Documente Academic
Documente Profesional
Documente Cultură
C H E V R O L E T
1976
CHEVROLET
FOREWORD
This manual has been prepared as a supplement to the 1974
Light Duty Truck Service and Overhaul Manuals. It covers, in
separate sections, diagnosis, maintenance adjustments, service
operations, and overhaul procedures for the 1976 10-30 Series
truck models.
Complete wiring diagrams for the vehicles covered in this
manual will be found in the separate 1976 Truck Wiring Diagram
booklet (ST-352-76).
Any reference to brand names in this manual is intended
merely as an example of the types of lubricants, tools, mate
rials, etc., recommended for use. In all cases, an equivalent
may be used.
All information, illustrations and specifications contained in
this literature are based on the latest product information avail
able at the time of publication approval. The right is reserved to
make changes at any time without notice.
SECTION INDEX
NAME
SECTION
1976
10-30 SERIES TRUCK
CHASSIS SERVICE
and
OVERHAUL MANUAL
SUPPLEMENT
GENERAL INFORMATION
AND LUBRICATION
HEATER AND
AIR CONDITIONING
1A
1B
BODY
FRAME
FRONT SUSPENSION
REAR SUSPENSION
AND DRIVELINE
BRAKES
ENGINE
FOREWORD
This manual has been prepared as a supplement to the 1974
Light Duty Truck Service and Overhaul Manuals. It covers, in
separate sections, diagnosis, maintenance adjustments, service
operations, and overhaul procedures for the 1976 10-30 Series
truck models.
Complete wiring diagrams for the vehicles covered in this
manual will be found in the separate 1976 Truck Wiring Diagram
booklet (ST-352-76).
Any reference to brand names in this manual is intended
merely as an example of the types of lubricants, tools, mate
rials, etc., recommended for use. In all cases, an equivalent
may be used.
All information, illustrations and specifications contained in
this literature are based on the latest product information avail
able at the time of publication approval. The right is reserved to
make changes at any time without notice.
6K
6M
6T
6Y
7M
7A
ENGINE COOLING
ENGINE FUEL
EMISSION CONTROL
SYSTEMS
ENGINE ELECTRICAL
CLUTCH AND
MANUAL TRANSMISSION
AUTOMATIC
TRANSMISSION
FUEL TANK AND
EXHAUST SYSTEM
STEERING
SERVICE SECTION
The Service Section of this manual includes new or revised
procedures for maintenance and adjustments, minor service op
erations and replacement of components.
10
11
12
13
14
15
1976 General
M otors C orporation
Printed in U.S.A.
AT REAR
S E C TIO N 0
0-1
0-6
GENERAL INFORMATION
IN D E X
T ruck Model Identification.............................................. 0-1
Vehicle Identification Num ber and Rating P la te .......0-1
Engine N u m b er.................................................................. 0-1
Unit and Serial Number Locations................................0-1
ENGINE NUMBER
The engine num ber indicates manufacturing plant, month
and day of manufacture, and transmission type. A typical
engine number would be F1210TFA, which would
breakdown thus:
F - M anufacturing Plant (F-Flint, T-Tonawanda)
12 - M onth of M anufacture (December)
10 - Day of M anufacture (tenth)
T - Truck
Axles
Series 10, 20 and P30 Code is stamped on Front of Right
Rear Axle Tube.
Series C, G30 (except dual wheel) code is stamped at
the Forw ard Upper Surface of Carrier.
Dual Wheel P art Num ber and Production Code is
stamped on Front of Right Axle Tube.
Transmissions
3-Speed Transmission U nit Number Located on Lower
Left Side of Case Adjacent to Rear of Cover.
4-Speed Transmission Unit Number Stamped on Rear
of Case, Above Output.
Turbo Hydra-M atic 350 Transmission Unit Number
Located on Right Rear Vertical Surface of Oil Pan.
0-2
GENERAL IN F O R M A T IO N A N D L U B R IC A T IO N
CA Dimension/Model Type
Chassis Type
C C o n ve n tio n a l 4 x 2
G F orw ard C o n tro l 4 x 2
(B ody-F ram e In te g ra l)
K C o n v e n tio n a l 4 x 4
(Four W h e e l Drive)
P Forw ard C o n tro l 4 x 2
(C o n v e n tio n a l)
Series/GVW Range
1 4800 to 7300
2 6400 to 8400
3 6400 to 1 4,000
0 5 B la z e r, Jimmy,
S te p -V a n , V a lu e Van
07- 4 2 "/P ic k u p , C hassis-Cab
08- FC or M o to r Home
Chassis, S te p -V a n , V a lu e
Van
09- 5 6 'V S u b u rb a n ,
C hassis-C ab, Pickup
lO 60"/FC
i
Chassis, Chevy
V a n , V a n d u ra , S p o rtva n ,
R ally W a g o n ,
C hassis-C ab, S te p -V a n ,
V a lu e Van
1 1 M o to r Home Chassis
1 3 Chevy V a n , V a n d u ra ,
S p o rtva n , R a lly
W a g o n , C u ta w a y
V a n , H i-C u b e Van
14 84"/FC o r M o to r Home
Chassis, C hassis-C ab,
S te p -V a n , V a lu e Van
16 C u ta w a y V an,
H i-C u b e Van
18 M o to r Home Chassis
Body Code
Z W 9 Base Body
Z 5 8 B la ze r, Jimmy w /W h ite
Top
Z 5 9 B la ze r, Jimmy w /B la ck
Top
Z 6 4 RV C u ta w a y Van
E3 1 H i-C u b e Van (1 O' Steel
9 6 " W id e )
E32 S te p -V a n , V a lu e Van
(S teel)
E33 S te p -V a n , V a lu e Van
(A lum inum )
E 34 H i-C u b e Van (10' Steel
8 2 " W id e )
E 36 H i-C u b e Van
(1 O' A lum inum )
E 38 H i-C u b e Van (12' Steel)
E 39 H i-C u b e Van
(1 2' A lum inum )
E 55 S u b u rb a n (w/End G a te )
E 62 S tepside (F enderside)
Pickup
E 63 Fleetside (W id e S ide)
Pickup
E94 B e a u v ille S portvan,
R a lly STX
Engine Code
LD4 250 Six
L25 292 Six
LF5 350-2 V8
LS9 3 5 0 -4 V8
LF4 4 0 0 -4 V8
LF8 4 5 4 -4 V8
GENERAL IN F O R M A T I O N A N D L U B R IC A T IO N
0-3
Delcotrons
n
GVWRI
GAWR FRONT 1
Batteries
GAWR REAR
V IN l
Starters
I
CAMPER LOADING DATA
CWR]_____DIM A l
1 DIM B l
=
=
=
=
=
=
=
=
L6-250-1
V 8-350-4
L6-292-1
V 8-305-2
V 8-350-2
V 8-3 50-4
V 8-4 00-4
V 8-4 54-4
V 8-454-4
C = CHEVROLET
T = GMT
CHASSIS TYPE
SEQUENTIAL NUMBER
C = 2 WHEEL DRIVE
G = LIG H T DUTY
FORWARD CONTROL
K = 4 WHEEL DRIVE
L = LIGHT UTILITY
P = FORW ARD CONTROL
BO D Y STYLE
2-F orw a rd C ontrol
chassis only
3-C ab-chassis (C utaw ay)
4 -C a b a n d p ic k u p box
5 -Van and Panel
6 -S u b u rb a n bo dy
7 -M o to r Home
8 -U tility (Blazer)
ASSEMBLY
A -L a k e w o o d
B -B a ltim o re
F-Flint
J- J a n e s v ille
PLANT
V -G M T ru ck-P o n tia c
S-St. Louis
U -Lo rdsto w n
Z -F re m o n t
1-O shav/a
3-G M A D D e tro it
4-S ca rboroug h
Engines
6-Cylinder Engine U nit N um ber Located on Pad at
EMERGENCY STARTING
Engines in vehicles with autom atic transmissions cannot
be started by pushing or towing the vehicle.
Never tow or push trucks equipped with light duty
emission control systems to start engine.
A vehicle with a discharged battery may be started by
transferring electrical power from a battery in another
car - called "jump starting".
Jump Starting
Distributor.
TR U C K SUPP - S E R VIC E
0-4 GENERAL IN F O R M A T IO N A N D L U B R IC A T IO N
CAUTION:
Departures from these conditions or the procedure
below could result in: (1) serious personal injury
(particularly to eyes) or property damage from such
causes as battery explosion, battery acid, or electrical
burns; and/or (2) damage to electronic components
o f either vehicle.
Never expose battery to open flame or electric
spark-batteries generate a gas which is flammable and
explosive. Do not allow battery fluid to contact eyes,
skin, fabrics, or painted surfaces-fluid is a corrosive
acid. Flush any contacted area with water
immediately and thoroughly. Be careful that metal
tools, or jum per cables do not contact the
positive battery terminal (or metal in contact
with it) and any other metal on the vehicle,
because a short circuit could occur. Batteries
should always be kept out of the reach of
children.
TOW ING
All Except Four Wheel Drive Trucks
Normally your vehicle may be towed with all four wheels
on the ground for distances up to 50 miles at speeds of less
than 35 M PH. The engine should be off and the transmission
in neutral.
However, the rear wheels must be raised off the ground or
the drive shaft disconnected when the transmission is not
operating properly or when a speed of 35 M PH or distance
of 50 miles will be exceeded.
GENERAL IN F O R M A T I O N A N D L U B R IC A T IO N
VEHICLE LOADING
0-5
^Front C u rb
2261 lbs.
*R e a r C u rb
1549 lbs.
R ear C a rg o &
Front C a rg o &
Pass. Load
450 lbs.
Pass. Load
1940 lb s .
3 4 8 9 lbs.
2711 lbs.
Fig. 4 - T y p ic a l V e h ic le L o ad ed C o n d itio n
p a sse n g e r o r c a rg o , b u t in c lu d in g fu e l a n d c o o la n t.
TR U C K SUPP - S ER VIC E
0-6 GENERAL IN F O R M A T IO N A N D LU B R IC A T IO N
LUBRICATION
IN D E X
M aintenance Schedule.......................................................0-6
E ngine................................................................................... 0-6
Oil and Filter Recom m endations................................ 0-6
Drive B elts........................................................................0-7
Positive Crankcase Ventilation (P.C.V.)..................... 0-7
Air Injection R eactor System (A .I.R .)...................... 0-8
Controlled Combustion System (C.C.S.).................... 0-8
Evaporation C ontrol System (E.C.S.)..........................0-8
Early Fuel Evaporation (E.F.E.) System...................0-8
A ir Cleaner........................................................................0-8
Fuel F ilte r......................................................................... 0-8
G overnor............................................................................ 0-8
Accelerator L inkage........................................................ 0-8
Automatic Transmission Fluid Recommendations.... 0-8
M anual T ransm ission....................................................... 0-9
Transmission Shift L in k ag e.............................................0-9
C lu tc h ................................................................................... 0-9
Rear Axle
S tandard............................................................................. 0-9
M A IN T E N A N C E SC HED U LE
A separate maintenance folder has been provided with each
vehicle which contains a complete schedule and brief
explanation of the safety, emission control, lubrication and
general maintenance it requires. The maintenance folder
information is supplemented by this section of this manual,
as well as the separate vehicle and emissions warranty
booklet also furnished with each vehicle. Read all three
publications for a full understanding of vehicle maintenance
requirements.
The time or mileage intervals for lubrication and
maintenance services outlined in this section are intended as
a general guide for establishing regular maintenance and
lubrication periods for trucks with light duty emission
control systems (see chart). Sustained heavy duty and high
speed operation or operation under adverse conditions may
require more frequent servicing.
For maintenance and lubrication information on trucks
designated with heavy duty emission control systems,
continue to refer to Section 0 of the 1974 Light Duty Truck
Shop Manual.
ENGINE
T R U C K SUP P - S ER VICE
GENERAL IN F O R M A T I O N A N D L U B R IC A T IO N
-M o to r Home use.
Replace the oil filter at the first oil change, and every
second oil change thereafter. AC oil filters (or
equivalent) provide excellent engine protection.
The above recommendations apply to the first change as well
as subsequent oil changes. The oil change interval for the
engine is based on the use of SE oils and quality oil filters.
Oil change intervals longer than those listed above will
seriously reduce engine life and may affect the
m anufacturers obligation under the provisions of the New
Vehicle W arranty.
A high quality SE oil was installed in the engine at the
factory. It is not necessary to change this factory-installed
oil prior to the recommended norm al change period.
However, check the oil level more frequently during the
break-in period since higher oil consum ption is normal until
the piston rings become seated.
NOTE: Non-detergent and other low quality oils are
specifically not recommended.
Recommended Viscosity
Select the proper oil viscosity from the following chart:
The proper oil viscosity helps assure good cold and hot
starting.
10W JO, 1 0 W 40 2 0 W 4 0 W
11
2 0 W 50
V
-Extensive idling.
2 0 W 20
0-7
11
h
n u n
F - 2 0
l
r C 30
1
ii m
20
'
-2 0
40
-1 0
60
1<!>6
80
i
30
10
20
TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE
40
Drive Belts
Drive belts should be checked every 7,500 miles or 6 months
for proper tension. A loose belt will affect water pump and
generator operation.
VALVE
0-8 GENERAL IN F O R M A T IO N A N D L U B R IC A T IO N
(A.I.R.)--CONTROLLED COMBUSTION
SYSTEM (C.C.S.)
The Air Injection Reactor system should have the drive belt
inspected for wear and tension every 24 m onths or 30,000
miles, whichever occurs first. In addition, complete
effectiveness of either system, as well as full power and
performance, depends upon idle speed, ignition timing, and
idle fuel m ixture being set according to specification. A
quality tune-up which includes these adjustments should be
performed periodically to assure normal engine efficiency,
operation and performance.
AIR CLEANER
CAUTION: Do not remove the engine air cleaner
unless temporary removal is necessary during repair
or maintenance o f the vehicle. When the air cleaner
is removed backfiring can cause fire in the engine
compartment.
NOTE: U nder prolonged dusty driving conditions, it
is recommended that these operations be performed
more often.
Replace the engine air cleaner element under normal
operating conditions every 30,000 miles.
FUEL FILTER
DEXRO N II.
Check the fluid level at each engine oil change period.
Automatic transmissions are frequently overfilled
because the fluid level is checked when the fluid is cold
and the dipstick indicates fluid should be added.
However, the low reading is normal since the level will
rise as the fluid tem perature increases. A level change
of over 3 /4 inch w ill occur as fluid temperature rises
from 60F to 180F.
Overfilling can cause foaming and loss of fluid through
the vent. Slippage and transmission failure can result.
Fluid level too low can cause slipping, particularly,
when the transmission is cold or the car is on a hill.
Check the transmission fluid level w ith engine running,
the shift lever in PARK and the car level.
GOVERNOR
(6 5 -8 5 F .)
(1 8 -2 9 C .)
COOL
HOT
ACCELERATOR LINKAGE
Lubricate with engine oil every 30,000 miles as follows:
1. On V8 engine, lubricate the ball stud at the carburetor
lever.
W ARM
GENERAL IN F O R M A T I O N A N D L U B R IC A T IO N
Turbo
Hydra-Matic
400
and
Turbo
6 0,0 00
REAR AXLES
Standard
Every 6 m onths or 7,500 miles, whichever occurs first, check
lubricant level and add lubricant, if necessary, to fill to level
of filler plug hole. Use SAE 80W or SAE 80W-90 GL-5 G ear
Lubricant. For those vehicles normally operated in Canada,
use SAE 80W GL-5 G ear Lubricant.
To
0-9
Miles
400
UNIVERSAL JOINTS
All universal joints are the needle bearing type. Lubricate
those universal joints (depending on truck model) equipped
with lube fittings every 7,500 miles or 6 months with water
resistant EP chassis lubricant which meets General M otors
Specification GM 6031-M. M ore frequent lubes may be
required on heavy duty or "Off the Road" operations.
WHEEL BEARINGS
LUBRICANT
Front
Clutch
Rear
T R U C K SUP P - S E R VIC E
0 -1 0
GENERAL IN F O R M A T IO N A N D L U B R IC A T IO N
PARKING BRAKE
Every 7,500 miles or 6 months clean and lubricate all
parking brake pivot points with water resistant EP chassis
lubricant which meets General M otors Specification GM
6031-M.
STEERING
BODY LUBRICATION
Norm al use of a truck causes metal-to-metal movement at
certain points in the cab or body. Noise, wear and improper
operation at these points will result when a protective film
of lubricant is not provided.
For exposed surfaces, such as door checks, door lock bolts,
lock striker plates, dovetail bum per wedges, etc. apply a thin
film of light engine oil.
Where oil holes are provided in body parts a dripless oil can
be safely used, but any lubricant should be used sparingly,
and after application all excess should be carefully wiped off.
GENERAL IN F O R M A T I O N A N D L U B R IC A T IO N
0-11
UNDERBODY M AINTENANCE
SPEEDOMETER ADAPTER
The effects of salt and other corrosive m aterials used for ice
and snow removal and dust control can result in accelerated
rusting and deterioration of underbody components such as
T R U C K S UPP S ER VIC E
0-12
GENERAL IN F O R M A T IO N A N D LUB R IC A T IO N
Item
No.
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
33
34
35
36
37
Services
(For Details, See Numbered Paragraphs)
Chassis Lubrication
*F luid Levels Check
Engine Oil Change
*Oil Filter Change
Tire Rotation (Steel Belted Radial)
Rear Axle Lube Change
A ir Conditioning Check
*Cooling System Check
Coolant Change & Hose Replacement
Wheel Bearing Repack
*Auto. Trans. Fluid & Filter Change
Manual Steering Gear Check
Clutch Cross Shaft Lubrication
Owner Safety Checks
Tire and Wheel Inspection
*Exhaust System Check
*Drive Belt Check
* Belt Replacement
Suspension and Steering Check
Brake and Power Steering Check
Drum Brake and Parking Brake Check
Throttle Linkage Check
Underbody Flush & Check
Bumper Check
Thermo. Controlled A ir Cleaner Check
Carburetor Choke Check
Engine Idle Speed Adjustm ent
EFE Valve Check
Carburetor M ounting Torque
Fuel Filter Replacement
Vacuum Advance System & Hoses Check
PCV System Check
PCV Valve & Filter Replacement
Idle Stop Solenoid Check
Spark Plug Wires Check
Spark Plug Replacement
Engine Tim ing A djustm ent & Dist. Check
ECS System Check & Filter Replacement
Fuel Cap, Tank and Lines Check
A ir Cleaner Element Replacement
GENERAL IN F O R M A T IO N A N D L U B R IC A T IO N
E X P L A N A T IO N OF C O M P LE T E
V E H IC LE M A IN T E N A N C E SC H ED U LE
FOR SERIES 10, L-6 A N D V -8 EN G IN ES
A N D L IG H T D U T Y E M IS S IO N S Y S T E M
Presented below is a brief explanation of each of the Vehicle
M aintenance services.
N ORM AL VEHICLE USE -T h e maintenance instructions
contained in this maintenance schedule are based on the
assumption that vehicle will be used as designed:
S E C T IO N A
LUBE A N D G E N E R A L M A IN T E N A N C E
CHASSIS -L u b ricate all grease fittings in front
suspension steering linkage and constant velocity universal
joint. Also lubricate transmission shift linkage, hood latch,
hood hinges, and parking brake cable guides and linkage,
clutch linkage, propellor shaft slip joint, universal joints and
brake and clutch pedal springs. Lubricate suspension and
steering linkage every 3 m onths or 3,000 miles when
operating under dusty or m uddy conditions and in extensive
off-road use.
A-1
0-1 3
-R eplace at the first oil change and every other oil change
thereafter.
A-5 TIRES - T o equalize wear, rotate tires as illustrated in
shaft lever.
TRUC K SUP P - S E R V IC E
0 -1 4
GENERAL IN F O R M A T IO N A N D L U B R IC A T IO N
S E C TIO N B -S A F E T Y M A IN T E N A N C E
NOTE: Items B-l (a) thru (w) can be checked by the
owner, while Items B-2 thru B-10 should only be
checked by a qualified mechanic. It is particularly
im portant that any safety systems which may have
been adversely affected in an accident be checked and
repaired as necessary before the vehicle is returned to
use.
g. W H EEL A L IG N M E N T A N D BALANCE - I n
addition to uneven or abnormal tire wear, the need
for wheel alignment service may be indicated by a pull
to the right or left when driving on a straight and level
road. The need for wheel balancing is usually
indicated by a vibration of the steering wheel or seat
while driving at normal highway speeds.
h. BRAKES -B e alert to illumination of the brake
warning light or changes in braking action, such as
repeated pulling to one side, unusual sounds either
when braking or between brake applications, or
increased brake pedal travel. Any of these could
indicate the need for brake system inspection a n d /o r
service.
i. EX H A U ST SYSTEM -B e alert to any change in the
sound of the exhaust system or a smell of fumes which
may indicate a leak requiring inspection an d /o r
service. (See also Engine Exhaust Gas Caution in Item
B-3 of this section.)
j. W IN D SH IE L D W IPE R A N D W ASHER -C heck
operation of wipers, as well as condition and
alignment of wiper blades. Check amount and
direction of fluid sprayed by washers during use.
k. D EFR O STER -C h eck performance by moving
controls to "D EF" and noting am ount of air directed
against the windshield.
1. R EA R V IEW M IRRO RS A N D SUN VISORS
-C h eck that friction joints are properly adjusted so
m irrors and sun visors stay in the selected position.
m. H O R N -B low the horn occasionally to be sure that
it works. Check all button locations.
n. LAP A N D SH O U LD ER BELTS -C h e ck belts,
buckles, latch plates, retractors, rem inder systems and
anchors for proper operation or damage. Check to
make certain that anchor m ounting bolts are tight.
o. H EA D R ESTRA IN TS Check that head restraints,
if present, adjust properly in the up detent positions,
and that no components are missing, damaged or
loose.
p. SEAT AD JUSTERS -C h e ck that seat adjusters
securely engage by pushing forward and backward
whenever a manual seat is adjusted.
q. SEAT BACK LATCHES -C h e ck to see that seat
back latches are holding by pulling forward on the top
of each folding seat back.
r. LIG H TS A N D BUZZERS -C h e ck all instrum ent
panel illuminating and warning lights, seat belt
reminder light and buzzer, interior lights, license plate
lights, side m arker lights, headlamps, parking lamps,
tail lamps, brake lights, turn signals, backup lamps,
and hazard warning flashers. Have headlamp aim
checked every 12 m onths or 15,000 miles, or more
often if light beams seem to be aimed improperly.
s. GLASS -C h eck for broken, scratched, dirty or
damaged glass on vehicle that could obscure vision or
become an injury hazard.
TR U C K S UPP - S ER VICE
GENERAL IN F O R M A T IO N A N D L U B R IC A T IO N
0-15
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
NOTE: Additional recommended maintenance
instructions relating to vehicle use, evidence of
maintenance and service replacement parts are
included in the New Truck W arranty Inform ation
folder.
C-1
THERM O STATICALLY
CONTROLLED
AIR
CLEANER -In sp e ct installation to make certain that all
EARLY
FUEL
EVAPORATION
(EFE)
SYSTEM
0 -1 6
GENERAL IN F O R M A T IO N A N D L U B R IC A T IO N
VA C U UM
ADVANCE
SYSTEM
AND
HOSES
GENERAL IN F O R M A T I O N A N D L U B R IC A T IO N
0-1 7
F L U ID /L U B R IC A N T
P o w e r s te e rin g s y s te m a n d p u m p
re s e rv o ir
G M p o w e r s te e rin g f l u id P a rt N o . 1 0 5 0 0 1 7
if n o t a v a ila b le use D E X R O N - ll a u to m a tic
tr a n s m is s io n f l u id o r e q u iv a le n t
D if f e r e n t ia ls ta n d a rd
S A E -8 0 W o r S A E -8 0 W -9 0 G L -5 gear
lu b r ic a n t (S A E -8 0 W in C an a d a)
D if fe r e n t ia l P o s itr a c tio n
L u b r ic a n t G M P a rt N o . 1 0 5 0 0 81
M a n u a l S te e rin g G e a r
L u b r ic a n t G M P a rt N o . 1 0 5 1 0 5 2
M a n u a l tra n s m is s io n
S A E -8 0 W o r S A E -8 0 W -9 0 G L -5 gear
lu b r ic a n t (S A E -8 0 W in C an a d a)
B ra k e s y s te m a n d m a s te r c y lin d e r
D e lc o S u p re m e N o . 11 o r D O T -3 f lu id s
C lu tc h lin k a g e (M a n . tra n s . o n ly )
a. P iv o t p o in ts
b. Push ro d to c lu t c h f o r k j o in t ,
a n d cro ss s h a ft p re ssu re f i t t in g
E n g in e o il
Chassis grease m e e tin g r e q u ire m e n ts o f
o f G M 6 0 3 1 -M
M a n u a l tra n s m is s io n s h if t lin k a g e ,
c o lu m n s h if t
E n g in e o il
S h if t lin k a g e , f l o o r s h if t
E n g in e o il
H o o d L a tc h a s s e m b ly
a. P iv o ts a n d s p rin g a n c h o r
b . Release p a w l
E n g in e o il
Chassis grease
H o o d h in g e s
E n g in e o il
A u to m a tic tra n s m is s io n s h if t
lin k a g e
E n g in e o il
Chassis lu b r ic a t io n
C o n s ta n t V e lo c ity U n iv e rs a l J o in t
G M L u b r ic a n t P a rt N o . 1 0 5 0 6 7 0 o r
grease m e e tin g re q u ir e m e n ts o f G M -6 0 4 0 -M
A u to m a tic tra n s m is s io n
D E X R O N - ll a u to m a tic tr a n s m is s io n f lu id
P a rk in g b ra k e cables
C hassis grease
F r o n t w h e e l b e a rin g s
W h e el b e a rin g lu b r ic a n t G M P a rt N o .
1 0 5 1 3 4 4 o r e q u iv a le n t
B o d y d o o r h in g e p in s ,
fu e l d o o r h in g e ,
ta ilg a te h in g e s
E n g in e o il
W in d s h ie ld w a s h e r s o lv e n t
G M O p tik le e n w a s h e r s o lv e n t P a rt N o .
1 0 5 1 5 1 5 o r e q u iv a le n t
B a tte ry
C o lo rle s s , o d o rle s s , d r in k in g w a te r
E n g in e c o o la n t
M ix tu r e o f w a te r a n d a h ig h q u a lit y
E th y le n e G ly c o l base ty p e
a n ti-fre e z e c o n f o r m in g to G M
S p e c. 1 8 9 9 -M
0 -1 8
GENERAL IN F O R M A T IO N A N D L U B R IC A T IO N
DRIVE ON HOIST
HH
jjj
GENERAL IN F O R M A T I O N A N D L U B R IC A T IO N
L u b ric a tio n
Period
N o.
5
6
7
L o w er C o n tro l A rm s
U p p er C o n tro l A rm s
U p p er and Lo w er C o n tro l
A rm Ball Joints
In te rm e d ia te Steering
S h a ft (P A 1 0 )
T ie R od Ends
W heel Bearinqs
Steering Gear
7 ,5 0 0 M iles
3 0 ,0 0 0 M iles
3 0 ,0 0 0 M iles
A ir C leaner E lem en t
3 0 ,0 0 0 Miles
2
3
4
Chassis L u b ric a n t
Chassis L u b ric a n t
Chassis L u b ric a n t
7 ,5 0 0 M iles
Chassis L u b ric a n t
Chassis L u b ric a n t
W hl. Brq. L u b ric a n t
M aster C y lin d e r
7 ,5 0 0 M iles
12
7 .5 0 0
7 .5 0 0
7 ,5 0 0
7 ,5 0 0
7 ,5 0 0
16
17
18
Q u a n tity
7 ,5 0 0 Miles
7 ,5 0 0 M iles
7 ,5 0 0 M iles
11
13
14
15
Type of
L u b ric a tio n
M iles
M iles
M iles
M iles
Miles
7 .5 0 0 M iles
7 ,5 0 0 M iles
7 ,5 0 0 M iles
Delco S uprem e
N o . 11 or D O T -3 flu id s
G L -5
D e x ro n H or equivalent
Enqine O il
Enqine O il
Engine O il
As required
Chassis L u b ric a n t
Chassis L u b ric a n t
G L -5
As required
As required
As required
As
As
As
As
As
required
required
required
required
required
0 -1 9
Rem arks
C heck fo r Grease L e a k
D o n o t Lu b rica te
R ep laceSee V eh icle
M ain te n an ce S chedule
C heck add flu id
w hen necessary
Keep even w /fille r plug.
See L u b ric a tio n S ection
N o t shown
Check
See L u b ric a tio n section
TR U C K SUPP - S E R VIC E
0-20
N o.
1
2
3
4
b
6
L u b ricatio n
Period
7 ,5 0 0
7 ,5 0 0
3 0 ,0 0 0
3 0 ,0 0 0
7 ,5 0 0
7 ,5 0 0
3 0 ,0 0 0
M iles
M iles
Miles
Miles
Miles
Miles
M iles
9
10
T ransmissionManual
A u to m a tic
Rear A x le
O il F ilte r
11
7 .5 0 0 Miles
7 .5 0 0 M iles
7 ,5 0 0 Miles
Every Second
O il Chanqe
7 ,5 0 0 Miles
12
7 ,5 0 0 M iles
Type of
L u brication
Q u a n tity
Chassis L u bricant
Chassis Lu b rica n t
W hl. Brg. L u b rica n t
12 places as required
4 places as required
2 places as required
Chassis L u b rica n t
Chassis L u bricant
As required
As required
G L -5
D exron -II or Equivalent
G L -5
As required
As required
As required
D elco Suprem e
N o . 11 or D O T -3 fluids
Chassis L u bricant
As required
Rem arks
See V eh icle
M aintenan ce
Schedule
See L u b rica tio n Section
See L u b rica tio n S ection
See L u b rica tio n S ection
T R U C K SUP P - S ER VICE
S E C TIO N 1A
1A-1
1A-1
GENERAL INFORMATION
Refer to the 1974 Light Duty Truck Service M anual for
servicing the standard heater and auxiliary heater except as
follows:
AIR CONDITIONING
Refer to the 1974 Light Duty Truck Service M anual for
servicing an air conditioning system with a V8 engine or six
cylinder engine except as follows:
M A IN U N IT S OF THE S Y S T E M
AXIAL SIX CYLINDER COMPRESSOR (Fig. 1)
Teflon Piston Ring Type Pistons
Axial six cylinder compressors used on 1975 and 1976
vehicles are equipped with a Teflon ring type piston (Fig.
2), instead of the former Carbon ring type. The basic
compressor mechanism remains unchanged. The Teflon ring
type piston is dimensionally the same as the carbon ring type
except for the ring groove detail. The replacement procedure
for the Teflon ring type piston differs from that of the carbon
ring type. Refer to the Overhaul section of this manual for
the proper method of replacing the Teflon ring type pistons
or Teflon piston rings.
by the condenser.
The compressor has a displacement of 10.0 cu. in. The
compressor has variations in the pulley rim diameter
specified for the respective vehicle applications.
The basic compressor mechanism is a modified scotch yoke
with four cylinders located radially in the same plane.
Opposed pistons are pressed into a yoke which rides upon
a slider block located on the shaft eccentric. Rotation of the
shaft provides reciprocating piston motion with no
"connecting rods". The mechanism is completely balanced
with counterweights. Needle bearings are used for the shaft
journals and the shaft eccentric. Pistons and yokes, along
with the main cylinder housing and front cover, are made
from aluminum to provide light weight. Teflon piston rings
are used to provide both a gas compression seal and a
piston-to-bore bearing surface. The outer shell is a simple
steel band which encloses a large annular discharge muffler
space.
Two O-rings provide a seal between the compressor shell and
the compressor cylinder. A rubber seal ring seals the front
head to the cylinder assembly and the shaft seal assembly
provides a front head to shaft seal.
Refrigerant flows into the crankcase from the connector
block at the rear, is drawn through the reeds attached to the
piston top during the suction stroke, and is discharged
outward through the discharge valve plate which is held in
place at the top of the cylinder by a snap ring. Discharge
gas flows out of the compressor muffler cavity through the
connector block at the rear.
1A-2
HEATER
O -R ing
Front H ead
Shaft Seal Assembly
AND
Seal Seat
O -R ings
O -R ing
0 Ring
, Compressor Shell
Clutch Coil and Housing Assembly
Suction Screen
Fig. 1 -A x ia l Six Cylinder Com pressor Exploded
Pulley
Bearing
O il Pick-up Tube
S w itch O -R ing
AIR CONDITIONING
Bearing Retainer
O - Ring
Lock Nut
Rear Head
O uter O il Pump G e a r
Retainer Ring
Lock Nut
Ball
V ie w
Shoe Disc
T e flo n R ing T ype Piston
T e flo n Piston Ring
Shaft
Discharge Crossover Tube
Thrust Races
Front
Suction Reed
Front Discharge
V alve Plate Assembly
HEATER A N D A IR C O N D IT IO N IN G
1A-3
Front Head
The front head contains the front main shaft bearing pressed
in place and a drilled oil hole for lubrication to the shaft seal
cavity. The front head is mounted to the cylinder assembly
by four screw and washer assemblies.
Thrust Washers
Fig. 2 - T e f lo n Ring T y p e Piston
Clutch Coil
The clutch coil is molded into the steel coil housing and must
be replaced as a complete assembly. Three protrusions on
the rear of the housing fit into alignment holes in the
compressor front head. The coil is secured to the front head
by a pressed fit between the coil housing and neck portion
of the front head. The coil has 3.65 ohms resistance at 80F.
ambient and will require no more than 3.2 amperes at 12
volts D.C. The clutch coil has two term inals for the power
and ground leads.
Clutch-Pulley
The movable part of the clutch drive plate is in front of and
adjacent to the rotor and bearing assembly. The arm ature
plate, the movable member, is attached to the drive hub
through driver springs riveted to both members. The hub of
the drive plate is pressed on the compressor shaft and keyed
to the shaft by a square drive key. A self-locking nut threads
on the end of the shaft and is tightened against the shaft.
The rotor and hub is a welded assembly and contains six
threaded holes for mounting the pulley rim. The pulley rim
is secured to the rear portion of the rotor by six screws and
six special lock washers.
A two-row ball bearing is pressed into the rotor hub and held
in place by three punch stakes, 120 apart, into the rotor hub
near the hub bore. The entire clutch coil, pulley rim, rotor
and bearing assembly is pressed on the front head of the
compressor and secured by a retainer ring.
W hen power is supplied to the clutch coil the arm ature plate
of the drive plate and hub assembly electromagnetically
engages the slotted portion of the rotor face which then
drives the crankshaft through the drive plate leaf springs and
hub.
Shaft Seal
The main shaft seal, located in the neck of the compressor
front head, consists of the seal assembly with its ceramic seal
face in a spring loaded cage. An "O" ring seal, located within
the ceramic seal, provides a seal to the shaft surface. The
contact surface of the shaft seal seat is finished to a high
polish and m ust be protected against nicks, scratches and
even fingerprints. Any surface damage will cause a poor seal.
An "O" ring, located in an internal groove in the neck of
the front head provides a seal with the outer diameter of the
seal seat. A retainer ring, tapered side away from the seat,
secures the seat in place. The hub and arm ature plate must
be removed to gain access to the seal. A shaft seal kit
OIL CHARGE
Refer to the oil charge chart in Figure 5 for A-6 and R-4
compressor oil charge.
SYSTEM CONTROLS
General
1976 CK Series Truck (Fig. 6) Heating and Air Conditioning
mode selection has been simplified by the addition of a new
Maximum Mode position to the previous six mode
control. With the Temperature lever set to the extreme cold
position and the mode selector lever positioned in MAX,
maximum cooling is attained, and High blower speed is
automatically selected. The new MAX mode setting as
well as the other cooling settings (NORM and BI-LEVEL)
have been grouped under an A/C heading. The VENT and
HEATER settings have been grouped under an ECONOMY
heading.
Selector Lever
The system selector lever (air control lever) determines the
mode of operation: W hen the system selector lever is placed
in A /C (M AX, N O R M or BI-LEVEL) or D E F positions,
electrical circuit connection is made to the compressor
clutch through the control panel switch and the compressor
discharge pressure switch. If the compressor discharge
pressure switch is closed (ambient tem perature above
approximately 42F, the compressor will run. In the O FF,
or ECON OM Y (VENT or H EA TE R ) positions the
compressor clutch is not energized.
The system selector lever also determines the direction of
outlet air flow. Moving the lever from mode to mode varies
the position of a vacuum valve on the control. The position
of the vacuum valve will supply vacuum to, or vent, vacuum
diaphragms which position the upper and lower mode and
defroster air doors in the selector duct assembly. The
position of these air doors determines if output air flow is
from the heater purge outlet at O FF, the heater outlet with
slight air flow from defroster nozzles at H EA TER, heater
and A /C outlets at VENT, A /C outlets only at M AX and
NORM , heater A /C and defroster outlets at BI-LEVEL, or
the defroster outlets with slight airflow from the heater
outlet at DEF.
1 A-4
HEATER A N D AIR C O N D IT IO N IN G
1. Screw
2. Locking W ashe r
14. O -R ing
25. O -R ing
3. P ulley Rim
4. C o il an d H ousing Assy.
16. O -R ing
17. Screw
18. S h ip p in g P late
19. O -R ing
5. Rotor B e a rin g
6. Rotor a n d B e a rin g Assy.
7. R e ta in in g Ring
8. C lutch Drive Assy.
9. C lutch H ub Key
10. S h a ft N u t
11. C ap
12. R e ta in in g Ring
30. Screw a n d W a sh e r
31. O -R ing
32. S h a ft Seal
33. Seal Seat
34. R e ta in in g Ring
TRUC K S U P P - S ER VIC E
HEATER A N D AIR C O N D IT IO N IN G
1A-5
Fari Switch
The blower FA N switch provides a means of selecting the
am ount of airflow from the system by regulating the speed
of the blower motor. There are, however, limitations to the
T R U C K SUPP - S E R V IC E
1 A-6
HEATER A N D AIR C O N D IT IO N IN G
UNIT
ADD OIL
CONDENSOR ..................................
EVAPORATOR
..............................
EE -V IR
..........................................
COMPRESSOR
CONDITION
...............................................1 OUNCE
MORE THAN
- 4 OZ. IN A-6
- 1/2 OZ. IN R 4
LESS THAN
REPLACING COMPRESSOR
WITH A SERVICE REBUILT
COMPRESSOR.
4 OZ. IN A-6
1/2 OZ. IN R-4
MORE THAN
- 4 OZ. IN A-6
- 1/2 OZ. IN R-4
LESS THAN
- 4 OZ. IN A-6
- 1/2 OZ. IN R-4
ANY AMOUNT
MORE THAN
AMOUNT OF OIL
TO INSTALL
*DRAIN NEW COMPRESSOR, REFILL
WITH NEW OIL (SAME AMOUNT AS
DRAINED FROM OLD COMPRESSOR).
**DRAIN NEW COMPRESSOR.
INSTALL NEW OIL IN NEW
COMPRESSOR - 6 0Z. IN A-6
- 3 OZ. IN R-4
*SAME AS ABOVE PLUS AN
ADDITIONAL OUNCE (MORE OIL
IS RETAINED IN A DRAINED
COMPRESSOR THAN ONE THAT HAS
BEEN REBUILT).
**SAME AS ABOVE PLUS AN
ADDITIONAL OUNCE.
*SAME AS ABOVE.
**SAME AS ABOVE.
HEATER A N D A IR C O N D IT IO N IN G
1A-7
COMPRESSOR
BLOW ER
SPEEDS
A V A IL
A IR
SOURCE
A IR
EN TER S
V E H IC L E
H E A T E R A /C
DOOROPEN TO:
HEATER
D E FR O S TE R
D O O R -O P E N TO:
HEATER
O FF
O FF
LOW
O U T S ID E
FLO O R O U T L E T S
HEATER
M A X A /C
ON
HI
INSI DE%
D ASH O U T L E T S
A /C
HEATER
N O R M A /C
ON
A LL
O U T S ID E
DASH O U T L E T S
A /C
HEATER
B I-L E V E L
ON
ALL
O U T S ID E
FLO O R A N D
DASH O U T L E T S
A /C &
HEATER
HEATER
VENT
O FF
A LL
O U T S ID E
D ASH O U T L E T S
A /C
HEATER
H TR
O FF
A LL
O U T S ID E
FLO O R O U T L E T S
HEATER
HEATER
HEATER
D E FR O S T
D E FR O S T O U T L E T S
O U T S ID E
ALL
ON
D EF
NO TE % 100% Inside air is n o t available, some bleed throug h o f outside air is allow ed.
Fig. 7--S ystem O p e ra tio n - CK T ru c k
1A-8
HEATER A N D AIR C O N D IT IO N IN G
SERVICE OPERATIONS
CONDENSER - CK MODEL
Replacement
1. Disconnect the battery ground cable.
2. Disconnect
connector.
the
electrical
harness
at
the
switch
Replacement (Fig. 9)
Replacement
HEATER A N D AIR C O N D IT IO N IN G
1A-9
il
Installation
1. Insert the new expansion tube into insertion tool
J-26549 as illustrated in figure 12.
2. Coat a new expansion tube "O" ring with clean 525
viscosity refrigeration oil.
3. While slightly compressing the fingers of the tool
around the body of the expansion tube (to facilitate
entry into the inlet line) insert the expansion tube into
the core inlet line and push until the tube reaches a firm
stop. This will indicate proper seating of the "O" ring
in the inlet line.
SECTION 1B
TRUCK BODY
NOTE: Except for the items listed below, all information found in section
IB of the 1974 Light D uty Truck Service Manual is applicable to 1976
Light D uty Trucks.
IN D E X
C-K M o d els..........................................................................................
G M odels..............................................................................................
IB-1
1B-3
C-K MODELS
Fig. 1 -C o w l V e n t V a lv e s
Model 06
REAR SIDE DOOR (MODELS 06 AND 03)
Figure 3 shows the cloth check strap used for rear doors.
The door may be completely opened by removing the strap
pin from the bracket. The bracket attaches to the pillar with
three screws; the strap is fastened to the door panel with two
screws and an attaching bar. Refer to page IB-18 of the 1974
manual.
1B-2
BODY
REAR DOOR-STRIKER
AND WEDGE ADJUSTM ENTS
Figure 4 illustrates the rear door latch strikers and door
wedges. Be sure that adjustm ents are as shown to insure
proper latching of the rear doors. Refer to page IB-18, figure
48 o f the 1974 manual.
ENDGATE DISASSEMBLY
Model 0 6
Refer to page IB-20 of the 1974 Light Duty Truck Service
Manual.
T R U C K SUPP S ER VICE
BODY
1B-3
G MODELS
S E C T IO N 2
FRAME
Truck frames are essentially carryover, with some models
undergoing configuration
and alignment reference
dimension changes.
Model
CA107
13-3/8
15-1/4
16
19-7/8 12
CA109
13-3/8
15-1/4
16
19-7/8 12
CA209
13-3/8
15-1/4
17
CA210
310
13-3/4
15-1/4
16
13
10
14-7/8
13
10
14-7/8
17-3/4
17-3/4
17-3/4
17-3/4
19-7/8 12
13
10
14-7/8
17-3/4
18-1/2 10
13
10
14-1/4
17-3/4
19-7/8
16-3/4
15-5/8
17-3/4
69-5/8
19-7/8
16-3/4
15-5/8
17-3/4
69-5/8
17-3/4
19-7/8
16-3/4
15-5/8
17 3/4
17-3/4
19-7/8
15-5/8
17-3/4
76-1/2 110
16-7/8
16-7/8
14
86-1/2 120
16-7/8
16-7/8
14
69-5/8
86-1/2 120
16-7/8
16-7/8
14
69-7/8
105
131
16-7/8
16-7/8
14
155-1/2
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
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
69-5/8
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
69-5/8
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
10-7/8
13
71-7/8
67
153
16-7/8
16-7/8
14
9-1/2
13
9-1/2
14
PA314
7-5/8
9-3/8
11-5/8
14-5/8
13
10
13
10-7/8
10-7/8
13
71-7/8
91
177
16-7/8
16-7/8
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
PE
31132
(137)
PE
31432
(157)
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
31832
Fig. 1 -C -K -P T ru c k R efe re n ce D im en s io n s
T R U C K SUPP - S ER VIC E
2-2
FRAME
T R U C K SUP P - S ER VIC E
FRAME
2-3
S E C T IO N 3
FRONT SUSPENSION
GENERAL INFORMATION
Front suspension design and geometry are basically similar to 1974.
Except for the items listed on these pages, all information in Section 3
of the 1974 Light Truck Service Manual is applicable to 1976 Light
Trucks. Refer to the Specifications section of this m anual for complete
torque values, capacities, tolerances, alignment data, etc.
W ith vehicle on front end rack, jack at frame and raise the
wheel off the ground. This will allow the upper control arm
to drop down far enough to use a socket on the nuts and
permit shim removal.
