^ s W U 'gw

CHASSIS

a -« n
*V3»
 SECTION 0

GENERAL INFORMATION
AND LUBRICATION
INDEX
Page Page
Series and Model Identification..................... ................. o -l Manual Transm ission...................................................... 0-6
Unit and Serial Number L o c a t io n s ................................. 0-2 Towing ........................................................................... 0-6
G.V.W. Serial Number Plate .................................... 0-2 Push Starts - Trucks equipped with automatic
Engine N u m b e r ............................................................... 0-2 tra n s m is s io n ............................................................... 0-6
Service Parts .Identification P l a t e ................................. 0-4 Lifting Chevy Van with H o is t .......................................... 0-6
Keys and L o c k s ............ .................................................. 0-4 Lifting with Auto Jack ................................................ .. 0-6
Pushing, Towing, and L if t in g .......................................... 0-6 Load Capacity C h a rt................................................... 0-6

GENERAL INFORMATION
The 1967 Truck model line up consists of 474 models on the left door hinge pillar on Conventional and L.D.F.C.
on 37 wheelbases, an increase of 107 more models and 2 models, on the upper left hand side of dash panel on
more wheelbases. cowl models, and on the steering column on Forward
A lettered prefix and 5-digit basic series numbering Control models. On Tilt cab models (fig. 2) the serial
system is introduced for 1967 Truck model identification. number and G.V.W. plates are located on the left door
A new combination G.V.W. and serial number plate is hinge pillar.
used on all models (fig. 1) except Tilt Cab and is located

SERIES AND MODEL IDENTIFICATION

CHASSIS 1 ENGINE 2
fc] - Conventional (Conventional Cab, Panel, Suburban) A All
G - Light-Duty Forward Control D L-4 Diesel
H - Conventional (Short Conventional Cab) E V- 8 Gasoline
J - Tandem (Short Conventional Cab) G V- 6 Diesel (GMC Truck)
K - Four-Wheel Drive J V- 8 Diesel
M - Tandem (Conventional Cab) M V- 6 Gasoline
P - Forward Control [1] L- 6 Gasoline
S - School Bus T L-3 Diesel
T - Conventional (Tilt-Cab) V V- 6 Diesel (Detroit Diesel)
W - Tandem (Tilt-Cab)
EXAMPLE: 1 2 3 4 5 6 7
C S 1 0 7 0 4
BODY AND BRAKE* 6-7
GVW RANGE 3 CAB-TO-AXLE DIMENSION 4-5 (* - Hydraulic unless otherwise specified.)
0 - All 00 - All 18 - 108-113" 00 - All
E3- 3600-5600# (07] - 42-47" 19 - 114-119" 02 - Flat Face Cowl
2 - 5500-8100# 09 - 54-59" 2 0 - 120-125" 03 - Cab
3 - 6700-10000# 10 - 60-65" 2 1 - 126-131" Stepside Pickup
4 - 10000- 20000# 12 - 72-77" 2 2 - 132-137" 05 - Panel
5 - 15000-23000# (single axle) 13 - 78-83" 23 - 138-143" 06 - Suburban (Panel Rear Doors)
24000-30000# (tandem axle) 14 - 84-89" 25 - 150-155" 09 - Cab, Platform, and Stake Rack
6 - 15000-26000” (single axle) 15 - 90-95" 28 - 168-173" 1 2 - Windshield Cowl
30000-45000# (tandem axle) 16 - 96-101" 31 - 186-191" 13 - Cab (full air brakes)
7 - 18500-27000# (single axle) 17 - 102-107" 16 - Suburban (Tail and Liftgate)
36000-45000# (tandem axle) 26 - Custom Suburban (Panel Rear Doors)
8 - 25500-32000# (single axle) 34 - Fleetside Pickup
36000-48000# (tandem axle) 35 - Forward Control Panel (Square-Front)
ms 36 - Deluxe Suburban (Panel Rear Doors)
42 - Forward Control Chassis
T 45 - Forward Control Panel (Round-Front)
f, 62 - Flat Face Cowl (full air brakes)

CHEVROLET TRUCK SERVICE M ANUAL

GENERAL INFORMATION 0-2

UNIT AND SERIAL NUMBER LOCATIONS

cab2 MODELj ASSEMBLY3 UNIT4
For the convenience of servicemen when writing up STYLE YEAR PLANT NUMBER
certain business papers such as L.&M .R.'s, Product In­
formation Reports, or reporting product failures in any GS10705 7 P 100025
way, we are showing the location of the various unit num­
bers. These unit numbers and their prefix or suffix are
necessary on these papers for various reasons - such as 1. Last number of model year (1967).
accounting, follow-up on production, etc. 2. See Series and Model Identification in this Section.
The prefixes on certain units identify the plant in which 3. P -G M Truck
the unit was manufactured, and thereby permits proper 4. Unit numbering will start at 100,001 at all plants.
follow-up of the plant involved to get corrections made
when necessary. Engine Number
Always include the prefix in the number.
The engine number (fig. 16) shows manufacturing plant,
GVW AND SERIAL NUMBER PLATE month and day of manufacture, and transmission type. A
typical engine number would be F1210FA, which would
The combination GVW and serial number plate reveals breakdown thus:
the truck GVW rating and serial number. Also included
on the plate is a space for indicating the date the truck F - Manufacturing Plant (F-Flint, T-Tonawanda)
was delivered to the customer. 12 - Month of manufacture (December)
A typical serial number is explained in the following 10 - Day of manufacture (tenth)
chart. FA - Transmission and engine type

CHEVROLET
M A X IM U M G V W RATING

0^ ---------------------
1
VEHICLE o
1 w
IDENTIFICATION NUMBER

1 C S 107047P10 0 0 ^ 5 1
D PI I

Fig. 1 - G . V . W . and Serial Fig. 2 - V e h ic le Id entification Plate F ig . 3 - Rear A x le Serial Number

Number Plate and G . W . V . Plate T ilt Cab Located at the Bottom Flange of
C arrier Housing

F ig . 4 - Rear A x le (Except H a lf Ton) Fig . 5 - 2-Speed A x le Serial Number Fig. 6 - Tandem A x le , Forward U nit -
- Forward Upper Surface o f C arrier Unit and Assembly Numbers Stamped
on Left Side of C arrier
 GENERAL INFORMATION 0-3

Fig . 7 - Tandem A x le , Rear U n it - Unit Fig . 8 - 3-Speed Transmission U nit Fig. 9 - 4 -Speed Transmission Unit
and Assembly Numbers Stamped on Number Located on Lower Left Side Number Stamped on Rear of Case,
Upper Portion o f C arrier o f Case A d jacen t to Rear o f Cover Above Output

Fig . 10 - N e w Process 5-Speed Unit Fig . 11 - 5 -Speed C lark Transmission F ig . 12 - 4-Speed A u x ilia ry Transmission
Number Stamped on Rear Face of Case Unit Number Stamped on Left Rear Unit Number
to Left of Drain Plug, Spicer 3000 Series o f C ase, N e a r P . T . O . Plate
Above Plug, Spicer 5000 Series on
N am eplate Left Side of Case at Rear

IfwAT'C
tuffBO

F ig . 13 - A lliso n Transmission Part Fig. 14- Powerglide Transmission U nit Fig . 15 - The Turbo H yd ra-M atic
Number and Production Date on Tag Number Located on Right Rear Transmission Serial Number is Located
Left Side of Case V e rtic a l Surface of O il Pan on the Light Blue Plate on the Right
Side of the Transmission
GENERAL INFORMATION 0-4

Fig . 16 - 6 -C ylin d er Engine Unit Fig. 17 - 8-C ylin d er Engine Unit F ig . 18 - Diesel Engine (Four C y c le )
Number Located on Pad at Right Number Located on Pad at Front, Serial Number
Hand Side o f C y lin d e r Block at Right Hand Side of C ylin d er Block
Rear of Distributor

Fig . 19 - Diesel Engine Serial Number Fig. 20 - Delecotron Unit Serial Number Fig . 21 - Battery Code Number
6-C ylind er Forward of Right C y lin d e r Located on C e ll C over Top of Battery
Head, 3, 4 -C ylin d er Rear
Right of C y lin d e r Head

Fig . 22 - Starter Serial Number and

Production Date Stamped on O uter
IM P O R T A N T : R E T A IN T H IS P L A T E A S A P E R M A N E N T R E C O R D
Case, Toward Rear

Service Parte Identification Plate Fig . 23 - Se rv ic e Parts Id entification Pla te

The Chevrolet Truck Service Parts Identification Plate REFER TO THIS INFORMATION WHEN ORDERING
(fig. 23) is provided on all Truck models. On most series PARTS.
it will be located on the inside of the glove box door, on P
series it will be located on an inner body panel. The KEYS AND LOCKS
plate lists the vehicle serial number, paint information Two keys (hexagonal head) are provided with each ve­
and all Production options or Special Equipment on the hicle. The keys operate the ignition switch and door
vehicle when it was shipped from the factory. ALWAYS locks.
 GENERAL INFORMATION 0-5

Lock cylinders are furnished for service uncoded, this 1. Lay the key on the diagram (fig. 25) with bottom of
necessitates the coding of these replacement lock cyl­ key flush with edge of the drawing, head and point
inders. carefully lined up.
The side bar type lock (fig. 24) is used for the ignition 2. Read the code in numbers 12345 from the head of key
and doors. To protect owners, truck lock manufacturers to the end from positions 1 to 6 inclusive. As each
stamp the lock numbers on the lock core, shaft, etc., depth is determined write that number in the blank
where they will not show until lock is removed. space provided above the position numbers (1-2-3-4-
5-6).
3. With key properly lined up on diagram, all cuts that
show in the first section are to be marked " 1 ".
TUMBLERS
4. Cuts that fall in the first black section, mark "2”.
5. Cuts that fall in the first white section, mark "3".
o) C3 6 . Cuts that fall in second black section, mark "4".
7. Cuts that fall in the second white section, mark "5".
(prvvvvvj)
After the numbers have been determined and written
SPRING RETAINER
above the cutting positions the lock cylinder should be
assembled as follows.
Fig. 24 - Side Bar Lock
Lock Cylinder Assembly—Refer to Figure 26
In addition, when a lock cylinder requires replacement
the lock code number may be obtained either from the 1. Hold cylinder with head of cylinder away and starting
at the head of the cylinder, insert the tumblers in
key, if available, or from old lock cylinder which is being
their proper slots in the order called for by the
replaced.
code, ribbed side toward you and long point down.
Once the code number of the lock is obtained look up
2. After all tumblers are in place, check for correct­
this number in a key cutting book.
ness with the code. Then press tumblers down with
All side bar locks furnished to the field by the Parts
one finger.
Department are uncoded, that is, they are furnished with­
3. Insert one tumbler spring in the space provided
out tumblers, springs or spring retainers, these parts
above each tumbler.
are serviced separately. The tumblers come in five dif­
ferent depths, indicated by numbers. CAUTION: If the springs are tangled, do not
The side bar locks have six tumbler positions, and in pull them apart—unscrew them.
looking up the cutting code, the following may be used as
an example. After key code number is determined, either
from key or from number stamped on lock cylinder refer
to your code book and record the key cutting information
as follows:
Key of Lock Key Cutting
Code Number Code Numerical
0V11 545431
Cutting or Tumbler 123456
position from head
of lock
NOTE: Key blanks used for ignition and door
locks are stamped with an "A".
The number that is written above the cutting or tumbler
position indicates each different tumbler which is to be
dropped into each tumbler slot of the lock.
In cases where a code book is not available, the dia­
gram shown on Figure 25 may be used to determine the
tumblers required to assemble an uncoded lock cylinder.

Fig. 2 6 - Assembling Lock C ylin d er

CHEVROLET TRUCK SERVICE M ANUAL

 GENERAL INFORMATION 0-6

4. Reverse the lock cylinders so that the head of the vehicle is to be towed at speeds above 30 MPH.
cylinder is now toward you. Insert the spring re ­ Both manual and automatic transmissions should be ^
tainer so that one of its six prongs enters into each towed in neutral only, with parking brakes fully released.
of the springs and the two large end prongs slide When towing a vehicle on its front wheels only, the
into the slots at either end of the cylinder. P ress steering wheel should be secured to maintain a straight
the retainer down with one finger. forward position.
5. To check, insert proper key and if tumblers are
installed properly the side bar will be allowed to Push Starts—Trucks Equipped with
drop down. If bar does not drop down, remove the Automatic Transmission
key, spring retainer, springs and tumblers and re­
assemble correctly. Do not attempt to start the engine by pushing the truck.
Should the battery become discharged, it will be neces­
6 . If after checking it is found that the lock is as­
sembled properly, remove key and place cylinder in sary to use an auxiliary battery with jumper cables to
a vise using leather or wood on each side to prevent start the engine.
damage to the cylinder.
CAUTION: To prevent damage to electrical
7. Stake the retainer securely in place by staking the
system never connect booster batteries in ex"
cylinder metal over both edges of the retainer ends
cess of 1 2 volts and connect positive to positive
using a suitable staking tool at right angles to the
and negative to negative.
top of the retainer and from the cast metal of the
cylinder over the retainer at each corner.
Lifting Van With Hoist
PUSHING, TOWING, AND LIFTING Many dealer service facilities and service stations are
equipped with a type of automotive hoist which bears upon
NOTE: Towing to start is not recommended some part of the front and rear axles in order to lift the
due to the possibility of the disabled truck ac­ vehicle. In Figure 27 the shaded portions indicate areas
celerating into the tow vehicle. recommended for hoist contact.

MANUAL TRANSMISSION Lifting With Auto Jack

When a push start is necessary turn off all electrical
The shaded areas on both the front and the rear axles,
loads such as heater, radio and, if possible, lights, turn
as shown in Figure 27, are recommended Van jack lifting
on key, depress the clutch, and place the shift lever in
points. The jack load rest must locate under the axle at
3rd gear. Release the clutch when your speed reaches
these points.
10 to 15 miles per hour.
LOAD CAPACITY CHART
Towing
If a vehicle equipped with an automatic transmission New spring capacities and mandatory equipment options
becomes disabled and requires towing, speed must not are included in the Load capacity chart on the following
exceed 30 MPH. Drive shaft must be disconnected, if pages.

F ig . 27 - V e h icle Lifting Points - C hevy Van

MANUAL
 GENERAL INFORMATION 0-7

GROSS VEHICLE WEIGHTS FOR 1967 CHEVROLET TRUCKS AND

SCHOOL BUS CHASSIS

T IR E S A N D E Q U IP M E N T 1
W H EEL­ FRONT FRONT REAR REAR R E C O M M E N D E D T IR E S M IN IM U M M A N D A T O R Y E Q U IP M E N T F O R
MODEL BASE GVW GCW AXLE S P R IN G S AXLE S P R IN G S FRONT REAR G V W R A T IN G

133-13480 115 4300* 1900 1900 2700 2200 7. 3 5 -1 4 -4 7. 3 5 -1 4 -4

----
135-13680
3900* 1900 6. 9 5 -1 4 -4 6. 9 5 -1 4 -4
90 2250 2400
GS 10 4500 § 7. 3 5 -1 4 -8 7. 3 5 -1 4 -8 R P O G50 H ea vy Duty R e a r S p rin gs
2200
GE 10 3050 R P O F60 F ro n t S p rin g s, R P O G50 R e a r
108 50 0 0 ** 2450 2900 7. 0 0 -1 4 -8 7. 0 0 -1 4 -8
S p rin g s, R P O H04 o r H05 R e a r A x le
4400* 2500 8. 1 5 -1 5 -4 8. 1 5 -1 5 -4
CS 10 115
4800 ... 2500 2500 3500 8. 15-1 5 -8 8. 15 -1 5 -8 R P O G50 R e a r S p rin gs
CE 10 127 4000
5000 § 7-1 7 . 5-6 7-17. 5-6
4600* 8. 15-1 5 -4 8. 15 -1 5 -4
KS 10 115
5300 ... 3300 2900 3300 3600 8. 15-1 5 -8 8. 15 -1 5 -8
K E 10 127
5600 § 7-1 7 . 5-6 7-17. 5-6
4600* 2500 8. 15-1 5 -4 8. 1 5 -1 5 -4
PS 10 102 ... 2500 2500 3500
5400 § 4000 7-1 7 . 5-6 7-17. 5-6 R P O G50 R e a r S p rin gs
5200* 2550 3050 7. 7 5 -1 5 -8 7. 7 5 -1 5 -8
GS 20 5800 ... 3000 3600 8. 1 5 -1 5 -8 8. 1 5 -1 5 -8 R P O F60 F ro n t S p rin gs
108 2750 3800
G E 20 6200 § 8-16. 5-6 8-16. 5-6 R P O G50 R e a r S p rin gs
5500* 7-17. 5-6 7-17. 5-6
4000
CS 20 6000 ... 7-1 7 . 5-6 8-17. 5-6
127 3000 2700 5200
C E 20 6700 7-17. 5-8 8-17. 5-8 R P O G50 R e a r S p rin g s
6000
7500 § 8-19. 5-6 8-19. 5-10
5700* 3800 7-1 7 . 5-6 7-17. 5-6
KS 20 6100 ... 8-1 7 . 5-6 8-17. 5-6
127 3500 3050 5200
K E 20 7200 5000 8-1 7 . 5-8 8-17. 5 -8 R P O G50 R e a r S p rin g s
7600 § 8-1 9 . 5 -8 8 -1 9 .5 -1 0
104 5600* 7-1 7 . 5-6 7-1 7 . 5-6
P S 20 125 6200 ... 4000 4000 5200 4800 7-1 7 . 5-6 8-17. 5-6
137 7000 § 8-17. 5-6 8-17. 5 -8
6700* 4800 8-1 7 . 5-6 8-17. 5 -8
CS 310 7 800 t+i ... 3000 6200 8-19. 5-6 8-19. 5-10 R P O G50 R e a r S p rin gs
133 3500 7200
CE 310 9000 7-1 7 . 5-6 7-17. 5 -6 D R P O G60 R e a r S p rin g E qu ip m en t
8300
10000§ 3500 8-19. 5-6 8-19. 5-6D R P O F60 F ro n t S p rin gs
6700* 4800 8 - 1 7 .5 - 6 8-17. 5-8
7800 rh ... 3500 3000 6200 8-19. 5-6 8-19. 5- 10 R P O G50 R e a r S p rin g s
CS 314 7200
157 9000 7-1 7 . 5-6 7-17. 5 -6 D R P O G60 R e a r S p rin g E qu ip m en t
CE 314 8300
10000§ 3500 7 - 1 7 .5 - 6 8-17. 5 -8 D R P O F60 F ro n t S p rin gs
8 -1 9 .5 - 6 8-19. 5 -10D R P O Z51 r e q u ir e s : R P O H22 H. D. R e a r A x le ,
14000** 4000 4000 11000 11800
In c lu d e s H. D. F r o n t A x le and S p rin g s.
104 7500* 4000 4800 8 -1 9 .5 - 6 8-19. 5-6
10000§ 6800 8-19. 5-6 8-19. 5 -6 D R P O F60 F r o n t S p rin g s , R P O G60 R e a r S p rin gs
P S 30 125 ... 4000
5000 R P O Z51 r e q u ir e s : R P O F60 F r t . S p rin g s,
137 14000** 11000 11800 8 - 1 9 .5 - 6 8-19. 5-10D
R P O H22 R e a r A x le

10500* 7. 0 0 -2 0 -8 7. 0 0 -2 0 - 8D
12000 ... 4000 4000 11000 11000 7. 5 0 -2 0 -8 7. 5 0 -2 0 -8 D
125 14000 7. 5 0 -2 0 -8 7. 5 0 - 2 0 - 8D R P O J70 P o w e r b r a k e E q u ip m en t
CS 40 137 R P O Z71 r e q u ir e s : R P O F47 F r o n t A x le , R P O F60
15000**
149 15000 7 .5 0 - 2 0 - 8 7. 5 0 -2 0 -1 0 D F r o n t S p rin g s , R P O H07 R e a r A x le in clu d in g
CE 40 167 16000 § 15,000 lb R e a r S p rin g s , R P O J70 P o w e r B ra k e
5000 6000 13500
157 E qu ip m en t
P S 40 175 R P O Z85 r e q u ir e s R P O F47 F ro n t A x le , R P O F60
18000** 17500 8. 2 5 -2 0 -1 0 8. 2 5 -2 0 -1 2 D F r o n t S p rin g s , R P O H07 R e a r A x le , R P O G55
R e a r S p rin gs. R P O J70 P o w e r B ra k e E qu ip m en t
10500* 7. 0 0 -2 0 -8 7. 0 0 -2 0 - 8D
97 12000 11000 11000 7. 5 0 -2 0 -8 7. 5 0 -2 0 - 8D
TS 40 109 14000 7. 5 0 -2 0 -8 7. 5 0 -2 0 - 8D R P O J70 P o w e r B ra k e E qu ip m en t
133 R P O Z71 r e q u ir e s : R P O H07 R e a r A x le
15000**
T E 40 145 15000 7. 5 0 -2 0 -8 7. 5 0 -2 0 - 10D In clu d in g 15000 lb. R e a r S p rin g s, R P O J70
16000§ ... 5000 6000
175 13500 P o w e r B r a k e E qu ip m en t
R P O Z85 r e q u ir e s : R P O H07 R e a r A x le ,
18000** 17500 8. 2 5 -2 0 -1 0 8. 2 5 -2 0 - 12D R P O G55 R e a r S p rin gs
R P O J70 P o w e r B ra k e E q u ip m en t

CHEVROLET TRUCK SERVICE MANUAL

GENERAL INFORMATION 0-8

GROSS VEHICLE WEIGHTS FOR 1967 CHEVROLET TRUCKS AND

SCHOOL BUS CHASSIS

T IR E S A N D E Q U IP M E N T S
W H EEL­ FRO NT FRONT REAR REAR R E C O M M E N D E D T IR E S M IN IM U M M A N D A T O R Y E Q U IP M E N T F O R
MODEL BASE GVW GCW AXLE S P R IN G S AXLE S P R IN G S FRO NT REAR G V W R A T IN G
10500* 4500 4000 7. 0 0 -2 0 -8 7. 0 0 - 2 0 - 8D
11C00 11000 R P O F47 F r o n t A x le and
14000 7. 5 0 -2 0 -8 7. 50 -2 0 - 8D
R P O F60 F ro n t S p rin gs
15000** R P O F47 F r o n t A x le , R P O F60 F ro n t S p rin gs,
15000 7 .5 0 -2 0 -1 0 7. 5 0 -2 0 -1 0 R P O H07 R e a r A x le in clu d in g 15000 lb. R e a r
SS 40 16000§
149 ---- 5500 6000 S p rin g s R P O J70 P o w e r B r a k e E qu ip m en t
13500 R P O Z85 r e q u ir e s
18000** 8. 2 5 -2 0 - 12D R P O F47 F r o n t A x le , R P O F60 F ro n t S p rin gs,
17500 8. 2 5 -2 0 - 12
R P O H07 R e a r A x le , R P O G55 R e a r S p rin gs;
R P O J70 P o w e r B r a k e E qu ip m en t
1 5 0 0 0 **
15000 7. 5 0 -2 0 -8 7. 5 0 - 2 0 - 8D
16000* 5000 6000
CS 50 125 17000 32000 7. 5 0 -2 0 -8 8. 2 5 -2 0 - 10D
R P O G55 R e a r S p rin g s
137 19500 § (C S )
149 R P O Z86 r e q u ir e s
15000
167 R P O F4 8 F r o n t A x le in clu d in g 3500 lb
CE 50 189 8. 2 5 -2 0 -1 0 9. 0 0 -2 0 -1 0 D F r o n t S p rin g s , R P O G56 R e a r S p rin g s.
2 2 0 0 0 ** 7000 7000 20800
R P O F03 H e a v y Duty F r a m e .
In ad d itio n to a b o ve eq u ip m en t, m u st o r d e r
51000
R P O L41 366 E n gin e

97 150001^
15000 7. 5 0 -2 0 -8 7. 50 -2 0 - 8D
TS 50 109 16000*

T E 50
133 17000 _ 7000 7000 15000 17500 7. 5 0 -2 0 -8 8. 2 5 -2 0 - 10D R P O G55 R e a r S p rin g s
145 19500 §
175 R P O Z86 r e q u ir e s
22 0 0 0 ** 20800 8. 2 5 -2 0 -1 0 9. 0 0 -2 0 - 10D
R P O G56 R e a r S p rin g s
M S 50 149 24000* 7. 5 0 -2 0 -8 7. 5 0 - 2 0 - 8D
167 30000§
--- 7000 7000 28000 30000
M E 50 7. 5 0 -2 0 -8 8. 2 5 -2 0 - 10D
185
CS 60 19000* 32000 18400 8. 2 5 -2 0 -1 0 8. 2 5 -2 0 - 10D
125 7000 7000 17000
C E 60 24000 § 20800 9 .0 0 -2 0 -1 0 10. 0 0 -2 0 -1 2 D RPO G56 R e a r S p rin g s
137
149 RPO Z76 r e q u ir e s
CE 60 167 2 7 5 00** 51000 9000 9000 18500 23000 1 0 .0 0 -2 0 -1 2 10. 0 0 -2 0 -1 2 D RPO F43 F r o n t A x le , R P O F9 4 F ro n t S p rin gs
RPO H66 R e a r A x le , R P O G58 R e a r S p rin gs
189
RPO Z50 F r a m e R e in f. R P O L41 366 E n ein e
TS 60 „ 97 19000* 32000 18400 8. 2 5 -2 0 -1 0 8. 2 5 -2 0 - 10D
7000 7000 17000
T E 60 109 24000 § 20800 9. 0 0 -2 0 -1 0 10. 0 0 -2 0 -1 2 D RPO G56 R e a r S p rin gs
133 RPO Z76 r e q u ir e s
T E 60 145 RPO F43 F r o n t A x le , R P O F 94 F ro n t S p rin gs
27 5 0 0 ** 51000 9000 9000 18500 23000 10. 0 0 -2 0 -1 0 10. 0 0 -2 0 - 12D
175 RPO H66 R e a r A x le , R P O G58 R e a r S p rin g s
RPO Z50 F r a m e R e in f. R P O L41 366 E n ein e
30000* 7000 8. 2 5 -2 0 -1 0 8. 2 5 -2 0 - 10D
36000§ ... 9000 9 .0 0 -2 0 -1 0 9. 0 0 -2 0 - 10D R P O F43 F r o n t A x le
9000
149 39 0 0 0 ** 30000 34500 R P O Z82 r e q u ir e s R P O F4 3 F r o n t A x le
M E 60 167 R P O Z78 r e q u ir e s : R P O F4 4 F ro n t A x le
4 1 0 0 0 **
185 ... R P O F96 F ro n t S p rin g s R P O L41 366 E n gin e
11000 11000 1 0 .0 0 -2 0 -1 2 10. 0 0 -2 0 - 12D R P O Z79 r e q u ir e s : R P O F 44 F r o n t A x le
45 0 0 0 ** 34000 39000 R P O F96 F r o n t S p rin g s , R P O H58
34000 lb. B o g ie , in c lu d e s 19500 lb. S p rin gs
R P O L41 366 E n gin e
SS 520 16000* 15000 7. 5 0 -2 0 -8 7. 50 -2 0 - 8D
189 17000 5500 6000 8. 2 5 -2 0 - 10
SE 520 17500 8. 2 5 -2 0 - 10D
R P O G55 R e a r S p rin g s
19500§ 9 .0 0 -2 0 - 10 9. 0 0 -2 0 - 10D
SS 525
217-1/2 15000 R P O Z86 r e q u ir e s :
SE 525
SS 528 22 0 00** ... 7000 R P O F 48 F r o n t A x le
235 7000 20800 9 .0 0 -2 0 - 10 9. 0 0 -2 0 - 10D
SE 528 in clu d in g 3500 lb. e a c h F r o n t S p rin gs
R P O G56 R e a r S p rin g s
16000* 15000 7. 5 0 -2 0 -8 7. 50 -2 0 - 8D
SE 531 253-1/2 18000 ... 7000 7000 15000 17500 8. 2 5 -2 0 -1 0 8. 2 5 -2 0 - 10D R P O G55 R e a r S p rin g s
22000 § 20800 9 .0 0 -2 0 -1 0 9. 0 0 -2 0 - 10D R P O G56 R e a r S p rin g s
SE 600 235 19000* ... 18400 8 .2 5 -2 0 -1 0 8. 2 5 -2 0 - 10D
7000 7000 17000
253-1/2 23000 § 20800 9. 0 0 -2 0 -1 0 9. 0 0 -2 0 - 10D R P O G56 R e a r S p rin g s
 GENERAL INFORMATION 0-9

GROSS VEHICLE WEIGHTS FOR 1967 CHEVROLET TRUCKS AND

SCHOOL BUS CHASSIS

T IR E S A N D E Q U IP M E N T J
W H EEL­ FRONT FRONT REAR REAR R E C O M M E N D E D T IR E S M IN IM U M M A N D A T O R Y E Q U IP M E N T F O R
MODEL BASE GVW GCW AXLE S P R IN G S AXLE S P R IN G S FRONT REAR G V W R A T IN G

25000 §* 45000 7000 7000 9. 0 0 -2 0 -1 0 10. 0 0 -2 0 -1 2 D

127 18500 18500 R P O F43 F r o n t A x le , R P O F9 4 F r o n t S p rin g s,
2 7 5 0 0 ** 51000 9000 9000 1 0 .0 0 -2 0 -1 2 10. 0 0 -2 0 -1 2 D
R P O F06 F r a m e R e in fo r c e m e n ts .
139 R P O H74 o r H75 R e a r A x le , in c lu d e s 11, 000 lb.
2 9 0 0 0 ** 51000 7000 7000 ea ch r e a r s p rin g s , R P O F0 6 F r a m e R e in f o r c e ­
151 m en ts.
H M 70
22000 22000 R P O F43 F ro n t A x le , R P O F9 4 F r o n t S p rin g s,
169 R P O H74 o r H75 R e a r A x le , in clu d es 11,000 lb.
31 0 0 0 ** 55000
10. 0 0 -2 0 -1 2 11. 0 0 -2 0 -1 2 D ea ch R e a r S p rin g s, R P O F07 H i- T e n s ile F r a m e
191 9000 9000 R e in fo r c e m e n ts & on H M 714-7 1 7 -7 2 0 .
R P O F43 F ro n t A x le , R P O F 94 F r o n t S p rin g s ,
205 X
32 0 00** 55000 23000 24000 R P O H82 R e a r A x le , in c lu d e s 12,000 lb. ea ch
R e a r S p rin g s , R P O F07 H i- T e n s ile F r a m e
217 R e i n f o r c e m e n t s ^ on H M 714-7 1 7 -7 2 0 .

25500§* 51000 7000 7000 9 .0 0 -2 0 -1 0 10. 0 0 -2 0 -1 2 D

127 18500 18500
27 5 0 0 ** 51000 9000 9000 1 0 .0 0 -2 0 -1 2 10. 0 0 -2 0 - 12D R P O F 43 F r o n t A x le , R P O F9 4 F r o n t S p rin gs.
R P O H 74 o r H75 R e a r A x le , in c lu d e s 11, 000 lb.
139 2 9 0 0 0 ** 55000 7000 7000
ea ch R e a r S p rin g s.
R P O F43 F r o n t A x le , R P O F 9 4 F r o n t S p rin g s,
146 22000 22000
R P O H 74 o r H75 R e a r A x le , in clu d es 11, 000 lb.
31 0 0 0 ** 55000
1 0 .0 0 -2 0 -1 2 11. 0 0 -2 0 -1 2 D ea ch R e a r S p rin g s, R P O F07 F r a m e
151
R e in fo r c e m e n ts .
H M 80 9000
R P O F 43 F r o n t A x le , R P O F 9 4 F ro n t S p rin g s,
169
32 0 0 0 ** 55000 23000 24000 R P O H82 R e a r A x le , in c lu d e s 12, 000 lb. each
R e a r S p rin g s , R P O F07 F r a m e R e in fo r c e m e n ts .
191
R P O F43 F r o n t A x le , R P O F94 F r o n t S p rin g s,
65000 9000 9000 23000 24000 1 0 .0 0 -2 0 -1 2 11. 0 0 -2 0 -1 2 D R P O H82 R e a r A x le , in c lu d e s 12, 000 lb. e a ch
205
R e a r S p rin g s, R P O F07 F r a m e R e in fo r c e m e n ts
R P O L 29, 478M E n g in e.
217
24000 §* 45000 10. 0 0 -2 0 -1 2 D
97 7000 9 .0 0 -2 0 -1 0
2 5 5 0 0 ** 45000 18500
109
27 5 0 0 ** 45000 9000 9000 10. 0 0 -2 0 -1 2 1 0 .0 0 -2 0 -1 2 R P O F43 F r o n t A x le , R P O F 9 4 F r o n t S p rin g s.
133
T M 70 2 9 0 0 0 ** 45000 7000 7000 R P O H74 o r H75 R e a r A x le .
18400
145 R P O F43 F r o n t A x le , R P O F94 F r o n t S p rin g s,
22000
163 31 0 0 0 ** 55000 R P O H74 o r H75 R e a r A x le , R P O F06 F ra m e
10. 0 0 -2 0 -1 2 11. 0 0 -2 0 -1 2 D R e in fo r c e m e n ts .
175 9000 9000
X R P O F43 F r o n t A x le , R P O F 9 4 F r o n t S p rin g s,
32 0 0 0 ** 55000 23000 R P O H82 R e a r A x le , R P O F06 F r a m e
R e in fo r c e m e n ts .

24000* 51000 9 .0 0 -2 0 -1 0 9. 0 0 -2 0 - 10D

18500
98 27500 § 51000 1 0 .0 0 -2 0 - 12 10. 0 0 -2 0 -1 2 D
109 RPO H74 o r H75 R e a r A x le , in clu d es 10, 400 lb.
31 000** 55000 9000 9000 22000 20800
T M 80 133 ea ch R e a r S p rin gs.
1 0 .0 0 -2 0 -1 2 1 1. 0 0 -2 0 -1 2 D
146 RPO H82 R e a r A x le , in c lu d e s 11,000 lb. each
32 0 0 0 ** 55000 23000 22000
163 R ear S p rin g s.
RPO H82 R e a r A x le , in c lu d e s 1 1, 000 lb. each
65000 9000 9000 23000 22000 1 0 .0 0 -2 0 -1 2 10. 0 0 -2 0 -1 2 D
R ear S p rin g s , R P O L29, 478M E n g in e.
36000 §* 45000 7000 7000 9. 0 0 -2 0 -1 0 9 .0 0 -2 0 -1 0
151 R P O F43 F r o n t A x le , R P O F 94 F r o n t S p rin g s,
30000
39 000** 45000 R P O F06 F r a m e R e in fo r c e m e n ts , R P O M61
JM 70 169 9000 A u x ilia r y T r a n s m is s io n .
30000 R P O F43 F r o n t A x le , R P O F 94 F r o n t S p rin g s,
187 43 0 0 0 ** 55000 9000 1 0 .0 0 -2 0 -1 2 10. 0 0 -2 0 -1 2 D R P O F06 F r a m e R e in fo r c e m e n ts , R P O H55
R e a r A x le , R P O M61 A u x ilia r y T r a n s m is s io n .
34000 R P O F5 4 F r o n t A x le , in c lu d e s 4500 lb. e a ch
45 0 0 0 ** 55000 12000 F r o n t S p rin g s , R P O F06 F r a m e R e in fo r c e m e n ts ,
R P O H55 R e a r A x le , R P O M61 A u x ilia r y
T ra n s m is s io n .

CHEVROLET TRUCK SERVICE M ANUAL

GENERAL INFORMATION 0-10

GROSS VEHICLE WEIGHTS FOR 1967 CHEVROLET TRUCKS AND

SCHOOL BUS CHASSIS

T IR E S A N D E Q U IP M E N T J
W H EEL­ FRONT FRO NT REAR REAR R E C O M M E N D E D T IR E S M IN IM U M M A N D A T O R Y E Q U IP M E N T F O R
MODEL BASE GVW GCW AXLE S P R IN G S AXLE S P R IN G S FRO NT REAR G V W R A T IN G
36000* 55000 9. 0 0 -2 0 -1 0 9. 0 0 -2 0 - 10D
55000 9000
43000 §
65000 R P O L 29, 478M E n g in e .
R P O F5 4 F r o n t A x le , in c lu d e s 4500 L b . each
55000 34000 34000 F r o n t S p rin g s , R P O F07 F r a m e R e in fo r c e m e n ts ,
151 on JM 814-817, R P O M 61, M 65 o r M71
45 0 0 0 ** 12000
1 0 .0 0 -2 0 -1 2 10. 0 0 -2 0 - 12D A u x ilia r y T r a n s m is s io n .
169 65000 In A d d itio n to a b o ve e q u ip m en t, m u st o r d e r
JM 80 9000 R P O L 29, 478M E n g in e.
198 R P O G77 R e a r A x le , in c lu d e s 19, 000 lb. each
4 7 000** 65000 9000 R e a r S p rin g s , R P O L 29, 478M E n gin e R P O F07
210 F r a m e R e in fo r c e m e n t s on JM 814-817.
38000 38000 R P O F 54 F r o n t A x le , in clu d es 4500 lb. each
F r o n t S p rin g s , R P O G77 R e a r A x le , in clu d es
4 8 0 0 0 ** 65000 12000 1 0 .0 0 -2 0 -1 2 11. 0 0 -2 0 - 12D 19,000 lb. e a c h R e a r S p rin g s , R P O L 29, 478M
E n g in e , R P O F07 F r a m e R e in fo r c e m e n ts on
JM 814-817.

36000* 55000 9 .0 0 -2 0 -1 0 9. 0 0 -2 0 - 10D

43000 § 55000 9000
65000 R P O L 2 9 , 478M E n g in e .
34000 34000 R P O F 4 4 F r o n t A x le , in c lu d e s 4500 lb. each
45 0 0 0 ** 55000 11000 F r o n t S p rin g s , R P O F 0 8 F r a m e R e in f o r c e ­
122 m e n ts , R P O M61 A u x ilia r y T r a n s m is s io n .
1 0 .0 0 -2 0 -1 2 10. 0 0 -2 0 -1 2 D
65000 In a d d ition to a b ove equ ip m en t, m ust o r d e r
W M 80 140 9000 R P O L 29, 478M E n g in e.
R P O G77 R e a r A x le , in c lu d e s 19, 000 lb. ea ch
158 4 7 0 00** 65000 9000 R e a r S p rin g s , R P O L 29, 478M E n g in e , R P O
F 08 F r a m e R e in fo r c e m e n ts .
38000 38000 R P O F4 4 F r o n t A x le , in c lu d e s 4500 lb. each
4 8 0 0 0 ** 65000 11000 1 0 .0 0 -2 0 -1 2 11. 0 0 -2 0 -1 2 D F r o n t S p rin g s , R P O G77 R e a r A x le , in clu d es
19, 000 lb. e a ch R e a r S p rin g s , R P O L 2 9 , 478M
E n g in e, R P O F 0 8 F r a m e R e in fo r c e m e n ts .

V - M in im u m eq u ip m en t and t ir e s a re show p fo r e a ch G V W ra tin g . E x tr a p ly ra tin g an d/or o v e r s iz e t ir e s a r e a v a ila b le o p tio n a lly .

* - T i r e s shown a re in clu d ed in the b a se p r ic e . T i r e s iz e fo r a ll G V W ra tin g s to be d e te r m in e d by v e h ic le u sa ge.
§- G V W ra tin g shown on v e h ic le ra tin g p la te . R a tin g s a r e in c r e a s e d o r d e c r e a s e d in a c c o r d a n c e w ith the m in im u m eq u ip m en t shown
in the a b o ve chart.
rh - S p e c ia l R P O G V W p la te .
** - R P O G V W p la te .

#- B e c a u s e fro n t a x le lo a d in g on T i l t cab m o d e ls cou ld p o s s ib ly be g r e a t e r than that o f the C o n ven tio n a l m o d e ls , fr o n t end lo a d in g should be
c a lc u la te d to e n s u re that the fr o n t su sp en sion c a p a c ity is not e x c e e d e d . I f lo a d in g e x c e e d s the r a te d c a p a c ity o f the b a s e fro n t su spen sion ,
the o p tio n a l h e a v y -d u ty unit m u st be used.
A v a ila b le on A i r B ra k e ( ’ 13) m o d e ls on ly.
R e in fo r c e m e n ts r e q u ir e d f o r dump and o f f - r o a d a p p lic a tio n on ly.

CHEVROLET TRUCK SERVICE MANUAL

 LUBRICATION 0-11

LUBRICATION
INDEX
Page Page
E n g in e ............................................................ ....................... 0-11 Crankcase Ventilation S y s t e m ....................................... .... 0-13
G a s o l i n e ........................................................................... 0-11 Crankcase B re a th e r................................................... .... 0-14
Crankcase C apacities................................................... 0-12 T ran sm issio n s..................................................................... .... 0-14
Oil Viscosity N u m b e r s .......................................... ..... 0-12 P o w e r g lid e ..................................................................... .... 0-14
Maintaining Crankcase Oil Level ........................ ..... 0-12 Turbo H y d ra-M atic ......................................................... .... 0-14
When to Change Crankcase O i l .............................. ..... 0-12 S y nchrom esh.................................................................. .... 0-14
Crankcase D ilu tio n ................................................ ..... 0-12 Recommended L u b ric a n ts ................................................... .... 0-14
Oil Filter . ............................................................. ..... 0-12 Four-Wheel D r i v e ............................................................... .... 0-15
D is t r ib u t o r .................................................................. 0-12 Wheel Bearings .................................................................. .... 0-15
Fuel F i l t e r ...................................................................0-12 Rear A x l e s ........................................................................... .... o-15
D iesel................................................................................. 0-12 Master C y lin d e r .................................................................. .... 0-15
Oil Q u a l i t y ...................................................................0-12 Full A ir B r a k e s .................................................................. .... 0-15
Oil C h an ge s.................................................................. 0-13 Hydrovac and A ir Over Hydraulic Brakes ........................ .... 0-15
Multi-Viscosity Lubricating Oils ........................ ......0-13 Steering Gear ..................................................................... .... 0-16
Cold Weather O p e r a t io n ....................................... ......0-13 Propeller Shaft Slip Joints ................................................ .... 0-16
Oil F i l t e r ............................................................... ......0-13 Universal J o in t s .................................................................. .... 0-16
A ir Box Drain T u b e s ............................................. ......0-13 Brake and Clutch Pedals ................................................... .... 0-16
Fuel F i l t e r ...................................................................0-13 Speedometer Adapter ......................................................... .... 0-16
Fuel S t r a in e r ................................................................0-13 Parking Brake Linkage ...................................................... .... 0-16
A ir Cleaner ......................................................................0-13 Tachometer - M e c h a n ic a l................................................... .... 0-16
G o v e rn o r............................................................................0-13 Body Lubrication ............................................................... .... 0-16
B a tte ry ...............................................................................0-13 Diesel Oil Specifications...................................................... .... 0-16
Throwout B e a r i n g .............................................................0-13 Lubrication D ia g r a m s ......................................................... .... 0-18

The 1967 Truck engine and chassis recommended periods. Sustained heavy duty and high speed operation
lubrication intervals are outlined in this section. or operation under adverse conditions may require more
The time or mileage intervals are intended as a guide frequent servicing.
for establishing regular maintenance and lubrication

ENGINE—GASOLINE AND DIESEL

CRANKCASE CAPACITIES
Crankcase Oil Filter

With Oil Without Oil Capacity

Engine Type Filter Filter Type Standard
Change Change (Opt.)

194 Cu. In. L 6 (Gasoline) 5 4 Throw Away 1

230 Cu. In. L 6 (Gasoline) 5 4 Throw Away 1

250 Cu. In. L 6 (Gasoline) 5 4 Throw Away 1

292 Cu. In. L 6 (Gasoline) 6 5 Throw Away 1 (2 Qt.)

283 Cu. In. V8 (Gasoline) 5 4 Repl. Element 1

283 Cu. In. V8 (Gasoline) 400 Series 6 5 Repl. Element 1

327 Cu. In. V8 (Gasoline) 5 4 Repl. Element 1

327 Cu. In. V8 (Gasoline) 500-600 Series 6 5 Repl. Element 1

366 Cu. In. V8 (Gasoline) 8 6 Repl. Element 2

159 Cu. In. L3 (Diesel) 11.5 9.5 Repl. Element 2

212 Cu. In. L4 (Diesel) 14 12 Repl. Element 2

318 Cu. In. V6 (Diesel) 16 14 Repl. Element 2

CHEVROLET TRUCK SERVICE M ANUAL

LUBRICATION 0-12

ENGINE—GASOLINE which promote accumulation of moisture condensation in

the crankcase, it becomes necessary to drain the oil
Oil more frequently. For 10-30 Series vehicles in heavy
When the truck is delivered, the engine crankcase is duty operation involving continuous stop-start or pro­
filled with a high grade oil of the type designated "Serv­ longed idling, engine oil should be changed after 2,500-
ice MS" (see "Types of Oil" below). It also contains 3.000 miles of operation. Always drain oil after it has
a special "Anti-Wear" additive to assist in better "mat­ reached normal operating temperature. Flushing the
ing" of the moving parts. This oil should be drained engine with oils or solutions other than a good grade of
after 6,000 miles or 60 days on 10-30 Series Trucks and SAE 10W engine oil is not recommended.
2,000 miles or 60 days on 40-60 Series trucks. During
the first 1 , 0 0 0 miles, check the oil level frequently and Crankcase Dilution
if it is necessary to add oil, use one of the oils described A major cause of engine deterioration is crankcase
under “ Oil Viscosity Numbers” in this section. dilution, which is the thinning of the oil by fuel or fuel
vapors leaking by the piston rings and mixing with the
Oil Viscosity Numbers oil. This condition occurs during engine warm-up, when
SAE Viscosity Numbers indicate only the viscosity or the fuel is not thoroughly vaporized and burned. Rapid
body of the oil, that is, whether an oil is a light (SAE 5W warm-up is aided by the thermostatic water control and
or 10W) or a heavy body oil (SAE 20 and higher), and do the thermostatic heat valve located in the exhaust mani­
not consider or include other properties or quality fold. Efficient crankcase ventilation drives off fuel va­
factors. pors and aids in the vaporization of raw fuel and water
Oils are available which are designed to combine the which may find their way into the crankcase. Sparing use
easy starting characteristics of the lower SAE Viscosity of the choke, proper engine maintenance and more fre ­
Number with the warm weather operating characteristics quent oil changes during cold weather short-haul opera­
of the higher SAE Viscosity Number. These are termed tions (under 1 0 miles) will minimize or eliminate the
"multi-viscosity oils”; SAE 5W-20, and SAE 10W-30. danger of crankcase dilution.
The following chart will serve as a guide for the selec­
tion of the correct SAE Viscosity Number for use under Oil Filter
different atmospheric temperature ranges. It is recommended that the filter cartridge be changed
after every 6 , 0 0 0 miles or six months whichever occurs
If the lowest The following SAE Multi-Viscosity first for 10-30 Series models and the first 2,000 miles
anticipated Viscosity oils are oils and every 2 , 0 0 0 miles or two months whichever occurs
temperature is: RECOMMENDED: RECOMMENDED: first for 40-60 Series models. When 2 qt. filters are in­
stalled, change elements every 8,000 miles. This change
32°F SAE 20W or SAE 20 SAE 10W-30 should always be performed when the crankcase oil is
0°F SAE 10W SAE 10W-30 changed.
Below 0°F SAE 5W SAE 5W-20 Heavy sludge deposits found on the oil filter elements
at the time of an oil change must be taken as an indica­
NOTE: For sustained high speed driving, when tion that the detergency of the oil has been exhausted.
the prevailing daylight temperature is above When this occurs, the oil drain interval should be short­
90°F. SAE 30 may be used. ened. The removal of abrasive dust, metal particles,
and carbon must be ensured by replacement of the oil
Maintaining Crankcase Oil Level filter elements at the time of an oil change.
The Oil Gauge Rod is marked "Full" and "Add Oil".
These notations have broad arrows pointing to the level DISTRIBUTOR
lines. Cam lubrication - rotate lubricator 1/2 turn every
The oil level should be maintained between the two 12.000 miles; replace at 24,000 miles.
lines; neither going above the "Full" line nor under the Hinged Oiler - fill to top with engine oil every 12,000
"Add Oil” line. miles.

CAUTION: Do not overfill, after operating ve­ FUEL FILTER

hicle allow a few minutes for oil to return to
crankcase before checking oil level. Carburetor Type F ilter - Remove the fuel line and in­
let fitting to replace the filter only if carburetor flooding
occurs.
When to Change Crankcase Oil In-Line Filter - Replace the entire filter every 12,000
To insure best performance, low maintenance cost and miles.
long engine life, it is necessary to change the crankcase
oil whenever it becomes contaminated with harmful ENGINE—DIESEL
foreign materials. Draining the crankcase and replacing
with fresh oil every 60 days or 6 , 0 0 0 miles whichever Oil Quality
occurs first is recommended for 10-30 Series models Satisfactory long-time operation of Heavy-Duty Diesel
and every 60 days or 2,000 miles for 40-60 Series models. Engines requires the use of detergent type "Heavy-Duty
Under unfavorable driving conditions such as frequent Lubricating Oils". These oils provide better lubrication,
long runs at high speeds and high loads, driving under possess more heat resistance, and counteract sludge
severe dust conditions, and short runs in cold weather formation more effectively than the non-detergent type

CHEVROLET TRUCK SERVICE M ANUAL

 LUBRICATION 0-13

oils. These oils are grouped in accordance with their clogged, remove, clean, and reinstall tubes. Air box
ability to meet the service requirements common to drain tubes should be cleaned at tune-up intervals even
Heavy-Duty engine operation. though clogged condition is not apparent. If engine is
equipped with air box drain tank, drain sediment periodi­
Oil Changes cally.
It is recommended that new engines be started with
100 hour oil change periods. For highway vehicles this
FUEL FILTER
corresponds to approximately 3,000 miles and for city-
Drain daily and replace every 12,000 miles.
service vehicles approximately 1,000-2,000 miles. The
drain interval may then be gradually increased, or de­
creased following the recommendations of the oil sup­
FUEL STRAINER
plier until the most practical oil change period for the The frame mounted fuel strainer assembly, located
particular service has been established. between the fuel pump and fuel tank should be replaced
At each oil change, besides draining engine crankcase, every 1 2 , 0 0 0 miles or oftener if fuel pressure falls below
drain oil filter and oil cooler. An oil cooler, rear drain- recommended minimum (35 psi at operating speed).
cock is for oil drain.
Solvents should not be used as flushing oils in running AIR CLEANER
engines. Dilution of the fresh refill oil supply can occur
which may be detrimental. NOTE: Under prolonged dusty driving condi­
tions, it is recommended that these operations
TYPE USAGE be performed more often.

MIL-L-2104A Generally satisfactory for light general Oil Bath Type - Check every 1 2 , 0 0 0 miles (2 , 0 0 0 miles

service with fuels containing less than on Diesel engines). Clean, if necessary, and refill with
(API-DG) 0.5% sulphur. engine oil, SAE 50, when temperature is above freezing
and SAE 20 below freezing.
Supplement 1 All Diesel engines - Normal service
(S-l) Oil Wetted Paper Element - F irst 1 2 , 0 0 0 miles inspect
(API-DM) or test element; if satisfactory, re-use element but re ­
check every 6,000 miles until replaced. Element must
NOTE: Oils of higher additive levels such as not be washed, oiled, tapped, or cleaned with an air hose.
S-3 (API designation DS) tend to form excessive
ash deposits that could result in engine damage; Oil Wetted Paper Element with
such oils are not recommended for use in
Polyurethane Wrap
Chevrolet Diesel engines.
Every 12,000 miles inspect air cleaner. Remove poly­
Multi-Viscosity Lubricating Oils urethane wrap and wash in suitable solvent. Check oil
wetted element and replace if necessary. Check every
Multi-Viscosity lubricating oils may be used to facili­ 6 , 0 0 0 miles thereafter until element is replaced.
tate starting when prolonged exposure of the engine to
temperature below freezing is unavoidable. Consult your
GOVERNOR
supplier regarding the performance characteristics of
this type of oil and obtain his assurance of adequate lub­ Replace air filter every 12,000 miles.
rication before subjecting the engine to heavy-duty se r­
vice. BATTERY

Cold Weather Operation Every 6,000 miles clean and oil battery terminals and
oil felt washer. Clean top of battery with diluted am­
The proper lubricating oil viscosity grade when operat­ monia or soda solution and flush with clean water. Check
ing at temperatures above 30°F. is SAE 30. It is permis­ state of charge especially in freezing weather. An under­
sible to use a lighter grade of oil in order to facilitate charged battery may freeze and break.
starting as shown in the following table:
THROW OUT BEARING
AMBIENT VISCOSITY
TEMPERATURE GRADE On trucks equipped with a yoke and shaft type release
lever, the release bearing is lubricated by means of a
Above 30 °F SAE 30 hose attached to a grease cup. The grease cup is filled
O

SAE 20-20W
O
CO
O

-*o->

with a graphite type grease and should be rotated one turn

0° to -20°F SAE 10W
every 6 , 0 0 0 miles and refilled as required.
OIL FILTER CRANKCASE VENTILATION SYSTEM
See "Oil F ilter" under Gasoline Engines.
Valve Type
AIR BOX DRAIN TUBES Every 12,000 miles or 12 months the valve should be
With engine running, check for flow of air from air replaced. Connecting hoses, fittings, flame arrestor and
box drain tubes every 6 , 0 0 0 miles and, if tubes are crankcase breather cap (where used) should be cleaned.

CHEVROLET TRUCK SERVICE M ANUAL

LUBRICATION 0-14

At every oil change the system should be tested for 2. Remove any dirt or gravel from area around indica­
proper function and serviced, if necessary. tor in right side of engine compartment. With engine
running at 1 0 0 0 rpm remove indicator from case,
*Under prolonged dusty driving conditions, it is recom­ wipe clean, reinsert and carefully withdraw again.
mended that these operations be performed more often.
CAUTION: Exercise extreme care to prevent
Crankcase Breather dirt from entering filler tube when checking
fluid level.
At each oil change, crankcase breather should be re ­
moved and cleaned in suitable solvent. Do not oil ele­ Add fluid only when level reaches L mark (1 qt. low)
ment. on the indicator.
3. With engine operating at 1000 rpm add sufficient
TRANSMISSIONS "Automatic Transmission Fluid - Type A" or "Type
C" - to bring level to full mark on indicator.
Powerglide Transmission
NOTE: Every 12,000 m iles, it is recommended CAUTION: Fluid level should never go higher
that the Powerglide low band be adjusted as than " F " mark on indicator when fluid is at
specified in Section 7 of this manual. operating temperature. An excessively full
transmission will result in aeration of the fluid
General Motors Automatic Transmission Fluid (Part
The expanding fluid may then be forced out of
numbers 1050568, 69, 70) or equivalent should be used
the filler tube. Sufficient fluid may be lost to
in the Powerglide transmission. If this fluid is not avail­
seriously damage the transmission?
able, refill with Automatic Transmission Fluid type "A"
bearing mark AQ-ATF followed by a number and suffix
letter "A". 4. Reinstall indicator and turn the cap 1/4 turn to lock.

Checking Fluid Draining and Refilling

Check oil level every 6,000 miles with engine idling, Drain the transmission and replace the filter after the
parking brake set, transmission warm and control lever first 6,000 miles of operation. At the 12,000 mile inter­
in "N" position. Add fluid when level reached "Add" val of highway driving and 6 , 0 0 0 miles of driving over
mark on oil level rod located on right side of engine. unimproved roads, (or 6 mos. whichever occurs first) the
Do not overfill or allow dirt to enter filler tube. transmission should be drained and refilled and the
Every 12,000 miles or oftener depending on severity filter should be replaced. Approximately 9 qts. of fluid
of service - remove fluid from the transmission sump are required to refill the transmission after the pan has
and add two quarts of fresh fluid. Operate transmission been drained. Drain immediately after operation - while
through all ranges and check fluid level as described fluid is still warm. Do not flush transmission after
above. draining.

Turbo Hydra-Matic Synchromesh (incl. aux. 4-speed)

Lubrication of the Turbo Hydra-Matic will, except for The lubricant level in the housing should be checked
fluid capacity and filter change listed below, follow the every 6 , 0 0 0 miles or oftener under severe operating
Powerglide transmission recommendations. After check­ conditions. With unit at operating temperatures, lubri­
ing transmission fluid level it is important that the dip­ cant should be level with bottom of filler plug hole.
stick be pushed all the way into the filler tube. Either SAE 80 or SAE 80-90 multi-purpose gear lubricant
Every 12,000 miles - after removing fluid from the meeting requirements of U.S. Ordnance Spec. M IL-L-
transmission sump, approximately 7-1/2 pints of fresh 2105B may be used.
fluid will be required to return level to proper mark on
the dipstick. Transmission Controls
Every 24,000 miles the transmission sump strainer
should be replaced. The steering column manual shift mechanism on 1/2
Ton and 3/4 Ton models equipped with 3 speed transm is­
sion is factory lubricated and should not require periodic
Allison Automatic Transmission lubrication. However, should the shifting effort become
Every 6,000 miles the fluid level should be checked noticeably greater, lubricate all linkage points with en­
and fluid added as described below when necessary. Use gine oil. On G10 models, lubricate transmission shift
"Automatic Transmission Fluid - Type A" bearing an housing fitting every 6 , 0 0 0 miles with lubricant specified
AQ-ATF number, or "Hydraulic Transmission Fluid in Note 1.
Type C". A good grade of 10W engine oil may be used The brake retarder linkage and throttle valve linkage
temporarily in emergencies, but must be replaced with for Allison Automatic transmissions should be lubricated
Automatic Transmission Fluid as soon as possible. periodically. Contact points between rods, idlers, bell
cranks and supports should be lubricated with SAE 10
Checking Fluid engine oil.
1. Start engine, set parking brake and move control
lever into (3"-HI") position. Run engine at 1000 Recommended Lubricants
rpm until engine and transmission have reached NOTE 1: Lubricate with water resistant EP
normal operating temperature. lubricant.

CHEVROLET TRUCK SERVICE M ANUAL

 LUBRICATION 0-15

NOTE 2: Lubricate with Multi-Purpose gear The bearings should be thoroughly cleaned before re ­
lubricant meeting requirements of U.S. Ord­ packing with lubricant.
nance Spec. M IL-L-2105B. The front wheels are equipped with tapered roller
bearings on all trucks except P -20, P-30 that are
The following table shows the proper viscosity "Multi- equipped with ball bearings. Lubricate every 30,000
Purpose” gear lubricant to be used during vehicle opera­ miles with high melting point wheel bearing lubricant.
tion. Do not mix wheel bearing lubricants.

Outside Temperature Viscosity Lubricant to be Used CAUTION: " Long fibre" or "Viscous" type of
lubricants should not be used on bearings front
Below 10 °F SAE 80 wheel.
Up to 100 °F SAE 90
Above 100 °F REAR AXLES
Consistently SAE 140
Check lubricant level (including the interaxle differ­
FOUR WHEEL DRIVE ential) every 6,000 miles. When necessary, refill to level
of filler plug hole using Multi-Purpose Lubricant speci­
Most lubrication recommendations and procedures for fied in Note 2.
4 wheel drive equipped trucks remain the same as for Drain the lubricant every 24,000 miles. If the vehicle
corresponding components of conventional drive trucks. is operated in exceptionally heavy work or at continuous
Only the front axle, including the differential and Cardon high speeds, the lubricant should be changed every 1 2 , 0 0 0
joint, the transfer case, which permits power from the miles. It may be necessary to change lubricant more
transmission to either front or rear axles, and associated often if vehicle is used off road in dusty areas.
linkage points and air vents require special procedures.
NOTE: The electric or air-torsion spring shift
Front Axle units should be filled to the level of the filler
plug hole with SAE 10 engine oil every 12,000
The front axle should be checked every 6,000 miles miles or three months whichever comes first.
and refilled with lubricant specified in Note 2 when nec­ In Positraction axles use special Positraction
essary. With the differential at operating temperature, Rear Axle Lubricant.
fill to the level of filler plug hole. If differential is cold,
fill to the level of 1 / 2 " below the filler plug hole. On MA50 trailing axle, check lubricant level of each
wheel hub every 6,000 miles. When necessary, refill
Cardon Joint hub to oil level mark with lubricant specified in Note 2.

After every 6,000 miles of driving, remove the slotted MASTER CYLINDER
pipe plugs from the ball ends of the axle housing. Check
lubricant and refill with lubricant specified in Note 2 Check master cylinder fluid level every 6,000 miles.
(1/2 pt. per joint) if necessary. Replace the pipe plugs If the fluid is low in the reservoir, it should be filled to
securely. a point about 1/4" from the top rear of each reservoir
with GM Supreme No. 11 Hydraulic Brake Fluid or
Air Vent and Hose equivalent.
Check vent hose for kinks and proper installation every
FULL AIR BRAKES
miles.
6 .0 0 0

Compressor
Transfer Case
Check the transfer case level every 6,000 miles and, Every 6,000 miles - Remove compressor air strainer
if necessary, add lubricant to bring to the level of the and inspect or replace every 6,000 miles or oftener. The
filler plug hole. Use lubricant specified in Note 2. element can be cleaned in kerosene or mineral spirits.
Cleaners of the aromatic compound must not be used.
Control Lever and Linkage The element should be squeezed (not wrung) dry after
cleaning.
Since no grease fitting is provided in the control lever
it is necessary to brush or spray engine oil on the lever Camshaft Bracket Bushings
pivot point and on all exposed control linkage every
6 . 0 0 0 miles. Lubricate monthly or every 6,000 miles with chassis
lube. Avoid over lubrication because excess grease will
WHEEL BEARINGS ruin brake linings.

Front—All Trucks HYDROVAC AND AIR OVER

HYDRAULIC BRAKES
Due to the weight of the tire and wheel assembly it is
recommended that they be removed from hub before The air over hydraulic (Air-Pak) piston type assem­
lubricating bearings to prevent damage to oil seal. Then blies are equipped with lubrication plugs in the closed
remove the front wheel hub to lubricate the bearings. end of the shell approximately 1 " from the bottom of the

CHEVROLET TRUCK SERVICE M ANUAL

LUBRICATION 0-16

cylinder. Fill to plug level with Bendix Vacuum Cylinder BRAKE AND CLUTCH PEDALS
Oil or Delco shock absorber fluid or equivalent at 12,000
mile intervals or each six month period, especially prior On Forward Control models the clutch pedal is lubri­
to the start of cold weather. cated from a pressure gun lubrication fitting in the end
The Hydrovac assemblies are the diaphragm type. of the shaft and the brake pedal is also equipped with a
lubrication fitting.
CAUTION: These units do not require lubrica­ On Forward Control models, the clutch idler support
tion. Do not add oil of any type to diaphragm is equipped with a lubrication fitting. Use lubricant
chamber. specified in Note 1 at these points.

Vacuum brake air cleaner for frame mounted vacuum SPEEDOMETER ADAPTER
boosters should be cleaned semi-annually.
On trucks so equipped, lubricate adapter at fitting with
STEERING GEAR lubricant specified in Note 1 every 6,000 miles.

PARKING BRAKE LINKAGE

Conventional
Every 6,000 miles, clean and lubricate all parking
Check lubricant level every 36,000 miles. If required, brake pivot points with lubricant specified in Note 1.
add lubricant specified in Note 1 to level of filler hole.
On CA10, 20, 30, PA10 and GA10, 20 models, check
lubricant level in the following manner: TACHOMETER-MECHANICAL
1. Remove the forward and outboard (lower and forward
on GA10, 20 models) steering gear cover attaching Lubrucate drive cable with lubricant specified in Note
screws. 2 every 6 , 0 0 0 miles.
2. On CA10, 20, 30 and PA10 inject lubricant specified
in Note 1 into forward cover attaching screw hole BODY LUBRICATION
until lubricant begins to come out of the outboard
screw hole. On GA10, 20 models, inject lubricant Normal use of a truck causes metal-to-metal move­
into the lower hole until lubricant begins to come out ment at certain points in the cab or panel body. Noise,
of forward hole. wear and improper operation at these points will result
3. Replace cover attaching screws. when a protective film of lubricant is not provided.
On CA10, 20, 30 models equipped with power steering, For exposed surfaces, such as door checks, door lock
check steering gear lubricant in the following manner. bolts, lock striker plates, dovetail bumper wedges, etc.,
1. Remove the two inboard screws and remove the apply a thin film of light engine oil.
power steering hose support bracket. Reinstall top Where oil holes are provided in body parts, oil can
screw. be safely used, but any lubricant should be used sparingly,
2. Remove outboard screw. Inject lubricant into cover and after application all excess should be carefully wiped
forward attaching screw hole until lubricant begins off.
to come out outboard hole. The seat adjusters and seat track, ordinarily over­
3. Reinstall outboard screw and hose support bracket. looked, should be lubricated with cup grease, graphite,
grease, chassis lubricant or oil - used sparingly.
Power Steering There are other points on bodies which may occasion­
ally require lubrication and which are difficult to serv­
Service gear box in the same manner as prescribed ice. Window regulators and controls are confined in the
for the conventional steering gears. In addition, check space between the upholstery and the outside door panel.
fluid in power steering pump reservoir - while hot and Easy access to the working parts may be made by re ­
wheels in full left turn position - make additions using moving the trim . Door weatherstrips and rubber hood
GM Power Steering Fluid or if not available use Auto­ bumpers should be lightly coated with a rubber lubricant.
matic Transmission Fluid - Type A with AQ-ATF-A
mark required to bring level to full mark on filler cap
dipstick. DIESEL FUEL SPECIFICATIONS

PROPELLER SHAFT SLIP JOINTS The quality of the fuel oil used for high speed Diesel
engine operation is a dominating factor in satisfactory
Propeller shaft slip joints should be lubricated every engine life. Suitable fuel oil must be clean, completely
6,000 miles with lubricant specified in Note 1. distilled, well refined, non-corrosive and be of low sul­
fur content.
DISTILLATION RANGE, CETANE NUMBER, and SUL­
UNIVERSAL JOINTS FUR CONTENT are the three most important properties
of high-speed diesel engine fuel oils.
Universal joints equipped with lubrication fittings, The following shows the specifications which must be
should be lubricated every 6 , 0 0 0 miles with lubricant met in a suitable Diesel oil.
specified in Note 1. Engine operation at altitudes above 5,000 feet requires
More frequent lubes may be required on heavy duty use of next lighter class of fuel oil than would normally
or "off the road" operations. be used.

CHEVROLET TRUCK SERVICE MANUAL

 LUBRICATION 0-17

DIESEL FUEL SELECTION CHART

Distillation
Type of Typical General Fuel Cetane Sulfur
Engine Service Application Classification 90% Boiling Final Boiling Number Content
Point (Max.) Point (Max.) (Min.) (Max.)

Light Load and speed

City Buses No. 1-D 500° F. 550° F. 45 0.30%
with considerable idling.

Generator sets, industrial

Winter No. 1-D 500° F. 550° F. 45 0.30%
and automotive equipment
Light Load and speed.
in city and suburban Summer No. 1-D 550° F. 600° F. 40 0.50%
operation.

Marine Pleasure Craft,

Winter No. 1-D 550° F. 600° F. 45 0.50%
Medium Load and speed. Tractors, Industrial
equipment. Summer No. 2-D* 625° F. 675° F. 40 0.50%

Heavy Load and high Winter No. 2-D* 625° F. 675° F. 45 0.50%
Highway Trucks
speed with idling. Summer No. 2-D* 625° F. 675° F. 40 0.50%

Heavy Duty Off-the-road

Heavy Load and high
Equipment, Trucks, No. 2-D* 675° F. - 40 0.50%
speed.
Tractors.

♦NOTE: For most satisfactory engine life, use only those No. 2-D diesel fuel oils containing 0.50% or less sulfur.

CHEVROLET TRUCK SERVICE M ANUAL

LUBRICATION 0-18

Fig . 28

Vz AND 3A TON L.D. F.C.

Lubrication Type of
No. Lubrication Points Quantity Remarks
Period Lubrication

1 King Pins 6,000 Miles Chassis Lubricant 4 places as required

2 Tie Rod Ends 6,000 Miles Chassis Lubricant 2 places as required
3 Steering Connecting Rod 6,000 Miles Chassis Lubricant 2 places as required 1 fitting at each end
4 Wheel Bearings 30,000 Miles Whl. Brg. Lubricant 2 places as required
5 Steering Gear 36,000 Miles Chassis Lubricant As required Check - do not drain
6 Clutch Cross-Shaft 6,000 Miles Chassis Lubricant As required
7 Brake and Clutch Pedals 6,000 Miles Chassis Lubricant As reauired
8 Trans. Control Shift Housing 6,000 Miles Chassis Lubricant As required
9 Air Cleaner - Oil Wetted Check - If satisfactory
Paper Element 12,000 Miles - Reuse element
Recheck every 6,000
miles until replaced
- Oil Bath 12,000 Miles Engine Oil SAE 50 As required Check - Clean and refill
Above Freezing
Engine Oil SAE 20
Below Freezing
10 Distributor - L - 6 12,000 Miles 1/2 turn of Cam*
Lubricator
11 Transmission - Synchromesh 6.000 Miles Multi-Purpose As required See Lubrication Section
- Automatic 6.000 Miles AQ-ATF-A As required See Lubrication Section
12 Rear Axle 6,000 Miles Multi-Purpose As required See Lubrication Section
13 Oil Filter 6,000 Miles
or 6 Months
14 Battery 6,000 Miles Engine Oil Oil Terminals and
Felt Washers
15 Brake Master Cylinder 6,000 Miles Brake Fluid Delco As required Check - Add fluid when
Supreme #11 necessary
16 Parking Brake Linkage 6,000 Miles Chassis Lubricant Lubricate Linkage,
Pulleys and Cables

*Replace at 24,000 M ile Intervals

CHEVROLET TRUCK SERVICE MANUAL

 LUBRICATION 0-19

Fig . 29

V2 AND % TON CONVENTIONAL MODELS, V2 TON FORWARD CONTROL

Lubrication Type of
No. Lubrication Points Quantity Remarks
Period Lubrication

1 Lower Control Arms 6,000 Miles Chassis Lubricant 4 places as required

2 Upper Control Arms 6,000 Miles Chassis Lubricant 4 places as required
3 Upper and Lower Control 6,000 Miles Chassis Lubricant 4 places as required
Arm Ball Joints
4 Intermediate Steering 6,000 Miles Chassis Lubricant 2 places as required
Shaft (PA10)
5 Tie Rod Ends 6,000 Miles Chassis Lubricant 4 places as required
6 Wheel Bearings 30,000 Miles Whl. Brg. Lubricant 2 places as required
7 Steering Gear 36,000 Miles Chassis Lubricant As required Check only - Do
not drain
8 Air Cleaner - Oil Bath 12.000 Miles Engine Oil SAE 50 As required Check - Clean and refill
Above Freezing if necessary
Engine Oil SAE 20
Below Freezing
- Paper Element 12.000 Miles Check - If satisfactory
reuse but recheck
every 6 , 0 0 0 miles
9 Distributor - L - 6 12,000 Miles 1 / 2 turn of cam
lubricator*
10 Distributor - V- 8 12,000 Miles Rotate cam lubricator*
11 Master Cylinder 6,000 Miles Delco Supreme As required Check - add fluid
No. 11 when necessary
12 Transmission - Synchromesh 6.000 Miles Multi-Purpose As required Keep even with filler
- Automatic 6.000 Miles AQ-ATF-A As required plug. Check - See
Lubrication Section
13 Throttle Bell Crank - L- 6 6,000 Miles Engine Oil As required
14 Carburetor Linkage - V- 8 6,000 Miles Engine Oil As required
15 Brake and Clutch Pedal 6,000 Miles Engine Oil As required
Springs
16 Universal Joints 6,000 Miles Chassis Lubricant As required
17 Propeller Shaft Slip Joint 6,000 Miles Chassis Lubricant As required Not shown
18 Rear Axle 6,000 Miles Multi-Purpose As required Check
See Lubrication Section

♦Replace Lubricator at 24,000 m ile intervals.

CHEVROLET TRUCK SERVICE MANUAL

LUBRICATION 0-20

Fig. 30

% AND 1 TON FORWARD CONTROL MODELS

No. Lubrication Type of

Lubrication Points Quantity Remarks
Period Lubrication

1 Front Spring Shackles 6,000 Miles Chassis Lubricant 6 places as required

2 King Pins 6,000 Miles Chassis Lubricant 4 places as required
3 Wheel Bearings 30,000 Miles Whl. Brg. Lubricant 2 places as required
4 Tie Rod Ends 6,000 Miles Chassis Lubricant 2 places as required 1 each side
5 Steering Connecting Rod 6,000 Miles Chassis Lubricant 2 places as required
6 Steering Gear 36,000 Miles Chassis Lubricant As required Check
7 Distributor 12,000 Miles Engine Oil As required 1/2 turn of Lubricator*
8 Front Spring Bolt 6,000 Miles Chassis Lubricant 2 places as required 1 each side
9 Air Cleaner - Oil Bath 12.000 Miles Engine Oil SAE 50 As required Check - Clean and refill
Above Freezing if necessary
Engine Oil SAE 20
- Paper Element 12.000 Miles Below Freezing Check - If satisfactory
reuse but recheck
every 6 , 0 0 0 miles
10 Throttle Bell Crank 6,000 Miles Engine Oil As required
11 Brake and Clutch Pedals 6,000 Miles Chassis Lubricant As required See Lubrication Section
12 Transmission - Synchromesh 6,000 Miles Multi-Purpose As required Keep even w /filler plug
See Lubrication Section
- Automatic 6,000 Miles AQ-ATF-A As required Checking
13 Universal Joints 6,000 Miles Chassis Lubricant As required
14 Rear Axle 6,000 Miles Multi- Purpose As required Check
See Lubrication Section
15 Rear Spring Shackle 6,000 Miles Chassis Lubricant 6places as required
16 Propeller Shaft Slip Joint 6,000 Miles Chassis Lubricant 1place as required
17 Master Cylinder 6,000 Miles Delco Supreme As required Check - add fluid
No. 11 when necessary

^Replace Lubricator at 24,000 mile intervals.

**D iesel Engine not illustrated.

CHEVROLET TRUCK SERVICE MANUAL

 LUBRICATION 0-21

Fig . 31

1 TON CONVENTIONAL MODELS

Lubrication Type of
No. Lubrication Points Quantity Remarks
Period Lubrication

1 Lower Control Arms 6,000 Miles Chassis Lubricant 4 places as required

2 Upper Control Arms 6,000 Miles Chassis Lubricant 4 places as required
3 Upper and Lower Control
Arm Ball Joints 6,000 Miles Chassis Lubricant 4 places as required
5 Tie Rod Ends 6,000 Miles Chassis Lubricant 4 places as required
6 Wheel Bearings 30,000 Miles Whl. Brg. Lubricant 2 places as required
7 Steering Gear 36,000 Miles Chassis Lubricant As required Check
8 Air Cleaner - 12,000 Miles Check - If satisfactory
Paper Element reuse but recheck
every 6 , 0 0 0 miles
9 Distributor - L - 6 12,000 Miles 1/2 turn of Lubricator*
10 Distributor - V- 8 Rotate Cam
Cam Lubricator 12,000 Miles Lubricator*
11 Master Cylinder 6,000 Miles Delco Supreme As required Check - add fluid
No. 11 when necessary
12 Transmission - Synchromesh 6,000 Miles Multi-Purpose As required Keep even with filler
plug. Check
13 Throttle Bell Crank - L - 6 6,000 Miles Engine Oil As required
14 Carburetor Linkage - V- 8 6,000 Miles Engine Oil As required
15 Brake and Clutch
Pedal Springs 6,000 Miles Engine Oil As required
17 Propeller Shaft Slip Joint 6,000 Miles Chassis Lubricant 1 place as required
18 Universal Joints 6,000 Miles Chassis Lubricant 3 places as required
19 Spring Hanger 6,000 Miles Chassis Lubricant 6 places as required
20 Rear Axle 6,000 Miles Multi-Purpose As required Check
See Lubrication Section

^Replace Cam Lubricator at 24,000 m ile intervals.

CHEVROLET TRUCK SERVICE MANUAL

LUBRICATION 0-22

1-1/2-2 TON CONVENTIONAL, DIESEL FORWARD

CONTROL AND SCHOOL BUS MODELS**

No. Lubrication Type of

Lubrication Points Quantity Remarks
Period Lubrication

1 King Pins 6,000 Miles Chassis Lubricant 4 places as required

2 Tie Rod Ends 6,000 Miles Chassis Lubricant 4 places as required
3 Wheel Bearings 30,000 Miles Whl. Brg. Lubricant 2 places as required
4 Steering Gear 36,000 Miles Chassis Lubricant As required Check
5 Air Cleaner - Oil Bath 12.000 Miles Engine Oil SAE 50 As required Check - Clean and refill
Above Freezing if necessary
Engine Oil SAE 20
-Paper Element 12.000 Miles Below Freezing Check - If satisfactory
reuse but recheck
every 6 , 0 0 0 miles
6 Distributor - L- 6 12,000 Miles Engine Oil As required 1/2 turn of Lubricator*
7 Distributor - V- 8
Hinge Cap Oiler 12.000 Miles Engine Oil As required F ill to Top of Oiler
Cam Lubricator Rotate Lubricator*
Governor Air Cleaner 12.000 Miles Replace Air Cleaner
8 Master Cylinder 6,000 Miles Delco Supreme As required Check - add fluid
No. 11 when necessary
9 Transmission - Synchromesh 6.000 Miles Multi-Purpose As required Keep even w/filler plug
-Allison Automatic 6.000 Miles AQ-ATF-A As required See Lubrication Section
-Allison Automatic 12,000 Miles AQ-ATF-A 9 Quarts Approx. Checking Draining -
See Lubrication
10 Throttle Bell Crank - L- 6 6,000 Miles Engine Oil As required
11 Carburetor Linkage - V- 8 6,000 Miles Engine Oil As required
12 Brake and Clutch
Pedal Springs 6,000 Miles Engine Oil As required
13 Power Brake Air Cleaner Semi- Clean
Annually
14 Propeller Shaft Slip Joints 6,000 Miles Chassis Lubricant 2 places as required
15 Universal Joints 6,000 Miles Chassis Lubricant 4 places as required
16 Spring Hangers 6,000 Miles Chassis Lubricant 6 places as required 6 Cam surfaces
17 Rear Axle 6,000 Miles Multi-Purpose As required Check
See Lubrication Section

♦Replace Lubricator at 24,000 m ile intervals. **D iesel Engine not illustrated.

CHEVROLET TRUCK SERVICE MANUAL

 LUBRICATION 0-23

F ig . 33

TANDEM AXLE MODELS**

Lubrication Type of Remarks

No. Lubrication Points Quantity
Period Lubrication

1 King Pins 6,000 Miles Chassis Lubricant 4 places as required

2 Tie Rod Ends 6,000 Miles Chassis Lubricant 4 places as required
3 Wheel Bearings 30,000 Miles Whl. Brg. Lubricant 2 places as required
4 Steering Gear 36,000 Miles Chassis Lubricant 1 place as required Check
5 Air Cleaner 12,000 Miles Engine Oil SAE 50 As required Check - Clean and refill
Above Freezing if necessary
Engine Oil SAE 20
Below Freezing
6 Distributor - Hinge Cap
Oiler 12.000 Miles Engine Oil As required Fill to Top of Oiler
- Governor
Air Cleaner 12.000 Miles Replace Air Cleaner
7 Master Cylinder 6,000 Miles Delco Supreme As required Check - add fluid
No. 11 when necessary
8 Transmission - Synchromesh 6.000 Miles Multi-Purpose As required Keep even with filler
-Allison Automatic 6.000 Miles AQ-ATF-A As required See Lubrication Section
See chart in Checking. For off-high­
Lubrication Section way operation, change
after every 1 , 0 0 0 hours
of operation. For off-
highway dirt hauling or
mining, every 500 hours
-Allison Automatic 12,000 Miles* AQ-ATF-A 9 Quarts approx. of operation. Draining-
See Lubrication
9 Carburetor Linkage 6,000 Miles Engine Oil As required
10 Brake and Clutch
Pedal Springs 6,000 Miles Engine Oi} As required
11 Universal Joints 6,000 Miles Chassis Lubricant 3-6 places as See Lubrication Section
required
12 Power Brake Air Cleaner Semi- Clean
Annuallv
13 Propeller Shaft Slip Joint 6,000 Miles Chassis Lubricant 1-3 places as
required
14 Spring Hanger 6,000 Miles Chassis Lubricant 6 places as required 2 Spring Pins
4 Cam surfaces
15 Rear Axle 6,000 Miles Multi-Purpose See Specifications Check
See Lubrication Section
16 MA50 Trailing Axle
17 Wheel Bearings - MA60 Series 6,000 Miles Multi-Purpose 2 places as required See Lubrication Section

*Under favorable driving conditions, 25,000 miles. **Diesel Engines not illustrated.

CHEVROLET TRUCK SERVICE M ANUAL

LUBRICATION 0-24

Fig . 34

FOUR WHEEL DRIVE MODELS

No. Lubrication Type of

Lubrication Points Quantity Remarks
Period Lubrication

1 Air Vents 6,000 Miles Check

See Lubrication Section
2 Transfer Case 6,000 Miles Multi-Purpose As required Check
See Lubrication Section
3 Front and Rear Axle 6,000 Miles Multi- Purpose As required Check
See Lubrication Section
4 Steering Knuckles 6,000 Miles Multi-Purpose 2 places as required Remove pipe plugs
from ball ends of hsg.
and check lubricant
5 Drag Link 6,000 Miles Chassis Lubricant 2 places as required
6 Tie Rod Ends 6,000 Miles Chassis Lubricant 2 places as required
n
1 Propeller Shaft Slip Joints 6,000 Miles Chassis Lubricant 3 places as required
8 Universal Joints 6,000 Miles Chassis Lubricant As required See Lubrication Section
9 Control Linkage Points 6,000 Miles Engine Oil As required Brush or Spray
to apply
10 Wheel Bearings 30,000 Miles Wheel Bearing 2 places as required
Grease
11 Steering Gear 36,000 Miles Chassis Lubricant As required Check
12 Air Cleaner 12,000 Miles Clean in suitable
solvent
13 Distributor - L - 6 12,000 Miles 1/2 turn of Cam
Lubricator*
14 Distributor - V- 8 12,000 Miles Rotate Cam
Lubricator*
15 Master Cylinder 6,000 Miles Delco Supreme No. As required Check - add fluid
11 when necessary
16 Throttle Bell Crank - L - 6 6,000 Miles Engine Oil As required
17 Carburetor Linkage - V- 8 6,000 Miles Engine Oil As required
18 Brake and Clutch
Pedal Springs 6,000 Miles Engine Oil As required
19 Transmission - Synchromesh 6,000 Miles Multi- Purpose As required Keep even w /filler plug
See Lubrication Section
20 Rear Spring Hanger 6,000 Miles Chassis Lubricant 6 places as required

*Replace Lubricator at 24,000 mile intervals.

CHEVROLET TRUCK SERVICE MANUAL

 LUBRICATION 0-25

Figure 35 shows the differences between the tilt cab

and the conventional truck lubrication chart.
1. Steering Gear - The filler plug is located behind the
steering gear shaft.
2. Tilt Cab Body Hinges - Each hinge should be lubri­
cated through a fitting with chassis lube every 6 , 0 0 0
miles.
3. Tilt Mechanism Check Link - Every 6,000 m iles, a
small amount of lubriplate or equivalent should be
applied to the check link and roller.
4. Tilt Cab Operating Controls - The operating con­
trols and levers at the rear of the cab should be
lubricated at each pivot or bearing point with a
small amount of engine oil every 6,000 miles. An
additional lube fitting is provided on the hold-down
catch pivot. This should be lubricated every 6,000
miles with chassis lubricant.

F ig . 35 - T ilt Cab M odels

CHEVROLET TRUCK SERVICE MANUAL

 SECTION 1A
HEATER AND AIR CONDITIONING
CONTENTS OF THIS SECTION
Page
Heater .................................................................. ... 1A-1
A ir Conditioning ................................. ........................... 1A-10

HEATER
INDEX
Page Page
General Description............ ............................................. 1A-1 Control Assembly ....................................................... 1A-8
Component Replacement and R e p a i r .............................. 1A-4 Control C a b l e s ............................................................. 1A-8
Blower Assem bly.......................................................... 1A-4 Blower Switch................................................................ 1A-9
Blower, Core Case, and Core A s s e m b l y .................. 1A-5 Thermostatic V a lv e ............................ .. ....................... 1A-9

GENERAL DESCRIPTION

O UTLETS

Fig . 1 - Deluxe A ir H eater Schematic

DELUXE AIR HEATER switch. The third lever operates a temperature door
which passes the airflow either through the heater core,
Components of the heater attach to the right side of the around the core, or partially through and partially around
firewall. The blower motor, heater core, and hose as­ the core.
sembly mount on the engine side of the firewall while the
distributor ducting, and controls are under the dash (fig. 1 ). CHEVY VAN HEATER
The heater operates on outside air only with the blower
receiving its airflow from the cowl vent plenum chamber. The Chevy Van heater assembly is mounted on the toe
Engine coolant constantly flows through the heater core board inside the van. Outside air flows to the heater
during engine operation. Heater output is adjusted by through a grille in the front end panel and across to the
varying the airflow through the system. A dash mounted heater air inlet (fig. 3). The air passes by the tempera­
three lever control system is employed (fig. 2). One ture door where it is directed either through the core,
lever controls the defroster air deflector. The second bypassed around the core, or split between the two to
lever opens the air door and operates the three speed fan vary the air temperature. The bypass channel is a de-

CHEVROLET TRUCK SERVICE M ANUAL

HEATER AND AIR CONDITIONING 1A-2

the cab. Outside air flows through a grille in the front

end panel and across to the heater air inlet. A four lever
dash control regulates the fan speed, defroster, heater
core temperature, and airflow (fig. 6 ). The fan switch,
defroster, and air valve operate similarly to the Deluxe
Air Heater. The Tilt Cab Heater temperature control,
however, regulates coolant flow through the heater core
via a thermostatic valve which is mounted on the core.

CONTROLS
DELUXE AIR HEATER
DEF Lever

Moving the DEF (defroster) lever to the right moves an

air deflector in the distributor duct which channels the
airflow partially or fully to the defroster air outlets.

AIR FAN Lever

When this lever is fully left, no air passes through the

system. Moving the lever to the right about one-third of
its travel opens the air door in the air distributor duct.
Moving the lever further to the right operates the three
speed blower switch.

HEAT Lever

When this lever is fully left, the temperature door in

the blower duct causes the airflow to bypass the heater
core. Moving the lever to the right moves the tempera­
ture door allowing some air to pass through the core and
some to bypass the core. With the lever fully right, all
air flowing through the system passes through the core.

CHEVY VAN HEATER

AIR Knob

Pulling the AIR knob will open an air shut-off door

located in the distributor duct. Air will not flow through
the system with the knob pushed in.

FAN-HEAT Knob

Pulling the FAN-HEAT knob fully out moves a deflector

which causes the entire airflow to pass through the heater
core. When the knob is fully in, the entire air-flow
pression formed in the toe board. From the core housing passes around the heater core. Any intermediate position
the air passes by a shut-off valve which is either closed of the knob allows some air to bypass the core and some
or fully open. The air then passes through the defroster to pass through it in proportion to the knob setting.
valve which directs the airflow to the floor outlet, to both Turning the knob operates the three speed blower switch.
floor and defroster outlets, or to the defroster outlets.
Since temperature is adjusted by controlling airflow
through the core, the core is continuously supplied with DEFROSTER Knob
hot coolant while the engine is running. The blower, air,
temperature, and defroster controls are located on the Pulling the DEFROSTER knob moves a deflector in the
panel between the steering column and dash (fig. 4). air distributor which directs the airflow to the defroster
outlets. When the knob is fully in, all air is discharged
TILT CAB HEATER through the floor outlets. Intermediate positions of the
knob split the airflow between the floor and defroster
The Tilt Cab Heater is mounted on the toe board inside outlets in proportion to knob setting.

CHEVROLET TRUCK SERVICE MANUAL

 HEATER AND AIR CONDITIONING 1A-3

TEM PER A T U RE
DOOR
TO D EFR O ST ER
O U T S ID E
O UTLETS
A IR IN L E T TOE BO A RD

D EFRO STER
DOOR
L
FLO O R BLO W ER
O UTLETS A SSEM BLY
HEATER C O R E

Fig. 3 - C h evy Van Heater Schem atic

Fig. 5 - G -10 Heater Assembly

CHEVROLET TRUCK SERVICE MANUAL

 —

HEATER AND AIR CONDITIONING 1A-4

AIR CONTROL
CABLE

KNOB

SWITCH

TEMP.
CONTROL
CABLE f \
DEFROSTER BRACKET INSTRUMENT DEFROSTER AIR CONTROL
CONTROL CABLE PANEl CONTROL CABLE CABLE

Fig. 6 - T ilt Cab H eater Controls

COMPONENT REPLACEMENT AND REPAIR

BLOWER ASSEMBLY 6. Remove the blower assembly (pry the flange away
from the case carefully if the sealer acts as an ad­
10-60 Series (Exc. Tilt Cab and Chevy Van) hesive). (40-60 Series—turn the motor until its
flange clears the hood hinge.)
Removal 7. Remove the nut attaching the blower wheel to the
1. Disconnect battery ground cable. motor shaft and separate the assembly.
2. (10-30 Series) Support the right front of the hood
in the fully raised position. Installation
3. (10-30 Series) Carefully scribe the hood and fender 1. Assemble the blower wheel to the motor with the
locations of the right hood hinge and remove the open end of the blower away from the motor.
hinge. 2. Install the assembly to the blower case, connect
4. Unclip the blower wire at the blower flange terminal ground strap, and connect the motor wire.
and note or mark the motor flange position in re­ 3. (10-30 Series) Remount the hood hinge aligning it
lation to the blower case. carefully with the scribed lines. Check hood align­
5. Remove the blower assembly mounting screws. ment.
4. Connect battery ground cable.

Chevy Van

Removal
1. Disconnect battery ground cable.
2. Unclip the blower wire at the blower flange terminal
and note or mark the motor flange position in re­
lation to the blower case.
3. Remove the blower assembly mounting screws.
4. Remove the blower assembly (pry the flange away
from the case carefully if the sealer acts as an ad­
hesive).
5. Remove the nut attaching the blower wheel to the
motor shaft and separate the assembly.

Installation
1. Assemble the blower wheel to the motor with the
open end of the blower away from the motor.
2. Install the assembly into the blower case, connect
ground strap, and connect the motor wire.
3. Connect the battery ground cable.
SPACER RESISTOR DUCT HEATER AND
DEFROSTER ASM. Tilt Cab
DISTRIBUTOR

Removal
1. Disconnect the battery ground cable.
Fig . 7 - T ilt Cab H eater Assembly 2. Roll the floor mat back from the heater motor area.

CHEVROLET TRUCK SERVICE M ANUAL

I
 HEATER AND AIR CONDITIONING 1A-5

3. Remove the screw attaching blower housing brace

to cowl panel.
4. Remove screw attaching core case brace to cowl
panel.
5. Unclip the blower wire at the blower flange terminal
and note or mark the motor flange position in re­
lation to the blower case.
6 . Remove the blower assembly mounting screws.
7. Lower the blower assembly. Lift upward on the
heater assembly until the blower wheel clears the
housing opening while pulling downward and rear­
ward on the blower assembly to remove it.
8 . Remove the nut attaching the blower wheel to the
motor shaft and separate the assembly.

Installation
1. Assemble the blower wheel to the motor with the
open end of the blower away from the motor.
2. Position the blower assembly below the opening in
the housing and lift the heater assembly until the
blower wheel will enter the opening. Lift the assem­
bly into position and mount to the housing.
3. Connect the motor wire.
4. Replace core case brace to cowl panel screw and the Fig. 9 - H eater Hoses
blower housing brace to cowl panel screw.
5. Replace the floor mat and connect the battery ground outboard case attachments, the right front fender
cable. skirt should be loosened and moved. Remove enough
skirt mounting screws and bolts (from the rear for­
BLOWER, CORE CASE, AND CORE ASSEMBLY ward) to move the skirt a sufficient amount.
7. Remove the case retaining screws and sheet metal
10-60 Series (Exc. Tilt Cab and Chevy Van) nuts. Pull the case away from the mounting studs
and inboard to remove it.
Removal 8 . Remove the screws attaching the core retainers to
1. Drain radiator. the case and remove the core.
2. Disconnect battery ground cable.
3. Unclip the blower motor wire at the blower flange
terminal.
4. Disconnect heater hoses at the core tubes.
5. (Under dash) Remove the seal on the temperature
door cable at the distributor duct adapter and dis­
connect the cable from the temperature door.
6 . (10-30 Series) In order to gain access to the lower

F ig . 1 0 - Heater Distributor and Ducts

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HEATER AND AIR CONDITIONING 1A-6

6. Disconnect the defroster and air door control cables

at the distributor duct.
7. Remove distributor duct mounting screws.
8 . Remove defroster hoses from distributor duct.
9. Remove core tube grommet from the floor pan and
slide it up the core tubes.
10. Remove screws attaching heater case to toe pan.
11. Pull case away from toe pan and lower by sliding
core tubes further down through the toe pan. When
case is clear of the ash tray retainer and dash lower
edge, pull it toward the rear and withdraw the core
tubes from the toe pan hole.
12. Remove the temperature door cable.
13. Remove the screws attaching the core retainers to
the case and remove the core.

Fig. 11 - G -10 H eater Hoses Installation

1. Replace the core in the case using a non-hardening
Installation sealer. Attach the core retainers and screws.
1. Replace the core in the case using non-hardening 2. Attach the temperature door cable and operate the
sealer. Attach the core with the core retainers and temperature control to check adjustment.
screws. 3. Insert the core tubes through the toe pan hole, move
2. Remount the case to the firewall. the heater assembly forward under the dash, and lift
3. (10-30 Series) Replace and tighten the fender skirt the assembly to the mounting position.
attaching screws and bolts. 4. R eplace h eater case and d istribu to r mounting s c re w s
4. Connect the temperature door cable to the door and and tighten.
replace the seal. 5. Replace the core tube grommet in the toe pan.
5. Connect the heater hoses to the core tubes (the hose 6 . Attach the defroster hoses to the distributor duct.

to the water pump attaches to the upper core tube). 7. Connect the defroster and air door cables and check
6 . Connect the motor wire and battery ground cable. adjustment.
7. Refill the Cooling System. 8 . Connect the motor wire.
9. Replace the glove box.
Chevy Van 10. Connect heater hoses below the toe pan.
11. Refill the Cooling System.
Removal 12. Connect the battery ground cable.
1. Disconnect battery ground cable.
2. Drain the radiator. Tilt Cab
3. Disconnect heater hoses below toe pan.
4. Remove glove box. Removal
5. Unclip the blower motor wire at the motor flange 1. Disconnect battery ground cable.
terminal. 2. Drain radiator.
3. Remove exterior air intake grille panel below wind­
shield.
4. Loosen the clamp at the top of each rubber elbow

Fig. 12 - T ilt Cab Heat C ab le Access Plate Fig. 13 - T ilt Cab Thermostatic V a lv e C a p illa ry

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 HEATER AND AIR CONDITIONING 1A-7

and pull the elbows off the core tubes.

Remove the sheet metal nut from the stud next to the
core tube elbows.
Disconnect the air and defroster door cables.
Remove defroster hoses from the distributor duct.
Unclip the blower motor wire from the motor flange
terminal.
Remove air distributor bracket mounting screw at
left of distributor. Remove mounting screws at
lower left and right of core case.
Remove screws attaching core case air inlet to cowl
at top of core case (three screws at the top and one
at each side). Pull the heater assembly away from
the cowl panel.
10. Open the temperature cable access plate at the top
left of the core case and disconnect the cable (fig.
11).
11. Remove the top cover of the core case.
12. Remove screws which attach the inner core retaining
plate to the core case (not the screws at the core
corners).
13. Remove the inner plate with core attached from the
core case (pry the plate at the retaining lip if neces­
sary).
14. Remove the core tube bracket and core retaining
screws.
15. Separate the core and plate.
16. Remove thermostatic valve capillary tube from the
core by withdrawing the plastic retaining pin.
17. Remove screws attaching thermostatic valve to core
and remove valve assembly.
Installation
1. Assemble thermostatic valve assembly to core.
2. Attach the thermostatic valve capillary tube to the
core with the plastic pin. Locate the pin 6-1/2
inches away from the edge of the core (valve side),
and 2 - 1 / 2 inches back from the front edge of the core
(fig. 12). Before pinning the coil, bend the straight
section of tube in a gentle arc which will hold the
coiled end away from the core while unpinned. This
will prevent the tube from rattling against the core.
3. Mount the core to its retaining plate and mount the
core tube bracket.
4. Assemble the core retaining plate and core to the
core housing. "Shoehorn" the plate under the lip of
the housing if necessary.
5. Attach the top cover of the core case.
6 . Connect the temperature door cable and check its
adjustment. Secure the temperature cable access
plate.
7. Lift the heater assembly to the cowl panel and push
the mounting stud and core tubes into place.
8 . Install the screws retaining the core case to cowl
at the air inlet. Install the lower left and right
core case bracket screws.
Install the air distributor mounting screw.
9. Connect the blower motor wire at the motor flange
terminal.
10. Replace defroster hoses.
11. Attach the air and defroster door cables and check
adjustment.
12. At the front of the cab, tighten the sheet metal nut
to the core case stud.
13. Connect the rubber elbows to the core tubes and
clamp securely.
F ig . 14 - Defroster Hoses 14. Replace air intake grille.

CHEVROLET TRUCK SERVICE M ANUAL

HEATER AND AIR CONDITIONING 1A-8

15. Refill cooling system. 3. (AIR - FAN control) Connect the blower wire con­
16. Connect battery ground cable. nector to the control.
4. Install the control to the steering column mounting
DEFROSTER DUCT plate with the escutcheon and nut. Replace the knob.
All Models 5. Check control operation.
The defroster hose and outlet assemblies for all ve­
hicles are illustrated in Figure 8 . Tilt Cab
CONTROL ASSEMBLY Removal
Deluxe Air Heater 1. Remove the screws at the upper edge of the control
Removal unit.
1. Remove the control assembly retaining screws at 2. Remove the screws which attach the control unit
the lower edge of the dash. brace to the lower edge of the dash and lower the
2. Lower the unit and remove the blower switch. assembly.
3. Remove the cables from the control unit one by one 3. Remove the blower switch knob and blower switch.
and mount them in their respective positions on the 4. Remove cables from the control unit one by one and
replacement unit. Check cable adjustment. mount them in their respective positions on the re­
placement unit. Check cable adjustment.
Installation
1. Attach the blower switch and wiring to the control Installation
unit. 1. Attach the blower switch and wiring to the control
2. Place the unit in position in the dash and replace unit. P ress the knob onto the switch lever.
mounting screws. 2. Place the unit in position in the dash and replace
brace and unit mounting screws.
C h e v y V an
CONTROL CABLES
Removal
1. (Any control) Remove the knob from the control Deluxe Air Heater
shaft. Remove retaining nut and escutcheon, and
remove control from the steering column to dash Remove the control assembly as outlined under CON­
mounting plate. TROL ASSEMBLY and replace the affected cable or
2. (HEAT - FAN control) Disconnect the blower wiring cables. Check cable adjustment before installing control
connector from the control. assembly in dash. Access to the temperature door cable
3. (AIR or DEFROSTER control) Remove the cable from at the heater is through the plastic seal at the duct
the air distributor duct and actuating lever. adapter.
4. (TEMPERATURE control) Remove the glove box as­
sembly. Remove the cable end retainer from the Chevy Van
temperature door link. Remove the cable case clip
The control cables are complete control units covered
attaching screw, and remove the cable.
under CONTROL ASSEMBLY.
Installation
Tilt Cab
1. Attach the cable to the case and actuating lever.
2. (TEMPERATURE control) Replace the heater assem­ Remove the control assembly as outlined under CON­
bly and mount it to the firewall. Replace the glove TROL ASSEMBLY and replace the affected cable or
box assembly. cables. When replacing the temperature cable, remove
the glove box assembly to reach the temperature cable
access plate at the top of the core case. Check cable
adjustment before installing control assembly in dash.

Fig . 15 - Heater W iring F ig . 1 6 - G -1 0 Heater W iring

CHEVROLET TRUCK SERVICE MANUAL

 HEATER AND AIR CONDITIONING 1A-9

F ig . 17 - T ilt Cab W iring

BLOWER SWITCH Installation

1. Place resistor unit in duct and drive in mounting
All Heaters screws.
2. Connect the blower harness connector.
Blower switch replacement is covered as a part of
3. Mount the heater assembly to the toe pan and in­
CONTROL ASSEMBLY. Refer to that section for the
stall the glove box assembly.
necessary steps.
Tilt Cab
RESISTOR UNIT
Removal
Deluxe Air Heater 1. Remove the distributor duct to cowl mounting screws.
Remove the distributor duct to blower case attach­
Removal ing screws.
1. Remove glove box assembly. 2. Disconnect the defroster ducts at the distributor and
2. Unplug harness connector from resistor unit. Re­ move the distributor away from the cowl until the
move the unit attaching screws and remove unit. resistor unit is accessible.
Installation 3. Disconnect the blower harness connector and re­
1. Place resistor unit in distributor duct and drive in move the unit mounting screws. Remove unit.
attaching screws. Connect harness connector to unit.
Installation
2. Install glove box assembly.
1. Place the resistor unit in the distributor duct and
Chevy Van drive in the mounting screws. Connect the blower
harness connector.
Removal 2. Place the distributor duct in position and assemble
1. Remove the glove box assembly. it to the blower case.
2. Remove heater case and distributor duct to floor 3. Mount the case to the cowl and connect the defroster
pan attaching screws. Lower the assembly care­ ducts to it.
fully by allowing the core tubes to slide through the
grommet in the floor. THERMOSTATIC VALVE
3. Pull the case rearward far enough to gain access
to the resistor unit. Tilt Cab
4. Disconnect the blower harness connector and remove
the resistor unit mounting screws. Remove resistor Replacement of the thermostatic valve (tilt cab only)
unit. is covered under BLOWER AND CORE CASE AND CORE.

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HEATER AND AIR CONDITIONING 1A-10

AIR CONDITIONING
INDEX
Page Page
General Description..........................................................1A-10 Component Replacement and Minor R ep airs..................... 1A-22
General Information..........................................................1A-12 Refrigerant Line Connections .................................... 1A-22
Precautions in Handling Refrigerant— 1 2 .................. 1A-13 Repair of Refrigerant L e a k s ....................................... 1A-22
Precautions in Handling Refrigerant L i n e s ............... 1A-13 Refrigerant Hose F a ilu re ............................................. 1A-23
Maintaining Chemical Stability in the Conditioning System for Replacement of
Refrigeration System ............................................. 1A-14 Component P a r t s ...................................................... 1A-23
Gauge S e t ......................................................................1A-14 Sight Glass R eplacem en t............................................. 1A-23
Charging S ta tio n ..........................................................1A-15 Control A sse m bly ................................................... . . 1A-23
Leak T e s tin g ................................................................1A-15 Condenser......................................................... ... 1A-24
Vacuum P u m p .............................................................1A-16 Receiver D eh yd ra to r................................................... 1A-25
Availability of Refrigerant— 1 2 ................................. 1A-17 Expansion Valve ......................................................... 1A-26
Inspection and Periodic Service....................................... 1A-17 P.O.A. V a l v e ............................................................... 1A-26
Pre-D elivery Inspection............................................. 1A-17 Blower A s se m b ly ......................................................... 1A-26
6000 Mile Inspection................................................... 1A-17 E v a p o r a t o r .................................................................. 1A-27
Periodic S e r v ic e ..........................................................1A-17 Blower and Evaporator C a s e ....................................... 1A-27
Installing Gauge Set to Check System Operation . . . 1A-17 Heater C a s e .................................................................. 1A-28
Performance T e s t ...................................................... 1A-17 Heater C o r e .................................................................. 1A-28
Performance D a t a ...................................................... 1A-18 Blower Resistor U n i t ................................................... 1A-28
Evaporator Control Valve (POA) .............................. 1A-18 Muffler and Connector B lo c k ....................................... 1A-29
Expansion V a l v e ..........................................................1A-18 Kick Panel A ir Valve A ctu ato r.................................... 1A-29
Engine Idle Compensator .......................................... 1A-19 Kick Panel A ir V a l v e ................................................... 1A-30
Evacuating and Charging P ro ced u re s .............................. 1A-19 Plenum A ir V a lv e ......................................................... 1A-31
Purging the S y s t e m ....................................................1A-19 Compressor ............................................................... 1A-32
Evacuating and Charging the S y s t e m ........................ 1A-19 Wiring D i a g r a m ............................................................... 1A-33
Checking O i l ............................................................... 1A-20 Special T o o ls ..................................................................... 1A-34
Adding Oil to the System ............................................. 1A-22 Specifications ..................................................................

GENERAL DESCRIPTION
FOUR-SEASON SYSTEM
The Four-Season system uses an evaporator pressure The heater core will be hot at all times since no water
control known as the POA (Pressure Operated Absolute) valve is present in the system.
valve. The six-cylinder reciprocating compressor is System operation is as follows (See Figure 20): Air,
bracket-mounted to the engine and belt driven from the either outside air, recirculated air or a mixture enters
crankshaft pulley. The condenser is mounted ahead of the the system and is forced through the system by the
engine cooling radiator and the receiver-dehydrator is blower.
mounted in the refrigerant line downstream of the con­
denser. All cooling system components are connected The air passes by the temperature door and is directed
by means of flexible refrigerant lines. through the heating or cooling cores, or split to flow
Both the heating and cooling functions are performed through both. After flowing through the core or cores,
by this system. Air entering the vehicle must pass the air passes the outlets door which directs it to the
either through the cooling unit (evaporator) or through dash or floor outlets or both. Air directed to the dash
the heating unit, or through both. The system is thus outlets is finally controlled by the position of the air
referred to as a parallel system. outlets. Air directed to the floor outlets passes the
The evaporator provides maximum cooling of the air defroster door which directs the air out the floor outlets,
passing through the core when the air conditioning sys­ the defroster outlets, or both.
tem is calling for cooling. The control valve acts in the Linkage is so designed that when the system controls
system only to control the evaporator pressure so that are calling for heat, air will enter the vehicle through the
minimum possible temperature is achieved without core floor distributor duct, and when the system controls call
freeze-up. The valve is preset, has no manual control, for cooling, air will enter through the three dash outlets.
is automatically altitude compensated, and non­ The side dash outlets may be rotated to provide either
repayable. soft, diffused airflow or spot cooling. Rotate half way to
shut off airflow. The barrel type outlet in the center of
the dash will direct air up or down or, if desired, shut it
off.
Controls
Full control of the Four-Season System is obtained
through the use of a single control panel (fig. 18). The
control levers make use of bowden cables to activate the
various doors and switches necessary for system opera­
tion. Therefore, control adjustment is a matter of
properly setting these bowden cables. The following
F ig . 18 - Four-Season System Controls paragraphs explain each control.

CHEVROLET TRUCK SERVICE MANUAL

 HEATER AND AIR CONDITIONING 1A-11

EVAPORATOR

OUTLET

F ig . 20 - A irflo w Schematic

CHEVROLET TRUCK SERVICE M ANUAL

HEATER AND AIR CONDITIONING 1A-12

“ Outlet” Lever resulting in a higher outlet air temperature. In the full

This lever actuates an air diverter door within the duct HOT position, all air flows through the heater core. For
assembly which routes airflow when fully right (HEATER) cooler air, moving the lever toward COOL will send
to the floor distributor ducts (for heater operation) or some air through the evaporator core (inoperative when
when fully left (A/C) to the dash outlets (for cooling the OUTLETS lever is set for heater operation) which in
operation). effect bypasses the heater core resulting in less heat
Moving this lever toward the left from the HEATER output.
position will activate the compressor clutch switch and Air Control Lever
set the cooling portion of the system in operation pro­ When the control is properly adjusted, full left position
viding the FAN switch is turned on. ("INSIDE") will supply 100% recirculated inside air, and
When the lever is moved fully toward the right (heating moving the lever to the word "OUTSIDE” will supply
position) the AIR control lever will automatically move 100% outside air to the system. Lever movement con­
to the outside air position. trols a vacuum switch which in turn actuates an air inlet
Temperature Lever door in the plenum below the air inlet grille and a
The "TEMPERATURE” lever, through its bowden recirculating air door in the kick pad.
cable, actuates the door which controls outlet tempera­
ture. Since the heater core in this system is hot at all Defroster
times, this door is necessary to shut off the heat when As the Air control knob is moved to the right from the
not wanted as well as to permit mixing of hot and cool "OUTSIDE" position toward the word DEFROSTER the
air to provide the desired conditioned air outlet tempera­ diverter door within the distributor duct moves to send a
ture, whether during heating or cooling operations. portion of the airflow to the defroster ducts. Full "right"
The temperature door directs the airflow through position of the AIR knob, as indicated on the panel, is the
either the heater core, the evaporator core or through DE-ICE position which sends the total airflow to the
both. When the system is set for full cooling, all air defroster ducts.
passes through the evaporator core. When warmer out­
let air is desired, the temperature door is moved by the Fan Switch
temperature lever so that some air passes through the The fan switch controls the operation of the three
heater core. The warmed air mixes with the cooled air speed blower motor.

GENERAL INFORMATION
PRECAUTIONS IN HANDLING REFRIGERANT-12 operation. It would be unwise to place the drum on a
In any vocation or trade, there are established proce­ gas stove, radiator or use a blow torch while pre­
dures and practices that have been developed after many paring for the charging operation, for a serious
years of experience. In addition, occupation hazards accident can result. Don’t depend on the safety
may be present that require the observation of certain plug - many drums have burst when the safety plug
precautions or use of special tools and equipment. Ob­ failed. Remember, high pressure means that great
serving the procedures, practices and precautions of forces are being exerted against the walls of the
servicing refrigeration equipment will greatly reduce the container. A bucket of warm water, not over 125°F,
possibilities of damage to the customers’ equipment as or warm wet rags around the container is all the heat
that is required.
well as virtually eliminate the element of hazard to the
serviceman. Do not weld or steam clean on or near the system.
Refrigerant-12 is transparent and colorless in both the Welding or steam cleaning can result in a dangerous
gaseous and liquid state. It has a boiling point of 21.7°F pressure buildup in the system.
When filling a small drum from a large one, never
below zero and, therefore, at all normal temperatures
fill the drum completely. Space should always be
and pressures it will be a vapor. The vapor is heavier
allowed above the liquid for expansion. If the drum
than air and is noninflammable, nonexplosive, non-
were completely full and the temperature was in­
poisonous (except when in contact with an open flame)
and noncorrosive (except when in contact with water). creased, hydraulic pressure with its tremendous
force would result.
The following precautions in handling R-12 should be
observed at all times. Discharging large quantities of R-12 into a room can
• All refrigerant drums are shipped with a heavy metal usually be done safely as the vapor would produce
screw cap. The purpose of the cap is to protect the no ill effects, however, in the event of an accidental
valve and safety plug from damage. It is good prac­ rapid discharge of the system it is recommended
tice to replace the cap after each use of the drum. that inhalation of large quantities of R-12 be avoided.
• If it is ever necessary to transport or carry a drum This caution is especially important if the area con­
or can of refrigerant in a car, keep it in the luggage tains a flame producing device such as a gas heater.
compartment. Refrigerant should not be exposed to While R-12 normally is nonpoisonous, heavy con­
the radiant heat from the sun for the resulting in­ centrations of it in contact with a live flame will
crease in pressure may cause the safety plug to produce a toxic gas. The same gas will also attack
release or the drum or can to burst. all bright metal surfaces.
• Drums or disposable cans should never be subjected Protection of the eyes is of vital importance! When
to high temperature when adding refrigerant to the working around a refrigerating system, an accident
system. In most instances, heating the drum or can may cause liquid refrigerant to hit the face. If the
is required to raise the pressure in the container eyes are protected with goggles or glasses, no
higher than the pressure in the system during the serious damage can resu lt Just remember, any

CHEVROLET TRUCK SERVICE M ANUAL

 HEATER AND AIR CONDITIONING 1A-13

is in operation)

0 H. P. VAPOR | H. P. LIQUID 0 I. P. LIQUID £•] L. P. VAPOR | H. P. POWER ELEMENT

F ig. 21 - C y c le o f O peration - Four-Season

R - 1 2 liquid that you can touch or that touches you is • When disconnecting any fitting in the refrigeration
at least 21.7UF. below zero. The eyeballs can’t take system, the system must first be discharged of all
much of this temperature. If R-12 liquid should refrigerant. However, proceed very cautiously r e ­
strike the eyeballs, here is what to do: gardless of gauge readings. Open very slowly, keep­
1. Keep calm. ing face and hands away so that no injury can occur
2. Do not rub the eyes! Splash the affected area with if there happens to be liquid refrigerant in the line.
quantities of cold water to gradually get the tem­ If pressure is noticed when fitting is loosened, allow
perature above the freezing point. The use of min­ it to bleed off very slowly.
eral, cod liver or an antiseptic oil is important in
providing a protective film to reduce the possibility CAUTION: Always wear safety goggles wnen
of infection. opening refrigerant lines.
3. As soon as possible, call or consult an eye specialist
for immediate and future treatment. • In the event any line is opened to atmosphere, it
REMEMBER - "An ounce of prevention is worth a
should be immediately capped to prevent entrance
pound of cure." of moisture and dirt.
PRECAUTIONS IN HANDLING REFRIGERANT LINES • The use of the proper wrenches when making con­
• All metal tubing lines should be free of kinks, be­ nections on "O" ring fittings is important. The use
cause of the restriction that kinks will offer to the of improper wrenches may damage the connection.
flow of refrigerant. The refrigeration capacity of the The opposing fitting should always be backed up with
entire system can be greatly reduced by a single a wrench to prevent distortion of connecting lines or
kink. components. When connecting the flexible hose con­
• The flexible hose lines should never be bent to a nections it is important that the swagged fitting and
radius of less than 1 0 times the diameter of the hose. the flare nut, as well as the coupling to which it is
• The flexible hose lines should never be allowed to attached, be held at the same time using three dif­
come within a distance of 2 - 1 / 2 " of the exhaust ferent wrenches to prevent turning the fitting and
manifold. damaging the ground seat.
• Flexible hose lines should be inspected at least once • "O" rings and seats must be in perfect condition.
a year for leaks or brittleness. If found brittle or The slightest burr or piece of dirt may cause a leak.
leaking they should be replaced with new lines. • Sealing beads on hose clamp connections must be
• Use only sealed lines from parts stock. free of nicks and scratches to assure a perfect seal.

CHEVROLET TRUCK SERVICE M ANUAL

HEATER AND AIR CONDITIONING 1A-14

MAINTAINING CHEMICAL STABILITY IN THE

REFRIGERATION SYSTEM
The metal internal parts of the Chevrolet refrigeration
system and the refrigerant and oil contained in the sys­
tem are designed to remain in a state of chemical sta­
bility as long as pure R-12 and uncontaminated refrigera­
tion oil is used in the system.
However, when abnormal amounts of foreign m aterials,
such as dirt, air or moisture are allowed to enter the
system, the chemical stability may be upset. When ac­
celerated by heat, these contaminates may form acids
and sludge and eventually cause the breakdown of com­
ponents within the system. In addition, contaminates may
affect the temperature-pressure relationship of R-12,
resulting in improper operating temperature and pres­
sures and decreased efficiency of the system.
The following general practices should be observed to
insure chemical stability in the system.
• Whenever it becomes necessary to disconnect a
refrigerant or gauge line, it should be immediately Fig. 23 - G a u g e Set
capped. Capping the tubing will also prevent dirt and The face is graduated into pounds of pressure and, in
foreign matter from entering. the opposite direction, in inches of vacuum. This is the
• Tools should be kept clean and dry. This also in­ gauge that should always be used in checking pressures
cludes the gauge set and replacement parts. on the low pressure side of the system. When all parts of
• When adding oil, the container should be exception­ the system are functioning properly the refrigerant
ally clean and dry due to the fact that the refrigera­ pressure on the low pressure side never falls below 0
tion oil in the container is as m oisture-free as it is pounds pressure. However, several abnormal conditions
possible to make it. Therefore, it will quickly ab­ can occur that will cause the low pressure to fall into a
sorb any moisture with which it comes in contact. partial vacuum. Therefore, a low pressure gauge is
For this same reason the oil container should not be required.
opened until ready for use and then it should be
capped immediately after use.
• When it is necessary to open a system, have every­
thing you will need ready and handy so that as little
time as possible will be required to perform the
LOW PRESSURE HIGH PRESSURE
operation. Don’t leave the system open any longer CONTROL CONTROL (2)
than is necessary.
• Finally, after the operation has been completed and
the system sealed again, air and moisture should be
evacuated from the system before recharging. VACUUM
GAUGE SET CONTROL FREON
(3) CONTROL
The gauge set (fig. 23) is used when purging, evacuat­ (4)
ing, charging or diagnosing trouble in the system. The LOW
gauge at the left is known as the low pressure gauge. GAUGE LINE HIGH PRESSURE
GAUGE LINE

5 LB. CHARGING
CYLINDER

LEAK
DETECTOR

FREON DRUM
CONTROL VALVE

Fig . 22 - System Contaminants Fig . 24 - J-8393 Charging Station

CHEVROLET TRUCK SERVICE M ANUAL

 HEATER AND AIR CONDITIONING 1A-15

The high pressure gauge is used for checking pres­ All evacuation and charging equipment is hooked to­
sures on the high pressure side of the system. gether in a compact portable unit (fig. 24). It brings air
The connection at the left is for attaching the low conditioning service down to the basic problem of hooking
pressure gauge line and the one at the right the high on two hoses, and manipulating clearly labeled valves.
pressure gauge line. The center connector is common to This will tend to insure that the job will be done without
both and is for the purpose of attaching a line for adding skipping operations. As a result, you can expect to save
refrigerant, discharging refrigerant, evacuating the sys­ time and get higher quality work, less chance of an over
tem and other uses. When not required, this line or or undercharge, or comeback.
connection should be capped. The pump mount is such that the dealer may use his
own vacuum pump. The gauges and manifold are in com­
NOTE: Gauge fitting connections should be in­
mon use. Thus a current air conditioning dealer can use
stalled hand tight only and the connections leak
the equipment on hand and avoid duplication.
tested before proceeding.
The hand shutoff valves on the gauge manifold do not LEAK TESTING THE SYSTEM
control the opening or closing off of pressure to the
gauges. They merely close each opening to the center Whenever a refrigerant leak is suspected in the system
connector and to each other. During most diagnosing or a service operation performed which results in dis­
and service operation, the valves must be closed. The turbing lines or connections, it is advisable to test for
only occasion for opening both at the same time would be leaks. Common sense should be the governing factor in
to bypass refrigerant vapor from the high pressure to performing any leak test, since the necessity and extent
the low pressure side of the system, or in evacuating of any such test will, in general, depend upon the nature
both sides of the system. of the complaint and the type of service performed on
the system. It is better to test and be sure, if in doubt,
J-8393 CHARGING STATION than to risk the possibility of having to do the job over
The J-8393 Charging Station is a portable assembly of again.
a vacuum pump, refrigerant supply, gauges, valves, and
most important, a five (5) pound metering refrigerant NOTE: The use of a leak detecting dye within
charging cylinder. The use of a charging cylinder elim­ the system is not recommended because of the
inates the need for scales, hot water pails, etc. following reasons:
The chief advantage of this unit is savings. A very 1. Refrigerant leakage can exist without any oil leakage.
definite savings in refrigerant and time can be obtained In this case the dye will not indicate the leak, how­
by using this unit. Since the refrigerant is metered into ever, a torch detector will.
the system by volume, the correct amount may be added 2. The addition of additives, other than inhibitors, may
to the system and charged to the customer. This, coupled alter the stability of the refrigeration system and
with the fact that the unit remains "plumbed" at all times cause malfunctions.
and thus eliminates loss of refrigerant in purging of 3. Dye type leak detectors which are insoluble form a
lines and hooking-up, combines to enable the operator curdle which can block the inlet screen of the ex­
to get full use of all refrigerant purchased by the pansion valve.
dealership.
Leak Detector
Tool J-6084 (fig. 25) is a propane gas-burning torch
which is used to locate a leak in any part of the system.
Refrigerant gas drawn into the sampling tube attached to
the torch will cause the torch flame to change color in
proportion to the size of the leak. Propane gas fuel
cylinders used with the torch are readily available
commercially throughout the country.
CAUTION: Do not use lighted detector in any
place where combustible or explosive gases,
dusts or vapors may be present.

Operating Detector
1. Open control valve only until a low hiss of gas is
heard, then light gas at opening in chimney.
2. Adjust flame until desired volume is obtained. This
is most satisfactory when blue flame is approxi­
mately 3/8" above reactor plate. The reaction plate
will quickly heat to a cherry red.
3. Explore for leaks by moving the end of the sampling
hose around possible leak points in the system. Do
not pinch or kink hose.
NOTE: Since R-12 is heavier than air, it is
good practice to place open end of sampling tube
immediately below point being tested, particu­
F ig . 25 - Leak Detector larly in cases of small leaks.

CHEVROLET TRUCK SERVICE M ANUAL

HEATER AND AIR CONDITIONING 1A-16

FIVE A M P
TIME D ELAY
FUSE

C O R D TO PUM P PU M P D IS C H A R G E
110 A C S O U R C E INLET OUTLET

Fig . 27 - Refrigerant-12 Disposable Cans and V alves

NOTE: A refrigerant leak in the high pressure

side of the system may be more easily detected
when, if possible, the system is in operation. A
leak on the low pressure side may be most
easily detected after the engine has been shut
off for several minutes to allow system pres­
sures to equalize. This particularly applies to
the front seal.
VACUUM PUMP
A vacuum pump should be used for evacuating air and
moisture from the air conditioning system.
Vacuum pump, Tool J-5428, (fig. 26) is available for
this purpose. It is used as a component part of the
Charging Station J-8393, described previously. The fol­
lowing precautions should be observed relative to the
operation and maintenance of this pump.
• Make sure dust cap on discharge outlet of vacuum
pump is removed before operating.
• Keep all openings capped when not in use to avoid
moisture being drawn into the system.
• Oil should be changed after every 250 hours of nor­
mal operation.
To change oil, simply unscrew hex nut located on back
side of pump, tilt backward and drain out oil (fig. 26).
Recharge with 8 ounces of vacuum pump oil Frigidaire
150 or equivalent (fig. 26). If you desire to flush out the
pump, use this same type clean oil. Do not use solvent.
Fig . 26 - Vacuum Pump
NOTE: Improper lubrication will shorten the
CAUTION: Do not breathe the fumes that are
life of pump.
produced by the burning of R-12 gas in the de-
tector flame, since such fumes can be toxic in • If this pump is subjected to extreme or prolonged
large concentrations of R-12. cold, allow it to remain indoors until oil has reached
4. Watch for color changes. The color of the flame approximate room temperature. Failure to warm
which passes through the reaction plate will change oil will result in a blown fuse.
to yellow when sampling hose draws in very small • A five ampere time delay cartridge fuse has been
leaks of R-12. Large leaks will be indicated by a installed in the common line to protect the windings
change in color to a vivid purplish-blue. When the of the compressor. The fuse will blow if an ex­
sampling hose passes the leak, the flame will clear cessive load is placed on the pump. In the event the
to an almost colorless pale-blue again. If the flame fuse is blown, replace with a five ampere time delay
remains yellow when unit is removed from leak, fuse - do not use a substitute fuse as it will result in
insufficient air is being drawn in or the reaction damage to the starting windings.
plate is dirty. • If the pump is being utilized to evacuate a bumt-out

CHEVROLET TRUCK SERVICE MANUAL

 HEATER AND AIR CONDITIONING 1A-17

system, a filter must be connected to the intake system. It is available in 1 quart graduated bottles
fitting to prevent any sludge from contaminating the through Parts Stock. This oil is as free from moisture
working parts, which will result in malfunction of the and comtaminants as it is possible to attain by human
pump. processes. This condition should be preserved by im ­
• Do not use the vacuum pump as an air compressor. mediately capping the bottle when not in use.
See "Air Conditioning System Capacities” for the
AVAILABILITY OF REFRIGERANT-12
total system oil capacity.
Refrigerant-12 is available through Parts Stock in 25 Due to the porosity of the refrigerant hoses and con­
lb. drums and in 15 oz. disposable cans. Valves are nections, the system refrigerant level will show a definite
available for the disposable cans, which may be used as drop after a period of time. Since the compressor oil is
individual cans or as a group of up to four cans (fig. 44). carried throughout the entire system mixed with the
Tool J-6272 is used with one through four cans. The refrigerant a low refrigerant level will cause a dangerous
use of the four-can fixture makes it possible to charge lack of lubrication. Therefore the refrigerant charge in
the system with a known quantity of refrigerant without the system has a definite tie-in with the amount of oil
the use of weighing equipment necessary with the larger found in the compressor and an insufficient charge may
drum. The single can Valve J-6271 can be used for com­ eventually lead to an oil build-up in the evaporator.
pleting the charge and for miscellaneous operations such
as flushing. The valves are installed by piercing the top COMPRESSOR SERIAL NUMBER
seal of the cans. The compressor serial number is located on the serial
Evacuating and charging procedures later in this se c­ number plate on top of the compressor. The serial num­
tion will make use of the J-8393 Charging Station which ber consists of a series of numbers and letters. This
uses the 25 lb. drum of refrigerant. serial number should be referenced on all forms and
COMPRESSOR OIL correspondence related to the servicing of this part.
Special refrigeration lubricant should be used in the

INSPECTION AND PERIODIC SERVICE

PRE-DELIVERY INSPECTION • At least once a year, check the system for proper
1. Check that engine exhaust is suitably ventilated. refrigerant charge and the flexible hoses for brittle­
2. Check the belt for proper tension. ness, wear or leaks.
3. With controls positioned for operation of the system, • Every 6000 miles check sight glass for low refrig er­
operate the unit for ten minutes at approximately ant level.
2000 rpm. Observe the clutch pulley bolt to see that • Check belt tension regularly.
the compressor is operating at the same speed as • Every week - during winter months or other periods
the clutch pulley. Any speed variation indicates when the system is not being operated regularly - run
clutch slippage. the system, set for maximum cooling, for 10 or 15
4. Before turning off the engine, check the sight glass minutes to insure proper lubrication of seals and
to see that the unit has a sufficient Refrigerant moving parts.
charge. The glass should be clear, although during INSTALLING GAUGE SET TO CHECK
milder weather it may show traces of bubbles. Foam SYSTEM OPERATION
in the flow indicates a low charge. No liquid visible The Four-season System high pressure gauge connec­
indicates no charge. tion is located on the muffler. The low pressure con­
5. Check hose clamp connections. If clamp screw nection is located on the P.O.A. valve.
torque is less than 10 lb. in., retighten to 20-25 lb. 1. Install Gauge Adapter (J-5420 or J-9459) onto the
in. Do not tighten to new hose specifications or hose high and low pressure hoses of the gauge set.
leakage may occur. Leak test the complete system. 2. With the engine stopped, remove the caps from the
6 . If there is evidence of an oil leak, check the com­ cored valve gauge connector on the compressor
pressor to see that the oil charge is satisfactory. fittings block and P.O.A. valve.
7. Check the system controls for proper operation. 3. Connect the gauge lines with adapters to the threaded
connector on the compressor fittings block and
6000 MILE INSPECTION P.O.A. Valve.
1. Check unit for any indication of a refrigerant leak.
2. If there is an indication of an oil leak, check the CAUTION: When removing gauge lines from
compressor proper oil charge. the compressor fittings block be sure to remove
3. Check sight glass for proper charge of Refrigerant- the adapters from the fittings rather than the"
12 . gauge lines from the adapters.
4. Tighten the compressor brace and support bolts and
check the belt tension. PERFORMANCE TEST
5. Check hose clamp connections as in step 5 above. This test may be conducted to determine if the system
6 . Check thermostatic switch setting (Custom and All- is performing in a satisfactory manner and should be
Weather Systems.) used as a guide by the serviceman in diagnosing trouble
within the system. The following fixed conditions must be
PERIODIC SERVICE adhered to in order to make it possible to compare the
• Inspect condenser regularly to be sure that it is not performance of the system being tested with the stand­
plugged with leaves or other foreign material. ards below:
• Check evaporator drain tubes regularly for dirt or 1. Doors and windows closed. (Car inside or in shade.)
restrictions. 2. Hood up and engine exhaust suitably ventilated.

CHEVROLET TRUCK SERVICE MANUAL

HEATER AND AIR CONDITIONING 1A-18

3. Vehicle in NEUTRAL with engine running at 2000 EVAPORATOR CONTROL VALVE (POA)
rpm. Four Season
4. Air Conditioning controls set for -
• Maximum cooling. The only check for proper POA valve operation is to
• High blower speed. check the suction pressure at the valve as during a
5. TEMP knob and AIR knob set for full recirculating performance test. The POA valve is an absolute valve
air. On Comfortron systems move the control lever and will provide different gauge readings based on the
to REAR and pull the white vacuum hose from the altitude where the readings are being taken. Correct
transducer. Plug the hose. An alternate method is gauge reading at sea level is 29.5 psig. Gauge readings
to install the J-22368 Tester (described later in this will be one-half psi higher for each additional 1 0 0 0 feet
section) and operate it on MANUAL control to main­ of elevation. The following table lists gauge readings at
tain maximum cooling and blower speed. different altitudes. If a valve gives improper gauge
6 . Gauge set installed. readings, it must be replaced since it is not repairable
7. System settled out (run-in approximately 10 minutes). or adjustable.
8 . A thermometer placed in front of vehicle grille and
another in the right hand diffuser outlet. 29.5 psig. - - Sea Level
30.0 psig. — 1000 ft.
PERFORMANCE DATA 30.5 psig. — 2000 ft.
31.0 psig. — 3000 ft.
The following Performance Data define normal opera­ 31.5 psig. — 4000 ft.
tion of the system under the above conditions. Relative 3 2.0 psig. — 5000 ft.
humidity does not appear in the tables because after 32.5 psig. — 6000 ft.
running the prescribed length of time on recirculated air 33.0 psig. — 7000 ft.
and maximum cooling, the relative humidity of the air 33.5 psig. — 8000 ft.
passing over the evaporator core will remain at ap­ 34.0 psig. — 9000 ft.
proximately 35% to 40% regardless of the ambient tem­ 34.5 psig. — 10000 ft.
perature or humidity.
Should excessive head pressures be encountered at EXPANSION VALVE
higher ambient temperatures, an 18" fan placed in front
of the vehicle and blowing into the condenser will provide A malfunction of the expansion valve will be caused
the extra circulation of air needed to bring the pressures by one of the following conditions: valve stuck open,
to within the limits specified. valve stuck closed, broken power element, a restricted
screen or an improperly located or installed power
NOTE: Higher temperatures and pressures
element bulb. The first three conditions require valve
will occur at higher ambient temperatures. In
areas of high humidity it is possible to have replacement. The last two may be corrected by replacing
thermometer and gauge readings approach but the valve inlet screen and by properly installing the
not reach the figures listed in the performance power element bulb.
tables and still have a satisfactory operating Attachment of the expansion valve bulb to the evapo­
unit. However, it is important to remember that rator outlet line is very critical. The bulb must be
low pressure has a direct relationship to nozzle attached tightly to the line and must make good contact
outlet temperature. If pressure is too low, ice with the line along the entire length of the bulb. A loose
will gradually form on the evaporator fins, r e ­
stricting airflow into the passenger area and
resulting in insufficient or no cooling.
Four Season Systems

(Refrigerant Charge = 3 Lbs. - 4 Oz.)

Temperature of
Air Entering 70° 80° 90° 100° 110° 120°
Condenser

Engine rpm 2000

Compressor Head 145 185 200 215 255 285

Pressure 155 195 210 225 265 295

Evaporator Pressure Dependent Upon Altitude

at STV See Chart Under Evaporator Con­
trol Valve (POA)

Discharge Air 38 38 40 41 43 48
Temp, at Right 41 41 43 44 46 51
Hand Outlet
F ig . 28 - Evaporator Pressure Control V a lv e POA

CHEVROLET TRUCK SERVICE MANUAL

 HEATER AND AIR CONDITIONING 1A-19

bulb will result in high low side pressures and poor NOTE: If engine idle is erratic, hold the idle
cooling. On bulbs located outside the evaporator case compensator valve closed with a pencil or
insulation must be properly installed. wooden dowel while adjusting the idle mixture
The external equalizer line shown in Figure 55 is not screw(s). Never attempt to bend the bimetal
used in the Custom and Chevy II All-Weather systems. strip or attempt any valve adjustment.
Indications of expansion valve trouble provided by the
Performance Test are as follows:

VALVE STUCK OPEN OR BROKEN POWER fr

ELEMENT
Noisy Compressor.
No Cooling - Freeze Up.

VALVE STUCK CLOSED OR PLUGGED SCREEN

Very Low Suction Pressure.
No Cooling.

POORLY LOCATED POWER ELEMENT BULB

Normal Pressure.
Poor Cooling.

ENGINE IDLE COMPENSATOR

This additional aid to prevent stalling during prolonged

hot weather periods is included with all air conditioned
vehicles. The idle compensator is a thermostatically
controlled air bleed which supplies additional air to the
idle mixture. On V - 8 engines, with factory installed air EXTERNAL
EQUALIZER LINE
conditioning systems, the compensator is located within
the carburetor and is accessible when the engine air
cleaner is removed. On all other vehicles the compen­
sator is threaded into a manifold fitting below the car­
buretor. All compensators are factory set and are
F ig . 29 - Expansion V a lv e
non-adjustable. A malfunctioning unit should be replaced.

EVACUATING AND CHARGING PROCEDURES

AIR CONDITIONING SYSTEM CAPACITY frigerant has been released. Close both gauge valves.
Refrigerant EVACUATING AND CHARGING THE SYSTEM
Charge Oil Charge
GENERAL NOTE: In all evacuating procedures
Four-Season System 3 lbs. 4 oz. 10 ozs. 525 viscosity shown below, the specification of 26-28 inches
of Mercury vacuum is used. These figures are
PURGING THE SYSTEM only attainable at or near Sea Level Elevation.
For each 1000 feet above sea level where this
In replacing any of the air conditioning components the
operation is being performed, the specifications
system must be completely purged or drained of r e ­
should be lowered by 1 inch. Example: at 5000
frigerant. The purpose is to lower the pressure inside ft. elevation, only 21 to 23 inches of vacuum can
the system so that a component part can be safely
normally be obtained.
removed.
1. With engine stopped install high and low pressure Whenever the air conditioning system is open for any
lines of gauge set to the proper high and low pres­ reason, it should not be put into operation again until it
sure gauge fittings (see "Installing Gauge Set to has been evacuated to remove air and moisture which
Check Operation"). may have entered the system.
2. With plug removed from the centerline on the gauge The following procedures are based on the use of the
manifold, open the vapor slowly through the center J-8393 Charging Station.
connection.
Filling Charging Cylinder
CAUTION: Do not open valves too much or
compressor oil may be discharged with the
1. Open control valve on refrigerant drum.
refrigerant. A rag wrapped around the end of 2. Open valve on bottom of charging cylinder allowing
the center gauge line will prevent the splashing
refrigerant to enter cylinder.
of oil in the event of accidental rapid discharge. 3. Bleed cylinder valve on top (behind control panel) as
When the pressure is reduced to below 100 pounds required to allow refrigerant to enter. When re ­
on the high pressure gauge, open the low pressure frigerant reaches desired level (see "Air Condition­
gauge valve and continue discharging until all r e ­ ing System Capacities"), close valve at bottom of

CHEVROLET TRUCK SERVICE MANUAL

HEATER AND AIR CONDITIONING 1A-20

cylinder and be certain bleed valve is closed 8. After evacuating for 15 minutes, add 1/2 pound of
securely. R-12 to system as described in Step 7 above. Purge
this 1/2 pound and reevacuate for 5 minutes. This
NOTE: It will be necessary to close bleed second evacuation is to be certain that as much con­
valve periodically to allow boiling to subside to tamination is removed from the system as possible.
check level in sight glass. 9. Only after evacuating as above, system is ready for
charging. Note reading on sight glass of charging
Installing Charging Station to System cylinder. If it does not contain a sufficient amount
for a full charge, fill to the proper level.
1. Be certain all valves on charging station are closed. 10. With High and Low pressure Valves (1 and 2) open,
2. Connect high pressure gauge line to high pressure close Vacuum Control Valve (3) and open freon con­
gauge fitting. (See "Installing Gauge Set to Check trol valve (4 ). Operating the heater and air con­
System Operations.") ditioner blower with the controls set for cooling
3. See Figure 30. Turn high pressure control (2) one will help complete the charging operation.
turn counter-clockwise (open). Crack open low pres­
NOTE: If the charge will not transfer com­
sure control (1 ) and allow refrigerant gas to hiss
pletely from the station to the system, close
from low pressure gauge line for three seconds,
then connect low pressure gauge line to low pressure the high pressure valve at the gauge set, set
gauge fitting. the air conditioning controls for cooling, check
4. System is now ready for performance testing. that the engine compartment is clear of obstruc­
tions, and start the engine. Compressor opera­
Evacuating and Charging System tion will decrease the low side pressure in the
system.
1. Install charging station as previously described. System is now charged and should be performance
Refer to Figure 30 while performing the following tested before removing gauges.
operation.
2. Remove Low Pressure gauge line from compressor. CHECKING OIL
3. Crack open high (2) and low (1) pressure control
valves, and allow refrigerant gas to purge from In the six cylinder compressor it is not recommended
system. Purge slow enough so that oil does not that the oil be checked as a matter of course. Generally,
escape from system along with Refrigerant. compressor oil lever should be checked only where
4. When refrigerant flow stops, connect Low Pressure there is evidence of a major loss of system oil such as
gauge line to compressor. might be caused by:
5. Turn on vacuum pump and open Vacuum Control • A broken refrigerant hose.
Valve (3). • A severe hose fitting leak.
6 . With system purged as above, run pump until 28-29
• A very badly leaking compressor seal.
inches of vacuum is obtained. Continue to run pump • Collision damage to the system components.
for 15 minutes after the system reaches 28-29 inches As a quick check on compressor oil charge, with the
vacuum. engine off, carefully crack open the oil drain plug on the
7. If 28-29 inches cannot be obtained, close Vacuum bottom of the compressor. If oil comes out, the com­
Control Valve (3) and shut off vacuum pump. Open pressor has the required amount of oil. To further check
Refrigerant Control Valve (4) and allow 1/2 pound of the compressor oil charge, should the above test show
R-12 to enter system. Locate and repair all leaks. insufficient oil, it is necessary to remove the compressor
from the vehicle, drain and measure the oil.

Checking Compressor Oil Charge

1. Run the system for 10 minutes at 500-600 engine
rpm with controls set for maximum cooling and
1 2 high blower speed.
L O W PRESSURE H IG H P R E S S U R E
2. Turn off engine, discharge the system, remove
CONTROL CONTROL
compressor from vehicle, place it in a horizontal
position with the drain plug downward. Remove the
drain plug and, tipping the compressor back and
forth and rotating the compressor shaft, drain the
oil into a clean container, measure and discard the
oil.
3. a. If the quantity drained was 4 fluid oz. or more,
add the same amount of new refrigerant oil to
3 4 the replacement compressor.
VACUUM FR EO N b. If the quantity drained was less than 4 fluid oz.,
CONTROL CONTROL add 6 fluid oz. of new refrigeration oil to the
replacement compressor.
c. If a new service compressor is being installed,
drain all oil from it and replace only the amount
specified in Steps 3a and 3b above.
F ig . 30 - Charging Station Controls
d. If a field repaired compressor is being installed,

CHEVROLET TRUCK SERVICE MANUAL

 HEATER AND AIR CONDITIONING 1A-21

H IG H PR ESSU RE
G A U G E FITTING*

PO A VALVE
L O W PR ESSU RE
G A U G E FIT TIN G
M UFFLER

■COMPRESSOR

H IG H PR ESSU R E.
L O W PRESSURE
G A G E VALVE
G A G E VALVE

VALVE

VALVE
R EFR IG ER A N T
SU PPLY

► TO VACUUM SU PPLY

F ig . 31 - Charging Schematic

CHEVROLET TRUCK SERVICE M ANUAL

HEATER AND AIR CONDITIONING 1A-22

add an additional 1 fluid oz. to the compressor. ADDING OIL TO THE SYSTEM
4. In the event that it is not possible to idle the com­
pressor as outlined in Step 1 to effect oil return to The system should be completely assembled and un­
it, proceed as follows: charged before adding oil. Use only uncontaminated
a. Remove the compressor, drain, measure and refrigerant oil and add as follows:
discard the oil. 1. Connect the low pressure gauge line to the low
b. If the amount drained is more than 1-1/2 fluid pressure gauge fitting on the P.O.A. valve.
oz. and the system shows no signs of a major 2. Connect the high pressure line from the charging
leak, add the same amount to the replacement station gauge set to the compressor muffler.
compressor. 3. Disconnect the high pressure line from the gauge
c. If the amount drained is less than 1-1/2 fluid oz. set, make certain that the line is clean, and place
and the system appears to have lost an excessive the end in a graduated oil container.
amount of oil add 6 fluid oz. of clean refrigeration 4. Pour enough refrigerant oil in the container so that
oil to replacement compressor, 7 fluid oz. to a the required volume may be drawn into the system
repaired compressor. by the high pressure hose.
If the oil contains chips or other foreign ma­ 5. Close the high pressure valve at the gauge set, and
terial, replace the receiver-dehydrator and flush
open the low pressure valve.
or replace all component parts as necessary. Add 6 . Operate the vacuum pump to drop the pressure within
the full 1 1 fluid oz. of new refrigeration oil to the
the system and cause atmospheric pressure to force
replacement compressor.
oil through the high pressure line into the system.
5. Add additional oil in the following amounts for any When the oil level has dropped the required volume,
system components being replaced. pull the line out of the oil container and continue
E v a p o ra to r................................................ 3 fluid oz. vacuum pump operation to force the oil contained in
Condenser ................................................ 1 fluid oz. the line into the system.
Receiver-Dehydrator ............................ 1 fluid oz. 7. Shut off the vacuum pump and connect the high pres­
NOTE: When adding oil to the compressor, it sure line to the gauge set. Open the high pressure
will be necessary to tilt the rear end of the valve and evacuate the system through the high and
compressor up so that the oil will not run out low pressure side of the system. Complete the
of the suction and discharge ports. Do not set charging operation as outlined in Step 10 under
the compressor on the shaft end. "Evacuating and Charging System".
COMPONENT REPLACEMENT AND MINOR REPAIRS
REFRIGERANT LINE CONNECTIONS CAUTION: Use no sealer of any kind.
“ O” Rings
3. Install clamps on hose, hooking the locating arms
Always replace the ”0 '' ring when a connection has over the cut end of the hose.
been broken. When replacing the "O" ring, first dip it 4. Tighten the hose clamp screw to 35-42 lb. in.
in refrigeration oil. Always use a backing wrench on torque. DO NOT RETORQUE. The clamp screw
”0 " ring fittings to prevent the pipe from twisting and torque will normally decrease as the hose conforms
damaging the "O” ring. Do not overtighten. Correct to the force of the clamp. The screw should be
torque specifications are as follows: retorqued only if its torque falls below 1 0 lb. in.
In this case, retorque to 20-25 lb. in. Further
Metal Thread and Steel Alum. tightening may damage the hose.
Tube Fitting Tubing Tubing
Removal
O.D. Size Torque* Torque*
1. Carefully, with a sharp knife, make an angle cut in
1/4 7/16 13 6
the hose as shown in Figure 32. This should loosen
3/8 5/8 33 12
the hose so that it may be worked off the fitting.
1 /2 3/4 33 12
2. Cut off slit end of hose when reinstalling. Reinstall
5/8 7/8 33 20
as described above.
3/4 1-1/16 33 25 CAUTION: Use only approved refrigeration
* Pound Feet hose. Never use heater hose. Use extreme
care not to nick or score the sealing beads when
NOTE: Where steel to aluminum connections cutting off the hose. Cutting the hose lengthwise
are being made, use torque for aluminum tubing. may result in this problem"!
Hose Clamps REPAIR OF REFRIGERANT LEAKS
When hose clamp connections are encountered special
Any refrigerant leaks found in the system should be
procedures are necessary for both installation and r e ­
repaired in the manner given below:
moval.
Installation Leaks at “ O” Ring Connection
1. Coat tube and hose with refrigeration oil. 1. Check the torque on the fitting and, if too loose,
2. Carefully insert hose over the three beads on the tighten to the proper torque. Always use a backing
fitting and down as far as the fourth, or locating wrench to prevent twisting and damage to the "O"
bead. Hose must butt against this fourth bead. ring. Do not overtighten. Again leak test the joint.

CHEVROLET TRUCK SERVICE MANUAL

 HEATER AND AIR CONDITIONING 1A-23

2. If the leak is still present, discharge the refrigerant Compressor Leaks

from the system as described under "Evacuating
and Charging Procedures." If leaks are located around the compressor shaft seal
3. Inspect the "O" ring and the fitting and replace if or shell, replacement of necessary seals should be made
damaged in any way. Coat the "O" ring before r e ­ as outlined under "Compressor" in the Chassis Overhaul
installed with refrigeration oil and install carefully. Shop Manual.
4. Retorque the fitting, using a backing wrench, and
then add 1/2 to 1 lb. of R-12 to the system and REFRIGERANT HOSE FAILURE
recheck for leaks.
CAUTION: Do not operate the system with this After a leak or rupture has occurred in a refrigerant
small refrigerant charge. hose, or if a fitting has loosened and caused a consider­
able loss of refrigerant and oil, the entire system should
5. Purge the system, thus removing the 1/2 to 1 lb. be flushed and recharged after repairs have been made.
installed in Step 4 above. , If the system has been open to atmosphere for any pro­
6 . Evacuate and charge the system. longed period of time the receiver-dehydrator should be
replaced.
Leaks at Hose Clamp Connection
CONDITIONING SYSTEM FOR
1. Check the tightness of the clamp itself and tighten REPLACEMENT OF COMPONENT PARTS
if necessary. Recheck for leak.
2. If leak has not been corrected discharge the system Air conditioning, like many other things, is fairly
and loosen clamp and remove hose from connection. simple to service once it is understood. However, there
Inspect condition of hose and connector. Replace are certain procedures, practices and precautions that
scored or damaged parts. should be followed to prevent costly repairs, personal
3. Dip end of new hose in refrigerant oil and carefully injury or damage to equipment. For this reason it is
reinstall over connector. Never push end of hose strongly recommended that the preceding information in
beyond the locating bead. Properly torque the clamp. this section be studied thoroughly before attempting to
4. Recheck the system for leaks by installing 1/2 to 1 service the system.
lb. of R-12 into the system. Do not run compressor. Great emphasis must be placed upon keeping the sy s­
5. Purge the system, thus removing the 1/2 to 1 lb. tem clean. Use plugs or caps to close system components
installed in Step 4 above. and hoses when they are opened to the atmosphere. Keep
6 . Evacuate and charge the system. your work area clean.
In removing and replacing any part which requires
unsealing the refrigerant circuit the following operations,
MAKE A N G U LA R CUT which are described in this section, must be performed
FOR H O SE REM OVAL in the sequence shown.
1. Purge the system by releasing the refrigerant to the
atmosphere.
2. Remove and replace the defective part.
3. Evacuate and charge the system with R-12.

CAUTION: Always wear protective goggles

when working on refrigeration systems. Gogglei
J-5453 are included in the set of air conditioning
special tools. Also, beware of the danger of
carbon monoxide fumes by avoiding running the
engine in closed or improperly ventilated
LOCATING garages.
BEAD
SIGHT GLASS REPLACEMENT-ALL VEHICLES

If damage to the sight glass should occur, a new sight

glass kit should be installed. The kit contains the sight
glass, seal and retainer. (See Figure 33.)
1. Purge system.
2. Remove the sight glass retainer nut using a screw
driver and remove old glass and seal.
3. Install the new glass and seal and retainer nut, being
careful not to turn the nut past the face of the hous­
ing. To do so may damage the "O" ring seal.
SEA LIN G LOCATING 4. Evacuate and recharge the system.
BEADS BEAD
CONTROL ASSEMBLY

Removal
F ig . 32 - Hose Clamp Connections 1. Disconnect battery ground cable.

CHEVROLET TRUCK SERVICE M ANUAL

HEATER AND AIR CONDITIONING 1A-24

Fig. 33 - Sight Glass Replacement

2. Remove the screws in the lower lip of the dash which replace mounting bolts. Be certain shims are in­
attach the control assembly bracket to the dash. stalled at lower condenser mount bolts.
3. Move the unit toward the front of the vehicle and 2. Move radiator into place and replace mounting bolts.
lower it. Replace shroud lower mounting screws.
4. Disconnect the blower harness connector and illumi­ 3. Replace the hood catch assembly.
nating lamp sockets. Remove the blower switch and 4. Connect the refrigerant lines, to the condenser using
mounting bracket. new "O" ring seals.
5. Remove the control cables and transfer them to the 5. Add one fluid ounce of refrigerant oil to the system
replacement control unit. Check them for adjust­ if a new condenser was installed. Charge the system
ment. and check performance.

Installation 40-60 Series

1. Attach the blower switch to the unit. Connect the
harness connector and illuminating lamps. Attach Removal
the mounting bracket. 1. Purge the refrigerant from the system.
2. Lift the unit into position and attach it to the dash. 2. Drain the radiator.
3. Connect the battery ground cable. 3. Loosen the radiator hose clamps at the radiator
inlet and outlet and disconnect the hoses at the
CONDENSER radiator.
10-30 Series 4. Remove the two upper radiator mounts.
5. Push the top of the fan shroud rearward and lift the
Removal radiator out of the truck.
1. Purge the system of refrigerant. 6 . Disconnect the condenser inlet and outlet fittings and
2. Disconnect the refrigerant lines at the condenser and cap the open pipes. If the condenser is to be reused,
cap them. cap the inlet and outlet pipes.
3. Remove the hood catch assembly. Remove lower 7. Remove the screws which attach the lower frame of
shroud mounting screws. the condenser to the lower mounting brackets.
4. Remove radiator mounting bolts and push top of 8 . Remove the screws which attach the upper condenser
radiator back enough to make lower condenser mounting brackets to the grille header bar and lift
mounting nuts accessible by reaching down between the condenser out of the truck.
radiator and radiator support. 9. Remove the upper brackets from the condenser
5. Remove condenser attaching bolts and remove con­ frame if a new condenser will be installed.
denser (cap the condenser inlet and outlet if it is to
be reused). Installation
1. Mount the upper condenser mounting brackets
Installation (loosely) to the condenser frame.
1. Lower the replacement condenser into position and 2. Lower the condenser into position behind the grille.

CHEVROLET TRUCK SERVICE MANUAL

 HEATER AND AIR CONDITIONING 1A-25

3. Mount the upper condenser mounting brackets

(loosely) to the grille header bar.
4. Mount the condenser frame (firmly) to the lower
condenser mounting brackets.
5. Tighten the upper condenser brackets to the con­
denser frame and grille header bar.
6 . Uncap the refrigerant lines and condenser pipes
and connect the lines to the condenser using new
"O" rings wetted with refrigerant oil.
7. Hold the top of the fan shroud rearward and lower
the radiator into place. Be certain that the rubber
pads are in place in the lower radiator mounts and
that the header tank flange seats squarely in the
pads.
8 . Mount the two upper radiator mounts observing the
rubber pad location as in the previous step. Attach
the fan shroud to the rear of the mounts.
9. Connect the coolant hoses from the engine to the
radiator inlet and outlet. Clamp securely.
10. Check that the radiator drain plug (or valve) is
installed (or shut off).
11. Refill the cooling system.
12. Evacuate and recharge the refrigeration system.
If a new condenser was installed, add one fluid ounce
of refrigeration oil to the system before recharging.
Check system performance and leak test.

RECEIVER-DEHYDRATOR

The receiver-dehydrator should be replaced if it has

been damaged through an accident or if it leaks or be­
comes restricted or clogged. Do not attempt to repair
the receiver-dehydrator.
The receiver-dehydrator is merely a moisture collect­
ing device and a refrigerant storage area and is the least
likely component of the system to cause a malfunction.
If at any time when examining the compressor oil,
moisture is found or there is an indication of moisture
at the expansion valve needle, the receiver-dehydrator
should be replaced as follows (fig. 35):

N O TE: If the receiver- dehydrator is to be re­

used, cap the inlet and outlet connections imme­
diately. When installing a receiver-dehydrator,
do not uncap the connections until the last possi­
ble moment.

Removal
1. Purge the system.
2. Remove the inlet and outlet connections from the
receiver- dehydrator.
3. Remove the receiver-dehydrator mounting bolts and
carefully remove it.
4. Cap the system if the receiver-dehydrator will not
be replaced immediately. Cap the receiver if it
will be reused.

Installation
1. Place the receiver-dehydrator in position and re­
place attaching bolts. Do not uncap the unit until
immediately before connecting lines.
2. Uncap any previously capped connections and con­
nect the fittings using new "O" ring seals.
3. Evacuate and recharge the system. If a new
receiver-dehydrator was installed, add one fluid
ounce refrigerant oil to the system.

CHEVROLET TRUCK SERVICE MANUAL

HEATER AND AIR CONDITIONING 1A-26

P.O.A. VALVE
Removal
1. Purge the system.
2. Remove evaporator oil bleed line and expansion valve
equalizer line. Cap the connections.
3. Remove retaining clamp screw and loosen P.O.A.
valve outlet pipe clamp mounting screw.
4. Remove P.O.A. valve inlet and outlet connections
and remove P.O.A. valve. Cap the open tubes.
5. Remove clamp from P.O.A. valve.

Installation
1. Assemble clamp on P.O.A. valve and connect inlet
and outlet connections.
2. Secure P.O.A. valve clamp and outlet line clamp.
3. Connect the evaporator oil bleed line and the ex­
pansion valve equalizing line to the P.O.A. valve.
4. Evacuate and charge the system.

10-30 SERIES BLOWER ASSEMBLY

40-60 SERIES 10-60 Series

Rem oval
1. Disconnect battery ground cable.
2. (10-30 Series) Support the right front of the hood
in the fully raised position.
3. (10-30 Series) Carefully scribe the hood and fender
locations of the right hood hinge and remove the
hinge.
4. Unclip the blower wire at the blower flange terminal
and note or mark the motor flange position in rela­
tion to the blower case. Disconnect the rubber
cooling tube to the motor.
5. Remove the blower assembly mounting screws.
6 . Remove the blower assembly (pry the flange away
from the case carefully if the sealer acts as an
adhesive). (40-60 Series—turn the motor until its
flange clears the hood hinge.)
7. Remove the nut attaching the blower wheel to the
motor shaft and separate the assembly.
Installation
Fig. 35 - Condenser and Receiver Dehydrator 1. Assemble the blower wheel to the motor with the
open end of the blower away from the motor.
EXPANSION VALVE 2. Install the assembly to the blower case, connect
Removal
1. Purge the system.
2. Loosen the clamp retaining the high pressure line
to the bracket next to the expansion valve.
3. Disconnect the capillary bulb from the evaporator
outlet pipe. Disconnect the equalizer line from the
P.O.A. Cap the P.O.A. connector.
4. Disconnect the expansion valve inlet and outlet con­
nections and cap the lines.
5. Remove expansion valve to bracket mounting screw
and remove expansion valve.

Installation
1. Mount the expansion valve to the bracket.
2. Connect the inlet and outlet connections. Tighten
the inlet pipe clamp.
3. Connect the equalizer line to the P.O.A. and mount
the capillary bulb to the evaporator outlet pipe.
4. Evacuate and charge the system. Check perform­
ance. F ig. 3 6 - Evaporator and Blower Assembly

CHEVROLET TRUCK SERVICE MANUAL

 HEATER AND AIR CONDITIONING 1A-27

Fig . 37 - A /C and Heater Hose Routing

ground strap, and connect the motor wire. Connect the outboard case half. Replace case to case, case
cooling tube to motor. to back up plate, and case to firewall mounting
3. (10-30 Series) Remount the hood hinge aligning it screws.
carefully with the scribed lines. Check hood align­ 2. Attach the vacuum lines to the vacuum reservoir.
ment. 3. Mount the expansion valve capillary bulb to the
4. Connect battery ground cable. evaporator core outlet pipe.
4. Connect the evaporator outlet pipe to the P.O.A.
EVAPORATOR valve using a new "O" ring. Install the pipe clamp.
Removal 5. Connect the evaporator oil bleed line to the P.O.A.
1. Purge the system. valve.
2. Disconnect the line (between the evaporator and the 6. Connect the line from the evaporator to the expansion
thermostatic expansion valve) at the expansion valve. valve.
Cap the open connections. 7. If a new evaporator was installed, add three fluid
3. Disconnect the evaporator oil bleed line at the P.O.A. ounces of refrigerant oil to the system. Evacuate
valve. Cap the open connections. and charge the system. Check performance.
4. Disconnect the evaporator outlet pipe at the P.O.A.
valve. Cap the open connections. Remove the evap­ BLOWER AND EVAPORATOR CASE
orator outlet pipe clamp. Removal
5. Detach the expansion valve capillary bulb from the 1. Purge the refrigeration system and drain the radi­
evaporator outlet pipe. ator.
6 . Disconnect the vacuum lines at the vacuum reservoir. 2. Disconnect battery ground cable.
7. Remove the screws attaching the inboard case half 3. Unclip the blower motor wire at the blower flange
to the outboard case half, back up plate, and firewall. terminal.
8 . Remove inboard case half and evaporator core. 4. Disconnect heater hoses at the core tubes.
5. Disconnect the refrigerant lines at the P.O.A. valve
Installation outlet and the expansion valve inlet. Cap all open
1. Assemble evaporator core and inboard case half to connections.

CHEVROLET TRUCK SERVICE M ANUAL

HEATER AND AIR CONDITIONING 1A-28

6 . Remove vacuum hoses to vacuum reservoir and 3. Remove the sheet metal nuts from the heater case
plenum air valve actuator. studs which project through the firewall to the engine
7. Disconnect temperature door cable. side.
8 . (10-30 Series) In order to gain access to the lower 4. Remove the glove box.
outboard case attachments, the right front fender 5. Unplug the relay connector.
skirt should be loosened and moved. Remove enough 6. Remove the right ball outlet hose.
skirt mounting screws and bolts (from the rear 7. Remove the screw attaching the dash outlets air
forward) to move the skirt a sufficient amount. distributor to the heater case and move distributor
9. Remove the case retaining screws and sheet metal away from case.
nuts. Pull the case away from the mounting studs 8. Remove the heater case to firewall retaining screws.
and inboard to remove it. 9. Pull the heater case away from the firewall and
Installation reach in and disconnect the resistor connector.
1. Check the position of the blower and evaporator case 10. Remove the resistor harness grommet and remove
to firewall seals then position the case over the studs the harness from the case. Withdraw the heater
projecting through the firewall and attach the screws case.
and nuts to retain the case. Connect the blower Installation
motor ground strap. Replace spacer between case 1. Place the heater case under the cash and insert the
and firewall at the screw next to the temperature resistor harness and install the grommet and connect
door lever. the resistor connector.
2. (10-30 Series) Remount the right front fender skirt, 2. Position the heater case against the firewall and
skirt. push it into place. Check that nothing is pinched
3. Connect temperature door cable and vacuum hoses between the case and firewall. Install the heater
(hose to engine vacuum source attaches to vacuum case to firewall retaining screws.
tank connection nearest the engine). 3. Position the dash outlets distributor against the
4. Connect the refrigerant hoses to the expansion valve heater case, insert the forward lip into the retaining
inlet and the P.O.A. outlet using new "O" ring seals. clip, and install the retaining Screw.
5. Connect the heater hoses to the core tubes. 4. Install the right dash outlet hose.
6 . Connect the blower motor wire to the motor flange 5. Connect the relay connector.
terminal, and connect the battery ground cable. 6 . Install the glove box.
7. Refill the cooling system, and evacuate and charge 7. Install the sheet metal nuts to the heater case studs
the refrigeration system. which project forward through the firewall.
8 . Attach the heater hoses to the core tubes.
HEATER CASE 9. Refill the engine cooling system and test system
Removal operation.
1. Drain the radiator.
2. Remove the heater hoses from the core tubes. Heater Core
Removal
1. Remove the heater case as outlined under Heater
Case.
2. Remove the screws retaining the core mounting
straps.
3. Remove core.
Installation
1. Install the core into the case and seal it with non­
hardening sealer.
2. Mount the core with the core straps and retaining
screws.
3. Replace the heater case in the vehicle as outlined
under Heater Case.

BLOWER RESISTOR UNIT

Removal
1. Remove the screw attaching the floor outlet duct
(above the heater outlet) to the firewall.
2. Disconnect the dash outlet air hoses from the dis­
tributor.
3. Remove the screws (top, bottom, and seat side)
attaching the dash outlet distributor to the floor
outlet adapter.
4. Remove the screw attaching the distributor to the
heater case, slide the distributor rearward and
remove it.
5. Unplug the resistor unit connector.
6 . Remove the resistor unit retaining screws. Remove
F ig . 38 - Heater and Ducts the unit.

CHEVROLET TRUCK SERVICE MANUAL

 HEATER AND AIR CONDITIONING 1A-29

Fig. 39 - A ir O utlets and Hoses

Installation 4. Remove bolt retaining connector block to compressor

1. Place the replacement unit in position and install and remove the connector and muffler assembly.
mounting screws. Cap the compressor ports if not immediately re­
2. Connect the resistor connector. mounting muffler assembly.
3. Position the dash outlet air distributor against the Installation
heater case, insert the forward lip into the retaining 1. Assemble the connector block to the compressor
clip, and install the retaining screw. using new "O” ring seals.
4. Install the screws which attach the dash air dis­ 2. Secure the muffler outlet pipe in the pipe clamp.
tributor to the floor outlet adapter. 3. Connect the refrigerant hoses to the compressor inlet
5. Attach the dash outlet air hoses to the distributor. and muffler outlet pipes.
6 . Mount the floor outlet duct to the firewall with the 4. Evacuate and recharge the system.
attaching screw.
KICK PANEL AIR VALVE ACTUATOR
MUFFLER AND CONNECTOR BLOCK
Removal
Removal 1. Disconnect vacuum hose from actuator.
1. Purge the system. 2. Disconnect valve return spring.
2. Remove hoses at the compressor inlet and muffler 3. Remove actuator bracket mounting screws.
outlet pipes. Cap the connections. 4. Disconnect one link pin and remove actuator as­
3. Remove muffler outlet pipe clamp. sembly.

CHEVROLET TRUCK SERVICE MANUAL

HEATER AND AIR CONDITIONING 1A-30

5. Remove actuator from bracket.

Installation
1. Attach actuator to bracket.
2. Connect actuator rod to link and install pin. Fig. 42 - Vacuum Harness
3. Mount the bracket to the kick panel.
4. Connect the valve return spring. Connect the vacuum
hose to the actuator.
KICK PANEL AIR VALVE
Removal
1. Remove actuator mounting bracket from kick panel. PLENUM V A LV E
2. Remove valve return spring.
3. Pull the top pivot pin downward against spring tension
until it clears the upper pivot hole. Pull valve in­
ward and withdraw lower pivot from pivot hole.
4. Remove the valve from the actuator link.
Installation
1. Attach the valve to the actuator link.
2. Insert the lower pivot pin into the lower hole, retract

KICK PAD
VALVE

Fig. 43 - A ir Inlet V a lv e and Recirculating

A ir V a lv e

CHEVROLET TRUCK SERVICE M ANUAL

 HEATER AND AIR CONDITIONING 1A-31

L-6 ENGINE

283-327 V-8 ENGINE V-6 ENGINE

Fig. 44 - Compressor Mountings

the upper pivot pin and insert into the upper pivot 2. Disconnect the diaphragm link from the connecting
hole. shaft arm.
3. Install the valve return spring and mount the actuator 3. Remove the screw attaching the connecting shaft to
bracket to the kick panel. the tube extending forward from the valve.
4. Remove the screws attaching the nylon bearing plate
PLENUM AIR VALVE to the firewall and slide it forward. Remove valve
Removal return spring.
1. Remove cowl grille panel. Refer to Section 11. 5. Pull the rear valve pivot pin forward against spring

F ig . 45 - Vacuum Diagram

CHEVROLET TRUCK SERVICE M ANUAL

HEATER AND AIR CONDITIONING 1A-35

Fig . 46 - W irin g Harness

tension until it clears the rear bearing. Lift the evidence of contamination to determine if remainder
valve at the rear and withdraw the valve shaft from of system requires servicing. Compressor servic­
the firewall. ing information is located in the Chassis Overhaul
Installation Manual.
1. Insert the tube shaft on the valve into the firewall
hole and lower the valve into position with the rear Installation
pivot pin retracted. When the rear pin is aligned 1. If oil previously drained from the compressor upon
with its bearing, allow it to extend into position. removal shows no evidence of contamination, replace
2. Attach valve return spring and nylon bushing. a like amount of fresh refrigeration oil into the com­
3. Assemble the connecting shaft to the valve and pressor before reinstallation. It it was necessary
actuating diaphragm. to service the entire system because of excessive
4. Replace the cowl grille panel. contamination in the oil removed, install a full
charge of fresh refrigeration oil in the compressor.
COMPRESSOR 2. Position compressor on the mounting bracket and
install all nuts, bolts and lock washers.
Removal 3. Install the connector assembly to the compressor
1. Purge the refrigerant from the system. rear head, using new "O" rings.
2. Remove connector attaching bolt and connector. Seal 4. Connect the electrical lead to the coil and install
connector outlets. and adjust compressor belt.
3. Disconnect electrical lead to clutch actuating coil. 5. Evacuate and charge the system.
4. Loosen brace and pivot bolts and detach belt. 6 . Leak test the system and check for proper operation.
5. Remove the nuts and bolts attaching the compressor
brackets to the mounting bracket. Compressor Belt Tension Adjustment
6 . Before beginning any compressor disassembly, drain Adjust the compressor belt to the specifications shown
and measure oil in the compressor. Check for in the Tune-Up chart in the Engine section of this manual.

*
CHEVROLET TRUCK SERVICE M ANUAL
 HEATER AND AIR CONDITIONING 1A-33

WIRE PART OF- RELAY

EVAPORATOR ASM K
■20B— ...

r^nlnja
ED

EVAPORATOR ASM r-1 6LB L-

16Y-DBL-B/S
----14DBL
RESISTOR

-20B-
■120R1
■12PPL-
-14DBL-
-180R-'
16DG-DBL/WS COMPRESSOR
-14Y SWITCH
ON POS.

LIGHT
HARNESS
COMPRESSOR-
ASM
GROMMET- ■14Y-----------
16Y-DBL-B/S— [
■180R--------

FIREW ALL ■

■14BRN------ ^ |o)—

----------------------------------------- /
r
-FUSE
POS’N CONTACTS
12OR OFF B TO NONE
LOW B TO L
LEGEND

J
MED B TO L & M
---------- EXISTING WIRING HIGH B TO L & H
---------- WIRING PART OF EQUIPMENT
----------- AIR CONDITION WIRING

FUSE PANEL BATTERY UNFUSED

F ig . 47 - System A nalysis W iring Diagram

CHEVROLET TRUCK SERVICE MANUAL

HEATER AND AIR CONDITIONING 1A-34

SPECIAL TOOLS

Fig. 48 - A ir Conditioning Sp ecial Tools

1. J-8393 Charging Station 16. J-9403 Clutch Hub Holding Tool

1A. J-22368 Comfortron System Tester 17. J-9399 9/16" Thin W a ll Socket
IB . J-21530 Comfortron Temperature Dial Adjuster 18. J-9401 Hub and Drive Plate Assembly Remover
2. J-5453 Goggles 19. J-9480 Hub and D rive Plate Assembly Installer
3. J-9459 90 ° G au g e Line Adapter 20. J-9392 Seal Remover
4. J-5420 G auge Line Adapter 21. J-9393 Seal Seat Remover
5. J-6084 Leak Detector 22. J-9298 P u lley Bearing Remover
6. J-8433 Puller 23. J —9481 P u lley and Bearing Installer
7. J-9395 P u ller Pilot 24. J-8092 Handle
8. J-6272 N o . 3 M u lti- O p e n e r (3-Can) 25. J —9521 Internal Assembly Support Block
9. J —6271 F itz a ll V a lv e (Single Can) 26. J-5139 O il Pickup Tube Remover
10. J-7151 N o n -M a g n e tic C lutch Shims 27. J-9432 N e e d le Bearing Installer
11. J —5421 Pocket Thermometers (2) 28. J-9553 Seal Seat " O " Ring Remover
12. J-5403 ^21 Snap Ring Pliers 29. J-21508 Seal Seat " O " Ring Installer
13. J-6435 ^26 Snap Ring Pliers 30. J —21303 Shaft Seal Protector
14. J-9396 Compressor Holding Fixture 31. J-9527 Pressure Test Connector
15. J-9397 Compressing Fixture 32. J-9402 Parts Tray

CHEVROLET TRUCK SERVICE MANUAL

 SECTION IB

BODY
CONTENTS OF THIS SECTION
Page
Conventional B o d y ................................................... .. IB-1
Chevy V a n .............................................................................. IB-19
Step-Van B o d y ..................................................................... IB-27
Tilt Cab Body ..................................................................... IB-35
Special Tools ..................................................................... IB-55

CONVENTIONAL BODY
INDEX
Page Page
General Description ......................................................... IB -1 E n d g a t e s ............ .. ..................................................... IB -8
Service O p e ra tio n s ............................................................ IB-1 D o o r s ........................................................................... IB -9
Body S h e l l ..................................................................... IB-1 Door Assembly ...................................................... IB -9
General Body Construction .................................... IB -1 Door Lock and Striker .......................................... I B - 9
Body Mounting ......................................................... IB -1 Door C h e c k ............................................................ IB-10
Body Sealing ............................................................ IB -2 Door Ventilator Assembly .................................... IB-11
Front E n d ..................................................................... IB -4 Door Window A s s e m b ly .......................................... IB-12
Windshield G l a s s ...................................................... IB -4 Window R e g u la to r................................................... IB-13
Rear View M irror ................................................... IB -6 Door Opening W eath erstrip .................................... IB-13
Instrument Panel Compartment .............................. IB -6 Door Trim Panel Seal Replacement........................ IB-13
Instrument Panel Cover Assembly ........................ IB -6 Door Handles and Locks .......................................... IB-14
Cowl V en tilato r......................................................... IB -6 Rear Window W e a th e rs tr ip .................................... I B - 15
Grille .................................................................. IB -6 Seats ........................................................................... IB-16
Valve .................................................................. IB -7 Cleaning Soft Trim - A ll M o d e l s ........................... IB-16
Windshield W i p e r s ................................................... IB -7 Conventional Cab ................................................... IB-16
Arm Adjustm ent................................................... I B - 8 Level R i d e ............................................................... I B - 16
Wiper Arm Pivot Shafts and Link R o d ............... IB -8

GENERAL DESCRIPTION
The information contained in this part of Section 1
deals with servicing of components found on all models elsewhere in Section 1.
except Tilt Cab (T), Step Van (P) and Chevy Van (G) ve­ Service write-ups which follow may be applied to all
hicles which are covered under appropriate headings remaining models unless otherwise stated.

