transfer Case LH top of the transfer case Component Views —
Switch (M30) (Selectable 4WD)
Switch (MG5) (Selectable 4WD)
Switch (MT1) (Selectable 4WD)
Transfer Case LH top of the transfer case
Switch (MW3) Component Views
(Selectable 4WD)
—
Transfer Case Control Components (cont’d)
Transfer Case Top of the transfer case

—
Synchronizer Component Views
(Selectable 4WD)
Vehicle Control Module Engine Compartment, near EBCM — —
Vehicle Speed Under RH of IP —
Sensor Buffer
C100 Engine Harness to IP Harness, LR of — _ _
Engine Compartment, at Bulkhead
C120 Rear of the engine, near the transmission Component Views Connector End Views
(Selectable 4WD) (Selectable 4WD)
C131 IP Harness, approx. 8 cm from Wiper — —

Motor Breakout
C132 IP Harness, approx. 8 cm from Wiper — —
Motor Breakout
C200 Behind RH of IP, near Heater Motor, in —
foam wrap —
C210 At Convenience Center — —

C224 LH rear of the engine compartment, under Component Views Connector End Views
the brake master cylinder (Selectable 4WD) (Selectable 4WD)
C225 LH rear of the engine compartment, under Component Views Connector End Views
the brake master cylinder (Selectable 4WD) (Selectable 4WD)
C227 Near Stoplamp Switch — —
C228 Crossbody Harness to RF Seat — —
C298 RH Side of IP — —
G103 RF of Engine, front of Intake Manifold — —

G104 RF of Engine Component Views —
(Selectable 4WD)
G105 (Diesel) RH top of the cylinder head Component Views —
(Selectable 4WD)
G200 Behind LH of IP, below Fuse Block — —
G202 RH of IP, mounted to HVAC Plenum — —

Bracket
P100 LH rear of the engine compartment, at the Component Views —
bulkhead (Selectable 4WD)
Engine Harness, Approx. 13 cm from EGR
S103 Valve Breakout, toward Taillamp Harness — —
Breakout
S111 Engine Harness, Approx. 10 cm from — —
EBCM Breakout
Transfer Case Control Components (cont’d)
Engine Harness, Approx. 18 cm from
S107 EBCM Breakout, toward EGR Valve — —
Breakout
S147 Engine Harness, Approx. 8 cm from EGR — —
Valve Breakout
S204 IP Harness, approx. 10 cm from Steering — —
Column Harness Breakout
IP Harness, approx. 8 cm from Instrument
S215 Cluster Breakout, toward Radio Connectors — —
Breakout
S221 IP Harness, approx. 40 cm from Instrument — —
Cluster Breakout
S236 , IP Harness, approx. 10 cm from Steering — —
Column Harness, near P100
S298 IP Harness, approx. 24 cm from Instrument — —
Cluster Breakout, toward Radio Breakout
Selectable 4WD Harness, approx. 10 cm
S302 from Transfer Case Relay Breakout, toward — —
Front Axle Switch
Transfer Case Control Component Views

(Selectable 4WD)
Selectable Four-W heel Drive Indicator W iring
183901
Legend
(1) Convenience Center
(2) Selectable Four-Wheel Drive Indicator Lamp
(3) Transfer Case Shift Illumination Lamp
Transfer Case Sw itch (M T1) and S ynchronizer
Legend
(1) Engine Harness (5) Transfer Case Switch
(2) Heated Oxygen Sensor Connectors (6) Transmission Connector
(3) Vehicle Speed Sensor (7) Park/Neutral Position Switch
(4) Transfer Case Synchronizer (8) Transmission Input Speed Sensor
Transfer Case Switch (MW3) and C120
183908
Legend
(1) Connector C120 (6) Transfer Case
(2) Heated Oxygen Sensor (7) Transfer Case Switch (1 ton)
(3) Vehicle Speed Sensor (8) Engine Harness
(4) Transfer Case Synchronizer (9) Heated Oxygen Sensor Connector
(5) Transfer Case Switch (1/2 ton and 3/4 ton)
Transfer Case Sw itch (M G 5)
Legend
(1) Heated Oxygen Sensor Connectors (4) Transfer Case
(2) Vehicle Speed Sensor (5) Back-Up Lamp Switch
(3) Transfer Case Switch (6) Heated Oxygen Sensor Connector
Transfer Case Sw itch (M 30)
Legend
(1) Heated Oxygen Sensor Connectors
(2) Vehicle Speed Sensor
(3) Transfer Case Switch
(4) Transfer Case
Transfer Case Select Switch
183948
Legend
(1) Radio Connector (4) Rear Fan Switch
(2) Rear W iper Switch (5) Electric Shift Transfer Case Switch or Fog
(3) Cargo Lamp Switch Lamp Switch
Priveline/Axle Transfer Case 4-199
Transfer Case Relay
Legend
(1) Transfer Case Relay
(2) Front Axle Actuator
(3) Front Axle Switch
Driveline/Axle
4-200 Transfer Case
6.5L Diesel Engine, RH Side
172401
Legend
(1) Engine Harness (4) Grounds G150 And G105
(2) Generator Connector (5) Ground G104
(3) Turbo
C224 and C225
183911
Legend
0 ) Cruise Control Module (7) Rear Lamp Harness
(2) Pass Through Grommet P100 (8) Engine Harness
(3) Connector C100 (9) Windshield Wiper Motor
(4) Connector C110 (10) Connector C225
(6) Connector C111
P100
183913
Legend
(1) Connector C102 (5) Horn
(2) LH Front Headlamp Connectors (6) Connector C101
(Composite) (7) Ground G113
(3) Park And Turn Lamp LH Front (8) Connector C100
(4) LH Fog Lamp Connector (9) Pass Through Grommet P100
Transfer Case Control Component Views

(Automatic 4WD)
Autom atic 4W D Support W iring
Legend
(1) Automatic Transfer Case Control Module
(2) IP Harness
(3) Daytime Running Lights Control (DRL)
Module
(4) Convenience Center
(5) IP Reinforcement Brace
4W D Support W iring
Legend (5) Transfer Case Switch (1/2 Ton, 3/4 Ton)

(1) Engine Harness (6) Transfer Case
(2) Right Bank Heated Oxygen Sensor (7) Transfer Case Switch
Connector (8) Left Bank Heated Oxygen Sensor
(3) Vehicle Speed Sensor Connector
(4) Transfer Case Syncronizer
Transfer Case Control Connector End Transfer Case Control Module
Views (Selectable 4WD) (Wire Entry View) (confd)
Transfer Case Select Switch Transfer Case Control Connector End

Views (Automatic 4WD)
L : Automatic Transfer Case Control Module
1
' 1 I1 s
V
qp qp qp qp q? 3 _ /- c n = r. C * _ 5 H ------1 0 6 ^
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V d » LL i u i M
183888
• 12064769
Connector Part
Inform ation • 10-Way F Metri-Pack 150
Series Natural 73221
Circuit Connector Part • 12052107

Pin W ire C olor No. Function Information • ASM 32M (BLK)
A PNK 39 Ignition Fused Feed Wire Color
Circuit
900 Transfer Case Select Pin No. Function

B WHT Switch Output—2 High E1 TAN 1569 Transfer Case Lock
Solenoid Output
C GRY/BLK 1564 Transfer Case Select
Switch Output—4 High
E2 LT BLU/BLK 1567 Service 4WD/AWD
indicator Lamp Output
D DK Transfer Case Select
GRN/WHT 1559 Switch Output—4 Low E3 PNK 1561 AWD indicator Lamp
Indicator Lamp Output
E PPL/WHT 1565 Output—4 Low E4 LT GRN/BLK 1563 2Output
HI Indicator Lamp
F TAN/BLK Indicator Lamp
1566 Output—4 High Transfer Case Position
Indicator Lamp E5 BRN/WHT 1555 Switch Encoder Signal -
G PNK 901 Output—2 High Channel P
H BLK 150 Ground Transfer Case Position
E6 RED/WHT 1556 Switch Encoder Signal -
J GRY 8 Instrument Panel Channel C
Lamp Feed
Transfer Case Position
K — — Not Used E7 YEL/BLK 1558 Switch Encoder Signal -
Channel B
Transfer Case Position
E8 DK BLU/WHT 1557 Switch Encoder Signal -
Channel A
E9 PPL 1807 Serial Data Signal - Class
B - 10400 BAUD - Primary
E10 BRN Fuse Output - Ignition 3 -
241 Type III Fuse
E11 — — Not Used
E12 YEL 400 VSS Signal
E13 PPL 401 VSS Return
E14 BLK/WHT 4WD Front Wheel Lock
1695 Telltale Feed
E15 — — Not Used
E16 BLK/WHT 451 ECM Ground
Automatic Transfer Case Automatic Transfer Case Module
Control Module (cont’d)
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62450
73221 • 12052856
Connector Part
Connector Part • 12052107 Information • CONN 4F M/P 280 (BLACK)
Inform ation • ASM 32M (BLK) Circuit
Wire Color
W ire Color C ircuit Pin No. Function
Pin No. Function Transfer Case Motor
A BLK 1552
F1 PPL/WHT 1565 4 ’LO’ Indicator Lamp Feed - CW
Output Transfer Case Motor
B RED 1553
F2 TAN/BLK 1566 4 Hi Indicator Lamp Feed - CCW
Output C BLK 150 Ground
F3 BRN 1560 Neutral Indicator Lamp Fuse Output - Battery -
Output D ORN 1640
Type III Fuse
F4 GRY/BLK 1570 Front Axle Actuator Output
F5 LT BLU 2221 VSS Signal
F6 DK GRN 2222 VSS Return
F7 GRY/BLK 1694 4WD Switch Signal *Low
F8 — — Not Used
F9 — — Not Used
F10 — — Not Used
F11 — — Not Used
F12 BLK/WHT 1554 Transfer Case Encoder
Signal Return
F13 LT GRN/BLK 431 Reference Voltage Feed -
8 Volt Reference
F14 LT GRN/BLK 431 Reference Voltage Feed -
8 Volt Reference
Transmission Mounted
F15 LT GRN 275 Neutral Safety Switch
Output - Park
F16 LT BLU/BLK 1693 4WD Switch Signal
Automatic Transfer Case Select Switch, Automatic Transfer Case Select Switch,
Connector C1 Connector C2
IN - LINE CONNECTOR C236

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12045813
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62463 204352
Connector Part • 12064766 Connector Part • 12045813

Information • CONN 8F M/P 150 (BLACK) Information • CONN 4F M/P 150 (BLACK)
Circuit Circuit
Wire Color Wire Color Function
Pin No. Function Pin No.
Reference Voltage Feed - A — — Not Used
A LT GRN/BLK 431
8 Volt Reference B PPL/WHT 1382 LED Dimming Signal
B LT BLU/BLK 1693 4WD Switch Signal Use Output - Ignition 3 -
C BRN 241
4 ’LO’ Indicator Type III Fuse
C PPL/WHT 1565
Lamp Output Neutral Indicator
D BRN 1560
4 ’HI’ Indicator Lamp Output
D TAN/BLK 1566
Lamp Output
2 ’HI’ Indicator
E LT GRN/BLK 1563
Lamp Output
4WD Indicator
Front Axle Actuator
F PNK 1561
Lamp Output
G BLK 150 Ground
H GRY 8 IP Lamp Feed
38608
Connector Part • 12077591

Information • ASM 5F M/P 150 (BLACK)
Circuit
Wire Color
Pin No. Function
4WD Front Wheel Lock
A BLK/WHT 1695
Telltale Feed
B GRY/BLK 1570 Front Axle Actuator Output
Fuse Output - Ignition 3 -
C BRN 241
Type II Output
E BLK 150 Ground
Diagnostic Information and Troubleshooting Hints (Automatic 4WD)

Procedures • Make sure all mechanical components are
operative before diagnosing the electrical
Troubleshooting Hints (Selectable 4WD) portion of the Automatic Four-Wheel Drive
• Make sure all mechanical components are System.
operative before diagnosing the electrical • To determine whether the vehicle is in
portion of the Selectable Four-Wheel Drive two-wheel drive or four-wheel drive, lift the
(S4WD) system. vehicle so that the wheels can spin freely.
• To determine whether the vehicle is in • Make sure that the 4WD, TCASE, GAUGES,
two-wheel drive or four-wheel drive, lift the and ILLUM fuses are not open. If open,
vehicle so that the wheels can spin freely. LOCATE and REPAIR the source of the
• Make sure that the 4WD, TCASE, GAUGES, overload and replace the fuse(s).
and ILLUM fuses are not open. If open, • CHECK for a broken (or partially broken) wire
LOCATE and REPAIR the source of the inside of the insulation which could cause
overload and replace the fuse(s). system failure but prove good in a
• CHECK for a broken (or partially broken) wire continuity/voltage check with a system
inside of the insulation which could cause disconnected. These circuits may be intermittent
system failure but prove good in a or resistive when loaded, and if possible,
continuity/voltage check with a system should be checked by monitoring fuse voltage
disconnected. These circuits may be intermittent drop with the system operational (under load).
or resistive when loaded, and if possible, • CHECK for proper installation of aftermarket
should be checked by monitoring fuse voltage electronic equipment which may affect the
drop with the system operational (under load). integrity of other systems. See to
• CHECK for proper installation of aftermarket Troubleshooting Procedures.
electronic equipment which may affect the
integrity of other systems. Refer to
Troubleshooting Procedures.
• While performing diagnostic procedures, the
ignition switch must be in RUN and the S4WD
control lever must be in the S4WD ENGAGED
position.
System Diagnosis (Automatic 4WD) A range shift is a shift between high range (2H, 4H,
and AUTO) and low range (4L).
Self-Diagnosis The Auto Transfer Case (ATC) Control Module will
The two speed Auto transfer case system utilizes a permit a range shift into or out of Neutral only if the
part time front axle. The system allows the driver to following conditions are met:
select the transfer case position with a touch of a • Ignition ON
button. The following positions can be selected:
4-wheel drive high range (4H), All Wheel Drive Transmission in neutral
(AUTO), 2-W heel Drive high range (2H), Neutral (N), • Vehicle speed at zero
and 4-Wheel Drive low range (4L).
Diagnostic Aids
The Auto Transfer Case (ATC) Control Module
controls all the shifting action of the transfer case A Scan Tool reads and displays the following
based on input from the driver as well as information information:
from the Vehicle Control Module (VCM) /Powertrain • Diagnostic Trouble code(s)
Control Module (PCM). . Code status bit (are codes set or not)
4WD (4H or 4L) mode: This is accomplished by • Transfer case lock status
engaging the front axle, applying PWM to an electric • Lamp in the switch/lamp assembly
motor to apply maximum torque, (fully compressing
the transfer case clutch plates) to the front axle, then • Motor/Encoder gear position
removing the ground on circuit 1569, thus locking the • Ignition (3) voltage
motor in position and stop the PWM to the motor. • Front propshaft speed sensor (KPH)
AUTO mode: When in this mode of operation, the • Front axle switch (open/closed)
system should engage the front axle, then it monitors
• Front axle requested position
the front and rear propshaft speeds for any speed
(engaged/disengaged)
differences. When the system senses rear wheel slip,
a difference of propshaft speed between front and • Rear propshaft speed sensor (KPH)
rear, the Auto Transfer Case (ATC) Control Module • Mode switch position request
will use pulse width modulation (PWM) to drive an • Park switch (open/closed)
electric motor. This motor transfers only the required
torque to the front wheels to gain additional traction • 4WD (Adapt) Mode Auto bit
on slippery surfaces up to 75 mph. There is no • Current Mode corrective action PWM
torque applied to the front wheels until the module • Average and highest PWM applied during
senses rear wheel slip. last slip recovery event
Throttle anticipation (only operational when in AUTO • Throttle anticipation mode
mode): If the vehicle is below 5 mph and the • Average and highest PWM applied during last
accelerator is pressed quickly beyond a set point, Throttle anticipation corrective action event
the system will automatically transfer a percentage of
torque to the front wheels to help prevent the rear • Difference between front and rear
wheels from slipping, as in a hard acceleration from propshaft RPM
a stopped position. • Adapt event counter
The Auto Transfer Case (ATC) Control Module also • Throttle position sensor percentage
has the capability of engaging the front axle while A Scan Tool can actuate (turn on/off or change
the vehicle is in motion. It does this by applying modes) of the following:
PWM to the electric motor to apply torque to the • Clear Auto Transfer Case (ATC) DTCs
front axle, this action is used to match the speed of
the front and rear propshafts. After the module • Service 4WD lamp (tell tail)
senses the proper speed, it then supplies a ground • Transfer Case Lock
on circuit 1570 to engage the front axle. • All lamps in switch assembly (4WD, 2H, 4H,
The Auto Transfer Case (ATC) Control Module will 4L, and Neutral)
accept a mode shift only when the engine is running • Front Axle
and a valid Motor/Encoder signal is present. A mode
• Request 4WD (Adapt) Mode
shift is any shift between 2H, 4H, and AUTO.
• Request 2H Mode
The Auto Transfer Case (ATC) Control Module will
permit a range shift only if the following conditions • Request 4H Mode
are met within 30 seconds of the request: • Request 4L Mode
• Engine running • Request Neutral
• Transmission in Neutral • Drive ATC Motor to various position. 50% PWM
• Vehicle speed below 3 mph max with 5 second time out with 10 second
• Proper Motor/Encoder signal present wait before re-activating
Test Decription 4. This step checks the system operation (static)
The numbers below refer to the step numbers on the to see if it will set a DTC related to a system
diagnostic table. failure.
1. This step checks the class II communication 5. This step checks the Park Switch input for
between the ATC module and the scan tool as proper operation.
well as the other modules that communicate
over the Class II data bus.

1. Install a scan tool.
2. Turn the ignition switch to the ON position. Use a
scan tool in order to try to communicate with each
1 module on the Class II data bus, Auto Transfer Case
(ATC) Control Module, Electronic Brake Control —
Module (EBCM), and Vehicle Control Module (VCM),

or Powertrain Control Module (PCM). Go to DLC Pin
Does the scan tool communicate with all the modules? Go to Step 2 Assignment
Use a scan tool in order to check for any DTCs in the Go to Applicable
2 Antilock Brake System. DTC Table in the
Are there any DTCs in the Antilock Brake System?
—
Antilock Brake
System Go to Step 3
Use a scan tool in order to check for any DTCs in Go to Applicable
3 the PCM/VCM. —
DTC Table in
Are there any DTCs in the VCM/PCM? PCMA/CM
Section Go to Step 4
Check for any DTCs in the Auto Transfer Gase (ATC)
4 Control Module. — Go to Applicable
Are there any Auto Transfer Case DTCs? DTC Table Go to Step 5
1. Scan tool installed.
2. Set park brake. Place transmission in Neutral.
3. Start engine and let idle.
Important: Allow time to complete the shift request
5 before requesting the nest shift. —
4. With the scan tool, read the Motor/Encoder Gear
Position as you shift the transfer case through all
modes. Go to Diagnostic
Does the scan tool show the correct gear position or Table for DTC
requested gear position of the transfer case? Go to Step 6 C0327
2. Park brake set and transmission in Neutral. Go to Diagnostic
3. Use the scan tool in order to read the Gear Position table for DTC '
6 as you shift the transmission from Neutral to Park — C0357 or
and back to neutral. Symptom
Does the scan tool show the correct gear position or Diagnosis for park
requested gear position of the transmission? Go to Step 7 switch
1. Check for any DTCs. Road test vehicle if necessary
to identify customer complaint. While driving the
7 vehicle, shift from 2H to AUTO and 4WD. —
2. Use the scan tool in order to check for any DTCs. Go to Applicable
Are there any DTCs? DTC Table System OK
Diagnostic Trouble Codes 2. Connect pin 13 on the data link cable to a

(Selectable 4WD) vehicle ground source.
The data link connector is located in the cab
Diagnostic Trouble Code (DTC) 1 under the instrument panel on the drivers side.
When the ignition switch is positioned to RUN the Look fan an unplugged cable lead with a
TCCM test to determine if RAM standby Power connector that is housed by the bottom of the
(maintained battery power) to the TCCM was lost instrument panel trim.
since the ignition was last turned OFF. When power
3. Position the ignition switch to RUN.
is interrupted on pin C6 of the TCCM, the TCCM
stores a loss of RAM standby power. 4. Note the shift select buttons for blinking codes.
Refer to Diagnostic Trouble Codes
Diagnostic Trouble Code (DTC) 2 (Selectable 4WD).
During electronic shifting, the TCCM check the If the shift select buttons all blink one time and
motor/encoder fo r normal operation. If the stop, and do not continue to blink, no fault
motor/encoder does not function correctly enough codes are stored in the TCCM.
times, the TCCM stores a motor/encoder failure The transfer case shift select buttons w ill blink in
DTC 2. order to identify any stored DTC. If only one code is
stored in the TCCM memory, that code will blink
Diagnostic Trouble Code (DTC) 3 repeatedly with a three second delay between
The TCCM performs a test each time the blinking sequences. If more than one code is stored,
electronic-shift m otor is turned ON or OFF. If the the first code will blink once, then after a three
motor does not function properly the TCCM stores seconds delay, the next code will blink. This
a motor circuit failure DTC 3, and the shift select sequence will continue until pin 13 is no longer
buttons blink in order to inform the driver of a grounded.
problem.
When reading the diagnostic trouble codes, the
Diagnostic Trouble Code (DTC) 4 number of shift select buttons blinks will indicate
the code number.
Each time the ignition is turned ON, the TCCM tests
the memory, the program, and the internal system in Clearing Memory (Selectable 4WD)
order to ensure that the TCCM is operating properly.
If the TCCM detects a fault within the TCCM, the Im portant: The codes will not clear if the 20-amp
TCCM stores a RAM/ROM memory failure (DTC) 4. T-case fuse is not removed for at least 30 seconds.
When the TCCM is running a diagnostic, and a code The code 1 will continue to occur until the ignition
4 is displayed by the shift select buttons, replace the switch is cycled from RUN to OFF five times.
TCCM. 1. Perform the following in order to clear the
diagnostic trouble codes (DTC) and in order to
Obtaining Diagnostic Trouble Codes clear the stored memory from the transfer case
(Selectable 4WD) control module (TCCM).
The diagnostic trouble codes are displayed on the 2. Turn the ignition switch to the OFF position.
three transfer case shift select buttons. The shift
select buttons are located on the instrument panel, 3. Remove the 20-amp T-case fuse.
when the connector pin 13 on the data link cable is 4. Wait at least 40 seconds then replace the fuse.
grounded, and the ignition switch has been OFF for 5. Cycle the ignition switch from RUN to OFF five
at least five seconds prior to positioning the ignition times in order to clear the diagnostic trouble
switch to run the shift select buttons will blink various code 1 from the TCCM.
times together in order to indicate a diagnostic
trouble code from 1 to 4.
1. Position the ignition switch to OFF.
Ensure the ignition switch is positioned to
OFF fo r at least 6 seconds.
Transfer Case Functional Test (S electable 4W D)
1. Ensure the transmission shift select is in the
PARK position.
2. Turn the ignition switch to the OFF position for Refer to
1 6 seconds. Go to S te p 2
F u n c tio n a l T es t
3. Turn the ignition switch to the RUN position and F a ile d
note the three transfer case shift select buttons. (S e le c ta b le
Do all three shift select buttons blink once? 4W D ) Step 2
Did one of the shift select buttons stay lit in order to Refer to
indicate the transfer case shift position? F u n c tio n a l T e s t
2 F a ile d
(S e le c ta b le
Go to S te p 3 4W D ) Step 4
1. Shift the transfer case to 4HI. Refer to
2. Shift the transfer case to 2HI. F u n c tio n a l T e s t
3 3. shift the transfer case back to 4HI. F a ile d
(S e le c ta b le
Does the transfer case mode shift between 4HI and 2HI? Go to S te p 4 4W D ) Step 6
1. Apply the park brake.
2. For automatic transmissions, place the transmission
shift select in the PARK position.
3. For manual transmissions, shift the transmission
into first gear.
4 4. Place the ignition switch in the RUN position.
5. Place the transfer case in the 4HI position. Refer to
6. Press the 4LO transfer case shift select button. F u n c tio n a l T est
Does the 4LO shift select button blink for 30 seconds F a ile d
and the stop blinking when the 4HI shift select button (S e le c ta b le
illuminates? Go to S te p 5 4W D ) Step 8
1. Place the ignition switch in the RUN position.
2. Place the transfer case in the 4HI position.
3. Press the 4Lo transfer case shift select button and
note the blinking.
4. For automatic transmissions, position the
5 transmission shift select to NEUTRAL.
5. For manual transmissions, push the clutch pedal to
the floor panel. Refer to
Does the 4LO shift select button stop blinking and stay lit F u n c tio n a l
when the transmission is shifted to neutral (for automatic T e s t F a ile d
transmissions) or the clutch pedal is pushed in (for manual (S e le c ta b le
transmissions)? Go to S te p 6 4W D ) Step 8
1. Press the 2HI shift select button and shift the
transfer case into 2HI.
transmission shift select in the PARK position.
3. For manual transmissions, position the transmission
into the first gear.
6 4. Position the ignition switch to OFF.
5. Using a wire, connect pin 13 on the data link Test complete Refer to
connector to a vehicle ground source. transfer case F u n c tio n a l Test
6. Position the ignition switch to RUN. electronic shift F a ile d
Do all three shift select buttons blink once and then stay system operates (S e le c ta b le
OFF? properly. 4W D ) Step 9
Functional Test Failed (S electable 4W D)

Were you sent here from Electric Shift System Refer to
Functional Test? T ra n s fe r C a s e
1 Go to S te p 2 F u n c tio n a l T es t
(S e le c ta b le
4W D )
Did any of the three shift select buttons blink once? Refer to A ll
S h ift S e le c t
2 B u tto n s D o
N o t L ig h t
(S e le c ta b le
Go to S te p 3 4W D )
3 Did one of the shift select buttons stay lit in order to

indicate the transfer case shift position? Go to S te p 4 Go to S te p 5
4 Does the transfer case mode shift between 4HI and 2HI? Go to S te p 5 Go to S te p 6
1. Position the ignition switch to RUN. Refer to

2. Position the transmission to neutral. R educed o r
3. Push the vehicle forward about five feet.

N o M ode
5 and R ange
Does the transfer case mode shift between 4HI and 2HI? Refer to transfer S h ift O p e ra tio n
case mechanical (S e le c ta b le
diagnosis. 4W D )
Does more that one shift select button stay lit? Refer to
R educed o r
Refer to M o re N o M ode
6 T h a n O n e S h ift an d R ange
S e le c t B u tto n S h ift O p e ra tio n
R e m a in s L it (S e le c ta b le
(S e le c ta b le 4 W D ) 4W D )
1. Apply the park brake.

2. For automatic transmissions, place the transmission
shift select in PARK.
7 3. For manual transmissions, shift the transmission
into first gear.
5. Press the 4LO transfer case shift select button.
Does the 4LO shift select button blink for 30 seconds? Go to S te p 8 Go to S te p 9

2. Press the 4LO transfer case shift select button and
note the blinking.
transmission shift select to neutral. Refer to
8 4. For manual transmissions, push the clutch pedal to R educed o r No
the floor panel. M ode and
Does the 4LO shift select button stop blinking and stay lit Refer to P e rfo rm R a n g e S h ift
when the transmission is shifted to neutral (automatic a D ia g n o s tic O n O p e ra tio n
transmissions) or when the clutch pedal is pushed in th e T C C M (S e le c ta b le
(manual transmissions)? (S e le c ta b le 4 W D ) 4W D )
Does the transfer case range shift to 4LO? Refer to

R educed or N o
M ode and
9 Refer to A ll S h ift R a n g e S h ift
S e le c t B u tto n s O p e ra tio n
R e m a in L it (S e le c ta b le
(S e le c ta b le 4 W D ) 4W D )
All Shift Select Buttons Do Not Light (Selectable 4WD)
Were you sent here from a diagnostic table? Refer to
T ra n s fe r C a s e
1 Go to S te p 2 F u n c tio n a l T e s t
(S e le c ta b le
4W D )
1. Check the 10 Amp Gauges Fuse for an open. Refer to A ll S h ift
2. Check the 20 Amp T-Case Fuse for an open. S e le c t B u tto n s

2 Is one of the fuses open? R e m a in L it
(S e le c ta b le
1. Replace the fuse.

2. Turn the ignition switch to the RUN position. Refer to
3 3. Check the operation of the electronic shift system.
T ra n s fe r C a s e
F u n c tio n a l T est
4. Check the fuse for an open. (S e le c ta b le
Is the fuse open? Go to S te p 4 4W D )
1. Turn the ignition switch to the OFF position.

2. Check CKT 39 for a ground if the gauges fuse
4 was open.
3. Check CKT 1640 for a ground if the T-Case fuse
was open.
Was one of the CKT grounded? Go to S te p 5 Go to S te p 6

2. Repair the grounded CKT. Refer to T ra n s fe r
5 C a s e F u n c tio n a l —
3. Replace the fuse. T e s t (S e le c ta b le
Is the repair completed? 4W D )
Check pin A on the back of the shift select switch for

6 B+ voltage.
Is B+ voltage on pin A? Go to S te p 8 Go to S te p 7
1. Open wire in CKT 39 between the fuse and pin A.

2. Repair the open in CKT 39. Refer to T ra n s fe r
3. Check for loose electrical connectors on CKT 39. T e s t (S e le c ta b le
Is the repair complete? 4W D )

2. Do not unplug the harness connector from the shift
select switch.
8 3. Depress all three shift select buttons as the following
pins are checked for B+ voltage.
4. Check pins B, C, and D on the back of the shift
select switch for B+ voltage.
Is B+ voltage at pin B, C, or D? Go to S te p 9 Go to S te p 1 0

9 2. Ensure pins D10 and C10 on the TCCM are
grounded.
Are pins D10 and C10 grounded? Go to S te p 1 2 Go to S te p 11
1. Position the ignition switch to OFF. Refer to T ra n s fe r

10 2. Replace the shift select switch. C a s e F u n c tio n a l
—
Has the shift select switch been replaced? T e s t (S e le c ta b le
4W D )
All Shift Select Buttons Do Not Light (Selectable 4WD) (cont’d)

1. An open in CKT 150 between pin D10 and/or C10 Refer to T ra n s fe r
and ground.
2. Repair the open in CKT 150. T es t (S e le c ta b le
Is the repair completed? 4W D )
Check pins C6 and C8 on the TCCM for B+ voltage. Refer to P e rfo rm
12 Is B+ voltage at pins C6 and C8? a D ia g n o s tic O n

th e T C C M
(S e le c ta b le 4 W D ) Go to S te p 13
1. If no B+ is on C6, an open exists on CKT 1640

between the fuse and pin C6 on the TCCM. Refer to T ra n s fe r
13 2. If no B+ is on C8, an open exist on CKT 39 C a s e F u n c tio n a l —
between the fuse and pin C8 on the TCCM. T e s t (S e le c ta b le

Is the open repaired? 4W D )
One or Ttoo Shift Select Buttons Do Not Light (Selectable 4WD)

Were you sent here from a diagnostic table? Refer to T ra n s fe r
1 C a s e F u n c tio n a l
T e s t (S e le c ta b le
Position the ignition switch to OFF for at least 6 seconds. Refer to

Position the ignition switch to RUN. R educed o r N o
Can mode and range shifts be made?

M ode and
2 R a n g e S h ift
O p e ra tio n
(S e le c ta b le
1. If the 2H1 button will not light, check for and open
on CKT 1563 between pin G on the shift select
switch and pin C11 on the TCCM.
2. If the 4H1 button will not light, check for an open on
3 CKT 1566 between pin F on the shift select switch
and pin C12 on the TCCM.
3. If the 4L0 button will not light, check for an open on
CKT 1565 between pin E on the shift select switch
and pin C14 on the TCCM.
Is an open found on the CKT checked Go to S te p 4 Go to S te p 5
Repair the open CKT. Refer to T ra n s fe r

4 Is tiie repair completed? C a s e F u n c tio n a l
—
T e s t (S e le c ta b le
4W D )
1. If 2H1 does not light, check for B+ voltage at pin

C11 on the TCCM.
2. ti 4H1 does not light, check for B+ voltage at pin
5 C12 on the TCCM.
3. If 4L0 does not light, check for B+ voltage at pin
C14 on the TCCM.
Is B+ voltage at the checked pin? Go to S te p 8 Go to S te p 6
One or Ttoo Shift Select Buttons Do Not Light (Selectable 4WD) (cont’d)
1. If 2H1 does not light, check for a open in CKT 1563
between pin G on the shift select switch and pin C11
on the TCCM.
2. If 4H1 does not light, check for an open in CKT
1566 between pin F on the shift select switch and
6 pin C12 on the TCCM.
3. If 4L0 does not light, check for an open in CKT 1565
between pin E on the shift select switch and pin C14
on the TCCM.
Is the checked CKT open? Go to S te p 7 Go to S te p 8
1. Position the ignition switch to OFF. Refer to

7 2. Repair the open in the CKT. T ra n s fe r C a s e
—
Is the repair completed? F u n c tio n a l T e s t
(S e le c ta b le 4 W D )

2. If 2H1 does not light, position a jumper from pin C11
to a vehicle ground source.
3. If 4H1 does not light, position a jumper from pin C12
8 to a vehicle ground source.
4. If 4L0 does not light, position a jumper from pin C14 Refer to
to a vehicle ground source. P e rfo rm
a D ia g n o s tic O n
5. Position the ignition switch to RUN. th e T C C M
Does the shift select button light? (S e le c ta b le 4 W D ) Go to S te p 9
Replace the shift select switch. Refer to

9 Has the switch been replaced? T ra n s fe r C a s e
—
F u n c tio n a l T e s t
(S e le c ta b le 4 W D )
All Shift Select Buttons Remain Lit (Selectable 4WD)
Were you sent here from a diagnostic table? Refer to Transfer
1 Case Functional
Test
Go to Step 2 (Selectable 4WD)
1. Position the ignition switch to OFF for at least
6 seconds.
2 2. Position the ignition switch to RUN.
Can any mode or range shifting be made? Go to Step 3 Go to Step 8
3 Can shift modes (2H1 to 4H1 to 2H1) be made? Go to Step 4 Go to Step 7
1. Position the ignition switch to RUN. Refer to Perform
4 2. Check for B+ voltage at pins D2 and D16 on a Diagnostic On
the TCCM. the TCCM
Was B+ voltage on both pins? (Selectable 4WD) Go to Step 5
2. Check for an open between CKT 1737 and D16 on
5 the TCCM. Refer to Perform
3. Check for an open between CKT 275 and D2 on a Diagnostic On
the TCCM. the TCCM
Was an open found on one of the CKT? Go to Step 6 (Selectable 4WD)
1. Ensure the ignition switch is positioned to OFF. Refer to
6 2. Repair the open in the CKT. Transfer Case
—
Is the repair completed? Functional Test
(Selectable 4WD)
2. If 2H1 can not be selected, check for an open on
CKT 1562 between pin C4 on the TCCM and
7 Pin B on the shift select switch.
3. If 4H1 can not be selected, check for an open on Refer to Perform
CKT 1564 between pin C5 on the TCCM and a Diagnostic On
pin C on the shift select switch. the TCCM
Was an open found on one of the CKT? Go to Step 6 (Selectable 4WD)
1. Position the ignition switch to RUN. Refer to Perform
8 2. Check for an open on CKT 1555 between pin D5 on a Diagnostic On
the TCCM and pin C on the motor/encoder. the TCCM
Was an open found on CKT 1555? Go to Step 6 (Selectable 4WD)
More Than One Shift Select Button Remains Lit (Selectable 4WD)
Transfer Case
1 Functional Test
1. If 2H1 remains lit, check for a ground in CKT 1563
between pin C on the shift select switch and pin C11
on the TCCM.
2. If 4H1 remains lit, check for a ground in CKT 1566
2 between pin F on the shift select switch and pin C12
on the TCCM.
3. If 4L0 remains lit, check for a ground in CKT 1565 Refer to Perform
between pin E on the shift select switch and pin C14 a Diagnostic On
on the TCCM. the TCCM
Is the checked CKT grounded? Go to Step 3 (Selectable 4WD)
3 2. Repair the ground in the CKT. Transfer Case
—

(Selectable 4WD)
No Shift Select Buttons Remain Lit (Selectable 4WD)

1 Transfer Case
Functional Test
Check for an open in CKT 1554 between pin A on the Refer to Perform
2 motor/encoder and pin C9 on the TCCM. a Diagnostic On
Is CKT 1554 open? the TCCM
3 2. Repair the open in the CKT 1554. Transfer Case
—
(Selectable 4WD)
Reduced or No Mode and Range Shift Operation (Selectable 4WD)
1 Transfer Case
Functional Test
1. Ensure the electrical harness connector and pins to
the motor/encoder are clean and not corroded.
2. Ensure the electrical harness connector to the
motor/encoder is properly installed.
3. Check the following CKT between the motor/encoder
2 and the TCCM.
4. Check for opens and grounds on CKT 31, CKT 940,
CKT 1552, CKT 1553 and CKT 1555. Refer to Perform
5. Check for opens and grounds on CKT 1556, a Diagnostic On
CKT 1557 and CKT 1558. the TCCM
Are any opens or grounds found on any of the CKT? Go to Step 3 (Selectable 4WD)
1. Ensure the ignition switch is position to OFF. Refer to
3 2. Repair the open or ground in the CKT. Transfer Case
—
(Selectable 4WD)
Perform a Diagnostic On the TCCM (Selectable 4WD)

Were you sent here from a diagnostic table? Refer to Transfer
1 Case Functional
Test (Selectable
Go to Step 2 4WD)
2 Perform a diagnostic on the TCCM. Refer to Obtaining —

Stored Diagnostic Trouble Codes (DTC) in this section. —
Four-Wheel Drive Does Not Disengage (Selectable 4WD)

Step Action Vaiue(s) Yes No
1. Place the transfer case in the RWD position. Replace the
1 2. Disconnect the transfer case switch. — transfer case
Did the S4WD disengage? switch. Go to Step 2
Disconnect the front axle actuator. Repair the short
2 Did the S4WD disengage? — to battery in Replace the front
CKT 1296. axle actuator.
Four-Wheel Drive Does Not Engage (Selectable 4WD)
Step | Action | Value(8) | Yes No
DEFINITION: 4WD Will Not Engage
Disconnect Front Axle Actuator. Place Transfer Case
Select Switch in 4WD. Connect a test lamp from Front Check for open
1 Axle Actuator Terminal B to ground with the Ignition Switch — CKT 150. If OK,
in Run. REPLACE Front
Does the test lamp light? Axle Actuator. GO to Step 2.
Disconnect Transfer Case Switch. Connect a test lamp
from Terminal A for CKT 241 to ground with Ignition
2 Switch in RUN. — Repair Open in
Does the test lamp light? GO to Step 3. CKT 241.
Connect a fused jumper between CKT 241 and CKT 1296
of Transfer Case Switch. Connect a test lamp from
3 Terminal B to ground and the Front Axle Actuator with the — REPLACE the
Ignition Switch in the RUN position. Transfer Case REPAIR open in
Does the test lamp light? Switch. CKT 1296.
Four-Wheel Drive Indicator Does Not Light (Selectable 4WD)

Step Action Valuefs) Yes No
1. Disconnect the S4WD indicator lamp. Check for an
2. Place the transfer case switch to S4WD. open in
3. With the ignition switch in RUN, connect a test lamp Check or replace CKT 1695.
1 the bulb. If OK, replace the
—
from terminal B to ground.

Does the test lamp illuminate? If OK, repair the front axle
open in CKT 150. actuator.
Four-Wheel Drive Indicator Does Not TUrn Off (Selectable 4WD)

1. Place the transfer case in the RWD position. Replace the Repair the short
1 2. Disconnect the Transfer Case Switch. —
transfer case to battery in
Did the Indicator Lamp go off? switch. CKT 1296.
Transfer Case Electronic Shift System • The shift select refers to the selector that
Diagnosis (Selectable 4WD) positions or shifts the automatic transmission
or the transfer case.
Notice: Make any repairs that are necessary to • The blinking refers to flashing light passing
correct the operation of electric shift system. After
through the red plastic shift select buttons.
making repairs, clear the TCCM memory and
perform the functional test in order to ensure the • Shift the transfer case refers to pressing one
electric shift system operates properly. of the three shift select buttons to shift the
transfer case into either 2HI, 4HI, or 4LO.
Important: Perform a TCCM diagnostic test in order
to ensure the TCCM is operating properly before Transfer Case Diagnosis (Selectable 4WD)
performing the electronic shift system functional test.
Notice: Make any repairs that are necessary to
1. If DTC 4 is stored in the TCCM memory, correct the operation of electric shift system. After
replace the TCCM. making repairs, clear the TCCM memory and
perform the functional test in order to ensure the
electric shift system operates properly.
1. Prior to performing the electronic shift system
functional test, perform a TCCM diagnostic test
in order to ensure the TCCM is operating
properly. Refer to OBTAINING STORED
TROUBLE DIAGNOSTIC CODES.
If DTC 4 is stored in the TCCM memory,
replace the TCCM.
2. The following is information that may help you
understand some of the terminology used in the
diagnostic tables:
• Turn the ignition switch to the RUN position.
Position the ignition switch from OFF to RUN
but do not start the engine.
• The ground source refers to any exposed
metal surface on the vehicle connected
directly or indirectly to the negative terminal
of the battery.
2. The following is information that may help you • The shift select refers to the selector that
understand some of the terminology used in the positions or shifts the automatic transmission
diagnostic tables: or the transfer case.
• Turn the ignition switch to the RUN position. • The blinking refers to flashing light passing
through the red plastic shift select buttons.
Position the ignition switch from OFF to RUN
but do not start the engine. • Shift the transfer case refers to pressing one
of the three shift select buttons to shift the
• The ground source refers to any exposed transfer case into either 2HI, 4HI, or 4LO.
metal surface on the vehicle connected
directly or indirectly to the negative terminal
of the battery.
DTC B0768 Service Indicator Circuit High

|H o t In Run O r S tart |
I Pow er
IP
, D istribution G AUG ES Fuse
Fu se 4
!
C e «10
10 A
Block
J7V
1
b —
0.8 PNK 39
S213
0.35 PNK 39 1
22 A
l
inrtrument + - M aMuncBon
"* Instrument
Fuse B o ck
I C a l 81
f 1Cluster D e tafe
( ? ) L « ip ( W ) C e lT I
I w (S ervice
4WD) iA
24
0.35 LT BLU/BLK 1567

E2 A Cl
m ''Automatic
l C ontrol [Transfer
I
I ! Case (ATC)
I t Control
L. J Module
183150
Circuit Description Conditions for Clearing the MILVDTC

The Auto Transfer Case (ATC) Control Module • The Auto Transfer Case (ATC) Control Module
controls the Service AUTO/4WD, located in the will clear the DTC if the condition for setting the
Instrument Cluster, by grounding circuit 1567. DTC no longer exists.
Voltage to the lamp is supplied via the Gauge Fuse, • A history DTC will clear after 100 consecutive
circuit 39. The fuse is located in the l/P Fuse Block. ignition cycles without a fault present.
Conditions for Setting the DTC • Use a scan tool in order to clear history DTCs.
After the Auto Transfer Case (ATC) Control Module
commands the lamp on, the module senses a
voltage greater than 7 V on circuit 1567.
DTC B0768 Service Indicator Circuit High

Was the Auto Transfer Case (ATC) System Check Go to
performed? Auto Transfer
1 —
Case (ATC)
Go to Step 2 System Check
1. Turn the ignition ON, engine OFF.
2 2. Use the scan tool, command the Service AUTO/4WD
—
lamp on.
Does the lamp come on? Go to Step 8 Go to Step 3
DTC B0768 Service Indicator Circuit High (cont’d)
1. Tum the Ignition OFF.
2. Disconnect connectors C1 and C2 at the Auto
Transfer Case (ATC) Control Module.
3 3. Disconnect the Instrument Cluster connector.
4. Tum the ignition ON, engine OFF.
—
5. Connect a test lamp from cavity E2 (LT BLU/BLK)

of C1 to ground.
Does the test lamp light? Go to Step 4 Go to Step 5
4 Locate and repair LT BLU/BLK (1567) wire for a short to —

voltage. Is the action complete? —
Go to Step 9
1. Tum the ignition OFF.
2. Reconnect the Instrument Cluster.
5 3. Tum the ignition ON, engine OFF. —
4. Connect a fused jumper wire form cavity E2

(LT BLU/BLK) of C1 to ground.
Does the Service AUTO/4WD lamp light? Go to Step 6 Go to Step 7
Replace the Auto Transfer Case (ATC) Control Module.
Refer to Transfer Case Control Module Replacement
6
(Automatic 4WD) — —
Is the action complete? Go to Step 9
1. Check the Instrument Cluster printed circuit and
the Service AUTO/4WD lamp.
7
2. Repair/replace as necessary. — —
1. Check the Instrument Cluster printed circuit,
the Service AUTO/4WD lamp and circuit 1567
8 (LT BLU/BLK) for an intermittent short to voltage. — —
2. Repair /replace as necessary.

2. Reconnect all previously disconnected components.
9
3. Tum the ignition ON, engine OFF. —
4. Use the scan tool in order to command the Service
AUTO/4WD lamp ON, then OFF.
Does the lamp come on then off? System OK Go to Step 1
183183
C ircu it Description A ction Taken W hen th e DTC Sets

The Auto Transfer Case Module interfaces with four • All shifting will be disabled.
(4) instrument panel mounted, normally opened, • The service 4WD lamp will be latched on for
momentary push button switches and lamp assembly. the remainder of the current ignition cycle.
The switch assembly utilizes a resistor network to
provide an analog voltage signal to the module to C onditions fo r C learing th e DTC
determine a 4H, AUTO (Adapt), 2H, N, and 4L shift
request. The Auto Transfer Case (ATC) Control • The Auto Transfer Case (ATC) Control Module
Module supplies 8 volts to the switch assembly on will clear the DTC if the condition for setting the
circuit 431 and reads the voltage level back on DTC no longer exists.
circuit 1693. • A history DTC will clear after 100 consecutive
This DTC detects an open, short to ground, or ignition cycles without a fault present.
voltage on circuit 431 and circuit 1693, and a faulty • History DTCs can be cleared using a scan tool.
switch assembly.
C onditions fo r Setting the DTC
• The system constantly monitors the voltage on
circuit 1693.
• If the system detects a voltage level outside the
possible range produced when no buttons are
depressed, (approx.-0.5 to 1.0 volts), the DTC
is logged.
DTC B2725 M ode S w itch C ircuit M alfunction

Was the Auto Transfer Case (ATC) System Check Go to Auto
1 performed? — Transfer Case
(ATC) System
Go to Step 2 Check
1. Turn the ignition OFF.
2. Connect a scan tool.
4. Use the scan tool in order to record all Freeze
Frame and Failure Records.
2 5. Turn the ignition OFF. 7-9 V
6. Disconnect connectors C1 and C2 at Select/mode
Switch.
8. Use a DMM in order to measure the voltage form
cavity A (LT GRN/BLK) of C1 to ground.
Is the voltage within the value indicated? Go to Step 3 Go to Step 9
2. Disconnect connector C1 at Auto Transfer Case
(ATC) Control Module.
3 3. Turn the ignition ON, engine OFF. OV
4. Use a DMM in order to measure the voltage from
cavity B (LT BLU) of C1 to ground.
Connect a self powered test lamp from cavity B (LT BLU)
4 of C1 to ground. —
Is the test lamp on? Go to Step 5 Go to Step 6

Locate and repair the LT BLU (1693) wire for a short to
5 ground. — —
Use a DMM in order to measure the resistance from cavity
6 B of C1 to cavity F16 of C1 at module 0Q
Is the resistance within the value indicated? Go to Step 7 Go to Step 8
Replace the Select/mode Switch. Refer to Shift Select
7 Switch Replacement (Automatic 4WD) — —
Locate and repair the LT BLU (1693) wire for a open
circuit between the Auto Transfer Case (ATC) Control
8 Module and the Select/Mode Switch. — —
9
Was the voltage in step 2 within the value indicated? Greater
than 9 V Go to Step 10 Go to Step 14
2. Disconnect connector C1 at auto Transfer Case
10 3. Turn the ignition ON, engine OFF. OV
4. Use a DMM in order to measure the voltage form
cavity A (LT GRN/BLK) of C1 to ground.
DTC B2725 Mode Switch Circuit Malfunction (cont’d)
Locate and repair the LT BLU (1693) wire for a short to
11 voltage. — —
Is the repair complete? G o to S te p 1 8

12 Refer to T ra n s fe r C a s e C o n tro l M o d u le R e p la c e m e n t
(A u to m a tic 4 W D )
— —
Is the action complete G o to S te p 18
Locate and repair the LT GRN/BLK (431) wire for a

13 short to voltage. — —
Is the action complete? G o to S te p 1 8
Connect a self powered test lamp from cavity A

14 (LT GRN/BLK) of C1 to ground. —
Is the test lamp on? G o to S te p 1 5 G o to S te p 1 6

15 short to ground. — —
Is the action complete? G o to S te p 18
Use a DMM in order to measure the resistance from

16 cavity A and C1 to cavity F14 of C1 at module 0Q
Is the resistance within the value indicated? G o to S te p 1 2 G o to S te p 1 7
Locate and repair the LT GRN/BLK (431) wire for an open

circuit between the Select/Mode Switch and the Auto
17 Transfer Case (ATC) Control Module. — —
1. Ensure the ignition if OFF.

3. Set PARK brake.
5. Place the transmission in neutral.
18 Important: Allow time between shift request for the —
transfer case to complete the previous request.
6. Shift transfer case through all modes.
7. Use the scan tool and select Specific DTC and enter
DTC B2725.
Did the test run and pass? System OK G o to S te p 1
DTC C0300 Rear Speed Sensor Malfunction
** Automatic
tra n sfe r
'Case
'Control
HI R R S S LO _FSSHJL fss lo ' Module
'V “
F5 re E12 E13 Cl
0.5LTBLU 2221 0.5 YEL 400
0.5DKQRN 2222 0.5 PPL 401
P100
................ A A ................ B AC132
0.5LTBLU 2221 0.5 YEL 400
0.5DKQRN 2222 0.5 PPL 401
B BJL
J 4
Prop 4 4
Prop
Shaft Shalt
LO HI LO
hi
Speed Speed
Sensor Sensor
Front
183182
Circuit Description Action Taken When the DTC Sets

The Rear Propshaft Speed Sensor is a Permanent • All Shifts to AUTO (Adapt) mode will be
Magnet (PM) generator. The PM generator produces disabled. If the current mode is AUTO, the
a pulsing AC voltage. The AC voltage level and system will not allow any further adaptive
number of pulses Increases as speed increases. The events (correct slip).
module converts the pulsating AC voltage to a
propshaft RPM which is used for calculations. The • The service 4WD lamp will be latched on for
propshaft RPM can be displayed with a scan tool. the remainder of the current ignition cycle.
The module only monitors this input when the
vehicle is in 2H. Conditions for Clearing the DTC
This DTC detects an open , short to ground, or 1. The Auto Transfer Case (ATC) Control Module
faulty sensor. will clear the DTC if the condition for setting the
DTC no longer exists.
Conditions for Setting the DTC
2. A history DTC will clear after 100 consecutive
The system will log the DTC if the rear propshaft
input indicates a speed of less than 16 RPM for ignition cycles without a fault present.
30 seconds while all of the following are true: 3. History DTCs can be cleared using a scan tool.
• Transmission NOT in Park/Neutral
• Engine is running
• Front axle is engaged
• Rear Propshaft speed exceeds 512 RPM
• Vehicle Speed On Class 2 Data bus exceeds
10 mph
DTC C0300 Rear Speed Sensor Malfunction
(ATC) System
Go to Step 2 Check
4. Use a scan tool in order to record all Freeze Frame
and Failure Records.
2 5. Turn the ignition OFF. —
6. Disconnect the Rear Propshaft Speed Sensor and
remove from Transfer Case.
7. Inspect the sensor rotor for damage, misalignment or
slipping on the shaft.
Was a problem found? Go to Step 3 Go to Step 4
Replace/repair as necessary. Refer to AFWD Speed
3 Sensor Replacement (Rear Speed Sensor Replacement) — '; —
Use a DMM in order to measure the resistance of the
4 speed sensor. 1400-2700 Q
Replace the Rear Propshaft Speed Sensor.
5 Refer to AFWD Speed Sensor Replacement (Rear Speed — —
Sensor Replacement)
1. Ensure the ignition is OFF.
6 Transfer Case (ATC) Control Module.
—
3. Connect a self powered test lamp from cavity A of
the speed sensor connector to ground.
Locate and repair the LT BLU (2221) wire for a
Connect a self powered test lamp between cavity A
8 and cavity B of the speed sensor connector. —
Locate and repair the LT BLU (2221) wire shorted to the
9 DK GRN (2222) wire. -— —

1. Connect a jumper wire form cavity F5 (LT BLU) of
C1 to ground.
10 2. Connect a self powered test lamp for cavity A of the —
speed sensor connector to ground.
Is the test lamp on? Go to Step 12 Go to Step 11 I
DTC C0300 Rear Speed Sensor Malfunction (cont’d)

Locate and repair the LT BLU (2221) wire for an
open circuit between Auto Transfer Case (ATC) —
11 Control Module and sensor. —
1. Connect a jumper wire form cavity F6 (DK GRN)
of C1 to ground.
12 2. Connect a self powered test lamp from cavity B —
of the speed sensor connector to ground.
Locate and repair the DK GRN (2222) wire for a open
circuits between Auto Transfer Case (ATC) Control
13 Module and sensor. — —

14 Refer to Transfer Case Control Module Replacement
(Automatic 4WD) — —

15 3. Road the test vehicle in AUTO mode. —
4. Use the scan tool and select Specific DTC and
enter DTC C0300.
Did the test run and pass? System OK Go to Step 1
DTC C0305 Front Speed Sensor Malfunction
■*Automatic
•Transfer
•Case
/ • Control
1J W S S HI RR SSLO _ FS S H I f s s l o •Module
j
V* —
F5 F6 E12 E13TC1
0.5 LT BLU 2221 0.5 YEL 400
0.5 DKGRN 0.5 PPL 401
PI 00
J i ...................U ___ A- Cl 32
0.5 LT BLU 2221 0.5 YEL 400
0.5 DKGRN 9 0 0 0 0.5 PPL 401
B B
Prop 4 4*
Prop
Shaft Shaft
HI LO HI LO
Speed Speed
Sensor Sensor
Rear Front
1831B2
Circuit Description • Front axle is engaged

The Front Propshaft Speed Sensor is a Permanent • Rear Propshaft speed exceeds 512 RPM
Magnet (PM) generator. The PM generator produces • Vehicle Speed On Class 2 Data bus exceeds
a pulsing AC voltage. The AC voltage level and 10 mph
number of pulses increases as speed increases. The
module converts the pulsating AC voltage to a Action Taken When the DTC Sets
propshaft RPM which is used for calculations, and to
monitor the difference between the front and rear • All Shifts to AUTO (Adapt) mode will be
propshaft speed. It is also used in the AUTO (Adapt) disabled. If the current mode is AUTO, the
mode of operation to determine the amount of slip system will not allow any further adaptive
and the percent of torque to apply to the front axle events (correct slip).
The module only looks at this input when the vehicle • The service 4WD lamp will be latched on for
is in AUTO (Adapt) mode, 4H, and 4L ranges. The the remainder of the current ignition cycle.
propshaft RPM can be displayed with a scan tool.
The module only monitors this input when the Conditions for Clearing the DTC
vehicle is AUTO, 4H, or 4L.
1. The Auto Transfer Case (ATC) Control Module
This DTC detects an open , short to ground, or
will clear the DTC if the condition for setting the
faulty sensor.
Conditions for Setting the DTC 2. A history DTC will clear after 100 consecutive
The system will log the DTC if the front propshaft ignition cycles without a fault present.
input indicates a speed of less than 16 RPM for
30 seconds while all of the following are true: 3. History DTCs can be cleared using a scan tool.
• Transmission NOT in Park/Neutral
DTC C0305 Front Speed Sensor M alfunction

1 performed? Transfer Case
— (ATC) System
Go to Step 2 Check
6. Disconnect the Front Propshaft Speed Sensor and
remove from the Transfer Case.
7. Inspect the sensor rotor for damage, misalignment or
slipping on the shaft.
Did you find a problem? Go to Step 3 Go to Step 4
Replace/repair as necessary. Refer to AFWD Speed
3 Sensor Replacement (Front Speed Sensor Replacement) — —
Use a DMM in order to measure the resistance of the
4 speed sensor. 1400-2700 Cl
Replace the Front Propshaft Speed Sensor. Refer to
AFWD Speed Sensor Replacement (Front Speed
5 Sensor Replacement) — —
6 Transfer Case (ATC) Control Module. —
3. COnnect a self powered test lamp from cavity A
of the speed sensor connector to ground.
Locate and repair the YEL (400) wire for a short to
7 ground. — —
Connect a self powered test lamp between cavity A and
8 cavity B of the speed sensor connector. —
Locate and repair the YEL (400) wire shorted to the
9 PPL (401) wire. — —

DTC C0305 Front Speed Sensor Malfunction (cont’d)
1. Connect a jumper wire from cavity E12 (YEL)
of C1 to ground.
10 2. Connect a seif powered test lamp from cavity A of —
the speed sensor connector.
Locate and repair the YEL (400) wire for an open
circuit between Auto Transfer Case (ATC) Control
1. Connect a jumper wire form cavity E13 (PPL) of
C1 to ground.
of the speed sensor connector.
is the test lamp on? Go to Step 14 Go to Step 13
Locate and repair the PPL (401) wire for an open
circuit between Auto Transfer Case (ATC) Control

14 (Automatic 4WD) — —

2. Reconnect all previously disconected components.
15 3. Road test vehicle in AUTO mode. —

enter DTC C0305.
DTC C0308 Motor A/B Circuit Low
|H o t In R unj
p —- ---------- -|,p
i ’ Fuse
lp • Pow er
Fuse
i M2L4W D . Distribution T C A SE
i
i
Ntf F u m 24
20 A
Block J
I
C ell 10
D 8>
F u**2
20 A
Block
b
0.8 BRN 241 3 ORN 1640
Fuse H o ck
D etails ◄------- H 1S235 S236 Fuse B lock
D e ta is
C a ll 11
0.8 BRN 241 1 ORN 1640 C e l 11
E10 Cl E11^C1 DXC2
183176
Circuit Description • if the system detects a problem with the

The Transfer Case Motor is a bi-directional, circuits, the DTC is logged.
permanent magnet, D.C. motor. When energized, • The Auto Transfer Case (ATC) Control Module
(through circuits 1552, 1553, and the ground circuit senses a low voltage return on circuits 1552 or
150 the module utilize for the motor control), the 1553 when a high voltage is expected.
motor, through a series of gears, rotates a shaft
which moves the mode and range forks to shift the Action Taken When the DTC Sets
Transfer Case between 4H, AUTO (Adapt), 2H, N, • All shifting will be disabled.
and 4L ranges.
• The service 4WD lamp will be latched on for
This DTC detects a short to ground on circuits 1552 the remainder of the current ignition cycle.
and 1553, a shorted motor.
Conditions for Setting the DTC Conditions for Clearing the MILVDTC
• The system will test the motor circuits: 1. The Auto Transfer Case (ATC) Control Module
• First, the system checks for unwanted
voltage. DTC no longer exists.
• Then, the system supplies voltage on 2. A history DTC will clear after 100 consecutive
one circuit and reads the voltage back ignition cycles without a fault present.
on the other. 3. History DTCs can be cleared using a scan tool.
DTC C0308 M otor A/B C ircuit Low
(ATC) System
Go to Step 2 Check
7. Disconnect connector C1 at transfer case.
8. Connect a self powered test lamp from cavity A
(BLK) of C2 at transfer case to ground.
Connect a self powered test lamp from cavity B (RED) of
3 C2 at transfer case to ground. —
Locate and repair the BLK (1552) wire for a short to
4 ground. — —
Locate and repair the RED (1553) wire for a short to
5 ground. — —
Connect a self powered test lamp from cavity A of C2
6 at the transfer case connector to ground. —
Replace the Transfer Case Motor/Encoder. Refer to
7 Motor/Encoder Replacement (Automatic 4WD) — —
Connect a self powered test lamp from cavity B of C2
8 at the transfer case connector to ground. —
3. Set PARK brake.
4. Start the engine and let idle.
DTC C0308.
DTC C0309 Motor A/B Circuit High

|H o t In R util | H ot At All Tim es |
r ——
•;ip I Power
‘ - - “ IIP
U2K 4WD [Fuse Distribution T CASE Fuse
Fuse24 i Block C ell 10 Fuse 2 •
Block
N1 20 A 20 A I
I
k . _ _ _ _ j
0.8 BRN 241 3 ORN 1640
Fuse Block
D etails S235 S236 Fuse Block
D e tals
C e il 11
0.8 BRN 241 1 ORN 1640 C ell 11
E10j[ci E11.C1 Dj[C2
Ground
Distribution
C e l 14
183176

The Transfer Case Motor is a bi-directional, 1. All shifting will be disabled.
permanent magnet, D.C motor. When energized,
2. The service 4WD lamp will be latched on for
(through circuits 1552, 1553 , and the ground circuit
the remainder of the current ignition cycle.
2150, the module utilize for motor control), the motor,
through a series of gears, rotates a shaft which
Conditions for Clearing the DTC
moves the mode and range forks to shift the
Transfer Case between 4H, Adapt, 2H, N, and 4L 1. The Auto Transfer Case (ATC) Control Module
ranges. will clear the DTC if the condition for setting the
This DTC detects a short to Voltage on circuits 1552 DTC no longer exists.
and 1553, a shorted motor. 2. A history DTC will clear after 100 consecutive
Conditions for Setting the DTC ignition cycles without a fault present.
• The system will test the motor circuits by 3. History DTCs can be cleared using a scan tool.
reading the voltage on each circuit.
• If the system detects a problem with the
circuits, the DTC is logged.
• The Auto Transfer Case (ATC) Control Module
senses a high voltage on circuits 1552 or 1553
when a low voltage is expected.
DTC C0309 Motor A/B Circuit High
(ATC) System
Go to Step 2 Check
4. Use the scan tool in order to record ail Freeze
2 6. Disconnect connectors C1 and C2 at the Auto —
9. Connect a test lamp from cavity A (BLK) of C2
to ground.
Locate and repair the BLK (1552) wire for a short
3 to voltage. — —
Connect a test lamp from cavity B (RED) of C2 to ground. —
4
Locate and repair the RED (1553) wire for a short to
5 voltage. — —

Refer to Transfer Case Control Module Replacement —
6 (Automatic 4WD) —
3. Set PARK brake.
7 Important: Allow time between shift request for the
—
DTCC0309.
Did the test Run and Pass? System OK Go to Step 1
DTC C0310 Motor A/B Circuit Open
|H o t In R un| [HotWAITjmwJ
r ----------- T ------------- -»|p
■ Power 1 ,P
M2*s 4WD [Fuse . D istribution E7 L T CASE Fuse
*20!A" 24 Block | C ell 10 S ff2
20 A
.'Block
I
N1 D 8>
I
l_ _ _ _ _ _ _ _ _ _ j
0.8 BRN 241 3 0RN 1640
fu s e Block
D etails ◄------- H S235 S236 Fuse Block
D e ta ls
C ell 11
0.8 BRN 241 1 ORN 11640 C ell 11
E10 Cl E11^C1 DlC2
183176
Circuit Description • If the system detects a problem with the

The Transfer Case Motor is a bi-directional, circuits, the DTC is logged. The Auto Transfer
permanent magnet, D.C motor. When energized, Case (ATC) Control Module senses a low
(through circuits 1552, 1553 , and the ground circuit voltage return on circuits 1552 or 1553 when
150, the module utilize for motor control), the motor, a high voltage is expected.
through a series of gears, rotates a shaft which Action Taken When the DTC Sets
Transfer Case between 4H, AUTO (Adapt), 2H, N, 1. All shifting will be disabled.
and 4L ranges. 2. The service 4WD lamp will be latched on for
This DTC detects an open on circuits 1552 and the remainder of the current ignition cycle.
1553, an open motor. Conditions for Clearing the DTC
Conditions for Setting the DTC 1. The Auto Transfer Case (ATC) Control Module
• The system will test the motor circuits by will clear the DTC if the condition for setting the
checking for unwanted voltage. DTC no longer exists.
• Then, the system supplies voltage on each of 2. A history DTC will clear after 100 consecutive
the motor circuits and reads the voltage back ignition cycles without a fault present.
on the other circuit. 3. History DTCs can be cleared using a scan tool.
DTC C0310 Motor A/B Circuit Open
(ATC) System
G o to S te p 2 Check
2 Frame and Failure Records.
—

7. Connect a self powered test lamp from cavity A to
cavity B at C2 at the transfer case connector.
Is the test lamp on? G o to S te p 4 G o to S te p 3
Replace the Transfer Case Motor/Encoder. Refer to
3 M o to r/E n c o d e r R e p la c e m e n t (A u to m a tic 4 W D ) — —
Connect a self powered test lamp from cavity A (BLK) to

4 cavity B (RED) of C2. —
1. Disconnect connector C2 of the Auto Transfer Case

5 2. Connect a self powered test lamp from cavity C —
(BLK) of C2 to ground.