G30 Models, C 20 and 30 Models w ith 7 /8 " Nut:
TR U C K SUPP - S E R V IC E
3-2
FRO NT SUSPENSION
S E C TIO N 4
M AINTENANCE ITEM
K-MODEL CV JO INT LUBRICATION
RING GEAR
SIZE
SOURCE
TYPE /C A PA C ITY
C10
C hevrolet
S a lis b u ry /3 7 5 0 #
8 - 7 /8 "
K10
C hevrolet
S a lis b u r y /3 7 5 0 #
8 - 7 /8 "
K10
C hevrolet
S a lis b u r y /4 0 0 0 #
8 - 7 /8 "
P10
C h evrolet
S a lis b u r y /3 5 0 0 #
8 - 7 /8 "
G10
C hevrolet
S a lis b u r y /3 1 0 0 #
8 - 7 /8 "
G10
C hevrolet
S a lis b u ry /3 1 0 0 #
8 - 1 /2 "
MODEL
C20
(Except
Crew
Cab)
C hevrolet
S a lis b u r y /5 7 0 0 #
1 0 -1 /2 "
C20
(Crew Cab)
C hevrolet
S a lis b u r y /7 5 0 0 #
1 0 -1 /2 "
K20
C h evrolet
S a lis b u ry /5 7 0 0 #
1 0 -1 /2
P20
C hevrolet
S a lis b u r y /5 7 0 0 #
1 0 -1 /2 "
G20
C hevrolet
S a lis b u ry /3 5 0 0 #
8 - 7 /8 "
C30
(Except
Dual
Wheel
Camper)
C hevrolet
S a lis b u r y /7 5 0 0 #
1 0 -1 /2 "
C30
(Dual
Wheel
Camper)
Dana
S a lis b u r y /7 5 0 0 #
1 0 -1 /2 "
C h evrolet
S a lis b u r y /7 9 0 0 #
1 0 -1 /2 "
C hevrolet
B a n jo /1 1 ,0 0 0 #
1 2 -1 /4 "
C hevrolet
S a lis b u ry /'5 7 0 0 #
1 0 -1 /2 "
Dana
S a lis b u r y /6 2 0 0 #
9 - 3 /4 "
Dana
S a lis b u r y /7 5 0 0 #
1 0 -1 /2 "
P30
P30
(With
H 22/H 23)
G30
_ ,n
G30
r _n
G30
(Dual
Wheel)
(Dual
Wheel)
Fig. 1--Axle C h a rt
Propshaft
CV joints
can
be
lubricated
while
"on-the-vehicle", with the use of J-25512-1 and adaptor
J-25512-2.
Access to the joint is limited and can best be accomplished
by the following procedure. Figure 2 shows how the joint
conceals the lube fitting (A) when it is in the downward
position; and how it opens (B) when the fitting is in the
upward position. Access to the lube fitting can only be
gained from above the opened joint. This require a flex-hose
that can bend between the propshaft and the underbody.
Install the rigid needle tip, J-25512-2, on the end of the
flexhose. Use the tip to depress the ball into the lube fitting,
then pump grease into the fitting as shown in figure 3.
CLOSED POSITION
OPEN POSITION
TR U C K SUPP - S E R VIC E
4-2
PROPSHAFT
Universal Joint-Repair
Two methods of retaining trunnions to universal joint yokes
may be used. Each requires a different repair procedure.
The snap ring method is described on pages 4-9 through 4-10 of
the 1974 Light Duty Truck Service Manual.
An injection-molded plastic retainer ring is used on other universal
joints. For this type joint, the following repair procedure should
be used.
Disassembly
NOTE: Never clamp propshaft tube in a vise as the
tube may be dented. Always clamp on one of the yokes,
and support the shaft horizontally. Avoid damaging
the slip yoke sealing surface. Nicks may damage the
bushing or cut the seal lip.
BUSHING REPLACEMENT-
4-3
TRUNNION
'SPACER
J-9522-5
.BEARING
CUP
Reassem bly
A universal joint service kit is used when reassembling this
joint. See figure 7. This kit includes one pregreased cross
assembly, four service bearing cup assemblies with seals,
needle rollers, washers, grease and four bearing retainers.
M ake sure that the seals are in place on the service bearing
cups to hold the needle rollers in place for handling.
ROLLER BEARINGS
BEARING RETAINER
BEARING CUP
FLAT PLASTIC
WASHER
Fig. 7 --R e p a ir K it
TRUC K S UPP - S E R V IC E
4-4
ALIGNMENT
PLACE
FRONT YOKE OF
REAR PROP SHAFT
IN VER TIC A L POSITION
1 ) PLACE
TRANSMISSION
SLEEVE YOKE
IN VE R TIC A L
POSITION
REAR PROP
SHAFT
4-5
AXLE SHAFT
to gain clearance.
6. W hen the C-lock is positioned to pass through the end
of the thrust block, push the axle shaft inward as shown
in figure 16, and remove the C-lock. Remove the axle
shaft and repeat steps 5 and 6 for the opposite axle shaft.
7. When installing C-locks keep the pinion shaft partially
withdrawn. Place the C-lock in the same position shown
in figure 15. Carefully w ithdraw the axle shaft until the
C-lock is clear of the thrust block. W hen both locks are
installed, install the pinion shaft and lock screw.
S E C TIO N 5
BRAKES
The following caution 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 Caution on page 1 of this
section".
C A U T I O N : THIS FASTENER IS A N IMPORTANT A TTACHING PART
IN THAT IT COULD AFFECT THE PERFORMANCE OF VITAL
COMPONENTS AN D SYSTEMS, AND/OR COULD RESULT IN MAJOR
REPAIR EXPENSE. IT MUST BE REPLACED WITH ONE OF THE SAME
PART NUMBER OR WITH A N 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 REASSEMBL Y TO ASSURE PROPER
RETENTION OF THIS PART
C O N T E N T S OF T H IS S E C T IO N
Brake System Identification.............................................................. 5-1
Standard B rakes................................................................................... ..5-5
Vacuum Power Brakes.........................................................................5-10
Hydro-boost B rakes............................................................................ ..5-10
FR O N T B RAKES
R EAR BR A K ES
B R A K E ASSIST
JB1
JB3
JB5
JB6
JB7
JB8
H yd ra u lic - H yd ro bo ost
JB9
D rum 15.00 x 4 .0 0
H yd ra u lic - H yd ro b o o st
5-2 BRAKES
TON RATING
C10516
1/2
C10703
106.5
117.5
C10903
3 /4
C20906
C30943
JB5
Base
JB1
JB3
JB5
4900
5300-5600
5300-6200
Base
J50
J55
JB1
JB3
JB5
129.5
6050-7000
Base
JB5
131.5
6400-7100
6400-8200
Base
J55
JB6
JB7
7100
7100-8200
Base
J55
JB6
JB7
7500-8200
Base
JB7
8200
Base
JB7
164.5
Base
J50
J55
C20963
C30903
6050-6200
4900
129.5
C20943
GVW RATING
BRAKE
SYSTEM
5300-5600
5300-6200
131.5
C10906
C20903
WHEELBASE
M ERCH ANDIZING
OPTION
131.5
6600-8200
6600-10000
Base
J55
JB7
JB8
164.5
9000-10000
Base
JB8
9000-10000
Base
JB8
C30963
C31003
135.5
6600-8200
6600-10000
Base
J55
JB7
JB8
C31403
159.5
6600-8200
6600-10000
Base
J55
JB7
JB8
TR U C K S U P P SER VIC E
BRAKES 5-3
TON RATING
K10516
1/2
BRAKE
GVW RATING
OPTION
SYSTEM
106.5
6200-6300
Base
JB5
K 10703
117.5
6200-6400
Base
JB5
K 10903
131.5
6200-6400
Base
JB5
K 10906
129.5
6200-7300
Base
JB5
131.5
6800
6800-8400
Base
J55
JB6
JB7
129.5
6800
6800-8400
Base
J55
JB6
JB7
K20903
3/4
K20906
WHEELBASE
4800
4800-5600
Base
JB1
J50
JB3
5400-5600
Base
JB3
4900
4900-5600
Base
J50
JB1
JB3
5600
Base
JB3
6400
Base
JB5
6400
Base
JB5
6400
Base
JB5
6400
Base
JB5
110
6400-7100
6400-8100
Base
J55
JB6
JB7
125
6600-7400
6600-8400
Base
J55
JB6
JB7
G31306
6600-7400
6600-8400
Base
J55
JB6
JB7
G31303
6400-8400
8900
Base
JB7
J55
JB8
8900-10000
Base
JB8
G11005
1/2
110
G11006
125
G11305
G11306
G21005
3/4
110
G21006
125
G21305
G21306
G31005
G31305
G 31603
146
TRUC K SUPP - S E R V IC E
5-4 BRAKES
MODEL
TON RATING
WHEELBASE
GVW RATING
M ERCH ANDIZING
OPTION
P10542
1/2
102
6200
Base
JB5
P20842
3/4
125
6800
Base
6800-8000
J55
JB6
JB7
133
6800
6800-8000
Base
J55
JB6
JB7
125
7600-8200
7600-10000
12000-14000
Base
J55
H22 or H23
JB7
JB8
JB9
7600-12500
Base
JB8
P21042
P30842
P30832
SYSTEM
P31042
133
7600-8200
7600-10000
12000-14000
Base
J55
H22 or H23
JB7
JB8
JB9
P31132
137
7600-12500
Base
JB8
P31432
158.5
7600-12500
14000
Base
HF7 or HF8
JB8
Base
J55
H22 or H23
JB7
JB8
JB9
Base
JB9
P31442
157
P31832
I78
7600-8200
7600-10000
12000-14000
14000
JB9
T R U C K SUP P - S ER VIC E
BRAKES 5-5
STANDARD BRAKES
The 1976 Light Duty Truck standard brake components are essentially
the same as those described in the 1974 Light D uty Truck Service Manual.
Design modifications, differing from the 1974 manual, are outlined on the
following pages.
PARKING BRAKE
Installation (Fig. 2)
1. Install the mounting clip in the brake pedal flange from
the pedal side of the flange.
2. Depress the brake pedal and push the switch into the
clip until the shoulder on the switch bottoms on the clip.
Adjustm ent
1. Pull the brake pedal back against switch with 15-20 lbs.
force to properly adjust switch.
NEW
Fig. 1--Disc B ra ke R otor
5-6
BRAKES
C -K M O D E L S
P 0 0 0 (4 2 ) MODELS
G MODELS
P 3 0 0 (3 2 ) MODELS
1^1LW W
Fig. 3--P a rk in g B ra ke A s s e m b ly -T y p ic a l
TR U C K SUP P - S ER VIC E
BRAKES 5-7
5-8
BRAKES
BRAKES 5-9
7. Lift the brake shoes and linings with the adjusting nut
and bolt and connecting spring off the flange plate.
Inspection
Replace any worn or broken parts.
Installation
1. Place the flange plate in position on the rear bearing
retainer and fasten with four bolts. Torque bolts to 24
foot pounds.
5-10
BRAKES
INTEGRAL ACCUMULATOR/BOOSTER
BLEEDING HYDRO-BOOST/POW ER
STEERING HYDRAULIC SYSTEM
The following procedure should be used to bleed the power
steering hydraulic system on hydro-boost vehicles.
NOTE: If the power steering fluid has foamed due to
low fluid level, it will be necessary to park the vehicle
for approximately one hour (reservoir cap loose) so
that the foam can dissipate.
1. Raise the front of the vehicle on a hoist so that the tires
are clear of the floor.
2. Check reservoir and fill with G M Power Steering Fluid
(or equivalent).
NOTE: Leave the reservoir cap off during entire bleed
procedure.
PRESSURE PORT
T R U C K S U P P - SER VIC E
BRAKES 5-11
starter
switch.
Reinstall
BOOSTER INSTALLATION
Refer to Figure 8 for booster installation.
M in i-M a s te r Cylinder
1976 G Series trucks (with H ydroboost) and all P Series
trucks will incorporate new Bendix mini-master cylinders
(fig. 12). Due to the new size, the G series master cylinder
is mounted straight out from the dash rather than laterally
in the vehicle as in 1975 (fig. 8). Replacement procedures
remain basically unchanged to those described in the 1974
Truck Service Manual.
On four-wheel disc brake vehicles (JF9), the brake warning
light switch (fig. 6) is an integral part of the mini-master
cylinder assembly; it is non-serviceable. A brake line
distribution block is located on the frame crossmember. It
is not a combination valve; its only function is to act as a
distributor for attaching front and rear brake lines.
Disassembly
1. Remove the reservoir cover and diaphragm, and drain
the fluid from the reservoir.
2. Remove the four bolts that secure the body to the
reservoir using Socket J-25085.
3. Remove the small "O" ring and the two compensating
valve seals from the recessed areas on the bottom side
of the reservoir.
NOTE: Do not remove the two small filters from the
inside of the reservoir unless they are damaged and are
to be replaced.
4. Depress the prim ary piston using a tool with a smooth
rounded end. Then remove the compensating valve
poppets and the compensating valve springs from the
compensating valve ports in the master cylinder body
TR U C K SUPP - S E R VIC E
5-12
BRAKES
P MODELS (EXCEPT M O TO R H O M E )
M O TO R HO M E CHASSIS MODELS
Assembly
1. Lubricate the secondary piston assembly and the master
cylinder bore with clean brake fluid.
2. Assemble the secondary spring (shorter of the two
springs) in the open end of the secondary piston
actuator, and assemble the piston return spring (longer
spring) on the projection at the rear of the secondary
piston.
3. Insert the secondary piston assembly, actuator end first,
into the master cylinder bore, and press assembly to the
bottom of the bore.
4. Lubricate the prim ary piston assembly with clean brake
fluid. Insert the prim ary piston assembly, actuator end
first, into the bore.
5. Place the snap ring over a smooth round ended tool and
depress the pistons in the bore.
Bench Bleeding
1. Plug the outlet ports and fasten the master cylinder in
a vise with the front end tilted slightly down.
2. Fill the reservoir with clean brake fluid. Use any tool
with a smooth rounded end to depress and release the
BRAKES 5 -1 3
TRUC K SUP P - S E R V IC E
5 -1 4
BRAKES
BRAKES 5-15
TR U C K SUPP - S E R VIC E
5 -1 6
BRAKES
BRAKES 5 -17
TRUC K SUP P - S E R V IC E
5 -1 8 BRAKES
N O T E: B efore checking the hydraulic p o w e r booster for the source o f trouble, refer
to the trouble diagnosis procedures fo r Standard Brakes. A fte r these possible causes have
been elim inated, ch eck fo r the probable cause and rem edy as o u tlin ed below:
Normal Operating Characteristics
N O B O O S T - H A R D PEDAL
Preliminary Check
W ith the engine stopped, depress the brake pedal several tim es to e lim inate all accum ulato r reserve
fro m the system.
Hold the brake pedal depressed w ith m edium pressure (25 to 35 lbs.), start the engine. If the u n it is
operating c o rre c tly , the brake pedal w ill fall s lig h tly and then push back against the driver's fo o t,
rem aining at abo ut the same po s itio n . If the booster is not operating c o rre c tly , the tro u b le may be one
o f the fo llo w in g causes:
P r o b a b le C a u s e
Remedy
1.
1.
2.
No f l u i d in power s te e rin g r e s e r v o i r .
2.
F i l l r e s e r v o i r and check f o r
external le aks.
3.
3.
4.
4.
5.
5.
Replace booster.
6.
6.
Replace a l l booster s e a l s .
7.
7.
Replace a l l booster s e a l s .
8.
8.
Replace a l l booster s e a l s .
9.
9.
Replace a l l booster s e a l s .
10.
11
12.
10.
Replace booster.
Contamination in power s te e r in g f l u i d .
11.
Hydraulic l i n e s routed i n c o r r e c t ly .
12.
Re-route l i n e s .
T R U C K SUP P - S E R VIC E
BRAKES 5-19
Remedy
P r o b a b le C a u s e
1.
1.
2.
2.
3.
3.
Replace s p r in g .
4.
R e s t r i c t i o n in return l i n e from
booster to pump r e s e r v o i r .
4.
Replace li n e .
5.
5.
Replace s p r in g .
6.
6.
G R A B B Y BRAKES
Remedy
P r o b a b le C aus e
1.
1.
Replace s p r in g .
2.
2.
3.
No cargo body on c h a s s i s .
3.
Normal c o n ditio n .
Remedy
P r o b a b le C a u s e
1.
1.
Tighten bel t.
2.
2.
F i l l r e s e r v o i r and check fo r
external le a k s.
3.
3.
4.
4.
5.
5.
TR U C K SUPP - S E R VIC E
5 -2 0
BRAKES
Remedy
P r o b a b le C a u s e
1.
I n s u f f i c i e n t f l u i d in pump
reservoi r .
P r o b a b le C a u s e
1.
Remedy
R e s t r ic t i o n in gear or booster
return l i n e s .
1.
Replace li n e s or re p o s i t i o n
li n e s to eliminate r e s t r i c t i o n .
A C C U M U L A T O R L E A K D O W N - S YS TEM D O ES N O T H O L D C H A R G E
Prelim inary Check
Start engine and tu rn the steering wheel u n til the wheels contact the wheel stops lig h tly . Hold f o r a
m axim um of five seconds. Then release the steering wheel and tu rn o ff the engine.
Depress and release the brake pedal. There should be a m in im u m o f three power assisted brake
app lica tions before a hard pedal is obtained.
Re-start the engine and turn the steering wheel u n til the wheels contact the wheel stops lig h tly . There
should be a lig h t hissing sound as the accum ulator is charged. Hold steering wheel lig h tly against stop fo r
a m axim um of five seconds. Then release the steering wheel, and tu rn o ff the engine.
Wait one hou r and apply brake pedal (do not re-start the engine). There should s till be a m in im u m of
three pow er assisted brake applications before obtaining a hard pedal.
If eithe r o f these pre lim in a ry checks shows th a t the accum ulato r is not holdin g its charge, the tro u b le
may be one of the fo llo w in g causes.
P r o b a b le C a u s e
R em edy
1.
1.
2.
2.
Replace booster.
3.
3.
T R U C K S U P P - SER VICE
S E C T IO N 6
ENGINE
C O N T E N T S OF T H IS S E C TIO N
6-1
6-2
6-5
ENGINE TUNE-UP
Refer to 1974 Service M anual for the following engine
tune-up procedures:
Generator Service
Battery Service
VEHICLE M AINTENANCE
D uring engine tune-up, the Complete Vehicle Maintenance
Schedule (or Section 0 of this m anual) should be checked
and all required checks and services should be performed.
TR U C K SUP P - S E R VIC E
6-2
ENG INE
ENGINE MECHANICAL
IN-LINE ENGINES
COMPONENT REPLACEMENT AND ADJUSTMENT
EXHAUST MANIFOLD ASSEMBLY
Removal
1. Remove air cleaner.
2. Remove power steering pum p a n d /o r A .I.R. pump
brackets (if so equipped).
bolts;
then,
remove
Installation
1. Clean gasket surfaces on cylinder head and mainfold.
SSt
25/30
LBS FT
0 0
7 30/35
rF
T
0
-----25/30
LBS| FT\
LBS FT
O A <>
F ig . 1 A - E x h a u s t M a n ifo ld t o C y lin d e r H e a d B o lt
T ig h t e n in g S e q u e n c e an d T o rq u e
N U T(2)
OIL PAN
Removal (Fig. 4L)
THROUGH B O L K 2 )
ENGINE M O U N T(2)
ENGINE MECHANICAL
V-8 ENGINES
GENERAL INFORMATION
All vehicles utilize a high energy ignition system. Using this
system, the conventional external ignition coil and other
related components are eliminated.
Installation
1. Clean gasket surface on block and crankcase front
cover.
2. Use a sharp knife or other suitable cutting tool, to
remove any excess oil pan gasket m aterial that may be
protruding at the oil pan to engine block junction.
3. Apply a 1/8" bead of silicone rubber sealer, part num ber
1051435 (or equivalent) to the joint formed at the oil
pan and cylinder block, as well as the entire oil pan front
lip (fig. 1R).
4. Apply a 1/8" bead of silicone rubber sealer, part num ber
1051435 (or equivalent) to the bottom of the seal and
place in position on cover.
5. Loosely install cover-to-block.
NOTE:
Insert the top four bolts loosely
(approximately 3 turns). Install two 1/4-20 x 1/2"
screws one on each side at the lower hole in the front
cover. Apply a bead of silicone sealer on the bottom
of the seal and install on cover (fig. 2R).
Fig. 1 R -A re a s to A p p ly F ro n t C o v er S e a la n t
T R U C K SUP P - S E R VIC E
DOWEL P \ N l M
(ONE AT EACH SIDE)
Fig. 3 R -A lig n in g C o v er to D o w e l Pins
Fig. 2 RIn s ta llin g F ro n t C over and S eal
DIAGNOSIS
EN G IN E FAILS TO S T A R T
a. Clean and tighten loose battery term inal connections.
Using battery hydrometer, check specific gravity, if low,
recharge battery. Check battery state of charge indicator
on Freedom type battery.
b. Check for broken or loose ignition wires an d /o r ignition
switch and repair or replace as necessary.
c. Remove m oisture from spark plug wires an d /o r
distributor cap.
d. Inspect condition of distributor cap and rotor. Replace
if damaged or cracked.
e. Check inspect and regap spark plugs. Replace as
necessary.
f. Check for weak or faulty H E I System Coil as outlined
in Section 6Y of this manual.
g. Check carburetor float level, operation of secondary
vacuum break solenoid, air valve and enrichm ent system
EN G IN E LOPES W H IL E ID L IN G
EN G IN E M IS S E S W H IL E ID L IN G
TR U C K S UPP - S ER VIC E
6-6
ENGINE
EN GIN E M IS S E S A T V A R IO U S SPEEDS
i. Check engine
necessary.
operating
temperature.
Correct
as
EN GIN E STALLS
k. Check
engine
operating
tem perature.
Correct
as
necessary.
ENGINE 6-7
EN GIN E H A S L O W P O W E R
operating
temperature.
Correct
as
o. Check
pressure
regulator
valve
(automatic
transmission) for proper operation. Repair as necessary.
EN GIN E D E T O N A T IO N
a. Check for overadvanced ignition timing an d /o r faulty
ignition system and correct as necessary.
j. Check P.C.V.
necessary.
system
operation
and
correct
as
T R U C K S UPP - S E R VIC E
E X T E R N A L OIL LEAKAGE
drain
hole
for
E X C E S S IV E OIL C O N S U M P T IO N DUE TO O IL E N TE R IN G
C O M B U S T IO N C H A M B E R T H R O U G H H E A D A R E A
NO OIL PRESSURE W H IL E ID L IN G
NO OIL PRESSURE W H IL E A C C E L E R A T IN G
B U R N E D , S T IC K IN G OR BROKEN V A L V E S
N O IS Y V A LV E S
TR U C K S U P P - S E R VIC E
6 -1 0
ENGINE
N O IS Y P IS T O N S A N D R IN G S
repair as necessary.
d. Check for connecting rods alignment. Correct as
necessary.
e. Inspect for excessive clearance between rings and
grooves. Repair or replace as necessary.
f. Check for broken piston rings. Replace as necessary.
BROKEN P IS T O N S A N D /O R R IN G S
N O IS Y C O N N E C T IN G R O D S
N O IS Y M A IN B E A R IN G S
N O IS Y V A L V E LIFTERS
S E C T IO N 6K
ENGINE COOLING
GENERAL
W ith the exception of the following additions and changes, refer to Section
6K, Engine Cooling, and Section 13, Radiator and Grille, of the 1974
Light D uty T ruck Service M anual for maintenance and checking the
engine cooling system.
Adapter,
20. If handle has moved more than a 1/4 inch check again
for leaks, repressurize per step 9, remove Pressure
Tester, J-24460 per Step 11 and insert hose in a glass
of water so end is below liquid level and watch for
bubbles. Presence of bubbles indicates a leaking radiator
cap. Replace cap, if necessary.
T R U C K SUP P - S E R VIC E
6K -2
ENG INE
RADIATOR REPLACEMENT
Removal
1. Remove radiator cap when engine is cool by:
Slowly rotate cap counter clockwise to detent do not
press down while rotating.
Wait until any residual pressure (indicated by a
hissing sound) is relieved.
After hissing ceases, press down on cap while
continuing to rotate counterclockwise.
CAUTION: To a void the danger o f being burned, do
not remove radiator cap while engine and radiator are
hot because scalding fluid and steam will be blown out
under pressure.
2. Open drain cock and drain radiator.
3. Disconnect upper and lower radiator hoses and
transmission oil cooler lines or heater hose, if equipped.
4. Disconnect coolant recovery system hose.
5. If shroud installed, remove shroud to radiator screws
and lift shroud out of lower clips and carefully hang
Fig. 1 -R a d ia to r M o u n tin g - P 2 0 ( 4 2 )
FINGER
GUARD
L - 6 E N G IN E
V - 8 E N G IN E
Fig. 4 - R a d ia to r S h ro u d - G S eries
Installation
1. Inspect mounting pads and mounting panel or retainers
and replace as required.
2. W ith fan shroud positioned over fan, lower radiator into
lower mountings and install radiator upper m ounting
panel. On G Series with L6 engine, install finger guard.
3. Install fan shroud, if so equipped.
4. Connect upper and lower radiator hoses. Connect
coolant recovery system hose. Inspect hose clamps and
all hoses. Replace hoses whenever swollen, checked or
otherwise deteriorated.
5. Connect transmission oil cooler lines and heater hose,
if so equipped.
6. Remove coolant recovery tank and empty of fluid. Clean
inside of tank thoroughly with detergent and water,
scrubbing sides clean, and then flush with clean water
and drain.
7. Reinstall tank.
8. (C-K Models) Insert coolant recovery hose in tank as
far as the first white stripe (Fig. 5).
6K -4 ENG INE
S E C T IO N 6 M
ENGINE FUEL
C O N T E N T S OF T H IS S E C TIO N
1MV C arb u reto r.................................................................................. ..6M-1
2GC C a rb u re to r.................................................................................. ..6M-18
M 4M C /M 4M E C arburetor................................................................. 6M-31
4MV Quadrajet C arb u reto r................................................................ 6M-54
Accelerator C o n tro l............................................................................ .. 6M-65
Air C leaner........................................................................................... .. 6M-65
Fuel P u m p ............................................................................................ .. 6M-72
Special T o o ls........................................................................................... 6M-75
1 M V MONOJET CARBURETOR
IN D E X
General D escription......................................................... 6M-1
Theory of Operation........................................................ 6M-2
Float System ................................................................... 6M-2
Idle System ......................................................................6M-3
Main Metering System..................................................6M-4
Power Enrichm ent System...........................................6M-5
Accelerating Pum p System...........................................6M-5
Choke System ................................................................. 6M-6
M aintenance and A djustm ents...................................... 6M-7
Idle Speed........................................................................ 6M-7
Low Idle and Curb Idle
Speed A djustm ent...................................................... 6M-7
Idle M ixture.................................................................... 6M-8
Idle M ixture A djustm ent...........................................6M-8
GENERAL DESCRIPTION
The Monojet carburetor is a single bore downdraft
carburetor (fig. 1) using a triple venturi in conjunction with
a plain tube nozzle.
The main venturi is 1-5/16" in diameter and the throttle
bore is 1-11/16".
6 M -2
PRIMARY CHOKE
VAC U U M BREAK
DIAPHRAGM
CHOKE ROD
To get the best idle and keep emissions within standards set
by law, always follow adjustm ent procedures and
specifications, see Idle M ixture A djustm ent .
An Exhaust Gas Recirculation system (E.G.R.) is used on
all applications to control oxides of nitrogen.
Fig. 1 -1 M V M o n o je t C a rb u re to r
THEORY OF OPERATION
FLOAT SYSTEM (Fig. 2)
The float system controls the am ount and level of the fuel
in the carburetor float bowl. H igher than specified fuel levels
can cause flooding, hard, hot starting, rich fuel mixtures
causing poor economy, nozzle drip at idle and stalling.
Therefore, it is im portant that the float be set to
recommended specifications.
The float system on the Monojet carburetor is located
adjacent to the main venturi. It is designed so that angular
maneuvers such as steep hills and sharp turns will not affect
proper operation by keeping an adequate supply of fuel in
the bowl at all times. The float system consists of the
following: a fuel inlet filter and pressure relief spring, a solid
single pontoon float made of special lightweight plastic, a
conventional needle and seat and a float hinge pin. The float
hinge pin fits in dual slots cast in the float bowl and is held
in place by compression of the air horn gasket against the
upper loop of the hinge pin.
The float operates as follows: fuel from the engine fuel pump
is forced through the paper fuel inlet filter, located behind
the fuel inlet nut, passes from the filter chamber up through
the float needle seat and spills into the float bowl; as the float
bowl fills with fuel, it lifts the float pontoon upward until
the correct fuel level is reached in the float bowl. A t this
point, the float arm forces the float needle against the float
needle seat, shutting off fuel flow. As fuel is used from the
float bowl, the float drops downward, allowing the float
needle to move off its seat and more fuel to enter the float
bowl. This cycle continues throughout engine operation,
constantly m aintaining a positive fuel level in the float bowl.
The fuel inlet filter has a retention spring located at the rear
of the filter. It seats between the rear of the filter and the
inlet casting. Should the filter become clogged from
improper servicing or excess dirt in the system, the retention
spring will keep the filter on its seat. This will stop complete
stoppage of fuel flow to the carburetor until the filter can
be replaced.
The carburetor float chamber is internally vented through
a hole located in the air horn above the float chamber. The
purpose of the internal vent is to balance air pressure on the
fuel in the float bowl with carburetor inlet air. W ith this
feature, a balanced air/fuel mixture ratio can be maintained
during part throttle and power operation because the air
pressure acting on the fuel in the float bowl will be balanced
with the air flowing through the carburetor bore.
TUBE TO
E.G.R * VALVE
IN T E R N A L V E N T
PRESSURE
R E L IE F V A L V E
IDLE CHANNEL
RESTRICTION
V E N T H O LE
IDLE TUBE
I
FLOAT
H IN G E PIN
FLO AT
FLO AT
NEEDLE
'
.M A IN METERING JET
HOT IDLE
COMPENSATOR
TIMED VA C U U M
PORTS FOR E.G.R.
NEEDLE
SEAT
F IL T E R
R E L IE F
S PR IN G
FU E L
IN L E T
F IL T E R
THROTTLE VALVE
IDLE M IX TU R E NEEDLE
IDLE DISCHARG E HOLE
OFF IDLE
OPER ATION
Fig. 3 - ld le S ystem
Fig. 2 - F lo a t S ystem
of the idle channel through the idle air bleed hole. The
air/fuel mixture passes over through the cross channel and
then downward through the calibrated idle channel
restriction where it is further metered. The mixture
continues down the idle passage past the lower idle air bleed
hole and off-idle discharge port just above the throttle valve,
where it is again mixed with air. The air/fuel mixture then
moves downward past the idle mixture needle and out
through the idle discharge hole into the carburetor bore.
Here it mixes with the air passing around the slightly open
throttle valve and then continues through the intake
manifold into the engine cylinders as a combustible mixture.
OFF-IDLE OPERATION
As the throttle valve is opened from curb idle to increase
engine speed, additional fuel is needed to combine with the
extra air entering the engine. This is accomplished by the
slotted off-idle port. As the throttle valve is opened, it passes
the off-idle port, gradually exposing it to high vacuum below
the throttle valve. The additional fuel from the off-idle port
mixes with the increased air flow past the opening throttle
valve to meet increased engine air and fuel demands.
F urther opening of the throttle valve causes increased air
flow through the carburetor bore, which causes sufficient
pressure drop in the multiple venturi to start fuel delivery
from the main discharge nozzle. The off-idle port fuel
discharge does not cease at this transfer point but rather
diminishes as fuel flow from the main discharge nozzle
increases. In this way, the systems are so designed that they
combine to produce a smooth fuel flow at all engine speeds.
The lower idle air bleed is used strictly as an air bleed during
idle operation. It supplies additional air to the idle circuit
for improved atom ization and fuel control at low engine
speeds.
The same air bleed is used as an additional fuel feed at higher
engine speeds to supplement main discharge nozzle delivery
during operation of the main metering system.
6 M -4
The timed spark port has one tube which supplies vacuum
during the off-idle and part throttle operation of the
carburetor. The tube leads to the purge valve on the vapor
canister to provide a means of pulling fuel vapors from the
canister during periods of higher air flow through the
carburetor bore. A limited am ount of canister purge is also
provided by a separate tube which leads from the canister
to the PCV valve hose connection.
An exhaust gas recirculation (E.C.R.) system is used on all
models to control oxides of nitrogen emissions. The E.G.R.
valve is operated by a vacuum signal taken from the
carburetor throttle body.
A vacuum supply tube installed in the carburetor air horn
connects by a passage through the float bowl to the timed
vertical port in the throttle body bore. This provides a
vacuum signal to the E.G.R. valve in the off-idle and part
throttle operation of the carburetor. The purpose of the
E.G .R. system is to supply a metered am ount of exhaust
gases to the combustion mixtures and lower combustion
temperatures, thereby reducing oxides of nitrogen during
these ranges of engine operation.
T R U C K S U P P - S ER VIC E
M A IN
DISC H A R G E
NOZZLE
POWER P IS TO N
D R IV E ROD
BOOST V E N T U R I,
M A IN V E N T U R U
M A IN M E TE R IN G
POW ER PISTO N
A C T U A T IN G L IN K A G E
POWER PISTO N V A C U U M
LOWER IDLE A IR BLEED
F ig . 5 - P o w e r E n ric h m e n t S y s te m
PUMP LEVER
PUMP PLUNGER
'& D U R A TIO N
SPRING
PUMP DISCHARGE
SPRING & BALL
PUMP RETUR N
SPRING
Fig. 6 - A c c e l e r a t i n g P um p S ys te m
6 M -6
Fig. 7 - C h o k e S y s te m
TR U C K S U P P - SER VIC E
ENGINE FUEL 6 M -7
warm, the fast idle tang on the throttle lever will be off the
steps of the fast idle cam. A t this point, the idle stop solenoid
controls normal engine idle speed.
An unloader mechanism is provided should the engine
become flooded during the starting period. The unloader
partially opens the closed choke valve to allow increased air
flow through the carburetor to lean out the overly rich
mixtures. This is accomplished by depressing the accelerator
pedal to the floor so that wide open throttle is obtained.
When this is done, a tag on the throttle lever contacts an
arm on the fast idle cam and forces the choke valve partially
open. The extra air leans out the fuel mixture enough so that
the engine will start.
air
6 M -8
IDLE MIXTURE
The idle mixture is factory preset and idle m ixture screw is
capped with a plastic limiter cap. The cap permits screw to
be turned about one turn leaner (clockwise) without
breaking cap. The idle mixture is set to achieve the
smoothest idle while m aintaining emission levels within
standards prescribed by Federal Law.
A t major carburetor overhaul the idle m ixture may be
adjusted. Before suspecting idle m ixture as cause of poor idle
quality, check ignition system, distributor, timing, air
cleaner, PCV system, evaporation emission control and
compression pressures. Also check all vacuum hoses and
connections for leaks and check torques of carburetor
attachm ent bolts. Adjustm ent is made using a tachometer.
E NG INE FUEL 6 M -9
seated.
4. Push up on choke coil lever rod in end of slot.
(Fig. 14)
1. Place cam follower on highest step of fast idle cam.
2. Plug purge bleed hole with masking tape over vacuum
break end cover.
3. Using an outside vacuum source, apply vacuum to
prim ary vacuum break diaphragm until plunger is fully
B O T T O M OF ROD SH O U LD BE
EVEN W IT H TOP OF LEVER
< ^ - ( T ) c h o k e V A LVE
'
C O M PLETELY
CLOSED
2 ) PULL UP
O N R O D TO
E N D OF TR A VEL'
R O D S H O U L D BE
A G A IN S T STOP
IN H O U S IN G
NOTE: TO A D J U S T ,
R E M O V E R E T A IN IN G
C L IP A N D UPPER END
OF C H O K E C O IL ROD
R E C O N N E C T AFTER
ADJUSTM ENT.
IN S T A L L R E T A IN IN G
CLIP.
F ig . 1 2 -C h o k e C o il R od A d ju s tm e n t - Lt. D u ty E m is s io n s
6 M -1 0
SERVICE OPERATIONS
CARBURETOR REPLACEMENT (Fig. 16)
Removal
Flooding, stumble on acceleration and other performance
complaints are, in many instances, caused by presence of
dirt, water, 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
fuel bowl may then be examined for contam ination as
carburetor is disassembled. Check filter.
1. Remove air cleaner and gasket.
2. Disconnect fuel and vacuum lines from carburetor.
Installation
It is good shop practice to fill carburetor bowl before
installing carburetor. This reduces strain on starting m otor
and battery and reduces the possibility of backfiring while
attem pting 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 pum p jets before installing
carburetor.
CLIP
SPR IN G
FILTER
IN S U L A T O R
CH OK E
GASKET
T O R Q U E SEQUENCE
T IG H T E N
N U TS TO 36 IN. LBS. . . .T H E N
TO 18 FT. LBS.
H E A T STO VE
F ig . 1 6 - C a r b u r e to r , C h o k e a n d H e a t S to v e
F ig . 1 7 -F u e l F ilte r - M o n o je t
replaced.
Removal
1. Remove carburetor air cleaner.
2. Disconnect electrical connector at solenoid.
3. Unscrew and remove idle stop solenoid.
Installation
FUEL FILTER REPLACEMENT (Fig. 17)
TR U C K SUP P - S E R VIC E
6 M -1 2
F ig . 1 8 - A ir H o rn T ig h te n in g S e q u e n c e
TRUC K S U P P - S ER VIC E
E NG IN E FUEL 6 M -1 3
D IAG NO SIS
G EN E R A L
8. Spark plugs
1. Fuel Supply
9. Secure intake m anifold.
2. Fuel pum p pressure and volume.
10. Engine tem perature.
3. Plugged fuel filter or fuel lines.
Use the follow ing tables to diagnose carburetor
4. Linkage and emission control systems.
P r o b le m :
e n g in e id l e s r o u g h a n d s t a l l s
Re-set
Id le speed s e ttin g .
lo w
and
c u rb
idle
speeds u n d e r m a in te n a n ce and
a d ju stm en ts.
M a n ifo ld
va c u u m
hoses d is c o n n e c te d
or
im p r o p e rly
in
s ta lle d .
C h e ck
a ll
va c u u m
c a rb u re to r base fo r
hoses
le ad ing
in to
th e
m a n ifo ld
leaks o r be in g d is c o n n e c te d .
or
In s ta ll
o r re place as necessary.
C a rb u re to r loose o n in ta k e m a n ifo ld .
T o rq u e
c a rb u re to r
to
m a n ifo ld
b o lts
(1 0 -1 4
ft.
lbs.).
I f en g in e R P M changes,
N o rm a lly th e h o t id le c o m p e n s a to r s h o u ld be closed w h e n
e n gine is ru n n in g c o ld and o p e n w h e n en g in e is h o t (a p p ro x .
1 4 0 F a t c o m p .) re p la ce if d e fe c tiv e .
C a rb u re to r flo o d in g .
N O T E : A ls o check c a rb u re to r flo o d in g w h e n engine cranks
(tu rn ove r) b u t w ill n o t s ta rt o r s ta rts hard w hen co ld .
I f a needle
I f th e
I f w etness appears on
system
and
is fo u n d in th e c a r b u re to r, clean th e
c a rb u re to r.
R epla ce
fu e l
filte r
as
necessary.
6 M -1 4
ENG IN E FUEL
P ro b le m :
ENGINE CRANKS (TURNS OVER) BUT WILL NOT START OR STARTS HARD WHEN COLD.
C O R R E C TIVE A C TIO N
POSSIBLE CAUSE
Im p ro p e r s ta rtin g p ro c e d u re used.
N o fu e l in gas ta n k
A d ju s t th e ch o ke c o il ro d.
d ir t
and
g u m , clean
w ith
D o n o t o il c h o k e lin ka g e .
a u to m a tic
I f caused
c h o k e cleaner.
a d ju s tm e n ts .
N o fu e l in c a rb u re to r.
1. R em o ve fu e l lin e at c a rb u re to r.
lin e and ru n
C o n n e c t hose to fu e l
in to m e ta l c o n ta in e r.
R e m o ve th e high
C ra n k over e n gine i f th e re is no fu e l
I f n o ne, re place fu e l p u m p .
C heck p u m p fo r
To
check
C heck p ro p e r c a rb u re to r u n lo a d in g p ro ce d u re . Depress th e
fo r flo o d in g ,
w ith
th e engine o f f , and
Fuel
w ill
w ill
be
be v e ry
d rip p in g
o ff
lo o k
no zzle
a n d /o r th e
c a rb u re to r
a c ce le ra to r to
te rm in e
i f th e ch o ke valve is op e n in g .
If n o t, a d ju s t th e
w e t.
C a rb u re to r flo o d in g
NOTE:
B e fo re re m o v in g th e c a rb u re to r a ir h o rn , use th e
1. R em o ve th e fu e l lin e a t th e c a rb u re to r an d plug . C ra n k
and ru n th e e n g in e u n til th e fu e l b o w l ru ns d ry .
o f f th e e n gine and c o n n e c t fu e l lin e .
ru n engine.
T u rn
T h e n re -s ta rt and
f ilt e r
as necessary.
m ove th e c a rb u re to r u n it.
I f excessive d ir t is fo u n d , re
D isassem ble and clean.
I f a needle
I f th e needle is
(Check
w ith
know n
assem bly.
5. A d ju s t flo a t as spe cifie d in c a rb u re to r o ve rhau l sectio n.
T R U C K SUP P -
ENG IN E FUEL 6 M -1 5
Problem:
o r u n it is d e fe c tiv e .
2. I f a d ju ste d O .K ., che ck th e v a c u u m bre a k fo r p ro p e r
o p e ra tio n as fo llo w s :
O n th e e x te rn a lly m o u n te d va c u u m b reak u n it , c o n n e c t
a p iece o f hose to th e n ip p le o n th e v a c u u m b re a k u n it
and
a p p ly
s u c tio n
a p p ly va cu u m .
v a cu u m .
N OTE:
by
m o u th
or
use to o l
1-23418 to
<
P lu n g e r s h o u ld m o ve in w a rd and h o ld
If n o t, re p la ce th e u n it.
A lw a y s c h e ck th e fa st id le cam a d ju s tm e n t b e fo re
A d ju s t c h o k e c o il ro d .
R eplace if
necessary.
2. R e-a djust if p a rt re p la c e m e n t is necessary.
Id le speed s e ttin g
engine c o m p a rtm e n t.
N o t en ough fu e l in c a rb u re to r.
R epla ce if
d ir t y .
3. R em ove a ir h o rn and che ck flo a t a d ju s tm e n ts as spe cifie d
in c a rb u re to r o ve rh a u l sectio n.
1. C heck f lo a t ne edle and seat f o r p ro p e r seal.
C a rb u re to r flo o d in g .
I f a needle
(tu rn
a p p lie d
to
th e
needle
seat w ith
ne edle in s ta lle d .
If
(check
w ith
know n
good
flo a t),
replace th e flo a t
assem bly.
3. Check flo a t a d ju s tm e n ts as sp e cifie d in c a rb u re to r o v e r
haul se ctio n .
4. If excessive d ir t is fo u n d in th e c a rb u re to r, clean the fu e l
system and c a rb u re to r. R eplace fu e l f ilt e r as necessary.
i
TRUC K SUP P - SI
6 E N G IN E FUEL
P r o b le m :
e n g in e r u n s u n e v e n o r s u r g e s
POSSIBLE CAUSE
C O R R E C T IV E A C T IO N
F u el R e s tric tio n
D ir t o r w a te r in fu e l system .
Fuel level
A d ju s t
R em o ve and clean c a rb u re to r.
in
c a rb u re to r
o ve rh a u l
section.
Replace as necessary.
m a n ifo ld
s h o u ld
be
e v e n ly
tig h te n e d
to
sp e cifie d
to rq u e .
Pro b lem :
po o r f u e l e c o n o m y
C heck en g in e c o m p re s s io n .
E n g in e needs c o m p le te tu n e -u p .
E x a m in e spa rk p lug s, ( if d ir t y
C lean o r
C heck fo r re s tric te d
C h o k e valve n o t f u l l y o p e n in g .
2. Check ch o ke co il ro d fo r p ro p e r a d ju s tm e n t. Reset to
sp e cifica tio n s.
F u e l leaks.
C heck fu e l ta n k , fu e l
lines and fu e l p u m p fo r a n y fu e l
leakage.
Pow er system in c a rb u re to r n o t fu n c tio n in g p ro p e rly . P ow er
I f d e fe c tiv e , replace
be in g
p u lle d
fr o m
a c c e le ra to r
system
in to v e n tu ri
th ro u g h p u m p je t.
R u n en gine a t R P M w h e re n o z z le is fe e d in g fu e l.
p u m p je t.
O bserve
I f fu e l is fe e d in g fr o m je t, ch e c k p u m p discha rge
b a ll f o r p ro p e r seating b y fillin g
c a v ity ab o ve b a ll w ith
C lean c a rb u re to r o r o v e rh a u l as necessary.