SERVICE OPERATIONS
BODY SHELL Heading the list of standard safety features are seat
belts, shoulder belt anchorages, padded instrument panels
GENERAL BODY CONSTRUCTION and devices to prevent accidental pivoting of front seat
backs.
Figure 1 is a view of a typical cab showing assembled Improvements in durability are gained by new cab-to-
components in related position on the cab. Figure 1 is frame mounts, door hinges, and a standard steel floor on
not intended to accurately reflect the availability of serv­ pick-up beds.
ice repair parts. It will be apparent upon reviewing the New door locks require a revised procedure for window
parts catalog which of the panels shown are available for regulator, CV channel and lock servicing.
service installation. Seat tracks are strengthened, as are floor pans.
The Chevrolet Truck body is designed to provide a Windshield and back window glass replacement proce­
strong, fully welded unit which has a universal application dures are revised.
to as many model types as possible; thus the cab used on The basic cab is used on Models 10-60, with reinforce­
the Pickup is also used on heavier units with the addition ments for heavier duty usage.
of various combinations of front end sheet metal, rocker
panel extensions, transmission covers (floor plates), etc. BODY MOUNTING
This results in a line of trucks which answers any need The number one double rubber biscuit is retained for
but is easily serviced with a minimum parts inventory. heavy duty vehicles and extended to the light-duty units
The 1967 truck cabs are completely redesigned incor­ (fig. 2). The upper cushion features a steel flange collar
porating numerous engineering improvements and added on the bottom side to protect the cushion when fitted into
safety features. the body bracket.

CHEVROLET TRUCK SERVICE M ANUAL

BODY IB-2

Fig. 1 - Conventional Cab and Components

1. H eater Hole C o ver Assembly 8. Pad Assembly and Defroster O u tlet 15. Dome Lamp Assembly
2. Hole Tapping - Dash and Toe 9. Ash Tray Assembly and C over Cab and W / S Cowl 16. Door S ill Plate and Plugs Cab
3. Side Cowl V e n tila to r Cab and W / S Cowl 10. Instrument Panel Compartment 17. Sunshade and Inside M irror
4. W / S W ip er Motor 11. Instrument Panel Compartment Door 18. Short and Long Arm M irror
5. W / S W asher Ja r and Hoses 12. W / S and Back W indow Installation 19. Seat Belt Installation
6. W / S W ip e r Linkage 13. Transmission C over 20. Fuel Caution Plate
7. W / S W ip e r Blades 14. Dash M ats and Floor Insulators 21. Body Mounting

The #1 mount on heavy trucks has a formed scuff plate

added in the lower cushion. A shorter body bracket
moves the mounting holes inboard and provides the same
mounting location as present light trucks for the purpose
of eliminating interference with the tires due to the
shorter cab.
Body mounting-cab rear is shown in Figure 3.
The #2 mount on the 10-Series truck incorporates an
isolation collar to reduce noise transmitted into the cab.
A "Dairy queen" type mount replaces the shear type
recently used on 20-30 series, and the M60 series.
Windshield cowl series are shown in Figure 4.
The #2 mounts on heavy trucks are carryover except
that a 2 " spacer has been added which makes the clear­
ance between cab and frame 3".
Body bolts threaded into cage nuts should be torqued to
3 5-55 ft. lbs. On bolts retained by standard nuts, nuts
should be torqued 70-90 ft. lbs.

BODY SEALING

Cab construction details showing location and applica­ Close all windows and vents, turn air conditioning or
tion of sealing compound and undercoating are shown in heater blower motor to high position and outside air and
Figure 5 and 6 . In servicing complete panels or only a close doors. Run water over suspected leak area in a
portion of a particular section it is helpful to know where small controllable stream and observe area for pressure
the panel is sealed. bubbles.
An alternate method for locating leaks is as follows:
Locating Dust and Water Leaks Remove the following trim from inside the cab: Floor
mats, dash and toe panel pad and kick pads.
A quick method for locating many air and water leaks Dust leaks will be evident when these pads and mats
at windshield, backglass, bolt holes, weatherstripping and are removed. Leaks can be located sometimes by putting
joints is as follows: a bright light under the cab or body, while checking the

CHEVROLET TRUCK SERVICE MANUAL

 BODY IB-3

C-KA 10 C-KA 20, CA 30 C-MA 40-50-60

Fig. 3 - Body Mounting - Cab Rear

interior of the cab or body at joints and weld lines. NOTE: Water does not always enter the cab or
All openings that allow dust leaks will also provide body in the location where leaks show up, there­
water leaks. When checking for water leaks a helper fore, back-tracking the path of water will show
should be used on the inside of the cab or body to locate the true entrance of the leak.
the entrance of water, while it is applied on the outside.

CHEVROLET TRUCK SERVICE M ANUAL

BODY IB-4

the windshield opening by a moulded rubber weatherstrip.

This weatherstrip is sealed in the windshield opening and
sealed to the windshield glass.
When replacing a cracked windshield glass, it is very
important that the cause of the glass breakage be deter­
mined and the condition corrected before a new glass is
installed. Otherwise, it is highly possible that a small
obstruction or high spot somewhere around the windshield
opening will continue to crack or break the newly in­
stalled windshield; especially when the strain on the glass
caused by this obstruction is increased by such conditions
as wind pressures, extremes of temperature, motion of
the vehicle, etc.
The procedure for removal of the windshield applies to
the complete windshield assembly.

Removal
1. Before removing the windshield, mark the location of
the break on the windshield rubber channel and the
body. Protect the paint finish inside of the cab.
Mask around the windshield opening and outside, lay
a suitable covering across the hood and fenders.

Fig. 5 - Cab Sealing Areas (Typ ical)

1. Hinge P illa r to Cowl Side &

Cowl Top to Plenum - Cab
2. Dash Panel & Cowl Side Panel
to Floor Panel - Cab & W / S Cowl
3. Upper Cab & Drip M olding Cab
4. Hinge P illa r & Lock P illa r Cab
5. Roof O u ter & Back Panel Cab
6. Floor & Fender Bracket to Front Cross
S ill & Side Inner to P illa r F/F Cowl
7. Undercoating
8. Cab Door

FRONT END
C USTO M STANDARD
WINDSHIELD GLASS

The windshield is a one-piece type and is retained in Fig . 7 - Cross Section of W indshield W eatherstrip (Typ ical)

F ig . 8 - Loosening Weatherstrip

CHEVROLET TRUCK SERVICE MANUAL

 BODY IB-5

F ig . 9 - C hecking Body Opening

NOTE: The windshield glass rubber weather­

strip is one piece. The glass is held in a chan­
nel within the weatherstrip (fig. 7). Fig. 10 - String in Pinchw eld C a v ity

2. Remove the reveal moulding from the windshield on b. Outer edge of glass to parallel body metal.
custom models. 7. Mark areas of body metal or flange to be reformed,
remove glass and correct as necessary.
NOTE: Shift reveal moulding caps over to
8 . Recheck windshield in its opening and if satisfactory
either moulding of two being covered by cap, to
proceed as follows.
facilitate bending of rubber channel (fig. 7) for
windshield removal. Do not try to remove re­
Installation
veal mouldings while windshield is in body
opening.
CAUTION: Always wear gloves when handling
3. To free windshield rubber channel of weatherstrip glass.
loosen the lip of the windshield weatherstrip from the
pinchweld flange along the top and at the sides by 1. Lay glass on protective covering curved ends up.
applying pressure with palm of the hand to the edge 2. Place one piece rubber weatherstrip channel around
of the glass. At the same time assist the lip of the perimeter of glass.
rubber weatherstrip channel over the pinchweld 3. Place chalk string in depression of weatherstrip
flange with a flat bladed tool such as a tongue de- channel completely around perimeter twice. Tape
presser, or shaped mycarta blade (fig. 8 ). ends of chalk string to inside of glass at bottom
(fig. 1 0 ).
Checking Windshield Opening 4. Place protective covering over plenum grille, front
fenders and hood.
Due to the expanse and contour of the windshield it is 5. Smear caulking on windshield opening.
imperative in the event of a strain break that the wind­ 6 . Two men place windshield in position laying upper
shield opening be thoroughly checked before installing a angled corners in opening first and have assistant
replacement windshield. The replacement glass is used push from outside inward, while technician inside
as a template. cab pulls chalk line from under rubber channel
1. Check for the following conditions at the previous (fig. 1 1 ).
marked point of fracture. 7. Apply weatherstrip cement beneath outside lip of
a. Chipped edges on glass. weatherstripping.
b. Irregularities in body opening.
c. Irregularities in rubber channel weatherstrip.
2. Remove all sealer from flange and body around wind­
shield opening.
3. Check flange area for solder, weld high spots, or
hardened spot-weld sealer. Remove all high spots.
4. Check windshield glass to opening, by supporting
glass with six spacers contained in packet J - 22577
(fig. 9).
CAUTION: Do not strike glass against body
metal. Chipped edges on the glass can lead to
future breaks.
5. With the windshield supported and centered in its
opening, check the relationship of the glass to the
body opening flange around the entire perimeter of
the glass.
6 . Check the relationship of glass to opening as follows:
a. Inside edge of glass to body flange. F ig . 11 - Pulling String to Seat Rubber Lip

CHEVROLET TRUCK SERVICE M ANUAL

BODY 1B-6

REAR VIEW MIRROR

The standard equipment rear view m irror installations

are shown in Figure 12. Occasional tightening of mount­
ing and assembly bolts and screws will sharply decrease
occurrence of failure due to door slamming or road
shock.

INSTRUMENT PANEL COMPARTMENT

Replacement
Removal of the entire assembly including door may be
accomplished by removing ten screws just inside box and
compartment lamp wire (if so equipped),, The door may
be removed, leaving the compartment intact, by removal
of four screws and bumper shown in Figure 13. Access
to the door stop bumper is gained by reaching up beneath
instrument panel.
Also shown in Figure 13 is the lock. Engagement of
lock in striker may be adjusted by loosening striker re­
taining screws and moving the striker to desired position.
The lock cylinder may be serviced as outlined in Sec­
tion 0, General Information and Lubrication.

INSTRUMENT PANEL COVER ASSEMBLY

The instrument panel cover (fig. 14) is secured to the

instrument panel by studs, nuts and screws. The studs
are an integral part of the cover assembly.

Removal and Installation

1. Loosen or remove any necessary instrument panel
items, glove box, etc.
20 From underside of instrument panel remove attach­
ing screws and carefully remove cover assembly.
3. To install, reverse removal procedure.

COWL VENTILATOR {Fig. 15)

The cowl ventilator intake, a louvered opening, extends

across the top of the cowl. The opening permits outside
air to enter into a plenum chamber which distributes the
air to both sides of the cab. Air enters into cab through
openings at right and left interior cowl panels near the
floor.

Air flow is controlled by valves in the outlet openings.

Valves are opened and closed by means of handles.

Cowl Ventilator Grille

Removal
The plenum chamber, located below the air inlet grille,
can be flushed out without having to remove the air inlet
grille from the cowl. However, if necessary air inlet
grille can be readily removed from cowl opening as
follows:
1. Remove windshield wiper arms from wiper pivot
shafts.

2. Raise hood and remove screws, retaining cowl venti­

F ig . 12 - Rear V iew Mirrors lator grille and cowl hood ledge seal.

CHEVROLET TRUCK SERVICE MANUAL

 BODY IB -7

Replacement
Entire outlet valve assembly may be removed from the
vehicle by removing two screws and depress the pins.
Refer to Figure 16. Also refer to Figure 17 for disas­
sembly of the flat face cowl air ventilator assembly.

3, Remove cowl ventilator by tipping edge at cowl hood

ledge to remove from tabs.

Installation

1. Insert cowl ventilator grille onto tabs at plenum as­

sembly making sure they all engage.
2. Inspect cowl hood ledge seal for fatigue or cuts and
replace if necessary.
3. Secure front edge of grille over lip of hood seal with
seven retaining screws.
4. Reinstall windshield wiper arms on pivot shafts.

WINDSHIELD WIPERS
COWL AIR VENTILATOR VALVE ASSEMBLY
Windshield wiper units on all models are of the two-
speed electric type. A single wiper motor unit, mounted

CHEVROLET TRUCK SERVICE M ANUAL

BODY IB-8

to center of cowl inside cab, power both wiper blades. 4. Before installing wiper arm s, operate wiper motor
The wiper blade operating link rods and pivot mountings momentarily which should rotate pivot shafts to park
on these models are located in the outside air inlet position. Install arms and shafts.
plenum chamber.

Arm Adjustment ENDGATES

To adjust sweep of blades to provide maximum visi­ Fleetside

bility, turn on wipers, then note sweep of arms. If nec­
essary, remove one or both arms as follows: Pull outer The linkage for the fleetside endgate is designed for
end of arm away from glass which will trip lock spring at one hand balanced operation. The weld joints are sealed
base of arm and release spring from undercut of pivot with a sealer. The only adjustment is slight bending of
shaft. While holding arm in this position, pull outward on the actuating rods.
cap section at base of arm to remove arm. Arm can be
reinstalled in any one of several positions due to se rra­
tions on pivot shaft and in arm cap (fig. 18). Replacement (Fig. 19)
1. Open tailgate.
2. Remove screws attaching handle assembly to inner

(NOTEl CHAIN
ASM. IS MARKED
WITH LETTER "L”
OR "R" FOR |
LH OR RH USAGE.

Wiper Arm Pivot Shafts and Link Rod (Fig. 18) STEPSIDE

Removal
1. Remove windshield wiper arms from pivot shafts.
Procedure for removing arms is explained previ­
ously under "Arm Adjustments."
2. Remove screws which attach outside air cowl venti­
lator grille to cowl. Carefully remove grille forward
from cowl.
VIEW B
3. At center of cowl, remove retainer (fig. 18) which
attaches each link rod to motor drive linkage and
arm assembly. Disengage link rods from pins.
4. Remove two screws which attach arm transmission
pivot shaft assembly to cowl. Remove pivot shaft
assembly with link rod from plenum chamber.

Installation
1. Place pivot shaft assembly with link rod into position
at cowl brapket. Secure assembly to bracket with
two screws (fig. 18).
2. Attach end of link rod to linkage of motor drive and
arm assembly at center of cowl. Secure rod with FLEETSIDE In o t e I in stall rods
retainer. If opposite pivot shaft and link rod was IN POSITION SHOWN
removed, install it at the same time.
3. Install outside air cowl ventilator grille to top of
cowl using screws (fig. 15). F ig . 19 - Endgates - Stepside and Fleetside

CHEVROLET TRUCK SERVICE M ANUAL

 BODY IB -9

side of tailgate. where it should be 1/4" from the door sill.

3. Remove clips from handle assembly and remove The door should be adjusted in the opening so the edge
handle. of the door across the top and also at the lock side is
parallel with the body opening as nearly as possible.
4. Remove 2 screws from each latch assembly and lift
Tighten bolts to 20-25 ft. lbs. after adjustment and re­
off, with actuating rods. place and adjust the door striker plate as outlined under
Door Striker Plate.

Replacement of Trunnion Assembly

1. Lower tailgate half way.

2„ Pull center of hinge upward and unlatch from tail­
gate.
3. Lower tailgate all the way.
4. Remove two screws from trunnion and lift off tail­
gate.

Stepside

Replacement
1. Unhook end gate chain assembly at each side.
2. Remove bolt and lockwasher from each trunnion in
ca rrie r box end gate shown in Figure 19.
3„ Remove end gate.
4. Reverse procedure for installation. Align slot in
trunnion to coincide with hole in end gate to permit
using a tool to hold trunnion while tightening nut
view "A" (fig. 19).

DOOR ASSEMBLY

Replacement
F ig . 20 - Door Hinge Bolt W rench J-22585
Remove the door assembly from the body by removing
the hinge from the door.

Adjustment
Door adjustment may be accomplished at two places; at
the hinge straps-to-door panel and at the hinge cage-to-
pillar. Before adjustment is made on any door, however,
the strik er plate should be removed. The door can be
moved fore, aft, up and down at the hinge pillar and the
door also can be moved in and out at the hinge-to-door
panel. However, in order to adjust the door assembly at
the body hinge pillar it is necessary to use special door
hinge bolt wrench Tool J - 22585. Move door as required
and tighten bolts.
The door should have a normal clearance of 5/32"
around the entire outer lip of door except at the bottom

DOOR LOCK AND STRIKER

Adjustment of the door lock and striker plate should be

made after the door hinges have been assembled to the
doors, if removed, positioned in the door opening.

Replacement
See door lock and regulator assembly (remote control),
in this same section for the door lock. Remove and re­
place four bolts for replacing the striker plate at the
door lock pillar and adjust as required below. F ig . 21 - Striker Assembly on Body Lock P illa r

CHEVROLET TRUCK SERVICE M ANUAL

BODY IB -10

Adjustment
1. Position strik er assembly on body lock pillar so that
the rotor cover outer face on the door swings into the
striker assembly with . 1 0 clearance to the lock rotor
cover. Use special burred shims as required (fig. DOOR REAR
21 ). EDGE

NOTE: Under usual conditions, shims are not

required.
FLUSH
WITHIN
2. Vertical slots are provided in the body lock pillar to
± .06
vertically position the striker so that the lock rotor
and rotor cover assembly swing smoothly into the
Fig. 23 - Door Surface Adjustment (at Striker)
opening between the teeth and striker wedge block
(fig. 2 2 ).

load to hold the door in any position between full open and
closed. The front door check-hinge assembly is replaced
as a complete unit as follows:

Removal

1. Remove windshield wiper blade assemblies.

2. Remove cowl vent grille screws and lift off grille.
3. Loosen front fender rear bolts.
4. With special Tool J - 22585 remove 3 bolts securing
front door upper hinge to cowl pillar. Refer to
Figure 20.

a. Remove the door to upper hinge retaining bolts.

b. With the aid of an assistant to support weight of
door, remove the door to lower hinge retaining
bolts and remove.

Fig . 22 - Lock Rotor C o ver Assembly and Striker Plate Installation

1. Install hinge snugly on pillar in same location as

NOTE: The lock rotor cover assembly must hinge removed.
clear the striker plate as the lock enters the 2. With the aid of an assistant fasten the door to the
striker. hinge.
3. Adjustment of the door lock and striker plate should
be made after the door is positioned in the opening.
3. As an aid to striker adjustment, outline the striker 4. Position striker assembly on body lock pillar so the
in pencil or crayon for use as a base for adjustment. rotor cover outer face on the door swings into the
Horizontal slots are provided in the striker plate to striker assembly with . 1 0 inch clearance to the lock
position the striker assembly laterally so that the rotor cover. Use special burred shims as required.
door outer surface is flush with the pillar surface at
the door rear edge within 1/16" (fig. 23).
NOTE: Under usual conditions, shims are not
NOTE: The striker inner edge must be paral­ required.
lel to the striker mounting depression on the
pillar.
5. As an aid to striker adjustment outline the striker in
DOOR CHECK pencil or crayon for use as a base for adjustment.
Horizontal slots are provided in the striker plate to
The door check is part of the front door upper hinge on position the striker assembly laterally so that the
all but Step Van, Chevy Van and Tilt Cab models. The door outer surface is flush with the pillar surface at
new front door check hinge combination allows a friction the door rear edge within 1/16”. Refer to Figure 23.

CHEVROLET TRUCK SERVICE M ANUAL

 BODY IB-11

NOTE: The striker inner edge must be paral­

lel to the striker mounting depression on the
pillar.

DOOR VENTILATOR ASSEMBLY

Removal

NOTE: The channel between the door window

glass and door vent is removed as part of the
vent assembly.

1. Regulate the door window glass to the full down

position.
2. Remove one clip each from the door lock handle--
Tool J-7797 and window regulator handle.
3. Remove four (4) trim panel screws and trim panel.
4. Remove the bottom two screws directly below the
window regulator mechanism (fig. 24).
5. Remove three sheet metal screws at the upper front
of the door (fig. 25).
6 . Turn the vent assembly 90° and carefully remove by
guiding up and out (fig. 25).

Installation
NOTE: Replace the door window glass and
regulate to the full down position before install­
ing the door ventilator assembly.
TURN 9 0
1. Lower the ventilator assembly into the door fram e--
center into position.
2. Make certain the rubber lip is positioned before Fig. 25 - V en tila to r Assembly Removal
tightening screws.
3. Attach the two screws below the regulator assembly.

VENTILATOR ASSEMBLY
ADJUSTING NUT
AND TAB LOCK

F ig . 24 - Vent Assembly Inner Door Panel Attachment F ig . 26 - Adjusting V en tila to r Operating Tension

CHEVROLET TRUCK SERVICE MANUAL

BODY IB - 12

4. Install and tighten the three screws at the upper

front of the door.

Adjustment
1. Adjust the ventilator adjusting nut by turning clock­
wise to increase operating tension (fig. 26).
2. After making adjustment bend tabs over the hex nut.
3. Install four (4) trim panel screws and trim panel.
4. Install door and window regulator handles.

Ventilator Glass Replacement

1. Using an oil can or sim ilar means, squirt prepsol on

the glass filler all around the glass channel or frame
to soften the old seal. When the seal has softened,
remove the glass from the channel.
2. Thoroughly clean the inside of the glass channel with
sandpaper, removing all rust, etc.
3. Using new glass channel filler, cut the piece to be
installed two inches longer than necessary for the
channel. Place this piece of filler (soapstoned side
of filler away from glass) evenly over the edge of the
glass which will fit in the channel. The extra filler
extending beyond the rear edge of the glass should be
pinched together to hold it in place during glass Fig. 28 - Remove Run Channel from Door
installation.
NOTE: One side of this filler (the outside of
cess filler material around the channel and at the
the roll) is soapstoned. This is the side which
ends of the channel.
goes into the metal channel.
4. Brush the inside of the metal glass channel freely NOTE: Glass should be installed so that rear
with ordinary engine oil. This will enable the glass edge is parallel to the division post. Allow full
and filler to slide freely into the channel. Push the cure before water testing.
glass with the filler around it into the channel until it
is firmly seated. After the glass is firmly in place, DOOR WINDOW ASSEMBLY
the oil softens the filler, causing it to swell, thereby
making a perfect, watertight seal. Trim off the ex- Removal
1. Wind window all the way up.

F ig . 27 - Rubber Run Removal from Door F ig . 29 - Regulator Assembly & G lass (Side Door)

CHEVROLET TRUCK SERVICE MANUAL

 BODY IB - 13

2. Remove inside door handles with Tool J-7797. Installation

3. Remove screws securing door trim pad. Install regulator in reverse order of removal, lubricate
4. Loosen 3 screws for rear run channel (one screw regulator gears with lubriplate.
located on door edge).
5. Peel rubber run out of metal channel and pull down­
ward (fig. 27). DOOR OPENING WEATHERSTRIP
6 . Rotate channel outward and lift from door access
opening (fig. 28). Side Door Opening Weatherstrip Replacement
7. Reinstall window regulator handle and lower glass Side door sealing incorporates an inner seal. The
assembly to bottom of door. inner seal is mounted on the body opening welding flange
8 . Remove ventilator assembly (see above). (fig. 30) and goes completely around the periphery of the
9. Slide glass forward to opening notched in regulator opening. The molded weatherstrip material is cemented
roller channel. (fig. 30)
10. Next, slant window glass rearward for complete Success of weatherstrip replacement depends entirely
disengagement. upon the quality of the cement used and the care with
11. Lift glass upward, out of door. which it is applied. All rust, road dirt and grease or oil
must be completely removed as should all old cement and
Installation bits of old weatherstrip. After removing all foreign ma­
Install glass or sash in reverse order of removal. terial from door opening surface, wipe down with prep-
sol or its equivalent. Use only a good quality cement
WINDOW REGULATOR REPLACEMENT (Fig. 29) which is made specially for weatherstrip installation,
following the manufacturer's directions. Proceed as
Removal follows:
1. Wind window all the way up. 1. Open door and block open.
2. Remove inside door handles with Tool J-7797. 2. Remove sill plate retaining screws and remove sill
3. Remove door trim pad secured with 4 screws. plate.
4. Remove 4 screws securing regulator to inner panel. 3. Remove side door inner weatherstrip seal.
5. Push regulator out of circular opening while holding 4. Remove used adhesive from cab door opening with
rear of assembly, then slide assembly to the notches adhesive or cement remover.
in the carrier channel and out through the door ac­ 5. Apply adhesive to cab opening.
cess hole. 6 . Install molded corner of inner weatherstrip, starting
where windshield post joins the header panel.
7. Trim inner weatherstrip with a notch as shown in
Figure 30 and butt ends together.
8 . Reinstall sill plate and sill plate retaining screws.
TRIM WEATHERSTRIP
AS SHOWN. BUTT Door Trim Panel Seal Replacement
ENDS & CEMENT TOGETHER 1. Remove window regulator and door remote control
TUBULAR SECTION ^//
MUST BE OPEN TO x (7/
PROVIDE AIR PASSAGE/

iNOTE;
STRIP WITH SALVAGE
JOINT TO B E " ,
INSTALLED SO THATj
JOINT FALLS IN §
VIEW A THIS AREA v I

F ig . 30 - Door Opening W eatherstrip F ig . 31 - Installing Trim Panel Seal

CHEVROLET TRUCK SERVICE M ANUAL

BODY IB -14

handles. Handles are retained by clips.

2. Remove trim panel from door (fig. 31). Trim panel
is retained by four seal screws.
3. Remove trim panel shown in Figure 31 and remove
used cement with cement remover.
4 0 Apply cement to door groove. Then start at one end
of groove applying seal.

DOOR LOCKS—10-60 SERIES

The locks are of the free rotor type. They include a

safety interlock feature. Where necessary, striker
spacers should be used to insure satisfactory lock and
striker engagement.

Removal
1. Raise window.
2. Remove inside handles with Tool J-7797.
3. Remove trim panel.
4. Remove remote control sill knob.
5. From outside the door remove screws retaining lock
to door edge and lower the lock assembly.
6 . Remove 3 screws retaining remote control.
7. Remove lock, push button rod and remote control rod
as an assembly.

Installation
1. Transfer remote rod with clip to new lock. Fig. 33 - Lock C ylin d er Installed
2. Connect remote door handle rod to lock after lock is
positioned. Front Door Lock Remote Control and Connecting Rod
3. Secure lock screws.
4. Secure remote handle. The remote control is secured to the door inner panel
5. Check all controls for proper operation before rein­ by the three attaching bolts.
stalling trim and handles.
6 „ Install remote control sill knob.

Front Door Lock Cylinder Assembly

Removal and Installation

1. Raise door window and remove door trim pad.
2. With a screwdriver, or other suitable tool, slide lock
cylinder retaining clip (on door outer panel) out of
engagement and remove lock cylinder.
3. To install, reverse removal procedure.

CHEVROLET TRUCK SERVICE MANUAL

 BODY IB-15

Removal and Installation

1. Raise door window and remove door trim pad.
2. Remove bolts securing remote to door inner panel.
3. Pivot remote inboard slightly, to disengage connect­
ing rod, and remove remote from door.
4. To install, reverse removal procedure.
NOTE: Connecting rod can be removed at this
point by disconnecting spring clip from lock.

REAR WINDOW WEATHERSTRIP

Replacement
1. Using a pointed tool, raise one end of the weather­
strip retainer until it is far enough out to take hold
of by hand. Then pull retainer out of its channel all
around the window.
2. From inside the cab, carefully push the window glass
out through the rear of the opening.
Fig . 36 - Installing Weatherstrip Insert with J-2189
NOTE: The weatherstrip may remain in the
window opening during removal of glass. To
remove weatherstrip, merely pull it off the
edges of the door panels. On installation of new
weatherstrip, clean opening edge thoroughly,
then install with butt ends (lightly coated with
weatherstrip adhesive) at top center of opening.
3. Inspect the inner and outer flanges making sure they
are true and that there are no irregularities around
the window opening. Any irregularities must be
corrected.
4. Assemble the weatherstrip to the opening making
sure the outer channel of weatherstrip is firmly
seated on the edges of the panel all around the
opening.
5. Start one end of the glass into its channel in the
weatherstrip. Using a pointed tool, follow around
the rear lip of the glass channel so it bears against
the rear surface of the glass (fig. 35).

NOTE: Care should be used in this operation

not to chip the edge of the glass. A pointed
wooden tool, if available, should be used.

Fig. 35 - Rear W indow W eatherstrip Installation Fig. 37 - Cutting W eatherstrip Insert at 4 5 ° Angle

CHEVROLET TRUCK SERVICE M ANUAL

J
BODY IB -16

6. Feed one end of the weatherstrip retainer into the assembly which is being cleaned should be thoroughly
handle of Tool J-2189 and out through the end which brushed and gone over lightly with the solvent.
spreads the weatherstrip channel.
7. Starting at the bottom center, insert the end of the CONVENTIONAL CAB
tool and end of retainer in channel, tapered part of
the retainer toward the glass. Seat Replacement
8 . While holding the tool firmly, with spreading end in
channel, follow around the channel spreading it open NOTE: Seat with slide adjusters and seat back
and feeding retainer into the opening until the full can be removed as a unit.
length of the retainer has been fed into the channel.
The ends of the two retainers should join at the bot­ 1. Remove four cap screws and washers which attach
tom of both sides (at a 45° angle) (fig. 37). each seat to cab floor (fig. 38).
2. Tilt seat back forward; then lift seat assembly from
NOTE: Care should be used in this operation cab.
not to chip the edge of the glass. A pointed 3. Seat adjuster can be removed from seat after disen­
wooden tool, if available, should be used. gaging end of seat return spring and locking remove
rod and four cap screws and washers attaching ad­
SEATS justers to seat.
4. Install seat adjusters to seat finger tight with eight
CLEANING SOFT TRIM -A LL MODELS attaching cap screws and washers.

Care of the upholstery is a relatively simple but im­ Adjustment

portant matter. Accumulation of dirt on the surface Seat is provided with two adjustments. A lever at left
eventually turns into a hard, gritty substance which cuts of cab for positioning seat "F o re" or "Aft." Push down
into the surface of the upholstery. on lever to disengage seat position lock. An adjusting
screw is provided at each side of the seat back frame for
Vinyl Coated Cloth tilting seat back to the position desired. The release ac­
tion of right hand adjuster lock may be adjusted by kink­
To clean the seats, use lukewarm, not hot or cold ing the locking rod.
water, and any mild soap, such as castile. Work up thin
NOTE: A minimum clearance of 7/16" should
suds on a piece of cheesecloth and rub upholstery briskly.
exist between the seat back and gas tank.
Remove suds with a damp cheesecloth, using no soap, and
finish by rubbing with a dry soft cloth. Do not use furni­ LEVEL RIDE
ture polishes, oils, varnishes or ammonia.
Adjustment
Woven Nylon Fabric To get full benefit from the optional level ride seat,
proper adjustment is of primary importance.
Soap and water, regardless of the basic type of soap,
is not recommended for cleaning flat cloths, particularly Back Rest Adjustment
broadcloths. To adjust back rest angle (A, fig. 39) depress top of
1. Carefully brush all loose particles of dirt and soil. seat back and move to desired position.
2. Immerse small cloth in volatile type cleaning solu­
tion, wring out thoroughly, open cloth and allow
medium evaporation.
Do not use too much cleaning fluid; some interior
trim assemblies are padded with rubber, and volatile
cleaners are generally solvents for rubber. The ap­
plication of too much cleaner may destroy these
rubber pads or cause the rubber itself to penetrate
the upholstery fabric and soil it.
3. Place cloth on soiled spot, do not rub, apply slight
tapping pressure, several times. This will pick up
particles which are too embedded to be removed in
the brushing operation. This operation should be
repeated several times—in each instance using a
clean area of cloth.
4. Immerse a new cloth in cleaner, wring out thoroughly,
open and allow to evaporate until barely damp. Apply
increased pressure and rub soiled area in a back­
ward and forward motion. The cleaning cloth should
be reversed several times in this operation.
5. Immerse third cloth, wring out, allow evaporation
and apply to both the soiled and the area surrounding
same, using a light, brisk motion.
6 . Repeat brushing operation.
7. If a cleaning ring should form, the entire area of the

CHEVROLET TRUCK SERVICE M ANUAL

 BODY IB-17

Fore and Aft Adjustment

Any point within the 4" travel may be selected by mov­
ing lever B, Figure 39, toward right hand side of truck to
disengage seat lock.

Torsion Bar Adjustment

The ratcheting adjuster lever (C, fig. 39) regulates
the amount of weight the seat will support. Proper ad­
justment places the up and down travel of the seat sus­
pension at the midpoint, limiting the occurrence of bot­
toming or topping of the suspension.
Proper adjustment is indicated by the ride level indica­
tor, Figure 40, which is located behind left frame up­
right. Position 3 in Figure 40 indicates correct adjust­
ment (tip just flush with forward edge of upright). If seat
is too stiff, the indicator will be in position 1 ; if too soft,
in position 2. Adjust for position 3 by moving lever C,
Figure 39. Direction of ratcheting action may be changed
by moving control at base of lever. Turning lever clock­
wise increases the amount of weight the seat will support.

Service

Numbers in following procedures refer to Figure 41.

Torsion Bar

F ig . 3 9 - Level Ride Adjustments Removal

1. Wedge upper seat in top position by using wood shim
under tube located under front of seat cushion or by
shim under tube located below back cushion.
2. Remove preload on torsion bars by rotating adjuster
lever assembly (No. 30) counter-clockwise until ad­
juster assembly is disengaged from seat.
3. Disengage back cushion from seat assembly by re­
moving bolts and lockwashers (Nos. 52 and 47).
4. Disengage seat cushion from assembly by removing
nuts, lockwashers and washers (Nos. 48, 47 and 46).
Move seat cushion forward to free rubber rollers
(No. 45) from housing under seat cushion.
5. Remove right hand side panel assembly (No. 29) by
tapping out sideways. This allows yoke (No. 26) to
drop free (figs. 41 and 42).
6 . Remove torsion bar set (No. 27) from tube.

Installation
1. Insert torsion bar set (No. 27) in tube being sure
that bars are engaged in retainer (No. 25) inside
tube at left hand side of seat.
2. Replace right hand side panel assembly (No. 29) with
yoke (No. 26) held in position inside housing on side
panel. Engage yoke (No. 26) on free end of torsion
bar set (No. 27).
3. Line up side panels right hand and left hand retaining
the 2 0 " dimension over side panels.
4. Reassemble seat cushion moving from front of seat
toward rear in order to engage rubber rollers (No.
45) properly in housing under seat cushion.
5. Reassemble back cushion.
6 . Replace preload adjuster assembly being sure that
Nos. 38 through 41 are in their proper positions.
Engage yoke (No. 26) hooked ends over lugs on ad­
juster pin (No. 40).
7. Preload torsion bars by rotating adjuster lever as­
sembly (No. 30) clockwise (figs. 41 and 43).
F ig . 40 - Ride Level Indicator 8 . Remove wood shims.

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BODY IB-18

Fig. 41 - Exploded V ie w of Level Ride Seat

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 BODY IB - 19

1. Base Assy. , w/Bearings 22. Shock Absorber Assy. , w/Bearings 43. Knob (Plastic)
2. O uter Lever Assy. , w/Pins and Bearings 23. Bearing K it (Shock Absorber) 44. Thrust Washer
3. Bearing, Flanged 24. Bearing, Flanged 45. Roller and Bearing Assy. , (Rubber)
4. Pin-D rive 25. Retainer (T-Bar) 46. W asher, P la in , 5/16 SA E , Z in c Plated
5. C enter Lever Assy. 26. Yoke (Adjuster) 47. Lock Washer, 5/16 SAE M ed. , Z in c Plated
6. Bearing, Housing, L. H. 27. Torsion Bar Set (2 Bars per Set) 48. N u t, Hex. 5/16-18 (U N C - 2 B ) Z in c Plated
7. Bearing, Housing, R. H. 28. Side Panel Assy. , L. H. 49. Bumper (Topping)
8. Roller and Bearing Assy. 29. Side Panel Assy. , R. H. 50. Seat Adjuster, R. H.
9. Stud 30. Adjuster Screw and Lever Assy. 51. Seat Adjuster, L. H.
10. Snap Ring 31. G ear 52. Cap Screw , 5/16-18 x 5/8 Lg. ,
11. Washer, Plain 32. Adjuster Screw F illis te r—Ph iIIips Z in c Plated
12. Lockwasher, 3/8 SA E Med. 33. Lever Assy. 53. Bumper (Bottom)
13. N u t, Hex. 3/8-16 (U N C - 2 B ) 34. Washer 54. Seat Cushion Assy.
14. Bearing, Flanged 35. Spring (Tension) 55. C over Assy. , Seat Cushion
15. W asher, P lain 7 G a . x 17/32 x 7/8 36. Acorn N u t (S e lf Locking) 56. Pad, Seat Cushion
16. Shock Lever Assy. K it 37. Pin , Drive 57. Back Cushion Assy.
17. Shock Lever Assy. 38. W asher, Plain C over Assy. , Back Cushion
18. Hinge Shaft, Shock 39. Thrust Ball Bearing Pad, Back Cushion
19. Hinge Shaft, Shock, Rear 40. Adjuster Pin 58. Universal Riser K it
20. Roll Pin 41. W asher, Plain 5/16 Thick x 11/16 x 1-1/4 59. Fastener C lip , Cushion
21. Shock Absorber Assy. K it 42. Lub. Fittings (3/32 Shank) 60. Ride Level Indicator

Refer to Fig. 41

Fig. 44 - Shock Absorber

Shock Absorber

Removal
1. Wedge upper seat in top position following operation
1 , torsion bar removal.
2. Remove preload on torsion bars following procedure
sim ilar to operation 2, torsion bar removal. Do not
disengage adjuster assembly.
3. Remove seat cushion following operation 4, torsion
bar removal.
4. Wire side panel assemblies (Nos. 28 and 29) across
front of seat to retain their position (19-3/4" from
outer surface to outer surface).
5. Remove (2) snap rings (No. 10) from ends of hinge
shaft (No. 18) at front of shock absorber.
6 . Remove hinge shaft (No. 18) by tapping out from left
hand to right hand side. This operation frees (2)
washers (No. 15).
Fig. 43 - Adjuster Lever 7. Remove (2) roll pins (No. 20) from hinge shaft at

CHEVROLET TRUCK SERVICE MANUAL

BODY IB -20

rear of shock absorber. Use small Dia. punch.

8 . Remove hinge shaft (No. 19) at rear of shock ab­
sorber. This frees shock absorber.

Installation
1. With shock absorber (No. 22) in proper position,
replace hinge shaft (No. 19) at rear of shock. (Also
see fig. 44.)
2. Replace (2) roll pins (No. 20) in hinge shaft, locking
roll pin on right hand side in nibs in bent-up ear.
3. Replace hinge shaft (No. 18) at front of shock ab­
sorber, driving shaft from right hand to left hand
side. Serrated end of shaft to enter shock lever
(No. 17) last. Drive shaft through (2) washers (No.
15) and through shock absorber loop.
4. Replace (2) snap rings (No. 10) at ends of front hinge
shaft (No. 18).
5. Line up side panels right hand and left hand retaining
the 19-3/4" dimension over side panels.
6 . Reassemble seat cushion following operation 4—
torsion bar installation.
7. Preload torsion bars by rotating adjuster lever as­
sembly (No. 30) clockwise.
8 . Remove shims.

Lubrication
Lubrication fittings are shown in Figure 45. Level ride
seat should be lubricated whenever vehicle is lubricated.

SPECIAL TOOLS

A complete listing of special tools may be found at the

Fig 45 - Seat Lubrication end of Section IB.

CHEVY VAN-BODY-SPORTVAN
INDEX
Page Page
General Description......................................................... IB-20 Dash M a t ..................................................................... I B - 23
Body and F r a m e ......................................................... IB-20 Doors .............................................................................. IB-23
Front End Panel ................................................... IB-20 Front Side Doors ...................................................... IB-23
Side Panels ......................................................... IB-21 Trim Panel and Hardware .................................... IB-23
Roof Panel ............................................................ IB-21 Window G l a s s ......................................................... IB-23
Underbody............................................................... IB-21 Lock Striker ......................................................... IB-24
Sealing .................................................................. IB-21 Rear and Side Cargo Doors ....................................... IB-24
Service O p e ra tio n s ......................................................... IB-21 Rear Door Lock, Rod Assembly and Inside
Windshield G la s s ......................................................... IB-21 H a n d le .................................................................. IB-24
Side W in d o w ............................................................... IB-21 Rear Door Outside Handle and L o c k ..................... I B - 24
Windshield W ip e r s ...................................................... IB-21 Hinge S t r a p ............................................................ IB-24
Outside Rear View M irrors ........................................ IB-22 Hinge S to p ............................................................... IB-24
Instrument Panel Com partm ent................................. IB-22 Hinge Adjustm ent................................................... I B - 25
Step Assembly - Side D o o r ............................................. IB-25
Seats .............................................................................. I B - 25

GENERAL DESCRIPTION
BODY AND FRAME FRONT END PANEL
The "Chevy Van" has an integral body and frame. The The front end panel assembly consists of a plenum
unitized body consists of heavy gauge welded main struc­ panel assembly, instrument panel assembly, and support­
tural members with an underbody of longitudinal box ing pieces welded to the hinge pillar and front end panel.
section side rails and crossmembers which form the A partial front end panel is available for service; also the
integral frame. All outer panels are welded to a flat plenum and instrument panel as separate items for
floor. replacement.

CHEVROLET TRUCK SERVICE MANUAL

 BODY IB-21

SIDE PANELS

The left or roadside Body Side Panel extends from the

body front side door lock pillar to the double rear door
hinge pillar. The right side or curbside panels are the
Side Front Panel extending from the front side door lock
pillar to the double side (cargo) door front hinge pillar,
and the Side Rear Panel extending from the double side
door rear hinge pillar to the rear door hinge pillar.

ROOF PANEL

The roof panel is secured to the body side rails, rear

roof rail and front end panel with spotwelds, and to the
three roof bows with a special adhesive applied to bow
flanges. Bows are arc welded to the side rails.
A roof panel assembly, side and rear rails and rein­
forcements are available for service.

UNDERBODY

The underbody consists of the two floor panels, toe

panel, clips, brackets, an engine cover assembly, exten­
sions, supports and braces welded together. The under­
body is welded to the side rails, extensions, cross sills
and outriggers. Fig 46 - Front Wheelhouse Sealing
In the event of collision damage, underbody alignment
should be thoroughly checked and, if necessary, realigned SEALING
in order to accurately establish suspension, steering and
engine mounting locations. A body sealing compound is used for the roof, body
Checking information for purposes of alignment of the side, front and rear ends (fig. 46). The engine cover to
underbody components, repairing minor underbody dam­ the underbody uses two different sealing compounds. A
age or locating parts is covered with underbody dimen­ special sealer is available for the tail lamp protector
sions and alignment in Section 2. sealing.

SERVICE OPERATIONS
WINDSHIELD GLASS 3. Weatherstrip—Inner or Outer:
The Conventional Cab Windshield Service Procedure Removal of the window frame is necessary for
applies to the Chevy Van. Further information are the weatherstrip replacement.
six 5742-01 spacers used for windshield opening checking. SIDE AND REAR STATIONARY GLASS
Conventional windshield installation is expanded to in­ See Rear Window Weatherstrip—Conventional Cab
clude: WINDSHIELD WIPERS
Apply a minimum of 1/32" thickness of sealer between A single wiper motor unit, mounted off center in the
the glass and the outer wall of weatherstrip completely plenum chamber, powers both wiper blades. The wiper
around the perim eter of glass. blade operating link rods and pivot mountings on these
Apply medium bodied sealer to the flat of the wind­ models are located on the outside air inlet plenum
shield opening rabbet along the entire length of the pillar chamber. Wiper motor is controlled by switch marked
side and extending for approximately 5 inches beyond the
upper and lower corner.
Apply medium bodied sealer to the base of the weather­
strip rabbet channel along the entire perimeter of the
weatherstrip.

NOTE: After applying sealer, insert a pointed

tool through the weep holes at each end of wind­
shield channel to make sure holes are open.

SIDE W INDOW -SW ING OUT

Replacement (Fig. 48)
1. Latch:
Remove 2 screws on jamb and a pin at frame at­
tachment.
2. Frame:
Remove 4 screws on hinge to jamb plus 2 latch
screws. Fig. 47 - W indshield G lass and Sealer

CHEVROLET TRUCK SERVICE M ANUAL

BODY IB-22

1. Remove windshield wiper arms from pivot shafts.

A tool is available for removing the arms. See
above procedure for "Arm Adjustment".
2. Remove radio, if so equipped.
3. Remove the heater distributor and duct outlet as­
semblies (fig. 49) as outlined in Section 13.
4. Remove the two nuts attaching the short link to the
motor under dash.
5. Disconnect two screws securing each of the two
(right and left side) pivot shafts.
6 . Disengage the pivot shafts, gaskets and linkage and
remove the vehicle (fig. 50).
Installation
1. Connect the transmission and linkage assembly as a
unit and install with screws under dash with gaskets
in place.
2. Connect the short link to the motor and install the
nuts.
3. Install the radio.
4. Install the heater distributor and duct outlet assem­
blies as outlined in Section 1A.
5. Before installing wiper arm s, connect the battery
Fig. 48 - Side W ind o w - Sw ing-O ut and operate wiper motor momentarily which should
rotate pivot shafts to park position. Install arms and
"wiper" on dash. Wiper motor service operations are shafts so they are located in the park position. Again
outlined in Section 12. operate wipers and check wiper sweep pattern. Re­
Arm Adjustment position arms on pivot shafts if necessary.
To adjust sweep of blades, turn on wipers and note
sweep of arms\ If necessary, remove one or both arms OUTSIDE REAR VIEW MIRROR
as follows: Pull outer end of arm away from glass which The standard rear view m irror assembly is mounted to
will trip lock spring at base of arm and release spring the door and retained by a lock washer and acorn nut.
from undercut of pivot shaft. While holding arm in this The bracket assembly is secured with three screws. A
position, pull outward on cap section at base of arm to pad is located between the bracket and the door. The
remove arm. Align serrations on pivot shaft and in arm deluxe m irror bracket is mounted with 2 screws. An in­
cap with arm in position to obtain satisfactory sweep and board set screw fastens the m irror assembly to the
press cap onto shaft. bracket.

WINDSHIELD WIPER TRANSMISSIONS INSTRUMENT PANEL COMPARTMENT

AND LINKAGE Glove Box (Fig. 51)
Removal (Right and Left Side)
CAUTION: As a safety precaution, disconnect Removal
battery ground cable before working under in­
1. Remove three screws retaining the compartment
strument panel.
door hinge assembly to the compartment

2. Unhook the check rod and remove door assembly.

3. Remove three screws from the upper surface near

the front of the compartment and the three screws
located under the lower surface near the front of the
compartment.

4. Disengage the compartment by sliding rearward and

out.

Fig. 49 - Heater Duct and Distributor Removal Fig. 50 - Windshield W iper Linkage Removal (T y p ica l)

CHEVROLET TRUCK SERVICE MANUAL

 BODY 1B-23

a. Windshield washer hoses from wiper motor.

b. Windshield washer bag bracket.
c. Electrical harness from the quick disconnect
under dash.
d. Junction block.
e. Speedo-cable at instrument cluster.
f. Loosen the metal electrical harness shield on the
toe pan.
g. Headlamps.
h. Heater distributor and outlet ducts. Do not re­
move the heater.

DOORS
FRONT SIDE DOOR (Fig. 53)
Trim Panel and Hardware (Fig. 54)
Removal
1. Remove window regulator handle and washer by
loosening set screw and pulling from shaft.
2. Remove inside door handle and washer by loosening
Fig. 51 - Instrument Panel Compartment w/Door set screw and pulling from shaft.
3. Remove trim panel-to-door inner panel screws and
Installation remove trim panel.
4. Remove arm rest by removing two screws.
1. Slide the compartment into position and loosely in­
Installation
stall the six screws.
1. Install arm rest and attaching screws to trim panel.
2. Position the compartment and tighten all screws. 2. Align holes in trim panel with holes in door inner
panel.
3. Place door in opening so hinge holes are aligned, 3. Install washer on shaft and with end of door inner
loosely install hinge screws and insert check rod in handle pointing forward, align serrations in both
hole at side of compartment. handles with shaft serrations and install set screws.
Window Glass
4. Adjust door for fit in the opening and tighten screws.

DASH MAT (Fig. 52)

Replacement
Remove the dash mat by cutting off the plastic fasteners
with a sharp knife. New fasteners are required to install
the m at Before installing the fasteners, make certain
that each fastener is provided with an adequate supply of
sealing compound. Parts to be removed and installed for
replacement of the dash mat are as follows:

Fig. 52 - Dash Mat and Seal Fig. 53 - Front Side Door

CHEVROLET TRUCK SERVICE M ANUAL

BODY IB-24

The optional window glass in the rear and side cargo

doors may be replaced as outlined on Page 14.
The front side door window glass may be removed and
installed as outlined below:
Removal
NOTE: Do not remove arm rest.
1. Remove window regulator handle, door inside handle
and remove trim panel as indicated under "Trim
Panel and Hardware" above.
2. Remove door bottom channel retainer screw (fig. 55).
3. Roll window to full down position and push rear
channel retainer to one side (fig. 56).
4. Tilt window glass forward and disengage regulator
roller from guide rail (fig. 57).
5. Tip rear edge of glass upward and remove (fig. 58).
Installation
1. With regulator arm in full down position, insert
glass (vent side downward).
2. Move the regulator up approximately two turns of the
handle and slide roller onto guide.
3. Reposition metal channel retainer and adjust screw
so glass operates smoothly.
4. Install trim panel and hardware.
Door Lock Striker A djustm ent Fig. 55 - Bottom Channel Retainer Screw

Same as Conventional Cab.

opening.
REAR AND SIDE CARGO DOORS NOTE: Removal of lock assembly is not neces­
Rear Door Lock, Rod Assembly and Handle (Fig. 59) sary for handle removal. Access to the lock
Replacement cylinder retainer is through the inside door
1. Remove the rod assembly attaching snap on clips panel for removal.
(with a screw driver) located as shown in Figure 59 2. Remove handle and spring.
through the access hole. New clips must be used on NOTE: While handle is removed, the escutch­
reassembly of the rod. . eon and gasket can be removed.
2. Remove the rod assemblies and special spring clips 3. Reverse procedure to install.
(not shown) attached at the door rod opening in each Hinge Strap (Fig. 62)
end of the door. Replacement
3. Remove the inside handle set screw, handle and The hinge strap is replaceable by pulling the strap re­
washer. lease pin and removing two screws from the strap bracket
4. Remove the lock assembly attaching screws, rotate on the door.
the lock and remove through the access hole. Hinge Stop
5. Reverse removal procedure to install. The hinge stop is replaceable by removing the hinge
The forward load door is serviced the same as rear
doors (fig. 60).
Rear Door Outside Handle (Fig. 61)
Replacement
1. Remove spring retainer from inside door panel

Fig. 54 - Trim Panel and Hardware Fig. 56 - Channel Assembly Attachment

CHEVROLET TRUCK SERVICE MANUAL

 BODY IB-25

Fig. 57 - W ind o w Regulator Roller and G u id e Rail

pins. Make certain the stop is positioned the same as
when first installed.
Hinge Adjustment (Fig. 63)
Side cargo, rear and front side door hinge adjustments
are made in a sim ilar manner as other truck doors.
Fig. 59 - Rear Door Lock, Rod Assembly and Inside Handle
STEP ASSEMBLY—SIDE DOOR
The Sport Van step assembly is actuated by the for­ Removal (Fig. 64)
ward side load door. The step may be kept inoperative 1. Fully open forward side door—extending step as­
by pulling the pin linking the actuating rod to the door. sembly.
Proper adjustment of the door-step results in a slight 2. Pull pin securing rod end to door and tape rod end
effort at the door closing. to rod for reinstallation.
3. Remove 4 screws securing rod cover to floor.
4. Remove cotter pin, washer and spring from rod.
5. Remove 7 bolts securing step assembly to Van floor.
6 . From underside remove 2 screws, washers and nuts
attaching step assembly to rocker.
7. Remove 2 inboard bolts from underside.
8 . Standing outboard of step assembly pull step down
and out for removal.
Installation
1. Raise vehicle.
2. Balancing step assembly by pivot rod, start 2 inboard
bolts. Fasten 2 screws, washers and nuts to rocker.
3. Lower vehicle and install 7 bolts in Van floor.

Fig. 58 - Front Side Door W ind o w Replacement Fig. 60 - Forward Side Load Door - Sport Van

CHEVROLET TRUCK SERVICE MANUAL

 BODY IB-26

SEATS
REINFORCEMENT..: f DRIVERS (Fig. 65) AND FIXED AUXILIARY (Fig. 66)
ASSEMBLY 1
1. Remove four bolts and lock washers and remove seat
RETAINER ESCUTCHEON, assembly complete from vehicle. Install seat by re­
/ SPRING RC D versing procedure and torquing the bolts se 'urely to
SEMBLIES, the floor with lock washers.
1 < / / BUMPER B C D __ 1
SEAT BACK ADJUSTMENT (Fig. 67)
LOWER Replacement
GASKET The seat back is adjustable forward or backward by
loosening the top bolts (right and left side) at the lower
HANDLE - side of the seat back.
I
GASKET y \ \
ASSEMBLY
(
SPACER LOCK
OPTIONAL (FLIP-PASSENGER SEAT)
(Figs. 68 & 69)
LOCK / \
CYLINDER \ ...>> keplacement
RETAINER LOCK U N IT ^ > Remove the auxiliary seat assembly complete by re­
tK *£ moving four bolts, lock washers and nuts from the seat
I j
swivel base. The seat assembly may be removed with­
Fig 61 - Rear Door Outside Handle out base by lifting up and slipping off of the base. Refer
to Figure 69.
4. Connect rod through step lever with removed spring
washer and cotter pin.
5. Secure rod cover with 4 screws.
6 . Push pin through rod end and door.
7. Check door-step operation.
For adjustment, turn rod end counter-clockwise to
lengthen actuating rod; turn clockwise to shorten rod
(retract) step.
8 . From underside tighten 2 inboard bolts.

Fig. 63 - Side Cargo Door Hinge Adjustment

Fig. 62 - Hinge Strap and Hinge Assembly (Rear Door - T yp ica l)

CHEVROLET TRUCK SLXVICE M ANUAL

 BODY IB-27

CHEVROLET TRUCK SERVICE M ANUAL

BODY 1B-28

STORED!

Fig. 69 - Positioning Passenger Seat

Fig. 67 - Driver and A u x ilia ry Seat Back Adjustment CENTER AND REAR SEAT-SPORTVAN (Fig. 70)
The center and rear seat assemblies of the Sportvan
are optional equipment. The seats may be faced forward
or rearward.

Fig. 68 - Flip Swing Passenger Seat Fig. 70 - Center or Rear Seat - Sportvan

STEP-VAN BODY
INDEX
Page Page
General D e s c r ip t io n ...................................................... IB-29 P10 ..................................................................... I B -31
Service O perations...................................................... IB-30 Doors ..................................................................... I B -32
Front E n d ..................................................................... IB-30 Door A djustm ents................................................ IB-32
Windshield and Front Quarter G l a s s ..................... IB-30 Sliding Door Replacem ent.................................... IB-32
Access Doors and C o v e r s ....................................... IB-30 Window G l a s s ...................................................... IB-33
P-20-30 IB-30 Special T o o ls .................................................................. I B -36

CHEVROLET TRUCK SERVICE MANUAL

 BODY IB-29

GENERAL DESCRIPTION
The following information deals with servicing proce­
dures on P10, 20 and 30 Step-Van trucks. Items not under Conventional Body. Write-ups may be used on all
covered herein may be serviced as outlined in this section Step-Vans unless otherwise stated.

V/////7 / I I II I I ' \ \ \ V V
71 - P20 and 30 Access Doors and Panels

A. G lo v e Box. 2. To Carburetor.
B. Access Door to Radiator F ille r Cap. 3. To Block Drain Cock.
C. Tool Box. 4. To Dimmer Sw itch Wires.
D. Battery Access Door for Servicing or Removing. 5. To Choke and Throttle Connections to Carburetor
E. Access Door to H yd rau lic Band Adjusting Screws on Automatic 6. To Driver's Seat Bolts.
Transmission W here A p p lica b le . 7. To Vacuum W ip er Connection at Intake M anifold.
F. Removable Floor Pla te G iv e s Access As Follows: G Engine Box Lid.
1. To M ain Brake C ylin d er. H, Right Hand W indshield W ip er Inspection Plate.

CHEVROLET TRUCK SERVICE M ANUAL

BODY IB-30

Fig. 72 - P 10 Access Doors and Panels

A. G lo v e Box and W indshield W ip er Pivot Shaft Access. E. Switch - H eater Motor 2-Speed.
B. Access W indshield W ip e r Motor. F. Control - Fresh A ir Inlet to Heater.
C. Control Knob - W ind shield W ip er Switch. G. Access to V o ltag e Regulator and Horn Relay.
D. W indshield Defroster Diffusers. H. Engine Box Lid.

SERVICE OPERATIONS
FRONT END
P-20 and 30
WINDSHIELD AND FRONT QUARTER GLASS
Letters and numbers refer to figure 71 (F -l).
Both windshield and front quarter glass are retained in
body opening by wedge-type weatherstrip such as that Main Brake Cylinder
used on Conventional Cab rear window. To remove the floor plate in front of driver’ s seat,
release catch in stepwell, lift plate and pull out. This
ACCESS DOORS AND COVERS gives access to main brake cylinder.

The following information is intended as an accessi­ Battery (D)

bility guide. Components are removed as outlined for Open door in floor below the right rear corner of en­
conventional vehicles unless otherwise stated. gine box to service or remove the battery.

CHEVROLET TRUCK OVERHAUL M ANUAL

 BODY IB-31

Radiator Cap (B) 4. To adjust position of windshield wiper arms have

Open door in shelf panel on inside job just back of the them in park position. Mark this position on glass
windshield center post to get to radiator cap. with grease pencil.
5. Remove the holding nut and lockwasher from the
Gas Tank end of drive shaft.
1. F iller cap is located at the rear of the right hand 6 . Lift off wiper arm and knurled driver. In most
entrance stepwell behind a small door. Open door cases the knurled driver remains inside the wiper
and remove gas cap. arm. Tap on arm lightly to remove the driver and
2. To remove gas gauge, disconnect gas line and drop place it back on wiper drive shaft.
tank to ground. 7. Position the arm above or below the mark on wind­
shield as desired, replace lockwasher and tighten
Engine Housing (G) holding nut.
1. Release catch and open engine box lid and lock in
Three-Speed Transmission Gear Shift Control Box
open position with hinged support arm.
To gain access to the steering column manual shift
2. Release catch on inside of box at the upper right hand
mechanism mounted on the lower portion of the steer­
corner.
ing column mast jacket, remove the radiator grille and
3. Release catches on outside of box at floor level on
baffle plate on left side of radiator. Leave fresh air
the rear and left side.
hose connected to plate and push back out of way.
4. Grasp top flange of box at rear with left hand and
Neutral Safety Switch—Automatic Transmission
the lid with right hand. Raise slightly to release all
To gain access to this switch located on lower portion
catches and remove the box.
of steering column mast jacket follow same instructions
set forth for checking grease in steering gear or for
Windshield Wipers (H)
gaining access to manual shift mechanism on 3-speed
1. To service right hand windshield wiper motor re­
transmission models.
move inspection plate under shelf panel at right side
of firewall directly above tool box.
2. To service left hand wiper motor, remove sim ilar
P-10
panel on left side in back of instrument panel in upper
Numbers refer to figure 72.
left corner below shelf panel.
3. Controls are mounted on left side of instrument Brake Main Cylinder
panel. Open door in instrument panel just back of windshield

M A IN
C YLIN D ER

ifgjPif

Fig . 73 - P10 Main C ylin d e r and 6 C ylin d e r Radiator Access

CHEVROLET TRUCK SERVICE M ANUAL

BODY IB-32

glass in front of driver to gain access to main brake 2. Pivot assemblies service through openings on each
cylinder. Figure 73. side of wiper motor.
3. Wiper switch (C) is mounted in front end header
Battery accessible through left side opening (A).
Release catch and open the lid of the engine housing (H) 4. Circuit breaker for wiper motor is located on fire­
to service or remove the battery. wall directly above clutch pedal.

Radiator Fill Cap DOORS

On 6 cylinder models, open small door in the front
end outer cowl panel to gain access to radiator fill cap, ADJUSTMENTS
Figure 73.
Bottom of Doors
Gas Tank
1. The in and out adjustment for the bottom of sliding
1. Gas tank filler spout is located in a recessed box in
doors is controlled by two nylon rollers in the bot­
left side at the rear.
tom of the door. One at the front and one at the rear
2. To remove gas gauge disconnect gas line, gas tank
of door, each operating in a separate track.
filler spout, loosen gas tank hanger strap and drop
2. Note the 7/8 inch diameter hole in the bottom of the
tank to ground.
stepwell at the front of the rear track. Also note the
Voltage Regulator & Headlamp Relay
plug button in bottom of stepwell at the front of the
front track. With this plug button removed and the
Remove plate (G) on bulkhead panel at front side of
door in closed position the slot head of each bolt in
right hand sliding door to gain access to voltage regu­
lator and headlamp relay. center of the roller can be reached from underneath
through these holes.
Heater 3. To adjust these rollers use screw driver to hold the
1. Hose connections are accessible through door in bolt and with a thin open end wrench inserted be­
outer cowl panel (fig. 73). tween bottom of door and top of stepwell loosen the
hex jam nut on bolt at bottom of door. This frees the
Horn rollers and they can be adjusted in and out as
desired.
1. Horn wire connections accessible through door in
outer cowl panel (fig. 73). 4. Push the rollers in to move the door out and vice
versa. When rollers are adjusted properly tighten
the jam nut securely. Open door and replace plug
Engine Housing
button in front track.
1. Release catch, open engine box lid (H) and lock
hinge arm in open position.
2. Remove accelerator pedal by taking out 2 cap
Top of Doors
screws. 1. To make adjustments at top of doors remove the
3. Remove metal screws around bottom of box, on ver­ panels over the door opening and at the top of the
tical sides at right rear corner and left front corner. door pocket. This gives access to the door tracks
4. Remove box. and top roller assemblies.
5. Reverse procedure to install. 2. The two track assemblies on a side are identical.
The rear of each track can be raised and lowered by
Windshield Wipers adjusting the nuts on the vertical stud. The front of
1. To service windshield wiper motor remove inspec­ tracks or the curved ends can be adjusted in and out
tion plate (B) in center of front end header panel and also up and down by means of elongated holes in
above windshield. the brackets (fig. 74).

Fig. 74 - Door Track and Roller Assys,

CHEVROLET TRUCK SERVICE MANUAL

 BODY 11

Fig. 75 - Front Track Attachm ent to Body

Fig. 76 - D river's W indow Weatherstrip
3. The door tracks can be adjusted back by the use of
shims between the bracket on the front of each track holds the upper door roller assembly to the bracket
and the body bracket or post to which it is attached. at front of door (fig. 74).
Shims are made of 14 ga. steel or of approximately 4. Remove the nut and lockwasher from the bolt that
1/16" thickness material. They have holes slotted acts as the axle for the upper door roller assembly
in from one edge so they can be inserted without re­ at front of door (fig. 74).
moving the bolts. Figure 75 shows closeup of front 5. Block up door to take weight off of roller and re­
track bolted to body bracket. move the bolt. Be sure to catch the two outer
4. If door closes against the front body post too soon or spacers, center spacer, and the two roller assem­
before it gets out into proper position, the front blies.
track should be moved back so that the door can 6 . Remove bolts at the front of the front track and
travel out farther before it seals against the body raise the track to free the front roller yoke.
post. If this case exists insert one shim at the front 7. Remove the door.
of the front track and test the door. If not enough 8. To install door reverse the procedure above.
add the second shim. Two shims or 1/8" makes a
considerable change in door movement and should be COMPLETE DRIVER’S WINDOW
sufficient in most cases.
5. In cases where the door is not going out as far as it Installation
should, be sure that the track is out as far as the 1. Assemble weatherstrip rubber to the opening with
mounting brackets will allow. weatherstrip retainer groove to inside of body mak­
6 . After the adjustment on the front track is made ing sure the outer channel of weatherstrip is firmly
close the door and check the position of the rear seated on edge of door panel all around the opening.
roller on the rear track. If roller is not centered
on track, adjust the track as required to correct.
7. If front door lock striker is too low, it will raise the
rear roller off the track when door is in locked posi­
tion. Raise striker slightly by striking it with ham­
mer to correct.
8 . Letting the door travel out farther as it closes gives
tighter seal at the door lock post as mentioned in
paragraph 4.

SLIDING DOOR

Replacement
1. Remove the inside header panel over the door open­
ing.
2. Remove the upper panel on the door pocket just to the
rear of the above panel. Note the special washer
between the pivot bearing and top of mounting bracket.
3. Remove the nut and lockwasher from the bolt that Fig. 77 - W eatherstrip Installed

CHEVROLET TRUCK SERVICE M

BODY IB-34

between the run channel and inside edge of rubber.

Keep rear edge of glass ahead of weatherstrip at
rear of window opening. Using the tool shown in
Figure 79 or sim ilar instrument work glass into the
weatherstrip channel.
5. Work top of stationary glass into weatherstrip chan­
nel in same manner as the bottom.
6 . Use rubber mallet to tap glass back to the weather­
strip. Work into weatherstrip channel using paint
scraper or sim ilar tool and rubber mallet (fig. 80).
Tap glass firmly into weatherstrip.
7. From the outside of the door work the run channel
ends into weatherstrip rubber with the paint scraper
and mallet handle to tap them back. Channel ends
are shown in Figure 77.

Fig. 78 - Installing Sliding Glass

Watch this carefully on the corner radius. It is im­

portant to start the rubber at the top at the point
shown in Figure 76, going forward, down and around.
Cut off excess rubber about one-half to three-
quarters of an inch long. Butt the two ends together
and crowd excess rubber on. This makes tight joint
and prevents separation at joint after window is in
service.
2. Install the glass run channel inside the weatherstrip
rubber, starting half way up the rear side of open­
ing, coming down and around the opening to rear.
Cut off any excess channel at joint. Leave at least
6 inches of each end of channel out of rubber until
rear glass is in place (fig. 77).

NOTE: The installation of this window is made

from the inside of the job with door in closed
position. The use of a mixture of liquid soap
and water or some other type rubber lubricant
applied to the rubber will make the installation
of this channel as well as the other filler sec­
tions much easier to install.

3. Set lower edge of sliding glass (front section) in run

channel with upper edge of glass back of joint in
weatherstrip rubber. Place paint scraper or sim­
ilar object on top of glass and into channel—pry down
and push top of glass into channel. Push glass for­
ward as far as possible (fig. 78).
4. Set lower edge of stationary glass in weatherstrip Fig. 79 - Installing Stationary G lass

CHEVROLET TRUCK SERVICE MANUAL

 BODY IB-35

up to allow for the extra thickness of the glass thumb

pull. Use a block of wood slightly wider than chan­
nel and with one edge rounded smooth so as not to
damage channel drive it in spreading the area around
the thumb pull until glass enters channel with rea­
sonable ease.
14. Install sliding window lock keeper on front edge of
door. With window pushed forward in closed posi­
tion, place keeper behind lock plunger and attach to
door with sheet metal screws. To release window
pull out on knob and back on glass pull.
15. Locate (3) holes equally spaced across bottom of
window rubber on the outside. Keep holes in straight
part of rubber. Using 1/4" diameter drill bit start
holes 1 / 2 inch below top edge of rubber and drill up
through bottom side of run channel providing holes
for water to drain out of channel.
16. Place metal channel over leading edge of weather­
strip with the short leg of channel on the plush side
of weatherstrip and tap on with rubber mallet. In­
stall stationary glass retainer clips at top and bot­
tom of center weatherstrip as shown in Figure 3.
Please note that there is a difference between top
and bottom clips. It is important that they be in­
stalled correctly. Without these clips the impact of
closing door will drive the stationary glass forward
and out of the rubber at rear of window.

DRIVER’S WINDOW SLIDING GLASS

Replacement
1. Using a pointed tool, raise one end of the weather­
strip filler until it is far enough out to take hold of
by hand. Then pull filler out of its channel all
around the window.
Fig. 80 - Tapping Stationary G lass into Weatherstrip 2. Using a pointed tool, raise one end of heavy rubber
wedge in front of stationary g lass, until it can be
8 . Install heavy rubber wedge between run channel and grasped by hand. Pull entire wedge off its channel.
inside edge of weatherstrip from front edge of 3. Pull stationary rear glass forward until it is out of
stationary glass at top around to front edge at bot­ rubber at the rear.
tom. The round edge enters the rubber and the 4. Using special wire hook, furnished with Body Wea-
ribbed side goes next to the run channel. therstripping Tool Set (J-2189) or sim ilar tool, work
9. Install center weatherstrip on front edge of sta­ top of glass out of rubber and lift out of window.
tionary glass with plush side next to sliding glass. 5. If sliding glass is still intact, slide glass back until
Apply 3-M Weatherstrip Adhesive or its equivalent front edge at top is back of joint in weatherstrip
to the inside of this channel before installing. Push­ rubber. Using the paint scraper or sim ilar object,
ing each end of weatherstrip on before pushing up the slip blade between channel and glass at top. Lift
center will eliminate the ends catching in the rubber up on scraper to work glass out of channel.
and give it a crowding effect at top and bottom for 6 . If sliding glass is already out and there is no dam­
tighter seal. age to the weatherstrip rubber or the glass run
10. Feed one end of weatherstrip filler into handle of channel then you are ready to install a new sliding
special tool J-2189 and out through the end which glass.
spreads the weatherstrip channel. 7. To install the sliding glass follow the instructions
11. Starting at bottom center, insert the end of the tool and illustrations under "Complete Driver’s Window
and end of filler in channel, tapered part of the filler Installation." Begin with operation 3 and continue
toward the glass. through operation 12. Continue through to operation
12. While holding the tool firmly, with spreading end in 15 if new weatherstrip has been used.
channel, follow around the channel spreading it open
and feeding the filler into the opening around the en­ DRIVER’S WINDOW STATIONARY GLASS
tire weatherstrip. With the flat side of common
screw driver placed against the starting end of the Replacement
insert filler drive filler back an inch or two. Cut 1. Follow operations 1 through 4 under Driver's Window
off the other end to make snug joint and work into Sliding Glass Replacement. If glass is completely
channel. This prevents separation at joint after gone and there is no further damage to the window,
window has been in service. operations 1 and 2 will prepare the window for sta­
13. The run channel at front of window should be opened tionary glass replacement.

CHEVROLET TRUCK SERVICE MANUAL

BODY IB -36

2. To install the new glass follow the instruction set weight motor oil on the outside of the Everseal and
forth for "Complete Driver's Window Installation." press latch onto the glass. If it is necessary to use
Begin with operation 4 and continue through opera­ mallet or hammer to position latch, tap lightly. Too
tion 1 2 . hard a blow could chip or break glass or cause the
clip to open up slightly thus reducing the grip on
DRIVER’S WINDOW THUMB PULL AND glass. The Everseal should be allowed to setup a
LOCKING DEVICE few hours before too much pressure is applied to it.

Installation
1. Attach driver's window thumb pull and latch assem ­ SPECIAL TOOLS
bly to glass using .040 x 2 -1 /4 " Everseal glass glaz­
ing strip. Center the latch on leading edge of glass. A complete listing of special tools may be found at the
Fold the Everseal over edge of glass, apply No. 30 end of Section One.

TILT CAB
INDEX
Page Page
General D e s c r ip t io n ...................................................... IB-36 Body V entilation...................................................... I B -44
Service O p eratio n s......................................................... IB-37 Windshield W ip e r s ................................................... I B -45
Body Shell..................................................................... IB-37 Emblem Assembly and Front Access Panel . . . . IB-45
Cab Mounting............................................................ I B -37 Instrument Panel Com partm ent.............................. I B -45
Cab A s s e m b ly ......................................................... IB-38 Doors ........................................................................... IB-46
R e m o v a l................................................ .................. I B -3 8 A dju stm en ts............................................................ I B -46
Installation............................................................... IB-38 Door Assembly Removal and Installation............... IB-48
Tilting M echanism ................................................... I B -40 Window R e g u la t o r ................................................... I B -49
O p e r a t io n ............................................................ IB-40 Lock Striker P l a t e s ................................................ I B -49
Adjustment ......................................................... I B -40 Remote Control M echan ism .................................... IB-49
Torsion B a r ......................................................... I B -40 Door Window Glass ................................................ I B -49
Cab Rear Hold-Down and Safety Hook Assembly . . IB-41 Vent G l a s s ............................................................... IB-50
Cab In su la tio n ......................................................... IB-42 W eatherstrip............................................................ IB-52
Front End.................................................................. IB-42 Rear Quarter W i n d o w ........................... ..................... IB-54
Windshield Glass ................................................... IB-42 Rear Glass W i n d o w ................................................ IB-54
R e m o v a l............................................................... IB-42 S e a t s ........................................................................... IB-54
Checking Windshield Body O p en in g..................... IB-44 Standard Seat ......................................................... IB-54
Installation ......................................................... IB-44 Auxiliary S e a t ......................................................... IB-54
Rear View M i r r o r ................................................... I B -44 Special T o o l s .................................................................. IB-56

GENERAL DESCRIPTION

The tilt cab bodies are of all steel welded construction

fully surrounding the engine, and can be tilted 55 degrees gine coolant, is accomplished without tilting cab, through
to expose engine for servicing. The cab tilting mecha­ access doors in panel at the rear of passenger seat and
nism is integral with cab front mountings and tilting is on top of seat back riser. A central island control panel
accomplished by means of a torsion bar extending across (fig. 82) is located between the seats.
cab front hinge mountings. Raising or lowering is virtu­ Control panel contains transmission shift lever, hand
ally effortless since the preloaded torsion bar counter­ brake lever, ignition switch and choke.
balances the weight of the cab. The cab is retained in At upper rear of cab a seat back riser extends entire
lowered (operating) position by a positive locking mecha­ width of cab.
nism located at rear of cab (fig. 81). The underside of cab is completely insulated to deaden*
Access for minor engine servicing, such as oil and en­ sound and prevent corrosion.

CHEVROLET TRUCK SERVICE MANUAL

 BODY IB-37

CAB HOLD-DOWN CATCH HOLD-DOWN CATCH

V* * CAB REAR SUPPORT RELEASE LEVER

SAFETY CATCH

CHECK LINK

SAFETY CATCH
RELEASE ROD

Fig. 81 - T ilt Cab Latch Mechanism Fig. 82 - Control Panel

SERVICE OPERATIONS
BODY SHELL which limits the distance cab can be tilted forward and
automatically locks the cab in the full-tilt position. Check
CAB MOUNTING link must be released before cab can be returned to nor­
mal operation position.
Cab is three-point mounted with two pivot-type mount­ Interconnected with the cab front mountings is a torsion
ings at front and twin cushion-type mountings at rear. bar which is under load when cab is in either the operat­
Refer to Figures 83 and 84 for views of mountings. ing or full-tilted position. Right end of bar is anchored
Attaching bolts at front pivot mountings should be to cab bracket and left end is anchored to frame bracket
checked at regular intervals for tightness. Loose mount­ as shown.
ings will allow shifting of cab and eventual failure of Bar is free when cab is tilted part way, therefore, tor­
other items connecting cab to chassis. Front pivot sion bar assists operator in both the raising and lowering
mountings have fittings for lubrication purposes. of cab.
Rear mounting has positive locking mechanism to re­ CAUTION: Under no circumstances should the
tain cab in normal operating position in relation to chas­ bolts which attach torsion bar right anchor
sis frame. The rear mounting also includes an additional bracket to cab and the torsion bar left anchor
safety catch. bracket to frame be removed when cab is in op­
Cab hold-down catch shaft is equipped with a lubrica­ erating, or full tilt positions which is when bar
tion fitting. is loaded. An iniury could result when anchor
A check link is provided near the right front mounting bracket becomes free and torsion bar twist is

JRIC A TIO N FITTING H O LD -D O W N CATCH

C A B REAR RELEA SE ROD
SU PPO RT C A B H O LD - D O W N CATCH ** *
C A B RIGHT C A B LEFT
RETURN S P R IN G BRACKET BRACKET

LUBRICATIO N
FITTING

SAFETY
CATCH
T O R S IO N BAR
C A B REAR M O U N T IN G
C U S H IO N S CATCH
RELEA SE ROD RIGHT FRAME LEFT FRAME
SU PPO RT SUPPO RT
BRACKET BRACKET
SAFETY
CH A IN
C H ECK LINK
A N D RELEASE ROD
RELEASE
ROD LEVER

CAB REAR M O UN TING CAB FRONT M OUNTING

Fig. 83 - T ilt Cab Mounting

CHEVROLET TRUCK SERVICE MANUAL

BODY IB-38

nectors that junction cab with the chassis. Remove

cab to chassis ground straps.

NOTE: Remove or secure loose items in cab

before tilting. Place shift lever in neutral and
hand brake in full applied position.

6. Attach a suitable padded lifting sling (fig. 8 6 ) to cab

with doors partly open (lifting cab with doors closed
will distrub their alignment).
7. Using two helpers, and lifting device, tilt cab approx­
imately 45° to the unloaded position of cab mounting
torsion bar (refer to preceding caution) and suspend
safely there.
While cab is in this position, insert a pry bar in
Fig. 84 - Rear Mount Pads between cab left support bracket and cab sill (fig. 87).
Remove front bolt, lockwasher and nut ("A", fig. 8 8 ).
Remove three bolts, lockwashers and nuts from right
allowed to release. Attaching bolts can be re­ cab support to sill pivot bracket ("B ", fig. 89).
moved safely when bar is unloaded, cab tilted 8 . Remove cotter pin and clevis ("A", fig. 89) with at­
part way (approx. 45 degrees) as shown in Fig­ tached check link to right cab sill pivot brackets.
ure 85. Normally it should never be necessary Remove two retaining bolts from cap at left cab to
to remove above mentioned bolts. sill support bracket and remove cap. Raise cab
slightly, and remove rear mounting bolt ("C", fig. 89)
C A B A SSEM BLY attaching right support sill brackets.
9. Raise cab slightly, to clear cab lift mechanism, then
Removal forward and up to clear shift control panel.
1. Disconnect battery ground strap. Remove radiator 10. Lower cab onto a suitable pair of wood blocks and
grille and headlamp assembly as described in sec­ remove chain fall and lifting sling.
tion 13.
2. Remove bumper and bumper filler panel. NOTE: Left cab to sill support bracket can be
3. Open heater temperature control on dash to full open removed, if necessary.
position, and drain radiator. Disconnect heater hoses
at cab connections. Installation
4. Disconnect accelerator linkage and steering flexible 1. Install lifting sling and chain fall to cab with doors
coupling. Disconnect brake lines and clutch line. slightly open (fig. 8 6 ).
5. Disconnect speedometer cable and all electric con­ 2. Raise cab and install (if previously removed) left,

Fig. 85 - T ilt Cab Position - Torsion Bar Unloaded

CHEVROLET TRUCK SERVICE MANUAL

 BODY IB-39

PADDED
C H A IN FALL LIFTING SLIN G

Fig. 88 - Bracket Bolt Locations

Fig. 86 - Typ ical Lifting Arrangement

6 . Insert a pry bar in between cab left support bracket

cab-to-sill support bracket rear attaching bolt only and cab sill (fig. 87).
(fig. 90).
7. Use two helpers, one holding pry bar as shown in
Figure 87 and the other helping to tilt cab forward
NOTE: Cab tilt torsion bar, check link and (approximately 45 degrees). While cab is in this po­
right cab to sill support bracket, should be in sition install the three remaining bolts, lockwasher
position, on chassis as shown in Figure 92. and nuts ("B ", fig. 87) in the right cab support and
sill brackets. Torque bolts 40 to 50 ft. lbs. Install
3. Raise cab over chassis and lower into position, for­ front bolt, lockwasher and nut to left cab support and
ward slightly to clear shift control panel, then back sill brackets. Torque bolt 40 to 50 ft. lbs.
and down.
8. Install cab stop bracket on the right side as shown in
4. Position steering gear coupling and left cab-to-sill Figure 92, and on the left side the 45 degree notch is
bracket onto torsion bar and install cap with bolts, installed down and to the rear. Tighten attaching
torque 35-50 ft. lbs. bolts firmly.
5. Install check link retaining clevis pin with cotter pin
("A", fig. 89). Install bolt ("C ", fig. 89) to right cab
support to sill bracket.

CHECK
LINK

LEFT C A B \
SU P P O R T ,
BRACKET

Fig. 87 - A lign in g Bracket Bolt Holes Fig. 89 - Right Hand Support Bracket and Check Link Fastenings

CHEVROLET TRUCK SERVICE MANUAL

BODY IB -40

engaged. Pull downward on hold-down release lever

and engage lower end of lever in lever spring catch,
bracket-mounted to rear of cab.
3. Replace safety hook through matching holes in clip
bracket and lug on lever, starting hook from
underside.
CAUTION: Under no circumstances should the
torsion bar bracket cap retaining set screws be
loosened with cab in either position. Whenever
loosening or removing the cap retaining set
screws for any reason, the cab must be tilted
only to the point where the torsion bar is un­
Fig. 90 - Left Hand Support Bracket Installation
loaded. When torsion bar is inoperative, cab
must be safely supported.
9. Tighten steering coupling clamp bolt 15 to 22 ft. lbs.
Connect speedometer cable and all electric connec­ Adjustment
tors that junction with the cab-to-chassis.
10. Connect accelerator linkage and adjust as outlined The tilting mechanism incorporates a feature which
under Maintenance and Adjustments-Engines. Con­ permits adjustment of the torsion bar as required for
nect all ground straps. proper counter-balancing of the cab during the tilting
11. Connect brake hoses and bleed brakes as outlined procedure. Tension of the bar may be changed by mov­
under Service Operations-Brakes. ing the adjustment lever (fig. 92, view A). The cab must
12. Connect clutch flexible line and bleed as outlined be tilted to approximately 45° and supported before ad­
under Service Operations-Clutch. justments are made. Torsion bar must be unloaded.
13. Connect heater hoses and fill radiator. Connect Lever may be adjusted up or down as required to allow
battery ground strap and install radiator grille cab rear sill to be 6 ” ± 1 " above cab rear support cross­
assembly. member when cab is in normal unlatched position. See
14. Install bumper and bumper filler panel. View B, Figure 92.
NOTE: Check tilting and locking action. Ad­
Torsion Bar
just if necessary following procedure outlined in
this section. NOTE: The following instructions are to be
carried out only after cab is tilted (approxi­
TILTING MECHANISM mately 45 degrees) and supported safely there
with weight removed from chassis. Torsion bar
Operation must be unloaded.
Refer to Figure 92 for all models.
To Raise Cab
(Refer to Figure 91) Removal
1. Remove nut from adjusting lever clamping bolt and
NOTE: Before tilting cab forward, remove or
pull lever off end of torsion bar.
position loose articles safely in cab, also place 2. Remove two bolts retaining cap to left body bracket.
transmission shift lever in neutral and apply 3. Remove clamp bolt from right hand body bracket.
hand brake.
1. Close both doors of cab.
2. At right rear of cab remove safety chain hook, then
pull lower end of hold-down catch release lever
from spring catch attached to cab.
3. While holding safety catch release rod to the right,
raise hold-down release lever upward until hold-
down catch becomes disengaged and rear of cab
raises from mount. Tilt cab completely forward
until check link at right front mounting, locks cab
safely in full-tilt position.

To Lower Cab
(Refer to Figure 91)
NOTE: Before lowering cab to operating posi­
tion, make sure transmission shift lever is in
neutral position and hand brake lever is in the
applied position.
1. Release check link at right front mounting (see inset
view) by pulling rearward on link release rod then
pull cab back to operating position.
2. Safety catch at rear of cab will automatically become Fig. 91 - T ilt Cab Latch Mechanism

CHEVROLET TRUCK SERVICE MANUAL

 BODY IB-41

BUMPER

CAB REAR SUPPORT

CROSS MEMBER

VIEW A

Fig. 92 - T ilt Cab Lift Mechanism

1. Body Bracket Support— O uter 6. Body Bracket Cap 11. Frame Support Bracket C ap—R. H.
2. Body Bracket Support— Inner 7. Lube Fitting 12. Stop Bracket Assembly— R. H .
3. Stop Bracket Assembly— Left Hand 8. Adjusting Lever 13. Clamp Bolt— Body Bracket—R. H.
4. Body Bracket—Left Hand 9. Torsion Bar 14. Body Bracket—R. H.
5. Frame Support Bracket Assembly— L. H. 10. Frame Support Bracket Assembly— R. H.

4. Remove two bolts retaining cap to right hand frame as possible; secure lever with bolt and nut torqued
support bracket. to 130-180 ft. lbs.
5. Slide torsion bar toward left side of vehicle and out 4. Install right hand body bracket clamp bolt and torque
of support brackets. to 65-75 ft. lbs.
5. Lubricate fittings on right hand frame bracket and
Installation left hand body bracket and tilt the cab several times.
Before replacement of torsion bar, inspect frame 6 . Move adjusting lever to required position following
brackets and cab support brackets for cracks. Do not instructions elsewhere in this section.
weld or braze brackets. If cracked, replace. 7. Recheck torque of right hand body bracket clamp bolt
New torsion bars should be handled carefully so as to (65-75 ft. lbs.).
avoid nicking surface. Never hammer on a new bar dur­
ing installation. If entry into right hand body bracket is CAB REAR HOLD-DOWN AND SAFETY
difficult, open clamp with pry bar. Lubricate right hand LOCK ASSEMBLY
hex of bar with chassis grease and proceed as follows:
1. Insert bar through left hand frame support bracket Proper adjustment and lubrication of the hold-down as­
and into right hand body bracket. sembly is of prime importance. Periodic inspection of
2. Install caps on right hand frame support bracket and the condition and operation of the latch should be made
left hand body bracket; torque bolts to 50-60 ft. lbs. whenever the vehicle is lubricated. Details of hold-down
3. Coat inside of adjusting lever hex with chassis assembly mechanism may be seen in Figure 93. Note that
grease and install lever over end of bar with small the length of the control handle connecting rod must be
hole in lever as near center of slot in frame bracket adjusted to 22-7/8" from center of hole in clevis to cen­

CHEVROLET TRUCK SERVICE M ANUAL

BODY IB-42

Fig. 93 - Hold-Down and Safety Hook Assy.

ter of hole in rod to insure positive engagement of cab FRONT END

lock in latch.
WINDSHIELD GLASS
Check Link Assembly NOTE: When replacing a cracked windshield,
Figure 94 illustrates check link assemblies. Cab must resulting from causes other than from flying
be firmly and safely supported before check links are objects, it is very important that the cause of
disassembled. breakage be determined and the condition
Application of machine or light engine oil to the pivots corrected.
and clevises whenever truck is lubricated is necessary
If cracks in glass extend to outer edge of glass, mark
for proper operation. Always inspect condition and in­
cab or cowl with chalk at these points so that weather­
stallation of return spring when servicing vehicle. Spring
strip flange in cab opening can be examined later for
must be in good operating condition and installed in the
possible distortion.
frame hole exactly as shown in Figure 94. This is a
safety item. CAUTION: Always wear heavy gloves to pre­
vent possible injury when handling glass.
CAB INSULATION
NOTE: Each section of windshield glass is re­
Undercoating, applied to cab understructure directly tained in place with insert-type rubber seal as
over engine is highly resistant to abrasion and corrosion shown in Figure 95.
and is designed to give maximum sound deadening and
Removal
insulation.
In the event repair, such as welding is required to that
1. Pry end of insert out of vertical center seal with a
part of cab covered with undercoating, it is first neces­
pointed tool; pull insert completely out of seal.
sary to remove the undercoating from that area.
2. In same manner, remove insert from seal around
IMPORTANT: Before spraying new undercoat­
ing, clean area thoroughly.

CHEVROLET TRUCK SERVICE M ANUAL

 BODY IB-43

Fig. 94 - Check Link Assembly (T yp ica l)

CHEVROLET TRUCK SERVICE MANUAL

BODY IB -44

of seal over edge of glass.

3. Thread end of rubber insert through handle and loop
of installer tool (fig. 95). Pull tool loop and end of
insert into groove of seal. Feed in rubber insert,
while proceeding around window. Use a hitching
movement of tool to avoid elongating insert. If new
insert is being used, cut off insert allowing sufficient
overlap to tight joint; then butt into groove.
IN S T A L L IN G G L A S S IN S E A L
4. Install insert in center vertical seal in same manner
previously described in Step 3.

REAR VIEW MIRROR

Figure 96 shows installation of rear view m irror on

left door assembly. Note that m irror head should be in­
stalled so that drain holes are at the bottom.

BODY VENTILATION
Outside air enters cab through a vent (fig. 97) directly
in front of driver and through the outside air heating sys­
tem. Air entry is made through a louvered, removable
panel, located in center of front end just above grille
opening. Air flows through plenum chamber between
outer and inner cab paneling and is dispersed to heater
or vent outlet as desired.
Figure 98 illustrates construction of fresh air ventilat­
ing assembly. For ease of operation, the spring, rod and
tube shown in View "A" should be lubricated with machine
or light motor oil whenever vehicle is lubricated.

IN S T A L L IN G IN S E R T IN S E A L

Fig. 95 - Insert-Type Seal

that section of glass which is to be removed.

3. With aid of an assistant to hold glass, push glass
forward from inside cab.

Checking Windshield Opening

If it is suspected that the windshield opening has been
distorted through collision damage, or if the vehicle has a
history of windshield "strain breaks", the windshield
opening should be checked as follows:
1. Remove windshield, rubber seal and all foreign ma­
terial from windshield frame.
2. Place a new windshield glass in opening without
rubber seal.
3. Install checking blocks, Special Tool J - 9316, equally
spaced around perimeter of opening. Blocks may be
installed by inserting them between glass and metal
from outside of cab with the two notches toward in­
side of cab. Blocks are then rotated 1/2 turn so that
wide notch engages glass and narrow notch engages
pinchweld.

Installation
1. If necessary, pull rubber seal from glass opening,
then examine opening flanges for irregular surface
which could cause glass breakage. Straighten flanges
if necessary.
2. Reposition rubber seal on flange. Raise new glass
to outside of seal, then with hook end of installer
Tool (J-2189) in glass groove of seal as shown in
Figure 95 move tool around glass to force outer lip

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 BODY IB-45

INTERIOR VENT
AND CONTROL

Fig. 97 - Fresh A ir Flow

WINDSHIELD WIPERS vehicle only. Repair of wiper motors, etc. will be found
in Section 12, Electrical. Figure 99 is an exploded view
Two separate motors are used to power the wipers on of the left hand wiper assembly installation. Right hand
Tilt Cab Trucks, one switch controlling both. Covered assembly is identical; however it will be necessary to
here will be removal and installation of the units on the remove heater assembly before wiper motor may be
serviced.

Removal
1. Remove positive cable from battery terminal.
2. Remove nut retaining wiper onto shaft.
3. Pull arm, knurled driver and rain shield from shaft.
4. Remove nut retaining shaft ferrule to body outer
panel; remove washers.
5. From inside vehicle, remove four screws retaining
motor assembly to dash and remove assembly from
vehicle.

Installation
Install by following removal procedure in reverse
order. After connecting battery, test operation of wipers
thoroughly.

EMBLEM ASSEMBLY AND FRONT

ACCESS PANEL
Figure 100 illustrates installation of both the emblem
and access panel. The panel must be removed to gain
access to emblem retaining nuts. The panel also serves
as the air inlet grille for the ventilating system and is
fitted with a screen which should be checked periodically
and cleaned if necessary.

INSTRUMENT PANEL COMPARTMENT

Figure 101 illustrates installation and assembly details

of the instrument panel compartment. Note that if truck
Fig. 98 - Fresh A ir Vent Assy. is equipped with heater, it will be necessary to remove

CHEVROLET TRUCK SERVICE M ANUAL

BODY IB-46

Fig. 99 - W indshield W ip er Assy.

1. Crown N u t 7. O uter Washer

2. Lock Washer 8. Inner Washer
3. W ip er Arm Assembly 9. Shaft Ferrule (Part of
4. Knurled Driver Motor Assembly)
5. Rain Shield 10. Retaining Bolts
6. Shaft Ferrule 11. Motor Assembly opening. See Views A and C, Figure 102. A fiber shim
Retaining N u t (Includes Bracket)
(approx. 0.094" thick) is installed between cab and striker
support (View A, Figure 102) to provide adequate clear­
heater cover panel before fiber board liner may be re­ ance between top of door and cab.
moved from instrument panel. The position and purpose of door upper and lower
strikers must be considered when making door
DOORS adjustments.

ADJUSTMENTS

Door Assembly in Cab Opening

Door up and down adjustment in cab opening is provided

by means of floating hinge cap screw tapping plates within
door framing. Horizontal slotted cap screw holes in cab
half of hinge assembly provide the in or out adjustment of
door.
Only the upper portion of door can be adjusted "fore”
and "aft" with the adjustment being at the upper hinge.

NOTE: Before making door adjustments al­

ways remove striker plate assembly (View F,
fig. 1 0 2 ) from the cab lock pillar.

In addition to the door lock striker, rear of door is

supported in cab opening on two other strikers, one at top
of door and the other at bottom of door. Lower striker,
which is spring-loaded and self-adjusting is mounted to
bottom of door frame as shown in View D, Figure 102.
The adjacent striker support is mounted on door ledge of
cab as shown in View F, Figure 102.
Upper striker and striker support is employed at top of
door to restrict the up and down movement of door in cab

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To Reposition Door Up or Down NOTE: Access to one cap screw at door upper
hinge is gained after removing plug from door
NOTE: Door raised adjustment is limited by a inner panel. Use pointed tool to remove plug.
striker at top rear of door (View A, fig. 102).
The striker support at cab is mounted over a b. After satisfactory adjustment has been obtained,
shim which will usually provide the proper tighten hinge cap screws firmly. Open and close
clearance at top of door; however, shim can be door to check operation. If necessary, repeat
removed or another added as desired. adjustment. Install hinge cap screw access plug
in door inner panel after making final adjustment.
a. Loosen hinge-to-door cap screws slightly. Re­ c. Install striker plate assembly on cab lock pillar
position door on hinges to provide equal clearance as directed under "Striker Plate Adjustment."
around perimeter of door in cab opening.

...... ~
C O W L HALF 5 STRIKER
a .,,..— ,,,,,..
A D JU S T M E N T

V IE W A — D O O R UPPER SU PPO R T V IE W B — D O O R U P P E R H IN G E V IE W C— D O O R U P P E R ST R IK ER

D O O R HALF
A D JU S T M E N T STRIKER

V IE W F— LO C K ST R IK ER P LA T E
AND L O W E R ST R IK ER S U P P O R T V IE W E— D O O R L O W E R H IN G E V IE W D— D O O R L O W E R ST R IK ER

Fig. 102 - Door Adjustment Points

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BODY IB-48

To Reposition Door Fore or Aft c. After adjustment has been made, tighten hinge cap
screws firmly. Open and close door to check
NOTE: Only the upper portion of door can be operation. Readjust if necessary.
adjusted fore or aft. This adjustment is made
NOTE: It may be necessary to reposition door
at the upper hinge. No means for this adjust­
striker plate on lock pillar after making above
ment exists at the lower hinge.
adjustment.
a. Loosen upper hinge-to-door cap screws slightly. Door Lock Striker Plate

NOTE: Access to one cap screw at door upper Raised beads on the back of the striker plate and se r­
hinge is gained after removing plug from door rations on both the front and back of the striker plate
inner panel. Use pointed tool to remove plug. spacers, coupled with movable anchor plates in the pillar,
allow for "in and out" or "up and down" adjustment for a
Lift upward or pull downward at rear of door to close fit of the door on the lock side.
tilt upper portion of door fore or aft as desired. The striker plate spacers must be assembled so the
b. Tighten hinge cap screws firmly after making ad­ vertical serrations on the spacer are toward the lock
justment. Open and close door to check opera­ pillar (fig. 104). Likewise, the horizontal serrations on
tion. Repeat adjustment if necessary. Install cap the lower spacer must be toward the front so they match
screw access plug in door inner paneling. the horizontal slot in the striker plate.
c. Install striker plate assembly to cab lock pillar
as directed under "Striker Plate Adjustment." A djustm ent
1. Position striker on pillar as low as possible (bottom
To Reposition Door In or Out of lock rotor housing 27/32" below striker cam) and
still provide clearance between striker cam and lock
NOTE: Horizontal cap screw slots exist in cab rotor leading edge.
half of hinge assembly to permit this adjustment.
NOTE: Striker cam must not interefere with
See Views B and E, Figure 102. «
leading edge of rotor as door is being closed.
The outer surface of door when properly installed Outline striker with a pencil. This will provide a
should be flush with adjacent panel surfaces of cab (fig. base from which to make further adjustment.
103). If necessary, reposition door as follows:
a. Loosen slightly, all cap screws which attach hinge DOOR ASSEMBLY
half to cab pillar.
b. If door is to be brought outward from cab opening, Component sub-assemblies of cab doors, such as win­
apply pressure at door hinge area from inside dow regulator, door lock, remote control, vent window,
cab. If door is to be moved inward, apply pres­ and door window, can be replaced without necessity of
sure on door outer panel at hinge area. removing door from cab. Doors can be removed, how­
ever, without prior removal of above components. Re­
IMPORTANT: Excessive pressure will damage moval and installation of door window glass is described
door paneling. under Door Window Glass.

Fig. 104 - Door Lock Striker Plate

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 BODY IB-49

Removal 5. Rotate lock and remote control units to disengage the

1. With the aid of an assistant to support weight of door, connecting link.
remove six screws which attach hinge straps to door.
Installation.
NOTE: Access to one cap screw at door upper
hinge is gained by removing plug from door 1. Assemble connecting link between lock unit and re­
inner panel. Use pointed tool to remove plug. mote control unit.
2. Through access opening at bottom of door place re­
2. Carefully remove door assembly from cab. mote control mechanism into installed position. Se­
cure remote control unit to door inner panel loosely
Installation with three screws (5, fig. 105). Secure lock unit (16,
Attach door to hinge straps with six cap screws. Ad­ fig. 105) to door edge with three screws.
just door in cab opening as instructed under Door 3. Place handle with flat washer to remote control shaft
Adjustments. to the position marked prior to removal. Secure
handle to shaft with set screw.
WINDOW REGULATOR 4. Check operation of lock mechanism.
NOTE: Key numbers in text refer to Figure NOTE: Remote control shaft unit can be
105. shifted slightly to door inner panel to provide
Removal adjustment. When satisfactory adjustment is ob­
1. Perform Operations 1 and 5 under Door Window tained, final tighten three attaching screws se­
Glass- Removal. curely (5, fig. 105).
2. Remove regulator handle (11). 5. Install access panel (8 , fig. 105) to bottom of door.
3. Remove four screws retaining regulator to door
panel and pass regulator out through door lower DOOR WINDOW GLASS
opening.
Removal
Installation NOTE: Key numbers in text refer to Figure
Install regulator following removal instructions in re­ 105.
verse order. When installation is completed, check op­
eration of window and adjust, if necessary, as outlined in 1. Remove access panel (3 ) from door inner panel below
this section. vent window.
2. Unlatch vent window catch, then swing vent outward.
3. Remove two screws (17) at edge of door which attach
OUTSIDE HANDLE AND LOCK ASSEMBLY
run channel retainer shown in Figure 106 to door
The servicing of these parts may be performed as out­ frame.
4. Disengage lug of glass run channel from slot of run
lined in this section under Conventional Body-Side Door
channel retainer as shown in Figure 106. Remove
Assembly-Door Outside Handle, except that access to the
retaining bolts must be gained by the removal of the ac­ retainer (18).
cess panel, Item 8 , Figure 105. 5. Roll window to bottom, then referring to Figure 107,
detach regulator arm from window glass lower chan­
nel by removing retainer clip which retains arm pin
LOCK STRIKER PLATE
in channel slot. Disengage arm pin from channel,
For Service of striker plate consult Doors-Adjustments then lower glass assembly out door lower opening
in this section. (fig. 108).
6. Soak glass filler along glass channel to soften filler.
DOOR REMOTE CONTROL MECHANISM Remove glass from channel when filler is sufficiently
soft.
NOTE: Door remote control mechanism con­
sists of three parts: The remote control (door Installation
inside handle unit), the connecting link, and the
door lock assembly. NOTE: Key numbers in text refer to Figure
105.
Removal
1. Thoroughly clean inside of glass channel, removing
1. Remove eight screws which attach access panel (8 ,
all rust and foreign matter.
fig. 105) to lower portion of door. Remove access
panel. 2. Cut new piece of filler to length of glass regulator
channel.
2. Mark position of handle in relation to control shaft,
3. Brush inside of glass regulator channel freely with
then remove handle and handle washer from shaft.
light engine oil.
NOTE: Handle is retained with set screw. 4. Position filler (soapstone side away from glass)
around edge of glass, centered between corners of
3. Remove three screws which attach lock assembly
glass.
(16, fig. 105) to door outer framing.
4. While supporting remote control mechanism through IMPORTANT: Before installing new glass in
access opening, remove three screws (5, fig. 105) regulator channel, make sure that the outer edge
which attach remote control shaft unit to door inner of glass having rounder corner is located so that
panel. Lower both units of mechanism from access smooth side of channel is located as shown in
opening in door. Figure 109.

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INTERIOR OF DOOR DOOR CONSTRUCTION

Fig. 105 - Door Assembly

1. Vent W indow Glass 6. W eatherstrip Seal C lip 11. Regulator Handle 16. Door Lock Mechanism
2. Division Channel and Screw 12. Division Channel Upper 17. Run Channel Retainer Screws
3. Access Panel 7. Weatherstrip Seal A ttaching Screws 18. Run Channel Retainer
4. Remote Control 8. Access Panel 13. Door W indow Sash 19. Door W indow Stop Bumper
H andle 9. Division Channel Lower 14. Sash Channel 20. W indow Regulator Assy.
5. Remote Control Attaching A ttaching Screws 15. Door Lock Remote Control 21. Division Channel Center
Screws 10. Regulator A ttaching Screws Assembly Attaching Screw

5. When installed, bottom of glass must be centered in binding exists, division channel attaching screws (9
glass regulator channel (fig. 109). P ress glass with and 2 1 ) should be loosened to allow channel to shift
filler into channel until firmly seated. for free operation of window. Retighten screws after
6 . Position glass assembly into opening at bottom of making adjustment.
door (fig. 108) and engage edges of glass in door
10. Install access panel (8 ), to opening at bottom of door.
front and rear glass run channels.
7. Engage regulator arm pin in glass channel with DOOR VENT GLASS
leather washer located each side of channel as shown
NOTE: This procedure covers replacement of
in Figure 110. Install pin fastener (View B, fig. 106).
the vent glass only.
8 . Raise window, then referring to Figure 106, engage
lug of sash run channel into slot of run channel re­ Removal
tainer. Install two screws into holes (fig. 106) at­ 1. Remove small access panel from inner side of door
taching retainer to door edge framing. below vent window. Figure 111 shows access panel
9. Raise and lower door window to check for binding. If removed.

CHEVROLET TRUCK SERVICE MANUAL

 BODY IB-51

2. At bottom of vent glass (fig. I l l ) , place hand to catch

vent friction components, then remove screw from
friction clamp. Slide clamp, friction bushing and flat
steel washer from vent shaft.
3. At top of door through small access opening (see
inset, fig. I l l ) turn vent upper pivot screw from vent
frame.
NOTE: Screw need not be removed completely,
just enough to become disengaged from vent
glass channel.
4. Remove two screws which attach division channel to
vent channel just below vent latch. Using a screw­
driver pry down on vent channel as shown in Figure
1 1 1 , which will cause upper part of channel to be­
come disengaged from pivot screw. Rotate glass
channel lower pivot shaft up out of vent channel.
5. Referring to Figure 111, which shows components of
vent assembly, remove two screws which attach
glass upper channel to glass lower channel.
6 . Apply Prep-Sol on vent glazing rubber to soften old
rubber. When rubber softens sufficiently, separate
upper and lower glass channels, then remove old
glass.
Fig. 106 - Engagement of G lass Run Channel
Installation
1. Thoroughly clean inside of glass channels to remove
old glazing rubber, rust, or other foreign matter.
2. Brush inside of channels freely with light engine oil.
3. Position new glazing rubber (soapstone side away
from glass) around edge of glass. P ress glass with
glazing rubber into lower channel then press upper
channel over top of glass. Make sure channels are
firmly seated, then install two small screws which
attach channels together.
4. If necessary, trim glazing rubber at ends of channels
and along sides of channel each side of glass.
5. If necessary, seal cracks at latch bracket.
6 . Insert pivot stud of vent lower channel into hole of
vent frame as shown in Figure 111. Through small
access hole at top of door install vent upper pivot
screw. Install two screws which attach bracket of

Fig. 107 - Replacing Regulator Arm Retainer

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BODY 1B-52

DOOR W IN D O W
A SSEM BLY

Fig. 108 - In stalling Door W indow Glass

vent channel to glass division channel just below vent

latch.
7. Install special flat washer, nylon friction bushing and
friction clamp on vent lower channel pivot shaft, po­
sitioned as shown in Figure 111. Attach friction
clamp to vent lower frame with screw. Tighten Fig. 110 - Cross Section of W indow Assembly
screw (fig. I l l ) to obtain two to four lbs. torque
while moving vent window from a ten degree'open po­
sition to a full-open position. Use either a push or 2. Pull weatherstrip from door, then scrape any rubber
pull-type spring scale positioned at rear edge of or adhesive material which may have become bonded
glass. to door surface.
8 . Install small access panel to inner side of door. 3. Apply weatherstrip adhesive as directed by manu­
facturer of adhesive. Directions for application are
DOOR WEATHERSTRIP usually found on adhesive container.
Removal and Installation
4. Position seal around perimeter of door making sure
1. Remove three screw-retained clips from weather­ corners of seal engage respective corners of door.
strip around perimeter of door. 5. Install three screw-retained clips to door and weath­
erstrip. Tighten clip screws firmly.
NOTE: Figure 112 shows view of weatherstrip
installed at retainer clip.

PIVOT SCREW ACCESS HOLE

VENT WINDOW DIVISION

ROUND C O RN ER VEN T W IN D O W G LA SS TOP RETAINING CHANNEL
SCREWS SCREW

A C C E S S H O LE
T O P IV O T S C R E W

V EN T W IN D O W O UTER
SM O O TH S ID E OF FRA M E A N D RU BBER SEA L
SH ARP CO RN ER CHANNEL T H IS S ID E
D IV IS IO N C H A N N E L
FO R R IG H T DOOR
G LA SS A SSEM BLY FRA M E S C R E W
FLAT W A S H E R
BRA CKET TO P A N E L S C R E W
CH AN N EL C EN TERED
BETW EEN CO RN ERS
N Y L O N F R IC T IO N
OF G LA SS
B U S H IN G
BR A C K E T
mm

G L A Z IN G F R IC T IO N CLA M P
C LA M P SC REW
RUBBER

Fig. 109 - Door Window G lass Assembly Fig. I l l - Door Vent Window

CHEVROLET TRUCK SERVICE M ANUAL

 BODY IB-53

Fig. 112 - Door Weatherstrip

Fig. 114 - D river's Seat Assembly

IN S T A L L IN G G L A S S IN S E A L

G LA SS-

IN SER T

SEA L

PA N EL

T Y P IC A L

IN S T A L L IN G IN S E R T IN S E A L

Fig. 113 - Insert-Type Seat Fig. 115 - D river's Seat Adjuster Assembly

CHEVROLET TRUCK SERVICE MANUAL

BODY IB - 54

REAR QUARTER & REAR END elongation of insert.

6. Cut off end of insert, allowing sufficient overlap for
REAR WINDOW AND CORNER GLASS a tight joint; then butt into groove. Cement butt
ends.
Replacement
Rear window glass (and rear corner window glass- SEATS
when used) are retained by means of rubber seal and seal
insert (fig. 113). Cement butt ends of insert. Cleaning of soft trim and service of optional level ride
1. Pry end of seal insert out of seal with a pointed tool; seat may be performed as outlined in this section under
then remove rubber insert completely. Push glass Conventional Cabs-Seats, except that access to seat in­
from inside cab. Pull seal from panel. stallation nuts may be gained by tilting cab.
2. If necessary, straighten any irregularities of seal-
flange in cab opening which may have caused break­ STANDARD SEAT
age of glass.
3. Install new rubber seal over panel flange, pushing it Figures 114 and 115 illustrate assembly and installa­
completely into corners. Avoid stretching seal dur­ tion of standard driver’s seat. Seat track removal is
ing installation. Cut seal to allow sufficient overlap considerably eased by first removing entire seat assem­
for a tight joint, then butt ends into position. bly from cab. Track-adjuster assembly should be lubri­
4. Position glass to seal and insert hook end of in­ cated whenever vehicle is lubricated.
staller Tool J-2189 (fig. 113) into seal groove. Move
tool around glass to force outer lip of seal over OPTIONAL AUXILIARY SEAT
glass.
5. Thread end of rubber insert through handle and loop The optional auxiliary seat back may be moved from in
of installer, after applying RuGlyde or sim ilar rub­ front of the engine oil access door by raising the lower
ber lubricant to rubber insert (fig. 113). Push tool right hand corner pivoting seat back on bolt located at
and end of insert into groove at bottom center of lower left hand corner. Figure 116 illustrates exploded
window. Feed in rubber insert while proceeding view of auxiliary seat with seat back in position for ac­
around window. Use a hitching movement to avoid cess to engine.

CHEVROLET TRUCK SERVICE M ANUAL

 BODY IB-55

Fig. 116 - A u x ilia ry Seat

CHEVROLET TRUCK SERVICE M ANUAL

BODY IB-56

SPECIAL TOOLS

N A

mmm .«

i l l l

Fig. 117 - Sp ecial Tools

1. J-2189—Weatherstrip Tool Set

2. J-5742-01 and J-22577—W indshield Checking Blocks (T yp ical)
3. J-22585— Front Door Hinge Bolt Wrench
4. J —9316— W indshield C hecking Blocks

CHEVROLET TRUCK SERVICE M ANUAL

 SECTION 2

FRAME
INDEX

Page Page
General Description 10-60 Series T r u c k ........................ 2-1 Frame R epair..................................................................... 2-2
Frame Alignm ent............................................................... 2-1 W e ld in g ........................................................................... 2-2
Horizontal C h e c k ............................................................ 2-2 Bolting.............................................................................. 2-2
Vertical C h e c k ............................................................... 2-2 Frame Dimensions Drawings and Charts . . . 2-3 through 2-8
General Description - Chevy V a n .................................... 2-9
Underbody Alignment......................................................... 2-10

GENERAL DESCRIPTION

Light duty 10-30 Series frames are of the ladder Vehicle Preparation
channel section riveted type. Heavy duty 40-60 Series Points to remember when preparing vehicle for frame
frames are of channel section design. checking:
1. Place vehicle on a level surface.
Figures 1 and 2 illustrate typical light and heavy duty 2. Inspect damaged areas for obvious frame misalign­
frames with crossmembers, body mounts and suspension ment to eliminate unnecessary measuring.
attaching brackets. This section also included general 3. Support vehicle so that frame sidemembers are
instructions for checking frame alignment and recom­ parallel to the ground.
mendations on frame repair. Tramming Sequence
1. Dimensions to bolts and/or holes in frame extend to
dead center of the hole or bolt.
FRAME ALIGNMENT 2. Dimensions must be within 3/16".
3. If a tram bar is used, for horizontal alignment “ X ”
Horizontal frame checking can be made with tram­ - check from opposite and alternate reference points
ming gauges applied directly to the frame or by trans­ AA, BB and CC, as illustrated by the lines in Fig­
ferring selected points of measurement from the frame ure 3. Error will result if a tram bar is not level
to the floor by means of a plum bob and using the floor and centered at the reference points.
layout for measuring. Figure 3 may be used as a gen­ 4. Obtain vertical dimensions and compare the differ­
eral guide in the selection of checking points; however, ences between these dimensions with the dimensions
selection of these points is arbitrary depending on ac­ as shown in chart.
cessibility and convenience. An important point to r e ­
member is that for each point selected on one side of the
frame, a corresponding point on the opposite side of the
frame must be used for vertical checks, opposite and
alternate sides for horizontal checks.

Fig. 1-10-30 Series Frame—Typical Fig. 2-50-60 Series Frame—Typical

CHEVROLET TRUCK SERVICE MANUAL

FRAME 2-2

FRAME CENTERLINE A

Fig. 3—Frame Horizontal C h eck in g —Typical

Horizontal Check vertical pointer length of 5-1/4 inches (a height differ­

1. Measure frame width at front and rear. If widths ence of 3 inches), the tram bar should be parallel with
correspond to specifications, draw centerline full the frame. If the area is twisted or misaligned in any
length of vehicle halfway between lines indicating way, tram bar will not be parallel. Placing the tram
front and rear widths. If frame widths are not cor­ bar vertical pointers on opposite sides of the frame
rect, layout centerline as shown in Step 4. side rail is preferable in that frame twist will show up
2. Measure distance from centerline to corresponding during this vertical check. Figures 4-8 show typical
points on each side of frame layout over entire checking points, with dimensions for various frames
length. Opposite side measurements should cor­ shown in the chart below.
respond within 3/16". Frame Repair
3. Measure diagonals marked A, B AND C. If the Welding
lengths of intersecting diagonals are equal and these Before welding up a crack in frame, a hole should be
diagonals intersect the centerline, frame area in­ drilled at the starting point of the crack to prevent
cluded between these points of measurement may be spreading. Widen and V groove crack to allow com­
considered in alignment. plete weld penetration.
4. If front or rear end of frame is damaged and width
is no longer within limits, frame centerline may be NOTE: Do not weld into corners of frame or
drawn through the intersection of any two previously along edges of side rail flanges. Welding at
drawn pairs of equal, intersecting diagonals. these points will tend to weaken the frame and
encourage new cracks.
Vertical Check Bolting
Vertical dimensions are checked with a tramming bar Wherever rivets or failed bolts are replaced, bolt hole
from indicated points on the frame (figs. 4-8). For ex­ must be as near the O.D. of the bolt as possible to pre­
ample, if the tram bar is set at point B with a vertical vent bolt from working and wearing. Drill out and line
pointer length of 8-1/4 inches, and at point E with a ream hole (or holes) to the bolt O.D.

CHEVROLET TRUCK SERVICE M ANUAL

Fig . 4 - 1 0 - 3 0 Series Truck Frame
 FRAME
2-4
Fig . 5 - 4 0 - 6 0 Single A x le Truck Frames (E x c . T ilt Cab)
 t

DIM ENSIONS TO HOLES OR SLOTS ARE MEASURED TO THE CENTER OF HOLE OR SLOT
GAUGE HOLES ARE % " DIAMETER
© IN D IC A T E S THAT THE DIM ENSIO N IS TO THE UNDERSIDE OF THE FRAME TOP SURFACE OR INSIDE
OF THE FRAME OUTER SURFACE.

NOTE: FRAME ILLUSTRATED IS TYPICAL. FRAME DESIGN

VARIES ACCORDING TO TRUCK MODEL
CHEVROLET TRUCK
SERVICE MANUAL

FRAME
2-5
Fig. 6—40-60 Series Tandem A x le Truck Frames

J
 •1

FRAME
2-6
CHEVROLET TRUCK
SERVICE MANUAL

Ficu 7 - 4 0 - 6 0 Series T ilt Cab Truck Frames

 FRAME 2-7

10-30 SERIES DIMENSIONS

Model A B C D E F G H I J K L M N O P Q R S

CA107 9-3/8 11-7/8 13-1/4 16 10-1/4 7-1/8 10 9 15-1/2 12 11-3/8 13-3/8 43 70 127-3/4 14 16-7/8 19-1/8 16-7/8
CA109 9-3/8 11-7/8 13-3/8 16 10-1/4 7-5/8 10 9 15-1/2 12 11-3/8 13-3/8 43 82 134 14 16-7/8 19-1/8 16-7/8
CA209 9-3/8 11-7/8 13-3/8 16 10-1/4 7-1/8 10 9 15-1/2 12 11-3/8 13-3/8 43 82 134 14 16-7/8 19-1/8 16-7/8
CA310 9-3/8 11-7/8 12-3/4 16 7-1/2 - 10 10 15-1/8 - 10-1/4 13-3/8 49 90-3/8 158-1/4 14 16-7/8 16-7/8 16-7/8
CA314 9-3/8 11-7/8 12-3/4 16 7-1/2 6-1/8 10 8-3/8 17-1/8 14-1/4 14-1/4 17-1/8 49 90 180-1/2 14 16-7/8 16-7/8 16-7/8
KA107 9-3/8 11-7/8 13-3/8 16 10-1/4 7-1/8 10 9 14-5/8 12 10-3/4 13-3/8 43 70 127-3/4 14 16-7/8 16-7/8 16-7/8

KA109 9-3/8 11-7/8 13-3/8 16 10-1/4 7-1/8 10 9 15-1/2 12 10-3/4 13-3/8 43 82 139-3/4 14 16-7/8 16-7/8 16-7/8
^209
PA100 9-3/8 11-7/8 13-3/8 16 10-1/4 7-1/8 10 9 15-1/2 12 10-3/4 13-3/8 43 57 114-5/8 14 16-7/8 19-1/8 16-7/8

PA209 6-1/2 8-5/8 8-1/4 10 6-3/8 6-5/8 10 8-3/4 12-1/2 7-7/8 7-7/8 10 42-5/8 89-1/8 115-1/8 16-7/8 16-7/8 16-7/8 16-7/8
309

PA213 6-1/2 8-5/8 8-1/4 10 6-3/8 6-5/8 10 8-3/4 12-1/2 7-7/8 7-7/8 10 43-3/4 110-1/8 161 16-7/8 16-7/8 16-7/8 16-7/8
313

PA215 6-1/2 8-5/8 8-1/4 10 6-3/8 6-5/8 10 8-3/4 12-1/2 7-7/8 7-7/8 10 42-5/8 122-1/8 148-1/8 16-7/8 16-7/8 16-7/8 16-7/8
315

40-60 SERIES SINGLE AXLE DIMENSIONS

Wheel­
Model A B C D E F G H I J K L M N
base

CG5, 610 15-7/8 13-1/2 20 15-3/4 15-3/4 15-3/4 20 36 82-1/4 132 147-3/4 14-5/8 16-3/4 16-3/4 125-3/8
CG5, 612 15-7/8 13-1/2 20 15-3/4 15-3/4 17 20 36 94-1/4 144-1/2 169-7/8 14-5/8 16-3/4 16-3/4 137-3/8
CG5, 614 15-7/8 13-1/2 20 15-3/4 15-3/4 17 20 36 106-1/4 156 171-3/4 14-5/8 16-3/4 16-3/4 149-3/8
CG5, 617 15-7/8 13-1/2 20 15-3/4 15-3/4 17 20 36 127-1/4 177 218-1/4 14-5/8 16-3/4 16-3/4 167-3/8
CG5, 620 15-7/8 13-1/2 20 15-3/4 15-3/4 17 20 36 146-1/4 196 280-1/4 14-5/8 16-3/4 16-3/4 189-3/8
CG5, 623 15-7/8 13-1/2 20 15-3/4 15-3/4 17 20 36 160-1/4 210 285-1/4 14-5/8 16-3/4 16-3/4 203-3/8
SE520 15-7/8 13-1/2 20 15-3/4 15-3/4 17 20 36 146-1/4 196 280-1/4 14-5/8 16-3/4 16-3/4 189-3/8
SE525 15-7/8 13-1/2 20 15-3/4 15-3/4 17 20 36 174-3/4 224-1/2 299-3/4 14-5/8 16-3/4 16-3/4 217-7/8
SE5, 628 15-7/8 13-1/2 20 15-3/4 15-3/4 17 20 36 192-1/4 257-3/4 326-1/4 14-5/8 16-3/4 16-3/4 235-3/8
SE5, 631 15-7/8 13-1/2 20 15-3/4 15-3/4 17 20 36 210-3/4 260-1/2 344-3/4 14-5/8 16-3/4 16-3/4 253-7/8
SS414 15-7/8 13-1/2 20 15-3/4 15-3/4 17 20 36 106-1/4 156 171-3/4 14-5/8 16-3/4 16-3/4 149-3/8
PS414 15-3/4 13-1/2 20 15-3/4 15-3/4 17 20 45-1/2 106-1/2 156-1/4 185-1/2 16-1/4 16-3/4 16-3/4 157
PS421 15-3/4 13-1/2 20 15-3/4 15-3/4 17 20 45-1/2 124-1/2 174-1/4 215-1/2 16-1/4 16-3/4 16-3/4 175

CHEVROLET TRUCK SERVICE M ANUAL

FRAME 2-8

40-60 SERIES TANDEM AXLE DIMENSIONS

Model A B C D E F G H I J K L M N Wheelbase

MS 5, 614 15-7/8 13-1/2 20 15-3/4 15-3/4 15-3/4 20 36 107-1/4 137-1/4 192-1/4 14-5/8 16-3/4 16-3/4 238-5/8

MS 5, 617 15-7/8 13-1/2 20 15-3/4 15-3/4 15-3/4 20 36 107-1/4 192-1/4 222-1/4 14-5/8 16-3/4 16-3/4 268-5/8

MS 5, 620 15-7/8 13-1/2 20 15-3/4 15-3/4 15-3/4 20 — 137-1/4 192-1/4 252-1/4 14-5/8 16-3/4 16-3/4 298-5/8

40-60 TILT CAB DIMENSIONS

Wheel­
Model A B C D E F G H I J K L M N O P Q R
base

TT. c
TD 14-1/2 11-3/4 13-1/8 14-1/8 16-7/8 15-3/4 20 15-3/4 17 20 15-3/8 62-1/2 112-1/4 141-1/2 33-1/2 26-3/8 16-3/4 16-3/4 97
T C 6 1 2

TT _
TD 14-1/2 11-3/4 13-1/8 14-1/8 16-7/8 15-3/4 20 15-3/4 17 20 15-3/8 74-1/2 124-1/4 156-3/8 33-1/2 26-3/8 16-3/4 16-3/4 109
™ 614
TT, ,
TD 14-1/2 11-3/4 13-1/8 14-1/8 16-7/8 15-3/4 20 15-3/4 17 20 15-3/8 98-1/2 148-1/4 177-1/2 33-1/2 26-3/8 16-3/4 16-3/4 133
TG618

TT/. c
TD ’ ’ 14-1/2 11-3/4 13-1/8 14-1/8 16-7/8 15-3/4 20 15-3/4 17 20 15-3/8 110-1/2 160-1/4 201-1/2 33-1/2 26-3/8 16-3/4 16-3/4 145
TG620

14-1/2 11-3/4 13-1/8 14-1/8 16-7/8 15-3/4 20 15-3/4 17 20 15-3/8 128-1/2 177-1/2 246-1/2 33-1/2 26-3/8 16-3/4 16-3/4 163
TG623
TT. _
TD ’ 14-1/2 11-3/4 13-1/8 14-1/8 16-7/8 15-3/4 20 15-3/4 17 20 15-3/8 140-1/2 190-1/4 257-1/2 33-1/2 26-3/8 16-3/4 16-3/4 175
TG625

CHEVROLET TRUCK SERVICE MANUAL

 FRAME 2-9

GENERAL DESCRIPTION-CHEVY VAN

The frame side rails, cross sills and outriggers are fits and also influence the suspension system, causing
part of the underbody assembly which is a welded unit suspension misalignment. It is essential, therefore, that
of the body assembly (see Section 1). underbody alignment be exact to within ± 1/16" of the
Misalignment of the underbody can affect door opening specified dimensions.

UNDERBODY ALIGNMENT
One method of determining the alignment of the under­ of the reference locations is included in the misaligned
body is with a tram gauge which should be sufficiently area; then the parallel plane between the body and the
flexible to obtain all necessary measurements up to three tram bar may not prevail. After completion of the
quarters the length of the vehicle. A good tramming tool repairs, the tram gauge should be set at the specified
is essential for analyzing and determining the extent of dimension to check the accuracy of the repair operation.
collision misalignment present in underbody construction.
EXCESSIVE BODY DAMAGE
MEASURING (Fig. 8) If damage is so extensive that key locations are not
To measure the distance accurately between any two suitable as reference points, repair operations should
reference points on the underbody, two specifications always begin with the underbody area. All other com­
are required. ponents should be aligned progressively from this area.
1. The horizontal dimension between the two points Unlike the conventional type of frame design, the unitized
to be trammed. type of body construction seldom develops the two con­
2. The vertical dimension from the datum line to the ditions of “twist” and “ diamond” in the underbody area
points to be trammed. as a result of front or rear end collisions, therefore,
The tram bar should be on a parallel to that of the there usually is an undamaged area suitable as a begin­
body plane. The exception to this would be when one ning reference point.

CHEVROLET TRUCK SERVICE MANUAL

 FRAME
2-10
CHEVROLET TRUCK
SERVICE MANUAL

Fig. 8 —Underbody Reference Points and Dimensions—C h e vy Van G10 and 20

# ¥
 SECTION 3
FRONT SUSPENSION
CONTENTS OF THIS SECTION
Page
Front Suspension ............................................................... 3-1
Four-Wheel D r i v e ............................................................... 3-24

FRONT SUSPENSION
INDEX
Page Page
General Description............................................................ 3-2 Installation ...................................................... .....3-12
Maintenance and Adjustments............................................. 3-4 Steering Knuckle/Steering A r m .............................. .....3-13
Wheel Bearings - A dju st................................................ 3-4 R e m o v a l............................................................ .....3-13
10 Series and Chevy V a n ..................... .................... 3-4 Installation......................................................... .....3-13
20-30 Series, I-Beam 40-60 S e r i e s ........................ 3-4 Crossmember and Suspension U n it ........................ .....3-13
I-Beam P20-30 S e r i e s ............................................. 3-4 R e m o v a l............................................................ .....3-13
I-Beam S59-T50-60 S e r i e s ....................................... 3-4 Installation ...................................................... .....3-14
Steering Stop Screw - Adjust ....................................... 3-4 I-Beam Suspension A s s e m b ly .................................... .....3-14
Front End Alignment ................................................... 3-4 Stabilizer - P20-30 ................................................ .....3-14
C a s te r......................................................................... 3-5 R e m o v a l............................................................ .....3-14
C a m b e r ..................................................................... 3-5 Installation ...................................................... .....3-14
Toe-In ..................................................................... 3-5 Chevy Van - Stabilizer - G10-20 ........................ .....3-14
Cornering Wheel R elatio n sh ip ................................. 3-7 R e m o v a l............................................................ .....3-14
Steering Axis or Kingpin Inclin ation........................ 3-7 Installation......................................................... .....3-14
Component Parts R eplacem ent.......................................... 3-8 Shock Absorbers ................................................... .....3-14
Wheel Hubs, Bearings, Drums .................................... 3-8 Spring .................................................................. .....3-15
Removal .................................................................. 3-8 G-K10 and 20 S e r ie s .......................................... .....3-15
Inspection.................................................................. 3-8 Rem oval......................................................... .....3-15
R e p a i r s ..................................................................... 3-8 Inspection............... ,...................................... .....3-15
Bearing Cups - R e p la c e ....................................... 3-8 R e p a i r s ......................................................... .....3-15
Wheel Hub and Brake D r u m ................................. 3-8 Bushing Replacement.................................... .....3-15
CP10 - Chevy V a n .......................................... 3-8 Shackle Replacem ent.................................... .....3-16
CP20-30 ......................................................... 3-8 Spring Leaf Replacem ent.............................. .....3-16
CLS40, C D L S T 5 0 ............................................. 3-8 Installation......................................................... .....3-16
T60, and SE 531................................................ 3-9 P20-30 .................................................................. .....3-16
In sta llatio n ............................................................... 3-9 R e m o v a l............................................................ .....3-16
Shock A b s o r b e r s ............................................................ 3-9 Repairs ............................................................ .....3-17
R em oval..................................................................... 3-9 Front Bushing ............................................. .....3-17
In sta llatio n ............................................................... 3-9 Rear B u s h in g ................................................ .....3-17
Coil Spring Suspension A s s e m b ly ................................. 3-9 Spring L e a f ................................................... .....3-17
Stabilizer - P 1 0 ......................................................... 3-9 Installation......................................................... .....3-17
R e m o v a l............................................................... 3-9 40-60 Series ......................................................... .....3-17
In sp ectio n ............................................................ 3-9 R e m o v a l............................................................ .....3-17
Installation............................................................ 3-10 R e p a irs ............................................................... .....3-18
Springs C-P10-C20 and 3 0 ....................................... 3-10 B u s h in g ......................................................... .....3-18
R e m o v a l............................................................... 3-10 Spring L e a f ................................................... .....3-18
Installation ......................................................... 3-10 Installation......................................................... .....3-18
Ball Joint In sp ectio n ................................................ 3-10 Steering K n u c k le ......................................................... .....3-19
Upper .................................................................. 3-10 Removal ............................................................... .....3-19
L o w e r .................................................................. 3-11 Inspection ............................................................... .....3-19
Lower Control Arm A s s e m b ly ................................. 3-11 R e p a i r s .................................................................. .....3-19
R e m o v a l............................................................... 3-11 Kingpin ............................................................ .....3-19
Repairs ............................................................... 3-11 B u s h in g s ............................................................ .....3-19
B u s h in g s ......................................................... 3-11 In s ta lla tio n ............................................................ .....3-19
Ball J o i n t s ...................................................... 3-11 I - B e a m ........................................................................ .....3-21
Installation ......................................................... 3-11 R em o val.................................................................. .....3-21
Upper Control Arm A s s e m b ly ................................. 3-12 R e p a i r s .................................................................. .....3-21
R e m o v a l............................................................... 3-12 Steering Knuckle and K in g p in ........................... .....3-21
Repairs ............................................................... 3-12 Axle Center ...................................................... .....3-21
B u s h in g s ......................................................... 3-12 In s ta lla tio n ............................................................ .....3-22
Ball J o in t......................................................... 3-12 Special T o o l s ............................................................... 1 3-22

CHEVROLET TRUCK SERVICE M ANUAL

FRONT SUSPENSION 3-2

GENERAL DESCRIPTION

UPPER
CONTROL ARM

FRONT HUB
AND BRAKE
DRUM

LOWER CONTROL ARM

F ig . 1 - Independent Front Suspension

The Chevrolet Truck line incorporates two different crossmem ber with U-bolts. These control arms are
types of front suspension systems: Independent coil, and connected to the steering knuckle through pivoting ball
I-Beam axle with conventional leaf or tapered leaf joints. A coil spring is located between the lower control
springs (figs. 1, 2, 3). arm and a formed seat in the suspension crossmember,
The unequal length control arm coil spring independent thus the lower control arm is the load carrying member.
suspension is used on the forward control P-10 series The double acting shock absorbers are also attached to
and on conventional C -10-20-30 series (1/2, 3/4, and the lower control arms and connect with the frame to the
1-ton). This suspension consists of upper and lower con­ rear on the upper end. The forward control P-10 series
trol arms pivoting on steel threaded bushings on upper is equipped with a stabilizer bar connected to the lower
and lower control arm shafts which are attached to the control arm and transversely mounted to the frame side

SHOCK ABSORBER

SHACKLE

STABILIZER SPRING ASSY.

FRONT HANGAR
0
F ig . 2 - I-Beam Suspension P20-P30 F ig . 3 - I-Beam Suspension 4 0 , 50 and 60 Series

CHEVROLET TRUCK SERVICE MANUAL

 FRONT SUSPENSION 3-3

members. The front wheel bearings are tapered roller mounted stabilizer bar connected to the spring seat on the
type on the above models. axle, and ball front wheel bearings.
The I-Beam axles used on all 40-60 Series are of the The Chevy Van front suspension (fig. 4) incorporates
conventional reverse Elliott type, with solid kingpins and the ”I-Beam " type front axle; tapered leaf springs; and
delrin bushed steering knuckles. The springs are direct-acting hydraulic shock absorbers.
Chevrolet Vari-Rate, bushed at the front eye only and The "I-Beam " axle is of the conventional reverse
mounted to a rigid hanger. The rear end of the spring Elliott type, with spring and steering stop screw seats
rides in a special hanger designed to provide a relatively forged integral with the "I-Beam ". Constant diameter,
low spring rate at curb loads with increased rate at solid kingpins are used with the full-floating, "Delrin,"
higher loads. steering knuckle bushing. Front wheel spindles are cast
Front wheel bearings are tapered roller type on all integral with the steering knuckles; front wheel bearings
models. are tapered roller type.
Forward Control P20-30 I-beams incorporate conven­ The front spring assembly incorporates the berlin-type
tionally mounted sem i-elliptic springs, with a transverse spring eyes. The front eye is single-wrapped and has a

F ig . 4 - Front Suspension - C hevy Van

CHEVROLET TRUCK SERVICE M ANUAL

FRONT SUSPENSION 3-4

rubber insulated steel bushing through which the spring acting hydraulic shock absorbers.
is bolted to the spring front hanger. The rear eye is Service operation may be found at the back of this sec­
shackle mounted through rubber bushings to the spring tion. Front axle differential will be found in Section 3
rear hanger. Truck Overhaul. The adapter and transfer case are cov­
The K series "Four-Wheel Drive" vehicles incorporate ered in Section 7 Truck Overhaul.
a driving front axle, tapered leaf springs, and direct-

MAINTENANCE AND ADJUSTMENTS

WHEEL BEARINGS—ADJUST NOTE: At all times nut should be backed off
no more than 1 / 6 turn.
10 Series and Chevy Van
4. Install wheel and tire assembly and dust cap. Lower
1. Jack up front end of vehicle and remove wheel and
vehicle.
tire assembly. Remove dust cap from end of hub and
withdraw spindle cotter pin.
2. Tighten adjusting nut to 15 lb. ft. while rotating hub
I Beam—Series (S59, T50 and T60)
in both directions.
1. Follow Step 1 as outlined for 10 Series.
3. Back off nut one flat (1/6 turn) and insert new cotter
2. Tighten adjusting nut to 60 lb. ft. while rotating hub
pin. If nut and spindle hole do not line up, back off
in both directions.
slightly (1/6 turn) to align cotter pin. This adjust­
3. Back off nut 1/3 turn and install new cotter pin. If
ment provides for .000" to .007" bearing end
spindle hole does not line up, tighten nut until align­
clearance.
ment is obtained. This adjustment should result in
4. Spin hub to make sure it turns freely. Lock cotter
bearing end play of . 0 0 1 " to . 0 1 0 ".
pin by spreading the end and bending it around spin­
4. Spin drum to make sure it rolls freely. Lock cotter
dle. Install dust cap, and wheel and tire assembly.
pin by spreading the end and bending it around spin­
Lower vehicle.
dle. Install hub plate or cap, wheel and tire assem­
20-30 Series, I Beam 40-60 Series bly, and lower vehicle.
(Except SE531, T50 and T60)
Steering Stop Screw—Adjust
1. Follow Step 1 as outlined for 10 Series. (I Beam Only)
2. Tighten adjusting nut to 40 lb. ft. while rotating wheel
in both directions. Steering stop screws should be periodically checked and
3. Back off nut 1/3 turn and install new cotter pin. If adjusted to stop against the pads forged into the axle.
spindle hole does not line up, tighten nut until align­ Proper adjustment will prevent excessive shock loads on
ment is obtained. This adjustment should result in steering gear and also prevent steering worm shaft and
bearing end play of . 0 0 1 " to . 0 1 0 ". nut from bottoming on housing end cover. Place each
4. Spin hub to make sure it turns freely. Lock cotter front wheel on an alignment machine and adjust stop
pin by spreading the end and bending it around spin­ screw s, as shown in Figure 6 to the following dimensions:
dle. Install dust cap and wheel and tire assembly. All except Chevy Van
Lower vehicle. and P30 - 38-1/2° ± 1/2° both sides
P30 - 37° ± 1/2° left turn
I Beam—P20-30 Series - 32-1/2° ± 1/2° right turn
Chevy Van - 35-1/2° ± 1/2° both sides
1. Follow Step 1 as outlined for 10 Series.
If after adjustment tires have less than 5/8" clearance
2. Tighten adjusting nut to 33 lb. ft. while rotating wheel
from any chassis obstruction, turn stop screws to obtain
in both directions.
this clearance.
3. a. If at this point a slot in nut lines up with either of
two holes in spindle (fig. 5), back off nut 1/6 turn
Front End Alignment
until the next slot lines up with the next hole and
insert cotter pin (fig. 5).
Correct alignment of the front suspension must be
b. If at this point there is no alignment between slots
maintained to insure efficient steering and satisfactory
in nut and spindle holes (fig. 5), back off until slot
tire life. Check alignment at regular intervals and par­
lines up with the nearest hole in the spindle and
ticularly after front suspension has been subjected to
insert new cotter pin.
extremely heavy service or severe impact loads.
Before checking and adjusting alignment, such compo­
nents as wheel bearings, spring height, tie rods, steering
gear, kingpin bushings, shock absorbers and tire inflation
should be inspected and corrected where necessary.

Caster and Camber—Figure 7

Positive caster is the amount in degrees of the back­
ward tilt of the kingpin. Positive camber is the amount
F ig . 5 - Wheel Bearing Adjustment - P20-30 in degrees that the front wheels are tilted outward at the

CHEVROLET TRUCK SERVICE MANUAL

 FRONT SUSPENSION 3-5

2. Check caster angle on alignment machine.

3. Add angle "B " and caster angle to determine frame
corrected angle.
4. Measure dimension "A."
5. Using dimension MA" and the caster-cam ber chart
for the appropriate vehicle, shown below, find the
recommended caster angle.
6 . The frame corrected angle, Step 3 above, should cor­
respond to the recommended angle on the chart with­
in ± 1/2°. Make changes as necessary to bring
caster angle within limits.

Camber
1. Determine vehicle camber angle on alignment
machine.
2. Measure dimension "A."
3. Using dimension "A" and the caster-cam ber chart
for the appropriate vehicle, shown below, find the
recommended camber angle.
4. If the angle in Step 1 does not correspond to the rec­
ommended angle on the chart within ± 1 / 2 °, make
Fig . 6 - Stop Screw Adjustment necessary changes.
Shims may be changed at either front or rear to vary
top from a vertical position. Both angle adjustments are caster, or at both points equally to vary camber (fig. 1 0 ).
necessary for steering stability and safe vehicle handling.
I Beam Axle Models
Coil Spring Models On I beam axles, if camber angle does not fall within
On 10-30 Series coil spring models, caster and camber specified lim its, the axle center or steering knuckle is
adjustments are made by means of shims located betweer bent; if the axle center is bent, refer to Front Axle Re­
the upper control arm shaft and the mounting bracket at pair later in this section; if the steering knuckle is dam­
tached to the suspension crossmember. aged, replace as outlined under Steering Knuckle/Steering
A series of concave and convex spacers with flat oppo­ Arm later in this section. Caster angle is adjusted by
site sides are used. These spherical spacers allow a the use of tapered shims placed between the axle spring
positive cross-shaft-to-bracket attachment regardless of seat and spring. To increase caster, place thick end of
the number of caster/cam ber shims used. shim toward rear of vehicle; to decrease caster, place
Measure 10-30 Series caster and camber as follows thick end of shim toward front of vehicle.
(refer to Figure 8 ):
Toe-In
Caster
1. Measure frame angle ’B" at location shown in Fig- Toe-in is the amount in fractions of an inch that wheels
ure 8 . are closer together in front than at rear. Check steering

F ig . 7 Front End Alignment

CHEVROLET TRUCK SERVICE M ANUAL

FRONT SUSPENSION 3-6

Fig . 8 - Caster-Cam ber Adjustment - 10-30 Series

Fig. 11 - Caster Shims - I-Beam

-4 -3 -2 -1 0 +1 +2 +3 +4 +5 +6 +7 +8

CASTER AND CAMBER DEGREES

Fig . 9 - Caster-Cam ber Chart - 10-30 Series

Fig. 12 - Tilting Tie Rod Sockets

gear high point adjustment and place wheels in straight

ahead position before checking toe-in. Adjustments are
made by loosening clamp bolts at each end of tie rod,
then turning tie rod tube until wheels have proper toe-in.
Tighten clamp bolts securely after proper adjustment is
F ig . 10 - Caster-Cam ber Shims - 10-30 Series made. After toe-in adjustment on 4000, 5000 and 7000

CHEVROLET TRUCK SERVICE MANUAL

 FRONT SUSPENSION 3-7

lb. axles, tie rod sockets should both be tilted in the same later in this section.
direction, forward or rearward, before tightening clamp
bolts (fig. 1 2 ). Steering Axis or Kingpin Inclination

Cornering Wheel Relationship Steering axis or kingpin inclination is the tilt of the
steering knuckle kingpin. If the inclination is not within
Cornering wheel relationship, or toe-out on turns is the specified lim its, the steering knuckle is bent and must
determined by the angle of the steering arms. If, when be replaced on IFS models; on I beam axle models, the
checking this angle, toe-out does not fall within specified axle center is bent and must be repaired as outlined un­
lim its, it will be necessary to replace defective steering der Front Axle Repair later in this section.
arm as outlined under Steering Knuckle/Steering Arm

F ig . 13 - Wheel Hubs and Bearings

CHEVROLET TRUCK SERVICE M ANUAL

FRONT SUSPENSION 3-8

COMPONENT PARTS REPLACEMENT

Wheel Hubs, Bearings, Drums 3. Place brake drum and a new gasket over hub bolts
when installing hub to wheel spindle.
Removal
1. Jack up front end of vehicle and remove wheel and C P 2 0 -30—Figure 13
tire assembly. Remove dust cap from end of hub and 1. Remove two flat head screws securing drum to wheel
withdraw cotter pin. hub and remove drum and gasket. Discard gasket.
2. Remove hub and drum assembly. 2. If necessary to replace hub bolts, press bolts out of
hub and remove deflector and deflector gasket.
NOTE: In some cases it may be necessary to 3. Place new deflector gasket on hub and on P series
back off the brake adjustment because of scored align drain holes. Position deflector so that flared
drums or badly worn linings holding drum on. portion registers with drain hole in gasket and hub.
4. P ress new bolts into hub (fig. 16).
3. Remove outer bearing from hub. The inner bearing 5. Place brake drum on hub, indexing drain holes and
will remain in the hub and may be removed by prying retain with the two flat head screws.
out the inner grease seal.
4. Wash all parts in cleaning solvent. CLS40, CDLST50 (except S E 5 3 1 ) —Figure 13
1. Remove brake drum-to-hub bolts and lockwashers.
Inspection Separate deflector, gasket and brake drum from hub.
1. Check all bearings for cracked bearing cages, worn 2. If necessary to replace hub bolts, press out old bolts
or pitted balls or rollers. and press in new serrated bolts, making sure head is
2. Check bearing races for cracks or scoring, check
brake drums for out-of-round or scored condition
and check bearing outer races for looseness in hubs.

Repairs

Replacem ent of Bearing Cups

1. Using steel bar stock 3 /8" x 3 /8 " in cross section,
make press-out tools shown in Figure 14.
2. Place appropriate tool behind bearing cup, indexing
tool in provided notches, and press out cup with
arbor press.
3. Install inner and outer cups using driver handle
J-8092 ( J - 7079-2 on Chevy Van) (fig. 15) and suitable
cup installers for different vehicle series as listed
in Special Tools illustration, Figure 47.

Wheel Hub and Brake Drum

CP 10 and C h evy V an —Figure 13
1. Brake drum is retained to hub by hub bolts and wheel
nuts. Remove drum and discard gasket.
2. If necessary to replace hub bolts, press out old bolts
and press new bolts in making sure bolt heads seat
squarely on hub flange (fig. 16).

F ig . 1 4 - Wheel Hub Bearing Cup Removal F ig . 1 5 - Installing Bearing Cup (Typ ica l)

CHEVROLET TRUCK SERVICE M ANUAL

 FRONT SUSPENSION 3-9

Fig. 17 - Shock Absorber Location - CP10, C20-30

Installation
Place shock absorber into position over mounting bolts
or into mounting brackets. Install eye bolts and nuts and
Fig . 1 6 - Pressing Hub Bolt torque as shown in Specifications, Section 15.

square with hub flange and securely seated. COIL SPRING SUSPENSION ASSEMBLY
3. Place drum, deflector gasket and deflector over hub,
indexing drain holes with holes in hub. Install drum Front Stabilizer Bar—P-10 Figure 18
to hub bolts and lockwashers and tighten securely.
Removal
T60 and SE531 —Figure 13 1. Raise vehicle and remove nuts and bolts attaching
1. Brake drum is either bolted or screwed to hub de­ stabilizer brackets and bushings at frame location.
pending on type of wheel used. In either case, re­ 2. Remove brackets and bushings at lower control arms
move screws or bolts and separate hub and drum. and remove stabilizer from vehicle.
2. If necessary to replace hub bolts, press out old bolts
and press new serrated bolts into position, making Inspection
sure bolt head is square with hub flange and securely Inspect rubber bushings for excessive wear or aging -
seated. Install bolts or screws into hub and tighten replace where necessary. Use rubber lubricant when
securely. installing bushings over stabilizer bar.

Installation
1. Pack inner and outer wheel bearings with recom­
mended grease (see Section 0).
2. Place inner bearing in hub and install new seal as­
sembly (or assem blies), tapping into place with soft
hammer.
3. Position hub on spindle and install outer bearing,
pressing it firmly into position in hub.
4. Adjust wheel bearings as outlined under Wheel Bear­
ings-Adjust.

Shock Absorbers—Figure 17

Removal
1. Remove nuts and eye bolts securing upper and lower
shock absorber eyes.

NOTE: Remove burr formed by lockwashers

on control arm and on frame.

2. Withdraw shock absorber and inspect rubber eye

bushings. If defective, replace shock absorber
assembly.

CHEVROLET TRUCK SERVICE MANUAL

FRONT SUSPENSION 3-10

Installation b. Loosen upper ball stud in steering knuckle, using

1. Place stabilizer in position on frame and install Tool J-8806 positioned as shown in Figure 19.
frame brackets over bushings. Install nuts and bolts Remove the nut from the ball stud.
loosely. c. Swing the upper control arm up and away from the
2. Install brackets over bushings at lower control arm steering knuckle, supporting the arm in a raised
location. Be sure brackets are positioned properly position using an approximately 4" thick wood
over bushings. Tighten all nuts and bolts securely. block placed on top of the suspension cross­
member.
Springs d. Lift the knuckle off the lower ball stud, tilting the
assembly as necessary to permit the brake back­
Removal ing plate to clear the end of the lower control
1. Raise front of vehicle and place jack stands under arm. Lift the knuckle assembly and suspend it
frame, allowing control arms to hang free. from the upper control arm by loosely installing
2. Position floor jack under lower control arm at spring the ball stud nut.
pad location. Raise control arm until the coil spring e. Remove the front spring from the vehicle by
is compressed. slowly lowering the floor jack that is positioned
3. Remove wheel and tire assembly. Disconnect shock under the lower control arm.
absorber at lower end.
4. Remove cotter pin from lower ball stud and loosen Installation
stud nut until top of nut is slightly above top of the 1. Position a floor jack under the lower control arm
stud. spring pad and properly locate the spring in its seat
5. Install Ball Stud Remover J-8806 (fig. 19), position­ on the lower arm, then slowly raise the jack while
ing large cup end of the tool over the upper ball stud carefully guiding the spring into its upper seat, con­
nut and piloting the threaded end of tool on end of the tinue to compress the spring until the ball joints and
lower ball stud. Extend bolt from J-8806 tool to shock absorbers can be reconnected. Torque lower
loosen lower ball stud in steering knuckle. When the ball joint attaching nut on CP10 models 120 lb. ft. and
stud is loosened remove the tool and then remove nut 215 lb. ft. on C20-30 models. On C20-30, torque
from the lower stud. upper ball joint attaching nut to 1 2 0 lb. ft.

NOTE: If a fairly heavy torque on the tool bolt Ball Joint—Inspection

does not break the lower ball joint loose from
the steering knuckle then, with the tool still in­ Uppeir
stalled, rap the steering knuckle boss sharply 1. Raise vehicle and support on frame to allow control
with a hammer to shock the stud loose. arms to hang free. Remove wheel and tire assembly.
2. Support lower control arm with adjustable jackstand
6. ON MODEL CP10 ONLY - Remove the front spring and disconnect upper ball stud from steering knuckle.
from the vehicle by slowly lowering the floor jack 3. Reinstall nut on ball stud and measure torque re­
that is positioned under the lower control arm. quired to rotate stud with torque wrench. Limits are
7. ON MODELS C20 AND C30 ONLY - 5-10 lb. ft. If torque is not within these lim its, re­
a. Remove cotter pin from upper control arm ball place ball joint.
stud and loosen stud nut until bottom surface of
nut is slightly below end of stud.

Back Nut Up To
End of Threads I

F ig . 1 9 - Loosening Lower Ball Jo in t Stud F ig . 20 - Checking Lower Ball Jo in t (Typ ica l)

CHEVROLET TRUCK SERVICE MANUAL

 FRONT SUSPENSION 3-11

4. If ball joint inspection shows no defect, assemble

upper stud to steering knuckle and torque 70 lb. ft.
on CP10 models, 120 lb. ft. on C20-30 models.

Lower
Lower ball joints are a loose fit when not connected to
the steering knuckle. Wear may be checked without dis­
assembling the ball stud, as follows:
1. Support weight of control arms at wheel hub and
drum.
2. Measure distance between tip of ball stud and tip of
grease fitting below ball joint (fig. 2 0 ).
3. Move support to control arm to allow wheel hub and
drum to hang free. Measure distance as in Step 2.
If the difference in measurements exceeds .094"
(3/32") for all models, ball joint is worn and should
be replaced.

Lower Control Arm Assembly

Removal
1. Raise vehicle and remove spring as outlined under
Spring-Removal.
2. Disconnect control arm from crossmember by re­
moving four nuts securing cross-shaft.

Repairs
Fig. 22 - Positioning Lower Control Arm Shaft
Bushings
1. Remove grease fittings from bushing outer ends and 2. Place control arm over remover support and, with
unscrew bushings from control arm and shaft appropriate remover, press out ball joint (fig. 24).
(fig. 2 1 ). 3. Invert arm and place on installer support at ball
2. Slide new seal on each end of shaft and insert shaft joint area.
into control arm. 4. P ress new ball joint assembly into arm. If press
3. Start new bushings on shaft and into control arm. ram diameter is large enough to cover OD of ball
Adjust shaft until it is centered in control arm, then joint assembly, press joint into arm with ram in di­
turn bushings in and torque to specifications. Figure rect contact. If ram is sm aller, use metal tube or
22 shows correct final positioning of shaft. Check block (fig. 25). Make sure ball joint assembly is
shaft for free rotation and install grease fittings. fully seated and square with arm.

B all Joint Installation

1. Using heavy wall steel tubing or pipe, make re­ 1. Place control arm assembly into position in both tub
m over/installer tools to the dimensions shown in type brackets located on the crossmember. A spe-
Figure 23.

17
2"

h-------27/ . " -
,1
INSTALLER SUPPORT CP 10, C20-30 REMOVER C20-30

ITl %"
,1
I----- 2 V *" -----H
I-1 Vi"-J
REMOVER SUPPORT CP10, C20-30 REMOVER CP10

REMOVER—INSTALLER TOOLS

F ig . 21 - Removing Control Arm Bushing F ig . 23 - Ball Jo in t Tools

CHEVROLET TRUCK SERVICE M ANUAL

FRONT SUSPENSION 3-12

NOTE: Tape shims and spherical spacers to­

gether and tag for proper relocation when con­
trol arm is reinstalled.

Repairs

Bushings
1. Remove grease fittings from ends of bushings and
unscrew bushings from shaft and control arm. Re­
move shaft and seals.
2. Slide new seal on each end of shaft and insert shaft
into control arm.
3. Start new bushings on shaft and into control arm.
Adjust shaft until it is centered in control arm, then
turn bushings in and torque 160 lb. ft. for CP10,
190 lb. ft. for C20-30 if spacer is used, 95 lb. ft. for
CP10, 135 lb. ft. for C20-30 if no spacer is used.
Check shaft for free rotation. Figure 26 shows cor­
rect final positioning of shaft.

B all Joint
1. Center punch rivet heads and drill out rivets. Rivets
F ig . 24 - Removing Lower Ball Jo in t may also be chiseled or ground off.
2. Remove ball joint assembly and inspect arm for
cracks or distortion at the ball joint seat.
3. Install service ball joint assembly in arm using spe­
cial hardened bolts only, torquing bolts 45 lb. ft.

Installation
1. Place control arm in position on bracket and install
nuts. Before tightening nuts, insert caster and cam­
ber shims in the same order as when removed.
Tighten nuts 80 lb. ft. for CP10 models, 155 lb. ft.
for C20-30 models.
2. Insert ball joint stud into steering knuckle and install
nut. Tighten stud nut 70 lb. ft. on CP10 models,
120 lb. ft. on C20-30 models.
3. Remove spring compressor J-6874 if used, and re­
move adjustable support from under control arm.
Install wheel and tire assembly.

Fig . 25 - Installing Lower Ball Jo in t

cially designed rivet in the forward position has a

head on the bottom side which serves as a guide pin
to locate the pivot shaft in proper position. Install
U bolts and torque 40 lb. ft. on CP10 Series, 110
lb. ft. on C20-30 Series.
2. Install spring and steering knuckle as outlined under
Sp ring- Installation.

Upper Control Arm Assembly

Removal
1. Raise vehicle, remove wheel and tire assembly and
support lower control arm assembly with adjustable
jackstand.
2. Disconnect upper ball joint stud and raise upper arm
to clear steering knuckle.
NOTE: At this point or after Step 1, compres­
sor J-6874 may be installed to safely retain
spring.
3. Remove nuts securing control arm shaft studs to
crossmember bracket. Withdraw control arm
assembly. F ig . 26 - Positioning Upper Control Arm Shaft

CHEVROLET TRUCK SERVICE M ANUAL

 FRONT SUSPENSION 3-13

4. Lower vehicle and check front end alignment and 4. Place steering arm in position on back of steering
adjust where necessary. knuckle and insert two bolts through backing plate,
steering knuckle and steering arm. Install lock nuts
Steering Knuckle/Steering Arm and tighten 80 lb. ft. CP10, 105 lb. ft. C20-30.
5. Torque brake anchor pin to 65 ft. lbs.
NOTE: It is recommended that vehicle be 6 . Install brake shoes, brake shoe hold-down clips and
raised and supported on a twin-post hoist so that return springs.
the front coil spring remains compressed, yet 7. Install wheel hub, brake drum, wheel and tire assem­
the wheel and steering knuckle assembly remain bly over spindle.
accessible. If a frame hoist is used, support 8 . Insert outer wheel bearing race and roller assembly,
lower control arm with an adjustable jackstand washer and nut. Adjust front wheel bearing as shown
to safely retain spring in its curb height under Maintenance and Adjustments in this section.
position. Install new cotter pin, dust cap and hub cap.
9. Lower vehicle, recheck and readjust wheel alignment
Removal where necessary.
1. Raise vehicle and support lower control arm as noted
above. Crossmember and Suspension Unit— Figure 27
2. Remove hub cap, wheel hub dust cover, cotter pin ad­
justing nut and washer, withdraw wheel and tire, Component parts of the front suspension may be serv­
brake drum, and wheel hub and bearing assembly iced separately as outlined in the preceding service op­
from steering knuckle spindle. erations. However, if extensive service is to be per­
3. Disengage brake shoe return springs and remove formed to crossmember, frame, etc., the unit can be
brake shoe hold-down clips. Remove brake shoes removed and installed as follows:
from backing plate.
Removal
CAUTION: Keep brake shoes clean and dry. 1. Remove front springs as outlined under Spring-
Removal.
4. Remove brake anchor pin and two bolts securing 2. Support engine and remove front engine mount center
brake backing plate and steering arm to steering bolt.
knuckle. 3. Separate main brake feeder line from crossmember
5. Withdraw steering arm and brake backing plate from tee.
steering knuckle. Wire backing plate to frame. Do 4. Remove bolts retaining crossmember hangers to
not disconnect brake line. frame side rails.
5. Remove bolts securing crossmember to frame side
NOTE: Refer to Section 9-Steering, for further rail lower flange and lower the assembly from
steering arm service operations. vehicle.

6 . Remove upper and lower ball stud cotter pins and

remove ball stud nuts. Free steering knuckle from
ball studs by rapping steering knuckle bosses. With­
draw steering knuckle.

Installation
1. Place steering knuckle in position and insert upper
and lower ball studs into knuckle bosses.
2. Install ball stud nuts and tighten as follows: Upper
nuts 70 lb. ft. CP10, 120 lb. ft. C20-30; lower nuts
120 lb. ft. CP10, 215 lb. ft. C20-30.
3. Place brake backing plate and wheel cylinder in posi­
tion on steering knuckle and insert anchor pin.

F ig . 27 - Suspension Crossmember F ig . 28 - P20-30 Sta b ilize r

CHEVROLET TRUCK SERVICE M ANUAL

FRONT SUSPENSION 3-14

Installation Stabilizer—Chevy Van (Figure 29)

1. Jack crossmember into position under frame and
install frame side rail lower flange mounting bolts. Removal
2. Install bolts securing crossmember hanger to frame 1. Raise vehicle and remove radiator air deflector.
and torque nuts 70 lb. ft. on 10 Series, 95 lb. ft. on (See Section 11.)
20-30 Series. 2. Disconnect link bolt by removing upper nut. With­
3. Position engine on front mount and install mounting draw upper grommet retainer and grommet and slide
bolt and torque 45 lb. ft. link bolt, remaining grommets, spacer and retainers
4. Install springs as outlined under Spring-Installation. out of bracket. Repeat for other link bolt.
5. Connect front brake main feeder line and bleed 3. Remove side rail brackets and stabilizer bar from
brakes as described in Section 5. side rails.
6 . Check and Adjust front end alignment as outlined
under "Maintenance and Adjustments" in this section. Inspection
Inspect rubber grommets and side rail bushings for ex­
I Beam Suspension Assembly cessive wear or ageing and replace where necessary.
Use rubber lubricant, if necessary, to facilitate installa­
Stabilizer—P20-30 (Figure 28) tion of bushing over bar.

Removal Installation
1. Disconnect the stabilizer link bolts by removing the 1. Place stabilizer in position on side rail and install
nut from the top of the link bolt and pulling the bolt side rail brackets. Leave bolts loose until final
out from the lower bracket attached to the control tightening.
arm. 2. Install link bolts, spacers, and grommets to stabi­
2. Remove the bolts that attach the stabilizer brackets lizer as shown on Figure 29.
to the frame crossmember and remove bar and 3. Tighten link bolt nuts until threads bottom out.
brackets. 4. Install radiator air deflector. (See Section 11.)

Installation Shock Absorbers

1. Place rubber bushing on stabilizer bar and install
support brackets over bushings, then put brackets Shock absorbers are bolt retained at both the upper and
loosely to frame crossmember. the lower attaching points. Lower attachment is made at
2. The stabilizer link bolt, bushing and retainers may one of several general points; such as spring seat, spring
be assembled by placing one steel retainer and one
rubber bushing on the link bolt and threading the bolt
up through the bracket on the spring.
3. Assemble rubber bushing, retainer, steel spacer re­
tainer and rubber bushing over bolt and thread bolt
through eye on stabilizer bar.
4. Install rubber bushing and retainer over bolt and in­
stall nut tightening it to limit of bolt threads.
5. With wheels of truck on floor and supporting truck
weight, bounce front end up and down several times.
6 . Tighten mounting bracket 25 lb. ft.

F ig . 29 - Front S ta b ilize r - C hevy Van F ig . 30 - Shock Absorber Location (P20-30)

CHEVROLET TRUCK SERVICE M ANUAL

 FRONT SUSPENSION 3-15

spacer axle bracket or at the lower control arm. Upper

attachment is to the frame side rail by a through bolt ar­
rangement on to a special frame mounted bracket. Refer
to Figures 30, 31, 32 or 33 for specific mounting details.
Series G10 and G20 mounting details are shown in
Figure 4.

Spring

G-K 10 and 20 Series

Removal
1. Raise vehicle and place stand jacks under frame side
rails. Support axle so that tension and compression
are relieved in spring.
2. Remove spring-to-axle "U" bolts.
3. Remove spring front and rear eye bolts and withdraw
spring from vehicle.

Inspection
Inspect bushings for excessive wear, check spring
leaves for breaks and inspect spring clips for tightness.

Repairs

Bushing Replacem ent

1. Insert Tool J-21058-15 with J-22620-2 through eye of
bushing. Center Tool J - 21058-6 with J - 21058-7 over
threaded end and screw on Tool J - 21058-8. By
tightening nut J - 21058-8 withdraw bushing from eye
(fig. 34).
2. Place Tool J-21058-15 with J-22620-1 through bush­
ing and eye of spring. Center Tool J - 21058-6 and
J - 21058-7 and screw Tool J - 21058-8 on threaded end
of Tool J-21058-15. Pull bushing into spring eye
(fig. 35).

CHEVROLET TRUCK SERVICE M ANUAL

FRONT SUSPENSION 3-16

7. Align spring leaves by tapping with hammer, then

bend spring clips into place.

IMOTE: Spring clips should be tightened suffi­

ciently to maintain alignment, but not tight
J-21058-8 enough to bind spring action.
J-21058-6 ■J-22620-2
J-21058-7
Installation
1. Position spring assembly under vehicle so that head
of center bolt is indexed in axle spring seat.
2. Loosely install spring-to-axle "U" bolts.
3. Position spring to front and rear hangers, install eye
bolts and loosely install eye bolt nuts.
4. Lower vehicle to floor and bounce front of vehicle
several times to allow bushings to center in hangers.
Then torque all spring bolts to specifications.
F ig . 3 4 - Removing Spring Eye Bushing

NOTE: Outer shell of bushing must be flush

with spring eye to ensure proper alignment of
spring with spring hanger.

3. Disassemble and remove bushing installation tools.

NOTE: Install bushing so that it is flush with

spring leaf.

Shackle Replacement
The spring rear shackle details are shown in Figure 4.
Components may be serviced with the spring installed in
the vehicle or when the spring is removed. Inspect
shackle components and replace parts as required. Re­
assemble parts as shown in Figure 4.

Spring Leaf Replacement

FRONT HANGER REAR SHACKLE
1. Place spring assembly in a bench vise and remove
spring clips by removing clips.
2. Position spring in vise jaws, compressing leaves at
center and adjacent to center bolt.
3. File peened end of center bolt and remove center bolt F ig . 36 - P20-30 Spring and Bushings
nut. Open vise slowly to allow spring assembly to
expand.
4. Replace spring leaf as required, also replace any de­
fective spring leaf inserts at this time. Spring
5. Align center holes in spring by means of a drift and
compress spring leaves in a vise. P20-30—Figure 36
6 . Remove drift from center hole and install a new cen­
ter bolt - peen bolt to retain nut. Removal
1. Disconnect shock absorber from U bolt spacer
bracket.
2. Remove front U bolt and swing stabilizer link bracket
J-21058-8 J-21058-6 away from axle.
3. Raise front of vehicle high enough to take weight off
spring, then remove remaining (rear) U bolt and
U bolt spacer.
4. Remove lube fittings from shackle pins and bracket
bolt. Remove nuts and lockwashers from shackle
pins, then remove shackle plates and seals. Remove
threaded shackle pins from threaded bushings.
5. At front bracket, remove lock nut from bracket bolt,
and turn bracket bolt out of threads. Pull bolt out
and remove spring assembly.

Inspection
Inspect all bushings for excessive wear, check spring
F ig . 35 - Installing Spring Eye Bushing leaves for breaks and spring clips for tightness.

CHEVROLET TRUCK SERVICE M ANUAL

 FRONT SUSPENSION 3-17

Repairs 6 . Remove drift from center hole and install new center
bolt.
Front Bushing (Plain) 7. Install nut on center bolt and tighten securely and
1. Adapt suitable remover from J - 21058 and remove peen end of bolt to keep nut from loosening.
bushing. 8 . Align springs by tapping with a hammer and bend
2. Install new bushing in spring eye using suitable in­ spring clips back in position.
staller from J - 21058.
NOTE: Spring clips should be bent sufficiently
to maintain alignment, but not tight enough to
Rear Bushing (Threaded)
bind spring action.
1. Thread end of J-553 shackle bushing tool into
bushing. Installation
2. Turn pull nut on tool with wrench and remove 1. Assemble fixed end of spring to spring hanger and
bushing. install spring hanger bolt.
3. Insert end of J-553 shackle bushing tool through 2. Install nut, and tighten to 90 ft. lbs. torque.
spring eye or spring hanger and screw new bushing 3. Install shackle pins in rear spring support bushing
on end of tool until it is centered with hole in spring and in bushing in spring eye.
or hanger. 4. Locate shackle pins so that each end projects 21/32"
4. Turn pull nut of tool to press bushing into place from the ends of the bushings.
(fig. 37). 5. Place new seals and shackle plates over tapered ends
of the shackle pins.
Spring Leaf 6 . Install shackle plate, lockwashers and nuts, and
1. Place spring in a bench vise and remove spring tighten to 30 ft. lbs. torque.
clips. 7. Raise spring assembly and locate center bolt in loca­
tor hole of spring seat.
NOTE: Spring clips will have to be bent open. 8 . Install shock absorber anchor plate and "U" bolts.
2. File peened end of center bolt and remove center 9. Install "U" bolt lockwashers and nuts, and tighten to
bolt nut. specified torque (see "Specifications").
3. Open vise slowly and carefully to let spring assembly 10. Connect shock absorber link or eye to shock ab­
expand. Wire brush and clean spring leaves. sorber anchor plate.
4. Replace broken spring leaf. 11. Install lubrication fittings and lubricate.
5. Align center holes in spring by means of a long drift
and compress spring leaves in vise. Series 40-60—Figure 38

Removal
1. Raise vehicle to take weight off spring. Disconnect
shock absorber from lower bracket.
2. Support I-beam, disconnect "U" bolts and "U" bolt
spacers, and allow to drop. Remove caster shims
and set aside for reinstallation.
3. Remove spring front eye pivot pin nut and withdraw
pivot pin.
4. Drop spring and pull out of rear hanger.

HANGER
4 0 -6 0 SERIES

FRONT MOUNTING REAR HANGER

ALL MODELS T50, 60 SERIES
F ig . 37 - Installing Threaded Eye Bushing

F ig . 38 - 40-60 Spring Mounting

CHEVROLET TRUCK SERVICE M ANUAL

FRONT SUSPENSION 3-18

Fig. 41 - Installed Position o f Offset Bushing

7 0 0 0 # Axles
Fig. 3 9 - Removing Spring Eye Bushing

Removal and Installation procedures are the same as

outlined for the 4 and 5000# axle except use adapter
Repair J - 21979 for removal and installation of the spring eye
bushing.
Bushing There is no restriction on the installed position of the
oval (7000# axles) bushing as in the case of the offset type
4-5000# Axles (4 - 5000# axles) bushing.

Removal (With Spring on Vehicle) 9 0 0 0 # -1 1 0 0 0 # Axles

1. Raise vehicle to take weight off spring and remove
spring eye nut and bolt. Remove and replace front eye bushing using bushing
2. Raise vehicle further until spring eye clears hanger. rem over/installer J-21058 with correct bushing adapter
3. Using J-21978-1 remover adapter, J-21058 nut and plug (fig. 39).
screw, and J-21830-4, 7 receiver and bridge remove
bushing from spring eye (fig. 39). Front Spring Rear Hanger Cam

Installation On models so equipped, inspect cushion on spring rear

1. Using installer adapter J - 21978-2 and tools called hanger cam. Replace if worn or damaged.
out in Step 3 of removal procedure, install bushing
(fig. 40) with offset of bushing at top of spring eye as Installation
shown on Figure 41. 1. Place rear of spring into rear bracket and raise
2. Lower vehicle to position spring eye in hanger. front eye into hanger.
3. Install spring eye bolt and nut. Tighten nut to 370
ft. lbs. and lower vehicle.

Removal with Spring Off Vehicle

If bushing is replaced with spring off vehicle, use a
p ress, if available, and adapters J-21978-1, 2 to remove
and reinstall bushing.

