FOREWORD
This manual includes procedures fo r diagnosis, maintenance and adjust
ments, m inor service operations, and removal and installation fo r com
ponents o f Chevrolet Light D uty Trucks. Procedures involving disassembly
and assembly o f major components fo r these vehicles are contained in the
1981 Chevrolet Passenger Car and Light D uty T ruck U n it Repair (Overhaul)
Manual. W iring diagrams fo r 1981 trucks are contained in a separate Wiring
Diagram Booklet.
The Section Index on the contents page enables the user to q u ickly locate
any desired section. A t the beginning o f each section containing more than
one major subject is a Table o f Contents, which gives the page number on
w hich each major subject begins. An index is placed at the beginning o f each
m ajor subject w ith in the section.
Summaries o f Special Tools, when required, and specifications are found
at end o f major sections.
When reference is made in this manual to a brand name, number, or
specific to o k an equivalent product may be used in place o f the recom
mended item.
This manual should be kept in a handy place fo r ready reference. If pro
perly used, it w ill enable the technician to better serve the owners o f Chev
rolet b u ilt vehicles.
A ll in fo rm a tio n, illustrations and specifications contained in this literature
are based on the latest product in fo rm a tio n available at the tim e o f p u b li
cation approval. The right is reserved to make changes at any tim e w ith o u t
notice.
TABLE OF CONTENTS
SECTION
GENERAL INFORMATION
General In fo rm a tio n
M a in te n a n ce and L u brication
OA
OB
1981
LIGHT DUTY
TRUCK
(SERIES 10-35)
CHASSIS SERVICE
MANUAL
1A
1B
2A
2B
2C
2D
Front A lig n m e n t
S te e rin g Linkage
M a n u a l S teering
P o w e r S te e rin g
S te e rin g C o lu m n
F ront S uspension
Rear S uspension
W h eel and Tires
3A
3B1
3B2
3B3
3B4
3C
3D
3E
AXLE
4A
4B
4C
5
ENGINE
CAUTION
These vehicles contains some parts dimensioned in the metric
system as well as in the customary system. Some fasteners are
metric and are very close in dimension to familiar customary fast
eners in the inch system. It is important to note that, during any
vehicle maintenance procedures, replacement fasteners must
have the same measurements and strength as those removed,
whether metric or customary. (Numbers on the heads of metric
bofts and on surfaces of metric nuts indicate their strength.
Customary bolts use radial lines for this purpose, while most
customary nuts do not have strength markings.) Mismatched or
incorrect fasteners can result in vehicle damage or malfunction, or
possibly personal injury. Therefore, fasteners removed from the
vehicle should be saved for re-use in the same locations whenever
possible. Where the fasteners are not satisfactory for re-use, care
should be taken to select a replacement that matches the original.
For information and assistance, see your dealer.
Engine
In-Line 6
S m all Block
M ark IV
5.7L(Z) 350 Diesel
Engine Cooling
Engine Fuel
M o d e l 1ME
M o d el 2SE
M o d el M 2 M E
M odel M 4M E
Fuel S ystem
Engine Electrical
Engine Emission Controls
Engine Exhaust
Engine P erform ance Specifications
6
6A1
6A4
6A5
6A6
6B
6C
6C1
6C2
6C3
6C4
6C5
6D
6E
6F
6G
TRANSMISSION
A u to m a tic
M a nual
C lutch
T ra n s fe r Case
7A
7B
7C
7E
8A
8B
8C
ACCESSORIES
METRIC AND FASTENER INFORMATION
9
10
P r in te d in U . S .A .
GENERAL INFORMATION
OA-1
SECTION OA
GENERAL INFORMATION
CONTENTS OF THIS SECTION
G e n e ra l....................................................................................................................
Vehicle Identification N u m b e r.........................................................................
Service Parts Identification S tic k e r.................................................................
Vehicle L o a d in g ....................................................................................................
Engine Code N u m b e r.........................................................................................
U nit and Serial N um ber L ocations.................................................................
0-1
0-2
0-3
0-3
0-3
0-3
GENERAL
CAWR
GAV,R REAR
W A R R A N T Y V O ID E D IF L 0 A 0 E 0 IN E X C E S S OF R A T IN G S
SE E O W N E R S M A N U A L FO R O T H E R L O A D IN G A N D IN F L A T IO N D A T A
EXAMPLE ONL Y
and G)
LIG H T T R U C K SERVICE M A N U A L
OA-2
GENERAL INFORMATION
U .S .A .
CANADA
ASSEMBLY PLANT
CODE
M ANUFACTURER
G
G E N E R A L M O TO RS
1981
1982
19 8 3
19 84
19 8 5
19 8 6
19 8 7
IN C O M P L E T E V E H IC L E
19 8 8
TRUCK
19 8 9
10 9 0
BUS (V A N )
M U L T IP U R P O S E PA SS V E H IC L E
CODE
G M A D - LAKEW O O D
G M A D - ST
G M A D - B A L T IM O R E
G M T & C -- P O N T IA C
G M A D - D O R A V IL L E
G M A D - FREM ONT *
GM OF C A N A D A - O SHAW A
'
C H E V R O L E T - F L IN T
L O U IS
G M A D - J A N E S V IL L E
C H E V R O L E T - D E T R O IT
G M A D - LE ED S '
GM OF C A N A D A - SCAR B O R O U G H
G M A D - A R L IN G T O N '
G M A D - LO R D S TO W N
E L C A M IN O P L A N T S
1991
GVWR/BRAKE SYSTEM
CHECK D IG lT ]
GVW R
CODE
( IN P O U N D S )
3001
4001
5001
6001
7001
8001
9001
10001
14001
c
D
E
F
G
H
J
K
4000
5000
6000
7000
8000
9000
10000
14000
16000
BR A K E SYSTEM
TRUCK SERIES
H Y D R A U L IC O N L Y
D IS P L A C E M E N T L IT R E S (C U IN )
4.1 L L 6 2 B B L (2 5 0 )
C H EVROLET
R PO
LE 3
5 .0 L V 8 4 B B L (3 0 5 I
CHEVROLET
C -K -G
LF3
C -K -G
LG 9
5 .0 L V 8 2 B B L (3 0 5 )
1 12 T O N
5 .0 L V 8 4 B B L (3 0 5 )
CHEVROLET
C -K -G
LE 9
3 /4 T O N
5 . 7 L V 8 4 B B L (3 5 0 )
C H EVROLET
C -K -G
LS 9
1 TO N
CHEVRO LET
5 .7 L V 8 4 B B L (3 5 0 )
1 12 T O N
5 .7 L V 8 2 B B L (3 5 0 I
C HEVROLET
CK
LF5
( E L C A M IN O )
7 .4 L V 8 4 B B L (4 5 4 )
C HEVROLET
C -K -P
LE 8
4 . 8 L L 6 1 B B L (2 9 2 )
C HEVROLET
C -K -P
L25
5 .7 L V 8 D IE S E L (3 5 0 I
O L D S M O B IL E
CK
LF9
H I C U B E /C U T A W A Y V A N
C H A S S IS
FO U R DOOR CAB
TYPE
TW O D O O R C AB
C -K -G -P
LT9
(F O R E L C A M IN O O N L Y )
S E D A N P IC K U P
In c lu d e s G V a n Bus.
L IN E
M O D ELS
CHEVROLET
In c lu d e s El C a m in o
CODE
M A K E (G M )
E N G IN E S O U R C E
V I . N.
CODE
A
TYPE
D IS P L A C E M E N T L IT R E S (C U IN )
M A K E (G M )
E N G IN E S O U R C E
3 . 8 L V 6 2 B B L (2 3 1 )
B U IC K
M ODEL
RPO
E L C A M IN O
LD 5
5 . 0 L V 8 4 B B L (3 0 5 )
C H EVROLET
E L C A M IN O
LG 4
C O N V E N T IO N A L C A B
(C l
4X 2
VAN
4 4 L V 8 2 B B L (2 6 7 )
C H EVROLET
E L C A M IN O
L39
C O N V E N T IO N A L C A B
(K )
4X 4
SUBURBAN
3 . 8 L V 6 2 B B L (2 2 9 )
CHEVR O LET
E L C A M IN O
LC 3
F O R W A R D C O N T R O L C H A S S IS
(P)
4 X 2
M O TO R HOME
V A N . SPORT V A N & C U T A W A Y V A N
(G )
4X 2
BLAZER
E L C A M IN O
(A P U )
4X 2
S T A K E /P L A T F O R M
LIG H T T R U C K SE RV IC E M A N U A L
GENERAL INFORMATION
VEHICLE LOADING
Vehicle loading m ust be controlled so weights do not
exceed the num bers shown on the Vehicle Identification
N um ber an d /o r R ating Plate for the vehicle.
A typical example of a truck in a loaded condition is
shown in Figure OA-7. N ote th a t the axle or G V W capabili
ties are not exceeded.
OA-3
Axles
Chevrolet Built
LO AD ED -M AXIM UM GVWR:
FRONT GAWR: 2944 LBS.
4900-LBS.
2219 lbs.
* Front Curb
Front Cargo &
284 lbs.
Pass. Load
2503 lbs.
*Rear Curb
1003 lbs.
Rear Cargo &
Pass. Load
1394 lbs.
2397 lbs.
4900 lbs.
OA-4
GENERAL INFORMATION
PRIMARY V .I.N .
LOCATION ( M l 5)
PRIMARY V .I.N .
f \
OPTIONAL V .I.N .
LOCATION (M20)
V .I.N . LOCATION
(OPTIONAL) (M40)
V IE W
MANUAL
AUTOMATIC
Fig. 0A-6--Transmission V.I.N . Location
LIG H T T R U C K SE RV IC E M A N U A L
Generators
G enerator U nit Serial N um ber is located on the Drive
End Fram e Below the P art N um ber.
Batteries
Battery Code N um ber is Located on Cell Cover Top of
Battery.
Starters
S ta rte r S erial N u m b er and Production D ate are
Stam ped on O uter Case, Toward Rear.
GENERAL INFORMATION
E N G IN E V .I.N .
E N G IN E V .I.N .
OA-5
E N G IN E
CASE PAD
(O PTIO NAL)
E N G IN E
V .I.N .
DISTRIBUTOR PAD
ENGINE
L6 ENGINE
E N G IN E V .I.N .
(OPTIO NAL)
V8 ENGINE DIESEL
Fig. 0A-7-Engine V .I.N . Location
LIG H T T R U C K SERVICE M A N U A L
OB-1
SECTION OB
OB-2
0B-5
OB-15
OB-16
0B-18
OB-18
OB-19
LIG H T T R U C K SE RV IC E M A N U A L
OB-2
Item
No.
15,000
(24 000 km)
7.500
(12 000 km)
Services
22.500
(36 000 km)
30,000
(48 000 km)
37.500
(60 000 km)
45,000
(72 000 km)
S e c t io n A L u b r ic a t io n a n d G e n e r a l M a in t e n a n c e
A -1
Every 12 M onths or 7 ,5 0 0 M iles
( 1 2 0 0 0 km )
See Explanation
A -2
Every 1 0 0 ,0 0 0 M iles (1 6 0 0 0 0 km )
x j
_Al
X 1
*1
A -3
A -4
A -5
Chassis Lubrication
A -6
A -7
Tire Rotation
A -8
R ear A x le Lubrication
A -9
A -1 0
Every 3 0 ,0 0 0 M iles ( 4 8 0 0 0 km )
A -1 1
A -1 2
A -1 3
B-1
O w n er Safety Checks
B -2
S e c tio n B S a f e t y M a in t e n a n c e
B -3
B -4
B -5
B -6
B -7
B -8
X
X
X
X
B -9
B-10
Bumper Check
F u e l Cap, Tank and Lines Check
S e c tio n C E m issio n C o n tro l M a in te n a n c e S c h e d u le 1 (S e e E x a m p le fo r A p p lic a tio n ) E n qin e Fam ily 18F 2H A N Q R O nly
Every 1 5 ,0 0 0 M iles
( 2 4 ,0 0 0 km )
Every 2 2 ,5 0 0 M iles (3 6 0 0 0 km )
Every 3 0 ,0 0 0 M iles (4 8 0 0 0 km )
C-1
C -2
C -3
C -4
C -5
C -6
C -7
PC V System Check
C -8
C -9
C -1 0
C -11
C-1 2
C -13
C -14
C -1 5
EG R System Check
High Altitude Adiustment: Your 1981 General Motors vehicle has been certified to meet emission standards at low
altitude Certain vehicles sold for high altitude use have been adjusted prior to delivery for improved driveability and
emission control at high altitude. These vehicles may be identified by additional underhood tune-up label, "Supple-
X
mental Vehicle Emission Control Information. Information regarding adjustment of your vehicle, if permitted, can be
obtained from the Consumer Relations Office shown in the Owner Assistance Section of your Owner's and Driver's
Manual. Include your Vehicle Identification Number in your request.
Item
No.
30.000
(48 000 km)
22,500
(36 000 km)
15,000
(24 000 km)
7,500
(12 000 km)
Services
37,500
(60 000 km)
45.000
(72 000 km)
S e c t i o n A L u b r ic a t io n a n d G e n t r a l M a in te n ance
A-1
Every 1 2 M o n th s or 7 ,5 0 0 M iles
A -2
Every 1 2 M o n th s or 1 5 ,0 0 0 M iles
( 2 4 0 0 0 km )
A -3
A -4
* 0 i l Filter Change
A -5
Chassis Lubrication
A -6
A -7
Tire Rotation
A -8
R ear A x le Lubrication
A -9
Every 1 0 0 .0 0 0 M iles (1 6 0 0 0 0 km )
'
J L L .........
X1
* x
. ..
A -1 0
Every 3 0 ,0 0 0 M iles (4 8 0 0 0 km )
X |
A -1 1
A -1 2
A -1 3
<
S e c t i o n B S a f e t y M a in t e n e n c e
Every 1 2 M o n th s or 7 ,5 0 0 M iles
( 1 2 0 0 0 km )
B-1
O w n er Safety Checks
B -2
B -3
B -4
B -5
B -6
Every 1 2 M o n th s or 1 5 ,0 0 0 M iles
w U km j
B -7
B 8
X
X
X
X
B -9
B-10
Bumper Check
*F u e l Cap, Tank and Lines Check
C -2
C -3
C -4
C -5
C -6
C -7
E v ery 15,000 M ile s (24 000 km )
C-1
----------
xP
C -9
C -1 0
C -11
C -1 2
xT
X
X
PC V Valve R e p la cem en t
Hioh Altitude Adjustment: Your 1961 General Motors vehicle has been certified to meet emission standards at low
altitude. Certain vehicles sold for high altitude use have been adjusted prior to delivery for improved driveability and
emission control at high altitude. These vehicles may be identified by additional underhood tune-up label, "Supple
mental Vehicle Emission Control Information." Information regarding adjustment of your vehicle, if permitted, can be
obtained from the Consumer Relations Office shown in the Owner Assistance Section of your Owner's and Driver's
Manual. Indud* your Vehicle MentMcation Number in your request.
xt;
X
(1)
C -8
C -1 3
(1)
(1)
----
X
X (1)
(1)
X
(1) Only these emission control maintenance items are considered to be required maintenance as defined by the
California Air Resources Board (ARB) regulation and are, according to such regulation, the minimum maintenance an
owner in California must perform to fulfill the minimum requirements of the emission warranty. All other emission
maintenance items are recommended maintenance as defined by such regulation. General Motors urges that all
emission control maintenance items be performed.
(2) A separately driven air pump belt check is recommended but not required at 15,000 miles (24 000 km) and 45,000
miles (72 000 km).
S e e Explanation
X
X
OB-3
OB-4
S E C T IO N
*_
48,000
15,000
: 000 km)
1200 km)
(2,000
19,000
! 400 km)
13,000
! 800 km)
to
m
CO
<e
L u b ric a tio n an d G e n e ra l M a in te n a n c e
A-1
(4 8 0 0 km)
A -2
*O il Filter Change
A -3
Chassis Lubrication
A -4
A-5
X
X
(9 6 0 0 km)
See Explanation
A-6
A-7
Every 12 M onths or
1 2 ,0 0 0 Miles (1 9 2 0 0 km)
A-8
A-9
*!
*!
A-10
Every 1 0 0 ,0 0 0 Miles
(1 6 0 0 0 0 km)
A -11
Every 12 M onths or
B-1
6 ,0 0 0 Miles (9 6 0 0 km)
B -2
B -3
B -4
B -5
S E C T IO N
B -6
Every
B S a fe t y M a in te n a n c e
2 M onths or
B -7
1 5 ,0 0 0 M iles (2 4 0 0 0 km)
B -8
B -9
Bumper Check
*1
S E C T IO N
Every 15,0 0 0 M iles (2 4 0 0 0 km)
C-1
C-2
C-3
C E m issio n
C o n tr o l M a in te n a n c e
x|
X
X
X
High Altitude Adjustment: Your 1981 General Motors vehicle has been certified to meet emission standards at low
altitude. Certain vehicles sold for high altitude use have been adjusted prior to delivery for improved driveability and
emission control at high altitude. These vehicles may be identified by additional underhood tune-up label, "Supple
mental Vehicle Emission Control Information." Information regarding adjustment of your vehicle, if permitted, can be
obtained from the Consumer Relations Office shown in the Owner Assistance Section of your Owner's and Driver's
Manual. Include your Vahid* Identification Number in your request.
30,000
>7.000
1200 km)
CM
at
u lc*' "*?Is5/Performed
d '50> '!!
ColumnMrTth'
Closest.D?V'
To Mileage
When Service
M.OOO
1600 km)
o o
-s
18,000
1800 km)
E
o
15,000
1000 km)
12,000
1200 km)
600 km)
Services
(For D e ta ils , See Numbered Paragraphs)
6,000
Item
No.
3,000
800 km)
OB-5
W han
Item
No.
Services
(Far Details. Saa NumbaradParagraphs)
6.000
12.000
(9 600 km)
I t . 000
(21 100 km)
30 000
( U 000 km)
24.000
(31 400 km)
30.000
<57 OM km)
42 000
( (7 200 km )
41 0 M
(70 I N km)
S e c t io n A L u b r ic a t io n a n d G e n e r a l M a in t e n a n c e
Every 4
m o n th s o r 6 ,0 0 0 m ile s
(9 6 0 0 k m )
A -1
C h a s s is L u b ric a tio n
A -2
F lu id L e vels C he c k
A -5
E n g in e O il C h a n g e
A -6
*E n g in e O il F ilte r C h a n g e
A -3
A -4
See E x p la n a tio n
F ro n t W h e e l D riv e
C lu tc h P e d a l F ree T ra v e l C h e c k /A d ju s t
A -7
T ire R o ta tio n
A 8
R ea r A x le L u b r ic a tio n
A -9
W h e e l B e a rin g s R ep ack
A -1 0
C o o lin g S ystem C he c k
Every 2 4 ,0 0 0 m ile s ( 3 8 4 0 0 k m )
A -1 1
Eve ry 3 6 ,0 0 0 m ile s (5 7 6 0 0 k m )
A -1 2
M a n u a l S te e rin g G e ar C he c k
A -1 3
C lu tc h C ro ss S h a ft L u b ric a tio n
B-1
O w n e r S a fe ty C h e cks
B -2
(1 9 2 0 0 k m )
S e c t io n
Every 4 m o n th s o r 6 ,0 0 0 m ile s
(9 6 0 0 km )
B -3
B -4
B 5
BS a f e t y
M a in t e n a n c e
S u s p e n s io n a n d S te e rin g C he c k
Brake s an d P o w e r S te e rin g C he c k
E x h a u s t S ystem C he c k
Eve ry 1 2 ,0 0 0 m ile s ( 1 9 2 0 0 k m )
B -6
Every 1 2 m o n th s o r 1 2 ,0 0 0 m ile s
(1 9 2 0 0 k m )
B -7
D ru m B rake s a n d P a rk in g B rake C he c k
B -8
T h ro ttle L in k a g e C he c k
B -9
B u m p e rs
E v e ry 2 4 m o n th s o r 24 ,0 0 0 m ile s
(38 40 0 k m )
B -10
*E n g in e D riv e B e lts C he c k
F u e l C ap , L in e s a n d T a n k C he ck
X
S e c t io n C E m is s io n C o n t r o l M a in t e n a n c e
A t 1s t 4 m o n th s o r 6 ,0 0 0 m ile s
( 9 6 0 0 k m ) th e n a t 1 2 m o n th /
12 ,0 00 m il e (19 2 0 0 k m )in te r v a ls
C -1
E n g in e Id le S p ee d A d ju s tm e n t
C -2
Id le S to p S o le n o id C he c k
E very 1 2 ,0 0 0 m ile s (1 9 2 0 0 k m )
C -3
C -4
* E n g in e T im in g A d ju s t. & D is trib u to r C h e ck
C -5
A ir C lea ne r E le m e nt R ep lac e m e nt
Every 12 m o n th s o r 1 2 ,0 0 0 m ile s
(1 9 20 0 km )
C -6
C a rb u re to r M o u n tin g T o rq u e
C -7
C -8
M a n if o ld H ea t V a lv e C he c k
C -9
C a rb u re to r F ue l F ilte r R e p la c e m e n t
C -1 0
T h ro ttle R e tu rn C o n tro l C h e c k
C -1 1
PC V S y s te m C h e c k
A ls o A S a fe ty S e rvice
C -1 2
ECS S ystem C he ck
C -13
E n gin e Id le M ix tu r e A d ju s t (4 .8 L. L - 6 o n ly )
C -14
EFE System C he c k
C -1 5
V a c u u m A d v a n c e S ystem C he ck
C -1 6
C a rb u re to r C h o k e C he ck
*A ls o A n E m is s ion C o n tro l S e rv ic e
* A ls o a N o is e E m is s io n C o n tr o l S e rv ic e
MAINTENANCE SCHEDULE
T his is an explanation o f th e service listed in the
Vehicle M aintenance Schedule.
N O R M A L V E H IC L E U S E -T h e m ain ten an ce in
structions contained in the m aintenance schedule are based
on the assum ption th a t the vehicle will be used as designed:
To carry passengers and cargo within the lim itations
indicated on the T ire Placard located on the edge of the
drivers door,
on reasonable road su rfaces w ithin legal o perating
limits,
on a daily basis, as a general rule, for at least several
miles (km ), and
O n unleaded gasoline (gasoline light duty emission
only).
SECTION A
LUBE & GENERAL MAINTENANCE
A -l Fluid Levels
Check battery and the following fluid levels:
Battery Care
OB-6
Jump Starting
CAUTION:Batteries produce explosive gases, cor
rosive acid and levels of electrical current high
enough to cause burns. To lessen the chance of
personal injury or property damage, the instruc
tions below must be followed exactly.
OB-7
low reading is normal, the level will rise as the fluid gets
warm. The fluid level will increase more than 3/4 inch
(19m m ) as fluid warm s up from 60F to 180F (16C to
82C).
Gasoline Engine
LIG H T T R U C K SE RV IC E M A N U A L
OB-8
Diesel Engine
Use O N LY engine oils labeled with the A.P.I. (Ameri
can Petroleum Institute) designations "SF/C C " or "SF/
CD ". Do not use any other type of oil. The A.P.I. designa
tions are listed somewhere on the oil can, usually on the top
or label. The A.P.I. has several designations, such as: SC,
SD , SE, CB, CC, CD.
Several different designations may appear on the can.
Be sure the oil used has either the "SF/C C " or "SF/CD"
designations, regardless of the order in which they appear on
the oil can.
Using any type of oil other than "SF/C C " or "SF/
CD" may affect warranty.
NOTICE: Do N O T use engine oils labeled only SE or
only CC. These oils will not give the protection and
lubrication of diesel engine needs. When reading the
LIG H T T R U C K SE RV IC E M A N U A L
5W-20
C-30
--- r
-2 0
20_
-1 0
40
_L_
I
10
r~
100
40
30
TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE
.20
Cold- If you check the oil level when the oil is cold, do
not run the engine first. T he cold oil will not drain back
to the pan fast enough to give a tru e oil level.
SAE 30
WSAE 10W-30
F -20
I
OB-9
C -30
20
i i-----------1
-20
-10
32 40
'----------(
60
-------- 1-------- 1
10
80
i--------- 1
20
100
i--------- Li---------
30
40
L ubrication Intervals
LIG H T T R U C K SERVICE M A N U A L
OB-10
1
2
3
4
5
A ir Cleaner
C ontrol Linkage Points
Tie Rod Ends
Wheel Bearings
Steering Gear
1
2
3
4
6
7
8
9
10
Wheel Bearings
Steering Gear
A ir Cleaner - Element
Master C ylinder
Transmission - Manual
- A utom atic
11
12
13
14
15
LUBRICATION POINTS
6
7
8
9
10
Master Cylinder
Transmission - Manual
- A utom atic
Carburetor Linkage - V-8
Universal Joints
Propeller Shaft Slip Joints
11
12
13
14
15
LIG H T T R U C K SERVICE M A N U A L
OB-11
LUBRICATION POINTS
1
2
3
4
5
6
7
8
9
10
11
Rear Axle
Oil Filter
Brake Master Cylinder
Parking Brake Linkage
Hood Latches
W ipe off d irt and apply a thin coat of engine oil. Open
and close door several times to insure th at the oil has worked
in effectively.
OB-12
Accelerator Linkage
(Also a Safety Service)
A-7 Tires
Inspection and Rotation
ROTATION - BIAS
AND BIAS BELTED
ROTATION RAOIAL
OB-13
Lower inflation pressures can be used for light trucktype tires with reduced vehicle loads. A fter finding the load
on each tire by weighing the vehicle on a scale, the minimum
cold inflation pressures can be found in Section 3E.
T ire inflation pressures should be checked at least
m onthly (including the spare if so equipped). Always check
tire inflation pressures when tires are " cold ".
1. The "co ld " tire inflation pressure applies to the tire
pressure when a vehicle has not been driven more than
one mile (1.6 km) after sitting for three hours or more.
2. It is norm al for tire pressures to increase 4 to 8 pounds
per square inch (30 to 60 kilopascals) or more, when
the tires become hot from driving. Do not "bleed" or
reduce tire inflation pressures after driving vehicle.
TORQUE
DESCRIPTION
SERIES
K10
PROPERLY INFLATED
BIAS
OR BIAS-BELTED TIRE
PROPERLY INFLATED
IMPROPERLY INFLATED
t
J
-------------- y
OB-14
Service
OB-15
Thermostat
SECTION B
SAFETY MAINTENANCE
B-l Owner or Driver Safety Checks The m aintenance Schedule in the glove box lists items
to be checked by the owner or driver.
OB-16
B-9 Bumpers
Check the fuel tank, cap and lines for dam age or leaks.
Rem ove fuel cap, check gasket for an even filler neck
im print, and any dam age. Replace parts as needed. Refer to
Section 6C for fuel system repair procedures.
SECTION C
EMISSION CONTROL MAINTENANCE
GENERATOR
A.I.R. PUMP
P/S PUMP
50 LB.
(222 N)
MIN.
A/C
COMPRESSOR
65 LB.
(289 N)
MIN.
5.7L V8 DIESEL
GENERATOR
P/S PUMP
A.I.R. PUMP
(NON A/C)
70 LB.
(311 N)
MIN.
A/C
COMPRESSOR
A.I.R. PUMP
80 LB.
(356 N)
MIN.
OB-17
L IG H T T R U C K SERVICE M A N U A L
OB-18
SPECIFICATIONS
RECOMMENDED FLUIDS AND LUBRICANTS
USAGE
FLUID/LUBRICANT
a. E ngine oil
b. C hassis grease m eeting re q u ire m e n ts of GM 6031-M
Chassis Grease
E ngine oil
a. E ngine Oil
b. Chassis Grease
E ngine Oil
E ngine Oil
E ngine (G asoline)
E ngine (Diesel)
Chassis grease
W heel bearings lu b ric a n t GM Part No. 1051344 (One
E ngine C o o la n t
Key Lock C ylin d e r
E ngine Oil
GM O ptikleen w asher solvent Part No. 1051515
o r e quivalent
M ixtu re of w a te r and high q u a lity Ethylene G lycol base
type antifreeze c o n fo rm in g to GM Spec. 1899-M
WD-40 Spray L u b ric a n t or e q u ivale n t
L IG H T T R U C K SERVICE M A N U A L
OB-19
CAPACITIES
r<,M
D ifferential
8% '' Ring Gear
8 -7 /8 Ring Gear
101/2 " Ring Gear (Chev.)
10%'' Ring Gear (Dana)
9% " Ring Gear (Dana)
12%'' Ring Gear (Dana)
Engine Crankcase
250 L6 Drain & Refill
w /F ilte r Change
292 L6 Drain & Refill
w /F ilte r Change
305 V 8 )
_ . . _ ....
op-f. wc> ( - Drain & R efill
i w/FM
,erChan9e
400 V 8
454 V 8 - Drain & Refill
w /F ilte r Change
350 V8 Diesel Including F ilte r
Transmission
A u to m a tic
350 Total
- Refill
400 Total
- Refill
Manual
4 Speed 1 17mm
3 Speed 76mm
3 Speed 77mm
Four Wheel Drive
F ro n t Axle
Transfer Case
Fuel Tank
Pickup C10-35, K10-25 & Crew Cab
(Except 107 Models)
107 Models
A u x ilia ry Tank
Van Standard
Optional
Suburban Standard
O ptional
O ptional
Blazer/Jim m y Standard
Optional
P10, 15/20-35
P30042
P30032
IMPERIAL
MEASURE
U.S. MEASURE
1.9L
4% pts.
3Y2 pts.
2.8L
3L
2.6L
11.7L
31/2 pts.
6% pts.
7.2 pts.
6.0 pts.
26.8 pts.
3 pts.
5% pts.
5% pts.
5 pts.
21% pts.
3 .8L
4 .7L
4 .7L
5.7L
4
5
5
6
qts.
qts.
qts.
qts.
3% qts.
4% qts.
414 qts.
5 qts.
3.8L
4.7 L
4 qts.
5 qts.
31A qts.
5.7L
6 .6L
6 .6L
6 qts.
7 qts.
7 qts.
5 qts.
5% qts.
5% qts.
9 .5 L
2.8L
10.4L
3.8L
10 qts.
3 qts.
11 qts.
3.5 qts.
8% qts.
2% qts.
9% qts.
3 qts.
3 .8L
1.4L
1.4L
4 qts.
1.5 qts.
1.5 qts.
3% qts.
VA qts.
VA qts.
2.4L
2 .4L
2.5 qts.
2.5 qts.
2.qts.
2 qts.
76 L
60.5 L
83 L
125L
95 L
117L
151 L
95 L
117L
117L
114L
151 L
20 gal.
16 gal.
Same as Main Fuel Tank
22 gal.
33 gal.
25 gal.
31 gal.
40 gal.
25 qal.
31 gal.
31 gal.
30 gal.
40 gal.
4% qts.
16.8 gal.
13.3 gal.
18% gal.
27% gal.
20.8 gal.
25.8 gal.
33.3 gal.
20.8 gal.
25.8 gal.
25.8 gal.
25 gal.
33.5 gal.
LIG H T T R U C K SE RV IC E M A N U A L
0B-20
COOLING SYSTEM
Capacity
(Qts./Liters)
Engine
Series
C K10-15
C 20-25
250 CID
L6
G 10-30,
15-35
C 20-25
292 CID
L6
305CID
V8
C K30-35
P10-30, 15-35
C K10-15
G10-15
C K 10-30
15-35
P20-35
350 CID
V8
G 10-30
G 15-35
K20-25
400 CID
V8
454 CID
V8
G20-25
G30-35
C20-30
25-35
P30-35 (42)
P30-35 (32)
U.S.
Measure
15
15%
15
15!4
Imperial
Measure
Air
Cond.
Man.
Auto
Man.
Auto
Man.
X '
(14L)
(14.5L)
(14L)
(14.5L)
121/2
13
12%
13
17
14%
15 (14L)
1514 (14.5)
14% (13.7L)
15 (14L)
13% (12.7L)
17% (16.5L)
19 (18L)
20 (19L)
17% (16.5L)
18 (17L)
161/2 (15.6L)
17 (16L)
121/2
13
12
121/2
11%
14%
15%
16%
14%
15
13%
14%
X
X
X
X
X
X
X
X
X
X
20 (19L)
16%
18 (17L)
19 (18L)
15
15%
20 (19L)
20 (19L)
20 (19L)
21 (20L)
23 (21.7L)
16%
16%
16%
17%
19%
24 (22.7L)
24% (2 3 L )*
20
20%
19%
20%
23% (2 2 .2 L)
241/2 (23L)
Auto
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
L IG H T T R U C K SE R V IC E M A N U A L
H.D.
Radiator
Transmission
X
X
X
X
X
X
X
HEATER
1A-1
SECTION 1A
HEATER
CONTENTS
S tan d ard H e a te r................................................................................................ 1A-1
A uxiliary H e a te r ............................................................................................... 1A-15
Specifications...................................................................................................... 1A-19
STANDARD HEATER
INDEX
G eneral D escription................. ..........................................
System C om ponents........................................................
System C o n tro ls...............................................................
Diagnosis...............................................................................
On Vehicle Service
Blower M otor.....................................................................
H eater D istributor and Core Assem bly......................
1A-1
1A-3
1A-3
1A-4
1A-8
1A-8
H eater H o ses......................................................................1A-9
C enter D istributor D uct - G M odels.......................... .1A-12
Defroster D u c t....................................................................1A-12
Control A ssem bly..............................................................1A-12
Control C ab les.................................................................. .1A-13
Blower S w itch.....................................................................1A-13
Resistor U n i t ......................................................................1A-15
GENERAL DESCRIPTION
H eating com ponents are attach ed to the dash panel on
th e rig h t side of th e vehicle. T h e blow er and air inlet
assem bly and w ater hoses are located on the forw ard side of
the dash panel while the heater core and distributor duct are
on the passenger side.
The heater system is an air mix type system in which
outside air is heated and then mixed in varying am ounts
with cooler outside air to attain the desired air tem perature.
LIG H T T R U C K SERVICE M A N U A L
1A-2
HEATER
HE A T E R A D E F R O S T E R A S M
HEATER A
DEFROSTER A S M
AIR OUTLET
AIR OUTLET
VIEW A
STEERING
COLUMN
VIEW B
DEFROSTER DUCT A S M
INST PANEL
HEATER C O N T R O L
&
V IE W
AI R F L O W LEGEND
C-K MODELS
Q]
TEMPERATURE V A L V E [
[jjj
DEFROSTER VALVE
[3]
PURGE VALVE
L IG H T T R U C K SERVICE M A N U A L
f e j
] O U TS ID E AIR
M I X E D AIR
H I H E A T E D AI R
HEATER
1A-3
G Models
A ir flow is controlled by doors in the d istrib u to r
assembly. The air door can be adjusted to vary airflow. If air
is allowed to en ter the d istrib u to r assem bly, it is then
directed through an d /o r around the heater core by the
tem perature door. Air is directed into the passenger com
partm ent through the heater (floor) and/or defroster (dash)
outlets by the defroster door. The tem perature of the outlet
air is dependent of the ratio of heated to unheated air
(controlled by the tem perature door).
C-K Models
CONTROLS
LIG H T T R U C K SERVICE M A N U A L
1A-4
HEATER
DIAGNOSIS
CAUSE AND CORRECTION
TROUBLE
LIG H T T R U C K SE RV IC E M A N U A L
1.
1.
2.
3.
4.
5.
6.
1.
2.
3.
4.
5.
6.
1.
2.
1.
2.
3.
4.
5.
1.
2.
HEATER
1A-5
INSUFFICIENT HEAT D IA G N O S IS
Position the controls so that the:
Temperature lever is on full heat.
Selector or heater lever is on Heater.
Fan switch is on Hi.
CHECK DUMP DOOR OUTLET FOR AIR FLOW
AIR FLOW
NO AIR FLOW
I
A d ju st d u m p d o o r fo r n o air flo w .
~|
T..............
| Adjust defroster door for low air flow. |
145
0
. 150...
25
5b
40
...
165
75
|
NO AIR FLOW
NORMAL TEMPERATURE
|
CHECK FUSE
LOW TEMPERATURE
UNDER 10 VOLTS
BLOWS FUSE
OVER 10 VOLTS |
X
(Check the system temperature after re
pairing the item checked to complete the
diagnosis.)
_____
HEATER CORE
FUSE OK
I Feel temperatures of heater inlet and outlet hoses.
--------------T ------------- ---------------------
X
Remove hoses from heater core. Reverse
flush with tap water. If plugged, repair or
replace.
LIG H T T R U C K SERVICE M A N U A L
HEATER CIRCUIT D IA G N O S I S *
BLOWER MOTOR INOPERATIVE
(AN Y SPEED)
I
Check fuse
in fuse panel.
T
FUSE BLOWN
FUSE OK
1........
"
1-----
_L
Check blower motor ground
X
POOR OR NO GROUND
1
GROUND OK
Repair ground
LAMP LIGHTS
I
-------------- J------------ 1
LAMP DOES NOT LIGHT
1
Replace Motor
I
Check blower feed wire in connector
on resistor w ith 12 volt test light.
r
LAMP DOES NOT LIGHT
X
Use 12 volt test light and check feed
terminal (brown) on blower speed switch.
LA M P L IG H T S 1
..
1 _
HEATER
1A-7
LIG H T T R U C K SE RV IC E M A N U A L
1A-8
HEATER
ON VEHICLE SERVICE
BLOWER MOTOR
Removal (Fig. 1A-5)
G Models
Replacement (Fig. 1A-7)
L IG H T T R U C K SERVIC E M A N U A L
HEATER
1A-9
VIEW A
Fig. lA-7--Heater Distributor - G Models
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Replacement
HEATER HOSES
H eater hoses are routed from the therm ostat housing or
inlet m anifold and w ater pum p (radiator on some autom atic
transm ission vehicles) to the core inlet and outlet pipes as
shown in Figures 1A-8 thru 1A -1 1. Hoses are attached at
each end with screw type clamps.
LIG H T T R U C K SERVICE M A N U A L
1A-10
HEATER
L-6
C-K M O D E L S
TO WATER PUMP - f
1v IEw [a 1 ^ C36
G M ODELS
L IG H T T R U C K SE RV IC E M A N U A L
HEATER
1A -1 1
1A-12
HEATER
|vitwfA|
DUCT ASSEMBLY
DEFROSTER DUCT
D efroster assemblies attach m en t are shown in Fig. 1A - 13
UPPER IP EXTENSION
CONTROL ASSEMBLY
C-K Models
Replacement (Fig. 1A-14)
HEATER
1A-13
G Models
Replacement (Fig. 1A-17)
G Models
Replacement (Fig. 1A-15)
Adjustment - G Van
1. A ttach inner cable and sheath to I.P. Control.
2. W ith I.P. installed, move tem perature cable to cold and
attach loop on inner cable to tem perature door on
heater case.
3. A ttach cable sheath to heater case.
4. Move tem perature lever to full heat. This will require
some effort due to force required to slide inner cable
clip to its proper position.
BLOWER SWITCH
C-K Models
Replacement (Fig. 1A-14)
LIG H T T R U C K SERVICE M A N U A L
1A-14
HEATER
V IE W A
V IE W B
L IG H T T R U C K S fR V IC E M A N U A L
HEATER
1A-15
G Models
Replacement (Fig. 1A-15)
RESISTOR
Replacement (Figs. 1A-5 and 1A-18)
AUXILIARY HEATER
INDEX
G eneral Description .......................................................................................... ..1A-15
C o n tro l............................................................................................................... ..1A-15
D iagnosis.............................................................................................................. ..1A-16
On Vehicle S ervice..............................................................................................1A-17
Specifications...................................................................................... ..................1A-19
GENERAL DESCRIPTION
An auxiliary heater is available as a dealer installed
accessory to provide additional heating capacity for the
rearm ost extrem ities of the G (05 and 06) models.
This unit operates entirely independent of the standard
heater and is regulated through its own controls at the
instrum ent panel.
This system consists of a separate core and fan unit
m ounted as shown in Fig. 1A-23.
H eater hoses extend from the unit to the front of the
vehicle where they are connected to the standard heater
hoses with " te e s" . An "on-off" vacuum operated w ater
valve is installed in the heater core inlet line in the engine
com partm ent. The purpose of the valve is to cut off coolant
flow to th e auxiliary core d uring w arm w eather and
elim inate the radiant heat th a t would result.
CONTROLS
Two methods of control are employed with this system:
LIG H T T R U C K SERVICE M A N U A L
1A-16
HEATER
DIAGNOSIS
R efer to the "S tan d ard H eater" section of this m anual
for diagnostic inform ation; R efer to Electrical D iagram Fig.
1A-21.
LIG H T T R U C K SE RV IC E M A N U A L
HEATER
1A-17
rjrrw77m
n
rmarTTTuri
'iM
n.f'gm
m i r r u .iB i
29737818905426
-3
3
2984092
|3
3
W HT-952
BRN/WHT-5'
2
2
TEL-51----LT BLU-72
8905426
BRN/WHT-50
W H T-952A
-3
BRN/WHT-50-3
WHT-952A2
WHT-952B-
2984092
REAR BLO.
RESISTOR
i!
8905426
LT BLU-72
YE l-51
2984092
2 9 8 9 5 7 6 GROMMET-
G Series
FUSE PANEL
ON VEHICLE SERVICE
Since a detailed list o f installation instructions is
included with the auxiliary heater unit, replacement proce
dures will not be repeated in this section.
On G ModeIs--When replacing heater hoses, maintain
a 1/2 in. minimum clearance between hose clip and upper
control arm, a 1-1/2 in. minimum clearance between hoses
and propshaft and a 1-1/4 in. minimum clearance between
the auxiliary heater core lines and the exhaust pipe as shown
in Fig. 1A-24. All Models--Draw hoses tight to prevent sag
or rub against other components. Be sure to route hoses
through all clamps as originally installed.
LIG H T T R U C K SERVICE M A N U A L
1A-18
HEATER
LIG H T T R U C K SE RV IC E M A N U A L
HEATER
SPECIFICATIONS
SECTION 1A
HEATER
V olts
Am ps.
(C old)
RPM
(Cold)
Blower Motor
C-K Models
13.5
6.25 Max.
G Models
13.5
7.1 Max.
2550
2950
2850
3250
Min.
Max.
Min.
Max.
Fuses
C-K Models
G Models
A U XILIA R Y HEATER
Volts
Blower Motor . . . . 13.5
Amps.
(Cold)
9.6 Max.
RPM
(Cold)
2700 Min.
1A-19
. Kfei*!
;: . ^ r
\
J>
kl
-i
<
,Kr '
AIR CONDITIONING
IB-1
SECTION IB
AIR CONDITIONING
NO TICE: W hen perform ing air conditioning diagnosis on Chevrolet
vehicles equipped with a catalytic converter, it will be necessary to warm the
engine to a norm al operating tem perature before attem pting to idle the
engine for periods g reater than five (5) minutes. Once the choke is open and
fast idle speed reduced to a norm al idle, diagnosis and adjustm ents can be
m ade.
CONTENTS
G eneral D escription............................................................
C60 System (C -K & G M odels)..................................
O verhead Systems (C -K & G M o d e ls)......................
M otor Home Chassis S y stem ........................................
Pressure Cycling S w itch...............................................
System C o n tro l.................................................................
D iagnosis...............................................................................
Leak Testing The R efrigerant S y s te m .......................
Pressure Cycling System D iagnosis.............................
Com pressor Diagnosis......................................................
Insufficient Cooling...........................................................
Electrical System D iagnosis..........................................
E vacuating and C harging Procedures............................
Air Conditioning System C a p a c ity ..............................
Checking O il......................................................................
On Vehicle S erv ice.............................................................
C o m p resso r........................................................................
C60 S y ste m -C -K M o d els..............................................
C ondenser............................................................................
A ccum ulator-A ll.............................................................
Blower A ssem b ly ...........................................................;
E vaporator C ore..............................................................
Expansion T ube-A ll.......................................................
Selector D uct and H eater C o re..................................
Kick Panel A ir Valve.....................................................
Plenum A ir V a lv e ..........................................................
Control A ssem b ly ..........................................................
T em perature Door Cable A d ju stm e n t...................
M aster Switch an d /o r Blower S w itch.......................
V acuum T a n k .................................................................
Blower Resistor U n it.....................................................
Blower M otor R e la y ......................................................
F u se ......................................................................................
Overhead S y stem -C -K M odels....................................
IB-3
IB-3
IB-3
IB-3
IB-5
IB-7
IB-12
IB-12
IB-13
IB-16
IB-28
IB-28
IB-29
IB-29
IB-29
IB-29
IB-35
IB-38
IB-38
IB-38
IB-38
IB-38
IB-38
IB-40
IB-40
IB-40
IB-41
IB-41
IB-41
IB-41
IB-42
IB-42
IB-42
IB-42
LIG H T T R U C K SERVICE M A N U A L
IB-2
LIGHT
SERVICE
SHROUD.
M ANUAL
CONTROL
VIEW A
9
00
*
n3 "
Q
=5.
HEATER CORE
O
<D
Q_
BLOWER &
EVAPORATOR A S M
(CK) MODELS
AIR CONDITIONING
TRUCK
EVAPORATOR CORE
AIR CONDITIONING
IB-3
GENERAL DESCRIPTION
C60 A /C SYSTEM
Both the heating and cooling functions are performed
by this system. Air entering the vehicle must pass through
the cooling unit (evaporator) and through (or around) the
heating unit, in th at order, and the system is referred to as a
"re h e a t" system.
The evaporator provides m axim um cooling of the air
passing through the core when the air conditioning system is
calling for cooling.
On C-K and G Series, com pressor operation is control
led by a pressure sensing switch, located near the top of the
accum ulator. The switch responds to pressure changes to
turn the com pressor O N or O FF, as required.
System operation is as follows:
Air, either outside air or recirculated air, enters the
system and is forced through the system by the blower. As
the air passes th ro u g h th e ev ap o rato r core, it receives
m axim um cooling if the air conditioning controls are calling
for cooling. A fter leaving the evaporator, the air enters the
heater and air conditioner selector duct assembly where, by
means of diverter doors, it is caused to pass through or to
bypass th e h eater core in th e proportions necessary to
provide the desired outlet tem perature. Then conditioned air
enters the vehicle through either the floor distributor duct or
the dash outlets. D uring cooling operations, the air is cooled
by the evaporator to below com fort level, it is then warmed
by the heater to the desired tem perature. During "heating
only" operations, the evaporator will not be in operation and
am bient air will be warm ed to the desired level in the same
m anner.
G-Van
The dash outlets are rectangular in design and can be
rotated horizontally or vertically to direct air as desired.
Foot coolers are provided on both driver and passenger side.
In th e h eater-d efro st m odes, th e air conditioning
outside air door is closed. The heater air door is open and
outside air is allow ed to pass th ro u g h the h eater core
(receiving m axim um heating) and is then directed into the
passenger com partm ent through the heater an d /o r defroster
outlets.
System Components
Receiver-Dehydrator (Motor Home Chassis
Models)
The receiver-dehydrator, serving as a reservoir for
storage of high pressure liquid produced in the condenser,
incorporates a screen sack filled with the dehydrating agent.
The receiver-dehydrator, used prim arily as a liquid
storage tank, also functions to trap minute quantities of
m oisture and foreign m aterial which may have rem ained in
the system afte r installation or service operations. A
refrigerant sight glass is built into the receiver-dehydrator to
be used as a quick check of the state and condition of charge
of the entire system. The receiver-dehydrator is mounted
near the condenser.
Sight Glass (Motor Home Chassis Models Only)
IB-4
AIR CONDITIONING
AIR CONDITIONING
IB-5
>/<
LIG H T T R U C K SERVICE M A N U A L
IB-6
C O N D I T I O N E D AIR
D I S T R I B U T E D AB OU T
80% TO W /S H L D
& 20% TO FLOO R
4 SPEED FAN
C O N T R O L LE VE R
V A C U U M O P E R A T E D SYSTEM
SELECTOR (MODE) L E VE R
T E M P E R A T U R E L E V E R POSITION R E G U L A T E S TE M P E R A T U R E
OF THE A I R E N T E R I N G THE PASSENGER C O M P A R T M E N T BY
CABLE O P E R A T I O N OF THE HEATER CORE TE M P E R A T U R E D O O R
AIR CONDITIONING
AIR CONDITIONING
IB-7
SYSTEM CONTROLS
CK TRU CK
SELECTOR
LEVER
POSITION
COMPRESSOR
BLOWER
SPEEDS
A V A IL
AIR
SOURCE
AIR
ENTERS
VEHICLE
HEATER A/C
DOOROPEN TO:
HEATER
DEFROSTER
DO OR-OPEN TO:
OFF
OFF
LOW
OUTSIDE
FLOOR OUTLETS
HEATER
HEATER
M AX A/C
ON
HI
INSI DE%
DASH OUTLETS
A/C
HEATER
NORM A/C
ON
ALL
OUTSIDE
DASH OUTLETS
A/C
HEATER
OUTSIDE
FLOOR AND
DASH OUTLETS
A/C &
HEATER
HEATER
B I-LE V E L
ON
ALL
VE N T
OFF
ALL
OUTSIDE
DASH OUTLETS
A/C
HEATER
HTR
OFF
ALL
OUTSIDE
FLOOR OUTLETS
HEATER
HEATER
HEATER
DEFROST
DEF
OUTSIDE
DEFROST OUTLETS
ON
ALL
NOTE % 100% Inside air is not available, some bleed through of outside air is allowed.
LIG H T T R U C K SERVICE M A N U A L
IB-8
AIR CONDITIONING
COMPRESSOR
O FF
OFF
BLOW ER
SPEEDS
A V A IL
A IR
SOURCE
NONE
O U T S ID E
A IR
ENTERS
V E H IC L E
H E A TE R
A /C
DOOR
H E A TE R
D EFR O STER
DOOR
OPEN TO
OPEN TO
HEATER
H E A T E R -D E F
F LO O R O U T L E T S
MAX
ON
ALL
I NSIDE %
DASH O U T L E T S
HEATER
A /C
NO RM
ON
ALL
O UT SIDE
DASH O U T L E T S
HEATER
A /C
Bl LEV
ON
ALL
O U T S ID E
DASH O U T L E T S
F LO O R O U T L E T S
HEATER
A /C &
HEATER
VENT
OFF
ALL
O UT SIDE
DASH O U T L E T S
HEATER
A /C
H EA TER
OFF
ALL
OUTSIDE
B L E E D TO DEF RO ST
& F LO O R O U T L E T S
HEATER
HE A T E R
DEFR
ON*
ALL
O UT SIDE
DEF R O ST O U T L E T S
DEF RO ST
HEATER
DASH P A N E L
H EA TER CORE CASE
P IN K
A /C
^ HEATER
D ISTRIBUTOR
DUCT
O U T S ID E
A IR j
H E A T E R AI R
DEFROST
CONTROL
DK B L U E
S E L E C T VAL VE OPER A TIN G C HART
ORANGE
P O R T NC .
9
2
4
1
8
HEAT
DEF
A / C - 0 . S. A IR
H T R A IR
SOURCE
OFF
V AC
VA C
VENT
VA C
VAC
MAX
VAC
VENT
VENT
V AC
V AC
NO RM
V AC
VENT
VA C
VAC
VAC
HTR
V AC
VENT
VENT
VENT
VAC
DEFOG
VENT
VENT
VENT
VENT
VA C
DEF
VENT
V AC
VENT
VENT
VAC
AIR CONDITIONING
IB-9
IB -10
AIR CONDITIONING
A C CUM U LA TO R
'H P L "
'L P L "
'L P V "
'Ipl"
REFRIGERANT 12
PRESSURE TEMPERATURE
RELATIONSHIP
The table below indicates the pressure of Refri
gerant 12 at various temperatures. For in
stance, a drum of Refrigerant at a temperature
of 80PF (26.6?C) will have a pressure of 84.1 PSI
(579.9 kPa). If it is heated to 125F (51.6*0, the
pressure will increase to 167.5 PSI (1154.9
kPa). It also can be used conversely to deter
mine the temperature at which Refrigerant
12 boils under various pressures. For example,
at a pressure of 30.1 PSI (207.5 kPa), Refriger
ant 12 boils at 32F (O C).
CF)( C)
LIG H T T R U C K SE RV IC E M A N U A L
(PSIG)(kPa)
f F)(C)
55
60
65
70
75
80
85
90
95
100
105
110
115
120
125
130
140
12.70
15.5C
18.3C
21.1C
23.8C
26.6C
29.40
32.2C
35.00
37.7C
40.5C
43.3C
46.1C
48.8C
51.60
54.40
60. OC
(PSIGNkPa)
52.0
57.7
63.7
70.1
76.9
84.1
91.7
99.6
108.1
116.9
126.2
136.0
146.5
157.1
167.5
179.0
204.5
358.5
397.8
439.2
482.7
530.2
579.9
632.3
686.7
745.3
806.0
870.2
937.7
1010.1
1083.2
1154.9
1234.2
1410.0
AIR CONDITIONING
Refrigerant Charge
Overhead System
C K Models
G Models
5 lbs.-4 oz.
5 lbs.
C60 System
3 Lbs. -1 2 o*.
3 lbs.
IB -11
IB -12
AIR CONDITIONING
DIAGNOSIS
TESTING THE REFRIGERANT SYSTEM
If a m alfunction in the refrigerant system is suspected
due to abnorm al system pressures, check the following:
1. C heck outer surfaces of radiator and condenser cores to
be sure they are not plugged with dirt, leaves or other
foreign m aterial. Be sure to check between the con
denser and radiato r as well as the outer surfaces.
Operating Detector
1. D eterm ine if there is sufficient refrigerant in the system
for leak testing.
3. R efrigerant leaks.
IB -14
AIR CONDITIONING
C irc u m s ta n c e s S h o u ld a S ig h t G la s s Be In s ta lle d
Feel L iq u id L in e B e fo re E x p a n s io n T u b e
R e s tric tio n in H ig h S id e o f S y s te m .
V is u a lly C heck fo r F ro s t S p o t to Lo c a te
R e s tric tio n . R e p a ir as N ec e s s ary ,
i
I
S y s te m
E v a c u a te & C h a rg e
In s ta ll G a g e S e t a n d C h e c k C o m p re s s o r
C y c lin g Press
(O.K.)
R U N S C O N T IN U O U S L Y
W IT H IN L IM IT S
CYCLES H IGH OR LO W
(O N AB O V E 51 PSI
OR OFF BE LO W 20 PSD
C YC LES W IT H IN L IM IT S
--------1--------D e fe c tiv e
D is c o n n e c t B lo w e r W ir e a n d C he c k For
C y c lin g O ff a t 13 8-1 93 kPa (20 -2 8 PSI)
P ressu re
S w itc h
PRESSU R E F A L LS
B E L O W 20 PSI
D e fe c tiv e P re s s u re
S w itc h
R ep lace
*D o N o t D is c h a rg e
1
2.
3.
4.
5.
6.
S y s te m
(O .K .)
21C
(70 F)
A M B IE N T TEMP.
A/C
O U T LE T
TEMP.
S ystem
(O.K.)
SET T E M P LEVER TO F U LL C O LD
SET SELECTOR LEVER T O M A X A/C
SET BLO W ER S W IT C H O N HI
CLOSE D O O R S A N D W IN D O W S
R U N EN G IN E A T 20 00 R P M
USE A U X . F A N IN F R O N T OF GRILL
27 C
(8 0 F)
32 C
(90F)
38 C
(100F)
43 C
(1 10F)
PICK-UP
5-8C
(41-47)
5-8C
(41-47)
6-10C
(42-50)
6 -1 1C
(43-57)
6 -1 1C
(43-51)
SU B U R B A N
6-9C
(42-48)
6-9C
(42-48)
10-14C
(50-58)
12-17C
(54-62)
14-19C
(57 67)
O U T LE T TE M P E R A T U R E
HIGH A S PER C H AR T
O U T LE T TE M P E R A T U R E
W IT H IN LIM IT S
S y s te m
(O .K .)
C he ck C o m p re s s o r C y c lin g
O N C O N T IN U O U S L Y
CYCLE O N A N D OFF OR
R E M A IN S OFF FOR LO N G
PERIOD OF T IM E
D is c h a rg e S y s te m a n d C he c k For
M is s in g E x p a n s io n T u b e
D is c h a rg e S y s te m a n d
C he ck fo r P lu g g e d E x p a n s io n T ub e
| M IS S IN G
IN PLACE
i
i
S y s te m
E v a c u a te & C h a rg e
i_____
E v a c u a te fit C h a rg e
C LE AN
(O .K .)
R e p a ir o r R e p la ce S cree n
S y s te m O v e r C h a rg e d
I
E v a cu a te & C h a rg e
i
S ystem
E va cu a te & C h a rg e
(O .K.)
LIG H T T R U C K SE RV IC E M A N U A L
R ep lace
C heck C o m p re s s o r In le t
S cree n
_____________
In s ta ll E x p a n s io n T u b e
S ystem
(O K .)
S ys te m
(O .K.)
AIR CONDITIONING
IB -15
T h is S y s te m D oe s N o t H ave a S ig h t G lass. U n d e r N o
C irc u m s ta n c e s S h o u ld a S ig h t G lass Be In s ta lle d
F eel L iq u id L in e B e fo re E x p a n s io n T u b e
R e s tric tio n in H ig h S id e o f S y s te m .
V is u a lly C heck fo r F ro s t S p o t to Lo c a te
R e s tric tio n . R e p a ir as N ec e s s ary .
Feel E v a p o ra to r In le t a n d O u tle t P ip es
IN LE T PIPE A N D O U T LE T
PIPE S A M E T E M P E R A
TU RE OR O U T LE T
COLD ER T H A N IN LE T
I
I
S y s te m
E v a c u a te & C h a rg e
In s ta ll G a ge S e t a n d C h e c k C o m p re s s o r
C y c lin g Press,
(O .K.)
R U N S C O N T IN U O U S L Y
W IT H IN L IM IT S
| C YC LES W IT H IN L IM IT S
CYCLES H IG H OR LO W
(ON A B O V E 51 PSI
OR OFF B E LO W 20 PSI)
D is c o n n e c t B lo w e r W ir e a n d C he c k F or
C y c lin g O ff a t 13 8-1 93 kPa (20 -2 8 PSI)
P R ESSU R E FALLS
B E L O W 20 PSI
D e fe c tiv e
P re ssu re
S w itc h
CYCLES OFF A T 138-193
kP a (20 -2 8 PSI) OR D O ES
N O T PU LL D O W N TO
PRESS
D e fe c tiv e P re s s u re
S w itc h
R ep lace
D o N o t D is c h a rg e
S y s te m , T h e re
In s ta ll T h e rm o m e te r in A/C O u tle t an d
C he ck P e rfo rm a n c e
R eplace. D o N o t D is c h a rg e
S y s te m . T h e re is a S c h ra d e r
V a lv e in th e F ittin g
1.
2.
3.
4.
5.
6.
I
S ystem
(O .K.)
A M B IE N T TEMP.
A /C
O U T LE T
TEMP.
S yste m
(O .K.)
SET T E M P LEVER TO F U LL C O LD
SET SELECTOR LEVER TO M A X A/C
SET B LO W E R S W IT C H O N HI
CLOSE D O O R S A N D W IN D O W S
R U N EN G IN E A T 2000 R .P.M
U SE A U X . F A N IN F R O N T OF G R ILL
21C
(70 F)
27 C
(80 F)
32 C
(9 0 F)
38 C
(100 F )
43 C
( 1 10F)
PICK-UP
5-8C
(41-47)
5-8C
(41-47)
6-10C
(42-50)
6-1 f C
(43-57)
6 -1 1C
(43-51)
S U BU R BA N
6-9C
(42-48)
6-9C
(42-48)
10-14C
(50-58)
12-17C
(54-62)
14-19C
(57-67)
O U T LE T TE M P E R A T U R E
H IG H A S PER C H AR T
O U T LE T TE M P E R A T U R E
W IT H IN L IM IT S
T
S y s te m
(O .K.)
C he ck C o m p re s s o r C y c lin g
O N C O N T IN U O U S L Y
CYCLE O N A N D OFF OR
R E M A IN S OFF FOR LO N G
PERIOD OF T IM E
------------------------f -----------------------
D is c h a rg e S y s te m a n d C he ck For
M is s in g E x p a n s io n T u b e
D is c h a rg e S y s te m a n d
C heck fo r P lu g g e d E x p a n s io n T ub e
i
i
E v a c u a te & C h a rg e
i
S yste m
R ep lace
In s ta ll E x p a n s io n T u b e
C he ck C o m p re s s o r In le t
S cree n
E v a c u a te & C h a rg e
S y s te m
(O .K.)
(O .K.)
P LU G G E D
R ep air o r R ep lace S cree n
I
i
S ystem
E v a cu a te & C h a rg e
(O .K.)
S y s te m O v e r C h a rg e d
E v a cu a te & C h a rg e
S ystem
(O .K.)
L IG H T T R U C K SERVICE M A N U A L
IB-16
AIR CONDITIONING
LIG H T T R U C K SE RV IC E M A N U A L
COMPRESSOR DIAGNOSIS
CLUTCH SLIPPING.
Correct if necessary.
(.022-.057)
CO M PRESSO R E N G A G ED
B U T N O T O P E R A T IO N A L
BELT SLIPPING.
REFRIGERATION CHARGE
IS DEPLETED.
LEAKS
R E F R IG E R A N T .
Repair compressor.
Operate and leak
test system.
Repair compressor.
D O E S NOT L E A K
Wipe off oil - O.K.
LIGHT
TRUCK
Repair compressor
if noise is
objectionable.
If interference
exists, repair
compressor.
AIR CONDITIONING
NOTE:
SERVICE
IB -1 7
MANUAL
TRUCK
IB -18
LIGHT
M ANUAL
4. Check for broken, burst, or cut hoses. Also check for loose fittings on all components.
N O R M A L A IR FLO W
j CHECK
5.
6.
7.
8.
9.
Check
Check
Check
Check
Install
C H E C K A IR FLO W
NO O R LO W A I R F L O W
C H E C K B L O W E R O P E R A T IO N
D IS C H A R G E A I R T E M P E R A T U R E (S E E P E R F O R M A N C E D A T A ) |
B L O W E R N O T O P E R A T IN G
N O R M A L B L O W E R O P E R A T IO N
I
D IS C H A R G E T E M P E R A T U R E
A T O U T LET COLD
C H E C K F O R B L O W N F U S E , D E F E C T IV E B L O W E R SW IT C H ,
H IG H O U T L E T A IR
TEM PERATU RE
B R O K E N W IR E . L O O S E C O N N E C T IO N S , L O O S E B L O W E R M O T O R
G R O U N D W IR E O R I N O P E R A T IV E B L O W E R M O T O R .
C H E C K S IG H T G L A S S
IC E B L O C K IN G
EVAPO RATOR
|'f o a m i n g | "
SYSTEM
NO F O A M IN G
IS P R O B A B L Y L O W O N R E F R IG E R A N T .
C H E C K F O R L E A K S . R E P A IR , A N D A D D
R E F R IG E R A N T . IF F O A M IN G S T I L L O C C U R S ,
C H E C K F O R R E S T R IC T IO N IN R E F R I G E R A N T
S Y S T E M B E T W E E N C O N D E N S E R A N O S IG H T
G LA SS.
C H EC K FO R LOW E V A P O R A T O R P R E SSU R E
1. A L L O W S Y S T E M T O W A R M UP.
2. S T O P A N D R E S T A R T E N G IN E .
3. C H E C K E V A P O R A T O R P R E S S U R E
IM M E D IA T E L Y A F T E R R E S T A R T A N O
PU LL DOW N OF E V A P O R A T O R PR ESSU R E.
1. S Y S T E M M A Y B E E IT H E R F U L L Y C H A R G E D O R E M P T Y .
F E E L H IG H A N D L O W P R E S S U R E P IP E S A T C O M P R E S S O R .
H IG H P R E S S U R E P IP E S H O U L D B E W A R M . L O W P R E S S U R E
P IP E S S H O U L D B E C O L D .
2. IF P IP E S A R E N O T IN D IC A T IN G P R O P E R T E M P E R A T U R E S ,
R E C H A R G E S Y S T E M A S R E C O M M E N D E D . IF N O Z Z L E A IR
T E M P E R A T U R E IS S T IL L H IG H . C H E C K E V A P O R A T O R
PRESSU RE.
NO RM AL EVAPO RATO R
PRESSU RE
X
LOW E V A P O R A T O R
PRESSU RE
*C H E C K E V A P O R A T O R P R E S S U R E
Z= 1
B Y R E M O V IN G V A L V E A N D B L O W IN G T H R O U G H
V A L V E . IF U N A B L E T O B L O W T H R O U G H V A L V E ,
B U L B IS D IS C H A R G E D . R E P L A C E E X P A N S IO N
VALVE.
NORMAL
L O W D IS C H A R G E
*
PR ESSU RE
----
C H E C K C O M P R E S S O R D IS C H A R G E P R E S S U R E
1. C H E C K F O R L IQ U ID L IN E R E S T R IC T IO N
( F R O S T S P O T O N L IN E ). IF NO T,
2. C H E C K F O R P L U G G E D IN L E T S C R E E N IN
E X P A N S IO N V A L V E . IF N O T ,
3. C H E C K F O R D E F E C T IV E E X P A N S IO N V A L V E
1------T
S Y S T E M H A S E X C E S S M O IS T U R E . R E P L A C E R E C E I V E R
D E H Y D R A T O R AND EV A C U A T E TH O RO U G H LY . R E C H A R G E
SY STEM .
H IG H E V A P O R A T O R
*
P R ESSU RE
C H E C K E V A P O R A T O R O U T L E T L IN E
EV A PO RA T O R OUTLET
L IN E W A R M
LOW E V A P O R A T O R
*
PR ESSU RE
I
| Check Compressor Discharge Pressure.
,----- =3------------------| H IG H D IS C H A R G E P R E S S U R E
I
L O W D IS C H A R G E P R E S S U R E !
N O R M A L D IS C H A R G E P R E S S U R E
X
Check for restriction in liquid line,
partially plugged inlet screen at
expansion valve, or defective
expansion valve, replace valve if
defective.
JL
Refrigeration System is ok
1. Check for proper function of heater T E M P E R A T U R E door.
2. Check for proper sealing of evaporator case.
3. Check for proper operation and seal around temperature door.
4. N on-Foam ing sight glass does not always indicate a fully
charged system. A d d 1/2 lb. refrigerant and observe
performance.
5. Check for excess oil in system. A sym ptom of excess oil is a
slipping clutch or belt or broken belt. T o remove excess oil
in system see " C H E C K I N G
C H A R G E ".
D ash M o u n te d U n i t ( M o t o r H o m e C ha ssis)
O U T L E T A IR T E M P E R A T U R E
D R O PS A S C O M PRESSO R
D IS C H A R G E P R E S S U R E D R O P S
O U T L E T A IR T E M P E R A T U R E
IN C R E A S E S A S C O M P I " " ? R
D IS C H A R G E P R E S S U R E D R O P S
L E A K T E S T S Y S T E M , R E P A IR
A S N E C E S S A R Y . D IS C H A R G E .
R E P L A C E E X P A N S IO N V A L V E
EVACUATE. AN O RECHARG E.
O IL
R E F E R TO P E R F O R M A N C E
C H A RT FO R C O R REC T PR ESSU RES
CO M P RESSO R
70
80
90
110120
13 5 MS
160170
E ngine rpm
C o m pre ssor
H ead Pressure*
110
120
190200
22 0 230
260270
10
10
13
4247
4449
4449
200 0
Pressure psi*
D ischarge A ir .
T e m p e ra tu re *
100
4045
4146
4146
AIR CONDITIONING
SERVICE
The follow ing procedures should be applied before performance testing an A/C System.
1. Check for proper belt installation and tension with J-23600.
2. Check for proper clutch coil terminal connector installation.
3. Check for clutch air Gap (.022 .057).
B L O W E R M O T O R IN O P E R A T IV E
(A N Y S P E E D )
Check for proper
fuse
I fu se q k |
1 F U SE B L O W N !
----
I poor or
no
g r o u n d
Repair ground
Iground
ok
T E S T L IG H T D O E S N O T
| L A M P L IG H T S !
T E S T L IG H T L IG H T S ON
L IG H T O N A L L T E R M I N A L S
A L L T E R M IN A L S
X
Replace resistor
[ L A M P D O E S N O T L IG H T j
Replace motor
L A M P D O E S N O T L IG H T IN A L L P O S IT IO N S
.......- t ____
( l a m p l ig h t s !
Repair open in
wire from blower
motor to blower
| L A M P D O E S N O T L IG H T j
relay.
|L A M P L IG H T S
p L A M P D O E S N O T L IG H T ]
I L A M P L IG H T S !
Replace relay
X
LAM P OFF
L A M P L IG H T S
resistor to blower
speed switch.
LIGHT
TRUCK
[L A M P 0 FFJ
SERVICE
Replace blower
speed switch.
Replace resistor
1 (LAM P
- .......
Replace blower relay.
D O E S N O T L IG H T !
from resistor to
blower relay.
LAMP LIGHTS ON
A L L WIRES
affected wire.
Repair open in
AIR CONDITIONING
|l a m p 0 n |
IB -19
M ANUAL
IB-20
AIR CONDITIONING
.........
I
Check heater outlet temperature
w ith 220 F range thermometer.
150
25
155
40
75
LOW AIR FLOW |
NO AIR FLOW
CHECK FUSE
NORMAL TEMPERATURE
Check heater outlet for obstruction - re
move.
Remove all obstructions under fro n t seat.
LOW TEMPERATURE
(Check the system temperature after re
pairing the item checked to complete the
diagnosis.)
Check coolant level; if low, fill. Look for
or feel all radiator and heater hoses and
connections for leaks. Repair or replace.
Check the radiator cap for damage and re
place if required.
....................... I------------------
BLOWS FUSE
Remove positive lead from motor and
replace fuse.
[ HEATER CORE [
Feel temperatures of heater inlet and outlet hoses.
L IG H T T R U C K SE R V IC E M A N U A L
AIR CONDITIONING
IB-21
S H E E T M E T A L m _ .,
- BLK H g \
Q
BLCWER
MOTOR
(2004627
SEE NOTE A
r\
S T
BLOWER RELAY
RESISTOR
I LT GRN-6 6 B
I D K G R N -5 9
BLK-150----
[3 1
5 RED-2
(S I
I DK
ASM
iCRD
-
-1
-I
- I
-I
B L U -IO I
| } - . 8 0 R N - 5 2 ------
ORN-52-------TAN-63-------BRI'VWHT-646LT BLU-72----LTGRN-66A
---------1BRN/WHT-648,
'- I 0RN(WH>64A'^
& ORN-52-) TAN-63
-I LT BLU-72-
BLOWER SWfTCH
-5 PPL- 6 5
29649H
-5 RED-2 -
COMPRESSOR
12004268 - j
MOUNTNG
BLK-I50C
XSXLHSl!BRACKET
GND
->5 LT G RN(SXU------- E S
FAST ID L E
SOLENOID
DK GRN-59$XL)
NOTE:
* l USE WITH
12010191
SELECTOR SWITCH
RETAINER
AIR CONDITIONING
R P 0C -60
S E [ S S 2BRN-C
I
\ A 6917585
' ---- 917580
AIR CONDITIONING
RP.Q-C60
LIG H T T R U C K SERVICE M A N U A L
IB-22
AIR CONDITIONING
REAR BLOWER
WESISTgR
2 )t i
- w
m
-12004752 GROMMET
7541
9175422 LT BLIV6LK-872
> 2 YEL/BLK-851-2 0RI/ blk - i8 5 2 MNI-C6Q-
W
MC.
-2LTBLIVBLK
-2YEU/BLK---- [Ml ( Ml
2 LT BLLVBLK-872 i
- 2 YEL^LK-851
- 2 QRN/BLK-852A
-30R IVB LK -852B -1
-2 B R N -5 0
- 2 B R N -5 0 -
hi
SEAR BLOWER
MOTOR
SHEET
METAL
3 BRfVW HT-850
GRD
8 9 I7683
5 ORH^BLK-852-
L - 30RNfeLK-852B
891758
-2 B R N -50
12004493
RPQ-C60j
WR&
i
REF:
-2 B R N -50H
FUSE BLOCK
L IG H T T R U C K SE RV IC E M A N U A L
SELECTOR
CONTROL
R P 0-C 60
Diagram
(C-K Series)
AIR CONDITIONING
IB-23
IB -24
AIR CONDITIONING
L IG H T T R U C K SE RV IC E M A N U A L
HI
I TO
FUSE PANEL
||l G RO U N D
COM PRESSOR
Z
ctr
O
RESISTOR.
BLOWER
M OTOR
101 16 DK BLU
1
I
ft
52 16 DK BLU
72 16 LT BLU'
BLOWER SWITCH
51 16 YEL
SET AT
Diagram
B LO W E R -E V A P O R A T O R
ASSEMBLY
N TO N O N E
LOW
N TO 1 & 2
MED
N TO 1 & 4
HIGH
N TO 1, 3 & 4
AIR CONDITIONING
THERMOSTATIC
SWITCH
BLOWER
SWITCH
CONNECTIO N
OFF
IB-25
IB-26
AIR CONDITIONING
L IG H T T R U C K SE RV IC E M A N U A L
AIR CONDITIONING
IB-27
LIG H T T R U C K SERVICE M A N U A L
IB-28
AIR CONDITIONING
COMPRESSOR
A compressor defect will appear in one of four ways:
Noise, seizure, leakage, or low discharge pressure.
NOTICE: Resonant com pressor noises are not cause for
alarm ; however, irregular noise or rattles m ay indicate
broken parts or excessive clearances due to wear. To
check seizure, de-energize the m agnetic clutch and
check to see if drive plate can be rotated. If rotation is
im possible, com pressor is seized (R efer to "F alse
Compressor S eizu re"). To check for a leak, refer to
leak testing. Low discharge pressure may be due to a
faulty internal seal of the compressor, or a restriction in
the compressor.
Furtherm ore, low discharge pressure m ay be due to an
insufficient refrigerant charge or a restriction elsewhere
LIG H T T R U C K SE RV IC E M A N U A L
CONDENSER
A condenser may be defective in two ways: it may leak,
or it may be restricted. A condenser restriction will result in
excessive compressor discharge pressure. If a partial restric
tion is present, sometimes ice or frost will form immediately
after the restriction as the refrigerant expands after passing
through the restriction. If air flow through the condenser or
radiator is blocked, high discharge pressures will result.
D uring normal condenser operation, the outlet pipe will be
slightly cooler than the inlet pipe.
EXPANSION VALVE
A m alfunction of the expansion valve will be caused by
one of the following conditions: valve stuck open, valve stuck
closed, broken power element, a restricted screen or an
improperly located or installed power elem ent bulb. The
first three conditions require valve replacem ent. The last two
may be corrected by replacing the valve inlet screen and by
properly installing the power elem ent bulb.
A ttachm ent of the expansion valve bulb to the evapora
tor outlet line is very critical. The bulb must be attached
tightly to the line and must make good contact with the line
along the entire length of the bulb. A loose bulb will result in
high low side pressures and poor cooling.
Indications of expansion valve trouble are provided by
perform ance tests; consult diagnostic charts.
VALVE ST U C K O PE N
Noisy Compressor
N o Cooling - Freeze Up.
VALVE ST U C K C L O SE D , BR O K EN PO W ER
E L E M E N T O R PL U G G E D S C R E E N
Very Low Suction Pressure.
N o Cooling.
PO O R L Y LO C A TED PO W E R E L E M E N T BULB
N orm al Pressure.
Poor Cooling.
Diagnosis for Defective Valve
AIR CONDITIONING
EVAPORATOR
W hen the evaporator is defective, the trouble will show
up as an inadequate supply of cool air. A partially plugged
core due to dirt, a cracked case, or a leaking seal will
generally be the cause.
IB-29
ON VEHICLE SERVICE
EVACUATING AND CHARGING PROCEDURES
PRECAUTIONARY SERVICE MEASURES
Before any service is attem pted which requires opening
of refrigerant lines or com ponents, the person doing the
work should be thoroughly fam iliar with the inform ation
under P R E C A U T IO N S IN H A N D L IN G R E F R IG E R
A N T -12, P R E C A U T IO N S IN H A N D L IN G R E F R IG
E R A N T L IN E S A N D F IT T IN G S M A IN T A IN IN G
C H E M IC A L S T A B IL IT Y IN T H E R E F R IG E R A T IO N
S Y S T E M , A N D R E F R IG E R A N T C H A R G IN G P R E
C A U T IO N S and should follow very carefully the D IS
C H A R G IN G , E V A C U A T IN G , O IL A D D IT IO N A N D
C H A R G IN G T H E R E F R IG E R A N T S Y ST E M instruc
tions given on th e following pages for the unit being
serviced.
shown in
excessive
joints or
result in
IB-30
AIR CONDITIONING
M ETAL TUBE
TH R EA D AN D
OUTSIDE
F ITTIN G SIZE
DIA M ETER
1/4
3/8
1/2
5/8
3/4
STEEL
TU BING
TO RQ UE
LB, FT.
Nm
LB. FT.
Nm
10-15
30-35
30-35
30-35
30-35
14-20
41-48
4148
41-48
4148
5-7
11-13
15-20
21-27
28-33
7-9
15-18
20-27
29-37
3845
7/16
5/8
3/4
..
A L U M IN U M OR
COPPER
N O M IN A L
TUBING
TORQUE
TORQUE
WRENCH SPAN
. m ...... .
1 1/16
5/8
3/4
7/8
1 1/16
. liilJ
G Models
C60 System
5 lb.-4 oz.
3 Lbs. -1 2 ox.
5 lbs.
3 lbs.
AIR CONDITIONING
IB-31
A L W A Y S D IS C H A R G E SY ST E M AT LO W SID E
S E R V IC E F IT T IN G .
1. With ignition tu rn ed OFF, rem ove p ro tec tiv e cap
from low -side service hose fitting and connect Charg
ing S tation J-23500-01 G age Set as show n in Fig.
IB-22.
O r w ith ignition turned O F F and protective cap re
m oved from LO W -SID E service fitting, discharge
sy stem by SLO W LY c o n n ec tin g a gage h o se to
LO W -SID E service fitting on A ccum ulator and dis
charging into oil bottle (Fig. IB-23). As hose is slowly
tightened dow n into schrader valve, R-12 will be in to
discharge from the system into the container. If no
discharge o c cu rs, check fo r m issing or defective
schrader d ep ressor in
LIG H T T R U C K SERVICE M A N U A L
IB-32
AIR CONDITIONING
CLOSE A L L CO NTRO LS
J 23500-01
SE R V IC E C H A R G IN G
S T A T IO N
F U L L Y OPEN GAUGE
SET V A C U U M V A L V E
RE-CONNECT V A C U U M
HOSE TO PUMP A F T E R
DISCHARGE
DO NO T CONNECT
HIG H-SIDE HOSE
TO A /C SYSTEM
DISCO NNECT V A C U U M
HOSE A T V A C U U M PUMP
& PLACE IN T O CAN (SEE
N O T E " BELOW)
V A C U U M PUMP
NOTE:
L IG H T T R U C K SE R V IC E M A N U A L
AIR CONDITIONING
IB-33
IB-34
AIR CONDITIONING
J5725-04
MANIFOLD
USING J-5420
ADAPTER
OPEN DURING
EVACUATION
AND CHARGING
HIGH
SIDE
VALVE
VALVE
VACUUM PUMP
ACCUMULATOR
CLOSED D U R IN G /
EVACUATION X
OPEN AND INVERTED
DURING CHARGING
USING J23390
OPENER-VALVE
FOR 12 LB. CAN
Fig. 1 B-24--Charging the CCOT A /C System with Disposable Can or Refrigerant Drum.
AIR CONDITIONING
IB-35
COMPRESSOR
C-K SERIES
Removal (Fig. IB-33)
ACCUMULATOR ASSEMBLY
T he accum ulator assembly for the C C O T system has a
service replacem ent which includes two " O " rings (for the
inlet and outlet connections). The dessicant within the shell
is N O T serviced sep arately - it is p a rt of the sealed
accum ulator assembly.
R efer C C O T R efrigerant oil distribution for presence
of refrigerant oil and service conditions when the accum ula
tor m ust be rem oved from the vehicle to m easure the
am ount of oil present inside the accum ulator.
T he accum ulator assembly should be replaced only
when:
1. A physical perforation to the accum ulator is found
resulting in a leak.
LIG H T T R U C K SE RV IC E M AN U AL
IB-36
AIR CONDITIONING
3 0 5 - 3 5 0 V -8
C-K M O D E L S
^ T
3 0 5 - 3 5 0 V -8
4 5 4 V -8 C-
l t r ^
M O D E LS A N D M O T O R H O M E C H A SS IS
M O DELS
4 5 4 V -8
L IG H T T R U C K SERVICE M A N U A L
M O T O R H O M E C H A SS IS
AIR CONDITIONING
Installation
2.
3.
4.
5.
6.
7.
IB-37
Installation
LIG H T T R U C K SERVICE M A N U A L
IB -38
AIR CONDITIONING
ACCUMULATOR - ALL
Replacement
1.
2.
3.
4.
L IG H T T R U C K SE RV IC E M A N U A L
EVAPORATOR CORE
Replacement (Fig. IB-28)
EXPANSION TUBE-C-K,& G
The expansion tube is located in the evaporator core
inlet line.
Replacement
1. Discharge system.
2. Disconnect the condenser to evaporator line at the
evaporator inlet. C ap the open line at once.
3. Using needle-nose pliers, remove the expansion tube
from the evaporator core inlet line.
4. Remove the expansion tube " O " ring from the core
inlet line.
5. To install, reverse Steps 1 thru 4 above.
Install the expansion tube using a new " O " ring coated
w ith clean reg rig eratio n oil, by inserting the sh o rt
screen end of the tube into the evaporator inlet line.
6. Evacuate, charge and check the system.
AIR CONDITIONING
IB-39
LIG H T T R U C K SERVICE M A N U A L
IB-40
AIR CONDITIONING
1.
2.
3.
4.
AIR CONDITIONING
IB-41
Replacement
VACUUM TANK
The vacuum tank is m ounted to the engine side of the
dash panel above the blower assembly (Fig. IB-33).
LIG H T T R U C K SERVICE M A N U A L
IB-42
AIR CONDITIONING
GR A Y-TO
PLENUM VALVE
V A C U U M TANK
ORANGE
CAM
LEVER
CABLE
RECIRC. AIR
DEFROSTER
BLUE
V IE W
HEATER ASSEMBLY
C O N TR O L
A CTUA TO R
N O COLOR STRIPE
ACTUA TO R
V IE W
V IE W
Replacement
FUSE
A 25 am p fuse, located in the junction block protects
the entire air conditioning system except for the blower
circuit, the fuse for the blower circuit is located in the
electrical wiring between the junction block and the blower
relay.
OVERHEAD SYSTEM--C-K
MODELS
REAR DUCT
Replacement
L IG H T T R U C K SE RV IC E M A N U A L
AIR CONDITIONING
IB-43
A /C HARNESS ASM
PRESSURE C Y C L IN G SWITCH
BLOW ER
RESISTOR
BLOW ER
R ELAY
ACC UM ULATO R
BLOW ER ASM G R O U N D
E V A P O R A TO R
BLOW ER ASM
V IE W A
Installation
IB-44
AIR CONDITIONING
EXPANSION VALVE
This sytem incorporates an expansion valve which does
not utilize and external equalizer line (Fig. IB-40).
Removal
LIG H T T R U C K SE RV IC E M A N U A L
AIR CONDITIONING
6.
7.
8.
9.
Removal
5.
Installation
1.
2.
3.
4.
IB-45
Installation
FUSE
The Four Season portion of this system is protected by
a 25 am p fuse in the junction block.
The rear blower high speed circuit is protected by a 20
am p in-line fuse, located between the junction block and the
rear blower motor switch.
1. Install the wire screen to the front of the core and insert
the plastic pins.
2. Install the expansion valve inlet and outlet lines using
new " O " rings coated with clean refrigeration oil.
E VA PO R A TO R
SCREEN
B LO W E R -E V A P O R A TO R
UPPER CASE
IB-46
AIR CONDITIONING
1.
2.
3.
4.
AIR CONDITIONING
IB-47
EVAPORATOR CORE
Replacement (Fig. IB-54)
LIG H T T R U C K SERVICE M A N U A L
IB-48
AIR CONDITIONING
BLOWER SWITCH
Replacement (Fig. IB-48)
RESISTORS
Replacement (Fig. IB-49)
CONTROL - G SERIES
1.
2.
3.
4.
5.
6.
7.
8.
9.
AIR CONDITIONING
IB-49
L IG H T T R U C K SERVICE M A N U A L
IB-50
AIR CONDITIONING
L IG H T T R U C K SE R V IC E M A N U A L
AIR CONDITIONING
IB-51
LIG H T TR U C K SERVICE M A N U A L
IB-52
AIR CONDITIONING
COMPRESSOR
COMPRESSOR
ASSEMBLY
R IN G
HOSE & TUBE
ASSEMBLY C O N D .
OUTLET
A C C U M DEHYDR
ASSEMBLY OUTLET
PIPE
G MOD. V8 ENG.
C60/69
HOSE & TUBE ASSEMBLY
EVAP. OUTLET REAR
V IE W
LIG H T T R U C K SE RV IC E M A N U A L
G MOD. LE 3 ENG.
C60
AIR CONDITIONING
IB-53
CIRCUIT BREAKER
The entire air conditioning system is protected by a 45
am p circuit breaker located on the left side of the dash, in
the engine com partm ent.
A /C DUCTWORK
A ir C onditioning duct attachm ent is shown in Fig. 1B63.
DEFROSTER DUCT
D efroster duct m ounting is shown in Fig. 1B-64.
LIG H T T R U C K SERVICE M A N U A L
IB-54
AIR CONDITIONING
LIG H T T R U C K SERVIC E M A N U A L
AIR CONDITIONING
IB-55
LIG H T T R U C K SERVICE M A N U A L
IB-56
AIR CONDITIONING
CONDENSER
Replacement (Fig. IB-66)
AIR CONDITIONING
IB-57
RECEIVER-DEHYDRATOR
Replacement (Fig. IB-67)
Unit)
NOTICE: Use new " O " rings, coated with clean refrig
BLOWER ASSEMBLY
Removal (Fig. IB-71)
IB-58
AIR CONDITIONING
TERMINAL
SCREW DRIVER
(NARROW BLADE)
CONNECTOR
TANG
GROOVE
A. Insert screw driver in groove & press
tang toward terminal to release.
B. Pry tang back out to insure locking
when reinstalled into connector.
Fig. 1B-69--Blower-Evaporator (Motor Home Chassis
Units)
L IG H T T R U C K SE RV IC E M A N U A L
AIR CONDITIONING
CORRECT
BLOWER
BLADE
ANGLE
IB-59
THERMOSTATIC SWITCH
4. R e m o v e b lo w e r m o to r a n d h a rn e s s a s s e m b ly fr o m case.
Unit)
Installation
SCR EEN
M E SH
NOTICE: Use new " O " rings coated with clean refriger
ation oil when connecting lines. Add 3 oz. of new
refrigeration oil to a new core.
E X P A N S IO N V A LV E
RESISTOR
The blower motor resistor is located on the top of the
unit. The entire unit m ust be removed to replace the resistor.
FUSE
This U nit does not incorporate an in-line fuse. The lead
w ire is connected to the H eater W iring H arness and
operates off the 20 am p H eater Fuse.
LIG H T T R U C K SERVICE M A N U A L
IB-60
AIR CONDITIONING
SPECIFICATIONS
A IR C O N D IT IO N IN G
Compressor
T y p e .........................................
4 Cylinder Radial
Displacement
6 Cylinder Axial
4 Cylinder Radial
R o t a t i o n .............................
Volts
RPM
(Cold)
Blower M otor
C-K Four Season . . 12.0
C-K-G Overhead,
G Floor and
M otor Home
U n its .................... 12.0
12.8 Max.
13.7 M ax.
3400 Min.
3400 M in.
Torque Specifications
Compressor Suction and Discharge
Connector B o l t ...................................
Rear Head to Shell Stud Nuts ( 6 Cyl.)
Shaft Mounting N u t (6 C y l . ) ...............
Shaft Mounting Nut (4 Cyl.)
. . .
High Pressure Relief Valve (6 Cyl.)
Oil Charge Screw (6 Cyl.)
. . . .
Air Gapon Clutch (6 C y l.)
. . . .
Compressor Mounting Bracket
Compressor to Front Bracket Bolts
Belt Tension
.........................................
Fuse Block
C-K S y s te m s ...........................................
M o tor Home Chassis U n it.....................
In -L in e C-K S y s te m s ...........................................
M o tor Hom e Chassis U n i t ....................
Circuit Breaker
G Model Systems.....................................
LIG H T T R U C K SE R V IC E M A N U A L
.
.
. . . 25 ft. lbs.
See Tune-Up Chart
....
20 Amp.
. . . . 25 Amp.
............... None
....
45 Am p.
AIR CONDITIONING
IB-61
SPECIAL TOOLS
J-25031-2
J-25031-1
J-25008-1
J-25008-2
IB-62
AIR CONDITIONING
SPECIAL TOOLS
1. J -8 3 9 3
2. J -2 4 0 9 5
3. J -54 5 3
4. J -9 4 5 9
J -2 5 4 9 9
5. J -5 4 2 0
J -2 5 4 9 8
6. J -6 0 8 4
C h a rg in g Station
O il Inducer
G o ggles
7 /1 6 " -2 0 9 0 G a u g e Line
3 /8 " -2 4 A d a p te r
7 /1 6 " -2 0 S tra ig h t G a u g e Line
3 /8 " A d a p te r
Leak Detector
7. J -8 4 3 3
8. J -9 3 9 5
9. J -2 3 5 9 5
Puller
Puller Pilot
R efrig era n t C an V alve
10. J -6271-01
(S id e -T a p )
R efrig era n t C an V alve
(To p-Tap)
11. J -5 4 2 1 -0 2
12. J-54 0 3
13. J -64 3 5
14. J -9 3 9 6
15. J -2 5 0 3 0
16. J-94 0 3
17. J -9 3 9 9
18. J-9401
19. J-94 8 0 -01
20. J -93 9 2
21. J -2 3 1 2 8
Assembly Remover
H ub and Drive Plate
Assembly In staller
S eal Remover
S eal S eat Remover
LIG H T T R U C K SE RV IC E M A N U A L
22.
23.
2 4.
2 5.
J-93 9 8
J-9481
J-80 9 2
J -21 3 5 2
2 6. J -51 3 9
2 7. J-94 3 2
28. J-95 5 3 -01
29. J -2 1508
3 0. J -2 2 9 7 4
3 1. J-96 2 5
32. J-94 0 2
FRAME
2A-1
SECTION 2A
FRAME
CONTENTS
G eneral Description ................... ......................................................................2A-1
On Vehicle S ervice........................................................................................... .2A-1
M aintenance and Inspection........................................................................ .2A-1
U nderbody In sp ectio n................................................................................. .2A-1
F ram e Inspection.......................................................................................... .2A-1
Fram e A lig n m en t.............................................................................................2A-1
U nderbody A lignm ent......................................................................................2A-4
Excessive Body D am age................................................................................ ..2A-4
GENERAL DESCRIPTION
L ig h t d u ty 10-30 Series fram es are of th e ladder
channel section riveted type.
Figure 2A-1 thru 2A-4 illustrates typical light duty
truck fram es with crossm embers, body mounts and suspension attaching brackets. This section also includes general
instructions for checking fram e alignm ent and recommendations on fram e repair.
ON VEHICLE SERVICE
MAINTENANCE AND
INSPECTION
UNDERBODY INSPECTION
Raise the vehicle on a hoist (preferably a twin-post
type).
C heck for obvious floor pan deterioration.
C heck for loose dirt and rust around the inside of the
floor pan reinforcem ent m em ber access holes. This is the
first indication th a t corrosion m ay exist in hidden areas, and
th at repairs m ight be required before the final cleaning and
protective treatm en t is perform ed.
Using a chisel, ensure th at the drain provisions in the
floor pan reinforcem ent m em bers are open.
T here are drain holes in the body side panels also.
These holes can be opened by using a punch or drift. The
side panel drain holes are in the rear section of the rocker
panels, and in the lower rear q u arter panels.
FRAME INSPECTION
R aise the vehicle on a hoist (preferably a twin-post
type).
Check for obvious floor pan deterioration.
Check for loose dirt and rust around the inside of the
fram e rails, on top and at the ends where corrosion m ay exist
in hidden areas. Check especially in the fram e box sections
for accum ulation of debris.
FRAME ALIGNMENT
Horizontal fram e checking can be made with tra m
ming gages applied directly to the fram e or by transferring
selected points of m easurem ent from the fram e to the floor
by means of a plum bob and using the floor layout for
measuring. Fig. 2A-2 or 2A-4 may be used as a general
guide in the selection of checking points; however, selection
of these points is a rb itrary depending on accessibility and
convenience. An im portant point to rem em ber is th at for
each point selected on one side of the frame, a corresponding
point on the opposite side of the frame m ust be used for
vertical checks, opposite and alternate sides for horizontal
checks.
Vehicle Preparation
Points to rem em ber when preparing vehicle for fram e
checking:
1. Place vehicle on a level surface.
2. Inspect dam aged areas for obvious fram e misalignm ent
to elim inate unnecessary measuring.
3. Support vehicle so th at fram e sidemembers are parallel
to the ground.
2A-2
FRAME
Horizontal Check
1. M easure fram e width at front and rear. If widths
correspond to specifications, draw centerline full length
of vehicle halfway between lines indicating front and
rear widths. If fram e widths are not correct, layout
centerline as shown in Step 4.
2. M easu re d istan ce from cen terlin e to corresponding
points on each side of fram e layout over entire length.
Opposite side m easurem ent should correspond within
3/16 in. (4.7 mm).
3. M easure diagonals m arked A, B and C. If the lengths
of intersecting diagonals are equal and these diagonals
intersect the centerline, fram e area included between
these points of m easurem ent may be considered in
alignm ent.
4. If front or rear end of fram e is dam aged and width is no
longer within limits, fram e centerline m ay be drawn
through the intersection of any two previously drawn
pairs of equal, intersecting diagonals.
Vertical Check
Vertical dimensions are checked with a tram m ing bar
from indicated points on the fram e (Figs. 2A-2 and 2A-4).
For example, if the tram bar is set a t point B with a vertical
pointer length of 8-1/4 in. (206 m m ), and a t point E with a
vertical pointer length of 5-1/4 in. (131 mm ) (a height
difference of 3 in. (75 m m ), the tram bar should be parallel
with the fram e. If the area is tw isted or m isaligned in any
way, tram bar will not be parallel. Placing the tram bar
vertical pointers on opposite sides of the fram e side rail is
preferable in th at fram e twist will show up during this
vertical check. Fig. 2A-2 and 2A-4 show typical checking
points, with dimensions for various fram es shown in Fig. 2A3.
Frame Repair
Welding
v Vjf*,
FRAME
Model
2A-3
V
14
CA107
13-3/8
15-1/4
16
19-7/8
12
13
10
14-7/8
17-3/4
17-3/4
19-7/8
16-3/4
15-5/8
17 3/4
68-1/2
76-1/2
110
16-7/8
16-7/8
CA109
13-3/8
15-1/4
16
19-7/8
12
13
10
14-7/8
17-3/4
17-3/4
19-7/8
16-3/4
15-5/8
17-3/4
69-5/8
86-1/2
120
16-7/8
16-7/8
14
CA209
13-3/8
15-1/4
17
19-7/8
12
13
10
14-7/8
17-3/4
17-3/4
19-7/8
16-3/4
15-5/8
17-3/4
69-5/8
86-1/2
120
16-7/8
16-7/8
14
CA210
310
13-3/4
15-1/4
16
18-1/2
10
13
10
14-1/4
17-3/4
17-3/4
19-7/8
15-5/8
17-3/4
68-3/4
105
131
16-7/8
16-7/8
14
CA314
13-3/8
14 7/8
16
18-1/2
10
13
10
14-1/4
17-3/4
17-3/4
19-7/8
15-5/8
17-3/4
69-7/8
129
155-1/2
16-7/8
16 7/8
14
KA107
13-3/8
15-1/4
17
19-7/8
12-1/2
13
10
14-7/8
17-3/4
17-3/4
19-7/8
16-3/4
15-5/8
17-3/4
68-1/2
76-1/2
110
16-7/8
16-7/8
14
KA109
209
13-3/8
15-1/4
17
19-7/8
12-1/2
13
10
14-7/8
17-3/4
17-3/4
19-7/8
16-3/4
15-5/8
17-3/4
68-1/2
86-1/2
120
16-7/8
16-7/8
14
PA 100
7-5/8
9-3/8
11
14-5/8
9-1/2
13
10
PA208
308
7-5/8
9-3/8
11-5/8
14-5/8
9-1/2
13
10
9-1/2
PA210
310
7-5/8
9-3/8
11-5/8
14-5/8
9-1/2
13
10
9-1/2
9-1/2
13
10-7/8
13
71-7/8
36
89
16-7/8
16-7/8
14
13
9-1/2
13
10-7/8
13
72-1/4
59
131
16-7/8
16-7/8
14
9-1/2
13
9-1/2
13
10-7/8
13
71-7/8
67
153
16-7/8
16-7/8
14
9-1/2
13
10-7/8
PA314
7-5/8
9-3/8
11-5/8
14-5/8
13
10
9-1/2
13
10-7/8
10-7/8
13
71-7/8
91
177
16-7/8
16-7/8
14
CA105
13-3/8
15-1/4
17
19-7/8
12
13
10
14-1/4
20
17-3/4
15-5/8
17-3/4
69-5/8
46
88
16-7/8
16-7/8
14
KA105
13-3/8
15-1/4
17
19-7/8
12-1/2
13
10
14-1/4
20
17 3/4
15-5/8
17 3/4
69-5/8
46
88
16-7/8
16-7/8
14
9-1/8
11-1/2
10-7/8
9-1/2
13
10
9-1/2
13
9-1/2
13
10-7/8
10-7/8
13
68-1/2
71
157
16-7/8
16-7/8
14
9-1/8
11-1/2
10-7/8
9-1/2
13
10
9-1/2
13
9-1/2
13
9-7/8
10-7/8
13
68-1/2
92-1/2
178-1/2
16-7/8
16-7/8
14
9-1/8
11-1/2
10-7/8
9-1/2
13
10
9-1/2
13
9 1/2
13
10-7/8
10-7/8
13
68-1/2
112
240-3/16
16-7/8
16-7/8
14
PE
31132
(137)
PE
31432
(157)
PE
31832
LIG H T T R U C K SERVICE M A N U A L
2A-4
FRAME
Bolting
UNDERBODY ALIGNMENT
O ne m ethod of d eterm in in g th e alig n m en t of the
underbody is with a tra m gage which should be sufficiently
flexible to obtain all necessary m easurem ents up to three
quarters the length of the vehicle. A good tram m ing tool is
essential for an aly zin g and d eterm in in g th e extent of
collision m isalignm ent present in underbody construction.
MEASURING
To m easure the distance accurately between any two
reference points on the underbody, two specifications are
required.
1. The horizontal dim ension between the two points to be
tram m ed.
L IG H T T R U C K SERVICE M A N U A L
BUMPERS
2B-1
SECTION 2B
BUMPERS
NOTICE: Fasteners are im portant attaching parts in
th a t they could affect the perform ance of vital compo
nents and systems, an d /o r could result in m ajor repair
expense. They m ust be replaced with one of the same
part num ber or with an equivalent part if replacem ent
becomes necessary. Do not use a replacem ent part of
CONTENTS
G eneral D escription.............................................................2B-1
Service Procedures - 10 th ru 30 series.......................... ..2B-1
Front Bum per - C, K and P M o d els..............................2B-1
R ear Bum per - C and K M odels.................................. ..2B-1
2B-2
2B-2
2B-2
2B-3
GENERAL DESCRIPTION
All truck front and rear bumpers are of a single piece design. Bumper
attachm ents are the standard bracket and brace to fram e mountings. This
section contains procedures for the removal and installation of face bar,
brackets, braces and license plate brackets.
Installation
LIG H T T R U C K SERVICE M AN U AL
2B-2
BUMPERS
L IG H T T R U C K SE RV IC E M A N U A L
BUMPERS
2B-3
SPECIFICATIONS
LIG H T T R U C K SERVICE M A N U A L
2C-1
SECTION 2C
CONTENTS
G eneral D escription............................................................
On Vehicle S erv ice.............................................................
Hood Assem bly - CK S e rie s .........................................
Cowl Top Vent P a n e l....................................................
Hood H inge R eplacem en t............................................
Hood H in g e .....................................................................
Hood Lock M ech an ism ................................................
Hood A ssem bly...............................................................
Hood Assembly - G S eries................................. ...........
Hood H in g e .....................................................................
Hood Lock A ssem b ly ....................................................
2C-1
2C-1
2C-1
2C-1
2C -2
2C -2
2C -2
2C -2
2C -2
2C-3
2C -3
Hood B u m p er.................................................................
Front Sheet M etal - CK S eries....................................
R adiator S u p p o rt...........................................................
Front Fender...................................................................
Front Fender and S k ir t...............................................
Front Fender S k ir t........................................................
Running B o a rd ...............................................................
Fender Skirt - P S eries...................................................
Adhesive Bodyside Molding (All Vehicles)...............
Wood G rain Applique Installation Procedure..........
Decal Applique Procedure (All V ehicles).................
Specifications......................................................................
2C-3
2C -5
2C-7
2C-8
2C-8
2C-8
2C-8
2C-8
2C-8
2C-9
2C-10
2C-11
GENERAL DESCRIPTION
CK MODELS
The chassis sheet metal assembly is attached to the
fram e and body at adjustm ent points. The front of the
assembly is supported by two mounts located at the fram e
side rails. Fore and aft and side adjustm ent is allowed by
oversize holes at the fender rear attaching point and chassis
sheet m etal mounts. Special shims at the rear locations
allow adjustm ent of the rear of the assembly. The lower rear
edge of the assembly is attached to the body at the rocker
panel by bolts on each side. Shims are used at this location to
provide in and out adjustm ent at the rear of the fender. The
bolts th a t retain the sheet m etal braces m ust be torqued to
the required torques. If these bolts are loose, the braces will
not provide additional support for the sheet m etal assembly.
Anti-Corrosion Information
"Anti-corrosion m aterials have been applied to the
interior surfaces of some m etal panels to provide rust
resistance. W hen servicing these panels, areas on which this
m aterial has been disturbed should be properly recoated
with service-type anti-corrosion m aterial."
G MODELS
The front end sheet m etal design does not include the
radiator support and fenders as loose items inasmuch that
ON VEHICLE SERVICE
HOOD ASSEMBLY - CK MODELS
Replacement
2C-2
1. Open hood and remove the two bolts holding the hood
latch to the bracket.
If original hood lock assembly is to be replaced, scribe a
line around lock for alignm ent on installation.
2. Replace hood latch assembly and bolts loosely.
3. Align within scribe m arks and tighten bolts.
TYPICAL 2 PLACES
Hood Assembly
Removal
2C-3
Replacement
Alignment
2C-4
Hood Bumper
Adjust hood bumpers so that hood top surface is flush
with the fender and grille top surfaces.
Replacement
2C-5
FENDER ASSEMBLY
TIE BAR ASSEMBLY
LIG H T T R U C K SERVICE M AN U AL
2C-6
- /!- * ,
. ,,
W*
wr.SU"**lit-..'
2C-7
Installation
Radiator Support
Removal
Installation
2C-8
11.
12.
13.
14.
15.
Installation
RUNNING BOARDS
2C-9
2C-10
Removal
2C -11
TORQUE SPECIFICATIONS
27 N- m
CK
( 20 ft.
G
lb s .)
24
27
17
48
17
17
48
17 N- m (150 in . lb s .)
N- m
N- m
N. m
N- m
N- m
N- m
N- m
( 18
( 20
(150
( 35
(150
(150
( 35
ft. lb s.)
ft. lb s .)
in .lb s .)
ft. lb s.)
in .lb s .)
in . lb s .)
ft. lb s.)
17
54
17
24
24
24
N* m
N- m
N- m
N- m
N- m
N- m
(150
( 40
(150
( 18
( 18
( 18
i n .l b s . )
ft. lb s.)
i n .l b s . )
ft. lb s.)
ft. lb s.)
ft. lb s.)
LIG H T T R U C K SERVICE M AN U AL
BODY
2D-1
SECTION 2D
GENERAL DESCRIPTION
On the following pages, service procedures will be given
for components on all 10-20-30 series trucks in C, K and G
models. Reference will be made, both in text and illustra
tions, to vehicle model lines and to individual model
numbers within these model lines.
As an aid to identification of specific models, the
following general descriptions are given.
Utility
Utility vehicle models see figure 2D-4. Are available
with a removable roof or a convertible roof.
Chassis/Cabs
Chassis cab models see figure 2D-1. Two-wheel drive
units come in CIO, C-20 and C-30 series. Four-wheel drive
units may be either K -10 or K-20. Optional pickup boxes are
available.
Vans
G-Series Vans are available in three models See figures
2D-5 and 2D-6. Vans without body windows and/or passen
ger seats, sport vans with body windows and passenger seats
and commercial cutaway vans as shown in figure 2D-6.
Crew Cab/Chassis
Crew cab/chassis models see figure 2D-2. Optional
pickup boxes are available.
Suburban
Suburban model see figure 2D-3. Base models have
Anti-Corrosion Information
"Anti-corrosion materials have been applied to the
interior surfaces of some metal panels to provide rust
resistance. When servicing these panels, areas on which this
material has been disturbed should be properly recoated
with service-type anti-corrosion material."