P r o b le m :
e n g in e h e s it a t e s o n a c c e l e r a t io n
1. R e m o ve a ir
D e fe c tiv e a c c e le ra to r p u m p system
NOTE:
fo llo w s .
h o rn and ch e ck
2. C heck
th e
pum p
disch a rg e
lo c a tio n .
b r is k ly o p e n in g t h r o t t le valve.
n e x t to th e p u m p w e ll.
e m it fr o m
pum p
je t an d
A f u ll stre am o f fu e l s h o u ld
s trik e
near th e c e n te r o f th e
I f cra c k e d ,
b a ll
fo r
p ro p e r seating ar
v e n tu ri area.
p u m p cu p .
b a ll if le a kin g .
ta in e r are p r o p e r ly in s ta lle d .
D ir t in p u m p passages o r p u m p je t.
F u el level.
L e a k in g a ir h o rn to f lo a t b o w l gasket.
T o rq u e a ir
h o rn
to
flo a t
bowl
using
p ro p e r tig h te n in g
p ro ce d u re .
C a rb u re to r loose o n m a n ifo ld .
, -
T o rq u e c a rb u re to r t o m a n ifo ld b o lts .
P ro b le m :
o r a t h ig h s p e e d
C a rb u re to r t h r o t t le valve n o t g o in g w id e o p e n .
(C heck
A d ju s t t h r o t t le
lin k a g e to o b ta in w id e o p e n t h r o t t le
b y p u s h in g a c c e le ra to r pedal to flo o r ) .
c a rb u re to r.
D ir ty
R eplace w it h a ne w f i l t e r e le m e n t.
o r plugged
fu e l
(1 0 -1 4 f t . lbs.).
filte r .
in
P ow er system n o t o p e ra tin g .
F lo a t level to o lo w .
F lo a t n o t d ro p p in g fa r e n o u g h in to flo a t b o w l.
haul se ctio n .
m e n t in flo a t b o w l.
M a in
P ro b le m :
e n g in e s t a r t s h a r d w h e n h o t
C h o k e valve n o t o p e n in g c o m p le te ly .
Clean
E n g in e flo o d e d - C a rb u re to r flo o d in g .
N o fu e l in c a rb u re to r.
1. C heck fu e l p u m p .
6 M -1 8
2GC CARBURETOR
General D escription......................................................... 6M-18
Theory of Operation........................................................ 6M-19
Float System ................................................................... 6M-19
Idle System ......................................................................6M-19
Main Metering System..................................................6M-20
Power Enrichment System...........................................6M-20
Pum p System.................................................................. 6M-21
M aintenance and A djustm ent....................................... 6M-22
Idle Speed A djustm ent................................................. 6M-22
Idle M ixture.................................................................... 6M-22
Idle M ixture A djustm ent...........................................6M-22
GENERAL DESCRIPTION
The Model 2GC (Figs. 19 and 20) is equipped with an
integral choke attached to the throttle body assembly. A
large drilled hole in the air horn leads from inside the air
horn bore to a vapor dome located in the air horn casting
above the fuel in the float bowl.
Vapor canister purge ports are located in the throttle body
casting. The ports connect by a channel to a tube pressed
into the throttle body casting which leads directly to the
vapor canister. This provides adequate purge during engine
operation to remove all fuel vapors from the vapor collection
canister.
The pump system has a raised cast in boss on the floor of
the float bowl, which prevents entry of dirt into the
accelerator pum p - power valve fuel inlet passage. The pump
plunger head has an expander spring beneath the pump cup
T R U C K S U P P S E R VIC E
AIR HORN
S'
ACCELERATOR
PUMP ROD
FUEL INLET
CHOKE CLOSING
ASSIST. SPRING
THROTTLE
LEVER
FAST IDLE
CAM
CHOKE
BREAK DIAPHRAGM
THERMOSTATIC
COIL
PURGE TUBE
Fig. 1 9 -2 G C C a rb u re to r - Fro n t
FULL
SPARK PORT
GAS
RECIRCULATION
VACUUM PORT
Fig. 2 0 - 2 G C C a rb u re to r - 3 / 4 V ie w
THEORY OF OPERATION
FLOAT SYSTEM (Fig. 21)
The float system controls the level of the fuel in the
carburetor bowl. Fuel level is very im portant because it must
be m aintained to give proper m etering through all operating
ranges. As fuel is used from the carburetor bowl, the plastic
float drops, moving the float needle off its seat allowing more
fuel to enter the bowl, thereby keeping the fuel level
constant.
The fuel bowl is internally vented by a large drilled hole
which leads from inside the air horn bore to a vapor dome
above the fuel in the float bowl. The internal vent provides
a balance in air pressure to m aintain constant air/fuel
m ixture ratios. Also, the large internal hole vents fuel vapors
that form during periods of hot engine operation for
improved hot idle and restart.
T R U C K SUP P - S E R VIC E
6 M -2 0
HOLE
THROTTLE
VALVE
Fig. 2 2 Id le (L o w S p e e d ) S ystem
through the main well air bleeds is mixed with fuel through
calibrated holes in the main well tube. The mixture moves
up and out of the main discharge nozzles into a mixture
(high speed) passage where more air is added. The mixture
then travels down through the m ixture passage to the small
venturi where it is delivered to the air stream and on into
the engine intake manifold.
On some models, an additional fuel circuit, called
"pull-over" enrichm ent (P.O.E.), has been provided which
supplements the main metering system of the carburetor
unit. In order to provide sufficient enrichm ent to the main
metering system at higher air flows, two additional fuel feeds
are located in the air horn just above the choke valve. They
connect directly to the fuel in the float bowl, through
channels which lead directly into a tube that extends into
the fuel just above the main metering jets. A t approximately
8 pounds of air per minute and above, the extra fuel
enrichment is added to supplement the main metering
system.
W ith the addition of the pull-over enrichm ent system, leaner
mixtures can be m aintained during the part throttle or
cruising ranges and extra fuel supplied at higher air flows
to meet engine demands.
MANIFOLD VACUUM
VACUUM
RELIEF PASSAGE
P U L L -O V E R
E N R IC H M E N T
FUEL FEED
FUEL PIC K U P
TUBE -----M A IN NOZZLE
M A IN M ETERING
JET ----------------
PART THROTTLE
A D J U S T M E N T SCREW
POWER
RESTRICTIONS
MAIN WELL
TR U C K S U P P - S E R V IC E
6 M -2 2
IDLE MIXTURE
The idle m ixture is factory preset and idle mixture screws
are capped with plastic limiter caps. The cap permits screw
to be turned about one turn leaner (clockwise) without
breaking cap. The idle m ixture is set to achieve the
smoothest idle while m aintaining emission levels within
standards prescribed by Federal Law.
A t major carburetor overhaul the idle mixture may be
adjusted. Before suspecting idle m ixture as cause of poor idle
quality, check ignition system, distributor, timing, air
cleaner, PCV system, evaporation emission control and
compression pressures. Also check all vacuum hoses and
connections for leaks and check torques of carburetor
attachm ent bolts. Adjustm ent is made using a tachometer.
TR U C K SUP P - S ER VIC E
E NG INE FUEL 6 M -2 3
referring
to
Fig. 3 0 - F a s t Id le C am A d ju s tm e n t
T R U C K SUP P S E R V IC E
6 M -2 4
ENG IN E FUEL
4. Remove therm ostatic coil and cover and hold choke coil
lever inside choke housing towards the closed choke
position.
5. Gauge between upper edge of choke valve and air horn
wall.
referring
to
G A U G E BETWEEN
UPPER EDGE OF
CHOKE VALVE A N D
AIR HORN W ALL.
SEAT
PLUNGER USING
OUTSIDE V A C U U M
SOURCE
NOTE:
PLUG PURGE
HOLE W ITH A PIECE
OF M A S KIN G TAPE
THROTTLE VA LVES
W ID E O P E N
I__
2) HOLD TO W ARDS
CLOSED CHOKE
BEND TAN
NG
TO A D J U S T
Fig. 3 1 -V a c u u m B re a k A d ju s tm e n t
Fig. 3 2 -C h o k e U n lo a d e r A d ju s tm e n t
SERVICE OPERATIONS
CARBURETOR REPLACEMENT (Fig. 33)
Removal
Flooding, stumble on acceleration and other performance
complaints are, in m any instances, caused by presence of
dirt, water, or other foreign m atter in carburetor. To aid in
diagnosis, carburetor should be carefully removed from
engine without draining fuel from bowl. Contents of fuel
bowl may then be examined for contam ination as carburetor
is disassembled. Check filter.
1. Remove air cleaner and gasket.
2. Disconnect fuel and vacuum lines from carburetor.
3. Disconnect fresh air hose and choke hose from choke
system.
4. Disconnect accelerator linkage.
5. If equipped with autom atic transmission, disconnect
detent cable.
6. Remove carburetor
carburetor.
attaching
bolts
and
remove
7. Remove insulator.
Installation
It is good shop practice to fill carburetor bowl before
installing carburetor. This reduces strain on starting m otor
and battery and reduces the possibility of backfiring while
attem pting 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 pum p jets before installing
carburetor.
1. Clean throttle body and
surfaces.
TRUC K S U P P - S E R VIC E
E NG INE FUEL 6 M -2 5
Fig. 3 4 - F u e l F ilte r R e p la c e m e n t
TRUC K S U P P - S E R VIC E
6 M -2 6
DIAG NO SIS
GENERAL
8. Spark plugs
1. Fuel Supply
9. Secure intake m anifold.
2. Fuel pum p pressure and volume.
10. Engine tem perature.
3. Plugged fuel filter or fuel lines.
Use the follow ing tables to diagnose carburetor,
4. Linkage and emission control systems.
P r o b l em :
e n g in e id l e s r o u g h a n d s t a l l s
Re-set
Id le speed s e ttin g .
lo w
and
c u rb
id le speeds u n d e r m a in te n a n ce and
a d ju stm e n ts.
M a n ifo ld
vacuum
hoses d is c o n n e c te d
or
im p r o p e rly
in
sta lle d .
C heck
a ll
va cu u m
c a r b u re to r base fo r
hoses
lead ing
in to
th e
m a n ifo ld
leaks o r be in g d is c o n n e c te d .
or
In s ta ll
o r re place as necessary.
C a rb u re to r loose o n in ta k e m a n ifo ld .
T o rq u e
c a rb u re to r
to
m a n ifo ld
b o lts
(1 0 -1 4
ft.
lbs.).
I f en g in e R P M changes,
N o rm a lly th e h o t id le c o m p e n s a to r s h o u ld be closed w h e n
en gine is ru n n in g c o ld and o p e n w h e n e n g in e is h o t (a p p ro x .
1 4 0 ^ a t c o m p .) re place if d e fe c tiv e .
C a rb u re to r flo o d in g .
N O T E : A ls o che ck c a rb u re to r flo o d in g w h e n engine cranks
(tu rn over) b u t w ill n o t s ta rt o r sta rts hard w hen co ld .
I f a needle
I f th e
and
c a rb u re to r.
R e p la ce
fu e l
f ilt e r
as
necessary.
E NG INE FUEL 6 M -2 7
P ro b le m :
ENGINE CRANKS (TURNS OVER) BUT WILL NOT START OR STARTS HARD WHEN COLD.
C O R R E C TIV E AC TIO N
POSSIBLE CAUSE
Im p ro p e r s ta rtin g p ro c e d u re used.
N o fu e l in gas ta n k
A d ju s t th e ch o ke c o il ro d .
R ealig n th e c h o k e valve o r lin k a g e as necessary.
by
d ir t and
g u m , clean
w ith
D o n o t o il c h o k e lin ka g e .
a u to m a tic
I f caused
c h o k e cleaner.
a d ju s tm e n ts .
1. Insp ect ch o ke and va cu u m break fo r w o rn o r m issing
th e rm o s ta tic
c o il
fo r
p ro p e r o p e ra tio n .
N o fu e l in c a rb u re to r.
lin e and ru n
in to
C o n n e c t hose to fu e l
m e ta l c o n ta in e r.
R e m o ve th e high
te n s io n c o il w ire fr o m c e n te r to w e r o n d is tr ib u to r cap
and g ro u n d .
C ra n k ove r en gine if th e re is no fu e l
I f n o n e , re p la ce fu e l p u m p .
C h e ck p u m p fo r
E ngine F lo o d e d .
NOTE: To
check
engine
and
o ff
fo r
lo o k
flo o d in g ,
in to
rem ove
a ir cleaner, w ith
c a rb u re to r bore.
Fuel w ill
be
a cce le ra to r to
te rm in e
if th e c h o k e valve is op e n in g . If n o t, a d ju s t th e
C a rb u re to r flo o d in g
NOTE:
B e fo re re m o v in g th e c a rb u re to r a ir h o rn , use th e
T u rn
T h e n re -sta rt and
f ilt e r
as necessary.
m o ve th e c a rb u re to r u n it.
I f excessive d ir t is fo u n d , re
D isassem ble and clean.
I f a needle
I f th e needle is
(C heck w ith
know n
assem bly.
5. A d ju s t flo a t as spe cifie d in c a rb u re to r o ve rh a u l sectio n.
-28
P ro b le m :
e n g in e s t a r t s a n d s t a l l s
o r u n it is d e fe c tiv e .
2. If a d ju ste d O .K ., che ck th e v a c u u m break fo r p ro p e r
o p e ra tio n as fo llo w s :
O n th e e x te rn a lly m o u n te d va cu u m b reak u n it, c o n n e c t
a piece o f hose to th e n ip p le o n th e va cu u m break u n it
and a p p ly
s u c tio n
a p p ly va cu u m .
va cu u m .
NOTE:
by
m o u th
or
use to o l J -2 3 4 1 8 to
P lu n g e r s h o u ld m o ve in w a rd and h o ld
I f n o t, re place th e u n it.
A lw a y s ch e c k th e fa st id le cam a d ju s tm e n t b e fo re
A d ju s t c h o k e c o il ro d .
R eplace if
necessary.
2. R e-a djust if p a rt re p la c e m e n t is necessary.
Id le speed s e ttin g
N o t en o u g h fu e l in c a rb u re to r.
R epla ce if
d ir t y .
3. R em ove a ir h o rn and check flo a t a d ju s tm e n ts as spe cifie d
in c a rb u re to r ove rh a u l se ctio n .
C a rb u re to r flo o d in g .
If a needle
(tu rn
a p p lie d
to
th e
needle in s ta lle d .
If
(check w ith
know n
good
flo a t) ,
replace th e flo a t
assem bly.
3. Check flo a t a d ju s tm e n ts as sp e cifie d in c a rb u re to r o v e r
haul se ctio n .
4. If excessive d ir t is fo u n d in th e c a rb u re to r, clean th e fu e l
system and c a rb u re to r. R eplace fue l f ilt e r as necessary.
TR U C K S U P P - SER VIC E
ENG IN E FUEL 6 M -2 9
P ro b le m :
en g in e r u n s u n e v e n o r s u rg e s
C O R R E C T IV E A C T IO N
POSSIBLE CAUSE
F uel R e s tric tio n
D ir t o r w a te r in fu e l system .
Fuel level
A d ju s t
flo a t as sp e cifie d
R em o ve and clean c a rb u re to r.
in
c a rb u re to r ove rh a u l
sectio n.
Replace as necessary.
m a n ifo ld
s h o u ld
be
e v e n ly
tig h te n e d
to
s p e cifie d
to rq u e .
P ro b lem :
p o o r f u e l econo m y
C heck en gine c o m p re s s io n .
E n g in e needs c o m p le te tu n e -u p .
E x a m in e spark plug s, ( if d ir t y
C lean o r
C heck f o r re s tric te d
C h o k e valve n o t f u l l y o p e n in g .
F u e l leaks.
lines and fu e l p u m p fo r a n y fu e l
leakage.
P ow er system in c a rb u re to r n o t fu n c tio n in g p ro p e rly . P ow er
Free u p o r re p la ce as necessary.
If d e fe c tiv e , re place
be in g
p u lle d
fr o m
a c c e le ra to r system
in to v e n tu ri
th r o u g h p u m p je t.
R u n e n gine a t R P M w h e re n o z z le is fe e d in g fu e l.
p u m p je t.
O bserve
I f fu e l is fe e d in g fr o m je t, ch e ck p u m p discharge
R e-stake o r re p la ce le a k in g check
C lean c a rb u re to r o r o v e rh a u l as necessary.
T R U C K S UPP - S ER VIC E
6 M -3 0
P ro b le m :
e n g in e h e s it a t e s o n a c c e l e r a t i o n
1. R em o ve a ir
D e fe c tiv e a c c e le ra to r p u m p system
NOTE:
fo llo w s .
p u m p je t
an d
A f u ll stream o f fu e l s h o u ld
s trik e near th e c e n te r o f th e
h o rn and che ck
2. C heck
th e
lo c a tio n .
I f c ra c k e d ,
pum p
d ischa rge
b a ll
fo r
p ro p e r sea ting a r
n e x t to th e p u m p w e ll.
T o ch e ck f o r p ro p e r seating,
v e n tu ri area.
p u m p cu p .
b a ll if le a kin g .
ta in e r are p r o p e r ly in s ta lle d .
D ir t in p u m p passages o r p u m p je t.
F u el level.
L e a k in g a ir h o rn to flo a t b o w l gasket.
T o rq u e a ir
h o rn
to
flo a t
bowl
using
p ro p e r tig h te n in g
p ro c e d u re .
C a rb u re to r loose o n m a n ifo ld .
, -
T o rq u e c a rb u re to r to m a n ifo ld b o lts .
P ro b le m :
C a rb u re to r t h r o t t le valve n o t g o in g w id e o p e n .
(C heck
A d ju s t t h r o t t le
lin ka g e to o b ta in w id e o p e n t h r o t t le
b y pu s h in g a c c e le ra to r pedal to flo o r ) .
c a rb u re to r.
D ir ty
or
plugged
fue l
(1 0 -1 4 f t . lbs.).
filte r .
in
P ow er system n o t o p e ra tin g .
F lo a t level to o lo w .
F lo a t n o t d ro p p in g fa r e n o u g h in to flo a t b o w l.
haul sectio n.
m e n t in f lo a t b o w l.
M a in m e te rin g je t d ir t y , plugged o r in c o rre c t p a rt.
P ro b le m :
e n g in e s t a r t s h a r d w hen h o t
C h o k e valve n o t o p e n in g c o m p le te ly .
C lean
N o fu e l in c a rb u re to r.
1. C heck fu e l p u m p .
TRUC K S U P P - S E R VIC E
ENG IN E FUEL 6 M -3 1
M 4 M C /M 4 M E QUADRAJET CARBURETOR
INDEX
G eneral D escription..........................................................6M-31
Theory of O peration........................................................ 6M-32
Float System ....................................................................6M-32
Idle System ......................................................................6M-33
Exhaust Gas Recirculation...........................................6M-33
Canister Purge................................................................. 6M-34
M ain Metering System..................................................6M-34
Power System ................................................................. 6M-34
A ir Valve D ash p o t........................................................ 6M-36
Accelerating Pump System...........................................6M-37
Choke System ................................................................. 6M-37
Maintenance and A djustm ent....................................... 6M-40
Idle Speed A djustm ent..................................................6M-40
Idle M ixture.....................................................................6M-40
Idle M ixture A djustm ent............................................. 6M-40
Pum p Rod A djustm ent.................................................6M-41
Fast Idle A djustm ent....................................................6M-41
Choke Coil Lever A djustm ent.................................... 6M-41
GENERAL DESCRIPTION
The M 4M C-M 4M E model Quadrajet carburetors (fig. 36
and 36A) are two stage carburetors of downdraft design. The
triple venturi system (with 1-7/32" venturi) is used on the
prim ary side of the Quadrajet carburetor, with small 1-3/8"
throttle valve bores. The triple venturi stack-up, plus small
prim ary throttle valve bores, results in good fuel control
during idle and part throttle operation.
The secondary side has two large bores (2-1/4"). Using the
air valve principle in the secondary side, fuel is metered in
direct proportion to the air passing through the secondary
bores. The carburetor part number is stamped on a vertical
section of the float bowl, near the secondary throttle lever.
Refer to the part number on the bowl when servicing the
carburetor. W hen replacing the float bowl assembly, follow
the m anufacturers instructions contained in the service
TRUC K S U P P - S E R V IC E
6 M -3 2
ENG IN E FUEL
Fig. 3 6 - M 4 M C Q u a d r a je t C a rb u re to r
Fig. 3 6 A - M 4 M E Q u a d r a je t C a rb u re to r
THEORY OF OPERATION
FLOAT SYSTEM (Fig. 37)
The float system operates in the following manner:
Fuel from the engine fuel pum p enters the carburetor fuel
inlet passage. It passes through the pleated paper filter
element, fuel inlet valve, and on into the float bowl chamber.
As the incoming fuel fills the float bowl to the prescribed
level, the float pontoon rises and forces the fuel inlet valve
closed, shutting off fuel flow. As fuel is used from the float
bowl, the float drops allowing the float valve to open, when
more fuel again fills the bowl. This cycle continues,
maintaining a constant fuel level in the float bowl. A new
float assembly is used for improved fuel handling in the float
bowl.
The float pontoon is solid and is made of a light weight
closed cell plastic material. This feature gives added
buoyancy to allow the use of a single float to maintain
constant fuel levels. A float pull clip, fastened to the float
valve, hooks over the edge of the float arm at the center rear.
Its purpose is to assist in lifting the float valve off its seat
whenever fuel level in the float bowl is low.
CAUTION: Do not place pull clip through small
holes in top o f float arm. Severe flooding will result.
On some models, no side windows are used in the float valve
seat so that all fuel will be discharged over the top of the
float valve seat to control fuel turbulence in the float bowl.
T R U C K S U P P - S ER VIC E
E NG IN E FUEL 6 M -3 3
engine cylinders.
IDLE SYSTEM
Each bore of the Quadrajet carburetor has a separate and
independent idle system to supply the correct air/fuel
mixture ratios during idle and off-idle operation. The idle
system is used during this period because air flow through
the carburetor venturi is not great enough to obtain efficient
metering from the main discharge nozzles.
TR U C K S U P P - SER VIC E
6 M -3 4
main well through the main discharge nozzles into the boost
venturi. A t the boost venturi, the fuel m ixture then combines
with the air entering the engine through the carburetor
bores. It then passes as a combustible mixture through the
intake manifold and on into the engine cylinders.
The main metering system is calibrated by tapered and
stepped metering rods operating in metering jets and also
through the main well air bleeds.
D uring cruising speeds and light engine loads, manifold
vacuum is high. In this period, the engine will run on leaner
mixtures than required during heavy loads.
The primary main metering rods are connected to a vacuum
responsive piston which operates against spring tension.
Engine manifold vacuum is supplied to a power piston
through a vacuum channel. W hen the vacuum is high, the
piston is held downward against spring tension and the
larger diameter of the metering rod is in the main metering
jet orifice. This results in leaner fuel mixtures for economy
operation. As engine load increases and engine manifold
vacuum drops, spring pressure acting on the power piston
overcomes the vacuum pull and gradually lifts the metering
rods partially out of the main metering jets. This enrichens
the fuel mixture enough to give the desired power to
overcome the added load.
E NG INE FUEL 6 M -3 5
M A IN WELL AIR
BLEEDS
BOOST VENTURI
FACTORY-METERING
ADJUSTMENT SCREW
NOTE:
SIDE FUEL ENTRY
M A IN VENTURI
THROTTLE VALVE
M A IN POWER PISTON
(D O W N )
POWER PISTON
SPRING
VACUUM
PASSAGE
JJ^IN
METERING
JETS (2)
M A IN
METERING
RODS (2 )
F ig . 3 9 - M a in M e te rin g S y s te m
TR U C K SUP P S E R V IC E
6 M -3 6
SECONDARY
M E T E R IN G R O D S ( 2 )
BOOST
VENTURI
ACCELERATO R
W ELL & TU B E
F A C T O R Y -M E T E R IN G
ADJUSTM ENT SCREW
A IR
VALVE
M E T E R IN G
R O D LEVER
NOTE:
SIDE FUEL ENTRY
!
<Ls
hz .
' V M A IN I \ M A IN
W f;
**~ F U E L
I d is c h a r g e !
| i | WELL I
N O ZZLE^H
Jr t
M A IN P O W E R
P IS T O N (U P )
P O W E R P IS T O N
S P R IN G
VACUUM
PASSAGE
M E T E R IN G
D IS C
M E T E R IN G
JETS ( 2 )
M A IN
M E T E R IN G
RODS (2 )
Fig. 4 0 -P o w e r S ystem
T R U C K SUP P - S E R VIC E
E NG INE FUEL 6 M -3 7
and down on the pum p plunger head - see inset). W hen the
pump plunger is moved upward, the flat on the top of the
cup unseats from the flat on the plunger head and allows
free movement of fuel through the inside of the cup into the
bottom of the pump well. This also vents any vapors which
may be in the bottom of the pump well so that a solid charge
of fuel can be maintained in the fuel well beneath the plunger
head.
When the throttle valves are opened, the connecting linkage
forces the pum p plunger downward. The pump cup seats
instantly and fuel is forced through the pump discharge
passage where it unseats the pump discharge check ball and
passes on through the passage to the pump jets, located in
the air horn, where the fuel sprays into the venturi of each
bore.
restriction in the vacuum inlet nipple in the diaphragm
cover. This gives the dashpot action required to delay air
valve opening enough for efficient fuel flow from the
secondary discharge nozzles.
PUM P
LEVER
EXPANDER SPRING
TR U C K S UPP - S ER VIC E
6 M -3 8
CHOKE
ROD
CHOKE
VALVE
VACUUM BREAK
ADJUSTING SCREW
VACUUM
BREAK
DIAPHRAGM
THERMOSTA
COIL
INSIDE
CUP
BAFFLE
SECONDARY
LOCKOUT
LEVER
FAST
IDLE
CAM
FOLLOWER
FAST
IDLE
ADJUSTING
SCREW
UNLOADER
TANG
CHOKE SYSTEM
(HOT AIR TYPE)
Fig. 4 3 -C h o k e System - M 4 M C
TR U C K S U P P - SER VIC E
C A M PULL-OFF FEATURE
PULL-OFF
TANG
FRO NTVACUUM
BREAK A D JU S TIN G
SCREW
VACUUM
BREAK
LEVER
CHOKE
VALVE
PLUNGER
C A M PULL-OFF
TANG
CHOKE
ROD
LINK TO REAR
V A C U U M UNIT
FRO NTVACUUM
BREAK
D IA P H R A G M
FAST
IDLE
CAM
REAR
VACUUM
D IA P H R A G M
ELECTRIC
CHOKE
ASSEM BLY
(SEE INSET 2)
THERM O STATIC
COIL
PLUNGER
BUCKING
SPRING
SECONDARY
LOCKOUT
LEVER
INSET 2
UNLOADER TANG
FAST IDLE C A M
FOLLOWER
FAST IDLE
A D JU S TIN G
SCREW
CHOKE SYSTEM
(ELECTRIC CHOKE TYPE)
Fig. 4 3 A ~ C h o k e S ystem - M 4 M E
the therm ostatic coil, and a large outer section for additional
rapid heating of the therm ostatic coil.
The ceramic resistor functions as follows:
AIR TEMPERATURE BELOW 50F
Electric current, applied to the small section of the
ceramic resistor causes the section to heat up and
w arm the thermostatic coil which allows gradual
opening of the choke valve for good cold engine
warm-up performance. As the small section of the
ceramic resistor continues to produce heat, a
temperature sensitive bi-metal disk causes a spring
loaded contact to close also applying electric current to
the large section of the ceramic resistor causing the
large section to heat up. Heat from the larger section
of the ceramic resistor increases the rate of heat flow
to the thermostatic coil for more rapid opening of the
choke valve.
AIR TEMPERATURE 70F AND ABOVE
Electric current is applied directly to both the small
section, and through the spring contact, to the large
TR U C K SUP P - S E R V IC E
THERM OSTATIC
COIL
POST & GROUND
COVER
RIVET (2)
RING
TERM INALS
As the therm ostatic coil warms up, the choke coil lever in
the housing moves the choke rod up in the slot in the upper
choke lever to open the choke valve further to the near wide
open position, while still keeping the cam follower lever on
the low step of the fast idle cam. In this way, the fast idle
speed is maintained long enough to keep the engine from
stalling, yet allows use of a choke coil which lets the choke
valve open quickly. As the therm ostatic coil warms up to
the fully hot position, the choke coil lever allows the fast idle
cam to drop down so that the cam follower is completely
off the steps of the fast idle cam.
1
INSULATOR
TERM INAL PLATE
(ELECTR ICA L CONNECTION)
CER AM IC RESISTO R
F ig . 4 3 B - -E le c tric C h o k e A s s e m b ly
Idle M ix tu re A d ju s tm e n t
1. W ith engine at norm al operating temperature, air
cleaner on, choke open, and air conditioning O FF,
connect a tachom eter to engine.
2. Set parking brake and block drive wheels.
3. Disconnect vacuum advance hose at distributor and
plug hose.
4. Start engine, check timing and adjust as required.
Connect vacuum advance hose.
IDLE MIXTURE
The idle mixture is factory preset and idle m ixture screws
are capped with plastic lim iter caps. The cap permits screw
to be turned about one turn leaner (clockwise) without
breaking cap. The idle m ixture is set to achieve the
smoothest idle while maintaining emission levels within
standards prescribed by Federal Law.
LEVER
SUPPORT
SCREWDRIVER WHILE
BENDING LEVER
TANG AWAY TO
CLOSE PRIMARY VALVE
THEN RE ADJUST
F ig . 4 4 - P u m p R od A d ju s tm e n t
On Bench
1. Place cam follower on high step of the fast idle cam and
hold the follower against the cam.
2. While holding the follower against the high step of the
fast
idle
cam,
back
out
fast
idle
screw
(counterclockwise) until it pulls away from the fast idle
cam follower. T urn in fast idle screw (clockwise) until
the screw just contacts the fast idle cam follower.
3. Then turn the fast idle screw in an additional 3 turns
to adjust.
4. Recheck fast idle speed on the vehicle, setting to
specifications listed on the underhood Vehicle Emission
Control Inform ation label.
On Vehicle
1. Connect a tachom eter to the engine.
coil
referring
to
6 M -4 2
coil
referring
to
(Fig. 49)
(M 4M E)
coil
referring
to
Hot A ir (Fig. 5 1)
6 M -4 4
Procedure
In order to have good engine performance during warm up
and be able to pass Federal exhaust emission standards, the
electric choke must function properly.
If coil is cooled off suficiently the choke valve will close when
throttle is opened slightly. A ttach a jum per wire between the
positive battery term inal and choke coil terminal. Choke coil
should warm up and the choke blade can be observed
opening, indicating a good and properly grounded choke coil
assembly. A t room tem perature the choke blade should be
Opening Clearance
4. Hold choke valve wide open by pushing down on tail
of fast idle cam.
5. Hold secondary throttle valves slightly open.
2. Hold choke valve wide open with cam follower lever off
as shown to adjust.
TR U C K SUPP - S E R VIC E
6 M -4 6
SERVICE OPERATIONS
1. Clean throttle body and intake manifold sealing
surfaces.
6. Remove carburetor
carburetor.
attaching
bolts
and
remove
7. Remove insulator.
Installation
It is good shop practice to fill carburetor bowl with a small
am ount of unleaded fuel before installing carburetor. This
reduces strain of starting m otor and battery and reduce the
possibility of backfiring while attem pting to start engine.
The carburetor float and intake needle and seat can also be
checked. Operate throttle lever several times and check
discharge from pump jets before installing carburetor.
F ig . 5 9 ~ C a r b u r e to r a n d C h o k e P ip e s - V 8 , 4 B b l.
F ig . 6 0 - A i r H o rn T ig h te n in g S e q u e n c e
T R U C K SUP P - S E R V IC E
6 M -4 8
E NG IN E FUEL
DIAGNOSIS
GENERAL
5. Engine compression.
8. Spark plugs
1. Fuel Supply
9. Secure intake manifold.
2. Fuel pum p pressure and volume.
10. Engine tem perature.
3. Plugged fuel filter or fuel lines.
Use the following tables to diagnose carburetor.
4. Linkage and emission control systems.
P ro b le m :
engine id le s r o u g h a n d s t a l l s
Id le speed settin g.
M a n ifo ld
vacuum
hoses disconnected o r
im p ro p e rly
in
Check
all
vacuum
hoses
leading
in to
th e
m a n ifo ld
stalled.
C a rb u re to r loose o n in ta k e m a n ifo ld .
or
Install
o r replace as necessary.
If wetness appears on
If excessive d ir t is fo u n d in c a rb u re to r o r id le channels,
clean fue l system and carbure tor.
necessary.
Poor secondary th r o ttle valve alignm ent.
ENG IN E FUEL 6 M -4 9
Problem :
ENGINE CRANKS (TURNS OVER) BUT WILL NOT START OR STARTS HARD WHEN COLD.
CORRECTIVE ACTION
POSSIBLE CAUSE
Im p ro p e r s ta rtin g pro ce d u re used.
N o fu e l in gas tank
manual.
I f caused
a u to m a tic ch o ke cleaner.
a d ju stm e n ts.
1. R em ove fue l line at ca rb u re to r.
N o fu e l in ca rb u re to r.
C o n n e ct hose to fue l
R em ove th e high
If none, replace fu e l pu m p.
C heck p u m p fo r
E ngine F lo o d e d .
N O TE :
w ith
To
check
Fuel w ill
be d rip p in g
lo o k in to the ca rb u re to r bore.
o ff nozzle a n d /o r the c a rb u re to r
c a rb u re to r
accelerator
de term in e
to
if
the
the
unlo adin g
flo o r
choke
and
procedure.
check
the
valve is opening.
Depress
the
ca rb u re to r
to
If
n o t, adjust
unloader, as specified.
NOTE:
T u rn
If a needle
I f th e needle is
(Check w ith
assembly.
5. A d ju s t flo a t as specified in ca rb u re to r overhaul section.
T R U C K S UPP S ER VIC E
-52
P O SSIBLE CAUSE
C a rb u re to r th r o ttle valve n o t going w id e open.
(Check
carburetor.
D irty
F lo a t level to o low .
F lo a t n o t d ro p p in g fa r enough in to flo a t b o w l.
overhal section.
m ent in flo a t b o w l.
Problem :
engine s t a r t s h a r d when h o t
Clean
N o fu e l in c a rb u re to r.
1. Check fue l pu m p.
TR U C K S U P P -
P r o b le m :
poor f u e l e c o n o m y
POSSIBLE CAUSE
C O R R E C T IV E A C T IO N
Check engine com pression.
Clean o r
Check fo r re stricte d
2. Check
Fuel leaks.
leakage.
Main m etering rod n o t adjusted to spe cifica tion.
M etering
rod
in carburetor overhaul
section.
Free
section.
up
or
replace
as necessary
If de fe ctive , replace
fro m
accelerator system in to v e n tu ri
th ro u g h p u m p jet.
Observe
6 M -5 4
ENG IN E FUEL
4 M V QUADRAJET CARBURETOR
INDEX
General D escription......................................................... 6M-54
Theory of Operation........................................................6M-55
Float System ...................................................................6M-55
Idle System ..................................................................... 6M-55
Main Metering System................................................. 6M-56
Power System .................................................................6M-57
Accelerating Pump System.......................................... 6M-58
Choke System ................................................................. 6M-59
Maintenance and A dju stm en t....................................... 6M-60
Idle Speed A djustm ent................................................. 6M-60
Idle Mixture A djustm ent.............................................6M-60
Fast Idle A djustm ent....................................................6M-60
Choke Rod (Fast Idle Cam) A d justm ent................6M-60
Pump Rod A djustm ent................................................ 6M-61
GENERAL DESCRIPTION
The non-California and California 350/400 V8, and
non-California 454 V8 vehicles of 6,000 pound gross vehicle
weight (G.V.W .) and above use the 4MV qudrajet
carburetor.
The 4MV model Quadrajet carburetor (Figure IQ) is a two
stage carburetor of downdraft design. The primary (fuel
inlet) side uses the triple venturi system (with 1-7/32"
venturi) with small 1-3/8" throttle valve bores. The triple
venturi stack-up, plus the smaller prim ary bores, give
excellent fuel control in the idle and economy stages of
operation. Fuel metering in the prim ary side is accomplished
with metering rods, operating in metering jets, positioned by
ENG IN E FUEL 6 M -5 5
CHOKE VALVE
AIR VALVE
VACUUM BREAK
PART NUMBER
DARY
THROTTLE LEVER
PRIMARY THROTTLE
LEVER
F ig . 1 Q ~ M o d e l 4 M V Q u a d r a je t C a r b u r e to r
THEORY OF OPERATION
FLOAT SYSTEM (FIG. 2Q)
The float system consists of a float bowl, pontoon assembly
made of a closed cellular plastic m aterial, float hinge pin,
a float needle valve and seat, and a float valve pull clip.
Fuel from the engine fuel pump enters the carburetor fuel
inlet passage and passes through the filter and needle seat.
As fuel fills the float bowl to the prescribed fuel level, the
float pontoon rises and forces the fuel inlet valve closed,
shutting off all fuel flow. As fuel is used from the float bowl,
the float drops and allows more fuel to enter the float bowl
until the correct fuel level is reached. This cycle continues,
constantly maintaining a positive fuel level in the float bowl.
A float needle pull clip, fastened to the float valve, hooks
over the center of the float arm. Its purpose is to assist in
lifting the float valve off its seat whenever fuel level is low.
A plastic filler block is located in the top of the float bowl
in the area just above the fuel inlet. This block prevents fuel
slosh on severe brake applications or turning maneuvers.
This maintains a constant fuel level during these maneuvers,
to prevent stalling.
The carburetor float bowl is internally vented. The internal
vent tubes are located in the prim ary bore section of the
carburetor air horn just above the float chamber. The
purpose of the internal vent is to balance incoming air
pressure beneath the air cleaner with air pressure acting on
fuel in the float bowl, thereby maintaing a balanced air/fuel
mixture ratio during part throttle and power operation. The
internal vent tubes allow the escape of fuel vapors in the float
cham ber during hot engine operation. This prevents fuel
vaporization from causing excessive pressure buildup in the
float bowl, which could result in excessive fuel spillage into
the manifold.
F ig . 2 Q ~ F lo a t S y s te m
T R U C K S UPP - S E R VIC E
6 M -5 6
ENG IN E FUEL
Canister Purge
On California vehicles, the fuel tank is not vented to
atmosphere and all fuel vapors are collected in a vapor
collection canister from the fuel tank vent. In order to
remove the fuel vapors collected in the vapor canister, it is
necessary to provide a means of purging the canister and
burning the vapors in the engine.
IDLE
BLEED
M A IN
METERING
IDLE LIMITER
.
CAP
t
CANISTER
PURGE TUBE
IDLE
DISCHARGE
HOLE
F ig . 3 Q ~ ld le S y s te m
extend down into the well. A fter passing up the idle tube,
the fuel is mixed with air at the top of each tube through
an idle air bleed. The fuel mixture then crosses over to the
idle down channels where it passes through a calibrated idle
channel restriction.
It then passes down the idle channel past the lower idle air
bleed holes and off idle discharge ports, just above the
throttle valves, where it is mixed with more air. The air/fuel
m ixture then moves down to the idle needle discharge holes
where it enters the carburetor bores and mixes with air
passing the slightly open throttle valves.
The venturi system is very sensitive to air flow and on
applications where large am ounts of idle air are needed to
maintain higher idle speeds, the fixed idle air by-pass system
is used. This consists of air channels which lead from the
top of each carburetor bore in the air horn to a point below
each prim ary throttle valve. A t norm al idle, extra air passes
through these channels supplementing the air passing by the
slightly opened throttle valves. The purpose of the idle air
by-pass system is to allow reduction in the am ount of air
going past the throttle valves so that they can be nearly
closed at idle. This reduces the am ount of air flowing
through the carburetor venturi to prevent the main fuel
nozzles from feeding during idle operation.
Off-Idle Operation
As the prim ary throttle valves are opened from curb idle to
increase engine speed, additional fuel is needed to combine
with the extra air entering the engine. This is accomplished
by the slotted off-idle discharge ports. As the primary
throttle valves open, they pass by the idle ports, gradually
exposing them to high engine vacuum below the throttle
valves. The additional fuel added from the off-idle ports
mixes with the increasing air flow past the opening throttle
valves to meet increased engine air and fuel demands.
F urther opening of the throttle valves increases the air
velocity through the carburetor venturi sufficiently to cause
low pressure at the lower idle air bleeds. As a result, fuel
begins to discharge from the lower idle air bleed holes
(located at the bottom of the large venturi skirt) and
ENG IN E FUEL 6 M -5 7
POWER PISTON
| ECCENTRIC
CAM
POWER PISTON
SPRING
PART THROTTLE
ADJUSTMENT SCREW
MAIN METERING'
JET
F ig . 4 Q ~ M a in M e te r in g S y s te m
F ig . 5 Q --P o w e r S y s te m
Fuel flows from the float bowl through the main metering
jets into the main fuel well and is bled with air from the vent
at the top of the main well and side bleeds. The fuel in the
main well is mixed with air from the main well air bleeds
and then passes through the main discharge nozzle into the
boost venturi. A t the boost venturi the fuel mixture then
combines with the air entering the engine through the
carburetor bores and passes through the intake manifold and
on into the engine cylinder as a combustible mixture.
6 M -5 8
TR U C K S U P P - S ER VIC E
6 M -6 0
F ig . 9 Q ~ F a s t Id le A d ju s tm e n t
GA U G E FROM TOP OF CH O KE
V A LV E W ALL, NEXT TO VENT
S T A C K , TO TOP OF PUMP STEM
A S S P E C IF IE D
ROD IN
OF PUM
)S U P P O R T LEVER Wl
S C R E W D R IV E R W HILE
BENDING LEVER
( 7 ) t H R 0 T T L E V A LV E S
^ C O M P LET E LY CLO SE D
F ig . 1 1 Q ~ P u m p R od A d ju s tm e n t
Fig. 1 2 Q ~ A ir V a lv e D a s h p o t A d ju s tm e n t
T RUC K S U P P S ER VIC E
6 M -6 2
CHOKE VALVE
COMPLETELY
Opening Clearance
4. Hold choke valve wide open by pushing down on tail
of fast idle cam.
5. Hold secondary throttle valves slightly open.
TR U C K S U P P - SER VIC E
CHOKE VALVE
W ID E OPEN CA M FOLLOWER
TR U C K S UPP - S E R V IC E
6 M -6 4
SERVICE OPERATION
checked. Operate throttle lever several times and check
discharge from pump jets before installing carburetor.
attaching
bolts
and
remove
7. Remove insulator.
Installation
CHOKE (BOSS ON
CHOKE INTO INBOARD
HOLE)
F ig . 1 9 Q - M o d e l 4 M V Q u a d r a je t C a r b u r e to r C h o k e
F ig . 2 0 Q - - A ir H o rn T ig h te n in g S e q u e n c e
E N b lN E FUEL 6 M -6 5
DIAGNOSIS
Refer to M 4M C /M 4M E Quadrajet section of this manual for diagnosis
of the 4MV Quadrajet.
ACCELERATOR CONTROL
of cable.
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
OUTER
INNER SPRING
SPRING
ACCELERATOR PEDAL
Refer to figures 5C through 8C for removal and installation
of accelerator pedal.
CABLE
SUPPOR
FASTENER
STUD
RETAINER
LEVER
F ig . 1 C - A c c e le r a to r C o n tr o ls L 6 - L ig h t D u ty E m is s io n s
C A U T IO N :
FI e x ib le c o m p o n e n ts (hoses
w ire s , c o n d u its , e tc .) m u s t n o t be ro u te d
w it h in 2 in ch e s o f m o v in g p a rts o f
a c c e le ra to r lin k a g e fo r w a r d o f S u p p o rt,
unless r o u tin g is p o s itiv e ly c o n tr o lle d .
E N G IN E S U P P O R T
STUD
CARBURETOR
FASTENER
S P R IN G O U T E R
NO TE:
W ith
In n e r S p rin g in s id e O u te r S p rin g ,
a n c h o r b o th S p rin g s th r u h o le in C a rb u re to r
L e ver an d h o le s in S u p p o r t a n d B ra c k e t.
Fig. 3 C -A c c e le r a to r C o n tro ls V 8 -2 B b l
T R U C K SUP P - S E R V IC E
6 M -6 6
N O T E : Slip a c c e le ra to r co ntrol
c a b le thru slot in rod. Install
re ta in e r, b e in g sure it is s e a te d .
'CABLE RETAINER
C A U T IO N : C a r e must b e used
in pressing the re ta in e r into
ho le in ro d to assure c a b le is
not kin ked or d a m a g e d in an y
w a y . ^ - " ^ R E IN F O R C E M E N T
A C C ELER A TO R
C O N T R O L CABLE
PEDAL
T IG H T E N T O
4 2 IN . LBS.
F ig . 7 C - A c c e le r a to r P e d a l-P 4 2
TR U C K S U P P - SER VIC E
F ig . 8 C - A c c e le r a to r P e d a l-P 3 2
AIR CLEANER
GENERAL
V IE W B - U N D E R H O O D TEMPERATURE
BELOW 8 5 F
V IE W A E N G IN E OFF
DIAPHRAGM SPRING
VACUUM CHAMBER
SNORKEL TUBE
TEMP. SENSING
SPRING
SNORKEL TUBE
DIAPHRAGM
"""TTV _
V IE W D - U N D E R H O O D TEMPERATURE
BETWEEN 8 5 F A N D 1 2 8 F
V IE W C -U N D E R H O O D TEMPERATURE
ABOVE 128F
AIR BLEED VALVE OPEN
SNORKEL TUBE
DIAPHRAGM SPRING
DIAPHRAGM SPRING
VACUUM CHAMBER
VACUUM CHAMBER r
TEMP. SENSING
SPRING
SNORKEL TUBE
N.