7 0 0 0 # AXLES

F ig . 4 0 - Installing Spring Eye Bushing F ig . 42 - Spring Eye Bushing

CHEVROLET TRUCK SERVICE M ANUAL

 FRONT SUSPEf <.
O

breaks. If equipment is available, us

penetrant method to check for minute fractuiv,-.
3. Examine thrust bearings or washers for excessive
wear or scoring.
4. Examine steering knuckle bushings and kingpin for
excessive wear or scoring.

Repairs

Kingpin
If kingpin is damaged, it must be replaced during reas­
sembly of steering knuckle.

Bushings
Steering knuckle bushings are split type floating Delrin
bushings and can be removed by sliding them out of
knuckle bores without the use of special tools. After re­
Fig . 43 - Front Spring Rear Hanger Floating Cam - moval, clean up bushing bores using medium grit abra­
4-5000^ A x le Shown sive cloth. Wipe bores clean, lubricate bushing OD and
install into knuckle.
Also, lubricate and place "O" ring seal in upper
2. Install front pivot pin and nut. Tighten nut 370 lb. ft. knuckle bore under the upper bushing (fig. 44).
Heavy duty spring bushings are steel-backed bronze
and must be lubricated prior to installation of pivot Installation
pin. 1. a. On 2 200#-4000# Models
3. Raise I-beam with caster shims in position, index Position steering knuckle on axle end and slide
spring center bolt into I-beam spring seat and install thrust washer assembly, consisting of one center
"U" bolts, spacers and nuts. Torque "U" bolt nuts steel washer and two bi-m etallic upper and lower
120 lb. ft. Connect shock absorber. washers encased in dust shields, between lower
face of axle end and steering knuckle lower yoke.
Steering Knuckle—Figure 44 Grooved cooper side of upper and lower thrust
washers must be assembled toward center steel
Steering knuckle and kingpin may be removed and washer (fig. 45). Lubricate kingpin and install
serviced without removing the axle assembly from the temporarily to maintain knuckle-to-1 -beam
vehicle. alignment.
b. Chevy Van
Removal Position steering knuckle on axle end and slide
1. Raise front of vehicle and remove wheel and tire and thrust washer assembly, consisting of a bronze
front hub and bearing assembly as outlined under washer between two steel washers and encased in
"Front Hubs and Drums-Removal." dust shields, between lower face of axle end and
2. Remove bolts retaining brake backing plate to steer­ steering knuckle lower yoke. Dust shield is
ing knuckle and withdraw plate. Attach backing plate marked must face upward (fig. 45). Lubricate
to frame or body to prevent damage to brake hoses. kingpin and install temporarily to maintain
3. Swing steering and tie rod arm out of work area. knuckle-to-1 -beam alignment.
c. On 5000#-7000#-9000#-11,000# and P20-30
P 20-30 and 40-60 Series Position and align steering knuckle on axle cen­
(Except Heavy Duty 9 0 0 0 # —1 1,00 0# ) ter slide thrust bearing assembly between lower
4. a. Remove upper and lower dust caps. face of axle end and knuckle lower yoke. Make
b. Remove kingpin lockpin nut and pull out lockpin. certain retainer is on top of bearing with lip of
c. Tap kingpin out from bottom and withdraw steer­ retainer down. Lubricate kingpin and install
ing knuckle, shim, and thrust bearing pack. temporarily to maintain knuckle-to-I-beam
alignment.
9 0 0 0 # -1 1 ,0 0 0 #
a. Remove upper dust cap and lower expansion plug NOTE: P ress kingpin upper sleeve over king­
lock ring. pin before installing. Install kingpin from bot­
b. Remove kingpin upper cotter pin and nut. On tom of steering knuckle (9000#-11,000# only).
1 1 , 0 0 0 lb. axle remove metal spacer under king­
2. Place a jack under steering knuckle and raise
pin nut. knuckle enough to take up clearance between knuckle
c. Drive kingpin downward out of axle and knuckle. yoke, axle end and thrust bearing or washers. Check
Withdraw steering knuckle, thrust bearing and clearance between upper face of axle end and knuckle
spacer washers. upper yoke. On 2200-4000-5000-7000# models, if
d. Remove upper kingpin bushing. This bushing is a this clearance exceeds .005”, add shims as neces­
.001"-<,003M fit and may be pushed out by hand. sary to bring clearance below this dimension. On
Inspection 9000#-11,000# models, if this clearance exceeds
1. Wash all parts in solvent and air dry. .015", add shims as required to obtain a clearance
2. Inspect steering knuckle for distortion, cracks or of .003" to .008" (fig. 46).

CHEVROLET TRUCK SERVICE MANUAL

 <T SUSPENSION 3-20

40 SERIES
(4000#)

P 20-30

50-60 SERIES
(4-5-7000*) 60 SERIES
(9-11000*)

F ig . 4 4 - Steering Knuckles and Kingpins

1. Kingpin lockpin 2. Kingpin 3. Bushing 4. Thrust bearing 5. Seal

3. Lubricate and install kingpin if not already installed front and tighten nut securely.
in Step 1. On all models except 9000#-11,000#, make 5. On P20-30 and Chevy Van models install new kingpin
sure milled slot on side of pin indexes with kingpin plugs in yoke and stake in place at four points. On
lockpin hole in axle end. Install kingpin from top, 4000#-5000#-7000# models install kingpin dust caps
driving it down through knuckle upper yoke, shim, with new gaskets. On 9000#-11,000# models install
axle end, thrust washer pack and lower knuckle yoke, inverted expansion plug in lower knuckle bore and
until milled slot aligns with lockpin hole in axle end. seat retaining ring. Install upper dust cap with new
On 9000#-11,000# models, install kingpin from bot­ gasket.
tom and install kingpin upper nut. Torque nut 250 6 . Place brake backing plate into position on steering
lb. ft. and insert new cotter pin. knuckle and install two upper locking plate to steer­
4. Insert threaded end of lockpin through axle end from ing knuckle retaining bolts. Raise steering and tie

CHEVROLET TRUCK SERVICE M ANUAL

 FRONT SUSPENSION 3-21

BRONZE
W A SH ER
STEEL
W A SH ER

P20-30

STEEL
W A SH ER
TH RU ST
W A SH ER
I____ D U ST S H IE L D

4 ,0 0 0 #

5 ,0 0 0 # -7 ,0 0 0 # 9 ,0 0 0 # -1 1 ,0 0 0 #

Fig. 45 - Thrust Bearing D etail

rod arm into position on back of steering knuckle and

install two lower backing plate-to-steering knuckle
retaining bolts and nuts. Torque nuts to specifi­
cations.
7. Install front hub and bearing assemblies and adjust
as outlined under Wheel Bearings-Adjust. Install
front wheel and tire assembly, and lower vehicle.
8 . Check front end alignment and steering stop screw
and adjust where necessary as outlined earlier in
this section.

I Beam

Removal
1. Raise vehicle and support at frame to rear of spring
rear bracket. Remove wheel and tire assembly.
2. Disconnect shock absorber lower mount from U-bolt
spacer bracket or spring seat bracket. Disconnect
stabilizer lower link on P20-30 models.
3. Remove wheel hub and drum assembly. Fig. 46 - Checking Steering K nuckle Free Play
4. Remove brake backing plate and fasten to frame to
prevent damage to brake hose. See Steering Knuckle- Repairs
Removal for removal procedure. Let steering arm
tie rod and third arm hang attached to the drag link. Steering Knuckle an d Kingpin
5. Support I-beam with floor jack. Remove spring Remove and service kingpin and steering knuckle as
U-bolt nuts, lower shock absorber brackets, U-bolts outlined under Steering Knuckle.
and U-bolt spacers.
6 . Lower axle center and remove from under vehicle. A x le Center
Tape or wire camber shims to spring seats. There are two conditions which, if either exists, will

CHEVROLET TRUCK SERVICE MANUAL

FRONT SUSPENSION 3-22

necessitate replacement of axle center. raise up against spring seats, making sure spring
1. If kingpin holes in axle center ends are worn to such center bolts index in spring seats.
an extent that a new standard or oversize kingpin fits 2. Place U-bolts and U-bolt spacers over springs. In­
loosely, axle center must be replaced. stall shock absorber lower mounting brackets (where
2. If axle center has been twisted or bent more than 5 used), U-bolt nuts and torque as outlined in
degrees from original shape, center should be re­ Specifications.
placed. As a general rule, when an extreme bent 3. Connect shock absorber lower eye and stabilizer link
condition exists, minute fractures which may be in­ on P20-30 models.
visible will occur, and failure under ordinary operat­ 4. Install brake backing plate assembly to steering
ing conditions will result. Check axle center for knuckle as outlined in Section 5 -Brakes.
twist with alignment instruments. If equipment is 5. Install steering arm and the rod assembly and torque
available, use Magna-Flux method to check axle cen­ bolts as shown in Specifications.
ter for minute fractures. Axle centers should always 6 . Place hub and drum assemblies over spindles and
be straightened cold. Under no circumstances should adjust wheel bearings as outlined under Wheel Bear­
heat be applied. ings-Adjust.
7. Install wheel and tire assemblies, and lower vehicle.
Installation. Check front end alignment and adjust where
1. Roll axle into position, insert caster shims, and necessary.

Fig . 47 - W h e e l Bearing Cup Installers

1. J-8458 Inner Cup In staller - CP10

2. J-8849 O u ter Cup Installer - CP10
5
3. J-21067 Inner Cup In staller - P20-30
4. J-7585 O u ter Cup Installer - P20-30
5. J-9276-2 Inner Cup Installer - C20-30-50, 60 O uter
6. J-8457 O uter Cup In staller - C 20-30-40 Fig. 48 - A dditional Special Tools
7. J-21059 Inner Cup Installer - 50
8. J- 2 1 060 O uter Cup In staller - 50 1. J-6874 Spring Compressor
9. J-21066 Inner Cup Installer - 60 2. J-8092 Handle
10. J- 2 1 108 Inner Cup Installer - 9,000^ 3. J-7079-2 Handle
11. J-9276-1 O u ter Cup Installer - 9,000^ 4. J-553 Spring Bushing Rem over/Installer
12. J- 2 1 106 Inner Cup Installer - 11,000^ 5. J-21058 Spring Bushing Rem over/Installer
13. J- 2 1 107 O uter Cup Installer - 11,000^ J-0554 Hub Bolt Peening Tool (not shown)

i
CHEVROLET TRUCK SERVICE M ANUAL
 FRONT SUSPENSION 3-23

..T..-.... m r~ ------— ~\

F ig . 4 9 - Front Suspension Sp ecial Tools

1. J-8806 Ball Jo in t Stud Remover 7. J-21058 N u t, Screw , and Thrust Bearing

2. J-21830-7 Spring Bushing R e ce iver Bridge
3. J-21830-4 Spring Bushing R eceiver S P E C IA L T O O L S N O T ILLUSTRATED
4 . J-21979 7000^ A x le Spring Bushing Rem over/Installer
5. J-21978-1 4-5000^ A x le Spring Bushing Remover J-22620-1, 2 Spring Bushing Remover and Installer
6. J —21978—2 4-5000^ A x le Spring Bushing Installer

CHEVROLET TRUCK SERVICE M ANUAL

FRONT SUSPENSION 3-24

FOUR WHEEL DRIVE

(SERIES K 1 0 AND K 2 0 )
INDEX
Page Page
Introduction.........................................................................3-24 Front Axle Shaft A s s e m b ly ....................................... ..... 3-27
General Description ......................................................... 3-24 Removal ............................................................... ..... 3-27
Front A x l e ..................................................................... 3-24 R e p a ir s .................................................................. ..... 3-27
Steering Knuckle and "U " J o in t .................................... 3-24 In stallatio n ............................................................ ..... 3-27
Transfer C a s e ............................................................... 3-24 Steering Knuckle ...................................................... ..... 3-27
Adapter A s s e m b ly ......................................................... 3-24 Removal ............................................................... ..... 3-27
Free-wheeling H u b s ...................................................... 3-25 Bearing Cup R ep lacem en t.................................... ..... 3-29
Power T a k e - o f f ............................................................ 3-25 Seal Replacement................................................... ..... 3-29
Other Components......................................................... 3-25 In stallatio n ............................................................ ..... 3-29
Maintenance and Adjustments............................................. 3-25 Transfer C a s e ............................................................ ..... 3-29
King Pin Trunnion B e a r i n g .......................................... 3-25 Removal.................................................................. ..... 3-29
Component Parts Replacem ent.......................................... 3-25 Adapter A sse m bly ............................................. ..... 3-29
Free-wheeling H u b s ...................................................... 3-25 R e m o v a l...................................................... .....3-29
Front Axle A s s e m b ly ................................................... 3-25 Installation................................................... ..... 3-30
Removal ...................................................................3-25 In stallatio n ............................................................ ..... 3-30
Installation , . , 3-26

INTRODUCTION
The four-wheel drive models are essentially conven­ service information on components which are common
tional vehicles which have been modified to include a to four-wheel drive and conventional vehicles.
driving front axle, a transfer case to distribute power Disassembly and repairs to the Front Axle Differen­
to front and rear axles with the required propeller tial can be found in Section 3 "Front Suspension" of the
shafts and controls (fig. 1). Service information on these 1967 Truck Overhaul Manual. The Adapter and Trans­
components is included in this section. fer Case assemblies are covered in Section 7 "Trans­
Refer to the applicable section of this manual for mission", 1967 Truck Overhaul Manual.

GENERAL DESCRIPTION
Primary purpose of four wheel drive is to provide STEERING KNUCKLE AND UNIVERSAL JOINT
additional tractive effort in off-the-road driving in order To permit the front wheels to be driven as well as
to overcome such obstacles as sand, deep mud or snow, turned, the axle is equipped with steering knuckles and
hilly terrain with steep grades, etc. the axle shafts are equipped with yoke and trunnion type
With four wheels capable of driving, all the vehicle universal joints.
and payload weight is utilized to give maximum tire TRANSFER CASE
traction.
The transfer case, also known as a drop gear box, is
The power unit is driven through a Muncie three-speed the unit which transmits power from the transmission to
or Chevrolet four-speed transmission and consists of an the rear and/or front axles and power take-off (fig. 2 ).
adapter and a two speed transfer case with a steering Engagement of front wheel drive, power take-off or speed
and driving front axle. A single control lever (fig. 1) is range is accomplished through control levers in the cab.
used to shift the transfer case from direct drive to low The case is mounted to an adapter at the rear of the
four wheel drive at a ratio of 1.94 to 1, thus eight for­ transmission.
ward speeds and two in reverse are provided. Model number, ratio and production date are stamped
Front wheel drive may be engaged or disengaged at any on a plate located on top of the transfer case.
time without clutching when the transfer case is in direct ADAPTER ASSEMBLY
drive; however, in returning to 2 wheel from 4 wheel the
An adapter assembly has been designed to locate the
accelerator may have to be varied as steady pressure is
transfer case directly behind the transmission (fig. 2 ).
applied on lever. This releases gear tooth pressure dur­
Presently there are two adapters available, one for use
ing shifting.
with the Muncie three-speed transmission, and one for
A yoke and trunnion universal joint permits continuous
use with the Chevrolet truck four-speed. This adapter
power flow to each front wheel, regardless of the turning
assembly design will allow the vehicle body to be lowered
angle.
approximately 3 inches and will also eliminate the need
Provisions for Power Take-off have been incorporated
for an intermediate propeller shaft;
in the transfer case.
The two adapters are sim ilar in that they both contain
FRONT AXLE a splined sleeve mounted in seals. The one for the
three-speed Muncie takes the place of the transmission
The front axle is a Spicer hypoid gear axle unit extension and has a straight spline input to match the
equipped with steering knuckles. Axle assembly number transmission output shaft spline. The output spline is
and production date are stamped on left tube of assembly. involute to match the input spline of the transfer case.
Refer to Specifications for Spicer Model application. The adapter assembly for the Chevrolet truck four-speed
Conventional truck service brakes are provided on all mounts on the back face of the transmission and has a
4-wheel drive units. straight through involute spline sleeve since the trans-

CHEVROLET TRUCK SERVICE M ANUAL

 FRONT SUSPENSION 3-25

mission output spline and transfer case input spline are wheels when the vehicle is operated under conditions
identical. To summarize, the transfer case adapters where front wheel drive is not needed.
differ in their splined sleeves and mounting faces only. The engagement and disengagement of free-wheeling
hubs is a manual operation which must be performed at
FREE-WHEELING HUBS
Free-wheeling hubs are available for the front wheels each front wheel. The transfer case control lever must
of four wheel drive vehicles. The purpose of these hubs be in 2 -wheel drive position when locking or unlocking
is to reduce friction and wear by disengaging the front hubs. Both hubs must be in the fully locked or fully
axle shafts, differential and drive line from the front unlocked position. They must not be in the free-wheeling
position when low all wheel drive is used as the additional
torque output in this position can subject the rear axle to
severe strain and rear axle failure may result.

POWER TAKE-OFF
Provision is made for mounting a shaft type Power
Take-Off at the rear of the transfer case input shaft.

OTHER COMPONENTS
The rear axle assembly, including service brakes, is
identical to the axle used on conventional drive models.
The parking brake operates by mechanical activation of
the service brake shoes in the rear wheels through a
pistol-grip type parking brake lever mounted under the
left side of the instrument panel.

[ADAPTER1

ITRANSFER;
ICASE

Fig . 1 - Control Lever Fig. 2 - Transfer Case and Adapter Assembly

MAINTENANCE AND ADJUSTMENTS

KING PIN TRUNNION 4. If torque is too low, remove the bearing retainer and
Front axle trunnion bearing adjustment is necessary remove shims up to .005" (fig. 6 ).
only when there is excessive play in steering, irregular 5. Reinstall retainer, tighten bolts to 30-40 ft. lbs.
wear on tires or persistent loosening of the tie rod. torque and recheck torque necessary to turn the
1. Raise front end of truck so both front wheels are off knuckle.
the ground and place jack stands behind front springs. 6 . If there is still excessive play, repeat Steps 3, 4,
2. Disconnect connecting rod and tie rod to allow inde­ and 5.
pendent movement of each steering knuckle. NOTE: Do not remove shims in excess of
3. Apply torque wrench to bearing retainer bolt and .010". If there is still excessive play after re ­
check torque necessary to turn the steering knuckle. moving .0 1 0 " shim, the steering knuckle should
The knuckle should turn easily but have no play with be disassembled and inspected as outlined under
120-180 in. lbs. torque. "Service Operations."

COMPONENT PARTS REPLACEMENT

FREE WHEELING HUB Removal From Wheel Hub
The free wheeling hub assembly used on the front 1. Turn hub key to set hub to "free" or "disengage"
wheels is serviceable. Service operations are as follows: position (fig. 3).

CHEVROLET TRUCK SERVICE M ANUAL

FRONT SUSPENSION 3-26

2. Install outer clutch ring, cap and cam assembly as

follows:
a. On K10 models, start assembly straight into hub
taking care to work "O" ring seal past the snap
ring groove in hub. Install snap ring in hub.
b. On K20 models, place gasket on hub, align mount­
ing holes in clutch ring and cap with holes in hub
and install bolts and lockwashers.
3. Turn knob to check for proper locking.

FRONT AXLE ASSEMBLY

Refer to Fig. 6

Removal
1. Disassemble propeller shaft from front axle differ­
ential.
2. Raise front end of truck until weight is removed
from front springs. Support truck with jack stands
behind front springs.
3. Disconnect connecting rod from steering arm.
4. Disconnect brake hoses from frame fittings.

Fig . 3 - Hub K ey Positions

2. Remove outer clutch ring, cap and cam assemblies

as follows:
a. On K10 models, remove internal snap ring from
hub and pull assembly out of hub.
b. On K20 models, remove bolts retaining hub cap
assembly to wheel hub, pull assembly and exten­
sion housing away from hub and remove gaskets.
3. Remove snap ring from end of axle shaft.
4. Pull bushing and inner clutch ring assembly from
shaft.
MODEL-K1
Disassembly
(Refer to Figures 4 and 5)
1. Turn key to engaged position (fig. 3) to release pres­
sure from springs.
2. With suitable size drift punch, remove key knob re ­
taining pin through holes in outer clutch gear as-
semly.
3. Lift key knob and retaining flange from inner clutch
gear springs.
4. Remove snap ring from key knob.
Assembly
All parts should be clean and lubricated during assem ­
bly to prevent deterioration before the unit is put into
service. Replace all gaskets and "O" rings during as­ MODEL-K2Q
sembly.
1. Place springs in holes in clutch gear.
2. Install key knob into center of the assembly and in­ Fig. 4 - Hub Assembly
stall retaining pin and install snap ring.
3. Place retaining flange down over springs, lining up 1. K ey Knob 8. A x le Shaft Lock Ring
the "locking or aligning” pin in position hole. 2. Retainer Cap 9. C o lla r (Bushing) Internal
3. K ey Knob Seal Clutch G e a r
Installation 4. K ey Knob Retainer Pin 10. Internal C lutch G e a r
1. Place bushing and inner clutch ring over axle spline 5. Cap Aligning Pin 11. W h eel Hub Housing
with clutch teeth outward. Slide on until bushing 6. Spring 12. Extension Housing Gaskets
bottoms in wheel hub and install snap ring in axle 7 . O uter Clutch G e a r 13. Extension Housing
shaft. Assembly 14. Snap Ring

CHEVROLET TRUCK SERVICE MANUAL

 FRONT SUSPENSION 3-27

5. Remove bearing lock nut and lock ring and remove

adjusting nut.
6 . Remove wheel, hub and drum as an assembly.
7. Remove bolts and lock washers holding brake flange
plate and spindle to steering knuckle.
Remove flange plate from steering knuckle and sup­
port the plate so brake hose will not be damaged.
9. Slide spindle from shaft.
10 . Remove axle shaft and joint assembly.
Repairs
1. Remove lock rings from trunnion bearings.
2. Support shaft yoke in a bench vise or on a short
length of pipe.
3. Using soft drift and hammer, drive on one end of
MODEL-K10 trunnion bearing just far enough to drive opposite
bearing from yoke.
4. Support the other side of yoke in bench vise and
drive other bearing out using brass drift on end of
trunnion.
5. On other joints, remove trunnions from yokes in
sim ilar manner.
6 . Remove trunnion.
7. Clean and inspect bearings, relubricate with a high
melting point wheel bearing type grease.
Replace trunnion and press new or relubricated
bearings into yokes and over trunnion hubs far
enough to install lock rings.
9. Hold trunnion in one hand and tap yoke lightly to
seat bearings against lock rings.
Installation
MODEL-K2Q 1. Slide axle shaft assembly into housing, engaging
splines in differential side gear.
2. Install spindle and bushing assembly on shaft.
3. Install brake flange plate on spindle, align mounting
F ig . 5 - Hub Installation
holes and install bolts and lock washers. Tighten
bolts to 25-30 ft. lbs.
1. Lock Ring 5. Extension Housing
4. Install wheel and drum assembly on spindle.
2. " O " Ring Seal 6. Gaskets
7. Lock Washer (6)
5. Install outer bearing cone and adjusting nut.
3. Hub Assembly
6 . Adjust bearings by tightening nut using "T " handle
4. W h ee l Hub Housing 8. Bolts (6)
wrench (12" long on each side). Rotate drum and
5. Disconnect shock absorbers from axle brackets. tighten snug. Loosen nut 45° and assemble lock
6 . Dismount U-bolts from axle to separate axle from washer by loosening nut to nearest hole, then as­
truck springs. semble outer nut. Tighten nut to 40 ft. lbs. mini­
7. Roll front axle out from under the truck. mum.
Installation 7. Install drive flange as follows:
1. Truck should be on jack stands as in Step 2 of re ­ a. On K10 models, install spacer in hub and install
moval instructions. splined drive flange on shaft and into hub.
2 . Place axle in position under truck. b. On K20 models, install gasket on hub and install
3. Install U-bolts attaching axle to front springs. drive flange on studs. Install lock washers and
4. Attach shock absorbers to axle brackets. nuts.
5. Connect brake hoses to frame fittings. 8 . Install snap ring in axle shaft.
6 . Attach connecting rod to steering arm. 9. Install hub cap.
7. Remove jack stands and lower front of truck. 10. Fill knuckle with recommended lubricant. Coat plug
8 . Assemble propeller shaft to front axle differential. with Permatex No. 3 or equivalent and install in arm.

FRONT AXLE SHAFT ASSEMBLY FRONT AXLE STEERING KNUCKLE

Removal Removal
1. Support vehicle with front wheel free. 1. Remove axle shaft and joint assembly.
2. Place drain pan under wheel and remove hub grease 2. Disconnect steering connecting rod from steering
cap. arm.
3. Remove snap ring from axle shaft. 3. Disconnect the tie rod from steering knuckle.
4. Remove drive flange as follows: 4. Remove the seal retainers (2 pieces) from knuckle.
a. On K10 models, pull splined drive flange from 5. Remove the felt seal, rubber seal and the seal ring
shaft and hub and remove spacer from hub. from knuckle and let them hang on axle housing.
b. On K20 models, remove stud nuts and washers, 6 . Remove upper and lower bearing retainers and shims
remove drive flange and gasket. from knuckle.

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FRONT SUSPENSION 3-28

Fig . 6 - Steering Knuckle and W h eel Hub

1. Hub Cap 7. Shims 13. A x le Housing 19. Brake Flange Plate

2. Snap Ring 8. Steering Arm 14. A x le Shaft 20. W h eel Bearing Seal
3. Lock N ut 9. Seal Retainer 15. Bearing Cup 21. W h eel Bearing (Inner)
4 . Lock Ring 10. Sea 1 Ri ng 16. Bearing Cone 22. W h eel Hub
5. Adjusting Nut 11. Rubber Seal 17. Bearing Retainer 23. D rive Flange
6. Steering Knuckle 12. Felt Seal 18. Spindle

CHEVROLET TRUCK SERVICE MANUAL

 FRONT SUSPENSION 3-29

7. Remove knuckle from housing and remove bearing b. On 44-5HDF models—use a torque wrench posi­
cones from axle housing. tioned on upper bearing retainer nut; knuckle
should turn with 15-35 ft. lbs. torque. Adjust
NOTE: On K20 HD models the upper king pin
preload by increasing or decreasing shim packs
bearing consists of a cup and bushing assembly.
at lower bearing only. Upper shim pack should
The king pin and bushing are slotted to receive
be .060 inch thick.
a key which acts to connect the two components
4. Position seal ring, rubber seal and felt seal against
so that they will pivot together. Removal pro­
inboard face of knuckle and align bolt holes. Install
cedure for this installation is as listed above.
steel retainer ( 2 pieces).
Bearing Cup 5. Connect the steering connecting rod and tie rod.
6 . Install axle shaft assembly.
Replacement
If new bearings are to be installed, remove cups from TRANSFER CASE
axle housing. Start new cups straight in counterbore
and using a suitable driver, press cups firmly to bottom. Refer to Fig. 7
Seal Removal
1. Drain transfer case.
Replacement 2. Disconnect propeller shafts from U-joint yoke at
If new seals and retainer are to be installed, hang them case.
on axle housing in place of old parts—felt seal inboard, 3. Remove cotter pins from clevis pins. Withdraw
rubber seal next and the seal ring outboard. clevis pins to remove lever-selector from transfer
case.
Installation 4. Remove access cover on side of the Adapter Assem­
1. Install bearing cones or bushing in cups in axle bly and remove two attaching bolts to the transfer
housing. case (fig. 7).
2. Place the steering knuckle over axle housing yoke 5. Remove seven bolts located on outside of Adapter
and install bearing retainers. Use same shims re ­ Assembly.
6 . Support transfer case in suitable cradle.
moved, or equivalent amount and tighten bearing
retainer bolts or nuts to 25 ft. lbs. torque. 7. Remove two bolts from bracket at right side of the
transfer case and remove case from adapter.
NOTE: On K20 models position key in king pin
and install in bushing by aligning king pin and ADAPTER ASSEMBLY
key with key way in bushing.
Removal
3. Check bearing preload. 1. Remove bolts holding the bracket assembly, and
a. On 44-5F models—use a spring scale positioned control lever to the adapter assembly: lock, washer
in the tie rod hole; knuckle should turn with 1 1 - 2 0 and spring from lower end of lever actuating arm
lbs. pull. Add shim to decrease preload, remove (fig. 1). Push assembly to one side.
shim to increase preload. 2. Remove two bolts from mounting assembly.

Fig . 7 - Transfer Case Assembly (Typ ical)

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FRONT SUSPENSION 3-30

F ig . 8 - Access C o ver and Adapter Assembly

Fig . 9 - Four W h eel D rive Sp ecial Tools

3. Place jack under transmission, raise transmission

in order to clear adapter from mounting. 2. With transfer case on suitable cradle line up the
4. Remove bolts connecting adapter to transmission output spline on the adapter and input spline on the
and remove adapter. transfer case.
3. Push transfer case against adapter.
Installation 4. Line up outer attaching bolt holes and loosely install
1. Using chassis lubricant place gasket on facing of bolts and washers.
transmission. 5. Install two attaching bolts which are on inside of
2. Line-up transmission and adapter splines and push adapter case.
adapter against transmission. Install all bolts which 6 . Torque to specifications all nine attaching bolts and
hold adapter to transmission loosely. Then torque install access cover to the adapter assembly (fig. 8 ).
all bolts to specifications. 7. Install two bolts with lock washers, through bracket
3. Lower jack under transmission and line up holes in on right side of transfer case and torque to specifi­
mounting and adapter. cations .
4. Install two mounting bolts and torque. 8 . Remove cradle from transfer case.
5. Install bolts and lock which hold bracket assembly 9. Connect lever selector to transfer case by installing
and control lever to the adapter. the two clevis pins through clevis and insert cotter
pins.
Installation 10. Connect prop shafts to yoke at transfer case. Torque
1. Using chassis lubricant install new gaskets to bolts to specifications.
adapter case. 11. F ill transfer case with proper lubricant.

CHEVROLET TRUCK SERVICE MANUAL

 SECTION 4
REAR SUSPENSION AND DRIVE LINE
CONTENTS OF THIS SECTION
Page Page
Rear Suspension ............................................................ 4-1 Rear Axle (Eaton) ................................................... ...... 4-44
Single Axle ............................................................... 4-1 Single Speed ......................................................... ...... 4-44
Tandem ..................................................................... 4-11 Two Speed ............................................................ ...... 4-46
Drive Line .................................................................. 4-16 Tandem and Power Divider (E a to n )........................... ...... 4-48
Rear Axle (Chevrolet) ............................................. 4-16 Propeller Shafts, Universal Joints and
Single Speed ......................................................... 4-16 Bearing Support ......................................................... ......4-53
Two Speed ............................................................ 4-35 Speedometer Gears — Speed A d a p t e r ........................... ...... 4-56

REAR SUSPENSION
(SINGLE AXLE)
INDEX
Page Page
General Description ........................... . ........................ 4-1 Shackle Replacement............................................. 4-6
Series C-P10 and C20 ............................................. 4-1 Series P20 and C-P30 .................................... 4-6
Series G10 and G20 ................................................ 4-1 Series K10 and K20 ....................................... 4-7
Series K10, K-P20 and C-P30 ................................. 4-2 Series G10 and G20 . ..................................... 4-7
Series 40, 50 and 60 ................................................ 4-3 Bushing Replacement .......................................... 4-7
Component Parts Replacem ent....................................... 4-4 Series P20 and C-P30 .................................... 4-7
Shock Absorber Replacement ................................. 4-4 Series GK10 and 20 ....................................... 4-8
Tie Rod (Series C-P10 and C 2 0 ) .............................. 4-4 Spring Replacement ............................................. 4-9
Stabilizer Shaft (Series P 3 0 ) .................................... 4-4 Series P20 and C-P30 .................................... 4-9
Control Arm (Series C-P10 and C20) ..................... 4-5 Series K10 and K 2 0 .......................................... 4-9
Coil Spring and Auxiliary Leaf Spring Series G10 and G 2 0 .......................................... 4-9
(Series C-P10 and C 2 0 ) .......................................... 4-6 Series 40, 50 and 60 ....................................... 4-10
Leaf Springs ............................................................ 4-6 Spring Leaf R ep lacem en t.......................................... 4-10

GENERAL DESCRIPTION
Series C-P10 and C20 Series G10 and G20
Series C-P10 (fig. 1) and C20 (fig. 2) trucks use a two- The rear suspension is of the tapered leaf spring,
link suspension with a control arm attached between each Hotchkiss drive type, with the spring rear shackle eye
end of the axle housing and the central area of the frame. mounted to the vehicle frame bracket (fig. 5).
A single "U" bolt attaches each control arm to the axle
housing and a rubber bushing is used in connecting the
forward end of each arm to a bracket on the frame be­
tween the side rails and the tunnel.
A two-stage, pigtailed coil spring is seated and clamped
between each control arm and the frame, forward of the
axle.
Shock absorbers are installed between brackets riveted
to the frame, forward of axle housing, and brackets held
beneath the rear of each control arm by the MU" bolt.
The tie rod on the C-P10 (fig. 3) models is attached to
a stud inserted through a cast ear of the differential car­
rie r. A rubber-bushed attachment is utilized at the
frame bucket. On the C20 models the tie rod is rubber-
bushed at both ends and is supported between an axle
housing bracket and at the frame.
Auxiliary leaf springs, available as an option on C
series vehicles, are mounted rearward of the axle and
secured by a frame mounted bracket at the rear. The
auxiliary spring bumper is retained by the "U" bolt at the
control arm (fig. 4). Fig. 1 - Rear Suspension (Series C and P10)

CHEVROLET TRUCK SERVICE M ANUAL

REAR SUSPENSION AND DRIVE LINE 4-2

through rubber bushings to the spring rear hanger.

Series K10, K-P20 and C-P30

Series K10 and 20 (fig. 6 ), trucks use a tapered leaf

spring Hotchkiss Drive Suspension with " Y " type
rubber-bushed shackles at rear hangers. Series P20 -
C-P30 (fig. 7) trucks use a conventional leaf spring with
tension mounted clevis type shackles at the rear hangers.
Shock absorbers are installed between brackets welded
to the axle housing and riveted to the frame, forward of
the axle housing.
Series 30 optional auxiliary springs (fig. 8 ) are at­
tached so as to provide a variable rate and capacity
spring. This design provides a low rate at curb and a
high rate at design; primary function of the auxiliary
spring is to increase vehicle capacity.
The four-point rubber bushed stabilizer shaft (fig. 9) is
standard equipment on the Series P30 vehicles only. The
stabilizer shaft is attached by bolt retained brackets at
two locations on the frame and at "U" bolt retained an­
chor plates at the axle housing.

F ig . 3 - Series C-P10 Tie Rod Installation

Fig. 4 - A u x ilia ry Rear Spring (Series C10-C20)

The spring assembly incorporates the berlin-type

spring eyes and plastic liners between the spring leaves.
A spacer is located on both the top and bottom of the
spring mounting. The front eye has a rubber insulated
steel bushing through which the spring is bolted to the
spring front hanger. The rear eye is shackle mounted F ig . 6 - Series K10 and K20 Rear Suspension

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 REAR SUSPENSION AND DRIVE LINE 4-3

Fig. 8 - Series C30 A u x ilia ry Rear Spring

Series 40, 50 and 60

Series 40, 50 and 60 vehicles use leaf-type springs with

a variable rate of deflection (fig. 10). A straight-ended
main leaf rests against cam surface of the front and rear
hangers, thereby allowing the springs a full fore and aft
float to effect spring length changes. The second or third
leaf has hooked ends which contact rebound pins in the
spring hanger to prevent excessive fore and aft travel in
event of a radius leaf failure.
At the bottom of the spring pile a spacer separates the
last leaf from the control arm (radius leaf), which is a
half-leaf formed with an eye and bushed for attachment to
the front hanger. The spring assembly makes use of a
stress plate below the control arm.
Two slanted "U" bolts attach the spring pile and control
arm to the axle housing.
The optional auxiliary spring pile (fig. 11) is of the
variable rate design sim ilar to the main spring assembly.
Spring attachment is accomplished by the ”U" bolt method
whereby both the main and auxiliary springs are secured
to the axle housing as a unit. Separate frame-mounted,
cam-type hangers are utilized to provide a deflection
surface for the auxiliary springs. F ig . 10 - Rear Suspension (Series 4 0 , 5 0 , and 60)

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REAR SUSPENSION AND DRIVE LINE 4-4

COMPONENT PARTS REPLACEMENT

Shock Absorber Tie Rod (Series C-P10 and C20)
Replacement Removal
1. Remove shock absorber pivot bolt nuts and washers, Remove nuts and bolts from each end of rod and re­
pull bolts and remove from vehicle. move rod from vehicle.
2. Position eye at large end of shock absorber in frame Inspection
bracket or crossmember, install bolt, washer and
1. Check rod for deformation by sighting down its length
nut.
or by using straight edge. Minor defects may be re­
3. Align opposite end of shock absorber with anchor
moved by bending. A badly bent rod, however, should
bracket at axle, install bolt, washer and nut.
be replaced.
4. Tighten nuts to specifications.
2. Bushings should be replaced if any abnormal condi­
tions exists, such as looseness, damage to or swell­
ing of rubber parts or general wear.
Bushing
Replacement
1. Position end of rod on a suitable tube-type support as
shown in Figure 12.
2. P ress bushing from rod, using Tool J-7079-2.
3. Position new bushing over rod eye.
4. Using Tool J-8518 on Series C-P10 or Tool J-7574-6
on Series C20, place tool on bushing and press bush­
ing into rod eye until tool contacts rod.
Installation
1. Position rod ends in mounting brackets at frame and
axle, lining up holes with drift.
2. Insert pivot bolts and install nuts finger tight.
3. Let weight of unloaded vehicle rest on suspension and
torque pivot nuts to 130 ft. lbs.

Fig. 11 - A u x ilia ry Rear Spring (Series 40, 50, and 60)

Fig . 13 - Removing Control Arm Spring Clamp Bolt

F ig . 12 - T ie Rod Bushing Replacement (Series C -P10 and C20) (Series C-P10 and C20)

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 REAR SUSPENSION AND DRIVE LINE 4-5

Fig . 14 - Control Arm Bushing Replacement (Series C-P10 and C20)

Stabilizer Shaft (Series P30)

Removal Fig. 15 - Control Arm and Spring Details (Series C-P10 and C20)
NOTE: If vehicle is to be raised during re­
moval procedure, support axle assembly so that
weight is not sustained by "U" bolts. Bushing Replacement
1. Insert Tool J - 8448-3 in fork of control arm astride
1. Remove the forward MU” bolt retaining nuts, and re­ bushing (fig. 14).
move shaft anchors from ends of shaft (fig. 9). 2. Rest bushed end of arm on Tool J - 5888-3 with bush­
2. Remove the frame-mounted shaft retaining brackets ing flange centered in tool.
and withdraw shaft from the underside of vehicle. 3. Place Tool J-8448-2 on top of bushing, indexing pin
Inspection of tool in center hole of bushing and, using Tool
1. Observe shaft for defects that would affect future J - 7079-2 press bushing from arm.
effectiveness--position shaft on flat surface and 4. Support control arm just as in removing bushing,
check to see that shaft is parallel from side to side. center new bushing flanged side up over control arm
2. Inspect bushings for excessive wear and other dam­ hole.
age. Replace parts as required. 5. Place Tool J - 8448-1 on top of bushing and, after
Installation carefully seating bushing in tool, press bushing into
1. Position shaft-to-fram e bushings on shaft and posi­ arm until flange contacts arm wall.
tion shaft to frame. Loosely install the shaft-to- Installation
frame retaining brackets. Refer to Figure 15
2. Install bushings in shaft anchors, position shaft in
anchors and loosely install anchors to "U" bolts.
3. Relieve tension on rear "U" bolts. Then alternately
and evenly tighten nuts to 1 2 0 ft. lbs. making sure
that axle is properly positioned during nut tightening.
4. Align stabilizer shaft so that both ends protrude
equally from the anchors. Alternately torque frame
bracket retaining nuts to 25 ft. lbs.
Control Arm (Series C-P10 and C20)
Removal
1. Remove load from springs by jacking up frame.
2. Remove spring clamp bolt from underside of control
arm.
3. Remove "U” bolt nuts and separate shock absorber
bracket from control arm. Separate control arm
from "U" bolts and lower the rear of the arm
(fig. 13).
4. Disconnect parking brake lever at clip on bracket at­
tachment on control arm.
5. Remove pivot bolt and remove arm from vehicle.

CHEVROLET TRUCK SERVICE M ANUAL

REAR SUSPENSION AND DRIVE LINE 4-6

1. Position bushed end of control arm in pivot yoke be­ to 270 ft. lbs.
tween tunnel and frame, align holes with drift and 2„ Position auxiliary spring assembly in frame mounted
insert pivot bolt. Place nut on bolt finger tight. bracket so that free end of spring is positioned above
2. Position clamp inside spring as shown in Figure 16 bumper and align spring-to-bracket bolt holes. In­
so that it seats freely on spring end without any stall bolt with washer through top side of bracket
hang-up. Raise control arm to the spring then pass then install nut and washer to through bolt. Torque
bolt, with flat washer installed, up through control nut to 370 ft. lbs. and install cotter pin.
arm and clamp. Install lockwasher and nut. Torque
to 50 ft. lbs.
3. Place arm adjacent to axle. Pass "U" bolt over axle
and through holes in arm.
4. Place shock absorber bracket on ends of "U" bolt,
install nuts and torque to 2 0 0 ft. lbs.
5. Lower the vehicle to put full weight of unloaded ve­
hicle on the front and rear suspension, torque control
arm pivot bolts to 140 ft. lbs.
COIL SPRING AND AUXILIARY LEAF SPRING
(Series C-P10 and C20)
Removal
Coil Spring
1. Remove shock absorber bolt from mounting bracket
at control arm.
2. Remove vehicle weight from rear suspension by
jacking up frame and adjust axle-to-fram e height so
that spring is not under tension.
3. Remove upper and lower clamps from spring by
backing out lower bolt from underside of control
F ig . 17 - Spring Removal (Series C-P10 and C20)
arm, and upper bolt from inside spring (fig. 17).
4. Lower control arm sufficiently to permit removal of
spring.
A uxiliary Spring
1. The auxiliary spring is secured to the frame mounted
retaining bracket by one retaining bolt. Before at­
tempting to remove spring, make sure there is no
load on spring and that spring leaf does not contact
the control arm mounted bumper (fig. 4).
2. Remove cotter pin from spring retaining bolt then
remove nut and remove spring from the frame
bracket.
3. If auxiliary spring contact bumper is to be removed,
support vehicle at rear axle, remove "U" bolts and
remove bumper from its position on the control arm.
Installation
Coil Spring
1. Place spring clamp inside spring. Position clamp so
that the end of the spring coil is within the area of Fig. 18 - Spring Shackle Details (Series P20 and C-P30)
the notch as shown in Figure 16 so that it seats
freely on spring end without any hang-up and locate LEAF SPRINGS
over bolt hole in control arm.
Shackle Replacement (Series P20 and C-P30)
2. Pass clamp bolt with washer up through hole in con­
trol arm and loosely install nut. 1. Remove load from spring by jacking frame.
3. Position upper clamp inside spring and install bolt 2. Remove lubrication fitting from spring eye and
and washer. Torque nut to 50 ft. lbs. shackle pins (fig. 18).
4. Connect shock absorber to control arm bracket-- 3. Remove lock bolts from shackle and hanger.
torque nut to 130 ft. lbs. 4. Install Tool J-8118 in end of spring eye pin, and us­
5. Torque spring lower clamp bolt to 45 ft. lbs. Remove ing slide hammer (Tool J-2619 with adapter
jack from beneath frame. J - 2619-4) pull pin out of spring. Pull shackle pin out
A uxiliary Spring of hanger and separate shackle from spring and
1. Position auxiliary spring bumper between the control hanger.
arm and the axle housing. Align holes in spring 5. Place bushed portion of new shackle in hanger.
bracket with those in the control arm; position shock 6 . Insert plain end of pin into hanger and shackle with
absorber bracket to underside of control arm; install slot in pin positioned to receive locking bolt when in­
"U" bolt over axle and through auxiliary spring stalled. Push pin in until slot lines up with locking
bracket control arm and shock absorber bracket; bolt hole in bracket. Install locking bolt, washer and
install and alternately torque "U" bolt retaining nuts nut.

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 REAR SUSPENSION AND DRIVE LINE 4-7

7. Align spring eye in shackle yoke and install spring

eye pin, locking bolt, washer and nut.
8 . Install lubrication fittings and lubricate the bushings.

Shackle Replacement (Series K10 and K20)

1. Remove load from spring by jacking fram e.

2. Loosen spring-to-shackle retaining bolt, but do not
remove.
3. Remove shackle-to-frame bracket retaining bolt—
then remove shackle bolt from spring eye (fig. 19).
4. Position shackle to spring eye and loosely install re­
taining bolt--do not torque retaining bolt at this
time.
5. Position shackle to frame bracket and install retain­
ing bolt.
6 . Lower vehicle so that weight of vehicle rests on
suspension components and torque both shackle bolt
retaining nuts to 155 ft. lbs.

Shackle Replacement (Series G10 and G20)

1. Support vehicle by jacking frame to remove load

from spring. Fig. 20 - Series G 10 and G 20 Spring Shackle
2. Loosen spring-to-shackle retaining nut (fig. 20).
3. Remove shackle-to-frame retaining bolt, making
sure that all tension is removed from spring. eye with the spring installed on the vehicle; to
4. Remove spring-to-shackle retaining bolt and disas­ replace the rear spring eye bushing, remove
semble shackle by removing bushing halves from spring from vehicle before attempting to replace
frame and spring eye. bushing.
5. Insert bushing halves in frame and spring eye.
6 . Position shackles to bushing halves and install re­ 1. Remove load from spring by jacking frame.
taining bolts as shown in Figure 20. 2. Remove lock bolt from spring hanger bracket and re­
7. Loosely install nuts to retain bolts; then lower ve­ move lubrication fitting from spring eye retainer pin.
hicle so that weight of vehicle rests on suspension 3. Install Tool J-8118 in end of spring eye pin, and us­
and torque nuts to 50 ft. lbs. ing slide hammer (Tool J-2619 and adapter J - 2619-4)
pull pin out of spring eye and bracket.
Bushing Replacement 4. Replace bushing using Tool J-8459 as follows.
a. Lubricate threads of J - 8459-1 and position in
Series P20 and C-P30 spring eye.
b. Position J-8 4 5 9 -5, -2 , thrust bearing, washer and
NOTE: The following bushing replacement J-8 4 5 9 -6 in that order over the threaded portion
procedure may be performed on the spring front of J - 8459-1 as shown in Figure 21.
c. Hold J-8459-1 from turning and turn J-8 4 5 9 -6 to
draw bushing out of spring eye.
d. Disassemble tool, lubricate threads, position
J-8 4 5 9 -2 and a new bushing over threaded portion
of J-8459-1.
e. Insert tool with bushing through spring eye, install
J-8459-5, -4, thrust bearing, washer and J-8459-6
in that order over the threaded portion of
J-8459-1 (fig. 22).
f. Make sure bushing is started straight, hold
J-8459-1 from turning and turn J-8459-6 until
J-8 4 5 9 -2 contacts spring eye.
g. Remove tool and check bushing for proper seat­
ing.
h. Check pin for slip fit in bushing--burnish or ream
bushing if required.
5. Lower frame until spring eye is aligned with holes
in hanger bracket, then install retainer pin--align
retainer pin so that locking bolt will index in slot
(Refer to Figure 18). Install locking bolt and secure
with washer and nut.
Lower vehicle to floor and remove jack. Install lu­
brication fitting in retainer pin and lubricate bushing.

CHEVROLET TRUCK SERVICE M ANUAL

REAR SUSPENSION AND DRIVE LINE 4-8

place bolt through hanger and bushing. Install washer

and nut on bolt. Tighten nut to specifications.

Bushing Replacement

Series 40, 50 and 60

1. Lock parking brake and jack up frame so that hooked
spring leaf touches rebound stop pin.
2. Relieve radius leaf tension on pivot bolt by com­
pressing leaf with a "CMclamp.
3. Remove bolt from spring eye and release "C" clamp
to allow sufficient access to spring eye bushing.
4. Replace bushing, using Tool J - 21058 as follows,
a. Assemble J - 21058-2 and J - 21058-15 so that guide
pin end of remover is against hex end of bolt--
Fig. 21 - Removing Spring Eye Bushing (Series P20 and C-P30) lubricate threads of tool.

NOTE: Use J-21058-2 to remove bushing from

3 inch spring; use J - 21058-5 to remove bushing
from 2 - 1 / 2 inch spring.

b. Insert tool in bushing and install J-21058-6, -7,

thrust bearing, washer and J - 21058-8 in that
order as shown in Figure 25.
c. Hold J - 21058-15 from turning and turn J - 21058-8
to draw bushing from spring eye.

NOTE: Use a breaker bar as shown in Figure

25 to start bushing. Impact wrench may then be
used to complete removal of the bushing.
Fig . 22 - Installing Spring Eye Bushing (Series P20 and C-P30)

Bushing Replacement

Series G-Kf 10 and 20

NOTE: Only the front bushings are the same

on both the G and K series truck. Both front and
rear bushings on the K series are the same.
Before attempting to replace the rear bushing on
the K series, remove the spring from the vehicle
(fig. 19 and 20).

1. Raise and support rear of vehicle at frame side rail

to relieve tension in springs.
2. Remove nut, washer and bolt from front bushing and
hanger. Continue to raise vehicle until access to Fig . 23 - G -K 1 0 and G - K 2 0 Removing Spring Eye Bushing
spring front eye is obtained.
3. Insert Tool J - 21058-15 with J - 22620-2 through eye of
bushing. Center Tool J-21058-6 with J-21058-7 over
threaded end and screw on Tool J - 21058-8. By
tightening nut J - 21058-8 withdraw bushing from eye
(fig. 23).
4. Place Tool J - 21058-15 with J - 22620-1 through bush­
ing and eye of spring. Center Tool J-21058-6 and
J-21058-7 and screw Tool J - 21058-8 on threaded end
of Tool J - 21058-15. Pull bushing into spring eye
(fig. 24).

NOTE: Outer shell of bushing must be flush

with spring eye to ensure proper alignment of
spring with spring hanger.

5. Disassemble and remove bushing installation tools.

6 . Lower vehicle to align spring eye and hanger. Re- F ig . 2 4 - G - K 1 0 and G - K 2 0 Installing Spring Eye Bushing

CHEVROLET TRUCK SERVICE M ANUAL

 REAR SUSPENSION AND DRIVE LINE 4-9

d. Disassemble tool, lubricate threads, install

J-21058-2 and new bushing on J-21058-15--p ilot
new bushing on guide pin of J-21058-2.

NOTE: Use J-21058-2 to install bushing in

3 inch spring; use J - 21058-4 to install bushing in
2 - 1 / 2 inch spring.

e. Lubricate spring eye and bushing, insert tool with

bushing into spring eye, then install J-21058-6,
-7 , thrust bearing, washer and J-21058-8 in that
order as shown in Figure 26.
f. Hold J - 21058-15 from turning and turn J-21058-8
until bushing is flush with spring eye. Remove
tool and check bushing for proper seating. Fig . 26 - Installing Spring Eye Bushing (Series 40, 50, and 60)
5. Lower frame until top spring leaf touches cam sur­
face of hanger.
6 . Compress radius leaf with "C" clamp until spring 2. Install " U " bolt retaining nuts—torque nuts alter­
eye bushing lines up with holes in spring hanger. In­ nately and evenly to properly seat spring on axle
stall retaining bolt, washer and nut--torque nut to pad. Torque nuts to 120 ft. lbs.
160 ft. lbs. 3. Jack frame as required to align spring eyes; install
7. Remove "C" clamp and frame lift. spring retainer pins, lock bolts and lubricating fit­
tings--lubricate spring bushings and lower vehicle.

Series K10 and K20

Removal
1. Raise rear of vehicle to relieve tension in spring and
position supports at frame side rails.
2. Loosen, but do not remove, spring-to-shackle retain­
ing nut.
3. Remove nut and bolt securing shackle to spring
hanger.
4. Remove nut and bolt securing spring to front hanger.
5. Remove "U" bolt retaining nuts, withdraw "U" bolts
and spring plate from spring-to-axle housing attach­
ment.
6 . Withdraw spring from vehicle.
7. Inspect spring--replace bushings, repair or replace
spring unit as outlined in this section.
Fig . 25 - Removing Spring Eye Bushing (Series 40, 50, and 60)

Spring Replacement Installation

1. Position spring assembly on axle housing. Make
Series P20 and C-P30 sure spring is in position at both spring hangers.

Removal NOTE: The shackle assembly must be at­

1. Jack vehicle at frame to relieve tension on spring. tached to the rear spring eye before installing
2. Remove lubrication fitting at front hanger and at rear shackle to rear hanger (fig. 19).
shackle.
3. Remove lock bolt at retainer pins and install J - 8118 2. Install spring retainer plate and "U" bolts--loosely
in end of spring eye pin, then using slide hammer install retaining nuts, but do not torque at this time.
(Tool J-2619 with adapter J-2619-4) pull pin from 3. Jack frame as required to align spring and shackle
spring. with spring hangers.
4. Remove " U " bolt retaining nuts, withdraw " U " bolts 4. Install shackle bolt and nut and again reposition
and remove spring assembly from the vehicle. spring, if necessary to align front eye--install front
5. Inspect spring--replace bushings, repair or replace eye bolt and nut.
spring unit as outlined in this section. 5. Lower vehicle so that weight of vehicle is on suspen­
sion components and torque affected suspension
Installation parts.
1. Position spring assembly on axle housing--on a. Spring "U" bolt nuts to 150 ft. lbs. (Tighten nuts
Model C314, install spacer assembly between axle alternately and evenly to ensure uniform draw on
housing and spring with thick edge forward. Make bolts.)
sure spring is in position at rear shackle and at front b. Spring eye and shackle retaining nuts to
hanger, then install " U " bolts. 155 ft. lbs.

CHEVROLET TRUCK SERVICE M ANUAL

REAR SUSPENSION AND DRIVE LINE 4-10

Series G10 and G20 spring.

4. Seat "U" bolt in spacer and secure spring to axle by
Removal installing anchor plate and nuts on "U" bolts. Torque
1. Raise vehicle and place stand jacks under frame side nuts alternately and evenly to 300 ft. lbs.
rails. Support axle so that tension and compression 5. Lower frame so that ends of spring enters hanger
are relieved in spring. and that top of spring touches cam surface of hanger.
2. Remove spring-to-axle "U" bolts, spacers and clamp Compress radius leaf with a "C" clamp until pivot
plate. bushing and hanger holes are aligned. Insert re­
3. Remove spring eye front bolt and loosen shackle as tainer bolt and torque to 85 ft. lbs.
required to withdraw shackle lower bolt. 6 . Remove "C" clamp from radius leaf, lower vehicle
4. Withdraw spring from vehicle--inspect spring and and install rebound pins at front and rear hangers.
repair or replace spring as outlined in this section. Install rebound pin locks, secure locks with bolts and
Installation bend tab of lopk over flat of retaining bolt.
1. Position spring assembly between axle assembly and
underbody so that head of center bolt is indexed in
axle spring seat. Spring Leaf Replacement
NOTE: Make sure that spring spacer is prop­ 1. Place spring assembly in a bench mounted vise and
erly positioned under spring and on axle bracket. remove spring clips by bending tabs or if so equipped
2. Position spring-to-axle "U" bolts through lower remove bolts and spacer of upper portion of clips.
spring spacer. Install upper spring spacer and 2. Position spring in vise jaws, compressing leaves at
clamp--loosely install "U" bolt retaining nuts. center and adjacent to center bolt.
3. Position spring to front hanger and rear shackle, in­ 3. File peened end of center bolt and remove nut. Open
stall eye bolts and loosely install eye bolt nuts. vise slowly to allow spring assembly to expand.
4. With vehicle at curb, tighten "U" bolts to 80 ft. lbs., 4. Wire brush and clean spring leaves. Inspect spring
spring front bolt to 80 ft. lbs., and both shackle bolts leaves to determine if replacement is required; also
to 50 ft. lbs. replace defective spring leaf liners at this time.
5. Align center holes in spring leaves by means of a
Series 40, 50 and 60 long drift and compress spring leaves in a vise.
6 . Remove drift from center hole and install a new
Removal center bolt—peen bolt to retain nut.
Refer to Figure 27. 7. Align spring leaves by tapping with hammer, then
bend spring clips into place or install bolts and
CAUTION: Do not jack under radius leaf. If it spacer if so equipped.
is deemed necessary to jack under stress plate,
make sure surface of jack is smooth so as to NOTE: Spring clips should be bent sufficiently
avoid nicking stress plate. to maintain alignment, but not tight enough to
bind spring action.
1. Straighten tabs on rebound stop pin retainers at front
and rear hangers and remove retainer bolts and re­
bound pins.
2. Install a "C" clamp on radius leaf to relieve load on
spring eye bolt. Remove eye bolt and slowly release
tension on radius leaf.
3. Remove nuts from "U" bolts, remove "U" bolts and
"U" bolt spacer plate from spring.

NOTE: As an aid in reinstalling spring, note

position of caster shim placed between spring
assembly and axle housing. Record position as
"thick edge forward" or "thin edge forward" as
the position dictates.

4. Remove spring and camber shim from spring seat

and from beneath the vehicle.
5. Inspect spring--replace bushing, repair or replace
spring unit as outlined in this section.

Installation
1. Install spring camber shim making sure shim is po­
sitioned so that it corresponds to shim on opposite
side and that it is as noted in step 3 of "Removal"
procedures.
2. Place spring on shim with center bolt indexed in pad
center hole and spring ends positioned in hangers.
3. Install "U" bolt spacer over center bolt on top leaf of F ig . 2 7 - 4 0 , 5 0 , and 60 Spring Removal (Typ ica l)

CHEVROLET TRUCK SERVICE M ANUAL

 REAR SUSPENSION AND DRIVE LINE 4-11

REAR SUSPENSION
(TANDEM)

INDEX

Page Page
General Description ......................................................... 4-11 Equalizing B e a m s ............................................................... 4-15
Component Parts Replacem ent.......................................... 4_13 Torque Rod and B ra c k e t...................................................... 4-16
S p rings........................................................................... 4_13

GENERAL DESCRIPTION
The tandem rear suspension (fig. 28) consists of the two equalizing beams between the forward and rear­
springs, spring saddles and top plates, equalizing beams, ward axle housings. Replaceable bushings are used at
cross tube and torque rods. beam-to-axle mountings (fig. 30) and at cross tube-to-
The semi-elliptic spring leaves are assembled by a saddle and beam mounting (fig. 31).
center bolt and two rebound clips. The forward end of the Axle driving and braking forces are transmiited to the
upper two spring leaves form the spring eye which is vehicle through two torque rods, one at each axle. Torque
fitted with a replaceable bushing (fig. 29). This end of rod connections at each axle and at frame brackets are
the spring is secured in a hanger by a pin which is held made through tapered ball studs which are rubber
in place by a lock bolt. The rear end of the spring rides mounted in torque rod ends (fig. 32).
free in a spring hanger. Lubrication fittings are provided in spring eye pins and
Each spring is mounted at its center on a saddle sup­ in spring rear hangers.
ported on the end of a cross tube which passes through

TORQUE ROD
BRACKETS

TOP PLATES

SPRING

SADDLE x' c;

SADDLE

EQUALIZING
BEAMS

F ig . 28 - Tandem Rear Suspension

CHEVROLET TRUCK SERVICE MANUAL

REAR SUSPENSION AND DRIVE LINE 4-12

F ig . 2 9 - Spring Front Hanger Mounting

Fig . 31 - Cross Tube-to-Spring Saddle Mounting
1. Spring Eye Pin 4. Spring Front Hanger
2. Spring Eye Bushing 5 . Frame Side Rail 1. Center Bushing 6. Lock Nut
3. Spring Eye 6. Spring Pin Lock Bolt 2. Spring Saddle 7. Set Screw
3. Spring Assembly 8. Equalizing Beam
4. Spring Saddle Top Pad 9. Cross Tube
5. Top Pad to Spring 10. Spring Saddle Cap
Saddle Bolts 11. Stud

Frame Bracket

Torque Rod
1 Axle Bracket 5 Bolt
2 Equalizing Beam 6 Nut
3 End Bushing 7 W asher
4 Adapter T-699

Fig . 30 - Beam to A x le Mounting

A x le Bracket 5. Bolt
Equalizer Beam 6. N ut
End Bushing 7. Washer
4 . Adapter F ig . 32 - Torque Rod Stud

CHEVROLET TRUCK SERVICE M ANUAL

 REAR SUSPENSION AND DRIVE LINE 4-13

COMPONENT PARTS REPLACEMENT

SPRINGS b. Remove old bushing from tool and position new
bushing on tools J-8 4 5 9 -4 and -1. Insert tool
Spring Bushing Replacement through spring eye and install J-8 4 5 9 -2, bearing
washer and nut J-8459-6 in that order. Tighten
1. Raise vehicle frame to remove load from spring. nut to start bushing straight in spring eye, then
Support frame securely. use impact wrench to draw bushing into spring
2. Remove forward rear wheels and tires. until bushing stops against J-8 4 5 9 -2. Remove
3. At both springs, remove lubrication fitting from tool.
spring eye pin, remove nut and washer from lock 6 . Check pin for slip fit in bushing and ream if neces­
bolt and tap bolt out of hanger, then drive pin out of sary, using a standard 1.250" reamer.
spring and hanger. Jack rear axle if necessary, to 7. Repeat steps 4, 5, and 6 at opposite spring.
lower front axle so pin will clear brake flange plate. 8. At both springs, align spring eye in hanger, install
4. Raise rear axle to bring front spring eye out of pin so slot in pin lines up with lock bolt holes in
hanger just far enough to clear hanger. hanger and install lock bolt so wedge mates with slot
in pin. Install lock bolt washer and nut.
NOTE: On some vehicles it may be necessary 9. Install wheels and tires. Lower vehicle to ground
to loosen forward torque nuts and loosen studs in and, with vehicle at curb weight, tighten torque rod
axle brackets. (See "Torque Rod Removal" in nuts to 300 ft. lbs.
this section.)
Removal of Spring
5. Remove old bushing and install new bushing using
Tool J-8459 as follows (See Figure 33). Refer to Figure 34.
a. Install J-8 4 5 9 -4 on J - 8459-1, lubricate threads 1. Remove rebound bolt and spacer from bottom of
and insert tool through the bushing. Install spring rear hanger.
J-8 4 5 9 -3 , -2 , bearing, washer and nut J-8459-6 in 2. Raise vehicle frame to remove load from spring.
that order. Use breaker bar to start bushing, Support frame securely.
then use impact wrench to draw bushing out of 3. Remove nut and washer from spring eye pin lock bolt
spring eye. at inside of front hanger and tap out bolt. Remove
lubrication fitting from inner end of pin, then drive
pin out from inner side of hanger, using a brass drift
and hammer.
4. Remove four bolts attaching spring saddle top pad to
spring saddle; hold nuts at bottom while turning bolts
at top.
5. Loosen lock nuts on top pad set screws, then loosen
set screws. Lift top pad and locating slide from top
of spring.
6 . Lift spring assembly up and rearward to remove
from spring saddle.

Disassembly of Spring

Clamp spring leaves firmly together, using one "C"

clamp on each side of center bolt, or use an arbor press.
Remove rebound clip bolts and spacers, then remove
spring center bolt. Release "C" clamps or arbor press
slowly to avoid possible injury.

Cleaning and Inspection

1. Clean all rust and dirt from spring leaves, using a

wire brush if necessary. Make sure machined sur­
faces of spring saddle are clean.
2. Inspect each spring leaf for cracks or breaks and
replace any that are damaged.
3. Thoroughly clean spring eye pin, making sure lubri­
cant passages are open. Replace pin if excessive
wear is evident.
4. Inspect spring eye bushing for wear. If excessive
wear is evident, replace bushing using Tool J-8459
(See Figure 33).
Fig . 33 - Removing and Installing Spring Eye Bushing 5. Replace rebound clip bolts or center bolt if damaged
with Tool J-8459 in any way.

CHEVROLET TRUCK SERVICE M ANUAL

REAR SUSPENSION AND DRIVE LINE 4-14

m j ■19
-----20

Fig. 3 4 - Spring Details

1. Spring Hanger Pin 8. Top Pad Slide 15. Center Bolt

2. Spring Front Hanger 9. Top Pad Set Screw , N u t and Lockwasher 16. Spring Assembly
3. Spring Saddle Top Pad Bolt 10. Spacer 17. Spring Saddle
4. Spring Rear Hanger 11. Spacer Bolt, N u t and Lockwasher 18. Saddle Cap Stud
5. Lubrication Fitting 12. Bushing 19. Saddle Cap Stud N ut
6. Spring Hanger Pin Lock Bolt, N ut and Washer 13. C lip 20. Saddle Cap
7. Spring Saddle Top Pad 14. Bolt 21. Top Pad Bolt Nut

Assembly of Spring Installation of Spring

Coat spring leaves with a light film of graphite grease. 1. Position spring assembly on spring saddle with cen­
Stack spring leaves in correct order, then compress ter bolt head in locating hole in saddle, and with
leaves using "C" clamps or an arbor press. Install cen­ spring ends in place at frame hangers.
ter bolt, then install rebound clip bolts and spacers. 2. Place top pad locating slide on top spring leaf, then
Tighten center bolt firmly; tighten rebound clip bolts position top pad to saddle bolts and nuts and tighten
enough to hold leaves in alignment without restricting snugly. Tighten top pad set screws to 140 ft. lbs.
free movement. torque, then tighten set screw lock nuts.

CHEVROLET TRUCK SERVICE M ANUAL

 REAR SUSPENSION AND DRIVE LINE 4-15

IMPORTANT: The top pad set screws must be

tightened to specified torque to properly seat
spring against machined face of saddle before
tightening top pad to saddle bolts.

4. Tighten top pad to saddle bolts to 290 ft. lbs. torque;

hold nuts at bottom while using torque wrench on bolt
heads at top.
5. Install spring eye pin through hanger and spring eye,
with slot in pin aligned with lock bolt holes in hanger.
Use a soft hammer to drive pin in from outer side.
Install spring eye pin lock bolt, washer and nut and
tighten firmly. Install lubrication fitting in inner end
of pin.
6 . Install rebound bolt and spacer in lower end of rear
hanger and install lock nut. Lubricate spring ends
as directed in Section O of this manual. Remove
support from under vehicle frame.

EQUALIZING BEAMS
Removal

1. Support frame so springs are lifted just enough to Fig. 36. - Equalizing Beam Details
remove weight of equalizing beam from beam-to-axle
hanger adapters. 1. Bolt 5. Nut
2. Remove nut from beam-to-axle adapter bolt and re­ 2. Adapter 6. C enter Bushing
move bolt and adapter by prying adapter at head of 3. End Bushing 7. Washer
bolt out of hanger (See Figure 35), then pry out oppo­ 4. Equalizing Beam
site adapter. Repeat this operation at other end of
beam and at both ends of opposite beam.
3. Support equalizing beams and cross tube to take
weight off center bushings. Remove nuts from four Bushing Replacement
studs securing spring saddle caps to bottom of spring End and center bushings may be removed and new
saddle (two caps at each beam). Remove caps from bushings installed using suitable tools.
studs.
Installation
CAUTION: Keep cross tube level so beams do
not slide off tube. Refer to Figure 36.
1. Apply an anti-rust lubricant to inside of beam center
4. Lower the beams and tube from vehicle and pull bushing, insert end of cross tube in bushing and push
beams off tube. tube into bottom of sleeve.
2. Apply an anti-rust lubricant to inside surface of the
Repairs center bushing in other beam and slide onto cross
tube until tube bottoms in bushing sleeve.

CAUTION: Be_ sure cross tube is all the way

into both bushing sleeves and, while beams are
on the cross tube, keep cross tube level so
beams do not slide off the tube.

3. Position the assembly under vehicle and move the

beams outboard on cross tube just far enough so
beam ends are in line with axle hangers and center
bushings are in line with spring saddles.
4. Support cross tube securely on suitable lift and raise
tube and beams so ends enter hangers and center
bushings enter saddles.
5. Install saddle caps on studs and install nuts.
6 . Line up beam end in axle hanger bracket, install
adapter and bolt in one side of hanger and install
second adapter and nut on end of bolt.
AD A PTER 7. Repeat step 6 at other end of beam and at both ends
of opposite beam.
8 . Position vehicle so suspension supports weight and
F ig . 35 - Adapter and Retaining Bolt at A x le Bracket tighten all nuts to specifications.

CHEVROLET TRUCK SERVICE M ANUAL

REAR SUSPENSION AND DRIVE LINE 4-16

TORQUE ROD AND BRACKET Installation

Removal 1. Position torque rod in a vise, install frame bracket

and nut. Torque nut to 300 ft. lbs. Install cotter pin
1. Support the axle housing so that it will not pivot when in end of ball stud and bend over flat of nut.
torque rod is loosened. 2. Position ball stud in axle housing and position shim
2. Remove nuts and bolts that secure the torque rod and frame bracket to crossmember. Install and
bracket to frame crossmember. Remove spacer and torque bracket retaining bolts and nuts to 65 ft. lbs.
allow torque rod to pivot downward until it rests on 3. Install ball stud nut, torque to 300 ft. lbs., position
housing. cotter pin in end of ball stud and bend over flat of
3. Remove nut from torque rod stud at axle housing nut.
bracket. 4. Remove support from axle housing.
4. Rap surface of bracket to loosen stud; then, using a
suitable puller, remove torque rod stud from axle NOTE: Recheck the torque on these nuts after
housing bracket. approximately 500 miles of driving.
5. Position torque rod and frame bracket in a vise and
remove stud nut, then press stud from frame bracket
in an arbor press.

DRIVE LINE
REAR AXLE (CHEVROLET) SINGLE SPEED
INDEX
Page Page
General Description ......................................................... ...4-17 Axle Assembly ......................................................... 4-26
2400, 2900, 3300, 3500 and 3600 Lb. Capacity Removal ............................................................... 4-26
(Salisbury-Type) Axles ............................................. ...4-17 Installation............................................................ 4-27
5200 and 7200 Lb. Capacity A x le s ................................. ...4-17 Axle Vent R ep lacem en t............................................. 4-27
11,000, 13,500, 15,000 and 17,000 Lb. Axle Shaft—Removal and Installation........................ 4-27
Capacity A x l e s ............................................................ ...4-17 5200 and 7200 Lb. A x l e s ....................................... 4-27
Maintenance and Adjustments .......................................... ...4-17 11,000, 13,500 and 15,000 Lb. A x l e s ..................... 4-27
Lubricant........................................................................ ...4-17 17,000 Lb. A x le ...................................................... 4-28
U-Bolt and Hub N u t s ...................................................... ...4-17 Hub and D r u m ............................................................ 4-29
Rear Axle Noise D i a g n o s is .......................................... ...4-17 Removal ............................................................... 4-29
Component Parts Replacem ent.......................................... ...4-22 Cleaning ............................................................... 4-29
2400, 2900, 3300, 3500 and 3600 Lb. Capacity Inspection............................................................... 4-30
(Salisbury-Type) Axles ............................................. ...4-22 R e p a ir s .................................................................. 4-30
Axle A s s e m b ly ......................................................... ...4-22 Bearing Cup Replacement................................. 4-30
R em o v al............................................................... ...4_22 Drum R ep lacem en t.......................................... 4-31
Installation............................................................ ...4-22 Demountable-Type .................................... 4-31
Axle Vent Replacement .......................................... ...4-23 Non-demountable T y p e .............................. 4-32
Axle Shaft ............................................................... ... 4 _ 2 3 Wheel Bolt Replacement ................................. 4 - 3 2
R e m o v a l............................................................... ...4_23 Hub Stud Replacement .................................... 4-32
Wheel Bolt Replacem ent................................. ...4-23 Oil Seal Sleeve and Bearing Thrust Spacer
Oil Seal and/or Bearing Replacem ent............ 4-23 Replacem ent................................................... 4-32
Brake Flange Plate R ep lacem en t.................. ...4-23 Wheel Hub Oil Seal R eplacem ent..................... 4-33
Installation ......................................................... ...4-23 Installation............................................................ 4-34
Pinion Flange, Dust Deflector and/or Bearing A d ju s tm e n t............................................. 4-34
Oil Seal R ep lacem en t....................................... ...4-24 Drive Pinion Oil Seal
Positraction Differential U n it.............................. ...4-26 R e p la c e m e n t...................................................... 4-34
On The Vehicle C h e c k .................................... ...4-26 No-Spin Differential U n it....................................... 4-34
5200 Through 17,000 Lb. Capacity A x l e s ..................... ...4-26 On The Vehicle Check....................................... 4-35

CHEVROLET TRUCK SERVICE M ANUAL

 REAR SUSPENSION AND DRIVE LINE 4-17

GENERAL DESCRIPTION
an outer race and roller assembly—a precision ground
2400, 2900, 3300, 3500 AND 3600 LB. diameter on the pinion pilot functions as an inner race.
CAPACITY (SALISBURY-TYPE) AXLES Basically the two axle assemblies are identical with the
exception of drive gear ratios and brake assemblies;
The 2400, 2900, 3300, 3500 and 3600 lb. capacity however, Series C-K20 vehicles utilize a two-pinion dif­
(Salisbury-Type) axle (fig. 37) is a semifloating, fabri­ ferential while all other series are equipped with a four-
cated construction type consisting of a cast ca rrier with pinion differential.
large bosses on each end into which two welded steel
tubes are fitted. The carrier contains an overhung hypoid 11,000, 13,500 15,000 AND 17,000 LB.
pinion and ring gear. The differential is a two pinion CAPACITY AXLES
arrangement.
The axle housing is made up of two steel welded tubes The 11,000 and the 13,500, 15,000 and 17,000 lb. capac­
pressed into the crossbore of the cast carrier--each tube ity, single-speed hypoid axles, illustrated in Figures 39
is puddle welded to the carrier. Welded-on brackets and 40 respectively, have a straddle mounted drive pinion
provide attachment points for suspension components which is supported at the rear by a straight roller bear­
such as spring seats, shock absorbers and control arms. ing. The pinion front bearing consists of a double row
A welded flange is provided for brake flange plate attach­ ball on the 1 1 , 0 0 0 lb. axle and two opposed tapered roller
ment. bearings on the 13,500, 15,000 and 17,000 lb. axles. Se­
An overhung hypoid drive pinion is supported by two lective shims placed between the pinion front bearing and
preloaded tapered roller bearings. The pinion shaft is its seat in the carrier housing provide a means of adjust­
sealed by means of a molded, spring loaded, rubber seal. ing pinion depth to attain correct ring gear and drive
The seal is mounted on the pinion flange which is splined pinion tooth contacts on the 13,500, 15,000 and 17,000 lb.
and bolted to the hypoid pinion shaft. axles.
The hypoid ring gear is bolted to a one-piece differen­ The differential is a conventional four-pinion type.
tial case which is supported by two preloaded tapered Thrust washers are used between the side gears and case
roller bearings. and also between differential pinions and the differential
case.
5200 AND 7200 LB. CAPACITY AXLES A thrust pad mounted on the end of an adjusting screw
threaded into the carrie r housing on all axles except the
The 5200 and 7200 lb. capacity truck rear axles (fig. 38) 13,500, limits deflection of the ring gear under high
are of the full floating type with hypoid ring gear and torque conditions.
drive pinion. The full floating construction enables easy Involute splines are incorporated in the axle shaft
removal of axle shafts without removing truck load and flange and in the wheel hubs of the 11,000 through 15,000
without jacking up the axle. The differential carrier is lb. axles. This design provides for the driving torque to
heavily ribbed to provide rigid support for the differential be transmitted from the axle shaft to the hub through the
assem bly--differential caps are doweled to the carrier to mating splines.
assure perfect alignment. The 15,000 and 17,000 lb. axles have a removable in­
The straddle-mounted drive pinion is supported at the spection cover; 11,000 and 13,500 lb. axles do not incor­
front by a one-piece double row ball bearing. The pinion porate this feature, the cover is an integral part of the
rear bearing is a roller bearing assembly consisting of axle housing.

MAINTENANCE AND ADJUSTMENTS

LUBRICANT U-BOLTS AND HUB NUTS

The lubricant level should be periodically checked and From a safety standpoint, axle housing to rear spring
maintained at level of filler plug with a warm axle. See "U" bolts and wheel hub nuts should be periodically
the lubrication section of this manual for lubricant inspected for secure installation.
recommendations.
REAR AXLE NOISE DIAGNOSIS
LUBRICANT LEAKS
Mechanical failures of the rear axle are relatively
Lubricant leaks should be checked for at the pinion simple to locate and correct. Noise in a rear axle is a
flange oil seal, sealing area of joint between differential little more difficult to diagnose and repair. One of the
ca rrie r and axle housing, lubricant filler plug, housing most essential parts of rear axle service is proper
bowl cover, and at axle shaft bearings. Correction of diagnosis.
these leaks consists of replacing the defective seals or One of the cardinal points of axle noise diagnosis is the
gaskets involved as described in this section. fact that all rear axles are noisy to a certain degree. The

CHEVROLET TRUCK SERVICE M ANUAL

REAR SUSPENSION AND DRIVE LINE 4-18

Fig. 37 - Rear A x le Cross-Section (2400 lbs Through 3600 lbs)

1. Companion Flange 7. D ifferential Case 13. Cover 19. Thrust W asher

2. Deflector 8. Shim (A) with Service Shim 14. Pinion Shaft 20. D ifferential Pinion
3. Pinion O il Seal 9. G asket 15. Ring G e a r 21. Shim
4. Pinion Front Bearing 10. D ifferential Bearing 16. Side G e a r 22. Pinion Rear
5. Pinion Bearing Spacer 11. " C " Lock 17. Bearing Cap Bearing
6. D ifferential C arrier 12. Pinion Shaft Lock Bolt 18. A x le Shaft 23. Drive Pinion

CHEVROLET TRUCK SERVICE M ANUAL

 REAR SUSPENSION AND DRIVE LINE 4-19

Fig. 38 - 5200 and 7200 Lb. C a p a c ity A x le - Cross Section

1. Universal Jo in t Yoke 6. Drive Pinion 11. D ifferential Pinion (Spider) 15.

2. Pinion Bearing Retainer and 7. Pinion Bearing Shim G ear 16.
O il Seal 8. Rear Pinion Bearing 12. D ifferential Side G e a r Nut
3. O il Seal Packing 9. Ring G e a r 13. D ifferential Case - Left H alf 17.
4. O il Seal 10. Differential Spider 14. A x le Shaft 18. Differential Case - Right H alf
5. Front Pinion Bearing

CHEVROLET TRUCK SERVICE MANUAL

REAR SUSPENSION AND DRIVE LINE 4-20

Fig. 3 9 - 11,000 Lb C a p acity A x le - Cross Section

1. Universal Jo in t Yoke 6. Drive Pinion 11. D ifferential Pinion (Spider) 15. D ifferential Bearing
2. Pinion Bearing Retainer and 7. Rear Pinion Bearing G ear 16. D ifferential Bearing Adjusting
O il Seal 8. Ring G e a r Thrust Pad 12. D ifferential Side G e a r Nut
3. O il Seal Packing 9. Ring G e a r 13. D ifferential Case - Left H alf 17. Adjusting N u t Lock
4. O il Seal 10. D ifferential Spider 14. A x le Shaft 18. D ifferential Case - Right H alf
5. Front Pinion Bearing

CHEVROLET TRUCK SERVICE MANUAL

 REAR SUSPENSION AND DRIVE LINE 4-21

F ig . 40 - 13,500, 15,000 and 17,000 Lb. C a p acity A x le - Cross Section

1. Universal Jo in t Y oke 6. Drive Pinion 11. D ifferential Pinion (Spider) 15. Differential Bearing
2. Pinion Bearing Retainer 7. Rear Pinion Bearing G ear 16. Differential Bearing Adjusting
3. O il Seal 8. Ring G e a r Thrust Pad 12. D ifferential Side G e a r Nut
4. Shims 9. Ring G e a r 13. D ifferential Case (Left H alf) 17. Adjusting Nut Lock
5. Pinion Bearing Assembly 10. D ifferential Spider 14. A x le Shaft 18. Differential Case (Right H alf)

CHEVROLET TRUCK SERVICE MANUAL

REAR SUSPENSION AND DRIVE LINE 4-22

action of transmitting the high engine torque through a ing of the ring gear and pinion teeth as a result of insuf­
90° turn reducing propeller shaft speed produces noise in ficient or improper lubricant in new assemblies. Side
rear axles. This point establishes the need for a line gears rarely give trouble as they are used only when the
between normal and abnormal or unacceptable axle rear wheels travel at different speeds.
noises.
Slight axle noise heard only at a certain speed or under BEARING NOISE
remote conditions must be considered normal. Axle
noise tends to "peak" at varying speeds and the noise is Defective bearings will always produce a rough whine
in no way indicative of trouble in the axle. that is constant in pitch and usually most noticeable under
If noise is present in an objectionable form, loud or at "drive" conditions. This fact will allow you to distinguish
all speeds, an effort should be made to isolate the noise between bearing noise and gear noise.
as being in one particular unit of the vehicle. Axle noise 1. Pinion bearing noise resulting from a bearing failure
is often confused with other noises such as tire noise, can be identified by a constant rough sound. Pinion
transmission noise, propeller shaft vibration and uni­ bearings are rotating at a higher speed than differen­
versal joint noise. Isolation of the noise as in any one tial side bearings or axle shaft bearings. This par­
unit requires skill and experience. An attempt to elimi­ ticular noise can be picked up best by testing the car
nate a slight noise may baffle even the best of diagnosti­ on a smooth road (black top). However, care should
cians. Such practices as raising tire pressure to elimi­ be taken not to confuse tire noise with bearing or
nate tire noise, listening for the noise at varying speeds gear noise. If any doubt exists, tire treads should be
and on drive, float and coast, and under proper highway examined for irregularities that would produce such
conditions, turning the steering wheel from left to right noise.
to detect wheel bearing noise, will aid even the beginner 2. Wheel bearing noise may be confused with rear axle
in detecting alleged axle noises. Axle noises fall into two noise. To differentiate between wheel bearings and
categories: gear noise and bearing noise. rear axle, drive the vehicle on a smooth road at
medium-low speed. With traffic permitting, turn the
GEAR NOISE vehicle sharply right and left. If noise is caused by
wheel bearings, it will increase in the turns because
Abnormal gear noise can be recognized since it pro­ of the side loading. If noise cannot be isolated to
duces a cycling pitch and will be very pronounced in the front or rear wheel bearings, inspection will be
speed range at which it occurs, appearing under either necessary.
"drive," "float" or "coast" conditions. Gear noise tends 3. Side bearings will produce a constant rough noise of
to peak in a narrow speed range or ranges, while bearing a slower nature than pinion bearings. Side bearing
noise will tend to remain constant in pitch. Abnormal noise will not fluctuate in the above wheel bearing
gear noise is rare and usually originates from the scor- test.

COMPONENT Pt S REPLACEMENT
2400, 2900, 3300, 3500 AND 3600 LB. position vent hose to one side.
CAPACITY (SALISBURY-TYPE) AXLES 7. Disconnect hydraulic brake hose at connector on axle
housing. Remove brake drum, disconnect parking
AXLE ASSEMBLY brake cable at actuating levers and at flange plate.
Refer to Section 5 for cable removal and brake
Construction of the axle assembly is such that service
details.
operations may be performed with the housing installed in
8 . On vehicles so equipped, check coil springs to make
the vehicle or with the housing installed in a holding fix­
sure that they are compressed; then on all vehicles,
ture. The following removal and installation procedure
remove axle "U" bolt nuts, "U" bolts, spacers and
is necessary only when the housing requires replacement.
clamp plates.
Removal 9. Lower axle assembly and remove from vehicle.
1. Raise vehicle, place stand jacks under frame side
rails and remove rear wheels. Installation
2. Support rear axle assembly with a hydraulic jack, or 1. Position axle assembly under vehicle and align with
other suitable lifting device, so that tention is re­ springs or control arms as applicable.
lieved in springs, tie rod, and shock absorbers. 2. Install spacer, clamp plate and "U" bolts to axle as­
3. On vehicles so equipped, disconnect tie rod at axle sembly, loosely install retaining nuts to "U" bolts.
housing bracket or at differential carrier. 3. Position shock absorbers in lower attachment brack­
4. Remove trunnion bearing "U" bolts from the axle ets and loosely install nut to retain shock.
companion flange, separate trunnion from flange, po­ 4. Connect axle vent hose to vent connector at carrier.
sition propeller shaft to one side and tie it to frame 5. Connect hydraulic brake hose to connector on axle
side rail. housing, connect parking brake cable to actuating
levers. Install brake drum and wheel and tire as­
NOTE: Secure trunnion bearings caps to trun­
sembly--bleed brakes and adjust parking brake as
nion, using masking tape or a large rubber band,
outlined in applicable portion of Section 5.
to prevent loss of bearings.
6 . Reassemble the propeller shaft to companion flange,
5. Disconnect shock absorbers at lower attachment making sure that bearing caps are indexed in flange
points and position out of the way. seat. Install and torque bearing cap retaining nuts to
6 . Disconnect axle vent hose from vent connector and specifications.

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 REAR SUSPENSION AND DRIVE LINE 4-23

7. Remove stand jacks from frame side rails--position drain are aligned with drain hole in flange before
vehicle so that weight is placed on suspension com­ installing bolts.
ponents and torque affected parts to specifications.
OIL SEAL AND/OR BEARING REPLACEMENT
AXLE VENT REPLACEMENT
1. Remove the oil seal by using the button end of the
The axle vent system consists of the vent connector, axle shaft--insert the button end of the shaft behind
vent hose and associated attaching parts. When replacing the steel case of the oil seal, then pry seal out of
vent hose make sure that it is routed along original path bore being careful not to damage housing. Refer to
in such a manner that the hose is free from kinks or Figure 43 for detail of seal and bearing installation.
binds that would restrict air flow. In replacing the vent 2. Insert Tool J-8119 into bore and position it behind
connector; pry old connector from carrier, being sure bearing so that tangs on tool engage bearing outer
that entire connector is removed. Tap new connector into race. Remove bearing, using slide hammer as shown
ca rrie r with a soft-faced hammer, prick punch around in Figure 44.
edge of hole to insure fit of new connector (fig. 54). 3. Lubricate new bearing with wheel bearing lubricant,
and install bearing so that it bottoms against shoul­
der in housing bore (fig. 45). To install bearing, use
Tool J - 21491 for the 2400 and 2900 lb. axles; Tool
J-21051 for the 3300 lb, 3500 lb, and 3600 lb. axles.
4. Pack cavity between the seal lips with a high-melting
point wheel bearing lubricant, position seal in axle
housing bore and tap seal into position so that it bot­
toms against bearing (fig. 45). To install seal, use
Tool J - 21491 for the 2400 and 2900 lb. axles; Tool
J-21051 for the 3300 lb, 3500 lb, and 3600 lb. axles.

Fig. 41 - D ifferen tial Pinion Shaft Removal

AXLE SHAFT
Fig. 42 - W h eel Bolt Replacement
Removal

1. Raise vehicle to desired working height and remove BRAKE FLANGE BACKING PLATE REPLACEMENT
wheel and tire assembly and brake drum.
2. Clean all dirt and foreign material from area of 1. Remove brake line at wheel cylinder inlet and disas­
carrier cover. semble brake components from flange plate. Refer
3. Loosen carrier cov er-to-carrier bolts slightly to al­ to Section 5 for brake disassembly procedure.
low lubricant to drain from carrier. Remove car­ 2. Remove four nuts securing flange plate to axle hous­
rier cover and gasket. ing (fig. 43).
4. Remove the differential pinion shaft lockscrew and 3. Install new flange plate to axle housing and torque
the differential pinion shaft (fig. 41). nuts to specifications.
5. Push flanged end of axle shaft toward center of vehi­ 4. Install brake components on flange and connect hy­
cle and remove "C" lock from button end of shaft. draulic line to wheel cylinder inlet. Refer to Section
6 . Remove axle shaft from housing, being careful not to 5 for brake assembly procedure.
damage oil seal at end of housing. 5. Bleed and adjust brakes as outlined in Section 5.

WHEEL BOLT REPLACEMENT Installation

1. Slide axle shaft into place.
P ress bolts out of axle shaft flange and press new bolts
into place, making sure that they are tight and square
CAUTION: Exercise care that splines on end
with flange (fig. 42).
of shaft do not damage oil seal and that they en­
gage with splines of differential side gear.
NOTE: On those models equipped with an oil
deflector, make sure that deflector and gasket 2. Install axle shaft "C" lock on button end of axle shaft

CHEVROLET TRUCK SERVICE MANUAL

REAR SUSPENSION AND DRIVE LINE 4-24

CAUTION: Make sure both gasket surfaces on

carrier and cover are clean before installing
new gasket. Torque carrie r bolts in a cross­
wise pattern to ensure uniform draw on cover
gasket.

5. F ill axle with lubricant to a level even with bottom of

filler hole. See Section O for proper lubricant.
6 . Install brake drum and wheel and tire assembly.
7. Lower vehicle and test operation of axle.

F ig . 45 - W h eel Bearing and/or O il Seal Installation

PINION FLANGE, DUST DEFLECTOR

AND/OR OIL SEAL
Replacement

1. Raise rear of vehicle and place stand jacks under

frame side rails so that axle hangs freely to allow
sufficient working room.
2. Check wheels for freedom of rotation.
3. Separate rear universal joint, tape trunnion bearings
Fig . 43 - Sectional V ie w of Housing at W h eel Bearing
to joint, position propeller shaft to one side and tie it
to frame side rail.
and push shaft outward so that shaft lock seats in 4. Using Tool J-5853 with Adapter J-5810 and a suitable
counterbore of differential side gear. socket on the pinion flange nut, rotate the pinion
3. Position differential pinion shaft through case and through several complete revolutions and record the
pinions, aligning hole in shaft with lock screw hole in torque required to keep the pinion turning (fig. 46).
case. If flange is to be reused, mark pinion and flange for
4. Using a new gasket, install carrier cover and torque reassembly in the same relative position.
bolts to specifications. 5. Install Tool J-8614-1 on pinion flange and remove
pinion flange nut (fig. 47). (Position J-8614-1 on
flange so that the four notches are toward flange.)
Discard nut and use a new one upon reassembly.
6 . Thread pilot end of Tool J-8614-3 into small O.D.
end of J-8614-2. Then with J-8614-1 installed as in
Step 4, insert J-8614-2 into J-8614-1 and turn it 45
degrees to locked position. Remove flange by turn­
ing J-8614-3 while holding J-8614-1 (fig. 48).
7. Pry old seal out of bore, using a screwdriver or a
hammer and chisel.
8 . Inspect pinion flange for smooth oil seal surface,
worn drive splines, damaged ears, and for smooth­
ness of bearing contact surface. Replace if
necessary.
9. If deflector requires replacement, remove by tapping
from flange, clean up stake points; install new de­
flector, and stake deflector at three new equally
F ig . 4 4 - W heel Bearing Removal spaced positions.

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 REAR SUSPENSION AND DRIVE LINE 4-25

Fig. 48 - D rive Pinion Flange Removal

CAUTION: Pinion oil seal flange must not bot­

tom against carrier. P ress seal into carrier
bore until it seats against internal shoulder--at
this point there should be a gap of approximately
1 / 8 " between seal flange and carrier (fig. 51)^
Do not apply unnecessary pressure after seal is
seated, to do so will destroy rubber seat and
distort seal.

11. Position and align pinion flange on pinion shaft using

Fig. 46 - Measuring Pinion Bearing Preload Tools J-9458 and J - 8614-1. Tool J - 9458-1 is
threaded onto pinion shaft and nut tightened against
NOTE: Staking operation must be performed in J-9 4 5 8 -2 to pull flange on shaft (fig. 52). Remove
such a manner that the seal operating surface is J-9458 after flange is seated.
not damaged.
NOTE: The position of the pinion and flange
10. Pack the cavity between the seal lips of the pinion was previously marked so that reinstallation
flange oil seal with a lithium-base extreme pressure may be made with flange and pinion in same
lubricant, position seal in bore then using Tools relative position.
J - 21468 and J-9458 for 2400 lb. axles (fig. 49) and
Tool J-21057 for 2900, 3300, 3500 and 3600 lb. axles CAUTION: Do not attempt to hammer flange
(fig. 50). P ress seal into bore until it seats against onto pinion shaft. To do so will damage ring
internal shoulder. gear and pinion.

F ig . 47 - D rive Pinion N ut Removal F ig . 4 9 - Drive Pinion Flange O il Seal Installation (Light-D uty)

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REAR SUSPENSION AND DRIVE LINE 4-26

the vehicle check” listed below.

On The Vehicle Check

If vehicle is equipped with a manual transmission,

shift transmission into neutral.
1. Raise rear of vehicle until wheels are off the ground,
remove one wheel and tire assembly.
2. Attach Adapter J-5748 to axle shaft flange and install
a 1/2”-13 bolt into adapter (fig. 53).
3. With wheel and tire assembly still on vehicle held
firmly to prevent turning, measure torque required
to rotate opposite axle shaft with a 0-150 lb. torque
wrench attached to J-5748. Torque should be 70 ft.
Fig. 5 0 - D rive Pinion Flange O il Seal Installation (H eavy-D uty) lbs. minimum new, and no less than 40 ft. lbs. if
used.

Fig . 53 - Measuring Positraction Rotating Torque

5200 THROUGH 17000 LB CAPACITY AXLE

AXLE ASSEMBLY

Service operations on these axle assemblies may be

performed with the housing installed in the vehicle or
with the housing installed in a holding fixture. There may
Fig. 52 - Pinion Flange Installation be occasions, however, when it will be necessary to re­
move the complete housing assembly. The following axle
12. Pack the cavity between end of pinion splines and assembly removal and installation procedure, therefore,
pinion flange with a non-hardening sealer (such as is necessary only when housing replacement is required.
Permatex Type A) prior to installing nut on pinion.
13. Install a new self-locking washer face type nut on Removal
pinion shaft. Tighten nut to remove end play and con­
tinue alternately tightening in small increments and 1. Raise vehicle, place stand jacks under frame side
checking preload with torque wrench until it is the rails, and remove rear wheels.
same as that recorded in Step 4. 2. Remove two trunnion bearings "U" bolts from the
14. Reassemble the rear universal joint, and torque ”U” rear yoke, split rear universal joint, position propel­
bolt nuts to specifications. ler shaft to one side, and tie it to the frame side rail.
15. Lower vehicle to floor and road test for leaks.
NOTE: The bearings can be left on the trun­
POSITRACTION DIFFERENTIAL UNIT nion and held in place with tape.

The optionally available Positraction differential unit is 3. On K and P20 series vehicles, remove brake drum
installed in the conventional carrier to replace the stand­ and disconnect parking brake cable at lever and at
ard differential unit. flange plate. (See Section 5 for cable removal.)
Service procedures for the Positraction equipped axle 4. Disconnect hydraulic brake hose at connector on rear
are the same as on a conventional axle except for the ”oji axle housing. (If vehicle is equipped with air brakes,

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 REAR SUSPENSION AND DRIVE LINE 4-27

disconnect air line at brake chambers, and tie lines sealer (such as Permatex Type A) to bolt
out of the way.) threads. Use care in the amount of sealer ap­
5. Disconnect shock absorbers at axle brackets. plied, as in too heavy an application, the sealer
6 . Support axle assembly with hydraulic jack, remove may be forced out as the bolt is installed and
spring "U" bolts, and lower axle assembly to the may destroy sealing effect of the flange-to-hub
floor. gasket.
ll,0 0 0 r 13,500 AND 15,000 LB. AXLES
Installation 1. Remove hub cap, and install Tool J-8117 in tapped
hole on shaft flange.
1. Place axle assembly under vehicle, raise into posi­ 2. Install slide hammer (Tool J-2619) and remove axle
tion, install spring "U" bolts, anchor plates and nuts, shaft (fig. 56).
and tighten securely. (On P30 series vehicles make 3. Thoroughly remove old gasket material from hub and
sure that stabilizer anchor plates are properly posi­ hub cap. Clean shaft flange and mating surfaces in
tioned on forward "U" bolts.) the wheel hub.
2. Connect and secure shock absorbers to axle 4. Install axle shaft so that the flange splines index into
brackets. hub splines. Tap shaft into position, using J-8117
3. Connect hydraulic brake hose to connector on axle and J-2619.
housing, and bleed hydraulic system as specified in
Section 5. (If vehicle is equipped with air brakes,
connect air line at brake chambers—test connections
to make sure that there is no leakage.)
4. On K and P20 series vehicles, connect hand brake
cables and adjust parking brakes as specified in
Section 5.
5. Reassemble the rear universal joint, making sure
that "U" bolts are drawn up tight and locked prop­
erly. Caution should be taken not to overtighten ”U"
bolt nuts and cause bearing cups to become distorted.
6 . Install rear wheels, remove stand jacks, and lower
vehicle.
7. Test operation of brakes and rear axle.

AXLE VENT REPLACEMENT

Service replacement axle housing assemblies are not
equipped with an axle vent; therefore, always make sure
that a new vent assembly is installed when replacing the
housing. If axle vent requires replacement, pry old vent
from housing being sure that entire vent is removed.
P rick punch around carrier hole to insure fit of replace­
ment vent. Tap new vent into housing using a soft-faced
hammer. Vent should be positioned in housing so that
flat surface is toward centerline of differential carrier
(fig. 54).

Axle Shaft—Removal and Installation

5200 and 7200 Lb. Axles
1. Remove bolts and lockwashers that attach the axle
shaft flange to the wheel hub.
2. Install two l/2 " -1 3 bolts in the threaded holes pro­
vided in the axle shaft flange. By turning these bolts Fig. 55 - Removing A x le Shaft (5200 and 7200 Lb. A x le)
alternately the axle shaft may be easily started and
then removed from the housing (fig. 55).
3. Thoroughly clean both the axle shaft flange and the
end of the wheel hub.
NOTE: Any lubricant on these surfaces tends
to loosen axle shaft flange bolts.
4. Place a new gasket over the axle shaft and position
the axle shaft in the housing so that the shaft splines
enter the differential side gear. Position gasket so
that holes are in alignment and install flange-to-hub
attaching bolts--torque bolts to 90 ft. lbs.
NOTE: To prevent lubricant from leaking
through flange holes, apply a non-hardening F ig . 5 6 - Removing A x le Shaft (1 1 ,0 0 0 , 13,500 and 15,000 Lb. A x le )

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REAR SUSPENSION AND DRIVE LINE 4-28

5. Install new hub cap-to-hub gasket, position hub cap to to loosen flange and dowels.
hub and install attaching bolts—torque bolts to 14 ft. 3. Remove tapered dowels from studs and pull axle
lbs. shaft from housing. In some instances it may be
necessary to spread dowels to permit removal.
17,000 LB. AXLE 4. Thoroughly clean old gasket material from wheel hub
1. Remove the axle shaft flange-to-hub retaining nuts. and axle shaft flange, and install a new gasket over
(Refer to Figure 57.) hub studs and against hub.
2. Strike the center of shaft flange with a lead hammer 5. Install axle shaft so that splines are aligned with dif-

Fig. 57 - Hub and Drum Details (Nondemountable - Type Drum)

1. A x le Shaft 7. Drum 12. Drum-to-Hub Retaining 17. A x le Shaft Thrust 21. W h ee l Stud
2 . A x le Shaft-to-W heel Bolt 8. O il Deflector Screw Spacer 22. Drum-to-Hub Retaining Bolt
3. Adjusting N u t Lock N u t 9. O il Deflector 13. Thrust Washer 18. Hub Cap 23. Tapered Dowel
4 . Hub O uter Bearing Assembly 10. O il Seal 14. Bearing Adjusting N ut 19. Hub Cap Retaining 24. Axle-to-H ub Retaining Stud
5 . Hub O uter Bearing Retainer 11. Hub Inner Bearing 15. Adjusting N u t Lock Bolt 25. A x le Shaft-to-Hub Retaining
6. W h eel Bolt Assembly 16. G asket 20. O il Seal N ut

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 REAR SUSPENSION AND DRIVE LINE 4-29

Fig . 58 - Hub and Drum Details (Demountable-T/pe Drum)

1. A x le Shaft 6. W h eel Bolt 11. Hub Inner Bearing Assembly 16. Gasket
2. A x le Shaft-to-W heel Hub 7. Drum 12. Drum-to-Hub Retaining Screw 17. A x le Shaft Thrust Spacer
Retaining Bolt 8 . O il Deflector 13. Thrust Washer 18. Hub Cap
3. Adjusting N u t Lock N u t 9. O il D eflector 14. Bearing Adjusting N ut 19. Hub Cap Retaining Bolt
4. Hub O u ter Bearing Assembly 10. O il Seal 15. Adjusting N u t Lock 20. Hub Inner Bearing Spacer
5. Hub O uter Bearing Retainer

ferential side gear and flange holes index over hub NOTE: On 5200 through 15,000 lb. axles, re ­
studs. move thrust washer from housing tube.
6 . Install tapered dowel over each hub stud. Install and
tighten stud nuts to 90 ft. lbs. torque. 5. Pull hub and drum assembly straight off axle hous­
7. Observe that clearance exists between face of stud ing, using care on the 11,000, through 17,000 lb.
nuts and axle shaft flange. If no clearance exists, axles to avoid dropping outer bearing inner race and
this indicates excessive wear at studs, tapered dow­ roller assembly.
els, or flange holes—replace worn part if necessary.
NOTE: The hub oil seal should be replaced
HUB AND DRUM whenever the hub is removed for any reason.
(Refer to Figures 57 and 58.)
6 . Remove oil seal.
Removal

1. Remove wheel assembly and axle shaft as specified Cleaning

in applicable "Axle Shaft Removal" procedure of this
section. 1. Immerse bearing cone and roller assemblies in
2. Disengage tang of nut lock from slot or flat of lock cleaning solvent. Clean with stiff brush to remove
nut, then remove lock nut from housing tube, using old lubricant. Blow bearings dry with compressed
appropriate tool (fig. 59): air, directing air stream across bearing. Do not
a. J-2 2 2 2 —5200 and 7200 lb. axles. spin bearings while blowing them dry.
b. J-0 8 7 0 —11,000 and 13,500 lb. axle.
c. J-22343-15,000 lb. axle. NOTE: To remove inner and outer bearings
M50 Trailing and cups see "Bearing Cup Replacement" for
15.000 lb. Axle (Two-Speed) various axles.
M50 Trailing Axle (Two-Speed)
17.000 lb. Axle (Two-Speed) 2. Thoroughly clean all lubricant off axle housing tube
d. J-7 3 4 1 —17,000 lb. axle. and out of inside the hub, wipe dry. Make sure all
3. Disengage tang of nut lock from slot of flat of ad­ particles of gasket are removed from outer end of
justing nut and remove nut lock from housing tube. hub, axle shaft, and hub cap.
4. Use appropriate tool as specified in Step 2 to remove 3. Scrape old sealing compound out of oil seal bore in
adjusting nut from housing tube. the hub.

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REAR SUSPENSION AND DRIVE LINE 4-30

PRESS TOO L

BAR STOCK

Fig. 5 9 - Removing Bearing Adjusting N ut Lock N u t (Typ ical)

Inspection F ig . 60 - Removing Hub Inner Bearing Cup

1. Inspect bearing rollers for excessive wear, chipped

edges, and other damage. Slowly move rollers
around cone to detect any flat or rough spots on rol­
lers or cone.
2. Examine bearing cups in hub for pits, cracks, and
other damage.
3. Examine axle shaft flange studs, wheel studs, hub
splines, hub bore, and tapped holes for evidence of
damage—clean up threads or replace parts where
required.
4. Examine oil seal sleeve for evidence of wear or
roughness, check axle housing oil deflector and brake
drum oil deflector for evidence of damage--replace
parts where required.
5. Examine brake drum for excessive scoring and other
damage. To replace brake drum refer to "Brake
Drum Replacement."

Repairs Fig. 61 - Installing Hub Inner Bearing Cup (T yp ical)

Bearing Cup Replacement and 13,500 lb. axle.

Replace inner cup (all axles) and outer bearing cup for c. J-5669--15,000 lb. axle with 15 x 4 inch brakes.
17,000 lb. axle as follows: d. J-22359-15,000 lb. axle with 15 x 5 inch brakes.
1. Cut a suitable length of 1/2 inch steel bar stock for M50 Trailing Axle.
press-out tool as shown in Figure 60. 15,000 lb. Axle (Two-Speed)
2. Place appropriate press-out tool behind bearing cup, M50 Trailing Axle (Two-Speed)
index tool in provided notches, and press out cup e. J-21160 - 17,000 lb. (Two-Speed)
with an arbor press. f. J-21160 (Use with J-8092 driver handle)--17,000
lb. axle (inner bearing).
NOTE: Hub outer bearing (all axles except g. J-21108 (Use with J-8092 driver handle) —17,000
17,000 lb. axle) cannot be replaced with inner lb. axle (outer bearing).
bearings in position; therefore, replace outer Replace outer bearing assembly (all axles except
bearings (if required) before proceeding. 17,000 lb. single speed) as follows:

3. Position bearing cup in hub--thick edge of cup toward NOTE: Inner bearing assembly must be re ­
shoulder in hub—then, using applicable cup installer moved before attempting to replace outer bear­
as specified, press cup into hub until it seats on hub ing assembly.
shoulder (fig. 61). Make certain that cup is not
cocked and that it is fully seated against shoulder. 1. Using a punch of suitable length, tap bearing outer
a. J-8114 (Use with J-8092 driver handle)—5200 and race away from bearing retaining ring (fig. 62). Then
7200 lb. axles. remove retaining ring from hub—using pliers for re ­
b. J-8093 (Use with J-8092 driver handle)--11,000 moval of ring on 5200 and 7200 lb. axle (fig. 62),

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 REAR SUSPENSION AND DRIVE LINE 4-31

Fig . 62 - Removing Bearing Retainer Ring (5200 and 7200 Lb. A xles)

using Tool J-22380 for removal of ring on 15,000 lb.

axle.
M50 Trailing Axle (single-speed)
M50 Trailing Axle (two-speed)
15.000 lb. two-speed axle
17.000 lb. two-speed axle (fig. 63)
2. P ress bearing assembly from hub:
a. 5200 and 7200 lb. axles--Position Tool J-2230 in
axle flange retaining bolt holes as shown in Fig­
ure 64 and press bearing from its position. Fig. 64 - Removing Hub O u ter Bearing (5200 and 7200 Lb. Axles)

b. 11,000, 13,500 and 15,000 lb. axles with 1 5 x 4

inch brakes—Remove the bearings by driving on M50, V50 and X50 trailing axle
the axle shaft spacer, using the splined flange cut (two-speed) (fig. 6 6 )
from an old axle shaft (fig. 65). d. Tool J-22350 17,000 lb. two speed axle (fig. 6 6 )
c. Tool J-22360 (See fig. 6 6 ) 15,000 lb. axle with 3. On 11,000, 13,500 and 15,000 with 1 5 x 4 inch brakes
15 x 5 inch brake place axle shaft spacer in hub first. Place inner
15,000 lb. two-speed axle race and roller assembly in hub--larger O.D. of rol­
M50 trailing axle (single-speed) ler assembly towards outer end of hub--then position
bearing cup in hub—thin edge of cup toward outer
end of hub--press cup into hub, using Tool J-2223
for 5200 and 7200 lb. axles; Tool J-8114 with J-8092
drive handle for 11,000 and 13,500 lb. axle; Tool
J-5698 for 15,000 lb. with 1 5 x 4 inch brake and Tool
J-22357 with J-8092 handle for 15,000 lb. axle with
1 5 x 5 inch brake, M50 trailing axle, 15,000 lb. (Two-
Speed), M50 trailing. Tool J - 22349 with 17,000 lb.
(Two-Speed) axle (fig. 67).
4. Withdraw cup installer and install retainer ring using
pliers for 5200 and 7200 lb. axles (fig. 62) or Tool
J-22380 for 11,500, 13,500, 15,000, 17,000 lb. (Two-
Speed) axles (fig. 63).
5. P ress the bearing cup into positive contact with re ­
tainer ring, using Tool J-2230 for 5200 and 7200 lb.
axles as shown in Figure 64, a splined axle shaft
flange for 11,000, 13,500, and 15,000 lb. axles with
1 5 x 4 inch brake shown in Figure 65 or Tool J-22360
for 15,000 lb. axle with 15 x 5 brake and M50 trailing
axle, 15,000 lb. (two-speed); M50, trailing. Tool
J22350 for 17,000 lb. (Two-Speed) axle (fig. 6 6 ).

NOTE: The bearing cup-to-retainer ring seat­

ing procedure is essential to assure that an ac­
curate wheel bearing adjustment will be obtained,
and that the adjustment will not loosen during
vehicle operation.

Drum Replacement

Dem ountable-Type (Fig. 58)

The demountable-type drum may be separated from the

F ig . 63 - Removing Wheel Hub O uter Bearing Retaining Ring hub and removed from the vehicle without disturbing the

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REAR SUSPENSION AND DRIVE LINE 4-32

Fig. 66 - Removing Hub O u ter Bearing

(15,000 and 17,000 Lb. Axles)

Hub Stud Replacement

Hub studs can be removed and replaced by using a con­
ventional stud remover and replacer. Make sure that
studs are firmly bottomed in holes and that threads are
not damaged during installation.

Oil Seal Sleeve and Bearing Thrust Spacer

Fig. 65 - Removing Hub O u ter Bearing
(11,000, 13,500 and 15,000 Lb. Axles) The hub inner bearing spacer and sleeve assembly

axle shaft and hub. The drum is held to the hub by coun­
tersunk, slotted screws, which are easily removed with a
screwdriver.

Nondemountable-Type (Fig. 57)

Construction, of the nondemountable-type hub and drum
assembly, is such that replacement cannot be accom­
plished with the hub assembly installed on the vehicle.
1. Separate the drum and hub by removing the drum-to-
hub retaining bolts, hub stud nuts, or by pressing out
the wheel studs, as applicable.
2. Position brake drum to hub assembly, making certain
that all drain holes are in alignment.
3. Apply a light, even coating of sealing compound to the
hub oil deflector contact surface, and position de­
flector to drum.
4. Install drum-to-hub retaining bolts, hub stud nuts, or
press wheel studs into drum, as applicable.

Wheel Bolt Replacement

Wheel bolts are serrated and may also be swaged in
place; however, replacement procedure remains the same
for both types of installation.
P ress bolts out of hub flange (as illustrated in Figure
6 8 ) and press new bolts into place, making sure they are
a tight fit. If all bolts were removed, be sure that hub oil
deflector is in position under bolt heads. F ig . 6 7 - Installing Hub O uter Bearing (Typ ica l)

CHEVRO tET TRUCK SERVICE M ANUAL

 REAR SUSPENSION AND DRIVE LINE 4-33

Fig . 70 - 17,000 Lb. A x le W heel Hub Details

1. Adjusting N u t Lock N u t 5. Inner Bearing Assembly

2. Adjusting N ut Lock 6. O il Seal
REM O VAL IN S T A L LA T IO N 3. Adjusting N u t 7. O il Seal S le e v e
4. O uter Bearing Assembly 8. D eflector

F ig . 68 - W h ee l Bolt Replacement should be inspected when the hub and bearing assembly is
removed from the axle housing (fig. 70).
If inspection dictates the need for replacement, pry the
sleeve and spacer assembly from the housing, being
careful not to damage machined surface of axle housing.
P ress a new bearing spacer into the ID of a new
sleeve - spacer should seat against bottom of sleeve.
CAUTION: The O P of the sleeve is the running
surface for the hub oil seal. Use extreme care
to prevent damage to this surface when install­
ing the bearing spacer (fig. 70).
Tap the sleeve assembly onto the axle housing until the
bearing spacer contacts shoulder on housing.

Wheel Hub Oil Seal Replacement

Pry old seal from its location in the hub bore, using
care so as not to damage bore surface. Thoroughly clean
all oil and foreign matter from seal contact area in hub
bore. Pack the cavity between the seal lips with a high-
melting point wheel bearing lubricant, and position seal
in hub bore. Carefully press the seal into the hub bore,
using appropriate tool until seal is properly seated
(fig. 69)
1. J-22351 5200 and 7200 lb. axles - Seal should be
installed flush with end of hub.
2 . J-22354 11.000 lb. axle - Seal should be installed
flush with end of hub.
3. J-22352 13,500 lb. axle - Seal should be installed
flush with end of hub.
4. J-22353 15.000 lb. axle with 15 x 4 inch brake -
Seal should be installed so that it makes
direct contact with bearing race.
5. J-22335 15,000 lb. axle with 15 x 5 inch brake
M50 trailing axle (single-speed)
M50 trailing axle (two-speed)
15.000 lb. two-speed axle
17.000 lb. single-speed axle (fig. 70)
17.000 lb. two-speed axle
Seal should be installed flush with end of
F ig . 6 9 - Installing Wheel Hub O il Seal hub.

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REAR SUSPENSION AND DRIVE LINE 4-34

Installation c. J-22343-15,000 lb. axle with 15 x 5 inch brake

M50 trailing axle (single-speed)
1. On the 15,000 lb. axle with 4 inch brake, install inner M50 trailing axle (two-speed)
bearing oil seal in the inner bearing race and posi­ 15.000 lb. two-speed axle
tion bearing race on axle housing. 17.000 lb. two-speed axle
2. Using a smooth cup grease, liberally pack bearings (Tighten adjusting nut to approximately
and apply a light coat of I.D. of hub bearing contact 50 ft. lbs. torque, then back off nut 1/8
surface on O.D. of axle housing tube. to 1/4 turn to align nearest slot with
3. Make sure inner bearing, oil seal, oil seal sleeve, short tang of nut lock.)
axle housing oil deflector, and inner bearing race and d. J - 7341-17,000 lb. axle. (Tighten adjusting nut to
oil seal are properly positioned. 65 ft. lbs. torque, then back off nut 1/16 to 1/4
4. Install hub and drum assembly on axle housing, exer­ turn to align slot with short tang on nut lock.)
cising care so as not to damage oil seal or dislocate 4. Install the nut lock (align nut so that a tang of the nut
other internal components. lock will engage nearest flat or slot of nut).
5. On the 11,000, 13,500, 15,000 with 15 x 4 inch brake, 5. Make sure wheel turns freely, then install lock nut
and 17,000 lb. (single-speed) axles, place outer bear­ and tighten to specifications. Bend tang of nut lock
ing cone and roller assembly on axle housing and over flat or slot of lock nut.
press firmly into hub with hand (fig. 70). a. 5200 and 7200 lb. axles - Tighten lock nut to 175
6 . On 5200 through 15,000 lb. with 4 inch brake axles, ft. lbs. torque.
install thrust washer so that tang on I.D. of washer b. 11,000 and 15,000 lb. axle with 15 x 4 inch brake-
is in keyway on axle housing. Tighten lock nut to a minimum of 250 ft. lbs.
7. Install adjusting nut and complete the installation as torque.
directed under "Bearing Adjustment." c. Tighten lock nut to approximately 135 ft. lbs.
torque on the 13,500 lb. axle.
Bearing Adjustment d. Tighten lock nut to approximately 135 ft. lbs.
Before checking bearing adjustment, make sure brakes torque on: 15,000 lb. axle with 1 5 x 5 inch brake.
are fully released and do not drag. M50 trailing axle (single speed)
Check bearing play by grasping tire at top and pulling M50 trailing axle (two-speed)
back and forth, or by using a pry bar under tire. If bear­ 15.000 lb. two-speed axle
ings are properly adjusted, movement of brake drum in 17.000 lb. two-speed axle
relation to brake flange plate will be barely noticeable e. 17,000 lb. axles - Tighten lock nut to 135 ft. lbs.
and wheel will turn freely. If movement is excessive, torque.
adjust bearings as follows: 6 . Lower vehicle to floor and install axle shaft.
1. Remove axle shaft and raise vehicle until wheel is
free to rotate. DRIVE PINION OIL SEAL (Figure 72)
2. Disengage tang of nut lock from lock nut and remove
them from axle housing tube. Replacement
3. Using appropriate tool, tighten the adjusting nut to
specifications, at the same time rotating hub to make NOTE: The pinion oil seal may be replaced
sure that all bearing surfaces are properly seated with the carrier assembly installed in the
(fig. 71). vehicle.
a. J-2222-5200 and 7200 lb. axles. (Tighten adjust­
ing nut to 55 ft. lbs. torque, then back off nut 1/8 1. Disconnect propeller shaft and remove pinion flange
turn to align nearest slot with short tang on nut and deflector.
lock.) 2. Remove bolts retaining the oil seal retainer to car­
b. J-0870-11,000 and 13,500 lb. axle. (Tighten ad­ rie r, and withdraw retainer from pinion.
justing nut to 90 ft. lbs. torque, then back off nut 3. Pry old seal from bore, using care so as not to dam­
1 / 8 turn to align nearest slot with short tang on age machined surface of retainer.
nut lock.) 4. Thoroughly clean all foreign matter from seal con­
tact area in retainer.
5. Pack the cavity between the seal lips with a high-
melting point bearing lubricant, position seal on
installer Tool J - 22281 so that seal shoulders against
installer drive surface.
6 . P ress seal into retainer until it bottoms against
shoulder.
7. Carefully position seal retainer over pinion to pre­
vent damage to seal, and torque retaining bolts to
specifications.
8 . Reinstall pinion flange and propeller shaft.

NO-SPIN DIFFERENTIAL UNIT

The optionally available No-Spin differential unit is in­
stalled in a conventional 5200 or 7200 lb. rear axle hous­
F ig . 71 - Tightening W heel Hub Bearing Adjusting Nut (Typ ical) ing. Service procedures are the same as conventional

CHEVROLET TRUCK SERVICE M ANUAL

 REAR SUSPENSION AND DRIVE LINE 4-35

axles except for Diagnosis, Disassembly, Assembly and

Adjustment procedure.

On-the-Vehicle Check

1. Raise rear of vehicle until both rear wheels are off

the floor.

2. Shift transmission into gear.

3. Rotate both rear wheels as far forward as possible.

4. With assistant holding left wheel forward, rotate the

right wheel to the rear, checking for free rotation.

5. Rotate both wheels as far to the rear as possible.

6 . While holding the left wheel rearward, rotate the

right wheel forward, again checking for free rotation.

7. Repeat Steps 3-6, holding the right wheel and rotating

the left wheel for left side forward and rearward
operation check.

8 . If wheels cannot be rotated freely as described

above, remove and inspect the No-Spin.
Fig. 72 - 5200 Through 17,000 Lb. A x le Pinion O il Seal

DRIVE LINE
REAR AXLE (CHEVROLET) TWO-SPEED

INDEX

Page Page
General D e s c r ip t io n ......................................................... 4-35 Shifter Spring R eplacem en t.......................................... 4-43
Maintenance and A djustm en t............................................. 4-37 Vacuum Shift Control Switch R ep lacem en t.................. 4-43
Component Parts Replacem ent.......................................... 4-37 Speedometer Adapter Control Switch Replacement . . . 4-44
Electric Shift S y s t e m ................................................... 4-37 Speedometer Adapter Control Switch Housing
Vacuum Cylinder Diaphragm R eplacem en t.................. 4-42 or Case R e p la c e m e n t................................................ 4-44
Vacuum Cylinder Oil Seal Replacement ..................... 4-42

GENERAL DESCRIPTION
The Chevrolet two-speed axle (fig. 73) is optionally vere service. A distinctive feature is that only the
available in both the 15,000 and 17,000 lb. capacity. In straddle mounted drive pinion and the ring gears operate
low gear, torque is transmitted to the differential case to produce the high range reduction, the planet and sun
through four planetary pinions to provide long life in se­ gears being locked to revolve with the ring gear.

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REAR SUSPENSION AND DRIVE LINE 4-36

Fig, 73 - Two-Speed A x le Cross Section

1. Pinion Flange 10. Pinion Rear Bearing 18. Thrust Washers 26. Planet Gears (4)
2. Dust D eflector 11. D ifferential and Planet 19. D ifferential and Planet 27. D ifferential and Planet
3. Pinion O il Seal Support Support Case Support Case Cover
4. Pinion Front Bearing 12. D ifferential Bearing (Right) 20. A x le Housing Cover 28. Shift Yoke
5. Pinion Adjusting Shim 13. A x le Shaft g e ld e d ) 29. Shift Sleeve
6. Pinion Bearing Preload 14. A x le Housing 21. D ifferential Pinion 30. Anchor Bolt Lock
Spacer 15. Differential Bearing Adjusting 22. F ille r Plug 31. Anchor
7. Pinion Interm ediate Bearing N u t (Right) 23. D ifferential Pinion Shaft 32. Sun G e a r
8. Pinion 16. O il Baffle 24. D ifferential Side G e a r (Left) 33. Ring G e a r
9. D ifferential C arrier 17. Adjusting N u t Lock (Right) 25. M agnetic C hip C o lle c to r 34. Pinion and Bearing Retainer

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 REAR SUSPENSION AND DRIVE LINE 4-37

MAINTENANCE AND ADJUSTMENTS

Maintenance and adjustments for the two-speed axle rolet single-speed axles. Refer to "Rear Axle (Chevro-
are performed the same as those outlined for the Chev- let) Single-Speed."

COMPONENT PARTS REPLACEMENT

Service operations in this section are restricted to the two-speed and single-speed axles, refer to applicable
those operations pertaining to items peculiar to the two- procedure as outlined in "R ear Axle (Chevrolet) Single-
speed axle only. For those operations common to both Speed."

ELECTRIC SHIFT SYSTEM

An electric shift control is used on conjunction with the repair of the electric shift mechanism is presented here
Chevrolet 2-speed axles. The information necessary to under self-explanatory headings,
understand the construction, operation, maintenance, and

CONSTRUCTION WIRING SYSTEM

The electric shift control system is composed of the The power lead for the shift unit is connected to the
manual control switch, speedometer adapter, axle shift "cold" side of the ignition switch at the accessory term i­
unit, circuit breaker, and connecting wiring or "harness" nal, therefore, the entire system will be "dead" until the
(fig. 74). ignition switch is turned to the "ON" position.
A thermal type circuit breaker installed on the front of
MANUAL CONTROL SWITCH the dash panel provides protection in case of a short c ir­
The control switch, incorporated in the transmission cuit in the electric shift system during vehicle operation.
control lever (fig. 75), has two positions, up for high axle Should a short circuit occur the breaker will intermit­
range and down for low axle range. When the switch op­ tently de-energize the circuit until the trouble has been
erating knob is in either of these positions, a wiper con­ corrected.
tact on the arm completes a circuit between the battery Three wires in the shift main harness (fig. 74) are
and the motor in the axle shift unit (fig. 74). connected to the control switch. The red wire connects
To inspect or replace the control switch, disassemble the battery (thru the ignition switch and circuit breaker)
the transmission control lever knob by removing the to the control switch. The white wire connects the con­
screw at top center of the knob, then lift off the knob top trol switch (thru the automatic switch) to one field of the
half to expose the switch. axle shift unit motor. The black lead connects the con­
trol switch (thru the automatic switch) to the other field
SPEEDOMETER ADAPTER of the axle shift unit motor and also connects the speed­
ometer adapter.
The speedometer adapter, installed behind the speed­
ometer, provides correct speedometer reading with the
axle in either high or low range. By introducing a gear
OPERATION
reduction into the speedometer drive upon shift to axle The operation of the units in each speed range is ex­
low range, the unit compensates for the increased pro­ plained in the following paragraphs.
peller shaft speed relative to vehicle forward speed en­
countered in axle low range. When the axle is shifted to
high range, the speedometer drive is "straight thru" the HIGH SPEED RANGE
adapter.
The inner mechanism is prelubricated and sealed by When the control switch operating arm is moved to the
the manufacturer. In the event of failure, the adapter is up (HI) position, current is supplied to one field of the
replaced as a unit. motor in the axle shift unit. This current turns the a r­
mature and the drive screw in a clockwise direction and
AXLE SHIFT UNIT moves the nut toward the bottom of the screw (fig. 77).
When the nut has traveled far enough to wind the
The axle shift unit is mounted on the differential car­ spring, a contact bumper on the nut breaks an electrical
rie r as shown in Figure 76. This unit contains a rev ers­ connection on the automatic switch which de-energizes
ible electric motor, which when energized, shifts the axle the motor and stops armature rotation. The nut is held
into the desired range through the mechanism contained at the end of its travel on the screw by a detent spring on
in the unit (fig. 74). the shift housing front cover.

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REAR SUSPENSION AND DRIVE LINE 4-38

SPEEDOMETER
ADAPTER
IGNITION
SWITCH
A CCESSO R Y
T E R M IN A L

MANUAL
' RED"-' CONTROL
(TO T E M P . P IN K ) SWITCH

CIRCUIT BREAKER

SHIFT MOTOR

B LA C K

R IB B E D ,

V— □ ----
CONNECTOR
AUTOMATIC
SWITCH

Fig . 7 4 - Electric Shift Control System W irin g Diagram and Shift Unit Details

1. M otor Attaching Screw 9. Jam N ut 15. Actuating Lever Shaft 22. C o ver Screw
2. C ab le C lip 10. Bearing Assembly 16. Actuating Lever 23. Drive Screw Assembly
3. Motor Assembly 11. Lock N ut 17. Torsion Spring 24. Contact Bumper
4 . M otor C over Gasket 12. Bearing Cover 18. Spring W inding Lever 25. Terminal N u t
5. Shift Housing G asket 19. C over G asket 26. Switch Screw
6. Bushing 13. Bearing C over 20. Front C over 27. Sw itch Assembly
7. Insulator 14. Screw 21. F ille r Plug 28. Sw itch G asket

As the nut moves downward, the spring winding lever,

which pivots on a pin in the nut, winds the torsion spring. LOW SPEED RANGE
Thus the tension of the spring is increased, and in this
position, the axle is ready to shift into the high speed
ratio as soon as the load on the axle gears is relieved. When the control switch operating arm is moved to the
The torsion spring is assembled in the unit so that it is down (LO) position, current is supplied to the other field
under 65 pounds pressure. When the spring is wound by of the motor and to the speedometer adapter. The cur­
the winding lever, this tension is increased to 115 pounds. rent now causes the armature and screw to turn counter­
This additional pressure is used to shift the axle. When clockwise, and the nut travels toward the top of the screw
the shift is completed, the ends of the spring come to­ (fig. 78). This winds the torsion spring for a shift to low
gether, leaving the original tension in the spring. This range which is accomplished in the same manner as the
preload tension holds the axle in either range. shift to high range.

CHEVROLET TRUCK SERVICE M ANUAL

 REAR SUSPENSION AND DRIVE LINE 4-39

AXLE

Fig. 77 - Shift U n it in High Range Position

F ig . 75 - E le c tric Shift Control Switch

Fig . 76 - E le c tric Shift U nit Mounting Fig. 78 - Shift U nit in Low Range Position

SERVICE OPERATIONS
GENERAL MAINTENANCE SHIFT UNIT SERVICE
The only general maintenance necessary on the shift Removal
control system is to make sure that all wiring is in good 1. Disconnect one of the battery cables.
condition, with connections tight at terminals, connectors, 2. Remove two shift housing to carrie r stud nuts and
and that the axle shift unit is filled with lubricant to lock washer (fig. 76).
proper level. 3. Remove shift unit assembly from carrier (fig. 79).
The shift unit should be filled with lubricant to the Check condition of rubber seal assembly between
filler opening on the front cover using SAE 10 engine oil. shift unit and ca rrier. This seal must be in good
At ambient temperatures below 0 °F use SAE 5W. The oil condition and be held tightly to the shift yoke by the
level should be checked every 10,000 miles or 3 months, spring clamp to prevent axle lubricant from leaking
whichever occurs first. into shift unit.

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REAR SUSPENSION AND DRIVE LINE 4-40

4. Disconnect wire at plug.

Disassembly
Key numbers in text refer to Figure 74.
1. Remove six screws (22) and lock washers which at­
tach cover (20) to shift motor housing (5). Drain
lubricant from housing. Remove gasket (19).
2. After removing cover, the drive screw nut (25) will
be at either top or bottom depending upon the posi­
tion in which the control switch was left.
3. By turning drive screw, run nut from top or bottom
to the center of the screw (fig. 80).

NOTE: Performing step 3 is essential to pre­

vent damage to drive nut contact bumper (24).

4. Remove shift fork actuating lever (16), torsion spring

(17), and spring winding lever (18) as an assembly by
pulling shaft (15) up. Swing the assembly away from
the drive nut and lift out of the housing (fig. 81).
5. Remove three screws and lock washers (14) which
attach bearing cover (13). Remove cover ans gas­
ket ( 1 2 ). Fig. 80 - Shift U nit D rive N u t Position for Disassembly
6 . Push down on drive screw assembly (23) until bear­
ing assembly (1 0 ) is free of housing. Inspection and Test
7. Insert screwdriver in drive slot of screw (fig. 82);
then remove bearing lock nut (1 1 ) and bearing with F irst clean all parts except motor in cleaning solvent,
snap ring (10). Drive screw assembly can then be then inspect and test as follows:
lifted out of housing. Automatic Switch. The switch is serviced only as an
8 . Remove the two lock nuts (fig. 83) from terminals on assembly. The switch should have clean, flat, free mov­
switch (27) and pull off motor wires. ing points which close squarely under spring tension.
9. Remove three screws and lock washers (1) which at­ Points should open when a force ranging from 14 to 24
tach motor cover to housing (5). Pull out motor with ounces is applied against spring pressure in the point
cover attached and remove cover gasket (4). area of the movable contact.
10. Remove two jam nuts (9), and insulator (7) from Drive Screw. While holding the nut, rotate the screw
outside of housing. On inside, remove switch center from one end to the other. It should rotate freely. When
screw (26). Pull out automatic switch as shown in
Figure 84.
11. Do not disassemble the shift fork actuating lever (16),
torsion spring (17), and spring winding lever (18).
Replace actuating lever, torsion spring and spring
winding lever as an assembly.

F ig . 7 9 - Shift Unit Removed from C a rrie r F ig . 81 - Removing Shaft, Actuating Lever and Spring

CHEVROLET TRUCK SERVICE M ANUAL

 REAR SUSPENSION AND DRIVE LINE 4-41

the nut gets to either end of the screw, the screw should Observe condition of fiber contact bumper (24); if
continue to turn, but the nut should not jam or run off the broken or excessively worn, pull out old bumper and
ends. press in new.
Electric Motor. The closed type reversible field motor
(serviced only as an assembly) requires no lubrication NOTE: All gaskets removed should be re ­
and cannot be disassembled for repair. Motor service­ placed by new gaskets to assure proper sealing
ability can be determined by performing the following of the unit.
tests.
With the motor housing connected to one battery term i­
nal, and either one of the two motor wires connected to Assembly
the other battery terminal, the motor will run in one di­
rection. With the other motor wire connected to the bat­ 1. Install automatic switch assembly into housing using
tery, motor will run in the opposite direction. flat head screw to attach switch to housing. On out­
Connected to a 12 volt test circuit, the shift motor, free side of housing, install insulator, and jam nuts on
running (no load), should "turn up" 10,000 RPM with a switch terminal screws. Tighten nuts firmly.
maximum draw of 6 amperes. 2. Position motor cover gasket on housing and insert
CAUTION: Do_ not overheat the motor while motor (with cover) into housing. Install cable clip
making the following tests: and the three cover screws and lock washers.
Tighten screws firmly.
Place motor in vise, then clamp a small crescent 3. Attach motor wires to switch terminals. The longer
wrench on the rectangular drive on the armature shaft wire attaches to bottom terminal. Tighten terminal
and grasp wrench handle with one hand. Connect one nuts.
motor wire to a battery terminal and connect motor hous­ 4. With a screwdriver inserted into slot of drive screw,
ing to the other battery terminal. The wrench should tend install bearing on end of screw with shielded side of
to turn with a torque of about 6 in. lbs. Allow wrench to bearing toward inside as shown in Figure 82. Retain
turn very slowly, making sure that this pull or torque is bearing with bearing lock nut.
present the full 360 degrees turn of the wrench. If one 5. Run drive nut to center of drive screw, then insert
section of the armature is defective, the torque will dis­ slotted end of screw into housing, meshing slotted
appear for a small part of the 360 degrees. end with armature shaft.
Apply enough load to the motor in test circuit to mo­
mentarily stop armature rotation (stall the motor). The MOTE: Fiber bumper contact on drive nut
current draw at stall should be a minimum of 40 must be toward switch.
amperes.
Miscellaneous P arts. Inspect bearing (10), if balls are 6 . Install bearing gasket and cover with three screws
rough or chipped, replace with new bearing and snap ring and lock washers. Tighten screws securely.
assembly. Pack bearing assembly with chassis lubricant. 7. Dip above assembly in S.A.E. 10 engine oil. With
Check torsion spring (17) for breaks or wear at lever drive nut on drive screw assembly in center of
contact points. screw, and fiber contact bumper down toward switch,
position the slots of winding lever over the drive nut.
Install the lever shaft through center of assembly
into depression in housing.
8 . Install front cover gasket on housing. Install housing
front cover with detent spring against drive nut. At­
tach cover securely with screws and lock washers.

F ig . 82 - Removing D rive Screw Bearing F ig . 83 - Removir^ Motor W iring Lock Nuts

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REAR SUSPENSION AND DRIVE LINE 4-42

5. Install new diaphragm and plates to push rod and

tighten the retaining nut securely.

NOTE: Apply Permatex around push rod hole

between diaphragm plates.

6 . Assemble outer half of vacuum cylinder to inner half,

install retaining screws and tighten securely.
7. Install a new gasket and install the vacuum shifter
assembly on the differential carrier housing.
8 . Replace hose connections and install clamps.

CAUTION: Be careful not to transpose hose

connections.

9. Test operation of shifting mechanism in all speeds.

VACUUM CYLINDER OIL SEAL

Replacement
Fig . 84 - Removing Autom atic Switch 1. Remove clamps from hose connections and remove
hoses from fittings.
Installation 2. Remove the three lower retaining bolts and lock
washers that attach the vacuum cylinder to the dif­
1. Check the two lead wires on the housing terminals. ferential carrier housing and remove the vacuum
2. With the seal between the carrier and shift unit po­ cylinder assembly from the differential carrier
sitioned correctly; slide the shift unit on the differ­ housing.
ential carrier studs with the torsion spring swivel 3. Remove the two retaining bolts and lock washers at­
block inserted in the shift fork slot. taching the vacuum cylinder to its housing and sepa­
3. Install the stud nuts, tightening to 50-70 foot-pounds rate the two assemblies.
torque. 4. Remove the screws that attach the two halves of the
4. F ill the shift unit to operating capacity with lubricant vacuum cylinder and remove the outer half.
as specified under "General Maintenance." 5. Remove the diaphragm plates, and shaft as an as­
5. Check installation by making a "LO" and "HI" range sembly.
shift. Ignition must be turned on before check can be 6 . Drive the old seal out of the housing.
made. 7. Soak new seal in engine oil to provide for initial lu­
brication. Coat outer diameter of seal with Perm a­
NOTE: The shift unit motor runs equally well tex and replace it in the inner half of the cylinder
in either direction, however, if the lead wires with the free side of the leather down and press it
are reversed at the terminals on the shift unit, into place with seal installer Tool J-0968.
the axle will shift to the opposite range of that 8 . Assemble the diaphragm shaft assembly into the
indicated on the control switch. housing.
9. Install the outer cover, and retaining screws.
6 . Connect wire at plug.
CAUTION: Install the cover with the vacuum
VACUUM CYLINDER DIAPHRAGM line connection aligned with the connection on the
lower outer cover.
Replacement
10. Assemble the vacuum cylinder assembly into its
1. Remove clamps on hose connections at the vacuum housing, install the two retaining bolts and lock
cylinder and slip hoses off the connecting fittings. washers and tighten securely.
2. Remove the three retaining bolts and lock washers
NOTE: The felt seal and felt seal in the hous­
retaining the vacuum cylinder assembly to the dif­
ing should be inspected for damage and replaced
ferential ca rrier housing and remove the vacuum
when necessary.
cylinder assembly from the vehicle.
3. Remove the screws that attach the two halves of the 11. Install the completed assembly to the carrie r housing
vacuum cylinder and remove the outer half. with new gasket and the three retaining bolts and lock
4. Using two 1/2" open end wrenches, one to hold the washers and tighten securely.
push rod inner nuts and the other to remove the outer 12. Replace the hose connections and install clamps.
nut from the push rod, remove the diaphragm plates 13. Test the operation of the shifting mechanism in all
and diaphragm. speeds.

CHEVROLET TRUCK SERVICE M ANUAL

 REAR SUSPENSION AND DRIVE LINE 4-43

SHIFTER SPRING

Replacement

1. Follow instructions given in Steps 1, 2, 3, 4 under

"Vacuum Cylinder Diaphragm Replacement."
2. Remove the piston rod from the housing.
3. Push in on end of piston rod to relieve spring load
and remove snap ring from inside of piston rod. Pull
push rod assembly out of piston rod.
4. Place head of push rod bolt in bench vise and remove
two nuts, short spacer, stop washer, spring, long
spacer, and stop washer from push rod bolt.
5. Install stop washer, long spacer, new spring, stop
washer and short spacer.
6 . Install adjusting nut on push rod and tighten until
distance between outer faces of stop washers is Fig . 8 6 - Shift U nit Control Switch
2-13/16" (fig. 85).
7. Install lock nut on push rod and tighten, being careful
not to change the 2-13/16" adjustment.
8 . Lubricate inside of piston rod with engine oil and
install push rod assembly.
9. Push in on push rod to compress spring and install
snap ring.
10. Install push rod assembly in the housing.
11. Complete the assembly of the vacuum cylinder ac­
cording to instructions given in Steps 5, 6 , 7, 8 , 9
under "Vacuum Cylinder Diaphragm Replacement."

VACUUM SHIFT UNIT CONTROL

SWITCH REPLACEMENT
The manually operated control switch, mounted on the
transmission shift lever (fig. 8 6 ) is an electromechanical,
two-position switch which controls the axle vacuum shift
unit and the associated speedometer adapter.
1. Disconnect switch electrical leads at the dash panel
mounted fuse block and speedometer adapter.
2. Remove the two screws securing the axle shift con­ Fig . 87 - Vacuum Control Shift C ab le Removal
trol valve to the frame side member mounted
bracket. 3. Tilt or slide control valve as required to obtain ac­
cess to cable retaining screw and disconnect cable
NOTE: Do not disconnect control valve vac­ from valve (fig. 87). Disconnect conduit from valve
uum, atmosphere or air cleaner lines. assembly and remove all cable retaining clips.
4. Remove the transmission shift lever knob, then re ­
move the two screws retaining switch housing to
transmission shift lever and withdraw cable and
housing assembly from vehicle.
5. Make sure cable shift knob is in down position, then
attach switch housing rubber case on transmission
shift lever so that the distance from top of cable
shift knob to top of transmission shift lever is
2 -1 /4 ". Torque retaining screws to 40 in. lbs.

CHEVROLET TRUCK SERVICE MANUAL

REAR SUSPENSION AND DRIVE LINE 4-44

Reinstall transmission shift lever knob. VACUUM SHIFT UNIT CONTROL SWITCH
6 . Route cable to axle shift control valve, insert control
cable into valve assembly and tighten conduit retain­
HOUSING OR CASE REPLACEMENT
ing fitting to 115 in. lbs. 1. Remove the two screws securing the axle shift con­
7. Seat shoulder on control cable knob against housing, trol valve to the frame side member mounted
then tighten set screw to retain cable and install bracket.
valve-to-bracket retaining screws.
8 . Connect electrical leads to speedometer adapter and NOTf: Do not disconnect control valve vac­
fuse block. Make sure all cable retaining clips are uum, atmosphere or air cleaner lines.
secured.
9. Test operation of shift system. 2. Tilt or slide the control valve as required to obtain
access to cable retaining screw and disconnect cable
SPEEDOMETER ADAPTER CONTROL from valve.
SWITCH REPLACEMENT 3. Withdraw cable from conduit by pulling shift knob
from switch housing on transmission shift lever.
1. Remove the transmission shift lever knob, then re ­ 4. Remove the transmission shift lever knob, then re ­
move the two screws retaining switch housing to move the two screws retaining switch housing case to
transmission shift lever. Remove pin that retains transmission lever. Transfer conduit and speedom­
switch housing to rubber case and slide switch hous­ eter adapter switch to new housing.
ing from rubber case. 5. Loosely install the new switch housing case in ap­
2. Remove two screws retaining adapter control switch proximately the same position as the old housing,
to switch housing and disconnect electrical leads and install control cable and knob assembly by feed­
from switch (fig. 8 8 ). ing end of cable through switch housing and conduit.
3. Connect electrical leads to new switch, position and 6 . Secure switch housing to transmission lever as spec­
secure adapter control switch to switch housing with ified in Step 5 of "Vacuum Shift Unit Control Switch
retaining screws. Replacement."
4. Reinstall switch housing to rubber case and secure 7. Seat shoulder on control cable knob against housing,
with pin. Secure switch housing rubber case to then tighten set screw to retain cable at the axle shift
transmission shift lever as specified in Step 5 of control valve, and install valve-to-bracket retaining
"Vacuum Shift Unit Control Switch Replacement." screws.
5. Test operation of shift system. 8 . Test operation of shift system.

DRIVE LINE
REAR AXLE (EATON) SINGLE SPEED

INDEX
Page
General Description ......................................................... ....4-44
Maintenance and Adjustments .......................................... ... 4_46
Component Part Replacement .......................................... ....4 - 4 6
Axle Assembly ............................................................ ... 4_46
Removal .................................................................. ... 4_46
In stallation ............................................................... ... 4-46
Axle Vent R ep lacem en t................................................ ... 4-46
Axle Shaft Removal and Replacem ent........................... ... 4 _ 4 6
Hub and D r u m ............................................................... ... 4-46

GENERAL DESCRIPTION
The Eaton 18,500 Single Speed Spiral Bevel Drive rear pinion. Pinion bearings are of the opposed tapered roller
axle is used in regular production on the 60 Series truck, bearing type, and are a press fit on the drive pinion shaft.
except on flat face cowl models. A straight roller type pilot bearing is pressed onto the
Model 17121 and 17101 use an identical differential inner end of the drive pinion and seats in a machined bore
head assembly, the only difference being the size of the in the differential carrier.
ring and pinion gear (fig. 89). Drive pinion bearing preload adjustment is controlled
by thickness of the bearing spacer installed between the
DRIVE PINION AND CAGE two tapered roller bearings.
Shims between the pinion cage and carrier provide a
Both axles are equipped with a straddle mounted drive means for adjusting pinion depth in the carrie r to attain

CHEVROLET TRUCK SERVICE M ANUAL

 REAR SUSPENSION AND DRIVE LINE 4-45

correct tooth contact between the ring gear and pinion. carrier provide for adjustment of differential side bear­
ing pre-load and ring gear-drive pinion backlash.
DIFFERENTIAL

The differential carrier assembly may be removed, AXLE SHAFTS AND HOUSING
while the axle is still installed in the truck, after the axle
shafts have been removed. Axle shafts are full-floating type, splined to differential
The drive pinion assembly and the differential case side gears at inner ends and attached at flanged outer
assembly are mounted in the differential ca rrier, and are ends to hubs by studs and nuts. Stud holes in each shaft
removed as part of the ca rrie r when the ca rrie r is re ­ flange are taper-reamed to accommodate split tapered
moved from the axle housing. dowels.
The differential is a conventional four pinion type with The banjo-type axle housing is one-piece design with
ring gear bolted to flanged half of differential case. Dif­ spring seats welded in place. Brake flange plates are
ferential case is a two-piece type machined as a matched riveted to flanges welded on the axle housing tube. Outer
assembly, and must be replaced as such. ends of housing are machined to accommodate wheel
Thrust washers are used between differential side bearings and threads are cut at extreme outer ends for
gears and case, and between differential pinions and case. installation of wheel bearing nuts. The axle housing bowl
Adjusting rings in the differential bearing bores of the cover is welded to the axle housing.

Fig . 89 - 18,500 Lb. Eaton Single Speed A x le

1. Flange Nut 7. Bearing Cone - O uter 13. Bearing 18. Case Bolt 23. Bearing Cap
2. Pinion Flange 8. Adjusting Spacer 14. A x le Shaft - R .H . 19. Pinion Thrust 24. Bearing Cone
3. O il Seal 9. Bearing Cup - Inner 15. D ifferential Case Washer 25. Adjusting N u t
4. Pinion Cage 10. Bearing Cone - Inner 16. Side G e a r Thrust 20. D ifferential Pinion 26. Adjusting N u t Lock
5. Adjust ng Shims 11. D rive Pinion Washer 21. Ring G e a r 27. A x le Shaft - L.H .
6. Bearing Cup - O u te r 12. D ifferen tial C arrier 17. Side G e a r 22. Ring G e a r Bolt

CHEVROLET TRUCK SERVICE MANUAL

REAR SUSPENSION AND DRIVE LINE 4-46

MAINTENANCE AND ADJUSTMENTS

Maintenance and adjustments for the Eaton single- the Chevrolet single-speed axles. Refer to "Rear Axle
speed axle are performed the same as those outlined for (Chevrolet) Single-Speed."

COMPONENT PART REPLACEMENT

AXLE ASSEMBLY position under the truck.
2. Attach axle to the rear springs with the "U" bolts.
Service operations on the axle may be performed with­ Tighten the "U" bolt nuts to 215 ft. lbs.
out removing the complete axle assembly from the vehi­ 3. Connect propeller shaft to the axle, drawing "U"
cle. There may be occasions, however, when it will be bolts up to torque specifications.
necessary to remove the complete assembly as a result 4. Connect the hydraulic brake hose to the brake pipe on
of collision or other damage resulting in distortion of the the rear axle, then bleed the brakes and check fluid
axle housing. The following axle assembly removal, is to level in the master cylinder. If the truck is equipped
be used only when replacement of axle housing is neces­ with air brakes, connect air lines to the rear brake
sary. chambers.
5. Lower vehicle to floor and tighten rear wheel nuts.
Removal 6 . F ill axle to proper level with lubricant.
7. Check brake operation. Inspect for air or hydraulic
1. Loosen the rear wheel stud nuts, then raise the rear fluid leaks at brake line fittings. Road test vehicle.
of the vehicle enough to remove the load from the
rear springs. Support vehicle with stand jacks under Axle Vent Replacement
frame side rails.
2. Disconnect the hydraulic brake hose from the brake See "Axle Vent Replacement" Chevrolet 5200 through
pipe at the rear axle, or, if the truck is equipped with 17,000 lb. Single Speed axle.
air brakes, bleed the system, then disconnect the air
brake hose from the rear brake chambers. A xle Shaft
3. Remove the two trunnion bearing "U" bolts from the
pinion flange and split the rear universal joint. Swing Removal and Replacement
the propeller shaft to one side and tie it to the frame
side rail. See 17,000 lb. Chevrolet Single Speed "Axle Shaft
4. Remove the rear spring "U" bolts and roll the axle Removal and Replacement."
assembly out from under the truck. Raise the axle
clear of the floor and remove the wheels. Hub and Drum

Installation Removal, Service and Installation

1. Install the wheels, then roll the axle assembly into See 17,000 lb. Chevrolet Single Speed "Hub and Drum."

DRIVE LINE
REAR AXLE (EATON) TWO-SPEED

INDEX
Page
General Description ......................................................... .... 4 - 4 7
Maintenance and Adjustments .......................................... .... 4-47
Component Part Replacement .......................................... .... 4-48
Axle Assembly ............................................................ .... 4-48
Removal ...................................................................... 4-48
In stallatio n ............................................................... .... 4-48
Axle Vent Replacement ................................................ ... 4-48
Axle Shaft Removal and Installation ............................... 4-48
Hub and D r u m ............................................................... .... 4-48

CHEVROLET TRUCK SERVICE MANUAL

 REAR SUSPENSION AND DRIVE LINE 4-47

GENERAL DESCRIPTION
The Eaton 18,500 capacity two-speed axles, Models for description and maintenance information on electrical
17201 and 17221 are optionally available on all 60 Series system.
trucks. The Axle Shafts, Housing, Wheels and Hubs used on the
Both models are equipped with a spiral bevel ring gear 17201 and 17221 Model axles are the same as those out­
and pinion. The two axles are sim ilar in construction, lined in 17,000 lb. Chevrolet Single-Speed.
the only difference being the drive gear diameter is An improved lubrication system (fig. 90) which has a
larger on the 17221 model. steel reinforced nitrite scraper mounted to the inside of
An electric power shifting arrangement is used to as­ the carrier. This scraper is positioned to collect oil
sist in making ratio changes. The driver selector control from the surface of the rotating gear support case. Oil
is mounted on the shift lever. Refer to "Rear Axle (Chev­ is channeled to the right-hand differential bearing,
rolet) Two-Speed E lectric Shift System" in this section through the differential and planetary unit to the left-hand
differential bearing and back to the reservoir.

Fig . 90 - 18,500 Lb. Eaton Two-Speed

MAINTENANCE AND ADJUSTMENTS

Maintenance and adjustments for the Eaton Two-Speed Chevrolet Single-Speed axle. Refer to "Rear Axle (Chev-
axles are performed the same as those outlined for the rolet) Single-Speed."

CHEVROLET TRUCK SERVICE MANUAL

REAR SUSPENSION AND DRIVE LINE 4-48

COMPONENT PART REPLACEMENT

Service operations on the axle may be performed with­ Installation
out removing the complete axle assembly from the vehi­
cle. There may be occasions, however, when it will be 1. Install the wheels, then roll the axle assembly into
necessary to remove the complete assembly as a result position under the truck.
of collision or other damage resulting in distortion of the 2. Attach axle to the rear springs with the "U" bolts.
axle housing. The following axle assembly removal, is Tighten the bolt nuts to 300-320 foot-pounds
to be used only when replacement of axle housing is torque.
necessary. 3. Connect propeller shaft to the axle drawing "U”
bolts up tightly.
AXLE ASSEMBLY 4. Connect wiring to the axle electric shift unit and in­
stall shift unit on carrier.
Removal 5. Connect the hydraulic brake hose to the brake pipe on
the rear axle, then bleed the brakes and check fluid
1. Loosen the rear wheel stud nuts, then raise the rear level in master cylinder. If the truck is equipped
of the vehicle enough to remove the load from the with air brakes, connect air lines to the rear brake
rear springs. Support vehicle with stand jacks under chambers.
frame side rails. 6 . Lower vehicle to floor and tighten rear wheel nuts.
2. Disconnect the hydraulic brake hose from the brake 7. Fill axle and electric shift unit to proper level with
pipe at the rear axle, or, if the truck is equipped with lubricant.
air brakes, bleed the system, then disconnect the air 8 . Check brake operation. Inspect for air or hydraulic
brake hose from the rear brake chambers. fluid leaks at brake line fittings. Road test vehicle.
3. Remove the 2 stud nuts retaining rear axle electric
shift unit and pull unit from differential carrier. Axle Vent Replacement
Disconnect the electric wiring from the shift unit and
See "Axle Vent Replacement" Chevrolet 5200 through
tape wire terminals separately.
17,000 lb. Single Speed Axle.
4. Remove the two trunnion bearing "U" bolts from the
pinion flange and split the rear universal joint. Swing Axle Shaft—Removal and Installation
the propeller shaft to one side and tie it to the frame See 17,000 lb. Chevrolet Single Speed Axle Shaft Re­
side rail. moval and Replacement.
5. Remove the rear spring "U" bolts and roll the axle Hub and Drum
assembly out from under the truck. Raise the axle Removal, Service and Installation
clear of the floor and remove the wheels. See 17,000 lb. Chevrolet Single Speed "Hub and Drum."

DRIVE LINE
TANDEM AND POWER DIVIDER (EATON)
INDEX
Page
General Description ......................................................... ....4-50
Maintenance and A djustm ent............................................. ....4-50
Rearward Rear Axle ................................................... ....4-50
Forward Rear A x l e ...................................................... ....4-50
Service O p e ra tio n s............................................................ ....4-50
Inter-Axle Differential Lock Shift S y s t e m .................. ....4-50
Vacuum Operated...................................................... ....4-50
O p e ra t io n ............................................................ ....4-50
Checking for L e a k a g e .......................................... ....4-51
Solenoid Lock Valve . . . ................................. ....4-51
Locking C y l i n d e r ................................................ ... 4-52
A ir O p e ra te d ............................................................ ....4-52
O p e ra t io n ............................................................ ....4-52
Checking for L e a k a g e .......................................... ....4-52
Control V a l v e ...................................................... .... 4 - 5 3
A ir Shift C y lin d e r................................................ ... 4-53
Differential Lockout
Removal and In s ta lla tio n .................................... ... 4-53

CHEVROLET TRUCK SERVICE M ANUAL

 REAR SUSPENSION AND DRIVE LINE 4-49

F ig . 91 - Tandem Rear Axles and Power D ivid er

CHEVROLET TRUCK SERVICE M ANUAL

REAR SUSPENSION AND DRIVE LINE 4-50

GENERAL DESCRIPTION
The tandem rear axle installation (fig. 91) consists of a allow differential action between the two axles. When
rearward rear axle (Eaton Model 30R) and a forward rear extra traction is required to move the vehicle, the inter­
axle (Eaton Model 30D) which carries a single speed axle differential can be locked out so equal power can be
power divider with an inter-axle differential. An air or delivered to each axle. A toggle switch in the driver's
vacuum operated shift mechanism is used to lock out the compartment actuates the solenoid-controlled, vacuum
inter-axle differential to provide positive drive to both operated, lock-out shift lever at the axle. The air system
axles when required. is controlled by a lever operated valve in the drivers
Drive is transmitted from the transmission through a compartment. Air pressure actuates a shift cylinder
conventional propeller shaft to the power divider input which is mounted on the axle. Both systems move the
shaft (fig. 91). The input shaft supports the inter-axle sliding clutch into engagement with the input shaft helical
differential which transmits equal driving force to two gear. A light installed on the dash warns when differen­
helical gears, one mated to a gear on the forward rear tial is locked out.
axle pinion shaft to drive the forward axle and the other
mated to a gear on the power divider output shaft to NOTE: Use lockout only in slippery going.
transmit drive force through an inter-axle propeller shaft When differential is to be locked out, vehicle
to the rearward axle. Both axles drive at all times, so must be completely stopped. Continuous unnec­
the inter-axle differential (3rd differential) is provided to essary use of lockout must be avoided.

MAINTENANCE AND ADJUSTMENTS

REARWARD REAR AXLE
The rearward axle assembly is maintained in the same of the forward rear axle differential carrier cover as­
manner as outlined for the single speed Eaton rear axle. sembly and may be removed when the carrier is either in
or out of the vehicle. The differential, ring gear and
FORWARD REAR AXLE pinion are serviced in the same manner as outlined for
the single speed Eaton rear axle.
The power divider and inter-axle differential are part

SERVICE OPERATIONS
INTER-AXLE DIFFERENTIAL
LOCK SHIFT SYSTEM
VACUUM OPERATED

Operation

The toggle switch on the center instrument panel con­

trols the warning light in the instrument cluster (fig. 93)
and the solenoid operated lock valve at the frame side
rail (fig. 94).
The solenoid, when energized, actuates the lock valve
connected between the locking cylinder, mounted at the
front of the forward rear axle, and the engine vacuum
supply (fig. 94).
The locking cylinder (fig. 95) operates the lockout shift
lever so the sliding clutch engages the input shaft helical
and differential side gear to divide power equal to both
axles.

Checking For Leakage

Place the truck on level ground with the parking brake

released and the transmission in neutral. Start the en­
gine with the control switch at "on" (the power divider
differential locked out). Accelerate the engine for a few F ig . 93 - D ifferen tial Lock Switch and Warning Light Installation
 REAR SUSPENSION AND DRIVE LINE 4-51

Fig . 9 4 - Differential Lock Vacuum System (Typ ical)

seconds, release the accelerator, and turn off the ignition

switch. Immediately measure the distance between the
face of the locking cylinder mounting bracket and the
center of the push rod yoke to the lever pin and make
note of the dimension. At the end of ten minutes, re­
measure the distance. If the distance has not increased,
the system may be considered vacuum tight. However, if
the distance has increased, a vacuum leak exists in the
system.
F irst check all connections. After all the hoses and
the pipe connections have been checked and tightened, test
the system again.

SOLENOID LOCK VALVE

The solenoid valve is positioned at the frame left side

rail by the vacuum pipe clips and may be removed by dis­
connecting the three fittings at the valve.

LOCKING CYLINDER
1. D ifferential C arrier Cover 10. Diaphragm
When leakage tests indicate the locking cylinder as­ 2. Bracket 11. C ylin d er (O uter H alf)
sembly leaks, it must be removed and disassembled, and 3. Push Rod Yoke 12. Vacuum Line Fitting
the rubber diaphragm in the cylinder must be replaced. 4. Boot 13. N ut
1. Disconnect the control valve hose from the cylinder. 5. Lock N ut 14. Plate Washer
Remove the cotter pin and the clevis pin which se­ 6. Push Rod 15. Plate (Large)
cure the bracket lever to the push rod. Remove the 7. Snap Ring 16. Plate (Sm all)
snap ring which secures the cylinder in the bracket, 8. Dowel 17. Lock-Out Shift
and remove the assembly from the bracket. Remove 9. C y lin d e r (Inner H alf) Lever

CHEVROLET TRUCK SERVICE MANUAL

REAR SUSPENSION AND DRIVE LINE 4-52

the boot from the push rod. sure limit (100 to 105 lbs.). Place lock control lever
2. Remove the clevis yoke and nut from the push rod in "LOCK" position.
(fig. 95). Remove the screws, nuts, and lock wash­ 2. Coat all air line connections with soap suds to check
ers which attach the two halves of the cylinder and for leakage. No leakage is permissible. Leakage
the rubber diaphragm together. Remove the outer can sometimes be corrected by tightening the con­
half of the cylinder, and separate the rubber dia­ nection. If this fails to correct leakage, disconnect
phragm from the inner half of the cylinder. leaking fitting and replace seal ring around tube
3. Install a new diaphragm and push rod assembly in the flare.
rear half of the cylinder. 3. Coat entire surface of lock shift cylinder and control
4. Make certain the mating faces of the cylinder halves valve with soap suds to check for leakage. If leakage
are clean. Position the outer half of the cylinder on is evident in either unit, remove faulty unit and over­
the rubber diaphragm, and install the screws, nuts, haul as directed under individual heads.
and new lock washers. Install the boot, nut, and
clevis yoke on the push rod. CONTROL VALVE
5. Make certain that the snap ring groove on the inner
Control valve (fig. 97) used in "Air-Operated Differen-
half of the cylinder is clean. Position the cylinder in
the bracket on the power divider with the slot in the
rear half of the cylinder at the bottom.
6 . Install the retaining snap ring and seat it solidly in
the groove. Attach the bracket lever to the rod
clevis with a clevis pin and a new cotter pin. Attach
the vacuum line to the locking cylinder. Test the
system for vacuum leaks.

AIR OPERATED

Operation
Air operated differential lock utilizes air pressure
from the air brake system for its operation. Units used
in air-operated power shift system are: Shift Control
Valve, mounted on engine side of dash; check valve, in­
stalled in air line at control valve air inlet; differential
lock shift cylinder, mounted on forward rear axle torque
divider case cover; and interconnecting air lines and
fittings.
With lock control lever (fig. 96) in "UNLOCK” position,
there is no air pressure in differential lock shift cylin­
der. Shift return compression spring holds cylinder
piston and lock linkage in unlocked position.
When lock control lever (fig. 96) is moved to "LOCK"
position, air pressure is admitted behind lock shift cylin­
der piston. As air pressure forces the piston outward,
the differential lock is shifted into locked position.

Checking For Leakage

1. Build up air pressure in system to maximum pres-

INTER AXLE
DIFFERENTIAL
CK ! I N i n

Fig. 97 - Sectional V ie w of Control V a lv e (T yp ical)

1. Instrument 8. V a lv e Spring
Panel 9. O-ring
2. Name Plate 10. Cap Nut
3. Fulcrum Pin 11. To Intake M anifo ld
4. Control Lever or A ir Tank
5. Exhaust Port 12. To Shift C ylin d er
6. Body 13. Plunger Spring
F ig . 9 6 - D iffe re n tial Lock Control Lever and Plate (Typ ical) 7 . V a lv e Disc 14. Plunger

CHEVROLET TRUCK SERVICE M ANUAL

 REAR SUSPENSION AND DRIVE LINE 4-53

tial Lock" system is the same as previously described in Shift cylinder should be removed, disassembled, and
this section under "Vacuum-Operated Differential Lock." the piston seals replaced whenever leakage is indicated
at the cylinder.
AIR SHIFT CYLINDER
DIFFERENTIAL LOOKOUT
A piston type shift cylinder is mounted on forward rear
axle torque divider case cover. Piston rod is connected
to sliding clutch. As air pressure is applied to piston,
Removal and Installation
sliding clutch is shifted into locked position. When air Removal and installation instructions may be found in
pressure is exhausted from shift cylinder, spring pres­ the "Truck Overhaul Manual" under "Vacuum Operated
sure returns sliding clutch to unlocked position. Lockout” or "Air Operated Lockout."

PROPELLER SHAFTS, UNIVERSAL JOINTS

AND BEARING SUPPORTS
INDEX
Page
General D e s c r ip t io n ............... .. .......................................4-53
Maintenance and A djustm en t............................................. 4-53
Component Part R e p la c e m e n t.......................................... 4-53
R e m o v a l.......................................... ..............................4-53
D is a s s e m b ly ............................................................ 4-55
A s s e m b ly ...................................................................4-55
Installation ...................................................................4-55

GENERAL DESCRIPTION
Tubular type propeller shafts and needle bearing type the wheel base of the vehicle. On vehicles which use two
universal joints are used on all model trucks. An inter­ or more propeller shafts, each shaft (except the rear) is
nally splined sleeve which compensates for variation in supported near its splined end in a rubber cushioned ball
distance between rear axle and transmission is located at bearing which is mounted in a bracket attached to a frame
the forward end of single or rear propeller shafts cross member. The ball bearing is a permanently sealed
(fig. 98). and lubricated type.
The number of propeller shafts used is dependent upon

MAINTENANCE AND ADJUSTMENTS

An extended-life universal joint, which does not require sleeve to lubricate the splines. A plug is staked into the
periodic inspection and lubrication, has been incorporated yoke end of sleeve to retain lubricant and a small hole is
in several applications on the 1 0 and 2 0 series vehicles. drilled in the end of this plug to relieve trapped air. The
This extended-life universal joint is identified by the opposite end of the sleeve is sealed by means of a cork
absence of the lubrication fitting, which is present on all packing in a retainer which screws on the end of the
trunnions not equipped with the extended-life feature. sleeve.
A lubrication fitting is also provided on each sliding

COMPONENT PART REPLACEMENT

REMOVAL propeller shaft and pull back to disengage the sleeve at
front of shaft. Remove shaft from under vehicle.
CAUTION: When trunnion bearing "U" clamps
are removed to remove the propeller shaft, tape
the bearings to keep them clean and from be­ Front
coming damaged. Propeller shaft guards may
Remove four front flange nuts at transmission and, if
be removed, if necessary, by removing nut at
equipped with intermediate propeller shaft, remove the
each end of the guard.
rear trunnion "U" clamps. Remove nuts and lockwash­
Single or Rear ers attaching bearing support to frame cross member and
pull shaft assembly from vehicle.
Remove rear trunnion "U" clamps, lower the rear of

CHEVROLET TRUCK SERVICE MANUAL

REAR SUSPENSION AND DRIVE LINE 4-54

Fig. 98 - Propeller Shafts, Universal Jo in ts and Bearing Supports

1. Front Propeller Shaft and Bearing 8. Rear Propeller Shaft 17. Trunnion
Support Assy. 9. Lock Ring 18. Seal Ring
2. Front Intermediate Propeller Shaft and 10. Bearing Assembly 19. Flange and D eflecto r Assy.
Bearing Support Assy. 11. Lubrication Fitting 20. Bracket
3. Rear Intermediate Shaft and Bearing 12. Plug 21. Cushion
Support Assy. 13. Sleeve 22. S linger
4. Rear Propeller Shaft and Sleeve Assy. 14. Retainer 23. G rease Retainer
5. Frame Cross-member 15. Washer 24. Inner Deflector
6. Guard 16. Cork Packing 25. Dust Shield
7 . " U " Clamp

Intermediate or Rear Intermediate Front Intermediate

Remove the front trunnion "U” clamps and the bearing Remove the front and rear trunnion "U" clamps and the
support mounting bolt nuts and lockwashers. Lower the bearing support mounting bolt nuts and lockwashers.
front of the shaft and pull forward to disengage splines at Lower shaft and bearing support assembly from vehicle.
rear of shaft. Remove shaft and bearing support assem­
bly from under vehicle.

CHEVROLET TRUCK SERVICE MANUAL

 REAR SUSPENSION AND DRIVE LINE 4-55

INSPECTION f. Force rubber cushion onto bearing and coat out­

Wash ends of propeller shaft in cleaning solvent, in­ side diameter of cushion with brake fluid.
g. Force bracket onto cushion.
spect for damage and excessive wear on splines, trun­
nions and bearings. Examine sleeve seal, washer and 2. Assemble trunnion bearings to propeller shaft as
retainer for damage or deterioration. follows:
a. On extended life universal joints when performing
DISASSEMBLY service operations that require disassembly of
the universal joint, repack bearings with a high-
1. Remove trunnion bearings from propeller shaft yoke melting point wheel bearing lubricant and replace
as follows: trunnion assembly dust seals.
a. Remove lock rings from yoke and lubrication fit­
NOTE: In addition to packing the bearings,
ting from trunnion.
b. Support yoke in a bench vise. make sure the lubricant reservoir at the end of
c. Using soft drift and hammer, drive on one trun­ each trunnion is completely filled with lubricant.
nion bearing to drive opposite bearing from yoke. In filling these reservoirs, pack lubricant into
d. Support other side of yoke and drive out other the hole so as to fill from the bottom. This will
bearing. prevent air pockets and ensure an adequate sup­
ply of lubricant.
e. Remove trunnion from propeller shaft yoke.
2. If equipped with sliding sleeve, remove trunnion To replace trunnion dust seal, remove the old dust seal
bearings from sleeve yoke in the same manner as and place new seal on trunnion - cavity of seal toward end
above. Remove seal retainer from end of sleeve and of trunnion - then position Tool J - 21548 over end of trun­
pull seal and washer from retainer. nion and into cavity portion of seal. P ress seal onto
3. Remove bearing support as follows: trunnion until tool bottoms against shoulder on trunnion
a. Remove dust shield, or, if equipped with flange, (fig. 99).
remove cotter pin and nut and pull flange and de­
flector assembly from shaft.
b. Pull support bracket from rubber cushion and pull
cushion from bearing.
c. Pull bearing assembly from shaft. Remove
grease retainers and slingers (if used) from
bearing.
d. Remove inner deflector from shaft if replacement
is necessary.
ASSEMBLY
1. Assemble bearing support as follows:
a. Install inner deflector on propeller shaft, if re­
moved, and prick punch deflector at two opposite
points to make sure it is tight on shaft.
b. Pack retainers with waterproof grease, insert a
slinger (if used) inside one retainer and press
this retainer over bearing outer race. Fig . 9 9 - " U " Jo in t Trunnion Seal Installation

NOTE: Waterproof grease is required to pre­

vent entrance of water and foreign material into
bearing. NOTE: Installation of seal is critical to proper
sealing - use specified tool during installation to
c. Start bearing and slinger assembly straight on prevent seal distortion and to assure proper
shaft journal. Support propeller shaft and, using seating of seal on trunnion.
suitable length of pipe over splined end of shaft,
press bearing and inner slinger against shoulder b. On all other universal joints lubricate trunnion
on shaft. bearing rollers and install new seal rings.
d. Install second slinger on shaft and press second c. Insert trunnion in propeller shaft yoke and press
retainer over bearing outer race. bearings into yoke and over trunnion hubs far
e. Install dust shield over shaft, small diameter enough to install lock rings.
first and press into position against outer slinger d. Hold trunnion in one hand and tap propeller shaft
or, if equipped with flange, install flange and de­ yoke lightly to seat bearings against lock rings.
flector assembly as follows: 3. On rear propeller shafts, install sleeve yoke over
(1) Install deflector on flange, if removed, and trunnion hubs and install bearings in the same man­
prick punch at two opposite points to make ner as above.
sure it is tight on flange.
(2) Align centerline of flange yoke with center- INSTALLATION
line of propeller shaft yoke and start flange
straight on splines of shaft with end of flange Propeller shafts may be installed by reversing the pro­
against slinger. cedure used in removal when the following notes are
(3) Install retaining nut and tighten to 160-180 observed.
ft. lbs. torque. Install cotter pin. NOTE 1: Before installing a rear propeller

CHEVROLET TRUCK SERVICE MANUAL

REAR SUSPENSION AND DRIVE LINE 4-56

shaft and sleeve assembly, slide seal retainer, size or rear axles of different ratios than those furnished
steel washer and cork seal on spline of mating as standard equipment for the various units. Either one,
shaft. Assemble these parts to sleeve by turn­ or both, of these things will, of course, change tire revo­
ing retainer onto sleeve after rear propeller lutions per mile and result in speedometer inaccuracies.
shaft is installed. When such change or changes are made, it is necessary
to change the speedometer gears or to use a speedometer
NOTE 2: Tighten front flange (transmission
adapter with the present gears. In certain combination
attachment) nuts to 29-42 ft. lbs., propeller shaft
changes of both rear axle and tires, it may be necessary
flange nuts to 100-150 ft. lbs., bearing support
to change the speedometer gears and use, in addition, an
nuts to 25-35 ft. lbs., propeller shaft guard nuts
adapter to bring about proper speedometer readings.
to 160-180 ft. lbs., and trunnion bearing "U"
Speedometer gear adapters are available if needed, to
clamp nuts to the following torques: 5 /1 6 "-2 4 --
be used separately or in conjunction with a change in
14-18 ft. lbs., 3 /8 "-2 4 — 18-22 ft. lbs.; 7 /16"-24—
speedometer gear sets.
29-43 ft. lbs.
The adapter is installed by removing the speedometer
NOTE 3: Over torquing "U" clamp nuts will cable fitting from the transmission case and screwing the
result in bearing cap distortion which will re­ adapter into the case. The speedometer cable is then
duce roller bearing life. connected to the adapter.
When replacing speedometer gears it is very important
SPEEDOMETER GEARS-SPEED ADAPTERS that the drive gear be pressed onto the spacer or front
In some special types of operation, purchasers of yoke of the universal joint with the shoulder or chamfer
Chevrolet trucks may desire to use tires of a different on the gear away from the universal joint.