LIG H T T R U C K SERVICE M AN U AL
2D-2
BODY
LIG H T T R U C K SERVIC E M A N U A L
BODY
2D-3
LIG H T T R U C K SERVICE M AN U AL
2D-4
BODY
ON VEHICLE SERVICE
C-K MODELS
INDEX
Front End
Windshield W ip e rs........................................................ .2D-4
Glove B o x ........................................................................ .2D-5
Rear View M irro rs........................................................ .2D-5
Body Glass
Windshield G lass..............................................................2D-6
Stationary Body G lass.................................................. ..2D-8
Side Doors
A djustm ents.......................................................................2D-10
Front Side D oor.............................................................. ..2D-11
R ep lacem ent......................... ,.................................... ..2D-11
H inges.............................................................................2D-11
V entilator............... ..................................................... ..2D-12
Window and R e g u la to r..............................................2D-13
Locks, Handles, Rods.................................. ............ ..2D-15
W eath erstrip............................................................... ..2D-16
Rear Side D o o rs...............................................................2D-16
R ep lacem en t........................................ ...................... ..2D-16
H inges.......................................................................... .2D-16
Stationary G la s s .................................... .....................2D-16
Window and R egu lato r.............................................2D-17
Locks, Handles, Rods............................................... .2D-18
W eatherstrip............................................................... .2D-19
Rear Doors
A djustments.......................................................................2D-19
Locks, Handles, Rods......................................................2D-19
H inges............................................................................... ..2D-19
Gates
E n d g a te s .......................................................................... ..2D-21
T a ilg a te s.......................................................................... ..2D-27
Removable Top (Utility).................................................. ..2D-27
Seat Belts................................................................................2D-29
S eats.........................................................................................2D-29
Body M ounting................................................................... ..2D-34
Applique Procedures......................................................... ..2D-34
Adhesive Body Side M oldings........................................ ..2D-34
FRONT END
WINDSHIELD WIPERS
Windshield wiper units on all models are of the twospeed electric type. A single wiper motor unit, mounted to
the left side of the dash panel inside the engine com part
ment, powers both wiper arms. The wiper arm operating
link rods and pivot mountings on these models are located in
the outside air inlet plenum chamber.
Arm Adjustment
To adjust sweep of blades, turn on wipers and note
sweep of arms. If necessary, remove one or both arms as
follows:
Pull outer end of arm away from glass which will trip
lock spring at base of arm and release spring from undercut
of pivot shaft. While holding arm in this position, pull
outward on cap section at base of arm to remove arm. Arm
can be reinstalled in any one of several positions due to
serrations on pivot shaft and in arm cap. See figure 2D-7.
BODY
2D-5
i
Two styles are shown in Figure 2D-12. Removing the
attaching screws allows removal of the valve from the side
panels.
L IG H T T R U C K SERVICE M A N U A L
2D-6
BODY
BODY GLASS
CAUTION:A!ways wear gloves and eye glasses
when handling glass to avoid personal injury.
LIG H T T R U C K SE RV IC E M A N U A L
BODY
2D-7
2D-8
BODY
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
BODY
2D-9
LIG H T T R U C K SE RV IC E M AN U AL
2D-10
BODY
LIG H T T R U C K SERVIC E M A N U A L
.19 inch clearance at the top and side edges, and .25 inch
clearance at the bottom. The door should be adjusted in the
opening so the edge of the door across the top and also at the
lock side is parallel with the body opening as nearly as
possible.
BODY
2D-11
Hinge Adjustment
Door hinge bolt holes are oversized to make adjustment
possible. Alignment adjustments can be made by loosening
the proper hinge bolts, aligning door to proper position, and
tightening bolts securely (fig. 2D-22).
Installation
DOOR HINGE
Removal
Removal
1. Loosen front fender rear bolts.
2D-12
BODY
Installation
Before installing door trim assembly, check that all
trim retainers are securely installed to the assembly and are
not damaged.
1. To install door trim assembly, pull door inside handle
inward; then position trim assembly to inner panel,
inserting door handle through handle hole in panel.
2. Position trim assembly to door inner panel so trim
retainers are aligned with attaching holes in panel and
tap retainers into holes with a clean rubber mallet.
3. Install previously removed items.
IIN S ID E H A N D L E
V
PUSH T O O L IN
D m E C T I O N OF
ARROW
-M
Jj^
T O O L J-9886-01
3. Remove arm rest screws and trim panel. See figure 2D27.
4. Remove screws attaching ventilator lower assembly to
door panel.
5. Remove three screws at the upper front of the door
frame.
6. Pull upper portion of vent assembly rearward and raise
upward while rotating counter clockwise.
7. T urn vent assembly 90 and carefully remove by
guiding up and out. See figure 2D-29.
BODY
2D-13
Installation
1. Lower the ventilator assembly into the door frame.
2. M ake certain the rubber lip is positioned inside the
inner and outer panel before tightening screws.
3. Reinstall all screws and tighten.
4. Install and tighten the three screws at the upper front
of the door.
Adjustment
1. Adjust the ventilator by placing wrench on adjusting
nut thru access hole and turning vent window to the
desired tension. See figure 2D-30.
2. After making adjustment bend tabs over the hex nut on
base of assembly. See figure 2 D -3 1.
3. Install arm rest screws and trim panel.
4. Install window regulator handle.
2D-14
BODY
NO TCH
SASH
CHANNEL;
Replacement
CAUTION:Electrical connectors must be removed
from window lift motor before performing any
operation on the regulator, or personal injury
could occur. Figure 2D-35 illustrates location of
regulator on door and wiring.
1. Raise glass to full up position and tape to door frame
using cloth body tape.
2. Disconnect battery ground cable.
3. Remove door trim panel as previously outlined.
N O TC H
ROLLER
Connector
BODY
10.
11.
12.
13.
14.
15.
16.
1.
2.
3.
4.
5.
2D-15
LOCK'
2D-16
BODY
Replacement
LIG H T T R U C K SERVIC E M A N U A L
BODY
2D-17
Replacement
1. Lower glass to full down position.
2. Remove remote control push botton knob, window
regulator handle and trim pad.
3. Remove stationary glass as previously outlined. Re
move screws from rear division channel, and slide
channel rearward in the opening.
4. Raise glass as far as possible, then slide glass until the
roller is in line with the notch in the sash channel. See
figure 2D-46. Disengage roller from channel.
5. Tilt window outboard and move until other roller can
be removed from channel.
6. Raise window up and out.
7- Reverse above procedure for installation.
LIG H T TR U C K SERVICE M A N U A L
2D-18
BODY
Replacement
Replacement
BODY
WEATHERSTRIP-FIG. 2D-50
The procedure outlined in Front Door Weatherstrip
may be applied to the Rear Side Door Weatherstrip, shown
in figure 2D-50 with the following exception:
a. Begin installation by positioning the weatherstrip
"internal core" (approximately 6" long) center in
the upper front corner of the door opening.
b. Proceed as outlined previously.
2D-19
WEATHERSTRIP
Weatherstrip installation is shown in Figs. 2D-55 and
2D-56. Proper installation is dependent on completely
cleaning all foreign material from old installation and using
a quality cement on the new installation.
LIG H T T R U C K SERVICE M A N U A L
2D-20
BODY
BODY
2D-21
-(Suburban)
HINGES
Replacement
Replacement
2D-22
BODY
ENDGATE DISASSEMBLY
1. Remove access cover shown in figure 2D-59, to gain
access to interior components.
2. Detach remote control rods from lock assembly by
removing clips.
3. Remove bolts securing lock assembly, and remove lock
assembly.
4. Remove handle assembly bolts and remove inside
handle.
5. Remove R.H. torque rod bracket screws, figure 2D-58,
then remove torque rod from endgate.
6. Remove screws connecting cam assemblies to sash
assembly, figure 2D-60, then remove cam assemblies.
7. Remove glass from endgate.
8. Unclip and remove inner and outer seal assemblies.
9. Remove screws connecting window regulator assembly
to endgate, figure 2D-60, and remove regulator.
Adjustments
Loosen bolts, adjust at either endgate hinge position or
endgate latch, then retighten bolts.
LEVER ASSEMBLY
SEAL
^ ^ IN S U L A T O R
- HANDLE
ASSEMBLY
^
LATCH \ A *
^ASSEMBLY a L /
CONTROL
ASSEMBLY
NYLON
GUIDEi
REMOTE
CONTROL
LIG H T T R U C K SERVICE M A N U A L
BODY
2D-23
HINGE
Replacement
LIG H T T R U C K SERVICE M AN U AL
2D-24
BODY
TORQUE ROD
Replacement
1. L o w e r e n d g a te a n d re m o v e a cc e ss cover, a s sh o w n in
figure 2D-65.
2. Disconnect torque rod anchor plate. It is necessary to
remove the lower bolt only, then let plate swing down.
See figure 2D-66.
3. Loosen four bolts retaining endgate hinge to body.
4. Move endgate slightly away from body.
5. Remove torque rod retaining bracket on lower edge of
endgate. See figure 2D-66.
6. Remove torque rod retaining clip on side edge of
endgate.
7. Lift torque rod up and slide from endgate as shown in
figure 2D-67.
8. Reverse the procedure above for installation.
BRACKET
SILENCER
TORQUE
ROD
FRAME
BODY
2D-25
BLOCKOUT
ROD
INSIDE HANDLE
BRACKET
CONTROL ROD
CONTROL
ASSEMBLY
Fig. 2D-70--Control Assembly and Blockout Rod
Drive Cable
The drive cable can be replaced by disengaging the
cable from the motor and jackscrew assembly and removing
the cable. Reverse removal procedure to reinstall cable.
LIG H T T R U C K SERVICE M AN U AL
2D-26
BODY
VIEW
REG U LA TO R
L IG H T T R U C K SERVIC E M A N U A L
BODY
3.
2D-27
Remove endgate.
1. Open tailgate.
Stepside
Endgate Replacement (Fig. 2D-77)
3.
2D-28
BODY
** V f>
UNSNAP AND REMOVE
COVER BOOT AND STORE
IN VEHICLE
Fig. 2D-79--Folding Top Assembly
L IG H T T R U C K SE RV IC E M A N U A L
BODY
2D-29
SEATS
SEAT BELTS
SERVICING LAP AND SHOULDER
BELTS - ALL MODELS
Before servicing or replacing lap and shoulder belts,
including single loop belt systems, refer to the following
precautionary items:
1. Lap and shoulder belts will be serviced as follows:
a. All belts will be serviced in complete sets.
b. Do not intermix standard and deluxe belts on front or
rear seats.
2. Keep sharp edges and damaging objects away from
belts.
3. Avoid bending or damaging any portion of the belt
buckle or latch plate.
4. Do not bleach or dye belt or strap webbing (clean with a
mild soap solution and water).
5. When installing lap or shoulder belt anchor bolt, start
bolt by hand to assure that bolt is threaded straight.
6. Do not attempt repairs on lap or shoulder belt retractor
m echanism s or lap belt re tra c to r covers. Replace
defective assemblies with new service replacem ent
parts.
7. Do not attem pt to remove seat belt retractor cover. The
cover and the long rivet securing the cover to the
retractor are not available as service replacement parts.
SEAT MOUNTING
Typical Seat Mounting provisions are shown in figures
2D-83 through 2D-89.
NOTICE: See N O T I C E on page 1 of this section
regarding fasteners used on seats and seat belts.
L IG H T TR U C K SERVICE M A N U A L
2D-30
BODY
L IG H T T R U C K SERVICE M A N U A L
BODY
2D-31
LIG H T TR U C K SERVICE M A N U A L
2D-32
BODY
LIG H T T R U C K SERVIC E M A N U A L
BODY
2D-33
LIG H T T R U C K SERVICE M A N U A L
2D-34
BODY
BODY MOUNTING
The removal of anyone bodymount necessitates the
loosening of adjacent body mountings to permit the frame to
be separated from the body. Care should be exercised to
prevent breakage of plastic fan shroud, or damage to frame
attachments such as steering column, brake pipes, etc.,
during replacement of body mounts.
During installation of a body mount, caution should be
used to insure that the body mount is properly seated in the
frame mounting hole, otherwise a direct metal to metal
contact will result between the frame and body. The tube
spacer should be in all bolt-in body mounts and the insulator
or metal washer positioned to prevent contact with the
frame side rail. Do not over-torque the body mount or a
stripped bolt may result.
Do not use lubricants of any kind on the rubber parts of
the mounts. Proper clamping by the mount depends on clean
and dry surfaces. If the body mount bolt does not screw in
smoothly, it maybe necessary to run a tap through the cage
nut in the body to remove foreign material. Caution should
also be used to insure th at tap doesnt punch through
underbody.
The sequence of mounting attachments is shown in
figures 2D-91 through 2D-94.
APPLIQUE PROCEDURES
Refer to Section 2C, Chassis Sheet Metal, for proce
dures relating to decal and woodgrain appliques.
L IG H T T R U C K SE RV IC E M A N U A L
BODY
2D-35
C-30 J
LIG H T T R U C K SERVICE M AN U AL
2D-36
BODY
LIG H T T R U C K SE RV IC E M A N U A L
BODY
2D-37
G MODELS
INDEX
Front End
Windshield W ipers........................................................ 2D-37
Cowl Ventilator Grille................................................... 2D-38
Side Ventilator V alve.................................................... 2D-38
R ear View M i r r o r ......................................................... 2D-38
Body Glass
Windshield G lass............................................................ 2D-39
Stationary G la s s ............................................................. 2D-42
Swingout G la ss ............................................................... 2D-42
Front Door
A djustm ents..................................................................... 2D-43
R eplacem ent.................. ................................................. 2D-44
W eatherstrip.................................................................... 2D-44
H inges............................................................................... 2D-44
Ventilator.......................................................................... 2D-44
Window and R eg u lato r................................................ 2D-45
Locks, Handles, R od s...................................................... 2D-46
Sliding Side Door
Description....................................................................... 2D-48
A djustm ents......................................................................2D-48
Front L atch .................. ................................................. 2D-52
Rear L a tc h ..................................................................... 2D-53
Upper Rear Hinge...................................................... 2D-53
Strikers............................................................................ 2D-55
Rear Door
H i n g e ................................................................................ 2D-55
Remote C o n tro l.............................................................. 2D-55
Latches and R o d s.......................................................... 2D-55
Adjustm ents..................................................................... 2D-56
Seats
Drivers S e a t ........................................................ ............ 2D-57
Passenger S e a t ................................................................ 2D-58
Rear S e a t s ....................................................................... 2D-60
Roof V e n t .......................................................... ............. 2D-60
2D-($0
Seat Belts......................................................................
Decal Applique P ro c e d u re ............................................... 2D-60
Adhesive Body Side M o ld in gs........................................ 2D-60
FRONT END
WINDSHIELD WIPERS
Windshield wiper units on all models are of the twospeed electric type. A single wiper motor unit, mounted to
dash panel at top and to left of engine cover inside cab,
powers both wiper blades. The wiper blade operating link
rods and pivot mountings on these models are located in the
outside air inlet plenum chamber.
Arm Adjustment
2D-38
BODY
Replacement
1.
2.
3.
4.
L IG H T T R U C K SE RV IC E M A N U A L
BODY
2D-39
BODY GLASS
CAUTION:Always wear gloves and eye glasses
when handling glass to avoid personal injury.
obstruction is increased by such conditions as wind pressures, extremes of temperature, motion of the vehicle, etc.
WINDSHIELD GLASS
Removal
2D-40
BODY
LIG H T TR UC K SERVIC E M A N U A L
BODY
2D-41
5. With the aid of a helper, lift the glass into the opening.
Carry the glass with one hand on the inside of glass, and
one hand on the outside. At the windshield opening, set
the glass in a horizontal position. While one partner
holds the glass in this position, the other can reach one
arm around the pillar and support the glass from the
inside, while the first person assumes the same position.
With the glass centered in the opening, place the glass
against the inside support molding, use small rubber
blocks to support the glass in the correct position. Use
the last screw on either side of the cowl grille cover as a
guide for the positioning of these blocks in the wind
shield opening. Be sure to center the glass so that gaps
on opposite sides and top-to-bottom are equalized.
Trim rubber blocks as necessary. If the short method is
used, check reveal molding fit and cut away additional
solidified urethane base as necessary. See Fig. 2D-104.
6. Cut the tip of the adhesive cartridge to make asmall
opening of approximately 3/16 inch. First, fill in behind
and around spacer blocks with urethane.
7. Then apply a smooth, continuous bead of urethane.
Direct the flow of urethane down into gap as shown in
Fig. 2D-105. The material should fill the gap between
the glass edge and the sheet metal. If necessary, use a
flat-bladed instrument to paddle material into position.
Be sure that adhesive contacts the entire edge of the
glass, and extends to fill the gap between the glass and
primed sheet metal or solidified urethane base from the
original installation.
8. Spray a mist of water onto the urethane. This adhesive
is moisture curing. W ater will assist in the curing
process. Dry the area where the reveal molding will
contact the glass and the body.
2D-42
BODY
fully contacts the adhesive all around and that the gap
is entirely covered by the crown of the molding. Slide
molding caps into position between moldings connect
ing them. Use tape to hold the molding down in the
correct position against the body and glass until the
adhesive cures.
10. Install wiper arms, and clean up surrounding areas as
required.
Vehicle should not be driven and remain at room
te m p e ra tu re for six hours to allow proper cure of
adhesive.
11. W ater leak test the vehicle. If a leak is found, refer to
Windshield W aterleak Correction procedure.
SWINGOUT WINDOW
Replacement
BODY
2D-43
^A D H E S IV E TO WEATHERSTRIP
AND PINCHWELD
FRONT DOOR
DOOR ADJUSTMENTS
Doors can be adjusted for alignment of clearance in the
cab door opening, and for proper latching. Door alignment
adjustments are made at the striker bolt, and at door hinges.
T he door, when properly located in door opening, will have
equal clearance around its perimeter. The door should be
adjusted in the opening so the edge of the door across the top
and also at the lock side is parallel with the body opening as
nearly as possible.
Hinge Adjustment
Door hinge bolt holes are oversized to make adjustment
possible. Alignment adjustments can be made by loosening
the proper hinge bolts, aligning door to proper position, and
L IG H T T R U C K SERVICE M AN U AL
2D-44
BODY
DOOR HINGE
Remove
DOOR WEATHERSTRIP
Success of weatherstrip replacement depends entirely
upon the quality of the cement used and the care with which
it is applied. All rust, road dirt and grease or oil must be
completely removed as should all old cement and bits of old
weatherstrip. After removing all foreign material from door
opening surface, wipe down with prepsol or its equivalent.
Use only a good quality cement which is made specially for
w eatherstrip installation, following the m a n u f a c tu re r s
directions. Proceed as follows:
1. Open door and block open.
2. Remove side door weatherstrip.
3. Remove used adhesive from door with adhesive or
cement remover, and remove all plastic nails.
4. Apply adhesive to door.
5. Position weatherstrip by locating part number at top of
vent window, making sure that plastic nails align with
holes in door.
6. Install weatherstrip by pressing each nail into the door.
BODY
2D-45
1.
2.
3.
4.
5.
2D-46
BODY
1.
2.
3.
4.
5.
1.
2.
3.
4.
1.
2.
3.
4.
5.
Raise window.
Remove inside handles with Tool J-9886-01.
Remove trim panel.
Remove door lock knob.
From outside the door remove screws retaining lock to
door edge and lower the lock assembly.
6. Remove screws retaining remote control.
7. Remove screws securing glass run guide channel.
im
BODY
2D-47
R EM O TE
Installation
LO C K
LIG H T T R U C K SERVICE M AN U AL
2D-48
BODY
ADJUSTMENTS
LIG H T TR UC K SE RV IC E M A N U A L
BODY
2D-49
W INDO W SWITCH
AS S E M B LY
DOOR LOCK
SW ITCH
REAR DOOR
M OTO R ACTUATOR
(DOOR LOCK)
MOTOR
(POWER W INDOW )
SW ITCH CONTACT
(DOOR)
SWITCH CO NTACT
(PILLAR )
Fig. 2D-120--Power Door Lock Actuators, Power Window Motor, Wiring and Switches
LIG H T T R U C K SERVICE M A N U A L
2D-50
BODY
STRIKER
F O R E - A N D -A F T A D J U S T M E N T S L O T S
C E N T E R ROLLER VERT ICA LLY
IN T R A C K S O IT D O E S N O T
CONTACT
THE T R A C K
IN FULL O P E N
U P -A N D -D O W N
O R FULL
A D J U S T M E N T SLO T S
CLOSED
-------- ^
... . .., .. J1
^
P O S IT IO N
TOP VIEW
UPPER LE V E R .___.L O W E R LEVER
U P -A N D -D O W N
A D JU ST M EN T SLO TS / j f /
STRIKER,
U PPER
F R O N l Y N
in
-a
n d
-o u t
FACE VIEW
G U ID E
U P -A N D -D O W N
A DJU STM EN T
IN - A N D -O U T
ADJUSTM EN T
R U B B E R '"
C U S H IO N
LATCH
SECTION C-C
LOWER ROLLERS i
AND CATCH ASM
SECTION
E-E
HOLD-OPEN
i CATCH
LIG H T T R U C K SERVICE M A N U A L
BODY
2D-51
Up and Down
122 .
In and Out
Front in and out adjustments are provided by means of
an adjustable lower roller mounting bracket, view D of
figure 2D-121, and by a slotted upper bracket, view B of
figure 2D-121. Rear in and out adjustment is provided by
adjusting the rear latch striker, view E of figure 2D-121. To
position the door in or out:
1. Loosen front latch striker.
2. Loosen upper front roller from its bracket.
3. Loosen lower front roller bracket-to-arm bolts.
4. Adjust front of door in or out, then tighten bolts to
specifications.
5. A djust door hold open catch bracket, rear wedge
assembly, rear latch striker, upper front roller and front
latch striker as outlined later in " Adjustments ".
2D-52
BODY
1.
2.
3.
4.
Installation
attaching
screws.
BODY
2D-53
4.
Installation
1. Connect rods to latch and install latch to door. Torque
screws to specifications.
2. Connect rods to front latch assembly.
3. Install access covers and trim panels (if so equipped).
LIG H T T R U C K SERVICE M A N U A L
Installation
W hen holding hinge assembly as in figure 2D-129, the
lower latch must engage cam.
1. Install hinge assem bly to door. T orque bolts to
specifications.
2. Check and adjust latch to striker position as outlined
under "A djustm ents".
3. Open the door and reconnect the hinge spring.
4. Install the rear track cover and hinge cover.
5. Check the operation of the door hinge.
2D-54
BODY
1.
2.
3.
4.
5.
6.
7.
Roller
Lockwashers
Nut
Cam
Washer
Bushing
Bushing
8.
9.
10.
11.
12.
13.
14.
Bolt
15.
Plate
16.
Upper lines
17.
Spacer
18.
Spring (Upper Lever) 19.
Spring (Lower Level) 20.
Lower Lever
Screw
Guide Block
Hinge (Body Half)
Nut
Bushing
Bushing
21.
22.
23.
24.
25.
26.
Cam
Bushing
Hinge (Door Half)
Spring
Spring retainer
Hinge liner
LIG H T T R U C K SERVICE M A N U A L
BODY
2D-55
STRIKERS
The front and rear strikers are shown in figure 2D-121.
The rear striker can be removed with J-23457 as in figure
2 D -1 11, and the front striker can be removed by removing
a tta ch in g screws. R efer to "A d ju stm en ts" when
reinstalling.
REAR DOORS
REAR DOOR HINGE STRAP
4.
Replacement
1. Remove strap release pin. See figure 2D-130.
2. Remove screws retaining strap to door.
3. Install stra p to door. T orque retain in g screws to
specifications.
Installation
1. Install grom m et into door hinge opening (if removed).
2. Install hinge into door. Snug bolts.
3. Install seal and retainer on body half of hinge (if
removed).
4. Install hinge into body opening and install bolts.
5. Take care to compress seal between body and retainer
and snug bolts.
6. Install hinge strap and its retaining pin.
7. Adjust door and torque hinge bolts to specification.
Installation
1. Install remote control screws loosely.
2. A ttach upper and lower control rods.
3. R otate remote control lever clockwise, and hold in this
position while torquing the screws to specifications.
4. Install the trim panel.
2D-56
BODY
Installation
1. Install lock cylinder and retainer.
2. Install remote control. Torque screws to specifications.
3. Remove latch retaining screws and w ithdraw latch and
control rod.
4. Remove spring clip retaining rod to latch.
Installation
1. Install latch rod to latch.
W hen reinstalling the lower latch rod to control, the
short straight section attaches to the latch.
3. Install latch
specifications.
re ta in in g
screws
and
torque
to
Installation
and
gaskets.
T orque
screws
to
BODY
SEATS
NOTICE: See N O T IC E on page 1 of this section
regarding fasteners used on seats and seat belts.
DRIVERS SEAT
Seat Adjuster
Replacement
1. Remove seat by removing nuts securing seat adjuster to
seat riser.
2. Remove adjuster from seat. See figure 2D-134.
3. Install seat a d ju ste r
specifications.
to
seat.
T orque
bolts
to
SEAT RISER
Replacement
1. Remove seat and adjusters as an assembly by removing
nuts securing seat to riser.
2. Remove nuts securing seat riser to floor.
3. Install seat riser to floor. Torque nuts to specifications.
4. Install seat and torque nuts to specifications.
LIG H T T R U C K SERVICE M A N U A L
2D-57
2D-58
BODY
Installation
1. Install brackets to seat. T orque to specifications.
2. Install seat to seat riser. Torque to specifications.
SEAT RISER
Removal
1. Remove seat and m ounting bracket as an assembly.
2. Remove riser from floor.
Installation
1. Install riser to floor. T orque nuts to specifications.
2. Install seat riser. Torque nuts to specifications.
LIG H T T R U C K SERVICE M A N U A L
2D-60
BODY
LIG H T T R U C K SERVICE M A N U A L
BODY
LIG H T T R U C K SERVICE M A N U A L
2D-61
2D-62
BODY
SPECIFICATIONS
FRONT END
TAILGATE-FLEETSIDE
2. N* m
2. N 'm
2. N-m
2. N 'm
DOORS
Window Regulator Assembly
to Door Panel............................................85 in. lb. 9.5 N 'm
Remote Control Door Lock
to Door Panel........................................... 45 in. lb. 8. N 'm
Lock Striker to Body Pillar................... 45 ft. lb. 60. N 'm
Outside Door Handle................................ 85 in. lb. 9.5 N-m
Inside Door Handle.................................. 85 in. lb. 9.5 N-m
Hinges to Body and Do o r.........................31 ft. lb. 42. N- m
Front Door-Window Rear Channel
Upper Bolt Assem bly..................... 85 in. lb. 9.5 N-m
Lower Bolt Assembly..................... 85 in. lb. 9.5 N-m
Front Door-Ventilator and Glass Run Assembly
Top Vent Screw................................ 20 in. lb. 2.2 N 'm
Side Vent Screws and Spacers........22 in. lb. 2.5 N-m
Lower Vent Channel Bolts............. 85 in. lb. 9.5 N-m
Side Rear Door-Run Channel
Front Upper Bolt to Door............... 85 in. lb. 9.5 N-m
Rear Upper Screw to Door............. 20 in. lb.
2. N-m
Front Lower Nut to Door.............. 45 in. lb.
5. N- m
Rear Lower Bolt to Door............... 85 in. lb. 9.5 N-m
Lock Lever to D o o r .......................85 in. lb. 9.5 N-m
Rear DoorLock Striker (Suburban).........................19 ft. lb. 26. N-m
Rear Door-Latch LH and RH
to Door (Suburban)..................................85 in. lb. 9.5 N-m
Rear Door-Latch Control Assembly to Door (Suburban)
Upper Assembly............................. 19 ft. lb. 26. N-m
Lower Assembly............................ 85 in. lb. 9.5 N-m
END GATE
Hinges-Body Half and Gate Half........... 35 ft. lb. 48. N-m
Support Assembly-Cable Bolts............. 35 ft. lb. 48. N-m
Torque Rod to Hinge Pocket................. 85 in. lb. 9.5 N-m
Torque Rod to Body.......................... .
18 ft. lb. 2. N-m
Latch Assembly to End Gate................. 33 ft. lb, 44. N 'm
Latch Control Assembly
to End Gate............................................. 45 in. lb. 5. N-m
Handle to Latch Control Assembly........45 in. lb. 5. N-m
Glass Channel (Suburban)......................45 in. lb. 5. N-m
Glass Channel (Utility).......................... 85 in. lb. 9.5 N-m
Outside Handle........................................55 in. lb. 6. N-m
Cap Assembly to Channel Assembly... .24 in. lb. 2 .6 N-m
Striker-Body Mounted............................ 25 ft. lb. 34. N-m
TAILGATE-STEPSIDE
Trunnion Assembly..................................18 ft. lb. 24. N-m
Chain Support Assembly..........................90 in. lb. 10. N-m
SEATS
Front Bench Seat
Adjuster-to-Seat.......................... 50 in. lb.
Adjuster-to-Floor........................ 25 ft. lb.
Front Bucket Type
Driver
Adjuster-to-Seat................. 18 ft. lb.
Adjuster-to-Floor............... 25 ft. lb,
Passenger Chassis Cab
Support-to-Seat................... 18ft. lb.
Support-to-Floor
(Front)..................................25 ft. lb.
Support-to-Floor
(Rear)....................................40ft. lb.
Passenger Suburban
Latch Support
to Seat (Rear).......................18 ft. lb.
Striker to Floor
(Rear)..................................25 ft. lb.
Support (Upper)
to Seat (Front).....................18 ft. lb.
Support (Lower)
to Floor (Front)................... 25 ft. lb.
Support (Upper)
to Support (Lower)............. 30 ft. lb.
Rear Bench Utility, Suburban
Support-Lo-Seat............................ 18 ft. lb.
Support-to-Floor.......................... 50ft. lb.
Rear Bench Crew Cab
Support-to-Seat.......................... 150 in. lb.
Support-to-Floor.......................... 35 in. lb.
Folding Rear Seat Suburban
Support Asm-to-Floor................. 150 in, lb.
Seat-to-Support A s m .....................18 in. lb.
17. N-m
34. N 'm
24. N-m
34. N-m
24. N-m
34. N-m
54. N-m
24. N 'm
34. N-m
24. N-m
34. N-m
40. N-m
24. N-m
70. N-m
17. N-m
17. N 'm
24. N-m
LIG H T T R U C K SERVICE M AN U AL
BODY
2D-63
#2
#1
CHASSIS C A B
55 ft. lb.
75 N- m
55 ft. lb.
75 N- m
C R E W CAB
55 ft. lb.
75 N- m
35 ft. lb.
48 N- m
SU B U R B A N
55 ft. lb.
75 N*m
35 ft. lb.
48 N-m
U TILITY
55 ft. lb.
75 N-m
45 ft. lb.
60 N .m
#3
#4
#6
#5
55 ft. lb.
75 N- m
35 ft. lb.
48 N-m
35 ft. lb.
48 N- m
35 ft. lb.
48 N* m
35 ft. lb.
48 N- m
G MODELS
MIRRORS AND SUNSHADE
Outside Rear View Mirror to Panel... .150 in. lb. 17. N-m
Sunshade Support to Header Panel-lb. 1.6 N-m
lb 4 .6 N*m
lb. 6 .0 N-m
r HUN 1 blUfc U U U K d
Door Hinges..........................................
Remote Control Retaining Screws . . . . . .45 in.
Door Lock Striker................................ .. 45 ft.
Door Lock to D o o r ..............................
Outside Door Handle............................ . .90 in.
Regulator Assembly.............................
40. N-m
5. N-m
lb.
lb. 60. N-m
lb. 30. N-m
lb. 10. N-m
10. N-m
REAR DOOR
Hinge (to body and door).......................
Remote Control RH
Retaining Screws..................................
Latch-to-Door Retaining
Screws Upper........................................
Latch-to-Door Retaining
Screws Lower........................................
Door Strikers-to-Body.........................
Outside Door Handle............................
8. N- m
LIG H T T R U C K SERVICE M A N U A L
SEATS
lb. 10. N* m
lb. 10. N* m
lb. 32. N* m
lb. 32. N m
lb. 10. N* m
lb. 32. N 'm
lb. 27. N* m
2D-64
BODY
SPECIAL TOOLS
1.
2.
3.
4.
J-2 25 85
J-22577
J-7797
J-23457
LIG H T T R U C K SE RV IC E M AN U AL
FRONT ALIGNMENT
3A-1
SECTION 3A
FRONT ALIGNMENT
CONTENTS
G eneral D escrip tio n..................
M aintenance and A djustm ents
S pecifications...............................
3A-1
3A-2
3A-5
GENERAL DESCRIPTION
FRONT ALIGNMENT
T he term "fro n t alig n m en t" refers to the ang ular
relationships between the front wheels, the front suspension
attaching parts and the ground.
The pointing in or "toe-in" of the front wheels, the tilt
of the front wheels from vertical (when viewed from the
front of the vehicle) and the tilt of the suspension members
from vertical (when viewed from the side of the vehicle), all
these are involved in front alignm ent. The various factors
th at enter into front alignm ent are covered here each one
under its own heading.
CASTER
C aster is the tilting of the front steering axis either
forward or backward from the vertical (when viewed from
the side of the vehicle). A backward tilt is said to be positive
( + ) and a forward tilt is said to be negative (-).
On the short and long arm type suspension you cannot
see a caster angle without a special instrum ent, but you can
understand th at if you look straight down from the top of the
upper control arm to the ground you would find that the ball
joints do not line up (fore and aft) when a caster angle other
than 0 is present. If you had a positive caster angle the
lower ball joint would be slightly ahead (toward the front of
the vehicle) of the upper ball joint center line. In short then,
caster is the forward or backward tilt of the steering axis as
CAMBER
Cam ber is the tilting of the front wheels from the
vertical when viewed from the front of the vehicle. W hen the
wheels tilt outward at the top, the cam ber is said to be
positive ( + ). W hen the wheels tilt inward at the top, the
cam ber is said to be negative (-). The am ount of tilt is
m easured in degrees from the vertical and this m easurem ent
is called the cam ber angle. C am ber is designed into the front
axle assembly of all K series vehicles and is non-adjustable.
See cam ber copy under A D JU ST M E N T S.
TOE-IN
Toe-in is the turning in of the front wheels. The actual
am ount of toe-in is normally only a fraction of an inch. The
purpose of a toe specification is to ensure parallel rolling of
the front wheels. (Excessive toe-in or toe-out will cause tire
wear). Toe-in also serves to offset the small deflections of the
wheel support system which occurs when the vehicle is
rolling forward. In other words, even when the wheels are set
to toe-in slightly when the vehicle is standing still, they tend
to roll parallel on the road when the vehicle is moving. See
toe-in copy under A D JU S T M E N T S .
L IG H T T R U C K SE RV IC E M AN U AL
3A-2
FRONT ALIGNMENT
(J. OF WHEEL
DIRECTION
CAMBER ANGLE
CASTER ANGLE
FRONT V IE W
SIDE V IE W
FRONT ALIGNMENT
ALIGNMENT ADJUSTMENTS
Caster
All caster specifications are given assum ing a frame
angle of zero. Therefore, it will be necessary to know the
angle of the fram e (whether "u p " in rear or "dow n" in
rear) before a corrected caster reading can be determ ined.
C am ber and toe can be read "as is" from the alignm ent
equipment.
3A-3
Camber
1. D eterm ine the cam ber angle from the alignm ent
equipment.
2. Add or subtract shims from both the front and rear
bolts to affect a change.
CAMBER
FORWARD
3A-4
FRONT ALIGNMENT
Toe-In
"B IS LESS THAN A W H E N WHEELS TOE-IN
CROSSMEMBER
LIG H T T R U C K SERVIC E M A N U A L
FRONT ALIGNMENT
3A-5
SPECIFICATIONS
WHEEL ALIGNMENT SPECIFICATIONS
CASTER
D IM E N S IO N " A "
MODELS
2 1/2"
2%
(mm)
6 3 .5
69 .8
C10
2.4
2.1
1.8
1.5
1.2
1.0
0.7
0.5
0.2
0.1
0.3
C20, 30
1.5
1.2
0.9
0.6
0.3
0.1
-0.1
-0.7
-1.0
-1.2
"
3"
3 %"
3 1/2"
3%
76.2
82.5
89.0
95.2
K10,20,30
(8)
"
474"
4 1/2"
4% "
5"
( N O A D J U S T M E :N T P R O V I S O N )
r / 2"
1% "
2"
21/4"
21/2"
2%"
3"
3% "
3 1/2"
3% "
4"
(mm)
38 .0
44 .4
51.0
57.1
63 .5
69.8
76 .2
82.5
89.0
95.2
102.0 107.9
G10, 20
3.5
2.8C
3.3
3.1
2:2
2.9
2.7
1.6
2.4
2.2C
2.1
1.9
1.0
.7
.5
2 1/2"
2%
G30
(mm)
63 .5
P10
2.3
(mm)
*P20, 30
2.5
474"
1.9C
.2
4%
4% "
1.8
0
5"
3"
3 1/4"
3 1/2"
3 3/4"
4"
69.8
76 .2
82.5
89.6
95.2
2.0
1.7
1.5
1.2
0.9
0.6
0.4
"
4 1/2"
0.1
2"
2 1/4"
21/2"
2 %"
3"
3V4"
3 1/2"
3 3/4" 4 "
51.0
57.1
63 .5
6 9 .8
76.2
82.5
89.0
95.2
2.9
2.6
2.3
2.0
1.7
1.4
1.2
0.9
"
-0.1
4 1/4"
1.6
-0.2
-0 .3 *
41/2"
4% "
0.4
0.2
0.1
* A D D .3 W IT H J B 8 O R J F 9
S U B T R A C T .4 W IT H R 0 5
2%
(mm)
4 1/2"
3"
374"
3 1/2"
3% "
4"
63 .5
69.8
76.2
82.5
89.0
9 5.2
5.5
5.3
5.0
4.7
4.4
4.1
"
4 1/4
3.8
3.6
3.3
4% "
3.1
5"
2.9
C A M BER
MODEL
.2
C 10, 20, 30
1.0 ( N O A D J U S T M E N T P R O V I S I O N )
K 10, 20
K30
G 1 0 ,20
G30
P10, 20, 30
.5 (N O A D J U S T M E N T P R O V I S I O N )
.5
.2
.2
.2
M O T O R HO M E (32)
A L IG N M E N T T O L E R A N C E S
Warranty
Repair
Checking
Caster
C am ber
T o e -In
1
0.7
1 / 8 "(3 .2 m m )
T O E -IN
Periodic
M otor
3 /1 6 "
Vehicle
Inspection
G10, G20, G 30
3 /1 6 "
(4.7 m m )
3 /1 6 "
(4.7 m m )
0.5
M O T O R HO M E
0.5
1.5
5 /1 6 "
(7.9 m m )
Resetting
Target
P30 (32)
3 /1 6 "
(4.7 m m )
1 /1 6 "(1 .6 m m ) 3 / 8 "(9 . 5 m m )
Specifications
L IG H T T R U C K SE RV IC E M A N U A L
STEERING LINKAGE
3B1-1
SECTION 3B1
STEERING LINKAGE
T he following notice applies to one or more steps in the assembly
procedure of components in this portion of the m anual as indicated at
appropriate locations by the terminology "See N otice on page 1 of this
Section ".
N O TICE: These fasteners are im portant attaching parts in th a t they
could affect the perform ance of vital components and systems, an d /o r could
result in m ajor repair expense. They must be replaced with one of the same
part num ber or with an equivalent part if replacem ent becomes necessary. Do
not use a replacem ent part of lesser quality or substitute design. Torque
values m ust be used as specified during reassembly to assure proper retention
of these parts. For prevailing torque nut(s) and bolt(s), refer to the " Reuse of
Prevailing Torque N u t(s) and B olt(s)" chart in Section 10.
CONTENTS
G eneral D escription...................................................................................... 3B1-1
D iagnosis...........................................................................................................3B1-1
M aintenance and A d ju stm en ts...................................................................3B1-4
On-V ehicle S erv ice....................................................................................... .3B1-6
Tie R o d s...................................................................................................... .3B1-6
Relay R o d ....................................................................................................3B1-8
Idler A r m .....................................................................................................3B1-8
Pitm an A r m ............................................................................................... .3B1-9
Steering Connecting R o d ....................................................................... .3B1-9
GENERAL DESCRIPTION
The steering linkage is located forward of the front
crossmember. Refer to Fig. 3B1-1, for a typical system.
Steering effort is transm itted to left and right hand adjusta
ble tie rods through a relay rod. T he relay rod is connected to
an idler arm on the right and to the pitm an arm on the left.
DIAGNOSIS
Reference should be m ade to the correct method of
disassembly, repair, adjustm ent and reassembly. Dam aged,
broken or deformed parts must be replaced with the correct
replacem ent.
L IG H T TR U C K SERVICE M A N U A L
3B1-2
STEERING LINKAGE
CO N D ITIO N
POSSIBLE C A U SE
CORRECTIO N
Replace part.
LIG H T T R U C K SERVICE M A N U A L
STEERING LINKAGE
CONDITIO N
Poor Returnability.
PO SSIBLE C A U SE
3B1-3
CO RRECTIO N
Align column.
Align column.
LIG H T T R U C K SERVICE M A N U A L
3B1-4
STEERING LINKAGE
E R IN G D A M P E R
S T E E R IN G D A M P E R
(Fig. 3B1-4)
This type of steering dam per is nonadjustable, nonrefillable and is not repairable. A t each lubrication interval
m ake check # 1 and # 2 on the steering dam per system.
1. Inspecting Damper Mountings: C heck th e dam per
attachm ents to be sure they are properly and securely
installed. (T ig h ten , if loose). R eplace th e d am per
assembly if the rubber bushings are badly worn.
2. Inspecting Damper For Leaks: Inspect the dam per for
evidence of fluid leakage. A light film of fluid is
perm issible on the body of the dam per near the shaft
seal. A dripping d am per should be replaced.
If a Funtional or Noise C om plaint is R eported, M ake
the Following Inspections:
3. Inspecting Damper For Noise: Disconnect the fram e or
axle end of the dam per. Extend and compress the
dam per using as much travel as possible. The dam per
action should be smooth throughout each stroke.
4. Inspecting Damper For Functioning: W hile checking
the dam per in step (3) above, observe the operation of
LIG H T T R U C K SERVICE M A N U A L
MOTOR HOME
Fig. 3Bl-4--Steering Dampers
the dam per for fluid leakage, effort and lag. Items from
this check th at require dam per replacem ent are:
A.Any fluid leakage during this check.
B. Seizing or binding condition during travel of damper.
C.A skip or lag at reversal near m id-stroke of dam per.
5. Reinstall Disconnected End of Damper Using Proper
Torque.
STEERING LINKAGE
3B1-5
RELAY ROD
IDLER ARM
ASSEMBLY
TIE ROD
ASSEMBLY
[ a ] [c a u t i o n
KNUCKLE
STEERING GEAR
PITMAN ARM
IDLER ARM
ASSEMBLY
RELAY ROD
TIE ROD
ASSEMBLY
STEERING GEAR ^
ASSEMBLY
PITMAN
ARM
STEERING
ARM
G-SERIES
PITMAN ARM
K-SERIES
CONNECTING,
ROD
SUPPORT ASSEMBLY
SUPPORT PITMAN
ARM
,LEFT IDLER
ARM
RELAY ROD
IDLER ARM
ASSEMBLY
GEAR MOUNTING
BRACKET
STEERING GEAR
PITMAN ARM
KNUCKLE
TIE ROCr x
ASSEMBLY
P-SERIES
Fig. 3B1-5--Steering Linkage
LIG H T T R U C K SERVICE M A N U A L
3B1-6
STEERING LINKAGE
ON-VEHICLE SERVICE
NOTICE: See N O T IC E on page 1 of this section
regarding all fasteners referred to in servicing steering
linkage components.
TIE RODS
Removal
1. Raise vehicle on hoist.
2. Remove nuts from ball studs. The inner tie rod ends use
crim p nuts, while the outer ends use castellated nuts
and cotter pins.
3. To remove outer ball stud, tap on steering arm at tie rod
end with a ham m er while using a heavy ham m er or
sim ilar tool as a backing (Fig. 3 B 1-7).
4. Remove inner ball stud from relay rod using same
procedure as described in Step 3.
5. To remove tie rod ends from tie rod, loosen clam p bolts
and unscrew end assemblies.
Installation
NOTICE: See the N O T IC E on page 1 of this section
regarding the fasteners referred to in steps 4 and 6.
Tie rod adjuster com ponents often become rusted in
service. In such cases, it is recom m ended th at if the torque
required to remove the nut from the bolt after breakaw ay
PRODUCTION NUT
IMPORTANT
WHENEVER ANY OF THE CRIMP NUTS OR STUDS AT THE (5) LOCATIONS SHOWN ARE LOOSENED OR
REMOVED, THE FOLLOWING STEPS MUST BE TAKEN:
A. WHEN RE-ATTACHING ANY TWO COMPONENTS BY MEANS OF A BALL STUD, CAREFULLY POSITION
THE TWO PARTS. THEN IN STALL A FREE-SPINNING NUT, AND DRAW THE ITEMS TOGETHER TO SEAT
THE TAPER, TORQUE NUT TO 54 N m (40 FT-LBS), THEN REMOVE NUT.
B. THEN USE A TORQUE PREVAILING SERVICE REPLACEMENT NUT (#351249) AND TORQUE TO
90 N-m (66 FT-LBS),
L IG H T T R U C K SERVICE M A N U A L
STEERING LINKAGE
NOTE S lo t in adjuster
sleeve m ust n o t be
w itn in th is area o f
cla m p jaws.
C A U TIO N
T IE ROD A D JU S T E R
SLEEVE
SLO T
REARW ARDR O T A T IO N
NOTE Locate clam ps
w itn in to le ra n ce show n.
VIEW
3B1-7
RELAY
O UTER
S T E E R IN G K N U C K L E
TIG H T
NOTE S lo t in a djuster
sleeve m ust n o t be w ith in
th is area o f cla m p jaws.
H O R IZ O N T A L
L IN E
.005
M IN . G AP
C,K & P
A D JU S TE R
SLEEVE SLO T
REARW ARD
R O T A T IO N
V IEW
1. If the tie rod ends were removed, lubricate the tie rod
threads with EP Chassis lube and install ends on tie rod
m aking sure both ends are threaded an equal distance
from the tie rod.
2. M ake sure th at threads on ball studs and in ball stud
nuts are clean and smooth. If threads are not clean and
smooth, ball studs may turn in tie rod ends when
attem pting to tighten nut. Check condition of ball stud
seals; replace if necessary. Tool J-24434 may be used to
install ball stud seals.
3. Install ball studs in steering arm s and relay rod. F o r
the inner tie rod ends, use a free-spinning % - 1 8 nut to
seat the ta p e rs, p e r Fig. 3 B 1-6.
4. A t th e ou ter tie rod ends, install a ball stud n u t, tighten
to 70 N*m (50 lb. ft.), and install new c o tter pins.
L u b ricate tie rod ends.
Fig. 3B1 -9Tie Rod Inspection
LIG H T TR U C K SERVICE M A N U A L
3B1-8
STEERING LINKAGE
d. R otate both inner and outer tie rod housing rearw ard
to the lim it of ball jo in t travel before tightening
clam ps. Tighten clam ps to specifications. R eturn tie
rod assem bly to the center of travel.
e. All procedures for alignm ent, adjustm ent and assem
bly of tie rods applies to each side.
f. Check each assem bly to be sure th at a total travel of
at least 35 can be obtained using a bubble protractor
and a pair of vise grips (Fig. 3B1-9).
Inspection
To ensure proper installation, it is necessary to perform
the following inspection after any change of toe setting or
removal of any ball stud:
1. Check the total rotation of the tie rod assembly using
the following procedure:
a. L ubricate inner and outer tie rod ends.
b. A ttach vise grip pliers to the outer tie rod end.
c. R otate outer tie rod end counterclockwise (up) to
m axim um position. A ttach bevel protractor as shown
in Figure 3B1-9. C enter protractor bubble indicator
and record reading.
d. R otate tie rod end clockwise (down) to m axim um
position. C e n te r p ro tra c to r bubble in d icato r and
record reading.
e. Compare protractor readings obtained in Steps c
and d. Total rotation o f tie rod assem bly should
measure at least 35.
f. If rotation is less th an 35, loosen one tiS rod sleeve
clam p and rotate both tie rod ends to their m axim um
lim it both ends must be rotated in the same direction.
g. Tighten tie rod clam p and again rotate both ends to
their m axim um limits, repeating Steps c and d. This
recheck of total rotation will result in a m inim um of
35 travel.
h. A fter obtaining the correct am ount of rotation (35
or g reater), position the outer tie rod end approx
im ately m idway in this travel.
Installation
NOTICE: See the N O T IC E on page 1 of this section
regarding the fasteners referred to in steps 2 and 3.
1. M ake sure th at threads on the ball studs and in the ball
stud nuts are clean and smooth. If threads are not clean
and sm ooth, ball studs m ay tu rn in sockets when
attem pting to tighten nut. Check condition of ball stud
seals; replace if necessary.
2. Install the relay rod to the idler arm and pitm an arm
ball studs, m aking certain th e seals are in place. U se a
free-spinning nut to seat the ta p ers, p er Fig. 3 B 1 -6 .
Install the tie rods to the relay rod as previously
described under "T ie Rod- In stallatio n ". L ubricate the
tie rod ends.
4. Lower the vehicle to the floor.
5. A djust toe-in (see Section 3A) and align steering wheel
as described previously in Section 3 B 4 under "S teering
W heel A lignm ent and High Point C en tering".
3.
RELAY ROD
Removal
1. Raise vehicle on hoist.
2. Remove inner ends of the tie rods from relay rod as
described under "T ie R od-R em oval".
3. Remove the nuts from the pitm an and idler arm ball
studs a t the relay rod.
4. Remove the relay rod from the pitm an and idler arm s
by tapping on the relay rod ball stud bosses with a
ham m er, while using a heavy ham m er as a backing
(Fig. 3B1-7).
5. Remove the relay rod from the vehicle.
LIG H T T R U C K SERVICE M A N U A L
STEERING LINKAGE
Removal
1. Raise vehicle on a hoist.
2. Remove the nut from ball stud at the relay rod. Remove
the ball stud from the relay rod by tapping on the relay
rod boss with a ham m er, while using a heavy ham m er
as a backing (Fig. 3B1-7).
3. Remove the idler arm to fram e bolt and remove the
idler arm assembly.
Installation
NOTICE: See the N O T IC E on page 1 of this section
regarding the fasteners referred to in steps 1 and 3.
1. Position the idler arm on the fram e and install the
m ounting bolts (special plain w ashers under bolt
heads); torque the nuts to specifications.
2. M ake sure th at the threads on the ball stud and in the
ball stud nut are clean and smooth. If threads are not
clean and smooth, ball stud m ay turn in the socket
when attem pting to tighten nut. Check condition of ball
stud seal; replace if necessary.
3. Install th e idler arm ball stud in th e relay rod, making
certain the seal is positioned properly. U se a %-18
free-spinning nut to seat th e tap ers, p er Fig. 3B1-6.
4. Lower the vehicle to the floor.
PITMAN ARM
Removal
1. Raise vehicle on hoist.
2. Remove nut from pitm an arm ball stud.
3. Remove pitm an arm or relay rod from ball stud by
3B1-9
Installation
NOTICE: See the N O T IC E on page 1 of this section
regarding the fasteners referred to in steps 3 and 4.
1. Install pitm an arm on pitm an shaft, lining up the marks
made upon removal.
Installation
NOTICE: See the N O T IC E on page 1 of this section
regarding the fasteners referred to in step 3.
1. M ake sure th a t threads on ball studs and in ball stud
nuts are clean and smooth. If threads are not clean and
smooth, ball studs may turn in connecting rod when
attem pting to tighten nut. Check condition of ball stud
seals-replace if necessary.
2. Install ball studs in steering arm and pitm an arm . (Be
sure to install the long end of the connecting rod
assembly to the pitm an arm , as shown in Fig. 3B1-5).
3. Install ball stud nuts and torque to specifications.
Never back off nut to align cotter pin, always tighten
nut to next slot th a t lines up with hole in stud.
4. Install cotter pins and lubricate ball studs. For proper
alignm ent and orientation of connecting rod clam ps see
Figure 3B 1-11.
LIG H T T R U C K SERVICE M A N U A L
3B1-10
STEERING LINKAGE
STEERING GEAR
ASSEMBLY
.10
CLAMP
V IE W
LIG H T T R U C K SERVICE M A N U A L
ADJUSTER TUBE
3B2-1
SECTION 3B2
CONTENTS
G eneral D escription.....:.................................................................................3B2-1
D iagnosis.................................. ........................................................................3B2-1
M aintenance and A d ju stm e n ts................................................................. .3B2-4
On-V ehicle S erv ice....................................................................................... .3B2-5
M anual Steering G e a r............................................................................. .3B2-5
Pitm an S haft S eal......................................................................................3B2-6
S pecifications.................................................................................................. .3B2-7
Special T ools....................................................................................................3B2-7
GENERAL DESCRIPTION
The steering gear is of the recirculating ball type. This
gear provides for ease of handling by transm itting forces
from the w orm shaft to the pitm an shaft through the use of
ball bearings.
DIAGNOSIS
This section contains diagnostic inform ation to help
locate the cause of steering problems that may be related to
the m anual steering gear. Reference should be m ade to the
correct m ethod of disassem bly, repair, a d ju stm en t and
reassembly. D am aged, broken or deformed parts m ust be
replaced with the correct replacem ent.
LIG H T T R U C K SERVICE M A N U A L
3B2-2
C O N D IT IO N
P O S S IB L E C A U SE
C O R R E C T IO N
Poor Returnability
Align column.
Lubricate as specified.
Adjust to specifications.
LIG H T T R U C K SERVICE M A N U A L
C O N D IT IO N
P O S S IB L E C A U S E
3B2-3
C O R R E C T IO N
Adjust to specifications.
LIG H T TR U C K SERVICE M A N U A L
3B2-4
ON-VEHK
STEERING GEAR
Removal
1. S et the front wheels in s tra ig h t ahead position by
driving vehicle a short distance on a flat surface.
3B2-5
11. Install the horn button cap or shroud and connect the
battery ground cable.
12. Lower the vehicle to the floor.
1 SERVICE
2. Remove the flexible coupling to steering shaft flange
bolts (C-K models) or the lower universal joint pinch
bolt (P models). M ark the relationship of the universal
yoke to the worm shaft.
3. M ark the relationship of the pitm an arm to the pitm an
shaft. Remove the pitm an shaft nut or pitm an arm
pinch bolt and then remove the pitm an arm from the
pitm an shaft using Puller J-6632 (Fig. 3B2-9).
L IG H T T R U C K SE RV IC E M A N U A L
3B2-6
Installation
NOTICE: See N O T IC E on page 1 o f this section
regarding the fasteners referred to in steps la , lc, Id,
le, 2b, 2c and 3.
1. C-K Models
TOOLJ-5504
3B2-7
L IG H T TR UC K SE RV IC E M AN U AL
3B3-1
SECTION 3B3
CONTENTS
G eneral D escription..........................................................................................3B3-1
D iagnosis............................................................................................................ .3B3-2
M aintenance and A d ju stm e n ts.....................................................................3B3-10
On-V ehicle S erv ice.............................................................................. ............3B3-12
Power Steering G e a r ...................................................................................3B3-12
Power Steering P u m p ................................................................................ .3B3-13
Power Steering H oses................................................................................ .3B3-15
S p ecifications.................................................................................................... .3B3-15
Special T o o ls..................................................................................................... .3B3-15
GENERAL DESCRIPTION
The steering gear is of the recirculating ball type. This
gear provides for ease of handling by transm itting forces
from the w orm shaft to the pitm an shaft through the use of
ball bearings.
3B3-2
System Checks
LIG H T T R U C K SERVIC E M A N U A L
CONDITION
POSSIBLE CAUSE
3B3-3
CORRECTION
S Y ST E M N O IS E
There is some noise in all power
steering systems.
Common complaints are listed as
follows:
Pump noise-chirp .
Loose belt.
Belt squeal.
Loose belt.
Rattle.
Install properly.
Adjust to specifications.
Tighten to specifications
Rattle or chuckle.
Groan.
Groan.
Growl.
LIG H T T R U C K SERVIC E M A N U A L
3B3-4
CONDITION
POSSIBLE CAUSE
CORRECTION
Swish in pump
Replace valve
Whine in pump
Replace 0 ring.
Pump growl
Note: Most noticeable at full
wheel travel and stand still parking
SY STE M O P E R A T IO N
Excessive wheel kick-back or loose
steering.
Air in system.
Adjust to specification.
Adjust to specification.
Tires under-inflated.
Replace bearings.
L IG H T T R U C K SERVICE M A N U A L
CONDITION
Poor return of steering. (Contd.)
POSSIBLE CAUSE
3B3-5
CORRECTION
Replace bearings.
Adjust to specifications.
Align column.
Replace valve.
Adjust as required.
Correct clearance.
Check pump
pressure test).
L IG H T T R U C K SERVIC E M AN U AL
3B3-6
POSSIBLE CAUSE
CONDITION
Hard Steering or
lack of assist (Continued)
CORRECTION
Frame bent.
Remove kink.
Replace valve.
Replace valve.
L IG H T T R U C K SERVICE M A N U A L
POSSIBLE CAUSE
CONDITION
Low oil
pump:
pressure
due
to steering
3B3-7
CORRECTION
Loose belt.
Correct as necessary.
Tighten.
Replace part.
Note:
LIG H T TR U C K SE RV IC E M AN U AL
3B3-8
1.
2.
3.
4.
5.
L IG H T T R U C K SE RV IC E M A N U A L
3B3-9
C H E C K O IL L E V E L
IF L E A K A G E P E R S I S T S W IT H THE LEVEL
C R A C K E D O R BENT R E S E R V O IR .
3.
R E P L A C E R E S E R V O IR " 0 " R IN G .
4.
R E P L A C E FR O N T S E A L
R E P L A C E R E S E R V O IR .
M A K E C E R T A IN TH AT D R I V E SH A F T IS
C LE A N A N D FREE OF P IT T IN G IN S E A L R ID E AREA.
5.
6.
L E A K A G E P E R S IS T S .
P E R S IS T S .
R E P L A C E " 0 " R IN G S E A L
IF L E A K A G E
7.
8.
9.
R E P L A C E A D J U S T E R PL U G " 0 " R IN G S E A L
R E P L A C E S ID E C O V E R S E A L IF L E A K A G E P E R S IS T S .
10.
11.
R E P L A C E A D J U S T E R PLUG S E A L S.
12.
SE A T B A L L F L U S H W IT H P U N C H A N D R E ST A K E .
P E R S IS T S .
IF S E E P A G E
R E P L A C E H O U SIN G .
13.
R E P L A C E BOTH P IT M A N SH A F T S E A L S.
14.
15.
R E P L A C E S ID E C O V E R " 0 " R IN G S E A L
16.
R E P L A C E D U S T S E A L A N D P IT M A N SH A F T S E A L
17.
L IG H T TR UC K SE RV IC E M AN U AL
3B3-10
ADJUSTMENTS
Power Steering Gear Adjustment Procedure
A djustm ent of the steering gear in the vehicle is not
recom m ended because of th e difficulty encountered in
adjusting the worm thrust bearing preload and the confus
ing effects of the hydraulic fluid in the gear. Since a gear
adjustm ent is m ade only as a correction and not as a periodic
adjustm ent, it is better to take the extra tim e and make the
adjustm ent correctly the first time.
Since a handling stability com plaint can be caused by
improperly adjusted worm bearings as well as an improper
gear over-center adjustm ent, it is necessary th at the steering
gear assem bly be removed from the vehicle and both thrust
bearing and over-center preload be checked and corrected as
necessary. An in-vehicle check of the steering gear will not
pin-point a thrust bearing looseness.
Before any adjustm ents are m ade to the steering gear
attem p t to correct com plaints of loose or hard steering, or
other wheel disturbances, a careful check should be m ade of
front end alignm ent, shock absorbers, wheel balance and
tire pressure for possible steering system problems. See
Diagnosis steps listed earlier in this section.
Once it is determ ined to m ake adjustm ents, refer to
Section 3B of the O verhaul M anual for specific instructions.
LIG H T TR UC K SE RV IC E M AN U AL
3B3-11
B E L T T E N S IO N
5/16
3/8"
15/32
W ID E
W ID E
W ID E
NEW
BELT
350 N Max.
80 Lbs. Max.
620 N Max.
140 Lbs. Max.
750 N Max.
165 Lbs. Max.
USED
BELT
200 N M in.
50 Lbs. M in.
USED
CO G G ED
BELT
300 N
70 Lbs.
M in.
Min.
400 N
90 Lbs.
POWER ST EER IN G
a d a p TFR
GAGE J-5176-01
j_22326
P R E SSU R E HOSE TO
P /S G E A R
P R E SSU R E HOSE
FRO M PU M P
Min.
Min.
250 N M in.
60 Lbs. Min.
Fig. 3B3-11Belt Tension Chart
3B3-12
ON-VEHICLE SERVICE
Installation (Fig. 3B3-14)
TOOLJ-5504
TO OLJ-6632
L IG H T TR U C K SE RV IC E M A N U A L
P Models
3B3-13
Installation
1. Postion pump assembly on vehicle and install attaching
parts loosely.
2. Connect and tighten hose fittings.
3. Fill reservoir. Bleed pum p by turning pulley backward?
(counter-clockw ise as viewed from front) until air
bubbles cease to appear.
4. Install pump belt over pulley.
5. Tension belt as outlined under "Pum p Belt TensionA djustm ent" in this section.
6. B leed as o utlined u n d er B leeding P o w er Steering
S y ste m .
LIG H T T R U C K SERVICE M AN U AL
3B3-14
I F9 Enaine
L IG H T T R U C K SE RV IC E M A N U A L
3B3-15
LIG H T T R U C K SE RV IC E M AN U AL
3B3-16
L25 Engine
JB8
LIG H T TR U C K SE R V IC E M A N U A L
3B3-17
(Exc. H C 4 )
HC4
and JB8
L IG H T T R U C K SERVICE M AN U AL
3B3-18
Engine
Engine
L IG H T TR U C K SE R V IC E M A N U A L
STEERING C O L U M N S
3B4-1
SECTION 3B4
STEERING COLUMNS
The following notice applies to one or more steps in the assembly
procedure o f com ponents in this portion of the m anual as indicated at
appropriate locations by the term inology "See Notice on page 1 of this
Section".
NOTICE: This fastener is an im portant attaching part in th at it
could affect the perform ance of vital com ponents and systems, a n d /o r
could result in m ajor repair expense. It m ust be replaced w ith one of the
same part num ber or w ith an equivalent part if replacem ent becomes
necessary. D o not use a replacem ent part of lesser quality or substitute
design. T orque values m ust be used as specified during reassembly to
assure proper retention of this part.
CONTENTS
GENERAL DESCRIPTION
FUNCTION LOCKING COLUMNS
T he function locking energy absorbing steering colum n
includes three im portant features in addition to the steering
function:
1. T he colum n is energy absorbing, designed to
com press in a front-end collision to m inim ize the possibility
of injury to the driver o f the vehicle.
2. T he ignition switch and lock are m ounted
conveniently on the column.
3. W ith the colum n m ounted lock, the ignition,
steering and gearshifting operation can be locked to inhibit
theft o f the vehicle.
T he function locking energy abosrbing colum n may be
easily disassembled and reassembled. The serviceman
should be aware that it is im portant th at only the specified
screws, bolts and nuts be used as designated and th at they
are tightened to their specified torque. This precaution will
insure the energy absorbing action o f the assembly. O ver
length bolts should not be used, as they may prevent a
portion of the assembly from com pressing under impact.
Equally as im portant is correct torque o f bolts and nuts.
L IGHT T R U C K SE R V IC E M A N U A L
3B4-2
STEERING C O L U M N S
DIAGNOSIS
GENERAL INFORMATION
This section contains diagnostic inform ation to help
locate the cause of the problem in the colum n. Reference
should be m ade to the correct m ethod o f column
disassembly, repair, adjustm ent and reassembly. Damaged,
broken or deformed parts m ust be replaced w ith the correct
replacem ent.
To perform diagnostic procedures on the steering
colum n upper end com ponents, it is not necessary to remove
the colum n from the vehicle.
The steering wheel, horn com ponents, directional
signal switch, ignition switch and lock cylinder may be
removed w ith the colum n rem aining in the vehicle as
described in the Service M anual under "C om ponent P art
Replacem ent".
LIGHT TR U C K SE R V IC E M A N U A L
STEERING C O L U M N S
3B4-3
COLUMN JACKET
Inspect jacket section of column for looseness, a n d /o r
bends.
SHIFTER SHAFT
Separation of the shifter shaft sections will be internal
and cannot be visually identified. Hold lower end of the
"shifter shaft" and move "shift lever" on colum n through
its ranges and up and down. If there is little or no movement
o f the "shifter shaft", the plastic joints are sheared.
Steering Shaft
If the steering shaft plastic pins have been sheared, the
shaft will rattle when struck lightly from the side and some
lash may be felt when rotating the steering wheel while
holding the rag joint. It should be noted that if the steering
shaft pins are sheared due to m inor collision w ith no
appreciable dam age to other components, th at the vehicle
can be safely steered; however, steering shaft replacement
is recommended.
Because of the differences in the steering colum n types,
be sure to refer to the set of instructions below which apply
to the colum n being serviced.
i ifiU T t r i ICK
" * * * "AL
3B4-4
STEERING C O L U M N S
SU RFA CE A
Solution
B.
C.
Replace housing.
D. Replace sector.
E.
Replace rack.
F.
Replace.
LOCK SYSTEM
Cause
Solution
A. Replace spring.
B.
C.
D. Remove Burr.
E. Damaged housing.
E.
Replace housing.
F.
G. Replace rack.
H. I n te r f e r e n c e b e tw e e n b o w l a n d c o u p lin g ( tilt) .
I.
1.
Readjust or replace.
J.
J.
Readjust or replace.
Solution
B. Replace sw itch.
C. Replace spring.
D. Remove Burr.
E.
Replace shaft.
F.
F.
Replace rack
G.
D istorted rack.
G. M isa lig n m e n t o f h o u s in g to c o v e r ( t il t o n ly ).
LIG H T T R U C K SE R V IC E M A N U A L
STEERING C O L U M N S
LOCK SYSTEM
3B4-5
Cause
Solution
H.
Replace rack.
I.
I.
J.
J.
Straighten or replace.
Solution
A. Remove burr.
B. D istorted rack.
B. Replace rack.
Solution
A. Straighten or replace.
Solution
Solution
B.
C. Remove burr.
Solution
Solution
A. Replace fuse.
B. Tighten or replace.
C. Defective wiring.
C. Repair or replace.
LIGHT TRU C K SE R V IC E M A N U A L
3B4-6
STEERING C O L U M N S
Solution
Solution
Solution
B.
B.
S e c to r t o ra c k e n g a g e d in w ro n g t o o t h ( tilt) .
NOISE IN COLUMN
Cause
Solution
B.
B.
Realign colum n.
F. L ubricate bearings.
I.
I.
J.
J.
K.
L.
Norm al co n d itio n
- lock
b olt is seating.
LIGHT TR U C K SE R V IC E M A N U A L
STEERING C O L U M N S
3B4-7
Solution
A. Realign.
B.
C.
C.
Solution
A. Realign.
C.
C.
D. Remove burr.
E.
E. Reassemble properly.
Solution
B. Readjust linkage.
C.
Solution
C.
C.
E. L o o se sh o e s in h o u s in g ( t il t o n ly ).
E. Replace.
F. L o o se t ilt h e a d p iv o t p in s ( t il t o n ly ).
F.
G. L o o se sh o e lo c k p in in s u p p o r t ( t il t o n ly ).
G. Replace.
Replace.
M ISCELLANEOUS
Cause
Solution
LIGHT T R U C K SER V IC E M A N U A L
3B4-8
STEERING C O L U M N S
M A N U A L T R A N S M IS S IO N
COLUM NS
G E N E R A L INFORMATION
All of the preceding diagnosis information for autom atic transmission will apply to the manual transmission. The following
information is supplied in addition to and specifically for manual transmission columns.
D R I V E R C A N L O C K S T E E R IN G
SECO N D G EA R
IN
Cause
Solution
B.
C.
Solution
A. Realign column.
B. Reassemble correctly.
F.
F.
Solution
LIGHT T R U C K SE R V IC E M A N U A L
STEERING C O L U M N S
3B4-9
TILT COLUMNS
GENERAL INFORMATION
All of the preceding diagnosis will generally apply to tilt columns. The following is supplied in
addition to and specifically for tilt columns.
HOUSING SCRAPING ON BOWL
Cause
Solution
A. Replace bowl.
Solution
C. Replace both.
D. install seat.
Solution
A. Replace both.
Solution
B. Lubricate.
Solution
B. Replace shoe.
C.
Solution
C. Reposition wires.
LIGHT T R U C K SE R V IC E M A N U A L
3B4-10
STEERING C O L U M N S
Mechanical
1.
If the custom ers com plaint indicates the problem
is in the switch, function check as to return from full left
and full right turns.
A ctuate the turn lever into a full tu rn position in either
direction, then turn the steering wheel (m otor on - power
steering) at least 1/4 turn in the direction indicated and then
Electrical
Chassis Electrical
The most com m on tu rn signal system problems are
generally electrical and may easily, be fixed by the
replacem ent of fuses, bulbs, or flashers .
First m ake these checks and replace any non-operative
components.
1. Check fuses (Figure 3B4-9). Replace if blown. If
new fuse blows, replace flasher in system. (There are 2
flashers in the signal switch system. The hazard warning
flasher and tu rn signal flasher are located on the fuse block.
2. C heck for secure connection at the chassis to switch
connector. T his is the harm onica connector on the colum n
(Figure 3B4-10). Secure if loose. Check all individual wire
terminals for proper seating in the connector bodies.
Terminals should be locked in place.
3. Depress hazard w arning button and check all lights
in signal switch system. Replace any which do not work.
LIGHT T R U C K SE R V IC E M A N U A L
STEERING C O L U M N S
3B4-11
LANE CHANGE
RETURN SPRING
Fig. 3B 4-1 2--Checking Turn Signal Sw itch V isually
LIGHT T R U C K SER V IC E M A N U A L
3B4-12
STEERING C O L U M N S
Loose switch
mounting screws
Switch or anchor
bosses broken
Broken, missing or out
of position detent, return
or cancelling spring
Uneven or incorrect
cancelling cam to
cancelling spring
interference.
(,120)/side
A.
A.
B.
A.
B.
C.
D.
C.
D.
E.
Turn signal will not
indicate lane change
A.
B.
C.
A.
B.
C.
CORRECTION
POSSIBLE CAUSE
A.
B.
Tighten to specified
torque (25 in-lbs)
Replace switch
C.
Reposition or replace
springs as required
D.
A.
Yoke broken or
distorted
Loose or misplaced
springs
Foreign parts
and/or materials
Switch mounted
loosely
B.
Tighten mounting
screw (12 in-lb)
Replace switch
Foreign material or
loose parts impeding
movement of yoke
Broken or missing
detent or cancelling springs
None of the above
Foreign material
between hazard
support cancelling
leg and yoke
C.
D.
E.
Reposition or replace
springs
Remove foreign parts
and/or material
Tighten mounting
screws (25 in-lbs)
A.
Replace switch
B.
Replace or reposition
as required
C.
Loosen mounting
screws, reposition
base or wires and
retighten screws (25 in-lbs)
A.
Remove material
and/or parts
B.
Replace spring
C.
Replace switch
A.
LIGHT TR U C K S E R V IC E M A N U A L
STEERING C O L U M N S
3B4-13
POSSIBLE CAUSE
A.
C.
Loose switch
mounting screws
Interference with
other components
Foreign material
C.
D.
D.
A.
Defective or
blown fuse
Inoperative turn signal
flasher
Loose chassis to
column connector
Disconnect column
to chassis connector.
Connect new switch
to chassis and
operate switch by
hand.
If vehicle lights now
operate normally,
signal switch is
inoperative
If vehicle lights do
not operate check
chassis wiring for
opens, grounds, etc.
A.
B.
B.
C.
D.
E.
CORRECTION
A.
B.
B.
C.
D.
A.
B.
Loose chassis to
column connection
Inoperative turn
signal switch
To determine if turn
signal switch is
defective, substitute
new switch into
circuit and operate
switch by hand.
If the vehicle's lights
operate normally,
signal switch is
inoperative
If the vehicle's lights
do not operate,
check light sockets
for high resistance
connections, the
chassis wiring for
opens, grounds, etc.
B.
E.
Inoperative turn
, flasher
D.
Remove foreign
material
Replace switch
E.
A.
C.
Tighten mounting
screws (25 in-lbs)
Remove interference
C.
D.
E.
LIGHT T R U C K SE R V IC E M A N U A L
3B4-14
STEERING COLUMNS
CONDITION
Front or rear turn signal
lights not flashing
A.
B.
Burned out or
damaged turn signal
bulb
High resistance
connection to ground
at bulb socket
B.
L o o s e c h a s s is to
D.
C.
D.
E.
F.
column connector
Disconnect column to
chassis connector.
Connect new switch
into system and
operate switch
by hand.
If turn signal lights
are now on and
flash, turn signal
switch is inoperative.
If vehicle lights do
not operate, check
chassis wiring harness
to light sockets for
opens, grounds, etc.
C.
E.
F.
A.
A.
B.
Loose column to
chassis connection
Disconnect column to
chassis connector.
Connect new switch
into system without
removing old. Operate
switch by hand.
If brake lights work
with switch in the
turn position, signal
switch is defective
If brake lights do not
work check connector
to stop light sockets
for grounds, opens,
etc.
B.
C.
D.
CORRECTION
A.
B.
C.
C.
as required using
manual as guide
D.
Repair connector to
stop light circuits
using manual as guide.
A.
B.
Replace bulbs
Replace socket
C.
LIGHT TR U C K SE R V IC E M A N U A L
STEERING C O L U M N S
3B4-15
A.
B.
C.
D.
E.
F.
CORRECTION
POSSIBLE CAUSE
Inoperative turn
signal flasher
System charging
voltage low
High resistance ground
at light sockets
Loose chassis to
column connection
Disconnect column
to chassis connector.
Connect new switch
into system without
removing old. Operate
switch by hand.
If flashing occurs
at normal rate, the
signal switch is
defective.
If the flashing rate is
still extremely slow,
check chassis wiring
harness from the
connector to light
sockets for grounds,
high resistance points,
etc.
A.
Blown fuse
B.
Inoperative hazard
warning flasher
Loose chassis to
column connection
Disconnect column to
chassis connector.
Connect new switch
into system without
removing old. Depress
the hazard warning
button and observe
the hazard warning
lights. If they now
work normally, the
turn signal switch
is defective.
If the lights do not
flash, check wiring
harness "K" lead
(brown) for open
between hazard
flasher and harmonica
connector. If open,
fuse block is defective.
C.
D.
E.
A.
C.
D.
E.
F.
C.
D.
E.
LIGHT TRU C K SE R V IC E M A N U A L
3B4-16
STEERING C O L U M N S
Automatic Transmission
1. Place the shift tube lever in "N eutral" or "D rive".
2. Loosen adjusting ring clam p screws and rotate the
shift tube adjusting ring to obtain .33" to .36" clearance
between the shift tube lever and adjusting ring (Fig. 3B420).
3. Tighten the adjusting ring clam p screws to 70 in.
lbs.
LIGHT T R U C K SE R V IC E M A N U A L
STEERING C O L U M N S
3B4-17
Fig. 3 B 4 -2 0 --S h ift Tube A d justm ent-A utom atic Transm ission
LIGHT TR U C K SER V IC E M A N U A L
3B4-18
STEERING C O L U M N S
ON-VEHICLE SERVICE
INDEX
STEERING WHEEL
Removal
Steering W h eel...............................................................
Flexible C oupling..........................................................
Interm ediate Shaft.........................................................
Colum n U pper B earin g ........ .......................................
Colum n Lower B earing ...............................................
Tilt Colum n Bearing H ousing....................................
D irectional Signal Sw itch............................................
Steering C o lu m n ............................................................
Rem oval.........................................................................
Disassembly, Standard C olum n...............................
Disassembly, Tilt C o lu m n ........................................
Installation, M andatory Sequence..........................
3B4-35
3B4-35
3B4-36
3B4-38
3B4-38
3B4-39
3B4-40
3 B 4-41
3 B 4-41
3B4-41
3B4-44
3B4-48
Installation
COUPLING TO
STEERING SHAFT
FLANGE BOLTS
LIGHT T R U C K 8E RV ICE M A N U A L
STEERING C O L U M N S
OW ER
BEARING
BLOCKS
3B4-19
BOLT
COVER
SNAP
RING
ft I
UPPER
SHAFT
CLAMP
TENSION
NUT
QDD IKJn
Installation
NOTICE:
Disassembly
1. M ark cover to shaft relationship. Pry off snap ring
and slide cover from shaft.
2. Remove bearing blocks and tension spring from
pivot pin.
3. Clean grease off pin and end of shaft. Scribe location
m ark on pin on same side as chamfer in shaft.
4. Supporting shaft assembly securely, with cham fer
up, press pin out of shaft with arbor press.
Assembly
1. Be sure all parts are free of dirt. Slide seal onto
steering shaft. W ith lip of seal against step in shaft clamp
seal.
2. Press pin back into shaft from cham fered side.
Locate pin in shaft using scribe m ark as reference.
3B4-20
STEERING C O L U M N S
NOTICE:
5.
Slide the directional signal cancelling cam, upper
bearing preload spring and thrust w asher off the end of the
shaft.
LIGHT T R U C K SE R V IC E M A N U A L
STEERING C O L U M N S
3B4-21
Installation
3B4-22
STEERING C O L U M N S
LOCK CYLINDER INSTALLATION
DISASSEMBLE
ASSEMBLE
1.
1.
2.
Remove lock plate, turn signal switch and buzzer switch (see
service manual.)
2.
3.
Install screw. Tighten to 4.5 N*m for regular columns2.5 N*m for adjustable columns.
3.
LOCK
CYLINDER
SET
To-assemble Rotate to
stop while holding cylinder.
HOUSING
CYLINDER KEY
Replacement
IGNITION SWITCH
The ignition switch is m ounted on top of the colum n
jacket near the front of the dash. F o r anti-theft reasons, the
switch is located inside the channel section o f the brake
pedal support and is completely inaccessible w ithout first
lowering the steering colum n (see steering colum n removal).
The switch is actuated by a rod and rack assembly. A
portion of the rack is toothed and engages a gear on the end
of the lock cylinder, thus enabling the rod and rack to be
moved axially (w ith respect to the colum n) to actuate the
switch when the lock cylinder is rotated.
Removal
SWITCH IN LO C K PO SITIO N
LIGHT T R U C K SE R V IC E M A N U A L
STEERING C O L U M N S
3B4-23
STEERING COLUMN
To perform service procedures on the steering colum n
upper end components, it is not necessary to remove the
colum n from the vehicle.
T he steering wheel, horn com ponents, directional
signal switch, and ignition lock cylinder may be removed
with the colum n remaining in the vehicle as described
earlier in this section.
SteeringShaft
If the steering shaft plastic pins have been sheared, the
shaft will rattle when struck lightly from the side and some
lash may be felt when rotating the steering wheel while
holding the rag joint. It should be noted that if the steering
shaft pins are sheared due to m inor collision the vehicle can
be safely steered; however, steering shaft replacem ent is
recommended.
Because of the differences in the steering colum n types,
be sure to refer to the set of instructions below which apply
to the colum n being serviced.
Inspection
ColumnSupportBracket
ColumnJacket
ShifterShaft
3B4-24
STEERING C O L U M N S
Removal
LIGHT T R U C K SE R V IC E M A N U A L
STEERING C OLU M NS
STEERING COLUMN
RETAINER
NUT, Hexagon Jam
COVER, Shaft Lock
RING, Retaining
6. LOCK, Steering Shaft
7. CAM ASM, Turn Signal Cancelling
8. SPRING, Upper Bearing
9. SCREW, Pan Head Cross Recess
10. SWITCH ASM, Turn Signal
11. PROTECTOR, Wiring
12. SCREW, Hex Washer Head Tapping
13. WASHER, Thrust
14. BEARING ASM
17. HOUSING, Steering Column
18. SHAFT, Sector
19. SECTOR, Switch Actuator
20. SPRING, Rack Preload
21. CUP, Thrust
22. RACK ASM, Rod &
23. SCREW, Dimmer Switch Mounting
24. SWITCH ASM, Dimmer
25. SCREW, Flat Head Cross Recess
26. GATE, Shift Lever
27. WASHER, Spring Thrust
28. BOLT ASM, Spring &
29. SPRING. Upper Shift Lever
1.
2.
3.
4.
5.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
61.
62.
67.
68.
3B4-25
LIGHT TR U C K SE R V IC E M A N U A L
3B4-26
S TE E RI NG C O L U M N S
1.
2.
3.
4.
5.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
LIGHT T R U C K SE R V IC E M A N U A L
STEERING C O L U M N S
3B4-27
LIGHT T R U C K SE R V IC E M A N U A L
3B4-28
STEERING C O L U M N S
SHIFT GATE
RACK
LOCK BOLT
LOCK BOLT
SPRING
THRUST
CUP
SECTOR
LIGHT TR U C K SE R V IC E M A N U A L
STEERING C O L U M N S
_IVIAAOI
A. TO REDUCE CLEARANCE
SLIDE THE CLAMPING
SC REW S AROUND THE
M A S T JACKET IN THE
DIRECTION OF ARROW A.
A. TO REDUCE CLEARANCE
SLIDE THE CLAMPING
SC R EW S AROUND THE
M A ST JACKET IN THE
DIRECTION OF ARROW A.
.M A S T JACKET
.2 -3 SHIFT LEVER
.PICK UP LEVER
1 ST-REV.
SHIFT LEVER
B. TO INCREASE CLEARANCE
I
-2 -3 SHIFT LEVER
-PICK UP LEVER
B. TO INCREASE CLEARANCE
SLIDE THE CLAMPING
SC R EW S AROUND THE
M A S T JAC KET IN THE
DIRECTION OF ARROW B.
3B4-29
ALIGNMENT
LEVER
.0 0 5 IN. SHIM
UPPER STRG.
SHAFT
SPACER
\ L LOWER MAST
LOWER BEARING JACKET BEARING
RETAINER
"LOWER M AST
JACKET BEARING
LOWER BEARING
RETAINER
AD JU S TM EN T PROCEDURE
1. WITH THE TRANSMISSION IN NEUTRAL DISCON
NECT THE TRANSMISSION RODS.
2. TEST FOR R O TATIO NAL DRAG BY TURNING
THE S HIFT LEVER (INSIDE TRUCK) THROUGH
THE 2-3 S HIFT ARC. DRAG MEASURED AT THE
S HIFT KNOB MUST BE NO MORE THAN 2.0 LBS.
IF DRAG IS MORE THA N 2.0 LBS. CORRECTIONS
MUST BE MADE BEFORE PROCEEDING W ITH THIS
ADMUSTMENT.
3. LOOSEN THE THREE CLAMPING SCREWS.
4. INSTALL A .005 IN. THICK SHIM BETWEEN THE
SPACE AND EITHER OF THE SHIFT LEVERS. THE
ABOVE ILLUSTRATIO N SHOWS THE SHIM BE
TWEEN THE SPACER AND THE 2-3 SHIFT LEVER.
5. SLIDE THE CLAMPING SCREWS IN DIRECTIO N
OF ARROW B U N T IL THE SYSTEM IS LOOSE. THEN
SLIDE THE SCREWS IN OPPOSITE DIRECTIO N
U N T IL A D E FIN ITE DRAG IS FELT AT THE 1STREV. SHIFT LEVER.
6. TIG HTEN THE CLAMPING SCREWS.
7. REMOVE THE SHIM.
8. REINSTALL THE TRANSMISSION RODS.
A D JU S TM EN T PROCEDURE
1. WITH THE TRANSMISSION IN NEUTRAL DISCON
NECT THE TRANSMISSION RODS.
2. TEST FOR RO TATIO NAL DRAG BY TUR NING THE
SHIFT LEVER (INSIDE TRUCK) THROUGH THE
2-3 S HIFT ARC. DRAG. MEASURED AT THE SHIFT
KNOB, MUST BE NO MORE THAN 2.0 LBS. IF
DRAG IS MORE THA N 2.0 LBS. CORRECTIONS
MUST BE MADE BEFORE PROCEEDING WITH THE
ADJUSTMENT.
3. LOOSEN THE THREE CLAMPING SCREWS.
4. INCREASE CLEARANCE BY SLIDING THE CLAMP
ING SCREWS IN DIRECTIO N OF ARROW "B" ABOVE
UN TIL THE 1ST-REV. SHIFT LEVER COMPLETELY
FREE OF DRAG.
5. DECREASE CLEARANCE BY SLIDING THE CLAMP
ING SCREWS IN DIRECTIO N OF ARROW "A " ABOVE
U N TIL A SLIGHT DRAG IS FELT AT THE 1ST-REV.
SHIFT LEVER.
6. TIG HTEN THE THREE CLAMPING SCREWS.
7. RECONNECT THE TRANSMISSION RODS
NOTE: IF NO PROBLEM W ITH STEERING COLUMN
DRAG IS IN V O L V E D , THIS ADJUSTMENT CAN
BE MADE BY DISCONNECTING ONLY THE
1ST. REV. TRANSMISSION ROD AND O M ITTING
STEP 2.
,-n
-.
<
10.
Remove the steering shaft assembly from the upper
end of the column.
LIGHT T R U C K SE R V IC E M A N U A L
3B4-30
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
16.
17.
STEERING C O L U M N S
S T E E R IN G C O L U M N
B E A R IN G ASM
PIN , Release Lever
S P R IN G , Release Lever
S P R IN G , Shoe
PIN , Pivot
P IN , Dowel
S H A F T , Drive
SHO E, Steering Wheel Lock
SHO E, Steering Wheel Lock
S P R IN G , Lock Bolt
B O L T, Lock
B E A R IN G ASM
SCREW , Oval Head Cross Recess
R A CE, Inner
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
38.
39.
40.
41.
43.
44.
45.
21.
22.
23.
24.
46.
47.
48.
49.
25. R IN G , Retaining
50.
S P R IN G , Upper Bearing
P R O T E C T O R , Wiring
C O V E R , Lock Housing (Painted)
S H IE L D , T ilt Lever Opening
R E T A IN E R , Spring
SP R IN G , Wheel T ilt
G U ID E , Spring
SCREW , Hex. Washer Head
R IN G , Retaining
SEC TO R , Switch Actuator
H O U S IN G , Steering Column
S P R IN G , Rack Preload
R A C K , Switch Actuator
L E V E R , Shoe Release
A C T U A T O R A SM , Ignition Switch
S P R IN G , Shift Lever
W A S H E R , Wave
P L A T E , Lock
W A S H E R , Thrust
R IN G , S hift Tube Retaining
SCREW, Oval Head Cross Recess
G A T E , Shift Lever
SUPPO RT, Strg. Column Housing
65.
66.
77.
84.
85.
86.
87.
A D A P T E R , Lower Bearing
R E T A IN E R
SCREW, Flat Head
S H R O U D , Gearshift Bowl
BOW L, Gearshift Lever
LOCK C Y L IN D E R SET, Strg Column
SCREW, Lock Retaining
LIGHT T R U C K SE R V IC E M A N U A L
STEERING C O L U M N S
1.
2.
3.
4.
5.
6.
7.
8.
B E A R IN G ASM
PIN , Release Lever
S P R IN G , Release Lever
S P R IN G , Shoe
P IN , Pivot
PIN , Dowel
S H A F T , Drive
SHOE, Steering Wheel Lock
9. SHO E, Steering Wheel Lock
10. SPR IN G , Lock Bolt
11. B O LT, Lock
12. B E A R IN G ASM
S H IE L D , T ilt Lever Opening
C O V E R , Lock Housing
SCREW , Oval Head Cross Recess
R A C E, Inner
19. SE A T , Upper Bearing Inner Race
20. S W ITC H ASM , Turn Signal
13.
14.
17.
18.
R E T A IN E R
R IN G , Retainer
S P R IN G , Upper Bearing
P R O T E C T O R , Wiring
R E T A IN E R , Spring
S P R IN G , Wheel T ilt
G U ID E , Spring
SCREW, Hex. Washer Head
SEC TO R , Switch Actuator
PIN , Pivot
H O U S IN G , Steering Column
S P R IN G , Rack Preload
R A C K , Switch Actuator
L E V E R , Shoe Release
42. A C T U A T O R ASM , Switch
43. S H R O U D , Column Housing
44. S PR IN G , Key Release
26.
27.
28.
29.
30.
31.
32.
33.
35.
36.
37.
39.
40.
41.
3B4-31
LIGHT T R U C K SE R V IC E M A N U A L
3B4-32
STEERING C O L U M N S
LIGHT TR U C K SE R V IC E M A N U A L
STEERING C O L U M N S
3B4-33
1.
If the bearing housing was disassembled, repeat the
2.
Install the shift lever spring into the housing by
following steps:
windng
it
up
with pliers and pushing it into the housing.
a. Press the bearings into the housing, if removed,
On
floor
shift
models,
install the plunger, slide the gearshift
using a suitable size socket. Be careful not to dam age the
lever housing onto the m ast jacket.
housing or bearing during installation.
b. Install the lock shoe springs, lock shoes and shoe pin
in the housing. Use an approxim ate .180" rod to line up the
SHIFT BOWL
J 2 3 0 7 3 -3
J 23073 4
W AVEn
W ASH ER
LO C K
PLATE
J 23 07 3-1
J 2 3 0 7 3 -2
FLAT
W ASHER
UPPER SHIFT TUBE
LIGHT TRU C K SE R V IC E M A N U A L
3B4-34
STEERING C O L U M N S
STEERING C O L U M N S
3B4-35
nuts.
CAPTURING
STRAP
COUPLING TO
STEERING SHAFT
FLANGE BOLTS
LIGHT T R U C K SE R V IC E M A N U A L
3B4-36
STEERING C O L U M N S
BEARING
Installation
NOTICE:
may cause
reassembled.
5.
sticky
or
binding
bearings
when
Assembly
NOTICE:
STEERING C O L U M N S
3B4-37
Installation
3B4-38
STEERING C O L U M N S
1.
Replace all com ponent parts in reverse order of TILT COLUMN BEARING HOUSING ASSEMBLY
rem oval m aking sure th at directional switch is in neutral
- G AND P SERIES
position before installing steering wheel. Torque steering
Removal (Column in Vehicle)
wheel nut to specifications.
1. D isconnect the battery ground cable.
Tilt Column
2. Remove the steering wheel as outlined under
The upper bearings on the tilt colum n are spun into the
"Steering Wheel - Removal".
bearing housing assembly. I f the bearings indicate need of
3. Remove the directional signal switch as outlined
replacement, the entire bearing housing m ust be replaced.
under "D irectional Signal Switch - Rem oval".
See "Tilt Steering C olum n - D isassembly and Assembly" for
4. Column Shift Models - Using a suitable size
the correct replacem ent procedure.
punch, drive out the shift lever pivot pin and remove the
shift lever.
STEERING COLUMN LOWER BEARING P
5. Install the tilt release lever and place the column in
SERIES
the full "up" position. Remove the tilt lever spring and
Removal
retainer using a screwdriver that just fits into the slot
1.
Remove the interm ediate steering shaft and opening. Insert the screw driver into the slot, push in
universal jo in t assembly as outlined earlier in this section.
approxim ately 3/16", rotate clockwise approxim ately 1/8
Remove the preload spring clam p and spring from the end
tu rn until the retainer ears align with the grooves in the
o f the steering shaft.
housing and remove the retainer and spring.
LIGHT T R U C K SE R V IC E M A N U A L
STEERING C O L U M N S
3B4-39
3B4-40
STEERING C O L U M N S
DIRECTIONAL
SIGNAL SWITCH
as outlined
under
Removal
1. Remove the steering wheel as outlined under
"Steering W heel - Rem oval".
2. Rem ove the directional signal switch cancelling cam
and spring.
3. Rem ove the colum n to instrum ent panel trim plate
(if so equipped).
4. D isconnect the directional signal switch wiring
harness at the half-m oon connector.
J -2 2 7 0 8
LIGHT T R U C K SE R V IC E M A N U A L
STEERING C O L U M N S
3B4-41
out the lower end of the shift lever housing and under the
dash seal.
2. Place the directional signal switch in position and
install the three m ounting screws; torque to 25 lbs. in. after
screw head has been firmly seated.
3. Tilt Columns Onlya. Align the openings in the directional signal switch
cover with the proper lever positions and tap the cover into
place using a plastic ham m er.
b. Install the tilt release lever.
c. A utom atic Transm ission M odel - Install the
P R N D L dial, pointer, dial illum ination bulb and cap.
4. Install the directional signal switch lever and hazard
warning knob.
5. Bend the wire retaining tabs slightly outw ard on
each wire in the wiring harness as shown in Figure 3B4-71;
this will provide proper retention of the wire in the half
moon connector.
10.
Remove the three directional signal switch
6. Install each wire in its m arked location in the half
m ounting screws and then carefully remove the switch
moon connector. Push in until square p art of clip is flush
assembly from the colum n while guiding the wiring harness
with the bottom side of the connector. Connect the
through the opening in the shift lever housing.
directional signal switch wiring harness.
Installation
NOTICE:
3B4-42
STEERING C O L U M N S
Flexible Coupling
.2 5 0 /.3 7 5 .
4.
A: \
1.
2.
3.
LIG HT T R U C K SE R V IC E M A N U A L
STEERING C OLUM NS
3B4-43
1.
13.
25.
2.
Shiff Housing.Sushing
14.
26.
3.
Bushing Seat
15.
27.
4.
Mast Jacket
28.
29.
5. Column Cover
6.
18.
7.
19.
30.
31.
20.
32.
R u b b e rin g
21.
N u t and Lockwasher
33.
22.
Steering Shaft N u t
34.
1 1. N u t and Lockwasher
23.
24.
Lockwasher
Torn Signal C a n cellin g Cam
35.
36.
Shift Lever
the colum n.
10. Separate the directional signal switch, switch
control support assembly, directional signal housing and
shift lever housing (or housing extension) assemblies.
11. Press the steering shaft upper bearing out of the
switch contact support.
12. Remove the shift lever housing (or extension
housing) seat and bushing from the upper end of the
column.
13. Remove the bolt and screws from the adjusting ring
clamp and remove the clamp, adjusting ring and lower
bearing. Press the lower bearing out o f the adjusting ring.
14. 3-Speed C olum ns - Remove 1st-reverse shift lever
and lever spacer.
A utom atic C olum ns - Remove the selector plate
clam ping ring screws (3).
15. Place the colum n upright on the floor, supporting
it with two pieces o f wood. Place a block of wood on the
upper end o f the shift tube. Press down on the shift lever
with foot while tapping on the wood block to w ithdraw the
tube from the colum n jacket.
3B4-44
S TEE RI NG C O L U M N S
W hen
installation
grease.
1.
instrum ent
COVER
SHAFT ASSY.
----- RACE
WEDGE
SHAFT
RACE
SCREW (3)
SPRING
SWITCH ASSY.
PIN DOWEL
'
/
SHOEH O U S IN G ----- HO USING
/
ASSY.
BEARING \
BUMPER (3)
SHAFT
ASSY. STEERING
BEARING ASSY
\
RETAINER _
SPHERE
CENTERING (2)
SHAFT
JACKET
ASSY.-
JACKET
PROTECTOR
WIRE
SUPPORT
ASSY.
SPRING ( 2 ) - . \
Column-G
SPRING RELEASE,
PIN RELEASE - o \
SHOE RELEASE----- *
BEARING ASSY.
^
YOKE
INSTRU. PANEL
OPENING C O V E R -,
U * * \
SUPPORT
( 2 ) P,N PIVOT
TUBE
ASSY. SHIFT
(2 ) ^
BOWL ASSY.
SPRING TILT
SCREW
DASH SEAL
SCREW (4)
SPRING
CLIP
JACKET DASH
SEAL RETAINER
'-PLATE
& P
RETAINER
THRUST WASHER
\
PLATE LOCK
BOWL
"* LEVER
ADAPTER
RETAINER
BEARING
STEERING COLUMNS
WAVE WASHER
3B4-45
3B4-46
STEERING C O L U M N S
STEERING SHAFT
BEARING LO CKNUT
TILT LEVER
SPR IN G RETAINER
LIGHT TR U C K SE R V IC E M A N U A L
STEERING C O L U M N S
3B4-47
1 /1 6 4 5 CHA M FER
R E M O VE DOTTED
P O R T IO N
13. Place the housing in the full "up" position and then
install tilt spring and retainer (tapered end of spring first).
Push into the housing approxim ately 3/16" and rotate
counter clockwise 1/8 turn.
14. Lubricate and install the upper bearing upper race,
race seat and locknut. Tighten the locknut (using Socket
J-22549) to remove the lash and then further tighten 1/16
to 1/8 of a turn (colum n m ust be in straight ahead position).
15. Remove the tilt release lever.
16. Install the directional signal switch as outlined
under "D irectional Signal Sw itch-Installation".
17. C olum n Shift M odels - Install the shift lever and
pivot pin.
18. Install the neutral-safety or back-up lam p switch.
19. Remove the colum n from the bench vise.
SLOT IN
SHIFT TUBE
LIGHT T R U C K SE R V IC E M A N U A L
3B4-48
STEERING C O L U M N S
COLUMN INSTALLATION
Mandatory Installation Sequence G Series
NOTICE: See N O T IC E on page 1 o f this section
regarding the fasteners referred to in steps 3 and 10.
1. A djust the colum n lower bearing preload by
applying a force on the steering wheel end of the steering
shaft (A). Position the spring and clamp to m aintain the
dimension
as detailed
under
"M aintenance
and
A djustm ents.
2. Install the plastic spacers onto the flexible coupling
alignm ent pins.
3. From inside the vehicle, carefully insert the lower
end of the colum n through the toe pan opening guiding the
steering shaft flange onto the flexible coupling. Install and
torque the glange to coupling bolts.
4. Locate the index slot in the colum n jacket w ith the
protrusion on the clutch and brake pedal support.
STEERING C O L U M N S
3B4-49
2.
a fte r assembly.
harshness.
4.
M ast Jacket | K |
9.
harness.
LIGHT TR U C K SE R V IC E M A N U A L
3B4-50
STEERING C O L U M N S
1.
3.
LIGHT T R U C K SE R V IC E M A N U A L
STEERING C O L U M N S
3B4-51
SPECIFICATIONS
STEERING GEAR RATIOS
Power
Manual
V e h icle
Ge a r
R a tio
O v e r a ll
R a tio
Ge a r
R a tio
O v e r a ll
R a tio
G 10-20
24:1
29.4:1
to
36.7:1
14:1
21.4:1
to
26.7:1
G30
24:1
29.4:1
to
36.4:1
14:1
21.4:1
to
26.5:1
P20-30
17.5:1
21.2:1
to
25.7:1
M otor Home
14:1
16.0:1
to
21.9:1
C10
24:1
29.1:1
to
37.0:1
16:1
to
13:1
16.9:1
to
20.2:1
C20-30
24:1
29.4:1
to
36.3:1
16:1
to
13:1
17.2:1
to
20.6:1
16:1
to
13:1
13.2:1
to
17.2:1
K 10-20
A ll C-G
V e h ic le
C10-30
T hrust Bearing
Preload
5 to 8
lbs. in.
Adjuster Plug
Lock N ut
85 lbs. ft.
Over Center
Preload
4 to 10
lbs. in .*
Over Center
Lock N ut
25 lbs. ft.
Total Steering
Gear Preload
18 lbs. in.
Max.
G 10-20-30
w /o H ydroboost
G30
w ith Hydroboost
P10-30
Fig. 3B4~Specs
LIGHT TR U C K SE R V IC E M A N U A L
3B4-52
STEERING C O L U M N S
SPECIAL TOOLS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
J-6632
J-5504
J-23073
J-23072
J 5176
J-5822
J-8433
J-21854
J-23653
J-5421
J-5860
J-21239
J-2927
J 1614
J-7539
J-7624
J-4245
J-22670
Pitman A rm Puller
Pitman A rm Puller
Shift Tube Installer
Shift Tube Remover
Oil Pressure Gauge
W ormshaft Bearing Cup Remover
Pump Pulley Remover (Cast Pulley)
C olum n Pivot Pin Remover
Lock Plate Compressor
Thermometer
Torque Wrench Adapter
Pump Pulley Remover (Stamper Pulley)
Steering Wheel Puller
Sector Shaft Bushing Remover
Ball Retainer
Spanner Wrench
#23 Internal Pliers
Pump Shaft Seal Installer
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
J-6222
J-23600
J-8947
J-5755
J 2619
J-8092
J-6278
J-6278-2
J-7079-2
J-8524-1
J-8524-2
J-6219
J-22407
J-8937
J 6217
J-23980
STEERING C O L U M N S
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
J-6632
J-5504
J-5176
J-5822
J-5860
J-22670
J-6222
J-9226
J-7576
J-21239
J-2927
J-1614
J-7539
J-7624
J-4245
J-23600
J-5755
J-2619
Pitman A rm Puller
Pitman A rm Puller
Pressure Gauge
W orm shaft Bearing Cup Puller
Torque Wrench Adapter
Pump S haft Seal Installer
Shaft Seal P rotector
Pitman Shaft Bushing Replacer
Rack-Piston Seal Compressor
Pump Pulley Remover
Steering Wheel Puller
Sector Shaft Bushing Remover
Ball Retainer
Spanner Wrench
#23 Internal Pliers
Belt Tension Gauge
Wormshaft Bearing Cup Installer
Slide Hammer
J-6278
J-6278-2
J-7079-2
J-8524-1
J-8524-2
J-6219
J-6217
J-5421
J-22407
J-22727
J-22708
J-22573
J-22599
J-21854
J-22551
J-22549
3B4-53
LIGHT T R U C K SE R V IC E M A N U A L
; r ?
-f i W & K
5 3 '
FRONT SUSPENSION
3C-1
SECTION 3C
FRONT SUSPENSION
The following notice applies to one or more steps in the assembly
procedure of components in this portion of the m anual as indicated at
appropriate locations by the terminology "See N otice on page 1 of this
section".
N O TIC E This fastener is an im portant attaching part in th at it could
affect the perform ance of vital components and systems, an d /o r could result
in m ajor repair expense. It must be replaced with one of the same part
num ber or with an equivalent part if replacem ent becomes necessary. Do not
use a replacem ent part of lesser quality or substitute design. Torque values
m ust be used as specified during reassembly to assure proper retention of this
part.
3C-16
3C-16
3C-17
3C-18
3C-20
3C-21
3C-22
3C-40
3C-41
3C-2
FRONT SUSPENSION
GENERAL DESCRIPTION
C-G-P Series
The C -G -P Series trucks incorporate an independent
coil spring front suspension system, as shown in Figures 3C1 and 3C-2. The control arm s are of unequal length (S.L.A .
Type).
This suspension system consists of upper and lower
control arm s pivoting on steel threaded or rubber bushings
on upper and lower control arm shafts. The lower control
arm s are attached to the crossm em ber. The upper control
arm s are attached to a fram e bracket. These control arm s
are connected to the steering knuckle through pivoting ball
joints.
A coil spring is located between the lower control arm
and a formed seat in the suspension crossmember, thus the
lower control arm is the load carrying member. Double
acting shock absorbers are also attached to the lower control
arm s and connect with the fram e to the rear on the upper
end. The front wheel bearings are tapered roller type and
are used on all models.
FRONT SUSPENSION
3C-3
3C-4
FRONT SUSPENSION
DIAGNOSIS
SHOCK ABSORBER DIAGNOSIS
ON VEHICLE CHECKS
(Follow the Procedures O utlined Below in the O rder
Indicated).
FRONT SUSPENSION
3C-5
..........
HARD STEERING
Probable Remedy
Probable Cause
a.
a.
b.
b.
c.
c.
d.
d.
e.
e.
a.
L ubricate at p ro p e r intervals
Inflate tires to the p ro p e r re co m m e n d e d pressure
b.
b.
c.
c.
d.
d.
e.
e.
f.
Broken springs
f.
Replace springs
g-
g.
h.
a.
a.
b.
b.
c.
c.
d.
d.
e.
e.
a.
b.
b.
c.
c.
Replace spring
d.
d.
a.
b.
b.
Overhaul Gear
(Looseness) and (c) M anually O perating Shocks to Determine if Shocks are W eak, Leaking H ydraulic Fluid, an d/or
if Shocks have an Internal Noise Condition.
3C-6
FRONT SUSPENSION
a.
Probable Remedy
a.
Lubricate at r e c o m m e n d e d intervals
h.
b.
c.
c.
Replace bushings
d.
d.
c.
e.
f.
f.
g-
fi
h.
ll.
Reposition
i.
i.
a.
a.
Balance wheels
b.
b.
Replace tire
c.
Blister o r b u m p on tire
c.
Replace tire
d.
Im p ro p er sh ock a b so rb er action
d.
WHEEL TRAMP
a.
b.
b.
Adjust toe-in
c.
e.
Balance wheels
d.
Hard Driving
d.
Instruct driver
c.
e.
Instruct driver
SCUFFED TIRES
a.
Toe-in incorrect
a.
b.
b.
Advise driver
e.
c.
d.
d.
Replace arm
' >'
vxfc*
ftt : * "
CUPPED TIRES
a.
a.
b.
b.
c.
c.
d.
d.
c.
e.
Bounce Test
FRONT SUSPENSION
3C-7
Probable Remedy
a.
a.
Lubricate at re co m m e n d e d intervals
b.
b.
c.
c.
Replace bushings
d.
d.
0.
e.
f.
f.
(T
P-
h.
ll.
R eposition
i.
i.
W HEEL TRAM P
a.
a.
Balance wheels
b.
b.
Replace tire
c.
Blister or b u m p on tire
c.
Replace tire
d.
d.
a.
b.
Im p ro p er toe-in
b.
Adjust toe-in
c.
c.
Balance wheels
d.
Hard Driving
d.
Instruct driver
e.
e.
Instruct driver
SCU FFED T IR E S
a.
Toe-in incorrect
a.
b.
b.
Advise driver
e.
c.
d.
d.
Replace arm
CUPPED T IR E S
a.
a.
b.
b.
Replace ball jo in ts
c.
c.
d.
c.
e.
(4 ^ u m p stops missing
3C-8
FRONT SUSPENSION
FRONT SUSPENSION
3C-9
BENCH CHECKS
The bench checks are recommended if the proper type
hoist is not available to perform the "on vehicle" tests, or if
th ere is still some doubt as to w hether the shocks are
defective. In addition, the bench test allows a more thorough
visual inspection.
Bench check procedures are discussed for three general
types of shocks.
3C-10
FRONT SUSPENSION
TYPICAL REAR SH O C K
BOTTOM'
MOUNT
ROD EXTENDED
(REBOU ND)x
r\
SHOCKS
COLLAPSED
ROD EXTENOED
(REBOUND) '
TOP END
DOWN
INVERT.
THEN COLLAPSE
SHOCK
COLLAPSED
BOTTOM
MOUNT
fi
T~m
TOP END
DOWN
INVERT, THEN COLLAPSE
PLIACELL OR GENETRON
Pliacell and G enetron are some of the trade nam es used
to indicate a gas-filled cell in the shock reservoir. The
reservoirs of Pliacell and G en etro n shocks are sm ooth,
com pared to the spiral groove type. The cell takes the place
of air in the reservoir. Thus, aeration or foaming of the fluid
is elim inated, as air and fluid cannot mix.
