GMC 1986 C-K, 1986 G-VAN, 1986 P-Truck Service Manual

LIGHT DUTY TRUCKS
FOREWORD
This service manual contains diagnosis, “ On-Vehicle” maintenance, and light re­
pair for Light Duty Truck Models (“ C-K, P-Truck, and G-Van” ). Procedures involving
disassembly and assembly of major components for these vehicles are published in a
separate “ Truck Unit Repair Manual.” Wiring diagrams for these models are also
published in a separate “ Truck Wiring Diagram” booklet.
This manual should be kept in a handy place for ready reference. If properly used, it
will meet the needs of technicians and vehicle owners.
CAUTION:
These vehicles contain some parts dimensioned in the metric system as well as in
the customary system. Some fasteners are metric and are very close in dimension to
familiar customary fasteners in the inch system. It is important to note that, during any
vehicle maintenance procedures, replacement fasteners must have the same mea­
surements and strength as those removed, whether metric or customary. (Numbers on
the heads of metric bolts and on surfaces of metric nuts indicate their strength. Cus­
tomary bolts use radial lines for this purpose, while most customary nuts do not have
strength markings.) Mismatched or incorrect fasteners can result in vehicle damage or
malfunction, or possibly personal injury. Therefore, fasteners removed from the vehi­
cle should be saved for re-use in the same location whenever possible. Where the
fasteners are not satisfactory for re-use, care should be taken to select a replacement
that matches the original. For information and assistance, see your authorized dealer.
GMC TRUCK & COACH OPERATION
TRUCK & BUS GROUP
General Motors Corporation
Pontiac, Michigan
CAUTION
To reduce the chance of personal injury and/or property damage, the follow­
ing instructions must be carefully observed.
Proper service and repair are important to the safety of the service techni­
cian and the safe, reliable operation of all motor vehicles. If part replacement
is necessary, the part must be replaced with one of the same part number or
with an equivalent part. Do not use a replacement part of lesser quality.
The service procedures recommended and described in this service
manual are effective methods of performing service and repair. Some of these
procedures require the use of tools specially designed for the purpose.
Accordingly, anyone who intends to use a replacement part, service proce­
dure or tool, which is not recommended by the vehicle manufacturer, must
first determine that neither his safety nor the safe operation of the vehicle will
be jeopardized by the replacement part, service procedure or tool selected.
It is important to note that this manual contains various Cautions and No­
tices that must be carefully observed in order to reduce the risk of personal
injury during service or repair, or the possibility that improper service or repair
may damage the vehicle or render it unsafe. It is also important to understand
that these ‘Cautions’ and ‘Notices’ are not exhaustive, because it is impossi­
ble to warn of all the possible hazardous consequences that might result from
failure to follow these instructions.
SEC
NAME
GENERAL INFORMATION
OA
OB
1986
General Information
Maintenance and Lubrication
HEATING AND AIR CONDITIONING
1A
1B
Heating
Air Conditioning
I
I
FRAME AND CAB
2A
2B
2C
LIGHT DUTY
TRUCK
SERVICE
MANUAL
Frame and Body Mounts
Bumpers
Sheet Metal and Fiberglass
STEERING, SUSPENSION,
WHEELS AND TIRES
3A
3B1
3B2
3B3
3B4
3C
3D
3E
Front End Alignment
Steering Linkage
Manual Steering
Power Steering
Steering Column
Front Axle and Suspension
Rear Suspension
Wheels and Tires
PROPELLER SHAFT AND AXLES
4A
4B
4C
Propeller Shaft
Rear Axle
Front Axle
BRAKES
C-K, P-TRUCK
AND G-VAN
MODELS
ENGINE
6A
6A3
6A4
6A5
6A6
6A7
6B
6C
6C1
6C2
6D
6E
6E8
6E9
6F
6H
The Table of Contents on this page in­
dicates the sections covered in this
manual. At the beginning of each individ­
ual section is a Table of Contents which
gives the page number on which each
major subject begins.
Engine
4.3 Liter V6
4.8 Liter L6
Small Block
7.4 Liter V8
6.2 Liter Diesel
Engine Cooling
Fuel System
Carburetors
Diesel Fuel Injection
Engine Electrical
Drivability And Emissions
Drivability And Emissions — Carburetor
Drivability And Emissions — Diesel
Exhaust
Vacuum Pump
TRANSMISSION AND CLUTCH
7A
7B
7B1
7B2
7B3
7C
7D1
7D2
When reference is made in this manual
to a brand name, number, or specific tool,
an equivalent product may be used in
place of the recommended item.
All information, illustrations, and speci­
fications contained in this Manual are
based on the latest product information
available at the time of publication ap­
proval. The right is reserved to make
changes at any time without notice.
Automatic Transmission
Manual Transmission
3 Speed 76mm Transmission
4 Speed 89mm Transmission
4 Speed 117mm Transmission
Clutch
205 Transfer Case
208 Transfer Case
ELECTRICAL
8A
8B
8C
Cab Electrical
Chassis Electrical
Intrument Panel
RADIO AND CRUISE CONTROL
9A
9B
Printed in Canada
© 1985 General Motors Corporation
10
November, 1985
I
Radio
Cruise Control
BODY
INDEX
I
He knows
quality parts
make a difference
even on
simplejobs.
Mr. Goodwrench wants you to have the right parts for
your truck—whether you see him for service or whether
you do the work yourself.
That’s why Mr. Goodwrench wants to have a good
stock of genuine GM Parts available. Everything from
exclusive GM Goodwrench replacement engines and
transmissions to GM Goodwrench Motor Oil that meets
or exceeds all specifications for General Motors cars
or light trucks. And Mr. Goodwrench has a complete
line of GM chemicals for fine care of your GM vehicle.
Plus accessories to add convenience—
or just a little extra style.
So keep that great GM feeling with genuine GM parts
at participating independent Mr. Goodwrench dealers
selling Chevrolets, Pontiacs, Oldsmobiles, Buicks,
Cadillacs, GMC and Chevy Trucks.
O CNERAL M O T O R S C O R PO R A T IO N
B-05884
O A -1
SECTION 0
GENERAL INFORMATION
CONTENTS
SUBJECT
PAGE
General In fo rm a tio n ................................................................................................................................................... OA- 1
Maintenance and L u b ric a tio n ..................................................................................................................................OB- 1
SECTION OA
GENERAL INFORMATION
CONTENTS
SUBJECT
PAGE
Service Parts Identification L ab e l....................................................................................................................... OA- 2
Vehicle Identification P la te ..................................................................................................................................OA- 2
C ertification L a b e l................................................................................................................................................. OA- 2
Model Reference..................................................................................................................................................... OA- 2
Engine Identification N u m b e r............................................................................................................................. OA- 2
Emergency Starting Due to a Discharged B a tte ry .........................................................................................OA- 2
Graphic S y m b o ls ................................................................................................................................................... OA- 6
Metric Fasteners..........................................................................................................................................................OA- 8
Fastener Strength Id e n tific a tio n ......................................................................................................................... OA- 8
Prevailing Torque F asteners..................................................................................................................................OA-9
Six Lobed Socket Head F a ste n e rs....................................................................................................................... OA-9
RPO Listing (Regular Production O p tio n )............................................................................................................ OA-14
OA-2 GENERAL INFORMATION
SERVICE
PARTS
I D E N T I F I C A T IO N_________
V .I .N .M H H m A S E H H B H S E H H
________________
V I N VEHICLE ID EN TIFIC ATIO N NUMBER_____________________
NOTF
THE OPTIONAL -EQUIPMENT LISTED BELOW HAS BEEN IN STALLED ON THIS
VEHICLE FOR PROPER IDENTIFICATIO N OF REPLACEMENT PARTS BE
________SURE TO SPECIFY THE APPLICABLE OPTION NUMBERS______________________
models, the plate is on the dash and toe panel. To find
out the manufacturer, model and chasis type, engine
type, GVW range, model year, plant code, and
sequential number, refer to figure 3.
CERTIFICATION LABEL
IM P O R TA N T: RETAIN THIS LABEL AS A P ERM ANE NT RECORD
B-07003
Figure 1—Service Parts Identification Label
SERVICE PARTS
IDENTIFICATION LABEL
The Truck Service Parts Identification Label is
provided on all models (figure 1). It is located on the
inside of the glove box door (or on an inner body panel
for Forward Control models). The Label lists the VIN
(Vehicle Identification Number), wheelbase, paint
information and all Production options or Special
Equipment on the vehicle when it was shipped from
the factory. ALWAYS REFER TO THIS INFORMATION
WHEN ORDERING PARTS.
VEHICLE IDENTIFICATION
NUMBER
The VIN is the legal identifier of the vehicle. On all
models except Forward Control, it is located on a plate
which is attached to the left top of the instrument panel
and can be seen through the windshield from the
outside of the vehicle (figure 2). On Forward Control
The Certification Label shows the GVWR, and the
front and rear GAWRs, and the Payload Rating for your
vehicle (figure 4).
Gross Vehicle Weight (GVW) is the weight of the
orginally equipped vehicle and all items added to it
after it has left the factory. This would include bodies,
winches, booms, etc.; the driver and all occupants; and
the load the vehicle is carrying. The GVW must not
exceed the GVWR. Also, the front and rear gross axle
weights must not exceed the front and rear GAWRs.
The Payload Rating shown on the label is the
maximum allowable cargo load (including the weight of
the driver and all occupants) that the vehicle can carry
based on all factory installed equipment on the vehicle.
The Payload Rating is reduced if any accessories or
other equipment is added to the vehicle after final date
of manufacture. The weight of these items should be
determined and deducted from the Payload Rating.
The vehicle may also have a GCWR (Gross
C om bination W eight Rating). The GCW (Gross
Combination Weight) is the total weight of the loaded
tow vehicle (including passengers) and a loaded trailer.
The tires on the vehicle must be the proper size and
properly inflated for the load which you are carrying.
The vehicle Certification Label shows the originally
equipped tire size and recom m ended inflation
pressures. For more information on tires, refer to
WHEELS AND TIRES (Sec.3E).
MODEL REFERENCE
Refer to figures 5 and 6 to determine the vehicle
model. For C/K models, a “ C” is a two-wheel drive
vehicle and a “ K” is a four-wheel drive vehicle.
ENGINE IDENTIFICATION
NUMBER
Refer to figure 7 to determine the location of the
engine I.D. number.
EMERGENCY STARTING
YOUR VEHICLE DUE TO A
DISCHARGED BATTERY
F-00687
Figure 2—VIN Location
If your vehicle will not start due to a discharged
battery, it can often be started by using energy from
another battery - a procedure called ‘‘jump starting.”
GENERAL INFORMATION OA-3
VEHICLE IDENTIFICATION NUMBER
1
D
C
1
4
N
4
G
1
JX.
0
0
0
0
1
^ [Production^equence Number^"
Nation of Origin
Assem bly Plant
1 - U.S. Built
2 = Canadian Built
3 = Mexican Built
Code
G = General Motors
Code
Series
1/2 Ton
1
2
3
Manufacturers
^4 Ton
1 Ton
Make
Code Body Type
A Chevrolet Bus'
B Chevrolet Incomplete
C Chevrolet Truck
D GMC Incomplete
E Cadillac Incomplete
H GM ot Canada Bus
T GMC Truck
O GMC Bus
5 GMC MPV
8 Chevrolet MPV
'Van with 4th Seal
Code
0
1
2
3
4
5
6
7
8
9
3001-4000
4001-5000
C
5001-6000
D
6001-7000
E
7001-8000
F
G8001-9000
H
9,001-10,000
10,001 14.000
J
K
14,001-16,000
'In c lu d e s G - Van Bus
Hydraulic
H ydraulic
H ydraulic
Hydraulic
Hydraulic
Hydraulic
Hydraulic
Hydraulic
Hydraulic
Pickup/Panel Delivery
Hi-Cube/Cutaway Van
Forward C ontrol
Four-Door Cab
Two-Door C ab
Van
Suburban
M otor Home Chassis
U tility (Jimmy/Blazer)
Stake
Code
Line and C h a ssis Type
GVW R/BRAKE S YS TE M
Brake System
GVW R Range
B
Baltimore, MD
Flint, Ml
Janesville, Wl
St. Louis. MO
Pontiac, Ml
Oshawa, ON
Moraine, OH
D e tro it, M l
Scarborough, ON
Lordstown, OH
Shreveport, LA
Chassis
Code
C
D
K
G
P
S
T
M
Line
Type
C onventional Cab
M ilitary Truck
C onventional Cab
Van
Forward C ontrol
S m all C on ve n tion a l
Cab
Sm all C on ve n tion a l
Cab
Small Van
4x2
4x4
4x4
4x2
4x2
4x2
4x4
.4x2
Engine Type and Make
Producer
Type
RPO
B
C
E
F
H
J
K
L
M
N
R
T
Chevrolet
DDAD
Pontiac
Chevrolet
Chevrolet
DDAD
Chevrolet
Chevrolet
Chevrolet
Chevrolet
Chevrolet
GM de M exico
2.8L V6 2BBL
6.2L V8 Diesel
2 .5 L L4 TBI
5.0L V8 4BBL
5.0L V8 4BBL
6.2L V8 Diesel
5.7L V8 LPG
5.7L V8 4BBL
5.7L V8 4BBL
4.3L V6 4BBL
2 .8L V 6 T B I
4.8L L6 1BBL
LR2
LH6
LN8
LF3
LE9
LL4
LT9 & KL7
LS9
LT9
LB1
LL2
L25
W
Chevrolet
Chevrolet
7.4L V8 4BBL
4 .3 L V 6 T B I
LE8
LB4
z
.
F-00502
Figure 3—Vehicle Identification Number (VIN)
Should your vehicle have an optional diesel engine
with two batteries:
• P models and G Van models — use only the
battery on the driver’s side when jump starting.
• C/K models — use only the battery on the
passenger’s side when jump starting.
These battery locations are closer to the starter, thus
reducing electrical resistance. Ignore the second
battery.
M FD. BY G E N E R A L M O TO R S CO R PO R ATIO N
I A L L A PP LIC AB LE FEDE
' S AFE TY S TA N D A R D S IN EFFECT
'M A N U F A C T U R E SHOWN ABO VE.
BOC100001
MPV
THU VENICLf EOUmO FOR
1000/453
L IS PAYLOAD
SEE OWNER’S MANUAL FOR ADDITIONAL INFORMATION
F-00597
Figure 4—Certification Label
NOTICE: Do not push or tow this vehicle to
start it. Under some conditions this may
damage the catalytic converter or other parts
of the vehicle. Also, since this vehicle has a 12
volt battery, be sure the vehicle or equipment
used to jump start your engine is also 12 volt.
Use of any other type system may damage the
vehicle’s electrical components.
At low temperatures, it may not be possible to start
your diesel engine from a single battery in another
vehicle. However, you can use your vehicle to jump
start another vehicle.
OA-4 GENERAL INFORMATION
Pickup, Regular Cab
Chassis - Cab, Regular Cab
C-K MODELS
Chassis - Cab, Bonus/Crew Cab
Pickup, Bonus/Crew Cab
Suburban
U tility Vehicle
Jimm y (Blazer)
B-09177
Figure 5
JUMP STARTING INSTRUCTIONS
CAUTIO N: B a tte rie s p ro d u c e e x p lo s iv e
gases, contain corrosive acid, and supply
levels of electrical current high enough to
cause burns. Therefore, to reduce the risk of
personal injury when working near a battery:
• A lw ays sh ie ld yo u r eyes and avoid
le a n in g o v e r th e b a tte ry w h e n e v e r
possible.
• Do n ot expose the b atte ry to open
flames or sparks.
• Be sure any batteries that have fille r
caps are properly filled with fluid.
• Do not allow battery acid to contact
eyes of skin. Flush any contacted area
with water im m ediately and throughly,
and get medical help.
• Follow each step in the jum p starting
instructions.
C-K Models
1. Position the vehicle with the good (charged)
battery so that the booster (jumper) cables will
reach, but never let the vehicles touch. Also, be
sure booster cables do not have loose or missing
insulation.
2. In both vehicles:
• Turn off the ignition and all lights and
accessories except the hazard flasher or
any lights needed for the work area.
• Apply the parking brake firmly, and shift the
automatic transmission to Park (or manual
transmission to Neutral).
3. Making sure the cable clamps do not touch any
other metal parts, clamp one end of the first
booster cable to the positive ( + ) terminal on one
battery, and the other end to the positive terminal
on the other battery (figure 8). Never connect ( + )
to (-).
GENERAL INFORMATION OA-5
G VAN MODELS
RALLY (SPORTVAN)
VANDURA (CHEVY VAN)
CUTAWAY VAN
MAGNAVAN (HI-CUBE VAN)
P MODELS
VALUE VAN (STEP VAN)
(ALUMINUM)
VALUE VAN (STEP VAN)
(STEEL)
MOTOR HOME CHASSIS
FORWARD CONTROL CHASSIS
B-09178
Figure 6—G Van and P Models
OA-6 GENERAL INFORMATION
1
2
4. Engine I.D. {0[Dtional Location)
5. Engine Case F
6. Engine I.D.
L6 ENGINE
l3d
•
Jgj
1. Engine I.D.
2. D istributor Pad
3. Engine I.D. (Optional Location)
7. Engine I.D.
8. Engine Case Pad
V
V8 E N G I N E ^ A ^ ^ ^ ^
4 ^ /
V6 ENGINE
V8 ENGINES-DIESEL
F-00527
Figure 7—Engine I.D. Number Location
4. Clamp one end of the second cable to the
negative (-) terminal of the good (charged) battery
and make the final connection to a heavy metal
bracket (such as the mounting bracket for the
generator or air conditioner compressor if so
equipped) on the engine about 450 millimeters
(18 inches) from the discharged battery. Make
sure the cables are not on or near pulleys, fans,
Make Connections in Numerical Order
First Jum per Cable
Do N O T Allow
Vehicles to Touchl
or other parts that will move when the engine is
started.
5. Start the engine of the vehicle with the good
(charged) battery and run the engine at a
moderate speed for several minutes. Then, start
the engine of the vehicle that has the discharged
battery.
6. Remove the booster cables by reversing the
above installation sequence exactly. While
removing each clamp, take care it does not touch
any other metal while the other end remains
attached.
Discharged
Battery
GRAPHIC SYMBOLS
Second Jum per Cable
Graphic symbols are used on some controls and
displays on the vehicle (figure 9). Many of these
symbols are used internationally.
Make Last
Connection on
Engine or Frame,
Away from Battery
Battery in Vehicle
w ith Charged Battery I
A-9816
TD
Figure 8—Jump Starting Connections
GENERAL INFORMATION OA-7
(O)
BRAKE
1
•
t
I
•
1
$
POWER TRAIN
OIL TEMPERATURE
WINDSHIELD
WASHER
M
WINDSHIELD
WIPER & WASHER
FASTEN
SEAT BELTS
o
LIGHTS OR
HIGH BEAM
FUEL
A
mu
IDENTIFICATION
LAMPS
VENTILATING FAN
A B
-
REAR WINDOW
DEFOGGER
ID
LPS
E3
TURN SIGNALS
HAZARD WARNING
FLASHER
WINDSHIELD
DEFROSTER
t& r>
ENGINE OIL
PRESSURE
V
REAR WINDOW
WIPER & WASHER
WINDSHIELD
WIPER
cao
h rr
HORN
A
CHOKE
BRAKE
CAUSTIC
BATTERY ACID
COULD CAUSE BURNS
IIIUII
n
—
CAUTION
POSSIBLE INJURY
N
PARKING LIGHTS
SPEAKER
i
LIGHTER
>
\\|//
r
DOOR
LOCK/UNLOCK
a
»
HEATER
kPa
RADIO
SELECTOR
ENGINE COOLANT
TEMPERATURE
BATTERY
CHARGING
SYSTEM
RADIO VOLUME
&
SEATBACK
WINGS IN/OUT
SPARK OR FLAME
COULD
EXPLODE BATTERY
\\\W
FOG LAMP
D
HEADLIGHT
LOWER BEAM
A
e
ENGINE OIL
TEMPERATURE
MANIFOLD
VACUUM
TRANSMISSION
OIL TEMPERATURE
HOOD
RELEASE
F-00702
Figure 9—Graphic Symbols
OA-8 GENERAL INFORMATION
METRIC FASTENERS
1.
2.
3.
4.
5.
6.
7.
Grade 2 (GM 200-M)
Grade 5 (GM 280-M)
Grade 7 (GM 290-M)
Grade 8 (GM 300-M)
Manufacturer’s Identification
Nut Strength Identification
Identification Marks (Posidriv Screw Head)
1.
2.
A.
B.
C.
D.
F-00695
Customary B olt— 1/4-20
Metric B olt— M6.0x1
1/4-inch
6 mm
20 Threads Per Inch
1 Thread Per M illim eter
(25.4 Threads Per Inch)
F-00705
Figure 10—Bolt and Nut Identification
Figure 11—Thread Notation
Models are primarily dimensioned in the metric sys­
tem. Many fasteners are metric and are very close in
dimension to well-known customary fasteners in the
inch system. It is most important that replacement fas­
teners be of the correct nominal diameter, thread pitch
and strength.
ISO (International Standards Organization). This was
done to reduce the number of fastener sizes used and
yet retain the best strength qualities in each thread
size. For example, the customary 1/4-20 and 1/4-28
screws are replaced by the metric M6.0X1 screw which
has nearly the same diameter and has 25.4 threads per
inch. The thread pitch is in between the customary
coarse and fine thread pitches.
O rig in a l equ ip m e nt m etric fasteners (except
“ beauty” bolts, such as exposed bumper bolts, and
cross recess head screws) are identified by a number
marking indicating the strength of the material in the
fastener as outlined later. Metric cross recess screws
are identified by a Posidriv or Type 1A shown in figure
10. Either a Phillips head or Type 1A cross recess
screwdriver can be used in Posidriv recess screw
heads, but Type 1A cross recess screwdrivers will per­
form better.
NOTICE: Most metric fasteners have a blue
color coating. However, this should not be
used as positive identification as some fasten­
ers are not color coated.
General Motors Engineering Standards, along with
other North American Industries, have adopted a por­
tion of the standard metric fastener sizes defined by
Metric and customary thread notation differ slightly.
The difference is shown in figure 11.
FASTENER STRENGTH
IDENTIFICATION
Most commonly used metric fastener strength
property classes are 9.8 and 10.9 with the class
identification embossed on the head of each bolt.
Customary (inch) strength classes range from grade 2
to 8 with radial line identification embossed on each
bolt head. Markings correspond to two lines less than
the actual grade (i.e. grade 7 bolt will exhibit 5
embossed radial lines on the bolt head). Some metric
GENERAL INFORMATION OA-9
nuts w ill be marked with single d ig it strength
identification numbers on the nut face. Figure 10
shows the different strength markings.
When replacing metric fasteners, be careful to use
bolts and nuts of the same strength or greater than the
original fasteners (the same number marking or
higher). It is likewise important to select replacement
fasteners of the correct size. Correct replacement bolts
metric fasteners available in the aftermarket parts
channels were designed to m etric standards of
countries other than the United States, and may be of
a lower strength, may not have the numbered head
marking system, and may be of a different thread
pitch. The metric fasteners used on GM products are
designed to new, international standards that may not
yet be manufactured by some non-domestic bolt and
nut s u p p lie rs . In g e n e ra l, e xce p t for sp e c ia l
applicaitons, the common sizes and pitches are:
M6.0 x 1
M 10x1.5
M 8 x 1 .2 5
M 12x1.75
PREVAILING TORQUE FASTENERS
A prevailing torque nut is designed to develop an
interference between the nut and bolt threads. This is
most often accomplished by distortion of the top of an
all-metal nut by using a nylon patch on the threads in
the middle of the hex flat. A nylon insert may also be
used as a method of interference between nut and bolt
threads (figure 12).
A prevailing torque bolt is designed to develop an
interference between bolt and nut threads, or the
threads of a tapped hole. This is accomplished by
distorting some of the threads or by using a nylon
patch or adhesive (figure 12).
RECOMMENDATIONS FOR REUSE:
1. Clean, unrusted prevailing torque nuts and bolis
may be reused as follows:
a. Clean dirt and other foreign material off the
nut or bolt.
b. Inspect the nut or bolt to insure there are no
cracks, elongation, or other signs of abuse
or overtightening. (If there is any doubt,
replace w ith a new p revailing torque
fastener or equal or greater strength).
c. Assemble the parts and hand start the nut
or bolt.
d. Observe that, before fastener seats, it
develops torque per the chart in figure 10 (if
there is any doubt, replace with a new
prevailing torque fastener of equal or
greater strength).
e. Tighten the fastener to the torque specified
in the appropriate section of this manual.
2. Bolts and nuts which are rusty or damaged
should be replaced with new parts or equal or
greater strength.
SIX LOBED SOCKET
HEAD FASTENERS
Six lobed socket head (Torx) fasteners are used in
some applications on vehicles covered in this manual
(figure 13). The door striker bolt is of this design.
Tools designed for these fasteners are available
commercially. However, in some cases, if the correct
tool is not available, a hex socket head wrench may be
used.
0A-10 GENERAL INFORMATION
A
4 ,5
Nm
6 & 6.3
8
10
12
14
16
20
0.4
0.8
1.4
2.2
3.0
4.2
7.0
18
25
35
57
1.6
2.4
3.4
5.6
14
20
28
46
In. Lbs.
4.0
7.0
12
1,2, 3, 6,
Nm
0.4
0.6
1.2
7, 8, 9
In. Lbs.
4.0
5.0
10
B
.250
.312
.375
.437
.500
.562
.625
.750
Nm
0.4
0.6
1.4
1.8
2.4
3.2
4.2
6.2
In. Lbs.
4.0
5.0
12
15
20
27
35
51
1,2, 3, 6,
Nm
0.4
0.6
1.0
1.4
1.8
2.6
3.4
5.2
8, 9
In. Lbs.
4.0
5.0
9.0
12
15
22
28
43
4 ,5
A. Metric Sizes
B. Inch Sizes
1.
2.
3.
4.
5.
Top Lock Type
Center Lock
Dry Adhesive Coating
Out Of Round Thread
Deformed Thread Profile
6.
7.
8.
9.
Nylon
Nylon
Nylon
Nylon
Strip Or Patch
Washer Insert
Patch
Insert
B-02406
Figure 12—Torque Nuts and Bolts Chart
GENERAL INFORMATION OA-11
T - Internal Drive
E - External Drive
B-02221
Figure 13—Six Lobed Socket Head (Torx)
Fasteners
OA-12
CONVERSION TABLE
Inch
Foot
Yard
Mile
Inch2
Conversion Table
Foot’
Yard2
Inch3
Quart 0.946 4
Gallon
Yard3
Pound
Ton
Ton
Kilogram
Ounce
Pound
Degree
Fahrenheit
00
o
cn
co
-si
to get equivalent
number of:
by
LENGTH
25.4
0.304 8
0.9144
1.609
AREA
645.2
6.45
0.092 9
0.836 1
VOLUME
millimeters (mm)
meters (m)
meters
kilometers (km)
millimeters2(mm2)
centimeters2(cm2)
meters2(m2)
meters2
mm1
16.387
16.387
cm3
0.0164
liters (1)
liters
3.785 4
liters
0.764 6
meters3(m3)
MASS
0.453 6
kilograms (kg)
907.18
kilograms (kg)
0.907
tonne (t)
FORCE
9.807
newtons (N)
0.278 0
newtons
4.448
newtons
TEMPERATURE
(t°F-32)
1.8 degree Celsius (C)
Multiply
to get equivalent
by
number of:
ACCELERATION
Foot/sec2
Inch/sec2
0.304 8
meter/sec2(m/s2)
0.025 4
meter/sec2
TORQUE
Pound-inch
Pound-foot
0.112 98
newton-meters (N m)
1.355 8
newton-meters
POWER
Horsepower
Inches of water
Pounds/sq. in.
BTU
Foot-pound
Kilowatt-hour
Foot candle
0.746
kilowatts (kW)
PRESSURE OR STRESS
0.249 1
kilopascals (kPa)
6.895
kilopascals
ENERGY OR WORK
1 055
1.355 8
3 600 000
or 3.6 x 106
LIGHT
joules (J)
joules
joules (J * one W)
1.076 4
lumens/meter2(lm/m2)
FUEL PERFORMANCE
Miles/gal
Gal/mile
0.425 1
kilometers/liter (km/l)
2.352 7
liter/kilometer (l/km)
VELOCITY
Miles/hour
1.609 3
kilometers/hr. (km/h)
GENERAL INFORMATION
Multiply
GENERAL INFORMATION OA-13
DECIMAL AND METRIC EQUIVALENTS
Decimal
Metric
In.
MM.
33/64
.515625
13.09687
.79375
17/32
.53125
13.49375
.046875
1.19062
35/64
.546875
13.89062
1/16
.0625
1.58750
9/16
.5625
14.28750
5/64
.078125
1.98437
37/64
.578125
14.68437
3/32
.09375
2.38125
19/32
.59375
15.08125
7/64
.109375
2.77812
39/64
.609375
15.47812
1/8
.125
3.1750
5/8
.625
15.87500
9/64
.140625
3.57187
41/64
.640625
16.27187
5/32
.15625
3.96875
21/32
.65625
16.66875
11/64
.171875
4.36562
43/64
.671875
17.06562
3/16
.1875
4.76250
11/16
.6875
17.46250
13/64
.203125
5.15937
45/64
.703125
17.85937
7/32
.21875
5.55625
23/32
.71875
18.25625
15/64
.234375
5.95312
47/64
.734375
18.65312
1/4
.250
6.3500
3/4
.750
19.05000
17/64
.265625
6.74687
49/64
.765625
19.44687
19.84375
Decimal
Metric
In.
MM.
1/64
.015625
.39688
1/32
.03125
3/64
Fractions
Fractions
.28125
7.14375
25/32
.78125
19/64
.296875
7.54062
51/64
.796875
20.24062
5/16
.3125
7.93750
13/16
.8125
20.63750
21/64
.328125
8.33437
53/64
.828125
21.03437
11/32
.34375
8.73125
27/32
.84375
21.43125
23/64
.359375
9.12812
55/64
.859375
21.82812
3/8
.375
9.52500
7/8
.875
22.22500
9/32
25/64
.390625
9.92187
57/64
.890625
22.62187
.90625
23.01875
13/32
.40625
10.31875
29/32
27/64
.421875
10.71562
59/64
.921875
23.41562
7/16
.4375
11.11250
15/16
.9375
23.81250
29/64
.453125
11.50937
61/64
.953125
24.20937
15/32
.46875
11.90625
31.32
.96875
24.60625
31/64
.484375
12.30312
63/64
.984375
25.00312
1/2
.500
12.70000
1
1.00
25.40000
B-05496
Decimal and Metric Equivalents
OA-14 GENERAL INFORMATION
RPO LISTING
(REGULAR PRODUCTION OPTION)
The RPO list contains RPOs used on C-K Models, G
Vans, and Forward Control Chassis Models. Refer to
the Service Parts Identification Label for a list of the
RPOs used on each specific vehicle.
AA3 Windows - Deep Tint, Side Windows Only
AC2 Window - Sliding, Right Front Door
AD5 Window - Right Rear, Side, Sliding
AD8 Door Check
AJ1 Window - Deep Tint, Except Windshield and
Doors
AM7 Seat - Right Rear Folding
AP7 Partition - Sliding Plywood
AQ3 Seat - Rear Center
AQ4 Seat - Rear
AS1 Seat - Front Bucket, High Back, Driver
AS2 Seat - Front Bucket, High Back, Passenger
AS3 Seat - Right Rear, Suburban
AT5 Seat - Center Folding, Suburban
AU2 Lock - Cargo Door
AU3 Power Lock - Side Door
AU6 Power Lock - Tailgate Remote Control
AV5 Seat - High Back, Bucket
AW4 Door - Sliding Side Extension
AX5 Partition - Expanded Metal, Left Side
AX6 Partition - Expanded Metal w/Sliding Door
AX7 Partition - Expanded Metal w/Center Sliding Door
AX8 Seat - Front Bucket, Pedestal, Driver
AX9 Latch - Rear Cargo Door
A01 Window - Tinted, All Shaded Windshield
A02 Windshield - Tinted, Shaded Upper
A07 Window - Body
A08 Window - Body, Right Side
A12 Window - Stationary, Back Door
A13 Window - Stationary, Side Rear Door
A17 Window - Left Side Swing-Out
A18 Window - Rear Door, Swing-Out
A19 Glass - Side Rear Door, Swing-Out
A28 Window - Right Rear, Full Width, Sliding
A31 Window - Side, Power
A33 Window - Tailgate, Power
A51 Seat - Front Bucket
A52 Seat - Front Bench
A57 Seat - Auxiliary, One Passenger, Folding
A82 Head Restraints
A95 Seat - Front Bucket, High Back, Reclining
BA8 Compartment - Front Seat Storage
BB5 Ornamentation
BF3 Floor Covering - Step Well Mat
BW2 Ornamentation - Deluxe Body Side Molding
B3D School Bus Equipment
B3J Diesel Equipment
B3M School Bus Equipment - Deluxe
B30 Floor Carpet
B32
B33
B84
B85
B93
B96
CD4
C36
C42
C49
C55
C56
C60
C69
C91
DF1
DF2
DG5
D20
D31
D34
D44
D45
D46
D49
D73
D77
D92
E24
E31
E32
E33
E34
E36
E38
E39
E46
E52
E53
E71
E76
E79
E62
E94
E63
E89
FS3
F51
F58
F59
F60
F66
G50
Floor Mats - Front
Floor Mats - Rear
Extra Molding - Body Side
Extra Molding - Belt Reveal
Extra Molding - Door Edge Guard
Extra Molding - Wheel Opening
Wiper System - Pulse
Heater - Auxiliary
Heater - Deluxe Outside Air
Defogger - Rear Window, Electric
Vent - Roof
Vent - Forced Air, Right Side
Air Conditioning - Front Manual Controls
Air Conditioner - Roof Mounted
Lamp - Interior Courtesy
Mirror - Camper Type, Painted
Mirror - Camper Type, SST
Mirror - West Coast Type
Sunshade - Windshield, Passenger Side
Mirror - Tilt
Mirror - Visor Vanity
Mirror - Outside, Painted
Mirror - Outside, SST
Mirror - West Coast Type with Clearance Lights
Mirror - Chrome
Pickup Box Hand Rail
Mirror - Dual, Wide Angle, SST
Stripe - Lower Decor
Door - Cargo Side, Hinged
Body - Steel ,10 ft.
Body - Forward Control, Var. 3
Body - Forward Control, Var. 4
Body - Steel, 10 ft. Standard Width
Body - Aluminum, 10 ft.
Body - Steel, 12 ft. x 8 ft.
Body - Aluminum, 12 ft. x 8 ft.
Door - 66 in., Overhead Sliding w/Window
Door - 83 in., Wrap-Around
Door - 87 in., Wrap-Around
Cargo Floor - Steel
Door - 60 in., Rear
Door - 74 in., Rear, Strap Hinges
Pickup Box - Stepside (Fenderside)
Rally (Beauville) Equipment
Pickup Box - Fleetside (Wideside)
Panel - Driver Door w/Window
Axle - Front I-Beam
Shock Absorbers - Front and Rear, Heavy Duty
Stabilizer Shaft - Front, Heavy Duty
Stabilizer Shaft - Front
Spring - Front, Heavy Duty
Suspension System - Front
Spring - Rear, Heavy Duty
GENERAL INFORMATION OA-15
G51
G52
G60
G80
KC4
KL7
K05
K09
K22
K34
K46
K81
LB1
LE8
LE9
LF3
LH6
LL4
LS9
LT9
L25
MV4
MY6
NAS
NA6
NE2
NK7
NL2
NL7
NM5
NN4
NY1
N05
N31
N33
N40
N41
N51
N67
N90
PA1
PA6
P01
P10
P11
P13
P14
P15
P17
R05
TP2
TR9
TT4
TT5
TVR
T63
T84
T85
Spring - Rear, Special Heavy
Spring - Rear 15000 lbs.
Spring - Rear Auxiliary
Axle - Rear, Limited Slip
Engine Oil Cooler System
Gas Conversion - LP
Engine Block Heater
Generator - 120 Amp
Generator - 94 Amp
Cruise Control
Air Cleaner - Heavy Duty, Pre-Cleaner
Generator - 66 Amp
Engine - 4.3L V6 4BBL
Engine -4.7L V8 4BBL
Engine - 5.0L V8 4BBL, Hi Compression
Engine - 5.0 V8 4BBL, Regular Compression
Engine - 6.2L V8, Diesel
Engine - 6.2L V8, Heavy Duty Diesel
Engine - 5.7L V8 4BBL
Engine - 5.7L V8 4BBL, Heavy Duty
Engine - 4.8L V6 1BBL
Transmission - Auto. 3-Speed Clutch Converter
Transmission - Manual 4-Speed w/Overdrive
Emission System - Federal Requirements
Emission System - High Altitude Requirements
Fuel Tank - 40 gal.
Fuel Tank - 31 gal.
Fuel Tank - Auxiliary
Fuel Tank - 33 gal.
Emission system - Canadian Requirement
Fuel Tank - 60 gal.
Fuei Tank Shield
Fuel Filler Cap Lock
Steering Wheel - Custom
Steering Column - Tilt
Steering - Non-Variable
Steering - Power
Steering - Manual
Wheel - Rally Type
Wheel - Aluminum Cast
Wheel - Trim Discs, Var. 5
Wheel - Styled, Painted
Wheel - Trim Discs, Var. 1
Carrier - Spare Tire
Carrier - Spare Tire, Glide Out
Carrier - Spare Tire, Side-Mounted
Carrier - Inside Mounted Spare Tire, Left Side
Carrier - Inside Mounted Spare Tire, Right Side
Cover - Spare Wheel/Tire
Wheel Conversion - Dual Rear
Battery - Auxiliary Camper
Lamp Group
Headlamps - Halogen, Pencil Beam
Headlamps - Halogen
Lamp - Rear Dome and Reading
Headlamps - Warning System
Headlamps - Right Rule
Headlamps - Left Rule
UA1
UB4
UD4
UF2
UJ1
UM6
Battery - High Capacity
Lamps - Rear Side Marker
Alarm - Vehicle Speed
Lamp - Cargo
Indicator System, Brake Warning
Radio - AM/FM Stereo, Seek/Scan, Cassette,
Clock
UN3 Radio - AM/FM Stereo, Cassette
UY7 Wiring Harness - Truck Trailer, Heavy Duty
U01 Lamp - Roof Marker
U18 Speedometer - Kilometer
U35 Electric Clock
U37 Cigarette Lighter
U58 Radio - AM/FM Stereo
U63 Radio - AM
U66 Speaker System - Dual Front, Dual Rear
U69 Radio - AM/FM
U76 Antenna - Windshield
VE5 Bumper - Front and Rear Impact Strip
VF1 Bumper - Rear Chrome
VR2 Trailer Hitch
VR4 Trailer Hitch - Weight Distributing
V01 Radiator - Heavy Duty
V02 Radiator - Heavy Duty w/Trans. Oil Cooler
V05 Increased Cooling
V22 Radiator Grille - Chrome
V31 Bumper Guards - Front, Chrome
V35 Bumper, Rear w/Recessed Lighting
V37 Bumper - Front and Rear Chrome
V42 Bumper - Rear Step, Chrome
V43 Bumper - Rear Step, Painted
V46 Bumper - Front, Chrome
V76 Front Hook Towing Device
X6W Hub - Locking
YE9 Equipment Package, Level 3
YG1 Molding, Body Side and Wheel Opening
YJ6 Decor Package - Econo
ZM2 Trim Package, Bonaventure
ZW9 Base Body or Chassis
ZY1 Color Combination - Solid
ZY2 Color Combination - Two Tone
ZY4 Color Combination - Deluxe Two Tone
Z53 Guage Package - Voltmeter, Oil Press, and Temp.
Z62 Equipment Package - Level 1
Z72 Trailering Package - L.D. Ball-Type Hitch
Z73 Trim - Special Interior
Z75 Shock Absorbers - Four Front
Z76 Special Chassis - Camper Package
Z80 Trim - Special Exterior
Z81 Camper - Special
Z82 Trailer Hitch - Special Reese Type
12A Stripe Accent - White
12K Color Combination - White (Auxiliary Top)
12L Secondary Color - White
12U Primary Color - White
18C Trim Combination - Charcoal, Stnd. Cloth
18D Trim Combination - Charcoal, Velour Cloth
181 Interior Trim - Charcoal
OA-16 GENERAL INFORMATION
18V
18W
19A
191
19K
19L
19U
19W
21L
21U
23D
23G
23I
23V
23W
28L
28U
29A
29K
29L
29U
55L
55U
61K
61L
61U
62C
62D
62G
62I
62V
62W
66K
66L
66U
67L
67U
72A
72L
72U
76C
76D
76G
76I
76V
76W
77C
77D
77G
77I
77V
77W
78U
82D
82G
82I
82W
Trim Combination - Charcoal, Vinyl Striped
Trim Combination - Charcoal, Dual Grain Vinyl
Stripe Accent - Black and Grey Two Tone
Interior Trim - Black
Color Combination - Black (Auxiliary Top)
Secondary Color - Black
Primary Color - Black
Trim Combination - Black, Dual Grain Vinyl
Secondary Color - Lt. Blue Metallic
Primary Color - Lt. Blue Metallic
Trim Combination - Blue, Velour Cloth
Trim Combination - Blue Cloth
Interior Trim - Blue Vinyl
Trim Combination - Blue Vinyl, Striped
Trim Combination - Blue Dual Grain Vinyl
Secondary Color - Dk. Blue Metallic
Primary Color - Dk. Blue Metallic
Stripe Accent - Dk. and Lt. Blue
Color Combination - Dk. Blue (Auxiliary Top)
Secondary Color - Dk. Blue
Primary Color - Dk. Blue
Second Color - Russet Metallic
Primary Color - Russet Metallic
Color Combination - Tan (Auxiliary Top)
Secondary Color - Tan
Primary Color - Tan
Trim Combination - Lt. Saddle, Stnd. Cloth
Trim Combination - Lt. Saddle, Velour Cloth
Trim Combination - Saddle Cloth
Interior Trim - Lt. Saddle
Trim Combination - Lt. Saddle Vinyl, Striped
Trim Combination - Lt. Saddle, Dual Grain Vinyl
Color Combination - Dk. Brown
Secondary Color - Dk. Brown Metallic
Primary Color - Dk. Brown Metallic
Secondary Color - Lt. Saddle Metallic
Primary Color - Lt. Saddle Metallic
Stripe Accent - Bright Red
Secondary Color - Bright Red
Primary Color - Bright Red
Trim Combination - Bronze, Stnd. Cloth
Trim Combination - Bronze, Velour Cloth
Trim Combination - Dk. Claret and Gold, Garnet
Red
Interior Trim - Bronze
Trim Combination - Bronze, Striped Vinyl
Trim Combination - Bronze, Dual Grain Vinyl
Trim Combination - Dk. Maple, Stnd. Cloth
Trim Combination - Dk. Maple, Velour Cloth
Trim Combination - Dk. Maple Cloth
Interior Trim - Dk. Maple
Trim Combination - Dk. Maple, Striped Vinyl
Trim Combination - Dk. Maple, Dual Grain Vinyl
Primary Color - Med. Rosewood Metallic
Trim Combination - Med. Dk. Grey Velour Cloth
Trim Combination - Med. Dk. Grey Cloth
Interior Trim - Med. Dk. Grey
Trim Combination - Dk. Grey, Dual Grain Vinyl
90K
90L
90U
93U
9V8
Color Combination - Med. Grey (Auxiliary Top)
Secondary Color - Grey Metallic
Primary Color - Grey Metallic
Primary Color - Lt. Driftwood Pearlmist
Color Combination - Cardinal Red
___________________________________________________________________ OB-1
SECTION OB
MAINTENANCE AND LUBRICATION
CONTENTS
SUBJECT
PAGE
C a p a citie s.................................................................................................................................................................... OB- 1
L u b ric a tio n .................................................................................................................................................................. OB- 6
Maintenance Schedule and L o g ..............................................................................................................................OB- 7
CAPACITIES
Figures 2 through 6 show the approximate capacities of the dif­
ferential gear, the transmission, the cooling system, the crankcase,
the fuel tank, the front axle and the transfer case. Engine code letters
are used in the charts. Refer to figure 1 for an explanation of the code.
VIN
E N G IN E D ESCRIPlD ON
Liter
Displacement
Type
N
4.3
V6
F
H
5.0
5.0
5.7
V8
V8
Engine Code
Fuel
System
in GM Plant
Operated By:
4 BBL
4 BBL
Chevrolet Motor
V8
4 BBL
4 BBL
M
W
5.7
V8
4 BBL
7.4
T
4.8
V8
L6
4 BBL
1 BBL
C
6.2
F.l. @
J
6.2
V8
V8
L
Produced
F.l. @
Chevrolet Motor
Chevrolet Motor*
Chevrolet Motor
Chevrolet Motor
Chevrolet Motor
t
Det. Diesel Allison
Det. Diesel Allison
* or General Motors of Canada
t Produced in Mexico by General Motors de Mexico
@ Diesel
Figure 1-1986 Engine Code Identification
Metric
Measure
U .S .
Measure
Differential
8 V2" Ring Gear
2.0 L
9 1/2" Ring Gear
3.1 L
4.2 pts.
6.5 pts.
IOV2" Ring Gear (Chev.)
3.1 L
6 V2 pts.
93/4" Ring Gear (Dana)
2.8 L
6.0 pts.
12 Ring Gear (Rockwell)
5.9 L
12.5 pts.
3.3 L
9.5 L
20.0 pts.
4.0 L
10.0 L
9.0 pts.
22.0 pts.
Items
Transmission
Automatic
350C
—
Pan Removal
Overhaul
400
—
Pan Removal
Overhaul
700-R4
—
6.3 pts.
Pan Removal
4.7 L
10.0 pts.
Overhaul
10.9 L
23.0 pts.
4 Speed 117 mm
4.0 L
4.2 qts.
4 Speed 89 mm
4.0 L
4.2 qts.
3 Speed 76 mm
1.5 L
1.6 qts.
Manual
Figure 2—Approximate Capacities - All Models
OB-2 MAINTENANCE AND LUBRICATION
Items
Cooling System (Approx.)▲
Code: H, L, M
Without A/C
With A/C
Code: W
Without A/C
With A/C
Diesel Engines
Code: C, J
With or Without A/C
Crankcase*
Gasoline Engines
Code: H, L and M
Without Filter
With Filter
Code: W +
Without Filter
With Filter
Diesel Enginest
Code: C, J With Filter
Fuel Tank
Standard, All — Gas
— Diesel
NK7 Option, All — Gas
— Diesel
NE2 Option, Suburban Only
— Gas
— Diesel
Metric
Measure
U.S.
Measure
16.5 Liters
17 Liters
17.5 Quarts
18 Quarts
22 Liters
23 Liters
23 Quarts
24.5 Quarts
23 Liters
25 Quarts
3.8 Liters
4.8 Liters
4 Quarts
5 Quarts
5.7 Liters
6.5 Liters
6 Quarts
7 Quarts
6.5 Liters
7 Quarts
95 Liters
102 Liters
117 Liters
121 Liters
25
27
31
32
151 Liters
155 Liters
40 Gallons
41 Gallons
Front Axle
K15/10-K25/20
K35/30
1.9 Liters
2.8 Liters
2 Quarts
3 Quarts
Transfer Case
4.8 Liters
5.0 Quarts
Gallons
Gallons
Gallons
Gallons
• After refill, fluid level must be checked as outlined under “ Service
and Maintenance” in Section 5 of the owner’s manual.
+ K35/30 Models — 5 U.S. quarts (4.8 Liters) Without Filter.
6 U.S. Quarts (5.7 Liters) With Filter,
t Oil filter should be changed at EVERY oil change.
A Equipped with Auxiliary Heater add 2.68L/2.84 Qts.
Figure 3—Approxim ate Capacities - Blazer, Suburban
MAINTENANCE AND LUBRICATION OB-3
Items
Cooling System (approx.)
4.8L (L6) Engine Code (T)
P30042 Models
With or Without A/C
5.7L (V8) Engine Code (M)
P30042 Models
With or Without A/C
7.4 L (V8) Engine Code (W)
P30032 Models
Without A/C
6.2L (V8) Diesel Engine Code (J)
P30042 Models
With or Without A/C
P30032 Models
Without A/C
Crankcase (approx.)*
Engine Code: M
Without Filter
With Filter
Engine Code: T
Without Filter
With Filter
Engine Code: W
Without Filter
With Filter
Engine Code: J (Diesel)t
With Filter
Fuel Tank Data
P25-35
P30042 (School Bus)
P30032 (Motor Home)*
U.S.
Metric
Measure
Measure
13.1 Liters
13.8 Quarts
14.6 Liters
15.5 Quarts
21.2 Liters
22.5 Quarts
23.5 Liters
25 Quarts
23.4 Liters
24.7 Quarts
3.8 Liters
4.8 Liters
4 Quarts
5 Quarts
4.8 Liters
5.7 Liters
5 Quarts
6 Quarts
5.7 Liters
6.5 Liters
6 Quarts
7 Quarts
6.5 Liters
7 Quarts
114 Liters
114 Liters
114 Liters
30 Gallons
30 Gallons
30 Gallons
* After refill, fluid level should be checked as outlined under “ Service and
Maintenance” Section 5 of the owner’s manual.
t Oil Filter should be changed at EVERY oil change.
• Optional 60 gallon fuel tank available.
Figure 4—Approximate Capacities - Forward Control
OB-4 MAINTENANCE AND LUBRICATION
ITEMS
Cooling System (Approx.)
Code N-V6
W ith or W ithout A/C
Code T-L-6
W ithout A/C
With A/C
Code F, H, L & M — V-8
W ithout A/C
W ith A/C
Code W — V-8
W ithout A/C
W ith A/C
Diesel
W ith or W ithout A/C
C rankcaseA
G asoline Engines
Codes: N, F, H, L, M
W ithout Filter
With Filter
Code: T
W ithout Filter
With Filter
Code: W +
W ithout Filter
With Filter
Diesel Engines Code C, J t
Fuel Tank (Approx.)
Short Bed —
Single Tank, Gas, Diesel
‘ Dual Tanks, Gas, Diesel
Long Bed —
Single Tank, Gas
@ *D ual Tanks, Gas
Single Tank, Diesel
‘ Dual Tanks, Diesel
Metric
Measure
U.S.
Measure
10.3 Liters
10.9 Quarts
14.7 Liters
15.1 Liters
15.5 Quarts
16 Quarts
16.6 Liters
17 Liters
17.5 Quarts
18 Quarts
22 Liters
23 Liters
23 Quarts
24.5 Quarts
23 Liters
25 Quarts
3.8 Liters
4.8 Liters
4 Quarts
5 Quarts
4.8 Liters
5.7 Liters
5 Quarts
6 Quarts
5.7 Liters
6.5 Liters
6.5 Liters
6 Quarts
7 Quarts
7 Quarts
61 Liters
61 Liters
16 Gallons
16 Gallons
76
61
76
76
20
16
20
20
Liters
Liters
Liters
Liters
Gallons
Gallons
Gallons
Gallons
Front Axle
K15/10-K25/20
K35/30
1.9 Liters
2.8 Liters
2 Quarts
3 Quarts
Transfer Case
K15/10-K25/20
K35/30
4.8 Liters
2.4 Liters
5 Quarts
2.5 Quarts
A A fte r refill, fluid level must be checked as outlined under “ Service and M aintenance”
in Section 5 of the ow ner’s manual.
+ K30/35 M odels — 5 U.S. Q uarts (4.8 Liters) W ithout Filter.
6 U.S. Q uarts (5.7 Liters) W ith Filter,
t Oil Filter should be changed ai EVERY oil change.
* Listed quantity is for each tank.
@ Above 8600 GVWR — Both tanks 20 gallons (76 Liters)
Figure 5—Approxim ate Capacities - Pickup Models
MAINTENANCE AND LUBRICATION OB-5
ITEMS
Cooling System (Approx.)▲
4.3 L (N) V6 All
V8’s Except Diesel
Without A/C
With A/C
6.2 L (C) Diesel
With Automatic or
Manual Transmission
With or w/0 A/C
6.2 L (J) Diesel
With Automatic or
Manual Transmission
With or w/o A/C
Crankcase (Approx.)*
All Engines Except Diesel
Without Filter
With Filter
Diesel Engines
With Filtert
Fuel Tank (Approx.)
Gasoline and Diesel Engines
Standard
Optional
METRIC
MEASURE
U.S.
MEASURE
10.5 Liters
11.1 Quarts
16 Liters
16 Liters
17 Quarts
17 Quarts
23 Liters
24 Quarts
24.2 Liters
25.6 Quarts
3.8 Liters
4.8 Liters
4 Quarts
5 Quarts
6.5 Liters
7 Quarts
83 Liters
125 Liters
22 Gallons
33 Gallons
* After refill, fluid level should be checked as outlined under “ Service
and Maintenance” Section 5 of the owner’s manual.
A If equipped with Auxiliary Heater add 2.68L/2.84 Qts.
t Oil Filter should be changed at EVERY oil change.
Figure 6—Approxim ate Capacities - G Van
OB-6 MAINTENANCE AND LUBRICATION
LUBRICATION
Figures 7, 8 and 9 show chassis lubrication points for the C, K, G and P chassis.
1.
2.
3.
4.
5.
6.
7.
8.
9. Master Cylinder
10. Transmission - Manual
- Automatic
11. Throttle Bell Crank - L6
12. Carburetor Linkage - V8
13. Brake and Clutch Pedal Springs
14. Universal Joints
15. Rear Axle
Lower Control Arms
Upper Control Arms
Upper and Lower Control Arm Ball Joints
Intermediate Steering Shaft (PA10)
Tie Rod Ends
Wheel Bearings
Steering Gear
Air Cleaner - Element
F-00433
Figure 7—Lubrication Points For The Conventional
And Forward Control Models
3
8
1.
2.
3.
4.
5.
6.
7.
1
4
5 12 3
Air Cleaner
Control Linkage Points
Tie Rod Ends
Wheel Bearings
Steering Gear
Master Cylinder
Transmission - Manual
- Automatic
11
4
8.
9.
10.
11.
12.
13.
14.
15.
15
1
9
6
10
13
9
11
2
Carburetor Linkage - V8
Universal Joints
Propeller Shaft Slip Joints
Front and Rear Axle
Drag Link
Brake and Clutch Pedal Springs
Transfer Case
Throttle Bell Crank - L6
F-00434
Figure 8—Lubrication Points For The CK Four Wheel Drive Models
MAINTENANCE AND LUBRICATION OB-7
1. Control Arm Bushings and Ball Joints
5. Transmission
2. Tie Rod Ends
6. A ir Cleaner 3. Wheel Bearings
7. Transmission
4. Steering Gear and Clutch Cross-Shaft
Control Shaft
Element
- Manual
- Automatic
8.
9.
10.
11.
Rear Axle
Oil Filter
Brake Master Cylinder
Parking Brake Linkage
F-00435
Figure 9—Lubrication Points For The G Van
MAINTENANCE SCHEDULE AND LOG
The information shown on pages OB-7 through OB-18 is the same as shown in the 1986 Light Duty Mainte­
nance Schedule and Log.
1986 GENERAL MOTORS
LIGHT DUTY TRUCK
MAINTENANCE SCHEDULES
This booklet covers the maintenance required for your General Motors
vehicle. It is essential that your vehicle receive this maintenance to
retain the safety, dependability, and emission control performance
originally built into your vehicle.
Maintenance service should be done by your General Motors
tru ck dealer or any other qualified autom otive service or repair
establishm ent which is able to provide such services and which
can be relied upon to use proper parts and practices.
In addition to the in-shop type services shown in Sections A and B,
this booklet also includes owner inspections and services in Section
C which you or a qualified technician should perform periodically.
Always keep this booklet in your vehicle, and leave it w ith the
vehicle when sold. The maintenance record, plus maintenance
receipts, may be needed fo r warranty repairs. It is suggested that
receipts be kept w ith this booklet.
OB-8 MAINTENANCE AND LUBRICATION
SELECTING YOUR VEHICLES
MAINTENANCE
DETERMINING GVWR AND EMISSIONS
CLASSIFICATION
To determine the emissions classification for gasoline engine
equipped vehicles, refer to the certification label located on the edge
of the driver’s door. If the Gross Vehicle Weight Rating (GVWR) in the
u p p e r le ft c o rn e r of the c e rtific a tio n la b e l is less tha n
8600 lbs./3 900 kg, your vehicle is equipped with “ Light Duty Emis­
sions” ; if 8600 lbs./3 900 kg or more, your vehicle is equipped with
“ Heavy Duty Emissions” .
SELECTING THE PROPER
MAINTENANCE CHART
Select the proper maintenance from pages 4 through 11 depending
on your vehicle’s engine (gas or diesel) and engine emissions classifi­
cation.
SELECTING THE PROPER
MAINTENANCE SCHEDULE
Select and follow either Maintenance Schedule 1 or Maintenance
Schedule 2 based on how you use your vehicle.
MAINTENANCE SCHEDULE 1
Follow Maintenance Schedule 1 denoted by a white o if you mainly
operate your vehicle under one or more of the following conditions:
• When most trips are less than 4 miles (6 kilometers).
• When most trips are less than 10 miles (16 kilometers) and out­
side temperatures remain below freezing.
• Idling for extended periods and/or low-speed operations such as
found in delivery, police, rental or taxi operation.
• Towing a trailer.
• Operating in dusty areas.
MAINTENANCE SCHEDULE 2
Follow Maintenance Schedule 2 denoted by a black • only if none
of the driving conditions specified in Maintenance Schedule 1 apply.
SECTION A -SCH ED U LED MAINTENANCE SERVICES FOR YOUR
1986 VEHICLE WITH LIGHT DUTY EMISSIONS - UNDER 8600 GVWR
The corvlroc chnuun in this cchgriylg un In fin nnn mjjoc (inn OOfl kmt
o Maintenance Schedule 1
are to be performed after 60,000 miles (100 000 km) at the same intervals.
Item
No. Service
7.5
•
Maintenance Schedule 2
Miles (000)
3
6
9
12
15 18 21 22.5 24 27
30
Kilometers (000)
5
10 12.5 15
20
25 30 35 37.5 40 45
50
33 36 37.5 39 42 45 48 51 52.5 54 57 60
55 60 62.5 65 70 75 80 85 87.5 90 95 100
OB-9
NOTE: To determine the engine code, refer to the “ Specifications” section of your
Owner’s Manual.
4
MAINTENANCE AND LUBRICATION
1 Engine Oil Change *
o o • o o om o o • o o o » o o • o o om o o • o o o •
o o • o o o o o • o o o o o • o o 0 o o • o o o
Oil Filter Change *
o o • o o om o o • o o o # o o • o o om o o • o o o«
2 Chassis Lubrication *
o2 •
o1
3 Engine Idle Speed Adjustment * 1 - At 6 Months or
4 Cooling System Service * — Every 24 Months or
om
om
5 Air Cleaner Element and PCV Filter Replacement *
o m2
om
o
6 Front Wheel Bearing Repack
om
o
om
7 Transmission Service - See Explanation for
Service Intervals in Section B
8 PCV System Inspection *
om
om
9 Fuel Filter Replacement *
o1
o#1
o1
om
10 Carburetor Choke and Hoses Inspection * 1
o •
o#2
o
m
- At 6 Months or
11 Carburetor or Throttle Body Mounting Bolt
o2 • 2
o1
• '
Torque Check * - At 6 Months or
12 Vacuum Advance System Inspection *
o •
o*
om
•
- At 6 Months or
13 Spark Plugs *
o#2
o*
14 Wire Service *
o#
om
15 EGR System Check *
o#
om
16 Engine Timing Check *
o#
om
17 Fuel Tank, Cap and Lines Inspection *
o1
om
o1
om
18 Early Fuel Evaporation System Inspection * 1
o •
om
om
19 Thermostatically Controlled Air Cleaner Inspection *
om
om
20 Engine Accessory Drive Belts Inspection *
o
om2
o
om
21 Evaporative Control System Inspection * 1
om
om
FOOTNOTES:
1. All engines EXCEPT 2.5 L (VIN Engine Code E), 2.8 L (VIN Engine Code R),
The maintenance services contained in Maintenance Schedule 1 and 2 are based on
4.3 L (VIN Engine Code Z)
the assumption that your vehicle will be used as designed:
2. In California, these are the minimum Emission Control Maintenance Services an owner • To carry passengers and cargo within the limits shown on the tire placard located
must perform according to the California Air Resources Board. General Motors, how­
on the edge of the driver’s door.
ever, urges that all Emission Control Maintenance Services shown be performed. To • On reasonable road surfaces within legal driving limits.
maintain your other new vehicle warranties, all services shown in this booklet should • On unleaded gasoline.
be performed.
An Emission Control Service
o
The services shown in this schedule up to 60,000 miles (100 000 km)
are to be performed after 60,000 miles (100 000 km) at the same intervals.
3
Miles (000)
Item
10
9
12
15
20
o o# o
15
18
Maintenance Schedule 1
Maintenance Schedule 2
21
24
25
30
35
40
27
45
30
50
36
39
42
45
48
51
54
57
60
55
60
65
70
75
80
85
90
95
100
o *
33
09
o
09
o
o#
o
o#
o
0#
o
o#
o
o#
o
o#
o
O il F ilter C h a n g e *
o
o#
o
O
o
09
o
o
o
o#
o
0
o
o *
o
o
o
o •
o
2 C ha ssis L u b rica tio n
o
09
o
09
o
O•
o
o •
o
o#
o
09
o
o *
o
o *
o
09
o
1 E n g in e O il C h a n g e
3 E n g in e Idle S peed A d ju stm e n t *
— A t 6 M on th s or
09
O
4 C o o lin g System S e rv ic e * — Every 24 M on th s or
5 A ir Cleaner, A .I.R . and PCV F ilter
R e p la ce m e n t * A
o#
09
09
09
9
9
09
6 Front W heel B e a rin g R epack
O
O
o«
o
O9
7 Transm ission S e rvice - See E xp la n a tio n for
S e rvice Intervals in S ection B
09
09
8 PC V System In sp ectio n *
o
9 Fuel F ilter R e p la ce m e n t
10 C a rbu re to r C hoke and H oses
In sp ectio n * — A t 6 M on th s or
09
11 C a rbu re to r or T hro ttle B ody M ou n tin g Bolt
Torque C h e ck * — At 6 M on th s or
09
12 Vacuum A d va n ce System In sp ectio n
— A t 6 M on th s or
09
O
O9
o
O9
09
09
O
09
o
09
O*
09
o*
09
14 W ire S e rvice
15 EGR System C h e ck
o
09
09
o*
13 S p a rk P lu g s *
09
*
16 E n gine T im in g C h e ck
* ▲
17 Fuel Tank, C ap and L ines Insp ectio n
*
o
o
:~t
o«
■
o#
■
24 T h e rm o sta tica lly C o n tro lle d E n g in e C o o lin g
Fan C h e ck A " — Every 12 M onths or
*
FOOTNOTES:
* An Emission Control Service
▲ Also a Noise Emission Control Service
■ Applicable only to vehicles sold in the United States
6
09
09
09
o
09
09
O
09
0»
09
09
09
09
09
09
21 E vaporative C o n tro l S ystem Inspection
22 S h ie ld s and U n d e rh o o d In su la tion In sp ectio n A
25 M an ifo ld H eat Valve C h e ck A
09
09
20 E n g in e A cce sso ry D rive B elts In sp ectio n
— Every 12 M on th s or
23 A ir Intake System Insp ectio n A
09
09
18 E arly Fuel E vaporation S ystem In sp ectio n
19 T h e rm o sta tica lly C o n tro lle d A ir C le a n e r
Insp ectio n * ▲
09
09
09
09
o#
09
09
09
09
o*
09
09
09
09
The maintenance services contained in Maintenance Schedule 1 and 2 are based
on the assumption that your vehicle will be used as designed:
• To carry passengers and cargo within the limits shown on the tire placard lo­
cated on the edge of the driver’s door.
• On reasonable road surfaces within legal driving limits. • On leaded gasoline.
MAINTENANCE AND LUBRICATION
5
Kilometers (000)
No. Service
6
•
0B-10
SECTION A-SCHEDULED MAINTENANCE SERVICES FOR YOUR 1986 VEHICLE WITH HEAVY DUTY EMISSIONS - OVER 8600 GVWR (EXCEPT CALIFORNIA)
SECTION A -S C H E D U L E D MAINTENANCE SERVICES FOR YOUR 1986 VEHICLE WITH HEAVY DUTY EMISSIONS - OVER 8600 GVWR (CALIFORNIA ONLY)
The services shown in this schedule up to 60,000 miles (100 000 km)
are io se performed after 60,000 miles (100 000 km) ai the same intervals.
Item
No. Service
o Maintenance Schedule 1
m maintenance Schedule 2
Miles (000)
3
6
9
12
15
18
21
Kilometers (000)
5
10
15
20
25
30
o
o*
O
o»
o*
35 40
O om
o*
o
o
o
o#
O
1 Engine Oil Change *
Oil Filter Change *
24
o
27
30
33
36
39
42
48
51
54
57
45 50
o o*
55 60
o O*
65 70
O 0*
75 80
o 0#
85
90
O
o#
95 100
o om
o
o
o
o
o
om
o
om
om
o#
o
0*
45
60
2 Chassis Lubrication - Every 4 Months or
om
09
3 Engine Idle Speed Adjustment * - At First 4 Months or,
Then Every 12 Months or
o*
om
om
4 Cooling System Service *
om
om
om
om
o•
5 Air Cleaner Element Replacement ▲ *
om
om
om
om
om
6 Front Wheel Bearing Repack
om
om
om
om
om
om
om
o*
om
om
0*
o*
o#
om
7 Transmission Service - See Explanation for
Service Intervals in Section B
8 PCV System Inspection * - Every 12 Months or
om
om
om
om
om
9 Fuel Filter Replacement * - Every 12 Months or
om
om
om
om
om
10 Carburetor Choke and Hoses Inspection *
- Every 24 Months or
om
11 Carburetor or Throttle Body Mounting Bolt
Torque Check * — Every 12 Months or
om
13 Spark Plugs *
om
14 Wire Service *
om
om
om
om
om
om
om
om
om
om
om
om
om
om
o
12 Vacuum Advance System Inspection * - Every 24 Months or
om
15 EGR System Check * - Every 36 Months or
om
16 Engine Timing Check and Distributor Check * ▲
om
om
17 Fuel Tank, Cap and Lines Inspection * - Every 24 Months or
om
om
18 Early Fuel Evaporation System Inspection *
- Every 24 Months or
om
om
19 Thermostatically Controlled Air Cleaner Inspection * ▲
- Every 12 Months or
om
om
om
20 Engine Accessory Drive Belts Inspection *
om
om
om
om
21 Evaporative Control System Inspection * - Every 24 Months or
om
om
om
om
om
22 Shields and Underhood Insulation Inspection ▲ ■
om
om
om
om
om
23 Air Intake System Inspection A
om
om
om
om
om
24 Thermostatically Controlled Engine Cooling Fan Check
- Every 12 Months or
om
cm
om
om
om
25 Manifold Heat Valve Check ▲ * — Every 12 Months or
om
om
om
om
om
om
om
om
om
om
om
om
om
om
om
26 Idle Stop Solenoid Check * - At First 4 Months or
Then Every 12 Months or
27 Throttle Return Control Check * — Every 12 Months or
28 Engine Idle Mixture Adjustment (4.8 L only) *
— Every 24 Months or
29 Governor Check ▲ ■ - Every 48 Months or
8
om
om
om
The maintenance services contained in Maintenance Schedule 1 and 2 are based on the assumption that your
vehicle will be used as designed:
• To carry passengers and cargo within the lim its shown on the tire placard located on the edge ot the driver s
door
« On reasonable road surfaces within legal driving lim its .* On leaded gasoline___________________________
OB-11
FOOTNOTES:
* An Emission Control Service
▲ Also a Noise Emission Control Service
■ Applicable only to vehicles sold in the United States
om
MAINTENANCE AND LUBRICATION
om
om
Item
The services shown in this schedule up to 47,500 miles (76 000 km)
are to be performed after 47,500 miles (76 000 km) at the same intervals.
Miles (000) 2.5 5 7.5 10 12.5
No. Service
Kilometers (000)
1 Enqine Oil Change *
2
3
4
5
6
7
8
22
23
24
30
1986 VEHICLE WITH A 6.2 L DIESEL ENGINE
Oil Filter Change *
Chassis Lubrication *
Engine Idle Speed Adjustment *
Cooling System Service * — Every 24 Months or
Air Cleaner Element Replacement* 2
Front Wheel Bearing Repack
Transmission Service - See Explanation for
Service Intervals in Section B
PCV System Inspection * — Every 12 Months or
Shields and Underhood Insulation Inspection A ■
Air Intake System Inspection A ■
Thermostatically Controlled Engine
Cooling Fan Check A " —Every 12 Months or
Exhaust Pressure Regulator Valve Inspection *
4
8
12
16
20
o o « o 09 o
o 0# o o# o
o 0# o o« o
o#1
o Maintenance Schedule 1
• Maintenance Schedule 2
15 18 20 22.5 25 27.5 30 32.5 35 37.5 40 42.5 45 47.5
24 28 32 36 40 44 48 52 56 60 64 68 72 76
o•
o#
09
o o*
o o*
o o«
o 0#
o 0#
o 09
o
o
o
o
o
09
o
o
09
09
09
o
o
G9
09
o
09
o
09
o
09
09
09
09
G
O
O
O #1
0 9
0 9 1
09
O
09
O
O#
09
0 9
0 9
o*
09
09
09
09
09
09
09
09
09
09
o#
09
09
FOOTNOTES:
The maintenance services contained in Maintenance Schedule 1 and
1. In California, these are the minimum Emission Control Maintenance Services an owner 2 are based on the assumption that your vehicle will be used as
must perform according to the California Air Resources Board. General Motors, how­ designed:
ever, urges that all Emission Control Maintenance Services shown be performed. To • To carry passengers and cargo within the limits shown on the
maintain your other new vehicle warranties, all services shown in this booklet should
tire placard located on the edge of the driver’s door.
be performed.
• On No. 1, blend or No. 2 grade diesel fuel.
2. For engines with Engine Family GGM06.2DABX, replace element every 15,000 miles • On reasonable road surfaces within legal driving limits.
(24 000 km).
* An Emission Control Service
A Also a Noise Emission Control Service (applicable only to vehicles with Engine Family
GGM06.2DABX).
■ Applicable only to trucks sold in the United States
NOTE: To determine engine family refer to the Vehicle Emission Control Information label
located in the engine compartment.
10
11
OB-12 MAINTENANCE AND LUBRICATION
SECTION A-SCH ED U LED MAINTENANCE SERVICES FOR YOUR
SECTION B — EXPLANATION OF
SCHEDULED MAINTENANCE SERVICES
The services listed in the preceding Maintenance Schedules are
further explained below. After services are completed, fill in the Main­
tenance Record at the end of this booklet. When the following mainte­
nance services are performed, make sure all parts are replaced and
all necessary repairs are done before operating you vehicle. Be sure
to use the proper fluids and lubricants as shown in Section E.