SPECIAL TOOLS

F ig. 100 - Rear Suspension Special Tools

1. J-8459 Spring Eye Bushing Remover and Replacement 6. J —8118 Rear Spring Pin P u lle r (Used w ith J —2619)
2. J-21058 Spring Eye Bushing Remover and Replacement 7. J-8448 Series C-P10 and C -30 Control Arm
3. J -7079-2 D river Handle Bushing Installer
4. J-7574-6 Series C20 Tie Rod Bushing Installer 8. J —2619 Slid e Hammer Assembly
5. J —8518 Series C-P10 Tie Rod Bushing Installer 9. J-22620 Spring Eye Bushing Remover and Installer

CHEVROLET TRUCK SERVICE M ANUAL

 REAR SUSPENSION AND DRIVE LINE 4-57

SPECIAL TOOLS

Fig. 101 - 2400 Through 3600 Lb. C a p acity Drive Line Sp ecial Tools

1. J —8614 Companion Flange Remover—Consisting 7. J -21491 Rear W heel Bearing and O il Sebl
of J-8614-1 Holder J-8614-2 N ut In staller— Light Duty A x le — Used
and J-8614-3 Screw w ith J-8092
2. J-21057 D rive Pinion O il Seal In s ta lle r- 8. J —2619 Rear W heel Bearing and O il Seal
H eavy Duty A x le Remover (Slid e Hammer)
3. J-21468 D rive Pinion O il Seal In sta ller—Light 9. J —8119 Rear W heel Bearing and O il Seal
Duty A x le —Used w ith J-9458 Remover—Used w ith J —2619
4. J-5748 Positraction Torque Measuring Adapter 10. J-8092 D rive H andle—Threaded Type
5. J-9458 D rive Pinion O il Seal In s ta lle r - 11. J-7079-2 D rive H andle— Insert Type
Light Duty A x le — Used with 12. J-21548 Propeller Shaft " U ” Jo in t Trunnion
J-21468 Seal Installer
6. J-21051 Rear W h eel Bearing and O il Seal 13. J-5853 Torque W re n ch —in. lbs.
In sta ller— H eavy D u ty—Used w ith 14. J —5810 Torque W rench Adapter (3/4" to 3 / 8 ")
J -7079-2 15. J-1313 Torque W re n ch —ft. lbs.

CHEVROLET TRUCK SERVICE M ANUAL

REAR SUSPENSION AND DRIVE LINE 4-58

SPECIAL TOOLS

Fig . 102 - 5200 lb. C a p a c ity Sin g le Speed Through 18,500 lb. C a p a c ity Two Speed Sp ecia l Tools

1. J-22335 W heel O il Seal In staller 11. J-8092 D river Handle 21. J —22350—1 W heel Bearing Remover
2. J-22353 W heel O il Seal In staller 12. J-8093 W heel Bearing Installer 22. J-22350-2 Adapter (Used with
3. J -22351 W heel O il Seal In staller 13. J —21108 W heel Bearing Installer J —22350—1 and J -22360)
4. J -22352 W heel O il Seal In staller 14. J-22357 W heel Bearing Installer 23. J-22360 W heel Bearing Remover
5. J-22354 W heel O il Seal Installer 15. J-22349 W heel Bearing Installer 24. J —7341 W heel Bearing N u t W rench
6. J —22281 Pinion Flange O il Seal In staller 16. J-21160 W heel Bearing Installer 25. J-22343 W heel Bearing N u t W rench
7. J-2223 W heel Bearing In staller 17. J —8114 W heel Bearing Installer 26. J-5698 W heel Bearing Installer
8. J-2222 W heel Bearing N u t W rench 18. J-5669 W heel Bearing Installer
9. J-0870 W heel Bearing N u t W rench 19. J-22380 Tru-Arc Pliers Tools not Illustrated:
10. J-22359 W heel Bearing In staller 20. J —2619 Slid e Hammer w ith Adapter J-2230 W heel Bearing Remover

CHEVROLET TRUCK SERVICE M ANUAL

 SECTION 5
BRAKES
CONTENTS OF THIS SECTION
Page Page
Standard Hydraulic Brakes ............................................. 5-1 A ir B r a k e s
Bendix Power B r a k e s ...................................................... Trailer Equipm ent
Vacuum Booster Power Brake U n it................................. Special T o o ls

STANDARD HYDRAULIC BRAKES

INDEX
Page Page
General D e s c r ip tio n ............... '......................................... ... 5“]. Main Cylinder - Single Reservoir T y p e ..................... 5-16
Main Cylinder......................................................................5-1 Brake Components - Self Adjusting ........................... 5-18
Self Adjusting Duo-Servo B r a k e s ................................. ...5-1 Front and Rear B r a k e s ................................................ 5-18
Manually Adjusted Brakes - W a g n e r ........................... ... 5-1 Rear Brakes 40 and 50 S e r i e s .................................... 5-22
Wheel C y lin d e r s ............................................................ ... 5-4 Brake Components - Manually Adjusted (Wagner) . . . . 5-25
Brake Linings ............................................................... ... 5-5 Wheel C y lin d e r s ............................................................... 5-28
Parking B r a k e ............................................................... ... 5-5 Brake D r u m s ..................................................................... 5-30
Brake Pipe Distribution and Switch A s s e m b ly ............ ... 5-5 Brake Pedal (Except Tilt Cab and Chevy V an)............... 5-30
Maintenance and A dju stm en ts.......................................... ...5-5 Brake Pedal - Tilt C a b ................................................... 5-30
Brake Shoe Adjustment ................................................ ... 5-5 Brake Pedal - Chevy V a n ................................................ 5-33
Bleeding B r a k e s ............................................................ ...5-6 Parking Brake - Rear Wheel T y p e ................................. 5-33
Parking Brake Lubrication .......................................... ...5-8 Parking Brake - Propeller Shaft (Single Shoe Type) . . 5-35
Brake Pedal to Floor C le a r a n c e ................................. ...5-8 Parking Brake - Propeller Shaft (Band T y p e )............... 5-39
Brake Pedal Adjustment - G 1 0 -2 0 .............................. ... 5-8 Parking Brake Cable L ubrication .................................... 5-40
Brake Pedal and Push Rod Travel Adjustment............ 5-9 Anchor Pin Replacement - Chevy V a n ........................... 5-40
Parking Brake A dju stm en ts.......................................... ... 5-9 Hydraulic Brake Lines and T u b in g ................................. 5-40
Hydraulic Brake L in e s ................................................... ...5-11 Brake Pipe Distribution and Switch A s s e m b ly ............... 5-41
Service Operations ......................................................... ...5-13
Main Cylinder - Dual S y ste m ....................................... ... 5-13

GENERAL DESCRIPTION
MAIN CYLINDER rear axle which are equipped with Twinplex two
cylinder, self-adjusting rear brakes. All 60
All 1967 10 through 30 series models (except CA30 and series are equipped with Wagner, two-cylinder,
PA30/14,000 lb. GVW) are equipped with a new dual manually adjusted brakes, front and rear.
brake system as a safety feature. If a wheel cylinder or
brake line should fail at either the front end or rear end Brake shoe adjustment takes place when brakes are
of the vehicle, the operator can still bring the vehicle to a applied with a firm pedal effort while the vehicle is back­
controlled stop. The system is designed with separate ing. Applying the brake moves an actuator which turns
hydraulic systems for the front and rear brake using a the star wheel and lengthens the adjusting screw assem­
dual main cylinder (Fig. 1). The main cylinder has two bly (Fig. 2). This action adjusts the shoes until clearance
entirely separate reservoirs and outlets in a common between the lining and drum is within proper limits.
body pasting. The front reservoir and outlet is connected Fifty series models with 15,000 lb. single or two-speed
to the front wheel brakes, and the rear reservoir and rear axle are equipped with 15 x 4 o r l 5 x 5 inch rear
outlet is connected to the rear wheel brakes. Two pistons Twinplex brakes (Fig. 3). The Twinplex, self-adjusting
within the main cylinder receive mechanical pressure rear brake is self-centering in operation, utilizing the
from the brake pedal push rod and transmit it through the momentum of the vehicle to assist in the brake applica­
brakelines as hydraulic pressure to the wheel cylinders. tion. This self-energizing or self-actuating force is
Main cylinders for CA30, PA30 (14,000 lb. and over applied to both brake shoes at each wheel in both forward
GVW), and all 40 through 60 series models are of the and reverse motion.
single hydraulic system (single main cylinder reservoir)
type. MANUALLY ADJUSTED BRAKES (WAGNER)
NOTE: All 60 series models are equipped with
SELF-ADJUSTING DUO-SERVO BRAKES Wagner, two-cylinder, manually adjusted brakes,
front and rear.
NOTE: All models, 10 thru 40 series, have
self-adjusting duo-servo brakes, front and rear. The Wagner manually adjusted brakes are of two dif­
Fifty series models are equipped with self- ferent types: the Type “ F ” (Fig. 4), and the “ F R -3”
adjusting duo-servo brakes front and rear, ex­ (Fig. 5). The “ F ” has two identical brake shoes mounted
cept those with 15,000 lb. single or two speed on the backing plate so that their toes are diagonally

CHEVROLET TRUCK SERVICE M ANUAL

BRAKES 5-2

PA 20-30 PA 40

CA-SA 40, CD-CG-MA 50, CD-CG 60 TA 40-50-60

EXTENSION
SIDE RAIL-LEFT
SIDE

INBOARD FORWARD

GA 10-20 CE-CS-SA 50-60

Fig . 1—M ain C ylin d ers—A ll Models

CHEVROLET TRUCK SERVICE M ANUAL

 BRAKES 5-3

W IR E LINK
PRIMARY
SH O E
O VERRID E
LEVER

O VERRID E
S P R IN G

RETURN
S P R IN G

STAR W H E E L
PAW L

Fig. 2—S e lf Adjusting Brake

opposite. Two single-end wheel cylinders are arranged

so that each cylinder is mounted between the toe of one
shoe, and the heel of the other. The two-wheel cylinder
pistons apply an equal amount of force to the toe of each
shoe. Each cylinder casting is shaped to provide an Fig. 4 —W agner Type “ F ” Front Left Brake [rp
anchor block for the brake shoe heel.
self-centering shoes. The shoes anchor at either toe or
The “ F R -3 ” brake is used on all vehicles equipped heel, depending upon the direction of drum rotation. Both
with Eaton Rear Axles. Each brake is equipped with two-
double-end wheel cylinders which apply hydraulic pres­
sure to both th e toe and heel o f two identical

Fig. 5—W agn er Type " F R - 3 ” Rear Brake

Fig. 3—Twinplex Rear Brake O 1. W h eel C y lin d e r Heat 8. Brake Shoe and Lining
Shield Assembly
1. W heel C y lin d e r Heat Shield 7. Brake Shoe Return Spring 2. Upper W h eel C ylin d er 9. Return Spring (Long)
2. W h eel C ylin d er 8. Adjusting Screw Spur W h ee l 3. Anchor Pin 10. Adjusting W h eel Lock
3. W heel C ylin d er Push Rod 9. Brake Line 4. Return Spring (Short) Spring
4. Brake Shoe 10. W h eel C ylin d er 5. G u id e Washer 11. Adjusting W h eel
5. Brake Shoe Return Spring 11. Brake Shoe Anchors 6. G u id e Bolt 12. Lower W h eel C y lin d e r
6. Brake Shoe Hold Down Bolt 7. G u id e Bolt N u t Lock W ire 13. Backing Plate

CHEVROLET TRUCK SERVICE M ANUAL

BRAKES 5-4

DUO-SERVO
TYPE "F*

TWINPLEX
TYPE "FR-3”

Fig. 6 —Duo-Servo and Twinplex W h ee l Cylinders

1. Push Rod 5. Spring

Fig. 7—W h eel C ylinders Used w ith Types *‘F ” and
2. Boot 6. Housing
“ FR-3” Brakes
3. Piston 7. Spring
4. Piston Cup
1. Boot 6. Piston Spring
2. Brake Shoe G u id e 7. C ylin d er
shoes are always primary shoes, self-energizing in 3. Piston 8. Brake Shoe Anchor
either direction of drum rotation. Brake anchor supports, 4. Piston Cup Slot
5. Cup F ille r 9. Push Rod
bolted to the axle housing flange in conjunction with the
flange plate, have removable slotted anchor pins at the
shoe heels and adjusting screws at the shoe toes which
brakes, wheel cylinder housing construction varies on
act as anchors in the reverse direction of rotation. Each
different models, however, internal construction is the
adjusting screw is threaded into or out of its support by
same as illustrated in Figure 6 .
means of an adjusting wheel. Brakes are accessible for
On Duo-Servo brakes one wheel cylinder is used at
adjustment through adjusting slots in the flange plate.
each brake, mounted on the flange plate between upper
ends of brake shoes as shown in Figure 2. On Twinplex
WHEEL CYLINDERS
and Wagner, “ F ” and “ FR -3” type brakes, two cylinders
Four types of wheel cylinders are used on Chevrolet are used at each brake, mounted on the flange plate be­
Trucks. Wheel cylinders are identified with type of brake tween shoe ends as shown in Figures 3, and 4, and 5.
with which they are used (figs. 6 and 7). On Duo-Servo A bleeder valve for purging air from the hydraulic

SW ITC H SW ITCH
SW ITC H

G10-20 CA-KA-PA10, CA30 PA20-30

Fig . 8—-Brake Pipe Distribution and Sw itch Assembly

CHEVROLET TRUCK SERVICE M ANUAL

 BRAKES 5-5

system is provided on all wheel cylinders. On a Twin­ models are equipped with the propeller shaft type parking
plex brake installation a bleeder valve is used only on brake.
the upper cylinder of the two used on each wheel.
BRAKE PIPE DISTRIBUTION AND
BRAKE LININGS SWITCH ASSEMBLY
CA-KA-PA10-20, GA-PA-30, and GA10-20 models
Brake linings on all 10 series models are attached to
are equipped with a brake pipe distribution and switch
the brake shoes with a special brake bonding process.
assembly (Fig. 8 ). The front and rear hydraulic brake
Only the factory bonded shoe and lining assemblies
lines are routed from the main cylinder, through the
should be used for replacement. On 20 through 60 series
switch assembly, to the front and rear brakes. The
models, linings are riveted to the brake shoes.
switch is wired electrically to the brake alarm indicator
light on the instrument panel. In the event of fluid loss in
PARKING BRAKE either the front or rear brake system, the indicator on
The parking brake on all 1/2, 3/4, and 1 ton models is the instrument panel will illuminate red. (The indicator
the mechanical type which utilizes the action of the serv­ will also be illuminated when the parking brake is
ice brake shoes in the rear brake assemblies. All other applied.)

MAINTENANCE AND ADJUSTMENTS

In any service operation it is extremely important that brake drag is relieved, then move wrench an addi­
absolute cleanliness be observed. Any foreign matter in tional 7 to 10 degrees to provide running clearance
the system will tend to clog the lines, ruin the rubber (7 to 10 degrees is equal to 1 to 1 1/2 inches of
cups of the wheel and main cylinders and cause inefficient travel at end of an 8 - inch wrench).
operation or even failure of the braking system. Dirt or 3. Place wrench on opposite adjusting cam stud and
grease on a brake lining will cause that brake to grab adjust second shoe by repeating steps 1 and 2 .
first on brake application and fade out on heavy brake
application. Wagner Type “ FR-3”
1. Jack up wheels until clear of floor. Remove adjusting
BRAKE SHOE ADJUSTMENT hole covers from backing plate.
The duo-servo and Twinplex brakes used on all 10 thru 2. At one adjusting slot, insert suitable tool through slot
50 series models are equipped with self-adjusting mech­ and engage adjusting wheel (fig. 10). Move tool
anisms to compensate for normal facing wear. Sixty handle toward axle to rotate adjusting wheel and
series models are equipped with Wagner manually ad­ decrease lining clearance until lining drags on drum.
justed brakes; the adjustment is made through an opening Firmly depress foot pedal to center shoes and again
in the flange plate or externally as outlined below. decrease clearance until drag is felt on drum.
3. Relieve drag by rotating adjusting wheel in opposite
Wagner Type “ F” direction. Back off adjustment as follows:
For worn lining—3 notches (clicks)
1. Jack up axle. Place wrench on one adjusting cam For new lining—5 notches (clicks)
stud to adjust one shoe (fig. 9). Rotate wrench in
direction of forward wheel rotation to decrease
lining to drum clearance. Reduce clearance until FRONT SHOE
brake drag is felt as wheel is turned in forward ADJUSTMENT SLOT
direction by hand.
2. Move wrench slightly in opposite direction until

REAR SHOE
ADJUSTING WHEEL

Fig . 9—Adjusting Type “ F ” Front Brakes Fig . 10—Adjusting Type “ F R -3 ” Rear Brakes

CHEVROLET TRUCK SERVICE M ANUAL

BRAKES 5-6

4. At other adjusting slot, repeat steps 2 and 3 to adjust to bleeder adapter and open release valve on bleeder
other shoe. equipment.
5. Install adjusting hole covers in backing plate. 4. Install brake bleeder wrench, Tool J-7647 on bleeder
valve at wheel cylinder and install one end of bleeder
BLEEDING BRAKES 5. Pour a sufficient amount of brake fluid into a trans­
parent container to insure that end of bleeder hose
The hydraulic brake system must be bled whenever any
will remain submerged during bleeding. Place the
line has been disconnected or air has in some way
loose end of bleeder hose into the container. Be sure
entered the system. A ‘'spongy'’ pedal feel when the
the hose end is submerged in the fluid.
brakes are applied may indicate presence of air in the
6 . Open wheel cylinder bleeder valve by turning Tool
system. The system must be absolutely free of air at all
J-7647 counterclockwise approximately 1/3 of a turn
times. Bleeding should be done on the longest line first;
and observe flow of fluid at end of bleeder hose.
the proper sequence to follow is left rear, right rear,
7. Close bleeder valve tightly as soon as bubbles stop
right front, and left front. Bleeding of brake system may
and brake fluid flows in a solid stream from the
be performed by one of two methods—pressure or
bleeder tube.
manual.
8 . Remove brake bleeder wrench and bleeder hose from
wheel cylinder bleeder valve.
Brake Fluid 9. Repeat Steps 4 through 8 on the remaining wheel
Use GM Hydraulic Brake Fluid No. 11 or equivalent cylinders in the correct bleeding sequence.
when servicing brakes. This brake fluid is satisfactory 10. Disconnect bleeder equipment from brake bleeder
for any climate and has all the qualities necessary for adapter cover J-22489.
proper operation, such as a high boiling point to prevent NOTE: The main cylinder on certain passenger
vapor lock and the ability to remain fluid at low car models is tilted upward. When removing the
temperatures. bleeder adapter on these models, place a clean
In the event that improper fluid has entered the system, dry cloth behind and below the cylinder to absorb
it will be necessary to service the system as follows: any fluid spillage as the cover is removed.
1. Drain the entire system.
2. Thoroughly flush the system with clean alcohol, 188 11. Remove bleeder adapter J-22489. Wipe all area dry
proof, or a hydraulic system cleaning fluid such as of fluid if fluid was spilled during adapter removal.
“ Declene” . 12. Fill m aster cylinder reservoirs to within 1/4” of
3. Replace all rubber parts of the system, including reservoir rim s as shown in Figure 13.
brake hoses. 13. Install main cylinder diaphragm and cover.
4. Refill the system.
5. Bleed the system. Dual System (Dual Reservoir Main Cylinder)
1. Clean all dirt from top of main cylinder and remove
Dual System (Dual Reservoir Main Cylinder) cylinder cover and rubber diaphragm.
1. Clean all dirt from top of main cylinder and remove 2. Fill main cylinder reservoir.
cylinder cover and rubber diaphragm. 3. Install brake bleeder wrench, Tool J-7647 on bleeder
2. Reduce fluid level in main cylinder until reservoirs valve at wheel cylinder and install one end of bleeder
are approximately half full. tube J-0628 on bleeder valve.
4. Pour a sufficient amount of brake fluid into a trans­
NOTE: Make sure brake fluid in bleeder equip­ parent container to insure that end of bleeder tube
ment is at operating level and that the equipment will remain submerged during bleeding. Place the
is capable of exerting 30 to 50 lbs. hydraulic loose end of bleeder tube into the container. Be sure
pressure on the brake system. the tube end is submerged in the fluid.
3. Install brake bleeder adapter J - 22489 (fig. 11) on NOTE: Carefully monitor fluid level at main
main cylinder. Connect hose from bleeder equipment cylinder during manual bleeding operations. Do
not bleed enough fluid at one time to drain the
reservoir completely. Replenish the reservoirs

Fig. 11—Brake Bleeder Adapter Tool J-2 2 4 8 9 Installed Fig . 12—Brake Bleeder Tool J-7 6 4 7

CHEVROLET TRUCK SERVICE MANUAL

 BRAKES 5-7

Fig. 13—C orrect M a in C y lin d e r Fluid Level

with fluid while bleeding to insure a sufficient times. To insure that outside air is not sucked
amount of fluid is in the main cylinder at all back into the hydraulic system, the bleeder valve
should be closed before the brake pedal reaches
the floor.
5. Open wheel cylinder bleeder valve by turning Tool
J-7647 counterclockwise approximately 1/3 of a turn.
Slowly depress brake pedal. Just before brake pedal
reaches the end of its travel, close bleeder valve and
allow brake pedal to return slowly to the fully re ­
leased position. Repeat this procedure until expelled
brake fluid flows in a solid stream from the bleeder
hose and no bubbles are present, then close bleeder
valve tightly.
6 . Remove brake bleeder wrench and bleeder tube from
wheel cylinder bleeder valve.
7. Repeat Steps 2 through 7 on the remaining wheel
cylinders in the correct bleeding sequence.
8 . Fill the main cylinder to the levels shown in Figure
13.
9. Install main cylinder diaphragm and cover.

Pressure Bleeding—Single System

(Single Reservoir Main Cylinder)

1. Make sure fluid level of pressure bleeding unit is up

to operating level. Unit must be capable of producing
25-30 psi.
2. Clean all foreign matter from main cylinder reser­
voir area and remove reservoir cover.
3. Replace cover with Tool J - 8554 and attach pressure
bleeding unit.
4. With pressure on brake system, position bleeding
tube J-0628 over end bleeding valve (fig. 14).
5. Place other end of tube in transparent container
Fig . 14—Bleeding W heel C ylin d e r holding sufficient fluid to cover end of tube.

CHEVROLET TRUCK SERVICE M ANUAL

BRAKES 5-8 #

toe board to the forward edge of the pedal pad.

This clearance should be a minimum of 5 inches with
the floor mat removed. If reserve is less than 5
inches, rebleed the entire system as outlined.
PARKING BRAKE CABLE—LUBRICATION
Parking brake cables should be lubricated during a
brake reline job or when adjusting brakes if cables feel
stickly.
When lubricating the brake cables, the rear brake
drums must be removed on 1/2 and 3/4 ton vehicles in
order to make sure that lubricant is not forced into the
brake assembly during lubrication.
BRAKE PEDAL-TO-FLOOR CLEARANCE
Any time the brake pedal-to-floor reserve is less than
shown below, the brake system should be immediately
checked for malfunctions. Refer to Figure 16.
NOTE: Brake pedal reserve measurements to
be made with 75 lbs. pressure on brake pedal.
Take measurement with engine not running when
truck has standard or optional power brakes,
and with engine running when truck has standard
power brakes.
Fig. 15—Brake Pedal Free M ovem ent—G 10-20
BRAKE PEDAL ADJUSTMENT—G10-20 SERIES
6 . Open bleeder valve 3/4 turn and observe flow. When (Fig. 15)
bubbles no longer appear and fluid flows in a solid 1. Loosen check nut on the eccentric bolt attachment
stream, close valve securely. between the brake pedal and main cylinder push
7. Repeat operations 4, 5 and 6 at each bleed valve in rod.
system. 2. Turn eccentric bolt as required to provide correct
8 . Apply approximately 75 pounds pressure on the adjustment. Movement of pedal pad before push
brake pedal and check the pedal clearance from the rod contacts main cylinder piston must be 1/16" to
toe board to the forward edge of the pedal pad. This 1/4" (fig. 5).
clearance should be a minimum of 5 inches with the NOTE: Eccentric Adjustment bolt should be
floor mat removed. If reserve is less than 5 inches, installed with projection in up position before
rebleed the entire system in the sequence outlined adjustment.
above.
Manual Bleeding—Single System
(Single Reservoir Main Cylinder)
Manual bleeding is sim ilar to pressure bleeding except
that the brake fluid is forced through the lines by pumping
the brake pedal instead of by air pressure.
1. Clean all foreign matter from main cylinder re se r­
voir area and remove reservoir cover.
2. Fill main cylinder reservoir.
3. In sequence, bleed wheel cylinder in the following
manner. Position bleeding tube J-0628 over end of
first bleeding valve in sequence indicated. Place
other end of tube in transparent container holding
sufficient fluid to cover end of tube.
4. Open bleeder valve approximately 3/4 of a turn, de­
press the brake pedal a full stroke and allow it to
return slowly, making sure the end of the bleeder
tube is under the surface of the liquid in the con­
tainer. Continue operating the pedal, refilling the ja r
at the main cylinder when necessary, until liquid
containing no air bubbles emerges from the bleeder
tube. Close bleeder valve as brake pedal is on down
\
stroke.
5. Replace reservoir cover then readjust all brake
shoes.
6 . Apply approximately 75 pounds pressure on the
brake pedal and check the pedal clearance from the Fig . 16—Brake Pedal Reserve Measurement

CHEVROLET TRUCK SERVICE M ANUAL

 BRAKES 5-9

FW D

Fig. 19—Parking Brake Adjustment

Fig. 17—Eccen tric Bolt Adjustment to obtain the correct clearance between the push rod
and the m aster cylinder, rotate the eccentric bolt so
that the free pedal travel measured at the center of
3. Tighten check nut on eccentric bolt and recheck the pedal pad is approximately 1 / 8 inch (fig. 18).
movement. 2. After tightening the nut on the eccentric bolt to 40-50
ft. lbs. torque, recheck free travel.
BRAKE PEDAL & PUSH ROD TRAVEL 3. Stop light switch should be adjusted if necessary, so
ADJUSTMENT that the electrical contact is made at approximately
13/16 inch pedal pad travel.
A definite pedal push rod-to-main cylinder piston
clearance must be maintained on the dash mounted main Threaded Rod Type Adjustment
cylinder units. This clearance is adjusted as follows: 1. After the brake pedal and pedal bumper have been
assembled, install the push rod and its attaching
Eccentric Bolt Type Adjustment parts. Tighten nut to 40-50 ft. lbs. torque. Then to
Refer to Figure 17. obtain the correct clearance between the push rod
1. After the brake pedal and pedal bumper have been and the master cylinder, adjust the push rod so that
assembled, install the eccentric bolt with the pro­ the free pedal travel measured at the center of the
jection on the head in top or bottom position. Then pedal pad is approximately 1 / 8 inch (fig. 18).
2. After tightening the locknut on the adjustable push
rod to 17-23 ft. lbs. torque, recheck free travel.
3. Stop light switch should be adjusted if necessary, so
that electrical contact is made at approximately
13/16 inch pedal pad travel.

PARKING BRAKE ADJUSTMENTS

(Figs. 19, 20, 21, and 22)
Rear Wheel Parking Brake
Adjustment of the cable connected “ rear wheel type”
parking brake used on 1/2, 3/4, and 1 ton models must be
performed each time the service brakes are adjusted and
can be accomplished only when service brakes are in
adjustment.
The propeller shaft parking brake used on all other
trucks operates independent of the service brakes and
necessary adjustment of either the “ band type” or
“ shoe type” is covered in this section.

CA10-20-30 and KA10-20 Models

1. Jack up both rear wheels.
2. Apply parking brake 4 notches from fully released
position.
3. Loosen equalizer check nut and tighten the adjusting
nut until a moderate drag is felt when the rear
wheels are rotated.
4. Tighten the check nut securely.
5. Fully release parking brake and rotate the rear
Fig . 18—Brake Pedal Free Movement wheels. No drag should be present.

CHEVROLET TRUCK SERVICE MANUAL

BRAKES 5-10

Fig. 20—Parking Brake Systems—K Models

GIO and G20 Series (Fig. 21) Propeller Shaft Parking Brake—(Band Type)
(Fig. 24)
1. Pull parking brake lever two notches from fully
released position. 1. Set hand brake lever in the “ fully released” position.
2. Loosen the equalizer clevis forward check nut, and 2. Loosen lock nut on brake pull rod and disconnect pull
tighten the rear nut until a light to moderate drag is rod from brake operating cams by removing cotter
felt when rear wheels are rotated. pin and clevis pin. Set brake cam rest flat on the
3. Tighten check nuts securely. upper brake band bracket.
4. Fully release parking brake and rotate rear wheels;
no drag should be present.

PI 0-20-30 Models
1. Raise rear of vehicle and place on jack stands.
2. Set parking brake lever in fully released position.
3. Loosen front cable clevis check nut and adjust
clevis-to-equalizer lever connection to obtain a
clearance of 1/4 inch between idler lever and rear
end of slot in guide (fig. 22). Tighten lock nuts.
4. Pull parking brake lever to the applied position.
5. Check drag on each rear wheel. An equal amount of
drag should be present at each wheel. If drag is not
equal, loosen applicable rear cable connection and
adjust as required.
6 . Release parking brake lever. Check rear wheels to
insure no drag is present. If necessary adjust front
cable clevis-to-equalizer connection to eliminate
drag.
7. Tighten all lock nuts and lower vehicle. Fig. 21—Ch evy V an Parking Brake Idler Linkage—Exploded V ie w

CHEVROLET TRUCK SERVICE M ANUAL

 BRAKES 5-11

Adjustment
1. Turn adjusting knob of lever asm. counterclockwise
to bottom position. Attach brake cable to Orscheln
brake lever asm. With the lever in the “brake off”
position, adjust brakes for proper clearance and
remove slack from brake cables by adjusting clevis
at transmission.
2. Test the brakes by pulling to the “brake on”
position. A definite snap-over-center should be felt.
Turn the adjusting knob in a clockwise direction until
a snap-over-center is felt.
3. Oil all moving parts.

Propeller Shaft Parking Brake—Single Shoe Type

(Fig. 25)
1. Set hand brake lever in the fully release notch of the
ratchet sector.
2. Loosen lock nut “ D” and draw up adjusting bolt
“ A” to secure clearance between outer shoe facing
and brake drum of .010"-.015" measured at a point
directly above bolt “ A” . Then hold bolt and tighten
lock nut securely.
3. Loosen lock nut “ C” and draw up nut “ B ” to secure
.010"-.015" clearance between inner shoe facing and
brake drum. Then hold nut “ B ” and tighten lock nut
“ C” securely.
4. Recheck both facing to drum clearances.

Propeller Shaft Parking Brake (Double Shoe Type)

The double shoe type parking brake is sim ilar to a

wheel brake with two brake shoes and riveted linings.
F ig . 22—P I 0-20-30 Parking Brake Front C ab le Adjustment
The shoes are operated by moving an offset cam between
the brake shoes by means of a mechanical lever. Adjust­
3. Back off nuts “ E ” and “ F ” (fig. 24). Back off nut ment is sim ilar to the single shoe type whereby the
“ D” and adjusting nut on bolt “ C” . clearance between the brake shoe and drum should be
adjusted at the parking brake to give approximately a
NOTE: Do not remove nuts, loosen only.
. 0 1 0 " clearance measured by feeler gauges.
4. Remove lock wire from anchor screw “ B ” .
5. Adjust anchor screw “ B ” until there is .010 to .015
clearance between lining and drum at anchor screw. HYDRAULIC BRAKE LINES
6 . Tighten adjusting bolt “ C” until there is .020 clear­
ance between drum and lower end of brake band. Hydraulic Brake Hose
7. Tighten lock nut “ D” .
8 . Tighten up adjusting nut “ E ” until there is .020 These hoses require no maintenance other than peri­
clearance between drum and upper end of brake band. odic inspection for damage from road hazards or other
9. Tighten up lock nut “ F ” . like sources. See brake lines under Service Operations
10. Adjust brake pull rod so the clevis pin can be in­ for proper installation of brake lines.
stalled in the cams while the brake cam rests flat on
NOTE: A l w a y s disconnect hydraulic brake
the upper brake band bracket. hoses at frame bracket before hoses are torqued
11. Install cotter pin in clevis pin of brake pull rod and
at the wheel cylinder. Make certain that brake
tighten lock nut on pull rod.
hoses are not twisted.
12. Install lock wire on anchor screw “ B ” .
13. Recheck all points of facing for correct clearances.
Hydraulic Brake Tubing

T Models (Figs. 23 and 26) Hydraulic brake tubing used on all trucks is a double
layer flexible steel, copper coated and tin plated tubing
Tilt Cab vehicles are equipped with a compound type which resists corrosion and also stands up under high
lever that applies the transmission mounted parking pressures developed when brakes are applied. Mainte­
brake by means of a flexible cable. The lever incor­ nance of the tubing should consist of a periodic check on
porates a cable adjustment feature that allows the oper­ the tubing; especially, in the event of rattles and/or
ator to adjust the "ov er-cen ter” position required to lock crimping or slow leakage due to possible stone damage,
the parking brake in the applied position. loose connections, etc.

CHEVROLET TRUCK SERVICE M ANUAL

BRAKES 5-12

TD 50-60

Fig . 23—Parking Brake C ables—T Models

CHEVROLET TRUCK SERVICE MANUAL

 BRAKES 5-13

Fig. 24—Propeller Shaft Parking Brake (Band Type) Fig. 25—Propeller Shaft Parking Brake (Shoe Type)

V IE W A
TG 50 -60

V IE W A
TA40, TD-TE-TS50

Fig. 26—Parking Brake Hand Lever—T Models

SERVICE OPERATIONS
MAIN CYLINDER-DUAL SYSTEM "Main Cylinder - Single Reservoir Type (Mid­
land R oss)" under Power Brakes.
NOTE: This model cylinder is installed on
CA-KA.-PA10-20, and CA-PA30 series vehi­ When servicing the Delco Moraine dual master cylin­
cles. When service procedures for CE-CS- der, follow the rules below when replacing either com­
SA50-60 series models are required, refer to plete master cylinder or the component pistons of the

CHEVROLET TRUCK SERVICE M ANUAL

BRAKES 5-14

Fig. 27—Dual M ain C y lin d e r—Exploded V ie w

1. B ail W ire 7. Seal 13. Cup 19. Spring

2. C o ver 8. Piston 14. Seal 20. Stop Screw
3. Diaphragm Seal 9. Cup 15. Piston 21. Seal
4. Body 10. Sea l 16. Washer 22. Spring
5. V a lv e 11. Ring 17. V a lv e Seat 23. C h eck V a lv e
6. Spring 12. Retainer 18. V a lv e 24. C heck V a lv e Seat

CHEVROLET TRUCK SERVICE M ANUAL

 BRAKES 5-15

cylinder. It is equally important to use only the correct protector, and secondary seal from the primary
service parts when servicing a Bendix main cylinder. piston.
1. The two-letter identification stamp on the end of the Cleaning and Inspection
master cylinder indicates the displacement capa­ 1. Remove main cylinder casting from vice and inspect
bilities of that particular cylinder. Master cylinders the bore for corrosion, pits, and foreign matter. Be
should only be replaced with another cylinder bear­ sure that the outlet ports are clean and free of brass
ing the same two-letter identification. cuttings from the tube seat removal operation.
2. The length of the component pistons in the master 2. Inspect the fluid reservoirs for foreign matter.
cylinders are critical factors in displacement capa­ Check the bypass and compensating ports to the cyl­
bilities of a particular m aster cylinder. These pis­ inder bore to insure that they are not restricted. Do
tons are coded, using rings or grooves in the shank not use wire to check ports.
of the piston. It is mandatory that when pistons are
replaced, the replacing piston must contain the same NOTE: Before washing parts, hands must be
identification marks and the same contour at the push clean. Do not wash hands in gasoline or oil
rod ends as the piston which was removed. before cleaning parts. Use soap and water only.
3. Delco Moraine dual master cylinders, used with 3. Use Declene or equivalent to clean all metal parts
drum-type brakes, contain a rubber check valve and thoroughly. Immerse parts in the cleaning fluid and
check valve spring in each outlet boss. Follow in­ brush with hair brush to remove foreign matter.
structions given below under disassembly when re­ Blow out all passages, orifices, and valve holes. Air
placing check valves. dry the parts and place on clean paper or lint-free
clean cloth.
Removal
1. Wipe main cylinder and lines clean with a clean NOTE: Be sure to keep parts clean until re ­
cloth. Place dry cloths below main cylinder area to assembly. Rewash parts, if there is any occa­
absorb any fluid spillage. sion to doubt cleanliness.
2. Disconnect hydraulic lines at main cylinder. Cover
4. Check pistons for scratches or other damage; replace
line ends with clean lint-free material to prevent if necessary.
foreign matter from entering the system.
3. Disconnect the push rod from the brake pedal. Assembly( Fig. 27)
4. Unbolt and remove the main cylinder. Use care when reassembling the main cylinder check
5. Remove the main cylinder mounting gasket and boot. valves. Improper assembly of the check valve seats will
6 . Remove the main cylinder cover and dump-out the result in distortion of the seats. If this occurs, there will
fluid. Pump the remaining fluid from the cylinder by be no check valve action and a loss of brake pedal travel
depressing the push rod. will result; the pedal will have to be pumped one or more
times before actual car braking occurs.
Disassembly (Fig. 27) 1. Place the main cylinder in a vice with the outlet
1. Clamp main cylinder in a bench vice. holes facing up. Place the check valve springs in the
2. Remove push rod retainer. outlet holes. Be sure the springs are seated in the
3. Remove secondary piston stop bolt from bottom of bottom of the holes. Place new rubber check valves
front fluid reservoir. over the springs, being careful not to displace the
4. Remove the snap ring retainer and primary piston springs from the spring seats.
assembly. Remove the secondary piston, piston 2. Place new brass tube seats in the outlet holes. Be
spring, and retainer by blowing air through the stop sure seats are not cocked as this would cause burrs
bolt hole. (If no air is available, a piece of wire may to be turned up as the tube seats are pressed in.
be used. Bend approximately 1/4 inch of one end into Thread a spare brake line tube nut into the outlet
a right angle, hook the secondary piston and pull it hole and turn the nut down until the tube seat
out.) bottoms. Remove the tube nut and check the outlet
5. Position main cylinder in vice with outlet holes hole for loose burrs, which might have been turned
facing up. up when the tube seat was pressed down. Repeat this
6 . Drill a 13/64 inch hole through both check valve process to bottom the second seat.
seats. 3. Put new secondary seals in the two grooves in the
7. Tap out both seats using a 1/4 x 20 tap. end of the secondary piston assembly. The seal
8 . Install a spare brake line tube nut in the outlet hole. which is nearest the end will have its lips facing to­
Place a flat washer on a one inch screw (threaded to ward that end. The seal in the second groove should
screw into tapped hole), and thread screw into have its lips facing toward the portion of the second­
threaded hole in tube seat. Hold the screw to keep it ary piston which contains the small compensating
from turning and back out the tube nut. This will re­ holes.
move the tube seat. 4. Assemble a new primary seal protector and primary
9. Repeat Step 8 above on second tube seat. seal over the end of the secondary piston with the
10. Remove the check valves and springs from the cavi­ flat side of the seal seats against the seal protector,
ties beneath the tube seats. and the protector against the flange of the piston
11. Remove the primary seal, primary seal protector, which contains the small compensating holes.
and secondary seals from the secondary piston. Re­ 5. Assemble the new secondary seal into the groove on
move the piston extension screw securing the pri­ the push rod end of the primary piston. The lips of
mary piston spring to the primary piston. Remove this seal should face toward the small compensating
the spring retainer, primary seal, primary seal holes in the opposite end of the primary piston.

CHEVROLET TRUCK SERVICE M ANUAL

BRAKES 5-16

6 . Assemble the new primary seal protector and pri­ the other provides a hydraulic assist for clutch
mary seal on the end of the primary piston with the operation.
flat side of the seal seated against the seal protector,
Removal (Fig. 1)
and the protector against the flange on the piston
which contains the compensating holes. D ual C ylinder (except tilt cab)
7. Assemble the spring retainer in one end of the pri­ 1. Disconnect clutch and brake pedal return springs.
mary piston spring and the secondary piston stop in 2. Detach push rod boots from cylinder tubes.
the other end. Place the end of the spring over the 3. Remove clutch and brake cylinder lines from main
end of the primary piston with the spring retainer cylinder.
seats inside of the lips of the primary seal. 4. Remove the three bolts retaining cylinder assembly
8 . Remove all cleaning liquid from the threaded hole in to the front of dash.
the primary piston. Place the piston extension screw 5. Remove cylinder assembly from vehicle.
down through the secondary piston stop and the pri­ 6 . Remove cover and dump fluid out of cylinder.
mary spring retainer and screw it into the primary
Tilt Cab
piston until it bottoms out. 1. Tilt cab forward and block in place.
9. Coat the bore of the master cylinder with clean brake 2. Disconnect brake and clutch lines at cylinder and slip
fluid. Coat the primary and secondary seals on the rubber dust boots off cylinder tubes.
secondary piston with clean brake fluid. Insert the 3. Remove 3 cylinder attaching bolts and remove cyl­
secondary piston spring retainer into the secondary inder (allowing brake and clutch pedal push rods to
piston spring. Place the retainer and spring down fall loose).
over the end of the secondary piston until the re ­ 4. Repair the dual brake and clutch cylinder as re ­
tainer locates inside of the lips of the primary cup. quired. See disassembly, inspection and assembly
10. Hold the master cylinder with the open end of the procedures.
bore down. Push the secondary piston into the bore
until the spring seats against the closed end of the Single C ylind er
bore. 1. Disconnect brake pedal return spring.
11. Position the master cylinder in a vise with the open 2. Disconnect the brake hydraulic line at the main cyl­
end of the bore up. Coat the primary and secondary inder mounted on the cab. Also disconnect lines at
seal on the primary piston with clean brake fluid. the dash and toe pan.
Push the primary piston assembly, spring end first, 3. R e m o v e cylinder retaining bolts and remove
into the bore of the master cylinder. Hold the piston cylinder.
down and snap the lock ring into position in the small 4. Remove cover from top of cylinder and dump out
groove in the I.D. of the bore. fluid.
12. Push the primary piston down to move the secondary Disassembly (Fig. 28)
piston forward far enough to clear the stop screw
hole in the bottom of the front fluid reservoir. Install Dual Cylinder
the stop screw. Brake cylinder side
13. Install reservoir diaphragm in the reservoir cover 1. Remove piston stop snap ring.
and install the cover on the main cylinder. Push bail 2. Remove piston, primary cup, cup expander, piston
wire into position to secure the reservoir cover. return spring, check valve and check valve seat.
Installation Clutch cylinder side
1. Assemble the push rod through the push rod retainer, Remove same as brake cylinder side except for re ­
if it has been disassembled. moval of check valve and check valve seat.
2. Push the retainer over the end of the main cylinder.
Assemble new boot over push rod and press it down Single C ylinder
over the push rod retainer. Slide new mounting gas­ 1. Remove lock ring, secondary cup and piston from
ket into position. main cylinder.
3. Secure the main cylinder to the firewall or frame 2. Remove the primary cup, spring valve assembly and
rail as applicable, with mounting bolts. valve seat.
4. Connect the push rod clevis to the brake pedal with 3. Remove reservoir cover and gasket from top of main
pin and retainer. cylinder.
5. Connect the brake lines to the main cylinder.
6 . Fill the main cylinder reservoirs to the levels shown Inspection and Repair
in Figure 13. Bleed the brake system as outlined in Clean all dirt and grease from the main cylinder with a
this section. non-toxic, non-petroleum solvent.
7. If necessary, adjust the brake pedal free play as out­ 1. Wash all parts in clean alcohol. Make sure that in­
lined in this section. take and compensating ports in main cylinder hous­
ing, bleeder holes in piston and vent in filler cap are
clean and open.
MAIN CYLINDER-SINGLE RESERVOIR TYPE
NOTE: Before washing parts, hands must be
NOTE: These main cylinders are of the basic clean. Do not wash hands in gasoline or oil be­
single hydraulic reservoir type. Cylinders in­ fore cleaning parts. Use soap and water to
stalled on PA-TA40, and TA50-60 models have clean hands.
two pistons in the body casting, side by side.
One piston provides regular braking action and 2. Inspect cylinder bores to make sure they are smooth.

CHEVROLET TRUCK SERVICE MANUAL

 BRAKES 5-17

Fig. 28—Sin g le and C lutch Assist Type C ylin d ers—Exploded V ie w

Bail W ire 6. V a lv e Assembly .

11 Lock Ring 16. Retainer
Reservoir C over 7. Spring 12. Housing 17. Primary Cup
Seal 8. Primary Cup 13. Seal 18. Piston
Body 9. Piston 14. Check V a lv e 19. Piston Seal
V a lv e Seat 10. Secondary Cup 15. Return Spring 20. Snap Ring

Inspect primary and secondary cups, valve and valve a. Place spring assembly in the housing bore with
seat for damage or swelling. Swelling of rubber the stamped retainer toward the open end of the
parts is due to the use of improper brake fluid or bore.
washing parts in gasoline or kerosene. b. Place primary cup over the spring, with the flat
side outward.
NOTE: The primary cup has a brass support
c. Using the piston push the cup inward sufficiently
ring vulcanized in its base to prevent it from
to allow assembly of the piston stop snap ring,
imbedding in the bleeder holes during braking
then release piston against snap ring.
action.
d. Insert a straight wire (tag wire, or any wire of
Check piston fit in cylinder bore (fig. 29). The approx. . 0 2 0 dia.) through the small compensating
clearance between piston and wall of the cylinder port into the housing bore (fig. 30).
should be from .001” to .005". e. While moving the wire back and forth in the com­
Replace parts as required. pensating port, push the piston inward very gently
Check clearance between the edge of the primary cup until a slight drag on the wire is felt.
and the edge of the compensating port. To check this f. Check clearance between the end of the piston and
clearance, proceed as follows: the snap ring. This clearance should be .035

Fig . 29—Checking M ain C ylin d e r Piston Fit Fig . 30—M ain C y lin d e r—Cross Section

CHEVROLET TRUCK SERVICE M ANUAL

BRAKES 5-18

minimum. If the clearance is leSs than .035, the 4. Fill cylinder and bleed brakes and clutch systems as
primary cup should be replaced. noted in above installation (except tilt cab).
5. Install cover on main cylinder.
Assembly (Fig. 28)
6 . Adjust linkage if necessary.
Dual C ylinder
Single C ylind er (Fig. 1)
B rake C ylinder Side 1. Install boot in position and install main cylinder to
NOTE: Moisten all parts except snap ring with firewall with bolts, washers and nuts.
brake fluid as assembly progresses. 2. Connect hydraulic lines at dash, toe pan, and
cylinder.
1. Carefully position check valve seat at outlet end of 3. Connect brake pedal return spring.
cylinder bore. 4. Fill main cylinder reservoir and bleed brakes as
2. Insert check valve; then the piston return spring with outlined in this section.
primary cup expander toward open end of cylinder. 5. Install cover on main cylinder.
3. Install primary cup, skirt first. Take care that skirt
is not rolled back or torn during installation. BRAKE COMPONENTS-SELF ADJUSTING
4. Insert piston with secondary cup toward open end of
cylinder. Same care to be observed on secondary cup FRONT AND REAR BRAKES
as on primary.
5. Install piston stop snap ring. Brake shoe adjustment takes place when brakes are
applied with a firm pedal effort while vehicle is backing
Clutch C ylind er Side up. Applying the brakes moves an actuator which turns
the star wheel and lengthens the adjusting screw assem­
Replace same as brake cylinder except for replacement bly (fig. 31). This action adjusts the shoes until clearance
of check valve and check valve seat. between the lining and drum is within proper lim its.
Single C ylinder Should low pedal heights be encountered, it is rec­
NOTE: Moisten all parts except snap ring with ommended that numerous forward and reverse stops be
brake fluid as assembly progresses. performed with a firm pedal effort until a satisfactory
brake pedal height results.
1. Install valve seat, valve, spring, and primary cup in
cylinder bore. NOTE: Frequent usage of an automatic trans­
2. Install piston and secondary cup; secure with lock mission forward range to halt reverse vehicle
ring. motion may prevent the automatic adjusters
Installation from functioning, thereby inducing low pedal
heights.
D ual C ylinder (except Tilt Cab) (Fig. 1)
1. Reverse above applicable removal procedures. Retracting Self Adjusters
2 . Fill main cylinder reservoir end bleed brakes as
outlined in this section. A lanced “ knock out" area is provided in the web of
3. Check operation of brakes and clutch. the brake drum on all models except the P20, P30 and 50
4. Install cover on main cylinder. and the rear wheels of the K20 and C30. On these models
the access hole is located in the flange plate. This hole is
Tilt Cab (Fig. 1)
for service purposes in the event retracting of the brake
1. Align pedal push rods, position cylinder against shoes is required to remove the drum. However, in order
mounting flange and bolt in place. to back off the adjuster, it will be necessary to hold the
2. Slide end of rubber dust boots over cylinder tubes actuating lever away from the starwheel (fig. 32).
and connect fluid lines.
3. Tilt cab down. Brake Drums, Shoes and Linings
NOTE: If brake drums are worn severely, it
may be necessary to retract the adjusting screw
as previously outlined.
CAUTION: After knocking out the metal, be
sure to remove it from the inside of the drum
and clean all metal from the brake compartment.
A new hole cover must be installed when drum
is reinstalled.
\m JL o
Removal ^ 0
1. Raise the vehicle and place on stand jacks.
2. Loosen check nuts at forward end of parking brake
cable sufficiently to remove all tension from brake
cable.
3. Remove brake drums.
NOTE: Since boots are recessed in grooves on
wheel cylinders to prevent pistons from leaving
cylinders, it is not necessary to install wheel
F ig . 31—S e lf Adjusting Brake cylinder clamps when brake shoes are removed;

kvA
M sy
CHEVROLET TRUCK SERVICE M ANUAL
 BRAKES 5-19

Fig. 32—Brake Adjuster Access Hole Fig. 34—Removing Hold Down Springs and Pins
Using Tool J -22348

however, brake pedal must not be depressed

while drums are removed. NOTE: The actuator, pivot and override spring
4. Unhook brake shoe pull back springs from anchor pin are an assembly. It is not recommended that
and link end, using Tool J-8049 (fig. 33). they be disassembled for service purposes, un­
5. Remove the actuator return spring. less they are broken. It is much easier to
6 . Disengage the link end from the anchor pin and then
assemble and disassemble the brakes by leaving
from the secondary shoe. them intact.
7. Remove hold-down pins and springs using Tool 9. Separate the brake shoes by removing adjusting
J - 22348 (fig. 34). screw and spring.
8 . Remove the actuator assembly. 10. Remove parking brake lever from secondary brake
shoe (rear only).
11. Clean dirt out of brake drum using care to avoid
getting dirt into front wheel bearings. Inspect drums
for roughness, scoring or out of round. Replace or
recondition drums as necessary.
12. Inspect wheel bearings and oil seal and replace any
necessary parts.
13. Carefully pull lower ekges of wheel cylinder boots
away from cylinders and note whether interior is wet
with brake fluid. Excessive fluid at this point indi­
cates leakage past piston cups requiring overhaul of
wheel cylinder.
NOTE: A slight amount of fluid is nearly al­
ways present and acts as lubricant for the
piston.
14. If working at rear wheels, inspect backing plate for
oil leakage past axle shaft oil seals. Install new
seals if necessary.
15. Check all brake flange plate attaching bolts to make
sure they are tight. Clean all rust and dirt from shoe
contact faces on flange plate, using fine emery cloth.
Installation
CAUTION: Make certain to install recom­
mended shoe and lining assemblies. Otherwise,
series fade or permanent failure may occur.

CHEVROLET TRUCK SERVICE M ANUAL

BRAKES 5-20

Fig. 35—C hecking A ctuating Lever O peration

1. Inspect new linings and make certain there are no

nicks or burrs or bonding material on shoe edge Fig. 37— Installing Pull Back Springs Using Tool J-22348
where contact is made with brake flange plate or on
any of the contact surfaces. washer, lock washer and nut. Make sure that lever
NOTE: Keep hands clean while handling brake moves freely (fig. 35).
shoes. Do not permit oil or grease to come in 4. Before installation, make certain the adjusting screw
contact with linings. is clean and lubricated properly (fig. 36).

2. If working on rear brakes, lubricate parking brake NOTE: Loose adjustment may occur from an
cable. adjusting screw that is not properly operating.
3. On rear brakes only, lubricate fulcrum end of park­ If the lubrication in the adjusting screw of as­
ing brake lever and the bolt with brake lube, then sembly is contaminated or destroyed, the ad­
attach lever to secondary shoe with bolt, spring justing screw should be thoroughly cleaned and
lubricated.
5. Connect brake shoes together with adjusting screw
spring, then place adjusting screw, socket and nut
in position.
CAUTION: Make sure the proper adjusting
screw is used (left hand or right hand). The star
wheel should only be installed with the star
wheel nearest to the secondary shoe and the
adjusting screw spring inserted to prevent inter­
ference with the star wheel.
6 . Install parking brake cable (rear only).
7. Secure the primary brake shoe (short lining faces
forward) first with the hold down pin and spring using
a pair of needle nose pliers. Engage shoes with the
wheel cylinder connecting links.
8 . Install and secure the actuator assembly and second­
ary brake shoe with the hold down pin and spring
using a pair of needle nose pliers (on rear position
parking brake strut and strut spring).
9. Install guide plate over anchor pin.
10. Install the wire link.

NOTE: Do not hook the wire link over the

anchor pin stud with the regular spring hook
tool. This may damage the cylinder boot seals.
Fig . 36—Inspecting for Proper Lubrication Fasten'the wire link to the actuator assembly

CHEVROLET TRUCK SERVICE M ANUAL

 BRAKES 5-21

Fig. 38—Backing Plate C ontact Surfaces

Fig. 39—Using Drum to Brake Shoe C lea ra n ce G auge
Tool J -21177
first, and then place over the anchor pin stud by
hand while holding the adjuster assembly in full Recomm ended Method of Adjustm ent
down position. a. Use special Tool J-21177 or J-22364, Drum to
11. Install actuator return spring. Brake Shoe Clearance Gauge, to check the dia­
meter of the drum clearance surface (fig. 39).
NOTE: Do not pry actuator lever to install b. Turn the tool to the opposite side and fit over the
return spring. Ease it in place using the end of brake shoes by turning the star wheel until the
a screw driver or other suitable flat tool. gauge just slides over the linings (fig. 40).
12. If old brake pull back (return) springs are nicked, c. Rotate the gauge around the brake shoe lining
distorted, or if strength is doubtful, install new surface to assure proper clearance.
springs.
13. Hook springs in shoes using Tool J-8049 by installing
the primary spring from the shoe over the anchor
pin and then spring from secondary shoe over the
wire link end (fig. 37).
14. Pry shoes away from the backing plate and lubricate
shoe contact surfaces with a thin coating of brake
lube (fig. 38).
CAUTION: Be careful to keep lubricant off
facings.
15. After completing installation, make certain the actu­
ator lever functions easily by hand operating the
self-adjusting feature.
16. Follow the above procedure for all brakes.
17. Adjust the service brakes as outlined below, then
adjust the parking brake.

Adjustment
Although the brakes are self adjusting a preliminary or
initial adjustment may be necessary after the brakes have
been relined or replaced, or whenever the length of the
adjusting screw has been changed. The final adjustment
is made by using the self adjusting feature.
1. With brake drum off, disengage the actuator from the
star wheel and rotate the star wheel by spinning or Fig. 40—Checking Brake Shoe Lining C learan ce
turning with a small screwdriver. Using Tool J-21177

CHEVROLET TRUCK SERVICE M ANUAL

BRAKES 5-22

Fig. 43—Removing Pull Back Springs Using Tool J-22348

Fig. 41—A lign in g Drum Tang with W h ee l Hub

NOTE: 2: Make certain when installing drums
that drums are installed in the same position as
A lternate M ethod of Adjustment when removed with the drum locating tang in
a. Using the brake drum as an adjustment fixture, line with the locating hole in the wheel hub
turn the star wheel until the drum slides over the (fig. 41).
brake shoes with a slight drag.
b. Turn the star wheel 1-1/4 turns to retract the 4. Make final adjustment by driving and stopping ve­
shoes. This will allow sufficient lining to drum hicle until satisfactory brake pedal height is obtained
clearance so final adjustment may be made as as described under "S e lf Adjusting Features"
described in Step 4. earlier in this section.
3. Install the drum and wheel.
NOTE: 1: If lanced area in brake drum was REAR BRAKES (40 AND 50 Series)
knocked out, be sure all metal has been removed Brake shoe adjustment takes place when brakes are
from brake compartment. Install new hole cover applied with a firm pedal effort while the vehicle is
in drum to prevent contamination of the brakes. backing up. Applying the brakes moves actuators which
turn the star wheels and rotate the adjusting screws out­
ward from the anchor brackets (fig. 42). This action
ACTUATING LEVER adjusts the shoe until clearance between the lining and
ANCHOR ADJUSTING CAM drum is within proper limits.
SUPPORT
ACTUATING Should low pedal heights be encountered, it is recom­
FRICTION LEVER LINK mended that numerous forward and reverse stops be
SPRING
OVER RIDE performed with a firm pedal effort until a satisfactory
LEVER pedal height results.

Retracting Self Adjusters (Rear)

Access holes are located in the flange plate. These
holes are for service purposes in the event retracting of
the brake shoes is required to remove the drum. In order
to back off the adjuster, remove the cover from the
access hole and insert a screw driver. Index a corner of
RIDE
the screw driver blade with the hole in the actuating
SPRING
lever and hold the lever away from the star wheel. Using
a brake adjusting tool, back off the star wheel.
HOLD DOWN SPRING
PIN ACTUATING
STAR LEver Brake Drums, Shoes and Linings
WHEEL
Removal
1. Raise the vehicle and place on jack stands.
Fig . 42 —Tw inplex S e lf Adjusting Rear Brake (40 and 50 Series) 2. Retract self adjusters and remove brake drums.

CHEVROLET TRUCK SERVICE M ANUAL

 BRAKES 5-23

dercut of more than .045" is needed, replace the

drum.
10. Carefully pull lower edges of wheel cylinder boots
away from cylinders. If brake fluid flows out, over­
haul of the wheel cylinders is necessary.
NOTE: A slight amount of fluid is nearly al­
ways present and acts as a lubricant for the
piston.
11. Inspect flange plate for oil leakage past axle shaft
oil seals. Install seals if necessary.
12. Check all flange plate attaching bolts to make sure
they are tight (150 lb. ft. torque). Clean all dirt and
rust from shoe contact faces on flange plate using
emery cloth.
13. Thoroughly clean adjusting screws and threads in the
anchor brackets.
Installation
1. Put a light film of Bendix or Delco brake lube or
Lubriplate on shoe bearing surfaces of brake flange
plate and on threads of adjusting screw.
2. Thread adjusting screw completely into anchor
bracket without friction spring to be sure threads are
Fig. 44 — Removing Brake Shoe Hold Down Pins Using
Tool J -22348 clean and screw turns easily. Then remove screw,
position a new friction spring on screw and reinstall
in anchor bracket.
NOTE: If brake drums are worn severely, it 3. Assemble self adjuster assembly to brake shoe and
may be necessary to retract the adjusting position actuating lever link on override lever.
screws as previously outlined. 4. Position hold down pins in flange plate.
3. Using Tool J-22348 remove the brake shoe pullback 5. Install brake shoe and self adjuster assemblies onto
springs (fig. 43). hold down pins, indexing ends of shoes with wheel
cylinder push rods and legs of friction springs.
NOTE: Since wheel cylinder piston stops are
incorporated in the anchor brackets, it is not NOTE: Make sure the toe of the shoe is against
necessary to install wheel cylinder clamps when the adjusting screw (fig. 45).
the brake shoes are removed. However, the 6 . Install cup, spring and retainer on end of hold down
brake pedal must not be depressed while the pin. Using Tool J-22348 compress the spring. With
drums are removed. spring compressed, push the hold down pin back
4. Loosen the actuating lever cam cap screw and while through the flange plate toward the tool and install
holding the star wheel end of the actuating lever past the lock on the pin.
the star wheel, remove the cap screw and cam.
5. Remove the brake shoe hold down springs and pins
by compressing the spring with Tool J-22348 and, at
the same time, pushing the pin back through the
flange plate toward the tool. Then, keeping the spring
compressed, remove the lock from the pin with a
magnet (fig. 44).
6 . Lift off the brake shoe and self adjuster as an
assembly.
7. The self adjuster can now be removed from the brake
shoe by removing the hold down spring and pin.

NOTE: The actuating lever, override lever and

spring are an assembly. It is not recommended
that they be disassembled for service purposes
unless they are broken. It is much easier to as­
semble and disassemble the brakes leaving them
intact.
8. Thread the adjusting screw out of the anchor support
and remove and discard the friction spring.
9. Clean all dirt out of brake drum. Inspect drums for
roughness, scoring or out of round. Replace or re ­
condition drums as necessary.
NOTE: If, when reconditioning drums, an un- Fig . 45 —Brake Shoe and S e lf Adjuster Assembly

CHEVROLET TRUCK SERVICE MANUAL

BRAKES 5-24

A C T U A T IN G LEVER .

90

TOP VIEW

A C T U A T IN G LEVER

90c

Fig. 46—Measuring Points for Brake Shoe Centering

END VIEW
7. Using Tool J-22348 install brake shoe return
springs.
8 . Holding the star wheel end of the actuating lever as
far as possible past the star wheel, position the
adjusting lever cam into the actuating lever link and
assemble with cap screw.
9. Check the brake shoes for being centered by measur­
ing the distance from the lining surface to the edge
of the flange plate at the points shown in Figure 46.

Fig. 48— Plug G auge Position for C orrect Actuator

Lever Adjustment— Front or Rear Brakes

To center the shoes, tap the upper or lower end of

the shoes with a plastic mallet until the distances at
each end become equal.
10. Locate the adjusting lever .020" to .039" above the
outside diameter of the adjusting screw thread by
loosening the cap screw and turning the adjusting
cam.
NOTE: To determine .020” to .039", turn the
adjusting screw 2 full turns out from the fully
retracted position. Hold a .060" plug gauge
(from J - 9789-01 Universal Carburetor Gauge
Set) at a 90° angle with the star wheel edge of
the actuating lever. Turn the adjusting cam until
the actuating lever and threaded area on the
adjusting screw just touch the gauge (figs. 47
and 48).
11. Secure the adjusting cam cap screw and retract the
adjusting screw.
12. Install brake drums and wheels.
13. Adjust the brakes by making several forward and
reverse stops until a satisfactory brake pedal height
Fig . 4 7 —Positioning Actuator Lever results.

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 BRAKES 5-25

Fig. 49 —Type “ F ” Brake—Exploded V ie w

1. In let Fitting Bolts 9. W heel C ylin d er Anchor Screws 17. W heel C ylin d er Piston 24. Lining Rivet
2. In let Fitting Bolt Gaskets 10. A nchor Screw Lock Washer 18. Piston Cup 25. Brake Shoe Lining
3. In let Fittings 11. A nchor Screw Flat Washer 19. Piston Cup F ille r 26. Brake Shoe
4. W h e e l C ylin d er Connection Tube 12. Adjusting Cam and Shoe G u id e Stud 20. Piston Spring 27. Brake Shoe Return Spring
5. Bleeder V a lv e s 13. Cam Stud Flat W asher 21. W h eel C ylin d er Casting 28. Brake Shoe G u id e Washer
6. Inlet Fitting Gaskets 14. Adjusting Cam Spring 22. Brake Shoe Adjusting Cam 29. Brake Shoe G u id e C-W asher
7. W h eel C ylin d er M ounting Screws 15. Backing Plate 23. Shoe G u id e A n ti-R attle 30. Brake Shoe and Lining
8. Mounting Screw Lock Washers 16. W h eel C ylin d er Boot Washers Assembly

BRAKE COMPONENTS-MANUALLY ADJUSTED

(WAGNER)

BRAKE SHOES
In all cases of brake complaints denoting actual brake
lining or shoe failure, the brake drums should be re ­
moved and before disassembly of the shoes from the
flange plate, all linings should be inspected for wear,
improper alignment, causing uneven wear or oil and
grease on the linings. If any of these conditions exist, it
will be necessary to replace or reline the shoes. If, in
checking the linings, it is noticed that they have the
appearance of being glazed, this is a normal wearing
condition with the type lining used. It may be necessary
to use a wire brush or an abrasive on the lining to des­
troy this glazed surface.
When brake lining replacement is necessary, replace
the shoes and linings on both front wheels or both rear
wheels. On low mileage vehicles where a grease seal
leak or minor chatter has developed, replacement of both
shoes on that wheel is perm issible. In no case should a
single shoe or lining be replaced.

60 Series—Front (Wagner Type “ F” )

Removal (Figs. 49 and 50)
1. Jack up axle and remove hub and brake drum
assembly. Fig. 50—W agner Type “ F ” Left Front Brake

CHEVROLET TRUCK SERVICE M ANUAL

BRAKES 5-26

2. Remove both brake shoe return springs, using Tool

J-22348.
3. Remove C-washer and flat washer from adjusting
cam and hold-down stud. Lift shoes off backing
plate.
4. Clean all dirt out of brake drum. Inspect drum for
roughness, scoring, or out-of-round. Replace or
recondition brake drum as necessary.
5. Inspect wheel bearings and oil seals as outlined in
Section 3.
6 . Check flange plate attaching bolts to make sure they
are tight. Clean all dirt off flange plate.
7. Inspect brake shoe return springs. If broken,
cracked, or weakened, replace with new springs.
8 . Check cam and shoe guide stud and friction spring on
flange plate for corrosion or binding. Cam stud
should turn easily with an eight inch wrench, but
should not be loose. If frozen, lubricate with kero­
sene or penetrating oil and work free.
9. Examine brake shoe linings for wear. Linings should
be replaced if worn down close to rivet heads. Refer
to “ Brake Shoe Relining” in this section.
Installation (Figs. 49 and 50)
1. Install anti-rattle spring washer on each cam and
shoe guide stud, pronged side facing adjusting cam.
2 . Place shoe assembly on backing plate with cam and
shoe guide stud inserted through hole in shoe web; Fig. 51—Wagner Type “ FR-3” Rear Brakes
locate shoe toe in wheel cylinder piston shoe guide
1. W h eel C ylin d er Heat Shield 8. Brake Shoe and Lining
and position shoe heel in slot in anchor block. 2. Upper W h eel C ylin d er Assembly
3. Install flat washer and C-washer on cam and shoe 3. Anchor Pin 9. Return Spring (Long)
guide stud. Crimp ends of C-washer together. 4. Return Spring (Short) 10. Adjusting W h e e l Lock Spring
4. After installing both shoes, install brake shoe return 5. G u id e Washer 11. Adjusting W h eel
springs. To install each spring, place spring end 6. G u id e Bolt 12. Lower W h e e l C y lin d e r
7. G u id e Bolt N u t Lock W ire 13. Backing Plate
with short hook in toe of shoe, then using Tool
J-22348, stretch spring and secure long hook end in
9. Inspect wheel bearings and oil seals as directed in
heel of opposite shoe. Section 3.
5. Install hub and brake drum assembly.
10. Inspect brake shoe return springs. If broken,
6. Adjust brake as directed under “ Brake Adjustments" cracked, or weakened, replace with new springs.
in “ Maintenance and Adjustments.”
11. Inspect threads on adjusting screws and in adjusting
wheels for wear or damage. Replace as necessary.
60 Series—Rear 12. Examine brake shoe linings for wear. Linings should
(Wagner Type “ FR-3” ) be replaced if worn down close to rivet heads. Refer
Removal (Figs. 51 and 52)
to Brake Shoe Relining in this section.
1. Jack up axle and remove hub and brake drum assem­ Installation (Figs. 51 and 52)
bly as directed in Section 3. 1. Install adjusting screws and wheels in anchor sup­
2. Install wheel cylinder clamps to hold pistons in ports dry; use no lubricant. Insert each adjusting
cylinders. wheel in slot in anchor support, insert threaded end
3. Using Tool J-8049, remove brake shoe return of adjusting screw in anchor support, then turn
springs. adjusting wheel to thread adjusting screw into anchor
4. Remove lock wires, nuts, and washers from brake support.
s h o e guide bolts, then r e m o v e brake shoe 2 . Install brake shoes with cut-away end of shoe web
assemblies. next to adjusting screw and with ends of shoes en­
5. Remove screws attaching adjusting wheel lock gaging slots in wheel cylinder push rods. Install flat
springs to anchor supports. Thread each adjusting washer and nut on each brake shoe guide bolt.
screw from the shoe side of its anchor support by Tighten nuts finger-tight, then back off one full turn
turning adjusting wheels, then lift adjusting wheels and install lock wires.
out of slots in anchor supports. 3. Install brake shoe return springs, hooking one end of
6 . Clean all dirt out of brake drum. Inspect drum for each spring (short hook) in brake shoe web, then hook
roughness, scoring, or out-of-round. other end over anchor pins with Tool J-8049.
7. Recondition or replace drum as necessary. Inspect 4. Remove wheel cylinder clamps.
brake flange plate for oil leakage past axle shaft oil 5. Install hub and brake drum assembly as directed in
seal. Install new seals if necessary. Section 3.
8 . Clean all dirt out of anchor pin holes and adjusting 6 . Adjust brakes as previously directed under Brake
screw openings in anchor supports. Adjustments under Maintenance and Adjustments.

CHEVROLET TRUCK SERVICE MANUAL

 BRAKES 5-27

Fig. 52—Type “ FR-3” Brake Components

1. Fitting Bolt 9. Anchor Pins 16. W h eel C y lin d e r Cups 23. Adjusting W heels
2. Gaskets 10. Return Spring (Short) 17. W h eel C y lin d e r Pistons 24. G u id e Bolt N u t Lock W ire
3. W h ee l C y lin d e r Mounting Bolts 11. Return Spring (Long) 18. W h eel C ylin d er Boots 25. G u id e Bolt N ut
4. Adjusting Slo t Plugs 12. Shoe and Lining Assembly 19. W h eel C ylin d er Push Rods 26. G u id e Bolt W asher
5. Shoe G u id e Bolts 13. W h eel C y lin d e r Heat Shield 20. W h eel C ylin d er Assembly 27. Brake Shoe
6. Connector Tube 14. Bleeder V a lves 21. Piston Return Spring 28. Brake Shoe Lining
7. Backing Plate 15. W h eel C y lin d e r Body 22. Adjusting W h ee l Locks 29. Lining Rivet
8. Adjusting Screws

BRAKE SHOE LININGS brake shoes and may be replaced. Only brake linings
Bonded Lining specified in Chevrolet Parts Books should be used. These
linings may be purchased in replacement sets of four
Brake linings on front and rear brakes on Series 10 are linings and sufficient rivets of correct specifications.
attached to brake shoes by a special bonding process. When replacing linings, make sure that shoes are clean
When lining becomes worn to the extent that replacement and that linings are installed in a manner that will
is necessary, it is recommended that factory-bonded shoe prevent gaps between lining and shoe.
and lining assem blies be used for replacement. 1967 Conventional lining replacement equipment should be
Chevrolet Trucks 50 as well as 60 Series have premium used. Make sure lining fits firmly against shoe, and that
type facings. rivets are properly upset.

Riveted Lining NOTE: If brake drums have been refinished,

oversize lining should be used. Refer to Brake
Brake linings on Series 20 through 60 are riveted to the Drums.

CHEVROLET TRUCK SERVICE M ANUAL

BRAKES 5-28

WHEEL CYLINDERS
Removal (Fig. 53)
Duo-Servo Type

1. Jack up axle and remove wheel, brake drum and

brake shoes a s directed u n d e r “ Brake Shoe
Removal."
2. At front, disconnect metal brake tube from flexible
hose at frame, disconnect hose from frame, then un­
screw hose fitting from wheel cylinder connector, or
from wheel cylinder housing where connector is not
used. At rear, disconnect metal brake tube from TYPE "F”
wheel cylinder connector.
3. Remove cap screws and washers attaching wheel
cylinder to flange plate and remove cylinder assem ­
bly. Remove connector, i f used, f r o m cylinder
housing.
Tw inplex Type
1. Jack up axle and remove brake shoes as directed
under Brake Shoe Removal.
2. Disconnect brake tube from rear wheel cylinder
connector at inner side of flange plate. Remove
brake tube connecting wheel cylinders at outer side
of flange plate. Remove dust shield from upper end
of each cylinder. TYPE "FR-3”
3. Remove cap screws and lock washers attaching wheel
cylinders to flange plate, then remove wheel cylin­
ders and heat shield. Remove brake line connectors
from cylinder housings. Fig. 54—W h eel Cylinders Used w ith Types “ F ” and
“ FR-3” Brakes
Type “ F ” (Fig. 54)
1. Jack up axle and remove brake shoes as directed bolt attaching connecting tube fitting to lower cylin­
under “ Brake Shoe Removal." der. Remove connecting tube and fittings assembly.
2. Disconnect axle brake tube from inlet connector at 3. Remove one large and two small cap screws attach­
upper cylinder. Remove inlet connector attaching ing each cylinder to flange plate, then remove cylin­
connecting tube fitting to upper cylinder, and remove ders from backing plate.
Type “ FR-3”
1. Jack up axle and remove brake shoes as directed
under “ Brake Shoe Removal."
2. Remove bolts attaching brake line connectors to
wheel cylinders at inner side of flange plate.
3. Remove two cap screws and lock washers attaching
each wheel cylinder to flange plate. Remove wheel
cylinders and heat shields, then remove heat shields
from cylinders.
Disassembly
DUO-SERVO Type “ F ”
Pull boot off end of cylinder, then remove boot and
piston. Pull boot off piston. Brake shoe guide is pressed
into piston and cannot be removed. Remove piston cup,
cup filler, and spring from cylinder. Remove bleeder
valve from cylinder.
A ll Types Except Type “ F ”
Pull boots off ends of cylinders and remove push rods
from boots. Push pistons, cups and spring out of cyl­
inder. Duo-Servo and Twinplex type wheel cylinders are
equipped with spring assemblies consisting of a spring
between two lip expanders, as shown in Figure 53.
Inspection
TWINPLEX
--------- Repair kits are available which contain the parts to be
replaced when overhauling wheel cylinders.
1. Inspect cylinder bore for scores, scratches, or
Fig. 5 3 —Duo Servo and Tw inplex C ylinders corrosion. Light scratches or slightly corroded

CHEVROLET TRUCK SERVICE MANUAL

 BRAKES 5-29

spots may be polished out with crocus cloth. Never

use emery cloth or sandpaper. If scratches or cor­
Type“FR-3”
1. Install pistons, piston cups, and spring, with cup lips
rosion are too deep to be polished out, replace toward inside of cylinder.
cylinder. 2. Assemble push rods and boots, then install on cylin­
2. Check fit of new pistons in cylinder bore, using a der. Seat boots evenly in cylinder grooves.
feeler gauge (fig. 55). Clearance should be within
0.002" to 0.004". Replace cylinder if clearance
exceeds 0.004”.
Installation
Duo-Servo Type
1. Position wheel cylinder on flange plate and attach
Assembly
with cap screw and lock washers. Refer to torque
Before assembling wheel cylinder, be sure each part specifications at rear of manual for correct torque
has been cleaned in denatured alcohol. values.
CAUTION: Do not use kerosene or gasoline for 2. When brake line connector is used, install connector
cleaning wheel cylinder parts. Dip each internal with new copper gasket. Install bleeder valve in
part in hydraulic brake fluid before assembling. upper opening in cylinder housing.

Duo-ServoType
1. Place pistons, cups and spring or spring assembly
3. At rear, connect metal brake tube to wheel cylinder
or to connector. At front, thread brake hose fitting
into wheel cylinder housing or connector, using a
in cylinder with parts positioned as shown in new copper gasket on hose fitting. Insert fitting at
Figure 53. other end of hose through frame and secure with
2. Assemble boots and push rods, then install boots toothed lock washer and nut or with spring lock,
over ends of cylinders. depending upon type used. Connect metal brake tube
to hose fitting inside frame side rail.
TwinplexType
1. Place pistons, cups, spring and expander assembly
4. Install brake shoes as directed under "B rake Shoe
Installation . ' ’ Bleed brake system as previously
in cylinder. directed under “ Bleeding Brakes.”
2. Assemble boots on push rods, being sure bead on
boot engages groove in push rod. Install boots and
push rods on cylinder, engaging bead on outer edges
TwinplexType
of cylinder housing. NOTE: Upper and lower cylinders are not
interchangeable. Lower cylinder has threaded
Type“F”
1. Insert piston spring, cup filler, and cup into cylinder
inlet opening drilled near center of cylinder
bore. Upper cylinder has threaded bleeder valve
bore. Cup filler bumper and cup lip must face closed opening drilled at extreme outer edge of cylinder
end of cylinder. bore. Cylinders must be positioned with con­
2. Assemble boot on piston, making sure the boot snaps necting tube openings toward each other.
over the brake shoe guide. 1. Position heat shields on cylinder, place wheel cylin­
3. Install piston and boot, inserting piston into cylinder ders on flange plate, and attach with cap screws and
and engaging boot lip in groove in edge of cylinder. lock washers. Tighten cap screws firmly.
Position brake shoe guide so slot in guide is parallel 2. Install connecting tube between the two cylinders and
with flat mounting surface of cylinder. tighten connections firmly. Connect brake tube to
inlet opening in lower cylinder at inner side of flange
plate. Install bleeder valve in threaded opening in
upper cylinder at inner side of flange plate.
3. Install brake shoes as directed under "Brake Shoe
Installation.” Bleed brake system as previously
directed under "Bleeding Brakes.”
Type“F”
NOTE: The two wheel cylinders mounted on
each brake are identical; however, cylinders on
right-and left-hand brakes have opposite cylinder
castings. Clean mating surfaces of cylinders
and flange plate to insure proper alignment.
1. Place each cylinder on flange plate and attach with
one large and two small cap screws and lock
washers.
2. Position wheel cylinder connecting tube and fitting
assembly and attach fitting to lower opening in upper
cylinder with inlet connector, using new copper gas­
ket on both sides of fitting. ^Attach fitting to lower
opening in lower cylinder with special bolt, using
new copper gasket on both sides of fitting. Tighten
Fig . 55—C hecking Wheel C ylin d e r Piston Fit inlet connector and special bolt firmly.

CHEVROLET TRUCK SERVICE M ANUAL

BRAKES 5-30

3. Install bleeder valve in upper opening in each An out-of-round drum makes accurate brake shoe
cylinder. adjustment impossible and is likely to cause excessive
4. Install brake shoes as directed under "B rake Shoe wear of other parts of brake mechanism due to its
Installation." Bleed brake system as previously eccentric action.
directed under “ Bleeding B ra k es." A drum that is more than .010" out-of-round on the
diameter is unfit for service and should be rebored. Out-
Type “ FR -3”
of-round, as well as taper and wear can be accurately
NOTE: Upper and lower wheel cylinders on measured with an inside micrometer fitted with proper
both right-and left-hand brakes are interchange­ extension rods.
able. Cylinders must be positioned on flange If drum is to be rebored for use with standard size
plate so that the long stroke end of the cylinder brake facings which are worn very little, only enough
faces the shoe toe (adjustment end of shoe) or metal should be removed to obtain a true smooth braking
the adjusting slot in backing plate. Make sure surface. If drum has to be rebored more than .010" over
mating surfaces of cylinders, heat shields, and the standard diameter, however, it should be rebored to
flange plate a r e clean to assure proper .060" oversize on the diameter and the brake facing
alignment. should be replaced with .030" oversize facings.
A brake drum must not be rebored more than .060
1. Position heat shield on each wheel cylinder, and in­ (.090" on 15" by 4, 5, 6 or 7" wide) over the maximum
stall on flange plate. Attach each cylinder with two standard diameter, since removal of more metal will
cap screws and lock washers. affect dissipation of heat and may cause distortion of
2. Attach connecting tube fitting to lower opening in the drum. Chevrolet brake facing is not furnished larger than
upper cylinder, and to the upper opening in the lower .030" oversize and this will not work efficiently in drums
cylinder. Install bleeder screw in upper opening of bored more than .060" oversize.
the upper cylinder. Connect brake line at lower
Brake drums may be refinished either by turning or
cylinder fitting.
grinding. Best brake performance is obtained by turning
3. Install brake shoes as directed under “ Brake Shoe
drums with a very fine feed. To insure maximum lining
Installation." Bleed brake system as previously
life, the refinished braking surface must be smooth and
directed under “ Bleeding B ra k es."
free from chatter or tool marks, and run-out must not
exceed .005" total indicator reading.
BRAKE DRUMS
Installation
All front brake drums except those used on 3/4 and 1
1. Make sure mating surfaces of hub, drum and oil
ton trucks are the non-demountable type, that is, they
deflector are clean and smooth and assemble as out­
cannot be removed without removing the hub. Whenever
lined in Section 3.
this type drum is removed, wheel bearings must be ad­
2. On front, install drum and hub assembly to wheel
justed as outlined in Section 3. Rear brake drums on all
spindle and adjust bearings on 1 / 2 , 1 1 / 2 and 2 ton
models are demountable, that is, they may be removed
without removing the wheel hub. as outlined in Section 3. On 3/4 and 1 ton install
drum and retain in place with retaining screws.
Removal 3. On rear, assemble drum assembly over hub studs
Front
and install retaining screws, if used.
4. Replace wheel assembly and lower vehicle to floor.
1. Jack up front end of vehicle and remove wheel.
2. Remove hub and brake drum assembly. BRAKE PEDAL (EXCEPT TILT CAB AND
NOTE: 3/4 and 1 ton drums may be removed by
CHEVY VAN)
The brake pedal (fig. 56) is an integral design with the
removing 2 slotted head screws which retain
clutch pedal, necessitating the removal of the clutch pedal
drums to hub. On all other models, hub and
before removing the brake pedal.
drum are removed as an assembly.
Removal
3. Remove brake drum from hub as outlined in Section
3. 1. Remove the clutch pedal as outlined under “ Clutch
Pedal" in Section 7.
Rear 2. Remove the pull back spring from the body bracket.
1. Jack up rear end of vehicle and remove wheel. 3. Remove the sleeve assembly screw attachment and
2. Remove countersunk screws, where used, and re­ remove sleeve.
move brake drum from outer flange of hub. 4. Disengage the push rod from the master cylinder and
Inspection and Reconditioning drop the pedal to check for worn parts—inspect the
Whenever brake drums are removed they should be return spring, bracket attachment, and bushings for
thoroughly cleaned and inspected for cracks, scores, deep needed repairs.
grooves and out-of-round. Any of these conditions must Installation
be corrected since they can impair the efficiency of brake Reverse the above procedure and make certain the
operation and also can cause premature failure of other brake pedal (fig. 56) is secure and adjusted properly be­
parts. fore operating the vehicle. See Maintenance and Adjust­
Smooth up any slight scores by polishing with fine ments for brake pedal adjustment.
emery cloth. Heavy or extensive scoring will cause ex­
cessive brake lining wear and it will probably be neces­ BRAKE PEDAL-TILT CAB
sary to rebore in order to true up the braking surface.
The complete brake pedal consists of two separate

CHEVROLET TRUCK SERVICE M ANUAL

 BRAKES 5-31

ALL EXCEPT FLAT FACE COWLS FLAT FACE COWLS

VIEW A "-^ VIEW B

CA-KA-PA10, CA-KA20 SA40
CA30 CA-PA40,
CD-CG-MA50-60
HYDROVAC
ASSEMBLY

JJr VIEW A VIEW B

CE-CS50-60 SA50-60
CA-KA-MAOO, PA10-40, SAOO

VIEW A
MAIN
CYLINDER

MAIN BRAKE
PA20-30 TA40-50-60 CYLINDER

Fig . 5 6 —Brake Pedal C , K , P, M , S and T Models

CHEVROLET TRUCK SERVICE MANUAL

— __________________
BRAKES 5-32

assem blies—upper pedal assembly and lower pedal as­ Cleaning and Inspection
sembly. The following procedure applies to both pedal 1. Wash all metal parts with an approved cleaning
assemblies; however, it is not necessary to remove lower solvent.
assembly if only upper assembly is to be replaced. 2. Inspect
Removal Installation
1. Disconnect and remove brake pedal return spring and 1. Position lower pedal arm pivot shaft through
clutch pedal over-center spring. channel cutout.
2. Disconnect main cylinder push rod clevis at lower 2. Install pivot sleeve through channel cutout so that
pedal arm, and remove push rod and clevis from pedal arm pivot shaft is retained by sleeve. Install
main cylinder (fig. 56). retaining screws to sleeve bracket, and install
3. Disconnect and remove upper pedal arm. grease fitting. Install washer and retainer to pedal
4. Remove grease fitting from lower pedal arm pivot arm pivot shaft.
sleeve. Access at cutout in underside of channel. 3. Position upper pedal arm through toe pan, align
5. Remove retainer and washer from pedal arm pivot serrations on pedal arms, install retaining bolt,
shaft. s lockwasher and nut. Refer to torque specifications at
6 . Remove two screws from pivot sleeve and bracket rear of manual for correct torque value.
assembly, and remove assembly from channel. 4. Connect clutch pedal over-center spring and brake
7. Withdraw lower pedal arm from channel. pedal return spring.

CHEVROLET TRUCK SERVICE M ANUAL

 BRAKES 5-33

5. Insert main cylinder push rod through rubber boot ®gpween the brake pedal and main cylinder push rod
and into piston. Install retaining bolt, lockwasher
and nut. Refer to torque specifications at rear of 2 #T ttrn eccentric bolt as required to provide correct
manual for correct torque valve. adjustment. Movement of pedal pad before push rod
6 . Adjust push rod until 1/8 to 1/4 inch free movement contacts main cylinder piston must be 1/16" to 1/4".
is obtained at pedal pad. NOTE: Eccentric Adjustment bolt should be
7. Lubricate pivot shaft at fitting. installed with projection in down position before
adjustment.
BRAKE PEDAL-CHEVY VAN (Fig. -57)
3. Tighten check nut on eccentric bolt to 22 lb. ft.
Removal
torque, and recheck movement.
1. Disconnect brake pedal return spring.
2. Remove upper to lower brake pedal arm nut and
PARKING BRAKE-REAR WHEEL TYPE
remove upper arm.
3. Remove nut and eccentric bolt holding main cylin­ Refer to hand brake levers and cable routing as shown
der push rod to lower pedal assembly. by Figures 58 through 63.
4. Remove pivot shaft retainer and screw from bracket
assembly. Remove pivot shaft using a small brass PARKING BRAKE-CHEVY VAN
drift if needed. Handle Assembly (Fig. 63)
5. Remove grease fitting from arm assembly.
Removal
Inspection 1. Place parking brake handle in released position.
1. Inspect pivot shaft and pedal bushings for wear or 2. Remove front cable to equalizer by removing check
other damage. nut at rear of cable.
2. If necessary to remove bushings from pedal use a 3. Engage parking brake handle until ball on front end
cape chisel for removal, then deburr. of cable can be slipped out of handle assembly.
3. Install new bushings in each side of pedal bore 4. Remove two handle attaching screws, washers and
using a vise as a press. nuts from front of engine compartment housing and
Installation also nut from underside of floor, attaching base of
1. Reverse r e m o v a l procedure to install p e d a l handle assembly to floor.
assembly. Installation
NOTE: (A) Assemble eccentric push rod to 1. Reverse removal procedure.
pedal attachment bolt with projection in up 2. Adjust parking brake as outlined previously in this
position before adjustment. (B) Mark on upper section.
and lower pedal assemblies must be assembled
in line. Front Cable (Fig. 63)
2. Adjust push rod to main cylinder clearance as de­ Replacement
scribed in this section. 1. Refer to first three steps under Parking Brake
3. Check stop light operation and adjust switch if re ­ Handle Assembly Removal for cable replacement.
quired as described in Section 12. 2. Adjust parking brakes as described in this section.
4. Grease fitting until grease passes thru bushing and
comes out both sides of pivot bore. Rear Cables (Fig. 63)
Adjustment Removal
1. Loosen check nut on the eccentric bolt attachment 1. Place parking brake handle in released position.

F ig . 58 —Parking Brake Levers—C , K , P10—20—30 Models

CHEVROLET TRUCK SERVICE M ANUAL

BRAKES 5-36

V IE W C

Fig. 61—Parking Brake System C 10-20-30 Series

2. Install shoe and operating lever assembly on brake Brake Drum

drum, with upper end of outer lever in place on pivot Removal
pin. Install lock on pivot pin. 1. Remove brake shoes as previously directed under
3. Insert link through operating lever, with washer and Brake Shoe Removal.
spring in place on top of lever. Install adjusting nut 2. Disconnect propeller shaft at transmission. Remove
on link. Connect return spring to outer shoe. bolts attaching center bearing bracket to cro ss­
4. Adjust lining to drum clearance as previously member, then lower center bearing and front
directed under Parking Brake Adjustment. propeller shaft to floor (if necessary).

CHEVROLET TRUCK SERVICE MANUAL

 BRAKES 5-37

V IE W B

V IE W A

V IE W C

V IE W B
PA209-213-309-313

NV IE W B
V IE W A ^ PA215-315

PA20-30

Fig. 62—Parking Brake System—P10-20-30 Series

3. Remove bolt from transmission output shaft and Brake Drum

pull drum and flange assembly off end of shaft.
Installation
CAUTION: Do not hammer or pry on drum 1. Wipe clean mating surfaces of brake drum and output
during removal. shaft flange. Lineup brake drum and flange and press
4. Remove four nuts, lock washers, and bolts attaching four serrated bolts into place.
oil deflector to inner side of brake drum. 2. Position oil deflector in brake drum and attach with
5. P ress four serrated bolts from flange and drum four bolts, lock washers, and nuts. Tighten nuts to
assembly to separate drum from flange. 5-8 foot-pounds torque. #

CHEVROLET TRUCK SERVICE M ANUAL

BRAKES 5-38

Fig. 63—Parking Brake System—C h evy Van

3. Slide drum and flange assembly over splines onto shaft. Tighten bolt to 68-73 ft. lbs. torque.
output shaft.
4. Place lock washer and special serrated flat washer 5. Connect propeller shaft at transmission and attach
on flange retaining bolt and install bolt in output center bearing bracket to frame crossmember.

CHEVROLET TRUCK SERVICE M ANUAL

 BRAKES 5-39

and compress spring as band anchor bracket is

placed over anchor.
2. Install anchor screw through bracket and spring into
anchor. Insert lower brake band bracket adjusting
bolt through band lower bracket and hole in support
and start nuts on bolt.
3. Install new clevis pin through operating cams and
link plate. Position operating cams on top of band
upper bracket with toe of cam facing forward.
4. Insert threaded end of adjusting bolt down between
operating cams. Position hook toward rear. As bolt
is lowered into place it must pass through band upper
bracket, upper release spring, brake support lower
release spring, and band lower bracket. Install
tension spring, flat washer, adjusting nut, lock
washer, and lock nut on adjusting bolt.
NOTE: On remote control parking brake, no
tension spring is used.
5. Turn up anchor screw “ B ” (fig. 65) until there is
.010"-.015" clearance between lining and drum.
6 . Draw up adjusting bolt “ C ” until there is .020"
clearance between drum and lower end of band.
Fig. 65—Pro p eller Shaft Parking Brake (Band Type)
Tighten lock nut “ D” .
7. Turn up adjusting nut “ E ” until there is .020"
6 . Install brake shoes as previously directed under clearance between drum and upper end of band.
Brake Shoe Installation. Tighten lock nut “ F ” .
8 . Recheck all points of facing for correct clearances.
PARKING BRAKE-PROPELLER SHAFT 9. Set handbrake lever in the fully released position.
(Band Type Fig. 65) 10. Using a new clevis pin connect brake pull rod to
Brake Band operating cams. Length of rod must be adjusted
so that bottom of cams remain flat on band bracket
Removal when rod is connected.
1. Remove brake pull-rod clevis pin and disengage
brake pull rod. NOTE: On floor mounted installations, attach
2. Back off nuts from “ J ” bolt slowly because of cable to bottom hole. On dash mounted installa­
spring pressure. tions, attach cable to top hole of cam.
3. Remove nuts from lower brake band bracket adjust­
ing bolt, then remove bolt. Brake Drum
4. Remove “ J ” bolt by pushing up on bolt until it clears Removal
clevis pin in brake cam. 1. Remove brake band and lining assembly as pre­
5. Cut lock wire, back off anchor adjusting screw until viously directed.
clear of anchor. 2. Remove nuts and lock washers from bolts attaching
6 . Slide band assembly off drum, removing anchor propeller shaft U-joint flange and brake drum to
screw spring as band is removed. transmission output shaft flange. Telescope propel­
Inspection ler shaft at slip joint and lower end of propeller shaft
1. Examine braking surface of drum for roughness or to floor. Remove if necessary, nuts, lock washers,
scoring. If drum is worn or damaged, it must be and bolts attaching propeller shaft center bearing
replaced as directed later. hanger bracket to crossmember.
2. Inspect brake lining. If worn down close to rivet 3. On some vehicles, brake drum is mounted on for­
heads, new lining must be installed. ward side of transmission output shaft flange, and
3. Examine tension and release springs; replace if on other vehicles it is mounted on rear side of the
weak or broken. flange. In either case, the drum and output shaft
flange will be removed by removing the bolt or nut
Relining on the end of the output shaft, then pulling the
1. Remove rivets and lining from brake band and assembly from the splined output shaft.
thoroughly clean band.
2. Rivets should be installed from center, alternately CAUTION: Do not hammer or pry drum during
working toward each end of band. removal.
3. Check lining to band air gap. A .010" feeler must not 4. P ress serrated bolts (if used) or remove bolts and
enter at any point. nuts from flange and drum assembly to separate
drum and flange.
Installation Installation
1. Place band and lining assembly over brake drum. 1. Wipe clean mating surfaces of brake drum and output
Place anchor screw spring in depression in anchor shaft flange. Line up brake drum and flange and

CHEVROLET TRUCK SERVICE M ANUAL

BRAKES 5-40

press serrated bolts (if used) into place, or install a. Install new copper gasket on cylinder end of hose
bolts and nuts. (male end).
2. Slide drum and flange assembly over splines onto b. Moisten threads with brake fluid and install hose
output shaft. in wheel cylinder inlet.
3. On jobs with parking brake drum assembly attached 2. For junction block installations,
to output shaft by a center bolt place lockwasher and a. Moisten threads on male end with brake fluid.
special serrated flat washer on bolt. Install center b. Turn male end into junction block and tighten
bolt applying 83-100 foot pounds torque on Power- securely.
matic equipped vehicles, and 68-73 foot pounds with 3. With weight of vehicle on wheels and suspension in
other transmissions. normal position (front wheels straight ahead) pass
On vehicles with parking brake drum assembly re ­ female end of hose through support bracket, allowing
tained to output shaft by a nut on shaft end, install hose to seek its own position. Insert hex of hose
nut and torque to 230-280 foot pounds on 5 speed fitting into the 1 2 point hole in support bracket in
transmissions. Install cotter pin. position which induces least twist to hose (fig. 6 6 ).
4. Position propeller shaft flange against brake drum
NOTE: Do not twist hose unduly during this
(or output shaft flange). If removed, attach propeller
operation as its natural curvature is absolutely
shaft center bearing hanger bracket to crossmember.
necessary to maintain proper hose-to-suspen­
Replace all lockwashers and nuts and tighten
sion clearance through full movement of the
securely.
suspension and steering parts.
5. Install brake band and adjust brake as directed in
Brake Band Installation. 4. Install “ U” shaped retainer spring to secure hose in
support bracket.
5. Inspect by removing weight completely from wheel.
PARKING BRAKE CABLE—LUBRICATION
If working at front wheels, turn steering geometry
Refer to Maintenance and Adjustments in this section. from lock to lock while observing hose position. Be
sure that hose does not touch other parts at any time
during suspension or geometry travel. If contact
ANCHOR PIN REPLACEMENT-CHEVY VAN does occur, remove hose retainer spring and rotate
1. Raise vehicle and place on jack stand. the female hose end in the support bracket one or
2. Remove wheel and drum as outlined in this section. two points in appropriate direction, replace retainer
3. Remove brake shoe pull back springs, link and guide spring and re-inspect as outlined in this paragraph.
plate. 6 . Place steel tube connector in hose fitting and tighten
4. Disengage anchor pin lock and remove anchor pin re­ securely.
taining nut and washer and remove pin from flange 7. Bleed all brakes as outlined in this section.
plate. (Threaded type).
Two type anchor pins are used in production. The Hydraulic Brake Tubing
riveted type is not serviced and if failure or damage Hydraulic brake tubing used on all trucks is a double
should occur to either the anchor pin or flange plate,
both parts will have to be replaced and the threaded
type anchor pin used.
5. Position anchor pin to flange plate, install lock
washer and nut, and torque pin to 80 lb. ft. and lock
by peening over washer tabs.
6 . Install brake shoe guide plate, link and pull back
springs.
7. Adjust brakes, install drum and wheel as outlined
previously in this section. Test brake operation.

HYDRAULIC BRAKE LINES AND TUBING

Hydraulic Brake Hose
These hoses require no service other than periodic
inspection for damage from road hazards or other like
sources. Should damage occur and replacement become
necessary, the following procedure is to be followed.
Removal
1. Separate hose from steel line by turning double flare
connector out of hose fitting.
2. Remove shaped retained spring from hose
fitting and withdraw hose from support bracket.
3. Turn hose fitting out of wheel cylinder inlet or
junction block.
Installation
1. If hose is to be installed in wheel cylinder, Fig . 66—Brake Tube Support

CHEVROLET TRUCK SERVICE M ANUAL

 BRAKES 5-41

UPSET FLARE PUNCH r RAM GUIDE

RAM

Fig. 69—Flaring O p era tio n —Positioning Tubing

Fig. 67—H ydraulic Brake Tube Flaring Tool

single-lap flare “ A ” and the other with a double-lap
flare “ B ” . It will be noted that the single-lap flare splits
layer flexible steel, copper coated and tin plated tubing the tubing while the double-lap flare shown in “ B ” is a
which resists corrosion and also stands up under the high heavy, well-formed joint.
pressures which are developed when applying the brakes. The following procedure should be followed in making
On 1/2-ton models brake tubing of 3/16" diameter is used up hydraulic brake pipes:
for all hydraulic brake pipes except the line between 1. Cut the tubing to the desired length, using Tool
main cylinder and tee fitting on frame right hand side rail J-8000. Square off ends of tube and ream sharp
which is 1 /4 ". Excepting the 5/16" rear wheel trunk line edges with reamer tool provided on the tube cutter.
and main cylinder to brake booster line on tandem 2. Install compression couplings on tubing and dip end
models, all hydraulic lines on all except the 1 / 2 ton truck of tubing to be flared in hydraulic brake fluid. This
are 1/4" brake tubing. In making up hydraulic brake lubrication results in better formation of the flare.
pipes, it is important that the ends of the tubing be flared 3. Select the correct size upset flare punch. One end
properly for the compression couplings. Unless the of this punch is hollowed out to gauge the amount of
tubing is properly flared, the couplings will leak and the tubing necessary to form a double-lap flare.
brakes will become ineffective. 4. Slip the punch into the tool body with the gauge end
This safety steel tubing must be double-lap flared at toward the die blocks, install the ram and tap lightly
the ends in order to produce a strong leak-proof joint. until the punch meets the die blocks and they are
The Tool J-6892 (fig. 67) must be equipped with the forced securely against the stop plate (fig. 69).
proper size die block and upset flare punch for each size 5. Draw latch plate nuts down tight to prevent tube from
tubing to form the double-lap flare. slipping. Draw nuts down alternately beginning with
The proper size die blocks and upset flare punches nut on closed side to prevent distortion of plate.
are as follows: 6 . Remove punch and ram. Reverse punch and place
back in tool body. Install ram and tap lightly until
Upset Finish face of punch contacts face of die blocks to complete
Tubing Size Die Block Flare Punch Flare Punch first flare operation (fig. 70).
7. Remove ram and punch.
3/16" J-2185-27 J-2185-3 J-2185-26
8 . Insert finish flare and ram in tool body and tap ram
1/4" J-2185-28 J-2185-37 J-2185-26
until a good seat is formed (fig. 71).
5/16" J-2185-29 J-2185-4 J-2185-26
9. Blow tubing out with compressed air.
NOTE: These tools are also part of J-6892.
Figure 68 shows two pieces of tubing—one with a BRAKE PIPE DISTRIBUTION AND SWITCH
ASSEMBLY (Fig. 8)

Removal
1. Disconnect battery cable.
2. Disconnect electrical lead from pressure differential
switch.

Fig . 68—Single and Double Lap Flare Fig. 70—Flaring O peration—First Flare

CHEVROLET TRUCK SERVICE M ANUAL

BRAKES 5-42

3. Place dry rags below the switch to absorb any fluid

spilled during removal of switch.
4. Disconnect four hydraulic lines from connections at
switch. If necessary, loosen line connections at main
cylinder to loosen lines. Cover open line ends with
clean, lint-free material to prevent foreign matter
from entering the system.
5. Remove mounting screw and remove switch from
vehicle.
Installation
1. Make sure new switch is clean and free of dust and
lint. If any doubt exists, wash switch in Declene, or
equivalent, and dry with air.
2. Place switch in position and secure to bracket with
mounting screw.
3. Remove protective material from open hydraulic
brake lines and connect lines to switch. If neces­
sary, tighten brake line connections at main cylinder.
4. Connect switch electrical lead. Fig. 71—Flaring O p era tio n —First and Second Flare
5. Connect battery cable.
6 . Bleed the brake systems as outlined in this section.

BENDIX POWER BRAKES

Fig. 72A—Bendix Power Brake U n it—Single Diaphragm Type

8. Reaction Plate 14. Dust Boot 20. Diaphragm Lip

1. M ain C ylin d er
9. Plunger 15. V a lv e Push Rod 21. Front Shell
2. Vacuum Check V a lv e
10. Bearing Seal 16. F ilte r and Silencers 22. Push Rod Seal
3. Grommet
11. Poppet V a lv e 17. V a lv e Return Spring 23. C ylin d er-to -Sh ell Seal
4. Diaphragm
5. Diaphragm Plate 12. Poppet V a lv e Spring 18. Mounting Stud 24. H yd raulic Push Rod
13. Poppet Retainer 19. A ir V a lv e Lock Plate 25. Adjusting Screw
6. Rear Shell
7. Diaphragm Spring 14. Retainer

CHEVROLET TRUCK SERVICE M ANUAL

 BRAKES 5-43

Fig. 72B—Bendix Power Brake U n it—Double Diaphragm Type

1. Vacuum C heck V a lv e 9. Reaction Disc 16. A ir V a lv e Push Rod and 22. Center Plate
2. Grommet 10. Plunger Spring Plunger Assembly 23. Center Plate Hub
3. Front Sh ell 11. Bearing Seal 17. Dust Boot Seal
4. Front Diaphragm Plate 12. Poppet V a lv e 18. A ir Filters and 24. Power Piston Spring
5. Front Diaphragm 13. Poppet Retainer Silencers 25. Push Rod Seal
6. Rear Shell 14. A ir F ilte r and 19. Poppet Spring 26. H ydraulic Push Rod
7. Rear Diaphragm Silencers 20. Seal 27. Adjusting Screw
8. Rear Diaphragm Plate and 15. A ir F ilte r Retainer 21. Rear Diaphragm Retainer
Control V a lv e Body

GENERAL DESCRIPTION
The Master Vac (fig. 72) is a self-contained hydraulic sary—one a vacuum connection from manifold to check
and vacuum unit for power braking, utilizing manifold valve located on front shell; the other a hydraulic con­
vacuum and atmospheric pressure for its power. nection from the main cylinder outlet directly into the
The Master-Vac power brake unit permits the use of a hydraulic system. The unit is mounted on the engine side
low brake pedal as well as less pedal effort than is re­ of the fire wall and connected to the brake pedal through
quired with the conventional (nonpower) hydraulic brake an auxiliary lever and rod.
system. Only two external line connections are neces-

MAINTENANCE j D ADJUSTMENTS
Inspection 2. Inspect all hydraulic lines and connections at the
1. Check vacuum line and vacuum line connections as wheel cylinders and main cylinder for possible hy­
well as vacuum check valve in front shell of power draulic leaks.
unit for possible vacuum loss. 3. Check brake assemblies for scored drums, grease or

CHEVROLET TRUCK SERVICE MANUAL

BRAKES 5-44

brake fluid on linings, worn or glazed linings, and should be filled as described in this section, using only
make necessary adjustments. recommended brake fluid.
4. Check the brake fluid level in the hydraulic reser­
voir. The reservoir should be filled to within 1/2" Bleeding Instructions
of the top of the filler cap opening. Inspect the
The power system may be bled manually or with a
reservoir cover for fluid leaks at gasket.
pressure bleeder as outlined in this section.
5. Check for loose mounting bolts at main cylinder and
Use only recommended brake fluid. Do not use power
at power section.
assist while bleeding. The engine should not be running
6 . Check air cleaner filter located in the power piston
and the vacuum reserve should be reduced to zero, by
extension—replace filter if necessary.
applying the brake several times before starting the
7. Check brake pedal for bending and misalignment
bleeding procedure.
between pedal and push rod.
Air Cleaner Service
Lubrication
The air cleaner filter used with the power brake unit
The M aster-Vac power brake unit is lubricated at as­ should be cleaned at least twice a year. To clean, re­
sembly and needs no further lubrication other than main­ move air cleaner element and wash thoroughly in cleaning
taining normal reservoir fluid level. The reservoir solvent—allow element to dry before reinstalling.

SERVICE OPERATIONS
Removal (Fig. 73) MAIN CYLINDER-SINGLE RESERVOIR TYPE
1. Disconnect push rod clevis at brake pedal arm. (Midland Ross)
NOTE: This model cylinder is installed on
NOTE: If clearance hole through fire wall is
CE-CS-SA50-60 series vehicles.
not large enough, it may be necessary to remove
clevis from push rod. Note approximate location Removal (Fig. 1)
of clevis on rod. 1. Wipe main cylinder and line clean with a clean cloth.
Place dry cloths below main cylinder area to absorb
2. Disconnect vacuum hose from check valve in front any fluid spillage.
shell of power section. 2. Disconnect hydraulic line from main cylinder. Cover
3. Disconnect hydraulic lines at main cylinder. Cover open line end with clean lint-free material to prevent
main cylinder outlet ports and ends of brake tubes foreign matter from entering the system. Disconnect
to prevent entry of foreign matter. vacuum hose from manifold.
4. Disconnect stoplight switch wires. 3. Remove main cylinder from power booster.
5. Remove four nuts and lockwashers securing power
unit to fire wall, and remove power unit and spacer
from engine compartment.

Installation
1. Mount the power brake assembly and spacer in place
and install four attaching nuts and lockwashers. Be
certain to place push rod through cutout in fire wall.
2. Attach vacuum line to check valve.
3. Connect stoplight switch wires.
4. Secure hydraulic lines to main cylinder.
5. Adjust push rod clevis to brake pedal assembly.
Adjust pedal height by means of clevis on brake
pedal push rod at pedal. Pedal height is obtained
by measuring from floor covering at toe pan to top
of pedal pad.
NOTE: Check operation of stop light after ad­
justing pedal height.
6 . Bleed brakes as outlined in this section.
NOTE: After completing the bleeding opera­
tion, make sure reservoir fluid level is at cor­
rect height. The reservoir should be filled to
1/4 inch of filler cap opening.
7. Check operation of the brakes as outlined in this
section. Fig . 73—Power C ylin d e r Bracket and Spacer

CHEVROLET TRUCK SERVICE MANUAL

 BRAKES 5-45

ROTATED 90°

21 22 23 24 25 26 27

Fig. 74—M idland Ross M a in C ylin d er

1. Check V a lv e Spring 8. Diaphragm G asket 15. Push Rod Bushing 22. V a lv e Body
2. “ O ” Ring Seal 9. Spring Retainer 16. “ O ” Ring Seal 23. Spring
3. Check V a lv e Retainer 10. Snap Ring 17. Retainer 24. Washer
4. Check V a lv e Assembly 11. Push Rod Assembly 18. Washer 25. Snap Ring
5. Body 12. Push Rod Return Spring 19. Push Rod Cup 26. Piston Cup
6. C over 13. Lock Ring 20. Piston 27. “ O ” Ring Seal
7. Screw 14. Retainer 21. Piston V a lv e Insert

Disassembly (Fig. 74) 14. Remove check valve retainer (3) and discard "O ”
NOTE: The key numbers shown below in paren­ ring seal (2 ).
thesis refer to Figure 74. 15. Remove check valve (4) and spring (1).
Cleaning
1. Remove screw (7), cover (6 ), and diaphragm gasket
(8 ) from main cylinder body (5). Dump out hydraulic Wash all metal parts in alcohol or equivalent before
brake fluid. reassembly. Do not use a petroleum base cleaning agent.
2. Remove snap ring (10) and' spring retainer (9). Coat new block vees and rubber parts with hydraulic
3. Remove spring (12). If necessary, remove “ O” ring brake fluid.
seal (27).
4. Remove retainer (14) and unscrew lock ring (13) Assembly
counterclockwise. 1. Place spring (1) and check valve (4) into end of cyl­
5. Grasp push rod (11) and slide entire assembly out of inder body.
main cylinder body. 2. Place "O ” ring seal (2) over check valve retainer (3)
6 . Slide bushing (15) off push rod (11) and discard “O " and install check valve retainer into body.
ring seal (16). 3. Install new valve insert (21) in valve body (22).
7. Discard piston cup (26). 4. Slide bushing (15) onto push rod (11). Install new
8 . Remove retainer (17) and washer (18). " 0 ” ring seal (16).
9. Disengage snap ring (25) from piston. 5. Slide new piston cup (26) onto push rod and into
10. Slide piston (20) off push rod (11). Discard push rod bushing.
cup (19). 6 . Replace retainer (17) into piston cup (26). Install
11. Slide valve body off end of push rod (11). washer (18) on push rod.
12. Remove washer (24), spring (23), and snap ring (25). 7. Slide bushing (15), retainer (17), and washer (18)
13. Remove and discard valve insert (21). halfway down push rod.

CHEVROLET TRUCK SERVICE M ANUAL

BRAKES 5-46

8 . Place snap ring (25), washer (24), and spring (23)

over neck of push rod.
9. Push spring down on rod and engage push rod neck
into valve body.
10. Place spring (23) on valve body (22).
11. Place valve body (22) in piston (20) and push snap
ring (25) into place using snap ring pliers.
12. Install new push rod cup (19) in piston (20) with
lip facing end of piston.
13. Slide entire assembly into master cylinder body.
14. Push bushing (15) down push rod until washer (18)
hits stop inside main cylinder.
15. Screw retainer (14) into master cylinder body and
tighten using bushing retainer socket Tool J-22657
(fig. 75). Refer to torque specifications at rear of
manual for correct torque valve.
16. Install lock ring (13) into end of body.
17. Replace “O” ring seal (27).
18. Install spring (12) and retainer (9).
19. Install snap ring (10).
Installation (Fig. 1)
1. Install main cylinder on power booster.
2. Remove protective material from hydraulic line and
connect line to cylinder. Connect vacuum hose to
manifold.
3. Fill main cylinder to within 1/4 inch of top of
reservoir.
4. Bleed brakes as outlined in this section.
Fig. 75—Installing Retainer Using Bushing Retainer 5. Place rubber diaphragm in position on top of main
Socket Tool J -22657 cylinder.
6 . Place cover in position and secure with screw. Refer
to torque specifications at rear of manual for correct
torque value.

VACUUM BOOSTER POWER BRAKE UNIT

GENERAL DESCRIPTION
Two Midland-Ross vacuum power booster brake units cylinder applications and supplies pressure increased to
(a single and a tandem diaphragm), are used in 1967. all wheels.
Both types are installed between the master cylinder and The single diaphragm units are used on Van type ve­
the wheel cylinders in series in the hydraulic circuit, and hicles with the split brake system. Two units are used
use vacuum operated diaphragms to boost the brake pres­ on the vehicle, each one boosting the p ^ ss u re in half of
sure delivered to the wheel cylinders. Both units are the split system. Figure 77 illustrates a typical applica­
frame mounted. Refer to Figure 76. tion on the Van type vehicle.
The tandem diaphragm unit is used with single master

MAINTENANCE AND ADJUSTMENTS

BLEEDING THE SYSTEM 4. Apply brakes and check all lines for leaks.
5. Rebleed booster unit with engine running.
Pressure Bleeding
Manual Bleeding
If using a pressure bleeder, do not allow the air pres­
sure to exceed 25 pounds. Manual bleeding is sim ilar to pressure bleeding except
1. Check brake fluid in master cylinder and fill. that the brake fluid is forced through the lines by pumping
2. Open power cylinder bleeder screw and allow fluid the brake pedal instead of the air pressure. An assistant
to run until free of air bubbles. is required to pump the brake pedal.
3. Bleed all wheel cylinders until free of air bubbles. 1. Start engine and pump brake pedal three times or
until greatest pedal height is obtained—maintain foot
IMPORTANT: Do not apply brakes while en­
pedal pressure.
gine is running or booster unit may be damaged.

CHEVROLET TRUCK SERVICE M ANUAL

 BRAKES 5-47

2. Slowly open bleeder valve on power cylinder allowing

pedal to travel only 3/4 stroke. Close power cylinder
valve.
3. Repeat above operations until clear fluid containing
no air bubbles comes from this valve.
4. Bleed wheel cylinders in same sequence followed in
pressure bleeding.

Combination Pressure and Manual Bleeding

1. Connect bleeder tank to master cylinder.
NOTE: Be sure bleeder is filled with fluid and
charged to 25 psi air pressure.
2. Start engine and pump brake pedal three times or
until greatest pedal height is obtained and maintain
foot pressure.
3. Bleed power cylinder and wheel cylinders in same
F ig. 76—Vacuum Booster Unit sequence followed in pressure bleeding.

Fig. 77—Vacuum Booster Brake System

SERVICE OPERATIONS
The Hy-Power units are located with a bracket on the FLUSHING
truck chassis frame. The slave cylinder is located lower
than the master cylinder, and the bleeder screw on the When installing or servicing a booster unit on a vehicle
booster unit faces upward for ease of servicing. This which has had considerable service, flush entire hy­
unit is inserted between the master cylinder and the draulic brake system to remove dirt and sludge. Inspect
wheel cylinders. master cylinder for defects and repair. For flushing

CHEVROLET TRUCK SERVICE M ANUAL

BRAKES 5-48

purposes use either recommended brake fluid or Di- A manifold check valve is installed in the vacuum line
Acetone alcohol. Discard fluid after flushing. running from the engine intake manifold to the front
chamber of the booster unit.
CAUTION: Use care when filling hydraulic sys­
tem to prevent dirt from entering through top of
master cylinder.

AIR BRAKES

GENERAL DESCRIPTION
The air brake system (fig. 78) completely replaces primary air brake system and the auxiliary air operated
all hydraulic brake components with air brake parts for accessories. A minimum air pressure of approximately
producing and utilizing greater braking forces. The air 80 psi is required to lift the valve diaphragm off its seat
compressor in the all air brake system builds up and and permit air to pass to the accessories. Should the air
maintains the air pressure required to operate all of the pressure drop below 80 psi, the diaphragm closes off all
air powered devices. air to the accessories and all remaining air pressure is
A pressure protection valve is installed between the reserved for the brake system.

MAINTENANCE AND ADJUSTMENTS

COMPRESSOR If the element is cleaned, it should be washed in gasoline,
methyl alcohol, carbon tetrachloride, or soap and water.
The Tu-Flo 400 and 500 compressors are single stage The element should be saturated in clean engine oil then
reciprocating piston type compressors. Both the 400 and squeezed dry before replacing it in the strainer.
500 compressors have two cylinders. Check compressor drive alignment belt tension and
note that all mounting bolts are securely fastened.
5000 Miles:
35,000 Miles:
Depending on operating conditions and experience,
service the compressor air strainer. Remove and wash Remove compressor discharge valve cap nuts and
all parts. Strainer element should be cleaned or replaced. check for presence of excessive carbon deposits. Also,

Fig . 78—A ir Brake System

CHEVROLET TRUCK SERVICE M ANUAL

 BRAKES 5-49

check the discharge line for carbon. If excessive carbon RELAY VALVE
is found in either check, the cylinder head or discharge
line should be cleaned or replaced. Once each year the relay valve should be disassembled
and cleaned. Rubber parts and parts subject to wear
100,000 Miles: should be replaced if worn or damaged. Strainers at
Depending upon operating conditions and experience, relay diaphragm bleeder passage and exhaust port should
disassemble compressor, clean and inspect all parts be cleaned or replaced. If the relay valve does not
thoroughly. Repair or replace all worn or damaged parts. function as described under Service Checks—Relay Valve,
disassemble the valve and clean all parts.
IMPORTANT: Should it be necessary to drain
the engine cooling system to prevent damage QUICK RELEASE VALVE
from freezing, water cooled compressors must
be drained as both cylinder block and cylinder Every Year or 50,000 Miles
head are water cooled. Use drain cock or re­ Disassemble valve, clean all parts and replace the
move head and/or block pipe plugs. diaphragm.

INSPECTION BRAKE CHAMBERS

It is of the utmost importance that the compressor is Every Month or 2,000 Miles:
taking in clean air. The air strainer must be properly
installed and kept clean. If the compressor intake is con­ Check travel of brake chamber push rods and adjust
nected to the engine air cleaner, etc., these connections brakes if necessary. Push rod travel should be kept at
must be properly installed and maintained. the minimum without brakes dragging.
Excessive travel shortens the service life of brake
Check compressor mountings to be sure they are
chamber diaphragms and also results in slow braking
secure. Check drive for proper alignment, belt tension,
etc. Inspect oil supply and return lines. Be sure these response.
lines are properly installed and that the compressor is
getting the proper supply of oil, and just as important, Every Year or 50,000 Miles:
that the oil is returning to the engine properly. Disassemble brake chambers and clean all parts.
Check water lines to and from compressor if a water- Install new diaphragms. When replacing release springs
cooled type. be sure to use the correct spring, otherwise uneven
If the compressor is air-cooled, check to be sure the braking will result.
engine fan b l a s t is flowing by th e compressor
unrestricted. SLACK ADJUSTERS
Check unloader mechanism for operation.
The slack adjusters for 1967 are fully packed with
grease when assembled and need no periodic lubrication.
TESTS (AIR LEAKAGE)
If the slack adjuster is disassembled for any reason
Leakage past the discharge valves can be detected by it must be repacked with grease in the following way:
removing the discharge line, applying shop air back 1. Remove one plug from the slack adjuster side plate.
through the discharge port and listening for escaping 2. Using a pressure grease gun, inject grease into the
air. Also the discharge valves and the unloader pistons hole in side cover while turning the worm shaft
can be checked for leakage by building up the air system approximately 50 revolutions in one direction.
until the governor cuts out, then stopping the engine. With 3. Install side plate plug securely.
the engine stopped, carefully listen for escaping air at the 4. Rotate wormshaft about 3 revolutions in the opposite
intake. To pin-point leakage if noted, squirt soapy water direction.
around the loader pistons. If there is no noticeable leak­ 5. Refer to Section 0 - Lubrication for additional
age at the unloader pistons, the discharge valves may be information.
leaking.
RESERVOIRS
If the compressor does not function as described above, Drain air reservoirs regularly, as required. Local
or leakage is excessive, the compressor should be re­ conditions govern frequency; in dry climates, for ex­
paired with genuine service parts, in which case the fol­ ample, once a month may be sufficient, while in humid
lowing information should prove helpful. areas it may be necessary to drain reservoirs daily.
Satisfactory draining is only accomplished by leaving
GOVERNOR the drain cock open after the air has escaped and until
Every Six Months or 15,000 Miles: all drainage stops.
Many an efficient reservoir arrangement has failed in
Remove both governor air filters and wash thoroughly its normal function through haphazard maintenance.
in cleaning solvent that is known to have no detrimental
effect on metal, nylon, or rubber material.
DRAIN COCKS
BRAKE VALVE
All drain cocks should be periodically checked for
Every Year or 50,000 Miles:
leakage, both for leakage past the key and leakage through
Disassemble brake valve and clean all parts. Install the body around the key. Leakage of more than a one inch
new inlet valves and piston seal. soap bubble in one second is not permissible.

CHEVROLET TRUCK SERVICE M ANUAL

BRAKES 5-50

SAFETY VALVE AIR GAUGE

Every Year or 50,000 Miles: Check the accuracy of the air gauge semi-annually.
The simplest way to do this is to compare it with another
The safety valve should be removed, disassembled and
gauge known to be accurate.
thoroughly cleaned. Adjust to 150 psi blow-off pressure
Dash gauges may lose their accuracy after long periods
after reassembly.
of service and may require replacing. Continued use of
dash gauges showing error of more than 5 psi high or
SINGLE CHECK VALVE low is not recommended. Many state motor vehicle codes
Every Year or 50,000 Miles: require gauge accuracy within 1 0 percent.
The check valve should be dismantled and thoroughly
PRESSURE PROTECTION VALVE
cleaned.
Pressure protection valve service procedures are
LOW PRESSURE INDICATOR outlined under Service Operations in this section.
Every Month or 10,000 Miles:
AIR BRAKE ADJUSTMENTS
Check the electrical connections and the air pressure
at which the contacts close. This should be 58 to 65 psi. Air brake adjustments are described under Service
If above or below this range, replace switch. Operations in this section.

SERVICE OPERATIONS
to the compressor. Use a new discharge fitting
AIR COMPRESSOR
gasket.
Removal 9. Align compressor drive and adjust proper belt
These instructions are general and in some cases ad­ tension.
ditional precautions must be taken. 10. Tighten mounting bolts securely and evenly.
1. Drain air brake system. 11. After installation run compressor and check for air,
2. If water cooled type compressor, drain engine cool­ oil, or water leaks at compressor connections. Also
ing system, compressor cylinder head and block. check for noisy operation.
3. Disconnect all air lines, water and oil lines to and
from compressor. RELAY VALVE
4. Remove compressor mounting bolts and compressor
The relay valve is normally mounted to operate the
from engine.
brakes on the rear axle or axles of six wheel air braked
5. Use a gear-puller to remove the gear or pulley
tractors or trucks and long wheel base trucks. It is con­
from compressor crankshaft.
trolled by the brake valve and delivers the same air
Installation (Cleaning and Inspection) pressure to the brake actuators it controls as is being
1. Clean oil supply line. Before connecting this line to delivered to the relay valve by the brake valve. The relay
the compressor run the engine briefly to be sure oil valve has a direct compressed air supply as can be noted
is flowing freely through the supply line. in Figure 79. It operates as a remotely controlled high
2. Clean the oil return line or return passages through capacity brake valve.
the brackets; these passages must be unrestricted so Type R - l Relay Valves are mounted on a reservoir.
oil can return to the engine. Type R l-C Relay Valves are mounted away from, but
3. Prelubricate compressor cylinder walls and bearings connected to, a reservoir by tubing. Both types operate
with clean engine oil before assembling compressor. in a sim ilar manner.
4. Always use a new mounting gasket and be sure oil Leakage Tests
hole in gasket and compressor is properly aligned 1. Fully charge air brake system.
with oil supply line. 2. Make several service brake applications and check
5. Inspect pulley or gear and associated parts for wear for prompt application and release at all wheels.
or damage. They must be a neat fit on compressor 3. With service brakes released, coat the exhaust port
crankshaft. Replace pulley or gear if worn or of the relay valve with soap suds. A maximum leak­
damaged. age as indicated by a one inch soap bubble in not less
6 . Install pulley or gear on compressor crankshaft than three seconds is permissible.
making sure it properly contacts the shaft and does 4. Make and hold a service brake application and coat
not ride the key. Tighten crankshaft nut securely the exhaust port of the relay valve with soap suds.
and install cotter pin. A maximum leakage as indicated by a one inch soap
7. Be sure the air cleaner is clean and properly in­ bubble in not less than two seconds is permissible.
stalled. If the compressor intake is connected to 5. Release the brakes.
either the engine air cleaner or supercharger, these If valve does not function as described above, or if
connections must be tight with no leakage. leakage is excessive, replace relay valve, or repair
8 . Clean or replace any damage or dirty air or water or replace worn or damaged parts, in which case the
lines which may be corroded, before connecting them following information should prove to be helpful.

CHEVROLET TRUCK SERVICE M ANUAL

 BRAKES 5-51

BRAKE VALVE PORT 4. Inspect spring for breaks or deterioration.

5. Inspect valve seats for nicks or burrs.
6 . Inspect bleeder passage in body, diaphragm ring and

ACTUATOR cover and clear any restrictions noted.

PORTS 7. Clean or replace strainer and filter elements.
8 . Replace any parts which are no longer serviceable
by these inspections.
Assembly
Prior to assembly, lubricate lightly the following sur­
faces with Lubriplate or equivalent.
a. All grommets.
b. Diaphragm guide bore of relay valve.
RESERVOIR PORT c. Outside diameter and supply valve sterii bore of
TYPE R-1C diaphragm guide.
THROUGH M O U N T IN G FLA N G E d. Supply valve seat bore of relay valve body.
FOR TYPE R-1
1. Install exhaust port strainer. Be sure retaining ring
is firmly seated in its groove.
COVER
2. Install supply valve seat grommet and supply valve
BLEEDER P A S S A G E FILTER DIAPH RAGM seat. Note that seat is firmly seated on shoulder in
body.
BLEEDER P A S S A G E G RO M M ET DIAPHRAGM R IN G
3. Install supply valve, supply valve spring and seat
DIA PH RA G M COVER retainer spring.
G U ID E
G A SKET 4. Install grommet on supply valve cap nut.
GRO M M ET 5. Install and tighten the supply valve cap nut.
ACTUATOR
6 . Turn body over.
SUPPLY VALVE ADAPTER
SEAT G RO M M ET 7. Place grommet on diaphragm guide and install guide
SUPPLY VALVE
in relay valve body. Note that guide is neat sliding
SEAT fit in body bore and on supply valve stem.
8 . Install bleeder passage grommet in body.
SUPPLY VALVE
9. Install diaphragm ring.
SEAT RETAINER
10. Install relay diaphragm.
SPRIN G
11. Install bleeder passage filter in cover and position
SUPPLY VALVE
cover on body.
SP R IN G
SUPPLY VALVE GRO M M ET EXHAUST PORT NOTE: Bleeder passage openings in body, dia­
CAP NUT _______________ STRAINER
phragm ring, diaphragm, and cover must line up.
Fig. 79—Relay V a lv e 12. Install lock washers and cap screws and tighten
them evenly and securely.
Removal 13. Install gasket and actuator adapter.
1. Block or hold vehicle by a means other than air 14. Tighten cap screws evenly and securely.
brakes.
2. Open drain cocks and exhaust air pressure from air Installation
brake system. 1. Clean or replace lines to relay valve.
3. Disconnect air lines from relay valve. 2. Mount relay valve securely.
4. Remove mounting bolts and remove relay valve.
Disassembly SP R IN G N O N PRESSURE
INLET PLATE
1. Remove actuator adapter and its gasket.
PORT
2. Remove cover, diaphragm, diaphragm ring, bleeder
passage grommet, and bleeder passage filter. M O U N T IN G BOLTS
3. Remove diaphragm guide and grommet. DIA PH RA GM
4. Remove supply valve cap nut and grommet. PUSH ROD YO KE
PRESSURE
5. Remove supply valve spring, seat retainer spring, PLATE A SSY.
supply valve, supply valve seat, and supply valve seat
grommet. INLET
6 . Remove exhaust strainer. PORT

Cleaning and Inspection of Parts CLAMP R IN G

1. Wash all metal parts in a cleaning solvent such as NUTS A N D
BOLTS
alcohol or kerosene and dry them thoroughly. Keep
parts submerged in solvent for shortest possible
time to avoid damage to m aterials. CLAMP
2. Inspect all moving parts for wear or damage and R IN G
bores for out of round condition.
3. Inspect diaphragm and bonded rubber valve for wear
or deterioration. Fig . 80—A ir Brake Chamber (Clamp Ring Type)

CHEVROLET TRUCK SERVICE M ANUAL

BRAKES 5-52

on the vehicle, for example to change the diaphragm

or spring, first back off the slack adjuster to relieve
the return spring pressure against the pressure
plate, then follow disassembly procedure below.
2. Pull out push rod and clamp it at the non-pressure
plate with vise or vise grip pliers. If necessary, use
air pressure to move the push rod out. Grips of vise
or vise grip pliers should be covered or taped to
prevent damage to push rod.
3. Remove clamp ring nuts and bolts.
4. Spread clamp ring slightly, just enough to slip it off
the plates. It is sometimes necessary to use a screw
driver and gradually pry under the clamp ring to re­
move it. If the clamp ring is to be reused, caution
should be taken against bending it out of shape.
5. Remove pressure plate and diaphragm.
6. Remove yoke and lock nut from push rod.
7. Release grip on push rod.
8. Remove push rod assembly, spring and other details.
Cleaning and Inspection
Clean all metal parts and inspect them for damage.
Damaged parts should be replaced. If it is necessary to
replace the return spring, be sure the correct replace­
ment spring is used. Inspect diaphragm and any other
rubber parts for wear or deterioration and replace if
necessary.
Assembly
Fig. 81—A ir Brake Chamber Installed 1. Stand push rod assembly upright on a flat surface.

3. Connect air lines.

4. Test relay valve for serviceability as outlined in
"Operating and Leakage Test Section."
AIR BRAKE CHAMBERS (Figs. 80 and 81)
Brake chambers in the air brake system convert com­
pressed air pressure energy into mechanical force and
movement which applies the vehicle brakes.

Leakage Test
With a full pressure application, check the brake
chamber for leakage. No leakage is permissible.
If leakage is detected around the flange, or clamping
ring, the bolts should be tightened evenly but only enough
to stop the leakage otherwise the diaphragm, flange
sealing surface or clamping ring could be distorted.
Removal
1. Disconnect air line and push rod yoke.
2. Remove brake chamber.
Installation
1. Mount brake chamber to mounting bracket.
2. If possible, push rod should point down to obtain
maximum drainage.
3. Install yoke and its nut on push rod and connect to
slack adjuster.
4. Check the angle formed by the push rod and slack
adjuster. The angle should never be less than 90°
when full air pressure is applied to the brake
chamber when the brakes are cold and properly
adjusted.
Disassembly
1. After cleaning the exterior of the brake chamber,
mark it in such a way that it can be assembled the
same way. If the brake chamber is to be dismantled Fig . 8 2 —Governor

CHEVROLET TRUCK SERVICE M ANUAL

 BRAKES 5-53

ring over the clamping surface of the pressure plate

with the use of vise grip pliers or like tool drawing
the clamp lugs together.
7. Assemble bolt and nut in clamp. It is sometimes
necessary to tap the clamping ring to center it, and
this should be done only with a soft faced mallet.
8 . Release hold on push rod and install remaining clamp
ring nut and bolt.
9. Tighten the clamp ring nuts and bolts evenly and only
sufficiently to eliminate leakage.

GOVERNOR (Figs.82 and 83)

Removal
If it is necessary to remove or install a governor, the
following procedure will apply:
1. Drain air brake system.
2. Disconnect air lines at governor.
3. Remove governor mounting b o l t s and r e m o v e
governor.
Disassembly (Fig. 84)
1. Remove all dirt or grease from exterior of governor,
using cleaning solvent and a brush.
2. Unscrew the top cover.
3. Remove the spring assembly retaining ring.
4. Remove the adjusting screw and spring assembly.
5. Remove the lock nut, then the hex-shaped upper
spring seat from the adjusting screw.
6 . Remove the pressure setting spring, lower spring
seat, spring guide and the other lower spring seat
from the adjusting screw.
7. Remove the exhaust stem and its spring from the top
of the piston.
Fig. 83—G o ve rn o r—Cross Section
8 . With the body in the inverted position, tap it lightly
2. Position return spring and non-pressure plate on
to remove the piston.
push rod.
9. Remove the inlet and exhaust valve spring and the
3. P ress the non-pressure plate down against the ten­
valve from the piston.
sion of the spring until the plate bottoms on the flat
10. Remove the two piston grommets and with a hooked
surface.
wire. Remove the exhaust stem grommet.
4. Now clamp the push rod at the non-pressure plate in
11. Clean or remove the unloader and reservoir port
a vise or with vise grip pliers whose grips have been
filters.
taped or covered.
5. With the push rod held in this manner, place the Cleaning and Inspection
clamp ring over the clamping surface of the non­ 1. Clean all metal parts in cleaning solvent.
pressure plate. 2. Wipe clean all rubber parts.
6 . Position diaphragm in pressure plate and joint the 3. Inspect body for cracks or other damage. Be partic­
two with the non-pressure plate by working the clamp ularly careful that all air passages in the body,

19

1 2 3 4 5 8 9 10 1112 13 14 15 16 17 1

U liX A
Fig. 84—G o ve rn o r—Exploded V ie w

1. C o ver 6. Lower Spring Seats 11. Washer 16. In let and Exhaust V a lv e
2. Retaining Ring 7. Spring G u id e 12. Grommet 17. Inlet-Exhaust V a lv e
3. Adjusting Screw Lock N ut 8. Adjusting Screw 13. Grommet Spring
4. Upper Spring Seat 9. Exhaust Stem 14. Piston 18. Body
5. Pressure Setting Spring 10. Exhaust Stem Spring 15. Grommet 19. Filters

CHEVROLET TRUCK SERVICE M ANUAL

BRAKES 5-54

filters exhaust stem, and the pistons are not FOOT OPERATED AIR BRAKE CONTROL VALVE
obstructed.
4. Check springs for cracks, distortion, or corrosion. Removal
1. Exhaust all air from system.
5. Replace all parts not considered serviceable during
2. Remove all lines running to brake valve.
these inspections.
3. Remove pedal push rod clevis pin.
Assembly 4. Remove mounting bolts and remove valve.
NOTE: P rior to assembly lubricate the lower Disassembly (Fig. 85)
body bore, the top of the piston, the piston 1. Remove boot (18) from plunger (17) and bracket (16).
grooves, piston grommets, piston setting spring 2. Remove plunger (17).
guide and adjusting screw. 3. Remove mounting bracket (16) from valve body (10),
1. Install the exhaust stem grommet in its groove in by removing 3 bolts (19) and lock washers (20).
the stem bore of the piston. 4. Remove snap ring (15).
2. Drop the inlet and exhaust valve into place at the 5. Remove piston assembly (14) and spring (11) from
bottom of the piston. valve body (1 0 ).
3. Install the inlet valve spring with its narrow end 6 . Remove two seals (12 and 13) from piston assembly

against the valve. P ress the spring down until the (14).
large coiled end snaps into the groove inside the 7. Invert valve body.
piston. 8 . Remove screw (1), retainer (2), and diaphragm (3)

4. Position the exhaust stem spring over the exhaust from exhaust valve body (5).
stem. Then carefully press the stem into the stem 9. Remove ring (4) from exhaust valve body (5).
bore of the piston. 10. Remove exhaust valve body (5), seal (6 ), spring (7),
5. Install the piston in the body. and valve (9) from valve body (10).
6 . Install one lower spring seat, spring guide, the other 11. Remove seal (8 ) from valve (9).
lower spring seat, pressure setting spring, and the Cleaning and Inspection
hex-shaped upper spring seat on the adjusting screw, 1. Check mounting flange for cracks or breakage.
in that order. 2. Discard all rubber parts.
7. Screw the upper spring seat down until the dimension 3. Inspect the body for scoring and excessive wear. Be
from the top of the seat to the bottom of the stem sure all passages are clear.
head is approximately 1 -7 /8 ". Secure with lock nut. 4. Wash all metal parts in non-toxic cleaning solvent
NOTE: Before placing the adjusting screw and and dry with air.
stem assembly in the governor body, check to 5. Replace all parts found damaged or worn.
be sure the exhaust stem and its spring are in Assembly (Fig. 85)
place in the piston.
NOTE: Lubricate all seals with Lubriplate
Installation grease.
1. Clean or replace both air lines connected to the 1. Place seal (8 ) on valve (9) and place in valve body
governor. (10).
2. Mount governor in place with exhaust port pointing 2. Install spring (7) on valve (9).
toward the ground. 3. Place seal (6 ) on exhaust valve body (5) and install
3. Connect air lines to governor. assembly in valve body ( 1 0 ) piloting on coil spring
4. Test governor for proper operation. (V.

Fig. 85—A ir Brake Control V a lv e

1. Screw 6. Seal 11. Spring 16. M ounting Bracket

2. Retainer 7. Spring 12. Seal 17. Plunger
3. Diaphragm 8. Seal 13. Seal 18. Boot
4. Ring 9. V a lv e 14. Piston Assembly 19. Bolt
5. Exhaust V a lv e Body 10. V a lv e Body 15. Snap Ring 20. Lockwasher

CHEVROLET TRUCK SERVICE M ANUAL

 BRAKES 5-55

4. Secure exhaust valve body (5) into valve body (10) not fully release, it indicates that the exhaust valve is
with ring (4). not operating sufficiently. This can be caused by:
5. Secure diaphragm (3) and retainer (2) to exhaust 1. Insufficient exhaust valve to valve seat clearance.
valve body (5) with screw (1). 2. Improper adjustment of the brake pedal push rod.
6 . Invert valve body (10). 3. Lack of lubrication in the body causing the piston
7. Install seal (13) on piston (14). Install seal (12) on and spring assembly to bind.
piston (14). 4. Binding pedal and/or linkage.
8 . Install coil spring (11) into valve body (10). If the brake valve does not apply promptly, or does not
9. Install piston assembly (14) into valve body (10) and apply fully, it indicates that the inlet valve is not opening
secure with snap ring (15). sufficiently. This can be caused by:
10. Secure mounting bracket (16) to valve body (10) with 1. Improper adjustment of the linkage, which does not
bolts (19) and lock washers (20). permit the piston to travel far enough when the brake
11. Install plunger (17) into mounting bracket (16). is being applied.
12. Install boot (18) on plunger (17). 2. Binding pedal and/or linkage.
If the brake valve does not graduate the delivered pres­
Tests and Adjustments of Rebuilt Unit sure properly check to be sure the bleed hole to the
cavity immediately below the piston is not restricted.
Tests Installation
If facilities are available, the rebuilt brake valve can 1. Mount brake valve in position, install mounting bolts
be tested on a suitable test rack. If such facilities are and tighten.
not available, the brake valve can be tested on the 2. Connect air lines to brake valve.
vehicle. 3. Test operation thoroughly.
Both operating and leakage tests must be made in 4. Adjust brake pedal free play as outlined in this
either case to make certain the brake valve meets the section under Push Rod to Main Cylinder Adjustment.
following specifications:
1. The brake valve must deliver approximately full QUICK RELEASE VALVE
reservoir pressure when the pedal is fully de­
pressed. If this test is being made on a vehicle and Removal
brake valve does not deliver approximately full 1. Disconnect air lines at quick release valve (fig. 8 6 ).

reservoir pressure, check to see if the pedal ad­ 2. Remove mounting bolts and remove valve.
justment linkage is causing any interference. Disassembly
2. The brake valve must control delivered pressures Remove all dirt and grease from exterior of valve,
between approximately 5 and 75 psi. These pres­ using cleaning solvent and a brush. Inspect exterior of
sures must rapidly vary in accordance with the valve for broken or damaged parts. All broken or dam­
position in which the pedal is held. aged parts must be replaced.
3. Leakage at the exhaust port in both the fully applied Unscrew cover, lift out diaphragm spring, diaphragm
or fully released positions must not exceed a one- spring seat and diaphragm (fig. 87).
inch soap bubble in three seconds.
4. No leakage is permissible at any other point on the Cleaning and Inspection of Parts
brake valve with the pedal in the depressed position. Wash all metal parts in cleaning solvent.

Adjustments
If the brake valve does not release promptly, or does

BODY

S P R IN G

C O VER

Fig. 86—Q u ic k Release V a lv e Installed Fig . 87—Q u ick Release V a lv e Components

CHEVROLET TRUCK SERVICE M ANUAL

A.
BRAKES 5-56

Diaphragm: Examine diaphragm for signs of cracking,

wear or damage. Carefully examine the lower face of the
diaphragm which contacts the the port seat in the cover
for signs of pitting or grooving. Replace diaphragm if
any of these conditions are found.
Cover: Inspect condition of exhaust port seat on cover
for signs of pitting. The seat must be smooth and flat.
If the exhaust port seat shows deep scratches or pitting,
PUSH LOCK SLEEVE IN TO
it must be replaced. DISENGAGE HEAD OF WORM
SHAFT TO MAKE ADJUSTMENT
Spring Seat: If the spring seat is worn or damaged,
replace with new spring seat.
Repairs
If the exhaust port seat on cover shows scratches or
pitting, it can sometimes be repaired by carefully lap­
ping the seat, using a fine emery cloth on a flat surface
(fig. 8 8 ).
r.

Assembly
1. Insert diaphragm into spring seat.
t _.
2. Position diaphragm and spring seat in body with lo c k sleeve m u st come out
spring in place, install and tighten cover securely. AND ENGAGE HEAD OF WORM
sh a ft to lo c k a d ju s t m en t

Testing Rebuilt Unit

If facilities are available, the rebuilt quick release
valve can be tested on a suitable test rack. If such facil­
ities are not available, the valve can be tested on the
Fig. 89—Slack A djuster—Cutaw ay V ie w
vehicle.
Both operating and leakage tests must be made in 1. Lock Sleeve 5. Worm
either case to make certain the quick release valve meets 2. Spring 6. Worm Shaft
the tests outlined under Service Checks. 3. Dowel 7. G ear
4. Lever 8. C over Plate
Installation
1. With attaching bolts, mount quick release valve in 2. Cut off riveted ends of rivets attaching cover plates
place. to body. Drive out rivets and remove cover plates.
2. Connect air lines to the valve. 3. Remove welch plug from end of worm shaft bore.
3. Be certain exhaust port is open. Insert a flat end punch into the worm shaft bore and
drive worm shaft out of body and worm.
SLACK ADJUSTERS 4. Remove lock sleeve and spring from worm shaft.
Remove gear and worm from slack adjuster body.
Removal
1. Remove clevis pin attaching brake chamber push rod Inspection and Repair
yoke to slack adjuster. 1. Wash parts in cleaning fluid and wipe dry.
2. Remove lock ring and spacer securing slack adjuster 2. Inspect worm and gear and replace with new parts if
on camshaft. Slide slack adjuster off end of shaft. chipped or broken teeth are evident.
3. Inspect worm shaft for wear. Make sure corners on
Disassembly (Fig. 89)
hex end are not rounded.
1. Remove dirt and grease from outside of unit by
4. Inspect bushing in lever arm. If worn, out-of-round,
washing in a suitable cleaning fluid.
or otherwise damaged, it must be replaced. To re ­
place bushing, press old bushing out and press new
bushing into place. Bushing must be reamed after
installation to 0.503"-0.504".
5. Examine lock sleeve for cracks or other damage.
Replace if necessary.
6 . Examine lever (body) for cracks or distortion. If
lever is damaged in any way, a new body and bushing
assembly must be used.
Assembly (Fig. 89)
1. Place worm and gear assembly in position in body.
2. Place lock sleeve over worm shaft, with socket-like
end of sleeve at hex end of shaft. Place lock spring
in recess formed by sleeve and shaft.
3. Enter small end of worm shaft through hole in body
and worm. P ress worm shaft into worm and body,
making sure the groove in lock sleeve is aligned with
Fig. 88—Lapping Exhaust Port Seat pin in body. P ress shaft in until distance from small

CHEVROLET TRUCK SERVICE M ANUAL

 BRAKES 5-57

end of shaft to edge of body (A, fig. 89) is 0.625”. and that all are at the same angle. If angle is less than
Install new welch plug in worm shaft bore. 90 degrees with brakes applied, slack adjuster is going
4. Position cover plates on body and attach with new "over cen ter." Adjust brakes as previously described
rivets. Covers must be flat and in good contact with under "Brake Adjustments."
body after riveting.
BRAKE SHOES AND CAMSHAFTS
Installation (Figs. 89, 90, 91 and 92)
1. If a new slack adjuster is being installed, make sure Removal
it is the same size and type as that removed. Make
sure spacing washer is in place on camshaft. Slide
Front
1. Remove wheel nuts, rim locks and rim and tire
the slack adjuster onto camshaft and attach with assembly.
spacer and lock ring. 2. Remove cotter pin, spindle nut, spacer and outer
2. Connect brake chamber push rod yoke to slack ad­ bearing.
juster with clevis pin and cotter pin. Refer to 3. Remove wheel and brake drum assembly.
"B rake Chamber Installation" for adjustment of 4. Remove brake shoe pull back springs.
brake chamber push rod. 5. Remove brake shoe hold down nuts, washers and
3. Adjust brakes as previously directed under "Brake anchor pin "horseshoe" clips.
Adjustments." 6 . Remove brake shoes.

Lubrication 7. Remove cotter pin from end of camshaft and remove

Slack adjusters are permanently lubricated by the man­ spacers.
ufacturer and require no periodic lubrication. However, 8 . Tap out camshaft (fig. 90).

if a slack adjuster has been dismantled and repaired in

accordance with these procedures, it becomes necessary
Rear
1. Remove wheel nuts, rim locks, and outer tire and
to lubricate upon reassembly. rim assembly.
1. Remove one plug from slack adjuster side plate. 2. Remove rim spacer, then inner rim and tire
2. Using a pressure grease gun, inject grease into the assembly.
hole in side cover while turning the wormshaft 3. Remove axle shaft retaining nuts and "sp lit wedge"
approximately 50 revolutions in one direction. locks.
3. Install side plug securely. 4. Withdraw axle shaft.
4. Rotate wormshaft three revolutions in the opposite 5. Remove axle shaft lock nut, lock, and adjusting nut.
direction.
5. Refer to Section 0 - Lubrication in this manual for
additional information.
Slack Adjuster Operating Test
Apply brakes and make sure all slack adjusters rotate
freely and without binding. Release brakes and make
sure all slack adjusters return to released position
freely without binding.
With brakes released, make sure the angle formed by
slack adjuster arm and brake chamber push rod is
greater than 90 degrees. All slack adjusters should be
set at the same angle. With brakes applied, make sure
the angle formed by the slack adjuster arm and brake
chamber push rod is still slightly greater than 90 degrees

Fig. 91—Rear Brake Parts Id entification

1. A ctuating Cam 6. Anchor Pin

2. Roller 7. Flange Plate
3. Brake Shoe Facing 8. Shoe Return Spring
4. Brake Shoe 9. Roller Pin
Fig . 90—Removing Camshaft (Front shown as T yp ica l) 5. Anchor Pin Lock Ring

CHEVROLET TRUCK SERVICE M ANUAL

BRAKES 5-58

6 . Remove wheel and brake drum assembly, being 4. Install brake shoe pull back spring.
careful not to damage outer bearing. 5. Install wheel and brake drum assembly, front wheel
7. Slip pull back spring off of pins on inside of brake bearing, spacer and spindle nut. Tighten spindle nut
shoes. See Figure 91 for parts identification. to 55 foot pounds torque and insert cotter pin. (The
8 . Remove cotter pin from camshaft and tap out cam­ nut may have to be backed off slightly to allow
shaft (fig. 90). entrance of cotter pin.)
6 . Install rim and tire assembly, rim locks and wheel
Camshaft Bracket Byshing Replacement nuts. Tighten nuts on opposite sides alternately to
1. Using a suitable tool remove grease seal and old torque specified in Section 3 under Wheels and T ires.
bushings.
2. Using suitable bushing installer, install new bushing NOTE: Wheel nuts must be checked at the end
and line ream to a finished diameter of 1.499" to of 500 miles to be certain that rim locks and
1.501". Install a new grease seal. nuts have not loosened.
NOTE: Be certain that a lubrication fitting has
been installed in camshaft bracket.
Rear
1. Make certain camshaft is engaged properly before
installing retainer. Set brake shoes in place and
Installation
Front
1. Slide camshaft into place making certain brake shoes
make certain pins and rollers will engage proper
location on cam. Do not install rollers and pins at
this time.
will contact cam at proper location. 2. Install brake shoe pull back springs.
2. Replace same number spacers as removed and 3. Pry shoes apart and install brake shoe cam rollers
install cotter pin. and roller pins.
3. Install brake shoes, brake shoe “ horseshoe" clips, 4. Install rear wheel. Install axle outer bearing and
hold down nuts, and washers. Lock nuts in place with adjusting nut. Adjust bearing as follows:
cotter pins. a. Tighten adjusting nut with T-handle wrench 12"

Fig. 92—A ir Brake Camshaft Assembly

1. Cam (Integral with 4. Bushing 8. Camshaft 11. Slack Adjuster

Shaft) 5. Flange Plate 9. Camshaft and Brake 12. Lock Ring
2. Spacing Washers 6. Camshaft Bracket Chamber Bracket 13. S lack Adjusting
3. Seal 7. Seal Retainer 10. Spacer N ut

CHEVROLET TRUCK SERVICE M ANUAL

 BRAKES 5-59

long each side, until wrench tight, at the same With brakes released, the angle formed by the push
time rotating hub to make sure all surfaces are rod and camshaft lever must be greater than 90°, and
in proper contact. Then loosen nut at least 45 all units should be set at the same angle. With the brakes
degrees, or more if necessary, until a lip of the applied, after being adjusted, this angle should still be
nut lock will engage the nearest flat on the nut. greater than 90°. In other words, the camshaft lever
b. Make sure wheel turns freely, then install nut should not go "over center” when the brakes are applied.
lock and locking nut. Tighten locking nut firmly. The position of the push rod yoke on the push rod should
Bend lip of nut lock over flat of locking nut. be adjusted if necessary until these conditions prevail.
c. Apply a rope of smooth cup grease around outer Proper shoe-to-drum free play may be obtained by per­
bearing. forming the following procedures:
5. Install axle shaft and secure with "sp lit wedge”
locks and retaining nuts.
6 . Install inner rim and tire assembly (make certain
FrontandRear
1. Using the proper size "b o x " wrench or deep socket
valve points toward the outside), rim spacer and wrench, depress the spring loaded collar that locks
outer rim and tire assembly making certain tire the slack adjuster adjusting nut in place (fig. 94).
valve is 180° away from inner tire valve. 2. Turn the adjusting nut until a uniform light drag is
7. Install rim locks and nuts. Tighten nuts alternately felt on the wheels.
on opposite sides, to torque specified in Section 3 3. Back off on nut until wheel is just free; then back off
under Wheels and T ires. three more " fla ts " for facing-to-drum running
clearance. Repeat this operation at all slack
NOTE: Nuts and rim locks must be torqued at adjusters.
the end of 500 miles to be certain they have not
loosened. RESERVOIRS
AIR BRAKE Removal
Adjustment 1. Bleed all air out of brake system.
The brake shoe-to-drum freeplay adjustment of air 2. Disconnect air lines and remove drain cock.
brakes is accomplished by means of the slack adjuster 3. Remove mounting bracket nuts and bolts and remove
which is incorporated in the camshaft lever. reservoir.

Fig . 93—Front Wheel Brake Layout (Except Mounting)

CHEVROLET TRUCK SERVICE M ANUAL

BRAKES 5-60

Cleaning and Inspection Cleaning and Inspection of Parts

In most cases, major repairs on reservoirs are not Wash all metal parts in cleaning solvent.
economical or practical. If a reservoir has been dam­ If the key or body is badly scored, the complete drain
aged so as to be unfit for service, always replace it with cock should be replaced.
a new one. Do not attempt to fit a new key in an old body or vice
In exceptional cases where the inside of a reservoir versa.
has been coated with sludge that cannot be drained off it
can be removed with steam and hot water. Repairs
If slight leakage has been present due to a slight scor­
CAUTION: Never plug up reservoir and apply ing of the key or body, the key should be ground in with a
steam as serious damage will result. Under no good grade of #400 grinding compound. Before the key is
conditions should more than 150 PSI (steam again put in place, it should be given a light application of
pressure) be applied to reservoir. a good grade of cup grease.
Testing Assembly
When testing for leakage, only water pressure should 1. Insert key in body.
be used. In this case only, higher than normal pressures 2. Place spring and spring washer over key.
may be exceeded but only for a matter of seconds. 3. Push down on spring washer and insert pin in key.
Installation Installation
1. Install reservoir in place with mounting bracket nuts Using a wrench on hexagon portion of drain cock, screw
and bolts. But do not tighten securely at this time. in place.
2. Install drain cock and assemble and securely tighten
all air pressure lines. SAFETY VALVE
3. Tighten reservoir mounting bolts and nuts and make Removal
certain reservoir will not vibrate during service as Unscrew complete valve from line fitting.
this will cause premature pressure line failure.
Disassembly
DRAIN COCKS Unscrew the spring cage (fig. 95) from the body of the
safety valve. Lift ball valve from body and remove
Removal
spring, spring seat, and release pin from spring cage.
Apply wrench to the hexagon portion of the body only.
Unscrew and remove. Cleaning and Inspection of Parts
Clean all parts in cleaning solvent. Examine the ball
Disassembly
valve for signs of pitting or scratches. If any damage is
1. Push down on spring washer.
evident the safety valve should be replaced. Clean ball
2. Remove key pin.
3. Remove spring washer, spring and key.

STEM-

ADJUSTING
SCREW
LOCK NUT-
PUSH LOCK SLEEVE IN TO
D IS EN G A G E HEAD OF W O R M
SHAFT TO MAKE ADJUSTM ENT
SPRING

EXHAUST < ---------SPRING

VALVE CAGE

SPRING
SEAT BALL
VALVE

BODY-

r'7-miy.p a re
'E W
LOCK SLEEVE MUST CO M E OUT
A N D E N G A G E HEAD OF W O R M
PORT OF
SHAFT TO LOCK ADJUSTM ENT
RESERVOIR

Fig . 94—S lack Adjuster Nut Lock Sleeve Fig . 95—Safety V a lv e

CHEVROLET TRUCK SERVICE M ANUAL

 BRAKES 5-61

valve seat thoroughly. Check the body and spring cage for 2. Install grommet on cap nut and screw cap nut into
cracks. Be sure the exhaust port in the spring cage is body and tighten securely.
not plugged.
Installation
Assembly Position valve in place with arrow on side of body in­
1. Place the ball valve in the body of the safety valve. dicating direction of air flow. Secure air lines to each
2. Place spring release pin and spring seat in spring end of the valve.
cage with the adjusting screw assembly. Position
Testing Rebuilt Unit
the spring seat over the ball valve and screw the
Both operation and leakage tests must be made as out­
spring cage to the body.
lined under Service Checks—Single Check Valve.

Installation LOW PRESSURE INDICATOR SWITCH

Screw safety valve in place in proper reservoir line. Removal
Tests and Adjustments of Rebuilt Unit 1. Make certain ignition is off.
Both operating and leakage tests, indicated under 2. Exhaust all air from brake system.
Service Check, must be made after rebuilding the safety 3. Disconnect the electrical connections at the low
v a l v e and the valve m u s t meet the f o l l o w i n g pressure indicator switch.
specifications: 4. Disconnect the air line to the low pressure indicator
1. Leakage at the exhaust port should not exceed a one- switch.
inch soap bubble in one second. Installation
2. The safety valve should be set to "blow off" at ap­ 1. Mount indicator in place .
proximately 150 PSI. The pressure setting may be 2. Attach and tighten mounting nut and connect air line.
adjusted by loosening the lock nut and turning the 3. Attach and tighten electrical connection.
adjusting screw. Turning the adjusting screw clock­ Testing Replacement Unit
wise, raises the pressure setting. Turning the Both operating and leakage tests must be made as out­
adjusting screw counter-clockwise, lowers the pres­ lined under Service Checks—Low Pressure Indicator.
sure setting. The setting of the adjusting screw
AIR GAUGE
should be locked by lightening the adjusting screw
lock nut after each adjustment. An accurate test Removal
gauge should be used when adjusting the pressure 1. Remove air line and lamp socket.
setting of the safety valve. 2. Remove four instrument panel backing plate screws
and remove backing plate from vehicle.
SINGLE CHECK VALVE 3. Separate gauge from backing plate by removing two
retaining screws.
Removal
1. Exhaust air from brake system. <- Testing Replacement Unit
2. Remove air lines at single check valve and remove The simplest way to test any dash pressure gage is to
valve (fig. 96). compare it with a special test gauge that is known to be
accurate. By substituting one gauge for another at one
Disassembly
given point in the air brake system, this comparison can
Unscrew cap nut from body and remove grommet. Re­
be made.
move disc valve, spring, and valve stop bushing from
body. Installation
1. Attach gauge to instrument panel backing plate using
Cleaning and Inspection of Parts
original screws or equivalent.
Clean all parts in cleaning solvent. Inspect disc valve
and seat for corrosion. Inspect body and cap nut for
cracks or damage. If any damage is present, replace
UPPERBODY
entire valve assembly.
Assembly SPRING
1. Position valve stop bushing, spring and disc valve in
body. SPRING CAP

DIAPHRAGM

LOWER BODY

Fig . 96-*-Single Check V a lve Fig . 97—Pressure Protection V a lv e —Cross Section

CHEVROLET TRUCK SERVICE MANUAL

BRAKES 5-62

2. Mount backing plate-gauge assembly in instrument Cleaning and Inspection

panel. 1. Wash all parts in cleaning fluid.
3. Replace lamp socket and gauge line. 2. Inspect diaphragm for cuts and punctures. Some in­
4. Thoroughly check gauge connection for leakage. dentation of the diaphragm by the seat in the lower
body is normal.
PRESSURE PROTECTION VALVE (Fig. 97)
Assembly
Disassembly 1. Position diaphragm, spring cap and spring on lower
1. Remove four screws and separate the upper and body.
lower bodies. 2. Align upper body with lower body, install four screws
2. Remove diaphragm, spring cap and spring. and secure.

TRAILER EQUIPMENT
GENERAL DESCRIPTION
For 1967 trailer air brake equipment is available for valve, trailer connectors, separate stop light switch and
some models. The option includes a hand control valve, connecting lines, (fig. 98). Testing and servicing of these
double check valve, emergency air valve, breakaway units is outlined in this section.

OPERATION TEST AND LEAKAGE TESTS

HAND CONTROL VALVE probably caused by a worn or deteriorated inlet valve
seal, or binding or corrosion between the valves and
Operating Tests valve guides in valve cage, preventing the inlet valve
1. Check the delivery pressure of the valve, using an from fully closing.
accurate test gauge connected to the trailer brake 2. With operating lever in fully applied position coat
service line at the back of the cab. With air system exhaust port with soap suds. Leakage evidenced by
fully charged, and with valve operating handle in this test may be due to a worn or deteriorated ex­
fully applied position, test gauge should show the haust valve seal or by leaking piston seals.
same pressure (within 5 pounds) as registered on the
dash air gauge. DOUBLE CHECK VALVE
2. Move the handle to several positions between fully
Operating Tests
released and fully applied and note that pressure 1. Apply truck brakes and note that the brakes apply
registered on the test gauge varies in accordance promptly on both the truck and the trailer. Release
with the position of the handle. truck brakes and note that brakes on truck and
Leakage Tests trailer both release promptly.
1. Coat the exhaust port with soap suds with operating 2. Move hand control valve lever to applied position
handle in fully released position to check for leakage. and note that brakes apply only on the trailer. Move
Leakage in excess of a 1-inch bubble in one second is control valve lever to released position and note that
not permissible. Leakage evidenced by this test is trailer brakes release promptly.

EMERGENCY
AIR VALVE

H A N D CONTROL
VALVE

DOUBLE CHECK
VALVE A N D
STOPLIGHT SWITCH
TRAILER
CO NNECTORS

TO SERVICE BREAKAWAY
BRAKE VALVE

TO SERVICE
TANK

Fig . 98—T ra ile r Equipment C ircu its

CHEVROLET TRUCK SERVICE M ANUAL

 BRAKES 5-63

Leakage Tests should show full air system pressure. Then pull knob
1. Apply truck brakes and check for leakage at hand out; test gauge should drop to zero.
control valve exhaust port, using soap suds. 3. Again build up air pressure in system to operating
2. Apply trailer brakes only with hand control valve range, then stop engine. Push emergency air valve
and check for leakage at truck brake application knob in. Make a series of brake applications until
valve exhaust port, using soap suds. low air buzzer sounds. Slightly open drain cock in
3. Leakage of a one inch bubble in one second is per­ the dry air tank to obtain a slow (approx. 1 0 psi per
missible in either of these tests. If leakage exceeds minute) pressure drop in the tractor brake system.
this specification, replace the shuttle valve. When truck air system drops to 45 psi (approx.) the
emergency air valve knob should automatically come
EMERGENCY AIR VALVE AND out and pressure on test gauge should rapidly drop
BREAKAWAY VALVE to zero.
Operating Tests
1. Pull out emergency air valve knob to exhaust air Leakage Tests
pressure from breakaway valve control line. Dis­ 1. Build up air pressure in truck brake system to oper­
connect trailer emergency line from emergency out­ ating range. Push in emergency air valve knob to
let port at breakaway valve and connect an air charge trailer brake system. Use soap suds to coat
pressure test gauge to emergency outlet port. exhaust ports of emergency air valve and breakaway
2. Start engine and build up air pressure in system. valve.
Low air pressure buzzer should stop operating at 2. When emergency air valve leaks excessively, install
approximately 60 psi. With air pressure in operating new piston O-rings. When breakaway valve leaks
range, push emergency air valve knob in. Test gauge excessively, install new O-rings and plunger seal.

Fig. 99—A irbrake Hand Control V a lv e

1. Bolt 8. V a lv e Body 14. Spring 20. C over
2. Lock Washer 9. V a lv e Return Spring 15. Cam 21. Nut
3. Bracket 10. V a lv e Spring Retainer 16. Cam Shaft 22. Operating Lever
4. End Cap 11. Piston Return Spring 17. Cam Housing 23. Name Plate
5. Seal 12. Piston Cup 18. Adjusting Bearing 24. Lock Washer
6. N ut 13. Piston 19. C o lla r 25. Screw
7. V a lv e Disc

CHEVROLET TRUCK SERVICE MANUAL

BRAKES 5-64

SERVICE OPERATIONS

HAND CONTROL VALVE each other for evidence o f wear, scoring, o r

corrosion.
Removal 3. Inspect all metal parts for wear and deterioration
1. Exhaust air pressure from system. and replace if necessary. Replace all rubber parts.
2. Disconnect air lines from valve.
3. Remove bolts and washers securing valve bracket. Assembly
4. If valve is to be replaced with a new unit, remove 1. Position discharge valve return spring in body.
lock nut and 2 nd control lever for installation on 2. Install valve spring retainer in body.
replacement unit. Remove air line connector fittings 3. Compress discharge valve return spring, install
for installation on replacement unit. valve disc and secure with nut.
4. Install new seal on end cap and install end cap in
Disassembly body.
5. Install piston return spring in body.
1. Remove cover screw, name plate and cover.
6 . Install new piston cup on piston and install piston in
2. Loosen nut and remove operating lever.
valve body.
3. Scribe marks on valve body and cam housing to per­
7. Install piston spring in valve body.
mit proper reassembly.
8 . Install adjusting bearing in cam housing.
4. Unscrew and remove housing collar.
9. Install cam and camshaft in cam housing and place
5. Remove cam housing assembly, camshaft and cam.
assembly in position on valve body. Align scribe
Separate the individual parts.
marks made during disassembly. Secure by install­
6 . Remove adjusting bearing from cam housing.
ing collar.
7. Remove piston spring from body.
10. Install operating lever and secure with nut.
8 . Remove piston and piston cup from body. Remove
11. Install cover and name plate and secure with pan
cup from piston.
head screw.
9. Remove piston return spring from body.
10. Remove end cap and seal from body. Remove seal Installation
from end cap.
11. Remove nut from inlet and valve spring retainer. 1. If a new valve assembly is being installed, install
Remove valve disc. operating lever and shaft which were removed from
12. Remove valve spring retainer from body. old unit. Also, install air line connector fittings in
13. Remove discharge valve spring from body. inlet and outlet ports, using sealing compound on
connector threads. Keep sealing compound off first
Cleaning and Inspection two threads of fitting.
2. Position valve and secure with two bolts and lock
1. Clean all metal parts in mineral spirits. Make sure
washers. Tighten bolts firmly.
all passages in valve body are open and clean.
3. Connect air lines to valve.
2. Inspect internal bores in valve body and external
4. Build up air pressure in system and test valve
surfaces of piston which have sliding contact with
operation as previously directed under "Serv ice­
ability T ests” .

To Stop
Light Switch DOUBLE CHECK VALVE (Fig. 100)
Gasket
Valve Guide Shuttle Valve Disassembly

Body Cover Remove two cap screws and lock washers attaching
valve cover to body. Remove cover and gasket, then
remove shuttle valve and valve guide.

Installation
Wash all parts in a cleaning solution and wipe dry.
Examine all parts for corrosion or deterioration and
From Trailer
replace as necessary. Make sure shuttle valve will slide
Brake freely back and forth in valve guide.
Application Brake Hand
Valve Control Valve
Assembly
Delivery Port
To Trailer Brake Apply a thin coating of Lubriplate or equivalent to in­
Service Line side of valve guide. Place valve guide and shuttle valve
in body. Position cover on body, using new gasket. Install
cover cap screws and lock washers, and tighten evenly
Fig. 100—Double Check V a lv e and firmly.

CHEVROLET TRUCK SERVICE M ANUAL

 BRAKES 5-65

SPECIAL TOOLS

tggjij

Fig. 101—Sp ecial Tools

1. J-8000 Brake Tube Cutter 8. J-4705

W h eel C ylin d er Piston Cup 12. J —21479 Pressure Bleeder
2. J-8554 Pressure Bleeding Adapter Plate Installer Adapter
3. J-4 7 0 7 Brake Adjusting Tool 9. J-22364 Drum to Brake Shoe C learance 13. J-22348 Brake Spring Remover
4. J-6892 (J-2185) Brake Tube Flaring Tool Set G auge and Installer
5. J-8049 Brake Spring Tool 10. J-21601 Power Brake Retainer Installer 14. J-22489 Brake Bleeder Adapter
6. J-0628 (J-628 ) Brake Bleeding Tube 11. J-21524 Power Piston Remover and 15. J-22657 Bushing Retainer
7. J-7647 Brake Bleeding W rench Installer Socket

CHEVROLET TRUCK SERVICE M ANUAL

 SECTION 6
ENGINE
CONTENTS OF THIS SECTION
Page Page
Gasoline E n g in e s ............................................................... 6-1 Specifications At Rear of Manual
Engine Tune Up ............................................................ 6-1 Special Tools .................. 6-42
Engine Mechanical (In L in e ).......................................... 6-11
Engine Mechanical ( V 8 ) ................................................ 6-24

GASOLINE ENGINES
ENGINE TUNE-UP
INDEX
Page Page
General D e s c rip tio n ......................................................... 6-1 Instrument C h e c k -O u t...................................................... .... 6-6
Mechanical Checks and A d ju stm en ts.............................. 6-1 Instrument H o o k -U p ...................................................... .... 6-6
Spark Plug R e m o v a l...................................................... 6-1 Check and Adjust D w e l l ................................................ .... 6-6
Test C o m p re s s io n ......................................................... 6-1 Check Dwell Variation ................................................ .... 6-6
Service and Install Spark Plugs ................................. 6-2 Check and Adjust T i m i n g ............................................. .... 6-6
Service Ignition S y s t e m ................................................ 6-2 Adjust Idle Speed and Mixture .................................... .... 6-7
Service Battery and Battery Cables ........................... 6-4 Additional Checks and Adjustm ents................................. .... 6-8
Service Delcotron and R e g u la t o r ................................. 6-4 Testing Crankcase Ventilation V a l v e ........................... .... 6-8
Service Fan B e l t ............................................................ 6-4 Testing Cranking V o l t a g e ............................................. .... 6-8
Service Manifold Heat Valve ....................................... Cylinder Balance T e s t ................................................... .... 6-8
Tighten M a n ifo ld ............ ................................................ 6-5 B a t t e r y ........................................................................... .... 6-8
Service Fuel Lines and Fuel Filter ........................... 6-5 Ig n it io n ............................................................... .. ............. 6-9
Service Cooling S y s t e m ................................................ 6-5 C a r b u r e t o r ..................................................................... .... 6-9
Check and Adjust Accelerator L in k a g e ........................ 6-5 Fuel P u m p ..................................................................... .... 6-9
Service Crankcase Ventilation....................................... 6-5 Cooling S y ste m ............................................................... .... 6-9
Service A ir Injection Reactor System ........................ 6-5 Cylinder Head Torque and Valve A d ju s t m e n t............ .... 6-9
Adjust C h o k e .................................................................. 6-5
Service A ir C le a n e r .................................... ..................