Refer to T ra n s fe r C a s e C o n tro l M o d u le R e p la c e m e n t
6 (A u to m a tic 4 W D )
— —
Locate and repair the BLK (150) wire for an open

7 between the Auto Transfer Case (ATC) Control Module
and Splice S204. — —

2. Connect a jumper wire form cavities A and B of C2
of Auto Transfer Case (ATC) Control Module to
8
ground. —
(BLK) of C2 to ground.
Is the test lamp on? G o to S te p 9 G o to S te p 1 0
Connect a self powered test lamp from cavity B (RED) of

9 C2 to ground. —
DTC C0310 Motor A/B Circuit Open (cont’d)

Locate and repair the open BLK (1552) wire between
transfer case and the Auto Transfer Case (ATC) Control —
10 Module. —
Locate and repair the open RED (1553) wire between

transfer case and the Auto Transfer Case (ATC) Control —
11 Module. —

3. Set PARK brake.
12 Im portant: Allow time between shift request for the —

DTC C0310.
DTC C0315 Motor Ground Circuit Open
iH o tln R u n l iHotAtAHThnoJ
---------- -IP
M2i, 4wd l-Fuse
'p • Pow er
. Distribution T C A SE Fuse
Fu m 2 4 l B k )c k 1 C ell 10
D8> 2 0 A Block
Nl 20 A
0.8 BRN 241 3 ORN 1640

Fuse Block
D etails S235 S236 Fuee& odT
D etato
<*"11 1 ORN 1640
0.8 BRN 241 £SL2___
E10|C1 E tl^C I d 1c 2
G round
Distribution
C a l 14
183176

The Transfer Case Motor is a bi-directional, 1. All shifting will be disabled.
permanent magnet, D.C. motor. When energized,
2. The service 4WD lamp will be latched on for
(through circuits 1552, 1553, and the ground circuit
150, the module utilize for motor control), the motor, the remainder of the current ignition cycle.
through a series of gears, rotates a shaft which
Transfer Case between 4H, AUTO (Adapt), 2H, N, 1. The Auto Transfer Case (ATC) Control Module
and 4I_ ranges. will clear the DTC if the condition for setting the
This DTC detects an open ground circuit 150. DTC no longer exists.
Conditions for Setting the DTC 2. A history DTC will clear after 100 consecutive
ignition cycles without a fault present.
The system test the motor circuits:
• First, the system checks for unwanted voltage. 3. History DTCs can be cleared using a scan tool.
• Then, the system supplies voltage on each of
the motor circuits and reads the voltage back
on the other circuit.
• After the system checks for opens and shorts
on the motor circuits, its applies voltage to the
motor and the voltage on the ground circuit.
• If the system detects a high voltage return on
the ground circuit, the DTC is logged. The Auto
Transfer Case (ATC) Control Module senses a
low voltage return on circuit 150 when a low
voltage is expected.
DTC C0315 Motor Ground Circuit Open

performed? Transfer Case
1 —
(ATC) System
4. Use the scan tool in order to record ail Freeze
2 5. Turn the ignition OFF. 0.5 V
6. Disconnect connector C2 at the Auto Transfer Case
cavity C (BLK) of C2 to ground.
Is the voltage within the value indicated? G o to S te p 4 G o to S te p 3
Locate and repair the BLK (150) wire for a loose or open
3 ground at G200. — —
Connect a self powered test lamp from cavity C (BLK) of

4 C2 to ground. —
Locate and repair the BLK (150) wire for an open between
Splice S204 and the Auto Transfer Case (ATC) Control
5 Module.
— —

Refer to Transfer Case C o n tro l M o d u le R e p la c e m e n t
6 — —
(A u to m a tic 4 W D )

3. Set PARK brake.
7
Im portant: Allow time between shift request for the —
DTC C0315.
Did the test Run and Pass? System OK G o to S te p 1
OTC C0323 T-Case Lock Circuit Low

|H o t At All T im e tl Circuit Description
r —“ ■•IP The Auto Transfer Case (ATC) Control Module
I Power
Distributioni E7 L T CASE [Fuse controls the Transfer Case Lock Solenoid.
C ell 10 Fuse 2 {Block The lock is energized (locking action released,
D 8> 20 A
grounding circuit 1569) during gear shifts and in
AUTO (Adapt) mode of operation. When power or
3 ORN 1640 ground is removed from the lock solenoid, (locking
+ S236 action applied), the Transfer Case Motor is prevented
1 0RN 1640 Fuse B lock from moving. In this manner, the system is capable
D j[C 2 Details
C ell 11
of providing a 4H and 4L lock-up without the need of
J" “ * 'v Automati additional vehicle power to hold the Transfer Case in
1 1 * Transfer these positions.
1 c*** /C ase This DTC detects an open lock solenoid coil, circuit
' u? I Control 1569 open, open feed (circuit 1640) to the solenoid.
1 I * Module
E1 Cl A
A A • The system will try to turn the lock solenoid off
5 TAN 1569 0.8 ORN 1640 by opening the ground circuit.
P100 • If the module is unable to de-energize the
A C131 solenoid, the system will not attempt to
0.8 TAN 1569 0.8 ORN 1640 de-energize the solenoid again during that
D C ignition cycle.
• Auto Transfer Case Lock output reads back as
0.8 TAN 1569 0.8 ORN 1640 a low voltage when a high voltage is expected.
■• Automatic
[ --------jam 1Transfer Action Taken When the DTC Sets
lease • All shifting will be disabled.
I
1 Solenoid I • The service 4WD larhp will be latched on for
j the remainder of the current ignition cycle.
• A history DTC will clear after 100 consecutive
• History DTCs can be cleared using a scan tool.
DTC C0323 T-Case Lock Circuit Low

1 —
(ATC) System
Go to Step 2 Check
6. Disconnect connectors C1 and C2 at the

transfer case.
8. Connect a test lamp from cavity C (ORN) of C2
to ground.
DTC C0323 T-Ca8e Lock Circuit Low (cont’d)

Step Action Value(8) Yes No
Locate and repair the open ORN (1640) wire between
3 splice S236 and transfer case. — —
is the action complete? Go to Step 11
Use a DMM in order to measure the resistance from
4 cavities C and D of C2 at the transfer case. 2 0 -8 0 0
5
(ATC) Control Module. —
3. Connect a self powered test lamp from cavity D
(TAN) of C2 to ground.
1. Connect a jumper wire from cavity E1 of C1 at Auto
Transfer Case (ATC) Control Module to ground.
6 2. Connect a self powered test lamp from cavity D —
(TAN) of C2 to ground.
Replace the Transfer Case Lock Solenoid. Refer to

Locate and repair the TAN (1569) wire for a short
8 to ground. — —
Locate and repair the open TAN (1569) wire between
the Auto Transfer Case (ATC) Control Module and — —
9 transfer case.
Refer to Transfer Case Control Module Replacement — —
10 (Automatic 4WD)
3. Ensure PARK brake is set.
11 Important: Allow time between shift request for the
—
DTC C0323.
Did the test Run and Pass? System OK Go to Step 1
DTC C0324 T-Case Lock Circuit High
| H ot At All Tim es! Circuit Description
IP The Auto Transfer Case (ATC) Control Module
'Fuse
■ Power
. Distribution* E7 Is T CASE controls the Transfer Case Lock Solenoid. The lock
1 C ell 10
I D 8'
Fuse 2
8 S 20 A
Block is energized (locking action released, by grounding
I circuit 1569) during gear shifts and in AUTO (Adapt)
L_ _ _ _ _ _ _ — — _ j mode of operation. When power or ground is
3 ORN 1640 removed from the lock solenoid (locking action
-----------------------, ! S236 applied, releasing the ground on circuit 1569), the
1 ORN 1640 \ Fuse Block Transfer Case Motor is prevented from moving. In
C2 Details
C ell 11
this manner the system is capable of providing a 4H
and 4L lock-up without the need of additional vehicle
■y * Transfer power to hold the Transfer Case in these positions.
C ase
Lock
/ Case This DTC detects a shorted lock solenoid coil, circuit
1 Control 1569 shorted to a 12 V circuit.
* I * Module
L w w mm mm m & * Conditions for Setting the DTC
E1 01 A Auto Transfer Case Lock output reads back as a
5 TAN 1569 0.8 ORN 1640 high voltage when a low voltage is expected.
£ PI00 Action Taken When the DTC Sets
A JL Cl 31 • The system will try to turn the lock solenoid on,
0.8 TAN 1569 0.8 ORN 1640 grounding circuit 1569; if can not energize the
D C solenoid, the system will not attempt to energize
the solenoid again during that ignition cycle.
0.8 TAN 1569 0.8 ORN 1640
r —
: "* Automatic • All shifting will be disabled.
I I- BanI Transfer • The service 4WD lamp will be latched on for
I 1Case the remainder of current ignition cycle.
I I
'— Conditions for Clearing the DTC
I Solenoid l
L_ __ _ j
183193
DTC C0324 T-Case Lock Circuit High

1 performed? Transfer Case
—
(ATC) System
Go to S te p 2 Check
2 6. Disconnect connector C1 at the Auto Transfer Case —
transfer case.
9. Connect a test lamp from cavity D (TAN) of C2
to ground.
DTC C0324 T-Case Lock C ircuit High (cont’d)

Use a DMM in order to measure the resistance between
3 cavities C and D of the transfer case connector. Is the 20-80 O
resistance within the value indicated? Go to Step 6 Go to Step 4
Replace the Transfer Case Lock Solenoid. Refer to

Locate and repair the TAN (1569) wire for a short to
voltage between Auto Transfer Case (ATC) Control Module
5 and the transfer case, — —

6 Refer to Transfer Case Control Module Replacement —
(Automatic 4WD) —
7 5. Place the transmission in neutral. —
Im portant: Allow time between shift request for the
DTC C0324.
DTC C0327 Encoder Circuit Malfunction

|H o jjn R u ^ |H o t At A ilT lm eel
-------- **IP 4
I 4W D Fuse
■ Pow er
T CASE
V'Fuse
P
. Distribution
I Fuse 2 4 'B lo c k 1 C e l 10 Fuse 2
JBlock
I 20 A I I 20 A
I I
b _ _ _ j b j
fu s e Block'
0.8 BRN 241 ftis e Block
3 0RN 1640
Details ----------OS235 D etails --------HS236
C eil 11 C ell 11
0.8 BRN 241 1 ORN 1640
E10 Cl E11 ^ Cl D |C 2
183191
Circuit Description Conditions for Setting the DTC

The Transfer Case Encoder is a switch that converts The Auto Transfer Case (ATC) Control Module reads
a shaft position, representing a mode or range back all high or low voltage on the Encoder channel
position, into electrical signals for use by the Auto circuits.
Transfer Case (ATC) Control Module. The encoder
houses 4 Hall effect sensors that are used for Action Taken When the DTC Sets
channels P, A, B, and C. These sensors provide a
• All motor activity will stop and the Transfer
path to ground, when a magnet, (part of the shift
rail), passes over them. Case Lock engaged.
The Auto Transfer Case (ATC) Control Module • A default rail to rail shift may be allowed,
supplies an 8 V reference and a ground circuit for (toggle between 4H and 2H).
the encoder Hall effect sensors to function via circuit • The service 4WD lamp will be latched on for
431 and 1554 respectfully. the remainder of the current ignition cycle.
supplies 5 V on all the channels, thus as these Conditions for Clearing the DTC
channels are pulled to ground, the module can • The Auto Transfer Case (ATC) Control Module
interpret the location of the transfer case shift will clear the DTC if the condition for setting the
position.
This DTC detects an open, short to ground, or a
short to voltage (12 V) in circuit 431, an open in • A history DTC will clear after 100 consecutive
circuit 1554, an open, short to ground, or short to ignition cycles without a fault present.
voltage (12 V) in the Encoder channel circuits 1555, • History DTCs can be cleared using a scan tool.
1557, 1558, or 1556.
DTC C0327 Encoder Circuit Malfunction

1 —
(ATC) System
Go to Step 2 Check
4. Use the scan tool in order to record Freeze
2 Frame and Failure Records.
7-9 V
transfer case.
cavity E (LT GRN/BLK) of C2 to ground.
Measure the voltage from cavity F (BRN/WHT) of C2
3 to ground. 4-6 V
Measure the voltage from cavity B (DK BLU/WHT)
4 of C2 to ground. 4-6 V
Measure the voltage from cavity D (YEL/BLK)
Measure the voltage form cavity C (RED/WHT)
Connect a self powered test lamp from cavity A
7 (BLK/WHT) of C2 to ground. —
1. Connect a jumper wire from cavities B, D, and F to
cavity A.
8 —
3. Use the scan tool in order to read the Encoder
Gear Position.
is the gear position 4WD (4H Adapt) Go to Step 9 Go to Step 10
Replace the Motor/Encoder. Refer to Motor/Encoder
9 Replacement (Automatic 4WD) — —
11
2. Disconnect connector C1 at the Auto Transfer
Case (ATC) Control Module.
12 3. Turn the ignition ON.
4. Use a DMM in order to measure the voltage
from cavity E (L.T GRN/BLK) of C2 at the transfer
case to ground. Greater
Is the voltage within the value indicated? than 0.5 V Go to Step 13 Go to Step 10
DTC C0327 Encoder Circuit Malfunction (confd)
Locate and repair the LT GRN/BLK (431) wire for a short
13 to voltage. — —
2. Disconnect the Auto Transfer Case (ATC) Control
Module.
14 —
3. Connect a self powered test lamp from cavity E
(LT GRN/BLK) of C2 at the transfer case to ground.

1. Connect a jumper wire from cavity F13 of C1 at the
Auto Transfer Case (ATC) Control Module connector
to ground.
16 2. Connect a self powered test lamp from cavity E —
(LT GRN/BLK) of C2 at the transfer case connector

to ground.
Locate and repair the LT GRN/BLK (431) wire for an open
between the Auto Transfer Case (ATC) Control Module
17 and the transfer case. — —
18 3. Connect a jumper wire from cavity F12 of C1 at Auto
—
Transfer Case (ATC) Control Module to ground.
(BLK/WHT) of C2 at transfer case to ground.
Locate and repair the BLK/WHT (1554) wire for a open
between Auto Transfer Case (ATC) Control Module and
19 Motor/Encoder. If no open is found, replace the Auto — —
Transfer Case (ATC) Control Module. Refer to
20
21 2. Use a DMM in order to measure the voltage from
0V
cavity F (BRN/WHT) of C2 at the transfer case to
ground.
Locate and repair the BRN/WHT (1555) wire for a short to
22 voltage. — —
23
DTC C0327 Encoder Circuit Malfunction (cont’d)

24 2. Use a DMM in order to measure the voltage from 0V
cavity B (DK BLU/WHT) of C2 at the transfer case
connector.
Locate and repair the DK BLU/WHT (1557) wire for a
26
27 2. Use a DMM in order to measure the voltage from 0V
cavity D (YEL/BLK) of C2 at the transfer case
connector.
Locate and repair the YEL/BLK (1558) wire for a
29 Go to Step 30 Go to Step 38
than 6 V
2. Use a DMM in order to measure the voltage from 0V
30
cavity C ( RED/WHT) of C2 at the transfer case
connector.
Locate and repair the BRN/WHT (1556) wire for a
32 3. Connect a self powered test lamp from cavity F —
(BRN/WHT) of C2 at the transfer case connector
to ground.
Locate and repair the BRN/WHT (1555) wire for a
(DK BLU/WHT) of C2 at the transfer case connector
to ground.
Locate and repair the DK BLU/WHT (1557) wire for a

DTC C0327 Encoder Circuit Malfunction (cont’d)
36 3. Connect a self powered test lamp from cavity D —
(YEL/BLK) of C2 at the transfer case connector
to ground.
Locate and repair the YEL/BLK (1558) wire for a short
37 to ground. — —
38 3. Connect a self powered test from cavity C —
(RED/WHT) of C2 at the transfer case connector
to ground.
Locate and repair the RED/WHT (1556) wire for a
Locate and repair the open BRN/WHT (1555) wire. If no
open is found, replace the Auto Transfer Case (ATC)
40 Control Module. — —
Refer to
Locate and repair the open DK BLU/WHT (1557) wire.
If no open is found, replace the Auto Transfer Case
41 (ATC) Control Module. — —
Refer to
Locate and repair the open YEL/BLK (1557) wire.
Refer to
Locate and repair the open RED/WHT (1556) wire.
Refer to
44 —
Important: Allow time between shift request for the
6. Shift transfer case through all modules
7. Use the scan tool and select Specific DTC.
Decoding of Encoder Channels

Encoder Channels
F A B C Transfer Case Gearing
5 0 0 0 4L>-35 degrees
5 0 5 0 4L<-35 degrees
0 0 5 o 4L Adapt (AUTO) CCW
0 0 5 5 4L Adapt (AUTO) CW
5 0 5 5 Between Gears
5 0 0 5 Between Gears
0 0 0 5 Neutral
5 5 0 t 5 Between Gears
0 5 0 5 2H CCW
0 5 0 0 2H CW
5 5 0 0 4H Adapt (AUTO) Range < 35 degrees
5 5 5 0 4H Adapt (AUTO) Range >35 degrees
DTC C0357 Park Switch Circuit High

The Park Switch supplies a 12 V input to the module • Whenever PARK/NEUTRAL was true, the
when the vehicle is in PARK. The module uses this module would believe the transmission was
input to determine if the vehicle is in in PARK.
PARK/NEUTRAL. If the vehicle is in PARK, the
• All range shifts will be disabled.
module will not allow a range shift from 2H, 4H, or
AUTO (Adapt) mode to 4L range. • The service 4WD lamp will be latched on for
This DTC detects voltage on LT GRN CKT 275 at the remainder of the current ignition cycle.
the module when the module sees a front or rear
propshaft speed signal, or vehicle speed form the Conditions for Clearing the DTC
VCM/PCM over the Class 2 data bus. 1. The Auto Transfer Case (ATC) Control Module
Conditions for Setting the DTC will clear the DTC if the condition fo r setting the
detects voltage on CKT 584 at the module when the 2. A history DTC will clear after 100 consecutive
module sees a front or rear propshaft speed signal, ignition cycles without a fault present.
or vehicle speed form the VCM over the Class 2 3. History DTCs can be cleared using a scan tool.
data bus 10 mph or over for 10 consecutive
seconds.
DTC C0357 Park Switch Circuit High

1 —
(ATC) System
Go to Step 2 Check
2. Set PARK brake and place transmission in DRIVE.
3. Disconnect the PARK/NEUTRAL position switch.
2 4. Turn the ignition ON, engine OFF. —
5. Use the scan tool in order to read the switch

position.
Does the scan tool show the switch open? Go to Step 4 Go to Step 3
1. Disconnect the Brake Switch Assembly.
3 2. Use the scan tool in order to read the switch
—
position.
Replace the PARK/NEUTRAL Position Switch. Refer to
4 Park/Neutral Back Up Switch Replacement — —

Replace the Brake Switch Assembly.
5 — —
1. Locate and repair the LT GRN (275) wire for a
short to voltage.
6 2. If no short is found, replace the Auto Transfer — —
Case (ATC) Control Module. Refer to

7 4. Use the scan tool in order to read the Park Switch —
status as you shift the TRANS between P and D

ranges.
Does the PARK Switch status toggle between open
and close? System OK Go to Step 1
DTC 00362 4LO Discrete Output Circuit High
r -------- *. vehicle J* 1 Powertrain

! !Control Control
! !Module
. ! Module
i | (VCM) ! * (PCM)
l. — — — «a
23YC4 *"d2Y ci j
0.5 GRY/BLK 1694
0.5 GRY/BLK 1694
G as
0.5 GRY/BLK 1694

:P101 (DfssaO
A iC l2 0
0.8 GRY/BLK 1694
D£C131
*P100
0.5 GRY/BLK 1694
F7JL
Automatic
rn •Transfer
I 4wbu> lease
L --------J Control
Module
183189

The 1694 circuit is used to notify the Vehicle Control • May affect the transmission shift points.
Module (VCM) Powertrain Control Module (PCM) that • The service 4WD lamp will be latched on for
the vehicle is in 4WD low range. The Vehicle Control
Module (VCM) Powertrain Control Module (PCM)
supplies 12 V on this circuit. The Auto Transfer Case
(ATC) Control Module supplies a ground on this
circuit when the vehicle is in 4WD low range. • The Auto Transfer Case (ATC) Control Module
This DTC detects an Auto Transfer Case (ATC) will clear the DTC if the condition fo r setting the
Control Module problem, a short to voltage on DTC no longer exits.
circuit 1694. • A history DTC w ill clear after 100 consecutive
Conditions for Setting the DTC ignition cycles without a fault present
• After the system turns the output on, (grounding • History DTCs can be cleared using a scan tool.
circuit 1694), and reads back a high voltage,
the DTC is set. The system will not attempt it
again during that ignition cycle.
reads back a high voltage when a low voltage
is expected on the 4 low discrete output,
circuit 1694.
DTC C0362 4LO Discrete Output Circuit High

Step Action Valuefs) Yes No
1 —
(ATC) System
Go to Step 2 Check
DTC C0362 4L0 Discrete Output Circuit High (cont’d)

3. Set PARK brake.
5. Place the transfer case in 2H mode.
2 7. Turn the ignition OFF. 11.0-13.5 V
cavity F7 (GRY/BLK) of C1 to ground.
2. Disconnect the Vehicle Control Module
(VCM)/Powertrain Control Module (PCM).
3. Turn the ignition ON, engine OFF. 11.0-13.5 V
4
cavity F7 (GRY/BLK) of C1 to ground at the Auto
Locate and repair the GRY/BLK (1694) wire for a
2. Reconnect the VCM/PCM.
4. Connect a test lamp from cavity F7 of C1 to ground.
Replace the Vehicle Control Module (VCM)/Powertrain
7 Control Module (PCM). — —
3. Set PARK brake.
DTC C0362.
DTC C0367 Front Axle Control Circuit High
Front Front
Automatic
Axle Axle Transfer
Switch C ontrol Case Control
.... - A , i Module
E14
0.8BLK/WHT
0.8BLK/WHT
0.8 BLK/WHT
150
Cl 20
150
S162 (Ga»)
S107 (Diesel)
183187

The Auto Transfer Case (ATC) Control Module • All shifting for 4WD and AUTO (Adapt) mode
controls the engagement and disengagement of the will be disabled.
front axle by grounding (engaging) circuit 1570. The • The service 4WD lamp will be latched on for
front axle will be disengaged in 2H and neutral only, the remainder of the current ignition cycle.
it should be engaged in the all other modes. This
DTC detects a shorted actuator, a short to 12 V on Conditions for Clearing the DTC
circuit 1570. • The Auto Transfer Case (ATC) Control Module
Conditions for Setting the DTC will clear the DTC if the condition for setting the
• The system will try to engage the front axle. If
it can not engage the front axle, the system will
not attempt it again during that ignition cycle. ignition cycle without a fault present.
reads back the front axle output as a high
voltage when a low voltage is expected.
DTC C0367 Front Axle Control Ciroult High

(ATC) System
G o to S t e p 2 Check
6. Disconnect connector at the Front Axle
Switch/Actuator Assembly.
8. Connect a test lamp from cavity B (LT BLU) to
ground.
Is toe test lamp on? G o to S te p 3 G o to S t e p 4

4. Connect a test lamp from cavity B (LT BLU) to
ground.
Is toe test lamp on? G o to S t e p 5 G o to S t e p 6
4 Replace the Front Axle Switch/Actuator. —

—
Is toe action complete? G o to S t e p 7
Locate and repair the BLK/WHT (1570) wire for a

Is toe action complete? G o to S t e p 7

Refer to T r a n s fe r C a s e C o n tr o l M o d u le R e p la c e m e n t —
6 (A u to m a tic 4 W D )
—
Is the action complete? G o to S t e p 7

3. Set PARK brake.
5. Place toe transmission in neutral.
7 Im portant: Allow time between shift request for the —
DTC C0367.
DTC C0374 General System Malfunction
Circuit Description Conditions for Clearing the MIL/DTC
The Auto Transfer Case (ATC) Control Module • A history DTC will clear after 100 consecutive
senses rear to front slip, a difference of rear to front ignition cycles without a fault present.
wheel speed, attempts to correct the difference by • Use a scan tool in order to clear history and
turning on the motor, internal to the Transfer Case, current DTCs.
to apply torque to the front wheels.
Possible Causes
Internal mechanical malfunction in the Transfer Case,
The Auto Transfer Case (ATC) Control Module is internal Auto Transfer Case (ATC) Control Module
unable to correct sensed slip for 10 consecutive malfunction, shorted motor coil, or a mechanical
seconds. malfunction in the Front axle.
DTC C0376 Front/Rear Shaft Speed Mismatch
11Automatic
[Transfer
'Case
'Control
F5 F6 ..................................E l* r E13 Cl
0.5LTBLU 2221 0.5 YEL 400
0.5DKGRN 2222 0.5 PPL 401
&P100
................. K; L.................................. A i t ................ I .
0.5LTBLU 2221 0.5 YEL 400
0.5DKGRN 9999 0.5 PPL 401
AJL B Bi
4 4
Prop 4 4
Prop
Shaft Shaft
Hi 10 Hi 10
Speed Speed
Sensor Sensor
Rear Front
183182
Circuit Description • Front Propshaft indicates speed less than

The Front and Rear Propshaft Speed Sensor is a 75 mph
Permanent Magnet (PM) generator. The PM • Front Propshaft or Rear Propshaft speed
generator produces a pulsing AC voltage. The AC exceeds 512 RPM
voltage level and number of pulses increases as • Vehicle Speed On Class 2 Data bus exceeds
speed increases. The module converts the pulsating
10 mph
AC voltage to a propshaft RPM which is used for
calculations. The module only looks at these inputs Action Taken When the DTC Sets
together when the vehicle is in 4H, 4L, and AUTO
(Adapt) range only. The propshaft RPM can be • All Shifts to AUTO (Adapt) mode w ill be
displayed with a scan tool. disabled. If the current mode is AUTO, the
This DTC detects greater than 20% difference in system will not allow any further adaptive
the speed sensor inputs. events (correct slip).
Conditions for Setting the DTC • The service 4WD lamp will be latched on for
detects continued readings of front and rear Conditions for Clearing the DTC
propshaft speed signal which do not match. Module
can not determine propshaft speed. 1. The Auto Transfer Case (ATC) Control Module
The system will log the DTC if the the front and rear will clear the DTC if the condition fo r setting the
propshaft inputs indicates a speed of less than 20% DTC no longer exists.
difference for 40 seconds while all of the following 2. A history DTC will clear after 100 consecutive
are true: ignition cycles without a fault present.
• Transmission NOT in Park/Neutral 3. History DTCs can be cleared using a scan tool.
• Front axfe is engaged
DTC C0376 Front/Rear Shaft Speed Mismatch
Im portant: If DTC C0300 is also present perform the Go to Auto
diagnostic for DTC C0300 before continuing. Transfer Case
1 —
Was the Auto Transfer Case (ATC) System Check (ATC) System
performed? Go to Step 2 Check
2. Inspect the following for a mismatch:
2.1. Front and rear Axle ratios.
2.2. All tires
2 2.3. Front or rear propshaft - missing. —
3. Inspect that the speed sensors are mounted in the
proper position, front in the front and rear in rear.
4. Inspect all the connectors for proper connection and
for loose terminals.
1. Disconnect the Front and Rear Propshaft Speed
Sensors and remove. Refer to AFWD Speed Sensor
Replacement (Front Speed Sensor Replacement) and
AFWD Speed Sensor Replacement (Rear Speed
3 Sensor Replacement) —
2. Inspect the sensor Rotors for damage, misalignment,
and slipping.
Repair/replace as necessary.
4 —
Is the action complete? —
Go to Step 8
Use a DMM in order to measure the resistance of
5 the two speed sensors. 1400—2700 Q
Replace speed sensor(s). Refer to AFWD Speed Sensor
Replacement (Front Speed Sensor Replacement) and
6 AFWD Speed Sensor Replacement (Rear Speed Sensor — —
Replacement)
1. Check for high resistance or poor connections in
circuits YEL (400), LT BLU (2221), PPL (401), and
DK GRN (2222).
7 2. If no problem is found, replace the Auto Transfer — —
case (ATC) Control Module. Refer to Transfer Case
Control Module Replacement (Automatic 4WD)
3. Set park brake.
Im portant: Allow time between shift request for the
8 transfer case to complete the previous request. —
7. Place the Transfer Case in AUTO Mode and road
test vehicle.
enter DTC C0376.
DTC C0550 ECU Malfunction

Circuit Description • One or more RAM locations have failed
At each power up the module runs a self test on the operational test indicating that some portions
following: of RAM are not functional.
• EEPROM Checksum • Motor circuit test has indicated that one of the
module’s relays is not able to make contact
• ROM Checksum
• RAM Checksum Action Taken When the DTC Sets
• RAM Malfunction The "’Service AUTO/4WD" lamp will be latched on
• Relay Malfunction and the system will be disabled.
Conditions for Setting the DTC Conditions for Clearing the MILfDTC
• Critical operational parameters stored in 1. Replace the Auto transfer Case Control Module.
EEPROM have failed checksum test indicating 2. Perform the Auto transfer Case System Check.
invalid data.
• Masked ROM code has failed checksum
test indicating that masked ROM data is
no longer valid.
• ROM code has failed checksum test indicating
that ROM data is no longer valid.
DTC C0611 VIN Information Error

The Auto Transfer Case (ATC) Control Module uses • The ignition counts since last fault will
the V.I.N. information for calculations that are be cleared.
required for the different calibrations used based on • The system will be disabled until valid
axle ratio, transmission, tire size, and engine. The
VIN data is received.
system does not know which calibration to use
without this information. • The Service AUTO/4WD lamp will be latched on.
Conditions for Setting the DTC Conditions for Clearing the MIL/DTC
The Auto Transfer Case (ATC) Control Module A history DTC will clear after a valid VIN
does not receive a valid V.I.N. digit for the digit is received.
correct application, K truck, L van or T truck
within 2 seconds after power up. Possible Causes
Class 2 Data bus malfunction, Vehicle Control
Module (VCM)/Powertrain Control Module (PCM)
malfunction, module installed in wrong vehicle.
DTC C0895 Device Voltage Malfunction

The direct battery supply line (circuit 1640) provides There are no default actions associated with this
the power to the module and motor circuitry. DTC. The service AUTO/4WD will not be latched on.
This DTC detects a intermittent absence of battery Conditions for Clearing the DTC
voltage at the module when the module sees an
1. The Auto Transfer Case (ATC) Control Module
ignition on voltage.
Conditions for Setting the DTC DTC no longer exists.
The Auto Transfer Case (ATC) Control Module has 2. A history DTC will clear after 100 consecutive
been powered-up from the battery input for at least ignition cycles without a fault present.
11 times out of the last 19 ignition cycles. 3. History DTCs can be cleared using a scan tool.
DTC C0895 Device Voltage Malfunction
1 —
(ATC) System
Go to Step 2 Check
2 3. Connect a test lamp from cavity D (ORN)
—
of C2 to ground.
4. While observing the test lamp, wiggle the
wire harness.
Did the test lamp go out at any time? Go to Step 3 Go to Step 4
Locate and repair the ORN (1640) for an intermittent
3 open circuit between module and Splice S236. — —

1. Connect a self powered test lamp from cavity E16
(BLK/WHT) of C1 to ground.
4 2. While observing the test lamp, wiggle the wire —
harness.
Did the test lamp go out at any time? Go to Step 5 Go to Step 6
Locate and repair the BLK (451) for an intermittent open
5 circuit between module and Splice S215. — —
1. No problem found at this time.
Go to Auto
6 3. Turn the ignition ON, engine OFF. — —
Transfer Case
4. Use the scan tool in order to clear all DTCs. (ATC) System
Is the action complete? Check
Go to Auto
7 — Transfer Case —
3. Use the scan tool in order to clear all DTCs. (ATC) System
Front Axle W ill Not Engage (A utom atic 4W D)

1 —
(ATC) System
Go to Step 2 Check
2. Ensure the vehicle is in 2WD mode.
2 3. Use the scan tool in order to read the Front Axle —
Switch status.
Does the scan tool show switch closed? Go to Step 8 Go to Step 3
2. Disconnect the Front Axle Actuator.
4. Connect a test lamp from cavity C to ground.
1. Locate and repair the open BRN (241) wire between Go to Auto
Front Axle Actuator and Fuse. Transfer Case
4 — —
2. Reconnect all disconnected components. (ATC) System
1. Connect a self powered test lamp from cavity B
to ground.
Important: Look at the test lamp while using the —
5
scan tool.
2. Use the scan tool in order to engage the front axle.
6 3. Connect a jumper wire from cavity B to ground . —
4. Connect a self powered test lamp from cavity F4
of C1 to ground.
1. Locate and repair the open BLK/WHT (1570) wire
between the Auto Transfer Case (ATC) Control Go to Auto
7 Module and Transfer Case. — Transfer Case —
1. Disconnect the Front Axle Actuator connector.
2. Use the scan tool in order to read the Front Axle —
8
Switch status.
Does the scan tool show switch closed? Go to Step 9 Go to Step 13
1. Locate and repair the BLK/WHT (1695) wire for a
short to voltage. If no short is found, replace the
Auto Transfer Case (ATC) Control Module. Refer to
9 Transfer Case Control Module Replacement — Go to Auto —
(Automatic 4WD) Transfer Case
Front Axle Will Not Engage (Automatic 4WD) (cont’d)
Connect a self powered test lamp from cavity E of
10 Transfer Case to ground. —
1. Locate and repair the open BLK (150) wire between Go to Auto
the Transfer Case and ground G105. Transfer Case
11 2. Reconnect all disconnected components. — —
(ATC) System
1. Reconnect the Auto Transfer Case (ATC) Control
Module connectors.
12 3. Connect a jumper wire from cavity A of Transfer —
Case to ground.
4. Use a scan tool in order to read the Front Axle
Switch status, (open/closed).
Is the switch status closed? Go to Step 13 Go to Step 14
1. Check for mechanical problems. If no problem is Go to Auto
found, replace the Front Axle Actuator. Transfer Case
(ATC) System
1. Replace the Auto Transfer Case (ATC) Control
Module. Refer to Transfer Case Control Module Go to Auto
14 Replacement (Automatic 4WD) — Transfer Case —
Front Axle W ill Not Disengage (A utom atic 4W D)

(ATC) System
2. Disconnect the Front Axle Actuator.
4. Connect a test lamp from cavity C to ground.
Does the test lamp light? G o to S t e p 4 G o to S t e p 3
1. Locate and repair the open BRN (241) wire between Go to Auto
Front Axle Actuator and Fuse. Transfer Case
(ATC) System
Connect a self powered test lamp from cavity E of
4 Transfer Case to ground. —
Does the test lamp light G o to S te p 6 G o to S te p 5
the Transfer Case and ground. Transfer Case
(ATC) System
Connect a self powered test lamp from cavity B to ground. —
6
Does the test lamp light? G o to S te p 8 G o to S te p 7
1. Check for mechanical problems. If no problem is Go to Auto

found, replace the Front Axle Actuator. Transfer Case
(ATC) System
Transfer Case (ATC) Control Module. —
8
3. Connect a self powered test lamp from cavity B
to ground.
Does the test lamp light? G o to S t e p 9 G o to S t e p 1 0
1. Locate and repair the BLK/WHT (1570) wire for a

short to ground between the Auto Transfer Case Go to Auto
9 (ATC) Control Module and Transfer Case. — Transfer Case —
2. Reconnect all disconnected components, (ATC) System
is the action complete? Check
Module. Refer to T ra n s fe r C a s e C o n tro l M o d u le Go to Auto
10 R e p la c e m e n t (A u to m a tic 4 W D ) — Transfer Case
Range/M ode Sw itch Inoperative (A utom atic 4 WD)
(ATC) System
1. Scan the tool installed.
2 3. Use the scan tool in order to actuate lamps (turn all — System operating
lamp on) in lamp/switch assembly to ON. normal at
Do all the lamps light? this time G o to S te p 3
3 Does any of the lamps light? — G o to S t e p 1 3 G o to S te p 4
1. Disconnect the lamp/switch assembly.

4 2. Connect a test lamp from cavity A of C2 to ground. —
Does the test lamp light? G o to S te p 6 G o to S te p 5
1. Locate and repair the open PNK (39) wire between Go to Auto
the lamp/switch assembly and fuse. Transfer Case
(ATC) System
Connect a self powered test lamp from cavity H of C2
6 to ground. —
Does the test lamp light? G o to S t e p 8 G o to S te p 7
switch and ground. Transfer Case
(ATC) System
1. Reconnect the lamp/switch assembly.
8 2. Connect a fused jumper wire (back probe) from —
cavity H of C2 to ground.
Does the 4L lamp light? G o to S te p 10 G o to S te p 9
1. Replace the lamp/switch assembly. Refer to S h ift

S e le c t S w itc h R e p la c e m e n t (A u to m a tic 4 W D )
1. Remove the jumper wire.

2. Connect a fused jumper wire from (back probe)
10 cavity F1 of C2 at the Auto Transfer Case (ATC) —
Control Module to ground.
Does the 4L lamp light? G o to S te p 1 2 G o to S te p 11
1. Locate and repair the open PPL/WHT (1565) wire

between the switch and the module

Module. Refer to T ra n s fe r C a s e C o n tro l M o d u le
12 R e p la c e m e n t (A u to m a tic 4 W D ) — —
2. Reconnect all disconnected components.
Is the action complete? G o to S t e p 1
Connect a fused jumper wire (back probe) of the cavity of

the inoperative lamp at switch assembly to ground. Use —
13 the chart below for cavity, wire color, and lamp.
Does the suspect lamp light? G o to S te p 1 4 G o to S te p 9
Range/M ode Sw itch Inoperative (A utom atic 4 W D) (cont’d)

1. Remove jumper wire at switch.
2. Connect a fused jumper wire (back probe) of the
14 cavity of the inoperative lamp at module to ground, —
use the chart below for cavity, wire color, and lamp.
Does the suspect lamp light? Go to Step 12 Go to Step 15
1. Locate and repair the open wire between switch Go to
assembly and module. Auto Transfer
15 — —
2. Reconnect all disconnected components. Case (ATC)
Is the action complete? System Check
Cavity and Connector at Cavity and Connector at

Lamp Circuit and Wire Color Switch Module
4L 1565 PPL/WHT C C1 F1 C1
4H 1566 TAN/BLK B C1 F2 C1
2H 1563 LT GRN/BLK E C1 E4 C1
AUTO (Adapt) Mode 1561 PNK F C1 E3 C1
Neutral 1560 BRN D C2 F3 C1
No C orrection fo r S lip in AWD M ode (A utom atic 4W D)

1 — Case (ATC)
2. Set park brake. Place transmission in Neutral.
4. Shift the Transfer Case between AUTO and
2 2H mode. —
5. Use the scan tool in order to read the Front Axle
Switch status while shifting the Transfer Case.
Does the scan tool show the switch toggle between
Closed and Open? Go to Step 3 Go to Step 5
Ensure the Front Propshaft Speed Sensor is mounted in
3 the proper location, circuits 400 (YEL), and 401 (PPL). —
Was the problem found? Go to Step 4 Go to Step 5

Remove and relocate the speed sensor in the proper
location. Refer to AFWD Speed Sensor Replacement Go to
4 (Front Speed Sensor Replacement) and AFWD Speed — Auto Transfer —
Sensor Replacement (Rear Speed Sensor Replacement) Case (ATC)
Inspect the Front Axle and the Front Axle Actuator for Perform Symptom
proper operation, mechanically and electrically. Diagnosis Front
5 —
Is the Front Axle Actuator or circuits the suspect area? Axle Will Not
Engage Go to Step 6
No C orrection fo r S lip in AWD M ode (A utom atic 4W D ) (cont’d )
Step | Action Value(s) Yes No
1. Reconnect all previous disconnected components.
6 2. Road test vehicle in 4H or 4L range(s). —
Does 4H or 4L operate correctly? Go to Step 7 Go to Step 8
Replace the Auto Transfer Case (ATC) Control Module. Go to
Refer to Transfer Case Control Module Replacement Auto Transfer
7 — —
(Automatic 4WD) Case (ATC)
Repair/replace the Auto Transfer Case. Refer to
Transfer Go to
8 Case Replacement (Auto Four Wheel Drive 2 Speed)
— Auto Transfer —
Is the action complete? Case (ATC)
System Check
Two or M ore Indicator Lam ps Rem ain ON (A utom atic 4W D )

1 performed? — Auto Transfer
Case (ATC)
2 3. Use a scan tool in order to command the all —
lamps off.
Do the lamp go off? Go to Step 3 Go to Step 4
3 — —
Is the lamp off? Go to Step 3 Go to Step 5
1. Locate and repair the BRN (1560) for NEUTRAL,
PNK (1561) for AUTO, LT GRN/BLK (1563) for 2H,
TAN/BLK (1566) for 4H, PPL/WHT (1565) for 4L
wire(s) for a short to ground.
5 — —
2. If not short is found, replace the Select Switch Go to
Assembly. Refer to Shift Select Switch Replacement Auto Transfer
Service 4WD Lamp Stays ON when Key is ON (Automatic 4WD)

1 —
Case (ATC)
2 3. Use a scan tool in order to command the Service —
4WD lamps OFF.
Does the lamp go off? Go to Step 3 Go to Step 4
Case (ATC)
Is the lamp off? Go to Step 3 Go to Step 5
Locate and repair the LT BLU/BLK (1567) wire for a short Go to
to ground. Auto Transfer
5 — —
Is the action complete? Case (ATC)
System Check
T-Case will Shift Ranges When Trans is in Park (Automatic 4WD)
1 —
Case (ATC)
1. Set park brake and ensure the transmission is
in PARK.
2 —
3. Use the scan tool in order to read the Park switch
position.
Inspect the Turn B/U Fuse.
3 —
Is the Fuse open? Go to Step 5 Go to Step 6
Locate and repair the source of the overload and replace
5 the Turn B/U Fuse. — —
1. Disconnect the Park/Neutral Position Switch.
6 2. Connect a test lamp from cavity C to ground. —
Locate and repair the open PNK (139) wire.
7 — —
1. Connect a fused jumper wire between cavity C to
cavity B.
8 —
2. Use the scan tool, read the PARK switch position.
1. Locate and repair the open LT RN (275) wire
between the Auto Transfer Case (ATC) Control
Module and the PARK/NEUTRAL Position Switch.
9 2. If no open is found, replace the Auto Transfer Case — —
(ATC) Control Module. Refer to Transfer Case
Control Module Replacement (Automatic 4WD)
Replace the PARK/NEUTRAL Position Switch. Refer to
10 Park/Neutral Back Up Switch Replacement — —
11 4. Use the scan tool, read the PARK Switch status as —
you shift the TRANS between P and D ranges.
Does the Park Switch status toggle between open and
close? System OK Go to Step 1
Repair Instructions
Fluid Drain and Fill
Removal Procedure
1. Raise and support the vehicle. Refer to General
Information.
2. Place a container under the drain plug in order
to catch the oil.
3. Remove the fill plug.
4. Remove the drain plug. Allow the oil to drain.
Notice: Refer to Fastener Notice in Cautions and
Notices.
1. Install the drain plug.
Tighten
• Tighten the New Venture Gear drain plugs
to 47 N.m (35 lb ft).
• Tighten the Borg-Warner drain plugs to
25 N.m (18 lb ft).
2. Install the transfer case oil. Refer to
Approximate Fluid Capacities.
3. Fill the transfer case until the oil level is at the
bottom of the oil fill plug hole.
4. Install the fill plug.
Tighten
• Tighten the New Venture Gear drain plugs
to 47 N.m (35 lb ft).
• Tighten the Borg-Warner drain plugs to
25 N.m (18 lb ft).
Shield Replacement
Removal Procedure
1. Raise and support the vehicle.
2. Remove the four bolts and the nuts securing
the transfer case shield to the frame.
3. Remove the shield from the frame.
175368
Driveline/Axle_________________________ Transfer Case 4-275
1. Install the shield to the frame.
2. Install the four bolts and the nuts securing the
transfer case shield to the frame.
Tighten
Tighten the bolts and the nuts to
35 N.m (26 lb ft).
Shift Cable Replacement

1. Place the shift lever in the 4HI position.
3. Disconnect the linkage rod from the console
shift lever.
4. Shift the transfer case into 4HI position (the
transfer case shift lever in full forward detent).
A click sound indicates that the transfer case
lever is all the way back.
5. Adjust the swivel in order to align with the

notch in the console shift lever.
6. Connect the linkage rod to the console
shift lever.
175315
Shift Lever Replacement

Removal Procedure
1. Remove the shift knobs from the transfer case
shift lever.
2. Remove the four screws securing the transfer
case shift control bezel to the floor panel
bracket and the shift bracket.
3. Remove the wiring harness from the transfer
case shift control bezel.
Raise and support the vehicle. Refer to General
Information.
4. Remove the shift lever end from the transfer

case linkage rod.
175315
175387
1. Install the four bolts securing the transfer case
shift control to the floor panel bracket.
Tighten
Tighten the transfer case control bolts to
11 N.m (97 lb in).
2. Install the shift lever end to the transfer case

linkage rod.
Lower the vehicle.
3. Install the wiring harness to the transfer case

shift control bezel.
4. Install the four screws securing the transfer
case shift control bezel to the floor panel
bracket and the shift bracket.
Use the locator pin on the transfer case shift
control bezel in order to aid in positioning the
bezel onto the brackets.
Tighten
Tighten the transfer case shift control bezel
screws to 2 N.m (18 lb in).
5. Install the shift knob to the transfer case
shift lever.
175319
Transfer Case Output Shaft Seal

Replacement (New Venture)
Rem oval Procedure
Tools Required
Rear Output Shaft Seal Installer (NV241 Transfer
Case)
Im portant: This procedure applies to the front output
shaft seal replacement and to the rear output shaft
seal replacement.
Refer to General Lifting and Jacking in General
Information.
2. Remove the front or the rear propeller shaft.
Refer to Propeller Shaft Replacement (Front
Drive) or Propeller Shaft Replacement (System
Balanced Assembly) in Propeller Shaft.
175414
3. Remove the propeller shaft yoke nut and the
flat washers.
The yoke nut and the fiat washers are not used
at the rear on some models.
4. Remove the propeller shaft yoke.
5. Remove the transfer case shield. Refer to
Shield Replacement.
6. Remove the seal.
Use a screwdriver in order to remove the seal.
Do not damage the sealing bore.
911
Tools Required
J29162 Front Output Shaft Seal Installer (NV241
Transfer Case)
1. Install the seal using the following procedure:
1.1. Lubricate the seal lips with petroleum
jelly or with transmission oil.
1.2. Install the seal using the J 33843
1.3. For all of the vehicles except the K30
with dual rear wheels, install the New
Venture Gear transfer case.
2. Install the transfer case shield. Refer to Shield
Replacement
3. Install the propeller shaft yoke.
4. Install the flat washers and the nut, if used.
Tighten
Tighten the New Venture Gear propeller shaft
yoke nuts to 149 N-m (110 lb ft).
• Check the transfer case oil level and add oil
as necessary. Refer to Approximate Fluid
Capacities.
Transfer Case Output Shaft Seal

Replacement (Borg-Warner)
Rem oval Procedure
Tools Required
Output Shaft Seal Installer (4401 and 4470 Transfer
Case)
Important: This procedure applies to the front output
shaft seal replacement and to the rear output shaft
seal replacement.
Information.
2. Remove the front or the rear propeller shaft.
Refer to Propeller Shaft Replacement (Front
Drive) or Propeller Shaft Replacement (System
Balanced Assembly) in Propeller Shaft.
175421
3. Remove the propeller shaft yoke nut and the
flat washers.
The yoke nut and the flat washers are not used
at the rear on some models.
4. Remove the propeller shaft yoke.
Shield Replacement
6. Remove the seal.
Use a screwdriver in order to remove the seal.
Do not damage the sealing bore.
In s ta lla tio n P ro ce d u re
Tools Required
J29162 Front Output Shaft Seal Installer (NV241
Transfer Case)
1. Install the seal using the following procedure:
1.1. Lubricate the seal lips with petroleum
jelly or with transmission oil.
1.2. Install the seal using the Output Shaft
Seal Installer (4401 and 4470 Transfer
Case)
1.3. For the K30 with dual rear wheels, install
the Borg-W arner transfer case.
Replacement
3. Install the propeller shaft yoke.
4. Install the flat washers and the nut, if used.
911 Tighten
• Tighten the Borg-Warner rear propeller
shaft yoke nuts to 170 N-m (125 lb ft).
• Tighten the Borg-Warner front propeller
shaft yoke nut to 225 N-m (165 lb ft).
• Check the transfer case oil level and add oil
as necessary. Refer to Approximate Fluid
Capacities.
Rear Extension Housing Replacement

Removal Procedure
Information.
Propeller Shaft Replacement (System Balanced
Assembly).
3. Remove the yoke.
4. Remove the four bolts that secure the rear
extension housing to the rear retainer housing.
Remove the rear extension housing from the
rear retainer housing.
Tap the extension housing with a rubber mallet
in order to free the rear retainer housing.
2233
5. Remove the rear bearing retainer snap ring.

6. Remove the five bolts securing the rear retainer
housing to the transfer case.
7. Remove the rear retainer housing.
8. Remove the seal.
Use a screwdriver. Do not damage the
sealing bore.
9. Clean the gasket surfaces with a suitable
solvent.
1. Install the rear retainer housing.
• Make sure the gasket surfaces are clean and
free of grease and oil.
. Apply the RTV sealer GM P/N 12345739 to
the rear retainer housing sealing surfaces.
2. Secure the rear retainer housing to the transfer 2234
case with the five bolts.
Apply GM P/N 12345382 or the equivalent to
the threads of the bolts.
Tighten
Tighten the rear retainer housing bolts to
40 N.m (30 lb ft).
3. Install the snap ring.
4. Install the rear extension housing to the
transfer case.
• Clean the gasket surfaces thoroughly.
• Apply RTV sealer GM P/N 12345739 to the
rear extension housing sealing surfaces.
5. Install the four bolts that secure the rear
extension housing to the rear retainer housing.
Apply GM P/N 12345382 or the equivalent to
the threads of the bolts.
Tighten
Tighten the rear extension housing bolts to
31 N.m (23 lb ft).
6. Install the seal.
• Lubricate the seal lips with transmission oil
or with petroleum jelly.
• Install the seal using the J29162 Front
Output Shaft Seal Installer (NV241
Transfer Case)
7. Install the rear propeller shaft and the yoke.
• Check the transfer case oil level. Add oil if
necessary. Refer to capacities.
Transfer Case Replacement
(Selectable Four Wheel Drive)
Removal Procedure
1. Disconnect the negative battery cable.
Caution: Refer to Battery Disconnect
Caution.
Refer to General Lifting and Jacking in
Shield Replacement
4. Remove the front propeller shaft. Refer to
Two-Piece Propeller Shaft Replacement in
Propeller Shaft.
Assembly) in Propeller Shaft.
6. Remove the vent hose from the transfer case.
Refer to Vent Hose.
7. Disconnect the vehicle speed sensor
8. Disconnect the wiring harness from the
transfer case.
9. Remove the transfer case motor/encoder.
Support the transfer case with a jack.
10. Remove the bolts securing the transfer case to

the transmission adapter.
11. Remove the gasket.
12. Discard the gasket.
2214
1. Install a new gasket to the transmission.
Use a gasket sealer in order to hold the
gasket in place.
2. Install the transfer case to the transmission

adapter.
3. Install the bolts that secure the transfer case to

Tighten
Notice: Refer to Fastener Notice Cautions
and Notices.
2217
4. Install the transfer case motor/encoder.
5. Remove the jack from the transfer case.
6. Install the electrical connectors and the wiring
harness to the transfer case with the new
straps.
7. Install the vent hose to the transfer case. Refer
to Vent Hose.
8. Install the rear propeller shaft. Refer to
9. Install the front propeller shaft. Refer to
Propeller Shaft Replacement (Front Drive) in
Propeller Shaft.
Replacement
• Check the transfer case lubricant level. Add
oil as necessary. Refer to Approximate Fluid
Capacities.
11. Connect the negative battery cable.
Transfer Case Replacement (Manual Shift)
Removal Procedure
Caution: Refer to the Battery Disconnect
Caution in Cautions and Notices.
Lifting and Jacking in General Information.
Shield Replacement
Two-Piece Propeller Shaft Replacement in
Propeller Shaft.
5. Remove the rear propeller shaft. Refer to in
Assembly) Propeller Shaft.
Refer to Vent Hose.
7. Disconnect the vehicle speed sensor electrical
connector.
transfer case.
9. Disconnect the transfer case shift cable at the
transfer case. Refer to Shift Cable.
10. Remove the bolts securing the transfer case to

2214
1. Install a new gasket to the transmission. Use a
gasket sealer in order to hold the gasket in
place.

adapter.
3. Install the bolts that secure the transfer case
to the transmission adapter.
Tighten
Notice: Refer to Fastener Notice
in General Information.
5. Install the transfer case shift linkage at the
transfer case. Refer to Transfer Case
Replacement (Selectable Four Wheel Drive) or
Transfer Case Replacement (Manual Shift).
straps.
7. Install the vent hose to the transfer case. Refer
to Vent Hose.
Propeller Shaft Replacement (Front Drive) in
Propeller Shaft.
Replacement.
• Check the transfer case lubricant level. Add
oil as necessary. Refer to Approximate Fluid
Capacities.
Transfer Case Replacement

(Auto Four-Wheel-Drive 2-Speed)
Removal Procedure
Caution: Refer to Battery Disconnect Caution
In Cautions and Notices.
Lifting and Jacking in General Information.
Shield Replacement
Assembly)
Refer to Vent Hose.
7. Disconnect the vehicle speed sensor electrical
connector.
transfer case.
9. Remove the transfer case motor/encoder.
165643
10. Remove the bolts securing the transfer case
175410
Installation
1. Install a new gasket to the transmission.
Use a gasket sealer in order to hold the
gasket in place.
2214
adapter.
3. Install the bolts that secure the transfer case

Tighten
in General Information.
2217
4. Install the transfer case motor/encoder.

straps.
6. Install the vent hose to the transfer case.
Refer to Vent Hose.
Assembly)
Propeller Shaft Replacement (Front Drive)
10. Install the transfer case shield. Refer to
Shield Replacement
• Check the transfer case lubricant level.
Add oil as necessary. Refer to Approximate
Fluid Capacities
Adapter Replacement
Removal Procedure
1. Remove the transfer case. Refer to Transfer
Case Replacement (Selectable Four Wheel
Drive) or Transfer Case Replacement
(Manual Shift).
2. Remove the bolts securing the adapter and the
seal to the transmission.
Raise the rear of the transmission slightly.
3. Remove the adapter from the transmission.
4. Remove the seal.
1. Install the new seal to the transmission.
Lubricate the seal lips with the transmission
oil or the petroleum jelly.
2. Install the adapter to the transmission.
3. Install the four bolts that secure the adapter
to the transmission.
Tighten
Tighten the adapter bolts to 45 N.m (33 lb ft).
4. Install the transfer case. Refer to Transfer Case
Replacement (Selectable Four Wheel Drive) or
Transfer Case Replacement (Manual Shift).
Motor/Encoder Replacement
(Selectable 4WD)
Removal Procedure
Caution.
Shield Replacement.
3. Remove the transfer case wiring harness
connectors from the motor/encoder.
177160
4. Remove the four bolts that secure the
motor/encoder to the transfer case.
1. Install the with a motor/encoder.
2. Install the four bolts securing the motor/encoder
to the transfer case.
Tighten
Tighten the motor/encoder bolts to
25 N.m (18 lb ft).
• Remove all gasket material remaining from
the motor/encoder.
• Ensure the motor/encoder aligns properly
with the transfer case interior shifting
components.
• Align the motor/encoder mating surface
detent with the transfer case mating
surface detent.
3. Install the wiring harness connectors to the

motor/encoder.
Shield Replacement
6. Perform a functional test on the electronic shift
select system in order to test the
motor/encoder. Refer to Transfer Case
Functional Test (Selectable 4WD).
177160
Motor/Encoder Replacement
(Automatic 4WD)
Removal
1. Remove the negative battery cable.
Caution.
Shield Replacement
3. Remove the transfer case wiring harness
connectors from the motor/encoder.
4. Remove three bolts securing the motor/encoder

gasket and motor/encoder to the transfer case.
Installation
1. Install three bolts securing the motor/encoder
gasket and motor/encoder to the transfer case.
Tighten
Tighten the motor/encoder bolts to
25 N.m (18 lb ft).
• Remove all gasket material remaining from
the motor/encoder.
• Ensure the motor/encoder aligns properly
with the transfer case interior shifting
components.
• Align the motor/encoder mating surface
detent with the transfer case mating
surface detent.
165625
2. Install the transfer case wiring harness
connector to the motor/encoder.
Shield Replacement
Shift Select Switch Replacement

(Selectable 4WD)
Removal Procedure
1. Remove the shift select switch from the
instrument panel.
• Pull the tabs on the rear of the switch in.
• Pull the switch straight out from the panel.
2. Remove the electrical connector from the shift
select switch.
1. Install the electrical connector to the shift
select switch.
2. Install the shift select switch into the
instrument panel.
Ensure the shift select switch locks into the
instrument panel.
177180
Shift Select Switch Replacement

(Automatic 4WD)
Removal Procedure
1. Remove the automatic transfer case switch
from the instrument panel.
• Puli the tabs on the rear of the switch in.
• Pull the switch straight out from the panel.
automatic transfer case switch.
1. Install the electrical connector to the automatic
transfer case switch.
2. Install the automatic transfer case switch into
the instrument panel.
3. Ensure the automatic transfer case switch locks
into the instrument panel.
Transfer Case Control Module
Replacement (Selectable 4WD)
Removal Procedure
1. Remove the lower instrument panel trim.
2. Remove the two screws securing the transfer
case control module to the bracket.
The bracket is mounted on the l/P
reinforcement.
transfer case control module.
177176
1. Install the electrical connector to the transfer
case control module.
2. Install the two screws securing the transfer
Tighten
Tighten the transfer case control module screws
to 8 N.m (71 lb ft).
3. Install the lower instrument panel trim. Refer to
Exterior/lnterior Trim in Body and Accessories.
177176
Transfer Case Control Module

Replacement (Automatic 4WD)
1. Remove the lower instrument panel trim.

2. Remove the two screws securing the auto
transfer case control module to the bracket.
The bracket is mounted on the l/P
reinforcement.
3. Remove the electrical connector from the auto
1. Install the electrical connector to the auto
2. Install the two screws securing the auto transfer
177176 Tighten
Tighten the transfer case control module screws
to 8 N.m (71 lb ft).
3. Install the lower instrument panel trim.

(Front Speed Sensor)
Removal Procedure
speed sensor.
2. Remove the front speed sensor from the
transfer case.
1. Install the front speed sensor into the
transfer case.
Tighten
Tighten the front speed sensor to
31N.m (23 lb ft).
2. Install the electrical connector to the
speed sensor.

(Rear Speed Sensor)
Removal Procedure
1. Remove the two electrical connectors from
the two rear speed sensors.
2. Remove the two rear speed sensors from
the transfer case.
163714
1. Install the two rear speed sensors to the
transfer case.
Tighten
Tighten the rear speed sensors to
31N-m (23 lb ft).
2. Install the two electrical connectors to
the two rear speed sensors.
163714
Transfer Case Electrical Connector

Replacement (Selectable 4WD)
Removal Procedure
Remove the four electrical connectors from the
speed sensors and the motor/encoder.
Install the four electrical connectorx to the speed
sensors and the motor/encoder.
Description and Operation 2HI to 4HI

Important: Shifting into the 4HI range causes the
Transfer Case Description following conditions to occur.
(Selectable 4WD) 1. The front axle indicator lamp does not come
The transfer case is used to provide power flow from on until the front axle engages.
the transmission to the front axle. The transfer case 2. The torque flows from the input gear to the
also provides a way of disconnecting the front axle mainshaft the same as in the two-wheel
in order to provide better fuel economy and quieter position.
operation when the vehicle is driven on the roads The shift linkage moves the mode synchronizer
where the four-wheel drive is not required. The sleeve into engagement with the clutch teeth of
transfer case provides an additional gear reduction the drive sprocket. This locks the drive sprocket
wen placed in low range. This is useful when difficult to the mainshaft through the synchronizer
off-road conditions are encountered. sleeve.
The New Venture Gear Models NV241 or NV243 3. The torque is transmitted through the drive
transfer case is used on all of the four-wheel drive sprocket and the drive chain to the driven
vehicles under 9200 lb GVW. The NV243 is similar sprocket and the output shaft. The torque then
to the NV241 except that it contains an electric shift flows through the front propeller shaft to the
motor/encoder attached to the transfer case in the front axle.
area where the shift lever is ordinarily mounted. 4. The shift mechanism in the transfer case closes
the transfer case switch.
The K30 Models with single or dual rear wheels will
use the Borg-Warner Models 4401 or 4470 transfer The current is then applied to the front axle
thermal actuator and the front axle switch. In
case. Both of these transfer cases use a shift lever
the K30 vehicles, the power is also supplied by
and a shift linkage in order to change the operating
the transfer case relay to the transfer case
range. synchronizer.
The Models NV241, 4401, and 4470 are aluminum 5. The thermal actuator contains a heating
case, chain driven units with four modes of element, a gas charge, and a piston.
operation; neutral, two-wheel drive high range, When the current is applied, the heating
four-wheel drive high range, and four-wheel drive low element heats the gas. The gas expands,
range. The gear reduction for low range is provided pushing the piston out after a delay of a few
by a planetary gear set. seconds. The piston actuates the shift fork in
A floor mounted shift lever is used in order to select the front axle. This connects the right axle
the operating range for the NV241, the 4401, and output shaft to the front axle differential. The
the 4470. The indicator lamps on the floor console torque is then available at the front wheels.
show the current mode of operation. When 6. The front axle shift mechanism, when fully
four-wheel drive indicator lamp is designed to come engaged, closes a switch, causing the front
ON whenever the front axle has engaged. A slight axle indicator lamp to come ON. For more
delay for the front axle indicator lamp to come ON information on the front axle shift mechanism
is normal. and the actuator, refer to Electric Motor
Actuator Replacement
The New Venture Gear Model NV243 is electronically
7. If the shift lever is moved back to the 2
actuated. The vehicles equipped with this model
WHEEL position, the operations in the
have no transfer case selector lever. The operator
preceding steps are reversed. The current to
selects 2HI, 4HI, or 4LO by pushing one of three the thermal actuator is turned OFF. The gas
switches mounted on the instrument panel. During cools and the piston retracts allowing the shift
normal driving the transfer case is in the 2HI mode. fork in the front axle in order to return to the
When the transfer case is in 2HI both the 4HI and two-wheel drive position.
the 4LO switch circuits are open, and both lights are
OFF. When the four-wheel drive has been selected, Four-Wheel Drive Low Range Operation
the four-wheel drive indicator lamp on the switch When the transfer case is shifted into the 4LO
turns on when the front axle has engaged. The lamp position, the torque flow and the operation is similar
will blink while the front axle is engaging. For more to the 4HI range, except that the range shift hub
information on the electrical operation of the NV243, engages the planetary carrier. The planetary gear set
refer to Transfer Case System Description then provides a gear reduction to the front and the
(Selectable 4WD). rear axles.
Electronic Synchronizer Operation
Two-Wheel Drive Operation (Borg-Warner)
When the transfer case is in the 2 WHEEL range, The electronic synchronizer is used in model 4401
the torque flows from the input gear to the range and 4470 transfer cases in order to provide
shift hub and the main shaft, through the propeller smoother shifting. The system requires no
shaft to the rear axle. maintenance or service.
The system consists of a relay and a clutch coil The Auto Transfer Case (ATC) Control Module also
(electromagnet) inside the transfer case. The clutch has the capability of engaging the front axle while
coil replaces the conventional blocker ring. When the vehicle is in motion. It does this by applying
energized, the clutch coil provides synchronization, PWM to the electric motor to apply torque to the
resulting in a smooth shift. When the transfer case front axle, this action is used to match the speed of
lever is moved to 4HI or 4LO position, the current is the front and rear propshafts. After the module
supplied to the normally closed relay. The current senses the proper speed, it then supplies a ground
flows through the relay to the clutch coil, when the on circuit 1570 to engage the front axle.
front axle engages, the axle switch energizes the The Auto Transfer Case (ATC) Control Module will
relay coil. The relay switch then opens, and the accept a mode shift only when the engine is running
current to the clutch coil is interrupted. and a valid Motor/Encoder signal is present. A mode
Identification shift is any shift between 2H, 4H, and AUTO.
The Auto Transfer Case (ATC) Control Module will
For New Venture Gear Transfer Cases, an
permit a range shift only if the following conditions
identification tag is attached to the rear case half.
are met within 30 seconds of the request:
The tag provides the transfer case model number,
the low range reduction ratio, and the assembly part • Engine running
number. • Transmission in Neutral
For the Borg-Wamer Transfer Cases, an identification • Vehicle speed below 3 mph
tag is attached to an extension housing bolt. The tag • Proper Motor/Encoder signal present
provides the transfer case model number, the serial
A range shift is a shift between high range
number, a build date, and a low range reduction
(2H, 4H, and AUTO) and low range (4L).
ratio.
Transfer Case System Description will permit a range shift into or out of Neutral
(Automatic 4WD) only if the following conditions are met:
The two speed Auto transfer case system utilizes a • Ignition ON
part time front axle. The system allows the driver to Transmission in neutral
select the transfer case position with a touch of a • Vehicle speed at zero
button. The following positions can be selected:
4-wheel drive high range (4H), All Wheel Drive Automatic 4WD Diagnostic Aids
(AUTO), 2 Wheel Drive high range (2H), Neutral (N), A Scan Tool reads and displays the following
and 4-Wheel Drive low range (4L). information:
The Auto Transfer Case (ATC) Control Module • Diagnostic Trouble code(s)
controls all the shifting action of the transfer case • Code status bit (are codes set or not)
based on input from the driver as well as information • Transfer case lock status
from the Vehicle Control Module (VCM) /Powertrain • Lamp in the switch/lamp assembly
Control Module (PCM).
• Motor/Encoder gear position
4WD (4H or 4L) mode: This is accomplished by
engaging the front axle, applying PWM to an electric • Ignition (3) voltage
motor to apply maximum torque, (fully compressing • Front propshaft speed sensor (KPH)
the transfer case clutch plates) to the front axle, then • Front axle switch (open/closed)
removing the ground on circuit 1569, thus locking the
• Front axle requested position
motor in position and stop the PWM to the motor.
(engaged/disengaged)
AUTO mode: When in this mode of operation, the
system should engage the front axle, then it monitors • Rear propshaft speed sensor (KPH)
the front and rear propshaft speeds for any speed • Mode switch position request
differences. When the system senses rear wheel slip, • Park switch (open/closed)
a difference of propshaft speed between front and • 4WD (Adapt) Mode Auto bit
rear, the Auto Transfer Case (ATC) Control Module
will use pulse width modulation (PWM) to drive an • Current Mode corrective action PWM
electric motor. This motor transfers only the required • Average and highest PWM applied during last
torque to the front wheels to gain additional traction slip recovery event
on slippery surfaces up to 75 mph. There is no • Throttle anticipation mode
torque applied to the front wheels until the module
• Average and highest PWM applied during last
senses rear wheel slip.
Throttle anticipation corrective action event
Throttle anticipation (only operational when in AUTO
• Difference between front and rear propshaft
mode): If the vehicle is below 5 mph and the
RPM
accelerator is pressed quickly beyond a set point,
the system will automatically transfer a percentage of • Adapt event counter
torque to the front wheels to help prevent the rear • Throttle position sensor percentage
wheels from slipping, as in a hard acceleration from
a stopped position.
A Scan Tool can actuate (turn on/off or There is a difference between when the TCCM
change modes) of the following: sends voltage signals in order to engage a four
• Clear Auto Transfer Case (ATC) DTCs wheel drive shift and when the vehicle is truly in four
wheel drive. The transfer case can be shifted into
• Service 4WD lamp (tell tail)
4HI and the front axle may not be engaged.
• Transfer Case Lock The 4HI shift select button will blink until the axle
• All lamps in switch assembly (4WD, 2H, becomes engaged. During periods of cold weather,
4H, 4L, and Neutral) (below -1 2 * Celsius, 10* Fahrenheit) the front axle
• Front Axle shift engagement can take much longer. Vehicles in
cold weather with extreme extended front axle shift
• Request 4WD (Adapt) Mode times should have the front axle gear lube replaced
• Request 2H Mode with a synthetic gear lube (75 W-90).
• Request 4H Mode The driver can shift from 4HI back to 2HI by
• Request 4L Mode pressing the 2HI shift select button. The 2HI shift
• Request Neutral select button blinks until the shift to 2HI is complete.
The 2HI shift select button will remain on once the
• Drive ATC Motor to various position. 50% PWM shift is mechanically complete.
max with 5 second time out with 10 second
wait before re-activating Range Shifts (Selectable 4WD)
Transfer Case System Description 1. The range shifts are the shifts between the HI
and the LO ranges.
(Selectable 4WD)
. 2HI to 4LO
The New Venture Gear Model NV243 is an
electronically controlled optional transfer case for use . 4HI to 4LO
on four wheel drive K trucks. The driver selects 2HI, . 4LO to 4HI
4HI, or 4LO by pushing one of three illuminating shift • 4LO to 2HI
select buttons mounted on the instrument panel. The
2. A range shift can only be made with the
shift select buttons display the transfer case mode
automatic transmission in neutral or with the
and range, self-test, diagnostic trouble codes, and
manual transmission clutch fully depressed. The
electronic shift mechanical engaging problems.
shift occurs when the vehicle speed is below
During normal driving the transfer case is in the 2HI three miles per hour.
mode. When the transfer case is in the 2HI mode.
whenever a shift into 4LO is initiated, the 4LO
When the transfer case is in 2HI both the 4HI and
shift select button blinks. The 4LO Shift select
4LO switch circuits are open, and both lights are
button will continue to blink until the shift is
OFF. When the four-wheel drive shift select button
completed mechanically or until 30 seconds
has been pressed, the four-wheel drive indicator
elapses. The 4LO shift select button must be
lamp under the sift select button turns ON when the
on and not blinking prior to shifting the
front axle has engaged. The shift select button will
transmission into gear or releasing the clutch
blink while the front axle is engaging. This is a
pedal.
normal condition.
If a range shift is initiated when the transmission is
The shifting of the transfer case is performed by a engaged or the vehicle speed is above 3 mph, the
motor/encoder that receives drive signals from the 4LO shift select button will blink for 30 seconds and
transfer case control module (TCCM). When the no range shift actually occurs, the TCCM will default
driver selects one of the transfer case shift select and position the transfer case into 4HI.
buttons, request signals are sent to the TCCM. If the
correct input signals exists, the TCCM will send drive
voltages to the motor/encoder. The motor/encoder
will position the transfer case to the ordered shift
position.
Mode Shifts (Selectable 4WD)

The mode shifts are shifts from 2HI to 4HI and 4HI
to 2HI. A mode shift can be accomplished in any
gear position and at any vehicle speed. If the system
is in 2HI, the driver can shift into 4HI merely by
pressing the 4HI shift select button. The 4HI button
will blink status whenever a 2HI or 4HI shift is
initiated and will continue to blink until the TCCM
completes the shift. After the shift into 4HI is
accomplished, the 4HI status lamp remains lit to
indicate that the system is in 4HI.
Transfer Case Control Module Description

(Selectable 4WD)
177152
1. The TCCM performs the following functions: RAM/ROM Check (Selectable 4WD)
• Receives input signals The TCCM compares the current internal operating
• Processes the signal information program with a stored operating program. This
• Develops output signals comparison allows the TCCM in order to evaluate if
the TCCM’s RAM and ROM are operating properly.
• Sends the output signal in order to control Should the TCCM detect a problem with the internal
the shifting of the transfer case operating program, a diagnostic trouble code (DTC)
2. The TCCM receives input signals from the of 4 is stored indicating the TCCM memory is
following sources: damaged. Replace the TCCM. Refer to Transfer
• The transfer case shift select buttons Case Control Module Description (Selectable 4WD).
• The NSBU switch on the vehicles with Data Memory Retention Check
automatic transmissions
(Selectable 4WD)
• The clutch safety switch on the vehicles with
The TCCM checks the stored diagnostic trouble code
manual transmissions
memory to see if the memory has changed since the
• The vehicle sped sensor calibrator module ignition switch was last positioned to OFF> This self
• The encoder/motor range and the mode test checks in order to see if the RAM standby
feedback signals power supply has been interrupted. If the TCCM
• The diagnostic enable detects a RAM standby power supply interruption,
(the loss of stored diagnostic trouble code) the
• The front axle mechanical status signal TCCM stores a DTC of 1 indicating RAM standby
3. In order to ensure the electronic shift system is power failure.
operating properly, the transfer case control
This condition occurs when the TCCM is
module (TCCM) continually performs diagnostics disconnected from the wiring harness or battery
checks on itself and other parts of the
power is removed. The DTC of 1 automatically
electronic shift system when the ignition switch
clears from the TCCM after cycling the ignition
is in the run position. The following are different switch ON and OFF five times.
types of system checks that the TCCM
continually performs.
Encoder Signal Check (Selectable 4WD) If one or both relays fail to detect the proper voltage
The TCCM checks the encoder signal in order to after de-energizing, both relays are turned ON by
verify that the transfer case is in either 2HI, 4HI, the TCCM, (even with the ignition switch positioned
or 4LO. OFF) in order to prevent the motor from running.
The TCCM then stores a DTC of 3 in order to
Encoder Switch Monitor Check indicate a faulty TCCM motor circuit. All of the status
(Selectable 4WD) lamps blink three times, stop, and repeat the blinking
continuously In order to alert the driver that the
While the transfer case shifts, the encoder within the electronic shift system requires immediate repair. The
electric-shift motor is monitored for the proper battery will drain when this condition occurs,
operating sequence. If during a shift, the encoder regardless of the ignition switch position.
changes to an incorrect position, an error counter in
the TCCM starts to count the number of times the Motor/Encoder Circuit Operation
encoder fails. If the encoder fails eight times, the (Selectable 4WD)
TCCM produces a DTC of 2 indicating an Encoder
Fault. When this happens, the TCCM outputs a The TCCM operates the motor/encoder in one
signal in order to default the rail shift pattern in the direction by energizing one relay while the second
encoder in order to allow for only shifts into 2HI relay is de-energized. The TCCM operates the
and 4LO. motor in the reverse direction by energizing the
second relay while the first relay is de-energized.
In order to protect against transient, random encoder The encoder part of the motor/encoder sends shift
faults caused by vibration, contamination, electrical positioning signals to the TCCM.
noise, etc., the error counter reduces the count by
one each time a good encoder value is detected. The motor/encoder converts a shaft position,
The encoder must fail 25 percent of the time for the representing a mode of range selection, into
TCCM to store a DTC of 2 and indicate a damaged electrical signals for use by the TCCM. By
encoder. Interpreting the four channels (P, A, B, C) of the
encoder, the transfer case control module can detect
Motor and Relay Voltage Checks what position the transfer case is in 2HI, 4HI, 4LO,
(Selectable 4WD) or in transition between any of the two.
Whenever the electric-shift motor is turned ON or The four hall effect sensors of the motor/encoder are
OFF the motor and the electrical circuits are tested used for channels (A, B, C, and P). These sensors
both in the de-energized and energized condition. If provide a path to ground when a magnet passes
one or both voltage relays fail to detect the proper over them. A rotating magnetic ring causes the hall
voltage after energizing or de-energized and effect sensors voltage to drop from 5 to 0 volts. The
energized condition. If one or both of the voltage TCCM detects the voltage of all the channels and
relays fail to detect the proper voltage after interprets the current transfer case shift position.
energizing or de-energizing, the shift is aborted by
the TCCM and a DTC of 3 is stored in order to
indicate a faulty TCCM motor circuit.
Control Module Data Information they should be very close.