Due to this featu re, these shocks should be bench
checked in an inverted position (top end down). If, when
stroked, a lag is noticed, it m eans the gas-filled cell has been
ruptured, and the shock should be replaced. If no lag is
noticed, the rem ainder of the bench check is the same as
given in the Spiral Groove Reservoir, Section 1, Bench
Check Procedure.
FRONT SUSPENSION
3C-11
DIAGNOSIS
EXCESS NO ISE C O M P L A IN T
D IA G N O S T IC PRO CEDURE
Road Test
1.
2.
3.
4.
5.
5.
Engine or
Exhaust
Noises
1.
2.
3.
4.
Drive slightly above speed where noise occurs, place transmission in neutral
Let engine speed drop to idle
Stop car
Run engine at various speeds
Test for
Wheel Bearing
Noise
1.
2.
3.
4.
Test for
Differential
Bearing Noise
1.
2.
3.
4.
1.
2.
3.
4.
Tire Noises
Test for
Pinion Bearing
Noise
1.
2.
3.
4.
5.
6.
7.
3C-12
FRONT SUSPENSION
GOOD BEARING
BENT CAGE
CAGE D AM AG E
DUE TO
H A N D L IN G OR TOOL USAGE.
BENT CAGE
IMPROPER
REPLACE BEARING.
G A LLIN G
M E T A L SMEARS ON R O L L E R ENDS DUE
TO O V E R H E A T , L U B R IC A N T F A IL U R E OR
OVERLOAD.
REPLACE BE ARING - CHECK SEALS A N D
CHECK FOR PROPER L U B R IC A T IO N .
M IS A L IG N M E N T
OUTER RAC E M IS A L IG N M E N T DUE TO
FOREIGN OBJECT.
CLEA N R E L A T E D PARTS A N D REPLACE
BE ARING. M A K E
SURE RACES ARE
PROPERLY SEATED.
IMPROPER
REPLACE BEARIN G.
ETCHING
IN D EN TA TIO N S
FA TIG U E SPALLING
METAL
OF
SURFACE
SURFACE DEPRESSIONS ON RACE AND F L A K I N G
RO LLERS CAUSED BY H AR D PA RTICLES RESUL TING FROM F ATIG U E .
OF FOREIGN M A T E R I A L .
CLEA N A L L
REPLACE
BE ARING
CLEAN A L L PARTS A N D HOUSINGS, R E L A TE D PARTS.
CHECK SEALS A N D REPLACE BE ARINGS
IF ROUGH OR NOISY.
CAGE DAM AG E
DUE TO
H A N D L IN G OR TOO L USAGE.
FRONT SUSPENSION
3C-13
B R IN ELLING
CAGE WEAR
SMEARS
SMEARING OF M E T A L DUE TO SLIPPAGE,
SLIPPAGE CAN BE CAUSED BY POOR
F IT S ,
L U B R IC A T IO N , O V E R H E A T IN G ,
O VE RLO ADS OR H A N D L IN G DA MAGE.
REPLACE BEARINGS, CLEA N R EL A TE D
PARTS AND CHECK FOR PROPER FIT
AND LUBRICA TIO N.
REPLACE
SHAFT
IF
RO LLERS
FRETTAGE
CORROSION
SET
UP
BY
SMALL
R E L A T IV E M O VEM ENT OF PARTS WITH
NO L U BR IC A TIO N .
REPLACE BE ARIN G. CLEAN R E L A TE D
PARTS. CHECK SEALS A N D CHECK FOR
PROPER L U BR IC A TIO N .
DAM AG E D.
3C-14
FRONT SUSPENSION
2.
3.
4.
Inspection
5.
Repairs
See N O T IC E on page
regarding the fasteners referred to in
1. C lean off any grease in th e hub
thoroughly clean out any grease in
NO TICE:
1 of this section
steps 8 and 9.
and spindle and
the bearings. Use
m an u a }
6.
7. Install a new grease seal using a flat plate until the seal
is flush with the hub. L ubricate the seal lip with a thin
layer of grease.
8. Carefully install the hub and rotor assembly. Place the
outer bearing cone and roller assembly in the outer
bearing cup. Install the washer and nut and initially
tighten the nut to 12 ft. lbs. while turning the wheel
assembly forward by hand. Put an additional quantity
of grease outboard the bearing. This provides extra
grease availability to the bearing.
9. Final wheel bearing adjustm ent should be perform ed as
previously outlined.
FRONT SUSPENSION
SHOCK ABSORBER
COIL SPRING
Installation
Place shock absorber into position over mounting bolts
or into mounting brackets. Install eye bolts and nuts and
torque as shown in Specifications Section. Lower vehicle to
floor.
STABILIZER BAR
Removal (Fig. 3C-16)
1. Raise vehicle on hoist and remove nuts and bolts
attaching stabilizer brackets and bushings at frame
location.
2. Remove brackets and bushings at lower control arms
and remove stabilizer from vehicle.
Installation
Inspection
Inspect rubber bushings for excessive wear or agingreplace where necessary. Use rubber lubricant when install
ing bushings over stabilizer bar.
1.
Installation
NOTICE: See N O T I C E on page 1 of this section
3C-15
2.
3.
4.
5.
6.
3C-16
FRONT SUSPENSION
Installation
NOTICE: See N O T I C E on page 1 of this section
regarding the fasteners referred to in steps 3, 5 and 6.
FRONT SUSPENSION
3C-17
J2 4 4 35 -7
J24435-1
2. Slide new seal on each end of shaft and insert shaft into
control arm.
3. Start new bushings on shaft and into control arm.
Adjust shaft until it is centered in control arm, then
turn bushings in and torque to specifications. Check
shaft for free rotation. Figure 3C-20 shows correct final
positioning of shaft.
Installation
NOTICE: See N O T I C E on page 1 of this section
regarding the fasteners referred to in steps 4 and 5.
1. Install shaft to control arm and install end nuts. Do not
torque nuts at this time.
2. Raise jack and position shaft into crossmember saddle.
Be sure to index hole in shaft to mate with bolt head in
saddle.
J 2 4 4 3 5 -7
J2 4 4 3 5 -4
J 2 4 4 3 5 -5
(HIDDEN)
3C-18
FRONT SUSPENSION
FRONT SUSPENSION
3C-19
Installation
NOTICE: See N O T I C E on page 1 of this section
regarding the fasteners referred to in step 5.
1. Install new bushings as shown in Figure 3C-26 using
spacer J-24435-6, installer J-24435-4 and " C " clamp
J-24435-7.
2. Turn clamp in until bushing seats firmly.
Be sure outer tube hole is to the front or forwards to the
staked bushing.
3C-20
FRONT SUSPENSION
R E M O VE
UPPER
R EM O VE
LO W ER
HE A V Y
FLAT
W ASHER
J 2 3 7 4 2 ,
J 2 3 7 4 2
Upper-Removal
1. Raise vehicle on hoist. If a frame hoist is used, it will be
necessary to support the lower control arm with a floor
jack.
2. Remove cotter pin from upper ball stud and loosen stud
nut (two turns) but do not remove nut.
3. Install J-23742 between the ball studs as shown in
Figure 3C-27.
It is necessary to remove the brake caliper assembly
and wire it to the frame to gain clearance for tool
J-23742. See section 5 for the proper procedure.
4. Be sure lower control arm is supported as pointed out in
step 1. Extend bolt from Tool J-23742 to loosen ball
stud in steering knuckle. When stud is loose, remove
tool and stud nut.
5. Center punch rivet heads and drill out rivets.
6. Remove the ball joint assembly.
Lower
Lower ball joints are a loose fit when not connected to
the steering knuckle. W ear may be checked without disas
sembling the ball stud, as follows:
1. Support weight of control arms at wheel hub and drum.
2. Accurately measure distance between tip of ball stud
and tip of grease fitting below ball joint.
3. Move support to control arm to allow wheel hub and
drum to hang free. Measure distance as in Step 2. If the
difference in measurements exceeds 2.38 mm (.094"
(3 /3 2 " ) for all models, ball joint is worn and should be
replaced (Fig. 3C-29).
Lower-Removal
1. Raise vehicle on a hoist. If a frame hoist is used it will
be necessary to support the lower control arm with a
floor stand.
2. Remove the tire and wheel assembly.
3. Remove the lower stud cotter pin and loosen (two
turns) but do not remove the stud nut.
Installation
NOTICE: See N O T I C E on page 1 of this section
regarding the fasteners referred to in steps 1, 3 and 6.
FRONT SUSPENSION
5).
5. Install ball stud nut and torque as follows. All Series,
110 - 140 N-m (80-100 ft. lbs.) plus additional torque
to align cotter pin hole not to exceed 175 N-m (130 ft.
lbs.) maximum. Never back off to align cotter pin.
6. Install a lube fitting and lube the joint.
7. Install tire and wheel assembly and lower vehicle to
floor.
3C-21
STEERING KNUCKLE
It is recommended that vehicle be raised and supported
as on a twin-post hoist so that the front coil spring remains
compressed, yet the wheel and steering knuckle assembly
remain accessible. If a frame hoist is used, support lower
control arm with an adjustable jackstand to safely retain
spring in its curb height position.
Removal
1. Raise vehicle on hoist and support lower control arm as
noted above.
2. Remove wheel and tire assembly.
3. Remove caliper as outlined under "Front Wheel Hub Removal".
4. Remove disc splash shield bolts securing the shield to
the steering knuckle. Remove Shield.
5. Refer to Section 3B-Steering for service removal
operations.
6. Remove upper and lower ball stud cotter pins and
loosen ball stud nuts. Free steering knuckle from ball
studs by installing Special Tool J-23742. Remove ball
stud nuts and withdraw steering knuckle.
Installation
NOTICE: See N O T I C E on page 1 of this section
regarding the fasteners referred to in steps 2, 3 ,4 and 5.
1. Place steering knuckle in position and insert upper and
lower ball studs into knuckle bosses.
Steering knuckle hole, ball stud and nut should be free
of dirt and grease before tightening nut.
2. Install ball stud nuts and tighten nut to specifications.
(See Specification Section.)
If necessary, tighten one more notch to insert cotter
pins. Do not loosen nut to insert cotter pin. Refer to Ball
Joint text for proper nut installation sequence.
3. Reverse rem aining removal procedure, and tighten
splash shield m ounting bolt. Tighten two caliper
assembly mounting bolts to 48 N-m (35 ft. lbs.) torque.
4. Adjust wheel bearings as outlined under Front Wheel
Bearing Adjustment.
5. Tighten wheel nuts to 100 N-m (75 ft. lbs.).
J-9519-2
(HIDDEN)
J-9519-29
J -9 5 19-16
J -9 5 19-1 0
J -9 5 19-10
BALL JOINT
REMOVAL
BALL JOINT
INSTALLATION
3C-22
FRONT SUSPENSION
G-MODEL
Fig. 3C-32--Suspension Unit to Frame
LIG H T T R U C K SE RV IC E M A N U A L
11.
12.
13.
14.
15.
16.
FRONT SUSPENSION
Installation
1. Raise hoist to align new suspension unit with frame rail
holes.
3C-23
3C -2 3
3 C -2 6
3 C -2 6
3 C -2 6
3 C -2 6
3C -27
3C -27
3C -3 0
S p in d le ...........................................................................
Steering Knuckle (K10, K 2 0 )..................................
Steering Knuckle (K 3 0 ) .............................................
Shock A b s o rb e r............................................................
Stabilizer Bar................................................................
Leaf Sp rin g ....................................................................
Specifications.....................................................................
Special Tools......................................................................
3 C -3 2
3C -3 3
3 C -3 6
3C -3 8
3C-38
3C-39
3 C -4 0
3C-41
GENERAL DESCRIPTION
Front drive axles used on K10, K20, and K30 trucks
have several styles of wheel-end construction.
Knuckle Attachment
At the wheel ends of the axle tubes, two types of
steering knuckle attachment are used. Figure 3 C -lK (a)
shows the K10 and K20 knuckle attached with ball joints.
Figure 3C -lK (b ) shows the king-pin attachment used in
K30. The tapered upper king pin fits in a tapered nylon
bushing. The lower king pin is part of the bearing cap, and
this king pin rides in a tapered roller bearing.
Hub Design
An automatic locking hub is used on all K10 and K20
models. This system, shown in Figs. 3C -lK (a ) and in 3C3K, automatically engages the hub whenever four-wheel
drive is selected.
A free-wheeling hub is used on all K30 models. This
design is shown in Figs. 3 C -lK (b ) and in 3C-5K. This hub
allows the driver to manually engage or disengage the hub
from the axle shafts.
L IG H T T R U C K SERVICE M AN U AL
3C-24
1.
2.
3.
4.
5.
FRONT SUSPENSION
R E T A IN IN G S C R E W
C O V E R PLATE
COVER
S E A L I N G R IN G
S P R IN G , B E A R IN G
RACE
6\
7 > B E A R IN G A S S E M B L Y
9. W I R E R E T A I N I N G R IN G
10. O U T E R C L U T C H
H O U S IN G
11. S E A L B R I D G E
R E T A IN E R (N O T
SH O W N )
12. R E T A I N I N G R IN G
13. S P R I N G S U P P O R T
W ASHER
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
S P R I N G R E T A IN E R
R E T U R N S P R IN G
S P R I N G R E T A IN E R
CLUTCH G EA R
HUB SLEEVE
C T Y P E R E T A IN IN G
R IN G
C O N IC A L S P R IN G
CAM FOLLOW ER
OUTER CAGE
IN N E R C A G E
S N A P R IN G
BRAKE BAND
DRAG SLEEVE AND
DETENT
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
SPACER
R E T A I N IN G R IN G
LO CK NUT
R E T A I N IN G W A S H E R
A D J U S T IN G N U T
O U T E R -W H E E L
B E A R IN G
IN N E R - W H E E L
B E A R IN G
S P IN D L E
S P IN D L E B E A R IN G
SEAL
H U B - A N D - D IS C
A SSEM BLY
O IL S E A L
SPACER
Fig. 3C-1 K(a)--K10, K20 with Free-Wheeling Hub and Bbll Joints
LIG H T TR U C K SE RV IC E M A N U A L
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
D U ST SEAL
DEFLECTOR
A X LE O U T ER SHAFT
KNUCKLE
A D J U S T IN G S L E E V E
U P P E R B A L L J O IN T
YOKE
L O W E R B A L L J O IN T
R E T A IN IN G R IN G
C A L IP E R S U P P O R T
BRACKET
50. S P I N D L E R E T A I N I N G
NUT
51. S P I N D L E R E T A IN IN G
BO LT
FRONT SUSPENSION
1.
2.
R E T A IN IN G P L A T E
" 0 R IN G
13.
14.
3.
4.
5.
A X L E S H A F T S N A P R IN G
15.
16.
17.
6.
7.
A C T U A T IN G C A M B O D Y
18.
IN T E R N A L S N A P R IN G
19.
8.
O U T E R C L U T C H R E T A I N I N G R IN G
9.
20.
21.
22.
23.
24.
25.
10.
11.
12.
R E T A IN IN G P L A T E B O L T
L O C K -A D J . N U T
P IN - A D J . N U T
A D J U S T IN G N U T
O U T E R W H E E L B E A R IN G
IN N E R W H E E L B E A R IN G
SEAL
H U B -A N D - D IS C A S M
S P IN D L E
S P IN D L E B E A R IN G
SEAL
DEFLECTOR
SPACER
L U B E F IT T IN G
26.
27.
28.
29.
30.
U P P E R B E A R IN G C A P
P R E S S U R E S P R IN G
G ASKET
B U S H IN G , K IN G - P IN
K IN G -P IN
31.
YOKE
32.
33.
34.
G R E A S E R E T A IN E R
35.
36.
37.
38.
39.
3C-25
L O W E R B E A R IN G
SEAL
B E A R IN G C A P
L U B E F IT T IN G
S P IN D L E A T T A C H IN G N U T
S P IN D L E A T T A C H IN G B O L T
LIG H T T R U C K SERVICE M AN U AL
3C-26
FRONT SUSPENSION
BEARING LUBRICATION
Front Wheel Bearings
Spindle Bearings
W henever front wheel bearings are lubricated, the
spindle needle bearings should also be lubricated, with the
same chassis' grease. Under normal conditions, the lubrica
tion interval should be 12,000 miles; off-road use such as in
mud or water will require shorter intervals. The spindle
LIG H T T R U C K SERVICE M A N U A L
FRONT SUSPENSION
3C-27
COMPONENT REPLACEMENT
HUB REPLACEMENT
NOTICE: See N O T I C E on page 1 of this section,
regarding the fasteners in the following procedures for
H ub Replacement.
plastic outer cage, causing the cage to rotate and move to the
disengaged condition. The release spring then moves the
clutch gear out of mesh with the outer clutch housing to
disengage the wheel from the axle shaft.
Preliminary Checking
Before disassembling a unit for complaint of abnormal
noise, read the following:
To obtain all-wheel drive, the transfer case lever must
be placed in (4L) o r (4H), at which time the hub locks
will automatically engage.
To unlock (free wheel) the hubs, shift the transfer case
lever to (2H), th en slowly reverse vehicle direction a p
proxim ately ten feet.
Incom plete shift from 2W D to 4WD, or disengagem ent
o f only one hub lock may cause an abnorm al sound
from the front axle. Shift to 4W D to stop the noise, then
unlock the hubs as described above.
DISASSEMBLE HUB
1. Remove the snap ring ( # 2 8 ) from the groove of the
hub sleeve ( # 1 8 ) .
2. Turn the clutch gear ( # 1 7 ) until it drops into engage
ment with the outer clutch housing ( # 1 0 ) . Lift and
cock the drag sleeve ( # 2 6 ) to unlock the tangs of the
brake band ( # 2 5 ) from the window of the inner cage
( # 2 3 ) and remove drag sleeve and brake assembly.
It is important that the brake band should never be
removed from the drag sleeve. The spring tension of the
brake band can be changed if the coils are overexpanded and this could affect the operation of the hub.
3. Remove the snap ring ( # 2 4 ) from the groove in the
outer clutch housing.
LIG H T T R U C K SERVICE M AN U AL
3C-28
FRONT SUSPENSION
1. M achine Screw
2. Cover Plate
3. Cover
4. Sealing Ring
5. Bearing Race Spring
6 . Bearing Inner Race
7. Bearing
8 . Bearing Retainer Clip
9. W ire Retaining Ring
10. O uter Clutch Housing
1 1. Seal Bridge Retainer
12.
13.
14.
1 5.
16.
17.
18 .
19.
20.
21.
22.
Retaining Ring
Spring Support W asher
Spring Retainer
Return Spring
Spring Retainer
Clutch G ear
Hub Sleeve
"C" Type Retaining Ring
Conical Spring
Cam Follower
O uter Cage
23.
24.
25.
26.
27.
28.
29.
30.
31.
Inner Cage
Snap Ring
Brake Band
Drag Sleeve and Detent
Small Spacer
Retaining Ring
Lock Nut
Drag Sleeve Retainer W asher
Adjusting Nut, W heel Bearing
LIG H T T R U C K SERVICE M A N U A L
FRONT SUSPENSION
SHAPED
CLAMP
"C "
REASSEMBLE HUB
1. Snap the tangs of the cam follower ( # 2 1 ) over the flats
of the clutch gear ( # 1 7 ) .
2. Compress the conical spring ( # 2 0 ) and slide it into
position with the large diameter of the spring located
against the clutch gear.
3. Position the clutch gear assembly over the splines of the
hub sleeve ( ( # 1 8 ) . The teeth of the cam follower
should be located at the end of the hub sleeve which has
no splines. The clutch gear and spring should slide
freely over the splines of the hub sleeve.
4. Assemble the " C " shaped retainer ring ( # 1 9 ) in the
groove of the hub sleeve.
RETAINING RING
3C-29
3C-30
FRONT SUSPENSION
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
LIG H T T R U C K SERVIC E M AN U AL
FREE-WHEELING HUBS
K30 (Fig. 3C-5K)
Hub Removal
1. Turn actuator lever to set hub to "L O C K " position
(Fig. 3C-5K) and raise vehicle on hoist. Rotate tire to
assure that hub lock is engaged.
2. Remove six retaining plate bolts and remove retaining
plate, actuating knob, and " O " ring.
3. Remove internal snap ring, outer clutch retaining ring,
a c tuating cam body, outer clutch gear, and clutch
spring.
4. Relieve pressure on the axle shaft snap ring and remove
snap ring.
5. Remove the inner clutch gear.
6. Remove spring retainer plate.
7. Remove the wheel bearing outer lock nut, lock ring,
and wheel bearing inner adjusting nut using Tool
J-6893 and Adapter J-23446 or Tool J-6893-01.
8. Remove the hub-and-disc assembly, outer wheel bear
ing and the spring retainer plate.
a. Remove the oil seal and inner bearing cone from the
hub using a brass drift and tapping with a hammer.
Discard the oil seal.
b. Remove the inner and outer bearing cups using a
brass drift and hammer.
c. Clean, inspect and lubricate all parts as required.
FRONT SUSPENSION
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
3C-31
3C-32
FRONT SUSPENSION
Installation of Hub
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Installation
1. Install the bronze thrust washer over the axle shaft with
the chamfer toward the slinger and install the spindle
as shown in Figure 3C-8K.
2. Assemble spindle to knuckle. Use new spindle nuts and
torque to 88 N-m (65 lb. ft.).
SPINDLE
Removal
1. Remove the hub-and-disc assembly as outlined earlier.
2. Remove the spindle retaining bolts.
3. Remove the spindle and bronze thrust washer by
tapping the end of the spindle lightly with a soft
hammer to break it loose from the knuckle as shown in
Figure 3C-6K. Replace the thrust washer if excessive
wear has occurred.
L IG H T T R U C K SERVICE M AN U AL
FRONT SUSPENSION
3C-33
KNUCKLE
K10, K20, (WITH BALL JOINTS)
Removal
1. Remove hub and spindle components as outlined
earlier.
2. If the steering arm is to be removed, disconnect the tie
rod.
a. Remove cotter pin.
L IG H T T R U C K SERVIC E M AN U AL
3C-34
FRONT SUSPENSION
J-23454-1
FRONT SUSPENSION
3C-35
J -6 3 8 2 -3 OR
J -2 3 4 5 4 -3
J-2 3 4 4 7
BALL J O IN T
J -2 3 4 5 4 -2
Installation
NOTICE: See N O T I C E on page 1 of this section
regarding the fasteners in the following steps.
1. Position the knuckle and sockets to the yoke. Install
new nuts finger tight to the upper (the nut with the
cotter pin slot) and lower ball socket studs.
2. Push up on the knuckle (to keep the ball socket from
turning in the knuckle) while tightening the lower
socket retaining nut. Torque lower nut to 95 N-m (70
ft. lbs.).
BALL JO IN T
J -2 3 4 5 4 -2
J-6382-3
OR
J-23454-3
J-9519-10
3C-36
FRONT SUSPENSION
4. Torque the upper ball socket nut to 100 ft. lbs. as shown
in Figure 3 C -16K. After torquing the nut, do not loosen
to install cotter pin, apply additional torque, if neces
sary, to line up hole in stud with slot in nut.
5. If the tie rod and steering arm were removed:
a. Assemble the steering arm using the three stud
adapters and three new self-locking nuts. Torque the
nuts to 120 N-m (90 ft. lbs.).
b. Assemble the tie rod to the knuckle arm. Torque the
tie rod nuts to 60 N-m (45 ft. lbs.) and install cotter
pin.
KNUCKLE
K30 (WITH KING PINS)
Removal
1. Remove the hub and spindle as outlined earlier. If
necessary, tap lightly with a rawhide ham mer to free it
from the knuckle. Check bronze spacer located
between axle shaft joint assembly and bearing. If wear
is evident, replace with a new one. See Figure 3C-17K.
L IG H T T R U C K SERVIC E
MANUAL
FRONT SUSPENSION
3C-37
Installation
See the N O T I C E on page 1 of this section
regarding the fasteners in the following steps.
NOTICE:
3C-38
FRONT SUSPENSION
SHOCK ABSORBER
Removal (Fig. 3C-30K)
1. Raise vehicle on hoist.
2. Remove nuts and eye bolts securing upper and lower
shock absorber eyes.
3. W ith draw shock absorber and inspect rubber eye
bushings. If defective, replace shock absorber
assembly.
Installation
Place shock absorber into position over mounting bolts
or into mounting brackets. Install eye bolts and nuts and
torque as shown in Specifications Section. Lower vehicle to
floor.
STABILIZER BAR-TYPICAL
Removal (Fig. 3C-31K)
Fig. 3C-28K--lnstalling Lower Bearing Cap-and-King
Pin
TYPICAL L.&R.H.
VIEW A
SPRING
PLATE
TYPICAL L &R.H.
VIEW B
FRONT SUSPENSION
3C-39
Inspection
Inspect rubber rushings for excessive wear or agingreplace where necessary. Use rubber lubricant when install
ing bushings over stabilizer bar.
Installation
NOTICE: See N O T I C E on page 1 of this section
regarding the fasteners referred to in step 2.
Slit in bar to frame bushings should be facing forward.
1. Place stabilizer in position on frame and install frame
brackets over bushings. Install nuts and bolts loosely.
2. Install brackets over bushings at lower control arm
location. Be sure brackets are positioned properly over
bushings. Torque all nuts and bolts to specifications.
3. Lower vehicle to floor.
Installation
NOTICE: See N O T IC E on page one of this section
regarding the fasteners referred to in steps 5 and 6.
1. Install spring shackle bushings into spring and attach
shackle. Do not tighten bolt.
2. Position spring upper cushion on spring.
3. Insert front of spring into frame and install bolt. Do not
tighten.
4. Install shackle bushings into frame and attach rear
shackle. Do not tighten bolt.
5. Install lower spring pad and spring retainer plate.
Torque bolts to specifications, Fig. 3C-35.
6. Torque front and rear spring eye and shackle bolts to
specifications.
7. Remove stands and lower vehicle to floor.
Bushing Replacement
1. Place spring on press and press out bushing using a
suitable rod, pipe, or tool.
TIG H TE N IN G SEQUENCE
1.
2.
3.
LIG H T T R U C K SE RV IC E M AN U AL
3C-40
FRONT SUSPENSION
SPECIFICATIONS
FRONT SUSPENSION BOLT TORQUE (ft. lbs.) * t
CP-10
CP-20-30
K-AII
G-10-20
85
85
65
85
70
105
70
105
115
New 190
115
**10 0
***8 0
* 50
**9 0
Used 115
New
280
Used 130
* 50
**9 0
Nut, Spindle-to-Knuckle
**9 0
**90
G-30
N ew 190
Used 115
N ew 280
Used 130
**9 0
**9 0
65
65
65
65
90
90
90
90
60
60
60
60
25
Anchor
Plate
130
25
25
25
.55
25
140
140
65
75
60
120 in. lbs.
60
120 in. lbs.
.001-.005
35
.001-.005
35
.001-.010
.001-.005
35
25
65
65
120 in. lbs.
Inner 35
Outer
75
120 in. lbs.
90
50
50
150
25
Suspension Bumper
15
15
25
130
*
**
***
t
tt
Plus additional torque to align cotter pin. Not to exceed 90 ft. lbs. maximum.
Plus additional torque to align cotter pin. Not to exceed 130 ft. lbs. maximum.
Plus additional torque to align cotter pin.
All specifications are given in foot pounds of Torque unless indicated otherwise,
C10, G10-20 Rubber Bushings; C20-30, P10-30 Steel Bushings.
P300 (32), P300 (42) and JF9 100 ft. lbs.
P300 (32) 215 ft. lbs., P300 (42) and JF9 130 ft. lbs.
(K10-20) 205 ft. lbs., (K30) 65 ft. lbs.
Specs Page
LIG H T TR U C K SE R V IC E M AN U AL
15
FRONT SUSPENSION
3C-41
SPECIAL TOOLS
1.
2.
3.
4.
5.
J-8457
J-8458
J-8849
J-9276-2
J-24435-1
thru 7
Bearing
Bearing
Bearing
Bearing
Bushing
C 10, G
Race Installer
Race Installer
Race Installer
Race Installer
Replacement
10-20
6.
7.
8.
9.
10.
11.
J-8092
J-9519-9
J-9519-7
J-9519-10
J-23028-01
J-23742-1
Driver Handle
Ball Joint Installer
Ball Joint Remover
" C " Clamp
Spring Remover
Ball Joint Remover
REAR SUSPENSION
3D-1
SECTION 3D
REAR SUSPENSION
The following notice applies to one or more steps in the assembly
procedure of components in this portion of the manual as indicated at the
appropriate locations by the terminology "See Notice on page 1 of this
Section ".
N OTICE This fastener is an important attaching part in that it could
affect the performance of vital components and systems, and /o r could result
in major repair expense. It must be replaced with one of the same part
number or with an equivalent part if replacement becomes necessary. Do not
use a replacement part of lesser quality or substitute design. Torque values
must be used as specified during reassembly to assure proper retention of this
part.
INDEX
General D escription......................................................................................... ..3D-1
Component Parts R ep lacem en t.......................................................................3D-2
Shock Absorbers..............................................................................................3D-2
Stabilizer S h a f t ............................................................................................. ..3D-3
Leaf Spring Assembly................................................................................. ..3D-4
Specifications...................................................................................................... ..3D-10
GENERAL DESCRIPTION
All 10-30 series vehicles use a leaf spring/solid rear
axle suspension system. Typical systems are illustrated in
Fig. 3D-1, 3D-2 and 3D-3.
LIG H T T R U C K SE R V IC E M AN U AL
3D-2
REAR SUSPENSION
Replacement
Refer to Figs. 3D-4 through 3D-8 for specific vehicle
mounting provisions.
1. Raise vehicle on hoist, and support rear axle.
2. At the upper m ounting location, disconnect shock
absorber by removing nut and washers shown, and bolt
on G-models.
3. At the lower mounting location, remove nut, washers
and bolt as shown.
4. Remove shock absorbers from vehicle.
REAR SUSPENSION
3D-3
STABILIZER SHAFTS
Refer to Fig. 3D-9, 3D-10 and 3D -11 for specific rear
stabilizer shaft mounting on C and P models.
Replacement
1. Raise vehicle on hoist and support rear axle.
2. Remove nut, washer and grommet from link bolt at the
frame side member on each side.
3. W ithdraw link bolt, washers, grommets and spacer.
3D-4
REAR SUSPENSION
SPACER
GROMMET
SHAFT
P300(32)
LINK BOLT
ANCHOR
PLATE
NOTE
T orqu e by running nut to
unthreaded portion of bolt.
Bushing Replacement
1. Place spring on press and press out bushing using a
suitable rod, pipe or tool as shown in Fig. 3D-21.
2. Press in new bushing; assure that tool presses on steel
outer shell of bushing.
R ear Spring, Front Eye-Heavy Duty leaf springs on
C20, CK30, and some P30 trucks use a staked- in-place
flanged front eye bushing. Before this bushing is
pressed out of the spring, the staked locations must be
straightened with a chisel or drift. After a new bushing
is installed, it must be staked in three equally spaced
locations.
LIG H T T R U C K SERVICE M A N U A L
P300(42)
REAR SUSPENSION
3D-5
G 1 0 0 + 2 0 0 ( 0 5 + 0 6 ) ALL
G 3 0 0 ( 0 5 + 0 6 ) ex c G 50
C 3 0 0 (0 5 + 0 6 ) & G 50
Fig. 3D-12--Rear Spring Hangers And Installation-G Models
L IG H T T R U C K SE RV IC E M AN U AL
3D-6
REAR SUSPENSION
SHACKLE REPLACEMENT
1. Raise vehicle on hoist. Place adjustable lifting device
under axle.
2. Remove load from spring by jacking frame.
3. Loosen spring-to-shackle retaining bolt, but do not
remove.
4. Remove shackle-to-frame bracket retaining bolt then
remove shackle bolt from spring eye.
5. Position shackle to spring eye and loosely install
retaining bolt. Do not torque retaining bolt at this time.
6. Position shackle to frame bracket and install retaining
bolt. Arrow stamped on shackle must point forward.
7. Rest vehicle weight on suspension components and
torque both shackle bolt retaining nuts to
specifications.
LIG H T T R U C K SERVICE M A N U A L
REAR SUSPENSION
3D-7
3D-8
REAR SUSPENSION
LIG H T T R U C K SE RV IC E M A N U A L
REAR SUSPENSION
3D-9
L IG H T T R U C K SERVICE M A N U A L
3D-10
REAR SUSPENSION
SPECIFICATIONS
TORQUE SPECIFICATION
C-K
140
G10 120
P10 140
G20 120
P20 140
G30 150
90/135*
110
110
(G316 . . .90)
Rear Shackle Bolt
90/135*
110
110
(G316 . . .90)
Shock Absorber
Upper Attachment
150
75
P10 25
P20 140
P30 50
Lower Attachment
115
75
115
12-17
12-17
12-17
18-22
18-22
18-22
Bearing Support-to-Hanger
20-30
20-30
20-30
Hanger-to-Frame
40-50
20-30
20-30
Propeller Shaft
--Specifications
LIGHT TRUCK SERVICE MANUAL
3E-1
SECTION 3E
INDEX
General Description.............................................................3E-1
Replacement T ire s.............................................................3E-1
Metric T ir e s ....................................................................... .3E-2
Replacement W h e e ls....................................................... .3E-2
Certification L ab el.............................................................3E-3
Service O perations.............................................................. .3E-3
Tire Inspection and R o ta tio n ........................................ .3E-3
Tire Inflation Pressure......................................................3E-4
Correcting Irregular Tire W e a r .....................................3E-7
Wheel Installation .............................................................3E-8
Tire Mounting and D em ounting.................................. .3E-9
Tire R epair......................................................................... .3E-10
Wheel N u t T orqu es......................................................... .3E-10
GENERAL DESCRIPTION
The factory installed tires and wheels are designed to
operate satisfactorily with loads up to and including the full
rated load capacity when inflated to the recommedned
inflation pressures.
Correct tire pressures and driving techniques have an
important influence on tire life. Heavy cornering, exces
sively rapid acceleration, and unnecessary sharp braking
increase tire wear.
REPLACEMENT TIRES
CAUTION:Do not mix different types of tires on the
same vehicle such as radial, bias, and bias-belted
tires except in emergencies, because vehicle
handling may be seriously affected and may
result in loss of control.
Some truck-type tires and most passenger-car-type
radial tires have a T P C Spec. No. (T ire Perform ance
Criteria Specification Num ber) molded into the tire side
wall near the tire size marking. This shows that the tire
meets rigid size and performance standards which were
developed for the vehicle. The TPC Spec. No. assures a
proper combination of endurance, load capacity, handling,
and traction on wet, dry and snow covered surfaces. When
replacing tires with tires having the same TPC Spec. No.,
tires will be compatible with the vehicle. When replacing
tires with those not having a TPC spec, use the same size,
load range, and construction type (bias, bias-belted, or
radial) as the original tires on the vehicle (see the Certifica
tion Label Fig. 3E-3). Use of any other size or type tire may
3E-2
METRIC TIRES
Metric tires are available in two load ranges, Standard
load and Extra load. Figure 3E-1 shows the meaning of the
metric tire format. Most metric tire sizes do not have exact
corresponding alpha tire sizes. For example, a P205/75R15
is not exactly equal in size and load carrying capacity to an
FR78-15. For this reason, replacement tires should be of the
same size, load range, and construction as those originally
on the car. If metric tires must be replaced with other sizes,
such as in the case of snow tires, a tire dealer should be
consulted. Tire companies can best recommend the closest
match of alpha to metric sizes within their own tire lines.
_
...........
ASPECT RATIO
RIM DIAMETER
(INCHES)
[SECTION HEIGHT)
13
(SECTION WIDTH)
14
70
15
SECTION WIDTH
75
(MILLIMETERS)
CONSTRUCTION TYPE
80
185
R - RADIAL
195
B - BIAS - BELTED
205
D - DIAGONAL (BIAS)
ETC.
kPa
psi
kPa
140
20
21
215
220
31
32
22
230
23
24
235
240
33
34
25
26
250
275
36
40
185
190
27
310
45
28
345
50
200
29
380
55
205
30
415
60
145
155
160
165
170
180
C onve rsion:
35
REPLACEMENT WHEELS
Wheels must be replaced if they become damaged (for
example: bent, heavily rusted, leak air) or if wheel nuts often
LIG H T T R U C K SERVIC E M A N U A L
r.
L B /'k i)
GVW R
Cj A W R F R T
4 0 0 0 /1 8 1 4
1 4 0 0 0 /6 3 5 0
T IR E S
R IM S
P S l/k P .
3E-3
10
16
C O LD
DUAL
5X16
5D
5 X 9
/5
3 6 /2 4 8
G AW R RR
10000 4 5 36
10
5 X16
16 6 X 9
4 2 290
51
75
f ON
TH
> E DATE M ANUF AC TU R E
SHO W N A B O V E
I c G Q I 691100001
B U S - N O T S C H O O L BU S
SE E O W NERS M A N U AL F OH A D D IT IO N A L IN FO R M A TIO N
E XAMPL E ONLY
FRONT
FRONT
FRONT
FRONT
4 WHEEL
ROTATION
5 WHEEL
ROTATION
4 WHEEL
ROTATION
5 WHEEL
ROTATION
PREFERRED FOR
RADIAL TIRES
OPTIONAL FOR
RADIAL TIRES *
MANDATORY FOR
BIAS TIRES
SERVICE OPERATIONS
CAUTION:Servicing of tires mounted on multi
piece rims requires proper tools, safety equipment
and specialized training. Severe injuries can result
from improper servicing techniques. It is recom
mended that tires on multi-piece rims be serviced
only by competent personnel with proper equip
ment or by competent truck tire repair shops.
3E-4
INFLATION PRESSURE
The maximum cold inflation pressures for the factory
installed tires are listed on the Certification Label. Tires
must be inflated to these pressures when the G V W R or an
axle G A W R is reached. Improper tire inflation pressures for
the load the vehicle is carrying can adversely affect tire life
and vehicle performance.
For improved ride comfort in vehicles rated at 8600
G V W R , it is permissible to use the lower tire pressure valves
shown on the label located on the rear edge of the drivers
door provided there is a m aximum of 200 lbs. cargo, no slide
in camper, and there are three or less occupants. The lower
G V W R and G A W R (rear) reflect the m axim um load
carrying capacity of the tires at lower pressure.
Tire
Size
Load
Range
30
35
40
65
70
75
T IR E S U SED AS S IN G L E S
YF
YF
9.50-16.5
9.50-16.5
ZX
ZX
ZX
7.00-16
7.50-16
7.50-16
C
C
D
1260
1430
1430
1365
1565
1565
1475
1690
1690
1580
1815
1815
1930
2040
2140
YD
YD
8.75-16.5
8.75-16.5
C
D
1380
1380
1515
1515
1630
1630
1750
1750
1855
1970
2070
D
E
1860
1860
2030
2030
2190
2190
2350
2350
2500
2500
2650
2650
2780
2780
2920
3050
3170
T IR E S U SED AS D U A L S
Code
CF, BU
BT, CK
Size of
Wheel
15 x 7 JJ
15 x 8 JJ
XH
15 x 6 JJ
16.5 x 6.00
YD
CC
15 x 6 JJ
ZY
19.5 x 6.00
BW, ZC 15 x 8 JJ
W heel Limits
Max.
Max.
Load
Press.
(Lb*.)
(PSI)
1670
1910
1670
2680
1670
2540
2030
40
40
55
85
55
80
46
Code
YC
YF
BF
XW
ZT
ZX
YD
Size of
Wheel
16.5 x 6.00
16.5 x 6.75
16 x 6 V2 L
15 x 6 JJ
19.5 x 6.00
16 x 6 KS
16.5 x 6.00
Wheel Limits
Max.
Max.
Load
Press.
(Lbs.)
(PSI)
2350
3170
2780
1910
2780
2440
2680
70
85
85
70
95
75
55
Optional Location
Location For:
Maximum Load
Maximum Pressure
Wheel Code
Wheel Size Stamps
L IG H T T R U C K SERVICE M A N U A L
Wheel
Code
YF
Load
Range
30
35
40
D
E
1860
1860
2030
2030
2190
2190
9.50-16.5
9.50-16.5
YF
2500
2500
2650
2650
65
70
75
2920
3050
3170
2780
2780
Code
Size of
Wheel
CH
ZW. YD
CC
ZV
BW. ZC
15 x 8 JJ
16.5 x 6.00
15 x 6 JJ
19.5x6.00
15 x 8 JJ
Wheel Limits
Max.
Max.
Press.
Load
(PSI)
(Lba.)
40
1760
85
2680
55
1670
80
2540
40
2030
Wheel Limits
Max.
Max.
Press.
Load
(PSI)
(Lbs.)
Code
Size of
Wheel
YC
YC
BF
XX
ZT
zx
16.5 x 6.00
16.5 x 6.75
16 x 6 V2 L
15 x 6 JJ
19.5x6.00
16 x 6 KS
2350
3170
2780
2040
2780
2440
70
85
85
70
95
75
Wheel Code
Wheel Size Stamps
WHEEL USAGE AND TIRE LOAD LIM ITS AT VARIOUS INFLATION PRESSURES*
BIAS TIRES FOR LIG H T TRUCKS
USED AS SINGLES
Wheel Code
Regular
O p tio n a l
YJ
YJ
Tire
Size
8.75-16.5
8.75-16.5
Load
Range
Ply
Rating
30
35
45
50
55
60
D
E
8
10
1570
1570
1720
1720
1850
1850
1990
1990
2110
2110
2240
2240
2350
1620
1710
1800
2350
YH
YH
8.00-16.5
8.00-16.5
6
8
1195
1195
1310
1310
1415
1415
1520
1520
Wheel load limits are shown below. Vehicle loading must be limited such that neither the wheel or tire load limits are exceeded.
W H E E L C O D E A N D L IM IT S
Code
YH
YD, YH
YJ
CD
XW
BX
A LU M .
Size of Wheel
Wheel Limits
Max. Press.
Max. Load
(PSI)
(Lbs.)
15 x 6 JJ
16.5 x 6.00
16.5 x 6.75
15 x 6V2 JJ
15 x 6 Jj
15 x 7 JJ
1585
40
2680
2680
1690
1916
85
85
1690
40
15 x 6 'A JJ
1690
40
40
70
Wheel Code
LIG H T T R U C K SERVICE M A N U A L
65
70
75
2470
2570
2680
3E-5
3E-6
CODE
STAMPING LOCATION
I
FOR RIM SIZE
M A X.
PRESS.
(P S I)
85
1 6 .5 x 6 .0
2680
YC
1 6 .5 x 6 .0
2350
70
YF
1 6 .5 x 6 .7 5
3170
85
BF
16 x 6 .5 0 L
2780
85
ZX
16 x 6 .0 0 KS
2440
75
Y D , YJ
OPTIONAL LOCATION
DUAL WHEELS
M AX.
LOAD
(L B S .)
LOCATION FOR:
/
MAXIMUM^MAXIMUM / WHEEL
LOAD / PRESSURE/ CODE STAMPS
/;
WHEEL USAGE AND TIRE LOAD LIMITS (LBS) AT VA RIO U S INFLATION PRESSURES
PASSENGER TYPE TIRES FOR LIGHT TRUCKS
Wheel
Code
Tire
Size
Load
Range
XW
xw
L78-15
L78-15
26
1590
1590
32
1790
1790
30
1727
1727
28
1663
1663
34
36
38
40
1854
1905
1972
2025
W heel
Code
T ire
Size
Range
30
BF
BF
BF
7 .5 0 -1 6 L T
7 .5 0 -1 6 L T
7 .5 0 -1 6 L T
C
D
E
YC
YC
YF
YF
YF
8 .7 5 - 1 6 .5
8 .7 5 - 1 6 .5
8 .7 5 - 1 6 .5
9 .5 0 - 1 6 .5
9 .5 0 - 1 6 .5
C
D
E
0
E
Load
35
40
45
SO
55
60
65
70
75
1620
1620
1620
1770
1770
1770
1930
1930
1930
2060
2060
2060
2190
2190
2310
2310
2440
2440
2560
2670
2780
1570
1570
1570
1860
1860
1720
1720
1720
2030
2030
1 85 0
1850
1850
2190
2190
1990
1990
1990
2350
2350
2110
2110
2500
2500
2240
2240
2650
2650
2350
2350
2780
2780
2470
2570
2680
2920
3050
3170
T ire
Size
R egular
ZY & ZT
Load
Range
8 -1 9 .5
D -E
35
40
45
50
55
60
65
70
75
2110
2270
2410
2540
2680
2800
70
75
Code
ZX
ZX
T ire
Size
Load
Range
30
35
40
45
7 .5 0 -1 6 L T
7 .5 0 -1 6 L T
8 .7 5 - 1 6 .5
8 .7 5 - 1 6 .5
C
D
C
D
1430
1430
1380
1380
1565
156 5
1 51 5
1515
1690
1690
1630
1630
1815
18 1 5
1750
1750
8 -1 9 .5
8 -1 9 .5
D
E
50
55
60
1930
2040
2140
185 5
1970
2070
2230
2230
2350
2350
65
1850
1850
1990
1990
2110
2110
2460
2460
2570
2 6 8 0 (#;
(#) 2 7 8 0 lb s . a t 8 0 lb s . p re s s u re .
LIG H T T R U C K SE RV IC E M A N U A L
Side Wear
This may be caused by incorrect wheel camber, un
derinflation, high cambered roads or by taking corners at too
high a rate of speed. The first two causes are the most
common. Camber wear can be radily identified because it
occurs only on one side of the treads, whereas underinflation
causes wear on both sides. Cam ber wear requires correction
of the camber first and then interchanging tires. There is, of
course, no correction for high cambered roads. Cornering
wear is discussed further on.
3E-7
Misalignment Wear
Uneven Wear
Cornering Wear
When a truck makes an extremely fast turn, the weight
is shifted from an even loading on all wheels to an abnormal
load on the tires on the outside of the curve and a very light
load on the inside tires, due to centrifugal force. This
unequal loading may have two unfavorable results.
First, the rear tire on the inside of the curve may be
relieved of so much load that it is no longer geared to the
road and it slips, grinding off the tread on the inside half of
the tire at an excessive rate. This type of tire shows much the
same appearance of tread wear as tire wear caused by
negative camber.
Second, the transfer of weight may also overload the
outside tires so much th a t they are laterally distorted
LIGHT TRUCK SERVICE MANUAL
Static Balance
Dynamic Balance
Dynamic balance (sometimes called running balance
means that the wheel must be in static balance, and also run
smoothly at all speeds.
To insure successful, accurate balancing, the following
precautions must be observed:
Wheel and tire must be clean and free from all foreign
matter.
The tires should be in good condition and properly
mounted with the balance mark on the tire, if any, lined
up with the valve.
3E-8
WHEEL INSTALLATION
Single Wheels
When installing the tire and wheel on the vehicle, the
following procedure should be followed:
After wheel nuts are put on loosely, turn the wheel until
one nut is at the top of the bolt circle; tighten the nut just
snug. Snug up the remaining nuts criss-cross to minimize
runout, then tighten the nuts to the recommended torque
alternately and evenly to avoid excessive runout.
TUBELESS TIRES
Tubeless tires mounted on one piece full drop center
rims are standard on some trucks. These tires have a safety
inner liner which if punctured, tends to cling to the
penetrating object forming a partial seal until the object is
removed from the tire.
3E-9
RADIAL TIRES
Recommended truck tire mounting and inflation proce
dures are especially im p ortant with radial truck tires.
Failure to follow these recommendations can cause bead
deformation in both tube type and tubeless tires due to
incorrect bead seating. Bead deformation may lead to
chafing, lower sidewall and bead area cracking, demounting
difficulties, eccentric wear, ride vibration and non-retreadable casing.
Mounting
To insure correct mounting and bead seating and to
prevent bead deform ation, the following steps must be
taken:
A. Tube Type Tires
1. Only use rims approved for radial tire usage by rim
manufacturer. Thoroughly clean rim parts, removing
all rust and other foreign material. Make sure rim
parts match and are not sprung or broken.
2. Thoroughly lubricate tire beads, portion of tube
between beads, and flaps with an approved rubber
lubricant. Radial tubes are identifiable by the letter
" R " in the size designation. Example 100R20. Also,
to further identify the radial tube, a red band on the
valve stem has been required since March, 1975.
Radial flaps are also identified by the letter " R " .
Example - 20R8.
L IG H T T R U C K SERVICE M A N U A L
3E-10
TIRE REPAIR
There are many different materials and techniques on
the market to repair tires. As not all of these work on all
types of tires, tire manufacturers have published detailed
instructions on how and when to repair tires. These instruc
tions can be obtained from the tire manufacturer.
Series
Description
K
C 1 0 ,P 1 0 , G 1 0 ,G 2 0
C20,P20
C30, P30 and
K20, G30
Torque
9 /1 6 "
B o lts (8)
9 /1 6 "
B o lts (8)
Single Wheels
CKPG30
D u al W heels
H eavy D u ty
W heels
5 /8 "
B o lts
LIG H T T R U C K SE RV IC E M A N U A L
PROPELLER SHAFT
4A-1
SECTION 4A
PROPELLER SHAFT
The following notice applies to one or more steps in the assembly
procedure of components in this portion of the manual as indicated at
appropriate locations by the terminology "See Notice on page 1 of this
Section".
N O T IC E : This fastener is an important attaching part in that it could
affect the performance of vital components and systems, a nd/or could result
in major repair expense. It must be replaced with one of the same part
number or with an equivalent part if replacement becomes necessary. Do not
use a replacement part of lesser quality or substitute design. Torque values
must be used as specified during reassembly to assure proper retention of this
part.
CONTENTS
General D escription...........................................................................................4A-1
Universal Jo in ts............................................................................................... .4A-1
Propeller S h a f t ................................................................................................ ..4A-2
Diagnosis.............................................................................................................. ..4A-2
On C ar Service....................................................................................................4A-5
GENERAL DESCRIPTION
Universal Joints
The simple universal joint is basically two Y-shaped
yokes connected by a crossmember called a spider. The
spider is shaped like an X and arms that extend from it are
called trunnions. See figure 4 A - 1.
The spider allows the two yoke shafts to operate at an
angle to each other. When torque is transmitted at an angle,
through this type of joint, the driving yoke rotates at a
constant speed while the driven yoke speeds up and slows
down twice per revolution. This changing of velocity
(acceleration) of the driven yoke increases as the angle
between the two yoke shafts increases. This is the prime
reason why single universal joints are not used for angles
Velocity
LIG H T T R U C K SERVICE M AN U AL
4A-2
PROPELLER SHAFT
Propeller Shafts
PROPELLER SHAFT
4A-3
D IA G N O STIC CH ART
CO M PLAINT
N O T E : An occasional d ro p o f
lu b ric a n t leaking fro m splined
y o k e is n o rm al and re q u ire s n o
a tte n tio n .
CO RRECTIO N
POSSIBLE CAUSE
a.
b.
a.
b.
c.
a.
a.
b.
Side gear h u b c o u n te rb o re in
d iffe re n tia l w o rn oversize.
b.
a.
L oose u p p e r o r lo w e r c o n tro l
arm b u sh in g b o lts.
a.
T ig h te n b o lts to specified to rq u e .
N O T E : U sually o ccu rs o n
initial lo ad a p p lic atio n a fte r
tran sm issio n has b e en p u t
in to gear, e ith e r fo rw a rd o r
reverse.
b.
L oose c o m p a n io n flange.
b.
4A-4
PROPELLER SHAFT
C O M P L A IN T
Roughness, Vibration or
Body Boom at any speed.
POSSIBLE CAUSE
C O R R E C T IO N
a. Replace.
g. Burrs or gouges on
companion flange. Check
snap ring locating surfaces
on flange yoke.
i.
i.
j.
j.
Scraping noise.
Roughness on heavy
acceleration (short duration.)
PROPELLER SHAFT
4A-5
UNIT REPAIR
PROPELLER SHAFT
The rear universal joint to propshaft bolt on some CK 1
ton dual wheel models requires a # 10 "Six Lobed Socket"
(J-25085), for proper removal and installation. 34 N-m,
(Torque to 25 lbs. ft.).
Removal
1. Raise vehicle on hoist. M ark relationship of shaft to
companion flange and disconnect the rear universal
joint by removing trummion bearing " U " bolts or
straps. Tape bearing cups to trunnion to prevent
dropping and loss of bearing rollers.
2. For models with two-piece shafts remove bolts retain
ing bearing support to hanger.
3. Slide propeller shaft forward disengaging trunnion
from axle flange, then slide assembly rearward disen
gaging from transmission.
For models using strap or U-bolt atta ch m e n ts to
transmission or transfer case use same removal proce
dure as above.
may be more
removal and
In this case,
procedure as
Universal Joints
On models with between center slip propshaft it is
important that components are marked prior to dissassembly for proper phasing.
The universal joints are of the extended-life design and
do not require periodic inspection or lubrication; however,
when these joints are disassembled, repack bearings and
lubricate reservoir at end of trunnions with high-melting
point wheel bearing lubricant. Use care not to damage or
dislodge seals from trunnion.
4A-6
PROPELLER SHAFT
Reassembly Fig. 4 A -1 0
PROPELLER SHAFT
4A-7
ROLLER BEARINGS
BEARING RETAINER
BEARING CUP
CROSS
Fig. 4 A -1 3 -R e p a ir Kit
STRIKE TUBE YOKE
EAR IN THIS AREA
4A-8
PROPELLER SHAFT
NOTICE:
PROPELLER SHAFT
4A-9
3. For G-K models with two piece shafts, install front half
into transmission and bolt support to crossmember.
a. Slide grease cap and gasket onto rear splines.
b. Rotate shaft so front U-joint trunnion is in correct
position. See figure 4 A - 19.
c. Take rear propeller shaft and before installing, align
U-joint trunnions as shown in figure 4A-19. Attach
rear U-joint to axle. Tighten grease cap.
d. Torque bearing support to crossmember and U-joint
to axle attachments.
4A-10
PROPELLER SHAFT
WASHER
SEAL
TUBE
BALL STUD
YOKE
COUPLING YOKE
FLANGE YOKE
FLANGE YOKE
COUPLING YOKE
BALL SUPPORT
TUBE YOKE
PROPELLER SHAFT
4 A -11
LUBRICATION
The front axle propshaft found on all four-wheel drive
trucks requires special lubrication procedures at two loca
tions: The C /V joint, and the slip yoke.
4A-12
PROPELLER SHAFT
Slip Spline
SPECIFICATIONS
PROPELLER SHAFT
CK
P ro p e lle r S h a ft
To R ear A x le (S tra p )
B e a rin g S u p p o rt-to -H a n g e r
H a n g e r-to -F ra m e
1 2 -1 7
2 0 -3 0
4 0 -5 0
1 2 -1 7
2 0 -3 0
1 2 -1 7
2 0 -3 0
To T ra n s fe r Case
D a n a Style
G M Style
2 0 -3 0
7 0 -8 0
REAR AXLE
4B-1
SECTION 4B
REAR AXLE
The following notice applies to one or more steps in the assembly
procedure of components in this portion of the manual as indicated at
appropriate locations by the terminology "See Notice on Page 1 of this
Section ".
N O T IC E : This fastener is an important attaching part in that it could
affect the performance of vital components and systems, a nd/or could result
in major repair expense. It must be replaced with one of the same part
number or with an equivalent part if replacement becomes necessary. Do not
use a replacement part of lesser quality or substitute design. Torque values
must be used as specified during reassembly to assure proper retention of this
part.
CONTENTS
General Description...........................................................................................
Differential Diagnosis.......................................................................................
General Diagnostic Procedure......................................................................
Differential and Rear Axle Bearing Diagnosis........................................
On Vehicle Serv ice............................................................................................
8-1 /2 ", 8 -7 /8 ", and 9-1/2" Ring G e a r.....................................................
Chevrolet 10-1/2" Ring G e a r ......................................................................
Dana 10-1/2" Ring G e a r ............................................................... ..............
Dana 9 - 3 /4 "R ing G e a r ..................................................................................
Chevrolet 12-1/4" Ring G e a r ......................................................................
Specifications......................................................................................................
Special Tools............................................................. ............ ...................... ......
4B-1
4B-8
4B-8
4B-12
4B-14
4B-14
4B-18
4B-21
4B-21
4B-22
4B-24
4B-27
GENERAL DESCRIPTION
A differential is an arrangement of gears that divides
the torque between the axle shafts and allows them to rotate
at different speeds. A basic differential consists of a set of
four gears. Two of these gears are called differential side
gears, and the other two are differential pinion gears. Some
differentials have more than two pinion gears. Each side
gear is splined to an axle shaft. Consequently, each axle
shaft must turn when its side gear rotates.
The differential pinion gears are mounted on a differ
ential pinion shaft, and the gears are free to rotate on this
shaft. The pinion shaft is fitted into a bore in the differential
case and is at right angles to the axle shafts.
Power flow through the differential is as follows: The
drive pinion roates the ring gear. The ring gear, being bolted
to the differential case, rotates the case. The differential
pinion, as it rotates with the case, forces the pinion gears
against the side gears. W hen both wheels have equal
traction, the pinion gears do not rotate on the pinion shaft
because the input force on the pinion gear is equally divided
between the two side gears. See figure 4B-1. Consequently,
the pinion gears revolve with the pinion shaft, but do not
rotate around the shaft itself. The side gears, being splined
to the axle shafts and in mesh with the pinion gears, rotate
the axle shafts.
LIG H T T R U C K SE R V IC E M AN U AL
4B-2
REAR AXLE
REAR AXLE
1.
C om panion Flange
7.
13.
C over
19.
2.
D e fle c to r
8.
Shim
14.
P inion S haft
3.
Pinion O il Seal
9.
G a sket
15.
Ring G e a r
2 1 . Shim
4.
10.
16.
Side G e a r
5.
11.
17.
Bearing C a p
2 3 . D riv e Pinion
6.
D iffe r e n tia l C a rr ie r
12.
18.
A x le Shaft
Screw
Fig. 4B-3--8-1 /2 " and 8 -7 /8 " Ring Gear Axle Cross-Section Typical
Thrust W asher
4B-3
4B-4
J9HT
REAR AXLE
U&mg W
REAR AXLE
1.
2.
3.
4.
5.
6.
7.
8.
9.
C o m p a n i o n F la n g e
O il D e f le c to r
Oil Seal
B e arin g R eta ine r
S h im
P in io n F r o n t B e a r in g
C o lla p s i b le Sp a ce r
P in io n R ear B e a r in g
D rive P in io n
10.
11.
12.
13.
14.
15.
16.
17.
18.
S t r a d d le Be arin g
R in g Gear
D iff e re n tia l S p i d e r
D iff e re n tia l C ase
D iff e re n tia l P i n io n
D iff e re n tia l S id e G e a r
S id e B e a r in g
S id e B e a r i n g A d j u s t i n g N u t
A d j u s t i n g N u t R eta in e r
4B-5
19. R e ta in e r S c r e w
20. B e a r i n g C a p
21. C a s e - t o - R i n g G e a r B o lt
22. D iff e re n tia l C o v e r
23. B e a r in g C a p B o lt
24. C o v e r S c r e w
25. A x l e S h a f t
4B-6
REAR AXLE
P inion N ut
Washer
Com panion Flange
O il Seal
O il Slinger
P inion F ro n t Bearing
F ro n t Bearing Cup
Preload Shim Pack
P inion D epth Shim Pack
Rear Bearing Cup
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22 .
23.
24.
25
26.
27.
28.
29.
REAR AXLE
1. Nut
2. Washer
3. Companion Flange
4. Pinion Oil Seal
5. Gasket
6. Outer Pinion Oil Slinger
7 and 8. Cone and Roller
(Outer Pinion Bearing)
9. Shims (Outer Pinion
Bearing)
10. Inner Pinion Oil Slinger
11.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
4B-7
Bolt (Differential
Bearing Cap)
Bolt (Ring Gear)
Pinion Shaft
Thrust Washer
(Pinion)
Pinion
Side Gear
Thrust Washer (Side
Gear)
4B-8
REAR AXLE
1.
U n iversal J o in t Yoke
2.
3.
4.
5.
6.
7.
O il Seal
O il S e al G asket
Front Pinion Bearing
D rive Pinion
R ear Pinion Bearing
14.
A xle S h aft
9.
10.
11.
Ring G ear
D iffe re n tia l S p ider
D iffe re n tia l Pinion
15.
16.
12.
13.
(S pider) G ear
D iffe re n tia l S ide G ear
D iffe re n tia l C a s e -L e ft
17.
18
8.
H alf
DIFFERENTIAL DIAGNOSIS
STANDARD DIFFERENTIAL
Noise
The most essential part of rear axle service, as with any
mechanical repair, is proper diagnosis of the problem, and,
in axle work one of the most difficult areas to diagnosis is
noise. Locating a broken axle shaft, or broken differential
gear, presents little or no problem , but, locating and
isolating axle noise can be an entirely different m atter.
Degree of Noise
REAR AXLE
SOME A/O/SE / S \
ACCEPTABLE \<C
often m istaken for axle noise. Such practices as: raising tire
pressure to elim inate tire noise (alth o u g h this will not
silence tread noise of mud and snow tires), listening for the
noise at varying speeds and road surfaces, on drive, float,
and coast conditions will aid in locating the source of alleged
axle noises. Thus, every effort should be m ade to isolate the
noise to a specific drive line com ponent instead of making a
random guess th at could be a costly waste of time.
Elimination of External Noises
4B-9
4B-10
REAR AXLE
Gear Noise
T here are two basic types of gear noise. The first type is
produced by broken, bent, or forcibly dam aged gear teeth
and is usually quite audible over the entire speed range and
presents no particular problem in diagnosis.
For example, hvpoid gear tooth scoring as seen in figure
4B-10 generally results from th e following: insufficient
lubricant im proper breakin, im proper lubricant, insufficient
gear backlash, im proper ring and pinion gear alignm ent, or
loss of drive pinion nut torque. The scoring will progressively
lead to complete erosion of the gear tooth, or gear tooth
pitting and eventual fracture if the initial scoring condition
is not corrected. A nother cause of hypoid tooth fracture is
extended overloading of the gear set which will produce
fatigue fracture, or shock loading which will result in sudden
failure.
Differential pinion and side gears rarely give trouble.
Common causes of differential failure are shock loading,
extended overloading, and seizure of the differential pinions
to the cross shaft resulting from excessive wheel spin and
consequent lubrication breakdown.
The second type of gear noise pertains to the mesh
pattern of the gear teeth. This form of abnorm al gear noise
can be recognized as it produces a cycling pitch (whine) and
will be very pronounced in the speed range at which it
occurs, appearing under either "d riv e", "float" or "coast"
conditions. "D rive" is acceleration or heavy pull. "C o ast"
is with a closed throttle and vehicle in gear and "float" is
using just enough throttle to keep the car from driving the
engine-the vehicle slows down gradually but engine still
pulls slightly. G ear noise tends to peak in a narrow speed
range or ranges, and will tend to rem ain constant in pitch.
Bearing noise will vary in pitch with vehicle speeds. See
figure 4B -11.
REAR AXLE
4B-11
Problem
1.
1. a)
b)
c)
Road noise
Tire noise
Front wheel bearing noise
2.
2. a)
b)
Road noise
Tire noise
3.
3. Tire noise
4.
4. a)
b)
Engine noise
Transmission noise
5.
Vibration
5. a)
b)
c)
d)
e)
f)
6.
7.
8.
8. Pinion bearing
9.
10.
11.
Grunt on stops
12.
13.
Chatter on turns
13. a)
b)
14.
4B-12
REAR AXLE
U il &
ABRASIVE
ROLLER
GALLING
WEAR
BENT
CAGE
REPLACE BEARING.
mm m m m
ABRASIVE
STEP
WEAR
BENT
ETCHING
BEARING SURFACES APPEAR GRAY OR GRAYISH
BLACK IN COLOR WITH RELATED ETCHING AWAY
OF MATERIAL USUALLY AT ROLLER SPACING.
ML
..
CAGE
//Ill w
INDENTATIONS
CAGE
WEAR
M ISALIG N M EN T
OUTER RACE MISALIGNMENT DUE TO FOREIGN
OBJECT.
CLEAN RELATED PARTS AND REPLACE BEARING.
MAKE SURE RACES ARE PROPERLY SEATED.
r
Fig. 4B-12-Differential and Axle Bearing Diagnosis Chart A
REAR AXLE
4B-13
FATIGUE
SPALLI
BRINELLING
SURFACE INDENTATIONS IN RACEWAY CAUSED BY
ROLLERS EITHER UNDER IMPACT LOADING OR
VIB RATIO N WHILE THE BEARING IS NOT ROTATING.
REPLACE BEARING IF ROUGH OR NOISY.
FRETTAGE
STAIN
HEAT
DISCOLORATION
DISCOLORATION
SMEARS
SMEARING OF METAL DUE TO SLIPPAGE.
SLIPPAGE CAN BE CAUSED BY POOR FITS.
LUBRICATION, OVERHEATING, OVERLOADS
OR HANDLING DAMAGE.
REPLACE BEARINGS, CLEAN RELATED PARTS
AND CHECK FOR PROPER FITS AND
LUBRICATION.
4B-14
REAR AXLE
ON-VEHICLE SERVICE
8-1 /2 , 8 -7 /8 and 9-1 /2 RING
GEAR AXLE
AXLE ASSEMBLY
C onstruction of the axle assembly is such th at service
operations may be perform ed with the housing installed in
the vehicle or with the housing installed in a holding fixture.
The following removal and installation procedure is neces
sary only when the housing requires replacem ent.
NOTICE: See N O T IC E on page 1 of this section,
AXLE SHAFT
Removal
Installation
REAR AXLE
4B-15
4B-16
REAR AXLE
BEARING]
Axle Shaft-lnstallation
REAR AXLE
4B-17
4B-18
REAR AXLE
Inspection
J-21057
REAR AXLE
4B-19
AXLE SHAFT
Replacement
1.
2.
3.
4.
5.
6.
7.
A xle S haft
S haft-to-H ub B o lt
R etainer
Key
A d ju stin g Nut
Hub O uter B earing
Snap R ing
4B-20
REAR AXLE
3. W ith J-24426 on H andle J-8092, as shown in figure 4B33, drive outer bearing and cup from the hub assembly.
Inspection and Cleaning o f Bearings
Drum-Non-Demountable-Type-Fig. 4B-31
Replacement
Wheel Bolt
Replacement
REMOVAI
INSTALLATION
REAR AXLE
4B-21
BEARING ADJUSTMENT
Before checking bearing adjustm ent, m ake sure brakes
are fully released and do not drag.
C heck bearing play by grasping tire at top and pulling
back and forth, or by using a pry bar under tire. If bearings
are properly adjusted, m ovem ent of brake drum in relation
to brake flange plate will be barely noticeable and wheel will
turn freely. If movement is excessive, adjust bearing as
follows:
1. Remove axle shaft and raise vehicle until wheel is free
to rotate.
2. Keyways and threads on tube and nut m ust be clean
and free from chips, burrs and shavings.
3. Disengage tang of retainer and remove retainer from
axle housing tube.
4. T orque adjusting nut to 50 ft. lbs., at the sam e tim e
rotating the hub assem bly and m aking sure bearing
cones are seated and in co n ta c t w ith the spindle
shoulder.
Proper wheel bearing adjustm ent can be m ade using
tool J-2222-02 with some modification or tool J-2222-L
(Fig. 4B-36).
5. Back off nut until loose.
4B-22
REAR AXLE
AXLE VENT
Replacement
AXLE SHAFT
Replacement
REAR AXLE
4B-23
DRUM-DEMOUNTABLE-TYPE
Replacement
BEARING ADJUSTMENT
4B-24
REAR AXLE
REAR AXLE
4B-25
SPECIFICATIONS
><
O ri'
Ov
(X
BOLT TORQUES
(FT.-LBS.)A
G ear Backlash
Preferred
Filler Plugs
Differential Pinion
Lock
Pinion Bearing
Preload (In.-Lbs.)
New
Used
15-30
15-30
20-25
20-40
25-35
5-10
5-10
5-15
10-20
5-15
Carrier Cover
20
20
20
35
30
Ring G ear
80
60
110
110
120
Differential
Bearing Caps
55
55
65
85
135
Chevrolet
05
0
c
0
a
i
O rf'
o-
00
oo
IOV 2 "
00
Chevrolet
00
0
c
0
O
lO W '
DIFFERENTIAL SPECIFICATIONS
CN
25
18
18
10
18
10
2 0"#
2 0"#
220
o.
Differential Carrier
to Axle Housing
85
Differential Bearing
Adjusting Lock
20
20
15
65
165
135
35
105
105
105
155
115
115
15
105
205
Axle Shaft To
Hub Bolts
35
Lubricant Capacity
8 V2 "
4.2 Pints
8% "
3.5 Pints
Chevrolet 10'/j"
5.4 Pints
Dana 10 V2 "
7.2 Pints
Dana 9 % "
6.0 Pints
12>/4"
14.0 Pints
Chevrolet 9 V i"
5.5 Pints
4B-26
REAR AXLE
RING GEAR
SIZE
SOURCE
TYPE/CAPACITY
CIO
C h e v ro le t
S a lis b u r y /3 7 5 0 #
8 -7 /8 "
C10
C h e v ro le t
S a lis b u ry /3 7 5 0 #
8-1/2"
K10
C h e v ro le t
S a lis b u ry / 3 7 5 0 #
8 -1 /2
K10
C h e v ro le t
S a lis b u r y /3 7 5 0 #
8 - 7 /8
K10
C h e v ro le t
S a lis b u r y /4 0 0 0 #
8 - 7 /8
P10
C h e v ro le t
S a lis b u r y /3 5 0 0 #
8 -7 /8 "
G10
C h e v ro le t
S a lis b u r y /3 5 0 0 #
8 -7 /8 "
G10
C h e v ro le t
S a lis b u r y /3 5 0 0 #
8 -1 /2 "
MODEL
C20
(Except
Crew
Cab)
C h e v ro le t
S a lis b u r y /6 0 0 0 #
9 -1 /2
C20
(Crew Cab)
C h e v ro le t
S a lis b u r y /7 5 0 0 #
1 0 - 1 /2 "
K20
C h e v ro le t
S a lis b u r y /6 0 0 0 #
9 -1 /2 "
P20
C h e v ro le t
S a lis b u r y /6 0 0 0 #
9 -1 /2
G20
C h e v ro le t
S a lis b u r y /3 5 0 0 #
8 -7 /8 "
G20
C h e v ro le t
S a lis b u ry /3 5 0 0 #
8 -1 /2 "
C h e v ro le t
S a lis b u r y /7 5 0 0 #
1 0 - 1 /2 "
Dana
S a lis b u r y /7 5 0 0 #
1 0 - 1 /2 "
C h e v ro le t
S a lis b u r y /7 9 0 0 #
1 0 - 1 /2 "
C h e v ro le t
B a n jo /1 1 , 0 0 0 #
1 2 - 1 /4 "
C h e v ro le t
S a lis b u r y / 5 7 0 0 #
1 0 - 1 /2 "
Dana
S a lis b u r y /6 2 0 0 #
9 -3 /4 "
D ana
S a lis b u r y /7 5 0 0 #
10 1 /2 "
C30
K30
(Except
Dual
Wheel
Camper)
C30
*Dual
K 3o
yyheel
Camper)
P30
P30
(With
H22/H23)
G30
030
__n
030
(Dual
Wheel)
(Dual
Wheel)
BEARING ADJUSTING
NUT TORQUE*
50 FT. LBS.
50 FT. LBS.
12-1/4
90 FT. LBS.
ADJUSTING NUT
BACK-OFF*
OUTER LOCKNUT
TORQUE
RESULTING
BEARING ADJUSTMENT
TYPE OF
BEARING
**
65 FT. LBS.
.001 TO .010
END PLAY
TAPERED
ROLLER
SLIGHT
PRELOADED
BARREL
ROLLER
1/8
**B a ck-o ff n ut and retighten to 35 Ft. Lbs. then, back-off nut 1/4 turn.
*W ith wheel rotating.
REAR AXLE
4B-27
SPECIAL TOOLS
*>
10
-"v >p
.Avfi:',
11
13
H*
16
m
17
I
19
20
21
22
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
J-2 15 4 8
J-2 36 9 0
J-2 36 8 9
J-21128
J-21057
J-22804-1
J-5 74 8
J-6 62 7
J-8 09 2
J -5 8 5 3
J-8 61 4 -II
12. J-2 61 9
13. J-2 22 2
14. J-2 44 2 9
15. J-2 44 3 3
16.
17.
18.
19.
20.
J-2 44 3 0
J-2 3 3 2 2
J-2 44 2 6
J-2 4 4 3 2
J-24427
21. J-8 60 8
22. J-2 43 8 4
23. J-2 44 2 8
24. J-2 4 4 3 4
B earing C up
Bearing C up
Bearing C up
Bearing C up
Tool
In s ta lle r
In s ta lle r
In s ta lle r
25. J-870
26. J-2 23 8 0
27. J -2 2 3 5 4
T ru -A rc Pliers
W heel O il Seal In s ta lle r
28. J-22281
29. J-8 11 4
30. J-8 09 3
1*
: v
KI
##
----------- .
fiOieM 3
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. I*.,. H'9& - f 1?
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'..
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ii.cC
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I bP| 'l^ifjr'
- Vr.
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4 :,
4C-1
SECTION 4C
CONTENTS
G eneral D escription...................................................... .................................... 4C-1
Front Axle A ssem bly................................. ...................................................... 4C-1
R em o v al....................................................................... ..................................... 4C-1
In stallatio n ........................................ ............................. .................................. 4C-1
D iagnosis.............................................................................................................. 4C-2
R epair Axle Joint C om ponents...................................................................... 4C-3
Specifications.......................................................... ........................................... 4C-4
GENERAL DESCRIPTION
The front axle is a hypoid gear axle unit equipped with
steering knuckles. Axle assembly num ber and production
date are stam ped on left tube of assembly.
K 10-20 M odels use a C hevrolet front axle, both
incorporate a 8-1/2" ring gear. A 4500 lb. capacity unit is
used on the K-30 Model. The K-30 axle assembly is a Dana
(60 Series) which incorporates a 9 -3 /4 " ring gear.
Axle Shaft
Removal
1. Syp h on m aster cylinder.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Raise vehicle.
Remove wheel and tire.
Remove caliper.
Remove hub lock mechanism.
Remove gears and snap rings.
Remove rotor.
Remove inner bearing and seal.
Remove spindle and backing plate.
Remove axle shaft.
8. Install caliper.
9. Install tire and wheel.
10. Lower vehicle.
11. Add fluid and check brake operation.
Installation
4C-2
FRONT WHEEL, PINION, DIFFERENTIAL SIDE AND REAR WHEEL ROLLER BEARINGS
DIAGNOSIS
Road Test
1.
2.
3.
4.
5.
Tire Noises
1.
2.
3.
4.
5.
Engine or
Exhaust
Noises
Test for
Wheel Bearing
Noise
Test for
Differential
Bearing Noise
Test for
Pinion Bearing
Noise
1.
2.
3.
4.
1.
2.
3.
4.
1.
2.
3.
4.
1.
2.
3.
4.
5.
6.
7.
Installation
NOTICE: See N O T IC E on page 1 of this section
1.
2.
3.
4.
5.
6.
7.
8.
9.
4C-3
Disassembly
4C-4
SPECIFICATIONS
CHEVROLET
Axle
G ear and Backlash Preferred
Min. and Max.
New Pinion Bearing Preload
Used Pinion Bearing Preload
Bolt Torques
(Ft.-Lbs.)
Axle
.005-.008
.003-.010
15-30 in.-lbs.
5-10 in.-lbs.
C arrier Cover
Ring G ear
Differential Bearing Caps
Filler Plugs
Bolt Torques
(Ft.-Lbs.)
20
80
55
25
DANA
Axle
Gear Backlash Preferred
Min. and Max.
New Pinion Bearing Preload
Used Pinion Bearing Preload
Bolt Torques
(Ft.-Lbs.)
.004"-. 009"
.004"-.009"
20-40 in.-lbs.
10-20 in.-lbs.
Axle
Carrier Cover
Ring Gear* K-30
Differential Bearing Caps
Filler Plugs
Drive Pinion Nut** K-30
Bolt Torques
(Ft.-Lbs.)
35
110
85
10
270
BRAKES
5-1
SECTION 5
BRAKES
T he following notice applies to one or more steps in the assembly
procedure of com ponents in this portion of the m anual as indicated at
appropriate locations by the term inology "See N otice on page 1 of this
section ".
N O TICE: This fastener is an im portant attaching p art in th a t it could
affect the perform ance of vital components and systems, an d /o r could result
in m ajor repair expense. It m ust be replaced with one of the same part
num ber or with an equivalent p art if replacem ent becomes necessary. Do not
use a replacem ent p art of lesser quality or substitute design. Torque values
m ust be used as specified during reassem bly to assure proper retention of this
part.
C A U TIO N : W hen servicing wheel brake parts, do not create dust by
grinding or sanding brake linings or by cleaning wheel brake parts with a dry
brush or with compressed air. (A w ater dam pened cloth should be used.)
M any wheel brake parts contain asbestos fibers which can become airborne if
dust is created during servicing. Breathing dust containing asbestos fibers
m ay cause serious bodily h a rm ."
CONTENTS
G eneral D escrip tio n ............................................................
Diagnosis................................................................................
On-V ehicle Service..............................................................
Pedal T ravel......................................................................
Stop L ight S w itc h ...........................................................
Bleeding and Flushing B ra k e s.....................................
Hydro-Boost Bleeding P ro c e d u re ...............................
Brake P ip es.......................................................................
Brake H oses.......................................................... ...........
Parking Brake Pedal or H a n d le ..................................
Parking Brake (Propshaft) Internal E xpanding......
Parking Brake C a b le ......................................................
C om bination V a lu e ........................................................
Brake P e d a l......................................................................
Brake Pedal R o d .............................................................
M aster C y lin d er..............................................................
5-1
5-2
5-10
5-10
5-10
5-10
5-12
5-17
5-17
5-21
5-21
5-22
5-22
5-22
5-23
5-24
GENERAL DESCRIPTION
OPERATION OF MASTER CYLINDER
W hen the brake pedal is depressed, force is transferred
through the push rod to the m aster cylinder prim ary piston,
which moves forw ard. U nder norm al conditions, the com
bination of hydraulic pressure and the force of the prim ary
piston spring move the secondary piston forw ard a t the same
time. W hen th e pistons have moved forw ard so th at their
prim ary cups cover the bypass holes, hydraulic pressure is
b u ilt up and tra n sm itte d to the fro n t and re a r brake
assemblies. H ydraulic pressure behind the wheel cylinder
cups forces the pistons outw ard, causing the brakes to be
applied.
As brake pedal force is reduced, brake fluid pressure in
the m aster cylinder is also reduced. This allows the drum
5-2
BRAKES
DIAGNOSIS
INSPECTION AND TESTING BRAKES
Testing Brakes
HYDRO-BOOST
Prior to perform ing the Booster Function Tests, or the
A ccum ulator L eakdow n T est, th e following prelim inary
checks m ust be made:
1.
2.
3.
4.
5.
6.
BRAKES
5-3
Replace seal.
6. E X T E R N A L L E A K A G E A T T H E R E T U R N PO R T
F IT T IN G : Tighten fitting to 7 lb. ft. (10 N -m ). If it
continues to leak, replace "O " ring under fitting.
7. E X T E R N A L L E A K A G E A T T H E H IG H P R E S
S U R E G E A R O R PU M P: T orque tube nut to 30 lb. ft.
5-4
BRAKES
BRAKES
5-5
CAUSE
CORRECTION
Leaks in Hydro-Boost
Replace line.
Crabby Brakes
Tighten belt.
Accumulator Leak
Down-System does
not hold charge
5-6
BRAKES
CONDITION
POSSIBLE CAUSE
CORRECTION
5. Malfunctioning caliper
assembly.
6. Defective or damaged
shoe and lining (grease
or brake fluid on
lining or bent shoe).
7. Malfunctioning rear
brakes.
9. Loose calipers.
1. Replace linings.
Pulls
BRAKES 5-7
CONDITION
POSSIBLE CAUSE
CORRECTION
1. Malfunctioning power
brake.
2. Insufficient fluid in
master cylinder.
3. Bleed system.
Dragging Brakes
(A very light drag is
present in all disc
brakes immediately after
pedal is released.)
5-8
BRAKES
CONDITION
POSSIBLE CAUSE
CORRECTION
Dragging Brakes
(A very light drag i t
present In all disc
brakes immediately after
pedal is released.) Continued
Grabbing or Uneven
Braking Action
2. Malfunction of combination
valve.
3. Malfunction of power
brake unit.
Pulsation (roughness)
Felt during normal
brake application.
BRAKES
<5- \
<0. \
<. \
XX
XX
XX
A ir In Brake System
<. \
<\
sc \
< ^ \
< \
XX
X
X
X
XX
XX
X
XX
Improperly Assembled
Power Head Valvinq
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
X
X
X
X
X
X
X
X
X
X
XX
XX
XX
X
XX
XX
X
XX
XX
XX
XX
XX
5-9
XX
XX
X
X
X
X
X - Indicates causes
XX
X
X
5-10
BRAKES
ON-VEHICLE SERVICE
PEDAL TRAVEL
A t reasonably frequent intervals, the brakes should be
inspected for pedal travel, which is the distance the pedal
moves tow ard th e floor from a fully-released position.
Inspection should be m ade with the brake pedal firmly
depressed (approxim ately 90 lbs.) while the brakes are cold.
C-K -G M a n u a l......... 4.5" (115 mm)
C-K -G P o w e r.......... 3.5" (90 mm)
P (Except J F 9 ) ....... 3.5 " (90 m m)
P ( J F 9 ) ...............6.0" (1 5 0 m m )
On power brake-equipped vehicles, pum p the pedal a
minimum of 3 tim es with the engine off before m aking pedal
travel checks. This exhausts all vacuum from the power
booster.
BRAKES
2.
3.
4.
5.
e. A fter all air has been rem oved a t the forw ard
connection, bleed the m aster cylinder at the rear
(cowl) connection in the sam e m anner as the front in
step " d " above.
f. If it is known th at the calipers and wheel cylinders do
not contain any air, then it will not be necessary to
bleed them.
3. Individual wheel cylinder or calipers are bled only after
all air is removed from m aster cylinder.
a. Place a proper size box end wrench or Tool J - 2 1472
over the bleeder valve. A ttach transparent tube over
valve and allow tube to be hand subm erged in brake
fluid in a transparent container. Depress the brake
pedal slowly one tim e and hold. Loosen the bleeder
valve to purge the air from the cylinder. Tighten
bleeder screw and slowly release pedal. W ait 15
seconds. R ep eat th e sequence, including the 15
second w ait u n til all air is rem oved. It m ay be
necessary to repeat the sequence 10 or more times to
remove all the air.
JB1 thru JB6 gas engine vehicles Rapid pumping of
the brake pedal pushes the master cylinder secondary
piston down the bore in a manner that makes it difficult to
bleed the rear side of the system..
4. If it is necessary to bleed all of the wheel cylinders and
calipers, the following sequence should be followed: 1)
R ight rear wheel cylinder; 2) L eft rear wheel cylinder;
3) R ight front caliper; 4) Left front caliper.
5. Check the brake pedal for "sponginess" and the brake
warning light for indication of unbalanced pressure.
Repeat entire bleeding procedure to correct either of
these two conditions.
Pressure Bleeding
5-11
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
5-12
BRAKES
1.
2.
3.
4.
BRAKES
5-13
5-14
BRAKES
Models
5-16
BRAKES
G MODELS
VIEW
CK MODELS
CK10-20
(EXCEPT C20-43)
VIEW
VIEW
CK10
P MODELS
VIEW
BRAKES
BRAKE PIPES
Replacement (Figs. 5-5 thru 5-7)
NOTICE: N ever use copper tubing because copper is
subject to fatgue cracking and corrosion which could
result in brake failure.
1. Procure the recom m ended tubing and steel fitting nuts
of the correct size. (O utside diam eter of tubing is used
to specify size.)
2. C ut tubing to length. C orrect length may be deter
mined by measuring old pipe using a cord and adding
1/8 " (3 m m) for each double flare.
3. Double flare tubing ends using a suitable flaring tool
such as J-23530. Follow instructions included in tool
set.
M ake sure fittings are installed before starting second
flare.
NOTICE: Double flaring tool m ust be used as single
flaring tools cannot produce a flare strong enough to
hold the necessary pressure.
4. Bend pipe assembly to m atch old pipe using a tubing
bender. C learance of .75" (19 m m ) m ust be m ain
tained to all moving or vibrating parts.
BRAKE HOSES
5-17
Installation
Rear Hose
Removal (Fig. 5-8)
Inspection
Front Hose
Removal (figs. 5-5 thru 5-7)
Installation
5-18
BRAKES
v ie w
[a ]
BRAKES
5-19
5-20
BRAKES
BRAKES
5-21
snap-over-center feel.
5-22
BRAKES
2. Turn the tool to the opposite side and fit over brake
shoes by turning the star wheel until the gauge just
slides over the linings.
3. R otate the gauge around the brake shoe lining surface
to insure proper clearance.
4. Install propeller shaft flange at m ainshaft as outlined in
transm ission section.
5. Lower rear wheels. Remove jack and wheel blocks.
2.
3.
1.
2.
3.
4.
5.
6.
7.
8.
COMBINATION VALVE
Electrical Circuit Test
1. Disconnect wire from switch term inal and use a jum per
to connect wire to a good ground.
2. Turn ignition key on "O n " - warning lam p should
light. If lam p does not light, bulb is burned out or
electrical circuit is defective. R eplace bulb or repair
electrical circuit as necessary.
3. W hen w arning lamp lights, turn ignition switch off.
D isconnect ju m p er and reconnect w ire to switch
term inal.
Warning Light Switch Test
5.
Replacement
BRAKE PEDAL
The brake pedal mounting is an integral design with the
cluth pedal (except autom atic transm ission), necessitating
the removal of the clutch pedal before removing the brake
pedal.
Removal (Fig. 5*12)
Clean all parts and inspect for wear, cracks or any other
dam age th at m ight im pair operation; replace if required.
Installation
BRAKES
5-23
5-24
BRAKES
MASTER CYLINDER
Replacement
Filling Cylinder
BRAKES
NOTICE:
To prevent damage to brake parts, use
all components included in repair
kits. Lubricate parts with clean, fresh
brake fluid. Do not use lubricated
shop air on brake parts. Torque values
specified are for dry, unlubricated
fasteners.
RESERVOIR COVER
5-25
5-26
BRAKES
INSTALL
REMOVE
INSTALL
MASTER CYLINDER
NUTS
TUBE
NUTS
SPRING
INSTALL
2. Install assembly on
reservoir.
SECONDARY
PISTON
ASSEMBLY
PRIMARY
PISTON
ASSEMBLY
A.
REMOVE
INSTALL
SPRING RETAINER
SECONDARY
PISTON
SECONDARY
SEAL
BRAKES
5-27
INSTALL
REMOVE
INSTALL
A.
2. Press grommets into master
cylinder body. Make sure
grommets are properly
seated.
REMOVE
GROMMET
PRY
BAR
RESERVOIR
B.
INSTALL
5-28
BRAKES
SECONDARY
----------------
PRIMARY
SEAL
SPRING AND
RETAINER
BRAKES
Assembly
5-29
Disassembly
5-30
BRAKES
COVER
DIAPHRAGM
FILTER
RESERVOIR
COMPENSATING
VALVE
VALVE
SEAL
POPPET
SPRING
SECONDARY
SPRING
SECONDARY
PISTON
PISTON
RETURN
PRIMARY
SNAP
SPRING
PISTON
RING
worn to the approxim ate thickness of the shoe, the shoe and
lining should be removed. A fter removal, m easure the lining
thickness. The shoe and lining should be replaced at any
tim e when the lining is worn to within 1/32" (0.80 mm) of a
rivet or 1/32" (0.80 m m ) of the shoe at any point or when
wear indicator contacts the rotor. Always replace linings in
sets (both right and left front).
All front disc brakes have a wear indicator th a t makes a
noise when the linings w ear to a degree where replacem ent is
required, (fig. 5-19). The spring clip is an integral part of the
inboard shoe and lining. W hen the lining is worn, the clip
contacts the rotor and produces a w arning noise.
C heck flatness o f b rak e pads. P lace inboard and
outboard pad surfaces together and check for gap between
pad surfaces. If more th an 0.13mm (.005 ") gap is m easured
at m iddle of pad (m idw ay between attaching lugs), pad
m ust not be used. This applies to new or used brake pads.
W henever the front disc brakes are relined, the rear brakes
should also be checked.
Caliper Removal
NOTICE: See "N o tice" on Page 5-1 of this section.
BRAKES
5-31
5-32
BRAKES
BRAKES
5-33
5-34
BRAKES
Completion
1. Replace the shoe and linings on the other front wheel
disc brake in exactly the sam e m anner as just de
scribed. Relining is to be done in full axle sets only.
W hen completed, reinstall the wheel and tire assem
blies. Torque wheel nuts to specifications. Install wheel
covers and lower the vehicle to the floor.
BRAKES
5-35
Clamp
Installation
If original disc pads are being reinstalled, they m ust be
installed in original positions (as m arked at removal).
1. Lubricate the caliper and steering knuckle (or support)
sliding surfaces and the support spring with Delco
Silicone Lube (or equivalent).
5-36
BRAKES
CALIPER OVERHAUL
Delco
Removal
1. Removal of the caliper for overhaul is the same as for
shoe and lining rep lacem en t except th a t it will be
necessary to disconnect the brake hose; (R efer to front
brake hose replacem ent).
2. First, disconnect the hose from the steel brake pipe and
cap the fittings to prevent dirt from entering the pipe or
the hose. Then, remove the U -shaped retainer from the
hose fitting. W ithdraw the hose from the fram e support
Disassembly
1. Before beginning disassembly, thoroughly clean the
exterior of the caliper using brake cleaner. Place the
caliper on a clean work surface.
2. Remove the brake hose from the caliper, discarding the
copper gasket. Check the hose for worn spots, cracks or
other signs of deterioration, discard the hose, if dam
aged, to be replaced with a new hose a t reassembly.
D rain brake fluid from the caliper.
3. Use clean shop towels to pad the interior of the caliper.
Remove the piston by directing compressed air into the
caliper inlet hole (fig. 5-37).
BRAKES
Reassembly
5-37
Installation
1. Installation of the caliper and m ounting parts (rubber
bushing, sleeves, shoe and lining assemblies and pins) is
the sam e as for lining replacem ent except for the
following:
a. The brake hose m ust be connected to the brake pipe
a t the fram e or fram e bracket.
Use extrem e care to orient the hose so th at the keyed
hose end fitting aligns with the slot in the bracket
without twisting or kinking the hose.
b. A fter overhaul -- or any tim e that the brake hose or
line is disconnected -- the calipers m ust be bled.
Bendix
Removal
CALIPER
PISTON
BOOT
SQUARE
RING SEAL
SCREW
SUPPORT
KEY
INBOARD SHOE
CALIPER SPRING
OUTBOARD SHOE
ANfl-RATTLE SPRING
BOOT INSTALLER
(EXCEPT JB7) J -2 2 9 0 4
(JB7) J -2 8 7 3 5
DUST
BOOT
5-38
BRAKES
J-24548
PISTON
Assembly
1. Lubricate the caliper piston bore and the N E W piston
seal with the clean brake fluid. Position the square ring
seal in the caliper bore groove.
2. L ubricate both sealing lips of the dust boot and the
piston with a light film of clean brake fluid. Place the
new boot over Piston Installer Tool J-24548. This is
most easily accomplished by placing the boot large
diam eter over the tool first, then riding the sm aller
diam eter onto the tool. T he large diam eter lip must
then be slid off the tool to m ake ready for installation
into the bore groove. Install the boot (large bead) into
th e piston bore groove by reaching inside of Tool
J-24548 and pressing the boot bead into the groove (fig.
5-41).
Be sure boot is fully seated in the groove before
proceeding.
3. Place the piston inside of Tool J-24548, force the piston
halfway into the piston bore using a wood ham m er
BRAKES
Installation
Installation of the caliper and m ounting parts is the
sam e for: "Shoe and Lining-Disc B rake" except for steps
given below:
1. C onnect the brake hose to the caliper using N E W
copper gaskets.
ROTOR SERVICING
Lateral Runout
1. L ateral runout is the movement of the rotor from side
to side as it rotates on the steering knuckle spindle. This
could be described as " rotor wobble ".
2. The movement of the rotor from side to side in the
lateral plane causes the brake shoe and lining and
pistons to be knocked back into their bores. This results
in additional pedal travel required and a vibration
during the braking action.
3. To check lateral runout, first tighten the wheel bearings
until all of the play is out of the bearings. Fasten a dial
indicator to some portion of the suspension so th a t the
point of the stylus contacts the rotor face approx
im ately 1" (25 mm) from the rotor edge (fig. 5-43). Set
the dial at zero. Move the rotor one complete rotation,
checking the indicator as the rotor moves.
4. L ateral runout should not be over .004" (0.10 mm)
total indicator reading.
5-39
Machining
Since accurate control of the rotor tolerances is neces
sary for proper perform ance of the disc brakes, m achining of
the rotor should be done only with precision equipm ent.
All brake rotors have a minimum thickness dimension
cast into them. This dimension is the minimum wear
dimension and not a refinish dimension. Do not use a brake
rotor that will not meet the specifications, as shown below,
after refinishing. Replace with a new brake rotor.
ROTOR THICKNESS
REPLACEMENT
(DISCARD)
MINIMUM
AFTER REFINISHING
1.480
1.230
.980
Parallelism
1. Parallelism is the m easurem ent of the thickness of the
rotor at four or more points around the circum ference
1.465
1.215
.965
5-40
BRAKES
BACKING PLATE
HOLD DO W N PINS
-A D JU S T IN G SCREW
BRAKE SHOE RETURN SPRING
BRAKES
5-41
5-42
8.
9.
10.
11.
BRAKES
Inspection
Replace any worn or broken parts.
Installation
NOTICE: Refer to "N o tice " on Page 1 of this section
when installing fasteners in steps 1, 2 and 4 below.
1. Place the flange plate in position on the rear bearing
retainer and fasten with four bolts. Torque bolts to 24
lb. ft. (33 N-m ).
RETURN
SPRINGS
W AVE
WASHER
FLANGE
LOCK
BRAKE
LEVER
ANCHOR
PIN
STRUT ^
HOLD
DOW N
PIN
STRUT
GUIDE
PLATE
SPRING
DRUM
HOLD D O W N
SPRING
SOCKET
A D JU STIN G SCREW
BACKING
PLATE
BRAKE
CABLE
BRAKES
2. Install transm ission output flange on spline of mainshaft and fasten with flange nut. Torque nut to 100 lb.
ft. (136 N-m).
3. Install cable assembly from back of flange plate. Push
retainer through hole in flange plate until tangs se
curely grip the inner side of the plate.
4. Place washer and reinforcem ent over the threaded end
of anchor pin. Hold anchor pin nut (flat side against
flange on flange plate) in position behind flange plate
and insert threaded end of anchor pin from front side.
T hread the anchor pin into nut and tighten securely
(140 lb. f t . - 190 N -m ). Bend tan g of w asher over
reinforcem ent and side of w asher over hex of anchor
pin.
5. In stall lever on cable by com pressing spring and
inserting cable in channel of lever. Release spring.
6. Install prim ary shoe (short lining) to lever as follows:
Place pin in lever, place w asher on pin and push pin
through hole in prim ary shoe. Fasten parts together by
installing the clip in groove of pin.
7. Fasten two brake shoes and linings together by install
ing connecting spring. Move the shoes toward each
other and install adjusting screw.
8. L ubricate the flange plate contact surfaces with a very
light coat of Delco Brake Lube (or equivalent).
9. Place shoe and linings in position on flange plate.
W hen facing the brake assembly, the shoe with the
short lining should be to th e left w ith the lever
assem bled to it (autom atic transm ission), to the right
(m anual transmission).
10. Pull brake shoes ap art and install stru t lever and spring
between them . The loop on the stru t spring should be in
the " u p " position.
11. Install hold down pins, washers, springs and cups from
flange plate to shoes.
12. Place guide plate on anchor pin.
13. Install pull back springs.
14. Remove the "knock o u t" plug (if necessary) and install
a new m etal plug in the brake drum adjusting hole.
15. Install the brake drum .
16. Install the propeller shaft.
5-43
DRUM D IA M E TE R S
O R IG IN A L
MAXIMUM R E F IN IS H
R E PL A C E M E N T
(D ISC A R D )
11.060
11.210
12.060
13.060
11.090
11.240
12.090
13.090
11.000
11.150
12.000
13.000
BRAKE DRUMS
Brake Drum Balance
WHEEL CYLINDER
Removal
1. Remove wheel, drum and brake shoes. Be careful not to
get grease or dirt on brake lining.
2. Remove wheel cylinder from backing plate.
Disassembly
1. Inspect cylinder bore for scoring or corrosion. It is best
to replace a corroded cylinder.
2. Polish any discolored or stained area with crocus cloth
by revolving cylinder on cloth supported by a finger.
3. Rinse cylinder in clean brake fluid.
LIG H T T R U C K SERVICE M AN U AL
5-44
BRAKES
Assembly
1. L ubricate cylinder bore and counterbore with clean
brake fluid and insert spring-expander assembly.
2. Install new cups. (Be sure cups are lint and dirt free.)
Do not lubricate cups prior to assembly.
3. Install new pistons.
4. Press new boots into cylinder counterbores by hand. Do
not lubricate boots prior to assembly.
Installation
NOTICE: See "N o tic e " on page 1 of this section.
1. Install wheel cy linder on brak e backing plate and
connect brake pipe to hose. Torque rear wheel brake
Installation
1. Install the filter. Be sure the vacuum check valve on the
power brake unit is positioned from vertical as shown in
figure(s) 5-48 and 5-49.
2. Position hose clam p to retain filter.
BRAKES
5-45
C-K MODELS
P MODELS
LIG H T T R U C K SERVICE M A N U A L
5-46
BRAKES
Pneumatic Accumulator
CAUTION:The accumulator contains compressed
gas. Always use proper tools and follow recom
mended procedures or personal injury may result.
Do not apply heat to accumulator. Do not attempt
to repair an inoperative accumulator, always
replace with a new accumulator. Dispose of an
inoperative accumulator by drilling a 1/16" (1.6
mm) diameter hole through the end of the accu
mulator can opposite the "O " ring.
Removal
LIG H T TR U C K SE RV IC E M A N U A L
BRAKES
5-47
Installation
1. Using clean power steering fluid, lubricate accum ulator
seal. Install seal and accum ulator in housing and then
place the retaining ring over the accum ulator (fig.
5-52). Place Tool J-26889 over accum ulator.
2. Using Tool J-22269-01 or a large " C " clamp (6 " (150
mm ) m inim um ) depress the accu m u lato r m aking
certain th a t the accum ulator is compressed straight
(fig. 5-51).
3. Snap the retaining ring into the housing groove by
pushing it down all the way around w ith a sm all
screwdriver.
4. Remove Tool J-22269-01 or " C " clam p and retaining
cap Tool J-26889.
Carefully check to make sure the retaining ring was
completely installed properly.
5. Connect high pressure hose and check power steering
fluid.
6. Install the m aster cylinder two nuts and accum ulator
retaining cap Tool J-26889 and close the vehicle hood.
Test the unit by starting the engine and turning the
steering wheel from stop to stop a few times. Turn off
engine and apply brake pedal 4 or 5 times.
7. Remove accum ulator retaining cap Tool J-26889 and
install m aster cylinder nut.
LIG H T T R U C K SERVICE M A N U A L
5-48
BRAKES
Installation
1. Install " O " ring and spool valve plug (fig. 5-53).
2. Push spool valve plug in and install retaining ring.
3. Install m aster cylinder and two nuts to booster.
O" RING
SPOOL
'P LU G
SPOOL
PLUG
RETAINER
Tube Seat
Replacement
1. T urn engine off and pum p brake pedal 4 or 5 tim es to
deplete accum ulator.
2. Clean dirt around fitting before removing fitting, then
disconnect pressure hose a t Hydro-Boost and secure
hose in a raised position to prevent loss of fluid.
3. To prevent m etal chips from entering booster, pack
inside of tube seat with petrolatum .
4. Remove tube seat using N o. 4 easy-out as shown in
Figure 5-54.
5. W ipe p etro latu m from housing and clean housing
thoroughly to remove any m etal chips or dirt.
6. Install tube seat with Tool J-6217 as shown in Figure
5-55.
7. Fill and bleed system. R efer to "H Y D R O -B O O S T
B L E E D IN G P R O C E D U R E ".
BRAKES
5-49
G MODELS
LIG H T T R U C K SERVICE M AN U AL
5-50
BRAKES
LIG H T T R U C K SERVIC E M A N U A L
BRAKES
5-51
LIG H T T R U C K SERVICE M A N U A L
5-52
BRAKES
LIG H T T R U C K SERVICE M A N U A L
BRAKES
Hydro-Boost Unit
Replacement (fig. 5-56 thru 5-59)
1. D epress and release th e b rak e pedal several tim es
(engine not running) to be sure th at all pressure is
discharged from the accum ulator prior to disconnectiong the hoses from the booster.
2. P30(32) Models- Raise the vehicle on a hoist.
3. Clean all dirt from the booster at the hydraulic line
connections and m aster cylinder.
4. Rem ove th e nuts and lockw ashers th a t secure the
m aster cylinder to the booster and the support bracket.
S upport the m aster cylinder, being careful to avoid
kinking or bending the hydraulic lines attached to the
m aster cylinder. Cover the end of the m aster cylinder
with a clean cloth.
It should not be necessary to disconnect the hydraulic
lines from the m aster cylinder.
5. Disconnect the hydraulic lines from the booster ports.
Plug all lines and the booster ports to prevent loss of
fluid and to keep out foreign m aterial.
6 . P30(42) and C-K-G Modelsa. Rem ove booster pedal push rod co tter pin and
w asher and disconnect the push rod from the brake
pedal (C and K models) or booster bracket pivot
lever (G and P models).
5-53
SPECIFICATIONS
REAR BRAKES
FRONT BRAKES
GASOLINE ENGINE VEHICLES
C-MODELS
Drum 11.00 x 2.00
Disc 11.86 x 1.04
Drum 11.00 x 2.00
Disc 11.86 x 1.04
G-MODELS
Drum 11.00 x 2.00
Disc 11.86 x 1.28
Drum 11.00 x 2.00
Disc 11.86 x 1.28
ALL MODELS
Drum 11.15 x 2.75
Disc 11.86 x 1.28
Drum 11.15 x 2.75
Disc 12.50 x 1.28
Drum 13.00 x 2.50
Disc 12.50 x 1.28
Drum 13.00 x 3.50
Disc 12.50 x 1.53
Disc 13.75 x 1.53
Disc 14.25 x 1.53
SYSTEM
BRAKE ASSIST
LIG H T T R U C K SERVICE M A N U A L
5-54
BRAKES
SPECIFICATIONS
c
M aster C y lin d e r
to Dash o r B o o ste r
34 Nm 125 ft. lb s .l
48 N .m (35 ft. lbs.)
C a liper
B ra cke t
M o u n tin g B o lt
S u p p o rt Plate to K n u ckle
Brake Pedal
B ra c k e t to Dash
B ra c k e t to I.P.
Pivot B o lt Nut
Sleeve to B ra cke t
S to p la m p S w itch B ra cke t
Cable C lip s
Screw s
B o lts
Flange Plate
Drum
B ra cke t to Trans.
5.5 N*m (50 in. lbs.)/20 N*m (180 in. lbs.) on JB5, JB6, JB 7 and JB8
to Fram e Nut
B ra cke t B o lt
B ra cke t to Axle
R e ta in in g C lip s
Screws
B o lts
Brake B le e d e r Valves
H yd ro-B o o st
Pedal Rod
Pivot Lever B o lt
B o o ste r B ra cke ts
Pedal Rod B o o t
17 N .m (150 in lbs.)
L IG H T T R U C K SE RV IC E M AN U AL
(CKP20-30)
BRAKES
5-55
SPECIAL TOOLS
1.
2.
3.
4.
5.
6.
7.
L IG H T T R U C K SERVICE M A N U A L
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ENGINE
6-1
SECTION 6
ENGINE
CONTENTS
E N G IN E D IA G N O S IS
Engine Perform ance D iagnosis............................. .....6-1
Engine M echanical Diagnosis - G asoline.......... .....6-10
Engine M echanical Diagnosis - D iesel............... .....6-14
Engine Diagnosis - Electronic Spark C o n tro l... .....6D-1
E N G IN E - G A S O L IN E
4.1 L (250) V IN (D) L -L -R P O L E 3................ 6 A 1-1
4.8 L (292) VIN (T) L -6 -R P O L 2 5 ................. 6 A 1-1
5.0 L (305) V IN (G ) V -8 -R P O L G 9................ 6 A 4 -1
5.0 L (305) V IN (F) V -8 -R P O L F 3 ................. .... 6A4-1
5.0 L (305) V IN (H ) V -8 -R P O L E 9 ................ .... 6A4-1
GENERAL INFORMATION
STATEMENT ON CLEANLINESS
AND CARE
An autom obile engine is a com bination of m any
m achined, honed, polished and lapped surfaces with toler
ances th at are measured in the ten thousands of an inch.
W hen any internal engine parts are serviced, care and
cleanliness are im portant. A liberal coating of engine oil
should be applied to friction a reas d uring assem bly to
p rotect and lu b ricate the su rfaces on initial operation.
T hroughout this section, it should be understood that proper
cleaning and protection of machined surfaces and friction
areas is part of the repair procedure. This is considered
standard shop practice even if not specifically stated.
W henever valve train com ponents are removed for
service, they should be retained in order. At the tim e of
installation, they should be installed in the same locations
and with the sam e m ating surfaces as when removed.
Battery cables should be disconnected before any major
work is performed on the engine. Failure to disconnect
cables may result in dam age to wire harness or other
electrical parts.
GENERAL INFORMATION ON
ENGINE SERVICE
T H E F O L L O W IN G IN F O R M A T IO N ON E N
G IN E S E R V IC E S H O U L D BE N O T E D C A R E FU L L Y ,
AS IT IS IM P O R T A N T IN P R E V E N T IN G D AM AGE,
A N D IN C O N T R IB U T IN G TO R ELIA B LE E N G IN E
PERFO RM A N CE.
W hen raising or supporting the engine for any reason,
do not use a jack under the oil pan. Due to the small
clearance between the oil pan and the oil pump screen,
jacking against the oil pan may cause it to be bent against
the pump screen resulting in a dam aged oil pick-up unit.