AIR INLET
LINKAGE
DIAPHRAGM
AIR INLET
r
HOT AIR PIPE
Fig. 9 C - A ir C le a n e r O p e ra tio n
T RUC K S U P P - S E R VIC E
6 M -6 8
Paper Element
Polywrap Element
AIR CLEANER
Refer to figures 12C and 13C for air cleaner used with in
line L6 engine.
Refer to figure 14C for air cleaner used on CK truck with
350/400 V8 engine.
2. Remove element.
Refer to figure 16C for air cleaner used with 454 V8 engine.
Inspection
Visual
W IN G NUT
TO RQ UE A T 2 0 LBS. IN
must w ra p
CLEANER ELE
( BAND S H O W N )
o v e r b o th e nd seals o f p a p e r e le m e n t as
sh ow n .
NOTE |
AIR C LE A
ELE M E N T______
( PAPER FILTER
PO R TIO N )
P o ly u re th a n e Band must
c o m p le te ly c o v e r th e o u te r scre e n
P O LY W R A P
AIR CLEANER El
su rfa ce o f p a p e r e le m e n t as sh ow n .
Fig . 1 0 C - P o ly w r a p A ir C le a n e r E le m e n t
F ig . 1 1 C - C le a n in g P o ly w r a p B a n d
GASKET (P O S ITIO N
COLORED SURFACE
DOW N)
G A S K E T (P O S IT IO N
R ED S U R F A C E
DOW N)
EXTENSION
SUPPORT
TUBE
E X T E N S IO N
GASKET (P O S ITIO N
COLORED SURFACE
DOW N)
G A S K E T (P O S IT IO N
RED S U R F A C E
D OW N)
, PLATE
/ v \
'
R O U TE HOSE O U T B O A R D
OF F U E L L IN E
Fig. 1 2 C -A ir C le a n e r - L6 - In te rg ra te d H ead
Operational
1. Remove air cleaner cover and install tem perature gauge
(Tool J-22973) as close as possible to sensor (fig. 18C).
Reinstall cover w ithout wing nut. (Tem perature must
be below 85F before proceeding.)
2. W ith the engine "Off", observe dam per door position
through snorkel opening. Snorkel passage should be
open. (fig. 68 view A) If not, check for binds in linkage.
3. Start and idle engine. W ith air tem perature below 85F,
snorkel passage should be closed, (fig. 9C view B) When
dam per door begins to open snorkel passage, remove air
cleaner cover and observe therm om eter reading. It
should be between 85F and 115F.
4. If dam per door does not close completely or does not
open at correct tem perature continue with the following
vacuum m otor check:
a. Turn off engine. Disconnect diaphragm assembly
vacuum hose at sensor unit.
b. Apply at least 9 in. Hg. of vacuum to diaphragm
assembly through the hose. This can be done by
mouth. D am per door should completely close snorkel
passage when vacuum is applied. If not, check to see
if linkage is hooked up correctly. Also check for a
vacuum leak.
Replacement
1. Drill 7/64" hole in snorkel tube at center of vacuum
m otor retaining strap (fig. 19C).
2. Connect vacuum m otor linkage to dam per door. Fasten
retaining strap to air cleaner with sheet metal screw.
3. Replace air cleaner on engine and check operation of
vacuum m otor and control dam per assembly.
TRUC K SUP P - S E R V IC E
6 M -7 0
Fig. 1 4 C -A ir C le a n e r - 3 5 0 /4 0 0 V 8 -C K
W ING NUT
GASKET
(POSITION RED
SURFACE DOW N)
EXTENSION
G A S K E T ------------(POSITION RED
SURFACE DOW N)
STOVE
/
Fig. 1 5 C -A ir C le a n e r 3 5 0 / 4 0 0 V 8-G
Fig. 1 6 C -A ir C le a n e r -4 5 4 V 8
W ING N UT
W ING N U T
LOWER STO VE
N O TE : Inboard flange
o f low er stove m ust be
installed on to p o f rib
o f exhaust m anifo ld .
V IE W
G A S K E T (PO SITIO N
RED SU R F A C E
DOWN)
E XTEN SIO N
G A S K E T (POSITIO N
RED SU R FAC E DOWN)
TUBE
UPPER STO VE
LOW ER STO VE
F ig . 1 7 C - A ir C le a n e r- P 2 0 (4 2 ), P 3 0 ( 4 2 ), P 3 0 ( 3 2 )
Replacement
1. Install sensor and gasket assembly in air cleaner in
position as noted above.
VACUUM
RETAINING
STRAP
F ig . 1 8 C - D a m p e r D o o r T h e rm o m e te r R e a d in g
INSTALL REPLACEMENT
SENSOR ASSM. IN SAME
POSITION AS O RIG INAL ASSM.
F ig . 1 9 C - V a c u u m D ia p h ra g m R e p la c e m e n t
6 M -7 2
ENG IN E FUEL
AIR INTAKE
DUCT
AIR INT
DUCT
AIR INLET
V 8 ENGINE
F ig . 2 1 C - C a r b u r e to r A ir In ta k e - C K
F ig . 2 0 C - R e m o v in g S e n s o r U n it
FUEL PUMP
GENERAL
The fuel pump is a diaphragm type. The pump is actuated
by an eccentric located on engine camshaft. On in-line
engine, the eccentric actuates the rocker arm. On V-8
engines, a push rod (located between camshaft eccentric and
fuel pump) actuates the pump rocker arm. Because of design,
this pump is serviced as an assembly only.
INSPECTION
The fuel pump (figs. 22C through 25C) should be checked
to make sure mounting bolts and inlet and outlet connections
are tight.
TEST
Always test pump while it is mounted on engine and be sure
there is gasoline in tank.
The line from the tank to the pum p is the suction side of
system and the line from pum p to carburetor is the pressure
side of system. A leak on pressure side, therefore, would be
made apparent by dripping fuel, but a leak on the suction
would not be apparent except for its effect of reducing
volume of fuel on pressure side.
1. Tighten any loose line connections and look for bends
or kinks in lines.
2. Disconnect fuel pipe at carburetor. Disconnect
distributor to coil prim ary wire so that engine can be
cranked without firing. Place suitable container at end
of pipe and crank engine a few revolutions. If little or
no gasoline flows from open end of pipe, then fuel pipe
is clogged or pump is inoperative. Before removing
pump, disconnect fuel pipe at gas tank and outlet pipe
and blow through them with an air hose to make sure
they are clear. Reconnect pipes and retest while
cranking engine.
test
gauge
to
REMOVAL
NOTE: W henever disconnecting or connecting fuel
pump outlet pipe fitting, always double wrench to
avoid damaging fuel pump.
1. Disconnect fuel inlet and outlet pipes at fuel pump.
2. Remove fuel pump mounting bolts and remove pump
and gasket.
3. On V8 engines if push rod is to be removed, remove pipe
plug and push rod (454 cu. in. engines), and fuel pump
adapter and gasket and push rod (350 and 400 cu. in.
engines).
INSTALLATION
1. On V8 engines, if fuel pump push rod has been removed,
install push rod and pipe fitting or fuel pump adapter
using gasket sealer on gasket or pipe fitting.
F ig . 2 3 C --F u e l P u m p - 2 6 2 L 6
6 M -7 4
IN IT IA L INSPECTION
SPECIAL TOOLS
F ig . 1 S T - S p e c ia l T o o ls
S E C TIO N 6 T
GENERAL
LIGHT DUTY EMISSIONS
Federal
Underfloor Converter
All Vehicles except 4 5 4 V8
The flow of exhaust gases down through the catalyst, within
the converter, effectively controls the hydrocarbon and
carbon monoxide to a more desirable emission. Refer to
Section 8 for service procedures.
6T-2
California w ith 4 5 4 V8
EGR
VALVE
EGR
VALVE
EFE ACTUATOR
EFE ACTUATOR
/
v
m (PURPLE
C IO 350-V 8 2 BBL.X
STRIP)
TO AIR
CLEANER
[Q(PURPLE STRIP)
PCV
VALVE
/-E F E ^ %(
ACTUATOR
...\
DIVERTER
VALVE
SPARK CONTROL
...SWITCH ^
K 1 0 & 20 4 0 0 -V 8 W /O A .I.R .
,/
/
EGR VALVE
THROTTLE
' RETURN
CONTROL
\ VALVE
" TO AIR
f CLEANER ^
DIVERTER
VALVE
' EFE
ACTUATOR^
[0
^DIVERTER VALVE
[f
(PURPLE STRIP)
i THROTTLE LEVER A C T U A T O R >
THROTTLE LEVER A C TU A fO R
TO AIR
aEr
SPARK
ER
TO A IR "
CLEANER
DIVERTER VALVE
CK10, 20, 3 0 = ^
350/400-V 8 CAL.
P20 & 30 350-V 8 CAL
THROTTLE RETURN
CONTROL VALVE
DIVERTER VALVE
./ /
'.
THROTTLE RETURN
CONTROL VALVE
Fig. 3 -E m is s io n H ose R ou tin gs - CKP
T R U C K SUP P - SER VIC E
6T-4
EGR VALVE
EGR VALVE
(YELLOW STRIP)
TO AIR
CLEANER
EFE,.,
(PURPLE STRIP)
D] (PURPLE STRIP)
EFE ACTUATOR
ACTUATOR
TO AIR
CLEANER
SPARK
CONTROL
SWITCH
PCV
VALVE
EGR VALVE
^
DIVERTER
VALVE
E (YELLOW STRIP)
TO AIR ^
CLEANER
//E F E w
ACTUATOR
DIVERTER VALVE
THROTTLE
RETURN
CONTROL
SPARK
_
I rra CONTROL
EJ / T
SWITCH
TO AIR
CLEANER
THROTTLE RETURN
CONTROL
TO AIR
CLEANER
THROTTLE RETURN
CONTROL VALVE
PCV
VALVE
THROTTLE RETURN
CONTROL VALVE
DIVERTER
VALVE
G 20 & 30 350/4 0 0 -V 8 CAL
Fig. 4 -E m is s io n H ose R ou tin gs - G
TR U C K SUP P - SER VIC E
8T-5
SERVICE PROCEDURES
INSPECTION
Visually inspect exhaust heat valve for damage or
binding linkage.
Check that linkage is connected and vacuum hoses are
properly routed and connected.
Move exhaust heat valve by hand. If binding or stuck,
free with manifold heat valve lubricant, GM Part No.
1050422 or equivalent. If valve cannot be freed, replace
valve.
Coolant Temperature
Oil Temperature
Replacement
Replacement
TRUC K SUP P - S E R V IC E
6T-6
Replacement
1. Disconnect hose from actuator.
2. Remove 2 nuts attaching actuator-to-bracket.
3. Disconnect rod from valve and remove actuator and
rod.
4. Install actuator and rod reversing steps 1 through 3.
Tighten nuts to 25 pound inches.
Replacement
Replacement
3. Remove valve.
4. Install valve and connect rod.
6T-7
DIAGNOSIS
If there is no vacuum
TVS-to-vacuum source.
disconnect
hose
at
SERVICE PROCEDURE
CONTROL VALVE (Fig. 9)
TR U C K SUPP - S ER VIC E
6T-8
FROM CARBURETOR V A C U U M
COVER
V A C U U M S W TIC H
A D J U S T IN G SCREW
V EN T FILTER
M O U N T IN G BRACKET
TO THROTTLE LEVER
A C TU A TO R D IA P H R A G M
THROTTLE
T IG H T E N TO
LEVER
150 IN . LBS.
A C TU A TO R
T IG H T E N TO
20 FT. LBS.
C O N TR O L
VALVE
C O N TR O L VALVE
F ig . 9 - T h r o t t le R e tu rn C o n tro l V a lv e
Replacement
Disconnect vacuum hoses at control valve. Remove nut,
washer and control valve. Reverse procedure to install and
check operation of control valve.
6T-9
Replacement
S E C T IO N 6 Y
ENGINE ELECTRICAL
NOTE: Except for the following changes, all information listed in Section
6Y of the 1974 Truck Service M anual is applicable to 1976 light duty
trucks. Refer to 1974 Truck Service M anual for any service procedure not
contained herein.
Illustrations showing complete engine wiring for each truck line are shown
in figures 1 through 11.
TR U C K S U P P - S ER VIC E
6Y-2
ENGINE ELEC TR IC A L
\
S TA R TIN G M O T O R
FW D^
V IE W B
LEFT SIDE
O IL PRESS.
TEMPERATURE
S W IT C H
V IE W A
LEFT SIDE
N O T E INSTALL G E N E R A T O R LEAD P O IN T IN G
IN B O A R D S O TH A T C O N D U IT W ILL N O T
INTERFERE W IT H TH E R M A C H EAT TU B E .
V ]E W B
R IG H T SIDE
Fig. 3 - C - K -1 0 th ru 3 0 T ru c k V -8 ( L F 4 /L G 9 /L S 9 ) E n g in e W irin g
ENG INE E LE C TR IC A L
6Y-3
C A R B U R E TO R
W /S W IP E R M O T O R
D IS TR IB U TO R A S M
BAT. CABLE
GENERATOR
T O FUEL METER
N O T E PRESS B O O T O VER
TE R M IN A L W IT H SMALL E N D UP
LP H A R N
REAR LP H A R N
O IL PRESS. S W
V IE W B
HARN
V IE W A
\
TEM P. S W
TEM P. S W .
S T A R T IN G M O T O R
BAT. CABLE (1 2 A )
O IL PRESS. S W .
FW D
=*
R IG H T SIDE
O IL PRESS. EAD
V IE W A
WyJ
V IE W B
V IE W C
V IE W C
p u r p le
^
N O T E T H IS C O N N E C T IO N
M U S T BE P O S IT IO N E D AS S H O W N .
V )E W D
ft
IDLE STOP SOL
| O IL PRESSURE
/ EXC.
153
"1
B U LK H E A D C O N N
P A R K IN G BRAKE CABLE
SPE E D O CABLE
N O T E R O UTE H A R N .
R E AR W A R D OF P U M P BRACE.
BAT. CABLE
N O T E PRESS B O O T
y
V IE W A
TEM P. G A G E
O V E R T E R M IN A L W IT H
SMALL E N D D O W N .
\ X
S T A R T IN G M O T O R
V IE W A
F W D . LAMP H A R N
E N G . HARN
D A SH PANELCOOLANT
\ ^
HEATER B LO W ER
R ECO VERY
TANK
O IL SEN D E R A S M .
V IE W C
V IE W C
&
152
R IG H T SIDE
V IE W B
TR U C K S U P P - S ER VIC E
6Y-4
ENGINE E LE C TR IC A L
CARB. SOL
TO TEM P S W IT C H
W
^
COOLANT
B U LK H E A D C O N N . ^
-
TEMP. S W IT C H
\>vi i iU , ^
RECOVERY
TANK
P A R K IN G BRAKE C A B L E T ^ '
''W '
SPE E D O CABLE
BAT. CABLES
TEMP. S W IT C H
X
Wf .
EN.
S T A R T IN G M O T O R A S M .
V
V |E W B
O IL PRESSURE S W IT C H
I
V IE W A
M
rf/Z
N O T E PRESS B O O T OVER
{[ff'7
TE R M IN A L W IT H
SMALL E N D D O W N .
j y li
s e n d e r a s m .v O
ENG. HARN.
HEATER B LO W ER
FW D .
LAAAP
HARN
D A S H PANEL
V IE W A
V IE W C
R IG H T SIDE
V IE W C
V IE W B
HARN
O IL PRESS. S W
B U LK H E A D C O N N
SPE E D O CABLE
BAT. CABLE
STARTER M O T O R
HARN
P A R K IN G BRAKE CABLE
E N G . H A R N (1 2 H )
F W D . LAMP H A R N
V IE W A
V IE W A
TEM P. S W IT C H
N O T E T H IS C O N N E C T IO N
V IE W B
M U S T BE P O S IT IO N E D AS S H O W N
V IE W B
N O T E PRESS. B O O T O VER
T E R M IN A L W IT H
SMALL E N D D O W N .
V IE W C
C O O L A N T R ECO VERY T A N K
M O D U L A T O R PIPE (7 A )
E N G . HARN
HEATER BLOW ER
V IE W C
R IG H T SIDE
T R U C K S U P P S ER VIC E
ENG INE E LE C TR IC A L
6Y-5
E N G IN E H A R N E S S
CA R B . SOL
D A S H PA NEL
PCV H O S E
m / / E N G .y ^
f O J T E M P .S w l
V IE W A
HARN
:HARN
B A C K IN G LP S W
W A TE R TEM P. S W
V IE W A
SENSOR ASM
GENERATOR
B A C K IN G LAMP
V IE W C
BATTERY CABLE
PURPLE
N E U TR A L SAFETY B A C K IN G LAMP S W
V IE W B
N O T E PRESS B O O T
O V E R T E R M IN A L W IT H
SMALL E N D D O W N .
R IG H T SIDE
V IE W D
BATTERY CABLE
HARN
SENSOR ASM
TEMP. SW ITCH
B A C K IN G LAMP
SW ITC H M 2 0
V IE W A
STARTING MOTOR
S O LEN O ID
FW D
FUEL PIPE Ta
TRANS. ASM
HARN
E N G . W R G . HARN
V IE W C
V IE W A
V IE W B
NEUTRAL SAFETY
STARTING MTR
SO LE N O ID
BAT. CABLE
B A C K IN G LAMP SW ITCH
LEFT SIDE
RIGHT SIDE
TR U C K S U P P - S E R VIC E
6Y-6
ENGINE ELEC TR IC A L
GENERATOR
NEUTRAL SAFETY
& B A C K IN G LAMP
CONNECTOR
SENSOR ASM
TO J U N C T IO N
BLOCK
TO DASH PANEL
TEMP SW ITCH
LEAD
V IE W B
END D O W N .
V IE W A
V IE W A
BATTERY CABLE
TRANS. S O LEN O ID
NEUTRAL SAFETY &
BATTERY CABLE
B A C K IN G LAMP
WIRE ASM. (7A)
TO FUEL METER
VIEW B
V IE W C
V ltW C
PURPLE
RIGHT SIDE
SO LE N O ID EXC. NB2
GENERATOR BRACE
TO DASH PANEL
V IE W C
TO DASH PANEL
V IE W A
to
|DLE
STOP SOL
BATTERY CABLE
SW ITCH ASM
WM. V /
V IE W A
STARTING
M OTOR
SO LE N O ID
TRANS. SO LE N O ID
PURPLE
VIEW B
BATTERY
CABLE
SO LE N O ID EXC. NB2
FUEL PIPE ASM
.SENSOR ASM
STARTING
M OTOR
SO LE N O ID
TO FUEL METER
VIEW B
RIGHT SIDE
V IE W A
ENGINE E LE C TR IC A L
6Y-7
CHARGE
IN D IC A TO R
VEN T (2)
TERMINAL
FREEDOM BATTERY
The Freedom (M aintenance Free) Battery (fig. lb) has more
electrolyte in the cells than regular vent cap type batteries.
W ith the reduced water usage, water never needs to be
added. Actually, water can not be added. There are no vent
plugs in the cover. The battery is completely sealed except
for 2 small vent holes on the side. These vent holes allow
what small am ount of gases that are produced in the battery
to escape. The special chemical composition inside the
battery reduces the production of gas to an extremely small
am ount at norm al charging voltages.
C h a r g e I n d ic a to r - D a rk (G re e n D o t N o t V isib le)
(Fig. 2 b)
If the charge indicator is dark and the green dot is not visible,
charge battery until dot appears, but not more than 60
ampere-hours (for example, 15 amperes for four hours).
NOTE: Some chargers are constant current chargers
while others are constant voltage chargers. If a
constant voltage charger is used for charging the
battery and the green dot fails to appear after
prolonged charging, it may be necessary to tip the
battery slightly from side to side a few times for the
green dot to appear.
C h a r g e I n d ic a to r - L ig h t (Fig. 2 b )
Load Test
AMPS FOR
LOAD TEST
R85-5
Y 854
R87-5
170
130
210
6Y-8
ENGINE ELEC TR IC A L
MINIM U M VO LTA G E
60 F
9.5
50 F
9.4
40 F
9.3
30 F
9.1
20 F
8.9
10F
8.7
0 F
8.5
BRUSH
HOLDER
4 0 -O H M
RESISTOR
EGULATOR
INSULATED
HEAT SINK
IN S U L A T IN G
W ASHER
GROUNDED
HEAT SINK
Fig. 2 C -R e s is to r L o catio n
ENG INE E LE C TR IC A L
6Y-9
STARTER SYSTEM
The 1976 starter is mostly carryover from 1974. The only difference being
that the "R " terminal of the starter solenoid has been removed. This
term inal was removed because with the High Energy Ignition System
there is no longer any requirem ent for the electrical lead from the starter
solenoid to the ignition coil. Refer to Section 6Y of the 1974 Truck Service
M anual for all service procedures.
6Y-10
6Y-11
6Y-12
6Y-12
6Y-12
6Y-12
6Y-12
6Y-12
6Y-12
6Y-12
6Y-12
6Y-12
Installation................................................................ 6Y -13
Disassembly............................................................... 6Y-13
Assem bly................................................................... 6Y-13
Ignition Coil (8 C ylinder)....................................... 6Y-15
R em oval.................................................................... 6Y-15
Installation................................................................ 6Y-15
Ignition Coil (6 C ylinder)....................................... 6Y-15
R em oval..................................................................... 6Y -15
Installation................................................................ 6Y-15
Diagnosis..................................................................... 6Y-17
T R U C K SUP P - S E R VIC E
6Y-10
GENERAL DESCRIPTION
There are two types of High Energy Ignition (H EI)
distributors. The 8 cylinder distributor (fig. li) combines all
ignition components in one unit. The ignition coil is in the
distributor cap and connects directly to the rotor. The 6
cylinder distributor (fig. 2i) has an external mounted coil.
Both operate basically in the same m anner as a conventional
ignition system except the module and pick-up coil of the
H E I system replace the contact points of the conventional
system.
IGNITION CO IL
CONN ECT TACHOMETER
FROM THIS TERM INAL
TO GROUND.
BAT. TERMINAL
(CONNECTED TO
IGNITION SWITCH)
H IGH ENERGY
IGNITION DISTRIBUTE
GROUND
TERMINAL
(SOME TACHOMETERS
MUST CO NNECT FROM
THIS TERMINAL TO
ENERGIZER POSITIVE (+ ).
SOME TACHOMETERS
M AY NOT W O RK AT ALL.
CONSULT TACHOMETER
MANUFACTURER.)
CO N N ECTO R
BAT. TERMINAL
(CONNECTED TO
IGNITION SWITCH)
LATCH (4)
LEAD
\
TO
SPARK
PLUG
VACUUM
UNIT
H O U SIN G
LATCH (4)
li
CONNECT TACHOMETER
FROM THIS TERMINAL
TO GROUND.
TACH TERMINAL
(SOME TACHOMETERS
MUST CONNECT FROM
THIS TERMINAL TO
ENERGIZER POSITIVE ( + )
CONSULT TACHOMETER
MANUFACTURER.)
F ig . 2 i6 C y lin d e r HEI D is tr ib u to r
Ignition Coil
In the 8 cylinder H EI system, the igntion coil is built into
the distributor cap. In the 6 cylinder H EI system, the
ignition coil is mounted externally. The coil is somewhat
smaller physically than a conventional coil, but has more
primary and secondary windings. It is built more like a true
transformer with the windings surrounded by the laminated
iron core. A conventional coil has the iron core inside the
windings. A lthough the H EI coil operates in basically the
same way as a conventional coil, it is more effective in
generating higher secondary voltage when the primary
circuit is broken.
Electronic M odule
The electronic module is a solid state unit containing five
complete circuits which control spark triggering, switching,
current limiting, dwell control and distributor pick-up.
Dwell angle is controlled by a transistor circuit within the
module and is varied in direct relation to engine speed.
TRUC K S U P P - S E R VIC E
ENGINE E LE C TR IC A L
6Y-11
THEORY OF OPERATION
The pick-up coil is connected to transistors in the electronic
module. The electronic module is connected to the primary
windings in the coil. As the distributor shaft turns the timer
core teeth out of alignment with the teeth of the pole piece
a voltage is created in the magnetic field of the pick-up coil.
The pick-up coil sends this voltage signal to the electronic
F ig . 3 i- H ig h E n e rg y Ig n itio n B a s ic W ir in g
T R U C K S U P P - S E R VIC E
6Y-12
ENGINE ELEC TR IC A L
SERVICE OPERATIONS
CYL N O . 6
Routine M a in ten an ce
CYL N O . 5
CYL N O . 4
CYL N O . 3
CYL N O . 2
CYL N O . I
Electronic M odule
The electronic module is serviced by complete replacement
only. When replacing the module a liberal coating of special
silicone grease M UST be applied to the metal mounting
surface on which the module will be installed. If this grease
is not applied the module will not cool properly which can
cause the module to malfunction. A tube of this special
silicone grease is supplied with each replacement module.
CYL # 8
CYL
CYL
CYL # 2
CYL # 5
CYL # 7
CYL #1
CYL
CYL # 6
CYL # 4
CYL # 2
D istributor
CYL # 5
Removal
1. Disconnect wiring harness connectors at side of
distributor cap.
2. Remove distributor cap and position out of way.
3. Disconnect vacuum
advance mechanism.
advance
hose
from
vacuum
ENG INE E LE C TR IC A L
6Y-13
Installation
1. Install distributor using same procedure as for standard
distributor.
2. Install distributor hold-down clamp and snugly install
nut.
3. Move distributor housing to approximate position
relative to engine noted during removal.
4. Position distributor cap to housing with tab in base of
cap aligned with notch in housing and secure with four
latches.
5. Connect wiring harness connector to terminals on side
of distributor cap. C onnector will fit only one way.
6. Adjust ignition timing as described in Specification
Section of this manual.
F ig . 6 i- D is t r ib u t o r C e n tr ifu g a l A d v a n c e
D istribu tor
Disassembly (Figs. 6i - 8i)
1. Remove distributor as described above.
2. Remove rotor from distributor shaft by removing two
screws.
3. Remove two advance springs, weight retainer, and
advance weights.
4. Remove two screws holding module to housing and
move module to a position where connector may be
removed from B and C terminals.
5. Remove wires from "W " and "G " terminals of module.
6. Remove roll pin from drive gear.
C A U T I O N : Distributor gear should be supported in
F ig . 7 iR olI P in R e m o v a l
(with
rotor
attached)
in
TRUC K S UPP S E R V IC E
6Y-14
ENGINE ELEC TR IC A L
is not applied, the module will not cool properly, which can
cause the module to malfunction. A tube of this special
silicone grease is supplied with each replacement module.
1. Raise hood and remove air cleaner.
2. Release distributor cap
out-of-the-way place.
and
place
aside
in
an
Electronic Module
Replacement (Fig. 8i)
The electronic module is serviced by complete replacement
only. When replacing the module a liberal coating of special
silicone grease M UST be applied to the metal mounting
surface on which the module will be installed. If this grease
ENGINE E LE C TR IC A L
(with
rotor
attached)
in
6Y-15
6Y-16
ENGINE ELEC TR IC A L
COVER
SEAL
SPRING
ROTOR
VACUUM
UNIT
H O U S IN G
WASHER
GEAR
CONNECTOR
F ig . 1 0 i- E x p lo d e d V ie w o f 8 C y lin d e r HEI D is tr ib u to r
ENG INE E LE C TR IC A L
6Y-17
DIAGNOSIS
HIGH ENERGY IGNITION SYSTEM L-6 engines
PROBLEM:
engine CRANKS but
WILL NOT START
C O IL
PIC K -U P C O IL
MODULE
SEQUENCE
STEP
RESULT
AU TO TRANS.
LEVER IN PARK
TEST LIG H T
ON
M A N U A L TRANS.
TEST LIGH T
OFF
IG N ITIO N SW.
-------- Q
STARTS
REPAIR OR
REPLACE AS
NECESSARY
- " |
TEST LIG H T |
ON
NO START
NO
SPARK
_________________
PROBLEM IS
NOT IG N ITIO N
SYSTEM
CHECK
SPARK
EXTENSION
FUEL SYSTEM
P LU G S
F L O O D E D
-----------( s t o p )
STARTS
O 3
I
V IS U A L L Y INSPECT
REPAIR AS
l_
FOR MOISTURE. DUST, NECESSARY
CRACKS, BURNS, ETC.
NO START
T R U C K S U P P - SER VIC E
6Y-18
ENGINE ELEC TR IC A L
STEP
SEQUENCE
CONNECT
OO
-V _ _ .
OHMMETER READS ABOVE 1 OHM
(X 1 SCALE)
RESULT
STARTS
REPLACE
COIL
NO START
DISCONNECT
CONNECTOR
READS 0 TO 1 OHM
(X 1 SCALE)
READS 6.000 TO
30,000 OHMS
CONNECT
OHMMETER
STARTS
READS MORE THAN 30,000 REPLACE
OHMS OR LESS THAN
C 0| L
6,000 OHMS
CONNECT
OHMMETER
LESS
THAN INFINITY
NO START
STARTS
---REPLACE C0IL
NO START
READS INFINITE
(X 1000 SCALE)
REMOVE GREEN & WHITE
LEADS FROM MODULE
STARTS
o-----'
U
@
X
-------------
CONNECT
OHMMETER FROM
GRQUND TO EITHER
LEAD
y
f
LESS
THAN INFINITY REPLACE COIL
(PICK UP)
(X 1000 SCALE)
/ ------------- \
V - ------- > / _
READS INFINITE
(X 1000 SCALE)
CONNECT OHMMETER
ACROSS 2 LEADS
READS 500 TO
1500 OHMS
NO START
REPLACE COIL
(PICK-UP)
NO START
REPEAT STEPS
5 THRU 9
CHECK MODULE
WITH TESTER
REMOVE AND
REPLACE MODULE
ENGINE E LE C TR IC A L
6Y-19
STEP
RESULT
- ------------- ,
X -X
C H EC K SPARK
PLUG S & PLUG W IR ES
|r u n s s m o o th
&r~--------1
R E P A IR OR
RE PLA CE
RUNS ROUGH
CD ^ J ^ ) REM0VE
CAP ASSY.
--------------
R U N S SM O O TH
V IS U A L L Y INSPEC T
FO R M O IS T U R E , DU ST,
R E P A IR AS
NECESSARY
RU NS R O U G H
------------------------------------------------------------------------------------------------------ ----
r EAD
F 4n<:
nnn
R
S k
6,0
00 m
TO
__
3 0 ,000 OHM S
r - @
C ^>
READ S M O R E T H A N 30,0 0 0
OHMS OR LESS T H A N
REPLA CE
C 0 (L
R U N S SM O O TH
-0 ,
SN
('' ')
6,0 0 0 O HM S
R U N S R O UG H
R E M O V E G R EE N & W H ITE
I l e a d s FR O M M O D U L E
CONNECT
O H M M E TER FROM
oo
G R O U N D TO E IT H E R R E A D S IN F IN IT E
LEAD
(X 1000 SC A LE )
CO NNECT O H M M E TER
ACROSS 2 LE ADS
READ S 5 0 0 TO
1500 O HM S
R E P E A T STEPS 4 A N D 5
W H IL E M O V IN G VA C.
A D V A N C E W IT H SCREW
D R IV E R . IF R E A D IN G
IS S T IL L OK
'R U N S SM O O TH
DO ES N O T R E A D
500 T O 1500 O HM S
REPLA CE C O IL
(PICK-U P)
RU N S R O UG H
R E P E A T STEPS
(OK)
1 THRU 5
IF O K
CHECK M O D ULE
W IT H TESTER
----------------------- ( s t o p )
IF NO T OK
R E M O VE A N D
REPLACE M O D ULE
TR U C K S U P P - S ER VIC E
6Y-20
ENGINE ELEC TR IC A L
PROBLEM:
engine CRANKS but
WILL NOT START
3-W IRE
CONNECTO R
C O IL
PICK-UP C O IL
STEP
SEQUENCE
RESULT
AU TO TRANS.
LEVER IN PARK
TEST LIG H T
ON
M A N U A L TRANS.
LEVER IN N EU T R A L
TEST L IG H T
OFF
-------------- ( s t o p )
STARTS
TEST LIG H T
OFF
REPAIR
LEAD OR
CONNECTOR
7 -
- - ~
NO STAR T
INSERT TEST LIG H T
IN RED B+ WIRE
IG N ITIO N SW.
STARTS
REPAIR OR
REPLACE AS
NECESSARY
"
TEST LIG H T |
ON
|____
NO STAR T
41
USING IN S U LA T E D PLIERS
HOLD SPARK PLUG WIRE 1/4 '
A W AY FROM ENG. BLOCK
W H ILE C R A N K IN G ENGINE
PROBLEM IS
N O T IG N IT IO N
SYSTEM
CHECK
EXTENSION
SPARK
FU EL SYSTEM
P LU G S
F L O O D E D
T R U C K S U P P -S E R V IC E
ENGINE E LE C TR IC A L
6Y-21
STEP
SEQUENCE
RESULT
REMOVE
CAP ASSY.
STARTS
IG N ITIO N
OFF
V IS U A L L Y INSPECT
FOR MOISTURE, DUST
CRACKS, BURNS, ETC.
DISCONNECT
3-WIRE CONNECTOR
REPAIR AS
NECESSARY
OHMMETER
NO
START
STARTS
READS ABOVE 1 OHM
(X 1 SCALE)
CONNECT
OHMMETER
REPLACE
COIL
NO START
READS 0 TO 1 OHM
(X 1 SCALE)
OHMMETER
O
7)
EITHER TEST
READS 6,000
TO 30,000 OHMS
STARTS
CONNECT
OHMMETER
BOTH TESTS
READ IN F IN IT Y
REPLACE
COIL
NO START
LESS
TH AN IN F IN IT Y
(X 1000 SCALE)
CONNECT
OHMMETER FROM
GROUND TO EITHER
LEAD
REPLACE COIL
(PICK-UP)
NO START
READS IN F IN IT E
(X 1000 SCALE)
CONNECT OHMMETER
ACROSS 2 LEADS
READS 500 TO
1500 OHMS
REPEAT STEPS 8 AN D 9
W HILE M OVING VAC.
ADVANC E W ITH SCREW
D R IV ER . IF R EADING
IS S T IL L OK
STARTS
REPLACE COIL
(PICK-UP)
NO START
REPEAT STEPS
5 TH R U 9
CHECK MODULE
WITH TESTER
REMOVE AND
REPLACE MODULE
6Y -22
ENGINE E LE C TR IC A L
SEQUENCE
RESULT
<>-------------------7---------- _
rtSv
( tmJ--------- ~ ~ \< rr
CHECK SPARK
PLUGS & PLUG WIRES
RUNSSM00TH
M- r
V IS U A L L Y INSPECT
REPAIR AS
U
FOR MOISTURE, DUST, NECESSARY
CRACKS, BURNS, ETC.
,
M )
EITHER TEST
READS 6,000
t o 30,000 OHMS
-------- "(0 ) ^
CONNECT
OHMMETER
BOTH TESTS
READ IN F IN IT Y
RUNS SMOOTH
-----TH A N IN F IN IT Y
(X 1000 SCALE)
REPLACE COIL
(PICK-UP)
CONNECT
OHMMETER FROM oo
GROUND TO EITHER READS IN F IN IT E
LEAD
(X 1000 SCALE)
CONNECT OHMMETER
ACROSS 2 LEADS
L -
>
RUNS ROUGH
REPEAT STEPS 4 A N D 5
W HILE M OVING VAC.
AD VANC E W ITH SCREW
D R IV E R . IF READING
IS S T IL L OK
R x x >
READS 500 TO
1500 OHMS
I "
RUNS SMOOTH
REPLACE COIL
(PICK-UP)
RUNS ROUGH
REPEAT STEPS
1 THRU 5
IF OK
------------------------( s t o p )
CHECK MODULE
WITH TESTER
IF NOT OK
REMOVE AND
REPLACE MODULE
T R U C K S U P P - S E R VIC E
ENG INE E LE C TR IC A L
Chart 1
G ENERATO R(
6Y -23
PROBLEM:
generator light ON engine RUNNING
G ENERATO R
BELT
STEP
FUSE B LO C K
RESULT
SEQUENCE
GENERATOR
LIGHT OFF
REPLACE IF
NECESSARY
ADJUST
TENSION TO 80 LBS.
CHECK
GENERATOR
BELT
TURN ENGINE
OFF
IF ALL
LIGHTS OFF
GO TO
STEP 2
START ENGINE
START ENGINE
GENERATOR
LIGHT ON
(DIM OR BRIGHT)
GENERATOR
LIGHT ON
GO TO
STEP 4
TEST LIGHT
FULLY BRIGHT
CONNECT
TEST LIGHT
TO NO. 1
TERMINAL
TEST LIGHT
1/2 BRIGHT
TEST VOLTAGE
REGULATOR WITH
APPROVED TESTER
GROUND
GENERATOR
"D"SHAPED
HOLE
GO TO
STEP 5
TEST LIGHT
1/2 BRIGHT
REPLACE
VOLTAGE REGULATOR
REPAIR GENERATOR
TR U C K S U P P - S ER VIC E
6Y-24
Chart 2
C LU S TE R
C O N N EC TO R
G E N E R A T O R L IG H T
G E N E R A TO R
PROBLEM:
generator light OFF ignition ON
engine NOT RUNNING
BULKHEAD
C O N N EC TO R
STEP
SEQUENCE
IGNITION ON
FUSE B LO C K
CHECK ALL
INDICATOR LIGHTS
IF ALL
LIGHTS OFF
RESULT
REPLACE
GAUGES FUSE
IF NEW
FUSE -----BLOWS
GO TO
STEP 2
IF FUSE
DOES -----NOT BLOW
GO TO
STEP 3
LIGHT OFF
REPAIR
IF NECESSARY
REPLACE
GAUGES FUSE
GENERATOR
LIGHT OFF
GENERATOR
LIGHT ON
GO TO
STEP 4
REPAIR OPEN IN
NO. 18 PINK WIRE
(INDICATOR FEED WIRE)
GENERATOR
LIGHT OFF
GENERATOR
LIGHT ON
CHECK GENERATOR
INDICATOR BULB AND
SOCKET ASSY.
REPLACE
IF NECESSARY
W J
v s / "
GENERATOR
LIGHT OFF
GO TO
STEP 5
GO TO
STEP 6
DISCONNECT
BROWN/WHITE
WIPE
GROUND NO. 1
TERMINAL
WIRE
GENERATOR
LIGHT ON
GO TO
STEP 7
GENERATOR
LIGHT OFF
T R U C K S U P P - SER VIC E
ENG INE E LE C TR IC A L
RESULT
SEQUENCE
STEP
6Y-25
REPAIR
GENERATOR
18 BROWN/WHITE
REPAIR OPEN
C hart 3
G E N E R A T O R L IG H T
G ENERATO R
C~\
C LU S TE R
C O N N EC TO R
PROBLEM:
generator light ON ignition OFF
BU LKHEAD
C O N N EC TO R
STEP
RESULT
SEQUENCE
GENERATOR
LIGHT ON
FUSE B LO C K
DISCONNECT
GENERATOR
LIGHT OFF
T R U C K S UPP - S E R VIC E
6Y-26
c o il(8 )
9)
c a rb u re to r
G ENERATO R( 1
BATTERY
PROBLEM:
battery UNDERCHARGED
GENERATOR
BELT
SEQUENCE
REPLACE IF NECESSARY
ADJUST TENSION
TO 80 LBS.
DISCONNECT
[n e g a t iv e
CABLE
RESULT
CONNECT TEST
|LIGHT BETWEEN
CABLE & BATTERY
.POST
MAKE SURE NO
ACCESSORIES
WERE LEFT ON,
IGNITION OFF,
DOORS CLOSED,
UNDER HOOD
LIGHTS DIS
CONNECTED
CHECK
GENERATOR
BELT
TEST LIGHT
ON
GO TO
STEP 3
TEST LIGHT OFF
NO DRAIN ON
BATTERY
TEST LIGHT
ON
CONNECT
VOLTMETER
(+) TERMINAL
AND GROUND
RECONNECT
NEGATIVE
CABLE
CONNECT
JUMPER
(-) TERMINAL
AND GROUND
( ON H.E.I. DISCONNECT
FEED WIRE)
IF READING IS
WITHIN .5 VOLT
OF VOLTAGE AT GEN
IF READING IS NOT
WITHIN .5 VOLT OF
READING AT GEN.
CHECK FOR BATTERY
CABLE AND STARTER
TO DELCOTRON
CIRCUIT RESISTANCE
CHECK
VOLTAGE
ACROSS
POST
WHILE
CRANKING
REPLACE
BATTERY
GO TO
STEP 6
NEEDLE ABOVE
9.0 VOLTS
CRANK ENGINE
LONG ENOUGH
FOR STABILIZED NEEDLE BELOW
9.0 VOLTS
READING
TEST BATTERY
USING BATTERY
LOAD TEST
PROCEDURE
GO TO
STEP 4
BATTERY OK
CHARGE AS
SPECIFIED BY
TEST
BATTERY
NOT OK
GO TO
STEP 6
T R U C K SUP P - S E R VIC E
ENGINE E LE C TR IC A L
STEP
RESULT
SEQUENCE
CONNECT
VOLTMETER
ACROSS
BATTERY
PLACE CARB.
ON HIGH STEP
FAST IDLE CAM
DISCONNECT
COIL JUMPER
OR RECONNECT
HEI FEED WIRE
START ENGINE
DO NOT TOUCH
ACCELERATOR
PEDAL
HEADLIG HTS-HllW f
TURN ON
ACCESSORIES
6Y-27
IF VOLTAGE
READS LOWER
TH AN PREVIOUS
READING
GO TO
STEP 9
IF VOLTAGE
READS HIGHER
THAN PREVIOUS
READING
GO TO
STEP 8
A/C - HI
RADIO
BLOWER TYPE
DEFOGGER
CHECK
VOLTAGE
READING
TR U C K S U P P - S E R V IC E
6Y-28
ENGINE ELEC TR IC A L
Chart 5
PROBLEM:
battery OVERCHARGED
(uses too much water)
STEP
SEQUENCE
RESULT
BATTERY OK
BATTERY
NOT OK
REPLACE
BATTERY
PLACE CARB.
ON HIGH STEP
FAST IDLE CAM
CONNECT
VOLTMETER
ACROSS
BATTERY
START ENGINE
DO NOT TOUCH
ACCELERATOR
PEDAL
CHECK
VOLTAGE
READING
TURN O F F A L L
ACCESSORIES
W AIT U N TIL UPPER
RADIATOR IN LET
AND
IS HOT
GO TO
STEP 3
READING
IS
12.5 to 15.5
READING
IS NOT
12.5 to 15.5
VOLTMETER
NEEDLE STOPS
------ 0
PERFORM
NEXT TWO
STEPS 4 & 5
GO TO
STEP 5
IF
GROUNDED
CHECK FOR
GROUNDED
BRUSH LEAD
CLIP________
REPAIR
GRQUND
IF NOT
TEST VOLTAGE
GROUNDED REGULATOR W ITHX
_____________ APPROVED TESTER
GO TO
STEP 5
GO TO
STEP 5
REPLACE
VOLTAGE REGULATOR
REPLACE ROTOR
AND VOLTAGE
REGULATOR
CHECK FOR
SHORTED
FIELD
WINDINGS
OHMMETER
(SEE SERVICE M AN U AL
FOR SPECIFICATIONS)
REPLACE
VOLTAGE
REGULATOR
S E C T IO N 7 M
7M-1
7M-3
CLUTCH CONTROLS
GENERAL DESCRIPTION
The clutch operating controls for "G " models (fig. IT) are
a mechanical type consisting of a pendant type pedal, return
spring, pedal pull rod, cross-shaft, fork push rod, clutch fork
and throw out bearing. The 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 throw out bearing against the clutch release fingers,
releasing the clutch.
TR U C K S UPP - S E R V IC E
7 M -2
C LU TCH A N D M A N U A L T R A N S M IS S IO N S
F ig . 1 T -C lu tc h L in k a g e A s s e m b ly - G M o d e ls
C LU TCH A N D M A N U A L T R A N S M IS S IO N S
7 M -3
MANUAL TRANSMISSIONS
SERVICE OPERATIONS
The service procedures for the Trem ec 3 speed will be the
same as 3 speed listed in the 1974 Service Manual.
Installation
1. Support transfer case in suitable stand and position case
to transmission adapter. Install bolts attaching case to
adapter and torque to 45 ft. lbs.
2. Remove stand as required and install bolts attaching
transfer case to frame rail. Bend lock tabs after
assembly.
3. Install connecting rod to shift rail link or connect shift
levers to transfer case, as applicable.
4. Connect front prop shaft to transfer case front output
shaft.
5. Connect rear prop shaft to transfer case rear output
shaft.
6. Install crossmember support and skid plate, if removed.
7. Connect speedometer cable, back-up lamp and TCS
switch.
Removal
torques.