(Automatic 4WD) Do not use a scan tool that displays faulty data.
Report the problem to the manufacturer. The use of
Use the scan tool data listed in this table for a faulty scan tool can result in misdiagnosis and
comparison after Auto Transfer Case (ATC) System unnecessary parts replacement. Use only the
Check and finding the on-board diagnostics function parameters listed in the table for diagnosis. If a scan
properly with no diagnostic codes displayed. The tool reads other parameters, the values are not
typical Scan Tool Data Values are an average of recommended by General Motors for use in
display values recorded from normal operating diagnosis. For more information on the values and
vehicles. The Typical Scan Tool Data Values are the use of the scan tool diagnosis the Auto Transfer
intended to represent what a normal functioning Case (ATC) Control Module inputs, refer to the
system would display. The values you get may vary applicable diagnosis. If all values are within the
due to a low battery charge or other reasons. But range illustrated, refer to Symptom Diagnosis.
Scan Position Units Displayed Typical Data Value

TP Sensor % 0% at idle Varies otherwise
Front Propshaft Speed RPM Varies
Rear Propshaft Speed RPM Varies
ATC Slip Speed RPM Varies
Slip Adapt Mode on/off —
Slip Adapt PWM % Varies
Current Slip Adapts Counts Varies
Last Adapt Highest PWM Counts Varies
Throttle Anticipation Mode on/off —
Current Throttle Anticipation Counts Varies
Ignition 3 Volts 13.6
Ignition Cycles Since 12 V Low Counts Varies
Park Switch Open/Closed Closed in Park
Scan Tool Data Definitions Current Throttle Anticipation: The number of times
(Automatic 4WD) the system applied torque to the front axle to limit
rear wheel slip.
Throttle Position (TP) Sensor: The VCM/PCM
Ignition 3: The Ignition 3 indicates the condition of
computes the TP angle from the TP signal voltage
the voltage input to the Auto Transfer Case (ATC)
input. The TP angle should read 0% at idle. The TP
Control Module.
angle should read 100% at Wide Open Throttle. The
Auto Transfer Case (ATC) Control Module receives Ignition Cycles Since 12 V Low: The number of
this information over the class 2 data bus from the key cycles the system sensed a battery disconnect.
VCM/PCM. Command Mode Indicator: The Indicator Lamp in
Front Propshaft Speed: The speed indicates in the Select Switch Assembly requested on, No Lamp
RPM of how fast the Front Propshaft is turning. Requested, Neutral, 2WD, 4WD Low, 4WD High,
Auto 4WD.
Rear Propshaft Speed: The speed indicates in RPM
of how fast the Rear Propshaft is turning. Encoder Gear Position: The current position of the
encoder, Invalid, Neutral, 2WD, 4WD Low, 4WD
ATC Slip Speed: The speed at which the system High, 2WD Low, 4WD High, Auto 4 WD Low.
senses slip, measured in RPM.
Mode Switch Selected: The current mode switch
Slip Adapt Mode: The state of the current mode, position selected, No Switch Depressed, Neutral,
(AUTO), enabled or disabled. 2WD, 4WD Low, 4WD High, Auto 4WD.
Slip A dapt PWM: The PWM measured in percent Transfer Case Lock: The state of the Transfer Case
(%), the system applied to correct slip Lock solenoid engagement, enabled/disabled.
Current Slip Adapts: The number of slip events the Front Axle Switch: The state of the front axle
system had during the current ignition cycle switch, open/closed.
Last Adapt Highest PWM: The number of times the Front Axle Requested: If the system has requested
system applied a PWM to the motor to correct slip. the front axle engagement, Yes/No.
Throttle Anticipation Mode: The state of the current Park Switch: The Park Switch input indicated if the
mode, (Auto only in AUTO mode), enabled or transmission is in park/neutral or not. The switch is
disabled. closed when in park, open otherwise.

J 29162
Front Output Shaft
Seal Installer (NV241
Transfer Case)
191283
J 29162
Rear Output Shaft
Seal installer (NV241
Transfer Case)
191283
BLANK
Brakes Table of Contents 5-1
Section 5
Brakes
Hydraulic Brakes ..................................................5-5 Master Cylinder Replacement

S pecifications........................................................ 5-5 (Vacuum Booster).......................................5-50
Fastener Tightening Specifications.................. 5-5 Master Cylinder Replacement
(Hydraulic Booster).................................... 5-51
Brake System Specifications............................5-5
Master Cylinder Replacement (Hydraulic
GM SPO Group Numbers................................. 5-6 Booster C 3500HD)....................................5-52
Schematic and Routing D iagram s................... 5-7 Master Cylinder Overhaul............... 5-54
Brake Warning System Master Cylinder Bench Bleeding................... 5-58
Schematic References............................. 5-7
Brake Pedal Replacement...... ....................... 5-59
Brake Warning System Schematic Icons.......5-7
Combination Valve Replacement................... 5-61
Brake Warning System Schematics............... 5-8
Pipe Replacement............................................5-62
Component Locator........................................... 5-10
Front Brake Hose Replacement (2WD)........ 5-62
Brake Warning System Components............ 5-10
Front Brake Hose Replacement (4WD)........ 5-63
Brake Warning System
Component Views........................................5-11 Hydraulic Brake System Bleeding................. 5-65
Brake Warning System Connector Hydraulic Brake System Flushing................. 5-68
End Views (Brake Pressure Vacuum Brake Booster Replacement........... 5-68
Connector Views)........................................ 5-19 Vacuum Brake Booster Hose
Diagnostic Inform ation and P rocedures...... 5-24 Replacement................................................5-70
Brake Warning Indicator Always O n .............5-24 Hydraulic Brake Booster Replacement
Brake Warning Indicator Inoperative.............5-27 (Booster)....................................................... 5-71
Brake System Testing..................................... 5-30 Hydraulic Brake Booster Replacement
(Accumulator Overhaul)..............................5-73
External Conditions that Affect Brake
Performance.................................................5-30 Hydraulic Brake Booster Replacement
(Check Valve Replacement).......................5-76
Brake System Diagnosis........................ 5-31
Hydraulic Brake Booster Replacement
Brake Pedal Travel.......................................... 5-39 (Booster Replacement C3500 H D )...........5-78
Brake Fluid Leaks............................................5-39 Brake Booster Push Rod Gauging
Master Cylinder Diagnosis.............................. 5-39 Procedure (Vacuum Brake Booster).........5-81
Brake Hose and Pipe Diagnosis................... 5-40 Brake Booster Push Rod Gauging
Hydraulic System Fluid Loss..........................5-40 Procedure (Hydraulic Brake Booster).......5-81
Vacuum Booster Diagnosis............................. 5-41 Stoplamp Switch Replacement.......................5-81
Hydraulic Booster Diagnosis Description and O peration............................... 5-83
(Erratic Operation)....................................... 5-42 Stoplamp Switch Description..........................5-83
Hydraulic Booster Diagnosis Master Cylinder Description....... ....................5-83
(Excessive Effort)........................................ 5-43 Brake Fluid and Brake Fluid Handling..........5-83
Hydraulic Booster Diagnosis Vacuum Brake Booster Description...............5-84
(General Diagnosis).................................... 5-45
Hydraulic Brake Booster Description............. 5-84
Hydraulic Booster Noise Diagnosis............... 5-46
Brake Warning/lndicator Lamp
Hydraulic Booster Functional Test................. 5-48 Description....................................................5-86
Accumulator Leak-Down Test.........................5-48 Brake Warning/lndicator Lamp Operation.....5-86
Seal Leak Diagnosis....................................... 5-49 Special Tools and Equipm ent......................... 5-88
Repair In s tru ctio n s.............................................5-50 Special Tools....................................................5-88
Master Cylinder Reservoir Filling....................5-50
5-2 Table of Contents Brakes
Disc B rakes ..........................................................5-89 Brake Drum Inspection

(Drum Inspecting)...................................... 5-124
S pe cifica tio ns......................................................5-89
Brake Shoe Inspection.................................. 5-125
(Front Disc Brakes)..................................... 5-89 Brake Lining Replacement
(Duo-Servo Drum Brakes)........................5-126
(Rear Disc Brakes)...................................... 5-89 Brake Lining Replacement
(Leading/Trailing Drum Brakes)............... 5-131
Component Specifications...................... 5-89
Brake Backing Plate Replacement
Caliper Wear Shim Specifications.................. 5-89
(Duo-Servo Drum Brakes)...................... 5-135
GM SPO Group Numbers...............................5-90
D iagnostic Inform ation and Procedures...... 5-91 (Leading/Trailing Drum Brakes)............... 5-135
Brake Rotor Thickness Variation Check...... 5-91 Brake Backing Plate Replacement
Brake Rotor Lateral Runout Check............... 5-91 (Rear A xle).................................................5-136
Brake Rotor Tolerance..................................... 5-91 Wheel Cylinder Replacement
Repair In s tru c tio n s ............................................ 5-92 (Leading/Trailing Drum Brakes)............... 5-137
Brake Pad Inspection...................................... 5-92 Wheel Cylinder Replacement
Brake Pads Replacement (Rear)................... 5-93 (Components-Leading/Trailing)................ 5-138
Brake Pads Replacement (Front Delco)........5-95 Wheel Cylinder Replacement
Brake Pads Replacement (Duo-Servo Drum Brakes ) .......................5-141
(Front Bendix).............................................. 5-98 Drum Brake Adjustment
Burnishing Pads and Rotors........................ 5-101 (Leading/Trailing Drum Brakes)............... 5-142
Brake Caliper Replacement (Rear)..............5-101 Drum Brake Adjustment
(Duo-Servo Drum Brakes)........................5-142
Brake Caliper Replacement
(Front Delco).............................................. 5-104 Description and O pe ra tio n .............................5-143
Brake Caliper Replacement System Description
(Front Bendix)............................................ 5-106 (Leading/Trailing Drum Brakes)............... 5-143
Brake Caliper and Anchor Plate Wear System Description (Duo-Servo
Adjustment..................................................5-108 Drum Brakes).............................................5-143
Brake Caliper Inspection............................... 5-110 Park Brake.......................................................... 5-145
Brake Caliper Overhaul (Front Delco).........5-110 S pe cifica tio ns.................................................... 5-145
Brake Caliper Overhaul Fastener Tightening Specifications.............. 5-145
(Rear; Front Bendix)................................. 5-113 GM SPO Group Numbers............................. 5-145
Brake Caliper Bracket Replacement............ 5-116 Diagnostic Information and
Brake Rotor Replacement (K Models P rocedures....................................... 5-146
Below 8600 G VW ).................................... 5-116 Hydraulic Park Brake Diagnostic................. 5-146
Brake Rotor Replacement (K Models Repair In stru ctio n s...........................................5-147
Above 8600 GVW).................................... 5-117 Park Brake Shoe Replacement................... 5-147
Refinishing Brake Rotors................. 5-119 Park Brake Lubrication Procedure............... 5-149
Description and Operation ............................. 5-120 Park Brake Lever Replacement................... 5-149
Disc Brakes System Description.................. 5-120 Park Brake Cable Replacement
Special Tools and E quipm ent....................... 5-121 (Front Cable)..............................................5-151
Special Tools...................................................5-121 Park Brake Cable Replacement
Drum B rakes ......................................................5-123 (Rear Cable - 1 Ton)................................ 5-153
S p e c ific a tio n s ....................................................5-123 Park Brake Cable Replacement
(Parking Brake Cable)............................... 5-154
(Duo-Servo Drum Brakes)....................... 5-123 Park Brake Cable Replacement
(Rear Cable - 1/2 and 3/4 Ton).............. 5-157
(Leading/Trailing Drum Brakes)............... 5-123 Brake Drum Replacement............................. 5-157
Component Specifications Park Brake Cable Service/Adjustment
(Drum Diameter)........................................ 5-123 (Adjustment)...............................................5-159
GM SPO Group Numbers.............................5-123 Park Brake Cable Service/Adjustment
(Parking Brake Adjustment)..................... 5-159
Repair In s tru c tio n s .......................................... 5-124
Description and O pe ra tio n .............................5-161
Brake Drum Replacement.............................5-124
System Description........................................ 5-161
Brake Drum Inspection
(Drum Servicing)........................................ 5-124 Special Tools and E quipm ent........................5-162
Special Tools (Tension Scale).......................5-162
Brakes Table of Contents 5-3
Antilock Brake System ................................. 5-163 DTC C0237 Rear Wheel Speed
S pecifications.................................................... 5-163 Signal Erratic (Diesel)............................... 5-214
Fastener Tightening Specifications.............. 5-163 DTC C0237 Rear Wheel Speed
Signal Erratic (Gas).................................. 5-217
GM SPO Group Numbers............................. 5-163
DTC C0238 Wheel Speed
Schematic and Routing D ia g ra m s............... 5-164 Mismatch (Diesel)..................................... 5-220
BPMV Hydraulic Flow Chart.........................5-164 DTC C0238 Wheel Speed
Antilock Brakes System Mismatch (Gas)......................................... 5-222
Schematic References.............................. 5-169 DTC C0241-C0254 EBCM Control
Antilock Brakes System Valve Circuit...............................................5-224
Schematic Icons.........................................5-169 DTC C0265 or C0266 EBCM
ABS Schematics.............................................5-169 Relay Circuit...............................................5-227
Component Locator......................................... 5-173 DTC C0267 or C0268 Pump
Antilock Brakes System Components.........5-173 Motor Circuit Open/Shorted.............. 5-230
Antilock Brakes System DTC C0269 or C0274 Excessive
Component Views..................................... 5-175 Dump/lsolation Tim e................................. 5-233
Antilock Brakes System Connector DTC C0271-C0273 EBCM Malfunction...... 5-236
End Views..................................................5-177 DTC C0281 Brake Switch Circuit................ 5-238
Diagnostic Information and P rocedures.... 5-178 DTC C0286 ABS Indicator Lamp
Self-Diagnostics..............................................5-178 Circuit Shorted to B+.................... 5-241
Displaying Diagnostic Trouble Codes.......... 5-178 DTC C0288 Brake Warning Lamp
Clearing Diagnostic Trouble Codes............. 5-178 Circuit Shorted to B+................................ 5-243
Intermittents and Poor Connections............ 5-178 ABS Indicator Off No DTC S e t....................5-245
Scan Tool Diagnostics................................... 5-178 ABS Indicator On No DTC S e t....................5-248
ABS Diagnostic System C heck................... 5-179 Repair Instructio n s........................................... 5-250
DTC List.......................................................... 5-182 ABS Bleed Procedure....................................5-250
DTC C0221 RF Wheel Speed Electronic Brake Control Module
Sensor Circuit O pen................................. 5-183 Replacement..............................................5-250
DTC C0222 RF Wheel Speed Brake Pressure Modulator Valve
Signal Missing............................................5-186 Replacement.............................................. 5-251
DTC C0223 RF Wheel Speed Wheel Speed Sensor Replacement
Signal Erratic..............................................5-189 (2WD (except C3500HD))........................5-254
DTC C0225 LF Wheel Speed Wheel Speed Sensor
Sensor Circuit O pen................................. 5-192 Replacement (4W D)................................. 5-255
DTC C0226 LF Wheel Speed Wheel Speed Sensor Replacement
Signal Missing............................................5-195 (C 3500HD)................................................5-256
DTC C0227 LF Wheel Speed Front Wheel Speed Sensor Bracket
Signal Erratic..............................................5-199 Replacement..............................................5-258
DTC C0229 Drop Out of Front Tube Adapter Replacement..........................5-259
Wheel Speed Signals............................... 5-202 Description and O peration............................. 5-260
DTC C0235 Rear Wheel Speed Service Precautions.......................................5-260
Signal Circuit Open (Diesel).................... 5-204 General System Description.........................5-260
DTC C0235 Rear Wheel Speed Abbreviations and Definitions.......................5-260
Signal Circuit Open (G as)........................5-207 Basic Knowledge Required...........................5-260
DTC C0236 Rear Wheel Speed ABS System Description............................... 5-261
Signal Circuit Missing (Diesel)................. 5-209
ABS System Operation................................. 5-261
DTC C0236 Rear Wheel Speed
Signal Circuit Missing (Gas).....................5-212 Special Tools and Equipm ent........................5-264
5-4 Table of Contents Brakes
BLANK
Brakes Hydraulic Brakes 5-5
Hydraulic Brakes
Specifications

Bleeder Valves 13 — 110
Booster Mounting Nuts 36 26 —
Brake Pedal Through Bolt 47 35 —
Brake Pipe Clip Bolts 17 13 —

Brake Pipe Fittings 24 18 '—
Combination Valve Bolts 16 12 ’ —
Front Brake Hose to Caliper Bolt 44 32 —
Hydraulic Booster Cover Bolts 30 22 —

Hydraulic Booster Hose Fitting 30 22 —
Master Cylinder Mounting Nuts 27 20 —

Master Cylinder Mounting Nuts (Vacuum Booster System) 30 22 —
Return Port Fitting 10 88
Brake System Specifications

Front Brakes Rear Brakes
System Brake Assist
Type Metric English Type Metric English
JB5 Disc 295.0 x 11.57 x 1.25 in Leading/Trailing 254 x 57 mm 9.96 x Vacuum

31.8 mm 2.24 mm
JD5 Disc 295.0 x 11.57 x 1.25 in Leading/Trailing 254 x 57 mm 9.96 x Hydraulic
31.8 mm 2.24 mm
JB6 Disc 295.0 x 11.57 x 1.25 in Duo-Servo 284 x 11.15 x 2.75 in Vacuum
31.8 mm 70.1 mm
JD6 Disc 295.0 x 11.57 x 1.25 in Duo-Servo 284 x 11.15 x 2.75 in Hydraulic
31.8 mm 70.1 mm
JB7 Disc 319 x 12.5 x 1.26 in Duo-Servo 331.5 x 13.00 x 2.5 in Vacuum
32.1 mm 64 mm
JD7 Disc 319 x 12.5 x 1.26 in Duo-Servo 331.5 x 13.00 x 2.5 in Hydraulic
32.1 mm 64 mm
JB8 Single Disc 319 x 12.5 x 1.26 in Duo-Servo 331.5 x 13.00 x 2.5 in Hydraulic
Rear Wheel 32.1 mm 64 mm
JB8 Disc 319 x 12.5 x 1.26 in Duo-Servo 331.5 x 13.00 x 2.5 in Hydraulic
Dual Wheel 32.1 mm 64 mm
JF9 Disc 353.4 x 13.86 x Disc 346.3 x 13.58 x Hydraulic
36.59 mm 1.435 in 36.59 mm 1.435 in
Z56 Disc 319 x 12.5 x Duo-Servo 284 x 11.15 x Vacuum
32.1 mm 1.26 mm 70.1 mm 2.75 mm
5-6 Hydraulic Brakes Brakes
Brake Pedal 4.625
Brake and Clutch Cover 4.626
Brake Pedal Nut 4.634
Brake Master Cylinder Kit 4.649
Brake Master Cylinder Diaphragm 4.650
Brake Master Cylinder Connector, Cover, Harness and Cover Kit 4.651
Brake Master Cylinder Secondary Piston 4.653
Master Cylinder Adjusting Nut and Retainer 4.662
Brake Warning Connector 4.663
Brake Hose Bolt 4.671
Wheel Brake Hose 4.680
Brake Hose or Pipe Bracket, Clip, Retainer and Spacer 4.681
Brake Cylinder and Hydraulic Line, Clip and Spacer 4.685
Brake Hose or Pipe Clip, Connector, Fitting, Gasket and Nut 4.686
Brake Pressure Regulator Bolt, Switch and Valve Kit 4.690
Power Hydraulic Brake Booster Gasket 4.805
Power Brake Booster Valve Kit 4.810
Power Hydraulic Brake Booster Accumulator Kit 4.820
Power Brake Booster Clamp, Fitting, Hose, Nut and Seal 4.845
Brake Pressure Indicator Alarm, Connector, Gasket, Module and Switch 4.874
Power Vacuum Brake Booster Reinforcement 4.898
Power Vacuum Brake Booster 4.901
Power Vacuum Brake Booster Clip, Fitting and Plug 4.931
Power Vacuum Brake Booster Valve Kit 4.955
Brake Warning System Schematic References

Service Category Type Number
Reference on Schematic - Service Category
Brakes 5 - Anti-Lock Brakes
Fuse Block Details - Cell 11 8 - Wiring Systems
Ground Distribution - Cell 14 8 - Wiring Systems
Headlights: Daytime Running Lights - Cell 102 8 - Wiring Systems
Instrument Cluster - Cell 81 8 - Instrumentation
Power Distribution - Cell 10 8 - Wiring Systems
Brake Warning System Schematic Icons

Refer to Electrostatic Discharge (ESD) Sensitive Devices in Section 8A-3 Symbols
>
19384
5-8 Hydraulic Brakes________________________________________________________ Brakes
191766
Brake Warning System Schematics (Brake Warning Controls)
Brakes _____________________________________________ Hydraulic Brakes 5-9
191771
Brake Warnina Svstem Schematics {Brake Warnina Controls)
Component Locator
Brake Warning System Components

Part of the electronic brake control module,
Brake Pressure Brake Warning System Brake Warning System
LH frame rail, near the center of the
Differential Switch Component Views Connector End Views
vehicle
Efectronic Brake Control LH frame rail, near the center of the Brake Warning System Brake Warning System
Module (EBCM) vehicle Component Views Connector End Views
LH lower kick panel Brake Warning System Brake Warning System
IP Fuse Block
P/B Booster Fluid Under the LH of the IP Brake Warning System Brake Warning System
Flow Alarm Component Views Connector End Views
P/B Booster Fluid Flow Under the LH of the IP
Brake Warning System Brake Warning System
Alarm and Pressure
Delay Module
P/B Booster Fluid LF of the engine compartment Brake Warning System Brake Warning System
Flow Switch Component Views Connector End Views
Brake Warning System Component Views

Daytime Running Lights (DRL) Module Instrument Panel Wiring, LH Side
Legend
(1) Connector C227 (4) TCC/Stoplamp Switch
(2) Connector C266 (5) Daytime Running Lamp (DRL) Module
(3) Connector C202
Underhood Fuse-Relay Center
Legend
(1) Fuel Pump Relay (8) Underhood Fuse-Relay Center
(2) Forward Lamp Harness (9) Brake Lamp Relay
(3) Vehicle Control Module (VCM) (10) Maxi Fuses
(4) Auxiliary Battery (11) Auxiliary Cooling Fan Relay
(5) Charge Lead, Auxiliary Battery (12) A/C Compressor Clutch Relay
(6) Electronic Brake Control Module (EBCM) (13) Horn Relay
(7) Engine Harness
Legend
(1) Connector C298 (6) Pass Through Grommet P100
(2) Headlamp And Panel Dimmer Switch (7) Connector C102
Connector (8) Connector C104
(3) l/P Fuse Block (9) Connector C266
(4) Ground G200 (10) Instrument Cluster Connector
(5) Connector C100
Auxiliary Battery Wiring
172390
Legend
(1) Underhood Fuse-Relay Center
(2) Auxiliary Battery Relay
(3) Forward Lamp Harness
(4) Washer Pump Hose
Legend
(2) LH Front Headlamp Connectors (7) Horn
(Composite) (8) Connector C100
(3) Park And Turn Lamp LH Front (9) Pass Through Grommet P100
(4) LH Fog Lamp Connector
(5) Ground G113
5.0 And 5.7L Engines, RH Side
Legend
(1) MAP Sensor (5) Crankshaft Position Sensor
(2) Evaporative Emissions Canister Purge (6) Ground G105
Solenoid (7) Generator Connector
(3) Fuel Injectors Connector (8) Ignition Coil Module
(4) Evaporative Emissions Purge Solenoid (9) Ignition Coil Connector
Vacuum Switch
172401
Legend
(1) Engine Harness (4) Grounds G150 And G105
(2) Generator Connector (5) Ground G104
(3) Turbo
Glow Plug Connectors (LH Side)
172403
Legend
(1) Glow Plug Connectors (LH Side)
Brake Warning System Connector End

Views (Brake Pressure Connector Views)
C100 P \
m [EDG3] B1 [AT
R ® 02 B2 A2
m [D3 C3 —
f \ x M £=2“ B3[A3
mm in ai « 1—
lE5l
, |CH[M1 \ =
ys«4d ® ® IC 6 llB 6 l 5
El lls lc z liz l
A
pi E l § V H [2 H [C 8 ][B 8 | l *
s
n
E 7D 7 o 7
m Tn 172671
E8 D8 C 8 |mI
\ Connector Part
• 12146331
• 36 Way F M/P 150, 180, 630
Information
(Light Gray)
172671 Circuit
Connector Part
• 12146331 Pin
C1
Wire Color
BLK
No.
28
Function
Horn Relay Output-Coil
Information • 36 Way F M/P 150, 180, 630
(Light Gray) Neutal Safety
Circuit C2 YEL 1737 Switch Output-Park/
Pin Wire Color No. Function Neutral Position
TCC/Stoplamp Switch Charge Indicator
A1 WHT 17 C3 BRN 25
Output (Pickup Only) Lamp Output
Battery Fused Feed Oil Pressure Indicator

A1 RED 542 C4 TAN 31
(Suburban/Utility Only) Lamp Output
Ignition Feed-Off, Run, Coolant Temperature

A2 PNK 1020 C5 DK GRN 35
Crank (Automatic Only) Indicator Lamp Output
A3 ORN 1440 Battery Fused Feed Brake Warning Indicator

C6 TAN/WHT 33
Lamp Output
Stoplamp Feed
A4 LT BLU 20 C7 PNK 139 Ignition Feed (Fused)
(Pickup Only)
Rear Window Washer ABS Failure
C8 LT GRN 867
A4 392 Pump Motor Feed Indicator Output
DK GRN
(Suburban/Utility Only) D1 TAN/WHT 799 ABS Diagnostic Signal
A6 RED 42 Battery Fused Feed Cruise Control Engage
D2 LT BLU/BLK 396
A7 RED 142 Battery Fused Feed Signal (Automatic Only)
242 Battery Fused Feed Cruise Control, Clutch

A8 RED
D2 BRN/WHT 379 Pedal Switch
Windshield Washer Pump Output (Manual)
B1 RED 228
Motor Feed
Vehicle Speed Signal
B2 WHT 1294 EVO Solenoid Feed D2 YEL/BLK 1827 128,000 Pulses Per Mile
B3 BRN 1295 EVO Solenoid Output (Diesel Only)
Vehicle Speed Signal D3 LT GRN 24 Backup Lamp Feed
B5 DK GRN 389
(Gas Only) Vehicle Speed Signal
DK 4000 Pulses Per Mile
Check Engine Indicator D4 817
B6 BRN/WHT 419 GRN/WHT
Lamp Output (Gas Only)
B7 PPL 1807 Serial Data Class 2 D4 DK BLU 507 Wait Lamp (Diesel Only)
DK Air Inlet Valve Motor Feed Four Wheel Drive Front
B8 1614 D6 BLK/WHT 1695
GRN/WHT Wheel Lock Indicator
C266
r1 “ □ □ □ □ □ □ □ □ □ □ □ □ □ « [hf “ □ □ □ □ □ □ □ □ □ □ □ □ a *
“ 1-----II-----II-----1||------ l/ ^-Nl------ 1ll___II___ II___ 1« Ml ll II i l l ------- -------------- i l l II II I D1
- " i i — 11— □ N CQ) Hi— ii....i i . _ ic ce| || || ) pi II II let
r Ml-----II-----II-----lU = 3 CZZuLIl-----II-----II-----let »[ I f II 0 = ^ I-----IJC l l HI 1bi
172674 172674
Circuit Circuit
Pin W ire Color No. Function Pin W ire Color No. Function
• 120778221/P • 120778221/P
• 48-Way M Metri-Pack Mixed • 48-Way M Metri-Pack Mixed
Connector Part Series Connector Part Series
Inform ation • Black Inform ation • Black
• Harness To Steering Column • Harness To Steering Column
harness harness
B5 LT BLU 1134 Park Brake Switch Signal E1 GRY 1696 Tum/Hazard Flasher Feed
C1 WHT 1390 Ignition Switch Output, Off, E2 LT BLU 20 Stoplamp Feed (Gas)
Run, Crank (Automatic)
C2 BLK 150 Ground E3 PPL 92 Windshield Wiper Motor
Feed-High Speed
Ref Voltage, 5 Volt E4 YEL 143 Accessory Feed
C3 GRY 705 (Steering Wheel
Position Sensor) E5 BRN 96 Windshield Wiper Switch
Signal-Pulse Delay
Sensor Return (Steering
C4 ORN/BLK 1057 Wheel Position Sensor) E6 DK GRN 19 Stop, Turn Lamp
Feed-Right Rear
C5 PNK 3 Ignition Feed Stop, Turn Lamp Feed-
Q6 ORN 300 Ignition Feed E7 YEL 18 Left Rear
D1 YEL Ignition Switch

5 Output-Crank E8 ORN 140 Battery Feed
D2 Red 342 Battery Feed E9 PPL 1697 Tum/Hazard
Output
Flasher
D3 — — Not Used E11 LT GRN 11 High Beam

Headlamp Feed
,
D4 LT BLU 1059 Steering Wheel Position
Sensor Signal DRL Relay Output
E12 PPL 359 (Low Beam)
D5 RED 242 Battery Feed
Ignition Switch E13 YEL 10 Headlamp Switch Output
D6 BRN 4 Output-Accessory
Instrument Cluster
Circuit
Wire Color
Pin No. Function
Circuit • 12146397
Wire Color Connector Part
Pin No. Function Information • 32 W PTD CKT BOW
Fuel Gauges
Information • 32 W PTD CKT BOW 16 PPL 30
Sensor Signal
1 BRN 358 SIR Indicator Lamp Daytime Running Light
17 LT GRN/BLK 592
2 DK BLU 507
WAIT to START Indicator
Lamp (Diesel)
Relay Output-Coil
WATER-IN-FUEL Indicator
18 YEL/BLK 508
Turn Signal Indicator Switch Ground (Diesel)
3 LT BLU 14
Lamp Feed Charge Indicator
19 BRN 25
4 BLK/WHT 451 Ground Lamp Output
5 LT GRN 11 High Beam Headlamp

Indicator Lamp Feed 20 TAN/BLK 456
Shift Indicator Lamp
Output (Manual
6 WHT 121 Tachometer Signal
Transmision Only)
Service Throttle Soon
7 PNK 39
Ignition Fused Feed
(Manual Transmission)
21 WHT/BLK 176 Indicator Lamp
Output (Diesel)
7 PNK 1020
Ignition Feed-Off,
Run, Crank 22 PNK 39 Ignition Fused Feed
(Automatic Transmission) Check Engine Indicator
23 BRN/WHT 419
8 PPL/WHT 1382 LED Dimming Signal Lamp Output
Low Coolant Level
9 BLK/WHT 771
Transmission Position
Switch Signal-BIT 1
25 YEL/BLK 68 Indicator Lamp
Output (Diesel)
10 GRY 773
Switch-BIT 3 26 — — Not Used
ABS Failure Indicator
11 YEL 772
Switch-BIT 2
27 LT GRN 867
Lamp Output
Brake Warning Indicator
12 WHT 776
Switch Signal-PARITY BIT
28 TAN/WHT 33
Lamp Output
13 DK GRN 35
Coolant Temperature 29 GRY 8 Instrument Panel
Lamp Feed
Indicaor Lamp Output
Vehicle Speed Signal-4000 Seat Belt Indicator
14 DK GRN 389 30 YEL 234
Pulses Per Mile Lamp Output
Oil Pressure Indicator 31 BLK 451 Ground

15 TAN 31
Lamp Output Turn Signal Indicator
32 DK BLU 15
Lamp Feed
Brake Pressure Differential Switch Connector
35437
Circuit
Pin Wire Color No. Function
Information • ASM 2F M/L 150 (WHITE)
Brake Warning Indicator
A TAN/WHT 33
Lamp Output
B BLK 150 Ground

Procedures
Brake Warning Indicator Always On

1 Does the vehicle have P/B booster fluid flow alarm? — Go to Step 21 Go to Step 2
1. Disconnect the park brake warning switch connector.
2 2. Turn the ignition switch to RUN. —
Does the brake indicator remain on? Go to Step 3 Go to Step 4
Disconnect the brake pressure differential switch connector.
3 —
4 Is the park brake warning switch properly adjusted? — Go to Step 35 —
Disconnect electronic brake control module connector C1.
5 —
Does the brake indicator remain lit? Go to Step 7 Go to Step 8
Refer to Brake System Testing for diagnosis of the
6 hydraulic brake system. — —
Does the brake indicator run correctly? System OK
Disconnect the daytime running lamp control module slide
7 board connector. —
Refer to Four Wheel Antilock Brake System Diagnosis.
8 — —
1. Disconnect the instrument cluster connector.
2. Connect a test lamp from instrument cluster
9 connector cavity A13 to B+. —
3. Test for a short to ground.
1. Connect a test lamp from daytime running lamp
control module connector cavity H to B+.
10 —
Repair the short to ground in the TAN/WHT (33) wire
between the instrument cluster and the daytime running
11 lamp control module. — —
Does the brake indicator turn off? System OK
Replace the instrument cluster printed circuit.
12 — —
control module connector cavity F to B+.
13 —
1. Locate the open in BLK (150) wire between the
daytime running lamp control module and
ground G201.
14 2. Repair the open in BLK (150) wire between the — —
daytime running lamp control module and
ground G201.
Brake Warning Indicator Always On (cont’d)
1. Locate the short to ground in the TAN/WHT (33) wire
between the daytime running lamp control module
and the brake pressure differential switch/electronic
brake control module.
15 2. Repair the short to ground in the TAN/WHT (33) wire — —
and the brake pressure differential switch/electronic
brake control module.
control module connector cavity B to B+.
16 —
1. Locate the short to ground in the TAN/WHT (33) wire
and the park brake warning switch.
17 — —
2. Repair the short to ground in the
TAN/WHT (33) wire.
control module connector cavity A to B+.
18 —
2. Test for short to ground.
Locate and repair short to ground in the TAN/WHT (33)
wire between the daytime running lamp control module and
19 the park brake warning switch. — —
Replace the daytime running lamp control module.
20 — —
1. Disconnect the park brake warning switch connector.
2. Disconnect connector C217
21 —
3. Turn the ignition switch to RUN.
Does the brake indicator turn off? Go to Step 22 Go to Step 3
Measure the P/B booster fluid pressure and flow. Refer to
22 Power Steering. —
Is the P/B booster fluid flow or pressure low? Go to Step 23 Go to Step 24
Refer to Power Steering Gear and Pump.
23 — —
With the engine still running, connect an unpowered test
24 lamp from connector C217 pin A to B+. —
1. With the engine still running, connect an unpowered
test lamp from connector C217 pin A to B+.
25 —
2. Disconnect the park brake warning switch.
Replace the daytime running lamp control module.
26 — —
Brake Warning Indicator Always On (cont’d)
2. Disconnect the P/B booster fluid pressure flow
alarm switch.
27 3. Connect a test lamp from connector C217 —
pin A to B+.
4. Start and idle the engine.
1. Check for proper adjustment of the park brake
warning switch.
28 2. If the adjustment is OK, replace the park brake — —
warning switch.
1. Turn the ignition off.
2. Disconnect the P/B booster fluid flow alarm switch.
3. Connect an unpowered test lamp from connector
29 —
C217 pin A to B+.
Replace the P/B booster fluid flow alarm switch.
30 — —
1. Disconnect the P/B booster fluid flow indicator/
alarm module.
2. Connect an unpowered test lamp from connector
31 C217 pin A to B+. —
1. Locate the short to ground in the DK GRN (860)
wire between P/B booster fluid pressure alarm switch
and the P/B booster fluid flow alarm switch.
32 — —
2. Repair the short to ground in the
DK GRN (860) wire.
Repair the short to ground in the LT GRN (966) wire
between P/B booster fluid pressure alarm switch and the
33 P/B booster fluid flow and pressure alarm delay module. — —
Replace the instrument cluster printed circuit.
34 — —
Replace the park brake warning switch.
35 — —
Properly adjust the park brake warning switch.
36 — —
Brake Warning Indicator Inoperative
1. Apply the parking brake.
1 2. Place the ignition switch in RUN. —
Is the brake indicator illuminated? Go to Step 5 Go to Step 2
1. Disconnect the connector at the park brake
warning switch.
2 2. Connect a fused jumper wire between park bake —
warning switch connector cavity A for the
TAN/WHT (33) wire and ground.
Is the brake indicator illuminated? Go to Step 6 Go to Step 3
1. Disconnect the connector at the instrument cluster.
2. Connect a test lamp between instrument cluster
3 —
connector cavity B17 and ground.
1. Disconnect the daytime running lamp control module.
2. Connect a self -powered test lamp at the instrument
cluster connector cavity A13 for the TAN/WHT (33)
4 wire and daytime running lamp control module —
connector cavity E.
3. Test for continuity.
1. Reconnect all components.
2. Position the vehicle safely for the release of the
parking brake.
3. Release the parking brake.
5 —
4. Start the engine while observing the
instrument cluster.
Is the brake indicator illuminated while the ignition switch
is in START? Go to Step 9 Go to Step 10
Adjust the park brake warning switch.
6 —
Is the brake indicator illuminated? System OK Go to Step 24
Repair the open in the PNK (39) wire between the IP fuse
7 block and the instrument cluster. — —
Is the brake indicator illuminated? System OK
Repair the open in the TAN/WHT (33) wire between the
instrument cluster and the daytime running lamp control
8 module connector cavity E. — —
1. Connect a self-powered test lamp between connector
C200 pin B2 for the BLK (150) wire and ground.
9 —
1. Stop the engine.
2. Backprobe ignition switch connector C200 from cavity
10 B5 with a fused jumper to ground. —
3. Turn the ignition switch to START.
Does the brake indicator light? Go to Step 12 Go to Step 13
Brake Warning Indicator Inoperative (cont’d)

1. Disconnect the connector at the park brake
warning switch.
2. Disconnect the connector at the P/B booster fluid
flow and pressure alarm delay module.
3. Connect a self-powered test lamp between the park
11 brake warning switch connector cavity A for the —
TAN/WHT (33) wire and P/B booster fluid flow and

pressure alarm delay module connector cavity E for
the YEL/BLK (965) wire.
Test the ignition switch ground connection from the ignition
12 switch to G201. —
Is the connection OK? Go to Step 25 Go to Step 26
Repair the open in the TAN/WHT (33) wire between the
daytime running lamp control module connector cavity B
13 and the ignition switch. — —
Does the brake indicator light? System OK
1. Disconnect the connector at the brake pressure
differential switch.
2. Disconnect the daytime running lamp control module.
3. Connect a self-powered test lamp between brake
14 pressure differential switch connector cavity A for the —
TAN/WHT (33) wire and daytime running lamp
control module connector cavity F.
Is there an open in the TAN/WHT (33) wire or in the
YEL/BLK (965) wire between the Park Brake Warning
15 —
Switch and the P/B booster fluid flow pressure alarm
delay module? Go to Step 27 Go to Step 28
1. Connect a self-powered test lamp between brake
pressure differential switch connector cavity B for the
16 BLK (150) wire and ground. —
Repair the open in the TAN/WHT (33) wire between
daytime running lamp control module connector cavity F
17 and the brake pressure differential switch. —
Is the brake indicator illuminated? System OK Go to Step 29
Check the operation of the brake pressure differential
switch per combination valve warning switch test. Refer to
18 Hydraulic Brakes in Brakes. —
Does the brake pressure differential switch operate
as designed? Go to Step 20 Go to Step 21
Repair the open in the BLK (150) wire between the brake
19 pressure differential switch and ground G103. — —
Brake Warning Indicator Inoperative (cont’d)

1. Disconnect connector C1 at the electronic brake
control module.
2. Connect a self-powered test lamp between electronic
brake control module connector C1 cavity H for the
20 TAN/WHT (33) wire and the daytime running lamp —
control module cavity F.
Perform diagnostic testing of the electronic brake control
21 module. Refer to Antilock Brake System Diagnosis. —
Is the condition repaired? System OK Go to Step 30
Repair the open in the TAN/WHT (33) wire between splice
22 S156 and the electronic brake control module. — —

1. Locate the open in the BLK (150) wire between
connector C200 and ground G201
23 — —
2. Repair the open.
Replace the park brake warning switch.
24 — —
Replace the ignition switch.
25 — —
Does the brake indicator light? System OK
Repair the ignition switch ground connection from the
26 ignition switch to G201 — —
Is the Brake Indicator illuminated? System OK
Repair the open in the TAN/WHT (33) wire or in the
YEL/BLK (965) wire between the Park Brake Warning
27 Switch and the P/B booster fluid flow and pressure alarm — —
delay module.
Replace the in-line diode D202.
28 — —
Verify diode D101 at the underhood fuse-relay center is
29 also not open. — —
Replace the electronic brake control module.
30 — —
Brake System Testing • Loose front wheel bearings may cause
Test the brakes at different speeds with light pedal the following:
pressure and with heavy pedal pressure. Avoid - Brake rotor tilt
locking the wheels. Avoid sliding the tires on the - Spotty contact with the brake linings
roadway. Locked wheels and sliding tires do not - Erratic braking action
show brake efficiency. A locked wheel and a sliding
tire reduce the tire friction on the roadway. • The brakes will pull the vehicle to one side if
the front suspension is not aligned correctly.
Test the brakes on a dry, clean, reasonably smooth This will be very noticeable if the caster and
and level roadway. You cannot accurately test brake the camber are not within specifications.
performance without these conditions. The tires will
not grip the roadway equally if the roadway is wet or Brake System Diagnosis
greasy or covered with loose dirt. A crowned
roadway causes the weight of the vehicle to shift Belt Tension
toward one side. The wheels bounce on a When servicing any part of the brake system,
rough roadway. check the power steering pump belt for the
External Conditions that Affect Brake
• Improper belt tension
Performance
• Wear
• Tires with unequal contact and unequal grip on
the road will cause unequal braking. The serpentine belt is not adjustable. Refer
to Diagnosis of the Drive Belt System in
- The tires must be equally inflated. Engine Cooling.
- The tread pattern of the right-hand tire and
the left-hand tire must be almost equal. Power Steering Fluid Level
• When the vehicle is loaded unequally, the most When servicing any part of the brake system, check
heavily loaded wheels require more braking the fluid level in the power steering fluid reservoir.
power than the other wheels. Check the fluid level at regular intervals. Add fluid
as needed. Refer to Fluid Level in Power
Steering System.
Brake System Diagnosis
Sym ptom Causes
Excessive Brake Pedal Travel • Leaking brake pipe, hose, or connection. Refer to
Brake Fluid Leaks
• Leaking piston seal. Refer to Seal Leak Diagnosis
• Leaking master cylinder (internal). Refer to Master
Cylinder Diagnosis
• Air in brake system. Refer to Hydraulic Brake
System Bleeding
• Contaminated or improper brake fluid. Refer to Brake
Fluid and Brake Fluid Handling
• Improper thickness variation. Refer to Brake Rotor
Thickness Variation Check in Disc Brakes, Brake Drum
Inspection (Drum Servicing), or Brake Drum Inspection
(Drum Inspecting) in Drum Brakes.
• Uneven brake lining wear. Refer to Brake Pad
Inspection in Disc Brakes, or to Brake Shoe Inspection
in Drum Brakes.
• Excessive lateral runout. Refer to Brake Rotor Lateral
Runout Check in Disc Brakes.
• Brake Assembly Attachments Missing or Loose. Refer
to Brake Pad Inspection in Disc Brakes, or Brake Shoe
Inspection in Drum Brakes.
Brake Pedal Travel Gradually Increases • Leaking brake pipe, hose, or connection. Refer to
Brake Fluid Leaks
Cylinder Diagnosis
• Restricted Passage in the Vacuum Booster. Refer to
Vacuum Booster Diagnosis
• Damaged Vacuum Booster System. Refer to Vacuum
Booster Diagnosis
• Restricted Brake Fluid Passage. Refer to Hydraulic
Brake System Bleeding
Brake System Diagnosis (cont’d)

Symptom Causes
Excessive Brake Pedal Effort • Leaking Booster/Vacuum System. Refer to Vacuum
Brake Booster Hose Replacement
Booster Diagnosis
• Worn Out Brake Lining. Refer to Brake Pad Inspection
in Disc Brakes, or Brake Shoe Inspection in Drum
Brakes.
• Glazed Brake Lining. Refer to Brake Pad Inspection in
Disc Brakes, or Brake Shoe Inspection in Drum
Brakes.
• Incorrect Brake Lining Material. Refer to Brake Pad
Inspection in Disc Brakes, or Brake Shoe Inspection in
Drum Brakes.
• Contaminated Brake Lining. Refer to Brake Pad
Drum Brakes.
• Brake Lining Damage By Abuse. Refer to Brake Pad
Drum Brakes.
• Brake Pedal or Brake Linkage Interference (Binding).
Refer to Brake Pedal Replacement
• Operator Riding the Brake Pedal.
Excessive Braking Action • Damaged Vacuum Booster System. Refer to Vacuum
Booster Diagnosis
• Worn Out Brake Lining. Refer to Brake Pad
Drum Brakes.
• Uneven brake lining wear. Refer to Brake Pad
Drum Brakes.
Drum Brakes.
• Brake Lining Damage By Abuse. Refer to Brake Pad
Drum Brakes.
• Rotor Surface or Drum Surface Finish. Refer to
Refinishing Brake Rotors in Disc Brakes, or Brake
Drum Refinishing, in Drum Brakes.
• Heat Spotted or Scored Rotors. Refer to Brake Rotor
Tolerance in Disc Brakes.
Symptom Causes
Brakes Slow To Respond • Contaminated or improper brake fluid. Refer to Brake
• Leaking Vacuum System. Refer to Brake Hose and
Pipe Diagnosis
Booster Diagnosis
• Glazed Brake Lining. Refer to Brake Pad Inspection
in Disc Brakes, or Brake Shoe Inspection in
Drum Brakes.
• Sticking Caliper or Caliper Pistons. Refer to Brake
Caliper Inspection
Brakes Slow To Release • Contaminated or improper brake fluid. Refer to Brake
Booster Diagnosis
Caliper Inspection in Disc Brakes.
• Parking Brake not Releasing. Refer to Park
Brake Cable Service/Adjustment (Adjustment) in
Parking Brake.
Brakes Drag • Contaminated or improper brake fluid. Refer to Brake
• Improperly adjusted Stoplamp Switch. Refer to
Stoplamp Switch Replacement
• Improperly adjusted Cruise Control Vacuum Dump.
Refer to Functional Check in Cruise Control
• Improperly Adjusted Parking Brake. Refer to Park
Parking Brakes.
• Loose Front Suspension Attachments. Refer to
Fastener Tightening Specifications in Front Suspension.
• Operator Riding the Brake Pedal.
Caliper Inspection
Symptom Causes
Uneven Braking Action (Side to Side) • Contaminated or improper brake fluid. Refer to Brake
• Worn Out Brake Lining. Refer to Brake Pad
Drum Brakes.
• Uneven Brake Lining Wear. Refer to Brake Pad
Drum Brakes.
Drum Brakes.
Drum Brakes.
Drum Brakes.
• Brake lining Damage By Abuse. Refer to Brake Pad
Drum Brakes.
• Heat Spotted or Scored Rotors. Refer to Brake
Rotor Tolerance
• Incorrect Front End Alignment. Refer to Wheel
Alignment Specifications (C Model) or Wheel Alignment
Specifications (K Model)
• Incorrect Tire Pressure. Refer to Tire
Inflation Description
Caliper Inspection
• Parking Brake not Releasing. Refer to Park
Parking Brake.
Symptom Causes
Uneven Braking Action (Front to Rear) • Leaking brake pipe, hose, or connection. Refer to
Brake Fluid Leaks
Cylinder Diagnosis
System Bleeding
• Worn Out Brake Lining. Refer to Brake Pad Inspection
Drum Brakes.
Drum Brakes.
Drum Brakes.
Drum Brakes.
Drum Brakes.
Drum Brakes.
Rotor Tolerance
• Improperly Adjusted Parking Brake. Refer to Park
Parking Brake.
Caliper Inspection

Symptom Causes
Scraping Noise From Brakes • Worn Out Brake Lining. Refer to Brake Pad
Drum Brakes.
Drum Brakes.
Drum Brakes.
Drum Brakes.
Brakes Squeak Without Application • Worn Out Brake Lining. Refer to Brake Pad
Drum Brakes.
Drum Brakes.
Drum Brakes.
Drum Brakes.
Drum Brakes.
Drum Brakes.
Rotor Tolerance.
Symptom Causes
Brakes Squeak During Application • Worn Out Brake Lining. Refer to Brake Pad
Drum Brakes.
Inspection in Disc Brakes, or Brake Shoe Inspection
Drum Brakes.
Drum Brakes.
Drum Brakes.
Drum Brakes.
Drum Brakes.
Rotor Tolerance.
Brakes Chatter (Roughness) • Heat Spotted or Scored Rotors. Refer to Brake
Rotor Tolerance.
• Improper thickness variation. Refer to Brake Rotor
Thickness Variation Check in Disc Brakes, or Brake
Drum Inside-Diameter Check.
• Excessive lateral runout. Refer to Rotor Inspection.
to Brake Pad Inspection in Disc Brakes, Brake Drum
Inspection (Drum Servicing), or Brake Drum Inspection
(Drum Inspecting) in Drum Brakes.
• Out-Of-Balance Wheel Assemblies. Refer to Balancing
Tires and Wheels in Vibration Diagnosis.
Symptom Causes
Brakes Groan At End Of Stop Brake lining Damage By Abuse. Refer to Brake Pad
Drum Brakes.
Brake Warning Lamp ON • Leaking brake pipe, hose, or connection. Refer to
Brake Fluid Leaks
Cylinder Diagnosis
System Bleeding
Drum Brakes.
• Park Brake Switch Circuit Grounded.
• Parking Brake not Releasing. Refer to Park Brake Cable
Service/Adjustment (Adjustment) in Parking Brake.
• Low Brake Fluid. Refer to Master Cylinder
Reservoir Filling
Brake Pedal Travel 3. Maintain constant foot pressure on the brake

pedal. If the pedal slowly sinks to the floor,
Tools Required
the hydraulic system may have internal
J 28662 Brake Pedal Effort Gauge
leakage, external leakage or improperly
Check the brake pedal travel at frequent intervals. adjusted components.
Brake pedal travel is the distance the brake pedal
4. Perform a visual inspection of the
moves toward the floor from a fully released position.
Make this check with the brakes cold and with hydraulic system.
tool J 28662. 5. Check the fluid level of the master cylinder.
1. With the engine off, press the brake pedal and • A slightly low fluid level in either reservoir
release the brake pedal. Do this five times in can result from normal wear of the front
order to release vacuum from the brake lining.
vacuum booster. • An abnormally low fluid level indicates a leak
in the hydraulic system.
• Even with a high fluid level there may be
small leaks. Refer to Master Cylinder
Reservoir Filling.
If you find no external leaks, internal leakage may
be the cause. The master cylinder must be
disassembled in order to diagnose internal leakage.
Refer to Master Cylinder Overhaul.
Brake Hose And Pipe Inspection
Inspect the brake hoses and the brake pipes at least
two times a year with the following procedure:
• Inspect the outer cover for road damage,
cracks, and chafing.
• Inspect the brake hose and the pipe
connections for leaks and damage. Replace
any leaky or damaged hose or pipe.
• Check that all hose and pipe mounting
hardware is securely in place. Repair the
mounting hardware as needed.
Master Cylinder Diagnosis

the steering wheel to the brake pedal with the These tests will not find all master cylinder
brake pedal released. malfunctions. If you cannot find the cause with these
3. Apply about 455 N (100 lb) on the brake pedal. tests, refer to Brake System Diagnosis.
Use the J 28662.
Visual Inspection
4. Measure the distance (2) from the bottom of
the steering wheel to the brake pedal. • Check for a cracked casting or brake fluid leaks
around the master cylinder.
5. Subtract the first measurement (1) from the
second measurement (2). A leak will have at least one drop of fluid. A
damp condition is normal.
6. Compare the difference with the specifications
below. If the brake pedal travel exceeds • Check the pedal linkage for binding and for
specifications, refer to Brake System Diagnosis. incorrect pushrod length.
If you do not find improper brake pedal travel
System Metric English or brake pedal binding disassemble the master
cylinder. Refer to Master Cylinder Overhaul.
Vacuum Booster 80 mm 3.1 in
• Check the master cylinder for swollen or
Hydraulic Booster 110 mm 4.3 in elongated primary piston seals.
Four Wheel Disc If you find swollen seals, refer to Brake Fluid
102 mm 4 in
Brakes and Brake Fluid Handling.
Brake Fluid Leaks Low Pressure Check

Use the following procedure in order to test for brake This procedure inspects for the following conditions:
problems that may be caused by fluid leaks: • Internal seal damage
1. Start the engine and run the engine at • Porosity
idle speed. • Component bore integrity
2. Shift the transmission into neutral.
Procedure 5. If you find a leak at a connection, tighten the
1. With the ignition switch in the OFF position, connection to specification. Refer to Fastener
pump the brake pedal in order to relieve Tightening Specifications. Perform the High
the vacuum. Pressure Check again.
• Pump the brake pedal 5 times for Brake Hose and Pipe Diagnosis
vacuum-assisted brakes.
Inspect all pipes, hoses, and fittings for leaks at
• Pump the brake pedal 25 times for regular intervals. The fittings must be tight. All clips,
hydraulic-assisted brakes. clamps, and unions supporting the pipes and hoses
2. Apply the brake pedal slowly (approximately must be securely in place. Ensure that all hoses and
3 mm {1/8 in} per second). This generates tubes do not contact parts of the vehicle that could
pressure in the master cylinder. chafe or wear the hoses.
3. 'Gradually increase pedal force. Observe for Wipe clean any area suspected of leaking. Leaking
gradually increasing brake pedal travel fluid will then be easily seen. If you find a leak,
(Falling Away). tighten, repair, or replace nearby fittings and bolts.
4. If the brake pedal tends to Fall Away, perform
the High Pressure Check.
Hydraulic System Fluid Loss
5. If the High Pressure Check does not locate a Notice: Do not run the engine without fluid in the
leak, then the master cylinder has an internal power steering pump reservoir. Doing so could
leak. Refer to Master Cylinder Overhaul. damage the pump bearing and seals. The belt that
drives the power steering pump also drives the
High Pressure Check coolant pump and other components. Do not
This procedure tests for the following conditions: disconnect the belt and run the engine. A
malfunctioning power steering pump and/or system
• Leaks at the following locations:
still serves as an idler pulley for the belt. If the pump
- Connections is allowed to run without fluid in it, the bearings will
- Hoses seize up and cause the coolant pump to stop. This
- Casting can cause damage to the engine.
• Gross internal leaks If the hydraulic booster system fails because fluid
Procedure loss, take the following steps before starting
the vehicle.
1. With the engine running, apply the brake pedal
slowly (approximately 3 mm {1/8 in} per 1. If the failed component is not the power
second). This generates pressure in the steering pump, route the pressure pipe back to
master cylinder. the fluid reservoir.
2. Gradually increase pedal force. Observe for 2. Make all necessary repairs.
gradually increasing brake pedal travel 3. Replace the power steering fluid.
(Falling Away). 4. Bleed the power steering system. Refer to
3. Check for evidence of external fluid leaks. Bleeding the Power Steering System in Power
Examine the following items: Steering System.
• The ground Metal shavings from a worn power steering pump
• The pipe connections often contaminate the system. If you replace the
power steering pump, clean and flush the hydraulic
• The tires booster system. Refer to Flushing the Power
4. If you observe fluid around any component, that Steering System in Power Steering System. Remove
component has failed. Replace the component. the pipes and hoses. Blow the pipes and hoses
clean of all metal shavings.
Hard Pedal
Checks Action
Inspect for the following conditions: Replace any faulty pipes or hoses.
• Broken or damaged hydraulic
pipes or hoses
• A damaged or loose
vacuum hose
• A collapsed vacuum hose
Inspect for a plugged or loose Clean and correctly tighten the vacuum fitting.
vacuum fitting.
Inspect for the following conditions: Replace the vacuum booster
• A faulty vacuum check valve
or grommet
• Faulty air valve seal or
support plate
• Damaged floating control valve
• Bad stud welds on the front or
rear housing or power head
• Faulty booster diaphragm
• Worn or distorted reaction plate
or levers
• Cracked or broken power
pistons or retainer
Grabby Brakes
Checks Action
DEFINITION: Apparent Off-On Condition
Inspect for broken or damaged Replace any faulty pipes or hoses.
hydraulic brake pipes and hoses.
Inspect the master cylinder for a low • Fill reservoirs with the proper brake fluid.
fluid level. • Check for leaks.
Inspect the master cylinder for Repair or replace any faulty seals.
faulty seals.
Inspect the master cylinder for a Replace the master cylinder.
cracked casing.
Inspect the following components Repair or replace any faulty components.
for leaks:
• Front calipers
• Rear wheel cylinders
• Pipes
• Connections
Check the hydraulic system for air. Bleed the system.
Brakes Fail to Release

Checks Action
inspect for the following conditions: Replace the vacuum booster.
• A blocked passage in the
power piston
• An air valve sticking shut
• A broken piston return spring or
air valve spring
Inspect for a tight brake Repair or replace any faulty component.
pedal linkage.
Inspect for misadjusted stoplamp or Correctly adjust the switches.
cruise control switches.
Hydraulic Booster Diagnosis (Erratic Operation)

DEFINITION: Brake pedal sticks, binds, or grabs.
1. Run the engine at a fast idle.
2. Pull the brake pedal rearward with 44 N (10 lb) of
force. Release the pedal.
3. Measure the distance from the pedal to the
1 floor board. —
4. Apply the brakes with 444 N (100 lb) of force.
5. Release the pedal. Measure the distance from the
pedal to the floor board.
Did the pedal return to the same position? Go to S te p 3 Go to S te p 2
The brake pedal is sticking or binding. Repair the pedal

2 as necessary. — —
Is the repair complete? Go to S te p 9
Do the brakes self-apply? The condition is

intermittent.
3 — Re-verify the
condition. Go to
Go to S te p 4 S te p 1
1. Inspect the return hose between the hydraulic

booster and the power steering pump reservoir for
and obstruction, or kinked connections.
4 —
2. Remove the obstruction, or replace the hose
as necessary.
Verify the repair. Is the condition still present? Go to S te p 5 System OK
1. Remove the cover from the master cylinder reservoir.
The condition is
2. Rapidly apply the brake pedal 3 cm (1 in), observing intermittent.
5 the brake fluid in the reservoir. — Re-verify the
Does the fluid surface in the forward reservoir show condition. Go to
movement, or spouting? S te p 1 Go to S te p 6
The hydraulic booster or the master cylinder is faulty.

Determine if the master cylinder is faulty. Refer to M a s t e r
6 C y lin d e r D ia g n o s is .
—
Is the master cylinder faulty? Go to S te p 7 Go to S te p 8
Repair or replace the master cylinder as necessary. Refer

7 to M a s t e r C y lin d e r O v e rh a u l. — —
Is the repair complete? Go to S te p 9
Hydraulic Booster Diagnosis (Erratic Operation) (cont’d)
Repair or replace the hydraulic booster as necessary.
8 Refer to Hydraulic Brake Booster Replacement (Booster). — —
Is the repair complete? Go to Step 9
Verify the repair. Begin the
9 Is the condition still present? — diagnosis again.
Go to Step 1 System OK
Hydraulic Booster Diagnosis (Excessive Effort)

1. With the engine OFF, apply and release the brake
pedal four times. This will relieve pressure in the
hydraulic booster.
2. Apply the pedal. Maintain light pressure on
the pedal.
1 —
3. Start the engine.
If the power section is operating, holding the pedal
requires less pressure. The pedal will fall slightly,
then hold.
Did the pedal fall slightly, then hold? G o to S t e p 2 G o to S t e p 7
1. Accelerate the engine to medium speed.

2. Apply the brake pedal with 444 N (100 lb) for no
more than 5 seconds.
3. Stop the engine. This will stop the power
2 steering pump. —
4. Wait 90 seconds.
5. Repeatedly apply the brakes.
Are two or more brake applications power assisted? G o to S t e p 3 G o to S te p 6
The accumulator is functioning properly. Perform the

following test.
1. Thoroughly clean the hydraulic booster and all of the
hose connections.
2. Start the engine. Run the engine at idle speed.
3. Apply the brake pedal with 444 N (100 lb).
3 —
Important: Do not hold the brake pedal with 444 N
(100 lb) for more than 5 seconds at a time.
4. Maintain the pressure on the brake pedal while
inspecting the hydraulic booster and hose
connections for leaks.
Did you find any leaks? G o to S te p 1 7 G o to S te p 4
1. Apply and release the brake pedal several times.
4 2. Apply 110-155 N (25-35 lb). Maintain the pressure. — —
Does the brake pedal fall away? G o to S t e p 5
The hydraulic brake system is leaking. Refer to B rak e

5 F lu id L e a k s . — —
Did you find and correct the condition? G o to S te p 1 8
Repair or replace the hydraulic booster.

6 — —
Is the procedure complete? G o to S te p 1 8
Check the fluid level of the power steering pump reservoir.