GENERAL DESCRIPTION
The engine tune up is important to the modern auto­ equipment available for this purpose. Always follow the
motive engine with its vastly improved power and per­ instructions provided by the manufacturer of the par­
formance. The higher compression ratios, improved ticular equipment to be used.
electrical systems and other advances in design, make Additional checks and adjustments are included in the
today's engines more sensitive and have a decided effect latter part of this section for use as required. Many of
on power, performance and fuel consumption. these operations can be used to isolate and correct
It is seldom advisable to attempt a tune up by correction trouble located during the tune up. Where conditions
of one or two items only. Time will normally be saved are uncovered requiring major corrective action, refer
and more lasting results assured if the technician will to the appropriate section of this manual or the
follow a definite and thorough procedure of analysis and Truck Chassis Overhaul Manual for detailed service
correction of all items affecting power, performance information.
and economy. Typical illustrations and procedures are used except
The tune up will be performed in two parts. The first where specific illustrations or procedures are necessary
part will consist of mechanical checks and adjustments; to clarify the operation. Illustrations showing bench
the second part will consist of an instrument checkout operations are used for clarifications, however, all
that can be performed with any one of the units of service operations can be performed on the vehicle.

MECHANICAL CHECKS AND ADJUSTMENTS

Spark Plug Removal Test Compression (Fig. 1)
The compression check is important because an engine
Remove any foreign matter from around spark plugs with low or uneven compression cannot be tuned success­
by blowing out with compressed air, then disconnect fully. It is essential that improper compression be cor­
wires and remove plugs. rected before proceeding with the engine tune up.

CHEVROLET TRUCK SERVICE M ANUAL

ENGINE 6-2

P O R C E L A IN
IN S U L A T O R
IN S U L A T O R C R A C K S
O F T EN O C C U R H ERE

SH ELL

(P R O P E R G A P )

Fig. 1—Checking Compression

C EN T ER ELEC TR O D E
FILE FLAT W H E N
1. Remove air cleaner and block throttle and choke in
A D JU S T IN G G A P - SID E ELEC TR O D E
wide open position.
D O N O T B EN D ! (B E N D TO A D JU S T G A P )
2. Hook up starter remote control cable and insert
compression gauge firmly in spark plug port.
CAUTION: Whenever the engine is cranked Fig. 2—Spark Plug D etail

remotely at the starter, with a special jumper 3. Inspect each spark plug for make and heat range.
cable or other means, the primary distributor All plugs must be of the same make and number.
lead must be disconnected from the negative 4. Adjust spark plug gaps to specifications using a
post on the coil and the ignition switch must be round feeler gauge.
in the “ ON” position. Failure to do this will
result in a damaged grounding circuit in the CAUTION: Never bend the center electrode to
ignition switch. adjust gap. Always adjust by bending ground or
side electrode.
3. Crank engine through at least four compression
strokes to obtain highest possible reading. 5. If available, test plugs with a spark plug tester.
4. Check and record compression of each cylinder. 6. Inspect spark plug hole threads and clean before
5. If one or more cylinders read low or uneven, inject installing plugs. Corrosion deposits can be removed
about a tablespoon of engine oil on top of pistons with a 14 mm. x 1.25 SAE spark plug tap (available
in low reading cylinders (through s p a r k plug through local jobbers) or by using a small wire
port). Crank engine several times and recheck brush in an electric drill. (Use grease on tap to
compression. catch chips.)
• If compression comes up but does not necessarily CAUTION: Use extreme care when using tap to
reach normal, rings are worn. prevent cross threading. Also crank engine sev-
• If compression does not improve, valves are eral times to blow out any material dislodged
burnt, sticking or not seating properly. during cleaning operation.
• If two adjacent cylinders indicate low compression
and injecting oil does not increase compression, 7. Install spark plugs with new gaskets and torque to
the cause may be a head gasket leak between the specifications.
cylinders. Engine coolant and/or oil in cylinders NOTE: The following are some of the greatest
could result from this defect. causes of unsatisfactory spark plug performance.
NOTE: If a weak cylinder cannot be located • Installation of plugs with insufficient torque to
with the compression check, see “ Cylinder B al­ fully seat the gasket.
ance Test” under “ Additional Checks and Ad­ • Installation of the plugs using excessive torque
justments” in this section. which changes gap settings.
Service & Install Spark Plugs (Fig. 2) • Installation of plugs on dirty gasket seal.
1. Inspect each plug individually for badly worn elec­ • Installation of plugs to corroded spark plug hole
trodes, glazed, broken or blistered porcelains and threads.
replace plugs where necessary. Refer to spark 8 . Connect spark plug wiring.

plug diagnosis information presented in Section 6 Y

for an analysis of plug conditions. Service Ignition System
2. Clean serviceable spark plugs thoroughly, using an 1. Remove distributor cap, clean cap and inspect for
abrasive-type cleaner such as sand blast. File the cracks, carbon tracks and burned or corroded ter­
center electrode flat. minals. Replace cap where necessary.

CHEVROLET TRUCK SERVICE M ANUAL

 ENGINE 6-3

ROTOR

(RO U N D )
LOCATOR
(SQ U A R E )

CAM
LUBRICATOR
CENTRIFUGAL
ADVANCE
M EC H A N ISM

CAM
ADJUST DWELL LUBRICATOR
ANGLE SETTING OR REPLACEM ENT
POINT OPENING

CA U TIO N !
N EVER O IL
C A M LU B R IC A T O R —
REPLACE W IC K
Fig. 3— Distributor (In Line) W H E N N EC ESSA R Y
2. Clean rotor and inspect for damage or deterioration.
Replace rotor where necessary. A D JU ST SQ UA RELY
3. Replace brittle, oil soaked or damaged spark plug A N D JU ST
wires. Install all wires to proper spark plug. Proper T O U C H IN G LOBE
OF CAM
positioning of spark plug wires in supports is im­
portant to prevent cross-firing.
4. Tighten all ignition system connections. Fig. 4— Distributor (T yp ica l V8)
5. Replace or repair any wires that are frayed, loose clean contact points since particles will embed and

Pulse(Breakerless)Distributor
or damaged. cause arcing and rapid burning of points. Do not
Magnetic attempt to remove all roughness nor dress the
There are no moving parts in the ignition pulse amp­ point surfaces down smooth. Merely remove scale
lifier, and the distributor shaft and bushings have or dirt.
permanent type lubrication, therefore no periodic main­ • Clean cam lobe with cleaning solvent, lubricate
tenance is required for the magnetic pulse ignition cam lobe with “ Delco Remy Cam and Ball Bearing
system. Refer to Section 6 Y for an analysis of problems Lubricant" or its equivalent and rotate cam lub­
and/or repair procedures encountered on the Transis­ ricator wick 1 / 2 turn.
torized (Magnetic Pulse) ignition system. • Replace points that are burned or badly pitted.
Standard (Breaker Point) Distributor (Figs. 3 or 4)
NOTE: Where prematurely burned or badly
1. Check the distributor centrifugal advance mechanism
pitted points are encountered, the ignition sys­
by turning the distributor rotor in a clockwise direc­
tem and engine should be checked to determine
tion as far as possible, then releasing the rotor to
the cause of trouble so it can be eliminated.
see if the springs return it to their retarded position.
Unless the condition causing point burning or
If the rotor does not return readily, the distributor
pitting is corrected, new points will provide no
must be disassembled and the cause of the trouble
better service than the old points. Refer to
corrected.
Section 6 Y for an analysis of point burning or
2. Check to see that the vacuum control operates freely
pitting.
by turning the movable breaker plate counterclock­
wise to see if the spring returns to its retarded • Check point alignment (fig. 5) then, adjust distri­
position. Any stiffness in the operation of the vacu­ butor contact point gap to .019" (new points) or
um control will affect the ignition timing. Correct .016" (used points). Breaker arm rubbing block
any interference or binding condition noted. must be on high point of lobe during adjustment.
3. Examine distributor points and clean or replace if
NOTE: If contact points have been in service,
necessary.
they should be cleaned with a point file before
• Contact points with an overall gray color and
adjusting with a feeler gauge.
only slight roughness or pitting need not be
replaced. • Check distributor point spring tension (contact
• Dirty points should be cleaned with a clean point point pressure) with a spring gauge hooked to
file. breaker lever at the contact and pull exerted at 90
Use only a few strokes of a clean, fine-cut con­ degrees to the breaker lever. The points should be
tact file. The file should not be used on other closed (cam follower between lobes) and the read­
metals and should not be allowed to become greasy ing taken just as the points separate. If not within
or dirty. Never use emery cloth or sandpaper to lim its, replace.

CHEVROLET TRUCK SERVICE MANUAL

ENGINE 6-4

LATERAL PROPER
MISALIGNMENT LATERAL ALIGNMENT
HOLD
DO NOT SUCK
IN T O O M U C H
ELECTROLYTE VERTICAL

FLOAT M UST
BE FREE

Fig. 5— Point Alignm ent

Excessive point pressure will cause excessive TAKE R E A D IN G

wear on the points, cam and rubbing block. Weak AT EYE LEVEL
point pressure permits bouncing or chattering,
resulting in arcing and burning of the points and
an ignition miss at high speed. Fig. 6—Testing Sp e c ific G ra v ity o f Battery
4. Install rotor and distributor cap. P ress all wires high resistance in the charging circuit, oxidized
firmly into cap towers. regulator contact points, or a low voltage setting.
Service Battery and Battery Cables If the battery has been using too much water, the
1. Measure the specific gravity of the electrolyte in voltage output is too high.
each cell (fig. 6 ). If it is below 1.230 (corrected to Service Delcotron and Regulator
80°F.) recharge with a slow rate charger, or if The Delcotron and regulator tests during tune up con­
desired, further check battery. s ist of the above battery tests; the condition of the
2. Connect a voltmeter across the battery terminals battery indicating further tests and adjustments as out­
and measure the terminal voltage of the battery lined in Section 6 Y.
during cranking (disconnect the coil primary lead
Service Belts (Fig. 7)
at the negative terminal during this check to prevent
engine from firing). If the terminal voltage is less Inspect belt condition.
than 9.0 volts at room temperature, approximately Check and adjust if necessary for correct tension of
80° ± 20°F., the battery should be further checked. belt, as follows:
See Section 6 Y for further tests. • Using a strand tension gauge, check the belt tension.
3. Inspect for signs of corrosion on battery, cables • If belt is below the minimum, adjust until the spec­
and surrounding area, loose or broken ca rriers, ified tension is reached. (See Tune Up Chart.)
cracked or bulged cases, dirt and acid, electrolyte
leakage and low electrolyte level. F ill cells to
proper level with distilled water or water jpassed
through a "de m ineralizer".
The top of the battery should be clean and the
battery hold-down bolts properly tightened. P ar­
ticular care should be taken to see that the top of
the battery is kept clean of acid film and dirt.
When cleaning batteries, wash first with a dilute
ammonia or soda solution to neutralize any acid
present and then flush off with clean water. Keep
vent plugs tight so that the neutralizing solution does
not enter the cell. The hold down bolts should be
kept tight enough to prevent the battery from shaking
around in its holder, but they should not be tightened
to the point where the battery case will be placed
under a severe strain.
To insure good contact, the battery cables should
be tight on the battery posts. Oil battery terminal
felt washer. If the battery posts or cable terminals
are corroded, the cables should be cleaned sepa­
rately with a soda solution and wire brush. After
cleaning and before installing clamps, apply a thin
coating of petrolatum to the posts and cable clamps
to help retard corrosion.
If the battery has remained undercharged, check
for loose or defective fan belt, defective Delcotron, Fig. 7—C hecking Belt Tension

CHEVROLET TRUCK SERVICE M ANUAL

 ENGINE 6-5

Service Manifold Heat Valve (Figs. 8 or 9)

Check manifold heat control valve for freedom of
operation. If shaft is sticking, free it up with GM Mani­
fold Heat Control Solvent or its equivalent.
NOTE: Tap shaft end to end to help free it up.
Tighten Manifold
Tighten intake manifold bolts to specifications in the
sequence outlined on Torque Sequence Chart. A slight
leak at the intake manifold destroys engine performance
and economy.
Service Fuel Lines and Fuel Filter
1. Inspect fuel lines for kinks, bends or leaks and cor­
rect any defects found.
2. Inspect filter and replace if plugged.
NOTE: If a complaint of poor high speed per­
formance exists on the vehicle, fuel pump tests
described in Section 6 M should be performed.
Service Cooling System
1. Inspect cooling system for leaks, weak hoses, loose
hose clamps and correct coolant level, and service
as required.
NOTE: A cooling system pressure test, as de­
scribed in “ Additional Checks and Adjustments” Fig. 9—M anifold Heat Control V a lv e (V 8 )
in this section, may be performed to detect
internal or external leaks within the cooling sitive” ventilation systems utilizing manifold vacuum to
system. draw fumes and contaminating vapors into the combustion
chamber where they are burned. Since it affects every
Check and Adjust Accelerator Linkage part of the engine, crankcase ventilation is an important
1. Disconnect accelerator rod at carburetor throttle function and should be understood and serviced properly.
lever. In both “ Positive” and “ Closed Positive” ventilation,
2. Hold carburetor throttle lever in wide position. a ir is drawn through the engine, (through a regulating
3. Pull accelerator rod to wide open position. (On valve) into the manifold, drawing crankcase vapors and
vehicles equipped with automatic transmission, pull fumes with it to be burned. “ Positive” ventilation uses
through detent). a vented-meshed cap for clean air intake to the engine,
4. Adjust accelerator rod to freely enter hole in ca r­ while “ Closed Positive” ventilation system draws the
buretor throttle lever. clean air from the carburetor air cleaner and has a
NOTE: Accelerator linkage is outlined in detail nonvented oil filler cap.
in Section 6 M. 1. Ventilation valve may be checked as outlined under
“ Additional Checks and Adjustments” .
5. Connect accelerator rod at throttle lever. 2. Inspect for deteriorated or plugged hoses.
Service Crankcase Ventilation (Fig. 10) 3. Inspect all hose connections.
All engines have either “ Positive” or “ Closed Po- 4. On closed positive ventilation systems, remove flame
arrestor and wash in solvent then dry with com­
pressed air.
Service Air Injection Reactor System
Inspect air injection reactor (A.I.R.) system for evi­
dence of leaks, deteriorated hoses, cracked air manifolds
or tubes and loose hose clamps. Inspect air injection
pump belt condition and tension. Make all necessary
repairs as outlined in “ Section 6 T ” .
Because of the relationship between “ Engine Tune Up”
and “ Unburned Exhaust Gases” , the condition of Engine
Tune Up should be checked whenever the A.I.R. System
seems to be malfunctioning. Particular care should be
taken in checking items that affect fuel-air ratio such as
the crankcase ventilation system, the carburetor and the
carburetor air cleaner. Carburetors and distributors
for engines with the A.I.R. System are designed, particu­
larly, for these engines; therefore, they must not be
interchanged with or replaced by a carburetor or dis­
tributor designed for an engine without the A.I.R. System.
Choke Adjustment
F ig . 8—M anifold Heat Control V a lv e (In Line) 1. Remove air cleaner.

CHEVROLET TRUCK SERVICE M ANUAL

ENGINE 6-6

VALVE
FLAME ARRESTO R VENTED CAP

VALVE
NO N-VEN TED C A P

VALVE

CLO SED PO SITIVE IN LINE (TYPICAL) POSITIVE IN LINE TYPICAL

FLAME
ARRESTOR VALVE
VENTED CAP

VALVE

FLAME ARRESTOR

NON-VENTED CAP

CLOSED POSITIVE V8 (283-327) (TYPICAL) POSITIVE V8 (283-327) (TYPICAL) CLOSED POSITIVE V8 (366)

Fig. 10—Crankcase V en tila tio n Systems

2. Push hand choke knob in to within 1/8" of instrument
panel. 4. Tighten cable clamp at carburetor bracket and check
3. Loosen choke cable at carburetor bracket and adjust operation of choke valve to ensure full closed and
cable through the clip until the choke valve is wide wide open positions.
open.
INSTRUMENT CHECK-OUT
Instrument Hook Up
Connect vacuum gauge, dwell meter, tachometer and V8 ENGINES
timing light as recommended by the manufacturer of the • With engine running at idle, raise the adjustment
equipment being used. screw window and insert an Allen wrench in the
Check and Adjust Dwell socket of the adjusting screw (fig. 1 1 ).
1. Start engine then check ignition dwell. • Turn the adjusting screw as required until a dwell
2. If dwell is not within specifications, adjust dwell as reading of 30° is obtained. A 2° variation is allow­
follows: able for wear.
• Close access cover fully to prevent the entry of
dirt into the distributor.

WINDOW NOTE: If a dwell meter is not available, turn

adjusting screw clockwise until engine starts to
r "HEX” TYPE
m isfire, then turn screw one-half turn in the
WRENCH opposite direction to complete adjustment.
IN LINE ENGINES
• Remove distributor cap and recheck point setting.
If dwell is still not within specifications check the
distributor as outlined in Section 6 Y.
Check Dwell Variation
Slowly accelerate engine to 1500 rpm and note dwell
reading. Return engine to idle and note dwell reading.
If dwell variation exceeds specifications, check for worn
distributor shaft, worn distributor shaft bushing or loose
ADJUSTING
breaker plate.
SCREW Check and Adjust Ignition Timing (Fig. 12)
1. Disconnect the distributor spark advance hose and
plug the vacuum source opening.

CHEVROLET TRUCK SERVICE MANUAL

 ENGINE 6-7

ing is TDC and all BTDC settings fall on the " A "
(advance) side of “ O ".
4. Adjust the timing by loosening the distributor clamp
and rotating the distributor body as required, then
tighten the clamp.
5. Stop engine and remove timing light and reconnect
the spark advance hose.
Adjust Idle Speed and Mixture (Fig. 13) (Except When
Equipped With Air Injection Reactor System)
1. As a preliminary adjustment, turn idle mixture
screws lightly to seat and back out 2 turns.
CAUTION: Do not turn idle mixture screw
tightly against seat or damage may result.
2. With engine running at operating temperature (choke
wide open) adjust idle speed screw to bring idle speed
to specified rpm (automatic transmission in drive,
manual transmission in neutral).
3. Adjust idle mixture screw to obtain highest steady
idle speed (1/4 turn out from lean roll).
4. Repeat Steps 2 and 3 as needed for final adjustment.
5. Shut down the engine, remove gauges and install air
cleaner.
Adjust Idle Speed and Mixture (Fig. 13) (With Air
Fig. 12—Ignition Timing Marks Injector Reactor System)
To produce an acceptable level of exhaust emissions
2 . Start engine and run at idle speed (see tune up chart).
the idle speed and mixture should not be adjusted to
3. Aim timing light at timing tab. obtain the highest steady vacuum reading.
The recommended adjustment procedure for Air In­
NOTE: The markings on the tabs are in 2° jection Reactor System equipped engines is as follows:
increments (the greatest number of markings 1. As a preliminary adjustment, turn idle mixture
on the “ A ” side of the “ O” )- The "O ” mark- screws lightly to seat and then back out 3 turns.

IDLE SP EE D
SC REW
IDLE M IXTURE
SC REW

F ig . 13—Idle Speed and M ixture Screws

CHEVROLET TRUCK SERVICE MANUAL

ENGINE 6-8

CAUTION: Do not turn idle mixture screw 3. Adjust idle mixture screw (turn in) to "lean roll”
tightly against seat or damage may result. position; then turn screw out 1/4 turn (1/4 turn
rich from "lean roll” ). The definition of "lean
2. With engine running at operating temperature, choke
roll” point is a 20 to 30 rpm drop in engine speed,
wide open, and parking brake applied, adjust idle
obtained by leaning the idle mixture.
speed screw to specified idle speed (automatic
4. Repeat Steps 2 and 3 as needed for final adjustment.
transmission in "d riv e” - manual transmission in
"neutral” ).

ADDITIONAL CHECKS AND ADJUSTMENTS

Testing Crankcase Ventilation Valve (Fig. 14)
1. Connect tachometer and vacuum gauge as for idle
speed and mixture adjustment.
2. Set parking brake, start engine and adjust idle speed
and mixture.
3. Disconnect ventilation hose at valve, block opening
of valve and read engine rpm change.
4. A change of less than 50 rpm indicates a plugged
ventilation valve - replace the valve.
Cylinder Balance Test (Fig. 15)
It is often difficult to locate a weak cylinder. A com­
pression test, for example, will not locate a leaky intake
manifold, a valve not opening properly due to a worn
camshaft, or a defective spark plug.
With the cylinder balance test, the power output of one
cylinder may be checked against another, using a set of
grounding leads. When the power output of each cylinder
is not equal, the engine will lose power and run roughly.
Perform a cylinder balance test as follows:
1. Connect the tachometer and vacuum gauge.
2. Start engine and run at 1500 rpm. Battery
3. Ground large clip of grounding leads and connect Two battery checks should be made to determine the
individual leads to all spark plugs except the pair condition of the battery in a minimum amount of time.
being tested.
1. Hydrometer Test
Divide the firing order in half and arrange one half
2. Light Load Test
over the other. The cylinders to be tested together ap­
pear one over the other. NOTE: If a battery failure is encountered, the
cause may be outside the battery itself. Do not
L 6 Firing Order
be satisfied merely to recharge or replace it.
1 -5 -3 -6 -2 -4 = 1-5-3 = 1-6, 5-2, 3-4
Find the cause of failure and prevent reoccur­
6-2-4
rence.
V 8 Firing Order
See Section 6 Y for a description of above tests.
1 -8 -4 -3 -6 -5 -7 -2 = 1-8-4-3 = 1-6, 8-5, 4-7, 3-2
6 -5 -7 -2 Ignition
The following additional ignition checks may be made
4. Operate engine on each pair of cylinders in turn and
with any of several pieces of equipment available for
note engine rpm and manifold vacuum for each pair.
uncovering the source of engine difficulties. The specific
A variation of more than 1 inch of vacuum or 40 rpm
operating instructions of the equipment manufacturer
between pairs of cylinders being tested indicates that
should be followed:
the cylinders are off balance.
• Cranking voltage
• Ignition switch
• Distributor resistance
• Secondary resistance
• Ignition output and secondary leakage
C rankingVoltage(Fig.16)
1. Disconnect coil primary lead at the coil negative
terminal to prevent engine from firing during
cranking.
2. Connect voltmeter between primary terminal of coil
(resistance wire side) and ground.
3. Operate starting motor.
a. If voltage is 9 volts or more and cranking speed
F ig . 14—Crankcase V entilatio n V a lve is satisfactory, the battery, starter, cables,

CHEVROLET TRUCK SERVICE M ANUAL

 ENGINE 6-9

facturer indicate all secondary circuit components

are in good condition.
• If all readings are "below norm al," check for cor­
roded coil tower terminal, poorly connected or
broken coil wire, center cap electrode or rotor tip
burned, or an open secondary in coil.
• If readings are "higher than norm al" at two or more
plugs adjacent in firing order, cross firing is occur­
ring in distributor cap or between spark plug cables
concerned.
• If meter reads off scale to left, the coil polarity is
reversed. Check for reversed coil primary wires,
wrong coil or reversed vehicle battery connections.
IgnitionOutputandSecondaryLeakage
Use equipment as directed by manufacturer.
• GOOD readings indicate both ignition output and
secondary insulation are good.
• If all readings are BAD or if ignition test calibrator
cannot be adjusted to Set Line, check for high re sis­
tance in primary circuit, defective distributor points,
coil or condenser.
• If readings are BAD when certain plug wires are
lifted off, check for cracks or carbon tracks in dis­
tributor cap or defective insulation on those plug
wires being lifted off.
Carburetor
Refer to Section 6 M to perform adjustments such as
idle vent, float level, pump rod and secondary valve.
Fuel Pump
If the owner has complained of poor high speed per­
Fig. 16—Testing Cranking V oltage
formance, the fuel pump may be at fault. Too low a
pump pressure or volume will cause a high speed " m is s "
starter switch and ignition circuit to coil (by­
because of lack of fuel delivered to the carburetor,
passing resistance wire) are in good condition,
while too high a pressure will cause carburetor flooding.
b. If below 9 volts, check circuit until difficulty is
Check fuel pump as outlined in Section 6 M.
located.
Meter reading below specification—Weak bat­ Cooling System
tery; defective cables, connections, switch or The following test may be performed with pressure
starter; defective ignition circuit to coil. testing equipment available commercially for this pur­
Cranking speed below normal—Excessive re­ pose. This test provides an excellent means of detecting
sistance in cables or starting motor; excessive internal or external leaks within the cooling system.
mechanical drag in engine. 1. Remove radiator cap.
Uneven cranking speed—Uneven compression, 2. Apply a test pressure of 3 pounds higher than the
defective starter or starter drive. radiator cap (fig. 17). i.e. 18 pounds for a 15 pound

IgnitionSwitch
With voltmeter connected as described for the Cranking
cap.
3. If the pressure will not hold, there is either an
internal or external leak in the system.
Voltage Test, turn ignition switch to ON. Voltage should
drop to 5 to 7 volts as current is now passing through Cylinder Head Torque and Valve Adjustment
high resistance wire connected between ignition switch Retorquing the cylinder head bolts is not necessary
and (+) positive terminal of coil. If battery voltage of unless a gasket has been replaced, or a leak is suspected.
12 volts is obtained, the starter solenoid is by-passing Valve lash must always be adjusted after the head has
the high resistance wire connected between ignition been torqued.
switch and (+) positive terminal of coil, thus the starter Before adjusting the valve lash, it is extremely im­
solenoid is not functioning properly to bypass the ignition portant that the engine be thoroughly warmed up to
resistance wire or the ignition circuit is incorrectly normalize the expansion of all parts. This is very im­
portant because during the warm-up period, the valve
wired.
DistributorResistance
Use equipment as directed by manufacturer. Excessive
clearance will change considerably.
1. After the engine has been normalized, remove rocker
arm covers and gaskets.
resistance in primary circuit must be eliminated before
CAUTION: Do not pry rocker arm cover loose.
continuing with test procedure.
SecondaryResistance
Use equipment as directed by manufacturer.
Gaskets adhearing to cylinder head and rocker
arm cover may be sheared by bumping end of
rocker arm cover rearward with palm of hand or
• Uniform "normal readings" as specified by manu­ a rubber mallet.

CHEVROLET TRUCK SERVICE M ANUAL

ENGINE 6-10

Fig. 18— O il Deflector Clips Installed

ditional 1/4 turns, pausing 10 seconds each time,

until nut has been turned down 1 full turn from
the zero lash position.
NOTE: This 1 turn preload adjustment must be
Fig. 17—C ooling System Pressure Test
done slowly to allow the lifter to adjust itself to
prevent the possibility of interference, between
the inlet valve head and top of piston, which
2. With the engine running at idle, back off valve rocker
might result in internal damage and/or bent push
arm nut until the valve rocker arm starts to clatter.
rods. Noisy lifters should be replaced.
3. Turn rocker arm nut down slowly until the clatter
just stops. This is the zero lash position. 5. Repeat Steps 2, 3 and 4 to adjust the rest of
the valves.
NOTE: Oil deflector clips are commercially
6 . Clean gasket surfaces on cylinder heads and rocker
available (fig. 18).
arm covers with degreaser then install rocker arm
4. Turn nut down 1/4 additional turn and pause 10 covers, using new gaskets, and torque bolts to
seconds until engine runs smoothly. Repeat ad- specifications.

CHEVROLET TRUCK SERVICE M ANUAL

 ENGINE 6-11

ENGINE MECHANICAL
IN LINE
INDEX
Page Page
General D e s c r ip tio n ......................................................... 6-11 Oil P u m p ........................................................................ ...6-18
Component Replacement and A djustm ent........................ 6-11 Rem oval............... ........................................................ ...6-18
Engine A s s e m b lie s ......................................................... 6-11 In sta lla tio n .................................................................. ...6-18
Rem oval........................................................................ 6-11 Oil Seal (Rear M a in )...................................................... ...6-18
In sta llatio n .................................................................. 6-13 Replacement ............................................................... 6-18
Manifold A s se m b ly ......................................................... 6-14 Torsional D a m p e r ......................................................... ...6-18
Rem oval........................................................................ 6-14 R em oval........................................................................ ...6-18
In sta llatio n .................................................................. 6-14 In sta llatio n .................................................................. ...6-19
Rocker Arm C o v e r......................................................... 6-14 Crankcase Front C o v e r ................................................ ...6-20
Rem oval........................................................................ 6-14 R em oval........................................................................ ...6-20
In sta llatio n .................................................................. 6-14 In sta llatio n .................................................................. ...6-20
Valve M echanism............................................................ 6-14 Oil Seal (Front C o v e r )................................................... ...6-20
Removal ......................................................................... 6-14 Replacement.................................................................. ...6-20
Installation and A d ju stm e n t....................................... 6-15 C a m s h a ft ........................................................................ ...6-20
Valve L i f t e r s .................................................................. 6-15 Measuring Lobe L i f t ................................................... ...6-20
Locating Noisy L ift e r s ................................................ 6-15 Rem oval........................................................................ ...6-21
R em oval.............................. * ....................................... 6-15 In sta llatio n .................................................................. ...6-21
In sta lla tio n .................................................................. 6-15 Timing Gears ............................................................... ...6-22
Valve Stem Oil Seal and/or Valve S p r i n g .................. 6-16 Replacement ............................................................... ...6-22
R e p la c e m e n t............................................................... 6-16 Flywheel ........................................................................ ...6-22
Cylinder Head A sse m b lies............................................. 6-16 R em oval........................................................................ ...6-22
Rem oval......................................................................... 6-16 In sta llatio n .................................................................. ...6-22
In sta llatio n .................................................................. 6-16 Engine M o u n t s ............................................................... ...6-22
Oil P a n ............................................................................ 6-17 Replacement ( F r o n t ) ................................................... ...6-22
Rem oval......................................................................... 6-17 Replacement (Rear) ................................................... ...6-22
In sta llatio n .................................................................. 6-17

GENERAL DESCRIPTION
The In Line engines covered in this section are the Because of the interchangeability and sim ilarity of
230, 250 and 292 cu. in. L 6 engines used in 10-60 Series many engine sub-assemblies and parts, regardless of
truck vehicles. which truck vehicle they are used in, typical illustrations
This section covers the removal and installation of en­ and procedures are used (except where specific illus­
gine assem blies; the removal, installation and adjustment trations or procedures are necessary to clarify the
of some sub-assemblies and replacement of some com­ operation). Although illustrations showing bench opera­
ponents. For service to all components and sub- tions are used, most single operations, when not part of a
assem blies (after removal) and r e m o v a l of some general overhaul, should be performed (if practical) with
sub-assem blies, refer to Section 6 of the Truck Chassis the engine in the vehicle.
Overhaul Manual.

COMPONENT REPLACEMENT AND ADJUSTMENT

(IN LINE)
Engine Assemblies • Disconnect neutral safety switch wire at connector
(Powerglide).
Removal • Disconnect upper and lower radiator hoses at
1. Disconnect battery cables and drain cooling system. radiator.
2. Remove the air cleaner.
3. Perform the following preliminary operations. ON PS 10-20-30-40 SERIES:
• Remove the engine box, drivers seat, floor panel
ON CS 10-20-30, KS 10-20 SERIES:
between stepwells and floor panel around steering
• Remove the hood as outlined in Section 11.
column and pedals as outlined in Section IB .
• Remove the radiator and shroud as outlined in
• Remove the battery.
Section 13. • Remove the radiator and shroud as outlined in
Section 13.
ON CS 40-50-60, MS 50, SS 40-50 SERIES:
ON TS 40-50-60 SERIES
• Remove the front end sheet metal (with hood and • Remove the radiator, radiator support and shroud
radiator attached) as outlined in Section 11.
as outlined in Section 13.
ON GS 10-20 SERIES: • Disconnect shfft linkage at control island.
• Remove engine splash shields. • Disconnect choke cable at carburetor.

CHEVROLET TRUCK SERVICE MANUAL

ENGINE 6-12

• Disconnect emergency brake cable at emergency • Disconnect Powerglide cooler lines at both ends
brake and retaining brackets. then remove cooler lines.
• Remove bolts retaining control island to support • Place a suitable jack, with the engine cradle (Tool
and swing control island forward. J-21741) attached, under the engine (fig. 1L) then
• Disconnect hoses at radiator surge tank. take engine weight off mounts.
• Remove bolts retaining surge tank to island sup­
NOTE: Place the cradle so the forward legs of
port and remove surge tank.
the cradle straddle the fifth pan bolt from the
• Disconnect throttle cable at carburetor and re ­ rear of the engine then install the safety chain
taining brackets. over the flywheel housing.
• Remove left and right island supports.
• Disconnect cab safety lock at rear cab support. • Remove the engine mount bolts and the front mount
• Remove rear cab support. crossmember.
4. Disconnect wires at: 9. Remove engine from vehicle as follows.
• Starter Solenoid CAUTION: Check often during engine removal
• Delcotron to be sure all necessary disconnects have been
• Temperature Switch
made.
• Oil Pressure Switch
• Coil ON CS 10-20-30 SERIES:
5. Disconnect: • On vehicles with automatic or four speed trans­
• Accelerator linkage at manifold bellcrank. mission, remove rear mount crossmember.
• Choke cable at carburetor. • Raise engine and transmission assembly and pull
• Fuel line (from tank) at fuel pump. forward until removed.
• Heater hoses at engine connection. ON CS 40-50-60, KS 10-20, MS 50,
• Oil pressure gauge line (if so equipped). SS 40-50 SERIES:
• Vacuum or air lines at engine (as required). • Raise engine and pull forward until disconnected
• Power steering lines at pump end (if so equipped). from transmission.
• Ground straps at engine. • Continue to raise engine until removed from
• Exhaust pipe at manifold. vehicle.
NOTE: Hang exhaust pipe at frame with wire. ON GS 10-20 SERIES:
6 . Remove fan and pulley as outlined in Section 6 K. • Lower the engine and transmission assembly slow­
7. Remove clutch cross-shaft or disconnect clutch slave ly, pulling to the rear to clear the front axle.
cylinder (if so equipped). • Move engine and transmission assembly out from
8 . Perform the following operations: under vehicle.
ON PS 10-20-30-40 SERIES:
ON ALL SERIES EXCEPT GS 10-20: • Raise engine and push forward to clear cro ss­
• Remove the rocker arm cover as outlined. member and disconnect from transmission.
• Attach lifting adapter at proper cylinder head bolt • Remove engine from vehicle through right side
location. door opening.
• Attach lifting device and take engine weight off
mounts. ON TS 40-50-60 SERIES:
• Raise engine and pull forward until disconnected
NOTE: On Step Vans (PS Series) a crane type from transmission.
lift must be used. Bring arm of crane in right • Continue to raise engine until high enough to come
side door opening. out either side.
ON ALL SERIES EXCEPT CS 10-20-30, 10. If engine is to be mounted in an engine stand perform
GS 10-20: the following:
• Support transmission and disconnect from engine.
• Refer to "Section 7” . ON GS 10-20 SERIES:
• Remove engine mount bolts. • Remove the rocker arm cover as outlined.
• Attaching lifting adapter at proper cylinder head
ON CS 10-20-30, GS 10-20 SERIES: bolt location.
• Remove propeller shaft as outlined in Section 4. • Attach lifting device and remove engine assembly
from engine cradle.
NOTE: If plug for propeller shaft opening in ON CS 10-20-30, GS 10-20 SERIES:
transmission is not available, d r a i n • Remove synchromesh transmission and clutch (if
transmission. so equipped).
a. Remove clutch housing rear cover bolts.
• Disconnect speedometer cable at transmission. b. Remove bolts attaching the clutch housing to
• Disconnect shift linkage at transmission. engine block then remove transmission and
• Disconnect clutch linkage (as required). clutch housing as a unit.
• Remove engine mount bolts (exc. GS 10-20).
NOTE: Support the transmission as the last
ON GS 10-20 SERIES: mounting bolt is removed and as it is being
• Remove the flywheel housing bolt retaining starter pulled away from the engine, to prevent damage
wire harness clip and engine ground strap. to clutch disc.

CHEVROLET TRUCK SERVICE MANUAL

 ENGINE 6-13

a. Position engine adjacent to the transmission

and align the convertor with the flywheel.
b. Bolt transmission to engine then raise engine
and transmission assembly and install flywheel
to convertor bolts.
c. Install convertor housing underpan and starter.
d. Connect throttle linkage and vacuum modulator
line.
ON ALL SERIES EXCEPT CS 10-20-30,
GS 10-20:
• Install clutch assembly and clutch housing as out­
lined in Section 7.

ON GS 10-20 SERIES:
• Mount engine in engine cradle so the forward legs
of the cradle straddle the fifth pan bolt from the
rear of the engine.
• Remove the lifting device and lifter adapter from
cylinder head bolt location then torque cylinder
Fig. 1L—Engine C rad le Under Engine (G S 10-20) head bolts to specifications.
• Install rocker arm cover as outlined.
c. Remove starter and clutch housing rear cover. 2. Install engine in vehicle as follows:
d. Loosen clutch mounting bolts a turn at a time ON ALL SERIES EXCEPT CS 10-20-30,
(to prevent distortion of clutch cover) until the GS-10-20:
spring pressure is released. Remove all bolts, • Install engine and lower until transmission shaft
clutch disc and pressure plate assembly. lines up with clutch.
• Remove automatic transmission (if so equipped). • Push engine rearward and rotate crankshaft until
a. Lower engine, secured by the hoist, and sup­ transmission shaft and clutch engage.
port engine on blocks. • Install the engine mount bolts and torque to
b. Remove starter and converter housing under specifications.
pan. • Connect transmission to engine.
c. Remove flywheel-to-converter attaching bolts.
d. Support transmission on blocks. ON CS 10-20-30 SERIES:
e. Disconnect throttle linkage and vacuum modula­ • Lower engine and transmission assembly and push
tor line. rearward until engine mounts line up.
f. Remove transmission-to-engine mounting bolts. • On vehicles with automatic or four speed trans­
g. With the hoist attached, remove blocks from missions, install rear mount crossmember.
the engine only and slowly guide the engine • Install the engine mount bolts and torque to
from the transmission. specifications.
• Install the propeller shaft as outlined in Section 4.
ON ALL SERIES EXCEPT CS 10-20-30,
GS 10-20: ON GS 10-20 SERIES:
• Remove clutch housing. • Move engine and transmission assembly under
• Loosen clutch mounting bolts a turn at a time (to vehicle then raise engine and push forward until
prevent distortion of clutch cover) until the spring engine mounts line up.
pressure is released. Remove all bolts, clutch • Install the front mount crossmember and all en­
disc and pressure plate assembly. gine mount bolts and torque to specifications.
11. Mount engine in engine stand and remove lifting de­ • Remove jack and engine cradle from under engine.
vice and lifting adapter. • Install and connect transmission cooler lines (if
so equipped).
Installation • Install the flywheel housing bolt that retains start­
1. If engine was mounted in an engine stand, attach er wire harness clip and engine ground strap.
lifting adapter to engine then using lifting device, • Install the propeller shaft as outlined in Section 4.
remove engine from stand and perform the following: ON ALL SERIES EXCEPT GS 10-20:
ON CS 10-20-30, GS 10-20 SERIES: • Remove the lifting device and lifting adapter from
• Install synchromesh transmission and clutch (if cylinder head- bolt location then torque cylinder
so equipped). head bolts to specifications.
a. Install the clutch assembly on flywheel as out­ • Install rocker arm cover as outlined.
lined in Section 7. 3. Connect transmission linkage (as required).
b. Install clutch housing rear cover and starter. 4. Install clutch cross-shaft or connect clutch slave
c. Install the transmission and clutch housing as cylinder (as required).
outlined in Section 7. 5. Install fan and pulley as outlined in Section 6 K.
d. Install clutch housing rear cover bolts and 6. Connect:
torque to specifications. • Exhaust pipe at manifold.
• Install automatic transmission (if so equipped). • Power steering lines at pump (as required).

CHEVROLET TRUCK SERVICE MANUAL

ENGINE 6-14

• Vacuum or a ir lines at engine (as required). 7. Check for cracks in manifold castings.
• Oil pressure gauge line (as required). 8 . If necessary to replace either intake or exhaust
• Heater hoses at engine connection. manifolds, separate them by removing one bolt and
• Fuel line at fuel pump. two nuts at center of assembly. Reassemble mani­
• Choke cable at carburetor. folds using a new gasket. Tighten finger tight and
• Accelerator linkage at manifold bellcrank. torque to specifications after assembly to cylinder
7. Connect wires at: head. Transfer all necessary parts.
• Coil
Installation
• Oil Pressure Switch 1. Clean g a s k e t surfaces on cylinder head and
• Temperature Switch
manifolds.
• Delcotron
2. Position new gasket over manifold end studs on head
• Starter Solenoid
and carefully install the manifold in position making
8 . Complete installation as follows:
sure the gaskets are in place.
ON TS 40-50-60 SERIES: 3. Install bolts and clamps while holding manifold in
• Install rear cab support. place with hand.
• Connect cab safety lock at rear cab support. 4. Torque bolts to specifications.
• Install left and right island supports.
• Connect throttle cable at carburetor and retaining NOTE: Center bolt and end bolt torque differ.
brackets. 5. Connect exhaust pipe to manifold using a new
• Install radiator surge tank on island support and packing.
connect hoses to surge tank. 6 . Connect crankcase ventilation hose at rocker arm
• Swing control island rearward and connect to cover.
support. 7. Connect fuel and vacuum lines at carburetor.
• Connect emergency brake cable at emergency 8 . Connect choke cable and adjust as outlined in Sec­
brake and retaining brackets.
tion 6 M.
• Connect choke cable at carburetor and adjust. 9. Connect throttle rods at bellcrank and install throt­
• Connect shift linkage at control island.
tle return spring.
• Install the radiator, radiator support and shroud
10. Install air cleaner, start engine, check for leaks and
as outlined in Section 13.
adjust carburetor idle speed and mixture.
ON PS 10-20-30-40 SERIES:
• Install the radiator and shroud as outlined in Rocker Arm Cover
Section 13. Removal
• Install the battery. 1. Disconnect crankcase ventilation hose(s) at rocker
• Install the floor panel, drivers seat and engine arm cover.
box as outlined in Section IB . 2. Remove air cleaner.
ON GS 10-20 SERIES: 3. Disconnect temperature wire from rocker arm cover
• Connect neutral safety switch wire at connector clips.
(as required). 4. On TS 40-50-60 series, disconnect oil filler tube
• Install engine splash shields. at bracket.
5. Remove rocker arm cover.
ON CS 40-50-60, MS 50, SS 40-50 SERIES:
• Install the front end sheet metal (with hood and CAUTION: Do^ Not pry rocker arm cover loose.
radiator attached) as outlined in Section 11). Gaskets adhering to cylinder head and rocker
arm cover may be sheared by bumping end of
ON CS 10-20-30, KS 10-20 SERIES: rocker arm cover rearward with palm of hand
• Install the radiator and shroud as outlined in or a rubber mallet.
Section 13.
• Install the hood as outlined in Section 11. Installation
9. Install the air cleaner, connect battery cables, fill 1. Clean gasket surfaces on cylinder head and rocker
cooling system and crankcase then start engine and arm cover with degreaser then, using a new
check for leaks. gasket, install rocker arm cover and torque to
specifications.
Manifold Assembly 2. Connect temperature wire at rocker arm cover
clips.
Removal 3. Install air cleaner.
1. Remove air cleaner. 4. Connect crankcase ventilation hoses.
2. Disconnect both throttle rods at bellcrank and re ­
move throttle return spring. Valve Mechanism
3. Disconnect fuel and vacuum lines and choke cable at
Removal
carburetor.
1. Remove rocker arm cover as outlined.
4. Disconnect crankcase ventilation hose at rocker arm
2. Remove rocker arm nuts, rocker arm balls, rocker
cover.
arms and push rods.
5. Disconnect exhaust pipe at manifold flange and dis­
card packing. NOTE: Place rocker arms, rocker arm balls
6 . Remove manifold attaching bolts and clamps then re ­ and push rods in a rack so they may be re ­
move manifold assembly and discard gaskets. installed in the same location.

CHEVROLET TRUCK SERVICE M ANUAL

 ENGINE 6-15

Installation and Adjustment The lifters are extremely simple in design, readjust­
NOTE: Whenever new rocker arms and/or ments are not necessary, and servicing of the lifters
rocker arm balls are being installed, coat bear­ requires only that care and cleanliness be exercised in
ing surfaces of rocker arms and rocker arm the handling of parts.
balls with Molykote or its equivalent. Locating Noisy Lifters
1. Install push rods. Be sure push rods seat in lifter Locate a noisy valve lifter by using a piece of garden
socket. hose approximately four feet in length. Place one end of
2. Install rocker arms, rocker arm balls and rocker the hose near the end of each intake and exhaust valve
arm nuts. Tighten rocker arm nuts until all lash is with the other end of the hose to the ear. In this manner,
eliminated. the sound is localized making it easy to determine which
lifter is at fault.
3. Adjust valves when lifter is on base circle of cam­
shaft lobe as follows: Another method is to place a finger on the face of the
valve spring retainer. If the lifter is not functioning
a. Mark distributor housing, with chalk, at each properly, a distinct shock will be felt when the valve
cylinder position (plug wire) then disconnect plug returns to its seat.
wires at spark plugs and coil and remove distrib­ The general types of valve lifter noise are as follows:
utor cap and plug wire assembly (if not previ­ 1. Hard Rapping Noise - Usually caused by the plunger
ously done). becoming tight in the bore of the lifter body to such
b. Crank engine until distributor rotor points to an extent that the return spring can no longer push
number one cylinder position and breaker points the plunger back up to working position. Probable
are open. Both valves on number one cylinder causes are:
may now be adjusted. a. Excessive varnish or carbon deposit causing ab­
c. Back out adjusting nut until lash is felt at the push normal stickiness.
rod then turn in adjusting nut until all lash is b. Galling or “ pickup” between plunger and bore of
removed. This can be determined by checking lifter body, usually caused by an abrasive piece
push rod side play while turning adjusting nut of dirt or metal wedging between plunger and
(fig. 2L). When play has been removed, turn ad­ lifter body.
justing nut in one full additional turn (to center 2. Moderate Rapping Noise - Probable causes are:
lifter plunger). a. Excessively high leakdown rate.
d. Adjust the remaining valves, one cylinder at a b. Leaky check valve seat.
time, in the same manner. c. Improper adjustment.
4. Install distributor cap and spark plug wire assembly. 3. General Noise Throughout the Valve Train - This
5. Install rocker arm cover as outlined. will, in almost all cases, be a definite indication of
6 . Adjust carburetor idle speed and mixture. insufficient oil supply, or improper adjustment.
4. Intermittent Clicking - Probable causes are:
Valve Lifters a. A microscopic piece of dirt momentarily caught
Hydraulic valve lifters very seldom require attention. between ball seat and check valve ball.
b. In rare cases, the ball itself may be out-of-round
or have a flat spot.
c. Improper adjustment.
In most cases, where noise exists in one or more
lifters all lifter units should be removed, disassembled,
cleaned in a solvent, reassembled, and reinstalled in the
engine. If dirt, varnish, carbon, etc. is shown to exist in
one unit, it more than likely exists in all the units, thus
it would only be a matter of time before all lifters caused
trouble.
Removal
1. Remove valve mechanism as outlined.
2. Mark distributor housing, with chalk, at each cylin­
der position (plug wire) then disconnect plug wires
at spark plugs and coil and remove distributor cap
and plug wire assembly.
3. Crank engine until distributor rotor points to number
one position, then disconnect distributor primary
lead at coil and remove distributor.
4. Remove push rod covers (discard gaskets).
5. Remove valve lifters.
NOTE: Place valve lifters in a rack so they
may be reinstalled in the same location.
Installation
1. Install valve lifters.

Fig. 2L—V a lv e Adjustment

NOTE: Whenever new valve lifters are being

* CHEVROLET TRUCK SERVICE M ANUAL

 ENGINE 6-16

installed, coat foot of valve lifters with Molykote

or its equivalent.
2. Install push rod covers, using new gaskets, and
torque to specifications.
3. Install distributor, positioning rotor to number one
cylinder position, then connect primary lead at coil.
4. Install and adjust valve mechanism as outlined.
5. Adjust ignition timing and carburetor idle speed and
mixture.
Valve Stem Oil Seal and/or Valve Spring
Replacement
1. Remove rocker arm cover as outlined.
2. Remove spark plug, rocker arm and push rod on the
cylinder(s) to be serviced.
3. Apply compressed air to the spark plug hole to hold
the valves in place.
NOTE: A tool to apply air to the cylinder is
available through local jobbers or may be manu­
factured. In manufacturing this tool a AC-46N
Spark Plug or its equivalent is recommended.
This will make the tool universal for all Chevro­
let engines. Chisel the spark plug as shown, Fig. 4 L—Compressing V a lv e Spring
then drive the porcelain out of the plug by tap­
ping the center electrode against a hard block. 8. Install spark plug, using a new gasket, and torque to
Using a 3/8" pipe tap, cut threads in the re ­ specifications.
maining portion of the spark plug and assemble 9. Install and adjust valve mechanism as outlined.
as shown (fig. 3L).
Cylinder Head Assemblies
4. Using Tool J-5892 to compress the valve spring, Removal
remove the valve locks, valve cap (or rotator) valve 1. Remove manifold assembly as outlined.
shield and valve spring and damper (fig. 4L). 2. Remove valve mechanism as outlined.
5. Remove the valve stem oil seal. 3. Drain cooling system.
6 . To replace, set the valve spring and damper, valve 4. Remove fuel and vacuum line from retaining clip
shield and valve cap (or rotator) in place. The close at water outlet then disconnect wires from tempera­
coiled end of the spring is installed against the cyl­ ture sending units.
inder head. Compress the spring with Tool J-5892 5. Disconnect upper radiator hose at water outlet hous­
and install oil seal in the lower groove of the stem, ing and battery ground strap at cylinder head.
making sure the seal is flat and not twisted. 6 . Remove coil.

NOTE: A light coat of oil on the seal will help 7. Remove cylinder head bolts, cylinder head and gas­
prevent twisting. ket. Place cylinder head on two blocks of wood to
prevent damage.
7. Install the valve locks and release the compressor
Installation
tool, making sure the locks seat properly in the
upper groove of the valve stem. CAUTION: The gasket surfaces on both the
head and the block must be clean of any foreign
NOTE: Grease may be used to hold the locks
matter and free of nicks or heavy scratches.
in place while releasing the compressor tool.
Cylinder bolt threads in the block and threads on
the cylinder head bolt must be cleaned” (Dirt
will affect bolt torque). Do Not use gasket sealer
on composition steel asbestos gaskets.
1. Place the gasket in position over the dowel pins with
the bead up.
2. Carefully guide cylinder head into place over dowel
pins and gasket.
3. Coat threads of cylinder head bolts with sealing
compound and install finger tight.
4. Tighten cylinder head bolts a little at a time in the
sequence shown on the torque sequence chart until
the specified torque is reached.
5. Install coil (if removed).
6 . Connect upper radiator hose and engine ground strap.
7. Connect temperature sending unit wires and install
Fig . 3L—A ir Adapter Tool fuel and vacuum lines in clip at water outlet.

CHEVROLET TRUCK SERVICE MANUAL

 ENGINE 6-17

8 . F ill cooling system. 11. Remove the crossmember to frame bolts and lower
9. Install manifold assembly as outlined. the crossmember to rest on the front springs.
10. Install and adjust valve mechanism as outlined. 12. Remove oil pan and discard gaskets and seals.
NOTE: Do Not install rocker arm cover. CAUTION: If any further operations are to be
11. Start engine and allow to warm up retorque cylinder performed or the oil pan is not being reinstalled
head and readjust valves. immediately, the crossmember should be re-
installed and the engine lowered.
Oil Pan
Installation
ExceptGS10-20Series
Removal

1. Disconnect battery ground cable then remove starter.

1. Thoroughly clean all gasket sealing surfaces.
2. Install new rear seal in rear main bearing cap.
2. On CS 10-20-30. 3. Install new front seal on crankcase front cover
a. Remove engine front mount bolts (frame bracket- pressing tips into holes provided in cover.
to-mount). 4. Install new side gaskets on cylinder block (fig. 6 L).
b. Using a suitable jack with a flat piece of wood 5. Install oil pan and torque bolts to specifications.
(to prevent damaging oil pan), raise engine enough NOTE: Bolts into crankcase cover should be
to insert 2" x 4” wood blocks between the engine installed last. They are installed at an angle
mounts and frame brackets. and holes line up after rest of pan bolts are
3. Drain engine oil. snugged up.
4. Remove oil pan and discard gaskets and seals.
GS10-20Series
1. Disconnect the battery ground cable.
6. Complete installation as follows:

2. Remove the fan and pulley as outlined in Section 6 K.

3. Remove the engine splash shields and the starter.
4. Remove the engine front mount bolts (frame bracket-
to-mount).
5. On vehicles equipped with automatic transmissions,
remove the cooler lines.
6. Drain the radiator and disconnect the lower radiator
hose at the radiator.
7. Remove accessory drive pulley (if so equipped).
8. Remove the shroud.
9. Install Tool J - 6978-1 on the torsional damper. Place
the shoulder of the tool toward damper (fig. 5L).
10. Place a suitable jack, or jack stand under Tool
J-69 7 8 -1 and raise the engine enough to clear the
front mounts (fig. 5L).

Fig . 5 L—Supporting the Engine ( G .S . 100-200) Fig . 6L—O il Pan G asket and Seal Location

CHEVROLET TRUCK SERVICE M ANUAL

ENGINE 6-18

EXCEPT GS 10-20-30 SERIES hammer to tap a brass pin punch on one end of seal
a. ON CS 10-20-30: until it protrudes far enough to be removed with
• Using a suitable jack with a flat piece of wood pliers (fig. 8 L).
(to prevent damaging oil pan), raise engine
NOTE: Always wipe crankshaft surface clean
enough to remove 2" x 4" wood blocks from
before installing a new seal. Also clean seal
between the engine mounts and frame brackets.
groove.
• Lower engine, install front mount bolts and
torque to specifications. 5. Lubricate the lip and O.D. of a new seal with engine
b. Install starter and connect battery cable. oil. Keep oil off the parting line surface. Gradually
GS 10-20 SERIES push with a hammer handle, while turning crank­
a. I n s t a l l t h e crossmember and torque to shaft, until seal is rolled into place. (Similar to
specifications. installing a main bearing). Be careful that seal bead
b. Lower the engine to rest on the front mounts then on O.D. is not cut. Compress seal towards crank­
remove the jack stand and Tool J - 6978-1. shaft as much as possible.
c. Install the front mount b o l t s and torque to 6 . Install the rear main bearing cap (with new seal) and

specifications. torque to specifications. Be sure cross seal tabs

d. Install the shroud and connect lower radiator are in place and properly seated.
hose.
e. Install the accessory drive pulley (if so equipped).
f. On vehicles equipped with automatic transm is­ Torsional Damper
sion install the cooler lines.
g. Install the starter and engine splash shields. Removal
h. Install the fan and pulley as outlined in Section 1. Drain radiator and disconnect radiator hoses at
6 K. radiator.
i . Connect the battery cable. 2. Remove radiator core, as outlined in Section 13.
7. Fill with coolant and engine oil then start engine 3. Remove fan belt and (if so equipped) accessory drive
and check for leaks. pulley and belt. If so equipped, remove retaining
bolt.
Oil Pump 4. Install Tool J-6978 to damper and turn puller screw
to remove damper (fig. 9L). Remove tool from
Removal damper.
1. Remove oil pan as outlined.
2. Remove two flange mounting bolts, pickup pipe
bolt, then remove pump and screen as an assembly.

Installation
1. Align oil pump drive shafts to match with distributor
tang, then install oil pump to block positioning flange
over distributor lower bushing. Use no gasket.
NOTE: Oil pump should slide easily into place,
if not, remove and reposition slot to align with
distributor tang.
2. Install oil pan as outlined.

Oil Seal (Rear Main)

Replacement
The rear main bearing oil seal can be replaced (both
halves) without removal of the crankshaft.
NOTE: Always replace the upper and lower
seal as a unit. Install with the lip facing toward
the front of the engine.
1. With the oil pan removed, remove the rear main
bearing cap.
2. Remove oil seal from the groove by lifting the end
tab (fig. 7L) then clean seal groove.
3. Lubricate the lip and O.D. of a new seal with engine
oil. Keep oil off the parting line surface. Insert seal
in cap and roll it into place with finger and thumb,
using light pressure so beads on seal O.D. are not
cut by seal groove at cap parting line. Be sure tabs
on seal are properly located in cross grooves.
4. To remove the upper half of the seal, use a small Fig . 7 L—Removing O il Seal (Lower H alf)

CHEVROLET TRUCK SERVICE M ANUAL

 ENGINE 6-19

Fig. 10L— Installing Torsional Damper

Installation
CAUTION: The inertia weight section of the
torsional damper is assembled to the hub with a
rubber type material. The installation proce­
dures (with proper tool) must be followed or
movement of the inertia weight section on the
hub will destroy the tuning of the torsional
damper.

1. Coat front seal contact area (on damper) with engine

oil.
2. Install torsional damper as follows:
DRIVE ON TYPE (Without retaining bolt)
a. Attach damper installer Tool J - 22197 to damper.
Tighten fingers of tool to prevent inertia weight
Fig. 8L— Removing O il Seal (Upper H alf) from moving (fig. 10L).
b. Position damper on crankshaft and drive into
position until it bottoms against crankshaft gear
(fig. 10L). Remove installer tool.
PULL ON TYPE (With retaining bolt)
a. Use a 7/16"-20 x 4" bolt, nut and washer to pull
torsional damper onto crankshaft.

F ig . 9 L —Removing Torsional Damper Fig . 11L—J —21742 Centering Tool in Cover

CHEVROLET TRUCK SERVICE M ANUAL

ENGINE 6-20

CAUTION: Install bolt in crankshaft with suf-

ficient thread engagement (min. l / 2 t?)I
b. Remove bolt, nut and washer and install retaining
bolt and torque to specifications.
3. Install fan belt and adjust using strand tension gauge.
4. If so equipped, install accessory drive pulley and
belt.
5. Install radiator core as outlined in Section 13.
6. Connect radiator hoses.
7. F ill cooling system and check for leaks.

Crankcase Front Cover

Removal
1. Remove oil pan as outlined.
2. Remove crankshaft pulley and hub or damper as
outlined.
3. Remove crankshaft front cover attaching screws,
remove cover and gasket.
Installation
1. Clean gasket surfaces on block and crankcase front
cover.
2. Install centering Tool J-0966 or centering Tool
J - 21742 in crankcase front cover seal (fig. 11L).
3. Coat the gasket with gasket sealer and place in posi­
tion on cover, then install crankcase front cover to
block and torque to specifications.
4. Remove centering tool.

NOTE: It is important that centering tool be

Fig. 12L— Installing O il Seal (C o ve r Removed)
used to align crankcase front cover so that
crankshaft hub or damper installation will not rod in consecutive order and record th e
damage seal and to position seal to seal evenly readings.
around the damper or hub surface.
1. Remove valve mechanism as outlined.
5. Install crankshaft hub and/or damper as outlined. 2. Position indicator with ball socket adapter on push
6 . Install oil pan as outlined.
rod (fig. 14L).

Oil Seal (Front Cover)

Replacement
W
ithCoverRem
oval
1. With cover removed, pry old seal out of cover from
the front with a large screw driver.
2. Install new seal so that open end of the seal is to­
ward the inside of cover and drive it into position
with Tool J-9 9 5 (fig. 12 L).
CAUTION: Support cover at sealing area. (Tool
J-971 may be used as support).

W
ithoutCoverRem
oval
1. With crankshaft pulley and hub or damper removed,
pry old seal out of cover from the front with a large
screw driver, being careful not to damage the seal
surface on the crankshaft.
2. Install new seal so that open end of seal is toward
the inside of cover and drive it into position with
Tool J-8340 (fig. 13L).

Camshaft
Measuring Lobe Lift
NOTE: Procedure is sim ilar to that used for
checking valve timing. If improper valve opera­
tion is indicated, measure the lift of each push Fig. 13L— Installing O il Seal (C over Installed)

CHEVROLET TRUCK SERVICE M ANUAL

 ENGINE 6-21

T IM IN G
M ARKS

TH RUST
PLATE
SCREW S

Fig. 15L—Timing G e a r Marks

block, being careful not to damage camshaft bearings

or camshaft.
2. Turn crankshaft and camshaft so that the valve tim­
ing marks on the gear teeth will line up (fig. 19L).
Push camshaft into position. Install camshaft thrust
Fig. 14L—M easuring Camshaft Lobe Lift
plate to block screws and torque to specifications.
3. Check camshaft and crankshaft gear run out with a
3. Rotate the torsional damper slowly in the direction dial indicator (fig. 16L). The camshaft gear run out
of rotation until the lifter is on the heel of the cam should not exceed .004" and the crankshaft gear run
lobe. At this point, the push rod will be in its lowest out should not exceed .003”.
position. 4. If gear run out is excessive, the gear will have to be
4. Set dial indicator on zero, then rotate the damper removed and any burrs cleaned from the shaft or
slowly, or attach an auxiliary starter switch and the gear will have to be replaced.
“bump” the engine over, until the push rod is in the 5. Check the backlash between the timing gear teeth
fully raised position. with a dial indicator (fig. 17L). The backlash should
CAUTION: The primary distributor lead must not be less than .004” nor more than .006".
be disconnected from the negative post on the
coil and the ignition switch must be in the on
position. Failure to do this will result in a
damaged grounding circuit in the ignition switch.
5. Compare the total lift recorded from the dial indica­
tor with specifications.
6 . Continue to rotate the crankshaft until the indicator
reads zero. This will be a check on the accuracy of
the original indicator reading.
7. If camshaft readings for all lobes are within speci­
fications, remove dial indicator assembly.
8 . Install and adjust valve mechanism as outlined.
Removal
1. Remove valve lifters as outlined.
2. Remove crankcase front cover as outlined.
3. Remove grille as outlined in Section 13.
4. Remove fuel pump as outlined in Section 6 M.
5. Align timing gear marks then remove the two cam­
shaft thrust plates screws by working through holes
in the camshaft gear (fig. 15L).
6 . Remove the camshaft and gear assembly by pulling
it out through the front of the block.
NOTE: Support camshaft carefully when r e ­
moving so as not to damage camshaft bearings.
Installation
1. Install the camshaft and gear assembly in the engine Fig . 16 L —Checking Camshaft G e ar Runout

CHEVROLET TRUCK SERVICE MANUAL

ENGINE 6-22

Fig. 19L— Installing Crankshaft G e a r

NOTE: On Automatic Transmission equipped

engines, the flywheel must be installed with the
flange collar to transmission side (fig. 20L).
3. Install flywheel retaining bolts and torque to
specifications.
NOTE: The interference fit dowel pins used on
292 cu. in. engines must be replaced with an
Fig. 17L—C hecking Timing G e a r Backlash oversize dowel pin when installing the flywheel.
Remove the old dowel pins and install the fly­
6. Install fuel pump as outlined in Section 6 M. wheel as outlined above then, using Tool
7. Install grille as outlined in Section 13. J - 7049-2 ream the dowel pin hole and install
8 . Install crankcase front cover as outlined. new dowel pins.
9. Install valve lifters as outlined.
Engine Mounts
Timing Gears Engine mounts (fig. 21L) are the non-adjustable type
Replacement and seldom require service. Broken or deteriorated
With camshaft removed, crankshaft gear may be re­ mounts should be replaced immediately, because of the
moved using Tool J-8105 (fig. 18L). To install crankshaft added strain placed on other mounts and drive line
gear use Tool J-5590 (fig. 19L). For camshaft gear components.
replacement, refer to "Camshaft Disassembly" in the Front Mount Replacement
Chassis Overhaul Manual. 1. Remove frame bracket to mount bolt.
Flywheel 2. Raise engine enough to clear mount.
3. Remove mount and install new mount.
Removal
4. Install new mount and torque bolts to specifications.
With transmission and/or clutch housing and clutch
5. Lower engine then install frame bracket to mount
removed from engine, remove the flywheel.
bolt and torque to specifications.
Installation
Rear Mount Replacement
1. Clean the mating surfaces of flywheel and crankshaft
to make certain there are no burrs.
2. Install flywheel on crankshaft and position to align
ExceptGS10-20Series
1. Raise and support vehicle.
dowel hole of crankshaft flange and flywheel (fig.
20L).
CONVERTER l ^ R I N G
BOLT AREA GEAR
DEPRESSED

WELDS

^ENGINE TRANS.

SYNCHROMESH AUTOMATIC

F ig . 18L—Removing Crankshaft G ear Fig . 20L—Flyw heel Installation (T y p ica l)

CHEVROLET TRUCK SERVICE MANUAL

 ENGINE 6-23

Fig. 21 L— Engine Mounts

2. Bend mount bolt french lock tabs away from bolt sion from the vehicle. Replace both halves as a unit.
head, then remove mount bolts, lower mount and 1. Position the fan blade with the blades pointing at the
spacer. four corners of the radiator and insert a piece of
3. Raise engine enough to clear upper mount assembly heavy corrugated cardboard between the fan and the
and remove upper mount from frame member. radiator. (This will prevent the fan from damaging
the radiator in the event the engine is lowered
NOTE: On models using a propeller shaft brake
too far).
of any type, it is necessary to remove screws
2. Raise the vehicle and remove the rear support nut.
from transmission hole cover to allow the engine
3. Place a jack or jack stand under the transmission
to raise because of the limited clearance be­
extension and raise until the pressure is off the
tween the brake and transmission hole cover.
rear support.
4. Place new upper mount in place on frame member, 4. Remove the rear support bolt and lower the jack
then lower engine within 1/4 inch of mount. until the rear support is clear of the frame.
5. Align mount so guide dowel enters hole in mount, 5. Remove both halves of the rear support.
install bolt through french lock, lower mount and 6 . Install a new rear support (both halves).
spacer, then install bolt up through frame, upper 7. Raise the jack until the rear support hole lines up
mount and thread into engine bell housing loosely. and install the rear support bolt.
6 . Lower engine completely and tighten mount bolt, 8 . Remove the jack and install the rear support bolt
then bend tabs of french lock to lock the bolt in place. nut and torque to specifications.
GS 10-20Series
The two piece rear support in transmission case ex­
9. Lower the vehicle and remove the cardboard from
between the fan and radiator.
tension may be removed without removing the transm is­

CHEVROLET TRUCK SERVICE MANUAL

ENGINE 6-24

ENGINE MECHANICAL
V-8
IN D EX

Page Page
General D e s c r ip tio n ......................................................... 6-24 Oil P u m p ........................................................................ ...6-31
Component Replacement and Adjustment ( V 8 ) ............... 6-24 Rem oval........................................................................ ...6-31
Engine A s s e m b lie s ......................................................... 6-24 In sta lla tio n .................................................................. ...6-31
R em oval............... ......................................................... 6-24 Oil Seal (Rear M a in )...................................................... ...6-31
In stallatio n ....................................... .......................... 6-26 Replacement.................................................................. ...6-31
Intake M an ifold............................................................... 6-27 Torsional D a m p e r ......................................................... ...6-32
Removal .........................................................................6-27 Rem oval........................................................................ ...6-32
In sta llatio n ...................................................................6-27 In s ta lla tio n .................................................................. ...6-32
Exhaust M an ifold ............................................................ 6-27 Crankcase Front Cover ................................................ ...6-33
Rem oval........................................................................ 6-27 Removal ............................................................................6-33
In sta llatio n .................................................................. 6-27 In sta lla tio n .................................................................. ...6-33
Rocker Arm C o v e r......................................................... 6-28 Oil Seal (Front C o v e r )................................................... ...6-33
Rem oval........................................................................ 6-28 Replacement.................................................................. ...6-33
In sta llatio n .................................................................. 6-28 Timing Chain and/or Sprockets.................................... ...6-34
Valve Mechanism............................................................ 6-28 Replacement.................................................................. ...6-34
Rem oval........................................................................ 6-28 C a m s h a ft ........................................................................ ...6-35
Installation and A d ju stm en t....................................... 6-28 Measuring Lobe L i f t ................................................... ...6-35
Valve L i f t e r s .................................................................. 6-29 R em oval........................................................................ ...6-36
Locating Noisy L ift e r s ................................................ 6-29 In s ta lla tio n .................................................................. ...6-36
Rem oval........................................................................ 6-29 Timing G e a r s .................................................................. 6-37
In sta llatio n .................................................................. 6-29 Replacement.................................................................. 6-37
Valve Stem Oil Seal and/or Valve S p r i n g .................. 6-29 Flywheel ........................................................................ 6-37
R e p la c e m e n t............................................................... 6-29 R em oval........................................................................ 6-37
Cylinder Head A ssem b lies............................................. 6-30 In s ta lla tio n .................................................................. 6-37
Rem oval........................................................................ 6-30 Engine M o u n t s ............................................................... 6-37
In sta llatio n .................................................................. 6-30 Replacement (F r o n t )................................................... 6-37
Oil P a n ........................................................................... 6-30 Replacement (Rear) ................................................... 6-38
Rem oval........................................................................ 6-30
In stallatio n ........................ ..........................................6-30

GENERAL DESCRIPTION
The V8 engines covered in this section are the 283, Because of the inter changeability and similarity of
327 and 366 cu. in. engines used in 10-60 Series Truck many engines, engine sub-assemblies and parts regard­
vehicles. less of which passenger vehicle they are used in, typical
This section covers the removal and installation of illustrations and procedures are used (except where
engine assemblies; the removal, installation and adjust­ specific illustrations or procedures are necessary to
ment of some sub-assemblies and replacement of some clarify the operation). Although illustrations showing
components. For service to all components and sub- bench operations are used, most single operations, when
assemblies (after removal) and removal of some sub- not part of a general overhaul, should be performed (if
assemblies, refer to Section 6 of the Truck Chassis practical) with the engine in the vehicle.
Overhaul Manual.

COMPONENT REPLACEMENT AND ADJUSTMENT

(V8)
Engine Assemblies
ON GE 10-20 SERIES:
Removal
• Remove engine splash shields.
1. Disconnect battery cables and drain cooling system.
• Disconnect neutral safety switch wire at connector
2. Remove the air cleaner.
(Powerglide).
3. Perform the following preliminary operations:
• Disconnect upper and lower radiator hoses at
ON CE 10-20-30, KE 10-20 SERIES: radiator.
• Remove the hood as outlined in Section 11.
ON TE 40-50-60 SERIES:
• Remove the radiator and shroud as outlined in
• Remove the radiator, radiator support and shroud
Section 13.
as outlined in Section 13.
ON CE 40-50-60, KE 10-20, ME 50-60, • Disconnect shaft linkage at control island.
SE 50-60 SERIES: • Disconnect choke cable at carburetor.
• Remove the front end sheet metal (with hood and • Disconnect emergency brake cable at emergency
radiator attached) as outlined in Section 11. brake and retaining brackets.

CHEVROLET TRUCK SERVICE M ANUAL

 ENGINE 6-25

• Remove bolts retaining control island to support

and swing control island forward.
• Disconnect hoses at radiator surge tank.
• Remove bolts retaining surge tank to island sup­
port and remove surge tank.
• Disconnect throttle cable at carburetor and re­
taining brackets.
• Remove left and right island supports.
• Disconnect cab safety lock at rear cab support.
• Remove rear cab support.
4. Disconnect wires at:
• Starter Solenoid
• Delcotron
• Temperature Switch
• Oil Pressure Switch
• Coil
5. Disconnect:
• Accelerator linkage at manifold bellcrank
• Choke cable at carburetor.
• Fuel line (fro m tank) at fu el pump. Fig. IV —Engine C rad le Under Engine (G E 10-20)
• Heater hoses at engine connection.
• Oil pressure gauge line (if so equipped). rear of the engine then install the safety chain
• Vacuum or air lines at engine (as required). over the flywheel housing.
• Power steering lines at pump end (if so equipped).
• Ground straps at engine. • Remove the engine mount bolts and the front mount
• Exhaust pipe at manifold. crossmember.
9. Remove engine from vehicle as follows:
NOTE: Hang exhaust pipe at frame with wire.
CAUTION: Check often during engine removal
6 . Remove fan and pulley as outlined in Section 6 K. to be sure all necessary disconnects have been
7. Remove clutch cross-shaft or disconnect clutch slave
made.
cylinder (if so equipped).
8 . Perform the following operations: ON CE 10-20-30 SERIES:
• On vehicles with automatic or four speed trans­
ON ALL SERIES EXCEPT GE 10-20: missions, remove rear mount crossmember.
• Remove the rocker arm covers as outlined. • Raise engine and transmission assembly and pull
• Attach lifting adapter at proper cylinder head forward until removed.
bolt location.
• Attach lifting device and take engine weight off ON CE 40-50-60, KE 10-20, ME 50-60, SE
SE 50-60 SERIES:
ON ALL SERIES EXCEPT CE 10-20-30, • Raise engine and pull forward until disconnected
GE 10-20: from transmission.
• Support transmission and disconnect from engine. • Continue to raise engine until removed from
• Remove engine mount bolts. vehicle.

ON ALL SERIES EXCEPT CE 10-20-30, ON GE 10-20 SERIES:

GE 10-20: • Lower the engine and transmission assembly slow­
• Remove propeller shaft as outlined in Section 4. ly, pulling to the rear to clear the front axle.
• Move engine and transmission assembly out from
NOTE: If plug for propeller shaft opening in
under vehicle.
t r a n s m i s s i o n is not available, d r a i n
transmission. ON TE 40-50-60 SERIES:
• Raise engine and pull forward until disconnected
• Disconnect speedometer cable at transmission.
from transmission.
• Disconnect shift linkage at transmission.
• Continue to raise engine until high enough to come
• Disconnect clutch linkage (as required).
out either side.
• Remove engine mount bolts (exc. GE 10-20).
10. If engine is to be mounted in an engine stand perform
the following:
ON GE 10-20 SERIES:
• Remove the flywheel housing bolt retaining starter ON GE 10-20 SERIES:
wire harness clip and engine ground strap. • Remove the rocker arm covers as outlined.
• Disconnect Powerglide cooler lines at both ends • Attach lifting adapter at proper cylinder head bolt
then remove cooler lines. location.
• Place a suitable jack, with the engine cradle (Tool • Attach lifting device and remove engine assembly
J - 21741) attached, under the engine (fig. IV) then from engine cradle.
take engine weight off mounts.
ON CE 10-20-30 SERIES, GE 10-20 SERIES:
NOTE: Place the cradle so the forward legs of • Remove synchromesh transmission and clutch (if
the cradle straddle the fifth pan bolt from the so equipped).

CHEVROLET TRUCK SERVICE M ANUAL

ENGINE 6-26

a. Remove clutch housing rear cover bolts. ON GE 10-20 SERIES:

b. Remove bolts attaching the clutch housing to • Mount engine in engine cradle so the forward legs
engine block then remove transmission and of the cradle straddle the fifth pan bolt from the
clutch housing as a unit. rear of the engine.
• Remove the lifting device and lifter adapter from
NOTE: Support the transmission as the last
cylinder head bolt location then torque cylinder
mounting bolt is removed and as it is being
head bolts to specifications.
pulled away from the engine, to prevent damage
• Install rocker arm covers as outlined.
to clutch disc.
2. Install engine in vehicle as follows:
c. Remove starter and clutch housing rear cover. ON ALL SERIES EXCEPT CE 10-20-30,
d. Loosen clutch mounting bolts a turn at a time
GE 10-20:
(to prevent distortion of clutch cover) until the
• Install engine and lower until transmission lines up
spring pressure is released. Remove all bolts,
with clutch.
clutch disc and pressure plate assembly.
• Push engine rearward and rotate crankshaft until
• Remove automatic transmission (if so equipped).
transmission shaft and clutch engage.
a. Lower engine, secured by the hoist, and support
• Install the engine mount bolts and torque to
engine on blocks.
specifications.
b. Remove starter and converter housing under
pan. • Connect transmission to engine.
c. Remove flywheel-to-converter attaching bolts. ON CE 10-20-30 SERIES:
d. Support transmission on blocks. • Lower engine and transmission assembly and push
e. Disconnect throttle linkage and vacuum modu­ rearward until engine mounts line up.
lator line. • On vehicles with automatic or four speed trans­
f . Remove transmission-to-engine mounting bolts. missions, install rear mount crossmember.
g. With the hoist attached, remove blocks from the • Install the engine mount bolts and torque to
engine only and slowly guide the engine from specifications.
the transmission. • Install the propeller shaft as outlined in Section 4.
ON ALL SERIES EXCEPT CE 10-20-30, ON GE 10-20 SERIES:
GE 10-20: • Move engine and transmission assembly under
• Remove clutch housing. vehicle then raise engine and push forward until
• Loosen clutch mounting bolts a turn at a time (to engine mounts line up.
prevent distortion of clutch cover) until the spring • Install the front mount crossmember and all en­
pressure is released. Remove all bolts, clutch gine mount bolts and torque to specifications.
disc and pressure plate assembly. • Remove jack and engine cradle from under engine.
11. Mount engine in engine stand and remove lifting • Install and connect transmission cooler lines (if
device and lifting adapter. so equipped).
• Install the flywheel housing bolt that retains start­
Installation er wire harness clip and engine ground strap.
1. If engine was mounted in an engine stand, attach • Install the propeller shaft as outlined in Section 4.
lifting adapter to engine then using lifting device,
remove engine from stand and perform the following: ON ALL SERIES EXCEPT GE 10-20:
ON CE 10-20-30, GE 10-20 SERIES: • Remove the lifting device and lifting adapter from
• Install synchromesh transmission and clutch (if so cylinder head bolt location then torque cylinder
equipped). head bolts to specifications.
a. Install the clutch assembly on flywheel as out­ • Install rocker arm covers as outlined.
lined in Section 7. 3. Connect transmission linkage (as required).
b. Install clutch housing rear cover and starter. 4. Install clutch cross-shaft or connect clutch slave
c. Install the transmission and clutch housing as cylinder (as required).
outlined in Section 7. 5. Install fan and pulley as outlined in Section 6 K.
d. Install clutch housing rear cover bolts and 6. Connect:
torque to specifications. • Exhaust pipe at manifold.
• Power steering lines at pump (as required).
• Install automatic transmission (if so equipped).
•Vacuum or air lines at engine (as required).
a. Position engine adjacent to the transmission
•Oil pressure gauge line (as required).
and align the converter with the flywheel.
• Heater hoses at engine connection.
b. Bolt transmission to engine then raise engine
• Fuel line at fuel pump.
and transmission assembly and install flywheel
• Choke cable at carburetor.
to converter bolts.
• Accelerator linkage at manifold bellcrank.
c. Install converter housing underpan and starter.
7. Connect wires at:
d. Connect throttle linkage and vacuum modulator
line. • Coil
• Oil Pressure Switch
ON ALL SERIES EXCEPT CE 10-20-30, • Temperature Switch
GE 10-20: • Delcotron
• Install clutch assembly and clutch housing as out­ • Starter Solenoid
lined in Section 7. 8 . Complete installation as follows:

1
CHEVROLET TRUCK SERVICE MANUAL
 ENGINE 6-27

ON TE 40-50-60 SERIES: 2. Install manifold seals on block and gaskets on cyl­

• Install rear cab support. inder heads (fig. 2V). Use sealer at water passages
• Connect cab safety lock at rear cab support. and where seals butt to gaskets.
• Install left and right island supports. 3. Install manifold and torque bolts to specifications in
• Connect throttle cable at carburetor and retaining the sequence outlined on the torque sequence chart.
brackets. 4. Install (if removed) oil filler bracket, air cleaner
• Install radiator surge tank on island support and bracket, air compressor and bracket, coil, accelera­
connect hoses to surge tank. tor return spring and bracket and accelerator
• Swing control island rearward and connect to bellcrank.
support. 5. Install distributor, positioning rotor at chalk mark,
• Connect emergency brake cable at emergency then install distributor cap.
brake and retaining brackets. 6 . Connect:
• Connect choke cable at carburetor and adjust. • Spark advance hose and governor line (if so
• Connect shift linkage at control island. equipped) at distributor.
• Install the radiator, radiator support and shroud • Crankcase ventilation lines (as required).
as outlined in Section 13. • Fuel line and choke cable at carburetor.
ON GE 10-20 SERIES: • Accelerator linkage at pedal lever.
• Water pump bypass at water pump (use new
• Connect neutral safety switch wire at connector
(as required). gasket).
• Install engine splash shields. • Battery cables at battery.
7. Adjust choke cable and accelerator linkage as out­
ON CE 40-50-60, ME 50-60, lined.
SE 50-60 SERIES: 8 . Install air cleaner.
• Install the front end sheet metal (with hood and 9. Fill with coolant, start engine, adjust ignition timing
radiator attached) as outlined in Section 11. and carburetor idle speed and mixture and check for
leaks.
ON CE 10-20-30, KE 10-20 SERIES:
• Install the radiator and shroud as outlined in
Section 13.
• Install the hood as outlined in Section 11. Exhaust Manifolds
9. Install the air cleaner, connect battery cables, fill
cooling system and crankcase then start engine and Removal
check for leaks. NOTE: On 10 Series equipped with Air Injection
Reactor System, disconnect air manifold as out­
lined in Section 6 T.
Intake Manifold
1. On vehicles so equipped, remove carburetor heater.
Removal 2. On left exhaust manifold, disconnect and remove
1. Drain radiator and remove air cleaner. Delcotron.
2. Disconnect: 3. On 366 cu. in. engines, remove spark plug and spark
• Battery cables at battery. plug shields.
• Upper radiator hose and heater hose at manifold. 4. Disconnect exhaust pipe from manifold and hang
• Water pump bypass at water pump. exhaust pipe from frame with wire.
• Accelerator linkage at pedal lever. 5. Bend french lock tabs, remove end bolts then remove
• Fuel line and choke cable at carburetor. center bolts and remove manifold.
• Crankcase ventilation lines (as required).
NOTE: A 9/16 thin-wall 6 point socket, sharp­
• Spark advance hose and governor line (if so ened at the leading edge, and started on the head
equipped) at distributor.
of the bolt and tapped in place with a hammer,
3. Remove distributor cap and mark rotor position with
simplifies bending of french locks.
chalk, then remove distributor.
4. Remove (as required) oil filler bracket, air cleaner
bracket, air compressor and bracket, coil, accelera­ Installation
tor return spring and bracket, and accelerator 1. Clean mating surfaces on manifold and head, then
bellcrank. install manifold in position and install center bolts
5. Remove manifold attaching bolts, then remove mani­ (finger-tight).
fold and carburetor as an assembly. Discard gaskets 2. Install end bolts with french locks, then torque all
and seals. bolts to specifications and bend french locks on end
6 . If manifold is to be replaced, transfer: bolts.
• Carburetor and carburetor mounting studs. 3. Connect exhaust pipe to manifold. Use new gasket or
• Temperature sending unit. packing.
• Water outlet and thermostat (use new gasket). 4. On 366 cu. in. engines, install spark plug shields and
• Heater hose and water pump bypass adapters. spark plugs. Torque plugs to specifications.
5. On left exhaust manifold, install and connect Delco­
Installation tron. Adjust belt as outlined in Engine Tune Up.
1. Clean gasket and seal surfaces on manifold, block, 6 . On vehicles so equipped, install carburetor heater.
and cylinder heads. 7. Start engine and check for leaks.

CHEVROLET TRUCK SERVICE MANUAL

ENGINE 6-28

REAR SEAL

FRONT SEAL

Fig. 2 V — Intake M anifo ld G asket and Seal Location Fig. 3V—V a lv e Adjustment

Rocker Arm Cover Installation and Adjustment

Removal NOTE: Whenever new rocker arms and/or
1. Remove air cleaner. rocker arm balls are being installed, coat bear­
2. On 366 cu. in. engines, disconnect crankcase ventila­ ing surfaces of rocker arms and rocker arm
tion hoses at rocker arm cover. balls with Molykote or its equivalent.
3. Disconnect temperature wire from left rocker arm
clips. 1. Install push rods. Be sure push rods seat in lifter
socket.
4. On vehicles so equipped, remove carburetor heater
from left exhaust manifold. 2. Install rocker arm s, rocker arm balls and rocker
5. Remove rocker arm cover. arm nuts. Tighten rocker arm nuts until all lash is
eliminated.
CAUTION: Do Not pry rocker arm cover loose. 3. Adjust valves when lifter is on base circle of cam­
Gaskets adhearing to cylinder head and rocker shaft lobe as follows:
arm cover may be sheared by bumping end of a. Crank engine until mark on torsional damper
rocker arm cover rearward with palm of hand lines up with center or “O” mark on the timing
or a rubber mallet. tab fastened to the crankcase front cover and the
engine is in the number 1 firing position. This
Installation
may be determined by placing fingers on the
1. Clean gasket surfaces on cylinder head and rocker
number 1 valve as the mark on the damper comes
arm cover with degreaser then, using a new gasket,
near the “ O” mark on the crankcase front cover.
install rocker arm cover and torque to specifications.
If the valves are not moving, the engine is in the
2. Install carburetor heater (if removed).
number 1 firing position. If the valves move as
3. Connect temperature wire at clips on left rocker the mark comes up to the timing tab, the engine
arm cover.
is in number 6 firing position and should be
4. Connect crankcase ventilation hoses (as required).
turned over one more time to reach the number
5. Install air cleaner, start engine and check for leaks. 1 position.
b. With the engine in the number 1 firing position
Valve Mechanism as determined above, the following valves may be
adjusted.
Removal
1. Remove rocker arm covers as outlined.
Exhaust - 1, 3, 4, 8
2. Remove rocker arm nuts, rocker arm balls, rocker
Intake - 1, 2, 5, 7
arms and push rods.
NOTE: Place rocker arm s, rocker arm balls c. Back out adjusting nut until lash is felt at the
and push rods in a rack so they may be re ­ push rod then turn in adjusting nut until all lash
installed in the same locations. is removed. This can be determined by checking

CHEVROLET TRUCK SERVICE M ANUAL

 ENGINE 6-29

push rod side play while turning adjusting nut Removal

(fig. 3V). When play has been removed, turn 1. Remove intake manifold as outlined.
adjusting nut in one full additional turn (to center 2. Remove valve mechanism as outlined.
lifter plunger), 3. Remove valve lifters.
d. Crank the engine on revolution until the pointer
NOTE: Place valve lifters in a rack so they
“ O” mark and torsional damper mark are again
may be reinstalled in the same location.
in alignment. This is number 6 firing position.
With the engine in this position the following Installation
valves may be adjusted. 1. Install valve lifters.
NOTE: Whenever new valve lifters are being
Exhaust - 2, 5, 6, 7
installed coat foot of valve lifters with Molykote
Intake - 3, 4, 6, 8
or its equivalent.
4. Install rocker arm covers as outlined. 2. Install intake manifold as outlined.
5. Adjust carburetor idle speed and mixture. 3. Install and adjust valve mechanism as outlined.

Valve Lifters Valve Stem Oil Seal and/or Valve Spring

Hydraulic valve lifters very seldom require attention.
The lifters are extremely simple in design, readjust­ Replacement
ments are not necessary, and servicing of the lifters 1. Remove rocker arm cover as outlined.
requires only that care and cleanliness by exercised in 2. Remove spark plug, rocker arm and push rod on the
the handling of parts. cylinder(s) to be serviced.
3. Apply compressed air to the spark plug hole to hold
the valves in place.
Locating Noisy Lifters
Locate a noisy valve lifter by using a piece of garden NOTE: A tool to apply air to the cylinder is
hose approximately four feet in length. Place one end available through local jobbers or may be fab­
of the hose near the end of each intake and exhaust valve ricated using an AC-46N Spark Plug or its
with the other end of the hose to the ear. In this manner, equivalent. This will make the tool universal for
the sound is localized making it easy to determine which all Chevrolet engines. Chisel the spark plug as
lifter is at fault. shown, then drive the poreclain out of the plug
Another method is to place a finger on the face of the by tapping the center electrode against a hard
valve spring retainer. If the lifter is not functioning block. Using a 3/8” pipe tap, cut threads in the
properly, a distinct shock will be felt when the valve remaining portion of the spark plug and assem ­
returns to its seat. ble as shown (fig. 4V).
The general types of valve lifter noise are as follows: 4. Using Tool J-5892 to compress the valve spring,
1. Hard Rapping Noise — Usually caused by the plunger
remove the valve locks, valve cap (or rotator) and
becoming tight in the bore of the lifter body to such
valve spring and damper (fig. 5V).
an extent that the return spring can no longer push
5. Remove the valve stem oil seal.
the plunger back up to working position. Probable
6 . Assemble as follows:
causes are:
283 and 327 cu. in. Engines
a. Excessive varnish or carbon deposit causing
a. Set the valve spring and damper, valve shield and
abnormal stickiness.
valve cap (or rotator) in place. The close coiled
b. Galling or "pick-up" between plunger and bore of
end of the spring is installed against the cylinder
lifter body, usually caused by an abrasive piece
head. Compress the spring with Tool J-5892 and
of dirt or metal wedging between plunger and
install oil seal in the lower groove of the stem,
lifter body.
making sure the seal is flat and not twisted.
2. Moderate Rapping Noise - - Probable causes are:
a. Excessively high leakdown rate.
b. Leaky check valve seat.
c. Improper adjustment.
3. General Noise Throughout the Valve Train - - This
will, in almost all cases, be a definite indication of
insufficient oil supply, or improper adjustment.
4. Intermittent Clicking — Probable causes are:
a. A miscroscopic piece of dirt momentarily caught
between ball seat and check valve ball.
b. In rare cases, the ball itself may be out-of­
round or have a flat spot.
c. Improper adjustment.
In most cases where noise exists in one or more lifters
all lifter units should be removed, disassembled, cleaned
in a solvent, reassembled, and reinstalled in the engine.
If dirt, corrosion, carbon, etc. is shown to exist in one
unit, it more likely exists in all the units, thus it would
only be a matter of time before all lifters caused trouble. Fig. 4V—A ir Adapter Tool

CHEVROLET TRUCK SERVICE M ANUAL

ENGINE 6-30

Installation
CAUTION: The gaskets surfaces on both the
head and the block must be clean of any foreign
matter and free of nicks or heavy scratches.
Cylinder bolt threads in the block and threads on
the cylinder head bolts must be clean. (Dirt
will affect bolt torque.)
1. On engines using a STEEL gasket, coat both sides of
a new gasket with a good sealer. Spread the sealer
thin and even. One method of applying the sealer
that will assure the proper coat is with the use of a
paint roller. Too much sealer may hold the gasket
away from the head or block.
CAUTION: Use no sealer on engines using a
composition STEEL ASBESTOS gasket.
Place the gasket in position over the dowel pins with
the bead up.
3. Carefully guide the cylinder head into place over the
dowel pins and gasket. *
4. Coat threads of cylinder head bolts with sealing
compound and install bolts finger tight.
5. Tighten each cylinder head bolt a little at a time in
the sequence shown in the torque sequence chart until
the specified torque is reached.
Install exhaust manifolds as outlined.
Install intake manifold as outlined.
Install and adjust valve mechanism as outlined.
Fig. 5V —Compressing V a lv e Spring

Oil Pan
NOTE: A light coat of oil on the seal will help
Removal
prevent twisting.
1. Drain engine oil.
b. Install the valve locks and release the com­ 2. Remove oil dip stick and tube.
pressor tool making sure the locks seat properly 3. On vehicles so equipped remove exhaust crossover
in the upper groove of the valve stem. pipe.
NOTE: Grease may be used to hold the locks in 4. On vehicles equipped with automatic transmisssion
place while releasing the compressor tool. remove converter housing under pan.
366 cu. in. Engines 5. Remove oil pan and discard gaskets and seals.
a. Install new valve stem oil seal (coated with oil) NOTE: The oil pan on the 366 cu. in. engine
in position over valve guide. has three 1/4" x 20 attaching bolts at crankcase
b. Set the rotator (exhaust valve), valve spring and front cover. One located at each corner and
damper and valve cap in place. one at lower center.
c. Compress the spring with Tool J-5892 and install
the valve locks then release the compressor tool,
Installation
making sure the locks seat properly in the groove
1. Thoroughly clean all gasket and seal surfaces on oil
of the valve stem.
pan, cylinder block, crankcase front cover and rear
NOTE: Grease may be used to hold the locks main bearing cap.
in place while releasing the compressor tool. 2. Install new oil pan side gaskets on cylinder block
using gasket sealer as a retainer. Install new oil
Install spark plug, using a new gasket, and torque
pan rear seal in rear main bearing cap groove, with
to specifications.
ends butting side gaskets. Install new oil pan front
Install and adjust valve mechanism as outlined.
seal in groove in crankcase front cover with ends
butting side gaskets (fig. 6 V).
Cylinder Head Assemblies 3. Install oil pan and torque bolts to specifications.
Removal NOTE: On 366 cu. in. engines, start bolts
1. Remove intake manifold as outlined. into crankcase front cover before tightening any
2. Remove exhaust manifolds as outlined.
other bolts.
3. Remove valve mechanism as outlined.
4. Drain cylinder block of coolant. 4. Install converter housing under pan (if removed).
5. Remove cylinder head bolts, cylinder head and gas­ 5. Install exhaust crossover pipe (if removed).
ket. Place cylinder head on two blocks of wood to 6. Install oil dipstick tube and dipstick.
prevent damage. 7. F ill with oil, start engine and check for leaks.

CHEVROLET TRUCK SERVICE MANUAL

 ENGINE 6-31

Fig. 7 V — Removing O il Seal (Low er H alf)

1. With the oil pan and oil pump removed, remove the
FR O N T rear main bearing cap.
SEAL 2. Remove oil seal from the groove by prying from
the bottom with a small screw driver (fig. 7V).
3. Lubricate the lip of a new seal with engine oil. Keep
oil off the parting line surface as this is treated with
glue. Insert seal in cap and roll it into place with
finger and thumb, using light pressure so seal tangs
at parting line do not cut bead on back of seal.
4. To remove the upper half of the seal, use a small
Fig. 6 V — O il Pan G asket and Seal Location hammer to tap a brass pin punch on one end of seal
until it protrudes far enough to be removed with
pliers (fig. 8 V).
Oil Pump NOTE: Always wipe crankshaft surface clean
Removal
before installing a new seal.
1. Remove oil pan as outlined. 5. Lubricate the lip of a new seal with engine oil. Keep
2. Remove pump to rear main bearing cap bolt and re­
move pump and extension shaft.
Installation
1. Assemble pump and extension shaft to rear main
bearing cap, aligning slot on top end of extension
shaft with drive tang on lower end of distributor
drive shaft.
2. Install pump to rear bearing cap bolt and torque to
specifications.
NOTE: Installed position of oil pump screen is
with bottom edge parallel to oil pan rails.
3. Install oil pan as outlined.

Oil Seal (Rear Main)

Replacement
The rear main bearing oil seal can be replaced (both
halves) without removal of the crankshaft.
NOTE: Always replace the upper and lower
seal as a unit. Install with the lip facing toward
the front of the engine. F ig . 8 V —Removing O il Seal (Upper H alf)

CHEVROLET TRUCK SERVICE M ANUAL

ENGINE 6-32

oil off the parting line surface as this is treated with

glue. Gradually push with a hammer handle, while
turning crankshaft, until seal is rolled into place.
(Similar to installing a main bearing.) Be careful
that seal tangs at parting line do not cut bead on back
of seal.
6 . Install the rear main bearing cap (with new seal) and
torque to specifications.
Torsional Damper
Removal
1. Remove fan belt, fan and pulley.
2. Remove the radiator and shroud assembly as outlined
in Section 13.
NOTE: If additional operations (such as cam­
shaft removal) are not being performed, the ra­
diator removal will not be necessary on vehicles
using the 366 cu. in. engine.
3. Remove accessory drive pulley then, if so equipped,
remove damper retaining bolt.
4. Install Tool J-6978 on damper then, turning puller
screw, remove damper (fig. 9V).
NOTE: Tool J-6978 has holes forming two pat­ Fig. 10V— Installing Torsional Damper (283 and 327)
terns. A two bolt and a three bolt pattern. The
holes for the two bolt pattern must be elongated b. Using Tool J-21058 pull torsional damper onto
for use on the 366 cu. in. engine. crankshaft (fig. 11V).
Installation NOTE: If radiator has not been removed from
CAUTION: The inertia weight section of the the vehicle a l/2 " -2 0 x 5” bolt and a 1/2"-20
torsional damper is assembled to the hub with nut may be used in place of the bolt and nut
a rubber type material. The installation pro­ from Tool J-21058.
cedures (with proper tool) must be followed or CAUTION: Install bolt in crankshaft with suf-
movement of the inertia weight section on the ficient thread engagement (min. 1 / 2 " ).
hub will destroy the tuning of the torsional
damper. c. Remove tool from crankshaft then install damper
retaining bolt and torque to specifications.
1. Coat front cover seal contact area (on damperj with 3. Install accessory drive pulley.
engine oil. 4. Install radiator and shroud as outlined in Section 13.
2. Install damper on crankshaft as follows: 5. Install fan and pulley to water pump hub and tighten
283 and 327 cu. in ENGINE securely.
a. Attach damper installer Tool J-22197 on damper
then adjust fingers of tool to prevent inertia
weight moving (fig. 10V).
b. Position damper in alignment with crankshaft
keyway then drive into position (fig. 34) (until it
bottoms on crankshaft sprocket) and remove tool
from balancer.
366 cu. in. ENGINE
a. Place damper in position over key on crankshaft.

Fig . 9 V —Removing Torsional Damper F ig . 11V —Installing Torsional Damper (366)

CHEVROLET TRUCK SERVICE M ANUAL

 ENGINE 6-33

Fig. 12V—C entering Tool in C over (366)

6. Install fan belt and adjust to specifications using

strand tension gauge. Fig. 13V—Installing O il Seal (C o ver Removed) 283 and 327
7. F ill cooling system, start engine and check for leaks.
Oil Seal
Crankcase Front Cover Replacement
With Cover Rem oval
Removal
1. Remove oil pan as outlined. 1. With cover removed, pry old seal out of cover from
the front with a large screw driver.
2. Remove torsional damper as outlined.
2. Install new seal so that open end of the seal is toward
3. Remove water pump as outlined in Section 6 K.
the inside of cover and drive it into position with
4. Remove crankcase front cover attaching screws
Tool J-995 on 283 and 327 cu. in. engines (fig. 13V)
and remove front cover and gasket, then discard
or Tool J-22102 on 366 cu. in. engines (fig. 14V).
gasket.
CAUTION: Support cover at seal area. (Tool
J-971 may be used as support.)
Installation
2 8 3 an d 3 2 7 cu. in. Engines
1. Make certain that cover mounting face and cylinder
block front end face are clean and flat.
2. Coat the oil seal with engine oil and using a new
cover gasket, coated with gasket sealer install cover
and gasket over dowel pins and cylinder block.
3. Install cover screws and torque to specifications.
4. Install water pump as outlined in Section 6 K.
5. Install torsional damper as outlined.
6 . Install oil pan as outlined.

366 cu. in. Engines

1. Make certain that cover mounting face and cylinder
block front end face are clean and flat.
2. Coat the oil seal with engine oil and install Aligning
Tool J-22102 in oil seal (fig. 12V) then using a new
cover gasket coated with gasket sealer, install cover
and gasket on cylinder block.
3. Install cover screws and torque to specifications.
Then remove Aligning Tool J-22102.
4. Install water pump as outlined in Section 6 K.
5. Install torsional damper as outlined.
6 . Install oil pan as outlined. Fig . 14V—Installing O il Seal (C over Removed) 366

CHEVROLET TRUCK SERVICE MANUAL

ENGINE 6-34

Fig. 15V— Installing O il Seal (C o ver Installed) 283 and 327

Without Cover Rem oval

1. With torsional damper removed, pry seal out of
cover from the front with a large screw driver,
being careful not to damage the surface on the
crankshaft.
2. Install new seal so that open end of seal is toward
the inside of cover and drive it into position with
Tool J-8340 on 283 and 327 cu. in. engines (fig. 15V)
or Tool J-22102 on 366 cu. in. engines (fig. 16V).

Timing Chain and/or Sprockets (283 and 327)

Replacement Fig. 17V—Timing Sprocket Marks
1. Remove torsional damper and crankcase front cover
as outlined.
2. Crank engine until marks on camshaft and crankshaft edge of the sprocket (with a plastic mallet) should
sprockets are in alignment (fig. 17V). dislodge the sprocket.
3. Remove camshaft sprocket to camshaft bolts. 5. If crankshaft sprocket is to be replaced, remove
4. Remove camshaft sprocket and timing chain together. sprocket using Tool J-5825 (fig. 18V). Install new
Sprocket is a light press fit on camshaft. If sprocket sprocket using Tool J-5590 (fig. 19V).
6 . Install timing chain on camshaft sprocket. Hold the
does not come off easily, a light blow on the lower
sprocket vertical with the chain hanging down and
orient to align marks on camshaft and crankshaft
sprockets (fig. 20V).
NOTE: Do not attempt to drive sprocket on
camshaft as welsh plug at rear of engine can
be dislodged.

Fig . 16V—Installing O il Seal (C over Installed) 366 Fig . 18V—Removing Crankshaft Sprocket

CHEVROLET TRUCK SERVICE M ANUAL

 ENGINE 6-35

Fig. 19V— Installing Crankshaft Sprocket

7. Draw camshaft sprocket onto camshaft, using the

three mounting bolts. Torque to specifications.
8 . Lubricate timing chain with engine oil.
9. Install crankcase front cover and torsional damper
Fig. 21V —Measuring Camshaft Lobe Lift
as outlined.
Camshaft checking valve timing. If improper valve opera­
tion is indicated, measure the lift of each push
Measuring Lobe Lift rod in consecutive order and record the
NOTE: Procedure is sim ilar to that used for readings.
1. Remove the valve mechanism as outlined.
2. Position indicator with ball socket adapter on push
rod (fig. 21V).
NOTE: Make sure push rod is in the lifter
socket.
3. Rotate the crankshaft damper slowly in the direction
of rotation until the lifter is on the heel of the cam
lobe. At this point, the push rod will be in its lowest
position.
4. Set dial indicator on zero, then rotate the balancer

Fig . 20V —Instal ling Timing Chain Fig . 2 2V —Removing Camshaft

CHEVROLET TRUCK SERVICE MANUAL

ENGINE 6-36

slowly, or attach an auxiliary starter switch and

"bump” the engine over, until the push rod is in
fully raised position.
CAUTION: The_ primary distributor lead must
be disconnected from the negative post on the
coil and the ignition switch must be in the on
position. Failure to do this will result in a TIMING
damaged grounding circuit in the ignition switch. MARKS

5. Compare the total lift recorded from the dial indi­

cator with specifications.
6 . Continue to rotate the engine until the indicator reads
zero. This will be a check on the accuracy of the
original indicator reading.
7. If camshaft readings for all lobes are within speci­
fications, remove dial indicator assembly.
8 . Install and adjust valve mechanism as outlined.
THRUST
PLATE
Removal SCREWS
1. Remove valve lifters as outlined.
2. Remove crankcase front cover as outlined.
3. Remove grille as outlined in Section 13. Fig. 23V—Timing G e a r Marks
4. Remove fuel pump push rod as outlined in Section
9. Install valve lifters as outlined.
366cu.in.Engines
6 M.
5. Complete camshaft removal as follows:
CAUTION: All camshaft journals are the same 1. Install the camshaft and gear assembly in the engine
diameter and care must be used in removing block, being careful not to damage camshaft bear­
camshaft to avoid damage to bearings^ ings on camshaft.
2. Turn crankshaft and camshaft so that the valve tim­
On 283 and 327 cu. in Engines: ing marks on the gear teeth will line up (fig. 47).
Remove camshaft sprocket to camshaft bolts then Push camshaft into position. Install camshaft thrust
remove sprocket and timing chain together. Sprocket plate to block screws and torque to specifications.
is a light fit on camshaft. If sprocket does not come 3. Check camshaft and crankshaft gear run out with a
off easily a light blow on the lower edge of the dial indicator (fig. 24V). The camshaft gear run out
sprocket (with a plastic mallet) should dislodge the should not exceed .004" and the crankshaft gear run
sprocket. out should not exceed .003".
Install two 5/16" x 18 x 4" bolts in camshaft bolt 4. If gear run out is excessive, the gear will have to be
holes then remove camshaft (fig. 22V). removed and any burrs cleaned from the shaft or
On 366 cu. in. engines: the gear will have to be replaced.
Align the timing gear marks then remove the two
camshaft thrust plate screws through holes in the
camshaft gear (fig. 23V).
Remove camshaft and gear assembly.

Installation
NOTE: Whenever a new camshaft is installed
coat camshaft lobes with Molykote or its
equivalent.

283and327cu.in.Engines
1. Lubricate camshaft journals with engine oil and in­
stall camshaft.
2. Install timing chain on camshaft sprocket. Hold the
sprocket vertical with the chain hanging down, and
orient to align marks on camshaft and crankshaft
sprockets. Refer to Figure 41.
3. Align dowel in camshaft with dowel in hole in cam­
shaft sprocket then install sprocket on camshaft.
Refer to Figure 20V.
4. Draw the camshaft sprocket onto camshaft using the
mounting bolts. Torque to specifications.
5. Lubricate timing chain with engine oil.
6 . Install fuel pump push rod as outlined in Section 6 M.
7. Install grille as outlined in Section 13.
8 . Install crankcase front cover as outlined. F ig . 24V —C heckin g Camshaft G e ar Runout

CHEVROLET TRUCK SERVICE MANUAL

 ENGINE 6-37

Fig. 27V— Installing Crankshaft G ea r

Flywheel
Removal
With transmission and/or clutch housing and clutch
removed from engine, remove the flywheel.
Installation
1. Clean the mating surfaces of flywheel and crankshaft
to make certain there are no burrs.
Fig. 25V —Checking Timing G e a r Backlash 2. Install flywheel on crankshaft and position to align
dowel hole of crankshaft flange and flywheel (fig.
5. Check the backlash between the timing gear teeth 28V).
with a dial indicator (fig. 25V). The backlash should NOTE: On Automatic Transmission equipped
not be less than .004" nor more than .006". engines, the flywheel must be installed with the
6 . Lubricate timing gears with engine oil. flange collar to transmission side (fig. 28V).
7. Install fuel pump push rod as outlined in Section 6 M.
8 . Install grille as outlined in Section 13.
Coat thread end of bolts with sealer then install
9. Install crankcase front cover as outlined. bolts and torque to specifications.
10. Install valve lifters as outlined. Engine Mounts
Engine mounts (fig. 29V) are the non-adjustable type
Timing Gears and seldom require service. Broken or deteriorated
mounts should be replaced immediately, because of the
Replacement
added strain placed on other mounts and drive line
366 cu. in. Engines components.
With camshaft removed crankshaft gear may be re­
Front Mount Replacement
moved using Tool J-8105 (fig. 26V). To install crankshaft
With 283 or 3 2 7 cu. in. Engine
gear use Tool J-21058 (fig. 27V). For camshaft gear re ­
1. Remove distributor cap.
placement refer to Section 6 , "Camshaft Disassembly”
2. Remove mount retaining bolt from below frame
of the Overhaul Manual.
mounting bracket.
3. Raise front of engine and remove mount-to-engine
bolts and remove mount.

Fig . 26V —Removing Crankshaft G ear Fig . 28V —Flyw heel Installation (T y p ic a l)

CHEVROLET TRUCK SERVICE M ANUAL

ENGINE 6-38

Fig. 29V—Engine Mounts

CAUTION: Raise engine only enough for suf­ GE 10-20 Series

ficient clearance. Check for interference be­ The two piece rear support in transmission case ex­
tween rear of engine and cowl panel. tension may be removed without removing the transm is­
4. Replace mount to engine and lower engine into place. sion from the vehicle. Replace both halves as a unit.
5. Install retaining bolt and torque all bolts to 1. Position the fan blade with the blades pointing at the
specifications. four corners of the radiator and insert a piece of
heavy corrugated cardboard between the fan and the
With 366 cu. in. Engine radiator. (This will prevent the fan from damaging
1. Remove cotter keys then loosen front mount bolt. the radiator in the event the engine is lowered too
2. Raise engine enough to remove weight from cushions. far).
3. Remove nut, bolt, spacer and cushions and reinstall 2. Raise the vehicle and remove the rear support nut.
with new cushions. 3. Place a jack or jack stand under the transmission
4. Lower engine and torque bolt to specifications. extension and raise until the pressure is off the
5. Install cotter key. rear support.
Rear Mount Replacement 4. Remove the rear support bolt and lower the jack
Except GE 10-20 Series until the rear support is clear of the frame.
1. Support engine weight to relieve rear mounts. 5. Remove both halves of the rear support.
6 . Install a new rear support (both halves).
2. Remove mount attaching bolts from frame outrigger
7. Raise the jack until the rear support hole lines up
and clutch housing and remove rear mounting
cushions. and install the rear support bolt.
8 . Remove the jack and install the rear support bolt
3. Install new mounting cushions and bolts.
4. Lower engine onto mounts. nut and torque to specifications.
5. Torque bolts to specifications then bend lock tabs 9. Lower the vehicle and remove the cardboard from
to bolt head. between the fan and radiator.
 ENGINE 6-39

CYLINDER HEAD TORQUE SEQUENCE

L6 L4

V8-283-327 & 350 V8-396 & 427

INTAKE MANIFOLD TORQUE SEQUENCE

FRONT
FRONT

V8-283 & 327 V 8 -3 9 6 & 4 2 7

F ig . I T —Torque Sequence
ENGINE 6-40

SPECIAL TOOLS

Fig. 2T—G a so lin e Engine Sp ecial Tools

1. J-4536 Engine Lift K it 15. J-5860 C ylin d er Head Bolt W rench

2. J —1264 (0-200 ft. lb.) Torque W rench 16. J —5715 (.003") Rocker Arm Stud Reamer
J-8058 (0-50 ft. lb.) J-6036 (.013")
J-5853 (0-100 in. lb.) 17. J-6880 Rocker Arm Stud Installer
3. J-8087 In d icator Set (C ylin d er Bore) 18. J-5802 Rocker Arm Stud Remover
4. J —8001 In d icator Set (U niversal) 19. J-9534 Distributor lo w e r Bushing Remover
5. J —7316 B elt Tension G auge 20. J-9535 Distributor Lower Bushing In staller
6. J-8037 Piston Ring Compressor 21. J —22144 O il Pick-up Screen In staller
7. J-8020 (3 9/16") Piston Ring Expander 22. J-8369 O il Pick-up Screen Installer
J —8021 (3 7/8 ") 23. J-6098 Cam Bearing Tool
J-8032 (4 ") 24. J —0971 Camshaft G e a r Support
J - 22249 (3 15/16") 25. J-6987 Torsional Damper Puller
J —22147 (4 3/32") 26. J —22197 Torsional Damper Installer
J-22250 (4 1/4") 27. J-21058 Torsional Damper and Sprocket In staller
8. J-6994 Piston Pin Assembly Tool 28. J-1619 Crankshaft Sprocket Pu ller
9. J —9510 Piston Pin Assembly Tool 29. J-5825 Crankshaft Sprocket Pu ller
10. J-5239 (3 /8 ") C onnecting Rod G u id e Set 30. J-8105 Crankshaft G e a r Pu ller
J-6305 (11/32") 31. J-5590 Crankshaft Sprocket or G e a r Installer
11. J-8062 V a lv e Spring Compressor 32. J-0966 Crankcase C over Centering G auge
12. J-8101 V a lv e G u id e C leaner 33. J —21742 Crankcase C over Centering G auge
13. J-5830 (11/32") V a lv e G u id e Reamer Set 34. J —22102 Crankcase C o ver Tool
J-7049 (3/8") 35. J-8340 Crankcase Cover Seal In staller
14. J-8089 Carbon Removing Brush 36. J-5595 Crankcase C o ver Seal In staller

CHEVROLET TRUCK SERVICE MANUAL

 SECTION 6K
ENGINE COOLING
IN D EX
Page Page
General D e s c r ip tio n ......................................................... ... 6K-1 Cylinder Block and Cylinder H e a d ........................ 6K-2
Maintenance and A dju stm en ts.......................................... ...6K-1 Hot Water H eater................................................... 6K-2
Coolant L e v e l .................................................................. ... 6K-1 Fan B e lt .................. ........................................................ 6K-2
Coolant System Checks................................................... ... 6K-1 A d ju s tm e n t.................................................................. 6K-2
Periodic Maintenance...................................................... ... 6K-2 T h erm o stat..................................................................... 6K-2
C leaning........................................................................ ... 6K-2 Replacement.................................................................. 6K-2
Reverse Flushing......................................................... ... 6K-2 Water Pum p..................................................................... 6K-3
R ad iato r..................................................................... ... 6K-2 R em oval........................................................................ 6K-3
In sta lla tio n .................................................................. 6K-3

GENERAL DESCRIPTION
A pressure cooling system is provided for on all For radiator, refer to Section 13 of this manual. For
models by a pressure type radiator cap (fig. 1). The radiator shroud, refer to Section 11 of this manual.
pressure type radiator cap used is designed to hold a
pressure above atmospheric pressure in the cooling
system. Excessive pressure is relieved by a valve within
the cap that opens to radiator overflow.
The water pump is a ball bearing, centrifugal vane
impeller type. It requires no care other than to make
certain the air vent at the top of the housing and the drain
holes in the bottom do not become plugged with dirt or
grease. Removal and installation of the water pump is
covered in this section. For overhaul procedures of the
water pump refer to Section 6 K of the Passenger Chassis
Overhaul Manual. Fig. 1—Pressure Radiator Cap

MAINTENANCE AND ADJUSTMENTS

Coolant Level cooling system should be checked for loose hose con­
nections, defective hoses, gasket leaks, etc.
The radiator coolant level should only be checked when
the engine is cool, particularly on cars equipped with air
Coolant System Checks
conditioning. If the radiator cap is removed from a hot
cooling system, serious personal injury may result. 1. Test for restriction in the radiator, by warming the
The cooling system fluid level should be maintained engine up and then turning the engine off and feeling
one inch below the bottom of the filler neck of the radia­ the radiator. The radiator should be hot at the top
tor when cooling system is cold, or at the bottom of the and warm at the bottom, with an even temperature
filler neck when the system is warm. It is very impor­ rise from bottom to top. Cold spots in the radiator
tant that the correct fluid level be maintained. The seal­ indicate clogged sections.
ing ability of the radiator cap is affected when the cooling 2. Water pump operation may be checked by running the
level is too high. engine while squeezing the upper radiator hose. A
All passenger car cooling systems are pressurized pressure surge should be felt. Check for' a plugged
with a pressure cap which permits safe engine operation vent-hole in pump.
at cooling temperatures of up to 247°F.
NOTE: A defective head gasket may allow ex­
When the radiator cap is removed or loosened, the
haust gases to leak into the cooling system.
system pressure drops to atmospheric, and the heat
This is particularly damaging to the cooling
which had caused water temperature to be higher than
system as the gases combine with the water to
212°F, will be dissipated by conversion of water to
form acids which are particularly harmful to
steam. Inasmuch as the steam may form in the engine
the radiator and engine.
water passages, it will blow coolant out of the radiator
upper hose and top tank, necessitating coolant replace­ 3. To check for exhaust leaks into the cooling system,
ment. Engine operating temperatures higher than the drain the system until the water level stands just
normal boiling point of water are in no way objectionable above the top of the cylinder head, then disconnect
so long as the coolant level is satisfactory when the the upper radiator hose and remove the thermostat
engine is cool. and fan belt. Start the engine and quickly accelerate
Upon repeated coolant loss, the pressure radiator cap several times. At the same time note any appreci­
and seat should be checked for sealing ability. Also, the able water rise or the appearance of bubbles which

CHEVROLET TRUCK SERVICE MANUAL

ENGINE COOLING 6K-2

are indicative of exhaust gases leaking into the cool­ 3. Attach a new piece of hose to the radiator outlet
ing system. connection and insert the flushing gun in this hose.
4. Connect the water hose of the flushing gun to a water
Periodic Maintenance outlet and the air hose to an air line.
5. Turn on the water and when the radiator is full, turn
Periodic service must be performed to the engine cool­ on the air in short blasts, allowing the radiator to
ing system to keep it in efficient operating condition. fill between blasts of air.
These services should include a complete cleaning and
reverse flushing as well as a reconditioning service. CAUTION: Apply air gradually as a clogged
In the course of engine operation, rust and scale ac­ radiator will stand only a limited pressure.
cumulate in the radiator and engine water jacket. The 6. Continue this flushing until the water from the lead-
accumulation of these deposits can be kept to a minimum away hose runs clear.
by the use of a good rust inhibitor but it should be
remembered that an inhibitor will not remove rust al­ Cylinder Block and Cylinder Head
ready present in the cooling system. 1. With the thermostat removed, attach a lead-away
Two common causes of corrosion are: (1) air suction-- hose to the water pump inlet and a length of new hose
Air may be drawn into the system due to low liquid level to the water outlet connection at the top of the engine.
in the radiator, leaky water pump or loose hose con­ NOTE: Disconnect the heater hose when re ­
nections; (2 ) exhaust gas leakage—Exhaust gas may be
verse flushing engine.
blown into the cooling system past the cylinder head
gasket or through cracks in the cylinder head and block. 2. Insert the flushing gun in the new hose.
3. Turn on the water and when the engine water jacket
Cleaning is full, turn on the air in short blasts.
A good cleaning solution should be used to loosen the 4. Continue this flushing until the water from the lead-
rust and scale before reverse flushing the cooling away hose runs clear.
system. There are a number of cleaning solutions avail­
able and the manufacturer's instructions with the particu­ Hot Water Heater
lar cleaner being used should always be followed. 1. Remove water outlet hose from heater core pipe.
An excellent preparation to use for this purpose is GM 2. Remove inlet hose from engine connection.
Cooling System Cleaner. The following directions for 3. Insert flushing gun and flush heater core. Care must
cleaning the system applies only when this type cleaner be taken when applying air pressure to prevent
is used. damage to the core.
1. Drain the cooling system including the cylinder block Fan Belt
and then close both drain plugs.
2. Remove thermostat and replace thermostat housing. Adjustment
3. Add the liquid portion (No. 1) of the cooling system 1. Loosen bolts at Delcotron slotted bracket.
cleaner. 2. Pull Delcotron away from engine until desired ten­
4. F ill the cooling system with water to a level of about sion reading is obtained with a strand tension gauge.
3 inches below the top of the overflow pipe. Refer to Section 6 , "Engine Tune Up” .
5. Cover the radiator and run the engine at moderate 3. Tighten all Delcotron bolts securely.
speed until engine coolant temperature reaches 180
degrees.
Thermostat
6 . Remove cover from radiator and continue to run the The thermostat consists of a restriction valve actuated
engine for 20 minutes. Avoid boiling. by a thermostatic element. This is mounted in the hous­
7. While the engine is still running, add the powder ing at the cylinder head water outlet above the water
portion (No. 2) of the cooling system cleaner and pump. Thermostats are designed to open and close at
continue to run the engine for 1 0 minutes. predetermined temperatures and if not operating properly
8 . At the end of this time, stop the engine, wait a few should be removed and tested as follows.
minutes and then open the drain cocks or remove
pipe plugs. Also remove lower hose connection. Replacement
1. Remove radiator to water outlet hose.
CAUTION: Be careful not to scald your hands. 2. Remove thermostat housing bolts and remove water
NOTE: Dirt and bugs may be cleaned out of outlet and gasket from thermostat housing (fig. 2 ).
the radiator air passages by blowing out with air 3. Inspect thermostat valve to make sure it is in good
pressure from the back of the core. condition.
4. Place thermostat in hot water 2 5 ° above the temper­
Reverse Flushing
ature stamped on the thermostat valve.
Reverse flushing should always be accomplished after
5. Submerge the valve completely and agitate the water
the system is thoroughly cleaned as outlined above.
thoroughly. Under this condition the valve should
Flushing is accomplished through the system in a direc­
open fully.
tion opposite to the normal flow. This action causes the
6 . Remove the thermostat and place in water 10° below
water to get behind the corrosion deposits and force
temperature indicated on the valve.
them out.
7. With valve completely submerged and water agitated
Radiator thoroughly, the valve should close completely.
1. Remove the upper and lower radiator hoses and re ­ 8 . If thermostat checks satisfactorily, re-install, using
place the radiator cap. a new housing gasket.
2. Attach a lead-away hose at the top of the radiator. 9. Refill cooling system.

CHEVROLET TRUCK SERVICE MANUAL

 ENGINE COOLING 6K-3

Water Pump
Removal
1. Drain radiator and break loose the fan pulley bolts.
2. Disconnect heater hose, lower radiator hose and
by pass hose (as required) at water pump.
3. Loosen Delcotron and remove fan belt then remove
fan bolts, fan and pulley.
4. Remove pump to cylinder block bolts and remove
pump from engine.
NOTE: On in line engines, pull the pump
straight out of the block first, to avoid damage
to impeller.
Installation
1. Install pump assembly on cylinder block and tighten
bolts securely. Use on new pump to block gasket(s).
2. Install pump pulley and fan on pump hub and tighten
bolts securely.
NOTE: A guide stud (5/16"-24 x 1 -1 /2 " bolt
with the head removed) installed in one hole of
the fan hub will aid in aligning hub, pulley and
fan. Remove stud after starting the remaining
three bolts.
c- o d i - tu
rig . 2 —Replacing Thermostat-
3. Connect hoses and fill, cooling system,
, ,,
4. Install fan belt and adjust as previously outlined.
5. Start engine and check for leaks.

CHEVROLET TRUCK SERVICE MANUAL

 II

/
 SECTION 6M
ENGINE FUEL
CONTENTS OF THIS SECTION
p age Page
Carburetors 6M-1 Fuel Pumps ..................................................................... 6M-13
Governors . 6M-4 Special Tools .................................................................. 6M-17
A ir Cleaners 6M-8

CARBURETORS
INDEX
Page Page
General Description.......................................... Additional Adjustm ents........................... .................. 6M-3
Service P ro c e d u re s .......................................... R em oval...................................................
Preliminary C h e c k s .................................... Test Before Installation ........................
Idle Speed and Mixture A d ju s tm e n t............ In sta lla tio n .............................................
Choke A d ju stm en t....................................... ............ 6M-2 Fuel Filter M aintenan ce........................ .................. 6M-3
Throttle Linkage Adjustm ent.................. .................. 6M-3

GENERAL DESCRIPTION

Various carburetors, designed to meet the particular This section covers removal, installation and adjust­
requirements of engines, transmission and vehicles are ment (on engine) of carburetors. Also covered in this
used; therefore, carburetors that look alike are not al­ section are maintenance procedures for choke cables,
ways interchangeable. (Refer to carburetor part number throttle linkages and fuel filters. For carburetor over­
and/or specifications.) Carburetors for engines with the haul procedures and additional adjustments (bench), refer
Air Injection Reactor System are designed, particularly to Section 6 M of the Overhaul Manual under the carbu­
for these engines; therefore, they should not be inter­ retor being serviced.
changed with or replaced by a carburetor designed for an Specifications for carburetors are located in the back
engine without the Air Injection Reactor System. of this manual.

IDLE IDLE
SPEED M IXTURE

CHEVROLET TRUCK SERVICE M ANUAL

ENGINE FUEL 6M-2

M IX T U R E

Fig. 3C - Rochester 2 G Fig. 4C - Rochester 4 G

SERVICE PROCEDURES
Preliminary Checks 7. Shut down the engine, remove gauges and install air
1. Thoroughly warm-up engine. If the engine is cold, cleaner.
allow to run for at least 15 minutes.
2. Inspect torque of carburetor to intake manifold bolts Idle Speed and Mixture Adjustment (With Air Injection
and intake manifold to cylinder head bolts to exclude Reactor System)
the possibility of air leaks. The following is the recommended procedure for Air
3. Inspect manifold heat control valve (if used) for free­ Injection Reactor System equipped engines.
dom of action and correct spring tension.
NOTE: This adjustment should be performed
Idle Speed and Mixture Adjustment (Except Air Injection with engine at operating temperature and parking
Reactor System) brake applied.
NOTE: This adjustment should be performed 1. Remove air cleaner.
with engine at operating temperature and parking 2. Connect tachometer to engine, then set hand brake
brake applied. and shift transmission into neutral.
3. As a preliminary adjustment, turn idle mixture
1. Remove Air Cleaner.
screws lightly to seat and back out 3 turns.
2 .
Connect tachometer and vacuum gauge to engine, then
set hand brake and shift transmission into neutral. CAUTION: Do not turn idle mixture screw
3. As a preliminary adjustment, turn idle mixture tightly against seat or damage may result.
screws lightly to seat and back out 1 - 1 / 2 turns.
4. With engine running (choke wide open) adjust idle
CAUTION: Do not turn idle mixture screw speed screw to specified idle speed, (automatic
tightly against seat or damage may result. transmission in drive, synchronized transmission in
neutral).
4. With engine running (choke wide open) adjust idle
5. Adjust idle mixture screw (turn in) to "lean roll"
speed screw to specified idle speed, (automatic
position; then turn screw out 1/4 turn (1/4 turn rich
transmission in drive, synchronized transmission in
from "lean roll"). The definition of "lean roll"
neutral). point is a 20 to 30 rpm drop in engine speed, obtained
5. Adjust idle mixture screw to obtain highest steady
by leaning the idle mixture.
vacuum at specified idle speed.
NOTE: On air conditioned vehicles, turn air
NOTE: On air conditioned vehicles, turn air conditioning "O FF" on in-line, 283, and 327 cu.
conditioning to the "on" position and hold the hot
in. engines.
idle compensator valve closed while adjusting
idle speed and idle mixture screws. 6. Repeat steps 3 and 4 as needed for final adjustment.
NOTE: On Rochester B carburetors the idle NOTE: If necessary, final adjustment of the
mixture screw should be turned out 1/4 turn carburetor may be made with air cleaner
from the "lean roll" position. The definition of installed.
"lean roll" point is a 20 to 30 rpm drop in en­
7. Turn off engine, remove gauges and install air
gine speed obtained by leaning the idle mixture.
cleaner.
6 . Repeat Steps 4 and 5 as needed for final adjustment.
Choke Adjustment
NOTE: If necessary, final adjustment of the 1. Remove air cleaner.
carburetor may be made with the air cleaner 2. Push hand choke knob in to within 1/8" of instrument
installed. panel.

CHEVROLET TRUCK SERVICE M ANUAL

 ENGINE FUEL 6M-3

3. Loosen choke cable clamp at carburetor bracket and Installation

adjust cable through the clip until the choke valve is 1. Be certain throttle body and intake manifold sealing
wide open. surfaces are clean.
4. Tighten cable clamp at carburetor bracket and check 2. Install new carburetor to manifold flange gasket (if
operation of choke valve to ensure full closed and required).
wide open positions. 3. Install carburetor over manifold studs.
5. Install air cleaner. 4. Start vacuum and fuel lines at carburetor.
5. Install attaching nuts and tighten securely.
Additional Adjustments 6 . Tighten fuel and vacuum lines.
The following adjustments may be made without remov­ 7. Connect and adjust accelerator and TV linkage.
ing the carburetor from the engine. For procedure refer 8 . Connect choke tube or choke rod.
to Section 6 M of the Overhaul Manual under the carbure­ 9. Adjust idle speed and mixture, then install air
tor being serviced. cleaner.

RochesterB
• Float
Fuel Filter Maintenance
1. Disconnect fuel line connection at inlet fuel filter nut.
• Idle Vent 2. Remove inlet fuel filter nut from carburetor with a

Rochester2G
• Float
1 " box wrench or socket.
3. Remove filter element and spring (fig. 5c).
4. Check element for restriction by blowing on cone
• Accelerator Pump end, element should allow air to pass freely.
• Idle Vent 5. Clean element by washing in solvent and blowing out.
• Choke Rod (Fast Idle) Blow in opposite direction of fuel flow.

Rochester4G
• Float
NOTE: Element should be replaced if plugged
or if flooding occurs. A plugged filter will re­
sult in a loss of engine power or rough (pulsat­
• Accelerator Pump
ing) engine feel, especially at high engine speeds.
• Idle Vent
• Air Valve 6 . Install element spring, then install element in carbu­
• Choke Rod retor so small section of cone faces out.

CarterYF
• Float
7. Install new gasket on inlet fitting nut then install nut
in carburetor and tighten securely.
8 . Install fuel line and tighten connector.
• Idle Vent
• Choke Rod (Fast Idle) Throttle Linkage Adjustment

M
odels: C
EE10-20-3K0E-4100--5200-6K
G 0SC
S0-1200-,20-30r
1 ,
Removal
Flooding, stumble on acceleration and other perform­
ance complaints are, in many instances, caused by the
ME 10-20,
SE
50-60, PS 10,
,
50-60

presence of dirt, water, or other foreign matter in the

carburetor. To aid in diagnosing the cause of the com­
plaint, the carburetor should be carefully removed from
S P R IN G
the engine without draining the fuel from the bowl. The
contents of the fuel bowl may then be examined for con­
tamination as the carburetor is disassembled.
1. Remove air cleaner and gasket.
2. Disconnect fuel and vacuum lines from carburetor.
3. Disconnect choke cable. FILTER
4. Disconnect accelerator linkage.
5. If equipped with Automatic transmission, disconnect
TV linkage.
6 . Remove carburetor attaching nuts and remove
carburetor.

Test Before Installation

It is good shop practice to fill the carburetor bowl be­
fore installing the carburetor. This reduces the strain
on the starting motor and battery and reduces the possi­
bility of backfiring while attempting to start the engine.
A fuel pump clamped to the bench, a small supply of fuel
and the necessary fittings enable the carburetor to be
filled and the operation of the float and intake needle and
seat to be checked. Operate the throttle several times
and check the discharge from the pump jets before in­
stalling the carburetor.

CHEVROLET TRUCK SERVICE M ANUAL

ENGINE FUEL 6M-4

1. Depress accelerator pedal to floor. position.

2. Hold carburetor throttle lever in wide open throttle 3. Install accelerator control cable assembly with
position. sleeve tube nut and ball joint sleeve into ball joint
3. Adjust threaded swivel on throttle control rod until it and tighten sleeve tube nut.
freely enters hole in throttle lever.

Mode/s: CS-M
S-SS40-50-60,PS20-30 Mode/s: CD 50-60, CT40,M
D50,PT20-30
1. Depress accelerator pedal to floor.
1. Depress accelerator pedal to floor. 2. Hold governor lever in wide open throttle position.
2. Hold carburetor throttle lever in wide open throttle 3. Adjust swivel on accelerator control rod until it
position. freely enters hole in accelerator pedal lever.
3. Adjust swivel on accelerator control rod until it
freely enters hole in accelerator pedal lever. Mode/s: CG-M
G-TG50-60
M
odels:GS10-20,PS40
1. Depress accelerator pedal to floor.
1. Depress accelerator pedal to floor.
2. Hold governor lever in wide open throttle position.
3. Adjust swivel on accelerator control rod until it
2. Hold carburetor throttle lever in wide open throttle freely enters hole in governor control lever.
position.
3. Adjust swivel on accelerator control rod until it
freely enters hole in accelerator control lever.
M
odels:TD50-60,TT40
1. Depress accelerator pedal to floor.

M
odels:TE-TS40-50-60
1. Depress accelerator pedal to floor.
2. Hold governor lever to wide open throttle position.
3. Install accelerator control cable assembly with
sleeve tube nut and ball joint sleeve into ball joint
2. Hold carburetor throttle lever in wide open throttle and tighten sleeve tube nut.

GOVERNORS
INDEX
Page Page
Velocity T y p e .................................................................. 6M-4 General D e s c r ip tio n ................................................... 6M-5
General D escrip tion ................................................... 6M-4 Major Service O p e ra t io n s .......................................... 6M-6
Maintenance and A djustm ents.................................... 6M-5 Control V a l v e ......................................................... 6M-6
Adjustments ......................................................... 6M-5 Governor H ousing................................................... 6M-6
Vacuum Spinner Type - 2G C a rb u re t o r s ........................ 6M-5 Trouble Shooting......................................................... 6M-7

ENGINE GOVERNOR (VELOCITY TYPE)

GENERAL DESCRIPTION
A velocity type governor is used as optional equipment
on 230, 250, 292 and 283 truck engines.
The governor is mounted between the carburetor and
the intake manifold and automatically governs the maxi­
mum speed at which the truck engine may be operated, STABILIZER (NON-CHEATING) GOVERNOR
PISTON AND ROD THROTTLE VALVE
which in turn limits the maximum speed at which the THROTTLE SHAFT THROTTLE SHAFT
vehicle may be operated. NEEDLE TYPE
The governor (fig. 1G) is operated by the vacuum exist­ ROLLER BEARING -I—

ing in the intake manifold under varying conditions of

engine operation and the flow of air past the governor ADJUSTING
valve. A shaft carried on a needle type roller bearing
extends through the body of the governor and this shaft is
offset from the center line of the throat. On the shaft is
mounted a throttle plate or throttle valve. The valve is
slightly offset on the shaft and in its wide open position is
about 10 degrees from the vertical (fig. 1G).
ADJUSTING
The gas mixture rushing from the carburetor through SCREW
the governor throat strikes the offset throttle valve and
tends to draw it closed. This action is opposed by a ADJUSTING GOVERNOR
SCREW SPRING
governor spring which is attached to the valve shaft BUSHING CAM RIBBON
through a cam ribbon and cam. By adjusting the pull of
this spring, the governor valve can be made to remain
open, and then closed at a predetermined engine speed.
Adjustment of the spring pull is accomplished by changing
the number of spring coils operating by turning the ad­
justment cap. Fig . 1G - Diagrammatic V ie w of Governor for 6 -C y lin d e r Engine

CHEVROLET TRUCK SERVICE MANUAL

 ENGINE FUEL 6M-5

MAINTENANCE AND ADJUSTMENTS

Adjustments the adjustment as follows by means of the calibrating nut
All governors are calibrated and adjusted in assembly shown at "A."
to insure accurate control of the maximum engine speed
of the model vehicle for which it is intended. However, NOTE: Do not use the following adjustments
there will be occasions when minor adjustments are re­ unless absolutely necessary. These adjustments
quired to satisfy local conditions where the truck is affect basic governor calibration and should only
operating. be used if speed adjustment does not produce
To adjust a governor for higher speed, turn the adjust­ satisfactory results.
ing cap "C " (fig. 2G) counter-clockwise or to the left: for
lower speeds turn adjusting cap "C" clockwise or to the Too Sensitive
right. One turn on the adjusting screw will change the 1. If a governor is too sensitive or on the point of surg­
speed approximately 300-400 rpm or 4-5 mph. ing, remove adjusting cap and hexagonal shaft as­
When a more sensitive regulation is desired or if the sembly and place special hollow wrench A -24283 in
governor is too sensitive and inclined to surge, correct position on nut "A." Insert special adjusting wrench
A -25264 through this wrench and turn main adjusting
screw "B ” to the right one turn.
2. With hollow wrench in slot of nut “A,” turn this nut
to the right about 1/4 turn using the special wrench
A -25264. The main adjusting screw "B ” must be
kept from turning while nut "A" is adjusted.

Not Stable
1. If a more senstive governor is desired, adjust main
screw "B " to the left one turn and while holding this
screw in new position, turn nut "A" to the left 1/4
turn at a time until desired regulation is obtained.
2. When adjustment is completed, tap lightly on end of
hollow wrench so that nut "A" will seat properly.

2G ENGINE GOVERNOR
(VACUUM SPINNER TYPE)
GENERAL DESCRIPTION
The Model 2G Carburetor Governor (fig. 3G) provided valve will be determined by vacuum on the diaphragm and
with 327 and 366 V- 8 engines is a mechanically driven the tension of the governor or spring acting on the gov­
vacuum actuated mechanism set to govern engine speed at ernor lever.
4000 rpm maximum under full load conditions. With this Vacuum is applied to the diaphragm through a system
limit, full advantage of engine horsepower is allowed
without danger of excessive wear due to overspeeding.
This 4000 rpm limit establishes an excellent pattern for
shift control for automatic type transmissions.
The governor is comprised of two basic units; the cen­
trifugal control valve housed in the distributor (see En­
gine Distributors in Section 6 Y), and a carburetor actua­
tor which is mounted on the carburetor throttle body
(fig. 4G). These two components are inter-connected by
tubing.
An engine overspeed warning device is incorporated
into the governor as shown in Figure 4G. A description
of the overspeed warning system will be found in Sec­
tion 6 Y of this manual.

Operation
The function of the 2G governor is to limit engine speed
and yet allow a wider throttle opening when power is re­
quired. The throttle lever is connected to the throttle
shaft in such a manner that turning the throttle lever does
not actually force the throttle valves open but rather al­
lows them to follow the throttle lever because of the
governor spring tension. Thus when the throttle lever is
moved to wide open position, the position of the throttle Fig . 3 G - Distributor and Governor Mounting

CHEVROLET TRUCK SERVICE MANUAL

ENGINE FUEL 6M-6

of vacuum passages and restrictions in the throttle body plied to the diaphragm which acts to close the throttle
and governor housing. A speed sensitive centrifugal valves in opposition to the governor spring tension.
valve in the distributor acts as a vacuum break so that When power is required as load is increased, engine rpm
there is no vacuum applied to the diaphragm until the will drop causing distributor valve to open and allow the
desired governed speed is reached. When the governed governor spring to open the throttle valves further.
speed is reached the valve is closed and vacuum is ap­

DISTRIBUTOR CARBURETOR

BUTTERFLY VALVE

AIR INLET

SPIN N ER VALVE
ACTUATOR

LAMP BURN-OUT CHECKIN G CIRCUIT

IGN ITIO N
SWITCH - ~ £ -
OIL PRESSURE
SWITCH

I I I I I Is
AMBER
LAMP
BATTERY

Fig. 4 G - G overnor and Overspeed Warning Light Cross-Section

MAJOR SERVICE OPERATIONS

CONTROL VALVE
damaged in any way, it must be replaced.
Whenever the distributor is removed for overhaul, the 5. Remove the three governor attaching screws, then
governor control valve mechanism should be disassem­ remove the leather seal retainer and leather seal.
bled and cleaned (see Engine Distributors in Section 6 Y). 6 . Detach the governor housing from the throttle body.
7. The throttle lever and bearing assembly can be re­
GOVERNOR HOUSING moved by detaching the fast idle cam and pump rod
and removing the four attaching screws. No attempt
Removal should be made to service the throttle lever bearing.
1. Remove the four governor cover attaching screws If the action is sticky or binding to the point that the
and then the governor cover and gasket if used. throttle return spring cannot overcome the binding,
2. Detach and remove the governor spring. the throttle lever assembly should be replaced.
3. Remove the eight diaphragm cover attaching screws
and then th# diaphragm cover. Hold the throttle CAUTION: Since the idle ports in the throttle
lever to avoid damage to the throttle valves and body were drilled after the throttle body was
loosen the nut attaching the governor lever and pin assembled, the throttle valves were nicked dur­
assembly to the throttle shaft. Remove the governor ing the drilling operation. No attempt should be
lever from the throttle shaft, then detach it from the made to remove the throttle valve or to further
diaphragm rod by rotating the lever until the tang on disassemble the throttle body, since any slight
the rod clears the slot in the lever. change in positioning of the throttle valves with
4. Remove the diaphragm assembly from the housing relation to the idle ports would seriously disrupt
and inspect for cracks or holes. If the diaphragm is carburetor operation.

CHEVROLET TRUCK SERVICE MANUAL

 ENGINE FUEL 6M-7

Cleaning and Inspection 4. Check the throttle shaft for free rotation in the seal,
The throttle lever and bearing assembly should not be then tighten the housing screws. The throttle valves
immersed in any carburetor cleaner, since it might cause must be held in a closed position while tightening the
damage to the neophrene seal protecting the ball bear­ screws. Recheck for free rotation and repeat as­
ings. If the throttle body itself is immersed in solvent, sembly procedure if necessary.
great care must be taken that the throttle shaft bearings 5. Install the diaphragm in the governor housing with
are blown completely dry with compressed air. They may the end of the diaphragm rod pointing inward. With
then be lubricated with very light machine oil. Since the the diaphragm in this position the hole for the vac­
calibration of vacuum versus spring tension is of extreme uum passage in the diaphragm should line up with the
importance in governor operation, it can readily be seen vacuum passage in the housing. Assemble the gov­
that there should be no bind whatsoever in throttle shaft ernor lever and pin assembly to the diaphragm rod
rotation. If any binding is found, the throttle body as­ and position the lever on the throttle shaft. Install
sembly must be replaced. the nut and lockwasher, holding one of the throttle
valves between thumb and forefinger while tightening,
Installation to avoid damage to the throttle valves.
1. Position the gasket carefully on the throttle body and 6 . Position the diaphragm carefully over the screw
assemble the throttle lever and bearing assembly to holes in the housing. Position the cover so that
the throttle body with the four screws provided. To cover restriction pilots through the gasket and into
be certain that the throttle lever and throttle shaft the vacuum passage in the body. Install the eight
are in proper relation hold the throttle valve closed screws finger tight. Open the throttle valves wide to
while attaching the throttle lever assembly. Position provide maximum travel of the diaphragm and tighten
the throttle lever during assembly so that it fits the eight cover screws to 25 to 28 inch pounds of
easily onto the throttle body. If this procedure is torque while holding the diaphragm in this position.
followed the assembly will operate freely and Install lockwire on screws (shown in Figure 3G).
correctly. Install the governor spring over the lever pin and the
2. Place the governor housing to throttle body gasket in stationary post in the housing.
place, noting that the narrower edge goes toward the 7. Check again for free operation of the throttle shafts,
top of the carburetor. Then put the housing in place then install the governor, cover and four attaching
over the gasket. screws, and install lockwire (shown in Figure 3G).
3. Slide the leather seal and retainer over the throttle 8 . Attach the pump rod and fast idle cam to the throttle
shaft, position the screw holes in correct relation lever assembly.
and install the housing to throttle body screws 9. Install vacuum tube to diaphragm cover and distribu­
loosely. tor and install lockwire in attaching nuts (fig. 3G).

TROUBLE SHOOTING
(2G VACUUM SPINNER TYPE) the vacuum passages were to become clogged with
dirt, oil, or other foreign materials. Areas most
1. Loss of speed control: likely to "clog" are the orifices in the actuator, and
Check for vacuum leaks and operation of bleed valve the area where air bleeds through the distributor
in distributor. Also for proper seal of diaphragm "spinner" valve.
cover and condition of diaphragm itself. Vacuum in Either type of malfunctioning could be caused by:
the governor housing can be checked by removing the improper spinner setting; spring post out of position in
connection to the distributor and attaching a vacuum the carburetor actuator; bent or stretched spring in
line. If there is no vacuum reading check the dia­ actuator.
phragm for holes and be sure the vacuum passage is
clear. SUGGESTED PROCEDURE FOR FINDING
2. E rratic operation under load: CAUSES OF IMPROPER GOVERNING
Check for binding in throttle shaft and throttle lever.
1. Localize the trouble on the vehicle. With the vacuum
NOTE: Vacuum and free operation are two tube disconnected at the distributor, run the engine at
keys to correct operation of the Rochester gov­ about 3,000 rpm and place a finger over the end of
ernor. If all parts are free to move as intended the tube. If there is no noticeable change in engine
and there are no vacuum leaks, the unit will operation, the trouble is probably in the actuator or
operate correctly.
tubing. If the engine speed is noticeably affected by
Governing systems generally malfunction in one of two this, the distributor "spinner” can be suspected.
ways: 2. If distributor trouble is indicated perform the follow­
1. They do not govern at all. This could result from: ing operation (refer "Ignition System, Servicing units
a. A vacuum leak in the units or tubing. off the Vehicle" in Section 6 Y for detailed operation).
b. "Spinner" unit stuck due to dirt, oil, or some a. Remove distributor from engine, remove spinner
other material depositing in the mechanism. valve and clean and visually inspect the parts and
c. Orifices in the carburetor clogging so no vacuum passages for possible faults.
could be developed in the governing system. b. Check the seals. Do this by connecting the lower
2. The system "over governs”: governs when it should vacuum connector to a vacuum pump, and "plug­
not, causes loss of power, etc. This could result if ging" the valve hole in the shaft either with the

CHEVROLET TRUCK SERVICE MANUAL

ENGINE FUEL 6M-8

fingers or other suitable means. Slight "seepage" tube leakage and tube should be replaced.
around the seals is not abnormal; however, a vac­ If the tubing is alright, check the actuator unit for
uum gauge reading within 2 " hg. of the maximum leakage. With the orifices "stopped up" with the
that can be obtained with the vacuum hose fingers, or other means, no leakage should occur.
"squeezed" should be possible if the seals are in Also check for proper seal of diaphragm cover
satisfactory condition. If the seals leak exces­ and condition of diaphragm itself. Vacuum in the
sively they should be replaced. governor housing can be checked by removing the
c. When the spinner parts are reassembled, they connection to the distributor and attaching a vac­
should be wiped with a rag saturated with light oil uum line. If there is no vacuum reading check
to provide slight, but not excessive lubrication. the diaphragm for holes and be sure the vacuum
3. If actuator or tubing trouble is indicated: passage is clear.
a. Remove the vacuum tube at the actuator, run the c. If no leakage is found, clean all of the component
engine at about 3000 rpm and place a finger over parts.
the end of the actuator. If there is no change in If tampering is suspected, visually check parts
engine operation, probably the actuator is at fault. with the governing parts of an engine that is gov­
A significant change in engine rpm would indicate erning properly.

AIR CLEANERS
INDEX
Page Page
General Description......................................................... 6M-8 Tool J-7825 .................................................................. 6M-10
Maintenance P r o c e d u r e s ................................................ 6M-9 Cleaning Polyurethane B a n d ....................................... 6M-10
Element R ep lacem en t................................................ 6M-9 Cleaning Oil Bath C l e a n e r .......................................... 6M-11
Testing Paper E l e m e n t ............................................. 6M-9

GENERAL DESCRIPTION
Air cleaners on all models operate primarily to re­ is used in conjunction with an exhaust manifold heat stove
move dust and dirt from air before it is drawn into the (fig. 4A). Air temperature is automatically controlled by
carburetor and engine. The air cleaner also helps to a thermostatic valve which selects warmed air from the
reduce engine noise and quenches any flame that may be heat stove and/or cooler air from the engine compart­
caused by engine backfire through the carburetor. ment or from outside the vehicle.
Three types of air cleaners are used on 1967 Chevrolet Diesel engine applications require the use of several
trucks. They are the oil wetted paper element air types of oil bath air cleaners. All types are serviced in
cleaner, the two element air cleaner and the oil bath air a manner sim ilar to the gasoline engine oil bath air
cleaner. cleaners.
The oil wetted paper element air cleaner (fig. 1A) con­
sists of an accordian pleated oiled paper filter supported
by wire mesh with a plastisol seal on both top and bottom.
The two element air cleaner (fig. 2A) consists of an oil
wetted polyurethane band wrapped around an oil wetted
paper element.
The oil bath air cleaner (fig. 3A) utilizes an oil sump
in the air cleaner bottom and a fibre element.
On most applications of the two element air cleaner it

OIL RESISTANCE
SEAL

BONDED PAPER
BOTTOM ELEMENT COVER

Fig . 1A - Paper Element A ir Cleaner Fig . 2A - Two Element A ir Cleaner

CHEVROLET TRUCK SERVICE M ANUAL

 ENGINE FUEL 6M-9

MAINTENANCE PROCEDURES
Element Replacement Testing Paper Element
1. Remove air cleaner cover. Tool J-7825, is designed to check paper element air
2. Remove element and on two element air cleaners re­ cleaners to determine whether the element has materially
move polyurethane band from paper element. decreased in efficiency and should be replaced or has
3. Remove bottom section of air cleaner and remove only slightly increased air restriction and is suitable for
and discard air cleaner gasket. further service. In combination with a tachometer, this
4. Clean bottom section of air cleaner and air cleaner instrument will quickly and accurately determine the air
cover thoroughly. cleaner element condition.
NOTE: Check seal on bottom of air cleaner NOTE: Before testing, inspect for holes or
for tears or cracks. Refer to Figure 1A. breaks in the element, as these defects require
immediate replacement. If no holes or breaks
5. Install bottom section of air cleaner with a new air
exist, proceed as follows:
cleaner gasket.
6 . Install new paper element on bottom section of air 1. Remove all hoses and plug all openings except air
cleaner with either end up. On two element air cleaner inlet.
cleaners, install cleaned polyurethane band over 2. Install air cleaner (without polyurethane band on two
paper element before installing paper element. element air cleaner), using Tool J-7825 in place of
7. Install air cleaner cover. the wing nut. Screw Tool J-7825 onto the stud until
it seals tightly against the air cleaner cover. Rotate
the entire tool so that the scale can be read from the
left side of the truck. Be sure the vent hole is to­
ward the dash (fig. 5A).
3. Connect a tachometer and place it so that it may be
read simultaneously with Tool J-7825 (fig. 5A).
4. Zero oil level in the inner tube by pulling inner tube
upward until the rubber seal is above the vent hole,
then raise or lower as required until the inner tube
oil level is exactly to the " 0 " mark.
5. Start engine. If engine is cold, allow to run for 2 to
3 minues. The choke must be fully open.
6 . Accelerate the engine slowly until the inner tube oil
level of Tool J-7825 just reaches the 1/4 mark. Al­
low engine speed to stabilize and note tachometer
(rpm) reading. Decelerate engine.
Fig. 3A - O il Bath A ir C leaner 7. If the tachometer reading is at or below the follow­

CONVENTIONAL CAB

Fig . 4A - Carburetor Heat Stove

CHEVROLET TRUCK SERVICE MANUAL

ENGINE FUEL 6M-10

ing, the oil wetted paper air cleaner element is re­

stricted beyond the allowable limit and should be
replaced. If testing indicates that the element re­
striction is satisfactory at 1 2 , 0 0 0 m iles, the element
need not be replaced but should be retested every
6 , 0 0 0 miles thereafter until replaced.

Minimum Allowable RPM

Engine Paper Two Element
230 cu. in. 2700 N.A.
250 cu. in. 1425 1550
292 cu. in. 3300 1100
283 cu. in. 2300
327 cu. in. 2100
366 cu. in. N.A. 1375

8 . Remove tachometer and Tool J-7825 from vehicle Fig. 6A - F illin g Tool W ith O il
and push down inner tube until seal is below vent
hole to prevent oil loss.
Cleaning Polyurethane Band
CAUTION: Install polyurethane band on two
1. Remove air cleaner element and remove polyure­
element air cleaners.
thane band from paper element.
2. Inspect the polyurethane band for tears and replace if
Tool J-7825 necessary. If not torn, wash polyurethane band in

FilingTool
Tool J-7825 is shipped dry and must be filled with the
kerosene or mineral spirits; then squeeze out excess
solvent (fig. 7A).
NOTE: Never use a hot degreaser or any sol­
red gauge oil (specific gravity .826) provided.
vent containing acetone or sim ilar solvent.
Pull the knurled inner tube completely out of the gauge
and add oil to the reservoir until the oil level is between 3. Dip element into light engine oil and squeeze out ex­
the two "F IL L " lines (fig. 6 A). Refill whenever the level cess oil.
falls below the lower "F IL L " line.
NOTE: Never shake, swing or wring the ele­
ment to remove excess oil or solvent as this
Storing Tool
may tear the polyurethane material. Instead,
When the tool is not in use, fully depress the inner
"squeeze" the excess oil from the element.
tube. This seals off the oil reservoir from the vent hole
to prevent oil loss if the tool is tipped. 4. Check the paper element as previously outlined
(without the polyurethane band).
Install the polyurethane band around the paper ele­
ment and install the air cleaner element.

F ig . 5A - Testing Paper Element F ig . 7A - Cleaning Polyurethane Band

CHEVROLET TRUCK SERVICE M ANUAL

 ENGINE FUEL 6M -11

Cleaning Oil Bath Cleaner 4. Screw in a new thermostatic element until it just
1. At every engine oil change period, remove the air bottoms on the push rod (with the valve held closed
cleaner assembly. by the spring). Immerse cover and element in water
2. Remove cover and filter element assembly. of 83°F for two to three minutes, then screw the ele­
3. Empty oil out of cleaner and clean out all oil and ac­ ment in further until the cover air valve just begins
cumulated dirt. to open. Tighten jam nut. Raise water temperature.
4. Wash body with cleaning solvent and wipe dry. Valve should be fully open at 120°F.
5. Wash filter element by sloshing up and down in 5. Replace the cover and wing nut, and the sheet metal
cleaning solvent. to air cleaner cover hose.
6 . Dry filter unit with an air hose or let stand until dry.
7. F ill body of cleaner to full mark with SAE 50 engine
oil. If expected temperatures are to be consistently
below freezing, use SAE 20 engine oil.
8 . Assemble filter and cover assembly to body of
cleaner.
9. Install cleaner, making sure it fits tight and is set
down securely.

CHECKING THERMOSTATIC ELEMENT

Before replacing the thermostatic element, check the
operation of the air valve to see that it works freely and
does not bind. Replace any bent or broken air valve
components and before making the following check of the
thermostatic element.
The air valve thermostatic element may be easily
checked for proper operation whenever the cover is re­
moved for regularly scheduled element cleaning. At this
tim e, immerse the cover (far enough to cover the ther­
mostat pellet) in water of less than 80°F. The valve
should remain closed. Gradually raise temperature of
the water. The valve should begin to open at a water
temperature of 83 °F and be fully open at a temperature of
120°F.

Thermostat Replacement
1. Remove sheet metal to air cleaner hose from the air
cleaner cover.
2. Remove the wing nut and cover.
3. Loosen the jam nut and unscrew the thermostatic
element. Fig. 8A - Thermostatic A ir V a lv e P a llet Replacement

AIR CLEANERS

CHEVROLET TRUCK SERVICE M ANUAL

ENGINE FUEL 6M-12

CHEVROLET TRUCK SERVICE MANUAL

 ENGINE FUEL 6M-13

FUEL PUMPS
INDEX
Page Page
General Description..........................................................6M-13 Installation . ............................................................ 6M-14
Service P ro c e d u re s ......................................................... 6M-13 Disassembly ......................................................... 6M-14
Fuel Pump Inspection and T e s t ................................. 6M-13 Cleaning and In sp ectio n .......................................... 6M-15
Vacuum Section Inspection and T e s t ........................... 6M-14 A ssem b ly .................................................................. 6M-15
Removal ............................................................... 6M-14

GENERAL DESCRIPTION

The fuel pumps used on both six and eight cylinder en­
gines are of the diaphragm type. Two types of diaphragm
fuel pumps are used, a servicable combination fuel and
vacuum pump and a non-servicable fuel pump that be­
cause of design, is serviced as an assembly only.
The pumps are actuated by an eccentric located on the
engine camshaft. On in-line engines, the eccentric actu­
ates the pump rocker arm. On V- 8 engines, a push rod
(located between the camshaft eccentric and fuel pump)
actuates the rocker arm.

Fig. 2P - Step-Van Fuel and Vacuum Pump

1. O u tlet V a lv e 10. Pulsator Diaphragm

2. Fuel Cover 11. Fuel Inlet V a lv e Assembly
OUTLET
3. Fuel Diaphragm 12. Pump Body
4. Fuel Diaphragm Spring 13. Rocker Arm Return Spring
5. Vacuum Link 14. Seal
INLET 6. Fuel Link 15. Rocker Arm
7. Vacuum O u tlet V a lv e 16. Bushing
Assemblies 17. Vacuum Diaphragm
8. Diaphragm Spring 18. Vacuum Inlet V a lv e Assemblies
Fig. I P - Fuel Pump (N o n -Serviceab le) 9. Pulsator Cover 19. Vacuum Cover

SERVICE PROCEDURES
FUEL PUMP INSPECTION AND TEST sure there is gasoline in the tank.
The line from the tank to the pump is the suction side
The fuel pump should be checked to make sure the of the system and the line from the pump to the carbure­
mounting bolts and inlet and outlet connections are tight. tor is the pressure side of the system. A leak on the
Always test pump while it is mounted on the engine and be pressure side, therefore, would be made apparent by

CHEVROLET TRUCK SERVICE MANUAL

ENGINE FUEL 6M-14

dripping fuel, but a leak on the suction would not be ap­ 3. A further test of vacuum pump may be made by at­
parent except for its effect of reducing volume of fuel on taching a vacuum gauge to the inlet port (port con­
the pressure side. nected to wiper motor) with outlet pipe disconnected.
1. Tighten any loose line connections and look for bends
or kinks in lines which would reduce fuel flow. CAUTION: Always make this test of vacuum
2. Tighten diaphragm flange screws. pump with outlet open.
3. Disconnect fuel pipe at carburetor. Disconnect dis­
tributor to coil primary wire so that engine can be 4. With engine operating at 750 rpm the gauge should
cranked without firing. Place suitable container at show 10 to 12 inches of vacuum. Less than 10 inches
end of pipe and crank engine a few revolutions. If of vacuum indicates an inoperative vacuum pump.
little or no gasoline flows from open end of pipe then
fuel pipe is clogged or pump is inoperative. Before Removal
removing pump disconnect fuel pipe at gas tank and 1. Disconnect fuel inlet and outlet pipes at fuel pump.
outlet pipe and blow through them with an air hose to On "P " Models, disconnect vacuum lines at pump.
make sure they are clear. Reconnect pipes and re­ 2. Remove fuel pump mounting bolts and remove pump
test while cranking engine. and gasket.
3. On V- 8 engines: if push rod is to be removed, re­
CAUTION: Whenever the engine is cranked re­
move fuel pump adapter and gasket then remove push
motely at the starter, with a special jumper
rod (283 and 327 engines).
cable or other means, the primary distributor
4. If a new fuel pump is to be installed, transfer fittings.
lead must be disconnected from the negative post
on the coil and the ignition switch must be in the NOTE: After removal of pump from engine and
”ON” position. Failure to do this will result in a before disassembly is started, plug all openings
damaged grounding circuit in the ignition switch. and thoroughly wash exterior of pump with
cleaning solvent to remove all dirt and grease.
4. If fuel flows from pump in good volume from pipe at
carburetor, check fuel delivery pressure to be cer­ Installation
tain that pump is operating within specified limits as 1. On V - 8 engines: if removed, install fuel pump push
follows: rod and fuel pump adapter. Use gasket sealer on
a. Attach a fuel pump pressure test gauge to discon­ gasket or pipe fitting.
nected end of pump to carburetor pipe. 2. Install fuel pump using a new gasket and tighten se­
b. Run engine at approximately 450-1,000 rpm (on curely. Use sealer on fuel pump mounting bolt
gasoline in carburetor bowl) and note reading on threads.
pressure gauge.
NOTE: On V- 8 engines, a pair of mechanical
c. If pump is operating properly the pressure will be
fingers may be used to hold fuel pump push rod
within specifications and will remain constant at
up while installing fuel pump (fig. 3P).
speeds between 450-1,000 rpm. If pressure is
too low, too high, or varies materially at different 3. Connect fuel pipes to pump. On "P ” Models connect
speeds, the pump should be replaced. vacuum lines to pump.
4. Start engine and check for leaks.
VACUUM SECTION INSPECTION AND TEST
NOTE: These procedures can be used only on
FUEL AND VACUUM PUMP UNIT
the combination pump.
Disassembly
Test the vacuum section of the pump by fully opening 1. Scratch locating marks on fuel cover and pump body
the windshield wiper valve and observe wiper blade speed so that inlets and outlets will be properly located
while alternately idling and accelerating the engine. when pump is reassembled.
Wiper blade speed should be fairly constant regardless of 2. Remove bolt and lockwasher holding down pulsator
engine speed or throttle opening. cover on fuel side of pump. Remove pulsator cover
and pulsator diaphragm.
NOTE: A dry windshield will slow wiper
3. Remove screws and washers holding fuel cover to
speed. If windshield wiper does not operate
pump body and remove cover.
properly, make the following inspection and test.
4. Place pump rocker arm in soft jawed vise so that
1. Make certain that hoses are properly connected at vacuum side is up and remove all vacuum cover
pump, wiper motor and control at instrument panel screws except any two that are diametrically
and double check valve, and that connections are air opposite.
tight. Replace cracked or deteriorated hose. 5. P ress down firmly on vacuum cover to hold heavy
2. If windshield wiper does not operate properly after vacuum diaphragm spring compressed and remove
all points of leakage have been corrected, detach both remaining two screws. Release vacuum cover slowly
pipes at vacuum pump and join them with a piece of and remove cover assembly, diaphragm spring and
tubing. Slowly operate engine from idle to about spring retainer.
1 0 0 0 rpm; the wiper should run at full speed operat­
ing on engine vacuum only. If it does not, it can be NOTE: If desired, two 10-32NF 1-1/2" screws
assumed that the wiper motor or tubing is defective. may be screwed diametrically opposite into cover
The pump vacuum section is inoperative if the wind­ to aid in relieving diaphragm spring pressure
shield wiper operated properly on engine vacuum, but when removing cover.
not on pump vacuum. 6 . Lift vacuum diaphragm and remove vacuum valve

CHEVROLET TRUCK SERVICE M ANUAL

 ENGINE FUEL 6M-15

Cleaning and Inspection

1. Clean and rinse all metal parts in solvent. Blow out
all passages with air hose.
2. Inspect pump body, fuel cover, and vacuum cover for
cracks, breakage and distorted flanges. Examine all
screw holes for stripped or crossed threads. If any
of these three parts are damaged or if pressed in
vacuum pipes in vacuum cover are bent or loose the
pump should be replaced.
3. Inspect rocker arm for wear or scoring at camshaft
pad, at point of contact with links and at pivot hole 0
Inspect bushing for wear.

Assembly
1. Install seals by placing seal and retainer in pull rod
recess of pump body with rubber end down toward
Fig. 3P - Installing 283, 327, V8 Engine Fuel Pump links and press down firmly with flat end of 7/8"
diameter round bar.
from body under diaphragm at rocker arm side. 2. Stake die cast lip in four places to retain seals.
7. Unhook vacuum diaphragm pull rod from vacuum 3. Assemble link spacer over fuel link.
link. This can best be done by extending vacuum 4. Place one vacuum link on each side of fuel link. The
diaphragm and tilting towards rocker arm while roll­ hook ends of vacuum link should come together so
ing pull rod off link (fig. 4P). that they surround fuel link. All link hooks should
8 . Remove pump from vise, invert pump so fuel side is point in same direction.
up, and reinstall rocker arm in vise. Have pump 5. Place assembly of links and spacer between lobes of
body flush with jaw of vise. rocker arm with one spacer washer on outer side of
9. Use a 3 /8 ” or slightly larger drill or a file to re­ each vacuum link.
move portion of rocker arm pin which is upset over 6 . Slide rocker arm bushing through hole in rocker
pin washer. arm, spacer washers, links and link spacer. Place
10. Drive out rocker arm pin using a long tapered drift. thick washer over both ends of bushing. (See Figure
11. Remove rocker arm, rocker arm spring, spacer 5P for correct placement of all parts in rocker arm
washers, fuel and vacuum links, link spacer and and link assembly.)
rocker arm bushing from pump. 7. Set fuel pump on bench with mounting flange up.
12. Remove fuel diaphragm. 8 . Install rocker arm spring into body placing one end
13. Remove metal around diaphragm pull rod seals, over cone-like projection in pump body.
which was displaced by staking, with chisel, small 9. Holding washers onto rocker arm bushing, slide the
round file or small grinding wheel. Pull seals out of rocker arm and link assembly into pump body (fig.
body with hook shaped tool, using care not to damage 6 P). Projection on link spacer should fit into end of
seal seats. rocker arm spring and open end of link hooks must
14. Remove all valves in fuel and vacuum covers in the point toward vacuum flange.
same manner. 10. Drive new rocker arm pin through bushing and install

F ig . 4P - Removing Vacuum Diaphragm F ig . 5P - Rocker Arm and Link Assembly

CHEVROLET TRUCK SERVICE M ANUAL

ENGINE FUEL 6M-16

ROCKER
ARM A N D
LINK
A SSEM BLY

Fig. 8P - Hooking Vacuum Pull Rod to Vacuum Link

13. Install gaskets and fuel valves in fuel cover. Stake

valves into position.
14. Soak fuel diaphragm in clean kerosene. Fuel oil may
Fig. 6P - Installing Rocker Arm and Link Assembly be used, but do not use shellac or sealing compound.
15. Set fuel diaphragm on bench with pull rod pointing up.
flat washer on small end. Peen over end of pin to Assemble retainer and diaphragm spring over fuel
retain in position. diaphragm pull rod.
11. Install gaskets and vacuum valves in vacuum cover. 16. Pick up pump body, with vacuum flange up, in one
After pressing down to accomplished seal against hand, and the fuel diaphragm assembly in the other.
gasket, stake valves in position. Position end of diaphragm spring into well of fuel
side of pump body.
NOTE: Do not install inlet valve in pump body 17. With vacuum side of pump still up, shake fuel link
until diaphragm is installed. into position to engage with pull rod.
18. Position diaphragm in palm of hand so that flat of
12. Install inlet screen, gasket and retainer in fuel cover pull rod is parallel with fuel link (fig. 7P). Push
inlet passage. pull rod through oil seal against spring tension.
Turn diaphragm 90° so that pull rod "ro lls" onto
link. This motion should engage hook end of link
with "eye" of pull rod. If not, repeat this operation
until connection is made.
CAUTION: Extreme care must be used when
inserting diaphragm push rod through seal to
prevent damage to seal.
19. Install fuel cover on body making sure that scratch
marks on cover and body line up. Push on rocker
arm until diaphragm is flat across body flange.
Install cover screws and lockwashers loosely until
screws just engage lockwashers. Push rocker arm
through its full stroke and hold in that position while
tightening cover screws securely.
NOTE: Diaphragm must be flexed before tight­
ening cover screws to insure proper clearances
and pump stroke.
20. Place pulsator diaphragm on pump body. Install
pulsator cover with bolt and lockwasher.
21. Place rocker arm in vise with vacuum flange of pump
up.
22. With one hand push pump down against spring tension
Fig. 7P - Installing Fuel Diaphragm so it travels through half a stroke and hold. With the

CHEVROLET TRUCK SERVICE M ANUAL

 ENGINE FUEL 6M-17

other hand insert the vacuum diaphragm pull rod piece of metal between rocker arm stop and body.
through oil seal. Have flat of pull rod parallel to This tool can be made from a piece of steel 3/16" x
vacuum links. 3/32" x 6 ". Bend one end to form a right angle 3 /8 ”
from bend to end.
CAUTION: Be extremely careful when insert­ 26. Place spring retainer on riveted end of diaphragm
ing diaphragm push rod through seal to avoid pull rod and place the diaphragm spring on the re­
damaging seal. tainer. Place vacuum cover over spring and align
holes.
23. Let up slightly on pump and turn diaphragm 90° so 27. P ress vacuum cover firmly down against diaphragm
that pull rod rolls onto link (fig. 8 P). and body flange and install two screws diametrically
24. Lift diaphragm cloth and position valve and cage in opposite. (Two 10-32NF x 1-1/2" screws may be
recess close to mounting flange. No gasket is re­ installed to pull vacuum cover down.) Install re­
quired because the diaphragm seals the valve cage. maining vacuum cover screws and tighten until
25. Before installing vacuum cover, rocker arm must be screws just engage lockwashers.
positioned so that vacuum diaphragm will be held 28. Release rocker arm to allow heavy vacuum spring to
level with the body flange while the vacuum cover is push diaphragm to flexing stop in body. Tighten all
installed. This can be done by inserting a 3/32 inch cover screws securely.

SPECIAL TOOLS

J —7825

5% ^
J —11 37
J —5197
J —4552

3
J-6058A

J —6556
J —54961
Lnj
BENDING TOOLS

F ig . IT - Engine Fuel Special Tools

CHEVROLET TRUCK SERVICE MANUAL

 SECTION 6T

AIR INJECTION REACTOR SYSTEM

INDEX
Page Page
General D e s c r ip t io n ......................................................... 6T-1 Check V a l v e ( s ) ............................................................... 6T-3
Maintenance P ro c e d u re s ................................................... 6T-2 Inspection..................................................................... 6T-3
Drive Belt ......................................................................6T-2 Replacement ............................................................... 6T-3
Inspection..................................................................... 6T-2 Mixture Control Valve ....................................................6T-3
A d ju stm en t.................................................................. 6T-2 Inspection..................................................................... 6T-3
Replacement ............................................................... 6T-2 Replacement ............................................................... 6T-3
Drive P u l l e y .................................................................. 6T-2 A ir Injection T u b e ......................................................... 6T-3
Replacement ............................................................... 6T-2 Inspection..................................................................... 6T-3
Pump P u l l e y ...................................................................6T-2 Replacement ............................................................... 6T-4
Replacement ............................................................... 6T-2 A ir Injection Pump ...................................................... 6T-4
A ir Manifold, Hose and T u b e ........................................6T-2 Inspection..................................................................... 6T-4
Inspection......................................................................6T-2 Pressure Relief Valve Replacement........................... 6T-4
R e p la c e m e n t................................................................6T-2 Special T o o l s ..................................................................... 6T-5

GENERAL DESCRIPTION
The Air Injection Reactor (A.I.R.) System (fig. 1), used it through the air manifolds, hoses and injection tubes
on all engines in 10 Series and Suburban Carry-All 20 into the exhaust system in the area of the exhaust valves.
Series Trucks in California consists of: the air injection The fresh air ignites and burns the unburned portion of
pump (with necessary brackets and drive attachments), the exhaust gases in the exhaust system, thus minimizing
air injection tubes (one for each cylinder), a mixture exhaust contamination.
control valve, check valves (one for In Line engines, two The mixture control valve (fig. 3) when triggered by a
for V8 engines) and air manifold assemblies, tubes and sharp increase in manifold vacuum, supplies the intake
hoses necessary to connect the various components. manifold with fresh filtered air to lean out the fuel-air
Carburetors and distributors for engines with the mixture and prevent exhaust system backfire.
A.I.R. System are designed, particularly, for these en­ The check valve(s) prevent exhaust gases from entering
gines; therefore, they should not be interchanged with or and damaging the air injection pump, as back flow can
replaced by a carburetor or distributor designed for an occur even under normal operating conditions.
engine without the A.I.R. System. When properly installed and maintained, the A.I.R.
The air injection pump (fig. 2) picks up fresh filtered System will keep exhaust emissions well below the re­
air from the air cleaner, compresses the air and injects quirements. However, if any A.I.R. component or any

Fig . 1—A ir Injectio n Reactor System

CHEVROLET TRUCK SERVICE M ANUAL

AIR INJECTOR REACTOR SYSTEM 6T-2

VALVE IN AIR INLET

PU M P
OPEN VALVE IN
PU M P
H O U S IN G C O VER
POSITION CLOSED
POSITION

CHECK
DIAPHRAGM VALVE
POSITIONS

P R ESSU R E IN TAK E
RELIEF V A LV E TUBE
Fig. 3—M ixtu re Control V a lv e

and “ Unburned Exhaust Gases” , the condition of the En­

gine Tune Up should be checked whenever the A.I.R. Sys­
tem seems to be malfunctioning. Particular care should
be taken in checking items that affect fuel - air ratio such
Fig. 2—A ir In jectio n Pump as the crankcase ventilation system, the carburetor and
the carburetor air cleaner.
engine component that operates in conjunction with the Because of the similarity of many parts, typical illus­
A.I.R. system should malfunction, the exhaust emissions trations and procedures are used except where specific
might be increased. illustrations or procedures are necessary to clarify the
Because of the relationship between "Engine Tune Up" operation.