It should be kept in mind, while working on the engine,
that the 12-volt electrical system is capable of violent and
dam aging short circuits. W hen perform ing any work where
electrical term inals could possibly be grounded, the ground
cable of the battery should be disconnected at the battery
Any tim e the carburetor or air cleaner is removed, the
intake opening should be covered. This will protect against
accidental entrance of foreign m aterial which could follow
the intake passage into the cylinder and cause extensive
dam age when the engine is started.
LIG H T T R U C K SERVICE M AN U AL
6-2
ENGINE
IN
THE
M E C H A N IC A L
PR O C E D U R ES
DESCRIBED IN TH IS SECTIO N , G E N E R A L L Y NO
R EFEREN C ES W IL L BE M A D E TO T H E REM O V A L
OF O P T IO N A L E Q U IP M E N T SUCH AS PO W ER
STEER IN G
PU M P,
A IR
C O N D IT IO N IN G
COM PRESSOR, ETC.
SH O U LD IT BECO M E N ECESSA RY TO REM OVE
\N Y SUCH ITEM TO P E R FO R M O T H E R SERVICE,
R.EFER TO T H E A P P R O P R IA T E SECTIO N O F TH IS
SERVICE M A N U A L FO R SPE C IFIC IN FO R M A T IO N .
INTRODUCTION
Engine Perform ance Diagnosis procedures are guides
that will lead to the most probable causes of engine
performance complaints. They consider all of the
components of the fuel, ignition, and mechanical systems
that could cause a particular com plaint, and then outline
repairs in a logical sequence.
It is im portant to determ ine if the Check Engine light
is ON or has come O N for a short interval while
driving. If the Check Engine light has come O N , the
Computer Com m and Control System should be checked for
stored Trouble Codes (See Section 6E) which may
indicate the cause for the perform ance complaint.
SYMPTOM
DEFINITION
A. Dieseling
Engine continues to run after the switch is turned off. It runs unevenly
and makes knocking noises.
B. D etonation
A mild to severe ping, usually worse under acceleration. The engine makes sharp
metallic knocks that change with throttle opening. Sounds like pop corn popping.
C. & D. Stalls,
Cold or H ot
The engine runs unevenly at idle. If bad enough, it may make the car shake.
E. Miss
F. Hesitates
G. Surges
Engine power variation under steady throttle or cruise. Feels like the
car speeds up and slows down with no change in the accelerator pedal.
H. Sluggish
Engine delivers limited power under load or at high speed. W ont accelerate
as fast as normal; loses too much speed going up hills, or has less top speed
than normal.
I. Spongy
LIG H T T R U C K SERVICE M AN U AL
ENGINE
6-3
to increase cruising speed. C ontinuing to push the pedal down will finally
give an increase in speed.
J. Poor Gas Mileage
Self describing.
K. Cuts O ut
Self describing
Self describing
Refer to emission la
C. Stalls or Rough
Idle - Cold
1. W ith engine running, remove air cleaner cover and filter. D am per door
in air cleaner snorkel should be closed when engine is cold. It may be
necessary to place cold wet rag over sensor to close it if engine is too warm.
If dam per door does not close, apply vacuum directly to vacuum motor. If
door closes, replace sensor. If door stays open, replace vacuum motor.
2. Visually check the following:
a. H ot air tube to air cleaner connection and condition of hot air stove.
b. Vacuum hoses for splits, kinks and proper connections. See Hose R outing
Schematic on Vehicle Emission Control Inform ation Label.
c. A ir leaks at carburetor m ounting and intake manifold.
d. Ignition wires for cracking, hardness and proper connections.
R epair or replace as necessary.
LIG H T T R U C K SERVICE M A N U A L
6-4
ENGINE
D. Stalls or Rough
Idle - Hot
1. W ith engine running, remove air cleaner cover and filter. D am per door in
air cleaner snorkel should be open. If closed and engine is hot, check
tem perature operation of sensor unit. See air cleaner tem perature test,
Section 6E.
2. Visually check the following:
a. Vacuum hoses for splits, kinks and proper connections. See hose routing
Schematic, Vehicle Emission Control Inform ation Label.
b. A ir leaks at carburetor m ounting and intake manifold.
c. Ignition wires for cracking, hardness and proper connections. Repair or
replace as necessary.
d. Check idle solenoid - Replace as necessary - See idle solenoid Section 6E.
3. Check engine tim ing and idle speed. See emission control inform ation label.
4. Check P.C.V. valve for proper operation by placing finger over inlet hole
in valve end several times. Valve should snap back. If not, replace valve.
5. Remove vacuum hose from E.G .R. valve and connect an extra hose from any
manifold source to valve. If rpm doesnt drop, valve is leaking. See E.G.R.
Section 6E for further functional tests, cleaning a n d /o r replacement.
6. Remove carbon with top engine cleaner. Follow instructions on can. If
idle is still rough, run a cylinder compression check.
E. Miss
LIG H T T R U C K SERVICE M A N U A L
ENGINE
6-5
replace as necessary.
2. Disconnect air cleaner and E.G .R. vacuum hoses and cap both vacuum sources.
3. Remove one spark plug wire at a time with insulated pliers. If there is
an rpm drop on all cylinders, go to rough idle (hot) diagnosis charts.
4. If there is no rpm drop on one or more cylinders (See
Section 6D Interm ittent Operation or Miss), remove spark plug(s)
and check for:
a. Cracks
b. W ear
c. Im proper gap
d. Burned Electrodes
e. Heavy Deposits
Repair or replace as necessary.
5. Check spark plug wires by connecting ohm m eter to ends of each wire in question.
If m eter reads over 50,000 ohms, replace wire(s).
:
' '
6. Visually check distributor cap and rotor for moisture, dust, cracks,
burns, etc. Clean a n d /o r repair as necessary.
7. Perform compression check on questionable cylinder(s). If compression is low,
repair as necessary.
8. Remove rocker covers. Check for bent push rods, worn rocker arms, broken
valve springs, worn cam shaft lobes. Repair as necessary.
Laaofte tx'iiros'/ .m jjuzsv "clr.viqQf b m jinyq rtujsz&v I'bsmit-O
F. Hesitates
LIG H T T R U C K SERVICE M A N U A L
6-6
ENGINE
air cleaner snorkel should be closed when engine is cold. It may be necessary
to place cold wet rag over sensor to close if engine is too warm.
If dam per door does not close, apply vacuum directly to vacuum motor. If
door closes, replace sensor. If door stays open, replace vacuum motor.
7. Check TPS adjustm ent if applicable see Section 6C.
G. Surges
1. W ith engine running, remove air cleaner cover and filter. D am per door in
air cleaner snorkel should be closed when engine is cold. It may be necessary
to place cold wet rag over sensor to close if engine is too warm.
2. Visually check the following:
a. Vacuum hoses for splits, kinks and proper connections. See hose routing
Schematic, Vehicle Emission Control Inform ation Label.
b. A ir leaks at carburetor m ounting and intake manifold.
c. Ignition wires for cracking, hardness and proper connections. R epair or
replace as necessary.
3. Non EST check ignition timing per emission control inform ation label.
To check m echanical advance, observe timing marks. It should advance
as throttle is opened and return to m ark as throttle is closed.
Check EST operation if applicable.
4. Non EST with engine off, remove vacuum hose from distributor vacuum advance
Connect vacuum pum p and apply 15" vacuum. Vacuum should hold steady for 15
seconds. If vacuum drops, replace vacuum advance unit.
5. Check carburetor fuel inlet filter. Replace if dirty or plugged.
6. Test fuel pum p by connecting hose from carburetor fuel feed line to a suitable
container. Start engine and let idle for 15 seconds.
a. M echanical pum p should supply 1/2 pint or more. If not, go to step 7.
If O K, go to step 9.
7. To check m echanical fuel pum p connect a vacuum gage. Crank or run
engine until m aximum vacuum is reached. If less than 12 inches, replace
pump. If vacuum reading is 12 inches or more, go to step 8.
8. Check fuel lines and hoses for splits, leaks or kinks by disconnecting each
section of line and connect vacuum gage. Crank or run engine until vacuum
gage peaks. Vacuum should be at least 12 inches. If less, repair or replace
defective line or hose.
9. If fuel lines and pum p check O K , remove tank unit, replace strainer and
clean fuel tank, if necessary.
10. Remove spark plugs, Check for cracks, wear, im proper gap, burned electrodes,
heavy deposits. R epair or replace as necessary.
LIG H T T R U C K SERVICE M A N U A L
ENGINE
H. Sluggish or Spongy
6-7
1. Rem ove air cleaner and check air filter for dirt or being plugged.
Replace as necessary.
2. W ith engine running, dam per door in air cleaner snorkel should be closed when
engine is cold. It may be necessary to place cold wet rag over sensor to close
if engine is too warm.
If dam per door does not close, apply vacuum directly to vacuum m otor. If
door closes, replace sensor. If door stays open, replace vacuum m otor.
3.
4. Remove air cleaner and check for full throttle valve opening in carburetor
by depressing accelerator pedal to floor; also check for full choke valve
opening and free operating air valve (if equipped). R epair as necessary.
See carburetor cleaning and inspection, Section 6C.
5. Rem ove vacuum hose from E.G .R . valve and connect an extra hose from any
m anifold vacuum source to valve. If rpm doesnt drop, valve is leaking.
See E .G .R . Section 6E for further functional tests, cleaning, a n d /o r replacem ent.
6. N on EST with engine off, remove vacuum hose from distributor vacuum advance
vacuum pum p and apply 15" vacuum. Vacuum should hold steady for 15 seconds.
If vacuum drops, replace vacuum advance unit.
7. Remove spark plugs. Check for cracks, wear, im proper gap, burned electrodes,
heavy deposits. Repair or replace as necessary.
8. Remove carburetor air horn and check the following:
a. Power piston for freeness
b. D irt in carburetor
c. Float adjustment
d. M etering rods
e. Power valve(s)
Refer to carburetor cleaning and inspection, Section 6C.
I. Poor Gasoline
Mileage
1. W ith engine running, remove air cleaner cover and filter. Check
filter for dirt or being plugged. Replace as necessary. D am per door in air
cleaner snorkel should be closed when engine is cold. It may be necessary
to place cold wet rag over sensor to close it if engine is too warm.
If dam per door does not close, apply vacuum directly to vacuum motor.
If door closes, replace sensor. If door stays open, replace vacuum motor.
2. Visually check the following:
a. Vacuum hoses for splits, kinks and proper connections. See hose routing
Schematic, Vehicle Emission Control Inform ation Label.
b. A ir leaks at carburetor m ounting and intake manifold.
c. Ignition wires for cracking, hardness and proper connections. Repair
or replace as necessary.
3. Check ignition timing per emission control information label.
Non EST To check mechanical advance, observe timing mark. It should advance
throttle is opened and return to m ark as throttle is closed.
LIG H T TR U C K SERVICE M A N U A L
6-8
ENGINE
LIG H T T R U C K SERVIC E M A N U A L
ENGINE
6-9
7. Check fuel lines and hoses for splits, leaks or kinks by disconnecting
each section of line and connecting a vacuum gage. Crank or run engine until
vacuum gage peaks. Vacuum should be at least 12 inches. If less, repair or
replace defective line or hose as necessary.
8. If fuel pum p and fuel lines check O K , remove tank unit, replace strainer
and clean fuel tank, if necessary.
If carburetor is suspected, remove the air horn and check the
following:
a. Power Piston(s) or main fuel piston for freeness.
b. D irt in jets and m etering passages.
c. M etering rods.
d. Power valve(s) or main fuel valve(s).
e. Float adjustment.
See C arburetor Cleaning Inspection and A djustm ent, Section 6C.
K. H ard Starting - Cold
(Engine Cranks O K )
LIG H T T R U C K SERVICE M A N U A L
6-10
ENGINE
LIG H T T R U C K SERVICE M A N U A L
b. Im proper reading of
dipstick.
ENGINE
e. P.C.V. system
m alfunctioning.
1. Service as necessary.
f. Valve guides a n d /o r
valve stem seals worn,
or seals omitted.
h. Piston im properly
installed or misfitted.
1. Replace piston or
repair as necessary.
b. Incorrect or
m alfunctioning oil
pressure switch.
c. Incorrect or
malfunctioning oil
pressure gage.
1. Replace tube.
i. Excessive bearing
clearance.
1. Replace as necessary.
j. Cracked, porous or
plugged oil galleys.
1. Install plugs or
repair as necessary
6-11
LIG H T TR U C K SERVICE M A N U A L
6-12
ENGINE
1. Replace gasket.
1. Replace as necessary.
1. Replace spring.
e. Sticking valves.
1. Free valves.
1. Replace camshaft.
1. Repair as necessary.
POSSIBLE CAUSE
CORRECTION
a. Engine knocks
cold and continues
for two to three
minutes. Knock
increases with torque.
1. E FE equipped engines
may have valve knock.
2. Flywheel contacting
splash shield.
3. Loose or broken
balancer or drive
pulleys.
4. Excessive piston to
bore clearance.1
1. Replace E FE valve.
LIG H T T R U C K SERVIC E M A N U A L
1. Broken balancer or
pulley hub.
2. Loose torque converter
bolts.
3. Accessory belts too
tight or nicked.
4. Exhaust system
grounded.
5. Flywheel cracked.
6. Excessive main bearing
clearance.
7. Excessive rod bearing
clearance.
2. Reposition splash
shield.
3. Tighten or replace
as necessary.
4.
Replace piston.
1. Replace parts as
necessary.
2. Tighten bolts.
3. Replace a n d /o r tension to specs
as necessary.
4. Reposition as necessary.
5. Replace flywheel.
6. Replace as necessary.
7.
Replace as necessary.
ENGINE
load conditions.
d. Engine knocks on
initial start up
but only lasts a
few seconds.
e. Engine knocks at
idle hot.
1. D etonation or spark
knock.
6-13
1. Replace pump.
2. Install proper oil viscosity
for expected temperatures.
3. Clean, test and replace
as necessary.
4. Replace crankshaft thrust
bearing.
1. Tension a n d /o r replace
as necessary.
2. Replace as necessary.
3. Replace pump.
4. Replace parts as necessary.
5. Install proper viscosity oil
for expected tem perature.
6. Ream and install oversize pins.
7. Check and replace rods
as necessary.
8. Hone and fit new piston.
Cold engine piston knock usually disappears when the cylinder is grounded out. Cold engine piston knock which
disappears in 1.5 minutes should be considered acceptable.
2W hen the engine is stopped, some valves will be open. Spring pressure against lifters will tend to bleed lifter down.
A ttem pts to repair should be m ade only if the problem is consistent and appears each time engine is started.
L IG H T T R U C K SERVICE M A N U A L
6-14
ENGINE
CONDITION
Engine Will Not Crank
POSSIBLE CAUSE
CORRECTION
1. Loose or Corroded
Battery Cables
2. Discharged Batteries
3. Starter Inoperative
1. Battery Cable
Connections Loose
or Corroded
2. Batteries Undercharged
1. Incorrect Starting
Procedure
Remove any one glow plug. Depress the th ro ttle part way
and crank the engine for 5 seconds. If no fuel vapors come
out o f the glow plug hole, go to step 5. If fuel vapors are
4 noticed remove the rem ainder o f the glow plugs and see if
fuel vapors come out o f each hole when the engine is
cranked. If fuel comes out o f one glow plug hole only
replace the injection nozzle in that cylinder. Crank the
engine and check to see that fuel vapors are coming out o f
all glow plug holes. If fuel is coming from each cylinder,
go to step 11.
5. No Fuel To Injection
Pump
Loosen the line coming out o f the filter. Crank the engine,
the fuel should spray out o f the fitting, use care to direct
fuel away from sources o f ignition. If fuel sprays from the
fitting go to step 10.
Loosen the line going to the filter, if fuel sprays from the
fitting, the filter is plugged and should be replaced. Use care
to direct the fuel away from sources o f ignition.
Remove fuel tank and check filter. (Filter for diesel fuel is
blue).
Diesel Diagnosis 1
LIG H T T R U C K SERVIC E M A N U A L
ENGINE
10. No Voltage To
Fuel Solenoid
11. Incorrect or
Contam inated Fuel
3. Restricted Fuel
R eturn System
6. Limited Fuel To
Injection Pump
Test the engine fuel pum p, check for plugged filters; check
fuel lines. Replace or repair as necessary.
7. Incorrect or
C ontam inated Fuel
8. Low Compression
6-15
Diesel Diagnosis 2
LIG H T TR U C K SERVICE M AN U AL
6-16
ENGINE
4. Air In System
5. Inco rrecto r
C ontam inated Fuel
6. Nozzle(s) M alfunction
1. Injection Pump
Timing Incorrect
2. Insufficient Engine
Break-in Time
3. Air in System
4. Nozzle(S) Malfunction
Replace filters.
2. Incorrect Injection
Pump Timing
3. Incorrect or
C ontam inated Fuel
3. Internal Injection
Pump M alfunction
2. Injection Pump
Internal Seal Leak
2. EGR Malfunction
3. Restricted or Damaged
Exhaust System
Replace filter.
.".m ! r r j
Noticeable Loss
Of Power
Diesel Diagnosis 3
LIG H T T R U C K SERVIC E M A N U A L
ENGINE
7. Restricted Fuel
Tank Filter
Remove fuel tank and check filter. (Filter for diesel fuel is
blue).
8. Pinched or Otherwise
Restricted Return System
9. Incorrect or
Contam inated Fuel
Check for com pression leaks at all nozzles and glow plugs,
using Leak-Tec or equivalent. If leak is found, tighten
nozzle or glow plug.
2. Mechanical Problem
2. EGR Malfunction
4. Injection Pump
Internal Problem
6-17
Diesel Diagnosis 4
LIG H T T R U C K SERVICE M A N U A L
6-18
ENGINE
V A C U U M PU M P D IA G N O S IS
Excessive noise or clattering
noise.
Hooting noise.
Stripped threads.
Loose plug.
Bad crimp.
1. Defective valves.
2. Defective diaphragm.
3. Worn push rod seal.
4. Loose tube.
Diesel Diagnosis 5
LIG H T T R U C K SERVIC E M A N U A L
1. Seat Plug.
2. Replace drive assy.
ENGINE
6-19
REMOVE A IR CLEANER
INSTALL COVER J-26996-1
INSTALL MAG-TACH J-26925 - CHECK IDLE SPEED (SLOW & FAST)
__________________ I_____________
IDLE SPEED INCORRECT
IDLE SPEEDS OK
_____________________________________ ___________________________________
T IM IN G OFF
T IM IN G OK
ALIGN M A R K S
IDLE IMPROVES
NO IMPROVEMENT
---------
I
LEAKS
NO LEAKS
CORRECT
I
LEAKS
NO LEAKS
CORRECT
PRESSURE EVIDENT
NO PRESSUR: EVIDENT
DETERMINE CAUSE OF LACK
nr'O R |
ppr;<;iipr
Diesel Diagnosis 6
L IG H T T R U C K SERVIC E M AN U AL
6-20
ENGINE
NO BU BBLES OR FOAM
BU BBLES EVIDENT
F IN D C A U SE IN FUEL SU P PLY
LOOSEN THE LINE AT THE NOZZLES TO BLEED A SM ALL AMOUNT OF FUEL FROM THE
L IN E IF S O L ID FUEL APPEARS, GO ON TO THE NEXT NOZZLE. IF FOAM A P P E A R S
SHUT THE ENGINE OFF AND DISCONNECT THE LINE FROM THE N O Z ZLE MOVE THE
LINE SO THE INLET TO THE NOZZLE CAN BE OBSERVED. REMOVE THE P IN K W IRE
TO THE PU M P AND CRANK THE ENGINE AND O BSERVE THE NOZZLE INLET FOR
BUBBLES. IF BUBBLES ARE EVIDENT, REPLACE THE N O Z ZLE S Q U IR T SOME
O IL OR FUEL IN THE NEW NOZZLE INLET AND RECHECK FOR BUBBLES. IF BU BBLES
ARE NOT EVIDENT RECONNECT THE LINE AND P IN K W IR E AND GO ON TO THE
NEXT NOZZLE AND REPEAT THE PROCESS. CHECK THE REMOVED NOZZLE ON A
TESTER TO DETERMINE IF IT IS INOPERATIVE OR IF IT IS IN C O M PA T IB LE WITH
THE C YLIN D ER HEAD.
Diesel Diagnosis 7
LIG H T T R U C K SERVIC E M A N U A L
IN-LINE 6
6A1-1
Valves..............................................................................
Torsional D am per.......... ............ .................................
C rankcase Front C o v e r..............................................
Oil Seal (Front C o v er)...............................................
C a m s h a ft.......................................................................
C am shaft B earings......................................................
Oil P a n .......................... .................................................
Oil Pum p........................................................................
Engine Bearings............................................................
Oil Seal (R ear M a in ).................................................
Piston and Connecting Rod A ssem blies................
Flyw heel..........................................................................
Engine A ssem bly..........................................................
C ra n k sh a ft.....................................................................
Specifications...................................................................
6A1-16
6A1-16
6A1-16
6A1-17
6A1-17
6A1-18
6A1-19
6A1-19
6A1-20
6A1-24
6A1-25
6A1-28
6A1-29
6A1-30
6A1-32
Section 6A1
Contents
:br
GENERAL DESCRIPTION
CYLINDER BLOCK
The cylinder block is m ade of cast iron and has 6
cylinders arranged "In -L in e". Seven main bearings support
the crankshaft which is retained by recessed bearing caps
th at are m achined with the block for proper alignm ent and
clearances. Cylinders are completely encircled by coolant
jackets.
CYLINDER HEAD
The cast iron cylinder head has individual intake and
exhaust ports for each cylinder. Valve guides are integral
and rocker arm s are retained on individual threaded studs
pressed into head. The 4.1 L(D ) heads have integrated inlet
manifolds. The 4.8 L(T) uses separate inlet manifolds.
VALVE TRAIN
A very simple ball pivot-type train is used. M otion is
transm itted from the cam shaft through the hydraulic lifters
and push rods to the rocker arms. The rocker arm pivots on
its ball and transm its the cam shaft motion to the valve. The
rocker arm ball is retained by a self locking nut.
6A1-2
IN-LINE 6
INTAKE MANIFOLD
The intake manifold is of cast iron, single level design
for efficient fuel distribution. The 4.1 L (D) manifold is an
integral unit with the head on all vehicles. 4.8 L (T) engines
use separate components. The carburetor pad is centrally
located w ith an early fuel evaporation (E F E ) passage
running underneath the pad, through which exhaust gases
are forced, to promote faster fuel vaporization when the
engine is cold. An exhaust gas recirculation port is also cast
into the manifold on 4.1 L (D ) engines, for the induction of a
m etered am ount of exhaust gases into the air and fuel
m ixture which has entered through the carburetor.
EXHAUST MANIFOLD
On 4.8 L (T) engines a single four port, underslung,
center take down manifold of cast ironl is used to direct
exhaust gases from the com bustion cham bers. On 4.1 L (D)
engines a single four port, underslung, dual center take
down manifold of cast iron is used. A heat shield is m ounted
to the manifold th a t is used to route heated air to the air
cleaner for better fuel vaporization.
Engine Lubrication
Full pressure lubrication, through a full flow oil filter is
furnished by a gear-type oil pump. The distributor, driven
by a helical gear on the cam shaft, drives the oil pump.
Oil draw n by the pick-up screen and pipe is pressurized
in the pum p and routed to the oil filter. If excessive
backpressure is encountered at the filter, a bypass valve
allows oil flow to the m ain oil gallery, located along the right
side of the block. This rifle drilled gallery supplies oil to the
cam shaft bearings, the hydraulic lifters and the crankshaft
main bearings.
LIG H T T R U C K SERVICE M A N U A L
IN-LINE 6
6A1-3
OIL PRESSURE
SENDING UNIT
LIG H T T R U C K SERVIC E M AN U AL
6A1-4
IN-LINE 6
LIG H T T R U C K SERVIC E M A N U A L
IN-LINE 6
6A1-5
L IG H T TR U C K SERVIC E M AN U AL
6A1-6
IN-LINE 6
VIEW
ENGINE BRACKET
ALL C SERIES
WITH L-6 ENGINE
VIEW
LIG H T T R U C K SERVICE M A N U A L
L
ENGINE MOUNT & BRACKET
ALL K SERIES WITH L-6 ENGINE
Z........... 7
VIEW A \
FWD
X
292 CU. IN. R. SIDE
6A1-8
IN-LINE 6
LIG H T T R U C K SERVICE M A N U A L
IN-LINE 6
6A1-9
M AR MOUNT
FRONT MOUNT
ON VEHICLE SERVICE
ENGINE MOUNTS
Engine mounts (Fig. 6A1-2 - 6A 1-8) are the nonad ju sta b le type and seldom req u ire service. Broken or
d e te rio ra ted m ounts should be replaced im m ediately,
because of the added strain placed on other m ounts and
drive line components.
6A 1-10
IN-LINE 6
Installation
1. Clean gasket surfaces on cylinder head and manifolds.
2. Lay a straight edge along the full length of the exhaust
port faces and m easure any gaps between the straight
edge and the port faces. If at any point a gap of .030"
(.80m m) or more exists, it is likely th at the m anifold
has distorted to a point where it will not seat properly.
If a good exhaust seal is to be expected, the exhaust
manifold must be replaced.
3. Assem ble intake and exhaust manifolds using a new
gasket by reinstalling the one bolt and two nuts at the
center of the manifold to finger tight.
4. Position a new gasket over m anifold end studs on the
cylinder head.
5. Install manifold assembly bolts, clamps and washers
while holding manifold assembly in place by hand.
LIG H T T R U C K SERVIC E M A N U A L
Installation
If a new exhaust manifold is being installed, the E.F.E.
valve and actuator and rod assembly m ust be transferred
from the old component.
1. C lean gasket surface and position new gasket on
exhaust manifold.
2. Install manifold bolts, while holding manifold assembly
in place.
3. Torque all manifold to cylinder head bolts in sequence
to torques shown in figure 6 A 1-9.
4. Raise vehicle on hoist.
5. Connect exhaust pipe at manifold flange and converter
bracket at transm ission mount. A ttach exhaust pipe
and align exhaust system. Torque attaching bolts to
specification.
/ 12W
w
1 8 -2 5 ( 5 }
ft. lbs
w
&
ex.
3 5 -4 0
<ET
4 0 _ 45
Ix d
18~ 25
f t . | bs.
<3
&
ft.lb s .
" * 0
4 0 -4 5
ft. lbs.
TIGHTENING SEQUENCE
Fig. 6 A l-9 --C y lin d e r H ead To Exhaust M an ifo ld
Tightening Sequence
IN-LINE 6
6. Lower vehicle.
7. Install P A IR pipes as outlined in Section 6E.
8. Install power steering pum p an d /o r A .I.R . pum p and
brackets, if so equipped. Tighten drive belt using strand
tension gage.
9. Install air cleaner.
10. Connect negative b attery cable.
11. S ta rt engine and check for leaks.
6A1-11
VALVE MECHANISM
Removal
1. Remove rocker arm cover as previously outlined.
2. Remove rocker arm nuts, rocker arm balls, rocker arm s
and push rods. Place rocker arm s, rocker arm balls and
push rods in a rack so th a t they may be reinstalled in
the same location.
6AM 2
IN-LINE 6
VALVE LIFTERS
H ydraulic valve lifters very seldom require attention.
The lifters are extrem ely simple in design. Readjustm ents
are not necessary, and servicing of the lifters requires only
th at care and cleanliness be exercised in the handling of
parts.
Rem oval
1. Hold the plunger down with a push rod, and using the
blade of a small screw driver, remove the push rod seat
retainer.
2. Remove the push rod seat and m etering valve (fig. 6A112).
I.
L ifte r B o d y
2
3
C h e c k B a ll
C h e c k B a ll R e ta in e r
6
7
8
9
Push Rod S e a t
R e ta in e r
P lu n g e r
C h e c k B a ll S p rin g
P lu n g e r S p rin g
IN-LINE 6
6A1-13
O IL FEED HO LE
Installation
1. C oat foot of valve lifters with "M o ly k o te" or its
equivalent. Install valve lifters.
2. Using a 1/8" (3m m ) bead of RTV, # 1 0 5 2 3 6 6 or
equivalent, on the covers, install push rod side covers
and torque bolts to specifications.
3. Install distributor cap.
L IG H T T R U C K SERVIC E M AN U AL
6A 1-14
IN-LINE 6
Disassembly
1. W ith the cylinder head removed, use tool J-8062 to
compress the valve springs and remove the valve keys.
Release the com pressor tool and remove rotators or
spring caps, oil shedders springs and spring dam per
assem blies, then rem ove oil seals and valve spring
shims.
2. Remove valves from cylinder head and place them in a
rack in their proper sequence so th at they can be
assembled in their original positions.
Cleaning
1. Clean all deposits from combustion cham bers and valve
ports using Tool J-8089.
2. Thoroughly clean the valve guides using Tool J-8101.
3. Clean all carbon and sludge from push rods, rocker
arm s and push rod guides.
4. Clean valve stems and heads on a buffing wheel.
5. Clean carbon deposits from head gasket m ating
surface.
Inspection
Assembly
1. Insert valves in the proper ports.
2. Set the valve spring shim, valve spring (with dam per),
oil shedder and valve cap or rotator in place (fig. 6A117).
3. Compress the spring with Tool J-8062.
LOCKS CAP
SEAL
SHIELDJ j
SPRING i
* H A A A P F P '" 1
* N O T USED O N
250 CU. IN . L6
IN-LINE 6
6A1-15
Installation
J- 6 8 8 0
6A 1-16
IN-LINE 6
VALVE SEATS
R econditioning the valve seats is very im p o rtan t,
because the seating of the valves must be perfect for the
engine to deliver the power and perform ance built into it.
Installation
1. C oat front cover oil seal contact area of dam per with
engine oil.
2.
3.
4.
5.
VALVES
Valves th at are pitted can be refaced to the proper
angle, insuring correct relation between the head and stem
on a valve refacing m echanism . Valve stems which show
excessive wear, or valves th a t are warped excessively should
be replaced. W hen a valve head which is warped excessively
is refaced, a knife edge will be ground on part or all of the
valve head due to the am ount of m etal th a t m ust be removed
to completely reface. Knife edges lead to breakage, burning
or pre-ignition due to heat localizing on this knife edge. If
the edge of the valve head is less than 1/32" (.80m m ) thick
after grinding, replace the valve.
Several different types of equipm ent are available for
refacing valves. The recom m endations of the m anufacturer
of the equipm ent being used should be carefully followed to
attain proper results.
TORSIONAL DAMPER
Removal
1. D rain radiator and remove.
2. Rem ove accessory drive belt(s) and pulley (if so
equipped).
3. Remove drive pulley from torsional dam per.
4. Install Tool J-23523 to dam per and turn puller screw to
remove dam per (fig. 6A 1-21).
6.
7.
Installation
1. Clean gasket surfaces on block and crankcase front
cover.
2. C ut tabs from the new oil pan front seal (fig. 6A1-22)
use a sharp instrum ent to ensure a clean cut (L25
engine only).
CUT THIS P O R T IO N
FR OM N E W SEAL
IN-LINE 6
6A1-17
7.
8.
9.
10.
1. W ith cover removed, pry old seal out of cover from the
front with screw driver, being careful not to distort
cover.
2. Install new seal so th at open end of the seal is toward
the inside of cover and drive it into position with Tool
J-23042.
CAMSHAFT
M easu ring Lobe Lift
5. Align tim ing gear m arks then remove the two cam shaft
thrust plate bolts by working through holes in cam shaft
gear.
6. Remove the cam shaft and gear assembly by pulling it
out through the front of the block. Support cam shaft
carefully when rem oving so as not to dam age the
cam shaft bearings.
Inspection
6 A 1-18
IN-LINE 6
CAMSHAFT BEARINGS
Removal
IN-LINE 6
OIL PAN
All except 'G' Van
Removal
1.
2.
3.
4.
5.
6.
7.
8.
Installation
"G" Van
Removal
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
6A1-19
Installation
OIL PUMP
Removal
6A1-20
IN-LINE 6
1.
2.
3.
4.
5.
Pressure Regulator
Valve
Pressure Regulator
Spring
Retaining Pin
Screws
Pump Cover
6.
7.
8.
9.
10.
Cover Gasket
Idler Gear
Drive Gear and Shaft
Pump Body
Pickup Screen and
Pipe
Hi
IN-LINE 6
6.
7.
8.
9.
6A1-21
1. W ith oil pan and oil pum p rem oved, remove the
connecting rod cap and bearing.
Before removal of connecting rod cap, m ark the side of
the rod and cap with the cylinder num ber to assure
m atched reassembly of rod and cap.
2. Inspect the bearings for evidence of wear or dam age.
(Bearings showing the above should not be installed.)
3. W ipe both upper and lower bearing shells and crankpin
clean of oil.
4. M easure the crankpin for out-of-round or taper with a
m icrom eter. If not w ithin specifications replace or
recondition the crankshaft. If within specifications and
a new bearing is to be installed, m easure the maximum
diam eter of the crankpin to determ ine new bearing size
required.
5. If within specifications m easure new or used bearing
clearances with Plastigage or its equivalent.
If a bearing is being fitted to an out-of-round crankpin,
be sure to fit to the m axim um diam eter of the crankpin.
6A1-22
IN-LINE 6
Checking Clearance
IN-LINE 6
6A1-23
6.
7.
8.
9.
10.
Replacement
6A1-24
IN-LINE 6
.0 0 4 S H IM STOCK
1 1 /6 4
APPLY
SEALANT
TO SHADED
AREAS ONLY
1. W ith the oil pan and oil pum p removed, remove the
rear main bearing cap.
2. Remove oil seal from the bearing cap by prying from
the bottom with a small screw driver (fig. 6 A 1-35).
3. Use a small ham m er to tap a brass pin punch on one
end of the upper seal until it protrudes far enough to be
removed with pliers (fig. 6 A 1-36).
4. Clean all sealant and foreign m aterial from cylinder
case bearing cap and crankshaft, using a nonabrasive
cleaner.
Replacement
IN-LINE 6
6A1-25
PRESS
-PISTON PIN
REMOVER
J -2 4 0 8 6 -8
FIXTURE &
SUPPORT
ASSEMBLY
J -2 4 0 8 6 -2 0
Disassembly
1. Remove connecting rod bearings from connecting rods
and caps. If bearings are being reused, place them in a
rack so they m ay be reinstalled in th e ir original
positions.
2. Remove piston rings by expanding and sliding them off
the pistons. Tools J-8021 (3 -7 /8 ") and J-22249 (3-15/
16") are available for this purpose.
3. Place connecting rod and piston assem bly on tool
J-24086-20. U sing an arbor press and piston pin
remover, J-24086-8, press the piston pin out of connect
ing rod and piston (fig. 6 A 1-40).
Cleaning and Inspection
Connecting Rods
6A1-26
IN-LINE 6
Piston Pins
Piston Rings
Inspect piston pin bores and piston pins for wear. Piston
pin bores and piston pins m ust be free of varnish or scuffing
when being m easured. The piston pin should be measured
with a m icrom eter and th e piston pin bore should be
measured with a dial bore gage or an inside m icrom eter. If
clearance is in excess of the .001 " wear limit, the piston and
piston pin assembly should be replaced.
ASSEMBLY
PRESS
PISTON PIN
INSTALLER
J -2 4 0 8 6 -9
PISTON PIN
Installation
IN-LINE 6
ENGINE LEFT
ENGINE FRONT
6A1-27
ENGINE RIGHT
FRONT OF
ENGINE
A " O IL R IN G
SPACER G A P
B" O IL R IN G RAIL G A P S
C"
2N D
C O M P R E S S IO N
'D ' 1 TO P C O M P R E S S IO N
R IN G
R IN G
GAP
GAP
CYLINDER BLOCK
Cleaning and Inspection
1. W ash cylinder block thoroughly in cleaning solvent and
clean all sealing surfaces.
LIGHT TRUCK SERVICE MANUAL
6A1-28
IN-LINE 6
Conditioning
The perform ance of the following operation is contin
gent upon engine condition at tim e of repair.
If the cylinder block inspection indicated th at the block
was suitable for continued use except for out-of-round or
tapered cylinders, they can be conditioned by honing or
boring.
If the cylinders were found to have less than .005"
taper or wear they can be conditioned with a hone and fitted
with the high limit standard size piston. A cylinder bore of
less then .005 " wear or taper may not entirely clean up when
fitted to a high limit piston. If it is desired to entirely clean
up the bore in these cases, it will be necessary to rebore for
an oversize piston. If m ore than .005" taper or wear, they
should be bored and honed to the sm allest oversize th at will
perm it complete resurfacing of all cylinders.
W hen pistons are being fitted and honing is not
necessary, cylinder bores may be cleaned with a hot water
and d eterg en t w ash. A fter cleaning, the cylinder bores
should be swabbed several times with light engine oil and a
clean cloth and then wiped with a clean dry cloth.
Boring
Honing
1. W hen cylinders are to be honed follow the hone
m anufacturers recom m endations for the use of the
hone and cleaning and lubrication during honing.
2. Occasionally during the honing operation, the cylinder
bore should be th oroughly cleaned and th e piston
selected for the individual cylinder checked for correct
fit.
3. W hen finish honing a cylinder bore to fit a piston, the
hone should be moved up and down at a sufficient speed
LIGHT TRUCK SERVICE MANUAL
PISTON SELECTION
1. C heck U SE D piston to cylinder bore clearance as
follows:
a. M easure the "C y lin d er Bore D iam eter" w ith a
telescope gage (2 -1 /2 " (64m m ) from top of cylinder
bore).
b. M easure the "P iston D ia m e te r" (a t skirt across
center line of piston pin).
c. S ubtract piston diam eter from cylinder bore diam e
ter to determ ine " Piston to Bore C learance ".
d. D eterm ine if piston to bore clearance is in the
acceptable range.
2. If used piston is not acceptable, determ ine if a new
piston can be fitted to the cylinder bore.
3. If cylinder bore must be reconditioned, m easure new
piston diam eter (across center line of piston pin) then
hone cylinder bore to correct clearance.
4. M ark the piston to identify the cylinder for which it
was fitted.
FLYWHEEL
Removal
All Except L25 Engines
IN-LINE 6
Repair
Only repair recom m ended at flywheel used with con
ventional clutch is replacem ent of starter gear in event gear
is worn or otherwise dam aged.
Use torch to heat the gear around entire circum ference,
then drive the gear off flywheel, using care not to dam age
the flywheel.
U niform ly heat the flywheel gear to tem perature which
will expand gear to perm it installation. [T em perature must
not exceed 400F (204 C )|.
As soon as gear has been heated, install on flywheel.
5. Install
6.
ENGINE ASSEMBLY
Removal ("G " Van/Code D Engine)
6A1-29
7.
8.
9.
10.
11 .
6A1-30
IN-LINE 6
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
1.
2.
3.
4.
17.
18.
19.
16.
17.
18.
19.
20.
CRANKSHAFT
Removal
IN-LINE 6
APPLY
SEALANT
TO SHADED
AREAS ONLY
6A1-31
REMOVAL
IN
TRUCK
M AN U AL
4.1 (D)
4.8 (T)
LE3
L25
.9270-.9273
.00015-.00025
PRODUCTION
CLEARANCE
.001 M A X .
SERVICE
RPO
3.876
BORE
STROKE
COMPRESSION RATIO
4.120
8.25:1
8.0:1
MAIN
JOURNAL
DIAMETER
TAPER
ALL
2.2979-2.2994
DIAMETER
1-5-3-6-2-4
C YLIN D ER BORE:
TAPER
3.8750-3.8780
PRODUCTION
.0005 M AX.
SERVICE
.002 M AX.
PRODUC
TION
.0008-.0016 INTERFERENCE
FIT IN ROD
CRANKSHAFT
3.530
FIRING ORDER
OUT OF
ROUND
L25
THRUST
SIDE
OUT OF
ROUND
PRODUCTION
.0002 M A X .
SERVICE
.001 M A X .
PRODUCTION
.0002 M A X .
SERVICE
.001 M A X .
.0005 M AX.
RELIEF
SIDE
MAIN
BEARING
CLEARANCE
.0005 M AX.
# 1 -6 .0010-.0024
# 7 .0016-.0035
PRODUCTION
.001 M AX.
SERVICE
SERVICE
# 1 -6
.0010-.0025
PRODUCTION
.0010-.0020
.0026-.0036
.0030 M AX.
.0045 M A X .
DIAMETER
#7
1.999-2.000
2.099-2.100
CLEARANCE
SERVICE
PRODUCTION
.0005
SERVICE
.001 M A X .
PRODUCTION
.0005
TAPER
CRANKPIN
PISTON RIN G:
0
M
P
R
E
S
S
1
o
TOP
GROOVE PRODUC
CLEAR TION
2ND
ANCE
SERVICE
GAP
PRODUC
TION
0
1
GROOVE
CLEAR
ANCE
.0020-.0040
.0012-.0032
HI LIM IT + .001
.0 1 0.0 2 0
2ND
.010-.020
PRODUCTION
OUT OF
ROUND
.0020-.0040
TOP
SERVICE
.0012-.0027
SERVICE
.001 M A X .
.0010-.0026
PRODUCTION
SERVICE
.0030
HI LIM IT + .010
.005 M AX.
ROD BEARING
CLEARANCE
.005-.0055
.006-.017
CAMSHAFT
LOBE LIFT
.002
INTAKE
EXHAUST
.2315
.2217
.2315
SERVICE
HI LIM IT + .001
PRODUCTION
.015-.055
JOURNAL DIAMETER
1.8677-1.8697
SERVICE
HI LIM IT + .010
.003-.008
GAP
* VIN Designation
ggJI
.002-.006
PISTON:
IN-LINE 6
SERVICE
LITRE (*)
6A1-32
LIGHT
DIAMETER
IN LINE L-6
TYPE
DISPLACEMENT
LE3
PISTON PIN
GENERAL DATA:
TORQUE SPECIFICATIONS
VALVE SYSTEM_______________ LE 3
L25
L IF T E R
H YD RAULIC
RO CKER A R M R A T IO
1.75:1
IN T A K E
VALVE
LASH
45
46
SE AT A N G L E ( IN T. & EXH.)
46
SEAT R U N O U T
SE AT
W ID T H
STEM
CLEARANCE
.002 M A X .
IN T A K E
1/32-1/16
EXHAUST
1/16-3/32
P R O D U C TIO N
SE RVIC E
FREE LENG TH
VALVE
SPRING
( O U TE R )
.0010-.0027
INT.
EXH.
PRESSURE
LBS. @ IN.
.0015-.0032
HI I IM IT
MIU[V111
INTAKE
+ .002 EXHAUST
2.08
CLOSED
7 8 -8 6 @ 1.66
OPEN
1 7 0 -1 8 0 @ 1.26
I N S T A L L E D H E IG H T
1.66
1 /3 2 "
FREE L E N G TH
1.94
APPROX. # OF COILS
D AM PER
SMALL BLOCK
6A4-1
SECTION 6A4
6A4-1
6A4-2
6A 4-11
6A 4-11
6A4-11
6A4-12
6A 4-12
6A4-13
6A4-14
6A4-14
6A4-15
6A4-18
6A4-19
6A4-19
6A4-19
Torsional D am per........................................................
Crankcase Front C o v er..............................................
Oil Seal (Front C ov er)...............................................
C a m s h a ft.......................................................................
C am shaft B earings......................................................
Oil P a n ...........................................................................
Oil Pum p........................................................................
Connecting Rod B earin g s........................... .............
M ain B earings..............................................................
Oil Seal (R ear M a in ).................................................
Connecting Rod Piston A sem blies..........................
Cylinder Block..............................................................
Oil Filter Bypass V alve..............................................
Engine A ssem bly.........................................................
C ra n k sh a ft.....................................................................
Sprocket or G ear R eplacem ent................................
Specifications..................................................................
6A4-19
6A4-20
6A4-20
6A4-21
6A4-21
6A4-22
6A4-23
6A4-23
6A4-24
6A4-26
6A4-28
6A4-31
6A4-32
6A4-32
6A4-33
6A4-34
6A4-35
GENERAL DESCRIPTION
CYLINDER BLOCK
The cylinder block is made of cast iron and has 8
cylinders arranged in a "V " shape with 4 cylinders in each
bank. Five main bearings support the crankshaft which is
retained by bearing caps th at are m achined with the block
for proper alignment and clearnances. Cylinders are com
pletely encircled by coolant jackets.
CYLINDER HEAD
The cylinder heads are cast with individual intake and
exhaust ports for each cylinder. Valve guides are integral,
and rocker arm s are retained on individual studs.
6A4-2
SMALL BLOCK
offset 1/16" (1.6m m ) tow ard the thrust side (right hand
side) to provide a gradual change in thrust pressure against
the cylinder wall as the piston travels its path. Pins are
Chrom ium steel and have a floating fit in the pistons They
are retained in the connecting rods by a press fit.
Connecting rods are m ade of forged steel. Full pressure
lubrication is directed to the connecting rods by drilled oil
passages from the adjacent main bearing journal. Oil holes
at the connecting rod journals are located so th at oil is
supplied to give m axim um lubrication just prior to full
bearing load.
VALVE TRAIN
A very simple ball pivot-type train is used. Motion is
transm itted from the cam shaft through the hydraulic lifter
and push rod to the rocker arm . The rocker arm pivots on its
ball and transm its the cam shaft motion to the valve. The
rocker-arm ball is retained by a nut.
below the plunger. The plunger and lifter body then rise as a
unit, pushing up the push rod and opening the valve.
As the lifter body rides down the other side of the cam,
the plunger follows with it until the valve closes. The lifter
body continues to follow the cam to its low point, but the
plunger spring keeps the plunger in contact with the push
rod. The ball check valve will then move off its seat and the
lifter reservoir will rem ain full.
INTAKE MANIFOLD
The intake manifold is of cast iron double level design
for efficient fuel distribution. The carburetor pad is centrally
located with a passage running underneath the pad (E .F.E .)
through which exhaust gases are forced to promote faster
fuel vaporization when the engine is cold. An EG R port is
also cast into the manifold for the m ixture of exhaust gases
with the fuel air mixture.
EXHAUST MANIFOLDS
Two cast iron exhaust manifolds are used to direct
exhaust gases from the combustion cham bers to the exhaust
system. The right hand side m anifold receives a heat shield
th at is used to route heated air to the air cleaner for better
fuel vaporization.
COMBUSTION CHAMBERS
C om bustion C ham bers are cast to insure uniform
shape for all cylinders. Spark plugs are located between the
intake and exhaust valves.
The contoured wedge shape of the combustion cham ber
minimizes the possibility of detonation, facilitates breath
ing, and provides swirling turbulence for smooth, complete
combustion.
ENGINE LUBRICATION
Full pressure lubrication through a full flow oil filter, is
furnished by a gear-type oil pump. The distributor, driven
by a helical gear on the cam shaft, drives the oil pump. The
main oil gallery feeds oil, through drilled passages, to the
SMALL BLOCK
6A4-3
6A4-4
SMALL BLOCK
L IG H T TR U C K SERVICE M AN U AL
SMALL BLOCK
6A4-5
LIG H T T R U C K SERVICE M A N U A L
6A4-6
SMALL BLOCK
L IG H T T R U C K SERVICE M A N U A L
SMALL BLOCK
6A4-7
LIGHT T R U C K SERVICE M A N U A L
6A4-8
SMALL BLOCK
LIG H T T R U C K SERVIC E M A N U A L
SMALL BLOCK
6A4-9
L IG H T TR U C K SERVICE M AN U AL
6A4-10
SMALL BLOCK
L IG H T T R U C K SERVIC E M A N U A L
SMALL BLOCK
6A4-11
ON VEHICLE SERVICE
ENGINE MOUNTS
INTAKE MANIFOLD
E ngine m ounts (fig. 6 A 4 -3 - 6 A 4 -8 ) are the nonad ju sta b le type and seldom req u ire service. Broken or
d e te rio ra ted m ounts should be replaced im m ediately,
because of the added strain placed on other m ounts and
drive line components.
Removal
3.
4.
5.
6.
Rear Mount
7.
6A4-12
SMALL BLOCK
W IN G NUT
LOWER STOVE
NOTE: Inboard flange
of lower stove must be
installed on top of rib
of exhaust manifold.
CARBURETOR TEE
AIR CLEANER
HOSE
3 5 0 /4 0 0 V8 4Bbl
IvSwfBl
UPPER STOVE
LOWER STOVE
EXHAUST MANIFOLD
Removal
1.
2.
3.
4.
5.
6.
covers.
4. Disconnect electrical wiring harness from rocker arm
clips.
5. Remove carburetor heat stove pipe from right exhaust
manifold.
6. If the vehicle is equipped with air conditioning, remove
the A /C compressor rear brace (fig. 6 A 4 -11).
L IG H T T R U C K SERVIC E M A N U A L
SMALL BLOCK
6A4-13
VALVE MECHANISM
Removal
6A4-14
SMALL BLOCK
1. Install valve stem seal over valve stem and seat against
head.
2. Set the valve spring and dam per, oil shedder and valve
cap in place. Compress the spring with Tool J-5892 and
install oil seal in the lower groove of the stem , making
sure the seal is flat and not twisted. A light coat of oil on
the seal will help prevent twisting.
3. Install the valve locks and release the compressor tool
m aking sure the locks seat properly in the upper groove
of the valve stem. G rease may be used to hold the locks
in place while releasing the compressor tool.
4. Using tool J-23994, apply vacuum to the valve cap to
m ake sure no air leaks past the seal.
-- Exhaust--2, 5 ,6 , 7
- I n ta k e - 3 ,4 ,6 , 8
4. Install rocker arm covers as previously outlined.
5. S ta rt engine and a d ju st c a rb u re to r idle speed, if
needed.
VALVE LIFTERS
H ydraulic valve lifters very seldom require attention.
The lifters are extrem ely simple in design, readjustm ents
are not necessary, and servicing of the lifters requires only
th at care and cleanliness be exercised in the handling of
parts.
Removal
1. Hold the plunger down with a push rod, and using the
blade of a small screw driver, remove the push rod seat
retainer.
2. Remove the push rod seat and m etering valve (fig. 6A414).
J-2 3 5 9 0
ADAPTER
Fig. 6A4-13--Compressing Valve Spring
L IG H T T R U C K SERVIC E M A N U A L
SMALL BLOCK
6A4-15
Assembly
1. Lifte r Body
2. Push Rod Seat
3. M etering Valve
4 Check Ball
5 Check Ball Retainer
6
7
8
9
6A4-16
SMALL BLOCK
1. Clean all carbon from com bustion cham bers and valve
ports using Tool J-8089 (fig. 6 A 4 -19).
2. Thoroughly clean the valve guides using Tool J - 8 101.
3. Clean all carbon and sludge from push rods, rocker
arm s and push rod guides.
4. Clean valve stems and heads on a buffing wheel.
5. C lean carbon deposits from head gasket m ating
surface.
Inspection
SMALL BLOCK
6A4-17
SEAL
SHIELD
DAMPER
6A4-18
SMALL BLOCK
Replacement
OVERSIZE
SMALL BLOCK
6A4-19
TORSIONAL DAMPER
Removal
J- 6880
VALVE SEATS
4.
5.
6.
7.
8.
VALVES
Valves th at are pitted can be refaced to the proper
angle, insuring correct relation between the head and stem
on a valve refacing mechanism. Valve stems which show
excessive wear, or valves th at are warped excessively should
be replaced. W hen a valve head which is warped excessively
is refaced, a knife edge will be ground on part or all of the
valve head due to the am ount of metal th at must be removed
to completely reface. Knife edges lead to breakage, burning
or pre-ignition due to heat localizing on this knife edge. If
the edge of the valve head is less than 1/32" (.80m m ) thick
after grinding, replace the valve.
Several different types of equipm ent are available for
refacing valves. The recom m endation of the m anufacturer
of the equipm ent being used should be carefully followed to
attain proper results.
6A4-20
SMALL BLOCK
1. W ith cover removed, pry oil seal out of cover from the
front w ith a large screw driver.
LIG H T T R U C K SERVICE M A N U A L
SMALL BLOCK
6A4-21
Inspection
CAMSHAFT
Measuring Lobe Lift
Installation
3. Remove grille.
4. Remove fuel pump and push rod (see section 6C).
5. Com plete cam shaft removal as follows:
Sprocket is a light fit on cam shaft. If sprocket does
not come off easily a light blow on the lower edge of
the sprocket (with a plastic m allet) should dislodge
the sprocket.
6. Install two 5 /1 6 " - 18 x 4" bolts in cam shaft bolt holes
then remove cam shaft (fig. 6A4-34).
CAMSHAFT BEARINGS
Removal
NOTICE: All cam shaft journals are the same diam eter
and care m ust be used in removing cam shaft to avoid
dam age to bearings.
6A4-22
SMALL BLOCK
Installation
OIL PAN
Removal
SMALL BLOCK
6A4-23
body.
5. Inspect inside of pum p cover for w ear th a t would
OIL PUMP
Removal
2.
3.
4.
5.
6.
Installation
1.
2.
3.
4.
5.
6.
S haft Extension
Pump Body
Drive Gear and Shaft
Idler Gear
Pump Cover
Pressure Regulator
Valve
7.
8.
9.
10.
Pressure R egulator
Spring
R etaining Pin
Screws
Pickup Screen and
Pipe
6A4-24
SMALL BLOCK
1. W ith oil pan and oil pum p rem oved, rem ove the
connecting rod cap and bearing.
Before removal of connecting rod cap, m ark the side of
the rod and cap with the cylinder num ber to assure
m atched reassembly of rod and cap.
2. Inspect the bearing for evidence of wear or dam age.
(Bearings showing the above should not be installed.)
3. W ipe both upper and lower bearing shells and crankpin
clean of oil.
4. M easure the crankpin for out-of-round or taper with a
m icrom eter. If not w ithin specifications replace or
recondition the crankshaft. If within specifications and
a new bearing is to be installed, m easure the maxim um
diam eter of the crankpin to determ ine new bearing size
required.
5. If within specifications m easure new or used bearing
clearances with Plastigage or its equivalent.
If a bearing is being fitted to an out-of-round crankpin,
be sure to fit to the m axim um diam eter of the crankpin.
If the bearing is fitted to the m inim um diam eter and
the cran k p in is o u t-of-round .001" interference
between the bearing and crankpin will result in rapid
bearing failure.
a. Place a piece of gaging plastic, the length of the
bearing (parallel to the crankshaft), on the crankpin
or bearing surface (fig. 6A 4-40). Plastic gage should
be positioned in the middle of upper or lower bearing
shell. (B earings are eccen tric and false readings
could occur if placed elsewhere).
M AIN BEARINGS
M ain bearings are of the precision insert type and do
not utilize shims for adjustm ent. If clearances are found to
be excessive, a new bearing, both upper and lower halves,
will be required. Service bearings are available in standard
size and .001", .002 ", .009 " ,.0 1 0 " and .020 " undersize.
Selective fitting of both rod and m ain bearing inserts is
necessary in production in order to obtain close tolerances.
For this reason you may find one half of a standard insert
with one half of a .001" undersize insert which will decrease
the clearance .0005 " from using a full standard bearing.
S/ALL BLOCK
6A4-25
Inspection
6A4-26
SMALL BLOC
fitte to the m inim um diam eter and the journal is outof-rund .001", interference between the bearing and
jounal will result in rap id bearing failure. If the
flatened gaging plastic tapers toward the middle or
en6, there is a difference in clearance indicating taper,
lo\ spot or other irregularity of the bearing or journal.
Bfsure to m easure the journal with a m icrom eter if the
fUtened gaging plastic indicates m ore th an .001"
dference.
6. I the bearing clearance is within specifications, the
baring insert is satisfactory. If the clearance is not
nth in specifications, replace the insert. Always replace
>oth upper and lower inserts as a unit,
if a new bearing cap is being installed and clearance is
less than .0 0 1 ", inspect for burrs or nicks; if none are
found then install shims as required.
1. W ith oil pan, oil pum p and sp ark plugs rem oved,
remove cap on main bearing requiring replacem ent and
remove bearing from cap.
2. Install a main bearing removing and installing tool in
oil hole in crankshaft journal. If such a tool is not
availale, a cotter pin may be bent as required to do the
job.
3. R otate the crankshaft clockwise as viewed from the
front of engine. This will roll upper bearing out of
block.
4. Oil new selected size upper bearing and insert plain
(unnotched) end between crankshaft and indented or
notched side of block. R otate the bearing into place and
remove tool from oil hole in crankshaft journal.
5. Oil new lower bearing and install in bearing cap.
6. Install main bearing cap with arrows pointing toward
front of engine.
7. Torque all main bearing caps E X C E P T T H E R E A R
M A IN C A P to specifications. Torque rear main bear
ing cap to 10-12 lb. ft. (14-16N -m ) then tap end of
crankshaft, first rearw ard then forward with a lead
ham m er. This will line up re a r m ain bearing and
crankshaft thrust surfaces. R etorque all main bearing
caps to specifications.
U PPER
AND
SMALL BLOCK
6A4-27
1 / 2
1
I
t
h I
.............. '
11/64
DUST SEAL
APPLY
SEALANT
TO SHADED
AREAS ONLY
6A4-28
SMALL BLOCK
PRESS
Removal
FIXTURE
SUPPORT
ASSEMBLY
J-24086-20
Disassembly
Fig. 6A4-52--Removing Piston Pin
Piston Pins
LIG H T T R U C K SERVICE M A N U A L
SMALL BLOCK
Inspect piston pin bores and piston pins for wear. Piston
pin bores and piston pins m ust be free of varnish or scuffing
when being m easured. The piston pin should be m easured
w ith a m icrom eter and th e piston pin bore should be
m easured with a dial bore gage or an inside m icrom eter. If
clearance is in excess of the .001" wear limit, the piston and
piston pin assembly should be replaced.
Assembly
6A4-29
Piston Rings
6A4-30
SMALL BLOCK
Assembly
3. W ith bearing caps removed, install Tool J-5239 (3 /8 " )
on connecting rod bolts.
4. Install each connecting rod and piston assembly in its
respective bore. Install with connecting rod bearing
tang slots on side opposite cam shaft. Use Tool J-8037
to compress the rings (fig. 6A4-58). G uide the connect
ing rod into place on the crankshaft journal with Tool
J-5239 ( 3 /8 " ) Use a ham m er handle and light blows to
install the piston into the bore. Hold the ring com pres
sor firmly against the cylinder block until all piston
rings have entered the cylinder bore.
5. Remove Tool J-5239.
6. Install the bearing
specifications.
caps
and
torque
nuts
to
SMALL BLOCK
CYLINDER BLOCK
Cleaning and Inspection
6A4-31
6A4-32
SMALL BLOCK
W ith the oil filter removed, check the spring and fibre
valve for operation. Inspect for a cracked or broken valve. If
replacem ent is necessary, the oil filter adapter and bypass
valve assembly m ust be replaced as an assembly. Clean
valve cham ber in cylinder block thoroughly. Torque retain
ing screws to specifications.
ENGINE ASSEMBLY
Removal ("G " V an )
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
SMALL BLOCK
6A4-33
CRANKSHAFT
The crankshaft can be removed while the engine is
disassembled for overhaul, as previously outlined, or without
complete disassembly as outlined below.
or
convertor
splash
shield,
as
6A4-34
SMALL BLOCK
LIG H T T R U C K SERVICE M A N U A L
APPLY
SEALANT
TO SHADED
AREAS ONLY
5.0 (F)
5.0 (G)
5.0 (H)
L ITR E (* )
LF3
RPO
LG9
CLEARANCE
.001 M A X .
S E R V IC E
.0008-.001 6 IN T E R F E R E N C E
F IT IN R O D
LS9 /L T 9
LE9
00025-.00035
P R O D U C T IO N
5.7 (L)
5.7 (M)
3.736
BORE
CRANKSHAFT
4.000
#1 2.44 84 -2 .4 4 93
3.480
STROKE
C O M P R E S S IO N R A T IO
j 8.3:1
D IA M E T E R
# 2 -3 -4
1-8-4-3-6-5-7-2
F IR IN G O R D E R
LS9/LT9
.9270-.9273
D IA M E T E R
90 V-8 G A S O LIN E
TYPE
D IS P L A C E M E N T
LF3.LG9,LE9,
PISTON PIN
GENERAL DATA:
#5
M A IN
JO UR NAL
C YLINDER BORE:
2.4481 -2 .4 4 90
2.4479 -2 .4 4 88
.0002 M A X .
P R O D U C T IO N
1A r t H
3.7350-3.7385
D IA M E T E R
O U T OF
ROUND
TAPER
3.9995-4.0025
P R O D U C T IO N
.001 M A X .
S E R V IC E
.002 M A X .
PRODUC
T IO N
THRUST
S ID E
.0005 M A X .
R E L IE F
S ID E
.001 M A X .
O UT OF
ROUND
.0002 M A X .
P R O D U C T IO N
.001 M A X .
S E R V IC E
#1
M A IN
B E A R IN G
C L E A R A N I: e
#5
S E R V IC E
#1
.0 0 1 .0 0 1 5
P R O D U C T IO N
.0007-.0017
S E R V IC E
.0027 M A X .
.0011-.0023
.001 7-.0032
# 2 -4
.0 0 1 .0 0 2 5 # 5 .0 0 2 5 .0035
.0 0 2 .0 0 6
PISTON:
.0 0 8 .0 0 2 0
#2-3-4
P R O D U C T IO N
.001 M A X .
S E R V IC E
.001 M A X .
S E R V IC E
2.0988-2.0998
D IA M E T E R
CLEARANCE
G ROOVE
CLEAR
ANCE
PRODUC
T IO N
R
S
S
I
O
N
2N D
PRODUC
T IO N
.001 2-.0032
HI L IM IT PR O D U C TIO N
TO P
.0 1 0 .0 2 0
2N D
.0 1 0 .0 2 5
S E R V IC E
GROOVE
CLEAR
ANCE
O U T OF
ROUND
S E R V IC E
GAP
.001 2 .0 0 3 2
P R O D U C T IO N
S E R V IC E
P R O D U C T IO N
GAP
S E R V IC E
HI L IM IT PR O D U C TIO N
.001
.010
.0013-.0035
P R O D U C T IO N
.0030
S E R V IC E
.008-.014
CAMSHAFT
L O B E L IF T
002
.001
.01 5-.055
HI L IM IT PR O D U C TIO N
.001 M A X .
S E R V IC E
R O D S ID E C L E A R A N C E
.002-.007
HI L IM IT P R O D U C TIO N
R O D B E A R IN G
CLEARANCE
.0005
P R O D U C T IO N
.010
IN T A K E
.2484
.2600
EXHAUST
.2667
.2733
J O U R N A L D IA M E T E R
1.8682-1.8692
.0 0 4.0 1 2
SMALL BLOCK
O
I
L
TO P
.001 M A X .
S E R V IC E
C R A N K P IN
PISTON RING:
C
O
M
p
.0005
P R O D U C T IO N
* VIN D esignation
6A4-35
TRUCK
6A4-36
LIGHT
MANUAL
LF3.
ROCKER A R M R A T IO
EXHAUST
45
46
.002 M AX.
1/32-1/16
IN T A K E
1/1 6-3/32
EXHAUST
STEM
CL E A R A N C E
P R O D U C T IO N
IN T .
.0010-.0027
EX H
.0010-.0027
SERVICE
FREE L E N G T H
2.03
CO
VALVE
SPRING
(O UTE R)
LT9
IN T A K E
SEAT
W ID T H
LS9;
1.50:1
SEAT R U N O U T
n
3I
n
>
LE9
H Y D R A U LIC
L IF T E R
VALVE
LASH
LG9L J L
PRESSURE
LBS. @ IN.
CLOSED
OPEN
IN S T A L L E D H E IG H T
1-23/32 INT.
1-19/32 EXH.
1/32"
FREE L E N G T H
DAMPE R
APPROX. # OF COILS
1.86
80 LB. IN.
CRANKCASE FRONT C O V E R ...........................
80 LB. IN.
FLYW H EEL HOUSING C O V E R ........................
O IL FILTE R BYPASS V A L V E ...........................
80 LB. IN.
O IL PAN (TO CRANKCASE) (1 /4 -2 0 )..............
80 LB. IN.
O IL PUMP C O V E R ................................................
80 LB. IN.
ROCKER ARM C O V E R ........................................
45 LB. IN.
CAM SHAFT S P R O C K E T ......................................
20 LB. FT.
O IL PAN TO CRANKCASE (5 /1 6 -1 8 )..............165 LB. IN.
CLUTCH PRESSURE P L A T E ..............................
30 LB. FT.
DISTR IBU TO R CLAMP . . . .................................
25 LB. FT.
FLYW H EEL H O U S IN G ........................................
30 LB. FT.
M A N IF O LD (E X H A U S T )......................................20 LB. F T .i
M A N IF O LD (IN L E T )..............................................
30 LB. FT.
WATER O U T L E T ...................................................
30 LB. FT.
WATER P U M P .........................................................
30 LB. FT.
CONNECTING ROD CAP......................................
45 LB. FT.
C Y LIN D E R H E A D ................................................
65 LB. FT.
M AIN BEAR IN G C A P ................................ ..
80 LB. FT.2
65 LB. FT.
O IL P U M P ................................................................
F L Y W H E E L ..............................................................
60 LB. FT.
T O R S IO N A L D A M P E R ........................................
60 LB. FT.
TEM PER ATU RE SENDING U N IT ......................
20 LB. FT.
O IL F I L T E R ...........................................................
25 LB. FT.
O IL PAN D R A IN PLUG ........................................
20 LB. FT.
SPARK P L U G ........................................................ 17-27 LB. FT.
1 Inside bolts on 5.7 (L) 30 LB. FT.
2 Intermediate outer bolts are 70 LB. FT.
SMALL BLOCK
SERVICE
T O R Q U E S P E C IF IC A T IO N S
VA LV E SYSTEM
MARK IV
6A5-1
SECTION 6A5
6A5-1
6A5-4
6A5-4
6A5-9
6A5-9
6A5-10
6A5-10
6A5-11
6A5-11
6A5-12
6A5-13
6A5-16
6A5-16
6A5-16
6A5-16
6A5-16
6A5-17
6A5-18
6A5-18
6A5-19
6A5-20
6A5-20
6A5-21
6A5-22
6A5-24
6A5-25
6A5-28
6A5-29
6A5-29
6A5-30
6A5-30
6A5-31
tim ing chain which in turn drives the cam shaft through an
alum inum and nylon sprocket.
Cam lobes are ground, hardened and tapered with the
high side toward the rear. This, coupled with a spherical
face on the lifter, causes the valve lifters to rotate.
C am shaft bearings are lubricated through oil holes
which intersect the main oil gallery. The main oil gallery is
rifle drilled down the left side of the cylinder case.
CYLINDER HEAD
The cast iron cylinder heads have individual intake and
exhaust ports for each cylinder. Valve guides are integral,
and rocker arms are retained on individual threaded studs.
VALVE TRAIN
A very simple ball pivot-type train is used. Motion is
transm itted from the cam shaft through the hydraulic lifter
and push rod to the rocker arm. The rocker arm pivots on its
ball and transm its the cam shaft motion to the valve. The
rocker-arm ball is retained by a nut.
LIG H T T R U C K SERVICE M A N U A L
6A5-2
MARK IV
CO VER
DISTRIBUTO R
STUD
NUT
BALL
CLAMP
OUTLET
ARM
STUD
GASKE T
G U ID E
THERMOSTAT
M A N IFO L D
SPRING
BO L T
SEAL
SHIM
BOLT
ROTATOR
PLUG
GSKT
HEAD
G ASKE T
BOLT
M A N IFO L D
VALVE
L IF T E R
VALVE
LIG H T T R U C K SERVIC E M A N U A L
MARK IV
6A5-3
PISTON
BOLT
BEARING SET
CAMSHAFT
FLYWHEEL
CHAIN
GEAR
PLUG
WASHER
BOLT (5/16-18 x 3/4)
BOLT
PUMP
GASKET
GASKET
BLOCK
BOLT
(3/8-16 x 1 3/4)
CRANKSHAFT
ADAPTER
WASHER ( 5 / 1 6 ) ^ '
GASKET
PRO LOC A
COVER
SEAL
EXTENSION
CONNECTOR
SEAL
GEAR
SHAFT
FILTER
DAMPER
BOLT
PUMP
WASHER
BOLT
BOLT
SCREEN
BOLT
GASKET
SEAL
GASKET
BOLT
BOLT
PLUG
LIG H T TR U C K SERVICE M A N U A L
6A5-4
MARK IV
INTAKE MANIFOLD
EXHAUST MANIFOLDS
Two cast iron exhaust manifolds are used to direct
exhaust gases from the combustion cham bers to the exhaust
system. The right hand side manifold receives a heat shield
th at is used to route heated air to the air cleaner for better
fuel vaporization.
COMBUSTION CHAMBERS
C om bustion C ham bers are cast to insure uniform
shape for all cylinders. Spark plugs are located between the
intake and exhaust valves.
The contoured wedge shape of the com bustion cham ber
minimizes the possibility of detonation, facilitates breath
ing, and provides swirling turbulence for smooth, complete
combustion.
ENGINE LUBRICATION
Full pressure lubrication through a full flow oil filter, is
furnished by a gear-type oil pump. The distributor, driven
by a helical gear on the cam shaft, drives the oil pump. The
main oil gallery feeds oil, through drilled passages, to the
ON VEHICLE SERVICE
LIG H T T R U C K SERVICE M A N U A L
MARK IV
6A5-5
LIG H T T R U C K SERVICE M A N U A L
6A5-6
MARK IV
MANUAL TRANSMISSION
AUTOMATIC TRANSMISSION
WITH PROPELLER SHAFT PARKING BRAKE
LIG H T T R U C K SERVIC E M A N U A L
MARK IV
6A5-7
LIG H T T R U C K SERVICE M A N U A L
6A5-8
MARK IV
LIG H T T R U C K SERVIC E M A N U A L
MARK IV
ENGINE MOUNTS
E ngine m ounts (fig. 6A 5-4 - 6A 5-7) are the nonad ju stab le type and seldom req u ire service. Broken or
d e te rio ra ted m ounts should be replaced im m ediately,
because of the added strain placed on other m ounts and
drive line components.
Checking Engine Mounts
Front Mount
6A 5-9
INTAKE MANIFOLD
Removal
Installation
MARK IV V8
6A 5-10
MARK IV
EXHAUST MANIFOLD
Removal
Installation
STUD
DUCT
ASSEMBLY
MARK IV
VALVE MECHANISM
Removal
6 A 5 -1 1
J-23590
Fig. 6 A 5 -1 1--Valve Adjustment
6A 5-12
MARK IV
L ifte r B o d y
Push Rod Seat
M e te rin g V a lv e
C h e c k B a ll
C h e c k B a ll R e ta in e r
2. Set the valve spring and dam per and valve cap in place.
3. Com press the spring with Tool J-5892 and install the
valve locks then release the compressor tool, making
sure the locks seat properly in the groove of the valve
stem. G rease m ay be used to hold the locks in place
while releasing the compressor tool.
4. Install spark plug, and torque to 22 lb. ft. (30 N-m).
5. Install and ad ju st valve m echanism as previously
outlined.
VALVE LIFTERS
H ydraulic valve lifters very seldom require attention.
The lifters are extrem ely simple in design, readjustm ents
are not necessary, and servicing of the lifters requires only
that care and cleanliness be exercised in the handling of
parts.
Removal
1. Hold the plunger down with a push rod, and using the
blade of a small screw driver, remove the push rod seat
retainer.
2. Remove the push rod seat and m etering valve (fig. 6A514).
3. Remove the plunger, ball check valve assembly and the
plunger spring.
4. Remove the ball check valve and spring by prying the
ball retainer loose from the plunger with the blade of a
small screw driver (fig. 6A5-15).
LIGHT TRUCK SERVICE MANUAL
i
Fig. 6A5-15--Removing Ball Check Valve
MARK IV
6A 5-13
Assembly
6A 5-14
MARK IV
Inspection
J- 8101
MARK IV
6 A 5 -1 5
\
L
G R IN D O U T THIS P O R T IO N
T j T T T ] T | l | ' | l | T F j ' l ' | U lj TP | rTTj
<1| rr 1j n 7] 1
'
'2
r^ ry n y T T j
Fig. 6 A 5 -2 4 ~ C u ta w a y Scale
6A 5-16
2.
3.
4.
5.
6.
7.
8.
MARK IV
VALVES
Valves th at are pitted can be refaced to the proper
angle, insuring correct relation between the head and stem
on a valve refacing m echanism. Valve stems which show
excessive wear, or valves th at are w arped excessively should
be replaced. W hen a valve head which is warped excessively
is refaced, a knife edge will be ground on part or all of the
valve head due to the am ount of m etal th at must be removed
to completely reface. Knife edges lead to breakage, burning
or pre-ignition due to heat localizing on this knife edge. If
the edge of the valve head is less than 1/3 2 " (.80m m ) thick
after grinding, replace the valve (fig. 6A 5-29).
Several different types of equipm ent are available for
refacing valves. The recom m endation of the m anufacturer
of the equipm ent being used should be carefully followed to
attain proper results.
TORSIONAL DAMPER
VALVE SEATS
Removal
MARK IV
6A 5-17
Installation
NOTICE: The inertial weight section of the torsional
dam per is assembled to the hub with a rubber type
m aterial. The installation procedures (with proper tool)
m ust be followed or movement of the inertia weight
section on th e hub will destroy the tuning of the
torsional dam per.
1. C oat front cover seal contact area (on dam per) with
engine oil.
2. Place dam per in position over key on crankshaft.
3. Pull dam per onto crankshaft as follows:
a. Install appropriate threaded end of Tool J-23523
into crankshaft. Install tool in crankshaft so th at at
least 1 /2 " (6.5m m ) of th re a d engagem ent is
obtained.
4.
5.
6.
7.
8.
6A 5-18
MARK IV
1. W ith cover removed, pry oil seal out of cover from the
front with a large screw driver.
2. Install new seal so th a t open end of the seal is toward
the inside of cover and drive it into position with Tool
J-22102. Support rear of cover at seal area.
With Cover Installed
CAMSHAFT
Measuring Lobe Lift
1.
2.
3.
4.
MARK IV
6A 5-19
CAMSHAFT BEARINGS
Removal
#6 C Y LIN D ER
AT T.D.C.
6A 5-20
MARK IV
Installation
OIL PAN
Removal
1.
2.
3.
4.
5.
OIL PUMP
Removal
MARK IV
6A5-21
1.
2.
3.
4.
5.
6.
7.
S h a ft Extension
S h a ft C ouplin g
Pump Body
Drive Gear and S haft
Id le r Gear
P ickup Screen and
Pipe
Pump Cover
8.
9.
10.
11.
12.
Pressure R e gulator
Valve
Pressure R egulator
S p rin g
W a sh e r
R etaining Pin
S crew s
1. W ith oil pan and oil pum p rem oved, rem ove the
connecting rod cap and bearing. Before removal of
connecting rod cap, m ark the side of the rod and cap
with the cylinder num ber to assure m atched reassem
bly of rod and cap.
2. Inspect the bearing for evidence of wear or dam age.
(Bearings showing the above should not be installed.)
3. W ipe both upper and lower bearing shells and crankpin
clean of oil.
4. M easure the crankpin for out-of-round or taper with a
m icrom eter. If not w ithin specifications replace or
recondition the crankshaft. If within specifications and
a new bearing is to be installed, m easure the m axim um
diam eter of the crankpin to determ ine new bearing size
required.
5. If within specifications m easure new or used bearing
clearances with Plastigage or its equivalent.
If a bearing is being fitted to an out-of-round crankpin,
be sure to fit to the m axim um diam eter of the crankpin.
If the bearing is fitted to the minimum diam eter and
the crankpin is out-of-round .001" in terference
between the bearing and crankpin will result in rapid
bearing failure.
6A 5-22
MARK IV
MAIN BEARINGS
Inspection
1. W ith the oil pan and oil pum p removed, and starting
with the rear main bearing, remove bearing cap and
wipe oil from journal and bearing cap.
MARK IV
6A 5-23
6A 5-24
MARK IV
Replacement
11/64
1. W ith oil pan, oil pum p and spark plugs rem oved,
remove cap on m ain bearing requiring replacem ent and
remove bearing from cap.
2. Install a m ain bearing removing and installing tool in
oil hole in crankshaft journal. If such a tool is not
availale, a cotter pin m ay be bent as required to do the
job.
3. R otate the crankshaft clockwise as viewed from the
front of engine. This will roll upper bearing out of
block.
4. Oil new selected size upper bearing and insert plain
(unnotched) end between crankshaft and indented or
notched side of block. R otate the bearing into place and
remove tool from oil hole in crankshaft journal.
5. Oil new lower bearing and install in bearing cap.
6. Install m ain bearing cap with arrows pointing toward
front of engine.
7. Torque all m ain bearing caps E X C E P T T H E R E A R
M A IN C A P to specifications. Torque rear m ain bear
ing cap to 10-12 lb. ft. (14-16N -m ) then tap end of
crankshaft, first rearw ard then forward with a lead
ham m er. T his will line up re a r m ain bearing and
crankshaft th ru st surfaces. R etorque all m ain bearing
caps to specifications.
MARK IV
DU ST SEAL
6A 5-25
PRESS
-PISTON PIN
REMOVER
J-24086-8
Fig. 6A5-50--Crankshaft Oil Seal - Rear Main
APPLY
SEALANT
TO SHADED
AREAS ONLY
FIXTURE &
SUPPORT
ASSEMBLY
J-24086-20
6A 5-26
MARK IV
PRESS
PISTON PIN ^
INSTALLER
J-24086-9
PISTON PIN
Piston Pins
Assembly
MARK IV
6A 5-27
6A 5-28
MARK IV
CYLINDER BLOCK
Cleaning and Inspection
MARK IV
W ith the oil filter removed, check the spring and fibre
valve for operation. Inspect for a cracked or broken valve. If
replacem ent is necessary, the oil filter adapter and bypass
valve assembly must be replaced as an assembly. Clean
valve cham ber in cylinder block thoroughly. Torque retain
ing screws to specifications.
ENGINE ASSEMBLY
Removal
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Remove hood.
Disconnect battery cables at battery.
Remove air cleaner.
D rain radiator and block.
D isconnect ra d ia to r and h eater hoses and remove
radiator and fan shroud.
Disconnect wires at:
S ta rte r Solenoid
G enerator
T R C Speed Switch
T R C Solenoid
T em perature switch
Oil Pressure Switch
D istributor
Disconnect:
A ccelerator linkage a t inlet manifold.
Fuel line, from tank, at fuel pump.
Hoses at fuel vapor storage canister (if applicable).
Vacuum line to power brake unit a t manifold, if so
equipped.
Remove power steering pump and A /C compressor and
lay aside, if so equipped.
Raise vehicle on hoist.
D rain crankcase.
D isconnect exhaust pipe at m anifold and, if so
equipped, converter b rack et a t transm ission rear
m ount.
Remove starter.
6A 5-29
6A 5-30
MARK IV
CRANKSAHFT
APPLY
SEALANT
TO SHADED
AREAS ONLY
2.
3.
4.
5.
6.
7.
8.
9.
tow ard front of engine. W here seal has two lips install
lip with helix towards front of engine.
Lubricate lips of seal with engine oil. Keep oil off
parting line surface.
Install m ain bearings in cylinder block and m ain
bearing caps then lubricate bearing surface with engine
oil.
Install crankshaft, being careful not to dam age bearing
surfaces.
Apply a thin coat of brush-on type oil sealing com
pound to block m ating su rface and corresponding
surface of cap only (fig. 6A 5-58). Do not allow sealant
on crankshaft or seal.
Install main bearing caps with arrows pointing toward
front of engine.
T orque all except rea r m ain bearing cap bolts to
specifications. Torque rear m ain bearing cap bolts to
10-12 lbs. ft. (14-16 N-m) then tap end of crankshaft,
first rearw ard then forward with a lead ham m er. This
will line up rear main bearing and crankshaft thrust
surfaces. R etorque all m ain bearing cap bolts to
specifications.
M easure crankshaft end play with a feeler gage. Force
crankshaft forward and m easure clearance between the
front of the rear main bearing and the crankshaft
thrust surface.
Install flywheel and torque to specifications. A wood
block placed between the crankshaft and cylinder block
will prevent crankshaft from rotating.
Align dowel hole in flywheel with dowel hole in
crankshaft. On vehicles equipped with autom atic
transm issions, install flywheel w ith th e converter
attaching pads towards transm ission.
G ENERAL DATA:
LE8
PISTON PIN
.9895-.9898
D IA M E T E R
90 V -8 G A S O L I N E
TYPE
PRODUCTION
DISPLACE MENT
LITRE (*)
7.4 (W)
.000 25-.0003 5
CLEARANCE
SERVICE
RPO
LE8
BORE
4.250
STROKE
4 .0 0 0
COMPRESSION RA TIO
8.5:1
F IR IN G ORDER
1-8-4-3-6-5-7-2
DIAM ET ER
SERVICE
.002 M A X .
O
D
C
0
1
.001 M A X .
TAPER
PF
TION
D IA M E T E R
THRUST
SIDE
RELIEF
SIDE
TAPER
SERVICE
OUT OF
RO UND
PRODUCTIO N
SERVICE
.001 M A X .
PRODUCTIO N
.0 002 M A X .
SERVICE
.001 M A X .
# 1 -2 -3 -4
M AIN
BEARING
CLEARANCE
#5 .0 0 2 4 .0 0 4 0
SERVICE
C R A N K S H A F T END P L A Y
PRODUCTION
.0 0 3 0 -.0 0 4 0
SERVICE
.0050 M A X .
.001 3 -.0 0 2 5
PRODUCTION
.001 M A X .
P IS T O N :
2 .7 4 7 6 -2 .7 4 8 6
.0 0 0 2 M A X .
.0005 M A X .
.001 M A X .
IN T E R F E R E N C E
# 1 -2 -3 -4 2 .7 4 8 1 -2 .7 4 9 0
#5
4.2495-4.2525
PRODUCTION
.0 0 1 3 -.0 0 2 1
CRANKSHAFT
M AIN
J O URNAL
C Y L IN D E R BORE:
OUT OF
ROUND
FIT IN ROD
.001 M A X .
D IA M E T E R
CLEARANC E
n .
m
.
.0 0 1 4 .0 0 2 5
+U-
'*0
.006-.010
2.20 00-2.199 0
PRODUCTION
.0 0 0 5
SERVICE
.001 M A X .
PRO DUCTION
.000 5
SERVICE
.001 M A X .
TAPER
CRANKPIN
P IS T O N R I N G :
c
o
M
p
R
PRODUC
TION
O
1
L
TOP
.0017-.0032
2ND
.0017-.0032
SERVICE
GAP
PRODU C
T IO N
2 O
S
S
1
GROOVE
CLEAR
ANCE
TOP
.010 - . 0 2 0
2ND
.010 - . 0 2 0
SERVICE
GROOVE
CLEAR
ANCE
HI L I M I T P R O D U C T I O N +.001
PRODUCTION
SERVICE
HI L I M I T P R O D U C T I O N + .01 0
.0 0 5 - . 0 0 6 5
HI L I M I T P R O D U C T I O N +.001
PRODU CTION
.0 1 5 -.0 5 5
SERVICE
HI L I M I T P R O D U C T I O N + .01 0
GAP
OUT OF
ROUND
ROD BEARING
CLEARANCE
PRO DUCTION
SERVICE
.0 0 0 9 -0 0 2 5
.0030 M A X .
.0 1 3 -.0 2 3
CAMSHAFT
LOBE L IF T
.002
IN T A K E
.2 343
E X HAUST
.2530
J O URNAL D IA M E T E R
1 .9 4 8 2 -1 .9 4 9 2
.0 0 2 5 .0 0 3 5
V A L V E SYSTEM
LE8
L IF T E R
H Y D R A U L IC
ROCKER A R M R A T IO
1.70:1
VALVE
LASH
8 0 LB . IN.
80 LB. IN.
EXHAUST
O I L P A N ( T O F R O N T C O V E R ) .....................
55 LB . IN.
O I L P U M P C O V E R ...........................................
80 LB . IN .
45
46
.002 M AX.
C O V E R ....................................
50 LB . IN.
C A M S H A F T S P R O C K E T .................................
ROCKER ARM
20 LB . FT.
O I L P A N T O C R A N K C A S E ( 5 / 1 6 - 1 8 ) ............ 13 5 LB . IN.
C L U T C H P R E S S U R E P L A T E ..........................
30 LB . FT.
D I S T R I B U T O R C L A M P ....................................
25 L B . FT.
F L Y W H E E L H O U S I N G ....................................
3 0 LB . FT.
IN TA K E
1 /3 2 -1 /1 6
EXHAUST
1 /1 6 -3 /3 2
M A N IF O L D
( E X H A U S T ) .................................
20 LB . FT.
IN T .
.0010-.0027
M A N IF O L D
( I N L E T ) ........................................
30 LB . F T.
EXH.
W A T E R O U T L E T .............................................
30 LB . FT.
W A T E R P U M P ..................................................
30 LB. FT.
P R O D U C T IO N
S E R V IC E
HI L IM IT + .001 IN . + .0 0 2 E X .
C O N N E C T IN G
R O D C A P ...............................
50 LB. FT.
H E A D ...........................................
8 0 LB . FT.
O I L P U M P .........................................................
6 5 LB . FT.
C Y L IN D E R
FREE L E N G T H
SPRING
(OUTER)
80 LB . IN.
O I L F I L T E R B Y P A S S V A L V E ........................
SE A T R U N O U T
VALVE
F R O N T C O V E R ........................
F L Y W H E E L H O U S I N G C O V E R .....................
SE AT A N G L E ( IN T . & EX H .)
STEM
CLEARANCE
CRANKCASE
IN T A K E
FACE A N G L E ( IN T . & E X H .)
SE AT
W ID T H
TORQUE SPECIFICATIONS
PRESSURE
LBS. @ IN.
2.12
CLOSED
8 4 -9 6 @ 1.80
OPEN
2 1 0 -2 3 0 @1.40
IN S T A L L E D H E I G H T
1/32"
1-51/64
FREE L E N G T H
1.86
APPROX. # O F COILS
DAM PE R
R O C K E R A R M S T U D ......................................
5 0 LB . FT.
FLYW HEEL
6 5 LB . FT.
M A IN
....................................................
T E M P E R A T U R E S E N D I N G U N I T ...................
20 LB . FT.
T O R S I O N A L D A M P E R ....................................
8 5 LB . FT.
O I L F I L T E R ............................................. ..
25 LB . FT.
O IL PA N D R A IN
20 LB . F T.
SPA R K PLUG
PLUG
.................................
................................................17-27 LB . FT.
V8-D IE SE L
6A6-1
Oil P a n ............................................................................
Oil P um p........................................................................
Connecting Rod and P is to n ......................................
Rod B earings................................................................
Rod Assem bly...............................................................
P isto n ..............................................................................
Rod and P isto n .............................................................
Piston P in s .....................................................................
C rankshaft Pulley........................................................
B alancer.........................................................................
Front C o v e r...................................................................
Oil S e a l...........................................................................
Timing Chain and G ears............................................
C am shaft, Injection Pum p Drive and Driven
Gears
. . '. . . .............................................................
C am shaft and Injection Pum p Driven G ear
B earings............................................................................
U N IT R E P A IR ..............................................................
E ng ine.............................................................................
C ra n k sh a ft.....................................................................
M ain B earings..............................................................
M ain Bearing Upper Oil S e a l..................................
R ear M ain Bering Lower Oil S e a l.........................
Flex P la te .......................................................................
Engine Oil Dipstick and G u id e s..............................
Specifications...................................................................
6A6-26
6A6-26
6A6-27
6A6-27
6A6-28
6A6-28
6A6-30
6A6-31
6A6-32
6A6-32
6A6-32
6A6-34
6A6-34
SECTION 6A6
6A6-1
6A6-4
6A6-4
6A6-4
6A6-6
6A6-6
6A6-7
6A6-8
6A6-8
6A6-8
6A6-9
6A6-10
6A6-11
6A6-12
6A6-13
6A6-14
6A6-14
6A6-16
6A6-16
6A6-19
6A6-22
6A6-23
6A6-24
6A6-25
6A6-34
6A6-34
6A6-37
6A6-37
6A6-37
6A6-39
6A6-40
6A6-41
6A6-41
6A6-41
6A6-44
GENERAL DESCRIPTION
ENGINE CONSTRUCTION
6A 6-2
V8 - DIESEL
INLET FITTING
NOZZLE GASKET
NOZZLE BODY
GOVERNOR
SPRING
HOUSING
PRESSURE
REGULATOR
METER NG VALVE
I k
VENT WIRE
ASSEMBLY
HEAD PRESSURE
TRANSFER PRESSURE
TAP HOIf PLUG
CAM
BALL
CHECK
'
ASSEMBLY
^GOVERNOR;
AUTOMATIC ADVANCE
MECHANISM
HQUSW g LUBEI
CHARGING
PASSAGE
FILTER
DELIVERY
TRANSFER PUMP
NOZZLE
FILTER
V 8 - DIESEL
HOUSING PRESSURE
COLD ADVANCE TERMINAL
THROTTLE SHAFT
ADVANCE CAM
PRESSURE TAP
PLUG AND SEAL
FUEL SOLENOID
. TERMI NAL
/ tfS k V ft
GUIDE S T U D - ^ ^ v
PS^TH RO TTLE
SHAFT
PIN
"
ADVANCE CAM
^ ^ A C T U A T I N G ARM
Fig. 6A6-5--lnjection Pump Housing Right Side View
l.
O IL PICK-U P
LIFTER FEED
3. ROCKER ARM
VALVE TIP FEED
4. SPLASH LUBE TO
TIM IN G CHAIN FUEL
PUMP CAM & DIST.
& OIL PUMP DRIVE
LEFT
MAIN GALLERY
5.
FEED
6. CAM BEARING FEED
7. M A IN BEARING FEED
ROD BEARING FEED
9. INJECTION PUMP
DRIVE BEARING FEED
RIGHT MAIN
GALLERY
VACUUM PUMP
AND OIL PUMP DRIVE
6A 6-3
I f FT MAIN
GALLERY
COOLING
Fig. 6 A 6 -6 -E n g in e Lubrication
6A 6-4
V 8 - DIESEL
\\ \ \
WK
ENGINE CLEANING
Do not clean the engine until it has cooled down to
surrounding tem perature. Spraying w ater or engine clean
ing fluid on the diesel injection pum p when it is warm or hot
will dam age the pump.
ELECTRICAL
Eight glow plugs are used to heat the pre-cham ber to
aid in starting. They are 6 volt heaters th at pulse when the
ON VEHICLE SERVICE
Reinstall the guide stud with a new washer making
certain th a t the upper extension of the m etering valve
spring rides on top of the guide stud. Torque the guide
stud to 9.5 N-m (85 in. lbs.) O vertorquing the guide
stud may strip the alum inum threads in the housing
(Figs. 6A6-5 and 6A6-8).
not in the cover and position the cover about 1/4 inch
forw ard (tow ard shaft end) and about 1/8 inch above
the pum p (Fig. 6A 6 -10).
11
IDLE GOVERNOR
S P R IN G
ST E PS 6, 7 and 8 A R E FO R G U ID E ST U D SEA L
R EPLA CEM EN T ONLY.
6. Observe position of m etering valve spring over the top
of the guide stud. T his position m ust be exactly
duplicated during reassem bly (Fig. 6A6-8).
7. Remove the guide stud and washer. N ote location of
parts prior to removal.
LIGHT TRUCK SERVICE MANUAL
V 8 - DIESEL
13. T urn the ignition switch to the run position and touch
the pink solenoid wire to the solenoid. A clicking noise
should be heard as the wire is connected and discon
nected. If this clicking is not observed, the linkage may
be jam m ed in a wide open throttle position and the
engine M U ST N O T be started. If clicking is observed,
connect the pum p solenoid and (housing pressure cold
advance if equipped) wires (Fig. 6A 6-5), then proceed
to step 16.
11.
12.
13.
.005" CLEARANCE
THROTTLE
SHAFT
PIN
J-29601
15.
16.
17.
ADVANCE CAM
ACTUATING ARM
6A 6-5
18.
19.
6A 6-6
V8 - DIESEL
LONGER
BOLT
GASKET
1.
2.
3.
4.
5.
6.
Installation
ENGINE MOUNTING
R efer to Fig. 6A6-12.
V 8 - DIESEL
6A 6-7
EXHAUST MANIFOLD
Removal and Installation (Left Side)
1. Hoist vehicle.
6A 6-8
V 8 - DIESEL
COMPRESSION TEST
To determ ine if the valves or rings are the cause of low
com pression, a test should be m ade to determ in e the
cylinder compression pressure.
W hen checking compression, the batteries should be at
or near full charge. The lowest reading cylinder should not
be less than 70% of the highest and no cylinder reading
should be less than 275 p.s.i. (1900 kPa).
1. Remove air cleaner then install air crossover cover
J-26996-1.
2. Disconnect the wire from the fuel solenoid term inal of
the injection pump.
3. Disconnect wires from glow plugs then remove all glow
plugs.
4. Screw the compression gage J-26999 into the glow plug
hole of the cylinder th at is being checked.
5. C rank engine.
This should be done with six "puffs" per cylinder.
N orm al-Com pression builds up quickly and evenly
to specified compression on each cylinder.
Piston R ings Leaking-C om pression low on first
stroke tends to build up on following strokes but does
not reach normal.
NOTICE: Do not add oil to any cylinder to compression
test as extensive dam age may result.
FUEL
ELB0W
SHUT-OFF
SO LE N O ID
(H ID D EN )
SLOW IDLE
A DJU ST M EN T
SCREW
FUEL RETURN
H O U S IN G P R E S S U R E
L IN E CONNECTOR
COLD A D V A N C E
T ER M IN A L
(H ID D EN )
P R E-SET
DO NOT A D J U S T
P R E S S U R E TAP
PLUG & SEA L
THROTTLE
LEVER
V 8 - DIESEL
6A 6-9
14. W ith the driving wheels blocked and the parking brake
on, sta rt the engine and adjust the solenoid (energized)
to th e specification listed on th e Em ission C ontrol
Inform ation Label.
15. Check and adjust the slow idle speed with the engine at
operating tem perature.
To check idle speeds, it will be necessary to insert the
probe of the m agnetic pickup tach, J-26925, in the
tim ing indicator hole.
16. W ith the driving wheels blocked and the parking brake
on, adjust the slow idle screw on the injection pum p to
the specification shown on the emission control label.
17. If equipped with cruise control, adjust the servo throttle
rod to m inim um slack (engine off) then put clip in first
free hole closest to the bellcrank, but within the servo
bail.
Vacuum Adjustment
LIGHT TRUCK SERVICE MANUAL
6 A 6-10
V8 - DIESEL
3. Put the seal from the pressure tap plug on the pressure
tap adapter J-29382, then screw the adapter into the
pump housing.
4. Screw pressure tap adapter J-28526 into pressure tap
adapter J-29382 then attach a low pressure gage to the
adapter.
5. Install m agnetic pick-up tachom eter J-26925.
6. Check the pressure with the engine running at 1000
R PM (P A R K ), parking brak e on, drive wheels
blocked. The pressure should be 8-12 PSI (55-83 kPa)
with not more than 2 PSI (14 kPa) fluctuation.
7. If equipped with H PC A and the pressure is zero, check
the operation of the houing pressure cold advance as
follows:
a. Remove the electrical connector from the housing
pressure cold advance term inal, Fig. 6A6-5. If the
pressure rem ains zero, remove the injection pump
cover and check the operation of advance solenoid. If
it is binding, free up or replace parts as needed.
b. If the pressure becam e norm al with lead off, check
the operation of the te m p e ra tu re switch on the
cylinder head bolt. See "D iesel E lectrical".
8. If the pressure is still incorrect, replace the fuel return
line connector assembly. If the pressure is too high, the
fuel retu rn system m ay be restricted . Remove the
return line at the injection pump. Install a fitting and
short piece of hose to allow the return flow to em pty into
a small container.
9. If th e pressure is lower th an before, correct the
restriction in the fuel line.
10. If still to high, replace the fuel return line connector
assembly.
11. If it rem ains too high, remove the injection pump for
repair.
12. Remove the tachom eter, pressure gage, and adapters.
13. Put a new pressure tap plug screw seal on the pressure
tap plug, then screw in the tap plug.
14. Remove screened covers, then install air crossover.
V 8 - DIESEL
6A6-11
BREATHER CAP
AND VALVE ASSY.
Removal
6A 6-12
V8-D IE SE L
20 FT. LBS.
FUEL FILTER
12. Remove pum p and cap all open lines and nozzles.
V8 - DIESEL
Installation
6A 6-13
6A 6-14
V8-D IE SE L
VALVE COVER
Removal
Installation
INTAKE MANIFOLD
Removal
V 8-D IE SE L
6A 6-15
INTAKE MANIFOLD
RAIN TUBE
Installation
ADAPTER
SEAL
ADAPTER
LUBRICATE SEAL TOOL ADAPTER & MANIFOLD
''C
20 FT. LBS:
(27 N-m)
6A 6-16
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
V8 - DIESEL
1.
2.
3.
4.
VALVE LIFTERS
Roller hydraulic lifters are used to reduce the am ount
of friction between the valve lifter and the cam shaft lobe.
Guides keep the lifters from rotating on the cam shaft lobes.
Installation
Operation
V8-D IE SE L
ENGINE
VALVE CLOSED
6A 6-17
V IE W A
ENGINE
VALVE OPEN
valve disc spring which traps the oil in the base of the lifter
body below the plunger. The plunger and lifter body then
raise as a unit, pushing up the push-rod to open the valve.
The force of the valve spring which is exerted on the plunger
through the rocker arm and push-rod causes a slight am ount
of leakage between the plunger and lifter body. This "leakdow n" allows a slow escape of trapped oil in the base of the
lifter body. As the lifter rides down the other side of the cam
lobe and reaches the base circle or "valve closed" position,
the plunger spring quickly moves the plunger back (up) to
its original position. This movement causes the check valve
disc to open against the check valve disc spring and oil from
within the plunger is draw n into the base of the lifter. This
restores the lifter to zero lash.
1.
2.
3.
4.
Removal
6A 6-18
V 8 - DIESEL
2.
3.
4.
5.
6.
7.
V 8 - DIESEL
6 A 6-19
GLOW PLUG
A burned out FA ST G LO W glow plug tip may bulge
then break off and drop into the pre-cham ber when the glow
plug is removed. W hen this occurs, the cylinder head must
be removed and the pre-cham ber removed from the head to
remove the broken tip.
a. W orn push-rod.
b. W orn rocker arm .
c. L ifter plunger stuck in down position due to dirt or
carbon.
d. Defective lifter.
Checking of the above four items:
1. Look at the upper end of push-rod. Excessive wear of
the spherical surface indicates one of the following
conditions.
a. Im proper hardness of the push-rod ball. T he pushrod and rocker arm m ust be replaced.
b. Im proper lubrication of the push-rod. The push-rod
and rocker arm m ust be replaced. The oiling system
to the push-rod should be checked.
2. If push-rod appears in good condition and has been
properly lubricated, replace rocker arm and recheck
valve lash.
3. If valve lash exists and push-rod and rocker arm are
okay, trouble is in the lifter. L ifter should be replaced.
Installation
6A 6-20
V 8 - DIESEL
Test Preparation
To ensure correct preparation of the nozzle for testing,
the following procedure should be performed.
1. Clean the carbon from the tip of the nozzles with a
brass wire brush. Do not use motorzed brush or a steel
wire brush as they could dam age the nozzle tip.
Diesel fuel should never be used as a test fluid. It is
recom m ended th at SA E J967D or equivalent be used.
M ake sure th at the tester reservoir has a sufficient
am ount of fluid to complete test.
A t this point the proper connecting adapter to be used
from th e nozzle to the te ste r should be selected
(adapters are available from the tester m anufacturer).
Connect the nozzle to the tester (available tool) with
the tip pointing down.
Testing Procedure
12 FT. LBS.
(16 N-m)
25 FT. LBS.
(34 N-m)
NOZZLE
(TORQUE MUST BE
APPLIED TO LARGEST
NOZZLE HEX)
Fig. 6A6-48a~lnjection Nozzle Installation
V8-D IE SE L
4. C h atter Test
W ith gage valve closed, the nozzle should ch atter when
the tester is operated rapidly. C h atter is rapid opening
and closing of the nozzle valve while fuel is being
pumped through the nozzle. This checks the nozzle
under extrem e load conditions.
C h atter should be audible and can also be felt in the
handle of the tester. C h atter does not occur in the
engine. It is an indication of valve freedom. C h atter
action is generally also an indication of proper seat
width and interference angle.
5. R eturn Fuel Test
Loosen connector nuts and reposition nozzle tip slightly
above horizontal plane, as shown in Figure 6A6-49.
R e-tighten connector nuts and raise pressure to 1500
PSI. N ozzle should not open. Observe fluid from nozzle
return. A fter the first drop forms on return fuel end of
nozzle, there should be 3 to 10 more drops in 30 seconds
while m aintaining 1500 O SI.
If a nozzle fails to m eet any of th e specifications
described in the five tests above, it should be serviced by
R oosa-M aster.
6A6-21
6A 6-22
V 8 - DIESEL
Gasket
V 8 - DIESEL
Installation
n s s fo
VALVE
FACE
ANGLE
VALVE
SEAT
ANGLE
VALVE
SEAT
I NSERT
I NTAKE
44
45
NO
YES
EXHAUST
30
31
NO
NO
I NDUCTI ON
HARDENED
VALVE SEAT
t?
Installation
.(nfi'iBO
HEAD
DI AMETER
bn'R -..'s?!/-
Removal
V A L V E T RA IN IN F O R M A T IO N
TYPE
6A 6-23
3.
4.
5.
6.
6A 6-24
V 8 - DIESEL
IN T A K E V A L V E
FACE A N G LE
IN T A K E V A L V E
SEAT A N G LE
E XH AUST V A L V E
FACE A N G LE
EXH AUST V A L V E
SEAT A N G LE
Reconditioning
.015" M IN IM U M BETWEEN
VALVE STEM AND GAGE
V8 - DIESEL
6A 6-25
Reaming
Removal
Checking Rotators
6A 6-26
V8 - DIESEL
6.
7.
8.
9.
OIL PUMP
Removal
OIL PAN
Removal
V 8 - DIESEL
1. Install the gears and shaft in the oil pump body and
check the gear end clearance by placing a straight edge
over the gears and m easure the clearance between the
straight edge and the gasket surface. The clearance
should be betw een .0 0 0 5 " to .0 0 7 5 ". If the end
clearance is to the high lim it, check for scores in the
cover th a t would bring the total clearance over the
specified am ount.
2. Install the cover screws and tighten alternately and
evenly. The torque is 8 lbs. ft. (1 lN -m ).
3. Position the pressure regulator valve into the pump
cover, closed end first, then install th e spring and
retaining pin.
4. Assemble the drive shaft extension to the drive shaft.
6A 6-2 7
Installation
ROD BEARINGS
The connecting rod bearings are designed to have a
slight projection above the rod and cap faces to insure a
positive contact.
6A 6-28
V8 - DIESEL
ROD ASSEMBLY
If a rod is twisted or bent, a new rod m ust be installed.
NO
ATTEM PT
SH O U LD
BE
MADE
TO
S T R A IG H T E N C O N N E C T IN G RO D S.
V 8 - DIESEL
6A 6-29
Honing
1. W hen cylinders are being honed, follow the m anufac
tu re rs recom m endations for the use of the hone.
2. Occasionally during the honing operation, the cylinder
bore should be thoroughly cleaned and the selected
piston checked for correct fit.
3. W hen finish honing a cylinder bore, the hone should be
moved up and down at a sufficient speed to obtain very
fine uniform surface finish m arks in a cross hatch
pattern of approxim ately 45 to 65 degrees included
angle. The finish m arks should be clean but not sharp,
free from imbedded particles and torn or folded metal.
4. Perm anently m ark the piston for the cylinder to which
it has been fitted and proceed to hone the rem aining
cylinders.
NOTICE: H andle pistons with care. Do not attem pt to
force pistons through cylinders until the cylinders have
been honed to correct size. Pistons can be distorted
through careless handling.
5. Thoroughly clean the bores with hot w ater and deter
gent. Scrub well with a stiff bristle brush and rinse
thoroughly with hot w ater. It is extrem ely essential that
a good cleaning operation be performed. If any of the
abrasive m aterial is allowed to remain in the cylinder
bores, it will rapidly wear the new rings and cylinder
bores. The bores should be swabbed several tim es with
light engine oil and a clean cloth and then wiped with a
clean dry cloth. C Y L IN D E R S S H O U L D N O T BE
C L E A N E D W IT H K E R O S E N E O R G A S O L IN E .
Clean the rem ainder of the cylinder block to remove the
excess m aterial spread during the honing operation.
Checking Cylinder Bore
6A 6-30
V8 - DIESEL
Each ring and rail gap m ust be m easured with the ring
or rail positioned squarely and at the bottom of the ringtravel area of the bore. (Fig. 6A6-73).
FEELER
GAUGE
.015"-. 025"
.015"-. 025"
.015"-. 055"
SIDE CLEARANCE*
Top Comp. Ring
2nd Comp. Ring
.004"-. 006"
.0018"-. 0038"
V8 - DIESEL
6A6-31
PISTON PINS
The piston pin is free floating and the correct fit in the
piston is .0003 " to .0005 " and rod is .0003 " to .0013 " loose.
If the pin to piston clearance is to the high lim it (.0005"
piston or .0013" rod)., the pin can be inserted in the piston
or rod with very little hand pressure and will fall through the
piston or rod by its own weight. If the clearance is .0003",
6A 6-32
V8 - DIESEL
CRANKSHAFT PULLEY
Removal
1. Remove belt(s).
2. Hoist vehicle.
3. Remove pulley bolts and pulley.
Installation
BALANCER
Removal
FRONT COVER
Removal
Installation
V8 - DIESEL
6A 6-33
86 .
7. Place cover on front of block and press downward to
compress seal. R otate cover left and right and guide
pan seal into cavity using a small screwdriver as shown
in Fig. 6A6-85.
8. Apply engine oil to bolts (threads and heads).
9. Install two bolts finger tight to hold cover in place.
10. Install two dowel pins (cham fered end first).
Downward
INJECTION P U M P D R IV E
GEAR - P U SH CAM
A G A IN S T REAR CUP
PLUG
KEY
CRANKSHAFT SPROCKET
35 FT. LBS.
GASKET
(47 N-m I
1 FT. LBS.
(30 N-m)
CAM SH A FT SPROCKET
T IM IN G C H A IN
CRANKSHAFT O IL SLINGER
6A 6-34
V8 - DIESEL
11. Install tim ing in d icato r and w ater pum p assem bly.
Then torque bolts evenly as shown in Fig. 6A6-86.