7 —
Is the fluid level correct? G o to S te p 8 G o to S te p 1 5
Hydraulic Booster Diagnosis (Excessive Effort) (cont’d)
Check the drive belt for wear and incorrect tension. Refer
8 to Diagnosis of the Drive Belt System in Engine Cooling. —
Did you find and correct a problem? Go to Step 18 Go to Step 9
Check the power steering pump speed.
9 — —
Is the pump speed slow? Go to Step 10
1. Adjust the power steering pump speed.
10 2. Repeat the Basic Test, refer to Step 1. —
Did you find and correct a problem? Go to Step 18 Go to Step 11
Perform the Power Steering Pump Flow and Relief
Pressure Test. Refer to Power Steering System Test in
11 Power Steering System. —
Is the pump output within specifications? Go to Step 14 Go to Step 12
12 Is the pump output low? — Go to Step 13 —
1. Replace the pump.
13 2. Repeat the Basic Test, refer to Step 1. — —
Is the procedure complete? Go to Step 18
Repair or replace the hydraulic booster. Refer to Hydraulic
14 Brake Booster Replacement (Booster) — —
15 Is the power steering pump reservoir fluid level low? — Go to Step 16 —
1. Add fluid.
2. Repeat the Basic Test, refer to Step 1.
3. Thoroughly clean the hydraulic booster and all of the
hose connections.
4. Start the engine. Run the engine at idle speed.
16 5. Apply the brake pedal with 444 N (100 lb). — —
Important: Do not hold the brake pedal with
444 N (100 lb) for more than 5 seconds at a time.
6. Maintain the pressure on the brake pedal while
inspecting the hydraulic booster and hose
connections for leaks.
Did you find any leaks? Go to Step 17
Repair or replace any leaking components.
17 — —
Verify the repair. Begin the
18 Does the original condition still exist? — diagnosis again.
Go to Step 1 System OK
Hydraulic Booster Diagnosis

(General Diagnosis)
Slow Brake Pedal Return

Checks Action
Check for excessive seal friction in Overhaul the booster. Use a new seal kit.
the booster.
Check for faulty spool action. Flush the steering system while pumping the brake pedal.
Check for a restriction in the return Replace the hose.
hose from the booster to the
pump reservoir.
Check for a damaged input rod end. Replace the input rod. Replace the piston assembly.
The Brakes Grab—the Hydraulic Booster Chatters—the Pedal Vibrates

Checks Action
Check for faulty spool action, caused Flush the steering system while pumping the brake pedal.
by contamination.
Check the power steering pump belt Refer to Diagnosis of the Drive Belt System in Engine Cooling.
for slippage.
Check for a low fluid level in the Fill the reservoir. Check for external leaks.
power steering pump.
The Accumulator Leak-down System Does Not Hold a Charge

Checks Action
Check for contamination in the Flush the steering system while pumping the brake pedal.
steering system.
Check for contamination in the Flush the steering system while pumping the brake pedal.
booster system.
Check for internal leakage in the Overhaul the accumulator. Use a rebuild kit and a seal kit.
accumulator system.
The Brakes Self-apply (When You Turn the Steering Wheel)

Checks Action
Check for contamination in the Replace the hydraulic booster. Flush the complete system.
steering system.
Check for contamination in the Replace the hydraulic booster. Flush the complete system.
booster system.
Check for a restriction in the return Replace the hose.
hose from the booster to the
pump reservoir.
Hydraulic Booster Noise Diagnosis The following noises come from the hydraulic
booster. The noises may be cause for a customer
System Tests complaint. Noises may be normal and temporary.
The hydraulic booster uses fluid pressure from the Noises may be a sign of wear, or evidence of air in
power steering system. A malfunctioning power the hydraulic booster or power steering system
steering system can affect the hydraulic booster. A • A moan or low frequency hum (usually
malfunctioning booster can affect the steering accompanied by a vibration in the brake pedal
system. Before beginning extensive testing, perform or steering column) may be noticed during
the following procedure. parking or other low speed maneuvers. The
1. Check all power steering and brake pipe moan may be caused by insufficient power
connections for leaks and restrictions. steering fluid, or air in the fluid. Holding the
steering wheel turned as far as possible in one
Notice: Power steering fluid and brake fluid direction holds the power steering pump at
cannot be mixed. If brake seals contact power relief pressure. Holding the pump at relief
steering fluid or steering seals contact brake pressure for more than 5 seconds causes air to
fluid, seal damage will result. enter the system. Verify the cause of the noise
2. Ensure that the master cylinder is using the following procedure.
properly filled. 1. Check the fluid level. Fill as needed.
Notice: Power steering fluid and brake fluid 2. Turn OFF the engine.
cannot be mixed. If brake seals contact power 3. Allow the vehicle to sit for 1 hour. Any air
steering fluid or steering seals contact brake in the system will escape.
fluid, seal damage will result.
4. Verify that the moan is no longer
3. Ensure that the power steering pump reservoir present. If the moan persists, refer to
is properly filled. Diagnosis of the Power Steering System
If the power steering fluid contains air, refer to in Power Steering System.
Diagnosis of the Power Steering System in • You may hear a high-speed fluid noise
Power Steering System. when fully applying the brake pedal. The
4. Check the power steering pump belt for wear noise is normal.
and improper tension. Refer to Diagnosis of the • You may notice a slight hiss while the
Drive Belt System in Engine Cooling. accumulator pressure is in use. This is
5. Check the power steering pump pressure. Refer hydraulic fluid escaping through the accumulator
to Power Steering System Test in Power valve. The noise is normal.
Steering System. • If the accumulator is empty when the engine is
Noise from the relief valve is normal when applying started, a hissing noise may be heard during
the brakes. Firmly applying the brake pedal while the first brake application or steering maneuver.
the vehicle is parked also causes noise. The The noise is fluid rushing through the
noises are the result of air allowed into the fluid accumulator charging orifice. The noise is
during these conditions. The air remains in the fluid normal. The noise should be heard only once
only temporarily. after the accumulator is emptied.
Power steering pump noise can be confused with If the noise continues, even though no apparent
transmission, rear axle, or generator noise. accumulator pressure assist occurred, the noise
may indicate that the accumulator is not holding
pressure. Check the accumulator. Refer to
Accumulator Leak-Down Test
Normal Operating Noises

Normal hydro-boost units produce characteristic noises. These noises usually occur when the brake pedal is manipulated in
an unusual manner. The general types of normal operating noises are hissing noises and clunk/click/clatter noises.
Hissing Clunk/Click/Clatter
Hissing noises that occur with a brake pedal effort of
266 N (60 lb) or more are normal. The noise is particularly
noticeable with the vehicle motionless.
The noise will increase in intensity with the Clunk, clatter, or clicking noises will be heard when you
following conditions. quickly release the brake pedal from hard efforts (222-444 N
• Pedal pressure increases above 266 N (60 lb) {50-100 lb}).
• Operating temperature increases
Important: Loud hissing noises at, or below, normal pedal
effort (111 N {25 lb}) warrant investigation.
Brakes____________________________ ___________________________Hydraulic Brakes 5-47
Hydraulic Brake Booster Diagnosis—Noisy Brake Booster
Verify the complaint. Define the type of noise, and when
1 the noise occurs. — —
Did you verify the complaint? Go to Step 2

Does the noise occur during high brake pedal efforts, with
2 —
quick pedal release? Go to Step 3 Go to Step 4
Refer to Normal Operating Noises. Compare the system to Re-verify the
3 a known acceptable system. — complaint. Go to
Does the acceptable system make the same noise? System OK Step 1
Does the noise occur under any of the
following conditions?
4 • Low brake pedal effort — —
• With the engine idle and no brake pedal effort
• Under normal driving conditions Go to Step 5
1. Obtain a vehicle with a known acceptable brake
booster system.
2. Run both vehicles until the engines reach normal
operating temperature.
5 —
3. In both vehicles, duplicate the operating condition
associated with the noise. Listen for the noise.
Re-verify the
4. Compare the results. complaint. Go to
Does the acceptable system make the same noise? System OK Step 1
Hydraulic Booster Functional Test 5. If the accumulator failed to hold a charge after
one hour, but functions normally after charging,
System Tests the accumulator valves are malfunctioning.
The hydraulic booster uses fluid pressure from the In order to repair this condition:
power steering system. A malfunctioning power
steering system can affect the hydraulic booster. A 5.1. Disassemble the power brake booster.
malfunctioning booster can affect the steering Refer to Hydraulic Brake Booster
system. Before beginning extensive testing, perform Replacement (Booster) or Hydraulic
the following procedure. Brake Booster Replacement (Booster
1. Check all power steering and brake pipe Replacement C3500 HD).
connections for leaks and restrictions. 5.2. Replace the accumulator valves. Refer to
N otice: Power steering fluid and brake fluid
(Accumulator Overhaul).
cannot be mixed, if brake seals contact power
steering fluid or steering seals contact brake 6. If the charging and discharging of the
fluid, seal damage will result. accumulator is audible, but the accumulator still
2. Ensure that the master cylinder is fails to hold a charge, the accumulator valves
properly filled. are malfunctioning.
Notice: Power steering fluid and brake fluid In order to repair this condition:
cannot be mixed. If brake seals contact power 6.1. Disassemble the power brake booster.
steering fluid or steering seals contact brake Refer to Hydraulic Brake Booster
fluid, seal damage will result. Replacement (Booster).
3. Ensure that the power steering pump reservoir 6.2. Replace the accumulator valves. Refer to
is properly filled. Hydraulic Brake Booster Replacement
If the power steering fluid contains air, refer to (Accumulator Overhaul).
Diagnosis of the Power Steering System in
Power Steering System. 7. Empty the accumulator by pressing the brake
pedal 30 times.
4. Check the power steering pump belt for wear
and improper tension. Refer to Diagnosis of the 8. The accumulator can will rotate or wobble if the
Drive Belt System in Engine Cooling. accumulator has lost its gas charge. This
5. Check the power steering pump pressure. Refer requires replacement of the accumulator. Refer
to Power Steering System Test in Power to Hydraulic Brake Booster Replacement
Steering System. (Accumulator Overhaul).
Functional Test
1. With the ignition OFF, apply and release the
brake pedal several times. This will empty
the accumulator.
2. Apply and hold the brake pedal with
180 N (40 lb) of force.
The pedal should fall away, and then push back
against your foot.
Accumulator Leak-Down Test

2. Charge the accumulator by pressing the brake
pedal or by completely turning the steering
wheel in one direction and then in the other.
3. Turn the engine off. Let the vehicle sit for
an hour.
4. Perform two power assisted applications with
the engine off.
Seal Leak Diagnosis Power Piston Seal
Fluid leaking between the brake master cylinder and
the power brake booster indicates damage of the
power piston seal (3). This can possibly reduce the
power assist. Remove and disassemble the power
brake booster. Check the piston for any scratches
that may be the cause of the leak. If no scratches
are present, replace all the seals using the power
brake booster seal kit. Refer to Hydraulic Brake
Booster Replacement (Accumulator Overhaul) and
Hydraulic Brake Booster Replacement (Check
Valve Replacement).
Housing Seal
A fluid leak between the two housings indicates a
damaged housing seal (6). Remove and disassemble
the power brake booster. Replace the housing seal
(6), input rod seal (5) and power piston seal (3)
using the power brake booster seal kit. Refer to
Hydraulic Brake Booster Replacement (Accumulator
Overhaul) and Hydraulic Brake Booster Replacement
(Check Valve Replacement).
Spool Valve Plug Seal
Input Rod Seal Damage to the spool valve plug seal (2) causes fluid
A fluid leak from the inside of the driver’s to leak past the accumulator cap. Replace the spool
compartment at the power brake booster vent hole valve plug seal (2) with the power brake booster on
indicates a damaged input rod seal (5). Remove and the vehicle.
disassemble the power brake booster. Check the Accumulator Seal
input rod bore for any scratches that may cause the Damage to the accumulator seal (4) causes fluid to
leak. If scratches are present, replace the housing leak past the accumulator cap. Replace the
cover. If no excessive scratches are present, replace accumulator seal (4) with the power brake booster
all the seals using the power brake booster seal kit. on the vehicle. Refer to Hydraulic Brake Booster
Refer to Hydraulic Brake Booster Replacement Replacement (Accumulator Overhaul).
(Accumulator Overhaul) and Hydraulic Brake Booster Return Port Fitting
Replacement (Check Valve Replacement).
Notice: Tighten the return port fitting (3) to
10 N-m (88 lb in). Refer to Fastener Notice
If the leak continues, replace the seal ring under the
return port fitting.
For information on diagnosing the warning system,
refer to Electrical Diagnosis.
Repair Instructions
Master Cylinder Reservoir Filling
Notice: Do not use fluid that has a petroleum base.
Do not use a container that has been used for
petroleum based fluids or is wet with water.
Petroleum-based fluids cause swelling and distortion
of rubber parts in the hydraulic brake system and
water lowers the brake fluid’s boiling point. Keep all
fluid containers capped to prevent contamination.
Thoroughly clean the master cylinder reservoir cover
before removal. This prevents dirt from entering
the reservoirs.
1. Remove the cover and the diaphragm.
2. Add brake fluid in order to fill the reservoirs to
the full mark. The full mark is typically located
inside the reservoir. Use Delco Supreme 11®
Hydraulic Brake Fluid GM P/N 12377967 or
equivalent DOT 3 motor vehicle brake fluid.
Master Cylinder Replacement

(Vacuum Booster)
Removal Procedure
2. Disconnect the brake pipes.
3. Plug the pipes in order to prevent brake fluid
loss or contamination.
4. Remove the master cylinder nuts.
5. Remove the master cylinder and bracket.
156454
Before you install the master cylinder, bench bleed
the master cylinder. Refer to Master Cylinder
Bench Bleeding.
1. Install the master cylinder and bracket.
2. Install the master cylinder nuts.
Tighten
and Notices.
3. Connect the brake pipes.
Tighten
Tighten the pipe fittings to 24 N-m (18 lb ft).
4. Bleed the brakes. Refer to Hydraulic Brake
System Bleeding.

(Hydraulic Booster)
Removal Procedure
Bench Bleeding.
156510
Tighten
and Notices.
Tighten
Tighten the pipe fittings to 24 N-m (18 lb ft).
System Bleeding.
156508

(Hydraulic Booster C 3500HD)
Removal Procedure
157572
Bench Bleeding.
1. Install the retainer.
157572
Tighten
and Notices.
Tighten
Tighten the pipe fittings to 27 N.m (20 lb ft).
System Bleeding.
Master Cylinder Overhaul

Notice: Do not hone the master cylinder bore. When
the brake master cylinder is overhauled, it is
recommended that the cylinder body be replaced
rather than CLEANED UP by honing the bore. The
master cylinder has a hard, highly polished
BEARINQIZED surface, which is produced by
diamond boring followed by ball or roller burnishing
under heavy pressure. Honing will destroy this hard
smooth surface and cause rapid wear of the
rubber cups.
1. Remove the cover.
2. Remove the diaphragm.
3. Drain the brake fluid from the reservoir.

4. Remove the reservoir and two grommets from
the master cylinder body.
5. Clamp the master cylinder mounting flange in a
vise. Pry the reservoir off with a bar.
1341
6. Remove the snap ring.
7. Remove the primary piston assembly from the
master cylinder body.
Caution: If air pressure Is used to remove the

secondary piston, place the open end o f the
cylinder bore approximately 25 mm (1 In) from a
padded workbench or other surface to catch the
piston when It comes out o f the bore. Apply low
a ir pressure very carefully to ease the piston out
o f the bore. Never point the open end o f the bore
a t anyone when applying a ir pressure. The piston
may come out of the bore with considerable
force and cause personal Injury.
8. Remove the secondary piston from the master
cylinder body.
Plug the rear port. Apply a small amount of air
pressure to the front port.
9. Remove the seals.
10. Remove the spring retainer and the spring from
the master cylinder body.
Notice: Use approved solvents only when
cleaning or flushing the master cylinder and
related components. The use of these liquids
as cleaning solvent will damage the rubber
parts in the system if they have any trace of
mineral oil or other contaminants.
11. Clean all the parts using the
• Clean the metal parts in denatured alcohol.
• Clean the rubber parts in clean brake fluid.
12 . Check the diaphragm for cuts, cracks,
or swelling.
13. Inspect the cylinder bore for scoring
or corrosion.
• Replace the master cylinder if corrosion
is present.
• Do not attempt to hone the cylinder bore.
14. Check the reservoir for cracks.
Assembly Procedure
1. Lubricate the grommets, seals, and the cylinder
bore with clean brake fluid.
2. Use new seals when assembling the
master cylinder.
3. Install the spring.
4. Install the spring retainer.
5. Install the primary seal on the secondary piston.

6 . Install the secondary seal on the
secondary piston.
7. Install the secondary piston in the master

cylinder body.
1345
8. Install the primary piston assembly in the
master cylinder body.
9. Install the snap ring.
10. Compress the primary piston in order to install
the snap ring.
11. Install two new grommets to the

master cylinder.
12. Install the reservoir on the master cylinder body.
13. Press on the body while using a
rocking motion.
14. Install the diaphragm in the cover.

15. Install the cover on the reservoir.
1340
Master Cylinder Bench Bleeding 5. Reposition the master cylinder in the vise with
the front end tilted slightly up.
Bench bleed the master cylinder before installation
on the vehicle. Bench bleeding removes air from the 6 . Stroke the primary piston about 25 mm (1 in)
master cylinder. Bench bleeding reduces the time several times again.
required in order to bleed the brake hydraulic system 7. Level the master cylinder in the vise.
after installation. 8 . Loosen the plugs in the outlet ports one at
1 . Plug the outlet ports. a time.
2. Mount the master cylinder in a vise with the 9. Push the piston into the bore in order to force
front end slightly down. the air from the cylinder. Tighten the plug(s)
3. Fill the master cylinder reservoir with clean before allowing the piston to return to its
brake fluid. original position. This prevents air from being
drawn back into the cylinder.
4. Stroke the primary piston about 25 mm (1 in)
several times using a smooth round-end tool. 10. Fill the master cylinder reservoir with clean
The primary piston will not travel the full brake fluid.
25 mm (1 in) stroke as air bleeds from the 11. Follow normal bleeding procedures after
master cylinder. installing the master cylinder. Refer to Hydraulic
Brake System Bleeding.
Brake Pedal Replacement

Removal Procedure
Caution: Refer to Battery Disconnect Caution In
2 . Disable the SIR. Refer to Disabling the
SIR System in Supplemental Inflatable
Restraints.
stopiamp switch.
4. Remove the pushrod retainer.
5. Remove the stopiamp switch.
6 . Remove the pushrod.
7. Remove the nut.

8 . Remove the brake pedal bolt.
9. Remove the bushings and the spacer.
10. Remove the brake pedal.
156233
1. Install the brake pedal.
2. Install the spacer and the bushings.

3. Install the bolt and nut.
Tighten
and Notices.
4. Install the pushrod.
5. Install the stoplamp switch.

6 . Install the pushrod retainer.
7. Install the electrical connector on the
stoplamp switch.
8 . Enable the SIR. Refer to Enabling the
SIR System in Supplemental Inflatable
Restraints.
156233
Combination Valve Replacement

Removal Procedure
1. Prior to replacement of the combination valve,
note the identification code on the valve. It is
necessary to have the proper code when
replacing the valve.
2. Remove the combination valve
3. Remove the front and rear brake pipes.
4. Remove three alien bolts securing combination
valve to the BPMV.
5. Remove the combination valve from the BPMV.
6 . Remove two transfer tubes
184208
Important: Do not reuse the transfer tubes.

Always install new transfer tubes with a new
combination valve.
Verify that the replacement combination valve has
the same pin punched identification code as the
code found on the old part.
1. Install two new transfer tubes into the
combination valve until fully seated.
2. Install combination valve to BPMV.
and Notices.
3. Install three combination valve bolts.
Tighten
Tighten bolts first to 8 N.m (6 lb ft), then to
16 N.m (12 lb ft).
4. Front and rear brake pipes to
combination valve. 184208
Tighten
Tighten brake pipe fittings to 24 N.m (18 lb ft).
5. Connect combination valve electrical connector.
6 . Bleed the brake system. Refer to
ABS Bleed Procedure.
Important: Verify that the combination valve
metering rod is depressed during bleeding.
Pipe Replacement
Caution: Always use double-flared steel brake
pipe when replacing brake pipes. The use of any
other pipe Is not recommended and may cause
brake system failure. Carefully route and retain
replacement brake pipes. Always use the correct
fasteners and the original location for
replacement brake pipes. Failure to properly
route and retain brake pipes may cause
damage to the brake pipes and lead to brake
system failure.
Important: Maintain a 6 mm (1/4 in) clearance
between parallel brake pipes.
Front Brake Hose Replacement (2WD)

Removal Procedure
1.Clean the hose fittings at both ends. Remove
all dirt, grease, and other foreign material.
2. Disconnect the steel pipe.
3. Remove the clip.
4. Remove the bolt and the washers.

156274
Important: Use new copper washers when installing
the brake hose.
Important: After installation, the brake hose must
not be twisted. The brake hose must not contact any
other components.
1. Install the brake hose. Ensure the hose in
not twisted.
2. Install new copper washers.
3. Install the bolt.
Tighten
Tighten the bolt to 44 N-m (32 lb ft).
and Notices.
4. Install the clip.

5. Connect the steel pipe. Refer to
Pipe Replacement.
6 . Bleed the brakes. Refer to Hydraulic Brake
System Bleeding.
Front Brake Hose Replacement (4WD)

Removal Procedure
1. Clean the hose fittings at both ends. Remove
all dirt, grease, and other foreign material.
2. Disconnect the steel pipe.
3. Remove the clip.
156280
4. Remove the bolt and the washers.
Important: Use new copper washers when installing
the brake hose.
Important: After installation, the brake hose must
not be twisted. The brake hose must not contact any
other components.
1.Install the brake hose. Ensure the hose in
not twisted.
2. Install new copper washers.
3. Install the bolt.
Tighten
Tighten the bolt to 44 N.m (32 lb ft).
and Notices.
1562B9
4. Install the clip.

5. Connect the steel pipe. Refer to
Pipe Replacement
6 . Bleed the brakes. Refer to Hydraulic Brake
System Bleeding.
156280
Hydraulic Brake System Bleeding

If air has entered the hydraulic brake system, bleed
the system. You may need to bleed the hydraulic
brake system at all four wheels due to one of the
• Air entered the system due to a low fluid level.
• The brake pipes have been disconnected at the
master cylinder.
• The brake pipes have been disconnected at the
combination valve.
If a pipe is disconnected at one wheel, then only
bleed that wheel.
If the master cylinder has been removed, bleed the
master cylinder before installing it on the vehicle.
This will reduce the time required to bleed the
system. Refer to Master Cylinder Bench Bleeding.
Notice: Brake fluid will damage electrical
connections and painted surfaces. Use shop cloths,
suitable containers, and fender covers to prevent
brake fluid from contacting these areas. Always
re-seal and wipe off brake fluid containers to
prevent spills.
Manual Bleeding
Tools Required
J 28434 Wheel Cylinder Bleeder Wrench
1. If the vehicle has a vacuum booster, apply the
brakes several times with the ignition OFF. This
relieves the vacuum reserve.
2. Fill the master cylinder reservoir. Use Delco
Supreme 11® Hydraulic Brake Fluid GM
P/N 12377967, or equivalent DOT 3 motor
vehicle brake fluid.
Maintain the fluid level during bleeding.
3. If the master cylinder has air in the bore,
bleed the master cylinder using the
3.1. Disconnect the forward brake pipe
connector at the master cylinder. Refer to
Master Cylinder Bench Bleeding.
3.2. Allow the brake fluid to flow from the
connector port.
3.3. Connect the brake pipe connector. Do
not tighten the brake pipe connector.
3.4. Slowly apply the brake pedal. Allow the
air to bleed from the loose connector.
3.5. Tighten the connector before releasing
the brake pedal.
3.6. Wait 15 seconds.
3.7. Repeat this sequence, including the
15-second wait, until you purge all the air
from the master cylinder bore.
3.8. Repeat this procedure for the rear brake
pipe after you purge all the air from the
forward pipe connection.
4. If you replaced the Brake Pressure Modulator
Valve of the 4WAL system, or If you suspect
that air is trapped inside, bleed the Brake
Pressure Modulator Valve next. Refer to Brake
Pressure Modulator Valve in Four Wheel
Antilock Brake System.
5. Using J 28434, bleed each wheel cylinder in
the following sequence:
5.1. Right rear wheel cylinder
5.2. Left rear wheel cylinder
5.3. Right front wheel caliper
5.4. Left front wheel caliper
6 . Attach a hose to the wheel cylinder/caliper
bleeder valve.
7. Immerse the opposite end of the hose into a
container partially filled with clean brake fluid.
8 . Slowly apply the brake pedal one time
and hold.
9. Loosen the bleeder valve in order to purge the
air from the wheel cylinder/caliper.
10. Tighten the bleeder valve.
Tighten
Tighten the bleeder valve to 13 N-m (110 lb in).
and Notices.
11. Slowly release the brake pedal.
12. Wait 15 seconds.
13. Repeat this sequence, including the 15-second
wait, until you purge all the air from the wheel
cylinder or caliper.
14. Repeat steps 6-12 at each wheel until you
purge all the air from the brake system.
15. Check the brake pedal for sponginess. Check
the brake warning lamp for an indication of
unbalanced pressure. Repeat the bleeding
procedure in order to correct either of
these conditions.
Pressure Bleeding
Tools Required
• J 29567 Brake Bleeder Adapter
• J 28434 Wheel Cylinder Bleeder Wrench
Use a diaphragm-type pressure bleeder. The
pressure bleeder must have a rubber diaphragm
between the air supply and the brake fluid. This
prevents air, moisture, oil and other contaminants
from entering the brake hydraulic system.
1. Fill the pressure tank at least 2/3 full of
brake fluid.
2. Bleed the bleeder each time you add fluid.
3. Charge the bleeder to 140-170 kPa
(20-25 psi).
4. Install the J 29567 Brake Bleeder Adapter.
5. If the Brake Pressure Modulator Valve of the
4WAL system is replaced, or if you suspect that
air is trapped inside, bleed the Brake Pressure
906 Modulator Valve first. Refer to Brake Pressure
Modulator Valve in Four Wheel Antilock
Brake System.
6. Using J 28434, bleed each wheel cylinder or
caliper in the following sequence:
6.1. Right rear wheel cylinder
6.2. Left rear wheel cylinder
6.3. Right front wheel caliper
6.4. Left front wheel caliper
7. Connect the hose from the bleeder to the
adapter at the master cylinder.
8 . Open the tank valve.
9. Attach a hose to the bleeder valve.
container partially filled with clean brake fluid.
11. Slowly open the bleeder valve at least 3/4 of a
turn. Allow the fluid to flow until you see no air
in the fluid.
Tighten
Tighten the wheel cylinder or caliper bleeder
valve to 13 N-m (110 lb in).
and Notices.
12. Check the brake pedal for sponginess.
Repeat the bleeding procedure if the brake
pedal is spongy.
13. Repeat steps 9-12 at every wheel.
14. Disconnect the hose from the bleeder adapter.
15. Remove the J 29567 Brake Bleeder Adapter.
16. Fill the master cylinder to the proper level.
Hydraulic Brake System Flushing

Flushing the hydraulic brake system at each bleeder
valve. Open the valve 1 1/2 turns. Force brake fluid
through the pipes, hoses and bleeder valves until the
brake fluid comes out clear in color. Refer to
Hydraulic Brake System Bleeding.
Check the master cylinder fluid level after you flush
at each bleeder valve. Refill the master cylinder as
required. After you flush, fill the master cylinder to
the correct fluid level.
Vacuum Brake Booster Replacement

Removal Procedure
Caution: Refer to Battery Disconnect Caution in
5. Disconnect the vacuum hose.

7. Remove the stoplamp switch.
8 . Remove the pushrod.
156233
9. Remove four nuts.
10. Remove the booster assembly.
156455
1. Install the gasket.
2. Install the booster assembly.
3. Install four nuts.
Tighten
and Notices.
156455
4. Install the pushrod.

5. Install the stoplamp switch and retainer.
6 . install the vacuum hose.
156233
7. Gauge the booster pushrod. Refer to Brake
Booster Push Rod Gauging Procedure
(Vacuum Brake Booster).
913

Tighten
and Notices.
Vacuum Brake Booster Hose Replacement

Route the hose as shown.
156488

(Booster)
Notice: Hydraulic brake systems use two distinct and
incompatible fluids. Power steering fluid is used in
the hydraulic brake booster system. Brake fluid is
used in the master cylinder and brake pipes. Use
extreme care when selecting brake system fluids, or
seal damage can result. Refer to General Information
to select the correct fluid.
Checking and Adding Fluid
For information on checking and adding fluid to the
hydraulic booster system, refer to Fluid Level in
Power Steering System.
Bleeding the Hydraulic Booster System
Refer to Bleeding the Power Steering System in
Flushing the Hydraulic Booster System
Refer to Flushing the Power Steering System in
Hydraulic Booster System Pipes, Hoses,
and Fittings
Refer to Power Steering Hoses in Power
Steering System.
Power Steering Pump
Refer to Refer to Power Steering Pump Replacement
in Power Steering System.
Hydraulic Booster Assembly Removal
Procedure
3. Disconnect the inlet hose, the steering gear,
and the return hoses from the
booster assembly.
5. Remove the master cylinder and wiring
harness bracket.
6. Remove the stoplamp switch and the pushrod.
156510
7. Remove the nuts.
156511
Hydraulic Booster Assembly

Tighten
and Notices.
4. Install the stoplamp switch and pushrod.
156510
Tighten
7. Connect the return hose, steering gear, and
inlet hoses.
9. Bleed the hydraulic booster system. Refer to
Bleeding the Power Steering System in Power
Steering System.

(Accumulator Overhaul)
Removal Procedure
Caution: The accumulator contains compressed
gas. Always use the proper tools and follow the
recommended procedures or personal Injury may
result do not apply heat to accumulator. Do not
attempt to repair an Inoperative accumulator,
always replace an Inoperative accumulator with a
new one. Dispose o f an Inoperative accumulator
by drilling a 1/16 Inch diameter hole through the
end o f the accumulator can, opposite the O-rlng.
Caution: Push rod removal Is not recommended.
Improper staking o f the push rod to the
Hydroboost reaction piston can result In a loss
of brakes. If the rod or seals require service, the
entire unit must be replaced.
Tools Required 156561
J 26889 Accumulator Piston Compressor.
1. Place the J 26889 over the end of
the accumulator.
2. Install the nuts on the stud.
3. Depress the accumulator with a C-clamp.
4. Remove the accumulator retainer ring (1).
5. Release the C-clamp.

6. Remove the nut from the stud.
8. Remove the accumulator (2) and O-ring

seal (3).
156554
1. Lubricate all seals and metal friction points with
power steering fluid.
2. Install the accumulator (2) and O-ring seal (3).
3. Place the J 26889 over the end of

the accumulator.
4. Install the nuts on the stud.
5. Depress the accumulator with a C-clamp.
156561
6. Install the accumulator retainer ring (1).

1 2 3
156554
7. Release the C-clamp.
8. Remove the nut from the stud.

(Check Valve Replacement)
Removal Procedure
Caution: The accumulator contains compressed
gas. Always use the proper tools and follow the
recommended procedures or personal Injury may
result do not apply heat to accumulator. Do not
attempt to repair an Inoperative accumulator,
always replace an inoperative accumulator with a
new one. Dispose of an Inoperative accumulator
by drilling a 1/16 inch diameter hole through the
end o f the accumulator can, opposite the O-rlng.
Caution: Push rod removal Is not recommended.
Improper staking of the push rod to the
Hydroboost reaction piston can result in a loss
of brakes. If the rod or seals require service, the
entire unit must be replaced.
156556
1. Remove the bolts fastening the booster cover
to the booster housing.
2. Separate the booster cover (2) from the booster
housing (1).
156559
3. Remove the check valve. Use a locally
fabricated wire hook with dimensions as shown.
1. Install the check valve.
2. Assemble the booster cover (2) to the booster
housing (1).
3. Install the bolts fastening the booster cover to

the booster housing.
Tighten
and Notices.
156556

(Booster Replacement C3500 HD)
Notice: Hydraulic brake systems use two distinct and
incompatible fluids. Power steering fluid is used in
the hydraulic brake booster system. Brake fluid is
used in the master cylinder and brake pipes. Use
extreme care when selecting brake system fluids, or
seal damage can result. Refer to General Information
to select the correct fluid.
Checking and Adding Fluid
For information on checking and adding fluid to the
hydraulic booster system, refer to Fluid Level in
Bleeding the Hydraulic Booster System
Refer to Bleeding the Power Steering System in
Flushing the Hydraulic Booster System
Hydraulic Booster System Pipes, Hoses,
and Fittings
Refer to Power Steering Hoses in Power
Steering System.
Power Steering Pump
Refer to Refer to Power Steering Pump Replacement
in Power Steering System.
Hydraulic Booster Assembly Removal
Procedure
3. Disconnect the inlet hose, the steering
gear, and the return hoses from the
booster assembly.
5. Remove the master cylinder and wiring
harness bracket.
157572
7. Remove the stoplamp switch and the pushrod.
8. Remove the nuts.


Tighten
and Notices.
4. Install the stoplamp switch and pushrod.
156511
5. Install the retainer.

Tighten
8. Connect the return hose, steering gear, and
inlet hoses.
10. Bleed the hydraulic booster system. Refer to
Bleeding the Power Steering System in Power
Steering System.
156513
Brake Booster Push Rod Gauging
Procedure (Vacuum Brake Booster)
Tools Required
J 37839 Power Brake Pushrod Height Gauge
1. Gauge the vacuum booster with 85.0 kPa
(25 in Hg) vacuum or maximum engine vacuum.
2. Check the maximum and minimum piston rod
length using J 37839.
3. If the piston rod is not within limits, obtain a
service adjustable piston rod, and adjust the
rod to the correct length.
913
Brake Booster Push Rod Gauging

Procedure (Hydraulic Brake Booster)
Tools Required
J 37839 Push Rod Height Gauge
Gauge the piston rod. Use the J 37839. Check the
maximum and minimum rod length.
If the piston rod is not within limits, replace the rod
with a service adjustable piston rod. Adjust the
replacement rod to the correct measurement.
913
Stoplamp Switch Replacement

Removal Procedure
For information on stopiamp circuit diagnosis, refer to
Lighting Systems in Body and Chassis; and
Electrical Diagnosis.
2. Disable the SIR. Refer to Disabling the SIR in
Supplemental Inflatable Restraints.
3. Remove the pushrod retainer from the brake
pedal pin. Use snap ring pliers.
4. Unsnap the stoplamp switch from the pushrod.
5. Disconnect the electrical connector from the
stoplamp switch.
156233
1. Connect the electrical connector to the
stoplamp switch.
2. Snap the stoplamp switch onto the pushrod.
3. Install the pushrod retainer on the brake pedal
pin. Use an 11 mm (7/16 in) socket in order to
push a new clip onto the pin.
5. Enable the SIR. Refer to Enabling the SIR in
Supplemental Inflatable Restraints.
156233
Description and Operation Brake Fluid and Brake Fluid Handling

Stoplamp Switch Description Caution: Brake fluid may be Irritating to the
skin or eyes. In case o f contact, take the
Because the switch is installed along with the brake following actions:
push rod, Stoplamp switch adjustment is not needed.
The switch is held by a single retainer. • Eye contact - rinse eyes thoroughly
with water.
Master Cylinder Description • Skin contact - wash skin with soap
and water.
Notice: Brake fluid will damage electrical
connections and painted surfaces. Use shop cloths,
suitable containers, and fender covers to prevent
brake fluid from contacting these areas. Always
re-seal and wipe off brake fluid containers to
prevent spills.
Use Delco Supreme 11® Brake Fluid GM
P/N 12377967, or an equivalent DOT-3 motor vehicle
brake fluid. Always store brake fluid in a closed,
sealed container. Never use previously opened
containers of stored brake fluid. Always use new
brake fluid from a sealed container. Brake fluid left in
open or improperly sealed containers will absorb
moisture. Moisture can lower the brake fluid boiling
point, causing the following problems:
• Brake system contamination.
• Corrosion.
• Deterioration of rubber components.
The master cylinder is designed for a brake system
with low drag calipers. In addition to the standard Substandard Or Contaminated Brake Fluid
master cylinder functions, systems with a vacuum Notice: Power steering fluid and brake fluid cannot
booster include a quick take-up feature. The quick be mixed. If brake seals contact power steering fluid
take-up feature provides a large volume of low or steering seals contact brake fluid, seal damage
pressure brake fluid to the wheels upon the initial will result.
brake application. The large volume of brake fluid
overcomes the clearance created by the retracted Use the correct fluids on models with a hydraulic
brake caliper pistons. booster. The master cylinder and brake system use
brake fluid. The hydraulic booster system uses
Reservoir And Cover power steering fluid.
The reservoir and cover are made of plastic. The If the brake fluid contains improper fluid, water, or
cover snaps onto the top of the reservoir. A seal, other contaminates, the brake fluid may boil or may
located between the cover and reservoir, keeps deteriorate rubber components in the hydraulic
contaminants out of the brake fluid. brake system.
Keep the master cylinder reservoir properly filled with Evidence of rubber deterioration occurs in the
brake fluid. This ensures adequate reserve brake
following areas:
fluid and prevents air from entering the hydraulic
system. Do not over fill the reservoir. The brake fluid • Swollen master cylinder piston seals
absorbs heat from the brakes, and expands. An • Swelling of the wheel cylinder boots
over-filled reservoir cannot allow fluid expansion. • Swelling of caliper boots
Master Cylinder Identification • Swelling of the master cylinder
Identifying information is stamped into the reservoir diaphragm
master cylinder. If rubber deterioration is found, replace all rubber
A Delphi master cylinder has the following parts, including the hoses, in the brake system.
information stamped into the front surface: Check for brake fluid on the brake linings. Replace
the brake linings that are contaminated with
• The first two digits are the build code. brake fluid.
• The third digit indicates the year the master
If the brake fluid is contaminated and the master
cylinder was built (Example: 5 means 1995).
cylinder piston seals are good, check for leaks and
• The last digits indicate the day the master excessive heat conditions. If no leaks or excessive
cylinder was built (Example: 271 means the heat conditions are found, flush the brake system.
271st day of the production year). Refer to Hydraulic Brake System Flushing.
Flushing The Hydraulic Brake System A pipe located on the left side of the intake manifold
Flushing the brake hydraulic system is running new supplies vacuum to the vacuum booster. A flexible
brake fluid through the brake system until the brake hose connects the pipe to the booster check valve.
fluid at each bleeder valve comes out clear. The check valve mounts in a grommet on the front
of the booster assembly.
Flush the brake hydraulic system for the
following reasons: Hydraulic Brake Booster Description
• When new hydraulic brake parts are installed.
• When contamination may be present. Flushing
is the only way to clean contaminated fluid out Some C/K models have a hydraulic booster. The
of the system. hydraulic booster provides power assist using fluid
pressure from the power steering pump. The booster
• When you do not know the grade of brake fluid assembly is located on the left front cowl. The
in the brake system. master cylinder mounts onto the booster assembly.
• When mineral oil is present in the brake fluid.
Vacuum Brake Booster Description
The vacuum booster is a tandem diaphragm vacuum
suspended unit. During normal operation, with the
brake pedal released, manifold vacuum is applied to
both sides of the diaphragms. Applying the brakes
allows air at atmospheric pressure to enter one side
of each diaphragm. This pressure difference provides
the power assist.
The booster assembly is located on the left front
cowl. The master cylinder mounts on the
booster assembly.
156501
157771
Legend
(1) Check Valve Seat (27) Input Rod
(2) Check Valve Body (28) Input Rod Bracket
(3) Check Valve Relief Spring (29) Input Rod Spring
(4) Check Valve Washer (30) Input Rod End
(5) Checkball (31) Input Rod Seals
(6) Body Insert (32) Housing/Cover Seal
(7) Plunger (33) Booster Cover
(8) O-ring (34) Output Push Rod Retainer
(9) Housing Plug (35) Piston Return Spring
(10) Spool Valve (36) Output Push Rod
(11) Spool Valve Checkball (37) Piston Retainer Spring
(12) Sleeve Spring (38) Baffle Retainer Spring
(13) Actuator (39) Spool Spring
(14) External Retainer Ring (40) Spool Plug O-ring
(15) Spool Sleeve (41) Spool Plug
(16) Spool Valve Pin (42) Spool Plug Retaining Ring
(17) Piston Seal (43) Accumulator Retainer Ring
(18) Piston (44) Accumulator
(19) Input Lever Pin (45) Accumulator Ring
(20) Input Lever (46) Accumulator Piston
(21) Retainer Spring (47) Accumulator Piston O-ring
(22) Relief Valve Spring (48) Accumulator Piston Rings
(23) Relief Valve Checkball (49) Retainer Ring
(24) Relief Valve Seat (50) Housing/Cover Bolts
(25) Input Rod Ring (51) Booster Housing
(26) Rod and Plunger
Power Steering Pump If contamination occurs, flush the hydraulic booster

The power steering pump supplies the hydraulic system. Flushing the system involves draining the
old fluid and replacing that fluid with clean fluid.
pressure needed to operate the brake booster. The
pump is belt-driven. The pump mount to the engine. Power Steering System.
The pump provides a continuous fluid flow to the
booster, when the engine is running. Service booster components in a clean work area
separate from the brake servicing area. Wash hands
Pipes, Hoses, and Fittings before changing work areas. Do not use the same
containers for brake and power steering fluids.
Three flexible hoses route power steering fluid
through the hydraulic booster system. Brake Warning/lndicator Lamp Description
• One hose supplies pressurized fluid from the
Brake Lamp
power steering pump.
The brake warning lamp in the instrument cluster
• A second hose routes pressurized fluid from the warns the driver of the following conditions:
booster to the power steering gear.
• A loss of hydraulic fluid pressure
• The third hose returns the fluid to the power
steering pump. • Parking brake operation
• A possible malfunction in the antilock
brake system
The brake lamp illuminates when ground is supplied
from one of the following switches or valves:
• The combination valve switch
• The parking brake switch
• The brake pressure modulator valve
Antilock Lamp
Models with four wheel antilock brakes use the
antilock indicator lamp in the instrument cluster. The
lamp informs the driver of antilock system operation
and malfunctions. When a malfunction occurs, the
brake pressure modulator valve completes the circuit
to the lamp. The lamp may stay on or turn back off
depending on the nature of the malfunction. The
brake lamp serves as a backup if a malfunction
occurs in this circuit. Refer to Antilock Lamp in Four
Wheel Antilock Brake System.
Brake Warning/lndicator Lamp Operation

Brake Fluid and Brake Fluid Handling The brake indicator in the instrument cluster serves
to alert the operator to problems in the vehicle’s
Notice: Hydraulic brake systems use two distinct and braking system. With the ignition switch in the RUN
incompatible fluids. Power steering fluid is used in or the START position, voltage flows to the
the hydraulic brake booster system. Brake fluid is Instrument Cluster from the PNK (39) wire from
used in the master cylinder and brake pipes. Use GAUGES Fuse 4. The BRAKE indicator lamp is
extreme care when selecting brake system fluids, or illuminated whenever the TAN/WHT (33) wire from
seal damage can result. Refer to General Information the instrument cluster is grounded.
to select the correct fluid. The BRAKE indicator lamp is tested whenever the
vehicle’s engine starts. Placing the ignition switch in
Use the correct fluids. The master cylinder and brake the START position connects a ground path from the
system use brake fluid. The hydraulic booster system ignition switch to ground G201 through the BLK
uses power steering fluid. (150) wire. With this ground connection, current flows
Do not reuse brake system fluids. Do not mix power through the TAN/WHT (33) wire to the Daytime
steering fluid with brake fluid. Fluid contamination Running Lamp (DRL) Control Module. The DRL
may result in swelling and deterioration of rubber Control Module logic allows the current to complete
parts. This can lead to reduced brake performance the circuit, and the brake indicator lamp is
and the eventual loss of braking capability. illuminated. Placing the ignition switch in the RUN
position breaks the connection and the lamp
goes out.
The BRAKE indicator also illuminates if you apply This voltage is only available when the Ignition
the parking brake while the ignition switch is in the Switch is in the ACC or the RUN position. The
RUN or the START position. This alerts the operator P/B Booster Fluid Flow Alarm does not operate
to release the parking brake. The parking brake unless there is sufficient current flow through in-line
warning switch is mechanically grounded. The switch resistor R208. With current flow, the voltage drop
contacts close when you apply the parking brake, across the resistor provides the operating voltage to
grounding the TAN/WHT (33) wire through the drive the audible alarm. The P/B Booster Fluid Flow
Daytime Running Lamp Control Module. The and Pressure Alarm Delay Module is grounded
DRL Control Module logic prevents the operation of through the LT GRN (966) wire to the P/B booster
the Daytime Running Lamps while the parking brake fluid pressure alarm switch. The P/B Booster Fluid
is engaged. The Daytime Running Lamps also will Pressure Alarm Switch contacts close when fluid
not operate if either of the following conditions pressure is low. The P/B Booster Fluid Flow Alarm
are present: Switch contacts close when fluid flow is low. Both
• Lamp operation by the brake pressure switches will close and ground through the BLK
differential switch (150) wire to Ground G112 causing the alarm
to sound.
• Lamp operation by the Electronic Brake
Control Module Under normal operating conditions, in-line diode
D202 prevents the park brake warning switch from
Additionally, in vehicles equipped with the Audible
providing a ground path that would cause the
Brake Warning, the Daytime Running Lamps will not
P/B Booster Fluid Flow Alarm to operate. However, if
operate if a low power brake booster fluid flow and a
the brake fluid pressure and the fluid flow are low,
low power brake booster pressure alarm condition
the diode allows the ground path to light the BRAKE
is present.
indicator lamp on the instrument cluster.
The brake pressure differential switch closes its
When fluid pressure and fluid flow are both low, the
contacts when conditions in the hydraulic brake
normally open contacts in the P/B booster fluid
system are abnormal. This grounds the TAN/WHT
pressure alarm switch and the P/B booster fluid flow
(33) wire through the BLK (150) wire to ground
alarm switch will close. The closing of these contacts
G103. See Antilock Brake System for detailed
provides a ground path for the P/B Fluid Flow Alarm
information about the function of this switch.
Delay Module. The P/B Fluid Flow Alarm Delay
The Electronic Brake Control Module also grounds Module is needed because the normal start and stop
the TAN/WHT (33) circuit if there are abnormal operation of the brakes causes momentary low
conditions in the Antilock Brake System (ABS). The pressure conditions. The module has an internal time
BRAKE indicator lamp and the antilock brakes delay function that prevents these short-term
warning indicator lamp both light for ABS failures. conditions from driving the alarm. With the P/B Fluid
See Section Antilock Brake System for detailed Flow Alarm Delay Module, low pressure/low fluid flow
information about the operation and grounding of the conditions must exceed the normal operating limits of
Antilock Brake System. the system before the alarm will sound.
Vehicles with the UJ1 option code are equipped with The alarm may occasionally sound on start-up due
additional brake warning equipment. On these to low pressure and lack of fluid in the system.
vehicles, the P/B Booster Fluid Flow Alarm will When the power steering pump starts operating,
sound and the BRAKE indicator lamp will light if both pressure and flow increases to normal. This
of the following conditions are present: deactivates the alarm.
• The power brake booster fluid flow is low.
• The brake fluid pressure is low.
Voltage is available to the P/B Booster Fluid Flow
and Pressure Alarm Delay Module through the
following sources:
• The YEL (43) wire through the in-line
resistor R208
• The P/B Booster Fluid Flow Alarm YEL/BLK
(965) wire
5-88 Hydraulic Brakes_________ Brakes

Illustrations Tool Number/Description Illustrations Tool Number/Description
J 26889 J 29567
Accumulator Piston Universal Brake Bleeder
Compressor Adapter
156598 1005
r t R n
J 28434 J 37839
Wheel Cylinder Bleeder Push Rod Height Gauge
Wrench
1007 1008
J 28662
Brake Pedal Effort Gauge
1006
Brakes Disc Brakes 5-89
Disc Brakes
Specifications
Fastener Tightening Specifications (Front Disc Brakes)

Brake Hose to Caliper Bolt 45 33 —
Splash Shield to Knuckle Bolt 26 19 —
Bendix
Bleeder Valve 13 — 110
Delco
Caliper Mounting Bolt 51 38 —
C 3500HD
Caliper Lock Mounting Bolt 20 15 —
Front Anchor Plate to Knuckle Nut 285 210 —
Front Rotor to Hub Bolt 237 175 —
Front Splash Shield Bolt 16 12 —
Rear Anchor Plate to Axle Flange Nut 105 78 —
Fastener Tightening Specifications (Rear Disc Brakes)

Anchor Plate Mounting Nut 105 78 —
Brake Hose to Caliper Bolt 45 33 —
Caliper Support Key Bolt 20 15 —
Component Specifications
System Original Thinnest (Refinishing) Replacement (Discard)
JB5/JD5/JB6 31.75 mm (1.25 in) 31.25 mm (1.23 in) 30.86 mm (1.215 in)
JB7/JD7/JB8 32 mm (1.26 in) 31.25 mm (1.23 in) 30.86 mm (1.215 in)
JB8 Dual 38.10 mm (1.50 in) 37.59 mm (1.480 in) 37.21 mm (1.465 in)
JF9 36.26-36.64 mm 35.1 mm (1.382 in) 34.7 mm (1.366 in)
(1.428-1.443 in)
Z56 32 mm (1.26 in) 31.25 mm (1.23 in) 30.86 mm (1.215 in)
Caliper Wear Shim Specifications

More Than But Not Exceeding Shim Thickness Shim P/N
0 0.058 in None Required None Required
0.058 0.101 in 0.025 in 15625734
0.101 0.145 in 0.045 in 15625735
*lf the bumper gap exceeds 0.145 inch, then remove caliper exceeds 0.145 inch, then replace the anchor
the old caliper and replace it with a new caliper. If plate. Use a new key and a new spring when
the bumper gap with the new caliper measures assembling the new components.
between 0.058 and 0.145 inch, then select a shim
from the table. If the bumper gap with the new
5-90 Disc Brakes Brakes
Brake Caliper Bolt, Bolt Kit, Bushing, Caliper Assembly 4.665
Bleeder Screw Cover 4.666
Wheel Cylinder Piston Caliper Kit 4.667
Brake Flange Plate 5.001
Brake Flange Plate Gasket and Shield 5.002
Brake Pad 5.017
Front Caliper Hardware Kit 5.019
Brake Rotor 5.809

Procedures
Brake Rotor Thickness Variation Check
Check for thickness variation by measuring the rotor
thickness at four or more points around the
circumference of the rotor. Use a micrometer
calibrated in ten-thousandths of an inch. Make all
measurements at the same distance in from the
edge of the rotor.
that the indicator button contacts the rotor surface

about 13 mm (0.5 in) from the outer edge.
3. Set the dial indicator to zero.
4. Turn the wheel one complete revolution and
observe the runout indicated on the dial.
5. The total indicated runout (TIR) for front
disc brake rotors must not exceed 0.08 mm
(0.003 in). The TIR for rear disc brakes and
for C3500 HD Models must not exceed
0.25 mm (0.010 in).
6. Refinish or replace any rotor which is not within
A rotor that varies in thickness by more than
the lateral runout specifications.
0.013 mm (0.0005 in) causes brake pedal pulsation
and/or vehicle vibration during brake application. In some cases, indexing the rotor on the hub by one
Refinish to specifications or replace a rotor that does or two bolt positions away from the original position
not meet these specifications. C3500 HD Models will reduce the lateral runout. If it is impossible to
must not exceed 0.25 mm (0.001 in) correct the amount of lateral runout by indexing the
thickness variation. rotor, then check the hub and bearing assembly for
excessive lateral runout or looseness. If the hub and
Brake Rotor Lateral Runout Check the bearing assembly lateral runout exceeds
Leave the wheels on the vehicle when performing a 0.040 mm (0.0015 in), then repair or replace the hub
lateral runout check in order to obtain the most and the bearing assembly.
accurate reading of the total indicated runout (TIR) Notice: Any time the brake rotor is separated from the
under real breaking conditions. If equipment is not wheel bearing flange, clean any rust or foreign material
available to perform the check with the wheels from the mating surfaces of the wheel bearing flange
installed, then remove the wheels leaving the caliper and the rotor. Failure to do so can result in increased
in place. lateral runout of the rotor and brake pulsation.
Notice: Any time the brake rotor is separated from Brake Rotor Tolerance
the wheel bearing flange, clean any rust or foreign
During the manufacture of the brake rotor, tolerances
material from the mating surfaces of the wheel
of the braking surfaces for flatness, parallelism, and
bearing flange and the rotor. Failure to do so can
lateral runout are closely held. Maintaining close
result in increased lateral runout of the rotor and
tolerances on the shape of the braking surfaces is
brake pulsation.
necessary to prevent brake roughness or pulsation.
1. Clean the surface of the rotor. It is necessary to hold the surface finish to a
Important: If it is necessary to remove the wheel, specified range of 60 Ra roughness or less. The
then reinstall the wheel nuts to retain the rotor. control of the braking surface finish is needed to
Tighten the wheel nuts to the correct torque avoid problems of hard pedal apply, excessive brake
specification. Refer to Wheel Removal (Single fade, pulls, and erratic performance. In addition,
Wheels) or Wheel Removal (Dual Rear Wheels) in control of the surface finish can improve lining life.
Tires and Wheels. Failure to properly tighten the Light scoring of the rotor surfaces not exceeding
wheel nuts may cause pedal pulsation and/or front 1.5 mm (0.06 in) in depth is normal and not
end vibration during brake applications. detrimental to brake operation.
Repair Instructions
Brake Pad Inspection
Inspect the brake linings every 9,650 km (3,000 mi)
or any time the wheels are removed, for example in
the case of tire rotation.
Check both ends of the outer lining by looking in at
each end of the caliper. The ends are the points
where the highest rate of wear normally occurs. At
the same time, check the thickness of the inner
lining to make sure it has not worn prematurely.
Some inboard shoe and linings have a thermal layer
against the shoe, integrally molded with the lining.
Do not confuse this extra layer with uneven
inboard-outboard lining wear. Look down through the
inspection hole in the top of the caliper to view the
inner lining. Replace the shoe and the lining
assemblies whenever the thickness of any lining is
worn to within 0.76 mm (0.030 in) of the shoe.
156302 Replace the riveted shoe and the assemblies when
the lining is worn to within 0.76 mm (0.030 in) of any
rivet head. Always replace the disc brake shoe and
the lining assemblies as complete sets.
Check the flatness of the linings. Place the inboard
and the outboard lining surfaces together and check
for a gap between the surfaces. Any gap should not
exceed 0.13 mm (0.005 in) at the center of the lining
surfaces. This applies to both new and used shoe
and lining assemblies.
The shoe and the lining assemblies have a wear
indicator that makes noise when the lining are
worn (2) and need replacement.
125
Brake Pads Replacement (Rear)

Linings
The use of GM brake lining material will help to
maintain a balance between the front and the rear
brake performance. In addition, the use of GM brake
lining material will provide the proper brake balance
for the purposes of stopping distance and control
over the full range of operating conditions. The
installation of any front or rear lining material with a
performance different from that of the suggested GM
replacement parts for this vehicle may change the
intended brake balance of this vehicle.
Removal Procedure
1. Remove the caliper. Refer to Brake Caliper
Replacement (Rear). Do not disconnect the
brake hose as in Caliper.
2. Suspend the caliper.
Notice: Do not allow calipers to hang from the 156335
flexible hoses. Doing so can damage the hoses.
3. Remove the inboard lining and the
outboard lining.
4. Use a wire brush to remove any corrosion from
the machined surfaces of the steering knuckle
and the caliper.
1. Lubricate the caliper and the steering knuckle,
or support, sliding surfaces and the spring with
Aeroshell® #5 or the equivalent.
2. Place the new pad in a vise.
156338
3. Compress the brake pad tangs as necessary to
obtain a secure fit between the outer brake pad
and the caliper.
156341
4. Install the outer brake pad onto the caliper.

• Use a C-clamp to install the pad (3) onto the
caliper (1) if it is necessary.
• Do not allow the C-clamp to come in contact
with the lining.
• Insert a used brake pad between the
C-clamp and the new brake lining.
5. File the leading edge of the brake pad tang to

aid in the installation of the brake pad to
the caliper.
6. Install the caliper. Refer to Brake Caliper
Replacement (Rear).
Important: Pump the brakes until the brake
pedal is firm before moving the vehicle. Check
the brake fluid level in the master cylinder after
pumping the brakes.
156344
Brake Pads Replacement (Front Delco)

Linings
Removal Procedure
Replacement (Front Delco). Do not disconnect
the brake hose as in Caliper.
2. Suspend the caliper using a wire hanger (1).
3. Remove the outboard shoe and lining (3).
Use a screwdriver to disengage the buttons on
the pad from the holes in the caliper housing.
4. Remove the inboard shoe and the lining.

5. Remove the bolt boots.
156299

8. Inspect the mounting bolts, the key, the spring,
and the sleeves for any corrosion. Do not
attempt to polish away any corrosion. Replace
any corroded parts.
9. Inspect the bolt boots for any nicks, cuts, or
corrosion. Replace any corroded parts.
Important: Clean the caliper assembly. Install a
new brake hardware kit any time it is necessary
to remove it from the rotor.
1. Lubricate the bushings and the mounting bolt
seals with Delco Silicone Lube GM
P/N 18010909 or the equivalent.
2. Install the new bushings.
i
t
156329
3. Install the bolt seals.
4. Install the new bolt boots.
5. Install the inboard lining.
156299
6. Snap the retainer spring into the piston.

• The pad retainer spring is already staked to
the inboard shoe.
• The pad must lay flat against the piston.
142254
7. Install the outboard lining with the wear
indicator at the leading edge of the pad during
a front wheel rotation. The back of the pad
must lay flat against he caliper.
Replacement (Front Delco).
the fluid level in the master cylinder after
pumping the brakes.
Brake Pads Replacement (Front Bendix)

Linings
Removal Procedure
Replacement (Front Bendix). Do not disconnect
the brake hose as in Caliper.
2. Suspend the caliper.
Notice: Do not allow calipers to hang from the
flexible hoses. Doing so can damage the hoses.
3. Remove the inboard lining.
4. Remove the outboard lining.
5. Inspect the caliper assembly for signs of fluid
leakage. If any leakage is detected refer to
Unit Repair.
the machined surfaces of the steering knuckle
and the caliper.
156330
1. Lubricate the caliper and the steering knuckle,
or support, sliding surfaces and the spring with
Shell Aeroshell® #5 or the equivalent.
2. Place the new pad in a vise.
3. Compress the vise as needed to obtain a

secure fit between the outer brake pad and
the caliper.
4. Install the outer brake pad (3) onto the

caliper (1).
• If it is necessary use a C-clamp to install the
pad onto the caliper.
• Do not allow the C-clamp to come into
contact with the lining.
• Insert a used brake pad between the
C-clamp and the new brake lining.
156343
5. File the leading edge of the brake pad tang to
aid in the installation of the brake pad to
the caliper.
Replacement (Front Bendix).
the brake fluid level in the master cylinder after
pumping the brakes.
156344
Burnishing Pads and Rotors

After replacing the brake linings and/or refinishing
rotors, the new braking surface should be broken in,
or burnished. To burnish, make 20 stops from 48 km
(30 mph) using a medium to firm brake pedal
pressure. Be careful not to overheat the breaks while
performing the burnishing procedure.
Brake Caliper Replacement (Rear)

Removal Procedure
1. Remove two-thirds of the brake fluid from the
master cylinder.
4. Mark the relationship between the wheel and
the hub.
6. Position a C-clamp and tighten it until the
piston bottoms in the bore.
7. Remove the C-clamp.
8. Remove the brake hose. Refer to Pipe
Replacement in Hydraulic Brakes.

10. Remove the support key (3) and the spring (4).
157504
11. Drive out the support key using a brass punch
and a hammer.
12. Remove the caliper assembly (1).

13. Inspect the inside of the caliper assembly for
signs of fluid leakage. Refer to Brake Caliper
Overhaul (Rear; Front Bendix) if any leakage
is detected.
the machined surfaces of the anchor plate and
the caliper.
157504
1. Lubricate the caliper and the anchor plate
sliding surfaces with Shell Aeroshell® Grade 5
lubricant or equivalent.
Notice: Do not use NEVER SEIZE type
products on the caliper V-ways and anchor
plate guide way surfaces. These products are
not lubricants and result in high caliper slide
forces which can cause increased wear of the
brake pads.
2. install the caliper assembly (1).
3. Install the spring (4) and the support key (3).
157504
4. Drive the support key in place using a brass
punch and a hammer.
5. Install the bolt (2). The boss on the bolt must fit
into the circular cutout in the key.
Tighten
Tighten the bolt to 20 N-m (15 lb ft).
and Notices.
Notice: Make sure the brake hose is not
twisted or kinked after installation. Damage to
the hose could result.
Tighten
Tighten the brake hose to 45 N.m (33 lb ft).
7. Bleed the system. Refer to Hydraulic Brake
System Bleeding in Hydraulic Brakes.
8. Install the tire and the wheel assembly.
Important: Pump the brake pedal until it is firm
before moving the vehicle. Check the brake
fluid level in the master cylinder after pumping
the brakes.
Brake Caliper Replacement (Front Delco)

Removal Procedure
master cylinder.
4. Remove the tire and the wheel. Refer to Wheel
Removal (Single Wheels) or Wheel Removal
(Dual Rear Wheels) in Tires and Wheels.
Reinstall two lug nuts to retain motor on models
with composite rotors.
5. Compress the piston using adjustable pliers
over the inboard lining tab and the caliper
housing flange.
6. Remove the brake hose from the caliper by
removing the inlet fitting bolt.
7. Remove the mounting bolts (1), (2).
8. Remove the bolt boots (1), (2).

9. Remove the caliper.
• Inspect the inside of the caliper assembly fpr
signs of fluid leakage. Refer to Brake
Caliper Overhaul (Front Delco) if any leakage
is detected.
• Remove the mounting bolt seals if they
were used.
156298
11. Inspect the mounting bolt and the sleeve
assemblies for corrosion. Replace any
corroded parts. Do not attempt to polish away
any corrosion.
12. Inspect the bolt boots for any nicks, cuts, or
corrosion. Replace any damaged parts.
Important: Clean the caliper assembly and
install a new brake hardware kit. Replace the
brake hardware kit with each removal from
the rotor.
1. Install the new bushings and the bolt seals.
2. Lubricate the bushings and the mounting bolt
seals with GM P/N 18010909 or the equivalent.
3. install the new bolt boots (1), (2).

4. Install the caliper.
156298
5. Fill both housing cavities between the bushings
with GM P/N 18010909 or the equivalent.
6. Install the mounting bolt and the
sleeve assemblies.
* Tighten
Tighten the bolt to 51 N-m (38 lb ft). The bolts
4 =
0**
boots must remain secure after tightening
the bolts.
I Notice: Refer to Fastener Notice in Cautions

and Notices.
7. Connect the brake hose to the caliper.
T Tighten
Tighten the brake hose bolt to 45 N-m (33 lb ft).
156329
8. Measure the clearance between the caliper and

the bracket stops.
• If necessary, remove the caliper and file the
ends of the bracket to obtain a 0.26 to
0.60 mm (0.010 to 0.024 in) total clearance.
• Measure the clearances individually and then
add them together.
• Install the tire and the wheel.
Important: Pump the brake pedal until it is
firm before moving the vehicle. Check the
fluid level in the master cylinder after
pumping the brakes.
Brake Caliper Replacement (Front Bendix)

Removal Procedure
master cylinder.
4. Mark the relationship between the wheel and
the hub.
Removal (Single Wheels) or Wheel Removal
(Dual Rear Wheels) in Tires and Wheels.
6. Position a C-clamp and tighten until the piston
bottoms in the bore.
7. Remove the C-clamp.
156331
10. Remove the support key and the spring using a

brass punch and a hammer to drive out the
support key.
11. Remove the caliper assembly.
12. Inspect the inside of the caliper assembly for
signs of fluid leakage. Refer to Brake Caliper
Overhaul (Rear; Front Bendix) if any leakage
is detected.
the machined surfaces of the anchor plate and
the caliper.
1. Lubricate the caliper and the anchor plate
sliding surfaces with Shell Aeroshell® #5 or
the equivalent.
2. Install the caliper assembly.
Notice: Make sure the brake hose is not
twisted or kinked after installation. Damage to
the hose could result.
Notice: Do not use NEVER SEIZE type
products on the caliper V-ways and anchor
plate guide way surfaces. These products are
not lubricants and result in high caliper slide
forces which can cause increased wear of the
brake pads.
3. Install the spring and the support key using a
brass punch and a hammer to drive the support
key into place.
156336
4. Install the caliper lock mounting bolt (2). The
boss on the bolt must fit into the circular cutout
in the key.
Tighten
and Notices.
Tighten
Tighten the brake hose bolt to 45 N-m (33 lb ft).
6. Bleed the brake system. Refer to Hydraulic
Brake System Bleeding in Hydraulic Brakes.
7. Install the tire and the wheel. Refer to Wheel
Installation (Single Wheels-Front or Rear) or
Wheel Installation (Dual Rear Wheels) in Tires
and Wheels.
Brake Caliper and Anchor Plate Wear
Adjustment
Bendix® calipers have wear shims available to
compensate for wear at the caliper to anchor plate
contact points. A rattling sound, originating from the
front brake area, will occur when the caliper and
anchor plate are excessively worn. Use the following
procedure to measure and correct this condition.
Replacement (Rear) or Brake Caliper
2. Clean surfaces (1-4) with a wire brush.
3. Smooth any deep nicks or gouges with a file.
4. Measure the caliper contact surface for wear by

performing the following steps.
4.1. Lay a straight edge (1) across the
caliper surfaces.
4.2. Measure the maximum depth of any
wear on the surfaces using feeler
gage (2).
4.3. Replace any calipers worn to a depth of
1.25 mm (0.050 in) or more.
156354
5. Measure caliper to anchor plate wear by
performing the following steps.
5.1. Install the caliper.
5.2. Install a new standard size key without
the spring.
5.3. Install the key retention bolt.
5.4. Insert a screw driver into the center of
the key bumper gap (1).
5.5. Pry the screw driver firmly into the center
of the key bumper gap to ensure that the
caliper is sitting at the surfaces.
5.6. Measure the bumper gap with the largest
feeler gauge that will fit into the gap on
either side of the screw driver.
5.7. Based on the bumper gap
measurement, select a shim. Refer to
Component Specifications.
158357
6. Replace the caliper by performing the
following steps.
6.1. Remove the caliper from the anchor
plate.
6.2. Install the shim on the anchor plate
V-way opposite from the key and the
spring V-way.
6.3. Install the caliper using a new key and a
new spring.
7. Remeasure the bumper gap. Install a thicker
shim or replace the components if the gap
exceeds 1.50 mm (0.058 in). Refer to
Component Specifications.
Brake Caliper Inspection

1. Remove the caliper to inspect the inside of the
caliper assembly for signs of fluid leakage.
Overhaul the caliper if any leakage is detected.
Refer to Brake Caliper Overhaul (Front Delco)
or Brake Caliper Overhaul (Rear; Front Bendix).
2. Inspect the mounting bolts and the sleeves lor
any corrosion.
3. Replace any corroded bolts or sleeves. Do not
attempt to polish away the corrosion.
Brake Caliper Overhaul (Front Delco)

Removal Procedure
Tools Required
• J 36474 75 mm Boot Seal Installer or
• J 36476 80 mm Boot Seal Installer or
• J 38453 86 mm Boot Seal Installer
1. Remove the fluid from the caliper (1).
2. Remove the brake pad. Clean the interior of the
caliper with clean shop towels.
Caution: Do not place your fingers In front
o f the piston In order to catch or protect the
piston while applying compressed air. This
could result In serious Injury.
Notice: Use just enough air pressure to ease
the piston out of the bore. You can damage a
blown-out piston even with the padding.
3. Remove the piston.
• Direct compressed air into the caliper fluid
inlet.
• Use just enough air pressure to ease the
piston out of the bore.
4. Remove the boot using care not to scratch the
housing bore.
167141
5. Remove the piston seal with a nonmetai type
of tool.
156363
6. Remove the bleeder valve.

7. Use denatured alcohol in order to clean the
following parts:
• The bleeder valve
• The caliper bore
• The caliper passages
• The piston
• Use dry, filtered, compressed air to dry the
parts and to blow out the passages.
8. Replace any piston with the
• Scoring
• Nicked
• Corroded
• Worn
• Damaged chrome plating
9. Replace any caliper bore or seal groove with
the following conditions:
• Scoring
• Nicked
• Corroded
• Worn
• Attempt to remove any light corrosion on
the caliper bore or seal groove using a
crocus cloth.
1. Use clean brake fluid in order to lubricate the
following parts:
• The new piston seal
• The caliper bore
• The piston
2. Install the piston seal using care not to twist
the seal.
156363
3. Install the boot on the piston.
4. Install the piston and the boot into the

caliper bore.
5. Push the piston to the bottom of the bore.
156403
7. Install the bleeder valve.

Tighten
Tighten the bleeder valve to 13 N.m (115 lb in).
and Notices.
Brake Caliper Overhaul

(Rear; Front Bendix)
Rem oval Procedure
Tools Required
J 24548 Piston Seal Installer
1. Remove the fluid from the caliper.
Caution: Do not place your fingers in front
of the piston in an attem pt to catch or
protect it when applying compressed air.
This could result in serious injury.
Notice: Use only enough air to ease the piston
out of the bore. If the piston is blown out, even
with the padding, it can be damaged.
2. Remove the brake pad. Clean the interior of the
caliper with clean shop towels.
3. Remove the piston.
4. Direct the compressed air into the caliper
fluid inlet.
5. Remove the boot.
6. Remove the piston seal with a nonmetal tool.
142

8. Clean the bleeder valve, the caliper bore, the
caliper passages, and the piston with denatured
alcohol. Use dry, filtered, compressed air to dry
the parts and to blow out the passages.
9. Replace any piston which is scored, corroded,
or contains damage to the chrome plating.
10. Replace any caliper bore which is scored,
pitted, or corroded. Attempt to polish off any
light corrosion with a crocus cloth.
1. Lubricate the new piston seal, the caliper bore,
the piston and the seal lips on the boot with
clean brake fluid.
2. Install the piston seal being careful not to twist
the seal in the caliper bore.
156371
3. Install the boot on J 24648.
3.1. Place the large diameter of the boot over
the tool, then carefully work the smaller
diameter onto the tool.
3.2. Slide the large diameter of the boot off
the tool.
4. Install the boot in the caliper bore groove. The
lip of the boot must firmly sit in the groove.
5. Install the piston inside J 24548.