7. TRANSMISSION SERVICE
Automatic Transmission — Change the transmission fluid and
filter every 15,000 miles (25 000 km) for vehicles under 8600
GVWR or every 12,000 miles (20 000 km) for vehicles over 8600
GVWR if the vehicle is mainly driven under one or more of these
conditions:
• In heavy city traffic where the outside temperature regularly
reaches 90°F (32°C) or higher.
• In hilly or mountainous terrain.
• Frequent trailer pulling.
Item No.
1. ENGINE OIL AND OIL FILTER CHANGE * — ALWAYS USE
SF/CC or SF/CD QUALITY, ENERGY CONSERVING OILS OF
THE PROPER VISCOSITY Also always change oil and filter as
soon as possible after driving in a dust storm. If following Main­
tenance Schedule 1, change oil and filter every 6 months or
recommended mileage; otherwise, change the oil and filter ev­
ery 12 months or recommended mileage. See your Owner’s
Manual for further details.
3. ENGINE IDLE SPEED ADJUSTMENT * — Adjust to the specifi­
cations shown on the underhood label. You must use calibrated
test equipment. Check that idle stop solenoid or dashpot work
properly (if so equipped).
4. COOLING SYSTEM SERVICE * — Drain, flush and refill system
with new coolant. See your Owner’s Manual for further details.
5 AIR CLEANER ELEMENT REPLACEMENT, A.I.R. AND PCV
FILTER REPLACEMENT (SOME MODELS) * — Replace at
specified intervals. Replace more often under dusty conditions.
Ask your dealer for the proper replacement intervals for your
driving conditions.
6. FRONT WHEEL BEARING REPACK — Clean and repack the
front wheel bearings at each brake relining, or at the specified
interval, whichever comes first.
km), then every 30,000 miles (50 000 km).
Manual Transmission (Except S-Truck 4-Speed, 4-Speed O/
D, and 5-Speed) — Manual transmission fluid does not require
periodic changing.
8. PCV SYSTEM INSPECTION * — Check that PCV (Positive
Crankcase Ventilation) system works properly. Replace the valve
as necessary and any worn, plugged or collapsed hoses.
9. FUEL FILTER REPLACEMENT * — Replace the fuel filter at the
specified interval or sooner if clogged.
10. CARBURETOR CHOKE AND HOSES INSPECTION * — Verify
that choke and vacuum break work properly and within specifi­
cations. Correct any binding caused by damage or gum on the
choke shaft. Inspect hoses for proper hookup, cracks, chafing,
or decay. Correct as necessary.
11. CARBURETOR OR THROTTLE BODY MOUNTING BOLT
TORQUE CHECK * — Check torque of mounting bolts and/or
nuts.
12. VACUUM ADVANCE SYSTEM INSPECTION * — Check that
the system works properly. Check hoses for proper hookup,
cracks, chafing or decay. Replace parts as needed.
An Emission Control Service
12
13
OB-13
* An Emission Control Service
Manual Transmission (S-Truck 4-Speed, 4-Speed O/D, and
5-Speed) — Change transmission fluid at 7,500 miles (12 500
MAINTENANCE AND LUBRICATION
2. CHASSIS LUBRICATION — Lubricate the front suspension,
steering linkage, constant velocity universal joint, transmission,
clutch, transfer case shift linkage, parking brake cable guides,
propshaft, universal joints, brake pedal springs, and clutch pedal
springs. Lubricate clutch cross shaft every 30,000 miles (50 000
km).
• Uses such as taxi, police or delivery service.
If the vehicle is not used mainly under any of these conditions,
change the fluid and filter every 30,000 miles (50 000 km) for
vehicles under 8600 GVWR or every 24,000 miles (40 000 km)
for vehicles over 8600 GVWR. See your Owner’s Manual for
further details.
16. ENGINE TIMING CHECK AND DISTRIBUTOR CHECK (SOME
MODELS)* — Adjust timing to underhood label specifications.
Inspect the inside and outside of the distributor cap and rotor for
cracks, carbon tracking and corrosion. Clean or replace as
needed.
17. FUEL TANK, CAP AND LINES INSPECTION * — Inspect the
fuel tank, cap and lines for damage or leaks. Remove fuel cap,
inspect gasket for an even filler neck imprint, and any damage.
Replace parts as needed.
18. EARLY FUEL EVAPORATION (EFE) SYSTEM INSPECTION *
— Check that valve works properly; correct any binding. Check
that thermal vacuum switch works properly. Check hoses for
cracks, chafing, or decay. Replace parts as needed.
19 THERMOSTATICALLY CONTROLLED AIR CLEANER INSPECTION * A — Inspect all hoses and ducts for proper
hookup. Make sure valve works properly.
20. ENGINE ACCESSORY DRIVE BELTS INSPECTION * — In­
spect belts. Look for cracks, fraying, wear, and proper tension.
Adjust or replace as needed.
21. EVAPORATE CONTROL SYSTEM (ECS) INSPECTION * —
Check all fuel and vapor lines and hoses for proper hookup,
routing, and condition. Check that bowl vent and purge valves
work properly, if equipped. Remove canister, and check for
cracks or damage. Replace as needed.
22. SHIELDS AND UNDERHOOD INSULATION INSPECTION
— Inspect shields and underhood insulation for damage or
looseness. Adjust or replace as required.
23. AIR INTAKE SYSTEM INSPECTION ▲ ■ — Check the air in­
take system installation to see that gaskets are seated properly
and all hose connections, fasteners, and other components are
tight. Also check to be sure that the air cleaner housing is prop­
erly seated on the carburetor, that the cover fits tightly, and the
wingnut is tight. Tighten connections and fasteners or replace
damaged parts as required.
24. THERMOSTATICALLY CONTROLLED ENGINE COOLING
FAN CHECK A ■ — (If so equipped.) With the engine off and
below normal operating temperature, check to see that the fan
can be rotated by hand on fluid coupling or viscous drives. Re­
place as necessary.
MAINTENANCE AND LUBRICATION
your Owner's Manual.
14. WIRE SERVICE * — Clean wires and inspect for burns, cracks
or other damage. Check the wire boot fit at the distributor and at
the spark plugs. Replace wires as needed.
15. EGR SYSTEM CHECK * — Conduct EGR SYSTEM CHECK.
Refer to DRIVEABILITY AND EMISSIONS (SEC. 6E8).
OB-14
13. SPARK PLUGS * — Replace spark plugs with the type listed in
25 MANIFOLD HEAT VALVE CHECKA ■ — Some engines are
equipped with a manifold heat valve which should be inspected
and repaired as necessary to insure free operation.
26. IDLE STOP SOLENOID AND/OR DASHPOT CHECK * —
Check that parts work properly. Replace them as needed.
27 THROTTLE RETURN CONTROL (TRC) SYSTEM CHECK * —
Check hoses for proper connections, cracking, abrasion, or de­
terioration and replace as necessary. Check for proper operation
of system. Check for shorted or broken wires and ensure electri­
cal connectors are fully engaged at distributor, speed switch and
vacuum solenoid.
28. ENGINE IDLE MIXTURE ADJUSTMENT (4.8 L ONLY) * — At
designated intervals or in case of a major carburetor overhaul, or
when poor idle quality exists, adjust mixture by a mechanical
method (lean drop), following the specifications shown on the
label under the hood.
29. GOVERNOR CHECK A ■ — (If so equipped). Check the engine
no-load governed speed and reset to specifications as required.
30. EXHAUST PRESSURE REGULATOR VALVE INSPECTION *
— Check that valve works properly. Correct any binding. Check
hoses for cracks, chafing or decay. Replace parts as needed.
* An Emission Control Service
AAlso a Noise Emission Control Service
■ Applicable only to vehicles sold in the United States
* An Emission Control Service
AAlso a Noise Emission Control Service
■ Applicable only to vehicles sold in the United States
14
15
SECTION C — OWNER
INSPECTIONS AND SERVICES
Listed below are inspections and services which should be made
by either you or a qualified technician at the intervals shown to help
ensure proper safety, emission performance and dependability of
your vehicle. Take any problems promptly to your dealer or a qualified
technician for service advice. Whenever repairs are necessary, have
them completed at once. For your safety and that of others, any
safety-related parts that could have been damaged in an accident
should be inspected, and all needed repairs should be done before
operating your vehicle. Be sure to use the proper fluids and lubricants
as shown in Section E.
AT EACH FUEL FILL
Engine oil ievei check t — Check engine oii ievei and add if nec­
essary. See your Owner’s Manual for further details.
Engine coolant level and condition f — Check engine coolant
level in coolant reservoir tank and add if necessary. Replace if dirty or
rusty. See your Owner’s Manual for further details.
Windshield washer fluid level check — Check washer fluid level
in container and add if necessary.
Hood latch operation — When opening hood, note the operation
of secondary latch. It should keep hood from opening all the way
when primary latch is released. Make sure that hood closes firmly
after services are performed.
WHILE OPERATING YOUR VEHICLE
AT LEAST MONTHLY
Automatic transmission shift indicator operation — Make sure
the indicator points to the gear chosen.
Tire pressure check — Keep pressures as shown on Tire Placard
on the driver’s door (including spare). Pressure should be checked
when tires are cold.
Brake system operation — Be alert to abnormal sounds, in­
creased brake pedal travel or repeated pulling to one side when brak­
ing. Also, if a brake warning light goes on, something may be wrong
with part of the brake system.
Exhaust system — Be alert to any changes in the sound of the
system or any smell of fumes. These are signs the system may be
leaking or overheating. Have it inspected and repaired at once. Also,
see “ Engine Exhaust Gas Caution (Carbon Monoxide)” and “ Cata­
lytic Converter” in your Owner’s Manual.
Tire and wheel — Be alert to a vibration of the steering wheel or
seat at normal highway speeds. This may mean a wheel balance is
needed. Also, a pull right or left on a straight, level road may show the
need for a tire pressure adjustment or wheel alignment.
Steering system operation — Be alert to changes in steering ac­
tion. An inspection is needed when the steering wheel is harder to
turn or has too much free play or if abnormal sounds are noted when
turning or parking.
Fluid leak check — After the vehicle has been parked for a while,
inspect the surface beneath the vehicle for water, oil, fuel or other
fluids. Water dripping from the air conditioning system after use is
normal. If you notice fuel leaks or fumes, the cause should be found
and corrected at once.
AT LEAST TWICE A YEAR
(FOR EXAMPLE, EVERY SPRING AND FALL)
Power steering pump level check f — Check power steering
pump fluid in accordance with Owner’s Manual instructions and keep
at proper level.
Brake master cylinder reservoir fluid level check f — Check
fluid level in accordance with your Owner’s Manual, and keep at
t A large loss in these systems may indicate a problem. Have them
inspected and repaired at once.
17
16
OB-15
Headlight aim — Take note of the light pattern occasionally. If
beam aim doesn’t look right, headlights should be adjusted.
Light operation check— Check operation of license plate light,
side marker light, headlights including high beams, parking lights,
taillights, brake lights, turn signals, backup lights, instrument panel
illumination and hazard warning flashers.
MAINTENANCE AND LUBRICATION
Horn operation — Blow the horn occasionally to make sure it
works. Check all button locations.
Clutch pedal free travel — Note the clutch pedal free travel. It
should be about 1” . Adjust linkage whenever there is little or no free
travel.
Throttle linkage inspection — Inspect for interference, binding,
damaged or missing parts.
EACH TIME OIL IS CHANGED
Autom atic or manual transm ission fluid level check t — Check
transmission fluid level and add as required. See your Owner’s
Manual for further details.
Tire and wheel inspection and rotation — Check tires for abnor­
mal wear or damage. Also, check for damaged wheels. To equalize
tire wear and obtain maximum tire life it is suggested that the tires be
rotated at the first oil change, then at every other oil change thereaf­
ter. See “ Tires” in your Owner’s Manual for further information. For
dual wheels, whenever the truck, wheels, or fasteners are new, have
the wheel fastener torque set at the first 100, 1,000 and 6,000 miles
(160, 1 600 and 10 000 km).
Steering and suspension — Inspect front and rear suspension
and steering system for damage, loose or missing parts, signs of wear
or lack of lubrication. Inspect power steering lines and hoses for
proper hookup, binding, leaks, cracks, chafing, etc. (On vehicles
equipped with manual steering gear, check for seal leakage.) Inspect
final drive axle output shaft seals for leaking, t
Brake system s inspection — For convenience the following
should be done when wheels are removed for rotation: Inspect lines
and hoses for proper hookup, binding, leaks, cracks, chafing, etc. In­
spect disc brake pads for wear and rotors for surface condition. Also
inspect drum brake linings for wear and cracks. Inspect other brake
parts, including drums, wheel cylinders, parking brake, etc. at the
same time. Check parking brake adjustment. Inspect brakes more
often if driving habits or conditions result in frequent braking.
Exhaust system inspection * — Inspect complete system includ­
ing catalytic converter. Inspect body near the exhaust system. Look
for broken, damaged, missing or out-of*position parts as well as open
seams, holes, loose connections or other conditions which could
Engine drive belts inspection — Inspect all belts for cracks, fray­
ing, wear and proper tension. Adjust or replace as needed.
Axle rear/front, transfer case (four-wheel drive) — Check fluid
level and add if needed.
• Locking differential - under 8600-lbs. GVWR — Drain fluid at
first oil change and refill. Check fluid level and add as needed at
subsequent oil changes. In dusty areas, or trailer towing applica­
tions drain fluid at every oil change and refill, f
• Locking differential - over 8600-lbs. GVWR — Drain fluid at
first oil change and refill. Change fluid at every other oil change
and check and add fluid at subsequent oil changes. In dusty
areas, or trailer towing applications, drain fluid at every oil
change and refill as specified, t
• Standard differential - under 8600-lbs. GVWR — Check fluid
level and add as needed at every oil change. In dusty areas, or
trailer towing applications, drain fluid every oil change and
refill, f
• Standard differential - over 8600-lbs. GVWR — Drain fluid
every fourth oil change and refill. Check fluid level and add as
needed at every oil change. In dusty areas, or trailer towing ap­
plications, drain fluid at every oil change and refill, t
• Transfer case (four-wheel drive) — Every 12 months or at oil
change intervals, check front axle and transfer case and add
lubricant when necessary. Lubricate propeller shaft slip joint,
constant velocity universal joint and steering linkage. Oil the
control lever pivot point and all exposed control linkage. Check
vent hose at transfer case for kinks and proper installation. More
frequent lubrication may be required on heavy-duty off-road
use. f
t A large loss in these systems may indicate a problem. Have them
inspected and repaired at once.
* An Emission Control Service
t A large loss in these systems may indicate a problem. Have them
inspected and repaired at once.
18
19
MAINTENANCE AND LUBRICATION
cause a heat buildup in the floor pan or could let exhaust fumes seep
into the passenger compartments.
OB-16
proper level. A low fluid level can indicate worn disc brake pads may
need to be serviced.
AT LEAST ONCE A YEAR
Starter safety switch operation —
CAUTION: Before performing the following safety switch
check, be sure to have enough room around the vehicle.
Then, firmly apply both the parking brake (see your Owner’s
Manual for procedure) and the regular brakes. Do not use
the accelerator pedal. If the engine starts, be ready to turn
off the ignition promptly. Take these precautions because
the vehicle could move without warning and possibly cause
personal injury or property damage.
On automatic transmission vehicles, try to start the engine in each
gear. The starter should crank only in “ Park” or “ Neutral.”
CAUTION: Before checking the holding ability of the parking
brake and automatic transmission “ Park” mechanism, park
on a fairly steep hill with enough room for movement in the
downhill direction; to reduce the risk of personal injury or
property damage, be prepared to apply the regular brakes
promptly if the vehicle begins to move.
To check the parking brake with the engine running and transmis­
sion shift lever in “ Neutral,” slowly remove foot pressure from the
regular brake pedal until the vehicle is held by only the parking brake.
To check the automatic transmission “ Park” mechanism holding
ability, release all brakes after shifting the transmission to “ Park.”
Movable head restraint operation — On vehicles with movable
head restraints, make sure restraints stay in the desired position. (See
adjustment instructions in your Owner’s Manual.)
Seatback latch and recliner operation on vehicles equipped
with recliner seat — Be sure seatbacks latch on those vehicles with
folding seats using mechanical latches. Make sure the recliner is
holding by pushing and pulling on the top of the seatback while it is
reclined. See your Owner’s Manual for seat operating information.
Spare tire and jack storage — Be alert to rattles in the rear of the
vehicle. Make sure the spare tire, all jacking equipment, and any cov­
ers or doors are securely stowed at all times. Oil jack ratchet or screw
mechanism after each use.
Underbody flushing — At least every spring, flush from the under­
body with plain water any corrosive materials used for ice and snow
removal and dust control. Take care to thoroughly clean any areas
where mud and other debris can collect. Sediment packed in closed
areas of the vehicle should be loosened before being flushed.
Engine cooling system service * f — Inspect coolant and freeze
protection. If dirty or rusty, drain, flush and refill with new coolant.
Keep coolant at the proper mixture as specified in your Owner’s
Manual. This provides proper freeze protection, corrosion inhibitor
level and engine operating temperature. Inspect hoses and replace if
cracked, swollen or deteriorated. Tighten hose clamps. Clean outside
of radiator and air conditioning condenser. Wash radiator filler cap
and neck. To help ensure proper operation, a pressure test of both the
cooling system and cap is also recommended. See maintenance
schedule charts in Section A for the recommended coolant change
interval.
Key Lock Service — Lubricate key lock cylinder at least annually.
Body Lubrication Service — Lubricate all hody door hinges in­
cluding the tailgate (if equipped) also lubricate the body hood, fuel
door and rear compartment hinges and latches including interior
glove box and console doors, and any folding seat hardware.
20
21
OB-17
* An Emission Control Service
t A large loss in these systems may indicate a problem. Have them
inspected and repaired at once.
MAINTENANCE AND LUBRICATION
On manual transmission vehicles place the shift lever in “ Neutral,”
push the clutch halfway and try to start. The starter should crank only
when the clutch is fully depressed.
Steering column lock operation — While parked, try to turn to
“ Lock” in each gear range. The key should turn to "Lock” only when
gear is in “ Park” on automatic or "Reverse” on manual transmission.
On vehicles with a key release lever, try to turn the key to “ Lock”
without depressing the lever. The key should turn to “ Lock” only with
the key lever depressed. On all vehicles, the key should come out
only in “ Lock.”
Parking brake and transmission “ Park" mechanism operation—
Lap and shoulder belts condition and operation — Inspect belt
system, including: webbing, buckles, latch plates, retractors, guide
loops and anchors.
SECTION E —
RECOMMENDED FLUIDS & LUBRICANTS
NOTE: Fluids and lubricants identified below by name, part number
or specification may be obtained from your GM Truck Dealer.
USAGE
C hassis Lubrication
Chassis grease m eeting requirem ents
of GM-6031-M (GM Part No. 1052497)
W inshield W asher Solvent
GM O ptikleen washer solvent (GM Part
No. 1051515) or equivalent
Hood Latch Assem bly
a. Pivots and spring anchor
b. R elease pawl
Front W heel Bearings
GM Lubricant Part No. 1051344 or equiva­
lent
C onstant V elocity Universal Joint
GM Lubricant Part No. 1052497 or equiv­
alent.
F LU ID /LU B R IC AN T
E ngine Oil
GM G oodw rench M otor O il or equivalent
for API Service SF/CC or SF/CD of the
recom m ended viscosity
E ngine C oolant
M ixture of w ater and a good quality
e th yle ne glyco l base an tifre e ze c o n ­
form ing to GM-1825-M (GM Part No.
1052753)
Brake and H ydraulic Clutch
System s
Delco Suprem e 11 fluid (GM Part No.
1052535) or DOT-3
Parking Brake C ables
C hassis grease m eeting requirem ents
o f GM-6031-M (GM Part No. 1052497)
Power Steering System
GM Power Steering Fluid (GM Part No.
1050017) or equivalent
M anual Steering G ear
G M L u b ric a n t P art No.
e quivalent
A u to m a tic T ra n sm issio n , 4-S p d O /D
M anual T ransm ission, 5-S pd M anual
T ransm ission, S-Truck 4-S pd M anual
T ransm ission, Transfer C ase (E xcept
K30/35 Series)
DEXRON ® II Autom atic Transmission
Fluid (GM Part No. 1051855)
D iffe re n tia l— S ta n d a rd , K30/35 Series
Transfer C ase, M a n u a l T ra n sm issio n
(Except S-Truck 4-Spd, 4-Spd O/D, and
5-Spd)
SAE-80W, or SAE-80W -90 GL-5 gear lu­
bricant (SAE-80W GL-5 in Canada) (GM
Part No. 1052271).
D ifferential — Locking
Som e m odels require a special gear lu­
bricant additive in addition to (GM Part
No. 1052271).*
M anual Transm ission S hift Linkage, Col­
um n Shift, P ropeller Shaft Slip Joint
C hassis grease m eeting requirem ents
o f GM-6031-M (GM Part No. 1052497)
Key Lock C ylinders
Light oil or general-purpose silicone lu­
bricant (GM Part No. 1052276)
1052182 o r
a. Engine oil or GM Part No. 1050109
b. Chassis G rease m eeting requirem ents
of GM-6031-M (GM Part No. 1052497)
Engine oil
Autom atic Transmission Shift Linkage,
F lo o r S h ift Linkage, Hood and D oor
Hinges, Body Door Hinge Pins, Tailgate
Hinge and Linkage, Folding Seat, Fuel
Door H inge
Clutch Linkage (Manual Transmission
only)
a. Pivot points
b. Pushrod to clutch fork joint, and
shaft pressure fitting
a. Engine oil
b. Chassis grease m eeting
requirem ents of GM-6031-M (GM
No. 1051344)
* See your Owner’s Manual for further details.
MAINTENANCE AND LUBRICATION
After each of the preceding Scheduled Maintenance Services is
performed, record the date, odometer reading, services performed
(list item numbers) and who performed the services in the appropriate
column. In addition, retain copies of your receipts. It is suggested that
receipts be kept with this booklet.
SECTION E —
RECOMMENDED FLUIDS & LUBRICANTS
OB-18
SECTION D — MAINTENANCE RECORD
1A-1
SECTION 1
HEATING AND AIR CONDITIONING
CONTENTS
SUBJECT
PAGE
H e a tin g ..................................................................................................................................................................................1A-1
A ir C o n d itio n in g ..................................................................................................................................................................1B-1
SECTION 1A
HEATING
CONTENTS
SUBJECT
PAGE
C-K And G Series Heaters — General D e scrip tio n ............................................................................................. 1A - 2
Blower And A ir Inlet A ssem bly........................................................................................................................... 1A- 2
Heater D istributor A sse m b ly................................................................................................................................1A - 2
Insufficient Heat D ia g n o sis...................................................................................................................................... 1A- 3
Healer C ircuit D ia g n o s is .......................................................................................................................................... 1A- 4
Diagnosis of Heater S y s te m ....................................................................................................................................1A- 5
C-K Series Heater — On-Vehicle S e r v ic e ............................................................................................................ 1A - 6
Blower Motor R eplacem ent.................................................................................................................................. 1A - 6
Heater Hoses — Engine R o u tin g ....................................................................................................................... 1A - 6
Heater D istributor And Core A s s e m b ly ............................................................................................................ 1A- 7
Control Assembly R e p lace m e n t......................................................................................................................... 1A- 9
Control Cables Replacem ent................................................................................................................................1A - 9
Cable A d ju stm e n t................................................................................................................................................... 1A - 9
Blower Switch R e p lacem ent................................................................................................................................1A-11
Resistor R e p la ce m e n t...........................................................................................................................................1A-12
Vent R e p la c e m e n t................................................................................................................................................. 1A-12
C-K Series A uxiliary Heater...................................................................................................................................... 1A-12
General D e s c rip tio n ...............................................................................................................................................1A-12
D iagnosis...................................................................................................................................................................... 1A-12
On-Vehicle S ervice..................................................................................................................................................... 1A-14
G Series Heater — On-Vehicle S e rv ic e .................................................................................................................1A-15
Blower Motor R eplacem ent..................................................................................................................................1A - 15
Heater Hoses — Engine R o u tin g ....................................................................................................................... 1A-15
Heater D istributor And Core A s s e m b ly ............................................................................................................ 1A -1 6
D istributor And Defroster D u c ts ......................................................................................................................... 1A-16
Control Assembly R e placem ent......................................................................................................................... 1A-16
Control C a b le s ....................................................................................................................................................... 1A-19
Cable A d ju stm e n t................................................................................................................................................... 1A-20
Blower Switch R eplacem ent................................................................................................................................1A-20
Resistor R e p la ce m e n t...........................................................................................................................................1A-20
Vent R e p la ce m e n t................................................................................................................................................. 1A-20
G Series Auxiliary H e a te r........................................................................................................................................ 1A-21
General D e s c rip tio n ...............................................................................................................................................1A-21
D iagnosis...................................................................................................................................................................... 1A-21
On-Vehicle S ervice..................................................................................................................................................... 1A-21
Specifications — C-K and G S e rie s ....................................................................................................................... 1A-24
1A-2 HEATING
C-K AND G SERIES HEATERS —
GENERAL DESCRIPTION
Heating components are attached to the right side of
the cowl. The blower and air inlet assembly and water
hoses are located on the forward side of the cowl panel
while the heater core and distributor duct are on the
passenger side.
The heater system is an air-mix type system in which
outside air is heated and then mixed in varying
amounts with cooler outside air to attain the desired air
temperature. The system consists of (1) a blower and
air inlet assembly, (2) a heater distributor assembly
and (3) a heater control assembly.
BLOWER AND AIR INLET
ASSEMBLY
The blower and air inlet assembly draws outside air
through the outside air inlet grille located forward of the
windshield reveal molding and channels the air into the
heater distributor assembly. The operation of the
blower motor is controlled by the fan switch on the
heater control. The motor is connected in series with
the fan switch and the blower resistor assembly.
HEATER DISTRIBUTOR
ASSEMBLY
The heater distributor assembly houses the heater
core and the doors necessary to control mixing and
channeling of the air. Since the unit has no water valve,
water circulation keeps the core hot at all times. That
portion of the air passing through the core receives
maximum heat from the core. Air entering the
distributor assembly is channeled as follows:
C-K AND G MODELS
Air entering the distributor can be directed out the
purge door opening on the right end of the distributor
assembly by the temperature door. If the temperature
door is closed, air is directed through and/or around
the heater core by the temperature door. Air is then
directed into the passenger compartment through the
heater (floor) outlets and/or the defroster (dash) outlets
by the defroster door. The temperature of the outlet air
is dependent on the ratio of heated to unheated air
(controlled by the temperature door).
HEATING 1A-3
INSUFFICIENT HEAT DIAGNOSIS
P o s itio n th e c o n tro ls so th a t the:
T e m p e ra tu re lever is on fu ll heat.
S e le c to r o r h e a te r lever is on Heater.
Fan S w itc h is on xHI._
'C H E C K DUM P DOOR O U TLE T FOR A lt i FLO W l
I AIR FLOW
IN O AIR FLOWl
A d ju s t d u m p d o o r fo r no a ir flo w .
C H E C K D EFRO STER O U TLE TS FOR AIR FLOW
(If in d o u b t as to H ig h o r Low a ir flo w
se t s e le c tp o r o n DEF w h ic h is H ig h and
c o m p a re . R eset s e le c to r on H eater).__________
=L
I HIG H AIR FLOW
|A d ju s t d e fro s te r d o o r fo r lo w a ir flo w "
NO OR LOW AIR FLO W l
| LITT LE OR NO C H A N G E IN AIR FLOW I
C H E C K HEATER O U TLE T AIR FLOW.
(If in d o u b le , s w itc h fan
s w itc h fro m Hi to Lo).________________
I LOW OR NO AIR F L O W l
i-------------^
-----------‘ C h e c k s h u to ff d o o r p o s itio n fo r fu ll
s y s te m a ir flo w . A d ju s t if ne ce ssary.
IC H A N G E IN A IR F LO W
I
LOW AIR FLOW ]
I N O R M A L A IR FLOW.l
IN O AIR FLOW
C h e c k h e a te r o u t le t te m p e r a ­
tu r e w it h 2 2 0 ° F (1 0 4 °C ) ra n g e
C h e c k h e a te r o u tle t fo r o b s tru c tio n
th e r m o m e te r ._____________________
rem ove._______________________________
145 °F (6 3 °C) 1 5 0 ° F (6 6 ° C ) 1 5 5 ° F (6 8 ° C ) 1 6 5 ° F (7 4 ° C )
A m b ie n t A ir
oo
o
o
O u tlet A ir
O
o
(A p p ro x im a te o u tle t a ir te m p e ra tu re s ).
2 5 ° F ( -4 ° C )
40°F(4°C )
7 5°F(2 4 °C )
r^ £ r
C h e c k m o to r v o lta g e at c lo s e t m o to r th e
c o n n e c tio n w ith a vo ltm e te r.
1U N DER 10 VOLTSl
I OVER 10 VOLTS I
FUSE BLOW N re p la ce fu s e .
E
AIR FLOW s y s te m okay.
C h e ck b a tte ry v o lts - u n d e r 10 v o lts ,
re ch a rg e th e n re c h e c k m o to r vo lta g e .
■
rR c m o v e all o b s tru c tio n s u n d e r fro n t se a t.l
i
t
C h e ck w irin g and c o n n e c tio n s fo r
u n d e r 10 v o lts fro m m o to r to fan
s w itc h . R e p a ir o r re p la ce la st p o in t
o f u n d e r 10 v o lt rea d in g .
C a r d o e s n o t b u ild up h eat - o p e ra te vent
c o n tro ls and see th a t th e a ir ve n t d o o rs
c lo s e c o m p le te ly , if n o t, a d ju s t.___________
I LOW
I BLOW S FUSE
tem peratureI
(C h e c k th e s y s te m te m p e ra tu re a fte r
re p a irin g th e ite m ch e c k e d to c o m p le te
A p p ly e x te rn a l g ro u n d , (ju m p e r w ire ) to
m o to r ca se . IN C R E A S E D AIR FLOW -
th e d ia g n o s is ).__________________ _________
C h e c k c o o la n t level; if low, fill. L ook fo r
o r fe e l all ra d ia to r and h e a te r h o s e s and
c o n n e c tio n s fo r leaks. R e p a ir o r rep la ce .
C h e c k th e ra d ia to r ca p fo r d a m a g e and
re p la c e if req u ire d .________________________
C h e c k h e a te r and ra d ia to r h o s e s fo r k in k s s tra ig h te n and re p la ce as n e ce ssary._______
re p a ir g ro u n d
R em ove p o s itiv e lead fro m
m o to r and re p la ce fu se .
IT
S A M E AIR FLOW - rem ove m o to r and
c h e c k fo r o b s tru c tio n in syste m
o p e n in g . If none, R EPLACE MOTOR. If
o b s tru c tio n , rem ove m a te ria l and
re in s ta ll m o to r __________________________
FUSE R E M A IN S O K - rem ove m o to r
and c h e c k fo r o b s tru c tio n in s y s te m
o p e n in g , if none REPLACE MOTOR.
If o b s tru c tio n , rem ove m a te ria l and
re -in sta l! m otor._______________________
BLOW S FUSE - c h e c k fo r s h o rte d
w ire in b lo w e r e le c tric c ir c u it See H e a te r C irc u it D ia g n o s tic C h a rt.
C h e c k te m p e ra tu re d o o r fo r m ax
he a t p o s itio n . A d ju s t if n e ce ssary.
Th e a t e r CORE I
If u s e
Feel te m p e ra tu re s o f h e a te r
in le t and o u tle t hoses.
o k
!
FUSE O K - See H e a te r C irc u it
D ia g n o s tic C h a rt.______________
HOT INLET A N D W ARM
OUTLET HOSES
W ARM IN LET AN D
OUTLET HOSES
C h e ck pu lle ys, b e lt te n s io n , e tc. fo r
p ro p e r o p e ra tio n . R e p la ce o r se rv ic e
as necessary.
C h e c k e n g in e th e rm o s ta t
R e m ove h o s e s fro m h e a te r c o re . R everse
flu s h w ith ta p w ater. If p lu g g e d , re p a ir o r
*C H E C K FOR C-K M O D E LS ONLY
“ C H E C K FOR G M O D E LS ONLY
F-00033
re p la c e .
Figure 1—Insufficient Heat Diagnosis
1A-4
HEATER CIRCUIT DIAGNOSIS*
—
T
=
Check fuse
in fuse panel.
.......
X
1
.... -
FUSE BLOWN
FUSE OK
Figure 2—Heater Circuit Diagnosis
With ignition switch in
“ RUN” position and blower
speed switch “ON” use
meter to locate short in one
of the following wires:
1. From fuse panel to blower
speed switch.
2. From blower speed switch
to heater resistor.
3. From heater resistor to
blower.
Note. Short in circuit may be
intermittent. If meter does
not indicate a short circuit,
move harness around as
much as possible to re-create
short circuit. Watch artd
listen for arcing.
I
The following tests should be made with
the ignition switch in “ RUN” position
the blower speed switch “ ON” and the
lever on heat position.
TEST LIGHT DOES NOT
LIGHT ON ALLTERMINALS
I
Replace resistor.
Check blower motor ground. |
1POOR OR NO GROUND!
| Repair ground.
Replace Motor
j GROUND OK~]
Check motor connector
with 12 volt test light.
"
1
|LAMP DOES NOT LIGHT|
1
,
| LAMP LIGHTS |
Check blower feed wire in connector
on resistor with 12 volt test light.
I
LAMP DOES NOT LIGHT
Use 12 volt test light and check feed
terminal (brown) on blower speed switch.
1
TEST LIGHT LIGHTS ON
ALL TERMINALS
With ignition “OFF” disconnect 3 wire
connector from resistor. Connect a
jumper lead from battery positive
terminal to any wire terminal in
connector. Use 12 volt test light to
check for voltage at the corresponding
wire on blower speed switch. Repeat
same test on other wires.
LAMP LIGHTS ON
ALL THREE WIRES
LAMP LIGHTS
Repair open in feed wire
from resistor to blower motor.
Replace blower
speed switch.
LAMP LIGHTS ON
ALL THREE WIRES
LAMP DOES NOT
LIGHT ON ALL
THREE WIRES
Repair open in
affected wire.
LAMP DOES NOT LIGHT
I
Repair open in brown wire
from blower speed switch
to fuse panel.
o
o
o
rv)
co
j LAMP LIGKTS
‘ See heater circuit diagrams.
Replace switch.
HEATING
BLOWER MOTOR INOPERATIVE
(CERTAIN SPEEDS)
:
i
z
Disconnect resistor connector, connect one lead
of a self powered test light to any one terminal
and use the other lead to probe each of the other
two terminals.
BLOWER MOTOR INOPERATIVE
(ANY SPEED)
HEATING 1A-5
DIAGNOSIS OF HEATER SYSTEM
PROBLEM
POSSIBLE CAUSE
CORRECTION
Temperature Of
Heater A ir At The
O utlets Is Too Low
To Heat Up
Passenger
Compartment
1. Refer to “ Insufficient Heat Diagnostic
Chart.”
1. Refer to “ Insufficient Heat Diagnostic
Chart.”
Temperature Of
Heater A ir At The
O utlets Is Adequate
But The Vehicle W ill
Not Build Up
S ufficient Heat
1. Floor side kick pad ventilators partially
open.
2. Leaking grommets in dash.
3. Leaking welded seams along the
rocker panel and windshield.
4. Leaks through the access holes and
screw holes.
5. Leaking rubber molding around the
door and windows.
6. Leaks between the sealing edge of
blower and the air inlet assembly and
cowl, and between the sealing edge of
the heater distributor assembly and
cowl.
1. Check and adjust.
Inadequate
Defrosting A ction
1. Check that the DEFROST lever com­
pletely opens the defroster door in the
DEF position.
2. Insure that the temperature and air
doors open fully.
3. Look for obstructions in the defroster
ducts.
4. Check for air leak in the ducting be­
tween the defroster outlet on heater
assembly and the defroster duct under
the instrument panel.
5. Check the position of the bottom of the
nozzle to the heater locating tab.
6. Check the position of the defroster
nozzle openings relative to instrument
panel openings. Mounting tabs provide
positive position if properly installed.
Inadequate
1. Check the heater outlet for correct in­
Circulation Of Heated
stallation.
A ir Through The
2. Inspect the floor carpet to insure that
Vehicle
the carpet lies flat under the front seat
and does not obstruct air flow. Also in­
spect around the outlet ducts to insure
that the carpet is well fastened to floor
to prevent cupping of the air flow.
2. Reseal or replace.
3. Clean and rewash.
4. Reseal or replace.
5. Reseal or replace.
6. Reseal or replace.
1. Adjust if necessary.
2. Adjust.
3. Remove any obstructions.
4. Seal area as necessary.
5. Adjust.
6. Adjust the defroster nozzle openings.
1. Remove and install.
2. Correct as necessary.
1A-6 HEATING
DIAGNOSIS OF HEATER SYSTEM (CONT.)
PROBLEM
Erratic Heater
Operation
Hard Operating Or
Broken Controls
CORRECTION
POSSIBLE CAUSE
1. Check the coolant level.
2. Check for kinked heater hoses.
3. Check the operation of all bowden ca­
bles and doors.
4. Sediment in the heater lines and radia­
tor causing the engine thermostat to
stick open.
5. Partially plugged heater core.
1. Fill to the proper level.
2. Relieve kinks or replace hoses.
3. Adjust as necessary.
1. Check for loose bowden cable tab
screws or mis-adjusted bowden ca­
bles.
2. Check for sticking heater system
door(s).
1. Correct as required.
4. Flush the system and clean or re­
place thermostat as necessary.
5. Backflush core as necessary.
2. Lubricate as required using a silicone
spray.
C-K SERIES HEATER — ON-VEHICLE SERVICE
BLOWER MOTOR
REPLACEMENT
Remove or Disconnect (Figures 3 and 4)
1. Battery ground cable.
2. Blower motor lead cable (figure 3).
3. Motor and wheel assembly (figure 4).
— Five mounting screws.
— Gently pry on the blower flange if the sealer
acts like an adhesive.
4. Blower wheel to motor shaft nut.
5. Blower wheel from the motor.
Install or Connect (Figures 3 and 4)
1. Blower wheel to the motor.
• Locate the open end of the wheel away from
the blower motor.
2. Motor shaft nut.
3. Motor and wheel assembly.
4. New bead of sealer to the mounting flange.
5. Blower motor lead wire.
6. Battery ground wire.
7. Test the blower.
1.
2.
3.
4.
5.
Heater/Blower Assembly
Dash
Blower Wiring
Resistor Connector
Motor Connector
F-00625
HEATER HOSES — ROUTING
Heater hoses are routed from the therm ostat
housing or inlet manifold and water pump (radiator on
some automatic transmission vehicles) to the core inlet
Figure 3—Blower Motor Assembly W iring—CK
and outlet pipes (figure 5). Hoses are attached at each
end with screw-type clamps,
HEATING 1A-7
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Connector
Screw
Motor
Case
Fan
Nut
Bolt
Clamp
Clamp
Core
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Shaft
Valve
Valve
Case
Shaft
Shroud
Plate
Bolt
Elbow
Tube
B-09826
Figure 4—Blower Motor Assem bly — Component View
REPLACEMENT
The heater core can be damaged near the tube
attachment seams if force is applied on them. If the
heater hoses do not come off, cut the hoses forward of
the core tubes. Cut the hose on core tubes to remove.
Im portant
• Draw hoses tight to prevent sagging or
rubbing against other components. Route
hoses through all clam ps as installed
originally.
7. Screw that holds the defroster duct to the heater
distributor (figure 8).
8. Screws that hold the heater distributor to the
dash panel.
• Pull the assembly rearward to reach the
wiring harness.
9. Wiring harness.
10. Heater distributor.
11. Core retaining clamps (figure 4).
12. Core (figure 5).
Install or Connect (Figures 4, 5, 6, 7, and 8)
HEATER DISTRIBUTOR
AND CORE ASSEMBLY
1. Core (figure 5).
2. Core retaining clamps (figure 4).
3. Heater distributor.
Remove or Disconnect (Figures 4, 5, 6, 7 and 8)
1. Battery ground cable.
2. Heater hoses at the core tubes (figure 6).
— Drain engine coolant into a clean pan.
— Plug the core tubes to prevent spillage.
3. Nuts from the distributor duct studs that project
into the engine compartment (figure 6).
4. Instrument panel compartment assembly.
5. Air defroster and temperature cables (figure 7).
6. Floor outlet (figure 8).
4. Wiring harness.
5. Defrost duct to heater distributor (figure 5).
6. Floor outlet (figure 4).
7. Air-defroster and temperature cables (figure 6).
8. Instrument panel compartment.
9. Heater hoses to the core tubes (figure 4).
• Unplug the hoses.
10. Replace coolant.
11. Battery ground wire.
1A-8
HEATING
Figure 5—Heater Hoses Routing Diagram
V8 (5.0, 5.7 and 7.4 Liter) Gas Engines
V6 (4.3 Liter) Gas Engine
yi
o
o
CD
cn
co
— —.............
...........
V8 (6.2 Liter) Diesel Engine
L6 (4.8 Liter) Gas Engine
1.
40.
41.
42.
Heater/Blower Assem bly
Hose - Inlet
Hose - O utlet
Radiator
HEATING 1A-9
3. Control to instrument panel screws.
4. Cable push nuts and tab attaching screws.
• Raise or lower the control as necessary.
5. Instrument panel compartment.
6. Cable push nut and tab attaching screws at the
door end of the cable.
7. Cable from the retaining clip.
8. Cable assembly.
Install or Connect (Figure 7)
1. Cable assembly.
Im portant
• Do not kink the cable. Route the cable as
removed. Check adjustment.
2. Cable to retaining clip.
3. Cable push nut and the tabe attaching the screw
at the door.
4. Instrument panel compartment.
5. New cable push nuts and the tab attaching screws.
6. Instrument panel to control screws.
7. Instrument panel bezel.
8. Battery ground cable.
CONTROL ASSEMBLY
REPLACEMENT
CABLE ADJUSTMENT
|+ + | Remove or Disconnect (Figures 7 and 9)
1.
2.
3.
4.
5.
Battery ground cable.
Instrument panel bezel.
Bowden cables (figure 7).
Blower switch wiring harness (figure 9).
Assembly through the opening above the control.
-►4- Install or Connect (Figures 7 and 9)
• If a new unit is being installed, transfer the blower
switch to the new unit.
1. Assembly through the opening above the control.
2. Blower switch wiring harness.
3. Bowden cables.
4. Instrument panel bezel.
5. Battery ground cable.
CONTROL CABLES
□
+ + Remove or Disconnect (Figure 7)
1. Battery ground cable.
2. Instrument panel compartment.
3. Eyelet clip.
4. Cable from the door.
• With pliers, hold the cable and rotate the
mounting tab to lengthen or shorten the
cable.
NOTICE: Do not pinch the cable.
0
Install or Connect (Figure 7)
1. Cable to the door.
Remove or Disconnect (Figure 7)
1. Battery ground cable.
2. Instrument panel bezel.
2. Eyelet clip.
3. Instrument panel compartment.
4. Battery ground cable.
1A-10 HEATING
F-00656
Figure 7—Control Assembly And Cables
HEATING 1A-11
1.
45.
46.
47.
48.
Heater/Blower Assembly
Grille
Nozzle Assembly
Instrument Panel
Outlet
B-09822
Figure 8—Defroster Vents
BLOWER SWITCH
REPLACEMENT
• Lower control onto the radio.
4 Switch wiring harness.
5 Switch.
Remove or Disconnect (Figure 9)
-►«- Install or Connect (Figure 9)
1
2
3
4
Battery ground cable.
Instrument panel bezel.
Control to instrument panel screws.
Control.
50. Heater/Defroster Control Assembly
55. Instrument Panel W iring Harness
56. Blower Switch
Figure 9—Blower Switch
1 Switch.
2 Wiring harness.
3 Control to instrument panel.
B-09811
1. Heater and Blower Assembly
3. Blower Wiring
60. Resistor
B-09812
Figure 10—Blower Motor Resistor
1A-12 HEATING
65. Bezel
66. Valve Assembly
67. Instrument Panel Garnish
68 . Kickpanel
69. Control Cable
Figure 11—Vent Assembly — CK
Install or Connect
4. Instrument panel bezel.
5. Battery ground cable.
RESISTOR REPLACEMENT
1.
2.
3.
4.
Resistor.
Mounting screws.
Wiring harness.
Battery ground cable.
Remove or Disconnect (Figure 10)
1.
2.
3.
4.
Battery ground cable.
Wiring harness.
Two resistor mounting screws.
Resistor (figure 10).
VENT
Right and left vents are installed in the kick panels
under the instrument panel. Replace the vents by
removing the attaching screws (figure 11).
C-K SERIES AUXILIARY HEATER
GENERAL DESCRIPTION
WATER VALVE
This unit operates independently of the standard
heater, and is regulated through its own controls at the
instrument panel.
When heat is desired, and the fan switch is any
position except off, a vacuum operated water valve
controlled by the switch, opens the water line to permit
hot water circulation through the heater core. In the
OFF position the valve is closed to prevent unwanted
heat.
This system consists of a separate core and fan unit
mounted in the rear of the vehicle.
FAN SWITCH
An auxiliary heater provides additional heating
capacity for the rear of the Suburban model.
Heater hoses extend from the unit to the front of the
vehicle where they are connected to the standard
heater hoses with “ tee s.” An “ on-off” vacuum
operated water valve is installed iin the heater core inlet
line in the engine compartment. This valve cuts off
coolant flow to the auxiliary core during warm weather
and eliminates radiant heat (figure 12).
The three speed fan switch is located in the
instrument panel to the right of the steering column.
DIAGNOSIS
Refer to “ C-K and G Model Heaters.”
Two control methods are used:
HEATING 1A-13
75.
76.
77.
78.
79.
80.
81.
82.
83.
84.
85.
86.
87.
88.
89.
90.
91.
Upper Case
Seal
Core
Lower Case
Screw
Fan
Support
Grommet
Washer
Screw
Motor
Clamp
Stud
Resistor
Seal
Nut
Harness
Clamp
Auxiliary Heater Inlet Rear Hose
Auxiliary Heater Outlet Rear
Clip
Screw *
Water Heater Outlet Hose
Water Heater Inlet Hose
Screw
Valve
Harness
Screw
Auxiliary Heater Switch (Single Function) Bezel
Auxiliary Heater Control Switch
Screw
Auxiliary Heater/Rear A ir Conditioning
Control Switch (Dual Function)
107. Connector
92.
93.
94.
95.
96.
97.
98.
99.
100.
101.
102.
103.
104.
105.
106.
Figure 12—Auxiliary Heater—Suburban
1A-14 HEATING
88. Resistor
W iring Harness
108. Auxiliary Heater
109. Platform
101.
F-00662
Figure 13—Resistor Location
Install or Connect (Figure 13)
ON-VEHICLE SERVICE
RESISTOR PRELACEMENT
Remove or Disconnect (Figure 13)
1.
2.
3.
4.
Battery ground cable.
Wiring connector.
Screws.
Resistor (88).
1.
2.
3.
4.
Resistor.
Screws.
Wiring connector.
Battery ground cable.
HEATING 1A-15
G SERIES HEATER— ON-VEHICLE SERVICE
113
110. Nut
111. Fan Assem bly
112. Washer
113. M otor
114. Tube
115. Fitting
116. Case
117. Gasket
118. Pin
119. Valve
120. Shaft
114
121. Housing
122. Core
123. Strap
124. Case
125. Bracket
126. Valve
127. Shaft Assem bly
128. Duct
B-09761
Figure 14—G-Model Component View
BLOWER MOTOR REPLACEMENT
Remove or Disconnect (Figure 14)
1. Battery ground cable.
2.
3.
4.
5.
6.
Coolant overflow hose from the recovery bottle.
Fasteners.
Bottle from the vehicle.
Blower motor lead wire.
Motor and wheel assembly (113).
• Five mounting screws.
• Gently pry on the blower flange if the sealer
acts like an adhesive.
7. Blower sheel shaft nut (112).
8. Blower wheel from the motor (111).
Install o r Connect
1. Blower wheel to the motor shaft.
• Locate the open end of the wheel away from
the blower motor.
2. Blower wheel shaft nut.
3. Motor and wheel assembly.
4. Bead of sealer to the mounting flange.
5.
6.
7.
8.
9.
10.
Blower motor lead wire.
Coolant bottle to the vehicle.
Fasteners.
Coolant hose.
Battery ground cable.
Test the blower.
HEATER HOSES—ROUTING
Heater hoses are routed from the therm ostat
housing or inlet manifold and water pump (radiator on
some automatic transmission vehicles) to the core inlet
and outlet pipes (figure 15). Hoses are attached at
each end with screw-type clamps.
REPLACEMENT
When replacing heater hoses, maintain a 13 mm (V2inch) minimum clearance between the hose clip and
the upper control arm, a 38 mm ( 1 1/2 -inch) minimum
clearance between the hoses and the propshaft, and a
32 mm (11/4-inch) minimum clearance between the
auxiliary heater core lines and the exhaust pipe. Refer
to figure 15.
1A-16 HEATING
11/4-inch (32 mm) minimum clearance between the
auxiliary heater core lines and the exhaust pipe. Refer
to figure 15.
HEATER DISTRIBUTOR AND
CORE ASSEMBLY
0 Remove or Disconnect (Figures 15, 16 and 17)
1. Battery ground cable.
2. Coolant recovery tank.
3. Heater core hoses (figure 15).
— Place a clean pan under the vehicle to catch
any coolant spillage.
— Plug the hoses.
— Allow coolant in the core to drain into the
pan.
4. Heater distributor duct (figure 16).
— Remove the screws that hold the distributor
duct to the d is trib u to r case and the
distributor duct to the engine cover.
5. Engine housing cover.
— Remove the screws at the windshield, all
lower screws and the right instrument panel
support bracket at the door pillar and the
engine housing.
6. Instrument panel.
7. Lower the steering column.
* Raise and support the right side of the in­
strument panel.
8. Defroster duct to distributor case attaching
screws.
9. Distributor to heater case (2!) screws.
10. Temperature door cable (figure 17).
— Fold the cable back for access.
11. Heater case and core.
— Three nuts at the engine compartment side
of the distributor case and one screw on the
passenger side.
— Tilt the case assembly rearward at the top
while lifting up until the core tubes clear the
dash openings.
12. Core retaining strap screws (figure 15).
13. Core.
+ 4-
1.
2.
3.
4.
Install or Connect (Figures 15, 16 and 17)
Core to the heater case.
Sealer between the core and case.
Core retaining strap screws.
Apply new sealer between the heater case and
the opening in the vehicle.
5. Heater core and case to the vehicle.
• Tilt the case until the core tubes clear the
cowl opening.
6. Temperature door cable.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Distributor duct to the heater case.
Defroster duct to the distributor case.
Instrument panel.
Steering column.
Engine housing cover.
Heater distributor duct.
Heater core hoses.
Coolant recovery tank.
Battery ground cable.
DISTRIBUTOR AND
DEFROSTER DUCTS
Remove or Disconnect (Figure 16)
1. Battery ground cable.
2. Raise the instrument panel at the right side.
Refer to “ Heater Distributor and Core Assembly.”
3. Engine cover.
— Unsnap the engine cover front latches and
remove the two cover-to-floor pan screws.
4. Screws that hold the heater distributor duct to the
heater case.
5. Screw at the left center of the distributor duct.
6. Distributor duct.
• Pull the center distributor duct to the right.
7. Defroster duct.
• Screws that hold the defroster duct to the
instrument panel.
+ 4 j Install or Connect (Figure 16)
1.
2.
3.
4.
5.
Defroster duct.
Distributor duct.
Engine cover.
Instrument panel.
Battery ground cable.
CONTROL ASSEMBLY
REPLACEMENT
Remove or Disconnect (Figure 17)
1. Battery ground cable.
2. Instrument panel bezel.
3. Control out of the instrument panel (figure 17).
• Pull the control out to reach the bowden
cable.
4. Bowden cables.
5. Control illumination bulb.
6. Blower switch connector.
7. Control from the vehicle.
8. Blower switch.
HEATING 1A-17
Figure 15—Heater Hose Distribution
1A-18 HEATING
133. Left-hand Outlet Assembly
134. Duct Assembly
F-00659
Figure 16—Distributor Ducts
HEATING 1A-19
147
124.
130.
145.
146.
147.
Heater Assembly
Defroster Plenum
Temperature Cable
Defroster Cable
Control Assembly
F-00658
Figure 17—Control Assembly And Cables
Install or Connect (Figure 17)
1.
2.
3.
4.
5.
6.
7.
Blower switch to control assembly (147).
Blower switch connector.
Control illumination bulb.
Bowden cables.
Control to the instrument panel.
Instrument panel bezel.
Battery ground cable.
CONTROL CABLES
REPLACEMENT
Remove or Disconnect (Figure 14)
1. Battery ground cable.
2. Instrument panel bezel.
• Place transmission lever in “ low.”
3. Control to instrument panel screws.
4. Cable push nuts and tab attaching screws.
• Raise or lower control as necessary.
5. Instrument panel compartment.
6. Cable push nut and tab attaching screws at the
door end of the cable.
7. Cable from the retaining clip.
8. Cable assembly.
-►«- Install or Connect (Figure 14)
1. Cable assembly.
Im portant
— Do not kink cable. Route the cable as
removed.
— Check adjustment.
2. Cable to retaining clip.
3. Cable push nut and the tab attaching the screw at
the door.
1A-20 HEATING
4. Instrument panel compartment.
5. Cable push nuts and the tab attaching screws.
6. Instrument panel to control assembly screws.
7. Instrument panel bezel.
8. Battery ground cable.
CABLE ADJUSTMENT
f t
Adjust (Figure 14)
1. Attach inner cable and sheath to the instrument
panel control.
2. Move the temperature cable to cold.
3. Attach the loop on the inner cable to the
temperature door on the heater case.
4. Attach the cable sheath to the heater case.
5. Move the temperature lever to full heat. This will
require force to slide the inner cable clip to its
proper position.
BLOWER SWITCH
REPLACEMENT
Figure 18—Resistor Replacement
4-+ Remove or Disconnect (Figure 14)
VENT REPLACEMENT
1. Battery ground cable.
2. Blower switch wiring harness connector at the
switch.
Remove or Disconnect (Figure 19)
3. Switch attaching screws.
4. Switch assembly.
Install or Connect (Figure 14)
1. Switch.
2. Switch attaching screws.
3. Blower switch wiring harness.
4. Battery ground cable.
RESISTOR REPLACEMENT
4- + Remove or Disconnect (Figure 18)
1. Screws.
2. Resistor (171).
0
Install or Connect (Figure 18)
1. Resistor.
2. Screws.
1. Screws (5).
2. Valve assembly (202).
+«-
Install or Connect (Figure 19)
1. Valve assembly (202).
2. Screws (5).
HEATING 1A-21
200. Seal
201. Outlet
202. Valve Assembly
203. Clip
204. Screw
205. Knob
206. Rod
207. Guide
208. Outlet
209. Seal
210. Inlet Assembly
211. Cover
F-00657
Figure 19—Vents
G SERIES AUXILIARY HEATER
GENERAL DESCRIPTION
An auxiliary heater provides additional heating for
the rear area on some models.
It operates independently of the standard heater, and
is regulated through its own control at the instrument
panel.
FAN SWITCH
For heating, the fan switch is placed in any position
except off. The switch opens the water valve which
permits hot water to enter the heater core. In the OFF
position, the valve is closed to prevent unwanted heat
during warm weather.
ON-VEHICLE SERVICE
This system consists of a separate core fan vent.
Heater hoses extend from the unit to the front of the
vehicle where they are connected to the standard
heater hoses with “ tees” (figure 21).
DIAGNOSIS
RESISTOR REPLACEMENT
Remove or Disconnect (Figure 18)
1.
2.
3.
4.
Battery ground cable.
Wiring harness at the resistor connector.
Resistor mounting screws.
Resistor.
Refer to “ C-K and G Series Heaters.’
♦«-
WATER VALVE
An “ on-off” vacuum-operated water valve, installed
in the heater core inlet in the engine compartment,
controls coolant flow to the auxiliary core and
eliminates radiant heat during warm weather.
1.
2.
3.
4.
Install or Connect (Figure 18)
Resistor.
Mounting screws.
Wiring harness.
Battery ground cable.
1A-22 HEATING
150.
151.
152.
153.
154.
155.
156.
157.
158.
159.
160.
161.
162.
163.
164.
165.
166.
167.
168.
Case
Core
Seal
Tube
Resistor
Case
Washer
Fan
Nut
Plate
Screw
Screen
Harness Assembly
Stud
Motor
Strap
Terminal
Screw
Screw
B-09752
Figure 20—Auxiliary Heater Component View
HEATING 1A-23
175
185
180
170
182172
176
170.
171.
172.
173.
174.
175.
176.
177.
178.
179.
180.
181.
182.
183.
184.
185.
186.
187.
188.
Heater Assembly
Seal
Clamp
Screw
Washer
Clip
Screw
Strap
Material
Hose
189. Screw
Hose
190. Hose
Strap
191. Nut
Clip
192. Switch
Tee
193. Nut
Tee
194. Label
Screw
195. Knob
Hose
196. Harness
Tee
197. Retainer
Tank
198. Wire Assembly
180 179 176
178
Figure 21— A uxiliary Heater Plumbing Component View
B-09753
1A-24 HEATING
SPECIFICATIONS
C-K AND G SERIES
HEATER
Volts
Amps.
(Cold)
Blower Motor
C-K M o d e ls ..............................................................................
13.5
6.25 Max.
G M odels..................................................................................
13.5
7.1 Max.
RPM
(Cold)
2550
2950
2850
3250
Min.
Max.
Min.
Max.
Fuses
C-K M o d e ls .................................................................................................................................... 20 Amp.
G M odels........................................................................................................................................ 20 Amp.
AUXILIARY HEATER
Blower M o tors.........................................................................
Volts
13.5
Amps.
(Cold)
9.6 Max.
RPM
(Cold)
2700 Min.
1B-1
SECTION 1B
AIR CONDITIONING
CONTENTS
SUBJECT
PAGE
D e s c rip tio n .................................................................................................................................................................. 1B- 3
CCOT System Components, Temperature and Pressure R elationships.................................................... 1B- 5
Handling Refrigerant-12........................................................................................................................................ 1B- 5
System C o m p o n e n ts .............................................................................................................................................1B- 4
Refrigerant-12 Operating C h a ra c te ris tic s ............................................................................................................ 1B- 5
CCOT System Components and Temperature and Pressure Relationships............................................. 1B- 5
Handling R efrigerant-12........................................................................................................................................ 1B- 5
Handling Refrigerant Lines and F itt in g s .......................................................................................................... 1B- 5
Maintaining Chemical S ta b ility ........................................................................................................................... 1B- 8
D ia g n o s is .................................................................................................................................................................... 1B- 9
Testing The Refrigerant S yste m ......................................................................................................................... 1B- 9
Leak Testing The Refrigerant S y s te m .............................................................................................................. 1B- 9
Pressure Sensing S w itch ...................................................................................................................................... 1B- 9
Electrical/Vacuum Trouble D ia g n o s is ...................................................................................................................1B-16
Operational T e s t..................................................................................................................................................... 1B-16
Vacuum System D ia g n o sis...................................................................................................................................... 1B-21
C-K and G S e r ie s ................................................................................................................................................... 1B-21
A/C Refrigerant System D iagnosis......................................................................................................................... 1B-21
Insufficient Cooling “ Quick Check” P ro c e d u re ............................................................................................. 1B-21
A/C Evacuating and Charging P ro c e d u re s .......................................................................................................... 1B-22
Evacuation and Charging P ro c e d u re s .............................................................................................................. 1B-22
Discharging, Evacuating, Adding Oil, and Charging Procedures fo r CCOT A/C S y s te m ......................1B-22
Discharging the CCOT A/C S y s te m ...................................................................................................................1B-22
CCOT Refrigerant Oil D is trib u tio n .....................................................................................................................1B-24
Evacuating and Charging the CCOT A/C S y s te m ...........................................................................................1B-24
Gage C a lib ra tio n ..................................................................................................................................................... 1B-25
Vacuum System C h e c k ........................................................................................................................................ 1B-25
Charging Station M e tho d ...................................................................................................................................... 1B-25
Disposable Can or Multi-Can M e th o d ................................................................................................................ 1B-25
Refrigerant Drum M e th o d .................................................................................................................................... 1B-25
Charging of the CCOT A/C S ystem .....................................................................................................................1B-25
Accum ulator A s s e m b ly ........................................................................................................................................ 1B-26
Specific Component D iagnosis................................................................................................................................1B-26
Com pressor.............................................................................................................................................................. 1B-26
C ondenser................................................................................................................................................................ 1B-26
Receiver-Dehydrator (Motor Home C h a ssis)....................................................................................................1B-26
Expansion V a lve ..................................................................................................................................................... 1B-27
E vaporator................................................................................................................................................................ 1B-27
Refrigerant Line R e s tric tio n s ............................................................................................................................. 1B-27
Sight Glass Diagnosis (Motor Home Chassis U n its ).......................................................................................1B-27
On-Vehicle S ervice..................................................................................................................................................... 1B-28
Compressor Replacement (C -K )......................................................................................................................... 1B-28
Compressor Replacement (G and Motor Homes Chassis M o d e ls ).............................................................1B-29
Compressor Belt Tension Adjustm ent (G and Motor Home Chassis M o d e ls )......................................... 1B-29
1B-2 AIR CONDITIONING
CONTENTS (CONTINUED)
CCOT A/C System—C-K S e r ie s ............................................................................................................................. 1P-32
Condenser R e p la ce m e n t......................................................................................................................................1B-33
A ccum ulator Replacement....................................................................................................................................1B-34
Blower Assembly Replacem ent........................................................................................................................... 1B-34
Evaporator Core R e p la c e m e n t........................................................................................................................... 1B-34
O rifice (Expansion Tube) R e p lace m e n t............................................................................................................1B-35
Selector Duct and Heater Core R e p la ce m e n t................................................................................................. 1B-37
Actuator-Plenum Side Vent R e p lace m e n t........................................................................................................1B-38
Plenum Valve Replacem ent..................................................................................................................................1B-39
Control Assem bly R e p la ce m e n t.........................................................................................................................1B-39
Temperature Door Cable A djustm e n t................................................................................................................ 1B-40
Blower Switch R e p lace m e n t............................................................................................................................... 1B-40
Vacuum Tank Replacem ent..................................................................................................................................1B-40
Vacuum Lines-Engine C o m p a rtm e n t................................................................................................................ 1B-40
Vacuum Harness-Dash.......................................................................................................................................... 1B-40
Refrigerant-12 Hose R o u tin g ............................................................................................................................... 1B-40
Blower Motor Resistor R e p la ce m e n t................................................................................................................ 1B-42
Blower Motor Relay Replacem ent.......................................................................................................................1B-45
Fuse R e p la ce m e n t.................................................................................................................................................1B-45
Rear Interior Roof Mounted System—Suburban................................................................................................. 1B-45
Rear Duct R eplacem ent........................................................................................................................................ 1B-45
Blower Motor Resistor R e p la ce m e n t................................................................................................................ 1B-45
Blower Motor Assem bly R eplacem ent.............................................................................................................. 1B-45
Expansion Valve R e p la ce m e n t........................................................................................................................... 1B-46
Evaporator Core R e p la c e m e n t........................................................................................................................... 1B-48
Blower Motor Switch Replacement.....................................................................................................................1B-49
Fuse R e p la ce m e n t.................................................................................................................................................1B-49
CCOT A/C System—G S e rie s ..................................................................................................................................1B-49
Condenser R e p lace m e n t......................................................................................................................................1B-49
Accum ulator Replacement....................................................................................................................................1B-49
Heater Core R e p la ce m e n t....................................................................................................................................1B-50
O rifice (Expansion Tube) R e p lace m e n t............................................................................................................ 1B-54
Blower Motor Insulation (w/Diesel) R eplacem ent...........................................................................................1B-54
Evaporator Core (w/Diesel) R e p la c e m e n t........................................................................................................1B-55
Evaporator Core R e p la c e m e n t........................................................................................................................... 1B-56
Blower Motor R eplacem ent..................................................................................................................................1B-57
Control Assembly R e p la ce m e n t.........................................................................................................................1B-58
Temperature Door Cable A djustm e n t................................................................................................................ 1B-58
Blower Switch R e p lace m e n t............................................................................................................................... 1B-58
Resistor R e p la c e m e n t.......................................................................................................................................... 1B-58
Blower Motor Relay Replacem ent.......................................................................................................................1B-59
A/C Ductwork Replacem ent................................................................................................................................. 1B-59
Defroster Duct R eplacem ent............................................................................................................................... 1B-59
Temperature Door Cable R e p la ce m e n t............................................................................................................1B-59
Vacuum Tank Replacem ent................................................................................................................................. 1B-60
Vacuum Line Engine C o m p a rtm e n t.................................................................................................................. 1B-60
Refrigerant-12 Hose R o u tin g ............................................................................................................................... 1B-60
Rear Interior Roof Mounted Systems—G S eries................................................................................................. 1B-62
CCOT A/C System—P S e r ie s ................................................................................................................................. 1B-64
AIR CONDITIONING 1B-3
CONTENTS (CONTINUED)
Dash Mounted System—Motor Home C h a s s is ................................................................................................... 1B-64
Condensor R e p lacem ent...................................................................................................................................... 1B-64
Receiver—Dehydrator Replacem ent...................................................................................................................1B-65
Sight Glass Replacement...................................................................................................................................... 1B-65
Blower—Evaporator Assembly R e p la c e m e n t................................................................................................. 1B-66
Blower Assembly Replacement........................................................................................................................... 1B-66
Expansion Valve, Evaporator and/or Evaporator Case R eplacem ent........................................................ 1B-67
Thermostatic and/or Blower Switches Replacem ent...................................................................................... 1B-67
Blower Motor Resistor R e p la ce m e n t................................................................................................................ 1B-67
Fuse R e p lace m e n t.................................................................................................................................................1B-67
S pecifica tio ns..............................................................................................................................................................1B-68
DESCRIPTION
CCOT A/C SYSTEM
The CCOT (Cycling Clutch Orifice Tube) A/C system
performs heating and cooling. Air enters the vehicle
and passes through the cooling unit (evaporator) and
through (or around) the heating unit. The system is
called a “ reheat” system. The evaporator cools the air
passing through the core when the air conditioning
system is in the cooling mode.
On C-K and G series, a pressure sensing switch,
located near the top of the accumulator, controls
com pressor operation. The switch responds to
pressure changes to turn the compressor ON or OFF.
System operation:
Outside air or recirculated air enters the system and
is forced through the system by the blower. As the air
passes through the evaporator core, it receives
maximum cooling if the air conditioning controls are
positioned for cooling.
From the evaporator, the air enters the heater and air
conditioner selector duct assembly where, by means of
diverter doors, it passes through or bypasses the
heater core in proportions necessary to provide the
desired outlet temperature. The air enters the vehicle
through either the floor distributor duct or the dash
outlets.
During cooling, the air is cooled by the evaporator to
below comfort level then warmed by the heater to the
desired temperature. During “ heating only” the evapo­
rator does not operate, and ambient air is warmed to
the desired level in the same manner.
REAR INTERIOR ROOF
MOUNTED SYSTEMS
(SUBURBAN & G SERIES)
These systems operate with the front system - they
do not operate independently. However, control of the
rear blower motor speed is possible when the front
1.
2.
3.
4.
5.
6.
7.
Power Element Thermobulb
Cover
Diaphragm Back-up Plate
Body
Screen
Orifice
Carriage Spring
8.
9.
10.
11.
12.
A.
B.
Spring Seat
Carriage Seat
Seat
Actuating Pin
Diaphragm
Inlet
Outlet
F-00190
Figure 1—Thermostatic Expansion Valve
system at OFF. Rear air circulation without the refriger­
ant function is possible by operating the rear blower
control switch.
These self-contained units operate on inside
(recirculated) air. Air enters the unit and passes
through the evaporator core into the passenger
compartment through the air distributor duct. The front
system controls the rear system. A three-speed blower
switch controls the rear interior roof mounted system.
1B-4 AIR CONDITIONING
passes on to the seat and orifice where it changes into
a low pressure liquid.
C
The low pressure liquid leaves the valve and flows
into the evaporator core where it absorbs heat from the
evaporator core and changes to a low pressure vapor
and leaves the evaporator core. The power element
bulb is clamped to the low pressure vapor line just
beyond the outlet of the evaporator.
ACCUMULATOR C-K & G SERIES
The accumulator is located at the evaporator outlet.
It separates liquid retained from vapor, retains the
liquid and releases the vapor to the compressor (figure
2 ).
A.
B.
C.
15.
16.
17.
18.
19.
Flow from the accum ulator to the compressor
consists of vapor, entrained liquid and liquid flow
through the oil bleed hole.
Inlet
Outlet
Refrigerant Vapor Outlet
Baffle
Internal Tube
Desiccant Bag Assembly
Filter Assembly
Oil Bleed Hole
A bag of desiccant (dehydrating agent), located in
the accumulator, collects moisture.
There is no sight glass in the accumulator with the
CCOT system.
ORIFICE (EXPANSION TUBE) C-K & G SERIES
Pressure differences and sub-cooling determines
expansion tube flow. The orifice is located in the
evaporator inlet line (figure 3).
F-00191
Figure 2—Accum ulator C-K & G Series
PRESSURE CYCLING SWITCH
This switch controls evaporator temperature. It
cycles the compressor clutch off when the evaporator
temperature gets too low. It cycles the compressor
back on after evaporator temperature has increased
(figure 4).
SYSTEM COMPONENTS
THERMOSTATIC EXPANSION VALVE
Suburban and G rear interior roof mounted and
motor home chassis systems use a thermostatic ex­
pansion valve (figure 1).
The valve consists of the power element, body,
actuating pins, seat and orifice. At the high pressure
liquid inlet, a fine mesh screen prevents dirt, filings or
other foreign matter from entering the valve orifice.
The cycling pressure switch provides inherent
compressor protection so a separate low pressure
switch is not necessary. The switch also acts as an
ambient switch since at ambient freezing temperatures
it will not allow the compressor to engage. Adjusting
the set screw one-half turn left or right will rise or lower
the settings 20.7 kPa (3 psi) (figure 5).
When the valve is connected in the system, high
pressure liquid refrigerant enters the valve through the
screen from the receiver-dehydrator or condenser and
/-T.... ..-........... 1——
B
|§
27
26
25
=
— I-------------- J-
_
jIW
||jn .__1
1 L _ Z .□
in
sia5=j
i |I
— __— .
28
A. Inlet (R-12 From Condenser)
B. Outlet (To Evaporator)
D. Dent In Tube (Retains The Expansion Tube)
25. Outlet Screen
26. Expansion Tube
27. Inlet Screen
28. Seal (O Ring)
F-00192
Figure 3—Orifice (Expansion Tube)
AIR CONDITIONING 1B-5
CYCLING PRESSURE SWITCH SETTING
(ACCUMULATO R READINGS)
COMPRESSOR CUT OUT COMPRESSOR CUT IN
PRESSURE RANGE
PRESSURE RANGE
21-24
43-49
F-00333
Figure 5—Cycling Pressure Switch Settings
(Accum ulator Readings)
Figure 4—Pressure Cycling Switch
REFRIGERANT-12 OPERATING CHARACTERISTICS
CCOT SYSTEM COMPONENTS,
TEMPERATURE AND
PRESSURE RELATIONSHIPS
To review system components and Refrigerant-12
flow, refer to figure 6.