MAINTENANCE PROCEDURES
Drive Belt Pump Pulley
Inspection Replacement
• Inspect drive belt for wear, cracks or deterioration • Hold pump pulley from turning by compressing drive
and replace if required. belt then loosen pump pulley bolts.
• Inspect belt tension and adjust if below 50 lbs. using • Remove drive belt as outlined above then remove
a strand tension gauge. pump pulley.
• Install pump pulley with retaining bolts hand tight.
Adjustment
• Install and adjust drive belt as outlined above.
• Loosen pump mounting bolt and pump adjustment
• Hold pump pulley from turning by compressing drive
bracket bolt.
belt then torque pump pulley bolts to 25 ft. lbs.
• Move pump until belt is tight (55 ± 5 lb. used belt or
• Recheck drive belt tension and adjust if required.
75 ± 5 lb. new belt using a strand tension gauge) then
tighten adjustment bracket bolt and mounting bolt.
Air Manifold, Hose and Tube
CAUTION: Do not pry on the pump housing. Inspection (Fig. 4)
Distortion of the housing will result in extensive • Inspect all hoses for deterioration or holes.
damage to the Air Injection Pump. • Inspect all tubes for cracks or holes.
Replacement • Check all hose and tube connections.
• Loosen pump mounting bolt and pump adjustment • Check all tube and hose routing. Interference may
bracket bolt then swing pump until drive belt may be cause wear.
removed. • If leak is suspected on the pressure side of the sys­
• Install a new drive belt and adjust as outlined above. tem or any tubes and/or hoses have been discon­
nected on the pressure side, the connections should
Drive Pulley be checked for leaks with a soapy water solution.
With the pump running, bubbles will form if a leak
Replacement
exists.
• Remove drive belt as outlined above then replace
drive pulley. Replacement
• Install and adjust drive belt as outlined above. • To replace any hose and/or tube, note routing then

CHEVROLET TRUCK SERVICE M ANUAL

 AIR INJECTOR REACTOR SYSTEM 6T-3

Replacement
• Disconnect pump outlet hose at check valve. Remove
check valve from air manifold, being careful not to
bend or twist air manifold.

Mixture Control Valve

Inspection
• Check condition and routing of all lines especially
the signal line. A defective signal or outlet line will
cause malfunctioning of the mixture control valve.
• Disconnect pump to valve inlet hose at pump.
• Leaking valve will be indicated by an air gushing
noise coming from the hose. Place palm of hand over
hose; little or no pull with a gradual increase is
normal. If immediate strong pull is felt or air noise
is heard, valve is defective and should be replaced.
• Open and close throttle rapidly. Air noise should be
evident and then gradually decrease. Check for
proper valve usage. If strong pull is not felt im­
mediately or air noise is not present, valve is not
functioning properly and should be replaced.
• A noisy valve should be replaced.
Replacement
• Disconnect the signal line, air inlet and air outlet
hoses then remove the valve.
• Install new valve and connect air outlet, air inlet
and signal line hoses.

CAUTION: Mixture c o n t r o l valves, though

sim ilar in appearance are designed to meet the
particular requirements of various engines,
therefore, be sure to install the correct valve.

Air Injection Tube

Inspection (Fig. 5)
• There is no periodic service or inspection for the
Fig. 4 —A ir M an ifo ld , Hose and Tube Routing

remove hose(s) and/or tube(s) as required.

CAUTION: The 1/4" pipe threads at the cylin­
der head (In Line) or exhaust manifold (V8 ) are
a straight pipe thread. Do not use a 1/4” tapered
pipe tap. The hoses of the A.I.R. System are a
special material to withstand high temperature.
No other type hose should be substituted.
• Install new hose(s) and/or tube(s), routing them as
when removed.
• Tighten all connections.
NOTE: Use anti seize compound on threads of
the air manifold to exhaust manifold or cylinder
head connections.
Check Valve
Inspection
• The check valve should be inspected whenever the
hose is disconnected from the check valve or when­
ever check valve failure is suspected. (A pump that
had become inoperative and had shown indications
of having exhaust gases in the pump would indicate
check valve failure).
• Orally blow through the check valve (toward air
manifold) then attempt to suck back through check
valve. Flow should only be in one direction (toward
the air manifold).

CHEVROLET TRUCK SERVICE MANUAL

AIR INJECTOR REACTOR SYSTEM 6T-4

air injection tubes, yet on In Line engines whenever

the cylinder head is removed or on V8 engines when­
ever the exhaust manifolds are removed, inspect the
air injection tubes for carbon build up and warped or
burnt tubes.
• Remove any carbon build up with a wire brush.
• Warped or burnt tubes must be replaced.
Replacement
• On In Line engines remove carbon from tubes and
using penetrating oil, work tubes out of cylinder
head.
• On V8 engines clamp exhaust manifold in a vise,
remove carbon from tubes and using penetrating oil,
work tubes out of manifold.
• Install new tubes in cylinder head or manifold.

Air Injection Pump

Inspection
Accelerate engine to approximately 1500 RPM and ob­
serve a ir flow from hose(s). If air flow increases as
engine is accelerated, pump is operating satisfactorily.
If air flow does not increase or is not present, proceed
as follows:
• Check for proper drive belt tension.
• Check for a leaky pressure relief valve. Air may be
heard leaking with the pump running.
NOTE: The A.I.R. System is not completely
noiseless. Under normal conditions noise rises
in pitch as engine speed increases. To deter­
mine if excessive noise is the fault of the Air
Injection Reactor System, operate the engine
with the pump drive belt removed. If excessive Fig. 7— Installing Pressure R e lief V a lv e

noise does not exist with the belt removed

proceed as follows:
• Check for a seized Air Injection Pump.
• Check hoses, tubes, air manifolds and all connec­
tions for leaks and proper routing.
• Check carburetor air cleaner for proper installation.
• Check air injection pump for proper mounting.
• If none of the above conditions exist and the air in­
jection pump has excessive noise remove then repair
as outlined in the Overhaul Manual.
Replacement
• Disconnect the hoses at the pump.
• Remove pump pulley as outlined.
• Remove pump mounting bolts and remove pump.
• Install pump with mounting bolts loose.
• Install pump pulley as outlined.
• Install and adjust belt as outlined.
• Connect the hoses at the pump.
Pressure Relief Valve Replacement
1. Using J - 7055-5 and J-6585 pull relief valve from
housing (fig. 6 ).
2. Using a 15/16" socket tap the relief valve into hous­
ing until the valve shoulders on the housing (fig. 7).
CAUTION: Use extreme care to avoid distort­
ing housing.
NOTE: Various length pressure setting plugs
(fig. 8 ) designed for the particular requirements
Fig. 6 —Removing Pressure R e lie f V a lv e of vehicle - engine combinations, determine the

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 AIR INJECTOR REACTOR SYSTEM 6T-5

pressure required to open the relief valve. For

identification, the pressure setting plugs are
color coded. To remove the pressure setting
plug, carefully unlock legs from inside surface
of relief valve with a small screw driver. To
install the pressure setting plug, carefully push
into relief valve until legs lock. If a pressure
setting plug is to be reused be sure leg angles
are sufficient for the pressure setting plug to
lock in place.

SILVER-250
RED-292
GREEN-283

Fig. 8— Pressure Setting Plug

SPECIAL TOOLS

J-7055-5

J-6585

1-21844

J-21058

F ig . 9—Sp ecia l Tools

CHEVROLET TRUCK SERVICE MANUAL

'

.
 SECTION 6Y

ENGINE ELECTRICAL

CONTENTS OF THIS SECTION

Page Page
B a t t e r y ...............................................................................6Y-1 Starting System 6Y-34
Charging S y s te m ................................................................6Y-7 Special Tools . 6Y-37
Ignition S y ste m ...................................................................6Y-18

BATTERY

INDEX

Page Page
General D e s c r ip tio n ......................................................... 6Y-1 Safety Precautions . . ................................................... 6Y-4
Types of B a tte rie s ......................................................... 6Y-1 Charging Procedures......................................................... 6Y-4
Dry Charged Batteries ............................................. 6Y-1 Slow Charging ............................................................... 6Y-4
Activating Dry Charged B atteries.............................. 6Y-2 Fast C h a r g i n g ............................................................... 6Y-4
Wet Charged Batteries ............................................. 6Y-3 Emergency Boost C h a r g in g .......................................... 6Y-5
Periodic S e r v ic e ............................................................... 6Y-3 Test P r o c e d u re s ............................................................... 6Y-5
Common Causes of Failure ...........................................6Y-3 Visual Inspection ......................................................... 6Y-5
Electrolyte Level ......................................................... 6Y-4 In s tru m e n t......................................................................6Y-5
Water U s a g e .................................................................. 6Y-4 Full Charge Hydrometer Test .................................... 6Y-5
Cleaning........................................................................... 6Y-4 Specific Gravity R e a d in g s ............................................. 6Y-5
Cables ........................................................................... 6Y-4 Cell Comparison T e s t ................................................ 6Y-6
C arrier and H olddow n................................................... 6Y-4 Installing Battery ............................................................ 6Y-6

GENERAL DESCRIPTION

The Battery (fig. lb) is made up of a number of sepa­ The hard, smooth one-piece cover greatly reduces the
rate elements, each located in an individual cell in a tendency for corrosion to form on the top of the Battery.
hard rubber case. Each element consists of an assembly The cover is bonded to the case with sealing compound
of positive plates and negative plates containing dis­ that forms an air tight seal between the cover and case.
sim ilar active materials and kept apart by separators. Protection for the Battery charging circuit (10 gage
The elements are immersed in an electrolyte composed wire) is provided by a pigtail lead which is a fusible
of dilute sulfuric acid. Plate straps located on the top link off the battery positive cable (14 gage wire). This
of each element connect all the positive plates and all lead is an integral part of the Battery cable assembly
the negative plates into groups. The elements are con­ and servicing requires replacing the complete cable
nected in series electrically by .connectors that pass assembly.
directly through the case partitions between cells. The
battery top is a one-piece cover of hard rubber con­
struction. The cell connectors, by-passing through the
cell partitions, connect the elements along the shortest DRY CHARGED BATTERIES
practical path (fig. 2b). With the length of the electrical
circuit inside the Battery reduced to a minimum, the There are two types of Batteries—the “ dry charge”
internal voltage drop is decreased resulting in improved type and the “ wet charge” type. The difference in types
performance, particularly during engine cranking at low depends on the method of manufacture. A “ dry charge”
temperatures. Battery contains fully charged elements which have been

CHEVROLET TRUCK SERVICE MANUAL

ENGINE-ELECTRICAL 6Y-2

ONE PIECE
CELL COVER ELECTROLYTE LEVEL

VENT PLUG

HOLD-DOWN SLOT

F ig. l b —Battery

thoroughly washed and dried. This type of Battery con­

tains no electrolyte until it is activated for service in
the field and, therefore, leaves the factory in a dry state.
Consequently, it is called a "dry-charge” Battery.
Each vent well in a "dry charge” Battery has an
integral hard rubber seal to prevent the entrance of Fig . 2b— Internal V ie w of Two C e lls Showing Connector
air and moisture which would oxidize the negative active Through Partition
materials and reduce the freshness of the Battery The electrolyte level of each cell should be checked
(fig. 3b). The integral hard rubber seals and the sealing
after filling the Battery initially. If the level has fallen
compound between the case and one-piece cell cover
make possible a vacuum sealed assembly which can be
stored for very long periods of time without detrimental
effects. VENT WELL SEAL
Before activating the "dry charge” Battery, the inte­
gral hard rubber seals may be broken simply by pushing
the Delco Eye down into each vent well. The seals drop
into the cells, and can remain there since they are not
chemically active and will cause ho harm. (The Delco
Eye is a special type of vent plug that is described in
the section entitled "Periodic Servicing,\)

ACTIVATING DRY CHARGED BATTERIES

A "dry charge” Battery is activated by filling each
cell with electrolyte, which is a dilute solution of sulfuric
acid having a specific gravity of 1.265 at 80°F. The
cells are properly filled when the electrolyte level
reaches the bottom of the "sp lit vent” at the bottom
SPLIT VENT
of the vent well. The split vent is a visual level fill
feature designed into the cell cover of Delco Batteries
(fig. 4b). The electrolyte surface will appear distorted
when it contacts the split vent. F ig . 3b—Vent W ell Construction Showing Seal

CHEVROLET TRUCK SERVICE MANUAL

 ENGINE-ELECTRICAL 6Y-3

below the split vent, additional electrolyte should be

added. NEVER ADD WATER TO THE ELECTROLYTE
WHEN ACTIVATING BATTERY.
Long and trouble-free service can be anticipated only
if the Battery is properly activated. Improper activation
results in poor performance and short Battery life.
After electrolyte has been added to a "dry charge”
Battery, it then becomes a wet charged Battery and
should be maintained in the same manner as any other
"w et” Battery.

WET CHARGED BATTERIES

Wet charged Batteries contain fully charged elements
and are filled with electrolyte before being shipped from
F ig . 4b —V ie w inside V ent W e ll Showing Electro lyte the factory.

PERIODIC SERVICING
5. Battery abuse, including failure to keep the Battery
COMMON CAUSES OF FAILURE
top clean, cable clamps and posts clean and tight,
Since the Battery is a perishable item which requires and improper addition of water to the cells.
periodic servicing, a good maintenance program will
insure the longest possible Battery life. If the Battery LEVEL INDICATOR
tests good but fails to perform satisfactorily in service
The Battery features an electrolyte level indicator,
for no apparent reason, the following are some of the
which is a specially designed vent plug with a trans­
more important factors that may point to the cause of
parent rod extending through the center (fig. 5b). When
the trouble. the electrolyte is at the proper level, the lower tip of the
1. Vehicle accessories inadvertently left on overnight
rod is immersed, and the exposed top of the rod will ap­
to cause a discharged condition. pear very dark; when the level falls below the tip of
2. Slow speed driving of short duration, to cause an
the rod, the top will glow.
undercharged condition.
3. A vehicle electrical load exceeding the generator The Indicator reveals at a glance if water is needed,
capacity. without the necessity of removing the vent plugs (fig. 6 b).
4. Defect in the charging system such as high re s is­ The Level Indicator is used in only one cell (second
tance, slipping fan belt, faulty generator or voltage cell cap from positive Battery post) because when the
regulator. electrolyte level is low in one cell, it is normally low

INDICATOR

I ELECTROLYTE LEVEL
LOW

Fig . 5b—C u t- A w a y V ie w Showing Electro lyte at Proper Fig . 6b—C u t-A w ay V ie w Showing Electro lyte a t Low
Le ve l, with Indicator Having Dark Appearance Lever, with Indicator Having Light Appearance

CHEVROLET TRUCK SERVICE MANUAL

ENGINE-ELECTRICAL 6Y-4

in all cells. Thus when the Indicator shows water is so that it will support the Battery securely and keep it
needed, check the level in all six cells. level.
An alternate method of checking the electrolyte level To prevent the Battery from shaking in its ca rrier,
is to remove the vent plug and visually observe the the hold-down bolts should be tight (50-80 in. lbs.).
electrolyte level in the vent well. The bottom of the However, the bolts should not be tightened to the point
vent well features a split vent which will cause the where the Battery case or cover will be placed under a
surface of the electrolyte to appear distorted when it severe strain.
makes contact. The electrolyte level is correct when
the distortion first appears at the bottom of the split BATTERY SAFETY PRECAUTIONS
vent (fig. 4b).
When Batteries are being charged, an explosive gas
ELECTROLYTE LEVEL mixture forms in each cell. Part of this gas escapes
through the holes in the vent plugs and may form an
The electrolyte level in the Battery should be checked explosive atmosphere around the Battery itself if venti­
regularly. In hot weather, particularly during trip driv­ lation is poor. This explosive gas may remain in or
ing, checking should be more frequent because of more around the Battery for several hours after it has been
rapid loss of water. If the electrolyte level is found to charged. Sparks or flames can ignite this gas causing
be low, then colorless, odorless, drinking water should an internal explosion which may shatter the Battery.
be added to each cell until the liquid level rises to the The following precautions should be observed to pre­
split vent located in the bottom of the vent well. DO NOT vent an explosion:
OVERFILL because this will cause loss of electrolyte 1. Do not smoke near Batteries being charged or
resulting in poor performance, short life, and excessive which have been very recently charged.
corrosion. 2. Do not break live circuits at the terminals of Bat­
CAUTION: During service only water should teries because a spark usually occurs at the point
be added to the Battery, not electrolyte. where a live circuit is broken. Care must always
V be taken when connecting or disconnecting booster
The liquid level in the cells should never be allowed to leads or cable clamps on fast chargers. Poor con­
drop below the top of the plates, as the portion of the nections are a common cause of electrical arcs
plates exposed to air may be permanently damaged with which cause explosions.
a resulting loss in performance.
BATTERY CHARGING
WATER USAGE
There are three methods of recharging Batteries.
Excessive usage of water indicates the Battery is They differ basically in the length of time the Battery
being overcharged. The most common causes of over­ is charged and the rate at which charging current is
charge are high Battery operating temperatures, too supplied. One is the Slow Charge method, the second is
high a voltage regulator setting or poor regulator ground the Fast Charge method, and the third is the Emergency
wire connection. Normal Battery water usage is ap­ Boost Charge method.
proximately one to two ounces per month per battery. Before recharging a Battery by any method, the elec­
CLEANING trolyte level must be checked and adjusted if necessary.

The external condition of the Battery should be checked SLOW CHARGING

periodically for damage or for the presence of dirt
and corrosion. The top of the Battery should be kept The Slow Charge method supplies the Battery with a
clean. An accumulation of acid film and dirt may permit relatively low current flow for a relatively long period
current to flow between the terminals, which will slowly of time. This is the only method that will bring the Bat­
discharge the Battery. For best results when cleaning tery to a full state of charge.
the top of B atteries, wash first with a diluted ammonia The Slow Charge method consists of charging at ap­
or a soda solution to neutralize any acid present, then proximately a 4 ampere rate for 24 hours or more if
flush with clean water. Care must be taken to keep vent necessary to bring the Battery to full charge. A fully
plugs tight, so that the neutralizing solution does not charged condition is reached when the cells are gassing
enter the cells. freely and three corrected specific gravity readings
taken at hourly intervals show no increase.
CABLES
To insure good electrical contact, the cables should FAST CHARGING
be clean and tight on the battery posts. If the posts The Fast Charge method supplies current to the Bat­
o r cable terminals are corroded, the cables should be tery at a 40 to 50 ampere rate for a 1 1/2 hour period
disconnected and the terminals and clamps cleaned sepa­ of time. If the electrolyte temperature reaches 125°F.
rately with a soda solution and a wire brush. After before the 1 1/2 hour period is completed, the Battery
cleaning and installing clamps, apply a thin coating of must be taken off charge temporarily, or the charging
petroleum jelly on the cable clamps to retard corrosion. rate reduced to avoid damage to the Battery.
Although a Battery cannot be brought to a fully charged
CARRIER AND HOLD-DOWN condition during Fast Charge, it can be substantially
The Battery ca rrie r and hold-down should be clean recharged or ''boosted” . In order to bring the Battery
and free from corrosion before installing the Battery. to a fully charged condition, the charging cycle must be
The ca rrie r should be in a sound mechanical condition finished by the Slow Charge method.

CHEVROLET TRUCK SERVICE M ANUAL

 ENGINE-ELECTRICAL 6Y-5

covered in the section entitled “ Periodic

EMERGENCY BOOST CHARGING Servicing” .
In cases where the Battery is not sufficiently charged • Check for loose cable connections, and for evi­
to crank the engine, an emergency boost charge may be dence of corrosion as covered in section entitled
applied as a temporary expedient in order to crank the “ Periodic Servicing” . Correct as required before
engine. The Emergency Boost Charge method consists proceeding with tests.
of charging at a 40 to 50 ampere rate for a period of
one-half hour. 2. INSTRUMENT TEST
It should be particularly noted that the Emergency A number of suppliers have approved testing equipment
Boost Charge will not necessarily restore the Battery available. These testers have a programmed test proce­
to a useful state of charge for continued service. After dure consisting of a series of timed discharge and charge
an emergency boost charge, failure to charge the Bat­ events, requiring approximately 2 to 3 minutes, that
tery further, either by a long uninterrupted driving will determine the condition of the Battery with a high
period or by the Fast Charge or Slow Charge method, degree of accuracy. When using these testers, the pro­
may result in failure to crank the engine the next time cedure recommended by the tester manufacturer should
cranking is attempted. A Battery should never be con­ be followed. Batteries should not be charged prior to
demned on the basis of failure to crank the engine after testing or doing so may alter the test results. If a
an emergency boost charge. Although an emergency tester is not available for testing, the “Specific Gravity
boost charge may put enough energy into the Battery Cell Comparison Test” may be used or an alternate
to crank the engine once, further charging usually is method, but with a sacrifice in testing accuracy.
necessary in order to create a sufficient reserve to
crank a second and third time.
3. FULL CHARGE HYDROMETER TEST
This test should be used only on Batteries which test
12 VOLT BATTERY good with testing equipment or “Specific Gravity Cell
SUGGESTED CHARGING RATES Comparison T est” but which subsequently fail in service.
• Remove the Battery from the vehicle, and adjust
(100 Amp/hr or Less Capacity) the electrolyte level as necessary, by adding color­
less, odorless, drinking water.
Type Length Charging • Fully charge the Battery at the Slow Charging
of Charge of Time Rate rate as covered in the section entitled “ Battery
Charging” .
Boost Charge for 50 Amps • Measure the specific gravity of the electrolyte in
20 Minutes
Light Load Test each cell and interpret as follows:
Hydrometer Reading Less Than 1.230—Full
Slow Charge 24 Hours 4 Amps charge hydrometer readings less than 1.230 cor­
rected for temperature indicate the Battery is
Fast Charge 1-1/2 Hours 40-50 Amps defective and should be replaced.
Hydrometer Readings Above 1.310—Full charge
Emergency Quick hydrometer readings above 1.310 corrected for
30 Minutes 40-50 Amps
Boost temperature indicate that the cells have been im­
properly filled (activation) or improperly serviced.
Dry Charge 15 Amps Poor service and short Battery life will result.
10 Minutes
Warm-up Boost
SPECIFIC GRAVITY READINGS
A hydrometer can be used to measure the specific
BATTERY TESTING PROCEDURES gravity of the electrolyte in each cell (fig. 7b).
The hydrometer measures the percentage of sulphuric
Testing procedures are used to determine whether acid in the battery electrolyte in terms of specific
the Battery is (1) good and usable, (2) requires re ­ gravity. As a battery drops from a charged to a dis­
charging or (3) should be replaced. Analysis of Battery charged condition, the acid leaves the solution and enters
conditions can be accomplished by performing a visual the plates, causing a decrease in specific gravity of
inspection. Instrument Test and the full charge hydro­ electrolyte. An indication of the concentration of the
meter test. electrolyte is obtained with a hydrometer.
When using a hydrometer, observe the following points:
1. VISUAL INSPECTION 1. Hydrometer must be clean, inside and out, to insure
The first step in testing the Battery should be a visual an accurate reading.
inspection, which very often will save time and expense 2. Hydrometer readings must never be taken immedi­
in determining Battery condition. ately after water has been added. The water must be
• Check the outside of the Battery for a broken or thoroughly mixed with the electrolyte by charging
cracked case or a broken or cracked cover. If for at least 15 minutes at a rate high enough to cause
any damage is evident, the Battery should be vigorous gassing.
replaced. 3. If hydrometer has built-in thermometer, draw liquid
• Note the electrolyte level. Levels that are too into it several times to insure correct temperature
low or too high may cause poor performance, as before taking reading.

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ENGINE-ELECTRICAL 6Y-6

DO N O T SUCK H O LD
IN T O O M U C H TUBE
ELECTROLYTE V ERTICAL

FLOAT M U ST
BE FREE

TAKE R E A D IN G
AT EYE LEVEL

Fig . 7b—Testing S p e c ific G r a v ity

4. Hold hydrometer vertically and draw in just enough

liquid from battery cell so that float is free floating.
Hold hydrometer at eye level so that float is vertical
and free of outer tube, then take reading at surface
of liquid. Disregard the curvature where the liquid
rises against float stem due to surface tension.
5. Avoid dropping battery fluid on car or clothing as
it is extremely corrosive. Any fluid that drops
should be washed off immediately with baking soda
solution.
The specific gravity of the electrolyte varies not only
with the percentage of acid in the liquid but also with Fig. 8b—Battery In stallation C - K A 10-20, CA-30
temperature. As temperature increases, the electrolyte
expands so that the specific gravity is reduced. As
temperature drops, the electrolyte contracts so that the • If specific gravity readings show a difference bet­
specific gravity increases. Unless these variations in ween the highest and lowest cell of .050 (50 points)
specific gravity are taken into account, the specific or more, the Battery is defective and should be
gravity obtained by the hydrometer may not give a true replaced.
indication of the concentration of acid in the electrolyte.
A fully charged Battery will have a specific gravity
reading of approximately 1.270 at an electrolyte tem­ INSTALLING BATTERIES (Fig. 8b)
perature of 80°F. If the electrolyte temperature is
above or below 80°F., additions or subtractions must Battery installation varies depending on the truck
be made in order to obtain a hydrometer reading cor­ model and series. To install a Battery properly, it is
rected to the 80°F. standard. For every 10° above 80°F., important to observe the following precautions:
add four specific gravity points (.004) to the hydrometer • Connect grounded terminal of Battery last to avoid
reading. Example: A hydrometer reading of 1.260 at short circuits which may damage the electrical
110°F. would be 1.272 corrected to 80°F., indicating a system.
fully charged Battery. For every 10° below 80°F., sub­ • Be sure there are not foreign objects in the carrier,
tract four points (.004) from the reading. Example: so that the new Battery will rest properly in the
A hydrometer reading of 1.272 at 0°F. would be 1.240 bottom of the carrier.
corrected to 80°F., indicating a partially charged Battery. • Tighten the hold-down evenly until snug (60-80 in.
lbs.). Do not draw down tight enough to distort or
crack the case or cover.
SPECIFIC GRAVITY CELL COMPARISON TEST • Be sure the cables are in good condition and the
terminal clamps are clean and tight. Make sure the
This test may be used when a instrument tester is ground cable is clean and tight at engine block or
not available. To perform this test measure the specific frame.
gravity of each cell., regardless of state of charge, and • Check polarity to be sure the Battery is not re ­
interpret the results as follows: versed with respect to the generating system.

CHEVROLET TRUCK SERVICE M ANUAL

 ENGINE-ELECTRICAL 6Y-7

CHARGING SYSTEM
INDEX
Page Page
General D e s c r ip tio n ......................................................... 6Y-7 Field Relay Check and A djustm ent........................... 6Y-13
Maintenance and A djustm ents.......................................... 6Y-9 Other Harness C h e c k s ................................................ ....
Static C h e c k s .................................................................. 6Y-10 6.6” System
System Condition Test Field Relay T e s t ......................................................... 6Y-15
Voltage Regulator Adjustm ent....................................... 6Y-10 Generator Field Circuit T e s t .................................... 6Y-15
System Component C hecks............................................. 6Y-11 Generator Field T est................................................... 6Y-15
5.5-6.2” Systems Circuit Resistance T e s t ............................................ 6Y-15
Generator Output......................................................... 6Y-11 Voltage Setting Adjustment.......................................... 6Y-15
Generator Diode and Field T e s t .................................6Y-11 Service O perations............................................................ 6Y-16
Indicator Lamp - Initial Field Excitation G en erato r........................................................................ 6Y-16
Circuit T e s t s ............................................................ 6Y-12 Pulley Replacement...................................................... 6Y-16
Field Circuit Resistance W ire T e s t s ........................6Y-13 Removal and Installation............................................. 6Y-17
Voltage Setting (See System Condition Brush Replacement (6.2” Unit).................................... 6Y-17
Test) ........................................................................ Special T o o ls ..................................................................... 6Y-37

GENERAL DESCRIPTION
The charging system includes the battery, generator, Two brushes are required to carry current through the
regulator, telltale light, and necessary wiring to con­ two slip rings to the field coils wound concentric with the
nect these components. The Delcotron is offered as shaft of the rotor. Six rectifier diodes are mounted in the
standard equipment, although there are various capacities slip ring end frame and are jointed to the stator windings
available on all models. at three internally located terminals.
The Delcotron continuous output A.C. generator (figs. Diodes are mounted in heat sinks to provide adequate
lc and 14c) consists of two major parts, a stator and a heat dissipation. The six diodes replace the separately
rotor. The stator is composed of a large number of wind­ mounted rectifier as used in other types of application.
ings assembled on the inside of a laminated core that is The diodes change the Delcotron A. C. current to D. C.
attached to the generator frame. The rotor revolves current.
within the stator on bearings located in each end frame. Three regulators are available on truck models. A

RELAY “ BAH”
TERM IN A L “ F” T ERM IN A L TERMINAL

“ BAT"
T ER M IN A GRD 7 T ERM IN A L

N tL L> LIGHT
RELAY RELAY
5.5" SERIES ID DELCOTRON 6.2" SERIES 2D, TYPE 150 DELCOTRON

F ig . l c —Delcotrons

CHEVROLET TRUCK SERVICE M ANUAL

ENGINE-ELECTRICAL 6Y-8

p...... | KCdtO I UR

* * ikimrtTAD

FIELD RELAY

“ LA TC H ”

“ F” TERM IN A L

N O . 2 TERM IN A L
N O . 3 T ERM IN A L V O LT A G E
DEICOTRON ' R. 6 3 AMP
N O . 4 T E R M IN A L R EG U LA TO R MODELS ONLY

DOUBLE CONTACT

Fig. 2 c — Double C ontact Regulator

double contact two unit type, a transistor unit with an in­ internally in the field circuit (fig. 2c). The added diode
ternal field relay and a completely static full transistor adapts the regulator to handle the higher field current and
regulator (130 amp generator only). The function of these enables it to absorb the increased inductive voltages of
regulators in the charging system is to limit the genera­ the field coil with satisfactory contact point life. A wir­
tor voltage to a pre-set value by controlling the generator ing diagram of the regulator internal circuit is illuatrated
field current. in Figure 2c.
The two unit double contact unit and the junior tran­ The light duty transistor regulator (fig. 3c) is an
sistor regulator (when applicable) use the field relay to assembly composed principally of transistors, diodes,
turn out the indicator lamp. The relay unit allows the resistors, a capacitor, and a thermistor to form a com­
lamp to light (as a bulb check) with the ignition key on pletely static voltage regulating unit in combination with
and engine not running. When the engine is started and a conventional vibrating type field relay.
the generator begins to charge, the indicator light goes The transistor is an electrical device which limits the
out indicating that the system is operating normally. generator voltage to a preset value by controlling the
The double-contact regulator assembly (fig. 2c) con­ generator field current. The diodes, capacitor and re ­
sists of a double-contact voltage regulator unit and a sistors act together to aid the transistors in controlling
field relay unit. This unit uses two sets of contact points the generator voltage. This is the only function that the
on the voltage regulator unit to obtain desired field regulator performs in the charging circuit. The ther­
excitation under variable conditions. This regulator, mistor provides a temperature-compensated voltage set­
when used with the special 63 amp air conditioning model ting. A wiring diagram of this regulator's internal circuit
generator (4 ohm field coil), uses a field discharge diode is shown in Figure 3c.

ACCESS PLUG TO
VOLTAGE ADJUSTMENT JUNCTION BLOCK

IN D IC A TO R
LAMP

O f , e ld Q

"F” TERMINAL

No. 2 TERMINAL

No. 3 TERMINAL
TRANSISTOR

No. 4 TERMINAL

Fig . 3 c—Transistor V oltage Regulator Assembly

CHEVROLET TRUCK SERVICE M ANUAL

 ENGINE-ELECTRICAL 6Y-9

The voltage at which the generator operates is deter­ corrections this unit is designed to make.
mined by the regulator adjustment. The regulator voltage 3. The regulator itself is not grounded.
setting can be adjusted externally by removing a pipe 4. It is used with an ammeter and a field relay in the
plug in the cover (fig. 3c) and turning the adjusting arm system.
inside the regulator. This procedure is explained in the Wiring harnesses are protected by fusible links. A
following section, and permits regulator adjustments fusible link is a length of special wire, normally four
without removing the cover. gauges sm aller than the circuit it is protecting, used
The full transistor regulator used with the 130 amp in circuits that are not normally fused such as the
generator (fig. 4c) is a completely static unit composed ignition circuit. The same size wire with a hypalon
principally of transistors, diodes, capacitors and re ­ insulation must be used when replacing a fusible link.
sistors. The rotor field current is controlled by differ­ The links are located in the engine compartment
ences in internal voltage and resistance values acting on wiring harnesses and each link will be identified with
the transistors, diodes and resistors within the regulator. its gauge size. On most models there is a 16 gauge,
This unit has certain differences from the other red wire fusible link installed as an integral part of
assemblies. the positive battery cable or located between the solenoid
1. The regulator units are not grounded in the regula­ battery terminal and the junction block. On tilt cab
tor. They are connected to a third lead which is models (TE 40-50-60, TT 40, TD-TG 50-60) this link
brought out of the regulator to a ground location. is a 14 gauge, red wire. School bus models have an
2. It does not use a thermistor for automatic tempera­ additional link (16 gauge, red wire) located in the battery
ture compensation, because the quantity of current feed circuitry between the engine generator and forward
handled by the system does not warrant the minute lamp harness connector and molded splice junction.

REGULATOR
PLUG FIELD RELAY
(REMOVE TO ADJUST
VOLTAGE SETTING)

"NEG."

"POS."
BATTERY GENERATOR

Fig. 4 c —V o lta g e Regulator for 130 Amp System

MAINTENANCE AND ADJUSTMENT

At regular intervals, inspect the terminals for cor­ 3. When connecting a charger to the battery, connect
rosion and loose connections, and the wiring for frayed the correct charger leads to the battery terminals.
insulation. Check mounting bolts for tightness. Check 4. Never operate the generator on an uncontrolled open
the drive belt for alignment, proper tension and wear. circuit. Make absolutely certain all connections in
Because of the higher inertia and load capacity of the the circuit are secure.
rotor used in A.C. generators, PROPER BELT TEN­ 5. Do not short across or ground any of the terminals
SION is more critical than on D. C. generators. on the generator or regulator.
Since the Delcotron and its companion regulator are 6 . Do not attempt to polarize the generator.
designed for use on negative polarity systems only, the 7. Do not disconnect lead at generator without first
following precautions must be observed. Failure to disconnecting battery ground cable.
observe these precautions may result in serious damage Trouble in the A.C. charging system will usually be
to the charging system. indicated by one or more of the following conditions:
1. When installing a battery, always make absolutely 1. Faulty indicator lamp or ammeter operation.
sure the ground polarity of the battery, generator 2. An undercharged battery (usually evidenced by
and regulator is the same. slow cranking speeds).
2. When connecting a booster battery, make certain 3. An overcharged battery (usually evidenced by ex­
to connect the correct battery terminals together. cessive battery water usage).

CHEVROLET TRUCK SERVICE M ANUAL

ENGINE-ELECTRICAL 6Y-10

4. Excessive generator noise or vibration. NOTE: At this point a field circuit has been
Described below are a series of on-the-vehicle quick established and any other problem will lie in
checks which are designed to assist the service techni­ generator or regulator.
cian in locating troubles within the various components
6 . Turn on high-beam headlights and heater blower
of the engine electrical system. Additional checks, ad­
motor to high speed, run engine at or above 1500
justments and overhaul procedures of these components
rpm (for a few minutes, if necessary) and read the
are also described in the “ Charging System s-Service
voltage on meter.
Operations Section” and should be referred to as
necessary. NOTE: Voltage will not greatly exceed 12-1/2
volts until the battery develops a surface charge,
STATIC CHECKS a few minutes generally, unless the battery is
Before making any electrical checks, perform the severely discharged or is hot.
following static checks:
1. Check for loose fan belt. If reading is:
2. Check for defective battery. (Refer to Battery.) a. 1 2 - 1 / 2 volts or more, turn off electrical loads,
3. Inspect all connections, including the slip-on con­ stop engine and proceed to step 7.
nectors at the regulator and Delcotron. b. Less than 12-1/2 volts, perform “ Delcotron Out­
put Test-V oltm eter Method.”
NOTE: Do not short field to ground to check if
generator is charging since this will seriously (1) Delcotron tests bad - refer to “ Service Op­
damage the charging system. erations” and repair Delcotron, then repeat
Step 6 .
(2) Delcotron tests good - disconnect regulator
SYSTEM CONDITION TEST connector, remove regulator cover and re ­
(5.5"-6.2" DELCOTRON SYSTEMS) connect the connector. Then repeat step 6
This test is used to indicate the overall condition of and turn voltage adjusting screw (fig. 6 c) to
the charging system (both good and defective) and to raise setting to 12-1/2 volts. On transistor
isolate the malfunctioning unit if the system is defective. regulator remove pipe plug (fig. 6 c), insert
1. With ignition off, perform the prescribed Static screwdriver into slot and turn clockwise one
Checks outlined in this section. Then set hand brake or two notches to increase setting. Turning
and shift transmission into neutral. counterclockwise decreases setting. For each
2. Connect a voltmeter from junction block on horn notch moved, the voltage setting will change
relay to ground at regulator base. approximately .3 volt. Turn off loads, stop
engine and proceed to step 7. If 12-1/2 volts
CAUTION: Be sure meter clip does not touch cannot be obtained, install a new regulator
a resistor or terminal extension under regulator. and repeat Step 6 .
3. Connect a tachometer on engine.
4. Turn ignition switch to “ ON” and check indicator
ADJUSTING REGULATOR VOLTAGE
lamp. If lamp fails to glow, perform appropriate
tests and corrections (see Indicator Lamp Circuit 7. Connect a 1/4 ohm-25 watt fixed resistor (purchased
tests) before continuing test. commercially) into the charging circuit at horn relay
5. If lamp glows, start the engine and run it at 1500 junction block as shown in Figure 7c.
rpm or above. Check indicator lamp. If lamp fails
to go out, perform appropriate test and corrections NOTE: Between both leads and the terminal.
(see Indicator Lamp Circuit tests) before continuing
test.

DO NOT TURN THIS NUT

UNDER ANY CONDITION

ADJUSTING SCREW
(Turn To Adjust
Voltage Setting)

Fig . 6 c —Adjust V oltage Setting

CHEVROLET TRUCK SERVICE MANUAL

 ENGINE-ELECTRICAL 6Y -11

8 . Run engine at 1500 rpm or above for at least 15 7. Connect an adjustable carbon pile across the battery
minutes of warm-up, then cycle regulator voltage posts.
control (by disconnecting and re-connecting regula­ 8 . Start the engine and slowly bring the speed to 1500
tor connector) and read voltage. RPM and at the same time adjust the carbon pile
load to hold the voltage at 14 volts.
If voltage is 13.5 to 15.2, the regulator is okay. 9. Read the amperage and compare with a specifications
a. Disconnect four terminal connector and remove
chart.
regulator cover. Then re-connect four terminal
10. Turn off ignition, disconnect battery ground cable,
connector and adjust voltage to 14.2 to 14.6
and remove all test equipment.
(Refer to Step 6 and fig. 6 c).
11. If the Delcotron meets the test specifications, the
b. Disconnect four terminal connector and reinstall
problem is not in the generator.
regulator cover, then reinstall connector.
12. If the Delcotron fails to meet the test specifications,
c. Continue running engine at 1500 rpm for 5-10
remove it and perform bench tests and make repair
minutes to re-establish r e g u l a t o r internal
needed.
temperature.
d. Cycle regulator voltage by disconnecting and
re-connecting regulator connector. Read voltage. DELCOTRON DIODE AND FIELD TEST (Fig. 9c)
A reading between 13.5 and 15.2 indicates a NOTE: These tests will indicate good, shorted
good regulator.
CAUTION: Be sure four terminal regulator
connector is disconnected when removing or in­
stalling cover. This is to prevent regulator
damage by short circu its.

SYSTEM COMPONENT TESTS

DELCOTRON OUTPUT TEST

Ammeter Method
1. Disconnect the battery ground cable at the battery.
2. Disconnect the red wire at Delcotron battery
terminal and connect an ammeter in series between
the wire and terminal.
3. Connect a voltmeter from battery terminal to a
good ground on the generator.
4. Disconnect the F -R terminal connector at the
Delcotron.
5. Connect the jumper wire between Delcotron “ F ”
and battery terminals.
6 . Connect the battery ground cable at the battery. F ig . 8 c —Ammeter Method Output Test Connections

CHEVROLET TRUCK SERVICE M ANUAL

ENGINE-ELECTRICAL 6Y-T2

should read high in one direction and low in the

other.
NOTE: A high or low reading in both directions
indicates a defective diode.
4. Open Field Check:
a. Connect an ohmmeter from " F ” terminal to
“ GRD” terminal stud and note reading on the
lowest range scale. Meter should read 7 to 20
ohms.
b. If meter reads zero or excessively high re s is­
tance the Delcotron is faulty.
5. If above tests indicate a defective Delcotron, remove
and completely check Delcotron as outlined under
“ Service Operations.”

INDICATOR LAMP/INITIAL FIELD

EXCITATION CIRCUIT TESTS
5.5"-6.2" Systems
On standard models the indicator lamp circuit provides
initial field excitation (causing lamp to glow). The light
Fig. 9c— Delcotron Diode and Field Test is cancelled by closing the field relay which applies
battery voltage to both sides of bulb (bulb goes out).
or open field or shorted diode but will not in­ The indicator light should glow when ignition switch
dicate a failed open diode. If output was low is “ON” and go out almost immediately when engine
and following tests show good, refer to service starts.
operations to determine cause and repair. Ammeter equipped vehicles use the same initial field
excitation and control circuits as the indicator lamp
1. Disconnect battery ground cable at battery. except the lamp is omitted. The continuity tests on both
2. Positive diodes (Test A) connect an ohmmeter be­ type vehicles can be made as follows:
tween “ R” terminal and “ BAT” terminal and note
reading, then reverse the leads at same terminals If Lamp Fails to Glow or Ammeter Fails to Function
and note this reading. Meter should read high re ­ the Possible Causes are:
sistance in one direction and low in the other. 1. Faulty bulb or bulb socket.
3. Negative diodes (Test B) connect ohmmeter between 2. Faulty ammeter.
“ R” terminal and “ GRD” and note reading, then 3. An open circuit in wiring, regulator, or field.
reverse the leads and note this reading. Meter 4. A shorted positive diode - (may also cause glow

Fig . 10c—In itia l Field Excitatio n C irc u it Tests

CHEVROLET TRUCK SERVICE M ANUAL

 ENGINE-ELECTRICAL 6Y-13

W IRIN G HARNESS
CO N N ECTO R

Fig. 12c— Field R e lay Closing V o lta g e Test

NOTE: This test lamp procedure may be used

on lamp type circuits and on ammeter circuits.
W IR IN G H A R N ESS
C O N N EC T O R If Lamp Fails to Go Out, or if Ammeter Shows Dis­
charge the Possible Causes are:
Fig. 11c—Testing Field Relay 1. Loose drive belt - adjust as necessary.
2. Faulty field relay - (see relay test and adjustment).
with ignition switch “ O FF” ). 3. Defective Delcotron - (see Delcotron output test).
Test as Follows: 4. At normal idle - parallel resistance wire open (see
1. Disconnect connector from regulator and turn igni­ Resistance test). Ammeter models the initial field
tion switch to "ON” . Connect a test lamp from excitation wire to "ACC” terminal is open.
connector terminal " 4 ” to ground (Fig. 10c, Step 1) 5. Switch off - positive diode shorted (see Diode test).
and note lamp.
a. Lamp fails to glow - check for faulty bulb, FIELD CIRCUIT RESISTANCE WIRE CHECKS
socket or open circuit between switch and regu­ The resistance wire is an integral part of the ignition
lator connector. Repair as needed. harness. However, the resistance wire is not solderable;
b. Light goes on - failure is in regulator, Delcotron, it must be spliced with a crimp-type connector. It is
or wire between " F ” terminals on regulator and rated at 10 ohms, 6.25 watts minimum.
Delcotron. Go to Step 2. The check for an open resistor or field excitation wire
2. Disconnect lamp lead at ground end and connect (connected to the ignition switch "ACC” terminal) is as
between connector " F ” and " 4 ” terminals (Fig. 10c, follows:
Step 2), and note lamp: 1. Connect a test lamp from the wiring harness con­
a. Test lamp glows - problem is in regulator. An nector terminal " 4 ” to ground as shown in Figure
open circuit in regulator or relay is stuck closed. 10c (Step 1).
See "Service Operations” for repair. 2. Turn the ignition switch to the "ON” position and
b. Fails to glow - problem is in wire between " F ” note test bulb.
terminals on generator and regulator or in field a. Test lamp glows - resistance is O.K.
windings. Go to Step 3. b. Test lamp does not glow - the resistor is open
3. Disconnect test lamp at connector " F ” terminal and circuited - note also that dash lamp does not
connect to " F ” terminal on Delcotron (Fig. 10c, glow during this test because series resistance
Step 3), and note lamp: of the 2 bulbs causes amperage to be too low.
a. Lamp glows - an open circuit in wire between
" F ” terminals - correct as needed. Field Relay Checks and Adjustment
b. Fails to glow - Delcotron field has open circuit, To check for a faulty relay proceed as follows:
see "Service Operations” to repair. 1. Connect a voltmeter into the system at the regulator

CHEVROLET TRUCK SERVICE M ANUAL

ENGINE-ELECTRICAL 6Y-14

4. If voltage at regulator exceeds closing voltage speci­

fication and light remains on, regulator field relay
is faulty (Refer to specifications). Check and adjust
regulator as follows:

Closing Voltage Adjustment

1. Make connections as shown in Figure 12c using a
50 ohm variable resistor.
NOTE: This gives us a variable resistance in
series from a hot lead to the relay coil.
2. Turn resistor to “ open” position.
3. Turn ignition switch off.
4. Slowly decrease resistance and note closing voltage
of the relay. Adjust by bending heel iron in the
manner illustrated in Figure 13c.

Other Harness Checks

Other wires in the charging system harness need be
checked for continuity by use of an ohmmeter or a test
light (12 Volt). Connect the test so the wire in question
is in series in the test circuit.

Fig. 13c—Adjusting Field Relay Closing V o ltag e

FULL TRANSISTOR REGULATOR
No. 2 terminal to ground (fig. 11c). TEST PROCEDURE
2. Operate the engine at fast idle (1500 to 2000 rpm)
and observe voltmeter reading.
6.6 " GENERATOR SYSTEM -130 AMP (Fig .l4 c)
3. If voltmeter shows zero voltage at regulator, check
circuit between No. 2 terminal on regulator to “ R” The full transistor test procedures are made for the
terminal on Delcotron. purpose of isolating the unit that is causing the charging

POSITIVE
END CASE BRUSH GREASE BALL
FRAME DIODES ASSEMBLY ROTOR ASSEMBLY RESERVOIR BEARING

SLIP
RINGS

GREASE
RESERVOIR

BALL
BEARING

CASE HEAT SLIP RING STATOR

DIODES SINK END FRAME ASSEMBLY

F ig . 14c—130 Amp Series 4D , Type 150 Delcotron

CHEVROLET TRUCK SERVICE M ANUAL

 ENGINE-ELECTRICAL 6Y-15

system malfunction. Like any other system, we make a TO TEST THE GENERATOR FIELD CIRCUIT
continuity check, voltage setting test, and circuit re ­
sistance test. 1. Connect the voltmeter to test adapter as shown in
In order to easily make these tests, it is necessary to Figure 14c, Part 2.
use an adapter at the regulator harness connector. 2. Turn the switch on and read the voltmeter.
Notice that the adapter shown in the illustrations has a. If voltmeter reads 1-2 volts less than battery
three different length test leads. This is only for pur­ voltage, field is O.K. - check generator output.
poses of differentiating during this program. b. If voltmeter reads zero, an open circuit in the
regulator itself is indicated.
c. If voltmeter reads battery voltage, look for an
open field winding or a shorted regulator.
MAKE THE TEST AS FOLLOWS:
1. Make usual visual checks. TEST THE FIELD AS FOLLOWS:
2. Make the battery light load test. IMPORTANT: The regulator defect may have
3. Make a complete charging system test as follows: been caused by a defective generator field.
a. Test the field relay. Check the field as follows before installing the
b. Check the field circuit. new regulator.
c. Check generator output. (Same as on any other)
d. Check circuit resistance. 1. Turn the switch off and disconnect the battery ground
e. Test and adjust the voltage setting. strap.
2. Disconnect the adapter from the regulator.
3. Connect an ohmmeter to the adapter as shown in
TO CHECK THE FIELD RELAY Figure 15c.
4. If the ohmmeter reads high, there is an open, or
1. Connect a voltmeter at test adapter as shown in excessive resistance in the field winding, or in lead.
Figure 14c, Part 1. 5. If the ohmmeter reads low the winding is shorted
2. Make sure the switch is off, then read voltmeter. or grounded.
a. Voltmeter reads zero - relay O.K.
b. Voltmeter reading battery voltage - relay points NOTE: The specified resistance value can be
stuck closed or relay damaged. determined by dividing the voltage by the cur­
3. Turn the switch on and read the voltmeter. rent given in specifications. Since the reading
a. Voltmeter reads battery voltage - relay O.K. is taken through the adapter, leads, brushes and
b. Voltmeter reads zero - relay winding bad or slip rings, the ohmmeter reading on a good field
open circuit in wiring to relay. winding will be slightly higher than the specified
4. Make necessary repairs and recheck. value. This is true because the specified value
is for an ohmmeter reading directly across the
slip rings.
6 . Disconnect ohmmeter and reconnect the battery
ground strap.

TESTING CIRCUIT RESISTANCE

Excessive resistance in the sensing circuit, consisting
of all field leads and the regulator, can cause an over­
charged battery.
1. Turn on switch but do not start engine.
2. Alternately connect a voltmeter as shown in Part 1
and Part 2 in Figure 16c.
3. If the two voltmeter readings total more than .3
volt, check for excessive resistance in field circuit
leads. If these leads are satisfactory, the field relay
contacts may have excessive resistance. In this case
replace the relay.

VOLTAGE SETTING ADJUSTMENT

A voltage setting not tailored to meet vehicle require­
ments can result in an undercharged or an overcharged
battery. To adjust the voltage setting, proceed as follows:
1. Connect a voltmeter to the adapter as shown in
Figure 14c, Part 1.
2. Connect an ammeter in the circuit at the “ BAT”
terminal on the generator.
3. Turn all accessories off.
4. Operate generator at approximately 3000 rpm (1500-
F ig . 15c—Voltage Tests 2 0 0 0 engine rpm).

CHEVROLET TRUCK SERVICE MANUAL

ENGINE—ELECTRICAL 6Y-16

D IS C O N N E C T TO G R O U N D
FROM O N GEN ERATO R
R E G U LA TO R

6 i
PART 2

OHM M ETER

OHM M ETER

W IR IN G H A R N ESS

F ig . 16c—Fie ld Resistance Test

F ig . 17c—C irc u it Resistance Test
5. The generator output should be at least 10 amperes
below the rated generator output for this check.
Example: If generator rated output is 130 amps, the by turning one notch and then check for an improved
regulator is limiting voltage if amperage is 1 2 0 battery condition after a service period of reasonable
or less. length.
6 . To adjust voltage setting, remove pipe plug and 8 . For an overcharged battery, lower voltage setting
turn slotted adjusting button inside regulator. by turning one notch and then check for an im­
proved battery condition after a service period of
NOTE: After two notches in each direction,
reasonable length.
there is a positive stop.
9. If the regulator cannot be adjusted to a value within
7. For an undercharged battery, raise voltage setting the specified range, replace the regulator.

SERVICE OPERATIONS
Service Operations described in the following section 2. Remove washer and slide pulley from shaft.
are for the 5.5" Series ID aluminum Delcotron, 6.2" 3. Reverse Steps 1 and 2 to install, use a torque wrench
Series 2D, Type 100 Delcotron and the 6 . 6 " Series 4D, with a craw-foot adapter (instead of box wrench)
Type 150 Delcotron. Where important differences in and torque the nut to 50 ft. lbs. (fig. 18c).
testing and/or service operations are encountered,
separate mention will be made of the three generators.
Double Groove Pulley
1. Place a 15/16" socket (with wrench flats on the
GENERATOR drive end or use Adapter J-21501 and a box wrench)
on retaining nut, insert a 5/16" alien wrench through
PULLEY REPLACEMENT socket and adapter into hex on shaft to hold the
shaft while removing the nut.
2. Remove washer and slide pulley from shaft.
Single Groove Pulley 3. To install, slide pulley and washer on shaft and
1. Place 15/16" box wrench on retaining nut and in­ start the nut.
sert a 5/16" alien wrench into shaft to hold shaft 4. Use the socket and adapter with a torque wrench
while removing nut (fig. 17c). and tighten nut to 50 ft. lbs. torque.

CHEVROLET TRUCK SERVICE MANUAL

 ENGINE—ELECTRICAL 6Y-T7

F ig . 18c—P u lle y Removal

REMOVAL AND INSTALLATION

1. Disconnect battery ground strap at battery to pre­
vent damaging wiring harnesses.
2. Raise and support vehicle. Fig. 20c—6.2" Delcotron Brush H older Assy.
3. Disconnect wiring leads at Delcotron. dicator light relay wire from the terminal post.
4. Remove generator brace bolt and detach drive belt. 2. Remove two screws retaining the capacitor and
5. Support generator and remove generator mount bolt
brush holder to rear end frame. Remove brush
(6.2" Delcotron uses 2 mount bolts) and remove
holder.
from vehicle.
6 . Reverse removal procedure to install, then adjust NOTE: Capacitor lead is connected inside the
drive belt. generator. Allow capacitor to remain with the
generator to avoid undue strain on the lead wire.
BRUSH REPLACEMENT 3. Inspect brushes for wear. If they are worn halfway,
replace. Inspect brush springs for distortion or
6 .2 " Delcotron weakening. If brushes appear satisfactory and move
1. Remove two nuts retaining the blade connectors freely in brush holder, springs may be reused.
and remove the connectors (fig. 20c). Slide the in- 4. To install brushes, push brushes into holder and
install pin to keep the brushes in holder.
5. Attach brush assembly and condenser to the end
frame with hex-head stud on the left side only.
6 . Rearrange leads as shown in Figure 21c with right-
hand brush lead connected under the right hand
hex-head stud.
7. Attach terminal cover with two screws, making sure
leads are not caught underneath the cover.

F ig . 19c—Torquing P u lle y Nut F ig . 2 1 c—Lead Arrangement A fte r Assembly

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ENGINE—ELECTRICAL 6Y-18

IGNITION SYSTEMS
INDEX
Page Page
General D e s c r ip tio n ............ ............... 6Y-18 R em oval........................................................................ 6Y-23
Maintenance and Adjustments ............... 6Y-19 Disassem bly.................................................................. 6Y-24
Periodic Maintenance. . . . ............... 6Y-19 Cleaning and In sp ectio n .......................................... ... 6Y-25
Breaker Point System . . ............... 6Y-19 A s s e m b ly ..................................................................... 6Y-26
Breakerless System . . . ............... 6Y-19 Governor S e ttin g ......................................................... 6Y-28
Ignition Coil Check . . . . ...................6Y-19 Installation..................................................................... 6Y-28
Spark Plugs ..................... ...................6Y-19 Breakerless Type............................................................ 6Y-29
C a b le s .............................. ...................6Y-20 Rem oval........................................................................ 6Y-29
Governor ........................ ...................6Y-20 Disassembly.................................................................. 6Y-29
Service O perations............... ...................6Y-20 In sta llatio n .................................................................. 6Y-30
Distributor Contact Points . ...................6Y-20 Ignition Pulse A m p lifie r ................................................... 6Y-31
Cleaning.................. . . . ...................6Y-20 Disassembly..................................................................... 6Y-31
Replacement..................... ...................6Y-20 Component C h e c k s ......................................................... 6Y-31
Setting Dwell Angle . . . . ...................6Y-22 Reassemble .................................................................. 6Y-32
Distributor Condenser . . . ...................6Y-23 Ignition Switch Replacem ent............................................. 6Y-32
Performance Diagnosis . . ...................6Y-23 Spark P lu g s ........................................................................ 6Y-32
R e p la c e m e n t.................. .................. 6Y-23 Cleaning and R e g a p p in g ................................................ 6Y-32
Distributor In sta lla tio n ..................................................................... 6Y-33
Breaker Point Type . . . . .................. 6Y-23 Truck Engine Overspeed W arn in g.................................... 6Y-33

GENERAL DESCRIPTION
There are two ignition systems available on 1967
vehicles. The breaker point type which is continued as
the regular production system and the optional transis­
tor controlled breakless ignition system (magnetic pulse
type). The transistor ignition system features a specially
designed distributor, control unit (ignition pulse ampli­
fier), and a special coil. Two resistance wires are also
used in the circuit; one as a ballast between the coil
negative terminal and ground, while the other resistance
wire provides a voltage drop for the engine run circuit
and is by-passed at cranking. The other units in the
system (the ignition switch, spark plugs, and battery)
are of standard design. The distributor and control unit
(ignition pulse amplifier) are shown in Figures li and
2 i.
Although the external appearance of the distributor
resembles a standard distributor, the internal construc­
tion is quite different. As shown in the exploded view
(fig. 23i) an iron timer core replaces the conventional
breaker cam. The timer core has the same number of
equally-spaced projections, or vanes as engine cylinders.

F ig . l i —M agnetic Pulse Distributor F ig . 2i —Ignition Pulse A m p lifie r U nit

CHEVROLET TRUCK SERVICE M ANUAL

 ENGINE-ELECTRICAL 6Y-19

The tim er core rotates inside a magnetic pick-up as­ tooth for each cylinder of the engine.
sembly, which replaces the conventional breaker plate, The magnetic pick-up assembly is mounted on a plate
contact point set, and condenser assembly. The mag­ over the main bearing of the distributor housing. The
netic pick-up assembly consists of a ceramic permanent tim er core is made to rotate about the shaft by conven­
magnet, a pole piece, and a pick-up coil. The pole piece tional advance weights, thus providing centrifugal
is a steel plate having equally spaced internal teeth, one advance.

MAINTENANCE AND ADJUSTMENTS

PERIODIC M A IN TEN A N C E IGNITION COIL CHECK (BREAKERLESS)

The ignition coil primary can be checked for an open
BREAKER POINT SYSTEM condition by connecting an ohmmeter with car battery
disconnected across the two primary terminals. Primary
The distributor breaker points and spark plugs are the
resistance at 75°F. should be between .35 and .55 ohm.
only ignition system components that require periodic
service. The remainder of the ignition system requires An infinite reading indicates the primary is open. For
only periodic inspection to check operation of the units, the engine to run but miss at times, the primary open
tightness of the electrical connections, and condition of may be of the intermittent type.
The coil secondary can be checked for an open by con­
the wiring. When checking the coil, test with a reputable
necting an ohmmeter from the high tension center tower
tester.
to either primary terminal. To obtain a reliable reading,
Breaker type distributors are equipped with cam lubri­
a scale on the ohmmeter having the 2 0 , 0 0 0 ohm value
cator and should have the wick replaced at the same time
within, or nearly within, the middle third of the scale
contact point set is replaced. It is not necessary to
should be used. Secondary resistance at 75°F. should be
lubricate the breaker cam when using a cam lubricator.
between 8,000 and 12,500 ohms. If the reading is in­
Do not attempt to lubricate the wick - Replace when
finite, the coil secondary winding is open.
necessary. When installing a new wick, adjust its position
A number of different types of coil testers are avail­
so the end of the wick just touches the lobe of the breaker
able from various test equipment manufacturers. When
cam.
using these testers, follow the procedure recommended
Distributor shaft lubrication is accomplished by a
by the tester manufacturer.
reservoir of lube around the mainshaft in the distributor
body or through a hinged cap oiler on governor type units. NOTE: Make sure the tester will properly
check this special coil.

BREAKERLESS SYSTEM
Since there are no moving parts in the ignition pulse SPARK PLUGS
amplifier unit mounted forward of the radiator bulkhead,
and the distributor shaft and bushings have permanent Should be removed, inspected cleaned and regapped at
type lubrication, no periodic maintenance is therefore tune-up. Defective plugs should be replaced, see Servic­
required for the breakerless ignition system. The dis­ ing of Units Off the Vehicle.
tributor lower bushing is lubricated by engine oil through
a splash hole in the distributor housing, and a housing
cavity next to the upper bushing contains a supply of
lubricant which will last between overhaul periods. At
time of overhaul, the upper bushing may be lubricated
by removing the plastic seal and then adding SAE 20
oil to the packing in the cavity. A new plastic seal will
be required since the old one will be damaged during
removal.
Tachometer readings for test purposes can be made on
the primary circuit of the breakerless ignition system
in the same manner as on the conventional ignition sys­
tem, however before attempting to connect a test tachom­
eter into the primary circuit check with your instrument
supplier to insure that satisfactory readings can be ob­
tained and the breakerless system will not be damaged by
the tachometer that is to be used.
CAUTION: Never install a condenser of any
rating between the coil positive and ground. The
use of a condenser at this location for radio
suppression can damage the power transistor in
the ignition amplifier unit. F ig . 3 i—Adjusting Spinner Governor

CHEVROLET TRUCK SERVICE MANUAL

ENGINE-ELECTRICAL 6Y-20

ving” up the engine against the governor with the trans­

CABLES mission in neutral.
The low and high tension cables should be examined The spinner mechanism can be adjusted by holding
carefully for brittle or cracked insulation and broken the slotted end of the valve with a screwdriver (fig. 3 i)
strands. Defective insulation will permit missing or and turning the adjusting nut on the other end. Increase
cross firing of the engine. Connections should be clean the governing speed by turning the adjusting nut
and tight. clockwise, decrease the speed by turning the nut
counterclockwise.
The governing system will operate satisfactorily for
GOVERNOR long periods if:
1. The vacuum passages are kept free from dirt.
Since governing speed is a function of both the dis­ 2. The governor air cleaner should be cleaned often
tributor spinner and the carburetor actuator, the only enough to prevent restrictions to the supply of clean
positive method of accurately setting speed is to adjust air necessary in operating the governing system.
the spinner on the vehicle. For extremely accurate full 3. Maintain tight cover bands or plugs on the dis­
throttle governing, road testing is necessary; however, tributor “ spinner” compartment. Since a partial
for practical purposes it can be assumed full throttle vacuum exists in this chamber, dirt could be drawn
governed speed will be about 2 0 0 rpm below no-load thru a leaking cover band and upset the operation of
governed speed. The adjustment can be made by “ rev­ the spinner valve.

SERVICE OPERATIONS
DISTRIBUTOR C O N TA C T POINTS sarily an indication that they are not functioning satis­
factorily. Do not attempt to remove all roughness nor
CLEANING dress the point surfaces down smooth; merely remove
scale or dirt.
Dirty contact points should be dressed with a few Badly burned or pitted contact points should be re­
strokes of a clean, fine-cut contact file. The file should placed and the cause of trouble determined so it can be
not be used for other metals and should not be allowed to eliminated. High resistance or loose connections in the
become greasy or dirty. Never use emery cloth to clean condenser circuit, oil or foreign materials on the contact
contact points. Contact surfaces, after considerable use, surfaces, improper point adjustment or high voltages may
may not appear bright and smooth, but this is not neces- cause oxidized contact points. Check for these conditions
where burned contacts are experienced. An out-of­
balance condition in the ignition system, often the result
of too much or too little condenser capacity, is indicated
where point pitting is encountered.

REPLACEMENT
CAM LUBRICATOR
Four and Six Cylinder Engine Distributor
CONTACT SET
ATTACHING 1. Release distributor cap hold-down screws, remove
SCREW cap and place it out of work area.
2. Remove rotor.
3. Pull primary and condenser lead wires from contact
point quick disconnect terminal (fig. 4i).
4. Remove contact set attaching screw, lift contact point
set from breaker plate.
5. Clean breaker plate of oil smudge and dirt.
6 . Place new contact point assembly in position on
breaker plate, install attaching screw.
CAUTION: Carefully wipe protective film from
point set prior to installation.
QUICK
DISCONNECT NOTE: Pilot on contact set must engage match­
TERMINAL ing hole in breaker plate.
7. Connect primary and condenser lead wires to quick
disconnect terminal on contact point set.
8 . Check and adjust points for proper alignment and
breaker arm spring tension (fig. 5i). Use an aligning
BREAKER PLATE
ATTACHING SCREWS tool to bend stationary contact support if points need
alignment.
F ig . 4 i—Breaker Plate and Attaching Parts NOTE: The contact point pressure must fall

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 ENGINE-ELECTRICAL 6Y-21

PRIM ARY
LEAD

F ig . 5 i—C h eckin g Breaker Arm Spring Tension

within specified lim its. Weak tension will cause

Fig . 6 i—Distributor Lead Arrangements
chatter resulting in arcing and burning of the
points and an ignition m iss at high speed, while
excessive tension will cause undue wear of the
contact points, cam and rubbing block. Breaker together at base and lift out. Remove all old lubri­
arm spring tension should be 19-23 ounces. The cant from cam surface. Replace in same manner.
contact point pressure should be checked with a
spring gauge. The scale should be hooked to the NOTE: End of cam lubricant wick should be
breaker lever and the pull exerted at 90 degrees adjusted to just touch cam lobes. Over lubri­
to the breaker lever as shown in Figure 5i. The cation of cam resulting in grease on contact
reading should be taken just as the points sepa­ points can be caused by cam lubrication wick
rate. The pressure can be adjusted by bending bearing too hard against cam surface. A cor­
the breaker lever spring. If the pressure is ex­ rectly adjusted cam lubricator wick will provide
cessive, it can be decreased by pinching the
spring carefully. To increase pressure, the
lever must be removed from the distributor so ROTOR
the spring can be bent away from the lever.
Avoid excessive spring distortion.
9. Set point opening (.019" for new points).
10. Reinstall rotor, position and lock distributor cap to
LOCATOR
housing. (R O U N D )
LOCATOR
11. Start engine and test dwell and ignition timing. (SQ U A R E )

Eight Cylinder Engine Distributor CAM

CENTRIFUGAL LUBRICATOR
1. The contact point set is replaced as one complete ADVANCE
assembly and only dwell angle requires adjustment MECHANISM
after replacement. Breaker lever spring tension and
point alignment are factory set.
2. Remove the distributor cap by placing a screw driver CAM
in the slot head of the latch, press down and turn 1/4 LUBRICATOR
turn in either direction. REPLACEMENT
3. Remove the two attaching screws which hold the base
of the contact set assembly in place. CAUTION!
4. Remove the primary and condenser leads from their NEVER OIL
nylon insulated connection (fig. 6 i) in contact set. CAM LUBRICATOR—
5. Reverse Steps 2, 3 and 4 to install new contact set. REPLACE WICK
WHEN NECESSARY
CAUTION: Install the primary and condenser
leads as shown in Figure 6 i. Improper installa­ ADJUST SQUARELY
tion will cause lead interference between the AND JUST
cap, weight base and breaker advance plate. TOUCHING LOBE
OF CAM
6 . If car has 20,000 to 25,000 miles (or sooner if
desired) the cam lubricator wick (fig. 7i) should be
changed. Using long nosed pliers squeeze assembly Fig . 7 i—Top V ie w of Distributor

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ENGINE-ELECTRICAL 6Y-22

F ig . lO i—Setting Point O pening

F ig . 8 i—Inaccurate G auging of Rough Points New points must be set to the larger opening as the
adequate lubrication for cam. Do not apply ad­ rubbing block will wear down slightly while seating to the
ditional grease to cam surface. cam. Contact points should be cleaned before adjusting if
they have been in service.
7. Start engine and check point dwell and ignition To adjust the contact point opening:
timing. 1. If necessary, align points (fig. 9i) by bending the
fixed contact support. Do not bend the breaker lever.
SETTING DWELL ANGLE Do not attempt to align used points; replace them
Four and Six Cylinder Engine Distributors where serious misalignment is observed. Use an
aligning tool if available.
The point opening of new points can be checked with a 2. Turn or crank the distributor shaft until the breaker
feeler gauge, but the use of a feeler gauge on rough or arm rubbing block is on the high point of the cam
uncleaned used points is not recommended since accurate lobe. This will provide maximum point opening.
mechanical gauging cannot be done on such points (fig. 8 i). 3. Loosen the contact support lock screw.
Contact points must be set to the proper opening. 4. Use a screw driver (fig. lOi) to move the point sup­
Points set too close may tend to burn and pit rapidly. port to obtain a .019" opening for new points and a
Points with excessive separation tend to cause a weak .016" opening for used points.
spark at high speed. Proper point setting for all models 5. Tighten the contact support lock screw and recheck
are: the point opening.
.019" for new points 6 . After checking and adjusting the contact point opening
.016" for used points to specifications, the cam angle or dwell should be
checked with a dwell angle meter if such equipment
is available (see Specifications for proper dwell
angle). If the cam angle is less than the specified
minimum, check for defective or misaligned contact
points or worn distributor cam lobes. The variation
in cam angle readings between idle speed and 1750
engine rpm should not exceed 3°. Excessive variation
in this speed range indicates wear in the distributor.
NOTE: Cam angle readings taken at speeds
above 1750 engine rpm may prove unreliable
on some cam angle meters.

Eight Cylinder Engine Distributor

On the Vehicle
With the engine running at idle and operating tempera­
tures normalized, the dwell is adjusted by first raising

CHEVROLET TRUCK SERVICE MANUAL

 ENGINE-ELECTRICAL 6Y-23

the window provided in the cap and inserting a "Hex” which, up to a certain limit, is not objectionable.
type wrench into the adjusting screw head (fig. H i). 3. High Series Resistance - Excessive resistance in the
1. Preferred Method - Turn the adjusting screw until condenser circuit due to broken strands in the con­
the specified dwell angle is obtained as measured in denser leak or to a defective connection. This will
degrees (28° to 32°, 30° preferred) by a dwell angle cause burned points and ignition failure upon initial
meter. starts and at high speeds.
2. Alternate Method - Turn adjusting screw in (clock­ 4. Capacity - Capacity is determined by the area of the
wise) until the engine begins to m isfire, then turn metallic elements and the insulating and impreg­
screw 1 / 2 turn in the opposite direction (counter­ nating m aterials.
clockwise). This will give the approximate dwell For a complete check of the condenser, use a tester
angle required. (Use only when meter is not which will check for all of the above conditions. Follow
available.) the instructions given by the manufacturer of the test
equipment. Condenser capacity should be .18-. 2 3
Off the Vehicle
microfarads.
1. Distributor Test Method:
a. With the distributor mounted on a distributor
REPLACEMENT
testing machine, connect the dwell meter to the
distributor primary lead. Four and Six Cylinder Engine Distributor (Fig. 4i)
b. Turn the adjusting screw (fig. lli) to set the 1. Release distributor cap hold-down screws, remove
dwell angle to 30 degrees. cap and place it out of the work area.
2. Test Light Method:
2. Remove rotor.
a. With the distributor mounted in a vise, connect a 3. Disconnect condenser lead wire from contact point
testing lamp to the primary lead. quick-disconnect terminal.
b. Rotate the shaft until one of the circuit breaker 4. Remove condenser attaching screw, lift condenser
cam lobes is under the center of the rubbing from breaker plate and wipe breaker plate clean.
block of the breaker lever. 5. Install new condenser using reverse of procedure
c. Turn the adjusting screw clockwise (fig. lli)
outlined above.
until the lamp lights, then give the wrench 1 / 2
turn in the opposite direction (counter-clockwise)
to obtain the proper dwell angle. Eight Cylinder Engine Distributor
1. Remove distributor cap.
2. Loosen condenser lead attaching screw (fig. 6 i) and
lift out condenser lead clip.
DISTRIBUTOR CONDENSER
3. Remove screw holding condenser bracket to breaker
plate and slide condenser from bracket.
PERFORMANCE DIAGNOSIS
4. To replace condenser reverse the above procedure.
The following four factors affect condenser perfor­
mance, and each factor must be considered in making any
NOTE: Make sure that new condenser lead is
condenser test. installed in proper position (fig. 6 i).
1. Breakdown - A failure of the insulating material. A
direct short between the metallic elements of the
condenser. This prevents any condenser action.
2. Low Insulating Resistance (Leakage) - Low insula­ DISTRIBUTOR
tion resistance prevents the condenser from holding (BREAKER POINT TYPE)
a charge. All condensers are subject to leakage
REMOVAL
1. Release the distributor cap hold-down screws, re­
move the cap and place it clear of the work area.
NOTE: If necessary, remove secondary leads
from the distributor cap after first marking the
cap tower for the lead to No. 1 cylinder. This
will aid in the reinstallation of leads in the cap.
2. Disconnect the distributor primary lead from the coil
terminal.
3. Scribe a realignment mark on the distributor bowl
and engine in line with the rotor segment.
4. Disconnect external connections (vacuum line, drive
cables, etc.), remove the distributor hold-down bolt
and clamp, remove the distributor from the engine.
Note position of vacuum advance mechanism relative
to the engine.
CAUTION: Avoid rotating the engine with the
distributor removed as the ignition timing will
F ig . 11 i —Adjusting Dw ell Angle be upset.

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ENGINE-ELECTRICAL 6Y-24

DISASSEMBLY When mounting distributors for tests, first secure the

gear in the test drive mechanism, then push the distrib­
It is advisable to place the distributor in a distributor
utor housing downward toward the gear to take up any end
testing machine or synchroscope prior to disassembly.
play between the gear and the housing.
NOTE: When testing distributors that have their
lower shaft support bushing located in the engine
block ( 6 cylinder engines, a special adapter
should be used to insure the shaft will run true
in its housing.
Test the distributor for variation of spark, correct
centrifugal and vacuum advance and condition of contacts.
This test will give valuable information on distributor
condition and indicate parts replacement which may be
necessary. Check the area on the breaker plate just be­
neath the contact points. A smudgy line indicates that oil
or crankcase vapors have been present between the
points.

Four and Six Cylinder Engines

Refer to Figure 12i.
1. Remove the rotor.
2. Remove the vacuum control assembly retaining
screws, detach the unit from the distributor housing.
3. Disconnect the primary and condenser leads from
the contact point quick disconnect terminal, remove
the contact point set attaching screw, condenser at­
taching screw. Remove the point set and condenser
from the breaker plate.
4. Remove the breaker plate attaching screws, remove
the breaker plate from the distributor housing (fig.
1 2 i).

NOTE: Do not disassemble breaker plate any

further.
5. Remove the roll pin retaining the driven gear to the
mainshaft, slide the gear from the shaft.
6 . Slide the cam and mainshaft from the distributor
housing.
7. Remove the weight cover and stop plate screws,
remove the cover, weight springs, weights and slide
cam assembly from the mainshaft.

V-8 Engines
Refer to Figure 13i and 14i.
1. Remove the rotor.
2. Remove both weight springs and advance weights.
3. Remove roll pin retaining driven gear to distributor
shaft, slide the gear and spacers from the shaft.
On heavy duty models remove shock mounting unit.
NOTE: When servicing governor type distribu­
F ig . 12 i— L —6 Distributor tors (fig. 14i), remove the cover band and
spinner valve assembly at this time. Be sure to
1. Breaker P la te Attaching 10. C o ntact Point
Screws A ttach ing Screw
note the revolutions needed to remove the nut
2. Condenser Attaching 11. C ontact Point Assembly from the spinner valve.
Screws 12. W eigh t C over
3. Condenser A ttaching Screws
4. Before sliding the distributor shaft from the housing,
4. Breaker P la te Assembly 13. W eigh t C o ver check for and remove any burrs on the shaft. This
4a. Cam Lubricator 14. W eight Springs will prevent damage to the seals and bushing still
5. Vacuum Control Assembly 15. A d vance Weights positioned in the housing.
6. Vacuum Control 16. Cam Assembly
A ttaching Screws
5. Slide the distributor mainshaft and cam-weight base
17. M a in Shaft
7. Housing Assembly assembly from the housing.
8. Cap 18. Roll Pin 6 . Remove vacuum advance mechanism retaining
9. 19. D rive G e a r screws, remove the vacuum advance assembly.

CHEVROLET TRUCK SERVICE M ANUAL

 ENGINE—ELECTRICAL 6Y-25

Fig. 13i —V —8 Distributor (T y p ica l)

1. Condenser 5. F e lt W asher 8. Shim W asher 13. W eig h t Springs

2. C ontact Point Assembly 5a Plastic Seal 9. D rive G e a r Pin 14. M ainshaft
2a. Cam Lubricator 6 . Vacuum A d vance 10. D rive G e a r 15. A d va n ce Weights
3. Retaining Ring U nit 11. C ap 16. Cam W eigh t
4. Breaker Pla te 7. Housing 12. Rotor Base Assembly

7. Remove the spring retainer, remove the breaker CLEANING AND INSPECTION
plate assembly from the distributor housing. Remove
the contact point and condenser from the breaker 1. Wash all parts in cleaning solvent except cap, rotor,
plate. Remove the felt washer and plastic seal lo­ condenser, breaker plate assembly and vacuum con­
cated beneath the breaker plate. trol unit. Degreasing compounds may damage in­
sulation of these parts or saturate the lubricating
NOTE: Governor type distributors have no felt in the case of the breaker plate assembly.
breaker plate. The contact point assembly and 2. Inspect the breaker plate assembly for damage or
condenser are attached directly to the distribu­ wear and replace if necessary.
tor housing. 3. Inspect the shaft for wear and check its fit in the
8 . On distributor with governor remove main shaft bushings in the distributor body. If the shaft or
seals as follows: bushings are worn, the parts should be replaced.
a. With punch shaped as shown in Figure 15i reach 4. Mount the shaft in “ V” blocks and check the shaft
up through the bottom of housing and insert edge alignment with a dial gauge. The run-out should not
of punch between upper and lower seals and push exceed .0 0 2 ".
upper seal out. 5. Inspect the advance weights for wear or burrs and
b. Insert suitable punch into vacuum hole as shown free fit on their pivot pins.
in Figure 16i and loosen lower seal by denting one 6 . Inspect the cam for wear or roughness. Then check
side slightly. its fit on the end of the shaft. It should be absolutely
c. After lower seal has been loosened, use the free without any roughness.
special punch shown in Figure 17i to push out 7. Inspect the condition of the distributor points. Dirty
seal. points should be cleaned and badly pitted points

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ENGINE-ELECTRICAL 6Y-26

POINT UNIT CONDENSER HOUSING WASHER GEAR PIN BAND ASSY.

(LEVER & SUPPORT ASSY.)

Fig . 14i—G o vernor Type Distributor

should be replaced. (See Distributor Contact Points.) 7. Attach vacuum control assembly to distributor
8 .
Test the condenser for series resistance, micro­ housing.
farad capacity (.18 to .23) and leakage or breakdown, .
8 Check and adjust contact point opening and alignment.
following the instructions given by the manufacturer (See setting and alignment of points.)
of the test equipment used. 9. Check breaker lever spring tension which should be
9. Inspect the distributor cap and spark plug wires for 19-23 ounces. (See contact point replacement.)
damage and replace if necessary. V-8 EN G IN E-(Fig. 13i & 14i)
1. On distributor without governor:
ASSEMBLY a. Fill housing lubricating cavity with proper com­
pound, press in new plastic seal and install felt
Four and Six Cylinder Engine washer.
Refer to Figure 12i for Exploded View of Distributor. b. Replace the vacuum advance unit.
1. Replace cam assembly to mainshaft. c. Install the breaker plate in housing and the spring
retainer on the upper bushing.
NOTE: Lubricate top end of shaft with Delco 2. On distributor with governor install seals and as­
cam and ball bearing grease or equivalent prior semble governor as follows (figs. 18i and 19i):
to replacing. a. Insert lower seal through side opening and start
2. Install governor weights on their pivot pins, replace seal straight in bore with lip of seal down.
weight springs. Install weight cover and stop plate. b. Place a steel disc approximately 15/16" diam­
eter on top of seal. Insert a 7 /'6 " diameter rod
3. Lubricate mainshaft and install it in distributor
housing. through top of distributor and against disc. P ress
4. Install distributor driven gear to mainshaft and seal, to bottom of counterbore.
insert retaining roll pin. Check to see that shaft Install spring washer on top of seal.
turns freely. Start upper seal in bore with lip of seal up and,
5. Install breaker plate assembly in the distributor body using steel disc and rod, press seal flush with
and attach retaining screws. top of counterbore.
6 . Attach condenser and contact point set in proper NOTE: Spring should seat on the “ flat” ma­
location with appropriate attaching screws. chined on one side of the mainshaft.
NOTE: Contact point set pilot must engage 3. Lubricate and slide weight cam over mainshaft and
matching hole in breaker plate. Connect primary install weights and spring (fig. 2 0 i).
and condenser leads to contact set quick- 4. Insert mainshaft into housing, indexing it with drive
disconnect terminal. gear and washers.

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 ENGINE-ELECTRICAL 6Y-27

PUNCH
LOWER
SEAL

VACUUM HOLE

F ig . 16i— Loosening Lower Seal

LOWER
REMOVAL
PUNCH

HOUSING

LOWER
SEAL

SEAL
REMOVAL
F ig . 15i—Removing Upper Seal PUNCH

5. Slide distributor drive gear shims and gear over

shaft and install new pin. Tap new pin through gear
HOUSING
and mainshaft. Check shaft for free rotation. On
heavy duty models, install shock mounting assembly.
NOTE: Mainshaft end clearance should be
.002”-.0 0 7 ". Add or remove shims as necessary.
6 . Install contact point set and condenser to breaker
plate. Connect leads as shown in Figure 4i.
NOTE: Contact point spring tension is factory-
set above specifications to assure ease of final
adjustment. Correct tension is 19-23 oz.
7. Install rotor to cam assembly, indexing round and
square pilot holes.
8 . Set spinner governor as outlined under “ Governor
Setting.” F ig . 17i —Removing Lower Seal

CHEVROLET TRUCK SERVICE M ANUAL

ENGINE-ELECTRICAL 6Y-28

F ig . 20i—A d vance W eights Installed

F ig . 18i— Installing Seals in G o ve rn o r Distributor adjustment until reading returns to 5.0 each time the
hose is pinched.
4. Attach vacuum hose to the adapter on the distributor
GOVERNOR SETTING and start tester. Increase speed until the vacuum
reading reaches a maximum value. This maximum
Since governor speed is a function of both the distribu­ value will vary, depending on the type “ spinner”
tor “ spinner” and the carburetor actuator, the only parts used, but will probably be above 3.8” hg.
positive method of accurately setting speed is to adjust 5. After this maximum reading has been reached,
the spinner on the vehicle. slowly decrease the distributor speed until the vac­
If an approximate bench setting of the spinner is de­ uum gauge hand falls back .1" hg. The speed at which
sired, the following procedure can be followed: this . 1 " hg. drop occurs will be the approximate no
1. With “ spinner” valve adjusted so that at least two load governed speed. (Remember that distributor
threads on the valve are showing behind the nut, rpm is half engine rpm when making this adjustment.)
mount the distributor in a tester.
2. Screw vacuum adapter into lower vacuum opening
INSTALLATION—ENGINE NOT DISTURBED
on the distributor housing.
3. With the vacuum hose pinched or bent double to pre­ (ALL MODELS)
vent leakage through the hose, adjust vacuum so that 1. Turn the rotor about 1/8 turn in a clockwise direc­
gage reads 5.0 inches. Replace hose, then repeat tion past the mark previously placed on the distrib­
utor housing to locate rotor.
2. Push the distributor down into position in the block
with the housing in a normal “ installed” position
(figs. 2 1 i and 2 2 i).
NOTE: It may be necessary to move rotor
slightly to start gear into mesh with camshaft
gear, but rotor should line up with the mark
when distributor is down in place.
3. Tighten the distributor clamp bolt snugly and connect
vacuum line. Connect primary wire to coil terminal
and install cap. Also install spark plug and high
tension wires if removed.
NOTE: It is important that the spark plug
wires be installed in their proper location in the
supports (fig. 23i).
4. Time ignition as previously described under Tune-Up
in Section 6 .

INSTALLATION—ENGINE DISTURBED
(ALL MODELS)
1. Locate No. 1 piston in firing position by either of
F ig . 19i—Distributor G overnor Assembly two methods described below.

CHEVROLET TRUCK SERVICE M ANUAL

 ENGINE-ELECTRICAL 6Y-29

more toward left cylinder bank and push distributor

down to engine camshaft. It may be necessary to
rotate rotor slightly until camshaft engagement is
felt.
4. While pressing firmly down on distributor housing,
kick starter over a few times to make sure oil
pump shaft is engaged. Install hold-down clamp and
bolt and snug up bolt.
5. Turn distributor body slightly until points just open
and tighten distributor clamp bolt.
6 . Place distributor cap in position and check to see
that rotor lines up with terminal for No. 1 spark
plug.
7 . Install cap, check all high tension wire connections
and connect spark plug wires if they have been
removed. It is important that the wires be installed
in their location in the supports.
NOTE: The brackets are numbered to show the
correct installation. Wires must be installed as
indicated to prevent cross firing.
8 . Connect vacuum line to distributor and distributor
primary wire to coil terminal.
9. Start engine and set timing as described under
Turn-Up in Section 6 .

Fig . 21 i —Six C y lin d e r Engine Distributor MAGNETIC PULSE DISTRIBUTOR (Fig. 23i)

a. Remove No. 1 spark plug and, with finger on plug REMOVAL

hole, crank engine until compression is felt in the 1. Disconnect pick-up coil leads at connector.
No. 1 cylinder. Continue cranking until timing 2. Remove distributor cap.
mark on crankshaft pulley lines up with timing 3. Crank engine so rotor is in position to fire No. 1
tab attached to engine front cover. cylinder and timing mark on harmonic balancer is
b. Remove rocker cover (left bank on V - 8 engines) indexed with pointer.
and crank engine until No. 1 intake valve closes 4. Disconnect air intake and governor vacuum lines
and continue to crank slowly about 1/3 turn until from distributor.
timing mark on pulley lines up with timing tab. 5. Remove distributor clamping screws and hold-down
2. Position distributor to opening in block in normal clamp.
installed attitude (fig. 2 1 i and 2 2 i), noting position of 6 . Remove distributor and distributor-to-block gasket.
vacuum control unit. It will be noted that the rotor will rotate as the dis­
3. Position rotor to point toward front of engine (with tributor is pulled out of the block. Mark the rela­
distributor housing held in installed attitude), then tionship of the rotor and the distributor housing
turn rotor counter-clockwise approximately 1 / 8 turn after removal so that the rotor can be set in the
same position when the distributor is being installed.

DISASSEMBLY
1. Remove screws securing rotor and remove rotor.
2. Remove centrifugal weight springs and weights.
3. Remove cover band and spinner valve assembly. Be
sure to note the revolutions needed to remove the
nut from the spinner valve.
4. Remove pin (file or grind end of pin) retaining driven
gear, then remove distributor gear, washer and shock
mounting assembly from shaft.
CAUTION: To prevent damage to the perma­
nent magnet, support drive gear when driving
out gear retaining pin.
5. Remove drive shaft assembly. Check for and remove
burrs on the shaft to prevent damage to seals and
bushing still positioned in housing.
6 . Remove centrifugal weight support and timer core
from drive shaft.
F ig . 2 2 i—Eight C ylin d e r Engine Distributor 7 . Remove connector from pick-up coil leads.

CHEVROLET TRUCK SERVICE M ANUAL

ENGINE—ELECTRICAL—6Y-30

MOUNTING
SCREW
RESISTOR R5 DIODE D1

TRANSISTOR TR2 TRANSISTOR TR1

(UNDERNEATH) (UNDERNEATH)

CENTRIFUGAL
ROTOR ADVANCE

ROTATING
POLE PIECE

SCREW
STATIONARY CAPACITOR Cl R1
POLE PIECE MOUNTING C3
SCREW
CAPACITOR C2
TRANSISTOR TR3

MAGNETIC Fig . 24i—Pulse A m p lifier Panel Board

PICKUP
8. Remove retaining ring which secures magnetic core
ASSEMBLY support plate to distributor shaft bushing in housing.
9. As a unit, remove the entire magnetic pick-up
assembly from the distributor housing.
10. Remove brass washer and felt pad.
NOTE: Before removing plastic seal, refer to
instructions provided earlier in this article.
11. If necessary to replace the mainshaft seals refer to
the procedures previously described.
12. To reassemble distributor, perform the above steps
in reverse order.

INSTALLATION
1. Check to see that the engine is at firing position for
No. 1 cylinder (timing mark on harmonic balancer
indexed with pointer).
2. Position a new distributor-to-block gasket on the
DISTRIBUTOR block.
HOUSING 3. Before installing distributor, index rotor with hous­
ing as noted when distributor was removed.
4. Replace distributor clamp leaving screw loose
enough to allow distributor to be turned for timing
adjustment.
5. Install spark plug wires in distributor cap. Place
wire for No. 1 cylinder in tower (marked on old cap
during disassembly) then install remaining wires
clockwise around the cap according to the firing
order (1 -8 -4 -3 -6 -5 -7 -2 ).
6 . Attach distributor to coil primary wires.
7. Replace distributor cap.
8 . Attach governor vacuum and air intake lines to
distributor.
9. Adjust timing and then fully tighten distributor clamp
F ig . 2 3 i—Magnetic Pulse Distributor Components screw.

CHEVROLET TRUCK SERVICE MANUAL

 ENGINE-ELECTRICAL 6Y-31

CHECKING CHECKING CHECKING CHECKING CHECKING

DIODE D1 RESISTOR R3 RESISTOR R4 RESISTOR R5 RESISTOR R2

CHECKING CHECKING
RESISTOR R1 CAPACITOR Cl

F ig . 2 5 i—Pulse A m p lifie r Component Checks

Fig . 26i—Pulse A m p lifie r Internal C ircu itry

IGNITION PULSE AMPLIFIER In order to check the panel board assembly, it is nec­
essary to unsolder at the locations indicated in Figure 5i
the two capacitors C2 and C3. In all of the following
DISASSEMBLY
checks, connect the ohmmeter as shown and then reverse
To check the amplifier for defective components, pro­ the ohmmeter leads to obtain two readings. Internal
ceed as follows: circuitry of the amplifier is shown in Figure 26i.
1. Remove the bottom plate from the amplifier. 1. Transistors T R l and TR2: Check each transistor by
2. To aid in reassembly, note the locations of the lead referring to Figure 27i. If both readings in Step 1 are
connections to the panel board. zero, the transistor is shorted. If both readings in
3. Remove the three panel board attaching screw, and Step 2 are zero, the transistor is shorted; and if both
lift the assembly from the housing. readings are infinite, the transistor is open. Inter­
4. To aid in reassembly, note any identifying markings pret Step 3 the same as Step 3.
on the two transistors and their respective locations 2. Trigger Transistor TR3: If both readings in Step 1
on the panel board and heat sink assembly. are zero, the transistor is shorted. If both readings
5. Note the insulators between the transistors and the in Step 2 are zero, the transistor is shorted; and if
heat sink, and the insulators separating the heat sink both readings are infinite, the transistor is open.
from the panel board. Interpret Step 3 the same as Step 2.
6 . Remove the transistor attaching screws, and sepa­
3. Diode Dl: If both readings are zero, the diode is
rate the two transistors and heat sink from the panel shorted; and if both readings are infinite, the diode is
board. open.
7. Carefully examine the panel board for evidence of 4. Capacitor Cl: If both readings are zero, the capaci­
damage. tor is shorted.
5. Capacitors C2 and C3: Connect the ohmmeter across
COMPONENT CHECKS (Figs. 24i and 25i) each capacitor (not illustrated). The capacitor is
With the two transistors separated from the assembly, shorted if both readings are zero.
an ohmmeter may be used to check the transistors and 6 . Resistor R l: The resistor is open if both readings
components on the panel board for defects. An ohmmeter are infinite.
having a 1 - 1 / 2 volt cell, which is the type usually found 7. Resistor R2: Use an ohmmeter scale on which the
in service stations, is recommended. The low range 1800 ohm value is within, or nearly within, the mid­
scale on the ohmmeter should be used except where dle third of the scale. If both readings are infinite,
specified otherwise. the resistor is open.
A 25 watt soldering gun is recommended, and a 60% 8 . Resistor R3: Use an ohmmeter scale on which the

tin 40% lead solder should be used when re-soldering. 680 ohm value is within, or nearly within, the middle
Avoid excessive heat which may damage the panel board. third of the scale. If both readings are infinite, the
Chip away any epoxy involved, and apply new epoxy which resistor is open.
is commercially available. 9. Resistor R4: Select an ohmmeter scale on which the

CHEVROLET TRUCK SERVICE MANUAL

ENGINE-ELECTRICAL 6Y-32

F ig . 2 8 i—Setting Spark Plug G a p

to turn key counter-clockwise until lock cylinder can

be removed.
3. Remove the metal ignition switch nut using tool
Fig . 2 7 i—Transistor Checks J-7607.
4. Pull the ignition switch out from under the dash and
15000 ohm value is within, or nearly within, the mid­ remove the wiring connector.
dle third of the scale. If either reading is infinite, 5. To remove the “theft resistant” connector, the
the resistor is open. switch must be out from under the dash as outlined
10. Resistor R5: Use the lowest range ohmmeter scale. in Step 4. Using a screw driver unsnap the locking
The resistor is open if either reading is infinite. tangs on the connector from their position on the
switch. Unplug the connector.
NOTE: This resistor on some applications may
6 . Snap the connector into place on a new ignition
be located in the vehicle wiring harness, and not
switch.
on the panel board.
7. Place the switch into position from behind the dash
11. Resistor R 6 : An ohmmeter scale on which the 150 and install the metal ignition switch nut.
ohm value is within, or nearly within, the middle 8. Install the lock cylinder.
third of the scale should be used. If both readings 9. Install the battery cable to the battery and lower the
are infinite, the resistor is open. hood.
NOTE: This resistor is not used on some
amplifier models.
SPARK PLUGS
REASSEMBLY
During assembly, coat with silicone grease both sides
of the flat insulators used between the transistors and CLEANING AND REGAPPING
heat sink, and also the heat sink on the side on which the Clean the spark plugs thoroughly, using an abrasive-
transistors are mounted. The silicone grease, which is type cleaner. If the porcelains are badly glazed or
available commercially, conducts heat and thereby pro­ blistered, the spark plugs should be replaced. All spark
vides better cooling. plugs must be of the same make and number or heat
range. Use a round feeler gauge to adjust the spark plugs
gaps to .035" (fig. 28i).
IGNITION SWITCH REPLACEMENT
CAUTION: Before adjusting gap, file center
1. Raise hood and disconnect battery ground cable from electrode flat. In adjusting the spark plug gap,
battery. never bend the center electrode which extends
2. Remove lock cylinder by positioning switch in “ off” through the porcelain center. Always make
position and inserting wire in small hole in cylinder adjustment by b e n d i n g the ground or s i d e
face. Push in on wire to depress plunger and continue electrode.

CHEVROLET TRUCK SERVICE MANUAL

 ENGINE-ELECTRICAL 6Y-33

DISTRIBUTOR CARBURETOR

BUTTERFLY VALVE

SPINNER VALVE
CARBURETOR ACTUATOR

LAMP BURN-OUT CHECKING CIRCUIT

IGNITION
SWITCH
OIL PRESSURE
SWITCH

AMBER
LAMP
BATTERY

F ig . 2 9 i— Engine Overspeed W arning System

INSTALLATION In operation, when the engine reaches its governed

Install the spark plugs in the engine with new gaskets speed (4000 rpm with standard transmission or with
and torque to specifications. If torque wrench is not Powermatic transmissions maximum under full load con­
available, tighten plugs finger tight and 1 / 2 turn more. ditions) the centrifugally operated spinner valve will
close, thus applying a vacuum on the carburetor actuator
Plugs are of a 14 millim eter size and care must be exer­
cised when installing or the gap setting may be changed. diaphragm which in turn acts to close the throttle valves.
The overspeed warning system vacuum switch, being in
the spinner governor vacuum line, also senses the vacuum
applied when governed speed is reached and acts to close
TRUCK ENGINE OVERSPEED WARNING SYSTEM
the circuit to the battery thus lighting the amber warning
The purpose of this overspeed warning system is to lamp. The lamp burnout checking circuit consists of a
warn the driver of excessive engine speed in an over-run 1‘normally closed” engine oil pressure switch which
condition (such as during down hill operation when the completes the circuit from the battery, through the warn­
wheels may begin to drive the engine) and thus enable ing light, ignition switch and the oil pressure switch
steps to be taken to correct the condition. itself, and back to ground. The warning light should light
The system (fig. 29i) consists of an amber jeweled up when the ignition switch is turned "ON” but the engine
warning lamp mounted in the cab, a vacuum sensing is "O F F .” When the engine is started the oil pressure
switch in the spinner governor vacuum line, and a warn­ opens the switch, breaking the checking circuit. The
ing lamp burnout checking circuit. These components warning light will then go out and remain out until such
operate in conjunction with the 2G Engine Governor time as the engine reaches its predetermined governed
(Vacuum Spinner Type) described in Section 6 M of this speed. Thus the driver has a quick check of the condition
Shop Manual. of the warning light bulb.

CHEVROLET TRUCK SERVICE MANUAL

ENGINE-ELECTRICAL 6Y-34

STARTING SYSTEM
STARTING MOTOR
INDEX
Page Page

General D e s c r ip tio n ......................................................... 64-34 Starting Motor and Solenoid C h e c k .............................. 64-36
Maintenance and A djustm ents.......................................... 64-36 Service O perations............................................................ 64-36
L u b ric a tio n ..................................................................... 64-36 Removal and Installation ............................................. 64-36
Resistance C h e c k s ..........................................................64-36

GENERAL DESCRIPTION
The function of the starting system, composed of the solenoid completes the circuit to the starting motor, and
starting motor, solenoid and battery, is to crank the the motor then does the actual work of cranking the
engine. The battery supplies the electrical energy, the engine.

CONTACT SOLENOID
FINGER PLUNGER RETURN SPRING

SHIFT
LEVER

SPIRAL
SPLINES

riNION
STOP
OVERRUNNING
BRUSH INSULATED BRUSH HOLDER FIELD COIL CLUTCH
BRUSH SPRING ARMATURE
GROUNDED BRUSH HOLDER

Fig . I s —Starting M otor Cross Section (T y p ica l)

CHEVROLET TRUCK SERVICE MANUAL

 ENGINE-ELECTRICAL 6Y-35

SOLENOID SEAL
LINKAGE

SHIFT LEVER
COMMUTATOR
END FRAME
LEVER HOUSING

HOUSING
BRONZE
BUSHING

THRU BRONZE
BOLT BUSHING
BRUSH

GROUNDED INSULATED
BRUSH HOLDER COMMUTATOR ATTACHING INTERMEDIATE
BRUSH HOLDER
POLE SHOE FIELD COIL BOLT DUTY CLUTCH

F ig . 2s— Intermediate Duty Overrunning C lu tch Type Starting M otor

The starting motor (fig. Is) consists primarily of the housing is extended to enclose the entire shift lever and
drive mechanism, frame, armature, brushes, and field plunger mechanism, protecting them from dirt, splash,
windings. The starting motor is a 12-volt extruded and icing. The flange mounted solenoid switch operates-
frame type, having four pole shoes and four fields, con­ the overrunning clutch drive by means of a linkage to the
nected with the armature. The aluminum drive end shift lever.

GASKETS HEAVY-DUTY
SOLENOID SWITCH LINKAGE SEAL
LINKAGE
GASKET
COMMUTATOR
END FRAME SHIFT LEVER

LEVER HOUSING
OIL
RESERVOIR BRUSH NOSE HOUSING

OIL WICK
CABLE

BRONZE
BUSHING
COVER ARMATURE / " O ” RING
RINGS BAND HEAVY-DUTY
COMMUTATOR POLE SHOE SHAFT SEAL BRONZE ’BUSHING CLUTCH T-1041

F ig . 3s—Cross-Sectional V ie w of Motor with Heavy Duty C lu tch

CHEVROLET TRUCK SERVICE MANUAL

ENGINE-ELECTRICAL 6Y-36

Variations of the enclosed shift lever type starting flange mounted starting motor but a much heavier duty
motor are used in the Chevrolet Truck Programs. Gas­ design (fig. 3s). Specific mention is made where differ­
oline powered engines use the conventional starting ences in service procedures between the two types of
motor of either the flange or pad mounted (figs. 2 s and motors occur.
3s) type housing. Diesel powered truck engines use a

MAINTENANCE AND ADJUSTMENTS

LUBRICATION terminal of the solenoid.
The gasoline engine type starting motors have graphite 1. If this voltage drop exceeds 3.5 volts, excessive re­
and oil impregnated bronze bearings and therefore re­ sistance in the solenoid control circuit is indicated
quire no periodic lubrication between major overhauls. and should be corrected.
The V- 6 Diesel engine type motors have pipe plug oilers 2. If the voltage drop does not exceed 3.5 volts and the
and should have 8 - 1 0 drops of light engine oil every solenoid does not pull in, measure the voltage avail­
5000 miles or every 300 hours of operation. able at the SWITCH terminal of the solenoid.
3. If the solenoid does not feel warm, it should pull in
RESISTANCE CHECKS whenever the voltage available at the SWITCH te r­
minal is 7.7 volts or more. When the solenoid feels
Although the starting motor cannot be checked against warm, it will require a somewhat higher voltage to
specifications on the car, a check can be made for ex­ pull in.
cessive resistance in the starting circuit. Place a volt­
STARTING MOTOR AND SOLENOID CHECK
meter across points in the cranking circuit as outlined
below and observe the reading with the starting switch The following checks may be made if the specific
closed and the motor cranking (distributor primary lead gravity of the battery is 1.215 or higher.
grounded to prevent engine firing). 1. If the solenoid does not pull in, measure the voltage
1. From battery positive post To solenoid battery between the switch (S) terminal of the solenoid and
terminal. ground with the starting switch closed.
2. From battery negative post To starting motor
CAUTION: If the solenoid feels warm, allow to
housing.
3. From solenoid battery terminal To solenoid motor cool before checking.
terminal. If the voltage is less than 7.7 volts, check for ex­
If voltage drop in any of above check exceeds 0.2 volts, cessive resistance in the solenoid control circuit. If
excessive resistance is indicated in that portion of start­ the voltage exceeds 7.7 volts, remove the starting
ing circuit and the cause of the excessive resistance motor and check (1 ) solenoid current draw, (2 )
could be located and corrected in order to obtain maxi­ starting motor pinion clearance, and (3) freedom of
mum efficiency in the circuit. shift lever linkage.
CAUTION: Do not operate the starting motor
2. If the solenoid “ chatters” but does not hold in, check
continuously for more than 30 seconds to avoid the solenoid for an open “ hold-in” winding. When­
overheating. ever it is necessary to replace a starting motor
solenoid, always check starting m o t o r pinion
When the solenoid fails to pull in, the trouble may be clearance.
due to excessive voltage drop in the solenoid control 3. If motor engages but does not crank or cranks slow­
circuit. To check for this condition, close the starting ly, check for excessive resistance in the external
switch and measure the voltage drop between the BAT­ starting circuit, trouble within the starting motor, or
TERY terminal of the solenoid and the SWITCH (S) excessive engine resistance to cranking.

SERVICE OPERATIONS
STARTER MOTOR
REMOVAL AND INSTALLATION (Fig. 4s)
The following procedure is a general guide for all
vehicles and will vary slightly depending on the truck
series and model.
1. Disconnect battery ground cable at the battery.
2. Disconnect engine wiring harness and battery leads
at solenoid terminals.
3. Remove starter mounting bolts and retaining nuts and
disengage starter assembly from the flywheel
housing.
4. Position starter motor assembly to the flywheel
housing and install the mounting bolts and retaining
nuts. Torque the mounting bolts 25 - 35 ft. lbs.
5. Connect all wiring leads at the solenoid terminals.
6 . Connect the battery ground cable and check operation
of the unit.

CHEVROLET TRUCK SERVICE MANUAL

 ENGINE-ELECTRICAL 6Y-37

SPECIAL TOOLS

J-7607
IG N IT IO N SW ITCH
NUT REM O VER

J-9717-2 J-9717-1 J-9600-2 J 21501

SUPPO RT PRESS SH O ULD ERED PULLY
TO O L TO O L INSTALLER ADAPTER

J-5184
C H E C K IN G
SCALE J-21 600
H A R N ESS ADAPTER

F ig . 5s—Sp ecial Tools

CHEVROLET TRUCK SERVICE MANUAL

—
 SECTION 7
TRUCK CLUTCHES & TRANSMISSIONS
CONTENTS OF THIS SECTION
Page Page
Clutch Operating Controls ............................................. .... 7-1 Four Speed Transmission (M u n c ie )................................. 7-20
Diaphragm Spring C lu t c h ................................................ .... 7-8 Four Speed Transmission (New Process 43 5).................. 7-23
Coil Spring Clutch (Single P l a t e ) .................................... .... 7-10 Five Speed Transmission (New P r o c e s s ) ........................ 7-30
Two Plate Coil Spring C lu tc h .................. ....................... .... 7-10 Five Speed Transmission (Spicer 3000 S e r i e s ) ............... 7-32
Lipe - Roll way C lutch...................................................... .... 7-12 Auxiliary Four Speed Transm ission................................. 7-35
Three Speed Transmission (M u n c ie ).............................. .... 7-13 Aluminum Power g l i d e ...................................................... 7-38
O v e r d r iv e .................. .......................................................... 7-15 Turbo Hydra-Matic ......................................................... 7-45
Special T o o ls ..................................................................... 7-51

CLUTCH OPERATING CONTROLS

INDEX
Page Page
General Description......................................................... 7-1 Clutch Pedal Free Travel Adjustment . . . . . . . 7-3
Maintenance and Adjustments.......................................... 7-2 Clutch Pedal (Except Tilt and Step V a n ) ............ . . . 7-3
Clutch Free Pedal Travel Adjustment (Mechanical) . . 7-2 Step Van Clutch P e d a l ......................................... . . . 7-4
Insufficient Clutch R e le a s e .................................... 7-2 Tilt Cab Clutch Pedal L in k a g e ........................... . . . 7-5
Clutch Pedal Height Adjustment (Step V a n )............ 7-2 Slave Cylinder...................................................... . . . 7-5
Clutch Pedal Adjustment (H y d r a u lic )........................ 7-3 Clutch Cross S h a f t ............................................. . . . 7-6
Clutch Pedal Total T r a v e l .................................... 7-3

GENERAL DESCRIPTION
down through a seal boot on the toe pan, to the cross­
shaft lever. When the clutch pedal is depressed, the
pedal pull or push rod moves upward rotating the cross­
shaft, pushing the fork push rod rearward, and pivoting
the clutch fork to move the throwout bearing against the
clutch release fingers and releasing the clutch.
The Step Van uses mechanical linkage activated by a
floor pedal mounted through a pivot shaft on a frame
bracket (fig. 2). A short pull rod connects the pedal to
the cross-shaft to activate the clutch as before.
The hydraulic controls consist of pedal, pedal push rod,
main cylinder, tubing, slave cylinder, fork push rod,
clutch fork and throwout bearing.
When the clutch pedal is depressed, brake fluid is
forced from the main cylinder into the slave cylinder
(fig. 3) moving the push rod against the clutch fork to re­
lease the clutch as before. When the pedal is released,
the clutch fork return spring forces fluid from the slave
cylinder back to the master cylinder.
A fitting is provided on the slave cylinder for bleeding
air from the system as is done with hydralic brakes.
The fluid level should be maintained approximately 1/2"
below the top of master cylinder reservoir.
On 366 cu. in. and Diesel vehicles the clutch release
bearing is moved by a yoke attached to a shaft through the
transmission half of the clutch housing (fig. 4). The hy­
Fig . 1 - C lutch Linkage (except Step-Van) draulic slave cylinder pushes a lever attached at the end
of the throwout yoke shaft, rotating the shaft and yoke and
The operating controls for 1967 trucks are either me­ moving the throwout bearing against release fingers of
chanical or hydraulic. The mechanical linkage (used on clutch assembly.
6 cylinder and V- 8 engine equipped vehicles except "L " On vehicles equipped with a yoke and shaft type release
and "T " Models) consists of pendant type pedal, return lever, the grease cup (attached by hose to release bear­
spring, pedal push rod, cross-shaft, fork push rod, clutch ing) is filled with a graphite type grease and should be
fork and throwout bearing (fig. 1). The pedal push rod is turned one-turn each 1 , 0 0 0 miles and refilled each 6 , 0 0 0
routed vertically, inside the cab, from the pedal lever miles.

CHEVROLET TRUCK SERVICE M ANUAL

CLUTCHES AND TRANSMISSIONS 7-2

B BLEED
FITTING
CLUTCH SLAVE
FORK CYLINDER
FULCRUM ADJUSTING
NUT

Fig. 3 - Slav e C ylin d er and C lutch Fork

VIEW A

Fig. 2 - C lutch Linkage (Step-Van)

Fig. 4 - Diesel Clutch - Typical

MAINTENANCE AND ADJUSTMENTS

CLUTCH FREE PEDAL TRAVEL ADJUSTMENT proper clearance). Readjust if necessary.

(Mechanical Linkage) INSUFFICIENT CLUTCH RELEASE

Only one simple adjustment is necessary to maintain Where complaints of first or reverse gear clash due to
clutch efficiency and assure long life. This adjustment is insufficient clutch release are encountered, the following
for the amount of free clutch pedal travel before the may be helpful. Cut off the existing clutch pedal stop
throwout bearing contacts the clutch fingers (fig. 2). As bumper to a height of 3/8". Since shortening the bumper
clutch facings wear, the amount of free pedal travel is increases the lash and not the usable stroke, the lash
reduced and in time this will result in clutch slippage. must be reduced to specifications in order to gain the
Therefore, it is necessary to adjust pedal at periodic additional stroke benefit.
intervals to provide sufficient free pedal travel (3 /4"-1")
to permit full engagement of the clutch. CLUTCH PEDAL HEIGHT ADJUSTMENT
1. Disconnect clutch fork return spring at fork.
2. Loosen nut "A" (fig. 5) and back off from swivel ap­ (Step Van)
proximately 1 / 2 inch.
3. Hold clutch fork push rod against fork to move An adustable pedal stop (on the clutch pedal arm be­
throwout bearing against clutch fingers (push rod will neath floor level) is provided to adjust clutch pedal to the
slide through swivel at cross-shaft). same height as the brake pedal.
4. Adjust nut "B " to obtain approximately 3/16" to 1/4"
NOTE: Pedal free travel adjustment MUST be
clearance between nut "B " and swivel.
made after this adjustment is made.
5. Release push rod, connect return spring and tighten
nut "A" to lock swivel against nut "B ". 1. Loosen lock nut.
6 . Check free pedal clearance at pedal (3/4" to 1" is 2. Turn adjustment bolt until clutch pedal is equal

CHEVROLET TRUCK SERVICE MANUAL

 CLUTCHES AND TRANSMISSIONS 7-3

push rod, and the master cylinder piston. This will

—
amount to 1 / 8 " free pedal travel measured at the center
CROSS SHAFT LEVER line of the pedal pad, just before the clutch push rod
touches the m aster cylinder piston (fig. 7).
NOTE: This will insure the master cylinder
piston moving sufficiently to uncover the port in
the master cylinder reservoir.
CLUTCH PEDAL-ALL EXCEPT TILT CAB AND
STEP VAN (Refer to Figure 1)
Removal
1. Pull parking brake lever to applied position.
2. Remove bolt at cluch pedal push rod lever (1), then
remove lever from pedal shaft (5).
3. Hold pedal pad with one hand and slide pedal and
shaft assembly outboard enough to clear pedal stop,
then allow return spring (or overcenter spring) to
pull pedal up high enough to unhook spring from pedal
arm.

Fig. 5 - Free Travel Adjustment

height to brake pedal.

3. Tighten lock nut.
4. Adjust pedal free travel.

CLUTCH PEDAL ADJUSTMENT (Hydraulic)

Two adjustments can be made; pedal total travel

(bumper adjustment) and pedal free travel.
Fig. 6 - Adjusting Slave C ylin d er Push Rod
NOTE: The m aster cylinder must be filled to
1/2” below the top of reservoir. The system
must be free of air.
Clutch Pedal Total Travel

Disconnect the clutch fork return spring.

Bottom slave cylinder push rod and piston by pushing
the slave cylinder push rod to the front of vehicle as
far as it will go (fig. 6 ).
3. Pull clutch fork toward rear of vehicle until the
throwout bearing touches the pressure plate release
levers.
4. Adjust clearance between the slave cylinder push rod
fulcrum ("V" block) by adjusting nut behind it to
proper clearance between fulcrum pivot and clutch
fork (fig. 6 ).

DIMENSION MODEL USAGE

5/32” CLMT-80 with Fuller transmission

7/32” E & U-80 only
3/16" All Hydraulic except above.
NOTE: This clearance can be checked with the
shank of appropriate diameter drill.
Clutch Pedal Free Travel Adjustment
Adjust clutch m aster cylinder adjustable push rod to
obtain free travel between the clutch m aster cylinder F ig . 7 - C lutch Pedal Free Travel

CHEVROLET TRUCK SERVICE M ANUAL

CLUTCHES AND TRANSMISSIONS 7-4

from bracket and brake pedal.

6. Inspect pin and clutch and brake pedal bushings for
wear and other damage.
7. If necessary to replace pedal bushings, use a cape
chisel to remove the bushing, then deburr. Install
new bushing using a vise as a press (align grease
fitting hole on brake pedal bushing).

Fig. 9 - Removing Pedal Pivot Pin

Fig. 8 - C lutch Pedal Assembly
Installation
4. Remove pedal and shaft assembly from support 1. Install remover Tool J-8118 in grease fitting hole of
bracket. pivot pin, then align pin groove with lock pin hole and
drive pin through bracket boss and brake pedal using
Inspection slide hammer or plastic hammer.
1. Check clutch pedal bushings for excessive wear and
replace if necessary.
2. Check clutch pedal shaft for wear and alignment and
straighten or replace if necessary.

Installation
NOTE: Use new shaft bushing if needed and
lubricate with Lubriplate or petrolatum.
1. Slide one pedal shaft bushing over shaft, install shaft
in support enough to still clear pedal bumper stop,
hook pedal return (or overcenter) spring to pedal,
then rotate pedal forward of bumper stop; slide shaft
into position in support and release pedal against
bumper stop.
2. Install clutch pedal shaft bushing over pedal shaft end
and into place in sleeve.
3. Assemble pedal push rod lever over pedal shaft and
install bolts, washers, and nut. Torque to 25 ft. lbs.
4. Adjust clutch pedal free travel as needed.

STEP VAN CLUTCH PEDAL

(Refer to Figure 9)

Removal
1. Remove upper-to-lower clutch pedal arm nut and
remove upper arm from lower arm.
2. Disconnect clutch return spring and pedal-to-cross­
shaft pull rod.
3. Remove snap ring (retaining pedal on pivot pin) and
remove pedal from pivot pin, then remove brake
pedal return spring.
4. To remove pivot shaft remove nut, washer and drive
pin from boss on bracket using a small brass driver.
5. Remove grease fitting from pivot pin, install Tool
J-8118 and use a slide hammer to remove the pin Fig . 10 - T ilt Cab Clutch Pedal Linkage

CHEVROLET TRUCK SERVICE M ANUAL

 CLUTCHES AND TRANSMISSIONS 7-5

2. Install tapered lock pin (from lower side), lock 2. Disconnect slave cylinder hydraulic line, at slave
washer and nut. cylinder.
3. Install clutch pedal over pivot pin, then flat washer 3. Remove retaining bolts from slave cylinder and re­
and lock ring. move slave cylinder.
4. Connect pedal pull rod at pedal and at cross-shaft.
5. Install upper pedal arm into lower arm and install Disassembly
washer and nut. Refer to Figure 11.
6 . Adjust pedal height and free travel as previously 1. Remove slave cylinder push rod, push rod boot, and
outlined. fulcrum as a unit.
2. Remove snap ring from slave cylinder, using a small
TILT CAB CLUTCH PEDAL LINKAGE (Fig. 10) screwdriver blade, as shown in Figure 12, be careful
not to scratch the slave cylinder bore.
Removal 3. Remove piston and rubber seal assembly from slave
1. Tilt cab forward and block in place. cylinder bore.
2. Remove upper to lower clutch pedal arm bolt and 4. Wash all parts in clean alcohol.
slide upper arm through floor boards.
3. Disconnect clutch pedal return spring and over­ NOTE: Since the clutch hydraulic system on
center assist spring. vehicles equipped with a dual master cylinder,
4. Remove clutch push rod lever locking bolt and nut use the same hydraulic fluid and reservoir as
and remove lever from clutch pedal pivot shaft. Re­ the brake system, it is essential that the system
move push rod and lever from dust boot.
5. Slide clutch pedal lower arm out of mounting bracket
sleeve.
6 . If necessary, remove sleeve by first removing
grease fitting and 2 retaining screws and slide sleeve
from mounting bracket.

Fig. 11 - C lutch Slave C ylin d er Fig. 12 - Removing Slave C ylin d er Snap Ring

1. Bleeder V a lv e 5. Push Rod

2. Fluid Entry Port 6. Piston Retaining Ring be clean. Before washing parts, hands must be
3. C ylin d er Body 7. Piston
clean and free of all oil. Do not wash hands in
4. Push Rod Boot 8. Piston Seals
gasoline or oil before cleaning parts. Use soap
and water to clean hands.
Inspection
1. Check clutch pedal shaft and sleeve for excessive Inspection
wear. 1. Inspect slave cylinder bore, making sure that it is
2. Check clutch pedal shaft for alignment and, if bent, smooth. A scored or damaged cylinder must be
straighten or replace. replaced.
2. Check rubber cup for damage or swelling due to im­
Installation
proper brake fluid. Replace cup if necessary.
1. Reverse removal procedure to install (upper and
3. Check fit of the piston in the cylinder bore, using a
lower pedal arms are serrated for alignment during
feeler gauge. This clearance should be from .002"
assembly).
to .004”.
2. Adjust pedal free travel as outlined under Mainte­
nance and Adjustments.
Assembly
1. Install seals (new, preferably) on piston with lip edge
SLAVE CYLINDER of seals to solid end of piston.
Removal 2. Lubricate piston and seal assembly with brake fluid
1. Remove return spring from clutch fork. then install in cylinder as shown in Figure 11.

CHEVROLET TRUCK SERVICE M ANUAL

CLUTCHES AND TRANSMISSIONS 7-6

Fig. 14 - Installation of Slave C ylin d er Boot

F ig . 13 - Installing Snap Ring in G ro o ve

CLUTCH CROSS-SHAFT (Fig. 15)
3. Install snap ring (piston retainer) as shown in Fig­
ure 13. Removal
4. Install boot over push rod (fig. 14) and install push 1. Disconnect clutch fork return spring at fork.
rod and boot to slave cylinder. 2. Disconnect pedal push rod at cross-shaft lever and
allow clutch fork push rod to hang free from lower
Installation lever.
1. Bolt slave cylinder assembly to engine clutch housing 3. Loosen ball stud nut and slide stud out of bracket
(fig. 3). slot, then lift cross-shaft off engine ball stud and out
2. Adjust slave cylinder push rod clearance, as outlined of vehicle.
in this section, under "Clutch Pedal Total Travel." 4. Remove clutch fork push rod from cross-shaft lever
3. Attach hydraulic line to slave cylinder and bleed air if necessary.
from system at slave cylinder bleed fitting. 5. Reverse removal procedure to install.

CHEVROLET TRUCK SERVICE M ANUAL

 CLUTCHES AND TRANSMISSIONS 7-7
)
) CHEVROLET TRUCK SERVICE MANUAL
CLUTCHES AND TRANSMISSIONS 7-8

DIAPHRAGM SPRING CLUTCH

INDEX
Page Page
General Description.............................. .. 7-8 Service Operations............ i 7~9
Maintenance and Adjustments.................. 7-8 Clutch Assembly . . . . 7-9
Preliminary In s p e c tio n ..................... 7-8 Removal from Vehicle 7-9
Clutch Retracting Spring Replacement 7-8 Installation to Vehicle 7-9
Diaphragm Clutch Adjustment ................................. 7-E

GENERAL DESCRIPTION
The clutch, used on 230 and 250 cubic inch 6 - Cylinder
engine trucks, is a single plate dry disc type consisting of
two basic assem blies, the driven disc and facing assem­
bly and the cover, pressure plate and diaphragm and dia­
phragm spring assembly.

MAINTENANCE AND ADJUSTMENTS

PRELIMINARY INSPECTION

There are many things which affect good clutch opera­

tion. Therefore, it is necessary, before performing any
m ajor clutch operations, to make a preliminary inspec­
tion to determine whether or not the trouble is actually in
the clutch.
1. Check the clutch pedal and make sure that the pedal
has at least 1/8" free travel (Hydraulic Clutch Con­
trols), or 3 /4 "-1 " (Mechanical Linkage).
2. Check the clutch pedal bushing for wear and for
sticking on the shaft or loose mountings.
3. Lubricate the pedal linkage.
4. Tighten all front and rear engine mounting bolts.
Should the mountings be oil soaked, it will be neces­ Fig. 17 - Gauging Shim Requirement
sary to replace them.
checked by replacing the springs, as follows:
CLUTCH RETRACTING SPRING REPLACEMENT 1. Remove the clutch housing underpan.
2. Hand crank the engine until one retracting spring at­
A rattle in the clutch assembly at idling speeds with the taching bolt is at the bottom. Remove the bolt and
clutch released or failure of the clutch to release prop­ retracting spring and install a new spring.
erly may be caused by insufficient tention on the pressure 3. Replace the other retracting springs in the same
plate retracting springs. These troubles can easily be manner.
4. Replace clutch housing underpan.

DIAPHRAGM CLUTCH ADJUSTMENT

If clutch fails to release:
1. Check pedal for proper travel and linkage for loose­
ness, adjustments, etc.
2. Check clutch retracting springs for proper retention
of pressure plate to diaphragm spring, replace if
necessary. This can be done without removing clutch
from vehicle.
3. If Steps 1 and 2 do not cure trouble, check pressure
plate lift with dial indicator (fig. 16) as follows:
a. With proper linkage adjustment (and lash), zero
indicator with clutch fully engaged (pedal up).
b. Measure pressure plate lift at 3 strap bolt posi­
tions with full pedal travel.
NOTE: Use 5/8" thick board in place of floor
mat to give a positive stop.
All three readings should be within .010" and
Fig . 16 - Checking Pressure Plate Lift with D ial Indicator within total lift readings. If more than .010"

CHEVROLET TRUCK SERVICE MANUAL

 CLUTCHES AND TRANSMISSIONS 7-9

check retracting springs per step 2. If trouble fore checking.

still exists, loosen clutch-to-flywheel mounting NOTE: Excessively high readings indicate that
bolt at position of lowest reading (leave other the diaphragm spring is being over stressed
bolts tight), pry cover, away from flywheel, and which may eventually cause loss of load and
insert feeler gauge (fig. 17) to determine thick­ result in slippage.
ness of shim required to bring reading within If above measures fail to correct the trouble, check
. 010 ”. driven disc with clutch pedal depressed (it should spin
freely with transmission in neutral). If it does not,
NOTE: Use main bearing shim Part No.
trouble may be:
3703650, between the clutch cover and flywheel
1. Misalignment between pilot bushing in crankshaft and
at attaching bolt locations, trim if necessary.
clutch housing—see clutch housing alignment Sec­
Total lift readings should be as follows: tion 8 .
L - 4 and L - 6 230 .065 to .075 2. Faulty clutch pilot bushing.
HD 11” .065 to .085 3. Faulty driven disc.
Make sure proper pedal lash adjustment is made be­ 4. Improper slave cylinder adjustment.

SERVICE OPERATIONS
CLUTCH ASSEMBLY CAUTION: Be careful not to use too much lu-
bricant.
Removal From Vehicle
1. Remove transmission as outlined in "Transmission Replace clutch fork ball if removed in the clutch
Section." housing and snap clutch fork onto the ball.
2. Disconnect slave cylinder from clutch fork. 10 . Lubricate the recess on the inside of the throwout
3. Remove clutch throwout bearing from the fork. bearing collar and coat the throwout fork groove with
4. Remove clutch fork by pressing it away from its ball a small amount of graphite grease (fig. 18).
mounting with a screwdriver, until the fork snaps 11. Install throwout bearing assembly to the throwout
loose from the ball or remove ball stud from rear of fork.
clutch housing. 12 . Assemble transmission as outlined in Transmission
Section, and install flywheel underpan.
NOTE: The retainer may be removed from the
13. Align push rod to clutch fork and attach return spring
fork by prying out with a small screwdriver.
to clutch fork.
5. Install Tool J-5824 to support the clutch assembly 14. Adjust clutch linkage (See Adjustments in this sec­
during removal. tion).
6 . Loosen the clutch attaching bolts one turn at a time
to prevent distortion of clutch cover until dia­
phragm spring is released.
7. Remove clutch pilot tool and remove clutch assembly
from vehicle.

Installation to Vehicle
1. Install the pressure plate in the cover assembly lin­
ing up the notch mark on pressure plate with notch
mark on flange of cover.
2. Install pressure plate retracting springs and drive
strap to pressure plate bolts and lockwashers and
tighten to 11 ft. lbs. torque. The clutch is now ready
to be installed.
3. Hand crank the engine until "X " mark on flywheel is
at the bottom.
4. Install clutch disc, pressure plate and cover assem­
bly and support them with Tool J-5824.
5. Turn clutch assembly until "X " mark on clutch cover
flange lines up with "X " mark on flywheel.
6 . Install attaching bolts and tighten each one a turn at a
time to prevent distorting the cover as the spring
pressure is taken up.
7. Remove clutch pilot Tool J-5824.
8 . Pack clutch fork ball seat with a small amount of
high melting point grease and install a new retainer
in the groove of the clutch fork if the old retainer is
worn or damaged.

NOTE: Install retainer with high side up, away PACK THIS RECESS
from bottom of the ball socket and with open end
of retainer on the horizontal. Fig . 18 - Lubrication Points on Clutch Throwout Bearing C o lla r

CHEVRO LET TRUCK SERVICE M ANUAL

CLUTCHES AND TRANSMISSIONS 7-10

COIL SPRING CLUTCH

IN DEX
Page
General D e s c r ip t io n ......................................................... 7-10
Service O p eratio n s............................................................ 7-10
Removal from Vehicle ................................................ 7-10
Installation to V e h ic le ................................................... 7-10

GENERAL DESCRIPTION

The clutch used on all 292, 283 and 327 cubic inch and
Diesel truck engines is a coil spring single plate dry disc
type, no adjustment for wear being provided in the clutch
itself. An individual adjustment is provided for locating
each lever in manufacturing but the adjusting nut is
locked in place and should never be disturbed, unless the
clutch is dismantled for replacement of parts.
When the clutch pedal is depressed the release bearing
is moved toward the flywheel and contacts the inner ends
of the release levers, (1) (fig. 19). Each release lever is
pivoted on a floating pin which remains stationary in the
lever and rolls across a short flat portion of the enlarged
hole in the eyebolt (2). The outer end of each release
lever engages the pressure plate lug by means of a strut
(3), which provides knife-edge contact between the outer Fig. 19- Release Lever
end of the lever and the lug. The outer ends of the eye-
bolts extend through holes in the stamped cover (4), and 1. Release Lever 4. C over
are fitted with adjusting nuts (5) to correctly position the 2. Eyebolt 5. Adjusting Nut
levers. 3. Strut

SERVICE OPERATIONS
CLUTCH ASSEMBLY down as the holding screws are removed or when
clutch is removed from engine.
Removal From Vehicle
Installation to Vehicle
Before removing clutch from flywheel, mark with a
punch the flywheel, clutch cover and one pressure plate 1. Assemble driven plate and clutch cover assembly to
lug, so that these parts may be assembled in their same flywheel in accordance with marking on driven plate
relative positions, as they were balanced as an assembly. for flywheel side.
Loosen the holding screws a turn or two at a time to 2. Line up the driven plate assembly and the pilot bear­
avoid bending rim of cover. When removing driven plate ing with a dummy shaft before tightening cover hold­
be sure to mark flywheel side. ing screws. Tighten holding screws before removing
dummy shaft.
NOTE: It is advantageous to place wood or 3. After transmission has been assembled, adjust pedal
metal spacers (approximately 3/8 thick) between as described under "Clutch Pedal Adjustments,"
the clutch levers and the cover to hold the levers "Hydraulic Clutch Controls."

TWO PLATE COIL SPRING CLUTCH

Page
General D e s c r ip t io n ......................................................... 7-11
Service O p eratio n s............................................................ 7-11
Removal from V eh icle................................................... 7-11
Installation in Vehicle & Lever Adjustment ............... 7-11

CHEVROLET TRUCK SERVICE M ANUAL

 CLUTCHES AND TRANSMISSIONS 7-11

GENERAL DESCRIPTION
The 366 cu. in. engine for 1967 is equipped with a 2 The cover is bolted to the engine flywheel. Coil type
plate, dry disc type clutch consisting of three basic as­ pressure springs, located between the cover and rear
sem blies: The cover and rear pressure plate assembly, pressure plate, provide positive engagement between the
front pressure plate assembly and dual driven disc as­ cover, the pressure plates, driven disc assemblies and
sembly. The dual driven disc assemblies are splined to flywheel.
the transmission main drive gear (clutch gear) shaft. The No adjustment for wear is provided in the clutch itself.
front pressure plate, located between the driven discs, An individual adjustment is provided for locating each
has 2 friction surfaces and is coupled to both the rear lever. In manufacturing this lever adjusting nut is locked
pressure plate and cover through pairs of steel drive in place and should never be disturbed unless the clutch
straps bolted at each of its 4 driving bosses. is disassembled for overhaul.

SERVICE OPERATIONS
Removal From Vehicle
1. Refer to applicable procedure in Transmission Sec­
tion 7, and remove transmission. Release bearing
and actuating mechanism are assembled in housing at
front of transmission and may be inspected without
disassembly.
Look for "X ” mark stamped on pressure plates,
cover and flywheel. If ”X" is not stamped on all 4
pieces, punch mark them (with prick punch) in a line
at one location for alignment purposes during
installation.
Install aligning tool ( J - 21169) or an old transmission
main drive gear, through hubs of driven discs into
pilot bearing, and place a wood or metal spacer (ap­
proximately 1" x 1" x 3 /8" thick) between each re­
lease lever and clutch cover (fig. 41) to facilitate
removal and installation.
Rotate the flywheel (if necessary) to locate one cover
mounting bolt at top, then loosen all 4 cover mounting
bolts alternately and evenly until pressure is re­
leased from discs.
Remove top bolt and install alignment stud (part of
Tool J-21169) in its place. Fig. 21 - C lutch Release Finger Adjustment
Remove 3 remaining bolts (allowing clutch assembly
to hang from stud), then slide clutch assembly from
stud to remove from vehicle.
Installation to Vehicle
1. Place alignment tool (stud section) in upper clutch
mounting bolt hole.
2. Install alignment tool (arbor section) through rear
driven plate splines and install front driven plate
over tool with hub section of plate toward flywheel.
3. Lift complete clutch assembly (with one hole held to
top) and slide upper bolt hole over alignment stud in
flywheel, then work clutch discs as needed to slide
arbor pilot into pilot bearing.
4. Install three bolts loosely, then remove alignment
stud and install last bolt loosely.
5. Thread alignment stud in arbor (to act as arbor
handle), make sure discs are in good alignment, then
tighten the cover attaching bolts a turn or two at a
time in rotation to prevent distortion.
6 . Adjust clutch fingers (if cover was disassembled) by
placing a straight-edge over the alignment arbor end
and fingers, and adjust fingers level as shown in
Figure 21.
7. After adjustment is completed, stake the adjusting
nuts to eye bolts to lock the adjustment, then remove
arbor and install transmission as outlined in Sec­
tion 7.
Fig . 20 - C lutch Removal or Installation 8 . Adjust clutch pedal linkage as previously outlined.

CHEVROLET TRUCK SERVICE M ANUAL

CLUTCHES AND TRANSMISSIONS 7-12

LIPE-ROLLWAY CLUTCH
( 1 2 , 1 3 , AND 14-INCH)
GENERAL DESCRIPTION
The clutch consists of two basic assemblies - the driven bearing. The pilot bearing, pressed into engine flywheel,
disc and facing assembly, and the clutch cover and pres­ carries the forward end of the transmission main drive
sure plate assembly as shown. The dirven disc is splined gear. This bearing requires lubrication only at time of
to the transmission main drive gear. The cover assem­ clutch overhaul.
bly is bolted to the engine flywheel. The pressure plate The release fork engages a groove in the release bear­
is driven by the cover through driving lugs which engage ing collar for actuating the release levers. Clutch is
slots in the cover. Coil type pressure springs between disengaged by a foot pedal, hydraulically connected to the
the cover and pressure plate force the pressure plate release fork or lever.
against the driven member when clutch is engaged.
Clutch release bearing and support assembly slide on CLUTCH REPLACEMENT
the transmission main drive gear bearing cap. The re­
lease bearing is a permanently packed ball bearing and Instructions covering removal and installation of the
requires no additional lubrication during the life of the clutch are explained under the previous clutch section.

SPECIAL TOOLS

b3A3~1 " ,l
0

O
_LEV £* o

13" "

Fig. 22 - C lutch Special Tools

1. J-6456 Height G auge 7. J-9225 Ball Type Pilot Bearing Installer

2. J-1048 G auge Plate 8. J-21169 Pilot Arbor & Alignment Stud
3. J —1522 Pilot Bearing Driver (2 Plate Clutch)
4. J-5824 C lutch Pilot Tool 9. J-7126 Release Lever Adjusting Tool
5. J - 1448 Pilo t Bearing Puller 10. J —7816 Release Lever Adjusting Tool
6. J-5822 Ball Type Pilo t Bearing Remover

CHEVROLET TRUCK SERVICE M ANUAL

 CLUTCHES AND TRANSMISSIONS 7-13

THREE-SPEED TRANSMISSION (MUNCIE)

IN D EX
Page Page
General Description......................................................... 7-13 Transmission Side Cover .......................................... 7-14
Maintenance and Adjustments.......................................... 7-13 Service Operations............................................................ 7-15
Transmission Linkage A d ju s tm e n t........................... 7-13 Removal from V e h i c l e ................................................ 7-15
Speedometer Driven G e a r .......................................... 7-13 Installation in Vehicle................................................... 7-15
Mainshaft Oil S e a l .......................................... .. 7-13

GENERAL DESCRIPTION
Two three-speed synchromesh transmissions are used
as standard equipment on 10-20 Series (1/2 and 3/4
ton) trucks. The Muncie transmission incorporates all
helical gears which are machined from drop forged steel
gear blanks, heat treated and shot peened for strength and
long life. The shafts are machined from high grade steel,
heat treated and ground to close limits.
The rear end of the clutch gear is supported by a heavy
duty ball bearing at the front end of the transmission case
and is piloted at its front end in an oil impregnated bush­
ing mounted in the engine crankshaft. The front end of
the mainshaft is piloted in a double row of roller bearings
set into the hollow end of the clutch gear and the rear end
is carried by a ball bearing.
The countergear is carried on roller bearings at both
ends while thrust is taken on thrust washers located be­
tween ends of gear and front and rear of the case.
The reverse idler gear is carried on ball-indented
bronze bushings while thrust is taken on thrust washers
located between ends of gear and front and rear of the
case.
The Sagninaw three speed fully synchonized transmis­
sion is the same as used in passenger vehicles. Refer to
Fig. 1G - Steering Column G earshift
the Passenger Chassis Service Manual for service
procedures. tion. The shifter gate for selection between first and
Gearshifting is manual through steering column gear­ reverse and second and high is contained in the shifter
shift mechanism to the transmission cover located on the housing mounted on the lower portion of the steering col­
side of the transmission. Shifting is accomplished by umn mast jacket. Two shifter control rods connect the
two rotating cranks which directly engage the gears to be shifter levers on the transmission to the outer shifter
shifted, thus affording a highly efficient mechanical ac- levers on this housing.

MAINTENANCE AND ADJUSTMENTS

TRANSMISSION LINKAGE ADJUSTMENT (Fig. 1G) justment to the steering mainshaft should be
checked as outlined in the procedure in Section
In cases where gearshift linkage has been disconnected 9 of this manual.
or removed, proper adjustment sequence is important. SPEEDOMETER DRIVEN GEAR
1 . Install control rods to both second and third shifter
lever and first and reverse shifter lever. Set both Disconnect speedometer cable, remove lock plate to
shifter levers in neutral position. housing bolt and lock washer and remove lock plate. In­
2. Align both shifter tube levers on mast jacket in the sert screwdriver in lock plate slot in fitting and pry fit­
neutral position. Position relay lever so that gear­ ting, gear and shaft from housing. Pry "O" ring from
shift control lever is in neutral position. groove in fitting.
3. Connect control rods to tube levers making sure Install new "O” ring in groove in fitting, coat "O" ring
clamps are properly adjusted so that tube levers and and driven gear shaft with transmission lubricant and in­
transmission shifter levers remain in their neutral sert shaft.
positions while tightening. On Chevy Van Models, a Hold the assembly so slot in fitting is toward lock plate
small pin or nail may be used in the holes of the boss on housing and install in housing. Push fitting into
shift flange and shifter levers to obtain neutral align­ housing until lock plate can be inserted in groove and
ment of the shift levers.- attached to housing.
4. Move selector lever through all positions to check
adjustment and insure over-travel in all positions. MAINSHAFT OIL SEAL

NOTE: If mast jacket lower dash clamp has Replacement

been disturbed at its mounting on dash, its ad- 1. Remove nuts and U-bolts retaining rear universal

CHEVROLET TRUCK SERVICE M ANUAL

CLUTCHES AND TRANSMISSIONS 7-14

joint trunnion bearings to the drive flange. Lower Fig. 4 G - Transmission Controls (PA20 M odels)
the rear of the propeller shaft and slide front flange
off the mainshaft. it is necessary to remove cover from transmission case.
2. Using a punch against seal, drive oil seal out of ex­ 1. Drain transmission and disconnect control rods from
tension or use Tool J-5859 as shown in Figure 5. levers.
3. Coat new seal with Permatex or equivalent and start 2. Remove cover assembly.
seal straight in bore in extension. Using Tool 3. Remove outer shifter lever retaining bolts and pull
J-5154, tap seal into counterbore. levers from shafts.
4. Remove nuts and locks and remove shifter interlock
TRANSMISSION SIDE COVER ASSEMBLY retainer. This will allow removal of shifter shaft and
fork assembly, poppets and springs or interlock from
On any replacement of parts in the side cover assembly cover.
5. Replace necessary parts. Coat shifter shaft and "O"
ring seal with transmission lubricant before install­
ing in cover and bend tab on locks after installing
interlock retainer nuts.
6 . Install outer shifter levers on shafts and install re­
tainer bolts.
7. With transmission gears in neutral and shifter forks
in neutral, install cover to transmission using a new
gasket. Coat cover screws with Permatex No. 2 or
equivalent and tighten to 15-18 ft. lbs. torque.
NOTE: Hump on first and reverse shifter fork
(fig. 6 ) must be toward rear of transmission.
8. Attach control rods to shifter levers.
9. Fill transmission with lubricant.

Fig. 3 G - Transmission Controls (PS20 Models) F ig . 5 G - Removing Mainshaft O il Seal

CHEVROLET TRUCK SERVICE M ANUAL

 CLUTCHES AND TRANSMISSIONS 7-15

SERVICE OPERATIONS
REMOVAL FROM VEHICLE INSTALLATION IN VEHICLE

1. Install guide pins, Tool J-1126, in upper transmis­

1. Drain lubricant from transmission. sion to clutch housing bolt holes for alignment and
2. Disconnect the speedometer cable from speedometer place transmission on guide pin. Start clutch gear
driven gear fitting and disconnect shift control rods shaft into clutch disc and slide transmission forward.
from the shifter levers at the transmission. 2. Install the two lower transmission mounting bolts and
3. Remove the propeller shaft as outlined in Section 4. lock washers and tighten securely. Remove guide pin
4. Remove the 2 top transmission to clutch housing cap and install upper mounting bolts and lockwashers and
screws and insert 2 transmission guide pins, Tool tighten securely.
J-1126 in these holes. 3. Install propeller shaft. Align yokes and install
5. Remove the 2 lower transmission to clutch housing U-bolts and nuts which retain rear trunnion bearings
cap screws. to pinion flange and tighten securely.
6 . Slide the transmission straight back on guide pins 4. Connect first and reverse and second and third con­
until the clutch gear is free of splines in the clutch trol rods to shifter levers at side cover.
disc. 5. Check and adjust linkage as necessary as outlined
under "Maintenance and Adjustments".
NOTE: The use of the 2 guide pins during this 6 . Remove speedometer driven gear and add 1/2 pint
operation will support the transmission and pre­ transmission lubricant to housing. Reinstall speed­
vent damage to the clutch disc through springing. ometer driven gear.
7. Connect speedometer cable to driven gear and tighten
7. Remove transmission from under the body. securely.
8 . F ill transmission with lubricant (1 1/2 pts.).

TRANSMISSION OVERDRIVE
IN D EX
Page Page
General Description......................................................... 7-15 Closing V o ltage................................................... 7-16
Maintenance and Adjustments.......................................... 7-16 S o le n o id .................................................................. 7-17
Governor Switch and P i n io n ....................................... 7-16 Closing Coil ...................................................... 7-17
Sun Gear Solenoid, Oil Seal & Control Cable Bracket . 7-16 Engaging Spring ................................................ 7-17
Case Rear Oil S e a l...................................................... 7-16 Ignition Grounding Contact................................. 7-17
Control Shaft Lever and/or "O " Ring Oil Seals . . . . 7-16 Governor S w itch ...................................................... 7-17
Speedometer Driven G e a r .......................................... 7-16 Kickdown Sw itch ...................................................... 7-17
Electrical Unit C hecks................................................ 7-16 Linkage A djustm ent................................................ 7-17
Overdrive Relay ................................................... 7-16 Diagnosis - O v e rd riv e ...................................................... 7-18
A ir G ap ............................................................... 7-16 M e c h a n ic a l.................................................................. 7-18
Point O p e n in g ................................................... 7-16 E le c tric a l............................................................ ... . . 7-19

GENERAL DESCRIPTION

The overdrive unit is essentially a two-speed planetary

transmission attached to the rear of a fully synchronized
three-speed transmission. In overdrive, engine speed is mission, service operations on the transmission proper
approximately 30 per cent slower at a given road speed are the same as for the passenger car three-speed
since the drive train includes planetary gears which pro­ transmission.
vide a lower overall gear ratio than that obtained in high Repairs to the overdrive housing, output shaft, ring
gear with the conventional transmission. gear assembly, clutch cam, roller retainer, pinion cage,
The electrical equipment which controls the automatic sun gear, shift rail, sun gear control plate, output shaft
action of the mechanical portion of the overdrive unit bearing, oil seal, speedometer drive gear, solenoid pawl
consists of a solenoid, a speed-sensitive governor switch, and interlock plunger may be performed underneath the
a relay and a kickdown switch. The circuit including this vehicle, if so desired, by removing the overdrive housing
equipment makes it possible to operate in overdrive without disturbing the transmission. Refer to Passenger
above a pre-set cut-in speed, or in conventional drive at Overhaul Manual for Service Procedure.
any speed. If the transmission mainshaft, overdrive adapter or
transmission rear bearing which is retained in adapter
SERVICING THE OVERDRIVE require replacement, the entire transmission and over­
drive assembly should be removed and overhauled on the
With the overdrive assembly removed from the trans­ bench.

CHEVROLET TRUCK SFP.VICE MANUAL

CLUTCHES AND TRANSMISSIONS 7-16

MAINTENANCE AND ADJUSTMENTS

Servicing of the overdrive governor switch and pinion, are as follows:
the sun gear solenoid, oil seal and cable bracket, the out­ Air Gap...................................................... Oil inch minimum
put shaft rear oil seal, the control shaft lever, and the Point Opening.............................................................. 025 inch
speedometer driven gear may be accomplished without Closing V o lta g e .......................................... 8.3-10.2 volts
removing the overdrive from the vehicle, as discussed in Armature Sealing
the following paragraphs: Voltage.......................................... 11.2 volts maximum

GOVERNOR SWITCH AND PINION Three checks and adjustments are required on the
overdrive relay; air gap, point opening and closing volt­
To remove governor switch, disconnect wires at gover­ age. The air gap contact point opening checks and ad­
nor switch and screw governor out of housing, using Tool justments should be made with the battery disconnected.
J-4653 on the flat hexagonal surface of governor case.
The pinion may be separated from the governor by re­ Air Gap
moving the snap ring on the shaft. The air gap should not normally require adjustment
unless the relay has been misadjusted. Check the air gap
SUN GEAR SOLENOID, OIL SEAL AND with the points barely touching and adjust if necessary by
CONTROL CABLE BRACKET bending the lower point support (fig. IB).
Remove the solenoid by taking out the two mounting
Point Opening
bolts and lock washers, removing the cable bracket with
Check the contact point opening and adjust by bending
the lower bolt. Turn the solenoid 1/4 turn and pull sole­
the upper armature stop (fig. 2B).
noid plunger out of adapter. The oil seal may be pried
out of the adapter.
Closing V o lta g e

CASE REAR OIL SEAL To check the relay closing voltage, connect a potentiom­
eter or variable resistance of sufficient value (not less
Removal than 50 ohms) in series with the "KD" terminal, connect a
1. Remove propeller shaft as outlined in Section 4. voltmeter to the "IGN" and "KD" terminals. With the ig­
2. Using a punch against seal in housing, pry out seal nition switch on, slowly decrease the amount of re sist­
from housing. ance in order to check the relay closing voltage (the
overdrive solenoid and relay should click when the relay
Installation
closes). Adjust the closing voltage by bending the arma­
1. Prelubricate between sealing lips and coat outside of
ture spring post (fig. 3B). Bend down to increase the
new oil seal with a suitable sealant, then start seal
closing voltage and bend up to decrease the closing
into bore in overdrive housing.
voltage.
2. Using Tool J-5154 drive oil seal into counterbore.
To check the sealing voltage, increase the voltage after
3. Install propeller shaft as outlined in Section 4.
the relay closes until the armature seals against the
core. Decrease the sealing voltage by reducing the relay
CONTROL SHAFT LEVER AND/OR “ O” RING
a ir gap.
OIL SEALS
To remove the control shaft, disconnect the control
cable, remove tapered pin and pull lever out. Replace
the two "O" ring seals on the control shaft. Insert shaft
and new "O” ring seals into housing and install tapered
pin. Connect control wire to lever.

SPEEDOMETER DRIVEN GEAR

Disconnect speedometer cable, remove lock plate to

housing bolt and lock washer and remove lock plate. In­
sert screwdriver in lock plate slot in fitting and pry fit­
ting, gear and shaft from housing. Pry "O" ring from
groove in guide.
Install new ”0 " ring in groove in fitting and insert
shaft.
Hold the assembly so slot in fitting is toward lock plate
boss on housing and install in housing. Push fitting into
housing until lock plate can be inserted in groove and
attached to housing. (CHECK WITH
^ POINTS BARELY
POINT SUPPORT
(BEND TO ADJUST AIR GAP)
ELECTRICAL UNIT CHECKS ^ TOUCHING)

1
Overdrive Relay h..... ... --.....—
■
■■
*
Specifications and checking procedures fo r this relay Fig . IB - Checking Relay A ir Gap

CHEVROLET TRUCK SERVICE M ANUAL

 CLUTCHES AND TRANSMISSIONS 7-17

A R M A TU R E S P R IN G POST
(BEND TO ADJUST CLOSING VOLTAGE)

Fig . 2B - Adjusting Relay Point Opening

Solenoid
Closing Coil
Remove solenoid from transmission, connect a jumper
wire between negative terminal of battery and mounting
flange of solenoid. Connect a second jumper wire be­ Fig. 3B - Adjusting Relay Closing Vo ltage
tween the battery positive terminal and solenoid terminal
No. 4; this should cause the solenoid pawl to move out.
If solenoid chatters, Hold-In Coil is defective. or switch case is grounded.

Engaging Spring LINKAGE ADJUSTMENT (Fig. 4B)

With jumper wire connected as in paragraph above,
(solenoid energized, plunger extended) place ball end of After throttle linkage has been adjusted, adjust kick-
solenoid against bench. Push down on solenoid. The down switch (A) so the actuating lever (B) at full throttle
pawl rod should move in 3 /8 ” under a load of not less position rests against end of threaded barrel on switch.
than 8 lbs. nor more than 12. Pawl should move out to
extended position when load is removed.

Ignition Grounding Contact

Place a test lamp between negative battery teminal

and solenoid terminal No. 6 . Lamp should light when
this connection is made. Remove jumper from between
negative battery terminal and solenoid terminal No. 4.
Pawl rod should snap "in” and test lamp should go out.

Governor Switch
Remove overdrive wire at governor and connect test
lamp between governor overdrive terminal and positive
terminal of battery. Drive car on road or raise on jacks.
The lamp should light at a car speed of between 26 to 30
MPH. Upon decreasing speed, the lamp should go out at
between 28 and 23.5 MPH. The car speed differential
between light "on" and light "off" should be 2 or 3 MPH.

Kickdown Switch
Disconnect the 4 wires at kickdown switch.
1. Connect test lamp between "SW" terminal and posi­
tive terminal of battery; with switch in normal posi­
tion, lamp should light when "R E L " terminal is
grounded but should not light when "IGN" or "SOL"
terminals or switch case is grounded.
2. Connect test lamp between "IGN" terminal and posi­
tive terminal of battery; with switch stem pushed in,
lamp should light when "SOL" terminal is grounded,
but should not light when "SW" or "R E L " terminals Fig . 4B - O verdrive Linkage Adjustment

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CLUTCHES AND TRANSMISSIONS 7-18

DIAGNOSIS—OVERDRIVE
MECHANICAL switch through the switch bracket are tightened
sufficiently to bend the switch shank, thus pre­
Any one of the following general complaints may be due venting free motion of the switch stem. This may
to non-standard mechanical conditions in the overdrive usually be remedied by loosening the upper of the
unit: two nuts.
1. Does not drive unless locked up manually. d. Improper installation of solenoid—If car cannot
2. Does not engage, or lock-up does not release. be rolled backward under any circumstances and
3. Engages with a severe jolt, or noise. there is no relay click when the ignition is turned
These troubles may be diagnosed and remedied as de­ on, it probably indicates that the solenoid has
scribed in the following paragraphs. been installed directly, without twisting into the
1. Does not drive unless locked up manually bayonet lock between solenoid stem and pawl,
a. Occasionally, the unit may not drive the car for­ thus jamming the pawl permanently into over­
ward in direct drive, unless locked up by pulling drive engagement. If the car will occasionally
the dash control. This may be caused by one or roll backwards, but not always, (and there is no
more broken rollers in the roller clutch, the relay click when the ignition switch is turned on)
remedy for which is the replacement of the entire it may indicate that, upon installation, the bayonet
set of rollers. lock was caught, and the solenoid forcibly twisted
b. This may also be caused by sticking of the roller into alignment with the attaching flange, thus
retainer upon the cam. This retainer must move shearing off the internal keying of the solenoid.
freely to push the rollers into engaging position, Under these circumstances, the end of the sole­
under the pressure of the two actuating springs. noid stem may not catch in the pawl, and upon
c. Sometimes this is due to slight indentations, worn release of the solenoid, the pawl will not be with­
in the cam faces by the rollers spinning, reme­ drawn promptly from engagement, but simply
died by replacement of the cam. drift out. If the solenoid stem end has its two
2. Does not engage, or lock-up does not release flats exactly facing the two solenoid flange holes,
a. Dash control improperly connected--Unless the it will not withdraw the pawl properly. If the
overdrive dash control wire is connected to the stem can be rotated when grasped by a pair of
lockup lever on the left side of the overdrive pliers, it indicates that the internal keying has
housing in such a manner as to move the lever all been sheared.
the way back when the dash control knob is pushed e. Improper positioning of blocker ring--Occasion­
in, it may hold the shift rail in such a position as ally, either in assembly at the factory, or in
to interlock the pawl against full engagement re­ service operations in the field, the internal parts
sulting in a buzzing noise when overdrive engage­ of the overdrive unit may have been rotated with
ment is attempted. the solenoid pawl removed, causing the blocker
To correctly make this connection, loosen bind­ ring to rotate, so that its two lugs are not located
ing post at lever, pull dash control knob out 1/4", with respect to the pawl as shown in Figure 12B.
move lever all the way to the rear, and tighten In other words, the solid portion of the blocker
binding post. ring may be in alignment with the pawl, which
b. Transmission and overdrive improperly aligned-- will prevent full engagement of the pawl with the
The same symptoms as above may also result sun gear control plate.
from misalignment, at assembly, of the overdrive
housing to the transmission case, resulting in
binding of the overdrive shift rail, so that the re­
tractor spring cannot move the rail fully forward,
when the dash control knob is pushed in, and the
transmission is not in reverse. Under such con­
ditions, the unit may remain fully locked up.
To test for this, be sure that the transmission
is not in reverse; disconnect the dash control
wire from the lockup lever, and feel the lever for
free forward movement. If the lever can be
moved forward more than 1/4", it indicates that
misalignment probably exists. To correct this,
loosen the capscrews between the overdrive hous­
ing and transmission case, and tap the adapter
plate and overdrive housing until a position is
found where the rail shifts freely; tighten
capscrews.
c. Kickdown switch improperly adjusted--The posi­
tion of the kickdown switch should be adjusted, by
means of the two large nuts which clamp the
switch shank, so the switch plunger travels 3/16"
before the throttle lever touches its stop.
Occasionally the large nuts which clamp the F ig . 5B - O verdrive E le ctrica l C ircu it W iring Diagram

CHEVROLET TRUCK SERVICE M ANUAL

 CLUTCHES AND TRANSMISSIONS 7-19

To test for this condition, remove solenoid "R EL"). If the solenoid clicks when one terminal
cover, pull dash control knob out, roll car 2 ft. is grounded but not the other, replace the switch.
forward. Push dash control in, turn ignition If the solenoid does not click when either of the
switch on. Then ground the "KD" terminal of terminals is grounded, check the wiring between
relay, and watch movement of center stem of the relay and the kickdown switch and replace if
solenoid. It should not move more than 1/8" when defective.
the solenoid clicks. Then, with the relay terminal e. If the solenoid clicks as each terminal is
still grounded, shift into low gear, and roll car grounded in Step d, ground the governor switch
forward by hand. Solenoid stem should then move terminal. If the solenoid clicks, the governor
an additional 3 /8 ", as the pawl engages fully. switch may be defective. If the solenoid does not
These two tests indicate proper blocker action. click, check the wiring between the kickdown and
Unless both tests are met, the blocker ring is governor switches and replace if necessary.
probably not in the correct position. 2. Does not release
3. Engages with a severe jolt or noise a. Remove the connection to the "KD” terminal of
Insufficient blocker ring friction may cause the ring the relay. If this releases overdrive, look for a
to lose its grip on the hub of the sun gear control grounded control circuit between the relay and
plate. Check the fit and tension of the ring as de­ governor switch.
scribed under "Cleaning and Inspection". b. If the overdrive is not released in Step a, discon­
4. Free-wheels at speeds over 30 MPH nect the lead to the "SOL” terminal of relay. If
If cam roller retainer spring tension is weak the unit this releases the overdrive, replace the relay.
will free wheel at all times. Check spring action as 3. Does not kickdown from overdrive
described under "Cleaning and Inspection". a. With the engine running, connect a jumper lead
between the No. 6 terminal of the solenoid and
ground. Operate the kickdown switch by hand.
ELECTRICAL This should stop the engine. If it does, the sole­
noid is probably defective and it should be
Any one of the following general complaints may be due checked for dirty ground-out contacts or other
to electrical trouble in the overdrive circuit. defects within the ground-out circuit of the sole­
1. Does not engage. noid (fig. 4B). Clean the contacts or replace the
2. Does not release. contact plate as required.
3. Does not kickdown from overdrive. b. If the engine does not stop in Step a, ground one
These troubles may be traced and remedied as de­ and then the other of the two terminals (identified
scribed in the following paragraphs. as "IGN" and "SOL") farthest from the stem of
1. Does not engage the kickdown switch. The engine should stop when
a. With the ignition switch on, ground the "KD" ter­ one of the two terminals (IGN) is grounded. If the
minal of the solenoid relay with a jumper lead. If engine does not stop when the terminal is
the solenoid clicks, the relay and solenoid c ir­ grounded, the wiring or connections to the switch
cuits are in operating condition. If no click is between the switch and coil are defective. When
heard in the relay, check the fuse and replace if the other terminal (SOL) is grounded, the engine
defective. should stop when the kickdown switch is operated.
b. If the fuse is good, use a second jumper lead to If the engine does not stop when the kickdown
connect the "SOL" and "BAT" terminals of the switch is operated with the second terminal
relay. If a click is now heard in the solenoid, the grounded, the kickdown switch is defective. If the
relay is probably at fault and should be repaired trouble is in the kickdown switch, adjust the link­
or replaced. age to give more travel of the switch rod. If this
c. If the solenoid does not click in Step b, check the does not correct the trouble, replace the kickdown
wiring to the No. 4 terminal of the solenoid and switch.
replace if necessary. If the wiring is not defec­ If the kickdown switch operates as it should,
tive, the trouble is probably in the solenoid. Re­ check for an open circuit in the wiring between
move the solenoid cover, examine the solenoid the kickdown switch and the No. 6 terminal of the
contacts in series with the pull-in winding and solenoid.
clean if necessary. Test again for clicks, as in c. If the trouble is not located by the above checks,
Step b, after replacing solenoid cover and lead the upper contacts of the kickdown switch may not
wires. Replace the solenoid if trouble has not be opening. To check for this condition, ground
been corrected. the overdrive control circuit at the governor
d. If the relay and solenoid circuits are in good con­ switch. This should cause the solenoid to click.
dition as determined in Step a, leave the ignition Operate the kickdown switch by hand. This should
switch on and make sure the manual control knob cause a second click as the solenoid releases. If
is in the overdrive position. Ground one and then there is no second click, adjust the linkage to give
the other of the two terminals next to the stem of more travel of the switch rod. If this does not
the kickdown switch (identified as "SW" and correct the trouble, replace the kickdown switch.

CHEVROLET TRUCK SERVICE M ANUAL

CLUTCHES AND TRANSMISSIONS 7-20

FOUR-SPEED (CHEVROLET MUNCIE) TRANSMISSION

INDEX
Page Page
General Description......................................................... 7-20 Reverse Idler Gear A d ju s t m e n t................................. 7-22
Maintenance & Adjustments............................................. 7-21 Service Operations............................................................ 7-23
Transmission Gearshift Lever ................................. 7-21 Removal from V e h i c l e ................................................ 7-23
Transmission C o v e r ................................................... 7-21 Installation in V e h i c l e ................................................ 7-23
Rear Bearing Retainer Oil Seal and/or
Speedometer G e a r s ................................................... 7-22

GENERAL DESCRIPTION
The four speed transmission is a heavy duty type, de­ loose roller type bearing inside the clutch gear, while the
signed to give efficient service in every type of truck rear end receives its support from a ball bearing in the
operation. The transmission incorporates synchromesh transmission case.
action in second, third and fourth gears. All gears are The countershaft is supported at the rear by a single
helical except first and reverse. row ball bearing which takes the thrust load, and by a
The clutch gear is supported by a heavy-duty ball bear­ roller bearing at the front.
ing. The forward end of the mainshaft is supported by a

VIEW B
TG 500-600

VIEW A TT 400, TD 500-600 MODELS

TE-TS 400, TG 500-600 MODELS

F ig . 1J - Remote Control Rods

CHEVROLET TRUCK SERVICE M ANUAL

 CLUTCHES AND TRANSMISSIONS 7-21

MAINTENANCE AND ADJUSTMENTS

TRANSMISSION GEARSHIFT LEVER NOTE: Pin holding reverse shifter head to
shifter shaft must be removed and shifter head
Removal removed from cover before first and second
1. Slide the open side of Tool J-8109 over the lever, speed shifter yoke retainer pin can be removed.
engage the lugs of the tool in the open slot of the re­ 2. Turn shifter shafts one-half turn to raise yoke detent
tainer (fig. 2J), then press down on the tool and turn balls out of the notches in the shifter shafts and drive
it to the left to disengage the lugs on the retainer. shafts out of cover and shifter yokes. Shifter shafts
will push expansion plugs out ahead of them.

CAUTION: Care should be exercised so that

yoke detent balls and springs which are located
in the cover are not lost as the shifter shafts
are removed.
3. Should it be necessary to remove the shifter inter­
lock assembly, cut the ends from the three shifter
interlock pins and drive pins out of cover to remove
assembly. If interlock plate is removed, new shifter
interlock pins must be used. Properly support pins
when re-riveting.
4. Should it be necessary to replace reverse shifter
compression pin or spring, the reverse shifter com­
pression pin spring expansion plug must be removed
from the cover. Extreme care must be used in re­
moving this expansion plug as it is under spring
tension.
5. In replacing reverse shifter compression pin or
spring, support cover in a vise and apply pressure to
Fig . 2J - Removing G earshift Lever hold expansion plug in place while staking in position
(fig. 3J).
NOTE: It may be necessary to remove one
handle from Tool J-8109 in order to clear sheet Assembly
metal on some models. 1. In reassembling the transmission cover, care must
be used in installing the shifter shafts. They should
2. Lift the lever out of the cover. be installed in the order shown in Figure 4J, namely;
reverse speed, low speed and high speed.
Installation
2. Place yoke detent ball springs and balls in position in
1. Place the gearshift lever in position in transmission
holes in cover.
cover. 3. Start shifter shafts into cover, depress yoke detent
2. Slide the open end of Tool J-8109 over the lever, en­ balls with small punch and push shafts on over balls.
gage the lugs of the tool in the open slot of the re­ Hold shifter yokes and reverse shifter head in posi­
tainer, then press down on the tool and turn to the tion and push shafts on through yokes and reverse
right to engage the lugs on the retainer. shifter head, until retainer pin holes in yokes and
reverse shifter head align with holes in shafts. Then
TRANSMISSION COVER install retainer pins.
4. Install shifter shaft hole expansion plugs and stake
Removal them in place.
1. Remove accelerator pedal, floor mat and transm is­
sion cover from body floor on conventional models.
On Forward Control models, remove the front floor
pan.
2. Remove gearshift lever from transmission cover,
using Tool J-8109.
3. Remove capscrews attaching transmission cover to
transmission case and remove cover.

CAUTION: Place a piece of cardboard over

transmission cover opening, using two of the
cover attaching screws to hold it in place. This
will keep anything from falling into the trans­
mission case.
Disassembly
1. With a small punch drive out pins that retain shifter
yokes and reverse shifter head to shifter shafts. F ig . 3J - Staking Expansion Plug

CHEVROLET TRUCK SERVICE M ANUAL

CLUTCHES AND TRANSMISSIONS 7-22

washer and special washer and remove flange and

speedometer drive gear from mainshaft.
4. To replace rear bearing retainer oil seal:
a. Remove old seal from retainer.
b. Coat outer diameter of new seal with Permatex
and install in retainer (fig. 5J), until seal is flush
with outside of retainer.
5. To replace speedometer gear, press speedometer
drive gear off hub of universal joint flange and press
new gear into position using Tool J-4869.

NOTE: The drive gear must be pressed onto

the front yoke with the chamfer or step on the
O.D. of the gear away from the universal joint.

6 . Install universal joint flange and speedometer gear

Fig. 4 J - O rder o f Shifter Shaft Assembly assembly and install universal joint flange special
washer, lockwasher and retainer bolt. Tighten bolt
Installation to 68-73 ft. lbs.
1. Remove cardboard covering from transmission case. 7. Replace speedometer driven gear.
2. Make sure all transmission gears are in neutral and 8 . Install propeller shaft as outlined in Section 4 and,
install cover assembly with new gasket to transmis­ on all except 1 / 2 ton models, install and adjust pro­
sion case, making sure shifting yokes slide over peller shaft brake.
their proper gears and that reverse shifter lever 9. If the transmission was drained, refill with 5 pts. of
properly engages reverse shifter head. S.A.E. 90 gear lubricant.
3. Install transmission cover attaching bolts and tighten
to 20-25 ft. lbs. REVERSE IDLER GEAR ADJUSTMENT
4. Using Tool J-8109, replace gearshift lever and check
operation by shifting into all gears. Correct adjustment of the reverse idler lever eccentric
5. On conventional models, replace transmission cover bolt (fig. 6 J) is necessary to provide correct engagement
to body floor, install floor mat and replace accelera­ of the reverse gear train to eliminate reverse gear dis­
tor pedal. On Forward Control models replace front engagement. The reverse idler must not interfere with
floor pan. the first and reverse gear when the first and reverse
gear is shifted forward, synchronized and engaged with
REAR BEARING RETAINER OIL SEAL the second speed gear. Likewise, the reverse idler must
AND/OR SPEEDOMETER GEARS be positioned so that when shifted into reverse, maximum
engagement is provided between idler gear and first and
Removal and Installation reverse sliding gear without the reverse idler gear con­
1. Disconnect propeller shaft as outlined in Section 5 tacting the transmission case at the rear.
and, on all except 1 / 2 ton models, disconnect pro­ To adjust the position of the reverse idler gear, the
peller shaft brake as outlined in Section 6 .
2. Remove speedometer driven gear from bearing — _
retainer.
3. Remove universal joint flange retaining bolt, lock-

CHEVROLET TRUCK SERVICE M ANUAL

 CLUTCHES AND TRANSMISSIONS 7-23

transmission should be fully assembled except for the direction enough to obtain approximately 1/32" run­
power take-off cover. Then proceed as follows: ning clearance. This clearance can be observed
1. Loosen the eccentric nut and rotate the eccentric, through the power take-off opening.
using a screwdriver in the slot in outer end of ec­ 4. Shift the transmission into reverse and check for
centric, until slot with dot on end is to the rear. This clearance between reverse idler gear and transmis­
places the reverse idler in its extreme rear position sion case at the rear. If necessary, rotate the ec­
and will provide for maximum engagement when the centric an additional amount in a counterclockwise
transmission is shifted into reverse. direction to obtain running clearance at this point.
2. Shift the transmission into second gear. 5. Tighten the eccentric nut to 40 ft. lbs. and to next
3. Check for interference between the reverse idler lock index. Install lock spring.
gear and the first and reverse gear. If interference 6 . Reinstall the power take-off cover and tighten cover
exists, rotate the eccentric in a counterclockwise bolts to 20-25 ft. lbs.

SERVICE OPERATIONS
REMOVAL FROM VEHICLE INSTALLATION IN VEHICLE
1. Drain lubricant from transmission. 1. Install transmission through opening in floor.
2. On all except 1/2 ton models, disconnect parking 2. Place the transmission on guide pins and start main-
brake and remove lever as outlined in Section 5. shaft in clutch disc and slide forward.
3. Remove the propeller shaft as outlined in Section 4. 3. Install the lower transmission mounting bolts, re­
4. Remove transmission gearshift lever as outlined un­ move the upper guide pins and install the top mount­
der "Maintenance and Adjustments." ing bolts.
5. Remove screws which fasten steering jacket grom­ 4. Install the flywheel underpan.
met to floor and slide grommet up jacket out of the 5. Install the propeller shaft as outlined in Section 4.
way. 6 . On all except 1/2 ton models, install and adjust the
6 . Remove accelerator pedal and floor mat. parking brake as outlined in Section 5.
7. Remove the sheet metal screws attaching transm is­ 7. Install transmission gearshift lever and adjust re­
sion cover to body floor and remove cover. On verse idler gear eccentric as outlined under "Main­
Forward Control models, remove both front and rear tenance and Adjustments."
floor pans. 8 . Connect speedometer cable to the driven gear fitting
8 . Disconnect the speedometer cable from the driven in the transmission rear bearing retainer.
gear fitting at the transmission rear bearing 9. Fill the transmission with 5-1/2 pts. of S.A.E. 90
retainer. gear lubricant and tighten drain and filler plugs to
9. Remove the two top cap screws attaching the trans­ 30-35 ft. lbs.
mission to clutch housing and insert the two Guide 10. Install the transmission floor cover to body floor.
Pins, Tool J-1126, in these holes. On Forward Control models, install front and rear
10. Remove the flywheel underpan and remove the two floor pans.
lower transmission to clutch housing capscrews. 11. Install the floor mat and connect the foot accelerator
11. Slide the transmission straight back on the guide pins pedal.
until the clutch gear is free of the splines in the 12. Slide the mast jacket grommet in position and install
clutch disc. The guide pins in the top holes support the retainer screws.
the transmission during this operation and prevent 13. Road test the vehicle for operation of transmission
damage to the clutch disc. in all speeds.
12. Remove transmission from vehicle.