6. Install the piston halfway into the bore.
7. Remove J 24548. Make sure that the boot is
sitting firmly in the groove.

T ighten
156373
Brake Caliper Bracket Replacement

For anchor plate on-vehicle service Information, refer
to Front Suspension.
Brake Rotor Replacement

(K Models Below 8600 GVW)
Removal Procedure
Wheel Removal (Single Wheels) in Tires
and Wheels.
Caliper Replacement (Rear) or Brake Caliper
4. Remove the rotor.
5. Inspect all of the parts. Replace the parts
as necessary.
157043
1. Install the rotor to the hub and
bearing assembly.
5. Depress the brake pedal.
157043
Brake Rotor Replacement

(K Models Above 8600 GVW)
Removal Procedure
Wheel Removal (Single Wheels) in Tires
and Wheels.
Caliper Replacement (Rear) or Brake Caliper
4. Remove the nut.
5. Remove the hub/rotor retaining bolts.
156931
6. Using a wheel puller, remove the
rotor assembly.
7. Inspect all of the parts. Replace the parts
as necessary.
1. Install the hub/rotor to the hub and
bearing assembly.
2. Install the rotor and hub assembly to the axle.

Tighten
and Notices.
6. Depress the brake pedal.
157034
Refinishing Brake Rotors 3. As an alternate method, use a sanding block

with 150 grit aluminum oxide sandpaper.
You do not need to refinish the brake rotors when
doing a routine brake maintenance such as replacing 4. Sand each brake rotor surface using moderate
worn brake shoe and lining assemblies. Refinish the pressure for at least 60 seconds.
rotors only in the cases of brake pulsation, hot 5. With the brake rotor turning at about 150 RPM,
spots, or excessive scoring. sand each brake rotor surface using moderate
The brake rotors have a minimum thickness pressure for at least 60 seconds.
dimension cast into them. This dimension is the 6. Clean each brake rotor surface with denatured
minimum wear dimension, it is not a refinish alcohol or a substitute cleaner after sanding.
dimension. Do not use a brake rotor that will not
7. Locate the deepest score in the brake rotor.
meet the dimensions shown in the specifications
Turn the rotor micrometer knobs until the
chart after refinishing. Replace any rotors which are
tool bit bottoms out at the deepest point of
too thin as they will not have the proper heat
the score.
transfer capabilities. Refinishing the composite rotors
requires the use of a six lug or eight lug composite 8. Zero the scale and back out the tool bits.
rotor adapter. 9. Advance the cutter hand-wheel until the bits
An accurate control of the rotor tolerances is have cleared the inner edge of the brake
necessary for the proper performance of the disc rotor face.
brakes. Use precision equipment for all of the 10. Adjust the micrometer knobs about 0.0127 mm
machining. Service the machining equipment on a (0.005 in) more than the first reading. This will
regular basis following the manufacturer’s ensure clearing the brake rotor in one cut.
recommended maintenance procedures.
11. The finished brake rotor surface should be as
When refinishing the rotors, make sure the attaching close to that of a new brake rotor as possible.
adapters, tool holders, vibration dampeners, and tool Failure to obtain the best possible brake rotor
bits are in good condition. Make sure that all cutting finish can affect initial braking performance.
tools or bits are sharp and use only the replacement
cutting bits recommended by the equipment Ammco Brake Lathe Refinish
manufacturer, any dull or worn tools will leave a poor
surface finish that will affect the initial brake Rough Cut Finish Cut
performance. Always use vibration dampening Spindle Speed 150 RPM 150 RPM
attachments when refinishing the braking surfaces. Depth of Cut 0.127 mm 0.051 mm
The vibration dampening attachments will eliminate (Per Side) (0.005 in) (0.002 in)
tool chatter to allow for a better surface finish. Keep
the vibration dampening attachments clean and free Total Cross Feed 0.152-0.254 mm 0.051 mm
of nicks.
(Per Revolution) (0.006-0.010 in) (0.002 in) Max.
Following are two recommended procedures that
Vibration Damper Yes Yes
achieve adequate results using two different Swirl No Yes
off-vehicle drum/disc brake lathes, the Ammco Brake Patter-120 Grit
Lathe and the Accu Turn Lathe (GM dealer
equipment) off-vehicle brake drum and brake rotor Refinishing Brake Rotors
lathes. Follow the manufacturer’s instructions and
recommendations when using any other brake lathe.
Spindle Speed 150 RPM
Tool Cross Feed 0.076 mm (0.003 in)
Refinishing Procedure (Per Revolution)
1. Make the brake rotor surface non-directional. Tool Bit Nose Radius 1/64
2. Dress the brake rotor surfaces with a sanding Vibration Damper Yes
disc power tool using 120 grit aluminum oxide Swirl Patter-120 Grit Yes
sandpaper. Use a tool such as the Ammco
8350 or 8750 Safe Swirl Brake Rotor Grinder,
or the Accu Turn 433179 Non-Directional
Swirl Finisher.
Description and Operation • Use extreme care when doing any work around
antilock components in order to prevent
Disc Brakes System Description damage or misalignment.
The disc brake assembly consists of a caliper • Pump the brake pedal several times in order to
assembly, rotor, linings, anchor plate, and pads make sure it is firm prior to moving the vehicle.
mounted to the steering knuckle. The caliper mounts Do not move the vehicle until a firm pedal has
in a way that allows it to move laterally against the been obtained. Check the brake fluid level in
rotor. The caliper is a one-piece casting with the the master cylinder after pumping the brakes.
inboard side containing the piston bore. A square cut
rubber seal fits in a groove in the piston bore to
Rotor
provide a hydraulic seal and return mechanism for The front disc brakes use one of four different styles
the piston. of rotors. The smaller two wheel drive models
(C1, C2, and C3) use standard 1.250 inch rotors.
Applying the brake pedal causes the hydraulic
The heavy duty two wheel drive model (C3500 HD)
pressure that moves the caliper piston. The piston
has four wheel disc brakes with 1.435 inch rotors.
then forces the inboard brake lining assembly
The smaller four wheel drive models (K1 and K2)
against the inboard braking surface of the rotor.
use a composite rotor. The larger four wheel drive
Increasing the force against the rotor causes the
models (K2 and K3) use 1.250 inch rotors on single
caliper to move inboard. The outer brake lining
wheel models and 1.5 inch rotors on dual wheel
assembly then contacts the outboard braking surface
models. The 1.250 inch rotors are three-piece
of the rotor. The force of the two lining assemblies
assemblies consisting of a rotor, the bearings, and a
provides the desired clamping action on the rotor.
hub. Models with dual rear wheels (R05) use a
Releasing the brake pedal relieves the pressure four-piece rotor assembly consisting of a rotor, the
applied oh the piston. The square cut seal on the bearings, a hub, and an extension.
piston relaxes and the seal allows a running
The rear disc brakes use a combination rotor and
clearance between the brake lining assemblies and
the rotor. hub assembly. The rotor is integral with the rear hub.
During operation, the rotor turns between the linings
Servicing information and the basically free-wheels until the linings begin
to apply a clamping action onto the rotor, the vented
• Replace all components included in the
repair kits. area between the rotor braking surfaces allows for
efficient heat dissipation
• Lubricate the parts as specified.
• Do not use lubricated shop air on the Caliper
brake parts. Shop air can damage the The front disc brakes use three different types of
rubber components. calipers. The Delco 3400 calipers with 75 and
• If necessary, bleed all or part of the brake 80 mm single bores are used on the models with a
system after any hydraulic component has been 9600 or lower GVW rating. The Delco 3486 calipers
removed or disconnected. with an 86 mm single bore is used on models with
10,000, 11,000, and 12,000 GVW ratings. The
• Replace brake pads, shoes and linings in axle
C3500 HD model uses a Bendix® single bore
sets only.
caliper.
• The torques specified are for dry,
The rear disc brakes use a Bendix® caliper.
unlubricated fasteners.
The Delco calipers mount to the support bracket
• Perform service operations on a clean bench.
using two bolts. The Bendix® caliper mounts to the
Verify that the bench is free from mineral oil
support bracket using a support key, a spring, and a
and other contaminants.
bolt assembly.
x|
TOOL NUMBER AND TOOL NUMBER AND
ILLUSTRATION ILLUSTRATION
NAME NAME
J 8001 J 37620
Dial Indicator Set Composite Brake Rotor
Mounting Adapter
2014 156423
© 156422
J 24548
Disk Brake Piston Ring
Compressor
156420
J 38453
86 mm Caliper Piston Seal
Installer
J 36474 J 39913
75 mm Caliper Piston Seal Composite Brake Rotor
Installer Adapter
156415 156426
J 36475
80 mm Caliper Piston Seal
Installer
156417
BLANK
Brakes Drum Brakes 5-123
Drum Brakes
Specifications
Fastener Tightening Specifications (Duo-Servo Drum Brakes)

Backing Plate Mounting Bolt (JB6) 160 118 —
Backing Plate Mounting Bolt (JB7, JB8) 160 118 —
Pipe Fitting 17 13 —
Wheel Cylinder Mounting Bolt 25 18 —
Fastener Tightening Specifications (Leading/Trailing Drum Brakes)

Backing Plate Mounting Bolt 70 52 —
Pipe Fitting 17 13 —
Wheel Cylinder Mounting Bolts 20 15 —
Component Specifications (Drum Diameter)

Original Maximum Replacement (Discard)
254 (10 in) 255.30 mm (10.05 in) 356.30 mm (10.09 in)
283.21 mm (11.15 in) 284.73 mm (11.21 in) 285.50 mm (11.24 in)
330.20 mm (13 in) 331.72 mm (13.06 in) 332.49 (13.09 in)

Wheel Brake Cylinder Bolt, Bolt Kit, Bushing and Cover 4.665
Wheel Brake Cylinder Bleeder Cover and Valve 4.666
Wheel Cylinder to Brake Shoe Thrust Rod 4.675
Brake Flange Plate 5.001
Brake Shoe Kit 5.017
Brake Shoe Retracting Spring and Spring Kit 5.026
Brake Shoe Hold-Down Pin Kit 5.043
Brake Shoe Guide 5.045
Brake Shoe Anchor Pin Nut and Washer 5.056
Brake Shoe Automatic Adjusting Actuator, Bolt Kit and Pivot 5.103
Brake Shoe Automatic Adjusting Lever Link 5.105
Brake Adjuster Spring 5.107
Brake Shoe Adjuster and Washer 5.110
Brake Shoe Adjusting Screw Nut and Spring 5.111
Brake Adjusting Hole Plug 5.117
Parking Brake Lever 5.149
Parking Brake Lever Strut 5.150
Parking Brake Lever Pin 5.158
5-124 Drum Brakes Brakes
Repair Instructions When measuring a drum for out-of-round and taper,

take measurements at the open and closed edges
Brake Drum Replacement of the machined surface and at right angles to
each other.
Removal Procedure
Construction of this drum and hub assembly does
Refinishing
not allow replacement with the hub assembly If you determine a drum needs refinishing, remove
installed on the vehicle. only enough metal to obtain a true, smooth braking
surface. If a drum does not clean up when refinished
1. Raise the vehicle on a hoist and support with
to the maximum refinish diameter, replace the drum.
These guidelines are shown in Specifications at the
2. Remove the hub and drum assembly. Refer to end of this section. Removal of more metal will affect
Hub and Drum Assembly Replacement in Rear the heat dissipation and can cause drum distortion.
Drive Axle.
All brake drums have a maximum diameter cast into
3. Remove the retaining bolts, stud nuts, or them. This diameter is the maximum wear diameter
wheel studs. and not a refinish diameter. Do not refinish a brake
4. Separate the drum, hub, and oil deflector. drum that will not meet the Specifications at the end
5. Press the wheel studs out of the drum. of this section. Instead, replace the drum.
6 . Replace parts as necessary. When you refinish a brake drum, resurface the drum
to a dimension not more than 0.76 mm (0.030 in)
Installation Procedure less than the discard diameter. The refinish diameter
1. Connect the drum to the hub. is the maximum diameter the drum can be refinished
to and still allow safe braking action. If you exceed
2. Align the drain holes.
this diameter, the brake drum will wear beyond the
3. Apply a light coating of sealing compound to discard diameter during normal brake use.
the oil deflector contact surface.
Always use sharp cutting tools or bits. Dull or worn
4. Connect the oil deflector to the drum. tools leave a poor surface finish that will affect the
5. Install the retaining bolts, stud nuts, or initial braking performance. Always use vibration
wheel studs. dampening attachments when you refinish braking
6 . Press the wheel studs into the drum. surfaces. These attachments eliminate tool chatter so
you can obtain a better surface finish.
Brake Drum Inspection (Drum Servicing) The best speed for refinishing braking surfaces is a
spindle speed of 150 RPM. Crossfeed for rough
Cracked, Scored or Grooved cutting should range from 0.15 to 0.25 mm (0.006 to
A cracked drum is unsafe for further service and 0.010 in) per revolution. Finish cuts should be made
must be replaced. Do not attempt to weld a at crossfeeds no greater than 0.05 mm (0.002 in)
cracked drum. per revolution.
Smooth any slight scores. Heavy or extensive
scoring will cause excessive lining wear, and it may New Replacement Drum Refinishing
be necessary to resurface the drum braking surface. When installing new brake drums, do not refinish the
If the linings are slightly worn (but still reusable) and braking surface. These parts are already at the
the drum is grooved, polish the drum with a fine correct level of surface finish.
emery cloth, but do not refinish. Eliminating all
Balance
grooves in all drum and smoothing the ridges on the
lining would require removing too much metal and During manufacturing, weights are used to balance
lining. If left alone, the grooves and ridges match the brake drums. Do not remove these weights.
and satisfactory service can be obtained. After you refinish brake drums, or when maintaining
If you are replacing the brake linings, always refinish wheel balance is difficult, check the drums for
a grooved drum. Using a grooved drum with new balance. They can be checked on most off-vehicle
linings will wear the linings and make proper brake balancers. If found to be out of balance, replace
performance difficult to obtain. the drum.
Out-of-Round or Tapered Brake Drum Inspection (Drum Inspecting)

An out-of-round or tapered drum prevents accurate Any time you remove the brake drums, thoroughly
brake shoe adjustment and is likely to cause clean and inspect them for cracks, scores, deep
excessive wear of other brake parts due to the grooves and out-of-round.
eccentric action. An out-of-round drum can also
cause severe and irregular tire tread wear as well as Surface Finish
a pulsating brake pedal. When the drum exceeds the Slight scoring can be cleaned up with a fine emery
specification limits in taper and/or out-of-round, cloth. Heavy or extensive scoring causes lining wear.
refinish the drum to true up the braking surface. The drum braking surface will need machining to
Out-of-round and taper can be accurately measured remove these scores.
with an inside micrometer and extension rods.
If the drum is grooved, and the linings are slightly Taper Check
worn, the drum should not be machined. Instead, Measuring a drum for taper involves taking
polish the drum braking surface with a fine emery measurements at the inner and outer edges of the
cloth. Eliminating all of the drum grooves and ridges machined surface at two or more places around the
on the lining would require removing too much metal drum. These measurements should be equal.
and lining material. The grooves and ridges match
and satisfactory service can be obtained by leaving Brake Shoe Inspection
them alone.
Inspect the linings every 9,650 km (6,000 mi) and
Inside Diameter Check any time the wheels are removed (tire rotation, etc.).
Inspect the shoe and lining assemblies for wear by
Measure the inside diameter of the brake drum at
removing the brake drum. Replace shoe and lining
two or more places around the circumference of the
assemblies when the thickness of any lining is worn
braking surface. The measurements must be made
to within 0.76 mm (0.030 in) of the shoe. Replace
at the same distance in from the edge of the drum.
riveted shoe and lining assemblies when the lining is
Compare the results with the wear specifications in
worn to within 0.76 mm (0.030 in) of any rivet head.
Unit Repair at the end of this section.
Always replace shoe and lining assemblies as a
complete axle set.
Brake Lining Replacement

(Duo-Servo Drum Brakes)
Removal Procedure
QM replacement brake lining material is
recommended for all vehicles to maintain the
balance between front and rear brake performance.
GM replacement brake parts have been carefully
selected to provide the proper brake balance for the
purposes of stopping distance and control over the
full range of operating conditions. Installation of front
or rear lining material with performance different from
that of GM replacement parts recommended for this
vehicle can change the intended brake balance of
this vehicle.
1. Raise the vehicle and support the vehicle with
safety stands.
2. Mark the relationship of the wheel to the hub.
3. Remove the tire.
4. Remove the wheel. Refer Wheel Removal
(Single Wheels) or Wheel Removal (Dual Rear
Wheels) in Tires and Wheels.
5. Mark the relationship of the drum to the axle.
6 . Remove the drum.
7. Remove the return springs.
183
8. Remove the shoe guide.
185
9. Remove the hold down springs.
203
10. Remove the hold down pins.

11. Disconnect the actuator lever and the
lever pivot.
12. Remove the lever return spring.
13. Remove the actuator link.
14. Disconnect the parking brake strut and the
strut spring.
15. Remove the parking brake lever.
16. Remove the adjusting screw assembly.

17. Remove the screw spring.
18. Inspect all parts for discoloration due to heat or
stress. Replace as needed.
19. Inspect all parts for signs of wear. Replace
as needed.
20. Inspect the wheel cylinder for signs of leakage.
Refer to Wheel Cylinder Replacement
(Duo-Servo Drum Brakes).
21. Inspect the brake drum for scoring and
machining tolerance. Refer to Brake Drum
Inspection (Drum Servicing).
Important: Do not interchange the right and the left
adjusting screws.
1. Lubricate the shoe pads and adjusting screw
threads with a thin coat of white lithium grease
or equivalent.
231
2. Install the adjusting screw assembly and the
adjusting screw spring to both shoes. The coils
of the adjusting screw spring must not touch
the adjusting screw.
3. Connect the shoe assembly to the
backing plate.
207
4. Install the parking brake lever.
204
5. Install the strut spring onto the parking

brake strut.
6 . Install the parking brake strut.
204
7. Connect the actuator lever and the lever pivot.
8. Install the actuator link.
9. Install the lever return spring.

10. Install the hold down pins.
11. Install the hold down springs.
204
13. Install the return springs.

14. Install the drum. Align the marks made
during disassembly.
15. Install the tire and the wheel. Refer to Wheel
and Wheels. Align the marks made
during disassembly.
16. Adjust the rear brakes. Refer to Drum Brake
Adjustment (Duo-Servo Drum Brakes).
Brake Lining Replacement

(Leading/Trailing Drum Brakes)
Removal Procedure
GM replacement brake lining material is
recommended for all vehicles to maintain the
balance between front and rear brake performance.
GM replacement brake parts have been carefully
selected to provide the proper brake balance for the
purposes of stopping distance and control over the
full range of operating conditions. Installation of front
or rear lining material with performance different from
that of recommended GM replacement parts can
change the intended brake balance of this vehicle.
safety stands.
2. Mark the relationship of the wheel to the hub.
156770
and Wheels.
4. Mark the relationship of the drum to the axle.
5. Remove the drum. Refer to Hub and Drum
Assembly Replacement in Rear Axle.
6 . If the drum is difficult to remove, do
the following:
• Make sure the parking brake is released.
• Back off the parking brake cable adjustment.
• Remove the access hole plug from the
backing plate and insert a screwdriver
through the hole to push the parking brake
lever off the stop.
• Use a rubber mallet to tap gently on the
outer rim of the drum and/or around the
inner drum diameter. Be careful to not
deform the drum by excessive beating.
7. Remove the actuator spring and the
adjuster actuator.
8 . Raise the lever arm of the actuator until
the upper end is clear of the slot in the
adjuster screw.
9. Slide the actuator (10) off of the adjuster
pin (12).
10. Disconnect the actuator spring (13) from the
shoe (15).
11. Remove the hold-down spring assemblies (8)
and the pins.
12. Remove the lower return spring (6).
• Pull the bottom ends of the shoes apart.
• Lift the lower return spring (6) over the
anchor plate.
• Allow the shoe ends to come together.
• Release the spring.
13. Remove the shoe and lining
assemblies (1 and 15).
14. Remove the upper return spring (5).
15. Remove the adjusting screw assembly.
• Do not damage the wheel cylinder boots.
• Bring the bottom ends of the shoes together
(overlap if necessary) so the upper shoe
ends clear the wheel cylinder boots.
• Spread the bottom of the assembly to clear
the axle flange.
16. Remove the upper return spring (5).
17. Remove the adjusting screw assembly from
the shoes.
19. Remove the pin (14).
20. Remove the spring washer (3).
21. Remove the parking brake lever (2).
22. Inspect the wheel cylinder for signs of leakage.
Refer to Wheel Cylinder Replacement
(Leading/Trailing Drum Brakes).
23. Inspect the brake drum for signs of scoring and
machining tolerance. Refer to Brake Drum
Inspection (Drum Inspecting).
24. Replace any parts that show signs of
discoloration from heat, stress, or wear.
25. Inspect the threads of the adjuster screw (14)
for smooth rotation over the full length.
26. Using denatured alcohol, clean the
following components:
• The adjuster screw (14)
• The nut (10)
• The spring clip (9)
• The adjuster socket (7)
1. Install the parking brake lever (2).
2. Install the spring washer (3). The concave side
of the spring washer should face the parking
brake lever.
3. Install the pin (4).
5. Install the adjuster pin (12) in the shoe (15)
so the pin projects 6.8 to 7.0 mm
(0.268 to 0.276 in) from the side of the shoe
web where the adjuster actuator is installed.
6 . Apply brake lubricant GM P/N 5450032 or
equivalent to the threads of the adjuster
screw (14) and inside diameter and face of the
socket (7). Adequate lubrication is achieved
when there is a continuous bead of lubricant at
the open end of the adjuster nut (10) and the
socket (7) when the threads are fully engaged.
7. Install the upper return spring (5).
• Lay the shoes (1 and 15) on a clean, flat
work surface in the position they will be in
when installed on the backing plate.
• The shoe with the parking brake lever goes
to the rear of the vehicle.
Notice: Do not over-stretch the upper return
spring. Damage can occur if it is stretched to
more than 204.2 mm (8.04 inches).
8. Install the adjusting screw assembly.
• The adjusting screw assembly should engage
the adjuster shoe (1) and the parking brake
lever (2).
• The spring clip (9) must face the
backing plate.
9. Lubricate the shoe pads on the backing plate
with a thin coat of white lithium grease.
10. Install the shoe and lining
assemblies (1 and 15).
11. Install the upper return spring (5).
12. Install the adjusting screw assembly.
• Do not damage the wheel cylinder boots.
• Overlap the bottoms of the shoes so the
upper shoe ends clear the wheel
cylinder boots.
• Make sure the upper shoe ends rest on the
wheel cylinder piston ends.
• Do not place the lower shoe web ends under
the anchor plate until the lower return spring
is installed.
Notice: Do not over-stretch the lower return
spring. Damage can occur if it is stretched to
more than 107.3 mm (4.22 inches).
13. Install the lower return spring (6).
• Bring the ends of the shoe and lining
assemblies (1 and 15) together over the
anchor plate.
• Hook the spring ends to the shoe web holes.
• Spread the lower ends of the shoe and the
lining assemblies to clear the anchor plate.
• Position the shoes against the backing plate
and release them.
• Pull the spring into the groove at the bottom
of the anchor plate.
14. Connect the hold-down pins and the spring
assemblies (8).
15. Install the adjuster actuator (11) over the end of
the adjuster pin (12) so the top leg engages
the notch in the adjuster screw.
Notice: Do not over-stretch the actuator spring.
Damage can occur if it is stretched to more
than 83 mm (3.27 inches).
16. Install the actuator spring (13). The free end of
the adjuster actuator (11) must engage the
notch of the adjuster nut.
17. Connect the parking brake cable to the parking
brake lever (2).
18. Install the drum. Align the marks made
during disassembly.
19. Adjust the rear brakes. Refer to Drum Brake
Adjustment (Leading/Trailing Drum Brakes).
20. Install the tire and the wheel. Align the marks
made during disassembly. Refer to Wheel
and Wheels.
Removal Procedure
1. Remove the linings. Refer to Brake Lining
Replacement (Duo-Servo Drum Brakes).
2. Remove the wheel cylinder. Refer to Wheel
Cylinder Replacement (Duo-Servo
Drum Brakes).
5. Remove the backing plate.
1. Install the backing plate.
2. Install the bolts and the washers.
Tighten
and Notices.
3. Install the wheel cylinder. Refer to Wheel
Cylinder Replacement (Duo-Servo
Drum Brakes).
4. Install the linings. Refer to Brake Lining
5. Adjust the brakes. Refer to Drum Brake
Adjustment (Duo-Servo Drum Brakes).
Brake System Bleeding in Hydraulic Brakes.

Removal Procedure
Replacement (Leading/Trailing Drum Brakes).
2. Remove the wheel cylinder. Refer to Wheel
Cylinder Replacement
(Components-Leading/Trailing).
236
5. Remove the backing plate.
1. Install the backing plate.
2. Install the washers.
4. Install the wheel cylinder. Refer to Wheel
Cylinder Replacement (Leading/Trailing
Drum Brakes).
5. Install the Linings. Refer to Brake Lining
Replacement (Leading/Trailing Drum Brakes).
6. Install the adjust brakes. Refer to Drum Brake
Adjustment (Leading/Trailing Drum Brakes).
System Bleeding.

(Rear Axle)
Removal Procedure
1. Raise the vehicle on a hoist
2. Remove axle shaft. Refer to Axle Replacement
(11 Inch Ring Gear).
3. Remove the brake pipe from the wheel cylinder.
4. Remove the brake components from the brake
backing plate. Refer to Linings Replacement
Leading/Trailing Drum Brakes.
5. Remove the bolts and washers from the axle.
6. Remove the brake backing plate from the axle.
157327
1. Install the brake backing plate on the axle.
2. Install the bolts and washer to the brake
backing plate.
3. Install the brake components to the brake
backing plate. Refer to Linings Replacement
Leading/Trailing Drum Brakes.
4. Install the brake pipe to the wheel cylinder.
Refer to Bleeding Brake Hydraulic System in
Hydraulic Brakes for the bleeding and
adjustment procedure.
6. Install the wheel, tire, and brake drum.
Wheel Cylinder Replacement

Removal Procedure
1. Remove the shoe and linings. Refer to Brake
Lining Replacement (Leading/Trailing
Drum Brakes).
2. Clean the dirt and foreign material from around
the wheel cylinder.
3. Remove the inlet pipe. Plug the pipe to prevent
fluid loss and contamination.

5. Remove the wheel cylinder.
236
1. Install the wheel cylinder.
Tighten
and Notices.
3. Install the inlet pipe.

Tighten
Tighten the fitting to 17 N-m (13 lb ft).
4. Install the shoes and linings. Refer to Brake
Lining Replacement (Leading/Trailing
Drum Brakes).
Brake System Bleeding.

(Components-Leading/Trailing)
Removal Procedure
219
2. Remove the boots.
3. Remove the pistons.
4. Remove the seals.

5. Remove the spring assembly.
6. Inspect the cylinder bore for scoring
and corrosion.
7. Inspect the spring assembly for signs of
discoloration due to heat. Replace if necessary.
8. Clean the inside of the cylinder bore with a
crocus cloth. If the bore is still scored, replace
the wheel cylinder.
9. Clean the cylinder bore with clean brake fluid.
227
1. Lubricate the pistons, seals, and cylinder bore
with clean brake fluid.
2. Install the spring assembly.
3. Install the seals.
4. Install the pistons.
5. Install the boots.
223
Tighten
and Notices.

(Duo-Servo Drum Brakes )
Removal Procedure
2. Disconnect the brake pipe from the rear of the
master cylinder.
4. Remove the wheel cylinder.
1. Install the wheel cylinder.
Tighten
and Notices.
3. Install the brake pipe.
Tighten
Tighten the brake pipe fitting to
17 N.m (131b ft).
4. Install the linings. Refer to Brake Lining
158751
Drum Brake Adjustment Drum Brake Adjustment

(Leading/Trailing Drum Brakes) (Duo-Servo Drum Brakes)
Adjustment Procedure Adjustment Procedure
A manual adjustment of the rear drum brakes is 1. Remove the adjusting hole cover in the
required after replacing the rear linings. backing plate.
1. Remove the lanced area in the backing plate. 2. Turn the adjusting screw until the wheel can be
2. Turn the adjusting screw until the wheel can turned by hand. The brake drag should be
just be turned by hand. equal at both ends.
3. The brake drag should be equal at 3. Back off the adjusting screw 33 notches.
both wheels. Important: Brakes should have no drag after
4. Back off the adjusting screw 20 notches. the screw has been backed off about 15
Brakes should have no drag after the adjusting notches. If a heavy drag is present, refer to
screw is backed off about 10 notches. If a Park Brake Shoe Replacement in
heavy drag is still present, refer to Park Brake Parking Brake.
Cable Service/Adjustment (Adjustment). 4. Install an adjusting hole cover in the
5. Install an adjusting hole cover in the backing plate.
backing plate. 5. Check the parking brake adjustment. Refer to
6. Check the parking brake adjustment. Refer to Park Brake Cable Service/Adjustment
Park Brake Cable Service/Adjustment (Adjustment).
(Adjustment).
Description and Operation System Description

System Description
Applying the brakes causes the wheel cylinder piston
(Leading/Trailing Drum Brakes) to force the leading edge of the primary shoe and
Leading/trailing drum brakes are used on vehicles lining assembly to contact the rotating drum. The
with a 6450 pound GVW rating. Both brake shoes shoe tries to rotate with the drum and transfers force
are held against the wheel cylinder pistons by the to the secondary shoe and lining assembly through
upper return spring and the fixed anchor plate by the the star-wheel adjuster. The secondary shoe’s lining
lower return spring. Applying the brakes causes the leading edge bites into the drum and tries to rotate,
wheel cylinder pistons to move both shoes out to just like the primary shoe. Since the shoes cannot
contact the drum. With forward wheel rotation, the rotate, they wedge themselves into the drum. The
forward brake shoe wraps into the drum and rotating torque from the shoes increases the braking
becomes self-energized. force applied by the wheel cylinder. Because of this
With reverse wheel rotation, the rear brake shoe is wedging action, the design is a duo-servo, as
self-energized. Force from the brake shoes is opposed to a single-servo design where the
transferred to the anchor plate, through the backing wheel cylinder pressure alone is the source of
plate, and finally to the axle flange. Adjustment is braking force.
automatic and occurs on any brake application. It is The torque from the brake shoes is transferred
normal for the front (leading) shoe and lining through the backing plate to the axle flange. Brake
assembly to wear faster than the rear (trailing) shoe adjustments are automatic and occur during reverse
and lining assembly. brake applications except, on the Police Package
model vehicles which adjust in the forward
brake application.
BLANK
Brakes Park Brake 5-145
Park Brake
Specifications

Application N'in Lb Ft Lb In
Cable Clevis Jam Nut 37 27 —
Cable Clip Bolt 10 — 88

Drum to Yoke Bolts 37 27 ■
—
Parking Brake Lever Mounting Bolts 24 18 —
Support Plate Mounting Bolts 105 77 —
Yoke Shaft Bolt 122 90 ‘ —
Yoke Shaft Nut 475 350 —

Park Brake Alarm Switch and Connector 4.589
Parking Brake Apply Lever 4.591
Parking Brake Release Handle 4.594
Parking Brake Rod Connector, Equalizer, Nut and Retainer 4.765
Parking Brake Cable 4.779
Park Brake Cable Spring 4.784
Parking Brake Cable Bracket, Clip, Grommet, Guide and Strap 4.785
5-146 Park Brake Brakes
Diagnostic Information and Surface Finish

Procedures Slight scoring can be cleaned up with a fine emery
cloth. Heavy or extensive scoring causes excessive
Hydraulic Park Brake Diagnostic brake lining wear. The drum braking surface will
need machining to remove these scores.
Cable Inspection If the drum is grooved and the brake linings are
Check the parking brake for free operation. The slightly worn, the drum should not be machined.
brake lever must return to the released position Instead, polish the drum braking surface with a fine
without sticking or binding. If a problem is present, emery cloth. Eliminating all of the drum grooves and
check the cable routings for kinks or binding. ridges on the lining would require removing too much
metal and lining material. The grooves and ridges
Lining Inspection match and satisfactory service can be obtained by
Replace the brake shoe and the lining assemblies leaving them alone.
whenever the thickness of any lining is worn to
within 0.76 mm (0.030 in) of the shoe. For riveted Inside Diameter Check
shoe and lining assemblies, replace when the Measure the inside diameter of the brake drum at
lining is worn to within 0.76 mm (0.30 in) of any two or more places around the circumference of the
rivet head. braking surface. The measurements must be made
at the same distance in from the edge of the drum.
Drum Inspection
Any time the parking brake drum is removed, Taper Check
thoroughly clean and inspect it for cracks, scores, Measuring a drum for taper involves taking
deep grooves, and out-of-round. measurements at the inner and outer edges of the
machined surface at two or more places around
the drum.
Repair Instructions
Park Brake Shoe Replacement
Removal Procedure
1. Remove the drum. Refer to Brake
Drum Replacement.
156641
4. Disconnect the support plate and the shoe kits.

5. Remove the springs.
6. Remove the shoe kits.
7. Inspect the springs for signs of wear or
excessive heat. Replace as needed.
8. Inspect the support plate friction points for
wear. Replace if wear is excessive.
1. Connect the shoe kits to the support plate.
2. Connect the springs.
3. Install the support plate.
4. Install the shoe kits.
156625
5. Install the index lever between the shoes.

Tighten
and Notices.
7. Install the drum. Refer to Brake
Drum Replacement
156641
Park Brake Lubrication Procedure

Clean and lubricate the parking brake assembly and
cables with Lubricate GM P/N 10500109 or
equivalent. Do not allow the lubricant to contact the
drum or lining surfaces.
Park Brake Lever Replacement

Removal Procedure
The C3500HD lever looks the same as the other
models, but uses a different torque applying
lever assembly.
2. Lower the instrument panel section. Refer to
Instrument Panel Replacement in Interior Trim.
3. Disconnect the connector from the parking
brake switch.
4. Disconnect the release cable (4).
5. Remove the release handle (2).

156664
1. Install the lever assembly (1).
Tighten
and Notices.
3. Install the release handle (2).

4. Connect the release cable.
5. Connect the connector to the parking
brake switch.
6. Install the dash assembly. Refer to Instrument
Panel and Gauges.
7. Adjust the parking brake lever. Refer to Park
Brake Cable Service/Adjustment (Adjustment).
156664
Park Brake Cable Replacement

(Front Cable)
Removal Procedure
safety stands.
3. Loosen the adjusting nut at the equalizer (2).
4. Remove the connector (1).
156595
6. Bend in the retaining fingers at the
frame bracket.
7. Disconnect the front cable (2).
1. Install the front cable (2).
2. Connect the cable (2) to the parking brake
lever (1).
156595
3. Make sure all the retaining fingers are through
the hole.
156 6 6 6
4. Install the connector (1).

5. Adjust the front cable. Refer to Park Brake
Cable Service/Adjustment (Adjustment).

(Rear Cable - 1 Ton)
Removal Procedure
safety stands.
3. Loosen the nut at the equalizer.
4. Remove the connector.
5. Disconnect the rear brake assembly. Refer to
Brake Drum Replacement.
6. Bend the retaining fingers at the backing plate.
7. Disconnect the cable.
157501
1. Install the cable.
2. Connect the cable end into the backing plate.
Make sure all retaining fingers are completely
through the backing plate.
3. Connect the rear brake assembly. Refer to
Brake Drum Replacement
4. Install the connector.
5. Adjust the rear cable. Refer to Park Brake

(Parking Brake Cable)
Removal Procedure
safety stands.
3. Remove the cotter pin (4).
4. Remove the clevis pin (3).
5. Disconnect the clevis (5) and the nut (6) from
the cable.
6. Disconnect the grommet (7) from the bracket.

8. Remove the clip (5).
9. Disconnect the cable end from the lever (6).
156691
10. Disconnect the retaining fingers (1) from
the lever.
11. Remove the cable assembly.
1. Install the cable assembly (3).
2. Connect the retaining fingers (1) to the parking

brake lever.
3. Connect the cable end to the lever.
156577
4. Connect the grommet (7) to the bracket.
5. Connect the clip (5) and the bolt (4).

Tighten
Tighten the bolt to 10 N-m (88 lb in)
and Notices.
6. Connect thd nut (6) and the clevis (5) to the

park brake cable. Make sure the retaining
fingers are tight.
7. Adjust the parking brake cable. Refer to Park
Brake Cable Service/Adjustment (Adjustment)
156668

(Rear Cable - 1 /2 and 3/4 Ton)
Removal Procedure
safety stands.
3. Loosen the nut at the equalizer.
4. Remove the connector.
5. Disconnect the rear brake assembly. Refer to
Brake Drum Replacement in Drum Brakes.
6. Bend the retaining fingers at the backing plate.
7. Disconnect the cable.
1. Install the cable.
2. Connect the cable end into the backing plate.
Make sure all retaining fingers are completely
through the backing plate.
3. Connect the rear brake assembly. Refer to
Brake Drum Replacement in Drum Brakes.
4. Install the connector.
5. Adjust the rear cable. Refer to Park Brake
Brake Drum Replacement

Removal Procedure
safety stands.
3. Remove the propeller shaft. Refer to One-Piece
Propeller Shaft Replacement or Propeller Shaft
Replacement (Front Drive) in Propeller Shaft.
4. Remove the nut and washer if equipped with a
manual transmission.
5. Remove the bolt and washer if equipped with
an automatic transmission.
156611
6. Disconnect the drum and yoke assembly.
7. Remove the bolts and the washers.
8. Remove the drum from the yoke.
156609
1. Connect the drum to the yoke.
Tighten
and Notices.
3. Install the drum and the yoke assembly.
4. Install the washer and the nut if equipped with

manual transmission.
5. Install the washer and bolt is equipped with an
automatic transmission.
Tighten
• Tighten the bolt to 122 N.m (122 lb ft).
156611
Park Brake Cable Service/Adjustment

(Adjustment)
The parking brake must be adjusted any time the
parking brake cables are serviced, or the holding
ability is not adequate. Before adjusting the parking
brake, check the condition of the service brakes. The
service brakes must be adjusted properly before
adjusting the parking brake. Refer to Drum Brake
Adjustment (Leading/Trailing Drum Brakes) or Drum
Brake Adjustment (Duo-Servo Drum Brakes) in
Drum Brakes.
1. Block the front wheels.
safety stands.
3. Loosen the adjusting nut at the equalizer.
4. Set the parking brake by pushing the pedal
down 18 degrees.
• Insert a 3 mm (0.125 in) pin into locating
hole (1) in the pedal assembly.
• Push the pedal downward until the pin
contacts the parking brake outer flange.
5. Turn the adjusting nut until the wheels rotate
forward with a moderate drag.
6. Release the parking brake and rotate the rear
wheels. There should be no drag.
7. Lower the vehicle and unblock the front wheels.
Park Brake Cable Service/Adjustment
(Parking Brake Adjustment)
Tools Required
J 35999 Tension Scale
1. Remove the clevis pin (3) from the lever (2).
156668
2. Set the parking brake by pushing the pedal
down 18 degrees.
• Insert a 3 mm (.125 in) pin into locating
hole (1) in the pedal assembly
• Push the pedal down until the pin contacts
the parking brake outer flange.
3. Install J 3599 with a small length of cable or

chain, and a tightening device (like a turn
buckle) on the frame.
4. Install a small chain (6) on the lever (1) near
the spring on the bottom of the lever.
Tighten
Tighten the tightening device until J 3599 is at
222 N.m (50 lb ft).
5. Loosen the nut (4) and turn the clevis (3) until
the pin (2) slides freely in the lever (1) with all
slack removed from the cable.
6. Install the clevis pin (2) and the cotter pin.
Tighten
Tighten the nut (4) to 37 N.m (27 lb ft).
and Notices.
7. Remove J 35999 and all extensions used.
9. Rotate the drum to assure there is no drag.
Description and Operation Models with a propeller shaft parking brake use a
one-cable system. The cable connects to the
System Description front lever on one end and the rear lever on the
other end.
General Description
There are three basic types of parking brakes used.
Brake Lamp
The lower GVW models use leading/trailing rear The BRAKE warning lamp on the instrument cluster
drum brakes. The higher GVW models use turns on when the parking brake is applied. The
duo-servo rear drum brakes. The highest GVW lamp can also be turned on by the switch in the
model C3500HD has a propeller shaft parking brake combination valve and the antilock brake system.
mounted on the transmission.
Parking Brake Switch
Lever The parking brake switch is located on the lever
The parking brake lever is located on the left side of assembly. The switch serves as the device to turn
the driver’s compartment and is activated by foot on the BRAKE lamp when the parking brake is
pressure. The lever assembly has a ratchet applied and turn it off when the parking brake
mechanism in it to allow varying degrees of parking is released.
brake application. The parking brake handle on the Daytime Running Lights
instrument panel allows the driver to release the All vehicles are equipped with a daytime running
parking brake. light (DRL) system. This system uses the parking
brake switch to turn the headlamps off when the
Cable System ignition switch is ON and the parking brake is
The cable system will vary depending on the type of applied. For more information on DRL, refer to
parking brake system used. Models with rear drum Daytime Running Lamps Module and Diode Module
brakes use a system that includes one front cable Replacement in Lighting Systems.
and two rear cables. The front cable connects to the
lever on one end and the equalizer on the other
end. The rear cables attach to the equalizer on one
end and the parking brake struts in the drum brakes
on the other end.

Brakes Antilock Brake System 5-163
Antilock Brake System

Specifications

BPMV Bracket Mounting Bolts 28 21 —
Combination Valve to BPMV 16 12 —
EBCM to BPMV 5 — 39
EHCU to Bracket 9 7 —
Front Brake Line to Combination Valve 24 18 —
Front Wheel Speed Sensor Mounting Bolts (2WD) 26 19 —
Front Wheel Speed Sensor Mounting Bolts (4WD) 18 13 —
Front Wheel Speed Sensor Mounting Nuts (C 3500HD) 285 210 —

King Pin Cap to Knuckle Bolt (C 3500HD) 17 13 —
Rear Brake Line to Combination Valve 24 18 —
Splash Shield Mounting Bolts (2WD) 16 12 —
Splash Shield Mounting Bolt (C 3500HD) 17 13 —
Tube Adapters to BPMV 31 23 —

Brake Pressure Modulator Valve 4.730
Electronic Brake Control Module 4.720
Stoplamp Switch 2.447
Wheel Speed Sensor 4.710
5-164 Antilock Brake System________ Brakes

BPMV Hydraulic Flow Chart (Normal Braking Mode)
_i
184237
Legend
(1) Master Cylinder Reservoir (9) Rear Accumulator
(2) Master Cylinder (10) Right Front Dump Valve
(3) Combination valve (11) Front Brakes
(4) Right Front Isolation Valve (12) Front accumulator
(5) Rear Pump (13) Left Front Dump Valve
(6) Rear Isolation Valve (14) Left Front Isolation Valve
(7) Rear Dump Valve (15) Brake Pressure Modulator Valve (BPMV)
(8) Rear Brakes (16) Front Pump
Brakes_________________________________________________Antilock Brake System 5-165
BPMV Hydraulic Flow Chart (Isolation Mode)
184239
Legend
(1) Master Cylinder Reservoir (6) Rear Wheels
(2) Master Cylinder (7) Rear Accumulator
(3) Combination valve (8) Rear Pump
(4) Rear Isolation Valve (9) To Front Channels
5-166 Antilock Brake System Brakes
BPMV Hydraulic Flow Chart (Dump Mode)
184241
Legend
Brakes ___________ _________ ___________ Antilock Brake System 5-167
BPMV Hydraulic Flow Chart (Reapply Mode)
184243
Legend
(4) Rear isolation Valve (9) To Front Channels
BPMV Hydraulic Flow Chart (Brake Release Mode)
184863
Legend
Brakes________________________________________________ Antilock Brake System 5-169
Antilock Brakes System Schematic References
Service Category Type Number
Reference on Schematic - Service Category
Cruise Controls 8-Wiring Systems
Engine Controls 6-Engine Controls
Fuse Block Details Cell-11 8-Wiring Systems
Power Distribution Cell-10 8-Wiring Systems
Steering Controls Steering Controls
Data Link Connector (DLC) Cell 50 8-Wiring Systems
Ground Distribution Cell-14 8-Wiring Systems
Antilock Brakes System Schematic Icons

Notice: Refer t o ESD Notice.
19384
5-170
ABS Schematics (Indicator Control and Wheel Speed Sensors) (common)
I H o t In Run And S tart I | H ot At All T iro es]

----------------
Pow er — ■— IP !" Power m -“T AOe 1 Underhood
Antilock Brake System_________________________________________________ Brakes

[ G AUG ES| I Distribution N4 • )
D istribution H 8
C ell 10 r J Fuse 4 ■ I CeH10 r Fuse
J 7 ' • io a ; M 4 y 60 A
0
5 RED 442
^ Instrument
1 Cluster
27
0.5 LT GRN 867
C8: tC100
0.5 TAN/WHT 33 0.5 LT GRN 867
B Jl Cl A ! C3
A B S Indteator Pow er Sensor Low Sensor H igh Sensor H igh Sensor Low "I E le c t r o n ic
G round G round 'Brake
[ Control
Brake Lam p , Module
JndcatorOuJpi*___________________________________________ (EBCM)
E__
r ■*Daytime Cl
1 1Running
1 1Lamps
lF v J (DRL)
Module
0.5 TAN/WHT 33
0.5 TAN/WHT 33
C6 i C100
0.5 TAN/WHT 33
I d*”4
1I _2:__ 10881
0.5 PPL 1680
186 4 0 7
ABS Schematics (VSS, TCC Signal and Brake Indicator) (Gasoline Engines)
Brakes_____
( Hot In Run |
. Pow er d d a i/ c IP
1 Stoplamp 100,110
S H ? *” N 3SL 10/ Fuse
s
106,110 10 A I BlOCk
0.35 BRN 441 I Switch L —_ ____ ____ J
| (Show n W ith
l j Brake 0.35 BRN 441
Pedal
R eleased)
E v C227
0.5 PPL 420 Cm ise
D8 £ C100 S222 k ----------- > Control
C ell 34
0
0.5 PPL 420
E $ C200
0.5 BRN 441
SP101
Vehicle
0.5 PPL 420
S151 < Control S152
M odule
0.5 BRN 441 0.5 PPL 420

A C Cl
Ignition 3 Stoplam p Signal "j Electronic
Power Brake
Pum p Brake j Control
M otor Signal Indicator Serial D ata Module
(C lass 2 )
G round G round Input __________ j (EBCM)
Antilock Brake System

5-171
186408
5-172 Antilock Brake System______________________________________
ABS Schematics (VSS, TCC Signal and Brake Indicator) (Diesel Engines)
Brakes
186410
Component Locator
A ntilock Brakes System Com ponents

Automatic Transfer Case Under the LH of IP, near the 201-34 202-23
Control Module convenience center
Brake Pressure On the rear of the EBCM casting, near the
Warningl Switch brake master cylinder, at the 201-6 —
LF wheelhousing
Data Link Under the LH of the IP, at the LH of the
Connector (DLC) steering column, mounted to the bottom of 201-43 202-30
the knee bolster
Daytime Running Lamps Under the LH of the IP, taped on the IP 201-34 202-61
(DRL) Module harness
Electronic Brake Control Near the brake master cylinder at the LF 201-6 —
Module (EBCM) the wheelhousing
Electronic Variable
Orifice (EVO)/Passlock Under the center of the IP 201-40 202-31
Control Module
Front Axle Actuator At the RF of the front drive axle 201-19 202-62
Upper LH side of the IP,above the
Instrument Cluster steering 201-32 202-38
column
IP Fuse Block LH of the IP, near the LF door jamb switch 201-32 —
Powertrain Control Under the RH end of the IP, above the 201-37 —
Module (PCM) blower motor, behind the IP compartment
Stoplamp Switch At the top of the brake pedal 201-44 202-70
Underhood Fuse- At LR of the engine compartment, on 201-5 —
Relay Center the fender
Vehicle Control In the engine compartment, near the EBCM 201-37
Module (VCM) —
Vehicle Speed At the LR of the transmission 201-23

Sensor (w/RWD) —
Vehicle Speed Sensor At the LR of the transfer case 201-24 —

(w/Selectable 4WD)
Vehicle Speed Sensor Under the RH of the IP 201-37 202-70
Buffer (Diesel)
Wheel Speed Sensor, LF At the LF wheel — —
Wheel Speed At the RF wheel
Sensor, RF — —
C100 Engine Harness to the IP harness, LR of 201-8 202-0

the engine compartment, at the Bulkhead
C120 Engine Harness to the front axle actuator, 201-27 202-50
rear of the engine, near the transmission
C200 (Diesel) Behind the RH of the IP, near the heater 201-37 202-11
motor, in the foam wrap
C200 (Gas) Behind the RH of the IP, near the heater 201-37 202-10
motor, in the foam wrap
DIODE 1 In the underhood fuse-relay center, LR of —
the engine compartment, on the fender —
G105 At the RF of the engine block 201-13 —

Engine harness, approx. 25 cm from the
S107 (4.3L) EGR valve breakout, toward the tailamp — —
harness breakout
5-174 Antilock Brake System_________________________________________________ Brakes
A ntilock Brakes System Com ponents (cont’d)
S107 (5.0L.5.7L) EGR valve breakout, toward the tailamp — —
harness breakout
S107 (6.5L, HD) EBCM breakout, toward the EGR — —
valve breakout
S107 (7.4L) EBCM breakout, toward the tailamp — —
harness breakout
S111 (4.3L, 7.4L) Engine harness, approx 7 cm from the — —
EBCM breakouts
S111 (5.0L, 5.7L) EBCM breakout, toward the tailamp — —
harness breakout
S111 (6.5L) Engine harness, approx. 11 cm from the — —
EBCM breakout toward the glow plugs
Engine harness, approx. 5 cm from the fuel
S147(4.3L) injector breakout, toward the A/C — —
compressor clutch breakout
Engine harness, approx 5 cm from EGR
S147 (5.0L, 5.7L) valve breakout, toward the tailamp — —
harmess breakout
S147(6.5L) Engine harness, approx 4 cm from the — —
starter motor solenoid breakout
S150 Engine harness, approx 13 cm from the — —
EBCM breakout
S151 Engine harness, approx 7 cm from the — —
EBCM breakout
S152 (4.3L, 5.0L-LD, Engine harness, approx 7 cm from the — —
5.7L-LD, 7.4L) EBCM breakout
S152(5.0L - HD, Engine harness, approx 13 cm from the — —
5.7L - HD) EBCM breakout
S152 (6.5L) Engine harness, approx 4 cm from the IP — —
hamesss breakouut, toward the P101
S213 In the IP harness, approx 4 cm from the — —
steering column harness breakout
S222 In the IP harness, approx 20 cm from the — —
inflatable restraint switch breakout
S280 (Diesel) In the IP harness, approx 5 cm from the — —
DLC breakout
At the selectable 4WD harness, approx
S314 (K300) 5 cm from the transfer case relay breakout, — —
toward the front axle switch
Antilock Brakes System Component Views
VSSB and Low Coolant Level Ind. M odule
(1) Low Coolant Level Indicator Module

(2) Vehicle Speed Sensor Buffer (VSSB)
(3) Powertrain Control Module (PCM)
ABS Support W iring
Legend
(1) Fuel Pump Relay (8) Fuses
(2) Forward Lamp Harness (9) Brake Lamp Relay
(3) Vehicle Control Module (10) Circuit Breakers
(4) Battery (11) Starter Relay
(5) Battery Cable (12) A/C Relay
(6) Electronic Brake Control Module (13) Horn Relay
(7) Engine Harness
Brakes ____________Antilock Brake System 5-177
Antilock Brakes System Connector EBCM, Connector C2
End Views
EBCM, Connector C1
r 0 [ui] i
r a M m
n
LiJ l nLd
m m L iJ L J
v_r i_y • 12085030
62489
Connector Part
Inform ation • ASM 2F M/P 630 P2S
62473 (BLACK)
Connector Part • 12065425 Circuit
Inform ation • ASM 10F M/P 150 (BLACK) Pin Wire Color No. Function
Wire Color Circuit A RED Fuse Output - Battery -
442 Type
Pin No. Function II Fuse
A BRN 441 Type III Fuse- Ignition 3 -
Fuse Output B BLK 150 Ground
B LT GRN 867 ABS Failure Indicator

Lamp Output
EBCM, C onnector C3
C PPL 420 Stoplamp Switch Output

D BLK/WHT 1695 4WD Front Wheel Lock
Telltale Feed
E WHT EBCM to Instrument
1827 Cluster Speed Signal
F TAN/WHT 33 Lamp Output Indicator
Brake Warning
G PPL 1807 Serial Data Signal - Class

B - 10400 BAUD
H TAN/WHT 680 ABS Pressure Differential
Sensor Signal
J BLK 150 VCM/PCM Ground 68766
K — — Not Used Connector Part • 12124662
Inform ation • ASM 5F M/P 150 (BROWN)
W ire Color Circuit
Pin No. Function
A LT BLU 830 WSS Signal (LF)
C DK GRN 872 WSS Signal (RF)
D YEL 873 WSS Return (LF)
E TAN 833 WSS Return (RF)
Diagnostic Information and Intermittents and Poor Connections

Procedures Most intermittent faults are caused by a faulty
electrical connection or faulty wiring. Occasionally a
Self-Diagnostics damaged EBCM can be the cause of an intermittent
The EBCM performs self-diagnostics of the ABS. fault. Refer to Intermittents and Poor Connections in
The EBCM detects and isolates system failures. Electrical Diagnosis for a detailed explanation of how
When a malfunction is detected, the EBCM sets a to locate and repair intermittent conditions.
corresponding diagnostic trouble code (DTC). Scan Tool Diagnostics
Displaying Diagnostic Trouble Codes Refer to the Scan Tool Owner’s Manual for
Read DTCs using a Scan Tool. No provisions are information about the Scan Tool and the
made for Flash Code DTCs. various modes.
Clearing Diagnostic Trouble Codes

Use a Scan Tool in order to erase the DTCs in the
EBCM memory. Verify proper system operation and
absence of DTCs when the clearing procedure
completes. The EBCM will not permit DTC clearing
until all DTCs have been displayed. Also, DTCs
cannot be cleared by unplugging the EBCM, by
disconnecting the battery cables, or by turning the
ignition OFF.
ABS Diagnostic System Check
| h o < At A l Tlro asl |H o t In Runl
191485
System Description Test Description

The diagnostic system check is an organized The numbers below refer to the steps in the
approach to identifying an Antilock Brake System diagnostic table:
(ABS) malfunction. The diagnostic system check 3. This step checks for normal ABS indicator
must be the starting point for any ABS complaint lamp operation.
diagnosis. The diagnostic system check directs the
4. This step checks for ignition voltage at
service technician to the next logical step in
the EBCM.
diagnosing the complaint. Refer to the appropriate
table (below) for Gas, or Diesel engines. 5. This step checks for high resistance in the
ground circuit.
Diagnostic serial data is transmitted/received by the
EBCM through connector C1, terminal F (with 9. This step checks for high resistance in the
Diesel), or terminal G (with Gas). The EBCM is ignition voltage circuit.
supplied switched ignition voltage through connector 10. This step checks for a short to ground in the
C1, terminal A, and ground is provided through ignition voltage circuit.
connector C1, terminal J. 11. This step decides between ABS indicator lamp
on always, or off always as the symptom.
Diagnostic Aids
15. This step decides between a short to ground in
Excessive resistance in the ground or power supply the 10-way EBCM harness/connector, or an
circuits will not allow communication with the EBCM. internal EBCM fault.
If communication with the EBCM is not possible,
ensure that the ABS ground connection is good and
that there is no excessive resistance in any of the
power supply circuits.
ABS D iagnostic System Check
1. Verify that all of the EBCM connectors are
connected properly.
2. Install the Scan Tool.
1 3. Turn the ignition to RUN. —
4. Attempt to communicate with the EBCM using the
Scan Tool.
Is data being received from the EBCM? Go to Step 2 Go to Step 4
Using the Scan Tool, check for any DTCs.
2 —
Are any current or history DTCs displayed? Refer to DTC List Go to Step 3
1. Turn the ignition to OFF for 10 seconds.
2. Turn the ignition to RUN and observe the ABS System is
3 indicator lamp. — operating
Did the ABS indicator lamp turn on for three seconds and normally. Refer to
then turn off? Diagnostic Aids. Go to Step 11
1. Turn the ignition to OFF.
2. Disconnect the 10-way EBCM harness connector.
3. Turn the ignition to RUN.
4 4. Measure the voltage between the 10-way EBCM 10-15V
harness connector terminal A and ground using
a J 39200.
Is the voltage measured within the specified range? Go to Step 5 Go to Step 9
5 Cautions and Notices. 0-2D
3. Using a J 39200, measure the resistance between
the negative battery terminal and,the 10-way EBCM
harness connector terminal J.
Is the resistance measured within the specified range? Go to Step 6 Go to Step 12
1. Inspect the EBCM terminals and the EBCM harness
connector terminals for poor terminal contact.
2. Inspect the battery terminals and the battery cable
6 —
terminals for poor connection. Refer to Checking
Terminal Contact in Electrical Diagnosis.
Is the terminal contact or the connection poor? Go to Step 7 Go to Step 8
Replace the terminals or Repair the poor connection.
7 — —
Reconnect the EBCM connectors and the battery cables. Refer to Wiring
Are the EBCM connectors and the battery Systems for serial
8 — —
cables reconnected? data circuit
diagnosis
1. Disconnect the positive battery cable.
2. Turn the ignition to RUN. (This is to provide
circuit continuity.)
9 3. Using a J 39200, measure the resistance between 0-2Q
the positive battery cable and the 10-way EBCM
connector terminal A.
Is the resistance measured within the specified range? Go to Step 10 Go to Step 13
Brakes_________________________________________________Antilock Brake System 5-181
ABS Diagnostic System Check (cont’d)
S te p A c tio n Value(s) Yes No
2. Remove the BRAKE fuse 18.
10 3. Using a J 39200, measure the resistance between OL
the 10-way EBCM connector terminal A and ground.
Is the resistance measurement equal to the
specified value? Go to Step 15 Go to Step 14
Observe the ABS indicator lamp. Go to ABS Go to ABS
11 Does the ABS indicator lamp stay on? — Indicator On No Indicator Off No
DTC Set DTC Set
Repair open or high resistance in CKT 150.
12 — — ,
1. Repair open or high resistance in CKT 441.
13 2. Check the BRAKE fuse 18. — —

1. Repair short to ground in CKT 441.
14 2. Check the circuit breaker for damage. — —
Inspect CKT 441 and the 10-way EBCM harness connector
for physical damage which may result in a short to ground
15 with the 10-way EBCM harness connector connected to —
the EBCM.
Is there evidence of damage? Go to Step 16 Go to Step 17
Repair the terminals which are damaged.
16 — —
1. Replace the EBCM.
17 2. Check the BRAKE fuse 18 for an open. — —

DTC List DTC List (cont’d)

DTC Definition DTC Definition
DTC C0221 RF Wheel DTC C0241-C0254 EBCM
DTC C0221 DTC C0245
Speed Sensor Circuit Open Control Valve Circuit
DTC C0222 DTC C0246
Speed Signal Missing Control Valve Circuit
DTC C0223 DTC C0247
Speed Signal Erratic Control Valve Circuit
DTC C0225 LF Wheel DTC C0241-C0254 EBCM
DTC C0225 DTC C0248
Speed Sensor Circuit Open Control Valve Circuit
DTC C0226 DTC C0251
Speed Signal Missing Control Valve Circuit
DTC C0227 DTC C0252
Speed Signal Erratic Control Valve Circuit
DTC C0229 Drop Out of DTC C0241-C0254 EBCM
DTC C0229 DTC C0253
Front Wheel Speed Signals Control Valve Circuit
DTC C0235 Rear Wheel DTC C0241-C0254 EBCM
DTC C0254
DTC C0235 (Gas) Speed Signal Circuit Control Valve Circuit
Open (Gas) DTC C0265 or C0266
DTC C0265
DTC C0235 Rear Wheel EBCM Relay Circuit
DTC C0235 (Diesel) Speed Signal Circuit DTC C0265 or C0266
Open (Diesel) DTC C0266
EBCM Relay Circuit
DTC C0236 Rear Wheel DTC C0267 or C0268 Pump
DTC C0236 (Gas) Speed Signal Circuit DTC C0267
Motor Circuit Open/Shorted
Missing (Gas)
DTC C0267 or C0268 Pump
DTC C0236 Rear Wheel DTC C0268
Motor Circuit Open/Shorted
DTC C0236 (Diesel) Speed Signal Circuit
Missing (Diesel) DTC C0271-C0273 EBCM
DTC C0271
Malfunction
DTC C0237 Rear Wheel
DTC C0237 (Gas) DTC C0271-C0273 EBCM
Speed Signal Erratic (Gas) DTC C0272
Malfunction
DTC C0237 Rear Wheel
DTC C0237 (Diesel) DTC C0271-C0273 EBCM
Speed Signal Erratic (Diesel) DTC C0273
Malfunction
DTC C0238 Wheel Speed
DTC C0238 (Gas) DTC C0269 or C0274
Mismatch (Gas)
DTC C0274 Excessive
DTC C0238 Wheel Speed Dump/lsolation Time
DTC C0238 (Diesel)
Mismatch (Diesel)
DTC C0281 Brake Switch
DTC C0241-C0254 EBCM DTC C0281
DTC C0241 Circuit
Control Valve Circuit
DTC C0286 ABS Indicator
DTC C0242 Lamp Circuit Shorted to B+
DTC C0288 Brake Warning
DTC C0243 Lamp Circuit Shorted to B+
DTC C0241-C0254 EBCM
DTC C0244
DTC C0221 RF Wheel Speed Sensor Circuit Open
Circuit Description Conditions for Clearing the DTC

The wheel speed sensor coil emits an • Repair the conditions responsible for setting
electromagnetic field. A toothed ring on the wheel the DTC
passes by the wheel speed sensor and disrupts this • Use the Scan Tool Clear DTCs function
electromagnetic field. The disruption in the field
causes the wheel speed sensor to produce a Diagnostic Aids
sinusoidal (AC) voltage signal. The frequency and Any of the following conditions may cause an
amplitude of the sinusoidal (AC) voltage signal are intermittent malfunction:
proportional to the speed of the wheel. The
amplitude of the wheel speed signal is also directly • A poor connection
related to the distance between the wheel speed • Wire insulation that is rubbed through
sensor coil and the toothed ring. This distance is • A wire breaks inside the insulation
referred to as the air gap. Thoroughly check any circuitry that is suspected of
causing the intermittent complaint for the
Conditions for Setting the DTC following conditions:
• No output signal from the right front wheel
• Backed out terminals
speed sensor for 1.0 second
• Improper mating
• Excessive right front wheel speed sensor
resistance for 1.0 second • Broken locks
• Improperly formed or damaged terminals
Action Taken When the DTC Sets • Poor terminal to wiring connections
• The ABS indicator lamp turns on • Physical damage to the wiring harness
• The ABS disables If the customer says that the ABS indicator lamp is
DTC C0221 is a Condition Latched DTC, which on only during humid conditions such as rain, snow,
indicates that the above actions remain true only as or vehicle wash, then thoroughly inspect all wheel
long as the condition persists. speed sensor circuits for signs of water intrusion.
Use the following procedure: DTC C0221 RF Wheel Speed Sensor
1. Spray the suspected area with a 5% salt Circuit Open
water solution (two teaspoons of salt to 12 oz. •c •F Ohms
of water)
Temperature vs Resistance Values (Approximate)
2. Drive the vehicle above 24 km/h (15 mph) for at
-40 to 4 -40 to 40 702 to 1060
least 30 seconds
If the DTC returns, replace the suspected harness. 5 to 43 41 to 110 855 to 1230
When inspecting a wheel speed sensor, inspect the 44 to 93 111 to 200 1000 to 1440
sensor terminals and the harness connector for 94 to 150 201 to 302 1170 to 1661
corrosion. If evidence of corrosion exists, then
replace the wheel speed sensor. Refer to Wheel Test Description
Speed Sensor Replacement (2WD (except The numbers below refer to the steps in the
C3500HD)), or Wheel Speed Sensor Replacement diagnostic table:
(4WD), or Wheel Speed Sensor Replacement
2. This step checks the resistance of the right
(C 3500HD). front wheel speed sensor circuit.
Resistance of the wheel speed sensor will increase 3. This step checks for continuity in the right front
with an increase in sensor temperature. Refer to the wheel speed sensor harness.
following tables for temperature/resistance values. 4. - This step checks the resistance of the right
front wheel speed sensor.
WSS Temperature vs. Sensor Resistance
(2WD only)
*C *F Ohms
-40 to 4 -40 to 40 1575 to 2420
5 to 43 41 to 110 1980 to 2800
44 to 93 111 to 200 2250 to 3280
94 to 150 201 to 302 2750 to 3850
DTC C0221 RF Wheel Speed Sensor Circuit Open

Was the Diagnostic System Check performed? Go to ABS
1 — Diagnostic
3. Using a J 39200, measure the resistance
between terminals C and E of the 4-way EBCM
2 harness connector. —
Is the resistance measurement within the specified range?

(Refer to the tables on the facing page for applicable
sensor resistance values. The values in these tables are
for the resistance of the sensor, not the air temperature.) Go to Step 5 Go to Step 3
1. Disconnect the right front wheel speed sensor
harness connector from the wheel speed sensor.
2. Using a J 36169-A connect terminal A and terminal B
of the 2-way wheel speed sensor harness connector
3 (chassis harness side). 0-2 Q
between terminals C and E of the 4-way EBCM
harness connector.
Is the resistance measurement within the specified range? Go to Step 4 Go to Step 10
B ra k e s _______________________________________________ Antilock Brake System 5-185
DTC C0221 RF Wheel Speed Sensor Circuit Open (cont’d)
Using a J 39200, measure the resisatnce between
teminals A and B of the right front wheel speed
sensor connector.
4 Is the resistance measurement within the specified range? —
Inspect the 4-way EBCM harness connector for poor
5 terminal contact or corrosion. —
Does damage or corrosion exist? Go to Step 8 Go to Step 6
1. Reconnect all connectors.
6 2. Test drive the vehicle above 24 km/h (15 mph). —
Does the DTC set as a current DTC? Go to Step 9 Go to Step 7
1. Malfunction is intermittent.
2. Inspect all connectors and harnesses for damage
which may result in high resistance when all
7 components are connected. Refer to Diagnostic Aids — —
on the facing page for more information. Go to ABS
3. Perform all necessary repairs. Diagnostic
Is the repair complete? System Check
Make necessary repairs to the 4-way EBCM Go to ABS
8 harness connector. — Diagnostic —
Replace the EBCM. Go to ABS
9 Is the repair complete? — Diagnostic —
System Check
Repair the open or high resistance in CKT 833 or Go to ABS
10 CKT 872. — Diagnostic —

Replace the wheel speed sensor. Go to ABS
System Check
DTC C0222 RF Wheel Speed Signal Missing
The wheel speed sensor coil emits an • The ABS indicator lamp turns on
electromagnetic field. A toothed ring on the wheel • The ABS disables
passes by the wheel speed sensor and disrupts this
DTC C0222 is an Ignition Latched DTC, which
indicates that the above actions remain true until the
causes the wheel speed sensor to produce a
ignition is turned to OFF (even if the cause of the
sinusoidal (AC) voltage signal. The frequency and
DTC is intermittent).
amplitude of the sinusoidal (AC) voltage signal are
proportional to the speed of the wheel. The Conditions for Clearing the DTC
amplitude of the wheel speed signal is also directly
related to the distance between the wheel speed • Repair the conditions responsible for setting
sensor coil and the toothed ring. This distance is the DTC
referred to as the air gap. • Use the Scan Tool Clear DTCs function
Conditions for Setting the DTC Diagnostic Aids

• The right front wheel speed is less than Any of the following conditions may cause an
6 km/h (4 mph) intermittent malfunction:
• All other wheel speeds are greater than • A poor connection
13 km/h (8 mph) • Wire insulation that is rubbed through
• No unexpected wheel acceleration/deceleration. • A wire breaks inside the insulation
Anything that keeps the right front wheel speed
sensor low while the vehicle is moving above
13 km/h (8 mph).
Thoroughly check any circuitry that is suspected of WSS Temperature vs. Sensor Resistance
causing the intermittent complaint for the (2WD only)
*c *F Ohms
• Improper mating
-40 to 4 -40 to 40 1575 to 2420
• Broken locks
5 to 43 41 to 110 980 to 2800
44 to 93 111 to 200 2250 to 3280
• Poor terminal to wiring connections
94 to 150 201 to 302 2750 to 3850
• Physical damage to the wiring harness
If the customer says that the ABS indicator lamp is
on only during humid conditions such as rain, snow,
or vehicle wash, then thoroughly inspect all wheel *C *F Ohms
speed sensor circuits for signs of water intrusion. Temperature vs Resistance Values (Approximate)
Use the following procedure:
-40 to 4 -40 to 40 702 to 1060
1. Spray the suspected area with a 5% salt
5 to 43 41 to 110 855 to 1230
water solution (two teaspoons of salt to 12 oz.
of water) 44 to 93 111 to 200 1000 to 1440
2. Drive the vehicle above 24 km/h (15 mph) for at 94 to 150 201 to 302 1170 to 1661
least 30 seconds
If the DTC returns, replace the suspected harness. Test Description
When inspecting a wheel speed sensor, inspect the The numbers below refer to the steps in the
sensor terminals and the harness connector for diagnostic table:
3. This step checks the resistance of the right
replace the wheel speed sensor. Refer to Wheel
Speed Sensor Replacement (2WD (except
C3500HD)), or Wheel Speed Sensor Replacement 4. This step checks the voltage output of the right
(4WD), or Wheel Speed Sensor Replacement front wheel speed sensor.
(C 3500HD). 5. This step checks for a short in the wiring
Resistance of the wheel speed sensor will increase between the wheel speed sensor circuits.
with an increase in sensor temperature. Refer to the 6. This step checks for a short to ground in the
following tables for temperature/resistance values. right front wheel speed sensor circuits.