12. Apply lubricant # 1 0 5 0 1 6 9 or equivalent on balancer
seal surface.
13. Install balancer and balancer bolt. Torque from 2003101b. ft. (271-420N -m ).
14. Install necessary brackets.
15. Connect bypass hose and radiator hoses.
16. In stall c ra n k sh a ft pulley and four a tta c h in g bolts.
Torque to 20 lbs. ft. (27 N -m ).
17. Install fan pulley, fan and four attaching bolts. Torque
bolts to 20 lbs. ft. (27 N-m ).
18. Install belts and adjust, using Tool J-23600.
19. Fill radiator.
20. Road test vehicle and check for leaks. Use of spray foot
powder or equivalent m ay aid in detecting leaks.
OIL SEAL
Removal (Front Cover Installed)
Installation
Installation
1.
2.
3.
4.
5.
6.
7.
8.
9.
Disconnect battery.
D rain coolant from engine.
Remove upper radiator baffle.
Disconnect upper radiator hose at w ater outlet.
Disconnect upper radiator hose support clamp.
Disconnect cooler lines at radiator.
Remove radiator fan shroud.
Remove radiator.
Remove intake manifold and gasket, front and rear
seal.
10. Remove balancer pulley.
V 8 - DIESEL
6A 6-35
INJECTION PUMP
DRIVEN GEAR
SH IM
17. Remove bolt securing cam shaft gear and tim ing chain,
then remove tim ing gears and chain.
'3 O'CLOCK
'S '
CRANKSHAFT AND
CAMSHAFT SPROCKET
T IM IN G CH A IN
35 FT. LBS.
GASKET
CRANKSHAFT O IL SLINGER
22 FT. LBS.
ENGINE T IM IN G INDICATOR
Installation
6A 6-36
V8 - DIESEL
Installation
V 8 - DIESEL
6A 6-37
UNIT REPAIR
ENGINE
Removal
PROTECTORS
/
RUBBER
" 'V B A N D S
NOTE O VERLA P
OF ADJACENT RODS
FRONT OF ENGINE
CRANKSHAFT
Removal (Cylinder Heads On)
1. W ith engine on stand and oil pan, oil pump and front
cover removed, rotate crankshaft to the position where
the connecting rod nuts are most accessible. Fig. 6A694 shows the engine with the # 3 and # 4 rods in the
fully extended position.
2. Remove connecting rod caps and install thread protec
tors. Remove fuel pum p eccentric from crankshaft.
3. Remove main bearing caps.
4. N ote position of keyway in crankshaft so it can be
installed in the same position.
5. Lift crankshaft out of block. Rods will pivot to the
center of the engine when the crankshaft is removed.
Do not allow pistons to move in their bore during or
after crankshaft removal.
Installation
6A6-38
V8 - DIESEL
CENTER M A IN BEARING
THRUST FLANGES
WOOD
BLOCK
B U M P SHAFT IN EACH
DIRECTION TO A LIG N
THRUST FLANGES O F -------/^CENTER M A IN BEARIN G
----- ^
------x
Installation
R.H. O IL
P ASSAG E PLUG
.^ .p .p f M Q .O - O llP A S S A C E
L H . O IL
/
P ASSAG E PLUG
y
^
i
/-
C U P P lU G
L H. O IL
PASSAG E PLUG
CRANKSHAFT
J_
GROOVES IN UPPER
AND LOWER HALF
OF ALL BEA R IN G S
EXCEPT NUMBER
ONE. NUMBER ONE
LOWER DOES NOT
HAVE A GROOVE.
120 FT. LBS.
MAIN BEARINGS
Main bearing clearance must not exceed .0035" on all
bearings. The .0035" clearance is permissible only if the
LIG H T T R U C K SE RV IC E M A N U A L
V8 - DIESEL
6A6-39
SEALER
6A6-40
5.
6.
7.
8.
9.
10.
V8 - DIESEL
V8 - DIESEL
6A6-41
FLEX PLATE
Removal
One bolt hole in the flex plate is offset and the flywheel
will attach to the crankshaft in only one position. The flex
plate ring gear is not replaceable.
1.
2.
3.
4.
Installation
4 FRONT OF ENGINE
P O SIT IO N GUIDE TO
REAR OF OPENING
EXH AU ST M AN IFO LD
D IP S T IC K GUI
V .
-- 45
.,?
17
7/32
(YELLOW P L A ST IC PLUG
AND HANDLE COATING)
LIG H T T R U C K SERVICE M A N U A L
Fig. 6A6-104--Vacuum
Pump
K ey N o.
D R IV E G EAR
1
2
3
4
P a rt N a m e
PU M P ASSY, V A C U U M
SCREW , HEX.H E A D T A P P IN G
SEAL, O" RING
DR IVE ASSY, V A C U U M PU M P
Key No.
1
2
3
4
5
Part Name
PU M P AS SY , V A C U U M
SC REW , HE X H E A D T A P P IN G
SEAL, O R IN G
D R IV E AS SY , V A C U U M PU M P
B O LT AS SY , SE AL &
(B E L T D R IVE N ) - S ER V IC E C O M P O N E N T S
V8 - DIESEL
INSTALL
R e m o ve h o se fro m
p u m p in le t.
R e m o ve b o lt a nd
b ra c k e t h o ld in g p u m p
to e n g in e b lo ck.
R e m o ve p u m p .
V A C U U M HOSE
In s e rt p u m p in e n g in e ,
m a k in g s u re th e g ea rs
o n th e p u m p m esh
w ith th e g e a rs o n th e
e n g in e ca m sh a ft.
R o ta te th e p u m p in to
p o s itio n so th e
b ra c k e t a n d b o lt ca n
be in s ta lle d .
6A6-43
ASSEMBLE
1. In s ta ll " O R in g Seal
in c a v ity o f d riv e
2. R e m o v e O R in g
Seal
a s s e m b ly .
2. C o n n e c t d riv e
a s s e m b ly to v a c u u m
p u m p w ith h e x hea d
ta p p in g s c re w s .
In s ta ll v a c u u m h ose .
O R IN G S E A L
D RIVE & V A C U U M
PU M P A S S E M B LY
BO LT
Install Seal O" Ring
BRACKET
in cavity of drive
assembly.
S c re w s s h o u ld be
tig h te n e d e v e n ly a n d to a
to rq u e o f 12 N *m
(9 Ft. L bs.)
j
1. In s ta ll p u m p to
m o u n tin g o n e n g in e .
R e m o ve hose fro m
p u m p in le t.
2. In s ta ll v a c u u m hose,
3 |nstaM b e |t jn
R e m o ve b o lts h o ld in g
p u m p to b ra c k e t.
C la m p a s s e m b ly in
vise in a rea s h o w n . C a re
s h o u ld be ta k e n n o t
to o v e r tig h te n .
INSTALL
T h e g e a r s h o u ld
be fre e to tu rn w h e n
in s ta llin g th e
s c re w s to th e p u m p
a s s e m b ly .
p u lle y a nd a d ju s t
b e lt te n s io n .
R e m o ve p u m p .
T h e b e a rin g a s s e m b ly in th e b e lt
d riv e n p u m p n e e d s lu b ric a n t.
T h is s h o u ld be c h e c k e d a n d k e p t fille d
a t a ll tim e s (see b e lo w ).
Seal a n d b o lt a s s e m b ly
tig h te n to 4 to 6 N m
(4 Ft. Lbs.)
T h e s h a ft s h o u ld
be fre e to tu rn w h e n
in s ta llin g th e
s c re w s to th e p u m p
a s s e m b ly .
LIG H T TR U C K SE R V IC E M AN U AL
PISTON PIN
V -8 D IE S E L
DISPLACEMENT
LITRE {*)
5 .7 (N )
LF9
DIAMETER
1 .0 9 4 9 -1 .0 9 5 3
PRODUCTION
CLEARANCE
.0 0 0 3 -.0 0 0 5
SERVICE
RPO
LF9
BORE
4 .0 5 7
STROKE
3 .3 8 5
COMPRESSION RATIO
2 2 .5 :1
FIRING ORDER
1 - 8 - 4 - 3 - 6 - 5 -7 -2
DIAMETER
OUT OF
ROUND
TAPER
FIT IN ROD
i A rtH
PRODUCTION
PRODUC
TION
N .A .
RELIEF
SIDE
N .A .
SERVICE
PRODUCTION
N .A .
SERVICE
N .A .
PRODUCTION
N .A .
SERVICE
N .A .
# 1 -2 -3 -4
.0 0 0 5 -.0 0 2 1
MAIN
BEARING
CLEARANCE
#5
.0 0 1 5 -.0 0 3 1
N .A .
PISTON:
CLEARANCE
OUT OF
ROUND
N .A .
THRUST
SIDE
ALL
2 .9 9 9 3 -3 .0 0 0 3
DIAMETER
4 .0 5 6 -4 .0 5 8
SERVICE
.0 0 0 3 -.0 0 1 3
CRANKSHAFT
MAIN
JOURNAL
CYLINDER BORE:
N .A .
SERVICE
N .A .
N.A.
SERVICE
. 0 0 5 " .0 0 6
PISTON RING:
t
0 GROOVE PRODUC
* V IN D e s ig n a tio n
DIAMETER
PRODUCTION
CRANKPIN
TOP
M CLEAR TION
2ND
P ANCE
R
SERVICE
E
S
PRODUC TOP
S
TION
2ND
GAP
1
o
SERVICE
N
GROOVE PRODUCTION
CLEAR
0 ANCE
SERVICE
1
PRODUCTION
L
GAP
SERVICE
.0 0 5 -.0 0 7
OUT OF
ROUND
.0 0 1 8 -.0 0 3 8
N .A .
.0 1 5 -.0 2 5
.0 1 5 *.0 2 5
N .A .
.0 0 1 -.0 0 5
N .A .
.0 1 5 -.0 5 5
N .A .
.0 0 3 5 -.0 1 3 5
ROD BEARING
CLEARANCE
2 .1 2 3 8 -2 .1 2 4 8
N .A .
................................
(...
SERVICE
N .A .
PRODUCTION
N .A .
SERVICE
PRODUCTION
N .A .
.0 0 0 5 -.0 0 2 6
SERVICE
N .A .
.0 0 6 -.0 2 0
CAMSHAFT
LOBE LIFT
.002
INTAKE
N .A .
EXHAUST
JOURNAL DIAMETER
CAMSHAFT END PLAY
N .A .
#1 2 0357 2 0365
#2 2.0157-2 0166
#3 1 9957 1 9965
#4 1 9757 1 9765
#5 1.9567-1.9566
.0 1 1 -.0 7 7
V8 - DIESEL
TYPE
6A6-44
GENERAL DATA:
TORQUE SPECIFICATIONS
Ib. ft.
V A L V E SYSTEM
LF9
LIFTER
HYDRAULIC
N.A.
VALVE
LASH
INTAKE
NONADJUSTABLE
EXHAUST
</>
SEAT
WIDTH
.075.098
INTAKE
EXHAUST
.037-.075
INT.
PRODUCTION
STEM
EXH.
CLEARANCE
SERVICE
FREE LENGTH
VALVE
SPRING
(OUTER)
PRESSURE
LBS. e IN.
*
.003
SEAT RUNOUT
T5
.0010-.0027
.0015-.0032
N.A.
2.09
CLOSED
85-95 @ 1.670
OPEN
203-207 @ 1.300
INSTALLED HEIGHT
N.A.
1/32"
FREE LENGTH
N.A.
APPROX. # OF COILS
N.A.
DAMPER
@ 44 INTAKE 30 EXHAUST
* 45 INTAKE 31 EXHAUST
N-m
LIGHT
TRUCK
SERVICE
* Clean and d ip entire bolt in engine oil before tig htening to obtain a correct torq ue reading.
M AN U AL
ENGINE COOLING
6B-1
SECTION 6B
ENGINE COOLING
CONTENTS
General Description......................................................... .6B-1
Coolant Level.................................................................. ..6 B -1
Thermostat................. ..................................................... ..6B-2
Drive B elts....................................................................... .6B-7
Diagnosis...............................................................................6B-7
System C hecks................................................................ .6B-7
O verheat/N oise............................................................... ..6B-7
Fan C lu tch....................................................................... .6B-8
On Vehicle S ervice...........................................................
Water Pump.....................................................................
Thermostat.......................................................................
Radiator............................................................................
Fan Shroud......................................................................
Fan/Fan C lutch..............................................................
Coolant Recovery Bottle...............................................
Engine Oil C ooler...........................................................
6 B -1 1
6B-11
6B-11
6B-12
6B-12
6B-12
6B-13
6B-14
GENERAL DESCRIPTION
All Chevrolet Light Duty Trucks have pressure type
engine cooling systems with thermostatic control of coolant
circulation. The cooling system is sealed by a pressure type
radiator filler cap which causes the system to operate at
higher than atmospheric pressure. The higher pressure
raises the boiling point of the coolant which increases the
cooling efficiency of the radiator. The 15 pound (103 kPa)
pressure cap used raises the boiling point of coolant to
approximately 258 F (125C) at sea level.
The radiator cap should be washed with clean water
and pressure checked every 12 months.
All models have a closed cooling system using a round
pressure cap (Fig. 6B-1) and a coolant reservoir. Coolant
can be added without removing the radiator cap.
A pressure-vacuum valve radiator cap is used which
allows the coolant to expand through the pressure valve in
the center of the cap without building unnecessary pressure.
The expanding coolant flows into the coolant reservoir. The
vent valve closes due to expansion and coolant flow. The
nominal 15 pound (103 kPa) pressure will not be reached
until the system is working at maximum capacity.
Any air or vapor in the cooling system will be forced to
the coolant reservoir under the liquid level and leave
through the vent tube at the top of the reservoir. As the
system cools, the extra coolant in the reservoir will be drawn
back to the radiator through the vent valve. In this manner,
the radiator will keep itself full at all times.
COOLANT LEVEL
The need for additional coolant can be detected by
observing the level of coolant in the "see through" reservoir
6B-2
ENGINE COOLING
THERMOSTAT
The thermostat consists of a restriction valve actuated
by a thermostatic element. This is mounted in the housing at
the cylinder head coolant outlet above the water pump on
L-6, and in the forward part of the intake manifold, under
the coolant outlet on "small block" and "Mark". Thermo
stats are designed to open and close at predetermined
temperatures and if not operating properly should be
removed and tested.
GENERATOR
A.I.R. PUMP
P/S PUMP
50 LB.
(222 N)
MIN.
A/C
COMPRESSOR
65 LB.
(289 N)
MIN.
5.7L V8 DIESEL
GENERATOR
P/S PUMP
A.I.R. PUMP
(NON A/C)
70 LB.
(311 N)
MIN.
A/C
COMPRESSOR
A.I.R. PUMP
80 LB.
(356 N)
MIN.
LIG H T T R U C K SE RV IC E M A N U A L
ENGINE COOLING
ADJU STM EN T
BOLT
IN LIN E
PIVOT
BOLT
6B-3
IN L IN E /L 2 5
PIVOT
BOLT
VIEW
ADJU STM EN T BO LT
PIVO T BOLT
S M A L L BLOCK
DIESEL - EXCEPT A /C
ADJU STM EN T BOLT
PIVO T
BOLT
PIV O T BOLT
[ v i ew]
ADJU STM EN T
BOLTS
D IE S E L -A /C EQUIPPED
6B-4
ENGINE COOLING
IIM LINE/LE3
IN |iN E /W 5 ^ "
B0LT
ADJUSTMENT NUT
A D JUSTM EN^^
ADJUSTMENT
-W '
ll
^^JPIVOT BOLT
NUT
& NUT
MK IV
DIESEL
ENGINE COOLING
6B-5
PIVOT BOLT
& NUT
ADJUSTMENT BOLT
PIVOT BOLT
ADJUSTMENT
'I
BOLT
ADJUSTMENT BOLT
IN LINE-'G' MODEL
BRACE
ADJUSTING
BOLT
.SUPPORT
ADJUSTMENT
BOLTS.!
V
PIVOT BOLT
VIEW
TAPPED HOLE
PIVOT BOLT
.ADJUSTMENT/
BOLTS
PIVOT
BOLT
LIG H T T R U C K SERVICE M AN U AL
6B-6
ENGINE COOLING
L IG H T T R U C K SE RV IC E M A N U A L
ENGINE COOLING
DRIVE BELTS
Frayed or cracked belts should be replaced and tensioned to specifications using a strand tension gage, such as
tool J-23600-B or equivalent.
Loose belts may place an extremely high impact load
on driven component bearings due to the whipping action of
the belt.
An over tightened belt places unnecessary loads on the
component bearings.
6B-7
DIAGNOSIS
If the cooling system requires frequent addition of
coolant in order to maintain the proper level, check all units
and connections in the cooling system for evidence of
leakage. Inspection should be made with cooling system
cold. Small leaks which may show dampness or dripping can
easily escape detection when the engine is hot, due to the
rapid evaporation of coolant. Tell-tale stains of grayish
white or rusty color, or dye stains from anti-freeze, at joints
in cooling system are almost always sure signs of small leaks
even though there appears to be no damage.
Air may be drawn into the cooling system through
leakage at the water pump seal or through leaks in the
coolant recovery system. Gas may be forced into the cooling
system through leakage at the cylinder head gasket(s) even
though the leakage is not sufficient to allow coolant to enter
the combustion chamber.
SYSTEM CHECKS
Exhaust Leaks
Thermostat
6B-8
ENGINE COOLING
FAN CLUTCH
1
Noise
LIG H T T R U C K SE RV IC E M A N U A L
ENGINE COOLING
6B-9
4. IS O VERHEATING OCCURRING AFTER PROLONGED D RIVING IN SLOW CITY TRAFFIC, TRAFFIC JAMS.
PARADES. ETC.?
IF ANSWER IS "Y E S " - INSTRUCT OWNER ON DRIVING TECHNIQUES THAT WOULD AVO ID OVERHEATING - SAME AS
FOR PROLONGED IDLES - NO. 3. FURTHER DIAGNOSTIC CHECKS SHOULD NOT BE REQUIRED.
1. IF COMPLAINT IS HOT LIGHT OR HOT INDICATIO N ON TEMPERATURE GAGE WAS HOT LIGHT ACCOMPANIED BY BOILING? IF ANSWER IS "Y E S ",
GO TO
2. IF COMPLAINT IS BOILING -
GO TO
B O IL IN G
BOILING
HOT LIGHT
ON CHART
ON CHART
ON C H AR T
3. IF COMPLAINT IS COOLANT LOSS DETERMINE IF CUSTOMER IS O VERFILLING THE SYSTEM, THIS WOULD NORM ALLY RESULT IN SMALL AMOUNTS OF
COOLANT LOSS THROUGH THE OVERFLOW TUBE. IF THIS IS THE CASE, INSTRUCT THE CUSTOMER ON PROPER F ILL
LEVEL & NO FURTHER DIAGNOSTIC CHECKS SHOULD BE REQUIRED.
IF OVERFILLING IS NOT THE PROBLEM, GO TO
. y
j S
( CJ X
CAUTION - THE COOLING SYSTEM IS DESIGNED TO OPERATE AT 15 P.S.I. PRESSURE & TEMPERATURES
EXCEEDING 200 F. CAUTION SHOULD BE EXERCISED WHEN REMOVING PRESSURE CAP OR
SERVICING THE SYSTEM.
.
1316
L IG H T T R U C K SERVICE M A N U A L
6B-10
CHART
ENGINE COOLING
DIAGNOSIS
H O T L IG H T
C O O L A N T LOSS
B O IL IN G
'ON OR
C H E C K P R E S S U R E CA P
HOT TEMP
C H EC K PRESSURE CAP
OK
C H E C K S E N D IN G U N IT
REPLACE
OK
O.K.
A N T I FREEZE
REPLACE
CHECK C O O LA N T LE V E L
P R O T E C T IO N
REPLACE
i_fdE
V IS U A L S Y S T E M C H E C K
T O SPEC.
YES
ADD
1. L E A K S
Check Hoses, R a d ia to r, Clamps,
W ater Pum p, Therm ostat Housing, Rad.
D ra in , S o ft or Core Plugs, Heater W ater
H O T L IG H T
G O TO " B O IL IN G
OR LOW
TEMP?
ON C H A R T
CH E C K S E N D IN G U N IT
ON CAR TH E R M O S TA T CHECK J
_____________________________________ * SEE T H E R M O S T A T
D IA G N O S T IC C H A R T
2. F O A M IN G C O O L A N T
Observe
neck after engine w arm up.
3. O V E R F L O W
F A N B E L T T E N S IO N
T IG H T E N TO SPEC.
in fille r
S Y S T E M (Sem i-Sealed
System)
REPLACE
in
/
I
C O L L A P S E D UPPER OR
LO W ER R A D IA T O R
HOSE?
SYSTEM
O .K .
\
J
R E P A IR OR
REPLA CE D E FEC TS
D IR T , BU GS, B E N T F IN S . E T C . |
B L O C K IN G R A D IA T O R OR
A /C C O N D E N S E R ?
1
YES
C L E A N OR
S T R A IG H T E N
NO
A N Y F IX E S A B O V E ?
NO
If
none
of
the
above
required
is
R E P A IR
ENGINE COOLING
6B-11
ON VEHICLE SERVICE
WATER PUMP
Removal - L6
1.
2.
3.
4.
1.
2.
3.
4.
5.
6.
7.
8.
Installation - V8
1. Drain radiator.
2. Disconnect lower radiator hose at water pump.
3. Disconnect heater hose and by-pass hose at water
pump.
4. Remove fan assembly.
5. Remove all pulley belts.
6. Remove water pump pulley.
7. Disconnect generator, P /S pump bracket and, if
equipped, A /C compressor bracket.
8. Remove water pump attaching bolts and water pump.
Installation - Diesel
THERMOSTAT
Removal (All Engines)
6B-12
ENGINE COOLING
1.
2.
3.
4.
5.
6.
Installation
1.
2.
3.
4.
5.
6.
FAN/FAN CLUTCH
Removal (All)
ENGINE COOLING
6B-13
CK 2 0 0 -3 0 0 5.7 AUTO-ALL
CK-100 5 .0 -5 .7 AUTO W / A / C
OR H.D. COO LING
6.6-7.4-ALL
5.7-DIESEL-ALL
5 .0 -5 .7-M AN.-ALL
CK-100 5 .0 -5 .7-AUTO W / O A /C
OR H.D. COOLING
4.1-4.8-ALL W / A / C
4.1-4.8-ALL W / O
A /C
RADIATOR.
SUPPORT
RADIATOR SUPPORT
BRACE
P000(42)
RADIATOR ASM
W /L F 8
EXC. LF8
6B-14
ENGINE COOLING
STUD
B R AKE C YL
SUPPORT
VIEW
[z ]
LIG H T TR U C K SE RV IC E M AN U AL
ENGINE COOLING
6B-15
RADIATOR M O U N T IN G PANEL
RADIATOR SUPPORT 5 .0 /5 .7
jV IE W
|VIEW
&LE3 OR L25
Fig. 6B-11--"CK" Series Fan Shroud
M O T O R H O M E C H A S S IS
P (3 2 )
LIG H T T R U C K SERVICE M AN U AL
6B-16
ENGINE COOLING
LIG H T TR U C K SE RV IC E M A N U A L
S T R U T ROD
ENG INE MTG B R K T
CO O LER
/
/
R ETU R N HOSE
/
SUPPLY HOSE
A D A P T ASM
ENGINE COOLING
'G ' V A N
6B-17
ENGINE FUEL
6C-1
SECTION 6C
ENGINE FUEL
CONTENTS
General...
Diagnosis
Model 1ME Carburetor
Model 2SE Carburetor
6C-1
6C-1
6C1- 1
6C2- 1
Model M 2M E Carburetor
Model M4M Carburetor
Fuel System
6C3- 1
6C4- 1
6C5- 1
GENERAL
ALL N EW GM VEHICLES ARE CERTIFIED BY THE U N ITED
ST A T E S E N V IR O N M E N T A L PRO TECTIO N A G E N C Y A S C O N
FO RM ING TO THE R EQ U IR EM EN TS OF THE REG U LATIO NS
FOR THE CONTROL OF AIR POLLUTION FROM N EW MOTOR
VEHICLES. THIS CERTIFICATION IS C O N T IN G E N T O N CER
T A IN A D JU ST M E N T S BEING SET TO FACTORY ST A N D A R D S. IN
M OST C A SE S, TH ESE A D JU ST M E N T PO IN T S EITH ER HAVE
BEEN PE R M A N E N T L Y SEALED A N D /O R MADE INA CCESSIBLE
TO PREVENT IN D ISC R IM IN A T E OR ROUTINE A D JU ST M E N T IN
THE FIELD. FOR THIS REA SO N , THE FACTORY PROCEDURE
FOR TEM PORARILY REM OVING PLUGS, CAP, ETC., FOR PU R
POSES OF SE R V IC IN G THE PR O D U C T, M U ST BE STR IC TLY
FOLLOW ED A N D , W HEREVER PRACTICABLE, R E T U R N E D TO
THE O R IG IN A L IN TEN T OF THE DESIGN.
This section, divided into sub-sections by carburetor
model, covers the repair and adjustment procedure for fuel
system components. Typical illustrations and procedures are
used except where specific illustrations or procedures are
necessary to clarify the operation.
LIG H T T R U C K SERVICE M A N U A L
6C-2
ENGINE FUEL
CARBURETOR DIAGNOSIS
T h e fo llo w in g d ia g n o s tic p ro c e d u re s are f o r c a r b u re to r re la te d p ro b le m s a n d th e ir e ffe c ts o n c a r p e rfo rm a n c e . O th e r syste m s o f th e c a r can
also cause s im ila r p ro b le m s a n d s h o u ld be c h e c k e d w h e n lis te d o n th e c h a r t. T h e p r o b le m areas d e s c rib e d are:
1.
2.
3.
E n g in e s ta rts h a rd .
4.
5.
In c o n s is te n t e n g in e id le speeds.
6.
E n g in e die se ls (a fte r- ru n ) u p o n s h u t o f f .
7.
E n g in e h e sita te s o n a c c e le ra tio n .
8.
9.
10.
E n g in e surges.
11.
P o o r gas m ile a ge .
C O N D I T IO N
E n g in e C ra n k s N o r m a lly
P O S S IB L E C A U S E
Im p r o p e r s ta rtin g p ro c e d u re used.
- W ill N o t S ta r t.
C O R R E C T IO N
C h e c k w it h th e c u s to m e r t o d e te rm in e
if p r o p e r s ta rtin g p ro c e d u re is used,
as o u t lin e d in th e O w n e r's M a n u a l.
C h o k e va lve n o t o p e ra tin g
p r o p e r ly .
A d ju s t th e c h o k e th e r m o s ta tic c o il
to s p e c ific a tio n . C h e c k th e c h o k e
va lv e a n d /o r lin k a g e as nece ssa ry.
R e p la c e p a rts i f d e fe c tiv e . I f caused
b y fo re ig n m a te ria l a n d g u m , clea n w it h
s u ita b le n o n - o il base s o lv e n t.
N O T E : A f t e r a n y c h o k e s y s te m w o r k , c h e c k
c h o k e v a c u u m b re a k s e ttin g s a n d c o r r e c t
as necessary.
N o fu e l in c a rb u re to r .
R e m o v e fu e l lin e a t c a r b u r e to r . C o n n e c t
hose to fu e l lin e a n d ru n in t o m e ta l
c o n ta in e r . R e m o v e th e w ir e fr o m th e " b a t "
te r m in a l o f th e d is t r ib u t o r . C ra n k
o v e r e n g in e i f th e re is n o fu e l d is
ch arg e f r o m th e fu e l lin e , te s t fu e l
p u m p as o u t lin e d in S e c tio n 6 . I f fu e l
s u p p ly is o k a y , c h e c k th e f o llo w in g :
a. In s p e c t fu e l in le t f il t e r . I f
p lu g g e d , re p la c e .
b . I f fu e l f i l t e r is o k a y , re m o v e a ir
h o rn a nd c h e c k f o r a b in d in th e
f lo a t m e c h a n is m o r a s tic k in g in le t
n e e d le . I f o k a y , a d ju s t f lo a t as s p e c ifie d .
E n g in e flo o d e d . T o c h e c k
R e m o v e th e a ir h o r n .
f o r flo o d in g , re m o v e th e a ir
cle a n e r w it h th e e n g in e
C h e c k fu e l in le t n e e d le a n d seat f o r
im m e d ia te ly s h u t o f f a nd
p r o p e r seal. I f a n e e d le a n d seat
lo o k in t o th e c a rb u r e to r
te s te r is n o t a v a ila b le , a p p ly v a c u u m
b ore s. F uel w il l be d r ip p in g
to th e n e e d le seat w it h n e e d le in s ta lle d .
o f f n o zzle s.
I f th e n e e d le is le a k in g , re p la c e .
C h e c k f lo a t f o r fre e m o v e m e n t,
b e n t f lo a t h a n g e r o r b in d s in th e
f lo a t a rm .
I f fo r e ig n m a te ria l is in fu e l s y s te m , cle a n
th e s y s te m a nd re p la c e fu e l filt e r s as
n ece ssa ry. I f e xcessive fo r e ig n m a te ria l is
fo u n d , c o m p le te ly d is a s s e m b le a n d c le a n .
Fig. 6C-1--Diagnosis 1 of 8
LIG H T T R U C K SERVICE M A N U A L
ENGINE FUEL
6C-3
CORRECTION
POSSIBLE CAUSE
C h e c k fu e l p u m p p re ssu re a n d v o lu m e , re p la c e
Fuel pum p.
N o t K e e p R u n n in g
S e c tio n 6 .
Id le speed.
A d ju s t id le t o s p e c ific a tio n s .
C h o k e h e a te r s y s te m m a l
C h e c k v a c u u m s u p p ly a t h o t a ir in le t
f u n c tio n in g (m a y cause
t o c h o k e h o u s in g . S h o u ld be n o t less
th a n m a n ifo ld v a c u u m m in u s 3 " H g. w it h
lo a d in g ).
e n g in e r u n n in g a t id le . (E x c . IM V )
C h e c k w ir in g .
C h e c k f o r p lu g g e d , r e s tr ic te d , o r b ro k e n
h e a t tu b e s .
C h e c k r o u t in g o f a ll h o t a ir p a rts .
L o o s e , b ro k e n o r in c o r r e c t
C h e c k c o n d itio n a n d r o u t in g o f all
v a c u u m hose r o u tin g .
v a c u u m hoses c o r r e c t as necessary.
E n g in e doe s n o t have
C h e c k f o r fre e m o v e m e n t o f fa s t
e n o u g h fa s t id le speed
id le c a m . C le a n a n d / o r re a lig n as
w h e n c o ld .
C h o k e v a c u u m b re a k u n its
A d ju s t b o th v a c u u m b re a k assem blies
are n o t a d ju s te d to
to s p e c ific a tio n . I f a d ju s te d o k a y ,
c h e c k th e v a c u u m b re a k u n its f o r p ro p e r
d e fe c tiv e .
o p e r a tio n as fo llo w s :
T o c h e c k th e v a c u u m b re a k u n its , a p p ly
a c o n s ta n t v a c u u m s o u rc e o f a t least
1 0 " H g ., p lu n g e rs s h o u ld s lo w ly m o ve
in w a rd a n d h o ld v a c u u m . I f n o t , re pla ce
th e u n it .
A lw a y s c h e c k th e fa s t id le ca m a d ju s tm e n t
w h e n a d ju s tin g v a c u u m b re a k u n its .
C h o k e va lve s tic k in g
a n d / o r b in d in g .
I n s u ffic ie n t fu e l in
C h e c k fu e l p u m p p ressure a nd v o lu m e .
C a rb u re to r.
C h e c k f o r p a r t ia lly p lu g g e d fu e l
in le t f il t e r . R e p la c e if c o n ta m in a te d .
C h e c k th e f l o a t level a d ju s tm e n t
f o r b in d in g c o n d itio n . A d ju s t as
s p e c ifie d .
E n g in e S ta rts H a rd
L o o s e , b ro k e n o r in c o r r e c t
C h e c k c o n d itio n a nd r o u tin g o f
(C ra n k s N o r m a lly )
v a c u u m hose r o u tin g .
a ll v a c u u m hoses c o r r e c t as
nece ssa ry. See S e c tio n 6 E .
I n c o r r e c t s ta r tin g p ro c e d u re .
C h e c k t o be sure c u s to m e r is usin g
th e s ta r tin g p ro c e d u re o u t lin e d in
O w n e r 's M a n u a l.
Fig. 6C-2--Diagnosis 2 of 8
LIG H T T R U C K SERVICE M A N U A L
6C-4
ENGINE FUEL
POSSIBLE CAUSE
CORRECTION
E n g in e S ta rts H a rd
M a lf u n c t io n in a c c e le ra to r
C h e c k a c c e le ra to r p u m p a d ju s tm e n t
(C ra n k s N o r m a lly )
p u m p s y s te m .
an d o p e r a tio n .
(C o n tin u e d )
C h e c k p u m p d is c h a rg e b a ll f o r s tic k in g
o r leakage.
C h o k e v a lv e n o t c lo s in g .
A d ju s t c h o k e th e r m o s ta tic c o il. C h e c k
c h o k e v a lv e a nd lin k a g e f o r b in d s a n d
a lig n m e n t. C le a n a nd re p a ir o r re p la c e
as necessary.
V a c u u m b re a k s m is a d ju s te d
C h e c k f o r a d ju s tm e n t a n d fu n c tio n o f
o r m a lfu n c tio n in g .
v a c u u m b re a k s . C o r r e c t as necessary.
In s u ffic ie n t fu e l in b o w l.
C h e c k fu e l p u m p p ressu re a n d v o lu m e .
C h e c k f o r p a r t ia lly p lu g g e d fu e l
in le t f il t e r . R e p la c e i f d ir t y . C h e c k
f lo a t m e c h a n is m . A d ju s t as s p e c ifie d .
F lo o d in g .
C h e c k f lo a t a nd n e e d le a n d seat
f o r p r o p e r o p e r a tio n .
S lo w e n g in e c ra n k in g speed.
R e fe r to s ta r tin g c ir c u it d ia g n o s is .
S e c tio n 6 D .
E n g in e Id le s A b n o r m a lly
In c o r r e c t id le speed.
(T o o fa s t o r to o s lo w )
A i r leaks in t o c a rb u r e to r
C h e c k a ll v a c u u m hoses a nd re s tr ic to r s
b o re s b e n e a th t h r o t t le valve s,
le a d in g in t o th e m a n ifo ld o r c a r b u r e to r
base f o r leaks o r b e in g d is c o n n e c te d .
hoses d is c o n n e c te d o r in
s ta lle d im p r o p e r ly .
T o r q u e c a r b u r e to r to m a n ifo ld b o lts
to 10 f t . lbs. U s in g a p re ssu re o il c a n ,
s p ra y lig h t o il o r ke ro s e n e a ro u n d
m a n ifo ld to head su rfa ce s a n d c a r b u r e to r
t h r o t t le b o d y .
N O T E : D o n o t s p ra y a t t h r o t t l e s h a ft
end s.
I f e n g in e R P M ch an g e s, tig h te n o r re
p la ce th e c a r b u r e to r o r m a n ifo ld gas
k e ts as necessary.
C lo g g e d o r m a lf u n c t io n in g
C h e c k P C V s y s te m . C le a n a n d / o r re p la c e
P C V syste m .
as necessary.
C a rb u r e to r flo o d in g .
R e m o v e a ir h o rn a n d c h e c k f lo a t
a d ju s tm e n ts .
C h e c k b y u s in g p ro c e d u re
o u t lin e d u n d e r " E n g in e
C h e c k f lo a t n e e d le a n d seat f o r p r o p e r
Flooded".
seal. I f a n ee d le a n d seat te s te r is n o t
a v a ila b le , a p p ly v a c u u m t o th e n e e d le
seat w it h n ee d le in s ta lle d . I f th e
n e e d le is le a k in g o r d a m a g e d , re p la c e .
Fig. 6C-3--Diagnosis 3 of 8
LIG H T T R U C K SERVIC E M A N U A L
ENGINE FUEL
6C-5
CORRECTION
POSSIBLE CAUSE
E n g in e Id le s A b n o r m a lly
C h e c k f lo a t f o r fre e m o v e m e n t.
(T o o fa s t o r to o s lo w )
C h e c k f o r b e n t f l o a t h a n g e r o r b in d s
( C o n tin u e d )
in th e f l o a t a rm .
I f fo r e ig n m a te r ia l is fo u n d in
th e c a r b u r e to r , c le a n th e fu e l s y s te m
a nd c a r b u r e to r . R e p la c e fu e l f i l t e r
as n e ce ssa ry.
R e s tric te d a ir c le a n e r e le m e n t.
Id le s y s te m p lu g g e d
C le a n c a r b u r e to r , see S e c tio n 6 C 1 .
o r re s tric te d .
In c o r r e c t id le m ix tu r e
R e a d ju s t p e r s p e c ifie d p ro c e d u re . See
a d ju s tm e n t.
S e c tio n 6 C 1 .
D e fe c tiv e id le s to p s o le n o id ,
C h e c k s o le n o id a n d w ir in g .
id le sp e e d -u p s o le n o id o r
w ir in g .
T h r o t t le b la d e s o r lin k a g e
C h e c k t h r o t t l e lin k a g e a n d t h r o t t le
s tic k in g a n d / o r b in d in g .
b la d e s ( p r im a r y a n d s e c o n d a ry ) f o r
s m o o th a n d fre e o p e r a tio n . C o r r e c t
p r o b le m areas.
E n g in e D iesels ( A ft e r
L o o s e , b ro k e n o r im p r o p e r ly
C h e c k c o n d itio n a n d r o u t in g o f all
R u n ) u p o n S h u t O ff
ro u te d v a c u u m hoses.
v a c u u m hoses. C o r r e c t as necessary.
In c o rr e c t id le speed.
M a lf u n c t io n o f id le s to p
C h e c k f o r c o r r e c t o p e r a tio n o f id le
s o le n o id , id le s p e e d -u p
s o le n o id . C h e c k f o r s tic k y o r b in d in g
s o le n o id o r d a s h p o t.
s o le n o id .
F a st id le ca m n o t f u l ly o f f .
C h e c k fa s t id le c a m f o r fr e e d o m o f
o p e r a tio n . C le a n , re p a ir, o r a d ju s t
as r e q u ir e d . C h e c k c h o k e h e a te d a ir
tu b e s f o r r o u t in g , f it t in g s b e in g
t ig h t o r tu b e s p lu g g e d . C h e c k c h o k e
lin k a g e f o r b in d in g . C le a n a nd c o r r e c t
as nece ssa ry.
E x c e s s iv e ly lean c o n d itio n
A d ju s t c a r b u r e to r id le m ix tu r e as
caused b y m a la d ju s te d c a r
d e s c rib e d in S e c tio n 6 C 1 .
b u r e t o r id le m ix tu r e .
Ig n it io n tim in g re ta rd e d .
S e t to s p e c ific a tio n s .
E n g in e H e s ita te s O n
L o o s e , b ro k e n o r in c o r r e c t
C h e c k c o n d itio n a n d r o u tin g o f a ll v a c u u m
A c c e le r a tio n
v a c u u m hose r o u tin g
hoses c o r r e c t o r re p la c e .
A c c e le r a to r p u m p n o t a d ju s te d
A d ju s t a c c e le ra to r p u m p , re p la c e .
R e m o v e a ir h o r n a nd c h e c k p u m p c u p .
I f c ra c k e d , s c o re d o r d is t o r t e d , re
sy s te m .
p la c e th e p u m p p lu n g e r.
Fig. 6C-4--Diagnosis 4 of 8
L IG H T T R U C K SERVICE M AN U AL
6C-6
ENGINE FUEL
POSSIBLE CAUSE
CORRECTION
E n g in e H e s ita te s O n
N O T E : A q u ic k c h e c k o f th e
C h e c k th e p u m p d is c h a rg e b a ll f o r
A c c e le ra tio n
p u m p sy s te m can be m a de as
p ro p e r s e a tin g a n d lo c a tio n .
( C o n tin u e d )
fo llo w s : W ith th e e n g in e
o f f , lo o k in t o th e c a r b u r e to r
b o re s a n d o b se rve p u m p n o z z le s
w h ile q u ic k ly o p e n in g t h r o t t le
le ve r. A f u ll s tre a m o f fu e l
s h o u ld e m it f r o m each p u m p
n o z z le .
F o re ig n m a tte r in p u m p passages.
C le a n a n d b lo w o u t w it h c o m p re s s e d
a ir.
F lo a t leve l to o lo w .
C h e c k a nd re set f l o a t le v e l to
s p e c ific a tio n .
F r o n t v a c u u m b re a k d ia p h ra g m
C h e c k a d ju s tm e n t a n d o p e r a tio n o f
n o t f u n c tio n in g p r o p e r ly .
v a c u u m b re a k d ia p h ra g m .
C h e c k o p e r a tio n o f s e c o n d a ry a ir
va lv e . C h e c k s p rin g te n s io n a d ju s tm e n t.
P o w e r e n r ic h m e n t s y s te m n o t
C h e c k f o r b in d in g o r s tu c k p o w e r
o p e ra tin g c o r r e c t ly .
In o p e ra tiv e a ir c le a n e r h ea ted
C h e c k o p e r a tio n o f th e r m o s t a tic a ir
a ir c o n t r o l.
c le a n e r s y s te m .
F u e l f i l t e r d ir t y o r p lu g g e d .
R e p la c e f i l t e r a nd clea n fu e l s y s te m as
necessary.
D is t r ib u t o r v a c u u m o r m e c h a n ic a l
C h e c k f o r p r o p e r o p e r a tio n .
ad va n ce m a lfu n c tio n in g .
T im in g n o t to s p e c ific a tio n s .
A d ju s t to s p e c ific a tio n s .
C h o k e c o il m is a d ju s te d (c o ld
A d ju s t t o s p e c ific a tio n s .
o p e ra tio n .)
E G R v a lve s tu c k o p e n .
In s p e c t a nd cle a n E G R v a lv e .
E n g in e Has Less T h a n
L o o s e , b ro k e n o r in c o r r e c t
C h e c k c o n d itio n a nd r o u t in g o f a ll
N o rm a l P o w e r A t N o rm a l
v a c u u m hose r o u tin g .
v a c u u m hoses.
C lo g g ed o r d e fe c tiv e P C V s y s te m .
C le a n o r re p la c e as n e ce ssa ry.
C h o k e s tic k in g .
C h e c k c o m p le te c h o k e s y s te m f o r s tic k in g
A c c e le ra tio n s .
o r b in d in g . C le a n a n d re a lig n as
n ece ssa ry. C h e c k a d ju s tm e n t o f c h o k e
th e r m o s ta tic c o il.
C h e c k c o n n e c tio n s a n d o p e r a tio n o f
c h o k e h o t a ir s y s te m .
C h e c k je ts a n d c h a n n e ls f o r p lu g g in g ;
c le a n a n d b lo w o u t passages.
C lo g g e d o r in o p e ra tiv e p o w e r
R e m o v e a ir h o rn a nd c h e c k f o r fre e
syste m .
o p e r a tio n o f p o w e r p is to n s .
Fig. 6C-5-Diagnosis 5 of 8
L IG H T T R U C K SERVICE M A N U A L
ENGINE FUEL
6C-7
POSSIBLE CAUSE
CONDITION
E n g in e Has Less T h a n
A i r c le a n e r te m p e ra tu r e reg
C h e c k r e g u la tio n a n d o p e r a tio n o f
N o rm a l P o w e r A t N o rm a l
u la tio n im p ro p e r.
a ir c le a n e r s y s te m .
T ra n s m is s io n m a lf u n c t io n .
R e fe r t o tra n s m is s io n d ia g n o s is .
Ig n it io n s y s te m m a lf u n c t io n .
A c c e le ra tio n s . (C o n tin u e d )
R e fe r t o H .E .l. d ia g n o s is .
E x h a u s t s y s te m .
C h e c k f o r r e s tr ic tio n s . C o r r e c t as
re q u ire d .
Less T h a n N o rm a l P o w e r
C a r b u r e to r t h r o t t l e valves
C o r r e c t t h r o t t l e lin k a g e to o b ta in
O n H e a v y A c c e le ra tio n
n o t g o in g w id e o p e n . T u r n o f f
w id e o p e n t h r o t t l e in c a r b u r e to r .
O r A t H ig h Speed
e n g in e a n d c h e c k b y p u s h in g
a c c e le ra to r p e d a l to f lo o r .
S e c o n d a ry t h r o t t le lo c k o u t
n o t a llo w in g s e c o n d a rie s to
C h e c k f o r b in d in g o r s tic k in g lo c k o u t
le v e r.
open.
C h e c k f o r fre e m o v e m e n t o f fa s t id le
ca m .
C h e c k c h o k e h e a te d a ir s y s te m f o r p ro p e r
a n d t i g h t c o n n e c tio n s p lu s f lo w th r o u g h
s y s te m .
C h e c k a d ju s tm e n t o f c h o k e th e r m o s ta tic
c o il.
M a k e nece ssa ry c o r r e c tio n s a nd a d ju s tm e n ts .
S p a rk p lu g s fo u le d , in c o r r e c t
C le a n , re g a p , o r re p la c e p lu g s.
gap.
P lug g e d a ir c le a n e r e le m e n t.
R e p la c e e le m e n t.
A i r va lve m a lf u n c t io n .
(W h e re a p p lic a b le )
C h e c k s p rin g te n s io n a d ju s tm e n t. M a k e
n ecessary a d ju s tm e n ts a n d c o r r e c tio n s .
P lu g g e d fu e l in le t f ilt e r .
R e p la c e w it h a n e w f i l t e r e le m e n t.
In s u ffic ie n t fu e l to c a r b u r e to r .
C h e c k fu e l p u m p a nd s y s te m , ru n p ressu re
a nd v o lu m e te s t. See F U E L S Y S T E M
D IA G N O S IS , S e c tio n 6 .
P o w e r e n r ic h m e n t s y s te m
R e m o v e th e a ir h o r n a n d c h e c k f o r fre e
n o t o p e ra tin g c o r r e c t ly .
o p e r a tio n o f b o th p o w e r p is to n ( s ) , clea n
a n d c o r r e c t as n ece ssa ry.
C h o k e clo se d o r p a r t ia lly
F re e c h o k e v a lv e o r lin k a g e .
c lo s e d .
C h e c k f o r lo o se je ts .
F lo a t level t o o lo w .
C h e c k a n d re set f lo a t level to
s p e c ific a tio n .
Fig. 6C-6--Diagnosis 6 of 8
LIG H T T R U C K SERVICE M A N U A L
6C-8
ENGINE FUEL
POSSIBLE CAUSE
CORRECTION
T ra n s m is s io n m a lf u n c t io n .
R e fe r to tra n s m is s io n d ia g n o s is .
I g n it io n s y s te m m a lf u n c t io n .
O n H e a v y A c c e le ra tio n
O r A t H ig h Speed
(C o n tin u e d )
F u e l m e te rin g je ts re s tric te d .
C h e c k fu e l p u m p p ressu re a n d v o lu m e , in s p e c t
lin e s f o r leaks a nd r e s tr ic tio n s . See
F U E L S Y S T E M D IA G N O S IS , S e c tio n 6.
E x h a u s t s y s te m .
C h e c k f o r r e s tr ic tio n s . C o r r e c t as
required.
E n g in e Surges
L o o s e , b r o k e n o r in c o r r e c t
C h e c k c o n d itio n a n d r o u t in g o f all
v a c u u m hose r o u tin g .
P C V s y s te m clo g g e d o r
C h e c k P C V s y s te m . C le a n o r re p la c e
m a lf u n c t io n in g .
as necessary.
Lo o se c a r b u r e to r , E G R o r in ta k e
T o r q u e c a r b u r e to r to m a n ifo ld b o lts
m a n ifo ld b o lts a n d /o r le a k in g
t o 10 f t . lbs. U s in g a p re ssu re o il
gaskets.
c a n , s p ra y lig h t o il o r ke ro s e n e
a ro u n d m a n ifo ld t o hea d m o u n tin g s u r
fa c e a nd c a r b u r e to r base. I f e n g in e R P M
changes, tig h te n o r re p la c e th e c a r
b u r e t o r o r m a n ifo ld g aske ts as necessary.
C h e c k E G R m o u n tin g b o l t to r q u e .
L o w o r e r r a t ic fu e l p u m p p ressu re .
C h e c k fu e l d e liv e ry a n d p ressu re .
C o n ta m in a te d fu e l.
C h e c k f o r c o n ta m in a n ts in fu e l. C lean
s y s te m i f necessary.
F u e l f i l t e r p lu g g e d .
F lo a t level t o o lo w .
M a lf u n c t io n in g f lo a t a n d /o r
C h e c k o p e r a tio n o f s y s te m . R e p a ir o r
n e e d le a n d seat.
re p la c e as necessary.
P o w e r p is to n s tu c k o r b in d in g .
C h e c k f o r fre e m o v e m e n t o f p o w e r
p is to n ( s ) . C le a n a n d c o r r e c t as necessary.
F u e l je ts o r passages p lu g g e d
C le a n a n d b lo w o u t w it h c o m p re s s e d
o r re s tric te d .
a ir.
Ig n it io n s y s te m m a lf u n c t io n .
E x h a u s t s y s te m .
C h e c k f o r r e s tr ic tio n s . C o r r e c t as
necessary.
P o o r Gas M ile a g e
C u s to m e r d r iv in g h a b its .
R u n m ile a g e te s t w it h c u s to m e r d r iv in g
i f p o s s ib le . M a k e sure c a r has 2 0 0 0 - 3 0 0 0
m ile s f o r th e " b r e a k - in " p e r io d .
Fig. 6C-7--Diagnosis 7 of 8
L IG H T T R U C K SERVICE M A N U A L
ENGINE FUEL
6C-9
CORRECTION
POSSIBLE CAUSE
P o o r Gas M ile a g e
L o o s e , b ro k e n o r im p r o p e r ly
C h e c k c o n d itio n o f a ll v a c u u m hose
( C o n tin u e d )
ro u te d v a c u u m hoses.
r o u tin g s . C o r r e c t as necessary.
E n g in e in need o f s e rvice .
C h e c k e n g in e c o m p re s s io n , e x a m in e s p a rk
p lu g s ; if fo u le d o r im p r o p e r ly g a p p e d ,
c le a n a n d re ga p o r re p la c e . C h e c k ig n itio n
w ir e c o n d itio n a n d c h e c k a n d re s e t ig
n it io n t im in g . R e p la c e a ir c le a n e r e le m e n t
i f d ir t y . C h e c k f o r r e s tr ic te d e x h a u s t
s y s te m a n d in ta k e m a n ifo ld f o r leakage.
C h e c k c a r b u r e to r m o u n tin g b o lt to r q u e . C h e c k
v a c u u m a n d m e c h a n ic a l adva n ce .
C h e c k fu e l ta n k , fu e l lin e s a nd fu e l
F u e l lea ks.
p u m p f o r a n y fu e l leakage.
P o o r Gas M ile a g e
H ig h fu e l'le v e l in c a r b u r e to r .
C h e c k fu e l in le t n e e d le a n d seat f o r p r o p e r
a n d /o r B la c k S m o k e
seal. T e s t, u s in g s u c tio n fr o m a v a c u u m
f r o m T a il P ipe
s o u rc e . I f n e e d le is le a k in g , re p la c e .
C h e c k f o r lo a d e d f lo a t . R ese t f lo a t
level to s p e c ific a tio n .
I f e xcessive fo r e ig n m a te ria l is p re s e n t
in th e c a r b u r e to r b o w l, th e c a r b u r e to r
s h o u ld be c le a n e d .
P o w e r s y s te m in c a r b u r e to r
R e m o v e a ir h o rn a n d c h e c k f o r fre e
n o t fu n c tio n in g p r o p e r ly .
m o v e m e n t o f p o w e r p is to n (s ). C le a n
P o w e r p is to n (s ) s tic k in g o r
m e te rin g ro d s o u t o f je ts .
C h o k e s y s te m .
C h e c k c h o k e h e a te d a ir tu b e s f o r r o u tin g
a n d /o r p lu g g in g w h ic h w o u ld r e s tr ic t
h o t a ir f l o w to c h o k e h o u s in g . C h e c k c h o k e
lin k a g e f o r b in d in g . C le a n o r re p a ir
as r e q u ire d . C h e c k a d ju s tm e n t o f th e r m o
s ta tic c o il. R e a d ju s t t o s p e c ific a tio n
as r e q u ir e d . C h e c k e le c tr ic c h o k e
w ir in g .
P lu g g e d a ir c le a n e r e le m e n t.
R e p la c e e le m e n t.
E x h a u s t sy s te m .
C h e c k f o r r e s tr ic tio n s . C o r r e c t as re q u ire d .
L o w tir e p ressure o r in c o r r e c t
t ir e size.
c o r r e c t size tire s .
E v a p o ra tiv e e m is s io n c a n is to r
T ra n s m is s io n m a lf u n c t io n
R e fe r t o tra n s m is s io n d ia g n o s is .
o r in w r o n g gear*
C a r fe e ls lik e i t is
P lu g g e d fu e l filte r s .
R e m o v e a n d re p la c e filte r s .
F a u lt y fu e l p u m p .
P e r fo r m fu e l p u m p te s t.
r u n n in g o u t o f gas s u rg in g
o c c u rs in m id -s p e e d range
R e m o v e a n d re p la c e fu e l p u m p as re q u ir e d .
F o re ig n m a te ria l in fu e l s y s te m o r
In s p e c t p ip e s ,a n d hoses f o r k in k s a nd
k in k e d fu e l p ip e s o r hoses.
b e n d s , b lo w o u t to c h e c k f o r p lu g g in g .
R e m o v e a n d re p la c e as re q u ire d .
Fig. 6C-8--Diagnosis 8 of 8
L IG H T T R U C K SE RV IC E M A N U A L
6C-10
ENGINE FUEL
C O N D IT IO N
P O S S IB L E
CAUSE
C O R R E C T IO N
6. Leaking ta n k sw itch u n it
(Dual ta n k system)
6. Replace u n it
7. Inoperative ta n k switch u n it
(Dual ta n k system)
7. Replace u n it
8. Plugged or inoperative ta n k
pressure co n tro l valve
5. Disconnected, m isrouted,
kinked, deteriorated or
damaged vapor hoses or
c o n tro l hoses
Collapsed fuel ta n k
(Loss o f ta n k capacity)
8. Leaking or inoperative ta n k
pressure co n tro l valve
3. Plugged or ru p tu re d diaphragm
in ta n k pressure c o n tro l valve
and defective cap
ENGINE FUEL
6C-11
DIAGNOSIS
FUEL TANK
CORRECTION
POSSIBLE CAUSE
CONDITION
1.
Tank o v e rfille d .
2.
3.
C orrect as required.
Purge tan k and repair or replace ta n k as
required.
Gasoline O dor
4.
6.
1.
replace cap.
2.
1.
2.
B affle loose.
Replace fuel ta n k.
3.
1.
Replace filte r.
2.
Fuel S tarvation
LIG H T T R U C K SERVICE M A N U A L
- V
6C1-1
SECTION 6C1
6C1-1
6C1-7
6C1-7
6C1-7
6C1-7
6C1-7
6C1-7
6C1-8
GENERAL DESCRIPTION
The Monojet, carburetor (Fig. 6C1-1) is a single bore
downdraft carburetor using a triple venture in conjunction
with a plain tube nozzle.
Fuel flow through the main metering system is control
led by a main well air bleed and a variable orifice jet. A
power enrichment system is used to provide good perform
ance during moderate to heavy acceleration and at higher
engine speeds.
The model 1ME incorporates an integral automatic
choke system which uses and electrically heated choke coil.
The vacuum diaphragm unit is mounted externally on the
air horn and connects to the thermostatic coil lever through
a connecting line.
The electric choke coil is contained in a choke housing
mounted on a bracket attached to the float bowl. Special
rivets are installed to retain the factory setting of the choke
coil and provide a non-adjustable design.
An integral, pleated-paper fuel inlet filter is mounted in
the fuel bowl behind the fuel inlet nut to give maximum
filtraton of incoming fuel. A check valve on light duty
T H R O T T L E LEVER A C T U A T O R
(V A C U U M O PER A TED )
VACUUM
BR EAK
E L E C T R IC A L
CONNECTO R
(TO E LE C T R IC
CHOKE)
6C 1-2
INTERNAL VENT
TO P A IR BLEED
PRESSURE
RELIEF VALVE
IDLE C H A N N E L
R E S T R IC T IO N
FLOAT
CHECK VALVE
SEAT
T H R O TTLE
VALVE
IDLE D IS C H A R G E
HOLE
FACTORY ADJUSTED
M A IN WELL A IR BLEED TUBE
METERING ROD HANGER
POWER PISTON
METERING ROD
M A IN DISCHARGE
NOZZLE
DRIVE ROD
POWER PISTON
SPRING
BOOST VENTURI
M A IN VENTURI
M A IN METERING
JET
-P L U G
PARTTHROTTLE
ADJUSTM ENT SCREW *
LOWER IDLE
A IR BLEED
THROTTLE
VALVE
POWER PISTON
A C TU ATING LINKAGE
POWER PISTON VA C U U M
L IG H T T R U C K SERVICE M A N U A L
6C 1-3
F A C T O R Y ADJUSTED
"T" DISCHARGE
, SPRING RETAINER
,PUMP PLUNGER
ft DURATION
SPRING
PO W ER PIS TO N
S P R IN G
PUMP RETURN
SPRING
-AS PLUNGER
'MOVES UP.
FUEL FLOWS
PAST CUP INTO
PUMP WELL
M A IN M E TE R IN G
JET
PLUG
PARTTHROTTLE
AD JU STM EN T SC REW 1
PO W ER PIS TO N
A C T U A T IN G LIN K A G E
TH R O TTLE V A L V E
PO W ER P IS TO N V A C U U M
CHOKE ROD
CHOKE VALVE
CHOKE
HOUSING
CHOKE VACUUM
DIAPHRAGM UNIT
I
PLUNGER
e l e c t r ic
BUCKING
CHOKE
\
SPRING
CHOKE COIL
LINK
FAST IDLE
CAM FOLLOWER
VA CU UM
INLET
RESTRICTIOr
VA CU UM
BREAK LINK
INSIDE
COIL LEVER
MANIFOLD J )
VACUUM
r
HOSE
.jJ
CHOKE SYSTEM
Fig. 6CT8--Choke System
LIG H T T R U C K SERVICE M AN U AL
6C1-4
F L O A T LEVEL A D J U S T M E N T
G A U G E FROM TO P O F
C A S T IN G TO TO P O F
IN D E X P O IN T A T TO E
O F FLOAT
( T ) B E N D H E R E TO
A D JU S T F L O A T
UP O R DOW N
1 )H O L D F L O A T R E T A IN IN G
' ^ P I N F IR M L Y IN P L A C E PUSH D O W N ON EN D O F
F L O A T A R M , A G A IN S T
TO P O F F L O A T N E E D L E
M E T E R IN G R O D A D J U S T M E N T
( 3 )H O L D
POWER
PISTO N D O W N A N D SW ING
M E T E R IN G R O D H O L D E R
OVER F LA T SURFACE
( 5 ) BEN D HERE
T O A D JU S T
(G A S K E T R E M O V E D )
O F BO W L C A S T IN G N E X T
T O C A R B U R E T O R BORE
(7),
1 ) R E M O V E M E T E R IN G RO D
B Y H O L D IN G T H R O T T L E
V A L V E W ID E O PEN . PUSH
^ 4 J S P E C IF IE D P LU G
D O W N W A R D ON M E T E R IN G
G A U G E - S L ID E F IT
R O D A G A IN S T SPR IN G
T E N S IO N , T H E N S L ID E
B A C K O U T ID L E
M E T E R IN G ROD O U T OF
STOP S O L E N O ID
S L O T IN H O L D E R A N D
HO LD TH R O TT LE
R E M O V E FR O M M A IN
V A LV E C OM PLETELY
C LO S E D
M E T E R IN G JE T.
F A S T ID LE A D J U S T M E N T
SUPPORT LEVER WITH
PLIERS-BENDTANGIN
OR OUT TO OBTAIN SPECIFIED
FAST IDLE R.P.M. (SEE INSET).
NOTE: M A N U A L C H O K E
M ODELS W ITH SM O O TH
CONTOUR C A M SURFACE
ROTATE FAST IDLE C A M
CLOCKWISE TO ITS
FARTHEST UP PO SITIO N.
SECOND jC
HIGH
L IG H T T R U C K SERVICE M A N U A L
6C1-5
C H O K E C O IL LEVER A D J U S T M E N T - 1M E
120' PLUG
GAUGE M U S T
PASSTHRO UG H
HOLE IN LEVER
A N D ENTER HOLE
IN C ASTIN G
COMPLETELY CLOSED
PLACE FAST
IDLE CAM
FOLLOWER ON
H IG H EST STEP
OF FAST IDLE
CAM
C H O K E R O D (F A S T ID LE C A M ) A D J U S T M E N T (2N D STEP)
HOLD DOW N
ON CHOKE V A L V E ROD IN END OFSLO
LIG H T TR U C K SERVICE M AN U AL
6C1-6
V A C U U M BREAK A D J U S T M E N T - 1M E (B O W L S ID E )
v
NOTE:
HOLD GAUGE
PUSH DOW N ON
CHOKE VALVE
(COMPRESS PLUNGER
BUCKING SPRING A N D
SEAT PLUNGER STEM
ON M ODELS SO
EQUIPPED).
PLACE GAUGE
BETWEEN LOWER EDGE
OF CHOKE VALVE AND
IN SID E AIR HORN WALL
USE OUTSIDE
V A C U U M SOURCE
TO SEAT
D IA P H R A G M .
PLACE FAST
IDLE CAM
FOLLOWER ON
HIGHEST STEP
OF C A M .
HOLD THROTTLE
VALVE W IDE OPEN
BEND TA N G TO
A D JU S T (SEE INSET).
ID LE SP EE D A D J U S T M E N T
TO ADJUST BASE
IDLE TURN 1/8
HEX SCREW
(SOLENOID NOT
ENERGIZED)
NOTE: ENGINE M U ST BE
W A R M -C H O K E WIDE OPEN FAST IDLE CAM FOLLOWER OFF
STEPS OF C A M (SEE EM ISSIO N
LABEL)
LIG H T T R U C K SERVIC E M A N U A L
6C 1-7
ON-VEHICLE SERVICE
1ME CARBURETOR ADJUSTMENTS
Refer to figure 6C1-9 through 6C1-11 for adjustment
specifications and procedures.
Choke Checking Procedure
6C1-8
remove solenoid
from float
bowl
Installation
1.
2.
3.
4.
5.
6.
.V gff
SOLENOID REPLACEMENT
An inoperative solenoid should be replaced.
Removal
6 C 1-9
3 / 16
6C1-10
Fig. 6 C M 2 d -T R C
UNIT REPAIR
DISASSEMBLY
Place carburetor on a holding fixture to prevent
damage to throttle valve.
Air Horn
Removal
6C 1-11
Disassembly
1. If required, the choke valve and choke shaft can be
removed from air horn by removing the screw that
retains the vacuum break lever to the choke shaft. Care
should be exercised when removing this screw because
it is retained in place by thread torque retaining
compound. Remove the two attaching screws from the
choke valve, then, remove the choke valve and choke
shaft from air horn.
The choke valve screws are staked in place so it will be
necessary to file off staking and re-stake during assem
bly. Do not bend choke shaft when restaking.
2. N o further disassembly of the air horn is necessary.
6C 1-12
SPRING
CHECK VALVE
FUEL FILTER
GASKET
INLET NUT
6C 1-13
Float Bowl
1. Install fuel filter spring, filter, and check valve assem
bly, (if used), inlet nut and gasket rubber seal on check
valve faces fuel inlet nut.
The fuel inlet check valve must be installed (where
required) in the filter to meet Motor Vehicle Safety
Standards (M .V .S.S.) for roll-over. New service re
placement filter include the check valve, where
required.
CARBURETOR ASSEMBLY
PUMP RETURN
SPRING
-AS PLUNGER
MOVES UP.
FUEL FLOWS
PAST CUP INTO
PUMP WELL
6C1-14
B E N D IN G T O O L
H O L D POW ER
P IS TO N D O W N
/P L U G GAUGE
F L O A T BOW L
SURFACE
(G A S K E T R E M O V E D )
B A C K O U T ID L E SPEED SCREW
H OLD TH R O TTLE V A LV E
C O M P L E T E L Y C LO S E D
Air Horn
1. Open throttle valve, slide metering rod out of holder
and remove from main metering jet.
2. To check adjustment, back out 1/8" hex screw on idle
stop solenoid and rotate fast idle cam so that cam
follower is not contacting steps on cam.
3. With throttle valve completely closed, apply pressure to
top of power piston and hold piston down against stop.
6C 1-15
L IG H T T R U C K SERVICE M A N U A L
6C 1-16
CARBURETOR
NUMBER
FLOAT
LEVEL
METERING
ROD
CHOKE ROD
CAM ADJ
VACUUM
BREAK
UNLOADER
Inches
Inches
Inches
Inches
Inches
.090
.275
.400
.520
N.A.
.090
.275
.400
.520
.090
.275
.400
.520
N.A.
N.A.
17081009
ME
17081309
ME
11/32
11/32
17081329
ME
11/32
CHOKE
SETTING
t-
LIG H T T R U C K SERVIC E M A N U A L
6C2-1
SECTION 6C2
6C2-1
6C2-2
6C2-4
6C2-4
6C2-4
6C2-4
6C2-14
6C2-14
GENERAL DESCRIPTION
The Model 2SE is a two barrel, two stage carburetor of
down-draft design for use on the 4.1 litre engine. To reduce
carburetor weight, aluminum die castings are used for the
air horn, float bowl, throttle body and choke housing. A heat
insulator gasket is used between the throttle body and float
bowl to reduce heat transfer to the float bowl.
The primary stage has a triple venturi, with a small
35mm bore that results in good fuel control during idle and
part throttle operation.
The secondary stage has a large 46mm bore that
provides sufficient air capacity for engine power require
ments. An air valve is used in the secondary stage with a
single tapered metering rod.
On the 2SE models, an integral 2" pleated paper fuel
filter with check valve is mounted in the front of the float
bowl behind the fuel inlet nut to give maximum filtration of
incoming fuel. The check valve is used to shut off fuel flow to
the carburetor and prevent fuel leaks if a vehicle roll-over
should occur.
The float chamber is located adjacent to the primary
and secondary bores. This feature assures adequate fuel
supply to both carburetor bores during all vehicle normal
L IG H T T R U C K SERVICE M A N U A L
6C2-2
VENTSTACK
CHOKE VALVE
PUMP LEVER
CHOKE HOUSING
/P R IM A R Y SIDE
/V A C U U M BREAK
SECONDARY SIDE
VACUUM BREAK
SLOW IDLE
SPEED SCREW
Sr
FAST IDLE
ADJUSTING SCREW
LIG H T T R U C K SERVIC E M A N U A L
Carburetor Operation
The m odel 2SE carburetor has six basic system s.
T hey are float, idle, main metering, power, pump and
choke (Fig. 6C2-3).
FLOAT HINGE
HOT IDLE
COMPENSATOR
IDLE CROSS-OVER
PASSAGE
EXHAUST GAS
RECIRCULATION
PLASTIC
INSERT
6C2-3
UPPER
IDLE AIR BLEED
PULL CLIP
IDLE CHANNEL
RESTRICTION
VENT TUBE
TO CANISTER
FLOAT VALVE
TIMED VACUUM
PORT FOR E.G.R.*
LOWER IDLE
AIR BLEED
THROTTLE VALVE
(DOTTED LINE - OFF
IDLE POSITION)
OFF IDLE
PORT
_
IDLE DISCHARGE
HOLE
PLUG
IDLE MIXTURE
SCREW AND SPRING
IDLE SYSTEM
FLOAT SYSTEM
(TYPICAL)
SIDE MAIN WELL
AIR BLEED
METERING ROD
HANGER
SECONDARY
METERING
ROD
, SECONDARY
METERING
JET
MAIN (PRIMARY)
METERING ROD
MAIN DISCHARGE
NOZZLE
SECONDARY
AIR VALVE
(OPEN)
MAIN METERING
ROD
FUEL PICKUP
TUBE
MAIN METERING
JET
POWER PISTON
POWER PISTON
SPRING
PLUG
PART THROTTLE
CALIBRATION SCREW
(FACTORY ADJUSTED)
SECONDARY
THROTTLE
VALVE
VACUUM CHANNEL
(TO POWER PISTON)
(TYPICAL)
PUMP SUCTION
BREAKER
SECONDARY SIDE
VACUUM
BREAK LINK
PUMP ROD
(ACTUATED BY
THROTTLE LEVER)
VACUUM CHANNEL
(TO POWER PISTON)
POWER SYSTEM
(INCLUDING SECONDARY STAGE)
PUMP
DISCHARGE
SPRING
AND BALL
(SHOWN
UNSEATED)
FUEL WELL
(SECONDARY
P U M P LE V E R
INTERMEDIATE
CHOKE
IN T E R M E D IA T E
CHOKE
VALVE
CHOKE LEVER
VACUUM BREAK
AND CHOKE LEVER
---- VACUUM BREAK
LINK
AIR VALVE
ROD
AP DURATION
SPRING
PUMP PLUNGER
CUP SEAL
(SEATED)
PUMP CUP
OPERATION
AS PLUNGER MOVES
UP, CUP SEAL
UNSEATS FROM
PLUNGER HEAD
AND FUEL FLOWS
PAST CUP INTO
.
PUMP WELL
PRIMARY SIDE
VACUUM BREAK
UNIT
(AIR VALVE DASHPOT)
EXPANDER
SPRING
PUMP RETURN
SPRING
DISCHARGE
PASSAGE
FAST IDLE
CAM
SECONDARY SIDE
VACUUM BREAK
UNIT
SECONDARY
LOCKOUT LEVER
CHOKE SYSTEM
PUMP SYSTEM
LIG H T T R U C K SERVICE M A N U A L
6C2-4
ON-VEHICLE SERVICE
MODEL 2SE ADJUSTMENTS
Before checking or resetting the carburetor as the cause
of poor engine performance or rough idle, check ignition
system including distributor, timing, spark plugs and wires.
Check air cleaner, evaporative emission system, EFE
system, PCV system, EGR valve and engine compression.
Also inspect intake manifold vacuum hose gaskets and
connections for leaks and check torques of carburetor
mounting bolts/nuts.
Refer to Figures 6C2-A through 6C2-I for carburetor
adjustment procedures and specifications.
LIG H T T R U C K SERVIC E M A N U A L
6C2-5
FLOAT ADJUSTMENT
HOLD RETAINER
PUMP ADJUSTMENT
NON-ADJUSTABLE
LIG H T TR U C K SERVIC E M AN U AL
6C2-6
INSERT .0 8 5
PLUG G AG E INTO
HOLE PROVIDED
LIG H T T R U C K SERVICE M A N U A L
PUSH ON IN T E R
M EDIATE CHOKE
LEVER U N TIL
CHOKE VALVE
IS CLOSED
6C2-7
FIGURE 2
6. ROTATE SCALE SO THAT DEGREE SPECIFIED FOR ADJUSTMENT IS
OPPOSITE POINTER.
7. PLACE FAST IDLE SCREW ON SECOND STEP OF CAM AGAINST RISE OF
HIGH STEP.
8. HOLD CHOKE VALVE TOWARD CLOSED POSITION BY LIGHTLY PUSHING
ON INTERMEDIATE CHOKE LEVER.
9. TO ADJUST, BEND FAST IDLE CAM ROD UNTIL BUBBLE IS CENTERF.D.
10. REMOVE GAUGE.
^
DEGREE
SCA LF
LEVE LIN G
BUBBLE
(C E N T E R E D )
S P E C IF IE D A N G L E
SEE SP EC S .)
B EN D RO D T O A D J U S T
P O IN T E R
MAGNET
FIG U R E 1
HOLD C H O K E VALVE
TOW ARD C L O S E D
PO S ITIO N BY LIG H TLY
PU S H IN G ON IN T E R
M E D IA T E C H O K E LEVER
FIG U R E 2
PLACE FAST IDLE
SCREW O N S E C O N D
STEP OF C A M A G A IN S T
RISE OF H IG H STEP
FAST ID LE CAM
FIG U R E 2
R E M 0V E GAUGE
6C2-8
2 S E CARBURETO R A D J U S T M E N T S
FIGURE 1
1. USE CHOKE VALVE M EASURING GAUGE J-26701 . TO O L MAY
BE USED W ITH CARBURETOR ON OR OFF ENGINE. IF OFF ENGINE, PLACE
CARBURETOR ON HO LD IN G FIXTURE SO TH A T IT WILL REMAIN IN SAME
PO SITIO N WHEN G AUGE IS IN PLACE.
2. ROTATE DEGREE SCALE U N TIL ZERO (0) IS OPPO SITE POINTER.
3. W ITH CHOKE VALVE COM PLETELY CLOSED (FAST IDLE SCREW M UST
BE ON H IG H STEP OF FAST IDLE CAM ), PLACE M AG NET SQUARELY
ON TOP OF CHOKE VALVE.
4. ROTATE BUBBLE U NTIL IT IS CENTERED.
FIGURE 2
5. ROTATE SCALE SO TH A T DEGREE SPECIFIED FOR AD JU S TM EN T IS
O PPOSITE PO INTER.
6. SEAT CHOKE VAC UUM DIAPHRAGM USING VAC UUM SOURCE. OVER 5"
HG. VACUUM M UST BE APPLIED TO VACUUM BREAK. ALSO, AIR VALVE
ROD M UST N O T BE RESTRICTING VACUUM DIAPHRAG M FROM SEATING.
IT MAY BE NECESSARY TO BEND AIR VALVE ROD TO O BTAIN A SLIG HT
CLEARANCE BETWEEN ROD AND END OF SLOT IN AIR VALVE LEVER.
PROCEED TO AIR VALVE ROD AD JU S TM EN T AFTER PRIMARY VACUUM
BREAK ADJUSTM ENT.
7. DURING READING OF ANGLE GAUGE, HOLD CHOKE VALVE TOW ARD
CLOSED P O S ITIO N BY LIG H TLY P USHING ON INTER M ED IA TE CHOKE LEVER.
8. TO ADJUST, USING 1/8" HEX W RENCH, TURN SCREW IN REAR COVER
UNTIL BUBBLE IS CENTERED. APPLY SEALER (SUCH AS SILICO NE
SEALANT RTV RUBBER OR EQ UIVALENT) OVER SCREW HEAD TO SEAL
SETTING .
9. REMOVE GAUGE.
FI G U R E 2
6C2-9
ROTATE Al VALVE
IN THE DIRECTION
OF OPEN AIR VALVE
BY APPLYING ALIGHT
PRESSURE TO THE
AIR VALVE SHAFT.
L E V E L IN G
BUBBLE
(CENTERED)
ODEGREE
SCALE
SPECIFIED ANGLE
(SEE SPECS.)
AIR VALVE
CLOSED
POINTER
MAGNET
FIGURE 1
TO ADJUST,
BEND AIR
VALVE ROD
UNTIL BUBBLE
IS CENTERED.
SEAT VACUUM
DIAPHRAGM USING
VACUUM SOURCE
6C2-10
2 S E CARBURETOR A D J U S T M E N T S
FIG UR E 2
3. USE CHOKE VALVE M EASURING GAUGE J-26701 . TO O L MAY
BE USED W ITH CARBURETOR ON OR OFF ENG INE. IF OFF ENGINE,
PLACE CARBURETOR ON HO LDING FIXTURE SO TH A T IT WILL REMAIN
IN SAME PO S ITIO N WHEN GAUGE IS IN PLACE.
4. RO TATE DEGREE SCALE U NTIL ZERO (0) IS O PPOSITE POINTER.
5. W ITH CHOKE VALVE COM PLETELY CLOSED (FAST IDLE SCREW M UST BE ON
HIG H STEP OF FAST IDLE CAM), PLACE M AGNET SQUARELY ON TOP OF
CHOKE VALVE.
6. ROTATE BUBBLE U N TIL IT IS CENTERED.
FIGURE 3
7. ROTATE SCALE SO TH A T DEGREE SPECIFIED FOR AD JU S TM EN T IS O PPOSITE
POINTER.
8. SEAT CHO KE VAC UUM DIAPHRAGM USING VACUUM SOURCE. (AIR
BLEED SEALED AND OVER 5" HG. VAC UUM )
9. DU R IN G READING OF ANGLE GAUGE, HOLD CHOKE VALVE TOW ARD
CLOSED PO SITIO N BY LIG HTLY PUSHING ON INTERM EDIATE CHOKE
LEVER. MAKE SURE VACUUM DIAPHRAG M IS SEATED (OVER 5" HG. APPLIED
TO VACUUM BREAK).
10. TO ADJUST, USING 1/8" HEX W RENCH, TURN SCREW IN REAR COVER U N T IL
BUBBLE IS CENTERED. REMOVE CUP INSTALLED IN STEP 2 (FIG URE 1)
AFTER ADJUSTM ENT. APPLY SEALER (SUCH AS SILICO NE SEALANT RTV
RUBBER OR EQ UIVALENT) OVER SCREW HEAD TO SEAL SETTING .
11. REMOVE GAUGE.
S E A T D IA P H R A G M U S IN G V A C U U M S O U R C E .
(A IR B L E E D S E A L E D A N D O V E R
5 H g V A C U U M ).
SPECIFIED ANGLE
(SEE SPECS.)
ADJUSTMENT
SCREW ACCESS
(CAP REMOVED)
bubble
(C ENTERED )
Ii PUMP
;9 )
' CHOKE
/
VALVE
CLOSED
^ . ( F A S T IDLE
SCREW
MUST BE ON
HIGH STEP OF
FAST IDLE
CAM)
PLUNGER CUP
^ FIGURE 1
FIGURE 3
rj
TO ADJUST, USING 1 /8
HEX WRENCH, TURN
SCREW IN REAR COVER
UNTIL BUBBLE IS CENTERED.
REMOVECUP INSTALLED IN STEP 2
(FIGURE 1) AFTER ADJUSTMENT.
APPLY SEALER (SUCH AS SILICONE
'SEALANT RTV RUBBER OR EQUIVALENT) OVER
SCREW HEAD TO SEAL SETTING.
LEVELING
6C 2-11
FIGURE 2
5. ROTATE SCALE SO THAT DEGREE SPECIFIED FOR ADJUSTMENT IS
OPPOSITE POINTER.
6. HOLD PRIMARY THROTTLE VALVE WIDE OPEN.
7. DURING READING OF ANGLE GAUGE:
LIGHTLY PUSH CLOCKWISE ON INTERMEDIATE CHOKE LEVER (IN
DIRECTION OF CLOSED CHOKE VALVE) AND HOLD IN POSITION WITH
RUBBER BAND.
8. TO ADJUST, BEND TANG ON THROTTLE LEVER UNTIL BUBBLE IS CENTERED.
9. REMOVE GAUGE.
10. AT THIS POINT REINSTALL CHOKE COVER AND COIL ASSEMBLY (IF
PREVIOUSLY REMOVED AND NOT REINSTALLED) FOLLOWING
INSTRUCTIONS IN CHOKE STAT COVER RETAINER KIT (INCLUDES
REPLACEMENT ATTACHING RIVETS).
L E V E L IN G
V -T
B U B B LE
/
J (C E N T E R E D )
S P E C IF IE D A N G L E
(S E E S P E C S .)
"
CHOKE
V A LV E
CLOSED
BEND TANG TO
A D J U S T U N T IL
B U B B L E IS
CENTERED.
D U R I N G R E A D IN G O F A N G L E G A U G E ,
L IG H T L Y P U S H C L O C K W IS E ON
IN T E R M E D IA T E C H O K E LEVER (IN
D IR E C T IO N O F C L O S E D C H O K E
V A L V E ) A N D H O L D IN P O S IT IO N
W IT H R U B B ER B A N D .
H O L D P R IM A R Y T H R O T T L E
V A LV E W ID E O P E N
6C2-12
2S E CARBURETO R A D J U S T M E N T S
RECONNECT
SOLENOID
ELECTRICAL
LEAD AFTER
ADJUSTMENT
TURN SOLENOID
SCREW TO ADJUST
CURB IDLE SPEED
TO SPECIFIED RPM
(SOLENOID ENERGIZED)
Fig. 6 C 2 -H C a rb u re to r Adjustments
OPEN THROTTLE
SLIGHTLY TO
ALLOW SOLENOID
PLUNGER TO
FULLY EXTEND
REMOVE AIR
HORN SCREW
/T \
( 5) IF THE MECHANICAL
SETTING (STEP 4) VARIES
MORE THAN 1.5mm FROM
SPECIFICATIONS, REMOVE
AIR HORN AND ADJUST
FLOAT LEVEL TO SPECIFI
CATIONS FOLLOWING
NORMAL ADJUSTMENT
PROCEDURES.
I F MECHANICAL SETTING IS FOUND TO BE WITHIN
SPECIFIED TOLERANCE - REPLACE AIR HORN SCREW,
VENT STACK AND VENT STACK SCREWS.
SELECT
GAUGE
TO MATCH
CARBURETOR
SERIES BEING
CHECKED
TOOL J-9789-135
BLUE - 1979-81 2SE
RED - 1979 1/2-80 E2SE
WHITE - 1981 E2SE
6C2-14
3.
4.
5.
6.
6C 2-15
Removal
Flooding, stum ble on acceleration and other perform
ance com plaints are, in many instances, caused by presence
of dirt, w ater, or other foreign m atter in carburetor. To aid
in diagnosing cause, carburetor should be carefully removed
from engine w ithout draining fuel from bowl. Contents of
Installation
It is good shop practice to fill carburetor bowl before
installing carburetor. This reduces strain on starting motor
and battery and reduces the possibility of backfiring while
attempting to start engine. A small supply of fuel will enable
carburetor to be filled and the operation of float and intake
needle and seat to be checked. Operate throttle lever several
times and check discharge from pump jets before installing
carburetor.
1. Be certain throttle body and intake manifold sealing
surface are clean.
2. Install carburetor insulator.
3. Install carburetor over manifold studs.
4. Install vacuum and fuel lines at carburetor.
5. Install attaching nuts and tighten alternately to 21 N-m
(16 ft. lbs.).
6. Tighten fuel line.
7. Connect accelerator linkage and transmission cable.
8. Connect choke and solenoid electrical connectors.
9. Install air cleaner.
10. Check and adjust idle speed.
UNIT REPAIR
The procedures below apply to the com plete overhaul
with the carburetor removed from the engine. However, in
m any cases service adjustm ents of individual systems may
be com pleted without removing the carburetor from the
6C2-16
CARBURETOR DISASSEMBLY
Before perform ing any service on the carburetor, it is
essential th at the carburetor be placed on a holding fixture
such as tool J-9 7 8 9 -1 18 or equivalent. W ithout the use of
the holding fixture, it is possible to dam age throttle valves.
Air Horn
1. Remove clip from hole in pump lever. Do not remove
pump lever retaining screw or pum p lever from air horn
assembly.
2. Rem ove hose from prim ary side vacuum break
assembly.
3. Rem ove (2) screws securing p rim ary side vacuum
break bracket to air horn (Fig. 6C2-3b); then, rotate
vacuum break and b rack et assem bly to disengage
vacuum break link from slot in vacuum break and
choke lever and air valve rod from slot in air valve lever.
N O TIC E: Do not place vacuum break assem bly in
carburetor cleaner. Immersion in cleaner will dam age
vacuum break diaphragm .
4. If necessary to replace the vacuum break rod or air
valve rod, remove and discard retaining clips from end
of air valve rods. New retaining clip is required for
INTERMEDIATE CHOKE
CUP
BREAK
CHOKE LEVER
LO CATING LUG
VALVE
LEVER
BRACKET AT TAC H IN G
SCREWS
SECONDARY SIDE
VACUUM
PR IM AR Y SIDE
V A C U U M BREAK
LINK (PRIM ARY SIDE
V A C U U M BREAK!
BRACKET A TTAC H IN G
SCREWS
IDLE
SPEED SOLENOID
6C 2-17
H O T IDLE
A IR H O R N S C R E W S -
a id
lio d k i
c r o c u /c
Choke Disassembly
6C2-18
POWER
RETAINER
MAIN METERING
ROD
MAIN METERING
JET
Rivets
and
Retainers
Throttle Body
Disassem bly
HOLDER
GROD
R E T A IN E R
PO W ER P IS T O N
INTERMEDIATE CHOKE
SHAFT AND LEVER
ASSEMBLY
6C 2-19
THROTTLE BODY
**
ATTACHING SCREWS v
6C2-20
FLAT PUNCH
CENTER PUNCH
STEP#2
STEP #1
LOCATOR
p 0 |N T
\
HACKSAW
RECESSED IDLE MIXTURE
NEEDLE AND PLUG LOCATION
Fig. 6C2-15Idle Mixture Needle
6C2-21
C A U TIO N : DO N O T
HO O K PULL CLIP
IN THESE HOLES
FLOAT AND
LEVER ASSEMBLY
rod with slot in lever. End of rod should point outw ard
tow ard throttle lever.
2. If removed, install idle m ixture needle and spring using
tool J-29030-B Lightly seat needle and then back out 3
turns as a prelim inary idle m ixture adjustm ent. Final
Float Bowl
Assem bly
T H R O T T L E B OD Y TO
B O W L G A SK ET
6C2-22
5.
6.
7.
8.
9.
10.
11.
12.
13.
16. Install power piston and m etering rod assembly into the
float bowl and main m etering jet. Use care installing
the m etering rod into the jet to prevent dam aging the
m etering rod tip. Press down firmly on plastic power
piston retainer to make sure the retainer is seated in
recess in bowl and the top is flush with the top of the
bowl casting. If necessary, tap retainer lightly in place
using a drift and small ham m er.
17. Install plastic filler block over float valve, pressing
dow nw ard until properly seated (flush w ith bowl
casting surface).
18. Install air horn gasket on float bowl by carefully sliding
slit portion of gasket over the two dowel locating pins on
the float bowl.
19. Install pump return spring in pum p well.
20. Install pump plunger assembly in pump well.
Air Horn
Assembly
1. Install new pum p plunger stem seal and retainer in air
horn casting. Lightly stake seal retainer in three places,
choosing locations different from the original stakings.
2. Install fast idle cam rod in lower hole of vacuum break
and choke lever, aligning squirt on rod with small slot in
lever (squirt end of rod points inward toward air horn).
6C2-23
"TRAPPED S T A T
COIL
6C2-24
3 /1 6
ADAPTER (P ro c u re s te e l tu b in g lo c a lly )
CARBURETOR
NUMBER
FLOAT
LEVEL
PUMP
SETTING
m m /ln c h
m m /ln c h
FAST IDLE
CAM
(CHOKE ROD)
AIR VALVE
ROD
VAC. BREAK
PRI.
17081621
4.5
3/16
15.5
5 /8
15
26
38
17081622
.4 .5
3/16
15.5
5/8
15
26
38
38
17081623
4.5
3/16
15.5
5/8
15
26
38
38
170811624
4.5
3/16
15.5
5/8
15
26
38
38
17081625
4.5
3/16
15.5
5/8
15
26
38
38
17081626
4.5
3/16
15.5
5/8
15
26
38
17081627
4.5
3/16
15.5
5 /8
15
26
38
38
38
17081629
3/16
3/16
3/16
15.5
5/8
15
24
34
41
15.5
5/8
15
26
38
38
17081633
4.5
4.5
4.5
15.5
5/8
15
26
38
38
17081720
4.5
3/16
15.5
5/8
15
30
37
41
17081721
4.5
3/16
15.5
5 /8
15
30
37
41
17081725
4.5
3/16
15.5
5 /8
15
30
37
41
17081726
4.5
3/16
15.5
5/8
15
30
37
41
17081727
4.5
3/16
15.5
5/8
15
30
37
41
17081630
38
CARBURETOR
cX
o
6 C 2 -2 5
3<
o
2
MODEL 2SE
CD
6C3-1
SECTION 6C3
CARBURETOR MODEL M2ME
CONTENTS
G eneral D escription......................................................... ..6C3-1
C arb u reto r O peratio n ......................................................6C3-2
On-Vehicle S ervice.......................................................... ..6C3-2
A d ju stm en ts.......................................................................6C3-2
Checking C hoke................................................................6C3-11
Checking Idle S olen o id................................................ ..6C3-11
Idle M ixture A d ju stm e n t...............................................6C3-11
GENERAL DESCRIPTION
The M 2M E carburetors (Fig. 6C3-2) for light duty
emission vehicles are basically carryover for the 1981 model
except a new electric choke carburetor is used replacing the
hot air choke model (M 2M C ) previously used. All models
include ta m p e r-re sista n t featu res such as rivets, plugs,
covers, etc. to discourage readjustm ent of facotory settings
which could affect eith er or both em ission control and
driveability. For example, as a carryover feature, blind
^
j-
&
VAPOR VENTTUBE
(TO CANISTER)
IDLE SPEED
SOLENOID
FRONT VACUUM
BREAK
PLUG (IDLE
MIXTURE NEEDLE)
6C3-2
Carburetor Operation
Incorporated in the Model M 2M C carburetors are six
basic systems. They are float, idle, main metering, power,
pump, and choke (Figs. 6C3-3 and 4).
ON-VEHICLE SERVICE
CARBURETOR ADJUSTMENTS
Before checking or resetting the carburetor as the cause
of poor engine perform ance or rough idle, check ignition
system including distributor, timing, spark plugs and wires.
C heck air cleaner, evaporative em ission system , E F E
system, PCV system, E G R valve and engine compression.
Also inspect in tak e m anifold vacuum hose gaskets and
connections for leaks and check torques of c arb u reto r
m ounting bolts/nuts.
Refer to Figures 6C3-A through 6C 3-F for carburetor
adjustm ent procedures.
.FLOAT HINGE
PULL CLIP
6C3-3
FLOAT NEI
FLOAT NEEDLE
SEAT
VE NTTUBE
TO CANISTER
INLET FILTER
FUEL I
CHECK VALVE
SEAT
FLOAT SYSTEM
EXHAUST GAS RECIRCULATION
RICH MIXTURE SCREW
(FACTORY ADJUSTED)
COVER
IDLE AIR BLEED VALVE
(FACTORY ADJUSTED)
VALVE
STEM
IDLE AIR
BLEED
IDLE MIXTURE
IDLE
NEEDLE
DISCHARGE
(FACTORY ADJUSTED)
HOLE
PLUG
IDLE SYSTEM
IDLE AIR BLEED VALVE
(FA C TO R Y A D JU S TE D )
RIC H M IX TU R E SCREW
(F A C TO R Y A D JU S TE D )
M AIN W ELL
AIR BLEEDS
LEAN M IX TU R E SCREW
(FA C T O R Y A D JU S TE D )
S O L E N O ID
PLU N G ER
(SHO'.VN UP)
PU LL-OVER
E N R IC H M E N T
/
r M A IN D IS C H A R G E
N O ZZLE
M A IN VE N TU R I
M A IN M E TE R IN G RO DS ( 2 )'
M A IN M ETE R IN G JETS (2)
T H R O TTLE VALVE
6C3-4
R IC H M IX TU R E SCREW
(FA C TO R Y A D JU S TE D )
RIVETED
COVER
LEAN M IX TU R E SCREW
(FA C TO R Y A D JU S TE D )
SO LE N O ID
PLUNG ER
(SH O W N U P ).
M A IN D IS C H A R G E
N O ZZL E
W ID E-O P EN TH R O TTLE
EN R IC H M E N T S W IT C H
SEAL
PUMP
LE V E R
P U M P S U C T IO N
BREAKER
D IS C H A R G E
PASSAGE
D IS C H A R G E
B A L L R E T A IN E R
D IS C H A R G E
C H E C K BALL
CUP SEAL
! PUM P PLUNG ER
PUMP SYSTEM
CHOKE
CHOKE
INSET
VA CU UM BREAK
W IT H LE AF-TYP E
BUCKING SPRING
(S E E IN S E T)
UNLOADER
TANG
FAST
IDLE
ADJUSTING
SCREW
CHOKE SYSTEM
(ELECTRIC CHOKE TYPE)
Fig. 6C3-4--Basic Systems
6C3-5
FLOAT ADJUSTMENT
(M EC H A N IC AL SETTIN G )
G A U G E F R O M T O P O F C A S T I N G TO T O P
OF F L O A T G A U G I N G P O I N T 3 1 6 " B A C K
F R O M E N D OF F L O A T A T T O E (SEE IN S E T )
G A U G IN G PO INT
(3 1 6
BACK
F R O M TO E )
REM OVE FLOAT A N D BEND FLOAT
A R M U P OR D O W N TO A D J U S T
PUSH FLOAT D O W N
LIG H TL Y A G A I N S T NEEDLE
V IS U A L L Y CHECK FLOAT A L IG N M E N T
AFTER A D J U S T IN G
PUMP ADJUSTMENT
GAUGE FROM
TO P OF C H O K E
V A L V E W A L L , N E X T TO V E N T
S T A C K , TO TO P
OF P U M P S T E M
A S S P E C IF IE D
m u
5JB E N D
PUMP-
LEVER TO
ADJUST
ROD
IN S P E C IF I E D
HOLE
OF P U M P L E V E R
S U P P O R T LEVER W IT H
S C R E W D R IV E R
B E N D IN G
W H IL E
LEVER
THROTTLE VALVES
C O M PLETELY CLOSED
N O T E : M A K E S U R E F A S T ID L E
CAM
FO LLOW ER LEVER
IS OFF
S T E P S O N F A S T ID L E C A M
6C3-6
B E N D C H O K E R O D A T T H IS
P O IN T T O A D J U S T (SEE IN S E T )
i l ------1
C H O KE VALVE
C LO SED
n
INSET
C H O KE C O V ER . USE S TA T
C O V E R R E T A IN E R K IT .
3 ) P U S H U P O N T H E R M O S T A T IC
C O IL T A N G (C O U N T E R C L O C K W IS E )
U N T IL C H O K E V A L V E IS C L O S E D .
LO W E R E D G E O F LE V E R S H O U L D
J U S T C O N T A C T S ID E O F P L U G
GAUGE.
UJ
\
4 ; IN S E R T 1 2 0
PLUG G A U G E
IF N E C E S S A R Y , D R IL L OUT A N D R EM O V E
R IV E T S . R E M O V E T H E T H E R M O S T A T IC
C O V E R A N D C O IL A S S E M B L Y F R O M C H O K E
H O U S IN G
P L A C E F A S T ID L E C A M
F O L L O W E R O N H IG H S TE P
OF F A S T ID L E C A M .
H O LD CAM
FO LLO W ER ON
H IG H EST S T E P ----OF FAST ID L E CA M
TU RN SCREW IN TO
C O N T A C T L E V E R THEN
T U RN SCREW IN 4 V 2 T U R N S (NOTE)
T U R N FAST ID L E SCREW
OUT U N T IL P R IM A R Y
T H RO TTLE V A L V E S A R E
CLO SED.
6C3-7
2.
3.
4.
5.
6.
7.
8.
9.
10.
SPECIFIED
ANGLE (SEE SPECS.)
CLOSE CHOKE BY
PUSHING UPWARD
ON CHOKE COIL
LEVER OR
VACUUM BREAK
LEVER TANG (HOLD
IN POSITION WITH
RUBBER BAND).
REMOVE GAUGE.
6C3-8
SPECIFIED ANGLE
(SEE SPECS.)
DEGREE>,
SCALE
P O IN T E R
NOTE 2:
LEAF BUCKING
SPRING MUST BE
SEATED AGAINST
LEVER
(WHERE USED)
RUBBER
BAND
LEVELING
BUBBLE
(CENTERED)
CHOKE
VALVE
CLOSED
Y\
M A G N ET O j/-'\ }
TURN SCREW
TO ADJUST
UNTIL BUBBLE
FIGURE 1
IS CENTERED
S
SEAT DIAPHRAGM
?
(
W
LIGHTLY CLOSE CHOKE
FIGURE
BY PUSHING UPWARD
ON CHOKE COIL LEVER OR VACUUM
BREAK LEVER TANG (HOLD IN POSITION
WITH RUBBER BAND).
NOTE 1: MAKE CHOKE COIL LEVER AND FAST IDLE ADJUSTMENT (BENCH OR ON-THE-CAR SETTING).
DO NOJ REMOVE RIVETS AND CHOKE COVER TO PERFORM THIS ADJUSTMENT. USE RUBBER
BAND ON VACUUM BREAK LEVER TANG TO HOLD CHOKE VALVE CLOSED (STEP 8).
Fig. 6C3-D--Model M2ME Adjustments
6C3-9
2.
3.
4.
5.
6.
7.
8.
9.
10.
BREAK
MAKE CHOKE COIL LEVER AND FAST IDLE ADJUSTMENT (BENCH OR ON-THE-CAR
SETTING).
NOTE: DO NO T REMOVE RIVETS AND CHOKE COVER TO PERFORM THIS ADJUSTMENT.
USE RUBBER BAND ON VACUUM BREAK LEVER TANG TO HOLD CHOKE VALVE
CLOSED (STEP 9 ).
( 6 ) SPECIFIED
HOLD PRIMARY
V J ANGLE (SEE SPECS.)
THROTTLE VALVES
LEVELING
WIDE OPEN.
BUBBLE
(CENTERED
DEGREE
SCALE
^
POINTER-----
VACUUM BREAK
LEVER TANG
C i' CHOKE
:r& VALVE
CLOSED
M AGN ET*^
FIGURE 1
DISCONNECTED AT A/C
COMPRESSOR , A/C ON,
A /T TRANSMISSION IN
DRIVE, M /T IN NEUTRAL
ELECTRICAL
CONNECTION
MODEL M 2 M E
CARBURETOR
SERVICE M AN U AL
6 C 3 -10
LIGHT TRUCK
6C3-11
6C3-12
2.
3.
4.
5.
6.
Installation
INSULATOR
UNIT REPAIR
DISASSEMBLY
Before doing any service on the carburetor place it on a
holding fixture. W ithout the use of the holding fixture, it is
possible dam age to th ro ttle valves.
Air Horn
UPPER
CHOKE
LEVER
LEVER
RETAINING SCREW
Removal
1. Remove upper choke lever trom the end of choke shaft
by removing retaining screw (Fig. 6C3-6). Then rotate
upper choke lever to remove choke rod from slot in
lever.
2. Remove choke rod from lower lever inside the float
bowl casting. Rem ove rod by holding lower lever
outw ard w ith sm all screw driver and tw isting rod
counterclockwise.
3. W ith Tool J-25322 drive roll pin (pum p lever pivot pin)
inward ju st until pum p lever can be removed from air
horn. Then remove pum p lever from pum p rod (Fig.
6C3-7). N ote location of accelerator pum p rod for
reassembly.
LIGHT TRUCK SFRVICF M'NIIAI
PUMP
LEVER
PUMP
LEVER
PIN REMOVING
TOOL
6C 3-13
Float Bowl
Disassembly (Fig. 6C3-12)
1. Remove air horn gasket by lifting out of dowel locating
pins and lifting tab of gasket from beneath the power
piston hanger, being careful not to d isto rt springs
holding the main m etering rods.
2. Remove pum p plunger from pump well.
ATTACHING
SCREWS
Fig. 6C3-9--Removing A ir Horn
FR O N T V A C U U M
BREAK
Fig. 6C3-10--Removing Front Vacuum Break
LIGHT TRUCK SERVICE MANUAL
6C3-14
SEAL STAKE
PUMP
PLUNGER
SEAL
SCREWDRIVER
MAIN METERING
JETS
Choke Disassembly
Removal of Choke Cover (Fig. 6C3-17)
1. Support float bowl and throttle body as an assembly on
a suitable holding fixture such as Tool J-9789-118.
2. Align a #21 drill (.159") on rivet head and drill only enough
to remove rivet head. Drill the two (2) remaining rivet
heads and then use a drift and small hammer to drive the
remainder of the rivets out of the choke housing.
3. Remove the two conventional retainers, retainer with
tab and choke cover assembly from choke housing. Do
not remove baffle plate from beneath the therm ostatic
coil on the choke cover.
4. Remove choke housing assembly from float bowl by
removing retaining screw and washer inside the choke
housing (Fig. 6C3-18).
5. Remove lower choke lever from inside float bowl cavity
by inverting bowl.
LIGHT TRUCK SERVICE MANUAL
6C 3-15
RETAINING SCREW
AND WASHER
P U M P D IS C H A R G E
C H E C K BALL RE T A IN E R
PLASTIC INSE 1
W ITH CUP SEAL
FAST IDLE
CAM
INTERMEDIATE
CHOKE SHAFT
Throttle Body
Disassembly
6C3-16
2.
f il t e r
FU EL IN LE T N U T
S P R IN G
3.
4.
THROTTLE BODY
ATTACHING SCREWS_________________
Fig. 6C3-21--Throttle Body Screws
LOCATING
DOWELS
THROTTLE
30D Y GASKET
6C 3-17
D .P O O R
PERFORM ANCE
- POOR
GAS
M IL E A G E
1. Inspect power piston, m etering rods for d irt,
sticking, binding, d am aged p arts or excessive
wear.
2. Clean all fuel and vacuum passages in castings.
E. R O U G H ID LE
1. Inspect gasket and gasket m ating surfaces on
castings for dam age to sealing beads, nicks, burrs
and other dam age.
2. Clean all idle fuel passages.
3. If removed, inspect idle m ixture needles for ridges,
burrs, or being bent.
4. Check throttle lever and valves for binds, nicks,
and other dam age.
5. C heck all d iap h rag m s for possible ru p tu res or
leaks.
6. Clean plastic parts only in cleaning solvent - never
in gasoline.
Throttle Body
Assembly
1. If removed, install idle m ixture needles and spring
using Idle M ixture A djusting Tool J-29030. Lightly
seat needle and then back out 2 turns as a prelim inary
Float Bowl
Assem bly
6C3-18
meet U.S.
(M .V.S.S.).
M otor
V ehicle
S afety
S ta n d ard s
1. Install nev cup seal into insert on side of float bowl for
interm ediate choke sh aft. Lip on cup seal faces
outward.
2. Install fait idle cam onto the interm ediate choke shaft
(steps onfast idle cam face downward).
3. Install fast idle cam and in term ed iate choke shaft
assembl/ in choke housing, then install therm ostatic
coil lever onto flats on interm ediate choke shaft. Inside
therm oitatic choke coil lever is properly aligned when
both irside and outside levers face tow ard fuel inlet.
Installinside lever retaining screw into end of interm e
diate choke shaft. Tighten securely.
4. Instal lower choke rod inner lever into cavity in float
bowl. Install choke housing to bowl sliding interm edi
ate cloke shaft into lower choke inner lever (Fig. 6C324).
Tool J-23417 can be used to hold the lower choke lever
in correct position while installing the choke housing.
The interm ediate choke shaft lever and fast idle cam
are in correct position when the tang on lever is beneath
the fast idle cam. Do not install choke cover and coil
assembly until inside coil lever is ad ju sted . See
A djustnents.
H O L D IN G
TOOL
LO W ER CHOKE
R O D LE VE R
FUEL
6C 3-19
Air Horn
Assembly
1. If used, install new pum p plunger stem seal in air horn
casting (Fig. 6C3-11). Lightly stake seal retainer in
three places, choosing locations different from original
staking.
PIN REMOVING
TOOL
PUMP LEVER
6C3-20
6C3-21
NJ
on
17081103
17081142
13/32
5/16
INNER
38
13/32
INNER
38
17081143
17081144
13/32
13/32
5/16
5/16
25
25
INNER
5/16
INNER
17081145
13/32
5/16
INNER
25
38
25
00
00
0
38
00
00
0
INNER
00
00
0
5/16
38
38
00
00
0
13/32
17081101
LO
CM
VACUUM UNLOADER
BREAK
REAR
PUMP ROD
LOCATION
00
ro
VACUUM
BREAK
FRONT
PUMP
ROD
0
00
CO
FAST IDLE
CAM
(CHOKE ROD)
FLOAT
LEVEL
CARBURETOR
NUMBER
ENGINE
M A XIM U M ENGINE
(ENRICHED) SPEED
RPO LG9
ENG INE F A M IL Y
150 RPM*
18Y2 HAN
G SERIES
5 .0 L (305 CID)
RPO LG9
ENG INE F A M IL Y
A U T O M A T IC
50 RPM*
M ANUAL
150 RPM*
18Y2 HAN
A U T O M A T IC
C SERIES
50 RPM*
6C4-1
SECTION 6C4
CARBURETOR MODEL M4M
CONTENTS
G eneral D escription......................................................... ..6C4-1
C arburetor O p eratio n ......................................................6C4-2
On-Vehicle S erv ice.......................................................... ..6C4-5
Checking C hoke................................................................ ..6C4-5
Checking Idle S o len o id .................................................. ..6C4-5
A d ju stm en ts.......................................................................6C4-5
M ixture Control A djustm ents..................................... 6C4-16
6C4-17
6C4-17
6C4-17
6C4-17
6C4-22
6C4-24
6C4-27
GENERAL DESCRIPTION
The model M 4M C carburetor is used on Heavy D uty
Emissions vehicles. In addition, a new electric choke model
M 4M E carburetor is used on Light D uty Emissions vehicles
replacing th e hot air choke m odel previously used. All
models (Fig. 6C4-1,2 and 3) tam per - resistant features such
as rivets, plugs, covers, etc., to discourage readjustm ent of
factory settings which could affect either or both emission
control and driveability. For exam ple, as a carryover
VACUUM BREAK
(AIR VALVE DASHPOT)
VAPOR VENT
TUBE
(TO CANISTER)
f JP
ELECTRIC CHOKE
K jr
PLUG (IDLE
MIXTURE NEEDLE)
REAR V A C U U M BREAK
REAR V A C U U M
BREAK
THROTTLE LEVER
A C TU ATO R
ELECTRIC CHOKE
VAPO R VE N TT U B E
{TO CANISTER!
RIVETS
RIVETS
FRONT V A C U U M BREAK
PLUG (IDLE
M IX TU R E NEEDLE)
HO T AIR
CHOKE
6C4-2
CARBURETOR MODEL M 4 M
Carburetor Operation
The carburetor has six systems of operation. They are
float, idle, main m etering, power, pump, and choke (Figs.
6C4-4 and 4a).