To find the pressure and temperature relationship
between Refrigerant-12 and atmospheric pressure,
refer to figure 7.
To find the relationship between relative humidity, air
temperature, evaporator pressure, engine speed (2000
rpm), discharge air temperature and high pressure,
refer to figure 8.
To determine the refrigerant charge for Suburban
and G Series front and rear interior roof mounted
systems, refer to figure 9.
HANDLING REFRIGERANT-12
Air conditioning systems contain Refrigerant-12, a
chemical which requires special handling to avoid
personal injury.
Always wear goggles and wrap a clean cloth around
fittings, valves and connections when opening the
system. Work in a ventilated area and do not weld or
steam clean near air conditioning lines or components.
Refrigerant-12 drums are shipped with a metal screw
cap that protects the valve and safety plug from
damage. Replace the cap after each use.
Do not carry a container of Refrigerant-12 in the
passenger compartment of a vehicle. Never subject
any container to high temperatures. Do not breathe the
smoke or fumes produced by burning Refrigerant-12.
If Refrigerant-12 touches exposed flesh do the
following:
• Treat the area as if it were frost bitten or
frozen.
• Call a doctor or eye specialist and obtain
treatment.
• DO NOT RUB THE EYE. Splash the area
with cold water to raise temperature above
the freezing point.
• Use an antiseptic oil to provide a protective
film over the eyeball to reduce the possibility
of infection.
HANDLING OF REFRIGERANT
LINES AND FITTINGS
Tighten tubing connections to the specified torque
(figure 10). Insufficient or excessive torque causes
loose joints or deformed joint parts. Either condition
can cause refrigerant leakage.
• All metal tubing lines should be free of dents
or kinks to prevent loss of system capacity
due to line restriction.
• Never bend a flexible hose line to a radius of
less than 4 times the diameter oHhe hose.
• Never place a flexible hose line closer than
65 mm (21/2-inch) to the exhaust manifold.
• Inspect flexible hose lines regularly for leaks
or brittleness and replace if necessary.
• When disconnecting any fitting in the
refrigeration system discharge the system.
However, proceed with caution. Open
slowly. Keep face and hands away to pre­
vent injury if there is liquid Refrigerant-12 in
the line.
1B-6 AIR CONDITIONING
606
33.
130.
124.
600.
601.
604.
605.
606.
Accum ulator
Exapansion Tube (Orifice)
Evaporator
Compressor
Condenser
Pressure Cycling Switch
Oil Bleed Hole
Dessicant Bag
L. “ HPV” - High pressure vapor leaving compressor.
M. “ HPL” - Vapor is cooled down by condenser air flow
and leaves as high pressure liquid.
N. “ LPL” - O rifice meters the liquid R-12 into evapora-.
tor, reducing its pressure and warm blower air
across evaporator core causes boiling o ff of liquid
into vapor.
O. “ LPV” - Leaves evaporator as low pressure vapor
and returns with the small amount of . . .
“ LPV/lpi” - Low pressure liquid that didn’t boil o ff
com pletely back to the compressor to be com ­
pressed again.
F-00075
Figure 6—CCOT A/C System Components
REFRIGERANT - 12
PRESSURE - TEMPERATURE
RELATIONSHIP
The table below indicates the pressure of Refriger­
ant-12 at various temperatures. For instance, a
drum of Refrigerant at a temperature of 26.6°C
(80°F) will have a pressure of 579.9 kPa (84.1 psi).
If it is heated to 51.6°C (125°F), the pressure will
increase to 1 154.9 kPa (167.5 psi). It also can be
used conversely to determine the temperature at
which Refrigerant - 12 boils under various pres­
sures. For example, at a pressure of 207.5 kPa
(30.1 psi), Refrigerant - 12 boils at 0°C (32°F).
°C
°F
kPa
PSIG
°C
°F
kPa
PSIG
-29.8
21.7
0
-28.8
-23.3
-20.5
-17.7
-15.0
-12.2
- 9.4
- 6.6
- 3.8
- 1.1
0
1.6
4.4
7.2
10.0
-20
-10
-5
0
5
10
15
20
25
30
32
35
40
45
50
16.5
31.0
46.9
63.4
81.4
101.4
122.0
145.5
169.6
196.5
207.5
224.8
255.1
287.5
322.0
Atmos­
pheric
Pressure
2.4
4.5
6.8
9.2
11.8
14.7
17.7
21.1
24.6
28.5
30.1
32.6
37.0
41.7
46.7
12.7
15.5
18.3
21.1
23.8
26.6
29.4
32.2
35.0
37.7
40.5
43.3
46.1
48.8
51.6
54.4
60.0
55
60
65
70
75
80
85
90
95
100
105
110
115
120
125
130
140
358.5
397.8
439.2
482.7
530.2
579.9
632.3
686.7
745.3
806.0
870.2
937.7
1010.1
1083.2
1154.9
1234.2
1410.0
52.0
57.7
63.7
70.1
76.9
84.1
91.7
99.6
108.1
116.9
126.2
136.0
146.5
157.1
167.5
179.0
204.5
F-00177
Figure 7—Pressure Temperature Relationship of Refrigerant-12
AIR CONDITIONING
1B-7
In Front Of Condenser
Relative
H um idity
(%)
20
30
40
50
60
70
80
90
Air
Temp.
F°
C°
21
27
32
38
21
27
32
38
21
27
32
38
21
27
32
38
21
27
32
38
21
27
32
38
21
27
32
21
27
32
70
80
90
100
70
80
90
100
70
80
90
100
70
80
90
100
70
80
90
100
70
80
90
100
70
80
90
70
80
90
Evaporator
Pressure
Engine Speed
(rpm)
29.5
29.5
30.0
31.0
29.5
30.0
31.0
32.0
29.5
30.0
32.0
39.0
30.0
32.0
34.0
40.0
30.0
33.0
36.0
43.0
30.0
34.0
38.0
44.0
30.0
34.0
39.0
30.0
36.0
42.0
2000
2000
2000
2000
2000
2000
2000
2000
Discharge A ir
Temp.
F°
C°
4
7
9
14
6
8
11
16
7
9
13
18
8
12
15
21
9
13
17
23
10
14
18
24
10
15
19
10
17
22
40
44
48
57
42
47
51
61
45
49
55
65
47
53
59
69
48
56
63
73
50
58
65
75
50
59
67
50
62
71
High
Pressure
kPa
psi
1034.25
1310.05
1689.27
2102.97
1034.25
1413.47
1827.17
2240.87
1137.67
1432.42
1930.60
2378.77
1241.10
1620.32
2034.02
2413.25
1241.10
1654.80
2068.50
2482.20
1275.57
1689.27
2102.97
2516.67
1310.05
1723.75
2137.45
1379.00
1827.17
2275.35
150
190
245
305
150
205
265
325
165
215
280
345
180
235
295
350
180
240
300
360
185
245
305
365
190
250
310
200
265
330 F-00337
Figure 8—Relative Hum idity, Temperature and Pressure Relationships of Refrigerant—12
1B-8 AIR CONDITIONING
• W hen m a kin g stee l to a lu m in u m
connections, use torque for aluminum
tubing. (Refer to figure 10).
REFRIGERANT CHARGE
C60 System
C-K Models
G Models
3 lbs. 8 ozs.
3 lbs. 8 ozs.
MAINTAINING CHEMICAL
STABILITY
Overhead System
C-K Models
G Models
5 lbs. 4 ozs.
4 lbs. 8 ozs.
F-00652
Figure 9—CCOT A/C System Refrigerant Capacities
Allow any pressure to bleed off as described
under “ Discharging, Evacuating, Adding Oil
And Charging And Discharging The CCOT
A/C System.”
• Cap or tape any line open to atmosphere to
prevent dirt and moisture from entering the
system.
• Use p ro p e r w re n ch e s when m akin g
connections on seal (o-ring) fittings. Use two
wrenches to prevent distorting the lines or
components.
• W hen c o n n e c tin g the fle x ib le hose
connections, hold the swaged fitting, the
flare nut and the coupling at the same time
using three different wrenches to prevent
turning the fitting and damaging the ground
seat.
• Use seals (o-rings) in good condition. A burr
or piece of dirt may cause a leak.
The efficient operation of the air conditioning
refrigeration system is dependent upon the chemical
stability of Refrigerant-12.
Foreign m atter can change the s ta b ility of
Refrigerant-12, cause corrosion and wear. Do the
following:
1. Before disconnecting a refrigerant connection,
remove dirt or oil at and near the connection. Cap
or plug both sides of the connection.
2. Keep tools clean and dry.
3. When adding 525 viscosity refrigerant oil (refer to
ADDING OIL in the Discharging, Evacuating,
Adding Oil and Charging Procedures for CCOT
A/C systems), the transfer device and container
should be clean and dry.
4. Have everything ready before opening a line. Do
not leave the A/C system open longer than
necessary.
5. After opening, evacuate before recharging with
Refrigerant-12 according to the “ Discharging,
E va cu a tin g , A d d in g O il, C h a rg in g And
Discharging The CCOT A/C System.”
6. Service parts are dehydrated and seated before
shipping. Open just before making connections.
Keep at room temperature before uncapping (this
prevents moisture from entering the system). If
the connections are not made, reseal the parts.
• Replace the seal when a connection has
been broken. When replacing the seal first
dip it in clean 525 viscosity refrigeration oil.
Metal Tube
Outside
Diameter
Thread and
F itting Size
1/4
%
1/2
5/s
3/4
7/l6
5/s
3/4
7la
11/l6
Steel
Tubing
Torque
Nm
14-20
41-48
41-48
41-48
41-48
LB. FT.
10-15
30-36
30-36
30-36
30-36
Aluminum or
Copper
Tubing
Torque
Nm
7-8
15-18
20-27
28-37
36-45
LB. FT.
5-7
11-13
15-20
21-22
28-33
Nominal
Torque
Wrench Span
5/s
3/4
7/s
11/l6
VU
F-00161
Figure 10—Pipe and Hose Connections Torque
AIR CONDITIONING 1B-9
DIAGNOSIS
NOTICE: When performing air conditioning di­
agnosis on vehicles equipped with a catalytic
converter, warm the engine to a normal oper­
ating temperature before attempting to idle
the engine for periods greater than five (5)
minutes. Make adjustments after the choke is
open and fast idle speed is reduced to a nor­
mal idle.
TESTING THE
REFRIGERANT SYSTEM
If a malfuction is suspected due to abnormal system
pressures, check the following:
1. Outer radiator and condensor cores for plugging.
Check between the condenser and radiator.
2. R estrictions or kinks in evaporator core or
condensor core, hoses, tubes, etc.
3. Refrigerant leaks.
4. Air ducts for leaks or restrictions. Air restriction
may indicate a plugged (or partially plugged)
evaporator core.
5. Compressor clutch slippage.
6. Improper drive belt tension.
7. Plugged accumulator, orifice (expansion tube) or
plugged suction inlet screen (A6 compressor).
8. Moisture in the refrigerant system.
LEAK TESTING THE
REFRIGERANT SYSTEM
Liquid Leak Detectors
Check for leaks at fittings and valves with the swab
attached to the bottle cap. Bubbles will form if there is
a leak.
For restricted areas, use a leak detector, J-6084 or
equivalent.
J-6085 LEAK DETECTOR
Tool J-6084 is a propane gas-burning torch used to
locate refrigerant leaks. 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 available commercially.
CAUTION: Do not use a lighted detector
where c o m b u s tib le or e xp lo sive gasses,
dusts or vapors may be present.
Operating Detector
1. Determine if there is sufficient refrigerant in the
sytem for leak testing.
CAUTION: Do not breathe the fumes that are
produced by the burning of Refrigerant-12
gas in the detector flame. These fumes can
be toxic in large concentrations.
2. Open control valve until a low hiss of gas is
heard; then light gas at opening in chimney.
3. Adjust until the blue flame is about 10mm (3/ainch) above the reactor plate. The reaction plate
will heat to a cherry red.
4. Explore for leaks by moving the end of the
sampling hose around possible leak points in the
system. Do not pinch or kink hose. Since
Refrigerant-12 is heavier than air, place open end
of sampling tube below point being tested.
5. Watch for color changes. Small leaks will turn the
flame to green or yellow-green; large leaks will
turn the flame a brilliant blue or purple. After
passing through a leak the flame will turn to a
c o lo rle s s pale b lu e . Make te s ts in a
semi-darkened area. If the flame remains yellow
after removing it from a leak, the reaction plate is
dirty or the flame is drawing insufficient air.
To check a leak in the high pressure side of the
system, operate the system for a minute, shut down
and check. To check a leak on the low pressure, op­
erate the system and check several minutes after
turning off the system. This will equalize both sides.
PRESSURE SENSING SWITCH
A pressure sensing switch located near the top of
the accumulator, cycles the compressor clutch on C-K
and G series CCOT A/C systems. The switch also
shuts off the compressor clutch when there is a low
refrigerant charge.
The A/C system does not have to be discharged to
replace the switch. The pressure switch fitting is
equipped with a schrader-type valve.
When replacing the switch, use a new oiled seal
(o-ring), and torque to 10 N m (90 in. lbs.).
Refer to the following trouble shooting charts1. Pressure C ycling CCOT System Diagnosis
(figures 11 and 12).
2. System Diagnosis (Dash Mounted Unit) (figures
13, 14 and 15).
3. Compressor Diagnosis (figure 16).
1B-10 AIR CONDITIONING
INSUFFICIENT COOLING-A/C SYSTEMS WITH CYCLING CLUTCH-EXPANSION TUBE (PRESSURE SENSING)
Move Temp. Lever Rapidly Back And Forth From Hot to Cold. Listen For Door Hitting At Each End
Hitting
Not
T
.... 1
1 Set Temp Lever Full Cold
2. Set Selector Lever Norm A/C
3 Set Blower Switch On High
4 Open Doors And Hood
5. W arm Engine
6 Run Engine At Idle
H Adjust Temp.
Door |
| --------------------------------------Feel For Air Flow At Heater And A/C Outlets
Some Or All Air Flow
From Heater Outlet
Air Flow From A/C
Outlets Only
[ Repair As Per Service Manual
| Check Visually For Compressor Clutch Operation I
I Engaged Or Cyclingl...........
-----------------------
1
...
I---------------------------------------------------------
i
.... -............... — z
This System Does Not Have A Sight Glass Linder No Circumstances Should A Sight Glass Be Installed |
|
Feel Liquid Line Before Expansion Tube |
I Cold l -
------------------------ 1 W arm I
------
| Evacuate & Charge |
LJT J------------
Feel Evaporator Inlet And Outlet Pipes K
Restriction In High Side Of System. Visually Check For Frost
Spot To Locate Restriction. Repair As Necessary.
| Inlet Pipe And Outlet Pipe Same Temperature Or Outlet Colder Than ln le t|— { Install Gage Set And Check Compressor Cycling Press‘‘|
System
(O.K.)
| On At 2 826-3 516 kPa (41-51 PSI)
Off At 138-193 kPa (20-28 PSI) |
f - - ............ .......... .................
(
Cycles Within Limits
Runs Continuously Within Limits |
Disconnect Blower Wire And Check For
Cycling Off At 138-193 kPa (20-28 PSI)
Pressure Falls
Below 138 kPa (20 PSI)
Defective Pressure Switch I
---------------------------------------------- 1
Replace *Do Not Discharge
System. There Is A Schrader
Valve In The Fitting__________
,____I ____ t
| System (O.K.) |
Replace. Do Not Discharge System.
1. Set Temp. Lever To Full Cold
2. Set Selector Lever To Max A/C
3. Set Blower Switch On Hi
21 °C (70°F)
System
(O.K.)
4. Close Doors and Windows
5. Run Engine At 2000 RPM
6. Use Aux. Fan In Front Of Grill
32°C (90°F)
6-10°C
(42-50°F)
4 3 °C (110°F)
5-8 °C
(41 -47 °F)
2 7 °C (80°F)
5-8°C
(41 -47°F)
3 8 °C (100°F)
Pick-Up
6 -1 1°C
(43-57°F)
6 -1 1°C
(43-51 °F)
Suburban
6-9°C
(42-48°F)
6-9 °C
(42-48 °F)
10-14°C
(50-58 °F)
12-17°C
(54-62°F)
14-19°C
(57-67 °F)
Outlet Temperature Within Limits t
|
There Is A Schrader Valve in The Fitting
I Install Thermomete|r In A/C Outlet And Check Performance 1
Ambient Temp.
A/C
Outlet
Temp
Defective Pressure Switch
Cycles Off At 138-193
kPa (20-28 PSI) Or Does
Not Pull Down To Press
________ E_____ ,
-I
Cycles High Or Low (On Above 51 PSI)
Or Off Below 138 kPa (20 PSI)
j Outlet Temperature High As Per Chart |
3
System (O.K.
1 Check Compressor Cycling |
j Cycle On And Off Or Remains Off For Long Period Of Time |
I
\ Discharge System And Check For Plugged Expansion Tube |
| “ Discharge System And Check For Missing Expansion Tube |
j
| In Place |
Install Expansion Tube
| Check Compressor Inlet Screen
4
| Evacuate & Charge j
I System (O.K.) |
f
nr
Clean |
1 Repair Or Replace S creen l
j System Over Charged |
| Evacuate & Charge |
| Evacuate & Charge j
| Systern (O .K ) |
| System (O.K.) \
I
Replace
j
Evacuate & Charge
_------t
| SystenT(O.K.) j
F-00162
Figure 11—Pressure Cycling CCOT System Diagnosis
AIR CONDITIONING
1B -1 1
INSUFFICIENT COOLING-A/C SYSTEMS WITH CYCLING CLUTCH- EXPANSION TUBE (PRESSURE SENSING)
J Off A lim s
Time
i
Attach Fused Jum per Wire From Compressor Hot Lead To Positive ( + )
_____________ Battery Post And Check Compressor Operation
I
4 Inlet Pipe Colder Than Outlet P ip T j
Apply External Ground To Compressor,
Remove Jumper And Check Refrigerant
If Clutch Is Still Not Engaged Removed
Pressure At Accumulator Fitting
Clutch & Repair As Per Service Manual
| Leak Check System |
No Leak Found |
| System (O.K.) |
Leak Found I
I
Add 1 Lb Of Refrigerant— 12
'
| Below 345 kPa (50 PSI) \
Above 345 kPa (50 PSI) !
Check High Side Refigerant
Jump Pressure Switch
Pressure
Does Compressor Run
'
I Repair As Necessary I
Then Check Clutch Cycle Rate
Engaged
I
1
| Evacuate & Charge |
| System
(O.K.) \
| Above 345 kPa (50 PSI) |
| Above 6 Cycles Per Minute |
"D isc h arg e System And
Check For Plugged Orifice
| 8 Cycles Per Min. Or Less |
Feel Inlet & Outlet
Open Circuit,
Orifice Or High Side
Broken Wire,
Restriction
Pipes Again
— zzxiiz:
Check For
"D isc h arg e System
And Check For Plugged
etc. Repair
X
| Evacuate & Charge |
As Necessary
Repair Or Replace
I
Evacuate & Charge
| System (O.K.) |
I
Inlet And Outlet Same Tem p..
Inlet Pipe Colder
Or Outlet Colder Than Inlet
Than Outlet Pipe
_
Add One More Pound Of
Refrigerant— 12____
T
'
Replace
*Do Not Discharge
System
System. There Is A
(OK.)
Schrader Valve
I
System
'
Inlet & Outlet Pipes ngain
| Below 345 kPa (50 PSI) I
(O.K.)
Lost Charge
Leak Test & Repair
| System (O .K .)|
Evacuate & Charge
I
I
System
Inlet And Outlet Same Temp.,
| Inlet Pipe Colder" Than Outlet Pipe |
(O. K. )
Or Outlet Colder Than Inlet
‘ Discharge System And Check
Add One More Pound Of
For Plugged Orifice
Refrigerant — 12
| Evacuate & Charge |
| System (O.K.
| System (O.K.) |
F-00163
Figure 12—Pressure Cycling System Diagnosis (Cont.)
1B-12 AIR CONDITIONING
INSUFFICIENT COOLING DIAGNOSIS CHART
D A S H M O U N T E D U N IT (M O TO R H O M E C H AS S IS U N ITS )
THE FOLLOWING PROCEDURES SHOULD BE APPLIED BEFORE PERFORMANCE TESTING AN A/C SYSTEM.
CHECK FOR PROPER BELT INSTALLATION AND TENSION
WITH J-23600
CHECK FOR PROPER CLUTCH COIL TERMINAL
CONNECTOR INSTALLATION.
CHECK FOR CLUTCH AIR GAP (0.022-0.057) (.56-1.45
mm).
CHECK FOR BROKEN, BURST, OR CUT HOSES. ALSO
CHECK FOR LOOSE FITTINGS ON ALL COMPONENTS.
CHECK FOR CONDENSOR AIR BLOCKAGE DUE TO
FOREIGN MATERIAL.
CHECK AIR FLOW
NORMAL AIR FLOW
CHECK DISCHARGE AIR TEMPERATURE
SEE FIGURE 8.
DISCHARGE TEMPERATURE
AT OUTLET COLD
6. CHECK FOR PROPER AIR DUCTING HOSE CONNECTIONS.
7. CHECK HEATER TEMPERATURE DOOR ADJUSTMENT,
ADJUST IF INCORRECT.
8. CHECK EVAPORATOR SEALING FOR AIR LEAK, REPAIR IF
LEAKING.
9 INSTALL PRESSURE GAGES AND THERMOMETER AND
MAKE PERFORMANCE TEST.
NO OR LOW AIR FLOW
BLOWER NOT OPERATING - CHECK BLOWER OPERATION -
NORMAL BLOWER OPERATION
HIGH OUTLET AIR
TEMPERATURE
CHECK SIGHT GLASS
REFER TO FIGURE 14
CHECK FOR LOOSE OR DISCONNECTED AIR
DISTRIBUTION DUCTS, RESTRICTED OR LEAKING
AIR DUCTS, PARTIALLY CLOSED AIR OUTLET
VALVE OR CLOGGED EVAPORATOR CORE, IF
ABOVE CHECK IS OK, CHECK FOR ICE BLOCKING
EVAPORATOR.
CHECK FOR AIR LEAKS THROUGH DASH PANEL, DOORS,
WINDOWS, OR FROM HEATER.
CHECK FOR BLOW FUSE, INOPERATIVE BLOWER SWITCH,
BROKEN WIRE, LOOSE CONNECTIONS, LOOSE BLOWER
MOTOR GROUND WIRE OR INOPERATIVE BLOWER MOTOR.
ICE BLOCKING
EVAPORATOR
CHECK FOR LOW EVAPORATOR PRESSURE
1. ALLOW SYSTEM TO W ARM UP.
2 STOP AND RESTART ENGINE
3 CHECK EVAPORATOR PRESSURE
IMMEDIATELY AFTER RESTART AND PULL
DOWN OF EVAPORATOR PRESSURE.
NORMAL EVAPORATOR
PRESSURE
SYSTEM HAS EXCESS MOISTURE. REPLACE
RECEIVER DEHYDRATOR AND EVACUATE
THOROUGHLY. RECHARGE SYSTEM
LOW EVAPORATOR PRESSURE
CHECK FOR MALFUNCTIONING
EXPANSION VALVE. REFER
TO FIGURES 11 AND 12.
F-00164
Figure 13—Insufficient Cooling Diagnosis Chart
AIR CONDITIONING
1B-13
INSUFFICIENT COOLING DIAGNOSIS CHART (CONTINUED)
D A S H M O U N T E D U N IT (M O TO R H O M E C H AS S IS U N ITS )
FOAMING
SYSTEM IS PROBABLY LOW ON REFRIGERANT. CHECK
FOR LEAKS, REPAIR, AND ADD REFRIGERANT. IF FOAMING
STILL OCCURS, CHECK FOR RESTRICTION IN REFRIGERANT
SYSTEM BETWEEN CONDENSER AND SIGHT GLASS.
LOW EVAPORATOR
PRESSURE
REFER TO FIGURE 8
NO FOAMING
SYSTEM MAY BE EITHER FULLY CHARGED OR
EMPTY. FEEL HIGH AND LOWER PRESSURE PIPES AT
COMPRESSOR. HIGH PRESSURE PIPE SHOULD BE
WARM. LOW PRESSURE PIPES SHOULD BE COLD
IF PIPES ARE NOT INDICATING PROPER
TEMPERATURES, RECHARGE SYSTEM AS
RECOMMENDED. IF NOZZLE AIR TEMPERATURE IS
STILL HIGH, CHECK EVAPORATOR PRESSURE.
CHECK EVAPORATOR PRESSURE
REFER TO FIGURE 8
HIGH EVAPORATOR
PRESSURE
CHECK EVAPORATOR OUTLET LINE
CHECK COMPRESSOR DISCHARGE PRESSURE
EVAPORATOR OUTLET
LINE W ARM
HIGH DISCHARGE PRESSURE
CHECK FOR LIQUID LINE RESTRICTION (FROST SPOT
ON LINE). IF NOT,
CHECK FOR PLUGGED INLET SCREEN IN EXPANSION
VALVE. IF NOT,
3. CHECK FOR MALFUNCTIONING EXPANSION VALVE BY
REMOVING VALVE AND BLOWING THROUGH VALVE.
IF UNABLE TO BLOW THROUGH VALVE, BULB IS DIS­
CHARGED. REPLACE EXPANSION VALVE.
LOW DISCHARGE
PRESSURE
REFER TO
FIGURE 8
CHECK FOR MALFUNCTIONING EXPANSION VALVE.
1. CHECK ENGINE COOLING SYSTEM, FAN CLUTCH AND
CHECK FOR RESTRICTED AIR FLOW THROUGH
CONDENSER.
2. CHECK EXPANSION VALVE BULB CONTACT. CORRECT
IF NECESSARY.
3. CHECK FOR REFRIGERANT RESTRICTION IN
CONDENSER. RETURN BENDS AT EQUAL ELEVATION
SHOULD BE APPROXIMATELY SAME TEMPERATURE.
IF TEMPERATURE OF BENDS IS APPRECIABLY
DIFFERENT, THE COOLER BEND INDICATES A
RESTRICTED CIRCUIT, REPLACE CONDENSER IF
RESTRICTION IS FOUND. IF CONDENSER IS GOOD,
CHECK FOR AIR IN SYSTEM. TO CHECK OBSERVE
OUTLET AIR TEMPERATURE AND COMPRESSOR
DISCHARGE PRESSURE WHILE SLOWLY DISCHARGING
SYSTEM AT RECEIVER INLET CONNECTION.
OUTLET AIR TEMPERATURE
DROPS AS COMPRESSOR
DISCHARGE PRESSURE DROPS
OUTLET AIR TEMPERATURE
INCREASES AS COMPRESSOR
DISCHARGE PRESSURE DROPS
LEAK TEST SYSTEM, REPAIR
AS NECESSARY. DISCHARGE,
EVACUATE, AND RECHARGE.
REPLACE EXPANSION VALVE
F-00165
Figure 14—Insufficient Cooling Diagnosis Chart (Cont.)
1B-14 AIR CONDITIONING
INSUFFICIENT COOLING DIAGNOSIS CHART (Cont.)
DASH MOUNTED UNIT (MOTOR HOME CHASSIS UNITS)
DASH MOUNTED UNIT (MOTOR HOME CHASSIS)
Refrigerant Charge 1.474 kg (3 lbs., 4 oz.)
Temperature of
27° C - (80° F)
32° C - (90° F)
38° C - (100° F)
43° C (110° F)
cir
o
o
CVJ
21 °C - (70° F)
o
o
oo
Air Entering
Condenser
Engine rpm
Compressor
2000
931 Kpa (135 psi)
1 1031 kPa (160 psi)
1 310 kPa (190 psi)
1 517 kPa (220 psi)
1 792 kPa (260 psi)
1 000 kPa (145 psi)
1 172 kPa (170 psi)
1 379 kPa (200 psi)
1 586 kPa (230 psi)
1 862 kPa (200 psi)
43 kPa (6 psi)
48 kPa (7 psi)
62 kPa (9 psi)
69 kPa (10 psi)
69 kPa (10 psi)
90 kPa (13 psi)
Discharge Air
14° C - (40° F)
16° C - (41° F)
16° C - (41° F)
18° C - (42° F)
22° C - (44° F)
22° C - (44° F)
Temperature*
23° C - (45° F)
25° C - (46° F)
25° C - (46° F)
27° C - (47° F)
31° C - (49° F)
31° C - (49° F)
Head Pressure*
758 kPa (110 psi)
827 kPa (120 psi)
Suction
Pressure psi*
* Just before compressor clutch disengagement.
f
w 2b
F-00468
Figure 15—Insufficient Cooling Diagnosis Chart (Cont.)
COMPRESSOR DIAGNOSIS
Clutch slipping.
Check for proper air gap.
If previous step does not
Correct if necessary
correct clutch slippage,
repair compressor.
0.56 - 1.45 mm (0.022 - 0.057 in.
— I Belt slipping!
Check and correct belt tension.
Com pressor engaged
but not operational.
High torque
com pressor (seized).
L-
Add one pound refrigerant.
System has some refrigerant.
Leak test complete
Repair compressor.
system before removing
Operate and leak
test system.
compressor.
Blow oil seal cavity
Com pressor throws oil.
Leaks refrigerant.
Repair compressor.
with air hose and leak
test.
Noisy only when
clutch is engaged.
J- Does not leak refrigerant.
Wipe off oil - OK
Check for refrigerant lines touching
Check and adjust
Repair compressor
metal parts. Isolate and re-evaluate
belt tension.
if noise is
objectionable.
noise.
Noisy when clutch
Remove compressor belt to
Check for interference
If interference exists,
is not engaged.
determine if noise still persits.
between coil housing
repair compressor.
and pulley hub.
AIR CONDITIONING
Figure 16—Compressor Diagnosis
Refrigeration charge is depleted.
NOTE: A/C system noise is to be evaluated in the vehicle with doors and windows closed and low blower on.
1B-15
F-00166
1B-16 AIR CONDITIONING
ELECTRICAL/VACUUM TROUBLE DIAGNOSIS
When diagnosing problems in the electrical and vac­
uum systems consult electrical wiring diagrams and
vacuum diagrams (figures 17, 18, 19, and 20).
Ports on rotary vacuum valves are illustrated to pro­
vide simplicity in following vacuum schematic lines but
are numbered in consecutive order on the actual valve.
(Refer to figures 17 and 20).
OPERATIONAL TEST
To d e te rm in e if the e le c tric a l, vacuum and
refrigeration systems are operating efficiently, do the
following:
1. Operate the blower at four speeds and check the
compressor clutch engagement. This indicates
that the electrical circuits are working.
2. C heck the hand fe lt te m p e ra tu re of the
evaporator inlet pipe and accumulator surface.
The same temperature indicates a properly
charged system.
3. Operate the A/C control selector (mode) lever to
distribute air from the outlets. This will check the
vacuum and diaphragm function.
AIR CONDITIONING
1B-17
45
46
47
\
1
53
/
Jj" 1 l^
f
r
53
z
1
53
K
/
Port
Select Lever Valve Operation Chart
Connection
No.
Off
Vent
Heat
Defrost
Source
4
Vacuum
Vacuum
Vacuum
Vacuum
Vacuum
Vacuum
Vacuum
Bi Level
9
Vent
Vacuum
Vacuum
Vacuum
Vacuum
Vacuum
Vent
Heat/Defrost
3
Vacuum
Vacuum
Vacuum
Vacuum
Vacuum
Vacuum
Vent
OSA/REC
2
Vent
Vacuum
Vent
Vent
Vent
Vent
Vent
5
Vent
Vacuum
Vacuum
Vent
Vent
Vent
Vent
AC Mode
Max A/C Norm A/C Bi-Level
Ports 1,6,7 & 8 Not Used (Sealed On Vacuum Hose Assembly)
45.
46.
47.
52.
53.
Vacuum Source - Engine
Vacuum Tank - Gas
Cowl
Control
Actuator
E.
H.
K.
F.
Vacuum
Vacuum
Vacuum
Vacuum
Vacuum
Line
Line
Line
Line
Line
- Tan (Source)
- Gray (Bi Level)
- Dark Blue (A/C)
- Red (Heat/Defrost)
- Orange (Recirculate)
B-06944
Figure 17—G A/C Vacuum Schematic
1B-18 AIR CONDITIONING
ELECTRICAL SYSTEM DIAGNOSTIC CHART
BLOW MOTOR INOPERATIVE
(ANY SPEED)
CHECK FOR PROPER
FUSE.
JL
|
FUSE B L O W N ""]
|
FUSE OK
THE FOLLOWING TESTS SHOULD BE MADE WITH
THE IGNITION SWITCH IN “ RUN” POSITION,
HEATER OR A/C ON AND BLOW SWITCH ON
HIGH.
WITH IGNITION SWITCH IN “ RUN” POSITION AND
HEATER OR A/C ON, LOCATE SHORT IN ONE OF THE
FOLLOWING WIRES: (SEE NOTE)
1 FROM FUSE PANEL TO MASTER SWITCH ON
CONTROL.
2. FROM MASTER SWITCH TO COMPRESSOR
CLUTCH.
3. MASTER SWITCH TO BLOWER SWITCH.
4 FROM BLOWER SPEED SWITCH TO RESISTOR
5. FROM RESISTOR TO BLOWER MOTOR.
NOTE: SHORT CIRCUIT MAY BE INTERMITTENT. IF
TESTER DOES NOT INDICATE A SHORT CIRCUIT,
MOVE HEATER HARNESS AROUND AS MUCH AS
POSSIBLE TO RECREATE SHORT CIRCUIT WATCH
AND LISTEN FOR ARCING.
Z
CHECK BLOWER MOTOR GROUND.
[
|
POOR OR NO GROUND |
| GROUND OK 1
CHECK MOTOR CONNECTOR
WITH 12 VOLT TEST LIGHT
| REPAIR GROUND|
T
LAMP ON
CHECK WIRE CONNECTOR ON BLOWER
RELAY WITH 12 VOLT TEST LIGHT.
.... I
| REPLACE MOTOR
1
LAMP ON
LAMP DOES NOT LIGHT
|
1
|
|
REPAIR OPEN IN WIRE
FROM BLOWER MOTOR
TO BLOWER RELAY.
LAMP DOES NOT LIGHT
CHECK WIRE CONNECTOR ON
BLOWER RELAY WITH 12 VOLT
TEST LIGHT.
LAMP DOES NOT LIGHT
]
USE 12 VOLT TEST LIGHT AND
CHECK WIRE TERMINALS AT
RESISTOR.
£
[
LAMP ON
REPLACE RELAY.
1
LAMP ON
LAMP OFF
REPLACE RESISTOR.
CHECK FEED WIRE FROM
RESISTOR TO BLOWER
SPEED SWITCH.
JL
LAMP ON
|
I
|
LAMP OFF
|
,,.J____1
REPLACE BLOWER
SPEED SWITCH.
REPLACE OPEN IN WIRE
FROM BLOWER SPEED
SWITCH.
F -0 0 1 6 7
Figure 18—Electrical System Diagnostic Chart
AIR CONDITIONING
1B -1 9
ELECTRICAL SYSTEM DIAGNOSTIC CHART (CONTINUED)
F-00168
Figure 19—Electrical System Diagnostic Chart (Cont.)
1B-20 AIR CONDITIONING
Port
Select Lever Valve Operation Chart
Max A/C
No.
Source
1
A/C Mode
2
Vent
Vacuum
Heater/Mode
3
Vent
Optional
Optional
Vent
Optional
Vent
Vacuum
OSA/REC
4
Vacuum
Vent
Vent
Vent
Vent
Vacuum
Vacuum
Defroster
5
Vent
Vacuum
Vacuum
Vent
Vacuum
Vent
Vent
Off
Norm A/C
..
Bi-Level
Vent
Heat
Defrost
Connection
vac ............
.......■
*
vum
^
Ports 6,7,8 and 9 not used (sealed on vacuum hose assembly)
45.
46.
47.
48.
Vacuum Source - Engine
Vacuum Tank (Gas)
Cowl
Plenum Valve
49.
50.
51.
53.
Mode Door
Defroster Door
Recirculator Door
Actuator
E.
F.
H.
I.
J.
Vacuum Line ■ Gary (Source)
Vacuum Line - Orange (Defroster)
Vacuum Line - Dark Blue (Heat)
Vacuum Line - Tan (A/C)
Vacuum Line - Black (Defroster)
F-00182
Figure 20—C-K A/C Vacuum Schematic
AIR CONDITIONING 1B-21
VACUUM SYSTEM DIAGNOSIS
C-K AND G SERIES
Start the engine and allow it to idle. Move the
selector lever to each position and refer to the vacuum
diagrams and operational charts for airflow, air door
functioning and vacuum circuits. If air flow is not out of
the proper outlet at each selector lever position do the
following:
L*
Inspect
1. The hose connections at the vacuum actuators,
control head valve and vacuum tank.
2. The vacuum source circuit:
• Insta ll a vacuum tee and gage (with
restrictor) at the vacuum tank outlet. Idle the
engine and read the vacuum (a normal
vacuum is equivalent to manifold vacuum)
at all selector lever positions.
• Vacuum less than normal at all positions.
Remove the tee and connect the vacuum
gage line to the tank - read the vacuum. If
still low, then the problem lies in the feed
circuit, the feed circuit to the tank or in the
tank itself. If vacuum is now normal, then
the problem lies downstream.
• Vacuum less than normal at some positions.
If vacuum was low at one or several of the
selector lever positions, a leak is indicated
in these circuits.
• Vacuum normal at all positions.
If vacuum was normal and even at all
positions, then the malfunction may be
caused by improperly connected or plugged
lines or a malfunctioning vacuum valve or
valves.
3. Specific vacuum circuit check:
• P lace the s e le c to r le ve r in the
m alfunctioning position and check for
vacuum at the pertinent vacuum actuators.
• If vacuum exists at the actuator but the door
does not move, then the a c tu a to r is
defective or the door is jammed.
• If low or no vacuum exits at the actuator
determine whether the cause is the vacuum
harness or the vacuum valve.
• Check the vacuum harness first.
4. Vacuum harness circuit check:
• Disconnect the vacuum harness at the
control head.
• The black line should show engine vacuum;
if not, trace back through connector to
vacuum tank.
• To check any individual circuit, place the
selector lever at the involved circuit position
and check for vacuum presence.
A/C REFRIGERANT SYSTEM DIAGNOSIS
INSUFFICIENT COOLING
“ QUICK-CHECK” PROCEDURE
Use the following CCOT “ Hand-Feel” procedure if
the A/C system has the proper charge of Refrigerant-12
(providing ambient temperature is above 21 °C (70°F).
1. Engine must be warm (CHOKE OPEN and OFF
FAST IDLE SPEED CAM) and at normal idle
speed. Diesel engine at normal idle.
2. Hood and body doors open.
3. Selector (mode) lever set at NORM.
4. Temperature lever at COLD.
5. Blower on HI.
6. “ Hand-Feel” the temperature of the evaporator
inlet pipe after the orifice and accumulator with
the compressor engaged.
— BOTH THE SAME TEMPERATURE AND SOME
DEGREE COOLER THAN AMBIENT— Proper
condition: check for other problems (Refer to A/C
System Diagnostic Procedure).
— INLET PIPE COOLER than accumulator surface
indicates a low refrigerant charge.
• Add a m o un ts 120 ml (4 o u n ce s) of
refrigerant UNTIL BOTH feel the same
te m p e ra tu re . A llow s ta b iliz a tio n tim e
between additions.
• Then add 420 ml (14 oz.) one can additional
refrigerant. (The 420 ml (14 oz.) disposable
can of Refrigerant-12 is the equivalent to .88
lbs.).
1B-22 AIR CONDITIONING
A/C EVACUATING AND CHARGING PROCEDURES
EVACUATION AND
CHARGING PROCEDURES
Before opening any refrigerant hose or component,
read the information furnished in:
• Refrigerant-12 Operating Characteristics.
• D is c h a rg in g , E va cu a tin g , A dd in g O il and
Charging.
Remove sealing caps from subassemblies before
making connections for final assembly. Use a small
amount of clean 525 viscosity refrigerant oil on all tube
and hose joints.
Use new seal (o-ring) dipped in the clean 525
viscosity refrigerant oil when assembling joints. The oil
will aid in assembly and help provide a leak-proof joint.
When tightening joints, use a second wrench to hold
the stationary part of the connection.
55. Gage Set
56. Vacuum Pump
57. Empty 3 Lb.
Coffee Can
58. Refrigerant-12
T ig h te n all tu b in g c o n n e c tio n s (fig u re 10).
Insufficient or excessive torque can cause loose joints
or deformed joint parts. Either condition can cause
leakage.
DISCHARGING, EVACUATING
ADDING OIL AND
CHARGING PROCEDURES FOR
CCOT A/C SYSTEMS
Discharge, evacuate and charge using J-23500-01
air conditioning service Charging Station or the
J-5725-04 Manifold Gage Set, and 420 ml (14 oz.)
disposable cans of Refrigerant-12 (figures 21 and 22).
Use gage adapters to connect the charging lines
from the charging station or manifold and gage set to
system service fittings. A straight gage Adapter J-5420
and a 90° angle gage Adapter J-9459 is available.
Wear goggles and wrap a clean cloth around fittings
and connections.
• Discharge the system before removing and
replacing refrigeration lines or components.
• Use the service valve and pressure gage sets
during evacuation and charging procedures.
• Do not charge while the compressor system is
hot.
• Always discharge the system at the low side
service fitting and perform the entire evacuation
and charging procedure through the low side
service fitting.
• Do not connect the high pressure line or any line
to the high side service fitting during discharging
and charging procedures.
F-00169
Figure 21—J-23500-01 Charging System
CAUTION: Never remove a gage line from its
adapter when the line is connected to the
A/C system. Always remove the line adapter
from the service fittin g to disconnect a line.
Do not remove charging hose at gage set
while attached to service low side fittin g .
This w ill discharge the system due to the
depressed schrader valve in service low side
fittin g and may cause personal injury due to
escaping Refrigerant-12.
DISCHARGING THE CCOT
A/C SYSTEM
Before replacing any component, discharge the
system.
1. Discharge at the low side service fitting.
2. With the ignition turned OFF, remove the protec­
tive cap from LOW SIDE service fitting and con­
nect Charging Station J-23500-01 Gage Set.
(Refer to figure 22).
AIR CONDITIONING
1B-23
65. Accum ulator
F-00030
Figure 22—Charging The System With A Disposable Can Or Drum
a. If charging station J-23500-01 is not being
used, discharge the system by slowly
connecting a gage hose to the low side
service fitting on the accumulator and dis­
charge into a bottle (figure 23).
b. As the hose is SLOWLY tightened down
onto the schrader valve, Refrigerant-12 will
d is c h a rg e from the system into the
container. If no discharge occurs, check for
missing or defective schrader depressor in
the hose fitting.
3. With the low side of the system discharged,
check the high side system fitting (on the
liq u id lin e or m u ffle r) for re m a in in g
pressure.
4. If pressure is found, attempt to discharge
the high side using the same procedure as
used for the low side. (This condition
indicates a restriction on the high side.
Diagnose and correct before evacuating
and charging).
5. After discharging, (no vapor escaping with
the hose fully-tightened down), measure
and record the amount. If 15 ml (.05 ounce)
or more, add this amount of new 525
viscosity refrigerant oil plus any quantity in
removed parts before evacuation and
charging with Refrigerant-12 (refer to CCOT
Refrigerant Oil Distribution for the quantity
of oil normally retained in removed parts).
Figure 23—Discharging The CCOT A/C System
W ithout Charging Station J-23500-10
6. If adding oil is necessary, remove the
suction hose at the accumulator outlet pipe
connection and pour the correct quantity of
refrigerant oil into the hose or pipe and then
reconnect hose or pipe. (Refer to step
1B-24 AIR CONDITIONING
num ber 4 and CCOT R e frig eran t Oil
D is trib u tio n
fo r
s p e c ific
q u a n tity
instructions).
CCOT REFRIGERANT
OIL DISTRIBUTION
• A-6 COMPRESSOR—300 ml (10 ounces) of 525
viscosity refrigerant oil.
• R-4 COMPRESSOR 180 ml (6 ounces). Add new
oil during the following component replacement
and conditions:
1. With no excessive oil leakage, add;
— Compressor - Remove, drain oil, measure
replace the same amount of new oil plus 30
ml (1 ounce).
— Evaporator—Add 90 ml (3 ounces).
— Condenser—Add 30 ml (1 ounce).
— Accumulator - R-4 Compressor - Remove
drain oil, measure, replace the same
amount of new oil plus 60 ml (2 ounces) to
compensate for that retained by the original
accumulator dessicant.
— DA-6 Compressor - Remove, drain oil,
measure, replace same amount of new oil
plus 90 ml (3 ounces) to compensate for that
re tained by the o rig in a l a ccu m u la to r
dessicant. If no oil can be drained from old
accumulator, add 60 ml (2 ounces) new oil to
the new accumulator.
2. With signs of excessive oil leakage;
• If a new accumulator is installed add 90 ml
(3 ounces) additional oil to compensate for
that absorbed by the original accumulator
dessicant.
R-4 COMPRESSOR
Remove the accumulator. Drain, measure
and record quantity of oil in accumulator. It
is not necessary to remove and drain the
R-4 compressor because the compressor
only retains a minumum quantity of oil.
• If less than 90 ml (3 ounces), add 90 ml (3
ounces) of new oil to system.
• If more than 90 ml (3 ounces), add the same
amount of new oil as drained.
• If a new accumulator is installed to system,
add 60 ml (2 ounces) additional oil to
compensate for that retained by the original
accumulator dessicant.
EVACUATING AND CHARGING
THE CCOT A/C SYSTEM
B efore c h a rg in g , e vacu a te the system if
Refrigerant-12 is lost or if the system has been opened.
Evacuation and charging is a combined procedure.
Purge all gage lines with Refrigerant-12 before
charging.
There are three standard Refrigerant-12 evacuate
and charge procedures:
• J-23500-01 Charging Station Method
A-6 COMPRESSOR
• Disposable Can Method
Remove Compressor and Accumulator.
Drain measure and record total oil from both
components. Use new oil.
• Drum Method
• If less than 180 ml (6 ounces), add 180 ml (6
ounces) of new oil to system.
NOTICE: Do not use alcohol to remove
moisture from the system. Alcohol can
damage components.
• If more than 180 ml (6 ounces), add same
amount of new oil as drained.
• If a new accumulator is installed to A-6
system, add 60 ml (2 ounces) additional oil
to compensate for that held/absorbed by the
original accumulator dessicant.
DA-6 COMPRESSOR
Remove the accumulator. Drain, measure
and record quantity of oil in accumulator. It
is not necessary to remove and drain the
DA-6 compressor because the compressor
only retaines a minimum quantity of oil, it
doesn’t have an oil sump area.
• If less than 90 ml (3 ounces) add 90 ml (3
ounces) of new oil to the system.
• If more than 90 ml (3 ounces) add the same
amount of new oil as drained.
GAGE CALIBRATION
Before evacuation, check the low pressure gage for
proper calibration and vacuum system for proper oper­
ation. With the gage disconnected from the refrigera­
tion system, be sure that the pointer indicates to the
center of “ 0.” Tap the gage to be sure pointer is not
sticking. If necessary, calibrate as follows:
• Remove the cover from the gage.
• Holding the gage pointer adjusting screw
with one hand, carefully force the pointer in
the proper direction to position the pointer at
the “ 0” position. Tap the gage to be sure
the pointer is not sticking. Replace the gage
cover.
AIR CONDITIONING
VACUUM SYSTEM CHECK
Before connecting the vacuum pump to the A/C
system run the pump connected to the low pressure
gage to determine the vacuum pump capability. If the
vacuum system is unable to reach 711.2 - 736.6 mm
(28 to 29 inches) or more vacuum check for leaks. If no
leaks are found, check the vacuum pump.
CHARGING STATION METHOD
Follow the J-23500-01 Charging Station instructions.
Use with the following exceptions:
1. Do not connect the high pressure line to the air
conditioning system.
2. Keep the high pressure valve on the charging
station closed.
3. Perform the evacuate and charge procedure
through the accum ulator low side pressure
service fitting.
4. Following these procedures will prevent high side
pressure from damaging the charging station if
an error is made during the sequence.
DISPOSABLE CAN OR
MULTI-CAN METHOD
Tools Required:
J-6271-01 Single Can Refrigerant Dispensing Valve
J-6272-02 Four Can Refrigerant Dispensing Valve
1. Use tool J-6271-01 for single can or multi-can
dispensing unit.
2. Use tool J-6272-02 multi-can open valve. When
using disposable cans, close the tapping valve
and then a tta ch the can(s) fo llo w in g the
instructions included with the tapping valve or
tapping manifold adapter.
REFRIGERANT DRUM METHOD
Tool required:
J-23390 Refrigerant Dispensing Valve
1. Use tool J-23390 for a 12 lb. can.
2. A 30 lb. can has a built in opener-valve. Place the
drum on a scale and note weight before charging.
During charging, watch the scale to determine
the amount used.
Im portant
• Close the outlet valve on the opener
(clockwise) before installing the opener to
the R-12 container.
2. To evacuate the A/C system install Manifold
Gage Set and Vacuum Pump.
1B-25
• SLOWLY open high and low side gage
valves and begin vacuum pum p
operation. Pump the system until the
low side gage reaches 459 - 475 mm
(28 to 29 inches of mercury [vacuum])
or more.
The evacuation procedure will specify 459 475 mm (28 to 29 inches) of mercury at sea
level. For each 304.8 mm (1,000 ft.) above
sea level, lower the specification by one
inch of vacuum. At 1524 mm (5,000) feet
elevation only 376.9 mm (23 to 24 inches) of
mercury (vacuum) is required.
If the p re scrib e d vacuum c a n n o t be
reached, close the vacuum control valve,
shut off the pump and look for a leak at
the connections or the pump.
3. When the gage reaches the prescribed vacuum,
the system is evacuated. Close the high side
gage set valve and turn OFF the vacuum pump.
4. Watch the low side gage to be sure vacuum holds
for five minutes. If the vacuum holds, disconnect
the vacuum hose at the gage set and then
proceed to charging.
5. If the vacuum does not hold for five minutes,
charge the system with 420 ml (8 ounces)
Refrigerant-12 and leak check. Discharge the
system again and repair any leaks. Repeat the
evacuation procedure.
CHARGING OF THE CCOT
A/C SYSTEM
1. Start the engine, run with the choke open and the
fast idle speed reduced to normal idle, set the
A/C control lever on OFF.
2. With the drum or 420 ml (14 ounces) can(s)
inverted, open source valve(s) and allow 0.454 Kg
(one (1) pound) or more 420 ml (14 ounces) can of
liquid Refrigerant-12 to enter the system through
low side service fitting on accumulator.
3. When one 0.454 Kg (1 pound) or one 420 ml (14
ounces) can of liquid Refrigerant-12 enters the
system, engage the compressor by setting the
A/C control lever to NORM and blower speed on
HI to draw in the remainder of the charge.
To speed up the operation, use a fan to pass air over
the condenser. If the condenser temperature remains
below the c h a rg in g c y lin d e r te m p e ra tu re ,
Refrigerant-12 will enter the system faster.
4. Shut off the source valve and run the engine for
30 seconds to clear lines and gages.
5. With the engine running, remove the charging
low side hose adapter from the accumulator
service fittin g . Unscrew rapidly to prevent
Refrigerant-12 from escaping.
1B-26 AIR CONDITIONING
CAUTION: Never remove a gage line from its
adapter when the line is connected to the
A/C system. Always remove the line adapter
from the service fittin g to disconnect a line.
Do NOT remove the charging hose at the
g a g e s e t w h ile it is a tta c h e d to th e
accum ulator. This w ill discharge the system
because of the depressed schrader valve in
service low side fittin g . Also, the escaping
Refrigerant-12 may cause personal injury.
6. Replace the protective cap on the accumulator
fitting.
7. Turn the engine off.
8. Leak the check system with a J-6084 Leak
Detector.
9. Start the engine.
10. With the system charged and leak-checked,
operate the system and test for pressures, as
outlined under Relative Humidity, Temperature
and Pressure Relationship of Refrigerant-12
(figure 8).
ACCUMULATOR ASSEMBLY
The a c c u m u la to r a sse m b ly has a se rv ic e
replacement which includes two seals (o-rings for the
inlet and outlet connections). The desiccant is NOT
serviced separately - it is part of the sealed
accumulator assembly. Refer to CCOT Refrigerant Oil
and Distribution for presence of refrigerant oil and
service conditions when removing the accumulator
from the vehicle to measure the oil.
Replace the accumulator assembly when:
1. A physical perforation prduces a leak.
2. The (orifice) screen experiences continued or
repeated plugging.
3. An evaporator fails because of inside-out internal
corrosion.
DO NOT REPLACE the accumulator assembly
where:
1. A dent is found in the outer shell of the
accumulator.
2. A vehicle is involved in a collision and there
is no perforation to the accumulator. Cap or
place a p la s tic bag around an open
refrigerant line.
SPECIFIC COMPONENT DIAGNOSIS
COMPRESSOR
Compressor defects can appear as noise, seizures,
leakage or low discharge pressures.
NOTICE: Resonant compressor noises are
normal; however, irregular noise or rattles may
indicate broken parts or wear. To check
seizure, de-energize the magnetic clutch and
rotate the drive plate. If rotation is impossible
the compressor is seized.
To check for a leak, refer to “ Leak Testing The
R efrigerant S ystem .” A faulty internal seal, a
restriction or an insufficient refrigerant charge can
cause a low discharge pressure. Check before
servicing.
CONDENSER
A condenser may leak or be restricted. A restriction
will cause excessive compressor discharge pressure. If
a partial restriction is present, ice or frost will form after
the restriction as the refrigerant expands after passing
through the restriction.
Air flow restrictions through the condenser or
radiator can cause high discharge pressures. During
normal condenser operation, the outlet pipe will be
cooler than the inlet pipe.
RECEIVER-DEHYDRATOR
(MOTOR HOME CHASSIS)
An inlet restriction can cause high head pressure
and an outlet restriction can cause low head pressure,
or little or no cooling. A restricted outlet can cause a
cold receiver-dehydrator.
EXPANSION VALVE
There are five expansion valve malfunctions: valve
stuck open, valve stuck closed, broken power element,
a restricted screen or an improperly located or installed
power elem ent bulb. To correct the first three
conditions, replace the valve; to correct the last two,
replace the valve inlet screen and properly install a
power element bulb.
Operating the system will indicate valve trouble.
1. Valve stuck open.
— Noisy compressor.
— No cooling - freeze up.
2. Valve stuck closed, broken power element or
plugged screen.
— Very low suction pressure.
— No cooling.
3. Poorly located power element bulb.
— Normal pressure.
— Poor cooling.
AIR CONDITIONING
DIAGNOSIS FOR MALFUNCTIONING VALVE
Use the follo w in g procedure to determ ine a
malfunctioning valve.
1. Operate the system at normal idle. If the valve is
m a lfunctioning, the low pressure readings
(evaporator pressure) will be above specifications
(figure 8).
2. The loss of system performance is not as evident
when the compressor head pressure is below
1379 kPa (200 psi). Increase the system head
pressure by partially blocking the condenser.
Disconnect the blower lead wire and operate the
system to determine if the evaporator pressure
can be obtained.
3. Bubbles in the sight glass will indicate a low
re frig e ra n t charge (M otor Home C hassis
Systems).
EVAPORATOR
An inadequate supply of cool air can cause the
evaporator to malfunction. Check for a plugged core, a
cracked case or a leaking seal.
REFRIGERANT LINE
RESTRICTIONS
There are three refrigerant line restrictions:
1. Suction Line - A restriction will cause low suction
pressure at the compressor, low discharge
pressure and little or no cooling.
1B-27
2. Discharge Line—A restriction will cause the
pressure relief valve to open.
3. Liquid Line—A restriction will be caused by low
discharge and suction pressure, and insufficient
cooling.
SIGHT GLASS DIAGNOSIS
(MOTOR HOME CHASSIS UNITS)
At temperatures above 21 ° C (70° F), the sight glass
can indicate if the refrigerant charge is sufficient.
After operating five minutes, slow-moving bubbles
(vapor) or a broken column of refrigerant under the
glass may indicate a shortage of liquid refrigerant. On
a cool day, continuous bubbles will indicate a properly
charged system. If the sight glass is clear and
performance is satisfactory, occasional bubbles do not
indicate a refrigerant shortage.
If the sight glass shows foaming or a broken liquid
column, observe after partially blocking the air to the
co nd e nse r. If the s ig h t g la ss c le a rs and the
performance is satisfactory, the charge is adequate. If
the refrigerant shortage continues, add refrigerant in
120 ml (4 ounces) increments until the sight glass is
clear. Add an additional charge of 240 ml (8 ounces) as
a reserve after the glass clears. Do not overcharge the
system.
1B-28 AIR CONDITIONING
ON VEHICLE SERVICE
F-00157
Figure 24— C-K C om pressor M o unting C om ponent View L6 (4.8 Liter) Gas Engine
COMPRESSOR REPLACEM ENT
(C-K)
Remove or Disconnect (Figures 24, 25, 26 and
27)
Important
• Use new seals (o-rings) coated with clean
refrigeration oil.
5. Electrical lead to the coil.
6. Compressor belt.
1. Discharge the system.
Adjust
2. Connector attaching bolt.
3. Connector.
• Cap or plug open connections.
• Belt. Refer to Specifications.
7. Evacuate, charge and check the system.
4. Electrical lead to the clutch acutuating coil.
5. Bolt.
• Loosen the bracket and pivot bolts.
6. Compressor.
• Drain and measure the oil.
COMPRESSOR REPLACEMENT
(G AND MOTOR HOME
CHASSIS MODELS)
|+ + | Remove or Disconnect (Figures 28 and 29)
• Check for contamination.
-►«- Install or Connect (Figures 24, 25, 26 and 27)
1. Oil to the compressor.
1.
2.
3.
4.
Important
Important
• Replace with fresh oil. If the system was
serviced, install a full, fresh charge of
refrigeration oil.
2. Compressor.
• Position to the mounting bracket.
3. Nuts, bolts and spring washer.
4. C o n n e c to r a sse m b ly to the
compressor.
Battery ground cable.
Compressor clutch connector.
Purge the system of refrigerant.
Belt.
5.
6.
7.
rear of the
8.
— Release the belt tension at the idle pulley to
remove.
— On some vehicles remove the crankshaft
pulley.
Engine cover - G Series.
Air cleaner.
Fitting and muffler assembly.
® Cap or plug all open connections.
Compressor bracket.
AIR CONDITIONING
1B-29
F-00158
Figure 25—C-K Compressor Mounting Component V6 and V8 (4.3 and 5.0 Liter) Gas Engines
9. Engine oil tube support bracket bolt and nut.
10. Clutch ground lead.
11. Compressor.
6. Compressor belt.
f t
Im portant
• Drain and measure the oil. Check for
contamination.
+«- Install or Connect (Figures 28 and 29)
1. Oil to the compressor.
Im portant
• Replace with fresh oil. If the system was
serviced, install a full, fresh charge of
refrigeration oil.
2. Compressor.
• Position to the mounting bracket.
3. Nuts, bolts and spring washer.
4. C o n n e c to r a sse m b ly to the rear of the
compressor.
9
Im portant
• Use new seals (o-rings) coated with clean
refrigerant oil.
5. Electrical lead to the coil.
Adjust
• Refer to COOLING (SEC. 6B)
COMPRESSOR BELT TENSION
ADJUSTMENT (G AND MOTOR
HOME CHASSIS MODELS)
Adjust the compressor belt to the specifications
shown in the COOLING (SEC. 6B). On some units
increase idler pulley slack adjustment.
f t
Adjust
1. Remove idler adjustment bolt.
2. Remove idler backing plate.
3. Lengthen adjusting slots 13 mm (1/2 -inch)
inboard or outboard as required.
4. Install backing plate.
5. Install assembly.
If the belt is being replaced it may be necessary to
remove and replace the throttle cable during the belt
re p la c e m e n t. A d ju s t the th ro ttle ca b le upon
completion. It may be necessary to remove the
crankshaft pulley to install a new compressor belt.
1B-30 AIR CONDITIONING
V8 (7.4 Liter) Gas Engine - Federal Emissions
C-K Series Compressor Mounting Component View
V8 (7.4 Liter) Gas Engine - California Emissions
F-00159
Figure 26—C-K Compressor Mounting Component View V8 (7.4 Liter) Gas Engine
AIR CONDITIONING
1B-31
F-00160
Figure 27—C-K Compressor M ounting Component View V8 (6.2 Liter) Diesel Engine
Figure 28—G Compressor Mounting Component View V8 (5.7 Liter) Gas Engine
1B-32 AIR CONDITIONING
F-00152
Figure 29—G Compressor Mounting Component View V8 (6.2 Liter) Diesel Engine
CCOT A/C SYSTEM— C-K SERIES
CONDENSER REPLACEMENT
Remove or Disconnect (Figure 30)
1.
2.
3.
4.
5.
Battery ground cable.
Discharge the system.
Grille assembly.
Radiator grille center support.
Left grille support to upper fender support (2)
screws.
6. Condenser inlet and outlet lines, and the outlet
tube at the right end of the condenser (figure 30).
Im portant
• Cap or plug all open connections.
7. Condenser to radiator support screws.
8. Bend the left grille support outboard to gain
clearance for condenser removal.
9. Condenser assembly by pulling it forward and
then lowering it from the vehicle.
Install or Connect (Figure 30)
1. New condenser.
Important
• Add 30 ml (1 ounce) of clean refrigeration oil
to a new condenser.
2. Left grille support.
3. Radiator support screws.
4. Condenser inlet and outlet lines.
Im portant
• Use new seals (o-rings) coated with clear
refrigeration when connecting refrigerant
lines.
5. Left grille support to the upper fender support
screws.
6. Radiator center support.
7. Grille assembly.
8. Battery ground cable.
AIR CONDITIONING
80
82
81 I
83
82
1B-33
84 oc
I 8,5
109-
80.
81.
82.
83.
84.
85.
86.
87.
88.
89.
90.
91.
92.
93.
94.
95.
Harness Assembly
Resistor
Screw
Screw
Tank
Screw
Hose
Bolt
Washer
Fitting
Gasket
O-ring
Tube
Tube
Grommet
Screw
Nut
Condenser
Hose
Clip
Screw
Clamp
Cap
Resistor
Switch
Relay
Screw
Evaporator and
Blower Assembly
108. Seal
109. Washer
110. Accum ulator
96.
70.
97.
98.
99.
100.
101.
103.
104.
105.
106.
107.
F-00085
Figure 31— C-K Evaporator and Condenser Component View (Engine Compartment)
ACCUMULATOR REPLACEMENT
Remove or Disconnect (Figures 31 and 33)
1. Battery ground cable.
2. Compressor clutch connector.
3. Discharge the system.
4. Inlet and outlet lines (97).
90. Insulator
91. Stud
92. Nut
Important
F-00087
Figure 32—Dash Panel Insulator
Assem bly (Engine Compartment - Diesel)
• Cap or plug open connections.
5. Bracket screws.
6. Accumulator (110).
1B-34 AIR CONDITIONING
105. Relay
110. Accum ulator Dehydrator Assembly
120. Screw
121 Grommet
122 Case
123. Grommet
124. Core
125. Clamp
126. Screw
127 Rivet
128 Bracket
129. Plate
130. Orifice
131 Gasket
132 Motor Assembly
133. Hose
134. Wire Assembly
135. Switch Assembly
105
136. Case
137. Seal
81. Resistor
139. Clamp
140. Switch
110
139
F-00092
Figure 33—C-K Evaporator and Blower Compartment (Engine Compartment)
Im portant
• Drain excess refrigerant oil into a clean
container. Measure and add new oil.
♦«- Install or Connect (Figures 31 and 33)
1. New accumulator.
Im portant
2.
3.
4.
5.
6.
• Add 30 ml (one ounce) of clean refrigerant
oil. PLUS an amount equal to that drained.
Bracket screws.
Inlet and outlet lines.
Compressor clutch connector.
Battery ground cable.
Evacuate, charge and check the system.
BLOWER ASSEMBLY
REPLACEMENT
+ + Remove or Disconnect (Figures 32 and 33)
1.
2.
3.
4.
Battery ground cable.
Insulator—Diesel Engine.
Blower motor lead and ground wires (134).
Blower motor cooling tube.
5. Blower assembly.
• Case attaching screws.
• Carefully pry the blower flange away from
the case if the sealer acts as an adhesive.
6. Blower wheel from motor shaft.
• Remove shaft nut.
+«- Install or Connect (Figures 32 and 33)
1. Blower wheel to the motor shaft.
2. Blower assembly.
• Use a new bead of sealer on the flange.
3. Blower assembly.
4. Blower motor cooling tube.
5. Blower motor lead and ground wires.
6. Battery ground cable.
EVAPORATOR CORE
REPLACEMENT
Remove or Disconnect (Figure 33)
1. Battery ground cable.
2. Discharge the system.
3. Nuts from the selector duct studs projecting
through the dash panel.
4. Evaporator case cover (122).
5. Inlet and outlet lines.
AIR CONDITIONING
-
} 47 148 149
1B-35
umiHinumjm
^^<153
150 ^ — 152
•i
4=^)
^154
157
53.
145.
146.
147.
148.
149.
150.
151.
152.
153.
Actuator
Valve
Housing
Screw
Core
Strap
Screw
Clamp
Connector
Link
154.
155.
156.
157.
158.
159.
160.
161.
162.
Connector
Screw
Bracket
Shaft
Spacer
Spring
Shaft
Bracket
Case
163.
164.
166.
167.
168.
169.
170.
171.
Valve
Nut
Valve
Screw
Link
Pin
Seal
Vaive
Figure 34--C -K A/C ar
• Cap or inlet open connections.
6. Expansion tube. Refer to “ Orifice (Expansion
Tube) Replacement” .
7. Evaporator core assembly.
Install or Connect (Figure 33)
1. New core.
• Add 90 ml (3 ounces) of clean refrigeration
oil.
2. Expansion tube.
3. Inlet and outlet lines.
• Use new seals (o-rings) coated with clean
refrigeration oil.
4. Bead of sealer to cover.
• Remove old sealer before applying new
bead of sealer.
5. Evaporator case cover.
6. Nuts to the studs that project into the dash panel.
6. Battery ground cable.
172.
173.
174.
175.
176.
177.
Connector
Plate
Grommet
Hose
Screw
Yoke
F-00093
Heater Component View
7. Evacuate, charge and check the system.
ORIFICE (EXPANSION TUBE)
REPLACEMENT
The expansion tube is located in the evaporator core
inlet line.
+■► Remove or Disconnect (Figures 4 and 33)
1. Discharge the system.
2. C o n de n ser to the e va p o ra to r lin e at the
evaporator inlet (figure 35.)
• Cap or plug the open line.
3. Expansion tube from the evaporator core inlet
line.
• Use needle-nose pliers to remove the core.
4. Expansion tube seal (o-ring) from the core inlet
line.
1B-36 AIR CONDITIONING
186
180.
181.
182.
183.
184.
185.
186.
187.
188.
189.
190.
191.
192.
Adapter
Screw
Adapter
Hose
Duct Assembly
Screw
Duct Assembly
Seal
Seal
Duct Assembly
Gasket
Duct Assembly
Screw
196
193.
194.
195.
196.
197.
198.
199.
200.
201.
202.
203.
204.
Retainer
Adapter
Felt
Deflector
Outlet
A ir Conditioning Assembly
Bolt
Outlet Assembly
O utlet Assembly
Screw
Deflector
Deflector
F-00080
Figure 35—C-K A/C and Heater O utlets and Ducts Component View (Passenger Compartment)
AIR CONDITIONING
1B-37
Figure 36—Actuator-Plenum Side Vent
♦«“ Install or Connect (Figures 4 and 33)
1. Expansion tube seal (o-ring) to the core inlet line.
• Use new seal (o-ring) coated with clean
refrieration oil.
• Insert the short screen and end of the orifice
into the evaporator inlet line.
2. Expansion tube to the evaporator core inlet line.
3. C o n de n ser to the e vap o ra to r line at the
evaporator inlet.
4. Evacuate, charge and check the system.
SELECTOR DUCT AND HEATER
CORE REPLACEMENT
Remove or Disconnect (Figures 34 and 35)
1. Battery ground cable.
2. Drain the radiator.
3. Heater hoses from the core tubes (148).
• Plug the core tubes to prevent spillage.
4. Instrument panel compartment and door.
5. Center duct to the selector duct (200).
6. Center lower and center upper ducts.
7. Temperature door cable.
8. Nuts from the three selector duct studs that
project into the dash panel.
9. Selector duct to dash panel screw (inside the
vehicle).
10. Selector duct assembly.
• Pull rearward until the core tubes clear the
dash panel.
• Lower the selector assembly to reach the
vacuum and electrical harness.
11. Vacuum and electrical harness.
12. Selector duct assembly.
13. Core mounting strap screws.
14. Core.
1B-38 AIR CONDITIONING
Figure 39—C-K Control Assembly
8.
9.
10.
11.
12.
Center duct to selector duct.
Instrument panel bar and door.
Heater hoses.
Coolant to the radiator.
Battery ground cable.
f t
Adjust
T e m p eratu re d oo r ca b le . R efer
“ Temperature Door Cable Adjustment.”
Install or Connect (Figures 34 and 35)
1.
2.
3.
4.
5.
6.
7.
Core.
Core mounting strap screws.
Selector duct assembly.
Vacuum and electrical harnesses.
Selector duct assembly.
Temperature door cable.
Center lower and center upper ducts.
ACTUATOR-PLENUM SIDE
VENT REPLACEMENT
Remove or Disconnect (Figure 36)
1. Vacuum hose at the actuator.
2. Valve return spring at the actuator end (216).
241 244
240.
241.
242.
243.
244.
Cable-Temperature Control
Bolt/Screw
Retainer
Heater Control Assembly
Cam
VIEW B
VIEW A
Figure 38—Temperature Door Cable Adjustment
F-00106
to
AIR CONDITIONING
3.
4.
5.
6.
7.
0
1.
2.
3.
4.
5.
6.
7.
Actuator bracket mounting screws.
Cam to actuator arm screw (213).
Actuator and bracket from the cam.
Actuator to bracket nuts.
Actuator from the bracket (53).
1B-39
CONTROL ASSEMBLY
REPLACEMENT
+ + Remove or Disconnect
1. Battery ground cable.
Install or Connect (Figure 36)
Actuator to the bracket (53).
Bracket nuts.
Actuator and bracket to the cam (211).
Cam to the actuator arm screw.
Actuator bracket mounting screws.
Valve return spring at the actuator end (216).
Vacuum hose to the actuator.
2. Radio. Refer to RADIO (SEC. 9A).
3. Instrument panel bezel.
4. Control from the dash.
• Lower the control to gain access to the
control assembly.
Im portant
• Do not kink the cable.
PLENUM VALVE REPLACEMENT
|+*»| Remove or Disconnect (Figure 37)
5. Cable.
6. Vacuum harness.
7. Electrical harness.
1. Raise the hood.
2. Cowl plastic grille.
3. Three cowl to valve assembly screws.
• Valve assembly from the vehicle.