1 — Diagnostic
2. Inspect the right front wheel speed sensor,
sensor wire and the connectors for signs of damage
or corrosion.
3. Inspect the wheel speed sensor and the toothed ring
2 —
for looseness. Any deviation will affect the wheel
speed sensor output signal.
4. Inspect the 4-way EBCM harness connector and
harness for signs of damage or corrosion.
Can you observe physical damage? Go to Step 8 Go to Step 3
1. Disconnect the right front wheel speed sensor
harness connector from the wheel speed sensor.
terminal A and terminal B of the right front wheel
3 speed sensor connector. —
(Refer to the table on the previous page for applicable
for the temperature of the sensor, not the air temperature.) Go to Step 4 Go to Step 9
DTC C0222 RF Wheel Speed Signal Missing (cont’d)
1. With the J 39200 still connected, select the A/C
voltage scale.
2. Spin the wheel by hand while observing the 100 mV
4
voltage reading.
Is the voltage measured equal to or greater than the
1. Disconnect the 4-way EBCM harness connector from
the EBCM.
5 terminal C and terminal E of the 4-way EBCM OL
harness connector.
1. Reconnect the right front wheel speed sensor.
6 terminal C of the 4-way EBCM harness connector OL
and ground.
1. Inspect the 4-way EBCM harness connector
terminal C and terminal E for poor terminal contact
or corrosion.
2. Inspect CKT 833 and CKT 872 for damage that
could result in a shorted circuit. Repair any
evident damage.
7 3. Replace the terminals if poor contact or —
corrosion exists.
4. Reconnect all the connectors.
5. Clear all DTCs using the Scan Tool.
6. Test drive the vehicle above 24 km/h (15 mph).
Make the necessary repairs. Go to ABS
System Check
Replace the right front wheel speed sensor. Go to ABS
System Check
System Check
Repair the short between CKT 833 and CKT 872. Go to ABS
System Check
Repair the short to ground in CKT 833 or CKT 872. Go to ABS
System Check
Malfunction is intermittent. Inspect all connectors for
damage which may result in high resistance when all
components are connected. Refer to Diagnostic aids on
13 the facing page for more information. Repair all — •—
Go to ABS
damage found. Diagnostic
DTC C0223 RF Wheel Speed Signal Erratic

The wheel speed sensor coil emits an . The ABS indicator lamp turns on
passes by the wheel speed sensor and disrupts this DTC C0223 is an Ignition Latched DTC, which
electromagnetic field. The disruption in the field indicates that the above actions remain true until the
causes the wheel speed sensor to produce a ignition is turned to OFF (even if the cause of the
• Repair the conditions responsible for setting
related to the distance between the wheel speed
the DTC
sensor coil and the toothed ring. This distance is

• The average wheel speed for all wheel signals Any of the following conditions may cause an
is greater than 40 km/h (25 mph). intermittent malfunction:
• The average right front wheel speed is greater • A poor connection
than 40 km/h (25 mph). • Wire insulation that is rubbed through
• No speed signal input to the EBCM from the • A wire breaks inside the insulation
right front wheel speed sensor for 15ms.
Anything which suddenly prevents (intermittent)
the right front wheel speed signal to drop to
zero while the vehicle is moving greater than
40 km/h (25 mph).
*c •F Ohms
• Improper mating
-40 to 4 -40 to 40 1575 to 2420
• Broken locks
5 to 43 41 to 110 1980 to 2800
44 to 93 111 to 200 2250 to 3280
94 to 150 201 to 302 2750 to 3850
-40 to 4 -40 to 40 702 to 1060
water solution (two teaspoons of salt to 12 oz. 5 to 43 41 to 110 855 to 1230
of water) 44 to 93 111 to 200 1000 to 1440
least 30 seconds
corrosion. If evidence of corrosion exists, then 2. This step checks the EBCM 4-w ay connector
replace the wheel speed sensor. Refer to Wheel for looseness, corrosion, etc.
Speed Sensor Replacement (2WD (except 3. This step uses the wheel speed sensor
C3500HD)), or Wheel Speed Sensor Replacement resistance check to help isolate an
(4WD), or Wheel Speed Sensor Replacement intermittent connection.
(C 3500HD). 4. This step checks the right front wheel speed
Resistance of the wheel speed sensor will increase sensor for the proper resistance.
with an increase in sensor temperature. Refer to the 5. This step checks for proper mounting and
following tables for temperature/resistance values. orientation of the right front wheel
speed sensor.

1 — Diagnostic
2. Disconnect the 4-way EBCM harness connector
from the EBCM and inspect for signs of damage
2 or corrosion. —
3. Inspect the wheel speed sensor harness and sensor
harness connector for signs of damage or corrosion.
Are all connections clean and tight? Go to Step 3 Go to Step 6
Using a J 39200, measure the resistance between
terminals C and E of the 4-way EBCM harness connector.
Wiggle the WSS harness in various locations between the
sensor and the EBCM while performing this measurement.
3 Is the resistance measurement within the specified range —
without fluctuation when the harness is wiggled? (Refer to
the tables on the previous page for applicable sensor
resistance values. The values in these tables are for the
temperature of the sensor, not the air temperature.) Go to Step 5 Go to Step 4
Brakes___________________________ _________ ___________ Antilock Brake System 5-191
DTC C0223 RF Wheel Speed Signal Erratic (cont’d)
Stop Action Value(s) Yes No
1. Disconnect the wheel speed sensor from the wheel
speed sensor harness connector.
terminals A and B of the right front wheel
4 speed sensor. —
(Refer to the tables on the previous page for applicable
2. Remove tire and wheel. Refer to Wheel Removal
Wheel Removal.
3. Remove the hub and rotor. Refer to Brake
Rotor Replacement Brake Rotor Replacement
5 (Front Wheel). —
4. Verify that the front wheel speed sensor is
securely mounted and that the tone wheel is in
good condition.
Is the wheel speed sensor and tone wheel in
good condition? Go to Step 9 Go to Step 10
Repair the open, high resistance or short in CKTs 833 Go to ABS
7 or 872. — Diagnostic —
Replace the right front wheel speed sensor. Go to ABS
System Check
9 the facing page for more information. Repair all — —
Go to ABS
Make necessary repairs. Go to ABS
System Check
DTC C0225 LF Wheel Speed Sensor Circuit Open
referred to as the air gap. Thoroughly check any circuitry that is suspected
of causing the intermittent complaint for the
• No output signal from the left front wheel speed
sensor for 1.0 second
• Improper mating
• Excessive left front wheel speed sensor
resistance for 1.0 second • Broken locks
Action Taken When the DTC Sets • Poor terminal to wiring connections
• The ABS indicator lamp turns on
• The ABS disables
DTC C0225 is a Condition Latched DTC, which
indicates that the above actions remain true only as
long as the condition persists.
If the customer says that the ABS indicator lamp is DTC C0225 LF Wheel Speed Sensor Circuit
on only during humid conditions such as rain, snow, Open
or vehicle wash, then thoroughly inspect all wheel
speed sensor circuits for signs of water intrusion. •C *F Ohms
Use the following procedure: Temperature vs Resistance Values (Approximate)
1. Spray the suspected area with a 5% salt -40 to 4 -40 to 40 702 to 1060
of water)
44 to 93 111 to 200 1000 to 1440
2. Drive the vehicle above 24 km/h (15 mph) for at 1170 to 1661
94 to 150 201 to 302
least 30 seconds
2. This step checks the resistance of the left front
replace the wheel speed sensor. Refer to Wheel wheel speed sensor circuit.
3. This step checks for continuity in the left front
C3500HD)), or Wheel Speed Sensor Replacement
wheel speed sensor harness.
(C 3500HD). 4. This step checks the resistance of the left front
wheel speed sensor.
Resistance of the wheel speed sensor will increase
with an increase in sensor temperature. Refer to the
following tables for temperature/resistance values.

(2WD only)
*C *F Ohms
-40 to 4 -40 to 40 1575 to 2420
5 to 43 41 to 110 1980 to 2800
44 to 93 111 to 200 2250 to 3280
94 to 150 201 to 302 2750 to 3850
DTC C0225 LF Wheel Speed Sensor Circuit Open

1 — Diagnostic
between terminals D and A of the 4-way EBCM
2 harness connector. —

1. Disconnect the left front wheel speed sensor harness
connector from the wheel speed sensor.
2. Using a J 36169-A connect terminals A and B of the
2-way wheel speed sensor harness connector
3 (chassis harness side). 0-2 Q
between terminals D and A of the 4-way EBCM
harness connector.
5-194 Antilock Brake System__________________________________________ Brakes
DTC C0225 LF Wheel Speed Sensor Circuit Open (cont’d)
terminals A and B of the left front wheel speed
sensor connector.
4 Is the resistance measurement within the specified range? —
Inspect the 4-way EBCM harness connector for poor
5 terminal contact or corrosion. —
Does damage or corrosion exist? Go to Step 8 Go to Step 6
6 2. Test drive the vehicle above 24 km/h (15 mph). —
1. Malfunction is intermittent.
2. Inspect all connectors and harnesses for damage
which may result in high resistance when all
7 components are connected. Refer to Diagnostic Aids — —
on the facing page for more information. Go to ABS
3. Perform all necessary repairs. Diagnostic
System Check
Repair the open or high resistance in CKT 830 or Go to ABS
10 CKT 873. — Diagnostic —
Replace the wheel speed sensor. Go to ABS
System Check
DTC C0226 LF Wheel Speed Signal Missing

passes by the wheel speed sensor and disrupts this DTC C0226 is an Ignition Latched DTC, which
electromagnetic field. The disruption in the field indicates that the above actions remain true until the
causes the wheel speed sensor to produce a ignition is turned to OFF (even if the cause of the
sinusoidal (AC) voltage signal. The frequency and DTC is intermittent).
the DTC
sensor coil and the toothed ring. This distance is

• The left front wheel speed is less than Any of the following conditions may cause an
6 km/h (4 mph) intermittent malfunction:
• All other wheel speeds are greater than • A poor connection
13 km/h (8 mph) • Wire insulation that is rubbed through
• No unexpected wheel acceleration/deceleration. • A wire breaks inside the insulation
Anything that keeps the left front wheel speed
sensor low while the vehicle is moving above
13 km/h (8 mph).
Thoroughly check any circuitry that is suspected of Resistance of the wheel speed sensor will increase
causing the intermittent complaint for the with an increase in sensor temperature. Refer to the
following conditions: following tables for temperature/resistance values.
• Improper mating
• Broken locks *c *F Ohms
• Improperly formed or damaged terminals Temperature vs Resistance Values (Approximate)
• Poor terminal to wiring connections -40 to 4 -40 to 40 1575 to 2420
• Physical damage to the wiring harness 5 to 43 41 to 110 1980 to 2800
If the customer says that the ABS indicator lamp is 44 to 93 111 to 200 2250 to 3280
on only during humid conditions such as rain, snow, 94 to 150 201 to 302 2750 to 3850
or vehicle wash, then thoroughly inspect all wheel
speed sensor circuits for signs of water intrusion.
1. Spray the suspected area with a 5% salt •c *F Ohms
water solution (two teaspoons of salt to 12 oz. Temperature vs Resistance Values (Approximate)
of water) -40 to 4 -40 to 40 702 to 1060
least 30 seconds
44 to 93 111 to 200 1000 to 1440
If the DTC returns, replace the suspected harness.
94 to 150 201 to 302 1170 to 1661
When inspecting a wheel speed sensor, inspect the
sensor terminals and the harness connector for
corrosion. If evidence of corrosion exists, then Test Description
replace the wheel speed sensor. Refer to Wheel The numbers below refer to the steps in the
Speed Sensor Replacement (2WD (except diagnostic table:
C3500HD)), or Wheel Speed Sensor Replacement 3. This step checks the resistance of the left front
wheel speed sensor.
(C 3500HD).
4. This step checks the voltage output of the left
5. This step checks for a short in the wiring
between the wheel speed sensor circuits.
6. This step checks for a short to ground in the
left front wheel speed sensor circuit.

1 — Diagnostic
2. Inspect the left front wheel speed sensor,
sensor wire and the connectors for signs of damage
or corrosion.
2 3. Inspect the wheel speed sensor and the toothed ring
—
for looseness. Any deviation will affect the wheel
speed sensor output signal.
4. Inspect the 4-way EBCM harness connector and
Can you observe physical damage? Go to Step 8 Go to Step 3
Brakes ___ __ Antilock Brake System 5-197
DTC C0226 LF Wheel Speed Signal Missing (cont’d)
1. Disconnect the left front wheel speed sensor harness
connector from the wheel speed sensor.
terminals A and B of the left front wheel speed
3 sensor connector. —
(Refer to the table on the previous page for applicable
1. With the J 39200 still connected, select the A/C
voltage scale.
2. Spin the wheel by hand while observing the
4 100 mV
voltage reading.
Is the voltage measured equal to or greater than the
the EBCM.
5 between terminals D and A of the 4-way EBCM OL
harness connector.
1. Reconnect the left front wheel speed sensor.
6 terminal D of the 4-way EBCM harness connector
OL
and ground.
1. Inspect the 4-way EBCM harness connector
terminal D and terminal A for poor terminal contact
or corrosion.
2. Inspect CKT 830 and CKT 873 for damage that
could result in a shorted circuit. Repair any
evident damage.
7 3. Replace the terminals if poor contact or —
corrosion exists.
Make the necessary repairs. Go to ABS
System Check
Replace the left front wheel speed sensor. Go to ABS
System Check
System Check
5-198 Antilock Brake System_________________________________________________Brakes
DTC C0226 LF Wheel Speed Signal Missing (cont’d)
Repair the short between CKT 830 and CKT 873. Go to ABS
System Check
Repair the short to ground in CKT 873. Go to ABS
System Check
13 the facing page for more information. Repair all — —
Go to ABS
DTC C0227 LF Wheel Speed Signal Erratic
passes by the wheel speed sensor and disrupts this
indicates that the above actions remain true until the
causes the wheel speed sensor to produce a
ignition is turned to OFF (even if the cause of the
sensor coil and the toothed ring. This distance is the DTC

• The average wheel speed for all wheel signals Any of the following conditions may cause an
is greater than 40 km/h (25 mph). intermittent malfunction:
• The average left front wheel speed is greater • A poor connection
than 40 km/h (25 mph). • Wire insulation that is rubbed through
• No speed signal input to the EBCM from the • A wire breaks inside the insulation
left front wheel speed sensor for 15ms.
Anything which suddenly prevents (intermittent)
the left front wheel speed signal to drop to zero
while the vehicle is moving greater than
40 km/h (25 mph).
*c *F Ohms
• Improper mating
-40 to 4 -40 to 40 1575 to 2420
• Broken locks
5 to 43 41 to 110 1980 to 2800
44 to 93 111 to 200 2250 to 3280
94 to 150 201 to 302 2750 to 3850
-40 to 4 -40 to 40 702 to 1060
of water) 44 to 93 111 to 200 1000 to 1440
least 30 seconds
2. This step checks the EBCM 4-w ay connector
for looseness, corrosion, etc.
C3500HD)), or Wheel Speed Sensor Replacement 3. This step uses the wheel speed sensor
(4WD), or Wheel Speed Sensor Replacement resistance check to help isolate an intermittent
(C3500HD). connection.
Resistance of the wheel speed sensor will increase 4. This step checks the left front wheel speed
with an increase in sensor temperature. Refer to the sensor for the proper resistance.
following tables for temperature/resistance values. 5. This step checks for proper mounting and
orientation of the left front wheel speed sensor.

1 — Diagnostic
from the EBCM and inspect for signs of damage
2 or corrosion. —
3. Inspect the wheel speed sensor harness and sensor
harness connector for signs of damage or corrosion.
Are all connections clean and tight? Go to Step 3 Go to Step 6
terminate D and A of the 4-way EBCM harness connector.
Wiggle the WSS harness in various locations between the
sensor and the EBCM while performing this measurement.
3 Is the resistance measurement within the specified range —
without fluctuation when the harness is wiggled? (Refer to
the tables on the previous page for applicable sensor
resistance values. The values in these tables are for the
temperature of the sensor, not the air temperature.) Go to Step 5 Go to Step 4
Brakes________________________________________________ Antilock Brake System 5-201
DTC C0227 LF Wheel Speed Signal Erratic (cont’d)
1. Disconnect the wheel speed sensor from the wheel
speed sensor harness connector.
between terminals A and B of the left front wheel
4 speed sensor. —
(Refer to the tables on the previous page for applicable
2. Remove tire and wheel. Refer to Wheel Removal
(Single Wheels).
3. Remove the hub and rotor. Refer to Wheel Hub,
Bearing, and Seal Replacement (2WD), or Wheel
Hub, Bearing, and Seal Replacement (4WD), or
5 Wheel Hub, Bearing, and Seal Replacement —
(C3500 HD).
4. Verify that the front wheel speed sensor is
securely mounted and that the tone wheel is in
good condition.
Is the wheel speed sensor and tone wheel in
good condition? Go to Step 9 Go to Step 10
Repair the open, high resistance or short in CKTs 830 Go to ABS
7 or 873. — Diagnostic —
Replace the left front wheel speed sensor. Go to ABS
System Check
9
the facing page for more information. Repair all — —
Go to ABS
Make necessary repairs. Go to ABS
System Check
5-202 Antilock Brake System____________________ Brakes
DTC C0229 Drop Out of Front Wheel Speed Signals
referred to as the air gap. Thoroughly check any circuitry that is suspected
of causing the intermittent complaint for the
• EBCM losing both front wheel speed signals
when the vehicle is at speeds over 19 km/h
(12 mph) (brake released), or 32 km/h (20 mph) • Improper mating
(brake applied). • Broken locks
Action Taken When the DTC Sets
indicates that the above conditions remain true until
the ignition is turned to OFF (even if the cause of
the DTC is intermittent).
When inspecting a wheel speed sensor, inspect the Test Description
sensor terminals and the harness connector for The numbers below refer to the numbers on the
corrosion. If evidence of corrosion exists, then diagnostic chart.
2. This step checks the EBCM 4-way connector
Speed Sensor Replacement (2WD (except for looseness, corrosion, etc.
C3500HD)), or Wheel Speed Sensor Replacement
(C 3500HD).
DTC C0229 Drop Out of Front Wheel Speed Signals

1 — Diagnostic
the EBCM.
2 3. Inspect the 4-way EBCM harness connector and —
is the harness OK and are all the connections clean
and tight? Go to Step 3 Go to Step 4
2. Clear DTC.
3 3. Road test vehicle at speeds above 24 km/h —
(15 mph).
4. Use the scan tool to read the DTCs.
System Check
Malfunction is intermittent. Inspect all connectors and
harnesses for damage which may result in high resistance
6 when all components are connected. Refer to diagnostic — Go to ABS —
aids on facing page for more information. Diagnostic
5-204 Antilock Brake System___________________________ Brakes
DTC C0235 Rear Wheel Speed Signal Circuit Open (Diesel)
r ----------vehicle
• vehide 1Speed
I Speed I gongor
| O utput
Buffer
| ?® £so r
— — — *•
10
A
0.5 YEL/BLK 1827
D2*C100
0.5 YEL/BLK 1827
E AC1
r 1 Electronic
j J Brake
veh icle
S peed Control
input Module
L----- J A
191479
Circuit Description Diagnostic Aids

The EBCM receives the rear wheel speed signal This DTC can be set by a faulty EBCM or a fault in
from the Vehicle Speed Sensor Buffer. The rear CKT 1827.
wheel speed signal originates from the Vehicle If the voltage readings are low or varying, the battery
Speed Sensor (VSS) which is connected to the or charging system could be the cause. Check these
Vehicle Speed Sensor Buffer. When the vehicle is areas before replacing any components. In addition,
not moving, the Vehicle Speed Sensor Buffer will any of the following conditions may cause an
have 12 VDC present on the circuit. The EBCM intermittent malfunction:
checks for this voltage when the vehicle is
• A poor connection
not moving.
• Wire insulation that is rubbed through
Conditions for Setting the DTC • A wire breaks inside the insulation
• EBCM not seeing the correct voltage level from Thoroughly check any circuitry that is suspected
the Vehicle Speed Sensor Buffer at startup. of causing the intermittent complaint for the
• Improper mating
• Broken locks
indicates that the above actions are true until the • Improperly formed or damaged terminals
condition is cleared. • Poor terminal to wiring connections
the DTC
• Use the Scan Tool Clear DTCs function
Brakes ___________ Antilock Brake System 5-205
Test Description 3. This step checks the 1827 CKT for proper
The numbers below refer to the steps in the resistance.
diagnostic table: 5. This step checks for a short in the wiring
between the ECBM and the Vehicle Speed
2. This step uses the voltage output from the
Sensor Buffer.
Vehicle Speed Sensor Buffer to check the
1827 CKT.
DTC C0235 Rear Wheel Speed Signal Circuit Open (Diesel)

Was the Diagnostic System Check performed? Go to
1 — ABS Diagnostic
from the EBCM.
2 3. Turn the ignition to RUN. Greater than
10 volts
4. Using a J 39200, measure the voltage at terminal E
of the 10-way EBCM harness connector.
Is the voltage measurement within the specified range? Go to Step 4 Go to Step 3
2. Disconnect the Vehicle Speed Sensor Buffer
harness connector.
3 3. Using a J 39200, measure the resistance from 0-20
terminal E of the 10-way EBCM harness connector
to terminal 10 of the Vehicle Speed Sensor
harness connector.
4 4. Using a Scan Tool, clear DTCs. —
6. Use a Scan Tool to read DTCs.
Did the DTC set? Go to Step 6 Go to Step 7
Using a J 39200, measure the resistance from terminal E Refer to
of the 10-way EBCM harness connector to ground. DTC P0501
5 Is the resistance measurement within the specified range? OL Vehicle Speed
Sensor Circuit
Low Input Go to Step 9
Replace the EBCM. Go to
6 Is the repair complete? — ABS Diagnostic —
System Check
DTC C0235 Rear Wheel Speed Signal Circuit Open (Diesel) (cont’d)
when all components are connected. Refer to Diagnostic —
7 Aids on the facing page for more information. Perform all —
Go to
necessary repairs. ABS Diagnostic
Repair the open in CKT 1827. Go to
System Check
Repair short to ground in CKT 1827. Go to
System Check
DTC C0235 Rear Wheel Speed Signal Circuit Open (Gas)
E
p r
i_ i
p —— i vehicle
I 2® • Control
l S £5 j Module
15' r c i A
0.5 YEL/BLK 1827
E, ,C1
[■ vis 1 Electronic
spaed Brake
input Control
Module
>
191474
Circuit Description If the voltage readings are low or varying, the battery
The EBCM receives the rear wheel speed signal or charging system could be the cause. Check these
from the Vehicle Control Module (VCM). The rear areas before replacing any components. In addition,
wheel speed signal originates from the Vehicle any of the following conditions may cause an
Speed Sensor (VSS) which is connected to the intermittent malfunction:
VCM. When the vehicle is not moving, the VCM will • A poor connection
have 12 VDC present on the circuit. The • Wire insulation that is rubbed through
EBCM checks for this voltage when the vehicle • A wire breaks inside the insulation
is not moving.
Thoroughly check any circuitry that is suspected
Conditions for Setting the DTC of causing the intermittent complaint for the
• EBCM not seeing the correct voltage level from following conditions:
the VCM at startup. • Backed out terminals
• Improper mating
• Broken locks
indicates that the above actions are true until the • Physical damage to the wiring harness
condition is cleared. Test Description
Conditions for Clearing the DTC The numbers below refer to the steps in the
diagnostic table:
the DTC 2. This step uses the voltage output from the
VCM to check the 1827 CKT.
3. This step checks the 1827 CKT for
Diagnostic Aids proper resistance.
This DTC can be set by a faulty EBCM or a fault in 5. This step checks for a short in the wiring
CKT 1827. between the ECBM and the VCM.
DTC C0235 Rear Wheel Speed Signal Circuit Open (Gas)
1 — Diagnostic
from the EBCM.
Greater than
2 3. Turn the ignition to RUN. 10 volts
2. Disconnect the VCM harness connector C1 from
the VCM.
3 3. Using a J 39200, measure the resistance from 0-2Q
to terminal 15 of the VCM harness connector C1.
5 OL
Is the resistance measurement within the specified range? Vehicle Speed
Sensor Circuit Go to Step 9
System Check
when all components are connected. Refer to Diagnostic
7 Aids on the facing page for more information. Perform all — —
Go to ABS
necessary repairs. Diagnostic
Repair the open in CKT 1827. Go to ABS
System Check
Repair short to ground in CKT 1827. Go to ABS
System Check
DTC C0236 Rear Wheel Speed Signal Circuit Missing (Diesel)
Vehicle
i Vehicle I Speed
i Speed I
Output | Sensor
i I Buffer
Toy
0.5 YEL/BLK 1827
D2* C100
0.5 YEL/BLK 1827
E AC1
r n Electronic
Vehicle [ Brake
I Speed Control
I Input
Module
k
191479
Circuit Description In addition, any of the following conditions may

The EBCM receives the rear wheel speed signal cause an intermittent malfunction:
from the Vehicle Speed Sensor Buffer. The rear • A poor connection
wheel speed signal originates from the Vehicle • Wire insulation that is rubbed through
Speed Sensor (VSS) which is connected to the
Vehicle Speed Sensor Buffer. • A wire breaks inside the insulation
• EBCM losing the rear wheel speed signal for at following conditions:
least 5 seconds while the vehicle is moving • Backed out terminals
above 13 km/h (8 mph) with the brake • Improper mating
pedal released.
• Broken locks
Action Taken When the DTC Sets • Improperly formed or damaged terminals
• The ABS indicator lamp turns on • Poor terminal to wiring connections
• The ABS disables • Physical damage to the wiring harness
DTC C0236 is an Ignition Latched DTC, which If the customer says that the ABS indicator lamp is
indicates that the above actions are true until the on only during humid conditions such as rain, snow,
ignition is turned to OFF (even if the cause of the or vehicle wash, then thoroughly inspect the
DTC is intermittent). suspected circuits for signs of water intrusion. Use
the following procedure:
• Repair the conditions responsible for setting 1. Spray the suspected area with a 5% salt
the DTC water solution (two teaspoons of salt to 12 oz.
of water)
Diagnostic Aids least 30 seconds
This DTC can be set by a faulty EBCM or a fault in If the DTC returns, replace the suspected harness.
CKT 1827.
Test Description 3. This step checks the 1827 CKT for proper
The numbers below refer to the steps in the resistance.
between the ECBM and the Vehicle Speed
2. This step uses the voltage output from the Sensor Buffer.
Vehicle Speed Sensor Buffer to check the
1827 CKT.
DTC C0236 Rear Wheel Speed Signal Circuit Missing (Diesel)

from the EBCM.
Greater than
2 3. Turn the ignition to RUN.
10 volts
harness connector.
harness connector.

Sensor Circuit
System Check
Brakes _____________________________________________ Antilock Brake System 5-211
DTC C0236 Rear Wheel Speed Signal Circuit Missing (Diesel) (cont’d)
Go to ABS
System Check
System Check
DTC C0236 Rear Wheel Speed Signal Circuit Missing (Gas)
E
r —— ** Vehicle
1 i control
1 oSS. 'Module
15'
r° A
0.5 YEL/BLK 1827
E- ,C1
T “ "vss Electronic
speed Brake
input Control
k. . . Module
A
191474
Circuit Description In addition, any of the following conditions may

The EBCM receives the rear wheel speed signal cause an intermittent malfunction:
from the Vehicle Control Module (VCM). The rear • A poor connection
wheel speed signal originates from the Vehicle • Wire insulation that is rubbed through
Speed Sensor (VSS) which is connected to
the VCM. • A wire breaks inside the insulation
• EBCM losing the rear wheel speed signal for at following conditions:
least 5 seconds while the vehicle is moving • Backed out terminals
above 13 km/h (8 mph) with the brake • Improper mating
pedal released.
• Broken locks
Action Taken When the DTC Sets • Improperly formed or damaged terminals
• The ABS indicator lamp turns on • Poor terminal to wiring connections
• The ABS disables • Physical damage to the wiring harness
DTC C0236 is an Ignition Latched DTC, which If the customer says that the ABS indicator lamp is
indicates that the above actions are true until the on only during humid conditions such as rain, snow,
ignition is turned to OFF (even if the cause of the or vehicle wash, then thoroughly inspect the
DTC is intermittent). suspected circuits for signs of water intrusion. Use
the following procedure:
• Repair the conditions responsible for setting 1. Spray the suspected area with a 5% salt
the DTC water solution (two teaspoons of salt to 12 oz.
of water)
Diagnostic Aids least 30 seconds
This DTC can be set by a faulty EBCM or a fault in If the DTC returns, replace the suspected harness.
CKT 1827.
Test Description 3. This step checks the 1827 CKT for
The numbers below refer to the steps in the proper resistance.
between the ECBM and the VCM.
2. This step uses the voltage output from the
VCM to check the 1827 CKT.
DTC C0236 Rear Wheel Speed Signal Circuit Missing (Gas)

1 — Diagnostic
from the EBCM.
Greater than 10
volts
the VCM.
3 3. Using a J 39200, measure the resistance from 0-2Q
5 OL
System Check
Malfunction is intermittent, inspect all connectors and
Go to ABS
System Check
System Check
DTC C0237 Rear Wheel Speed Signal Erratic (Diesel)

The EBCM receives the rear wheel speed signal • The ABS indicator lamp turns on
from the Vehicle Speed Sensor Buffer. The rear • The ABS disables
wheel speed signal originates from the Vehicle DTC C0237 initially sets as a condition latched code.
Speed Sensor (VSS) which is connected to the This means that the ABS system will be disabled
Vehicle Speed Sensor Buffer. and the ABS indicator lamp stays on as long as the
condition exists. If the erratic DTC is set
3 consecutive times during the same ignition cycle,
• EBCM seeing the rear speed signal line drop the DTC will set as an ignition latched DTC. This
out and return. This malfunction can be caused means that the ABS system will be disabled and the
by a malfunction in the VSS, or a fault in ABS indicator lamp stays on until the ignition is
CKT 821, 822 or 1827. turned off; even if the fault goes away.
• The EBCM attempts to detect an erratic rear
speed signal every 5 milliseconds. If the rear Conditions for Clearing the DTC
speed signal is missing for greater than • Repair the conditions responsible for setting
15 milliseconds while a vehicle speed greater the DTC
than 32 km/h (20 mph) with brake applied, or • Use the Scan Tool Clear DTCs function
20 km/h (12 mph) with brake released a
DTC C0237 will set. At this point the DTC will Diagnostic Aids
be condition latched. This means that the ABS
This DTC can be set by a malfunction in the VSS,
system will be disabled and the ABS indicator
or a fault in CKT 821,822 or 1827.
lamp stays on as long as the condition exists. If
the erratic DTC is set 3 consecutive times In addition, any of the following conditions may
during the same ignition cycle, the DTC will set cause an intermittent malfunction:
as an ignition latched DTC. This means that the • A poor connection
ABS system will be disabled and the ABS
• Wire insulation that is rubbed through
indicator lamp stays on until the ignition is
turned off; even if the fault goes away. • A wire breaks inside the insulation
Thoroughly check any circuitry that is suspected of Test Description
causing the intermittent complaint for the The numbers below refer to the steps in the
following conditions: diagnostic table:
• Backed out terminals 2. This step uses the voltage output from the
• Improper mating Vehicle Speed Sensor Buffer to check the
• Broken locks 1827 CKT.
3. This step checks the 1827 CKT for
proper resistance.
• Physical damage to the wiring harness between the ECBM and the Vehicle Speed
Sensor Buffer.
DTC C0237 Rear Wheel Speed Signal Erratic (Diesel)

from the EBCM.
Greater than
10 volts
harness connector.
harness connector.
Sensor Circuit
Replace the EBCM. Go to
System Check
5-216 Antilock Brake System _______________________________________________ Brakes
DTC C0237 Rear Wheel Speed Signal Erratic (Diesel) (cont’d)
7 — —
Aids on the facing page for more information. Perform all Go to
necessary repairs. ABS Diagnostic
System Check
System Check
DTC C0237 Rear Wheel Speed Signal Erratic (Gas)
E
F/T
[_ i
p —“ Vehicle
1 S Li 1Control
! 5SS [Module
15' r c i A
0.5 YEL/BLK 1827
E. .C l
[■ vss 1 Electronic
spMd j Brake
input ; Control
b_ _ j Module
A
191474

The EBCM receives the rear wheel speed signal • The ABS indicator lamp turns on
from the Vehicle Control Module (VCM). The rear • The ABS disables
wheel speed signal originates from the Vehicle DTC C0237 initially sets as a condition latched code.
Speed Sensor (VSS) which is connected to
This means that the ABS system will be disabled
the VCM. and the ABS indicator lamp stays on as long as the
Conditions for Setting the DTC condition exists. If the erratic DTC is set 3
consecutive times during the same ignition cycle, the
• EBCM seeing the rear speed signal line drop DTC will set as an ignition latched DTC. This means
out and return. This malfunction can be caused that the ABS system will be disabled and the ABS
by a malfunction in the VSS, or a fault in indicator lamp stays on until the ignition is turned off;
CKT 821, 822 or 1827. even if the fault goes away.
• The EBCM attempts to detect an erratic rear
speed signal every 5 milliseconds. If the rear Conditions for Clearing the DTC
speed signal is missing for greater than • Repair the conditions responsible for setting
15 milliseconds while a vehicle speed greater the DTC
than 32 km/h (20 mph) with brake applied, or
20 km/h (12 mph) with brake released a
DTC C0237 will set. At this point the DTC will Diagnostic Aids
be condition latched. This means that the ABS
This DTC can be set by a malfunction in the VSS,
system will be disabled and the ABS indicator
or a fault in CKT 821,822 or 1827.
lamp stays on as long as the condition exists. If
the erratic DTC is set 3 consecutive times In addition, any of the following conditions may
during the same ignition cycle, the DTC will set cause an intermittent malfunction:
as an ignition latched DTC. This means that the • A poor connection
ABS system will be disabled and the ABS • Wire insulation that is rubbed through
indicator lamp stays on until the ignition is
turned off; even if the fault goes away. • A wire breaks inside the insulation
Thoroughly check any circuitry that is suspected of Test Description
causing the intermittent complaint for the The numbers below refer to the steps in the
following conditions: diagnostic table:
• Backed out terminals 2. This step uses the voltage output from the
• Improper mating VCM to check the 1827 CKT.
• Broken locks 3. This step checks the 1827 CKT for
proper resistance.
• Poor terminal to wiring connections between the ECBM and the VCM.
DTC C0237 Rear Wheel Speed Signal Erratic (Gas)

1 — Diagnostic
from the EBCM.
Greater than 10
2 3. Turn the ignition to RUN. volts
the VCM.
5 OL
System Check
Brakes ______________________________________ Antilock Brake System 5-219
DTC C0237 Rear Wheel Speed Signal Erratic (Gas) (cont’d)
7 Aids on the facing page for more information. Perform all —
Go to ABS
System Check
System Check
DTC C0238 Wheel Speed Mismatch (Diesel)
As a toothed ring passes by the wheel speed • Any wheel speed differing from the vehicle
sensor, changes in the electromagnetic field cause speed by greater than 10%.
the wheel speed sensor to produce a sinusoidal (AC) • The vehicie speed is greater than
voltage signal. The frequency and amplitude of the 40 km/h (25 mph)
sinusoidal (AC) voltage signal are proportional to the • No unexpected wheel acceleration: anything
wheel speed. The amplitude of the wheel speed that generates consistent differences between
signal is directly related to the distance between the the wheel speed signals
wheel speed sensor coil and the toothed ring. This
distance is referred to as the air gap. The EBCM
can detect wheel speed signal malfunctions as they • The ABS indicator lamp turns on
happen. An error in reported wheel speed can be • The ABS disables
compensated for by the EBCM up to a point. The DTC C0238 is an Ignition Latched DTC, which
error compensation will allow the EBCM to continue indicates the above actions remain true until the
to function normally instead of setting a DTC. If the ignition is turned to OFF (even if the cause of the
wheel speed mismatch increases beyond that point, DTC is intermittent).
the EBCM will set a DTC. Conditions for Clearing the DTC
the DTC
Diagnostic Aids
Installing significantly different tires on the vehicle
usually sets a DTC C0238.
Brakes ______________________________________________Antilock Brake System 5-221
DTC C0238 Wheel Speed Mismatch (Diesel)
1 — Diagnostic
Inspect the vehicle tires for a variation in tire size Refer to
2 —
Are all four tire sizes the same? Go to Step 3 Diagnostic Aids
2. Clear all DTCs.
3 3. While driving the vehicle, monitor and compare all — Malfunction is
the wheel speeds using the Scan Tool. intermittent. Refer
Does the Scan Tool indicate a mismatch in wheel speeds? Go to Step 4 to Diagnostic Aids
Does the scan tool indicate a mismatch with the right front Go to
wheel speed? DTC C0223 RF
4 —
Wheel Speed
Signal Erratic Go to Step 5
Does the scan tool indicate a mismatch with the left front Go to
wheel speed? DTC C0227 LF
5 —
Wheel Speed
Does the scan tool indicate a mismatch with the rear Go to
wheel speed? DTC C0237 Rear
6 — Wheel Speed —
Signal Erratic
(Gas)
5-222 Antilock Brake System__________ Brakes
DTC C0238 Wheel Speed Mismatch (Gas)
Circuit Description Conditions for Setting the DTC

As a toothed ring passes by the wheel speed • Any wheel speed differing from the vehicle
sensor, changes in the electromagnetic field cause speed by greater than 10%.
the wheel speed sensor to produce a sinusoidal (AC) • The vehicle speed is greater than
voltage signal. The frequency and amplitude of the 40 km/h (25 mph)
sinusoidal (AC) voltage signal are proportional to the • No unexpected wheel acceleration: anything
wheel speed. The amplitude of the wheel speed that generates consistent differences between
signal is directly related to the distance between the the wheel speed signals
wheel speed sensor coil and the toothed ring. This
distance is referred to as the air gap. The EBCM
can detect wheel speed signal malfunctions as they • The ABS indicator lamp turns on
happen. An error in reported wheel speed can be • The ABS disables
compensated for by the EBCM up to a point. The DTC C0238 is an Ignition Latched DTC, which
error compensation will allow the EBCM to continue indicates the above actions remain true until the
to function normally instead of setting a DTC. If the ignition is turned to OFF (even if the cause of the
wheel speed mismatch increases beyond that point, DTC is intermittent).
the EBCM will set a DTC. Conditions for Clearing the DTC
the DTC
Diagnostic Aids
Installing significantly different tires on the vehicle
usually sets a DTC C0238.
Brakes___________________________ ________ ____________ Antilock Brake System 5-223
DTC C0238 Wheel Speed Mismatch (Gas)
1 — Diagnostic
inspect the vehicle tires for a variation in tire size Refer to
2 —
Are all four tire sizes the same? Go to Step 3 Diagnostic Aids
2. Clear all DTCs.
3 3. While driving the vehicle, monitor and compare all — Malfunction is
the wheel speeds using the Scan Tool. intermittent. Refer
Does the Scan Tool indicate a mismatch in wheel speeds? Go to Step 4 to Diagnostic Aids
Does the scan tool indicate a mismatch with the right front Go to
wheel speed? DTC C0223 RF
4 —
Wheel Speed
Does the scan tool indicate a mismatch with the left front Go to
wheel speed? DTC C0227 LF
5 —
Wheel Speed
Does the scan tool indicate a mismatch with the rear Go to
wheel speed? DTC C0237 Rear
6 — Wheel Speed —
Signal
Erratic (Gas)
DTC C0241-C0254 EBCM Control Valve Circuit
191485

The EBCM microprocessor will ground the indicated • Repair the conditions responsible for setting
solenoid coil (RF dump/isolation, LF dump/isolation, the DTC
or Rear dump/isolation) circuit to energize the • Use the Scan Tool Clear DTCs function
solenoid coil whenever the solenoid valve is needed.
Refer to ABS Braking Mode in ABS System Diagnostic Aids
Description. The magnetic force created by the This DTC usually sets because of an open/shorted
solenoid coil will close the isolation valve. solenoid coil within the EBCM. The solenoid coil is
located within the BPMV and is not serviceable. If
Conditions for Setting the DTC the test does not repair the DTC, then replace
Open Circuit the EBCM.
• The ABS bulb check is complete If this DTC sets with other DTCs, check for the
• Low voltage exists on the EBCM solenoid driver following conditions:
circuit when high voltage is expected (the • A poor EBCM power or signal ground
solenoid is not energized) • A poor EBCM power or ignition feed
Shorted Circuit
Test Description
• High voltage is present on the EBCM solenoid
driver circuit when the voltage is expected to be The numbers below refer to the steps in the
low (solenoid energized). diagnostic table:
3. This step determines the resistance of the
Action Taken When the DTC Sets power ground circuit.
• The ABS indicator lamp turns on 4. This step determines the battery voltage
• The ABS disables available to the EBCM.
DTCs C0241-C0254 are Ignition Latched DTCs, 7. This step determines the resistance of the
which indicates the above actions remain true until signal ground circuit.
the ignition is turned to OFF (even if the cause of 8. This step determines the ignition voltage
the DTC is intermittent). available to the EBCM.
Brakes_______________ _________________________________Antilock Brake System 5-225
DTC C0241-C0254 EBCM Control Valve Circuit
1 — Diagnostic
1. Turn the ignition switch to OFF.
the EBCM.
2 —
3. Inspect the connector for damage or corrosion that
could cause a loss of power to the EBCM.
Is the connector in good condition? Go to Step 3 Go to Step 11
Measure the resistance between terminal B of the 2-way
3 EBCM harness connector and the ground using a J 39200. 0-2Cl
Measure the voltage between terminal A of the 2-way
4 EBCM harness connector and the ground using a J 39200. 10.0 V
Is the voltage equal to or greater than the specified value? Go to Step 6 Go to Step 5
Inspect the 60-amp ABS maxi-fuse.
5 —
Is the fuse open? Go to Step 13 Go to Step 14
from the EBCM.
6 2. Inspect the connector for damage or corrosion that —
Measure the resistance between terminal J of the 10-way
7 EBCM harness connector and the ground using a J 39200. 0-2fl
2. Measure the voltage between terminal A of the
8 10-way EBCM harness connector and the ground 10.0 V
using a J 39200.
Inspect the 10-amp BRAKE fuse.
9 —
1. Inspect the 10-way and 2-way EBCM harness
connectors for poor terminal contact or corrosion.
Inspect CKT 442 , CKT 150 and CKT 441 for
damage that could result in an intermittent open
circuit. Repair any evident damage. Replace the
10 terminals if poor contact or corrosion exists. —
Malfunction is
4. Test drive vehicle above the 16 km/h (10 mph) intermittent. Refer
Does the DTC set as a current DTC? Go to Step 19 to Diagnostic Aids
Repair the 2-way EBCM harness connector. Go to ABS
System Check
Repair the open or the high resistance in the CKT 150. Go to ABS
System Check
Repair the short to ground in the CKT 442. Go to ABS
System Check
5-226 Antllock Brake System Brakes
DTC C0241-C0254 EBCM Control Valve Circuit (cont’d)
System Check
Repair the 10-way EBCM harness connector. - Go to ABS
15 Is the repair complete? Diagnostic —
System Check
System Check
System Check
System Check
System Check
DTC C0265 or C0266 EBCM Relay Circuit

| Hot At Al Times | |Hot In Run]
191485
Circuit Description (DTCs C0265/C0266) Conditions for Clearing the DTC

The pump motor relay supplies power to all six • Repair the conditions responsible for setting
solenoid coils (three isolation solenoid coils and the DTC
three dump solenoid coils) and the pump motor • Use the Scan Tool Clear DTCs function
when the ABS is required. The relay and the six
solenoid coils are located within the EBCM. Diagnostic Aids (DTC C0265)
DTC C0265 usually sets because of an open relay
Conditions for Setting the DTC (DTC C0265) coil or non-closable relay contacts. The relay is
• The EBCM microprocessor commands the located within the EBCM. The relay is not
relay on serviceable. If the test does not repair the DTC, then
replace the EBCM.
• Low voltage exists on all six solenoid driver
circuits when high voltage is expected (the If DTC C0265 appears with other DTCs repair the
solenoid is not energized) other DTCs first. Clear all DTCs. Then run three
function tests with the Scan Tool. Refer to this
Conditions for Setting the DTC (DTC C0266) diagnostic chart if DTC C0265 resets.
• The ABS bulb check is complete Diagnostic Aids (DTC C0266)
• High voltage exists on the pump motor driver DTC C0266 usually sets when the relay contacts are
circuit when all are expected to be low (the stuck closed. The relay is located within the EBCM.
relay is not commanded on) The relay is not serviceable. If the test does not
repair the DTC, then replace the EBCM.
• The ABS indicator lamp turns on Test Description
The numbers below refer to the steps in the
diagnostic table:
DTCs C0265 and C0266 are Ignition Latched DTCs,
which indicates that the above actions remain true
power ground circuit.
until the ignition is turned to OFF (even if the cause
of the DTC is intermittent). 4. This step determines the battery voltage
available to the EBCM.
signal ground circuit.
8. This step determines the ignition voltage
DTC C0265 or C0266 EBCM Relay Circuit

1 — Diagnostic
the EBCM.
2 —
3 EBCM harness connector and the ground using a J 39200. 0-2Q
Inspect the 60-amp ABS maxi-fuse.
5 —
from the EBCM.
6 2. Inspect the connector for damage or corrosion that —

7 EBCM harness connector and the ground using a J 39200. 0-20
using a J 39200.
Inspect the 10-iamp BRAKE fuse.
9 —

Malfunction is
System Check
DTC C0265 or C0266 EBCM Relay Circuit (cont’d)

System Check
System Check
System Check
System Check
System Check
System Check
System Check
System Check
DTC C0267 or C0268 Pump Motor Circuit Open/Shorted
191485

The pump motor circuit is integral to the BPMV. The • The ABS indicator lamp turns on
EBCM microprocessor energizes the relay within the • The ABS disables
EBCM in order to supply the battery voltage to the DTCs C0267/C0268 are ignition latched DTCs, which
high side of the pump motor. The EBCM indicates that the above actions remain true until the
microprocessor grounds the low side of the pump ignition switch is turned to OFF (even if the cause of
motor when activation of the pump motor is required.
the DTC is intermittent).
Conditions for Setting the DTC (C0267) Conditions for Clearing the DTC
• The EBCM internal relay is on
• The pump motor is off the DTC
• Low voltage is present from the low side of the • Use the Scan Tool Clear DTCs function
pump motor when high voltage is expected
Diagnostic Aids
Conditions for Setting the DTC (C0268) The pump motor is integral with the BPMV. Do not
• Vehicle speed is 13 km/h (8 mph) service the pump motor separately. A poor
• The EBCM internal relay is on power/ground connection at the 2-way EBCM
• The pump motor is commanded ON and connector or the 2-way motor harness from the
then OFF EBCM to the pump motor can cause a DTC C0267.
A seized pump motor, shorted pump motor windings
• High voltage exists from the low side of the or a poor power/ground at the 2-way EBCM
pump motor for 100 ms when the voltage is connector can cause a DTC C0268. Replace the
expected to be low EBCM or the BPMV if the following tests show that
the pump motor EBCM internal circuits have failed.
Im portant: Reset the J 39200 test leads to zero
prior to making any resistance measurements. Refer
to the J 39200 in the user’s manual.
Test Description 5. This step determines the resistance of the
The numbers below refer to the steps in the EBCM ground circuit.
diagnostic table: 7. This step determines the ignition voltage
3. This step checks for an open pump motor
circuit. The pump motor circuit resistance
should not be above the 0.3 ohms. Reset the
J 39200 test leads to zero prior to making this
low resistance measurement.
DTC C0267 or C0268 Pump Motor Circuit Open/Shorted

Was the Diagnostic System Check performed? Go toABS
1 — Diagnostic
2. Disconnect the 2-way pump motor pigtail connector
from the EBCM.
2 3. Inspect the connector and the wiring for damage or —
corrosion that could result in an open circuit between
the pump motor and the EBCM.
Is the connector and the wiring in good condition? Go to Step 3 Go to Step 10
Measure the resistance between terminal A and
terminal B of the 2-way pump motor pigtail connector using
a J 39200.
3
Reset the J 39200 test leads to zero prior to making this 0.1-0.30
resistance measurement.
Is the resistance within the specified range? Go to Step 15 Go to Step 4
4 the EBCM. —
Is the resistance within the specified range? Go to Step 6 Go to Step 11
• Turn the ignition to RUN.
• Measure the voltage between terminal A of the
using a J 39200.
Inspect the 60A MaxiFuse in CKT 442.
7
Is the 60A MaxiFuse open? —
• Inspect the 2-way EBCM harness connector for poor
terminal contact or corrosion. Inspect CKT 2 and
CKT 150 for damage that could result in an open
• Reconnect all the connectors.
• Clear all the DTCs using the Scan Tool. Malfunction is
• Test drive vehicle above 16 km/h (10 mph). intermittent. Refer
Repair the 2-way EBCM harness connector if necessary. Go to ABS
System Check
DTC C0267 or C0268 Pump Motor Circuit Open/Shorted (cont’d)
Repair the 2-way pump motor pigtail connector or wiring Go to ABS
10 if necessary. — Diagnostic —
11 — Diagnostic —
System Check
System Check
System Check
Repair the open or the high resistance in CKT 442. Go to ABS
System Check
Replace the BPMV. Go to ABS
System Check
DTC C0269 or C0274 Excessive Dump/lsolation Time

| Hot At A l Tim — | |H o t In Runj
191485

The EBCM microprocessor grounds the isolation coil • Repair the conditions responsible for setting
to energize and close the isolation valve. This will the DTC
prevent any additional brake pressure applied by the • Use the Scan Tool Clear DTCs function
driver from reaching the wheel. Further increases in
brake pressure will be prohibited. Each isolation Diagnostic Aids
valve is closed independently to isolate each wheel.
Repair any other DTCs first. Then perform the
The EBCM microprocessor also uses a software
Function Test of the scan tool in order to ensure
subroutine to monitor for any ABS event which would
proper operation of the ABS.
initiate an isolation command. This subroutine is
performed every 1.0 second. Test Description
Conditions for Setting the DTC The numbers below refer to the steps in the
Isolation time (pressure hold) exceeding diagnostic table:
255 consecutive 1.0 second checks.
Action Taken When the DTC Sets power ground circuit.
• The ABS indicator lamp turns on 4. This step determines the battery voltage
• The ABS disables available to the EBCM.
DTC C0274 is an ignition latched DTC, which 7. This step determines the resistance of the
indicates that the above actions remain true until the signal ground circuit.
ignition switch is turned to OFF (even if the cause of 8. This step determines the ignition voltage
the DTC is intermittent). available to the EBCM.
DTC C0269 or C0274 Excessive Dump/lsolation Time
1 — Diagnostic
2 the EBCM. —
3 EBCM harness connector and the ground using a J 39200. 0-2D
Inspect the 60-amp ABS maxi-fuse. —
5
from the EBCM.
6 2. inspect the connector for damage or corrosion that —
using a J 39200.
Inspect the 10-amp BRAKE fuse.
9
Is the fuse open? —
3. Clear all DTCs using the Scan Tool. Malfunction is
System Check
System Check
System Check
DTC C0269 or 00274 Excessive Dump/lsolation Time (cont’d)
Repair the open or the high resistance in the CKT 442. Go toABS
System Check
Repair the 10-way EBCM harness connector. Go toABS
System Check
System Check
System Check
System Check
System Check
DTC C0271-C0273 EBCM Malfunction

iH o tA tA M T lm a tl |H o tln Run|
191485

The EBCM initializes a seif-test when the ignition is • Repair the conditions responsible for setting
turned to the RUN position. This internal self-test the DTC
verifies that all ABS circuitry is operating correctly. • Use the Scan Tool Clear DTCs function
Any condition within the EBCM which causes a DTCs C0271-C0273 are EBCM internal diagnosis
memory error will set this DTC. trouble codes. Replace the EBCM if these tests
show that the EBCM circuitry has failed.
• The ABS indicator lamp is turned on Test Description
• The ABS is disabled The numbers below refer to the steps in the
diagnostic table:
These DTCs are Permanent Latched DTCs, which
indicates that the above actions remain true until the 2. This step checks if the EBCM will Clear DTCs.
DTC is cleared using a Scan Tool. 3. This step checks if the DTC was set previously.
Brakes___________ _________________________________ Antilock Brake System 5-237
DTC C0271-C0273 EBCM Malfunction
1 — Diagnostic
Install the Scan Tool and attempt to clear the DTCs.
2 —
Did the DTCs clear? Go to Step 3 Go to Step 4
Check the history DTCs and the data. Go toABS
3 Was this the first time the DTC has set? — Diagnostic
System Check Go to Step 4
System Check
DTC C0281 Brake Switch Circuit
!" ""ignition3 ~ ’’ Electronic

> Power switch ■ Brake
I input I Control
I 1Module
I — —— —— —_ _ _ _ _ j
191494
Circuit Description Diagnostic Aids

The Stop Lamp Switch is normally closed. With the DTC C0281 can be set by a faulty Stop Lamp
ignition in the RUN position and the brake pedal not Switch, misadjusted Stop Lamp Switch or damage in
depressed, the EBCM will have ignition voltage CKT420 or CKT441.
present at terminal C of the 10-way connector. Thoroughly check any circuitry that is suspected
When the brakes are applied, the ignition voltage of causing the intermittent complaint for the
present at the EBCM will be zero. following conditions:
• Improper mating
• After power-up, the microprocessor never sees
• Broken locks
the brake switch released and the vehicle
reaches a speed above 24 km/h (15 mph), or • Improperly formed or damaged terminals
• The vehicle is in an ABS stop for more • Poor terminal to wiring connections
than 2 seconds and the brake switch is • Physical damage to the wiring harness
not depressed Test Description
Action Taken When the DTC Sets The numbers below refer to the steps in the
diagnostic table:
• The ABS indicator lamp will not be illuminated
2. This step checks the functionality of the Stop
• The ABS will not be disabled Lamp Switch circuit using the Scan Tool.
DTC C0281 is advisory code only. The DTC is stored 3. This step checks for a short to voltage in the
in memory, but the ABS indicator lamp will not light, Stop Lamp Switch circuit between the Stoplamp
and ABS will not be disabled. Switch and the EBCM.
4. This step checks the functionality of the Stop
Lamp Switch circuit using the Scan Tool.
• Repair the conditions responsible for setting 5. This step checks for an open in the Stop Lamp
the DTC Switch circuit between the Stoplamp Switch and
• Use the Scan Tool Clear DTCs function the EBCM.
DTC C0281 Brake Switch Circuit
1 — Diagnostic
3. Using the Data List function of the scan tool, check
2 the operation of the Stop Lamp Switch while applying —
and releasing the brake pedal.
Does the scan tool indicate that the Stop Lamp Switch to
be closed (when pedal is not applied)? Go to Step 3 Go to Step 4
2. Disconnect the Stoplamp Switch harness connector
from the Stoplamp Switch.
3
3. Turn the ignition to RUN —
4. Using the Data List function of the scan tool, check
the operation of the Stop Lamp Switch.
be closed? Go to Step 10 Go to Step 8
4
Does the scan tool indicate that the Stop Lamp Switch to —
be open constantly (pedal applied)? Go to Step 5 Go to Step 7
2. Disconnect the 10-way EBCM connector from
the EBCM.
5
3. Turn the ignition to RUN. 10-15V
4. Using a J 39200, measure the voltage between
terminal C of the 10-way EBCM harness connector
and ground.
Is the voltage within the specified range? Go to Step 6 Go to Step 11
6 5. Using the Data List function of the scan tool, check —
the operation of the Stop Lamp Switch .
be open constantly while applying and releasing the
brake pedal. Go to Step 9 Go to Step 7
Malfunction is intermittent. Refer to Diagnostic Aids. Repair Go toABS
7 all damage found. — Diagnostic —
Is repair complete? System Check
1. Check for misadjusted Stop Lamp Switch.
8 2. If the Stoplamp Switch is adjusted properly, replace — Go to ABS —
the Stoplamp Switch. Diagnostic
DTC C0281 Brake Switch Circuit (cont’d)
System Check
Repair the short to voltage in CKT 420. Go to ABS
System Check
Check for the following:
• Misadjusted Stop Lamp Switch
11 • Faulty Stoplamp switch — Go to ABS
—
• Open circuit between Stoplamp switch and EBCM Diagnostic
DTC C0286 ABS Indicator Lamp Circuit Shorted to B+
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191453

The amber ABS indicator lamp is supplied ignition • Repair the conditions responsible for setting
voltage through the GAUGE fuse. The indicator is the DTC
normally on unless the EBCM switches the indicator • Use the Scan Tool Clear DTCs function
off (normal mode). This logic ensures that the
indicator will be illuminated if there is an open in Diagnostic Aids
CKT 867 or a faulty EBCM.
DTC C0286 typically sets because of a shorted ABS
Conditions for Setting the DTC indicator lamp. Yet DTC C0286 can also set because
• High voltage is present on the ABS indicator of a short to voltage in the wiring between the ABS
lamp control circuit when low voltage is indicator lamp and the EBCM.
expected (lamp is turned on)
Test Description
• Anything that keeps the ABS indicator lamp
circuit high when the lamp is expected to be on The numbers below refer to the steps in the
diagnostic table:
Action Taken When the DTC Sets 2. This step checks for normal operation of the
• The ABS is not disabled. ABS indicator lamp.
• The EBCM will use the red BRAKE warning 3. This step turns off the ABS indicator lamp with
lamp to alert the driver of an ABS malfunction. a J 36169-A.
DTC C0286 ABS Indicator Lam p C ircuit Shorted to B+
Was the Diagnostic System Check performed? Go toABS
1 — Diagnostic
2
2. Observe the amber ABS indicator lamp operation. —
3. Did the ABS indicator lamp turn on and then turn off
after 3 seconds? Go to Step 5 Go to Step 3
from the EBCM.
3
3. Using a J 36169-A with a 3 amp fuse, connect
terminal B of the 10-way EBCM harness connector —
to ground.
4. Turn ignition to RUN.
Does the ABS indicator lamp turn on? Go to Step 6 Go to Step 4
Inspect the jumper wire fuse.
4 —
5 when all components are connected. Perform all — Go to ABS Malfunction is
necessary repairs. Diagnostic intermittent. Refer
Is repair complete? System Check to Diagnostic Aids
6 Is repair complete? — Diagnostic —
System Check
Repair a short to voltage in CKT 867. Go to ABS
System Check
DTC C0288 Brake Warning Lamp Circuit Shorted to B+
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191453
C ircuit Description Diagnostic Aids

The red BRAKE warning lamp is supplied ignition DTC C0288 is usually set by a short to voltage in
voltage through the GAUGES fuse. The BRAKE the wiring between the brake warning lamp and
warning lamp can be illuminated by the EBCM, the EBCM.
Daytime Running Lights Module (DRL), Brake
Pressure Warning Switch or by the Park Test Description
Brake Switch. The numbers below refer to the steps in the
diagnostic table.
C onditions fo r Setting the DTC
2. Determines if the BRAKE warning lamp circuit
• High voltage is present on the BRAKE warning is operating properly when controlled by the
lamp circuit when the circuit is expected to be EBCM (with diesel engines).
low (lamp commanded on by the EBCM)
3. This step determines which variation of circuitry
• Anything that keeps the Brake warning lamp the vehicle is equipped.
circuit high when the lamp is supposed to be
4. This step determines if the BRAKE warning
illuminated (such as a short to voltage on
lamp circuit is operating properly without the
CKT 33)
EBCM (with diesel engines).
Action Taken W hen th e DTC Sets 5. This step decides between a constant or
No action taken, the ABS is not disabled. intermittent short to voltage condition.
9. This step determines if the BRAKE warning
C onditions fo r C learing the MIL/DTC lamp circuit is operating properly without the
• Repair the conditions responsible for setting EBCM (with gas engines).
the DTC 10. This step decides between a constant or
• Use the Scan Tool Clear DTCs function intermittent short to voltage condition.
DTC C0288 Brake Warning Lamp Circuit Shorted to B+
Was the ABS Diagnostic System Check performed? Go to ABS
1 — Diagnostic
2. Observe the red BRAKE warning lamp.
2 —
Did the BRAKE warning lamp turn on and then off after
three seconds? Go to Step 5 Go to Step 3
Take note of the engine type in the vehicle.
3
Is the engine a Diesel type Engine? Go to Step 4 Go to Step 9
from the EBCM.
4 3. Using a 3 amp fused jumper wire, such as J 36169,
—
connect terminal H of the 10-way EBCM harness
connector to ground.
Does the BRAKE warning lamp turn on? Go to Step 7 Go to Step 5
Inspect the jumper wire fuse
5 —
Malfunction is intermittent,
Perform the following:
• Inspect all connectors and harnesses for damage
which may result in a short to voltage when all
6 components are connected. — —
• Refer to Diagnostic Aids on facing page.

Go to ABS
• Perform all necessary repairs. Diagnostic
System Check
System Check
from the EBCM.
9 3. Using a 3 amp fused jumper wire, such as J 36169,
—
connect terminal F of the 10-way EBCM harness
connector to ground.
Does the BRAKE warning lamp turn on? Go to Step 7 Go to Step 10
Inspect the jumper wire fuse
10 —
System Check
ABS Indicator Off No DTC Set

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191453
Circuit Description 5. After the power and ground circuits have been
The EBCM controls the ABS indicator lamp verified, this step uses the EBCM self test to
illumination by supplying a ground to the EBCM determine if the problem is intermittent or if the
10-way terminal B. When the vehicle is started or EBCM is faulty.
the ignition is turned to the RUN position, the ABS 6. The voltage check in step 3 failed. This
indicator should illuminate for three seconds and step goes further to check for the proper
turn off. voltage from CKT 39 at the input to the
instrument cluster.
Diagnostic Aids 7. This step checks for continuity in CKT 867, and
If the ABS indicator lamp is off constantly, an open decides between an open in CKT 867, or a
or short to voltage in the lamp circuit is present fault internal to the instrument cluster.
between the instrument panel and the ABS indicator 8. The voltage check in step 6 failed. This step
relay ground (this includes the ABS indicator relay checks for a short to ground in CKT 39 as a
contacts). Also check for an open instrument cluster potential cause.
fuse or an open ABS indicator lamp.
9. This step uses a resistance check of the EBCM
Test Description ground circuit to decide between an open
ground in CKT 150 or internal to the EBCM.
The numbers below refer to the steps in the
diagnostic table:
3. This step tests for ignition voltage up to the
EBCM harness connector.
4. This step uses a voltage check to tell if there is
a good ground path through terminal B in the
2-way harness connector. The ground supplied
through terminal B is used internal to the
EBCM to control the ABS indicator lamp
through terminal B in the 10-way
EBCM connector.
ABS Indicator Off No DTC Set

1 — Diagnostic
Check the condition of the ABS indicator lamp bulb.
2
Is the bulb OK? Go to Step 3 Go to Step 10
from the EBCM.
3. Turn the ignition switch to RUN. 10-15V
3
4. Using a J 39200, measure the voltage between
terminal B in the EBCM harness connector
and ground.
2. Using a J 39200, measure the voltage
4 between terminals A and B in the 2-way EBCM 10-15V
harness connector.
1. Reconnect the 10-way and 2-way EBCM
harness connectors.
Turn the ignition to RUN
5 —
2. Observe the ABS indicator Malfunction is
Did the ABS indicator lamp turn on for three seconds then intermittent. Refer
go out? to Diagnostic Aids Go to Step 11
1. Disconnect the instrument cluster harness connector
from the instrument cluster.
6 3. Using a J 39200, measure the voltage between 10-15V
terminal 22 (w/Automatic Trans.), or terminal 7
(w/manual Trans.) in the instrument cluster harness
connector and ground.
1. Connect a jumper between terminal 27 in the
instrument cluster harness connector and ground.
7 2. Using a J 39200, measure the resistance between
0-20
terminal B in the 10-way EBCM harness connector Refer to
and ground. Instrument Cluster
Is the resistance measurement within the specified range? Diagnosis Go to Step 12
2. Replace the GAUGES fuse.
8 3. Turn the ignition to RUN. —
4. Remove and inspect the 10 amp GAUGES fuse.
Is the GAUGES fuse open? Go to Step 13 Go to Step 14
Using a J 39200, measure the resistance between terminal
9 B in the 2-way EBCM harness connector and ground. 0-20
Replace the ABS indicator lamp. Go to ABS
System Check
System Check
Brakes___________________________________ _____________Antilock Brake System 5-247
ABS Indicator Off No DTC Set (cont’d)
Repair the open or the high resistance in CKT 867. Go to ABS
12 is the repair complete? — Diagnostic —
System Check
Repair the short to ground in CKT 39. Refer to Wiring Go to ABS
13 Systems Cell 10. — Diagnostic —

Repair the open or high resistance in CKT 39. Refer to Go to ABS
14 Wiring Systems Cell 10. — Diagnostic —
Repair the open in CKT 150. Refer to Wiring Systems Go to ABS
15 Cell 14. — Diagnostic —
ABS Indicator On No DTC Set

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191453
Circuit Description position), there is a short to ground in CKT 867

The EBCM controls the ABS indicator lamp between the instrument cluster and the EBCM or the
illumination by supplying a ground to terminal B. EBCM is internally shorted to ground.
When the vehicle is started or the ignition is turned Test Description
to the RUN position, the ABS indicator should
illuminate for three seconds and turn off. The numbers below refer to the steps in the
diagnostic table:
Diagnostic Aids 2. This step checks for a short to ground in
If the ABS indicator lamp is on always with no DTCs CKT 867.
set (never turns off after three seconds with the
vehicle started or with the ignition switch in the RUN
ABS Indicator On No DTC Set
1 — Diagnostic
2 from the EBCM. —
Does the ABS indicator lamp turn on? Go to Step 3 Go to Step 4
Repair the short to ground in CKT 867. Go to ABS
System Check
1. Inspect CKT 867 and the 10-way EBCM harness
connector for physical damage which may result in a
short to ground with the 10-way EBCM harness
connector connected to the EBCM.
4 2. Reconnect all the connectors. —
3. Clear all the DTCs using the scan tool. Malfunction is
4. Test drive the vehicle above 16 km/h (10 mph). intermittent. Refer
Is the ABS indicator lamp on constantly? Go to Step 5 to Diagnostic Aids
System Check
5-250 Antilock Brake System____________ Brakes
Repair Instructions Electronic Brake Control Module

Replacement
ABS Bleed Procedure
Removal Procedure
Important:
• Use the two-person bleed procedure under the Important: After installation, calibrate the new EBCM
following conditions: to the tire size that is appropriate to the vehicle.
Refer to Tire Size Calibration and to Trim Level
- Installing a new Electro-Hydraulic Control Calibration portions of ABS System Description
Unit (EHCU) or new Brake Pressure
Modulator Valve (BPMV). 1. Negative Battery Cable. Refer to Battery
- Air is trapped in the valve body Disconnect Caution.
• Do not drive the vehicle until the brake pedal
feels firm.
• Do not reuse brake fluid that is used
during bleeding.
• Use the vacuum, the pressure and the
gravity bleeding procedures only for base
brake bleeding.
Two Person Procedure
1. Raise the vehicle in order to access the system
bleed screws.
2. Bleed the system at the right rear wheel first.
3. Install a clear hose on the bleed screw.
container partially filled with clean DOT 3
brake fluid.
5. Open the bleed screw 1/2 to one full turn.
184226
6. Slowly depress the brake pedal. While the
pedal is depressed to its full extent, tighten the 2. Remove the four T-25 Torx® screws (1) that
bleed screw. fasten the EBCM to the BPMV.
7. Release the brake pedal and wait 3. Partially remove the EBCM (2) from the
10-15 seconds for the master cylinder pistons BPMV (4) enough to access the electrical
to return to the home position. connectors. Removal may require a light
8. Repeat the previous steps for the remaining amount of force.
wheels. The brake fluid which is present at Important: Do not use a tool to pry the
each bleed screw should be clean and free EBCM or the BPMV. Excessive force will
of air. damage the EBCM.
9. This procedure may use more than a pint of 4. Disconnect the four electrical connectors
fluid per wheel. Check the master cylinder fluid from EBCM.
level every four to six strokes of the brake
5. Fully remove the EBCM (2) from the BPMV (4).
pedal in order to avoid running the system dry.
10. Press the brake pedal firmly and run the Scan Installation Procedure
Tool Automatic Bleed Procedure. Release the
Important: Do not reuse the old mounting screws.
brake pedal between each test.
Always install new mounting screws with the new
11. Bleed all four wheels again using Steps 3-9. EBCM.
This will remove the remaining air from the
brake system. 1. Install the new EBCM gasket (3) onto the
BPMV (4).
12. Evaluate the feel of the brake pedal before
attempting to drive the vehicle. Important: Do not use RTV or any other
type of sealant on the EBCM gasket or
13. Bleed the system as many times as necessary
mating surfaces.
in order to obtain the appropriate feel of
the pedal. 2. Install EBCM (2) on to the BPMV (4).
3. Connect the four electrical connectors to
the EBCM.
4. Ensure that the new EBCM gasket (3) is
aligned correctly.
5. Install the four new T-25 Torx® screws (1) in
the EBCM (0).
Tighten
Tighten the four T-25 Torx® screws to
5 N-m (39 lb in) in an X-pattern.
and Notices.
7. Revise the tire calibration using the Scan Tool
8. Return to Diagnostic System Check. Refer to
ABS Diagnostic System Check
Brake Pressure Modulator Valve

Replacement
184208
Removal Procedure
5. Lift the EHCU partially out or the
engine compartment.
6. Disconnect the four electrical connectors
from EBCM (2).
7. Fully remove the EHCU from the vehicle.
8. Remove the three alien bolts (11) from the
combination valve (12).
184208
1. Disconnect the electrical connector from the

combination valve.
2. Remove the front and rear brake pipes (from
master cylinder) from the combination valve.
3. Remove the right front, left front and rear brake
pipes from the tube adapters. 184208
4. Remove the four 10mm bolts that fasten 9. Remove the combination valve (12).
the EHCU bracket (7) to the vehicle
mounting bracket. 10. Remove the two transfer tubes (13).
Im portant: Do not reuse the transfer tubes.
Always install new transfer tubes.
11. Remove the three 13mm bolts (9) that fasten
the bracket to the BPMV.
12. Remove the four T-25 Torx® bolts (1) from
the EBCM.
13. Remove the EBCM (2) from the BPMV (4).
Removal may require a light amount of force.
Important: Do not use a tool to pry the
EBCM or the BPMV. Excessive force will
damage the EBCM.
Important: Do not reuse the EBCM mounting
bolts (1). Always install new bolts.
184208
4. Install the EBCM gasket (3) onto the BPMV (4).