CARBURETOR MODEL M 4M
-FLOAT HINGE
PIN
6C4-3
FIXED IDLE
AIR BY-PASS
IDLE AIR
BLEED
FLOAT NEEDL
IDLE CHANNEL
RESTRICTION
INLET FILTER
E.G.R
CHECK VALVE
SEAT
FLOAT SYSTEM
(M4M MODELS)
IDLE SYSTEM
W/LD EMISSION
PULL-OVER ENRICHMENT
(PO E.) FUEL FEEDS (2)*
FIXED IDLE
AIR BY PASS
IDLE AIR
BLEED
ADJUSTS
IDLE CHANNEL
RESTRICTION
NOTE:
SIDE FUEL ENTRY
MAIN
METERING
POWER PISTON
VACUUM
SPRING
PASSAGE
MAJN
METERING
JETS
* (USED ON SOME MODELS)
IDLE SYSTEM
W/HD EMISSION
6C4-4
SECONDARY
METERING RODS
BOOST
VENTURI
FACTORY METERING
ADJUSTMENT SCREW
MAIN WELL A
BLEEDS
BAFFLE C A M B
L I
POWER PISTON
/ m a in
SPRING
'METERING
VACUUM
ICTe
PASSAGE
:|
SECONDARY
THROTTLE
PUMP RETURN
SPRING
CUP SEAL
PUMP PLUNGER
EXPANDER SPRING
PUMP SYSTEM
W/LD EMISSION
POWER SYSTEM
RETAINER
ELECTRIC
CHOKE COIL
PUMP RETURN
SPRING
REAR VACUUM
CUP SEAL
SECONDARY LOCKOUT
LEVER
FAST IDLE
ADJUSTING SCREW
FAST IDLE
CAM FOLLOWER
CHOKE SYSTEM
M4ME (FEDERAL)
PUMP SYSTEM
W/HD EMISSION
VACUUM BREAK
ADJUSTING SCREW
THERMOSTATIC
COIL
FRONT VACUUM
BREAK
FRONT VACUUM
BREAK
DIAPHRAGM UNIT
RETAINER
(WITH TAB)
SECONDARY LOCKOUT
LEVER
FAST IDLE
CAM FOLLOWER
FAST IDLE
ADJUSTING SCREW
SECONDARY LOCKOUT
LEVER
FAST IDLE
CAM FOLLOWER
CHOKE SYSTEM
M4ME (CALIFORNIA)
CHOKE SYSTEM
W/HD EMISSION
UNLOADER
TANG
VACUUM BREAK
ROD
FAST IDLE
ADJUSTING SCREW
CARBURETOR MODEL M 4M
6C4-5
ON-VEHICLE SERVICE
Adjustments
Before checking or resetting the carburetor as the cause
of poor engine perform ance or rough idle; check ignition
system including distributor, tim ing, spark plugs and wires.
C heck air clean er, evaporative em ission system , E F E
System , PCV system, EGR valve and engine compression.
Also inspect intake manifold, vacuum hoses and connections
for leaks and check torque of carburetor mounting bolts/
nuts.
M ake all adjustm ents with engine at normal operating
tem perature, choke full open, air cleaner installed. Except
as noted air conditioning should be "off" and all vacuum
lines and all electrical leads connected. Set parking brake
and block drive wheels. A ir cleaner can be removed for set
up accessibility but m ust be com pletely installed during
actual setting.
R efer to Figure 6C4-A through 6C 4-J for carburetor
adjustm ent procedures.
Checking Solenoid
1.
2.
3.
4.
5.
6.
7.
8.
6C4-6
HO LD RETA IN ER
F IR M L Y IN PLACE
TOE
V IS U A L L Y CHECK FLO AT A L IG N M E N T
AFTER ADJUSTING
PUMP ADJUSTMENT
G A U G E F R O M T O P OF C H O K E
V A L V E W A L L . N E X T TO V E N T
S T A C K , TO T O P
OF P U M P S T E M
A S S P E C IF IE D
BEND P U M P
LE VER TO
AD JUST
3^=0
R O D IN S P E C IF IE D H O L E
O F P U M P LE VER
'S U P P O R T LE VER W IT H
S C R E W D R IV E R W H IL E
B E N D IN G LE VER
>T H R O T T L E V A L V E S
CO M PLETELY CLOSED
NO TE
M A K E S U R E F A S T ID LE
C A M F O L L O W E R L E V E R IS OFF
S T E P S O N F A S T ID L E C A M
B E N D S E C O N D A R Y C L O S IN G T A N G
A W A Y T O C L O S E P R IM A R Y V A L V E S ,
T H E N RE A D J U S T
CARBURETOR MODEL M 4M
6C4-7
BEND C H O K E R O D A T T H IS
P O IN T TO A D JU S T (SEE IN S E T)
11
C H O K E VALVE
C LO SED
NO TE: IF A D JU S T M E N T
IS N E C E S S A R Y , DRILL
O UT R IV E TS AND REM O VE
C H O K E CO VER . USE S T A T
CO VER RETAINER KIT.
\
PUSH UP ON T H E R M O S T A T IC
C O IL T A N G (C O U N T E R C L O C K W IS E )
U N T IL C H O K E VALVE IS CLOSED.
W
LOW ER ED G E OF LEVER S H O U L D
JU ST C O N T A C T S ID E OF PLUG
G A U G E.
43 IN S E R T .1 2 0
PLUG G AUG E.
IF N E C E S S A R Y , DRILL OUT A N D REMOVE
R IV E T S . REM O VE TH E T H E R M O S T A T IC
CO VER A N D C O IL ASSEM BLY FRO M C H O K E
H O U S IN G .
cx
( 7 ) H O LD CAM
FOLLOW ER ON
H IG H E S T STEP
O F FAST ID L E C A M
T U R N SCREW IN T O
CO NTACT LEVER THEN
T U R N SC R EW IN S P E C IF IE D
N U M B E R O F T U R N S (N O T E )
T U R N F A S T ID L E SCREW
O U T U N T IL P R IM A R Y
T H R O T TL E V A L V E S ARE
CLOSED.
6C4-8
CARBURETOR MODEL M 4M
2.
3.
4.
FIGURE 2
ROTATE SCALE SO THAT DEGREE SPECIFIED FOR ADJUSTMENT IS
OPPOSITE POINTER.
7.
M A K E CHOKE COIL LEVER AND FAST IDLE ADJUSTMENT (BENCH OR ON-THECAR SETTING).
NOTE: DO NOT REMOVE RIVETS AND CHOKE COVER TO PERFORM THIS
ADJUSTMENT. USE RUBBER BAND ON VACUUM BREAK LEVER TANG TO HOLD
CHOKE VALVE CLOSED, (STEP 8).
{ ) SPECIFIED
ANGLE (SEE SPECS.)
( D TO ADJUST, BEND TANG
ON FAST IDLE CAM
RUBBER
UNTIL BUBBLE IS
BAND
CENTERED.
REMOVE GAUGE.
FIGURE 2
CARBURETOR MODEL M 4M
6C4-9
1.
2.
3.
4.
CH OK E VA LV E CO M PLETELY CLOSED.
5.
6.
7.
8.
H O L D C H O K E VA LVE T O W A R D C L O S E D P O S IT IO N , P U S H IN G U P W A R D
O N C H O K E C O IL LEVER OR V A C U U M B R EA K LEVER T A N G (H O L D IN
P O S IT IO N W IT H R U B B ER B A N D ).
9.
10.
N O T E 2:
LEAF B U C K IN G
S P R IN G M U S T BE
SE A TE D A G A IN S T ;
LEVER
_____ _
(W H ER E U S E D )
'
BA ND
S E A T D IA P H R A G M
\ / \ /}
U S IN G V A C U U M S O U R C E
/
/X
J ? N O T E : O N D E LA Y M O D E L S W IT H AIR
c /A m
o,
r e m o v e R U BB ER C O V E R O VER
E L E M E N T A N D P LU G SM A LL
BLEED HO LE IN V A C U U M T U B E W IT H
TA PE. R E M O VE TA PE A FTER A D J U S T
M ENT.
L IG H T L Y C L O S E C H O K E
BY P U S H IN G UP W A R D
O N C H O K E C O IL LEVER OR V A C U U M
BREAK LEVER T A N G (H O L D IN P O S IT IO N
W IT H R U BB ER B A N D ).
6C4-10
SPECIFIED
ANGLE (SEE SPECS.)
_
L
LEVELING
BUBBLE
(C E N TFR E D )
RUBBER
BAND
FIG U R E 3
PLUNGER
BUCKING
SPRING
SEAT DIAPHRAGM
USIN G VAC UUM SOURCE
(S E E NOTE 2)
NOTE 2: ON DELAY M O DELS, PLUG END COVER USING AN ACCELERATOR PUMP PLUNG ER CUP 2G
TYPE (FIG U R E 3 ) OR EQUIVALENT. SE A T VACUUM DIAPHRAGM M AKING SURE VAC UUM IS
ABOVE 5 " Hg WHEN READING GAUGE (STEP 9 ). REMOVE CUP AFTER A D JUSTM ENT.
NOTE 1: MAKE CHOKE COIL LEVER A D JU S TM EN T A N D FAST IDLE A D JU S TM E N T. DO NOT REMOVE
RIVETS A N D CHOKE COVER TO PERFORM THIS A D JU S TM E N T . USE RUBBER BAND ON V A C U U M
BREAK LEVER TANG TO HOLD CHOKE VALVE CLOSED (STEP 8).
CARBURETOR MODEL M 4M
6C 4-11
FIGURE 1
IF REMOVED, INSTALL CHOKE
THERMOSTATIC
COVER AND COIL
ASSEMBLY IN HOUSING.
BEND TANG TO
A D JU ST UNTIL
BUBBLE IS CENTERED.
6C 4-12
CARBURETOR MODEL M 4M
H O L D C H O K E V A L V E W ID E
O P E N BY P U S H IN G D O W N O N
CHOKE VALVE
CLOSED
THROTTLE
VALVES
CLOSED
B E N D P IN
TO A D J U S T
^ 5 '
x
----- --015 MAX
CLEARANCE
T A IL OF F A S T ID L E C A M
C H E C K L O C K O U T P IN
FO R C L E A R A N C E
FILE E N D OF P IN
(C H E C K FO R N O
B U R R S AFTER
F IL IN G )
S E C O N D A R Y L O C K O U T LEVER
S ID E C L E A R A N C E
^GAUGE
FOR C L E A R A N C E
2 )
O P E N IN G C L E A R A N C E
(7)c
HOKE V A L V E
^ ^ ^ W ID E OPEN CAM FOLLOW ER
O F F STEPS O F FAST ID L E CAM
( j H B E N D TANG
^ T O ADJUST
(7 ) .020"
^ -" C L E A R A N C E
6C 4-13
CARBURETOR ADJUSTMENTS
AIR VALVE SPRING ADJUSTMENT
C 3*J) T' U R N
T IG H T E N LOCK SCREW
PREPARE V E H I C L E
J
TURN SOLENOID SCREW TO
ADJUST TO SPECIFIED RPM.
(RECONNECT A/C COMPRESSOR
LEAD AFTER ADJUSTMENT)
\( 3
6C4-14
TWITH
PLUNGER HELD INWARD.
lRN PLUNGER SCREW IN OR OUT
TO OBTAIN SPECIFIED R.P.M.
WITH ENGINE SET AT SPECIFIED IDLE SPEED, USING OUTSIDE VACUUM SOURCE
APPLY SUFFICIENT VACUUM TO THE ACTUATOR TO EXTEND THE PLUNGER FULLY.
P O SITIO N T R A N S M IS S IO N
IN P A R K OR N EU TRAL
I T
y-
09
HOLD C A M FOLLOWER ON
P RO P ER STEP OF FAST IDLE
C A M PER E M IS S IO N LABEL
S____t
D IS C O N N E C T A N D PLUG
V A C U U M H O SE AT EGR
VALV E
TU RN FAST IDLE SC R E W
TO O B T A IN SP EC IF IED R P M
ON E M IS S IO N LABEL
o
n
LIGHT TRUCK
SERVICE M AN U AL
6C4-16
11. Lightly seat screws, then back out equally, just enough
so engine will run.
12. Place transmission in Drive (autom atics) or N eutral
(m anuals).
13. Back each screw out (richen 1/8 turn a t a time until
m axim um idle speed is obtained). Then set idle speed to
the enriched idle specification.
14. T urn each m ixture screw in (clockwise) 1/8 turn at a
tim e until idle speed reaches value given on Emission
Control Inform ation Label.
15. Re-check enriched speed with propane. If not within
specification, repeat adjustm ent beginning with Step
12 .
CARBURETOR MODEL M 4M
6C 4-17
CARBURETOR REPLACEMENT
Removal (Fig. 6C4-7)
Flooding, stum ble on acceleration and other perform
ance complaints are in many instances, caused by presence
of dirt, w ater, or other foreign m atter in carburetor. To aid
in diagnosis, carburetor should be carefully removed from
engine w ithout draining fuel from bowl. Contents of fuel
bowl may then be exam ined for contam ination as carburetor
is disassembled. Check filter.
1. Remove air cleaner and gasket.
2. Disconnect wire at solenoid, if equipped.
3. Disconnect fuel pipe and vacuum lines.
4. Disconnect choke system.
5. Disconnect accelerator linkage.
6. If equipped with autom atic transm ission, disconnect
downshift cable.
7. If equipped with cruise control, disconnect linkage.
8. Remove c a rb u re to r atta c h in g bolt, c a rb u re to r and
insulator.
Installation
UNIT REPAIR
DISASSEMBLY
Place c a rb u re to r on a holding fixture to prevent
dam age to throttle plates.
Air Horn
1. Remove upper choke lever from the end of choke shaft
by removing retaining screw (Fig. 6C4-8). Then rotate
upper choke lever to remove choke rod from slot in
lever.
2. Remove choke rod from lower lever inside the float
bowl casting by holding lower lever outw ard with small
screwdriver and twisting rod counterclockwise.
6C4-18
CARBURETOR MODEL M 4M
C O U N TE R S U N K
SCREWS (2)
(BELOW CHOKE
VALVE)
SHORT
SHORT
LO NG
LO NG
CARBURETOR MODEL M 4M
and the dashpot rod from the air valve lever. Do not
place vacuum break assembly in carburetor cleaner.
2. If used, remove pum p plunger stem seal by inverting air
horn and using a small screwdriverto remove staking
holding the seal re ta in e r in place (Fig. 6C 4-14).
Remove and discard retainer and seal.
F urth er disassembly of the air horn is not required for
cleaning purposes. If part replacem ent is required, proceed
as follows:
T he air valves and air valve sh aft should not be
removed. If it is necessary to replace the air valve closing
spring or center plastic eccen tric cam , a rep air kit is
available. Instructions for assem bly are included in the
repair kit.
6C 4-19
Float Bowl
1. Remove air horn gasket by lifting out of dowel locating
pins and lifting tab of gasket from beneath the power
piston hanger, being careful not to disto rt springs
holding the main m etering rods (Fig. 6C4-15).
2. Remove pum p plunger, and pump plunger stem seal
(Fig. 6 C 4 -14) if used, from pump well.
3. Remove pum p return spring from pump well.
4. Remove power piston and m etering rods by depressing
piston stem and allowing it to snap free (Fig. 6C4-16).
The power piston can be easily removed by pressing the
piston down and releasing it with a snap. This will cause
the power piston spring to snap the piston up against
the retainer. This procedure may have to be repeated
several times.
Do not remove power piston by using pliers on m etering
rod hanger.
Remove the power piston spring from the well.
The A.P.T. m etering rod adjustm ent screw is pre-set at
the factory and no attem pt should be m ade to change
this adjustm ent in the field. If float bowl replacem ent is
required during service, the new bowl assem bly will be
supplied with an A .P.T. m etering rod screw which will
be pre-set as required.
5. Remove m etering rods from power piston by discon
necting tension spring from top of each rod, then rotate
rod to remove from hanger.
Use care when disassem bling rods to prevent distortion
of tension spring an d /o r m etering rods. N ote carefully
position of tension spring for later reassembly.
6. Remove plastic filler block over float valve.
FLO AT BOWL
6C4-20
CARBURETOR MODEL M 4M
RETAINING
SPRING
METERING
ROD
POWER
PISTON
POWER
PISTON
SPRING
A N E R O ID
C A VITY
INSERT
PUMP DISCHARGE
CHECK BALL RETAINER
AND CHECK BALL
NEEDLE SEAT
R E M O V IN G TO O L
Choke
Disassembly
CARBURETOR MODEL M 4M
6C 4-21
ATTACHING
SCREWS
REAR VACUUM BREAK
C H O K E COVER
RETAINERS
A T T A C H IN G
CHOKE
H O U S IN G
SCREW
SCREW
6C4-22
INTERMEDIATE
CHOKE SHAFT SEAi
PLASTIC
TUBE SEAL
(HOT AIR CHOKE
MODELS ONLY)
INSULATOR
GASKET
HROTTLE VALVE
LOCKOUT LEVER
ST IDLE
CAM
CHOKE HOUSING
l/ACUUIVI fc S K fc A K M U U
[MONADJUSTABLE)
Jk lifc;.*,-
THROTTLE BODY
TO BOWL SCREWS (3)
6C4-23
FLAT PUNCH
SAW SLOTS
CENTER PUNCH
STEP #2
LOCATOR
POINTS
STEP #1
HACKSAW
RECESSED IDLE MIXTURE
NEEDLE AND PLUG LOCATIONS
Fig. 6 C 4 -2 6 a ~ ld le M ixture N eedle
6C4-24
CARBURETOR MODEL M 4M
ASSEMBLY
1. If removed, install idle mixture needle, washer, and
spring using Idle Mixture Adjusting Tool J-29030.
Lightly seat needle and then back out 4-1/2 turns as a
preliminary idle mixture adjustment. Final idle mix
ture adjustment must be made on car using the
procedures described under Idle Mixture Adjustment.
2. Install lower end of pump rod in throttle lever by
aligning tang on rod with slot in lever. End of rod
should point outward toward throttle lever.
Float Bowl
1. Install end of vacuum break rod in slot in rear vacuum
break plunger (Fig. 6C4-20). Then, install rear vacuum
break and bracket assembly on float bowl using two
large countersunk attaching screws. Tighten secure
ly.If vacuum break adjustment is necessary, see
adjustments.
2. If removed, install air baffle in secondary side of float
bowl with notches toward the top. Top edge of baffle
must be flush with bowl casting.
3. If removed, install baffle in pump well fill slot.
4. Install pump discharge check ball and retainer in
passage next to pump well. Tighten retainer securely.
5. Install primary main metering jets (if removed).
6. Install aneroid cavity insert into float bowl.
7. Install new needle seat assembly, with gasket.
8. To make adjustment easier, bend float arm upward at
notch in arm before assembly.
Install needle by sliding float lever under needle pull
clip-correct installation of the needle pull clip is to
hook the clip over the edge of the flat on the float arm
facing the float pontoon (Fig. 6C4-28). With float lever
in pull clip, hold float assem bly at toe and install
retaining pin from aneroid cavity side (ends of retain
ing pin face the accelerating pump well).
Do not install float needle pull clip into holes in float
arm.
9. Adjust float level as follow s:
Choke
1. Install new cup seal into plastic insert on side of float
bowl for intermediate choke shaft. Lip on cup seal faces
outward.
2. Install secondary throttle valve lock-out lever on boss
on float bowl with recess in hole in lever facing inward.
3. Install new cup seal into inside choke housing shaft
hole. Lips on seal face inward, towards inside of
housing.
4. Install fast idle cam onto the intermediate choke shaft
(steps on fast idle cam face downward) (Fig. 6C4-23).
5. Carefully install fast idle cam and intermediate choke
shaft assembly through seal in choke housing; then
install thermostatic coil lever onto flats on intermediate
choke shaft. Inside thermostatic choke coil lever is
properly aligned when both inside and outside levers
face towards fuel inlet. Install inside lever retaining
screw into end of intermediate choke shaft. Tighten
securely.
6. Using Tool J-23417, install lower choke rod lever into
cavity in float bowl. Install plastic tube seal into cavity
on choke housing before assembling choke housing to
bowl. Install choke housing to bowl sliding intermedi
ate choke shaft into lower choke lever (Fig. 6C4-27).
LIGHT TRUCK SERVICE MANUAL
CHOKE
ROD
J23417
lever
CARBURETOR MODEL M 4M
6C4-25
10.
11.
12.
13.
14.
15.
Air Horn
1. If used, install new pump plunger stem seal in air horn
casting (Fig. 6C4-32a). Lightly stake seal retainer in
three places, choosing locations diferent from the
original stakings.
6C4-26
RIVETS
A N D RETAINERS
Fig. 6 C 4 -3 T -C h o k e Cover - Typical
6C4-27
CARBURETOR
PART NUM BER
FLOAT
LEVEL
PUMP
ROD
LOCATION
PUMP
ROD
SETTING
FAST IDLE
CAM
(CHO KE ROD)
AIR
VALVE
ROD
VACUUM
BREAK
FRONT
VAC UUM
BREAK
REAR
AIR
VALVE
W INDUP
UNLOADER
17080212
3/8"
INNER
9/32"
46
.025"
24
30
3/4
40
17080213
17080215
17080298
17080507
17080512
17080513
17081200
17081201
17081205
17081206
17081220
17081226
17081227
17081290
17081291
17081292
17081506
17081508
17081524
3/8"
3/8"
3/8"
3/8"
3/8"
3/8"
15/32"
15/32"
15/32"
15/32"
15/32"
9/32"
37
.025"
37
37
37
.025"
.025"
.025"
30
30
30
30
1
1
1
1
40
9/32"
9/32"
9/32"
23
23
9/32"
46
37
46
46
.025"
30
9/32"
9/32"
9/32"
3/4
3/4
9/32"
46
9/32"
46
46
13/32"
INNER
INNER
INNER
INNER
INNER
INNER
INNER
INNER
INNER
INNER
INNER
INNER
INNER
INNER
INNER
INNER
INNER
INNER
13/32"
OUTER
13/32"
OUTER
17081526
15/32"
15/32"
13/32"
13/32"
13/32"
13/32"
.025"
.025"
.025"
.025"
.025"
23
23
24
23
24
23
23
23
30
23
23
23
40
40
40
7/8
7/8
7/8
7/8
40
40
42
42
42
.025"
23
23
23
46
.025"
9/32"
9/32"
9/32"
9/32"
46
46
46
46
.025"
.025"
24
24
23
23
23
23
24
24
23
24
9/32"
9/32"
46
.025"
23
36
7/8
7/8
7/8
46
.025"
7/8
46
.025"
23
25
36
5/16"
36
7/8
38
25
36
7/8
38
9/32"
9/32"
5/16"
46
.025"
.025"
.025"
42
7/8
42
7/8
7/8
7/8
42
42
42
42
42
36
36
6C4-28
CARBURETOR MODEL M 4M
TRANSM ISSION
A U T O M A T IC
20 R P M
A U T O M A T IC
40 R PM
18L4 H H N A
RPO LF3
C A N D G S E R IE S
MANUAL
5 .0 L (3 0 5 C I D )
E X C . C S E R IE S
E N G IN E F A M IL Y
W /4 S P E E D
18L4 H A N A
O V E R D R IV E
RPO LE9
C, K A N D G S E R IE S
100 R P M
MANUAL
C S E R IE S
150 R P M
W /4 S P E E D
O V E R D R IV E
5 .0 L (3 0 5 C I D )
E N G IN E F A M IL Y
A U T O M A T IC
50 RPM
18Y4 H G N
RPO LE9
MANUAL
150 R P M
C S E R IE S
5 .7 L (3 5 0 C I D )
A U T O M A T IC
2 0 -5 0 R P M
E N G IN E F A M IL Y
18L4 H A N A A N D
18L4 H H N A
RPO LS9
C, K A N D G S E R I E S
MANUAL
* R P M A B O V E ID L E S P E E D S H O W N O N E M IS S IO N L A B E L
100 R P M
FUEL SYSTEM
6C5-1
SECTION 6C5
FUEL SYSTEM
CONTENTS
Fuel Filter.......................................................................... ..6C5-1
Fuel Pump.......................................................................... ..6C5-1
Fuel Tank..............................................................................6C5-4
Cleaning Fuel S y stem .......................................................6C5-8
Fuel Feed and Vapor Pipes..............................................6C5-9
FUEL FILTER
GENERAL DESCRIPTION
All engine fuel filters are located in the carburetor fuel
inlet. These fuel filter elem ents are of pleated paper.
Elements are placed in the inlet hole with the gasket surface
outward. A spring holds the element outward, sealing it by
compressing a gasket surface against the inlet fitting.
ON-VEHICLE SERVICE
The carburetor inlet fuel filter should be replaced at
intervals shown in Section OB. A plugged filter and/or check
valve will restrict fuel flow.
After assembling any filter element in the carburetor,
always start the engine and check for leaks in the fuel line
and fittings before installing the air cleaner.
5.
O th e r Filters or Strainers
6.
7.
8.
FUEL PUMP
GENERAL DESCRIPTION
DIAGNOSIS
Complete diagnosis of all possible causes of the trouble
prior to replacement of the fuel pump will save time, expense
and possible causes of the trouble prior to replacement of the
fuel pump will save time, expense and possibly prevent a
repeat complaint.
6C5-2
FUEL SYSTEM
ON-VEHICLE SERVICE
Inspection and Test
If the fuel system is suspected of delivering an improper
amount of fuel to the carburetor, it should be inspected and
tested in the vehicle, as follows:
Inspection of Fuel System
Installation
1. Install push rod, gasket, mounting plate (if used) and
fuel pump.
2. Install two hex head bolts, turning them alternately and
evenly.
3. Install fuel outlet pipe. If it is difficult to start fitting,
time can be saved by disconnecting upper end of pipe
from carburetor. Tighten fitting securely, meanwhile
holding fuel pump nut with a wrench. Install and
tighten fitting at carburetor, if removed.
4. Install fuel inlet hose and clamp. Install vapor return
hose and clamp, if so equipped.
5. Start engine and check for leaks.
FUEL SYSTEM
6C5-3
30 N.m
(22 F T .-L B S .)
BO TH E N D S
O F P IP E
G ASKET
37 N.m
(27 F T .-L B S .)
PUSH ROD
PLUG
7.4L (LE-8)
6C5-4
FUEL SYSTEM
FUEL TANK
ON-VEHICLE SERVICE
O utside Fram e Rail Fuel T an kCab a n d C rew ca b (Figs. 6 C 5 -6 an d 8)
1.
2.
3.
4.
Drain tank.
Disconnect fuel lines, meter wire and ground lead.
Remove strap supports (lines, vent) and clip.
Loosen clamps from filler neck and vent line.
FUEL SYSTEM
SIDE M EM BER
6C5-5
R.H.
PLATFO RM ASSEM BLY
H O S E -V E N T
STRAP
BRACKET
CLAM P
HOSE-FILLER
6C5-6
FUEL SYSTEM
FUEL SYSTEM
6C5-7
6C5-8
FUEL SYSTEM
SPACER
STRAP
ASSEMBLY
AN TI-SQ U EAK
CEMENT
SPACER
TORQUE AT
10 FT. LBS.
ASSEMBLY: Cem ent anti-squeak to upper
surface of tan k flan ge w ith 1.00 w ide
coverage before installation of tan k assembly.
Tighten upper nut a fte r low er nut has been
tightened.
- P10
17)
1.
2.
3.
4.
5.
Drain tank.
Remove filler neck.
Disconnect meter unit fuel line and wiring.
Remove bolts attaching tank supports to frame.
Remove tank complete with mounting bracket and
support straps.
6. Remove tank from brackets and support straps, if
necessary.
7. Install in reverse order and replace antisqueak
material.
FUEL SYSTEM
6C5-9
6C5-10
FUEL SYSTEM
ON-CAR SERVICE
Fuel Line Repair
Replacem ent
Rem oval
ON-VEHICLE SERVICE
Maintenance requirement is that the oiled fiberglass
filter assembled in the bottom of the canister, be replaced at
intervals shown in Section 0B. Under extrem ely dusty
conditions, more frequent attention may be required.
Check operation of bowl vent and purge valve.
1.
2.
3.
4.
Inspection
FUEL SYSTEM
Checking Bowl V e n t V a lv e
6C5-11
1. Disconnect battery.
2. Remove hose shield and brace.
3. Remove fuel and vapor hoses noting their position for
later installation.
4. Remove two screws holding valve to frame and remove
valve.
5. Install valve and tighten screws.
6. Install fuel and vapor hoses in same positions noted at
removal.
7. Install brace and hose shield.
8. Connect battery.
6C5-12
FUEL SYSTEM
ACCELERATOR CONTROLS
GENERAL
The accelerator control system is cable type. There are
no linkage adjustments. A reference between the bottom of
accelerator pedal and floor pan should be used only as a
check for bent bracket assembly. Check torque references.
Check for correct opening and closing positions by
operating accelerator pedal and if any binding is present,
check routing of cable.
ACCELERATOR PEDAL
Refer to figures 6C5-22 through 25 for removal and
installation of accelerator pedal.
CAUTION
SUPPORT
ENGINE
SEALER
OUTER SPRING
CABLE
RETAINER'
FUEL SYSTEM
C A U T IO N
Flexible components (hoses,
wires, conduits, etc) must not be routed
within 2 inches of moving parts of
accelerator linkage forward of
Support, unless routing is
positively controlled.
k.
STUD
6C5-13
..
CARB
LEVE -
CARB
RETAINER
N O TE
N O TE
Springs can be installed with'
hook ends inboard or outboard.
INNER SPRING
CABLE ASSEMBLY
I NOTE 1 Cable is not to be
kinked or damaged in any
way during assembly.
SPRING OUTER
CARBURETOR STUD
FASTENER
l _____
QF
SPRING
INNER
6C5-14
FUEL SYSTEM
LE ASSEMBLY
SUPPORT,
SPRING
REINFORCEMENT
PEDAL* 1T ill'll j1
/
L N U I U Retainer must
bear against pedal rib.
TIGHTEN TO
27 IN. LBS.
SPRING (SHOWN IN
LOADED POSITION)
PEDAL
LUBRICATE
SUPPORT
SPRING'
REINFORCEMENT
ACCELERATOR
CO NTRO L CABLE
T IG H T E N T O
PEDAL
5 0 IN . LBS.
TIGHTEN TO
42 IN. LBS.
SUPPORT
Fig. 6 C 5 -24--A ccelerato r Pedal-P42
FUEL SYSTEM
6C5-15
SPECIFICATIONS
FUEL PUMP PRESSURE
ENGINE
P.S.I.
L6 (ALL)
4V2-6
V8 (ALL)
WITHOUT VAPOR RETURN LINE
71/2-9
V8 (EXC LF8)
WITH VAPOR RETURN LINE
51/2-7
V8 (LF8)
WITH VAPOR RETURN LINE
71
/2-9
TORQUE
SPECIFICATIONS
IM E C A R B U R E TO R
TORQUE
(IN. LBS.)
SCREW
SCREW
TORQUE
(IN. LBS.)
45
70
50
CHOKE LEVER
25
PUMP LEVER
30*
180
NEEDLE SEAT
45
METERING JET
40
400
SCREW
TORQUE
(IN. LBS.)
THROTTLE BODY
THROTTLE BODY TO BOWL
46
CHOKE HOUSING
CHOKE LEVER
CHOKE HOUSING ATTACHING
CHOKE HOUSING COVER
14
46
26
AIR HORN
AIR HORN TO BOWL 10-32
AIR HORN TO BOWL 8-32
AIR HORN TO THROTTLE BODY
CHOKE LEVER
VACUUM BREAK UNIT
FUEL INLET NUT
NEEDLE SEAT
METERING JET
SOLENOID BRACKET
46
26
46
14
26
400
45
40
71
Fig. 6C5-26--Specifications
6C5-16
FUEL SYSTEM
D E C IM A L E Q U IV .
ANGLE DEG REES
TOP OF V A L V E
TOP OF V A L V E
.023
33
.203
.028
34
.211
.033
35
.220
.038
36
.227
.043
37
.234
10
.049
38
.243
11
.054
39
.251
12
.060
40
.260
13
.066
41
.269
14
.071
42
.277
15
.077
43
.287
16
.083
44
.295
17
.090
45
.304
18
.096
46
.314
19
.103
47
.322
20
.110
48
.332
21
.117
49
.341
22
.123
50
.350
23
.129
51
.360
24
.136
52
.370
25
.142
53
.379
26
.149
54
.388
27
.157
55
.400
28
.164
56
.408
29
.171
57
.418
30
.179
58
.428
31
.187
59
.439
32
.195
60
.449
FUEL SYSTEM
6C5-17
SPECIAL TOOLS
Idle Mixture Socket................................................................................ J-29030-B
Adjustable Float G age........................................................................... J-9789-90
Bending T ool.......................................................................................... J-9789-111
Needle Valve Seat Remover..................................................................... J-22769
Carburetor S tand.................................................................................. J-9789-1 18
Float Level G age.................................................................................... J-9789-130
Float Level G age................................................................................... J-9789-135
Carburetor Choke Angle Gage............................................................. J-26701-4
Hand Vacuum D evice................................................................................ J-23738
Thermae Thermometer.............................................................................. J-22973
Carburetor Gage S e t................................................................................ J-9789-C
Fuel Tank Sending Unit Remover.......................................................... J-24187
S.iiix:?.
.. .... I
.........
ll>
........ ....
Jt j
"
,r
* -
ENGINE ELECTRICAL
6D-1
SECTION 6D
ENGINE ELECTRICAL
CONTENTS
Electric Choke Heater.......................................................
General Electrical System Diagnosis.............................
Battery..................................................................................
Charging System ................................................................
Ignition S y stem ..................................................................
6D-1
6D-1
6D-5
6D-8
6D-18
Diesel Engine.....................................................................
Conventional E ngine.......................................................
Cranking System ................................................................
Specifications.......................................................................
6D-18
6D-33
6D-53
6D-67
j cTVo
! 1
"GAUGE'
FUSE
CARB. CHOKE
HEATER
1*3
ir
((
||l-
IGNITION
SWITCH
01L PRESSURE
SWITCH
6D-2
ENGINE ELECTRICAL
3634
ENGINE ELECTRICAL
6D-3
6D-4
ENGINE ELECTRICAL
Wiring
JUNCTION BLOCK
TEMPERATUR
GAGE SENDER
POWER UNIT
W/S WIPER
MOTOR
OIL PRESS
SWITCH
exc Z53
TAIL COMBINATION
EXTENSION WIRE
|THROTTLE
/KICKER
.
ENDER ASM
W/GAGE PACK
SPEED
SWITCH
TEMPERATURE
SWITCH
CONNECTOR
CK 100+200
FORWARD LAMP
HARNESS
VIEW B
VIEW A
ENGINE ELECTRICAL
6D-5
BATTERY
General Description......................................................... .. 6 D -1
General Information....................................................... 6D-1
Common Causes of Failure........................................ .6 D -1
Electrolyte F reezing..................................................... 6 D -1
Carrier and Hold D ow n...............................................6D-1
Ratings..............................................................................6D-6
GENERAL DESCRIPTION
The sealed battery (see Fig. 6D-1B) is standard on all
vehicle lines (see Specifications for specific applications).
There are no vent plugs in the cover. The battery is
completely sealed, except for two small vent holes in the
side. These vent holes allow the small amount of gas
produced in the battery to escape. The battery has the
following advantages over conventional batteries:
B U ILT-IN
H YD RO M ETER
GENERAL INFORMATION
COMMON CAUSES OF FAILURE
A battery is not designed to last indefinitely; however,
with proper care, it will provide many years of service. If the
battery tests good but fails to perform satisfactorily in
service, the following are some of the more important factors
that may point to the cause of the trouble.
1. Accessories left on overnight.
2. Slow average driving speeds for short periods.
3. The cars electrical load is more than the generator
output particularly with the addition of after market
equipment such as radio equipment, air conditioning,
window defoggers or light systems.
Electrolyte Freezing
The freezing point of electrolyte depends on its specific
gravity. Since freezing may ruin a battery, it should be
protected against freezing by keeping it in a fully charged
condition.
6D-6
ENGINE ELECTRICAL
Visual Inspection
The external condition of the battery should be checked
periodically for damage such as cracked cover or case.
RATINGS
A battery has two ratings: (1) a reserve capacity rating
at 80F (27C) which is the time a fully charged battery will
operate the car with no generator operation, (2) a cold crank
rating at 0F (18C) which indicates the cranking load
capacity. (See Specifications for specific battery ratings).
The Ampere/Hour rating formerly found on batteries was
based on the reserve capacity rating and is no longer used.
Built-In Hydrometer
The sealed battery has a built-in temperature compen
sated hydrometer in the top of the battery. This hydrometer
is to be used with the following diagnostic procedure. When
observing the hydrometer, make sure that the battery has a
clean top. A light may be required in some poorly-lit areas to
see the right indication.
Under normal operation, two indications can be ob
served (see Figure 6D-2B):
1. G REEN DOT VISIBLE
Any green appearance is interpreted as a green dot and
the battery is ready for testing.
2. DARK; G REEN DOT N O T VISIBLE
If there is a cranking complaint, the battery should be
tested as described in the Diagnosis section. The charging
and electrical systems should also be checked at this time.
Occasionally, a third condition may appear:
3. CLEAR OR LIGHT YELLOW
This means the fluid level is below the bottom of the
hydrometer. This may have been caused by excessive or
prolonged charging, a broken case, excessive tipping or
normal battery wearout. When finding a battery in this
DIAGNOSIS
The following procedure should be used for testing
batteries:
1. VISUAL INSPECTION
INSULATOR STRAP
PREVENTS TOOL SEPARATION
A ND LOSS WHEN NOT IN USE
3. LOAD TEST
Load testing may require use of battery side terminal
adapters to insure good connections (see Fig. 6D-3B).
a. Connect a voltmeter and a battery load tester across
the battery terminals.
LIGHT TRUCK SERVICE MANUAL
ADAPTER CHARGING
TOOL ATTACHED
TO TERMINALS
ENGINE ELECTRICAL
MINIM UM VOLTAGE
B A TTER Y
Y 85-4
R85-5
R87-5
R89-5
9.6
9.5
9.4
9.3
9.1
8.9
8.7
8,5
TEST LOAD
130
170
210
230
AMPS
AMPS
AMPS
AMPS
6D-7
TEMPERATURE
F
70
60
50
40
30
20
10
0
21
*16
10
4
- 1
- 7
-1 2
-1 8
2996
ON-VEHICLE SERVICE
CHARGING PROCEDURES
When it is necessary to charge the battery, the follow
ing safety precautions must be followed:
1. DO NOT CHARGE battery if hydrometer is clear or
light yellow. Replace battery.
2. If the battery feels hot 125F (52C), or if violent
gassing or spewing of electrolyte through the vent hole
occurs, discontinue charging or reduce charging rate.
Charge the battery until the green ball appears.
Tipping or shaking the battery may be necessary to
make the green ball appear.
Temperature of the battery will effect the charging
rate, and most charging equipment will not charge at a
constant rate. For example, if the charger starts at 30
amperes and drops off to 10 amperes after 1 hour, the
average current for that hour was 20 amperes. The
actual boost charge was 20 ampere-hours. The sealed
battery can be fast charged or slow charged with
ordinary chargers in the same manner as conventional
batteries. Either method will restore the battery to full
charge.
Many chargers have special settings for sealed batter
ies. These settings reduce the charge voltage and limit
the current. It is not necessary to use these settings with
this sealed battery.
6D-8
ENGINE ELECTRICAL
CHARGING SYSTEM
General Description............................................................
Diagnosis...............................................................................
Faulty Indicator Lamp Operation...............................
Undercharged Battery.....................................................
Overcharged Battery............................................... .......
On-Vehicle Service.............................................................
Unit Repair..........................................................................
Disassembly.......................................................................
6D-8
6D-10
6D-12
6D-12
6D-13
6D-13
6D-14
6D-14
Stator C hecks...................................................................
Rotor Field Winding C hecks........................................
Diode Trio C heck............................................................
Rectifier Bridge Check....................................................
Brush Holder and Regulator Replacem ent...............
Slip Ring Servicing.........................................................
Bearing Replacement and Lubrication.......................
Reassembly.......................................................... .............
6D-14
6D-14
6 D -15
6D-15
6D-15
6D-16
6D-16
6D-16
GENERAL DESCRIPTION
The basic charging system is the SI integral regulator
charging system (Fig. 6D -1C ). The internal components are
connected electrically as shown in Fig. 6D-2C. The genera
tor is connected to the vehicle electrically as shown in Fig.
6D-3C.
The 15-SI generator is similar to the 10-SI except that:
1. It is slightly larger physically.
2. It produces 70 amps output at full speed.
3. It uses different drive end and slip ring end bearings.
4. The stator uses delta windings, which cannot be
checked for opens.
The brown field wire to the generator is used to initially
activate the generator. The 10 ohm resistance, provided by
either the generator warning lamp or the resistance wire
with optional gages, is needed to protect the diode trio.
Although several models of generators are available
with different outputs at idle and different maximum
outputs, their basic operating principles are the same.
The generator features a solid state regulator that is
mounted inside the generator slip ring end frame. All
regulator components are enclosed into a solid mold, and
this unit along with the brush holder assembly is attached to
the slip ring end frame. The regulator voltage setting never
needs adjusting, and no means for adjustment is provided.
The generator rotor bearings contain a supply of
lubricant sufficiently adequate to eliminate the need for
periodic lubrication. Two brushes carry current through the
two slip rings to the field coil mounted on the rotor, and
under normal conditions will provide long periods of
attention-free service.
The stator windings are assembled on the inside of a
laminated core that forms part of the generator frame. A
recitifier bridge connected to the stator windings contains
six diodes, and electrically changes the stator a.c. voltages to
a d.c. voltage which appears at the generator output
terminal. Generator field current is supplied through a diode
trio which also is connected to the stator windings. A
capacitor or condenser, mounted in the end frame protects
the rectifier bridge and diode trio from high voltages, and
suppresses radio noise.
N o periodic adjustments or maintenance of any kind
are required on the entire generator assembly.
NOISY GENERATOR
Noise from a generator may be caused by a loose drive
pulley, loose mounting bolts, worn or dirty bearings,
defective diode, or defective stator.
ENGINE ELECTRICAL
6D-9
6D-10
ENGINE ELECTRICAL
VOLTMETER
(R A L L Y GAUGE
ONLY)
GENERATOR WARNING
LAMP (EXC. R ALLY GAUGE)
SWITCH
BATTERY
BROWN (FIELD)
10 ohms RESISTANCE'
WIRE (R A LLY GAUGE
ONLY) [U
- ..............
10 ohms
RED (SENSING)
BULKHEAD
CONNECTOR
GENERATOR
Fig. 6 D -3 C --C h a rg in g Circuit - SI System
DIAGNOSIS
Most charging system troubles show up as a faulty
indicator lamp, an undercharged or an overcharged battery.
Since the battery itself may be defective, it should be
checked first to determine its condition. Also, in the case of
an undercharged battery, check for battery drain caused by
grounds or by accessories being left on.
A basic wiring diagram showing lead connections is
shown in Figure 6D-3C. To avoid damage to the electrical
equipment, always observe the following precautions:
Do not polarize the generator.
Do not short across or ground any of the terminals in
. the charging circuit except as specifically instructed.
Never operate the generator with the output terminal
open circuited.
Make sure the generator and battery are of the same
ground polarity.
IN D IC A T O R LAMP O P E R A T IO N
TEST NO. 1
Engine Running
Ig n itio n Sw itch
ON
Lam p O ff
NORMAL
See Test 2
TEST N O .2
Lam p O n
NORMAL
See Test 3
La m p On
C onnect v o ltm e te r to B A T .
te rm in al on generator and
chassis ground. T u rn
ignition key on.
Check 10 am p.
"G A U G E S "
" T R A N S ." fuse
in fuse block.
Engine S topped
Ig n itio n S w itch
ON
TEST NO. 3
La m p O n
D IM
L am p O ff
Ign. S w itch
OFF
L a m p O ff
NORMAL
La m p O n
If th e in d ic a to r lam p o p e ratio n
is norm al fo r all th re e tests,
refer to SI g enerator Diagnosis
Disconnect N o . 1 and 2
C o n n e c to r a t ge n era to r.
Fig. 6D-4C--CHarging
r
La m p On
B a tte ry V oltag e
Zero V o lta g e
System
D iagnosis
La m p b urned o u t.
Replace R e c tifie r
Bridge in g e n era to r.
1.
2.
5.
6.
O u tp u t N O T w ith in 1 0 am ps o f rated
output stam p ed on generator fra m e.
1.
C o n n e c t N o . 1 and N o . 2
co n n ec to r to generator.
2.
Lam p On
L a m p O ff
T
1.
M a k e sure N o . 1 w ire
co n n ec to r is m aking
good co n ta ct on te rm in a l.
2.
Disassemble generator
and check brushes, slip
rings and ro to r w inding
fo r open.
Replace R egulator
2427
6D -11
O u tp u t N O T w ith in 1 0 am ps o f rated
o u tp u t stam p ed o n generator fra m e.
ELECTRICAL
Replace Regulator
ENGINE
O u tp u t w ith in 1 0 am ps o f rated o u t
p u t stam ped on generator fram e.
L a m p On
Lam p O ff
Install N o . 1 and 2 C o n n e c to r.
Zero V oltag e
L a m p O ff
1.
A p p ro x im a te ly
2 to 4 V o lts
Check 10 am p.
"G A U G E S "
" T R A N S ." fuse
in fuse b lo c k.
6D-12
ENGINE ELECTRICAL
UNDERCHARGED BATTERY
Switch
Lamp
Engine
OFF
ON
ON
OFF
ON
OFF
STOPPED
STOPPED
RUNNING
END
FRAME
HOLE
ENGINE ELECTRICAL
OVERCHARGED BATTERY
1. To determine battery condition refer to Battery section.
6D-13
ON-VEHICLE SERVICE
The generator does not require periodic lubrication.
The rotor shaft is mounted on ball bearings at the drive end
and roller bearings at the slip ring end, and each contains a
permanent grease supply. A t periodic intervals, check
mounting bolts for tightness and adjust belt tension (see Sec.
6B).
When adjusting belt tension, apply pressure at center
of generator, never against either end frame.
Rem ove From Vehicle
6D-14
ENGINE ELECTRICAL
UNIT REPAIR
T E S TIN G STA TO R
(CHECK FOR OPENS)
OH
NO. 2 TERMINAL
"BAT
TERMINAL
THRU-BOLT
TEST HOLE
INSULATING
WASHERS
OHMMETER
(CHECK FOR
GROUNDS)
RECTIFIER
BRIDGE
__
DIODE
CAPACITOR
> .v,n.n.vi
NUTS
TR|0
OHMMETER
CHECK FOR OPENS
ENGINE ELECTRICAL
6D-15
TESTING TRIO
OHMMETER
BRUSH RETAINER
BRUSHES
SINGLE CONNECTOR
BEARING
SLINGER
REGULATOR
ARMATURE
SHAFT
[/
X
INSULATED
HEATSINK
GROUNDED
HEATSINK
^ ^
V-----
Vl
INSULATING
WASHER
RETAINER
COLLAR
/ y BEARING
COLLAR
________OHMMETER
ROTOR
SHAFT
END FRAME
SCREW
6D-16
ENGINE ELECTRICAL
P AR TIA L
W
R EC TIFIER END FRAME
15S1/100
20. Push slip ring end bearing out from outside toward inside
of end frame.
21. On 10SI and 27SI, place flat plate over new bearing, press
from outside toward inside until bearing is flush with end
frame.
22. On 15SI, see illustration.
23. Assemble brush holder, regulator, resistor, diode trio,
rectifier bridge and stator to slip ring end frame.
24. Assemble end frames together with thru-bolts. Remove
brush retainer wire.
Fig. 6D-9C--Generator Unit Repair
ENGINE ELECTRICAL
6D-17
6D-18
ENGINE ELECTRICAL
SPECIAL TOOLS
J-2150 1
PULLY
AD AP TER
Instrumentation
Electronic Module
Battery
Two 12 volt sealed top batteries connected in parallel
are required for the higher electrical load due to the glow
plugs and starter.
- ,,
Starter
The starter is larger and designed to crank the engine at
least the 100 RPM required for starting.
Charging
Thermal Probe
Ignition
Glow Plugs
ENGINE ELECTRICAL
6D-19
6D-20
ENGINE ELECTRICAL
ENGINE ELECTRICAL
6D-21
.8 YEL-508 (HW)
.8 PNK-30(HW)
PRODUCTION
TANK SENOER
6D-22
ENGINE ELECTRICAL
MODULE CIRCUITS
B
C
D
E
G
H
J
K
L
M
N
Relay Circuits
Circuit
Module Terminal
Blank
Blank
502 - Probe
Blank
503 Right Bank Glow Plugs (Monitor)
505 Glow Plug Relay Coil Feed (+)
3 - Ignition
150 Ground (Power)
506 - Glow Plug Relay Coil Feed (-)
B la n k
501 - Probe
5 0 0 Module Logic Ground
Generator Output (Monitor)
1
Ignition Switch-Off
Don't Start/Glow Plugs Lamp-Off
3
Ignition Switch "Start"
Don't Start/Glow Plugs Lp Pulsing on/off
2
Ignition Switch - "Run"
Don't Start/Glow Plugs Lp - On
4
Ign Sw Run
Don't Start/Glow Plugs Lp Pulsing on/off*
ENGINE ELECTRICAL
6D-23
ASM
6D-24
ENGINE ELECTRICAL
B R A K E LAM P
IN S T R U M E N T P A N E L
S W IT C H
W IR IN G H A R N E S S
BRAKE PEDAL
BEZEL
BRACKET
O P E N IN G
W A R N IN G
LAM P
IN S T R U M E N T
CLU STER
VIEW A
GROUND
BUS BAR
A u to m a tic
transm ission clutch
test connection.
VIEW B
________ _
ENGINE ELECTRICAL
6D-25
TO IG NITIO N
SWITCH
ii
BATT
C KT3PNK
Fig. 6D-10D--C-10
GEN
CKT 2
RED
PRINTED CIRCUIT
BOARD RELAY
25 CKT BRN
A
EN G IN E
TEM P C
PROBE E
B
D
LOGIC
GROUND
C K T 505 YEL
TIM IN G
LATCHING
AND LEVEL
DETECTION
CIRCUIT
LOGIC.
TRANSISTOR
SWITCH
CKT 506 LT BLU
GLOW
PLUG
RELAY
CKT 509
C K T 150 BLK
POWER
GROUND
ELECTRONIC MODULE
_________
D iagn osis
<
juuub^jTnnni' >
.flinty jtiiiuv .
jJUlfllb* RT
ENGINE ELECTRICAL
6D-27
2.
3.
W IT H IG N IT IO N SW IN " R U N "
Listen for G low Plug Relay clicking with cold engine.
Relay should come on for approxim ately 6 seconds.
(Varies with engine temperature) Then turn off and
then pulse O N /O F F .
R E L A Y C L IC K S O N /O F F
G LO W PLU G R E L A Y N O T C L IC K IN G O N /O F F
I
Connect 12 volt test light to ground.
Touch glow plug relay terminal with 2
red wires. Test light should turn
O N / O F F as relay clicks on/off.
T E S T L IG H T D O E S N O T
T E S T L IG H T P U L S E S O N / O F F
P U LSE O N /O F F
W IR IN G O K
Replace relay
O P E N C IR C U IT
I
Replace module and
check module ground
GLO W PLUG R E L A Y O P E R A T E S
Repair as necessary
T E S T L IG H T N O T
T U R N IN G O N / O F F
1
1
'----1
Ir/,
1
T
1
OFF
ON
ON ST E A D Y
Relay contacts
shorted, replace
relay & glow
plugs as required.
Locate and
repair open
circuit in wire
from glow plug
relay to battery
Replace relay
i.,
L IG H T P U L S E S O N / O F F
\>t i-
ON A L L 8
.1
NO T ON
ONE OR M O RE
6D-28
ENGINE ELECTRICAL
I
12 VOLTS OR MORE
0 VOLTS
NO GROUND
GOOD GROUND
12 VOLTS OR MORE
0 VOLTS
-------------------- ,
12 VOLTS OR MORE
I
I
OPEN CIRCUIT
......... *
2 TO 8 VOLTS (F)
2 TO 8 VOLTS (J)
Measure voltage at
module connector cavity M
-NO C O NTINUITY
J___________
--------1
0 VOLTS
I
Replace
module
0 VOLTS
Reconnect bulkhead connector,1
I
remove module. With Ign. ON
Replace the module
check voltage at module
connector cavity C
12 VOLTS OR M ORE'
I-----------------
___ I__
I
0 - OHMS
3 OHMS
I
Replace relay
and module
I
Remove module
check terminal
in cavity J for
damage
____ L
I
Disconnect probe and measure resistance
between probe terminals E to D with Ign. OFF
_________ L _
----------------------------- 1
I
LESS THAN 1 VOLT, BOTH
I
Measure voltage to ground at Glow Plug Relay coil
terminal 2 way connector (Y e ll/L t Blu)
______________ I____________
1
OPEN CIRCUIT
1 VOLT/1 VOLT
I
Replace probe
I
505 circuit open
Repair
Check continuity
from cavity D of probe
harness to ground
506 circuit
open
Repair
_________ I_________
r
NO C O NTINUITY
DAMAGED
NORMAL
I
Repair connector
I
Replace module
I
Repair open in 503 circuit
from probe to module
12 VOLTS/1 VO LT
-------------1
Replace relay
C O NTINUITY
I
Remove module, check for deformed
terminals in cavities C, G and H
I------------------ 1-------------------NORMAL
iFO R M ED
12 VO LTS/2 VOLTS
ENGINE ELECTRICAL
6D-29
1
11
I
11
N O C O N T IN U IT Y
C O N T IN U IT Y
I
1
C H EC K LAM P
r
11
I
1I
GOOD
BAD
Check lamp
ground continuity
Replace lamp
C O N T IN U IT Y
N O C O N T IN U IT Y
11
11
6D-30
ENGINE ELECTRICAL
NO CONTINUITY
Replace probe
CONTINUITY
0 VOLTS
I
(Measure the voltage
at module connector cavity F.
12 VOLTS
I
Turn ignition O F F ,
remove the module.
Turn ignition O N ,
Check voltage at cavity
F of the connector
CONTINUITY
12 VOLTS
Turn ignition O F F .
Remove the module.
Check continuity from
module connector
cavity C to ground.
505 circuit is
shorted to batt. plus
in the harness.
Repair as necessary
LAMP ON
LAMP OFF
Bad alternator
lamp or circuit 25
open from lamp
to alternator
Disconnect the tw o
terminal connector from
the alternator and check
the voltage of the 25 circuit
in the connector.
NO CONTINUITY
_________ L
---------- I
0 VOLTS
12 VOLTS
CONTINUITY
25 circuit is shorted
to ground in the harness.
Repair short.
Repair alternator
NO CONTINUITY
I
503 circuit is open
between the probe and
the glow plugs.
Repair as necessary.
ENGINE ELECTRICAL
6D-31
at m odule cavity L.
0 VOLTS
Turn ignition O F F .
Rem ove the module.
Check for con tinu ity to
ground from m odule
connector cavity L.
12 VOLTS
r J_______
I.
12 VOLTS
12 VOLTS
4 to 10 O H M S
10 to 20 O H M S
0 VOLTS
Turn Ign. off.
Reconnect the probe. Check
resistance to ground from
m odule connector cavity L
NO
Replace probe
OPEN
CONTINUITY
Repair
501 circuit
Replace
M odule
YES
CONTINUITY
Repair short to
ground in 506 circuit
harness
I
Replace the probe
NO CO N TINU ITY
CONTINUITY
OPEN CIRCUIT
OPEN CIRCUIT
NO CONTINUITY
6D-32
ENGINE ELECTRICAL
JUNCTION
BLOCK ASM
,W /S WIPER
MOTOR ASM
TEMP SENDER
Engine
I NOTE 1 For remainder of harness
routing see sheet 12H-17.
T A IL COMB
LP EXT ASM
BATTERY
CABLE
BRACE
FW D LA M P
HARNESS ASM
SENDER OR
SWITCH
GENERATOR
ASM &C60
/!J
GLOW
PLUG
VIEW C
VIEW B
TRANSMISSION
ASM
STARTER
Engine
ENGINE W IRING
HARNESS ASM
SOLENOID
Engine
FAST IDLE SOLENOID
TEMP CONTROL
SWITCH-Engine
GLOW PLUG W IR IN G
HARNESS ASM
SOLENOID
GENERATOR
ASM exc C60
VIEW E
ENGINE ELECTRICAL
6D-33
Distributor..................................................................... 6D-39
Vacuum Advance U nit............................................... ...6D-39
Integral Ignition C o il................................................. ...6D-40
Module.............................................................................. 6D-41
Pick-up C oil..................................................................... 6D-41
Set Ignition Tim ing............................................................ 6D-43
Spark Plug W ires............................................................... 6D-43
GENERAL DESCRIPTION
The ignition circuit consists of the battery, the distrib
utor, the ignition switch, the spark plugs, and the primary
and secondary wiring. Refer to the Battery portion of this
section for battery information.
H.E.l. DISTRIBUTOR
IGNITION TIMING
Timing specifications for each engine are
Section 6E and on the Vehicle Emissions Control
tion label on the radiator support. When using
light, connect an adapter between the No. 1 spark
GROUND
TERMINAL
listed in
Informa
a timing
plug and
BAT. TERMINAL
(CONNECTED TO
IGNITION SWITCH)
/
LATCH (4)
CONNECT TACHOMETER
FROM THIS TERMINAL
TO GROUND.
TACH TERMINAL
CONNECTOR
C-TERMINAL
(SOME TACHOMETERS
MUST CONNECT FROM
THIS TERMINAL TO
ENERGIZER POSITIVE ( + ).
CONSULT TACHOMETER
MANUFACTURER.)
6D-34
ENGINE ELECTRICAL
SECONDARY WIRING
The spark plug wiring used with the HEI system is a
carbon impregnated cord conductor encased in an 8mm
diameter silicone rubber jacket. The silicone wiring will
withstand very high temperatures and also provides an
excellent insulator for the higher voltage of the HEI system.
The silicone spark plug boots form a tight seal on the plug
and the boot should be twisted 1/2 turn before removing.
Care should also be exercised when connecting a timing
light or other pick-up equipment. Do not force contacts
between the boot and wiring or through the silicone jacket.
Connections should be made in parallel using an adapter.
DO NOT pull on the wire to remove. Pull on the boot, or use
a tool designed for this purpose.
LIGHT TRUCK SERVICE MANUAL
ENGINE ELECTRICAL
6D-35
IGNITION SWITCH
1
R T V
1
2
3
4
5 -
S X~
DIAGNOSIS
H.E.I. DISTRIBUTOR
Use Figure 6D-21D and 22D for H.E.I. Diagnosis.
SPARK PLUGS
Worn or dirty plugs may give satisfactory operation at
idling speed, but under operating conditions they frequently
fail. Faulty plugs are indicated in a number of ways: poor
fuel economy, power loss, loss of speed, hard starting and
general poor engine performance.
Spark plug failure, in addition to normal wear, may be
due to carbon fouled plugs, excessive gap or broken
insulator.
Fouled plugs may be indicated by checking for black
carbon deposits. The black deposits are usually the result of
slow-speed driving and short runs where sufficient engine
operating temperature is seldom reached. Worn pistons,
rings, faulty ignition, over-rich carburetion and spark plugs
which are too cold will also result in carbon deposits.
Excessive gap wear, on plugs of low mileage, usually
indicates the engine is operating at high speeds or loads that
are consistently greater than normal or that a plug which is
too hot is being used. In addition, electrode wear may be the
6D-36
ENGINE ELECTRICAL
6741
ENGINE ELECTRICAL
6D-37
IN T E R M IT T E N T OPERATION OR MISS
REM O VE GREEN
AN D W H ITE LEADS
FRO M M O DULE
C35
CUT A SPARK
PLUG BOOT
AS SHOWN
(TO BAT +)
TEST LIG H T
DISCARD
CONNECT V O LT M E T E R ,
"T A C H " T E R M IN A L
TO G RO UND
7 /1 6 " (11mm)
FROM TIP OF
SPARK PLUG
VIEW B
INSERT BOOT
OVER
PORCELAIN
END OF ST-125
6742
6D-38
ENGINE ELECTRICAL
DETACH
LEADS
FROM
MODULE
OHMMETER OHMMETER
ON-VEHICLE SERVICE
H.E.I. DISTRIBUTOR
Service Precautions
ENGINE ELECTRICAL
6D-39
Distributor
INSTALLATION
To install, reverse removal procedure.
LIGHT TRUCK SERVICE MANUAL
6D-40
ENGINE ELECTRICAL
UNIT REPAIR
DISTRIBUTOR DISASSEMBLY
TEST AND REASSEMBLY
(COIL IN CAP)
TESTING IGNITION COIL
TER MINA LS
B+
ASSEMBLY
OHMMETER
4 -TE RM IN AL
CONNECTOR
CONNECTOR
(DISCONNECTED
FROM CAP)
OHMMETER
IG NITIO N
/
COIL
3. Turn four latches and remove cap and coil assembly from
lower housing.
GROUND
LEAD
COIL
SECONDARY
C- GRD. B+
T ER MINA LS
ENGINE ELECTRICAL
SEAL
GROUND
6D-41
D RI VI NG PIN FROM S HA F T
IG NITIO N
COIL
CONNECTOR
9.
Remove ignition coil attaching screws and lift coil with
leads from cap.
10. Remove ignition coil arc seal.
11. Clean with soft cloth and inspect cap for defects. Re
place, if needed.
12. Assemble new coil and cover to cap.
18. Mark distributor shaft and gear so they can be reassem
bled in same position.
TESTING PICKUP COIL
19. Drive out roll pin.
OHMMETER
OHMMETER
PICKUP COIL LEADS
DISCONNECTED
FROM MODULE
4-T E R M IN A L
CONNECTOR
S HA F T A S S E M B LY REMOV ED
THREE
ATTA CH IN G
SCREWS
M AGNETIC
IELD
MODULE
PICKUP COIL
ASSEMBLY
T E R M IN A L
PICKUP COIL
LEADS DIS
CONNECTED
FROM MODULE
6D-42
ENGINE ELECTRICAL
PICKUP COIL
PICKUP COIL
LEADS DIS
CONNECTED
MODULE
22.
Remove retaining ring and remove pickup coil, magnet
and pole piece.
ENGINE ELECTRICAL
6D-43
6 D -4 4
E N G IN E ELECTRICAL
C Y L #1
_^CYL #2
Sfer CYL #7
j P ' ^ ' C Y L #5
F I L T E R ASM
r~POWER U N IT
F I L T E R ASM
V IE W -A
POWER U N I T
CYL #1
CYL^#3
CYL #5
V IE W
ENGINE ELECTRICAL
6D-45
IGNITION SWITCH
GENERAL DESCRIPTION
The electrical switching portion of the assembly is
separate from the key and lock cylinder. However, both are
synchronized and work in conjunction with each other
through the action of the actuator rod assembly. For a
complete explanation of the key and lock cylinder, and the
actuator rod assembly, refer to the Steering section of this
manual.
The ignition switch is key operated through the actua
tor rod assembly to close the ignition primary circuit and to
energize the starting motor solenoid for cranking. The
ignition switch used on all cars have five positions: OFF,
LOCK, A C C E S S O R Y , R U N and ST A R T . O F F is the
center position of the key-lock cylinder, and LOCK is the
next position to the left. A C C E S S O R Y is located one more
detent to the left of LOCK. Turning the key to the right of
the O F F position until spring pressure is felt will put the
ignition switch in the R U N position, and when turned fully
to the right against spring pressure, the switch will be in the
S T A R T position.
All ignition switches have five terminals which are
connected in different combinations for each of the three
operating positions. A brass plate, inside the switch, has
three contacts which connect these terminals. Figure 6D31D shows the positions of the contacts in all positions as
viewed from the key side of the switch. There is also a
ground pin in the switch which contacts the "ground"
terminal when the ignition switch is in the S T A R T position.
This pin contacts the IG N. terminal when in the O F F
position.
6D-46
ENGINE ELECTRICAL
12 R
12P P L / W
r\
I
SOL
L
BAT 2
1 BAT 1
12 ORN
IGN 1
---------
12 P
24 B R N / W
12 B R N
_GRD-1
20 D G
|0 D -2 l.g ^ 3 |
IG N ITIO N
SWITCH
(VIEW FROM TERMINAL
POSITIONS
SIDE OF SWITCH)
OFF
POSITION
ACC
IGN-3
IGN-3
BAT-3
so l
.
BAT-1 J
fORD-2\
LOCK
POSITION
ACC
IGN-3
SOL Q
BAT-2
UIGNU
RUN
POSITION
I/P HARN
A .I.R . ELBOW
H .E .I DISTRIBUTOR
Engine
GRD
ENGINE
ELECTRICAL
6 D -4 7
6D-48
ENGINE ELECTRICAL
ENGINE
6 D -4 9
TH IS DIAG NO SIS SHOULD BE INSERTED W ITH OR IM M E D IA TE LY AFTER ITEM a. (FAULTY IGNITION SYSTEM )
OF THE ENGINE DETO NATIO N SECTION ON PAGE 6A-7 OF THE 1980 LIGHT D U TY T R U C K SERVICE MANUAL
ELECTRICAL
6D-50
ENGINE
ELECTRICAL
T H IS DIAG NO SIS SHO ULD BE INSERTED IM M EDIATELY AFTER ITEM b. (IGNITION TIM IN G ) OF THE ENGINE
HAS LO W PO W ER SECTION ON PAGE 6A-3 OF THE 1980 LIG HT DUTY TRUCK SERVICE M ANUAL.
6D -51
6D-52
ENGINE ELECTRICAL
K
J
H
G
F
E
ESC
CO NTROLLER
D
C
B
- A
GRND
DELAY
LO
HI
BAT.
BROWN
BLACK
WHITE
GREEN
PINK/BLK
SENSOR
SHIELD
PINK
> C
> B
>
BROWN
>
BLACK
> A >
D >
GREEN
>
WHITE
BROWN
BLACK
WHITE
GREEN
ENGINE ELECTRICAL
6D-53
CRANKING SYSTEM
General Description.............................................................6D-53
Cranking C i r c u i t...............................................................6D-53
Starter M o t o r ................................................................... .6D-53
Diagnosis............................................................................... .6D-56
On-Vehicle Service............................................................ .6D-60
Remove and Replace........................................................6D-60
S ta r te r ................................ .............................................. .6D-60
GENERAL DESCRIPTION
CRANKING CIRCUIT
The cranking circuit consists of the battery, staring
motor, ignition switch, and related electrical wiring. These
components are connected electrically as shown in Figure
6D-1E. Only the starting motor will be covered in this
portion.
STARTING MOTOR
Two types of starter motors are used. The first, referred
to as the 10MT series, is shown in Fig. 6D-2E. The second
type, referred to as the 20MT series used on diesel equipped
engines, is shown in Fig. 6D-3E. The main difference is that
the 2 0 M T has a center bearing. Fig. 6D -4E shows an
exploded view of the 20M T series. Differences in service
procedures will be pointed out as they occur.
6D-54
ENGINE ELECTRICAL
SOLENOID
SWITCH
TERMINAL
PLUNGER
RETURN
SPRING
SHIFT
LEVER
BUSHING
PINION
STOP
INSULATED
BRUSH
HOLDER
BRUSH
RISER BARS
TO RISER BARS
TO ARMATURE
OVERRUNNING
CLUTCH
ENGINE ELECTRICAL
SOLENOID
SWITCH
TERMINAL
PLUNGER
6D-55
RETURN
SPRING
SHIFT
LEVER
BUSHING
PINION
STOP
INSULATED
BRUSH
HOLDER
BRUSH
RISER BARS
CONDUCTORS
TO RISER BARS
TO ARMATURE
OVERRUNNING
CLUTCH
6D-56
ENGINE ELECTRICAL
PLUNGER
D R IV E GEAR
HOUSING
RETURN
SPRING
SO LENOID
COM M UTATO R
END FRAME
T U P I I QT
WASHER
RETA IN ER
SNAP
RING
FIBER
WASHER
F IE LD FRAME
WASHER
CLUTCH AND
D R IV E ASM.
CENTER
BEARING
AR M A TU R E
DIAGNOSIS
Before removing any unit in a cranking circuit for
repair, the following checks should be mad?:
Battery:
ENGINE ELECTRICAL
PROBLEM
6D-57
CAUSE
1.
2.
3.
4.
6D-58
ENGINE ELECTRICAL
V8 ENGINE
SHIELD
BRACE
LF9 ENGINE
STARTER MOTOR
ENGINE ELECTRICAL
Motor:
6D-59
6D-60
ENGINE ELECTRICAL
S" TERMINAL
SOLENOID
GROUND
1 2-VOLT
BATTERY
Fig. 6D-9E--No Load Test Hook Up
ON-VEHICLE SERVICE
Starting motors do not require lubrication except
during overhaul.
W hen the motor is disassembled for any reason,
lubricate as follows:
1. The arm ature shaft and drive end and commutator end
bushings should be coated with no. 1960954 lubricant
or equivalent.
2. The roll type overrunning clutch requires no lubrica
tion. However, the drive assembly should be wiped
clean. Do not clean in any degreasing tank or with
grease dissolving solvents; this will dissolve the lubri
cant in the clutch mechanism. Use silicon grease
General Electric CG321, Dow Corning 33 Medium or
equivalent, on the shaft underneath the overrunning
clutch assembly.
ENGINE ELECTRICAL
6D-61
UNIT REPAIR
With the starter motor removed from the engine, the pinion
should be checked for freedom of operation by turning it on the
screw shaft. The armature should be checked for freedom of
rotation by prying the pinion with a screwdriver. If the armature
does not turn freely, the motor should be disassembled im
mediately. However, if the armature does rotate freely, the
motor should be given a no-load test before disassembly.
Make connections as shown. Close the switch and compare
the RPM, current, and voltage readings with the specifications
. If the specified current draw does not include
the solenoid, deduct from the ammeter reading the specified
current draw of the solenoid hold-in winding. Make disconnec
tions only with the switch open. Use the test results as follows:
1. Rated current draw and no-load speed indicates normal
condition of the starter motor.
2. Low free speed and high current draw indicates:
6D-62
ENGINE ELECTRICAL
S TA R T E R DI SASSEMBLY
DRIVE GEAR
RETURN
PLUNGER
HOUSING
SOLENOID
SPRING
END FRAME
INSULATOR
COMMUTATOR
END FRAME
THRUST
WASHER
RETAINER
FIBER
WASHER
FIELD FRAME
SNAP RING
WASHER
CENTER
CLUTCH AND
D RIVE ASM.
ARMA TUR E
BEARING
SHIFT LEVER
PIVOT BOLT
ROLL
PIN
PLUNGER
^ m hm ^
FIBER
^ A R MATURE
S H A FT
^W ASHER
THRUST
WASHER
RETAINER
RETURN
SPRING
SHIFT
CENTER/
BEARING
LEVER
D RIVE GEAR
HOUSING
CLUTCH AND D R IV E
ASSEMBLY
snap
RING
ENGINE ELECTRICAL
6D-63
REPLACE BR US H HOLDER
(SMALL 5MT S T A R TE R )
( S T A N D A R D S T AR TE R )
PIVOT P I N - ^ O
INTEGRAL
BRUSH
BRUSH HOLDER
FIELD FRAME
(INSULATED)
ASSEMBLY
BRUSH
SUPPORT
BRUSH H O L D E R V V
(G R O U N D E D )W
\
J BRUSH HOLDER
SPRING
14.
lows:
ROUTE WIRE
BRUSH HOLDER
AS SHOWN
SUPPORT
CLEANING INSPECTION
AND TESTS
TESTING S H U N T COIL FOR OPEN
TO TEST
LIG HT
GROUNDED
BRUSH
6D-64
ENGINE ELECTRICAL
SERIES COIL
CONNECTION
IN SULATED
BRUSH
c.
Using a test lamp, place one lead on the series coil ter
minal and the other lead on the insulated brush. If the lamp
fails to light, the series coil is open and will require repair or
replacement. This test should be made from each insulated
brush to check brush and lead continuity.
TESTING SE RI ES COIL FOR G R O U N D
THESE TWO T ER M IN A L S
MUST BE SEPARATED
AND NOT TOUCHIN G A
GROUND D URIN G TEST
INSULATED
BRUSH
GROUNDED
BRUSH HOLDER
e.
Check the current draw of the solenoid winding as fol
lows:
If solenoid is not removed from starting motor, the connec
tor strap terminals must be removed from the terminal on the
solenoid before making these tests. Complete tests in a
minimum of time to prevent overheating of the solenoid.
To check hold-in winding, connect an ammeter in series
with 12-volt battery and the switch terminal on the solenoid.
Connect a voltmeter to the switch terminal and to ground.
Connect carbon pile across battery. Adjust the voltage to 10
volts and note the ammeter reading. It should be 14.5 to 16.5
amperes for all starting motors.
To check both windings, connect as for previous test
Ground the solenoid motor terminal. Adjust the voltage to 10
volts and note the ammeter reading. It should be 41 to 47 am
peres for all starting motors.
NOTE: Current will decrease as windings heat up.
Current draw readings that are over specifications indicate
shorted turns or a ground in the windings of the solenoid and the
solenoid should be replaced. Current draw readings that are
under specifications indicate excessive resistance. No reading
indicates an open circuit. Check connections then replace sole
noid if necessary.
d.
On starters with shunt coil, separtate series and shunt
coil strap terminals during this test. Do not let strap terminals
touch case or other ground. Using a test lamp place one lead
on the grounded brush holder and the other lead on either
insulated brush. If the lamp lights, a grounded series coil is
indicated and must be repaired or replaced.
Fig. 6D -12E --Starter Unit Repair 4 of 6
E N G IN E ELECTRICAL
6 D -6 5
STARTER ASSEMBLY
I NSTALLING R E T A I N E R , WASHER A N D RING
6D-66
ENGINE ELECTRICAL
CHECKING PINION C LE A R AN CE
PRESS ON C L U T C H TO
R E M O V E S LA C K
\v
P IN IO N
,
R E T A IN E R
010
FEELER^
to .1 4 0 '
P IN IO N
CLEARAN CE
J
When the starter motor has been disassembled or the sole
noid has been replaced, it is necessary to check the pinion
clearance. Pinion clearance must be correct to prevent the but
tons on the shift lever yoke from rubbing on the clutch collar
during cranking.
31. Disconnect the motor field coil connector from the sole
noid motor terminal and insulate it carefully.
32. Connect one 12 volt battery lead to the solenoid switch
terminal and the other to the starter frame.
33. Flash a jumper lead momentarily from the solenoid motor
terminal to the starter frame. This will shift the pinion into
cranking position and it will remain so until the battery is dis
connected.
34. Push the pinion back as far as possible to take up any
movement, and check the clearance with a feeler gage. The
clearance should be .010" to .140".
Means for adjusting pinion clearance is not provided on the
starter motor. If the clearance does not fall within limits, check
for improper installation and replace all worn parts.
G AG E
ENGINE ELECTRICAL
6D-67
SPECIFICATIONS
GENERATOR
MODEL N O .
APPLICATION
1102394
1102491
(Except G -2 0 , 30 &
1102889
FIELD CURRENT
COLD OUTPUT*
AMPS @
@ 12 VOLTS
5000 RMP
4519
4 -4 .5
33
37
4521
4 -4 .5
38
42
4522
4 -4 .5
57
61
4525
4 -4 .5
76
80
DELCO REMY
SPEC. N O .
RATED HOT
O U T P U T ** AMPS
P-Truck)
All C-K -G Truck Base V-8
(Except K31303 &
G 30003)
1102485
1102841
1102887
All P-Truck Base V-8
(Except P31832)
1102480
1102486
1102886
1102888
454 V-8 (FL8) (Base)
K31303 & G 30003
Truck Base V-8
1101016
1101028
^G enerator tem perature approxim ately 27C. (80F.).
**A m b ien t tem perature 27C. (80F.).
Note: The only difference between generators within each group above is the position end fram e is rotated.
6D-68
ENGINE ELECTRICAL
SPECIFICATIONS
DISTRIBUTOR & SPARK PLUGS
Distributor and spark plug specifications are shown in the Emission Control Chart in Section 6E Specifications.
BATTERY
MODEL N O .
85-4
85-5
AMPS FOR
25 AMP. RESERVE
@ 0F (-18C)
LOAD TEST
CAPACITY (MINUTES)
275 Amps
130
60
350 Amps
170
80
465 Amps
230
125
43 0 Amps
210
100
APPLICATION
87-5
RPO TP2
STARTING MOTOR
MODEL N O .
1108778
APPLICATION
250 L-6 (LD4)
SPEC. N O .
FREE SPEED
VOLTS
AMPERES
RPM
3573
5 0 -8 0 *
5 5 00 -105 00
(C & K-10)
1108779
3573
5 0 -8 0 *
5 5 0 0 -105 00
1108780
2438
5 0 -8 0 *
3 5 00 -600 0
1109056
3573
5 0 -8 0 *
55 00 -105 00
1109798
3573
5 0 -8 0 *
5 5 0 0 -105 00
1109052
3563
6 5 -9 5 *
7500-10500
1108776
400 V -8 (LF4)
3563
6 5 -9 5 *
7500-10500
454 V -8 (LF8)
^Includes Solenoid
6E-1
SECTION 6E
6E-1
6E-1
6E-1
6E-1
6E-2
6E-2
6E-3
6E-3
6E-4
6E-4
6E-4
6E-4
6E-5
GENERAL DESCRIPTION
POSITIVE CRANKCASE VENTILATION (PCV)
SYSTEM
All engines have closed Positive Crankcase Ventilation
System to provide more complete scavenging of crankcase
vapors (Fig. 6E-1).
Ventilation air is drawn from the dirty air side of the air
cleaner, through a hose, down into the crankcase, up
through the ventilator valve, through a hose and into the
intake manifold. Intake manifold vacuum draws any fumes
from the crankcase to be burned in the engine.
Diagnosis and service procedures for the PCV system
can be found in this section.
6E-2
6E-3
N O R M A L F LO W SHOW N B Y B L A C K A R R O W S :
BY-PASS C O N D IT IO N S SHOW N BY CROSS H A T C H E D A R R O W S
TUBE ASSEM BLY
HOSE
CHECK V A L V E
A IR IN
IN JE C T IO N
TUBE
H IG H SPEED
BY-PASS
A IR PUMP
E X H A U S T PO RT
D E C E L E R A T IO N
BY-PASS
D IV E R T E R
VALVE
M A N IF O L D V A C U U M
SO URCE
Fig. 6E-4--AIR System
CARBURETOR CALIBRATION
While the carburetors main function is to provide the
engine with a combustible air/fuel mixture, the carburetor
calibration is critical to maintaining proper emission levels.
The carburetors idle, off-idle, main metering, power
enrichment, and accelerating pump systems are calibrated
to provide the best possible combination of engine perform
ance, fuel economy and exhaust emission control. C a r
buretor adjustments and service must be performed using
the recommended procedures to insure engine exhaust
emission levels remain within offical limits.
See Section 6C, Engine Fuel, for carburetor adjust
ment specifications and recommended service procedures.
6E-4
DISTRIBUTOR CALIBRATION
CATALYTIC CONVERTER
DIAGNOSIS
PCV SYSTEM DIAGNOSIS
C O N D IT IO N
POSSIBLE CAUSE
CORRECTION
Valve completely
plugged or stuck.
Replace valve.
Restricted filter
Replace valve.
Oil in a ir cleaner.
^
Fig. 6E-5--PCV System Diagnosis
. t **!1fli
J-Sx* * TO1*
6E-5
EGR DIAGNOSIS
CONDITION
Engine idles abnormally rough
and/or stalls.
POSSIBLE CAUSE
EGR valve vacuum hoses
misrouted.
Torque valve.
Failed EGR-TVS
(TVS open below 130F.)
EGR-TVS.
Improper vacuum to EGR valve
at idle.
CORRECTION
6E-6
CONDITION
Excessive belt noise.
POSSIBLE CAUSE
CORRECTION
1. Loose belt.
1. Tighten to spec.
2. Seized pump.
2. Replace pump.
Insufficient break-in.
1. Leak in hose.
2. Loose hose.
7. Pump failure.
7. Replace pump.
6E-7
POSSIBLE CAUSE
CORRECTION
1. Tighten to specs.
3. Leak atfitting(s).
3. Tighten or replace
clamps.
4. If air is expelled
through diverter m uffler
w ith vehicle at idle,
replace diverter valve.
7. Replace pressure
relief plug.
Mechanical damage.
Replace centrifugal
filte r fan.
Mechanical damage.
Do not replace
A.I.R. pump.
6E-8
POSSIBLE CAUSES
EXPLANATION
Hydrocarbons
(HC) *
Excessive hydrocarbons
are caused by an air
fuel m ixture that is
not burning completely.
Carbon m onox
ide (CO) *
Oxides of
nitrogen
(NOx )
Excessive oxides o f
nitrogen are generally
due to high tempera
tures in the combustion
chamber.
Obstructed/leaking/misrouted vacuum
lines.
Faulty EGR temperature sensor controls.
Improper operation o f the EGR system.
Incorrect EGR valve fo r engine type.
Plugged EGR passages.
Inoperative Thermae.
Maladjusted initial spark tim ing.
Improper operation o f d istrib u to r centrifugal
or vacuum spark advance.
Excessive emissions o f both hydrocarbons and carbon monoxide are related to an extrem ely rich air/fuel
m ixture. A rich air/fuel m ixture increases CO emissions, but if the m ixture is too rich, it w ill not burn
completely. This unburned fuel contributes to high hydrocarbon emissions. Check fo r possible causes
as stated in the HC and CO section. Check co-related causes first.
6E-9
ON-VEHICLE SERVICE
POSITIVE CRANKCASE VENTILATION
An engine which is operated without any crankcase
ventilation can be dam ag ed seriously. Therefore, it is
important to replace the PCV valve at intervals shown in
Section OB.
If an engine is idling too slow or rough, this
may be caused by a clogged ventilator valve or plugged
hose; therefore, never adjust the carburetor idle with
out first checking the PCV valve and hose.
NOTICE:
Removal
1. Remove PCV valve from intake manifold or rocker arm
shaft cover.
2. Run the engine at idle.
3. Place your th u m b over end of valve to check for
vacuum. If there is no vacuum at valve, check for
6E-10
CO N TR O L V A LVE
OPEN
ORIFICE O P E N IN G
.0 3 0
(SEE O P T IO N A L C O N S T R U C T IO N )
TRANSDUCER
V A C U U M S IG N A L
D IA P H R A G M
TUBE
PLATE
O P T IO N A L
C O N S T R U C T IO N
ORIFICE O P E N IN G
.020
EXHAUST
I EXHAUST GAS
G A S (IN )
6E-11
ID E N T IF Y P O S IT IV E EGR V A L V E
B Y D IA P H R A G M P L A T E D ESIG N
D IA P H R A G M P L A T E A S S E M B L Y
N E G A TI V E BACK P R ES SU R E EGR V A L V E
NOTE:
ID E N T IF Y N E G A T IV E EGR V A L V E
B Y D IA P H R A G M P L A T E D E S IG N
D IA P H R A G M P L A T E A S S E M B L Y
6E-12
Functional Checks
Checking N e g a tiv e Backpressure EGR V alv e
6E-13
6E-14
6E-15
Replacem ent
1.
2.
3.
4.
5.
Inspection
Accelerate engine to approximately 1500 R P M and
observe air flow from hose(s). If air flow increases as engine
is accelerated, pump is operating satisfactorily. If air flow
does not increase or is not present, proceed as follows:
1. Check for proper drive belt tension.
The A IR system is not completely noiseless. Under
normal conditions, noise rises in pitch as engine speed
increases. To determine if excessive noise is the fault of
the system, operate the engine with the pump drive belt
removed. If excessive noise does not exist with the belt
removed, proceed as follows:
2. Check for a seized Air Injection Pump Do not oil pump.
LIGHT TRUCK SERVICE MANUAL
6E-16
6E-17
s i,
6E-18
PIPE ASSY
CHECK VALV
EXTENSION
PIPE ASSY
EXTENSION
Check Valve
Inspection
1.
2.
3.
4.
Installation
1.
2.
3.
4.
6E-19
6E-20
R eplacem ent
6E-21
PLENUM PIP
GROMMETS
CHECK V A L V E ASM.
TORQUE TO 23 N-m (17 FT. LBS.)
PLENUM
PLENUM
CONNECTING
PIPE
6E-22
6E-23
2. Remove element.
7. Dip band into light engine oil and squeeze out excess
oil.
8. Install band around outer surface of new paper
element.
9. Install element in bottom section of air cleaner with
either end up.
10. Install air cleaner cover. Do not over-torque wing
nut(s).
Temperature Sensor
Removal
6E-24
TEMPERATURE SENSOR*
VACUUM DIAPHRAGM
MOTOR
DIAPHRAGM
SNORKEL
VACUUM HOSES
INLET-
DIAPHRAGM
DAMPER DOOR
HOT AIR DUCT
HOT AIR
TEMPERATURE SENSOR
MOTOR
REGULATING MOD E
6E-25
RETAINING
STRAP
INSTALL REPLACEMENT
SENSOR ASSM. IN SAME
POSITION AS ORIGINAL ASSMJ
Fig. 6E-37--Vacuum M o to r
6E-26
EX TE N D E D POSITION
(WHEN V A C U U M IS AP PLIED )
P R IM A R Y T H R O T T L E
LEVER
T H R O T T L E LEVER
ACTUATOR
M A N IF O L D V A C U U M
(V A L V E OPEN O N L Y )
ELECTRONIC
SPEED SENSO
V E N T TO ATM OSPHERE
\
SO LE N O ID
VACUUM
C O N TR O L
VALVE
E N G INE SPEED
S IG N A L FROM
D IS T R IB U T O R
HOSE
T R C S O L E N O ID
CONTROL
V A L V E ASM.
T H R O T T L E LE V E R A C T U A T O R
TRC S O LE N O ID
CO NTRO L
V A L V E ASM.
THRO TTLE V A LV E
ACTUATOR
A C C E LE R A T O R
SUPPORT
HOSE
VACUUM
F IT T IN G
6E-27
General Description
On heavy duty emission engines a check valve with an
internal beed is installed between the Trapped Vacuum
S park check valve and the distributor. W hen manifold
vacuum increases it opens the check valve which allows the
distributor vacuum to increase to the same level. Decreasing
manifold vacuum, as during vehicle acceleration; closes the
check valve and the distributor vacuum will decrease at a
rate controlled by the internal bleed.
DETONATION SENSOR
Replacement
The Detonation Sensor is an integral part of the
6E-28
AD JU STM EN T
PROCEDURE
S O I. H R
r 181 4 mAN A
1040 8
CATALYST
RMATION
G C N ER A l M O TO R S (O R P O P ,
E N G IN E A D J U S T M E N T
S P E C IF IC A T IO N S
TRANSMISSION
E M IS S IO N HO SC
R O U T IN S
r W HERE
1 EQUIPPE
AIK flPEGR/UC
IO W AlTITUOE ( ERIIFKATION
S IT P A R K IN G B K A K l A N D H O C K D K IV t W M fflS
AAR
CONTROLS
Fig. 6E-42--Vehicle
AAR
ENGINE EMISSION
LABEL CODE
E N G IN E S IZ E
E X H A U S T E M IS S IO N F A M IL Y
E V A P O R A T IV E E M IS S IO N F A M IL Y
A IR CLEANER
700 (N)
(SOLENOIO INACTIVE)
I
DISTRIBUTOR
O i l SP IE D SCREW
SPECIFIED ENGINI SP IE D
(SOLENOID ACTIVE)
DISCONNECT ELECTRICAL IEAD (ROM KHE SOLENOIO * EQUIPPED
ADJUST
f N O T! ]
THIS V IH IC ll CONFORMS TO U S
STOP ENGINE.
EPA REGULATIONS APPLICABLE TO 1911 MODEL YEAR NEW LIGHT DUTY TRUCKS
P I NO 14076117
Label
LABEL
PART NUMBER
E M IS S IO N C O M P O N E N T
A N D V A C U U M H O S E S C H E M A T IC
6F-1
SECTION 6F
ENGINE E X H A U S T S Y S T E M
G E N E R A L D E SC R IP T IO N
'ssntsjm oaskjafr j
ju
CATALYTIC CONVERTER
The catalytic converter is an emission control device
added to the exhaust system to reduce hydrocarbon and car
bon monoxide pollutants from the exhaust gas stream (Figs.
6F-1 & 6F-2).
THE CATALYTIC CONVERTER REQUIRES THE USE
OF UNLEADED FUEL ONLY.
Periodic maintenance of the exhaust system is not re
quired; however, if the vehicle is raised for other service, it is
advisable to check the general condition of the catalytic con
verter, pipes and muffler(s).
The catalyst in monolith converters is not serviceable.
The catalyst in bead type converters can be replaced, on
vehicle, using tool # J-29132 or off vehicle by removing the
converter or the exhaust system.
CO NVERT ER SHELL
CONVERTER SHELL
MONOLITH
LIGHT TR U C K SER V IC E M A N U A L
6F-2
CONDITION
Leaking E xh a u st Gases
POSSIBLE CAUSE
Leaks at pipe joints.
CORRECTION
Tighten U -b o lt nuts at
leaking joints to 30 lb. ft.
(40 N - m ) .
as necessary.
extension connections.
as required.
Tighten c lam ps at leaking
E xh aust Noises
Leaks at m anifold
or pipe connections.
Replace m uffler
assembly.
Tighten attaching
bolts nuts to 17 lb. ft.
(23 N -m )
E xh a u st m anifold
cracked or broken.
Replace m an ifold.
Tighten m a n ifold to
cylinder head stud
nuts or bo lts to specifications.
baffles in m uffler.
Lo ss of engine power.
Replace m uffler.
LIGHT T R U C K SE R V IC E M A N U A L
6F-3
ON-VEHICLE S E R V IC E
1. Raise vehicle.
2. Remove converter.
3. Remove converter pressed fill plug by driving a small
chisel between the converter shell and the fill plug (Fig. 6F-5).
Continue to deform fill plug until it can be removed with pliers
(Fig. 6F-6).
4.
Holding converter over a container, empty catalyst
from converter by shaking until all beads are removed.
Installation (Off Vehicle)
LIGHT TR U C K SE R V IC E M A N U A L
6F-4
5.
(28 lb.
6.
7.
BOTTOM COVER
BRIDGE
LIGHT TR U C K SE R V IC E M A N U A L
6F-5
LIGHT TR U C K SE R V IC E M A N U A L
6F-6
LIGHT T R U C K SE R V IC E M A N U A L
6G-1
SECTION 6G
ENGINE AND
E M IS S IO N FAMILY
EM ISSIO N
LABEL
CODE
IGNITION
T IM IN G
B.T.D.C.
DEGREES
SPARK
PLUG
TYPE
& GAP
10
R45TS
(.035)
SOLENOID
SCREW
(RPM)
CURB
IDLE
(RPM)
FAST
IDLE
(RPM)
4501N)
750(N)
2000(N)
ACR
ACS
ACR
ACS
ACS
ADA
10
R46TS
(.035)
450 (N)
ACW
AWA
ACK
AWB
10
R46TS
(.035)
450 (N)
ACX
ADB
AFA
10
R46TS
(035)
ACT
AUU
ACU
10
ADC
AAC
DIST.
MODEL
VACUUM
MODEL
17081621
1110589
644
17081629
ill 1388
691
CARBURETOR
PART NUM BER
0 @3"
16 @ 6.5"
0 @ 3"
20 @ 7.5"
0 @ 1100
14 @ 2300
24 @ 4100
17081625
1110590
665
17081633
1110753
626
2000 (N)
17081623
17081627
1110589
644
0 @ 3"
16 @ 6.5"
0@ 1100
14 @ 2300
24 @ 4100
750 (N)
2000 (N)
17081721
1110749
626
0 @ 4"
10 @ 8"
0 @ 1100
7 @ 2300
16 @ 4200
450 (N|
750 (N)
2000 (N)
17081727 G10
17081725 G20, 30
1110749
626
0 @ 4"
10 @ 8"
0 @ 1100
7 @ 2300
16 @ 4200
R46TS
(.035)
450 (D)
650 (D)
2200
(P or N)
17081622
1110589
644
0 @ 3"
16 @ 6.5"
0 @ 1100
14 @ 2300
24 @ 4100
R46TS
(.035)
450(D)
650 ID)
700 (D) AAC
2200
(P or N)
17081624
17081626
1110589
644
0 @ 3"
16 @ 6.5"
0 @ 1100
14 @ 2300
24 @ 4100
ACY
AWC
ACZ
AWD
10
R46TS
(.035)
450 (D|
650 (D)
2200
(P or N)
17081720
1110749
626
0 @ 4"
10 @ 8"
0 @ 1100
7 @ 2300
16 @ 4200
ACZ
ADD
AFB
10
R46TS
(.035)
450 (D)
650 (0)
2200
IP or N)
17081726
1110749
626
0 @ 4"
10 @ 8"
0 @ 1100
7 @ 2300
16 @ 4200
ADF
ADM
ADH
R44T
(.035)
4501N)
7001N)
2400(N)
17081309
17081680
1110753
626
0 @ 4"
10 @ 8"
0 @ 1100
14 @ 2300
24 @4100
10
R46TS
(.035)
750 (N)
450 (N)
Fig.
t r -
2000 (N)
750 (N)
LABEL 800 (N) ADA
-f
0 @ 4"
15 @ 10"
1
0 @ 1100
14 @ 2300
24 @ 4100
LIG H T T R U C K SERVICE M A N U A L
6G-2
ENGINE AND
EMISSION FAMILY
IGNITION
TIMING
B.T.D.C.
DEGREES
EMISSION
LABEL
CODE
SPARK
PLUG
TYPE
& GAP
SOLENOID
SCREW
(RPM)
CURB
IOLE
(RPM)
FAST
IDLE
(RPM)
CARBURETOR
PART NUMBER
DIST.
MODEL
VACUUM
MODEL
R44T
. (.035)
450 (N)
700 (N)
2400 (N)
17081309
17081680
1110753
626
0 @ 4"
10 @ 8"
0C @ 1100
14c @ 2300
24 @ 4100
R45TS
(.045)
700 (N)
600 (N)
1300 (N)
17081143
17081145 w/AC
1103381
691
0 @ 3"
1 0 7 .5 "
0 @ 1200
8 @ 2000
20 @ 4200
AAA
8C
R45TS
(.045)
700 (N)
600 (N)
1300 (N)
17081101
17081103 w/AC
1103369
644
0 @ 3*'
16 @ 6.5"
0 @ 1200
8 @ 2000
20 @ 4200
AAB
R45TS
(.045)
600 (D)
500 (D)
1600
(P or N)
17081142
17081144 w/AC
1103381
691
0 @ 3"
10 @ 7.5"
0 @ 1200
8 @ 2000
20 @ 4200
AAF
R45TS
(0.45)
700 (N)
1300 INI
17081201
1103464
Elect
Spark
Control
AAM
AAR
4C
R45TS
(0.45)
700 (N)
1300 (N)
17081220
1103464
Elect
Spark
Control
AUS
4 .
R45TS
(.045)
600 (N)
1500 (N)
17081200
1103465
Elect
Spark
Control
AAJ
6C
R45TS
(.045)
700 (N)
1300 (N)
17081220
1103464
Elect
Spark
Control
AAH
4C
R45TS
(045)
500 (D)
1600
(PI or (N)
17081206 w/AC
17081205
1103464
Elect
Spark
Control
AAN
R45TS
(.045)
500 (D)
1600
(P) or <N>
17081227
17081226 w/AC
1103464
Elect
Spark
Control
ADF
ADM
ADH
AAA
'r
026
,
'
AAS
AAK
R45TS
(.045)
ACC
AWF
ACD
ACF
R45TS
(.045)
AAT
AAW
SOLENOID
SCREW
(RPM)
FAST
IDLE
(RPM)
CARBURETOR
PART NUMBER
DIST.
MODEL
VACUUM
MODEL
500 (D)
1600
(P) or (N)
17081227
17081226 w/AC
1103464
Elect
Spark
Control
550(D)
1800
(P) or (N)
17081526 w/AC
17081524
1103432
620
0 @ 4"
15 @ 12"
0 @ 1000
10 @ 2000
14 @ 4000
R45TS
(.045)
700 (N)
1300(N)
17081291
1103353
624
0 @ 4"
20 @ 10
0 @
12 @
16 @
22 @
1100
1600
2400
4600
R45TS
(.045)
700 (N)
1300(N)
17081291
1103353
624
0 @ 4"
20 @ 10
0 @
12 @
16 @
22 @
1100
1600
2400
4600
AAU
R45TS
(.045)
600 (D)
500 (D)
1600'
(P) or (N)
17081290
17081292 w/AC
1103353
624
0 @ 4"
20 @ 10"
AAK
R45TS
(.045)
600 (D)
500 (D)
1600
(P) or (N)
17081290
17081292 w/AC
1103353
624
0 @ 4"
20 @ 10"
0 @
12 @
16 @
22 @
1100
1600
2400
4600
AAZ
AAD
R45TS
(.045)
650 (D)
550 (D)
1800
(P) or (N)
17081506
17081508 w/AC
1103433
620
0 @ 4"
15 @ 12"
0 @
12 @
16 @
22 @
1100
1600
2400
4600
AAZ
R45TS
(.045)
650 (D)
550 (D)
1600
(P or N)
17081506
17081508 w/AC
1103433
620
0 @ 4"
15 @ 12"
AAD
8
1103339
626
0 @ 4"
10 @ 8"
0@
12 @
16 @
22 @
1100
1600
2400
4600
1103433
620
0 @
12 @
16 @
22 @
1100
1600
2400
4600
ENGINE AND
EMISSION FAMILY
ACA
ACB
R45TS
(.045)
650 (D)
650 (D)
VACUUM ADVANCE
(In Crank Degrees
@ Inches
of Vacuum)
CURB
IDLE
(RPM)
I i i i
IGNITION
TIMING
B.T.D.C.
DEGREES
EMISSION
LABEL
CODE
550 (D)
1800
(P or N)
17081506
17081508 w/AC
LIG H T T R U C K SERVIC E M A N U A L
0 @ 4"
15 @ 12"
DISTRIBUTOR
EMISSION
LABEL
CODE
IGNITION
TIMING
B.T.D.C.
DEGREES
SPARK
PLUG
TYPE
& GAP
ACJ
ACJ
ACM
SOLENOID
SCREW
(RPM)
CURB
IDLE
(RPM)
FAST
IDLE
(RPM)
CARBURETOR
PART NUMBER
R44T
(.045)
*1600
700 (N)
1900 (N)
17080213
1103375
620
0 @ 4"
10 @ 8"
0 @ 1150
17 @ 2900
22 @ 4200
R44T
(.045)
*1600
700 (N)
1900 (N)
17080298
1103375
620
0 @ 4
14 @ 8"
0@ 3"
16 @ 6.5"
0 @ 1150
17 @ 2900
22 @ 4200
ACK
R44T
(.045)
*1500
700 (N)
1900 (N)
17080507
1103420
681
0 @ 10
10 @ 13"
0 @ 1800
24 @ 4000
ACK
R44T
(.045)
*1500
700 (N)
1900 (N)
17080507
1103420
681
0 @ 10"
10 @ 13"
0 @ 1800
24 @ 4000
ACJ
ACM
R44T
(.045)
*1600
700 (N)
1900 (N)
17080213
1103375
626
0 @ 4"
10 @ 8"
0 @ 1150
17 @ 2900
22 @ 4200
ACK
R44T
(.045)
*1500
700 (N)
1900 (N)
17080513
1103420
681
0 @ 10"
10 @ 13"
0 @ 1800
24 @ 4000
ACJ
R44T
(.045)
*1600
700 (N)
1900 (N)
17080213
1103375
626
0 @ 4"
10 @ 8"
0 @ 1150
17 @ 2900
22 @ 4200
ACJ
ACM
R44T
(.045)
*1600
700 (N)
1900 (N)
17080298
1103375
681
0 @ 4"
10 @ 8"
0 @ 1150
17 @ 2900
22 @ 4200
ACK
R44T
(.045)
*1500
700 (N)
1900 (N)
17080513
1103420
681
0 @ 4"
15 @ 10"
0 @ 1000
17 @ 1600
22 @ 4200
ENGINE AND
EMISSION FAMILY
DIST.
MODEL
VACUUM
MODEL
(Crank
Degrees @
Engine RPM)
(In Crank
Degrees @
Inches of
Vacuum)
MECHANICAL
ADVANCE (Crank
Degrees @
Engine RPM)
681
0 @ 4 "
15 @ 10"
0 @ 1000
17 @ 1600
22 @ 4200
1103375
626
0 @ 4 "
14 @ 8
0 @ 1000
8 @ 1600
19 @ 3450
17080513
1103420
681
0 @ 4 "
15 @ 10"
0 @ 1000
17 @ 1600
22 @ 4200
1900 (N)
17080212
17080512
1103376
682
0 @ 8 "
10 @ 13
0 @ 1100
14 @ 2800
20 @ 4200
700 (N)
1900 (N)
17080212
17080512
1103376
682
0 @ 8 "
10 @ 13"
0 @ 1100
14 @ 2800
20 @ 4200
G LO W
PLUG
575 ID)
650 (D)
Mechanical
Fuel Injection
Injector
Pump
GLO W
PLUG
600 (D)
750 (D)
Mechanical
Fuel Injection
Injector
Pum p
EM ISSIO N
LABEL
CODE
SPARK
PLUG
TYPE
& GAP
AC K
AC J
ACM
SOLENOID
SCREW
(RPM)
CURB
IDLE
(RPM)
FAST
IDLE
(RPM)
CARBURETOR
PART NUMBER
DIST.
MODEL
VACUUM
MODEL
R44T
(.045)
*1500
700 (N)
1900 (N)
17080507
1103420
R44T
(.045)
*1600
700 (N)
1900 (N)
17080213
17080215
AC K
R44T
(.045)
*1500
700 (N)
1900 (N)
ADJ
AD K
R44T
(.045)
*1500
700 (N)
ADJ
AD K
R44T
(.045)
*1500
O JD
HKD
OHD
ENGINE AND
EMISSIO N FAMILY
IGNITION
TIMING
B.T.D.C.
DEGREES
6G -3
it
u. ,;>
' . tv
<
. f.
A U T O M A T IC TRAN SM IS S IO N
7A-1
SECTION 7 A
AUTOMATIC TRANSMISSION
CONTENTS
T o rq u e C o n v e rter C lutch (T C C )...................................7A-1
350 A utom atic T ra n sm issio n .......................................... 7A-8
400 A utom atic T ra n s m is s io n ......................................... 7A-29
S p e c ific a tio n s.......................................................................7A-47
T O R Q U E CO N V ER T ER CLUTCH (TCC)
INDEX
G eneral D escription..........................................................
C onverter Clutch D iagnosis............................................
Com plaints and Possible C auses...............................
Converter Clutch Applied In All Ranges...............
Converter Clutch Applies E rratically ......................
Converter Clutch Applies At All T im e s................
Internal C ontrols C h eck ................................................
Internal H ydraulic/M echanical Controls Check...
7A-1
7A-4
7A-4
7A-4
7A-5
7A-5
7A-5
7A -5
7A-6
7A-6
7A-6
7A-6
7A-7
7A-7
7A-7
G EN ER A L D E SC R IP T IO N
The torque converter clutch (as shown in Fig. 7A -la)
is an internal mechanism (with a friction material attached
to the front plate) splined to the turbine assembly, and when
operated applies against the converter cover. This provides
a mechanical direct drive coupling of the engine to the
planetary gears. By applying the converter clutch, slippage
is eliminated, resulting in improved fuel economy and
reduced fluid operating tem peratures.
The operation of the converter clutch is determined by
a series of controls, and by drive range selection (as shown
in Fig. 7A-2a and 2b). The converter clutch is applied in
direct drive and above a m inimum preset vehicle speed. At
wider throttle openings, where the 2-3 upshift occurs above
converter clutch apply, the apply o f the converter clutch will
occur immediately after the 2-3 shift. W hen vehicle speed
decreases or the transmission shifts out of direct drive, the
fluid pressure is released, the converter clutch is released,
and the converter operates in a conventional manner.
The apply or release of the converter clutch is
determ ined by the direction that converter feed oil is fed to
the converter. Converter feed oil from the pressure regulator
valve flows to the converter clutch apply valve. The position
LIGHT T R U C K SE R V IC E M A N U A L
7A-2
TURBINE
THRUST
SPACER
C O N V E R T E R H O US IN G
COVER ASS EM B LY
PRESSURE
PLATE
ASSEMBLY
CONVERTER PUMP
ASSEMBLY
LIGHT TR U C K SE R V IC E M A N U A L
A U T O M A T IC T R A N SM IS S IO N
7A-3
ENGINE
(OPENS IF COOLANT
TEMP. GREATER THAN 130F)
VACUUM SWITCH
(CLOSES VAC. AT 7 IN. HG.
OPENS VAC. AT 2.5 IN. HG.)
PASSENGER
COMPARTMENT
ENGINE HARNESS
TRANSMISSION
GOVERNOR OIL
PRESSURE
SWITCH
(CLOSES WHEN
VEHICLE SPEED
EXCEEDS 24 TO 30 MPH)
CONVERTER CLUTCH
SOLENOID
(CLUTCH IS
ENGAGED IN
3RD GEAR AND
SOLENOID IS
ENERGIZED)
LIGHT T R U C K SE R V IC E M A N U A L
7A-4
C O N V ER T ER CLUTCH D IA G N O S IS
If engine perform ance indicates an engine tune-up is
required, this should be performed, before road testing or
attem pting to diagnose the transmission. Poor engine
perform ance can result in rough shifting or other
malfunctions.
On 4 wheel drive vehicles equipped with a Torque
Converter C lutch (TCC). W hen the driver shifts from 2H
to 4L or 4H, the circuit to the TCC system is opened. A
light is provided on the instrum ent panel to indicate when
the vehicle is in 4 wheel drive. In this position (4L or 4H)
converter clutch will not apply. W hen the driver shifts back
to 2H, the TCC system should operate in a norm al manner.
IF the vehicle does not shift out of 4 wheel drive, the light
on the instrum ent panel (IP) will stay lit. The converter
clutch will not apply. Use the diagnosis listed below to
determ ine the problem.
3.
R oad test vehicle to verify com plaint at norm al
operating tem perature.
1.
Disconnect electrical connector at transm ission case
and test female connector for 12 volts using v olt/ohm meter
(2000 rpm in N eutral).
correct as
LIGHT TR U C K SE R V IC E M A N U A L
A U T O M A T IC TRAN SM IS S IO N
7A-5
INTERNAL HYDRAULIC/MECHANICAL
CONTROLS CHECK
Instructions to test governor for internal H yd rau lic/
M echanical Check.