HEAVY-DUTY 4-SPEED TRANSMISSION

(NEW PROCESS MODEL 4 3 5 )
IN D EX
Page Page
General Description......................................................... .... 7-24 Installation ............................................................ ....7-25
Maintenance and Adjustments ....................................... .... 7-24 Transmission C o v e r ................................................... ....7-27
Rear Oil Seal Replacement ............................................ 7-24 D isa ssem bly ............................................................ ....7-27
Remote Control A s s e m b ly .......................................... .... 7-24 A s s e m b l y ............................................................... ....7-27
R em oval.................................................................. .... 7-24 Remote Control A s s e m b ly .......................................... ....7-28
In s ta lla tio n ............................................................ .... 7-24 D isassem bly ............................................................ ....7-28
A d ju s tm e n t............................................................ .... 7-24 Shift Rail Yoke Bushing Replacem ent..................... ....7-28
Service O p e ra t io n s ......................................................... .... 7-25 Shift Rail Cover Oil Seal R ep lacem en t.................. ....7-28
Transmission R ep lacem en t....................................... .... 7-25 Assem bly.................................................................. ....7-29
R em oval.................................................................. .... 7-25

CHEVROLET TRUCK SERVICE M ANUAL

CLUTCHES AND TRANSMISSIONS 7-24

GENERAL DESCRIPTION
The New Process four-speed heavy duty transmission tion. The main drive gear is supported by a ball bearing
is a synchromesh type with helically cut gear teeth. The assembly at the front of the transmission case. The front
transmission is bolted directly to the clutch and flywheel of transmission mainshaft is supported by bearing rollers
housing at the rear of the engine. The countergear located in a cavity in rear of transmission main drive
cluster is a solid type with trunnion bearings mounted on gear and a ball bearing assembly supports the mainshaft
rollers in the case. There are four sets of gear teeth, at rear of the transmission case. Rear end of the main­
three helical and one spur (low gear) cut on this one- shaft is fitted with a universal joint yoke, end of which
piece forging. Gear teeth at front end are constantly locates in an oil seal in end of the rear bearing cap. The
meshed with main drive gear and second and third speed conventional transmission shift lever is attached by
gear teeth are always meshed with mainshaft second and means of a bayonet lock and can be installed directly into
third speed gears. The reverse idler gear is driven by transmission cover from the outside without removing the
the countergear and mainshaft low and reverse sliding cover from transmission. Optional remote controls are
(spur) gear engages teeth on countergear for first speed the two rod type.
operation or with reverse idler gear for reverse opera­

MAINTENANCE AND ADJUSTMENTS

General maintenance of the transmission while mounted ometer drive cable.
in vehicle consists generally of lubrication at regular in­ 6 . Install drain plug in transmission case and refill
tervals as described in LUBRICATION (Sec. 0) of this transmission with lubricant as described in LUBRI­
supplement. In addition to lubrication, transmission CATION (SEC. 0).
mounting bolts should be kept tight.
The transmission must be removed from truck for all REMOTE CONTROL ASSEMBLY
m ajor repair operations. Detailed instructions for re­
moval and installation of transmission is described later NOTE: If transmission is equipped with re­
in this section under "Transmission Replacement." Pro­ mote controls and if the assembly requires re­
cedures for repair of the transmission are described pairs or overhaul, proceed as follows:
later in this section under "Transmission Overhaul."
Removal
REAR OIL SEAL REPLACEMENT 1. With transmission in "Neutral," disconnect control
rods from shift levers at transmission.
The lid type oil seal (24, fig. IN) at rear of transm is­ 2. Remove remote control bell crank retaining snap
sion can be replaced without removing the transmission ring.
from vehicle. Replace rear oil seal as described in the 3. Remove four bolts and lock washers attaching re­
following: mote control assembly to transmission cover.
4. Remove remote control assembly and gasket. Dis­
Removal card gasket.
1. Remove drain plug and remove lubricant from 5. Overhaul remote control assembly as described later
transmission. in this section under "Transmission Overhaul."
2. Disconnect propeller shaft from transmission output
yoke as described in PROPELLER SHAFT (SEC. 4). Installation
3. Remove propeller shaft brake parts (if used) from 1. Position remote control assembly and new gasket on
transmission as described in "HAND BRAKE" transmission cover.
(SEC. 5). 2. Install four attaching bolts and lock washers. Tighten
4. Remove speedometer driven gear from rear bearing bolts firmly.
retainer. 3. Install remote control bell crank retaining snap ring.
5. Remove output yoke retaining nut. Pull output yoke 4. Connect control rods to shift levers at transmission.
off mainshaft.
6 . Using a suitable puller, remove oil seal from rear Adjustment
bearing retainer. Discard oil seal. 1. Remove cotter pins and clevis pins attaching control
rods at adjustable clevis end of rods.
Installation 2. Position gearshift lever at control island panel per­
1. Using a suitable sleeve, install a new oil seal in rear pendicular (90°) to island panel and secure in this
bearing retainer with lip of seal pointing in. Prelube position.
between lips of seal. Drive seal into bore of retainer 3. Place selector lever and shift lever at transmission
flush with rear face. Sealing cement should be used in neutral position.
at outer diameter of seal to prevent leakage. Wipe 4. Adjust clevises on control rods as required to obtain
off excess cement. free entry of clevis pins. Install pins.
2. Install output yoke on mainshaft and into bearing re­ 5. Check adjustment by shifting transmission into all
tainer. Install retaining nut. Tighten nut securely. positions and check for free entry of clevis pin in
3. Install propeller shaft brake parts (if used) as de­ each position. After obtaining correct adjustment,
scribed in "HAND BRAKE" (SEC. 5). secure clevis pins with new cotter pins and tighten
4. Connect propeller shaft to output yoke as described locknuts against adjustable clevises.
in PROPELLER SHAFT (SEC. 4). 6 . Lubricate linkage as directed in Lubrication Sec­
5. Install speedometer driven gear and connect speed­ tion 0 .

CHEVROLET TRUCK SERVICE MANUAL

 CLUTCHES AND TRANSMISSIONS 7-25

SERVICE OPERATIONS
TRANSMISSION REPLACEMENT
Removal housing until main drive gear shaft clears clutch disc
1. On transmissions equipped with remote controls, splines.
disconnect control rods from shift levers at 8 . Lower transmission and remove it from the vehicle.
transmission.
2. Remove transmission cover from cab floor on mod­ Installation
els not equipped with remote controls.
3. Disconnect speedometer drive cable from driven NOTE: Before installing transmission in the
gear adapter at rear of transmission. vehicle, be sure rear surface of clutch housing
4. Disconnect propeller shaft as outlined in PROPEL­ and front surface of transmission case are
LER SHAFT (SEC. 4). clean. Coat main drive gear splines and pilot
5. Disconnect hand brake (if used) at transmission as bearing in engine flywheel with lubricant speci­
described in "HAND BRAKE" (Sec. 5). fied in LUBRICATION (SEC. 0).
6 . While properly supporting the transmission remove
transmission to clutch housing attaching bolts and 1. With transmission properly supported on sutable
lock washers. transmission jack, move transmission into position
7. Pull transmission straight away from the clutch under vehicle.

Fig . I K - Remote Control Assembly

1. Roll Pin 6. Lock Nut 10. Shift Finger 14. Ball Jo in t Assembly
2. Shift Yoke G u id e 7. Roll Pin 11. Bell Crank 15. Rail Selector
3. Shift Rail Yoke 8. C over 12. N ut 16. Lock Washer
4. Shift Rail Boot 9. Shift Rail 13. Lock Washer 17. N ut
5. Boot Retainer

CHEVROLET TRUCK SERVICE M ANUAL

CLUTCHES AND TRANSMISSIONS 7-26

Fig. 2K - Transmission C over Components

1. Gasket 9. Reverse Shift Rail 16. Shift Rail 22. Spring

2. Transmission C over 10. Lock Pin Interlock Pin 23. 3rd and 4th Shift Fork
3. Washer 11. Retaining Ring 17. 3rd and 4th Shift Rail 24. Lock Pin
4. Cap Screw 12. Reverse Shift Lug 18. Shift Rail Interlock 25. Lock Pin
5. Lock Pin 13. Detent Ball Plunger 26. 1st and 2nd Shift Lug
6. 1st and 2nd Shift Fork 14. Spring 19. Spring 27. 1st and 2nd Shift Rail
7. Reverse Shift Fork 15. Shift Rail 20. Detent Ball 28. Detent Ball
8. Lock Pin Interlock Plunger 21. Plunger 29. Spring

CHEVROLET TRUCK SERVICE M ANUAL

 CLUTCHES AND TRANSMISSIONS 7-27

2. Raise transmission into position aligning main drive roll pin (24) retaining 3rd and 4th shift fork (23) to
gear shaft with clutch disc hub. Guide pins screws 3rd and 4th shift rail (17).
into transmission mounting bolt holes in clutch hous­ 2. Remove 3rd and 4th shift rail (17) and shift fork (23)}
ing will help keep transmission in alignment with driving shift rail out through welch plug opening in
clutch during installation. Move transmission toward cover forcing out welch plug.
clutch housing, turning main drive gear as necessary 3. Remove detent ball (20) and spring (19).
to allow splines of drive gear to engage splines in 4. Using #2 easy out (fig. 3K), remove roll pin (25)
clutch disc hub. from 1 st and 2 nd shift lug (26).
3. Remove guide pins if used; then install transmission 5. With #2 easy out (fig. 3K), remove roll pin (5) from
to clutch housing bolts and lock washers. Tighten 1 st and 2 nd shift fork (6 ).
bolts securely. 6. Using hammer and drift, drive 1st and 2nd shift rail
4. Connect hand brake (if used) at transmission as de­ (27) out of cover (2) forcing out welch plug. Remove
scribed in "HAND BRAKE” (SEC. 5). shift rail (27), 1st and 2nd shift lug (26), and 1st and
5. Connect propeller shaft to output yoke as described 2 nd shift fork (6 ).
in PROPELLER SHAFT (SEC. 4). 7. Remove detent ball (28) and spring (29).
6 . Connect speedometer cable to driven gear adapter at 8. Using #2 easy out, remove roll pins ( 8 and 10) from
rear of transmission. Tighten connector firmly. reverse shift lug assembly (12) and shift fork (7).
7. On transmissions equipped with remote controls, 9. With hammer and drift, drive reverse shift rail (9)
connect control rods to levers. Refer to "Trans­ out of cover (2) forcing out welch plug. Remove re­
mission Shift Control Linkage” described earlier for verse shift lug assembly (1 2 ), and reverse shift
adjustment procedures. fork (7).
8 . If lubricant was removed from transmission, refill 10. Remove detent ball (13) and spring (14). Remove two
with proper lubricant as described in LUBRICATION shift rail interlock plungers (15 and 18) and interlock
(SEC. 0). pin (16) from cover (2 ).
9. Install cover in cab floor if previously removed. 11. Using a screw driver, remove retaining ring (11)
10. "Road Test" vehicle for operation in all speeds. from reverse shift lug assembly (12). Remove
washer, plunger (2 1 ), and spring (2 2 ) from reverse
shift lug (1 2 ).
TRANSMISSION COVER DISASSEMBLY
Transmission Cover Assembly
Key Numbers in Text Refer to Fig. 2K
Key Numbers in Text Refer to Fig. 2K
1. Using a #2 easy out as shown in Figure 3K, remove 1. Position detent spring (29) and ball (28) in bore of
cover (2 ).
2. Partially insert 1st and 2nd speed shift rail (27) into
bore of cover (2). Position 1st and 2nd speed shift
fork (6 ) and 1 st and 2 nd speed shift lug (26) on
rail (27).
3. Push 1st and 2nd speed shift rail (27) the remaining
distance (to neutral position) into cover and install
new lock pins (5 and 25).

NOTE: Tapered end of pins go in first.

4. Install reverse shift plunger spring (22) and lug

plunger (21) in bore of reverse shift lug (12). Com­
press plunger and install retaining clip (1 1 ).
5. Position detent spring (14) and ball (13) in bore of
cover (2 ).
6 . Partially insert reverse shift rail (9) into bore of
cover (2). Position reverse shift fork (7) and reverse
shift lug (12) on rail (9).
7. Push reverse shift rail (9) the remaining distance (to
neutral position) into cover (2 ) and install new lock
pins ( 8 and 1 0 ).
NOTE: Tapered end of pins go in first.
8. Install two rail interlock plungers (15 and 18) in
Fig . 3K - Removing Shift Fork Lock (Roll) Pin bores of cover (2) also (10) Figure 5K.
9. Position rail interlock pin (16) in 3rd and 4th shift
1. Transmission C over 7. 1st & 2nd Shift Fork rail (17).
o
CN
LU

2. 8. Reverse Shift Fork 10. Install detent spring (19) and ball (20) in bore of
o

D
>>

3. 3rd & 4th Shift Fork 9. W e lc h (Expansion) Plugs cover (2 ).

4. Reverse Shift Lug 10. Lock Pins 11. Partially insert 3rd and 4th shift rail (17) in bore of
5. 3rd & 4th Shift Rai 1 11. 1st & 2nd Shift Lug cover (2) and position 3rd and 4th shift form (23) on
6. Reverse Shift Rail 12. 1st & 2nd Shift Rail
rail (17).

CHEVROLET TRUCK SERVICE MANUAL

CLUTCHES AND TRANSMISSIONS 7-28

Fig. 4K - Remote Control Assembly Components

1. Expansion Plug 7. Shift Yoke G u id e 13. Ball Jo in t Assy. 19. Snap Ring
2. G earshift Lever Rail 8. Shift Rail Boot 14. Roll Pin 20. O-Ring Seal
3. Screw and Lock W asher Assy. 9. Shift Rail Yoke 15. Lock Washer 21. Boot Retainer
4. C over Gasket 10. Nut 16. Nut 22. O il Seal
5. Remote Control Cover 11. Lock Washer 17. Bell Crank 23. Shift Finger
6. Lock Nut 12. Rail Selector 18. Snap Ring 24. Roll Pin

12. Push 3rd and 4th shift rail (17) the remaining dis­ 5. Using hammer and punch, remove split pin (24) re­
tance into cover (2 ) and install new lock pin (24). taining shift finger (23) to shift rail (2).
6 . Drive shift rail (2) forward out of cover (5) forcing
NOTE: Tapered end of pin goes in first.
out expansion (welch plug).
13. Check interlocks by shifting reverse shift rail in re­ 7. Remove nut (10) and lock washer (11) retaining shift
verse position. Other shifts rails should not shift rail selector (12) to ball joint assembly (13). Re­
when this rail is shifted (fig. 5K). move selector from the assembly (13).
14. Install three new welch plugs in bores of shift rail 8 . Remove nut and lock washer retaining bell crank (17)
holes. Install rail interlock hole plug. to ball joint assembly (13). Turn bell crank off the
assembly (13).
REMOTE CONTROL ASSEMBLY 9. Remove grease fitting from bell crank (17).

Key Numbers in Text Refer to Fig. 4K Remote Control Shift Rail Yoke
Bushing Replacement
NOTE: Following procedures apply only to
On transmissions having remote controls, accomplish
transmissions having remote controls, such as
the following procedures:
transmissions used on Tilt Cab Model vehicles.
1. P ress or drive shift rail yoke bushing out of bore in
Disassembly yoke.
1. Using a punch and hammer, remove retaining split 2. Using a suitable sleeve, press or drive new bushing
pin (14) from remote control shift rail (2). Remove into bore of shift rail yoke.
shift yoke (9) and selector (12) from shift rail (2).
2. Remove rubber shift rail boot (8 ) and O-ring boot Remote Control Shift Rail
retainer (21). Discard boot and retainer. Cover Oil Seal Replacement
3. Remove O-ring seal (20) from shift rail (2). With
snap ring pliers, remove snap ring (19) from shift Key Numbers in Text Refer to Fig. 4K
rail (2 ).
4. Loosen lock nut (6 ) and remove shift yoke guide (7) On transmissions having remote controls, accomplish
from cover (5). Remove lock nut (6 ) from guide (7). the following procedures:

CHEVROLET TRUCK SERVICE MANUAL

 CLUTCHES AND TRANSMISSIONS 7-29

1. P ress or drive oil seal (22) out of remote control 5. Install snap ring (19) in groove of shift rail (2). In­
cover (5) bore. stall new O-ring seal (2 0 ) on shift rail against the
2. With a suitable sleeve, press or drive new oil seal snap ring.
(22) into bore of cover (5) flush. 6 . Install new shift rail boot (8 ) with new retaining ring
(2 1 ) on shift rail (2 ).
Remote Control Assembly 7. Position shift rail yoke (9) and rail selector (12)
(with offset toward front) on yoke guide (7) and shift
Key Numbers in Text Refer to Fig. 4K rail (2 ).
8 . Install retaining pin (14) into holes in rail selector
NOTE: On transmissions having remote con­ (1 2 ) and shift rail (2 ).
trols only, accomplish the following procedures: 9. Install ball joint assembly (13) on rail selector (12)
1. Insert remote control shift rail (2) part way into retaining with nut (1 0 ) and lock washer (1 1 ).
cover (5), with flat on rail toward gasket face.
2. Position shift finger (23) on shift rail (2) with off- NOTE: The word "L E F T " on ball joint assem­
center hole to front. Push shift rail the remaining bly goes down.
distance into cover.
3. Install roll pin (24) retaining shift finger (23) on shift 10. Install bell crank (17) on ball joint assembly (13)
rail (2 ). attaching with nut (16) and lock washer (15).
4. With locknut (6 ) installed on shift yoke guide (7), 11. Install expansion plug (1) in shift rail opening in
install guide in cover (5). Tighten locknut firmly. cover (5).

Fig. 5K - Transmission C o ver Assembled

4. Reverse Shift 7. Transmission Cover 10.~Rail Interlock Plungers

1. 3rd and 4th
Rai I 8. W e lc h (Expansion) 11. 3rd and 4th Shift Rail
Shift Fork
5. Rail Interlock Pin Plugs 12. 1st and 2nd Shift Rail
2. Lock Pins
6. Reverse Shift Fork 9. 1st and 2nd Shift Fork 13. 1st and 2nd Shift Lug
3. Reverse Shift Lug

CHEVROLET TRUCK SERVICE MANUAL

CLUTCHES AND TRANSMISSIONS 7-30

FIVE-SPEED TRANSMISSION (NEW PROCESS)

INDEX
Page Page
General Description......................................................... 7-30 Rear Bearing Retainer Oil Seal and/or
Maintenance and Adjustments ....................................... 7-30 Speedometer G e a r s ................................................... 7-31
Transmission Gearshift Lever ................................. 7-30 Service Operations............................................................ 7-32
Transmission C o v e r ................................................... 7-30 Removal from V e h i c l e ................................................ 7-32
Installation to V e h i c l e ................................................ 7-32

GENERAL DESCRIPTION
The 5 -speed transmission (New Process) is a selective is supported at the rear by a single row ball bearing lo­
synchromesh type with five speeds forward and one re­ cated in the rear of the transmission case. The counter­
verse housed in a cast iron case. A 9 -1 /2 " x 2-1/2" shaft is supported in a single row ball bearing at the front
band type parking brake is mounted on the rear of the which takes the thrust load and by a roller bearing at the
transmission, and standard S.A.E. six bolt power take-off rear. The reverse idler cluster gear rotates on two
openings are provided on both sides of the case. All steel backed bronze bushings which are a press fit in
gears are helical with the exception of the first and re­ each end of the gear.
verse gear and synchromesh action is provided in second, Pin type synchronizer assemblies are used. The syn­
third, fourth and fifth gears. The mainshaft, counter­ chronizer assembly used for 2nd and 3rd speeds consists
shaft, reverse idler shaft and all gears are machined of two inner synchronizer rings, or cones, and one outer
from alloy steel and carburized for durability. In addi­ synchronizing ring, or plate. The synchronizer for 4th
tion, all gear teeth are shot peened for high fatigue and 5th speeds consists of two inner rings, or cones, and
resistance. two outer rings, or plates.
The main drive or clutch gear is supported by a single Shifting is accomplished by a floor mounted gearshift
row ball bearing mounted in the front of the transmission lever attached directly to the transmission cover. Fig­
case. The mainshaft is supported at the front by roller ure 64 shows layout of transmission parts.
bearings located in the hollow end of the clutch gear and

MAINTENANCE AND ADJUSTMENTS

TRANSMISSION GEARSHIFT LEVER will keep anything from falling into the trans-
mission.
Removal
1. Slide the open side of Tool J-8109 over the lever, en­ Disassembly
gage the lugs of the tool in the open slot of the re­ 1. Using a square edged "Easy-out," remove the pin
tainer cap, press down on the tool and turn it to the retaining the 1 st shifter fork and shifter head to
left to disengage the lugs on the retainer cap. shifter shaft (fig. 1NP).
2. Lift the lever out of the cover. 2. Turn shifter shaft one-half turn to push lock ball out

Installation
4TH AND 5TH
1. Place the gearshift lever in position in transmission SHIFTER FORK
cover.
2. Slide the open end of Tool J-8109 over the lever,
engage the lugs of the tool in the open slot of the re­ 2ND AND 3RD
SHIFTER FORK
tainer cap, press down on the tool and turn to the
right to engage the lugs on the retainer cap.

TRANSMISSION COVER
Removal
1. Remove accelerator pedal, floor mat and transmis­
sion cover from body floor on conventional models.
On Forward Control models, remove the front floor
pan.
2. Shift transmission into 2nd or 3rd gear, then remove
gearshift lever from transmission cover, using Tool
J-8109.
3. Remove cap screws attaching transmission cover to
transmission case and remove cover.

CAUTION: Place a piece of cardboard over

transmission cover opening, using two of the
cover attaching screws to hold it in place. This Fig . 1 N P - Removing Retaining Pins

CHEVROLET TRUCK SERVICE MANUAL

 CLUTCHES AND TRANSMISSIONS 7-31

of the notch in the shifter shaft and, with other teeth on the 1 st speed sliding gear will butt against
shifter shafts in neutral position, drive 1 st shifter the low speed teeth on the countershaft, as the sliding
shaft out of cover. Shifter shaft will push out expan­ gear is pushed rearward. (This will prevent the
sion plug. sliding gear from moving too far rearward.)
4. Put shift forks in cover into 3rd gear position. Place
NOTE: The shifter shafts are in neutral posi­ new gasket on case and install cover as follows:
tion when the ends of all four shafts are in ap­ a. Engage reverse shifter fork on reverse idler
proximate alignment toward the rear end of the gear.
transmission cover. b. While keeping left side of cover up, align 4th-5th
shifter fork on 4th-5th synchronizer clutch.
3. Drive out the pins retaining the other forks and heads c. Engage 2nd-3rd shifter fork in 2nd-3rd synchro­
to their shaft and remove the shafts, one at a time as nizer clutch.
in Step 2. d. Make sure that 1st speed shifter fork is engaged
in 1 st speed sliding gear and drop cover in place.
CAUTION: Care should be taken so that the 5. Align holes in cover with holes in case and install a
shifter lock balls and springs and the interlock shouldered dowel screw, with lockwasher, in the
balls and pins are not lost as the shifter shafts second hole from front in each side of cover (arrows,
are removed. fig. 2NP). Install all other screws and lockwashers
in cover and torque to 20-25 ft. lbs.
6 . Using Tool J-8109, replace gearshift lever and check
operation by shifting into all gears.
7. Replace transmission cover to body floor, install
floor mat and replace accelerator pedal.

REAR BEARING RETAINER OIL SEAL

AND/OR SPEEDOMETER GEARS

Removal and Installation

1. Disconnect propeller shaft and disconnect propeller
shaft brake.
2. Remove speedometer driven gear from bearing
retainer.
3. Remove universal joint flange retaining nut and re­
move universal joint flange and brake drum assembly
from mainshaft.
4. Remove rear bearing retainer and gasket and speed­
ometer drive gear.
5. To replace rear bearing retainer oil seal:
a. Remove oil seal from retainer.
F ig. 2 N P - Shifter Shaft Installation b. Coat outer diameter of new seal with Permatex
and install seal in retainer using Tool J-6416
Assembly (fig. 3NP).
1. In reassembling the transmission cover, care should 6 . Install speedometer drive gear and bearing retainer
be used in reinstalling the shifter shafts. They using a new gasket. Install brake drum, universal
should be installed in order; reverse, 4th and 5th,
2nd and 3rd, and 1st speed.
2. Start shifter shafts into cover. Hold shifter forks
and heads in position and push shafts through forks
and heads.
3. Install shifter shaft detent springs and balls and in­
terlock ball and pins (fig. 2NP). Depress detent
balls with small punch and press shafts over balls.
Turn shafts, if necessary, to position balls in grooves
in shifter shafts.
4. Install shifter fork and shifter head retaining pins.
5. Install shifter shaft hole expansion plugs and stake
them in place. Use a small amount of Permatex or
equivalent around expansion plugs to seal.

Installation
1. Remove cardboard covering from transmission case.
2. Put reverse idler gear in neutral (move forward).
Put 2nd-3rd sliding clutch into 3rd gear position
(move foward) and put 4th-5th sliding clutch slightly
ahead of neutral.
3. Rotate mainshaft by turning clutch gear until the Fig. 3 N P - Installing O il Seal with Tool J-6416

CHEVROLET TRUCK SERVICE MANUAL

CLUTCHES AND TRANSMISSIONS 7-32

joint flange, and universal joint flange retainer nut on 8. Install propeller shaft and install and adjust propel­
mainshaft. Tighten retainer nut to 125 ft. lbs. and ler shaft brake.
install cotter pin. 9. If the transmission was drained, refill with S.A.E. 90
7. Replace speedometer driven gear. gear lubricant.

SERVICE OPERATIONS
TRANSMISSION 12. Remove the transmission from vehicle.

Removal From Vehicle Installation in Vehicle

1. Drain lubricant from transmission. 1. Install guide pins, J-1126, in clutch housing. Posi­
2. Disconnect and remove parking brake lever. tion transmission under vehicle and raise into posi­
3. Disconnect and drop propeller shaft at transmission. tion on guide pins.
4. Remove the transmission gearshift lever as outlined 2. Start clutch gear shaft in clutch disc and slide
under "Maintenance and Adjustments." forward.
5. Remove screws which fasten steering jacket grom- 3. Install the transmission mounting bolts. Torque bolts
met to floor and slide grommet up jacket out of the to 70-75 ft. lbs.
way. 4. Install the flywheel underpan.
6. Remove accelerator pedal and floor mat. 5. Reconnect the propeller shaft.
7. Remove the sheet metal screws attaching transmis­ 6 . Install and adjust the parking brake.
sion cover to body floor and remove cover. 7. If not installed with cover assembly, install trans­
8 . Disconnect the speedometer cable from the speedom­ mission gearshift lever as outlined under "Mainte­
eter driven gear fitting at the transmission rear nance and Adjustments."
bearing retainer. 8 . Connect speedometer cable to the driven gear fitting
9. Remove the two top cap screws attaching the trans­ in the transmission rear bearing retainer.
mission to clutch housing and insert two transm is­ 9. Tighten drain plug and fill transmission with S.A. E.
sion Guide Pins Tool J-1126 in these holes. 90 gear lubricant. Install filler plug and tighten.
10. Remove the flywheel underpan and remove the two 10. Install the transmission floor cover to body floor.
lower transmission to clutch housing capscrews. 11. Install the floor mat and connect the foot accelerator
11. Slide the transmission straight back on the guide pins pedal.
until the clutch gear is free of the splines in the 12. Slide the mast jacket grommet in position and install
clutch disc. The guide pins in the top holes support the retainer screws.
the transmission during this operation and prevent 13. Road test the vehicle for operation of transmission in
damage to the clutch disc. all speeds.

FIVE-SPEED TRANSMISSION (SPICER 3 0 0 0 SERIES)

INDEX
Page Page
General Description......................................................... 7-32 Service Operations............................................................ 7-35
Maintenance and Adjustments ....................................... 7-32 Removal from V e h i c l e ................................................ 7-35
Gearshift L e v e r .......................................................... 7-32 Installation in Vehicle ................................................ 7-35
Transmission C o v e r ................................................... 7-33

GENERAL DESCRIPTION
The 5 -speed transmission (Spicer) is a manually single row ball bearing at the rear. The reverse idler
shifted, synchromesh, helical gear type. Fifth forward cluster rotates on two straight roller bearings. A 9 -1 /2 "
speed is direct drive. The clutch or main drive gear x 3" band type propeller shaft parking brake is mounted
bearing is a single row ball type. The mainshaft is sup­ at the rear of the transmission, except tandems with
ported by a straight roller pilot bearing at the front and a auxiliary transmissions. Power take-off openings are
single row ball bearing at the rear. The countershaft is provided on both the right and left sides of the transmis­
mounted on a straight roller bearing at the front and a sion case.

MAINTENANCE AND ADJUSTMENTS

GEARSHIFT LEVER tap out slotted pin. Lift lever out of housing.

Removal Installation
1. P ress down on gearshift lever spring cup and drive 1. Insert lever in housing with slot in lever in line with
locking pin out of lever. Lift off cup, spring, cap and hole through side of cover, and curve in lever to
seal (fig. IS). rear.
2. Remove snap ring from groove in lever housing and 2. Install slotted pin through housing and lever and in­

CHEVROLET TRUCK SERVICE M ANUAL

 CLUTCHES AND TRANSMISSIONS 7-33

stall snap ring.

3. Slide a new seal over lever onto the top of the hous­ CONTROL LEVER
ing and install the cap, spring and cup. P ress down HOUSING
on cup to compress spring, and install locking pin TRANSMISSION
through hole in lever above cup. COVER
OUTER
PLUNGER

SPRING

Fig. 2S - Removing Plunger Retainer

Remove fork. Slip interlock pin from shaft (fig. 7S).

Remove interlock poppet through hole for shaft
(fig. 6 S).
8 . Remove set screw from first-and-reverse shifter
Fig . IS - Removing G ea rsh ift Lever fork and from shifter head. Tap shaft out through
hole in front of cover, removing fork and head from
shaft.
TRANSMISSION COVER
Assembly
Removal 1. With cover upside down on bench, insert first-and-
1. Remove accelerator pedal, floor mat and transmis­ reverse (longest) shifter shaft through hole in front
sion cover from body floor. of cover and through forward boss. Then slide
2. Remove gearshift lever from transmission cover. shifter head on shaft with slot in head toward center
3. Remove capscrews attaching transmission cover to of cover as shown in Figure 8 S. Push shaft through
transmission case and remove cover. rear boss and install set screw through head into
shaft and install lockwire.
CAUTION: Place a piece of cardboard over 2. Install first-and-reverse (smallest) shifter fork on
transmission cover opening, using two of the end of shaft, install set screw and lock with wire.
cover attaching screws to hold it in place. This 3. Tilt cover and install interlock poppet into position
will keep anything from falling into the trans­ against first-and-reverse shaft (fig. 6 S).
mission case. 4. Insert second-and-third shifter shaft (shaft with hole
for interlock pin) through hole in front of cover and
Disassembly through forward boss. Slide fork having largest web
1. Remove plunger retainer (fig. 2S) and spring from onto end of shaft, with fork to rear and install inter-
transmission cover, then tilt cover so outer plunger
pin will come out of cover.
2. Remove control lever housing-to-cover bolts, lift FIRST AND REVERSE
housing from cover and remove gasket. INNER /SHIFTER LEVER
3. Remove inner plunger pin from first-and-reverse PLUNGER PIN CONTROL
shifter lever (fig. 3S) and, if control lever housing or LEVER HOUSING
first-and-reverse shifter lever is to be replaced,
remove nut and lockwasher from shifter lever stud.
Tap stud into housing to remove lever.
4. Lift poppet springs from holes in cover (fig. 4S).
Turn cover upside down over a clean container so
poppet balls will drop out of holes into container.
5. Place cover upside down, remove plugs from front of
cover and remove lock wire from set screws in
shifter forks (fig. 5S).
6 . Remove set screws from fourth-and-fifth speed
shifter fork and tap shaft out through hole in front of
cover. Remove fork. Remove interlock poppet
through opening for shaft (fig. 6 S).
7. Remove set screw from second-and-third shifter
shaft and tap shaft out through hole in front of cover. F ig . 3S - Removing Inner Plunger Pin

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CLUTCHES AND TRANSMISSIONS 7-34

2nd & THIRD

SHIFTER FORK

INTERLOCK

SHIFTER SHAFT
Fig. 4S - Removing Poppet Springs

lock pin in shaft as shown in Figure 7S. Fig. 7S - Removing Interlock Pin
5. Slide shaft the rest of the way in, holding shaft level
so pin will stay in shaft. Install set screw in shaft 6 . Tilt cover and install interlock poppet into position
and lock with wire. against second-and-third shifter shaft (fig. 6 S).
7. Insert fourth-and-fifth shifter shaft through hole in
2nd & 3rd front of cover. Position previously installed shifter
SHIFTER FORK 4th & 5th shafts so interlock poppet will permit passage of this
1st & REVERSE SHIFTER FORK
SHIFTER FORK shaft and slide shaft through forward boss.
8 . Install shifter fork on shaft with fork to front as
shown in Figure 9S. Install set screw and lock with
PLUGS
wire.
9. Install plugs in front of cover (fig. 5S), using a small
amount of Permatex or equivalent around plugs to
seal.
10. Place cover right side up on bench and install poppet
balls and springs in holes in cover (fig. 10S).
11. Position first-and-reverse shifter lever in control
lever housing with boss next to housing and install
stud from inside housing. Secure stud with nut and
lockwasher, then insert plunger pin in first-and-
reverse shifter lever (fig. 3S). Assemble new gasket
Fig. 5S - Shifter Shaft and Fork Installation on cover and install housing so lever fits in slot in
shifter head.
12. Insert outer plunger pin in cover and install spring
and retainer as shown in Figure 2S.

Installation
1. Remove cardboard covering from transmission case.
2. Make sure all transmission gears are in neutral and

SHIFTER
HEAD

FORWARD
BOSS

1st & REVERSE

SHIFTER SHAFT

F ig . 6S - Location of Interlock Poppets F ig . 8S - Installing Shifter Head

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 CLUTCHES AND TRANSMISSIONS 7-35

install cover assembly with new gasket to transmis­ 3. Install transmission cover attaching bolts and tighten
sion case, making sure shifter forks slide over their to 20-25 ft. lbs.
proper gears and that reverse shifter lever properly 4. Install gearshift lever and check operation by shifting
engages reverse shifter head. into all gears.
5. Install transmission cover to body floor, install floor
mat and replace accelerator pedal.

4th & 5th

SHIFTER FORK

4th & 5th

SHIFTER SHAFT

Fig. 9S - Installing 4th and 5th Shifter Fork Fig. 10S - Installing Poppet Balls and Springs

SERVICE OPERATIONS
TRANSMISSION Installation in Vehicle

Removal From Vehicle 1. Slide transmission into position and install mounting
bolts, using Permatex or equivalent to seal. Torque
1. Drain lubricant from transmission. bolts to 70-75 ft. lbs.
2. Disconnect parking brake and remove lever as out­ 2. Install flywheel underpan and the access panel on
lined in Section 5. housing.
3. Remove the propeller shaft as outlined in Section 4. 3. Install propeller shaft as outlined in Section 4.
4. Remove floor mat and transmission floor pan cover 4. Install parking brake lever and adjust brake as out­
and seal. lined in Section 5.
5. Remove gearshift lever. 5. Install transmission gearshift lever as outlined under
6 . Disconnect the speedometer cable from the driven "Maintenance and Adjustments."
gear fitting at the transmission. 6 . Connect speedometer cable to the driven gear fitting

7. Remove flywheel under pan and remove access panel in the rear bearing retainer.
from clutch housing. 7. Install the drain plug and fill the transmission with
8 . Support transmission and remove mounting bolts. 12 pts. of SAE 90 gear lubricant. Install filler plug.
Move transmission to rear until the clutch gear is 8 . Install the transmission floor cover and mat and in­

free of the splines in the clutch disc, and lower the stall accelerator pedal.
transmission away from vehicle. 9. Road test the vehicle.

AUXILIARY 4-SPEED TRANSMISSION (SPICER 6 0 4 1 )

INDEX
Page Page
General Description...............................................................7-36 Removal of Transm ission............................................. ....7-36
Maintenance and Adjustments ....................................... .....7-36 Installation of T ra n s m is s io n ....................................... ....7-36
Gearshift Lever A sse m b ly .......................................... .....7-36 Shift Cover and Forks ................................................ ....7-37
Shift Rod Adjustment................................................... .....7-36 D isassem bly ............................................................ ....7-37
Lubrication.................................................................. .....7-36 Assem bly.................................................................. ....7-37
Service Operations ................................................... .....7-36

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CLUTCHES AND TRANSMISSIONS 7-36

The four-speed auxiliary transmission is used as op­ take-off is provided on the right and left hand side of the
tional equipment for model M600 tandem axle trucks. The transmission and a disc-type parking brake is mounted at
transmission is manually shifted and has four speeds for­ the rear of the transmission.
ward: 1st, 2nd, direct, and overdrive. A six bolt power

GEARSHIFT LEVER ASSEMBLY

Removal and Installation
l e Disconnect the two shift rods at the gearshift lever
by removing the cotter pin and clevis pin.
2. Remove four nuts and lockwashers to remove gear­
shift from cab, then remove two gaskets and stop
plate.
3. Install in reverse order.

Fig. 2 Q - Transmission Control Rods

SHIFT ROD ADJUSTMENT

With the shift control rods disconnected at the gear­
shift, place the gearshift lever in neutral and place the
two transmission shift rods in the neutral (center detent)
position. Adjust the length of the shift control rods by
loosening the jam nuts, then turning the clevises to
lengthen or shorten the rods as required so the holes
Fig. I Q - Transmission Control Lever align with those in the gearshift lever shafts. Install
clevis pin and secure with cotter pin. Tighten jam nuts
Overhaul against clevises.
1. Apply downward pressure to cap, then rotate slightly
to free it from pins in tower. LUBRICATION
2. Remove knob and nut; then remove cap, spring cup,
and spring. The auxiliary transmission should be lubricated as
3. Assemble in reverse order. prescribed in Section 0 of this manual.
SERVICE OPERATIONS
TRANSMISSION REMOVAL transmission, remove the two nuts and lockwashers
1. Disconnect prop shafts at the input and output ends of securing the U-bolt at the front to the second cross­
transmission. member and disconnect the left and right bolts, nuts,
2. Disconnect gearshift lever rods at their connection to and remove spacers from the crossmember support
the shift rods at the transmission. at rear of transmission.
3. Disconnect any connections to the power take-offs on 6 . Lower transmission and remove from vehicle.
the left and right sides of the transmission.
4. Disconnect speedometer cable at rear of trans­ TRANSMISSION INSTALLATION
mission. 1. Place transmission on suitable lift and raise into
5. Using a suitable jack and some means to secure the position.

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 CLUTCHES AND TRANSMISSIONS 7-37

2. Place U-bolt under nose of the transmission housing

and secure front of transmission with two bolts and
lockwashers to crossmember.
3. Place a spacer between the rear left transmission
mounting flange and crossmember support. Secure
transmission to crossmember support by installing
bolt, nut, and lockwasher. Similarly secure right
side.
4. Connect speedometer cable to adapter at rear of
auxiliary transmission.
5. Install any connections to the left or right power
take-offs.
6 . Connect control rods to transmission shift rods
(refer to Shift Rod Adjustment).
7. Connect input and output prop shafts.

Fig. 4 Q - C over and Shifting Mechanism

1. Direct and O ve rd rive Shift Rod 5. 1st and 2nd Shift Fork
2. Shifter Housing (Cover) 6. 1st and 2nd Shift Rod
3. Lock W ire 7. Direct and O ve rd rive
4. Shift Fork Screw Shift Fork

3. Remove shift rods (1 and 6 ) from cover, stripping off

forks (5 and 7) as shift rods are removed. Tip cover
on one side and ja r interlock out of shift rod boss.
4. Remove shift rod oil seals, if new seals are
required.
5. Remove transmission breather assembly from cover.

Assembly
1. Mount cover (2) in vise. Coat oil seal recesses with
sealing cement, and press new shift rod oil seals into
recess.
2. Insert 1st and 2nd shift rod (6 ) (longest rod) in bot­
tom hole of cover (2 ) being careful not to damage oil
seal.
3. Move shift rod through support and install 1st and
2nd shift fork (5) on rod with offset toward front as
rod is moved into position.
Fig. 3Q - Transmission Mounting 4. Install clamp screw (4 ), move rod to neutral position,
and tighten clamp screw. Install lockwire (3) re­
Shift Cover and Forks taining clamp screw.
5. Insert interlock in rod support, then insert direct and
Refer to Figure 4Q overdrive shift rod (1 ) (short rod) in top of cover.
6 . Install direct and overdrive shift fork (7) on rod with
Disassembly offset toward front and move rod through rod support
1. Mount cover in vise and remove lock wires (3) and boss.
shift fork clamp screws (4). 7. Install poppet balls, springs, retainer, and poppet
2. Remove poppet screw from each side of cover and screws.
ja r springs, balls, and retainer out through poppet 8 . Move rod (1) to neutral position, tighten fork clamp
holes. screw (4 ) firmly and retain with lockwire (3).

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CLUTCHES AND TRANSMISSIONS 7-38

ALUMINUM POWERGLIDE
INDEX
Page Page
General Description......................................................... .... 7-38 Warming Up Transm ission .......................................... 7-41
Maintenance and Adjustments ....................................... .... 7-38 Shop Warm U p ......................................................... 7-41
Oil Level C h e c k ......................................................... .... 7-38 Road Warm Up ...................................................... 7-41
Periodic Oil C h a n g e ................................................... .... 7-38 Checking Fluid Level and C o n d itio n ........................... 7-41
Periodic Low Band A d ju stm e n t................................. .... 7-39 Manual L in k a g e............................................................ 7-42
Manual Shift Linkage Check and A d j u s t ............... .... 7-39 Oil L e a k s ..................................................................... 7-42
Throttle Valve L in k a g e .......................................... .... 7-40 Basic Pressure Checks ............................................. 7-42
Neutral Safety S w itch ............................................. .... 7-40 Wide Open Throttle Upshift Pressure Check . . . . 7-42
Throttle Return Check Valve (Dashpot) ............... .... 7-40 Idle Pressure in Drive R a n g e ................................. 7-42
Component Parts R eplacem en t....................................... .... 7-40 Manual "Low " Range Pressure C h e c k .................. 7-43
Transmission R e p lacem en t....................................... .... 7-40 Drive Range Overrun (Coast) P r e s s u r e .................. 7-43
Other Service O p erations................................................ .... 7-41 Powerglide Shift P o in ts................................................ 7-43
D ia g n o s is .................................... .. ..................................... 7-41

GENERAL DESCRIPTION
The case and converter housing of the two speed alumi­ ernor which requires a hole through the output shaft.
num Powerglide Transmission is a single case aluminum The reverse clutch assembly is a multiple disc type
unit. When the manual control is placed in the drive po­ clutch. The steel plates are splined directly to the case
sition, the transmission automatically shifts to low gear while the face plates are splined to the internal or ring
for initial vehicle movement. As the car gains speed and gear. The clutch piston operates within the rear portion
depending on load and throttle position, an automatic shift of the case. The internal diameter of the piston is sealed
is made to high gear. A forced downshift feature pro­ to an integral hub portion of the case rear bulkhead. The
vides a passing gear by returning the transmission to low outside diameter is sealed to a machined portion of the
range. case. The piston is hydraulically applied and is released
The oil pump assembly is a conventional gear type and by separate coil springs. The valve body assembly is
the oil pump housing is of the large diameter type acting bolted to the bottom of the transmission case and is ac­
as the front bulkhead of the transmission. The torque cessible for service by removing the oil pan assembly.
converter is a conventional three element welded design The valve body consists of an upper and lower body lo­
bolted to the engine flywheel which drives through a two- cated on either side of a transfer plate. The vacuum
speed planetary gearset. The high clutch assembly is modulator is located on the left rear face of the trans­
typical of the designs used in this type transmission. The mission case. The modulator valve bore is located in the
aluminum Powerglide uses an output shaft mounted gov­ upper valve body.

MAINTENANCE AND ADJUSTMENTS

OIL LEVEL CHECK thorough inspection should be made to find and correct all
external oil leaks.
The transmission oil level should be checked periodi­
cally as recommended in Section 0. Oil should be added PERIODIC OIL CHANGE
only when level is on or below the "ADD" mark on the dip The transmission oil should be changed periodically as
stick with oil hot or at operating temperature. The oil recommended in Section 0, and whenever transmission is
level dip stick is located at the right rear of the engine to be removed from the vehicle for repairs.
compartment. Fill with oil specified in Section 0. 1. Run engine for one minute in neutral prior to
In order to check oil level accurately, the engine should changing.
be idled with the transmission oil hot and the control 2. Be sure vehicle is level or raise from the rear only.
lever in neutral (N) position. 3. Remove the oil pan drain plug and allow oil to drain
It is important that the oil level be maintained no thoroughly into a pan or can.
higher than the "FU LL" mark on the transmission oil 4. Replace drain plug and refill with approximately two
level gauge. DO NOT OVERFILL, for when the oil level quarts of oil specified in Section 0.
is at the full mark on the dip stick, it is just slightly be­
low the planetary gear unit. If additional oil is added, NOTE: To refill the transmission, remove dip
bringing the oil level above the full mark, the planetary stick from oil filler tube and refill transmission
unit will run in the oil, foaming and aerating the oil. This with oil specified in Section 0 using filler tube
aerated oil carried through the various oil pressure pas­ and funnel J-4264. Then, after shifting into all
sages (low servo, reverse servo, clutch apply, converter, ranges at idle speed to fill all oil passages, the
etc.) may cause malfunction of the transmission assem­ engine should be run at 800-1000 rpm with the
bly, resulting in cavitation noise in the converter and transmission in Neutral until the oil warms up,
improper band or clutch application. Overheating may then add oil as required to raise the fluid level
also occur. to the full mark on the dip stick. Refill capacity
If the transmission is found consistently low on oil, a is approximately 2 qts.

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 CLUTCHES AND TRANSMISSIONS 7-39

PERIODIC LOW BAND ADJUSTMENT (Fig. IPG ) wheel. Allow the selector lever to be positioned in
drive (D) by the transmission detent.
Low band adjustment should be periodically performed
at 1 2 , 0 0 0 mile intervals, or sooner, as necessary if op­ NOTE: Do_ not use the indicator pointer as a
erating performance indicates low band slippage. reference to position the selector lever. When
1. Raise vehicle and place selector lever in neutral. performing linkage adjustment, pointer is ad­
2. Remove protective cap from transmission adjusting justed last.
screw.
3. On some models: To gain clearance between under­ 3. Release the selector lever. The lever should be in­
body and transmission, it may be necessary to re­ hibited from engaging low range unless the lever is
move rear mount bolts from crossmember, and move lifted.
transmission slightly toward passenger side of 4. Lift the selector lever towards the steering wheel,
vehicle. and allow the lever to be positioned in neutral (N) by
4. Loosen adjusting screw lock nut 1/4 turn and hold in the transmission detent.
this position with wrench. 5. Release the selector lever. The lever should now be
5. Using Special Tool J - 21848 adjust band to 70 in. lbs. inhibited from engaging reverse range unless the
and back off four (4) complete turns for a band which lever is lifted.
has been in operation for 6 , 0 0 0 miles or more, or 6 . A properly adjusted linkage will prevent the selector
three (3) turns for one in use less than 6,000 miles. lever from moving beyond both the neutral detent,
and the drive detent unless the lever is lifted to pass
CAUTION: Be sure to hold the adjusting screw over the mechanical stop in the steering column. See
lock nut at l / 4 turn loose with a wrench during schematic diagram.
the adjusting procedure. 7. In the event that an adjustment is required, place the
selector lever in drive (D) position as determined by
6. Tighten the adjusting screw lock nut to specified the transmission detent. See Steps 2 and 3.
torque. 8 . Loosen the adjustment swivel at the mast jacket
lever, and rotate the transmission lever so that it
CAUTION: The amount of back-off is not an contacts the drive stop in the steering column.
approximate figure, it must be exact. 9. Tighten the swivel and recheck the adjustment. See
Steps 2 and 6 .
10. Readjust indicator needle if necessary to agree with
the transmission detent positions. See Section 9.
11. Readjust neutral safety switch if necessary to pro­
vide the correct relationship to the transmission

Fig. I P G - Adjusting Low Band Using J —21848

MANUAL SHIFT LINKAGE CHECK & ADJUST

1. The shift tube and lever assembly must be free in the

mast jacket. See Section 9 for alignment of steering
column assembly if necessary.
2. To check for proper shift linkage adjustment, lift the
transmission selector lever towards the steering Fig. 2 P G - Powerglide Control Rod Linkage

CHEVROLET TRUCK SERVICE MANUAL

CLUTCHES AND TRANSMISSIONS 7-40

detent positions. See Section 12. same time the ball stud contacts end of slot in upper
T. V. rod.
Throttle Valve Linkage Adjustment 5. Adjust swivel on end of upper T. V. rod to obtain set­
ting described in Step 4. Allowable tolerance is ap­
L-6 Models proximately 1/32”.
With accelerator pedal depressed, bell crank on L - 6 6 . Connect and adjust accelerator linkage as described
models must be at wide open throttle position. in Section 6 .
Dash lever must be 1/64”-1 /1 6 " off lever stop and 7. Check for throttle linkage freedom.
transmission lever must be against transmission internal
stop.

V-8M
odelswithUni-DirectionalLinkage Neutral Safety Switch Adjustment

The adjustment at the neutral safety switch is de­

1. Remove air cleaner.
2. Disconnect accelerator linkage at carburetor. scribed in the E lectrical Section 12.
3. Disconnect accelerator return and T. V. rod return
springs. Throttle Return Check Valve
4. With right hand, pull T. V. upper rod forward until (Dashpot) Adjustment
transmission is through detent. With left hand, open
carburetor to wide open throttle position. Carbure­ The adjustment of the throttle return check valve is
tor must reach wide open throttle position at the described in Section 6 M for each carburetor installation.

COMPONENT PART REPLACEMENT

TRANSMISSION REPLACEMENT while the transmission rear end is being
lowered.
Removal
1. Raise vehicle on hoist (preferably) or on stand jack 10. Remove remainder of transmission housing-to-en­
and remove oil pan to drain oil, then replace pan gine attaching bolts.
using several bolts. 11. Remove the transmission by moving it slightly to
the rear and downward, then remove from beneath
NOTE: If desired, the oil may be drained after the vehicle and transfer to a work bench.
transmission removal.

2 . Disconnect the vacuum modulator line and the speed­

ometer drive cable fitting at the transmission. Tie
lines out of the way.
3. Disconnect manual and TV control lever rods from
transmission.
4. Disconnect propeller shaft from transmission.
5. Install suitable transmission lift equipment to jack or
other lifting device and attach on transmission.
6 . Disconnect engine rear mount on transmission ex­
tension, then remove the transmission support
crossmember.
7. Remove converter underpan, scribe flywheel-con­
verter relationship for assembly, then remove the
flywheel-to-converter attaching bolts.

NOTE: The "light" side of the converter is de­

noted by a "blue" stripe painted across the ends
of the converter cover and housing. This mark­
ing should be aligned as closely as possible with
the "white" stripe painted on the engine side of
the flywheel outer rim (heavy side of engine) to
maintain balance during assembly.

Support engine at the oil pan rail with a jack or other

suitable brace capable of supporting the engine
weight when the transmission is removed.
9. Lower the rear of the transmission slightly so that CO NVERTER H O LDING STRAP DIM EN SIO NS
I------------ — ----------------------------------- 18 9/ l 6 " ---------------------------------
the upper transmission housing-to-engine attaching
bolts can be reached using a universal socket and a "{I ° - % " HOLE
long extension. Remove upper bolts. % " h-------------------------- 1725/32"

CAUTION: It is best to have an assistant ob­

serve clearance of upper engine components Fig . 3PG - Converter Holding Tool

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 CLUTCHES AND TRANSMISSIONS 7-41

NOTE: Observe converter when moving the 3. Raise transmission into place at rear of engine and
transmission rearward. If it does not move with install transmission case to engine upper mounting
transmission, pry it free of flywheel before bolts, then install remainder of the mounting bolts.
proceeding. Torque bolts to 25-30 ft. lbs.
4. Remove support from beneath engine, then raise
CAUTION: Keep front of transmission upward
rear of transmission to final position.
to prevent the converter from falling out. Install
5. Through flywheel cover opening align as closely as
converter holding Tool J-9549 immediately (or
possible the "white" flywheel balance mark stripe
a sim ilar tool constructed as shown in Figure
and the "blue" painted stripe on end of converter
3PG, or, in an emergency, a length of strong
cover and housing. If scribed during removal, align
wire may be used) after removal from the scribe marks on flywheel and converter cover. In­
engine. stall converter to flywheel attaching bolts. Torque
bolts to 18 ft. lbs. (75 ft. lbs. on 292 cu. in. engines)
Installation
6 . Install flywheel cover.
NOTE: The "light" side of the converter is de­ 7. Reinstall transmission support cross member to
noted by a "blue" stripe painted across the ends transmission and frame.
of the converter cover and housing. This mark­ 8 . Remove transmission lift equipment.
ing should be aligned as closely as possible with 9. Connect propeller shaft to transmission.
the "white" stripe painted on the engine side of 10. Connect manual and TV control lever rods to
the flywheel outer rim, denoting the "heavy" transmission.
side of the engine. 11. Connect vacuum modulator line, and speedometer
drive cable to transmission.
1. Mount transmission on transmission lifting equip­ 12. Refill transmission through filler tube, using funnel
ment installed on jack or other lifting device. J-4264 and following the recommended procedure
2. Remove converter holding tool. provided earlier in this section.
CAUTION: Do not permit converter to move 13. Check transmission for proper operation and for
forward after removal of holding tool. leakage. Check and, if necessary, adjust linkage.

OTHER SERVICE OPERATIONS

Although certain operations, such as oil pan or gasket vehicle without removing the Powerglide; their service
replacement, valve body, governor, filler pipe "O" ring, procedure is covered in the Truck Overhaul Manual and
speedometer drive gear, case extension "O" ring and is not repeated here. Refer to the Powerglide Section of
rear oil seal, vacuum modulator, and servo cover or the Truck Overhaul Manual for all other service oper­
gasket service may be performed from underneath the ations not covered here.

DIAGNOSIS

Proper operation of the Powerglide transmission may Shop Warm Up

be affected by a number of factors, all of which must be
considered when trouble in the unit is diagnosed. 1. Connect tachometer to engine.
Proper trouble diagnosis can only be accomplished 2. Set parking brake tight and start engine.
when performed in a thorough step by step procedure. 3. Place selector light in "D" (drive) range.
The following procedure has been devised and tested and 4. Adjust carburetor idle speed adjusting screw to run
is recommended for all trouble diagnosis complaints and engine at approximately 750 rpm and operate in this
if the service man will follow this checking procedure, manner for two minutes. At the end of two minutes
accurate and dependable diagnosis may be accomplished. of operation, the transmission will be sufficiently
This will result in a savings of time, not only to the serv­ warmed up for diagnosis purposes.
ice man, but to the customer as well.
NOTE: At this point, readjust the engine idle
speed to 450-475 rpm in "D" range.
WARMING UP TRANSMISSION
Road Warm Up
Before attempting to check and/or correct any com­
plaints on the Powerglide transmission it is absolutely Drive the vehicle approximately 5 miles with frequent
essential that the oil level be checked and corrected if starts and stops.
necessary. An oil level which is either too high or too
NOTE: At this point, make sure the engine
low can be the cause of a number of abnormal conditions
idle speed is set to 450-475 rpm in "D" range.
from excessive noise to slippage in all ranges.
It must be remembered that cold oil will slow up the CHECKING FLUID LEVEL AND CONDITION
action of the hydraulic controls in the transmission. For
this reason a trouble or oil leak diagnosis should not be After transmission has been warmed up, check the
attempted until the transmission has been warmed up by fluid level with the engine idling, parking brake set and
either of the following procedures: control lever in "N" (neutral). If the fluid level is low,

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CLUTCHES AND TRANSMISSIONS 7-42

add fluid to bring level up to the full mark on gauge rod.

CAUTION: If fluid level is too high, fluid may
be aerated by the planet carrier. Aerated fluid
will cause turbulence in the converter which will
result in lost power, lower stall speed and lower
pressures in control circuits. Lower fluid level
to full mark, then shut off engine to allow air
bubbles to work out of fluid.
When checking oil level, a burned smell and discolora­
tion indicate burned clutches or bands and the transmis­
sion will have to be removed.

MANUAL LINKAGE

Manual linkage adjustment and the associated neutral

safety switch are important from a safety standpoint. The
neutral safety switch should be adjusted so that the engine
will start in the Park and Neutral positions only.
With the selector lever in the Park position, the park­
ing pawl should freely engage and prevent the vehicle
from rolling. The pointer on the indicator quadrant
should line up properly with the range indicators in all
ranges.

OIL LEAKS
Fig. 4 P G - Pressure Test Plug
Before attempting to correct an oil leak, the actual
source of the leak must be determined. In many cases operational checks for the Aluminum Powerglide trans­
the source of the leak can be deceiving due to ’’wind flow" mission. All checks should be made only after thoroughly
around the engine and transmission. warming up the transmission.
The suspected area should be wiped clean of all oil
before inspecting for the source of the leak. Red dye is • Wide Open Throttle Upshift Pressure.
used in the transmission oil at the assembly plant and • Idle Pressure in "Drive" Range.
will indicate if the oil leak is from the transmission. • Manual "Low" Range Pressure.
The use of a "black light" to identify the oil at the • "Drive" Range Overrun (Coast) Pressure.
source of leak is also helpful. Comparing the oil from
the leak to that on the engine or transmission dip stick It is not recommended that stall tests be conducted
(when viewed by block light) will determine the source of which would result in engine vacuum falling below 1 0 "
the leak. Hg.
Oil leaks around the engine and transmission are gen­ Pressure gauge hose connections should be made at
erally carried toward the rear of the car by the air the low servo apply (main line) test point (fig. 11PG).
stream . For example, a transmission "oil filler tube to Run the gauge line into the driving compartment by push­
case leak" will sometimes appear as a leak at the rear ing aside the mast jacket seal. Tie line out of the way of
of the transmission. In determining the source of an oil the drivers feet and connect to pressure gauge J - 21867.
leak it is most helpful to keep the engine running.
The mating surfaces of servo cover, converter housing, • Wide Open Throttle Upshift Pressure Check
transmission case and transmission case eJrtension
should be carefully examined for signs of leakage. The Refer to the pressure check chart for upshift pressure
vacuum modulator must also be checked to insure that points as indicated on the low servo apply (main line)
the diaphragm has not ruptured as this would allow trans­ gauge.
mission oil to be drawn into the intake manifold. Usually,
the exhaust will be excessively smoky if the diaphragm • Idle Pressure in "Drive” Range
ruptures due to the transmission oil added to the com­
bustion. The transmission case extension rear oil seal In addition to the oil pressure gauges, a vacuum gauge
should also be checked. All test plugs should be checked is needed for this check.
to make sure that they are tight and that there is no sign With the parking brake applied and the shift selector
of leakage at these points. The converter underpan should lever in "Drive", low servo apply (main line) pressure
also be removed. Any appreciable quantity of oil in this should be as shown on the pressure check chart.
area would indicate leakage at the oil pump square seal If pressures are not within these ranges, the following
ring, oil pump seal assembly, or oil pump bolt sealing items should be checked for oil circuit leakage:
washers. 1. Pressure regulator valve stuck.
2. Vacuum modulator valve stuck.
BASIC PRESSURE CHECKS 3. Hydraulic modulator valve stuck.
4. Leak at low servo piston ring (between ring and
Four basic pressure checks are used fo r diagnosis and bore).

CHEVROLET TRUCK SERVICE M ANUAL

 CLUTCHES AND TRANSMISSIONS 7-43

5. Leak at low servo piston rod (between rod and bore). lowing possibilities:
6. Leak at valve body to case gasket. 1. Partially plugged oil suction screen.
7. Leak at valve body gaskets. 2. Broken or damaged ring low servo.
8 . Front pump clearances. 3. Pressure regulator valve stuck.
9. Check passages in transmission case for porosity. 4. Leak at valve body to case gasket.
5. Leak between valve body gaskets.
• Manual "Low” Range Pressure Check 6 . Leak at servo center.
7. Front pump clearances.
Connect a tachometer, apply the parking brake, place • Drive Range Overrun (Coast) Pressure
the selector lever in "Low” range, and adjust the engine
speed to 1 0 0 0 rpm with the car stationary. With the vehicle coasting in "Drive" range at 20-25
Low servo apply (main line) pressure should be as MPH with engine vacuum at approximately 20" Hg., low
shown on the pressure check chart. servo apply (main line) pressure should be as shown on
P ressures not within this range can indicate the fol­ the pressure check chart.

POWERGLIDE BASIC PRESSURE (MAINLINE) CHECKS

Idle Pressure "Drive" Drive Range
Wide Open Manual "Low" Overrun (Coast)
Throttle Range @ Range @ 1000 Engines
@ 20-25 MPH
Upshift RPM
16" Hg. 10" Hg.* 20" Hg. Approx.

L-230
L-250
96 - 112 60 - 74 88 - 101 124 - 139 48 - 54
L-292
283 V- 8

104 - 119 60 - 74 88 - 101 124 - 139 48 - 54 327 V- 8

^Partially open throttle until vacuum reads 10" Hg.

CHEVROLET TRUCK SERVICE M ANUAL

 TRUCK SHIFT POINTS

CLUTCHES
CE 20 MODEL
CS 10 MODEL TRUCK (MPH) CE 10 MODEL TRUCK (MPH) CS 20 MODEL TRUCK (MPH)

AND
TRUCK (MPH)
L250 (BASE) L292 (L25) V283 (Base) V327 (L30) L250 (Base) L292 (L25) V283 (Base)
Engine

TRANSMISSIONS
3.73 Axle - 8.15-15 3.73 Axle - 8.15-15 3.73 Axle - 8.15-15 3.73 Axle - 8.15-15 4.57 Axle - 7-17.5 4.57 Axle - 7-17.5 4.57 Axle - 7-17.5
Tire Tire Tire Tire Tire Tire Tire

Throttle
Up Down Up Down Up Down Up Down Up Down Up Down Up Down
Position

Closed 12.3-15.3 11.2-14.4 12.3-15.3 11.2-14.4 12.3-15.3 11.2-14.4 12.4-15.3 11.3-14.4 10.7-13.4 9.8-12.6 10.9-13.4 9.8-12.6 10.7-13.4 9.8-12.6

7-44
Detent
36.0-45.0 19.3-29.9 36.0-45.0 19.3-29.9 36.0-45.0 19.3-29.9 40.9-49.9 14.0-21.4 31.4-39.3 16.9-26.1 31.4-39.3 16.9-26.1 31.4-39.3 16.9-26.1
Touch

Full
43.6-50.2 40.0-47.2 43.6-50.2 40.0-47.2 43.6-50.2 40.0-47.2 50.1-56.3 46.8-53.4 38.1-43.9 35.0-41.2 38.1-43.9 35.0-41.2 38.1-43.9 35.0-41.2
Detent

CE 20 MODEL
CE 10 MODEL TRUCK (MPH) PS 20 MODEL TRUCK (MPH) GS 10 MODEL TRUCK (MPH)
TRUCK (MPH)

V327 (L30) L230 (Base) L250 (L22) L250 (Base) L292 (L25) L230 (Base) L250 (L22)
Engine
4.57 Axle - 7-17.5 4.11 Axle - 8.15-15 4.11 Axle - 8.15-15 4.57 Axle - 7-17.5 4.57 Axle - 7-17.5 3.36 Axle - 6.95-14 3.36 Axle - 6.95-14
Tire Tire Tier Tire Tire Tire Tire

Throttle
Up Down Up Down Up Down Up Down Up Down Up Down Up Down
Position

Closed 10.8-13.4 9.9-12.6 11.1-13.9 10.2-13.0 11.1-13.9 10.2-13.0 10.7-13.4 9.8-12.6 10.7-13.4 9.8-12.6 12.4-15.5 11.4-14.6 12.4-15.5 11.4-14.6

Detent
35.8-43.6 12.3-18.7 32.6-40.8 17.5-27.1 32.6-40.8 17.5-27.1 31.4-39.3 16.9-26.1 31.4-39.3 16.9-26.1 36.5-45.6 19.6-30.3 36.5-45.6 19.6-30.3
Touch

Full
43.8-49.2 40.9-46.7 39.6-45.6 36.4-42.8 39.6-45.6 36.4-42.8 38.1-43.9 35.0-41.2 38.1-43.9 35.0-41.2 44.2-51.0 40.7-47.9 44.2-51.0 40.7-47.9
Detent

GE 10 MODEL GE 20 MODEL
GS 20 MODEL TRUCK (MPH)
TRUCK (MPH) TRUCK (MPH)

L230 (Base) L250 (L22) V283 (Base) V283 (Base)

Engine
4.11 Axle - 7.75-15 4.11 Axle - 7.75-15 3.36 Axle - 6.95-14 4.11 Axle - 7.75-15
Tire Tire Tire Tire
CHEVROLET TRUCK

Throttle
Up Down Up Down Up Down Up Down
Position

Closed 11.4-14.2 10.4-13.3 11.4-14.2 10.4-13.3 12.4-15.5 11.4-14.6 11.4-14.2 10.4-13.3

Detent
SERVICE MANUAL

33.3-41.7 17.9-27.7 33.3-41.7 17.9-27.7 36.5-45.6 19.6-30.3 33.3-41.7 17.9-27.7

Touch

Full
40.4-46.6 37.2-43.7 40.4-46.6 37.2-43.7 44.2-51.0 40.7-47.9 40.4-46.6 37.2-43.7
Detent
 CLUTCHES AND TRANSMISSIONS 7-45

TURBO HYDRA-MATIC TRANSMISSION

NDEX
Page Page
General Description......................................................... .....7-45 Rear S e a l ......................................................................... 7-48
Maintenance and Adjustments ....................................... .....7-46 Other Service O p e ra t io n s ................................................ .... 7-49
Transmission F l u i d ................................................... .....7-46 Transmission R ep lacem en t............................................. .... 7-49
Fluid Level Indicator ................................................ .....7-46 Turbo Hydra-Matic Diagnosis P ro c e d u re ........................ .... 7-49
Shift Control Linkage A dju stm en t.............................. .....7-46 Sequence ..................................................................... .... 7-49
Neutral Safety Switch A dju stm en t.............................. .....7-48 Oil Level and Condition C h e c k .................................... .... 7-49
Draining and Refilling T r a n s m is s io n ........................ .....7-48 Manual Linkage ......................................................... .... 7-49
Pressure Regulator V a l v e .......................................... .....7-48 Oil L e a k s ..................................................................... .... 7-49
Control Valve Body...................................................... .....7-48 Case Porosity - Repair ............................................. .... 7-50
G o v e rn o r..................................................................... .....7-48 Oil Pressure C heck...................................................... .... 7-50
Modulator and Modulator V a l v e ................................. .....7-48 Transmission Shift P o i n t s .......................................... .... 7-51
Parking L in k a g e ......................................................... .....7-48

GENERAL DESCRIPTION
The Turbo Hydra-Matic transmission is a fully auto­ Manual Linkage - To select the desired op­
matic unit consisting primarily of a 3 - element hydraulic erating range.
torque converter and a compound planetary gear set. Engine Vacuum - To operate a vacuum mod­
Three multiple-disc clutches, one sprag unit, one roller ulator unit.
clutch, and two bands provide the friction elements re­ 12 Volt Electrical - To operate an electrical
quired to obtain the desired function of the compound Signal detent solenoid.
planetary gear set.
The torque converter couples the engine to the plane­ A vacuum modulator is used to automatically sense
tary gears through oil and provides hydraulic torque any change in the torque input to the transmission. The
multiplication when required. The compound planetary vacuum modulator transmits this signal to the pressure
gear set produces three forward speeds and reverse. regulator for line pressure control, to the 1 - 2 accumula­
The 3 -element torque converter consists of a pump or tor valve, and to the shift valves so that all torque re­
driving member, a turbine or driven member, and a sta­ quirements of the transmission are met and smooth
tor assembly. The stator is mounted on a one-way roller shifts are obtained at all throttle openings.
clutch which will allow the stator to turn clockwise but The detent solenoid is activated by an electric switch
not counterclockwise. on the carburetor. When the throttle is fully opened, the
The torque converter housing is filled with oil and is switch on the carburetor is closed, activating the detent
attached to the engine crankshaft by a flex plate and solenoid and causing the transmission to downshift for
always rotates at engine speed. The converter pump is passing speeds.
an integral part of the converter housing, therefore the The selector quadrant has six selector positions: P,
pump blades, rotating at engine speed, set the oil within R, N, D,L2, L I.
the converter into motion and direct it to the turbine, P. - Park position positively locks the output shaft to
causing the turbine to rotate. the transmission case by means of a locking pawl
As the oil passes through the turbine it is traveling in to prevent the vehicle from rolling in either di­
such a direction that if it were not re-directed by the rection. The engine may be started in Park
stator it would hit the rear of the converter pump blades position.
and impede its pumping action. So at low turbine speeds, R. - Reverse enables the vehicle to be operated in a
the oil is re-directed by the stator to the converter pump reverse direction.
in such a manner that it actually assists the converter N. - Neutral position enables the engine to be started
pump to deliver power or multiply engine torque. and run without driving the vehicle.
As turbine speed increases, the direction of the oil D. - Drive Range is used for all normal driving condi­
leaving the turbine changes and flows against the rear tions and maximum economy. Drive Range has
side of the stator vanes in a clockwise direction. Since three gear ratios, from the starting ratio to direct
the stator is now impeding the smooth flow of oil, its rol­ drive. Detent downshifts are available by de­
ler clutch releases and it revolves freely on its shaft. pressing the accelerator to the floor.
Once the stator becomes inactive, there is no further L2. - L2 Range has the same starting ratio as Drive
multiplication of engine torque within the converter. At Range, but prevents the transmission from shifting
this point, the converter is merely acting as a fluid coup­ above second speed to retain second speed accel­
ling as both the converter pump and turbine are being eration when extra performance is desired. L2
driven at approximately the same speed - or at a one-to- Range can also be used for engine braking. L2
one ratio. Range can be selected at any vehicle speed, and
A hydraulic system pressurized by a gear type pump the transmission will shift to second gear and re­
provides the working pressure required to operate the main in second until the vehicle speed or the
friction elements and automatic controls. throttle are changed to obtain first gear operation
External control connections to transmission are: in the same manner as in D Range.

CHEVROLET TRUCK SERVICE M ANUAL

CLUTCHES AND TRANSMISSIONS 7-46

L I. - LI Range can be selected at any vehicle speed, and It is very important that any communication concerning
the transmission will shift to second gear and re­ the Turbo Hydra-Matic always contain the transmission
main in second until vehicle speed is reduced to serial number and that all transmission parts returned to
approximately 40 MPH, depending on axle ratio. Chevrolet Motor Division always be tagged with the
LI Range position prevents the transmission from transmission serial number.
shifting out of first gear.

MAINTENANCE AND ADJUSTMENTS

TRANSMISSION FLUID the mast jacket. See Section 9 for alignment of
steering column assembly if necessary.
Transmission fluid level should be checked with trans­
2. To check for proper shift linkage adjustment, lift the
mission warm and selector lever in "P " Park position,
transmission selector lever towards the steering
every time engine oil level is checked or as specified in
Section 0 when engine oil is changed. wheel. Allow the selector lever to be positioned in
drive (D) by the transmission detent.
CAUTION: Since the Turbo Hydra-Matic
NOTE: Do_ not use the indicator pointer as a
transmission is very sensitive to oil level, spe­
reference to positon the selector lever. When
cial precautions should be taken when checking
the oil level, to insure against an overfill. performing linkage adjustment, pointer is ad­
justed last.
Transmission fluid should be changed as specified in
Section 0. 3. Release the selector lever. The lever should be in­
hibited from engaging low range unless the lever is
FLUID LEVEL INDICATOR lifted.
4. Lift the selector lever towards the steering wheel,
The fluid level indicator is located in the filler pipe at and allow the lever to be positioned in neutral (N)
the right rear corner of the engine. To bring the fluid by the transmission detent.
level from the add mark to the full mark add 1 pint. 5. Release the selector lever. The lever should now be
Fluid level should be to the full mark with transm is­ inhibited from engaging reverse range unless the
sion at normal operating temperature. With cold fluid lever is lifted.
the level should be at the add mark or slightly below. 6 . A properly adjusted linkage will prevent the selector
from moving beyond both the neutral detent, and the
SHIFT CONTROL LINKAGE ADJUSTMENT drive detent unless the lever is lifted to pass over
Adjust linkage as described below: the mechanical stop in the steering column. See
schematic diagram.
COLUMN SHIFT 7. In the event that an adjustment is required, place the
selector lever in drive (D) position as determined
1. The shift tube and lever assembly must be free in by the transmission detent. See Steps 2 and 3.

Fig . 2T - Upper Control Linkage (PS20 Models)

CHEVROLET TRUCK SERVICE M ANUAL

 CLUTCHES AND TRANSMISSIONS 7-47

8. Loosen the adjustment swivel at the mast jacket, and 12. When properly adjusted the following conditions must
rotate the transmission lever so that it contacts the be met by manual operation of the steering column
drive stop in the steering column. shift lever:
9. Tighten the swivel and recheck the adjustment. See a. From reverse to drive position travel, the trans­
Steps 2 and 6 . mission detent feel must be noted and related to
10. Readjust indicator needle if necessary to agree with indicated position on dial.
the transmission detent positions. See Section 9. b. When in drive and reverse positions, pull lever
11. Readjust neutral safety switch if necessary to pro­ rearward (towards steering wheel) and then re­
vide the correct relationship to the transmission lease. It must drop back into position with no
detent positions. See Section 12. restrictions.

VIEW B

VIEW A

Fig . 3T - Lower Control Linkage (PS20)

CHEVROLET TRUCK SERVICE M ANUAL

CLUTCHES AND TRANSMISSIONS 7-48

NEUTRAL SAFETY SWITCH ADJUSTMENT 5. Remove the governor pipes and manual valve from
control valve body.
The neutral safety switch must be adjusted so that the
car will start in the park or neutral position, but will not Installation
start in the other positions. For replacement refer to Installation of the control valve body is the reverse of
Section 12 of this Manual. the removal.

DRAINING AND REFILLING TRANSMISSION GOVERNOR

Drain oil immediately after operation before it has had Removal
an opportunity to cool. 1. Remove governor cover attaching screws, cover, and
To drain oil proceed as follows: gasket.
1. Remove bottom pan attachin screws, pan, and 2. Discard gasket.
f gasket. 3. Withdraw governor assembly from case.
2. Remove oil strainer. Remove "O" ring seal from
pick-up pipe and discard. Installation
3. Discard strainer if dirty. Installation of the governor assembly is the reverse of
4. Install new ”0 " ring seal on pick-up pipe and install the removal. Use a new gasket under the governor cover.
strainer and pipe assembly.
5. Thoroughly clean bottom pan. MODULATOR AND MODULATOR VALVE
6 . Affix new gasket to bottom pan with petroleum jelly.
Removal
7. Install bottom pan with attaching screws and torque
1. Remove modulator assembly attaching screw and
to specifications.
retainer.
8 . If only the pan has been removed, pour approximately
2. Remove modulator assembly from case. Discard
7-1/2 pints of fluid into the transmission. If the
valve body has also been removed use 9-1/2 pints. "O" ring seal.
3. Remove modulator valve from case.
After a complete overhaul approximately 19 pints
are required. Be sure container, spout, or funnel is Installation
clean. Installation of the modulator assembly and modulator
9. Start engine and let idle (carburetor off fast idle valve is the reverse of the removal. Use a new "O" ring
step). Place selector lever in P position and apply seal on the modulator assembly.
hand brake.
10. With transmission warm (approximately 150° F), add PARKING LINKAGE
fluid to bring level to full mark on indicator.
Removal
CAUTION: Do * not overfill. Foaming will 1. Remove bottom pan and oil strainer.
result. 2. Unthread jam nut holding detent lever to manual
PRESSURE REGULATOR VALVE shaft.
3. Remove manual shaft retaining pin from case.
Removal 4. Remove manual shaft and jam nut from case.
1. Remove bottom pan and strainer.
2. Compress regulator boost valve bushing against NOTE: Do not remove manual shaft seal un­
less replacement is required.
pressure regulator spring and remove snap ring,
using J-5403 pliers. 5. Remove parking actuator rod and detent lever
3. Remove regulator boost valve bushing and valve. assembly.
4. Remove pressure regulator spring. 6 . Remove parking pawl bracket attaching screws and
5. Remove regulator valve, spring retainer, and bracket.
spacer(s) if present. 7. Remove parking pawl return spring.
Installation NOTE: The following steps should not be com­
Installation of the pressure regulator valve is the re­ pleted unless part replacement is required.
verse of the removal.
8. Remove parking pawl shaft retainer.
CONTROL VALVE BODY 9. Remove parking pawl shaft, cup plug parking pawl
shaft, and parking pawl.
Removal
Installation
1. Remove bottom pan and strainer.
Installation of the parking linkage is the reverse of the
2. Disconnect solenoid lead from connector terminal.
removal. Use new seal and cup plug, if removed, and
3. Remove control valve body attaching screws and de­
new bottom pan gasket.
tent roller spring assembly.
NOTE: Do not remove solenoid attaching REAR SEAL
screws.
Removal
4. Remove control valve body assembly and governor 1. Remove propeller shaft.
pipes. If care is taken in removing control valve 2. Pry seal out with screw driver.
body the six (6 ) check balls will stay in place above
Installation
the spacer plate.
1. Using Tool J-5154 or J-21359 install new seal.
CAUTION: Do not drop manual valve. 2. Re-install propeller shaft.

CHEVROLET TRUCK SERVICF M AN UAl

 CLUTCHES AND TRANSMISSIONS 7-49

OTHER SERVICE WITH TRANSMISSION IN VEHICLE

The following operations when done as single opera­ d. Valve body spacer plate, gasket and check balls.
tions and not as part of a general overhaul should, as a e. Front accumulator piston.
practical matter, be performed with the transmission in f. Rear servo and rear accumulator assembly.
the vehicle. Refer to the "Transmission Disassembly g. Rear band apply checking with Tool J - 21370.
and Reassembly” section of the Overhaul Manual for h. Front servo assembly.
service procedures. i. Speedo driven gear.
a. Oil filler pipe and ”0 ” ring seal. j. Case extension or gasket.
b. Oil pan and gasket. k. Strainer and "O” ring.
c. Down shift solenoid or connector.

TRANSMISSION REPLACEMENT
Before raising the car, disconnect the battery and re­ 9. Remove converter to flywheel bolts.
lease the parking brake. 10. Loosen exhaust pipe to manifold bolts approximately
1. Remove propeller shaft. 1/4 inch, and lower transmission until jack is barely
2. Disconnect speedometer cable, electrical lead to supporting it.
case connector, vacuum line at modulator, and oil 11. Remove transmission to engine mounting bolts and
cooler pipes. remove oil filler tube at transmission.
3. Disconnect shift control linkage. 12. Raise transmission to its normal position, support
4. Support transmission with suitable transmission engine with jack and slide transmission rearward
jack. from engine and lower it away from vehicle.
5. Disconnect rear mount from frame crossmember.
CAUTION: Use converter holding Tool J-5384
6 . Remove two bolts at each end of frame crossmember
when lowering transmission or keep rear of
and remove crossmember.
transmission lower than front so as not to lose
7. Remove oil cooler lines, vacuum modulator line,
converter.
speedo cable, and detent solenoid connector wire at
transmission. The installation of the transmission is the reverse of
8 . Remove converter under pan. the removal.

TURBO HYDRA-MATIC DIAGNOSIS PROCEDURE

Accurate diagnosis of transmission problems begins cle. Erratic shifting, pump noise, or other malfunctions
with a thorough understanding of normal transmission can in some cases be traced to improper oil level.
operation. In particular, knowing which units are in­ Oil level should be checked with the selector lever in
volved in the various speeds or shifts so that the specific the Park (P) position, engine running, and the vehicle on
units or circuits involved in the problem can be isolated level pavement.
and investigated further. Analytical diagnosis will pro­ Fluid level should be to the FULL mark with the trans­
tect the technician from come backs and certainly will mission at normal operating temperature (170°-190°F.).
improve owner satisfaction. With warm fluid (room temperature), the level should be
An important and often overlooked aspect of diagnosis at or slightly below the ADD mark.
is finding out specifically what the customer is complain­ If oil level was low, refer to Oil Leaks.
ing of. For this purpose a short ride with the customer The condition of the oil is often an indication of whether
will often prove beneficial. It may be found that the con­ the transmission should be removed from the vehicle, or
dition the customer wants corrected is standard and to make further tests. When checking oil level, a burned
should not be altered. smell and discoloration indicate burned clutches or bands
The following sequence, based on field experience, pro­ and the transmission will have to be removed.
vides the desired information quickly and in most cases
actually corrects the malfunction without requiring the MANUAL LINKAGE
removal of the transmission. Details of the items listed
in this sequence are covered further in the text. Manual linkage adjustment and the associated neutral
safety switch are important from a safety standpoint.
SEQUENCE FOR TURBO HYDRA-MATIC The neutral safety switch should be adjusted so that the
DIAGNOSIS PROCEDURE engine will start in the Park and Neutral positions only.
With the selector lever in the Park position, the park­
1„ Check oil level and condition. ing pawl should freely engage and prevent the vehicle
2. Check and correct detent switch. from rolling. The pointer on the indicator quadrant
3. Check and correct vacuum line and fittings. should line up properly with the range indicators in all
4. Check and correct manual linkage. ranges.

OIL LEVEL AND CONDITION CHECK OIL LEAKS

Always check the oil level before road testing. Oil Before attempting to correct an oil leak, the actual
must be visible on dip stick prior to operating the vehi­ source of the leak must be determined. In many cases

CHEVROLET TRUCK SERVICE M ANUAL

CLUTCHES AND TRANSMISSIONS 7-50

\
the source of the leak can be deceiving due to "wind d. Foreign material between pump and case, or be­
flow" around the engine and transmission. tween pump cover and body.
The suspected area should be wiped clean of all oil e. Case - porous, pump face improperly machined.
before inspecting for the source of the leak. Red dye is f. Pump - shy of stock on mounting faces, porous
used in the transmission oil at the assembly plant and casting.
will indicate if the oil leak is from the transmission.
The use of a "black light"* to identify the oil at the CA Si POROSITY—REPAIR
source of leak is also helpful. Comparing the oil from
the leak to that on the engine or transmission dip stick Transmission leaks caused by aluminum case porosity
(when viewed by black light) will determine the source of have been successfully repaired with the transmission in
the leak. the vehicle by using the following procedure.
Oil leaks around the engine and transmission are gen­ 1. Road test and bring the transmission to operating
erally carried toward the rear of the car by the air temperature.
stream. For example, a transmission "oil filler tube 2. Raise the car and, with the engine running, locate the
to case leak" will sometimes appear as a leak at the rear source of the oil leak. Check for leaks in all operat­
of the transmission. In determining the source of an oil ing leaks.
leak it is most helpful to keep the engine running.
NOTE: The use of a m irror will be helpful in
POSSIBLE POINTS OF OIL LEAKS finding leaks.
3. Shut off engine and thoroughly clean area with a sol­
1. TRANSMISSION OIL PAN LEAK vent and air dry.
a. Attaching bolts not correctly torqued. 4. Using the instruction of the manufacturer, mix a
b. Improperly installed or damaged pan gasket. sufficient amount of epoxy cement, part #1360016, to
c. Oil pan gasket mounting face not flat. make the repair.
2. REAR EXTENSION LEAK 5. While the transmission is still hot, apply the epoxy
a. Attaching bolts not correctly torqued. to the area, making certain that the area is fully
b. Rear seal assembly - damaged or improperly covered.
installed. 6 . Allow epoxy cement to dry for three hours and re­
c. Gasket seal - (extension to case) damaged or im­ test for leaks, as outlined in Steps 1 and 2.
properly installed.
d. Porous casting. OH. PRESSURE CHECK
3. CASE LEAK
a. F iller pipe "O" ring seal damaged or missing; With Vehicle Stationary
misposition of filler pipe bracket to engine -
"loading" one side of "O" ring. Transmission oil pressure gauge and engine tachom­
b. Modulator assembly "O" ring seal - damaged or eter should be connected and the oil pressures should
improperly installed. check as follows:
c. Governor cover, gasket and bolts - damaged, 1. Pressures indicated below are at 0 output speed with
loose; case face leak. the vacuum modulator tube disconnected and with
d. Speedo gear - "O" ring damaged. engine at 1 2 0 0 rpm.
e. Manual shaft seal - damaged, improperly
installed. Approximate Drive Ll
f. Line pressure tap plug - stripped, shy sealer Altitude of Check Neutral or
compound. (Ft. above seal level) Park L2 Reverse
g. Parking pawl shaft cup plug - damaged, improp­
erly installed. 0 150 150 244
h. Vent pipe (refer to Item 5). 2 ,0 0 0 150 150 233
i. Porous case. 4,000 145 150 222
4. FRONT END LEAK 6 ,0 0 0 138 150 212
a. Front seal - damaged (check converter pack for 8 ,0 0 0 132 150 203
nicks, etc., also for pump bushing moved for­ 1 0 ,0 0 0 126 150 194
ward); garter spring missing from pump to con­ 1 2 ,0 0 0 121 150 186
verter seal. 14,000 116 150 178
b. Pump attaching bolts and seals - damaged, m iss­
ing, bolts loose. 2. Pressures indicated below are with the vacuum tube
c. Converter - leak in weld. connected for normal modulator operation, and with
d. Pump "O" ring seal - damaged. (Also check the engine at 1 2 0 0 rpm.
pump groove and case bore).
NOTE: Pressures are not significantly af­
e. Porous casting (pump or case).
fected by altitude or barometric pressure when
5. OIL COMES OUT VENT PIPE
the vacuum tube is connected.
a. Transmission over-filled.
b. Water in oil. Drive, Neutral, Park L l or L2 Reverse
c. Pump to case gasket mispositioned. 70 150 107

*A "Black Light" testing unit may be obtained from several different service tool suppliers.

CHEVROLET TRUCK SERVICE MANUAL

 CLUTCHES AND TRANSMISSIONS 7-51

TURBO HYDRA-MATIC SHIFT POINTS

Shift Position Shift Range Shift Points M.P.H.

Upshift (Full Throttle)

Drive 1-2 25-38
2-3 43-60
Kickdown
Drive 3-2 53-40
2-1 23-15
LO
L 0 W2 2-1 41-27

SPECIAL TOOLS

Fig. 1ST - C lutch Sp ecial Tools

1. J-6456 Height G aug e 7. J-9225 Ball Type Pilo t Bearing Installer

2. J —1048 G auge Plate J —21169 Pilot Arbor & Alignm ent Stud
3. J —1522 Pilo t Bearing Driver (2 Plate C lutch )
4. J-5824 C lutch Pilo t Tool 9. J-7126 Release Lever Adjusting Tool
5. J —1448 Pilo t Bearing Puller .
10 J —7816 Release Lever Adjusting Tool
6. J-5822 Ball Type Pilo t Bearing Remover

CHEVROLET TRUCK SERVICE M ANUAL

CLUTCHES AND TRANSMISSIONS 7-52

Fig. 2ST - C hevrolet Truck (exc. C h evy Van) Three-Speed Transmission Special Tools

1. J-0936 (J-936) - C lutch G e a r Bearing Remover 6. J-5154A (J-5154) - Rear Bearing Retainer Seal Installer
2. J-0933 (J-933) - C lutch G e a r Bearing Retainer W rench 7. J-0932 (J-932) - Synchronizer Ring Retaining Spring Remover and
3. J-0937 (J-937) - C lutch G e a r and Bearing Puller Replacer
4. J-5750 - Transmission Holding Fixture 8. J-1126 - Transmission G u id e Pins
5. J-5778 - Extension Housing Bushing Remover and Installer 9. J -5777 - Countergear Assembly Tool
 CLUTCHES AND TRANSMISSIONS 7-53

Fig. 3ST - Truck Three-Speed W id e Ratio Transmission Special Tools

1. J-4869 - Speedometer G e a r Remover and Replacer Set 5. J-5589 - Countershaft Assembly Tool
2. J- 1 1 2 6 - Transmission G u id e Pins 6. J-8039 - (K M O 410) - Snap Ring Pliers
3. J-5590 - Transmission Front Bearing Installer 7. J-5750 - Transmission Holding Fixture
4. j-5154 - Rear Bearing Retainer Seal Installer

CHEVROLET TRUCK SERVICE MANUAL

CLUTCHES AND TRANSMISSIONS 7-54

Fig. 4ST - Four-Speed Transmission Special Tools

1. J-2680 - Reverse Id ler G e a r Bushing Staking Tool 9. J —1453 - Clutch G e a r Bearing Replacer
2. J- 1 6 1 9 - Transmission Mainshaft Bearing Puller 10. J-2228 - Clutch G e a r Bearing Remover Plate
3. J-8109 (K-353) - G e a r Shift Lever Remover and Replacer 11. J-1614 - Reverse Idler G e a r Bushing Remover and Replacer
4. J-8107 (TR-278-R) - Countershaft Rear Bearing Remover 12. J —1488 - Rear Bearing Retainer O il Seal Driver
5. J-1126 - Transmission G u id e Pin Set (2) 13. J-4869 - Speedometer G e a r Replacer
6. J —2671 - Third Speed G e a r Bushing Installer 14. J-0358 ( J —358-1) - Press Plate Holder
7. J-7785 - O il Seal Installer 15. J-2668 - Reverse Idler G e a r Bushing Reamer (1 .1 2 8 ")
8. J-2667 - M ainshaft and Bearing Assembly Remover and Replacer (10-30 M odels)
(10-30 M odels)

CHEVRO LET TRUCK SERVICE M ANUAL

 _ - V

CLUTCHES AND TRANSMISSIONS 7-55

Fig. 5ST - Five-Speed (N e w Process) Transmission Special Tools

1. J-8109 (K-353) - G ea rsh ift Lever Remover 3. J-8108 (K-342) - C lutch G e a r Bearing 6. J-6416 - Rear Bearing Retainer Seal Installer
and Replacer Replacer 7. J - l 126 - Transmission G u id e Pins
2. J-2228 - C lutch G e a r Bearing Remover 4. J-0358 - Press Plate Holder 8. J-1619 - Transmission M ainshaft Bearing
Plate 5. J-6382 - Reverse Idler Shaft Remover Pu ller

CHEVROLET TRUCK SERVICE M ANUAL

r
CLUTCHES AND TRANSMISSIONS 7-56

Fig. 6ST - Five-Speed (Sp icer) Transmission Sp ecial Tools

1. J —1619 — M ainshaft Bearing Remover 5. J —6419 — Bearing Installer

2. J-4761 - Reverse Id ler Shaft Remover 6. J-0996 (J-996) Bearing Remover
3. J-8107 (TR-278-R) - Differential Side Bearing Remover 7. J-5740 - Bearing Remover
4. J —6418 - Synchronizer Hub Remover

CHEVROLET TRUCK SERVICE M ANUAL

 CLUTCHES AND TRANSMISSIONS 7-57

Fig. 7ST - Five-Speed (C lark) Transmission Special Tools

1. J-1619 - M ainshaft Bearing Remover

2. J-6382 - Reverse Idler G e a r Shaft Remover
3. J —6419 — Bearing Installer Set

CHEVROLET TRUCK SERVICE M ANUAL

CLUTCHES AND TRANSMISSIONS 7-58

Fig. 8ST - Aluminum Powerglide Special Tools

1. J-9506 Holding Fixture Adapters 15. J-7079 Handle

2. J —3289-01 Holding Fixture (Use with J-3289-20 Base) 16. J-6582 Rear Pump Bushing Installer
3. J-9549 C onverter Safety Strap 17. J-9543 Vacuum M odulator W rench
4. J- 2 1 867 Transmission Pressure G au g e and Hose 18. J-5778 Extension Bushing Remover and Installer
5. J-4264 O il F ille r Tube and Funnel 19. J —5154 Extension O il Seal Installer
6. J-3387 Pilot Stud Set 20. J-5403 Snap Ring Pliers
7. J-9539 Front Pump Pu ller Bolts (Use with Weights 21. J —5814 Speedometer D rive G e a r Remover and Installer
from Slid e Hammers J-6585) 22. J-5853 Torque W rench
8. J-6839 Front Pump Seal Driver 23. J-8039 Snap Ring Pliers
9. J-9546 C lutch Drum Bushing Remover and Installer 24. J- 2 1 848 Low Band Adjuster
10. J-7782 C lutch Spring Compressor Adapter Plate J-8001 Dial Indicator (N o t Illustrated)
11. J-5133 C lutch Spring Compressor J-5492 Dial Indicator Support Strap (N o t
12. J-4599 Planet Pinion Assembly Tool Set Illustrated
13. J-9542 Reverse Piston Spring Compressor J-6585 Slide Hammers (N o t Illustrated)
14. J-9557 Transmission Case Rear Bushing Remover and J-6585-3 Slid e Hammer Adapters (N o t Illustrated)
Installer and Rear Pump Bushing Remover J-9534 Bushing Remover (N o t Illustrated)

■CHEVROLET TRUCK SERVICE M ANUAL

 CLUTCHES AND TRANSMISSIONS 7-59

F ig. 9ST - Turbo H yd ra-M atic Sp ecial Tools

1. J- 6 1 16-01 Rear U nit Holding Fixture 15. J-5384 Converter Holding Strap
2. J-8092 D river Handle 16. J- 2 1 465-01 Bushing Tool Set
3. J —21359 Pump O il Seal Installer 17. J - 2 1465-5 Part of Bushing Too Set
4. J -21364 Holding Fixture Adapter (Used w ith J- 6 1 16-01 18. J - 2 1465-3 Part o f Bushing Too Set
Fixture) 19. J-21465-2 Part of Bushing Too Set
5. J-2619 Slid e Hammer (Used w ith 2619-4 Adapter and 20. J - 2 1465-1 Part o f Bushing Too Set
Remover Tools J- 2 1 465-01) 21. J - 2 1465-17 Part of Bushing Too Set
6. J-5154 Extension O il Seal Installer 22. J- 2 1465-8 Part of Bushing Too Set
7. J-6585 Slid e Hammer W eights 23. J- 2 1 465-13 Part o f Bushing Too Set
8. J-9539 S lid e Hammer Bolts (3/8 - 16 Threads) 24. J- 2 1465-6 Part of Bushing Too Set
9. J-5590 Speedo G e a r Installer 25. J- 2 1 465-15 Part of Bushing Too Set
10. J -21867 Pressure G auge and Hose 26. J- 2 1465-16 Part of Bushing Too Set
11. J - 2 1370-6 Rear Band A p ply Fixture 27. J- 2 1 465-9 Part of Bushing Too Set
12. J-21370-5 Rear Band A p ply Pin 28. J- 2 1 465-10 Part o f Bushing Too Set
13. J - 2 1795-1 G e a r Unit Assembly Holding Tool 29. J-22182 Extension Bushing Remover and Installer
14. J- 2 1 795-2 Part of Above Holding Tool (N o t Illustrated)

CH EVRO LET TRUCK S E R V K e M ANUAL

CLUTCHES AND TRANSMISSIONS 7-60

Fig. 10ST - Turbo H yd ra-M atic Special Tools

1. J-8763 Transmission Holding Fixture 9. J - 2 1363 Seal Protector - Intermediate C lutch - Inner
2. J-3289-14 Holding Fixture Base 10. J —21409 Seal Protector - Forward Clutch - O uter
3. J - 2 1427-1 Speedo G e a r Remover 11. J-21664 Clutch Spring Compressor Adapter Ring
4. J-9539 Slid e Hammer Bolts (3/8" - 16 Threads) 12. J-4670 Clutch Spring Compressor
5. J-8105 Speedo G e a r Remover Puller 13. J-8059 Snap Ring Pliers
6. J - 2 1885 Accum ulator Piston Installer 14. J-5586 Snap Ring Pliers
7. J - 2 1369 C onverter Pressure Check Fixture 15. J-5403 Snap Ring Pliers
8. J - 2 1362 Seal Protector - Forward and D irect C lutch - Inner 16. J —1313 Torque W rench 0-140 Ft. Lbs.

CHEVROLET TRUCK SERVICE MANUAL

 SECTION 8
FUEL TANK AND EXHAUST
CONTENTS OF THIS SECTION
Page
Fuel Tank ........................................................................ 8-1
Exhaust System .................................................................. 8-7

FUEL TANK
INDEX
Page Page
General Description............... 8-1 Filler Neck Assembly - Chevy V a n ........................... 8-4
Service O p e ra t io n s ............... 8-1 Fuel Line Service ...................................................... 8-5
Draining T a n k .................. 8-1 Fuel F i l t e r .................................................................. 8-5
Gauge Unit or Fuel Strainer 8-2 Special Tools .................................................................. 8-8
Fuel Tank........................... 8-2

GENERAL DESCRIPTION
All cab model trucks (except Tilt Cabs) have a 21 gal­ Fuel tank filler caps and neck assemblies conform to
lon capacity (approx.) fuel tank mounted behind the seat the latest SAE Standards for filler caps and related filler
within the cab. The tank is constructed of two steel neck cams. These units are not directly interchangeable
sections, seam welded together. The filler neck extends with past models for service replacement.
through the left side of the cab, at a convenient height Upper and lower filler necks vary as to size, length and
from the ground. Exceptional stiffness is secured by the shape, depending on model requirements. These necks
combination of the welded flanges and depressed ribs in are treated so that rust will not form and get into the
both the front and rear halves. The tank is bolted to the fuel system. Lower filler necks are first bolted or riv­
rear of the cab and to the floor panel. eted to the tank except on cab models, and then sweat
Frame mounted tanks are located on the right side of soldered in place to eliminate any possibility of leakage
the chassis and lay lengthwise outside the frame side rail at this point.
on Forward Control, 1-1/2, and 2 ton models. All tanks are equipped with a vented filler neck cap.
On 1 ton models, the above information also applies All 40 through 60 Series trucks incorporate a pressure
except that the tank is mounted on the outside of the left relief valve which reduces fire hazard by eliminating an
side frame rail. A strong mounting of two metal straps open vent to the atmosphere and preventing spillage in
anchor these tanks to mounting brackets which are bolted case of overturn.
to the frame side member. The fuel pickup pipe is built integrally with the tank
On 1/2 and 3/4 ton conventional and 4-wheel drive gauge unit, located at the top of the tank in line with
models the tank is located to the rear of the axle and be­ safety recommendations. A large area, fine-mesh screen
tween the side rails and envelopes the forward edge of the located on the bottom of the fuel pickup pipe. This screen
spare tire. These tanks are supported by a single steel is designed to prevent the entrance of dirt or water into
strap which is held at either end by a hook into the side the fuel system, and operates with a self-cleaning action.
rail. Metal to metal contact between tank and brackets Frame mounted tanks consist of an upper and lower
or straps is prevented by the use of anti-squeak material. half, each with a wide flange and baffles which are
The Chevy Van Fuel Tank is 20 gallon capacity (ap­ pressed into the tank halves. The two tank sections are
proximate), with left hand side fill and is mounted between seam welded at the flange around the entire tank to a s­
the frame rails behind the rear axle. The tank is held in sure leakproof construction. Exceptional stiffness is
place by two metal straps attached individually to the secured by the combination of the welded flanges and de­
underbody at each end. The straps hinge at the forward pressed ribs in both upper and lower tank sections. Baf­
end and secure the tank at the rear with an adjustable bolt fle plates are incorporated to provide additional stiffness
and nut assembly (fig. 6 ). and to prevent the surging of gasoline within the tank.

SERVICE OPERATIONS
DRAINING THE TANK less, I.D. is not recommended as it is quite dif­
ficult to erect and maintain a siphon using this
The following procedure is <recommended for con- method with a larger hose.
•structing a siphon hose and draining the tank: 2. Insert a small nipple (at least 1/8" larger O.D. than
1. Obtain an 8 to 10 foot length of 3/8", or slightly less, the hose I.D.) into opposite end of hose from slit.
I.D. hose and cut a flap type slit 18" from one end. 3. Lift or jack rear of vehicle so that tank is at least
See Figure 1. one foot higher than normal.
4. Insert nipple end of hose into tank until it strikes
NOTE: Hose with larger than 3/8", or slightly bottom.

CHEVROLET TRUCK SERVICE M ANUAL

FUEL TANK AND EXHAUST SYSTEMS 8-2

GAUGE UNIT OR STRAINER

-*— FUEL FLO W Replacement

The following procedure is intended as a general guide
only and will vary according to truck series and model.
1. Drain tank to a level below gauge unit mounting loca­
tion or if unit is inaccessible remove fuel tank.
2. Disconnect fuel feed line and wiring from gauge unit.
3. Unlock gauge cam ring using Tool J-8950 and remove
gauge unit from tank.
NOTE: On some chassis mounted tanks, re ­
move gauge attaching screws and then disengage
unit from tank.
4. Replace or clean strainer with compressed air as
required.
5. Install gauge unit using reverse of removal
Fig . 1 - Siphon Construct-ion
procedure.

FUEL TANK
5. With the opposite end of the hose in a suitable con­ Removal and Installation—
tainer, insert an air hose into the flap type slit and Cab Mounted Tanks (Fig. 2)
trigger the flow of fuel. 1. Remove front seat and back cushions.

F ig . 2 - Cab Mounted Fuel Tank (E x c . T ilt)

CHEVROLET TRUCK SERVICE M ANUAL

 FUEL TANK AND EXHAUST SYSTEMS 8-3

Fig. 3 - Center Mounted Tank

2. Remove tank cover if so equipped. Removal and Installation—P Models and

3. Drain tank. 1 Ton Chassis (Frame) Mounted Tanks (Fig. 4)
4. Disconnect fuel line, meter wire and ground lead.
5. Remove nine bolts and fasteners securing tank to 1. Drain tank.
cab. 2. Remove filler neck.
6 . Remove tank from cab simultaneously disengaging 3. Disconnect gauge unit fuel line and wiring. Ignition
filler neck from the rubber grommet in the cab switch must be in OFF position.
opening. 4. Remove bolts attaching tank supports to frame.
7. Remove meter assembly from fuel tank using Tool 5. Remove tank complete with mounting brackets and
J-8950. support straps.
8 . To install reverse removal procedure. 6 . Remove tank from brackets and support straps, if
necessary.
Removal and Installation—!^ and % Ton Chassis 7. To install, reverse the removal procedure. Replace
(Center) Mounted Tanks (Fig. 3) all anti-squeak material.

1. Drain tank. Removal and Installation—1Vi, and 2 Ton Chassis

2. Unclamp filler neck and vent tube hose. (Frame) Mounted Tanks (Fig. 5)
3. Unclamp gauge unit hose at frame end.
4. Support tank and remove support strap. 1. Drain tank.
5. Lower tank until gauge unit wiring can be removed. 2. Disconnect filler neck hose connection at lower
6. Remove fuel tank. clamp.
7. Install in the reverse order, being sure that the anti­ 3. Disconnect fuel line and wiring from tank unit. Igni­
squeak material is replaced. tion switch must be in OFF position.

CHEVROLET TRUCK SERVICE MANUAL

FUEL TANK AND EXHAUST SYSTEMS 8-4

FILLER NECK ASSEM BLY-CHEVY VAN

Removal (Fig. 6)
1. Remove screws securing upper filler neck flange to
body panel.
2. Raise and support vehicle.
3. Loosen the screw clamps securing the filler neck and
vent hoses to the filler neck and the fuel tank.
4. Disconnect the filler neck and vent hoses from the
fuel tank and filler neck assem blies. Remove the
filler neck from the vehicle.

Installation

1. Position the filler neck to the body panel and connect

the filler neck and vent hoses to the filler neck and
tank assemblies.
2. Tighten the screw clamps securing the hoses to the
filler neck and tank assemblies.
3. Lower the vehicle and install the screws securing
the upper filler neck flange to the body panel.
4. Check alignment of the filler neck hose through the
frame rail opening and check all hose connections
for leaks.

NOTE: On models where top of tank is not

readily accessible, loosen tank support straps
enough to disconnect gauge wire on float unit.

5. Remove tank support straps and lower tank to floor.

6. To install, reverse the removal procedure. Replace
all anti-squeak material.

Removal and Instalation—Chevy Van (Fig. 6)

1. Drain fuel tank.

2. Raise and support vehicle.
3. Disconnect fuel pickup line and gauge wire from tank
unit.
4. Unclamp filler neck and vent tube hoses and discon­
nect hoses at tank.
5. Remove tank support straps, disconnect sending unit
wire and lower tank carefully.
6 . To install, reverse the removal procedure.

CHEVROLET TRUCK SERVICE MANUAL

 FUEL TANK AND EXHAUST SYSTEMS 8-5

Fig. 6 - Fuel Tank and F ille r N e c k Assembly - C h evy Van

FUEL LINE SERVICE FRAME MOUNTED FUEL FILTER

The fuel lines should be inspected occasionally for Frame mounted fuel filters are standard equipment on
leaks, kinks or dents. If evidence of dirt is found in the P20-30, T40 and C-M -S-T 50-60 series vehicles. The
carburetor, fuel pump or on a disassembly, the lines fuel filter element should be replaced at the recom­
should be disconnected and blown out. Check the fuel mended mileage intervals outlined in Section 0, this
strainer in the tank for damage or omission. manual. Typical installation is shown in Figures 7 and 8 .
All fuel lines are 5/16" diameter tubing except: L - 6
and 283 cu. in. engines equipped with an optional frame
FUEL LINE RETAINER CLIP
mounted fuel filter; 327 and 366 cu. in. V - 8 engines; and
all diesel engine models. Joints must be of the double-
Removal and Installation
lap flare type, constructed as shown in Section 5 of this
manual. If fuel pipes and retainer clips are removed, Tool
CAUTION: Always completely drain gasoline J-7777 should be used to install new retainer clips (fig.
from fuel tank and all fuel lines if vehicle is to 9). After removal of the old clip from the frame, posi­
be stored for any appreciable length of time. tion the new clip in the location of the old clip. Index the
This precaution will prevent gum formation and "blind rivet” and press hard (hand pressure should do) to
resultant improper engine performance. expand rivet.

CHEVROLET TRUCK SERVICE M ANUAL

FUEL TANK AND EXHAUST SYSTEMS 8-6

F ig . 7 - Fuel Lines and F ilte r - CD 50-60

CHEVROLET TRUCK SERVICE M ANUAL

 FUEL TANK AND EXHAUST SYSTEMS 8-7

VIEW B

Fig. 8 - Fuel Lines and Filte r Mounting CG 50-60, M A - M G 6 0

Fig. 9 - Installing Fuel Line Retainer

EXHAUST SYSTEM

COMPONENT PART REPLACEMENT

Truck exhaust systems vary according to series and correct replacement parts when servicing these
model designation. Series 10-30 trucks use a split-joint systems.
design system in which the exhaust pipe-to-muffler and
muffler-to-tailpipe connections are clamped together.
The series 40-60 models use basically a welded system When installing a new exhaust pipe, muffler or tailpipe,
in which all muffler and tailpipe connecting points are on any model, care should be taken to have the correct
welded. Regardless of which production system, all alignment and relationship of the components to each
service muffler, exhaust pipe and tailpipe unions are se ­ other. Particular care should be given to the installation
cured with clamps. of the exhaust pipe and crossover pipe assembly on V- 8
engine single exhaust systems. Incorrectly assembled
NOTE: Exhaust systems on vehicles equipped parts of the exhaust system are frequently the cause of
with A.I.R. assemblies incorporate special ma­ annoying noises and rattles due to improper clearances
terials, such as stainless steel and heavier or obstructions to the normal flow of gases. Leave all
gauge metals. These m aterials are necessary clamp bolts and muffler strapbolts loose until all parts
because of the increased heat generated by the are properly aligned and then tighten, working from front
burning of the exhaust gases. Always use the to rear.

CHEVROLET TRUCK SERVICE M ANUAL

FUEL TANK AND EXHAUST SYSTEMS 8-8

SPECIAL TOOLS

TAPER
I
TO 1 / 2 "

Fig . 10 - Special Tools

1. J-8950 Fuel Tank G auge Unit Spanner 2. J -7777 Fuel Line C lip Installer

CHEVROLET TRUCK SERVICE MANUAL

 SECTION 9
STEERING
CONTENTS OF THIS SECTION
Page
Standard Steering............................................................... 9-1
Power S teerin g.................................................................. 9-13
Special T o o ls ..................................................................... 9-19

STANDARD STEERING
INDEX
Page Page
General D e s c rip tio n ......................................................... 9-1 Intermediate Steering Shaft - Models with
Maintenance and A djustm ents.......................................... 9-1 Splined Slip Joint......................................................... ...9-5
L u b ricatio n ...................................................................... 9-1 Steering Gear - Except Chevy Van and P20-30 . . . . 9-5
Adjustments...................................................................... 9-1 Steering Gear - P20-30 ................................................ ...9-6
Steering G e a r ............................................................... 9-1 Steering Gear - Chevy V a n .......................................... ...9-6
Steering Gear High Point Centering Sector Shaft Oil Seal R ep lacem en t.............................. ...9-7
C-P10, C20-30 ......................................................... 9-2 Mast Jacket - Except Tilt Cab M o d els........................ ...9-7
Steering Wheel A lig n m e n t.......................................... 9-3 Mast Jacket - Tilt Cab M o d e ls .................................... ...9-10
Mast Jacket Lower Bearing A d ju stm en t.................. 9-3 Steering L in k a g e ............................................................... ...9-10
Shifter Tube A djustm ent............................................. 9-3 Tie R o d ........................................................................... ...9-10
Component Replacement and R e p a i r s .............................. 9-4 Relay Rod - C-P10, C20-30 .......................................... ...9-11
Steering W h e e l ............................................................... 9-4 Idler Arm - C-P10, C20-30 .......................................... ...9-11
Mast Jacket Upper B e a r i n g .......................................... 9-4 Pitman A r m ..................................................................... ...9-11
Steering Coupling............................................................ 9-4 Steering Connecting R o d ................................................ ...9-12
Flexible Joint T y p e ................................................... 9-4 Steering A r m s ............................................................... .. 9-12
Universal Joint T y p e ................................................... 9-5

GENERAL DESCRIPTION
The steering gear used on all truck models is of the transmitted to the tie rods through a relay rod connected
recirculating ball type and the service procedures are to the pitman arm on the left and an idler arm on the
basically the same for all units. right. All other models use a single adjustable tie rod,
Two types of steering linkages are used. C-P10 and connecting the left and right steering arms. Steering
C20-30 series units have an adjustable tie rod connected effort is relayed to the left steering arm, from the pit­
to the steering arm at each wheel. Steering effort is man arm, by a non-adjustable connecting rod.

MAINTENANCE AND ADJUSTMENTS

LUBRICATION in an attempt to correct such conditions as shimmy, loose
or hard steering and road shocks, a careful check should
The steering gear is filled at the factory with a water
resistant grease. Seasonal change of this lubricant is un­
necessary and the housing should not be drained. The
steering gear lubricant level should be checked every
36,000 miles. Whenever required, additions should be
made using a water resistant EP Chassis Lubricant.
If a filler plug is used on the steering gear, fill the
gear to the plug opening level. On models without a filler
plug, check and fill the steering gear as follows:
1. Remove lower and outboard cover retaining screws,
(fig. 1 ).
2. Insert filling device in lower screw hole.
3. Inject lubricant until it appears in the outboard screw
hole (forward hole on Chevy Van); gear is now filled
to correct level.
ADJUSTMENTS
Steering Gear
Before any adjustments are made to the steering gear Fig. 1—Steering G e a r C over Retaining Screws

CHEVROLET TRUCK SERVICE M ANUAL

STEERING 9-2

be made of front end alignment, shock absorbers, wheel

balance and tire pressure for possible cause.
Correct adjustment of steering gear is very important.
While there are but two adjustments to be made, the
following procedure must be followed step-by-step in the
order given.
1. On Chevy Van and 10, 20 and 30 series trucks, re­
move pitman arm nut and mark relation of pitman
arm position to sector shaft. Remove pitman arm.
Use Tool J-5504 for Chevy Van, J-6632 or J-5504
(fig. 2) for 10, 20 and 30 Series. On 40, 50 and 60
Series Trucks, remove steering connecting rod from
pitman arm.
2. Disconnect horn wire at mast jacket and remove
horn button cap from center of steering wheel.
3. Loosen the pitman shaft lash adjuster screw locknut
and turn the adjuster screw a few turns in a counter­
clockwise direction (fig. 3). This removes the load
imposed on the worn bearings by the close meshing
of rack and sector teeth. Turn steering wheel gently
in one direction until stopped by gear, then turn
wheel back exactly half way to center position. Fig. 3—Steering G e a r Adjustment Points (T y p ica l)

CAUTION: Do not turn steering wheel hard juster screw. F irst turn the steering wheel gently
against stops when steering relay rod is dis­ from one stop all the way to the other, carefully
connected as damage to ball guides may result. counting the total number of turns. Then turn wheel
4. Using an inch pound torque wrench and socket on back exactly half way, to center position. Turn lash
steering wheel nut, measure torque required to keep adjuster screw clockwise to take out all lash in gear
the wheel in motion. If torque does not lie within teeth, and tighten locknut. Check torque at steering
limits given in specifications section, worm bearing wheel, taking highest reading as wheel is turned
preload adjustment is necessary. through center position. See Specifications for prop­
5. To adjust worm bearings, loosen worm bearing ad­ er sector lash adjustment. Readjust if necessary to
juster locknut and turn worm bearing adjuster shown obtain proper torque.
in Figure 3 until there is no perceptible end play in NOTE: If maximum specification is exceeded,
worm. Check torque at steering wheel, readjusting turn lash adjuster screw counterclockwise, then
if necessary to obtain proper torque. Tighten lock- come up on adjustment by turning the adjuster in
nut and recheck torque. If the gear feels "lumpy” a clockwise motion.
after adjustment of worm bearings, there is probably
damage in the bearings due to severe impact or to 7. Tighten locknut then recheck torque as it must lie
improper adjustment and the gear must be disas­ between specified limits.
8 . On 10, 20 and 30 Series trucks reassemble pitman
sembled for replacement of damaged parts.
6 . After proper adjustment of worm is obtained, and all
arm to sector shaft, lining up marks made on dis­
mounting bolts securely tightened, adjust lash ad- assembly. Torque nut to specifications. On 40, 50
and 60 Series trucks assemble steering connecting
rod to pitman arm.
9. Install horn cap or ornament and connect horn wire
at chassis connector.

Steering Gear High Point Centering—C-P10, C20-30

TO O L—J-5504
1. Set front wheels in straight ahead position. This can
be checked by driving vehicle a short distance on a
flat surface to determine steering wheel position at
which vehicle follows a straight path.
2. With front wheels set straight ahead, check position
T O O L —J-6632 of mark on wormshaft designating steering gear high
point. This mark should be at the top side of the
shaft at 1 2 o'clock position and lined up with the
mark in the coupling lower clamp.
3. If gear has been moved off high point when setting
wheels in straight ahead position, loosen adjusting
sleeve clamps on both left and right hand tie rods,
then turn both sleeves an equal number of turns in
the same direction to bring gear back on high point.
Fig . 2—Removing Pitman Arm CAUTION: Turning the sleeves an unequal

CHEVROLET TRUCK SERVICE M ANUAL

 STEERING 9-3

DO N O T M ISA LIG N
M ORE THAN O N E
INCH FROM VERTICAL

Fig. 4 —Steering W h e e l Alignm ent Fig. 6-10-20-30 Lower Bearing Adjustment

number of turns or in different directions will from center (figs. 4 & 5), remove steering wheel and
disturb the toe-in setting of the wheels. reposition.
4. R e a d j u s t toe-in as outlined in Section 3 (if
necessary). Mast Jacket Lower Bearing Adjustment
1. Loosen clamp on steering shaft.
Steering Wheel Alignment 2. Adjust clamp to allow steering shaft end play indi­
NOTE: On C-P10-C20-30 series units check cated in specifications section.
steering gear for high point centering before NOTE: On 10, 20 and 30 Series trucks check
checking steering wheel alignment. distance from top edge of washer to lower edge
1. Set wheels in straight ahead position by driving of bearing (fig. 6 ).
vehicle a short distance. 3. Tighten clamp bolt.
2. Note steering wheel position. If off more than 1 inch
Shifter Tube Adjustment
3-Speed Transimission
1. Loosen adjusting ring attaching screws and clamp
bolt.
2. Rotate adjusting ring to give .005" end play between
adjusting ring and first and reverse shifter lever
(fig. 7).
3. Tighten attaching screws and clamp bolt.

Fig . 5 —Steering W heel Alignment F ig . 7 —Checking Adjusting Ring C learance

CHEVROLET TRUCK SERVICE MANUAL

STEERING 9-4

With Automatic Transmission mum to .060" maximum between the adjusting ring and
shift lever. Also, “ C ” type clamp is used in place of the
The correct end play for the shift tube is .020" mini- hose type at the adjusting ring.

COMPONENT REPLACEMENT AND REPAIRS

STEERING WHEEL MAST JACKET UPPER BEARING
Removal
Removal
1. Remove steering wheel as outlined in this section.
1. Disconnect directional signal switch harness from 2. Remove directional signal handle by removing at­
chassis wiring harness at connector. taching screw.
2. Mark steering wheel to steering shaft relationship 3. Remove hazard switch knob from right side of turn
and remove horn button, receiving cup, belleville signal housing.
spring and bushing. 4. Remove three directional signal switch attaching
3. Remove steering shaft nut and washer. screws.
4. Use Tool J-2927 to remove wheel (fig. 8 ). It may be 5. Guide directional wiring while pulling out directional
necessary to tap on the bolt head of the tool with a signal switch and bearing assembly.
hammer as it is turned down, to loosen tight steer­ 6 . Remove bearing.
ing wheels.
Installation
Installation 1. Replace all component parts in reverse order of re­
NOTE: Directional signal control assembly moval making sure that directional signal switch is
must be in neutral position when assembling in neutral position before installing steering wheel.
steering wheel to prevent damage to cancelling
cam and control assembly.
STEERING COUPLING
1. With front wheels in the straight ahead position Flexible Type (Fig. 9)
place steering wheel on steering shaft and align.
NOTE: Before removing the steering coupling,
2. Tap wheel gently into place and secure with washer
and nut. either the steering gear must be lowered from
its proper position or the steering gear shaft
3. Install belleville spring, receiving cup, bushings and
must be loosened and pulled upward far enough
attaching screws.
to permit the coupling to be removed from the
4. Install horn button.
wormshaft.
5. Connect directional signal switch wiring harness to
chassis wiring harness. Removal
1. After marking wormshaft to steering shaft relation­
ship remove bolt from coupling clamp.

Fig . 8 —Steering W heel Removal Fig . 9 —F le xib le Type Steering Coupling

CHEVROLET TRUCK SERVICE M ANUAL

 STEERING 9-5

NOTE: This is a special bolt and will require steering gear wormshaft.
a 12 pt. socket or box wrench. 2. On tilt cab models, remove plate-to-floor panel
2. Tap with a soft mallet to remove coupling from screws.
wormshaft. The coupling is splined to the steering 3. From the upper yoke of the universal joint, remove
wormshaft. the two snap rings, then remove the two yoke bush­
3. Remove the two retaining nuts, bolts, reinforce­ ings and cork washers, by tapping yoke shaft with
ments, and lock washers. Separate the lower "sp lit- plastic mallet.
clamp” and, remove the wafer type coupling and 4. Move the center cross as necessary, to separate the
two locking pins. upper and lower portions of the coupling.
5. Remove the coupling from the vehicle.
6 . Disassemble lower portion of coupling on bench, by
Installation
repeating Steps 3 and 4.
1. If disassembled, first set the flexible coupling in
place, then match up the large locking pin with the Installation
large slot in the flange. Be sure pins are centered
in flange slots. Install and tighten the attaching 1. Position center cross in lower yoke of coupling.
bolts, nuts, washers and retainers. Torque to 20 2. Position bushing and new cork washer on center
ft. lb. cross. Install retaining snap ring.
2. Align the "sp lit-clam p '’ to the steering gear worm 3. Place a second bushing and new cork washer on
shaft and install the coupling. center cross and retain with snap ring.
3. Install the special bolt into the clamp and tighten. 4. With cross installed in lower yoke, install coupling
in vehicle by assembling lower yoke to upper yoke as
Universal Joint Type (Fig. 10) outlined in Steps 2 and 3.
5. Assemble coupling to steering gear wormshaft align­
NOTE: Some models use an intermediate shaft ing mark on wormshaft with mark on steering shaft.
with a splined slip joint. On these models, 6 . Install clamp bolt nut and washer and tighten.
lowering the steering gear or steering column 7. On tilt cab models secure floor pan seal plate to
is not necessary. Separate the upper coupling floor pan.
as described below, remove intermediate shaft
and coupling and disassemble lower coupling on Intermediate Steering Shaft Models with Splined
bench.
Slip Joint (Fig. 10)
Removal Removal and Installation
1. After making steering shaft to worm shaft relation­ Remove and install as outlined under "Steering
ship remove bolt, nut and washer from clamp on Coupling—Universal Joint Type".
Disassembly
1. With shaft on bench straighten tangs on dust cap and
slide yoke shaft out of yoke tube.
2. Remove felt washer dust cap and plastic washer.
Discard felt washer.
3. On Tilt Cab models, remove toe panel seal and seal
plate from shaft.

Assembly
1. On tilt cab models, install toe panel seal and seal
plate on yoke shaft.
2. Position dust cap, plastic washer, and new felt
washer on yoke shaft.
3. Aligning the arrow on the yoke shaft with the arrow
on the yoke tube, insert yoke shaft into yoke tube.
4. Push plastic washer, felt washer and dust cap into
position, on end of yoke tube, and bend tangs of dust
cap down against yoke tube.

STEERING GEAR-EXCEPT CHEVY VAN AND

P20-30
Removal
1. Set wheels in straight ahead position. Mark steer­
ing shaft to worm shaft relationship and loosen bolt
attaching lower end of shaft coupling to steering gear.
2. Disconnect pitman arm from steering gear. Use
Fig. 10— Universal Jo in t Type Steering Couplings and Tool J-6632 on light-duty models and Tool J-3186 on
Interm ediate Steering Shaft S lip Jo in t medium and heavy-duty models.

CHEVROLET TRUCK SERVICE M ANUAL

STEERING 9-6

6 . Remove mast jacket to dash panel support.

7. Lift steering gear and mast jacket assembly out of
vehicle and place on bench.
8 . After marking mast jacket to steering gear rela­
tionship, loosen mast jacket to steering gear clamp
and slide mast jacket off steering shaft.

Installation
1. With steering gear fully assembled, slip mast jacket
over steering shaft and secure with clamp.
2. From inside the vehicle, position steering gear on
frame rail and loosely assemble mast jacket to dash
panel clamp.
3. Install steering gear to frame rail mounting bolts
and tighten.
4. Install pitman arm to sector shaft and tighten nut to
specifications.
5. Tighten mast jacket to dash panel support bolts.
6 . Install floor panel at mast jacket.
7. Locate and secure mast jacket to floor pan seal.
8 . Install steering wheel.

STEERING GEAR-CHEVY VAN (Fig. 12-13)

Removal
Because the steering gear is cradle mounted in the
frame rail, the steering gear must be removed from in­
side the vehicle as follows:

3. Remove all steering gear to frame mounting bolts

and remove gear from vehicle.

Installation
1. When reinstalling steering gear assembly after re ­
placement of worm shaft, determine the correct mid­
position of the worm shaft as follows:
a. Turn the shaft all the way through its travel,
counting the number of turns.
b. Turn the shaft back one-half the total number of
turns. The gear should now be on high point.
NOTE: On production C-P10-C 20-30 Series
worm shafts, this mark will coincide with the
mark already on the shaft.
2. Position steering gear in place on frame, at the
same time sliding the worm shaft into the flexible or
universal joint coupling. Check that the steering
wheel is in the straight ahead position.
3. Attach and tighten mounting bolts and tighten bolt at
the coupling or universal joint.
4. Install pitman arm.

STEERING GEAR—P20-30 (Fig. 11)

Removal
1. Remove steering wheel.
2. Loosen and pull mast jacket seal away from floor
pan.
3. Remove floor pan from around mast jacket.
4. Remove pitman arm from steering gear.
5. Remove steering gear to frame mounting bolts.

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 STEERING 9-7

Fig. 13—C h evy Van Steering G e a r Mounting

1. Remove steering wheel as outlined under Steering

Wheel—Removal. Fig. 14— Installing Sector Shaft O il Seal
2. Place vehicle on suitable jackstand or hoist. Remove
deflector and extension assembly and, using Tool SECTOR SHAFT OIL SEAL REPLACEMENT
J-5 5 0 4 , disconnect pitman arm (with drag link
1. Remove pitman arm from sector shaft.
attached) from sector shaft after marking position of
2. Pry out old seal.
pitman arm on sector shaft.
3. Using Tool J-9225 install new seal (fig. 14).
3. Disconnect brake pedal from lower brake pedal
4. Install pitman arm and torque nut or clamping bolt to
assembly. specifications.
4. Disconnect transmission shift linkage from levers.
5. Remove bolts retaining gear to frame rail. MAST JACKET-EXCEPT TILT CAB MODELS
6 . From inside vehicle remove the brake pedal pre­
viously disconnected. NOTE: For Chevy Van and P20-30 mast jacket
7. Pull back floor mat as required and disconnect toe removal, disassembly, assembly and installa­
pan seal and remove toe pan cover. tion, s e e S t e e r i n g G e a r —Removal and
8 . Remove mast jacket bracket from support and re­ Installation.
move steering gear, mast jacket, and transmission Removal (Figs. 15-16)
controls as an assembly from vehicle and place on
bench. 1. Remove clamp bolt from steering coupling at steer­
9. Remove transmission lever housing from steering ing gear.
gear mounting pad and loosen mast jacket after not­ 2. On 3 -speed and automatic transmission models, re­
ing mast jacket to steering shaft relationship. move shifter rods.
10. Remove mast jacket from steering gear shaft. 3. On light-duty models, loosen clamp on engine side of
firewall and slide clamp down on mast jacket. From
inside cab, on medium and heavy-duty models, re­
Installation move screws from cover at firewall opening and
pull cover and seal away from firewall. On models
1. With steering gear fully assembled, slip mast jacket with parking brake cable routed through seal dis­
over steering shaft and attach mast jacket clamp connect cable at handle.
and transmission lever housing to steering gear. 4. Remove steering wheel, as outlined under Steering
2. Position steering gear in frame rail and attach mast Wheel—Removal, and reinstall nut and washer on
jacket bracket to support, leaving bolts loose. steering shaft.
3. Insert steering gear retaining bolts from left hand 5. Disconnect wiring from connectors at steering
side and install lock washers and nuts finger tight. column.
4. Attach transmission shift linkage to levers. 6 . On 10, 20, and 30 series remove dash panel trim
5. Install toe pan cover and seal. Insert brake pedal plate, parking brake lever and support assembly.
through cover opening, install seal and spacer and 7. Remove cap screws from mast jacket support clamp
attach to lower brake pedal assembly. Line up in­ at dash panel.
dexing marks. Torque to 40 ft. lbs.
8 . Carefully lower mast jacket and withdraw assembly,
6 . Tighten support bracket bolts.
rotating so shift levers clear opening in firewall.
7. Torque steering gear attaching nuts.
8 . Install pitman arm to sector shaft and tighten nut.
Installation (Figs. 15-16)
9. Install deflector and extension assembly.
10. Install steering wheel as outlined in this section. 1. From passenger side of firewall, carefully insert

CHEVROLET TRUCK SERVICE M ANUAL

STEERING 9-8

Fig. 15— Light Duty Mast Ja c k e t Mounting

lower end of mast jacket through opening in firewall, Fig. 16—Medium and H eavy Duty Mast Ja c k e t
guiding the steering coupling onto the steering gear Mounting (T y p ica l)
wormshaft.
2. Loosely install mast jacket support clamp at dash 6 . Install seal at firewall and reconnect parking brake
panel and, on light-duty models, at firewall. cable if necessary.
3. Adjust position of mast jacket and tighten clamps at 7. Adjust lower mast jacket bearing as outlined under
steering gear and mast jacket supports. Maintenance and Adjustments.
4. On 3-speed and automatic transmission models, con­ 8 . Connect wiring.
nect transmission shift linkage.
Disassembly—10-20-30 Series (Fig. 17)
5. On 10, 20, and 30 series trucks install parking brake
support and lever assembly, and trim plate at dash NOTE: For units without shifter tube, omit
panel. Steps 1, 8, 9, 10 and 11.

Fig . 17—3-Speed Mast Ja ck e t and Shifter Tube

CHEVROLET TRUCK SERVICE M ANUAL

 STEERING 9-9

1. Slide rubber grommet back from shift lever support 3. Place felt seal on shifter tube. Push in place up to
housing, drive out selector lever pivot pin and re­ spring.
move shift lever. 4. Insert shifter tube into mast jacket.
2. Remove steering wheel retaining nut and washer 5. On 3-speed models;
from shaft. Temporarily install spacer, low and reverse shifter
3. Slide steering shaft from mast jacket and remove lever and lower adjusting ring. Place a block of
back-up lamp switch. wood on top of adjusting ring and tap until shifter
4. Remove three locking screws from the directional tube bottoms. Remove spacer, low and reverse shift
signal housing, rotate the housing and remove hous­ lever and adjusting ring.
ing assembly.
5. Remove spacer and thrust washer from shifter lever NOTE: Bearing must be seated against the
housing and remove housing. three locating tabs.
6 . Remove bushing and bushing seat from upper end of
mast jacket. On automatic transmission models;
7. Remove bolt and screws from adjusting ring clamp at Align three holes in selector (detent) plate with
lower end of mast jacket and remove clamp lower three holes in bottom of mast jacket. Position
bearing and adjusting ring. clamping ring, align holes and install the three bolts.
8 . On 3-speed models, also remove first and reverse 6 . On 3-speed models;
shift lever and spacer. Lubricate and install spacer, low and reverse shifter
9. On automatic transmission models, remove 3 screws lever (tang on lever must be towards top of mast
from selector plate clamping ring. jacket).
10. Place mast jacket upright on floor while supporting 7. Install lower adjusting ring with clamp and attaching
with two pieces of wood. Push down on shift lever screws.
with foot and place block of wood on upper end of 8 . Position bushing seat and bushing on upper end of
tube. Tap on block to remove tube and withdraw from mast jacket.
mast jacket assembly. 9. Lubriplate inner diameter of shifter lever support
housing and install on upper end of mast jacket
NOTE: In some tolerance stack-up cases it
assembly, fitting keyway in housing over key on
may be necessary to use a press. Be careful not shifter tube.
to damage shifter tube or mast jacket. 10. Position spacer and thrust washer onto upper end of
11. Remove felt seal from shifter tube. shifter housing.
12. Remove firewall clamp and seal and dash panel seal 11. Install directional signal switch and housing assem­
from mast jacket. bly, feeding wires through gear shift lever support
housing. Secure with three attaching screws.
Assembly (Fig. 17) 12. Adjust shifter tube as outlined under Shifter Tube
Adjustment.
NOTE: For units without shifter tube omit
13. Position clamp, washer, spring and lower mast
Steps 3, 4, 5, 6 , and 12.
jacket bearing on steering shaft, and insert shaft
1. Install dash panel seal, firewall seal and clamp onto into mast jacket from bottom.
mast jacket. 14. Install nut and washer on steering wheel end of
2. Lubricate all bearing surfaces on shift tube. steering shaft to hold the shaft in position.

F ig . 18—Medium and Heavy Duty Mast Ja ck e t Components

CHEVROLET TRUCK SERVICE M ANUAL

STEERING 9-10

MAST JACKET—TILT CAB MODELS (Fig. 19)

Removal
1. Bend tabs of dust cap away from yoke tube, on inter­
mediate steering shaft yoke tube.
2. Slide dust cap, plastic washer and felt washer down
on yoke shaft.
3. Disconnect wiring harness from mast jacket.
4. Remove mast jacket support clamps.
5. Remove mast jacket assembly from vehicle.
6 . If necessary, remove steering wheel.

NOTE: Disassembly and assembly procedures

for the tilt cab mast jacket are the same as
those outlined previously for 40-50 and 60
series.

Installation
1. With mast jacket completely assembled and inter­
mediate steering shaft yoke tube assembled to upper
steering shaft, place assembly in vehicle and assem­
ble intermediate shaft yoke tube to yoke shaft align­
ing the arrows.
2. Hold mast jacket in position at dash panel and
assemble support clamps.
3. Push felt washer, plastic washer and dust cap into
position and secure by bending tabs of dust cap
against yoke tube.
4. Connect wiring harness to mast jacket.

STEERING LINKAGE (Figs. 20-21-22)

TIE ROD
Removal
1. Remove cotter pins from ball studs and remove cas­
tellated nuts.
2. To remove outer ball stud, tap on steering arm at
Disassembly—40-50-60 Series (Fig. 18)
tie rod end with a hammer while using a heavy ham­
1. Loosen lower bearing clamp, push steering shaft mer or sim ilar tool as a backing (fig. 23). If neces­
slightly upward and remove snap ring retainer at sary pull downward on tie rod to remove from
upper mast jacket bearing. steering arm.
2. Slide steering shaft out of mast jacket from bottom, On C-P10 and C20-30 series, remove inner ball
along with lower bearing clamp, seal spring and stud from relay rod using same procedure as des­
bearing seat. cribed in Step 2.
3. Loosen turn signal switch retaining screws and re­ To remove tie rod ends from tie rod loosen clamp
move turn signal housing and switch assembly. bolts and unscrew end assemblies.

Installation
Assembly (Fig. 18) 1. If the tie rod ends were removed, lubricate the tie
1. Install turn signal switch and housing assembly on rod threads with EP Chassis lube and install ends on
upper end of mast jacket. tie rod making sure both ends are threaded an equal
2. Position clamp, seal, spring, lower bearing and distance from the tie rod.
lower bearing on steering shaft. 2. Make sure that threads on ball studs and in ball stud
nuts are perfectly clean and smooth. Install neoprene
NOTE: Lubricate seal with a silicone grease. seals on ball studs.
3. Carefully insert steering shaft into mast jacket from
bottom. NOTE: If threads are not clean and smooth,
4. Install upper mast jacket bearing retainer (snap ring) ball studs may turn in tie rod ends when
in groove in steering shaft. attempting to tighten nut.
5. Adjust lower mast jacket bearing as outlined under
Maintenance and Adjustments. 3. Install ball studs in steering arms and relay rod.

CHEVROLET TRUCK SERVICE M ANUAL

I
 STEERING 9-11

Fig. 20—C10-20-30 Steering Linkage

4. Install ball stud nut, tighten and install cotter pins. Fig. 22— K10-20 Steering Linkage
Lubricate tie rod ends.
5. Adjust toe-in as described in Section 3. 3. Detach relay rod from pitman arm. Shift steering
linkage as required to free pitman arm from relay
NOTE: Before locking clamp bolts on the rods, rod.
make sure that the tie rod ends are in align­ 4. Remove cotter pin and nut from idler arm and re­
ment with their ball studs (each ball joint is in move relay rod from idler arm.
the center of its travel). If the tie rod is not in Installation
alignment with the studs, binding will result.
Also, the slit in the tie rod must be in alignment 1. Install relay rod to idler arm, making certain idler
with the slot in the clamp and, on C-P10 and stud seal is in place, then install and tighten nut to
C20-30 series, facing foreward. specifications. Advance nut just enough to align
castellation with cotter pin hole and install pin.
RELAY ROD—C-Pl 0 and C20-30 2. Raise end of rod and install on pitman arm. Secure
Removal with nut and cotter pin.
1. Remove inner ends of tie rods from relay rod as 3. Install tie rod ends to relay rod as previously de­
described under Tie Rod - Removal. scribed under Tie Rods. Lubricate tie rod ends.
2. Remove cotter pin and nut from relay rod ball stud 4. Adjust toe-in (see Section 3) and align steering wheel
attachment at pitman arm. as described previously in this section under Steer­
ing Wheel Alignment and High Point Centering.

IDLER ARM—C-Pl 0r C20-30

Removal
1. Remove cotter pin and nut from end of idler arm
and remove relay rod from idler arm.
2. Remove idler arm from frame.

Installation
1. Position idler arm on frame and install mounting
bolts (with special plain washers under heads); tight­
ening nuts to specifications.
2. Install relay rod to idler arm, making certain seal is
on stud, and install and tighten nut to specifications.
3. Install cotter pin and secure.
PITMAN ARM
Removal
1. Remove cotter pin from pitman arm ball stud and
remove nut.
2. Remove relay rod from ball stud by tapping on side
of rod or arm in which the stud mounts with a ham­
Fig . 2 1 - 4 0 -5 0 -6 0 Series Steering Linkage - Typ ical mer while using a heavy hammer or similar tool as

CHEVROLET TRUCK SERVICE M ANUAL

STEERING 9-12

NOTE: On Chevy Van, the pitman arm must be

removed from the steering gear because of in­
sufficient clearance between the forward ball
stud and the frame rail.
Installation
1. Make sure that threads on ball studs and in ball stud
nuts are clean and smooth. Install neoprene seals on
ball studs.
NOTE: If threads are not clean and smooth,
ball studs may turn in connecting rod when
attempting to tighten nut.
2. Install ball studs in steering arm and pitman arm.
3. Install ball stud nuts and torque to specifications.
Continue to tighten nuts enough to align castellations
with holes in studs.
4. Install cotter pins and lubricate.

STEERING ARMS
If, through collision or other damage, it becomes nec­
essary to remove and replace either steering arm,
proceed as follows:
Rem oval
Fig. 23—B a ll Stud Removal - Typical
1. Remove tie rod and, on models so equipped, steering
connecting rod, from steering arm as outlined in
a backing (fig. 23). Pull on linkage to remove from
this section.
stud.
2. Remove front wheel, hub and brake drum as a unit by
3. Remove pitman arm nut from sector shaft or clamp
removing hub cap and dust cap, cotter pin from spin­
bolt from pitman arm, and mark relation of arm
dle nut and the spindle nut. Pull assembly toward
position to shaft.
outside of vehicle. If removal is difficult, it may be
4. Remove pitman arm, using Tool J-5504 for Chevy
necessary to back off brake adjustment to increase
Van, J-6632 or J-5504 for 10-20-30 Series, and
brake shoe-to-drum clearance; see Hydraulic Brake
J-3186 for 40-50-60 Series.
Adjustment, Sec. 5.
Installation 3. With wheel and drum assembly removed, steering
arm retaining bolt heads are accessible and removal
1. Install pitman arm on sector shaft, lining up the
of steering arm from vehicle may be accomplished
marks made upon removal.
by removing retaining nuts.
NOTE: If a clamp type pitman arm is used,
spread the pitman arm just enough, with a wedge, Installation
to slip arm on to sector shaft. Do not spread 1. Place steering arm in position on vehicle and install
pitman arm excessively or damage to arm will
retaining bolts. Note that longer bolt is installed in
result. Do not hammer or damage to steering
forward hole.
gear will result.
2. Install nuts and torque to specifications. Use only
2. Install sector shaft nut or pitman arm clamp bolt and the special locknut listed for this use in the
torque to specifications. Chevrolet Parts Catalog.
3. Position ball stud on to pitman arm. Install nut and 3. Pack wheel bearings using a high quality wheel
torque to specifications. Continue to tighten nut bearing lubricant. Install bearings and wheel-hub-
enough to align castellation with hole in stud and in­ brake drum assembly removed previously.
stall cotter pin. 4. Install keyed washer and spindle nut. Proceed as
outlined under “ Front Wheel Bearings - Adjust’ ’ in
STEERJNG CONNECTING ROD Section 3.
5. Install tie rod ball stud and if used, steering con­
Removal
necting rod ball stud, in steering arm. Be sure that
1. Remove cotter pins from ball studs and remove cas­ the dust cover is in place on ball stud.
tellated nuts. 6 . Install castellated nut on ball stud, tighten to speci­
2. Remove ball studs from steering arm and pitman fications and install cotter pin.
arm by backing up steering arm boss and/or pitman 7. Following directions given in Section 3 to check cor­
arm boss with a heavy hammer and striking other nering wheel relationship and toe-in; correct as
side of boss with lighter hammer (fig. 23). required.

CHEVROLET TRUCK SERVICE MANUAL

 STEERING 9-13

POWER STEERING
INDEX
Page Page

General D e s c r ip tio n ......................................................... 9-13 Component Replacement and R e p a i r s .............................. ... 9 - 1 5

Maintenance and A djustm en ts.......................................... 9-13 Power Steering P u m p ................................................... ... 9-15
Power Steering Gear A djustm en t................................. 9-13 Control Valve - C -K 1 0 -2 0 -C 3 0 .................................... ... 9-15
Bleeding Hydraulic S y s t e m .......................................... 9-13 Power Steering Gear and Control Valve -
Fluid L e v e l ..................................................................... 9-14 40-50-60 s e rie s ............................................................ ...9-16
Pump Belt Tension......................................................... 9-14 Power C ylin der............................................................... ... 9-16
Hydraulic System C h e c k s ............................................. 9-14 Power Steering H o s e s ................................................... ... 9-17

GENERAL DESCRIPTION
All truck power steering installations consist of three The power cylinders used differ in capacity and mount­
basic components, pump, control valve and power cyl­ ing. C10-20-30 series have the cylinder mounted between
inder, connected by hydraulic lines. The pump is a vane the frame and relay rod. The mounting for units equipped
type with the mounting to the engine peculiar to the par­ with 9000 lb. front axle is between the frame and pitman
ticular model and engine application involved. arm. Axle-to-tie rod mounting is used on all other
Two types of control valves are used, light-duty models models.
use the linkage type mounted between the pitman arm and Some medium and heavy-duty models use a power
relay rod or steering connecting rod. Medium and heavy- steering oil cooler mounted at the front of the vehicle.
duty models use a rotary valve type, mounted on the
steering gear box between the steering shaft and worm
shaft.

MAINTENANCE AND ADJUSTMENTS

POWER STEERING GEAR ADJUSTMENT BLEEDING HYDRAULIC SYSTEM
C-K10, 20 and C30 Series
1. Fill oil reservoir to proper level and let oil remain
The steering gear used with power steering is adjusted undisturbed for at least two minutes.
in the same manner as the manual steering gear. 2. Start engine and run only for about two seconds.
3. Add oil if necessary.
4. Repeat above procedure until oil level remains con­
40, 50 and 60 Series (Fig. 24)
stant after running engine.
Sector lash adjustment is the only power steering gear 5. Raise front end of vehicle so that wheels are off the
adjustment that can be made on the vehicle. However, in ground.
order to make this adjustment, it is also necessary to 6 . Increase engine speed to approximately 1500 rpm.
check the combined valve drag and worm bearing preload. 7. Turn the wheels (off ground) right and left, lightly
1. Remove steering connecting rod from pitman arm. contacting the wheel stops.
2. Loosen sector lash adjusting screw lock nut and back
off adjusting screw to the limit of its travel.
3. Disconnect horn wire and remove horn button cap.
4. Turn the steering wheel through its full travel, then
locate wheel at center of its travel.
5. Check combined valve drag and worm bearing pre­
load, with an inch-pound torque wrench on the steer­
ing shaft nut, by rotating through the center of travel
(approximately 10° in each direction). Note the
highest reading.
6 . Tighten the sector lash adjusting screw until torque
at steering wheel nut falls within specifications.
NOTE: If maximum specification is exceeded,
turn lash adjuster screw counterclockwise, then
come up on adjustment by turning adjuster in a
clockwise direction.
7. Tighten locknut and recheck pull as it must lie within
specifications. Fig. 24-40-50-60 Series Power Steering G e a r and
8 . Reassemble steering connecting rod to pitman arm. Control V a lv e (T y p ica l)

CHEVROLET TRUCK SERVICE M ANUAL

STEERING 9-14

Fig. 26—Tool J-5176 Installed

PUMP BELT TENSION

1. Loosen nut on pivot bolt and pump brace adjusting
nut.
CAUTION: Do not move pump by prying against
reservoir or by pulling on filler neck^
Fig. 25—Checking Belt Tension w ith Tool J —7316
2. Move pump, with belt in place until belt is tensioned
8 . Add oil if necessary.
to specifications as indicated by Tool J-7316 (fig. 25).
9. Lower the vehicle and turn wheels right and left on
3. Tighten pump brace adjusting nut. Then tighten pivot
the ground.
bolt nut.
10. Check oil level and refill as required.
11. If oil is extremely foamy, allow vehicle to stand a HYDRAULIC SYSTEM CHECKS
few minutes with engine off and repeat above
procedure. The following procedure outlines methods to identify
a. Check belt tightness and check for a bent or loose and isolate power steering hydraulic circuit difficulties.
pulley. (Pulley should not wobble with engine This test is divided into two parts. Test number one pro­
running.) vides means of determining whether power steering sys­
tem hydraulic parts are actually faulty. If test number
b. Check to make sure hoses are not touching any
other parts of the car, particularly sheet metal. one results in readings indicating faulty hydraulic opera-
c. Check oil level, filling to proper level if neces­ ation,test number two will identify the faulty part. Before
performing hydraulic circuit test, carefully check belt
sary, following operations 1 through 10. This step
tension and condition of driving pulley.
and Step “ D” are extremely important as low oil
level and/or air in the oil are the most frequent Test Number One—Oil Circuit Open
causes of objectionable pump noise. Engine must be at normal operating temperature. In­
d. Check the presence of air in the oil. Air will show flate front tires to correct pressure. All tests are made
up as a milky appearing oil. If air is present, with engine idling, so adjust engine idle speed to correct
attempt to bleed system as described in opera­ specifications listed in Section 6 and proceed as follows:
tions 1 through 10. If it becomes obvious that the a. With engine not running, disconnect flexible pres­
pump will not bleed after a few trials, proceed as sure line from pump and install Tool J-5176 as
outlined under Hydraulic System Checks. shown in Figure 26. Gauge must be between shut-
off valve and pump. Shut-off valve must be open.
FLUID LEVEL b. Remove filler cap from pump reservoir and check
1. Check oil level in the reservoir by checking the dip fluid level. Fill pump reservoir to full mark on
stick when oil is at operating temperature. On dip stick. Start engine and, holding steering wheel
models equipped with remote reservoir, the oil level against stop, check connections at Tool J-5176 for
should be maintained approximately 1 / 2 to 1 inch leakage. Bleed system as outlined under Mainte­
from top with wheels in full left turn position, unless nance and Adjustments. Insert thermometer (Tool
a side mounted power cylinder is used. On these J-5421) in reservoir filler opening (fig. 27). Move
models, check with wheels in full right turn position. steering wheel from stop to stop several times
2. Fill, if necessary, to proper level with G M Power
until thermometer indicates that hydraulic fluid
Steering Fluid or, if this is not available, automatic in reservoir has reached temperature of 150° to
transmission fluid “ Type A” bearing the mark 170°.
“ AQ-ATF” followed by a number and the suffix CAUTION: To prevent scrubbing flat spots on
letter “ A ” . tires, do not turn steering wheel more than five

CHEVROLET TRUCK SERVICE MANUAL

 STEERING 9-15

tim es without rolling car to change tire-to-floor

contact area.
c. Hold steering wheel against a stop momentarily
and read pressure gauge. If the maximum pres­
sure is below specifications, a faulty hydraulic
circuit is indicated. To determine which part is
faulty, proceed with test number two.

Test Number Two—Oil Circuit Closed

a. Slowly turn shut-off valve on J-5176 to closed
position and read pressure indicated on gauge.
Quickly reopen valve to avoid pump damage. If
indicated pressure is less than specification,
pump output is below requirement and pump may
be considered faulty. If pressure indicated is
within specifications, it may be safely assumed
that the external hoses, connections, valve and
adapter or steering gear is at fault.

NOTE: If pump proves faulty in test number

two, test should be repeated after pump is re­
paired and installed in vehicle. This will provide
a means of checking the repairs made to the
pump and the condition of the steering gear or
valve and adapter which may also be faulty.

Fig. 27—Checking Fluid Temperature

COMPONENT REPLACEMENT AND REPAIRS

POWER STEERING PUMP 6 . Remove drive pulley attaching nut.
Removal 7. Remove pulley from shaft. Do not hammer pulley off
1. Disconnect hoses at pump. When hoses are discon­ shaft as this will damage pump. Use Tool J - 2 1 239-1
nected, secure ends in raised position to prevent for pulling stamped pulleys or Tool J-8433-1 with
drainage of oil. Cap or tape the ends of the hoses to Adapter J-8433-2 for cast pulleys.
prevent entrance of dirt.
2. Install two caps at pump fittings to prevent drainage Installation
of oil from pump. 1. Install pump pulley.
3. Loosen bracket-to-pump mounting nuts.
4. Remove pump belt. CAUTION: Do not hammer on pump shaft. Use
5. Remove bracket-to-pump bolts and remove pump pulley nut to pull pulley onto shaft.
from vehicle. 2. Position pump assembly on vehicle and install
attaching parts loosely.
3. Connect and tighten hose fitting.
4. Fill reservoir. Bleed pump by turning pulley back­
ward (counterclockwise as viewed from front) until
air bubbles cease to appear.
5. Install pump belt over pulley.
6 . Tension belt as outlined under "Pump Belt Tension—
Adjustment" in this section.
7. B l e e d as o u t l i n e d under’TMaintenance and
Adjustments. ”

CONTROL V A LV E -C -K 10-20, C30 (Figs. 28-29)

Removal
1. Raise the front of the vehicle off the floor and place
on stands.
2. Remove the relay rod or connecting rod to control
valve clamp bolt.
3. Disconnect the two pump to control valve hose con­
nections and allow fluid to drain into a container,
Fig. 28—C l 0-20-30 Control V a lv e and Power then disconnect the two remaining valve to power
C ylin d er Installed cylinder hoses.

CHEVROLET TRUCK SERVICE M ANUAL

I
STEERING 9-16

Fig . 29— K10-20 Control V a lv e

4. Remove the retaining nut from the ball stud to pit­ Fig . 30—Side Mounted P .S . C y lin d e r
man arm connection and disconnect the control valve
from the pitman arm.
5. Turn the pitman arm to the right clear of the control
Cl0-20-30Series
a. Remove cotter pin, nut, retainer and grommet
valve and unscrew the control valve from the relay from power cylinder rod attached to the frame
rod on conventional models or from steering con­ bracket. Also remove grommet and retainer
necting rod on 4 -wheel drive models. from bracket if replacement parts are required.
6 . Remove the control valve from the vehicle. b. Remove cotter pin, nut and ball stud at relay rod.

F4r0o-n5t0A
-6x0
lesS)eries(Except9,000lb.and11,000lb.
Installation
1. Install the control valve on the vehicle by reversing
the removal procedure.
2. Reconnect the hydraulic lines, fill the system with a. Loosen dust covers from ball joints at each end of
fluid and bleed out air using the procedure outlined cylinder.
under "Maintenance and Adjustments” . Grease ball b. On each end of power cylinder remove the cotter
joint. pin locking the adjusting screw in position and
back out adjusting screw far enough to pull cyl­
inder off ball stud.
POWER STEERING GEAR AND CONTROL V A LV E -
40, 50 and 60 Series (Fig. 24) K10-20Series
Removal a. Remove cotter pin, nut, retainer and grommet
1. Mark steering shaft to control valve stub shaft re­ from power cylinder rod attached to tie rod.
lationship and disconnect the steering shaft from the b. Remove cotter pin, nut and ball stud at relay rod.
lower coupling.
2. Remove hoses from valve.
3. Remove pitman arm bolt, nut, washer and pitman
60 Serieswith9,000lb.or11,000lb.FrontAxles(Fig.30)
arm. a. At frame attachment, loosen dust cover, remove
4. Remove mounting bolts and steering gear. cotter pin locking the adjusting screw in position
and back out adjusting screw sufficiently to pull
Installation cylinder off ball stud.
1. Install power steering gear on vehicle by reversing b. Remove cotter pin, nut and ball stud at pitman
removal procedure. arm.
2. Check steering gear for proper lubricant level.
2. Remove power cylinder from vehicle.
3. Fill power steering system with fluid and bleed out
air using the procedure outlined under "Maintenance
Installation
and Adjustments” .
1. Install the power cylinder on the vehicle by reversing
removal procedures.
POWER CYLINDER NOTE: When installing power cylinders incor­
Removal porating an adjusting screw at the ball stud at­
1. Disconnect the two hydraulic lines connected to the tachment, tighten screw, with ball stud in place
power cylinder and drain fluid into a container. until it bottoms, then back off to nearest hole
Do not reuse. and secure with cotter pin.

CHEVROLET TRUCK SERVICE M ANUAL

 STEERING 9-17

2. Reconnect the two hydraulic lines, fill the system the straight ahead position, then turn the wheels to the
with fluid and bleed out air using the procedure out­ right and left, while observing movement of the hoses.
lined under "Maintenance and Adjustments". Grease Note and correct any hose contact with other parts of the
ball joint. vehicle that could cause chafing or wear.
Any maintenance operation, on the power steering
POWER STEERING HOSES equipment, should include a thorough inspection of the
hydraulic line system, including the oil cooler if used.
When servicing power steering hoses, avoid twisting Figure 31 illustrates typical installations.
the hoses unnecessarily. Install hoses with the wheels in

CHEVROLET TRUCK SERVICE M ANUAL

STEERING 9-18

Fig . 31—T yp ical Power Steering Hose Routing

CHEVROLET TRUCK SERVICE MANUAL

 STEERING 9-19

SPECIAL TOOLS

F>g . 32—M anual and Power Steering Sp ecial Tools

1. J -7079-2 Handle 8. J —8526—1 Top C over Seal and 20. J —2619—4 Slid e Hammer Adapter
2. J-8522 Steering G e a r .and Idler Arm Bearing Installer 21. J-5822 Puller
Support Bushing Installer 9. J -8526-2 Top C over Seal and 22. J —5741 (8619-1) Bearing Removing Plates
(50 and 60 Series) Bearing Remover 23. J-9225 Sector Shaft Seal Installer
3. J-1614 Steering G e a r and Idler Arm 10. J -2565-3 Mast Ja c k e t Bearing Installer 24. J-9226 Sector Shaft Bushing Tool
Support Bushing Remover 11. J -2565-4 M ast Ja c k e t Bearing Remover 25. J-8119 Bearing Cup Remover
(50 and 60 Series) 12. J —6217 V a lv e Connector Seat 26. J-5853 Inch-Pound Torque W rench
4. J —8523—1 Steering G e a r and Idler Arm Instal ler 27. J-8359 Sector Bearing Remover
Support Bushing Installer 13. J-7624 Spanner W rench 28. J —5421 Thermometer
(70 and 80 Series) 14. J-4245 Snap Ring Remover 29. J-5245 Snap Ring Pliers
5. J-8523-2 Steering G e a r and Idler Arm 15. J -2927-A Steering W h ee l Puller 30. J-3186 Pitman Arm Remover
Support Bushing Remover 16. J-5178 P u ller Gauge 31. J —7316 Belt Tension Gauge
6. J -8524-1 Adjuster Plug Bearing 17. J-6632 Pitman Arm Pu ller 32. J —21239-1 Power Steering Pu lley Remover
and Seal 1nstaller 18. J-5176 C hecking G auge with J-5900 for Stamped Pulleys
7. J -8524-2 Adjuster Plug Bearing and Adapter Kit 33. J-8433-1 Power Steering Pu lley Remover
Seal Remover 19. J —2619 S lid e Hammer J -8433-2 for Cast Pulleys

CHEVROLET TRUCK SERVICE M ANUAL

w

j
 SECTION 10

WHEELS AND TIRES

INDEX
Page Page
General Description ........................ ....................................10-1 Service Operations .................. ....................................... 10-2
Maintenance .............................. ... .............................. ...... 10-1 Wheel Nut T o r q u e s .............................. ............................ 10-2
Tire Inflation ............................................................. ...... 10-1 Correcting Irregular Tire Wear .............................. .....10-2
Puncture Inspection and R e p a i r ........................................10-1 Wheel and Tire Balancing .......................................... .....10-3
Jacking In struction s..........................................................10-1 Wheels ........................................................................ .....10-4
Tire Inflation Tables for Highway Service . . . . . . 10-1 Tire Removal and In sta llatio n .................................... .....10-4
Tube Type . ............................................................ .....10-5
Tubeless T y p e ......................................................... .....10-9

GENERAL DESCRIPTION
The 1967 truck is equipped with a wide range of tube or short spoke, pierced disc, or cast spoke type depending
tubeless type tires and wheels selected according to the on model application. The dual rear wheel option is
truck GVW rating and type of service. Wheels are of the available beginning with the C20 series trucks.

MAINTENANCE
Tire Inflation Jacking Instructions
Tire pressures should be checked at least once a week The chart will assist in performing wheel and tire
and inflated according to the following table. If payload changes using vehicle jacks supplied with or recom­
distribution or special equipment is such as to impose mended for use on Chevrolet Trucks.
heavy loads on the front axle, inflation of front tires
Jacking Point on Vehicle
should be increased accordingly but should not exceed Model
pressure shown for rear tires. Front Rear
CP10, C20-30 Lower Control Arm Pivot Axle Housing
• Avoid under inflation to prevent rim bruises, excessive K10-20 Under Front Axle Near Axle Housing
heat, and irregular or rapid wear. P20-30-50 Spring Seat
40-60
• Avoid overinflation to prevent tire ruptures, hard rid­
ing, irregular or rapid wear and reduction of skid Chevy Van Under Axle at Front Axle Housing
resistance. Spring
• Valve Caps should always be installed and tightened
TIRE INFLATION TABLES FOR
firmly to prevent dust and water entering arid dam­
age to valve seats. The caps also act as an air seal. HIGHWAY SERVICE
PASSENGER CAR TYPE
Puncture Inspection and Repair Tire pressures should be adjusted to the load being
carried by the tire as shown in the following charts. For
At each lubrication, tires should be checked for for­ severe service and heavy duty operation, it is perm issi­
eign objects in the tread or breaks in the tread or side­ ble to increase maximum pressures of passenger type
wall. If tire is punctured or otherwise damaged, it tires shown 6 psi with no increase in load carrying ca­
should be repaired using one of several repair kits avail­ pacity. However, for optimum ride comfort, minimum
able through tire manufacturers' outlets. required pressures are recommended for front tires.
Loads and Inflation Pressures (Lb./Sq. In.)
Tire Size Ply
For Heavy Duty Operation, Pressures Listed Below May be increased 6 P.S.I.
Tubeless Tube-Type Rating 32 34 36
20 22 24 26 28 30
6.95-14 4 950 1000 1050 1100 1140 1190 1230
7.35-14 8 1040 1100 1160 1210 1260 1310 1360 1400 1450
7.75-15 7.75-15 8 1150 1210 1270 1330 1380 1440 1500 1550 1600
8.15-15 8.15-15 4 1240 1300 1370 1430 1490 1550 1610
8.15-15 8 1240 1300 1370 1430 1490 1550 1610 1660 1720
6.50-16 6.50-16 6 1105 1165 1225 1280 1330 1380

CHEVROLET TRUCK SERVICE M ANUAL

WHEELS AND TIRES 10-2

TRUCK TYPE
Tire Size Ply Loads and Inflation Pressures (Lb./Sq. In.)
Tubeless Tube- Type Rating 35 40 45 50 55 60 65 70 75 80 85

7.00-14 6 990 1070 1145

7.00-14 8 990 1070 1145 1220 1290 1365
6.50-16 6 1225 1320 1420
7-17.5 7.00-15 6 1310 1420 1520
7.00-16 6 1365 1475 1580
7.50-16 6 1565 1690 1815
7o5 0 -16 8 1565 1690 1815 1930 2040 2140
7-22,5 6 1640 1760 1870
7.00-20 8 1640 1760 1870 1980 2080 2180
#8-16.5 6 1490 1610 1730
8-17.5 6 1620 1735
7.00-17 6 1620 1740
8-17.5 7.00-17 8 1620 1740 1850 1960 2060
8-19.5 6 1830 1960 2090
7.00-18 8 1690 1810 1920 2040 2140
8-19.5 7.50-17 8 1830 1960 2090 2220 2330 2440
8-19.5 7.50-17 10 1830 1960 2090 2220 2330 2440 2650
7.50-20 8 2060 2210 2350 2490 2620 2740
7.50-20 10 2060 2210 2350 2490 2620 2740 2860 2980 3090
8.25-20 10 2400 2570 2730 2890 3040 3180 3330
8.25-20 12 2400 2570 2730 2890 3040 3180 3330 3460 3600 3730
9.00-20 10 3040 3240 3440 3620 3790 3960
9.00-20 12 3040 3240 3440 3620 3790 3960 4120 4280 4480
10.00-20 12 3600 3820 4020 4220 4410 4580
#NOTE: 25 PSI - 1230 Load, 30 PSI - 1360 Load

SERVICE OPERATIONS
Wheel Nut Torques Misalignment W ear--This is wear due to excessive
On all vehicles equipped with disc or cast spoke toe-in or toe-out. In either case, tires will revolve with
a side motion and scrape the tread rubber off. If mis­
wheels, it will be necessary to retorque the wheel nuts at
alignment is severe, the rubber will be scraped off of
firs t 1000 miles and every 6000 miles thereafter. See
both tires; if slight, only one will be affected.
Specifications for correct nut torques.
The scraping action against the face of the tire causes
Correcting Irregular Tire Wear a small feather edge of rubber to appear on one side of
the tread and this feather edge is certain indication of
Heel and Toe W ear--This is a saw-toothed effect where
misalignment. The remedy is readjusting toe-in, or re­
one end of each tread block is worn more than the other.
checking the entire front end alignment if necessary.
The end that wears is the one that first grips the road
when the brakes are applied. Uneven Wear--Uneven or spotty wear is due to such
Heel and toe wear is less noticeable on rear tires than irregularities as unequal caster or camber, bent front
on front tires, because the propelling action of the rear suspension parts, out-of-balance wheels, brake drums
wheels creates a force which tends to wear the opposite out of round, brakes out of adjustment or other mechan­
end of the tread blocks. The two forces, propelling and ical conditions. The remedy in each case consists of
braking, make for more even wear of the rear tires, locating the mechanical defect and correcting it.
whereas only the braking forces act on the front wheels,
and the saw-tooth effect is more noticeable. Cornering Wear--When a truck makes an extremely
A certain amount of heel and toe wear is normal. Ex­ fast turn, the weight is shifted from an even loading on
cessive wear is usually due to high speed driving and ex­ all wheels to an abnormal load on the tires on the outside
of the curve and a very light load on the inside tires, due
cessive use of brakes. The best remedy, in addition to
to centrifugal force. This unequal loading may have two
cautioning the owner on his driving habits, is to inter­
change tires regularly. unfavorable results.
F irst, the rear tire on the inside of the curve may be
Side Wear—This may be caused by incorrect wheel relieved of so much load that it is no longer geared to
camber, underinflation, high cambered roads or by taking the road and it slips, grinding off the tread on the inside
corners at too high a rate of speed. half of the tire at the excessive rate. This type of tire
The first two causes are the most common. Camber shows much the same appearance of tread wear as tire
wear can be readily identified because it occurs only on wear caused by negative camber.
one side of the treads, whereas underinflation causes Second, the transfer of weight may also overload the
wear on both sides. Camber wear requires correction of outside tires so much that they are laterally distorted
the camber first and then interchanging tires. resulting in excessive wear on the outside half of the tire,
There is, of course, no correction for high cambered producing a type of wear like that caused by excessive
roads. Cornering wear is discussed further on. positive camber.

CHEVROLET TRUCK SERVICE MANUAL

 WHEELS AND TIRES 10-3

Cornering wear can be most easily distinguished from Wheel and Tire Balancing
abnormal camber wear by the rounding of the outside
shoulder or edge of the tire and by the roughening of the It is desirable from the standpoints of tire wear and
tread surface which denotes abrasion. vehicle handling ease to maintain proper balance of front
Cornering wear often produces a fin or raised portion wheel and tire assemblies on all models. All wheels in­
along the inside edge of each row in the tread pattern. tended for use on front of vehicle, such as those switched
In some cases this fin is almost as pronounced as a toe- during periodic tire rotation and those installed as new or
in fin, and in others, it tapers into a row of tread blocks repaired replacement equipment should be accurately
to such an extent that the tire has a definite "step wear” balanced. This may be accomplished by either of the two
appearance. types of balancing systems in current use which balance
The only remedy for cornering wear is proper instruc­ wheels either on the vehicle or off. The "on the vehicle”
tion of operators. Driving more slowly on curves and type, however, is the more desirable in that all rolling
turns will avoid grinding rubber off tires. To offset nor­ components (brake drums, bearings, seals, etc.) are in­
mal cornering wear as much as possible, tires should be cluded in the balancing procedure and thereby have any
interchanged at regular intervals. existing unbalance corrected.

FRONT WHEELS

CPK 10 S ER IE S C20-30 S E R IE S C30 W / D U A L REAR 50 SER IES

50, 60 SER IES

F ig. 1 - Front W h eels and Attachments

REAR WHEELS

F ig . 2 - Rear Wheels and Attachments

CHEVROLET TRUCK SERVICE M ANUAL

WHEELS AND TIRES 10-4

Truck Wheel Balance Weights CAUTION: When removing wheel, loosen all
All 1967 truck wheels equipped with a tubular side ring nuts approximately flush with end of stud, then
(rolled flange rim) on the outboard side of the wheel rims tap clamps to loosen wheel. Do not remove nuts
require special design weights to fit. Dynamic balancing until clamps are free as clamp may fly off stud.
can be accomplished through use of these special balance
Installation of Rims on Wheels
weights which are designed only for installations on the
outboard side of these wheels. Conventional weights fit
only the inboard side of these wheels. DualW
heels
1. Before positioning inner rim, thoroughly clean all
Static Balance contact surfaces on both rim and wheel.
2. After inner rim is positioned, install separator ring
Static balance (sometimes called still balance) is the as shown in Figure 3.
equal distribution of weight of the wheel and tire assem­ 3. Install outer rim and proceed as outlined under "Dual
bly about the axis of rotation in such a manner that the and Single Wheels".
assembly has no tendency to rotate by itself, regardless
of its position. For example: A wheel with a chunk of
dirt on the rim will always rotate by itself until the heavy
side is at the bottom. Any wheel with a heavy side like
this is statically out of balance. Static unbalance of a
wheel causes a hopping or pounding action (up and down)
which frequently leads to wheel "flutter" and quite often
to wheel "tramp".

Dynamic Balance
Dynamic balance (sometimes called running balance)
means that the wheel must be in static balance, and also
run smoothly at all speeds.
To insure successful, accurate balancing, the following
precautions must be observed:

• Wheel and tire must be clean and free from all foreign
matter.

• The tires should be in good condition and properly

mounted with the balance mark on the tire, if any, lined
up with the valve.
Fig. 3 - Installation of Spacer Ring
• Bent wheels that have runout over 1/16" on 1/2,
3/4 and 1 ton, or 1/8" on 1 1/2 and 2 ton trucks
should either be replaced or straightened before being DualandSingleW
heels
balanced. When installing the tire and rim on the wheel, the fol­
lowing procedure should be followed:
• Inspect tire and wheel assembly to determine if an After rim clamps and nuts are put on loosely, turn the
eccentric or out-of-round condition exists. Note that wheel until one spoke is pointing straight upward; tighten
this condition, if severe, cannot be "balanced out". An the nut on the spoke just snug. Snug up the remaining
assembly which has an out-of-round condition exceed­ nuts criss-cro ss to minimize runout, then tighten the nuts
ing 3/16" on tire sizes through 19.5" and 5/16" on to the recommended torque alternately and evenly to
sizes larger than 19.5", is not suitable for use on the avoid excessive runout.
front of the vehicle. Its use on the rear should be Runout should not exceed 1/8" on front wheel of 3/16"
governed by its general condition and whether the on rear wheel.
roundness defect seriously detracts from overall ride
Matching Side and Lock Rings
quality.
Side and lock rings of different rim types are not inter­
changeable. Some may appear to be, but they do not fit
• When balancing wheels and tires, it is recommended
properly on the rim base. Serious accidents have re­
that the instructions covering the operation of the wheel
sulted from the use of mismatched rings. Rim base and
balancer being used be closely followed.
rings must be matched according to manufacturer, size
and type. This information is stamped on each part.
WHEELS
TIRE REMOVAL AND INSTALLATION
Cast Spoke Wheels
Cast spoke wheels with demountable rims are available Tire Mounting
on 50 and 60 series only. Rim and tire may be removed
from the wheel after removing nuts and clamps. The Safety Precautions!
tires may then be serviced as outlined under When tires are mounted on dirty or corroded rim s, or
"Maintenance". when they are not properly centered on rim s, the tire

CHEVROLET TRUCK SERVICE MANUAL

 WHEELS AND TIRES 10-5

bead may "bind" on the rim, and refuse to seat. Allowing 3. Starting at the split in the clamp ring, raise its end
pressure to continue to build up within the assembly in an out of the rim gutter using a screwdriver and the tire
attempt to seat the tire bead is a DANGEROUS PRAC­ iron (fig. 5). Then remove the clamp ring by prying
TICE which can result in a broken tire bead, and serious it out of the gutter with the tire iron, moving pro­
injury to the serviceman. gressively around the rim (fig. 6).
4. Drive the curved end of the tire iron in between the
Be Safe!
side ring and the tire bead (fig. 7). Then pry down
1. Make sure that rim flanges and bead ledge (espe­
on the opposite end of tire iron to move the tire bead
cially hump and radius) areas are smooth and clean.
away from the side ring flange (fig. 8).
Remove any oxidized rubber, dried soap solution,
Continue the foregoing operation progressively
rust, heavy paint, etc. with a wire brush, or, in ex­
around the tire until the side ring is removed. In
treme cases, a file. some cases it may be necessary to work around the
2. Lubricate tire beads, rim flanges, and bead ledge
tire more than once.
areas with a liberal amount of thin vegetable oil soap
solution, or approved rubber lubricant. NOTE: The tire bead seat on the side ring is
3. Insure that air pressure build-up during the bead slightly tapered; this design makes removal of
seating process is not allowed to exceed 40 pounds ring much easier.
pressure. 5. Push the valve stem up inside the tire to prevent
If beads have not seated by the time pressure damage while removing the tire. The tire may be
reaches 40 pounds, assembly should be deflated, re­ removed from the rim by turning it over and follow­
positioned on rim, re-lubricated and re-inflated. ing the procedure in Step 4.
4. Make sure valve core is inserted in valve stem prior
to inflating.
5. Use an extension gauge with clip on chuck so air
pressure buildup can be closely watched and so that
you can stand well back from the assembly during
the bead seating process.
Tube Type Wheels and Tires
Tube type tires using two or three piece rims are
available as optional equipment. T ires and tubes may be
demounted and mounted as outlined in this section.