5. Insure gasket allignment is correct.
Important: Do not use RTV or any other
type of sealant on the EBCM gasket or
mating surfaces.
6. Install EBCM (2) onto BPMV (4).
7. Install the four EBCM bolts (1).
Important: Do not reuse the old mounting
bolts. Always install new bolts with the
new EBCM.
Tighten
184208 Tighten the four bolts to 5 N.m (39 lb in) in
1. Install the new transfer tubes(13) into the an X-pattern.
combination valve (12). 8. Install BPMV (4) to bracket (7).
2. Install the combination valve (12) onto the
BPMV (4).
3. Install the three alien bolts (11) that fasten the
combination valve (12) to the BPMV (4).
Tighten
Tighten the three alien bolts to 8 N.m (6 lb ft),
then to 16 N.m (12 lb ft).
184208
9. Install the three BPMV to bracket retaining 13. Install the front and rear brake pipes (from
bolts (9). master cylinder) to the combination valve (12).
Tighten Tighten
Tighten the three bolts to 9 N-m (7 lb ft). Tighten the three brake pipe fittings to
10. Connect the four electrical connectors to the 30 N-m (22 lb ft).
EBCM (2). 14. Connect the electrical connector (10) to the
11. Install the EHCU to the vehicle frame. combination valve (12).
Tighten 15. Connect the negative battery cable.
Tighten the three bolts to 12 N-m (9 lb ft). 16. Bleed the brake system. Refer to
ABS Bleed Procedure
12. Install the right front, left front and rear brake
pipes to the tube adapters (6). Important: Verify that the combination valve
Tighten metering rod is depressed during bleeding.
Tighten the three brake pipe fittings to 17. Returm to Diagnopstic System Check. Refer to
30 N-m (22 lb ft). ABS Diagnostic System Check.
184208
Wheel Speed Sensor Replacement

(2WD (except C3500HD))
Removal Procedure
1. Raise vehicle.
2. Remove tire and wheel. Refer to Wheel
Removal (Single Wheels)
3. Remove brake caliper. Refer to Brake Caliper
Replacement (Front Delco)
4. Remove the hub and rotor. Refer to Hub and
Rotor Assembly Replacement
5. Remove wheel speed sensor cable
6. Remove wheel speed sensor cable mountinig
clips (4) from frame attachment points.
7. Remove wheel speed sensor mounting bolts
and nut.
8. Remove two 11 mm splash shield
mounting bolts.
9. Remove wheel speed sensor and splash
shield assembly.
10. Remove splash shield gasket.
11. Clean gasket and knuckle surfaces thoroughly
with a dry cloth.
1. Install splash shield gasket.
2. Install wheel speed sensor splash shield.
3. Install two 11 mm splash shield mounting bolts.
Tighten
• Tighten the splash shield mounting bolts to
16 N-m (12 lb ft)
• Tighten the speed sensor mounting bolts
to 26 N-m (19 lb ft)
4. Install harness clips (4), fastening bolts and
nuts (5) to the frame attachment points.
5. Install the hub and rotor. Refer to Hub and
6. Install brake caliper. Refer to Brake Caliper
Replacement (Front Delco)
7. Install tire and wheel. Refer to Wheel
Installation (Single Wheels-Front or Rear)
Wheel Speed Sensor Replacement (4WD)

Removal Procedure
1. Raise vehicle.
Removal (Single Wheels).
5. Remove wheel speed sensor mounting clip (2)
on the control arm.
6. Remove wheel speed sensor mounting clip (2)
on the frame rail.
7. Remove wheel speed sensor electrical
connector (6).
Notice: Carefully remove the sensor by pulling
it straight out of the bore. DO NOT use a 191516
screwdriver, or other device to pry the sensor

out of the bore. Prying will cause the sensor
body to break off in the bore.
Important: The wheel speed sensor mounts
into a bore that leads to the center of the
sealed bearing. Use caution when cleaning or
working around the bore. Do not contaminate
the lubricant inside the sealed bearing. Failure
to do so can lead to premature bearing failure.
8. Remove wheel speed sensor from hub and
bearing assembly.
Important: The new speed sensor will have a new
O-ring. Dispose of the old O-ring. Lubricate the new
O-ring lightly with bearing grease prior to installation.
You may also lubricate the sensor just above and
below the new O-ring. Do Not lubricate the bore.
Important: The new sensor has new mounting clips
already installed on the wire. Do not reuse the old
clips.
1. Install sensor into the hub and
bearing assembly.
Tighten
Tighten the sensor mounting bolts to
18 N.m (13 lb ft).
2. Install wheel speed sensor electrical
connector (6).
3. Install wheel speed sensor mounting clip (2) to
the frame rail.
4. Install the wheel speed sensor mounting clip (2)
to the control arm.
Rotor Assembly Replacement.
Installation (Single Wheels-Front or Rear).
Wheel Speed Sensor Replacement

(C 3500HD)
Removal Procedure
1. Raise vehicle.
5. Remove the splash shield.
6. Remove the wheel speed sensor wire mounting
clip (2) attached to the upper king pin cap.
7. Wheel speed sensor wire mounting clip (5)
attached to the frame rail.
8. Remove wheel speed sensor cable
electrical connector (1).
9. Remove wheel speed sensor to bracket
mounting bolts and nuts.
• It is not necessary to remove the wheel
speed sensor mounting bracket (4) unless
the bracket is damaged.
10. Remove the wheel speed sensor from the
mounting bracket (4).
• It is not necessary to replace the sensor
mounting bracket unless there is visible
damage or distortion to the mounting bracket.
Notice: The wheel speed sensor used on the
C 3500HD models is adjustable by means of slots
provided in the mounting bracket. The sensor must
be properly adjusted in order to provide the correct
air gap between the wheel speed sensor and the
tone wheel. If the sensor is not properly adjusted,
the tone wheel may hit the wheel speed sensor, or
the output from the wheel speed sensor may be low,
missing or erratic. Follow the procedure outlined
below to properly adjust the front wheel speed
sensor.
1. Install the wheel speed sensor to the
mounting bracket (4).
2. Install wheel speed sensor to bracket mounting
nuts and bolts.
• Run down the nuts but do not torque. The
wheel speed sensor must remain loose and
move along the slots in the bracket.
3. Place the front hub and rotor assembly on a
flat surface with the tone wheel facing up. Take
care not to damage the wheel studs.
4. Mark the position of the rotor relative to the
hub so the rotor can be installed in the same
position later.
5. Remove bolts attaching the rotor to the hub.
6. Remove the rotor from the hub.
7. Install hub and tone wheel assembly on the
knuckle spindle.
8. Install the outer bearing, washer and
spindle nut.
Tighten
Spindle nut to 16 N-m (12 lb. ft.) while rotating
the nut in either direction.
• Do not back off the nut.
Notice: DO NOT use a rigid feeler gage or a
wire spark plug gap gage to set the wheel
speed sensor to tone wheel air gap as these
tools will not result in the correct air gap.
9. Insert flexible shim stock or equivalent between
the tone wheel and the wheel speed sensor.
• The thickness of the shim stock must be
1.25 mm (0.050 in.). The length and width of
the shim stock must be sufficient enough to
cover the face of the wheel speed sensor. If
shim stock is not available, regular notebook
or writing paper can be used provided the
specified thickness is inserted between the
tone wheel and the wheel speed sensor.
10. Press the wheel speed sensor firmly against
the shim stock and tone wheel.
Tighten
10.1. Tighten the left hand lower attaching nut
to 13 N.m (10 Ib.ft.).
10.2. Tighten the left hand upper attaching nut
to 13 N.m (10 Ib.ft.).
10.3. Tighten the right hand upper attaching
nut to 13 N-m (10 Ib.ft.).
10.4. Tighten the right hand lower attaching
nut to 13 N-m (10 Ib.ft.) while holding
the wheel speed sensor against the
shim stock.
11. Remove the shim stock from between the tone
wheel and the wheel speed sensor.
12. Inspect that the tone wheel does not contact
the wheel speed sensor when the hub and tone
wheel are rotated.
13. Install the splash shield to the front
anchor plate.
• Take care to route the wheel speed sensor
wire through the opening in the splash shield
near the center mounting hole.
Tighten
Tighten bolts to 17 N.m (13 lb. ft.).
14. Route the wheel speed sensor wire between
the splash shield and the knuckle.
15. Install the wheel speed sensor mounting clip to
the upper king pin cap.
Tighten
Tighten the bolt to 17N.m (13 Ib.ft.).
16. Connect the wheel speed sensor cable
17. Install front wheel hub and tone wheel
assembly to spindle.
18. Install rotor to front wheel hub.
• Take care to line up reference
position marks.
19. Install bolts.
Tighten
Tighten bolts to 237 N-m (175 Ib.ft.).
Rotor Assembly Replacement.
Installation (Single Wheels-Front or Rear).
Front Wheel Speed Sensor
Bracket Replacement
Removal Procedure
Notice: Whenever performing repairs to the wheel
speed sensor, wheel speed sensor mounting bracket,
steering arm, front caliper anchor plate, steering
knuckle, inner bearing dust shield or any attaching
fasteners, the wheel speed sensor air gap may be
moved out of adjustment. Always check and adjust
the wheel speed sensor air gap as outlined in
SECTION 5E1, FRONT WHEEL SPEED SENSOR
REPLACEMENT (C 3500HD), to prevent damage to
the wheel speed sensor and to endure proper
operation of the four wheel antilock brake system.
1. Raise vehicle.
3. Remove the hub and rotor. Refer to Wheel
Hub, Bearing, and Seal Replacement
(C3500HD).
4. Remove splash shield.
5. Remove wheel speed sensor bracket mounting
nuts and bolts.
6. Remove wheel speed sensor from
mounting bracket.
7. Remove wheel speed sensor mounting bracket
attaching nuts.
8. Remove wheel speed sensor.
1. Install wheel speed sensor mounting bracket.
2. Install wheel speed sensor mounting bracket
attaching nuts.
Important: Do not install washers between the
attaching nuts and the wheel speed sensor
mounting bracket, or insufficient thread
engagement may occur.
Tighten
• Tighten the attaching nuts to
285 N-m (210 lb ft).
3. Install wheel speed sensor to mounting bracket.
Refer to Wheel Speed Sensor Replacement
(C 3500HD).
Brakes ____________Antilock Brake System 5-259
Tube Adapter Replacement Installation Procedure

1. Install the new tube adapter.
Removal Procedure Tighten
Important: If you must remove more than one tube Tighten the tube adapter to 31 N-m (23 lb ft).
adapter at one time, stamp the BPMV with a number
(1, 2 or 3) in order to indicate the number of Notice: Refer to Fastener Notice in Cautions
grooves cut into the tube adapters. This procedure and Notices.
will aid proper reassembly. 2. Install the brake line.
Tighten
Tighten the brake line to 30 N-m (22 lb ft).
3. Bleed the system. Refer to
ABS Bleed Procedure.
184211
1. Remove the appropriate brake line from the

tube adapter.
2. Remove the tube adapter.
5-260 Antilock Brake System____________ Brakes
Description and Operation Wheel Slip

The ability of a vehicle to stop is related to the
Service Precautions friction of the road surface. At 0% slip, the tires
rotate freely; at 100% slip, the tire and wheel are
When working on this system, observe the locked. Stopping distance increases and steering
following precautions: control is diminished.
• Before welding on the vehicle with an electric With a 10%-20% slip, vehicle stopping distance will
welding unit, complete the following steps: be as short as possible and steering control will be
- Turn the ignition switch OFF. at its optimum. Some slip is necessary to stop the
wheel and achieve maximum braking.
- Disconnect the EBCM connectors.
When ABS operation occurs, the driver of the vehicle
• Do not use a fast charger for starting
should always continue to push hard on the brake
the engine.
pedal. Never pump the brakes. The ABS system will
• Disconnect the negative battery cable when automatically modulate the brakes.
fast charging. Steering Control
Caution: Refer to Battery Disconnect Caution in Steering control, like braking, also depends on tire
Cautions and Notices. traction. A locked tire in a 100% slip condition
delivers less than optimum braking and directional
• Never disconnect the battery from the vehicle
control. Thus, some tire rotation is desirable for
electrical system while the engine is running. steering control. The tires must regain traction before
• Connect all wiring harness connectors securely. steering control is restored to the vehicle.
• Proper speed sensor wiring, routing and
retaining are necessary in order to prevent false Abbreviations and Definitions
signals due to electrical noise. You can achieve 4WAL: Four Wheel Antilock
proper system operation only by restoring the BPMV: Brake Pressure Modulator Valve
system to its original condition. CKT: Circuit
When servicing the ABS system, note the DLC: Data Link Connector
routing, position, mounting and locations of the DMM: Digital Multimeter
following items:
DTC: Diagnostic Trouble Code
- All components
DUMP: Dump Valve
- The wiring
EBCM: Electronic Brake Control Module
- The connectors
EHCU: Electro-Hydraulic Control Unit
- The clips
Infinite: Open Circuit/Unmeasurably High Resistance
- The brackets ISO: Isolation Valve
- The brake pipes LPA: Low Pressure Accumulator
Follow the above mentioned precautions when OL: Open Circuit/Unmeasurably High Resistance
working on ABS. Familiarize yourself with ABS and it
2WD: Two Wheel Drive
relationships with other components on the vehicle.
4WD: Four Wheel Drive
General System Description VSS: Vehicle Speed Sensor
This section covers diagnostic and service WSS: Wheel Speed Sensor
procedures for the four wheel antilock brake system The EHCU is the entire ABS assembly, including the
(4WAL). These these models use the three sensor BPMV, the EBCM and combination valve. The BPMV
4WAL system. Speed information is obtained using a is defined as the hydraulic control (lower) portion of
wheel speed sensor (WSS) at each front wheel and the EHCU. It includes the internal control valves, the
the vehicle speed sensor (VSS) for rear wheel speed electric motor and the pumps. The EBCM is the
information. 4WAL reduces the occurrence of wheel electronic control (uper) portion of the EHCU. The
lockup during severe brake applications. The system EBCM mounts to the top of the BPMV. The EBCM is
regulates hydraulic pressure to all four wheels. The housed in aluminum with a black plastic top.
pressure is regulated by the brake pressure
modulator valve (BPMV). Basic Knowledge Required
You must have a basic knowledge of the following
ABS is designed to provide the average driver with
items before using this section. Without this basic
the following:
knowledge, you will have difficulties using the
• Optimal steering control and stability diagnostic procedures contained in this section.
when braking
If you need a review of basic electrical
• Optimal braking performance with troubleshooting, see the introduction to Electrical
available traction Diagnosis. Electrical Diagnosis also contains
information on the basic use of circuit testing tools.
Additionally, General Motors Service Training offers approaching lockup. Once the wheel regains traction,
courses in electrical and electronic service. brake pressure is increased until the wheel again
Basic Electrical Circuits approaches lockup. This cycle repeats until either the
vehicle comes to a stop, the brake is released, or
You should understand the basic electrical theory.
the wheel is no longer approaching lockup. The
You should also know the meaning of basic electrical
EBCM also runs self diagnostics in order to check
concepts and measurement: voltage (volts), current for any system malfunctions. Refer to
(amperes) and resistance (ohms). You should Self-Diagnostics. If the EBCM detects a
understand what happens in a circuit with an open malfunction with the system, the ECBM will illuminate
or shorted wire. You should be able to read and the amber ABS indicator in order to alert the driver
understand a wiring diagram. of a malfunction.
Use of Circuit Testing Tools Brake Pressure Modulator Valve
You should be familiar with the high impedance The Brake Pressure Modulator Valve (BPMV) is part
Digital Multimeter (DMM) J 39200. You should be of the EHCU. The BPMV is the hydraulic portion of
familiar with the meter controls and how to use them the EHCU. The EBCM controls the BPMV.
correctly. You should be able to measure voltage, The BPMV is split into the following three
resistance and current. You should also know how to hydraulic channels:
use jumper wires to bypass components in order to • Left front
test circuits. • Right front
ABS System Description • Rear
Each channel has an isolation valve and a dump
Electro-Hydraulic Control Unit valve. The front channels share a low pressure
The Electro-Hydraulic Control Unit (EHCU) is located accumulator, attenuator, and a pump. The rear
in the left hand side of the engine compartment. The channel shares use of the pump, but uses it’s own
EHCU assembly includes the Electronic Brake low pressure accumulator and attenuator.
Control module (EBCM) and the Brake Pressure
Wheel Speed Sensors
Modulator Valve (BPMV). The EHCU regulates The front Wheel Speed Sensors (WSS) are a
hydraulic pressure in the brake system during an magnetic coil/pickup type. Each WSS produces an
antilock stop. AC voltage signal which is transmitted to the EBCM
Electronic Brake Control Module in order to indicate how fast the wheel is turning.
The Electronic Brake Control Module (EBCM) is part The speed of the wheel is directly proportional to the
of the EHCU. The EBCM is the electronic portion of frequency and amplitude of the wheel speed signal.
the EHCU. The major function of the EBCM is to Wheel Speed Sensor Tone Wheels
control the BPMV. Inputs to the EBCM include the Each Wheel Speed Sensor uses a tone wheel in
following items: order to produce an AC voltage signal. Tone wheels
• Three wheel speed sensors are metal rings with teeth on the outside diameter.
The AC voltage is produced as the teeth pass
• Stop Lamp Switch through the magnetic field of the WSS pole piece.
• Differential pressure The tone wheels are attached to the rotor or the
• Ignition switch voltage drum. Any imperfections in the tone rings, such as a
broken tooth or a missing tooth, can cause an
• Unswitched battery voltage inaccurate wheel speed signal.
Outputs of the EBCM include the following items: Tire Size Calibration
• Three isolation solenoids (internal to the EHCU) The EBCM accepts wheel speed signals from
• Three dump solenoids (internal to the EHCU) several different sizes of tire and wheel
combinations. All vehicles are preprogrammed from
• The amber ABS indicator lamp the factory with the proper tire size calibration.
• The red BRAKE warning lamp Whenever you replace the EBCM or change the tire
• The pump motor size, you must reset the tire size calibration in the
EBCM using Scan Tool. Once programmed, this
A diagnostic serial data line (ABS only) is also
calibration will remain, even if the battery is
used for diagnostic service tools and assembly
disconnected or if the EBCM is removed from
plant testing.
the vehicle.
The EBCM monitors the speed of each wheel. If any
wheel approaches lockup, the EBCM controls the ABS System Operation
solenoids (isolation solenoid and dump solenoid) in ABS Indicator Lamp Operation
order to reduce brake pressure to the wheel The system uses an amber ABS indicator lamp in
the instrument cluster in order to show system
operation and malfunctions.
Normal Lamp Operation The EBCM constantly monitors wheel speed sensor
A bulb check occurs each time the ignition switch is inputs for rapid deceleration. If the ABS becomes
turned to the RUN position. The ANTILOCK and disabled for any reason, the driver will always have
BRAKE lamps should turn on, remain on for about base brakes. The normally-open isolation valves and
two seconds, then turn off. The ABS indicator lamp normally-closed dump valves will remain in these
also indicates system malfunctions. When the EBCM positions in order to allow normal fluid pressure to
detects a malfunction in the system, the EBCM turns the wheels.
the ANTILOCK and sometimes the BRAKE lamp on.
The lamp may remain on or turn off depending on ABS will not operate without wheel slip. The vehicle
the malfunction. In order to determine the specific must be going at least 13 km/h (8 mph) in order to
cause of the malfunction, refer to ABS Diagnostic begin ABS operation.
System Check. ABS Braking Mode
Tires and ABS The ABS will monitor the three-wheel speed sensors
Correct tire size, proper inflation, accurate alignment and control the hydraulic pressure changes at each
and even wear are needed for good brake wheel until the vehicle has come to a complete stop
performance. These items are essential for proper or until the driver has released the brake pedal. The
ABS performance. system operates through the following process:
Spare Tire 1. Pressure isolation/maintain
Use of the spare tire supplied with the vehicle will
not affect the performance of the system. 2. Pressure decrease
Replacement Tires 3. Pressure increase
If the replacement tires are not the same size as the 4. Brake release (fluid return)
original tires, you must change the tire size
Sequence Of Events
calibration within the EBCM using a Scan Tool. Refer
to Tire Size Calibration portion of ABS System 1. With the vehicle at 13 km/h (8 mph) or greater,
Description. Failure to change the tire calibration the driver depresses the brake pedal.
when replacing the original tires with a different size 2. The wheel speed begins to decrease as the
tire can affect the performance of the ABS. master cylinder pressure and brake
Self-Tests pressure increase.
The ABS performs the following two
3. As the wheel speed continues to decrease from
system self-tests:
vehicle speed, the normally-open isolation valve
• The first self-test is performed when the ignition for the affected channel closes to stop
is turned to RUN. Both the ABS indicator lamp additional pressure to the wheel. The master
and the BRAKE warning lamp will turn on for
cylinder pressure continues to increase as the
3 seconds, then they will turn off. This test
driver depresses the pedal, but the wheel
confirms correct operation of the EBCM and the
lamps. If one of the lamps remains on, either brake pressure is now limited to the
the ABS or the base brake system will ABS system pressure.
require service. 4. When the EBCM determines that the wheel is
• The second self-test is performed when the about to lock-up, the normally-closed dump
vehicle reaches a speed of greater than 3 mph. valve opens. This bleeds off some of the
At this time the internal EBCM relay, six pressure at the wheel cylinder (or caliper) in
solenoid coils and BPMV pump motor are order to allow the wheel to return to a speed
cycled and checked for shorts/opens. The closer to the speed of the vehicle.
BPMV pump will make a slight sound when this
5. The dump valve is again closed and the
function occurs.
isolation valve remains closed in order to allow
Normal Braking Mode the wheel speed to completely recover from
Refer to Normal Braking Mode in BPMV Hydraulic the lock-up.
Flow Chart.
During normal braking, pressure is applied through
6. Once the vehicle has recovered from the
lock-up tendency, the isolation valve is
the brake pedal. Fluid travels from the master
cylinder (2), through the combination valve (3) and momentarily pulsed open in order to allow the
into the BPMV (15). Once in the BPMV, the fluid master cylinder pressure and pump pressure to
travels through the normally-open isolation valves reach the brakes. This controlled pressure rise
(4, 6 and 14), through the normally-closed dump continues until the wheel is at optimum brake
valves (7, 10 and 13) and out into the brakes output or until the brake pressure is brought up
8 and 11). to master cylinder output pressure. The ABS
During normal braking, the pumps (5 and 16) are not allows the brake fluid to flow to the wheel, build
turned on. The low pressure accumulators and pressure and try to force another departure,
attenuators (9 and 12) are empty. Only residual repeating Step 3 through Step 6. The
pressure is stored in these accumulators following paragraphs describe the various
and attenuators. modes in detail.
Isolation Mode (Pressure Maintain) The fluid taken from the wheels forces a spring
Refer to Isolation Mode in BPMV Hydraulic back. The fluid is stored in the LPA at approximately
Flow Chart. 1034 kPa (150 psi). A portion of the fluid also primes
Isolation will occur when the driver applies excessive the pump (3) so it can begin building reapply
braking for the given road conditions, causing the pressure. The dump valves are opened
wheels to decelerate at a rate which exceeds the independently in order to control the deceleration of
vehicle’s capability. the wheel.
If the information from the wheel speed sensors Reapply Mode (Pressure Increase)
indicate excessive wheel deceleration (imminent Refer to Reapply Mode in BPMV Hydraulic
lock-up), the first step in the antilock sequence is to Flow Chart.
isolate the brake pressure being applied by The reapply sequence is initiated in order to obtain
the driver. optimum braking at each wheel. The isolation valve
The EBCM applies a voltage to the isolation coil in (4) is momentarily pulsed open in order to allow the
order to close the isolation valve (4). This will master cylinder (2) and pump (3) pressure to reach
prevent any additional brake pressure applied by the the brakes. This controlled pressure rise continues
driver from reaching the wheel. With the isolation until the wheel is at optimum brake output or until
valve closed, further increases in brake pressure the brake pressure is brought up to the master
from the driver will be prohibited. cylinder output pressure.
Dump Mode (Pressure Decrease) If more pressure is required, more fluid is drawn
Refer to Dump Mode in BPMV Hydraulic Flow Chart. from the master cylinder and applied to the brakes.
The driver will feel pedal pulsations or pedal drop.
Once the pressure is isolated, it must be reduced in This is normal and expected when in the
order to get the wheels rolling once again. Reducing antilock mode.
pressure is accomplished by dumping a portion of
the brake fluid pressure into a low pressure As fluid is reapplied, the wheels begin to slow down
accumulator (LPA). at the optimum rate. If the wheels approach
imminent lock-up again, the module will isolate,
The EBCM energizes the dump valve coil(s) in order dump and reapply. These control cycles (isolation,
to open the dump valve (5), allowing fluid from the dump and reapply) occur in millisecond intervals,
wheels to be dumped into the LPA (6). Very short allowing several cycles to occur each second.
activation pulses open and close the dump valve
passageway in order to control this action. Brake Brake Release
pressure is lowered at the wheel and allows the At the end of the antilock stop, when the driver
affected wheel to begin rolling again. releases the brake pedal, the motor will remain on
for a short time in order to help drain any fluid left in
the LPA. As the fluid drains back into the system,
the spring force in the LPA pushes the piston to the
home position. The isolation valve is turned off and
fluid returns through the isolation orifice.

J 39200 J 35616
Digital Multi-Meter Connector Adapter Test Kit
3430 11799
J 36169
Tech 2 Scan Tool
Fused Jumper Wire
1025 39438
INDEX 1
Air Cleaner (cont.)

A Assembly Replacement (7.4L)....................... 6-3192
Abbreviations and Their Meanings........................ 0-29 Element Replacement (4.3L)........................6-1595
ABS Handling..................................................................3 Element Replacement(5.0L, 5.7L).................. 6-2227
ABS/Traction Control Element Replacement (6.5L)........................6-2653
Bleed Procedure.................................................5-250 Element Replacement (7.4L)........................6-3192
Component Locations........................................ 5-173 Intake Duct Replacement (4.3L).................... 6-1598
Component Views.............................................. 5-175 Intake Duct Replacement (5.0L, 5.7L).......... 6-2230
Connector End Views................................. 5-177 Intake Duct Replacement (7.4L).................... 6-3194
Description Air Conditioning
Abbreviations and Definitions...................... 5-260 Compressor Control Circuit
ABS System ...................................................5-261 Diagnosis (7.4L).......................................... 6-3059
ABS System Operation.................................5-261 Diagnosis
Antilock Brakes System Introduction...........5-260 Compressor Control Circuit (4.3L).............6-1478
Basic Knowledge Required...........................5-260 Aluminum Wheel
Service Precautions.......................... ...........5-260 Clearcoat Damage.............................................. 3-118
Diagnosis Hub Cap Replacement...................................... 3-117
ABS Indicator Off No DTC S e t................... 5-245 Porosity Repair............................................. .....3-117
ABS Indicator On No DTC S e t................... 5-248 Recoating Procedure....................... ................. 3-118
Diagnostic System Check.............................5-179 Refinishing.......................................................... 3-117
Displaying Diagnostic Trouble Codes..........5-178 Automatic Transmission 4L60-E
Intermittents and Poor Connections............ 5-178 2-4 Servo............................................................ 7-182
Scan Tool Diagnostics................................... 5-178 Component Location......................................... 7-239
Self-Diagnostics............................................. 5-178 Component Location Table................................. 7-60
Schematic Description
ABS Schematic............................................. 5-169
Diagnosis........................................................ 7-232
ABS Schematic Icons................................... 5-169
Electronic Component................................... 7-233
ABS Schematic References......................... 5-168
Fluid Checking Procedure............................7-232
BPMV Hydraulic Flow Chart........................ 5-164
Transmission ID Information.........................7-229
Specification
Diagnosis
Fastener Tightening....................................... 5-163
2nd Gear S tart...............................................7-158
GM SPO Group Numbers.............................5-163
3-2 Flare or Tie-Up........................................7-154
ABS/T ractionControl
Component Resistance................................. 7-145
Diagnosis
Clearing Diagnostic Trouble Codes............. 5-178 Delay in Drive and Reverse.........................7-159
Accelerator Controls Drives in Neutral............................................7-158
Cable Replacement (4.3L)..............................6-1525 Electronic Component Malfunctions............ 7-149
Cable Replacement (5.0L, 5.7L).................... 6-2140 Fluid Leak....................................................... 7-160
Cable Replacement (7.4L)..............................6-3109 Front Oil Leak................................................ 7-159
Pedal Replacement (4.3L)..............................6-1529 Functional Test Procedure.............................. 7-52
Pedal Replacement (5.0L, 5.7L).................... 6-2143 Harsh Garage Shift........................................7-156
Pedal Replacement (7.4L)...............................6-3112 Harsh Shifts.................................................... 7-151
Accelerator Pedal Position Inaccurate Shift Points.................................. 7-151
Module Description (6.5L)...............................6-2666 Line Pressure Check Procedure................. 7-137
Module Replacement (6.5L)............................6-2589 No Drive in All Ranges................................. 7-159
Accessory Removal No Drive in Drive Range.............................. 7-159
(Engine Mechanical - 6.5L)...............................6-590 Noise and Vibration Analysis........................7-139
Accumulator and 2-1 Manual No P ark.......................................................... 7-158
Servo Replacement (Automatic 4L80-E).........7-518 Oil Out the Vent............................................. 7-158
Accumulator Assembly (Automatic 4L60-E).........7-217 Oil Pressure High or Low ............................. 7-150
Accumulator Housing Replacement Ratcheting Noise............................................7-159
(Automatic 4L80-E).............................................7-517 Road Test Procedure.................................... 7-138
Adapter Replacement Slipping or Rough 1-2 Shift..........................7-153
Transfer C ase..................................................... 4-291 Slips in 1st Gear............................................7-152
AFWD Speed Sensor Replacemen......... 4-296, 4-297 Third Gear O nly.............................................7-154
AFWD Speed Sensor Replacement..................... 4-297 Torque Converter Clutch................... 7-142
AIR Electronic Component Views.............................. 7-63
Check Valve/Pipe Replacement - Fluid/Filter Changing..........................................7-171
Bankl (7.4L)................................................. 6-3188 General Information............................................7-230
Air Cleaner Inline Harness Connector End View ..................7-64
Assembly Replacement (4.3L)....................... 6-1596 Internal Connector End Views............................7-65
Assembly Replacement (5.0L, 5.7L)..............6-2228 Oil Cooler Line Replacement............................ 7-174
Assembly Replacement (6.5L)....................... 6-2656 Oil Cooler Replacement.................................... 7-182
2 INDEX
Automatic Transmission 4L60-E (cont.) Automatic Transmission - 4L80-E (cont.)

Schematic Noise................................................................7-490
Controls Schematic Diagrams....................... 7-53 No P ark.......................................................... 7-481
Schematic Reference Table............................7-53 No Reverse.................................................... 7-481
Special Tools....................................................... 7-268 No Second Gear - D 1 .................................. 7-482
Specifications............... 7-39, 7-40, 7-41, 7-45, 7-49 No Second Gear - D 2 .................................. 7-483
Fluid Capacity...................................................7-48 No Second Gear - D 3 .................................. 7-484
Range Reference Table.................................. 7-48 No Second Gear - D 4 ................................. .7-486
Scan Tool Data Definitions............................. 7-43 No TCC Apply................................................7-488
Shift Speed Table.............................................7-50 No Third Gear - D 3 ...................................... 7-484
Temperature vs Resistance............................7-39 No Third Gear - D 4 ...................................... 7-487
Automatic Transmission - 4L80-E No Torque in Second G ear..........................7-491
Component Location..........................................7-555 No Torque Multiplication............................... 7-490
Component Location Table............................... 7-294 Oil Cooler Flow Test......................................7-472
Description Oil Out the Vent T ube.................................. 7-491
Adapt Function...............................................7-550 Overheating.................................................... 7-478
Component and System ............... 7-549 Overheating at W OT......................................7-478
Electronic Component................................... 7-550 Remains in Park.............................................7-481
General Description........................................7-549 Road Test Procedure.....................................7-463
General Service Information.........................7-547 Second Gear Only - D4................................ 7-485
Identification Information............................... 7-549 Second Gear Starts.......................................7-491
Diagnosis Slipping TC C .................................................. 7-489
Clutch Plate.................................................... 7-472 Soft Shift 2 to 1 .............................................7-495
Converter Ballooning......................................7-490 Soft Shift 2 to 3 .............................................7-495
Delayed Shift 1 to 2 .......................................7-496 Soft Shift 3 to 2 ............................................. 7-496
Does Not Stay in Park.................................. 7-481 Soft Shift D3 to D 2........................................7-496
Engine Coolant in Transmission.................. 7-472 Soft Shift into R .................. 7-495
Engine S ta ll........ ........................................... 7-490 Soft Shift R to D ............................................7-495
Engine Stall in Neutral.................................. 7-477 Soft Shifts....................................................... 7-495
Engine Starts in G ear................................... 7-479 Soft TCC Apply.............................................. 7-488
TCC Stuck O n................................................7-489
Erratic Shift Q uality....................................... 7-492
Third Gear Starts...........................................7-492
First Gear Only - D 4................................... 7-485
Torque Converter Clutc................................. 7-465
Fluid Foaming............................................. 7-490
Torque Converter Evaluation........................7-466
Fluid Leak
Transmission Seized......................................7-492
At Case Extension.................................... 7-497
Transmission S lips.........................................7-492
At Fill Tube............... ................................. 7-497
Vibration.......................................................... 7-491
At Oil Pan...................................................7-496
Electronic Component Views............................7-295
Forward Motion in Neutral............................7-477 Fluid/Filter Changing..........................................7-507
Fourth Gear Starts................................ 7-492 Internal Connector End Views..........................7-296
Functional Test Procedure............................7-286 Schematic
Harsh Shift 3 to 4 ..........................................7-494 Icon Table....................................................... 7-287
Harsh Shift 4 to 3 ..........................................7-494 Special Tools...................................................... 7-590
Harsh Shift D to R .........................................7-494 Specifcations
Harsh Shifts.................................................... 7-494 Component Resistance................................. 7-285
High Line Pressure........................................7-476 Specifications
Inaccurate Shift Points.................................. 7-493 Fastener Tightening......................... 7-269, 7-270
Inadequate Lubrication.................................. 7-477 Fluid Capacity................................................. 7-282
Line Pressure Check Procedure................. 7-463 General............................................................7-284
Loss of Drive................................ 7-479 Line Pressure Table................................. 7-285
Loss of Power................................................7-477 Range Signal.................................................. 7-284
Low Line Pressure........................... 7-478 Shift Speed Table...........................................7-283
No D2 to D1................................................... 7-496 Temperature vs Resistance..........................7-269
No D3 to D2.................. 7-496 Auxiliary
No Engine Braking - D 1 ............................... 7-482 Cooling Fan and Motor Replacement
No Engine Braking - D 2 ............................... 7-483 (Engine Cooling).............................................6-961
No Engine Braking - D 3 ...............................7-484 Cooling Fan Relay Replacement
No First Gear - D1........................................ 7-482 (Engine Cooling).............................................6-963
No First Gear - D2........................................ 7-483 Axle
No First Gear - D3........................................ 7-484 Shaft and Seal Replacement
No First Gear - D4........................................ 7-485 Front Drive A xle............................................... 4-60
No Fourth Gear - D 4 .................................... 7-487 Axle Replacement
No Gear Selection..........................................7-479 Rear Drive A xle........................ 4-147, 4-148, 4-150
INDEX 3
Brake Pedal
B Diagnosis
Backlash Adjustment Travel (Hydraulic Brakes)...............................5-39
Rear Drive A xle................................................. 4-143 Replacement (Hydraulic Brakes)....................... 5-59
Backlash Inspection and Adjustment Brake Rotor
Front Drive Axle.................................................... 4-90 Refinishing (Disc Brakes).................................. 5-119
Balance Shaft Replacement (Disc Brakes)..................5-116, 5-117
Clean and Inspect Brake Shoe
(Engine Mechanical - 4.3L)........................... 6-169 Inspection (Drum Brakes)................................. 5-125
Installation (Engine Mechanical - 4.3L)........... 6-204 Brake Warning
Removal (Engine Mechanical - 4.3L).............. 6-136 Description
Replacement (Engine Mechanical - 4.3L).........6-90 Brake Warning/lndicator Lamp
Ball Joint (Hydraulic Brakes)...................................... 5-86
Lower Ball Joint Replacement Brake Warning/lndicator Lamp Operation
Front Suspension................................. 3-53, 3-55 (Hydraulic Brakes)...................................... 5-86
Upper Ball Joint Replacement Diagnosis
Front Suspension................................. 3-48, 3-50 Indicator Always On (Hydraulic Brakes)...... 5-24
Battery Indicator Inoperative (Hydraulic Brakes)...... 5-26
Cable (Engine Electrical)................................. 6-1044 Burnishing Pads and Rotors
Charging (EngineElectrical).............................6-1039 Replacement (Disc Brakes).............................. 5-101
Replacement (Engine Electrical).................... 6-1043
Tray Replacement
(Engine Electrical)........................ 6-1045, 6-1047
Battery Disconnect......................................................... 3
c
Camshaft
Bearing Installation
Rear Drive A xle.....................................4-154, 4-156
(Engine Mechanical - 4.3L)......................... 6-167
Bearings Inspection Bearing Installation
Front Drive Axle.................................................... 4-82 (Engine Mechanical - 7.4L)......................... 6-865
Rear Drive A xle..................................................4-134 Bearing Removal
Boost Sensor Replacement (6.5L)..................... 6-2651 (Engine Mechanical - 4 .3L).............6-162, 6-164
Brake Backing Plate Replacement Bearing Removal
(Drum Brakes)........................................5-135, 5-136 (Engine Mechanical - 5.0L, 5.7L)................ 6-390
Brake Bluid Bearing Removal
Diagnosis (Engine Mechanical - 7.4L).......................... 6-862
Leaks (Hydraulic Brakes)................................ 5-39 Installation (Engine Mechanical - 4.3L)........... 6-203
Brake Booster Installation
Push Rod Gauging Procedure (Engine Mechanical - 5.0L, 5.7L)................ 6-424
(Hydraulic Brakes)............................................5-81 Installation (Engine Mechanical - 6.5L)........... 6-656
Brake Caliper Installation (Engine Mechanical - 7.4L)........... 6-900
Bracket Replacement (Disc Brakes).................5-116 Position Sensor Replacement (4.3L)............. 6-1591
Caliper and Anchor Plate Wear Position Sensor
Adjustment (Disc Brakes)............................. 5-108 Replacement (5.0L, 5.7L)...........................6-2220
Inspection (Disc Brakes)....................................5-110 Position Sensor Replacement (7.4L)............. 6-3183
Overhaul (Disc Brakes)........................5-110, 5-113 Removal (Engine Mechanical - 4.3L).............. 6-138
Replacement (Disc Brakes)..... 5-101, 5-104, 5-106 Removal (Engine Mechanical - 5.0L, 5.7L) ....6-365
Brake Drum Removal (Engine Mechanical - 6.5L).............. 6-610
Inspection (Drum Brakes).................................. 5-124 Removal (Engine Mechanical - 7.4L).............. 6-836
Replacement (Drum Brakes).............................5-124 Replacement (Engine Mechanical - 4.3L)......... 6-95
Brake D ust............................................................ 3 Replacement
Brake Fluid...................................................................... 4 (Engine Mechanical - 5.0L, 5.7L)................ 6-317
Description Replacement (Engine Mechanical - 6.5L)....... 6-560
Brake Fluid and Brake Fluid Replacement (Engine Mechanical - 7.4L).......6-785
Handling (Hydraulic Brakes).......................5-83 CDR Valve and Hoses Replacement (6.5L)......6-2652
Brake Hose Center Bearing Replacement
Front Brake Hose Replacement Propeller Shaft...................................................... 4-17
(Hydraulic Brakes).................................5-62, 5-63 Cleaning Carrier Components
Brake Lining Front Drive A x le ...................................................4-82
Replacement (Drum Brakes)............... 5-126, 5-131 Clutch
Brake Modulator Assembly..............................................................7-606
Pressure Modulator Valve Concentric Slave Cylinder................................. 7-608
Replacement (ABS)....................................... 5-251 Description
Brake Pads Clutch Driven Members................................ 7-610
Inspection (Disc Brakes)..................................... 5-92 Clutch Driving Members................................ 7-610
Replacement (Disc Brakes)............5-93, 5-95, 5-98 Clutch Operating Members...........................7-610
4 INDEX
Clutch (cont.) Crankshaft

Diagnosis Balancer Installation
Actuator Fluid Leaks..................................... 7-600 (Engine Mechanical - 4 .3 L )..........................6-218
Does Not Disengage..................................... 7-594 Balancer Installation
Grabbing (Chattering).................................... 7-595 (Engine Mechanical - 6.5L), 6-663
Master Cylinder Fluid Leaks.........................7-600 Balancer Installation
Noisy................................................................7-597 (Engine Mechanical - 7.4L)..........................6-913
Pedal Hard to P ush...................................... 7-598 Balancer Removal
Pedal Spongy................................................. 7-600 (Engine Mechanical - 4 .3 L )..........................6-126
Pedal Stays on Floor Balancer Removal
(Clutch Disengaged)................................. 7-597 (Engine Mechanical - 5.0L, 5.7L)................ 6-354
Pedal Sticks or Binds.................................... 7-601 Balancer Removal
Pedal Travels to Floor (Engine Mechanical - 6 .5 L )..........................6-604
(Fluid in Master Cylinder).........................7-599 Balancer Removal
Preliminary Checking Procedure................. 7-594 (Engine Mechanical - 7 .4 L )..........................6-825
Rattle (Trans C lick)....................................... 7-596 Balancer Replacement
Release Bearing Noisy (Engine Mechanical - 4 .3L)............................ 6-80
w/Clutch Engaged..................................... 7-597 Balancer Replacement
Slipping............................................ 7-595 (Engine Mechanical - 6 .5 L )........................ 6-538
Spin Down Time......................... 7-594 Balancer Replacement
Unable to Select G ears................................7-601 (Engine Mechanical - 7 .4 L )..........................6-764
Hydraulic Clutch Bleeding................................. 7-605 CKP System Variation
Master Cylinder Replacement...........................7-603 Learn Procedure (4.3L)............................... 6-1513
Pedal Replacement............................................7-602 Position Sensor Replacement (4.3L)............ 6-1588
Special Tools....................................................... 7-611 Position Sensor
Specifications Replacement (5.0L, 5.7L)........................... 6-2218
Fastener Tightening........................................7-593 Position Sensor Replacement (6.5L)............ 6-2639
Start Switch......................................................... 7-605 Position Sensor Replacement (7.4L)............ 6-3181
Clutch Dust...................................................................... 4 System Variation Learn Procedure (7.4L).... 6-3099
Coding Keys and Lock Cylinders............................0-34 Cylinder
Colors Boring and Honing
Exterior and Interior..............................................0-22 (Engine Mechanical - 4 .3 L )...................... 6-146
Combination Valve Boring and Honing
Replacement (Hydraulic Brakes).........................5-61 (Engine Mechanical - 5.0L,5.7L)...............6-373
Control and Shift Solenoids Boring and Honing
Replacement (Automatic 4L60-E).................... 7-202 (Engine Mechanical - 6 .5 L )...................... 6-618
Control Arm Boring and Honing
Lower Control Arm Replacement (Engine Mechanical - 7 .4 L )...................... 6-844
Front Suspension..................................3-63, 3-64 Head Assemble
Upper Control Arm Replacement (Engine Mechanical - 4 .3 L )...................... 6-178
Front Suspension................................. 3-60, 3-62 Head Assemble
Control Module Replacement (Engine Mechanical - 5.0L,5.7L)...............6-403
Transfer Case..................................................... 4-295 Head Assemble
Control Valve (Engine Mechanical - 6 .5 L )..........................6-640
Assembly (Automatic 4L60-E)...........................7-212 Head Assemble
Control Valve Body (Engine Mechanical - 7 .4L).......................... 6-875
Replacement (Automatic 4L80-E).................... 7-535 Head Clean and Inspect
Conversion Table (Engine Mechanical - 4 .3 L )..........................6-174
English/Metric...........................................................0-3 Head Clean and Inspect
Coolant (Engine Mechanical - 6 .5 L )..........................6-637
Recovery Reservoir Replacement Head Clean and Inspect
(Engine Cooling).............................................6-948 (Engine Mechanical - 7 .4 L )........................ 6-870
Recovery System Description...........................6-986 Head Disassemble
Cooler Lines (Engine Mechanical - 4 .3L).......................... 6-173
Engine Oil Cooler Line Replacement Head Disassemble
(Engine Cooling).............................................6-952 (Engine Mechanical - 5.0L, 5.7L)................ 6-396
Crankcase Head Disassemble
Description (Engine Mechanical - 6 .5 L )..........................6-636
Ventilation System (4.3L)...........................6-1637 Head Disassemble
Ventilation System (5.0L,5 .7 L )................. 6-2274 (Engine Mechanical - 7 .4 L )..........................6-869
Ventilation System (7.4L)...........................6-3235 Head Installation
Diagnosis (Engine Mechanical - 4 .3 L )..........................6-212
Ventilation System (4.3L)...........................6-1506 Head Installation
Ventilation System Description(6.5L)..............6-2673 (Engine Mechanical - 5.0L, 5.7L).... 6-430, 6-431
INDEX 5
Cylinder (cont.) Distributor
Head Installation Inspection (Engine Electrical)......................... 6-1076
(Engine Mechanical - 6.5L)..........................6-658 Installation (Engine Mechanical - 4.3L)........... 6-219
Head Installation Installation
(Engine Mechanical - 7.4L)..............6-905, 6-906 (Engine Mechanical - 5.0L, 5.7L).................6-438
Head Removal Installation (Engine Mechanical - 7.4L)........... 6-910
(Engine Mechanical - 4.3L)..........................6-131 Overhaul (Engine Electrical)...........................6-1068
Head Removal Removal (Engine Mechanical - 4.3L).............. 6-129
(Engine Mechanical - 5.0L, 5.7L)............... 6-359 Removal (Engine Mechanical - 5.0L, 5.7L) ....6-356
Head Removal Removal (Engine Mechanical - 7.4L).............. 6-827
(Engine Mechanical - 6.5L)..........................6-608 Replacement (Engine Electrical)..... 6-1060, 6-1066
Head Removal Drain Cock
(Engine Mechanical - 7.4L)..........................6-831 Replacement (Engine Cooling).........................6-974
Head Replacement Draining and Filling Cooling System
(Engine Mechanical - 4.3L)............................6-76 (Engine Cooling)................................................. 6-945
Head Replacement Drive Axle
(Engine Mechanical - 5.0L, 5.7L)............. 6-301 Disassemble
Head Replacement Rear Drive Axle..............................................4-129
(Engine Mechanical - 6.5L)..........................6-517 Final Assembly
Head Replacement Rear Drive Axle.............................................. 4-147
(Engine Mechanical - 7.4L)..........................6-757 Drive Belt
Diagnosis (Engine Mechanical - 7.4L)............ 6-702
Replacement
D (Engine Mechanical - 5.0L, 5.7L)................ 6-263
Replacement (Engine Mechanical - 4.3L)......... 6-47
Decimal and Metric Equivalents................................ 0-3
Defective Scan Tool....................................................... 6 Replacement (Engine Mechanical - 7.4L)....... 6-711
Definition of Caution, Notice, andImportant................ 3 Tensioner Diagnosis
Diagnosis (Engine Mechanical - 7.4L).............6-470, 6-706
Valve Train.............................................................6-32 Tensioner Replacement
Diagnostic Work Sheets.............................................0-6 (Engine Mechanical - 4.3L)............................ 6-48
Differential Tensioner Replacement
Case Assembly (Engine Mechanical - 7 .4L).......................... 6-712
Rear Drive Axle..............................................4-137 Drum Brake Adjustment.........................................5-142
Differential to Axle Housing Assemble Drum Brakes
Rear Drive Axle..............................................4-141 Specifications
Inspection Component..................................................... 5-123
Rear Drive Axle..............................................4-134 Fastener Tightening.......................................5-123
Differential Carrier GM SPO Group Numbers............................5-123
Assembly Replacement System Description.............................................5-143
Front Drive A xle ...............................................4-65 DTC B1015..............................................................9J-72
Bushing Replacement DTC B1016..............................................................9J-76
Final Assembly DTC B1018..............................................................9J-84
Overhaul DTC B1021.............................................................. 9J-90
Front Drive A xle ...............................................4-72 DTC B1022.......................... 9J-94
Differential Case Assembly DTC B1024..............................................................9J-98
Assemble DTC B1025............................................................9J-101
Front Drive A xle ...............................................4-87 DTC B1026............................................................9J-104
Differential Pilot DTC B1035............................................................9J-108
Bearing Replacement DTC B1036............................................................ 9J-110
Front Drive A xle ............................................... 4-61 DTC B1051............................................................ 9J-113
Disc Brakes DTC B1053............................................................9J-114
Description...........................................................5-120 DTC B1054............................................................9J-115
Diagnosis DTC B1061........................................................... 9J-122
Brake Rotor Lateral Runout Check............... 5-91 DTC B1071............................................................9J-124
Brake Rotor Thickness Variation C heck...... 5-91 DTC P0101 ................ 6-1177, 6-1743, 6-2346, 6-2759
Brake Rotor Tolerance.................................... 5-91 DTC P0102................. 6-1182, 6-1748, 6-2349, 6-2763
Special Tools....................................................... 5-121 DTC P0103 ................ 6-1186, 6-1752, 6-2353, 6-2767
Specifications DTC P0106............................................ 6-1189, 6-1755
Caliper Wear Shim...........................................5-89 DTC P0107 ..............................6-1192, 6-1758, 6-2770
Component....................................................... 5-89 DTC P0108 ..............................6-1196, 6-1761, 6-2773
Fastener Tightening..........................................5-89 DTC P0112 ................6-1200, 6-1765, 6-2356, 6-2777
GM SPO Group Numbers............................... 5-89 DTC P0113 ................6-1203, 6-1767, 6-2359, 6-2779
6 INDEX
DTC P0117..................6-1206, 6-1770, 6-2362, 6-2782 DTC P0304........................................................... 6-2458
DTC P0118.................. 6-1208, 6-1773, 6-2365, 6-2785 DTC P0305........................................................... 6-2460
DTC P0121 ................ 6-1211, 6-1776, 6-2368, 6-2788 DTC P0306........................................................... 6-2462
DTC P0122................. 6-1214, 6-1778, 6-2371, 6-2790 DTC P0307........................................................... 6-2464
DTC P0123................. 6-1217, 6-1781, 6-2374, 6-2793 DTC P0308........................................................... 6-2466
DTC P0125............................................ 6-1220, 6-1784,6-2796 DTC P0325............................... 6-1283, 6-1877, 6-2874
DTC P0126........................................................... 6-2377 DTC P0327............................... 6-1286, 6-1880, 6-2877
DTC P0131 ...............................6-1222, 6-1786, 6-2798 DTC P0335........................................................... 6-2468
DTC P0132............................................6-1225, 6-1789,6-2801DTC P0336............................... 6-1290, 6-1884, 6-2881
DTC P0133............................................ 6-1228, 6-1792,6-2804 DTC P0337............................... 6-1293, 6-1887, 6-2884
DTC P0134................ 6-1231, 6-1795, 6-2807 DTC P0338............................... 6-1296, 6-1890, 6-2887
DTC P0135............................................ 6-1234, 6-1798,6-2810 DTC P0339............................... 6-1299, 6-1893, 6-2890
DTC P0137...........................................................6-1801,6-2813DTC P0340............................... 6-1302, 6-1896, 6-2893
DTC P0138...........................................................6-1805,6-2817DTC P0341 ...............................6-1305, 6-1899, 6-2896
DTC P0140...........................................................6-1808,6-2820DTC P0370........................................................... 6-2471
DTC P0141 ............................................. 6-1811, 6-2823 DTC P0380........................................................... 6-2475
DTC P 0143.......................................................... 6-1237,6-1815
DTC P0400.............. 6-2478
DTC P0144.......................................................... 6-1240,6-1819DTC P0401...............6-1307, 6-1901, 6-2481, 6-2898
DTC P0146 ............................................ 6-1243, 6-1822 DTC P0402........................................................... 6-2483
DTC P0147...........................................................6-1246,6-1826DTC P0404................. 6-1311, 6-1905, 6-2485, 6-2902
DTC P0151 .............................. 6-1249, 6-1830, 6-2827 DTC P0405.................6-1315, 6-1909, 6-2487, 6-2906
DTC P0152............................................ 6-1252, 6-1833,6-2830 DTC P0406........................................................... 6-2490
DTC P0153............................................ 6-1255, 6-1836,6-2833 DTC P0410..............................................6-1912, 6-2909
DTC P0154............................................ 6-1258, 6-1839,6-2836 DTC P0420............................... 6-1319, 6-1917, 6-2913
DTC P0155.............................................6-1261, 6-1842,6-2839 DTC P0430..............................................6-1921, 6-2917
DTC P0157......... 6-1845, 6-2842 DTC P0440............................... 6-1323, 6-1924, 6-2920
DTC P0158...........................................................6-1848,6-2845DTC P0442............................... 6-1328, 6-1929, 6-2925
DTC P0160 ............................................ 6-1851, 6-2848 DTC P0446............................... 6-1332, 6-1933, 6-2929
DTC P0161 ............................................. 6-1854, 6-2851 DTC P0452............................... 6-1336, 6-1937, 6-2933
DTC P0171...............................6^1264, 6-1858, 6-2855 DTC P0453............................... 6-1340, 6-1940, 6-2937
DTC P0172............................................ 6-1268, 6-1862,6-2859 DTC P0461.................6-1343, 6-1943, 6-1945, 6-2940
DTC P0174............................................ 6-1272, 6-1866,6-2863 DTC P0462.................6-1346, 6-1947, 6-1949, 6-2943
DTC P0175............................................ 6-1276, 6-1870,6-2867 DTC P0463.................6-1349, 6-1952, 6-1955, 6-2946
DTC P0182............................................................6-2380 DTC P0500............................... 6-1352, 6-1958, 6-2949
DTC P0183............................................................6-2383 DTC P0501 ............................................................6-2493
DTC P0215............................................................6-2386 DTC P0502.................................................... 7-69, 7-304
DTC P0216 ............................................................6-2389 DTC P0503.................................................... 7-72, 7-308
DTC P0218...................................... 7-67, 7-298, 7-301 DTC P0506............................... 6-1355, 6-1961, 6-2952
DTC P0219............................................................6-2393 DTC P0507............................... 6-1357, 6-1963, 6-2954
DTC P0220 ............................................................6-2395 DTC P0560.................................................. 7-312, 7-315
DTC P0221 ............................................................ 6-2397 DTC P0567............................................................6-2496
DTC P0222............................................................6-2400 DTC P0568............................................................6-2498
DTC P0223........ 6-2403 DTC P0571 ............................................................6-2501
DTC P0225............................................................6-2406 DTC P0601 ............................................. 6-2504, 6-2956
DTC P0226............................................................ 6-2408 DTC P0602.............................................. 6-2505, 6-2957
DTC P0227............................................................ 6-2411 DTC P0603............................................................6-2959
DTC P0228............................................................ 6-2414 DTC P0604.............................................. 6-2506, 6-2960
DTC P0231 ............................................................ 6-2417 DTC P0605............................................................6-2961
DTC P0236 ............................................................ 6-2420 DTC P0606...................................................... 6-2507
DTC P0237..................................................... 6-2423 DTC P0704................................6-1369, 6-1975, 6-2962
DTC P0238 ............................................................ 6-2426 DTC P0711 ....................................... 7-75, 7-318, 7-322
DTC P0251 ........................................................... .6-2429 DTC P0712........................................7-79, 7-326, 7-329
DTC P0263............................... ...6-2433 DTC P0713........................................7-83, 7-332, 7-336
DTC P0266 ............................................................6-2435 DTC P0716.................................................. 7-340, 7-343
DTC P0269 ............................................................6-2437 DTC P0717.................................................. 7-347, 7-350
DTC P0272............................................................6-2439 DTC P0719........................................ 7-87, 7-353, 7-357
DTC P0275............................................................6-2441 DTC P0722..............................................................7-360
DTC P0278............... 6-2443 DTC P0723..............................................................7-365
DTC P0281 ............................................................ 6-2445 DTC P0724........................................ 7-90, 7-370, 7-373
DTC P0284............................................................6-2447 DTC P0730.................................................. 7-375, 7-378
DTC P0300............... 6-1280, 6-1874, 6-2449, 6-2871 DTC P0740 ................................................................7-92
DTC P0301 ............................................................ 6-2452 DTC P0741 ..................................................7-381, 7-384
DTC P0302........................ 6-2454 DTC P0742........................................ 7-95, 7-387, 7-390
DTC P0303 ............................................................6-2456 DTC P0748........................................7-98, 7-393, 7-397
INDEX 7
DTC P0751 .............................................................7-102 EGR (cont.)
DTC P0753............................................... 7-105, 7-407,7-411 System Description (4.3L)...............................6-1636
DTC P0756................................................7-109, 7-415,7-418 System Description (6.5L)............................... 6-2673
DTC P0758................................................ 7-112, 7-421,7-425 System Description (7.4L)............................... 6-3233
DTC P0785..............................................................7-116 Valve Replacement (4.3L)............................... 6-1593
DTC P1106.............................................6-1372, 6-1978,6-2965 Valve Replacement (5.0L, 5.7L).....................6-2225
DTC P1107.............................................6-1376, 6-1981,6-2968 Valve Replacement (6.5L)............................... 6-2647
DTC P1111 ...............................6-1379, 6-1984, 6-2971 Valve Replacement (7.4L)...............................6-3191
DTC P1112.............................................6-1382, 6-1987,6-2974 Vent Solenoid Replacement (6.5L)................ 6-2649
DTC P1114.............................................6-1385, 6-1989,6-2976 Electrical Connector Replacement
DTC P1115.............................................6-1388, 6-1991,6-2979 Transfer Case.....................................................4-298
DTC P1121............................... 6-1391, 6-1994, 6-2982 Electric Coolant Fan...................................................... 4
DTC P1122.............................................6-1394, 6-1997,6-2985 Electric Motor Replacement
DTC P1125............................................................ 6-2508 Transfer Case........................................ 4-291, 4-293
DTC P1133............................................. 6-1397, 6-2000,6-2988 Electronic Brake Control
DTC P1134............................................ 6-1400, 6-2003,6-2991 Module Replacement (ABS).............................. 5-250
DTC P1153............................................ 6-1403, 6-2006,6-2994 Engine Block
DTC P1154............................................. 6-1406, 6-2009,6-2997 Clean and Inspect
DTC P1191............................................................ 6-2510 (Engine Mechanical - 4 .3 L ).......................... 6-145
DTC P1214........................................................... 6-2512 Clean and Inspect
DTC P1216........................................................... 6-2514 (Engine Mechanical - 6 .5 L ).......................... 6-617
DTC P1217........................................................... 6-2517 Clean and Inspect
DTC P1218........................................................... 6-2520
(Engine Mechanical - 7 .4 L )..........................6-843
DTC P1336............................................6-1409, 6-2012,6-3000
Plug Installation
DTC P1345............................................6-1413, 6-2015,6-3003
(Engine Mechanical - 4.3L)..........................6-196
DTC P1351 .............................. 6-1415, 6-2018, 6-3005
Plug Installation
DTC P1361 .............................. 6-1418, 6-2021, 6-3009
DTC P1380............................................6-1421, 6-2024,6-3012 (Engine Mechanical - 7 .4 L )..........................6-892
DTC P1381 .............................. 6-1423, 6-2026, 6-3014 Plug Removal
DTC P1404............................................6-1425, 6-2028,6-3016 (Engine Mechanical - 4.3L)..........................6-142
DTC P1406........................................................... 6-2522 Plug Removal
DTC P1409........................................................... 6-2524 (Engine Mechanical - 5.0L, 5.7L).................6-369
DTC P1415............................................. 6-2031, 6-3019 Plug Removal (Engine Mechanical - 7 .4 L )..... 6-840
DTC P1416............................................. 6-2034, 6-3021 Engine Controls - 4.3L
DTC P1441 .............................. 6-1428, 6-2037, 6-3023 Connector End Views....................................... 6-1148
DTC P1508............................................ 6-1432, 6-2040,6-3026 Engine Controls - 4.3L
DTC P1509............................................ 6-1435, 6-2043,6-3030 Component Location Table............................. 6-1128
DTC P1621 ........................................................... 6-2527 Component Views............................................. 6-1133
DTC P1626...............6-1440, 6-2048, 6-2528, 6-3034 Description
DTC P1627........................................................... 6-2530 Air Intake System.........................................6-1637
DTC P1630............................................. 6-2531, 6-3036 Long Term Fuel T rim .................................. 6-1628
DTC P1631...............6-1445, 6-2053, 6-2532, 6-3037 Serial Data Communications...................... 6-1611
DTC P1635........................................................... 6-2536 Short Term Fuel Trim.................................. 6-1627
DTC P1641 ........................................................... 6-2539 Speed Density System ............................... 6-1628
DTC P1643........................................................... 6-2541 Diagnosis
DTC P1653........................................................... 6-2543 Alcohol-in-Fuel.............................................. 6-1494
DTC P1654........................................................... 6-2547 Backfire..........................................................6-1474
DTC P1655........................................................... 6-2549 Cuts Out, Misses..........................................6-1469
DTC P1656........................................................... 6-2553 Detonation/Spark K nock............................. 6-1467
DTC P1810................................................ 7-120, 7-429,7-433 Dieseling, Run-On........................................6-1474
DTC P1811...............................................................7-437 EGR System................................................. 6-1503
DTC P1860................................................ 7-124, 7-440,7-444 Hard Start..................................................... 6-1464
DTC P1870................................................ 7-128, 7-448,7-452 Hesitation, Sag, Stumble............................6-1468
DTC P1875................................................ 7-133, 7-456,7-459 Idle Air Control System............................... 6-1507
Poor Fuel Economy.................................... 6-1470
Powertrain OBD System Check................ 6-1153
E Surges/Chuggles..........................................6-1465
EGR Symptoms..................................................... 6-1461
Control Pressure Password Learn Procedure............................. 6-1513
Sensor Replacement (6.5L)........................6-2650 Schematic
Description Engine Controls.............................................6-1115
System Description (5.0L, 5.7L)................ 6-2273 Icon Table...................................................... 6-1114
Solenoid Filter Replacement (6.5L)............... 6-2649 Reference Table........................................... 6-1114
Solenoid Replacement (6.5L)..........................6-2648 Special Tools.................................................... 6-1639
8 INDEX
Engine Controls - 4.3L (cont.) Engine Controls - 6.5L....................................... (cont.)