4. Actuator arm pushnut.
5. Actuator to valve nuts.
• Separate the valve and actuator.
8. Control.
Install or Connect
1. Blower switches to the new control.
2. Electrical harness.
3. Vacuum harness.
♦«- Install or Connect (Figure 37)
1. Actuator to valve nuts.
2. Actuator arm push nut (53).
3. Valve assembly to the vehicle.
4. Cowl plastic grille.
5. Close the hood.
4. Cable.
5. Control to the dash.
6. Instrument panel bezel.
7. Radio. Refer to RADIO (SEC. 9A).
8. Battery ground cable.
1B-40 AIR CONDITIONING
TEMPERATURE DOOR
CABLE ADJUSTMENT
A djust (Figure 38)
1. Remove instrument panel compartment and door.
2. Loosen the cable attaching screw at the selector
duct assembly.
• Make sure the cable is installed in the
bracket on the selelctor duct assembly.
3. Place the temperature lever in full COLD position
and hold while tightening the cable attaching
screw.
4. Install instrument panel compartment and door.
BLOWER SWITCH
REPLACEMENT
The blower switch is located on the rear of the
control assembly.
+ + Remove or Disconnect (Figure 39)
1. Battery ground cable.
2. Instrument panel bezel.
3. Control to instrument panel screws.
• Reset the control on top of the radio.
4. Switch to control screws.
5. Electrical harness.
6. Vacuum harness at the master switch.
7. Switch assembly (235).
+«- install or Connect (Figure 39)
1. Switch.
2. Vacuum harness.
3. Electrical harness.
4. Switch to control screws.
5. Control to the instrument panel.
6. Instrument panel bezel.
7. Battery ground cable.
VACUUM TANK REPLACEMENT
The vacuum tank is mounted to the cowl behind the
left front fender.
Remove or Disconnect (Figure 40)
1. Vacuum lines at the tank.
2. Tank to dash panel screws.
3. Tank (251).
+4* Install or Connect (Figure 40)
1. Tank (251).
2. Vacuum lines.
VACUUM LINES
ENGINE COMPARTMENT
For vacuum line routing refer to figures 40-43.
1. L6 Engine (4.8 Liter) (figure 40).
2. V6 Engine (4.3 Liter) (figure 41).
3. V8 Engines (5.0, 5.7 and 7.4 Liter) (figure 42).
4. V8 Engine (6.2 Liter, Diesel) (figure 43).
VACUUM LINE
HARNESS - DASH
Figure 44 presents the dash vacuum harness and
activator installation.
REFRIGERANT-12
HOSE ROUTING
For Refrigerant-12 hose assemblies, refer to fiqures
45-49.
1. L6 Engine (4.8 Liter) (figure 45).
2. V6 Engine (4.3 Liter) (figure 46).
AIR CONDITIONING
1B-41
Pi
C36 And C60
7. Vacuum Hose
260. Rear Heater Harness
261. K34 Vacuum Harness
C36, C60 And K34
Figure 43—C-K Vacuum Hose - Diesel Engine
C36 Or C60
F-00353
1B-42 AIR CONDITIONING
E.
F.
G.
H.
I.
Vacuum Line—Gray To Source
Vacuum Line—Orange
Vacuum Line—Stripe
Vacuum Line— Dark Blue
Vacuum Line—Tan
7.
53.
236.
244.
265.
Vacuum Harness
Actuator
Cable
Cam
Control Assembly
266.
267.
268.
269.
270.
Plenum Valve (Actuator)
Recirc A ir Valve (Actuator)
Heater Assembly
A ir Cond. Valve (Actuator)
Defrost (Actuator)
F-00234
Figure 44—C-K Vacuum Control Hose - Dash
3 V8 Engines (5.0 and 5.7 Liter) (figure 47).
4. V8 Engine (7.4 Liter) (figure 48).
5. V8 Engine (6.2 Liter) (figure 49).
BLOWER MOTOR
RESISTOR REPLACEMENT
The blower motor resistor is located in the blower
side of the blower-evaporator case.
Remove or Disconnect (Figure 33)
1. Wiring harness at the resistor.
2. Resistor to case attaching screws.
70.
97.
107.
275.
276.
Condenser
Refrigerant Hose
Evaporator And Blower Assembly
Compressor
Radiator
F-00280
3. Resistor (81).
|-»<-| install or Connect (Figure 33)
1. Resistor (81).
2. Screws.
Figure 45—C-K L6 (4.8 Liter) Refrigerant
Hose Assembly
3. Wiring harness.
AIR CONDITIONING
Figure 47—C-K V8 (5.0 Liter and 5.7 Liter) Refrigerant Hose Assembly
1B-43
1B-44 AIR CONDITIONING
Figure 49—C-K V8 (6.2 Liter - Diesel) Refrigerant Hose Assembly
AIR CONDITIONING
Install or Connect (Figure 31)
BLOWER MOTOR RELAY
REPLACEMENT
1. Relay (105).
2. Mounting screws.
3. Wiring harness.
The blower motor relay is located on the blower side
of the blower-evaporator case.
□
FUSE REPLACEMENT
Remove or Disconnect (Figure 31)
1. Wiring harness at the relay.
2. Attaching screws.
3. Relay (105).
1B-45
A 25-amp fuse, located in the junction block, projects
the system except for the blower circuit. The fuse for
the blower circuit is located in the electrical wiring
between the junction block and the blower relay.
REAR INTERIOR ROOF MOUNTED SYSTEM— SUBURBAN
The rear interior roof mounted system is used with
the front air conditioning system.
3. Blower motor ground strap.
4. Blower motor lead wire.
5. Lower to upper blower-evaporator case screws.
REAR DUCT
REPLACEMENT
6. Case and motor assembly (326) (336).
This duct covers the blower-evaporator assembly
located at the rear of the vehicle. It has four adjustable
air outlets (figure 50).
Im portant
• Before removing the case screws, support
the lower case to prevent damage to the
case or motor assembly.
Remove or Disconnect (Figure 50)
7. Motor retaining strap.
1. Drain tube from the rear duct.
2. Screws securing the duct to the roof panel and
rear header brackets.
3. Duct (303).
-►4- Install or Connect (Figure 50)
1. Duct (303).
2. Screws and brackets.
3. Drain tube.
BLOWER MOTOR RESISTOR
REPLACEMENT
The blower motor resistor is located on the cover
side of the blower-evaporator. To remove, refer to
“ Blower Motor Resistor, CCOT A/C System (C-K
Series).”
8. Motor and wheels (330).
9. Wheel from the motor shaft.
□
Install or Connect (Figures 50 and 51)
1. Wheels to the motor shaft (330).
• Place the tension springs on the wheel
hubs.
2. Motor and wheels to the case.
• Align the wheels to prevent contact with the
case.
3. Motor retaining strap and foam.
4. Lower case and blower motor assembly in the
vehicle (336).
5. Lower to upper case screws.
BLOWER MOTOR ASSEMBLY
REPLACEMENT
• Turn the blower wheels to prevent rubbing
against the case.
6. Center ground strap.
I++I Remove or Disconnect (Figures 50 and 51)
1. Battery ground cable.
2. Rear duct (303).
7. Blower lead wire.
8. Rear duct.
9. Battery ground cable.
1B-46 AIR CONDITIONING
303
301.
302.
303.
304.
305.
Washer
Screw
Shroud
Screw
Clip
306.
307.
308.
309.
310.
Deflector
Outlet
Bracket
Nut
Screw
F-00224
Figure 50—C-K Rear Interior Roof Mounted A/C Shroud
Im portant
EXPANSION VALVE
REPLACEMENT
This system incorporates an expansion valve which
does not utilize and external equalizer line.
7.
8.
9.
Remove or Disconnect (Figure 51)
1. Battery ground cable.
10.
2. Purge the system of refrigerant.
0
3. Rear duct.
4. Blower motor lead.
5. Ground wire.
6. Lower to upper blower-evaporator case screws.
• Before removing the case screws, support
the lower case and motor assemblies to
prevent damage to the case or motor
assembly.
Lower case and motor assembly (336).
Expansion valve sensing bulb clamps.
Valve inlet and outlet lines.
• Cap or plug open lines.
Expansion valve assembly (342).
Install or Connect (Figure 51).
1. New expansion valve assembly (342).
• Remove caps or plug.
• Use new seals (o-rings) coated with clean
refrigeration oil.
2. Sensing bulb.
3. Lower case and blower motor assembly.
AIR CONDITIONING
320.
321.
322.
323.
324.
325.
326.
327.
328.
329.
330.
331.
332.
Screw
Bracket
Screw
Screw
Support
Screw
Case
Plate
Screw
Seal
Motor Asm.
Eyelet
Terminal
333.
334.
335.
336.
337.
338.
339.
340.
341.
342.
343.
344.
1B-47
Bracket
Screw
Seal
Case
Clip
Seal
Core Asm.
Seal (O-ring)
Refrigerant Lines
Valve Asm.
Screw
Clamps
F-00602
Figure 51—C-K Rear Interior Roof Mounted A/C Evaporator and Blower Component View
1B-48 AIR CONDITIONING
365
364
351.
352.
353.
354.
355.
Fittings
Clip
Screw
Cover
Nut
356.
357.
358.
359.
360.
Bracket
Screw
Clamp
Hose
Strap
361.
362.
363.
364.
365.
Hose Assembly
Seal
Screw
O-ring
O-ring
366.
367.
368.
369.
370.
371.
Clip
Clip
Screw
Hose Assembly
Hose Assembly
Clip
B-06946
Figure 52—C-K Rear Interior Roof Mounted A/C Hoses and Cover Component View
4.
5.
6.
7.
8.
• Cap or plug the open connections.
7. Blower-evaporator support to roof rail screws.
8. Blower-evaporator (339).
• Place the blower-evaporator upside down
on a work bench.
9. Lower case assembly.
10. Upper case from the evaporator core.
11. Expansion valve inlet and outlet lines.
• Cap or plug open connections.
12. E xp a n sio n valve c a p illa ry bulb from the
evaporator oulet line.
13. Valve.
14. Plastic pins that hold the screen to the core.
15. Screen.
Blower motor lead.
Ground wires.
Rear duct.
Battery ground cable.
Evacuate, charge and check the system.
EVAPORATOR CORE
REPLACEMENT
Remove or Disconnect (Figures 51 and 52)
1.
2.
3.
4.
5.
6.
Battery ground cable.
Purge the system of refrigerant.
Rear duct.
Blower motor lead.
Ground wire.
R e frig e ra n t lin e s at the rear
blower-evaporator assembly (351).
+«- Install or Connect (Figures 51 and 52)
of
the
1. Wire screen to the front of the core.
2. Plastic pins.
3. Expansion valve inlet and outlet lines (341).
AIR CONDITIONING
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
• Use new seals (o-rings) coated with clean
rerfrigeration oil.
Sensing bulb to the evaporator outlet line (342).
• Bulb must make good contact with the line.
• Add 30 ml (3 ounces) of clean refrigeration
oil to new core.
Upper case and supports to the core.
Lower core case and blower assembly.
Blower-evaporator assembly to the roof.
Support to roof rail screws.
Refrigerant lines to the blower-evaporator unit.
• Use new se als (o -rin g s ) w ith clean
refrigeration oil.
Blower lead wire.
Ground wire.
Rear duct.
Battery ground cable.
Evacuate, charge and check the system.
BLOWER MOTOR SWITCH
REPLACEMENT
1B-49
«--► Remove or Disconnect
Battery ground cable.
Switch retaining screws.
Wiring harness.
Switch.
+ 4-
1.
2.
3.
4.
Install or Connect
Switch.
Wiring harness.
Switch retaining screws.
Battery ground cable.
FUSE REPLACEMENT
A-25 amp fuse at the junction box protects this
system. A 20-amp fuse, located between the junction
block and the rear blower motor switch, protects the
rear blower high speed circuit.
The three-speed (LO-MED-HI) blower motor switch is
located in the instrument panel to the left of the ash
tray.
CCOT A/C SYSTEM — G SERIES
CONDENSER REPLACEMENT
Remove or Disconnect (Figure 53)
1.
2.
3.
4.
5.
6.
7.
8.
Battery ground cable.
Purge the system of refrigerant.
Grille, hood lock, and center hood lock support.
Condenser inlet and outlet lines at the condenser
(70).
Screws attaching the left side condenser bracket
to the radiator.
Screws attaching the right side condenser
bracket to the condenser.
Condenser.
Left bracket from the condenser.
5. Condenser inlet and outlet lines at the condenser
(70).
6. Grille, hood lock and center hood lock support.
7. Refrigerant.
8. Evacuate, charge and test the system.
ACCUMULATOR
REPLACEMENT
Remove or Disconnect (Figure 53 and 54)
1. Battery ground cable.
2. Compressor clutch cable.
Install or Connect (Figure 53)
1. Left bracket to condenser.
2. Condenser (70).
• Add 30 ml (1 ounce) of clean refrigeration oil
to a new condenser.
3. Screws attaching the left side of the condenser
bracket to the condenser.
4. Screws attaching the right side of the condenser
bracket to the condenser.
3. Discharge the system.
4. Inlet and outlet lines.
Important
• Cap or plug open connections.
5. Bracket screws.
6. Accumulator.
1B-50 AIR CONDITIONING
^ = a r=
416
70.
401.
402.
403.
404.
405.
406.
407.
409.
Condenser Assembly
Material (Trim)
Hose Assembly
Clip
Screw
Fitting Assembly
Fitting Assembly
Seal (O-ring)
Hose Assembly
411.
413.
414.
415.
416.
417.
418.
Screw
Nut
Grommet
Strap
Screw
Hose
Compressor
407
F-00086
Figure 53—G Condenser and Related Parts Component View
Im portant
Drain excess refrigerant oil into a clean
container. Measure and record amount. Use
fresh oil.
Install or Connect (Figure 53 and 54)
1. New accumulator.
Im portant
• Add 30 ml (1 ounce) of clean refrigerant oil
PLUS an amount equal to that drained.
2. Bracket screws.
3. Inlet and outlet lines.
4. Compressor clutch connector.
5. Battery ground cable.
6. Evacuate, charge and check the system.
HEATER CORE
REPLACEMENT
«■+ Remove or Disconnect (Figure 54)
1. Battery ground cable.
2. Engine cover.
3. Steering column to instrument panel.
• Lower column.
4. Upper and lower instrument pane! attaching
screws and radio support bracket attaching
screw.
5. Raise and support right side of the instrument
panel.
6. Right lower instrument panel support bracket.
7. Recirculating air door vacuum actuator.
8. Temperature cable and vacuum hoses at the
distributor case.
AIR CONDITIONING
Nut
Actuator Assembly
Case
Valve
Nut
Fan Assembly
Washer
Terminal
Motor Assembly
Tube
Accum ulator
Dehydrator
^
Assembly
Clamp
rjy
Clamp
i
Clamp
Case
ll> ^
Assembly
4 5 5'
Case
Seal
Seal
Clamp
E vaporator***^
Assembly
Seal
Filter
Retainer
Switch Assembly
Case
O rifice
Gasket
46
Gasket
Bracket
Gasket
Stud
456.
457.
458.
459.
460.
461.
462.
463.
464.
465.
466.
467.
468.
470.
471.
472.
473.
474.
475.
1B-51
Valve Assembly
Core
Clamp
Valve
Shaft
Connector
Link
Connector
Shaft
Valve Assem bly
Valve Assembly
Case
Duct
Housing
Retainer
Duct
Seal
Valve
Shaft Assembly
F-00094
Figure 54—G A/C Heater and Evaporator-Blower Component View
1B-52 AIR CONDITIONING
Figure 55—G Blower Motor Cover (Diesel)
9. Heater distributor duct.
10. Defroster duct to dash panel attaching screws
(below the windshield).
11. Heater hoses (457).
• Plug to prevent spillage.
12. Three nuts from the bolts that hold the heater
core case to the dash panel and one screw at the
lower right corner (inside).
13. Distributor assembly from the vehicle.
14. Gasket to expose the screws attaching the case
sections together.
15. Temperature cable support bracket.
16. Case attaching screws and separate the case.
17. Heater core (457).
Install or Connect (Figure 54)
1. New heater core.
2. Screws and case.
3. Temperature cable support bracket.
4. Gasket.
5. Distributor assembly.
6. Heater core nuts to bolts.
7. Heater hoses.
8. Defroster duct to dash panel screws.
9. Heater distributor duct.
10. Temperature cable and vacuum hoses at the
distributor.
11. Right lower instrument panel support bracket.
12. Right side of the instrument panel.
13. Upper and lower instrument panel screws.
^ 4 9 0 . Instrument Panel
491. Control
492. Screw
492
F-00332
^ ...
Figure 56—Control Assembly - A/C and Heater
14. Radio support bracket screw.
15. Steering column to instrument panel attaching
bolts and raise the column.
16. Engine cover.
17. Battery ground cable.
AIR CONDITIONING
1B-53
491.
495.
496.
497.
Control Assembly
Defroster Duct
Temperature Cable
Heater And Defroster
Assembly
498. Bracket
499. Retainer
F-00324
Figure 57—Temperature Control Cable
I s
*
*
'
K. Orange Double Black
Stripe Wire
491. Control Assembly
495. Defroster Duct
501. Body Wiring Harness
502. A/C Wiring Harness
503. Blower Motor Switch
504. Instrument Panel Harness
505. Ignition
F-00348
Figure 58—Instrument Panel Wiring Harness
1B-54 AIR CONDITIONING
Figure 59—Vacuum Harness Assembly
ORIFICE (EXPANSION TUBE)
REPLACEMENT
The orifice tube is located in the evaporator core
inlet line.
□
Remove or Disconnect (Figure 4)
1. Discharge the system.
2. C o n de n ser to the e vap o ra to r line at the
evaporator inlet.
• Cap or plug the open line.
491. Control
Assembly
493. Blower Motor
Switch
3. Expansion tube from the evaporator core inlet
line.
• Use a needle nose pliers to remove the
orifice from the tube.
4. Expansion tube seal (o-ring) frim the core inlet
line.
♦ a Install or Connect (Figure 4)
0
1. Expansion tube seal (o-ring) to the core inlet line.
• Use a new seal (o-ring) coated with clean
refrigeration oil.
• Insert the short screen end of the orifice into
the evaporator inlet line.
2. Expansion tube to the evaporator core inlet line.
3. C o n de n ser to the e vap o ra to r lin e at the
evaporator inlet.
4. Evacuate, charge and check the system.
BLOWER MOTOR INSULATION
(W/DIESEL) REPLACEMENT
Figure 60—Blower Switch
The 6.2 Liter Diesel Engine has extra insulation
around the blower motor on vehicles without air
conditioning and around the blower motor and
evaporator core with air conditioning option (figure 55).
AIR CONDITIONING
433
418.
433.
435.
497.
497
435
Compressor
Motor
Accumulator/Dehydrator Assembly
Evaporator Blower Motor Assembly
502.
510.
511.
512.
513.
1B-55
A/C Harness
Resistor Assembly
Relay Assembly
Junction Block
Throttle Solenoid
F-00327
Figure 61—A/C W iring - Engine Compartment
im portant
Remove or Disconnect (Figure 55)
1. Parking lamp assembly.
2. Radiator overflow tank.
3. Blower motor insulation (481).
5.
• Insulation through the hood opening.
4. Blower motor (482).
♦ 4-
Install or Connect (Figure 55)
6.
7.
8.
1. Blower motor (482).
2. Insulation (481).
9.
10.
3. Radiator overflow tank.
11.
4. Parking lamp assembly.
12.
13.
EVAPORATOR CORE
(W/DIESEL) REPLACEMENT
Remove or Disconnect (Figures 54 and 55)
1. Cold air intake.
2. Hood latch assembly and cable retainer a. id
place it out of the way.
3. Windshield solvent tank.
4. Discharge the A/C system.
14.
15.
16.
• When removing A/C components, cap the
lin e s
and
o p e n in g s
to
p re ve n t
contamination.
Low pressure vapor line and move it out of the
way.
Accumulator.
High pressure line inlet to the evaporator and the
connecting bracket.
Wiring harness going to the blower motor relay
and resistor.
Blower motor relay and resistor.
Fan shroud upper half.
Radiator.
Heater valve assembly bracket and move it out of
the way.
Upper screws of the lower section.
• Push it down and out of the way.
Insulation mounting screws.
Insulation through the hood opening.
Proceed with the A/C evaporator procedure.
+ 4- Install or Connect (Figures 54 and 55)
1.
2.
3.
4.
A/C evaporator core procedure.
Insulation (481).
Insulation mounting screws.
Lower section.
1B-56 AIR CONDITIONING
525.
526.
527.
528.
529.
530.
Duct Assembly
Screw
Duct Assembly
Washer
Deflector Assembly
Bezel
531.
532.
533.
534.
535.
536.
Screw
Seal
O utlet Assembly
Gasket
Gasket
Duct
537.
538.
539.
540.
541.
542.
Heater Assembly
Support
Outlet Assembly
Screw
Nut
Inlet Assembly
543.
544.
545.
546.
547.
548.
Seal
Duct
Nut
Duct
Duct
Duct
F-00279
Figure 62—A/C O utlets and Ducts
5. Heater valve assembly bracket.
9.
10.
11.
12.
13.
14.
15.
16.
6. Radiator.
7. Fan shroud upper half.
8. Blower motor relay and resistor.
Wiring harness.
High pressure line inlet and bracket.
Accumulator.
Low pressure vapor line.
Charge the A/C system.
Windshield solvent tank.
Hood latch assembly and cable retainer.
Cold air intake.
EVAPORATOR CORE
REPLACEMENT
Remove or Disconnect (Figure 54)
550. Vacuum Tank
551. Hood Assembly
552. Vacuum Line
F-00356
Figure 63—Vacuum Tank Location
1.
2.
3.
4.
Battery ground cable.
Purge the system of refrigerant.
Coolant recovery tank and bracket.
E le ctrica l connectors from the core case
assembly.
AIR CONDITIONING
1B-57
Vacuum
Hood
Vacuum Line
Vacuum Fitting
Cap
F-00328
Figure 64—G - V6 (4.3 Liter) Vacuum Tank Assembly
5. Bracket at the evaporator case.
6. Right marker lamp for access.
7. Accumulator inlet and outlet lines, and the two
brackets that attach the accumulator to the case.
8. Evaporator inlet line.
9. Three (3) nuts and one (1) screw attaching
module to the dash panel.
10. Core case assembly from the vehicle.
11. Screws and separate the case sections.
12. Evaporator core.
♦ 4-
Install or Connect (Figure 54)
6. Accumulator inlet and outlet lines.
7. Two brackets that hold the accumulator to the
case.
8. Right marker lamp.
9. Bracket to the evaporator case.
10. Electrical connectors.
11. Coolant recovery tank and bracket.
12. Evacuate, charge and check the system.
13. Battery ground cable.
BLOWER MOTOR
REPLACEMENT
1. New core.
2.
3.
4.
5.
• Add 90 ml (3 ounces) or 525 viscosity
refrigeration oil to a new condenser.
Screws and the case sections.
Core case assembly to the vehicle.
Module to the dash panel.
Evaporator inlet line.
Remove or Disconnect (Figure 54)
1. Battery ground cable.
2. Coolant recovery tank.
3. Power antenna.
1B-58 AIR CONDITIONING
4. Blower motor lead wire.
5. Motor and wheel assembly (433).
• Five blower motor mounting screws.
• Pry gently on the blower flange if the sealer
acts as an adhesive.
6. Blower wheel to motor shaft nut.
7. Separate the wheel and motor assemblies.
Install or Connect (figure 54)
□
1. Wheel to the blower motor.
• Assemble the blower wheel to the motor
with the open end of the wheel away from
the blower motor.
2. Blower wheel to the motor shaft nut.
3. Blower wheel and motor assembly to the vehicle.
• If the motor mounting flange sealer has
hardened or is not intact, remove the old
sealer and apply a bead of sealer to the
mounting flange.
• Check blower operations: blower wheel
should rotate with no interference.
4. Blower motor lead wire.
5. Coolant recovery tank and power antenna.
6. Battery ground cable.
CONTROL ASSEMBLY
REPLACEMENT
Remove or Disconnect (Figures 56, 57, 58 and
59)
1.
2.
3.
4.
Battery ground cable.
Headlamp switch control knob.
Instrument panel bezel.
Control.
• Screws.
• Temperature cable eyelet clip and retainer
(499).
• Control lower right mounting tab through
dash opening.
• Upper tab.
• Lower right tab.
5. Electrical harness.
6. Vacuum harness (506).
7. Control assembly.
4. Instrument panel bezel.
5. Headlmap switch control knob.
6. Battery ground cable.
TEMPERATURE DOOR
CABLE ADJUSTMENT
J P Adjust (Figure 57)
1. Remove instrument panel compartment and door.
2. Loosen the cable attaching screw at the selector
duct assembly.
• Make sure the cable is installed in the
bracket on the selector duct assembly.
3. Place the temperature lever in full HOT position
and hold while tightening the cable attaching
screw.
4. Install instrument panel compartment and door.
BLOWER SWITCH
REPLACEMENT
Remove or Disconnect (Figure 60)
1. Battery ground cable.
2. Left-foot cooler outlet assembly at the instrument
panel attachment.
3. Electrical harness.
4. Mounting screws.
5. Control assembly (491).
6. Switch (493).
Install or Connect (Figure 60)
1. New switch.
• Mounting screws.
2. Electrical harness.
3. Control Assembly (491).
4. Left-foot cooler outlet assembly.
5. Battery ground cable.
RESISTOR REPLACEMENT
Remove or Disconnect (Figure 61)
Install or Connect (Figures 56, 57, 58 and 59)
1. Electrical and vacuum connection to the control.
2. Control into the opening in the dash panel.
3. Temperature cable.
1. Electrical harness.
2. Resistor mounting screws.
3. Resistor (510).
-►4- install or Connect (Figure 61)
Adjust
• Temperature door operation. Refer to
“ Temperature Door Cable Adjustment.”
1. Resistor (510).
• Screws.
2. Electrical harness.
AIR CONDITIONING
1B-59
502. A/C Wiring Harness
550. Vacuum Tank
552. Vacuum Line
552
^
__ -
C36 And C60
502
Figure 65—G - V8 (5.0 and 5.7 Liter) Vacuum Tank
BLOWER MOTOR RELAY
REPLACEMENT
• Pull the right side of the instrument panel
rearward.
7. Duct (distributor) attaching screws.
8. Center deflector (527).
+ + Remove or Disconnect (Figure 61)
+«- Install or Connect (Figure 62)
1. Electrical harness.
2. Relay mounting screw.
3. Relay (511).
1. Center deflector (527).
2. Instrument panel.
3. Radio support bracket.
Install or Connect (Figure 61)
4. Steering column.
5. Engine cover.
1. Relay (511).
• Screws.
2. Electrical harness.
A/C DUCT WORK
REPLACEMENT
6. Battery ground cable.
DEFROSTER DUCT
REPLACEMENT
To remove the defroster duct mounting, refer to
figure 64.
|+ + | Remove or Disconnect (Figure 62)
1. Battery ground cable.
2. Engine cover.
3. S tee rin g colum n to the in stru m e n t panel
attaching screws.
4. Radio support bracket screw.
TEMPERATURE DOOR
CABLE REPLACEMENT
To remove the temperature door cable, refer to
“ Control Assembly Replacement” and figure 57.
1B-60 AIR CONDITIONING
VACUUM TANK REPLACMENT
|+ + | Remove or Disconnect (Figures 63 and 65)
1.
2.
3.
4.
Raise the hood.
Vacuum harness at the tank (552).
Tank attaching screws.
Tank (551).
[-»+[ Install or Connect (Figures 63 and 65)
1. Tank (551).
2. Vacuum harness.
3. Lower the hood.
VACUUM LINES
ENGINE COMPARTMENT
For vacuum line assemblies, refer to figures:
1. L6 Engine (4.6 Liter) (figure 64).
2. V6 - V8 Engine (4.3, 5.0 and 5.7 Liter) (figure 65).
3. V8 Engine (6.2 Liter, Diesel) (figure 66).
REFRIGERANT-12
HOSE ROUTING
For Refrigerant-12 hose assemblies refer to figures:
1. L6 Engine (4.8 Liter) (figure 67).
2. V8 Engine (5.0 and 5.7 Liters) (figure 68).
3. V8 Engine (6.2 Liter Diesel) (figure 69).
AIR CONDITIONING
Figure 66—G - V8 (6.2 Liter - Diesel) Vacuum Hose Assembly
1B-61
1B-62 AIR CONDITIONING
70. Condenser
97. Refrigerant
Hose
107. Evaporator
and Blower
Assembly
275. Compressor
276. Radiator
70
«------ 276
F-00325
Figure 67-----L6 (4.8 Liter)
Refrigerant Hose Assembly
70.
97.
107.
275.
276.
Condenser
Refrigerant Hose
Evaporator And Blower Assembly
Compressor
Radiator
F-00387
Figure 69—G - V8 (6.2 Liter - Diesel)
Refrigerant Hose
70. Condenser
97. Refrigerant Hose
107. Evaporator and
Blower Assembl
275. Compressor
276. Radiator
F-00386
Figure 68—G - V8 (5.0 and 5.7 Liter)
Refrigerant Hose Assembly
REAR INTERIOR ROOF MOUNTED SYSTEM— G SERIES
This system is used in conjunction with the front
mounted air conditioning system, and is almost identi­
cal to the C-K rear interior roof mounted system. For
servicing, refer to figure 70 for plumbing and figure 71
for unit component view.
AIR CONDITIONING
401.
107.
565.
566.
567.
568.
569.
1B-63
Hose Assembly
Evaporator and Blower Assembly
Rear Evaporator and Blower Assembly
Hose Drain
Hose Outlet
Hose Inlet
Hose and Plate
Assembly
F-00283
Figure 70—G Rear Interior Roof Mounted A/C Hoses and Drain Component View
575.
576.
577.
578.
579.
580.
581.
582.
583.
584.
585.
586.
Screw
Screw
Washer
Pad
Screw
Shroud
Deflector Assembly
Clip
Screw
Seal
Evaporator Assembly
Support
F-00282
Figure 71—G Rear Interior Roof Mounted A/C Evaporator Mounting and Shroud
1B-64 AIR CONDITIONING
CCOT A/C SYSTEM — P SERIES
F-00369
Figure 72—P Truck Condenser Installation
V8 (5.7 Liter) Engine
Figure 73—P Truck Compressor Installation
The compressor and condenser are installed on the
vehicle during assembly. They are removed and
shipped separately.
For reference refer to the following figures:
1. Condenser Mounting - refer to figure 72.
2. Compressor Installation - refer to figure 73.
DASH MOUNTED SYSTEM — MOTOR HOME CHASSIS
This system is installed on the vehicle and checked
at assembly. The blower-evaporator is then discon­
nected and shipped with the chassis unit to the body
supplier. For this reason, it will only be possible to give
basic replacement procedures on some components.
70. Condenser
276. Radiator
277. Bracket
/r < r
CONDENSER REPLACEMENT
I++I Remove or Disconnect (Figure 74)
1. Battery ground cable.
2. Purge the system of refrigerant.
3. Condenser inlet and outlet lines.
• Cap or plug all open connections.
Figure 74—Condenser
4. Condenser to radiator support screws.
5. Condenser (70).
AIR CONDITIONING
900.
901.
902.
903.
1B-65
Retainer
Washer
Glass
Seal
F-00397
Figure 76—Sight Glass Replacement
|+ + | Install or Connect (Figure 75)
1. Bracket and receiver-dehydrator.
2. Screws.
3. Inlet and outlet lines at the receiver-dehydrator.
• Use new seals (o-rings) coated with clean
re frig e ra tio n oil when c o n n e c tin g all
refrigerant lines.
0 Install or Connect (Figure 74)
4. Evacuate, charge and check the system.
1. Condenser.
2. Screws.
SIGHT GLASS
REPLACEMENT
3. Condenser inlet and outlet lines.
• Add 30 ml (1 ounce) of clean refrigeration oil
to new condenser.
• Use new seals (o-rings) coated with clean
refrigeration oil when connecting refrigerant
lines.
4. Evacuate, charge and check the system.
If the sight glass is damaged, install a new sight
glass kit. The kit contains the sight glass, seal and
retainer.
|+ + | Remove or Disconnect (Figure 76)
1. Purge the system.
RECEIVER-DEHYDRATOR
REPLACEMENT
|+ + | Remove or Disconnect (Figure 75)
1. Battery ground cable.
2. Purge the system of refrigerant.
3. Inlet and outlet lines at the receiver-dehydrator.
• Cap or plug the open lines.
4. Receiver-dehydrator bracket attaching screws.
5. Bracket and receiver-dehydrator (65).
2. Sight glass retainer nut using a screwdriver (900).
3. Old glass and seal (o-ring) (902 and 903).
♦«- Install or Connect (Figure 76)
1. New glass and seal and retainer nut.
9
Important
• Do not turn the nut past the face of the
housing. This may damage the seal (o-ring).
2. Evacuate, charge and check the system.
1B-66 AIR CONDITIONING
Hose Assem blies
Evaporator Assembly
Motor Blower Assembly
A/C W iring Harness
F-00398
Figure 77—Blower - Evaporator Assembly
BLOWER-EVAPORATOR
ASSEMBLY REPLACEMENT
□
Remove or Disconnect (Figures 77 and 78)
1. Battery ground cable.
2. Purge system of refrigerant.
3. Inlet and outlet refrigerant lines.
• Cap or plug all open connections (401).
4. Drain tube from evaporator case.
5. Electrical connector from the compressor.
6. Terminal (910).
— Allow connector to hang on the ground wire.
7. Screws securing the grommet retainer to the
dash panel.
8. Wire from the grommet through the slit.
9. Electrical lead at the connector.
P. Correct Blower Blade Angle
F-0040Q
Figure 79—Blower Assembly
10. Unit mounting bolts.
11. Unit from the vehicle carefully pulling the
compressor electrical lead through the dash.
-►*- Install or Connect (Figures 77 and 78)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Unit to the vehicle.
Mounting bolts.
Electrical lead to the connector.
Wire from grommet through the slit.
Screws that secure the grommet retainer to the
dash.
Terminal.
Ground wire.
Electrical connector from the compressor.
Drain tube.
Refrigerant lines.
Battery ground cable.
Evacuate, charge and check the system.
BLOWER ASSEMBLY
REPLACEMENT
Remove or Disconnect (Figure 79)
1. Cover plate.
• Separate the upper and lower case halves.
2. Blower motor mounting strap screw.
3. Blower assembly.
4. Wheels from the motor shaft.
(Narrow Blade)
911. Terminal
913. Tang
914. Groove
A. Insert screwdriver in groove and press tang
toward terminal to release.
B. Pry tang back out to insure locking when
reinstalled into connector.
F-00399
Figure 78—Terminal Removal
Install or Connect (Figure 79)
1. Wheels to the motor shaft.
• Place the wheels with the lower blades
curved toward the dash panel side of the
unit when the motor is placed in the case
(P).
2. Mounting strap.
AIR CONDITIONING
920
922
922
923
920. Thermostatic Switch 922. Bumper
Capillary Tube
923. Expansion Valve
921. Screen Mesh
p 0041Q
Figure 80—Therm ostatic and Blower Switches
• Place the motor in the bracket with the
electrical connector side of the motor to the
right side of the bracket.
• Align the blower wheels so they do not
touch the case.
3. Assemble the case halves and attach the cover
plate.
EXPANSION VALVE,
EVAPORATOR AND/OR
EVAPORATOR CASE
REPLACEMENT
Remove or Disconnect (Figure 80)
1. Cover plate.
• Separate the upper and lower case halves.
2. Inlet and outlet lines from the expansion valve
(923).
3. Sensing bulb from the evaporator outlet manifold.
• Cap or plug open connections.
5. Core.
6. Blower motor and harness assembly.
Install or Connect (Figure 80)
1.
2.
3.
4.
5.
Blower motor and harness assembly.
Core.
Expansion valve (923).
Sensing bulb.
Inlet and outlet lines.
• Use new seals (o-rings) coated with clean
refrigeration oil when connecting lines.
• Add 90 ml (3 ounces) of new refrigeration oil
to a new core.
920.
922.
923.
924.
1B-67
924
923
Thermostatic Switch Capillary Tube
Bumper
Blower Switch
Thermostatic Switch
F-00411
Figure 81—Therm ostatic and Blower Switches
THERMOSTATIC AND/OR
BLOWER SWITCHES
REPLACEMENT
Remove or Disconnect (Figure 81)
1. Cover plate assembly from the evaporator case.
2. Switch (923 or 924).
Install or Connect (Figure 81)
1. Switch (923 or 924).
• Place the sensing capillary in the same
position before it was removed.
2. Cover plate.
BLOWER MOTOR
RESISTOR REPLACEMENT
The resistor is located on the top of the unit. Remove
the unit to replace.
FUSE REPLACEMENT
This unit does not have an in-line fuse. The lead wire
is connected to the heater wiring harness and operates
off the 20 amp heater fuse.
1B-68 AIR CONDITIONING
SPECIFICATIONS
A-6 COMPRESSOR
Type............................................................................................................................................................. .6 Cylinder Axial
Displacement.......................................................................................................................................................12.6 Cu. In.
Rotation................................................................................................................................................................... Clockwise
SYSTEM CAPACITIES
R efrigerant................................................................................................................... 1 587 6 kg (3 lbs. 8 ounces)
525 Viscosity Compressor O i l ............ ..................................................................................... 330 ml (11 ounces)
TORQUE SPECIFICATIONS
Compressor Suction and Discharge Connector B o lt .....................................................................24 N m (18 ft. Ib.s)
Oil Drain Screw ....................................................................................................................................17 N m (13 ft. lbs.)
Cycling Pressure S w itc h ................................................................................................................... 10 N m (7.5 ft. lbs.)
All Compressor Mounting B olts........................................................................................................ 34 N m (25 ft. lbs.)
DA-6 COMPRESSOR
Type............................................................................................................................................................... 6 Cylinder Axial
Displacement.......................................................................................................................................................10.0 Cu. In.
Rotation................................................................................................................................................................... Clockwise
SYSTEM CAPACITIES
Refrigerant....................................................................................................................... 1 587 kg (3 lbs. 8 ounces)
525 Viscosity Compressor O il.................................................................................................... 240 ml (8 ounces)
TORQUE SPECIFICATIONS
Compressor Suction and Discharge Connector B o lt.....................................................................24 N m (18 ft. lbs.)
Shaft N u t.............................................................................................................................................. 16 N m (12 ft. lbs.)
Cycling Pressure Switch . ...............................................................................................................10 N m (7.5 ft. lbs.)
Front Compressor Mounting Bolts.................................................................................................... 43 N m (32 ft. lbs.)
Rear Compressor Mounting B olts....................................................................... .............................30 N m (22 ft. lbs.)
R-4 COMPRESSOR
Type.............................................................................................................................................................4 Cylinder Radial
Displacem ent...................................................................................................................................................... 10.0 Cu. In.
Rotation................................................................................................................................................................... Clockwise
SYSTEM CAPACITIES
R efrigerant................................................................................................................... 1 587 6 kg (3 lbs. 8 ounces)
525 Viscosity Compressor O i l .................................................................................................. 330 ml (11 ounces)
TORQUE SPECIFICATIONS
Compressor Suction and Discharge Connector B o lt .....................................................................24 N m (18 ft. Ib.s)
Oil Drain Screw....................................................................................................................................17 N m (13 ft. lbs.)
Cycling Pressure S w itc h ................................................................................................................... 10 N m (7.5 ft. lbs.)
All Compressor Mounting B olts........................................................................................................ 34 N m (25 ft. lbs.)
AIR CONDITIONING 1B-69
SPECIFICATIONS (CONT.)
Blower Motor
C-K All Weather
C-K-G Rear Interior Roof Mounted
G Floor and Motor Home Units
Volts
Amps
(Cold)
RPM
(Cold)
12.0
12.8 Maximum
3400 Minimum
12.0
13.7 Maximum
3400 Minimum
Compressor Clutch Coil
Ohms (at 80° F ) ............................................................................................................................................................... 3.70
Amps (at 80° F ).............................................................................................................................................3.33 @ 12 Volts
Belt Tension.............................................................................................................................................See Tune-Up Chart
Fuse Block
C-K System s......................................................................................................................................................... 25 Amps
Motor Home Chassis U n it .................................................................................................................................. 20 Amps
In Line
C-K System s............................................................................................ <>.......................................................... 25 Amps
Motor Home Chassis U n it........................................................................................................................................ None
Circuit Breaker
G Systems............................................................................................................................................................. 45 Amps
SPECIAL TOOL LIST
J-5420...........................................................................................................................................Across Valve Quick Fitting
J-5725-04 .........................................................................................................................................Mainifold and Gage Set
J-6084............................................................................................................................................................... Leak Detector
J-6271-01 ..........................................................................................................................Refrigerant Can “ Taps-AII” Valve
J-6272-02 .................................................................................................................................. Multi-Can Dispensing Valve
J-9459 .........................................................................................................................................Access Valve Quick Fitting
J-23390 ..................................................................................................................... 12 Lb. Disposable Can Control Valve
J-23500-01 ..................................................................... Portable Air Conditioning Evacuation and Recharging Station
J-23600 ..................................................................................................................................................... Belt Tension Gage
2A-1
SECTION 2
FRAME AND CHASSIS SHEET METAL
CONTENTS
SUBJECT
PAGE
F ra m e ............................................................................................................................................................................. 2A-1
B u m p e rs .........................................................................................................................................................................2B-1
Sheet M etal.....................................................................................................................................................................2C-1
SECTION 2A
FRAME
CONTENTS
SUBJECT
PAGE
C/K And P Model F ra m e s ...........................................................................................................................................2A-1
D e s c rip tio n ................................................................................................................................................................ 2A-1
Diagnosis Of The F ra m e .............................................................................................................................................2A -2
Minim izing Frame S e rv ic e ...................................................................................................................................... 2A -3
Checking Frame A lig n m e n t.................................................................................................................................... 2A -4
Straightening Fram es............................................................................................................................................... 2A -5
Repairing C ra c k s ..................................................................................................................................................... 2A-5
W e ld in g .......................................................................................................................................................................2A -6
G Model U nderbody......................................................................................................................................................2A -7
D e s c rip tio n ................................................................................................................................................................ 2A -7
Underbody A lig n m e n t.............................................................................................................................................2A -7
C/K AND P MODEL FRAMES
DESCRIPTION
The models covered under this part of the section
include C/K, and P. The service information for the G
model will be found in the underbody portion of this
section.
Proper frame alignment is important to assure
normal life and functioning of many other parts of the
vehicle. If the vehicle has been involved in a fire,
collision, or has been overloaded, there is cause to
check the frame alignment. If, for any other reason,
alignm ent is suspected it should be checked. A
procedure for this is described later in this section
under “ Checking Frame Alignment.”
It is possible that certain conditions make the frame
appear to be out of alignment when, in fact, it is not.
These conditions are also described under “ Checking
Frame Alignment.”
Terms used later in this section are briefly defined
below:
1. SECTION MODULUS—This is a measure of the
strength of a frame, based on height, width,
thickness and shape of the side rails. It does not
account for the strength of the material used in
the frame.
2. YIELD STRENGTH—This is a measure of the
strength of the material from which the frame is
made. It is the maximum load [kPa (psi)] that can
be placed on a material and still have it return to
its original shape.
3. RESISTANCE TO B EN D IN G
M O M ENT
(RBM)—This is a single measure of frame
strength that accounts for both the section
modulus and the strength of the material used. (It
is the product of section modulus and yield
strength.)
4. SAG—This refers to a frame or side rail that is
bent down from where it should be.
5. BUCKLE—This refers to a frame or side rail that
is bent up from where it should be.
2A-2 FRAME
6. DIAMOND—This refers to the condition where
one entire frame rail is moved forward from, or to
the rear of, its correct alignment with the other
rail.
7. TWIST—This refers to the condition where the
entire frame has been twisted. One rail will
basically slope up while the other rail will
basically slope down. ,vnc
8. SIDESWAY—This refers to a side rail that is bent
to the side of where it should be.
9. TRACKING—This refers to the alignment of the
vehicle axles with each other. A misaligned frame
can cause improper tracking. If the vehicle is
tracking correctly, all axles will be parallel to each
other and perpendicular to the center line of
frame.
10. WEB—The vertical part of a channel-type frame
rail.
DIAGNOSIS OF THE FRAME
POSSIBLE CAUSE
CORRECTION
Sag
1. Loads greater than the frame is de­
signed to carry.
2. Uneven load distribution.
3. Abrupt changes in section modulus.
(For a brief definition of section modu­
lus, see the “ Description” at the begin­
ning of this section.
4. Improper body, or accessory, mount­
ing:
— Holes drilled in the flange of the frame
rail.
— Too many holes in the web section of
the rail.
— Holes in the web section which are too
close to each other.
— Four or more holes in the same vertical
line of the rail web.
— Welds on the flange, p a rticu la rly
across the flange or along its edge.
— Cutting holes in the rail with a torch.
— Cutting notches anywhere on the rails.
5. A fire involving the vehicle.
6. A collision involving the vehicle.
7. The use of equipment for which the
frame has not been designed or rein­
forced.
1-7. Straighten and reinforce the frame as
described later in this section. See
“ Straightening Frames” and “ Rein­
forcements.”
Buckle
1. The use of equipmient such as snow
plows for which the frame was not de­
signed.
2. A collision involving the vehicle.
3. A fire involving the vehicle.
4. In addition to these causes, refer to
possible causes 3 and 4 under “ Sag.”
These may contribute to “ Buckle.”
1-4. Straighten and reinforce the frame as
described later in this section. See
“ Straightening Frames” and “ Rein­
forcements.”
PROBLEM
FRAME 2A-3
DIAGNOSIS OF THE FRAME (CONT.)
PROBLEM
POSSIBLE CAUSE
CORRECTION
Sidesway
1. A collision involving the vehicle.
2. A fire involving the vehicle.
3. The use of equipment such as snow
plows for which the frame was neither
designed nor properly reinforced.
4. In addition to these causes, refer to
possible causes 3 and 4 under “ Sag.”
These may be contributing factors.
1-4. Straighten and reinforce the frame as
described later in this section. See
“ Straightening Frames” and “ Rein­
forcements.”
Diamond
1. A collision involving the vehicle.
2. Towing another vehicle with a chain at­
tached to one corner of the frame.
1-2. Straighten and reinforce the frame as
described later in this section. See
“ Straightening Frames” and “ Rein­
forcements.”
Twist
1. An accident or collision involving the
vehicle.
2. Operating the vehicle in very rough ter­
rain.
1-2. Straighten and reinforce the frame as
described later in this section. See
“ Straightening Frames” and “ Rein­
forcements.”
Improper Tracking
1. Frame is out of alignment.
2. Front or rear axle has shifted.
3. Incorrect wheel alignment may make
the vehicle appear to be tracking incor­
rectly.
Cracks In The Web
Of The Rails
1. Loose crossmember attaching bolts.
2. Concentration of stress that may result
from many different factors. (See
“ Sag” under “ Diagnosis” previously
described in this chart. Also see
“ M inim izing Frame Damage” and
“ Reinforcements” (later in this sec­
tion.)
MINIMIZING FRAME SERVICE
Generally, frame service can be minimized or
eliminated by minimizing the concentration of stress in
small areas of the frame.
1. Vehicles should be used only for those purposes
for which they were designed.
• They should not be overloaded.
• They should be loaded evenly; localized
loads should be avoided.
• Do not operate the vehicle on extremely
rough terrain.
1. Straighten and reinforce the frame as
described later in this section.
2. Realign and secure the axle.
3. Align the wheels. Refer to FRONT
END ALIGNMENT (SEC. 3A) of this
manual.
1. Replace, or weld and reinforce rail.
Ream bolt holes and replace with
larger bolts if necessary. Retighten
bolts.
2. Replace, or weld and reinforce the
rail. See the appropriate heading,
later in this section.
• Take into account the forces that will be
placed on a frame from the operation of
equipm ent such as snow plows when
picking a fram e for a new vehicle or
reinforcing a frame.
2. Follow recommended practices when repairing a
frame or when mounting a body or equipment on
a frame.
• Avoid sudden changes in the section
modulus.
• Do not drill holes in the frame rail flanges.
• Space holes in the web section of a rail at
least 13 mm (1/2 -inch) from one another.
• Use existing holes whenever possible.
2A-4 FRAME
Figure 1—C/K And P Model Frames
•
•
•
•
Do not cut holes with a torch.
Do not overheat the frame rails.
Avoid welding on the flanges.
Do not allow four or more holes to exist on
the same vertical line of the web.
• Holes made in a reinforcement should be
placed a distance of at least two times the
material thickness from the edge of the
reinforcement.
CHECKING FRAME ALIGNMENT
The main parts of a frame are the side rails and
crossmembers. The rails carry the load and the
crossmembers stabilize the rails.
Types of frame misalignment can be divided into five
groups. The five groups are sag, buckle, diamond,
sidesways, and twist. For a brief definition of these
terms, refer to “ Description” at the beginning of this
section.
A misaligned frame rail may have moved forward
from, up or down from, or to the side of where it should
be. These possibilities must be checked.
The easiest way to check frame alignment is with
gages made for this purpose. Detailed instructions are
normally supplied with gages at the time of purchase.
Therefore, instructions for gage use are not given in
this manual.
It is possible to check certain portions of frame
alignment without the proper gages. The procedure is
described later in this section.
Whether alignment is checked with or without gages,
the vehicle must be parked on a level section of floor.
Certain conditions call for preliminary checks before
actually checking the frame. Suspension or axle
problems may make it appear that the vehicle frame is
out of alignment. If an axle has shifted, “ Diamond” or
“ Sidesway” may appear to exist when, in fact, they do
not. A weak spring may make the vehicle appear to
have a twisted frame.
A visual inspection of the top and bottom flanges of
each rail may reveal the specific area where sag or
buckle exists. In the case of sag, wrinkles may appear
on the top of the upper flange; such wrinkles are
definite evidence of sag. Wrinkles on the bottom of the
lower flange are definite evidence of buckle
DETERMINING THE FRAME CENTERLINE (Figure 1)
1. Move the vehicle to a level, well-lighted section of
the floor.
2. Make a diagram of the frame on the floor beneath
the vehicle as follows:
a. Using a plumb bob, transfer points 1, 2, 11,
12 from the inside of the web to the floor.
Mark the points (figure 1).
FRAME 2A-5
3.
4.
5.
6.
7.
b. Using a plumb bob, transfer the remaining
points from the outside of the web to the
floor. Mark the points. The actual placement
of these points is not so important as is the
fact that the points must be taken from the
same place on both the right and left frame
rail.
Move the vehicle away from the points on the
floor.
Measure the distance between points 1 and 2.
This distance should be 704.85 mm (27.75-inch)
for the standard front axle, and 847.25 mm
(33.75-inch) if equipped with a 5000# I-Beam
Front Axle.
Measure the distance between points 11 and 12.
This distance should be 847.25 mm (33.75-inch).
If both the measurements in steps 4 and 5 were
c o rre c t, c o n tin u e the p ro ce d u re . If the
m e a su re m e n ts are not c o rre c t, re fe r to
“ H orizontal C h e ck” step 2, and mark the
centerline through the intersection of two sets of
diagonals that have equal measurements.
Make a mark on the floor exactly halfway
between points 1 and 2. Make a similar mark
between points 11 and 12.
Use a chalk line to mark a line through the points.
This is the centerline of the frame.
HORIZONTAL CHECK
1. Measure the distance between the frame rails,
and the centerline at points 3-10. Each pair of
co rre sp o n d in g points should be an equal
distance from the ce nte rlin e w ithin 3 mm
('/s-inch ). Example: Points 3 and 4 should
measure equally from the centerline as should
points 5 and 6, 7 and 8, and points 9 and 10.
2. Measure diagonally from point 1 to point 6, and
from point 2 to point 5. Mark the floor where the
diagonals pass the centerline. The diagonals
should measure the same distance within 5 mm
(3/ie-inch), and should cross at the centerline. If
the frame is within specifications, the frame
within these points is properly aligned.
3. Repeat step 2 on other pairs of diagonals until
the entire frame has been checked. Example:
Point 3 to point 10 and point 4 to point 9 or point 5
to point 12 and point 6 to point 11, etc.
4. Refer to “ Straightening Frames” to repair any
damage that is found.
STRAIGHTENING FRAMES
Frame straightening can be complicated and usually
requires special equipment. It should be attempted by
competent personnel only.
A complete analysis of the condition of the frame
should be made before any steps are taken to
straighten it. Analyzing the cause of failure will help
determine the correct sequence of steps in the repair.
(See “ Possible Causes” under “ Diagnosis” and
“ Minimizing Frame Service” previously outlined in this
section.) Corrective procedures should be set up to
reverse the flow of the damaging forces. In many
instances, to reverse the flow of forces, pressure must
be applied from different directions at the same time.
Careful use of controlled heat is important. Too much
or too little heat, or the improper application of heat, is
a major source of trouble. Frame heating should be
done with a large sized tip (multi-hole heating tip) and
a neutral flame should be used (oxygen adjust opened
just enough to remove the feathers or stringers from
the blue center at tip of torch). Heat the area that will
be stretched as frame is straightened. Heat the area
AFTER S U F F IC IE N T PRESSUR E HAS BEEN
EXERTED to cause a slight checking, or silvery cracks,
to appear on the surface of the metal. Gradually
increase the pressure while heating. Do not heat
beyond 606°C (1200°F). A red glow indicates that the
m aterial is overheated. O verheating w ill cause
distortion and stretching, as well as a change in the
characteristics of the metal.
REPAIRING CRACKS
Two common types of cracks are shown in figure 2.
The straight crack will normally start from the edge of a
flange. It will go across the flange and through the web
section of a rail. Finally, it will continue through the
other flange. This type of crack may result from high
concentrations of stress in small areas of the frame,
excessive bending moment, and torsional loading.
(See “ Minimizing Frame Service,” previously outlined
in this section).
Sunburst crack(s) will radiate out from a hole in the
web section of a rail or crossmember. They are caused
by high loads being applied at a mounting bracket or
crossm em ber which is not securely or properly
attached to the rail.
If cracks occur to both the rail and reinforcement at a
particular area of the frame, they must be repaired
separately. The flanges must react independently to
prevent localized stress concentration. Use a copper
spacer between the flanges of cracked base rail
flanges and reinforcement flanges.
Crossmember mounting flange cracks may be
repaired in the same manner as side rail cracks.
However, weld bead should be built up to provide a
good smooth radius. If a crossmember is greatly
damaged it should be replaced.
It may be necessary to align the frame and level the
rails before repairing the frame.
1. Remove any equipment that will interfere with
access to the crack.
2. Locate the extreme end of the crack and drill a 6
mm (0.25-inch) hole.
2A-6 FRAME
Over-welding can be harmful, especially if it is in an
area of the frame that receives high concentrations of
stress.
Small cracks in a crossmember may be welded (see
“ Repairing Cracks” previously outlined in this section).
13. Straight Crack
14. Sunburst Cracks
B-09088
Figure 2—Types Of Frame Cracks
3. “ V” grind the entire length of the crack from the
starting point to the 6 mm (0.25-inch) hole at the
extreme end.
4. The bottom of the crack should be opened up 2
mm (1/ie-inch) to allow good penetration of the
weld. (A hack-saw blade may be used for this).
5. Weld with proper electrode and proper welding
techniques. See “ Welding” outlined later in this
section for tips on welding.
6. Grind the weld smooth on both the inside and the
outside of the rail or crossmember. Be extremely
careful to eliminate weld build-up or notches on
the edge of the flange.
WELDING
Improper welding techniques are the cause of many
weld and/or frame failures. The following information
points out potential areas of difficulty and provides
some general guidelines for successful frame welding.
Most weld failures occur at the end of the weld in
areas of the frame that are under high stress. By
elim inating the ends of a weld, failures can be
reduced; this can be done by making a hole or slot in
the part to be attached and then using a fillet weld
around a slot or plug weld. Do not leave a notch at the
end of a weld.
When welding:
1. Do not use oxyacetylene welding equipment.
2. W henever possible, use sm a lle r diam eter
electrodes and make several passes; this is
preferred to using a large diameter electrode and
making fewer passes.
3. Do not use more heat than is necessary to give
good penetration.
4. Do not run more passes than necessary.
5. Make sure the weld is free from craters and
undercuts.
6. Make sure sca le is rem oved from each
successive pass.
7. If repairing a crack, grind the surface of the weld
flush with the parent material.
8. When mounting accessories, do not weld across
the flanges.
9. When mounting accessories, do not weld within
19 mm (3/4-inch) of a flange.
10. Do not weld up to the edge of a part being welded
to a frame. Leave 6 mm (0.25-inch) between the
end of the weld and the edge of the part.
11. Do not weld cast brackets to the frame.
12. Do not weld the fla n g e s of cracked
reinforcements and base rails together.
13. Connect the welding machine ground cables as
close to the working area as possible.
14. Avoid direct contact between the welding cables
and any part of the vehicle.
15. Do not get the welding cables near the vehicle
wiring.
FRAME 2A-7
G MODEL UNDERBODY
15.
16.
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
K.
Front Gage Holes
Rear Gage Holes
789.4 mm (31.08-inch)
1041.4 mm (41.0-inch)
1340 mm (52.76-inch)
1041.4 mm (41.0-inch)
126 mm (4.96-inch)
123 mm (4.8-inch)
L.
113.3 mm (4.46-inch)
13 mm (0.51-inch)
M.
96 mm (3.78-inch)
145.2 mm (5.72-inch) N.
701 mm (27.6-inch)
1465 mm (57.66-inch) 110-inch wheelbase
1845 mm (72.66-inch) 125-inch wheelbase
2772 mm (109.17-inch) 110-inch wheelbase
3153 mm (124.17-inch) 125-inch wheelbase
2833 mm (111.54-inch) 110-inch wheelbase
3442 mm (135.54-inch) 125-inch wheelbase
B-09120
Figure 3—G Model Underbody
DESCRIPTION
The G Model incorporates a unitized body design
comprised of side rails, cross sills, and outriggers
which are all part of the welded underbody.
A misaligned underbody can affect the opeartion of
many ve hicle com ponents. It is e ssen tia l that
underbody alignm ent be exact to within 1.6 mm
(1/i e-inch).
UNDERBODY ALIGNMENT
To determine the alignment of the underbody it is
necessary to use a good quality traming gage. This
gage must be capable of measuring all points of the
underbody up to three quarters of the body length.
Following the instructions given by the manufacturer
of your gage, measure the horizontal and vertical
p o in ts as show n in fig u re 3. C o m pare each
measurement with the specifications given in the
figure to determine the damaged areas and the extend
of the damage. When repairing the underbody it will be
necessary to return the underbody to these original
specifications within 1.6 mm (1/ie-inch).
Many different types and brands of unibody repair
equipment are available; each system may be slightly
different. A multiple pull system is most desirable in
order to correct the damage in the same direction in
which it was created. When making multiple pulls use
the last in, first out procedure. This means that you
correct the damage in the reverse sequence by which
it was created. It is also important to correct the
damage in the opposite direction in which the damage
was created.
BUMPERS 2B-1
SECTION 2B
BUMPERS
CONTENTS
SUBJECT
PAGE
C/K Model B um pers................................................................................................................................................... 2B - 1
Front Bumper Replacement..................................................................................................................................2B - 1
Rear Bumper Replacement (U tility Vehicle and S u b u rb a n )......................................................................... 2B- 4
Rear Bumper Replacement (Regular Cab, Bonus Cab, and Crew C a b ) ....................................................2B- 6
Rear Step Bumper Replacem ent......................................................................................................................... 2B- 7
Rear Bumper License Plate Bracket R eplacem ent.........................................................................................2B- 7
Dead Weight Trailer Hitch Replacement (U tility Vehicle and S u b u rb a n )..................................................2B- 8
Weight D istribution Hitch Replacement (Suburban O n ly ) ............................................................................2B-10
Weight D istribution Hitch Replacement (U tility Vehicle O nly)..................................................................... 2B-10
P Model Bum pers....................................................................................................................................................... 2B-12
Front Bumper Replacement..................................................................................................................................2B-12
Front Bumper Replacement (With RPO FS3 Front A x le ) ..............................................................................2B-12
G Model B u m p e rs ..................................................................................................................................................... 2B-14
Front Bumper Replacement............................................................. ................................................................. 2B-14
Rear Bumper R e placem ent..................................................................................................................................2B-15
Rear License Plate Bracket R e p lace m e n t........................................................................................................2B-16
Dead Weight Trailer Hitch R e p lace m e n t..........................................................................................................2B-16
Weight D istribution Hitch Replacem ent............................................................................................................ 2B-17
C/K MODEL BUMPERS
FRONT BUMPER
REPLACEMENT
Remove or Disconnect
□
1.
2.
3.
4.
5.
Brace to bumper nuts (2) (figure 1).
Bracket to bumper nuts (3).
Bumper from the vehicle.
Guard assemblies (where used) (figure 2).
Rub strips from the bumper and guards (where
used) (figure 3).
• From the rear of the bumper, press the
tangs of the rub strip together, and push the
strip from the bumper and/or guard.
6. Bumper bolts (6 and/or 8).
7. Brace bolts and washers (17 and 18) (figure 4)
from the inside of the frame rail.
• Braces (4).
8. Bracket bolts, washers, and nuts (16, 15 and 14)
from the frame.
9. Tow hooks (20) (where used).
10. Brackets (5).
Install or Connect (Figures 1-4)
1. Brackets and tow hooks (where used) to the
frame rails.
• On vehicles without tow hooks, install the
bolts and washers through the brackets and
through the outside of the frame rail.
• On vehicles with tow hooks, install the tow
hook bolts and washers from inside the
frame rail, then through the brackets and
the tow hooks. Install the top bracket bolts
and washers through the bracket, and into
the top rail flange.
2. Washers and nuts to the bolts.
2B-2 BUMPERS
Tighten
• Nuts to 95 N m (70 ft. lbs.).
a
Tighten
• Bolts to 50 N m (37 ft. lbs.).
4. Bumper bolts (6) onto the bumper.
3. Brace bolts and washers (17 and 18) through the
frame rails and into the braces.
5. Rub strips to the bumper and guards (where
used).
• Place the tangs of the strips onto the slots in
the bumper or guard. Using a rubber mallet,
set the tangs in place starting at the center
of the strip, and working toward each end.
6. Guard assemblies (where used).
7. Bumper to the vehicle.
• Install the bumper with bolts through the
right and left braces, and brackets.
8. Bracket to bumper nuts (3).
Figure 3—C/K Front Bumper Rub Strip
BUMPERS 2B-3
4.
5.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
A.
B.
Brace
Bracket
Bolt
Washer
Nut
Nut
Washer
Bolt
Bolt
Washer
Washer
Tow Hook
Frame
Weld Nut
16
F-00131
Figure 4—C/K Front Bumper Brackets, Braces, and Tow Hooks
2B-4 BUMPERS
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
Nut
Brace
Bracket
Nut
Washer
Nut
Nut
Washer
Bolt
Bolt
Bumper Bar
Bolt
F-00132
Figure 5—U tility Vehicle and Suburban Rear Bumper Components
$
Tighten
• Nuts to 90 N m (66 ft. lbs.).
9. Brace to bumper nuts (2).
Q
Tighten
• Nuts to 90 N m (66 ft. lbs.).
REAR BUMPER REPLACEMENT
(UTILITY VEHICLE AND
SUBURBAN)
+ + Remove or Disconnect (Figure 5)
1.
2.
3.
4.
Brace to bumper nuts (21).
Bracket to bumper nuts (24).
Rear bumper.
Filler panel bolts (figures 6 and 7).
• Filler panel.
5. Rub strips from the bumper (where used) (figure
8).
• From the rear of the bumper, press the
tangs of the bump strip together, and push
the strip from the bumper.
6. Bumper bolts (32).
7. Brace nuts, washers, and bolts (26, 25 and 30).
• Braces (22).
8. Bracket nuts, washers, and bolts (27, 28 and 29).
• Brackets (22).
Install or Connect (Figures 5-8)
1. Brackets to the frame rails (22).
• Bracket bolts, washers, and nuts (29, 28 and
27).
Tighten
• Nuts to 95 N m (70 ft. lbs.).
Braces to the frame rails (22).
• Brace bolts, washers, and nuts (30, 25 and
26).
&
Tighten
• Nuts to 95 N m (70 ft. lbs.).
3. Bumper bolts to the bumper (32).
4. Rub strips to the bumper (where used).
• Place the tangs of the strips onto the slots in
the bumper guard. Using a rubber mallet,
set the tangs in place starting at the center
of the strip, working toward each end.
5. Filler panel supports (Utility vehicle only) (figure
6 ).
BUMPERS 2B-S
31.
33.
34.
35.
36.
37.
38.
Bumper Bar
Bar
“ U” Nut
Nut & Washer
Support
Bolt
Filler Panel
37
F-00133
Figure 6—Rear Bumper Fiiler Strip
• Place the filler panel bolts through the panel
and into the support “ U” nuts.
Tighten
• Bolts to 2.8 N m (25 in. lbs.).
a
Tighten
• Bolts to 10 N m (89 in. lbs.).
6. Filler panel (Suburban only) (figure 7).
• Bolts through the filler panel, and into the
platform.
Figure 7—Rear Bumper Center Filler
7. Bumper to the vehicle.
• Install the bumper bolts (32) into the braces,
and brackets.
8. Filler Panel (Utility vehicles only).
Figure 8—Rear Bumper Rub Strip
2B-6 BUMPERS
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
Brace
Nut
Spring Washer
Washer
Bracket
Washer
Spring Washer
Nut
Nut
Nut
Spring Washer
Bolt
Bolt
Bumper Bar
Bolt
F-00128
Figure 9—Regular Cab, Bonus Cab, and Crew Cab Rear Bumper Components
• Place the filler panel behind the bumper,
and place the supports onto the bumper
bolts behind the braces.
9. Filler panel bracket bolts (Utility vehicle only).
Tighten
• Bolts to 10 N-m (89 in. lbs.).
10. Bracket nuts (24).
$
2. Bracket nuts (49), spring washers (48), and
washers at the bumper.
3. Rear bumper from the vehicle.
4. Bumper bolts (56).
5. Gravel deflector nuts (59) and bolts (57) (where
used) (figure 10).
• Gravel deflectors (58).
6. Brace to frame nuts (50), spring washers (52),
and bolts (54).
Tighten
• Nuts to 41 N-m (30 ft. lbs.).
11. Brace nuts (21).
• Braces (42).
7. Bracket to frame rail nuts (51), spring washers
(52) and bolts (53).
• Brackets (46).
Tighten
-n - Install or Connect
• Nuts to 41 N-m (30 ft. lbs.).
1. Brackets to the frame rails.
REAR BUMPER REPLACEMENT
(REGULAR CAB, BONUS CAB,
AND CREW CAB)
Remove or Disconnect (Figure 9)
• Bolts (53), spring washers (52), and nuts
(51).
&
Tighten
• Nuts to 95 N-m (70 ft. lbs.).
2. Braces to the frame rails.
1. Brace nuts (43), spring washers (44), and
washers (45) at the bumper.
• Bolts (54), spring washers (52), and nuts
(50).
BUMPERS 2B-7
REAR STEP BUMPER
REPLACEMENT
+ + Remove or Disconnect (Figure 11)
1. Bracket to bumper nuts (63), and bolts (64).
2. Brace to bumper nuts (73), spring washers (72),
washers (71), and bumper bolts.
3. Bumper from the vehicle.
4. Brace to frame nuts (60) and bolts (62).
• Braces (70).
5. Bracket reinforcement nuts (68) and bolts (61)
(and washers (67) where used).
• Bracket reinforcements (66).
6. Bracket to frame nuts (60), and bolts (62).
• Brackets (65).
+ 4- Install or Connect (Figure 11)
1. Brackets (65) and braces (70) to the frame.
• Bolts (62) and nuts (60) loosely.
2. Bracket reinforcements (66).
• The reinforcements are marked as right or
left on their inboard sides.
• Bolts (61) and nuts (68), and washers (67)
(where used).
$
Tighten
• Nuts to 95 N m (70 ft. lbs.).
3. Gravel deflectors (where used).
• Nuts (59) and bolts (57).
Tighten
• Reinforcement nuts to 70 N m (52 ft. lbs.).
• Bracket and brace nuts to 70 N m (52 ft.
lbs.).
3. Bumper to the vehicle.
4. Bumper to brace bolts (69), washers (71), spring
washers (72), and nuts (73).
$
• Nuts to 10 N m (89 in. lbs.).
4. Bumper bolts (56) onto the bumper.
5. Rear bumper.
• Nuts to 70 N m (52 ft. lbs.).
5. Bumper to bracket bolts (64), and nuts (63).
• Place the bumper bolts through the brackets
and braces.
Tighten
• Nuts to 70 N m (52 ft. lbs.).
6. Bracket washers (47), spring washers (48), and
nuts (49) to the bumper.
REAR BUMPER LICENSE
PLATE BRACKET
REPLACEMENT
• Nuts to 90 N m (66 ft. lbs.).
7. Brace washers (45), spring washers (44), and
nuts (43) to the bumper.
Tighten
• Nuts to 90 N m (66 ft. lbs.).
Tighten
f4
Remove or Disconnect (Figure 12)
1. License plate bracket to bumper nuts (78), spring
washers (77), washers (76), and bolts (76).
2. License plate bracket (75).
2B-8 BUMPERS
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
Nut
Bolt
Bolt
Bolt
Bolt
Bracket
Reinforcement
Washer
Nut
Bolt
Brace
Washer
Spring Washer
Nut
Bumper Bar
Figure 11—Rear Step Bumper Components
■+«- Install or Connect (Figure 12)
1. License plate bracket (75).
2. License plate bracket to the bumper bolts (76),
washers (76), spring washers (77), and nuts (78).
Tighten
Remove or Disconnect (Figures 13 and 14)
• Nuts to 29 N m (21 ft. lbs.).
75
DEAD WEIGHT TRAILER
HITCH REPLACEMENT
(UTILITY VEHICLE AND
SUBURBAN)
1. Bracket assembly nuts, washers, and bolts from
the frame.
2. Support nuts, washers, and bolts from the
bumper.
3. Hitch assembly.
4. Chain bracket nut, washer, and bolt.
• Chain bracket.
• Support.
5. Bar assembly bolt and washer from the bracket.
• Bar assembly.
76 77
+4- Install or Connect (Figures 13 and 14)
1. Bracket assem bly to the fram e with bolts,
washers, and nuts.
74.
75.
76.
77.
78.
79.
Bumper Bar
License Plate Bracket
Washer
Spring Washer
Nut
Bolt
• Nuts to 70 N m (52 ft. lbs.).
2. Bar assembly to the support.
• Place the bolt through the bar assembly,
support and the chain bracket. Install the
washer and nut loosely.
3. Support assembly bolts through the support and
the bumper.
F-00119
Figure 12—Rear License Plate Bracket
• Washers and nuts loosely.
4. Bar assembly bolt with washer through the bar
and into the bracket assembly.
BUMPERS 2B-9
31
31.
80.
81.
82.
83.
84.
85.
86.
87.
88.
89.
90.
91.
92.
93.
94.
Bumper Bar
Bolt
Washer
Nut
Washer
Bolt
Nut
Washer
Chain Bracket
Bolt
Support
Bar Assembly
Bolt
Bracket Assembly
Washer
Nut______________
F-00120
Figure 13—Suburban Dead W eight Trailer
Hitch Components
Tighten
• Bar to bracket bolt to 95 N m (70 ft. lbs.).