T R U C K S U P P - S E R VIC E
7 M -4
C LU TCH A N D M A N U A L T R A N S M IS S IO N S
N O T E : Install B o o t
p rio r to in sta lla tio n o f
N u t & Knob.
N O T E : No insulation
to be installed under
Retainer.
N O TE : W ith trans case in
" N e u tra l" p o sitio n , align
In d ic a to r Plate to center
o f S h ift Lever.
N O T E : No insulation
to be installed under
retainer.
N O TE : Do n o t lub ricate
b o lt threads o n ly shank
groove.
M O D E L 203
M O D E L 2 05
F ig . 2 Q - T r a n s fe r C ase C o n tro ls
T R U C K SUP P S E R VIC E
S E C T IO N 7 A
AUTOMATIC TRANSMISSION
C O N T E N T S OF T H IS S E C T IO N
Turbo H ydra-M atic 350 Transm ission...........................................
Turbo H ydra-M atic 400/475 Transm ission..................................
7A -1
7A-5
GENERAL DESCRIPTION
VACUU M MODULATOR ASSEMBLY (FIG. 1G)
The engine vacuum signal is provided by the vacuum
modulator, which consists of a diaphragm and one spring.
The external spring applies a force which acts on the
m odulator valve. This force acts on the m odulator valve so
that it increases m odulator pressure. Engine vacuum acts in
the opposite direction to decrease modulator, or low engine
vacuum, high m odulator pressure. High engine vacuum, and
low modulator pressure.
F ig . 1 G ~ V a c u u m M o d u la to r A s s e m b ly
TR U C K SUP P - S ER VIC E
7 A -2 A U T O M A T IC T R A N S M IS S IO N
P. WASHER
GROMMET,
COLUMN SHIFT LEVER.
BUSHING.
CLAMP E
L. WASHER
NUT F
COLUMN ASSEMBLY
SWIVEL D
ROD A
TRANS
LEVER C
RETAINER
GROMMET
SHAFT ASSEMBLY B
GROMMET
SHIFT CONTROLS
and
disconnect snap-lock
Installation
5. Slide swivel (D) and clamp (E) onto rod (A) align the
column shift lever and loosely attach as shown.
6. Hold column lever against "neutral" stop "park"
position side.
7. Tighten nut (F) to 18 foot pounds.
8. Readjust indicator needle if necessary to agree with the
transmission detent positions.
9. Readjust neutral start switch if necessary to provide the
correct relationship to the transmission detent positions.
CAUTION:
Adjustment
With snap-lock disengaged, position carburetor to wide open
throttle (W .O.T.) position and push snap-lock downward
until top is flush with rest of cable.
T R U C K SUP P - S E R VIC E
A U T O M A T IC T R A N S M IS S IO N
7A -3
V -8 EN G IN E
SNAP LO C K
L-6 EN G IN E
C A U T IO N : Flexible com ponents (hoses,
wires, conduits, etc) m ust n o t be routed
w ith in 2 inches o f m oving parts o f
accelerator linkage fo rw a rd o f the Bracket
unless ro u tin g is positive ly co n tro lle d .
V IE W
7A -4 A U T O M A T IC T R A N S M IS S IO N
F ig . 4 G ~ D e te n t D o w n s h ift C a b le CK a n d P S e rie s
DIAGNOSIS
OIL PRESSURE CHECK
A U T O M A T IC T R A N S M IS S IO N
7A -5
The oil pan should be drained and filter replaced every 30,000 miles and fresh fluid added to obtain the proper level
REAR SEAL
Removal
,4// M o d e ls E x c e p t CL
1. Use a non-hardening sealer on outside of seal body; and
using Tool J-21359, drive seal in place.
T R U C K SUP P - S E R V IC E
7 A -6
A U T O M A T IC T R A N S M IS S IO N
F ig . 1 L - D e te n t D o w n s h ift S w itc h
TR U C K S U P P -S E R V IC E
S E C T IO N 8
8-1
8-2
FUEL TANK
Refer to the 1974 Light D uty Truck Service M anual for servicing of the
fuel tank and evaporation control system with the following exception:
Replacement
If replacement of a fuel feed pipe, vapor pipe or return pipe
is required, use only double wrap and brazed steel tubing
meeting GM Specification 123M or its equivalent. Under no
condition use copper or aluminum tubing to replace steel
tubing. Those materials do not have satisfactory fatique
durability to w ithstand normal vehicle vibrations.
Repair
1. Do not use fuel hose for pipe repair within 4 inches of
any part of the exhaust system.
2. In repairable areas, cut fuel hose 4 inches longer than
the portion of pipe removed. Use only hose stated for
T R U C K SUPP - S E R VIC E
8-2
FUEL T A N K A N D E X H A U S T S Y S T E M
EXHAUST SYSTEM
GENERAL DESCRIPTION
For alignment purposes, the muffler outlet flange is notched
and mates to a welded tab located on the outside diameter
of the tailpipe. The exhaust pipes and muffler use locater
tabs for alignment.
The CIO with light duty emissions (except 454 V8) and G10
vehicles have an exhaust system with a catalytic converter
between the front exhaust pipe and the rear exhaust pipe.
C 10 Model
Refer to Figure 2 for converter heat shield.
T R U C K S U P P - S ER VIC E
FUEL T A N K A N D E X H A U S T S Y S T E M
8-3
support
attaching
pipe
and
Installation
1. W ith sealer on exhaust pipes, install pipes into
converter.
2. On CIO model, loosely connect support attaching
converter-to-transm ission.
3. Install new "U" bolts and clamps at front and rear of
converter.
Catalyst Removal
If necessary, the catalyst in the converter can be replaced
on the truck with Tool No. J-25077.
1. Install aspirator J-25077-2 (Fig. 5).
2. Connect air supply line to aspirator to create a vacuum
in the converter to hold beads in place when fill plug
is removed.
3. Remove converter fill plug with 3/4" hex wrench or
Tool J-25077-3 and 4 (Fig. 6).
Catalyst Installation
1. Fill container with approved replacement catalyst.
2. Install fill tube extension to the fixture J-25077-1 (Fig.
9 ).
3. Connect air supply to aspirator and vibrator.
8-4
FUEL T A N K A N D E X H A U S T S Y S T E M
Bottom Cover
If, for any reason, the bottom cover of the converter is torn
or severely damaged, it can be replaced with a repair kit.
AIR SUPPLY
LINE
F ig . 5 In s ta llin g A s p ir a t o r
Fig . 6 - R e m o v in g F ill P lu g
J-25077-1
F ig . 7 In s ta llin g V ib r a t o r
FUEL T A N K A N D E X H A U S T S Y S T E M
8-5
J -2 5 0 7 7 -1
A IR SUPPLY
LINE
CA TA LYST
C O N T A IN E R
F ig . 8 - C o n ta in e r In s ta lle d o n V ib r a t o r
F ig . 9 - F ill T u b e E x te n s io n
Fig. 1 0 -R e m o v in g B o tto m C o v e r
F ig . 1 1 -R e m o v in g B o tto m C o v e r
8-6
FUEL T A N K A N D E X H A U S T S Y S T E M
F ig . 1 3 - C a ta ly tic C o n v e rte r In n e r S h e ll
IN S U L A T IO N
S E A L IN G
COMPOUND
R E T A IN IN G C H A N N E L
F ig . 1 5 1n s ta llin g B o tto m C o v e r R e ta in in g C h a n n e ls
F ig . 1 4 In s t a llin g B o tto m C o v e r R e p la c e m e n t
FUEL T A N K A N D E X H A U S T S Y S T E M
8-7
C LA M P
8-8
FUEL T A N K A N D E X H A U S T S Y S T E M
DIAGNOSIS
EXHAUST SYSTEM
CONDITION
L e akin g E xh a u st Gases
POSSIBLE CAUSE
Leaks a t pip e jo in ts .
CORRECTION
T ig h te n U -b o lt nuts a t
leakin g jo in ts to 3 0
fo o t-p o u n d s .
D am aged o r im p ro p e rly
as necessary.
Loose e x h au st p ip e h e at tu b e
ex te n s io n co n n ectio n s .
re q u ire d . T ig h te n
stud nuts o r b o lts
to s p e cificatio n s.
B urn e d or rusted o u t ex h au st
as re q u ire d .
T ig h te n cla m p s a t leaking
E xh a u st Noises
Leaks a t m a n ifo ld
o r p ip e c o n n ectio n s .
c o n n e c tio n s to sp ecified
to rq u e . R ep lace gasket o r
packin g as re q u ire d .
B urned o r b lo w n o u t
m u ffle r .
R ep lace m u ffle r
assem bly.
B urn e d o r rusted o u t
ex h au st pipe.
R ep lace e x h a u s t p ip e.
E x h a u s t p ip e leakin g
a t m a n ifo ld flang e.
T ig h te n a tta c h in g
b o lts nuts to 17 f o o t
pounds.
E x h a u s t m a n ifo ld
crack ed o r b ro k e n .
R ep lace m a n ifo ld .
Leak b e tw e e n m a n ifo ld
and c y lin d e r head.
T ig h te n m a n ifo ld to
c y lin d e r head stud
nuts o r b o lts to s p ecificatio n s.
Loss o f engine p o w e r a n d /o r
in te rn a l ra ttle s in m u ffle r .
b a ffle s in m u ffle r .
Loss o f engine p o w e r.
Im p lo d in g (in n e r w a ll collapse)
R ep lace m u ffle r .
R ep lace e x h a u s t p ip e .
o f e x h au st pip e (C T r u c k )
SPECIAL TOOLS
1. J-2507 7-1
V ib r a t o r Include C atalyst
C o n tain er an d Fill Tube Extension
2. J -2 5 0 7 7 -2 A sp irator
F ig . 1 S T -S p e c ia l T o o ls
TR U C K S U P P - SER VIC E
S E C T IO N 9
STEERING
The following caution 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 Caution on Page 1 of this
Section".
C A U T I O N : THIS FASTENER IS A N IMPORTANT A TTACHING PART
IN D E X
General D escription................................................................. 9-1
M aintenance and Adjustm ents.............................................. 9-1
Power Steering Pum p Belt A djustm ent........................... 9-1
Power Steering G e a r.............................................................9-1
Service O perations................................................................... 9-3
Steering W heel........................................................................9-3
Directional Signal Switch.....................................................9-3
GENERAL DESCRIPTION
All 1976 truck models have basically the same steering systems as the 1974
models. All service procedures outlined in the 1974 Light D uty Truck
Service M anual apply as well to the 1976 truck steering systems except
the following procedures.
T R U C K S U P P - SER VICE
9-2
STEERING
Key No.
1
2
3
4
5
Part Name
67 -
COLUM N ASM
HOUSING ASM
RACK ASM
SPRING
SECTOR
SHA FT
CLIP
8 -
S W IT C H
9
10
11
12
- BEA RING
- WASHER
- SCREW (4)
- R E T A IN IN G RING
13 - NU T
14 - COVER ASM (SHIPPED SE PA R A TELY)
15
16
17
18
- R ING
- LOCK
- CAM ASM
- SPRING
SCREW (3)
Key No.
Part Name
20 21 -
S W IT C H A S M
P R O T E C T O R W IR E
22 -
H O U S IN G
23 24 25 -
CUP
B O LT ASM
W ASHER
26
27
28
29
- G ATE
- SC REW (2)
- JA C K E T ASM
- S W IT C H A S M , IG N IT IO N
Key No.
Part Name
39 -
W ASHER
40 41 42 -
S P R IN G
ADAPTER
R E T A IN E R
43 -
B E A R IN G
44 45 -
R IN G
S H A F T ASM
C L IP
S H A F T ASM
C O U P L IN G A S M
SC R E W (2)
46 47 48 -
31 -
B OW L A S M
49 -
B OLT
32 -
S P R IN G
33 34 -
BOWL
SHROUD
50 51 -
NUT
R IN G
35 -
B E A R IN G
52 53 54 -
S P R IN G
B E A R IN G (2)
A B R A S IO N S H IE L D
30 -
36 -
JA C K E T ASM
37 -
S E A L -D A S H
55 -
BO LT
38 -
TU B E ASM
56 -
NUT
Fig. 1 -T y p ic a l S ta n d a rd C olu m n
T R U C K S U P P - SER VIC E
S TEERING
9-3
SERVICE OPERATIONS
STEERING COLUMN
COVER
STEERING LINKAGE
Installation
W hen installing the steering wheel, replace the snap ring
after tightening the steering wheel nut to proper torque
specifications.
IDLER ARM
Use of the proper diagnosis and checking procedure is
essential to prevent needless replacement of good idler arms.
The proper checking procedure is as follows:
1. Raise the vehicle in such a manner as to allow the front
wheels to rotate freely and the steering mechanism
freedom to turn. Position the wheels in a straight ahead
position.
2. Using a push pull type spring scale located as near the
relay rod end of the idler arm as possible, exert a 25 lb.
force upward and then downward while noticing the
total distance the end of the arm moves. This distance
should not exceed 1/8 inch (Figure 3A). It is necessary
to ensure that the correct load is applied to the arm since
it will move more when higher loads are applied. It is
also necessary that a scale or ruler be rested against the
frame and used to determine the am ount of movement
since observers tend to over-estimate the actual
movement when a scale is not used. The idler arm
should always be replaced if it fails this test.
NOTE: Jerking the right front wheel and tire assembly
back and forth thus causing an up and down
movement in the idler arm is not an acceptable method
of checking since there is no control on the am ount
of force being applied.
TR U C K S UPP - S ER VIC E
9-4
STEERING
Id le r M o v e m e n t
TIE RODS
Service procedures for the 1976 tie rod assemblies are
identical to those outlined in the 1974 Light D uty Truck
Service Manual, Section 9.
Figure 5 shows the updated tie rod clamp relationships for
1976 models.
Installation
1. Position pum p assembly on vehicle (Fig. 6) and install
attaching parts loosely.
2. Connect and tighten hose fittings.
STEERING
9-5
SUPPORT
,LEFT IDLER
ARM
PITMAN ARM
IDLER ARM
ASSEMBLY
STEERING
GEAR ASSEMBLY
RELAY ROD
STEERING GEAR
MOUNTING BRACKET
TIE ROD
ASSEMBLY
STEERING GEAR
ASSEMBLY
PITMAN ARM
STEERING ARM
G-SERIES
F ig . 4 --S te e rin g L in k a g e
11. The presence of trapped air in the system will cause the
fluid level in the pump to rise when the engine is turned
off. Continue to bleed system until this condition no
longer occurs.
TR U C K SUP P S E R V IC E
9-6
STEERING
NOTE: S lo t in a d ju s te r
sleeve m u s t n o t
w it h in th is area
c la m p ja w s.
NOTE: E q u a l th r e a d le n g th s m u s t be
v is ib le a t in n e r a n d o u te r en d s o f a d ju s te r
sleeve w h e n a sse m b le d t o s te e rin g k n u c k le .
NOTE: L o c a te c la m p s w i t h i n
to le ra n c e s h o w n .
\
CAUTION:
C la m p m u s t be
b e tw e e n & c le a r o f d im p le s
b e fo re to r q u in g n u t.
H O R IZ O N T A L '
L IN E
AD JU S TER
S LEEVE
REARW ARD
R O T A T IO N
S L O T
VIEW
NOTE: E q u a l th r e a d le n g th s m u s t be
v is ib le a t in n e r a n d o u te r e n ds o f a d ju s te r
sleeve w h e n asse m b le d t o s te e rin g k n u c k le .
SLO Ti
H O R IZ O N T A L
L IN E
/
NOTE: L o c a te c la m p s w i t h i n
to le ra n c e s h o w n .
,A D J U S T E R
SLEEVE
/
/
CAUTION:
C la m p m u s t be
b e tw e e n & c le a r o f d im p le s
b e fo re t o r q u in g n u t.
REARW ARD
R O T A T IO N
NOTE: S lo t in a d ju s te r
sleeve m u s t n o t be
w it h in th is area o f
c la m p ja w s.
NOTE: E q u a l th r e a d le n g th s m u s t be
v is ib le a t in n e r a n d o u te r en ds o f a d ju s te r
sleeve w h e n a sse m b le d to s te e rin g
k n u c k le .
V E R T IC A L
L IN E
N
SLO T
AD JU S TER
NOTE:
S lo t in a d ju s te r
sleeve m u s t n o t
w it h in th is area
c la m p ja w s.
'S L E E V E
NOTE: L o c a te c la m p s ,
w it h in to le ra n c e sh o w n .
CAUTION:
C la m p m u s t be
b e tw e e n & c le a r o f d im p le s
b e fo re t o r q u in g n u t.
REARW ARD
R O T A T IO N
VIEW
TR U C K S U P P - SER VIC E
STEERING
250
G 10
L-6
C 10
K10
Fig . 6 - P o w e r S te e r in g P u m p
292
9-7
V-8
WITH C-60
F ig . 9 --P o w e r S te e r in g P u m p
L-6
G 20-30 C 10-30
K 20
P 20-30
Fig . 7 --P o w e r S te e r in g P u m p
350 V-8
MOTOR HOME
F ig . 1 0 - P o w e r S te e r in g P u m p
454 V-8
C 10-30
F ig . 1 1 - P o w e r S te e r in g P u m p
9-8
STEERING
R o ta te ho se a s s e m b ly a g a in s th y d r a b o o s t h o u s in g a sse m b ly
b e fo re t ig h te n in g n u t.
HA
.6 4 IN C H
M IN I M U M
CLEARANCE
R o ta te ho se asse m bly,
a g a in st s te e rin g gear
h o u s in g b e fo re
tig h te n in g n u t.
VIEW B
292 L-6
G 30
W/HYDRABOOST
F ig . 1 5 ~ P o w e r S te e r in g H o se R o u tin g
o r ie n ta t e p re s s u re hose
w h e n in s ta llin g , ro ta te p ip e
ends t o re s t a g a in s t p u m p
s u p p o r t lo w e r.
S p e e d o c a b le a n d p a rk in g b ra k e
c a b le t o be r o u te d a b o v e p o w e r
s te e rin g p ip e s a n d m a in ta in
cle a ra n c e .
F ig . 1 3 --P o w e r S te e r in g H o s e R o u tin g
T R U C K SUPP - S ER VICE
STEERING
9-9
R o ta te ho se a s s e m b ly
a g a in s t h y d r a b o o s t
h o u s in g a s s e m b ly
b e fo re tig h te n in g n u t.
R o ta te ho se a s se m b ly
a g a in s t s te e rin g gear
h o u s in g b e fo re
tig h te n in g n u t.
VIEW
-.6 4 M I N I M U M
C LEARANCE
F ig . 2 1 - P o w e r S te e r in g H o se R o u tin g
T o o r ie n ta te p re s s u re
ho se w h e n in s ta llin g ,
r o ta te p ip e en d s t o
re s t a g a in s t s te e rin g
p u m p h o u s in g .
S p e e d o c a b le a n d
p a rk in g b ra k e
c a b le t o be ro u te d
above p o w e r
s te e rin g p ip e s a n d
m a in ta in c le a ra n ce .
C la m p m u s t be in s ta lle d
w it h b o lt h e ad to w a r d
f r o n t o f v e h ic le .
B
6 IN C H E S
VIEW A
H ose a s s e m b ly
m u s t be lo c a te d
a g a in s t h y d ra
b o o s t m o u n t in g ^
b ra c k e t.
VIEW
350 V-8
MOTOR HOME
Fig. 2 3 - P o w e r S te e rin g Hose Routing
9-10
STEERING
VIEW A
454 V-8
C 10-30
EXCEPT HYDRABOOST
R o u te P ip e A s s e m b ly - ln le t
p a ra lle l t o
o f s te e rin g gear.
F ig . 2 4 - P o w e r S te e r in g H o s e R o u tin g
454 V-8
C 20-30
W/VACUUM POWER
BRAKES AND 4.56 AXLE
R o u te p ip e a s s e m b ly -in le t
o u tb o a r d 1 5 t o p a ra lle l
o f s te e rin g gear.
F ig . 2 7 - P o w e r S te e r in g H o s e R o u tin g
454 V-8
MOTOR HOME
H ose a s s e m b ly m u s t be
lo c a te d a g a in s t h y d r a b o o s t
m o u n tin g b ra c k e t.
F ig . 2 8 - P o w e r S te e r in g H o s e R o u tin g
H ose
a s s e m b ly m u s t
be in s ta lle d
a g a in s t s te e r in g y
gear c o v e r.
1
R o u te p ip e a s s e m b ly
1 5 to p a ra lle l o f
s te e rin g gear.
454 V-8
C 30
W/HYDRABOOST
AND 4.56 AXLE
STEERING
9-11
TRUC K S U P P - S E R VIC E
9-12
STEERING
Fig. 3 1 ~ S p e c i a l To ols
S E C T IO N 10
A T T A C H M E N T OF D U A L W H E E L S ON
P 300 MODELS
To assure secure attachm ent of the dual disc wheels, it is
im portant that all dirt or rust scale be removed from the
mating surface of the wheels, hub, and clamp ring as well
as the stud and nut. PO W ER D R IV E NUTS T H E N
M A N U A LLY IN SPEC T TO RQ U E AT 130-180 FT. LBS.
M A N U A L TO R Q U E ONLY: 150-200 FT. LB.
DUAL WHEEL
SINGLE WHEEL
Fig . 1 - W h e e l C o d e L o c a tio n
T R U C K S U P P - S ER VIC E
10-2
WHEELS A N D TIR ES
Range
Load
20
970
1060
1140
1140
1140
1240
1240
1300
1300
1380
1380
1380
1380
1140
B
B
B
D
B
B
D
B
B
B
C
C
D
D
22
24
1030
1110
1190
1190
1190
1310
1310
1370
1370
1460
1460
1460
1460
1190
1080
1160
1260
1260
1260
1370
1370
1440
1440
1530
1530
1530
1530
1260
1130
1220
1310
1310
1310
1440
1440
1500
1500
1590
1590
1590
1590
1310
1180
1270
1370
1370
1370
1500
1500
1570
1570
1670
1670
1670
1670
1370
1230
1320
1420
1420
1420
1560
1560
1630
1630
1730
1730
1730
1730
1420
1270
1370
1470
1470
1470
1610
1610
1690
1690
1790
1790
1790
1790
1470
36
38
40
1530
1570
1620
1670
1670
1720
1770
1830
1860
1860
1860
1530
1910
1910
1910
1570
1970
1620
2030
1670
T IR E S FO R L IG H T TR U C K S U SED IN HIGHW AY S E R V IC E
TIRES USED AS SINGLES
Tire
Size
6.50-16
7.00-15
7.00-15
7.00-16
7.50-16
7.50-16
7.50-16
8 *.17.5
8-19.5
Load
Range
C
c
D
C
C
D'
E
D
D
40
35
45
50
60
55
65
60
75
1270
1350
1350
1430
1620
1620
1620
1390
1480
1480
1560
1770
1770
1770
2670
2780
1640
2800
2040
2440
2410
2560
Load
Range
20
22
24
26
28
30
1390
1470
1540
1620
1690
1760
30
35
40
45
1080
1440
1360
1360
1360
1570
1570
1570
1860
1860
1840
1840
1180
1580
1490
1490
1490
1720
1720
1720
2030
2030
2010
2010
1280
1710
1610
1610
1610
1850
1850
1850
2190
2190
2170
2170
1370
1830
1730
1730
1730
1990
1990
1990
2350
2350
2330
2330
Load
Range
C
C
c
D
E
C
D
E
D
E
C
D
32
34
36
38
55
60
65
70
75
1840
1840
1945
1945
2045
2045
2145
2240
2330
2110
2110
2500
2500
2240
2240
2650
2650
2350
2350
2780
2780
2470
2570
2680
2920
3050
3170
2480
2620
2750
65
70
Load
Range
30
35
40
75
8-17.5
8-19.5
8-19.5
C
C
D
C
D
1120
1260
1260
1430
1430
D
D
E
1850
1990
2110
2230
2350
2460
1850
1990
2110
2230
2350
2460
1225
1365
1365
1565
1565
1320
1475
1475
1690
1690
1420
1580
1580
1815
1815
1685
1780
1870
1930
2040
2140
2570
2680 (#)
W ) 2780 lb s . a t 80 lb s. pre ss u re .
WHEELS A N D TIR ES
10-3
Load
Range
30
35
40
45
C
D
C
D
E
1195
1195
1380
1380
1380
1310
1310
1515
1515
1515
1415
1415
1630
1630
1630
1520
1520
1750
1750
1750
50
55
60
1620
1710
1800
1855
1855
1970
1970
2070
2070
65
70
75
2175
2260
2360
PRO PERLY IN F L A T E D
R A D I A L TIRE
P R O P E R L Y I N F L A T E D B IA S
O R B IA S - B E L T E D TIRE
CODE
BT
BJ
BC
BS
DT
FJ
XH
XL
XU
BR
CY
CF
DK
DJ
XS
BH
FT
AX
AB
YW
CU
CM
15 x 7 JJ
15 x8JJ
15 x 7 JJ
1 5 x 8 .0 0 JJ
15 x 6 JJ
1 6 .5 x 6 .0
1 5 x 6 JJ
16 x 5K
15 x 6 JJ
16 x 5K
19.5 x 5.25
16 x 5.50 F
16.5 x 6.0
16.5 x 6.75
16 x 6VzL
16.5 x 8.25
15 x 6JJ
1 5 x 6 JJ
19.5 x 6.75
16 x 6 K
19.5 x 5.25
17.5 x 5.25
MAX.
MAX.
LOAD (LBS) PRESS (PSI)
2040
1760
1910
70
40
70
40
55
85
55
55
55
55
75
70
70
85
85
70
70
70
85
75
85
1760
1670
2680
1670
1800
1670
1800
2460
2440
2350
3170
2780
2750
1910
2040
2780
2440
2800
2155
70
Load Range
A
B
C
D
E
2
4
6
8
10
S E C T IO N 11
GENERAL DESCRIPTION
The service procedures for all 1976 truck chassis sheet metal
are essentially the same as those outlined in the 1974 Light
D uty Truck Service Manual, Section 11, except as described
below.
Installation
Reverse removal procedure to install snorkel.
TR U C K S U P P - S ER VIC E
11-2
C H A S S IS SHEET M E T A L
F ig . 5 --R u n n in g B o a rd , H a n g e r, a n d B ra c e -C K S e rie s
S E C T IO N 12
LIGHTING SYSTEM
MAINTENANCE AND ADJUSTMENTS
HEADLAMP ADJUSTM ENT
HEADLAMP AIM IN G
The headlamps must be properly aimed in order to provide
maximum allowable road illumination. Headlamps should
be checked for proper aim at new car predelivery, every 12
months, after installing a new sealed beam unit or if front
end sheet metal is adjusted or repaired.
Some state and local authorities have special or additional
requirem ents for headlamp aiming and these requirements
should be followed.
H orizontal and vertical aiming of each sealed beam unit is
provided by two adjusting screws which move the mounting
ring in the body against the tension of the coil spring (fig.
1). Both circular and rectangular headlamps are aimed in
the same manner. There is no adjustm ent for focus since the
sealed beam unit is set for proper focus during
m anufacturing assembly.
Before headlam p aiming process begins, it is necessary to
prepare vehicle as follows:
1. Remove any large am ounts of mud or ice from
underside of fenders.
2. Place vehicle on a fairly level flat surface. It is not
necessary that this surface be exactly level.
3. M ake sure tires are properly inflated.
4. Clean headlam p lenses.
5. Fuel tank should be one half full. If heavy load is
normally carried in load area, it should remain there.
6. Driver should remain in vehicle or an equivalent weight
placed in drivers seat.
7. "Rock" vehicle sideways so as to equalize the springs.
Also check springs for sag, broken leaves or coils.
Using headlam p aiming device J-25300, aim headlamps as
follows:
12-2
ELEC TR IC A L-BO DY A N D C H A S S IS
A D J U S T IN G K N O B
LEVEL V IA L
(U S E D O N L Y FO R C A L IB R A T IO N )
F ig . 2 - F lo o r S lo p e A d a p te r J - 2 5 3 0 0 - 6
VERTICAL DIAL
LO CKING HANDLE
HORIZONTAL KNOB
SUCTION CUP
SIGHT O PEN IN G
V IEW ING PORT
LEVEL VIAL
M O C K IN G HANDLE
Fig. 3 - H e a d l a m p A im e r
ELE C TR IC A L-B O D Y A N D C H A S S IS
12-3
A IM E R J -2 5 3 0 0 -2
A IM E R J -2 5 3 0 0 -2
A IM E R J -2 5 3 0 0 -1
PORT
^ M l l 'iH I %I 1:W *
S IG H T O P E N IN G
TARGETS M U S T FACE EA CH O T H E R
A IM E R J -2 5 3 0 0 -1
7 " C IR C U LA R H E A D L A M P
ADAPTER J -2 5 3 0 0 -4
R E C T A N G U LA R H E A D L A M P
A DAPTER J - 2 5 3 0 0 -3
13 and
5 " C IR C U LA R H E A D L A M P
ADAPTER J -2 5 3 0 0 -5
T R U C K S U P P - S E R VIC E
12 -4
ELEC TR IC A L-BO DY A N D C H A S S IS
LEVEL V IA L
V IE W IN G PORT
H EAD LA M P AIMER
J-2 5 3 0 0 -1
SERVICE OPERATIONS
HEADLAMPS W ARNING BUZZER
Replacement (Fig. 7).
1. Disconnect electrical connector from LPS (Lamps)
socket o f fuse panel.
Diagnosis
12-5
12-6
ELEC TR IC A L-BO DY A N D C H A S S IS
F ig . 9 - S e a t B e lt R e m in d e r S y s te m S c h e m a tic
S E C T IO N 14
BUMPERS
Service procedures for the 1976 Light Duty Truck are basically carryover
except for the G model truck bumper procedures listed below.
Installation
Reverse removal steps to install bumpers. Refer to torque
specifications for proper torque values.
Installation
Install in reverse order of removal. Refer to torque
specification for correct torque values.
S E C T IO N 15
ACCESSORIES
NOTE: Except for the following changes, all information listed in Section
15 of the 1974 Light D uty T ruck Service M anual is applicable to 1976
light duty trucks. Refer to 1974 Light Duty Truck Service M anual for
any service procedure not contained herein.
CRUISE MASTER
IN D E X
G eneral D escription...........................................................15-1
Theory of O peration......................................................... 15-1
Cruise M aster U n its........................................................ 15-2
M aintenance and A dju stm en ts....................................... 15-3
Regulator...................................... ......................................15-3
Servo U n it......................................................................... 15-3
Brake Release Sw itches..................................................15-4
E lectric.............................................................................. 15-4
V acuum ............................................................................ 15-4
Component Part Replacem ent........................................ 15-6
Regulator............................................................................. 15-6
Servo....................................................................................15-6
Column M ounted Engagement Switch........... ............ 15-6
Diagnosis...............................................................................15-6
Electrical System Troubleshooting.............................. 15-6
Engagement Switch T e st.............................................. 15-6
Harness T e s t....................................................................15-6
Servo and Vacuum System T e st.................................15-7
System Diagnosis C harts................................................ 15-9
GENERAL DESCRIPTION
The Cruise M aster is a speed control system which employs
engine manifold vacuum to power the throttle servo unit.
The servo moves the throttle, when speed adjustment is
necessary, by receiving a varying amount of controlled
vacuum from the regulator unit. The speedometer cable
(from the transmission) drives the regulator, and a cable
(from the regulator) drives the instrum ent panel
speedometer. The engagement of the regulator unit is
controlled by an engagement switch located at the end of the
THEORY OF OPERATION
The purpose of the Cruise M aster 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.
TR U C K S U P P - SER VIC E
15-2 A C C ES S O R IE S
Speed Changes
Override -The accelerator pedal may be depressed at any
time to override the cruise system. Release of the accelerator
pedal will return the vehicle to the previous cruise speed.
THE
C RU ISE
CONTROL
ENGAGE SWITCH
A S S E M B L IE S ,
BOTH
TURN
S IG N A L
&
IN S TR U M E N T
PANEL
MOUNTED
TYPES,
INCORPORATE
THREE
POS IT IO N SWITCHES.
THESE POSITIONS ARE:
( A) T H E R E L E A S E D O R N O R M A L P O S I T I O N
(B) T H E E N G A G E P O S I T I O N
(C) T H E T R I M - D O W N P O S I T I O N .
P A R T IA L L Y DEPRESSING TH E ENGAGE SWITCH
WILL A C T IV A T E THE SYSTEM A N D IT W ILL
REMAIN
ACTIVITED WHEN
T H E S W I T C H IS
R E LE A S E D .
THE
C R U IS E
SYSTEM
IS
DEA C TIVATED
WHEN
THE
BRAKES ARE
A P P L I E D O R W H E N T H E E N G A G E S W I T C H IS
DEPRESSED
FULLY
AND
HELD
IN T H E
TR IM -D O W N POSITION.
T H E TR I M -D O W N
SW ITCH
POSITION
IS
NORM ALLY
USED
TO
DECREASE
THE
C R U I S I N G S P E E D . W H I L E T H E S W I T C H IS H E L D
IN T H E T R I M - D O W N P OS IT IO N T H E CRUISE
S Y S T E M IS O F F A N D T H E C A R S P E E D W I L L
G R A D U A L L Y DECREASE. WHEN THE DESIRED
C R U I S I N G S P E E D IS R E A C H E D , T H E S W I T C H IS
SLOWLY RELEASED A N D TH E CRUISE SYSTEM
W ILL
RE-ENG AG E.
IF
THE
SW ITCH
IS
R ELEA SED
FROM
THE
TR IM -D O W N
P O S I T I O N V E R Y R A P I D L Y , I T IS Q U I T E L I K E L Y
T H A T THE SYSTEM W IL L N OT RE-ENGAGE.
T H I S IS N O R M A L A N D IS A V O I D E D B Y A
SLO WER, M O R E D E L I B E R A T E R EL EA SE OF
THE
SW ITCH
FROM
THE
TRIM-DOWN
POSITION.
NOTE:
A SPEED-SWITCH
B UILT INTO THE
R E G U L A T O R
A S S E M B L Y
PR EVENTS
EN G A G IN G
THE
CRUISE SYSTEM
BELOW
A P P R O X . 30 MPH.
A C C ES S O R IE S
EN GAGE
T E R M IN A L
H O LD
T E R M IN A L
O U T P U T TO
SP E E D O M E T E R
*
TO TEE'
F IT T IN G
15-3
IN PU T F R O M
T R A N S M IS S IO N
LO CKN U T
- O R IF IC E TU BE &
C O N N E C TO R ASSEM BLY
F R O M E N G IN E
VACUUM
A IR FILTER & S O L E N O ID
H O U S IN G C O V E R
T R U C K SUP P - S ER VIC E
replacement.
Vacuum
The vacuum valve plunger must clear the pedal arm when
the arm is moved 5/16 inch, measured at the switch (fig. 6C).
Electric
The Cruise M aster brake release switch electrical contacts
must be switched open when the brake pedal is depressed
.38" to .64", measured at the brake pedal.
n ^CRUISE CONTROL
V AC U U M HOSE
CABLE
SERVO BOOT
ACCELERATOR
CABLE SUPPORT
SERVO
CABLE
____
A
[ v ie w
CARB
LEVER
- H
SERVO
CABLE
LF4/LF8/LS9
Fig. 4C -- Serv o C o m p o s it e (C-K Tr ucks)
T R U C K S U P P - SER VIC E
A C C ESSO R IES
15-5
B R A K E P E D A L IN
N O R M A L P O S ITIO N
B R A K E P E D A L P O S ITIO N
W HEN V A C U U M V A L V E
OPENS
.38 TO .64
IN S T A L L A T IO N OF S E L F -A D JU S T IN G
V A C U U M R E LE A S E V A L V E
1.
2.
3.
15-6 A C C ES S O R IE S
REGULATOR
Replacement
harness on column.
SERVO
Installation
Replacement
Removal
DIAGNOSIS
ELECTRICAL SYSTEM TROUBLESHOOTING
1. Check fuse and connector.
2. Check electric brake switch as follows:
a. Unplug connector at switch.
b. Connect ohm m eter across cruise master contacts on
brake switch. The ohm m eter must indicate no
continuity when the pedal is depressed and continuity
when pedal is released. The cruise release brake switch
(electric) is adjusted as is the standard stop light brake
switch.
c. Replace electric brake switch if needed.
3. Check clutch release switch (manual transmission only)
same as electric release switch above.
A C C ES S O R IE S
15-7
15-8
ACCESSORIES
Fig. 7C--Electro-Pneumatic
Schematic
A C C ES S O R IE S
15-9
CHECK II
FIG. 8
FIG. 9
CHECK I
1.
2.
3.
4.
5.
6.
CHECK FOR PROPER O PERATIN G PROCEDURE OF THE ENGAGE SWITCH (SEE FIG . 1)
7.
1 5 -1 0 A C C ES S O R IE S
CHECK n
T R U C K SUP P S ER VICE
S E C T IO N IN D E X
SECTION
1976
10-30 SERIES
TRUCK
CHASSIS SERVICE
and
OVERHAUL MANUAL
SUPPLEMENT
NAME
FRONT AXLE
REAR AXLE
DIFFERENTIAL CARRIER
BRAKES
ENGINE
O V E R H A U L S E C T IO N
T h e o v erh au l section o f this m anual inclu d es new o r re
vised p ro c e d u re s in volved in d isassem b ly and assem b ly o f
m ajo r co m p o n e n ts.
6M
CARBURETORS
6Y
STARTING MOTOR
SOLENOID AN D
DELCOTRON
7M
CLUTCH AND
M A N U A L TR A N S M IS S IO N
7A
A U TO M A TIC
TR A N S M IS S IO N
MANUAL
STEERING GEAR,
POWER STEERING
P U M P AND GEAR
SPECIFICATIONS AT REAR
OF M A N U A L
Printed In U.S.A.
SECTION 1
AIR CONDITIONING
C O N T E N T S OF T H IS S E C T IO N
Axial Six-Cylinder Com pressor........................................................ .. 1-1
Radial Four-Cylinder C om pressor.................................................... 1-26
Special T o o ls........................................................................................... 1-38
TRUC K SUP P - O V E R H A U L
1-2 AIR
Front Head
\
CONDITIONING
O -R ing
O -R in g s
A bsorbent Sleeve
Seal Retainer
Clutch Coil Retainer Ring
COMPRESSOR
Compressor Shell
Clutch Coil and Housing Assembly
Pulley
Bearing
Fig. 1--Exploded
Superheat
Switch
Bearing Retainer
Pulley Retainer Ring
Switch O-Ring
lo c k Nut
Rear Head
O uter O il Pump G e a r
Retainer Ring
Lock Nut
View
of A-6
Bushing
Needle Bearing
Compressor
O - Ring
Rear Cylinder H alf
T eflo n Piston R in g -
Bolt
Shoe Disc
'
Shaft
Discharge Crossover Tube
Thrust Races
Front
Suction Reed
Front Discharge
V alve Plate Assembly
A IR C O N D IT IO N IN G COMPRESSOR 1-3
SUCTION REED
BALL
SHAFT \
PISTON
FRONT
DISCHARGE V A L V E PLATE
PULLEY
A X IA L PLATE
PULLEY BEARING
SHOE DISC
CLUTCH PLATE
AND
HUB ASSEMBLY
REAR H E A D n
-SEAL SEAT
O IL PUMP
GEARS
RETAINER RING
SUPERHEAT >
SWITCH
-SEAL SLEEVE
FRONT
/ ABSORBENT
HEAD
/ SLEEVE
/
PRESSURE RELIEF
VALVE
O IL PICK-UP TUBE
O IL SUMP
THRUST
RACE
THRUST
BEARING
REAR C YLINDER
HALF
'--LI
AN
CH COIL
HOUSING
FRONT C YLINDER
SPACER
HALF
RETAINER RING (C O N VEX .
SIDE FACING SPACER)
SHAFT NUT
F ig . 2 --A -6 C o m p re s s o r C ro s s S e c tio n
F ig . 3 --R e m o v in g S h a ft L o c k N u t
TR U C K SUP P - O V E R H A U L
Replace
1. Insert the square drive key into the hub of driven plate;
allow it to project approximately 3/16" out of the
keyway.
Inspection
Check the appearance of the pulley and bearing assembly.
See Fig. 6. The frictional surfaces of the pulley and bearing
assembly should be cleaned with a suitable solvent before
reinstallation.
T R U C K SUPP - O V E R H A U L
A IR C O N D IT IO N IN G COMPRESSOR 1-5
D R IV E P L A T E
D R IV E N P L A T E
SC O R IN G O F D R IV E AND D R IV E N P L A T E S IS N O R M A L .
DO N O T R E P L A C E F O R T H IS C O N D IT IO N .
F ig . 6 --C lu tc h D riv e n P la te a n d D riv e P la te
DRIVE PLATE
INSTALLER
J-9480-01
SPACER
J-9480-2
KEY
K E Y W A Y IN
SHAFT
J-9396
HOLDING
FIXTURE
HOLDING FIXTURE
J-9396
F ig . 8 In s t a llin g D riv e P la te
F ig . 7 - - A lig n in g D riv e P la te K e y
Replace
1. If original pulley and bearing assembly is to be
reinstalled, wipe frictional surface of pulley clean. If
frictional surface of pulley shows any indication of
damage due to overheating, the pulley and bearing
should be replaced.
2. Check bearing for brinelling, excessive looseness, noise,
and lubricant leakage. If any of these conditions exist,
bearing should be replaced.See Compressor Pulley
Bearing Replacement Procedure.
3. Press or tap pulley and bearing assembly on neck of
compressor until it seats, using Pulley and Bearing
Installer J-9481 with Universal H andle J-8092 (Fig. 12).
The Installer will apply force to inner race of bearing
PULLER
J843 3
CLEARANCE
.022 " TO .057
PULLER PILOT
PULLEY A N D
B E A R IN G
ASSEMBLY
F ig . 9 --C h e c k in g A ir G a p
F ig . 1 1 - R e m o v in g P u lle y a n d B e a r in g A s s e m b ly
SNAP RING
PLIERS J6 4 3 5
(# 2 6 )
PULLEY
ASSEMBLY
UN IVERSAL
HANDLE
J-8 0 9 2
RETAINER
RING
PULLEY A N D
BEARING
INSTALLER
J 9481
PULLEY BEARING
Remove
BEARING
RETAINER
Replace
1. Install new bearing in pulley using Pulley and Bearing
Installer J-9481 with Universal Handle J-8092 (Fig. 15).
The Installer will apply the force to the outer race of
the bearing.
CAUTION: D O N O T C L E A N N E W B E A R IN G
A SS E M B LY W IT H A N Y TYPE O F S O LV E N T
Bearing is supplied with correct lubricant when
assembled and requires no other lu brican t a t any time.
TR U C K S UPP O V E R H A U L
A IR C O N D IT IO N IN G COMPRESSOR 1-7
UNIVERSAL HANDLE
J-8092
Remove
1. Remove clutch plate and hub assembly as described in
Compressor Clutch Plate and Hub Asm. Removal
procedure.
ASSEMBLY
Replace
1. Position coil and housing assembly on compressor front
head casting so that electrical terminals line up with
marks previously scribed on compressor (Fig. 17).
F ig . 1 4 --R e m o v in g B e a r in g fr o m P u lle y A s s e m b ly
THIS RIDGE
OF TOOL
MUST BE
UP WHEN
INSTALLING
BEARING
R etainer Ring
SUPPORT
BLOCK
J 21
PULLEY A N D
BEARING
INSTALLER
J9481
F ig . 1 6 -R e m o v in g C o il H o u s in g R e ta in e r R ing
TRUC K S U P P O V E R H A U L
ELECTRICAL
TERMINALS
Fig. 1 7 1n s ta llin g C o il H o u s in g
SHAFT SEAL
Seal Leak Detection
A SHAFT SEAL SHOULD NOT BE CHANGED BECAUSE
OF AN OIL-LINE ON THE HOOD INSULATOR. The seal
is designed to seep some oil for lubrication purposes.
Only change a shaft seal when a leak is detected by the
following procedure .
TRUC K S U P P - O V E R H A U L
A IR C O N D IT IO N IN G COMPRESSOR 1-9
F ig . 1 9 --R e m o v in g S h a ft S e a l S e a t a n d O -R ing
W H E N R E PL A C IN G T H E SH A FT SEAL ASSEMBLY,
even if the compressor remains on the vehicle during the
operation, IT W ILL BE N ECESSARY TO P U R G E TH E
SYSTEM O F R E F R IG E R A N T as outlined earlier in the
Service Manual.
Remove
1. A fter first purging the system of refrigerant, remove the
clutch plate and hub assembly and shaft key as described
in Compressor Clutch Plate and H ub A sm . Removal
procedure.
Inspection
SEALS SHOULD NOT BE REUSED. ALW AYS USE A
NEW SEAL KIT ON REBUILD. Be extremely careful that
the face of the seal to be installed is not scratched or
damaged in any w a y . M ake sure that the seal seat and seal
are free of lint and dirt that could damage the seal surface
or prevent sealing.
Replace
2. Coat the O-ring and seal face of the new seal assembly
with clean 525 viscosity refrigerant oil. Carefully m ount
the seal assembly to Seal Installer J-9392 by engaging
the tabs of the seal with the tangs of the tool (Fig. 20).