7A-6
A U T O M A T IC TRANSM ISSIO N
A U TO M A TIC TR A N SM IS S IO N
7A-7
LIGHT TRU CK SE R V IC E M A N U A L
7A-8
350 A U T O M A T IC T R A N S M IS S IO N
INDEX
Road T e st..........................................................................
Trouble D iagnosis...........................................................
Clutch Apply C h a rt........................................................
Diagnosis C h a r t...............................................................
H ydraulic C ircuit.............................................................
On Vehicle Service.............................................................
Transmission Replacement (Except K M odels)......
Transm ission Replacem ent (K M odels).....................
Extension Housing Oil Seal........ ..................................
Speedometer Driven G e a r.............................................
Speedometer Drive G e a r ...............................................
M anual Shaft, Range Selector Inner Lever and
Parking L inkage..........................................................
G o v e rn o r...........................................................................
Vacuum M odulator and M odulator V alve...............
Valve Body A ssem bly.....................................................
1-2 A c c u m u la to r............................................................
Oil C o oler P i p e s ............................................................
7A -17
7A -17
7A-21
7A-22
7A-23, 24
7 A -25
7A-25
7A-25
7A-26
7A-26
7A-26
7A-27
7A-27
7A-28
7A-28
7A-28
7A-29
G EN ER A L D E SC R IP T IO N
The 350 transmission is a fully autom atic unit
consisting prim arily of a 3-element hydraulic torque
converter and two planetary gear sets. Four multiple-disc
clutches, two roller clutches, and an interm ediate overrun
band provide the friction elements required to obtain the
desired function of the two planetary gear sets.
The 3-element torque converter consists of a pump,
turbine and a stator assembly, with the addition of a
converter clutch. The stator is m ounted on a one way roller
clutch which will allow the stator to turn clockwise, but not
counterclockwise.
References
to
clockwise
and
counterclockwise are determ ined by looking toward rear of
vehicle.
The torque converter is of welded construction and is
serviced as a complete assembly. The unit is filled with oil
and is attached to the engine crankshaft by a flywheel, thus
always rotates at engine speed. The converter pum p is an
integral part of the converter housing, therefore, the pump
blades, rotating at engine speed, set the oil within the
converter into m otion and direct it to the turbine, causing
the turbine to rotate.
As the oil passes throughout the turbine it is traveling
in such a direction th at if it were not redirected by the stator
it would hit the rear of the converter pum p blades and
impede its pumping action. So at low turbine speeds, oil is
redirected by the stator to the converter pum p in such a
m anner that it actually assists the converter pum p to deliver
power, or multiply engine torque.
As turbine speed increases, the direction of oil leaving
the turbine changes and flows against the rear side of the
stator vanes in a clockwise direction. Since the stator is now
LIGHT T R U C K SE R V IC E M A N U A L
CONVERTER
ASSEMBLY
INTERMEDIATE
CLUTCH
INTERMEDIATE
BAND
7A-9
FORWARD
CLUTCH
LOW AND
REVERSE
CLUTCH
SUN
GEAR
OUTPUT
SHAFT
REACTION
CARRIER
GOVERNOR
AND REVERSE
OVERRUN ROLLER
INPUT
SHAFT
PARKING
PAWL
OUTPUT
CARRIER
STATOR
SHAFT
INTERMEDIATE
OVERRUN
ROLLER CLUTCH
MANUAL
SHAFT
M A IN T E N A N C E A N D A D J U S T M E N T S
TRANSMISSION FLUID
F luid Level an d C a p a c ity
7A-10
NOTICE:
overfilled.
A d d in g F luid to Fill D ry T ra n s m is s io n an d C o n v e rte r
A s s e m b ly
SHIFT CONTROLS
Column S h ift Linkage - CK and P Series
(Fig. 7A-3 and 4)
1. The shift tube and lever assembly must be free in
the mast jacket. See Section 3B for alignment of steering
column assembly if necessary.
2. To check for proper shift linkage adjustm ent, lift the
transmission selector lever towards the steering wheel.
Allow the selector lever to be positioned in D R IV E (D) by
the transm ission detent.
Do not use the indicator pointer as a reference to
position the selector lever. W hen performing linkage
adjustm ent, pointer is adjusted last.
7 A -1 1
7A-12
A U T O M A T IC TRAN SM ISSIO N
P. WASHER
GROMMET,
COLUMN SHIFT LEVER
BUSHING
CLAMP E
L. WASHER
NUT F
COLUMN ASSEMBLY
SWIVEL D
ROD A
TRANS
LEVER C
TRANSMISSION (7)
GROMMET
SHAFT ASSEMBLY B
LIGHT TR U C K SE R V IC E M A N U A L
A U T O M A T IC TRAN SM IS S IO N
7 A -1 3
TRANSMISSION
ASSEMBLY
I VIEW A
B RA CK ETENGINE
LEVER CARBURETOR
VIEW B
LIGHT TRU C K SE R V IC E M A N U A L
7A-14
AUTOMATIC TRANSMISSION
VIEW A
LOCK TAB
T.V./DETENT
CABLE
BRACKET
TERMINAL
VIEW B
LEVER ASSEMBLY
LIGHT T R U C K SE R V IC E M A N U A L
A U T O M A T IC TR A N SM IS S IO N
7 A -1 5
CABLE
T E R M IN A L
TO
CARBURETOR
3. O P E N C A R B U R E T O R L E V E R T O FU LL T H R O T T LE
S T O P P O S IT IO N TO A U T O M A T IC A L L Y A D JU S T
S L ID E R O N C A B L E TO C O R R E C T SET T IN G .
CAUTION
L O C K T A B M U S T NO T B E D E
P R E S S E D D U R IN G T H IS O P E R A T IO N .
4. R E L E A S E C A R B U R E T O R LE V E R .
D IA G N O S IS
DIAG NO SIS SEQUENCE
7A-16
A U T O M A T IC TRAN SM ISSIO N
7A -17
Fig. 7 A -8 ~ V a cu u m M o d u la to r A sse m b ly
7A-18
Low L1 Range
Position the selector lever in LI range and accelerate
the vehicle from 0 mph (0 k m /h). No upshift should occur
in this range.
COOLER O il TO
RADIATOR
1-2 CLUTCH
(INTERMEDIATE)
PRESSURE TAP
DETENT CONTROL
VALVE WIRE HOLE
...... *
2-3 CLUTCH
(DIRECT) PRESSURE TAP
W
4 m
Fig. 7 A -1 0 -P r e ss u r e T ap Lo cation s
M ANUAL LINKAGE
M anual linkage adjustm ent and the associated neutral
safety switch are im portant from a safety standpoint. The
neutral safety switch should be adjusted so that the engine
will start in the Park (P) and N eutral (N ) positions only.
W ith the selector lever in the PA R K (P ) position, the
parking pawl should freely engage and prevent the vehicle
from rolling. The pointer on the indicator quadrant should
line up properly with the range indicators in all ranges.
ROAD TEST
Drive Range
Position selector lever in D R IV E (D) range and
accelerate the vehicle from 0 m ph (0 km /h ). A 1-2 and 2-3
shift should occur at all throttle openings. (The shift points
will vary with the throttle opening). As the vehicle decreases
in speed to 0 m ph (0 k m /h ), the 3-2 and 2-1 shifts should
occur.
Low L2 Range
Position the selector lever in L2 range and accelerate
the vehicle from 0 m ph (0 km /h ). A 1-2 shift should occur
at all throttle openings. (No. 2-3 shift can be obtained in this
range). The 1-2 shift point will vary with throttle opening.
As the vehicle decreases in speed to 0 m ph (0 k m /h), a 2-1
shift should occur.
The 1-2 shift in IN T E R M E D IA T E (D ) range is
somewhat firm er than in D R IV E R A N G E . This is normal.
LIGHT T R U C K SE R V IC E M A N U A L
A U TO M A TIC TRAN SM IS S IO N
H ig h
or Low
O il
Pressure
(Refer to O IL PR ESSU R E C H EC K S)
High Line Pressure
Vacuum Leak:
a. Vacuum line disconnected.
b. Leak in line from engine to m oldulator.
c. Im proper engine vacuum.
d. Leak in vacuum -operated accessory (hoses, vacuum
advance, etc.).
M oldulator:
a. Stuck m odulator valve.
b. W ater in m odulator.
c. Damaged, not operating properly.
D etent System - detent valve or cable stuck in detent
position.
Valve Body:
a. Pressure regulator a n d /o r boost valve stuck.
b. Boost valve sleeve broken or defective.
c. Incorrect pressure regulator valve spring.
d. 2-3 shift control valve and sleeve installed in pressure
regulator bore.
e. Pressure regulator exhaust hole not drilled or
blocked.
Low Line Pressure
7A-19
No Pressure
No Upshift
G overnor valve stuck (chips).
1-2 shift control or shift valve stuck.
Nylon gear of governor assembly m utilated or
broken.
G overnor locating pin in case loose.
1-2 accum ulator piston ring omitted or broken.
Incorrect interm ediate clutch pack.
Interm ediate piston seals omitted or damaged.
G overnor inner weights jammed.
7A-20
A U T O M A T IC TRAN SM IS S IO N
Drive in Neutral
M anual Linkage - misadjusted, (correct alignment in
m anual lever shift quadrant is essential).
Internal Linkage - m anual valve disconnected or end
broken.
Oil Pum p - line pressure leaking into forward clutch
apply passage.
Forw ard Clutch - incorrect clutch plate usage or
burned clutches (Refer to B U R N E D ! r CH PLATES).
N o M o tio n in R e v e r s e o r S lip s in R e v e r s e
(Install pressure gage)
Low Oil Level - add oil.
M anual Linkage - m isadjusted (correct alignment in
m anual lever shift quadrant is essential).
Low Oil Pressure - Refer to LOW L IN E
PRESSU RE.
Control Valve Assembly:
a. Valve body gaskets - leaking, damaged or
incorrectly installed.
b. 2-3 shift valve train stuck open (in upshifted
position).
Interm ediate Servo - piston or pin stuck so
interm ediate overrun band is applied.
Low and Reverse Clutch - piston outer seal damaged
or missing.
D irect Clutch:
a. O uter seal damaged or missing.
b. C lutch plates burned (Refer to B U R N E D C LU TC H
PLATES).
Forw ard Clutch - clutch does not release (will cause
D R IV E in N EU TR A L).
S lip s In All R a n g e s O r S lip s O n S t a r t
(Install pressure gage)
Low Oil Level - add oil.
Low Oil Pressure - Refer to LOW L IN E
PRESSURE.
Forw ard clutch:
a. Clutch plates burned (Refer to B U R N E D
C LU TC H PLA TES).
b. Pum p cover oil seal rings broken or worn.
Case - cross leaks or porosity.
S lip p in g
1-2
S h if t
2-3
S h if t
A U TO M A TIC TRAN SM IS S IO N
Downshift
7A-21
Pressure - Refer to H IG H
L IN E
- Refer to
H IG H
L IN E
No Engine Braking in L2
(Install pressure gage)
Low Oil Pressure - pressure regulator a n d /o r boost
valve stuck.
Interm ediate Servo and 2-3 A ccum ulator:
a. Servo or accum ulator oil rings or bores leaking or
damaged.
b. Servo piston stuck or cocked.
No Engine Braking in L1
Transmission Noisy
P a rk , N e u tr a l a n d all D riv in g R a n g e s
Pum p Cavitation:
a. Low oil level.
b. Plugged or restricted strainer.
c. Strainer-to-valve body gasket damaged.
d. Porosity in valve body intake area.
e. W ater in oil.
f. Porosity or voids at transmission case (pum p face)
intake port.
g. Pump-to-case gasket off location.
Pum p Assembly:
LIGHT TR U C K SE R V IC E M A N U A L
7A-22
A U T O M A T IC TRAN SM ISSIO N
LO W A N D
ROLLER CLUTCH
INTERMEDIATE
CLUTCH
INTER. O VERRU N
ROLLER CLUTCH
INTERMEDIATE
BA ND
DIRECT
CLUTCH
NEUTRAL
OFF
In e ffe c tiv e
O FF
OFF
OFF
OFF
In e ffe c tiv e
O FF
In e ffe c tiv e
O FF
O FF
ON
OFF
Locked
ON
Locked
OFF
OFF
ON
O FF
F r e e - W h e e lin g
ON
F r e e - W h e e lin g
OFF
ON
ON
OFF
F r e e - W h e e lin g
Li
OFF
In e ffe c tiv e
OFF
O FF
ON
ON
Locked
L2
ON
Locked
ON
O FF
ON
O FF
F r e e - W h e e lin g
REVERSE
OFF
In e ffe c tiv e
OFF
ON
OFF
ON
In e ffe c tiv e
a. G ears damaged.
b. Driving gear assembled backwards.
c. Crescent interference.
d. Oil seal rings dam aged or worn.
Converter:
a. Loose flexplate-to-converter bolts.
b. Converter damage.
c. W ater in oil (causes whine).
F irs t, S ec o n d a n d /o r R e v e rs e G e a r
shaft
seal
requires
LIG HT T R U C K SE R V IC E M A N U A L
PROBLEM
CAR
R O A D TEST
LEGEND
X -P R O B LE M
* @ " O "
AREA
VS
VACUUM
O -B A L L S / #2/3/4
CA US E
ONLY
ONLY
L-LO C K E D
S-STUCK
PO SS IB LE
CA US E
L O W O I L L E V E L / W A T E R IN O IL
VACUUM
LEAK
R E G . & / O R BOOS T V A L V E
BALL
(# 1 ) SHY
1-2 S H I F T V A L V E
2 -3 S H I F T V A L V E
M A N U A L LOW C O N T 'L
VALVE
D E TE N T V A L V E & LIN K AG E
D E T E N T REG. V A L V E
2-3 A C C U M U L A T O R _________
PO RO SITY/CROSS LEAK
P U M P G E A R S
P R I M I N G V A L V E SH Y
COOLER V A LVE LEAK
C L U T C H S E A L R IN G S
PO RO U S /C R O S S L E A K
G A S K E T SCREEN-PRESSURE
B A N D - I N T E R M . O.R.
C A S E -P O R O U S /X
LEAK
1 2 ACCUMULATOR
IN T E R M E D . SERVO
F O R W A R D C L U T C H ASS Y
D I R E C T C L U T C H ASS Y
I N T E R M E D . C L . A S S 'Y
L & R E V . C L . A S S 'Y
I N T . R O L L E R C L . ASS Y
L.
&
R. R O L L E R C L . AS S' Y
AUTOMATIC TRANSMISSION
M A N U A L V A L V E /L IN K A G E
PA RK P A W L /L IN K A G E
C O N V E R T E R A S S' Y
7A-23
G E A R SE T & B E A R I N G S
7A-24
AUTOMATIC TRANSMISSION
[COOLER IN;
[COOLER OUT;
COOLER
CONV APPLY!
LUBE
Fig. 7 A -13 -3 5 0
PUMP PRESSURE!
conv r e l:
MOD
CONV F D l
zn 23 c l :
REVZ
Hydraulic
PRESSURE REGULATOR
CONVERTER CLUTCH
VALVE
s u c t io n :
d r iv e
Circuit - TCC
DRIVE
GOVERNOR
Applied
SUMP
SWITCH ASM
PRESSURE
SCREEN
;MOD OR DET
M ANUAL VALVE
DRIVE
2 3 SHIFT VALVE
MAN LOW CONT:
d r iv e
MODULATOR
1 2 SERVO:
A U T O M A T IC TRAN SM IS S IO N
7A-25
ON V EH IC LE S E R V IC E
TRANSMISSION REPLACEMENT
end
of
frame
TRANSMISSION REPLACEMENT
(K
MODEL)
1.
2.
LIG HT TRU CK SE R V IC E M A N U A L
7A-26
A U T O M A T IC TRAN SM IS S IO N
29.
install.
E X T E N S IO N H O U S IN G O IL S E A L
Removal
1. Drive a new oil seal into place with Installer J21426, as shown in Fig. 7A-16.
2. Install propeller shaft and adjust fluid level.
S P E E D O M E T E R D R IV E N G E A R
Removal
A U T O M A T IC TRAN SM IS S IO N
7A-27
MANUAL SHAFT TO
CASE RETAINER
SCREWDRIVER
V
Fig. 7 A - 1 8 -G o v e rn o r Cover
Installation
In s ta lla tio n
GOVERNOR
Rem oval
NOTICE:
1. Install governor.
2. Apply anerobic sealant to cover, then install
governor cover using a brass drift around the outside flange
of the cover.
NOTICE:
7A-28
A U T O M A T IC TRAN SM IS S IO N
GOVERNOR
PRESSURE
SWITCH
SERVO
TORQUE
CONVERTER
O R IN G SEAL
SOLENOID
SWITCH
iX B
VA C U U M MODULATO R
'ELECTRICAL
CONNECTOR
Fig. 7 A -1 9 ~ R e m o v in g V a cu u m M o d u la to r
Fig. 7A -2 0 ~ D e te n t S p r in g /V a lv e B o d y
4.
Connect speedom eter cable, lower vehicle and
check transm ission fluid level.
V A C U U M M O DULATO R AND M ODULATO R
VALVE ASSEM BLY
Removal
1. D isconnect vacuum hose from vacuum m odulator
stem and remove vacuum m odulator attaching screw and
retainer.
2. Remove m odulator assembly and its O-ring seal
from case. Refer to Fig. 7A-19.
3. Remove m odulator valve from case.
Installation
Installation of the m odulator and m odulator valve is
the reverse of REM O V A L. Install a new O-ring seal and
adjust the fluid level.
4. Remove tool and install oil pan bolts.
Installation
1-2
L IGHT T R U C K SE R V IC E M A N U A L
A U T O M A T IC TRAN SM IS S IO N
7A-29
In s ta ll
4 0 0 A U T O M A T IC T R A N S M IS S IO N
INDEX
G eneral D escription..........................................................
M aintenance and A d ju stm en t........................................
Checking Transmission M o u n t....................................
Transm ission F lu id .........................................................
Colum n Shift Linkage A dju stm en t.............................
D etent Switch A d justm ent............................................
N eutral Start Backup Lam p Switch A djustm ent....
Vacuum Regulator V alve.............................................
D iagnosis..............................................................................
Diagnosis Sequence.........................................................
Oil Checking P ro ced u re................................................
Oil Leak D iagnosis.........................................................
Oil Pressure C h e c k .........................................................
Case Porosity R e p a ir......................................................
Vacuum M odulator D iagnosis.....................................
M anual L inkage...............................................................
7A -29
7A -31
7A-31
7A-31
7A-32
7A-33
7A-33
7A-33
7A-34
7A -34
7A-34
7A-34
7A-34
7A-35
7A-35
7A -36
Trouble D iagnosis.............................................................7A-36
C lutch Apply C h a rt........................................................ .7A-41
H ydraulic C ircu it..............................................................7A-42
On Vehicle Service..............................................................7A-43
Transm ission R eplacem ent........................................... .7A-43
R ear S eal.............................................................................7A-44
G o v e rn o r.............................................................................7A-44
M odulator and M odulator V alve................................ .7A-44
Parking L inkage............................................................... .7A-44
C ontrol Valve B ody........................................................ .7A-45
Pressure Regulator V alve...............................................7A-45
Oil Cooler Pipes............................................................... .7A-46
O ther Service O perations.................................................7A-46
Specifications....................................................................... ..7A-47
Special T o o ls....................................................................... ..7A-48
G E N E R A L D E S C R IP T IO N
The 400 autom atic transm ission is a fully autom atic
unit consisting prim arily of a 3-element hydraulic torque
converter and a com pound planetary gear set. Three
m ultiple-disc clutches, one gear unit, one roller clutch, and
two bands provide the friction elements required to obtain
the desired function of the com pound planetary gear set.
The torque converter couples the engine to the
planetary gears through oil and provides hydraulic torque
m ultiplication when required. The com pound planetary
7A-30
A U T O M A T IC TRAN SM IS S IO N
12
solenoid.
A U T O M A T IC T R A N SM IS S IO N
L2. L2 Range has the same starting ration as Drive
Range, but prevents the transm ission from shifting ration
when extra perform ance is desired. L2 Range can also be
used for engine braking. L2 Range can be selected at any
vehicle speed, and the transmission will shift to second gear
and remain in second until the vehicle speed or the throttle
are changed to obtain first gear operation in the same
m anner as in D Range.
7A-31
M A IN T E N A N C E A N D A D J U S T M E N T S
CHECKING TRANSMISSION MOUNT
Raise the vehicle on a hoist. Push up and pull down
on the transm ission extension while observing the
transm ission m ount. If the rubber separates from the metal
plate o f the m ount or if the extension moves up but not down
(m ount bottom ed out), replace the m ount. If there is relative
m ovement between a m etal plate of the m ount and its
attaching point, tighten the screws or nuts attaching the
m ount to the transm ission or crossmember.
TRANSMISSION FLUID
HOT
(65-85 F.)
( 1 9 0 -2 0 0
(18-29C.)
F.)
(88-93 C.)
I~H
1 PT
FULL
W ARM
7A-32
A U T O M A T IC TRAN SM ISSIO N
CAUTION:
Transmission
fluid
temperature can exceed 350F (177C).
1. Raise vehicle and support transm ission with
suitable jack at transmission.
2. W ith fluid receptacle placed under transm ission oil
pan, remove oil pan attaching bolts from front and side of
pan.
3. Loosen rear pan attaching bolts approxim ately four
(4) turns.
4. Carefully pry transm ission oil pan loose with
screwdriver, allowing fluid to drain.
5. Remove rem aining screws and remove oil pan and
gasket. D iscard gasket.
6. D rain fluid from oil pan. Clean pan with solvent and
dry thoroughly w ith clean compressed air.
7. Remove oil filter retainer bolt, oil filter assembly,
O-ring seal from intake pipe and discard the filter and Oring seal.
8. Install new O-ring seal on intake pipe and install
new filter on pipe assembly.
9. W ith O-ring seal on intake pipe, install pipe and
filter assembly, attaching filter to the control valve assembly
with its retainer bolt, torquing to 10 ft. lb. (13 N*m).
10. Install new strainer-to-valve body gasket, strainer
and two (2) screws.
11. Install new gasket on oil pan and install oil pan.
Tighten its 13 attaching bolt and washer assemblies to 12
ft. lb. (16 N*m).
12. Lower vehicle add approxim ately 5 pints U.S.
measure (4 pints Im perial measure) of D E X R O N II
autom atic transm ission fluid or its equivalent through filler
tube.
13. W ith selector lever in P A R K (P) position, apply
hand brake, start engine and let idle (carburetor off fast idle
step). DO N O T R A C E E N G IN E .
14. Move selector lever through each range and, with
selector lever in P A R K (P) range, check the fluid level.
15. A dd additional fluid to bring level to 1/4 in. (6.35
mm) below the A D D m ark on the dipstick.
SHIFT CONTROLS
Column Shift Linkage - CK and P Series
(Figs. 7A-32 and 7A-33)
1. The shift tube and lever assembly m ust be free in
the m ast jacket. See Section 3B for alignm ent of steering
colum n assembly if necessary.
2. To check for proper shift linkage adjustm ent, lift the
transm ission selector lever tow ards the steering wheel.
Allow the selector lever to be positioned in Drive (D) by
the transm ission detent.
D o not use indicator pointer as a reference to position
the selector lever. W hen perform ing linkage adjustm ent,
pointer is adjusted last.
3. Release the selector lever. The lever should be
inhibited from engaging low range unless the lever is lifted.
4. Lift the selector lever tow ards the steering wheel
and allow the lever to be positioned in N eutral (N ) by the
transm ission detent.
5. Release the selector lever. The lever should now be
inhibited from engaging reverse range unless the lever is
lifted.
6. A properly adjusted linkage will prevent the selector
from moving beyond both the neutral detent, and the drive
detent unless the lever is lifted to pass over the mechanical
stop in the steering column.
LIGHT TR U C K SE R V IC E M A N U A L
A U T O M A T IC TRAN SM IS S IO N
7A-33
PLUNGER
PLUNGER
TRANSMISSION
CONTROL
SWITCH
P30 ( 42 ) SERIES
PLUNGER
CK SERIES
P30
7A-34
A U T O M A T IC TRAN SM ISSIO N
D IA G N O S IS
DIAGNOSIS SEQUENCE
1.
a.
b.
c.
2.
a.
LIGHT TR U C K SE R V IC E M A N U A L
A U T O M A T IC TRAN SM ISSIO N
M inim um
M axim um
145 psi
155 psi
M inim um
M axim um
L 2-2nd G e a r - S te a d y ro a d lo ad at a p p ro x im a te ly 25 m p h
G ear
S e le c to r L ever P o sitio n
7A-35
1st
2nd
3rd
D rive
( Z e ro th r o ttle to fu ll th r o t t l e ..................................
................
60
150
3rd
R everse
...............
................
60
95
260
Drive, N eutral,
Park
Li or L2
Reverse
LI or L2
Reverse
150
150
233
60
150
107
7A-36
COMPARISON
GAUGE
1 RYv
o r i
j -j
MANUAL LINKAGE
M anual linkage adjustm ent and the associated neutral
safety switch are im portant from a safety standpoint. The
neutral safety switch should be adjusted so th at the engine
will start in the Park (P) and N eutral (N) positions only.
W ith the selector lever in the P ark position, the parking
pawl should freely engage and prevent the vehicle from
rolling. The pointer on the indicator quadrant should line
up properly with the range indicators in all ranges.
MODULATOR IN
QUESTION
KNOWN GOOD
MODULATOR
LIGHT TR U C K SE R V IC E M A N U A L
A U T O M A T IC TR A N SM IS S IO N
7A-37
or Low
O il
Pressure
(Refer to F L U ID PR E SSU R E CH EC K S)
High Line Pressure
Vacuum Leak:
a. Vacuum line disconnected.
b. Leak on line from engine to m odulator.
c. Im proper engine vacuum .
d. Leak in vacuum -operated accessory (hoses, vacuum
advance, etc.).
M odulator:
a. Stuck m odulator valve.
b. W ater in m odulator.
c. Damaged, not operating properly.
D etent System:
a. D etent switch actuated (plunger stuck) or shorted.
b. D etent wiring shorted.
c. D etent solenoid stuck open.
d. D etent feed orifice in spacer plate blocked or
restricted.
e. D etent solenoid loose.
f. D etent valve bore plug damaged.
g. D etent regulator valve pin short.
Oil Pump:
a. Pressure regulator a n d /o r boost valve stuck.
b. Incorrect pressure regulator valve spring.
c. Too many pressure regulator valve spacers.
d. Pressure boost valve installed backwards or
defective.
7A-38
A U T O M A T IC TRAN SM ISSIO N
C ontrol valve:
a. 1-2 shift valve train stuck closed.
b. G overnor feed channels blocked, leaking, pipes out
of position, governor screen plugged.
c. Valve body gaskets leaking, damaged, incorrectly
installed.
Case:
a. Interm ediate clutch cup plug leaking or blown out.
b. Porosity between channels.
c. G overnor feed channel blocked; governor bore
scored or worn, allowing cross pressure leak.
Interm ediate clutch:
a. Case center support - oil rings missing, broken,
defective; orifice plug missing.
b. C lutch piston seals missing, im properly assembled,
cut.
Drive in Neutral
M anual linkage m aladjusted.
Internal Linkage:
a. M anual valve disconnected or end broken.
b. Inside detent lever pin broken.
Pum p Assembly - transm ission lube pressure leaking
into forward clutch apply passage.
Forw ard Clutch:
a. Burned plates - check cause.
b. C lutch doesnt release - will also cause no drive in
Reverse.
A U T O M A T IC TR A N SM IS S IO N
Case:
a. Interm ediate clutch ball missing or not sealing.
b. Porosity between channels.
R ear servo accum ulator:
a. Oil rings damaged.
b. Piston stuck.
c. Broken or missing spring.
d. Bore damaged.
Interm ediate clutch - clutch plates burnt (Refer to
B U R N E D C LU TC H PLATES.
7A-39
No Detent Downshifts
Transmission Noisy
NOTICE: Before checking transm ission for w hat is
believed to be "transm ission noise", make sure th at the
noise is not from the water pump, alternator, power
steering, etc. These components can be isolated by
removing the proper belt and running the engine no
more than two m inutes at one time.
Park, Neutral and all Driving Ranges
Pum p Cavitation:
a. Oil level low.
b. Plugged or restricted filter.
c. Intake pipe "O" ring damaged.
d. Intake pipe split, porosity in case intake pipe bore.
e. W ater in oil.
f. Porosity or voids at transmission case (pum p face)
intake port.
g. Pum p-to-case gasket off location.
Pum p Assembly:
LIGHT T R U C K SE R V IC E M A N U A L
7A-40
A U T O M A T IC TRAN SM ISSIO N
shaft
seal
requires
LIGHT T R U C K SE R V IC E M A N U A L
A U T O M A T IC TRAN SM IS S IO N
7A-41
FORWARD
CLUTCH
DIRECT
CLUTCH
FRONT
BAND
INTERMEDIATE
CLUTCH
INTERMEDIATE
ROLLER CLUTCH
LOW ROLLER
CLUTCH
REAR
BAND
NEUTRAL
O FF
O FF
OFF
O FF
In e ffe c tiv e
In e ffe c tiv e
O FF
D R IV E , First G e a r
ON
O FF
O FF
O FF
In e ffe c tiv e
E ffe ctive
O FF
D R IV E , S e cond G e a r
ON
O FF
OFF
ON
E ffe c tiv e
In e ffe c tiv e
O FF
D R IV E , T h ird G e a r
ON
ON
OFF
ON
In e ffe c tiv e
In e ffe c tiv e
O FF
Li
ON
O FF
O FF
O FF
In e ffe c tiv e
E ffe c tiv e
ON
L2
ON
O FF
ON
ON
E ffe c tiv e
In e ffe c tiv e
O FF
REVERSE
O FF
ON
O FF
O FF
In e ffe c tiv e
In e ffe c tiv e
ON
LIGHT T R U C K SE R V IC E M A N U A L
7A-42
I
1
I
1
[Z ^ l
CZZI
1
1
Fig. 7A-44--400
AUTOMATIC TRANSMISSION
M A IN L IN E PRESSURE
INTAKE PRESSURE
CONVERTER PRESSURE
G O VE R N O R PRESSURE
M O D U LA TO R PRESSURE
DETENT PRESSURE
1 -2 A C C UM ULA TO R PRESSURE
Hydraulic
Circuit
A U T O M A T IC TR A N SM IS S IO N
7A-43
ON V EH IC LE S E R V IC E
TRANSMISSION REPLACEMENT
If necessary, the catalytic converter may have to be
disconnected to provide adequate clearance for transm ission
removal. This procedure will include removal of the
converter support bracket.
Removal
Before raising the truck, disconnect the battery and
release the parking brake.
1. Raise truck on hoist.
Installation
1.
2.
LIGHT T R U C K SER V IC E M A N U A L
7A-44
A U T O M A T IC TRAN SM ISSIO N
Installation
GOVERNOR
Removal
A U T O M A T IC TRAN SM IS S IO N
7A-45
C O N T R O L VALVE
A SS Y .
GOVERNOR
PIPES
G O V E R N O R SCREEN
A SSY.
G O V E R N O R FEED
PIPE H O L E
Rem oval
NOTICE:
PUMP COVER
7A-46
A U T O M A T IC TRAN SM IS S IO N
meeting G M specification 123M or its equivalent. U nder no
condition use copper or alum inum tubing to replace steel
tubing. Those m aterials do not have satisfactory fatique
durability to w ithstand norm al vehicle vibrations.
Steel tubing should be flared using the upset (double
lap) flare m ethod which is detailed in Section 5.
LIGHT TR U C K SE R V IC E M A N U A L
A U T O M A T IC TR A N SM IS S IO N
7A-47
SPECIFICATIONS
350 C (MV4)
P u m p C o v e r to P u m p B o d y ..............................................
P u m p A sse m b ly to C a s e ..................................................
V alv e Body and A u x ilia ry V alve Body
P a rk in g L o c k B r a c k e t . ..................................................
____23
. . . . 24
. . . . 14
____39
..........4
. . . . 14
. . . . 33
. . . . 14
....3 3
..........6
. . . . 47
___ 12
....4 7
O il P a n to C a s e .....................................................................
E x te n sio n to C a s e ............ .................................................
M o d u la to r R e ta in e r to C a s e ...........................................
In n e r S e le c to r L e v e r to S h a ft............ ............................
D e te n t V alv e A ctu atin g B r a c k e t ....................................
C o n v e r te r to F ly w h e e l B o lts .........................................
U n d er P a n to T r a n s m is s io n C a s e ...............................
T r a n s m i s s i o n C a s e to E n g in e .........................................
O il C o o le r P ip e C o n n e c to rs to T r a n s m is s io n
C a s e o r R a d i a t o r ............................................................ ____14
O il C o o le r P ip e to C o n n e c to r s ...................................... ..........13
D e te n t C ab le to T r a n s m i s s i o n ................... .................. ..........8
D e te n t C a b le to C a r b ......................................................... . . . . 12
S o len o id A s s e m b l y .............................................................. ..........4
G o v e rn o r P r e s s u r e S w itc h .............................................. . . . . 10
N- m .
N- m .
N- m .
N- m .
N- m .
N- m .
N- m .
N* m .
N- m .
N- m .
N- m .
N- m .
N- m .
. . .1 7
.1 8 .5
..1 3 0
. . .2 9
...4 0
..1 3 0
...2 5
...3 0
...2 5
...5 2
...3 5
. .1 1 0
...3 5
f t.
f t.
in .
f t.
in .
in .
ft.
in .
ft.
in .
f t.
in .
ft.
lb .
lb .
lb .
lb .
lb .
lb .
lb .
lb .
lb .
lb .
lb .
lb .
lb .
N- m .
N- m .
N* m .
N- m .
N*
N-
..1 2 5
...1 0
...7 5
..1 1 2
____3
___ 8
in .
f t.
in .
in .
f t.
ft.
lb .
lb .
lb .
lb .
lb .
lb .
400 (AMO)
........ 24 N- m . . . . 1 8 f t. lb .
..........24 N- m . . . .1 8 ft. lb .
____29
P u m p to C a s e A tta c h in g B o l t s ...................................... ..........24
E x te n s io n H o u sin g to C a s e A ttac h in g B o lts ............
..........24
............ 9
C o n tro l V a lv e Body B o l t s ................................................ ..........10
B o tto m P a n A tta c h in g S c r e w s ....................................... ..........14
..........24
..........24
M an u al L e v e r to M an u al S haft N u t ............................. ..........10
M an u al S h aft to In s id e D e te n t L e v e r ........................... ..........24
L in k a g e S w iv el C la m p N u t .............................................. ..........57
C o n v e r te r D u s t S h ield S c r e w s ...................................... ___ 124
T r a n s m i s s i o n to E n g in e M ounting B o l t s ................. ..........47
C o n v e r te r to F ly w h e e l B o l t s ......................................... ..........47
R e a r M ount to T r a n s m i s s io n B o l t s ............................. ..........54
R e a r M ount to C r o s s m e m b e r B o lt . ........................... ..........54
C r o s s m e m b e r M o u n tin g B o l t s ....................................... ..........32
O il C o o le r L i n e ..................................................................... ..........13
L in e P r e s s u r e T a k e -O ff P l u g ....................................... ..........17
S t r a i n e r R e ta in e r B o l t ..................................................... ..........13
O il C o o le r P ip e C o n n e c to rs to T r a n s m is s io n
C a s e o r R a d ia to r .............................................................. .......... 14
O il C o o le r P ip e to C o n n e c to r ......................................... .......... 1
D o w n sh ift S w itch to B r a c k e t........................................... ............ 2
N- m . . . . 2 3
N* m . . . .1 8
. . .23
N- m . . . . 1 8
____7
N.
____8
NN- m . . . . 1 2
N* m . . . . 1 8
N- m . . . . 1 8
8
NN- m . . . . 1 8
N- m . . . .4 3
N* m . . . . 9 3
N- m . . . . 3 5
N* m . . . .3 5
N- m . . . . 4 0
N- m . . . . 4 0
N- m . . . . 2 5
N* m . . . . 1 0
N* m . . . . 1 3
N- m . . . . 1 0
f t.
f t.
f t.
f t.
ft.
f t.
f t.
f t.
ft.
ft.
ft.
ft.
ft.
ft.
ft.
ft.
ft.
ft.
ft.
ft.
ft.
lb .
lb .
lb .
lb .
lb .
lb .
lb .
lb .
lb .
lb .
lb .
lb .
lb .
lb .
lb .
lb .
lb .
lb .
lb .
lb .
lb .
N* m . ..1 2 5 in. lb .
N* m . . . . 1 0 in . lb .
N- m . . . . 2 2 in . lb .
LIGHT TR U C K SE R V IC E M A N U A L
7A-48
A U T O M A T IC TRAN SM IS S IO N
S P E C IA L T O O LS
1.
J-8763-02
2.
J-3289-20
3.
4.
5.
J-8092
J-21465-13
J-23062-3
6.
7.
J-23062-7
J-21465-15
8.
9.
10.
11.
J-23329
J-9534-01
J-23327
J-23062-2
12.
13.
J-23062-1
J-21424-9
14.
J-21424-7
15.
J-23062-5
16.
17.
18.
J-5154 or
J-21426
J-21359
J-7004
19.
J-21885
20.
J-23069
*
21.
J-2619-01
Not Illustrated
J-21369
J-8001
A U T O M A T IC TRAN SM IS S IO N
1 . J-61 16-01
2 . J -8 0 9 2
3.
4.
J -2 1 3 5 9
J -2 1 3 6 4
5.
J -2 6 1 9
6.
7.
8.
J -5 1 5 4
J -6 5 8 5
J -9 5 3 9
9. J -5 5 9 0
10. J -2 1 8 6 7
11. J - 2 1370-6
12. J - 2 1370-5
13. J - 2 1795-1
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
J - 2 1 7 95-2
J -5 3 8 4
J - 2 1465-01
J - 2 1465-5
J - 2 1465-3
J -2 1 4 6 5 -2
J - 2 1465-1
J -2 1 4 6 5 -1 7
J - 2 1465-8
J -2 1 4 6 5 -1 3
J - 2 146 5 -6
J -2 1 4 6 5 -1 5
J - 2 1 4 6 5 -1 6
J - 2 1465-9
J -2 1 4 6 5 -1 0
J -2 2 1 8 2
7A-49
Part of A b o v e H o ld in g Tool
Converter H o ld in g Strap
B u sh in g Tool Set
Part.of B u sh in g Tool Set
Part of B u sh in g Tool Set
Part of B u sh in g Tool Set
Part of B u sh in g Tool Set
Part of B u sh in g Tool Set
Part of B u sh in g Tool Set
Part of B u sh in g Tool Set
Part of B u sh in g Tool Set
Part of B u sh in g Tool Set
Part of B u sh in g Tool Set
Part of B u sh in g Tool Set
Part of B u sh in g Tool Set
Ext. B u sh in g Rem. and Inst.
(Not Illustrated)
7A-50
A U T O M A T IC TRAN SM ISSIO N
1. J-8763
2 . J-3289-14
3.
4.
J-21427-1
J-9539
5.
J-8105
6 . J-22269-01
7.
J-21369
8 . J-21362
9.
J-21363
10.
J-21409
11.
J-21664
12.
13.
14.
15.
16.
Not
J-4670
J-8059
J-5586
J-5403
J 1313
Illustrated
J-24684
J-24675
MANUAL TRANSMISSIONS
7B-1
SECTION 7B
MANUAL TRANSMISSION
CONTENTS
G eneral D escription............................................................ 7B-1
76mm (3 S p e e d )............................................................. 7B-1
77mm (3 S p e e d )............................................................. 7B-1
89mm (4 S p e e d ).............................................................7B-1
117mm (4 S p e e d )........................................................... 7B-2
M aintenance and A d ju stm e n ts....................................... 7B-9
D iagnosis............................................................................... 7B-11
Free Pedal T ra v e l...........................................................7B-11
Spin Down T im e .............................................................7B-11
Shift L in k ag e.................................................................. 7B -11
GENERAL DESCRIPTION
THREE-SPEED TRANSMISSIONS
3-Speed 76mm
3-Speed 77mm
M anual transmissions are designated according to: (A)
the num ber of forward gears, and (B) the m easured distance
between centerlines of the m ainshaft and the countergear.
The three speed synchrom esh transm issions (Figs. 7B-1
through 7B-3) are representative of a constant-m esh tran s
mission design. Fundam ental components of these units are
the case, which houses the gears and shaft; the shift control
mechanism and the various shafts and gears. The input
shaft has an integral main drive gear and rotates with the
clutch driven plate; th at is, the shaft rotates all the tim e the
clutch is engaged and the engine is running. The input shaft
is supported in the case by a ball bearing and at the front end
by an oil im pregnated bushing m ounted in the engine
crankshaft. The drive gear is in constant mesh with the
countershaft drive gear. Since all gears in the countershaft
cluster are integral to the shaft, they also rotate at the time
the clutch is engaged. The countergear is carried on roller
bearings at both ends and thrust is absorbed by thrust
washers located between the countergear and thrust bosses
in the case. The transm ission m ainshaft is held in line with
the input shaft by a pilot bearing at its front end, which
allows it to rotate or come to rest independently of the input
shaft. In the 76mm unit, the m ainshaft is carried at the rear
by a ball bearing m ounted in the front face of the extension
housing. In the 77mm unit, the m ainshaft is carried at the
rear by a ball bearing m ounted in the rear face of the case.
Helical gears are incorporated throughout, except for
reverse gear in the 77 mm transm ission. The m ainshaft
gears are free to rotate independently on the m ainshaft and
are in co n stan t mesh w ith the c o u n te rsh a ft gears. The
reverse idler gear is carried on a bushing, finish bored in
place, and thrust is taken on the thru st bosses of the case.
The transm issions are fully synchronized in all forward
speeds; how ever, reverse gear is not. T he synchronizer
assemblies consist of a hub, sleeve, two key springs and three
FOUR-SPEED TRANSMISSION
4-Speed 89mm
The four speed transm ission with overdrive has an
89mm center distance and is designed to combine normal
perform ance in the city with improved fuel economy on the
highway. G ear ratios are: first 3.09 to 1; second 1.67 to 1;
third 1.00 to 1; fourth (overdrive) 0.73 to 1. All forward
gears are fully synchronized. The synchronizer assemblies
consist of a hub, sleeve, two key springs and three synchro
nizer keys. T he synchronizer hubs are splined to the
m ainshaft and retained by snap rings. These assemblies
perm it gears to be selected w ithout clashing, by synchroniz
ing the speeds of m ating parts before they engage.
The drive pinion (input shaft) is supported by a ball
bearing in the transm ission case and an oil im pregnated
bushing pressed in the end of the crankshaft.
The m ainshaft front end is supported by roller bearings
in the end of the main drive pinion and a ball bearing in the
front of the extension housing. T he o u tput end of the
LIGHT T R U C K SE R V IC E M A N U A L
7B-2
MANUAL TRANSMISSIONS
4-Speed 117mm
The 117mm, Model C H 465 truck transm ission (Fig.
7B-4 and 7B-5) uses a constant mesh first gear th at engages
LIGHT T R U C K S E R V IC E M A N U A L
MANUAL TRANSMISSIONS
30
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
31
32
Clutch Gear
Bearing Retainer
Pilot Bearings
Case
3rd Speed Blocker Ring
2-3 Synch. Snap Ring
2-3 Synch. Hub
2nd Speed Blocker Ring
2nd Speed Gear
1st Speed Gear
1st Speed Blocker Ring
1st Speed Synch. Hub
1st Speed Synch. Snap Ring
Reverse Gear
33
34
35
10
36
11
12 13
37
38
14
39
15
16
17
18
19
20
7B-3
21
40
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
LIGH T T R U C K SE R V IC E M A N U A L
7B-4
MANUAL TRANSMISSIONS
1.
2
3.
4.
5.
6
7
8
9
10
11.
12.
13
19.
33.
34.
35
36
37.
38
39
40.
41.
42.
43
44.
45.
46.
LIGHT T R U C K S E R V IC E M A N U A L
47.
48.
49
Gasket
2-3 S hift Fork
1st and Reverse Shift
Fork
50. 2-3 S hifter Shaft
Assembly
51
1st and Reverse
Shifter Shaft
Assembly
52 0 " Ring Seal
53 "E " Ring
54
Spring
2nd and 3rd Detent
55
Cam
56
1st and Reverse
Detent Cam
57. Side Cover
58 TCS Switch and
Gasket
59
Lip Seal
MANUAL TRANSMISSIONS
1.
2.
3.
4.
35.
36.
37.
38.
7B-5
5.
2 N D & 3 R D S Y N C H R O N IZ E R S L E E V E
3 9 . S P E E D O M E T E R D R IV E G E A R
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
LIG H T T R U C K S E R V IC E M ANU AL
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
1 1.
12.
13.
14.
15.
16.
17.
1 8.
1 9.
20.
21.
22.
23 .
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34 .
Reverse Id le r G e a r Bushing
Reverse Id le r S h a ft
S n ap Ring
W o o d ru ff Key
Thrust W a s h e r
C o u n te rs h a ft Roller B earings
C o u n te rs h a ft
C o u n te rs h a ft G e a r
C o u n te rs h a ft S leeve
Expansion Plug
S n ap Ring
D riv e G e a r Roller B earings
MANUAL TRANSMISSIONS
34
1.
1 1.
12.
13.
14
15.
16.
17.
18.
19.
20.
21.
22.
23.
33 32
31
24
25
26.
27.
28.
29.
30.
31.
32,
33
34.
35.
36.
7B-7
30
M ainsh a ft Rear
Bearing
Rear Bearing Snap
Ring
Snap Ring
C ountershaft
C ountershaft Rear
Bearing
Bearing Snap Ring
Reverse Idler Gear
Reverse id le r Shaft
Case M agnet
Spacer
C ountergear
T hrust W asher
Snap Ring
37.
Front C ountershaft
Bearing
38, C ountergear Front
Cover
Pilot Bearing Rollers
39
40. Clutch Gear Oil
Slinger
41. Snap Ring
42. 3rd Speed Gear
Bushing
43. T hrust W asher
44. 2nd Speed Gear
Bushing
45. 1st Speed Gear
Bushing
LIG H T T R U C K S E R V IC E M AN U AL
7B-8
MANUAL TRANSMISSIONS
Fig. 7B-6--4-Speed
117mm, Exploded
View
1.
2.
3.
4.
5.
6.
7.
O il SI in ger
Bearings
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
1st-2nd Speed
Synchronizer Hub
Synchronizer Keys
Synchronizer Spring
Reverse Driven Gear
1st Gear Bushing
1st Gear
Thrust Washer
Rear Main Bearing
Bearing Snap Ring
Speedometer Gear
26.
27.
28.
29.
30.
34
35.
31.
32,
33.
25.
37.
38.
39.
40.
41.
42.
43.
44.
Hub
N ut
24.
36.
Synchronizer Spring
3rd-4th Speed
Blocker Ring
3rd-4th Speed
Synchronizer Sleeve
45.
46.
47.
Snap Ring
Snap Ring
Thrust Washer
Clutch Countergear
Spacer
3rd Speed
Countergear
Countergear Shaft
Countergear Rear
Bearing
Snap Ring
Bearing Outer Snap
Ring
Rear Retainer Gasket
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
Rear Retainer
Retainer Bolts
Retainer Lip Seal
Reverse Idler Shaft
Drain Plug
Reverse Idler Gear
Case
Fill Plug
Countergear Front
Bearing
Gasket
Front Cover
Cover Screws
MANUAL TRANSMISSIONS
7B-9
LIGH T T R U C K S E R V IC E M AN U AL
7B-10
S H IF T
LEVER
ROD
RELA Y LEVER
COLUM N CONTROL
LEVER
R E T A IN E R
ROD
G
G A G E P IN
Fig. 7B-8--C
S H IF T L E V E R
ROD
TRANS LEVER
and
BO LT
K-Truck
S W IV E L
C
D
Column
Shift Linkage
NOTE
O b ta in
2.
3.
4.
T u rn ign itio n key to " U N L O C K " p o sitio n an d p o sitio n Levers (A ), (B ) an d (E ) in " N E U T R A L " .
NOTE O b ta in
" N E U T R A L " p o sitio n by m o vin g Levers (B ) and (E ) c lo c k w ise to fo rw a rd detent then c o u n te r-c lo ck w ise o n e detent.
5.
6.
7.
NOTE W ith sh ift lever in " R E V E R S E " the ign itio n key m u st m ove freely to " L O C K " p o sitio n .
to o b ta in ig n itio n " L O C K " p o sitio n in " N E U T R A L " or a n y gear o th e r tha n " R E V E R S E " .
Insert Sw iv e l (D )
It m u st n ot be p ossib le
MANUAL TRANSMISSIONS
S H IF T L E V E R
MANUAL TRANSMISSIONS
7 B -1 1
DIAGNOSIS
Preliminary Inspection
Before attempting to repair the clutch, transmission or
related linkages for any reason other than an obvious
failure, the problem and probable cause should be identified.
A large percentage of clutch and m anual transmission
problems are manifested by shifting difficulties such as high
shift effort, gear clash and grinding or transmission blockout. When any of these problems occur a careful analysis of
these difficulties should be accomplished, and the following
checks and adjustments performed in the presented se
quence before removing the clutch or transmission for
repairs.
CLUTCH ADJUSTMENT
Clutch Free Pedal Travel
1. The clutch free pedal travel adjustment should be made
as outlined in Section 7C.
2. Check clutch linkage for lost motion caused by loose or
worn swivels, deflection of mounting brackets or
damaged cordon shaft.
7B-12
MANUAL TRANSMISSIONS
S H IFT T O R Q U E
3 -S P D
In ch -P oun ds
76m m
50
LIGHT T R U C K SER V IC E M A N U A L
MANUAL TRANSMISSIONS
7B-13
CONDITION
High Shift Effort-Column Shift
(Effort exceeds 2 ft. lbs. at
lever knob with transmission
linkage disconnected.)
CORRECTION
PROBABLE CAUSE
Binding of column levers
Adjust levers
Adjust levers
Lost motion
LIGH T T R U C K S E R V IC E M A N U A L
7B-14
MANUAL TRANSMISSIONS
PROBABLE CAUSE
CORRECTION
a. Insufficient lubricant
b. Worn countergear bearings
c. Worn or damaged main drive gear and
countergear
d. Damaged main drive gear or main
shaft bearings
e. Worn or damaged countergear anti
lash plate
a. Insufficient lubricant
b. Worn or damaged main drive gear or
countergear
LIGH T T R U C K SER V IC E M AN U AL
MANUAL TRANSMISSIONS
7B-15
CORRECTION
CONDITION
Noisy in Reverse Only
a. Replace bearings
b. Replace countergear thrust washers
Leaks Lubricant
c. Replace gasket
Tighten cover or replace gasket
e. Replace seal
f. Replace case
g. Replace seal
d.
COMPONENT REPLACEMENT
TRANSMISSION REPLACEMENT
3-Speed and 4-Speed Transmission Removal
(Except K Series)
1. Raise vehicle on suitable hoist and drain lubricant from
transm ission.
2. Disconnect speedom eter cable.
3. Remove shift controls from transm ission.
7B-16
MANUAL TRANSMISSIONS
2.
3.
4.
5.
6.
7.
LIGHT T R U C K SER V IC E M A N U A L
MANUAL TRANSMISSIONS
7B-17
TRANSMISSION ALIGNMENT
In some instances where excessive gear whine or high
gear hop out, particularly at 50 mph (80 km/h) and up, are
encountered, and after all other probable causes have been
checked, an alignment check of the transmission and clutch
housing may be helpful.
A special tool, on which a dial indicator is mounted, is
necessary to check the transmission case rear bore align
ment. This tool may be made from a new or good used clutch
gear which has a good bearing surface on the crankshaft
pilot end and at the front main bearing location.
The splines on the clutch gear shaft and the teeth on the
clutch gear should be ground off so the shaft may be rotated
in a clutch disc hub without interference when assembled in
the car. Weld a piece of 1/4 in. (6.3m m) rod in the
mainshaft pilot bore long enough to extend out the case rear
bore. Assemble a good bearing on the clutch gear shaft and
secure it with the clutch gear bearing snap ring. Attach a
suitable dial indicator to the rod.
1. Remove the transmission from the vehicle and com
pletely disassemble, except for the reverse idler gear.
In any case where the clutch gear pilot or pilot bearing
is excessively loose or worn, the pilot bearing should be
replaced before checking the transmission case rear
bore alignment by the dial indicator method.
2. Carefully install the special tool with the dial indicator
in the transmission case with the face of the indicator to
the rear of the case and with the tracing finger
contacting the I.D. of the case rear bore. Secure in
place with a clutch gear bearing retainer.
3. Assemble the transmission case to the clutch housing
and tighten the four transm ission mounting bolts
securely.
Be sure to clean off any paint or other foreign material
on the mating faces of the clutch housing and transmis
sion as any foreign material on these faces will change
alignment; also, check carefully for dings or burrs on
these m ating surfaces and remove carefully as
necessary.
4. Dial indicate the transmission case rear bore and
record the indicator readings in the 12, 3, 6 and 9
o'clock positions.
It is best to start the reading at the 3, 6, 9 or 12 oclock
position closest to the point where the indicator plunger
reaches its m axim um outward travel. Set the dial
indicator at " 0 " at this location and then record the 3,
6, 9 and 12 oclock readings in rotation.
5. Install temporary slotted shims between the transmis
sion case and the clutch housing in the quantities and at
the bolt locations as necessary to bring misalignment at
the transmission case rear bore to a miximum of 0.005
in. indicator reading in either the vertical or horizontal
direction.
LIGH T T R U C K SE R V IC E M ANU AL
7B -18
MANUAL TRANSMISSIONS
J-22834-2
J-22834-1
NOTE PARKING
BRAKE M O U N T IN G
FLANGE
J- 22834-2
ONLY
MANUAL TRANSMISSIONS
DETENT C A M
DETENT SP R IN G
CAM
2 -3 SHIFT
FORK
SHIFT FORK
2 -3 SHIFTER SHAFT
DETENT C A M
RETAINER R IN G
7B-19
5. Remove detent cam spring and pivot retainer " C " ring.
Remove both detent cams.
6. With detent spring tang projecting up over the 2nd and
3rd shifter shaft cover opening, install the first and
reverse detent cam onto the detent cam pivot pin. With
the detent spring tang projecting up over the first and
reverse shifter shaft cover hole install the 2nd and 3rd
detent cam.
7. Install detent cam retaining " C " ring to pivot shaft,
and hook spring into detent cam notches.
8. Install both shifter shaft assemblies in cover being
careful not to damage seals. Install both shift forks to
shifter shaft assemblies, lifting up on detent cam to
allow forks to fully seat into position.
9. Install outer shifter levers, flat washers, lock washers
and bolts.
10. Shift shifter levers into neutral detent (center) position
and slide cover into place making sure the shift forks
are aligned with their respective m ainshaft clutch
sliding sleeves.
11. Install cover a tta c hing bolts and tighten evenly to
specified torque, then connect wiring.
12. Remove filler plug and add lubricant specified in
Section OB to level of filler plug hole.
L IG H T T R U C K S E R V IC E M AN U AL
7B-20
MANUAL TRANSMISSIONS
SPECIFICATIONS
THREE-SPEED 76mm
C lu tc h G e a r R e ta in e r to C a s e B o lts ...................................... 20
S id e C o v e r to C a s e B o l t s ............................................................ 20
E x te n s io n to C a s e B o l t s .............................................................. 61
S hift L e v e r to S h ifte r Shaft B o l t s ........................................... 32
L u b r ic a tio n F i l l e r P l u g .............................................................. 17
T r a n s m is s io n C a s e to C lu tch H o u sin g B o l t s ................. 101
C r o s s m e m b e r to F r a m e N u t s .................................................. 32
C r o s s m e m b e r to M ount B o l t s ...................................................54
2 -3 C r o s s O v e r Sh aft B r a c k e t R e ta in in g N u t ................... 24
1 -R e v . S w ivel A ttach in g B o l t .................................................. 27
M ount to T r a n s m is s io n B o l t .....................................................68
N- m . . . . 15
N- m . . . . 15
N m . . . . 4 5
N- m . . . . 25
N - m . . . . 13
Nm....75
N* m . . . . 25
N * m . . . .4 0
N* m . . . . 18
N m . . . . 2 0
N - m . . . . 50
ft.
f t.
ft.
ft.
ft.
ft.
f t.
ft.
ft.
ft.
ft.
lb .
lb .
lb .
lb .
lb .
lb .
lb .
lb .
lb .
lb .
lb.
N* m . . . . 35
N *m . . . . 3 0
N* m . . . . 45
N* m . . . . 25
N m . . . . 15
N- m . . . . 75
N - m . . . .25
N* m . . . . 4 0
N- m . . . . 18
N- m . . . . 20
N* m . . . . 50
ft.
ft.
ft.
ft.
ft.
ft.
ft.
ft.
ft.
ft.
ft.
lb .
lb .
lb .
lb .
lb .
lb .
lb .
lb .
lb .
lb .
lb.
lb .
lb .
THREE-SPEED 77mm
C lu tc h G e a r R e ta in e r to C a s e B o l t s .......................................47
T op C o v e r to C a s e B o l t s .............................................................. 40
E x te n s io n to C a s e B o l t s .................................................................61
S h ift L e v e r to S h ifte r Sh aft B o lts ..............................................32
L u b r ic a tio n F i l l e r P lu g . . . . . . ...................................................20
T r a n s m i s s i o n C a s e to C lu tc h H o u sin g B o l t s ................... 101
C r o s s m e m b e r to F r a m e N u ts ..................................................... 32
C r o s s m e m b e r to M ount B o l ts ..................................................... 54
2 -3 C r o s s O v e r Sh aft B r a c k e t R e ta in in g N u t......................24
1 -R e v . S w ivel A ttach in g B o l t ..................................................... 27
M ount to T r a n s m i s s i o n B o l t ....................................................... 68
LIGHT T R U C K S E R V IC E M ANU AL
lb.
lb .
lb .
lb .
lb.
MANUAL TRANSMISSIONS
7B-21
SPECIAL TOOLS
1.
J-1126
Tr a n s m i s s i o n G u i d e Pins
6.
J-2228
2.
J-8059
R e t a in e r S n a p R in g Pliers
7.
J-5590
C lu t c h G e a r B ea rin g Ins ta ll er
3.
J-22246
C o u n t e r g e a r L o a d in g T o o l
8.
J-9772
C l u t c h G e a r B ea rin g Ins ta ll er
4.
J-5778
9.
J-23096
5.
J-5154
E x t e n s i o n Seal In st a ll er
7B-22
MANUAL TRANSMISSIONS
14-16
7.
1.
2.
J - 2 142 4 -9
J-8059
P L A T E S A N D PRESS P L A T E
J-358-1
J- 5778
J- 2228
REAR B E A R IN G
9.
J-933
M A IN D R I V E GEAR W R E N C H
10 .
J -1126
TR A N S M IS S IO N
G U I D E PINS
11.
J- 5590
CLUTCH GEAR
B E A R IN G
IN STA LL ER
12 .
J-9772
CLUTCH GEAR B E A R IN G
IN S TA LL E R
IN S TA LL E R
13.
J -2 3 0 9 6
CLUTCH GEAR
14.
J -2 1 4 2 6
REAR E X T E N S IO N SEAL IN S TA LL E R
15.
J- 575 2
16.
J-23596
T R A N S M IS S IO N H O L D IN G F IX T U R E
REAR E X T E N S IO N B US H IN G IN S T A L L E R
COUNTER
GEAR
LO AD IN G TO OLS
E X T E N S IO N BUSHING
REMOVER AND
5.
J-51 54
E X TE N S IO N SEAL IN S TA LL E R
6.
J - 5 8 14-01
S P E E D O M E TE R D R IV E GEAR
A N D A D A P T E R J- 5814 -15
REMOVER
LIGHT T R U C K S E R V IC E M ANU AL
HOLDER
8.
R E T A I N E R S N A P R IN G P L I E R S
3c. J - 29 7 9 3
4.
S P E E D O M E T E R D R I V E G E A R PRESS
H A N D L E J-8092
3a. J -2 2 2 4 6
3b. J-22379
J -145 3-01
R E A R B U S H IN G R E M O V E R W I T H
PRES S P L A T E S
R E T A IN E R
SEAL IN S TA LL E R
MANUAL TRANSMISSIONS
7B-23
1.
J--1126
T r a n s m i s s i o n G u i d e Pins
2.
J-8059
R e t a i n e r S n a p R in g Pliers
3.
4.
J-22246
J-5778
5.
J-5154
E x t e n s i o n Seal In st a ll er
6.
7.
J-2228
J-5590
R ea r B e a r in g Press Plates
C l u t c h G e a r B ear in g In st a ll er
C o u n t e r g e a r L o a d in g T o o l
8.
J-9772
E x t e n s i o n Bu s hi n g R e m o v e r an d In st a ll er
9.
J-23096
C l u t c h G e a r R e t a i n e r Seal Ins ta ll er
L IG H T T R U C K S E R V IC E M AN U AL
: .ic.
.riv:V
n'ikft?;! .
j rr
flv
; ckk-:>
?!ooT'
Z^-Cpi.
i5
-i.bn-. -Avor:
CLUTCH
7C-1
S E C T IO N 7 C
CLUTCH
INDEX
G eneral D escription..........................................................
Clutch System s...............................................................
D iaphragm T y p e ................................................... .
Coil Spring T y p e.......................................................
C lutch C ontrols..............................................................
M aintenance and A djustm ents.......................................
In sp ectio n .......................................................... .............
Free Pedal A djustm ent................................................
D iagnosis..............................................................................
7C-1
7C-1
7C-1
7C-2
7C-3
7C-8
7C-8
7C-8
7C-10
G E N ER A L D E SC R IP T IO N
CLUTCH S Y S TE M S
Driving Members
The driving members of a clutch usually consist of two
iron plates or flat surfaces m achined to a sm ooth finish. Iron
is desirable because it contains enough graphite to provide
some lubrication when the driving m em ber is slipping
during engagement. One of these surfaces is usually the rear
face of the engine flywheel, and the other is a com paratively
heavy flat ring with one side m achined. This part is known
as the pressure plate. It is fitted into a steel cover, which
also contains some of the operating members, and is bolted
to the flywheel.
Driven Members
The driven m em ber is the clutch disc with a splined
hub which is free to slide lengthwise along the splines of the
clutch shaft, but which drives the shaft through these same
splines. Grooves on both sides of the clutch disc lining
prevent sticking of the plate to the flywheel and pressure
plate. Suitable frictional facings are attached to each side
of the clutch disc by means of brass rivets. These facings
must be heat resistant since friction produces heat. The most
commonly used factings are made of cotton and asbestos
fibers woven or molded together and im pregnated with resin
Operating Members
The driving and driven members are held in contact
by spring pressure. This pressure may be exerted by a onepiece conical or diaphragm spring. In the diaphragm design
clutch, the clutch release bearing moves forward against the
spring fingers forcing the diaphragm spring to pivot around
the pivot ring, dishing the fingers tow ard the flywheel. The
outer circumference of the spring now lifts the pressure plate
away from the driven disc, through a series of retracting
springs placed around the outer circumference of the
pressure plate.
The clutch release bearing is a ball-thrust bearing
contained in the clutch housing, m ounted on a sleeve
LIGHT TRU C K SE R V IC E M A N U A L
7C-2
CLUTCH
D R IV E N PLATE A S S Y .
PRESSURE PLATE
A N D COVER ASSY.
C LUTCH H O U S IN G
COVER
C L U T C H RELEASE B E A R IN G
C LU TC H FORK
C LUTCH H O U S IN G
C LU TC H FO RK
JALL S TU D
CLUTCH
1. Flywheel
2. Dowel-hole
3. Pilot Bushing
4. Driven Disc
5. Pressure Plate
6. Diaphragm Spring
7C-3
Fi g. 7 C - 2 - - C r o s s - S e c t i o n V i e w o f D i a p h r a g m - T y p e
CLUTCH CONTROLS
The clutch operating controls for C-K trucks (Fig. 7C6) are a mechanical type consisting of a pendant type pedal,
return spring, pedal push rod, cross-shaft, fork push rod,
routed vertically, inside the cab, from the pedal lever down
through two boots on the toe pan, to the cross-shaft lever.
W hen the clutch pedal is depressed, the pedal push rod
moves rotating the cross-shaft, pushing the fork push rod
rearward, and pivoting the clutch fork to move the release
bearing against the clutch release fingers and releasing the
clutch.
The clutch operating controls for "G " and "P" models
are a mechanical type similar to the C-K models. On "G "
models (Fig. 7C-7) a pedal pull rod is routed vertically from
the clutch pedal lever down through the toe-panel to the
cross shaft. W hen the pedal is depressed, the pedal pull rod
moves, rotating the cross shaft, pushing the clutch fork rod
rearw ard and pivoting the clutch fork. This action moves
the release bearing against the clutch release fingers,
releasing the clutch.
7C-4
CLUTCH
1. Release Lever
2. E ye bo lt
3. Strut
4. C o ve r
5. A d j u s t i n g N u t
Fi g. 7 C - 4 ~ C r o s s - S e c t i o n V i e w o f C o il S p r i n g T y p e
U G H T TRU C K SE R V IC E M AN U AL
CLUTCH
7C-5
7C-6
CLUTCH
CLUTCH
7C-7
7C-8
CLUTCH
M A IN T E N A N C E A N D A D J U S T M E N T S
CLUTCH LINKAGE INSPECTION
LIGHT T R U C K SE R V IC E M A N U A L
CLUTCH
7C-9
Fi g. 7 C - 1 0 - - P - T r u c k F r e e P e d a l T r a v e l
Fi g. 7 C - 1 1 - - G - T r u c k F r e e P e d a l T r a v e l
7C-10
CLUTCH
D IA G N O S IS
PROBABLE CAUSE
CONDITION
Fails to Release (Pedal pressed
to floor-shift lever does not
move freely in and out of
reverse gear
a.
b.
c.
d.
e.
f.
CORRECTION
a.
b.
c.
d.
e.
f.
Adjust Linkage
Trim bumper stop and adjust linkage
Replace as necessary
Replace bearing
Replace disc
Install properly and* lubricate fingers
at release bearing with wheel bearing
grease.
g. Repair or replace clutch gear and/or
disc.
h. Replace disc (run-out should not
exceed .020").
*Very lightly lubricate fingers
Slipping
Grabbing (Chattering)
Rattling-Transmission Click
Noisy
a. Replace bearing.
b. Install properly and lubricate fork
fingers at bearing.
c. See Section 6 for bearing fits.
Bearing loose
in crankshaft.
a. Bind in linkage.
b. Driven plate worn.
Fig. 7C-1 2--Clutch Diagnosis Chart
LIGHT TRU C K SE R V IC E M A N U A L
b.
c.
d.
e.
a. Adjust linkage.
b. Clean, relubricate, check for burrs,
nicks,etc.
c. Replace fork.
c. Pilot
Pedal Stays on Floor When
Disengaged
d. Install properly.
e. Replace spring.
CLUTCH
7 C -1 1
7C-12
CLUTCH
NOTICE:
NOTICE:
Installation To Vehicle
1. Assemble driven plate and clutch cover assembly to
flywheel in accordance with marking on driven plate for
flywheel side. Use Tool J-5824 or a dum m y shaft to support
assembly.
2. Line up the clutch assembly with "X" m ark or
painted white letter with "X" m ark on flywheel, before
tightening cover holding screws.
3. Tighten holding screws, a turn at a time, before
removing dum m y shaft.
4. Remove clutch pilot tool.
5. Pack clutch fork ball seat with a small am ount of
high melting point grease and install a new retainer in the
groove of the clutch fork if the old retainer is worn or
damaged.
L IG HT TRU C K SE R V IC E M A N U A L
Installation
1. Install new bushings and spacer in pedal arm.
Com ponents should be lubricated prior to assembly.
2. Position clutch pedal upper arm in support bracket
and install pivot bolt through support and pedal arms.
CLUTCH
7C-13
Inspection
1. Check clutch pedal bushings for excessive wear and
replace as necessary.
2. Check clutch pedal shaft for wear and alignment.
Straighten or replace as necessary.
Installation
NOTICE: Use new shaft bushing if needed. Lubricate
with petrolatum .
1. Slide one pedal shaft bushing over shaft, install shaft
in support enough to still clear pedal bum per stop, hook
pedal return (or overcenter) spring to pedal, then rotate
pedal forward of bum per stop; slide shaft into position in
support and release pedal against bum per stop.
2. Install clutch pedal shaft bushing over pedal shaft
end and into place in sleeve.
3. Assemble pedal push rod lever over pedal shaft and
install bolts, washers, and nut.
7C-14
CLUTCH
J ^
(Figs. 7 C -6 , 7 C -7 , 7 C -8 )
1. Disconnect clutch fork return spring at fork.
2. Disconnect pedal push rod at cross-shaft lever and
allow clutch fork push rod to hang free from lower lever.
S P E C IA L T O O LS
Fi g. 7 C - S T ~ C l u t c h S p e c i a l T o o l s
LIG HT TR U C K SE R V IC E M A N U A L
TRANSFER CASE
7E-1
SECTION 7E
TRANSFER CASE
CONTENTS
Model 208 T ransfer Case (10 and 20 S e rie s)..........................................
Model 205 T ransfer Case (30 S eries)........................................................
Specifications....................................................................................................
Special T ools.....................................................................................................
7E-1
7E-9
7E-15
7E-16
GENERAL DESCRIPTION
MODEL 208,PART TIME (ALUMINUM CASE)
The Model 208 transfer case (as shown in Fig. 7E-1) is
an alum inum case, chain drive, four position unit providing
four-wheel drive high and low ranges, a two-wheel high
range, and a neutral position. The model 208 is a part-tim e
four-wheel drive unit. Torque input in four-wheel high and
low ranges is undifferentiated. The range positions on the
Model 208 are selected by a floor m ounted gearshift lever.
Models equipped with the 208 transfer case are also
with au to m atic locking front drive hubs as stan d a rd
equipm ent.
The Model 208 case is a two-piece alum inum case
containing front and rear output shafts, two drive sprockets,
a shift m echanism and a planetary gear assembly. The drive
sprockets are con- nected and operated by the drive chain.
The planetary assembly which consists of a four pinion
carrier and an annulus gear provide the four-wheel drive low
range when engaged. Reduction ratio is 2.61:1 in this range.
LIGH T T R U C K S E R V IC E M ANU AL
7E-2
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
TRANSFER CASE
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
LIGH T T S U C K s e r v i c e m a n u a l
TRANSFER CASE
7E-3
Shift Pattern
REAR
YOKE
IDENTIFICATION
TAG
DRAIN
FILL
PLUG
Identification
An identification tag is attached to the rear half of the
transfer case (Fig. 7E-3). This tag provides the transfer case
model num ber, low range reduction ratio, and assembly
num ber. The inform ation on this tag is necessary for
servicing inform ation. If the tag is removed or becomes
dislodged during service operations, it should be reattached
using an adhesive sealant such as Loctite 312, or equivalent.
INDICATOR
SWITCH
Power Flow
Lubrication
The M odel 208 tran sfer case lu b rican t should be
changed at the intervals specified in the M aintenance
Schedule. W hen adding lubricant to or refilling the transfer
case after service, use Dexron II. Refer to the m aintenance
7E-4
TRANSFER CASE
SERVICE DIAGNOSIS
GENERAL
Before attem pting to repair a suspected transfer case
m alfunction, check all o th er driveline com ponents. The
actual cause of a problem may be related to such items as
Raise vehicle.
Position drain pan under transfer case.
Remove drain and fill plugs and drain lubricant.
Install drain plug. Tighten plug to 18 ft. lb.(24 N-m).
Remove drain pan.
Fill tra n sfe r case to edge of fill plug opening with
Dexron II.
7. Install fill plug. Tighten plug to 18 ft. lb. (24 N-m).
8. Lower vehicle.
LIGH T T R U C K S E R V IC E M AN U AL
TRANSFER CASE
7E-5
Fig. 7E-4 Transfer Case Linkage Skid Plates and Strut Rods
LIGH T T R U C K S E R V IC E M AN U AL
7E-6
TRANSFER CASE
LIGH T T R U C K S E R V IC E M ANU AL
TRANSFER CASE
7E-7
Service Diagnosis
Condition
.awn* u# vo *
Possible Cause
T R A N S FE R CASE
(1) Vehicle speed to o great to perm it
shifting.
D IFF IC U L T TO SH IFT
.
O R WILL NOT SH IFT
cniilj Off) t?flfegri
INTO D ESIRED
RANGE
bnjd n ft! 10 usihob ?
icy, (2) If vehicle was o perated for extended
period in 4H m ode on dry paved
^ i^ J n p jrfg iT
surface, driveline to rq u e load may
cause difficult shifting.
>
roforisi'i '4'i.a'jg novi 1*11.**ft)0 h 0 1 r:i;K
(3) T ransfer case external shift linkage
na:,- 1 * ;1 V, pj feJiBila iai[: qOiC
binding.
, i ,'i/fs uz
" 4j i grti^ij as A? / -u.
- m r i c / . " . ;T i t t/m -"i grtr, - i
(4) Insufficient or incorrect lubricant.
isb n u iTTO* 1 br ^j/ l7oqc5c-a*:vcni.v.>i
(5) Internal com ponents binding,
w orn, or damaged.
> i)f
>l*nivU;i no a$i& ishnuii o. Ju}j
(1) Insufficient or incorrect lubricant.
T R A N SFE R CASE
NOISY IN ALL DRIVE
MODES
NOISY I N - O R JUMPS
OUT O F FOUR WHEEL
D RIV E LOW RANGE
LUBRICANT LEAKING
FROM OUTPUT SHAFT
SEALS OR FROM
VENT
ABNORMAL TIR E
WEAR
Correction
(1) S top vehicle and shift into desired
range. Or reduce speed to 2-3 m ph
(3-4 k m /h) before attem p tin g to
shift.
(2) Stop vehicle, shift transm ission to
n eutral, shift transfer case to 2H
m ode and o p erate vehicle in 2H on
dry paved surfaces.
(3) L ubricate or repair or replace link
age, or tighten loose com ponents as
necessary.
(4) Drain and refill to edge of fill hole
w ith DEXRON-II only.
LIGHT T R U C K S E R V IC E M A N U A L
7E-8
TRANSFER CASE
ON VEHICLE SERVICE
2. Shift transfer case to 4H position if not done previously.
LIGH T T R U C K SE R V IC E M A N U A L
case
gasket
on
TRANSFER CASE
7E-9
7E-9
7E-11
7E-11
7E-12
7E-12
7E-12
7 E -12
7E-12
GENERAL DESCRIPTION
MODEL 205 TRANSFER CASE (30 SERIES)
A transfer case mounts behind the transmission and
allows drive torque to be transm itted in a proportional split
to both the front axle and the rear axle, resulting in fourwheel drive. The shift control lever for the transfer case is
floor-mounted in the passenger com partm ent. Depending on
the type of transfer case and the shift lever position, various
com binations of rear wheel drive, four wheel drive, high
traction (gear reduction) or direct drive may be selected.
The model 205 transfer case shown in Fig. 7E-7 is a
two-speed unit which can be used for either two-wheel or
four-wheel drive. Direct drive (1:1 ratio) is available in two
modes, 2H for two-wheel drive, or 4H for four-wheel drive.
G ear reduction (1.96:1 ratio) is used in the 4L position. This
unit uses constant mesh helical gears to connect the input
shaft, idler gear and two output gears, thus allowing gear
selection to m atch driving conditions. The front input shaft
gear (Item # 2 7 ) is in constant mesh with the idler gear
( # 4 4 ) and, through the idler gear, with the front output
gears ( # 5 9 and # 6 7 ) and the rear output gear ( # 1 7 ) .
S liding clutches ( # 2 6 , # 6 4 ) allow for selective gear
engagem ent resulting in High or Lo range, and two-wheel or
four-wheel drive. Ball bearings support the input shaft, rear
output shaft and front output shaft. Tapered roller bearings
are used on the idler shaft. W hen driving in a four-wheel
mode (4L or 4H ) the hubs on the front wheels must be
turned to the "L ocked" position.
LIG H T T R U C K S E R V IC E M ANU AL
7E-10
TRANSFER CASE
1.
Rear O u tp u t S h a ft L o c k n u t
26
S lid in g C lu tch
49
Cover Gasket
W asher
27
In p u t S h a ft
3
4
Yoke
B e a r i n g R e t a i n e r a n d Se a l
28
29
Fro n t O u tp u t S h a ft L o c k n u t
W asher
A ss e m b ly
5
S n a p R in g
30
31
T ra n s fe r Case
P o p p e t P lu g , S p r i n g a n d Ba ll
P T 0 G a ske t and C over
50
5 1
52
6
7
B e a rin g
S p e e d o m e te r Gear
Gasket
10
11
12
13
14
15
R ea r C o v e r
53
54
Yoke
55
56
57
Gasket
S n a p R in g
32
S n a p R in g a n d R u b b e r
R ing
S h i f t L in k C le v i s Pm
58
Thrust W a sh e r
H ou sin g
33
34
Gasket
35
R a n g e S h i f t Rail
S h i f t Rail C o n n e c t o r L in k
59
60
Front W h e e l H ig h G ear
F ro n t O u tp u t S h a ft
B earing
36
F r o n t W h e e l D r iv e S h i f t Rail
61
S n a p R in g
37
I n t e r l o c k Pins
62
N ee d le B e a rin g s
Spacer
T hrust W a sh er
38
N eedle B e a rin g
39
63
T h r u s t W a s h e r L o c k Pin
64
S lid in g C lu tc h G ear
16
T h r u s t W a s h e r (Ta n ge d )
S h ift Fork
S h i f t Rail S e a ls
Idler S h a ft B e a rin g
65
17
40
4 1
66
Roll Pm
18
N eedle B e a rin g s
42
Bearing Cup
67
Front O u tp u t L ow Gear
19
Spacer
43
44
S h im s
Idler Gear
68
20
69
T h r u s t W a s h e r L o c k Pin
T hrust W a sh er
Front B earing
2 1
N ee d le B e a rin g s
Tanged W asher
45
Bearing Cup
70
S n a p R in g
22
Rear O u tp u t S h a ft
46
Spacer
71
Rear C o v e r G a s k e t
23
24
N ee d le B e arings
47
Idler S h a ft B earing
72
Re a r C o v e r a n d B e a r i n g
W a s h e r and R etainer
48
Idler S haft
25
S h i f t F o rk
LIGHT T R U C K SE R V IC E M ANU AL
TRANSFER CASE
7E -11
DIAGNOSIS
COMPLAINT
Excessive
Noise
POSSIBLE CAUSES
1.
2.
3.
4.
5.
6.
Shifter Lever
Difficult to Move
Shifter Lever
Disengages
from Position
1.
2.
1.
2.
3.
4.
Lubricant
Leaking
1.
2.
3.
4.
Lubricant level-low
Worn or damaged bearings
Worn or damaged chain
Misalignment of drive shafts or universal joints
Yoke bolts loose
Loose adapter bolts
Dirt/contamination on linkage
Binding inside transfer case
Linkage misadjusted/loose
Gears worn or damaged
Shift rod bent
Missing detent ball or spring
Excessive lubricant in case
Leaking seals or gaskets
Loose bolts
Scored yoke in seal contact area
REMEDIES
1.
2.
3.
4.
5.
6.
1.
2.
1.
2.
3.
4.
1.
2.
3.
4.
Fill as required
Replace
Replace
Align
Torque to specs.
Torque to specs.
Clean and lubricate
Repair as required
Readjust/tighten
Replace
Replace
Replace
Adjust level
Replace
Tighten
Refinish or replace
LIGHT T R U C K SE R V IC E M A N U A L
7E-12
TRANSFER CASE
ON VEHICLE SERVICE
TRANSFER CASE REPLACEMENT
Removal (Fig. 7E-10)
1. Raise and support vehicle on hoist. Drain transfer case.
2. Disconnect speedom eter cable.
3. Rem ove skid p late and crossm em ber supports as
necessary.
4. Disconnect rear prop shaft from transfer case and tie
up away from work area.
5. Disconnect front prop shaft from transfer case and tie
up shaft away from work area.
6. Disconnect shift lever rod from shift rail link.
7. S upport tra n sfe r case and rem ove bolts attach in g
transfer case to transm ission adapter.
8. Move transfer case to rear until input shaft clears
adapter and lower assembly from vehicle.
Installation
1. Support transfer case in suitable stand and position
case to transm ission adapter. Install bolts attaching
case to adapter and torque to 45 ft. lb. (61 N-m).
2. Remove stand.
LIGHT T R U C K SE R V IC E M ANU AL
TRANSFER CASE
7E-13
LIGH T T R U C K SE R V IC E M AN U AL
7E-14
TRANSFER CASE
A U T O M A T IC
Fig. 7 E -1 1 -S k id Plates
LIGH T T R U C K S E R V IC E M AN U AL
TRANSFER CASE
7E-15
SPECIFICATIONS
N*m
MODEL 205
Nm
MODEL 208
26-40
26-40
120-150
120-140
14-20
14-20
2.2-3.2
2.2-3.2
27-34
122-176
BOLT, ADAPTER-TO-TRANSMISSION
26-40
26-40
26-40
26-40
FILLER PLUG
40-48
40-54
20-24
55-70
55-70
40-54
40-54
150-200
150-200
19-27
1.00 TO 1
1.96 TO 1
2.61 TO 1
LEVER POSITIONS
LEVER LOCATION
MODEL NO.
AVAILABILITY
RATIOS: HI RANGE
LO RANGE
LUBRICANTS:
OIL CAPACITY
5.2 PINTS*
8 PINTS*
TYPE, GRADE
LIGHT T R U C K SER V IC E M A N U A L
208--Special Tools
SPECIAL TOOLS
Fig. 7E-ST1
1.
2.
3.
4.
5.
6.
7.
TRANSFER CASE
7E-17
10
1.
2.
3.
4.
5.
6.
J 23432 1
J-23432
J-8092
J-23429
J 22836
J 21359
7.
J -23 4 3 1
9.
J 713 7
J -9276-2
J 22875
10 .
Rear O u t p u t
Remover and
A d a p t e r Seal
In te r m e d ia te
Rear O u t p u t
2.
3.
4.
5.
LIG H T T R U C K SE R V IC E M AN U AL
8A-1
SECTION 8A
8A-1
8A -1
8A-2
8A-9
8A-9
8A-11
8A-11
8A-11
8A-11
8A-12
8A-12
8A-16
8A-16
8A-16
8A-16
8A-17
8A-17
8A-21
LIGHT T R U C K SER V IC E M A N U A L
8A-2
Q]
0
0
0
0
0
0
0
0
0
0
0
C U IT BREAKER
-CHOKE
(TJ
CIRCUIT B R E A K E R
[_Aj FUSE-WINDSHIELD W IP E R
| b ] RECEPTACLE-IGN ACC-RADIO & AUX BAT.
j C~j FUSE-STOP & TRAF H A ZA R D LPS
[d ] P O W E R ACCESSORY
[jfj R E C E PT A C L E- PO W ER D OOR LOCK>
|_Fj FUSE-INST PA N EL LAM PS
[g ] RECEPTACLE-DIR SIG LP F LA SH ER
|H| FUSE-HEATER & A./C
IT]
[ k]
[Y]
FUSE-HORN D M
1~M|
RECEPTACLE-IGN-AUTO TRANS.
CRUISE C O N T R O L , PU LSE W IPER ,
TRANS IND LP
[p ]
FUSE-GAUGES
IqJ
FUSE-TAIL LAM PS
[R~|
R EC EPTACLE- TRAFFIC H A ZA R D F LA SH E R
[sl
"
j_Tj
FUSE-AUX H E A T E R & A C
[u | FUSE-RADIO
LIGHT T R U C K SER V IC E M A N U A L
8A-3
D IA G N O S IS
HEADLAMP DIAGNOSIS
Condition
Possible Cause
1. Loose connection
Correction
1. Voltage regulator
misadjusted
1. Readjust regulator to
specifications.
1. Loose connection
2. Defective dimmer
switch
LIGH T T R U C K SER V IC E M A N U A L
8A-4
1. Open connection or
defective dimmer switch
A ll lam ps inoperative
LIGHT T R U C K S E R V IC E M A N U A L
Possible Cause
Correction
2. R eplace bulb.
3. L oose connection or
open in wiring
1. L oose connection or
open ground connection
1. Blow n fuse
2. L oose connection
3. O pen in wiring
-1 0*1 U *,
lb
.?
3 ?-; 1 U *1
8A-5
B o th sides in o p erativ e
Possible Cause
Correction
1. B ulb b u rn t o ut
1. R ep la ce bulb
2. L oose co n n ectio n
2. S ecure c o n n e c to r at light
sw itch.
3. O p en w iring
4. M u ltip le bulb
b u rn o u t
LIGH T T R U C K SE R V IC E M A N U A L
8A-6
Condition
T u r n signals inoperative
one side
T u r n signals inoperative
Possible Cause
Correction
1. Bulb(s) b u rn t out
(F la sh e r canno t be
he a rd )
1. T u r n h a z a rd w a rn in g system on.
I f one o r m o re b ulbs are
inoperative replace necessary
bulbs.
2. O p en wiring or
gro u n d c o n n e c tio r
2. T u r n H a z a rd w a r n in g sy ste m on.
If o n e o r m o re b u lb s are
in o p era tiv e , use te st la m p and
check circu it at la m p so c k e t. If
test lam p lights, r e p a ir o p e n
g ro u n d c o n n e c tio n . I f n o t,
re p a ir o p e n w iring b e tw e e n
bu lb s o c k e t a n d t u r n signal
switch.
3. Im p r o p e r bulb or
defective turn signal
switch.
3. T u r n h a z a rd w a rn in g system on.
I f all front a n d rea r lamps
operate, check for im p ro per
bulb (1034 instead o f 1157).
I f bulbs are O K , replace defective
tu r n signal switch.
4. Short to ground.
(F la sh e r can be heard,
no bulbs operate)
1. Blown tu rn signal
fuse
1. T u r n h a z a rd w a rn in g system
on. If all lam ps operate, replace
blow n fuse. If new fuse blows,
repair sh ort to g ro u n d between
fuse an d lamps.
2. Defective flasher
(L o c a te d behind
in stru m e n t panel near
steering colum n)
3. Loose connection
1. Blown stop-hazard
fuse
2. Defective hazard
warning flasher. (Located
on fuse panel).
3. Open in wiring or
defective turn signal
switch.
8A-7
BACK-UP LAMP
Condition
One lamp inoperative or
intermittent
Possible Cause
Correction
2. Loose connection
2. Tighten connectors.
3. Open ground
connections
2. Loose connection or
open circuit
3. Blown fuse
Defective neutral
start switch
5. Defective ignition
switch
8A-8
L a m p will n o t t u r n off
STOP LIGHTS
Condition
Possible Cause
Correction
O ne bulb inoperative
1. Bulb b u rn t out.
1. R eplace bulb.
O n e side inoperative
1. Loose connection,
open wiring or defective
bulbs
1. T u r n o n d ir e c tio n a l signal. If
lam p d oes n o t o p e r a t e , check
bulbs. If b u lb s are O K , secure all
c o n n e c tio n s . I f la m p still d o e s
n o t o p e r a te , use test la m p an d
ch eck fo r o p e n wiring.
2. Defective directional
signal switch or
cancelling cam
2. I f lam p will o p e ra te by tu rn in g
directional signal on, the switch
is not c e n te rin g properly d u rin g
cancelling operatio n. Replace
defective cancelling cam or
directional signal switch.
1. S to p -h az a rd fuse
blown
2. W ith b ra k e p e d a l d e p re sse d , ch e c k
w h ite wire te r m in a l in steering
c o lu m n c o n n e c t o r w ith test
lam p. If la m p d o e s n o t light,
ch eck s to p sw itc h fo r p ro p e r
a d ju s tm e n t . I f a d j u s t m e n t is
O K , replace s to p sw itch.
1. Stop switch
m isadjusted or defective.
All inoperative
8A-9
ON-VEHICLE SERVICE
Maintenance of the lighting units and wiring system
consists of an occasional check to see that all wiring
connections are tight and clean, that the lighting units are
securely mounted to provide good ground and that the
headlamps are properly adjusted. Loose or corroded connec
tions may cause a discharged battery, difficult starting, dim
lights, and possible damage to the generator. Wire harnesses
must be replaced if insulation becomes burned, cracked, or
deteriorated. Whenever it is necessary to splice a wire or
repair one that is broken, always use solder to bond the
splice. Always use rosin flux solder on electrical connections.
Use insulating tape to cover all splices or bare wires.
When replacing wires, it is important that the correct
size be used. Never replace a wire with one of a smaller size.
Fusible links in the wiring are four gage sizes smaller than
the cable it is designed to protect. The links are marked on
the insulation with wire gage size because of the heavy
insulation which makes the link appear a heavier gage than
it actually is.
Each harness and wire must be held securely in place
by clips or other holding devices to prevent chafing or
wearing away the insulation due to vibration.
By referring to the wiring diagram manual, circuits
may be tested for continuous circuit or shorts with a
conventional test lamp or low reading voltmeter. These
wiring diagrams use metric wire size designations, a chart
showing metric to A W G size conversions is provided in the
manual.
8 A -10
RADIATOR
FRO NT FEN D ER
VIEW A
RADIATOR
SUPPO R T
RADIATOR GRILLE
LOWER PANEL
Fig. 8A-3--Front Lighting (C-K Models)
FORW ARD
LAMP
8 A -1 1
FRONT LAMP
HARNESS ASSEMBLY
FRONT
MARKER
LAMP
VIEW A
E94 O R Z80
8A -12
Left Side
C-K Models
Replacement (Fig. 8A-3)
G Models
Replacement (Fig. 8A-4)
Right Side
1.
2.
3.
4.
5.
6.
LICENSE LAMP ,
WIRE ASSEMBLY
LICENSE
LAMP
ASSEMBLY
DARK GREEN
BROW N
MARKER LAMP
LIGHT GRFEN
LIGHT GREEN
BROW N
LICENSE '
I
LAMP WIRE jfc
ASSEMBLY
&
BROW N
( L H SIDE O NLY)
FUEL TA NK
METER ASSEMBLY
RIGHT SIDE
8 A -13
8 A -14
LICENSE PLATE
LAMP WIRE
VIE W 1
FRONT MARKER
LAMP HARNESS
CENTER MARKER
\ X LA M P S WIRE
| v ie w ]
FRONT WIRE
ASSEMBLY
SIDE MARKER
LAMP \
REAR LICENSE ^
LAMP ASSEMBLY
TAIL & STOP
LAMP HARNESS
SIDE MARKER
LAMP
C 3 0 ( 0 3 ) W IT H O P T IO N E56
CK 1 0 - 2 0 A N D C 3 0 9 ( 0 3 ) W IT H O P T IO N E62
Fig. 8AA-8A--Rear Lighting (C30 03 Models with E56 and C-K Models with E62)
8 A -15
C 3 0 9 W ITH O P T IO N E63
MARKER LAMP ( CREAM)
TAIL C O M B IN ATIO N LAMP ( GRAY)
MARKER LAMP
(CREAM)
[ ^ 0
TYPICAL
0 3 -6 3 BASE M O DELS
8 A -16
AND/OR HOUSING
LIGHT SWITCH
Replacement
1.
2.
3.
4.
^OST'vO HTIW
.
|
1. Disconnect battery ground cable.
2. Reaching up behind instrument cluster, depress shaft
retaining button and remove switch knob and rod.
3. Remove instrument cluster bezel screws on left end.
Pull out on bezel and hold switch nut with a wrench.
4. Disconnect multiple wiring connectors at switch
terminals.
5. Remove switch by rotating while holding switch nut.
6. To install; reverse Steps 1-5 above.
V-:-
i
8A -17
STOPLAMP SWITCH
Replacement
1. Fold back upper left corner of the floor mat and remove
two screws retaining switch to the floor pan.
2. Disconnect wiring connector from switch terminals.
3. Connect wiring to replacem ent switch and check
operation.
4. Position switch to floor pan and install retaining screws.
5. Replace floor mat.
8 A -18
PARKING BRAKE
BRACKET
FRONT MARKER
LAMP
FRO NT LAMP
4 $*
BRAKE DIST.
& SW. ASSEMBLY
HORN
ASSEMBLY
NUT
BATTERY
GROUND
PARKING
BRAKE
CABLE
VIEW C
VIEW B
PARKING
BRAKE
NUT
VIEW D
FUSE PANEL
REINFORCEMENT
GROUND
WIRE
GROUND WIRE
SIDE MARKER
LAMP
PARKING LAMP
BRACKET
DIST & SWITCH
.RADIATOR GRILLE
PANEL
FRAME
(2B)
8 A -19
VIEW B
VIEW A
CR O SSM EM BER
2-9.00
8A -20
8 A -2 1
S P E C IF IC A T IO N S
LAMP BULB DATA
C-K-P TRUCK
USED IN
Q UANTITY
Dome Lamps:
Cab
U tility & Suburban
Oil Pressure indicator lamp1
Generator indicator lamp1
Instrument cluster lamps2
Headlamp beam indicator
lamp
Lamp assembly - tail &
stop lamp
License Lamp4
Directional signal
(front park lamps)6
Head Lamps
Temperature indicator lamp
Directional signal indicator
lamp
Clearance and marker lamps
Roof marker lamps5
Brake warning indicator
Transmission control (auto)
Backing lamp (exc.
motor home)
Backing lamp (motor home)
Heater or A/C
Corner marker lamps
(platform)
Cargo lamp (C-K cab)
Radio dial lamp - AM
- AM/FM
Courtesy lamp
Windshield wiper switch
Clock
Rear identification7
Underhood lamp
Seat belt warning
Cargo/dome lamp
Four wheel drive indicator
Choke heater Ind
TRADE # POWER
1
1
1
1
5
1004
211-2
168
168
168
168
3 CP
2
1
1157
67
3-32 CP
4 CP
2
2
1
1157
6014
168
3-32 CP
50-60 W
3 CP
2
4
5
1
1
168
168
194
168
1445
3 CP
3 CP
2 CP
3 CP
0.7 CP
2
2
1
1156
1295
161
32 CP
50 CP
1 CP
7
1
1
1
1
1
1
10
1
1
2
1
1
67
1142
1816
216
1003
161
168
1895
93
168
211-2
161
168
4 CP
21 CP
3 CP
1 CP
15 CP
1 CP
3 CP
2 CP
15 CP
3 CP
12 CP
1 CP
3 CP
15
12
3
3
3
CP
CP
CP
CP
CP
USED IN
Dome lamps
Oil pressure indicator lamp
Generator indicator lamp
Instrument cluster lamps11
Headlamp beam indicator
lamp
Park, directional signal
lamps
Tail, stop lamps
License lamp
Head lamps12
Temperature indicator lamp
Directional signal indicator
lamp
Marker lamps
Brake warning indicator lamp
Back-up lamp
Radio dial lamp
Heater or A/C control
Transmission control w /tilt
wheel
W/S wiper switch lamp
Transmission control
Choke heater ind
Seat belt warning
Instrument cluster lamps9
Instrument cluster lamps10
9
10
11
12
211-2
161
194
161
161
1 CP
2
2
1
2
1
1157
1157
67
6014
194
3-32 CP
3-32 CP
4 CP
50-60 W
2 CP
2
4
1
2
1
1
194
168
194
1156
1893
194
2 CP
3 CP
2 CP
32 CP
2 CP
2 CP
1
1
1
1445
161
73
1893
194
194
168
0.7 CP
1 CP
.3 CP
2 CP
2 CP
2 CP
3 CP
1
1
5
1
12 CP
1 CP
2 CP
1 CP
J'
:-r
r ':
8B-1
SECTION 8B
8B-1
8B-3
8B-4
8B-4
8B-4
8B-5
8B-5
Diagnosis.......................................................................... 8B-5
On-Vehicle Serv ice........................................................ 8B-6
Headlamp Warning Buzzer........................................... 8B-6
Seat Belt Warning S y s te m ............................................ 8B-6
Anti-Theft Alarm S ystem .............................................. 8B-8
Specifications.....................................................................8B-12
RADIO RECEIVER
3. AM Radio -Remove the radio support bracket stud nut
and lockwasher.
C-K Series
Replacement (Fig. 8B-1)
8B-2
G Models
8B-3
AM /FM
REAR SPEAKER
FRONT SPEAKER
C-K Series
C-K Models
1.
2.
3.
4.
5.
G Models
G Models
G ModelsLeft Side
CK 1 0 5 (0 0 ) & Z 8 4
.0 9 + 2 0 9 (0 6 )
Fig. 8B-4--Speaker lnstallation--G Series
8B-4
REINFORCEMENT
SPEAKER
SPEAKER
GRILLE
[v ie w [ a 1
SPEAKER
CIRCUIT PROTECTION
GENERAL DESCRIPTION
All electrical circuits are protected against excessive
loads which might occur due to shorts or overloads in the
wiring system. Such protection is provided by either a
circuit breaker, fuse or fusible link. Each of these protective
devices are explained below.
BREAKER
8B-5
TO JUNCTION
BLOCK
CON NEC TOR C O V E R IN G
DIAGNOSIS
FUSE (Fig. 8B-8)
A common method of protection is to use a fuse in the
circuit. Whenever there is an excessive current through the
circuit, the fusible element will melt and open the circuit.
The disadvantage of using a fuse instead of a circuit breaker
is the fuse in a one-time protection and replacement is
required.
8B-6
ON-VEHICLE SERVICE
HEADLAMPS WARNING BUZZER
CONNECTOR
F U SIB LE LIN K
CONNECTOR C R IM P E D
AND SOLDERED
Diagnosis
ELECTRICAL AND
WIRING
8B-7
8B-8
8B-9
8B -10
8B-11
8B-12
SPECIFICATIONS
FUSES CIRCUIT BREAKERS
The wiring circuits are protected from short circuits by a combi
nation of fuses, circuit breakers, and fusible thermal links in the
wiring itself. This g reatly reduces the hazard of electrically
caused fires in the vehicles.
10 Amp
G TRUCK
C-K TRUCK
Heater, Front A/C, G enerator W arning
Lam p ...........................................................................
Idle Stop Solenoid, Aux. Battery, Radio,
Time D elay Relay, Emission Control Solenoid,
Transmission Downshift ( M 4 0 ) ..........................
Cigarette Lighter, Clock, Dome Lamp,
Cargo L a m p ............................................................
Fuel G au g e , Brake W arning Lamp,
Temperature W arning Lamp, O il
Pressure W arn ing Lamp ....................................
Courtesy Lamp, Roof M arker Lamp,
License Plate Lamp, Parking Lamp,
Side M arker Lamp, Tail Lamp,
Clearance Lamp ..................................................
Directional Signal Indicator Lamp, Stop Lamp,
Traffic H a z a r d .......................................................
Instrument Cluster Lamp, H eater Dial Lamp,
Radio Dial Lamp, Cruise Control Lamp,
W indshield W ip e r Switch L a m p ......................
W indshield W ip e r /W a s h e r ....................................
Cruise Control, Rear W indow Aux., Fuel Tank,
Tachometer, Back-up Lamp, Directional
Signal Indicator Lamp, Directional
Signal Lamp, H ead lam p Buzzer ........................
20 Amp
15 Amp
20 Amp
4 Amp
20 Amp
15 Amp
4 Amp
25 Amp
H eater, A / C .................................................................
Idle Stop Solenoid, Cruise Control,
Directional Signal Lamp, Directional
Signal Indicator Lamp, Transmission
Downshift ( M - 4 0 ) ...................................................
C igarette Lighter, Dome Lamp, Spot Lamp . . .
Fuel G au ge, Brake W arning Lamp,
Temperature W arning Lamp, G enerator
W arning Lamp, O il Pressure W arning Lamp
Stop Lamp, Traffic H a z a r d ....................................
A uxiliary Battery, Backing Lamp, Radio
Dial Lamp, Radio ................................................
Instrument Cluster Lamp, H eater Dial Lamp,
Transmission Control Lamp with Tilt W h e el,
Cruise Control Lamp, W /S W ip e r
Switch Lamp, H ead lam p B u z z e r......................
License Lamp, Parking Lamp, Sid e
M arker Lamp, Tail L a m p ....................................
W indshield W i p e r .....................................................
25 Amp
10 Amp
15 Amp
3 Amp
15 Amp
15 Amp
3 Amp
15 Amp
25 Amp
15 Amp
P TRUCK
H e a te rt, A ir C o n d it io n in g t..................................
Instrument Cluster Lamp, W indshield
W ip er Switch L a m p ..............................................
Directional Signal Indicator Lamp, Stop Lamp,
Traffic H a z a r d .......................................................
Fuel G au g e , Brake W arn ing L a m p ...................
License Plate Lamp, Parking Lamp,
Side M arker Lamp, Tail Lamp,
C learance Lamp, Identification L a m p ..........
W indshield W a s h e r /W ip e r ....................................
C ig arette Lighter!, C lo ckt, Courtesyt,
Dome Lampt ..........................................................
A uxiliary Batteryf, Back-up Lamp,
R a d i o ........................................................................
25 Amp
CIRCUIT BREAKERS
3 Amp
15 Amp
3 Amp
15 Amp
25 Amp
15 Amp
15 Amp
DEVICE OR
CIRCUIT
PROTECTED
MODELS
AMPERES
LOCATION
C-K-P-G
15
Light
switch
C-K
30
Dash
(forward side)
Rear A/C
(C69 overhead)
35
Dash
(forward side)
H eadlam p and
.parking lamp
circuit
8C-1
SECTION 8C
8C-1
8C-1
8C-2
8C-7
8C-7
8C-7
8C-7
8C-7
8C-7
8C-10
8C-10
8C-11
8C-11
8C-11
8C-11
8C-11
8C-12
8C-12
8C-15
8C-15
8C-I5
8C-15
.8C-18
8C-18
8C-18
8C-21
8C-21
8C-21
8C-32
8C-32
8C-32
8C-32
8C-32
8C-32
8C-32
8C-33
8C-33
8C-38
8C-38
8C-40
8C-40
8C-45
8C-45
8C-46
8C-56
GENERAL DESCRIPTION
All instruments and gages are installed in the instru
ment cluster. Instruments and gages can be serviced in the
vehicle (C-K Series); however, the entire cluster must be
removed from the vehicle for servicing of the instruments
and gages (G Series). Illuminating and indicator lamps may
be replaced without removing the cluster from the vehicle.
8C-2
D IA G N O S IS
OIL PRESSURE INDICATOR
Condition
L ight not lit, ignition
on and engine not running.
Possible Cause
Correction
1. Bulb bu rn e d out.
1. R ep lace bulb.
switch.
L ight on, engine ru n n in g
above idle speed.
1. G r o u n d e d wiring between
light an d switch.
1. L o cate a n d re p a ir ground.
switch.
3. Low oil pressure.
Possible Cause
Correction
1. Bulb b u rn e d out.
1. R e p la c e bulb.
3. D efective ignition
3. R e p la c e ignition switch.
switch.
L ight on, engine
running.
1. W iring g ro u n d e d between
light an d switch.
1. L o cate a n d co rre c t
g r o u n d e d wiring.
2. Defective te m p e ra tu re
switch.
2. R eplace te m p e r a tu r e switch.
4. C o o la n t te m p e ra tu re
above 258 degrees F.
4. L o c a te a n d c o rre c t cause
o f high c o o la n t te m p e ra tu re.
8C-3
Correction
C h e c k and tig h te n c o n n e c tio n s . Be sure to check
g r o u n d stra ps.
R e p la ce d e fe c tiv e pa rts.
R ep lace relay.
R eplace h o r n .
Cause
L o w available voltage at h o r n .
D e fe c ts w ith in h o rn .
C h e c k b a t t e r y a n d ch arging circuit.
A lth o u g h h o r n sh o u ld b lo w at a n y v oltage above
7.0 volts, a w e a k o r p o o r t o n e m a y o c c u r at
o p e r a tin g voltages b e lo w 11.0 volts. If h o r n has
w eak o r p o o r to n e a t o p e r a tin g voltage o f 11.0
v olts o r highe r, re m o v e h o r n and replace.
Cause
L oo se o r i n t e r m i t t e n t c o n n e c tio n s in h o r n
relay o r h o r n circuit.
D efe c tiv e h o r n sw itch.
D e fe c tive relay.
D e fec ts w ith in h o rn .
C h e c k a n d tig h te n c o n n e c tio n s .
R eplace sw itc h.
R eplace relay.
R eplace h o r n .
Correction
Replace relay.
C heck a n d a d ju s t wiring.
A d ju s t o r replace d a m a g e d parts.,,
SPEEDOMETER
Cause
N oisy s p e e d o m e te r cable.
P o in te r a n d o d o m e t e r in o p e ra tiv e .
In a c c u r a te reading.
K ink ed cable.
D efective s p e e d o m e te r head .
Correction
8C-4
GAS GAUGE
D A S H U N IT N E V E R R E A D S F U L L
1.
C o n n e c t G a s G a u g e T e ste r J-2 2 3 4 4 to ta n k u n it
feed w ire an d o b se rv e dash unit.
2.
3.
N o te d ash u n it p o in te r w ith en g in e ru n n in g .
4.
5.
6.
C h e ck c lu ste r fuse.
2.
4.
R em o v e d ash u n it a n d c h e c k .
8C-5
8C-6
Possible Cause
Correction
1. Locate a n d replace
sh o rte d diode.
1. R eplace bulb.
2. O p en in light circuit.
3 . Open
3. R e p la c e
in f i e l d .
rotor.
1. N o g en e ra to r output.
1. C h e c k a n d co rre c t cause
o f no o u tp u t.
3. Loose or broken
g e n e rato r belt.
3. T ig h te n o r replace an d
tighten g e n e ra to r belt.
098 DIA.
SWITCH LEVER
TRANS LEVER
SWITCH LEVER
SWITCH
SWITCH
TRANS LEVER\
M O U N T IN G
BRACKET
COLUM N
LO CK IN G PIN
C -K M O D E L S
VIEW A
LO CKING PIN
G M ODELS
P M ODELS
VIEW A
8C-7
ON-VEHICLE SERVICE
NEUTRAL START SWITCH
C-K Models (Fig. 8C-1)
Replacement and Adjustment
G-P Series
Replacement (Fig. 8C-1)
1.
2.
3.
4.
5.
6.
7.
8.
9.
G Models
Replacement
IGNITION SWITCH
C-K Series
See Section 3B - Steering, for ignition switch replace
ment procedure.
G Series
Replacement (Fig. 8C-2)
8C-8
8C-9
BEZEL
(TYPICAL)
INSTRUMENT BEZEL
CLUSTER
INSTRUMENT
CLUSTER
PRINTED CIRCUIT
INSTRUMENT CLUSTER
HI BEAM IN D .