31.
95.
96.
97.
98.
99.
100.
101.
102.
103.
104.
105.
106.
107.
108.
109.
Figure 14—U tility Vehicle Dead W eight
Trailer Hitch
Install or Connect (Figure 15)
1. Hitch platform to the vehicle.
• Bar to support nut to 70 N m (52 ft. lbs.).
• Support to bumper nuts to 33 N m (24 ft.
lbs.).
Bumper Bar
Bolt
Washer
Nut
Washer
Bolt
Nut
Washer
Chain Bracket
Bolt
Support
Bar Assembly
Bolt
Bracket Assembly
Washer
Nut
• There must be no contact between the
platform and the rear bumper.
2. Front bolts, washers, and nuts to the hitch.
• Assemble loosely.
WEIGHT DISTRIBUTION
HITCH REPLACEMENT
(SUBURBAN ONLY)
3. Rear nuts, washers, and bolts to the hitch.
• Insta ll the nuts w ith the cu t-o ff side
outboard.
&
Remove or Disconnect (Figure 15)
1. Rear bolts, washers, and nuts from the hitch.
2. Front nuts, washers, and bolts from the hitch.
3. Hitch platform from the vehicle.
Tighten
• Rear bolts to 95 N m (70 ft. lbs.).
• Front nuts to 70 N m (52 ft. lbs.).
2B-10 BUMPERS
116
31.
110.
111.
112.
113.
114.
115.
116.
117.
118.
Bumper Bar
Nut
Washer
Bolt
Washer
Spring Washer
Bolt
Nut
Washer
Platform
31.
119.
120.
121.
122.
123.
124.
125.
126.
127.
128.
Bumper Bar
Nut
Washer
Nut
Washer
Washer
Spring Washer
Bolt "
Bolt
Washer
Platform
F-00123
F-00122
Figure 15—Suburban W eight D istribution
Hitch Components
WEIGHT DISTRIBUTION
HITCH REPLACEMENT
(UTILITY VEHICLE ONLY)
|+ + | Remove or Disconnect (Figure 16)
1. Rear bolts, washers, and nuts from the hitch.
2. Front bolts, washers, and nuts from the hitch.
3. Hitch platform from the vehicle.
Install or Connect (Figure 16)
1. Hitch platform to the vehicle.
2. Front bolts, washers, and nuts to the hitch.
• Assemble loosely.
3. Rear bolts, washers, and nuts to the hitch.
• Install nuts with the cut off side inboard.
Figure 16—U tility Vehicle W eight
D istribution Hitch Components
Tighten
Rear bolts to 73 N m (54 ft. lbs.).
Front bolts to 70 N m (51 ft. lbs.).
BUMPERS 2B-11
P MODEL BUMPERS
129.
130.
131.
132.
133.
134.
135.
136.
137.
Washer
Spring Washer
Nut
Bracket
Washer
Spring Washer
Nut
Nut
Spring Washer
143
138.
139.
140.
141.
Washer
Brace
Washer
Bolt
141 140
142. Spacer
143. Bumper Bar
Figure 17—P-Front Bumper Components
FRONT BUMPER
REPLACEMENT
Remove or Disconnect (Figures 17 and 18)
1. Brace to frame nuts (149), spring washers (148),
washers (147), and bolts (145).
2. Bracket to frame nuts (152), spring washers (151),
washers (150), and bolts (144).
3. Bumper to frame nuts (131), spring washers (130),
washers (129), spacers (142) (where used), and
bolts (141).
Tighten
• Nuts to 47 N m (35 ft. lbs.).
5. Brackets to the frame rails with bolts (144),
washers (150), spring washers (151), and nuts
(152).
Tighten
• Bracket to frame nuts to 95 N m (70 ft. lbs.).
• Bracket to bumper nuts to 47 N m (35 ft.
lbs.).
6. Braces to the frame rails with bolts (145), washers
(147), spring washers (148), and nuts (149).
4. Bumper from the vehicle.
5. Brace to bumper nuts (136), spring washers (137),
washers (138), and bolts (141).
• Braces (139).
Tighten
• Brace to frame nuts to 85 N m (63 ft. lbs.).
2. Brace to bumper nuts to 47 N m (35 ft. lbs.).
6. Bracket to bumper nuts (135), spring washers
(134), washers (133), and bolts (141).
-►+ Install or Connect (Figures 17 and 18)
1. Braces to the bumper with bolts (141), washers
(138), spring washers (137), and nuts (136).
• Assemble loosely.
2. Bracket to the bumper with bolts (141), washers
(138), spring washers (137), and nuts (135).
• Assemble loosely.
3. Bumper to vehicle.
4. Bumper to frame spacers (142) (where used),
spring washers (130), washers (129), bolts (141),
and nuts (131).
FRONT BUMPER
REPLACEMENT (WITH
RPO FS3 FRONT AXLE)
Remove or Disconnect (Figures >9 and 20)
1. Bracket to frame nuts (153) and washers (154).
2. Brace to frame nuts (170), washers (169), and
bolts (167).
3. Front bumper from the vehicle.
4. Bracket to bumper nuts (166 and 171), spring
washers (165 and 172), washers (164 and 173),
spacers (174), and bolts (161).
2B-12 BUMPERS
• Brackets (162).
5. Brace to bumper nuts (155), spring washers (156),
washers (157), and bolts (161).
• Braces (158).
+«- Install or Connect (Figures 19 and 20)
1. Braces to the bumper with bolts (161), washers
(157), spring washers (156), and nuts (155).
Tighten
• Nuts to 47 N-m (35 ft. lbs.).
2. Brackets to the bumper with bolts (161), spacers
(174), spring washers (165 and 172), washers (164
and 173), and nuts (166 and 171).
Tighten
132.
139.
144.
145.
146.
147.
148.
149.
150.
151.
152.
Bracket
Brace
Bolt
Bolt
Washer
Washer
Spring Washer
Nut
Washer
Spring Washer
Nut
• Nuts to 47 N-m (35 ft. lbs.).
3. Front bumper to the vehicle.
• Place the bracket assembly studs into the
frame crossmember.
4. Brace to frame bolts (167), washers (169), and
nuts (170).
$
Tighten
• Nuts to 40 N-m (30 ft. lbs.).
5. Bracket to frame washers (154) and nuts (153).
Tighten
• Nuts to 64 N-m (47 ft. lbs.).
F-00125
Figure 18—P-Front Bumper Braces, and
Brackets
153.
154.
155.
156.
157.
158.
159.
160.
161.
162.
Nut
Washer
Nut
Spring Washer
Washer
Brace
Bumper Bar
Washer
Bolt
Bracket
F-00126
Figure 19—P-Front Bumper Components (RPO FS3 Front Axle)
BUMPERS 2B-13
158
158.
159.
160.
161.
162.
164.
165.
166.
167.
168.
169.
170.
171.
172.
173.
174.
Brace
Bumper Bar
Washer
Bolt
Bracket
Washer
Spring Washer
Nut
Bolt
Washer
Washer
Nut
Nut
Spring Washer
Washer
Spacer
161
174
173
F-00127
Figure 20—P-Front Bumper Braces, and Brackets (RPO FS3 Front Axle)
G MODEL BUMPERS
FRONT BUMPER
REPLACEMENT
Remove or Disconnect (Figure 21)
1. Bracket to cross sill bolts (181).
2. Brace to bumper nuts (180) and bolts (182).
3. Bumper from the vehicle.
4. Bracket to bumper nuts (178), bolts (182), and
guards (where used).
• Brackets (177).
Install or Connect (Figures 21 and 22)
1. Braces to the frame.
• Place braces through the holes in the cross
sill, and install the bolts (179) loosely.
2. Bolts (184) into the guards (where used).
3. Rub strips to the juards (where used).
• Place the tangs of the strips onto the slots in
the guard. Using a rubber mallet, set the
tangs in place starting at the center of the
strip, and working toward each end.
4. Bracket to bumper bolts (182) or guards (where
used), nuts (178), and guard lower bolts.
5. Rub strips from the guards (where used) (figure
22).
• From the rear of the guard, press the tangs
of the bump strip together, and push the
strip from the guard.
6. Brace to frame bolts (179).
• Braces (176).
• Nuts to 29 N m (21 ft. lbs.).
• Guard lower bolts to 41 N m (30 ft. lbs.).
5. Bumper to the vehicle.
6. Bracket to cross sill bolts (181).
2B-14 BUMPERS
176
175.
176.
177.
178.
179.
180.
181.
182.
Bumper Bar
Brace
Bracket
Nut
Bolt
Nut
Bolt
Bolt
F-00108
Figure 21—G-Front Bumper Components
Tighten
• Bolts to 41 N m (30 ft. lbs.).
7. Brace to bumper bolts (182) and nuts (180).
Tighten
REAR BUMPER REPLACEMENT
□
Remove or Disconnect (Figure 23)
1. Outer brace to bumper nuts (192) and bolts (196).
2. Inner brace to cross sill bolts (194).
Brace to bumper nuts to 29 N m (21 ft. lbs.).
Brace to frame bolts to 41 N m (30 ft. lbs.).
3. Bracket to frame bolts (188) and washers (187).
4. Bumper from the vehicle.
5. Outer brace to cross sill bolts (193).
• Outer braces (186).
6. Bracket to bumper nuts and bolts (196).
• Brackets (189).
7. Inner brace to bumper nuts (192) and bolts (196).
• Inner braces (190).
Install or Connect (Figure 23)
1. Inner braces (190) to the bumper.
• Assemble the top bolts (191) and nuts (192).
• Nut to 30 N m (22 ft. lbs.)
• Assembly the lower bolts (196) and nuts
(192).
• Nut to 30 N m (22 ft. lbs.).
2. Brackets to the frame with washers (187) and
bolts (188).
• Assemble loosely.
3. Outer braces (186) to the cross sill with bolts
(193).
BUMPERS 2B-15
186.
187.
188.
189.
190.
186
Outer Brace
Washer
Bolt
Bracket
Inner Brace
191.
192.
193.
194.
195.
196.
Bolt
Nut
Bolt
Bolt
Bumper Bar
Bolt
F-00110
Figure 23—G-Rear Bumper Components
$
Tighten
• Bolts to 41 N m (30 ft. lbs.).
4. Bumper to the vehicle.
• Place the inner braces into the inner brace
panel holes.
5. Inner braces to the cross sill with bolts (194).
Tighten
• Bolts to 41 N m (30 ft. lbs.).
6. Bumper to bracket bolts (196) and nuts.
• Nuts to 29 N m (21 ft. lbs.).
• Bracket to frame bolts to 68 N m (50 ft. lbs.).
7. Outer bracket to bumper bolts (196) and nuts
(192).
Tighten
Tighten
• Nuts to 29 N m (21 ft. lbs.).
DEAD WEIGHT TRAILER
HITCH REPLACEMENT
+ + Remove or Disconnect (Figure 25)
1. Hitch bracket to bumper bracket nuts, washers,
and bolts.
2. Support to bumper nuts and bolts.
3. Hitch from the vehicle.
4. Chain bracket to bar assembly nut and bolt.
• Chain bracket.
• Support.
• Bar assembly.
5. Bar assembly to hitch bracket nut and bolt.
• Bar assembly.
• Shim(s).
• Hitch bracket.
• Nuts to 68 N m (50 ft. lbs.).
Install or Connect (Figure 25)
REAR LICENSE PLATE
BRACKET REPLACEMENT
1. Hitch bracket to the bumper brackets with bolts,
washers, and nuts.
Tighten
Remove or Disconnect (Figure 24)
1. License plate bracket nuts and bolts.
2. License plate bracket.
Install or Connect (Figure 24)
1. License plate bracket.
2. License plate bracket nuts and bolts.
• Nuts to 24 N m (18 ft. lbs.).
2. Bar assembly with shims (as required) to the
hitch bracket with bolts and nuts.
• Assemble loosely.
3. Support to the bumper with bolts and nuts.
• Assemble loosely.
4. Bar assembly and chain bracket to the support
with a bolt and nut.
2B-16 BUMPERS
Tighten
WEIGHT DISTRIBUTION
HITCH REPLACEMENT
• Bar assembly to chain bracket nut to 68 N m
(50 ft. lbs.).
□
• Bar assembly to hitch bracket bolt to 68 N m
(50 ft. lbs.).
• Support to bumper nuts to 29 N m (21 ft.
lbs.).
189.
195.
200.
201.
202.
203.
204.
205.
206.
207.
208.
209.
210.
211.
212.
213.
Remove or Disconnect (Figure 26)
1. Bumper nuts and bolts.
• Bumper.
2. Rear hitch nuts and washers.
Bracket
Bum per Bar
Washer
Nut
Bolt
Bolt
Nut
Bracket Assem bly
Bolt
Bar Assem bly
Bolt
Nut
Chain Bracket
Support
Nut
Shim
Figure 25—Dead Weight Trailer Hitch
BUMPERS 2B-17
Figure 26—W eight D istribution Hitch
3. Front bolts and washers.
4. Hitch from the vehicle.
3. Rear washers and nuts.
Install or Connect (Figure 26)
1. Hitch to the vehicle.
2. Front bolts and washers.
• Nuts to 63 N m (47 ft. lbs.).
4. Bumper to the vehicle with nuts and bolts.
Tighten
• Nuts to 29 N m (21 ft. lbs.
• Bolts to 70 N m (52 ft. lbs.).
2C-1
SECTION 2C
SHEET METAL
NOTICE: All hood latch fasteners are im portant attaching parts in that they could affect the perform ance of
vital parts and systems, and/or could result in major repair expense. They must be replaced w ith one of the
same part number of w ith an equivalent part if replacement becomes necessary. Do not use a replacement
part of lesser quality or substitute design. Torque values must be used as specified during reassembly to
assure proper retention of all parts.
CONTENTS
SUBJECT
PAGE
C/K M o d e ls .................................................................................................................................................................. 2C- 2
Hood R eplacem ent................................................................................................................................................. 2C- 2
Spring Assembly R eplacem ent........................................................................................................................... 2C- 2
Hood Hinge R e p la ce m e n t....................................................................................................................................2C- 2
Primary Hood Latch R e p la ce m e n t.....................................................................................................................2C- 3
Secondary Hood Latch And Spring Replacem ent........................................................................................... 2C- 4
Hood Release Cable R e p lace m e n t.....................................................................................................................2C- 4
Hood Ornament Replacem ent............................................................................................................................. 2C- 4
Cowl Vent Grille Replacement............................................................................................................................. 2C- 5
Grille And Molding R e p la c e m e n t....................................................................................................................... 2C- 5
Front Fender R e p la ce m e n t..................................................................................................................................2C- 7
Wheelhouse Panel Replacement......................................................................................................................... 2C- 8
Rear Fender R eplacem ent.................................................................................................................................... 2C- 9
Radiator Support Replacem ent........................................................................................................................... 2C-11
Sheet Metal Unit R e p la ce m e n t........................................................................................................................... 2C-12
Sheet Metal A djustm e n ts...................................................................................................................................... 2C-14
G M odels.......................................................................................................................................................................2C-14
Hood R eplacem ent................................................................................................................................................. 2C-14
Hood Hinge R e p la ce m e n t.................................................................................................................................... 2C-14
Primary Hood Latch R e p la ce m e n t.....................................................................................................................2C-15
Secondary Hood Latch And Spring Replacem ent...........................................................................................2C-16
Hood Release Cable R e p lace m e n t.....................................................................................................................2C-16
Cowl Vent Grille Replacement............................................................................................................................. 2C-16
Grille Replacem ent................................................................................................................................................. 2C-18
Front End Sheet Metal Cross Panel R e p la c e m e n t.........................................................................................2C-18
Sheet Metal Vertical Support R eplacem ent......................................................................................................2C-19
Front End Panel Replacem ent............................................................................................................................. 2C-20
S pe cifica tio ns.............................................................................................................................................................. 2C-21
Special T o o ls .............................................................................................................................................................. 2C-21
2C-2 SHEET METAL
C/K MODELS
Tighten
• Bolts to 25 N m (18 ft. lbs.).
SPRING ASSEMBLY
REPLACEMENT
♦♦ Remove or Disconnect (Figure 1)
• Raise and support the front of the hood.
1. Spring assembly to hood bolts (4).
2. Spring assembly to fender bolts (1).
3. Spring assembly from the vehicle.
Install or Connect (Figure 1)
1. Spring assembly to the vehicle.
2. Spring assembly to fender bolts (1).
Tighten
• Bolts to 25 N m (18 ft. lbs.)
3. Spring assembly to hood bolts (4).
£
Tighten
• Bolts to 25 N m (18 ft. lbs.).
HOOD REPLACEMENT
Remove or Disconnect (Figure 1)
• Raise and support the hood at front and rear.
• Place protective coverings over the cowl and the
fenders.
HOOD HINGE
REPLACEMENT
Remove or Disconnect (Figure 1)
• Mark the position of the hinge on the hood.
• Raise and support the hood at front and rear.
1. Spring assembly to hood bolts (4).
2. Hood hinge to hood bolts (5).
1. Cowl vent grille. Refer to “ Cowl Vent Grille
Replacement.”
3. Hood from the vehicle.
2. Hinge to hood bolts (5).
3. Hinge to cowl bolts (6).
Install or Connect (Figure 1)
1. Hood to the vehicle.
• Align the hood with the previously made
marks.
2. Hood hinge to hood bolts (5).
Tighten
• Bolts to 25 N m (18 ft. lbs.).
3. Spring assembly to hood bolts (4).
4. Hinge from the vehicle.
Install or Connect (Figure 1)
1. Hinge to the vehicle.
2. Hinge to cowl bolts (6).
Tighten
• Bolts to 43 N m (32 ft. lbs.).
3. Hinge to hood bolts (5).
SHEET METAL 2C-3
Figure 2—Hood Primary Latch Components
Install or Connect (Figure 2)
• Bolts to 25 N m (18 ft. lbs.).
4. Cowl vent grille. Refer to “ Cowl Vent Grille
Repacement.”
1. Bracket to the radiator support.
2. Bracket to support bolts (10) loosely.
3. Primary hood latch to the bracket.
4. Latch to bracket bolts (9) loosely.
PRIMARY HOOD LATCH
REPLACEMENT
NOTICE: See “ Notice” on page 2C-1 of this
section.
5. Hood latch release cable to the latch.
f t
Adjust
Hood latch bracket left and right until the striker
in the hood easily engages the primary latch.
Raise the hood.
Remove or Disconnect (Figure 2)
• Raise the hood.
1. Hood latch release cable from the latch. Refer to
“ Hood Release Cable Replacement.”
2. Bracket to hood latch bolts (9).
3. Hood latch from the vehicle.
4. Bracket to radiator support bolts (10).
5. Bracket from the vehicle.
Adjust
• Front hood bumpers, so that the top of the hood
is flush with the fenders.
• Bracket to radiator support bolts to 27 N m
(20 ft. lbs.).
Hood latch height so that when the hood is
closed, the hood is held securely against the front
hood bumpers. Mark this height.
Raise the hood.
Tighten
• Bracket to hood latch bolts to 27 N m (20 ft.
lbs.).
2C-4 SHEET METAL
HOOD RELEASE CABLE
REPLACEMENT
+ + Remove or Disconnect (Figure 4)
• If the cable is broken, release the hood by
pressing the primary latch tab on the right side of
the lock assembly. Use a rod to press the tab.
• Raise the hood.
1. Cable from the primary latch.
• Insert a screwdriver into the clip, and lift the
cable from the lock. Then, carefully pry the
cable grommet from the lock flange.
2. Cable from the ra diator support, and the
wheelhouse retaining strap.
16
I
3. Grommet from the cowl.
• Cut the grommet down to the cable casing
on the engine side of the cowl.
i
3.
15.
16.
17.
18.
Hood
Reinforcement
Spring
Secondary Hood Latch
Bolt
B-07272
Figure 3—Hood Secondary Latch Components
• Push the cable and grommet through the
cowl.
4. Cable handle to air vent bezel bolts.
5. Cable from the vehicle.
0* ± l
Install or Connect (Figure 4)
1. New cable to the vehicle.
SECONDARY HOOD LATCH
AND SPRING REPLACEMENT
4 -4
Remove or Disconnect (Figure 3)
Mark the position of the secondary hood latch on
the hood.
1. Secondary hood latch to hood bolts (18).
2. Cable through the drivers side of the cowl.
• Push the grommet into the drivers side of
the cowl.
3. Cable bolts through the cable handle, and into
the air vent bezel.
4. Cable through the wheelhouse retaining strap,
and the radiator support.
5. Cable to the primary latch.
2. Secondary hood latch from the vehicle.
HOOD ORNAMENT
REPLACEMENT
3. Spring from the hood.
• Twist the spring from the reinforcement.
Install or Connect (Figure 3)
0
Remove or Disconnect (Figure 5)
• Raise hood.
1. Spring to the hood.
• Twist the spring into the reinforcement.
2. Secondary hood latch to the vehicle.
3. Secondary hood latch to hood bolts (18).
Tighten
• Bolts to 27 N m (20 ft. lbs.).
1. Hood ornament nuts (21).
2. Hood ornament from the hood.
3. Seal from the hood.
+4- Install or Connect (Figure 5)
1. Hood seal to the ornament.
2. Hood ornament to the hood.
3. Hood ornament nuts (21).
SHEET METAL 2C-5
COWL VENT GRILLE
REPLACEMENT
+ + Remove or Disconnect (Figure 6)
1. Wiper arms.
2. Cowl vent grille panel screws.
3. Cowl vent grille plastic fasteners from the
windshield frame.
4. Cowl vent grille from the vehicle.
Install or Connect (Figure 6)
1. Cowl vent grille to the vehicle.
2. Cowl ve nt g rille p la s tic fa s te n e rs to the
windhsield frame.
3. Cowl vent grille panel screws.
4. Wiper arms.
GRILLE AND MOLDING
REPLACEMENT
Remove or Disconnect (Figure 7)
1. Lower radiator grille to grille bolt (39).
2. Radiator support to grille bolts (30).
3. Grille from the vehicle.
• Slide the bottom of the grille from the
vehicle, and then lower the grille from the
vehicle.
4. Headlamp bezels.
5. Headlamp assemblies.
6. Molding assembly to fender, radiator support, and
lower grille panel nuts (33, 34 and 37).
7. Molding assembly from the vehicle.
8. Right and left moldings from the upper and lower
moldings.
9. Clips from the moldings.
10. Lower radiator grille to fender bolts (38).
11. Lower radiator grille to the sheet metal support
bolts (40).
12. Lower radiator grille from the vehicle.
2C-6 SHEET METAL
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
Radiator Grille
Bolt
Radiator Support
Bolt
Nut
Nut
Bolt
Side Molding
Nut
Bolt
Bolt
Bolt
Lower Molding
Lower Radiator Grille
Upper Molding
Clip
37
36
B-07274
Figure 7—Grille Components
SHEET METAL 2C-7
+ + Install or Connect (Figure 7)
5.
6.
7.
8.
9.
10.
11.
12.
Lower radiator grille to the vehicle.
Lower radiator grille to the sheet metal support
bolts (40).
Lower radiator grille to fender bolts (38).
Upper molding to the radiator support with clips
(44), and nuts (33).
• Assemble loosely.
Lower molding to the radiator support with clips
(44), and nuts (37).
• Assemble loosely.
Right and left moldings to the fenders.
• The moldings must butt against the upper
and lower moldings, and be joined to those
moldings by the clips.
Right and left molding nuts (34).
Tighten upper and lower molding nuts (33 and
37).
Headlamp assemblies.
Headlamp bezels.
Grille to the vehicle.
• Insert the top of the grille to the underside of
the radiator support, and then slide the
bottom of the grille into place.
Lower radiator grille to grille bolt (39).
Radiator support to grille bolts (30).
Figure 8—Front Fender Attachm ent
FRONT FENDER
REPLACEMENT
17. Fender from the vehicle.
18. Insulator from the fender.
Remove or Disconnect (Figures 8 and 9)
•
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
•
16.
Tool Required:
J-24595-B Door Trim Pad Remover.
Raise and support the hood.
Head lamp bezel.
Head lamp.
Right or left radiator grille molding nuts (34).
Upper and lower molding clip nuts (33 and 37).
Right or left radiator grille molding (36).
Lower radiator grille to fender bolts (38).
Cowl vent grille. Refer to “ Cowl Vent Grille
Replacement.”
Hood s p rin g assem bly. R efer to “ S prin g
Assembly Replacement.”
Radiator support to fender bolts (119).
Wheelhouse panel to shield bolts.
Shield to underbody retainers using J-24595-B.
Shield from the vehicle.
Wheelhouse panel to fender bolts (50).
Lower door pillar to fender bolt (45) and shim(s)
(46).
Fender to cowl bolt (47) and shim(s) (46).
Open the front door.
Upper fender to door pillar bolt (48) and shim(s)
(46).
Install or Connect (Figures 8 and 9).
1. Insulator to the fender.
2. Fender to the vehicle.
\
4g
49. Bolt
50. Bolt
51. Nut
52. Bolt
53. Bolt
54. Wheelhouse Panel
B-07284
Figure 9—Wheelhouse Panel Attachment
2C-8 SHEET METAL
3. Upper fender to the door pillar bolt (48) and
shim(s) (46) as required.
• Assemble loosely.
4. Fender to cowl bolt (47) and shim(s) (46) as
required.
• Assemble loosely.
5. Lower door pillar to fender bolt (45) and shim(s)
(46) as required.
• Assemble loosely.
6. Radiator support to fender bolts (119).
$
Tighten
• Bolts to 17 N m (13 ft. lbs.).
7. Wheelhouse to fender bolts (50).
7. Wheelhouse panel to underbody shield bolts.
8. Wheelhouse panel reinforcement to underbody
bolts (52) and (53).
9. Wheelhouse panel to fender bolts (50).
10. Wheelhouse panel from the vehicle.
• Slide the panel forward to clear the lower
back side of the fender well.
• Tilt the wheelhouse panel out of the vehicle.
Install or connect (Figure 9)
1. Wheelhouse panel to the vehicle.
• Tilt the wheelhouse panel into the vehicle.
• Slide the panel into position.
2. Wheelhouse panel to fender bolts (50).
Tighten
• Wheelhouse to fender bolts (50) to 17 N m
(13 ft. lbs.).
• Lower door pillar to fender bolt to 43 N m (31
ft. lbs.).
8. Shield to the vehicle.
9. Shield to underbody retainers.
10. Wheelhouse panel to shield bolts.
Tighten
11.
12.
13.
14.
15.
16.
17.
18.
• Fender to cowl bolt (47) to 43 N m (31 ft.
lbs.).
• Upper fender to door pillar bolt to 43 N m
(31 ft. lbs.).
Hood sp rin g assem bly. R efer to “ S pring
Assembly Replacement.”
Cowl vent grille. Refer to “ Cowl Vent Grille
Replacement.”
Lower radiator grille to fender bolts (38).
Right or left radiator grille molding (36).
Upper and lower molding clip nuts (33 and 37).
Right or left radiator grille molding nuts (34).
Head lamp.
Head lamp bezel.
WHEELHOUSE PANEL
REPLACEMENT
RIGHT PANEL REPLACEMENT
4-+ Remove or Disconnect (Figure 9)
1.
2.
3.
4.
•
5.
6.
Jack handle.
Lug wrench.
Coolant recovery reservoir.
Air conditioning line retainers (if equipped).
Raise and support the vehicle.
Right front wheel.
Wheelhouse panel to radiator support bolts (49).
• Bolts to 17 N m (13 ft. lbs.).
3. Wheelhouse panel reinforcement to underbody
bolts (52) and (53).
Tighten
• Bolts (52) to 17 N m (13 ft. lbs.).
• Bolt (53) to 47 N m (35 ft. lbs.).
4. Wheelhouse panel to underbody shield bolts.
5. Wheelhouse panel to radiator support bolts (49).
a
Tighten
• Bolts to 17 N m (13 ft. lbs.).
6. Right front wheel.
• Lower the vehicle.
7. Air conditioning line retainers (if equipped).
8. Coolant recovery reservoir.
9. Lug wrench.
10. Jack handle.
LEFT PANEL REPLACEMENT
Remove or Disconnect (Figure 9)
1.
2.
3.
4.
5.
•
6.
7.
8.
9.
Jack.
Windshield washer fluid reservoir.
Wiring harness.
Hood release cable.
Air conditioning hose bracket (if equipped).
Raise and support the vehicle.
Left front wheel.
Wheelhouse panel to radiator support bolts (49).
Wheelhouse panel to underbody shield bolts.
Wheelhouse panel reinforcement to underbody
bolts (52) and (53).
10. Wheelhouse panel to fender bolts (50).
SHEET METAL 2C-9
11. Wheelhouse panel from the vehicle.
• Slide the panel forward to clear the lower
back side of the fender well.
• Tilt the wheelhouse panel out of the vehicle.
3. Cross sill to brace bolt (63).
• Assemble loosely.
4. Brace (58) to the vehicle.
5. Side panel to brace bolt (56).
Install or Connect (Figure 9)
1. Wheelhouse panel to the vehicle.
• Tilt the wheelhouse panel into the vehicle.
• Slide the panel into position.
2. Wheelhouse panel to fender bolts (50).
• Assemble loosely.
6. Fender to the vehicle.
7. Side panel to fender bolts (56).
• Assemble loosely.
8. Brace to fender bolts (59).
Tighten
• Bolts to 17 N m (13 ft. lbs.).
3. Wheelhouse panel reinforcement to underbody
bolts (52) and (53).
Tighten
• Bolt (52) to 17 N m (13 ft. lbs.).
• Bolt (53) to 47 N m (35 ft. lbs.).
4. Wheelhouse panel to underbody shield bolts.
5. Wheelhouse panel to radiator support bolts (49).
$
6.
•
7.
8.
9.
10.
11.
Tighten
• Brace to fender bolts to 17 N m (13 ft. lbs.).
• Side panel to fender bolts to 10 N m (7 ft.
lbs.).
• Cross sill to brace bolt to 17 N m (13 ft. lbs.).
9. Parking lamp wiring to the fender.
• Clean excess sealant from the fender.
DUAL REAR WHEEL MODEL FENDER
REPLACEMENT
Tighten
• Bolts to 17 N m (13 ft. lbs.).
Left front wheel.
Lower the vehicle.
Air conditioning hose bracket (if equipped).
Hood release cable.
Wiring harness.
Windshield washer fluid reservoir.
Jack.
Remove or Disconnect (Figure 11)
1. Parking lamp wiring from the fender.
2. Fender to brace bolts (71).
3. Fender to side panel bolts (72 and 69) and nuts
( 68 ).
4. Side panel to fender nuts (66).
5. Fender from the vehicle.
6. Sealer from the side panel and fender.
REAR FENDER REPLACEMENT
FENDERSIDE MODEL FENDER REPLACEMENT
□
Remove or Disconnect (Figure 10)
-►+ Install or Connect (Figure 11)
1. A medium bodied sealer onto the fender to side
panel flange.
2. Fender to the vehicle.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Parking lamp wiring from the fender.
Brace to fender bolts (59).
Side panel to fender bolts (56).
Fender from the vehicle.
Side panel to brace bolt (56).
Brace (58).
Cross sill to brace bolt (63).
Brace (62).
Sealer from the fender and the side panel.
-►* Install or Connect (Figure 10)
1. A medium bodied sealer onto the fender to side
panel flange.
2. Brace (62).
3. Side panel to fender nuts (66).
• Assemble loosely.
4. Fender to side panel bolts (72 and 69) and nuts
(68 ).
• Assemble loosely.
5. Fender to brace bolts (71).
Tighten
• All of the nuts and bolts to 17 N m (13 ft.
lbs.).
6. Parking lamp wiring to the fender.
• Clean excess sealant from the fender.
2C-10 SHEET METAL
Figure 10—Fenderside Rear Fender Attachm ent
Figure 11—Dual Rear Wheel Rear Fender Attachment
SHEET METAL 2C-11
73.
74.
75.
76.
77.
78.
79.
80.
81.
Bolt
Washer
Retainer
Cushion - Upper
Bracket
Cushion - Lower
Retainer
Nut
Radiator Support
B-07280
Figure 12—Radiator Support Mounting
RADIATOR SUPPORT
REPLACEMENT
Remove or Disconnect (Figure 12)
1. Radiator from the vehicle. Refer to ENGINE
COOLING (SEC. 6B).
2. Air conditioning condenser from the vehicle.
Refer to AIR CONDITIONING (SEC. 1B).
3. Battery from the vehicle.
4. Headlamp and parking lamp wires from the
lamps.
5. Headlamp and parking lamp wiring harness from
the radiator support.
6. Headlamp bezels.
7. Headlamp assemblies.
8. Ground wires from the radiator support.
9. Fuel vapor canister from the radiator support.
10. Air cleaner inlet from the radiator support.
11. Primary hood latch bracket to the radiator support
bolts.
12. Grille from the vehicle.
13. Lower radiator grille panel from the vehicle.
14. Sheet metal support to radiator support bolts.
15. Sheet metal support from the vehicle.
16. Radiator support to fender bolts (119).
17. Wheelhouse panel to radiator support bolts (49).
18. Radiator support to frame nuts (80), lower
re taine rs (79), lower cushions (78), upper
cushions (76), retainers (75), bolts (73), and
washers (74).
19. Radiator support from the vehicle.
• Tilt the radiator support to the rear, and lift it
up and out of the vehicle.
Install or Connect (Figure 12)
1. Radiator support to the vehicle.
• Lower the radiator support into the vehicle,
and tilt it into position.
2. Radiator support to frame washers (74), bolts (73),
retainers (75), upper cushions (76), lower
cushions (78), lower retainers (79), and frame
nuts (80).
• Assemble loosely.
3. Wheelhouse panel to radiator support bolts (49).
Tighten
• Bolts to 17 N m (13 ft. lbs.).
4. Radiator support to fender bolts (119).
&
Tighten
• Bolts to 17 N m (13 ft. lbs.).
5. Sheet metal support to the vehicle.
2C-12 SHEET METAL
6. Sheet metal support to radiator support bolts.
Tighten
• Bolts to 17 N-m (13 ft. lbs.).
• Radiator support to frame nuts (80) to 47
N-m (35 ft. lbs.).
Lower radiator grille panel to the vehicle.
Grille to the vehicle.
Primary hood latch bracket to the radiator support
bolts.
Hood latch left or right so that the hood
properly engages the hood latch.
11.
12.
13.
14.
15.
16.
17.
18.
Wheelhouse panel to fender bolts (50).
Fender to cowl bolts (47).
Upper fender to door pillar bolt (48).
Wheelhouse panel to shield bolts.
Shield to underbody retainers using J-24595-B.
Shield from the vehicle.
Lower fender to door pillar bolt (45).
Radiator support to frame nuts (80), lower
re tainers (79), lower cu shion s (78), upper
cushions (76), retainers (75), bolts (73), and
washers (74).
19. Sheet metal assembly.
• With the aid of a helper, lift the sheet metal
from the chassis.
Install or Connect
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
• Bracket to radiator support bolts to 27 N-m
(20 ft. lbs.).
Air cleaner inlet to the radiator support.
Fuel vapor canister to the radiator support.
Ground wires to the radiator support.
Headlamp assemblies.
Headlamp bezels.
Headlamp and parking lamp wiring harness to
the radiator support.
Headlamp and parking lamp wires to the lamps.
Battery to the vehicle.
Air conditioning condenser to the vehicle. Refer
to AIR CONDITIONING (SEC. 1B).
Radiator to the vehicle. Refer to ENGINE
COOLING (SEC. 6B).
1. Sheet metal assembly.
• With the aid of a helper, lift the sheet metal
onto the chassis.
2. Radiator support to frame washers (74), bolts (73),
retainers (75), upper cushions (76), lower
cushions (78), lower retainers (79), and nuts (80).
3. Lower fender to door pillar bolts (45).
Tighten
4.
5.
6.
7.
• Bolt to 43 N-m (31 ft. lbs.).
Shield to the vehicle.
Shield to underbody retainers.
Wheelhouse panel to shield bolts.
Upper fender to door pillar bolt (48).
Tighten
SHEET METAL UNIT
REPLACEMENT
• Bolt to 43 N-m (31 ft. lbs.).
8. Fender to cowl bolts (47).
Tool Required:
J-24595-B Door Trim Pad Remover.
Remove or Disconnect
1. Hood from the vehicle.
2. Battery from the vehicle.
3. Radiator from the vehicle. Refer to ENGINE
COOLING (SEC. 6B).
4. Air conditioning condenser from the vehicle.
Refer to AIR CONDITIONING (SEC. 1B).
5. Headlamp and parking lamp wires from the
lamps.
6. Headlamp and parking lamp wiring harness from
the radiator support.
7. Ground wires from the radiator support.
8. Fuel vapor canister from the radiator support.
9. Air cleaner inlet from the radiator support.
10. Bumper from the vehicle.
Tighten
• Bolts to 43 N-m (31 ft. lbs.).
9. Wheelhouse panel to fender bolts (50).
10.
11.
12.
13.
14.
15.
16.
• Wheelhouse panel to fender bolts to 17 N-m
(13 ft. lbs.).
Bumper to the vehicle.
Air cleaner inlet to the radiator support.
Fuel vapor canister to the radiator support.
Ground wires to the radiator support.
Headlamp and parking lamp wiring harness to
the radiator support.
Head lamp and parking lamp wires to the lamps.
Air conditioning condenser to the vehicle. Refer
to AIR CONDITIONING (SEC. 1B).
SHEET METAL 2C-13
82.
83.
84.
85.
86.
87.
A.
B.
C.
D.
E.
F.
Hood
Fender
Door
Cowl Vent Grille
Rocker Panel
Radiator Support Upper Panel
Flush Fit
Flush + or - 1mm (0.03-inch)
Flush + 0.00 mm or - 1.5 mm (0.00-inch or -0.06-inch)
4.6 mm ± 1 mm (0.18-inch ± 0.03-inch)
8 mm ± 1 mm (0.31-inch ± 0.03-inch)
5 mm ± 2.3 mm (0.19-inch ± 0.09-inch)
F-00183
Figure 13—Sheet Metal Gap Specifications
2C-14 SHEET METAL
17. Radiator to the vehicle. Refer to ENGINE
COOLING (SEC. 6B).
18. Battery to the vehicle.
19. Hood to the vehicle.
SHEET METAL ADJUSTEMENTS
In o rd e r to have the p ro p e r o p e ra tio n and
appearance of sheet metal components, it is important
that certain fits and gaps between components be
maintained. The gaps given in this procedure are
suggested as the best alignment for these components
(figure 13).
In aligning sheet metal, it is best to start with the
rearmost component, and work forward.
1. Starting with the fenders, align the rear edge of
each fender to the rocker panel, and the door.
The gap between these components should be 5
mm ± 2.3 mm (0.19-inch ± 0.09-inch). This
adjustment should be accomplished by moving
the fender forward or rearward. The surface of
the fender should be flush with the rocker panel
and the door. Add or remove shims to perform
this adjustment.
2. Align the fender to the cowl vent grille to obtain a
gap of 4.6 mm ± 1 mm (0.18-inch ± 0.03-inch).
The surface of the cowl vent grille should be flush
with the fender surface.
3. Align the hood with the cowl vent grille, so that
there is a gap of 8 mm ± 1 mm (0.31-inch ±
0.03-inch) between the rear edge of the hood and
the front edge of the cowl vent grille. The hood
surface should be flush with the cowl vent grille
s u rfa c e
w ith in
+
0.0
m m -1 .5
mm
(+ 0.00-inch-0.06-inch).
4. Align the left and right edges of the hood so that
a gap of 4.6 mm ± 1 mm (0.18-inch ± 0.03-inch)
exists between the hood and the fenders. The
hood surface should be flush with the fender
surface within + 0.0 mm, -1.5 mm ( + 0.00-inch,
-0.06-inch). If this gap is difficult to obtain, and the
hood appears to be cocked in between the
fenders, the radiator support may need to be
shifted. By shifting the radiator support, the entire
front end sheet metal can be aligned as a unit.
Loosen the support to the frame bolts, and shift
the radiator support to obtain the proper gaps.
Then, while holding the support in position,
retighten the radiator support to frame bolts.
5. Align the front face of the hood to obtain a gap of
4.6 mm ± 1 mm (0.18-inch ± 0.03-inch) between
the hood and the radiator support upper panel.
The hood bumpers on the top of the radiator
support should be adjusted to give the proper
support to hood gap. The surface of the hood
should be flush with the radiator support upper
panel (not the grille molding).
G MODELS
HOOD REPLACEMENT
Remove or Disconnect (Figure 14)
• Raise and support the hood. Place a protective
covering over the fenders, and the cowl vent
grille.
HOOD HINGE REPLACEMENT
4- + Remove or Disconnect (Figure 14)
• Raise and support the hood. Also support the
rear corner of the hood.
• Mark the position of the hinges on the hood.
• Mark the position of the hinge on the hood and
the cowl.
1. Hood hinge to hood bolts (89).
1. Hood hinge to hood bolts (89).
2. Hood from the vehicle.
2. Hood hinge to cowl bolts (90).
3. Hood hinge from the vehicle.
Install or Connect (Figure 14)
+«- Install or Connect (Figure 14)
1. Hood to the vehicle.
2. Hood hinge to hood bolts (89).
• Align the hood with the previously made marks.
1. Hood hinge to the vehicle.
2. Hood hinge to cowl bolts (90).
3. Hood hinge to hood bolts (89).
Tighten
• Bolts to 17 N m (13 ft. lbs.).
• Remove the protective coverings, and lower the
hood.
• Align the hinge with the previously made marks.
Tighten
• Bolts to 17 N m (13 ft. lbs.).
SHEET METAL 2C-15
PRIMARY HOOD LATCH
REPLACEMENT
NOTICE: See “Notice” on page 2C-1 of this
section.
+ + Remove or Disconnect (Figure 15)
•
1.
2.
3.
4.
5.
f t
Raise and support the hood.
Hood latch release cable from the latch.
Bracket to hood latch bolts (94).
Hood latch from the vehicle.
Bracket to the sheet metal cross panel bolts (91).
Bracket from the vehicle.
A djust
• Front hood bumpers, so that the top of the hood
is flush with the fenders.
I+ + I Install or Connect (Figure 15)
f t
Adjust
1. Hood latch bracket left and right until the striker
in the hood easily engages the primary latch.
• Raise and support the hood.
Tighten
• Bracket to radiator support bolts to 27 N m
(20 ft. lbs.)
2. Hood latch height so that when the hood is
closed, the hood is held securely against the front
hood bumpers.
• Raise and support the hood.
1.
2.
3.
4.
5.
Bracket to the sheet metal cross panel.
Bracket to cross panel bolts (91) loosely.
Primary hood latch to the bracket.
Latch to bracket bolts (94) loosely.
Hood latch release cable to the latch.
Tighten
• Bracket to hood latch bolts to 27 N m (20 ft.
lbs.).
2C-16 SHEET METAL
HOOD RELEASE CABLE
REPLACEMENT
□
Remove or Disconnect (Figure 17)
• If the cable is broken, release the hood by
pressing the primary latch tab on the right side of
the lock assembly. Use a rod to press the tab.
• Raise and support the hood.
1. Cable from the primary latch.
• Insert a screwdriver into the clip, and lift the
cable from the lock. Then, carefully pry the
cable grommet from the lock flange.
2. Cable from the sheet metal cross panel clip.
3. Grommet from the cowl.
88.
95.
96.
97.
98.
• Cut the grommet down to the cable casing
on the engine side of the cowl.
• Push the cable and the grommet through
the cowl.
Hood
Reinforcement
Spring
Bolt ~
Secondary
Hood Latch
4. Cable handle to dash screws.
5. Cable from the vehicle.
98 97
B-07283
-►+ Install or Connect (Figure 17)
1. New cable to the vehicle.
Figure 16—Secondary Hood Latch Attachm ent
SECONDARY HOOD LATCH
AND SPRING REPLACEMENT
2. Cable through the drivers side of the cowl.
• Push the grommet into the drivers side of
the cowl, and then push the insert into the
grommet.
3. Cable handle to dash screws.
Remove or Disconnect (Figure 16)
4. Cable into the sheet metal cross panel clip.
5. Cable to the primary latch.
Mark the position of the secondary hood latch on
the hood.
1. Secondary hood latch to hood bolts (97).
2. Secondary hood latch from the vehicle.
3. Spring from the hood.
• Twist the spring from the reinforcement.
COWL VENT GRILLE
REPLACEMENT
Remove or Disconnect (Figure 18)
• Raise and support the hood.
1. Windshield wiper arms.
|~n-| Install or Connect (Figure 16)
1. Spring to the hood.
• Twist the spring into the reinforcement.
2. Secondary hood latch to the vehicle.
3. Secondary hood latch to hood bolts (97).
2. Cowl vent grille to cowl bolts (104) and screws
(103).
3. Cowl vent grille from the vehicle.
4. Cowl seal from the vehicle.
+«- Install or Connect (Figure 18)
1. Cowl seal to the vehicle.
2. Cowl vent grille to the vehicle.
Q
Tighten
• Bolts to 27 N m (20 ft. lbs.).
3. Cowl vent grille to cowl bolts (104) and screws
(103).
4. Windshield wiper arms.
SHEET METAL 2C-17
92
101. Bolt
F-07277
Figure 18—Cowl Vent Grille Components
20-18 SHEET METAL
107
107. Grille
108. Nut
B-07287
Figure 19—Radiator Grille
GRILLE REPLACEMENT
4- + Remove or Disconnect (Figures 19 and 20)
•
1.
2.
3.
4.
Raise and support the hood.
Headlamp bezels.
Sheet metal cross panel to grille bolts.
Grille to lower front end panel boits.
Grille from the vehicle.
Figure 21—Front End Sheet Metal Cross
Panel Attachm ent
5. Sheet metal to upper and lower radiator grille
molding nuts (110 and 112).
6. Upper and lower radiator grille moldings from the
vehicle.
Install or Connect (Figures 19 and 20)
1. Upper and lower radiator grille moldings to the
vehicle.
2. Sheet metal to upper and lower radiator grille
molding nuts (110 and 112).
3. Grille to the vehicle.
4. Grille to lower front end panel bolts.
5. Sheet metal cross pane! to grille bolts.
6. Headlamp bezels.
• Lower the hood.
FRONT END SHEET METAL
CROSS PANEL REPLACEMENT
109. Front End Sheet Metal Cross Panel
110. Nut
1 1 1 . Upper Molding
112. Nut
113. Lower Molding
B-07288
Figure 20—Radiator Grille Molding Attachment
Remove or Disconnect (Figure 21)
•
1.
2.
3.
Raise and support the hood.
Headlamp bezels.
Grille. Refer to “ Grille Replacement.”
Primary hood latch. Refer to “ Primary Hood
Latch Replacement.”
SHEET METAL 2C-19
4. Air intake snorkel.
5. Upper radiator mount to sheet metal cross panel
bolts.
6. Upper radiator mounts.
7. Sheet metal cross panel to fender bolts (114).
8. Sheet metal cross panel to the hood latch bracket
bolts (91).
9. Sheet metal cross panel to radiator support baffle
panel bolts.
10. Sheet metal cross panel to the headlamp bezel
support bolts.
11. Sheet metal cross panel from the vehicle.
+«- Install or Connect (Figure 21)
1. Sheet metal cross panel to the vehicle.
2. Sheet metal cross panel to the headlamp bezel
support bolts.
• Assemble loosely.
3. Sheet metal cross panel to the radiator support
baffle panel bolts.
• Assemble loosely.
4. Sheet metal cross panel to the hood latch bracket
bolts (91).
• Assemble loosely.
5. Sheet metal cross panel to the fender bolts (114).
Tighten
• Bolts in steps 2 through 5 to 27 N m (20 ft.
lbs.).
6. Upper radiator mounts.
7. Upper radiator mount to sheet metal cross panel
bolts.
8. Air intake snorkel.
9. Primary hood latch. Refer to “ Primary Hood
Latch Replacement.”
10. Grille. Refer to “ Grille Repalcement.”
11. Headlamp bezels.
• Lower the hood.
SHEET METAL VERTICAL
SUPPORT REPLACEMENT
Remove or Disconnect (Figure 22)
1. Grille. Refer to “ Grille Replacement.”
Figure 22—Front End Sheet Metal
Vertical Support
Install or Connect (Figure 22)
1. Vertical support to the vehicle.
2. Sheet metal cross panel to vertical support bolts
(115).
Tighten
• Bolts to 27 N m (20 ft. lbs.).
3. Front end panel to vertical support bolts (120).
2. Vertical support to sill bolts (17).
3. Front end panel to vertical support bolts (120).
4. Sheet metal cross panel to vertical support bolts
(115).
5. Vertical support from the vehicle.
Tighten
• Bolts to 18 N m (13 ft. lbs.).
4. Vertical support to sill bolts (117).
2C-20 SHEET METAL
Tighten
• Bolt to 10 N-m (7 ft. lbs.).
Grille. Refer to “ Grille Replacement.’
FRONT END PANEL
REPLACEMENT
+ + Remove or Disconnect (Figure 23)
1. Headlamp bezels.
2. Grille. Refer to “ Grille Replacement.”
3. Front end panel to headlamp bezel support bolts
(118).
4. Front end panel to sill bolts (121).
5. Front end panel to vertical support bolts (120).
6. Front end panel from the vehicle.
+4-
Install or Connect (Figure 23)
1. Front end panel to the vehicle.
2. Front end panel to vertical support bolts (120).
• Assemble loosely.
3. Front end panel to sill bolts (121).
4. Front end panel to headlamp bezel support bolts
(118).
5. Grille. Refer to “ Grille Replacement.”
6. Headlamp bezels.
121
121
116. Sheet Metal
Vertical Support
117. Front End Panel
118. Bolt
120. Bolt
121. Bolt
F-07282
Figure 23—Front End Panel Attachm ent
SHEET METAL 2C-21
SPECIFICATIONS
TORQUE
Nm
Ft. Lbs.
C/K Models
Hood Hinge to Hood B o lts ...................................................................................................
Hood Hinge to Cowl Bolts.....................................................................................................
Spring Assembly to Hood B o lts ..........................................................................................
Spring Assembly to Fender B o lts........................................................................................
Primary Hood Latch Bracket to Radiator Support B o lts ..................................................
Bracket to Primary Hood Latch B olts..................................................................................
Secondary Hood Latch to Hood B o lts ................................................................................
Sheet Metal Support to Radiator Support Bolts.................................................................
Radiator Support to Fender B olts........................................................................................
Radiator Support to Frame Nuts..........................................................................................
Wheelhouse to Fender Bolt...................................................................................................
Fender to Cowl B o lt...............................................................................................................
Upper Fender to Door Pillar B o lt ........................................................................................
Wheelhouse Panel Reinforcement to Underbody Bolts (52)............................................
(53)............................................
Wheelhouse to Radiator Support B o lts ..............................................................................
Fenderside Models
Brace to Rear Fender Bolts...................................................................................................
Side Panel to Rear Fender B o lts ........................................................................................
Side Panel to Brace B olts.....................................................................................................
Fleetside Models
All Rear Fender to Side Panel Bolts, and N u ts .................................................................
G Models
Hood Hinge to Hood B o lts ...................................................................................................
Primary Hood Latch Bracket to Radiator Support B o lts ..................................................
Bracket to Primary Hood Latch B olts................................................ .............................
Secondary Hood Latch to Hood B o lts ................................................................................
Sheet Metal Cross Panel to Headlamp Bezel Support B o lts ..........................................
Sheet Metal Cross Panel to Radiator Support Baffle Panel Bolts....................................
Sheet Metal Cross Panel to Hood Latch Bracket B olts....................................................
Sheet Metal Cross Panel to Fender Bolts...........................................................................
Sheet Metal Cross Panel to Vertical Support B olts...........................................................
Front End Panel to Vertical Support B olts.........................................................................
Vertical Support to Sill Bolts................................................................................................
SPECIAL TOOLS
J-24595-B
Door Trim Pad Remover
25
43
25
25
27
27
27
17
17
47
43
43
43
17
47
17
18
32
18
18
20
20
20
13
13
35
31
31
31
13
35
13
17
10
10
13
7
7
17
13
17
27
27
27
27
27
27
28
27
18
10
13
20
20
20
20
20
20
20
20
13
7
3A-1
SECTION 3
STEERING, SUSPENSION,
WHEELS AND TIRES
CONTENTS
SUBJECT
PAGE
Front End A lig n m e n t................................................................................................................................................... 3A-1
Steering L in k a g e ........................................................................................................................................................3B1-1
Manual S te e rin g ..........................................................................................................................................................3B2-1
Power S tee rin g ............................................................................................................................................................3B3-1
Steering C o lu m n ........................................................................................................................................................3B4-1
Front S uspension..........................................................................................................................................................3C-1
Rear S u s p e n s io n ..........................................................................................................................................................3D-1
Wheels And T ire s ..........................................................................................................................................................3E-1
SECTION 3A
FRONT END ALIGNMENT
The following “ Notice” applies to one or more steps in the assembly procedure of components in this portion of
the manual as indicated at appropriate locations by the terminology: “ NOTICE” : See ‘Notice’ on page 3A-1 on this
section.”
NOTICE: Front end alignment fasteners are important attaching parts in that they could affect the perform­
ance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one
of the same part number or with an equivalent part if replacement becomes necessary. Do not use a replace­
ment part of lesser quality or substitute design. Torque values must be used as specified during reassembly
to assure proper retention of all parts.
CONTENTS
SUBJECT
PAGE
D e s c rip tio n .................................................................................................................................................................... 3A-2
D efinition o f T e r m s ................................................................................................................................................. 3A-2
Diagnosis of Front End A lig n m e n t........................................................................................................................... 3A-2
On-Vehicle S e r v ic e ..................................................................................................................................................... 3A-3
In s p e c tio n .................................................................................................................................................................. 3A-3
Front End A lignm ent R equirem ents.....................................................................................................................3A-3
Alignm ent A d ju s tm e n ts .......................................................................................................................................... 3A-4
S pe cifica tio ns................................................................................................................................................................ 3A-6
3A - 2 FRONT END ALIGNMENT
DESCRIPTION
“ Front End Alignment” refers to the angular relation­
ship between the front wheels, the front suspension
attaching parts and the ground.
Proper front end alignment must be maintained in
order to insure efficient steering, good directional sta­
bility and to prevent abnormal tire wear.
The most important factors of front end alignment
are wheel toe-in, wheel camber, and axle caster (Fig­
ure 1).
DEFINITION OF TERMS
CAMBER
Camber is the inward or outward tilting of the front
wheels from the vertical. When the wheels tilt outward
at the top, the camber is positive (+ ). When the wheels
tilt inward at the top, the camber is negative (—). The
amount of tilt measured in degrees from the vertical is
called the camber angle. Camber is designed into the
front axle assembly of all four-wheel drive vehicles and
is non-adjustable.
If camber is extreme or unequal between the wheels,
improper steering and excessive tire wear will result.
Negative camber causes wear on the inside tire, while
positive camber causes wear to the outside.
CASTER (Figure 1)
Caster is the tilting of the wheel axis either forward
or backward from the vertical (when viewed from the
side of the vehicle). A backward tilt is positive ( + ) and
a forward tilt is negative (—).
On the short and long arm type suspension you
cannot see a caster angle without a special instrument,
but if you look straight down from the top of the upper
control arm to the ground, the ball joints do not line up
(fore and aft) when a caster angle other than 0 degree
is present. With a positive angle, the lower ball joint
would be slightly ahead (toward the front of the vehicle)
of the upper ball joint center line. Caster is designed
into the front axle assembly on all four-wheel drive
vehicles, and is non-adjustable.
TOE-IN
Toe-in is the turning of the front wheels. The actual
amount of toe-in is normally a fraction of a degree.
Toe-in is measured from the center of the tire treads or
from the inside of the tires. The purpose of toe-in is to
insure parallel rolling of the front wheels and to offset
any small deflections of the wheel support system
which occurs when the vehicle is rolling forward.
Incorrect toe-in results in excessive toe-in and unstable
steering. Toe-in is the last alignment to be set in the
front end alignment procedure.
DIAGNOSIS OF FRONT END ALIGNMENT
PROBLEM
Noisy Front End
1. Worn tie rod ends.
2. Loose suspension bolts.
3. Lack of proper lubrication.
4. Loose shock absorbers or worn bush­
ings.
5. Loose stabilizer bar.
Wheel Bounce
1. Tire and wheel out of balance.
2. Blister or bump on the tire.
3. Improper shock absorber action.
4. Excessive wheel or tire run-out.
5. Tire “ Lead.”
Excessive Tire Wear
CORRECTION
POSSIBLE CAUSE
1. Incorrect wheel alignment.
2. Failure to rotate tires.
3. Faulty shock absorbers.
4. Improper tire pressure.
5. Overloaded or improperly loaded vehi­
cle.
6. Broken or sagging springs.
1. Replace ends.
2. Refer to FRONT SUSPENSIO N
(SEC. 3C).
3. Refer to MAINTENANCE AND LU­
BRICATION (SEC. OB).
4. Tighten bolts and/or replace the
bushings.
5. Tighten
1. Refer to
3E).
2. Replace
3. Replace
4. Refer to
3E).
5. Refer to
3E).
WHEELS AND TIRES (SEC.
the tire.
the shock absorber.
WHEELS AND TIRES (SEC.
WHEELS AND TIRES (SEC.
1. Align the wheels.
2. Refer to WHEELS AND TIRES (SEC.
3E).
3. Replace shock absorber.
4. Refer to WHEELS AND TIRES (SEC.
3E).
5. Avoid overloading vehicle.
6. Replace springs.
FRONT END ALIGNMENT 3A-3
ON-VEHICLE SERVICE
Front View
Side View
A minus B .. .Camber (Inches)
C . .Camber (Degrees Positive)
D . . .Caster (Degrees Positive)
E minus F .........Toe-In (Inches)
B-07371
Figure 1—Caster - Camber - Toe-In
INSPECTION
Before making any adjustments affecting caster,
camber or toe-in, the following front end inspection
should be made:
Inspect
1. Tires for proper inflation pressure. Refer to
WHEELS AND TIRES (SEC. 3E).
2. Front wheel bearing for proper adjustment. Refer
to FRONT SUSPENSION (SEC. 3C.).
3. Ball joints, tie rod ends, and relay rods. If exces­
sive looseness is noted, correct before adjusting.
Refer to STEERING LINKAGE (SEC. 3B1).
4. Wheels and tires for run-out. Refer to WHEELS
AND TIRES (SEC. 3E).
5. Dimension “ BC” in (figure 3). If not within specifi­
cations, the correction must be made before ad­
justing caster.
6. Steering gear for looseness at the frame.
7. Shock absorbers for leaks or any noticeable
noise. Refer to FRONT SUSPENSION (SEC. 3C).
8. Control arms or stabilizer bar attachments for
looseness. Refer to FRONT SUSPENSION (SEC.
3C).
9. Alignment equipment. Follow the manufacturer’s
instructions.
10. Level of the vehicle. The vehicle must be on a
level surface fore and aft and transversely.
FRONT END ALIGNMENT
REQUIREMENTS
Satisfactory vehicle operation may occur over a wide
range of front end alignment settings. If the settings
vary beyond certain tolerances, adjustments are
advisable. The “ Specifications” at the back of this
section is a guideline for vehicle diagnosis or for
repairs.
Set the front end alignment to specifications while
the vehicle is in its no rm a lly loaded condition.
Vehicles which are consistently operated with heavy
loads should have toe-in adjusted with the vehicle
under heavy load. This procedure should result in
longer tire life.
3A-4 FRONT END ALIGNMENT
A.
B. Camber
C. Add shims here to increase caster
E. Subtract shims here to increase caster
F. Add shims equally to increase camber
B-07372
Figure 2—Caster - Camber Adjustm ent Pivot Shaft Outboard Of Frame
ALIGNMENT ADJUSTMENTS
3. Determine whether the frame angle is “ up in
rear” or “ down in rear.”
A normal shim pack will leave at least two threads of
the bolt exposed beyond the nut. If two threads cannot
be obtained, check for control arms and related parts.
The difference between front and rear shim packs must
not exceed 7.62 mm (0.03 inch). Front shim pack must
be at least 2.54 mm (0.10 inch).
4. Determine the caster angle reading from the
alignment equipment.
ACESS TO SHIM PACKS
Models w ith 3/4-lnch Nut
Jack up the frame to raise the wheel off the ground.
This will allow the proper upper control arm to drop
down far enough to use a socket on the nuts and
permit shim adjustment. Torque to specifications, refer
to FRONT SUSPENSION (SEC. 3C).
Models with 7/s-lnch Nut
Remove the upper control arm bumper; then follow
the same procedure as with 3/4-inch Nut. Torque to
specifications. Reinstall the upper control arm bumper
when alignm ent is com pleted. Refer to FRONT
SUSPENSION (SEC. 3C).
CASTER
All caster specifications are given with a frame angle
of zero. Therefore, it will be necessary to know the
angle of the frame (whether “ up” in rear or “ down” in
rear) before a corrected caster reading can be
determined. Camber and toe-in can be read “ as is”
from the alignment equipment.
How To Determine Caster (Figure 2 and 3)
All caster specifications are given with vehicle frame
angle of zero.
1. Position the vehicle on a smooth level surface.
2. Use a bubble protractor or inclinom eter to
measure the frame angle. Frame angle is the
degree of tilt in the frame from the level position.
5. Refer to figure 3. To determine an “ actual
(corrected) caster reading” with various frame
angles and caster readings, one of the following
rules apply:
a. A “ DOWN IN REAR” frame angle must be
SUBTRACTED from a POSITIVE caster
reading.
b. An “ UP IN REAR” fram e angle m ust be
ADDED to a POSITIVE caster reading.
c. A “ DOWN IN REAR” frame angle must be
ADDED to a NEGATIVE caster reading.
d. An “ UP IN REAR” frame angle must be
SUBTRACTED from a NEGATIVE caster
reading.
6. Dimension “ BC” measured 90 degrees from the
lower surface of the crossmember (C) and to the
inboard rear corner of the jounce bumper bracket
(B).
7. Using dimension “ BC” and the caster, camber,
wheel toe-in chart sheet, find the recommended
caster angle.
8. If the actual (corrected) caster cycle (Step 5) is
not within the recommended caster angle (Step
7) make the necessary shim changes.
CAMBER
1. Determine the camber angle from the alignment
equipment.
2. Add or subtract shims from both the front and
rear bolts to affect a change.
FRONT END ALIGNMENT 3A-5
A. Dimension “ BC”
B. Jounce Bumper Bracket
C. Crossmember
B A
D. A “ DOWN IN REAR” frame angle must be SUB­
TRACTED from a POSITIVE caster reading.
_^o
F. A “DOWN IN REAR” frame angle must be ADDED
to a NEGATIVE caster reading.
r- HORIZONTAL
HORIZONTAL
FRAME ANGLE
= 1/2° DOWN
FRAME ANGLE = 1- V a " DOWN
CASTER ANGLE READING = + (2-1/4°)
ACTUAL (CORRECTED) CASTER ANGLE = + (1°)
E. A “UP IN REAR” frame angle must be ADDED to a
POSITIVE caster reading.
CASTER ANGLE READING = - ( - V a ° )
ACTUAL (CORRECTED) CASTER ANGLE = - ( 1 - 3/ 4 ° )
G. An “UP IN REAR” frame angle must be SUBTRACTED
from a NEGATIVE caster reading.
HORIZONTAL
HORIZONTAL
FRAME ANGLE
= 1 1/4 ° UP
FRAME ANGLE = 1° UP
CASTER ANGLE READING = + (2°)
ACTUAL (CORRECTED) CASTER ANGLE = + (3°)
■CASTER ANGLE READING = - ( 1/4 °)
ACTUAL (CORRECTED) CASTER ANGLE = + (1°)
B-07373
Figure 3—Determining Caster
TOE-IN
1. D eterm ine the toe-in from the a lig n m e n t
equipment.
2. Change the length of both tie rod sleeves to affect
a toe change. Toe-in can be increased or
decreased by changing the length of the tie rod
ends. A threaded sleeve is provided for this
purpose. When the tie rod ends are mounted
ahead of the steering knuckle they must be
decreased in length in order to increase toe-in.
When the tie rod ends are mounted behind the
steering kunckle they must be lenghtened in
order to increase toe-in. Refer to STEERING
LINKAGE (SEC. 3B1) for clamping instructions.
3A-6
K100 + 200
+ 300 (00)
-
+ 5°
+ 8°
3.2°
-
NOMINAL
NOMINAL
2.2°
2.9°
-
(References
(References
2.3°
1.9°
2.6°
5.5°
only.no
o n ly, no
1.8 °
2 .0 °
1 .6 °
2 .4 °
5 .3 °
m eans o f
m eans of
2 .3 °
1.5 °
1.7 °
1 .3 °
2 .1 °
5.0 °
a d ju stm e n t
a d ju stm e n t
0 .6 °
2 .2 °
1.2 °
1.4 °
1 .1 °
1.8°
4 .7 °
p rovided ).
p rovided ).
2 .6 °
0 .3 °
2 .0 °
1 .0 °
1 .2 °
0 .8 °
1.5°
4 .4 °
3.75
2 .4 °
0 .1 °
1 .8 °
0 .7 °
0 .9 °
0 .5 °
1.2°
4 .1 °
101.6
4.00
2 .1 °
-0 .0 1 °
1.7 °
0 .5 °
0 .6 °
0 .3 °
1.0°
3 .8 °
108
4.25
1 .8 °
-0 .1 5 °
1.5 °
0 .2 °
0 .4 °
0 .0 °
0 .7 °
3 .5 °
114.3
4.50
1 .5 °
-0 .7 °
1 .4 °
-0 .0 3 °
0 .2 °
-0 .2 °
0 .5 °
3 .3 °
120.7
4.75
1 .3 °
-1 .0 °
—
-
-0 .1 °
-0 .4 °
0 .2 °
3 .1 °
127
5.00
1 .0 °
-1 .2 °
—
—
—
—
-0 .1 °
2 .9 °
133.4
5.25
-1 .4 °
-
—
—
—
-0 .3 °
2 .6 °
139.7
5.50
0 .5 °
-1 .6 °
-
-
—
—
-0.5
2 .4 °
146
5.75
0 .3 °
-1 .8 °
—
-
-
—
-0 .7 °
2 .2 °
152.4
6.00
0°
-
—
-
-
—
—
2 .0 °
Dimension
“ BC”
Inches
38.1
1.50
44.5
P300 (32)
P300
w/JB8 or JB9 w/JB8 or JB9
Except FS3
Except FS3
C200 + 300
(00)
G100 + 200
(00)
G300
(00)
-
—
3.4°
3.1°
-
-
-
-
1.75
-
—
3.2°
3.0°
—
—
—
50.8
2.00
—
-
3.0°
2.7°
3.0°
2.5°
57.2
2.25
—
-
2.9°
2.4°
2.6°
63.5
2.50
3.7°
1.5°
2.7°
2.1°
70
2.75
3 .5 °
1.2 °
2 .5 °
76.2
3.00
3 .2 °
0 .9 °
82.5
3.25
2 .9 °
88.9
3.50
95.3
C100
(00)
c/>
g m
w O
m T1
= o
S >
>
2
3 0
V)
FRONT END ALIGNMENT
P200 + 300
(42) W/R05
Except FS3,
JB8 or JB9
o
oo
o
P200 + 300
(42) Except
FS3, R05,
JB8 or JB9
P30/3500
(32,42)
W/FS3
Dimension
“ BC”
MM
FRONT END ALIGNMENT 3A-7
SPECIFICATIONS (CONTINUED)
CAMBER AND TOE-IN CHART
Model
Camber
Toe Angle
Total Toe-In
C100 (00)
0.70°
0.36°
4.5 mm (0.18 inch)
C200 + 300 (00)
0.25°
K100 + 200 + 300 (00)
+ 1.5°
Nominal
(Reference only
no means of
adjustment provided).
0°
0 mm (0 inch)
G100 + 200 (00)
0.50°
0.36°
4.5 mm (0.18 inch)
G300 (00)
0.25°
0.36°
4.5 mm (0.18 inch)
0.1°
3.0 mm (0.12 inch)
P200 + 300 (32, 42)
Except FS3
0.25°
P30/3500 (32,42)
with FS3
+ 1.5°
Nominal
(Reference only
no means of
adjustment provided).
CASTER, CAMBER, WHEEL TOE-IN
ALIGNMENT SETTING TOLERANCES
Check
Re-Set
Caster
± 1.00°
± 0.50°
Camber
± 0.75°
± 0.50°
Total
Toe-In
± 3.0 mm (0.12 inch)
± 1.5 mm (0.06 inch)
± 0.232°
± 0.116°
STEERING LINKAGE 3B1-1
SECTION 3B1
STEERING LINKAGE
The following “ Notice” applies to one or more steps in the assembly procedure of components in this portion of
the manual as indicated at appropriate locations by the terminology: “ NOTICE: See ‘Notice’ on page 3B1-1 of this
section.”
NOTICE: All steering linkage fasteners are im portant attaching parts in that they could affect the perform ­
ance o f vital parts and systems, and/or could result in major repair expense. They must be replaced w ith one
o f the same part num ber o r w ith an equivalent part if replacement becomes necessary. Do not use a replace­
ment part o f lesser quality or substitute design. Torque values must be used as specified during reassembly
to assure proper retention o f all parts.
CONTENTS
SUBJECT
PAGE
D e s c rip tio n ................................................................................................................................................................ 3B1- 1
Diagnosis Of Steering L in kag e ............................................................................................................................. 3B1- 2
On-Vehicle S e r v ic e ................................................................................................................................................. 3B1- 2
Idler Arm Inspection.............................................................................................................................................3B1- 2
Idler Arm Adjustm ent (P30(32) M o to rh o m e )................................................................................................. 3B1- 3
Idler Arm R e p la c e m e n t...................................................................................................................................... 3B1- 3
Relay Rod Replacem ent...................................................................................................................................... 3B1- 5
Pitman Arm R e p la ce m e n t..................................................................................................................................3B1- 6
Steering Shock Absorber In s p e c tio n .............................................................................................................. 3B1 - 7
Steering Shock Absorber Replacem ent.......................................................................................................... 3B1- 8
Tie Rod Replacement (C, G, P20 And 30(42) M o d e ls .................................................................................. 3B1- 8
Tie Rod Replacement (K and P30(00)FS3 M o d e ls ).......................................................................................3B 1- 9
Connecting Rod Replacement (K and P30(00)FS3 M o d e ls)....................................................................... 3B1-11
Connecting Rod Replacement (P30(32) M o to rh o m e ).................................................................................. 3B1-12
S pecifications............................................................................................................................................................3B1 -14
Special T o o ls ............................................................................................................................................................3B1-15
DESCRIPTION
The steering linkage for the C, G, and P20 + 30(42)
model is composed of a pitman arm, idler arm, relay
rod, two adjustable tie rods and a steering shock ab­
sorber (G-model). When the steering wheel is turned,
the gear rotates the pitman arm which forces the relay
rod to one side. The tie rods, which are connected to
the relay rod by ball studs, transfers the steering force
to the wheels. The tie rods are adjustable and are used
for toe-in adjustments. The relay rod is supported by
the pitman arm and idler arm. The idler arm pivots on a
support attached to the frame rail. On the G-model the
steering shock absorber is attached to a relay rod and
a mounting bracket to the steering gear.