TR U C K S UPP - O V E R H A U L
O-RING
-INSTALLER
J-21508
L E A K T E S T superheat
ADAPTER
SHUTOFF
J-9 625
SWITCH
OIL FITTING
SEAL
INSTALLER
J -9 3 9 2 ^
SEAL
PROTECTOR
J-22974
F ig . 2 2 --L e a k T e s tin g A -6 C o m p re s s o r
1 /3 2 " (APPROX.)
l/VIRE GAGE
,026 SHOULD "GO"
.075 SHOULD "NOT GO'
A B S O R B E N T SLEEVE
SLEEVE RETAINER
SEAL SEAT
RETAINER R IN G
SEAL SEAT
O R IN G
SEAL ASSEMBLY
F ig . 2 1 --C o m p re s s o r S h a ft a n d S e a l
seat O-ring and being sure the seal seat makes a good
seal with the O-ring. Remove Seal Protector J-22974
from the end of the shaft (see Fig. 19).
5. Install the new seal seat retainer ring w ith its flat side
against the seal s e a t , using Snap-Ring Pliers J-5403
(# 2 1 ). See Fig. 18. Use the sleeve from Seal Seat
Rem over-Installer J-23128 (Fig. 19) to press in on the
seal seat retainer ring so that it snaps into its groove.
6. Install Compressor Leak Test Fixture J-9625 on rear
head of compressor and connect gage charging lines as
shown for bench test in Fig. 22 or pressurize SUCTION
SID E of compressor on car with Refrigerant-12 vapor
to equalize pressure to the drum pressure. Temporarily
install the shaft nut and, with compressor in horizontal
TRUC K SUP P O V E R H A U L
A IR C O N D IT IO N IN G COMPRESSOR 1-11
HI. PRESS
RELIEF
VALVE
SUPERHEAT
SWITCH
REAR HEAD
INTERNAL M ECHANISM
Service operations to the rear head or internal mechanism
of the compressor should be performed w ith the
compressor removed from the vehicle to insure that the
necessary degree of cleanliness may be maintained. Clean
hands, clean tools and a clean bench, preferably covered with
clean paper, are of extreme importance.
An inspection should be made of the internal mechanism
assembly to determ ine if any service operations should be
performed. A detailed inspection of parts should be made
to determine if it is economically feasible to replace them.
Remove
1. Before proceeding with disassembly, wipe exterior
surface of compressor clean.
2. All oil in compressor should be drained and measured.
Assist draining by positioning compressor with oil drain
plug down. Record the amount of oil drained from
the compressor.
F ig . 2 4 - C o m p r e s s o r In s ta lle d in H o ld in g F ix tu re
T R U C K SUPP - O V E R H A U L
SUPERHEAT
SHUTOFF
SWITCH
A LIN G
SURFACES
U C T IO N SCREEN
EAR HEAD
HELL TO HEAD
O ' R IN G
OIL PUMP
R O TO R S
F ig . 2 8 - R e m o v in g O il P ic k -U p T u b e
F ig . 2 5 - R e a r H e a d R e m o v a l
REAR DISCHARGE
REED RETAINERS
Discard O-ring.
Fig. 2 6 - R e m o v in g R e a r D is c h a rg e V a lv e P la te
Rear
Suction R
F ig . 2 7 - R e m o v in g R e a r S u c tio n R eed
Disassembly
TR U C K S U P P - O V E R H A U L
A IR C O N D IT IO N IN G COMPRESSOR 1-13
F ig . 3 1 - S e p a r a tin g C y lin d e r H a lv e s
CAUTION:
UNDER
NO
CIRCUM STANCES
SH O U LD S H A F T B E STR U C K A T E IT H E R E N D
in an effo rt to separate upper and low er cylinder
TR U C K S UPP - O V E R H A U L
F ig . 3 5 In s ta llin g N e e d le B e a rin g
Thrust Races
SUPPORT
BLOCK J-21352
Fig. 3 4 --R e m o v in g F ro n t T h r u s t R aces a n d B e a rin g s
This
is
necessary
only
on
original
factory
TRUC K SUP P - O V E R H A U L
A IR C O N D IT IO N IN G COMPRESSOR 1-15
PISTON DRIVE
FR O N T TH R UST
RACES
A N D B E A R IN G
REAR NEEDLE
THRUST BEARING
AND "ZERO THRUST
RACES
FRONT CYLINDER
F ig . 3 6 - - ln s ta llin g R e a r T h r u s t R a c e s a n d B e a rin g s
jm
TEFLON RING1
F ig . 3 7 - - ln s ta llin g F R O N T S h o e D is c
TRUC K SUP P O V E R H A U L
16. Now rotate shaft 120 and repeat Step 15 between same
ball and axial plate. Record this measurement.
TR U C K SUPP - O V E R H A U L
A IR C O N D IT IO N IN G COMPRESSOR 1-17
SHOE DISC
PART NO.
ENDING IN
IDENTIFICATION
STAMP
MIN.FEELER
GAGE READING
PART NO.
ENDING IN
IDENTIFICATION
STAMP
DIAL INDICATOR
READING
000
175
180
185
190
195
200
205
210
215
220
0
17-1/2
18
18-1/2
19
19-1/2
20
20-1/2
21
21-1/2
22
.0000
.0175
.0180
.0185
.0190
.0195
.0200
.0205
.0210
.0215
.0220
000
050
055
060
065
070
075
080
085
090
095
100
105
110
115
120
0
5
5-1/2
6
6-1/2
7
7-1/2
8
8-1/2
9
9-1/2
10
10-1/2
11
11-1/2
12
.0000
.0050
.0055
.0060
.0065
.0070
.0075
.0080
.0085
.0090
.0095
.0100
.0105
.0110
.0115
.0120
P O S ITIO N
1
P O S IT IO N
2
P O S IT IO N
3
SELECT
A N D USE
SHOE N O .
P IS TO N N O . 1
.0 1 9 "
.0 1 9 5 "
.0 1 9 "
19
P IS TO N N O . 2
.0 2 0 "
.0 2 0 "
.0 2 0 "
20
P IS TO N NO . 3
.0 2 1 "
.0 2 1 "
.0 2 2 "
21
C lam p J-8001-1
Sleeve J-8001-2
Dial Indicator
J-8001-3
Rear
Rear
Thrust
Races
Thrust
Bearing
TR U C K S U P P O V E R H A U L
Tray J-9402.
25. Remove rear outer ZERO thrust race from shaft and
install thrust race just selected.
The ZERO thrust race may be put aside for re-use in
additional gaging or rebuilding operations.
J-2460 8-3 O -R IN G
INSTALLER GUIDE
TRUC K SUP P O V E R H A U L
A IR C O N D IT IO N IN G COMPRESSOR 1-19
TEFLON RING
Assembly
TR U C K SUP P - O V E R H A U L
1-20 A IR C O N D IT IO N IN G COMPRESSOR
P ISTO N A N D R IN G ASSEMBLY
if**'
....
- -
/V fl
J -2 4 6 0 8 -6 R IN G S IZ IN G TO O L
TRUC K SUP P - O V E R H A U L
A IR C O N D IT IO N IN G COMPRESSOR 1-21
"S E L E C T E D "
REAR TH R U S T RACE
" Z E R O " TH R U S T
RACES. LI FT
S H A F T UPWARD
A N D H O LD TH E
TH R U S T RACES
A N D B E A R IN G
"Z E R O "F R O N T
SHOE DISC
D ischarge
C rosso ver Tube
TH R U S T B E A R IN G
P IS T O N S IN " S T A IR S T E P " P O S IT IO N
BALL AN D
F R O N T A N D REAR.
A X IA L P L A T E
F R O N T T H R U S T R A C ES A N D B E A R IN G S
________ f t ! ________________________
Fig. 5 2 In stallin g 2n d A -6 Piston
the
suction
cross-over
cover
(Fig.
56).
T R U C K SUP P - O V E R H A U L
: i. ''
B U S H IN G
-R IN G
l-ront
R eed P late
O il Return
Slot
SUPPORT BLOCK
J-21352
Fig. 5 8 1n s ta llin g F ro n t S u c tio n Reed
T R U C K SUP P - O V E R H A U L
A IR C O N D IT IO N IN G COMPRESSOR 1-23
Front
Discharge V alve
I
|
Plate Assembly
Front
Head Casting
Front
Discharge Valve
Plate Assembly
SUPPORT BLOCK
J-21352
F ig . 6 1In s t a llin g F r o n t H e a d C a s tin g
Fig . 5 9 - - ln s ta llin g F r o n t D is c h a r g e V a lv e P la te
Suction Reed
Front H ead
O -R in g
Larger Dia. H o le
Rear Discharge
V a lv e Plate
Front Discharge
V a lv e Plate
SUPPORT
BLOCK J-21351
Fig . 6 0 --F ro n t a n d R e a r D is c h a r g e V a lv e P la te s
rear-end
of
F ig . 6 2 - F r o n t H e a d O -R in g In s ta lle d
16. Install rear suction reed over dowel pins, w ith slot
TOW ARDS sump.
TRUC K SUP P - O V E R H A U L
IN N E R GEAR
CAVITY BETWEEN]
GEAR TEETH
(3 O'C LO C K )
j
O IL SUMP
(6 O'C LO C K )
Fig . 6 3 - - In s ta llin g A -6 C o m p re s s o r S h e ll
O IL DR A IN PLUG
F ig . 6 5 --P o s itio n in g O il P u m p G e a rs
F ig . 6 4 I n s ta II i ng O il P ic k -U p T u b e
AND INTERNAL
Bench-Check Procedure
1. Install Test Plate J-9625 on rear head of compressor.
2. A ttach center hose of gage manifold set on Charging
Station to a refrigerant drum standing in an upright
T R U C K SUP P - O V E R H A U L
A IR C O N D IT IO N IN G COMPRESSOR 1-25
F ig . 6 7 -I n s ta 11i n g R e a r H ead
TRUC K SUP P - O V E R H A U L
R4-COMPRESSOR OVERHAUL
GENERAL
When servicing a compressor, it is essential that steps be
taken to prevent dirt or foreign material from getting on or
into compressor parts and system during disassembly or
reassembly of compressor. Clean tools, a clean workbench
and a clean work area are very im portant for proper service.
The compressor connection areas and exterior of compressor
should be cleaned off as much as possible prior to any "on
vehicle" repairs or removing compressor for workbench
service. The parts must be kept clean at all times and any
parts to be reassembled should be cleaned with clean solvent
(trichlorethylene, or Stoddard solvent) and dried with dry
air. W hen necessary to use a cloth on any part, it should be
of a non-lint producing type. Refer to Figure 68 for the
exploded view of the compressor parts and nomenclature.
When a compressor is removed from the vehicle for
servicing, the am ount of oil remaining in the compressor
should be drained through compressor suction-discharge
ports and measured. This oil should then be discarded and
new oil added to the compressor before compressor is again
placed in operation on vehicle. Refer to Figure 5, Section
1A of this manual for compressor oil charge.
If for any reason the R-4 compressor air conditioning hose
assembly is removed from the compressor, care must be
taken to insure that the hose plate is fully seated to the
compressor during re-installation. Should the plate be
cocked and the retainer bolt driven, metal flanges in the
O-Ring cavities could damage the seal surface of the
compressor.
TRUC K SUPP O V E R H A U L
A IR C O N D IT IO N IN G COMPRESSOR 1-27
11
/
m
1. Screw
13.
S u p e r h e a t S w itch
24.
B e lle v ille W a s h e r
2.
L o c k in g W a s h e r
14.
O -R in g
25.
O -R in g
3.
P u lle y Rim
15.
P ressure R e lie f V a lv e
26.
S h e ll Assy.
4.
C o il a n d H o u s in g Assy.
16.
O -R in g
27.
R in g S e a l
5.
R otor B e a rin g
17.
S crew
28.
M a in B e a rin g
6.
18.
S h ip p in g P la te
29.
F ro n t H e a d Assy.
7.
R e ta in in g R ing
19.
O -R in g
30.
S cre w a n d W a s h e r Assy
8. C lu tc h D rive Assy.
20.
R e ta in in g R ing
9.
2 1 . V a lv e P la te Assy.
C lu tc h H u b Key
10. S h a ft N u t
22.
11. C a p
2 3 . T h ru s t W a s h e r
12.
C y lin d e r a n d S h a ft Assy.
31.
O -R in g
32.
S h a ft S e a l
33.
Seal Seat
34.
R e ta in in g R ing
R e ta in in g R in g
F ig . 6 8 - R a d ia l F o u r C y lin d e r C o m p re s s o r - E x p lo d e d V ie w
TRUC K SUP P - O V E R H A U L
D ISC HAR G E
PORT
S U C T IO N
PORT
SUPERHEAT
S W ITC H
J -9 3 9 9
CLUTCH ASSEMBLY
H IG H PRESSURE RELIEF
VALVE
J -2500 8-1
Installation
1. Install shaft key into hub key groove (Fig. 72). Allow
key to project approximately 3/16" out of key way. Shaft
key is curved slightly to provide an interference fit in
shaft key groove, to perm it key projection w ithout
falling out.
2. Be sure frictional surface of clutch plate and clutch rotor
are clean before installing clutch plate and hub
assembly.
3. Align shaft key with shaft key way and assemble clutch
plate and hub assembly on compressor shaft.
CAUTION: To a void internal damage to compressor,
do not drive or pound on clutch hub or shaft.
4. Place spacer bearing J-9480-2 on hub and insert end of
clutch plate and hub assembly installer J-9480-1
through spacer J-9480-2 and thread tool onto end of
compressor shaft (Fig. 73).
5. Hold hex portion of tool body with a wrench and tighten ^
center screw to press hub onto shaft until there is a .020
to .040 inch air gap between the frictional surfaces of
clutch plate and clutch rotor (Fig. 6).
T R U C K SUP P - O V E R H A U L
Pig. 7 4 --R e m o v in g S e a l S e a t
Installation
1. Dip new seal seat "O" ring in clean 525 Viscosity oil
and assemble onto "O" ring installer J-21508 (Fig. 76).
Inspect the inside of compressor neck and shaft area for any
lint, dirt or foreign material and be sure these areas are
perfectly clean before installing new seal parts. Be sure seal
TR U C K SUP P - O V E R H A U L
TR U C K SUP P - O V E R H A U L
J -2 5 0 3 1 -2
J-25031-1
LO C K IN G WASHER
SCREW
1-32 A IR C O N D IT IO N IN G COMPRESSOR
Installation
1. Assemble clutch coil, pulley rim and clutch rotor and
bearing assembly as shown in Figure 80, using Loctite
RC-75 or equivalent on screw threads and using new
lockwashers, but do not lock screw heads in place.
2. Place assembly on neck of front head and seat into place
using rotor bearing remover and rotor assembly installer
J-25029 as shown in Figure 84. Before fully seating the
assembly on front head, be sure the clutch coil terminals
are in the proper location in relation to compressor and
that the three protrusions on the rear of the clutch coil
align with the locator holes in front head.
3. Install rotor and bearing assembly retaining ring and
reassemble clutch plate and hub assembly.
4. R otate pulley rim and rotor to be sure pulley rim is
rotating "in line" and adjust or replace as required.
Tighten pulley rim m ounting screws to 100 inch pounds
torque and lock screw heads in place.
TR U C K S UPP - O V E R H A U L
A IR C O N D IT IO N IN G COMPRESSOR 1-33
S P A C E R -U S E
PIECE O F F L A T
S TO C K
J 25029
ROTO R AND
B E A R IN G A S M .
IN S T A L L E R
J 25008-1
H O L D IN G
F IX T U R E
Installation
1. Check front head and compressor cylinder area for any
dirt or lint and install a new thrust washer kit if
required.
2. Dip new front head seal ring in 525 Viscosity oil and
install seal in seal groove of front head (Fig. 87).
3. Position oil hole in front head to be "up" when
assembled to compressor cylinder to correspond with
"up" position of compressor. Install front head on
compressor shaft. Be sure seal ring stays in place and
front head seats correctly to cylinder. Tighten front
head mounting screws to 18-22 foot pounds.
4. Install a new compressor shaft seal.
5. Install clutch rotor and bearing assembly, clutch coil
and pulley rim assembly to front head (Fig. 84). Before
fully seating the assembly on front head be sure clutch
coil terminals are in the proper location in relation to
compressor and that the three protrusions on rear of
clutch coil align with the locator holes in front head.
6. Install rotor and bearing assembly retaining ring and
reassemble clutch plate and hub assembly.
7. Leak test compressor as described under "Leak Testing
the Compressor" and correct any leaks found.
T R U C K SUP P - O V E R H A U L
1-34 A IR C O N D IT IO N IN G COMPRESSOR
FR ON T H EAD
J-8092
J -2 5 0 2 9
F R O N T H EA D
SEAL R IN G
M A IN B E A R IN G
THR UST A N D
BELLEVILLE W A S H E R S
M A IN BEARING REPLACEMENT
Removal
1. Remove front head assembly.
2. Place front head assembly on two blocks (Fig. 89) and
using main bearing remover J-24896 drive bearing out
of front head.
Installation
1. Place front head with neck end down on a flat, solid
surface.
TR U C K SUP P - O V E R H A U L
J-24895
M A IN
BEARING
BELLEVILLE
W A SH ER
THRUST
W A SH ER
SHELL
R ETAIN IN G STRAP
J -2 4 8 9 6
FRONT HEAD
ill
\VJH
..iL r
Fig. 8 9 -R e m o v in g M a in B earin g
TR U C K S UPP - O V E R H A U L
P IS T O N A N D
REED A S S E M B L Y
Installation
1. Remove old cylinder to shell "O" rings and discard.
Check compressor assembly and interior of compressor
shell to be sure they are free of lint or dirt.
2. Dip a cylinder to shell "O" ring in 525 Viscosity oil and
install in rear "O" ring groove of cylinder. Be careful
in moving "O" ring across cylinder surface to prevent
damaging "O" ring.
TRUC K SUP P - O V E R H A U L
a hammer.
9. Remove shell installing fixture J-25008-2 and leak test
compressor.
OIL CHARGE
The radial four cylinder compressor is charged with 6.0
ounces of 525 viscosity oil. During normal operation a
certain amount of oil will circulate with the Refrigerant 12
(R-12) in the system.
When necessary to replace a system component it is
recommended that oil be added to the system in accordance
to the following procedure.
If compressor is operable, idle vehicle for 10 minutes with
the A /C controls set for Maximum Cooling and High
Blower prior to discharging the system.
Add additional oil as indicated in Section 1A of this manual.
TR U C K S UPP - O V E R H A U L
1-38 A IR C O N D IT IO N IN G COMPRESSOR
SPECIAL TOOLS
1.
2.
3.
4.
5.
6.
7.
8.
9.
J -8 3 9 3
J -2 4 0 9 5
J -5 4 5 3
J -9 4 5 9
J -2 5 4 9 9
J -5 4 2 0
J -2 5 4 9 8
J -6 0 8 4
J -8 4 3 3
J -9 3 9 5
J -2 3 5 9 5
10. J-6 2 7 1 -0 1
C h a rg in g S ta tio n
O il In d u c e r
G o g g le s
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 D e te cto r
P u lle r
P u lle r P ilo t
R e frig e ra n t C an V a lv e
(S id e -T a p )
R e frig e ra n t C an V a lv e
(T o p -T a p )
11.
12.
13.
14.
J-5 4 2 1 -0 2
J-5 40 3
J-6 4 3 5
J -9 3 9 6
15. J -2 5 0 3 0
16. J-9 40 3
17. J-9 3 9 9
18. J-9401
19. J-9 48 0 -0 1
2 0. J-9 3 9 2
2 1. J-2 3 1 2 8
P ocket Th e rm om e te rs (2)
N o . 21 S n a p Ring P liers
N o . 26 S n a p R ing P liers
C om p re sso r H o ld in g
F ix tu re
C om p re ssin g F ix tu re
C lu tc h H u b H o ld in g Tool
9 /1 6 " Thin W a ll Socket
H u b a n d D rive P la te
A sse m bly Rem over
H u b a n d D rive P la te
A sse m bly In s ta lle r
S eal Rem over
S e a l S e a t Rem over
22.
23.
24.
25.
J -9 3 9 8
J-9481
J -8 0 9 2
J -2 1 3 5 2
29. J -2 1 5 0 8
30. J -2 2 9 7 4
3 1 . J -9 6 2 5
3 2 . J -9 4 0 2
In s ta lle r
S h a ft S e a l P ro te c to r
Pressure Test C o n n e c to r
Parts T ra y
26. J -5 1 3 9
27. J -9 4 3 2
2 8 . J -9 5 5 3 -0 1
Fig. 9 6 - A i r C o n d it io n in g S p ec ia l T o ols
, \i
T R U C K SUP P - O V E R H A U L
S E C T IO N 3
FRONT AXLE
K10, K20 FRONT AXLE
INNER OIL SEAL INSTALLATION TOOL
The procedure for oil seal replacement on page 3-1 of the
1974 Overhaul Manual should be revised to include special
tool J -25 111 for installing the oil seals. The seals are
illustrated as item 28 in figure 1 below:
Fig. 1 ~ ln n e r O il S eal
S E C TIO N 4
Modification
The differential shown on page 4-55 of the 1974 Overhaul
M anual has been modified for some vehicles . For these
modified units,
TR U C K S U P P - O V E R H A U L
4-2
SOURCE
TYPE /C A PA C ITY
RING GEAR
SIZE
C10
C hevrolet
S a lis b u r y /3 7 5 0 #
K10
C h evrolet
S a lis b u r y /3 7 5 0 #
8 -7 /8
K10
C h evrolet
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 ry /3 5 0 0 #
8 -7 /8
G10
C h evrolet
S a lis b u ry /3 1 0 0 #
8 -7 /8
G10
C h e v ro le t
S a lis b u ry /3 1 0 0 #
8 -1 /2
MODEL
8 - 7 /8 "
C20
(Except
Crew
Cab)
C hevrolet
S a lis b u r y /5 7 0 0 #
1 0 -1 /2
C20
(Crew Cab)
C h e vro 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 ry /5 7 0 0 #
1 0 -1 /2
P20
C h e v ro le t
S a lis b u ry /5 7 0 0 #
1 0 -1 /2
G20
C h e vro le t
S a lis b u r y /3 5 0 0 #
8 - 7 /8 "
C30
Dual
Wheel
Camper)
(Dual
Wheel
Camper)
P30
p
(With
H22/H 23)
G30
_n
030
___
G30
(Dual
Wheel)
(Dual
Wheel)
C h e vro le t
S a lis b u ry /7 5 0 0 #
1 0 -1 /2 "
Dana
S a lis b u ry /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 ry /6 2 0 0 #
9 -3 /4
Dana
S a lis b u ry /7 5 0 0 #
1 0 -1 /2 "
Fig. 1 -A x le C h a rt
THE IN D IC A TO R NEEDLE
WILL MOVE TOWARD. . . .
TR U C K SUP P - O V E R H A U L
S E C T IO N 5
BRAKES
The 1976 brake boosters are essentially the same as those described in the
1974 Overhaul M anual, with the following exceptions.
GAUGING
All 1976 master cylinders incorporate shallow socket
prim ary pistons; therefore, all gauging procedures should
incorporate the use of Gauge J-22647.
T R U C K SUP P - O V E R H A U L
5-2
BRAKES
BENDIX
HYDRAULIC BRAKE BOOSTER (HYDRO-BOOST)
IN D E X
Disassembly............................................................................................5-2
Cleaning and Inspection.................................................................... ..5-3
A ssem bly............................................................................................... .5-4
OVERHAUL OPERATIONS
The Bendix H ydraulic Brake Booster utilizes the hydraulic
pressure supplied by the power steering pump to provide
power assist for brake applications (fig. 3). The dual master
cylinder is m ounted to the output push rod end of the
booster.
The procedures below include removal of the mounting
bracket even though it is not necessary to remove the bracket
for overhaul of the internal assembly.
Disassembly (Fig. 4)
1. Secure the booster in a vise (bracket end up) and use
a ham m er and chisel to cut the bracket nut that secures
the mounting bracket to the power section (cut the nut
at the open slot in the threaded portion of the housing).
Be careful to avoid damage to the threads on the booster
hub. Spread the nut and remove it from the power
section. Then remove the mounting bracket.
PRESSURE PORT
RETURN PORT
PEDAL ROD
ACCUMULATOR
MOUNTING BRACKET
OUTPUT PUSH ROD
11. Remove the booster assembly from the vise and while
holding the unit over a pan, separate the cover from the
housing. Remove the large seal ring from the groove in
the cover; discard the seal.
12. Remove the input rod and piston assembly, and the
spool assembly from the booster housing.
TRUC K SUP P - O V E R H A U L
BRAKES 5-3
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Plunger Seat
" 0 " Ring Seal
Plunger
Spacer
Check V a lv e Ball
A c c u m u la to r C heck V alve
" 0 Ring Seal
Piston Seal
Booster Housing
T u b e Seat Inserts
21 .
22 .
23 .
24 .
25 .
26 .
27.
28.
29 .
O u tp u t Push R od
Push Rod R etainer
S pool Spring
Plug " 0 Ring
S pool Plug
Snap Ring
Piston R etu rn Spring
Spring R etainer
Housing to C over Bolts
Fig. 4 - P o w e r B o o ste r C o m p o n e n ts (T y p ic a l)
13. Remove the input rod seals from the input rod end, and
the piston seal from the piston bore in the housing;
discard the seals.
14. Remove the plunger, seat, spacer and ball from the
accum ulator valve bore in the flange of the booster
housing. Remove the "O" ring from the seat; discard
the "O" ring.
15. Thread a screw extractor into the opening in the check
valve in the bottom of the accum ulator valve bore, and
remove the check valve from the bottom of the bore.
Discard the check valve and "O" ring.
NOTE: Using a screw extractor damages the seat in
the check valve. A new charging valve kit must be
installed whenever the check valve is removed from the
accum ulator valve bore.
16. Use a 1/4" or a 5/16" spiral flute type screw extractor
to remove the tube seats from the booster ports.
TR U C K S U P P O V E R H A U L
5-4 BRAKES
(T y p ic a l)
Assembly
CAUTION: Be sure to keep parts clean until
reassembly. Re-wash at reassembly if there is any
occasion to doubt cleanliness - such as parts dropped
or left exposed for eight hours or longer.
Lubricate all seals and metal friction points with
power steering fluid.
TRUC K SUP P O V E R H A U L
BRAKES 5-5
T R U C K SUP P - O V E R H A U L
5-6
BRAKES
SPECIAL TOOLS
m m m hm m m m u
awp i
in
'i
(dltaH H i
B fjp ^ r r g r *
i |
14
L
11
I
17
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
J-4880
J-25085
J-21183
J-21524
J-21601
J-22657
J-22647
J-22677
J-22733
J-22805
11. J-22839
12. J-22893
13. J-23101
14. J-23175
15. J-23188
16. J-24551
17. J-24553
18. J-24554
19. J-24569
20. J-9504
Fig. 1 0 -S p e c ia l To ols
TRUC K SUP P - O V E R H A U L
S E C T IO N 6
ENGINE
REPAIR PROCEDURES
CAM SH AFT
Inspection
W hen checking the camshaft for alignment, using the "V"
block method, the dial indicator will indicate the exact
am ount the cam shaft is out of true. If it is out more than
.001" dial indicator reading, the camshaft should be
replaced.
REPAIRS
Piston Selection
Piston-to-bore clearance for all engines is increased by
.0010" for 1976. Refer to page 6-35 (fig. 74) in the 1974
Overhaul Manual.
T R U C K SUP P - O V E R H A U L
'" I
S E C T IO N 6 M
CARBURETOR
C O N T E N T S OF T H IS S E C T IO N
In tro d u ctio n ............................................................................................ 6M -1
Rochester 1M V.................................................................................... .. 6M-1
Rochester 2G C..................................................................................... 6M-5
Rochester 4M V .................................................................................... .. See Introduction
Rochester M 4M C /M 4M E ................................................................. .. 6M-11
Special T o o ls......................................................................................... 6M-20
INTRODUCTION
A carburetor is designed to meet the particular requirements
of the engine, transmission and vehicle and although they
may look alike, they are not always interchangeable. Refer
to carburetor part num ber a n d /o r specifications.
ROCHESTER 1M V CARBURETOR
IN D E X
Disassembly........................................................................................... ..6M -1
Cleaning and Inspection.......................................................................6M-4
A ssem bly..................................................................................................6M-4
Special T o o ls...........................................................................................6M-20
DISASSEMBLY
Air Horn
from choke rod and choke rod from upper choke lever
Removal
reassembly.
NOTE: U pper choke lever is spun on end of choke
shaft and cannot be removed.
3. Remove six air horn to bowl attaching screws and
lockwashers (three long and three short screws).
'
TRUC K S U P P - O V E R H A U L
6M -2
C ARBURETOR
Disassembly
1. If desired, the choke valve and choke shaft can be
removed from air horn by first removing the
therm ostatic coil lever from the end of choke shaft by
removing attaching screw.
PRESSURE RELIEF
VALVE DISC
A U XILIARY V A C U U M
BREAK D IA P H R A G M
F ig . 1 - A ir H o rn A s s e m b ly
CHOICE SHAFT AN D
LEVER ASSEMBLY
AUXILIARY CHOKE
VACUUM BREAK
DIAPHRAGM
PUMP
LEVER
PRIMARY CHOKE
VACUUM BREAK
DIAPHRAGM
CHOKE ROD
FUEL
FILTER
Fig. 2 - 1 M V C a r b u r e t o r
IDLE MIXTURE
SCREW A N D
LIMITER CAP
Fig. 3 - F l o a t B o w l A s s e m b ly
TR U C K S U P P - O V E R H A U L
C AR BURETOR
6M -3
ACCELER ATO R
PUM P P LUN G ER
IDLE
M A IN W ELL
TU B E
BLEED
H IN G E P IN
POW ER
P IS T O N
FLO A T
M E T E R IN G
ROD
PUMP
D IS C H A R G E
S P R IN G
Fig. 4 - F lo a t a n d A c c e le r a to r P u m p
in lever.
F ig . 5 - R e m o v in g P u m p D is c h a rg e S p rin g
mixture needle, cut the tang from the plastic limiter cap.
readjusted.
TH R O TTLE
TH R O TTLE
V A LV E
17. Remove the fuel inlet nut and gasket; then, remove the
filter and relief spring.
No further disassembly of the float bowl is required.
SPAR K
PORTS
Fig. 6 - T h r o t t l e B od y A s se m b ly
TR U C K S UPP - O V E R H A U L
6M -4
C AR BURETOR
ASSEMBLY
T h ro ttle Body
1. Invert float bowl and install new throttle body to bowl
insulator gasket.
2. Install throttle body on bowl gasket so that all holes in
throttle body are aligned with holes in gasket.
3. Install two throttle body to bowl attaching screws and
lockwashers. Tighten even and securely to 15 ft. lbs.
Float Bowl
F ig . 7 - F lo a t L e ve l A d ju s tm e n t
T R U C K SUP P - O V E R H A U L
C A R BU RE TO R
F LO A T BOWL
SURFACE
(GASKET R EM OVED)
Air Horn
1. Install choke shaft assembly and choke valve into air
horn, if removed. Align choke valve, tighten two
retaining screws and stake securely or use Loctite or
equivalent.
2. Install air horn to float bowl by lowering gently onto
float bowl until seated. Install three long and three short
air horn to float bowl attaching screws and lockwashers.
Tighten screws securely.
Install the prim ary choke vacuum break diaphragm
assembly under the two short air horn screws next to
the therm ostatic coil lever. Connect the choke vacuum
break diaphragm link to slotted diaphragm plunger
stem and install lever to the end of the choke shaft, using
retaining screw. Tighten all screws securely.
PLUG GAUGE
BENDING TOOL
H O LD POWER
PISTON D O W N '
6 M -5
5. Install iow er end of choke rod into fast idle cam. Steps
on fast idle cam should face fast idle tang on throttle
lever. Install fast idle cam to, boss on float bowl with
attaching screw. Tighten securely.
6. Install auxiliary vacuum break diaphragm link attached
to the choke lever to slot in the diaphragm plunger stem.
Then, install the auxiliary vacuum break diaphragm
unit to air horn using two attaching screws. Tighten
securely.
Fig. 8 - M e te r in g Rod A d ju s tm e n t
ROCHESTER 2GC
INDEX
G eneral................................................................................................... ..6M-6
Disassembly........................................................................................... ..6M-6
Cleaning and Inspection.......................................................................6M-8
A ssem bly..................................................................................................6M-9
Special T o o ls...........................................................................................6M-20
TRUC K SUP P - O V E R H A U L
6M -6
C AR BU RETOR
GENERAL
Flooding, stumble on acceleration and other performance
complaints are, in m any instances, caused by the presence
of dirt, water or other foreign m aterial in the carburetor. To
aid in diagnosing the cause of complaint, the carburetor
should be carefully removed from the engine without
draining fuel from the bowl. The contents of the fuel may
then be examined for dirt or water problems as the
carburetor is disassembled.
The following is a step-by-step sequence by which the model
2GC carburetor (Fig. 1C) may be completely disassembled
and reassembled. Adjustments may be made and various
parts of the carburetor may be serviced without completely
disassembling the entire unit. Refer to service section for
external adjustments.
SPR IN G
LIP
AIR H O R N
S'
ACCELERATO R
PU M P ROD
FUEL INLET
THROTTLE
LEVER
C H O K E HEAT INLET
PURG E TUBE
Fig. 1 C -F to ch e ster 2 G C C a rb u re to r
DISASSEMBLY
Air Horn
1. Remove fuel inlet filter nut and gasket, and remove filter
and spring.
2. Disconnect lower end of pump rod from throttle lever
by removing spring clip (Fig. 2C).
3. Remove upper end of pump rod from pump lever by
rotating rod out of hole in lever.
4. Remove the vacuum break diaphragm hose from tube
on throttle body and tube on vacuum break diaphragm
unit. Then remove the vacuum break diaphragm
assembly from air horn by removing two attaching
screws. Remove diaphragm and link assembly from
lever on end of choke shaft.
5. Remove vacuum break lever from end of choke shaft by
removing retaining screw in end of shaft. Then, remove
the interm ediate choke rod from the vacuum break lever
and from the lever on the therm ostatic coil housing.
6. Remove fast idle cam attaching screw from side of float
bowl. Remove fast idle cam from end of choke rod by
rotating rod out of hole in fast idle cam. The upper end
Fig. 3 C - R e m o v i n g A ir Horn
T R U C K SUP P O V E R H A U L
C AR BU RETOR
6 M -7
INNER PUMP
LEVER
ACCELERATING
PUMP ASSEMBLY
SCREW (B)
M A IN
M ETERING
JET
FLOAT
UMP PLUNGER
RETURN SPR IN G
PUMP INLET
CHOKE VALVE
FLOAT
HINGE PIN
ruw cR
VALVE
NEEDLE
AND SEAT
Fig . 5 C - F lo a t B o w l
F ig . 4 C - A ir H o rn
ADJUSTABLE
PART THROTTLE
FUEL INLET
Throttle Body
1. Remove the three choke cover attaching screws and
retainers, then remove therm ostatic coil and cover
assembly and gasket from choke housing (Fig. 7C).
PLASTIC M A IN
WELL INSERT
Float Bowl
1. Remove pump plunger return spring from inside pump
well. Then remove aluminum check ball from bottom
of pump well by inverting bowl (Fig. 5C).
SPRING
RETAINER
TR U C K S UPP - O V E R H A U L
6M -8
C AR BU RETOR
O FF-ID LE
D IS C H A R G E PORT
!DLE M'XTURE
CHOKE
CO VER
SC R EW (3 )
E
H O U S IN G
SPEED
SCR EW
CHOKE
VACUUM
TUBE
R ETA IN ER (3)
FIXED IDLE
A IR BLEED
INTERM EDIATE
C H O K E LEVER
F ig . 7 C - T h r o ttle B o d y
F ig . 9 C - C h o k e H o u s in g
CAUTION:
b. Check float lip for wear and float for damage. Repair
or replace as necessary.
SCREW
BAFFLE
PLATE
Fig. 8 C - C a r b u r e t o r C h o k e
TR U C K S U P P - O V E R H A U L
C AR BURETOR
6M -9
3. Drop small alum inum inlet check ball into hole in pum p
well, install pump return spring, pressing with finger to
center in pump well.
ASSEMBLY
Throttle Body
1. Install idle speed screw and spring assembly in throttle
body if removed (Fig. 7C).
2. If it was necessary to remove the idle mixture needles,
install the idle m ixture needles and springs into the
throttle body until finger tight and seated. Back out
screws four turns as a preliminary idle adjustment.
3. Install new rubber dust seal into cavity inside choke
housing (Fig. 9C). Lip on seal faces towards carburetor
after the housing is installed.
4. Install inner choke coil lever and shaft assembly into
choke housing.
5. W ith the choke coil lever and shaft assembly installed
into housing, install the interm ediate choke lever on
flats of intermediate choke shaft and retain with screw.
Tighten securely.
6. Install new choke housing to carburetor gasket.
7. Position choke housing on throttle body and retain with
two attaching screws. Tighten securely (Fig. 8C).
8. Before installing the choke cover coil and baffle plate
assembly, refer to interm ediate choke rod adjustment
(Service) to adjust interm ediate choke rod so that with
the choke valve closed, the lever inside the choke
housing lines up with gauge.
9. Install choke therm ostatic coil and cover assembly with
new gaskets and end of coil below plastic tang on the
inner choke housing lever. Refer to autom atic choke coil
adjustm ent (Service) to index cover. Install three choke
therm ostatic coil retainers and screws. Tighten securely
(Fig. 1C).
10. Place a new gasket on the bottom of the float bowl with
holes in gasket aligned with holes in casting, then
position the throttle body on gasket and install the three
attaching screws. Tighten screws evenly and securely.
Float Bowl
1. Install two main metering jets into bottom of float bowl
(Fig. 5C).
2. Install power valve and gasket into bottom of float bowl
using slotted screwdriver. Tighten securely.
5. Install plastic main well inserts into the main fuel wells
located beneath the venturi cluster and make sure they
are seated in recesses provided (Fig. 6C). Then install
venturi cluster and gasket, tighten three screws evenly
and securely. M ake certain center screw is fitted with
a gasket to prevent pum p discharge leakage.
TRUC K SUP P - O V E R H A U L
6M -10
C ARBURETOR
(3 )V IS U A L L Y C H EC K
FO R FL O A T A LIG N M E N T
F ig . 1 2 C - A ir H o rn T ig h te n in g S e q u e n c e
T R U C K SUP P - O V E R H A U L
C AR BU RETOR
6M -11
M 4 M C /M 4 M E QUADRAJET CARBURETOR
IN D E X
G eneral................................................................................................... .. 6M-11
Disassem bly........................................................................................... .. 6M -11
Cleaning and Inspection....................................................................... 6M-16
A ssem bly...................................................................................................6M-17
Special T ools............................................................................................6M-20
GENERAL
Before performing any service on the carburetor, it is
essential that the carburetor be placed on a holding fixture
such as Tool J-8328. W ithout the use of the holding fixture,
it is possible to bend or nick throttle valves (Fig. 1MQ and
1MQ-A).
DISASSEMBLY
Fig. 1 M Q - M 4 M C Q u a d r a j e t C a r b u r e t o r
Air Horn
1. Remove upper choke lever from the end of choke shaft
by removing retaining screw (Fig. 2MQ). 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 outward with small
screwdriver and twisting rod counterclockwise.
3. Remove secondary metering rods by removing the small
screw in the top of the metering rod hanger. Lift upward
on metering rod hanger until the secondary metering
rods are completely out of the air horn. Metering rods
may be disassembled from the hanger by rotating ends
out of the holes in the end of the hanger. (Fig. 3MQ).
4. Using special tool J-25322, drive small roll pin (pump
lever pivot pin) inward just enough until pump lever can
be removed from air horn. Then remove pump lever
from pump rod (Fig. 4MQ).
Fig. 1 M Q - A - - M 4 M E Q u a d r a j e t C a r b u re t o r
TR U C K SUP P - O V E R H A U L
6M -12
C AR BU RETOR
P U M P LEVER
Fig . 2 M Q - R e m o v in g U p p e r C h o k e L e v e r
F ig . 4 M Q - R e m o v in g P u m p L e ve r
Fig. 3 M Q - R e m o v i n g S e c o n d a r y M e te r in g Rods
TR U C K S U P P - O V E R H A U L
C AR BU RETOR
6M -13
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 distort springs
holding the main metering rods (Fig. 8MQ).
2. Remove pump plunger from pump well.
3. Remove pum p return spring from pump well.
4. Remove power piston and metering rods by depressing
piston stem and allowing it to snap free (Fig. 9MQ).
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.
F ig . 6 M Q -R e m o v in g A ir H o rn
Fig. 7 M Q - R e m o v i n g Fron t V a c u u m B re ak
TRUC K SUP P - O V E R H A U L
6M -14
C A R BU RE TO R
R E T A IN IN G
F ig . 1 1 M Q - F lo a t A s s e m b ly
4 M
M o d e l
W ith
R e a r
V a c u u m
B r e a k
carburetor cleaner.
R E TA IN IN G
SPRING
METERING
ROD
POWER
PISTON
POWER
PISTON
SPRING
TRUC K SUP P O V E R H A U L
C AR BU RE TO R
PUMP DISCHARGE
6M -15
Fig. 1 3 M Q - F lo a t B o w l J e ts
Choke
1. Remove three attaching screws and retainers from
choke cover and coil assembly. Then pull straight
outw ard and remove cover and coil assembly from
choke housing. Remove choke cover gasket, if used.
CHOKE
H O U S IN G
Fig. 1 4 M Q - R e a r V a c u u m B re ak
A T T A C H IN G
SCREW
Fig. 1 5 M Q - R e m o v i n g C h o k e Housing
TRUC K S U P P O V E R H A U L
6M -16
C AR BU RETOR
ATTACHING
SCREWS
TUBE SEAL
REAR VACUUM
BREAK LEVER
FAST
IDLE
CAM
LOCKOUT
PIN
SECONDARY
LOCK OUT
LEVER
FAST IDLE
CAM FOLLOWER
INTERMEDIATE
CHOKE SHAFT
F ig . 1 8 M Q -R e m o v in g T h r o tt le B o d y
F ig . 1 6 M Q - C h o k e H o u s in g A s s e m b ly
FILTER
SPRING
Fig. 1 7 M Q - F u e l Filter
Fig. 19 M Q - R e m o v i n g In s u la to r G a s k e t
TR U C K SUP P - O V E R H A U L
CAR BU RETOR
passages.
3. Examine float needle and seat for wear. Replace, if
necessary, with new float needle and seat assembly.
4. Inspect upper and lower surfaces of carburetor castings
for damage.
5. Inspect holes in levers for excessive wear or out of round
conditions. If worn, levers should be replaced.
6. Examine fast idle cam for wear or damage.
7. Check air valve for binding conditions. If air valve is
damaged, air horn assembly m ust be replaced.
8. Check all throttle levers and valves for binds or other
damage.
ASSEMBLY
Throttle Body
1. If removed, install idle m ixture needles and springs until
seated. Back out the mixture needles 4 turns as a
preliminary idle adjustment. Final adjustm ent must be
made on the engine using the procedures described
under slow idle adjustment.
2. Install lower end of pum p rod in throttle lever by
aligning tang on rod with slot in lever. End of rod should
point outwards towards throttle lever.
6M -17
Float Bowl
M 4 M E M odel W ith Rear Vacuum Break
1. Holding down on fast idle cam (hot idle position), install
end of vacuum break rod in hole in intermediate choke
lever.
2. Install end of vacuum break rod in slot in rear vacuum
break plunger head. Then install rear vacuum break
control and bracket assembly to float bowl using two
attaching screws (Fig. 14MQ). Tighten securely.
NOTE: Do not attach vacuum break hose until after
the vacuum break adjustm ent is complete. Refer to
Service Section for adjustm ent procedure.
A ll Models
3. If removed, install air baffle in secondary side of float
bowl with notches tow ard the top. Top edge of baffle
must be flush with bowl casting.
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 interm ediate choke shaft
(steps on fast idle cam face downward) (Fig. 16MQ).
5. Carefully install fast idle cam and interm ediate choke
shaft assembly through seal in choke housing; then
install therm ostatic coil lever onto flats on intermediate
choke shaft. Inside therm ostatic choke coil lever is
TRUC K SUP P - O V E R H A U L
6M -18
C AR BU RETOR
Air Horn
1. If removed, install choke shaft, choke valve, and two
attaching screws. Tighten screws securely and stake
lightly in place.
2. Check choke valve for freedom of movement and proper
alignment before staking screws in place.
2. Install two long air horn screws, five short screws, and
two coutersunk screws into prim ary venturi area.
All air horn screws must be tightened evenly and
securely. See Figure 5MQ for proper tightening
sequence.
3. Install vacuum break diaphragm rod into the slot in
lever on the end of the air valve shaft. Then install the
other end of rod into hole in the front vacuum break
diaphragm plunger. Install front vacuum break control
and bracket assembly to air horn using two retaining
screws through the bracket. Tighten screws securely.
NOTE: Do not attach vacuum break hose until
vacuum break adjustment is completed. Refer to
Service Section for adjustm ent procedure.