Mounting and Demounting

ThreeSectionRim
s—
Dem
ountingTire
1. Completely deflate tire by removing the valve core.
2. Using a hammer, tap around the side ring progres­
sively to move it in toward the center of the rim until
it clears the clamp ring (fig. 4).

Fig. 5 - Raising End of Clamp Ring

F ig . 4 - Releasing Tire Clamp Ring Fig . 6 - Removing T ire Clamp Ring

CHEVROLET TRUCK SERVICE MANUAL

WHEELS AND TIRES 10-6

Fig . 7 - Starting Side Ring Removal

Fig. 9 - Replacing Clamp Ring

ter is exposed. Insert end of clamp ring in gutter

and work progressively around the tire until the
clamp ring is seated in the gutter (fig. 9).
CAUTION: Do not stand unprotected in front of
clamp ring when inflating tire. If a protective
inflation cage is not available, place the wheel
and tire in a vertical position close to solid wall
with clamp ring facing the wall. Inflate from
side opposite the ring. If no solid wall is avail­
able place tire and wheel on floor with clamp
ring down and inflate from above.
6. Inflate tire slowly; with tires lightly inflated, tap
gently around ring with hammer to make sure side
ring moves out over clamp ring, locking it into gut­
ter. Inflate tire until tire beads are firmly seated
against rim flanges.
7. Completely deflate tire by removing valve core.
F ig . 8 - Removing Side Ring 8. Reinflate tire to recommended pressure.

ThreeSectionRim
s—
MountingTire TwoSectionRim
s—
Dem
ountingTire(2Ton)
To facilitate assembly and removal, two cutaway sec­
1. Remove all rust scale from the rim, side ring and tions "A" (fig. 7) and an operating notch "B ” are incor­
clamp ring. porated in the locking flange of the side ring.
2. Insert tube in tire and inflate until tube is nearly In separating the side ring from the wheel rim of the
rounded out. spare or new wheel for tire installation, stand the wheel
3. Lubricate tire beads, rim sides of tube, and both up with the operating notch in the side ring at the top.
sides of flap with a solution of neutral vegetable oil The straight end of a tire iron is inserted and driven into
soap or Ru-Glyde or equivalent rubber lubricant. the operating notch (fig. 11). The tool is moved as a
Insert flap in tire. lever to lift the side ring away from the rim. After the
4. Place tire on rim with valve in line with the valve side ring has passed over the rim gutter at the operating
hole in rim. Insert valve through hole; then work notch work progressively around entire rim until side
tire onto rim. ring is separated from wheel rim.
5. Place side ring into position on tire and rim; then 1. Completely deflate tire by removing the valve core.
press the side ring into tire and onto the rim using 2. Loosen the tire bead from its seat in the side ring
the tapered end of tire iron until the clamp ring gut- by driving the bead loosening end of a tire iron be-

CHEVROLET TRUCK SERVICE M ANUAL

 WHEELS AND TIRES 10-7

Fig . 10 - Side Ring Assembly Points

Fig. 12 - Loosening Tire Bead

Fig. 1 1 - Iron in O perating N otch

tween the tire bead and the side ring (fig. 10). Repeat
this operation progressively around the side ring
prying until bead is loose. Fig . 13 - Disengaging Side Ring from Rim G u tter
3. Insert straight end of tire iron into operating notch
located at double pimples "B " (fig. 13).
4. Push side ring down at point opposite operating notch repair only. Simply loosen tire bead from wheel
and force tire iron handle down causing side ring to rim as in Figure 12. Then turn assembly over
disengage from rim gutter. Repeat progressively and remove ring with tire attached as in Figure
around side ring prying ring from rim gutter until 15.
free.
5. To free opposite tire bead from wheel rim, turn tire
over and repeat bead loosening operation (fig. 14).
TwoSectionRim
s—
MountingTire
1. Remove all rust scale from wheel rim and side ring.
NOTE: It is not necessary to remove side ring 2. Insert tube in tire and inflate until tube is nearly
from tire bead if tire is to be removed for tube rounded out.

CHEVROLET TRUCK SERVICE MANUAL

WHEELS AND'TIRES 10-8

F ig . 14- Loosening Tire Bead

Fig. 16- Positioning Rim into Rim G u tte r

Fig. 15 - Positioning Side Ring

3. Lubricate tire beads, rim sides of tube and both

sides of flap with a solution of neutral vegetable soap
or Ru-Glyde or equivalent rubber lubricant. Insert
flap in tire.
4. Place disc portion of wheel on floor with rim gutter Fig. 17 - Engaging Side Ring O v e r Rim G u tter
up and install tire and tube assembly indexing tube
valve stem with stem support in wheel rim and with 10. Remove tool and strike additional blows progres­
valve stem pointing in desired direction. sively toward other cutaway section until entire toe
5. Place side ring in position with operating notch "B M of side ring has passed over the rim gutter.
(fig. 15) approximately three inches from valve on 11. While the side ring is being applied to the wheel rim,
either side. it is tight and requires force or hammer blows to
6. The two cutaway sections opposite each other "A" complete the application. When the side ring is com­
(fig. 16) on inner diameter of side ring are positioned pletely installed on the rim, it is no longer tight and
so as to span the rim gutter. can be depressed or will yield to a light hammer
7. At point "C" opposite valve, force ring into rim gut­ blow. Precaution should be taken to see that the side
ter as far as possible. ring is not binding on the rim and can be freely de­
8. Insert straight end of tire iron into operating notch pressed (fig. 18) before inflating the tire.
"B " (fig. 17). Then pull in direction indicated.
9. Retain pressure with tool and strike side ring down­ Installing Synthetic Tubes
ward at a point between operating notch and cutaway 1. Before installing tube in tire, clean inside of casing
section, thereby engaging side ring over rim gutter thoroughly.
at these points. 2. Insert tube in tire and inflate until it is nearly

CHEVROLET TRUCK SERVICE M ANUAL

 WHEELS AND TIRES 10-9

present tire machines or standard tire irons following

the same procedure employed in servicing tube type
tires.

CAUTION: A hammer, or tools with sharp

edges, should never be used to demount or mount
tubeless tires as damage to rim flange or tire
sealing bead may result.

Inspection for Leaks

1. With wheel assembly removed from vehicle, inflate
the tire to recommended operating pressure.
2. Check for leaks at rim bead by placing wheel and tire
horizontal and allowing water to stand in groove be­
tween rim and tire. Check for large leaks by lower­
ing assembly into water tank or running water over
tire.

Demounting (all except 7.75-15 and 6.50-16 tires)

1. Remove valve core to completely deflate tire. With
tire lying flat on floor, loosen beads from rim seats
by walking around on tire with heels at points close
to rim. With wide side of rim down, apply tire lu­
Fig. 18 - C hecking Side Ring for Bind on Rim bricant to top bead. With stops toward rim, insert
spoon ends of two tire irons about 10" apart. While
rounded out. standing on tire to hold bead in gutter, pull one tool
3. Inspect rim for rust scale and bent flanges--clean toward center of rim (fig. 19).
rust scale and straighten flanges where necessary. 2. Hold one iron in position with foot and pull second
4. Using a brush or cloth swab, apply a solution of iron toward center of rim. Progressively work bead
neutral vegetable oil soap to the inside and outside of off rim, taking additional bites if necessary (fig. 20).
tire beads and also to the rim side of the tube. Do 3. Stand assembly in vertical position. Lubricate sec­
not allow soap solution to run down into tire. ond bead. At top of assembly insert straight end of
5. When mounting tire and tube on a drop center rim, tire iron between bead and back flange of rim at
follow the standard procedure. Be sure tire is cen­ about a 45 degree angle (fig. 21).
tered on rim so that beads are out of rim well before 4. Turn iron so that it is perpendicular to rim. Pry
inflating. Do not allow tire to hang loosely on wheel second bead off (fig. 22).
while inflating.
6. Center valve and pull it firmly against the rim. Hold
in this position and inflate until tire beads are firmly
seated on rim against flanges.
7. Completely deflate tire by removing valve core.
8. Reinflate tire to recommended pressure.
CAUTION: When tube and flap are not properly
lubricated and mounted, they will stretch thin in
the tire bead and rim region. This will cause
premature failure.

Tubeless Tires
Tubeless tires mounted on one piece full drop center
rim s are standard on some Chevrolet trucks. These
tires have a safety inner liner which if punctured, tends
to cling to the penetrating object forming a partial seal
until the object is removed from the tire.
The mounting and demounting of tubeless truck tires
will present no problem when a rubber lubricant, such as
Ru-Glyde or equivalent is applied to tire beads and rim
flanges. Ru-Glyde or equivalent in addition to materially
assisting in mounting and demounting also prevents rust­
ing at the tire sealing area and thus prevents tires from
adhering to the wheel.
Demounting and Mounting
All tubeless tires used on Chevrolet trucks with the
exception of the 7.75-15 and 6.50-16 sizes should be de­
mounted and mounted as described in this section. The
7.75-15 and 6.50-16 sizes may be demounted using Fig. 19- Inserting Tire Iron to Lift Bead

CHEVROLET TRUCK SERVICE M ANUAL

WHEELS AND TIRES 10-10

Fig . 22 - Prying Second Bead from Rim

Fig. 20 - Lifting Bead O ve r Rim

Fig . 21 - Inserting Tire Iron in Second Bead

Mounting (all except 7.75-15 and 6.50-16 tires)

All tubeless tires except the 7.75-15 and 6.50-16 sizes
will be mounted as follows:
1. Inspect rim to insure bead seats are clean and Fig. 23 - Lubricating Tire Bead
smooth. Then place rim on floor with wide side
down and lubricate first bead of tire and upper bead
seat of rim (fig. 23). of first bead over rim (fig. 24).
2. Push first bead into well of rim and onto rim as far 3. Hold second bead in well by standing on tire. When
as possible. Using straight end of tire iron and with necessary, push section of bead into rim well and
stop resting on rim flange, work remaining section anchor with vise-grip pliers by pinching pliers on

CHEVROLET TRUCK SERVICE M ANUAL

 WHEELS AND TIRES 10-11

Fig . 25 - W orking Second Bead Onto Rim

2. With tire beads still unseated, rotate tire on wheel

so that balance mark on tire lines up with the valve
Fig. 24 - W orking Bead O nto Rim stem.
3. Start tire beads into the rim bead seats as follows:
If a tire mounting machine is being used, lift the tire
rim flange. Using spoon end of tire iron with stop
high in the rim forcing the top tire bead against the top
toward rim, work progressively around bead using rim flange seating the top bead. The lower bead will be
small bites until bead slips over flange onto rim seated by the tire weight.
base. If necessary, insert second tire iron and lu­
When a tire mounting machine is not being used, beads
bricate last 6" of bead before completing mounting
may be seated by holding the tire and wheel assembly in
(fig. 25). a vertical position and bouncing on the floor at various
4. Check valve to be certain that hex nut at the valve points about the tire circumference.
base is tight. Inflate tire to recommended oper­
ating pressure. Check assembly for air leaks. 4. Install valve core and inflate tire with quick "shots"
of air to firmly seat the sealing beads.
Mounting (7.75-15 and 6.50-16 tires) 5. Check assembly for air leaks, then reduce tire pres­
1. Use present tire machines or standard tire irons fol­ sure to that recommended for vehicle operation.
lowing the same procedure used in mounting tube
type tires, however, extreme care must be exercised NOTE: If a seal connot be effected in the fore­
to prevent injury to the sealing bead when forcing going manner with the rush of air, it can be ac­
tire over the rim. A slight application of rubber lu­ complished by applying a mounting band or heavy
bricant on the last 1/3 of each bead circle to be sash cord to the circumference of the tire and
mounted will ease mounting. then tightening with a tire iron.

CHEVROLET TRUCK SERVICE MANUAL

 SECTION 11
CHASSIS SHEET METAL
CONTENTS OF THIS SECTION
Page
Conventional T r u c k s ............................................................ 11-1
Tilt C a b s .............................................................................. 11-11
Chevy Van and Sport Van ................................................... 11-12
Special T o o ls ........................................................................ 11-13

CONVENTIONAL TRUCKS
INDEX
Page Page
Service O p e ra tio n s ......................................................... 11-3 Front Sheet Metal Assem bly............................................. 1 1 - 4
Hood A s s e m b ly ............................................................... 11-3 Flat Face Cowl M o d e l s ............................................. 11-6
Hood Hinge Spring Replacement................................. 11-3 Radiator S u p p o rt......................................................... 11-6
Hood H in g e .................................................................. ..... 11-3 F e n d e r s .............................................................................. 11-9
Hood Lock Assembly ................................................ ..... 11-3 S k irt.............................................................................. 11-10
Running B o a r d .................................................................. 11-11
A d ju s tm e n t............................................................ ..... 11-3
Hood Assembly Removal and In stallatio n .................. ..... 11-4
Hood Assembly A lignm en t.......................................... ..... 11-4

F ig . 1 - Front Sheet M etal - 10 thru 30 Series Trucks

CHEVROLET TRUCK SERVICE MANUAL

CHASSIS SHEET METAL 11-2

GENERAL DESCRIPTION

Figures 1 and 2 show a typical front sheet metal as­

sembly for 10 thru 30 and 40 thru 60 series vehicles, assemblies.
respectively. The 1967 sheet metal design includes fewer The following pages contain servicing information for
service parts and an easier replacement for service pur­ removal, assembly and adjustment of front sheet metal
poses. A complete redesign of front end sheet metal components. The Conventional Truck sub-section may be
includes removal of lights from the hood, elimination of considered the basic write-up of the entire section. Any
the upper fender extension, a one piece fan shroud, component found on other series trucks which is not
elimination of the radiator support on 40 thru 60 series covered in that section may be serviced as is explained
trucks, and other design improvements of individual for its counterpart in the Conventional Truck sub-section.

F ig . 2 - Front End Sheet Metal - 40 thru 60 Series Trucks

CHEVROLET TRUCK SERVICE M ANUAL

 CHASSIS SHEET METAL 11-3

SERVICE OPERATIONS

HOOD ASSEMBLY

HOOD HINGE SPRING REPLACEMENT

Removal
1. Remove through bolt from Tool J - 5544-1, and lay
bolt aside.
2. Raise hood, slightly and hold in partially open
position.
NOTE: Tool J - 5544-1 is to be placed between
coils when spring is expanded. Raise hood as
required for access to spring.
3. Install Tool J - 5544-1 to spring.
4. Raise hood to fully open position and remove spring
and tool from vehicle.
5. Prop hood in open position, and install through bolt
in Tool J - 5544-1 and hinge spring.

Installation
1. Remove through bolt from Tool J - 5544-1 and hinge Fig. 4 - Hood Hinges and Springs (10 thru 60 Series)
spring.
NOTE: If installing a new spring, expand new
HOOD HINGE (Fig. 4)
spring and install Tool J - 5544-1 (fig. 3).
Removal
2. Install spring end in hinge mount bracket. 1. Prop the hood in the extreme open position and place
3. Lower hood sufficiently to allow opposite end of protective covering over the cowl and fenders.
spring to engage cutout in hood hinge. 2. Scribe position of hinge attachment on hood rear
4. Lower hood until Tool J - 5544-1 is freed, and remove reinforcement and remove two bolts.
tool. 3. Remove hood hinge spring as explained in preceding
5. Raise hood and check spring retention-close and se­ write-up.
cure hood. 4. Scribe position of hinge attachment on fender assem­
bly and remove bolts.
5. Remove hinge.
Installation
1. Install hinge assembly to fender and align within
scribe marks. Install bolts.
2. Install hood hinge spring.
3. Install bolts and align hood. See Hood Alignment in
this section.
HOOD LOCK ASSEMBLY
A bolt-type hood lock is used as shown in Figure 5 and
6. The lock bolt, located on the hood dovetails with the
mounted striker plate, preventing upward or downward
movement of the hood while the vehicle is in motion.
Integral with the striker plate is the combination lock re­
lease lever and safety catch.

Replacement
1. Open hood and remove the four bolts holding the
combination lock catch and lock bolt.
NOTE: If original hood lock assembly is to be
replaced, scribe a line around lock for alignment
on installation.
2. Place hood lock assembly in position.
3. Adjust as outlined under Adjustments.

Adjustment
1. Open hood and adjust tightness of lock bolt support so
that they are just "snug" enough to hold lock bolt in
F ig . 3 - Hood Spring Tool Installation position.

CHEVROLET TRUCK SERVICE M ANUAL

CHASSIS SHEET METAL 11-4

2. Close hood in a normal manner.

3. Raise hood again; lock bolt assembly will have
shifted to operating position. Tighten bolts fully.
Further adjustment may be made at lock bolt sup­
port, if necessary.
4. Adjust lock bolt to obtain a secure hood closure and
reasonable lock release effort.

HOOD ASSEMBLY

Removal
1. Lay a fender cover along cowl top to prevent hood
from scratching cowl top.
2. Open hood and prop in full open position.

NOTE: If hood is to be reinstalled and present

Fig. 6 - Hood Striker and Safety Catch (10 thru 30 Series)

alignment is satisfactory, mark each hinge in

relation to hood, to assure original alignment.

3. Remove two cap screws which attach each hinge to

hood; then with a helper remove hood from vehicle.

Installation
1. If original hood is to be installed, position hood to
hinges and install four cap screws snug which attach
hinges to hood.
NOTE: If a new hood is to be installed, per­
form procedures as outlined under Alignment,
directly below.
2. Shift hood on hinges to location marks made before
removal of hood, then tighten attaching cap screws at
hinges firmly. Close hood and check fit. If neces­
sary to align hood perform procedure as outlined
under "Alignment" which follows.

Alignment
1. Loosen hood hinge bolts. Note that rear most bolt
hole in hinge is slotted to allow hood trailing edge to
move up and down.
2. Adjust hood rear bumper so that hood and cowl sur­
faces are flush.
3. Perform hood lock adjustment as outlined in this
section if necessary.
NOTE: Hood Lock Assembly to be adjusted
fore and aft until nubbin (part of Hood Lock Bolt
Support Assembly) enters center of elongated
guide (Socket). Bending nubbin to accomplish
this adjustment may seriously effect lock opera­
tion and safety catch engagement and is, there­
fore, NOT RECOMMENDED.
FRONT SHEET METAL ASSEMBLY
Removal of entire front sheet metal assembly including
radiator is a relatively simple operation involving, basi­
cally disassembly of mounts, disconnecting radiator hoses
and removal of front bumper. Vehicles equipped with air
conditioning and/or power steering will require special
handling.
Refer to appropriate sections of this manual for
F ig . 5 - Hood Lock Assembly (40 thru 60 Series) instructions.

CHEVROLET TRUCK SERVICE M ANUAL

 CHASSIS SHEET METAL 11-5

Shims which are found at various locations should be 6 . Install bolts at steering column skirt reinforcement,
recorded to ease installation of sheet metal assembly. final torque 25 ft. lbs.
Proceed as follows: 7. a. Tighten each radiator support mounting bolt 33
ft. lbs. and bend tab over nut.
10 THROUGH 30 SERIES b. Torque bolts at fender to cowl 25 ft. lbs.
8 . Install front bumper.
Removal (See Fig. 6A) 9. Connect wire connectors at dash and toe panel, At­
1. Drain radiator and remove radiator hoses. Discon­ tach generator and regulator wires.
nect oil cooler lines if so equipped. 10. Connect upper and lower radiator hoses. Connect oil
2. Disconnect wire connectors at the dash and toe panel cooler lines to the radiator on models so equipped.
and wire connector to horn and voltage regulator. 11. Install cowl grille and wiper arms.

Fig . 6A - Front End Sheet M eta l (Typ ical)

3. Disconnect battery and generator wires.

4. Remove reinforcement on left fender skirt at steer­
ing column.
5. Remove front bumper bolts and remove bumper.
6 . Remove wiper arm assemblies and cowl grille.
7. Remove bolts attaching fender upper edge to plenum
and hinge pillar.
8 . Remove fan shroud, if required.
9. Working from underneath rear of fender, remove at­
tachment from each fender at the hinge pillar.
10. Bend tab away from nut and remove nut and washer
from each radiator support mounting. (See Figure 7.)
11. Remove bolts at each fender skirt to cab sill exten­
sion mounting.
12. With a helper, remove front sheet metal assembly,
with radiator, battery, horn and voltage regulator.

Installation
1. With a helper place sheet metal assembly in position.
NOTE: Install all bolts loosely to facilitate
aligning after complete installation.
2. Shim at radiator support to align fender to door lead­
ing edge.
3. Install combination bolt and flat washer assembly
into each fender reinforcement while inserting shims
required between fender reinforcement and body.
(See Figure 8 .)
4. Install two bolts and shims required at each fender
rear lower edge to hinge pillar.
5. Install bolt in each fender skirt to sill extension.

CHEVROLET TRUCK SERVICE M ANUAL

CHASSIS SHEET METAL 11-6

12. Connect battery and fill radiator. Start engine and

check for leaks.

40 THROUGH 60 SERIES

Removal
1. Remove windshield wiper arms and cowl grille.
2. Drain radiator and remove radiator hoses.
3. Disconnect transmission cooler lines; and disconnect
air cleaner intake hose at fender skirt, if so
equipped.
4. Disconnect wire connectors at dash and toe panel.
Disconnect the battery, generator and regulator wire
leads.
5. Disconnect power steering fluid reservoir from in­
side grille.
6 . Remove front bumper bolts and remove bumper,
a. Remove two bolts from underneath front frame
crossmember and attachments securing sheet
metal. (See Figure 8 a.)
7. Remove one screw, each side attaching cowl bracket
to fender (plastic plug covers) access from inside
cab, on cowl (fig. 9). DO NOT remove cowl bracket.
8 . Remove two bolts attaching fender upper edge to
plenum and hinge pillar (fig. 9).
9. Tape shims in their respective positions for reas­
sembly ease.
10. Remove two screws (each side) attaching fender gus­
set to cowl (fig. 1 0 ).
11. Working from underneath rear of fender, remove
bolts which attach each fender skirt to the fender
extension flange.
12. Remove two bolts from radiator support mount. Fig . 7 - Radiator Support Mounting
13. Remove bolt attaching each fender skirt to cab sill
extension. 14. Connect wire connectors at dash and toe panel. Con­
14. With a helper, remove front sheet metal assembly nect battery, generator and regulator leads.
with radiator, battery, horn and voltage regulator. 15. F ill radiator, start engine and check for leaks.

Installation FLAT FACE COWL

1. Tape washers and cushions to frame and fender
brackets with masking tape. Removal and installation operations for front sheet
metal of flat face cowl models, are the same as Conven­
NOTE: If sheet metal mounting cushions on tional Cab 40 thru 60 series, except as follows:
frame brackets are worn or deteriorated, re­ • Remove two bolts from inside of cab at the top of
place before installing front sheet metal. each fender.
2. With a helper place sheet metal assembly in position. • Remove bolt and plug at lower rear fender location.
• For installation, reverse the above added procedure.
NOTE: Install all bolts loosely to facilitate
alignment after complete installation.
RADIATOR SUPPORT
3. Install two bolts and shims required at each fender
rear upper edge. 10-30 Series
4. Install combination bolt and flat washer assembly
into each cowl bracket to fender. Removal
5. Tighten the sheet metal mounting bolt 35 to 55 ft. lbs. 1. Remove hood as described in this section.
torque. (See Figure 8 a.) 2. Drain radiator, saving coolant, loosen attachments
6 . Install spacer, washer and bolt in each fender skirt and remove.
to cab sill extension. 3. Remove right front fender as described in this
7. Install skirt attaching bolts to fender extension. section.
8 . Tighten all bolts. 4. Disconnect battery and remove.
9. Install front bumper bolts and bumper as outlined in 5. Remove battery tray, 1 bolt under skirt.
this section. 6 . Remove wiring from radiator support.
10. Connect upper and lower radiator hoses. 7. Disconnect fan shroud and lay back on engine.
11. Install transmission cooler lines. 8 . Remove 6 screws retaining lower grille baffle to
12. Connect power steering fluid reservoir hose to pump. radiator support.
See Section 9. 9. Remove both head lamp assemblies. Complete.
13. Connect air cleaner intake hose to fender skirt. 10. Remove left fender gusset (5 screws).

CHEVROLET TRUCK SERVICE M ANUAL

 CHASSIS SHEET METAL 11-7

11 . Remove screws securing fender skirts to radiator Installation

support bottom. 1. Rotate radiator support into position and loosely in­
1 2 . Remove bolt securing center grille support to radia­ stall attachments to frame.
tor support. 2. Connect center grille support to radiator support.
13. Remove bolts securing hood catch assembly to radia­ 3. Connect hood latch plate.
tor support. 4. Connect left radiator support gusset to left fender.
14. Remove radiator support bolts secured to fram e-- 5. Connect support to left fender.
Note and record stackup. 6. Connect 3 screws from underside of left skirt to
15. Tilt radiator support rearward and lift up and off. support bottom.

CHEVROLET TRUCK SERVICE M ANUAL

CHASSIS SHEET METAL I T -8

Fig. 8A - Front End Sheet M etal Mounting

(Crossmember to G r ille and Support)
Fig. 10 - Fender Gusset to Cow! Attachment
7. Starting in center, loosely attach 6 screws through \

grille filler panel to radiator support. 14. Install screw from underside of skirt to center of
8 . Place right fender in position and loosely install fender flange.
bolts and shims at fender top to cowl. 15. Tighten rearmost bottom screw of fender skirt
9. Attach grille upper to right fender bolts loosely. previously installed loosely.
10. Attach bolts from inside of grille lower to right 16. Install snugly remainder of skirt to right fender
fender lower (limited access between radiator sup­ screws.
port outer face and grille inner face).
11. Install radiator support to fender.
12. Using drift line up right fender skirt rearmost bot­
tom screw with fender flange and attach loosely.
13. Attach right fender skirt inner top bolts to fender
underside.

F ig . 9 - Fender to Cowl 40 to 60 Series

CHEVROLET TRUCK SERVICE MANUAL

 CHASSIS SHEET METAL 1

17. Tighten right fender skirt front 3 bolts from under­

side to radiator support.
18. Place battery tray in position and fasten to radiator
support.
19. From beneath skirt fasten screw to battery tray
bottom.
20. Install bolt and shim loosely bottom of front fender
rear to hinge pillar.
21. Tighten 6 grille filler panel screws previously at­
tached to radiator support.
22. Install radiator, hoses and shroud.
23. Connect removed wiring to radiator support.
24. Install both head lamp assemblies.
25. Tighten all previously installed bolts, screws loosely
attached.
26. Install battery and connect leads and wires.
27. Fill radiator with coolant as specified in Section 13.
28. Install hood on previously marked outline.
29. Install and secure cowl grille.
30. Install windshield wiper arm assemblies.

FRONT FENDER

10 thru 30 Series

Removal Fig. 13 - Front Fender and Skirt Attachment (10 thru 30 Series)
1. Remove windshield wiper arm s, cowl grille and at­
taching screws. 10. Remove two bolts and shims at top rear of fender
2. Remove hood and hinge assembly. attaching to cowl.
3„ Remove head lamp door, wiring and attachments
from fender. Installation
4. Remove screws attaching fender wheel opening flange To install, reverse the removal procedure using seal­
to skirt. ing tape between filler panel and fender. Check sheet
5. Remove 2 skirt to fender bolts, located inboard on metal alignment.
underside of skirt.
6 . Remove two screws attaching gusset to fender. 40 thru 60 Series
7. Remove two screws attaching radiator support to
front fender. Removal
8 . Remove four bolts attaching radiator grille to fender. 1. Remove windshield wiper arms.
9. Remove bolt and shim attaching to trailing edge of 2. Remove cowl grille--disconnecting radio antenna
fender to hinge pillar. lead.
3. Remove hood, outlining hinge bolts at fender before
removing.
4. Lift hood off.
5. Remove two bolts and shims attaching fender to cowl.
6 . Remove 1 screw from inside cab (plastic plug covers
access mounting). (Do not remove cowl bracket.)
7. Remove screws connecting skirt edge to fender
flange.
8 . Right fender removal necessitates removal of battery
cables, battery and three screws attaching battery
tray to fender.
9. Remove 1 bolt hidden from view connecting grille
lower panel to front inboard edge of fender (access
hole provided).
10. Remove bolts connecting grille to front fender from
inside of engine compartment.
11. Remove 3 bolts fastening gusset to fender and grille
(fig. 1 2 ).
12. Remove two bolts fastening gusset to fender.
13. Remove all electrical connections.

Installation
To install, reverse the removal procedure using seal­
ing tape between filler panel and fender. Check sheet
metal alignment.

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CHASSIS SHEET METAL 11-10

FRONT FENDER SKIRT

NOTE Inboard nut must be
10-30 Series flush with last thread of brace FRAME SIDEMEMBER
and outboard nut must run up /
Removal
1.
2.
Remove windshield wiper arms.
Remove cowl grille and attaching screws.
against frame to position brace
in furthest outboard position.
/
f'
3. Remove hood and hood hinge assembly.
4. Disconnect battery and remove (right side only) or
remove skirt reinforcement at steering column (left
skirt only) (Fig. 13).
5. Remove 2 top rear fender bolts and shims.
6. Remove bolt and shims at bottom of fender.
7. Remove bolt and shim(s) attaching skirt to sill ex­
tension.
8. Remove 4 screws attaching head light door to fender
and grille.
9. Remove screws attaching gusset to radiator support.
10. Remove 3 screws attaching skirt to radiator support.
11. Remove 2 screws securing fender to radiator support.
12. Remove 4 screws securing fender to grille.
13. Lift fender and skirt assembly from truck. Fig. 15 - Running Board and Braces (CA31004 Series)
Installation
1. Replace fender and skirt assembly. 3. Remove 3 screws attaching skirt to lower fender
2. Install bolts loosely. extension.
3. Install shims and secure all parts in reverse order 4. Remove 3 screws at front of skirt attached to fender.
of removal. 5. Remove 6 screws holding skirt to fender opening
4. Tighten shimmed bolts. flange.
6 . Remove screw attaching skirt to radiator grille.
FRONT FENDER SKIRT
Replacement
To replace the skirt alone, remove required screws
and rotate over tire. Reverse procedure to install.
FENDER SKIRT
40-60 Series
Removal
1. Turn steering wheel so tire front is inboard.
2. Underneath the skirt remove 2 screws at top at­
tached to fender.

F ig . 14 - Running Board and Fender Extension Fig. 16 - Running Board and Braces
(40 thru 60 Series) (See Illustration for Series)

CHEVROLET TRUCK SERVICE M ANUAL

 CHASSIS SHEET METAL 11-11

7. Underneath the skirt, inboard, remove a large bolt 40, 50 and 60 Series (Except F /F Cowl and School Bus)
fastened through the fender to the cowl extension.
Note shim and record. 1. Remove bolt from inside door opening attached to
8 . Under the hood remove 2 screws attaching skirt re­ lower extension.
inforcement to skirt. 2. Remove bolts from under front of running board to
9. Rotate skirt outward over tire, then remove extension bottom.
rearward. 3. Remove 3 bolts fastening skirt to flange of lower
Installation extension.
Reinstall in reverse order of removal. Note condition 4. Pull lower fender extension downward then out.
of tape sealing full length of fender skirt flange. Replace
if necessary. OTHER RUNNING BOARDS
RUNNING BOARD AND FENDER EXTENSION Refer to Illustrations

TILT CABS

F ig . 17 - Front Fender and Surge Tank Access Door - T ilt Cabs

FRONT FENDER AND SURGE

TANK ACCESS DOOR
2. Remove screws which attach shield to cab support
Each front fender is retained with attaching screws, and remove shield from vehicle.
nuts and lock washers as shown in Figure 17. The handle 3. Lower brace and distributor shield may be removed
attaches to the bottom at the rear of the fender with at this time if necessary.
external tooth washers, bolts and nuts. Tape is used 4. To install follow removal procedure in reverse
before installation. order.
The surge tank access door is retained with screws
and a stud as shown.
ENGINE SPLASH SHIELD EMBLEMS AND DESIGNATION PLATES
Refer to Figure 18
Removal and Installation
1. Tilt the cab to expose engine area. Refer to Illustrations (Figs. 19 and 20)

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CHASSIS SHEET METAL 11-12

V IE W A
V IE W B

TT40, TD-TG50-60

Fig. 19 - Designation and Name Plates Fig. 20 - Front End Access Panel and Emblem

CHEVY VAN AND SPORTVAN

The Chevy Van sheet metal consists of the radiator air ENGINE COMPARTMENT COVER ASSEMBLY
deflector, splash shields and the engine cover. (Fig. 23)
Removal
SPLASH SHIELDS AND RADIATOR AIR DEFLECTOR 1. Disengage the clamp at the front of the cover and re­
move the nut, washers and bolt from the check
Removal and Installation assembly.
The radiator air deflector (figs. 21 and 22) is attached 2. Remove hinge pins attaching the rear hinges to the
to the underside of the body forward of the radiator. The compartment and remove cover.
air deflector may be removed by first removing the right
and left side splash shields and then removing the deflec­ Installation
tor attaching screw and plain washers. Upon installation, 1. Position the cover on the compartment and align
make certain that all screws are installed and torqued hinges with holes. Install the hinge pins at the hinge
sufficiently to eliminate rattles or wind vibration. locations.
2. Install the check assembly, then install the bolt,
washers and nut.
3. Adjust the cover if required (fig. 23) by moving the
hinge in the elongated holes to insure a tight fitting
cover. Torque all bolts.

F ig . 21 - Radiator A ir Deflector and Splash Shields F ig . 22 - Installing Radiator A ir Deflector

CHEVROLET TRUCK SERVICE MANUAL

 CHASSIS SHEET METAL 11-13

Fig. 23 - Engine Compartment C over Assembly

SPECIAL TOOLS

Fig. 2 4 - J-5544-1 Hood Spring Remover

CHEVROLET TRUCK SERVICE M ANUAL

 1
•

•
 SECTION 12
ELECTRICAL-BODY AND CHASSIS
CONTENTS OF THIS SECTION
Page
Lighting System.................................................................. 12-1
Instruments and G a u g e s ................................................... 12-11
Directional S ig n a ls ............................................................ 12-21
Windshield Wipers and W a s h e r s ....................................... 12-24
Wiring D ia g ra m s ............................................................... 12-30

LIGHTING SYSTEM
INDEX
Page Page
General Description ........................................... ............... 12-1 Directional Signal Lamps ........................... ............ 12-5
Maintenance and Adjustments........................ Wiper Switch Replacem ent........................... ............ 12-8
Headlamp A d ju s tm e n t.............................. ............... 12-3 Light Switch R ep lacem en t........................... ............ 12-8
Service O p e ra t io n s ........................................... ............... 12-5 Stoplamp Switch R ep lacem en t ....................... ............. 12-8
Sealed Beam Unit R e p lacem en t ................. ................. 12-5 Dimmer Switch Replacement .......................... ............ 12-8
Parking Lamp R eplacem en t..................... ............... 12-5 Neutral Safety Switch Replacement . . . . . ............ 12-9
Rear Lighting .......................................... ............... 12-5 Backing Lamp Switch Replacement. . . . . . ............ 12-10

GENERAL DESCRIPTION
The lighting system includes the main light switch; stop All wiring systems incorporate a fusible link which
light, dimmer and backing lamp switches; head and park­ provides increased overload protection to all electrical
ing lamps; stop, tail and directional signal lamps; instru­ circuits, except the starting motor circuit, not protected
ment illumination and indicator lamps; and the necessary by fuses. Composite wiring diagrams (figs. 40 thru 76)
wiring to complete the various circuits. A bulk head fuse are included at the end of this section. The standardized
panel (fig. 1 ) provides convenient power take offs and fuse color code is common to all wiring harnesses. Under
clips for the appropriate circuits. The engine wiring this color code, the color of the wire designates a partic-
harness and forward lamp harness connectors are bolted lar circuit. The harness title indicates the type of har­
to the fuse panel. ness, single or multiple wire, and also describes the
location of the harness.

MAINTENANCE AND ADJUSTMENTS

Maintenance of the lighting units and wiring system tions may cause a discharged battery, difficult starting,
consists of an occasional check to see that all wiring dim lights, and possible damage to generator and regula­
connections are tight and clean, that the lighting units are tor. Wire harnesses must be replaced if insulation be­
tightly mounted to provide good ground and that the head­ comes burned, cracked, or deteriorated. Whenever it is
lamps are properly adjusted. Loose or corroded connec­ necessary to splice a wire or repair one that is broken,

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£l * c t r i C a l

12-2
 ELECTRICAL—BODY AND CHASSIS 12-3

always use solder to bond the splice. Always use rosin

flux solder on electrical connections. Use insulating
tape to cover all splices or bare wires.
When replacing wires, it is important that the correct
size be used. Never replace a wire with one of a sm aller
size. Fusible links in the Chevrolet wiring are four
gauge sizes sm aller than the cable it is designed to pro­
tect. The links are marked on the insulation with wire HORIZONTAL
gauge size because of the heavy insulation which makes A IM IN G
the link appear a heavier gauge than it actually is. SCREW
Each harness and wire must be held securely in place
by clips or other holding devices to prevent chafing or
wearing away the insulation due to vibration.
By referring to the wiring diagrams, circuits may be
tested for continuous circuit or shorts with a conventional
test lamp or low reading volt meter.
CENTER STRING OVER
“ 2R” O N AIMER ARM

Fig. 4 - Headlamp Horizontal Adjustment

The T-3 Safety Aimer-Type B (fig. 2), is used for the

headlamp aiming description that follows. An adapter is
required with the Type B T-3 Aimer when adjusting the
7 inch headlamp used on the single headlamp vehicle.
1., Drive vehicle onto selected aiming area. Bounce
vehicle several times and allow to settle.
2. Remove headlamp bezels.
3. Mount the T-3 Aimers on the headlamps so that the
points of the headlamps engage the smooth inner ring
Fig . 2 - T-3 Safety Aim er of the aimers.
4. Secure the aimers to the headlamp units by firmly
HEADLAMP ADJUSTM ENT- pressing knob at center of each aimer (fig. 3). Ro­
T-3 HEADLAMPS tate crossarm s inboard to approximate horizontal
position.
CAUTION: Check and tighten grille retaining NOTE: Moisten suction cups slightly to obtain
bolts prior to attempting headlamp aiming. Dis­ maximum holding force.
torted grille or supports in this area will hinder
proper aiming of headlamps. 5. With both aimers in place, knot both ends of elastic
string and, using slots provided, fasten string across
When aiming headlamps, vehicle should be filled to ca­
pacity with gas, oil, and water but no load. Tires should
be uniformly inflated to recommended pressure.

VERTICAL ADJUSTMENT SCREW

F ig . 3 - Installing Aim er on Headlamp Unit F ig . 5 - Headlamp V e rtica l Adjustment

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ELECTRICAL—BODY AND CHASSIS 12-4

horizontal crossarm s of each aimer.

6. Rotate both aim ers so that the string just clears the
points on the crossarm s.

HORIZONTAL ADJUSTMENT

7. a. Turn horizontal aiming screw, Figure 4, on left-

hand lamp until the string is positioned over the
crossarm centerline. Turn the screw clockwise
in making the final adjustment to take up play in
the headlamp mechanism,
b. Repeat the above procedure on the right-hand
lamp to complete the horizontal adjustment of the
headlamps.

VERTICAL ADJUSTMENT
8 . a. Numeral ”2" (fig. 5) should appear in the "down"
window of each aimer. If not, loosen knob at
underside of aimer arm and slide back and forth
until the numeral does appear. Fig. 7 - Selecting Level Aiming Area

NOTE: This setting will give a 2" drop of the smooth inner ring of the Aimer. To install Aimer,
headlamp high beam spot centerline on a screen press firmly on the knob extending out from the
placed 25 feet forward of the vehicle. Check center of the Aimer base. This forces the suction
state laws for proper vertical setting. cup into place on the Sealed Beam unit.
3. Loosen the slider knob beneath the aimer arm and
b. Turn headlamp vertical aim screw (fig. 5) on left- set the numeral ”2" in the DOWL view window
hand unit counter-clockwise until the bubble is at (fig. 7). Back vertical lamp adjusted out on each
the inner end of the glass tube. Then turn screw lamp until bubble is outside of black line of vial,
clockwise until bubble is centered in tube. then center bubble in between black line of vial by
c. Repeat this procedure on right-hand headlamp turning clockwise.
unit to complete vertical adjustment of lamps. 4. After both bubbles are centered, turn the car around
9. Recheck the string at the ends of each crossarm for end for end, making sure the tires are in the spots
correct setting and the bubble on each aimer for made on the floor before the car was moved.
centered position. 5. If the bubbles are still within the two outside black
10. Remove the aim ers by pulling on the suction cup tabs marks on the vials, the floor is level enough to use
through the openings in the aimers (fig. 6 ). the Aimer as it comes from the factory.
11. With headlamps properly aimed, replace headlamp
NOTE: A quick level check can be made by
bezels.
using the T-3 Safety-Aimer as a level. Use with
a true eight to ten foot two by four as an exten­
HOW TO SELECT A LEVEL AIMING AREA sion. Make sure pads on base of Aimer are
used. Place the board where you expect the
1. Select area you believe to be level.
wheels to be and take readings as outlined above.
2. Remove headlamp bezels and install Aimers on each
headlamp (fig. 3) making sure aiming lugs engage 6 . If either bubble moves outside the black lines of the
vial there is too much slant to the floor. Try driving
the car in at different angles onto the aiming area.
If bubbles can not be centered follow procedure under
"How to Compensate for Unlevel Floor."
NOTE: When level portion of floor is obtained,
mark tire spots on floor so spots can be used
next time without calibrating Aimer.

TO COMPENSATE FOR UNLEVEL FLOORS

If your floor is not level within the limits specified, the

T-3 Aimer can be calibrated to compensate for the error
in the floor. Follow this procedure with both aimers.
1. Drive the car onto the area for which you wish to
compensate the aim ers, and install the aimers in
place on the headlamps.
2. Loosen knob beneath the aimer arm and move the
slider until the bubble is centered.
3. Record the numeral in the view window. (This
Fig . 6 - Removing Aim er from Headlamp numeral is to be used only for re calibration.)

CHEVROLET TRUCK SERVICE MANUAL

 ELECTRICAL—BODY AND CHASSIS 12-5

4. Move the slider to a position halfway between this

recorded numeral and the numeral "2 " in the DOWN
window. (This numeral is used only in recalibration
and not for headlamp aiming.)

5. Recalibrate aimers by turning screw shown in Fig­

ure 8 until the bubble is centered.

6 . The T-3 Aimers are now calibrated for the selected

area. All future aiming must be done in the same
area and with the car pointed in the same direction.

Fig. 8 - Turning Level Adjusting Screw

to C a lib ra te Aim er

SERVICE OPERATIONS
SEALED BEAM UNIT REPLACEMENT (Fig. 9) PARKING LAMP BULB REPLACEMENT (Fig. 9)

1. Remove bezel retaining screws and bezel. 1. Remove headlamp bezel on 40-60 series trucks.
2. Disconnect wiring harness connector located at rear 2. Remove lamp housing retaining nuts, and disengage
of unit in engine compartment. assembly from grille or panel opening.
3. Disengage spring from retaining ring. 3. Disconnect parking lamp wiring from forward wiring
4. Turn headlamp unit to disengage assembly from harness.
headlamp adjusting screws. 4. Connect wiring of new unit to vehicle harness.
5. Position lamp housing in grille or panel opening, as
NOTE: Do not disturb adjusting screw setting. appropriate and install retaining nuts.
6 . Install bulb, lens and bezel as required.
5. Remove retaining ring and headlamp from mounting
ring.
6 . Position new sealed beam unit in mounting ring and REAR LIGHTING (Fig. 10)
install retaining ring.
Exploded views of the different rear lighting arrange­
NOTE: The number molded into lens face must ments are shown in Figure 10. The bulbs may be re­
be at top. placed by removing the lamp lens attaching screws and
lamp lens. The lamp housings may be replaced by re­
7. Install headlamp assembly in panel opening, twisting moving the housing attaching nuts or screws, or by
slightly to engage mounting ring tabs with adjusting removing the nuts and bolts from the bracket.
screws.
8 . Install retaining ring spring and attach wiring har­ DIRECTIONAL SIGNAL LAMPS
ness connector to unit, then check operation of unit
and install bezel. Directional Signal lights are either an integral part of
the parking and taillight assemblies or are mounted on
PARKING LAMP HOUSING REPLACEMENT (Fig. 9) each side of cab (tilt cab only).

1. Remove retaining screws and lens from housing. NOTE: On vehicles using parking and taillight
2. Replace bulb and check operation of unit. assemblies for directional signals; refer to ap­
3. Install lens and retaining screws. plicable light assemblies for bulb replacement.

CHEVROLET TRUCK SERVICE MANUAL

ELECTRICAL—BODY AND CHASSIS 12-6

VIEW C

F ig . 9 - Front Lighting Assemblies

CHEVROLET TRUCK SERVICE M ANUAL

 ELECTRICAL—BODY AND CHASSIS 12-7

CA 31 (04)

(34) CA 30 (03-12)

CA 20-30-40 (09) F/F COWLS

F ig . 10 - Rear Lighting Composite

CHEVROLET TRUCK SERVICE MANUAL

ELECTRICAL—BODY AND CHASSIS 12-8

Bulb Replacement (Cab mounted directional lamps)

1. Remove three screws which retain rear lens to lamp

assembly and remove lens.
2. Replace bulb and check operation of lamp.
3. Position lens and install attaching screws.

WIPER SWITCH REPLACEMENT (Fig. 17)

1. Disconnect battery ground cable.
2. Loosen set screw and remove wiper knob.
3. Remove bezel (using Tool J - 21932) and retaining nut.
4. Push switch from panel opening and remove from
behind instrument cluster.
5. Disconnect wiring at switch terminals.
6 . To install, reverse removal procedure and check
operation of unit.

LIGHT SWITCH REPLACEMENT (Figs. 11 & 17)

1. Disconnect battery ground cable.
2. Reaching up behind instrument cluster, depress shaft
retaining button and remove switch knob and rod.
3„ Remove bezel (using Tool J - 21932) and retaining nut. Fig. 12 - Stop Lamp Sw itch - C h evy Van
4. Push switch from panel opening and remove from
behind instrument panel. 3. Disconnect the two electrical connectors from the
5. Disconnect multiple wiring connectors at switch switch which is located under the toe pan adjacent to
terminals. the brake lever arm.
6 . To install, reverse removal procedure. 4. Remove two screws attaching the switch to the
underside of the toe pan and remove switch.
STOPLIGHT SWITCH REPLACEMENT 5. Install new switch with the switch lever arm between
the brake lever arm and the toe pan and connect the
Chevy Van (Fig. 12) two connectors.
6 . Switch adjustment should be such that 1/2" to 1/4"
1. Raise and support vehicle. pedal will make electrical contact. If necessary,
2. Remove radiator air deflector and extension adjust the switch by bending the switch bracket until
assembly. proper operation is obtained. Lower vehicle.

Tilt Cab Models (Fig. 13)

1. Disconnect the two electrical connectors from the

switch which is located under the toe pan adjacent to
the brake lever arm.
2. Remove two screws attaching the switch to the toe
pan and remove switch.
3. Install new switch and connect the two connectors.

Conventional Cab Models (Fig. 14)

1. Disconnect wiring harness connector from switch and
unscrew switch from mounting clip.
2. Depress brake pedal and push new switch into clip
until switch shoulder bottoms out against clip.
3. Check switch for proper operation. Electrical con­
tact should be made when pedal is depressed 3 /8 " to
5 /8" from fully released position.

DIMMER SWITCH REPLACEMENT

1. Fold back upper left corner of the floor mat and re­
move two screws retaining switch to the toe pan.
2. Disconnect wiring connector from switch terminals.
3. Connect wiring to replacement switch and check
operation.
4. Position switch to toe pan and install retaining
F ig . 11 - Light Switch - C hevy Van
screws.

CHEVROLET TRUCK SERVICE M ANUAL

 ELECTRICAL—BODY AND CHASSIS 12-9

Fig. 13 - Ele c tric a l Components - T ilt Cab

5. Replace floor mat. 6 . Connect wiring harness to terminals and check op­
eration of switch.
NEUTRAL SAFETY SWITCH REPLACEMENT Column Shift—Switch Located on Transmission
(Fig. 15)
Column Shift—Switch Located on Mast Jacket 1. Raise and support vehicle.
1. Disconnect wiring harness connectors at switch 2. Disconnect switch wiring from engine wiring harness
terminals. and remove bolt attaching the switch wiring retaining
2. Remove switch retaining screws and switch from clip to the transmission.
mast jacket. 3. Remove the bolt attaching the switch to the trans­
3. To install, position shift lever in drive and locate mission and disengage switch from shift lever rod.
lever tang against transmission selector plate. 4. Position new switch to transmission and install
4. Align slot in contact support with hole in switch and switch attaching bolt.
insert pin (3/32" dia.) to hold support in place. 5. Loosen transmission lever extension bolt and with
Switch is now in drive position. transmission in neutral position and the switch
5. Place contact support drive slot over shifter tube pinned in neutral position attach switch rod to switch.
drive tang and tighten screws. Remove clamp and 6 . Tighten transmission lever extension bolt to 12-16

pin. lbs. ft. torque and remove pin.

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ELECTRICAL—BODY AND CHASSIS 12-10

STOPLIGHT
SV/ITCH

HORN
RELAY

HORN RELAY
BACKING —
LAMP SWITCH

AIR BRAKE —
WARNING BUZZER STOPLIGHT
i SWITCH

DIMMER-
SWITCH

Fig. 14- Ele c tric a l Components - C onv. Cab

7. Connect switch wiring to engine wiring harness and NOTE: Position gear shift in neutral before
install wiring retaining clip bolt. assembling switch to mast jacket.
8 . Check operation of switch and lower vehicle.
4. Check operation of switch.
BACKING LAMP SWITCH REPLACEMENT
Switch Located on Transmission Side Cover (Fig. 16)
Switch Located on Mast Jacket (Fig. 13)
1. Raise and support vehicle.
1. Disconnect wiring at switch terminals. 2. Disconnect wiring at switch terminals.
2. Remove switch attaching screws and switch from 3. Remove two bolts attaching switch and switch wiring
mast jacket. retaining clip to transmission side cover; disengage
3. Position replacement switch to mast jacket, install switch from shift lever rod.
retaining screws and connect wiring to switch 4. Mount replacement switch loosely to transmission
terminals. side cover and connect wiring to switch terminals.

CHEVROLET TRUCK SERVICE MANUAL

 ELECTRICAL—BODY AND CHASSIS 12-11

5. Use suitable pin to lock switch lever in reverse 7. Tighten bolts to proper torque, remove pin from
position. switch lever and check operation of switch; lower
6 . With transmission lever in reverse position install vehicle.
shift lever rod.

Fig. 15 - N eutral Safety Sw itch - C h evy Van Fig. 16 - Backing Lamp Switch - C hevy Van

INSTRUMENTS AND GAUGES

INDEX
Page
General Description.............................................................12-11 Fuel Gauge Replacem ent............................................. 12-14
Service O p e ra t io n s ................................................... ... . 12-11 Temperature Indicator L ig h t....................................... 12-20
Instrument C lu ste r...................................................... ...12-11 Temperature Gauge R ep lacem en t.............................. 12-20
R em oval.................. ................................................12-11 Temperature Sender Unit R ep lacem en t..................... 12-20
In s ta lla tio n ........................... ....................................12-11 Oil Pressure Indicator L ig h t....................................... 12-20
Indicator and Illuminating Bulb R eplacem en t............ 12-12 Oil Pressure Gauge R ep lacem en t.............................. 12-20
Laminated Circuit Replacem ent................................. ...12-13 Oil Pressure Sender Unit R ep lacem en t..................... 12-20
Speedometer Replacem ent........................... .. ...............12-13 Generator Indicator...................................................... 12-20
Speedometer Cable Replacement Ammeter Gauge Replacement. .................................... 12-20
or L u b ric a t io n ......................................................... ...12-14 A ir Pressure Gauge R eplacem ent.............................. 12-21

GENERAL DESCRIPTION
All instruments and gauges of the 1967 Trucks are in­ cluster housing, on all other models the lamp sockets are
stalled in the instrument cluster. The entire cluster clip retained and can be quickly snapped in or out of
may be removed from the vehicle for servicing of the position.
instruments and gauges. Illuminating and indicator lamps Regular maintenance is not required on the instrument
may be replaced without removing the cluster from the cluster or its components other than maintaining clean,
vehicle. On models with a laminated die cut circuit the tight electrical connections, replacing defective parts and
bulbs are installed in plastic holders which lock into the keeping the speedometer cable properly lubricated.

SERVICE OPERATIONS
INSTRUMENT CLUSTER 3. Remove windshield wiper knob and bezel nut.
REMOVAL AND INSTALLATION 4. Remove light switch rod and bezel.
5. Disconnect speedometer cable and chassis wiring
10-30 Conventional Cab Models (Fig. 17) harness connector at rear of instrument panel.
6 . Protect mast jacket with suitable covering.
1. Disconnect battery ground cable. 7. Remove cluster retaining screws from face of as­
2. Remove choke control knob. sembly and remove cluster assembly from console.

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ELECTRICAL—BODY AND CHASSIS 12-12

Fig. 17 - Instrument Cluster Assembly - Conventional Cab

Chevy Van
8 . To install, reverse removal procedure. 1. Disconnect battery ground cable.
2. Disconnect speedometer cable at speedometer head.
40-60 Conventional Cab Models (Fig. 17) 3. Remove two nuts attaching cluster to dash panel.
Cluster may now be pulled clear of dash panel.
1. Disconnect battery ground cable. 4. Disconnect all indicator and illuminating bulb sock­
2 . Remove choke control knob and bezels. ets, carefully noting their location for proper rein­
3. Remove windshield wiper knob and bezel nut. stallation. Remove cluster.
4. Remove light switch rod and bezel. 5. To install, reverse removal procedure.
5. Disconnect speedometer cable and chassis wiring
harness connector at rear of instrument panel. Tilt Cab Models (Fig. 19)
6. Disconnect air pressure and oil pressure gauge feed
pipes. 1. Disconnect battery ground cable.
7. Loosen mast jacket upper support clamp bolts and 2. From under dash, disconnect speedometer cable and
lower mast jacket to prevent interference with lower wiring.
edge of instrument cluster. 3. Disengage cluster retaining clips by inserting Tool
J-7900 in provided slots as shown in Figure 19 and
CAUTION: Protect mast jacket with suitable remove cluster.
covering. 4. To install, reverse removal procedure.

8. Remove cluster retaining screws from face of as­

sembly and remove cluster assembly from console.
9. To install, reverse removal procedure. INDICATOR AND ILLUMINATING
BULB REPLACEMENT
Flatface Cowl Models (Fig. 18)
10-60 Conventional Cab Models
1. Disconnect battery ground cable.
2. Disconnect electrical connectors and oil pressure 1. Turn bulb holder counterclockwise to remove from
pipe. the cluster housing.
3. Remove three screws attaching cluster housing to 2. Pull bulb straight out to remove from holder.
dash panel. 3. Install replacement bulb in holder, press inward to
4. Pull cluster from opening in dash panel. lock in place.
5. To install, reverse removal procedure. 4. Insert holder into housing, with lugs on holder enter­

CH EVR O IET TRUCK SERVICE MANUAL

 ELECTRICAL—BODY AND CHASSIS 12-13

Fig . 18 - Instrument Cluster Assembly - F/F Cowl

ing notches in case, and turn clockwise to lock in the circuit and must be reinstalled to provide the
place. proper ground connections for the laminated
circuit.
All. Other Models
4. Remove fuel, temperature and ammeter terminal
To replace any indicator or illuminating bulb, unsnap nuts retaining laminated circuit to cluster cover.
the proper socket from rear of instrument cluster, re­ 5. Remove laminated circuit from rear of instrument
place bulb, and reinsert unit onto rear of cluster housing. cluster.
6 . To install, reverse removal procedure and check
LAMINATED CIRCUIT REPLACEMENT operation of unit.

10-60 Conventional Cab Models SPEEDOMETER REPLACEMENT

NOTE: Servicing of the speedometer assembly
1. Remove instrument cluster assembly as previously should be performed by an authorized AC Speed­
described in this section.
ometer Service Station.
2. Remove all instrument cluster lamp assemblies.
3. Remove laminated circuit retaining screws. Conventional Cab Models

NOTE: These screws serve as a ground fo r 1. Remove instrument cluster assembly and laminated

CHEVROLET TRUCK SERVICE M ANUAL

ELECTRICAL—BODY AND CHASSIS 12-14

circuit as previously described in this section.

2. Remove retaining screws and cluster rear cover.
3. Remove front cover from face of cluster.
4. Remove two retaining screws and speedometer from
cluster.
5. To install, reverse removal procedure and check op­
eration of unit.

Flatface Cowl Models

1. Disconnect battery ground cable.

2. Disconnect speedometer cable and all indicator and
illuminating sockets.
3. Remove three screws attaching speedometer housing
to dash panel.
4. Pull speedometer from opening in dash panel.
5. To install, reverse removal procedure and check
operation of unit.

Chevy Van

1. Remove instrument cluster assembly as previously

described in this section.
2. Remove four screws securing cluster back panel to
bezel assembly.

NOTE: Assemble the two parts with alignment Fig. 19 - Instrument- Cluster Removal - T ilt Cab
dowels properly positioned.
described in this section.
2. Remove instrument lamps, ground screws and term i­
3. Remove two screws securing speedometer head to
nal nuts retaining laminated circuit to fuel gauge
cluster back panel; carefully remove speedometer
section of cluster assembly.
head.
3. Carefully move the laminated circuit from fuel gauge
4. To install, reverse removal procedure and check
area and remove three retaining screws, cover and
operation of unit.
gauge assembly from cluster housing.
4. Remove attaching nuts and gauge from cover plate.
Tilt Cab Models 5. To install, reverse removal procedure and check op­
eration of unit.
1. Remove instrument cluster assembly as previously
described in this section.
2. Remove eight screws securing cluster bezel to back
panel assembly and remove bezel. Flatface Cowl Models
3. Remove two screws attaching speedometer head to
1. Remove instrument cluster assembly as previously
back panel assembly and carefully remove speedom­
described in this section.
eter head.
2. Uncrimp bezel (7 places) and remove bezel.
4. To install, reverse removal procedure and check
3. Remove nuts securing fuel gauge to cluster case and
operation of unit.
remove gauge.
SPEEDOMETER CABLE REPLACEMENT OR 4. To install, reverse removal procedure and check
LUBRICATION; ALL MODELS operation of unit.

1. Disconnect speedometer cable from the speedometer Chevy Van

head; remove old cable by pulling it out from speed­
ometer end of conduit. 1. Remove instrument cluster assembly as previously
described in this section.
NOTE: If old cable is broken it will be neces­ 2. Disconnect electrical connectors and remove nuts
sary to remove lower piece from transmission securing gauge to cluster assembly.
end of conduit. 3. Remove gauge from cluster opening.
4. To install, reverse removal procedure and check
2. Lubricate the lower 3/4 of cable with speedometer operation of unit.
cable lubricant and push the cable into the conduit.
Connect the upper end to the speedometer head and
road test vehicle for proper speedometer operation. Tilt Cab Models
FUEL GAUGE REPLACEMENT 1. Remove instrument cluster as previously described
10-60 Conventional Cab Models in this section.
1. Remove instrument cluster assembly as previously 2. Remove eight screws securing cluster bezel to back

CHEVROLET TRUCK SERVICE MANUAL

 ELECTRICAL—BODY AND CHASSIS 12-15

Fig. 20 - Instrument Panel W iring (Conv. Cab 10-30)

1. Fuse Panel 8. Bulkhead Conn.

2. Horn Relay 9. To Backing Lamp Switch
3. To Light Sw itch 10. To Stop Lamp Switch
4. To W ip e r Switch 11. To Dome Lamp Conn.
5. To D irectional Sw itch 12. Dimmer Switch
6. To W ip e r M otor 13. To Instrument Cluster Conn.
7. Ignition Switch

CHEVROLET TRUCK SERVICE M ANUAL

ELECTRICAL—BODY AND CHASSIS 12-16

Fig. 21 - Instrument Panel W iring (Conv. Cab 40-60)

1. Fuse Panel 8. To Ignition Switch

2. Horn Relay 9. Bulkhead Connector
3. To Light Switch 10. To Stop Lamp Switch
4 . To W ip e r Switch 11. A ir Brake Buzzer
5. To Directional Switch 12. Dome Lamp Conn.
6 . Instr. Cluster Connector 13. Dimmer Switch
7. To W ip e r Motor

CHEVROLET TRUCK SERVICE M ANUAL

 ELECTRICAL—BODY AND CHASSIS 12-17

1. Horn Relay 9. Ignition Switch

2. To Stop Lamp Switch 10. To Temp G auge
3. Hi Beam Lamp 11. R. H. Turn Ind.
4. C luster Lamp 12. To Ammeter
5. Brake W arning Lamp 13. L. H. Turn Ind.
6. Bulkhead Conn. 14. Light Sw itch Conn.
7. D irectio n al Signal Conn. 15. A ir Brake Buzzer
8. Fuel G au g e Conn. 16. Dimmer Switch

CHEVROLET TRUCK SERVICE M ANUAL

ELECTRICAL—BODY AND CHASSIS 12-18

Fig. 23 - Instrument Cluster W iring - C h evy Van

1. O il Pressure Ind. 8. L. H . Turn Ind.

2. Temperature Ind. 9. R. H. Turn Ind.
3. Cluster Lamp 10. G en erato r lnd„
4. W ip e r Sw itch 11. Ignition Switch
5. Light Switch Conn. 12. To D irectional Signal Switch
6. To H eater Switch 13.
7. Hi Beam Ind. 14.

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 ELECTRICAL—BODY AND CHASSIS 12-19

Fig. 24 - Instrument Cluster Connections - Conventional Cab

1. Instr. Cluster Conn. Brake Warning Ind. 9. O il Pressure Ind. 13. Battery Gauge
2. Laminated C ircu it G en erator Ind. 10. "H ig h " Beam Ind. 14. Ignition Terminal
3. Instr. Cluster Lamp R. H. D irectional 11. Overspeed W arning/Low Vacuum 15. Temperature Gauge
4. Temperature Ind. L. H. D irectional 12. G en erator G auge 16. Fuel Gauge

CHEVROLET TRUCK SERVICE M ANUAL

ELECTRICAL—BODY AND CHASSIS 12-20

panel assembly and remove bezel. the engine is started, one or more of the following condi­
3. Pull off plastic caps on terminal nuts and remove tions is indicated:
terminal nuts; carefully remove fuel gauge. Low oil pressure
4 . To install, reverse removal procedure and check Defective wiring or sender unit
operation of unit. Defective bulb
High engine temperature
TEMPERATURE INDICATOR LIGHT
OIL PRESSURE GAUGE REPLACEMENT
10-30 Conventional Cab Models, Chevy Van
The temperature indicator circuit consists of two re­
40-60 Conventional Cab Models
motely located units, indicator light and sender unit. The
1. Remove instrument cluster assembly and laminated
lamp unit is a single red light which indicates an over­
heated engine condition. circuit as previously described in this section.
2. Remove rear cover retaining screws, cover and
gauge assembly from cluster housing.
TEMPERATURE GAUGE REPLACEMENT 3. Remove pipe fitting and retaining nut and remove
gauge unit from cover.
40-60 Conventional Cab Models
4. To install, reverse removal procedure and check
1. Remove instrument cluster assembly as previously operation of unit.
described in this section.
2. Remove terminal nuts retaining laminated circuit to Flatface Cowl Models
gauge unit.
3. Remove three attaching screws, cover and gauge as­ 1. Remove instrument cluster assembly as previously
sembly from cluster housing. described in this section.
4. Remove terminal attaching nuts and gauge unit from 2. Uncrimp bezel (7 places) and remove bezel.
cover plate. 3. Remove nut securing oil pressure gauge to cluster
5. To install, reverse removal procedure and check case and remove gauge.
operation of unit. 4. To install, reverse removal procedure and check
operation of unit.
Flatface Cowl Models
1. Remove instrument cluster assembly as previously
OIL PRESSURE SENDER UNIT REPLACEMENT
described in this section.
All Models
2. Uncrimp bezel (7 places) and remove bezel.
3. Remove 2 nuts securing temperature gauge to cluster
1. Disconnect wiring harness connector from sender
case and remove gauge.
unit terminal (located in block above starter on L - 6
4. To install, reverse removal procedure and check
engines and at left front of distributor on V- 8
operation of unit.
engines).
2. Remove sender unit using Tool J - 21757, replace with
Tilt Cab Models new unit and check operation.
1. Remove instrument cluster as previously described
in this section. GENERATOR INDICATOR
2. Remove eight screws securing cluster bezel to back
panel assembly and remove bezel. 10-30 Conventional Cab Models, Chevy Van,
3. Pull off plastic caps on terminal nuts and remove Tilt Cab Models
terminal nuts; carefully remove temperature gauge.
Ignition on, engine not running and telltale light off:
4. To install, reverse removal procedure and check
1. Indicator bulb burned out; replace bulb.
operation of unit.
2. Open circuit or loose connection in the telltale light
circuit.
TEMPERATURE SENDER UNIT REPLACEMENT
Telltale light stays on after engine is started; refer to
Charging Systems under Engine Electrical, Section 6 Y.
All Models
1. Drain engine cooling system to a level below unit. AMMETER GAUGE REPLACEMENT
2. Remove sender unit (located in the inlet manifold
near water pump housing on V- 8 engines and in the 40-60 Conventional Cab Models
cylinder head near an exhaust port on L - 6 engines)
1. Remove instrument cluster assembly and laminated
and replace with new unit.
circuit as previously described in this section.
3. Refill cooling system and check operation of unit.
2. Remove terminal nuts retaining printed circuit to
gauge unit.
OIL PRESSURE INDICATOR LIGHT 3. Remove three attaching screws, cover and gauge as­
sembly from cluster housing.
10-30 Conventional Cab Models, Chevy Van, Tilt
4. Remove terminal attaching nuts and gauge unit from
Cab Models cover plate.
If the light does not come on when the ignition switch is 5. To install, reverse removal procedure and check
turned on, or if the light comes on and remains on after operation of unit.

CHEVROLET TRUCK SERVICE M ANUAL

 ELECTRICAL—BODY AND CHASSIS 12-21

AIR PRESSURE GAUGE REPLACEMENT operation of unit.

40-60 Conventional Cab Models
Flatface Cowl and Tilt Cab Models
1. Remove instrument cluster assembly as previously
described in this section. 1. Unsnap socket and bulb from top of gauge housing.
2. Remove rear cover retaining screws, cover and 2. Disconnect air pipe at rear of gauge.
gauge assembly from cluster housing. 3. Remove two attaching nuts, washers and clamp. Pull
3. Remove pipe fitting and retaining nut and remove gauge from opening in instrument panel.
gauge unit from cover. 4. To install, reverse removal procedure and check
4. To install, reverse removal procedure and check operation of unit.

DIRECTIONAL SIGNAL CONTROL

The 1967 directional signal switch is an electrically 6. Disconnect switch wiring from chassis harness at
operated self-contained unit which incorporates the can­ multiple connector under instrument panel.
celling mechanism, the hazard warning switch and the
lane changing signal. The switch is one complete plastic NOTE: On 40-60 Models, remove wire term i­
assembly and is serviced as a unit except for the spring nals from multiple connector.
detent, yoke assembly and cancelling springs.
The hazard warning circuit is activated by a push-pull 7. Remove mast jacket upper bracket.
switch which is located on the right side of the mast 8 . Remove switch wiring cover from column.
jacket, opposite the directional signal lever. 9. Remove switch mounting screws and remove switch,
The lane changing circuit is activated by holding the bearing housing, switch cover and shift housing from
directional signal lever in the first detent position; there column.
is no lock-in or cancelling device in this position. 10. To install, reverse removal procedure.
On Tilt Cab models and on P20 and P30 models the
hazard warning switch and the lane changing signal are Tilt Cab Models and P20, 30 Models
not incorporated in the directional signal switch, but
there is a separate hazard warning switch on the instru­ 1. Remove steering wheel (Refer to Section 9, Steering).
ment panel. 2. Disconnect signal wiring at chassis harness, discon­
nect directional signal wiring leads from multiple
DIRECTIONAL SIGNAL SWITCH REPLACEMENT connector.
10-60 Conventional Cab, Chevy Van and P-10
NOTE: Mark location of each wire in
(Fig. 25)
connector.
1. Disconnect battery ground cable.
2. Remove steering wheel assembly (Refer to Steering, 3. Disconnect wiring harness retaining clips.
Section 9), preload spring and cancelling cam. 4. Remove directional signal lever attaching screw and
3. Remove shift lever roll pin and shift lever (if lever.
applicable). 5. Remove three screws attaching directional signal
4. Remove directional signal lever retaining screw and control assembly to signal housing.
lever. 6 . Remove directional signal assembly and housing
5. Push in hazard warning knob, remove retaining from steering column.
screw and knob. 7. Remove upper shaft bearing and horn wire from
directional signal assembly.
NOTE: Hazard switch knob must be pushed in 8 . To install, reverse removal procedure and check
to prevent damage to switch when removing operation of unit.
from switch cover.

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ELECTRICAL—BODY AND CHASSIS 12-22

Fig. 25 - D irectio n al Signal Assembly—Conventional Cab and P10 Series

1. C ancel ling Cam .5. Upper Bearing 9. W irin g Connector

2. D irectio n al Lever Retaining Screw 6. Bearing Housing 10. W iring Cover
3. Sw itch M ounting Screw 7. Switch Cover 11. Retainer
4. Sw itch 8. Lever Arm 12. Hazard Warning Knob
 ELECTRICAL—BODY AND CHASSIS 12-23

Fig . 26 - D irectional Signal Assembly - C h evy Van

1. C ancel ling Cam 3. Switch Mounting Screw 6. Switch Cover

2 . Lever Screw 4. Directional Switch 7. D irectional Lever
5. Upper Bearing Assembly

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 ELECTRICAL—BODY AND CHASSIS 12-24

Fig. 27 - D irectional Signal Assembly - T ilt Cab and P20, 30 Series

WINDSHIELD WIPER AND WASHER

INDEX
Page Page
General Description . . ............... 12-28
Service Operations . . Windshield Washer Pump........................... ............... 12-28
Wiper Motor . . . . R e m o v a l................................................ ............... 12-28
R em oval............ Installation............................................. ............... 12-28
Installation . . . Disassembly .......................................
Disassembly . . Assem bly................................................ ............... 12-28
Inspection . . . .

CHEVROLET TRUCK SERVICE MANUAL

' . . ------------------------------------------------------------------------------------------
 ELECTRICAL—BODY AND CHASSIS 12-25

GENERAL DESCRIPTION
The Type "E " two-speed electric windshield wiper as­ ing, stopping and parking of the Type "E " wiper motor.
sembly (fig. 36) incorporates a non-depressed type The manually operated start, stop switch is located on the
(blades park approximately 2 " above windshield molding) instrument panel, while the cam operated park switch is
motor and gear train. The rectangular, 12 volt, com­ located in the wiper gear box.
pound wound motor is coupled to a train consisting of a The windshield washer pump used on the 2-speed Type
helical drive gear at the end of the motor armature shaft, "E " wiper motor assembly is a positive displacement
an intermediate gear and pinion assembly, and an output type pump employing a small bellows, bellows spring and
gear and shaft assembly. The crank arm is attached to valve arrangement. The pumping mechanism is actuated
the output gear shaft. Depending on the wiring harness by a four lobe cam and driven directly by the wiper
of the different trucks, the wiper motors are equipped motor (fig. 37). Thus, when the wiper is operated, this
with three or four terminals. For service replacement rotor is always turning with the gear. Programming is
a four terminal assembly is used, servicing both, the accomplished electrically and mechanically by a relay
three terminal and the four terminal models. assembly and ratchet wheel arrangement.
Two switches, connected in parallel, control the start­

SERVICE OPERATIONS
WIPER MOTOR

REMOVAL AND INSTALLATION

10-60 Conventional Cab Models (Fig. 29)

1. Disconnect battery ground cable.

2. Remove wiper arms and blades from transmission
shaft.
3. Remove plenum chamber grille.
4. Disconnect wiper drive rods from crank arm; re­
move crank arm nut and arm from motor shaft.
5. Working under instrument console, disconnect wiper
motor and washer wiring connectors.
6 . Disconnect washer hoses from washer pump.
7. Remove motor attaching screws and motor from cowl
mounting position.
8 . To install, reverse removal procedure.

NOTE: Make certain wiper motor and blades

are in the "Park" position.

Chevy Van (Fig. 30)

1. Disconnect battery ground cable.
2. Disconnect electrical connections and washer hoses.
3. Loosen nuts securing drive link to wiper motor crank
arm and disengage ball joint.
4. Remove motor attaching screws and motor from cowl
mounting position.
5. To install, reverse removal procedure.

Tilt Cab Models (Fig. 31)

NOTE: Two separate motors are used to
power the wipers, one switch controlling both.
Figure 31 is an exploded view of the left hand
wiper assembly installation. Right hand assem­
F ig . 29 - W iper Motor Installation - C o n v. Cab bly is identical, however, it will be necessary to

CHEVROLET TRUCK SERVICE M ANUAL

ELECTRICAL—BODY AND CHASSIS 12-26

remove heater assembly before wiper motor

may be serviced.

1. Disconnect battery ground cable.

2. Remove nut retaining wiper on to shaft.
3. Pull arm, knurled driver and rain shield from shaft.
4. Remove nut retaining shaft ferrule to body outer
panel; remove washers.
5. From inside vehicle, remove four screws retaining
motor assembly to dash and remove assembly from
vehicle.
6 . To install, reverse removal procedure.

WIPER MOTOR DISASSEMBLY

Gear Box

Refer to Figure 32.

1. Remove the two washer pump mounting screws (fig.
36) and lift pump off washer.
2. Remove washer pump drive cam as required (fig. 37).
The cam is pressed on the shaft but can be wedged
off by using two screw drivers between cam and
plate.
3. Clamp crank arm in a vise and remove crank arm
retaining nut.

Fig. 31 - W indshield W ip e r Assy. - T ilt Cab CAUTION: Failure to clamp crank arm may
result in stripping of wiper gears!
1. Crown Nut O u ter Washer
2. Lock W asher Inner Washer 4. Remove crank arm, seal cap, Tru-Arc retaining
3. W ip e r Arm Assembly Shaft Ferrule (Part of Motor ring, and end-play washers.
4. Knurled Driver Assembly)
5. Rain Shield 10 . Retaining Bolts
NOTE: Seal cap should be cleaned and re­
6. Shaft Ferrule Retaining 11. M otor Assembly (Includes
packed with a water-proof type grease before
Nut Bracket)
reassembly.

Fig. 32 - W ip er M otor and G e a r Box Assembly

1. Nut 5. W asher 8. Intermediate G e a r 12. Brushes 16. Thrust Plug
2. Crank Arm 6. G e a r Box Cover 9. W a v e Washer 13. W a ve Washers 17. Frame and Field
3. Seal Cap 7. Output G e a r and 10. G e a r Box Housing 14. Flat Washers 18. End Plate
4. Retaining Ring Shaft Assembly 11. Brush Plate Assembly and 15. Armature 19. Tie Bolts (Two Required)
Mounting Brackets

CHEVROLET TRUCK SERVICE M ANUAL

 ELECTRICAL—BODY AND CHASSIS 12-27

BRUSH HOLDER

R EM O V E BR U SH S P R IN G FR O M SLO T
A N D PLACE IT IN G R O O V E A S S H O W N

Fig. 33 - Releasing Brush Spring Tension

b. Drill out rivets securing terminal board and park

switch ground strap to mounting plate.
NOTE: Screws, nuts and washers for attaching
a replacement terminal board-park switch as­
sembly are included with the replacement
assembly.
Motor

1. Follow Steps 1 through 7b under gear box

disassembly.

F ig. 34 - End P la y W a v e W asher Installation

5. Drill out gear box cover retaining rivets, remove

cover from gear train.

NOTE: Screws, nuts and lock washers for re­

assembling cover to wiper are contained in a
service repair package.

6. Remove output gear and shaft assembly, then slide

intermediate gear and pinion assembly off shaft. PUMP M O U N TIN G
SCR EW S
7. If necessary, remove terminal board and park switch
assembly as follows:
a. Unsolder motor leads from terminals. Coding of
motor leads is not necessary on single-speed Fig. 36 - W asher Pump Attaching Screws
wipers.

CHEVROLET TRUCK SERVICE M ANUAL

ELECTRICAL—BODY AND CHASSIS 12-28

Motor
Reassemble motor using reverse of disassembly
procedures.

NOTE: Armature end play is controlled by end

play washers. See Figure 34 for proper assem­
bly of end play washers. Lubricate armature
shaft bushings with light machine oil.

Gear Box

1. Assemble gear box using reverse of disassembly

procedure.

NOTE: Lubricate gear teeth with Delco Cam

and Ball Bearing lubricant or equivalent. Be
sure cover is properly located over dowel pins
and be sure to reinstall ground strap.

2. Place wiper in park position and install crank arm

on output shaft, rotate crank so alignment marks line
up with those on cover (fig. 35).
Fig. 37 - W asher Pump Drive Cam 3. Replace retaining nut, place crank arm in vise,
tighten retaining nut.
2. Remove motor through bolts, tap motor frame
lightly, and remove motor from mounting plate. WINDSHIELD WASHER PUMP
3. Remove brush spring tension (fig. 33), slide arma­
ture and end plate from motor frame. Pull end plate Removal and Installation
from armature.
Removal of the washer pump from the wiper motor
NOTE: Thrust plug located between armature
shaft and end plate. consists of:
1. Disconnect wiring harness and washer hoses from
4. Remove end play adjusting washers from armature, washer.
noting arrangement for proper reinstallation. 2. Remove the two pump-to-wiper retaining screws and
remove washer from wiper (fig. 36).
WIPER MOTOR INSPECTION 3. Reverse removal procedure to install assembly.

Check and inspect all parts for serviceability, replace Disassembly—Assembly

as necessary. All parts can be replaced individually
except motor frame and field, which is serviced as an Refer to Figure 38.
assembly. Service kits also provide screws, nuts and 1. Remove washer pump cover.
washers to replace gear cover and terminal board rivets. 2. Relay.
a. To remove relay unsolder coil leads from
WIPER MOTOR DISASSEMBLY terminals.

Refer to Figure 32 for exploded view of motor and gear NOTE: No coil polarity is necessary when re­
train. soldering coil leads.

b. Remove coil retainer clip and slip coil assembly

BELLO W S A N D C O IL A N D PO LE out of mounting bracket.
S P R IN G H O U S IN G A S S E M B LY

H O LD IN G C O N T A C T S O P E N

W H EEL A C TU A TO R A C TUA TO R PIN

P LU N G E R ARM

F ig . 38 - Washer Pump Mechanism F ig . 3 9 - Releasing Pump from Lockout Position

CHEVROLET TRUCK SERVICE M ANUAL

 ELECTRICAL—BODY AND CHASSIS 12-29

3. Ratchet Pawl. CAUTION: It may be necessary to carefully

a. To remove ratchet pawl disengage spring from pry bellows lip out of the valve body groove.
ratchet pawl and slide ratchet pawl from shaft.
7. Bellows
CAUTION: Be sure spring is properly assem ­
a. To remove bellows first remove valve assembly.
bled before replacing washer pump cover.
b. Manually operate pump clockwise to release pump
4. Terminal Board from "lock-out” position (fig. 39).
a. Remove terminal board attaching screws, ratchet c. Hold bellows plunger arm from moving, then push
dog and board from washer base. in against bottom of bellows with thumb and twist
5. Ratchet Wheel bellows spring from housing.
a. Remove lock ring from shaft. 8 . Actuator Pin
b. Slide ratchet wheel from shaft. a. Remove actuator pin retaining spring and slide
6 . Valve Assembly pin from washer base.
a. To remove valve assembly remove screws that 9. Reverse disassembly procedure to assemble washer.
secure valve assembly to bellows housing.

CHEVROLET TRUCK SERVICE M ANUAL

ELECTRICAL—BODY AND CHASSIS 12-30

TO CLUTCH
HOUSING

IGNITION
SW

. 12R

SHUNT>“ 18b
AMMETER
RESISTOR V V ^

AMMETER GAGE

Fig . 40 - Engine Compartment - PA10

CHEVROLET TRUCK SERVICE M ANUAL

 ELECTRICAL—BODY AND CHASSIS 12-31

12R —
16B/W-
+ BAT _
(P
16B
•12R »12R • 12R* f — 4Bf PS 20
4B -30
SHUNT i JUNCTION BLOCK 6B PS 40
AMMETER Iw
RESISTOR
1 1
■18Y«
TO TRANS
*12P*

DDST

A Or
iiiijioiii 9
MM 1 I i 111 m mm

TEMP -WITH RPO M35

SW. OR M49 (EXCEPT PS 40 )
■18DG-
-WITH RPO M49
■12PPL (EXCEPT PS 400)
■12PPL"
EXCEPT
RPO M35 NEU SFT SW
& M49 .------ 12P - g — — 18B
•12PPL TRANS CONT
■12P---- SW TRANS
12R-

■18DG D IGNITION
SW
TEMP GAGE

16B----
16B/W*
AMMETER GAGE

F ig . 41 - Engine Compartment - PS 20-30-40

CHEVROLET TRUCK SERVICE M ANUAL

ELECTRICAL—BODY AND CHASSIS 12-32

F ig . 42 - Engine Compartment - PT 20-30

CHEVROLET TRUCK SERVICE M ANUAL

 ELECTRICAL—BODY AND CHASSIS 12-33

JU NCTIO N B LO C K

------ a a Z H I
FUSIB LE L IN K

DASH P A N E L -

T A IL & STO P
L P HARN
CONN

•20T—[

-*B R N —«
■*Y -
-*DG
-18 LG —
^20T-
OUTSIDE
FUEL I
TAN K __
■20T~oc® j
BRAKE W ARNING SW
♦"FOR W IRE GAGE SEE CHASSIS & T A IL L A M P W IRIN G SHEET

F ig . 43 - Engine Compartment - C S -K S 10-20, CS30 (E x c . 02)

CHEVROLET TRUCK SERVICE M ANUAL

ELECTRICAL—BODY AND CHASSIS 12-34

JUNCTION B LO C K
...............12R ■ ■*£
/ — v\A/— ^ DASH-
16R FUSIB LE L IN K
PANEL
I — 6 B --------

T A IL & STO P
L P HARN
CONN

/ 12 PP L
'20W /O R /PPL— 2QW/OR/PPLv

16LG

20DBL' »20DBL>v

^ >-20PPL-^
R. H. P A R K IN G &
DIR. SIG N AL L P . •18DG
18LG<

CE 30 (04-09)
C E -K E i0 -20 (04-09-34)
W /R PO M16-20-28
CE 20 -30 W /R PO E57
""" " 12PPL— s
> -2 0 D G "" 20D B L\
TEM P ,
<3 GEN & FWD L P 20DS
sw m A . C, Uh
H ARN CONN
GEN.*
/> — 16LG ------- - s ...

20PPL-
20PPL'
16BRN
12R —
16W—- '
16DBL —
►16BRN'
20 LB L 20 L B L ^ ENG HARN
CONN

20PPL
L . H. PA R K IN G &
DIR. SIG N AL L P .

TO SHEET M E T A L — * BRN •
—*Y---
16LG - *D G —
16LG - 18LG-
-1 8 T . ^**2 0 T “7
-1 8 T .
» 18B

OUTSIDE FUEL-
12DG
R A D IA T O R SU PPO RT TANK
HORN 20T— —<Jt=f]
♦F O R W IRE GAGE SEE CHASSIS & T A IL L A M P W IRIN G SHEET BRAKE W ARN IN G SW

F ig . 44 - Engine Compartment - C E - K E 10-20, CE30 (E x c . 02)

CHEVROLET TRUCK SERVICE M ANUAL

 ELECTRICAL—BODY AND CHASSIS 12-35

Fig . 45 - Engine Compartment - C S 40-50-60, MS60

CHEVROLET TRUCK SERVICE MANUAL

ELECTRICAL—BODY AND CHASSIS 12-36

JU NCTION B LO C K
........ 12R C fl'l
t-----s / W — i

T A IL & STOP
L P HARN CONN

V *B R W
Y‘
•*DG“
•18LG-

Fig . 46 - Engine Compartment - C E4 0 -5 0 -6 0 , M E50-60

CHEVROLET TRUCK SERVICE M ANUAL

 ELECTRICAL—BODY AND CHASSIS 12-37

•00 STRAP DASH'

TO FRAME 'lh PANEL

00B-
(FRAME MOUNTED)
TAIL It STOP
LAMP HARN
CONN

FUSE

JO
f PL*>
R.H. PARKING fc
DIR. SIGNAL LP TEMP
SENDER

PPG
■

B -
A.C,{ GEN &FWD LP
QENJ HARN CONN
14LG-
i
12R
•JOPPI

L.H. PARKING & 16BRN-

DIR. SIGNAL LP
20LBL-'

»20DBL«
-12R—
V 1 8 B/W- *BRN—
.18B — *Y -
'•DG —
1ST-

-RADIATOR ltDG*
SUPPORT

Fig. 47 - Engine Compartment - C D - C G 50, C D - C G - M G 6 0

CHEVROLET TRUCK SERVICE M ANUAL

ELECTRICAL—BODY AND CHASSIS 12-38

FUEL GAGE CONK

TAIL, STOP &DIRECTION

LP. CONN.
20DG

Fig . 48 - Chassis W iring Harness and Engine W iring Harness TS 40-50-60

CHEVROLET TRUCK SERVICE M ANUAL

 ELECTRICAL—BODY AND CHASSIS 12-39

CO IL

^ ^
k - r' 0/s sw
(327 & 366
|20W/OR/PPLv— 20W/OK —4^
ENG O N L Y )
(283 E N G )] (327 & 366 ENG)

20Y- *

2 4 6 8
9 9 g

V-8 EHSr
-----
y Do/l

6
1 3 5 7

O IL PRESS
SW

T A IL , STO P & DIRECTIO N

L P . CONN.
■20DG

F ig . 49 - Chassis Wiring Harness and Engine W iring Harness - TE 40-50-60

CHEVROLET TRUCK SERVICE M ANUAL

ELECTRICAL—BODY AND CHASSIS 12-40

TAIL STOP &DIRECTION

LP CONN.

F ig . 50 - Chassis W iring Harness and Engine W iring Harness - TT4 0, T D -T G 50-60

CHEVROLET TRUCK SERVICE MANUAL

 ELECTRICAL—BODY AND CHASSIS 12-41

♦F O R W IRE GAGE SEE CHASSIS & T A IL L A M P V . 14LB L-

W IRING SHEET 16LG*

F ig . 51 - Instrument Panel - C A - K A 10-20, C A30 (E x c . 02)

CHEVROLET TRUCK SERVICE MANUAL

ELECTRICAL—BODY AND CHASSIS 12-42

■24BRN/W- 124BRN/W
-1 2 P --------- » 12P —
— 20DG ■ «20DG">
. 12 PP L
1 2 PP L
• 12R
18B ‘
18B/LBL*
18DBL* HORN C O N TA C T
18BRN •
18PPL < -TO D IRE CTIO N SIG. SW. FU SE PN L
18B/Y «
18D G -
18B/W-

CLU S TE R
-18LB Lr
LAM P
•18DBL-
•18B----
-T E M P GAGE
LAM P

BRAKE W ARN IN G
-2 0 P LAM P
© • “ 20BRN
I39’ - 2 0 L G C LU STER
•12R — [EH 12* “ 20LB L LAM P
’ 20P — N. 2 0 T ---- G p - 20DBL
20PPL- 20DBL- 120GY R. H. DIR.
' 14LBL-
SIG. L A M P
■18W — C LU S TE R CONN
•20LG-
-G EN E RA TO R
‘ 20BRN-
LAM P
•18BRN-
' 20LBL-
-O IL PRESS
■20DBL.
LAM P
•20T—
•20DBL.
•L. H. DIR.
•20GY—
SIG. L A M P
■20T—
-20T — 18LB L ■ • C LU STER
•16DG — 18DBL- LAM P
-160R —
18B — V IS J w / s WASHER &
W IP E R SW •HIGH BEAM
LAM P

OUTSIDE C LU STER
FU E L T A N K n LAM P

L IG H T SW

20T _
-*B R N -
„ * Y ___
. *DG _
, 18LG .
180R -
180R-
18W—

OUTSIDE F U E L T A N K

Fig . 52 - Instrument- Panel - C A - K A 10-20, CA30 (E x c . 02)

CHEVROLET TRUCK SERVICE MANUAL

 ELECTRICAL—BODY AND CHASSIS 12-43

♦F O R W IRE GAGE SEE CHASSIS & T A I L L A M P W IRIN G v

SHEET.

F ig . 53 - Instrument Panel - C E - C S 4 0 , C E -C S -M S 5 0 , CE-M E60 (E xc . 02-13)

CHEVROLET TRUCK SERVICE MANUAL

ELECTRICAL—BODY AND CHASSIS 12-44

180R

Fig . 54 - Instrument Panel - C E-C S40, C E- C S- M S- M E5 0 , C E- C S-M E6 0 (Exc. 02-13-62)

CHEVROLET TRUCK SERVICE MANUAL

 ELECTRICAL—BODY AND CHASSIS 12-45

♦F O R W IR E GAGE SEE CHASSIS & T A I L L A M P W IRIN G SHEET D IM M ER SW.

Fig. 5 5 - Instrument Panel - C D - C G 5 0 , C D - C G - M G 6 0

CHEVROLET TRUCK SERVICE M ANUAL

ELECTRICAL—BODY AND CHASSIS 12-46

20T-
-*BRN> •*BRN■
•*Y— •*Y —
-*DG - -*DG“
200R - '200R-
•18W- ■18W-

Fig. 5 6 - Instrument Panel - C D - C G 5 0 , C D - C G - M G 6 0

CHEVROLET TRUCK SERVICE M ANUAL

 ELECTRICAL—BODY AND CHASSIS 12-47

♦ FO R W IRE GAGE SEE CHASSIS & T A IL L A M P W IRIN G SHEET

F ig . 57 - Instrument Panel - C A -S A 000 (02-12)

CHEVROLET TRUCK SERVICE M ANUAL

ELECTRICAL—BODY AND CHASSIS 12-48

■20T FUSE PNL

TEMP GA
CLUSTER LP
AIR GA LP
•16DG OVER SPEED
160R IND. LP.
•10P ■♦ 18P
(CE-SE 50 -60 )

LIGHT SW

18T—
*BRN<
*Y —
*DG—
18LG-

18T-

*FOR WIRE GAGE, SEE CHASSIS &TAIL LAMP WIRING SHEET.

F ig . 58 - Instrument Panel - C A -S A 000 (02-12)

CHEVROLET TRUCK SERVICE M ANUAL

 ELECTRICAL—BODY AND CHASSIS 12-49

16UK "■ V
160R------- «l a------------ 180R--------
18W-......- fl&j) S9 - 18W_____

♦FOR WIRE GAGE SEE CHASSIS &TAIL LAMP WIRING SHEET.

F ig . 5 9 - Instrument Panel - C E-C S -M E 6 0 (13)

CHEVROLET TRUCK SERVICE MANUAL

ELECTRICAL—BODY AND CHASSIS 12-50

• 12 P --------- •12P FUSE P N L

•24BRN/W- -24BRN/W
■ 1 2 P P I.---- ■1 2 PP L
-12 R --------- ■ 12R
* 20DBL
•20DBL
•18B ------
■18B/LBL—I
HORN C O N T A C T
y -------- 1 8 D B L -
r r -----------18BRN “ -TO D IRE C TIOIN
N -L IG N ITIO N SW
18PPL- SIG N AL SW
•18B/Y —
■18DG —
-18B/W — FWD
DIR. SIG. CONN
■20LB L- IN STR U M E N T
■18DBL- CLU S TE R
- C LU S TE R L P
■18B— C IR C U IT
■14LB L-
■18W—
•12R-----
fiPin O VER SPEED
• 20DG — € 3 0 - -*18B W A RN IN G L P
• 16DG— •20DBL— t e l & - •2 OGY‘ (327 & 366 CU. IN.
-16BRN-
■2 0 P P L *
•20T CS* “•20DBL
■ ON LY)
. 20P ■■-4 @ I p “•20LB L
-2 0 L G - - C L U S TE R L P
-180R »20B 120B /W ^

R .H . DIR.
SIG. L P
C L U S TE R CONN
-2 0 D B L . - L .H . DIR.
SIG. L P
-20DG —
■20GY— ~ C L U S TE R L P
•20D B L-
■20 LB L-
HIGH BEAM L P
■20LG —
• 2 0 B ----
•20B/W- C L U S TE R L P
■20P —
•20T—

160R-
-INSIDE F U E L
W/S W ASHER &
TA N K
W IP E R SW

18T-

L IG H T SW

18T —
-♦B RN - ♦BRN-
- * Y ---- *Y —
*DG —

-2 0 0 R - 200R -
-1 8 W - 18W -

F ig . 60 - Insturment Panel - C E-C S-M E 6 0 (13)

CHEVROLET TRUCK SERVICE M ANUAL

 ELECTRICAL—BODY AND CHASSIS 12-51

R .H . D IRECTION
SIG N AL

vv JjA M r

® r - i8FpL

L . H. D IRE CTIO N
SIGNAL

F ig . 61 - Instrument Panel and Forward Lamp W iring Harness - TE-TS 40-50 (E x c . 13)

CHEVROLET TRUCK SERVICE M ANUAL

ELECTRICAL—BODY AND CHASSIS 12-52

.18LB L. cf~| H R- H. w/s

' 1 8 B ---- U U
W/TO
IPTTR
ER SW.

• 18LBL L . H. W/S WASHER

• 18B & W IP E R SW.

O VER/SPEED IND L P

F U E L GA

D IR E C TIO N SIG. L P

O IL PRESS IND L P

C L U S TE R L P

C L U S TE R L P

H I BEAM IND L P

F ig . 62 - Instrument Panel - TE-TS 40-50-60 (E x c . 13)

CHEVROLET TRUCK SERVICE M ANUAL

 ELECTRICAL—BODY AND CHASSIS 12-53

R .H . D IRE C TIO N
SIG N AL ST" ln p

L .H . D IR E C TIO N
SIG N AL

F ig . 63 - Instrument Panel and Forward Lamp - TT4 0, T D -T G 50-60

CHEVROLET TRUCK SERVICE M ANUAL

ELECTRICAL—BODY AND CHASSIS 12-54

R .H . W/S WASHER
W IP E R SW

L .H . W/S W ASHER
& W IP E R SW

VAC W ARN L P

20P
2 ot
20DBL
JeT
........F U E L
^
20 L B L — DI RECT I ON SIG. L P .

20GY "7 > C O A IR PRESS

GA L P
18B-
2QGY — CL US T ER L P
20GY —
1Qp > =f ) C L U S TE R L P
18B i
2QLC > ~ r ^ HI BEAM IND. L P

12DG 20DG ■

F ig . 64 - Instrument Panel - TT40, T D -T G 50-60

CHEVROLET TRUCK SERVICE M ANUAL

 ELECTRICAL—BODY AND CHASSIS 12-55

R. H. D IRE C TIO N
SIG N AL

L . H. D IRE C TIO N
SIG N AL

F ig . 65 - Instrument Panel and Forward Lamp - TE60 (13)

CHEVROLET TRUCK SERVICE M ANUAL

ELECTRICAL—BODY AND CHASSIS 12-56

18LBL— ■ # 1 1 1 R. H.W/S WIPER SW

........ * t \

c f t r l L H.W/S WASHER
& WIPER SW.

OVERSPEED IND. LP.

DIRECTION SIGNAL LP.

OIL PRESSURE LP.

CLUSTER LP.

CLUSTER LP.

HIGH BEAM IND. LP.

10DG 20DG-

Fig . 66 - Instrument Panel - TE60 (13)

CHEVROLET TRUCK SERVICE MANUAL

 ELECTRICAL—BODY AND CHASSIS 12-57

W IRE
GAGE MODELS

14 CD -CG 50 , C D -C G -M G 60

CE-C S 40 , C E -C S -M E -M S 50 ,
16 C E -C S -M E 60 (EX C 02-62)

C A -S A 40 -50 -60 (02-62)

18 C A -K A 10 -20 , C A 30 ,

R. H. D IRE CTIO N & T A IL L A M P

■16LG
OUTSIDE F U E L GAGE
02, 05, 06,12, 16, 45 & 62 MDLS
R. H. BACKING L A M P
(04-09 & 34 MODELS O N L Y )
18B-|li

20T

■180R >
■18W-------i 1
Qaffll

r—
■16BRN" Id
DOME L A M P
LIC EN SE L A M P
INSIDE F U E L GAGE
03, 04, 09,13 & 34 MDLS

■16LG

L. H. BACKING L A M P
(04-09 & 34 MODELS O N L Y )
■16BRN*
■16BRN-

■16Y

L . H. D IRE CTIO N & T A IL L A M P

♦F O R W IRE GAGE SEE C H A R T ABOVE.

F ig . 67 - T a il and Stop Lamp - C A -K A - M A 00

CHEVROLET TRUCK SERVICE M ANUAL

ELECTRICAL—BODY AND CHASSIS 12-58

R. H. D IRE C TIO N , T A IL & ST O P L P

18W
’ 180P

DOME L P

F U E L GAGE -18BRN- Jo
LIC EN SE L P
■18B-HI'

18T

FUSE

•18W—
■180R-
18BRN
F U E L GAGE CONN
■18T«
18Y« -1 8 Y -

-18B RN -

18DG < L . H. D IRE CTIO N, T A IL & STO P L P

D IRE C TIO N , T A IL & STO P L P CONN

F ig . 68 - T a il and Stop Lamp - TA 00

CHEVROLET TRUCK SERVICE M ANUAL

 ELECTRICAL—BODY AND CHASSIS 12-59

•18 W *

■14 OR

•20 D B L

•12 DG ■
•18 T —
R .H . P A R K •14 L B L ' .18 OR.
& DIR SIG L P HEATER VJ • 16 LG <
RESISTOR •18 T —

20 P P L -
-12 DG

•20 PPL*
• 20 LBL*
• 20 LG —
• 14 LBL •
B R A K E F LU ID • 16 LG —
W A R N IN G SW ITCH • 18 T -----

V ■18 T *

18 W -
18 O R*
L .H . P A R K S T O P L P SW
& DIR SIG L P

■12 R ----
•12 DG -
■20 B ----
■14 O R-
■14 Y ----
•14 LBL

Fig . 69 - Front End G A 10-20

CHEVROLET TRUCK SERVICE M ANUAL

ELECTRICAL—BODY AND CHASSIS 12-60

18 DG -
12 PPL
20 DG -
16 BRN
20 DBL
12 R —
12 P —
r ) '
18 LG -

18 W- 18 W

20 DBL

S> <md
o o
&«SmQ0 Sj

•14 OR -
•14 Y —

I!
■14 LBL

14 OR
LEGEND 14 Y
"" CHEVROLET WRG 14 LBL
— FISHER BODY WRG
— —* CHEVROLET RPO WRG

F ig . 70 - Fuse Panel - G A 10-20

CHEVROLET TRUCK SERVICE M ANUAL

 ELECTRICAL—BODY AND CHASSIS 12-61

>18 DG 18 DG<

Fig . 71 - Instrument Panel - G A 10-20

CHEVROLET TRUCK SERVICE M ANUAL

ELECTRICAL—BODY AND CHASSIS 12-62

F ig . 72 - Engine and T ail Lamps - G A 10-20

CHEVROLET TRUCK SERVICE MANUAL

 ELECTRICAL—BODY AND CHASSIS 12-63

SPECIAL TOOLS

.JUNCTION BLOCK

OUTSIDE FUEL-
TANK
-----18T-
HORN BRAKE WARN
SWITCH
♦FOR WIRE GAGE SEE CHASSIS & TAIL LAMP WIRING SHEET

F ig . 73 - Engine Compartment - CS 10-20-30 (02)

CHEVROLET TRUCK SERVICE M ANUAL

ELECTRICAL—BODY AND CHASSIS 12-64

.JUNCTION BLOCK

HORN
♦FOR WIRE GAGE SEE CHASSIS & TAIL LAMP WIRING SHEET

F ig . 74 - Engine Compartment - CE 10-20-30 (02)

CHEVROLET TRUCK SERVICE M ANUAL

 ELECTRICAL—BODY AND CHASSIS 12-65

♦FOR WIRE GAGE SEE CHASSIS & TAIL LAMP WIRING SHEET

F ig . 75 - Engine Compartment - SS40-50 (02-62)

CHEVROLET TRUCK SERVICE M ANUAL

ELECTRICAL—BODY AND CHASSIS 12-66

F ig . 76 - Engine Compartment - SE50-60

CHEVROLET TRUCK SERVICE M ANUAL

 ELECTRICAL—BODY AND CHASSIS 12-67

SPECIAL TOOLS

J-21 932
BEZEL N U T R EM O V E R

F ig . 77 - Sp ecial Tools

CHEVROLET TRUCK SERVICE MANUAL

 SECTION 13
RADIATOR AND GRILLE
CONTENTS OF THIS SECTION
Page

General D e s c r ip t io n ......................................................... 13-1

Radiator Service Procedures .......................................... 13-1
Grille Service P r o c e d u re s ................................................ 13-6

GENERAL DESCRIPTION
P and T series trucks, and G series trucks with 230 on each side at the top, secure the radiator in position.
cu. in. engine and manual transmission, are equipped This section covers the service procedures for all
with down-flow type radiators. All other models are truck radiator and grille assemblies. Removal and in­
equipped with cross-flow type radiators. The cross- stallation procedures for air conditioning components are
flow radiator is sim ilar to the conventional down-flow covered in Section 1A. Refer to Section 14 for Front
radiator except it is mounted sideways in the vehicle and Bumper Service procedures and Section 11 for Front
attached in the conventional manner. Two retainers, one Sheet Metal.

RADIATOR SERVICE PROCEDURES

INDEX
Page Page
Service Operations - 10 thru 30 Series 13-1 Service Operations - 40 thru 60 S e r i e s .................. 13-3
C and K M o d e l s ........................... 13-1 CA40, CE-CS-M A-SA50, CE-CS-SA60 Models . . 13-3
P10 Models ................................. 13-1 CD-CG 50-60, MG60 M o d e l s .............................. 13-4
P20 and P30 M o d e l s ..................... 13-1 PA 40 M o d e ls ...................................................... 13-4
GE M o d e l s .................................... 13-2 ME 60 M o d e ls ...................................................... 13-5
GS M o d e l s .................................... 13-2 TA Models ......................................................... 13-5

SERVICE OPERATIONS-10 THRU 30 SERIES

C AND K MODELS (Fig. 1) powerglide coolant line if applicable.
2. Remove mounting screws attaching radiator to sup­
Radiator Replacement port and remove radiator from vehicle.
3. Replace radiator mounting components if necessary.
1. Drain radiator and disconnect water hoses and 4. Install radiator following removal procedure in r e ­
powerglide coolant line if so equipped. verse order. Connect radiator hoses and transm is­
2. If vehicle is equipped with a fan shroud, remove sion coolant line, fill cooling system and check for
shroud attaching screws and carefully hang shroud leaks.
over engine fan assembly to provide clearance for 5. Refer to torque specifications in rear of manual for
radiator removal. correct torque values.
3. Remove screws attaching two retainers to radiator
and support and remove retainers.
4. Lift radiator up out of lower mounts. Lift shroud P20 AND P30 MODELS (Fig. 3)
out of vehicle if applicable.
5. Inspect lower pads and retainers and replace if Radiator Replacement
necessary.
6 . Lower shroud and radiator into position and secure 1. Drain radiator and disconnect water hoses and trans­
shroud with two lower screws. mission coolant line if so equipped.
7. Install two retainers at top of radiator and shroud 2. Remove screws securing fan shroud to support
with six screws. assembly and carefully hang shroud over engine fan
8 . Connect radiator hoses and transmission coolant line, assembly to provide clearance for radiator removal.
fill cooling system and check for leaks. 3. Remove screws securing radiator to support and re ­
9. Refer to torque specifications in rear of manual for move radiator and shroud from vehicle.
correct torque values. 4. Replace radiator mounting components if necessary.
5. Install radiator and shroud following removal pro­
P10 MODELS (Fig. 2) cedure in reverse order. Connect radiator hoses
and transmission coolant line, fill cooling system and
Radiator Replacement check for leaks.
6 . Refer to torque specifications in rear of manual for
1. Drain radiator and disconnect water hoses and correct torque values.

CHEVROLET TRUCK SERVICE MANUAL

RADIATOR AND GRILLE 13-2

CA10-20-30, KAOO CE KE10-20, CE30

Fig. 1 - Radiator and Shroud Mounting - C and K Models

Fig . 2 - Radiator Mounting - P10 Models Fig. 3 - Radiator and Shroud Mounting P20 and P30 Models

GE MODELS (Fig. 4 and 5) 6 . Remove bolts securing radiator support to frame and
lower radiator and support from vehicle.
Radiator Replacement 7. Remove screws securing shroud to upper radiator
support and remove shroud from vehicle.
1. Raise vehicle and place on jack stands. 8 . Install radiator and shroud following the removal
2. Remove bolts attaching air deflector to radiator procedure in reverse order. Connect radiator hoses
support, frame, and body and remove air deflector. and transmission coolant line, fill cooling system,
(Refer to Figure 4.) and check for leaks. If no leaks are present, install
3. Remove bolts attaching left and right splash shields air deflector and splash shields.
to frame and remove splash shields. (Refer to
Figure 4.) GS MODELS (Fig. 6)
4. Drain radiator and disconnect radiator hoses and
transmission coolant line if so equipped. Radiator Replacement
5. Remove lower shroud screws. 1. Raise vehicle and place on jack stands.

CHEVROLET TRUCK SERVICE M ANUAL

 RADIATOR AND GRILLE 13-3

2. Remove bolts attaching air deflector to radiator

support, frame, and body and remove air deflector.
(Refer to Figure 4.)

F ig. 5 - Radiator and Shroud Mounting - G E Models

3. Remove bolts attaching left and right splash shields
to frame and remove splash shields. (Refer to
Figure 4.)

Drain radiator and disconnect radiator hoses and

transmission coolant line if so equipped.

5. Remove screws attaching shroud to radiator supports

and baffle and carefully hang shroud over engine fan
assembly to provide clearance for radiator removal.

6 . Remove radiator attaching screws and lower radiator

from vehicle. Remove shroud from vehicle.

7. Install shroud and radiator following the removal

procedure in reverse order. Connect radiator hoses
and transmission coolant line, fill cooling system,
and check for leaks. If no leaks are present, install
air deflector and splash shields.

Fig. 6 - Radiator and Shroud Mounting - G S Models

SERVICE OPERATIONS—40 THRU 60 SERIES

NOTE: CA-SA40, CS-CE-CD-MA-SA50, CS- mission coolant line if so equipped.
CE-ME-SA60 trucks are equipped with fan 2. If vehicle is equipped with a fan shroud, remove
shroud as shown in Figure 7. Radiator r e ­ shroud attaching screws (fig. 7) and carefully hang
placement procedures for these vehicles include shroud over engine fan assembly to provide clearance
replacement of the shroud as illustrated. for radiator removal.
CA40, CE-CS-MA-SA50, CE-CS-SA60 3. Remove screws securing radiator retainers to
MODELS (Fig. 8) radiator support and remove retainers and
bumpers.
Radiator Replacement 4. Lift radiator up out of lower mounts. Lift shroud
1. Drain radiator and disconnect water hoses and trans­ out of vehicle if applicable.

CHEVROLET TRUCK SERVICE M ANUAL

RADIATOR AND GRILLE 13-4

difference is that the radiator is turned around in its

vehicle position as illustrated by a comparison of Figures
Fig . 7 - Radiator Fan Shroud - C A -SA 4 0 , C S - C E - C D - M A - SA 5 0 , 8 and 9. Continue to refer to Figure 7 for trucks
C S-C E -M E-SA 6 0 Models equipped with fan shrouds.

5. Inspect lower pads and retainers and replace if PA40 MODELS (Fig. 10)
necessary.
6 . Lower shroud and radiator into position and secure
Radiator Replacement
shroud with bottom attaching screws. 1. Drain radiator and disconnect water hoses and trans­
7. Install two retainers at top of radiator and shroud mission coolant line if so equipped.
with four screws. 2. Remove screws securing fan shroud to supports and
8 . Connect radiator hoses and transmission coolant carefully hang shroud over engine fan assembly to
line, fill cooling system, and check for leaks. provide clearance for radiator removal.
9. Refer to torque specifications in rear of manual for 3. Remove screws securing radiator to supports and
correct torque values. remove radiator and shroud from vehicle.
4. Replace radiator mounting components if necessary.
CD-CG50-60, MG60 MODELS (Fig. 9) 5. Install radiator and shroud following removal pro­
cedure in reverse order. Connect radiator hoses
Radiator Replacement and transmission coolant line, fill cooling system,
and check for leaks.
Radiator replacement for these trucks is the same as 6 . Refer to torque specifications in rear of manual for
outlined in steps 1 thru 9 immediately above. The only correct torque values.

F ig . 8 - Radiator Mounting - C A 4 0 , C E -C S -M A -S A 5 0 ,
C E -C S -S A 6 0 Models

CHEVROLET TRUCK SERVICE M ANUAL

 RADIATOR AND GRILLE 13-5

Fig. 11 - Radiator Mounting - ME60 Models

ME 60 MODELS (Fig. 11)

Radiator replacement for these trucks is the same as

outlined above for ME—MS 50 models. Refer to ME— Fig. 13 - Fan Shroud Mounting - TS40-50-60 and
MS 50 radiator replacement procedure. The only differ­ TE40-50-60 Models
ence is in the radiator support area as illustrated by a
comparison of Figures 8 and 11; also, no ME 60 models 1. Drain cooling system and disconnect radiator hoses
are equipped with fan shrouds. and transmission coolant line if so equipped.
2. Remove fan shroud attaching screws and carefully
TA MODELS (Figs. 12, 13f and 14) hang shroud over fan assembly to provide clearance
for radiator removal.
Radiator and Shroud Replacement 3. Remove cotter pin and attaching hardware from
lower mount.
NOTE: TT 40, TD 50-60, and TG 50-60 are 4. Remove bolts, one on each side, and attaching hard­
equipped with the extended fan shroud shown in ware from upper mounts.
Figure 12. All other T models are equipped
with the shroud shown in Figure 13.

Fig . 12 - Fan Shroud Mounting - TT 40, TD 50-60

and T G 50-60 Models

CHEVROLET TRUCK SERVICE M ANUAL

RADIATOR AND GRILLE 13-6

5. Remove radiator and support assembly from the procedure in reverse order. Connect radiator hoses
vehicle as a unit. Remove fan shroud. and transmission coolant line, fill cooling system,
6. Replace radiator, supports, and mounting components and check for leaks.
as necessary. Refer to torque specifications in rear of manual for
7. Install shroud and radiator following the removal correct torque values.

GRILLE SERVICE PROCEDURES

INDEX
Page Page
Service Operations - 10 thru 30 S e r i e s .................. 13-6 Replacement........................... 13-6
CA-KA 10-20, CA 30 Models, Grille Replacement 13-6 R e m o v a l.............................. 13-6
R e m o v a l ......................................................... 13-6 Installation ........................ 13-6
Installation ................................................... 13-6 TA Models, Grille Replacement 13-7
Service Operations - 40 thru 60 S e r i e s .................. 13-6 R e m o v a l........................... .. T3-7
CA-SA 40-50-60, MA 50-60 Models, Grille Installation ........................ 13-7

SERVICE OPERATIONS-10 THRU 30 SERIES

Fig. 15 - G r ille Mounting - C A - K A 10-20, C A 30 Models

C A - K A 10-20, CA 30 MODELS, 6 . Unplug parking lamps from receptacles at radiator

GRILLE REPLACEMENT (Fig. 15) support.
7. Remove screws, four from each side, securing grille
Removal assembly to fenders and frame and remove grille
1. Disconnect battery ground cable. from vehicle.
8 . Replace extensions, mouldings, center support, and
2. Remove front bumper (Section 14).
3. Remove headlamp bezels. Disconnect and remove hood catch plate as necessary.
headlamps.
4. Remove screws securing baffle to bottom of grille Installation
and radiator support and remove baffle. Assemble and install grille and related components
5. Remove screws attaching hood catch to radiator following the removal procedure in reverse order. Refer
support. Remove screw securing bottom of center to torque specifications at rear of manual for correct
support to radiator support. torque values.

CHEVROLET TRUCK SERVICE MANUAL

 RADIATOR AND GRILLE 13-7

SERVICE OPERATIONS—40 THRU 60 SERIES

C A - S A 40-50-60, MA 50-60 MODELS 5. Remove bolts securing battery tray to grille.
GRILLE REPLACEMENT (Fig. 16) 6 . Remove screws, four from each side, securing skirt
to grille braces and remove braces.
Removal 7. Remove screws, three from each side, securing
gussets to grille and fenders and remove gussets.
1. Remove battery from vehicle. Remove radiator retainers from vehicle.
2. Remove front bumper (Section 14). 9. Remove bolts securing grille assembly to fenders,
3. Disconnect headlamp, parking lamp, horn, and volt­ skirts, and lower panels and remove grille assembly
age regulator electrical connections. from vehicle.
4. Remove screws from each headlamp bezel and r e ­ 10 . Remove three lower panels and retainer from ve­
move bezels and headlamps. hicle.

Fig. 16 - G r ille Mounting - C A - S A 40-50-60 MA 50-60 Models

11. Replace mouldings, catch plate, and other grille and

mounting components as required.
Installation
Assemble and install grille and related components
following the removal procedure in reverse order. Refer
to torque specifications at rear of manual for correct
torque values.

TA MODELS (Fig. 17)

GRILLE REPLACEMENT
Removal
1. Remove headlamp bezels from grille.
2. Disconnect headlamp wiring and remove headlamps.
3. From under vehicle, remove three screws from each
side securing grille to cab face.
4. Replace grille and mounting components as neces­
sary.
Installation
Assemble and install grille assembly and related
components following the removal procedure in reverse
order. Refer to torque specifications at rear of manual
F ig . 17 - G r ille Mounting - TA Models for correct torque values.

CHEVROLET TRUCK SERVICE MANUAL

 SECTION 14
BUMPERS
INDEX
Page
General Description......................................................... 14-1 Front Bumper - G Models ............................................. ..... 14-2
Service Operations - 10 thru 30 Series ........................ 14-1 Rear Bumper - G M o d e ls ................................................ ..... 14-3
Front Bumper - C and K M o d e l s .............................. 14-1 Service Operations - 40 thru 60 S e r i e s ..................... .. ........... 14-3
Rear Bumper - C and K M o d e ls ................................. 14-1 Front Bumper - C, S, M 40, 50, 60 and P40
Front Bumper - P10 M o d e l s .................................... 14-1 M o d e ls ........................................................................... ..... 14-3
Front Bumper - P 20 and P30 Models ......................14-1 Front Bumper - T M o d e l s ............................................. ..... 14-3

GENERAL DESCRIPTION
All 1967 truck front and rear bumpers are of a single
piece design. Bumper attachments are the standard
bracket and brace to frame mountings. This section
contains procedures for the removal and installation of
face bars, brackets, braces and license plate brackets.

SERVICE O PERA TIO N -10 THRU 30 SERIES

FRONT BUMPER-C AND K MODELS (Fig. 1) Installation
Install rear bumper following removal procedure in
Removal reverse order. Refer to torque specifications in rear of
1. Remove bolts securing left and right bumper braces
manual for correct torque values.
to frame.
2. Remove bolts securing two bumper brackets to FRONT BUMPER—P I0 MODELS (Fig. 3)
frame.
3. Remove bolts securing bumper face bar to frame, Removal
and remove bumper from vehicle. Remove nuts, washers, and bolts securing front bumper
4. If necessary, disassemble bumper by removing bolts to forward frame horns and remove bumper from vehicle.
attaching brackets and braces to bumper face bar.
Installation
Installation Place bumper in mounted position and secure to frame
Assemble and install front bumper following the re­ with bolts, washers, and nuts. Refer to torque specifi­
moval procedure in reverse order. Refer to torque cations in rear of manual for correct torque values.
specifications in rear of manual for correct torque
values. FRONT BUMPER—P20 AND P30 MODELS (Fig. 4)
REAR BUMPER-C AND K MODELS (Fig. 2) Removal
Removal 1. Remove left and right lower bumper brackets by
1. Remove bolts attaching bumper to each bumper removing speed nuts and plugs (one at center of
bracket.
2. Remove bolts attaching bumper to frame.
3. Remove bumper from vehicle.
4. If necessary, replace body dirt seal.

F ig . 1 - Front Bumper - C and K Models Fig . 2 - Rear Bumper - C and K Models

CHEVROLET TRUCK SERVICE MANUAL

BUMPERS 14-2

specifications in rear of manual for correct torque

Fig. 3 - Front Bumper - P10 Models values.

each bracket) securing brackets to frame. FRONT BUM PER-G MODELS (Fig. 5)
2. Remove left and right upper bumper connections by
removing speed nuts and plugs (one at center of each Removal
1. Remove screws securing bumper braces to frame
bracket); remove lock nuts, washers, and bolts se­
curing face bar to upper brackets. cross sill.
2. Remove bolts securing bumper face bar to frame
3. Remove bumper from vehicle. If necessary, re­
extensions.
move lower bumper brackets from face bar by re­
3. Remove bumper from vehicle.
moving lock nuts, washers, and bolts attaching
brackets to face bar. Disassembly
1. Remove bolts attaching bumper braces to face bar
Installation and remove braces.
Assemble and install front bumper following the re­ 2. Remove screws securing license plate bracket to
moval procedure in reverse order. Refer to torque face bar and remove license plate bracket.

Assembly and Installation

Assemble and install front bumper following the re-

CHEVROLET TRUCK SERVICE MANUAL

 BUMPERS 14-3

moval procedure in reverse order. Refer to torque braces to frame extensions.

specifications in rear of manual for correct torque 2. Remove bolts securing face bar to frame extensions
values. and remove bumper from vehicle.

REAR BUM PER-G MODELS (Fig. 6) Installation

Install rear bumper following the removal procedure
Removal in reverse order. Refer to torque specifications in rear
1. Remove screws attaching left and right bumper of manual for correct torque values.

SERVICE OPERATION—40 THRU 60 SERIES

FRONT BUMPER—C, S, M 40, 50, 60 AND P40 brakes, the air reservoir tank mounted inside
the front bumper must be removed before re­
MODELS (Fig. 7)
moving front bumper.
Removal 1. On T models with air brakes, vent air pressure from
1. Remove bolts attaching face bar to left and right system and remove air reservoir from inside front
bumper brackets. bumper.
2. Remove bolts securing face bar to frame and remove 2. Remove bolts securing bumper to frame extensions
bumper from vehicle. as shown in Figure 8 . After bumper removal,
bumper filler bar may be removed by removal of
NOTE: If necessary to remove bumper brack­ three retaining bolts.
ets from frame, drive out rivets and remove
Installation
brackets. Install brackets using bolts, washers, Install bumper following removal procedure in reverse
and nuts. order. Refer to torque specifications in rear of manual
for correct torque values.
Installation
Install bumper following the removal procedure in re­
verse order. Refer to torque specifications in rear of
manual for correct torque values.
FRONT BUMPER—T MODELS (Fig. 8)

Removal
NOTE: On tilt cab models equipped with air

CHEVROLET TRUCK SERVICE M ANUAL

 .1
’ ■ •

'

-------------------- „------
 SPECIFICATIONS
HEATING AND AIR CONDITIONING
SECTION 1

AIR CONDITIONING System Capacities

Refrigerant 1 2 .............................................. 3 lbs., 4 oz.

Compressor 525 Viscosity Compressor O il.........................10 fluid oz.

T yp e................................................................ 6 Cylinder Axial

D isplacem ent.........................................................12.6 Cu. In. Torque Specifications
Rotation ................................................................... Clockwise
Belt T e n s io n ...........................................See Tune Up Chart Compressor Suction and Discharge
Connector Bolt .............................................. 20 ft. lbs.
Rear Head to Shell Stud N u ts......................... 20 ft. lbs.
Blower Motor Shaft Mounting N u t.............................................. 15 ft. lbs.
F u s e s .......................................................................... 25 Amp.
V o l t s .........................................................................................14
Amps (Cold)................................................................20 (Max.)
RPM (C old ).......................................................................... 4000 HEATERS

Compressor Clutch Coil Fuses

Ohms (at 80 ° F ) ................................................................... 3.85

Amps (at 80°F ) .............................................. 3.2 @ 12 volts Deluxe Heater............................................................... 25 Amp.

CHEVROLET TRUCK SERVICE MANUAL

 SPECIFICATIONS
FRONT SUSPENSION
SECTION 3

ALIGNMENT SPECIFICATIONS

2
MA50
CA-SA TA40
CA-PA CA-20 C A -PA - SA531 TD50 CA-MA CA-MA
Models G10, 20 K10, 20 PA20, 30 50 (Exc. TE-TS MA60
10 30 SA-40 CA-MA TA60 TA60 TA60
SA531) TG50
SA60

3000C20 4000 5000

2500 2200 3300 4000 5000 7000 7000 9000 9000 11000
Axle 3500C30 and and
lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs. lbs.
lbs. 4500 lbs. 5500 lbs.

King 6 1/4°
Pin 7 1/4° 5 1/4° LH 5 3/4° LH
- - 7 1/4° to 7 1/4° 7 1/4° 7 1/4° 7 1/4° 7 1/4° 5°
Inclination 6 1/4° RH 6 1/4° RH
8 1/4°

See See
Chart Chart + 1/4° LH + 1/4° LH
Camber l-l/2°±l/4 ° 1 1/2° 1 1/2°± 1/4° 1 1/2° 1 1/2° 1 1/2° 1 1/2° 1 1/2° 1°
Fig. 9 Fig. 9 - 1/4° RH - 1/4° RH
Sec. 3 Sec. 3

See See
Curo Chart Chart
Caster 3 l/4 °±l° 3° 2° 1 1/2° 1 1/2° 1 1/2° 1 1/2° 1 1/2° 2 1/4° 2 1/4° 2 1/2°
Fig. 9 Fig. 9
Sec. 3 Sec. 3

Toe In
(Per l/32"-3/32 l/32"-3/32" l/ l6 "-l/ 8 " 1/16"-l/8" 1/16"-3/16" l/32"-3/32" l/32"-3/32” l/32"-3/32" l/32”-3/32” l/32”-3/32" l/32”-3/32" l/32"-3/32" l/32"-3/32"
Wheel)

Wheel
- - 20° 20° 20° 20° 20° 20° 20° 20° 20° 20°2 20°
Outer

Turn
Inner - - 35° to 36° 29° to 30° 22° to 23° 23 1/4° 22 3/4° 24° 24° 23 3/4° 24 1/2° 24 1/2° 23 1/4°

Note: Do not use Caster Shims on P20-30

CHEVROLET TRUCK
SERVICE MANUAL
 SPECIFICATIONS 3

TORQUE SPECIFICATIONS (FT. LBS.)

CP-10 C20-30 P20-30 G10-20 K10-20 40-60 Ser. 9000# 11000#

Lower Control Arm

40 110 - - - - - -
Shaft U-Bolt
Upper Control Arm
80 155 - - - - - -
Shaft
New 160 New 190
Upper Control Arm
Replacement Replacement - - - - - -
Bushings
95 115
New 280 New 280
Lower Control Arm
Replacement Replacement - - - - - -
Bushings
135 135
Ball Joint Studs —
70 120 - - - - - -
Upper
Ball Joint Studs - -
120 215 - - - - - -
Lower
Stabilizer Bar
- - 20 - - - - -
Link
Stabilizer Bar
- - 25 20 - - - -
Bracket
Suspension
65 100 - - - - - -
Cross member
Shock Absorber —
140 140 30 75 75 80 80 80
Upper Eye
Shock Absorber - -
75 75 30 55 75 80 80 80
Lower Eye
Leaf Spring 80
- - 75 80 120 120 120
U-Bolt
Leaf Spring -- 370 370 370
- - 90 75 90
Front
Leaf Spring - - 50 50 80 80 80
- - 30
Rear
Kingpin Upper 250 250
- - - - - -
Nut
Brake Backing 5000# 140
80 105 80 80 30 315 315
Plate 7000# 185
Kingpin Bearing 5 5 5
- - 5 3 -
Caps
Kingpin Lock - - 30 30 — 30 — —

CHEVROLET TRUCK SERVICE MANUAL

SPECIFICATIONS 4

REAR SUSPENSION
SECTION 4

TORQUE SPECIFICATIONS (FT. LBS.)

Wheel Adjusting Axle Shaft Brake

Hub Wheel
Axle Bearing Nut To Flange C arrier
Cap Stud
Capacity Adjusting Lock Hub Backing Cover
Bolts Nut
Nut Nut Bolts Plate

2400 through 3600 — — — — 35 65 20

5200 through 7200 55* 175 90 90 75 20

250 - 15 155 350 -

CO
•
o

1 1 ,0 0 0

13,000 90* 250 - 15 150 350 -

15,000
90* 250 - 15 150 350 -
with 15 x 4 inch Brakes
15,000 55* 350
135 - 20 150 -
with 15 x 5 inch Brakes
17,000 Single Speed
18,500 Single and 65* 135 35 - 150 200 @ -
Two Speed Eaton
15,000 and 17,000
50* 135 - 20 150 200 @ -
Two Speed

• Torque to Specification given, Back Off 1/8 Turn. Install Lock Nut and Torque
@Trucks equipped with Disc Wheels Torque to 475
All Torques given in Foot Pounds

CHEVROLET TRUCK SERVICE MANUAL

 SPECIFICATIONS 5

40

50

60

PA20, 30
CA-PA 10

Series

Series

Series
CA20

CA30
GIO

G20

K20
K10
Tie Rod Attaching
- - 135 135 - - - - - - -
Bolts - (Axle)
- (Frame) - - 135 135 — — — — — — —
Axle to Control Arm
- - 215 215 - - - - - - -
U Bolts
Spring U
125 125 - - 150 150 120 300 300 300 150
Bolts
Control Arm Front
- - 145 145 - - - - - - -
Attaching Bolts
Coil Spring Attaching
- - 45 45 - - - - - - -
Bolt Lower
Coil Spring Attaching
- - 50 50 - - - — - - -
Bolt Upper
Spring Front
65 65 - - 155 155 10 70 70 155 10
Bushing Bolt
Spring Rear Shackel
50 50 - - 155 155 5 - - - 5
Bolts
Shock Absorber
75 75 75 75 65 65 65 - - - 120
Attaching Bolts
Universal Joint
15 15 15 20 15 20 20 20 20 20 20
Rear
Inter mediant Shaft
- - 15 15 - - - - 20 20 -
Universal Joint
Front Universal
Joint - - - - - - 20 20 20 20 20

Rear Stabilizer — — — — — — — — — — 25

TANDEM
Equalizing Beam 270 270
- - - - - - - - -
Adapter Bolts
Saddle Cap Stud - - - 190 190
- - - - - -
Nuts
Spring Hinge - - — 35 35
- - - - - -
Lock Bolts
Top Pad Set - - -
- - - - - - 100 100
Screw
Spacer Bolts — - - - - - - - 65 65 -
Spring Saddle Top - - - - 290 290 -
- - - -
Pad B olts
Torque Arm - - - - - - 300 300 -
- -
Nuts
Torque Arm Bracket - - - - - 65 65 -
- - -
Bolts
Prop Shaft - - - - - - - - 50 50 -
SPECIFICATIONS 6

DIFFERENTIAL SPECIFICATIONS

34,000 Lb. Capacity

30,000 Lb. Capacity
17.000 Lb. Capacity

18,500 Lb. Capacity

18,500 Lb. Capacity
17,000 Lb. Capacity
15,000 Lb. Capacity
11,000 Lb. Capacity

13,000 Lb. Capacity

3600 Lb. Capacity

5200 Lb. Capacity

7200 Lb. Capacity

(Saulisbury Type)

15.000 Lb. and

(Single Speed)
(Single Speed)
2400 Through

(Single Speed

(Two Speed)

(Two Speed)

Tandem
Tandem

Eaton
Eaton
Eaton
Eaton
Gear Backlash
.005"- .005"- .005"- .005"- .005"- .205"- .005"- .006"- .005"- .006"- .006"- .006"-
Preferre .016" .016"
.008" .008" .008" .008" .008" .008" .008" .016" .008" .016"
.003"- .003"- .003"- .003"- .003"- .003"- .003"- .006" .003"- .006"- .006"- .006"-
Min and Max.
.0 1 0 " .0 1 2 " .0 1 2 " .0 1 2 " .0 1 2 " .0 1 2 " .0 1 2 " .016" .0 1 2 " .016" .016" .016"
Pinion Bearing
Preload (In. Lbs.)
New 20-30 6-14 25-35 6-14

Used 5-15 5-15

Bolt Torques (Ft. Lbs.)

Carrier Cover 20 20 20 - - 20 20 45 - 45 80 80

Ring Gear 50 110 110 105 110 160 160 90 140 140 90 90
Differential Bearing LH 230 LH 350
55 100 100 205 205 205 205 210 230 230
Caps RH 160 RH 425
Filler Plugs 20 10 10 10 10 10 10 10 10 10 10 10

Differential Pinion
Lock
20 - - - — - - - - - - -

Drive Pinion Nut - 220 220 220 220 220 220 500 - 500 600 600
Differential Carrier
- 45 45 85 85 85 85 165 150 165 130 230
to Axle House
Differential Case - 110 110 105 110 160 160 100 70 90 90 90
Differential Bearing
- 15 15 15 15 15 15 165 10 165 115 165
Adjusting Lock
Shift Unit to
Carrier — - - - - - - - 45 50 - -
Pinion Bearing Cage
- 95 95 165 165 95 95 115 95 115 145 145
To Carrier
Trust Pad Lock
- - - 135 - 135 135 - - - - -
Nut
Input Shaft
- - - - - - - - - - 425 425
Nut
Input Shaft
- - - - - - - - - - 80 80
Bearing Cover
Differential Carrier
- - - - - - - - - - 115 v 115
Cover to Carrier
Output Shaft
- - - - - - - - - - 425 425
Nut
Inter Axle
Differential Case - - - - - - - - - - 60 60
Lockout Shift Lever
- - - - - - - - - - 45 45
Bracket to Carrier
 SPECIFICATIONS 7

ENGINE

SECTION 6

*8.25:1 on CE & TE400 Series.

CHEVROLET TRUCK SERVICE M ANUAL

SPECIFICATIONS 8

Displacement 230 250 292 283 327 366

Horsepower 140 155 170 175 185 220 220

PISTON RING? (Cont.)

.0005" .0 0 0 " .0 0 2 0 "

Production .000"-.005" .002"-.007"
Groove .0055" .005" .0035"
Clearance
0 Service Hi Limit Production + .001"
I
L .0 1 0 "
Production .015"-.055"
Gap .023"
Service Hi Limit Production + .01"

PISTON PIN:

Diameter .9895"
.9270"-.9273"
.9898"
.00025" .00015"
Production .00015"-.00025" .00025"-.00035"
Clearance .00035" .00025"
Service .001" (Max.)
Fit in Rod .0008"-.0016" (Interference)

CRANKSHAFT:

#1 # l-2 -3 -4
2.2987"-2.2997" 2.7482"
All 2.7492"
Diameter #2-3-4
2.2983"-2.2993" 2.2983"-2.2993"
#5
Main #5 2.7478"
J ournal 2.2978"-2.2998" 2.7488"
Production .0002" (Max.)
Taper
Service .001" (Max.)
Out of Production .0002" (Max.)
Round Service .001" (Max.)

# l-2 -3 -4 # l-2 -3 -4
All .0003"
Main All .0008"-.0024"
Production .0025"
Bearing .0008"
.0003"-.0029" #5
Clearance .0034" #5
.0015"
.0010"-.0026"
.0031"
Service .004" (Max.)

Crankshaft End Play .002"-.006" .006"

.003"-.011"
.0 1 0 "

Diameter 2.099" 2.199"

1.999"-2.000" 1.999"-2.000"
2 .100" 2 .2 0 0 "

Production .0003" (Max.)

Crankpin Taper
Service .001" (Max.)
Out of Production .0002" (Max.)
Round Service .001" (Max.)

Production .0007" .0007"

Rod Bearing .0007"-.0027" .0007"-.0028"
.0028" .0027"
Clearance
Service .004" (Max.)

Rod Side Clearance .0085"-.0135" .015"-

.009"-.013"
.0 2 1 "

CHEVROLET TRUCK SERVICE M ANUAL

 SPECIFICATIONS 9

Displacement 230 250 292 283 327 366

Horsepower 140 155 170 175 185 220 220

CAMSHAFT:

Lobe Lift ± .002" (Int. & Exh.) .1896" .2217" .2315" .2658" .2343"

Journal Diameter 1.9487"

1.8682"-1.8692"
1.9497"
Camshaft Runout .0015" (Max.)

VALVE SYSTEM:

Lifter Hydraulic

Rocker Arm Ratio 1.75:1 1.50:1 1.75:1

Valve Lash (Int. & Exh.) One turn Down from Zero Lash

Intake 45°
Face Angle
Exhaust 45° 46° 45° 46° 46°

Seat Angle (Int. & Exh.) 46°

Seat Runout (Int. & Exh.) .002" (Max.)

Intake l/3 2 "-l/l6 "

Seat Width
Exhaust l/1 6 "-3 /3 2 " 3 /3 2 " -l/8 "

.0 0 1 0 "
Int. .0010"-.0027" .0025"
Production
Stem .0 0 1 2 "
Clearance Exh. .0015"-.0032" .0010"-.0027"
.0029"

Service Hi Limit Production (.001" Intake) (.002" Exhaust)

Free Length 1.90" 2.08" 2.05"

85-93 84-96
Closed 56-64 @ 1.66" 78-86 @ 1.66"
@ 1.69" @ 1.80"
Pressure
Valve lbs. @ in. 210-230
170-184 180-192 174-184
Spring Open 170-178 @ 1.26"
@ 1.33" @ 1.27" @ 1.30" @ 1.40"

Installed Intake 1-21/32" 1-13/16"

Height
± 1/32" Exhaust 1-21/32" 1-5/8" 1-21/32" 1-13/16"

1.80"
Free Length N.A. 1.94"
1.92"
Damper
Approx. # of Coils N.A. 4 3 -5 /8 "

CHEVROLET TRUCK SERVICE MANUAL

SPECIFICATIONS 10

ENGINE TORQUES

CHEVROLET TRUCK SERVICE M ANUAL

 SPECIFICATIONS 11

TUNE UP CHART

1 At cranking speed, throttle wide open—Maximum variation, 20 lbs. between cylinders.

2 At idle speed with vacuum advance line disconnected and plugged.
3 On Step Van vehicles, use number two cylinder and timing tab on bottom of cover.
PAPER ELEMENT—Service at 12,000 miles initially—Check every 6,000 miles thereafter, until replaced.
POLYURETHANE BAND-Service every 12,000 miles.
OIL BATH—Change oil at regular engine oil change intervals.
4 AIR CONDITIONED VEHICLES—Set engine idle to specifications with air conditioning turned on and hot idle
compensator held closed. Those indicated b y * Set engine idle to specifications with air conditioning turned “ off” .

CHEVROLET TRUCK SERVICE M ANUAL

SPECIFICATIONS 12

CARBURETOR

SECTION 6M

Carburetor Engine Trans. Vehicle

7026017 230 All All-exc. with Air Injection Reactor

B

7027029 250 (Gov.) All All-exc. with Air Injection Reactor

ROCHESTER

7027011 250 All All-exc. with Air Injection Reactor

7027009 292 All All-exc. with Air Injection Reactor

7037009 292 All All-with Air Injection Reactor

3908463
230 & 250 Syn. All-exc. with Air Injection Reactor
(4375S)

3908464
230 & 250 Auto. All-exc. with Air Injection Reactor
(4376S)
YF

3908465
230 & 250 Syr- All with Air Injection Reactor
(4369S)
CARTER

3908466
230 & 250 Auto. All with Air Injection Reactor
(4370S)

3908467 230 & 250

Syn. All-with Air Injection Reactor
(437 IS) 292 (w/Gov.)

3908468
230 & 250 Auto. All-with Air Injection Reactor
(437 2 S)

Specifications Rochester B Carter YF

05 05 05 CO IT5 CO ^ E~- -— * CO ^
Part Number CM O O CO CO
Tfl Lfi CD CO CD CO CO CO CD CQ CD CO
o © o o CO 05 O T f T -l ^ CM
(Mfg. Number) CD D- 00 t -
O CO
00 C - 0 0 CD 00 C - 00 c- 00 t -
CM CM eo O CO O CO O CO O CO O CO
o o O O o 0 5 Tt< 05 05 05 05 ^ 05
c- c- t- CO w CO eo CO w eo co

Float Level 1-9/32" 7/32"

Float Drop 1-3/4" 1 3 /1 6 ’

Idle Vent .066" . 065"

CHEVROLET TRUCK SERVICE M ANUAL

 SPECIFICATIONS 13

Carburetor Engine Transmission Vehicle

7027105 283 All Exc. O.D. All exc. with Air Injection Reactor

7027100 283 Overdrive All exc. with Air Injection Reactor

2G

7020109 283 All All exc. with Air Injection Reactor

ROCHESTER

7027106 283 Gov Syn. All exc. with Air Injection Reactor

7037105 283 All Exc. O.D. All with Air Injection Reactor

7037100’ 283 Overdrive All with Air Injection Reactor

7026113 366 All All

All exc. with Air Injection Reactor

ROCH. 4G

7027125 327 All

7037125 327 All All with Air Injection Reactor

CHEVROLET TRUCK SERVICE MANUAL

SPECIFICATIONS 14

ENGINE ELECTRICAL
SECTION 6Y

BATTERY

BATTERY 1980032 1980060 1980034 1980030 1980036 1980038 1980758 1980760

G-10 230 & 250 292L-6, School G-10 & 4-53 &
6V-53
Application G-10 Sport L -6 , 327 & 366 Bus & Optional D-478
Diesel
Van 283 V - 8 V- 8 Optional P-Models Diesel

Ground Neg. Neg. Neg. Neg. Neg. Neg. Neg. Neg.

No. of Plates 54 54 54 66 66 66 114 162

Cranking Power
2300 2300 2350 2900 3150 3150 - -
(Watts) @ 0°F.

Capacity @ 20 Hour
45 45 53 61 70 70 150 205
Rate (Ampere Hour)

GENERATOR

CHEVROLET TRUCK SERVICE M ANUAL

 SPECIFICATIONS 15

DISTRIBUTORS

For RPO K66 (Transistor Ignition System)

Centrifugal Vac. Adv. Idling Spark

Spark
Distributor Advance (Nom) Speed # Plug
Engine Timing
Part No. (Nom) Crank (Original
@ Idle
Crank Degrees Degrees Trans. Prod. A.I.R. Equipment)

C-4457 C-3936
L -6 - 230 Cu. In. - 140 HP 1110362 0 @ 900 RPM 0 @ 6” Hg. 4° BTDC Manual 500 AC-46N
G10 & P10 A ll Transmissions 1110363 10° @ 1200 RPM 21° @ 14.5" Hg. Automatic 500
(G10) 30° @ 3200 RPM
C-4627 C-3936
L6 - 230 Cu. In. - 140 HP 1110387 0 @ 950 RPM 0 @ 6" Hg. 4° BTDC Manual 700 AC-46N
G10 & P10 RPO K19 - 1110390 17° @ 2100 RPM 21° @ 14.5” Hg. Automatic 500
A ll Transmissions (G10) 26° @ 4000 RPM
C-4442 C-3936
L6 - 250 Cu. In. - 155 HP 1110351 0 @ 900 RPM 0 @ 6" Hg. 4° BTDC Manual 500 700 AC-46N
L.D. Truck - A ll Trans. - 1110395 7.5° @ 1200 RPM 21° @ 14.5” Hg. Automatic 500 500
w/ & w/o RPO K19 (G10) 15° @ 1600 RPM
28° @ 2800 RPM
C-4489 C-3036
V8 - 283 Cu. In. - 195 HP 1111150 0 @ 900 RPM 0 @ 8" Hg. 4° BTDC Manual 500 AC-44
L.D. Truck (175 HP) - 10° @ 1500 RPM 15° @ 15.5" Hg. Automatic 500 600
A ll Exc. Truck K19 15° @ 2000 RPM
w/Manual Transmission 28° @ 4200 RPM
C-4461 C-3036 6“ ATDC Manual 700 A C -44
V8 - 283 Cu. In. - 175 HP 1111114 0 @ 900 RPM 0 @ 8" Hg.
L.D. Truck RPO K19 with 17° @ 1200 RPM 15° @ 15.5" Hg.
Manual Transmission 30° @ 2400 RPM
40° @ 4000 RPM
C-4633 C-3036
V8 - 327 Cu. In. 1111249 0 @ 900 RPM 0 @ 8" Hg. Pass. Manual 500 AC-44
Truck - 4-bbl. (220 HP) 11° @ 1500 RPM 15° @ 15.5" Hg. 8° BTDC Automatic 500
A ll Exc. with RPO K19 26° @ 4100 RPM L.D. Truck
2° BTDC
C-4489 C-3036
V8 - 327 Cu. In. 1111150 0 @ 900 RPM 0 @ 8" Hg. Pass. Manual 700 AC-44
Truck - 4-bbl. (220 HP) 10° @ 1500 RPM 15° @ 15.5" Hg. 6° BTDC Automatic 600
RPO K19 - A ll Transmission 15° @ 2000 RPM L.D. Truck
28° @ 4200 RPM TDC
C-4462 C-3912
L6 - 292 Cu. In. Truck - 1110364 0 @ 900 RPM 0 @ 7" Hg. 4° BTDC Manual 500 AC-44N
170 HP, A ll Transmissions 6° @ 1200 RPM 23° @ 16" Hg. Automatic 500 600
and RPO K19 with 26° @ 2500 RPM
Powerglide Transmission
C-4497 C-3912
L6 - 292 Cu. In. Truck - 1110375 0 @ 900 RPM 0 @ 7" Hg. 2° ATDC Manual 700 AC-C44N
170 HP, RPO K19 with 11° @ 1200 RPM 23° @ 16" Hg.
Manual Transmission 30° @ 2450 RPM
C-2865
V8 - 327 Cu. In. - Truck 1112795 0 @ 700 RPM None 8° BTDC A ll 500 AC-C43
185 HP RPO L30, (Special 11° @ 1600 RPM
500-600 Series, Gear) 24° @ 4600 RPM
Governed @ 4000 RPM
C-3794
V8 - 366 Cu. In. Truck 1111309 0 @ 600 RPM None 6° BTDC A ll 500 AC-C42N
220 HP, RPO L41, - (Special 24° @ 2000 RPM
500-600 Series, Gear) 32° @ 4400 RPM
Governed @ 4000 RPM
C-4448
V8 366 Cu. In. Truck 1111303 0 @ 600 RPM None 6° BTDC A ll 500 AC-C42N
220 HP, RPO L41 - (Special 24° @ 2000 RPM
500-600 Series, Gear) 32° @ 4400 RPM
Governed @ 4000 RPM

CHEVROLET TRUCK SERVICE MANUAL

 SPECIFICATIONS
16
STARTING MOTOR

1107399 1107496 1107497 1107274 1107321 1107372 1107591 1113183 1113184 1113659 1114101 1107365 1108332 1107370 1107383

250 L-6,
250 L-6, 250 L-6,
Auto.
283 & 327 382 & 327 292 L-6, 366 V-8 D-351 3-53 4-53 D-478 6V-53 283 & 327
194 L-6 Trans. Optional
Application V-8 V-8 3 & 4 Spd. 4 & 5 Spd. Diesel Diesel Diesel Diesel Diesel V-8 Optional Optional
G-10 (Optional G-10
Power- 3-Spd. Trans. Trans. 50 Series 50 Series 60 Series 60 Series 80 Series Auto.
250 L-6
glide Trans. Trans.
Taxi)

Brush Spring
35 35 35 35 35 35 35 80 80 80 80 35 40 40 40
Tension, Oz.

Volts 10.6 10.6 10.6 10.6 10i6 10.6 10.6 11.5 11.5 11 11.5 10.6 11.8 11.8 11.8

Free Amperes 49-87* 49-87* 49-87* 65-100* 65-100* 55-95* 75-100* 57-70* 57-70* 105-155* 90-130* 70-99* 72 72 72
Speed

6200- 6200- 6200- 3600- 3600- 3800- 6450- 5000- 5000- 6800- 5600- 7800-
m 6025 6025 6025
10,700 10,700 10,700 5100 5100 6000 8750 7400 7400 10,400 7600 12,000

Volts 4.2 4.2 4.2 3.5 3.5 3.5 5 - - - - 3.0 3.5 3.5 3.5
Resistance Test
Armature Locked
Amperes 290-425* 290-425* 290-425* 300-360* 300-360* 300-360* 720-870* - - - - 410-480* 295-365 295-365 295-365
CHEVROLET

♦Includes Solenoid
TRUCK
SERVICE MANUAL

> ) \
 SPECIFICATIONS 17

IGNITION COIL

IGNITION COIL 1115208 1115242 1115210

Application L - 6 Engines V - 8 Engines V - 8 w/Transistor Ignition
Primary Resistance—Ohms 1.41-1.65 1.24-1.46 .38-.51
Secondary Resistance—Ohms 5,400-7,100 7,200-9,500 8,200-12,400
Type In Wiring Harness In Wiring Harness In Wiring Harness
Ignition Resistor .43 &
Ohms 1.8 1 .8 .6 8

CHEVROLET TRUCK O VERHAUL MANUAL

SPECIFICATIONS 18

TRANSMISSION AND CLUTCH

SECTION 7

THREE SPEED (MUNCIE)

Clutch Gear Retainer to Case B o l t s ........................................................................................................................... 15 ft. lbs.

Side Cover to Case B o l t s ................................................................................................................................................ 18 ft. lbs.
Extension to Case B o l t s ....................................................................................................................................................45 ft. lbs.
Shift Lever Clamping Bolt N u t ......................................................................................................................................15 ft. lbs.
Lubrication F iller P l u g ....................................................................................................................................................30 ft. lbs.
Shifter Interlock Retainer Stud and Nut........................................................................................................................5 ft. lbs.
Clutch Gear Bearing Retainer N u t ...............................................................................................................................40 ft. lbs.

FOUR SPEED (MUNCIE)

Rear Bearing Retainer (1/2 - 13) Bolt (30, 50, 60 S e r ie s )................................................................................. 65 ft. lbs.
Rear Bearing Retainer (3/8 - 16) B o l t s .................................................................................................................... 25 ft. lbs.
Cover B o lt s ............................................................................................................................................................................ 25 ft. lbs.
Filler P l u g ............................................................................................................................................................................ 35 ft. lbs.
Drain P l u g ............................................................................................................................................................................ 35 ft. lbs.
Clutch Gear Bearing Retainer B o l t s ........................................................................................................................... 18 ft. lbs.
Universal Joint Front Flange Nut (50 - 60 Series) or Bolt (10 - 20 - 30 S e r i e s ) .......................................... 110 ft. lbs.
Reverse Shifter Lever Nut........................................................................................................................... 40 Minimum ft. lbs.
Power Take Off Cover B o l t s ......................................................................................................................................... 20 ft. lbs.
Parking Brake Drum Oil Deflector Bolts ................................................................................................................. 8 ft. lbs.

THREE SPEED (SAGINAW)

Clutch Gear Retainer to Case B o l t s ........................................................................................................................... 22 ft. lbs.

Side Cover to Case B o l t s ................................................................................................................................................ 22 ft. lbs.
Extension to Case Bolts (except overdrive).................................................................................................................45 ft. lbs.
Overdrive Attaching Lower Left Hand Bolt (Marked X ) ........................................................................................ 30 ft. lbs.
Shift Lever to Shifter Shaft B o lts .................................................................................................................................. 20 ft. lbs.
Lubrication Filler P l u g ....................................................................................................................................................15 ft. lbs.
Transmission Case to Clutch Housing B o l t s ............................................................................................................. 55 ft. lbs.
Crossmember to Frame N u ts......................................................................................................................................... 25 ft. lbs.
Crossmember to Mount and Mount to Extension B o l t s .............. ......................................................................... 40 ft. lbs.

FOUR SPEED (SAGINAW)

Clutch Gear Retainer to Case B o l t s ........................................................................................................................... 22 ft. lbs.

Side Cover to Case B o l t s ................................................................................................................................................ 22 ft. lbs.
Extension to Case Bolts (except o v e r d r iv e )............................................................................................................. 45 ft. lbs.
Shift Lever to Shifter Shaft B o lts .................................................................................................................................. 20 ft. lbs.
Lubrication Filler P l u g ....................................................................................................................................................15 ft. lbs.
Transmission Case to Clutch Housing B o l t s ............................................................................................................. 55 ft. lbs.
Crossmember to Frame N u ts......................................................................................................................................... 25 ft. lbs.
Crossmember to Mount and Mount to Extension B o l t s ........................................................................................ 40 ft. lbs.

FOUR SPEED (MUNCIE)

Clutch Gear Bearing Retainer to Case Bolts ..........................................................................................................25 ft. lbs.
Cover to Case B o l t s ...........................................................................................................................................................20 ft. lbs.
Extension and Retainer to Case Bolts - (Upper) ...................................................................................................20 ft. lbs.
- (L o w e r )...................................................................................................30 ft. lbs.
Lubrication Filler P l u g ....................................................................................................................................................30 ft. lbs.
Shift Lever to Shifter Shaft N ut......................................................................................................................................20 ft. lbs.

CHEVROLET TRUCK SERVICE M ANUAL

 SPECIFICATIONS 19

FIVE SPEED (SPICER)

Countergear Rear Bearing N u t ................................. .............................................................................................. 235 ft. lbs.
Countergear Rear Bearing Retainer B o l t s ............................................................................................................. 20 ft. lbs.
Mainshaft Flange Yoke N u t ......................................................................................................................................... 235 ft. lbs.
Power Take Off Cover B o l t s ...................................................................................................................................... 15 ft. lbs.
Mainshaft Rear Bearing Retainer Bolts ................................................................................................................ 40 ft. lbs.
Clutch Gear Bearing Retainer B o l t s ........................................................................................................................ 40 ft. lbs.
Drain or F iller P lu g ....................................................................................................................................................... 35 ft. lbs.

POWERGLIDE

Transmission Case to E n g in e...................................................................................................................................... 35 ft. lbs.

Transmission Oil Pan to C a s e .................................................................................................................................. 8 ft. lbs.
Transmission Extension to C a s e ............................................................................................................................... 25 ft. lbs.
Speedometer Driven Gear Fitting R eta in er............................................................................................................. 4 ft. lbs.
Servo Cover to Transmission Case B o l t s ............................................................................................................. 20 ft. lbs.
Front Pump to Transmission Case Bolts ............................................................................................................. 15 ft. lbs.
Front Pump Cover to Body Attaching B o l t s .......................................................................................................... 20 ft. lbs.
Pinion Shaft Lock Plate Attaching S c r e w s ...................................................................................................... 2-1/2 ft. lbs.
Governor Body to Hub Attaching B o l t s .................................................................................................................... 7 ft. lbs.
Governor Hub Drive S c r e w ......................................................................................................................................... 8 ft. lbs.
Rear Pump to Transmission Case B o l t s ................................................................................................................. 10 ft. lbs.
Valve Body to Transmission Case B o l t s ................................................................................................................. 15 ft. lbs.
Valve Body Suction Screen Attaching Screw s......................................................................................................2-1/2 ft. lbs.
Upper Valve Body Plate B o lts...................................................................................................................................... 5 ft. lbs.
Lower to Upper Valve Body Attaching B o lt s .......................................................................................................... 15 ft. lbs.
Inner Control Lever Allen Head S cre w ................................................................................................................ 2-1/2 ft. lbs.
Parking Lock Pawl Reaction Bracket Attaching B o lts ........................................................................................ 10 ft. lbs.
Oil Cooler Plugs at Transmission C a s e ................................................................................................................. 5 ft. lbs.
Pressure Test Point P l u g s ......................................................................................................................................... 5 ft. lbs.
Low Band Adjustment Locknut...................................................................................................................................... 15 ft. lbs.
Converter to Engine B o lts ............................................................................................................................................. 35 ft. lbs.
Under Pan to Transmission C a s e ........................................................................................................................... 7-1/2 ft. lbs.
Oil Cooler Pipe Connectors to Transmission Case or R a d ia to r................................................................... 10 ft. lbs.
Oil Cooler Pipe to C o n n e c to rs.................................................................................................................................. 10 ft. lbs.
Vacuum Modulator to Transmission C a s e ............................................................................................................. 15 ft. lbs.
Oil Pan Drain Plug........................................................................................................................................................... 20 ft. lbs.
Converter Drain Plug (Taxies)...................................................................................................................................... 20 ft. lbs.
Parking Brake Lock & Range Selector Inner Lever Allen Head Screw.....................................................2-1/2 ft. lbs.

TURBO HYDRA-MATIC

Pump Cover B o l t s .............................................................................................................................................................. 18 lb. ft.

Parking Pawl Bracket B o lts .............................................................................................................................................18 lb. ft.
Case Center Support B o l t ................................................................................................................................................ 23 lb. ft.
Pump to Case Attaching B o lts......................................................................................................................................... 18 lb. ft.
Extension Housing to Case Attaching B o lts.................................................................................................................23 lb. ft.
Rear Servo Cover B o l t s ....................................................................................................................................................18 lb. ft.
Detent Solenoid B o lts........................................................................................................................................................... 7 lb. ft.
Control Valve Body B o l t s ................................................................................................................................................ 8 lb. ft.
Bottom Pan Attaching S c r e w s ......................................................................................................................................... 12 lb. ft.
Modulator Retainer B o l t ....................................................................................................................................................18 lb. ft.
Governor Cover B o l t s ....................................................................................................................................................... 18 lb. ft.
Manual Lever to Manual Shaft N u t ............................................................................................................................... 8 lb. ft.
Manual Shaft to Inside Detent L e v e r ........................................................................................................................... 18 lb. ft.
Linkage Swivel Clamp N ut................................................................................................................................................ 43 lb. in.
Converter Dust Shield S cre w s......................................................................................................................................... 93 lb. in.
Transmission to Engine Mounting B o l t s .................................................................................................................... 28 lb. ft.
Converter to Flywheel B o lts.............................................................................................................................................33 lb. ft.
Rear Mount to Transmission B o l t s ...............................................................................................................................40 lb. ft.
Rear Mount to Crossmember B o l t .................................................................................... ..........................................40 lb. ft.
Crossmember Mounting B o l t s ......................................................................................................................................... 25 lb. ft.
Oil Cooler Line ..................................................................................................................................................................113 lb. in.
Line Pressure Take-Off P lu g ......................................................................................................................................... 13 lb. ft.

CHEVROLET TRUCK SERVICE MANUAL

SPECIFICATIONS 20

STEERING
SECTION 9

40-50-60 9000#
G10-20 C-P10 C20-30 K10-20 P20-30 Except 11000#
T Model T Models

G10 155 lb. ft.

Tie Rod Ball Joint 26 lb. ft. 5000#
30 lb. ft. 50 lb. ft. 45 lb. ft. 155 lb. ft. 80 lb. ft.
Nut G20 240 lb. ft.
105 lb. ft. 7000#
G10 50 lb. ft.
Tie Rod Clamp 20 lb. ft. 5000#
20 lb. ft. 20 lb. ft. 35 lb. ft. 50 lb. ft. 70 lb. ft.
Bolt G20 90 lb. ft.
30 lb. ft. 7000#
Idler Arm Mounting lb. ft. - — - -
- 20 lb. ft. 20
Bolts
Idler Arm to Relay 60 lb. ft. 60 lb. ft. - - — -
-
Rod Nut
Pitman Arm to 60 lb. ft. - - - -
- 60 lb. ft.
Relay Rod Nut
Steering Connecting — 50 lb. ft. 50 lb. ft. 50 lb. ft. 50 lb. ft.
50 lb. ft. —
Rod Nut
Pitman Arm to Sector 125 lb. ft. 115 lb. ft. 95 lb. ft. lb. ft.
95 lb. ft. 140 lb. ft. 140 lb. ft. 200
Shaft Nut
Horizontal
Steering Gear 1 0 0 lb. ft.
100 lb. ft. 65 lb. ft. 65 lb. ft. 100 lb. ft. 100 lb. ft. 100 lb. ft.
Mounting Bolts Vertical
50 lb. ft.
Steering Wheel Nut 35 lb. ft. 35. lb. ft. 35. lb. ft. 35. lb. ft. 35 lb. ft. 35 lb. ft. 35 lb. ft.
.005 .1 2
Lower Mast Jacket 7 /8 ” — to to
— 7 /8 ” 7 /8 ”
Bearing Adj. .030 .15
Power Steering 125 lb. New — 75 lb. Used
Belt Tension

Steering Gear

5 to 9 5 to 9 5 to 9 4 to 7 9 to 13 4 to 7 4 to 7
Worm Bearing Preload in. lbs. in. lbs.
in. lbs. in. lbs. in. lbs. in. lbs. in. lbs.
Worm Bearing Lock 85 lb. ft. 85 lb. ft.
85 lb. ft. 85 lb. ft. 85 lb. ft. 85 lb. ft. 85 lb. ft.
Nut
5 to 11 ~ 5 to 11 ^ 4 to 7 ^ 18 to 72 4 to 7 4 to 7
Sector Lash Adjustment 5 ‘V 1 ® in. lbs.®
in. lbs. in. lbs.® in. lbs.® in. lbs.® in. lbs.® in. lbs.®
Sector Lash Lock Nut 30 lb. ft. 30 lb. ft. 30 lb. ft. 30 lb. ft. 30 lb. ft. 30 lb. ft. 30 lb. ft.
Total Steering Gear 18 in. lbs. 18 in. lbs. 18 in. lbs. 14 in. lbs. 35 in. lbs. 14 in. lbs. 14 in. lbs.
Preload Max. Max. Max. Max. Max. Max. Max.
Power Steering 1 to 3 + 1 to 3 1 to 3 *
- - - -
Adjuster Plug in. lbs. in. lbs. in. lbs.
Pump Pressure 850 — 1,000 psi

@In excess of worm bearing preload.

* In excess of valve assembly drag.

CHEVROLET TRUCK SERVICE M ANUAL

 SPECIFICATIONS 21

WHEEL ATTACHING NUTS TORQUE

SECTION 10

SERIES FRONT WHEEL REAR WHEEL

10 55-65 lbs. ft. 55-65 lbs. ft.

20-30 65-90 lbs. ft. 65-90 lbs. ft.
40-50 300-400 lbs. ft. 300-400 lbSo ft.
60 - (With Cast Wheels) 165-185 lbs. ft. 190-210 lbs. ft.
All - R.P.O. Disc. Wheel 450-500 lbs. ft. 450=500 lbs. ft.

BODY AND CHASSIS ELECTRICAL

SECTION 12

(LAMP USAGE-ALL EXCEPT CHEVY VAN)

Application Trade No. Rating Application Trade No. Rating

Instrument Cluster Low Vacuum (Diesel)

Conventional Cab 194 2CP Conventional Cab 194 2CP
F /F Cowl 1895 2CP F /F Cowl 67 4CP
Tilt Cab 1895 2CP Tilt Cab 1895 2CP
Temperature Indicator .Air Brake Gage 1895 2CP
Conventional Cab 194 2CP Oil Pressure Gage 1895 2CP
Brake Warning Indicator Vacuum Gage 1895 2CP
Conventional Cab 194 2CP Tachometer
F /F Cowl 1895 2CP Conventional Cab 194 2CP
Tilt Cab 1895 2CP Tilt Cab 1445 1CP
Generator Indicator Heater Control
Conventional Cab 194 2 CP Conventional Cab 1895 2CP
Tilt Cab 1895 2CP F /F Cowl 1895 2CP
Directional Indicator Tilt Cab 1445 1CP
Conventional Cab 194 2CP Dome Lamp 211 12CP
F /F Cowl 1445 1CP Parking Lamps 67 4CP
Tilt Cab 1895 2CP License Lamp — —
Oil Pressure Indicator Roof Lights — —
Conventional Cab 194 2CP Front Directional Signal 1156 32CP
Tilt Cab 1895 Back-Up Lamps
High Beam Indicator Parking and Directional
Conventional Cab 194 2CP Signal 1157 4-32CP
F /F Cowl 1445 1CP Tail, Stop and
Tilt Cab 1895 2CP Directional Signal 1157 4-32CP
Overspeed Warning (327 Cigarette Lighter - —
& 366 V - 8 only) Differential Lockout 1895 2CP
Conventional Cab 194 2 CP Headlamp 6012 50W - High Beam
F /F Cowl 67 4CP 40W - Low Beam
Tilt Cab 1895 2CP

CHEVROLET TRUCK SERVICE MANUAL

SPECIFICATIONS 22

CHEVY VAN FUSE AND CIRCUIT BREAKER USAGE

Trade Applicability Location Amps Type

Application Number Rating
Instrument 3 3AG/AGC
Cluster
Dome Lights 211 12 CP
License Plate Lamp 67 4CP Windshield
Parking and Direction Signal Wiper Motor 20 SAE
1157 4-32CP Air Conditioning
Tail, Stop and Direction Signal
Turn Signal Indicator
1895 2CP Heater Motor
Upper Beam Indicator 10 3 AG/AG C
Backup Lamps
Radio Dial Lamp 1893 2CP Fuse block
Instrument Illumination Tail Stop Dome in driver's
Temperature Tell-Tale License Lamps compartment
1895 2CP
Oil Pressure Tell-Tale Roof Marker 15 3AG/AGC
Generator Tell-Tale Lights
50W Spotlamp
High Beam Glove Box Lamp
H«idlimD High Beam 6012
Low Beam 40W 3 3 AG/AG C
Radio
Low Beam
Back-Up Lamp 1156 32CP Emergency
15 SAE
Disability
Headlamps &
Light switch 15
Park Lamps
Circuit breaker
2-Speed Rear
Driver
Axle w 10
compartment
Electric Shift
In-Line
Part of Gen.
Ammeter & fwd. lamp 3 3AG/AGC
harness
(2 Reqd.)

WINDSHIELD WIPERS

TWO-SPEED WIPER
Crank Arm Speed (RPM’s) (No Load)
L o ............................................................................. 34 Min.
H i ............................................................................. 65 Min.
Current Draw. AMPS
No Load (Lo S p e e d )..................................................... 3.6
Installed in Car—(Dry G l a s s ) ................................... 4.5
S t a l l ................................................................................. 12
WASHER
Number of “ squirts” at full p r e s s u r e ..................... 12
Pressure ( P S I ) ............................................................... 11-15
Coil Resistance (ohms)................................................. 20

CHEVROLET TRUCK O VERHAUL MANUAL

 SPECIFICATIONS 23

RADIATOR AND GRILLE

SECTION 13

TORQUE SPECIFICATIONS

C — K 10, 20, 30 Models (Radiator)

Radiator Retainer to Radiator Support S c r e w s ............................................................................................... 13 lb. in.
Radiator Drain Plug.................................................................................................................................................... 150 lb. in.
Radiator Shroud to Radiator S cre w s.................................................................................................................... 43 lb. in.
P10 Models (Radiator)
Radiator to Radiator Support S c r e w s ................................................................................................................. 18 lb. ft.
Radiator Support Bracket Attaching N u t s ......................................................................................................... 25 lb. ft.
Radiator Support Brace Attaching N u t s ............................................................................................................. 90 lb. in.
Radiator Drain Plug.................................................................................................................................................... 113 lb. in.
P20 and P30 Models (Radiator)
Radiator to Radiator Support S c r e w s ................................................................................................................. 18 lb. ft.
Shroud to Radiator Support S c r e w s .................................................................................................................... 43 lb. ft.
Radiator Drain Plug.................................................................................................................................................... 113 lb. ft.
GE Models (Radiator)
Air Deflector and Splash Shields to
Underbody B o lt s ..................* ........................... ......................................................................................................... 90 lb. in.
CE - CS - SA00, CD - ME - MS50, CT40, CD - MD - ME60
Models (Radiator)
Shroud Attaching S c r e w s ......................................................................................................................................... 43 lb. in.
CE - CS00, ME - MS50, SA40 - 60, SE - SS50
Models (Radiator)
Radiator Drain Plug.................................................................................................................................................... 113 lb. in.
Baffle to Radiator Support S cre w s........................................................................................................................ 25 lb. in.
Retainer to Radiator Support N uts........................................................................................................................ 150 lb. in.
CD - CG - CT - MD00, MG60 Models (Radiator)
Radiator Drain Plug.................................................................................................................................................... 113 lb. ft.
Baffle to Radiator Support S cre w s........................................................................................................................ 25 lb. in.
Retainer to Radiator Support N uts........................................................................................................................ 150 lb. in.
PA40 Models (Radiator)
Shroud to Radiator Support S c r e w s .................................................................................................................... 25 lb. in.
Radiator Support Bracket Attaching B o lts .......................................................................................................... 20 lb. ft.
Support Bracket to Radiator Support S c r e w s ................................................................................................... 18 lb. ft.
Radiator Drain Plug.............................................. ; .................................................................................................. 113 lb. in.
ME60 (Radiator
Baffle to Radiator Support Screws .................................................................................................................... 25 lb. in.
Retainer to Radiator Support S c r e w s ................................................................................................................ 150 lb. in.
Radiator Drain Plug.................................................................................................................................................... 113 lb. in.

CHEVROLET TRUCK SERVICE M ANUAL

SPECIFICATIONS 24

TA Models (Radiator)
Shroud and Radiator Brace Bolts. . . 120 lb. in.

Radiator to Radiator Support Screws 120 lb. in.

25 lb. in.
35 lb. in.
Radiator to Support Bar Nuts . . . . 50 lb. ft.
Radiator to Frame Lower Nut . . . . 40 lb. ft.
Lower Support to Frame Rear Bolts 45 lb. ft.
Lower Support to Frame Front Bolts 30 lb. ft.
CA - KA 10-20, CA 30 Models (Grille)
Grille Extension to Grille Nuts . . . 22 lb. in.
Center Support to Grille Screws . . . 30 lb. in.
Grille Bumper Jam N u ts..................... 85 lb. in.
150 lb. in.
150 lb. in.
CA - SA 40 - 50 - 60, MA 50-60 Models (Grille)
Hood Catch to Grille S cre w s................................... 13 lb. ft.
22 lb. in.
150 lb. in.
Lower Retainer to Lower Center Panel Screws............................................................................................... 150 lb. in.
TA Models (Grille)
Gusset to Grille and Grille Support Screws ................................................................................................... 18 lb. ft.

CHEVROLET TRUCK SERVICE MANUAL

 SPECIFICATIONS 25

BUMPERS
SECTIO N 14

TORQUE SPECIFICATIONS

C and K 10, 20, 30 Models — Front Bumper

Bumper Brace to Fram e B o l t s ............................................................................................................................... 45 lb. ft.
Bumper Brace to Face Bar N uts........................................................................................................................... 35 lb. ft.
Bumper Bracket to Frame B o l t s ........................................................................................................................... 100 lb. ft.
Face Bar to Frame N u t s ......................................................................................................................................... 35 lb. ft.
Face Bar to Bracket Nuts ...................................................................................................................................... 35 lb. ft.
C and K 10, 20, 30 Models — Rear Bumper
Face Bar to Fram e and Brace N u ts.................................................................................................................... 40 lb. ft.
Seal to Body S cre w s...................................................................................................... ....................... .................... 13 lb. in.
P10 Models — Front Bumper
Bumper Brace to Frame B o l t s ............................................................................................................................... 45 lb. ft.
Bumper Brace to Face Bar Nuts ........................................................................................................................ 35 lb. ft.
P20 and 30 Models — Front Bumper
Face Bar to Upper Bracket Lock Nuts ............................................................................................................. 36 lb. ft.
G10 and 20 Models — Front Bumper
Face Bar to Frame and Brace N u ts.................................................................................................................... 17 lb. ft.
Bumper Brace to Frame S c re w s ........................................................................................................................... 17 lb. ft.
Face Bar to License Plate Bracket S c r e w s ...................................................................................................... 43 lb. in.
G10 and 20 Models — Rear Bumper
Face Bar to Frame and Brace N u ts.................................................................................................................... 17 lb. ft.
C, S, M 40, 50, 60, and P40 Models — Front Bumper
Face Bar to Fram e N u t s ..........................................................................................................................................100 lb. ft.
Face Bar to Bracket Nuts ...................................................................................................................................... 41 lb. ft.
T Models — Front Bumper
Face Bar to Bracket Nuts ..................................................................................................................................... 35 lb. ft.
Face Bar to Filler Panel N u ts...............................................................................................................................100 lb. ft.
Gusset to Frame N uts................................................................................................................................................ 100 lb. ft.
Bracket to Frame N u t s ............................................................................................................................................. 100 lb. ft.
Face Bar to Gusset Rear N u ts...............................................................................................................................120 lb. ft.

CHEVROLET TRUCK SERVICE MANUAL