The P30(32) Motorhome model steering linkage has
a similar adjustable tie rod assembly as described
above. When the steering wheel is turned, the gear
rotates the pitman arm which forces the nonadjustable
connecting rod and relay arm to move the relay rod to
one side. The relay arm and idler arm are attached to
the frame by support assemblies. The support as­
semblies are adjustable for shaft end play. The
steering shock absorber is attached to the frame and
relay arm (figures 1 through 3).
The K model has a front driving axle assembly and
the P30(00) with RPO-FS3 has an I-Beam axle assem­
bly. The steering linkage consists of an adjustable con­
necting rod, steering shock absorber, pitman arm and
a tie rod which connects the two steering knuckles to­
gether (figures 7 and 8).
The overall condition of the steering linkage affects
steering performance. If parts are bent, damaged,
worn or poorly lubricated, improper and possibly dan­
gerous steering action will result.
Whenever any steering linkage components are re­
paired or replaced, check the steering geometry and
front end alignment. Refer to FRONT END ALIGN­
MENT (SEC. 3A).
3B1-2 STEERING LINKAGE
DIAGNOSIS OF STEERING LINKAGE
Refer to MANUAL STEERING (SEC. 3B2) or POWER STEERING (SEC. 3B3) in this manual, depending on
vehicle equipment.
ON-VEHICLE SERVICE
1.
2.
3.
4.
5.
6.
Idler Arm
Relay Rod
Tie Rod Assembly
Steering Knuckle
Pitman Arm
Steering Gear
B-09657
Figure 1—Steering Linkage (C and P20 + 30(42) Models)
IDLER ARM INSPECTION
Inspect (Figures 4 and 5)
1. Raise the vehicle. Allow the front wheels to rotate
freely and the steering mechanism freedom to
turn. Position the wheels in a straight ahead
position.
2. Place a spring scale near the relay rod end of the
idler arm. Exert a 110 N (25 lb.) force upward and
then downward (G model the force is forward and
rearward) while measuring the total distance the
arm moves. The allowable deflection is ± 3.18mm
(Vs inch) for a total of 6.35mm (1A> inch) (figures 4
and 5). Replace the idler arm if it fails this test
with the exception of the P model motorhome.
Refer to “ Idler Arm Adjustment (P 30(32) Mo­
torhome)” in this section.
Im portant
• Jerking the right wheel and tire assembly back
and forth, causing an up and down movement of
the idler arm, is NOT an acceptable testing
procedure. There is no control on the amount of
force being applied to the idler arm.
• Care sh o u ld be used w h e n e ve r sh im m y
complaints are suspected of being caused by
loose idler arms. Before suspecting suspension
or steering components, technicians should
consider areas such as dynamic imbalance,
runout or force variation of wheel and tire
assemblies and road surface irregularities. Refer
to WHEELS AND TIRES (SEC. 3E).
STEERING LINKAGE 3B1-3
1.
2.
3.
4.
5.
6.
7.
9.
Idler Arm
Relay Rod
Tie Rod Assem bly
Steering Knuckle
Pitman Arm
Steering Gear
Shock A bsorber
Bracket
B-09659
Figure 2—Steering Linkage (G Model)
IDLER ARM ADJUSTMENT
(P30(32) MOTORHOME)
IDLER ARM REPLACEMENT
Important
The frame mounted idler support assembly (10) is
adjustable for support shaft end play. Check for idler
arm movement as described in “ Idler Arm Inspection.”
If the idler arm fails this test, adjust the support shaft
end-play.
Do not attempt to free the ball stud by using a
pickle fork or wedge type tool, because seal or
bushing damage could result (figure 6). Use the
proper tool to separate all ball joints.
Remove or Disconnect (Figures 1 and 2)
Adjust (Figure 3)
1. Loosen the support assembly jam nut.
2. Tighten the adjuster plug to metal-to-metal
contact.
3. Back off the adjuster plug 1/b of a turn (V2 of a flat
on the square nut).
•
1.
2.
3.
L*
Tool Required:
J-24319-01 Steering Linkage Puller.
Raise the vehicle.
Idler arm frame bolts.
Nut from the idler arm ball stud.
Idler arm (1) from the relay rod (2). Use
J-24319-01.
Inspect
— Ball stud threads for damage.
— Ball stud seal for cuts or other damage.
• Jam nut to 40 N m (30 ft. lbs.). The adjusting
plug should not rotate.
Clean
• Threads on the ball stud and in the ball stud nut.
3B1-4 STEERING LINKAGE
1.
Idler Arm
2. Relay Rod
3.
4.
5.
6.
7.
8.
10.
11.
12.
13.
Tie Rod Assembly
Steering Knuckle
Pitman Arm
Steering Gear
Shock Absorber
Connecting Rod
Support Assem blies
Relay Arm
Washer
Grommet
B-09656
Figure 3—Steering Linkage (P30(32) Motorhome)
-►«- Install or Connect (Figures 1 and 2)
Tools Required:
J-29193 Steering Linkage Installer (12mm).
J-29194 Steering Linkage Installer (14mm).
NOTICE: For steps 1 and 3 see “Notice” on
page 3B1-1 of this section.
• Position the idler arm (1) on the frame.
1. Frame bolts to the idler arm.
Tighten
• Bolts to “ Specifications” at the end of this
section.
2. Relay rod (2) to the idler arm ball stud. Make
certain the seal is on the stud. Tighten tool
J-29193 or J-29194 to 54 N-m (40 ft. lbs.) to seat
the tapers. Remove the tool.
3. Prevailing torque nut to the idler arm ball stud.
Tighten
• Nut to “ Specifications” at the end of this
section.
• Lower the vehicle.
Adjust
• Toe-in if necessary. Refer to FRONT END
ALIGNMENT (SEC. 3A) in this manual.
STEERING LINKAGE 3B1-5
RELAY ROD REPLACEMENT
Im portant
• Use the proper tool to separate all tie rod and ball
joints.
+ + Remove or Disconnect (Figures 1 through 3)
Tool Required:
J-24319-01 Steering Linkage Puller.
• Raise the vehicle.
Inspect
1. Inner tie rod (3) from the relay rod (2). Refer to
“ Tie Rod Replacement” in this section.
• Threads on the tie rod and the tie rod end for
damage.
2. Nuts from the idler arm (1) and pitman arm (5) or
relay arm (11) ball studs at the relay rod (2).
• Ball stud threads for damage.
3. Relay rod (2) from the idler arm (1). Use
J-24319-01.
4. Relay rod (2) from the pitman arm (5) or relay arm
(11). Use J-24319-01.
• Ball stud seals for excessive wear.
3
Clean
• Threads on the ball stud and the ball stud nut.
Install or Connect (Figures 1 through 3)
Tools Required:
J-29193 Steering Linkage Installer (12mm).
J-29194 Steering Linkage Installer (14mm).
1. Relay rod (2) to the idler arm (1) and the pitman
arm (5) or relay arm (11) ball stud. Make certain
the seal is on the stud. Tighten J-29193 or
J-29194 to 54 N m (40 ft. lbs.) to seat the tapers.
Remove the tool.
A. 6.35 mm ( V a " )
B. Apply Spring Scale
B-07378
Figure 5—Checking idler Arm Movement (G-Model)
NOTICE: See “Notice” on page 3B1-1 of this
section.
2. Nuts to the idler arm and the pitman arm or relay
arm ball stud.
3B1-6 STEERING LINKAGE
3.
4.
5.
6.
7.
8.
Tie Rod Assembly
Steering Knuckle
Pitman Arm
Steering Gear
Shock Absorber
Connecting Rod Assembly
B-07367
Figure 7—Steering Linkage (P30(00)FS3)
Tighten
• Nuts to “ Specifications” at the end of this
section.
3. Inner tie rod (3) to the relay rod. Refer to “ Tie Rod
Replacement.”
• Lower the vehicle.
Mark the pitman arm and the pitman shaft. This
will permit proper alignment at assembly.
NOTICE: Do not hammer on pitman arm,
pitman shaft, or puller. Damage to pitman arm
or steering gear may result.
4. Pitman arm (5). Use J-6632-01 or J-29107.
PITMAN ARM REPLACEMENT
y | Inspect
Im portant
• Ball stud threads for damage.
• Use the proper tool to separate all ball joints.
• Ball stud seals for excessive wear.
Remove or Disconnect (Figures 1, 2, 3, 7 and
8)
•
1.
2.
3.
Tools Required:
J-24319-01 Steering Linkage Puller.
J-29107 Pitman Arm Puller.
J-6632-01 Pitman Arm Remover.
Raise the vehicle.
Relay rod nut or connecting rod nut and cotter pin
from the pitman arm ball stud.
Relay rod (2) or connecting rod (8) from the
pitman arm (5). Use J-24319-01.
Pitman arm nut and washer.
jQJ Clean
• Threads on the ball stud and ball stud nut.
-►4- Install or Connect (Figures 1, 2, 3, 7 and 8)
Tools Required:
J-29193 Steering Linkage Installer (12mm).
J-29194 Steering Linkage Installer (14mm).
STEERING LINKAGE 3B1-7
A.
3.
4.
5.
7.
8.
Tie Rod Assem bly (K30)
Tie Rod Assembly
Steering Knuckle
Pitman Arm
Shock Absorber
Connecting Rod Assembly
B-09660
Figure 8—Steering Linkage (K Model)
NOTICE: For steps 2 and 4 see ‘Notice” on
page 3B1-1 of this section.
NOTICE: If a clamp type pitman arm is used,
spread the pitman arm just enough, with a
wedge, to slip the arm onto the pitman shaft.
Do not spread the pitman arm more than
required to slip over the pitman shaft with
hand pressure. Do not hammer, or damage to
the steering gear may result.
1. Pitman arm (5) on the pitman shaft. Line up the
marks made at removal.
2. Pitman arm washer and nut.
3. Relay rod (2) or connecting rod (8) to the pitman
arm ball stud. Make certain the seal is on the
stud. Tighten tool J-29193 or J-29194 to 54 N m
(40 ft. lbs.) to seat the tapers. Remove the tool.
4. Relay rod nut or the connecting rod castellated
nut and cotter pin to the pitman arm ball stud.
• Castellated nut to “ S pe cifica tio ns” as
instructed at the end of this section.
• Lower the vehicle.
STEERING SHOCK ABSORBER
INSPECTION
S i Tighten
• Pitman arm nut to “ Specifications” at the
end of this section.
Steering shock absorbers are a sealed assembly
and are non re p airab le . Replace the com plete
assembly if damaged.
3B1-8 STEERING LINKAGE
Inspect (Figures 2, 3, 7 and 8)
I?
1. Shock absorber for fluid leakage. A slight film of
fluid is allowable near the shaft seal. If there is
excessive fluid leakage, be sure it’s from the
shock absorber and then replace the shock
absorber.
2. Shock absorber bushing for excessive wear.
Replace shock absorber if necessary.
3. Test the shock absorber.
• Disconnect the shock absorber from the
frame or axle end.
• Extend and compress the shock absorber
usin g as m uch tra ve l as p o s s ib le .
Resistance should be smooth and constant
for each stroking rate. Replace the shock
absorber if any binding or unusual noises
are present.
• Install the end of the shock absorber. Torque
to specifications.
STEERING SHOCK ABSORBER
REPLACEMENT
Tighten
• Castellated nut to “ S pecifications” as
instructed at the end of this section.
TIE ROD REPLACEMENT
(C, G, P20 AND 30(42) MODELS)
There are two tie rod assemblies. Each assembly is
of a five piece construction, consisting of an adjuster
tube, two clamps and two tie rod ends. The ends are
threaded into the sleeve and secured with the clamps.
Right and left hand threads are used for toe-in
adjustments and steering gear centering. The tie rod
ends should be replaced when excessive up and down
motion is present, or when excessive end play or loss
of motion at the ball stud exists.
Before servicing, note the position of the tie rod
adjuster tube and the direction the bolts are installed.
The tie rod adjuster tube components may be rusted. If
the torque required to remove the nut from bolt
exceeds 9 N m (7 ft. lbs.) discard the nuts and bolts.
Apply penetrating oil between the clamp and tube and
rotate the clamps until they move freely. Install all
parts, with the correct part number, in the proper
position.
Remove or Disconnect
B
1. Shock absorber mounting nuts and washers.
• Washer (12) and grommet (13) (P30(32) model).
2. Cotter pin and castellated nut.
Im portant
Use the proper tool to separate all tie rod and ball
joints.
3. Shock absorber (7).
Remove or Disconnect (Figures 1 through 3)
L * Inspect
— Shock absorber for leaks and damage.
— Shock absorber bushings for wear and damage.
— Grommet (13) for wear.
+4-
Install or Connect
NOTICE: For steps 2 and 3 see “ Notice” on
page 3B1-1 of this section.
1. Shock absorber with bushings to the axle
bracket.
• Washer (12) and grommet (13) (P30(32) model).
Tool Required:
J-6627-A Wheel Stud Remover and Tie Rod
Remover.
• Raise the vehicle.
1. Cotter pins and castellated nuts from the outer tie
rod ball stud.
2. Outer tie rod ball studs from the steering knuckle
(4). Use J-6627-A (figure 9).
3. Inner tie rod ball stud from the relay rod (2). Use
J-6627-A.
4. Tie rod ends from the adjuster tube. Loosen the
clamp bolts and unscrew the end assemblies.
J ? Inspect
2. Shock absorber mounting nuts and washers.
— Tie rod end for damage.
• Shock absorber nuts to “ Specifications” at
the end of this section.
3. Castellated nut and cotter pin.
— Tie rod end seals for excessive wear.
— Threads on the tie rod and tie rod end for
damage.
— Ball stud threads for damage.
— Adjuster tube for bending or damaged threads.
STEERING LINKAGE 3B1-9
Adjust
Clean
The tapered surfaces.
Threads on the ball stud and in the ball stud nut.
• Toe-in. Refer to FRONT END ALIGNMENT
(SEC. 3A) in this manual.
6. Adjuster tube clamp bolts (figures 10, 11 and 12).
Before tightening the clamp bolts, be sure the
following conditions have been met:
• The clamp must be positioned between the
locating dim ples at e ithe r end of the
adjuster tube.
• The clamps must be positioned within the
angular travel shown in figures 10, 11 or 12.
• Both inner and outer tie rod ends must
rotate for their full travel. The position of
each tie rod end must be maintained as the
cla m p s are tig h te n e d to e nsure free
movement of each joint.
• The clamp ends may touch when nuts are
torqued to specification, but the gap next to
the adjuster tube must NOT be less than the
minimum dimension shown in figures 10, 11
or 12.
Tighten
-►«- Install or Connect (Figures 1 through 3)
• A d ju s te r
tu b e
cla m p
b o lts
to
“ Specifications” at the end of this section.
Tools Required:
J-29193 Steering Linkage Installer (12mm).
J-29194 Steering Linkage Installer (14mm).
TIE ROD REPLACEMENT
(K AND P30(00)FS3 MODELS)
NOTICE: For steps 3 and 5 see “ Notice” on
page 3B1-1 of this section.
• If the rod ends were removed, lubricate the tie rod
threaas with chassis lubricant.
1. Tie rod ends to the adjuster tube. The number of
threads on both the inner and outer rod ends
must be equal within three threads.
2. Inner tie rod ball studs to the relay rod (2). The
seal must be on the stud. Tighten J-29193 or
J-29194 to 54 N m (40 ft. lbs.) to seat the tapers.
Remove the tool.
3. Prevailing torque nut to the inner tie rod ball stud.
Remove or Disconnect (Figures 7 and 8)
1.
2.
3.
4.
5.
• Nut to “ Specifications” at the end of this
section.
Tool Required:
J-6627-A Wheel Stud Remover and Tie Rod
Remover.
Cotter pins and castellated nuts from the rod
assembly (3).
Shock absorber (7) from the tie rod assembly (3).
The rod ball studs from the steering knuckle (4).
Use J-6627-A.
Tie rod end bodies. Count the number of turns
needed to remove the tie rod end bodies.
Tie rod ends from the adjuster tube. On K30
models, note the position of the adjuster tube,
and the direction from which the bolts are in­
stalled.
4. Outer tie rod ball studs to the steering knuckle.
5. Castellated nuts and cotter pins to the outer rod
ball studs.
I?
Inspect
— Tie rod for bending or damaged threads.
— Tie rod end seals for wear.
— Ball stud threads for damage.
• Castellated nuts to “ Specifications” as
instructed at the end of this section.
— Adjuster tube for bending or damaged threads
(K30).
3B1-10 STEERING LINKAGE
VIEW A
4.
C.
D.
E.
F.
G.
Steering Knuckle
Clamps Must Be Between And Clear Of Dimples Before Torquing Nuts
Adjuster Tube Slot
Slot In Adjuster Tube Must Not Be W ithin This Area Of Clamp Jaws.
Rearward Rotation
ki
Clamp Ends May Touch When Nuts Are Torqued To Specifications.
But The Gap Next To The Adjuster Tube Must Be Visible. Minimum Gap Is 0.127 mm (0.005 Inch).
B-07290
Figure 10—Tie Rod Clamp And A djuster Tube Positioning (C Model)
4FRT
4.
C.
D.
E.
F.
G.
Steering Knuckle
i
Clamp Must Be Between And Clear Of Dimples Before Torquing Nuts
Slot In A djuster Tube Must Not Be W ithin This Area Of Clamp Jaws
Rearward Rotation
Adjuster Tube Slot
Clamp Ends May Touch When Nuts Are Torqued To Specifications.
But The Gap Next To The Adjuster Tube Must Be Visible. Minimum Gap Is 0.127 mm (0.005-inch).
B-07291
Figure 11—Tie Rod Clamp And A djuster Tube P ositioning (G Model)
VIEW A
4.
C.
D.
E.
F.
G.
Steering Knuckle
Clamps Must Be Between And Clear Of Dimples Before Torquing Nuts
Adjuster Tube Slot
Slot In Adjuster Tube Must Not Be W ithin This Area Of Clamp Jaws.
Rearward Rotation
Clamp Ends May Touch When Nuts Are Torqued To Specifications.
But The Gap Next To The Adjuster Tube Must Be Visible. Minimum Gap Is 0.127 mm (0.005 Inch).
B-07292
Figure 12—Tie Rod Clamp And Adjuster Tube Positioning (All P Models Excluding FS3)
STEERING LINKAGE 3B1-11
Clean
Remove or Disconnect (Figures 7 and 8)
— The tapered surfaces.
— Threads on the ball stud and in the ball stud nut.
+ + Install or Connect (Figures 7 and 8)
• If the tie rod ends were removed, lubricate the tie
rod threads with chassis lubricant.
•
1.
2.
3.
1. Tie rod end bodies to the tie rod (if removed).
Screw the rod assembly on the same number of
turns as when removed.
Tool Required:
J-24319-01 Steering Linkage Puller.
Raise the vehicle.
C astellated nuts and cotter pins from the
connecting rod (8).
Connecting rod (8) from the pitman arm (5). Use
J-24319-01.
Connecting rod (8) from the steering knuckle (4).
Use J-24319-01.
Im portant
• Tie rod ends to the adjuster tube (K30).
2. Outer tie rod ball studs to the steering knuckle
(4).
3. Shock absorber (7) to the tie rod assembly.
NOTICE: See “Notice” on page 3B1-1 of this
section.
4. Castellated nuts and cotter pins to the tie rod
assembly.
&
Tighten
• Castellated nuts to “ Specifications” as
instructed at the end of this section.
• B efore rem oving the co n n e c tin g rod
adjuster tube, note the position of the tube
and the direction from which the bolts are
installed.
4. Connecting rod ends from the adjuster tube.
Loosen the clamp bolts and unscrew the end
assemblies.
• The c o n n e c tin g rod a d ju s te r tub e
components may be rusted. If the torque
required to remove the nut from the bolt
exceeds 9 N m (7 ft. lbs.) discard the nuts
and bolts.
• Apply penetrating oil between the clamps
and the tube. Rotate the clamps until they
move freely.
L*
Ball stud threads for damage.
Ball stud seals for wear.
Adjuster tube for bending or damaged threads.
• Toe-in. Refer to FRONT END ALIGNMENT
(SEC. 3A) in this manual.
Tighten
• Jam nut at the tie rod end bodies to
“ Specifications” at the end of this section.
• A d ju s te r
tu b e
cla m p
b o lts
to
“ Specifications” at the end of this section
(K30).
Inspect
jg ,
Clean
Threads on the ball stud and ball stud nut.
+ «- Install or Connect (Figures 7 and 8)
NOTICE: For steps 3 and 5 see “Notice” on
page 3B1-1 of this section.
CONNECTING ROD
REPLACEMENT
(K AND P30(00)FS3 MODEL)
The adjustable connecting rod is used for centering
the steering gear with the front axle. Replace the
connecting rod if the rod is bent or if the ball stud is
loose.
Im portant
• Use the proper tool to separate all ball joints.
• If the connecting rod ends were removed,
lubricate the connecting rod threads with chassis
lubrication.
1. Connecting rod ends to the adjuster tube. The
number of threads on both the inner and outer
connecting rod ends must be equal within three
threads.
2. Inner connecting rod (8) ball stud to the pitman
arm (5) (on K models install the short end). Make
certain the seal is on the stud.
3. Castellated nut and cotter pin to the inner
connecting rod ball stud.
3B1-12 STEERING LINKAGE
l^l Tighten
• Castellated nut to “ S pecifications” as
instructed at the end of this section.
4. Outer connecting rod ball stud to the steering
knuckle (4).
5. Castellated nut and cotter pin to the outer
connecting rod ball stud.
Tighten
• Castellated nut to “ S pe cifications” as
instructed at the end of this section.
The connecting rod ends to the pitman arm and
steering knuckle must be in correct relationship
to each other after adjustm ent within ± 2
degrees (K model).
ft
Adjust
• Steering gear high point centering. Refer to
POWER STEERING (SEC. 3B3) in this
manual.
6. Adjuster tube clamp bolts (figures 13 and 14).
Before tightening the clamp bolts, be sure the
following conditions have been met.
• The clamps must be positioned between the
locating dim ples at either end of the
adjuster tube.
• The clamps must be positioned within the
angular travel shown in figures 13 and 14.
• The clamp ends may touch when nuts are
torqued to sp e c ific a tio n , but the gap
adjacent to adjuster tube must NOT be less
than minimum dimension shown in figures
13 and 14.
• Both inner and outer connecting rod ends
must rotate for their full travel. The position
of each connecting rod end must be
maintained as the clamps are tightened to
ensure free movement of each joint.
$
Tighten
• Adjuster tube bolts to “ Specifications” at
the end of this section.
• Lower the vehicle.
CONNECTING ROD
REPLACEMENT
(P30(32) MOTORHOME)
The non-adjustable connecting rod is used to
connect the pitman arm to the relay arm. Replace the
connecting rod if the rod is bent or the ball stud is
loose.
VIEW A
C. Clamps must be between and clear of
dimples before torquing nuts.
D. Outboard Rotation
E. Adjuster Tube Slot
F. Slot in adjuster tube must not be within
this area of clamp jaws.
G. Clamp ends may touch when nuts
are torqued to specifications. But the gap
next to the adjuster tube must be visible.
Minim um gap is 0.127 mm (0.005-inch).
B-07293
Figure 13—Connecting Rod Clamp And Adjuster
Tube Positioning (P30(00)FS3)
STEERING LINKAGE 3B1-13
C. Slot Of Adjuster Tube May Be In Any Position On Arc Shown But Not Closer Than 2.54 mm (0.10
Inch) To The Edge Of Clamp Jaws Or Between.
R_n7 ?q
Figure 14—Connecting Rod d a m p And Adjuster Tube P ositioning (K Model)
Im portant
Use the proper tool to separate the ball joints.
Remove or Disconnect (Figure 3)
•
1.
2.
3.
Tool Required:
J-24319-01 Steering Linkage Puller.
Raise the vehicle.
C astellated nuts and cotter pins from the
connecting rod (8).
Connecting rod (8) from the pitman arm (5). Use
J-24319-01.
Connecting rod (8) from the relay arm (11). Use
J-24319-01.
Inspect
— Ball stud threads for damage.
— Ball stud seals for excessive wear.
Clean
• Threads on the ball stud and ball stud nut.
Install or Connect (Figure 3)
1. Connecting rod (8) to the pitman arm (5) and relay
arm (11).
2. Castellated nuts and cotter pins.
£
Tighten
• Castellated nuts to “ Specifications” as
instructed at the end of this section.
• Lower the vehicle.
3B1-14
SPECIFICATIONS
P20 AND 30(42)
G Model
P30(32) IVotorhome
P30(00)FS3
K Model
Nm
F t. Lbs.
Nm
F t. Lbs.
Nm
F t. Lb s.
Nm
Ft. Lbs.
Nm
F t. Lbs.
Nm
F t. Lb s.
Tie Rod (3) End To Steering Knuckle (4)*
62
46
62
46
62
46
62
46
220
162
55
40
Tie Rod (3) Adjuster Tube Bolts
19
14
19
14
19
14
19
14
—
—
55
40
Tie Rod (3) To Relay Rod (2)
90
66
90
66
90
66
90
66
—
—
—
—
Idler Arm (1) To Relay Rod (2)
90
66
90
66
90
66
90
66
—
—
—
—
40
30
47
35
40
30
—
—
—
—
—
—
90
66
90
66
90
66
—
—
—
—
—
—
Pitman Arm (5) To Steering Gear (6)
250
184
250
184
250
184
170
125
Bolt To Shock Absorber Bracket (9)
—
—
100
75
—
—
—
—
Shock Absorber (7) To Tie Rod (3)*
—
—
62
46
—
—
—
—
Shock Absorber (7) To Frame
—
—
62
46
—
—
11
8
Shock Asborber (7) To Idler Arm (1)*
—
—
—
—
—
—
62
Connecting Rod (8) To Adjuster Tube Bolts
—
—
—
—
—
—
Connecting Rod (8) To Pitman Arm (5)*
—
—
—
—
—
—
Connecting Rod (8) To Steering Knuckle (4)*
—
—
—
—
—
—
Connecting Rod (8) To Relay Arm (11)*
—
—
—
—
—
Support Assemblies (10) To Frame
—
—
—
—
—
170
125
—
—
125
92
—
—
62
46
62
46
47
35
110
81
46
—
—
—
—
—
—
68
50
54
40
95
70
95
70
120
89
—
—
95
70
120
89
—
95
70
—
—
—
—
—
65
48
—
—
—
—
i 7 fi
1/U
I^D
—
—
—
—
Idler Arm (1) And Relay Arm (11) To
Support Assemblies (10)
Relay Rod (2) To Relay Arm (11)
—
—
—
—
—
—
90
66
Tie Rod Jam Nut (K10, 20) & P30(00)FS3
—
—
—
—
—
—
—
—
* Tightening Procedure (Castellated Nuts)
1. Tighten to the specified torque.
2. Advance the nut to align the nut slot with the cotter pin hole. Never back the nut off to align the cotter pin hole.
3. Insert a new cotter pin of the correct size.
375
277
125
92
LINKAGE
Idler Arm (1) To Frame
Pitman Arm (5) To Relay Rod (2)
STEERING
C Model
STEERING LINKAGE 3B1-15
SPECIAL TOOLS
J-6627-A
J-6632-01
J-29107
J-24319-01
J-29193
J-29194
Wheel Stud Remover & Tie Rod Remover
Pitman Arm Remover
Pitman Arm Puller
Steering Linkage Puller
Steering Linkage Installer (12mm)
Steering Linkage Installer ( 1 4 m m )
3B2-1
SECTION 3B2
MANUAL STEERING GEAR
The following notice applies to one or more steps in the assembly procedure of components in this portion of the
manual as indicated at appropriate locations by the terminology “ NOTICE: See ‘Notice’ on page 3B2-1 of this
Section.”
NOTICE: These fasteners are important attaching parts in that they could affect the performance of vital
components and systems, and/or could result in major repair expense. They must be replaced with one of
the same part number or with an equivalent part if replacement becomes necessary. Do not use a replace­
ment part of lesser quality or substitute design. Torque values must be used as specified during reassembly
to assure proper retention of these parts.
CONTENTS
SUBJECT
PAGE
Description .................................................................................................................................................................3B2Diagnosis Of Manual Steering System ................................................................................................................ 3B2On-Vehicle S e r v ic e ................................................................................................................................................. 3B2M a in te n a n ce ..........................................................................................................................................................3B2Steering Gear Replacem ent................................................................................................................................3B2Pitman Shaft Seal R e p lace m e n t....................................................................................................................... 3B2Steering Gear A d ju s tm e n ts ................................................................................................................................3B2Steering Gear High Point C e n te rin g .................................................................................................................3B2S pe cifica tio ns............................................................................................................................................................ 3B2Special T o o ls ............................................................................................................................................................3B2-
1
2
3
3
3
4
5
6
7
7
DESCRIPTION
The steering gear is the recirculating ball nut and
worm type. The worm is located on the lower end of
the steering shaft. The ball nut is mounted on the worm
and the steel balls act as a rolling thread between the
worm and nut to provide a low friction drive between
them.
Teeth on the ball nut engage teeth on the pitman
shaft sector. The teeth on the ball nut are made so that
a tighter fit exists between the ball nut and pitman
shaft sector teeth when the front wheels are in the
straight ahead position. The sector teeth are slightly
tapered so that a proper preload may be obtained by
moving the pitman shaft endways by means of a pre­
load adjuster screw which extends through the gear
housing side cover. The head of the preload adjuster
and a selectively fitted shim fit snugly into a T-slot in
the end of the pitman shaft, so that the screw also
controls the end play of the shaft (figure 1).
1.
2.
3.
4.
5.
6.
7.
8.
9.
Ball Nut
Worm Bearing
Seal
Wormshaft
Balls and Guides
Adjuster Plug
Nut
Worm Bearing (Lower)
Pitman Shaft Sector
B-07349
Figure 1—Manual Steering Gear
3B2-2 MANUAL STEERING GEAR
DIAGNOSIS OF MANUAL STEERING SYSTEM
PROBLEM
POSSIBLE CAUSE
Rattle Or Chuckle In
The Steering Gear
1. Insufficient or improper lubricant in the
steering gear.
2. Pitman arm loose on the shaft or the
steering gear mounting bolts loose.
3. Loose or worn steering shaft bearing.
4. Excessive over-center lash or worm
thrust bearings adjusted too loose. On
turns a slight rattle may occur, due to
the increased lash between ball nut
and pitman shaft as gear moves off the
center of “ high point” position. This is
normal and lash must not be reduced
to eliminate this slight rattle.
Poor Return Of The
Steering Wheel
1. Steering column misaligned.
2. Insufficient or improper lubricant in the
steering gear or front suspension.
3. Steering gear adjusted too tight.
4. Front w heel a lig n m e n t in c o rre c t
(Caster).
Excessive Play Or
Looseness In The
Steering System
1. Front wheel bearings loosely adjusted.
2. Steering system out of alignment.
3. Worn upper ball joints.
4. Steering wheel loose on the shaft,
loose pitman arm, tie rods, steering
arms or steering linkage ball nuts.
5. T ire s b ad ly w orn, edge of tire s
rounded off.
6. Excessive over-center lash.
7. Worm thrust bearings loosely ad­
justed.
Hard Steering —
Excessive Effort
Required At The
Steering Wheel
1. Low or uneven tire pressure.
2. Insufficient or improper lubricant in the
steering gear or front suspension.
3. Steering shaft flexible coupling mis­
aligned.
4. Steering gear adjusted too tight.
5. Front wheel alignment incorrect.
CORRECTION
1. Add specified lube.
2. Tighten to specified torque.
3. Replace steering shaft bearing.
4. Adjust steering gear to specified pre­
loads.
1. Align the column.
2. Lubricate as specified.
3. Adjust over-center and thrust bearing
preload to specifications.
4. Adjust to specifications.
1. Adjust bearings or replace with new
parts as necessary.
2. Align caster, camber, and toe-in.
3. Check and replace ball joints if nec­
essary.
4. Tighten to specification, replace if
worn or damaged.
5. Install new tires, and check align­
ment.
6. Adjust over-center preload to specifi­
cations.
7. Adjust the worm thrust bearing pre­
load to specifications.
1. Inflate to specified pressures.
2. Lubricate as specified. Relubricate at
specified intervals.
3. Align the column and couplings.
4. Adjust over-center and thrust bearing
preload to specifications.
5. Check the alignment and correct as
necessary.
MANUAL STEERING GEAR 3B2-3
ON-VEHICLE SERVICE
MAINTENANCE
The steering gear is factory-filled with steering gear
lubricant. Seasonal change of the lubricant should not
be performed and the housing should not be drained.
No additional lubrication is required for the life of the
steering gear.
At intervals specified in MAINTENANCE AND
LUBRICATION (SEC. OB) of this manual, the gear
should be inspected for seal leakage (actual solid
grease — not just oily film). If a seal is replaced or the
gear is overhauled, the gear housing should be refilled
with Steering Gear Lubricant meeting GM specification
1051052 (or equivalent).
NOTICE: DO NOT USE EP Chassis Lube to
lubricate the gear. DO NOT OVER-FILL the
gear housing, or damage may occur.
STEERING GEAR
REPLACEMENT
+ + Remove or Disconnect
Tools Required:
J-6632-01 Pitman Arm Remover
J-5504-D Pitman Arm Puller
• Place the front wheels in a straight ahead
position.
1. F le xib le co u p lin g to ste e rin g sh aft bolts
(C-Models).
2. Lower universal joint pinch bolt (G-Models). Mark
the relationship of the universal yoke to the
wormshaft.
• Mark the relationship of the pitman arm to the
pitman shaft.
3. Pitman shaft nut and washer.
4. Pitman arm from the pitman shaft. Use J-6632-01
or J-5504-D (figure 2).
B-07355
Figure 2—Removing Pitman Arm
C-Models
1. F le xib le c o u p lin g onto the ste e rin g gear
wormshaft.
• Align the flat in the coupling with the flat on
the shaft.
• Push the coupling onto the shaft until the
w o rm s h a ft b o tto m s on the c o u p lin g
reinforcement.
2. Pinch bolt and torque to 41 N m (30 ft. lbs.). The
bolt must pass through the shaft undercut.
• Place the steering gear in position, guiding the
coupling bolt into the shaft flange.
3. Steering gear to frame bolts and torque to 100
N m (75 ft. lbs.).
Im portant
• If flexible coupling alignment pin plastic
spacers were used, make sure they are
bottomed on the pins.
• If flexible coupling alignment pin plastic
spacers were not used, center the pins in
the slots in the steeering shaft flange.
4. Washer and nut onto the coupling bolts.
5. Frame bolts.
6. Pinch bolt, coupling, washers and nuts from the
wormshaft (C-Models).
7. Gear assembly.
-►4- Install or Connect (Figure 3)
NOTICE: See “Notice” on page 3B2-1 of this
section for steps 3, 5 and 8.
Tighten
Nut to 24 N m (18 ft. lbs.).
G-Models (Figure 4)
• Place the steering gear in position, guiding the
wormshaft into the universal joint assembly and
lining up the marks made at removal. If a new
gear was installed, line up the mark on the
wormshaft with the slit in the universal joint yoke.
3B2-4 MANUAL STEERING GEAR
B-07353
Figure 3—Steering Gear Attachm ent (C-Models)
5. Steering gear to frame bolts.
Tighten
• Bolts to 100 N m (75 ft. lbs.).
6. Universal joint pinch bolt. The pinch bolt must
pass through the shaft undercut. Torque to 60
N m (44 ft. lbs.).
ALL MODELS
7. Pitman arm onto the pitman shaft. Line up the
marks made at removal.
8. Washer and nut.
Tighten
• Nut to 250 N m (185 ft. lbs.)
PITMAN SHAFT SEAL
REPLACEMENT
The pitman shaft seal may be replaced without
removing the steering gear. Remove the pitman arm as
outlined under “ Steering Gear Replacement” or refer
to STEERING LINKAGE (SEC. 3B1).
Remove or Disconnect
• Rotate the steering wheel from stop to stop,
counting the total number of turns. Then turn
back exactly halfway, placing the gear on center
(the wormshaft flat should be at the 12 o’clock
position).
1. Side cover bolts.
2. Pitman shaft and side cover assembly from the
housing.
3. Pitman shaft seal from the gear housing using a
screwdriver. Be careful not to damage the
housing bore.
4. Jam nut (11).
5. Side cover from the pitman shaft assembly. Turn
the adjuster screw (10) clockwise.
Inspect
G ear lu b ric a n t for c o n ta m in a tio n .
If
contaminated, the gear must be removed and
overhauled.
+«- Install or Connect
• Lubricate the new pitman shaft seal with steering
gear lubricant.
1. Pitman shaft seal. Position the seal in the pitman
shaft bore and tap into position using a 25 mm (1
inch) pipe or socket (figure 5).
MANUAL STEERING GEAR 3B2-5
Figure 6—Steering Gear Adjustm ent Points
Remove or Disconnect
• Place the pitman shaft in the steering gear so
that the center tooth of the pitman shaft sector
enters the center tooth space of the ball nut.
• Fill the steering gear housing with Steering Gear
Lubricant meeting GM Specification 1051052 (or
equivalent).
2. New gasket onto the gear housing.
3. Side cover onto the adjuster screw (10). Reach
through the threaded hole in the side cover with a
small screwdriver and turn the adjuster screw
counterclockwise until it bottoms and turns back
in 1/4 turn.
4. Side cover bolts and torque to specifications.
5. Jam nut (11).
Adjust
• Steering gear as outlined under “ Steering
Gear Adjustments.”
6. Pitman arm.
STEERING GEAR
ADJUSTMENTS
Before any adjustments are made to the steering
gear, in an attempt to correct such conditions as
shimmy, loose or hard steering etc., a careful
inspection should be made of the front end alignment,
shock absorbers, wheel balance and tire pressure for
the possible steering system problem.
Correct adjustment of the steering gear is very
im p o rta n t. P erform a d ju stm e n ts fo llo w in g the
sequence listed below.
1.
•
2.
•
3.
Tools Required:
J-6632-01 Pitman Arm Remover
J-5504-D Pitman Arm Puller
Battery ground cable.
Raise the vehicle.
Pitman arm nut and washer.
Mark the relationship of the pitman arm to the
pitman shaft.
Pitman arm using J-6632-01 or J-5504-D (figure
2 ).
• Loosen the adjuster nut (7) and then back the
adjuster plug (6) off 1/4 turn (figure 6).
4. Horn cap or cover.
• Turn the steering wheel gently in one direction
until stopped by the gear; then turn back one-half
turn.
NOTICE: Do not turn the steering wheel hard
against the stops when the steering linkage is
disconnected from the gear as damage to the
ball guides could result.
Measure
“ Bearing drag” by applying a torque wrench with
the socket on the steering wheel nut and rotate
through a 90 degree arc. Do not use a torque
wrench having a maximum torque reading of
more than 6 N-m (50 in. lbs.) (figure 7).
Adjust
Thrust bearing preload as follows:
1. Tighten the adjuster plug (6) until the proper
“ loading preload” is 0.6-1 N-m (5-8 in. lbs.).
3B2-6 MANUAL STEERING GEAR
Important
If maximum torque is exceeded, turn
over
ce n te r
a d ju s te r
screw
counter-clockwise, then come up on
adjustment by turning the jam nut (11)
in a clockwise motion.
-►4- Install or Connect
1. Pitman arm onto the pitman shaft. Line up the
marks made during disassembly.
NOTICE: See “Notice” on page 3B2-1 of this
section.
2. Washer and nut.
Figure 7—Checking Torque at Steering Wheel
NOTICE: See “Notice” on page 3B2-1 of this
section.
2. Tighten the adjuster nut (7) to 115 N m (85 ft.
lbs.).
3. If the gear feels “ lumpy” after adjustment,
there is probably damage in the bearings
due to severe im p a ct or im p ro p e r
adjustment; the gear must be disassembled
for replacement of damaged parts.
• Over-center preload as follows:
1. Turn the steering wheel gently from one stop
all the way to the other carefully counting
the total number of turns. Turn the wheel
back exactly half-way to the center position.
2. Turn the over center adjuster screw (10)
clockwise to take out all lash between the
ball nut (1) and pitman shaft sector (9) teeth
and then tighten the jam nut (11).
Tighten
Jam nut (11) to 30 N m (22 ft. lbs.)
3. Check the torque at the steering wheel,
taking the highest reading as the wheel is
turned through center position. Refer to
“ Specifications” for the proper over-center
preload.
4. If necessary, loosen jam nut (11) and adjust
over center adjuster screw to obtain proper
torque. Tighten the jam nut and recheck
torque reading through center of travel.
S i Tighten
• Nut to 250 N m (185 ft. lbs.).
3. Horn cap or cover.
• Lower the vehicle to the floor.
4. Battery ground cable.
STEERING GEAR HIGH
POINT CENTERING
1. Set the front wheels in the straight ahead posi­
tion. This can be checked by driving the vehicle a
short distance on a flat surface.
2. With the front wheels set straight ahead, check
the position of the mark on the wormshaft de­
signating the steering gear high point. This mark
should be at the top side of the shaft at 12 o’clock
position and lined up with the mark in the cou­
pling lower clamp.
3. If the gear has been moved off high point when
setting wheel in straight ahead position, loosen
adjusting sleeve clamp 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.
Important
• Turning the sleeves an unequal number of
turns or in different directions will disturb
the toe-in setting of the wheels.
4. A djust toe-in as outline d in FRONT END
ALIGNMENT (SEC. 3A) (if necessary).
5. Orient sleeves and clamps when fastening and
torqueing clamps to specifications. Refer to
STEERING LINKAGE (SEC. 3B1).
MANUAL STEERING GEAR 3B2-7
SPECIFICATIONS
MANUAL STEERING GEAR
Manufacturer......................................................................................................................Saginaw Steering Gear
R a tio ................................................................................................................................................................24 to 1
Type...............................................................................................................................................Recirculating Ball
PRELOAD ADJUSTMENTS
Nm
In. Lbs.
0.6-1.0
5-8
Over Center Sector Preload
0.5-1.2*
4-10*
Total Steering Gear Preload
1.8 Max.
16 Max.
Worm Thrust Bearing Preload
In excess of worm bearing preload.
TORQUE SPECIFICATIONS
Nm
Ft. Lbs.
Steering Gear to Frame Nuts
100
75
Pitman Shaft Nut
250
185
Side Cover Bolts
45
33
Adjuster Screw Jam Nut
30
22
Adjuster Plug Nut
115
85
SPECIAL TOOLS
J-6632-01
J-5504-D
Pitman Arm Remover
Pitman Arm Puller
3B3-1
SECTION 3B3
POWER STEERING
The following “ Notice” applies to one or more steps in the assembly procedure of components in this portion of
the manual as indicated at appropriate locations by the terminology: “ NOTICE: See ‘Notice’ on page 3B3-1 of the
section.”
NOTICE: All steering fasteners are important attaching parts in that they could affect the performance of vital
parts and systems, and/or could result in major repair expense. They must be replaced with one of the same
part number or with an equivalent part if replacement becomes necessary. Do not use a replacement part of
lesser quality or substitute design. Torque values must be used as specific during reassembly to assure
proper retention of all parts.
CONTENTS
SUBJECT
PAGE
D e s c rip tio n ................................................................................................................................................................ 3B3- 2
Integral Power Steering G e a r........................................................................................................................... 3B3- 2
Hydraulic P u m p s ................................................................................................................................................. 3B3- 2
Diagnosis Of Power Steering S y s te m .................................................................................................................3B3- 5
Oil Leak C h e c k ..................................................................................................................................................... 3B3- 8
Power Steering System T e s t..............................................................................................................................3B3- 8
Power Steering System On-Vehicle S e rv ic e ......................................................................................................3B3-12
M a in te n a n ce ..........................................................................................................................................................3B3-12
Pump Belt Tension A d ju s tm e n t....................................................................................................................... 3B3-12
Fluid Level A d ju s tm e n t........................................................................................... ...........................................3B3-12
Bleeding The Power Steering S y s te m ............................................................................................................ 3B3-13
Flushing The Power Steering S y s te m ............................................................................................................ 3B3-13
Steering Gear High Point C e n te rin g .................................................................................................................3B3-13
Power Steering Gear Replacem ent...................................................................................................................3B3-14
Pitman Shaft Seal R e p lace m e n t....................................................................................................................... 3B3-16
Steering Gear A d ju s tm e n ts ................................................................................................................................3B3-16
Power Steering Pump Replacem ent.................................................................................................................3B3-18
Power Steering H o s e s ........................................................................................................................................ 3B3-23
S pe cifica tio n s............................................................................................................................................................3B3-31
Special T o o ls ............................................................................................................................................................3B3-33
3B3-2 POWER STEERING
DESCRIPTION
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Pitman Shaft
Housing Ball Plug
Adjuster Plug
Stub Shaft
Torsion Bar
Adjuster Plug Nut
Return Line
Stud Bolt O-ring Seals
Reservoir
Reservoir Cap
Reservoir O-ring Seal
Pump Shaft Seal
Pump Housing
Pressure Port Seat
Pressure Hose
Pressure And Return Port Seat
Adjusting Screw Jam Nut
End Cover O-ring Seal
Side Cover Seal
Gear Housing
Figure 1—Power Steering System — Typical
The hydraulic power steering system consists of a
pump, an oil reservoir, a steering gear, a pressure
hose, and a return hose (figure 1).
INTEGRAL POWER
STEERING GEAR
The power steering gear (figure 2) has a recirculating
ball system which acts as a rolling thread between the
worm shaft and the rack piston. The worm shaft is
supported by a thrust bearing preload and two conical
thrust races at the lower end, and a bearing assembly
in the adjuster plug at the upper end. When the worm
shaft is turned right, the rack piston moves up in gear.
Turning the worm shaft left moves the rack piston down
in gear. The rack piston teeth mesh with the sector,
which is part of the pitman shaft. Turning the worm
shaft turns the pitman shaft, which turns the wheels
through the steering linkage.
The control valve in the steering gear directs the
power steering fluid to either side of the rack piston.
The rack piston converts the hydraulic pressure into a
mechanical force. If the steering system becomes
damaged and loses hydraulic pressure, the vehicle can
be controlled manually.
HYDRAULIC PUMPS
The hydraulic pump is a vane-type design. There are
two type s, su b m e rg e d and n o n su b m e rg e d .
Submerged pump (P models) have a housing and
internal parts that are inside the reservoir and operate
submerged in oil. The nonsubmerged pump (TC
models with or without reservoir) function the same as
the submerged pump except that the reservoir is
separate from the housing and internal parts (figure 3).
There are two bore openings at the rear of the pump
housing. The larger opening contains the cam ring,
pressure plate, thrust plate, rotor and vane assembly,
and end plate. The smaller opening contains the
pressure line union, flow control valve, and spring. The
flow control orifice is part of the pressure line union.
The pressure relief valve inside the flow control valve
limits the pump pressure (figure 4).
POWER STEERING 3B3-3
34
1. Pitman Shaft
3. Adjuster Plug
4. Stub Shaft
5. Torsion Bar
20. Gear Housing
21. Side Cover
22. Lower Thrust Bearing And Races
23. Inlet Port
24. Outlet Port
25. Stub Shaft Bearing
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
Adjuster Plug Seal
Torsion Bar Seal
Stub Shaft Seal
Upper Thrust Bearing
Valve Body Seal Rings And Backup O-Rings
Spool Valve
Valve Body
Worm Shaft
Rack Piston
Rack Piston Seal Ring
B-07321
Figure 2—Power Steering Gear
TC MODEL
WITHOUT RESERVOIR
P MODEL
WITH RESERVOIR
Figure 3—TC And P Pump Models
B-07322
3B3-4 POWER STEERING
4
4.
9.
10.
11.
12.
13.
40.
41.
42.
43.
44.
45.
46.
47.
Stub Shaft
Reservoir
Reservoir Cap
Reservoir O-Ring Seal
Shaft Seal
Pump Housing
Dip Stick
Pump Ring
Thrust Plate
Vanes
Reservoir Hole
Spring
Pressure Relief Valve
Flow Control Valve
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
Exit Hole
Orifice
Filter
Pump Union
Seals
End Plate
Retaining Ring
Rotor
Spring
Discharge Cavity
Retaining Ring
Pressure Plate
Figure 4—Power Steering Pump
B-07324
POWER STEERING 3B3-5
DIAGNOSIS OF POWER STEERING SYSTEM
PROBLEM
POSSIBLE CAUSE
CORRECTION
O bjectionable “ H iss”
1. Noisy relief valve in the hydraulic
pump.
1. There is some noise in all power
steering systems. One of the most
common is a hissing sound most evi­
dent at standstill parking. Hiss is a
high frequency noise. The noise is
present in every valve and results
from high velocity fluid passing valve
orifice edges. There is no relationship
between this noise and performance
of the steering. “ Hiss” may be ex­
pected when steering wheel is at end
of travel or when slowly turning at
standstill.
Do not replace valve unless “ hiss”
is extremely objectionable. A replace­
ment valve will also exhibit slight
noise and is not always a cure for the
objection.
2. Align the steering shaft and gear so
the flexible coupling rotates in a flat
plane and is not distorted as the shaft
rotates.
2. Any metal-to-metal contacts through
flexible coupling.
Rattle Or Chuckle
Noise In Steering
Gear
1. Gear loose on the frame.
2. Steering linkage looseness.
3. Pressure hose touching other parts of
vehicle.
4. Loose pitman arm.
5. Improper over-center adjustment. A
slight rattle may occur on turns be­
cause of increase clearance off the
“ high point.” This is normal and clear­
ance must not be reduced below spe­
cified limits to eliminate this slight
rattle.
Excessive Wheel
Kick-Back Or Loose
Steering
1. Air in the system.
2. Steering gear mounting loose.
3. Steering linkage joints worn.
4. Front wheel bearings incorrectly ad­
justed or worn.
5. Steering gear improperly adjusted.
6. Worn or missing poppet valve (steering
gear).
7. Steering gear flexible coupling too
loose on the shaft or the rubber disc
mounting screws loose.
8. Damaged or worn steering gear.
1. Check the gear m ounting bolts.
Torque the bolts to specifications.
2. Check linkage pivot points for wear.
Replace if necessary.
3. Adjust the hose position. Do not bend
tubing by hand.
4. Torque the pitman arm bolt.
5. Adjust to specifications.
1. Add oil to the pump reservoir and
bleed. Check hose connectors for
proper torque.
2. Tighten attaching bolts to specified
torque.
3. Replace loose parts.
4. Adjust the bearings or replace with
new parts as necessary.
5. Adjust to specifications.
6. Replace the poppet valve.
7. Tighten to specifications.
8. Disassemble and repair the steering
gear as outlined in the unit repair
manual.
3B3-6 POWER STEERING
DIAGNOSIS OF POWER STEERING SYSTEM (CONT.)
CORRECTION
PROBLEM
POSSIBLE CAUSE
Vehicle Leads To
One Side Or The
Other (Keep In Mind
The Road And Wind
Conditions). Test
The Vehicle, Going
In Both Directions,
On A Flat Road.
1. Front end misaligned.
2. Unbalanced steering gear valve. If this
is cause, steering effort will be very
light in direction of lead and heavy in
opposite direction.
3. Steering shaft rubbing the ID of the
shaft tube.
4. Steering linkage not level.
1. Adjust to specifications.
2. Replace the gear valve.
Momentary Increase
In Effort When
Turning The Wheel
Q uickly To The Right
Or Left
1. Low oil level in the pump.
2. Pump belt slipping (if used).
3. High internal linkage (steering gear or
pump).
1. Add power steering fluid as required.
2. Tighten or replace belt.
3. Refer to “ Power Steering System
Test” in this section.
Poor Return Of
Steering
1. Tires under-inflated.
2. Lower coupling flange rubbing against
the steering gear adjuster plug.
3. Steering wheel rubbing against direc­
tional signal housing.
4. Tight or frozen steering shaft bearings.
5. Steering linkage or ball joints binding.
6. Steering gear to column misalignment.
7. Tie rod pivots not centralized.
1. Inflate to specified pressure.
2. Loosen the pinch bolt and assemble
properly.
3. Adjust the steering jacket.
8. Lack of lubricant in the suspension
ball joints and the steering linkage.
9. Sticky or plugged valve spool.
8.
10. Rubber spacer binding in the shift
tube.
10.
11. Improper front end alignment.
12. Tight steering shaft bearings.
13. Steering gear adjusted too tightly.
11.
12.
13.
14. Kink in return hose.
14.
Steering Wheel
Surges Or Jerks
When Turning With
Engine Running
Especially During
Parking
1.
2.
3.
4.
Low oil level in pump.
Loose pump belt.
Sticky flow control valve.
Insufficient pump pressure.
Hard Steering Effort
In Both Directions
1. Low tire pressure.
2. Lack of lubricant in suspension or ball
joints.
5. Faulty gear relief valve.
3. Steering gear to column misalignment.
4. Loose pump belt.
3. Align the column.
4. Adjust as required.
4.
5.
6.
7.
9.
Replace the bearings.
Replace the affected parts.
Align the steering column.
Adjust tie rod ends as required to
center pivots.
Lubricate. Refer to MAINTENANCE
AND LUBRICATION (SEC. OB).
Remove and clean or replace the
valve.
Make certain the spacer is properly
seated. Lubricate inside the diameter
with silicone lubricant.
Check and adjust to specifications.
Replace the bearings.
Adjust over-center and thrust bearing
preload to specifications.
Replace the hose.
1.
2.
3.
4.
Add power steering fluid as required.
Adjust tension to specification.
Replace or clean the control valve.
Refer to “ Power Steering System
Test” in this section.
5. Replace the gear relief valve.
1. Adjust the tire pressure.
2. Lubricate and relubricate at proper
intervals. Refer to MAINTENANCE
AND LUBRICATION (SEC. OB).
3. Align the steering column.
4. Adjust belt tension to specifications.
POWER STEERING 3B3-7
DIAGNOSIS OF POWER STEERING SYSTEM (CONT.)
PRO BLEM ’”
Hard Steering Effort
In Both Directions
(Continued)
POSSIBLE CAUSE
5. Low fluid level in reservoir.
6. High internal leakage (steering gear or
pump).
7. Sticky flow control valve.
8. Lower coupling flange rubbing against
steering gear adjuster plug.
9. Steering gear adjusted too tight.
10. Improper front end alignment.
F oam ing M ilky P ow er
Steering Fluid, Low
Level And Possible
Low Pressure
Low Oil Pressure
Due To Restriction
In The Hose
Low Oil Pressure
Due To Steering
Gear. Refer To
“ Power Steering
System Test” In
This Section.
Low Oil Pressure
Due To Steering
Pump. Refer To
“ Power Steering
System Test” In
This Section.
Air in the fluid, and loss of fluid due
to internal pump leakage causing over­
flow.
1. Check for kinks in the hose.
2. Foreign object stuck in the hose.
1. Pressure loss in cylinder due to worn
piston ring or scored housing bore.
2. Leakage at the valve rings and valve
body to the worm seal.
3. Leakage at the valve body or a loose
fitting spool.
4. Damaged poppet valve.
1. Flow control valve stuck or inoperative.
2. Pressure plate not flat against the cam
ring.
3. Extreme wear of cam ring.
4. Scored pressure plate, thrust plate or
rotor.
5. Vanes sticking in rotor slots.
6. Vanes not installed properly.
7. Air in oil.
8. Low oil level.
9. Loose belt.
10. Damaged hoses or steering gear.
CORRECTION
5. Fill to proper level. Inspect lines and
joints for external leakage.
6. Refer to “ Power Steering System
Test” in this section.
7. Replace or clean the valve.
8. Loosen the pinch bolt and assemble
properly.
9. Adjust over-center and thrust bearing
preload to specifications.
10. Check and adjust to specifications.
Check for leak and correct. Bleed
system. Extremely cold temperatures
will cause system aeriation should
the oil level be low. If oil level is cor­
rect and pump still foams, remove
pump from vehicle and separate res­
ervoir from housing. Check welsh
plug and housing for cracks. If plug is
loose or housing is cracked, replace
housing.
1. Remove the kinks or replace the
hose.
2. Remove the foreign object or replace
the hose.
1. Disassemble the steering gear as
outlined in the unit repair manual. In­
spect the ring and housing bore. Re­
place the affected parts.
2. Disassemble steering gear and re­
place seals.
3. Replace the valve.
4. Replace the poppet valve.
1. Replace or clean the valve.
2. Replace the pressure plate.
3. Replace and flush the system.
4. Replace parts. (If rotor, replace with
rotating group), flush the system.
5. Free-up by removing burrs, varnish or
dirt.
6. Install properly. Radius edge to the
outside.
7. Locate source of leak and correct.
Bleed the system.
8. Add power steering fluid as required.
9. Adjust tension to specifications.
10. Replace as necessary.
3B3-8 POWER STEERING
DIAGNOSIS OF POWER STEERING SYSTEM (CONT.)
PROBLEM
CORRECTION
POSSIBLE CAUSE
Chirp Noise In
Steering Pump
1. Loose belt.
1. Adjust belt tension.
Belt Squeal
(Particularly
Noticeable At Full
Wheel Travel And
Standstill Parking)
1. Loose belt.
1. Adjust belt tension.
Growl Noise In
Steering Pump
1. Excessive back pressure in hoses or
steering gear caused by restriction.
1. Locate restriction and correct. Re­
place part if necessary.
Growl Noise In
Steering Pump
(Particularly
Noticeable At
Standstill Parking)
1. Scored pressure plates, thrust plate or
rotor.
2. Extreme wear of cam ring.
1. Replace parts and flush system.
2. Replace parts.
Groan Noise In
Steering Pump
1. Low oil level.
1. Add power steering fluid as required.
2. Air in the oil. Poor pressure hose con­
nection.
2. Torque the connector. Bleed the sys­
tem.
1. Loose pump pulley nut.
2. Pump vanes sticking in rotor slots.
1. Torque nut.
2. Free up by removing burrs, varnish or
dirt.
3. Adjust hose position.
Rattle Or Knock
Noise In Steering
Pump
3. Pressure hose touching other parts of
vehicle.
Swish Noise In
Steering Pump
1. Faulty flow control valve.
1. Replace part.
Whine Noise In
Steering Pump
1. Pump shaft bearing scored.
1. Replace the housing and shaft. Flush
the system.
OIL LEAK CHECK
1. With the vehicle’s engine off, wipe the complete
power steering system dry (gear, pump, hoses,
and connections).
2. Check the oil level in the pump’s reservoir and
a djust as dire cted . Refer to “ Fluid Level
Adjustment” in this section.
3. Start the engine and turn the steering wheel from
stop to stop several times. Do not hold the wheel
against the stops as this may damage the pump.
POWER STEERING
SYSTEM TEST
The power steering system may be tested using
either J-5176-D, Power Steering Gage, or with J-25323,
Power Steering Analyzer. J-25323 will measure the
flow rate in addition to the pressure (figure 6).
The power steering system test is a method used to
identify and isolate hydraulic circuit difficulties. Prior to
performing this test the following inspection, and
corrections if necessary, must be made.
Inspect
4. Find the exact areas of leakage and use the
recommended method of repair as shown in
figure 5.
Pump reservoir for proper fluid level.
Pump belt for proper tension.
POWER STEERING 3B3-9
60. Replace the drive shaft seal. Make cer­
tain that the drive shaft is clean and free
of pitting in the seal area.
61. Replace the resen/oir O-ring seal.
62. Torque hose fittin g nut to 35 N m (25 ft.
lbs.). If leakage persists, replace the Oring seal.
63. Torque fittin g to 75 N m (55 ft. lbs.). If
leakage persists, replace the O-ring seal.
64. Torque hose fittin g nut to 48 N m (35 ft.
lbs.). If leakage persists, replace the
brass connector and reface the tube
flare. If nut threads are damaged, replace
the nut.
65. Replace the O-ring seal.
66 . If leakage is observed at (A), following
manufacturer’s directions apply Loctite
75559 solvent and Loctite 290 adhesive,
or equivalent, to tube-housing connec­
tion. If leakage is coming from (B), re­
place the return tube. If com ing from (C),
replace the hose or clamp.
67. Seat the plug in the housing. Following
manufacturer’s directions apply Loctite
75559 solvent and Loctite 290 adhesive,
or equivalent, to plug-housing area.
68 . Seat the ball in the housing with a blunt
punch. Following manufacturer’s direc­
tions apply Loctite 75559 solvent and
Loctite 290 adhesive, or equivalent, to
area.
69. Check the oil level; if leakage persists
with the level correct and cap tight, re­
place the cap.
70. If a cracked or bent reservoir is detected,
replace the reservoir.
71. Torque jam nut to 48 N m (35 ft. lbs.). Re­
place the nut if leakage persists.
72. Torque side cover bolts to 60 N m (45 ft.
lbs.). Replace the side cover seal if leak­
age persists.
73. Torque hose fittin g nut to 27 N m (20 ft.
lbs.). If leakage persists, replace the Oring seal.
74. Check for seepage between the torsion
bar and stub shaft. Replace the rotary
valve assembly.
75. Seat the ball in the housing with a blunt
punch. Apply Loctite 75559 solvent and
Loctite 290 adhesive, or equivalent, to
the ball area.
76. Replace the adjuster plug seals.
77. Replace both pitman shaft seals.
78. Replace end plug O-ring seal.
B-07323
Figure 5—Pump Leak Diagnosis
3B3-10 POWER STEERING
B-07325
Figure 6—Tools For Power Steering System Test
Tires for correct air pressure.
Power steering system, replacing parts as
necessary.
Im portant
• All tests are made with the engine idling at
normal operating temperature. Check the idle
adjustment and if necessary adjust the engine
idle speed to the correct specification. Refer to
FUEL SYSTEMS (SEC. 6C).
Test With J-5176-D
1. Place a container under the steering gear or
pump to catch the fluid when disconnecting or
connecting the hoses.
2. With the engine NOT running, disconnect the
pressure hose at the steering gear or power
steering pump and install J-5176-D to both hoses
using adapter fitting J-5176-20. The gage must be
between the shut-off valve and pump. Open the
shut-off valve.
3. Remove the filler cap from the pump reservoir
and check the fluid level. Fill the pump reservoir,
with power steering fluid, to the full mark on the
dipstick. Start the engine and, momentarily
holding steering wheel against stop, check the
connections at J-5176-D for leakage.
4. Bleed the system. Refer to “ Bleeding the Power
Steering System.”
5. Insert thermometer J-5421-02 in the reservoir
filler opening. Move the steering wheel from stop
to stop several times until the thermometer
indicates that the hydraulic fluid in the reservoir
has reached a temperature of 65° to 77°C (150°
to 170°F).
Important
• To prevent scrubbing flat spots on the tires,
do not turn the steering wheel more than
five times without rolling the vehicle to
change the tire-to-floor contact area.
6. Start the engine and check the pumps fluid level.
Add power steering fluid if required. When the
engine is at normal operating temperature, the
initial pressure read on the gage (valve open)
should be in the 550-860 kPa (80-125 psi) range.
Should this pressure be in excess of 1380 kPa
(200 psi) — check the hoses for restrictions and
the poppet valve for proper assembly.
NOTICE: Do not leave valve fully closed for
more than 5 seconds as the pump could be
damaged internally.
7. Close the gate valve fully 3 times. Record the
highest pressures attained each time.
• If the pressures recorded are within the
specifications at the end of this section, and
the range of readings is within 345 kPa (50
psi), the pump is functioning within its speci­
fications.
• If the pressures recorded are high, but do
not repeat within 345 kPa (50 psi), the flow
controlling valve is sticking. Remove the
valve, clean it and remove any burrs using
crocus cloth or fine hone. If the system
c o n ta in s som e d irt, flu s h it. If it is
exceptionally dirty, both the pump and gear
must be completely disassembled, cleaned,
flushed and reassembled before further us­
age.
• If the pressures recorded are constant but
more than 690 kPa (100 psi), below the
minimum listed specification, replace the
POWER STEERING 3B3-11
flow control valve and recheck. If the
pressures are still low, replace the rotating
group in the pump.
8. If the pump checks within specifications, leave
the valve open and turn (or have turned) the
steering wheel into both corners. Record the
h ig h e st p re ssures and com pare w ith the
maximum pump pressure recorded. If this
pressure cannot be built in either (or one) side of
the gear, the gear is leaking internally and must
be disassembled and repaired.
9. Shut the engine off, remove the testing gage,
reconnect the pressure hose, check the fluid level
and/or make the needed repairs.
10. If the problem still exists, the steering and front
suspension must be thoroughly examined. Refer
to “ Diagnosis of Power Steering System.”
Test With J-25323
1. Place a container under the steering gear or
pump to catch the fluid when disconnecting or
connecting the hoses.
2. With the engine NOT running, disconnect the
pressure hose at the steering gear or power
steering pump. Thread J-29525 female adapter
into the pressure hose and the male adapter into
the gear or pump. Connect J-25323 analyzer
hoses to the adapters.
3. If the analyzer has never been used, it will be
necessary to bleed the power steering system to
remove all the air. Refer to “ Bleeding the Power
Steering System” in this section. The analyzer
gate must be open during this procedure.
4. Add power steering fluid to the pump if required.
5. Run the engine at idle speed w ith the gate valve
open and record flow (A) and pressure (B).
• If the flow is below 7.4 L/min. (2 gpm), the
pump appears to be in need of repair, but
continue the test.
• If the pressure is above 1035 kPa (150 psi),
check the hoses for restriction and check
the steering gear.
6. Partially close the gate valve to build 4278 kPa
(620 psi). Record the flow (C).
• If the flow (C) drops more than 3.7 L/min. (1
gpm) under flow (A), disassemble the pump
and replace the ring, rotor, and vanes. If the
pressure plates are worn or cracked,
replace them. Replace all O-ring seals when
reassembling the pump. Continue the test.
7. Completely close and partially open the gate
valve three times (do not allow the valve to
rem ain closed fo r more than 5 seconds).
Record the “ gate closed” pressure (D).
8. Check the pressure specifications, at the end of
this section for the correct pump model, and if the
pump pressure recorded is 690 kPa (100 psi)
lower than the minimum specification listed,
9.
10.
11.
12.
replace the flow control valve in the pump. If the
pressure recorded is above the maximum
specification listed, the flow control valve in the
pump should be removed and cleaned or
replaced. If the system is exceptionally dirty, both
the steering gear and pump must be completely
disassembled and cleaned before reassembly.
Increase the engine speed from idle to about
1500 rpm. Record the flow (E).
• If flow (E) varies more than 1 gpm from flow
(A), then the flow control valve should be
removed and cleaned or replaced, the same
as in step 8.
Have the steering wheel turned into the left and
then right corner lightly against the wheel stops.
Record the pressure and flow (F).
• Pressures developed in both corners should
be nearly the same as the maximum pump
output (D). At the same time the flow should
drop below 1.85 L/min. (0.5 gpm).
• If the pressure does not reach maximum
output or the flow does not drop below the
specified value, excessive internal leakage
is occurring. Remove and disassemble the
steering gear and remove the control valve.
Repair the steering gear as outlined in the
Unit Repair Manual.
Have the steering wheel turned slightly in both
directions and release quickly while watching the
pressure gage. The needle should move from the
normal back pressure reading and snap back as
the wheel is released. If it comes back slowly, or
sticks, the rotary valve in the steering gear is
sticking. Remove, disassemble and clean the
rotary valve. If the system contains a lot of dirt
and foreign material, disassemble the pump the
gear, clean and reassemble.
If the problem still exists, the steering and front
suspension must be thoroughly examined. Refer
to “ Diagnosis of Power Steering System” in this
section.
3B3-12 POWER STEERING
POWER STEERING SYSTEM ON-VEHICLE SERVICE
MAINTENANCE
The hydraulic system should be kept clean and at
regular intervals the pump steering fluid level in the
reservoir should be checked and fluid added when
re q u ire d .
R efer
to
M A IN TE N A N C E
AND
LUBRICATION (SEC. OB) of this manual for type of
fluid to be used and intervals for filling.
If the system contains some dirt, flush it as detailed
later in this section. If it is exceptionally dirty, both the
pump and the gear must be completely disassembled
before further usage.
All tubes, hoses, and fittings should be inspected for
leakage at regular intervals. Fittings must be tight.
Make sure the clips, clamps and supporting tubes and
hoses are in place and properly secured.
Inspect the hoses with the wheels in the straight­
ahead position, then turn the wheels fully to the left
and right, while observing the movement of the hoses.
Correct any hose contact with other parts of the vehicle
that could cause chafing or wear.
Power steering hoses and lines must not be twisted,
kinked or tightly bent. The hoses should have sufficient
natural curvature in the routing to absorb movement
and hose shortening during vehicle operation.
Air in the system will cause spongy action and noisy
operation. When a hose is disconnected or when fluid
is lost, for any reason, the system must be bled after
refilling. Refer to “ Bleeding the Power Steering
System” in this section.
1. Place belt tension gage, J-23600-B or equivalent,
midway between the pulleys on drive belts being
checked.
• Power steering pump driven by a single belt.
• Loosen the pump attaching bolts and adjust
the belt to correct tension by moving the
pump outward, away from the engine.
• Tighten finger tight all pump mounting bolts
and remove the pry bar.
• Tighten all pump mounting bolts. Refer to
“ Power Steering Pump Replacement” in
this section.
• Inspect belt tension and remove the belt
tension gage.
2. Loosen the pivot bolt and pump brace adjusting
nuts.
NOTICE: Do not move the pump by prying
against the reservoir or by pulling on the filler
neck, or damage may occur.
3. Move the pump, with the belt in place until the
belt is tensioned to specifications. Refer to
ENGINE COOLING (SEC. 6B).
4. Tighten the pump bracket adjusting nut and the
pivot bolt nut. Refer to “ Power Steering Pump
Replacement” in this section.
5. Inspect the belt tension and remove the belt
tension gage.
PUMP BELT TENSION
ADJUSTMENT
When adjusting a power steering pump belt, never
pry against the pump reservoir or pull against the filler
neck. Two systems are used for belt adjustment. On
some models, the pump is loosened from the bracket
and moved outward to increase the tension. On other
models, a half-inch square drive hole is located in the
b ra cke t, and th is hole is used to ro ta te the
pump-and-bracket assembly outward to increase belt
tension.
Adjust
Tool Required:
J-23600-B Belt Tension Gage.
FLUID LEVEL ADJUSTMENT
1. Run the engine until the power steering fluid
reaches normal operating temperature, about
80°C (170°F), then shut the engine off.
2. Remove the reservoir cap and check the fluid
level on the dipstick. On models equipped with a
remote reservoir, the fluid level should be about
12.7 to 25.4 mm (V2 to 1-inch) from the top when
the wheels are in full left turn position.
3. If the fluid level is low, add power steering fluid
(GM #1050017 or equivalent) to the proper level
and install the reservoir cap.
4. When checking the fluid level after the steering
system has been serviced, air must be bled from
the system. Refer to “ Bleeding the Power
Steering System” in this section.
POWER STEERING 3B3-13
BLEEDING THE POWER
STEERING SYSTEM
When a power steering pump or gear has been
installed, or an oil line has been disconnected, the air
that has entered the system must be bled out before
the vehicle is operated. If air is allowed to remain in the
power steering fluid system, nosiy and unsatisfactory
operation of the system may result. Bleed air from the
hydraulic system as follows:
• When bleeding the system, and any time fluid is
added to the power steering system, be sure to
use only power steering fluid as specified in
MAINTENANCE AND LUBRICATION (SEC. OB).