4. Connect upper end of pump rod to pump lever by
placing rod in specified hole in lever. Align hole in pump
lever with hole in air horn casting using J-25322. Using
small screwdriver, push pump lever roll pin back
TR U C K SUP P O V E R H A U L
C AR BU RETOR
6M -19
G A U G E FR O M TO P OF C A S T IN G TO TOP
OF FLO AT G A U G IN G P O IN T 3 / 1 6 BACK
F R O M END OF FLO AT A T TOE (SEE INSET)
(IN S E T)
G A U G IN G P O IN T
( 3 / 1 6 BACK
FR O M TOE)
P U S H FLOAT D O W N
L IG H T L Y A G A IN S T NEEDLE
( 5 ) V IS U A L L Y CHECK FLO AT A L IG N M E N T
W AFTER A D J U S T IN G
Fig . 2 2 M Q - F lo a t Le ve l A d ju s tm e n t
6M -20
C ARBURETOR
SPECIAL TOOLS
C---
TRUC K S U P P - O V E R H A U L
S E C T IO N 6 Y
ENGINE ELECTRICAL
NOTE: Except for the following changes, all information listed in Section
6Y o f the 1974 Light Duty Truck Overhaul Manual is applicable to 1976
light duty trucks. Refer to 1974 Overhaul Manual for any overhaul
procedure not contained herein.
STARTING MOTOR
The 1976 starter is mostly carryover from 1974. The only difference being
that the R terminal of the starter solenoid has been removed. This
terminal was removed because with the High Energy Ignition System there
is no longer any requirement for the electrical lead from the starter
solenoid to the ignition coil. Refer to Section 6Y of the 1974 Overhaul
Manual for all overhaul procedures.
STARTING SOLENOID
The 1976 starter solenoid is mostly carryover from 1974. The only
difference being that the R terminal of the solenoid has been removed.
This terminal was removed because with the High Energy Ignition System
there is no longer any requirement for the electrical lead from the starter
solenoid to the ignition coil. Refer to Section 6Y of the 1974 Overhaul
Manual for all overhaul procedures.
SECTION 7M
MANUAL TRANSMISSIONS
CONTENTS OF THIS SECTION
3-Speed Tremec Transm ission.......................................................... 7M-1
4-Speed M uncie Transmission (CH 465)....................................... 7M-12
New Process Transfer Case Model 2 0 3 ......................................... 7M-15
G ears................................................................................7M-4
Repairs...............................................................................7M-4
Synchronizer Keys and Spring..................................7M-4
Extension Oil Seal or B ushing..................................7M-5
Clutch Bearing Retainer Oil Seal............................. 7M-6
M ainshaft A ssem bly........................................................ 7M-6
Transmission A ssem bly...................................................7M-8
OVERHAUL OPERATIONS
TRAN SM ISSIO N DISASSEMBLY
1. Remove lower extension housing bolt and drain
transmission (fig. 3R).
2. Remove top cover and gasket from case.
Fig. 1 R -3 -S p e e d T re m e c
TR U C K SUPP - O V E R H A U L
7M -2
M A N U A L TRA N S M IS SIO N
M AINSHA FT DISASSEMBLY
1. Remove snap ring from front of output shaft and
remove Second-Third synchronizer assembly and
second gear. M ark hub and sleeve for correct assembly.
2. Remove snap ring and tabbed thrust washer from shaft
and remove first gear and blocking ring.
3. Remove First-Reverse hub retaining snap ring.
NOTE: Observe position of spring and keys before
removal, also, m ark hub and sleeve for correct
assembly.
4. Remove sleeve and gear, spring and three keys from hub
(fig. 13R).
5. Using an arbor press, remove hub from output shaft.
18. Remove the bottom detent plug and short detent spring
from case.
TRUC K S U P P - O V E R H A U L
M A N U A L TRA N S M IS SIO N
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.
3 \.
32.
33.
34.
M A IN SH A FT ROLLER BEARINGS
2ND & 3RD SYNCHRONIZER RETA IN IN G RING
SYNCHRONIZER BLOCKER RINGS
2ND & 3RD SYNCHRONIZER SPRING
2ND & 3RD SYNCHRONIZER SLEEVE
2ND & 3RD SYNCHRONIZER KEYS
2ND & 3RD SYNCHRONIZER HUB
SECOND SPEED GEAR
1ST SPEED GEAR R ETA IN IN G RING
1ST SPEED GEAR TABBED WASHER
1ST SPEED GEAR
REVERSE SYNCHRONIZER SPRING
1ST & REVERSE SYNCHRONIZER SLEEVE & GEAR
REVERSE SYNCHRONIZER KEYS
1ST & REVERSE SYNCHRONIZER HUB
1ST & REVERSE SYNCHRONIZER RETA IN IN G RING
REAR BEARING RETA IN IN G RING
TRANSMISSION M AINSHAFT
REVERSE-SYNCHRONIZER ASSEMBLY
ACCESS COVER BOLTS
ACCESS COVER
ACCESS COVER GASKET
BEARING R E T A IN E R -T O CASE BOLTS
BEARING RETAINER CLUTCH GEAR
GASKET - CLUTCH GEAR BEARING RETAINER
SEAL ASSEMBLY - CLUTCH GEAR BEARING RETAINER
CLUTCH GEAR BEARING RETAIN ING RING
CLUTCH GEAR BEARING LOCK RING
CLUTCH GEAR BEARING ASSEMBLY
CLUTCH GEAR
EXPANSION PLUG
FILLER PLUG
TRANSMISSION CASE MAGNET
CASE
35.
36.
37.
38.
39.
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.
7M -3
T R U C K SUP P - O V E R H A U L
7M -4
M A N U A L T R A N S M IS SIO N
NOTE: A L IG N ROLL
PIN HOLE WHEN
IN S T A L LIN G
DU M M Y SH A FT
TOOL J-25232
C O UNTERSHAFT
A L IG N M E N T
MARKS
UPPER D ETEN T
SPRING (LONG)
Bearing Rollers
Fig. 6 R ~ R e m o v in g F ro n t B e a rin g R e ta in e r
REPAIRS
Replacement
Gears
1. Inspect all gears for excessive wear, chips, or cracks and
replace any that are worn or damaged.
2. Check both clutch sleeves to see that they slide freely
on their hubs.
T R U C K SUP P - O V E R H A U L
M A N U A L T R A N S M IS S IO N
7M -5
TU R N R A IL 90'
J-6654-01
F IR S T -R E V E R S E
S L E E V E A N D G E A R IN
F O R W A R D P O S IT IO N
TO CLEAR CASE
PULLER SCREWS
F ig . 8 R --R e m o v in g R e a r B e a rin g
F ig . 1 0 R - R e m o v in g O u tp u t S h a ft A s s e m b ly
(fig. 14).
TR U C K SUP P - O V E R H A U L
7M -6
M A N U A L T R A N S M IS S IO N
SPRING"
UNDER LIP OF
O - RING
LOCATION
KEYS
FIRST-REVERSE
SLEEVE A N D GEAR
HUB
>
R E T A IN IN G
SNAP RING
F ig . 1 1 RS h ift F o rk S h a fts
FIRST-REVERSE
SY N C H R O N IZER
F ig . 1 3 R --F irs t-R e v e rs e S y n c h r o n iz e r H u b
A L IG N M E N T
MARKS
KEYS<3)
A L IG N ROLL PIN
W ITH COUNTERBORE
WHEN IN STA LLIN G
SPRING
(UN DER
LIP OF
KEYS )
REVERSE IDLER
GEAR SH A FT
Fig. 1 2 R - R e m o v in g R e v e rs e Id le r G e a r S h a ft
ASSEMBLY OF M AINSHA FT
1. Install First-Reverse synchronizer hub on output shaft
splines by hand. Slotted end of hub should face front of
shaft. Use an arbor press to complete hub installation
on shaft and install retaining snap ring (in most
rearward groove).
SLEEVE
HUB
F ig . 1 4 R --S e c o n d -T h ird S y n c h r o n iz e r A s s e m b ly
TR U C K SUP P - O V E R H A U L
M A N U A L TR A N S M IS S IO N
O IL RETURN
SLOT
7 M -7
TOOL
J-25233
J-5778
/
FRO NT
BEARING
CAP
F ig . 1 5 RIn s t a llin g E x te n s io n H o u s in g B u s h in g
TABBED THRUST
WASHER (SHARP
EDGE MUST FACE
OUT)
F ig . 18 R--I n s ta 11i ng T a b b e d T h r u s t W a s h e r
F ig . 16 RI n s ta 11i ng E x te n s io n H o u s in g S e a l
TR U C K S U P P - O V E R H A U L
7M -8
M A N U A L TR A N S M IS S IO N
SECOND
GEAR
BLOCKING
RING
F ig . 19 R In s t a llin g S e c o n d G e a r
F ig . 2 0 R ~ M e a s u rin g O u tp u t S h a ft E nd P la y
T R U C K SUP P O V E R H A U L
M A N U A L TRA N S M IS SIO N
7M -9
11. Install shifter fork shafts in their case bores with the
pivot lug facing up.
NOTE: Shifter fork shafts are interchangeable.
12. Install (15) roller bearings in clutch shaft bore. Use
vaseline (or equivalent) to hold bearings in place.
18. T urn shift rail until detent notches in rail face bottom
of case. Insert a phillips screwdriver in detent bore to
depress lower detent plug and push shift rail into rear
bore. Move rail inward until detent plug engages
forward notch in shift rail (second gear position).
19. Secure fork to rail with setscrew and move second-third
synchronizer to N eutral (centered) position.
7M -10
M A N U A L TRA N S M IS SIO N
TR U C K SUP P - O V E R H A U L
M A N U A L TRA N S M IS SIO N
7M -11
SPECIAL TOOLS
1. J -2 4 4 3 3 FR O N T B E A R IN G INSTALLER
2 . J -2 2 6 0 9 REAR B E A R IN G INSTALLER
3 . J -2 5 2 3 2 C O U N T E R G E A R D U M M Y SH AFT
4 . J -8 4 3 3 -1 FR O N T B E A R IN G REM OVER
5 . J -6 6 5 4 -1 FR O N T B E A R IN G REM OVER
6. J -2 5 2 3 3 B E A R IN G R ETAIN ER O IL SEAL INSTALLER
7. J -5 1 5 4 E X T E N S IO N H O U S IN G SEAL INSTALL'ER
8 . J -5 7 7 8 E X T E N S IO N H O U S IN G B U S H IN G INSTALLER
9 . J - 8 1 5 7 -0 1 REAR B E A R IN G REM OVER
F ig . 2 5 R --T re m e c S p e c ia l T o o ls
T R U C K SUP P - O V E R H A U L
7M -12
M A N U A L TRA N S M IS SIO N
7M-12
7M-13
12
1.
2.
3.
4.
5.
6.
7.
Transmission Cover
Interlock Balls
3rd-4th Shifter Shaft
Reverse Shifter Shaft
Fork Retaining Pin
Detent Ball
Detent Spring
13.
14.
15.
16.
17.
11
Interlock Plunger
Spring
Reverse Interlock
Plunger
1st-2nd Shifter Shaft
Interlock Pin
Cover Gasket
Fig. 1 X - C o v e r A s s e m b ly - Exp lo de d V i e w
TR U C K S UPP - O V E R H A U L
M A N U A L T R A N S M IS S IO N
shaft through fork and cover bore keeping both balls and
pin in position between shafts until retaining holes line
up in fork and shaft. Install retaining pin and move to
neutral position.
6 . Place two (2) interlock balls between the 1st and 2nd
shift shaft and 3rd and 4th shifter shaft in the cross-bore
of the front support boss. Hold 1st and 2nd fork in
position and push shaft through cover bore in fork until
retainer hole and fork line up with hole in shaft. Install
retainer pin and move to neutral position.
7. Install new shifter shaft hole expansion plugs and
expand in place.
7 M -1 3
M A INSHA FT ASSEMBLY
F ig . 2 X - S h if t e r S h a ft In s ta lla tio n
T R U C K SUP P - O V E R H A U L
7 M -1 4
M A N U A L T R A N S M IS S IO N
1.
1s t S p e e d G e a r
R e v e rs e D riv e n G e a r
3.
1 s t G e a r B u s h in g
3 rd -4 th S pee d
1 4.
S n a p R in g
1 s t- 2 n d G e a r
7.
T h ru s t W a s h e r
S y n c h r o n iz e r H u b
15 .
M a in s h a ft
S y n c h r o n iz e r H u b
8.
3 r d S p e e d B u s h in g
A s s e m b ly
1 6.
A s s e m b ly
3 rd S p e e d G e a r
2 n d S p e e d B lo c k e r
10.
R in g
3 r d S p e e d B lo c k e r
13 .
R in g
1 1.
1 2.
3 rd -4 th S pee d
4 th S p e e d B lo c k e r
R in g
2n d S peed G ear
B u s h in g
S y n c h r o n iz e r S le e v e
F ig . 3 X - - M a in s h a ft A s s e m b ly E x p lo d e d V ie w
T R U C K SUP P - O V E R H A U L
M A N U A L T R A N S M IS S IO N
7 M -1 5
3R D G EAR
ND
GEAR
F ig . 4 X --D is a s s e m b ly o f M a in s h a ft
TR U C K S UPP - O V E R H A U L
7 M -1 6
M A N U A L T R A N S M IS S IO N
1 . A d a p te r
22 .
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
3.
4.
5.
Range S e le c to r S lid in g C lu tc h
Range S e le c to r H ousin g
L o w Speed Gear B ushing
6 . L o w Speed Gear
7. T h ru s t W asher & L o c a tin g Pin
8 . G asket
9. In p u t Brg. R e ta in e r
10. In p u t Brg.
11 . Brg. O u te r R ing
12. Brg. R e ta in in g R ing
13. T h ru s t W asher, L o c a tin g P in,
L u b ric a tin g W asher & Spacer
14. In te rm e d ia te (C ha in H ousin g)
15. D rive S h a ft S p ro c k e t
16. G asket
17. S lid in g L o c k C lu tc h
18. Rear O u tp u t H o usin g
19. Rear O u tp u t F r o n t Brg.
20 . V e n t
2 1 . O il Seal
O il P um p
S pee dom e ter D rive Gear
Brg. R e ta in e r Ring
Rear O u tp u t Rear Brg.
Rear O u tp u t S h a ft
W asher
Locknut
R u b b e r S p lin e Seal
Rear O u tp u t Y o k e
Rear O u tp u t Seal
S him s
In p u t S h a ft " O " R ing
In p u t S h a ft P ilo t Bearings
D iffe re n tia l C a rrie r A sse m b ly
S p rin g W asher C up
L o c k o u t C lu tc h S p rin g
Snap R ing
Snap R ing
F r o n t O u tp u t Rear Brg. C over
F r o n t O u tp u t Rear Brg.
F r o n t O u tp u t D riv e S p ro c k e t
G asket
44 .
45 .
46 .
47 .
48 .
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63 .
64 .
65.
M a gnet
D riv e C hain
G asket
Brg. O u te r R ing
F r o n t O u t p u t F r o n t Brg.
F r o n t O u tp u t S h a ft Seal
F r o n t O u tp u t Brg. R e ta in e r
R u b b e r S p lin e Seal
Locknut
F r o n t O u tp u t Y o k e
C o u n te rg e a r
C o u n te rg e a r Spacers and Brgs.
C o u n te rg e a r S h a ft
C o u n te rg e a r T h ru s t W asher
G asket
Brg. R e ta in e r G asket
Brg. O u te r R ing
In p u t Gear Brg.
In p u t Gear Seals (2)
Brg. Snap R ing
In p u t Gear
In p u t Gear Brg. R e ta in e r
TR U C K S UPP - O V E R H A U L
M A N U A L T R A N S M IS S IO N
7 M -1 7
TRUC K S U P P - O V E R H A U L
7 M -1 8
M A N U A L T R A N S M IS S IO N
<3b
85
1.
2.
3.
4.
5.
6.
7.
Adapter
P.T.O. Cover
Selector Housing to Chain Housing Gasket
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
88
89
90
91 92
35.
36.
37.
87
86
38.
39. " 0 " Ring Seal
40. Low Speed Gear and Bushing
41. T h ru st Washer
42. In p u t Shaft Bearing Retainer
T R U C K SUP P - O V E R H A U L
M A N U A L T R A N S M IS S IO N
7 M -1 9
FRONT O U TPUT
SHAFT ASS Y .
RANGE
H O U S IN G
COUNTER GEAR
F ig . 3 F - F r o n t V ie w o f T r a n s fe r C ase
REAR OUTPUT
HOU
L O C K O U T CLUTCH
SHIFT RAIL POPPET PLUG
R A N G E SELECTOR
HIFTER SHAFT
C H A IN
S IN G
FRO N T OUTPUT |
BEA R IN G REAR
C OVER
Fig. 4 F -R e a r V ie w o f T r a n s fe r C a se
Fig . 5 F -R e m o v in g R e a r O u t p u t B e a rin g R e ta in in g R ing
Assembly
1. Position rear bearing in housing and tap into place.
2. Install snap ring retaining bearing to case.
NOTE: Retaining Ring is a select fit. Use service ring
size A, B, C or D as required to provide tightest fit.
3. Position rear seal to bore and drive into place using tool
J-22388
(Fig.
7F)
or^ other
suitable
tool
until
TRUC K S U P P - O V E R H A U L
7 M -2 0
M A N U A L T R A N S M IS S IO N
Assembly
1. Position rubber seal in bearing bore. Use grease to hold
in place. Position roller bearing in bore and press into
place until bearing bottoms out in housing.
2. Position new "O" ring on housing.
F ig . 7 FIn s ta llin g R e a r O u t p u t H o u s in g S e a l
TR U C K S U P P - O V E R H A U L
M A N U A L T R A N S M IS S IO N
7M -21
T RUC K SUP P - O V E R H A U L
SECTION 7A
AUTOMATIC TRANSMISSIONS
CONTENTS OF THIS SECTION
Turbo H ydra-M atic 350 Transm ission...........................................
Turbo H ydra-M atic 375/400/475 T ransm ission.........................
7A-1
7A-3
O RING SEAL
VACUUM MODULATOR
INSPECTION OF CONVERTER
Fig. 1 A -R e m o v in g V a c u u m m o d u la to r A s s e m o iy
T RUC K SUP P - O V E R H A U L
7A -2
A U T O M A T IC T R A N S M IS S IO N
D R IVE
PLATE
DRIVEN
PLATES
CUSHION
SPRING
NONE
NONE
NONE
NONE
FORWARD
250 L-6, 262-305 V-8
350 V-8, 400 V-8
T A X I AND TRUCK
IN TER M E D IA TE
250 L-6, 262 V-8
305-350 V-8, 400 V-8
T A X I AND TRUCK
DIRECT
250 L-6, 262 V-8
305-350 V-8, 400 V-8
T A X I AND TRUCK
REVERSE
250 L-6, 262-305 V-8
T R U C K SUP P - O V E R H A U L
A U T O M A T IC T R A N S M IS S IO N
7A -3
T R U C K SUP P - O V E R H A U L
7A -4 A U T O M A T IC T R A N S M IS S IO N
attaching
screws,
detent
A U T O M A T IC T R A N S M IS S IO N
7A -5
PIN
D E N TIFIC A TIO N
PART NO.
r u
THIS STEP:
USE PIN NO. 8627195
LONGEST PIN
Oi
o
co
THIS STEP:
USE PIN NO. 8624141
mtQ
t=Q
CM
LOWER STEP
SHORTEST PIN
Note:
THIS STEP:
USE PIN NO. 8624140
EG
LOWER STEP:
USE PIN NO. 8627192
btQ
6B).
CONTROL VALVE
3. Install
Special
Tools
J-22269
and
J-24675,
on
Disassembly
accum ulator piston and remove retaining ring (fig. 8B).
1. Position control valve assembly with cored face up and
accum ulator pocket nearest operator.
T R U C K SUPP - O V E R H A U L
7 A-6 A U T O M A T IC T R A N S M IS S IO N
Inspection
IN S T A L L E R
S P E E D O M E TE R
GEAR
NOTE: See figure 9B. D o not remove the teflon oil seal
ring from the front accum ulator piston unless the oil
seal ring requires replacement. For service, the oil seal
ring is cast iron.
1. Inspect all valves for scoring, cracks and free movement
in their respective bores.
2. Inspect bushings for cracks, scratches or distortion.
3. Inspect body for cracks, or scored bores.
4. Check all springs for distortion or collapsed coils.
5. Inspect accum ulator piston and oil seal ring for damage.
Assembly
1. Install front accum ulator spring and piston into valve
body.
2. Install Special Tools J-22269 and J-24675 and compress
spring and piston and secure with retaining "E" ring.
3. Install the 1-2 accum ulator valve train into the lower
left hand bore as follows:
Fig. 6 BI n s ta llin g S te e l S p e e d o m e te r D riv e G e a r
A U T O M A T IC T R A N S M IS S IO N
11
12
mb
7A -7
13
|| '[iiiiBiiiilifr nil
a iu n u tt I g Q y ^ j
21
22
23
28
M O D E LS CJ & CL
vimm
14 15
29
16
M O D ELS C D , CF, C G ,
^CM , CP, CR, CT, & CZ
1.
M a n u a l V a lv e
9.
2.
R e ta in in g P in
10.
3.
B o re P lu g
4.
D e te n t V a lv e
5.
D e te n t R e g u la to r
1-2 D e te n t V a lv e
S p r in g
1 1.
12.
V a lv e
16.
1-2 R e g u la to r V a lv e
17.
1-2 R e g u la to r V a lv e
1-2 M o d u la to r
18.
B u s h in g
19.
6.
S pacer
13.
R e ta in in g Pin
7.
D e te n t R e g u la to r
14.
R e ta in in g Pin
20.
V a lv e S p r in g
15.
B o re P lu g
21
8.
1-2 A c c u m u la to r
2 -3 M o d u la t o r
B u s h in g
23
A c c u m u la to r S p r in g
24
3 -2 V a lv e
2 -3 S h if t V a lv e
25
Spacer
3 -2 V a lv e S p r in g
R e ta in in g P in
3 -2 In t e r m e d ia te
26.
S p r in g
27.
B o re P lu g
2 -3 M o d u la t o r V a lv e
28.
R e ta in in g P in
2 -3 S h if t V a iv e
29.
S p r in g
1-2 S h if t V a lv e
22.
V a lv e
1-2 P rim a r y
1-2 A c c u m u la to r
V a lv e S e c, S p r in g
F ig . 7 B - C o n tr o l V a lv e A s s e m b ly - E x p lo d e d V ie w
15. Install manual valve with detent pin groove to the right.
FORWARD CLUTCH
Disassembly
a. (Model CA) Remove four (4) radial grooved
composition-faced, three (3) thin (.0775") flat steel
and one ( 1) waved steel clutch plates from forward
clutch housing.
b. (Models CJ, CM, CP, CT and CZ) Remove five (5)
radial grooved composition-faced, four (4) thin
(.0775") flat steel and one (1) waved steel clutch plates
7A -8 A U T O M A T IC T R A N S M IS S IO N
Fig. 10 B In s ta llin g D e te n t R e g u la to r V a lv e a n d D e te n t V a lv e
4
>
\ *i '
_______________
Assembly
Assembly procedure, step num ber 10 should read:
10. Install forward clutch plates.
a. (Model CA) Install one (1) waved steel (plate with
"U" notch), four (4) composition and three (3) thin
(.0775") flat steel clutch plates, starting with waved
plate and alternating composition-faced and steel
clutch plates.
b. (Models CJ, CM, CP, CT and CZ) Install one (1)
waved steel (plate with "U" notch), five (5)
composition-faced and four (4) thin (.0775") flat steel
clutch plates, starting with waved plate and
alternating composition-faced and steel clutch plates.
Fig. 9 B - F r o n t A c c u m u la to r A s s e m b ly - E x p lo d e d
CL)
Remove
five
(5)
radial
grooved
A U T O M A T IC T R A N S M IS S IO N
7A -9
CHAMFER FOR
IDENTIFICATION
Disassembly
Disassembly procedure, step num ber 4 and 5 should read:
4. Remove direct clutch backing plate.
5. Remove direct clutch plates as follows:
a. (Model CA) Remove four (4) composition-faced, and
four (4) flat steel clutch plates from the direct clutch
housing.
b. (Models CG, CJ, CM, CP, CR and CT) Remove five
(5) composition-faced and five (5) flat steel clutch
plates from the direct clutch housing.
F ig . 1 1 B --D ire c t C lu tc h H o u s in g P la te P a ck
c. (Models
CL
and
CZ)
Remove
six
(6)
composition-faced and six ( 6) flat steel clutch plates
from the direct clutch housing.
NOTE: The production built transmissions use a
direct clutch piston w ithout a check ball. The forward
and direct clutch pistons look almost the same. Make
sure the direct clutch piston is identified during
disassembly so it will be re-assembled into the direct
clutch housing. The service replacement direct clutch
piston contains a check ball. (Models CL and CZ
contain 2 check balls.)
The production built direct clutch piston will be
aluminum or stamped steel.
CHECK BALL
DIRECT
CLUTCH
H O U S IN G
Inspection
Inspection procedure add steps num ber 6, 7 and 8 which will
read:
F ig . 1 2 B - D ir e c t C lu tc h H o u s in g
T RUC K S U P P - O V E R H A U L
7 A -1 0
A U T O M A T IC T R A N S M IS S IO N
CENTER SUPPORT
The procedure for disassembly, inspection and assembly
remains the same with the following exception:
Assembly
Assembly procedure, Step num ber 7, should read:
7. Install four (4) oil seal rings on the center support.
NOTE: W hen installing teflon oil seal rings, make sure
slit ends are assembled in same relation as cut (Fig.
13B). Also, make sure oil seal rings are seated in ring
grooves to prevent damage to rings during re-assembly
of m ating parts over rings. Retain with petrolatum.
F ig . 1 4 B - ln s p e c tin g S p a c e r R ing
TRUC K SUP P O V E R H A U L
A U T O M A T IC T R A N S M IS S IO N
7 A -1 1
Inspection
Inspection procedure, step num ber 4 and 5 should read:
Inspection
1. Inspect seal (case extension to case) groove for amage.
2. Inspect for cracks, or porosity.
3. Inspect dowel pin in rear face for damage.
4. Inspect oil seal for damage. If replacement is required,
proceed as follows:
a. Pry oil seal from extension.
b. Apply non-hardening sealer to outside of new oil seal,
and install oil seal into case extension using tool
(J-24057).
5. Inspect ball bearing assemblies. If they are damaged, or
if they require cleaning, proceed as follows:
REAR UNIT
Assembly
11. Install reaction carrier to output carrier metal or
non-metal thrust washer with tabs facing down in
pockets of output carrier and retain with petrolatum.
NOTE: The production built transmissions use a
non-metal washer here. However, the service
replacement washer is made of metal.
CASE
CASE ASSEMBLY
The procedure for inspection remains the same with the
following addition:
REAR OIL
SEAL
BALL BEARINGS
SNAP
RING
BEARING
SPACER
CASE EXTENSION
F ig . 1 5 B - M o d e l C L C a s e E x te n s io n
7 A -1 2
A U T O M A T IC T R A N S M IS S IO N
F ig . 1 6 B In s ta llin g In te r m e d ia te B a c k in g P la te a n d C lu tc h
P la te s
F ig . 1 7 B In s ta llin g E x te n s io n O il S e a l (T y p ic a l)
FRONT
SERVO ASSEMBLY, AND ELECTRICAL
CONNECTOR
CONVERTER ASSEMBLY
Installation
Assembly
that the converter hub drive slots are fully engaged with the
front servo).
T R U C K SUP P - O V E R H A U L
S E C TIO N 9
STEERING
IN D E X
Overhaul O perations........................................................................... 9-1
Power Steering Pum p....................................................................... 9-1
Power Steering G e a r.......................................................................... 9-1
Special T o o ls........................................................................................... 9-6
OVERHAUL OPERATIONS
R em oval
Disassembly
Assembly
NOTE: Steps 1-19 are identical to the 1974 Overhaul
Manual, Section 9, Pages 9-11 and 9-12.
Adjuster Plug
Disassembly
1. If the oil seal ON LY is to be replaced, and not the needle
bearing, install the adjuster plug (Fig. 3) loosely in the
gear housing. Remove the retaining ring with Internal
Pliers J-4245. W ith a screwdriver, pry the dust seal and
oil seal from the bore of the adjuster plug being careful
not to score the seal bore. Discard the oil seal.
TRUC K SUP P - O V E R H A U L
9-2
STEERING
i
1.
2.
3.
4.
5.
6,
Ring, Retaining
Seal, Stub Shaft Dust
7. Race, Upper Bearing (Large)
Seal, Stub Shaft
8. Bearing, Upper Thrust
Bearing, Needle
9. Race, Upper Thrust Bearing (Sm all)
Plug, Adjuster
10, Spacer, Thrust Bearing
Seal, " 0 Ring (Adjuster) 11, Retainer, Bearing
10
11
*r
4 V
4 ;
**
Fig. 3 ~ A d ju s te r P lu g
Assembly
1. If the needle bearing was removed, place new needle
bearing over Tool J-8524-1 and J-7079-2, with the
bearing m anufacturers identification against the tool,
and drive the bearing into the adjuster plug until the tool
bottoms in the housing (Fig. 6).
STEERING
9-3
BEARING W ITH
ID EN TIFIC ATIO N
T O W A R D TO O L
F ig . 6 I n s t a llin g B e a rin g
F ig . 5 --R e m o v in g B e a r in g a n d S e a l
P ow er S teering Gear
A d ju s tm e n t Procedure
Adjustm ent of the steering gear in the vehicle is discouraged
because of the difficulty encountered in adjusting the worm
thrust bearing preload and the confusing effects of the
hydraulic fluid in the gear. Since a gear adjustm ent is made
only as a correction and not as a periodic adjustment, it is
better to take the extra time and make the adjustment
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 adjustment, it is necessary that the steering
gear assembly 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.
thrust
bearing
adjustm ent
in
service
is
simplified.
Recommended procedure:
1. Drain power steering fluid from gear by rotating the
stub shaft full travel in both directions several times.
2. Loosen and remove adjuster plug lock nut (Fig. 9 and
10).
3. Using spanner wrench J-7624, turn the adjuster plug in
(clockwise) until the plug and thrust bearings are firmly
bottomed approximately 20 foot-pounds (Fig. 11).
4. M ark the housing even with one of the holes in the face
of the adjuster plug (Fig. 12).
5. Measure back (CCW direction) 1/2 inch (12.5
millimetres) and place a second mark on the housing
(Fig. 13).
TR U C K SUP P - O V E R H A U L
9-4 STEERING
J -7 0 7 9 - 2
F ig . 7 - -In s ta IIin g A d ju s te r P lu g S e a l
F ig . 9 - L o o s e n in g L o c k N u t
F ig . 1 0 --F te m o vin g L o c k N u t
F ig . 8 - -In s ta llin g R e ta in e r
TRUC K S U P P - O V E R H A U L
STEERING
9-5
Fig. 1 3 --M e a s u re B a c k a n d R e m a rk H o u s in g
TRUC K SUP P - O V E R H A U L
9-6 STEERING
F ig . 1 6 --S p e c ia l T o o ls
TR U C K S U P P - O V E R H A U L
S P E C IF IC A T IO N S
H E A T IN G
AND
A IR
C O N D I T IO N I N G
SECTION 1A
HEATER
V o lts
A m p s.
(C o ld )
RPM
(Cold)
Blower Motor
6.25 Max.
7.1 Max.
2550
2950
2850
3250
Min.
Max.
Min.
Max.
Fuses
System Capacities
Refrigerant 12
C-K Four-Season System ...................... 3 lbs. 12 oz.
C-K-G Overhead S y s te m s ........................ 5 lbs. 4 oz.
G Model C60 S y s te m ................................
3 lbs.
Motor Home Chassis U n i t ........................ 3 lbs. 4 oz.
525 Viscosity Compressor Oil
6 Cylinder A x ia l..............................
10.5 Fluid oz.
4 Cylinder Radial ..................................... 6.0 Fluid oz.
Overhead S y stem s................................................ 13 oz.
Torque Specifications
A U X IL IA R Y HEATER
Volts
Blower Motor . . . . 13.5
Amps.
(Cold)
9.6 Max.
RPM
(Cold)
2700 Min.
A IR C O N D ITIO N IN G
Compressor
Amps.
(Cold)
RPM
(Cold)
Fuses
Fuse Block
Blower Motor
12.8 Max.
13.7 Max.
3400 Min.
3400 Min.
Circuit Breaker
35 Amp.
TR U CK SU PP SPECS
SPECIFICATIONS 2
BODY
SECTION IB
C A N D K MODELS
FRONT END
Windshield Wiper Linkage to Plenum ........................25 in. lb.
Sunshade S u p p o r t...........................................................20 in. lb.
Inside Rear View Mirror to B rack et............................. 45 in. lb.
Outside Rear View Mirror to Door Panel
Base M ir r o r ............................................................. 25 in. lb.
West Coast M irror-Lower Bracket to Door . . . 20 in. lb.
Upper Bracket to Door. . . . 45 in. lb.
DOORS
Window Regulator Assembly to Door P a n e l............. 85 in. lb.
Remote Control Door Lock to Door P a n e l................ 45 in. lb.
Lock Striker to Body P illa r ........................................... 45 ft. lb.
Outside Door Handle........................................................ 85 in. lb.
Inside Door H a n d le ........................................................ 85 in. lb.
Hinges to Body and D o o r ............................................. 35 ft. lb.
Front DoorWindow Run C hannel-to-D oor
8 5 in. lb.
Front DoorVentilator Assembly
Top Vent S c re w ..................................................... 18 in. lb.
Side Vent Screws and S p a c e rs............................. 25 in. lb.
Lower Vent Channel B o l t s ...................................40 in. lb.
Side Rear DoorRun Channel
Front Upper to D o o r............................................. 40 in. lb.
Rear-Upper to Door ............................................. 20 in. lb.
Front and Rear Lower to Door............................. 85 in. lb.
Lock Lever to Door ............................................. 85 in. lb.
Rear DoorLock Striker (06) ..................................... 95 in. lb.
Rear DoorLatch L.H. and R.H. to Door (06) . . . . 85 in. lb.
Rear DoorLatch Control Assembly to Door (06)
Upper A ssem b ly ........................................85 in. lb.
Lower A ssem bly........................................ 90 in. lb.
Rear DoorWeatherstrip L.H. ( 0 6 ) ............................. 18 in. lb.
-C heck Arm
- Strap to D o o r ......................................... 45 in. lb.
Bracket to Body
4 5 in .lb .
T A IL G A T E
(0 3, 6 3 - w i t h E 62)
SEATS
Front Bench Seat (03 ,0 6 ,6 3 )
Adjuster-to-Seat ................................................ 155 in. lb.
A djuster-to-F loor...................................................25 ft. lb.
Front Bucket Type (14, 03)
Driver
Adjuster-to-Seat............................................. 18 ft. lb.
Adjuster-to-Floor ........................................ 25 ft. lb.
Passenger (03)
Support-to-Seat..............................................18 ft. lb.
Support-to-Floor (F ro n t)............................. 25 ft. lb.
Support-to-Floor ( R e a r ) ............................. 40 ft. lb.
Passenger (14)
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 (F ro n t) ............. 25 ft. lb.
Support (Upper)-to-Support (Lower) . . . . 18 ft. lb.
Rear Bench (06, 14)
S u p p o rt-to -S ea t......................................................18 ft. lb.
Support-to-Floor ...................................................40 ft. lb.
Rear Bench (63)
S u p p o rt-to -S e at...................................................150 in. lb.
Support-to-Floor ................................................ 18 in. lb.
Folding Rear Seat (06)
Support A sm -to-F loor........................................ 150 in. lb.
Seat-to-Support A s m ..............................................18 in. lb.
TR U CK SU PP SPECS
SPECIFICATIONS 3
#1
#2
45
55
55
55
45
35
45
35
#3
35
55
#4
35
35
-
#5
#6
35
G MODELS
MIRRORS A N D SUNSHADE
SEATS
REAR DOOR
Hinge Strap to D o o r........................................................45
Hinge Strap Bracket to B o d y ........................................45
Hinge (to body and d o o r ) ............................................. 30
Remote Control Retaining Screws ............................. 85
Latch-to-Door Retaining S crew s...................................90
Door Strikers-to-Body ...................................................90
Outside Door H a n d le ..................................................... 45
in. lb.
in. lb.
ft. lb.
in. lb.
in. lb.
in. lb.
in. lb.
TR U CK SUPP SPECS
SPECIFICATIONS 4
FR O N T S U S P E N S IO N
SECTION 3
WHEEL ALIGNMENT SPECIFICATIONS
CA STER *
D IM E N SIO N A IN IN C HES*
2 1/ 2 "
M O D ELS
2 3 /4 "
3"
+ 2
CIO
+ 1 1/ 2 + 1 1/4
C20.C 30
+ 1
3 1 /4 "
+ 3 /4
K 10.K 20
+ 1/ 2
3 3 /4 "
4"
4 1 /4 "
4 3 /4 "
5"
+ 1
+ 3 /4
+ 1/ 2
+ 1 /4 C
- 1/ 2
-1 /4
- 1/ 2
- 3 /4
- 1
+ 1/4
4 1 /2 "
+ 4 (NO A D JU S T M E N T P R O V IS IO N )
+ 2
G 10,G 20,G 30
+ 2 1/4
P 10.P 20.P 30
+ 2 1/ 2 + 2 1/4
M O TO R
HOM E
3 1 /2 "
+ 1 1/ 2 + 1 1 /4
(3 2 )
+5 3 /4
+5 1/2
+ 1 1/ 2 + 1 1/4
+ 2
+5
+ 1
+ 1 3 /4 + 1 1/ 2
+5
+4 1 /2
+ 3 /4
+ 1/ 2
+ 1/4
- 1 /4
- 1/ 2
+ 1
+ 3 /4
+ 1/ 2
+ 1 /4
- 1 /4
+4 1/4
+4
+4
+3 1 /2
+3 1/4
+3
CAM BER
C10.C 20.C 30
+ 1 /4 U
K 10.K 20
+ 1 1/2 N O A D JU S T M E N T P R O V IS IO N
G I0 .G 2 0 .G 3 0
+ 1/4
C am b er o n P -T ruck is d e p e n d e n t o n dim en sio n A , as ex p lain ed o n page 3-15 o f th e 1974 L ig h t D u ty T ru c k S ervice M anual.
A fte r m easuring d im en sio n A set cam b er as follow s:
2 1/ 2 "
2 3 /4 "
3"
3 1 /4 "
3 1 /2 "
3 3 /4 "
4"
4 1 /4 "
4 1 /2 "
5"
5 1 /4 "
5 1 /2 "
P10
+ 1 /4
+ 1/4
+ 1 /4
+ 1/4
+ 1/4
- 1 /4
- 1/ 2
-3 /4
P 20.P 30
+ 1 /4
+ 1/4
+ 1 /4
+ 1/4
+ 1/4
+ 1 /4
-1 /4
- 1/ 2
-3 /4
+ 1 /4
+ 1/4
+ 1/4
+ 1 /4
- 1/ 2
-3 /4
- 1
M O TO R
HOM E
(3 2 )
T O E -IN
C 10,C 20,C 30
K 10.K 20
3 /1 6 "
P 10.P 20.P 30
3 /1 6 "
-1 /4
R E PA IR
TARGET
P E R IO D IC
M O TO R
V E H IC LE
IN S P E C T IO N
1/ 2
-H
5/16
R E S E T T IN G
O
CN)
MOTORHOME
W ARRANTY
C H E C K IN G
CA STER
(3 2 )
A L IG N M E N T T O L E R A N C E S
3 /1 6 "
G 1 0 .G 2 0 .G 3 0
P30
4 3 /4 "
CA M BER
3 /4
1/ 2
1 1/ 2
T O E -IN
1/ 8 "
1 /1 6 "
3 /8
*R efer to page 3-15 o f the 1974 L ight D uty Truck Service M anual.
TR U CK SU PP SPECS
SPECIFICATIONS 5
CP-10
CP-20-30
K-AII
85
85
45
85
70
105
70
105
140
$$
New
Used
190
115
$$
New
Used
280
130
w/Spacer 190
No Spacer 115
w/Spacer 280
No Spacer 130
w/Spacer 280
No Spacer 130
*50
**90
**1 00
**90
**90
65
100
140
w/Spacer 160
No Spacer 95
G-10-20
*50
**90
***80
**90
**90
65
65
65
100
100
100
60
60
25
25
ANCHOR _ 130
PLATE
25
25
.5 5
25
140
140
65
75
60
60
65
75
120
In Lbs.
120
Zero
.0 0 1
In. L bs.
120
Inner # - 35
Outer -50
Zero
- .0 0 5
.0 0 1
35
In. Lbs.
25
120 l a Lbs.
Zero
Zero
.001 - .010"
.001 - .005
35
35
35
- .0 0 5
90
50
50
150
25
Suspension Bumper
15
15
25
15
130
S p rin g
*
**
***
#
$
$$
- F r o n t S u p p o r t t o F ra m e
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.
pius additional torque to align cotter pin.
Back nut off to align cotter pin at nearest slot.
All specifications are given in foot pounds of Torque unless indicated otherwise.
CIO, G10-20 Rubber Bushings; C20-30, G30, P I0-30 Steel Bushings.
F O U R W H EE L D R IV E
Axle
Bolt
Torques
(Ft. Lbs.)
5500#
(Dana)
.004 - .009
Carrier Cover
.004 - .009
Ring Gear
Filler Plugs
35
110
85
10
255
35
60
m ueK
supp
specs
SPECIFICATIONS 6
REAR SUSPENSION
S E C TIO N 4
B earing Adjusting
Nut Torque*
Adjusting Nut
Back-off*
Outer Locknut
Torque
R esulting
Bearing Adjustment
Type of
B earing
10-1/2 and
9-3/4
50 Ft. Lbs.
**
65 Ft. -Lbs.
.001 to .010
End Play
Tapered
R oller
1 2 - 1 /4M
90 Ft. Lbs.
Slight
P reloaded
B a rrel
R oller
1 /8
** B ack-off nut and retighten to 35 Ft. Lbs. then, back-off nut 1 /4 turn.
* With wheel rotating.
U N IVE R SA L J O IN T A T T A C H M E N T
T O R Q U E S PE C IFIC ATIO N S
15 Ft. Lbs.
L ubricant C apacity
8 -1 /2
4.2 Pints
8-7 /8
3.5 Pints
C hevrolet 10-1/2"
5.4 Pints
Dana 10-1/2"
7.2 P ints
Dana 9-3/4
12-1/4"
6.0 Pints
14.0 P ints
M in . a n d M a x .
Used
C hevrolet
10-1/2"
12-1/4
10-1/2 T_
Dana
9-3/4
10
18
10
2 0 #
2 0 #
.005".008"
.004".009"
.005".008"
.005".008"
D ifferential Pinion
Lock
.0 0 3
.0 1 0
.003".010"
.004".009"
.003".012"
.003".012"
220
D ifferential C arrier
to Axle Housing
85
D ifferential Bearing
Adjusting Lock
20
15
65
165
135
35
105
105
155
115
115
15
15-30
15-30
2040
25-35
5-10
10-20
5-15
5-10 |
C arrier Cover
18
OC
.0 0 5 .0 0 8
P inion B e arin g
P r e l o a d (In. L b s . )
New
25
Csl
F iller Plugs
G ear B acklash
P referred
Bolt Torques
(Ft. Lbs.) a
8 -7 /8 "
12-1/4"
1
OC
C h e v ro le t
(N
d
3
Q
10-1/2"
8 -7 /8 "
DIFFERENTIAL S P E C IF IC A T IO N S
20 #
2 0 #
35#
30#
Ring Gear
80
50
110
130
105
Brake - Backing
Plate
D ifferential
Bearing Caps
55
55
85
135
205
Axle Shaft To
Hub Bolts
35
SPECIFICATIONS 7
Leaf Spring
Front Bushing Bolt
140
C-K
G 10
G20
G30
120
120
150
P10
P20
P30
140
140
170 (Exc. w /3 /4 Bolt)
200 (W /3/4 Bolt)
90
90/135*
90
90
(G 3 1 6 .. .90)
90/135*
(G 3 1 6 .. .90)
90
Shock Absorber
Upper Attachment
140
75
P10 25
P20 140
P30 50
Lower Attachment
115
75
115
Propeller Shaft
To Rear Axle (Strap)
To Rear Axle (U Bolt)
Bearing Support-to-Hanger
Hanger-to-Frame
12-17
18-22
20-30
40-50
20-30
12-17
18-22
20-30
12-17
18-22
20-30
20-30
TR U CK SUPP SPECS
SPECIFICATIONS 8
BRAKES
S ECTIO N 5
TO R Q U E S P E C IFIC A T IO N S
IfC
C
M a ste r C y lin d e r -
to D ash or B o o s te r
M o u n tin g B o lts
- B ra c k e t to F ram e
C a lip e r
M o u n tin g B olt
S u p p o rt P late to K n u c k le
B rake P edal
150 in.
lbs.
25 ft.
lb s .
25 ft.
lb s .
35 ft.
lb s .
140 in .
lb s .
B ra c k e t/to D ash
25 ft.
lb s .
25 ft.
IbS.
B ra c k e t to I . P .
25 in .
lb s .
25 in .
lb s .