Specifications CDR Valve Test............................................6-2580
DTC Type..................................................... 6-1108 Contamination Testing................................. 6-2569
Fastener Tightening..... ............... 6-1089 Cruise Control..............................................6-2566
GM SPO Group Numbers........................... 6-1112 Cuts Out, Misses..........................................6-2563
Scan Tool Data Definitions.........................6-1096 Data Link Connector................................... 6-2338
Scan Tool Data List..................................... 6-1090 Excessive Smoke.........................................6-2564
Temperature vs Resistance........................6-1089 Fuel Heater Functional............................... 6-2573
Engine Controls - 5.0L, 5.7 Fuel Injection System ................................. 6-2577
Specifications Fuel Knock/Combustion N oise.................. 6-2562
Scan Tool Data Definitions.........................6-1651 Fuel Manager/Filter..................................... 6-2572
Engine Controls - 5.0L, 5.7L Fuel Pump Relay Circuit............................. 6-2343
Diagnosis Fuel Quality...... ........................................... 6-2570
Backfire..........................................................6-2080 Fuel Return System.................................... 6-2578
Electric Cooling Fan.................................... 6-2088 Fuel Sender.................................................. 6-2570
Engine Controls - 5.0L, 5.7L Fuel Supply System Check........................6-2571
Component Location Table............................. 6-1691 Fuel Tank Leak Check................................ 6-2569
Component Views.............................................6-1696 Glow Plug System Check........................... 6-2578
Connector End Views...................................... 6-1713 Hard Start..................................................... 6-2560
Description Hesitation, Sag, Stumble............................ 6-2563
Air Intake System........................................ 6-2274 Injection Nozzle(s)....................................... 6-2577
Long Term Fuel Trim................................... 6-2264 Poor Fuel Economy.................................... 6-2563
Diagnosis........................................... 6-2084, 6-2113 Powertrain OBD System Check................ 6-2333
Cuts Out, Misses......................................... 6-2075 Specific Gravity Testing.............................. 6-2570
Data Link Connector................................... 6-1725 Surges/Chuggles..........................................6-2561
Detonation/Spark Knock..............................6-2074 Symptoms..................................................... 6-2559
Dieseling, Run-On....................................... 6-2080 Water-in-Fuel Lamp Circuit.........................6-2575
EGR System................................................. 6-2117 Password Learn Procedure............................. 6-2583
EVAP Control System................................. 6-2105 Schematic
Fuel Injector Balance Test..........................6-2093 Schematic Diagrams................................... 6-2292
Fuel Injector Circuit..................................... 6-2099 Schematic Icon Table.................................. 6-2292
Fuel Injector Coil Test................................. 6-2097 Schematic Reference Table........................6-2291
Fuel S ystem ............... 6-1733 Special Tools.................................................... 6-2675
Fuel Tank Pressure Sensor........................6-2101 Specificaitons
Hard S tart..................................................... 6-2070 DTC Type.............................................. 6-2287
Poor Fuel Economy.....................................6-2077 Specifications
Surges/Chuggles..........................................6-2072 Fastener Tightening.................................... 6-2280
Symptoms..................................................... 6-2068 Fuel System................................................. 6-2290
Vehicle Control Module............................... 6-2083 GM SPO Group Number............................ 6-2290
Password Learn Procedure.............................6-2128 Scan Tool Data Definitions.........................6-2284
Schematic Scan Tool Data L is t.................................... 6-2281
Icon Table..................................................... 6-1673 Temperature vs Resistance........................6-2279
Reference Table...........................................6-1673 Engine Controls - 7.4L
Special Tools..................................................... 6-2276 Component Location Table............................. 6-2714
Specifications Component Views.............................................6-2719
DTC Type..................................................... 6-1662 Connector End Views.......................................6-2734
Fastener Tightening..................................... 6-1643 Description
GM SPO Group Numbers...........................6-1671 Air Intake System.........................................6-3235
Scan Tool Data List..................................... 6-1644 Enhanced Ignition System.......................... 6-3230
Temperature vs Resistance........................6-1643 Fuel Supply Component............................. 6-3222
Engine Controls - 6.4L Long Term Fuel T rim .................................. 6-3229
Diagnosis Serial Data Communications......................6-3209
Surges/Chuggles..........................................6-3044 Short Term Fuel Trim.................................. 6-3229
Engine Controls - 6 .5 L ........................................ 6-2325 Speed Density System ............................... 6-3229
Component Location Table............................. 6-2305 Diagnosis.......................................................... 6-3059
Component Views.............................................6-2309 Backfire......................................................... 6-3052
Connector End Views...................................... 6-2331 Crankcase Ventilation System....................6-3091
Description Cuts Out, Misses..........................................6-3047
Air intake System.........................................6-2674 Data Link Connector................................... 6-2742
Fuel Supply Component............................. 6-2670 Detonation/Spark K nock............................. 6-3046
Serial Data Communications......................6-2659 Dieseling, Run-On........................................6-3052
Diagnosis EGR System................................................. 6-3088
Air Cleaner.................................................... 6-2580 Electric Cooling Fan.................................... 6-3062
Air Conditioning Request Circuit................ 6-2565 Enhanced Ignition System..........................6-3081
INDEX 9
Engine Controls - 7.4L (cont.) Engine Diagnosis - 4.3L
EVAP Control System................................. 6-3078 Diagnosis
Fuel Injector Balance Test..........................6-3067 Cranks but Does Not Run..........................6-1162
Fuel Injector Circuit..................................... 6-3073 Fuel Pump Relay Circuit............................. 6-1164
Fuel Injector Coil Test................................. 6-3071 Fuel System .................................................6-1167
Fuel Pump Relay Circuit.............................6-2746 Engine Diagnosis - 4.3L
Fuel System .................................................6-2749 Diagnosis
Fuel Tank Pressure Sensor........................6-3075 Data Link Connector................................... 6-1159
Hard Start..................................................... 6-3042 Engine Electircal
Hesitation, Sag, Stumble............................6-3047 Starting and Charging
Idle Air Control System............................... 6-3092 Connector End Views.................................6-1002
Knock Sensor System................................. 6-3085 Engine Electric
Poor Fuel Economy.................................... 6-3049 Specifications
Powertrain OBD System Check................ 6-2737 Fastener Tightening...................................... 6-991
Secondary Air Injection System ................ 6-3085 Engine Electrical
Symptoms..................................................... 6-3040
:Schematic
Vehicle Control Module............................... 6-3055
Starting and Charging Icons.........................6-993
Vehicle Control Module Outputs................ 6-3056
Fuel Pressure Relief Procedure......................6-3117 Starting and Charging
Password Learn Procedure.............................6-3099 Component Views....................................... 6-1000
Schematic Component Locations........................................ 6-998
Schematic Diagrams................................... 6-2701 Description
Schematic Icons...........................................6-2700 Battery......................................................... 6-1079,6-1080
Schematic References................................ 6-2700 Battery Operation........................................6-1082,6-1084
Special Tools..................................................... 6-3236 Charging System......................................... 6-1084
Specifications Charging System Operation...................... 6-1085
DTC Type..................................................... 6-2695 Ignition System............................................ 6-1086
Fastener Tightening..................................... 6-2677 Starting System Circuit............ ..................6-1079
GM SPO Group Numbers...........................6-2698 Starting System Operation......................... 6-1079
Scan Tool Data List..................................... 6-2678 Diagnosis
Temperature vs Resistance........................6-2677 Battery Load Test......................... 6-1012
Engine Controls - 7.4LSpecification Charge Indicator Always On.......................6-1014
Scan Tool Data Definitions.............................. 6-2684 Charge Indicator Inoperative......................6-1014
Engine Coolant Temperature Charging System Check............................. 6-1005
Sensor Replacement (4.3L)............................6-1515 Generator Assembly
Sensor Replacement (5.0L, 5.7L).................. 6-2130
Bench Check.............................................. 6-1017,6-1018
Sensor Replacement (6.5L)............................6-2584
Generator Electrical Test............................6-1016
Sensor Replacement (7.4L)............................6-3100
Engine Cooling Ignition Coil Test...........................................6-1018
Component Views...............................................6-931 Noisy Generator...........................................6-1016
Connector End Views..................................... ...6-932 Parasitic Load Test..................................... 6-1012
Description Spark Plug Visual.........................................6-1019
Coolant Recovery System ............................6-986 Spark Plug Wire Harness...........................6-1021
Cooling System..............................................6-985 Starter Motor Noise.....................................6-1008,6-1010
Electric Engine Cooling Fan.........................6-988 Starter No Load Test..................... 6-1010
Radiator Assembly........................................ 6-986 Starter Solenoid Does Not C lick............... 6-1005
Radiator Filler Cap Assembly.......................6-987 Starting System Check............................... 6-1004
Thermostat...................................................... 6-989 Voltmeter Reading High/Low......................6-1015
Water Pump.................................................... 6-989 Schematic
Diagnosis Starting and Charging................................... 6-993
Coolant Concentration Testing......................6-941 Starting and Charging References.............. 6-993
Cooling System Special Tools....................................................6-1087
Leak Testing......................... 6-942, 6-943, 6-944 Specifications...................................................... 6-992
Fan Clutch...................................................... 6-940 Battery Usage Table..................................... 6-991
Loss of Coolant..............................................6-936 Starter Motor Usage Table...........................6-992
Overheating.................................................... 6-934
Engine Exhaust
Thermostat......................................... 6-938, 6-939
Catalytic Converter
Schematic
Replacement..... 6-3262, 6-3264, 6-3266, 6-3268
Cooling Fan.................................................... 6-929
Cooling Fan Icons..........................................6-929 Description
Cooling Fan References............................... 6-929 Exhaust System.......................................... 6-3270
Special Tools....................................................... 6-990 Diagnosis
Specifications Exhaust Leakage (Not OBD II)..................6-3260
Fastener Tightening........................................6-927 Restricted Exhaust................................... ...6-3260
GM SPO Group Numbers.............................6-927 Vibration or Rattling.................................... 6-3260
10 INDEX
Engine Exhaust (cont.) Engine Mechanical - 4 .3 L .................................. (cont.)
Specifications Disassembled View.............................................. 6-42
Fastener Tightening.....................................6-3259 Service Prior to Assembly................................. 6-196
GM SPO Group Numbers...........................6-3259 Specifications............................................. 6-25, 6-29
System Inspection................................. 6-3262 Fastener Tightening........................................ 6-23
Engine Flywheel GM SPO Group Numbers.............................. 6-27
Clean and Inspect Engine Mechanical - 5.0L, 5.7L
(Engine Mechanical - 4.3L)...........................6-155 Description
Clean and Inspect Engine Components.......................................6-444
(Engine Mechanical - 7.4L)...........................6-855 Lubrication...................................................... 6-446
Installation (Engine Mechanical - 4.3L)........... 6-223 Separating Parts.............................................6-449
Installation Thread Repair................................................ 6-447
(Engine Mechanical - 5.0L, 5.7L)................ 6-441 Diagnosis
Installation (Engine Mechanical - 6.5L)........... 6-676 Base Engine Misfire...................................... 6-246
Installation (Engine Mechanical - 7.4L)........... 6-917 Drive Belt........................................................ 6-253
Removal (Engine Mechanical - 4.3L).............. 6-124 Drive Belt Tensioner...................................... 6-257
Removal (Engine Mechanical - 5.0L, 5.7L).... 6-352 Engine Noise.................................................. 6-248
Removal (Engine Mechanical - 6.5L).............. 6-591 Oil Consumption.............................................6-251
Removal (Engine Mechanical - 7.4L).............. 6-821 Oil Leak...........................................................6-251
Replacement (Engine Mechanical - 4.3L)....... 6-111 Valve Train...................................................... 6-248
Replacement Disassembled V iew ............................................ 6-258
(Engine Mechanical - 5.0L, 5.7L)....6-339, 6-340 Service Prior to Assembly................................. 6-417
Replacement (Engine Mechanical - 6.5L).......6-570 Specifications...................................................... 6-245
Replacement (Engine Mechanical - 7.4L).......6-809 Engine Mechanical........................... 6-239, 6-241
Engine Front Cover Installation Fastener Tightening...................................... 6-237
(Engine Mechanical - 4.3L)...............................6-208 GM SPO Group Numbers............................ 6-243
Engine Front Cover Installation Engine Mechanical - 6.5L
(Engine Mechanical - 6.5L)...............................6-662 Description
Engine Front Cover Installation Cleanliness and C a re ................................... 6-681
(Engine Mechanical - 7.4L)............................... 6-902 Engine Components.......................................6-679
Engine Front Cover Removal Lubrication.................................................... ..6-680
(Engine Mechanical - 4.3L)............................... 6-135 Replacing Engine G askets........................... 6-681
Engine Front Cover Removal Separating Parts.............................................6-682
(Engine Mechanical - 5.0L, 5.7L).................... 6-363 Tools and Equipment.................................... 6-683
Engine Front Cover Removal Diagnosis
(Engine Mechanical - 6.5L)............................... 6-605 Drive Belt........................................................ 6-466
Engine Front Cover Removal Engine Compression Test............................. 6-462
(Engine Mechanical - 7.4L)............................... 6-834 Engine Noise.................................................. 6-462
Engine Front Cover Replacement Oil Leak...........................................................6-464
(Engine Mechanical - 4.3L)................................. 6-82 Valve Train...................................................... 6-463
Engine Front Cover Replacement Disassembled V iew ............................................ 6-471
(Engine Mechanical - 6.5L)............................... 6-545 Special Tools.............................. 6-684
Engine Front Cover Replacement Specifications.........................................6-456, 6-461
(Engine Mechanical - 7.4L)............................... 6-771 Fastener Tightening.......................................6-455
Engine ID and Partial VIN Location.......................0-12 GM SPO Group Numbers............................ 6-459
Engine Mechanical - 4.3L........................................ 6-32 Engine Mechanical - 7.4L
Description Description
Cleanliness and Care.................................... 6-230 Cleanliness and C a re ................................... 6-922
Identification.................................................... 6-227 Engine Comonents................................ 6-919
Lubrication...................................................... 6-229 Lubrication...................................................... 6-922
Replacing Engine Gaskets............................6-230 Replacing Engine Gaskets........................... 6-923
Separating Parts.............................................6-231 Thread Repair................................................ 6-922
Thread R epair................................................ 6-229 Tools and Equipment.................................... 6-924
Tools and Equipment.................................... 6-232 Desription
Desription Separating Parts.............................................6-924
Engine Components...................................... 6-226 Diagnosis
Diagnosis Base Engine Misfire.......................... 6-693
Base Engine Misfire........................................ 6-30 Engine Noise.................................................. 6-695
Drive B elt...........................................................6-37 Oil Consumption............................................. 6-700
Drive Belt Tensioner.........................................6-41 Oil Leak.......................................................... 6-700
Engine Compression Test............................... 6-32 Valve Train...................................................... 6-698
Engine Noise.................................................... 6-32 Disassembled V iew ............................................6-707
Oil Consumption............................................... 6-35 Identification........................................................ 6-921
Oil Leak.............................................................6-35 Service Prior to Assembly................................. 6-892
INDEX 11
Engine Mechanical - 7.4L (cont.) Exhaust Manifold (cont.)
Specifications.........................................6-688, 6-692 Clean and Inspect
Fastener Tightening....................................... 6-687 (Engine Mechanical - 6.5L)........................ 6-646
Engine Mount Clean and Inspect
Inspection (Engine Mechanical - 4.3L).............6-50 (Engine Mechanical - 7.4L)..........................6-889
Inspection Installation
(Engine Mechanical - 5.0L, 5.7L)................ 6-266 (Engine Mechanical - 4.3L)............ 6-222, 6-223
Inspection (Engine Mechanical - 6.5L)...........6-481 Installation (Engine Mechanical - 6.5L)...........6-667
Inspection (Engine Mechanical - 7.4L)...........6-715 Installation
Replacement (Engine Mechanical - 7.4L)............ 6-914, 6-916
(Engine Mechanical - 4.3L)....... 6-51, 6-53, 6-55 Removal (Engine Mechanical - 4.3L)............. 6-125
Replacement Removal
(Engine Mechanical - (Engine Mechanical - 5.0L, 5.7L)....6-352, 6-353
5.0L, 5.7L)....................... 6-267, 6-268, 6-270, Removal (Engine Mechanical - 6.5L).............. 6-600
6-271, 6-272, 6-273 Removal
Replacement (Engine Mechanical - 7 .4 L ).............6-822, 6-824
(Engine Mechanical - 6.5L)..............6-482, 6-484 Replacement (Engine Mechanical -4.3L).........6-74
Replacement Replacement
(Engine Mechanical - 7.4L)..............6-716, 6-718 (Engine Mechanical - 5.0L, 5.7L)....6-297, 6-299
Engine Oil Pressure Sensor/Switch Replacement
Replacement (6.5L)......................................... 6-2639 (Engine Mechanical - 6 .5 L ).............6-511, 6-514
Replacement
Engine Replacement
(Engine Mechanical - 7 .4 L )................... 6-752
(Engine Mechanical -4.3L).............................. 6-112
Extension Housing Rear
Engine Replacement
Oil Seal (Automatic 4L60-E)............................7-216
(Engine Mechanical -5.0L, 5.7L)....................6-341
Exterior and Interior Colors..................................... 0-22
Engine Replacement
(Engine Mechanical -6.5L).............................. 6-580
Engine Replacement
(Engine Mechanical -7.4L).............................. 6-811 F
Engine Set-Up and Testing Fan
(Engine Mechanical - 4.3L)............................... 6-225 Clutch Replacement
Engine Set-Up and Testing (Engine Cooling)................................. 6-959, 6-960
(Engine Mechanical - 5.0L, 5.7L).................... 6-443 Electric Engine Cooling Fan Description........ 6-988
Engine Set-Up and Testing Shroud Replacement
(Engine Mechanical - 6.5L).................... 6-678 (Engine Cooling)................................. 6-975, 6-978
Engine Set-Up and Testing Fastener Notice...............................................................6
(Engine Mechanical - 7.4L)............................... 6-918 Filler Tube and Seal Replacement
English/Metric Conversion Table............................... 0-3 (Automatic 4L80-E).............................................7-510
EVAP Filler Tube Replacement (4.3L)............. 6-1559, 6-1560
Canister Purge Solenoid Filler Tube Replacement
Valve Replacement (4.3L)...........................6-1584 (5.0L, 5.7L)..........................................6-2185, 6-2187
Filler Tube Replacement (7.4L)..............6-3154, 6-3156
Canister Purge Solenoid Valve
Filler Tube Replacement (Automatic 4L60-E).....7-188
Replacement (5.0L, 5.7L)...........................6-2214
Flushing (Engine Cooling)..................................... 6-947
Canister Purge Solenoid Valve
Flywheel to Torque Converter Bolts
Replacement (7.4L)..................................... 6-3179
(Automatic 4L60-E)....................................... , 7-190
Canister Replacement (4.3L)..........................6-1587
Forward Servo Replacement
Canister Replacement (5.0L, 5.7L).............. ,.6-2217 (Automatic 4L80-E).............................. 7-521
Canister Replacement (7.4L)..........................6-3180 Front Axle
Description Replacement
Control System (4.3L)................................. 6-1628 Front Suspension.............................................3-85
Control System (5.0L, 5 .7 L ).......................6-2264 Front Coil Springs
Control System (7.4L)................................. 6-3229 Replacement
Diagnosis Front Suspension............................................ 3-67
Control System (4.3L)................................. 6-1494 Front Drive Axle
System Cleaning (4.3L)................................... 6-1587 Assembly Replacement.......................................4-67
System Hoses/Pipes Description............................................................ 4-97
Replacement (5.0L, 5.7L)...........................6-2217 Diagnosis.............................................................. 4-51
Vent Valve Replacement (4.3L)..................... 6-1586 Four Wheel Drive Diagnosis...........................4-52
Vent Valve Replacement (5.0L, 5.7L)............ 6-2216 Noise Diagnosis...............................................4-50
Vent Valve Replacement (7.4L)......... 6-3180 Special Tools........................................... 4-98
Exhaust Manifold Specification
Clean and Inspect Fastener Tightening........................................ 4-49
(Engine Mechanical - 4.3L)...........................6-194 GM SPO Group Numbers.............................. 4-49
12 INDEX
Front Drive Axle (cont.) Fuel Pipe Fitting..............................................................4
Lubrication....................................... 4-49 Fuel Pressure..................................................................6
Front Suspension Connection Valve
Component Locations................. 3-37 Replacement (5.0L, 5 .7L)...........................6-2205
Description Connection Valve Replacement (7.4L).......... 6-3173
General Description......................................... 3-88 Regulator Replacement
Diagnosis (CSFI) (5.0L, 5.7L)...................................... 6-2206
Ball Joint Wear Check.................................... 3-42 Regulator Replacement (SFI) (7.4L)............. 6-3176
Special Tools......................................................... 3-90 Fuel Pressure Connection
Specifications Valve Replacement (4.3L)............................. 6-1575
Fastener Tightening......................................... 3-35 Fuel Pressure Regulator
GM SPO Group Number................................ 3-35 Replacement (CSFI) (4.3L)............................. 6-1576
Fuel and EVAP Pipe................................ 4 Fuel Pressure Relief Procedure (4.3L).............. 6-1533
Fuel Balance Pump Replacement (7.4L)...........6-3160 Fuel Pressure Relief Procedure
Fuel Feed and Fuel Return Pipe (5.0L, 5.7L)....................................................... 6-2148
Purge Procedure (6.5L)................................... 6-2632 Fuel Pump
Fuel Filter Relay Replacement (4.3L).............................6-1582
Element Replacement (4.3L)..........................6-1540 Relay Replacement(5.0L, 5.7L)...................... 6-2212
Element Replacement (5.0L, 5.7L)................ 6-2155 Relay Replacement (6.5L)............................. 6-2638
Element Replacement (6.5L)..........................6-2591 Relay Replacement (7.4L)............................. 6-3178
Element Replacement (7.4L)..........................6-3124 Replacement (4.3L)..........................................6-1563
Fuel Heater Replacement (5.0L, 5.7L).......................... 6-2190
Replacement (6.5L)......................................... 6-2601 Replacement (7.4L)..........................................6-3159
Fuel Hose/Pipes Fuel Pump and Engine Oil PRESS
Assembly Switch Replacement (7.4L)............................. 6-3178
Replacement (4.3L)...... 6-1568, 6-1569, 6-1571 Fuel Pump and Engine Oil PRESS
Assembly Replacement Sensor Replacement (4.3L)............................ 6-1583
(5.0L, 5.7L).................... 6-2196, 6-2197, 6-2198, Fuel Rail Assembly Replacement (7.4L)........... 6-3174
6-2199, 6-2201 Fuel Sender
Assembly Replacement (6.5L)........................6-2631 Assembly Replacement (4.3L)........................6-1562
Assembly Fuel Sender Assembly
Replacement (7.4L)..................... 6-3165, 6-3166, Replacement (5.0L, 5.7L)................................ 6-2188
6-3167, 6-3169 Replacement (6.5L)..........................................6-2627
Replacement Replacement (7.4L)..........................................6-3157
(Engine Compartment) (4.3L).................... 6-1565 Service (6.5L)................................................... 6-2629
Replacement Fuel Storage................................................................... 4
(Engine Compartment) (5.0L, 5.7L)...........6-2193 Fuel Supply Component
Replacement (Engine Description (4.3L).............................................6-1621
Compartment) (7.4L)................................... 6-3162 Fuel System
Cleaning (4.3L)................................................. 6-1573
Fuel Injection
Pump Installation Cleaning (5.0L, 5.7L)........................................6-2203
(Engine Mechanical - 6.5L)...........................6-664 Cleaning (6.5L)................................................. 6-2631
Pump Removal Description (6.5L).............................................6-2666
(Engine Mechanical - 6.5L)...........................6-602 Description - CSFI (4.3L)................................ 6-1619
Pump Replacement (6.5L).............................. 6-2633 Description - CSFI (5.0L, 5 .7 L )......................6-2254
Fuel Injector Description - SFI (7.4L)....................................6-3219
Balance Test (4.3L)..........................................6-1484 Fuel System Cleaning (7.4L).............................. 6-3171
Circuit Diagnosis (4.3L)................................... 6-1490 Fuel Tank
Coil Test (4.3L)................................................. 6-1488 Draining Procedure (4.3L)............................... 6-1541
Replacement (4.3L)..........................................6-1582 Draining Procedure (5.0L, 5.7L).....................6-2156
Replacement (CSFI) (5.0L, 5.7L)................... 6-2212 Draining Procedure (6.5L)............................... 6-2603
Replacement (SFI) (7.4L)................................6-3177 Draining Procedure (7.4L)............................... 6-3125
Fuel Lift Pump Replacement (6.5L)................... 6-2629 Pressure Sensor Diagnosis (4.3L)................. 6-1492
Fuel Manager/Filter Pressure Sensor Replacement (4.3L)........... 6-1558
Replacement (6.5L)......................................... 6-2594 Pressure Sensor Replacement
Water Draining Procedure (6.5L)................... 6-2596 (5.0L, 5.7L)................................................... 6-2184
Fuel Metering Pressure Sensor Replacement (7.4L)........... 6-3153
Description Replacement (4.3L)..........................6-1541, 6-1545,
System Components (5.0L, 5.7L).............. 6-2259 6-1550, 6-1555
System Component Description (4.3L)..........6-1623 Replacement (5.0L, 5.7L).... 6-2156, 6-2160, 6-2164,
System Component Description (7.4L)..........6-3225 6-2168, 6-2173,
6-2177, 6-2181
INDEX 13
Fuel Tank (cont.) Hydraulic Brakes (cont.)
Replacement (6.5L)......................... 6-2603, 6-2607, Diagnosis
6-2610, 6-2615, Accumulator Leak-Down Test........................ 5-48
6-2620, 6-2623 Brake Hose and Pipe Diagnosis....................5-40
Replacement (7.4L)...........6-3125, 6-3129, 6-3133, Brake System...................................................5-30
6-3137, 6-3142, Brake System Testing..................................... 5-30
6-3146, 6-3150 External Conditions that Affect Brake
Performance.................................................5-30
Hydraulic System Fluid Loss..........................5-40
Seal Leak......................................................... 5-49
G Pipe Replacement........................................ 5-62
Gasoline/Gasoline Vapors..............................................4 Scheamtic
Gear Tooth Brake Warning System Schematic Icons....... 5-7
Contact Pattern Check Schematic
Front Drive A xle ...............................................4-92 Brake Warning System..................................... 5-7
Rear Drive Axle..............................................4-144 Brake Warning System
General Information Schematic References.................................. 5-7
Special Tools Table...............................................0-40 Special Tools........................................................ 5-88
Generator Specification
Overhaul (Engine Electrical)............................6-1052 Brake System..................................................... 5-5
Replacement (Engine Electrical)..... 6-1049, 6-1051 Fastener Tightening...........................................5-5
Glow Plug GM SPO Group Numbers................................ 5-5
Relay Replacement (6.5L)............................... 6-2641 System Bleeding................................................... 5-65
Replacement (6.5L)......................................... 6-2644 System Flushing...................................................5-68
System Description (6.5L)............................... 6-2672
Ground Strap
Replacement (Engine Electrical).................... 6-1049 l
Identification
Vehicle...................................................................... 0-6
H Idle Air Control
Valve Replacement (4.3L)...............................6-1523
Handling Electrostatic Discharge (ESD) Valve Replacement (5.0L, 5 .7L).................... 6-2137
Sensitive Parts.................................................. 6 Valve Replacement (7.4L)...............................6-3106
Handling Idle Air Control (IAC) Valve..........................7 Ignition OFF When Disconnecting Battery..................7
Heated Oxygen Sensor (H02S) Indicator Switch
Replacement (4.3L)..........................................6-1518 Replacement
Replacement (5.0L, 5.7L)................................ 6-2133 Front Drive A xle...............................................4-55
Replacement (7.4L)......................................... 6-3102 Injection Line(s) Replacement (6.5L)................. 6-2637
Heat Shield Replacement (Automatic 4L80-E)....... 7-533 Injection Nozzle(s) Replacement (6.5L)............. 6-2638
How to Obtain Replacement Labels.......................0-22 Injection Timing Adjustment (6.5L)..................... 6-2636
How to Use the Paper Version of the In-Line Fuel Filter
Service Manual....................................................... 0-4 Replacement (4.3L).......................... 6-1538, 6-1539
Hub and Drum Assembly Replacement In-Line Fuel Filter Replacement (5.0L, 5.7L) ....6-2154
Rear Drive A xle .................................................. 4-151 In-Line Fuel Filter Replacement (7.4L).............. 6-3123
Hub and Rotor Assembly Replacement Intake Air Resonator Replacement (4.3L)......... 6-1599
Rear Drive A xle .................................................. 4-153 Intake Air Resonator
Hub Cap Replacement (5.0L, 5.7L)................................ 6-2231
Aluminum Wheel Hub Cap Replacement....... 3-117 Intake Air Resonator Replacement (7.4L)......... 6-3196
Hydraulic Booster Intake Air Temperature
Diagnosis Sensor Replacement (4.3L)..........................6-1522
Functional Test (Hydraulic Brakes)................ 5-48 Sensor Replacement(5.0L, 5.7L).................... 6-2136
Noise (Hydraulic Brakes)................................ 5-46 Sensor Replacement (6.5L)..........................6-2588
Diagnosis (Hydraulic Brakes).........5-42, 5-43, 5-45 Sensor Replacement (7.4L)..........................6-3106
Hydraulic Brake Intake Manifold
Booster Replacement Assemble (Engine Mechanical - 4 .3L)............ 6-190
(Hydraulic Brakes)............5-71, 5-73, 5-76, 5-78 Assemble (Engine
Hydraulic Brakes Mechanical - 5.0L, 5.7L)............................... 6-413
Brake Warning System Assemble (Engine Mechanical - 7.4L)............ 6-886
Component Locations..................................... 5-10 Clean and Inspect
Brake Warning System Components View....... 5-11 (Engine Mechanical - 4 .3 L )..........................6-189
Brake Warning System Clean and Inspect
Connector End View s..................................... 5-19 (Engine Mechanical - 6 .5L)..........................6-646
Description Clean and Inspect
Booster Description..........................................5-84 (Engine Mechanical - 7.4L)..........................6-884
14 INDEX
Intake Manifold (cont.)
Disassemble (Engine Mechanical - 4.3L)....... 6-185 M
Disassemble Maintenance and Lubricant
(Engine Mechanical - 5.0L, 5.7L)................6-409 Periodic Maintenance Inspection.............0-83, 0-84
Disassemble (Engine Mechanical - 7.4L)....... 6-881 Maintenance and Lubrication
Installation Explanation of Scheduled Services................... 0-76
(Engine Mechanical - 4.3L)..............6-214, 6-215 Inspections and Other Services..........................0-81
Installation Long Trip/Highway Maintenance
(Engine Mechanical - 5.0L, 5.7L)................6-434 Schedule.................................................. 0-66, 0-72
Installation Manitenance Schedule.........................................0-45
(Engine Mechanical - 6.5L).... 6-672, 6-673, 6-674 Owner Checks and Services.............................. 0-75
Installation (Engine Mechanical - 7.4L)........... 6-907 Short Trip/City Maintenance
Removal (Engine Mechanical - 4.3L).............. 6-130 Schedule.................................................. 0-46, 0-53
Removal (Engine Mechanical - 5.0L, 5.7L).....6-357 Specifications
Removal (Engine Mechanical - Drive Belt Tension............................................0-41
6.5L).......................................6-593, 6-594, 6-595 Fluid Capacities................................................0-41
Removal (Engine Mechanical - 7.4L).............. 6-829 Maintenance Items...........................................0-43
Replacement (Engine Recommended Fluids and Lubricants........... 0-42
Mechanical - 4.3L)................................6-57, 6-60 Tire Inflation Pressure..................................... 0-43
Replacement (Engine Manifold Absolute Pressure
Mechanical - 5.0L, 5.7L)............................ 6-274,6-282 Sensor Replacement (5.0L, 5.7L)...................6-2132
Replacement (Engine Sensor Replacement (7.4L)............................ 6-3101
Mechanical - 6 .5 L )...................................... 6-489,6-492 Manifold Air Pressure
Sensor Replacement (4.3L)............................ 6-1517
Replacement (Engine
Manual Transmission - New Venture
Mechanical - 7 .4 L )...................................... 6-723,6-729
Backup Lamp Switch.................................. 7-19, 7-20
Diagnosis
Clutch Spin Down Time.................................... 7-8
J Fluid Check..............................................................7-9
Jacking and Lifting................................................... 0-37 Fluid Replacement.......................................7-11, 7-12
Shift Lever............................................................ 7-14
Special Tools........................................................ 7-37
Specifications
K Fastener Tightening...........................................7-7
Key Coding and Lock Cylinders.............................0-34 Lubrication...................................... 7-7
Knock Sensor Transmission Replacement............ 7-22, 7-27, 7-31
Description Vehicle Speed Sensor................................7-15, 7-17
System Description (5.0L, 5.7L)................ 6-2271 Manual Transmission- New Venture
Replacement (4.3L)..........................................6-1592 Diagnosis
Replacement (5.0L, 5.7L)................................ 6-2221 Manual Transmission.........................................7-8
Replacement (7.4L)..........................................6-3184 Mass Air Flow
System Description (4.3L)............................... 6-1635 Sensor Replacement (4.3L)............................ 6-1516
System Description (7.4L)............................... 6-3232 Sensor Replacement (5.0L, 5.7L)...................6-2131
System Diagnosis (4.3L)................................. 6-1502 Sensor Replacement (6.5L)............................ 6-2585
Sensor Replacement (7.4L)............................ 6-3100
Master Cylinder
Bench Bleeding (Hydraulic Brakes)....................5-58
L Description (Hydraulic Brakes)............................ 5-83
Label Diagnosis (Hydraulic Brakes).............................. 5-39
Anti-Theft Labeling................................................0-17 Overhaul (Hydraulic Brakes)............................... 5-54
Service Parts ID ................................................... 0-17 Replacement
Labels, Replacement (Hydraulic Brakes)...................... 5-50, 5-51, 5-52
How to Obtain....................................................... 0-22 Reservoir Filling (Hydraulic Brakes)........ ..........5-50
Latched DTC B1018, B1024 Notice Meanings of Abbreviations.......................................0-29
(SDN-RSD).................................................................. 7 Moving Parts and Hot Surfaces....................................4
Leaf Springs Replacement MWheel Alignment
Front Suspension.................................................. 3-69 Measuring..............................................................3-23
Lifting and Jacking.................................................... 0-37
Lock Cylinders and Key C oding............................. 0-34
Lower O-Ring Removal................................................. 4
Lubricant Change N
Front Drive Axle.................................................... 4-53 Nylon Fuel Lines.............................................................7
INDEX 15
Oil Cooler
o On-Board Diagnostic (Level 2) (OBDII)
System Description....................................................7
One-Piece Propeller Shaft Replacement............... 4-10
Flushing (Automatic 4L80-E).............................7-545 Ordering Information
Oil Cooler Flushing (Automatic 4L60-E).............. 7-227 Special Tools.......................................................... 0-6
Oil Cooler Line Replacement Output Shaft
(Automatic 4L80-E).............................................7-522 Shaft, Bearing, and Tube Replacement
Oil Pan Front Drive A xle...............................................4-58
Clean and Inspect Output Shaft Seal Replacement
(Engine Mechanical - 4.3L)...........................6-185 Transfer Case........................................ 4-278, 4-279
Clean and Inspect
(Engine Mechanical - 5.0L, 5.7L)................ 6-409
Clean and Inspect P
(Engine Mechanical - 7.4L)............. 6-881
Installation (Engine Mechanical - 4.3L)........... 6-209 Park Brake
Installation (Engine Brake Drum
Mechanical - 5.0L, 5.7L)...............................6-428 Replacement...................................................5-157
Installation (Engine Mechanical - 6.5L)........... 6-656 Cable Replacement...... 5-151, 5-153, 5-154, 5-157
Installation (Engine Mechanical - 7.4L)........... 6-903 Cable Service/Adjustment................................. 5-159
Removal (Engine Mechanical - 4.3L).............. 6-133 Description
Removal (Engine Mechanical - 5.0L, 5.7L).... 6-361 System............................................................ 5-161
Diagnosis
Removal (Engine Mechanical - 6.5L).............. 6-611
Removal (Engine Mechanical - 7.4L).............. 6-833 Hydraulic Park Brake............................... 5-146
Lever Replacement........................................... 5-149
Replacement (Automatic 4L60-E).....................7-191
Lubrication Procedure....................................... 5-149
Replacement (Engine Mechanical - 4.3L).......6-103
Shoe Replacement............................................ 5-147
Replacement (Engine
Special Tools......................................................5-162
Mechanical - 5.0L, 5.7L)...............................6-327
Specification
Replacement (Engine Mechanical - 6.5L).......6-574
GM SPO Group Numbers........... ................5-145
Replacement (Engine Mechanical - 7.4L)...... 6-798
Specifications
Oil Pan Replacement (Automatic 4L80-E)........... 7-509
Fastener Tightening...................................... 5-145
Oil Pump
Park Lock Pawl and Actuator
Assemble (Engine Mechanical - 4.3L)............. 6-182
Assemble (Engine Mechanical -
Park/Neutral
5.0L, 5.7L)...................................................... 6-407
Back Up Switch Adjustment
Assemble (Engine Mechanical - 6.5L)............. 6-644
(Automatic 4L60-E)....................................... 7-171
Assemble (Engine Mechanical - 7.4L)............. 6-878 Back Up Switch Replacement
Clean and Inspect (Engine (Automatic 4L60-E)....................................... 7-170
Mechanical - 4 .3 L )........................................ 6-182 Park/Neutral Back Up Switch
Clean and Inspect (Engine Adjustment (Automatic 4L80-E)........................7-507
Mechanical - 5.0L, 5.7L)............................... 6-406 Replacement (Automatic 4L80-E).....................7-506
Clean and Inspect (Engine Pinion
Mechanical - 6 .5 L )........................................ 6-643 Bearing Cup Installation
Clean and Inspect (Engine Front Drive A xle...............................................4-83
Mechanical - 7 .4 L )........................................ 6-878 Depth Adjustment
Disassemble (Engine Mechanical - 4.3L)........6-180 Front Drive A xle...............................................4-84
Disassemble (Engine Rear Drive Axle..............................................4-135
Mechanical - 5.0L, 5.7L)............................... 6-404 Installation
Disassemble (Engine Mechanical - 6.5L)........6-642 Front Drive A xle...............................................4-85
Disassemble (Engine Mechanical - 7.4L)........ 6-876 Rear Drive Axle..............................................4-139
Drive Installation (Engine Oil Seal Replacement
Mechanical - 6 .5 L )........................................ 6-668 Rear Drive Axle..................... 4-118, 4-121, 4-125
Drive Removal (Engine Mechanical - 6.5L) ....6-600 Pinion, Flange, and Dust Deflector
Drive Replacement (Engine Replacement
Mechanical - 6 .5 L )........................................ 6-496 Front Drive Shaft............................................. 4-62
Installation (Engine Mechanical - 4.3L)........... 6-209 Pinion and Ring Gear Inspection
Installation (Engine Mechanical - 6.5L)........... 6-655 Rear Drive Axle..............................................4-134
Removal (Engine Mechanical - 4.3L).............. 6-134 Ring and Pinion Gear Inspection
Removal (Engine Mechanical - 6.5L).............. 6-611 Front Drive A xle...............................................4-82
Replacement (Engine Mechanical - 4.3L).......6-106 Piston and Connecting Rod Assemble
Replacement (Engine Mechanical - 6.5L).......6-578 (Engine Mechanical - 4.3L)........................... 6-161
Replacement (Engine Mechanical - 7.4L).......6-804 Piston and Connecting Rod Assemble
Oil Seal (Engine Mechanical - 6.5L)........................... 6-629
Oil Seal and/or Bearing Replaceme Piston and Connecting Rod Assemble
Rear Drive Axle............................... 4-113 (Engine Mechanical - 7.4L)........................... 6-861
16 INDEX
Piston Selection (Engine Mechanical - 4.3L)......6-160 Rear Drive Axle (cont.)
Piston Selection (Engine Mechanical - Specification
5.0L, 5.7L)........................................................... 6-388 GM SPO Group Numbers............................ 4-104
Piston Selection (Engine Mechanical - 6.5L)......6-629 Lubrication...................................................... 4-104
Piston Selection (Engine Mechanical - 7.4L)......6-860 Pinion Bearing and Differential
Powertrain Control Module Bearing Preload..............................................4-104
Connector End Views (6.5L)...........................6-2325 Specifications
Description Fastener Tightening...................................... 4-103
General (6.5L)..............................................6-2658 Spacer and Shim ...........................................4-103
Replacement/Programming (6.5L)..................6-2581 Rear Drive Axle - Locking/Limited Slip Rear Axle
Pressure Regulator Replacement Locking Differential Assemble........................... 4-179
(Automatic 4L80-E).............................................7-515 Rear Drive Axle - Locking/Limited Slip Rear Axle
Propeller Shaft Locking Differential Adjustment.........................4-178
Description............................................................ 4-23 Locking Differential Cam Unit Assembly......... 4-178
Center Bearing.................................................4-26 Locking Differential Cam Unit Disassembly ....4-177
Phasing Description........................................ 4-24 Locking Differential Cleaning and
Universal Joint.................................................. 4-25 Inspection....................................................... 4-178
Diagnosis Locking Differential Disassemble.........4-170, 4-176
Knock or Clunk Noise....................................... 4-7 Special Tools...................................................... 4-180
Leak at Front Slip Yoke.................................... 4-6 Specification
Ping, Snap, or Click Noise...............................4-6 Lubrication Specifications............................. 4-169
Roughness or Vibration.................................... 4-6 Reaction Block, 10 1/2 Inch Axle................ 4-169
Scraping Noise................................. 4-7 Thrust Block Sizes (Locking)........................4-169
Shudder on Acceleration at Low Speed........ 4-7 Specifications
Squeak Noise..................................................... 4-7 Fastener Tightening.......................................4-169
Replacement...................................................4-8, 4-9 Rear Extension Housing Replacement
Special Tools......................................................... 4-27 Transfer Case..................................................... 4-281
Specifications Rear Suspension
Fastener Tightening............................................4-5 Component Locations...........................................3-94
GM SPO Group Numbers................................. 4-5 Description
Runout Specifications........................................ 4-5 General Description........................................ 3-111
Proper Use of Torque W renches............................0-26 Specifications
Fastener Tightening.........................................3-93
GM SPO Group Numbers.............................. 3-93
Relieving Fuel Pressure................................................ 4
Q Reverse Servo Replacement
Quick Connect Fitting(s) Service (Automatic 4L80-E).............................................7-521
Metal Collar (4.3L)............................................6-1533 Road Test........................................................................ 4
Metal Collar (5.0L, 5.7L)................................. 6-2149
Metal Collar (7.4L)............................................6-3118
Plastic Collar (4.3L)......................................... 6-1536
Plastic Collar (5.0L, 5 .7 L )............................... 6-2152
s
Plastic Collar (7.4L)......................................... 6-3121 Safety Glasses and Compressed Air........................... 5
Safety Goggles and Fuel.............................................. 5
Schematic
Schematic Locations..........................................7-287
R Seat Belt
Radiator Child Seat Tether Outer Hardware K it............9J-39
Assembly Description........................................ 6-986 Seat Belts
Filler Cap Assembly Description.......................6-987 Child Restraint Tether Anchor........................... 9J-40
Hose Replacement Description
(Engine Cooling)................... 6-949, 6-950, 6-951 System Operation........................................... 9J-46
Replacement (Engine Cooling).........................6-981 Emergency Locking Retractor Checks...............9J-2
Rear Drive Axle Front Seat Belt Height Adjuster
Description Replacement................................................... 9J-23
Rear Axle Description................................... 4-164 Front Seat Belt Replacement....... 9J-3, 9J-6, 9J-9,
Disassembled V ie w ............................................4-161 9J-11, 9J-14,
Rear Drive Axle 9J-17, 9J-20
Axle Housing Inspection.................................... 4-134 Intermediate Seat Belt Replacement................9J-25
Determining Total Shim Pack S ize.................. 4-138 Rear Seat Belt Replacement..... 9J-28, 9J-29, 9J-31,
Diagnosis 9J-33, 9J-35, 9J-37
Determining Type of Noise...........................4-106 Seat Belt Checks.................................................. 9J-2
Rear Axle Wheel Bearing W ear.................. 4-108 Seat Belt Service Precautions............................ 9J-2
Inspection Before Disassembly.........................4-129 Specifications
Special Tools........................................................4-166 Fastener Tightening......................................... 9J-1
INDEX 17
Secondary Air Injection SIR........................................................................ (cont.)
Description Inflatable Restraint Instrument Panel
System Description.....................................6-2272 Inflator Module Replace..............................9J-130
Pump Replacement (5.0L, 5.7L).................... 6-2221 Inflatable Restraint Sensing and
Pump Replacement (7.4L)..............................6-3185 Diagnostic Module Replacement............... 9J-129
System Description (7.4L)...............................6-3233 Inflatable Restraint Steering Wheel
System Diagnosis (5.0L, 5.7L)........................6-2113 Module Coil Replacement...........................9J-134
Service Manual Inflatable Restraint Steering Wheel
Anti-Theft Labeling................................................0-17 Module Replacement.................................. 9J-134
Description of Arrows and Symbols.................... 0-5 Inflator Module Handling, Shipping,
General Information and Scrapping..............................................9J-138
Fasteners.......................................................... 0-22 Repairs and Inspections Required
Thread Inserts..................................................0-26 After an Accident........................................ 9J-136
How to Use the Paper Version.............................0-4 Schematics
Introduction SIR Schematic Diagrams.......................... ...9J-49
Tire Placard...................................................... 0-12 SIR Schematic Icons.................................... 9J-49
RPO Code L is t..................................................... 0-17 SIR Schematic References.......... ............... 9J-49
Service Parts ID Label............................................ 0-17 SIR Component Locations................................9J-52
Shield Replacement SIR Component Views...................................... 9J-53
Front Drive Axle....................................................4-54 SIR Connector End Views................... 9J-54, 9J-55
Transfer Case..................................................... 4-274 SIR Service Precautions.................................9J-126
Shift Cable Special Tools.................................................... 9J-156
Adjustment (Automatic 4L60-E)........................7-166 Specifications
Adjustment (Automatic 4L80-E)........................7-499 Fastener Tightening.......................................9J-47
Replacement (Automatic 4L60-E).................... 7-163 GM SPO Group Numbers............................ 9J-48
Replacement (Automatic 4L80-E).................... 7-502 Scan Tool Data Definitions........................... 9J-48
Shift Cable Replacement Scan Tool Data L ist................................. 9J-47
Transfer Case.....................................................4-275 Wiring Repair.................................................... 9J-134
Shift Fork SIR Handling................................................................... 5
Replacement SIR Inflator Module Disposal...................... 5
Front Drive A xle ...............................................4-57 SIR Inflator Module Handling and Storage.................5
Shift Lever Replacement SIR Special Tool.............................................................5
Transfer Case..................................................... 4-276 Spare Tire
Shift Select Switch Replacement Carrier Replacement............................. 3-123, 3-124
Transfer Case....................................... 4-294, 4-295 Spark Plug
Shims Inspection Replacement (Engine Electrical).................... 6-1059
Rear Drive A xle.................................................. 4-134 Wire Harness Replacement
Shock Absorber (Engine Electrical)......... ............................ .6-1059
Replacement Special Tools
Front Suspension..................................3-83, 3-84 Clutch................................................................... 7-611
Rear Suspension..............................3-99, 3-100 Disc Brakes......................................................... 5-121
ShopTowel Fuel L in k ..................................................... 5 Engine Cooling.................................. 6-990
Single Cylinder Flooding................................................7 Front Drive A x le ................................... 4-98
SIR....................................................................................5 Front Suspension................................................ 3-90
AIR BAG Warning Lamp Comes Hydraulic Brakes............................. 5-88
On Steady...................................................... 9J-63 Park Brake.......................................................... 5-162
AIR BAG Warning Lamp Replacement......... 9J-134 Propeller Shaft......................................................4-27
Description Rear Drive A xle.............................................. ...4-166
Special Tools................................................ 9J-155 Rear Drive Axle - Locking/Limited
System Component Description Slip Rear A xle............................................. 4-180
and Definitions.........................................9J-151 S IR .....................................................................9J-156
System Operation.........................................9J-150 Transfer Case..................................................... 4-305
Diagnosis Wheel Alignment..................................................3-33
AIR BAG Warning Lamp Does Not Wheel Drive S hafts............................................. 4-47
Come O n.................................................... 9J-68 Special Tools Ordering Information...........................0-6
Intermittents and Poor Connections............ 9J-57 Specification
SDM Integrity Check......................................9J-61 Brake System
SIR Diagnostic System Check......................9J-58 Hydraulic Brakes....................... 5-5
SIR General Diagnosis................................. 9J-57 Fastener Tightening
Disabling the SIR System............................... 9J-126 Front Drive A xle......................... 4-49
Enabling the SIR System................................ 9J-127 Hydraulic Brakes................................................5-5
General Service Instructions................. 9J-128 GM SPO Group Numbers
Inflatable Restraint Front End Front Drive A xle...............................................4-49
Discriminating Sensor Replacement.......... 9J-131 Hydraulic Brakes................................................5-5
18 INDEX
Specification (cont.) Stabilizer Shaft (cont.)
Park Brake...................................................... 5-145 Replacement
Rear Drive A xle........................... 4-104 Front Suspension....................... 3-45, 3-46, 3-47
Lubrication Rear Suspension...................................3-97, 3-98
Front Drive A xle ...............................................4-49 Starter
Rear Drive Axle..............................................4-104 Motor Inspection
Pinion Bearing and Differential (Engine Electrical)........................6-1034, 6-1037
Bearing Preload Motor Overhaul
Rear Drive A xle..............................................4-104 (Engine Electrical)........................6-1023, 6-1026
Specifications Motor Replacement (Engine Electrical).........6-1022
4.3L........................................................................ 6-25 Pinion Clearance Check
7.4L...................................................................... 6-688 (Engine Electrical)........................................6-1038
Caliper Wear Shim Steering Knuckle
Disc Brakes...................................................... 5-89 Replacement
Component Front Suspension................................. 3-57, 3-60
Drum Brakes................................................... 5-123 Stoplamp Switch
Components Description (Hydraulic Brakes)............................ 5-83
Disc Brakes................................ ..................... 5-89 Replacement (Hydraulic Brakes)........................5-81
Fastener Tightening Struts or Shock Absorbers
Automatic Transmission 4L60-E......... 7-39, 7-40 Diagnosis
Disc Brakes.......................................................5-89 Bench Test (Suspension)................................ 3-10
Drum Brakes................................................... 5-123 Struts or Shock Absorbers
Engine Cooling............................................... 6-927 Diagnosis
Front Suspension.............................................3-35 Leak (Suspension).............................................3-9
Park Brake...................................................... 5-145 Noisy
Propeller Shaft.................................................... 4-5 (Suspension)................. 3-9
Rear Drive Axle.............................................. 4-103 Weak(Suspension).............................................3-9
Rear Drive Axle - Locking/Limited Surge Tank
Slip Rear Axle............................................4-169 (Diesel) Replacement (Engine Cooling)..........6-947
Rear Suspension.............................................. 3-93 Suspension
Seat Belts..........................................................9J-1 Diagnosis
Tires and Wheels........................................... 3-113 Abnormal or Excessive Tire Wear..... 3-3, 3-4, 3-5
Wheel Alignment..............................................3-19 Excessive Road Shock......................................3-9
Wheel Drive Shafts..........................................4-29 Front Wheel Shimmy.......................................3-10
GM SPO Group Number Hard Steering................................................... 3-10
Front Suspension....... .....................................3-35 Low or Uneven Trim Height........................... 3-15
GM SPO Group Numbers Noise In The Front End.................................... 3-8
Tires and Wheels........................................... 3-113 Noisy Front Suspension.................................... 3-7
GM SPO Group Numbers Poor Directional Stability................................... 3-7
Disc Brakes...................................................... 5-89 Tire Hop or Poor Handling............................... 3-8
Drum Brakes................................................... 5-123 Trim Height......................................................... 3-5
Engine Cooling............................................... 6-927 Vehicle Leads/Pulls............................................3-3
Propeller Shaft.................................................... 4-5 Wheel Bearings................................................ 3-11
Rear Suspension..............................................3-93 Wheel Tramp.................................................... ..3-6
Wheel Alignment..............................................3-20
Runout Specifications
Propeller Shaft.................................................... 4-5 T
Sealers, Adhesives, and Lubricants TDC Offset Adjustment (6.5L)............................. 6-2636
4.3L............ 6-29 Thermostat
6.5L.......................................... 6-461 Description.......................................................... 6-989
7.4L.................................................................. 6-692 Housing Crossover Replacement
Spacer and Shim (Engine Cooling).............................................6-967
Rear Drive A xle..............................................4-103 Replacement (Engine Cooling)............6-963, 6-965
Wheel Alignment........................................ 3-17, 3-18 Thread Repair (Engine Mechanical - 6.5L)......... 6-680
Spring Three-Piece Propeller Shaft Replacement............ 4-14
Bushing Replacement Throttle Body
Rear Suspension............................................3-101 Assembly Replacement (4.3L)........................6-1529
Leaf Spring Replacement Assembly Replacement (5.0L, 5 .7 L )............. 6-2143
Rear Suspension.................. 3-101, 3-103, 3-105 Assembly Replacement (7.4L)........................ 6-3113
Shackle Replacement Installation (Engine Mechanical - 4.3L)........... 6-217
Rear Suspension...............................3-107, 3-108 Installation (Engine Mechanical -
Stabilizer Shaft 5.0L, 5.7L)...................................................... 6-436
Link Bracket Replacement Installation (Engine Mechanical - 7.4L)......... ..6-909
Rear Suspension..............................................3-98 Removal (Engine Mechanical - 4.3L).............. 6-129
INDEX 19
Throttle Body (cont.) Transcase Case (cont.)
Removal (Engine Mechanical - 5.0L, 5.7L).....6-356 DTC C0374....................................................4-259
Removal (Engine Mechanical -7.4L)................6-828 DTC C0376.................................................... 4-260
Throttle Position DTC C0550.................................................... 4-262
Sensor Replacement (4.3L)............................6-1521 DTC C0611..................................................... 4-263
Sensor Replacement (5.0L, 5.7L).................. 6-2135 DTC C 895...................................................... 4-264
Sensor Replacement (7.4L)............................6-3104 Electronic Shift System................................. 4-222
Thrust Washers, Shims,and Adjuster Sleeves Front Axle............................................4-265, 4-267
Front Drive Axle.................................................... 4-82 Functional Test...............................................4-212
Timing Chain Functional Test Failed................................... 4-213
Wear Check (Engine Mechanical -6.5L)..........6-605 Indicator Lamps..............................................4-271
Tire Range/Mode Switch...................................... 4-268
Chain Usage Description................................... 3-130 Shift Select
Hoist and Shaft Replacement..............3-126, 3-127 Buttons..... 4-214, 4-216, 4-217, 4-218, 4-219
Inflation Description............................................3-129 Slip in AWD M ode........................................ 4-270
Mounting and Dismounting............................... 3-121 Transfer Case
Placard Description.............................................3-131 Clearing Memory................................................4-212
Repair...................................................................3-121 Control Component Locations...........................4-190
Rotation................................................................3-122 Control Component V iew s......................4-193, 4-203
Tires and Wheels Control Connector EndViews.................4-205, 4-206
Description Control Module Data Information..................... 4-304
All Seasons Tires Description.......................3-131 Control Module Description...............................4-302
Aluminum W heels......................................... 3-131 Data Memory Retention Check.........................4-302
Chain Usage...................................................3-130 Description.......................................................... 4-299
General Description....................................... 3-129 Diagnosis
Inflation........................................................... 3-129 System Diagnosis.......................................... 4-210
Metric Wheel Nuts and Bolts........................3-129 Transfer Case................................................. 4-222
P-Metric Sized Tires...................................... 3-131 Diagnostic Trouble Codes................................. 4-212
Replacement T ires........................................ 3-130 Encoder Signal Check....................................... 4-303
Tire Placard.................................................... 3-131 Encoder Switch Monitor Check.........................4-303
Wheel Repair..................................................3-131 Fluid Drain and Fill.............................................4-274
W heels............................................................ 3-131 Mode Shifts......................................................... 4-301
Diagnosis Motor and Relay Voltage Checks.................... 4-303
Radial Tire Lead/Pull Correction...................3-115 Motor/Encode Circuit Operation....................... 4-303
Wheel Mounting Surface Check...................3-114 RAM/ROM Check...............................................4-302
Specifications Range Shifts....................................................... 4-301
Fastener Tightening........................................3-113 Replacement..............................4-282, 4-285, 4-288
GM SPO Group Numbers............................. 3-113 Scan Tool Data Definitions...............................4-304
Torque Converter Cover Replacement Schematic
(Automatic 4L60-E).............................................7-189 Control Schematic Diagrams....................... 4-182
Torque Wrenches Control Schematic Icons...............................4-182
Proper Use............................................................ 0-26 Control Schematic References.................... 4-182
Torsion Bar Special Tools......................................................4-305
Bar and Support Assembly Replacement Specification
Front Suspension..................................3-77, 3-79 Fastener Tightening...................................... 4-181
Transcase Case Fluid Capacities............................... 4-181
Diagnosis............................................................ 4-220 System Descriptio...................................4-300, 4-301
4WD Does Not Disengage...........................4-220 Troubleshooting Hints........................................ 4-209
4WD Does Not Engage................................4-220 Transmission
4WD Indicator................................................. 4-221 Replacement (Automatic 4L60-E).................... 7-220
DTC B0768..................................................... 4-223 Replacement (Automatic 4L80-E).................... 7-539
DTC B2725..................................................... 4-225 Transmission ID and Partial VIN Location............0-15
DTC C0300 .................................................... 4-228 Transmission Oil Cooler Replacement
DTC C 0305.................................................... 4-231 (Automatic 4L80-E)............................................ 7-533
DTC C 0308.................................................... 4-234 Tube Adapter
DTC C0309 .................................................... 4-236 Replacement (ABS)........................................... 5-259
DTC C 0310.................................................... 4-238 Turbocharger
DTC C 0315.................................................... 4-241 Description........................................................ 6-3251
DTC C 0323.................................................... 4-243 Diagnosis
DTC C 0324.................................................... 4-245 Blue Exhaust Smoke, Warm
DTC C 0327.................................................... 4-247 Engine O n ly.............................................6-3240
DTC C 0357.................................................... 4-253 Lacks Power, Black Smoke at WOT........ 6-3240
DTC C 0362....................................................4-255 Lacks Power, No Black Smoke
DTC C0367 ....................................................4-257 at WOT........................................ 6-3240
20 INDEX
Turbocharger (cont.) Valve (cont.)

Noise..............................................................6-3240 Rocker Arm Cover Replacement
Turbocharger................................................ 6-3241 (Engine Mechanical - 7 .4 L )..........................6-733
Wastegate Actuator..................................... 6-3243 Valve Body (Automatic 4L60-E)............................ 7-195
Installation (Engine Mechanical -6.5L)...........6-668 Vehicle Certification Label.......................................0-11
Removal (Engine Mechanical -6.5L)................6-598 Vehicle Control Module
Specifications Description
Fastener Tightening..................................... 6-3239 General (5.0L, 5.7L).................................... 6-2239
Turbocharger Replacement................................. 6-3244 General (7.4L)..............................................6-3204
Two-Piece Propeller Shaft Replacement............... 4-12 Description (4.3L).............................................6-1607
Diagnosis (4.3L)...............................................6-1477
Replacement/Programming (4.3L)..................6-1511
u Replacement/Programming (5.0L, 5.7L)........ 6-2124
Replacement/Programming (7.4L)..................6-3096
Universal Joints Replacement
Propeller Shaft........................................... 4-18, 4-20 Vehicle Identification................................................... 0-6
Vehicle Lifting.................................................................. 5
Vehicle Speed Sensor
V Replacement (Automatic 4L80-E).....................7-513
Vacuum Booster Vehicle Speed Signal
Diagnosis (Hydraulic Brakes)............................. 5-41 Buffer Replacement (6.5L).............................. 6-2651
Vacuum Brake Vent Hose
Booster Hose Replacement Replacement
(Hydraulic Brake)..............................................5-70 Front Drive A xle...............................................4-56
Booster Replacement (Hydraulic Brakes)......... 5-68 Rear Drive Axle.............................................. 4-126
Vacuum Brake Booster Vent Hose Replacement (Automatic 4L80-E)......7-534
Description (Hydraulic Brakes)............................5-84 Vibration
Vacuum Pump Balancing Tires and Wheels............................. 0-108
Diagnosis.............................. 6-3254 Correcting Driveline Vibration -
Specifications.................................................... 6-3253 RWD and 4 W D .............................................. 0-113
Vacuum Pump Replacement............................... 6-3255 Correcting Non-Uniform Tires........................... 0-112
Valve Correcting Tire and Wheel Vibration............... 0-104
Lash Adjustment Description
(Engine Mechanical - 5.0L, 5.7L)............... 6-433 General Description........................................0-130
Lifter Installation Diagnosis...............................................................0-86
(Engine Mechanical - 4.3L)........................... 6-211 Classifying the Vibration................................. 0-89
Lifter Installation Driveline Vibration Analysis w/ EVA.............. 0-94
(Engine Mechanical - 5.0L, 5.7L)............... 6-430 Engine Related Vibration................................ 0-99
Lifter Installation Road Test..........................................................0-87
(Engine Mechanical - 6.5L)...........................6-657 Tire and Wheel Vibration................................ 0-92
Lifter Installation Wheel Runout Measurement.......................... 0-92
(Engine Mechanical - 7.4L)...........................6-904 General Service Precautions............................ 0-104
Lifter Removal (Engine Mechanical - 4.3L).....6-132 Special Tools...................................................... 0-142
Lifter Removal Specifications
(Engine Mechanical - 5.0L, 5.7L)............... 6-360 Vibration Diagnosis..........................................0-85
Lifter Removal (Engine Mechanical - 6.5L).....6-609 VIN
Lifter Removal (Engine Mechanical - 7.4L).....6-832 Engine ID and Partial VIN Location.................. 0-12
Lifter Replacement Transmission ID and Partial VIN Location....... 0-15
(Engine Mechanical - 4.3L)............................ 6-72 VIN Derivative....................................................... 0-10
Lifter Replacement
(Engine Mechanical - 5.0L, 5.7L).............. 6-294
Lifter Replacement
(Engine Mechanical - 6.5L).......................... 6-533 w
Lifter Replacement Wastegate Actuator (Turbocharger)....................6-3249
(Engine Mechanical - 7.4L).......................... 6-744 Wastegate Solenoid Replacement (6.5L).......... 6-2652
Rocker Arm Cover Removal Water-in-Fuel Sensor Replacement (6.5L)........ 6-2597
(Engine Mechanical - 4.3L)..........................6-128 Water Pump
Rocker Arm Cover Removal Clean and Inspect
(Engine Mechanical - 6.5L).......................... 6-607 (Engine Mechanical - 4.3L).......................... 6-195
Rocker Arm Cover Removal Clean and Inspect
(Engine Mechanical - 7.4L)..............6-826, 6-827 (Engine Mechanical - 5.0L, 5.7L)................ 6-416
Rocker Arm Cover Replacement Clean and Inspect
(Engine Mechanical - 4.3L).................. 6-64, 6-66 (Engine Mechanical - 7.4L).......................... 6-891
Rocker Arm Cover Replacement Description.......................................................... 6-989
(Engine Mechanical - 6.5L).......................... 6-502 Installation (Engine Mechanical - 4.3L)........... 6-221
INDEX 21
Water Pump (cont.) Wheel Cylinder

Installation Replacement
(Engine Mechanical - 5.0L, 5.7L)................6-440 (Drum Brakes)...................... 5-137, 5-138, 5-141
Installation (Engine Mechanical - 6.5L)........... 6-666 Wheel Drive Shafts
Installation (Engine Mechanical - 7.4L)........... 6-914 Boot Cover Replacement.................................... 4-42
Removal (Engine Mechanical - 4.3L).............. 6-126 Special Tools........................................................ 4-47
Removal (Engine Mechanical - 5.0L, 5.7L).....6-353 Specifications
Removal (Engine Mechanical - 6.5L).............. 6-601 Fastener Tightening.........................................4-29
Removal (Engine Mechanical - 7.4L).............. 6-825 Wheel Hub
Replacement (Engine Cooling)..............6-968, 6-971 Bolt Replacement
Wheel Front Suspension....................... 3-43, 3-44, 3-45
Installation Wheel Hub, Bearing, Knuckle,
Tires and W heels...........................................3-120 and Seal Replacement
Removal Front Suspension............................3-72, 3-74, 3-76
Tires and W heels................................3-118, 3-119 Wheels
Wheel Alignment Aluminum Wheels Description..........................3-131
Description Description.......................................................... 3-131
General Description................................ 3-30, 3-31 Repair Description..............................................3-131
Diagnosis Wheel Speed Sensor
Preliminary Alignment Inspection.......... 3-21, 3-22 Replacement (ABS).................. 5-254, 5-255, 5-256
Frame Bracket Knock Out Removal........3-25, 3-27 Wheel Stud
Special Tools......................................................... 3-33 Replacement
Specifications............................................... 3-17, 3-18 Rear Suspension...............................3-109, 3-110
Fastener Tightening......................................... 3-19 Window Removal............................................................5
GM SPO GroupNumbers................................ 3-20 Window Retention...........................................................6
Wheel Bearing Adjustment Wiring Harness
Front Suspension.........................................3-81, 3-82 Assembly Removal
Rear Drive A xle .......................................4-158, 4-159 (Engine Mechanical - 6 .5 L )..........................6-596
Wheel Bolt Work Sheets, Diagnostic............................................0-6
Replacement Work Stall Test................................................................ 6
Rear Suspension............................................3-101
22 INDEX
BLANK

1998 Gmt-98 Ck-2 Service Manual-Volume 2 of 4

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1998 Gmt-98 Ck-2 Service Manual-Volume 2 of 4

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1998 C/K Truck

NORTH AMERICAN OPERATIONS

©1997 GENERAL MOTORS CORPORATION ALL RIGHTS RESERVED

When calling, be prepared with the following information:

United States and Canada General Motors Dealer Employees

Canada, French Speaking General Motors Dealer Employees

International English Speaking General Motors Dealer Employees

United States and Canadian Vehicle Owner/Operator

Cautions and Notices ............................................3 SIR Inflator Module Disposal Caution.................5

Cautions and Notices

commercially in order to to perform this washing Fuel Pipe Fitting Caution

Window Retention Caution locking compound or sealant are identified in the

Nylon Fuel Lines Notice Single Cylinder Flooding Notice

Steering Handwheel Speed (HWSS) S pe cifica tio ns................ 2F-16

POWER STEERING GEAR AND PUMP

DIAGNOSIS OF POWER STEERING SYSTEM

DIAGNOSIS OF POWER STEERING SYSTEM (cont’d)

DIAGNOSIS OF POWER STEERING SYSTEM (cont’d)

DIAGNOSIS OF POWER STEERING SYSTEM tcont’d)

DIAGNOSIS OF POWER STEERING SYSTEM (cont’d)

DIAGNOSIS OF POWER STEERING SYSTEM (cont’d)

Rattle Or Knock Noise 1. Loose pump pulley nut. 1. Torque nut.

LOCATING OIL LEAKS POWER STEERING SYSTEM

A. Return Tube Fitting

Figure 3—Checking Power Steering Pressure

Bleeding Air from Power Steering Systems

In case o f steering system noise Conventional Climate:

How to bleed: Special Conditions:

Switch ig nitio n off. W ait tw o m inutes. Recheck

© W ith assistant checking

Figure 4— Bleeding the Power Steering System

Tighten • Pitman shaft and seal areas using a crocus

• Lubricate the new seals with power steering fluid.

Remove or Disconnect (Figures 7 through 10)

• Place a drain pan below the pump.

+ 4- Install or Connect (Figures 7 through 10)

Legend NOTICE: Refer to Fastener Notice In Cau­

Four Wheel Drive Tighten

R Remove or Disconnect (Figures 5 and 6) • Nuts to 50 N.m (37 lb ft).

1. Pitman shaft seal. NOTICE: Do not use arbor press or internal

5. Drive belt. • Route hoses smoothly; avoid sharp bends and

Figure 9—Power Steering Pump Mounting (7.4L

Figure 10—Power Steering Pump Mounting (6.5L Diesel Engines)

Pitman Shaft Nut 285 215 —

POWER STEERING SYSTEM PRESSURES

1. POWER STEERING PRESSURE TESTER

POWER STEERING GEAR UNIT REPAIR

Power Steering Fluid Requirement.................................................................................................. GM Power Steering Fluid

FASTENER TIGHTENING SPECIFICATIONS

Figure 1 Power Steering Gear

Key No. Part Name Key No. Part Name

• Adjust the worm thrust bearing preload first, then

6. Starting at either stop, turn the stub shaft (40) back

STEERING GEAR SERVICE

|»+ | Remove or Disconnect Tools Required:

Disassemble Install or Connect

Assemble Remove or Disconnect

• Install valve spool (41) to valve body (43) by Hj+j Disassemble

Figure 14 Remove and Install Spool Figure 15 Engage Stub Shaft

• Insert J 21552 into bore of rack piston (26)

Tighten Steering gear. Refer to “Steering Gear Ad­

A-INSTALL BALLS IN THIS HOLE WHILE SLOWLY

fc d Install or Connect Inspect

Legend NOTICE: Refer to Fastener Notice In Cau

Tighten Steering gear. Refer to “Steering Gear Ad

NOTICE: Refer to Fastener Notice In Cau RELAY ROD REPLACEMENT

Tighten NOTICE: Refer to Fastener Notice in Cau

NOTICE: Refer to Fastener Notice in Cau |-M-| Install o r Connect (Figure 5)