INSTR. CLUSTER
INSTRUMENT
CLUSTER
OIL PRESSURE IN D
E N G IN E TEMP IN D .
BRAKE W A R N IN G IN D .
G E N . TELL TALE
FUEL G A G E CLIPPING
AMP G A G E CLIPPING
BRAKE W A R N (EXC U 35)
CLOCK & U35
TEMP GAGE CLIPPING
BRAKE W A R N & U 35
FUEL GA G E CLIPPING & 16
TURN SIGNAL IN D .
VIEW B
PRINTED CIRCUIT
8C -10
INSTRUMENT CLUSTER
C-K Series
Replacement (Fig. 8C-3)
1.
2.
3.
4.
5.
6.
G Series
SPEEDOMETER
Servicing of the speedometer assembly should only be
performed by trained technicians having the proper test
equipment.
FUEL GAGE
C-K Series
Replacement
C-K Models
G Models
Replacement
Replacement
1.
2.
3.
4.
5.
6.
7.
8.
G Series
Replacement
8C-11
TEMPERATURE GAGE
C-K Series
Replacement
G Models
Replacement
8 C -12
G Models
Replacem ent
8 C -13
INSTRUMENT
CLUSTER
TRANSFER
CASE
TRANS COVER
KOOO(OO)
& K30
TRANS
-HARN
C000(00)
& K30
8C-14
INSTRUMENT CL U ST ER
SPLG WIRES
TRANS. ASM.
ACCELERATOR
CABLE
DASH PANEL
V IE W
8C -15
All Models
Replacement
VOLTMETER
C-K Series
G Models
Replacement
Replacement
8C-16
L IG H T SW IT C H
CONN
IN S T P A N EL
H A R N E SS
L IG H T
CONN
R E C E IV E R
HARN
SW IT C H
R E C E IV E R
HARN
IN S T P A N E L
H AR N ESS
FU S E
IN S T P A N E L
H A R N E SS
PANEL
FU SE
P A N EL
VIEW
INST CLUSTER C O N N
HEATER C O N T A S M -
IG N
INST PANEL
SW
BLOWER
MOTOR
LEAD
LIGHT SW C O N N
\
W S W & W A SWITCH
CONN
l/P HARN
GRD WIRE
BODY W IR IN G ,
HARN & C O N N
V IE W
GROUNDINC W/0
BUS BAR
BRACKET
PARKING
BRAKE
VIEW
DIM M ER
TO DIMMER SW ITCH-
SWITCH
l/P HARNESS
STEERING C O LU M N
C. HEATER CONTROL
/
8C -17
LP
l/P
HARNESS ,
B. R A D IO C ONNECTOR
A .C IG
LIGHTER C O N N
HEATER SW C O N N
BOLTS
C IG LIGHTER
CONN
STOP LP
SWITCH
NEUTRAL
START
SWITCH
IG N IT IO N
SW C O N N
INST PANEL ^
COURTESY LAMP
BRACKET
TURN SIG N A L
CONN
BRAKE^
PEDAL
BRACKET
DIRECTIONAL
SIGNAL
FLASHER
ASM
B A C K IN G
LAMP
CONN
l/P
HARNESS
U)/U)
LAMP3WITCHCONNECTOR
SW CONN
LPMPSO)
RELfi
HORNy
GROUNDWIRE
P/MMEZ.
SWITCH
-PARK. BRAKE
BRACKET
V IE W
-D
IM
ERTSOW
CO
NM
NEC
RITCH
SEATBELT
8C-18
Jj
STAKING
^ ( 1 0 PLACES)
I GEAR
i CAM
8C-19
PARK SWITCH
(Normally Closed)
WASHER
RELAY COIL
I
WIPER/WASHER PUMP ASSY
|
Fig. 8C-10--Wiper M otor Schematic
8C-20
VALVE
ASSEMBLY
ELONGATED
SLOT n
TANG
PISTON
8 C -2 1
SPRING
COMPRESSED
INTAKE
VALVE
OPEN
DIRECTION OF TRAVEL
FROM
WASHER
JAR
'/ / / i
ACTUATOR PLATE
EXHAUST
VALVES
CLOSED
INTAKE STROKE
LEG IN SLOT
ON RIM OF GEAR
DIAGNOSIS
WIPER - ON VEHICLE
Troubleshooting with wiper installed on the vehicle
consists of two basic steps: (A) Preliminary inspection and
(B) Operating wiper independent of vehicle wiring and dash
switch.
8C-22
W ASHER PUMP
TERM INALS
- l^
__ _
-t-)
PARK
LO SPEED
[q
12V(
a|
+ ^ ^ H I SPEECH
12V( + )
8C-23
DIAGNOSIS CHART
SYMPTOM
PROCEDURE
NO.
7) Intermittent operation
10
Go To STEP 5
Go To STEP 2
Go To STEP 3
8C-24
Procedure 1 (cont.)
Go To STEP 4
Problem is in motor
refer to w iper repair
page
Problem is in motor
refer to w iper repair
Page
Ignition switch ON . Leave w iring connected to wiper. Connect jum per wire from
term inal no. 3 to ground. Dash switch in "H I" speed position!!____________
Wiper Runs in Hi
Problem is an open
wire from terminal no. 3
to dash switch,
or Dash Switch.
W iper Inop.
8C-25
PROCEDURE 5
(Wiper shuts off but blades dont return to park position)
8C-26
Ignition switch ON". Dash switch in OFF" position. Disconnect w iring from wiper
term inals 4 & 5.
W iper Stops
Go To STEP 2
STEP 2
Remove w iring from w iper term inals 1, 2,3. Connect 12v+ to wiper terminal 1 only.
Remove wiper fuse from fuse block and connect an ammeter (0-30 amp) across the
fuse block term inals where the fuse was. Turn ignition switch ON and run w iper in
Hi speed w ith w indshield dry. Note the lowest current draw reading.
C urrent Draw:
exceeds 5.0 Amps.
Current Draw:
less than 5.0 Amp.
A weak circu it breaker
s indicated. Replace
m otor end cap assy.
Remove arms and blades and repeat Step 1
STEP 2
C urrent Draw OK
Replace blade elements
STEP 3
C urrent Draw Hi
Go To Step 3
Disconnect wiper linkage from wiper crank arm and repeat Step 1.
Current Draw OK
Check w iper linkage
fo r a binding condition
and repair or replace
as reqd.
Go To STEP 2
Current Draw Hi
P r o b le m is in w ip e r
m o to r. C h e c k fo r
a r m a t u r e e n d p la y ,
s h o r te d o r g r o u n d e d
a r m a tu r e .
8 0 -2 7
Go To STEP 2
Go To STEP 4
Go To STEP 3
L o o k fo r open in
B + c irc u it to pum p.
G ro u n d th e d im lig h t
te rm in a l. If pu m p runs
OK ch e ck fo r open in w ire
betw een pum p and dash
sw itch or a def. dash sw.
O therw ise, Go To Step 4.
8C-28
STEP 4
Remove washer pump cover and re-connect wiring to wiper motor terminals 1, 2 and
3. Turn on wiper motor and observe if ratchet pawl is moving back and forth.
Not moving
leg\
SPRING
i>
awi
STEP 5
Moves back
and forth
Leave wiper running
and Go To STEP 5
Connect 12(+) volts to one of washer pump terminals (6 or 7) and ground the other for
approx. 2 seconds. Observe it relay armature is pulled toward the relay coil; armature
leg drops down on gear ramp and ratchet pawl starts rotating ratchet gear.
Refer to view in STEP 4.
Operates OK
Go To STEP 6
STEP 6
8C-29
Pump stops
Check for grounded wire
between pump terminal
and dash switch or
a defective dash sw.
Go To STEP 2
Disconnect wiring from wiper unit; remove washer pump cover and re-connect
w iring to wiper-washer. Turn on wiper and check the follow ing items.__________
a)
b)
c)
d)
8C-30
8C-31
-------
HG' W.
D iagn o sis
SVG
>q
W IP E R S DO NOT DELAY
icifeni 6
!J- / . I T 1 0 TO M l
B n tiV iU
o nwtt>
i *I
M
l v :--v hr xJ*':
iO fl j!c:
W IP ER S DO
NOT OPERATE
N ORM ALLY
ru inun
j i r m i s . tri
, *j*?.sq
iw<: j r i ! oi :* rim
j&i,] y j
H Dum ? w
D ETERM IN E
CONTROLLER IS
P R O P ER LY CONNECTED
CONTROLLER CONNECTED
^ I -3 8 S jSjSIi GJ T .b
__________________________
gnniv/ toyartjpaLCI
FUNCTIONS
RELAY
PR O PER LY
CHECK W IPER
SW ITCH
(SEE PRO CEDU RE)
K! m A:r
SWITCH OK
W IPER OPERATE
N O R M A LLY
TEST RELAY
(SEE PRO CEDU RE)
.n?
h . ,T >'* >
:GfT '
j
c v ia ;.!
REPLACE
CONTROLLER
REPLACE
RELAY
=L
SW ITCH
DEFECTIVE
S Y S T E M IS
R ESTO RED
REPLACE
SWITCH
SY S T E M IS
RESTORED
r~
SYST EM
RESTORED
Dark Blue
i if- *J*
control)
-J
in on
press
s=
o
(Oft Mode
Mist
W ash
Control
bh-i
(Rotate
;q#jo-,brf*
Delay
: t'.; /joa i
:>u:
Delay
uq bns
01 O'
Light Blue
Green
Black
Orange
White
.Hjfunfi'M-
:B /Gig 3fii oi ) rt..
8C-32
ON-VEHICLE SERVICE
WIPER MOTOR
C-K Models
Replacement (Fig. 8C-17)
5.
6.
7.
8.
9.
UNIT REPAIR
WIPER MOTOR
Repairs to the motor/gear box section of the wiper are
limited to the switch, armature, and cap and brush holder
assy., plus the external parts such as the crank arm, spacer/
seal (plastic) and output shaft seal.
PARK SWITCH
This is part of the washer pump relay coil assembly.
Refer to figui e 8 C -19.
Removal
G Series
1.
2.
3.
4.
8C-33
WASHER PUMP
Relay Coil
8C-34
C O N N E C T IO N S TO O P E R A T E W IP E R S IN D E P E N D E N T L Y OF V E H IC L E
W I R I N G A N D D A S H S W ITC H.
LO SPEED
12V(
PARK
This will allow gear collar to slide past the tab on the
piston actuator plate. (Refer to Figure 8 C -12).
8C-35
B E SU RE BRUSH L E A D S
ARE ROUTED CO RR EC T LY
A N D A R E N O T T O U C H IN G
E A C H OTHER
B R U S H S P R IN G L E G
IN C O R R E C T P O S IT IO N
F O R R E - A S S E M B L Y IN
M O T O R (3 S P R IN G S )
S P E E D BRUSH
LEA D ROUTED
CO RRECTLY
NOTE: B E SU R E LO W ER
B R U S H S P R IN G L E G S A R E
IN B R U S H H O L D E R S L O T S
Fig. 8C -20--Relay Coil Assembly
B R U S H S P R IN G IN R E L G A S E D
P O S IT IO N (3 S P R IN G S )
R O T A T E BRUSH
SP R IN G IN D IR E C T IO N
B R U S H S P R IN G LEG
OF AR R O W TO RE
RELEASED FROM RE
P O SITIO N IT B E H IN D
R E T A IN E R NOTCH
T A IN E R NOTCH
R E T A IN E R
NOTCH
8C-36
NUT
CRANK ARM
SHAFT SEA L
(RUBBER)
SP A CER
(PLASTIC)
ARMATURE
END PLAY
ADJUSTING
SCREW
A X - I D E N T I F IC A T IO N C O D E
G V A N C R A N K A R M
P A R K P O S I T IO N
A Y - ID E N T IF IC A T IO N
CODE
Fig. 8C -24--C ra n k A rm Sp a ce r Seal
8C-37
P A W L S P R IN G
E R E T A IN E R
R IN G
L E G O F R E T A IN E R
IN R A T C H E T G E A R
SH AFT GROOVE
D O G S P R IN G
RATCHET G EA R
8C-38
M O U N T IN G G R O O V E
(Both Sides)
8C-39
PER GEAR
TRAIN
DA S H
WIPER
TERMINAL
S WI TC H
BOARD
PARK
S WI TC H
TOTX
GRAY
ig n it io n
SHUNT F - NAT. W I R E
S WI TC H
8C-40
PARK
SWITCH
SERIES F*
DASH
SWITCH
OFF-LO-Hl
Fig. 8 C - 3 0 - P A R K IN G C ircuit
DIAGNOSIS
WIPER - ON VEHICLE
1. Inspect for the following items:
a. Wiring harness is securely connected to wiper and
switch.
b. Wiper motor is securely grounded to body.
c. Wiper switch is securely mounted and grounded.
d. Check fuse.
2. If items in Step 1 check out, try operating wiper in both
" L O " and " H I " speeds, then turn wiper off (blades
should return to park position). If wiper fails to operate
correctly, proceed to Step 3.
3. Disconnect wiring harness from wiper and try operat
ing wiper as shown in Figure 8C -3 1.
fiC-41
A PPA R E N T CAUSE
C O R R E C T IO N
A. Blown fuse
A. L o c ate s h o rt circuit
a n d repair. R ep lace fuse.
B. L o ca te b ro k e n wire and
re p a ir
:
I
C. T ig h te n sw itch mountirig
D. R e p la c e sw itch
E. L o c a te b ro k e n wire
a n d rep air
A. G r o u n d e d W ire (No. 1
term inal on w iper m o to r) to
w iper switch
A. L o c a te sh o rt circuit a n d
rep air
A. R e p la c e w iper switch
B. G r o u n d e d wire (No. 3
term inal on wiper m o to r) to
wiper switch
B. L o ca te a n d repair short
circuit
A. R e p la c e w iper switch
B. L o c a te a n d repair broken
wire
A. O p en circuit in wire (N o. 3
te rm in a l on wiper m o to r) to
w iper switch
A. G r o u n d e d wire (N o. 3
term inal on wiper m o to r) to
w iper switch
B. R e p la c e wiper switch
A. T ig h te n strap
co n n e c tio n
1. W ip er Inoperative or
in te rm itte n t
5. Blades do not r e tu rn to
full p a rk position
t
>
8C-42
C O N D IT IO N
1. Wiper In o p e ra tiv e or
In te rm itte n t
A PP A R E N T CAUSE
C O R R E C T IO N
A. B ro ken or d a m a g e d gear
train (only if inoperative)
B. P o o r solder c on nection s at
te rm in al b oard
C. Loose splice jo in ts at b ru sh
plate
C. R e c r im p o r solder splice
joints
D. Brushes binding in b ru sh
ho ld e r
D. C lean h o ld e r o r replace
bru sh , sprin g o r b ru sh
plate assembly.
E. O p e n circuit in a r m a tu r e
E. R eplace a r m a t u r e
A. Defective p a rk switch
A. R ep la c e te rm in a l board
assembly
B. R e p a ir sh o rt circuit in
red wire
A. G ro u n d e d sh u n t field coil
A. R ep la c e f ra m e and field
assem bly
B. G r o u n d e d black wire
B. R e p a ir sh o rt circuit in
black wire
A. O p en circuit in sh u n t field
coil
B. R e p a ir b ro k e n wire or p oo r
solder c o n n e c tio n
3. W ip e r sh u ts off - but
not in p a rk position
A. P a r k switch defective or
c o n ta c ts dirty
A. R ep lace te rm in a l bo ard
assem bly o r clean con ta c ts
A. R esisto r defective
A. R e p la c e te rm in a l board
assem bly
8C-43
LO SPEED - AS SHOWN
HI SPEED - DISCONNECT JUMPER WIRE FROM
TERMINAL NO. 3.
OFF - LEAVE JUMPER CONNECTED TO NOS. 1 & 3 BUT
DISCONNECT IT FROM GRD. STRAP. WIPER SHOULD
STOP WITH GEAR SHAFT FLATS AS SHOWN.
WIPER
GROUND STRAP
Fig. 8C-31--Jumper W ir e Connections
CHECK FOR
POOR WELD
JOINTS
8C-44
C O N D IT IO N
A PPA R E N T CAUSE
C O R R E C T IO N
1. W a sh e rs inoperative
A. In a d e q u a te q u a n tity of
w a sh er solution
A. A d d w a s h e r solution
B. H oses d am a g e d o r loose
B. C u t s h o rt le n g th off
end o f hose to insure
air tight co n n e c tio n
o r replace hose
C. C lean screen
D. Loose electrical
con nection to w asher
p u m p or wiper switch
D. C h e c k electrical
c o n n e c tio n s a n d
re p a ir if necessary
E. L o c a te op en circu it
a n d re p a ir
F. W ip e r switch defective
F. R e p la c e w ip e r sw itch
G . R a tc h e t relay coil
defective
G . R ep lace r a tc h e t relay
H. W a sh e r nozzles plugged
H . C lean w a s h e r nozzles
I. R a tc h e t wheel too th
missing
I. R e p la c e r a tc h e t wheel
J. R a tc h e t pawl spring
missing
J. R e p la c e r a tc h e t paw l
spring
K. D efective p u m p valve
assembly
K. R e p la c e p u m p valve
assem bly
A. G r o u n d e d wire from
ra tc h e t relay to switch
A. L o c a te g ro u n d e d wire
a n d re p a ir
B. W ip e r switch defective
B. R e p la c e w ip er sw itch
C. R a tc h e t wheel tooth
missing
C. R e p la c e ra tc h e t wheel
D. R a tc h e t wheel dog
b roken o r not c on ta c tin g
ratchet wheel teeth
D. R e p la c e o f re p a ir
ra tc h e t wheel do g
E. L oc k -o u t tan g b ro k e n o r
bent on piston a ctu a tin g
plate
E. R ep lac e p iston
a c tu a tin g p late
2. W a sh e r p u m p s co ntin ously
w hen wipers are o p e ra tin g
8C-45
ON-VEHICLE SERVICE
WIPER MOTOR
Wiper motor replacement procedures are not included
here since installation is performed by the individual body
UNIT REPAIR
5. Drill out gear box cover retaining rivets, remove cover
from gear train.
Screws, nuts and lockwashers for reassembling cover to
wiper are contained in the service repair package.
6. Remove output gear and shaft assembly, then slide
intermediate gear and pinion assembly off shaft.
7. If necessary, remove terminal board and park switch
assembly as follows:
a. Unsolder motor leads from terminals. Code motor
leads.
b. Drill out rivets securing terminal board and park
switch ground strap to mounting plate. Screws, nuts
and washers for attaching a replacement terminal
board park switch assembly are included with the
replacement assembly.
WIPER MOTOR
Disassembly (Fig. 8C-34)
Gear Box
Motor
1.
2.
Nut
Crank Arm
7.
3.
4.
Seal Cap
Retaining Cap
8.
5.
Washer
6.
G e a r Box Cover
O u tp u t Gear and
11.
15.
Armature
M ounting Brackets
16.
Thrust Plug
Brushes
W ave Washers
W ave Washer
12.
13.
18.
End Plate
G e a r Box Housing
14.
Flat Washers
19.
Shaft Assembly
9.
10.
8C-46
WINDSHIELD WASHER
Inspection
Assembly
Refer to Figure 8C-34 for exploded view of motor and
gear train.
------G E A R C A S E G R O O V E S
CRANK
ARM
GROOVES
Motor
8C-47
SO L EN O ID COIL
VALVE
ASSEM BLY
\
_ \
SO LEN OID
PLUNGER
RATCHET
PAWL
SPRIN G
C A M FOLLOW ER
UPPER PIN
4 LOBE C A M
(PRESS FIT
O N SHAFT)
"E R IN G
CAM
FOLLOW ER
RATCHET
PAWL
Fig. 8C -4 0 --W ash er Pump Mech anism
SOLENO ID
ASSEMBLY
RATCHET
PAWL
SPRING
VA LVE ASSEMBLY
M O U N T IN G SCREW
FRAME
ft
RATCHET
PAW L
RATCHET
G R O O V ES
BOTH SIDES
WHEEL
J.
8C-48
1 under solenoid
- ratchet dog
WIRING DIAGRAMS
Body and Chassis Wiring Diagrams and circuit identi
fication charts are shown on the pages which follow.
8C-49
FROM
WASHER
JAR
N U K E STROKE
INTAKE
VA L V E
CLO SED
EXHAUST STR O K E
Fig. 8C-43--Cross Section of Windshield W a s h e r Pump Valve
W IRE S IZ E C O N V E R S IO N T A B L E
M E T R IC S IZ E
(mm)2
.22
.5
.8
1
2
3
5
8
13
19
32
AWG S IZ E
24
20
18
16
14
12
10
8
6
4
2
8C-50
E L E C T R IC A L C IR C U IT ID E N T IF IC A T IO N
Circuit
Circuit
Number
C o lo r
C ir cu it N a m e
Red
Pink
Brown
Circuit
C ircuit
Number
C o lo r
C ir cu it N a m e
39
Pin k - B la c k
40
Orange
41
Br o w n -W h ite
42
Yellow
Feed, A / C A u t o Rela y C o n t r o ll e d
C o n tr o lle d - Fused
O n " C o n tr o ll e d - Fused
Y e l lo w
43
Yellow
R a d i o Feed
Purple
Starter S o le n o i d Feed
44
D a r k Green
Y ellow
B lack
46
D a r k Blue
47
D a r k Blue
A u x il i a r y C ir c u it (Trailer)
48
Gray
By-Pass
8
Gray
Brown
L ight S w . to Fuse)
(Trailers)
10
Y ellow
D i m m e r Sw. Feed
11
Light Green
H e a d la m p Feed, H i-B e am
12
Tan
H e a d la m p Feed, L o -B e a m
13
Purple
F r o n t Parking L a m p s
14
Light Blue
S in gle R a d i o or R ig h t Stereo
D a r k Blue
or Dir. S ig na l and S t o p -
Directional La m p s
15
D a r k Blue
16
Purple
17
White
Brown
51
Yellow
52
Orange
Direction al La m p s
F r o m Flasher
Fused
F r o m S t o p Sw.
18
Y e l lo w
S t o p and Directional L a m p
C o n tr o lle d
53
L ight Green
Valve Release S o le n o i d to
54
D a r k Green
C o n tr o l to Shie ld
or Direction al L a m p
O n l y - Rear L.H.
19
20
D a r k Green
C o n tr o l B o x
S t o p and Directional L a m p or
55
Orange
K i c k D o w n S o le n o i d Feed
Directional L a m p O n l y -
56
Tan
A m p li f i e r to Tra n sdu c er
Rear R.H .
57
Orange
L.H. C o r n e r in g L a m p Feed
Black
D a r k Green
R.H . C o r n e r in g L a m p Feed
C o m p r e s s o r Feed
Lig h t Blue
S t o p L a m p (O nly)
21
Pink
S p o t Light
58
59
22
White
Direct G r o u n d - Trailer
60
Or a n g e -B la c k
24
Light Green
B a c k U p L a m p Feed
25
Brown
61
Y e l lo w
G r o u n d , Resistive, A u t o A / C
26
D a r k Blue
62
Light Green
G r o u n d , Resistive, A u t o A / C
27
Brown
Tan
64
Brown
B lo w e r Sw. Feed F r o m A / C
65
Purple
Blo w e r M o t o r Feed
66
L ight Green
67
L ight Blue
68
Y e l lo w - B la c k
G r o u n d , Resistive, L o w C o o la n t
69
Gray
G r o u n d L o w C o o la n t M o d u l e
70
Pin k
Protected
C on trolled
Hazard Flasher
28
B lac k
G r o u n d , H o r n Sw. C o n troll ed
29
D a r k Green
H o r n Feed
30
Pi nk
Fuel G a u g e to T a n k Unit
31
T an
32
Y e l lo w
M a p L igh t Feed
33
T an -W h ite
W a r n in g L igh t - Brake
34
Purple
F o g or Drive L a m p
35
D a rk Green
G r o u n d , Eng. C o o la n t Temp.
Sw. or E C M C o n troll ed (H ot)
36
Light Green
L ight Green
D a rk Blue
C o n tr o lle d
Sele ctor Sw.
(C o m p . Ct.)
Sw. C o n t r o ll e d
Probe C o n tr o lle d
G r o u n d , Eng. Metal T em p.
Sw. C o n tr o lle d (H ot)
38
37
A m b . S e n so r C o n tr o lle d
C o n tr o lle d
Sw. C o n tr o ll e d
8C -S1
E L E C T R IC A L C IR C U IT ID E N T IF IC A T IO N (Cont'd)
C ir cu it
Cir cu it
C o lo r
Number
- '
B la c k
71
C ir c u it N a m e
G r o u n d , A / C Selector Sw. " D e f "
Circuit
C ir cu it
Number
C o lo r
131
B la c k -P in k
132
W hite
G r o u n d , Fuel E c o n o m y Sw.
133
Y ellow
G r o u n d , Fuel E c o n o m y Sw.
135
D a r k Green
Resist. 1 O h m / F o o t
C o n tr o lle d
72
L ight Blue
73
Purple-White
74
L ight Green
Feed to T h ro tt le S w it c h
75
D a r k Blue
C o n tr o lle d
C o n tr o lle d
W hite
139
P in k - B la c k
S e n so r C o n tr o lle d
C o n tr o lle d - Fused
Feed, Ign. Sw. C o n tr o lle d
C ir cu it N a m e
76
P in k
78
L ight Blue
Electric C h o k e Feed
80
L ight Green
G r o u n d K e y W ar n in g Buzzer
140
Orange
81
Nat. White
Electric R e m o t e Mirror, R ig h t
141
B r o w n -W h ite
82
L ig h t Blue
83
D a r k Green
142
B lac k
R r C o m p a r t m e n t Lid L o c k
84
D a r k Blue
143
P in k
144
Y ellow
Feed to Pw r A n t Sw.
85
W hite
G r o u n d , Cruise In dicator
145
D a r k Green
146
D a r k Green
G r o u n d , T r u n k Release Tell-Tale
C o n tr o lle d - Fused
C o n tr o lle d
Release
trolled
R e gu la to r C o n tr o lle d
86
Brown
150
B lac k
G r o u n d C ir c u it - Direct
88
Y e l lo w
Electric R e m o t e Mirror, U p
151
B lac k
G r o u n d C ir c u it - Direct
89
L ight Green
Electric R e m o t e Mirror, D o w n
152
B lac k
G r o u n d C ir c u it - Direct
90
Pink
153
B lack
G r o u n d C ir c u it - Direct
154
B lac k
G r o u n d C ir c u it - Direct
155
B lack
G r o u n d C ir c u it - Direct
156
W hite
G r o u n d C ir c u it - Sw. C o n tr o lle d
C o n tr o lle d
W in dsh ie ld W ip er - L o w
92
Purple
W in d s h ie ld W ip er - Hi
93
W hite
W in d s h ie ld W ip er M o t o r Feed
B o d y Interior L a m p s - such
94
95
Pin k
D a r k Green
as D o m e , Courtesy, M a p ,
91
C o n tr o lle d
96
Brown
W arning, etc.
157
Gray
B o d y Interior L a m p s - such as
C o n tr o lle d
Black-W hite
W in d s h ie ld W asher L o w Fluid
101
D a r k Blue
102
W hite
S L A lte r n a to r - Regu la to r
99
158
D o m e , Cou rtesy, M a p, W ar n in g
105
B lack
A m m e t e r - G enerato r
106
Gray
A m m e t e r - Batt ery
159
T an
107
D a rk Blue
160
W hite
Po wer A n t e n n a D o w n
111
Black
G r o u n d , A n t i - S k i L o w A ir Sw.
161
B lac k
Pow er A n t e n n a U p
162
Gray
Pow er T o p - U p
112
D a r k Green
Telltale T em p era tu re G a u g e (H o t )
163
Purple
Pow er T o p - D o w n
115
L ig h t Blue
164
D a r k Blue
W i n d o w C o n tr o l L F U p
116
Y ellow
165
Brown
W i n d o w C on trol L F D o w n
117
D a r k Green
166
D a r k Blue-
118
Gray
119
W hite
Gen e ra to r (A lt ernator) to
120
Purple
121
White
125
126
130
C o n tr o lle d
etc.
G r o u n d , K e y W a rn ing Buzzer
W hite
W in d o w Control R F Up
Tan
W i n d o w C o n tr o l R F D o w n
168
D a r k Green
W i n d o w C on trol L R U p
169
Purple
W i n d o w C o n tr o l L R D o w n
T a c h o m e te r to C oil
170
L ight Green
W i n d o w C o n tr o l R R U p
Y ellow
D o o r J a m b S w it c h
171
Purple-White
W i n d o w C o n tr o l R R D o w n
Blac k
Seat B a c k L o c k Feed
172
Light Green
V e n t C o n tr o l L F Close
Br ow n -W h ite
173
Y ellow
V e n t C o n tr o l L F O p e n
Resist. 2 O h m s / F o o t
174
D a r k Green
V e n t C o n tr o l R F C lo se
R egu la to r
167
8C-52
E L E C T R IC A L C IR C U IT ID E N T IF IC A T IO N (Cont'd)
Circuit
Circuit
Number
C o lo r
Circuit N a m e
Circuit
C ir cu it
Number
C o lo r
C ir c u it N a m e
175
Purple
V e n t C o n tr o l R F Open
213
D a r k Blue
176
D a rk Green
214
Gray
R H Seat Sen so r
177
Y e l lo w
21 5
T a n -B la c k
L H Sw.
178
D a r k Green
216
179
Tan
180
Light Green
D a r k BlueWhite
A ft
217
G ray -W hite
R H Sw.
218
D a rk Green
Inte rlock R e la y - G r o u n d
219
L ight Green-
22 0
Y e l lo w
221
Brown
22 2
D a r k Blue
223
Ligh t Blue
224
Light Green
225
D a r k Green
W a rn ing L a m p G r o u n d I R
W a rn ing L a m p Sen sor
181
L igh t Blue
182
Yellow
Po w er Seat - 6 -W ay - A f t and
183
L ight Blue
184
T an-W hite
185
Tan
V e n t C o n tr o l L R Op en
186
Gray
V e n t C o n tr o l L R Close
187
D a r k Blue
V e n t C o n tr o l R R O p en
188
Ligh t Blue
V e n t C on trol R R Close
189
D a r k Green
226
Orange
190
Y e l lo w
227
T an
191
L ight Green
Po wer Seat - 4 -W a y S o le n o id -
228
Y e l lo w
W a r n in g L a m p Feed
229
Pink
192
Purple
193
Purple-White
230
Pink
R ecorder Po w er Feed
231
Orange
194
B lack
Electric D o o r L o c k - U n lo c k
232
White
195
Ligh t Blue
Electric D o o r L o c k - L o c k
233
D a r k Green
Hi Level A c t u a t i o n Passenger
198
Ligh t Green
Bl ack
G r o u n d , Resistive, A / C In-Car
234
Yellow
199
Brown
235
Y e l lo w
200
Light Green
F r o n t Spe ak er - Feed F r o m R a d i o
236
Gray
201
T an
F r o n t S peaker - Feed f r o m R a d i o -
23 7
Y ellow
202
Bl ack
G r o u n d , C o m p r e ss o r over Heat
238
B lack
203
Ligh t Blue
23 9
P in k - B la c k
24 0
Orange
241
Purple
24 2
T an
Feed, T h ro tt le C o n tr o l S p a r k
24 3
Black-W hite
244
Purple
Feed, L T F / D S o le n o i d R ela y
245
D a r k Blue
Feed, R T F / D S o le n o i d R ela y
246
D a r k Green
Feed, A D L L o c k R e la y C oil
247
Brown
Feed, to A / C S h u t - O f f R e la y
B lack
Down
Feed
W in d o w Up
L o w Level, I R
W in d o w Dow n
Down
U p and D o w n
O h m s per f o o t
Level, I R
Level, IR
Feed, L o w Level, IR
Level I R
(Inactive)
S enso r C on troll ed
U n fu se d
R a d i o Left Stereo
Level IR
Level I R
Left Stereo
trolled ( T i m e d 3 9 Ct.)
Sw. C o n troll ed
204
D a rk Blue
205
W h it e-Bla c k
206
D a r k Blue
Y e l lo w
208
Gray
Sw. C o n tr o lle d G r o u n d ( T C S )
209
Purple
Park Bra ke W a r n i n g L a m p
210
W hite
D a r k Blue
Y ello w B lac k Stripe
C o n tr o lle d - Fused
Level, I R
Va lv e C o n tr o lle d
trolled
C o n tr o lle d
212
G r o u n d to Belt A s s y Sw.
211
Starter Feed
L H Seat S enso r
C o n tr o lle d
8C-53
E L E C T R IC A L C IR C U IT ID E N T IF IC A T IO N (Cont'd)
C ircuit
Circuit
Number
C o lo r
24 8
D a r k Blue
C ir cu it N a m e
Feed, to A / C C o m p r e ss o r Harn
Circuit
Circuit
Number
C o lo r
283
L ight Blue
284
Light Green
Po wer Seat, A f t M o t o r
Motor
R e la y C o n tr o lle d
249
D a r k Green
Feed, F r o m A / C Harn
250
Brown
251
Ora ng e
Passenger Initiator f e e d
252
Y e l lo w
G r o u n d , A D L M o d u l e U n lo c k
253
D a rk B r o w n
254
Ligh t Green
G r o u n d , A D L L T U n l o c k Rela y
285
T an
286
D a r k Green
Po wer Seat, F r o n t V e r t U p -
287
D a r k Blue
288
Motor
O u t p u t C o n tr o lle d
O u t p u t C o n tr o lle d
M otor
28 9
Coil
255
Y ellow
G r o u n d , A D L R T U n l o c k Rela y
256
D a rk Blue
G r o u n d , M o d u l e Controll ed,
257
Brown
G r o u n d , A / C Press, Sw. C o n
258
W hite
259
Purple
260
B lack
T h e ft Deterrent - H o o d Sw.
261
Y ellow
T heft Deterrent - A la r m A r m
T heft Deterrent - K e y - D o o r
291
D a r k Blue
292
Ligh t Blue
293
Pu rple-White
Feed, Heated G la ss T im e r
294
T an
D o o r L o c k M o t o r - U n lo c k
295
Gray
D o o r Lo ck M o to r - Lock
296
Brown
297
Gray
298
Purple
300
O rang e
31 8
Y e l lo w - B la c k
L a m p O u t In dicator
O n - O f f Sw. C on trolled
O n - O f f Sw. C on trolled
trolled
C o n tr o lle d
Level, I R
26 2
L ig h t Green
R ela y
U n l o c k and A l a r m Disa rm
263
L ight Blue
T heft Deterrent - A la r m
264
D a r k Green
T h e ft Deterrent - A r m Indication
265
Black-W hite
T h e ft Deterrent - A la r m O u t p u t
266
Pink
T h e f t Deterrent - A la r m A r m
Abort
267
D a rk Green
268
Y e l lo w
Pw r Seat - A f t and D o w n
269
L ight Green
270
B l a c k -Y e l lo w
271
Purple
272
L ight Green
U n fu se d
Stripe
31 9
D a rk GreenWhite
340
Orang e
35 0
Pink-White
351
D a rk Blue
352
White
Pink
370
383
L ight Blue
C on ve rt C lu tc h Release Sw. to Va c.
38 4
L ight Green
C o n tr o lle d
274
D a r k Green-
C o n tr o ll e d Fused
Feed, H d l p Sw . to A m p li fie r,
Fused
H d lp Sw. C o n tr o lle d
275
W hite
Feed, H d lp Sw. to A m p li fi e r
38 5
Purple
L ight Green
39 0
T an
39 4
L ight Green
G r o u n d , L T F / D R e m o te H an dle
276
L ight Green
277
Light Blue
27 8
W hite
A m p li f i e r to Phot oc ell
27 9
B lack
H e a d la m p Sw. to Photocell
28 0
Pink
Feed, P.M. M o t o r U p C yc le
( D e c k Lid Pull D o w n )
White
Y e l lo w
S w . C o n tr o lle d
395
L ight Blue
G r o u n d , R T F / D R e m o te H andle
402
L ight Green
403
D a rk Blue
404
L ight Green
E S T P i c k u p Coil to H E I M o du le,
Sw. C o n tr o lle d
V a lv e
G r o u n d , R e la y C oil D o w n C y c le
( D e c k Lid Pull D o w n )
28 2
Feed, A v I
Sw.
281
Lamp
P in k - B la c k
Recliner
Orang e
Lamp
R ela y A ctiva te d R ig h t D irectional
33 9
Recliner
273
290
Coil
Fused 6 Cir.
C ir cu it N a m e
Valv e
Hig h
Motor
8C-54
E LE C T R IC A L C IR C U IT ID E N T IF IC A T IO N (Cont'd)
Circuit
Circuit
Number
C o lo r
405
White
Circuit N a m e
E S T P ic k u p Coil to H E I M o dule ,
Circuit
Circuit
Number
C o lo r
465
W hite-Green
E S C M o d u le to H E I M o dule ,
Signal Lead
407
Bl ack
E m e r ge n cy Signal Lead, E C M to
408
T an -W hite
E C M to E S C By p ass
H E I M o d u le
White
Low
406
Da rk Green-
C ir c u it N a m e
46 6
Gray
I M C to T r i p C om p u ter, R P M Data
46 7
Ligh t Blue
" IM C
" IM C
C o n tr o lle d
468
L ight Green
410
Yellow
E C M to C o o la n t T e m p S enso r
469
411
Light Blue
470
B lack
C o o la n t T e m p and M a n if o l d
412
Purple
413
Tan
O 2 Sen sor L o w
471
P in k - B la c k
Ba ro Reference Voltage, 5 V
T e m p Return, L o w Level G r d
414
Pink
472
T an
M a n if o l d A i r T e m p S ig
415
Ligh t Green
E C M to E n r ic h m e n t Sw.
473
B l a c k -L ig h t
416
Gray
E C M 5 V Reference V o lta ge
417
D a rk Blue
Blue
474
Gray
Signal
Brown
E C M to A d a p tiv e Sw.
475
Pink-White
M a p Reference Voltage, 5 V
419
Brow n -W h ite
E C M to C h e c k E n g Lp
476
Blac k -P in k
420
Purple
E C M to Break Sw.
421
D a rk Blue-
E C M to C o ld Start Program
477
Brown
M P G R e q ue st Signal
478
Purple
479
L ight Green-
480
O rang e
481
Red
418
White
M o d ifie r
422
T an-W hite
E C M to T C C S o le n o id
42 3
White
E S T Signal
42 4
T a n -B la c k
E S T By p ass
42 5
Light Blue
E C M to I S C - M o t o r E x te n d
42 6
D a r k Blue
E C M to I S C - M o t o r Retract
42 7
Pink
E C M to I S C -Sw .
Return, L o w Level G rd
I M C C o n tr o lle d
B lac k
I M C C o n tr o ll e d
Fused
482
W hite
Yellow
E C M to Canister Purge
483
Green
429
Blac k -Pin k
E C M to A ir C o n tr o l S o le n o id
484
W hite
E S C Reference Pulse L o w
43 0
Purple-White
485
B lack
E S C Signal
E S C D ist rib u t o r G r d
42 8
431
D a rk Green-
L ight GreenBlack
" Fused
486
Brown
8 V R ef V o lta ge
49 6
D a r k Blue
E S C D e n o t a t i o n Sensor Input
E C M to M a p S ig
500
501
Black-W hite
Purple
M o d u le - P T C , G r o u n d Plane
Sensor, S e c o n d a r y P T C
Sensor, P r im a ry P T C
432
D a r k BlueGray
43 3
G r a y - B la c k
E C M to Baro S ig
502
Gray
43 4
O r a n g e -B la ck
E C M to Neutral Park S w
503
Orange
43 6
Brown
E C M to A i r S w itch S o le n o id
504
43 7
Brown
438
Red-White
E C M to H ig h G ear S w itch
50 5
Y e l lo w
439
P in k - B la c k
(D i o d e Isolated)
Feed, G l o w Plu g R ela y
50 6
Light Blue
Return, G l o w Plug R e la y
C o n tr o lle d - Fused
507
D a r k Blue
W ait L a m p
508
Y e l lo w
50 9
T a n k " In dica to r
O r a ng e-B la ck G l o w Plug, Feed or Sense,
610
Tan
Light Blue
440
Orange
450
Black-W hite
C L C C E C M Power G rd
451
W h it e-Bla c k
D ia g n o s tic Enable
45 2
B lack
L o w Level G r o u n d
45 3
B la c k -R e d
E S T R ef Pulse L o w
Passenger Sid e
D o w n R e la y to M o t o r
45 4
Bl ack-W hite
Critical G r o u n d Circuit
460
611
461
Orang e
Protected
I M C to E C C , Serial Data for M P G or
618
46 2
Pin k -B la c k
G r o u n d , I M C , Set T i m i n g
666
R e la y to M o t o r
Y e l lo w -B la c k Feed, Lt Sid e Trailer and Direction
Green-White Feed, R t Sid e Trailer and Direction
D a r k Blue
W d o C o n t r o l R f U p - Passenger Sw.
463
Black-O range
667
Brown
W d o C o n tr o l R f D o w n - Passenger Sw,
F l o w Da ta (Injector on T im e)
66 8
D a r k Blue
W d o C o n t r o l Lr U p - Lr Sw.
Di agnostics
464
T a n -B la c k
M P G Reset Signal
619
8C-55
E L E C T R IC A L C IR C U IT ID E N T IF IC A T IO N (Cont'd)
C ir cu it
Cir cu it
Number
C ir c u it N a m e
C o lo r
669
Brown
W d o C o n tr o l Lr D o w n - Lr Sw.
670
D a r k Blue
W d o C o n tr o l R R U p - R R Sw.
671
Brown
W d o C o n tr o l R R D o w n - R R Sw.
756
D a r k Green-
Feed, V a c S o l C o n tr o lle d (F or
W hite
Circuit
Circuit
Number
C o lo r
815
B lack
T an
Accelerator E n r ic h m e n t In pu t #1
81 8
Ligh t Green
819
Black-W hite
Clo ss ed T h ro tt le Sw.
820
Orang e
W id e O p e n T h ro ttle S w itch
Protected
821
D a r k Green
G r o u n d , E F I M o d u le C o o la n t
801
80 4
Purple
S u p p l y V o lta ge
Fusible L i n k Protected
80 7
Purple
80 8
D a r k Blue
T e m p . Sen sor O u t p u t C o n
trolled
822
D a r k Blue
G r o u n d Resistive, C o o la n t
82 3
Gray
G r o u n d , E F I M o d u l e A ir T em p .
82 4
O range
G r o u n d , Resistive A i r Temp.
827
D a rk Green
T em p . Sen so r C o n troll ed
trolled - Fused
810
Tan
811
White
Feed, E F I M o d u l e G r o u p T w o
S en so r O u t p u t C o n troll ed
C o n tr o lle d
S en so r C o n tr o lle d
Injector O u t p u t C o n troll ed
Fusible L i n k Protected
P u m p O u t p u t C on trolled -
Feed, E F I M o d u l e G r o u p On e
Fused
Injector O u t p u t C on trolled
Fusib le L i n k Protected
813
W hite
828
Gray
831
Brown
Feed, E F I M o d u l e E G R
Fused
814
Y ellow
A cc elera tor E n r ic h m e n t In p u t # 2
Pink
Pink
816
Brown
812
C ir cu it N a m e
Fused
ORIGINAL COLOR
REVISED COLOR
422
TAN-WHITE
TAN-BLACK
432
DARK BLUE
-GRAY
LIGHT GREEN
438
RED-WHITE
DARK GREEN-WHITE
508
YELLOW
YELLOW-BLACK
8C-56
------
8C-57
--------
I DK GRN - 29A
-------------- 8 BRN 9A---------------5 DK BUU I5A
---------- I LT GRN-I1A-----------------5 LT BLU-I4A------------
8C-58
8C-59
pimk-3CkH x O
8C-60
5 PNK/BLK-39G - - - SPLICE 39
5 TAN-31 -BULK HD CONN-31
0 PNK/BLK-39E- SPLICE 39
BLK- 150H----- SPLICE 150
GUAGE. CLUSTER
WITH IACHOMFTER
2965164
- .8 B L K -1 5 0 ----- "
- . 8 WHT-12KHDT)-
Tr.5
ACHORN-140 O
g|
A B q CLOCK
___ _
2 9 65961-^
r .8 PNK/BLK-139
^
----------------------------------------j .5 BLK-150 - 1
-5 TAN WHT-33B
- 5 DK GRN - 35A
LT G RN-24
- g DK BLU-75
- 8 P N K -94-----------.8 BLK-150E---------.8 PPL-9 2 ------------ 8 GRY-91-------------.8 BLK/LT BLU-97-.8 LT GRN-2 4 -------
8C-61
-2984369 TERM
8C-62
8C-63
628 8585
-8
-8
BR N -9
LT GRN-24
- 6 DK GRN-19
- 6 YEL-18
BULKHEAD CONN
B/U LP
y -0 9 1 7 2 3 4
CAB.CREW-CAB CHASSIS
8C-64
SPLICE 150
6294015 SOCKET-
BRN -96
TAIL STOP DIR
SIDE M K R t
tytl LAMP
-8 BLK-I50C
BRN- A
SPLCE 9-
-.8 LT G RN -24
-.8 BLK-I50B 8 9 1 1 0 2 7 SOCKET-
/''BLU OR A
- J PPL OR V LT GRN
r - 2977720
SPLICE-19-i
-SPLICE-9
FRAME
GRD
- 8 DK GRN-l9iA->
- 8 BRN-9A
"8 YEL-18
r -.8 PNK-30(HDT)
EXT WIRE
WHEN USED
-.8 BRN-9C---- ( x )
( l }-|
.8 BU
L
S )
-SPLICED
LIC LAMP
FUEL METER
TANK UNIT
------------------------- q ) 6C^6PM <-30(H XUa a n n ----------- A
M U in
8911027 SOCKET
- 8 B L K - I5 0 B - 8 LT GRN- 24
.8 BLK-I50A
*-^8
t8 YEL-18
YEL-8 BRN-9A -
SPLICE 9-
:8 B L K -I5 0C
8 B R N -9 B
6294015 SOCKET
JL
SPLICE 150-
.8 BLK-I50D
SUBURBAN
R EF BODY H AR N ESSRPO M V4
LT G R N 3 8 4 B
-1
top89l7583
m<
00
Z2
cc
o cr
o
00
rO rO
RPO
CE N G IN E )
M V4
TRA N SM ISSIO N
8C-65
8C -66
8900444
2989557 GROMMET
06 ONLY
CHANNEL-A FOR 06 S 16
RIGHT RR SPKR
8900444-
CHANNEL-B
FOR 03
RIGHT RR SPKR
1 2 0 0 4 5 4 5 7
.8DK B L U - 4 6 ---------- 1/
;8 L T B L L H '
'
8 Y E L - 1 16
8 B R IM -1 9 9
s;
-.8TAN-2 01
.8 GRA-118 rTO
.80KGRN-I 17-HT
-8L.T GRN-200 /
12004544
-1 2 0 0 4 5 4 5
-.8 DK BLU -4 6 J
- 8 L T BLU -115-
F (jr
-.8YEL-43- ___
-.8BLK-I50
-.8GRA-8------------
8900444-
-.8 BRN-199
.8 YE L-H 6
CHANNEL-A
FOR 03
LEFT RR SPKR
')
U80
R E A R SPEAKER
LEFT SIDE (16)
---.5 YEL-43-H43lKh
U --fi
B L K -1 5 0 - J V
12004543 -----4
- B G R A H ie - .8 T A N -201F R O N T SP K R .
("r a d i o e q u i p m e n t RPO.
U 63-U693U80
i IP 'jrr , S F R W .S MANUAL
8C-67
8C-68
8C-69
-.8 Y E L - 5 0 8 ( H W ) - . 8 P N K - 3 0 IH W )
---------- .8 PNK/BLK-39C
INST CLUSTER CONN-237----------- .8 Y E L -2 3 7 -------------------(SEAT BELT WARNING LAMP)
B L K -I5 0 J --------
EXTENDED
--------- ----------
RETRACTED
SEAT BELT
RETRACTOR SW
6294051
E X IS T IN G IN ST R U M E N T
PANEL W IRIN G H A RNESS
.8 GRA - 8.8 O R N - 4 0
12004962
-120 0 4 6 9 0
FUSE BLOCK
HEADLAMPWARNING BUZZER
RPO T 63
8C-70
S ID E M A R K E R L A M P
R E A R -S T O P &
.D IR E C T IO A L L A M P
BACK U P LA M P
BACK U P LAM P
R E A R -ST O P &
D IR E C T IO A L L A M P
S ID E M A R K E R L A M P
----------- BCSTER
T AIL,ST O P, + D IR SIG N A L L IG H T S
8900444
i DK B L U -4 6 ^ "
i L T B L U -1 1 5 % .
-.8
-.8
-B
-.8
LT B L U - II5 D K B L U -4 6 T A N -2 0 1 G R A - I 18
-------- .8 G R A - 8
7J
1
K
J
H
CENTER
SPEAKER
R IG H T
T A N -2 0 1 A :0 G R A -I I 8 A -
IH
jC! cr'
----
- S T A N -201 A - . 8 G R A -I I 8 A -
;cJ. If-J
I
s ji'" !
M
------------. 8 Y E L - 4 3 -----------.8 B L K - 1 5 0 -
M d
CB
REAR SPK R .
R P O U .8 0
12004545
- . 8 T A N - 2 0 IB
J
L
- . 8 G R A -I I S B
K H
11 5
-------- .8 Y E L - 4 3 - H T
-------- -.8 B L K -1 5 0
\ R A D IO W IT H
12004543 - ^ 8 0 R E A R S P K R .
irzf
46
R A D I O E Q U IP M E N T
RPO U P 5 - U 8 0
8C-71
8C-72
8C-73
8C-74
BLOWER MOTOR
(REAR)
AIR CONDITIONING
RPO C-69
EVAPORATOR
PRESSURE
CONTROL SW
Li
T U
NOTE:
* I. USE WITH
12010191
RETAINER
FUSED FEED
FROM IGN 3
__
--T V
SELECTOR SWITCH
AIR CONDITIONING
R P 0 C -6 0
IN S T R U M E N T P A N EL A N D G A G E S
8 C -7 5
8C-76
8C-77
J U N C T IO N B L O C K
C A M P E R E Q U IP M E N T
R P O -U Y I
8C-78
& B/U L A M P
8C-79
& B/U L A M P
FLEETStDE PICKUP
RPO. E63
PICKUP
RPO E62
8C-80
HARN
H E A V Y D U T Y T R A IL E R
R P O UY7
R X . DOOR
LOCK SW
L.H. D O O R
LH
DOOR
8C-81
LOCK
PM
MOTOR
FU SE
p e rm an e n t
m agnet
PO W ER DOOR L O C K S
12 D O O R ) R .P Q A U 3
BLOCK
6394742
r 2 B L K - I5 0 A O
166Q
FU U T
*-----11b=i 1 R|,h'
WINDOW
R H
SWITCH
a y
BU S BAR G RD
L H WINDOW
SWITCH
2 B L K - I5 0 B
MTR
BKT G RD
g )
M T R BKT G R D
2 B L K -1 5 0
L
2 D K B L U / W H T -1 6 6 2 T A N - 167
3 P N K -7 0 -
2 B L K -1 5 0
------------
2 D K B L U / W H T - I6 6 A -
L-2 TANH67B(HDT|
L - 2 D K BLU W H T-66B-
(HDT)
AUTO BESET
8917486
FUSE
BLOCK
L H MOTOR
W E P W IN D O W
(/ ^O O R
R.P.O. A 3
8C-82
LOCK
LH DOOR
I LOCK SW
M
--- ^*12004155
I2
R H
LH
c"CUT* ^
W IN D O W M O T O R
W IN D O W M O T O R
8C-83
RT SIDE M ARKER
6294015 SOC
.5 DK 8 L U -I5 B
.5 BRN-9F ----.8 B L K -I5 IB ---- w ---- .8 B L K - I5 IA --------j
<6
SHEET METAL
TAL X
GROUND
FRAME GROUND J -
.8 B LK-I5IC I LT G R N -IIG
.8 TAN-I2C
.8 DK BLU H 5C .8 B R N -9 G -----.8 B L K - I5 IF -
.8 B L K - I5 IE -
I LT G R N -IIF -
12004267
TO RT HAND HORN
i
(J
C\J
12004267
p
CO
UJ
CTI
CD
00
TO LT HAND HORN
.8 B L K -I5 0 A
.8 B LK-I50C I LT GRN-I IB
.8 L T B L U -I4 C
.8 B R N - 9 C ---.8 B L K -I5 0 E
.8 B L K -I5 0 B I LT G R N -1 1C
1 I DK G R N -2 9 A
5DK B L U -I5 A .5 LT B L U - I4 A
I LT G R N - I I A -
<Z
2977976
.8 B R N -9 A -----
4
33
II
12 1
14
15
29
.8 T A N / W H T -33 (HOT)
.8 TAN-I2B ------------------------------
.5 LT B L U - I4 B
.5 B R N -9 B
JTTU6294015
SOC
LT SIDE M ARKER
FORWARD LAMP
RPO V 2 2
8C-84
8C-85
8C-86
12010391
8C-87
8C-88
V / 8 -E N G IN E
H E A V Y DUTY TRUCK
- I
I
.8
.5
.5
.5
DK G R N -2 9 LT G R N -IIA
TAN -12 A
DK B L U -I5 A
LT B L U -I4 A
B R N -9 A
8C-89
[ FWD- LR WRGJHm]
8C-90
/-89I754S
-8917540
8917539
m \ .8 BLK/LT 8LU-97
1911 .8 GRA-9IB ------ -
B
URK
Sw
sh
SOL
[ M V - .8 PNK-94------ 1
co .8BLK/LT BLU-97
Q J r .8 WHT-93B |
<->j-.8 PNK-94---------
oJ-,8 W H T -9 3 -----------
-.8WHT-39A
-.8 PPL-92 -
W - .8 P P L - 9 2 -------------
-3PNK-3A
i W iPER MOTOR 1
I 0RN-240A
I 0RN-240B
-I DKGRN-29 .5 BLK-28-
3 BRNMB
2984164
HORN R ELAY
3 BRN-4A3RED-2A-----,5 TAM/WHT-33A
.5 B R N -2 5 -----.5
2
-2
-2
-1
-.5
-.5
-3
2973407
OK GRN-35ALT 6LU-72
ORN-52-----YEL 51-----0RN-I40---DKBLU-I5B
TAN-3 1----RED-2F-----
BACK UP 9W
M AN U AL
TRANS
8911921
NEUT START i
BACK UP SW
AU T O -TR AN S
1200414 7- *
.8 OK BLU
.8 BRN---- . 8 PPL
.8 Y E L --- .8 DK GRN
.8 WHT----12004148
rOfNj
CLUTCH START SW
|M^0 K IO C D N SW
------------ 3 PPL* 6 ------------------8PNK/BLK-I39
.22 BRfVWHT-130-
;8BRrVWHT-24l
3 RED-2E1 i 3RED-2A -------3RED-2B
'j
/
^ - N O T E : w ir e 130
IS A K> OHM
RESISTANCE
WIRE
FUSE BLOCK
--120)0082
3 P N K -3 A -
12004868REf GAUGE
CIRCUIT
-12004890
-1 DKGRN-44;8PPL-I6-----
-12010327
lBULK'HD.CONN.1
------ -.5 TAN/WHT-33A
p.5 DK BLU-15 A---------- 1 LT GRWIA---------- .5 LT BLU-(4 A ---I-------.8 TAN-12---------1 LTGRN;8TAN
-1 DKGRN-29
-.5 LT GRN-II B
2,1,164
IdlMMERSWl
- BRN-9A
.8 DK BLU-38*
-3 R E D -2 B ---------.8 YEL-18 ---------1 0RN-240B-----.8 DK GRN-19-----.8 LT GRN-24-----.8 DK BUJ-75 -----.8 BLK/LT BLU-97
-.8 PN K-94 --------.8 P P L -9 2 ----.8 GRA-91 --------.5 LT GRN-IIB--.8 BRN-9A ------ I YEL-10---------.8 ORN- 4 0 --------
- TAN/W HT-3JC-
-dT '
8 C -9 1
2904SM TERM-7
,
3 WHT*-<Ta
[tiR. JAMB S W
8C-92
------------------------------------ ( W
--
L.
-.5 GRA-8C
B L K -I5 0 H
-8 8 L K -I5 0 E
5 OK B L U -I5B --------4
.5
39
5
-35 1
-.5TAN -31-------- 1
9905917-
\ /-WITHOUJ ^ C T CHOKE
Lt
Tl I
---------- k
EEC
- ir f r r
.5DKGRN-35 -
&
4 !+
WITH ELECTRIC
1C CHOKE
L T .8 TAN-931i
| I
-LL-
-----------------
TO S P L IC E 3 3 ------ .5TA/VWHT-33B
----- s 5 LT GRN-II
---------- s LTBLU-I I
4
______ i
u=
i
'TP
LZJ
14BTT
PHHTED
C IR C U IT - G A U G E S
8-lLLUM INATIO N
11-HIGH B E A M
W -l T t u r n s i g n a l
15-RT TURN SIGNAL
-VOLT METER 'GN
30-FU E l jAUGE
ISO-GROUND
31-OIL SENDER
931-ELECTRIC CHOKE TT
33 B R A K E T T
3 5 -TEM P GAUGE
3 9 -IGNITION
237-SEAT BELT
0WHT-I56B
80RN -40B---- 8
8
5
-* 8
8C-93
DK GRN -19
T A N - 3 0 ------P N K -3 0 -------B R N -9 A -----
-=8 LT GRN-24A
- ^ L T G R N -2 4 A -
- . 8 Y E L -I-----------
8C-94
I P R .S ID E M A R K E R -R lT l
8C-95
8C-96
8C-97
8917548
i !
-i [
- . 5 GRN-901
.5 WKT-902
- .5 RED-903
8 YEL-93 A-------- 1
.8 LT BLU-92
8 905205
i____
>L
.8 B L K /W H T - 9 IA - J
8917544
- .5 DK BLU-9 4
.5 BIK-I50
-------.5 LT BLU-92
-.5 BLK/WHT- 91
-.5 BLK/LTBLU-9/
-.5 GRA-8
8917540' '
WIPER MOTOR
T
PULSE WIPER/WASHER
CONTROL
PULSE WIPER
CONTROL MODULE
MOM
REF l/P B+ACC FUSED-------- .8 WHT-93J
GROUND--------------- .8 BLKH50Ct
HARNESS IP S DIM CKT--------.5 GRA-8E
L j3 PNK -
= ;^ L
PK
Lz z r T i i i
-------------J | I
| 1--------- .8 BLK/LT BLU-------- -1 I
L------------ .5 G RA-8B---------------- 1
8 BLK-I50(HW>
89 0 5426
3BRIVW HT-50
3 WHT-952A
890 5 4 2 6
2 LT BLU-72
2 rEL-51
2984092
2989576 GROMMET
AUXILIARY HEATER
EQUIPTMENT RRO.C-36
8C-98
8C-99
KEY
SWITCH
ASM
8C -100
8C -101
1 PINK-76B
-2 P N K - 7 6 -------------- I T A N - 167 ------------' 1 DK BLU/W HT-166
---- 2 B L K - 1 5 0 --------------
167176
isjj-
166
A *
\
/-I20 0 40 29
12004267
1 fa5! fs
X2o
CIRCUIT
"0+\
T~
'
BAT
CIRCUIT
i ^ 12 0 0 4 8 8 9
- .
' S b
LEFT
INDOW
i___ u
BUS BAR
GROUND
LH WINDOW SW
FUSE BLOCK
12004155
UP
DN-LOCK
LH DOOR LOCK SW
-.8 BLK/WHT -194 - 2 0 R N /B L K -6 0 -.8 LT BLU-195
- 8905205
SPLICE-6 0
194
60
195
194
60
-2 0RN/BLK-60B
2 0RN/BLK-60C
194
60
195
667
1 *urotT
T "1
0J
\2s
RH WINDOW
MOTOR
UP-U
:h
POS, 2NEG=UP
RH DOOR LOCK SW
pfyj
LH WINDOW
MOTOR
___ _
, | COCUIT *
_ T M L c D-I UTO KCSET
CIRCUIT BKR
AUTORESET
POS. 2NEG- UNLOCK P M
-1 GRA-295 C
POS,. 2NEG-UNLOCK PM
-1 TAN-294C-
RH DOOR
LOCK MOTOR
- 8 BLK WHT-194 A-
LH DOOR
LOCK MOTOR
1 T A N -2 9 4 ------
-r6 LT BLU-195A
I G R A-295-
BODY HARNESS
DOME LP WIRE
CONTACT SW
NOTE:
PM = PERMANENT MAGNET
-.8 W HT-156BINSTRUMENT PANEL
HARNESS
DOME LP SW WIRE
RT DOOR
JAMB SW
8C -102
CONTROL
/120
MODIFIER CONTROL
2973324 TERM
BODY HARN
FOREWARD
BODY~_I~_7
W R G _______,
HARN---------- / I
8 C -103
8905206
-19
w9; TO
i 5 5 L !e
-01^ 116 - . 8
C H AN NE L-B
(" I E )
DK BLU -'R EA R
LT BLU (Rt AR
BRN------- (RFAh
>PL--------(RFAR
h - 8 DK BLU-46
.8 LT BLU-115
.8DKGRN-I17ggg y LT GRN200
B R N -199
YEL-H6
FEEDi
RE TURN)
FEED!
RETURN!
-SPLICE TO BODY
BUILDER WIRING
CUTAWAY
V AN
G 300(03) (32)
FOR 03 4 32
:8 DK BLU-4
n 8 L T BLU-II
120045457
.8 DK BLU-46
.8 LT BLUH I5~ p _L
.8 YEL-II6MJ<
.8 BRN-199 .8TAN-20T
.8GRA-118r .
.8 DK GRN-1171
3 LT GRN-200-----.8 GRA-8
RIGHT RR.SPKR.
M.
- .8 YEL-43
-.8 BLK-150
12004543
RADIO RCVR.
\7 3l
<8"4|'
{6___5|
12004267
8905220#
- . 8 DK BLU-46
r .8 L T BLU-115
.8 BRN-199
- . 8 YEL-II6
* 8 9 117 7 3 ^
^8911772
8C -104
REF
BODY
WIRING .
HARNESS RIGHT
SIDE
5 BRN-9-------------
r e f r ig h t
.5 DK GRN-19-----
REAR LAMP
WIRE ASM
5 LT GRN-24------
TO
TRAILER
REF
BODY
WIRING
HARNESS
LEFT SIDE
BR N-9C-----
Y EL-18-------
8 YEL-I8A------
-.5 DK G R N -I9-
LT GRN-24-
------ .8 LT GRN-24-------^
5 LT GRN-24-
REF
REAR
LAMP
WIRE
ASM
BRN-9--------
REF RIGHT
REAR LAMP
WIRE ASM
BATTERY
CIRCUIT
REF
BODY
WRG
HARNESS
LEFT SIDE
.8 BRN-9C
'3-
.8 YEL-18
LT GRN-24C
298467$'
.8 Y E L -I8 A -
WF
.8 LT GRN-24
.8 BRN-9
-5
BRN-9A----------
oi gi .5 DK GRN-19
LT GRN-24------- J
2984378
REF LEFT
REAR LAMP
WIRE ASM
______
8C-105
8C-106
8 C -107
PROVISIONS FOR
SIDE MARKER LP
DASH
HIGH - LOW
BEAM
8C-108
8 C -109
PROVISIONS FOR
SIDE MARKER LP
6294125 SOCKET
AWG SIZE
.22
.5
.8
1
2
3
5
8
13
19
32
40
24
20
18
16
14
12
10
8
6
4
2
1
-S
8BLK-151-
PROVISIONS FOR
BACK UP LP
PROVISIONS FOR
TAIL-STOP&DIR LP
trim
03 CD
0 BRN-9E(HOT)
c
D
SPLICE
PROVISIONS FOR
LIC PLT LP
TWO PLACES
.8 BRN-9C (HOT)
(K
SPLICE 9
111
OQtpCD
PROVISIONS FOR
TAIL-STOP 8 DIR LP
PROVISIONS FOR
BACK UP LP
SBLK-150-
TO SHEET METAL
-2
-2
-2
-2
PROVISIONS FOR
SIDE MARKER LP
BR N -9
YEL-18
DK GRN-19 LT GRN-24
8 C -1 10
FRAME GRD
(S>-50GRD STRAP
FPAME GRD
V W '
neut
\-Z '/
START
NEUT START
C BACK UP SW
START
OfF-LOCK
8C-111
/F R O N T \
VOF DASH/
N
OTE
rHE GROUND LEADS PROVIDED IN Al I
ELECTRICAL WIRING MUST BE
TERMINATED IN A MANNER TO
INSURE A COMPLETE UNIFORM A.
ONTINUOUSVEHICIE ELECTRICA1
GROUND CIRCUIT.
START
O FF-LO CK
8 C -112
RPO B3M
BATTERY
fu sib le lin k -
13RED-2B(GPT)--------------------------------------RPO B3K
TEMP
SENDER
YS
2962965
SEE
NOTE 1
2 BRN-9(GPT)
2YEL-18(GPT)
----- 2 DK GRN-I9(GPT) 2LT GRN-24CGPT) -
HIGH - LOW
BEAM
8 C -1 13
8905381 SOCKET
U W S WIPER
u
MOTOR
.0 GRA-91-----
2973407-
-2984164
HORN
RELAY
STOP LPSW
2984235
8911781
G RO MM ET
0911781 G R O M M E T
12010094
"T2004962
FUSE BLOCK
3 RED-2C 5PLICE-4-
SPLICE 3 - ^
-.5 DKBLU-15A
1 BRN-9A
1 LT GRN - 24
8900855
DIMMER
SW
100 AMP
JUNCTION BLOCK
8 C -1 14
PROVISIONS FOR
DOME LAMP
NOTE I
WIRES 9 ,1 8 ,1 9 +2 4 IN TAIL LT
EXTENTION ARE
FOR P 1 0 0 .
-2BRN -9(t3PT)-------2Y EL-I8(G P T)------ -
-2DKGRN-*9(GPT)-2 LT GRN-24(GPT)-
8C -1 15
B/U LAMP
RPO E32
AND E33 ONLY
^rSPLICE-9
2977107
- . 8 P N K -3 0 (H X L )
(EjOQ
B/U LAMP
RPO E32
AND E 33 ONLY
*B L K
-.8 B R N -9K (G P T)
.8 B R N -9D (H 0T)-P H
)BLK(GPT)
NOTE 2 S
WIRE 130 ISA 10
RESISTANCE WIRE.
TO SHEET METAL
' MSRRE r l a m
RPO E32 AND
E 33 ONLY
8 C -116
* <j >
GLOW
PLUG
GENTEBM1
TIMING
LATCHING
AND LEVEL
DETECTION
CIRCUITS
DRIVE
HI
-12010719
DIESEL ENGINE
GLOW PLUGS
CONTROL MODULE
12004267-
tp tp
LAMP
CHECK
RELAY
rh
SPLICE-150
TEST CONN
H 2 0 I0 9 9 7 (ORANGE)
12004826.
ASM
12010649
.6 LT G RN-384
C-TRUCK
t STOP LP
CONTACTS
8 PNK/BLK-39B
BRAKE SWITCH
12004215
SOCKET
NOTE- 3
i8 PNK/&LK-39C
.8 LT BLU/BLK-383
8905581
SOCKET
TO LAMP CHECK
RELAY
GLOW PLUGS
D
Q
4 WD IN LT
SWITCH
INST LPS
5 AMP
12010808-
g X )4 8 2 6 -
K-TRUCK
NOT USED
TO MOOULE
.8 LT BLU - 5 0 6
.8 B R N -2 5 ---------
^260488Sn^=':
FUSE BLOCK
.8 G R Y -5 02 -------.8 BLK/WHT-5 0 0
.8 Y E L /B L K -5 0 5 -
-12010649
TO BRAKE
SWITCH
TO WATER
IN FUEL LAMP
.8 Y E L -5 0 B A -----------
12010973-
12004215 SOCKET
.8 LT B LU /BLK-383A
.6 PNK/BLK- 39E-----.8 LT B LU /BLK-363B.8 P N K /B L K -39 F ------.8 W H T -1 5 6 A --------------
4 W DRIVE
IND LIGHT
120*0015
4WD RELAY
.8 W H T -I5 6 B -----------I 0 R N -5 0 3 A
8905381
SOCKET
WATER
IN
FUEL
NORMAL
4 WD SHIFT
LEVER LIGHT
" -----9905426
8 BLK-I50A<HW>
.0 BLK-I50BHW)FRAME GROUND
PRODUCTION
TANK SENOER
TO
GLOW
PLUGS
LAMP
DIESEL ENGINE
(RPO LF9) FOR RPO
8 C -117
Aj '
ACCESSORIES
9-1
SECTION 9
ACCESSORIES
CONTENTS
Cruise Master.......................................................................................................9-1
General Description................................................................................ .........9-1
Diagnosis.............................................................................................................9-4
On-Vehicle Service................................................... ...................................... .9-8
Specifications......................................................................................................9-8
R a d io ................................................. .................................................................. .9-8
General Description........................................................................................ .9-8
Diagnosis................................... ........................................... ............................ .9-9
On-Vehicle Service.......................................................................................... .9-21
CRUISE MASTER
GENERAL DESCRIPTION
The Cruise Master is a speed control system which
employs engine manifold vacuum to control the throttle
power unit. The power unit moves the throttle, when speed
adjustment is necessary, by receiving a varying amount of
controlled vacuum from the transducer. The speedometer
cable (from the transmission) drives the transducer, and a
cable (from the transducer) drives the instrument panel
speedometer. The engagement of the transducer unit is
controlled by an engagement switch located at the end of the
turn signal or multi-function lever. Two brake release
switches are provided: an electric switch disengages the
transducer and a vacuum valve decreases the vacuum in the
power unit to quickly return the throttle to idle position.
The purpose of the Cruise Master system is to allow the
driver to maintain a constant highway speed without the
necessity of continually applying foot pressure to the
accelerator pedal. Speed changes are easily made and
override features allow the vehicle to be stopped, slowed or
accelerated as described below.
SWITCH FUNCTIONS
The switch functions of the cruise control lever (Fig.
9-1C) are as follows:
DRIVER OPERATION
Engaging the Cruise System
9-2
ACCESSORIES
PORT "C"
ENGAGE
HOLD
PORT "B"
.RESUME VALVE PORT
TO MANIFOLD VACUUM
P O R T"A '
RESUMESOLENOID
RESUME'
CONNECTOR
ACCESSORIES
9-3
M ou n tin g
9-4
ACCESSORIES
DIAGNOSIS
ELECTRICAL SYSTEM TROUBLESHOOTING
1. Check fuse and connector.
2. Check brake electric switch as follows:
a. Unplug connector at switch.
b. Connect ohmmeter across cruise master contacts on
brake switch. The ohm m eter must indicate no
continuity when the pedal is depressed and continu
ity when pedal is released. The cruise release brake
switch (electric) is adjusted as is the standard stop
light brake switch.
c. Replace brake electric switch if needed.
Electrical Test
Refer to wiring diagram in Figure 9-5C to perform any
electrical test.
Harness Test
1. Disconnect engage switch wire harness connector from
the main harness connector (red, brown/white, and
white wires).
ACCESSORIES
PUSH BUTTC
SLIDER OPERATION
SLIDER
IN "ON"
POSITION
PUSH
BUTTON
IN REST
SLIDER
IN "ON"
POSITION
PUSH
BUTTON
IN REST
POSITION
~HOLD
ENGAGE
i
l
p o s it io n !
m iK iuttoh ~ |
tH O LD
9-5
OPERATION
r-HOLD-
1r
ENGAGE
m o ti
HOLD
I B+------!3
BRN
1} y2
BLKBLU
HOLD
SLIDER IN
"OFF"
SLIDER IN
j SMUTTLI
"ON" POSITION
PUSH
---PUSHIUTTMI |
BUTTON
IN "COAST"
Z HOLD
POSITION
B+
(DEPRESSING
MOTION)
ENGAGE
r~
SHUTTLE
U r u
PUSH BUTTON i n I
tuTTI>11
REST POSITION
t HOLD
-B+-
v v
HOLD----- ENGAGE
I SHUTTLE
SLIDER IN
"ON" POSITION
----^ PUSHHITTOW I
PUSH
BUTTON
t
C lO L D
IN "COAST"
l B + ----------POSITION
MIL
HOLD
ENGAGE
SLIDER IN
"RESUME"
POSITION
PUSH BUTTON IN
REST POSITION
-H O L D ENGAGE
(FULLY DEPRESSED)r
SLIDER IN
"ON" POSITION [s jilli1
PUSH BUTTON IP IN "ENGAGE"-*H pmhmttw
POSITION
I
HOLD
(RELEASING
Lb +
MOTION)
--------- SHOE!
T hold
B+
-H O L D
ENGAGE
xx Slider
1 &3
2& 1
Function
End Button
O ff
Released
O ff
R um
Released
Resume
Cruise
Released
On
C o ilt
H alf
Depressed
On
Coast
Fully
Depressed
On
Set
Releasing
On
O = Open
C = Continuity
x These test are continuity tests b etw een the term inals show n in figures of
resum s cruise control lever and lever electrical operation,
xx The slider m ust have a detent in the "o n " and " o ff" positions and must
return to the "o n " detent w hen released from the resum e position.
9 -6
ACCESSORIES
VEHICLE SURGES
PERFORM G ENERAL P R E L IM IN A R Y D IA G N O S T IC
SYSTEM CHECK
IF OK, A D J U S T ORIFICE TUBE IN W A R D 1 /4 OF
A T U R N A T A T IM E .
RECHECK A T 55 M P H .
NOTE: 1 /4 OF A T U R N EQUALS A P P R O X IM A T E L Y
1 MPH.
NO T OK
REPLACE
TRANSDUCER
REPLACE W IT H PROPER
P /N T R A N S D U C E R
RO A D TEST
EXCESSIVE SPEED D O W N H IL L
PERFO RM GENERAL P R E L IM IN A R Y D IA G N O S T IC
SY STEM CHECK
CHECK FOR V A C U U M LEAKS A T ALL HO SES, POWER
U N IT , BRAKE RELEASE VALVE
CHECK FOR TOO M U C H PLAY IN TH R O TTLE LINKAGE
OR CRUISE CO NTRO L BEAD C H A IN OR BO W DEN
CABLE
IF OK A D J U S T ORIFICE TUBE O U T W A R D 1 /4 OF A
T U R N A T A T IM E
RECHECK A T 55 M P H
NOTE: 1 /4 OF A T U R N EQ UALS A P P R O X IM A T E L Y
1 M PH.
ACCESSORIES
9-7
CRUISE CONTROL D IA G N O S IS
(ALL SERIES)
PRFI I M IN A R Y
CHECKS
o r leaks.
diag n osis.
C R U IS E C O NTRO L
IN O P E R A T IV E
J-----1.
If blown
2.
TEST L IG H T ON
T EST L IG H T OFF AT
ONE W IR E O NLY
AT BOTH W IR E S
BOTH W IR E S
(M A Y BE D I M ON
HOLD W IR E )
\
Test engagem ent switch.
C h e ck for poor g ro u n d
C h e ck fo r open c ir c u it in
at tra n sd u c e r.
If ok.
remove tra n sd u c e r
fo r repair.
switch.
C h e ck brake sw itch (sh o u ld
ENGAGED
SV /
4
SOLENOID
V ALVE
i
MB
4 - J k
SERVO
W*
^
p lu g -in .
TRANSDUCER
TO BRAKE
*RELEASE
VALVE
ENGINE
y VACUUM
SOURCE
RESUME
SOLENOID
sVALVE
v
NOT
ENGAGED
WITH SET
SPEED IN
MEMORY
ENGINE
VACUUM
jv S'"*'
SOURCE
RESUME
SOLENOID
VALVE
TO BRAKE
RELEASE
VALVE
ENGAGEMENT
SWITCH
E N G A G E M E N T S W IT C H T E S T P R O C E D U R E
SW IT C H P O S IT IO N S
ENGAGE
BUTTON
R ESU M E
SW IT C H
1 to 2
1 to 3
Released
on
closed
open
open
Fully
Depressed
on
open
open
closed
Partially
Released
on
closed
closed
closed
Released
resume
closed
closed
closed
Released
off
open
open
open
2 to 3
9-8
ACCESSORIES
ON CAR SERVICE
Power Unit Bead Chain Adjustment
1. With air conditioning off, adjust engine curb hot idle
speed, with the idle stop solenoid disconnected (if
equipped), to 500 rpm, then shut off engine.
2. Check bead chain slack by unsnapping swivel from ball
stud and holding chain taut at ball stud; center of swivel
should extend 1/8 inch beyond center of ball stud.
3. Adjust bead chain slack if necessary, by removing the
retainer from the swivel and chain assembly. Place
chain into swivel cavities which permits chain to have
slight slack. Place retainer over swivel and chain
assembly.
TRANSDUCER
Replacement
RADIO
GENERAL DESCRIPTION
Six types of radios are available: A M Pushbutton, A M /
Stereo 8-Track Tape, A M /F M , A M /F M Stereo, A M /F M
Stereo/Stereo tape, and A M /F M Stereo Cassette Tape.
The left knob operates the on-off switch and volumne
control, the left ring operates the tone control. The right
hand knob controls manual tuning. All A M /F M radios have
five push buttons (10 station selections) five on A M and five
on FM.
LIGHT TRUCK SERVICE MANUAL
ACCESSORIES
9-9
DIAGNOSIS
Diagnosis of radio portion of c a s s e tte - A M /F M is
shown on the diagnosis charts. For cassette diagnosis, refer
to Fig. 9-1R. If unit must be removed, it must be repaired by
an authorized service station. See Section 8 for removal
procedures and connections for speaker and power wiring.
TAPE W EAK
TAPE DEAD
IN S P E C T & CLEAN
C H E C K P L A Y E R FOR
O B S T R U C T IO N B E H IN D
C A P S T A N AND H E A D
TRY A KNOW N GOOD
DOOR
TAPE C A R T R ID G E
I________
NO O B S T R U C T IO N
O B S T R U C T IO N
TR Y A KNOW N
REMOVE
GOOD TAPE
O B S T R U C T IO N
C A R T R ID G E
r
DEAD
NOT OK
OK
R EM OVE R A D IO
A D V IS E C U ST O M E R
FOR R E P A IR
TAPE IS W ORN OR
DEFECTIVE
W ORKS
REMOVE R A D IO U N IT
A D V IS E C U S T O M E R
FOR R E P A IR
TAPE IS W O RN OR
DEFECTIVE
9-10
ACCESSORIES
CHECK
ACTION
No AM, FM or CB sound
No CB channel display.
Check Fuse
No AM, FM or CB sound
Channel display OK
Mode Switch
Squelch control
No AM,or FM sound;
CB sound OK
Mode switch
Squelch
Mode switch
Mode switch
Squelch
Replace antenna
Remove radio for repair
Cable connections
Mode switch
Selector switch
Power connector
ACCESSORIES
9-11
BRAIDED
GROUND
BLOWER MOTOR
CAPACITOR
AM/FM
FUSE PANEL
[v i e w
HOOD GROUND
CAPACITOR
BODY
BRAIDED
GROUND
FRAME
9-12
ACCESSORIES
f......
....................................
fT
REPLACE. |
....... ..................
...............................
| CORRECT OR REPLACE
F ------------------
f REPLACE.
= 3 -----| REPLACE.
REPLACE
CORRECT.
CLEAN.
TIGHTEN.
--------------------------------- 1
'
1
TIGHTEN.
WIRES. \
ACCESSORIES
9-13
9-14
ACCESSORIES
ACCESSORIES
9-15
AM AND FM DEAD
FM ONLY DEAD
CHECK FUSE.
FUSE OK
FUSE BLOWN
BAD CONNECTION
GOOD CONNECTION
UNPLUG RADIO POWER
LEAD. REPLACE FUSE.
REPAIR
CONNECTION.
RADIO W O RKS
STILL NO RECEPTION
REPLACE
MALFUNCTIONING
ANTENNA OR LEAD-IN.
RE-TRIM .
REMOVE RADIO.
FUSE D O E SN T BLOW
CHECK ALL
ACCESSORIES ON FUSE
FOR PROBLEM. (SEE
SERVICE MANUAL/TEST
DRIVE IF NECESSARY.)
CO RRECT PROBLEM.
PLUG RADIO POWER
LEAD BACK IN.
FAULTY
CONNECTION
REPAIR CONNECTION.
SUBSTITUTE SPEAKER.
(USE FADER IF SO
EQUIPPED.)
NO RECEPTION
REMOVE RADIO.
RADIO W ORKS
RADIO W O RKS
STOP.
FUSE BLOWS
REMOVE RADIO.
REPLACE
M ALFUNCTIONING
SPEAKER/W IRING
ASSEMBLY.
9-16
ACCESSORIES
NO
YES
S U B S T IT U T E B A D S P E A K E R ( S ) .
SU BST IT U T E S P E A K E R W O RKS,
BUT D EA D SP O T ON FADER*
FM O N LY D EAD
A M A N D FM D E A D
|A M O N L Y D E A D
SU BST IT U T E S P E A K E R
D O E S NOT W O R K
R E M O V E R A D IO
R E M O V E R A D IO .
R E P L A C E M A L F U N C T IO N IN G
S P E A K E R / W IR IN G A S S E M B L Y
A N D R E M O V E R A D IO .
*FADER D EA D SPOT:
A S FADER IS ROTATED, A
P O SIT IO N IS FO UND AT
WHICH O N E O R TWO S P E A K E R S
S U D D E N L Y GO DEAD.
S U B ST IT U T E S P E A K E R W O R K S
A N D NO D E A D SP O T ON FA D ER*
R E P L A C E M A L F U N C T IO N IN G
S P E A K E R / W IR IN G A S S E M B L Y .
CHECK FU SE]
FUSE OK
C H E C K T H A T A N T E N N A IS
P L U G G E D IN T O R A D IO . M A K E
S U R E P L U G I S N T C O C K E D
FU SE BLOW N
C H E C K A T T H E R A D IO F O R
F A U L T Y P O W E R C O N N E C T IO N
O R S P E A K E R C O N N E C T IO N S .
U N P L U G R A D IO P O W E R L E A D ,
R E P L A C E F U SE.
B A D C O N N E C T IO N
GO O D C O N N E C T IO N
R E P A IR
C O N N E C T IO N
C H E C K A N T E N N A A N D L E A D IN
W IT H S U B S T IT U T E A N T E N N A .
T R IM ( S E E P R O C E D U R E )
S T IL L NO R E C E P T IO N
R E M O V E R A D IO l
FU SE B L O W S A G A IN
R A D IO W O R K S
R E P L A C E M A L F U N C T IO N IN G
A N T E N N A O R L E A D IN.
FU SE D O E S N T BLO W
C H E C K A L L A C C E S S O R IE S O N
F U S E F O R P R O B L E M (S E E
S E R V I C E M A N U A L / T E S T D R IV E IF
NECESSARY)
P L U G R A D IO
PO W ER LEAD
B A C K IN.
CORRECT PROBLEM
FAULTY
C O N N E C T IO N
R A D IO W O R K S
R E P A IR C O N N E C T IO N
S U B S T IT U T E S P E A K E R ( U S E
F A D E R IF S O E Q U IP P E D . )
NO R E C E P T IO N
REM O VE
R A D IO
R A D IO W O R K S
R E P L A C E M A L F U N C T IO N IN G
S P E A K E R / W IR IN G A S S E M B L Y .
1S T O P |
FU SE B L O W S
R E M O V E R A D IO " !
A N T E N N A W IL L NO T
L O W ER
T R A V E L TO F U L L U P O R DO W N
(M O T O R D O E S N O T R U N )
P O S I T I O N S O R D O E S N 'T M O V E
C H EC K FUSE
C IG - C L K - D M
(M O T O R R U N S )
(BE S U R E M A S T I S C L E A N )
__________I_________
\
FU SE BLOW N
FU SE OK
P u ll up o n top s e c tio n
of m a s t
If se c t io n m oves
P ro b e o r a n g e w ir e t e rm in a l
D is c o n n e c t c o n n e c t o r w ith
at a n t e n n a re la y w ith 12V.
o r a n g e w ir e at relay.
test l i g h t
ne w f u s e a n d re ch e c k.
In s t a ll
1
FUSE O K
FU SE BLOW N
BROKEN
NOT B R O K E N
D R IV E C A B L E
L IG H T O N
N O L IG H T
1
R e p a ir s h o r t in
o r a n g e w ire .
D is c o n n e c t o t h e r
co n n e cto r. C o n n e ct
o r n w ire c o n n e c t o r,
Power Antenna
R em ove m ast a n d
Replace m ast a nd
U se a 12 v o lt test
Locate a n d re p a ir
s u p p o r t tube. C h e c k
su p p o rt tube.
lig h t a n d probe
ope n c i r c u i t in
m ast s e c t io n s fo r
w h ite w ire at a n t e n n a
o r a n g e w ire fro m
f re e m o v e m e n t
re la y c o n n e c to r.
re la y to f u s e panel.
re c h e c k f u se .
FU SE BLO W N
Diagnosis, Chart F
L IG H T OFF
L IG H T ON
R eplace relay.
B IN D IN G
FREE
FUSE OK
C h e c k a n d r e p a ir w h ite
w ir e to a n te n n a .
R eplace
f o r b ro k e n hook.
OK
If
replace ge a r
a sse m b ly .
C h e c k w h ite w ire
fro m re lay to a n t e n n a
R elay
C h e c k d riv e cable
If O K
r e p a ir a n t e n n a m otor
i
Free up s e c tio n s
f o r open c ir c u it.
o r replace m ast
If O K
ANTENNA R E LA Y
a n d su p p o rt tube.
L IG H T ON
C h e c k dk. g r e e n w ire
g r o u n d w ir e (black) a n d
re la y to c o n n e c t o r a nd
g r o u n d scre w .
c o n n e c t o r to a n t e n n a
replace relay.
If OK.
fo r loose c o n n e c t io n o r
open c ir c u it.
A C C E S S O R IE S
C h e c k re la y c o n n e c t io n s ;
NO L IG H T
If O K re p a ir
9 -1 7
9-18
ACCESSORIES
A N T tN N A W IL L NOT GO U P
IG N IT IO N A N D R A D IO
S W IT C H E S ON
(M O T O R D O E S NO T RUN)
C h e c k F u se s
(Radio a nd C ig - C lk - D m )
Fig. 9-11RSlimline
----------}
F U S E S BLOW N
FU SES OK
I
T u r n ig n itio n off.
C L K -C IG
R A D IO
FU SE
F U SE
Power Antenna
D isc o n n e c t 3 w ire
LIG H T ON
w ire at a n te n n a relay.
In st a ll new fu se
Diagnosis, Chart G
FU SE OK
F U SE B L O W S
(R E L A Y E N E R G IZ E D )
B LO W S
f
Locate and repair sh o rt
c ir c u it in orange w ire
from fu se panel to
con nector.
C h e ck f o r :
C h e ck yellow w ire from
Replace
a n te n n a
relay.
NO C L IC K
C L IC K S
FUSE
FU SE O K
T u rn o n ig n itio n and
ff
w ith o ra n ge w ire at a n te n n a
L IG H T OFF
and recheck.
D isc o n n e c t 3 w ire
jjeii
1.
2.
3.
If OK
If OK
replace
relay.
L IG H T OFF
Replace
sam e connector.
F U SE OK
relay.
t
Replace
relay.
LIG H T OFF
L IG H T ON
C h e c k co n n e cto r te rm in a ls
c irc u il
If O K remove an te n n a
motor fo r repair.
\
If
ACCESSORIES
9-19
POWER A N T E N N A
General D escription and O peration
T he po w e r a n te n n a a u to m a tic a lly raises the a n te n n a
mast to its full h eight w he n ev e r the radio and ignition are
t u rn e d o n . T he a n te n n a r e tra cts into the fender w h e n e ither
the ignition or radio is tu rn e d o ff.
T he p o w e r a n te n n a drive unit is h o u se d in a 2 piece
plastic housing a tta c h e d to th e mast a nd tu b e a ssem bly. A
p e r m a n e n t m agnet m o t o r w ith w o r m drive m oves the
a n te n n a m ast up and d o w n w ith a plastic cable a tta c h e d to
the to p m ast section. No clutch is used in this u n it. U pper
a nd lower travel limits are c o n tr o lle d b y sw itches o p e n e d b y
a r m a tu r e shaft th rust as the m ast reaches the end o f its
travel. A circuit bre ake r is used to p r o t e c t th e m o t o r
a r m a tu re from over heating .
T w o ty p e s o f p o w e r a n t e n n a s are used d e p e n d in g on the
t y p e o f radio used in the car:
1) AM -FM T yp e
2) AM-FM-CB (T ri-B a n d) T y pe
T he AM-FM a n te n n a e x te n d s to a m a x i m u m height o f
7 9 4 m m (31 1 / 4 ). T h e AM-FM-CB (T ri-B and) a n te n n a
e x te n d s to a height o f 9 1 4 m m ( 3 6 ). T h e tri-band a n te n n a
has a load coil m o u n te d o n th e c en ter mast section to tu n e it
to th e CB radio b a n d and a stub a n te n n a lead tape d to the
su p p o rt t u b e . The stub m a tc h e s the a n te n n a to the FM b a n d
a nd should no t be rem oved e x c e p t for re p la c e m e n t.
On Car Service
T h ere is no on car service o f th e AM-FM a n te n n a o t h e r
o e r v
N O T IC E : S W R
ch ec k in g
procedures
require
t r a n s m itte r o p e r a t io n a nd FCC regu lations governing
CB ra dio o p e r a t io n a p p ly . T he follow ing o p t io n s are
available.
Have SWR test p e rfo r m e d b y a tec h n ic ia n w h o has a
CB license.
Acquire a dealership CB radio o p e r a t o r s license
w h ic h allows tec h n ician s to use license d u r in g
business h o u rs .
Ask o w n e r or an o p e r a t o r possessing a p e r m a n e n t CB
R a d io license to p r o p e rl y o p e ra te t r a n s m itte r du ring
the test.
A d j u s t m e n t s or repairs re fe rre d to in the p r o c e d u re th a t
f ollo w s are limited to th e a n te n n a itself or the a n te n n a
lead in an d c o n n e c ti o n s .
MOTOR AND GEAR
HOUSING CO VER
CLIPS
C IR C U IT
B R EA K ER
LIM IT
SW ITCHES
BRUSHES
G EA R AND SPOOL
A SSEM BLY
BEAR IN G
TH R U ST
BLO CKS
F IE L D M AGNET
ASSEM BLY
MAST AND /
TUBE ASSEM BLY
ARM ATURE
ASSEM BLY
CABLE
STUB LEA D
CONNECTION
DRAIN TUBE
9-20
ACCESSORIES
SWR (S T A N D IN G W A V E R A T IO ) C H E C K
LEAD IN CABLE
FROM A N TE N N A
LE A D IN CA BLE
TO AM-FM RAD IO
SWR M ETER
RF JUMPER CA B LE
CB
R AD IO
IN -LIN E
S P LITTE R BOX
T R A N SM ITT ER SO CK ET
/
/
S
L O A D C O IL A D J U S T M E N T
S T U R N O N L Y 1 /8 th T U R N A T A T IM E
SWR
/
CH A N N EL 40
H IGH ER
PO SSIBLE SWR R E A D IN G S
MOVE B A N D ^
1.
b.
c.
L 40
CLOCKW ISE*
MOVES BAND DOWN
CO U N TER C LO C K W ISE'
M OVES BAND UP
A N Y R E A D IN G IN T H E R E D B A N D (A B O V E 3:1 SW R) C H E C K F O R :
Antenna mounting screws tight making a good ground connection Lead in cable connections
between antenna mounting surface and car sheet metal.
to
L e a d in c a b le s n o t p in c h e d a n d c u t t i n g t h e i n s u la t i o n .
ACCESSORIES
9-21
ON VEHICLE SERVICE
MAINTENANCE AND
ADJUSTMENTS
TAPE PLAYER MAINTENANCE
The only required m aintenance on tape players is
periodic cleaning of the tape player head and capstan. This
service should be performed every 100 hours of operation.
Since you can reach them through the tape door, you can
leave the tape player in the truck.
To clean the head and capstan, use a cotton swab
dipped in ordinary rubbing alcohol. Wipe the head and
capstan as shown in Figure 9-15R .
No lubricants should be used since they will cause the
player to operate improperly, especially at extreme
temperatures.
Do not bring any magnetized tools near the tape head.
If the head becomes magnetized, every cartridge played in
the player will be degraded.
To operate the tape player, completely insert a car
tridge into the unit. This turns the tape player on, autom ati
cally removes power from the radio, and switches the
speakers from the radio to the tape player. This feature
prevents accidental damage to the radio should the owner
attempt to operate it while the tape player is in use.
After the tape player is in operation, the front panel
controls of the player are then adjusted for the most pleasant
stereo listening.
The tape player is equipped with a cartridge locking
arm to hold the cartridge in a rigid position against the
capstan drive for minimum wow and flutter. As the car
tridge is withdrawn from the player, the on/off switch at the
other side of the cartridge is not completely disengaged
when the cartridge lock arm reaches a detent point on the
cartridge. Always withdraw the cartridge just beyond the
detent point for normal operation from the radio.
Tape cartridges should be handled carefully and should
be kept clean and out of direct sunlight. A cartridge should
not be left inserted fully in the player. This may cause
permanent damage to the cartridge.
COMPONENT PART
REPLACEMENT
RADIO OR RADIO TAPE REMOVAL
(Refer to Section 8).
ANTENNA
C-K Models
1.
T U R N R A D IO O N A N D TU N E R A D IO FOR
W EAK S T A T IO N A T OR N E AR 1400 KC.
2.
RE M O V E R IG H T H A N D KNOBS.
3.
T U R N V O L U M E UP.
4.
C A R E F U L L Y T U R N A N T E N N A T R IM M IN G
SCREW
BACK
AND
FORTH
U N T IL
M A X IM U M V O L U M E IS O B T A IN E D . SET
T R IM M E R A T PEAK V O L U M E .
N O TE: O N CARS W IT H POWER A N T E N N A ,
T R IM W IT H MAST F U L L Y E X T E N D E D
9 -1 6 R -T rim m in g R a d io
9-22
ACCESSORIES
Antenna Replacement
1.
2.
3.
4.
G Models
Antenna Replacement (Fig. 9 -1 8R)
POWER ANTENNA
DESCRIPTION A N D OPERATION
The power an ten na used on " G " models operates
automatically whenever the radio is turned on. The drive
gear unit on the automatic system consists of a drive gear
and pulley assembly and a spool for storing the excess nylon
ACCESSORIES
9 -23
PO W ER
ANTENNA
RELAY
"
9-24
ACCESSORIES
INSTALL
EY ELETS
MOTOR AN D GEAR
H O U S IN G CO VER
R o ll L ip o f Eye let
up or Dr ill Ou t to
Rem o ve Eye let.
MOTOR AN D GEAR
H O U S IN G
SC RE W D R I V E R
NOTCHES
MAST A N D TUBE
ASSEMBLY
CLIPS
IN S TA LL
MOTOR AN D GEAR
H O U S IN G C OVER
GREEN
CONNECT B A TT E R Y LEADS
CABLE HOOK
TO RAISE
MOTOR AN D GEAR
H O U S IN G
TO LOWER
ACCESSORIES
9-25
INSTALL
1. R em o v e parts as sh ow n .
1. Pos ition s w it ch .
S W IT C H A N D H A R N E S S
ASSEMBLY
be tw e e n th r u s t b lo c ks
REMOVAL
1. R em o v e parts as sh ow n .
2. Cle a n ou t o ld grease.
1.
Oil
2. A p p l y d r o p o f light o il t o bearings.
3. Reassemble and seal housing.
9-26 ACCESSORIES
REMOVAL
IN STA LL
1. Disassemble as shown.
2. Clean out old lubricant.
SWITCH A N D HARNESS
MOTOR A N D GEAR
H OUSING C OVER
MAST AND
TUBE ASSEMBLY
GEAR A N D SPOOL
ASSEMBLY
MOTOR AN D GEAR
H OUSING
CABLE
X
CABLE HOOK
6.
REMOVAL
IMSTALL
TIP
LOAD COIL
(USED ON AM FM CB
TR I BAND A N T E N N A O N LY )
SECTION 10
( /X;i
General Motors Engineering Standards have adopted a portion of the standard metric fastener sizes defined
by SI (Systeme International). This was done to reduce the number of sizes used and yet retain the best
strength characteristics in each thread size. For example, the customary 1/4-20 and 1/4-28 screws are
replaced by the metric M6.3 x 1 screw which has nearly the same diameter and 25.4 threads per inch. The
thread pitch is in between the customary coarse and fine thread pitches.
Metric and customary thread notation differ slightly. The difference is illustrated below.
CUSTOMARY
METRIC
1/4
M6.3
Thread Major
Thread Major
Diameter
Diameter
in Inches
in Millimeters
20
Number of
Distance
Threads
Between Threads
per Inch
in Millimeters
Care should be taken when servicing the car to guard against cross threading or improper retention due to
interchanged metric and inch nuts and bolts.
When obtaining metric or customary nuts, bolts, and screws locally for servicing the car, care must be
exercised in selecting parts that are equivalent to the original parts in dimensions, strength, and pitch of
threads.
10-1
10-2
P R E V A IL IN G T O R Q U E B O LT S A R E T H O S E B O LT S W H ICH
IN C O R P O R A T E A S Y S T E M TO D E V E L O P AN IN T E R F E R E N C E
B ETW EEN B O L T A N D N U T OR T A P P E D H O LE T H R E A D S .
IN T E R F E R E N C E IS A C H IE V E D BY D IS T O R T IN G SOME OF T H E
T H R E A D S (S E V E R A L M ETH O D S E X IS T ), BY A P P L Y IN G A
N Y LO N PA T C H OR S T R IP OR BY A D H E S IV E C O A T IN G ON
TH READ S.
(I I )
TOP LO CK M AN Y
TYPES
CEN TER
LO CK
D R Y A D H E S IV E C O A T IN G
GSD
N Y LO N
IN S E R T
O U T OF R O U N D T H R E A D A R E A
NYLON
P A TCH
N Y LO N
W ASH ER
IN S E R T
N Y LO N S T R IP OR P A TCH
T H R E A D P R O F IL E D E F O R M E D
R E C O M M E N D A T I O N S FOR REUSE
A.
C LEAN . UNRUSTED
FOLLO WS :
1.
2.
3.
4
5.
B
P R E V A ILIN G
TORQUI
BOLTS
AND
N IT S
MAY
Bl
R EU SE D
AS
C L E A N D IR T A N D O T H l R FO R E I G N M A T E R I A L OL E NI T A N D BOLT
INSPECT B O L T A N D N I T TO ASSURE T i l l Rl A R L NO ( RAC KS. E L O N G A T I O N OR
O T H E R SIGNS Of ABUSE OR O V E R T I G H T E N I N G . L IG H T L V L U B R I C A T E T H R E A D S . ( I F
A N Y D O U B T . RE PL A CE WI TH NEW P R E V A I L I N G TO RQ UE F A S T E N E R OF E Q U A L OR
G R E A T E R S T R E N G T H .)
ASSEMBLE PARTS A N D S T A R T B O L T OR N UT .
OBSERVE T H A T BEFORE F A S T E N E R SEATS. IT DE VE L OP S P R E V A I L I N G TO RQ UE PER
C H A R T Bl LOW ( IF A N Y D O U B T . I N S T A L L NEW P R E V A I L I N G T O R Q U I FA S T E N E R OF
E Q U A L OR G R E A T E R S T R E N G T H ) .
T I G H T E N TO TO RQ UE SPE C IF IE D IN S E R V K I M A N U A L .
NUT S A N D
A L L M E T A L BOLTS
s izes
6 & 6.3
10
i:
14
16
20
0.4
0.8
14
2.2
3.0
4.2
7.0
4.0
7.0
12
18
25
35
57
0.4
0.6
12
1.6
2.4
3.4
5.6
5.0
10
14
20
28
46
N Mil
In I bs.
N in
A D H E S I V E OR N Y L O N
C O A T E D BOLTS
In. I hs.
4.0
INCH SIZES
NUTS A N D
A L L M E T A I BOLTS
N in
In. Lbs.
N m
A D H E S I V E OR N Y L O N
C O A T E D BOLTS
In. Lbs.
.375
.437
.500
.562
.625
.750
0.6 .
1.4
1.8
2.4
3.2
4.2
6.2
4.0
5.0
12
15
20
27
35
51
0.4
0.6
1.0
1.4
1.8
2.6
3.4
5.2
4.0
5.0
9.0
12
15
11
28
43
.250
.312
0.4
10-3
Common metric fastener strength property classes are 9.8 and 10.9 with the class identification
embossed on the head of each bolt. Customary (inch) strength classes range from grade 2 to 8 with
line identification embossed on each bolt head. Markings correspond to two lines less than the
actual grade (i.e. grade 7 bolt will exhibit 5 embossed lines on the bolt head). Some metric nuts will
be marked with single digit strength identification numbers on the nut face. The following figure
illustrates the different strength markings.
GRADE 2
(GM 2 0 0 -M)
GRADE 5
(GM 280-M )
GRADE 7
(GM 290-M )
GRADE 8
(GM 300-M )
MANUFACTURERS
ID E N T IF IC A T IO N
NUT STRENGTH
ID E N T IF IC A T IO N
PO SID RIV
SCREW HEAD
ID E N T IF IC A T IO N MARKS (4)
10-4
Multiply
millimeters (mm)
meters (m)
meters
kilometers (km)
25.4
0.304 8
0.914 4
1.609
AREA
millimeters2 (mm2)
centimeters2 (cm2)
meters2 (m2)
meters
645.2
6.45
0.092 9
0.836 1
Inch2
Foot2
Yard2
16 387.
16.387
0.016
0.946
3.785
0.764
Quart
Gallon
Yard
meter/sec2 (m/s2)
meter/sec2
TORQUE
0 112 98
1.355 8
Pound-inch
Pound-foot
newton-meters (N*m)
newton-meters
POWER
0.746
Horsepower
kilowatts (kW)
PRESSURE OR STRESS
mm/
cm
liters (1)
liters
liters
meters3 (m3)
4
4
4
6
MASS
Inches of mercury
Pounds/sq. in.
3.377
6.895
kilopascals (kPa)
kilopa seals
ENERGY OR WORK
BTU
Foot-pound
Kilowatt-hour
kilograms (kg)
kilograms (kg)
tonne (t)
0.453 6
907.18
0.907
Pound
Ton
Ton
0.304 8
0.025 4
Foot/sec2
Inch/sec2
VOLUME
Inch*
to get equivalent
number of:
by
ACCELERATION
LENGTH
Inch
Foot
Yard
Mile
to get equivalent
number o f:
by
Multiply
1 055.
1.355 8
3 600 000
or 3 .6x10*
joules (J)
joules
joules (J = one Ws)
LIGHT
Foot candle
10.764
lumens/meter2 (lm/m2)
FORCE
FUEL PERFORMANCE
9.807
0.278 0
4.448
Kilogram
Ounce
Pound
newtons (N)
newtons
newtons
Miles/gal
Gal/mile
(F-32) v 1.8
F
-40
-40
20
1 i i i i i
1
i
i
32
1 40
t
0
20
120
i
40
37
Miles/hour
r 609 3
kilometers/hr. (km/h)
98.6
80
1 1 ..i..i i l l
VELOCITY
TEMPERATURE
Degree Fahrenheit
0.425 1
2.352 7
212
200 ,
160
i t
i i i i i i i il
1
i t
60
80
100
10-5
1/64
1/32
3/64
1/16
5/64
3/32
7/64
1/8
9/64
5/32
11/64
3/16
13/64
7/32
15/64
1/4
17/64
9/32
19/64
5/16
21/64
11/32
23/64
3/8
25/64
13/32
27/64
7/16
29/64
15/32
31/64
1/2
___ .
.
.
.
.
.
.
.
.
.
___ .
___ .
___ .
.
___ .
___ .
___ .
------- .
.
___ .
___ .
___ .
___ .
.
.
___ .
___ .
.
___ .
___ .
___ .
___
Decimal
In.
.015625 . . .
.03125 . . .
.046875 . . .
.0625 . . . .
.078125 . . .
.09375 . . .
.109375 . . .
.125 .........
.140625 . . .
.15625 . . .
.171875 . . .
.1875
.203125 . . .
.21875 . . .
.234375 . . .
.250 .........
.265625 . . .
.28125 . . .
.296875 . . .
.3125 ___
.328125 . . .
.34375 . . .
.359375 . . .
.375 .........
.390625 . . .
.40625 . . .
.421875 . . .
.4375 . . . .
.453125 . . . .
.46875 . . .
.484375 . . .
.500 ......... .
Metric
MM.
.39688
.79375
1.19062
1.58750
1.98437
2.38125
2.77812
3.1750
3.57187
3.96875
4.36562
4.76250
5.15937
5.55625
5.95312
6.35000
6.74687
7.14375
7.54062
7.93750
8.33437
8.73125
9.12812
9.52500
9.92187
10.31875
10.71562
11.11250
41.50937
11.90625
12.30312
12.70000
Fractions
33/64
17/32
35/64
9/16
37/64
19/32
39/64
5/8
41/64
21/32
43/64
11/16
45/64
23/32
47/64
3/4
49/64
25/32
51/64
13/16
53/64
27/32
55/64
7/8
57/64
29/32
59/64
15/16
61/64
31/32
63/64
1
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Decimal
In.
.515625 . .
.53125 . . .
.546875 . .
.5625 . . .
.578125 . .
.59375 . . .
.609375 . .
.625 . . . .
.640625 . .
.65625 . . .
.671875 . .
.6875 . . .
.703125 . .
.71875 . . .
.734375 . .
.750 ___
.765625 . .
.78125 . . .
.796875 . .
.8125 . . .
.828125 . .
.84375 . . .
.859375 . .
.875 . . . .
.890625 . .
.90625 . . .
.921875 . .
.9375 . . .
.953125 . .
.96875 . . .
.984375 . .
1.00 .........
Metric
MM.
13.09687
13.49375
13.89062
14.28750
14.68437
15.08125
15.47812
15.87500
16.27187
16.66875
17.06562
17.46250
17.85937
18.25625
18.65312
19.05000
19.44687
19.84375
20.24062
20.63750
21.03437
21.43125
21.82812
22.22500
22.62187
23.01875
23.41562
23.81250
24.20937
24.60625
25.00312
25.40000