P iv o t B o lt N ut
25 ft.
lb s .
25 ft.
Ib s.
S le e v e to B ra c k e t
S to p la m p S w itc h B ra c k e t
P a rkinq B rake
17 ft.
Ibs.
17 ft.
Ib s.
25 ft.
Ib s.
25 ft.
Ib s .
150 in .
Ib s.
25 ft.
Ib s.
25 ft.
lb s .
25 ft.
-
4 5 ft.
Ib s.
25 ft.
Ibs.
2 5 ft.
Ib s.
2 2 ft.
Ib s.
100 in .
Ibs.
100 in .
Ibs.
to I .P . , K ick P anel
or F lo orpa n
150 in .
lb s .
150 in .
Ib s.
100 in .
Ibs.
C a b le C lip s - S c re w s
150 in .
lb s .
100 in .
Ib s ,v
to D ash
- B o lts
100 in lb s .
Ib s.
100 in . Ib s.
18 ft.
Ib s.
P ro p s h a ft P arking B rake
- A d ju s tin g N ut
18 ft.
Ib s.
150 in .
Ib s.
55 in .
Ibs.
30 ft.
Ib s.
20 ft.
Ib s.
- C a b le C lip to Fram e
150 in .
Ibs.
- C a b le C lip to D ash
55 in .
Ibs.
B ra c k e t to T ra n s .
20 ft.
Ib s .
F la n g e P la te
30 ft.
Ibs.
D rum
80 ft.
Ib s.
Ib s.
- C a b le C lip to T ra n s .
B rk t.
140 ft.
lb s .
to C a lip e r
22 ft.
lb s .
to Fram e N ut
58 in .
lb s .
B ra c k e t B o lt
150 in .
Ib s.
150 in .
to A x le B ra c k e t
150 in .
lb s .
150 in .
Ib s.
90 in .
Ib s.
150 in .
Ib s . (P 10)*
B ra c k e t to A x le
150 in .
lb s .
150 in .
Ib s.
150 in .
Ib s .
150 in,
lbs.
150 in.
150 in .
Ibs.
150 in .
Ibs.
A tta c h in g N uts
R e ta in in g C lip s - S c re w s
- B o lts
150 in .
lb s .
lb s .
100 in .
150 in .
Ibs.
Ib s.
18 ft. Ibs.
B rake B le e d e r V a lv e s
H y d ro -B o o s t - P edal Rod -
lb s .
50 in .
25 ft.
P 30(32) M o d e ls
-
15 in .
Ib s.
25 ft.
Ib s .
45 ft.
Ib s .
25 f t.
Ib s .
P edal R od B oot -
P 3 0 (3 2 )M o d e ls
P iv o t L e ver B olt
B o o ste r B ra cke ts
B o o s te r B race at D ash or
R a d . S u p t.
P ow er S teering P um p to
B o o ste r Lin e
25 ft.
IbS.
25 ft.
B o o s te r to G ea r Line
25 ft.
lb s .
25 ft.
R e tu rn L in e a t B o o s te r & G e a r
25 ft.
lb s .
R etu rn L in e C la m p S crew
15 in .
lb s .
L in e C la m p to B ra c k e t S c re w
150 in .
lb s .
H o se C la m p to S k ir t S c re w
40 in .
lb s .
L in e C la m p to F ra m e B o lt
Ib s .
150 in .
Ib s .
Ib s.
25 ft.
Ib s .
Ibs.
25 ft.
Ib s.
25 ft.
Ibs.
25 ft.
Ib s.
15 in .
Ibs.
15 in .
Ib s.
150 ft.
Ibs.
150 in .
Ib s.
18
ft.
Ib s.
TR U C K SUPP SPECS
SPECIFICATIONS 9
ENGINE
SECTION 6
GENERAL DATA:
Type
I n L in e
250
V8
292
Bore
350
3 7/8
454
Stroke
3.53
4.12
3.48
4 1/4
4
8.25:1
8 .0 :1
8.5:1
8.25:1
Firing Order
1-5-3-6-2-4
1-8-4-3-6-5- 7-2
CYLINDER BORE:
3.8745 - 3.8775
Diam eter
Out o f
Round
Taper
3.9995 - 4.0025
.0005 Max.
Production
4.2495 - 4.2525
.001 Max
.002 Max.
Service
.0005 Max.
T hrust Side
P roduc
tion
Relief Side
.0005 Max.
.001 Max.
Service
.005 Max.
PISTON:
.0005-.0015
.0025 Max.
Production
Clearance
Service
.0018-.0028
.0026-.0036
.0045 Max.
.0007-.0013
.0027 Max.
.0035 Max.
.0020-.0040
.0012 - .0032
.0017 - .0032
PISTON RING:
C
0
M
P
R
E
S
S
I
Clear
ance
Groove
] P roduc
tion
.0012 - .0027
2 nd
.0012-.0032
Service
Produc
tion
Gap
Top
Top
2 nd
.010
.010 - .020
Production
I
L
Gap
.005 Max.
.005-.0055
.002 - .007
Service
P roduction
.015 - .055
Hi Limit Production + .01
Service
.010 - .020
Service
Groove
Clearance
.020
.013 - .025
.0005 - .0065
.010 - .630
PISTON PIN:
Diam eter
P roduction
.9270 - .9273
.00015 - .00025
Service
.001 Max.
Clearance
Fit in Rod
.9895 - .9898
.00025 - .00035
TR U CK S U P P SPECS
SPECIFICATIONS 10
CRANKSHAFT:
#1
All
2.2983 - 2.2993
Diam eter
Main
Journal
Main
Bearing
Clearance
.001 (Max.)
.0002 (Max.)
Production
.001 (Max.)
Service
All
.0003
All
.0008
.0029
.0034
#1
.0008 - .0020
.006 - .010
.002 - .006
Diam eter
1.999 - 1.2000
.0003 (Max.)
P roduction
.001 (Max.)
P roduction
.0002 (Max.)
.001 (Max.)
Service
.0007 - .0027
P roduction
Rod Bearing
Clearance
2.1985 - 2.1995
2.199 - 2.200
2.099 - 2.100
Service
O ut of
R ound
#5
.0024 - .0040
#5
.0017 - .0033
#1 - .002 (Max.) All O thers .0035 (Max.)
Service
Taper
#1-2-3-4
.0013 - .0025
#2-3-4
.0011 - .0023
Production
Crankpin
#5
2.7478 - 2.7488
.0002 (Max.)
Service
O ut of
R ound
#2-3-4
2.7481 - 2.7490
#5
2.4479 - 2 4488
Production
Taper
2.7485 - 2.7494
#1-2-3- 4
2.4484 - 2. 4493
.0009 - .0025
.0013 - .0035
.0035 (Max.)
Service
.008 - .014
.0006 - .0017
.013 - .023
CAMSHAFT:
Lobe
Lift .002"
Intake
.2217
.2315
.2600
.2343
E xhaust
.2217
.2315
.2733
.2343
1.8682 - 1.8692
1.9482 -1.9492
Camshaft R u n o u t
.0015 Max.
VALVE SYSTEM:
Hydraulic
L ifter
1.75:1
1.50:1
Intake
E xhaust
45
46
.002 (Max.)
1/32 - 1/16
Intake
E xhaust
Stem
Clearance
P roduc
tion
1/16 - 3/32
.0010 - .0027
Int.
Exh.
E xhaust 1.91
Inlet 2.03
2.12
Closed
55-64 @ 1.66
85-93 @ 1.69
76-84 @ 1.61
76-84 @ 1.70
74-86 @ 1.88
Open
180-192 @ 1.27
174-184 @ 1.30
183-195 @ 1.20
194-206 @ 1.25
288-312 @ 1.38
1-21/32
1-5/8
1-5/8
1-23/32
1-7/8
Installed Height
1 /3 2 "
Damper
.0012 - .0029
Free Length
Pressur e
lbs. @ i n.
.0010 - .0027
.0015 - .0032
Service
Valve
Spring
(Outer)
1.70:1
190
Free Length
1.94
1.86
A pprox. # o f Coils
TR U C K SUPP SPECS
SPECIFICATIONS 11
TUNE-UP CHART
ENGINIS Type
Displacement
Make &
Number
Gap
292
250
350
AC-R44T
ACR46TS
.035
454
150 psi
130 psi
COMPRESSION
SPARK
PLUG
V8
In Line
ACR45TS
.035
.045
DISTRIBUTOR Timing
DRIVE
BELT
A /C Compressor
AIR CLEANER
VALVE LASH
IDLE RPM
FUEL
PUMP
Pressure in lbs.
3 -1 /2 to 4 -1 /2
Volume
CRANKCASE VENTILATION
7 to 8 -1 /2
1 pint in 30-45 seconds (a) cranking speed
Refer to Section 0 of this Manual
PSI At Cranking Speed, throttle wide open - Maximum variation, 20 PSI between cylinders.
At idle speed with vacuum advance line disconnected and plugged. On Step Van vehicles, use number tw o cylinder
and timing tab on bottom of cover.
D o not pry against A.I.R. pump housing.
C A UTIO N :In addition to its function of filtering air drawn into the engine through the carburetor, the air cleaner
also acts as a flame arrestor in the event the engine backfires. Because backfiring may cause fire in the engine
compartment, the air cleaner should be installed at all times unless|its removal is necessary for repair or maintenance
services.
(5) Replace filter element located in carburetor inlet as indicated in Section 0 of this Manual.
TR U CK SUPP SPECS
SPECIFICATIONS 12
ENGINE TORQUES
Usage
Size
1 /4 -2 0
In Line
250
292
5 /1 6 -1 8
Camshaft Sprocket
Clutch P re ssu re Plate
Oil Pan (To Crankcase)
Oil Pump
Push Rod Cover
Water Pump
20 lb. ft.
75 lb.
115 lb.
50 lb.
15 lb.
7 /1 6 -1 4
Cylinder Head
Main Bearing Cap
Oil Pump
Rocker Arm Stud
7 /1 6 -2 0
Flyw heel
Torsional Damper
1 /2 -1 3
Cylinder Head
Main Bearing Cap
1 /2 -1 4
1 /2 -2 0
T orsicnal Damper
Oil F ilter
Oil Pan Drain Plug
F lyw heel
14mm
5/8
Spark Plug
454
80 lb. in.
80 lb. in.
50 lb. in.
70 lb. in.
45 lb. in.
35 lb. ft.
3 /8 -2 4
262& 350
80 lb. in.
80 lb. in.
Mark IV V-8
80 lb. in.
1 1/32-24
3 /8 -1 6
Sm all V -8
55 lb. in.
80 lb. in.
50 lb. in.
20 lb. ft.
in.
in.
in.
in.
65 lb. in.
35 lb. ft.
20 lb. ft.
30 lb. ft.
20 lb. ft.
/ tn
30 lb . f t . ^ '
30 lb. ft.
30 lb. ft.
|
35 lb. ft.
30 lb. ft.
30 lb. ft.
30 lb. ft.
40 lb. ft.
65 lb. ft.
45 lb. ft.
50 lb. ft.
65 lb. ft.
70 lb. ft.
80 lb. ft.
65 lb. ft.
50 lb. ft.
60 lb. ft.
60 lb. ft.
60 lb. ft.
65 lb. ft.
95 lb. ft.
110 lb. ft.
20 lb. ft.
Hand Tight
85 lb. ft.
25 lb. ft.
20 lb. ft.
110 lb. ft.
15 lb. ft.
TR U C K SUPP SPECS
SPECIFICATIONS 13
CARBURETOR
SECTION 6M
IDENTIFICATION
10
2 0- 30
20
20- 30 2 0- 3 0
and
Type
Type
LD4
1 MV
M anual
A u to m a tic
M anual
A u to m a tic
17056003
17056002
17056 303
17056302
250L6
HD
LD4
1 MV
17056007
1 7056006*
292L6
HD
L25
1 MV
17056009
17 056 008
1 7056309
17056308
350V8
LD
LF5
2GC
17056115 17 056116
350V8
LD
LF5
2GC
17056123
17056124
350V8
LD
LS9
M4MC 17056209
17 056 208
17056 509
17056508
10
350V8
LD
LS9
M4MC 17056219
17056218
1 7056519
17056518
20 - 30
350V8
HD
LS9
4MV
7045214
7 04 52 14
7 04 55 8 4
70455 84
350V8
HD
LS9
4MV
7045216
7 04 52 16
7 045 5 86
70455 86
350V8
HD
LS9
4MV
7045213
70452 13
7 045 5 83
70455 83
704 55 85
10
20- 30
10-20
350V8
HD
LS9
4MV
7 04 52 15
400V8
HD
LF4
4MV
7 04 52 25
70455 89
400V8
HD
LF4
4MV
70452 29
70455 88
454V8
LD
LF8
M4ME
17056221
454V8
HD
LF8
4MV
17 056212
454V8
HD
LF8
4MV
17056212
17056212
30
454V8
HD
LF8
4MV
17 056217
30MH
454V8
HD
LF8
M4MC
17056512
454V8
HD
LF8
M4MC
17056512
17056512
454V8
HD
LF8
M4MC
30MH
20 - 30
10-20
10
30MH
20- 30
10-20
and
C alifornia
10
10-20
rel
LD
Federal
B ar
m ent
250L6
10
10- 20- 30
RPO
D isplace
10
10
10
CARBL RETOR
ENGINE
VEHICLE
2 0- 30
30
17056517
CARBURETOR ADJUSTMENTS
2GC
Carburetor
Choke Rod
NUMBER
Float
Vacuum
Float
Pump Rod
(Fast Idle
Choke
Unloader
Break
Drop
Setting
Cam)
170561 1 5(M)
21/32
1-9/32
1 70561 16(A)
21/32
1-9/32
1 7 0 5 6 1 23(M)
17056124(A)
21/32
1-9/32
21/32
1-9/32
1-11/16
1-11/16
.260
.130
.325
INDEX
.260
.130
.325
1 NR
1-11/16
1-11/16
.260
.130
.325
INDEX
.260
.130
.325
1 NR
TR U CK SU PP SPECS
SPECIFICATIONS 14
CARBURETOR ADJUSTMENTS
1 MV
NUMBER
Float
Primary
A uxiliary
(Fast Idle
Vacuum
Vacuum
Cam)
Break
Break
M etering
Carburetor
Choke Rod
Choke
Unloader
Rod
Setting
17056002(A)
1 1/ 3 2
.080
.130
.165
.265
.335
17056003(M)
1 1/ 3 2
.080
.145
.180
W.O.
.335
1 7056004(A)
1 1/ 32
.080
.130
.165
.335
Refer to
17056006(A)
1/4
.080
.130
.165
.265
.270
Section
.165
.275
6M for
17056007(M)
1/ 4
.070
.130
1 7056008(A)
1/ 4
.070
.150
.190
.275
Service
17056009(M)
1/ 4
.070
.150
.190
.275
Procedure
1 7056302(A)
1 1/32
.080
.155
.190
W.O.
.325
17056303(M)
1 1/32
.080
.180
.225
W.O.
.325
.275
.275
1 7056308(A)
1/ 4
.070
.150
.190
17056309(M)
1/4
.070
.150
.190
4 M V Carburetor
NUMBER
(A ) A u to m a tic Trans.
(M )
Float
Pum p
Level
R od*
M a n u a l Trans.
C hoke
Rod
A ir
Vacuum
A ir
Un
C hoke
(Fast
V a lve
B reak
V a lv e
load er
S e t
Idle
D ashp ot
S p rin g
Cam )
7045213(A/M)
tin g
W in d u p
1 1/32
1 1/32
9/32
9/32
.290
.290
.015
.015
.145
.145
7/8
7/8
.295
9/32
.290
.015
.145
7/8
.295
7045216(A/M)
1 1/ 3 2
1 1/32
9/32
.290
.015
.145
7/8
.295
7045225(A)
1 1/32
9/32
.015
.138
3/4
.295
to
.015
.138
3/4
.295
Section
.015
.155
7/8
.295
6M
7/8
.295
for
7/8
.295
Choke
7/8
3/4
.295
Rod
Adjust.
3/4
7/16
7/16
.295
.295
.295
7045214(A/M)
7045215(A)
7045229(A)
7045583(A/M)
1 1/ 3 2
9/32
1 1/32
9/32
.290
.290
.290
7045584(A/M)
1 1/32
9/32
.290
.015
7045585(A)
7045586(A/M)
1 1/32
9/32
.290
.015
.155
.155
1 1/32
9/32
.290
.015
.155
7045588(A)
1 1/32
9/32
1 1/ 3 2
3/8
3/8
9/32
9/32
9/32
.290
.290
.290
.290
.015
7045589(A)
.155
.155
.155
.1 55
1 7 0 5 6 2 12(A/M)
1 705621 7(A)
.015
.015
.015
.295
.295
Refer
TR U C K SU PP SPECS
SPECIFICATIONS 15
Float
Pum p
Level
Rod*
C hoke
C hoke
Rod
A ir
F ro n t
R ear
A ir
U n
C hoke
lo a d e r
S e t
Coil
(Fast
V a lve
V acuum
V acuum
V a lv e
Lever
Idle
D ashp ot
B reak
B reak
S p rin g
Cam )
tin g
W in d u p
1 7056208(A)
9/32
.120
.325
.015
.185
1 7056209(M)
9/32
.1 20
.325
.015
.185
17056218(A)
5/16
9/32
.120
.325
.015
.185
___
7/8
.325
2NL
1 7 0 5 6 2 1 9(M)
5/16
9/32
.120
.325
.015
.185
7/8
.325
3NL
1 7056508(A)
9/32
.120
.325
.015
.185
7/8
.325
2NL
1 7056509( M)
**
9/32
.1 20
.015
.185
7/8
.325
1NL
1 705651 2(A/M)
17056517(A)
7/16
9/32
.1 20
.325
.325
.015
.185
7/8
.275
INDEX
7/16
9/32
.120
.325
.015
.185
7/8
.275
INDEX
17056518(A)
5/16
9/32
.1 20
.325
.015
___
7/8
.325
1 7 0 5 6 5 1 9(M)
5/16
9/32
.1 20
.325
.015
.185
.185
7/8
.325
2NL
1NL
7/8
.325
2NR
7/8
.325
2NL
7/8
.325
3NL
M4M E Carburetor
1 7056221(A)
*
7/16
9/32
120
.300
.015
1 60
IDLE SPECIFICATIONS
SHOWN IN RPM
LIGHT DUTY EMISSION REQUIREMENTS
ENGINE
DISPLACE
MENT
C.I.D.
BBL.
TRANS.
USAGE
LOW
(BASE)
IDLE
CURB
IDLE
FAST
IDLE
IDLE
MIXTURE
EMIS
SION
FAMILY
250
FED
FED
575/550DR
12F1U
425N
550DR
900N
2100N +
250
AUTO
MAN
425DR
2100N +
12F1U
250
CAL
425DR
600DR
2100N +
250
AUTO
MAN
1075/900N
630/600DR
CAL
425N
1000N
2100N +
1150/1000N
350
AUTO
350
350
350
350
350
454
12F1U
600DR
650/600DR
12FIU
12J2
800N
900/800N
12J2
FED
MAN
FED
AUTO
MAN
FED
600DR
1600N
650/600DR
12J4B
FED
800N
1600N
900/800N
12J4B
600DR
1600N
650/600DR
12J4
800N
600DR
1600N
900/800N
12J4
1600N
650/600DR
12R4D
CAL
AUTO
MAN
CAL
AUTO
FED
TR U CK SU PP SPECS
SPECIFICATIONS 16
250
292
A/M
FED
45 0
600N
2400N
700/600
GM111
A/M
F/C
600N
2400N
700/600
GM112A
350
A/M
FED
450
600N
1600N
750/600
GM1 13
CAL
700N**
1600N
800/700
GM 1 13
F/C
700N**
1600N
770/700
GM1 13
700N
1700N
800/700
GM1 15
700N*
1700N
750/700
GM1 15
350
+
*
A/M
400
454
A/M
FED
454
A/M
CAL
AUTO
**
TORQUE SPECIFICATIONS
1MV Carburetor
Screw
A ir Horn to Bowl
Air Cleaner Bridge
Throttle Body to Bowl
Needle Seat
Metering Jet
Fuel Inlet Nut
Fast Idle Cam
Choke Lever
Pump Lever
* L o c tite A W
2GC Carburetor
Torque
(in. Ibs.)
45
70
180
45
40
400
50
25
30*
o r e q u iv a le n t
M4MC/M4ME Carburetor
Torque
Screw
(in. Ibs.)
THROTTLE BODY
Throttle Body to Bowl
46
CHOKE HOUSING
Choke Lever
Choke Housing Attaching
Choke Housing Cover
14
46
26
AIR HORN
A ir Horn to Bowl 10-32
A ir Horn to Bowl 8-32
A ir Horn to Throttle Body
Choke Lever
Vacuum Break Unit
Fuel Inlet Nut
Needle Seat
Metering Jet
Solenoid Bracket
Torque
THROTTLE BODY
Throttle Body to Bowl
72
BOWL
Cluster
Fast Idle Cam
Metering Jet
46
58
40
CHOKE HOUSING
Choke Lever
Choke Hsg. to Throttle Body
Choke Housing Cover
14
46
26
AIR HORN
A ir Horn to Bowl
Vacuum Break Unit
Choke Shaft
Fuel Inlet Nut
Needle Seat
46
26
14
400
45
4MV Carburetor
Torque
Screw
46
26
46
14
26
400
45
40
71
(in. Ibs.)
Screw
(in. Ibs.)
46
26
46
46
26
71
400
40
45
TRUCK SU PP SPECS
SPECIFICATIONS 17
ENGINE ELECTRICAL
SECTION 6Y
STARTING MOTOR
Application
Model No.
1108778
Spec.
No.
Battery
Size
Volts
3573
2300 Watts
50-80*
5500-10500
3573
2300 Watts
50-80*
5500-10500
Free Speed
Amperes
RPM
(C & K-10)
250 L-6 (LD4)
1108779
(G-Van)
1108780
2438
2900 Watts
5 0- 8 0 *
3500-6000
1108781
350 & 40 0 V8
3563
2900 Watts
6 5- 9 0 *
7500-10500
3563
4000 Watts
6 5- 9 0 *
7 5 0 0 - 1 0 50 0
3563
40 00 Watts
65-90*
7500-10500
(LF4,LF5,LS9)
454 V8 (LF8)
1108781
(Exc P30032)
454 V8 (LF8)
1108782
(P30032)
i ncl udes Solenoid
GENERATORS
Application
M odel No.
Delco Rem y
Field C urrent A m p s
(8 0 F )
Spec. No.
@
1102491
A ll 2 5 0
L -6 (Base).
G -T ruck 2 9 2
Cold O u tp u t*
Amps @
5000
Rated Hot
RPM
O u tp u t* * Am ps
1 2 Volts
4519
4 .0
4 .5
33
37
L - 6 (Base).
1102478
A ll L -6 - w ith C 4 2
4520
4 .0
- 4 .5
51
55
1102479
A ll V -8
- w ith C 4 2
4520
4 .0
- 4 .5
51
55
- w ith
4522
4 .0
- 4 .5
57
61
4521
4 .0
- 4 .5
38
42
1102480
A ll V -8
K 7 6 . P 3 1 8 3 2 Truck
4 5 4 V -8 (Base). G 3 0 0 0 3 T ruck
3 5 0 V -8
1102489
(Base)
A ll L -6 - w ith
P -T ruck 2 9 2
K 79.
L -6 (Base)
1102490
A ll L -6 - w ith K 7 6
4522
4 .0
- 4 .5
57
61
1102394
A ll C -K -G T ru ck
4519
4 .0
- 4 .5
33
37
4521
4 .0
- 4 .5
38
42
(Exc G 3 0 0 0 3 ) V -8
1102841
(Base)
A ll P -Truck (Exc P 3 1 8 3 2 ) V -8
A ll V -8
- w ith
(Base)
K79.
TR U CK SU PP SPECS
SPECIFICATIONS 18
DISTRIBUTOR
APPLICATION
MODEL NO.
EMISS CLASS
L.D.
1112863
L -6
250
C -1 0
(L D 4 )
H.D.
Federal
(0 3 )
4 -S p d T rans
C -1 0
(0 3 )
&
CENTRIFUGAL
VACUUM
INITIAL
SPARK PLUG
ADVANCE
ADVANCE
TIMING
10 BTC
R 46TS
0 @
1100
0 @
7 @
2300
18 @
16 @
4200
4'
Hg
1 2" Hg
(.0 3 5 )
C -1 0
A u to Trans
1110667
L -6
250
(L D 4 )
C alif
C & G -1 0
M anual Trans
1110650
L -6
250
C alif
A u to Trans
L -6
250
(L D 4 )
Federal
3 -S p d Trans
L -6
250
C &
(L D 4 )
Federal
A ll Trans
L -6
4*
12'
Hg
6 BTC
Hg
R 46T S
(.0 3 5 )
(a) 4 2 0 0
0 @
1 100
0 @
7 @
2300
15 @
4*
12*
Hg
10 BTC
Hg
R 46T S
(.0 3 5 )
(a) 4 2 0 0
0 @
1000
0 @
7 @
1600
24 @
4*
15"
Hg
6 BTC
Hg
R 46T S
(.0 3 5 )
(a) 4 2 0 0
0 @
1 100
0 @
14 @
2300
10 @
10'
Hg
6 BTC
1 3 ' Hg
R 46T
(.0 3 5 )
24 @ 4 1 0 0
292
&
15 @
20
K -1 0
C.K.G
0 @
1600
16
C & G -1 0
1112887
1000
7 @
20
(L D 4 )
C & G -1 0
1110666
0 @
(L 2 5 )
P -2 0 .
8 BTC
30
R 44T
(.0 3 5 )
A ll Trans
1110664
L -6
C &
292
(L 2 5 )
C alif
P -1 0 -2 0 -3 0
G -2 0 -3 0 :
K -2 0
M anual Trans
0 @
1 100
0 @
6 @
2000
10 @
14 @
2300
10'
13'
Hg
8 BTC
Hg
R44T
(.0 3 5 )
24 @ 4 1 0 0
C -1 0 - 2 0 - 3 0
G -2 0 -3 0
P -1 0 -2 0
K -2 0
A u to Trans
1112880
1112905
0 @ 1200
Federal
A u to T rans
12 @ 2000
M an T rans
22
V -8
350
4BBL
C alif
(LS9)
V -8
(LS9)
350
4BBL
Federal
18 @ 1 2 H g
0 @
1200
0 @
12 @
2000
15 @
22
1112888
(a) 4 2 00
6 BTC
0 @ 4 Hg
12'
Hg
(.045)
2 BTC
6 BTC
Hg
R 45T S
(.0 4 5 )
(a) 4 2 0 0
0 @
1 100
0 @
12 @
1600
18 @
16
6'
R 45TS
4'
Hg
1 2 ' Hg
8 BTC
R 45T S
(.0 4 5 )
(a) 2 4 0 0
TR U CK S U PP SPECS
SPECIFICATIONS 19
DISTRIBUTOR Continued
E M IS S C LA S S
A P P LIC A T IO N
M O D E L NO.
L.D .
1112884
V -8
350
4BBL
400
4BBL
350
4BBL
H.D .
Calif
(LS9)
V -8
C E N T R IFU G A L
VACUUM
IN IT IA L
SPARK
ADVANCE
ADVANCE
TIM IN G
(TYPE &
1 150
0 @
17 @
2900
10 @
22 @
4200
0 @
8"
Hg
13"
PLUG
G AP)
R 44T X
2 BTC
Hg
(.0 6 0 )
(LF4)
1 1 12940
V -8
Federal
(LS9)
0 @
1200
15 @
2 700
0 @
15 @
8"
Hg
1 5 .5 "
8 BTC
R44TX
Hg
(.0 6 0 )
20 @ 4 2 0 0
1 1 12941
V -8
400
Federal
4BBL
(LF4)
0 @
1000
0 @
8 @
1600
10 @
8"
Hg
13"
4 BTC
R 44T X
Hg
(.0 6 0 )
19 (a) 3 4 5 0
1 1 12886
V -8
454
w/
1112494
454
Federal
4BBL
P /U
w /o
Cat C o n v e rte r
V -8
454
0 @
1300
0 @
12 @
4200
18 @
4"
Hg
7"
Hg
10"
Hg
12 BTC
R 45T S
(.0 4 5 )
C -1 0
&
454
17"
8 BTC
R 45T S
Hg
(.0 4 5 )
20 @ 4 2 0 0
R44T
(.0 4 5 )
P /U
P -3 0
1 100
0 @
14 @
2800
20 @
20 @
4200
0 @
Calif
4BBL
P /U
Cat C o n v e rte r
w /R P O
C -1 0
0 @
15 @
S ubu rban
(LF8) C -1 0
w /o
1 100
2800
F44
C 2 0 -3 0
V -8
0 @
14 @
Federal
4BBL
(LF8) C -1 0
w /R P O
P /U
Cat C o n v e rte r
V -8
(LF8) C -1 0
1112869
Federal
4BBL
(LF8) C -1 0
Or
6"
Hg
15"
R 44T
8 BTC
Hg
(.0 4 5 )
F44
S ub u rb a n
C 2 0 - 3 0 & P -3 0
- N one (E le c tro n ic a lly G ove rne d)
BATTERY
M odel No.
A p p lic a tio n
C ranking
Power @
25
A m p.
Reserve
0 F. (W atts)
C apacity (M inutes)
Y87P
250 L-6
275A @ 0 F
2500
60
R87P
350A @ 0 F
3200
80
465 A @ 0 F
400 0
125
350 V-8
R89WP
R89-5
RPO UA1
465 A @ 0 F
400 0
125
R87-5
RPO TP2
430 A @ 0 F
3500
100
TRUCK SU PP SPECS
SPECIFICATIONS 20
SECTION 7M
THREE SPEED SAG INAW
Clutch Gear Retainer to Case B o lts ................
Side Cover to Case Bolts ...................................
Extension to Case Bolts.....................................
Shift Lever to Shifter Shaft B o l t s ...................
Lubrication Filler P l u g .....................................
Transmission Case to Clutch Housing Bolts . .
Crossmember to Frame N u t s ...........................
Crossmember to Mount B o l t s ........................
2-3 Cross Over Shaft Bracket Retaining Nut .
1-Rev. Swivel Attaching B o l t ...........................
Mount to Transmission B o l t ...........................
lbs.
lbs.
lbs.
lbs.
lbs.
lbs.
lbs.
lbs.
lbs.
lbs.
lbs.
ft. lbs.
ft. lbs.
ft. lbs.
ft. lbs.
ft. lbs.
ft. lbs.
ft. lbs.
ft. lbs.
ft. lbs.
ft. lbs.
ft. lbs.
TR U C K SU PP SPECS
SPECIFICATIONS 21
A U T O M A T IC T R A N S M IS S IO N S
SECTION 7A
NEW PROCESS TRANSFER CASE MODEL 203
Adapter to Transfer Case Attaching Bolts . . .
Adapter to Transmission Attaching Bolts. . .
Transfer Case Bracket to Frame nuts (upper)
Transfer Case Bracket to Frame nuts (lower)
Transfer Case Shift Lever Attaching Nuts. . .
Transfer Case Shift Lever Rod Swivel
Lock N u t s .....................................................
Transfer Case Shift Lever Locking Arm Nut .
Skid Plate Attaching Bolt Retaining Nuts . . .
Crossmember Support Attaching Bolt
Retaining N u t ................................................
Adapter Mount B o lts ........................................
Intermediate Case to Range Box Bolts . . . .
Front Output Bearing Retainer B o lts ...........
O utput Shaft Yoke N u t s .....................
Front O utput Rear Bearing Retainer Bolts. . .
Differential Asrembly Screws. . . . ..............
Rear O utput Shaft H ousing..............................
Poppet Ball Retainer N u t ................................
Power Take Off Cover Bolts ...........................
Front Input Bearing Retainer B o lts................
Filler P l u g ...........................................................
38
40
50
65
25
ft.
ft.
ft.
ft.
ft.
lbs.
lbs.
lbs.
lbs.
lbs.
50 ft. lbs.
150 in. lbs.
45 ft. lbs.
45 ft.
25 ft.
30 ft.
30 ft.
150 ft.
30 ft.
45 ft.
30 ft.
15 ft.
15 ft.
20 ft.
25 ft.
lbs.
lbs.
lbs.
lbs.
lbs.
lbs.
lbs.
lbs.
lbs.
lbs.
lbs.
lbs.
TURBO HYDRA-MATIC 4 0 0 /4 7 5
TR U CK SU PP SPECS
SPECIFICATIONS 22
STEERING
SECTION 9
M A N U A L STEERING GEAR
Pow er
M anual
Components
G 1 0 -3 0
Thrust Bearing
Preload
6 to 11
C1p103
P20 - 30
K10 - 20
V e h ic le
G ear
R a tio
O v e ra ll
R a tio
24:1
29.4:1
to
36.7:1
17.5:1
24:1
29.4:1
to
36.4:1
17.5:1
21.4:1
to
26.5:1
P10
24:1
29.1:1
to
35.5:1
17.5:1
21.2:1
to
25.7:1
P20-30
24:1
29.1:1
to
35.3:1
17.5:1
21.2:1
to
25.7:1
G 10-20
G30
M otor Home
C 10
C20-30
14:1
O v e ra ll
R a tio
21.4:1
to
26.7:1
16.0:1
to
21.9:1
24:1
29.1:1
to
37.0:1
16:1
to
13:1
16.9:1
to
20.2:1
24:1
29.4:1
to
36.3:1
16:1
to
13:1
17.2:1
to
20.6:1
24:1
K 10-20
G ear
R a tio
24.6:1
to
28.0:1
16:1
to
13:1
13.2:1
to
17.2:1
lbs. in.
Adjuster Plug
Lock Nut
9 to 12
lbs. in.
85 lbs. ft.
5 to 11
lbs. in.*
Over Center
Preload
4 to 6
lbs. in.
Over Center
Lock Nut
9 to 13
lbs. in.*
4 to 10
lbs. in.*
25 lbs. ft.
Total Steering
Gear Preload
18 lbs. in.
Max.
14 lbs. in.
Max.
25 lbs. in.
Max.
All C, P, K and G
3 lbs. in. Max.
80 lbs. ft.
Over-Center Preload
lbs. in.
Over-Center Adjusting
Screw Locknut
35 lbs. ft.
Pressure
C10-30
G 10-20
G30
P10-30
SPECIFICATIONS 23
TORQUE SPECIFICATIONS
Component
C10-30
G10-30
K10-20
P10-30
M otorHom e
30 ft. lbs.
30 ft. lbs.
30 ft. lbs.
30 ft. lbs.
30 ft. lbs.
20 in. lbs.
20 in. lbs.
20 in. lbs.
20 in. lbs.
20 in. lbs.
35 in. lbs.
35 in. lbs.
35 in. lbs.
35 in. lbs.
35 in. lbs.
35 in. lbs.
35 in. lbs.
25 in. lbs.
25 in. lbs.
25 in. lbs.
25 in. lbs.
25 in. lbs.
45 in. lbs.
45 in. lbs.
45 in. lbs.
35 in. lbs.
35 in. lbs.
35 in. lbs.
35 in. lbs.
35 in. lbs.
60 in. lbs.
60 in. lbs.
60 in. lbs.
60 in. lbs.
60 in. lbs.
20 ft. lbs.
20 ft. lbs.
23 ft. lbs.
23 ft. lbs.
98 in. lbs.
98 in. lbs.
17 ft. lbs.
35 in. lbs.
35 in. lbs.
35 in. lbs.
35 in. lbs.
20 in. lbs.
30 in. lbs.
20 in. lbs.
30 ft. lbs.
30 ft. lbs.
30 ft. lbs.
70 in. lbs.
17 ft. lbs.
25 in. lbs.
43 in. lbs.
75 ft. lbs.
75 ft. lbs.
70 in. lbs.
70 in. lbs.
18 ft. lbs.
18 ft. lbs.
34 ft. lbs.
48 ft. lbs.
20 ft. lbs.
18 ft. lbs.
20 ft. lbs.
65 ft. lbs.
65 ft. lbs.
65 ft. lbs.
65 ft. lbs.
30 ft. lbs.
30 ft. lbs.
18 ft. lbs.
TR U CK SUPP SPECS
SPECIFICATIONS 24
TORQUE SPECIFICATIONS
Component
C10-30
G10-30
K10-20
P10-30
MotorHom e
45 ft. lb s.*
45 ft. lb s.*
45 ft. lb s.*
45 ft. lb s.*
45 ft. lbs *
90 ft. lbs.
30 ft. lbs.
30 ft. lbs.
30 ft. lbs.
30 ft. lbs.
60 ft. lbs.
70 ft. lbs.
60 ft. lbs.
60 ft. lbs.
60 ft. lbs.
70 ft. lbs.
60 ft. lbs.
60 ft. lbs.
48 ft. lbs.
48 ft. lbs.
50 ft. lbs.
70 ft. lbs.
70 ft. lbs. A
40 ft. lbs.
22 ft. lbs.
22 ft. lbs.
22 ft. lbs.
22 ft. lbs.
22 ft. lbs.
80 ft. lbs.
45 ft. lb s.*
15 in. lbs.
15 in. lbs.
15 in. lbs.
15 in. lbs.
15 in. lbs.
25 ft. lbs.
25 ft. lbs.
25 ft. lbs.
25 ft. lbs.
------
30 in. lbs.
18 ft. lbs.
15 in. lbs.
*P lus a d d itio n a l to rq u e re q u ire d to align ca s te lla tio n w ith c o tte r p in h o le in stud (n o t to exceed 6 0 f t . lbs. m a x im u m )
P lu s a d d itio n a l to rq u e re q u ire d to align ca s te lla tio n w ith c o tte r p in hole in stu d (n o t to exceed 100 f t . lbs. m a x im u m )
TR U CK SU PP SPECS
SPECIFICATIONS 25
1 0 -3 0 S e rie s
SERIES
DESCRIPTION
K 1 0 , 15
7 0 - 90 F t.
Lbs.
7 5 -1 0 0 Ft.
Lbs.
C , P 2 0 ,2 5 ,3 0 ,3 5
S in g le W h e e ls
9 0 - 1 2 0 F t.
Lbs.
C , P 2 0 ,2 5 ,3 0 ,3 5
D ual W h e e ls
1 1 0 -1 4 0 F t.
Lbs.
1 3 0 -1 8 0 F t.
Lbs.
C , P 1 0 , 15
TORQUE
SERIES
DESCRIPTION
G 1 0 , 15
5 5 - 75 F t.
Lbs.
G 2 0 ,2 5
7 5 - 1 0 0 F t.
Lbs.
G 3 0 ,3 5
S in g le W h e e ls
9 0 - 1 2 0 F t.
Lbs.
G 3 0 ,3 5
D ual W h e e ls
1 1 0 -1 4 0 F t.
Lbs.
TORQUE
TIRES
S ee "M in im u m T ire In fla tio n and "T ire Load
an d Infla tion P re s s u re C h a rts in S e c tio n 10 of
th is M a n u a l.
SHEET
M ETAL
SECTION 11
TORQUE SPECIFICATIONS
150
30
85
35
150
25
CK
in.
ft.
in.
ft.
in.
ft.
lbs.
lbs.
lbs.
lbs.
lbs.
lbs.
150
35
50
150
150
in.
ft.
in.
in.
in.
lbs.
lbs.
lbs.
lbs.
lbs.
G
150 in.
40 ft.
150 in.
18 ft.
18 ft.
P
lbs.
lbs.
lbs.
lbs.
lbs.
85 ft. lbs.
18 ft. lbs.
30 ft. lbs.
90 in. lbs.
150 in . lbs.
35 ft. lbs.
35 ft. lbs.
30 in. lbs.
150 in. lbs.
65 in. lbs.
92
150
150
150
in.
in.
in.
in.
lbs.
lbs.
lbs.
lbs.
TR U CK SU PP SPECS
SPECIFICATIONS 26
C-K TRUCK
Heater, Front A /C , Generator W arn in g Lamp ...................
2 0 Amp
15 Amp
.......
2 0 Amp
4 Amp
Heater, A /C
...............................................................................
......................
2 5 amp
10 amp
15 amp
3 amp
1 5 amp
15 amp
3 amp
15 amp
20 Amp
1 5 Amp
G TRUCK
The following wiring harnesses are protected by a "fusible link" which is a special wire
incorporated in the circuit; ignition, horn and headlamp hi-beam indicator circuits. Should
an electrical overload occur, this wire will fail and prevent damage to the major harness.
4 Amp
...................................................
25 Amp
1 5 Amp
CIRCUIT BREAKERS
P TRUCK
H eaterf. A ir C o n d itio n in g !
....................................................
25 Amp
3 Amp
1 5 Amp
.......................................
Models
Amperes
Location
C -K-P-G
15
Light
sw itch
Tailgate w in d o w m otor
C-K
Dash
3 0 (forw ard side)
Dash
(forw ard side)
3 Amp
Rear A /C (C69overhead)
1 5 Amp
W indshield W a s h e r/W ip e r
...................................................
25 Amp
1 5 Amp
1 5 Amp
10 Amp
TRUCK SU PP SPECS
SPECIFICATIONS 27
LA M P BULB DATA
C -K -P TRUCK
G TRU CK
Q uantity Trade
Used in
Power
Dome lamps:
Cab
1003
15 CP
21 1 -2
12 CP
168
3 CP
168
3 CP
168
3 CP
168
3 CP
1 157
3 - 3 2 CP
License lam p4
67
4 CP
1 157
3 - 3 2 CP
Head Lamps
6014
5 0 -6 0 W
168
3 CP
168
3 CP
168
3 CP
194
Used in
Q uantity Trade
Power
Dome lamps
2 1 1 -2
12 CP
168
3 CP
168
3 CP
168
3 CP
168
3 CP
1 1 57
3 - 3 2 CP
1 157
3 - 3 2 CP
License lamp
67
4 CP
6014
168
3 CP
168
3 CP
M arker lamps
16 8
3 CP
5 0 -6 0 W
168
3 CP
Back-up lamp
1 15 6
32 CP
1893
2 CP
2 CP
168
3 CP
Transmission Control
1445
0 .7 CP
Backing lamp
1 15 6
32 CP
H eater or A /C
1445
0 .7 CP
67
4 CP
Cargo lamp
1 142
21 CP
1816
3 CP
216
1 CP
53
1 CP
Courtesy lamp
1003
15 CP
W indshield w ip e r sw itch
161
1 CP
16 8
3 CP
10
1895
2 CP
Heater or A /C Contro,
1895
2 CP
1445
0 .7 CP
Cruise control
53
1 CP
W /S w ip e r sw itch lamp
161
1 CP
1Double filament sealed beam 60W high beam, 50W low beam.
Clock
Rear Ide n tific a tio n 7
U nderhood lamp
93
15 CP
168
3 CP
2 1 1 -2
12 CP
SPECIFICATIONS 28
R A D IA T O R
AND
G R IL L E
SECTION 13
TORQUE SPECIFICATIONS
CK
-
12
Grille
Grille B racket to
R adiator Support
50 in. lbs.
-
F an Guard
Coolant Recovery
T ank B rk t.
96 in . lbs.(bolts)
50 in . lbs.(screw s)
Hose Clamps
R adiator M ounting Panel
42 in . lbs.
96 in . lbs.
30 i n . lb s .
112
D rain Plug
in . lbs.
96 in. lbs.
1 5 0 in. lbs.
F an Shroud
23 in . lbs.
112
17 in . lbs.
in . lbs.
17 in. lbs.
18 f t. lbs.
To R adiator
To F ram e
in . lbs.
112
in . lbs.
18 in . lbs.
150 in . lbs.
150 in . lbs.
25 f t. lbs.
35 f t. lbs.
-
R adiator Baffle
150 in . lbs.
85 in . lbs.
42 in . lbs.
96 in . lbs.
BUMPERS
S E C TIO N 1 4
TORQUE SPECIFICATIONS C, P AND K
Front B um per.................................................................... ..35 ft. lbs.
Front Bumper Bracket and B r a c e ............................... 70 ft. lbs.
Rear Bumper to Outer B racket..................................... ..35 ft. lbs.
Rear Bumper Outer Bracket and Brace .................... 50 ft. lbs.
License Plate B r a ck et...................................................... ..18 ft. lbs.
Gravel D e f le c t o r .................................................................85 in. lbs.
Rear Step Bumper to Bracket or F r a m e .................... 40 ft. lbs.
TORQUE SPECIFICATIONS G
Front Face Bar to B r a ck et........................................ 24 ft. lbs.
Bracket to Cross S i l l ....................................................... 24 ft. lbs.
License Plate Bracket to Face B a r ................................100 in. lbs.
Rear Face Bar to Brackets ...............................................55 ft. lbs.
Bracket to Floor ................................................................ 55 ft. lbs.
ACCESSORIES
SECTION 15
CRUISE-MASTER
Solenoid R esista n ce........................................................................................................................................................................ 5 ohms 1 / 4 ohm
Solenoid Wire R e sista n c e .............................................................................................................................................................................. 40 ohms
Maximum allowable Vacuum Leakage rate for Servo u n i t ..................................................................... 5 inches o f Vacuum Per Minute
Not Greater than 1 inch o f Vacuum per 10 seconds
Operational Test S p e e d ...................................................................................................................................................................................... 55 MPH
TR U CK SUPP SPECS
CHEVROLET