1. Fill the pump fluid reservoir to the proper level
and let the fluid settle for at least two minutes.
2. Start the engine and let it run for a few seconds.
Then turn the engine off.
3. Add fluid if necessary.
4. Repeat the above procedure until the fluid level
remains constant after running the engine.
5. Raise the front end of the vehicle so that the
wheels are off the ground.
6. Start the engine. Slowly turn the steering wheel
right and left, lightly contacting the wheel stops.
7. Add power steering fluid if necessary.
8. Lower the vehicle and turn the steering wheel
slowly from lock to lock.
9. Stop the engine. Check the fluid level and refili as
required.
10. If the fluid is extremely foamy, allow the vehicle to
stand a few minutes and repeat the above
procedure.
I*
Inspect
• Belt for tightness.
• Pulley for looseness or damage The pulley
should not wobble with the engine running.
• Hoses so they are not touching any other parts of
the vehicle.
• Fluid level and fill to the proper level.
• Fluid for air and if present attempt to bleed the
system.
FLUSHING THE POWER
STEERING SYSTEM
1. Raise the front end of the vehicle off the ground
until the wheels are free to turn.
2. Remove the fluid return line at the pump inlet
connector and plug the connector port on the
pump. Position the line towards a large container
to catch the draining fluid.
3. While an assistant is filling the reservoir with new
power steering fluid, run the engine at idle. Turn
the steering wheel from stop to stop. DO NOT
contact wheel stops or hold the wheel in a corner
or fluid will stop and the pump will be in pressure
relief mode. A sudden overflow from the reservoir
may develop if the wheel is held at a stop.
4. Install all the lines, hoses and components (if re­
moved) on the vehicle. Fill the system with
new power steering fluid and bleed the system as
described in “ Bleeding The Power Steering
System .” Operate the engine for about 15
minutes. Remove the pump return line at the
pump inlet and plug the connection on the pump.
While refilling the reservoir, check the draining
fluid for contamination. If foreign material is still
evident, replace all lines, disassemble and clean
or re p la ce the pow er s te e rin g system
components. Do not re-use any drained power
steering fluid.
STEERING GEAR HIGH
POINT CENTERING
1. Set the front wheels in the straight ahead
position. This can be checked by driving the
vehicle a short distance on a flat surface.
2. With the front wheels set straight ahead, check
the position of the mark on the wormshaft
designating steering gear high point. This mark
should be at the top side of the shaft at the 12
o’clock position and lined up with the mark in the
coupling lower clamp.
3. On C, G and P models except P30(00)FS3, if the
steering gear has been moved off high point
when setting the wheel in the straight ahead
position, loosen the adjuster tube clamps on both
the left and right hand tie rods. Then turn both
adjuster tubes an equal number of turns in the
same direction to bring the gear back on high
point.
Im portant
• Turning the adjuster tubes an unequal
number of turns or in different directions will
disturb the toe-in setting of the wheels.
4. On K and P30(00)FS3 models, if the gear has
been moved off high point when setting the
wheels in the straight ahead position, loosen the
adjuster tube clamps on the connecting rod.
Then turn the adjuster tube to bring the gear back
on high point.
5. Adjust toe-in. Refer to FRONT END ALIGNMENT
(SEC. 3A).
6. Refer to STEERING LINKAGE (SEC. 3B1) for
adjuster tube clamping instructions.
3B3-14 POWER STEERING
Figure 7—Steering Gear Installation
POWER STEERING GEAR
REPLACEMENT
Remove or Disconnect (Figures 7 and 8)
• Place a drain pan below the steering gear.
1. Battery ground cable.
2. Hoses from the steering gear. Raise the hose up
to prevent oil d rainage. Cap or tape the
ends of the hose and gear fittings to prevent the
entrance of dirt.
• Remove the flexible coupling to steering shaft
flange bolts (C, K and P300(32) models).
• Remove the lower universal joint pinch bolt. Mark
the relationship of the universal yoke to the stub
shaft (G and P models).
3. Pitman arm. Refer to STEERING LINKAGE (SEC.
3B1).
4. Steering gear frame bolts and the steering gear.
• Tap lightly, using a soft mallet, on the flexible
coupling to remove the coupling from the steering
gear stub shaft (C, K and P300(32) models).
C, K And P300(32) Models
|-»<-| Install Or Connect (Figures 7 and 8)
NOTICE: For steps 2, 3 and 4 see “ N otice” on
page 383-7.
1. Flexible coupling onto the steering gear stub
shaft.
• Align the flat in the coupling with the flat on
the shaft.
• Push the coupling onto the stub shaft until
the coupling reinforcement bottoms against
the end of the shaft.
POWER STEERING 3B3-15
Figure 8—Steering Gear Installation
2. Pinch bolt into the split clamp. The pinch bolt
must pass through the shaft undercut.
Tighten
• Pinch bolt to 42 N m (31 ft. lbs.).
• Place the steering gear into position, guiding the
coupling bolts into the proper holes in the shaft
flange.
3. S te e rin g g e a r to fra m e b o lts. Torque to
“ Specifications” at the end of this section.
4. Coupling flange nuts and washers. The coupling
alignment pins should be centered in the flange
slots.
&
Tighten
• Coupling flange nuts to 27 N m (20 ft. lbs.).
Maintain a coupling to flange dimension of
6.4 to 9.5 mm (0.250 to 0.375-inch).
5. Pitman arm. Refer to STEERING LINKAGE (SEC.
3B1).
• Remove the plugs and caps from the steering
gear and hoses.
6. Hoses to the steering gear. Torque hose fittings to
“ Specifications” at the end of this section.
G And P Models
Install or Connect (Figures 7 and 8)
• Place the steering gear in position. Guide the
stub shaft into the universal joint assembly by
lining up the marks made at removal.
1. Steering gear to the frame bolts. Torque to
“ Specifications” at the end of this section.
2. In te rm e d ia te s h a ft p in ch b o lt. Torque to
“ Specifications” at the end of this section. The
p in c h b o lt m u st pass th ro u g h th e s h a ft
undercut.
3B3-16 POWER STEERING
3. Pitman arm. Refer to STEERING LINKAGE (SEC.
3B1).
• Remove the plugs and caps from the steering
gear and hoses.
4. Hoses to the steering gear. Torque hose fittings to
“ Specifications” at the end of this section.
PITMAN SHAFT SEAL
REPLACEMENT
+ + Remove or Disconnect
Tools Required:
J-29107 Pitman Arm Puller.
J-4245 Internal Snap Ring Pliers.
Mark the position of the pitman arm to the pitman
shaft. Remove the pitman arm using J-29107.
Refer to STEERING LINKAGE (SEC. 3B1).
Position a drain pan under the steering gear.
1. Retaining ring using J-4245.
Start the engine and full turn the steering wheel
to the left-turn position for one or two seconds at
a time. This will force the pitman shaft seals and
washers out of the housing.
Stop the engine.
Pitman shaft seals and washers from the pitman
shaft.
L*
Inspect
• Pitman shaft seal surfaces for roughness or
pitting. If pitted, replace the shaft.
• Housing for burrs. Remove the burrs before
installing the new seals.
jQ * Clean
• Pitman shaft and seal areas using a crocus cloth.
-n - Install or Connect
Tools Required:
J-6219 Steering Gear Pitman Shaft Oil Seal
Installer.
J-4245 Internal Snap Ring Pliers.
Lubricate the new seals with power steering fluid.
Apply a single layer of tape to the pitman arm
shaft to avoid damaging the seals.
1. Single lip seal and washer use J-6219. Install far
enough to provide clearance for the remaining
seal, washer and retaining ring. DO NOT allow
the seal to bottom on the end of the counter bore.
Double lip seal and washer use J-21553.
Retaining ring use J-4245.
Pitman arm. Refer to STEERING LINKAGE (SEC.
3B1).
STEERING GEAR
ADJUSTMENTS
Im portant
• Before any adjustments are made to the steering
gear, refer to “ Diagnosis of Power Steering
System” for reviewing the possible steering
system problems.
The steering gear adjustment is made only as a
correction and not as a periodic adjustment. Adjusting
the steering gear in the vehicle is NOT recommended
for two reasons:
1. The complexity involved in adjusting the worm
thrust bearing preload.
2. The friction effect provided by the hydraulic fluid
in the steering gear.
For proper adjustment, remove the steering gear
from the vehicle. Drain the power steering fluid from
the gear. Mount the gear in a vise and make the
following adjustments.
The steering gear requires two adjustments which
are: the worm thrust bearing preload and the pitman
shaft over-center preload adjustment.
The worm thrust bearing preload is controlled by the
amount of compression force exerted on the conical
worm bearing thrust races by the adjuster plug.
The pitman shaft over-center preload is controlled by
the pitman shaft adjuster screw which determines the
clearance between the rack piston and the pitman
shaft sector teeth.
Im portant
Adjust the worm thrust bearing preload first,
then adjust the pitman shaft over-center
preload.
Worm Bearing Preload
Adjust (Figures 1, 2, 9 through 13)
Tool Required:
J-7624 Adjustable Spanner Wrench.
1. Loosen and remove the adjuster plug nut (6)
(figure 9).
2. Turn the adjuster plug (3) in (clockwise), using
J-7624, until the plug and thrust bearing are firmly
bottomed in the housing.
• Adjuster plug to 27 N m (20 ft. lbs.).
3. Place an index mark on the housing even with
one of the holes in the adjust plug (figure 10).
POWER STEERING 3B3-17
5. Rotate the adjuster plug back (counterclockwise)
until the hole in the plug is aligned with the
second mark on the housing (figure 12).
6. Install the adjuster plug nut (6).
Tighten
• Nut to 110 N m (81 ft. lbs.). Be sure the
adjuster plug does not turn when tightening
the nut.
Figure 10—Marking Housing Even With
A djuster Plug
4. Measure back (counterclockwise) 4.7-6.3 mm
(3/ie-1/4-inch) from the index mark and mark the
housing (figure 11).
Figure 11—Remarking The Housing
7. Use a inch-pound torque wrench and a 12-point
deep socket to measure the required torque to
turn the stub shaft (4). Take the reading with the
handle of the torque wrench near the vertical
position. Turn the stub shaft to the right stop and
then back (counterclockwise) 1/4 turn at an even
rate (figure 13). Record the torque reading.
Figure 13—Checking Rotational Torque
3B3-18 POWER STEERING
8. The torque required to turn the stub shaft should
be 0.45-1.13 N m (4-10 in. lbs.). If the reading is
above or below the specified torque; the adjuster
plug may not be tightened properly or may have
turned when the adjuster plug nut was tightened,
or the thrust bearings and races (22) may be
damaged.
4. Stub Shaft
21. Side Cover
Over Center Preload
f t
Adjust (Figures 1, 2, 14 through 16)
1. Turn the pitm an shaft adjuster screw (79)
counterclockwise until fully extended, then turn
back V2 turn clockwise.
2. Rotate the stub shaft (4) from stop to stop and
count the number of turns.
3. Starting at either stop, turn the stub shaft back V2
the total number of turns. This is the “ center” of
the gear.
• When the gear is centered, the flat on the
stub shaft should face upward and be
parallel with the side cover (21) (figure 14)
and the master spline on the pitman shaft
should be in line with the adjuster screw (79)
(figure 15).
4. Place the torque wrench, in the vertical position,
on the stub shaft. Rotate the torque wrench 45
degrees each side of the center and record the
highest drag torque measured on or near center
(figure 16).
5. Adjust over-center drag torque by loosening the
adjuster screw jam nut (17) and turning the
pitman shaft adjuster screw (79) clockwise until
the correct drag torque is obtained.
• On new steering gears (under 400 miles),
add 0.6-1.2 N m (6-10 in. lbs.) torque to the
previously measured worm bearing preload
torque but do not exceed a total steering
gear preload of 2 N m (18 in. lbs.).
Figure 14—A ligning The Stub Shaft
POWER STEERING PUMP
REPLACEMENT
Remove or Disconnect (Figures 17 through 20)
Tool Required:
J-29785-A Water Pump and Power Steering
Pulley Remover.
• Place a drain pan below the pump.
1. Battery ground cable.
2. Hoses at the pump. Raise the hose up to prevent
drainage of the oil. Cap or tape the ends of the
hose and pump to prevent the entrance of dirt.
• On m o d els w ith rem ote re se rvo ir,
disconnect the reservoir hose at the pump.
Cap the hose pump fittings.
• On used steering gears (400 miles or more)
add 0.5-0.6 N m (4-5 in. lbs.) torque to the
previously measured worm bearing preload
torque but do not exceed a total steering
gear preload of 1.5 N m (14 in. lbs.).
Tighten
• Adjuster screw jam nut (17) to 47 N m (35 ft.
lbs.).
6. Install the steering gear. Refer to “ Steering Gear
Installation” in this section.
7. Fill the pump reservoir with power steering fluid
and bleed the system. Refer to “ Bleeding the
Power Steering System” in this section.
Figure 15—A ligning The Pitman Shaft
Master Spline
POWER STEERING 3B3-19
• Loosen the pump adjusting bolts and nuts.
3. Pump belt.
4. Pump adjusting bolts, nuts and brackets.
5. Pump assembly.
6. Pulley from the pump.
• Install J-29785-A. Be sure the pilot bolt
bottoms in the pump shaft by turning the nut
to the top of the pilot bolt.
• Hold the p ilo t b olt and tu rn the nut
counterclockwise (figure 21).
+ 4- Install or Connect (Figures 17 through 20)
Tool Required:
J-25033-B Power Steering Pump Pulley
Installer.
Figure 16—Checking Over-Center Rotational
Torque
1. Brackets to the pump.
2. Pulley to the pump.
CK 000(00) V6 (4.3 Liter) V8 (5.0, 5.7 And 7.4 Liter) LS9 And LT9
A. 34 N m (25 Ft. Lbs.)
Figure 17—Power Steering Pump Mounting
3B3-20 POWER STEERING
Figure 18—Power Steering Pump Mounting V8 (6.2 Liter)
POWER STEERING 3B3-21
P300(00) V8 (7.4 Liter)
L6 (4.8 Liter)
P000(42) JB6/JB7
CKOOO(OO) NB2
Figure 19—Power Steering Pump Mounting
B 07447
3B3-22 POWER STEERING
GOOO(OO) N40 V8 (5.0 And 5.7 Liter)
C.
D.
E.
F.
84
44
34
25
N-m
N-m
N-m
N-m
(62
(32
(25
(18
Ft.
Ft.
Ft.
Ft.
V6 (4.3 Liter) Excluding V8 (6.2 Liter)
Lbs.)
Lbs.)
Lbs.)
Lbs.)
P000(42) V8 (5.7 Liter)
B-07341
Figure 20—Power Steering Pump Mounting
POWER STEERING 3B3-23
B-07363
Figure 21—Installing And Removing Pulley
• Place pulley on the end of the pump shaft
and install J-25033-B. Be sure the pilot bolt
bottoms in the shaft by turning the nut to the
top of the pilot bolt.
• Hold the p ilo t b olt and turn the nut
clockwise (figure 21).
• On models equipped with a remote power
steering pump reservoir fill the pump housing
with as much fluid as possible before mounting.
3. Pump assembly and attaching parts loosely to
the engine.
4. Power steering hoses to the pump. Hoses
installed out of position may be subjected to
chafing or other abuses during sharp turns. Refer
to “ Power Steering Hoses” in this section.
Im portant
POWER STEERING HOSES
When either a hose is reinstalled or replaced, the
following points are essential:
• Route hoses in the same position they were in
before removal (figures 22 through 29).
• Route hoses smoothly, avoid sharp bends and
kinking.
• Tighten the pump end hose fitting, gear line
fitting, and booster line fitting to specifications.
Refer to “ Specifications” at the end of this
section.
• After hoses are installed, check for leaks while
the system is being bled. Refer to “ Bleeding the
Power Steering System” in this section.
NOTICE: Do not start the engine with any
pow er steering hose d isconnected , or
damage to the components could occur.
• Do not start the engine with any power
s te e rin g hose d is c o n n e c te d . Af ter
connecting the power steering hoses make
sure there is clearance between the hoses
and the drive belt, sheet metal or any other
components where hose rub or interference
could result.
Fill the reservoir. Bleed the pump by turning the
pulley backwards (counter-clockwise as viewed
Internal Snap Ring Pliers
appear.
Pump belt over the pulley.
Adjust
• Belt tension. Refer to “ Pump Belt Tension
Adjustment” in this section.
Fill and bleed the system. Refer to “ Bleeding the
Power Steering System” in this section.
A.
80.
81.
82.
34 N m (25 Ft. Lbs.)
Hydro-Boost Assembly
Clamp
Return Hose
Figure 22—Hydro-Boost Lines
B-07333
3B3-24 POWER STEERING
Figure 23—Power Steering Hoses
POWER STEERING 3B3-25
CK200(00)
L6 (4.8 Liter)
VIEW A
VIEW B
CK300(00)
L6 (4.8 Liter)
VIEW B
CKOOO(OO)
V6 (4.3 Liter) V8 5.0 And 5.7 Liter)
CK300(00)
V8 (5.7 Liter)
B-07448
Figure 24—Power Steering Hoses
3B3-26 POWER STEERING
Figure 25—Power Steering Hoses
POWER STEERING 3B3-27
4 | FRT
VIEW A
G100 + 200 V8 (5.0 And 5.7 Liter) G300 V8 (5.7 Liter) LS9 Or LT9 With JB7
G100 + 200 + 300 V8 (5.0 And 5.7 Liter)
G313(03) V8 (5.7 Liter)
B-07345
Figure 26—Power Steering Hoses
3B3-28 POWER STEERING
Figure 27—Power Steering Hoses
POWER STEERING 3B3-29
VIEW C
P300(42) L6 (4.8 Liter) JB8/JF9
P300(42) V8 (7.4 Liter) JB8/JF9
B-07449
Figure 28—Power Steering Hoses
3B3-30 POWER STEERING
Figure 29—Power Steering Hoses
POWER STEERING 3B3-31
SPECIFICATIONS
STEERING GEAR ADJUSTMENTS
Valve Assembly And Seal D rag..............................................................................0.1-0.4 N m (1-4 in.
Thrust Bearing Preload (In Excess Of Valve Assembly And Seal Drag).......... 0.3-0.4 N m (3-4 in.
Pitman Shaft Over Center Preload
New G ear......................................................................................................... 0.6-1.2 N m (6-10 in.
Used G ear......................................................................................................... 0.4-0.5 N m (4-5 in.
Final Over Center Reading (Total-Maximum)
New G e a r....................................................................................................................2 N m (18 in.
Used G e a r............................................................................................................... 1.6 N m (14 in.
lbs.)
lbs.)
lbs.)
lbs.)
lbs.)
lbs.)
TORQUE SPECIFICATIONS
Nm
Steering Gear To Frame Nuts (C, K, and G Models)............................................. 102
Steering Gear To Frame Nuts (P300(32) andP300(42)FS3)......................... ....... 108
Steering Gear To Frame Nuts (P200 + 300(42) Excluding F S 3 ).......................... 95
High Pressure Line Fitting (At G e a r)...................................................................... 34
Oil Return Line Fitting (At Gear)....................................................................... ....... 34
Pitman Shaft Adjuster Screw Jam N ut.................................................................... 47
Side Cover To Housing B o lt..................................................................................... 60
Adjuster Plug N u t .............................................................................................. ....... 110
Reservoir Bolt (At Pump)........................................................................................... 48
Flow Control Fitting (At P um p)......................................................................... ....... 48
Pressure Hose (At P um p)......................................................................................... 27
Power Steering Pump To Booster Line.................................................................... 34
Booster To Gear Line.......................................................................................... ....... 34
Return Line At Booster And Gear..................................................................... ....... 34
Coupling Flange N u ts ........................................................................................ ....... 27
Coupling Flange Pinch B o lt ..................................................................................... 42
Lower Intermediate Shaft Pinch Bolt (G Model).............................................. ....... 62
Upper Intermediate Shaft Pinch Bolt (G M o d e l)............................................ ....... 47
Intermediate Shaft Pinch Bolts (P200 + 300(42) Excluding F S 3 )...................... 102
Intermediate Shaft Pinch Bolts (P300(42)FS3)................................................ ....... 108
TORQUE
Ft. Lbs.
75
80
70
25
25
35
45
81
35
35
20
25
25
25
20
31
46
35
75
80
3B3-32 POWER STEERING
SPECIFICATIONS (CONTINUED)
PUMP SPECIFICATIONS
Minimum
Output (1)
Part
Vehicle
Maximum
Output (2)
Relief Valve Settings
Minimum
Maximum
Number
Model
G PM
L/M in.
GPM
L/M in.
PSI
kPa
PSI
kPa
7838933
132-P-122
1.32
5.00
3.1-3.5
11.7-13.2
1200
8274
1300
8964
7838934
132-P-123
1.32
5.00
3.1-3.5
11.7-13.2
1350
9308
1450
9998
7838935
132-P-124
1.32
5.00
3.1-3.5
11.7-13.2
1200
8274
1300
8964
7838936
132-P-125
1.32
5.00
3.1-3.5
11.7-13.2
1350
9308
1450
9998
7839797
132-P-143
1.32
5.00
3.1-3.5
11.7-13.2
1350
9308
1450
9998
7839798
132-P-144
1.32
5.00
3.1-3.5
11.7-13.2
1350
9308
1450
9998
C K
7839799
132-P-145
1.32
5.00
3.1-3.5
11.7-13.2
1350
9308
1450
9998
Model
7839800
132-P-146
1.32
5.00
3.1-3.5
11.7-13.2
1200
7839801
132-P-147
1.32
5.00
3.1-3.5
11.7-13.2
1200
8274
8274
1300
1300
8964
8964
7839802
132-P-148
1.32
5.00
3.1-3.5
11.7-13.2
1200
8274
1300
8964
7839804
132-P-150
1.32
5.00
3.1-3.5
11.7-13.2
1200
8274
1300
8964
7839813
132-P-159
1.32
5.00
3.1-3.5
11.7-13.2
1350
9308
1450
9998
7839816
132-P-161
1.32
5.00
3.1-3.5
11.7-13.2
1350
9308
1450
9998
7839818
132-P-163
1.32
5.00
3.1-3.5
11.7-13.2
1200
8274
1300
8964
26000518
132-P-260
1.32
5.00
3.1-3.5
11.7-13.2
1200
8274
1300
8964
7841731
132-P-222
1.32
5.00
3.1-3.5
11.7-13.2
1350
9308
1450
9998
1350
9308
1450
9998
G
7842049
132-P-228
1.32
5.00
3.1-3.5
11.7-13.2
Model
7847616
T115-PT-003
1.15
4.35
3.1-3.5
11.7-13.2
1350
9308
1450
9998
7849229
132-P-253
1.32
5.00
3.1-3.5
11.7-13.2
1350
9308
1450
9998
7839808
132-P-154
1.32
5.00
2.4-2.8
9.1-10.6
1200
8274
1300
8964
7839809
132-P-155
1.32
5.00
2.4-2.8
9.1-10.6
1200
8274
1300
8964
7839812
132-P-158
1.32
5.00
2.4-2.8
9.1-10.6
1350
9308
1450
9998
7839817
132-P-162
1.32
5.00
2.4-2.8
9.1-10.6
1200
8274
1300
8964
P
7842032
132-P-226
1.32
5.00
3.1-3.5
11.7-13.2
1200
8274
1300
8964
Model
7842033
132-P-227
1.32
5.00
3.1-3.5
11.7-13.2
1200
8274
1300
8964
7842489
132-P-230
1.32
5.00
3.1-3.5
11.7-13.2
1200
8274
1300
8964
1350
9308
1450
9998
1200
8274
1300
8964
7842490
132-P-231
1.32
5.00
2.4-2.8
9.1-10.6
7842491
132-P-232
1.32
5.00
3.1-3.5
11.7-13.2
1 — Output of Power Steering Fluid at 32°C (90°F) temperature when operating pump at 465 rpm against 45855068 kPa (665-735 psi) pressure.
2 — Output of Power Steering Fluid at 32°C (90°F) temperature when operating pump at 1500 rpm against 345 kPa
(50 psi) pressure.
POWER STEERING 3B3-33
SPECIAL TOOLS
J-5176-D
J-5176-20
J-5421-02
J-25323
J-29525
J-24600-B
J-29107
J-4245
J-6219
J-7624
J-29785-A
J-25033-B
Power Steering Gage
Power Steering Gage Adapter — 18 mm
Pocket Thermometer (0°-220°F)
Power Steering Analyzer
Power Steering Analyzer Adapter
Belt Tension Gage
Pitman Arm Puller
Internal Snap Ring Pliers
Steering Gear Pitman Shaft Oil Seal Installer
Adjustable Spanner Wrench
Water Pump And Power Steering Pulley Remover
Power Steering Pump Pulley Installer
3B4-1
SECTION 3B4
STEERING COLUMN
The following “ Notice” applies to one or more steps in the assembly procedure of components in this portion of
this manual as indicated at appropriate locations by the terminology “ See NOTICE on page 3B4-1 of this section.”
NOTICE: All steering column fasteners are important attaching parts in that they could affect the perform­
ance of vital components and systems, and/or could result in major repair expense. They must be replaced
with one of the same part number or with an equivalent part if replacement becomes necessary. Torque
values must be used as specified during reassembly to assure proper retention of all parts.
CONTENTS
S U B JE C T
PAGE
D e s c rip tio n ................................................................................................................................................................ 3B4- 2
Diagnosis Of The Steering C o lu m n .....................................................................................................................3B4- 2
Steering Column Electrical Component A n a lyze r.........................................................................................3B4-10
Steering Column On-Vehicle Service (All M o d e ls)........................................................................................... 3B4-10
In s p e c tio n .............................................................................................................................................................. 3B4-10
Steering Wheel R e p la ce m e n t............................................................................................................................3B4-11
Flexible Coupling R e p la c e m e n t....................................................................................................................... 3B4-11
Intermediate Shaft Replacem ent....................................................................................................................... 3B4-13
Steering Column On-Vehicle Service (C, K And G M odels)............................................................................3B4-15
CK Model Steering Column R e p la ce m e n t......................................................................................................3B4-15
G Model Steering Column R e p la c e m e n t........................................................................................................ 3B4-16
Turn Signal Switch R e p lace m e n t..................................................................... ............................................... 3B4-17
Lock Cylinder Replacement................................................................................................................................3B4-18
Tone Alarm Switch R eplacem ent.....................................................................................................................3B4-19
Ignition Switch Replacement..............................................................................................................................3B4-19
Standard Steering Column Unit Repair (C, K And G M o d e ls )....................................................................... 3B4-20
Standard Steering Column Lower Bearing A d ju s tm e n t.............................................................................. 3B4-24
Tilt Steering Column Unit Repair (C, K And G M o d e ls).................................................................................. 3B4-28
Steering Column On-Vehicle Service P(32) M o d e ls .........................................................................................3B4-34
Turn Signal Switch R eplacem ent..................................................................................................................... 3B4-34
Tilt Steering Column Replacem ent...................................................................................................................3B4-35
Tilt Steering Column Bearing Housing R eplacem ent.................................................................................. 3B4-36
Tilt Steering Column Unit Repair P(32) M o d e ls ............................................................................................... 3B4-40
Steering Column On-Vehicle Service P(42) M o d e ls .........................................................................................3B4-41
Standard Steering Column Replacem ent........................................................................................................3B4-41
Upper Bearing R eplacem ent..............................................................................................................................3B4-42
Lower Bearing R eplacem ent............................................................................................................................. 3B4-42
Steering Column Lower Bearing A d ju s tm e n t............................................................................................... 3B4-44
Shift Tube A d justm e n t........................................................................................................................................ 3B4-44
Standard Steering Column Unit Repair P(42) M o d e ls .................................................................................... 3B4-45
Intermediate Shaft Unit Repair P(42) M o d e ls ....................................................................................................3B4-46
S pecifica tio ns............................................................................................................................................................3B4-47
Special T o o ls ............. .............................................................................................................................................. 3B4-47
3B4-2 STEERING COLUMN
DESCRIPTION
The locking energy absorbing steering column in­
cludes three important features in addition to the
steering function:
1. The column is energy absorbing, designed to
compress in a front-end collision to minimize the
possibility of injury to the driver of the vehicle.
2. The ignition switch and lock are mounted conve­
niently on the column.
3. With the column mounted lock, the ignition,
steering and gearshifting operation can be locked
to inhibit theft of the vehicle.
The column may be disassembled and reassem­
bled. To insure the energy absorbing action, it is impor­
tant that the specified screws, bolts and nuts be used
only as designated and that they are tightened to the
specified torque.
When the column is removed from the vehicle, such
actions as a sharp blow on the end of the steering
shaft or shift lever, leaning on the column assembly, or
dropping of the assembly could shear or loosen the
plastic fasteners that maintain column rigidity.
DIAGNOSIS OF THE STEERING COLUMN
PROBLEM
POSSIBLE CAUSE
Lock System Will
Not Unlock
1.
2.
3.
4.
5.
Lock System Will
Not Lock
1.
2.
3.
4.
5.
6.
Lock System—High
Lock Effort
Lock bolt damaged.
Faulty lock cylinder.
Damaged housing.
Damaged or collapsed sector.
Damaged rack.
CORRECTION
1.
2.
3.
4.
5.
Replace
Replace
Replace
Replace
Replace
Lock bolt spring is broken.
Damaged sector tooth.
Faulty lock cylinder.
Damaged housing.
Damaged rack.
Interference between the bowl and
coupling.
7. Ignition switch stuck.
8. Actuator rod restricted or bent.
9. Transmission linkage adjustment is in­
correct.
1.
2.
3.
4.
5.
6.
Replace the spring.
Replace the sector tooth.
Replace the lock cylinder.
Replace the housing.
Replace the rack.
Adjust or replace.
1.
2.
3.
4.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Lock cylinder is faulty.
Ignition switch is faulty.
Rack preload spring is broken or weak.
Burrs on the sector, rack, housing,
support, tang of the shift gate or actua­
tor rod coupling.
Bent sector shaft.
Distorted rack.
Misalignment of the housing to the
cover (tilt only).
Distorted coupling slot in the rack (tilt
only).
Bent or restricted actuator rod.
Ignition switch mounting bracket is
bent.
the lock bolt.
or repair the lock cylinder.
the housing.
the sector.
the rack.
7. Adjust or replace.
8. Adjust or replace.
9. Adjust.
Replace
Replace
Replace
Remove
the
the
the
the
lock cylinder.
ignition switch.
spring.
burrs.
5. Replace the shaft.
6. Replace the rack.
7. Replace either or both.
8. Replace the rack.
9. Straighten or replace the rod.
10. Straighten or replace the bracket.
STEERING COLUMN 3B4-3
DIAGNOSIS OF THE STEERING COLUMN (CONT.)
PROBLEM
POSSIBLE CAUSE
CORRECTION
Lock Cylinder—High
E ffort Between The
“ O ff” and
“ O ff-Lock” Positions
1. Burr on tang of shift gate.
2. Distorted rack.
1. Remove the burr.
2. Replace the rack.
Sticks In “ S tart”
Position
1. Actuator rod is deformed.
2. Any high effort condition.
1. Straighten or replace the rod.
2. See “ correction” under the high ef­
fort diagnosis.
Key Cannot Be
Removed In The
“ O ff-Lock” Position
1. Ignition switch is not set correctly.
2. Faulty lock cylinder.
1. Adjust ignition switch.
2. Replace the lock cylinder.
The Lock Cylinder
Can Be Removed
W ithout Depressing
The Retainer
1. Faulty retainer.
2. Burr over the retainer slot in the hous­
ing cover.
1. Replace the lock cylinder.
2. Remove the burr.
Lock Bolt Hits The
Shaft Lock In The
“ O ff” And “ Park”
Positions
Noise In The Column
Ignition switch is not set correctly.
1. Flexible coupling pulled apart.
2. Column not correctly aligned.
3. One click in Off-Unlock position and
when the steering wheel is moved.
4. Horn contact ring not lubricated.
5. Lack of grease on the bearings or
bearing surface.
6. Lower shaft bearing is tight or frozen.
7. Upper shaft bearing is tight or frozen.
8. Lock plate retaining ring is not seated.
9. Steering shaft snap ring is not seated.
10. Shroud or housing is loose.
11. Sheared intermediate shaft plastic
joint.
High Steering Shaft
Effort
1. Column assembly is misaligned in the
vehicle.
2. Tight or frozen upper or lower bear­
ings.
3. Binding intermediate shaft U-joints.
Adjust the ignition switch.
1. Align the column and replace the
flexible coupling.
2. Align the column.
3. Norma! seating of the lock bolt.
4. Lubricate.
5. Lubricate the bearings.
6. Replace the bearing. Inspect the
shaft and replace if scored.
7. Replace the housing assembly.
8. Replace the retaining ring. Inspect
for proper seating in the groove.
9. Replace the snap ring. Inspect for
proper seating in the groove.
10. Tighten mounting screws.
11. Repair or replace the steering shaft.
Align the column.
1. Align correctly.
2. Replace the bearings.
3. Repair or replace the intermediate
shaft.
3B4-4 STEERING COLUMN
DIAGNOSIS OF THE STEERING COLUMN (CONT.)
High Shift Effort
Improper
Transmission Shifter
Lash In Mounted
Column Assembly
CORRECTION
POSSIBLE CAUSE
PROBLEM
1. Column assembly is misaligned in the
vehicle.
2. Lower bowl bearing is not aligned cor­
rectly.
3. Lack of grease on the bearing or seal
areas.
4. Shift tube is bent or broken.
1. Align correctly.
2. Align correctly.
3. Lubricate bearings and seals.
4. Replace the shift tubes.
1. Sheared shift tube joint.
2. Improper transmission linkage adjust­
ment.
3. Loose lower shift lever.
4. Sheared lower shift lever weld.
1. Replace the shift tube assembly.
2. Adjust the linkage.
1.
2.
3.
4.
5.
1.
2.
3.
4.
5.
Column mounting bracket bolts loose.
Broken weld nuts on the jacket.
Column bracket capsule sheared.
Loose shoes in the housing (tilt only).
Loose tilt head pivot pins (tilt only).
3. Replace the shift tube assembly.
4. Replace the shift tube assembly.
Tighten to specifications.
Replace the jacket assembly.
Replace the bracket assembly.
Replace the shoes.
Replace the pivot pins.
Driver Can Lock
1. Faulty upper shift lever.
Steering In The
2. Faulty shift lever gate.
Second Gear (Manual 3. Loose relay lever on the shift tube.
Transmission
Columns)
1. Replace the shift lever.
2. Replace the shift lever gate.
3. Replace the shift tube assembly.
Excessive Play In
The Mounted
Steering Column
Assembly (Tilt
Column)
1.
2.
3.
4.
1.
2.
3.
4.
Housing Loose (Tilt
Column)
1. Excessive clearance between the
holes in the support or the housing
and pivot pin diameter.
2. Faulty anti-lash spring in the cent ‘ring
spheres.
3. Upper bearing not seating in the bear­
ing race.
4. Upper bearing inner race seat miss­
ing.
5. Bearing preload spring broken.
6. Loose support screws.
Housing Scraping
On The Bowl (Tilt
Column)
Column mounting bracket bolts loose.
Loose support screws.
Loose tilt head pivot pins.
Loose lock shoe pin in the support.
Bowl bent or not concentric with the
hub.
Tighten to specifications.
Tighten to specifications.
Replace the pivot pins.
Replace the pin.
1. Replace either or both.
2. Replace the spring.
3. Replace both.
4. Install the seat.
5. Replace preload spring.
6. Tighten to specifications.
Replace the bowl.
STEERING COLUMN 3B4-5
DIAGNOSIS OF THE STEERING COLUMN (CONT.)
PROBLEM
Steering Wheel
Loose Every Other
Tilt Position (Tilt
Column)
POSSIBLE CAUSE
Loose fit between the lock shoe and
pivot pin.
CORRECTION
Replace both.
Steering Column
Will Not Lock In Any
T ilt Position (Tilt
Column)
1. Lock shoe grooves may have burrs or
dirt.
2. Lock shoe spring is weak or broken.
3. Lock shoe seized on its pivot pin.
1. Replace lock shoes and clean the
grooves.
2. Replace the spring.
3. Replace both lock shoes.
Noise When Tilting
The Column (Tilt
Column)
1. Tilt spring rubbing in the housing.
2. Tilt bumpers are worn.
1. Lubricate.
2. Replace the tilt bumpers.
Steering Wheel Fails
To Return To The
Top Tilt Position
(Tilt Column)
1. Pivot pins are bound up.
2. Wheel tilt spring is faulty.
3. The turn signal switch wires are too
tight.
1. Replace the pivot pins.
2. Replace the spring.
3. Reposition the wires.
Dimmer Switch Will
Not Function
1. Loose connector at the dimmer switch.
2. Improper adjustment.
3. Internally damaged or worn switch.
1. Tighten or replace.
2. Readjust.
3. Replace.
Turn Signal W ill Not
Cancel
1. Loose switch mounting screws.
1. Tighten screws to 2.8 N m (25 in.
lbs.).
2. Replace the switch.
3. Reposition or replace the springs as
required.
4. Adjust the switch position.
• If the interference is correct and
switch will still not cancel, replace
the switch.
• If the interference cannot be cor­
rected by the switch adjustment,
replace the cancelling cam.
2. Switch or anchor bosses broken.
3. Broken, missing or out of position de­
tent, return or cancelling spring.
4. Uneven or incorrect cancelling cam to
cancelling spring interference.
Turn Signal D ifficult
To Operate
1. Actuator rod loose.
2. Yoke broken or distorted.
3. Loose or misplaced springs.
4. Foreign parts and/or materials.
5. Switch mounted loosely.
Turn Signal W ill Not
Indicate Lane
Change
1. Broken lane change pressure pad or
spring hanger.
2. Broken, missing or misplaced lane
change spring.
3. Jammed base or wires.
1. Tighten mounting screw to 1.4 N m
(12 in. lbs.).
2. Replace the switch.
3. Reposition or replace the springs.
4. Remove the foreign parts and/or ma­
terial.
5. Tighten mounting screws to 2.8 (25
in. lbs.).
1. Replace the switch.
2. Replace or reposition as required.
3. Loosen mounting screws, reposition
base or wires and tighten the screws
to 2.8 N m (25 in. lbs.).
3B4-6 STEERING COLUMN
DIAGNOSIS OF THE STEERING COLUMN (CONT.)
PROBLEM
POSSIBLE CAUSE
Turn Signal W ill Not
Stay In Turn Position
1. Foreign material or loose parts im­
pending movement of the yoke.
2. Broken or missing detent or cancelling
springs.
3. None of the above.
No Turn Signal
Lights
Turn Indicator Lights
On, But Not Flashing
2. Replace the spring.
3. Replace the switch.
Remove the foreign material.
• No foreign material. Replace the
turn signal switch.
1. Loose switch, mounting screws.
1. Tighten mounting screws to 2.8 N.m
2. Interference with other components.
3. Foreign material.
4. None of the above.
(25 in. lbs.).
2. Remove the interference.
3. Remove the foreign material.
4. Replace the switch.
1.
2.
3.
4.
Faulty or blown fuse.
Inoperative turn signal flasher.
Loose chassis to column connector.
Disconnect column to chassis connec­
tor. Connect new switch to chassis and
operate switch by hand. If vehicle
lights now operate normally, signal
switch is inoperative.
5. If vehicle lights do not operate, check
chassis wiring for opens, grounds, etc.
1.
2.
3.
4.
1. Inoperative turn flasher.
2. Loose chassis to column connection.
1. Replace the turn flasher.
2. Connect securely and check opera­
tion.
3. Replace the turn signal switch.
4. Replace the signal switch.
3. Inoperative turn signal switch.
4. To determine if turn signal switch is
faulty, substitute a new switch into the
circuit and operate the switch by hand.
If the vehicle’s lights operate normally,
the signal switch is inoperative.
5. If the vehicle’s lights do not operate,
check light sockets for high resistance
connections, the chassis wiring for
opens, grounds, etc.
Front Or Rear Turn
Signal Lights Are
Not Flashing
1. Remove material and/or parts.
Foreign material between hazard sup­
port cancelling leg and yoke.
Hazard Switch
Cannot Be Turned
Off
Hazard Switch W ill
Not Stay On Or
D ifficu lt To Turn Off
CORRECTION
1. Burned out fuse.
2. Burned out or damaged turn signal
bulb.
3. High resistance connection to ground
at the bulb socket.
4. Loose chassis to column connector.
Replace
Replace
Connect
Replace
fuse and check operation.
the turn signal flasher.
securely, check operation.
the signal switch.
5. Repair the chassis wiring.
5. Repair the chassis wiring.
1. Replace fuse and check operation.
2. Replace the bulb.
3. Remove or repair the faulty connec­
tion and check operation.
4. Connect securely and check opera­
tion.
STEERING COLUMN 3B4-7
DIAGNOSIS OF THE STEERING COLUMN (CONT.)
PROBLEM
POSSIBLE CAUSE
Front Or Rear Turn
Signal Lights Are
Not Flashing (Cont.)
5. Disconnect column to the chassis con­
nector. Connect a new switch into the
system and operate the switch by
hand. If turn signal lights are now on
and flash, the turn signal switch is in­
operative.
6. If vehicle lights do not operate, check
the chassis wiring harness to light
sockets for opens, grounds, etc.
Stop Light Not On
When Turn Indicated
1. Burned out fuse.
2. Loose column to chassis connection.
3. Disconnect column to chassis connec­
tor. Connect new switch into system
without removing old. Operate switch
by hand, if brake lights work with
switch in the turn position, signal
switch is faulty.
4. If brake lights do not work, check con­
nector to stop light, the sockets for
grounds, opens, etc.
Turn Indicator Panel
Lights Not Flashing
Turn Signal Lights
Flash Very Slowly
CORRECTION
5. Replace the turn signal switch.
6. Repair the chassis wiring.
1. Replace fuse and check operation.
2. Connect securely and check opera­
tion.
3. Replace the signal switch.
4. Repair connector to stop lights cir­
cuits.
1. Burned out bulbs.
2. High resistance to ground at the bulb
socket.
3. Opens, grounds in wiring harness from
the front turn signal bulb socket to the
indicator lights.
1. Replace the bulbs.
2. Replace the socket.
1. Inoperative turn signal flasher.
2. System charging voltage low.
1. Replace the turn signal flasher.
2. Increase voltage to specifications.
Refer to (SEC. 6D ENGINE ELECTRI­
CAL) in this manual.
3. Repair high resistance grounds at the
light sockets.
4. Connect securely and check opera­
tion.
5. Replace signal switch.
3. High resistance ground at light sock­
ets.
4. Loose chassis to column connection.
5. Disconnect column to chassis connec­
tor. Connect new switch into system
without removing old. Operate switch
by hand. If flashing occurs at normal
rate, the signal switch is faulty.
6. If the flashing rate is still extremely
slow, check chassis wiring harness
from the connector to the light sockets
for high resistance.
3. Locate and repair as required.
6. Locate and repair as required. Refer
to SEC. 8B (CHASSIS ELECTRICAL)
in this manual.
3B4-8 STEERING COLUMN
DIAGNOSIS OF THE STEERING COLUMN (CONT.)
PROBLEM
Hazard Signal Lights
W ill Not Flash—Turn
Signal Functions
Normally
POSSIBLE CAUSE
1. Blown fuse.
2. Inoperative hazard warning flasher.
3. Loose chassis to column connection.
4. Disconnect column to chassis connec­
tor. Connect new switch into system
without removing old. Depress the
hazard warning button and observe
the hazard warning lights. If they now
work normally, the turn signal switch is
faulty.
5. If the lights do not flash, check wiring
harness “ K” lead (brown) for open be­
tween hazard flasher and harmonica
connector. If open, fuse block is faulty.
Tone Alarm Does
Not Sound With Key
Fully Inserted In
Lock Cylinder With
D river’s Door Open
1. Loose connection at the tone alarm.
2. Voltage not available to the tone alarm.
3. Faulty tone alarm.
4. Door jamb switch on the driver’s side
is maladjusted or inoperative.
5. Short in the chassis wiring.
6. Short or fault in the signal switch wir­
ing.
7. Chips, burrs, foreign material is pre­
venting actuator tip function. NOTICE:
Key must be removed or the cylinder
in the “ run” position before removing
the lock cylinder.
8. Faulty lock cylinder.
9. Chips, foreign material affecting the
tone alarm switch operation.
10. Damaged or broken tone alarm switch.
11. Inoperative tone alarm switch (switch
appears good but will not make the
tone alarm switch function check).
12. Tone alarm switch contact gap is too
large
CORRECTION
1. Replace fuse and check operation.
2. Replace the hazard warning flasher.
3. Connect securely and check opera­
tion.
4. Replace the turn signal switch.
5. Replace fuse block. Refer to SEC. 8B
(CHASSIS ELECTRICAL) in this
manual.
1. Connect securely.
2. Check the continuity of the chassis
wiring and repair as required.
3. Replace the tone alarm.
4. Adjust or replace as required.
5. Check by separating chassis to col­
umn connector. Connect E and F fe­
male contacts on the chassis side
(bent paper clip will work). If tone
alarm sounds, continue diagnosis. If
not, locate and repair chassis wiring.
6. Connect male E and F contacts of
connector with the jumper. Check
buzzer switch pads with the ohmmeter. If contact is made, function is nor­
mal. If not, replace the signal switch.
7. Remove chips and burrs. Reassem­
ble and check.
8. With the lock cylinder out (refer to
“ Notice” under step 7), fully insert
and remove the key. The actuator
should extend and retract smoothly.
Total expansion of tip should be
1.25 mm (0.050 inch). If not, replace
the lock cylinder.
9. Remove and clean as required—re­
assemble and check.
10. Replace the tone alarm switch.
11. Connect the ohmmeter leads to the
tone alarm switch probes. Press on
the actuator pad until the interior
points contact. If contact is not made,
replace the tone alarm switch.
12. Reset the contact gap.
STEERING COLUMN 3B4-9
DIAGNOSIS OF THE STEERING COLUMN (CONT.)
PROBLEM
POSSIBLE CAUSE
CORRECTION
Tone Alarm Does
Not Sound With Key
Fully Inserted In
Lock Cylinder With
D river’s Door Open
(Cont.)
13. If the tone alarm fault has not yet been
detected, connect a continuity meter
(or light) to the male E and F connector
contacts. Insert the key the full depth
into the lock cylinder. If contact is
made with the key in, and is not made
with it out, the function is normal. Re­
trace the initial diagnostic steps. If con­
tact is not established, the fault is in
the column.
13. With the fault isolated in the column,
disassemble the upper end of the col­
umn until the signal switch mounting
screws have been removed. Lift the
switch and check the probes of the
tone alarm switch to ensure good
contact with the pads in the signal
switch. Bend the probes, if required,
then reseat the signal switch and in­
stall the three screws. Check the
function.
14. Setting the contact gap. Press a
0.75 mm (0.030 inch) wire type spark
plug gap wire with flat piece of stock
on the actuator pad. If contact is not
made, adjust switch until positive
contact is made (use ohmmeter).
With positive contact at 0.75 mm
(0.030 inch) use a 0.65 mm (0.025
inch) plug gap wire beneath the flat
stock. No contact should occur. Ad­
just. When the switch will make con­
tact with the 0.75 mm (0.030 inch)
wire and not with the 0.65 mm (0.025
inch) wire, the tone alarm switch is
set at the low limit.
14. If the fault has not yet been isolated
and repaired, connect ohmmeter to the
tone alarm switch probes. Fully insert
and remove the key from the lock cylin­
der. If contact is made with the key in,
and is broken with it out, the function is
normal. Retrace the diagnostic steps.
If contact is not made, the fault is in
the lock cylinder or tone alarm switch.
Tone Alarm
Continues To
Operate With Key In
The Lock Cylinder
W ith The D river’s
Door Either Opened
Or Closed And
Ceases When Key Is
Removed
1. Door jamb switch on driver’s side mal­
adjusted or inoperative.
2. Wire from signal switch to door jamb
switch shorted.
Tone Alarm
Continues To
Operate With Key
Out, But Stops When
D river’s Door Is
Closed
1. Lock cylinder binding (turn lock toward
start position. If tone alarm stops in the
run position or when turned past run
run towards the start, the problem is a
sticky lock cylinder actuator).
2. Chips, foreign material in lock cylinder
bore.
3. Sticky lock cylinder actuator tip.
4. Damaged or broken tone alarm switch.
5. Tone alarm switch contact gap is too
close.
1. Adjust or replace as required.
2. If on signal switch side, replace sig­
nal switch. If on chassis side, find
and repair.
This condition indicates the lock
cylinder or tone alarm switch is at
fault. To verify, check for continuity at
the E and F male connector contacts
with the key removed from the cylin­
der. If continuity exists, the fault is in
the column.
1. Replace the lock cylinder.
2. Remove, assem ble and recheck
function.
3. Replace the lock cylinder.
4. Replace the tone alarm switch.
5. Adjust as specified.
3B4-10 STEERING COLUMN
STEERING COLUMN ELECTRICAL
COMPONENT ANALYZER
Use J-23980-B, the steering column electrical
component analyzer, for C, K, G models, to analyze the
steering column wiring harness for electrical problems.
To use J-23980-B, unfasten the harmonica connector
on the column and plug the harness from J-23980-B
into the vehicle chassis harness. Connect the single
black jumper to a good ground and use the analyzer.
The “ A ,” “ B ,” and “ C ” te rm in a ls on the
tester will overhang the chassis connector. This does
not affect the test results. These terminals are for
vehicles with cornering lights.
Move the analyzer switch (with the key in the “ on”
position) to the various functions that may be checked.
The switch positions are “ OFF,” “ Horn,” “ Left Turn,”
“ Right Turn,” “ Key Buzzer” and “ Hazard” (some
vehicles do not use a tone alarm switch). If the system
functions properly while using the analyzer, then the
problem has been narrowed to the column wiring or
components. When this is determined the column may
be serviced.
STEERING COLUMN ON-VEHICLE SERVICE
(ALL MODELS)
INSPECTION
SHIFTER SHAFT
Separation of the shifter shaft sections will be
internal and cannot be visually identified. Hold lower
end of the “ shifter shaft” and move the “ shift lever” on
the column through its ranges and up and down. If
there is little or no movement of the “ shifter shaft,” the
plastic joints are sheared.
STEERING SHAFT
If the steering shaft plastic pins have been sheared,
the shaft will rattle when struck lihtly from the side and
some lash may be felt when rotating the steering wheel
while holding the rag joint. If the steering shaft pins are
sheared due to minor collision without serious damage
to other components, the vehicle can be safely
steered; however, steering shaft replacem ent is
recommended.
COLUMN JACKET
Inspect the jacket section of the colum n for
looseness, and/or bends.
COLUMN SUPPORT BRACKET
Damage in this area will be indicated by separation
of the mounting capsules from the bracket. The
bracket will have moved forward toward the entire
compartment and will usually result in collapsing of the
jacket section of the steering column.
STEERING COLUMN FOR ACCIDENT DAMAGE
NOTICE: Vehicles involved in accidents
resulting in frame damage, major body or
sheet metal damage, or where the steering
column has been impacted may also have a
damaged or misaligned steering column.
1/
A. Capsules must be within 1.59 mm (Vie")
from bottom of slots. If not, replace bracket
assembly.
B. The bolt head must not contact surface
“ B.” If contact is made, the capsule shear
load will be increased— Replace bracket.
B-07380
Figure 1—Inspecting The Steering
Column For Collapse
Inspect (Figures 1 through 3)
1. C apsules on the steering colum n bracket
assembly. The capsules must be within 1.59 (1/ie
inch) from the bottom of the slots (figure 1). If not,
the bracket should be replaced.
2. Contact surface (figure 1). The bolthead must not
contact surface “ B” or the shear load would be
increased. If contact is made, replace the bracket.
STEERING COLUMN 3B4-11
3. Shift lever operation on vehicles with automatic
transmission and column shift. If the shift lever is
able to move to the “ Park” position without
raising the lever, the upper shift tube plastic
bearing is broken.
4. Jacket collapse. Measure the jacket collapse
dim ensions, depending on the vehicle and
steering column, in either of the following ways
(figure 2):
• Measure from the end of the bearing
assembly to the lower edge of the upper
jacket (C).
• Measure from the collar on the toe plate
flange to the lower edge of the upper jacket
(E, G and H).
• Measure from the edge of the back-up
switch window to the lower edge of the
upper jacket (D, F and J).
If the jacket dimensions are not within specifications,
a new jacket must be installed.
• Visually inspect for sheared injected plastic
in the shift tube, and the steering shaft
(figure 3). If either one or both are sheared,
replace with new parts.
5. Any frame damage that could cause a bent
steering shaft must have the steering shaft
runout checked in the following manner:
Remove intermediate shaft. Hold a ruler
against the lower end of steering shaft and
have the steering wheel rotated. The runout
must not exceed 1.59 mm (Vie inch). A dial
indicator may be used instead of a ruler.
STEERING WHEEL REPLACEMENT
Remove or Disconnect
Tools Required:
J-1859-03 Steering Wheel Puller
Battery ground cable.
Horn button cap.
Retainer and steering wheel nut.
Horn lead assembly (some models).
Mark the relationship of the steering wheel to the
steering shaft.
5. Steering wheel. Use J-1859-03 (figure 4). Do not
hammer on the puller, or damage could result to
the steering column.
Install or Connect
NOTICE: For step 3 see “Notice” on page
3B4#1.
1. Steering wheel onto the steering shaft. Align the
marks made at removal.
Important
• Do not misalign the steering wheel more
than 25.4 mm (1 inch) from the horizontal
centerline (figure 5).
2 . Horn lead assembly (some models).
3. Steering wheel nut.
Tighten
•
Nut to 40 N m (30 ft. lbs.).
Retainer.
Horn button cap.
Battery ground cable.
FLEXIBLE COUPLING
REPLACEMENT
Remove or Disconnect (Figure 6)
1. Coupling to flange bolt nuts and washers (2).
2. Clamp bolt (1).
3. Steering gear frame bolts. Lower the steering
gear far enough to remove the flexible coupling.
4. F le xib le c o u p lin g from the ste e rin g gear
wormshaft. Tap lightly with a soft mallet.
+ 4-
Install or Connect (Figure 6)
NOTICE: For steps 2, 3 and 4 see “ Notice” on
page 3B4#1.
1. F le xib le co u p lin g onto the ste e rin g gear
wormshaft. Align the flat on the shaft with the flat
in the coupling.
• Push the coupling onto the wormshaft until
the coupling reinforcement bottoms against
the end of the worm.
2. Clamp bolt (1) into the split clamp. The bolt must
pass through the shaft undercut.
• Bolt to 42 N m (31 ft. lbs.).
• Place the steering gear into position,
guiding the flexible coupling bolts into the
proper holes in the steering shaft flange.
3. Steering gear and frame bolts.
Tighten
• The turn signal control assembly must be in the
neutral position when assembling the steering
wheel.
Bolts to “ Specifications” at the end of this
section.
3B4-12 STEERING COLUMN
,
HM
IL
Sr
C. 346.7 mm (13.64 inches) CK MODEL (Tilt
Column)
D. 72 mm (2.8 inches) CK MODEL (Standard
Column-Column Shift)
E. 353 mm (14 inches) CK MODEL (Standard
Column-Floor Shift)
F. 81.7 mm (3.21 inches) G MODEL (Tilt Col­
umn-Column Shift)
G. 144.9 mm (5.70 inches) G MODEL (Tilt Col­
umn-4 Speed)
H. 192 mm (7.5 inches) G MODEL (Standard
Column-Column Shift)
J. 80 mm (3.1 inches) G MODEL (Tilt ColumnFloor Shift)
I J
B-07381
Figure 2—Inspecting The Steering Column For Collapse
STEERING COLUMN 3B4-13
.K
-jE
I
2
f
K. Inspect for sheared injected plastic in the
shift tube.
L. Inspect for sheared injected plastic in the
steering shaft.
B-07382
Figure 3—Inspecting The Steering Column
For Collapse
1. Clamp Bolt
2. Nuts And Washers
A.
B.
C.
D.
Capturing Strap
Reinforcement
Alignm ent Pins
Wafer
B-07385
Figure 6—Flexible Type Steering Coupling
4. Coupling to flange bolt nuts and washers (2).
• The coupling alignment pins should be
centered in the flange slots.
Tighten
• Nuts to 27 N m (20 ft. lbs.).
Measure
Coupling to flange dimension. Maintain a
6.4 to 9.5 mm (0.250 to 0.375 inch)
dimension.
INTERMEDIATE SHAFT
REPLACEMENT
+ + Remove or Disconnect (Figure 7)
• Set front wheels in the straight ahead position.
• Mark the upper universal joint yoke to steering
shaft and the lower yoke to steering gear
wormshaft relationship.
1. Upper and lower universal yoke pinch bolt.
2. Steering gear frame bolts. Lower the steering
gear.
• It is not necessary to disconnect the pitman
arm from the steering gear pitman shaft.
3. Intermediate steering shaft and universal joint
assembly.
A. Do not misalign more than 25.4 mm (1 inch)
from the horizontal centerline.
B-07384
Figure 5—Steering Wheel Alignment
Install or Connect (Figure 7)
NOTICE: For steps 2, 3 and 4 see “ Notice ” on
page 3B4#t.
3B4-14 STEERING COLUMN
Figure 7—Intermediate Shaft Installation
*F R T
1. Intermediate shaft lower yoke onto the steering
gear worm shaft. Align the marks made at
removal.
2. Pinch bolt. The pinch bolt must pass through the
shaft undercut.
Tighten
A. Angle must not exceed 39 degrees maximum
or 34 degrees minimum.
B-07387
• Pinch bolt to “ Specifications” at the end of
this section.
• Raise the steering gear into position while
guiding the upper yoke assem bly onto the
steering shaft. The marks on the coupling and
steering shaft must align.
3. Steering gear and frame bolts.
Tighten
Figure 8—Carden Joint Angle (G-Model)
Bolt to “ Specifications” at the end of this
section.
STEERING COLUMN 3B4-15
4. Pinch bolt to the upper yoke assembly. The pinch
bolt must pass through the shaft undercut.
Measure
Carden joint operating angle (G-Model). The
a ng le m ust not exceed 39 d e g re e s
maximum or 34 degrees minimum (figure
Tighten
Pinch bolt to “ Specifications” at the end of
this section.
8).
STEERING COLUMN ON-VEHICLE SERVICE
(C, K AND G MODELS)
CK MODEL STEERING
COLUMN REPLACEMENT
□
Remove or Disconnect (Figure 9)
1. Battery ground cable.
2. Transmission control linkage from the column
shift tube levers.
3. Nuts and washers (1) that secure the flanged end
of the steering shaft to the flexible coupling.
4. Nuts (10) and clamp (11).
5. Steering wheel. Refer to “ S teering Wheel
Replacement” in this section.
6. Steering column harness at the connector.
• Disconnect the neutral-start switch and
back-up lamp switch connectors (some
models). Refer to SEC. 8B (CHASSIS
ELECTRICAL) in this manual.
7. Transmission indicator cable (some models).
8. Screws (6), upper cover (3), lower cover (5), and
seal (4).
9. Screws (7), nuts (8) and bracket (9).
10. Steering column assembly. Rotate the column so
the shift lever clears the dash opening.
Install or Connect (Figure 9)
NOTICE: For steps 4 and 12 see “ Notice” on
page 3B4#1.
1. Plastic spacers onto the flexible coupling
alignment pins.
2. Lower end of the steering column through the
dash opening.
3. Lower steering shaft flange onto the flexible
coupling (13).
4. Flange to coupling washers and nuts (1).
Tighten
• Nuts to 27 N-m (20 ft. lbs.).
The flexible coupling (13) on manual steering
must be installed prior to column installation.
2.
3.
4.
5.
6.
7.
8.
Nuts And Washers
Upper Cover
Seal
Lower Cover
Screws
Screws
Nuts
9. Bracket
10. Nuts
1 1 . Clamp
12. Pot Joint
13. Flexible Coupling
B-07388
Figure 9—Steering Column Installation
(C-K Model)
5. Screws (7) and (8) and bracket (9) loosely. Tighten
screws and nuts finger tight.
6. Clamp (11) and nuts (10).
3B4-16 STEERING COLUMN
Tighten
• Nuts (10) to 24 N m (18 ft. lbs.).
• Screws (7) and nuts (8) to 30 N m (22 ft.
lbs.).
7. Seal (4) and covers (3, 5) to the dash.
8. Screws (6).
• Remove plastic spacers from the flexible
coupling pins.
Measure
• Pot joint (12) operating angle must not
exceed 12 degrees.
• Flexible coupling (13) must not be distorted
greater than ± 1.5 mm (0.06 inch) due to pot
joint bottoming, in either direction.
10. Transmission indicator cable (some models).
11. Connectors to the steering column harness.
• C onnect the n e u tra l-sta rt sw itch and
back-up lamp switch connectors (some
models). Refer to SEC. 8B (CHASSIS
ELECTRICAL) in this manual.
12. S teering wheel. Refer to “ S teering Wheel
Replacement” in this section.
13. Transmission control linkage.
14. Battery ground cable.
G MODEL STEERING COLUMN
REPLACEMENT
Remove or Disconnect (Figure 10)
1. Battery ground cable.
2. Transmission control linkage from the column
shift tube levers.
3. Upper universal joint pinch bolt (14) from the
intermediate shaft. Mark the relationship of the
universal yoke to the steering shaft.
6.
7.
8.
9.
14.
Screws
Screws
Nuts
Bracket
Pinch Bolt
B-07389
Figure 10—Steering Column Installation (G Model)
Install or Connect (Figure 10)
NOTICE: For steps 3 and 5 see “Notice” on
page 3B4H1.
1. Lower end of the steering column through the
dash opening.
2. Bracket (9), screws (7) and nuts (8) loosely.
Tighten screws and nuts finger tight.
• Guide the steering shaft into the universal yoke,
lining up the marks made at removal.
3. Upper universal joint pinch bolt (14). The pinch
bolt must pass through the shaft undercut.
Tighten
4. Screws (7), nuts (8) and bracket (9).
5. Screws (6) from the cover and seal.
• Pinch bolt to 47 N m (35 ft. lbs.).
6. S teering wheel. Refer to “ S teering Wheel
Replacement” in this section.
Measure
7. Steering column harness at the connectors.
Carden joint operating angle. The angle
must not exceed 39 degrees maximum or
34 degrees minimum (figure 8).
• Disconnect the neutral-start switch and
back-up lamp switch connectors (some
models). Refer to SEC. 8B (CHASSIS
ELECTRICAL) in this manual.
8. Steering column assembly. Rotate the column so
the shift lever clears the dash opening.
Tighten
Screws (7) and nuts (8) to 30 N m (22 ft.
lbs.).
STEERING COLUMN 3B4-17
Figure 12—Removing The Turn Signal
Wire Protector
3. Screws (6) through the cover and seal to the dash
panel.
4. Connectors to the steering column harness.
• C onnect the n e u tra l-sta rt sw itch and
back-up lamp switch connectors (some
models). Refer to SEC. 8B (CHASSIS
ELECTRICAL) in this manual.
4. S teering wheel. Refer to “ Steering Wheel
Replacement” in this section.
6. Transmission control linkage.
7. Batter ground cable.
TURN SIGNAL SWITCH
REPLACEMENT
1.
2.
•
•
• Pull the switch connector out of the bracket on
the jacket and feed switch connector through
column support bracket and pull switch straight
up, guiding the wiring harness through the
column housing and protector.
8. Wire protector. Pull downward out of the column
with pliers using the tab provided (figure 12).
• Position the turn signal and shifter housing in the
“ low” position. Remove the harness cover by
pulling toward the lower end of the column, be
careful not to damage the wires (tilt column).
9. Turn signal switch. Pull the switch straight up,
guiding the wiring harness and cover through the
column housing (figure 13).
Remove or Disconnect (Figures 11 through 13)
Install or Connect
Tools Required:
J-23653-A Lock Plate Compressor
Steering wheel. Refer to “ Steering Wheel
Replacement” in this section.
Instrument panel trim cover.
Position a screwdriver blade into the steering
shaft lock plate cover slot. Pry up and out to free
the cover from the lock plate.
Screw the center post of J-23653-A onto the
steering shaft as far as it will go. Compress the
lock plate by tu rn in g the center post nut
clockwise. Pry the retaining ring out of the shaft
(figure 11). Remove J-23653-A.
Tools Required:
J-23653-A Lock Plate Compressor
Im portant
Use only the specified screws, bolts and
nuts at assembly. The use of overlength
screws could prevent a portion of the
assembly from compressing under impact.
Im portant
3.
4.
6.
7.
• If the column is being disassembled on a
bench, the shaft could slide out of the end
of the mast jacket when the snap ring is
removed.
Lock plate.
Turn signal lever screw and lever.
Hazard warning knob. Press the knob inward and
then unscrew.
Turn signal mounting screws.
Figure 13—Removing The Turn Signal
Switch Assembly
3B4-18 STEERING COLUMN
• On non-tilt columns, be sure the wiring harness is
on the protector. Feed the connector and cover
down through the housing and under the
mounting bracket.
• On tilt columns, feed the connector down through
the housing and under the mounting bracket.
Install the cover on the harness.
1. Turn signal mounting screws.
• Clip the connector to the bracket on the
jacket.
A. Hold the lock cylinder sleeve and rotate the
knob clockwise against the stop.
B. Lock Cylinder Set
C. Cylinder Key
D. Lock Retaining Screw
B 07394
2. Instrument panel trim plate.
3. Hazard warning knob
Figure 15—Lock Cylinder Installation
4. Turn signal lever and screws.
• Put the turn signal switch in the “ Neutral”
position. Pull “ out” on the hazard warning knob.
5. Washer, upper bearing preload spring and
cancelling cam onto the upper end of the shaft.
6. Lock plate onto the end of the shaft.
• Screw the center post of J-23653-A onto the
steering shaft as far as it will go. Place a
NEW retaining ring over the center post.
Place the “ C” bar over the center post and
then compress the lock plate by turning the
nut clockwise. Slide the new retaining ring
down the tapered center post and into the
shaft groove (figure 14). Remove J-23653-A.
• It is not necessary to completely remove
turn signal switch from the column. Pull
switch rearward far enough to slip it over
end of the shift. Do not pull the harness
of the column.
3. Retaining screw and the lock cylinder set.
the
the
the
out
Im portant
If the retaining screw is dropped on removal,
it could fall into the column, requiring a
complete disassembly to retrieve the screw.
-►«" Install or Connect (Figure 15)
7. Cover on the lock plate and snap into position.
8. Steering wheel. Refer to “ Steering Wheel
Replacement” in this section.
LOCK CYLINDER REPLACEMENT
Remove or Disconnect (Figure 15)
• Place the lock cylinder in the “ Run” position.
1. Steering wheel. Refer to “ S teering Wheel
Replacement” in this section.
2. Turn signal switch. Refer to “ Turn Signal Switch
Replacement” in this section.
1. Lock cylinder set.
• Align he cylinder key with the keyway in the
housing. Rotate as shown in figure 15.
• Push the lock all the way in.
2. Retaining screw.
$
Tighten
• Screw to 4.5 N m (40 in. lbs.) (Non-Tilt
Columns).
• Screw to 2.5 N m (22 in. lbs.) (Tilt Columns).
3. Turn signal switch. Refer to “ Turn Signal Switch
Replacement” in this section.
STEERING COLUMN 3B4-19
4. S teering wheel. Refer to “ S teering Wheel
Replacement” in this section.
TONE ALARM SWITCH
REPLACEMENT
□
Remove or Disconnect
1. Steering wheel. Refer to “ S teering Wheel
Replacement” in this section.
• Pull the turn signal switch up far enough to
allow access to the tone alarm switch. Refer
to “ Turn Signal Switch Replacement” in this
section.
• The tone alarm switch may be removed
without removing the lock cylinder. The lock
cylinder must be in the “ Run” position.
2. Tone alarm switch assembly.
• Pull the tone alarm switch straight out of the
housing using a paper clip or similar tool. A
flat spring wedges the switch toward the
lock cylinder.
Im portant
Be careful not to let the flat spring fall down
into the housing and do not pull on the
switch contacts or plastic material of the
switch when removing.
+ + Install or Connect
1. Tone alarm switch to the spring clip with the
formed end of the clip around the lower end of the
switch. The spring is bowed away from the
switch.
• Lay the spring on the switch opposite the
contacts.
2. Tone alarm switch and spring into the hole with
the contacts toward the lock cylinder bore.
3. Turn signal switch. Refer to “ Turn Signal Switch
Replacement” in this section.
4. Steering Wheel. Refer to “ Steering Wheel
Replacement” in this section.
IGNITION SWITCH REPLACEMENT
The ignition switch is mounted on top of the column
jacket near the front of the dash. For anti-theft reasons,
the switch is located inside the channel section of the
brake pedal support.
The switch is actuated by a rod and rack assembly. A
portion of the rack is toothed and engages a gear on
the end of the lock cylinder. This enables the rod and
rack to be moved axially (with respect to the column) to
actuate the switch when the lock cylinder is rotated.
Figure 16—Ignition Switch Assembly
Remove or Disconnect
Lower the steering column. Refer to “ CK Model
or G Model Steering Column Replacement” in
this section. It is not necessary to remove the
steering wheel.
• Properly support the steering column if it is
not removed from the vehicle.
• Put the ignition switch in the “ Lock” position.
• If the lock cylinder was removed, the
actuating rod to the switch should be pulled
up until there is a definite stop, then moved
down one detent, which is the ’‘ Lock”
position.
1. Two ignition switch screws.
2. Ignition switch assembly.
-►4- Install or Connect (Figure 16)
• Put the ignition switch in the “ Lock” position
(figure 16).
1. Activating rod into the ignition switch.
2 Ignition switch and screws to the column
3. Steering column assembly. Refer to “ Steering
Column Replacement” in this section.
3B4-20 STEERING COLUMN
STANDARD STEERING COLUMN UNIT REPAIR
(C, K AND G MODELS)
+ + Remove or Disconnect
• Steering column assembly. Refer to “ CK or G
Model Steering Column Replacement” in this
section.
«+► Disassemble (Figures 17 through 25)
Tools Required:
J-23074 Steering Column Holding Fixture
1. Dash panel bracket and screws from the column.
• Install J-23074 onto the steering column and
place the tool in a bench vise.
16.
17.
18.
19.
•
Im portant
2.
3.
4.
5.
• Clamping the steering column directly in a
vise could result in a damaged column.
Steering wheel. Refer to “ Steering Wheel Re­
placement” in this section.
Turn signal switch. Refer to “ Turn Signal Switch
Replacement” in this section.
Lock cylinder. Refer to “ Lock Cylinder Replace­
ment” in this section.
Tone alarm switch, if it needs to be serviced. Re­
fer to “ Tone Alarm Switch Replacement” in this
section.
Important
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
• The buzzer switch does not have to be re­
moved to remove the upper bearing hous­
ing.
Ignition switch. Refer to “ Ignition Switch Replace­
ment” in this section.
Shift lever pivot pin and lever. (Column Shift
Models).
Upper bearing washer.
Screws attaching the turn signal and ignition lock
housing.
Housing assembly (figure 23).
Bushing and retainer from the lower side of the
housing.
Ignition switch actuating rod, rack assembly, rack
preload spring, shaft lock bolt and spring assem­
bly from the housing.
Shift lever detent plate.
Ignition switch actuator sector through the lock
cylinder hole by pushing firmly on the block tooth
of the sector with a blunt punch or screwdriver
(figure 24).
Gear shift lever housing and shroud from the
jacket assembly.
•
• On floor shift models remove the transmis­
sion control lock tube housing and shroud.
Shift lever spring from the gear shift lever hous­
ing.
• On floor shift models remove the lock tube
spring.
Steering shaft from the lower end of the jacket
assembly.
Back-up switch or neutral-safety switch. Refer to
SEC. 8B (CHASSIS ELECTRICAL) in this
manual.
Lower bearing retaining clip (figure 25).
On Automatic and Floorshift Columns.
• Remove the lower bearing retainer, bearing
adapter assembly, shift tube spring and
washer. The lower bearing may be removed
from the adapter by light pressure on the
bearing outer race.
• Slide out the shift tube assembly.
On Manual Transmission (Column Shift)
• Remove the lower bearing adapter, bearing
and the first reverse shift lever. The lower
bearing may be removed from the adapter
by light pressure on the bearing outer race.
• Remove the three screws from the bearing
at the lower and slide out the shift tube as­
sembly.
• Remove the gear shift housing lower bear­
ing from the upper end of the mast jacket.
Assemble (Figures 17 through 22, 26 and 27)
• Apply a thin coat of lithium grease to all friction
surfaces.
1. Sector into the turn signal and lock cylinder hous­
ing.
• Install the sector in the lock cylinder hole
over the sector shaft with the tang end to
the outside of the hole.
• Press the sector over the shaft with a blunt
tool.
2. Shift lever detent plate onto the housing.
3. Rack preload spring into the housing from the
bottom side. The long section should be toward
the handwheel and hook onto the edge of the
housing (figure 26).
4. Locking bolt onto the crossover arm on the rack
and insert the rack and lock bolt assembly into
the housing from the bottom with the teeth up (to­
ward hand-wheel) and toward the centerline of
the column.
STEERING COLUMN 3B4-21
48
44
49 I 47
B-07396
Figure 17—Standard Steering Column—Column Shift (CK-Model)
3B4-22 STEERING COLUMN
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
41.
42.
43.
44.
45.
46.
Retainer
Nut
Lock Plate Cover
Retainer
Lock Plate
Cancelling Cam
Bearing Preload Spring
Turn Signal Screws
Tap Screw
Actuator Arm
Turn Signal Switch
Turn Signal Housing Screws
Washer
Tone Alarm Switch
Retainer Clip
Retainer Screw
Ignition Lock
Actuator Sector
Housing Assembly
Bearing
Bushing
Horn Contact
Upper Bearing Retainer
Dimmer Pivot And
Wiper Switch
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
73.
74.
75.
76.
Shaft Lock Bolt
Switch Rack Preload Spring
Actuator Rack
Actuator Pivot Pin
Washer
Shift Lever Gate
Shift Lever Screw
Housing Cover
Cover Screw
Shift Lever Spring
Gear Shift Housing
Gear Shift Shroud
Washer
G earS hift Housing Bearing
Jacket
Wiring Protector
Actuator Rod
Dimmer Switch
Ignition Switch Screw
Ignition Switch
Dash Seal
Shaft
Shift Tube
Washer
Spring
77.
78.
79.
80.
81.
82.
83.
84.
85.
86.
87.
88.
89.
90.
91.
92.
93.
94.
95.
96.
97.
98.
99.
100.
Adapter
Reinforcement
Adapter Clip
Lower Bearing
Automatic Transmission
Shift Tube
Bolt
Spacer
Lower Shift Lever
Adapter Plate
Adapter
Retainer
Adapter Clip
Manual Transmission
Bolt
Nut
Coupling
Retainer
Bearing
Spring
Washer
Pin
Seal
Intermediate Shaft
B-07361
Figure 18—Standard Steering Column—Column Shift (CK-Model)
5.
6.
7.
8.
9.
10.
11.
•
• Align the first tooth on the sector with the
first tooth on the rack; if aligned properly,
the block teeth will line up when the rack
assembly is pushed all the way in.
Retainer and bushing.
Gear shift housing lower bearing. Insert the bear­
ing from the very end of the jacket.
• Align the indentations in the bearing with
the projections on the jacket (figure 27). If
the bearing is not installed correctly, it will
not rest on the stops provided.
Shift lever spring into the gear shift lever (or lock
tube) housing.
Housing and shroud assemblies onto the upper
end of the mast jacket.
• Rotate the housing to be sure it is seated in
the bearing.
Turn signal and lock cylinder housing onto the
jacket.
• The gear shift housing should be in the
“ Park” position and the rack pulled down­
ward.
• Seat the turn signal housing and install the
four screws.
Lower bearing into the adapter assembly.
Shift tube assembly into the lower end of the
jacket. Rotate until the upper shift tube key slides
into the housing keyway.
On Automatic and Floor Shift Columns
•
12.
13.
14.
15.
16.
• Install the spring and lower bearing adapter
assembly into the bottom of the jacket.
• Hold the adapter in place and install the
lower bearing reinforcement and retainer
clip. The clip snaps into the jacket and rein­
forcement slots.
On Manual Transmission (Column Shift)
• Loosely attach the three screws in the jacket
and shift tube bearing.
• Assemble the first reverse lever, lower bear­
ing and adapter assembly into the bottom of
the jacket.
• Hold the adapter in place and install the
bearing reinforcement and retaining clip.
The clip snaps into the jacket and reinforce­
ment slots.
• Adjust the lower bearing. Refer to the
“ Manual Transmission (Column Shift) Lower
Bearing Adjustment” in this section.
Back-up switch or neutral-safety switch. Refer to
SEC. 8B (CHASSIS ELECTRICAL) in this
manual.
Steering shaft into the column.
Upper bearing washer.
Ignition switch. Refer to “ Ignition Switch Replace­
ment” in this section.
Tone alarm switch, if removed. Refer to “ Tone
Alarm Switch Replacement” in this section.
STEERING COLUMN 3B4-23
Figure 19—Standard Steering Column (CK-Model)
3B4-24 STEERING COLUMN
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
Retainer
Nut
Lock Plate Cover
Retainer
Lock Plate
Cancelling Cam
Bearing Preload Spring
Turn Signal Screws
Tap Screw
Actuator Arm
Turn Signal Switch
Turn Signal Housing Screws
Washer
Tone Alarm Switch
Retainer Clip
Retainer Screw
Ignition Lock
Actuator Sector
Key Release Spring
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
57.
58.
59.
62.
63.
64.
Key Release Lever
Key Release Washer
Housing Assembly
Bearing
Bushing
Horn Contact
Upper Bearing Retainer
Dimmer Pivot And Wiper Switch
Shaft Lock Bolt
Switch Rack Preload Spring
Actuator Rack
Actuator Pivot Pin
Washer
Gear Shift Housing
Signal Switch Mounting Screws
Gear Shift Housing
Jacket
W iring Protector
Actuator Rod
65.
66.
67.
68.
69.
70.
71.
72.
73.
91.
92.
93.
94.
95.
96.
97.
98.
99.
100.
Dimmer Switch
Ignition Switch Screw
Ignition Switch
Dash Seal
Adapter
Bearing
Reinforcement
Adapter Clip
Shaft
Bolt
Nut
Coupling
Retainer
Bearing
Spring
Washer
Pin
Seal
Intermediate Shaft
B-07362
Figure 20—Standard Steering Column (CK-Model)
17. Lock cylinder. Refer to “ Lock Cylinder Replace­
ment” in this section.
18. Turn signal switch. Refer to “ Turn Signal Switch
Replacement” in this section.
19. Steering wheel. Refer to “ Steering Wheel Re­
placement” in this section.
20. Shift lever and pivot pin.
• Remove the column from the vise and J23074.
21. Dash panel bracket and screws to the column.
Install or Connect
Steering column assembly. Refer to “ CK or G
Model Steering Column Replacement” in this
section.
STANDARD STEERING COLUMN
LOWER BEARING ADJUSTMENT
MANUAL TRANSMISSION (COLUMN SHIFT)
f t
A djust (Figure 28)
1. Put the transmission in neutral and disconnect
the transmission rods.
2 . Test for rotational drag by turning the shift lever
through the 2-3 shift arc. The drag measured
must not be more than 9N (2 lbs.).
3. Loosen the three clamping screws.
• Increase clearance by sliding the clamping
screws in the direction of arrow “ B” until the
first reverse lever is free of drag (figure 28)^
• Decrease clearance by sliding the clamping
screws in the direction of arrow “ A” until a
slight drag is felt at the first reverse shift
lever (figure 28).
4. Install a 0.13 mm (0.005 inch) thick shim between
the space and either of the shift levers.
5. Slide the clamping screws in the direction of
arrow “ B” until the system is loose. Slide the
screws in the opposite direction until a drag is felt
at the first reverse shift lever.
Tighten the clamping screws.
Remove the shim.
Install the transmission rods.
STEERING COLUMN 3B4-25
B-07398
Figure 21—Standard Steering Column (G-Model)
3B4-26 STEERING COLUMN
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
Retainer
Nut
Lock Plate Cover
Retainer
Lock Plate
Cancelling Cam
Bearing Preload Spring
Turn Signal Screws
Tap Screw
Actuator Arm
Turn Signal Switch
Turn Signal Housing Screws
Washer
Tone Alarm Switch
Retainer Clip
Retainer Screw
Ignition Lock
Actuator Sector
Key Release Spring
Key Release Lever
Key Release Washer
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
Housing Assembly
Bearing
Bushing
Horn Contact
Upper Bearing Retainer
Dimmer Pivot And
Wiper Switch
Shaft Lock Bolt
Switch Rack Preload Spring
Actuator Rack
Actuator Pivot Pin
Washer
Shift Lever Gate
Shift Lever Screw
Housing Cover
Cover Screw
Shift Lever Spring
Gear Shift Housing
Signal Switch Mounting
Screws
Gear Shift Shroud
61. Gear Shift Housing
Bearing
62. Jacket
63. Wiring Protector
64. Actuator Rod
65. Dimmer Switch
66. Ignition Switch Screw
67. Ignition Switch
68. Dash Seal
102. Shift Tube
103. Washer
104. Spring
105. Adapter
106. Bearing
107, Reinforcement
108. Adapter Clip
109. Shaft
110. Bearing Washer
111. Retainer
112. Automatic Transmission
113. Manual Transmission
B-07364
Figure 22—Standard Steering Column (G-Model)
B-07400
Figure 24—Removing The Ignition Switch
Actuator Sector
Figure 23—Removing The Turn Signal Housing
STEERING COLUMN 3B4-27
B-07401
Figure 25—Removing The Lower Bearing Retainer
80 88
C. 2-3 Shift Lever
D. Shim 0.13 mm (0.005 inch)
62. Jacket
80. Lower
Bearing
83. Bolt
84. Spacer
85. Lower Shift
Lever
88. Retainer
89. Adapter Clip
B-07404
Figure 28—A djusting The Lower Bearing
B-07402
Figure 26—Installing The Rack Preload Spring
Figure 27—Installing The Gearshift
Housing Lower Bearing
3B4-28 STEERING COLUMN
TILT STEERING COLUMN UNIT REPAIR
(C, K AND G MODELS)
Remove or Disconnect
Steering column assembly. Refer to “ CK or G
Model Steering Column Replacement” in this
section.
*
Disassemble (Figures 29 through 36)
Tools Required:
J-22635 Lock Shoe and Release Lever Pin
Remover and Installer
J-23074 Steering Column Holding Fixture
J-21854-01 Pivot Pin Remover
J-23072 Shift Tube Remover
1. Dash panel bracket and screws from the column.
• Install J-23074 onto the steering column and
place the tool in a bench vise.
Im portant
• Clamping the steering column directly in a
vise, could result in a damaged column.
2. Turn signal switch. Refer to “ Turn Signal Switch
Replacement” in this section.
3. Lock cylinder. Refer to “ Lock Cylinder Replace­
ment” in this section.
4. Tone alarm switch, if it needs to be serviced. Re­
fer to “ Tone Alarm Switch Replacement” in this
section.
Important
5.
6.
7.
8.
•
9.
10.
11.
12.
• The tone alarm switch does not have to be
removed to remove the upper bearing hous­
ing.
Ignition switch. Refer to “ Ignition Switch Replace­
ment” in this section.
Tilt release lever.
Shift lever pivot pin and lever.
Housing cover screws and housing cover.
Install the tilt release lever and place the column
in the “ up” position.
Tilt lever spring retainer, spring and guide. Use a
screwdriver to turn the retainer until it aligns with
the grooves in the housing then remove the re­
tainer.
Pot joint to steering shaft clamp bolt and remove
the intermediate shaft and pot joint assembly (CK
Model).
Upper bearing inner race and seat. Push the up­
per steering shaft in enough to remove the race
and seat.
Lower bearing retainer clip.
13. Bearing reinforcement, bearing and bearing
adapter assembly from the lower end of the mast
jacket.
14. Upper bearing housing pivot pins. Use J-21854-01
(figure 33).
• Install the tilt release lever and disengage the
lock shoes.
15. Bearing housing by pulling upward to extend the
rack full down, and then moving the housing to
the left to disengage the ignition switch rack from
the actuator rod.
16. Steering shaft assembly from the upper end of
the column.
17. Steering shaft by removing the centering spheres
and the anti-lash spring.
18. Transmission indicator wire, if so equipped.
19. Bearing housing support to gearshift housing
screws and remove the bearing housing support.
20. Ignition switch actuator rod.
21. Shift tube retaining ring and washer.
NOTICE: When removing the shift tube, be
sure to guide the lower end through the slot­
ted opening in the mast jacket. If the tube is
allowed to interfere with the jacket in any way,
damage to the tube and jacket could result.
• Install J-23072 into the lock plate, making sure
that the tool screws have good thread engage­
ment in the lock plate. Then, turning the center
screw clockwise, force the shift tube from the
housing (Figure 34). Remove the shift tube (trans­
mission control lock tube on floor shift models)
from the lower end of the mast jacket. Remove J23072.
22. Lock plate and washer.
• Slide the lock plate out of the jacket notches
by tipping it down toward the housing hub
and sliding it under the jacket opening.
23. Shift lever housing from the mast jacket.
(Transmission control lock tube housing on
floor shift models).
• Disassemble the bearing housing as fol­
lows:
24. Tilt lever opening shield.
25. Lock bolt spring. Remove the retaining
screws and move the spring clockwise to re­
move it from the bolt (figure 35).
26. Snap ring from the sector drive shaft.
• With a small punch, lightly tap the drive
shaft from the sector (figure 36).
27. Drive shaft, sector and lock bolt.
28. Rack and rack spring.
STEERING COLUMN 3B4-29
Figure 29—Tilt Steering Column (CK And G Models)
3B4-30 STEERING COLUMN
120.
121.
122.
123.
124.
125.
126.
127.
128.
129.
130.
131.
132.
133.
134.
135.
136.
137.
138.
139.
140.
141.
142.
143.
144.
145.
Retainer
Nut
Lock Plate Cover
Retainer
Lock Plate
Cancelling Cam
Bearing Preload Spring
Turn Signal Screws
Tap Screw
Actuator Arm
Turn Signal Switch
Inner Race Seat
Bearing Race
Screw
Tone Alarm Switch
Retainer Clip
Lock Retainer Screw
Ignition Lock
Housing Cover
Dimmer Switch Actuator
Shield
Pin Preload Spring
Pivot Switch
Actuator Pivot Pin
Cap
Retainer
146.
147.
148.
149.
150.
151.
152.
153.
154.
155.
156.
157.
159.
160.
161.
162.
163.
164.
165.
166.
167.
168.
169.
170.
172.
173.
Tilt Spring
Spring Guide
Screw
Bearing
Lock Bolt
Lock Bolt Spring
Lock Shoe
Lock Shoe
Sector Shaft
Lock Shoe Pin
Pivot Pin
Actuator Sector
Housing Assembly
Shoe Release Springs
Spring
Shoe Release Lever Pin
Shoe Release Lever
Lower Bearing
Rack Preload Spring
Actuator Rack
Ignition Switch Actuator
Sphere Spring
Centering Spheres
Spring
Lower Steering Shaft
Housing Support Screws
174.
175.
176.
177.
179.
180.
181.
182.
183.
184.
185.
186.
187.
188.
189.
190.
191.
192.
193.
194.
195.
196.
197.
198.
Housing Support
Pin
Shift Lever Gate
Detent Plate Screw
Retaining Ring
Washer
Lock Plate
Wave Washer
Gear Shift Lever Spring
Gear Shift Lever Bowl
Shroud
Screw
Stud
Switch
Dimmer Switch Rod
Nut
Dimmer Switch
Jacket
Dash Seal
Shift Tube
Adapter
Lower Bearing
Retainer
Adapter Clip
B-07365
Figure 30—T ilt Steering Column (CK And G Models)
29. Tilt release lever pin. Use J-22635.
30. Release lever and spring.
9
Bearings into the bearing housing, if removed.
Im portant
• To relieve the load on the release lever, hold
the shoes inward and wedge a block be­
tween the top of the shoes (over slots) and
bearing housing.
31. Lock shoe retaining pin. Use J-22635.
32. Lock shoes and springs.
33. Bearings from the bearing housing only if they
are to be replaced.
• Remove the separator and balls from the
bearings.
• Place the housing on a work bench and with
a pointed punch against the back surface of
the race, carefully hammer the race out of
the housing until a bearing puller can be
used. Repeat for the other race.
*
Apply a thin coat of lithium grease to all friction
surfaces.
Assemble (Figures 29 through 32)
Tools Required:
J-23073-01 Shift Tube Installer
J-22635 Lock Shoe and Release Lever Pin
Remover and Installer
If the bearing housing was disassembled, repeat
steps 1-9.
Lock shoe springs, lock shoes and shoe pin in
the bearing housing. Use J-22635 or a 4.5 mm
(0.180 inch) diameter rod to line up the shoes for
pin installation.
Release lever, spring and pin.
Im portant
• To relieve the load on the release lever, hold
the shoes inward and wedge a block be­
tween the top of the shoes (over slots) and
bearing housing.
4. Sector drive shaft into the housing.
• Lightly tap the sector onto the shaft far
enough to install the snap ring.
5. Snap ring.
6. Lock bolt. Engage the bolt with the sector cam
surface.
7. Rack and spring. The block tooth on the rack
should engage the block tooth on the sector (fig­
ure 37).
8. Tilt release lever.
9. Lock bolt spring and retaining screw.
STEERING COLUMN 3B4-31
Figure 31—Tilt Steering Column—Floor Shift (CK And G Models)
3B4-32 STEERING COLUMN
120.
121.
122.
123.
124.
125.
126.
127.
128.
129.
130.
131.
132.
133.
134.
135.
136.
137.
138.
139.
140.
141.
142.
Retainer
Nut
Lock Plate Cover
Retainer
Lock Plate
Cancelling Cam
Bearing Preload Spring
Turn Signal Screws
Tap Screw
Actuator Arm
Turn Signal Switch
Inner Race Seat
Bearing Race
Screw
Tone Alarm Switch
Retainer Clip
Lock Retainer Screw
Ignition Lock
Housing Cover
Dimmer Switch Actuator
Shield
Pin Preload Spring
Pivot Switch
143.
144.
145.
146.
147.
148.
149.
150.
151.
152.
153.
154.
155.
156.
157.
159.
160.
161.
162.
163.
164.
165.
166.
Actuator Pivot Pin
Cap
Retainer
T ilt Spring
Spring Guide
Screw
Bearing
Lock Bolt
Lock Bolt Spring
Lock Shoe
Lock Shoe
Sector Shaft
Lock Shoe Pin
Pivot Pin
Actuator Sector
Housing Assembly
Shoe Release Springs
Spring
Shoe Release Lever Pin
Shoe Release Lever
Lower Bearing
Rack Preload Spring
Actuator Rack
167.
168.
169.
170.
172.
173.
174.
175.
176.
177.
181.
182.
187.
188.
189.
190.
191.
199.
200.
201.
202.
203.
204.
205.
Ignition Switch Actuator
Sphere Spring
Centering Spheres
Spring
Lower Steering Shaft
Housing Support Screws
Housing Support
Pin
Shift Lever Gate
Detent Plate Screw
Lock Plate
Screw
Stud
Switch
Dimmer Switch Rod
Nut
Dimmer Switch
Pad
Key Release Lever
Key Release Spring
Shroud
Lower Bearing
Retainer
Screws
B-07368
Figure 32—T ilt Steering Column- -Floor Shift
(CK And G Models)
$
Tighten
• On floor shift models, install the plunger and
slide the gearshift lever housing onto the
mast jacket.
• Screw to 4 N m (35 in. lbs.).
10. Shift lever spring into the housing. Wind the
spring up with pliers and push it into the housing.
J-2185401
B-07407
Figure 33—Removing The Bearing Housing Pivot
Pins
11. Washer and lock plate. Slide the lock plate into
the notches in the jacket.
STEERING COLUMN 3B4-33
150. Lock Bolt
151. Lock Bolt Spring
Figure 38— In sta llin g The S h ift Tube A ssem bly
B-07409
Figure 35—Replacing The Lock Bolt Spring
NOTICE: Do not push or tap on the end of the
shift tube. Be sure that teh shift tube lever is
aligned with the slotted opening at the lower
end of the mast jacket or damage to the shift
tube and mast jacket could result.
12. Shift tube into the lower end of the mast jacket.
• Align the keyway in the tube with the key in
the shift lever housing.
• Install the wobble plate end of J-23073-01
into the upper end of the shift tube far
enough to reach the enlarged portion of the
tube.
• Install the adapter over the end of the tool,
seating it against the lock plate.
• Place the nut on the threaded end of the
tool and pull the shift tube into the housing
(figure 38).
• Remove J-23073-01.
13. Bearing support washer and retaining ring. Pull
the shift lever housing up far enough to compress
the lock plate washer.
14. Bearing support. Align the “ V” in the support
with the “ V” in the jacket.
15. Screws through the support and into the lock
plate.
• Screws to 6.8 N m (60 in. lbs.).
• Align the lower bearing adapter with the
notches in the jacket.
16. Adapter into the lower end of the jacket.
17. Lower bearing, bearing reinforcement and retain­
ing clip.
• Align the retaining clip with the slots in the
reinforcement, jacket and adapter.
Figure 37—Installing The Lock Bolt And
Rack Assem blies
18. Centering spheres and anti-lash spring in the up­
per shaft.
19. Lower shaft from the same side of the spheres
that the spring ends protrude.
20. Steering shaft assembly into the shift tube from
the upper end. Carefully guide the shaft through
the shift tube and bearing.
3B4-34 STEERING COLUMN
26. Tilt lever opening shield.
• Remove the tilt release lever.
27. Turn signal housing and retaining screws.
Tighten
21. Ignition switch actuator rod through the shift lever
housing and insert it in the slot in the bearing
support.
• Extend the rack downward from the bearing
housing.
22. Bearing housing over the steering shaft.
• Engage the rack over the end of the actua­
tor rod (figure 39).
• With the release lever installed, hold the lock
shoes in the disengaged positions.
23. Bearing housing over the steering shaft until the
pivot pin holes line up.
24. Pivot pins.
• Place the bearing in the full “ up” position.
25. Tilt lever spring guide, spring and retainer.
• With a suitable screwdriver, push the re­
tainer in and turn clockwise to engage it in
the housing.
• Screws to 5 N-m (45 in. lbs.).
28. Tilt release lever and shift lever.
29. Ignition switch. Refer to “ Ignition Switch Replace­
ment” in this section.
30. Tone alarm switch, if removed. Refer to “ Tone
Alarm Switch Replacement” in this section.
31. Lock cylinder. Refer to “ Lock Cylinder Replace­
ment” in this section.
32. Turn signal switch. Refer to “ Turn Signal Switch
Replacement” in this section.
• Remove the column from the vise and J-23074.
• Align the groove across the upper end of the pot
joint with the flat on the steering shaft. Install the
pot joint and intermediate shaft assembly to the
upper shaft (CK Model).
• install the clamp, bolt and nut. The clamp
bolt must pass through the shaft undercut.
$
Tighten
• Nut to 60 N-m (44 ft. lbs ).
33. Dash panel bracket and screws to the column.
-►4- Install or Connect
Steering column. Refer to “ CK or G Model
Steering Column Replacement” in this section.
STEERING COLUMN ON-VEHICLE SERVICE
P(32) MODELS
TURN SIGNAL SWITCH
REPLACEMENT
2. Cancelling cam and spring (standard columns).
3. Instrument panel trim plate (some models).
4. Turn sig n al sw itch w irin g harness at the
half-moon connector.
Remove or Disconnect (Figures 40 and 41)
• Pry the wiring harness protector out of the
column retaining slots.
Tools Required:
J-22727 Electrical Terminal Remover
J-22708 Turn Signal Cover Remover
1. S teering wheel. Refer to “ S teering Wheel
Replacement” in this section.
• Mark the location of each wire in the
half-moon connector and then remove each
individual wire from the connector. Use
J-22727 (figure 40). Insert the tool into the
lower end of the connector and push in until
STEERING COLUMN 3B4-35
Install or Connect
NOTICE: For step 8 see “Notice” on page
3B4#1.
• Wrap the ends of the turn signal switch wires with
tape and then guide them through the opening at
the lower left hand side of the bearing housing
(tilt columns) out the lower end of the shift lever
housing and under the dash seal.
• Place the turn signal switch in position.
1. Turn signal switch mounting screws.
Figure 40—Removing The Wires
From The Connector
Tighten
• Screws to 2.8 N m (25 in. lbs.).
• On tilt columns.
• Align the openings in the turn signal switch
cover with the proper lever positions. Tap
the cover into place using a plastic hammer.
• Install the tilt release lever.
• In sta ll the PRNDL d ia l, pointer, dial
illu m in a tio n bulb and cap (A utom atic
Transmission Models).
2. Turn signal switch lever and screws.
3. Hazard warning knob.
• Bend the wire retaining tabs, on each wire in the
w iring harness, enough to provide proper
retention of the wire in the half-moon connector.
4. Each wire in its marked location in the half-moon
connector. Push in until the square part of the clip
is flush with the bottom side of the connector.
5. Turn signal switch wiring harness.
6. W iring harness p rotector into the colum n
retaining slots.
7. Cancelling cam and spring (non-tilt column).
8. Steering wheel. Refer to “ S teering Wheel
Replacement” in this section.
9. Instrument panel trim plate (some models).
the tool bottoms on the connector. Remove
the tool and then pull the wire from the
connector.
5. Turn signal lever screw and lever.
6. Hazard warning light knob. Press the knob inward
and unscrew.
• On tilt columns.
• Remove the PRNDL dial screws, dial and
indicator needle. Remove the cap and dial
illumination bulb from the housing cover
(Automatic Transmission Model).
• Unscrew and remove the tilt release lever.
• Install J-22708 inside the turn signal
housing cover and push in until the tangs
lock inside the cover flange (figure 41). Turn
the center screw on the tool clockwise to
pull the cover from the housing.
7. Turn signal switch mounting screws.
8. Turn signal switch assembly from the column.
Guide the wiring harness through the opening in
the shift lever housing.
TILT STEERING COLUMN
REPLACEMENT
□
Figure 41—Removing The Turn Signal
Housing Cover
Remove or Disconnect (Figure 42)
1. Battery ground cable.
2. Transmission control linkage from the column
shift tube levers.
3. Nuts and washers that secure the flanged end of
the steering shaft to the flexible coupling.
4. Steering wheel. Refer to “ Steering Wheel
Replacement” in this section.
5. Turn signal wiring harness.
3B4-36 STEERING COLUMN
• Adjust the lower bearing preload. Refer to
“ Steering Column Lower Bearing Adjustment” in
this section.
1. Plastic spacers onto the flexible coupling
alignment pins.
2. Lower end of the steering column through the toe
panel opening.
3. Lower steering shaft flange onto the flexible
coupling.
4. Flange to coupling nuts.
$
Tighten
• Nuts to 27 N m (20 ft. lbs.).
Align the index slot in the steering column jacket
with the protrusion on the column support
bracket.
5. Clamp (210) and screws (211) to the column
support bracket. Tighten bolts finger tight.
Push the column down until the steering shaft
flange bottoms on the plastic spacers on the
flexible coupling.
Tighten
• Screws (211) to 25 N m (18 ft. lbs.).
Remove the plastic spacer from the alignment
pins.
Measure
6.
7.
Figure 42—Steering Column Installation
P(32) Model
• On an automatic transmission, disconnect
the single wire at the fuse block and unclip it
from the parking brake bracket.
6. Screws from the cover of the dash and toe panel
assembly.
7. Screws (211) and clamp (210) from the column
support bracket.
8. Steering column assembly.
• Lower and then w ithdraw the colum n
assembly. Rotate the column so the shift
lever cle a rs the dash and toe panel
assembly.
+ 4-
Install or Connect (Figures 42 and 43)
NOTICE: For steps 4 and 8 see “Notice” on
page 3B4# 1.
8.
9.
10.
• Coupling assembly dimensions (figure 43).
Raise or lower steering column it necessary.
Cover and mounting screws to the dash and toe
panel assembly.
Turn signal switch wiring harness.
• On an automatic transmission, connect the
single wire to the fuse block and clip it to the
parking brack bracket.
Steering wheel. Refer to “ S teering Wheel
Replacement” in this section.
Transmission control linkage.
Battery ground cable.
TILT STEERING COLUMN BEARING
HOUSING REPLACEMENT
Remove or Disconnect (Figures 44 through 48)
Tools Required:
J-22635 Lock Shoe and Release Lever Pin
Remover and Installer
J-22599 Locknut Wrench
J-21854-01 Pivot Pin Remover
J-5822 Steering Gear Shaft Main Bearing
Cup Remover
J-2619-01 Slide Hammer
STEERING COLUMN 3B4-37
1. Battery ground cable.
2. Steering wheel. Refer to “ Steering Wheel
Replacement” in this section.
3. Turn signal switch. Refer to “ Turn Signal Switch
Replacement” in this section.
• On column shift models, use a suitable size
punch to drive out the shift lever pivot and remove
the shift lever.
• Install the tilt release lever and place the column
in the “ up” position.
4. R e ta in e r (230) and s p rin g (232). Use a
screwdriver to turn the retainer until it aligns with
the grooves in the housing, then remove the
retainer and spring.
5. Upper bearing nut (253). Use J-22599.
6. Seat (254) and race (255).
7. Housing pivot pins (221). Use J-21854-01 (figure
46).
8. Bearing housing (219). Pull up on the tilt release
lever, this will disengage the shoes (224), and
remove the housing.
9. Upper and lower bearings (218, 220).
• Remove the bearing races using J-5822 and
J-2619-01 (figure 47).
10. Tilt release lever.
11. Shoe release pivot pin (228). Use J-22635 or a
suitable punch (figure 48).
12. Spring (227) and lever (229).
13. Shoe kit assembly (225).
• If the upper steering shaft, lower steering shaft,
or centering spheres are being removed, proceed
as follows.
14. Steering shaft assembly through the upper end of
the column. If it is necessary to disassemble the
shaft, proceed as follows:
• D isconnect the shaft at the pot jo in t
coupling clamp and remove the lower
steering shaft.
• Turn the upper shaft 90 degrees to the lower
sh a ft and slid e the upper sh aft and
centering sphere from the lower shaft.
• Rotate the centering spheres 90 degrees
and remove the centering spheres and
spring from the upper shaft.
• If the bearing housing support is being replaced,
proceed as follows:
15. Screws (231).
A. (4.89 ± 0.12 inch) Excluding FS3
B. (4.71 inch) with FS3
16. Support (233).
B-07417
Figure 43—Measuring The Coupling Assembly
+ 4-
Install or Connect (Figures 44 and 45)
Tools Required:
J-22599 Locknut Wrench
3B4-38 STEERING COLUMN
225
236.
235
* 234
216
931
*
247
261
B-07418
Figure 44—Tilt Steering Column P(32) Model
STEERING COLUMN 3B4-39
215. Housing Cover
216. Turn Signal
Mounting Screw
217. Turn Signal Switch
218. Upper Bearing
219. Bearing Housing
220. Lower Bearing
221. Pivot Pins
222. Shoe Spring
223. Spacer
224. Shoes
225. Shoe Kit Assembly
226. Shoe Retaining Pin
227. Spring
228. Pivot Pin
Lever
Retainer
Screws
Spring
Support
Pin
Detent Plate
Screw
Retaining Ring
Washer
Lock Plate
Washer
Gear Shift Lever
Spring
242. Gear Shift Housing
229.
230.
231.
232.
233.
234.
235.
236.
237.
238.
239.
240.
241.
243. Guide
244. Jacket
245. Bearing
Retainer Clip
246. Reinforcement
247. Dash Seal
248. Seal
249. Shift Tube
250. Adapter
251. Bearing
252. Nut
253. Nut
254. Seat
255. Race
256. Shaft
257.
258.
259.
260.
261.
262.
263.
264.
265.
266.
267.
268.
269.
Spring
Sphere Assembly
Lower Shaft
Shaft Assembly
Bolt
Clamp
Nut
Retainer
Spring
CouplingAssembly
Bearings
Seal
Intermediate
Shaft Assembly
B-07369
Figure 45—Tilt Steering Column P(32) Model
NOTICE: For steps 4 and 11 see “Notice’’ on
page 3B4#1.
• Lubricate the ID of the bearing housing support
and install the support and screws.
1. Steering shaft assembly.
• Lubricate and assemble the centering
spheres and spring.
• Install the spheres into the upper (short)
shaft and rotate 90 degrees.
• Install the lower shaft 90 degrees to the
upper shaft and over the centering spheres.
S lo w ly s tra ig h te n the sh a fts w h ile
compressing the spring.
2. Steering shaft assembly into the housing from the
upper end.
3. Lower steering column shaft to the intermediate
shaft (pot joint) assembly (269).
4. Clamp (262) bolt (261) and nut (263). The bolt
must pass through the shaft undercut.
Tighten
• Bolt to 60 N-m (44 ft. lbs.).
5. Bearing housing (219) assembly.
Figure 46—Removing The Bearing Housing
Pivot Pin
• Press the new upper and lower bearing
races into the bearing housing.
\
AST
r
1
^
B-07421
Figure 48—Removing The Release Lever
Pivot Pin
3B4-40 STEERING COLUMN
• Lubricate and install the bearings into the
bearing races.
• Place the shoe springs in position in the
housing. Install each shoe in place and
compress the spring in position. Once the
shoes are in place, drive in the shoe
retaining pin (226).
• Install the shoe release lever (229), spring
(227) and pivot pin (228).
• Install the tilt release lever.
• Lubricate the shoes and release lever.
6. Bearing housing assembly to the support (233).
• Hold the tilt release lever in the “ up”
position until the shoes have fully engaged
the support.
• Lubricate and install the bearing housing
pivot pins (221). Press the pins in flush with
the housing.
• Place the housing in the “ up” position.
7. Spring (232) and retainer (230). Push the retainer
into the housing about 5 mm (3/ie inch) and rotate
counterclockwise 1/s turn.
• Lubricate the upper bearing race (255), seat (254)
and nut (253).
8. Race (255), seat (254) and nut (253). Tighten the
nut using J-22599.
• Remove the tilt release lever.
9. Turn signal switch. Refer to “ Turn Signal Switch
Replacement” in this section.
10. Shift lever and pivot pin. (Column Shift Models).
11. Steering Wheel. Refer to “ Steering Wheel
Replacement” in this section.
12. Tilt release lever.
L*
Inspect
Electrical and mechanical functioning of the
steering column.
TILT STEERING COLUMN UNIT REPAIR
P(32) MODELS
Remove or Disconnect
Steering column assembly. Refer to “ Tilt Steering
Column Replacement” in this section.
Disassemble (Figures 44 and 45)
❖
Tools Required:
J-23074 Steering Column Holding Fixture
J-23072 Shift Tube Remover
Install J-23074 onto the steering column and
place the tool in a bench vise.
Im portant
1.
2.
3.
4.
•
5.
• Clamping the steering column directly in a
vise could result in a damaged column.
Intermediate shaft assembly (270), with the uni­
versal joint (pot joint), from the steering column
shaft.
Bearing retainer clip (245) and reinforcement
(246).
Bearing (251) and adapter (250).
Bearing housing assembly and steering shaft as­
sembly. Refer to “ Tilt Steering Column Bearing
Housing Replacement” in this section.
If the shift tube index plate must be removed, re­
move the two retaining screws and plate. (Col­
umn Shift Models).
Shift tube retaining ring (237) and washer (238).
6. Neutral-safety or back-up lamp switch screws and
switch. Refer to SEC. 8B (CHASSIS ELECTRI­
CAL) in this manual.
7. Shift tube (249) assembly. Use J-23072. Do not
hammer or pull on the shift tube during removal
(figure 29).
• Insert the hooked end of the tool into the
notch in the shift tube just below the shift
lever housing key. Pilot the sleeve over the
threaded end of the tool and into the upper
end of the shift tube. Force the shift tube out
of the housing by turning the nut onto the
tool. If the shift tube is not completely free
when the nut is bottomed on the threads,
complete the removal by hand.
• On column shift models, guide the lower
shift lever through the slotted opening in the
column to prevent damage to the tube or
column.
8. Lock plate (239) and washer (240). Tip the lock
plate downward towards the housing, then re­
move.
9. Shift lever housing.
• Remove the shift lever spring by winding the
spring up with pliers (Column Shift Models).
10. Dash panel seal from the column jacket.
STEERING COLUMN 3B4-41
*
Assemble (Figures 44 and 45)
•
1.
•
2.
3.
4.
Tools Required:
J-23073-01 Shift Tube Installer
Apply a thin coat of lithium grease to all friction
surfaces.
Dash panes seal.
Press a new shift lever spring into the shift lever
housing (Column Shift Models).
Shift lever housing. Slide the housing over the
upper end of the column.
Washer (240) and lock plate (239).
• Apply lithium grease to the lock plate and
the upper end of the shift tube.
Shift tube (249) and seal (248) into the lower end
of the column. Do not hammer or force the shift
tube.
• Align the keyway in the shift tube with the
key in the shift lever housing and install the
shift tube using J-23073-01 (figure 38).
• The shift lever housing key must bottom in
the shift tube slot.
5. Neutral-safety or back-up lamp switch and
screws. Refer to SEC. 8B (CHASSIS ELECTRI­
CAL) in this manual.
6. Washer (238) and retaining ring (237). Pull up on
the shift lever housing when installing the washer
and retaining ring.
• Seat the retaining ring in both slots in the
shift tube.
7. Steering shaft assembly and bearing housing as­
sembly. Refer to “ Tilt Steering Column Bearing
Housing Replacement” in this section.
-►*- Install or Connect
Steering column assembly. Refer to “ Tilt Steering
Column Replacement" in this section.
STEERING COLUMN ON-VEHICLE SERVICE
P(42) MODELS
STANDARD STEERING COLUMN
REPLACEMENT
Remove or Disconnect (Figure 40)
1. Battery ground cable.
2. Transmission control linkage from the column
shift tube levers (Column Shift Models).
3. Upper universal jo in t pinch bolt from the
intermediate shaft. Mark the relationship of the
universal yoke to the steering shaft.
4. Nut (282), bolt (280) and clamp (281). Slide the
clamp down the column.
5. Screws (277) from the cover (278) and seal (279).
Slide the cover and seal up the column.
6. S teering wheel. Refer to “ Steering Wheel
Replacement” in this section.
7. Turn signal wiring harness.
• On an automatic transmission, disconnect
the conductor tube at the instrument panel.
8. Bolts (275) and clamp (276) from the column
support bracket.
9. Bolt, nut and outer brace (283) from the column
support bracket (P200 + 300 (42) models).
Install or Connect (Figure 49)
NOTICE: For steps 2, 3, 4 and 9 see “ Notice ”
on page 3B4#7.
1. Adjust the lower bearing preload. Refer to
“ Steering Column Lower Bearing Adjustment” in
this section.
2. Lower end of the steering column through the toe
panel opening.
• Guide the steering shaft into the universal yoke,
lining up the marks made at removal.
• Upper universal pinch bolt. The pinch bolt must
pass through the shaft undercut.
Tighten
• Pinch bolt to “ Specifications” at the end of
this section.
• Align the seal (279) and cover (278) with the
floor and dash panel assembly.
• Align the column support bracket protrusion
with the index slot in the steering column.
3. Clamp (281), bolt (280) and nut (282). Position the
clamp as shown in figure 49.
10. Steering column assembly.
• Lower and then w ithdraw the column
assembly. Rotate the column so the shift
lever cle a rs the dash and toe panel
assembly.
Tighten
• Nut to 15 N m (11 ft. lbs.).
4. Clamp (276) and bolt (275).
3B4-42 STEERING COLUMN
275.
276.
277.
278.
279.
280.
281.
282.
283.
Bolts
Clamp
Screws
Cover
Seal
Bolt
Clamp
Nut
Outer Brace
B-07422
Figure 49—Steering Column Installation P(42) Model
Tighten
• Bolt to 25 N m (18 ft. lbs.).
5. Seal (279), cover (278) and screws (277) to the
dash panel assembly.
6. Outer brace (283), bolt and nut to the column
support bracket (P200 + 300 (42) models).
Tighten
• Bolt to 25 N m (18 ft. lbs.).
7. Transmission control linkage to the shift tube
levers (Column Shift Models).
8. Turn signal wiring harness.
• On a standard column with autom atic
transmission connect the conductor tube at
the instrument panel.
9. Steering wheel. Refer to “ S teering Wheel
Replacement.”
10. Battery ground cable.
UPPER BEARING REPLACEMENT
|+ + | Remove or Disconnect (Figure 50)
1. Steering wheel. Refer to “ S teering Wheel
Replacement” in this section.
2. Cancelling cam (286).
3. Upper bearing (289).
♦«- Install or Connect (Figure 50).
NOTICE: For step 3 see “Notice” on page
3B4#1.
1. New upper bearing (289).
2. Cancelling cam (286).
3. S teering wheel. Refer to “ Steering Wheel
Replacement” in this section.
LOWER BEARING REPLACEMENT
Remove or Disconnect (Figure 50)
1. In te rm e d ia te s te e rin g s h a ft. R efer to
“ Interm ediate Shaft R eplacem ent’’ in this
section.
2. Nut (319), washer (318), bolt (317) and clamp
(316).
3. Bearing assembly (315, 314).
STEERING COLUMN 3B4-43
316
285
278.
279.
285.
286.
287.
288.
289.
290.
291.
292.
293.
294.
295.
296.
297.
298.
299.
300.
301.
302.
303.
Seal
Cover
Horn Blow Wire
Cancelling Cam
Turn Signal Switch Screws
Hazard Control Switch
Upper Bearing
Control Support Switch
Screw
Control Lever
Housing
Washer
Washer
Shift Lever Housing
Pivot Pin
Sleeve
Shift Lever
Knob
Shaft
Bushing
Seat
296
304.
305.
306.
307.
308.
309.
310.
311.
312.
313.
314.
Shift Tube
Jacket
Bolts
Washer
Washer
Nut
Clamp
Bolt
Spacer
Lever
Adjusting Pin And Bearing Assembly
315.
316.
317.
318.
319.
320.
321.
Spring
Clamp
Bolt
Washer
Nut
Seal
Cover
B-07423
Figure 50—Standard Steering Column P(42) Model
3B4-44 STEERING COLUMN
|-»<-| Install or Connect (Figures 50 and 51)
NOTICE: For steps 2 and 3 see “ Notice ” on
page 3B4#1.
1. New adjusting ring and bearing assembly (314,
315).
2. Clamp (316), bolt (317), washer (318) and nut
(319). Maintain the clearance dimension shown in
figure 51.
------ ►
A
A. 32 ± 0.5 mm (1.26 ± 0.02 inch)
B-07424
$
Tighten
• Nut to 14 N m (10 ft. lbs.).
3. Intermediate shaft. Refer to “ Intermediate Shaft
Replacement” in this section.
Figure 51—Lower Bearing Adjustm ent
STEERING COLUMN LOWER
BEARING ADJUSTMENT
1. Loosen clamp bolt (317).
2. Apply 222 N (50 lbs.) force to the steering wheel
end of the steering shaft.
3. Adjust the clamp to obtain a clearance of 32 ±
0.5 mm (1.26 ± 0.02 inch) (figure 51).
SHIFT TUBE ADJUSTMENT
3-SPEED MANUAL TRANSMISSION
1. Loosen the adjusting ring bolts (306).
2. Loosen the clamp bolt (317).
3. Rotate the adjusting ring to give a 0.13 mm (0.005
inch) end play between the adjusting ring and
first and reverse lever (figure 52).
Tighten
Figure 52—Shift Tube A djustm ent—
3-Speed Manual Transmission
304
• Adjusting ring bolt (306) to 8 N m (70 in.
lbs.).
• Clamp bolt (317) to 14 N m (10 ft. lbs.).
AUTOMATIC TRANSMISSION
1. Place the shift tube lever in “ Neutral” or “ Drive.”
2. Loosen the adjusting ring bolt (306).
3. Rotate the shift tube adjusting ring to obtain a 8.4
to 9.1 mm (0.33 to 0.36 inch) clearance between
the shift tube lever and adjusting ring (figure 53).
Q
Tighten
• Adjusting ring bolt to 8 N m (70 in. lbs.).
A. 8.4 to 9.1 mm (0.33 to 0.36 inch)
B. Adjusting Ring
C. Shift Lever
B-07426
Figure 53—Shift Tube A d ju s tm e n tAutom atic Transmission
STEERING COLUMN 3B4-45
STANDARD STEERING COLUMN UNIT REPAIR
P(42) MODELS
Remove or Disconnect
Steering column assembly. Refer to “ Standard
Steering Column Replacement” (P42 Model) in
this section.
1.
2.
3.
4.
5.
6.
7.
8.
9.
•
10.
11.
12.
13.
14.
Disassemble (Figure 50)
Slide the steering shaft assembly from the lower
end of the steering column.
Lower bearing bolt (317), washer (318), nut (319),
clamp (316) and spring (315).
Back-up lamp switch.
Pivot pin (297) and shift lever (299).
Cancelling cam (286).
Conrol lever screw (291) and lever (292).
Column wiring harness cover.
Turn signal switch screws (287).
Housing (293). Rotate the housing counterclock­
wise.
• The housing and switch cannot be comple­
tely removed from the column until the shift
lever housing is removed.
Washer assembly (294, 295) and shift lever hous­
ing (296) (or extension housing) from the column.
Separate the turn signal switch, switch control
support assembly, turn signal housing and shift
lever housing (or housing extension) assemblies.
Upper bearing (289). Press the bearing out of the
switch contact support (290).
Bushing (302) and seat (303).
Bolts (306), washers (307, 308) and adjusting ring
clamp (310).
Adjusting ring and bearing (314) assembly.
• Press the bearing out of the adjusing ring.
First-reverse shift lever and spacer (3-Speed Col­
umn).
15. Selector plate clamping screws (Automatic Col­
umns).
• Place the column upright on the floor, supporting
it with two pieces of wood. Place a block of wood
on the upper end of the shift tube. Press down on
the shift lever with foot while tapping on the wood
block to withdraw the tube from the column
jacket.
NOTICE: In some tolerance stack-up cases it
may be necessary to use a press. Be careful
not to damage the tube or jacket.
16. Seal (320) and cover (321).
17. Cover (279), seal (278) and clamp from steering
column jacket (305).
1.
•
2.
•
•
•
3.
4.
5.
•
•
6.
7.
8.
9.
10.
11.
Assemble (Figure 50)
Apply a thin coat of lithium grease to all friction
surfaces.
Clamp, seal (278) and cover (279) over the end of
the jacket (305).
Apply lithium grease to all bearing surfaces on
the shift tube.
Seal (320) onto the shift tube and place the shift
tube in the jacket.
Temporarily install the spacer, first-reverse shift
lever and lower adjusting ring. Place a block of
wood on top of the adjusting ring and tap until the
shift tube bottoms. Remove the adjusting ring,
shift lever and spacer (3-Speed Columns).
Align the three holes in the selector plate with the
three holes in the jacket. Position the clamping
ring and install the three screws. The shift tube
spring retainer must bottom against the jacket
stops (Automatic Columns).
Lubricate and install the spacer and first-reverse
shift lever. The tang of the lever is toward the top
of the column (3-Speed Column).
Bearing in the adjusting ring (314).
Adjusting ring and bearing (314) assembly, clamp
(310), washers (308, 307) and bolts (306).
Seat (303) and bushing (302) to the upper end of
the housing.
Thread the turn signal switch wiring harness
through the switch and lever (or extension) hous­
ing.
Lubricate the inner diameter of the shift housing.
Shift lever (or extension) housing onto the upper
end of the column.
Washer assembly (295, 294).
Upper bearing into the switch contact support.
Turn signal switch housing (293), contact support,
bearing, switch and switch screws. Tighten
screws to 2.8 N m (25 in. lbs.).
Wiring harness cover and back-up lamp switch.
Control lever (292) and the gear shift lever (299).
Adjust
Shift tube. Refer to “ Shift Tube Adjustment”
in this section.
12. Spring (315), clamp (316), bolt (317), washer (318)
and nut (319). Tighten the bolt finger tight.
• Slide the steering shaft assembly up through the
column assembly.
Install or Connect
Steering column assembly. Refer to “ Standard
Steering Column Replacement” in this section.
3B4-46 STEERING COLUMN
INTERMEDIATE SHAFT UNIT REPAIR P(42) MODELS
Figure 54—Intermediate Shaft P(42) Model
Remove or Disconnect
Assemble (Figure 54)
Intermediate shaft. Refer to “ Intermediate Shaft
Replacement” in this section.
• If the yoke trunnions were removed, assemble as
follows:
1. Trunnion (326) into the yokes (331, 330).
2. Trunnion (326) into the yokes (327, 321).
3. Bearing cups (325) into the yokes.
• Reassemble the intermediate shaft assembly as
follows:
4. Dust cap (329) and dust seal (328) over the shaft
of the lower yoke (330) assembly.
• Align the arrow on the lower yoke assembly shaft
with the arrow on the upper yoke assembly tube
and push the two assemblies together.
• Push the dust seal (328) and dust cap (329) into
position on the lower end of the upper yoke as­
sembly and bend the tangs of the dust cap down
against the yoke tube.
Disassembly (Figure 54)
• If the upper and lower half of the intermediate
shaft is to be replaced, preceed as follows:
• Place the intermediate shaft (320) on a bench
and straighten the tangs on the dust cap (329).
Separate the upper and lower portions of the
shaft assembly.
1. Dust cap (329) and dust seal (328).
• If the trunnion assembles are to be replaced, pro­
ceed as follows:
2. Bearing cups (325).
• Support the yoke on a bench vise and drive
out one bearing cup by tapping on the oppo­
site bearing cup. Use a soft drift and ham­
mer.
• Support the other side of the yoke and drive
out the re m a in in g b e a rin g cups, as
described in the previous step.
3. Trunnion (326) from the yokes (324, 327).
4. Trunnion (326) from the yokes, (331, 330).
□
Install or Connect
Intermediate shaft. Refer to “ Intermediate Shaft
Replacement” in this section.
STEERING COLUMN 3B4-47
SPECIFICATIONS
Turn Signal Switch Attaching Screws................................................
Ignition Switch Attaching Screws......................................................
Dimmer Switch Attaching Screws......................................................
Steering Wheel N u t..............................................................................
Flexible Coupling Clamp B o lt.............................................................
Flexible Coupling To Flange Bolt N uts..............................................
Steering Gear To Frame Bolts (C, K And G Models).......................
Steering Gear To Frame Bolts P300 (32, 42) FS 3...........................
Steering Gear To Frame Bolts P200 & 300(42) Excluding FS3 . . .
Upper Intermediate Shaft Pinch Bolt (G M o d e l).............................
Lower Intermediate Shaft Pinch Bolt (G Model)...............................
Intermediate Shaft Pinch Bolt P300 (42) F S 3 .................................
Intermediate Shaft Pinch Bolt P200 & 300(42) Excluding FS3. . . .
Steering Column Support Bracket Screws (C, K And G M odels). .
Steering Column Support Bracket Clamp Nuts (P M o d e ls )..........
Steering Column Shaft To Intermediate Shaft (Pot Joint) Assembly
Nm
4.0
4.0
4.0
40
42
27
102
108
95
47
62
108
102
30
25
60
Ft. Lbs.
SPECIAL TOOLS
J-23980-B
J-1859-03
J-23653-A
J-21854-01
J-23072
J-22599
J-5822
J-2619-01
J-22635
J-22727
J-23072
J-23073-01
J-23074
J-22708
Steering Column Electrical Component Analyzer
Steering Wheel Puller
Lock Plate Compressor
Pivot Pin Remover
Shift Tube Remover
Locknut Wrench
Steering Gear Shaft Main Bearing Cup Remover
Slide Hammer
Lock Shoe & Release Lever Pin Remover And Installer
Electrical Terminal Remover
Shift Tube Remover
Shift Tube Installer
Steering Column Holding Fixture
Turn Signal Cover Remover
In. Lbs.
35
35
35
30
31
20
75
80
70
35
46
80
75
22
18
44
3C-1
SECTION 3C
FRONT SUSPENSION
The following “ Notice” applies to one or more steps in the assembly procedure of components in this portion of
the manual as indicated at appropriate locations by the terminology “ NOTICE: Refer to ‘Notice’ on page 3C-1 of
this section.”
NOTICE: All front suspension fasteners are important attaching parts in that they could affect the perform­
ance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one
of the same part number or with an equivalent part if replacement becomes necessary. Do not use a replace­
ment part of lesser quality or substitute design. Torque values must be used as specified during reassembly
to assure proper retention of these parts.
CONTENTS
SUBJECT
PAGE
General D e s c rip tio n ................................................................................................................................................... 3C- 2
Diagnosis of Front S u s p e n s io n ..............................................................................................................................3C- 2
Diagnosis of Wheel B e a rin g s ..................................................................................................................................3C- 3
On-Vehicle Service: Two Wheel Drive Independent Front S usp e nsion ........................................................ 3C- 8
Shock A b s o rb e r..................................................................................................................................................... 3C- 8
Stabilizer B ar............................................................................................................................................................3C- 8
Wheel Hub/Rotor Assem bly..................................................................................................................................3C-12
Wheel Bearing A d ju s tm e n t..................................................................................................................................3C-15
Wheel Hub B o lt........................................................................................................................................................3C-16
Steering K n u c k le ................................................................................................................................................... 3C-16
Coil S p r in g .............................................................................................................................................................. 3C-18
Lower Ball J o in t ..................................................................................................................................................... 3C-19
Upper Ball J o in t ..................................................................................................................................................... 3C-20
Lower Control Arm Pivot Shaft and B ushings................................................................................................. 3C-21
Upper Control Arm Pivot Shaft and B ushings................................................................................................. 3C-25
Lower Control A rm ................................................................................................................................................. 3C-27
Upper Control A rm ................................................................................................................................................. 3C-28
Suspension U n it..................................................................................................................................................... 3C-29
On-Vehicle Service: Two Wheel Drive RPO FS3 (I-Beam) Front S u s p e n s io n ..............................................3C-31
Shock A b s o rb e r..................................................................................................................................................... 3C-31
Stabilizer B ar............................................................................................................................................................3C-33
Wheel Hub/Rotor A ssem bly..................................................................................................................................3C-35
Wheel Bearing A d ju s tm e n t..................................................................................................................................3C-36
Wheel Hub B o lt........................................................................................................................................................3C-36
Steering Arm, Knuckle and S p in d le ...................................................................................................................3C-37
Front A x le ................................................................................................................................................................ 3C-37
Leaf S p rin g .............................................................................................................................................................. 3C-39
On-Vehicle Service: Four Wheel Drive Front S uspension................................................ ............................ 3C-40
Shock A b s o rb e r..................................................................................................................................................... 3C-40
Stabilizer B ar............................................................................................................................................................3C-41
Wheel Hub/Rotor A ssem bly..................................................................................................................................3C-41
Bearing A d ju s tm e n t...............................................................................................................................................3C-47
Wheel Hub B o lt....................................................................................................................................................... 3C-47
S pindle.......................................................................................................................................................................3C-48
Steering Knuckle and A rm .................................................................................................................................... 3C-50
Ball J o in ts ................................................................................................................................................................ 3C-53
Leaf Spring And B ushings....................................................................................................................................3C-55
S pe cifica tio ns.............................................................................................................................................................. 3C-57
Special T o o ls .............................................................................................................................................................. 3C-59
3C-2 FRONT SUSPENSION
GENERAL DESCRIPTION
An independent suspension is standard on the C-GP series vehicles. This suspension features unequal
length control arms (the lower control arm is the load
carrying member), coil springs and shock absorbers to
reduce vibration and shock load, plus a stabilizer bar
to control sway or roll. Air cylinders inside coil springs
are available to minimize “ crash through” on large
road bumps. A special heavy duty front suspension is
available on P series vehicles. This suspension (RPO
FS3), centered around a solid I-beam axle, includes
leaf springs, shock absorbers, and a stabilizer bar.
The K series (four wheel drive) suspension includes
leaf springs, shock absorbers, and a stabilizer bar.
DIAGNOSIS OF FRONT SUSPENSION
PROBLEM
Hard Steering
POSSIBLE CAUSE
CORRECTION
1. Ball joints and steering linkage need
lubrication.
2. Low or uneven front tire pressure.
1. Lubricate the ball joints and linkage.
3. In c o rre c t fro n t w heel a lig n m e n t
(manual steering).
Poor Directional
S tability
1. Ball joints and steering linkage need
lubrication.
2. Low or uneven front or rear tire pres­
sure.
3. Loose wheel bearings.
4. In c o rre c t fro n t w heel a lig n m e n t
(caster).
5. Broken springs.
6. Malfunctioning shock absorber.
7. Broken stabilizer bar or a missing link.
Front Wheel Shimmy
(Smooth Road
Shake)
1. Tire and wheel are out of balance or
out of round.
2. Worn or loose wheel bearings.
3. Worn ball joints.
4. Malfunctioning shock absorber.
Vehicle Pulls To One
Side (No Braking
Action)
1. Low or uneven tire pressure.
2. Front or rear brakes dragging.
3. Broken or sagging front spring.
4. Incorrect front wheel alignment (cam­
ber).
2. Inflate tires to the recommended
pressure.
3. Check and align the front suspen­
sion.
1. Lubricate the ball joints and linkage.
2. Inflate tires to the recommended
pressure.
3. Adjust the wheel bearings.
4. Check and align the front suspen­
sion.
5. Replace the springs.
6. Check and replace the shock absor­
ber.
7. Replace the stabilizer bar or link.
1. Balance the tires, check run-out.
2. Adjust the wheel bearings.
3. Replace the ball joints.
4. Check and replace the shock absor­
ber.
1. Inflate the tires to the recommended
pressure.
2. Adjust the brakes.
3. Replace the spring.
4. Check and align the front suspen­
sion.
FRONT SUSPENSION 3C-3
DIAGNOSIS OF FRONT SUSPENSION (CONT.)
PROBLEM
POSSIBLE CAUSE
CORRECTION
1. Ball joints and steering linkage need
lubrication.
2. Loose shock absorber or worn bush­
ings.
3. Worn control arm bushings.
4. Worn or loose wheel bearings.
5. Loose stabilizer bar.
6. Loose wheel nuts.
7. Spring is improperly positioned.
8. Loose suspension bolts.
1. Lubricate at the recommended inter­
vals.
2. Tighten the bolts or replace the
shock absorber.
3. Replace the bushings.
4. Adjust or replace the wheel bearings.
5. Tighten all the stabilizer bar attach­
ments.
6. Tighten the wheel nuts.
7. Reposition the spring.
8. Tighten to specifications or replace.
Wheel Tramp
1.
2.
3.
4.
1.
2.
3.
4.
Excessive or Uneven
Tire Wear
1. Underinflated or overinflated tires.
Noise In The Front
End
2.
3.
4.
5.
Scuffed Tires
Cupped Tires
Tire and the wheel are out of balance.
Tire and the wheel are out of round.
Blister or bump on the tire.
Improper shock absorber action.
Improper toe-in.
Wheels are out of balance.
Hard driving.
Overloading the vehicle.
1. Toe-in is incorrect.
2. Excessive speed on turns.
3. Tires are improperly inflated.
Balance
Replace
Replace
Replace
the
the
the
the
wheels.
tire.
tire.
shock absorber.
1. Inflate the tire to the recommended
pressure.
2. Adjust toe-in setting.
3. Balance the wheels.
4. Follow proper driving techniques.
5. Do not exceed the maximum recom­
mended payload rating.
4. Suspension arm is bent or twisted.
1. Adjust toe-in setting.
2. Follow proper driving techniques.
3. Inflate the tires to the recommended
pressure.
4. Replace the suspension arm.
1. Front shock absorbers are defective.
2. Worn ball joints.
3. Wheel bearings are incorrectly ad­
justed or worn.
4. Wheel and tire is out of balance.
5. Excessive tire or wheel runout.
1. Replace the shock absorbers.
2. Replace the ball joints.
3. Adjust or replace the wheel bearings
(also replace the races).
4. Balance the wheel and tire.
5. Check and compensate for runout.
DIAGNOSIS OF WHEEL BEARINGS
When diagnosing bearing condition, keep in mind
the general condition of all parts during disassembly
and inspection. Use Figures 1, 2, 3 and 4 to classify
the failure, and follow the recommended repair procedures.
3C-4 FRONT SUSPENSION
ABRASIVE ROLLER WEAR
ABRASIVE STEP WEAR
Pattern on races and rollers caused by fine
abrasives.
Clean all parts and housings, check seals and
bearings and replace if leaking, rough or
noisy.
Pattern on roller ends caused by fine abra­
sives.
Clean all parts and housings, check seals and
bearings and replace if leaking, rough or
noisy.
GALLING
ETCHING
Metal smears on roller ends due to overheat,
lubricant failure or overload.
Replace bearing, check seals and check for
proper lubrication.
Bearing surfaces appear gray or grayish black
in color with related etching away of material
usually at roller spacing.
Replace bearings, check seals and check for
proper lubrication.
B-09194
Figure 1—Diagnosis Of Front Wheel Bearings
FRONT SUSPENSION 3C-5
BENT CAGE
Cage damaged due to improper handling or
tool usage.
Replace bearing.
BENT CAGE
Cage damaged due to improper handling or
tool usage.
Replace bearing.
CAGE WEAR
INDENTATIONS
Wear around outside diameter of cage and
roller pockets caused by abrasive material
and inefficient lubrication.
Clean related parts and housings.
Check seals and replace bearings.
Surface d e p re ssio ns on race and rollers
caused by hard particles of foreign material,
Clean all parts and housings. Check seals and
replace bearings if rough or noisy.
B-09195
Figure 2—Diagnosis Of Front Wheel Bearings
3C-6 FRONT SUSPENSION
FRETTAGE
SMEARS
Corrosion set up by small relative movement
of parts with no lubrication.
Replace bearing. Clean related parts. Check
seals and check for proper lubrication.
Smearing of metal due to slippage. Slippage
can be caused by poor fits, lu b rica tio n ,
overheating, overloads or handling damage.
Replace bearings, clean related parts and
check for proper fit and lubrication.
STAIN DISCOLORATION
HEAT DISCOLORATION
Discoloration can range from light brown to
black caused by incorrect lubricant or m ois­
ture.
Re-use bearings if stains can be removed by
light polishing or if no evidence of overheat­
ing is observed.
Check seals and related parts for damage.
Heat discoloration can range from faint yel­
low to dark blue resulting from overload or in correct lubricant.
Excessive heat can cause softening of races
or rollers. To check for loss of temper on
races or rollers a simple file test may be
made. A file drawn over a tempered part will
grab and cut metal, whereas, a file drawn over
a hard part will glide readily with no metal
cutting.
Replace bearings if over heating damage is
indicated. Check seals and other parts.
F-00531
Figure 3—Diagnosis Of Front Wheel Bearings
FRONT SUSPENSION 3C-7
MISALIGNMENT
CRACKED INNER RACE
Outer race m isalignm ent due to foreign ob­
ject.
Clean related parts and replace bearing. Make
sure races are properly seated.
Race cracked due to improper fit, cocking, or
poor bearing seats.
Replace bearing and correct bearing seats.
FATIGUE SPALLING
BRINELLING
Flaking of surface metal resulting from fa­
tigue.
Replace bearing, clean all related parts.
Surface indentations in raceway caused by
rollers either under impact loading or vibra­
tion while the bearing is not rotating.
Replace bearing if rough or noisy.
B-09860
Figure 4—Diagnosis Of Front Wheel Bearings
3C-8 FRONT SUSPENSION
ON-VEHICLE SERVICE:
TWO WHEEL DRIVE INDEPENDENT FRONT SUSPENSION
SHOCK ABSORBER
«--► Remove or Disconnect (Figures 5, 6, 7, 8, and
9)
• Raise the vehicle on a hoist.
1. Shock absorber (20) from the lower control arm.
• Nuts (23), washers (22) and bolts (21)
(Figure 9).
2. Shock absorber (20) from the frame.
• Nuts (16), washers (17), and bolts (21)
(Figure 9).
BENCH TEST: SPIRAL GROOVE SHOCK
ABSORBERS
1. Purge the air from the pressure chamber.
• Extend the shock vertically—top end up.
• Turn the shock over and co lla p se it
vertically—top end down.
• Repeat the above step five times.
2. Place the shock absorber in a vise with the jaws
clamped onto the shock’s bottom mount.
— Shock absorber should be positioned
vertically in the vise—top end up.
— Do not clamp the vise jaws on the shock’s
reservoir tube.
3. Pump the shock absorber at various rates of
speed and observe the rebound force.
— Rebound force is normally stronger than the
compression force (approximately two to
one).
— Rebound force should be smooth and
constant for each stroke rate.
4. Compare with a good shock absorber.
5. If one of the following are observed, replace the
shock absorber.
— A skip or lag at reversal near mid-stroke.
— A seize (except at the extreme ends of
travel).
— A noise (grunt or squeal) after completing
one full stroke in both directions.
— A clicking noise at fast reversal.
BENCH TEST: NON-SPIRAL GROOVE
RESERVOIR SHOCK ABSORBERS
• P urging air from non-spiral groove shock
absorbers is not necessary. The shock absorbers
have a gas filled cell in their reservoirs (as
opposed to the air filled cell in the spiral groove
shock absorber reservoirs).
1. Place the shock absorber in a vise with the jaws
clamped on the shock absorber’s top mount.
— Shock absorber should be held vertically in
the vise with its bottom end up.
— Do not clamp the vise jaws on the shock’s
reservoir tube.
2. Pump the shock absorber at various rates of
speed and observe the rebound force.
— Rebound force is normally stronger than the
compression force (approximately two to
one).
— Rebound force should be smooth and
constant for each stroke rate.
3. Compare with a good shock absorber.
4. If one of the following are observed, replace the
shock absorber.
— A skip or lag at reversal near mid-stroke.
— A seize (except at the extreme ends of
travel).
— A noise (grunt or squeal) after completing
one full stroke in both directions.
— A clicking noise at fast reversal.
Install or Connect (Figures 5 through 9)
NOTICE: Refer to “Notice” on page 3C#1 of
this section.
1. Shock absorber (20) onto the vehicle.
• Bolts (21), washers (17, 22), and nuts (16, 23)
(figure 9).
Tighten
• C and P series upper mount nuts (16) to 190
N m (140 ft. lbs.).
• C and P series lower mount bolts (21) to 80
N m (59 ft. lbs.).
• G series upper and lower mount bolts (21) to
103 N m (80 ft. lbs.).
2. Lower the vehicle.
STABILIZER BAR
Remove or Disconnect (Figures 5-8 and 10)
• Raise the vehicle and support with suitable safety
stands. Remove the wheel and tire assembly.
1. Stabilizer bar (59) from the frame.
• Bolts (54), nuts (58), washers (55, 57) and
clamps (52).
2. Stabilizer bar (59) from the lower control arm (36).
• Bolts (43), nuts (38), washers (39, 41) and
clamps (42).
• Stabilizer bar (59) drops down—remove the
bushings (40, 53).
FRONT SUSPENSION 3C-9
11
12
v
/H
67
66
64
63
/
14 15 16 17
62
B-07466
Figure 5—C Series Front Suspension
3C-10 FRONT SUSPENSION
Figure 6—G Series Front Suspension
FRONT SUSPENSION 3C-11
Figure 7—P Series Front Suspension
3C-12 FRONT SUSPENSION
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
Bolt
Washer
Nut
Bolt
Washer
Bolt
Washer
Reinforcement
Bracket
Nut
Rivet
Fitting
Upper Ball Joint
Nut
Cotter Pin
Nut
Washer
Shim Pack
Spacer
Shock Absorber
Bolt
Washer
Nut
Nut
Retainer
Bushing
Nut
Upper Control Arm
Pivot Shaft
Bumper
Steering Knuckle
Coil Spring
Bumper
Cotter Pin
Nut
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
Lower Control Arm
Lower Ball Joint
Nut
Washer
Bushing
Washer
Bracket
Bolt
U-Bolt
Rivet
Bushing
Bracket
Washer
Nut
Pivot Shaft
Rivet
Bracket
Bushing
Bolt
Washer
Bracket
Washer
Nut
Stabilizer Bar
Bolt
Washer
Washer
Nut
Brace
Bolt
Washer
Nut
Seal
Air Cylinder
B-07469
Figure 8—C-G-P Series Front Suspension
I*
Clamps (42), bolts (43), washers (39, 41) and
nuts (38).
• C and P series nuts (38, 58) to 33 N m (24 ft.
lbs.).
• G series bolt (54) to 33 N m (24 ft. lbs.).
• G series nut (38) to 29 N m (21 ft. lbs.).
3. Wheel and tire assembly. Lower the vehicle.
WHEEL HUB/ROTOR ASSEMBLY
+ + Remove or Disconnect (Figures 5 through 8,
and 11)
• Raise the vehicle and support it with suitable
safety stands. Remove the wheel and tire
assembly.
1. Caliper. Refer to BRAKES (SEC. 5).
NOTICE: Support the caliper with a piece of
wire to prevent damage to the brake line.
2. Wheel Hub/Rotor (81)
• Dust cap (79).
• Cotter pin (80), nut (78), and washer (77).
• Pull the hub/rotor free, making sure the
outer wheel bearing (76) comes free of the
hub/rotor.
• Do not damage the steering knuckle (70)
spindle threads.
3. Inner wheel bearing (73).
• Pry out the seal (72).
4. Races (75, 82).
• Drive out each race using a brass drift
inserted behind the race in notches in the
hub.
Inspect
Clean
• Rubber bushings (40, 53) for excessive
wear, aging, or other damage. Replace as
necessary.
Install or Connect (Figures 5, 6, 7, 8 and 10)
1. Bushings (40, 53) to the stabilizer bar (59).
• Slit on the insulator faces forward.
• Use rubber lubricant to ease the installation.
NOTICE: Refer to “Notice” on page 3C#1 of
this section.
2. Stabilizer bar (59) to the vehicle.
• Position the stabilizer bar and attach the
clamps (52), bolts (54), washers (55, 57) and
nuts (58).
1. Grease from the hub/rotor (81) and steering
knuckle spindle.
• Remove grease from inside the hub.
2. Grease from the wheel bearings (73, 76) and
races (72 , 75).
• Use clean solvent and a small brush (no
loose bristles).
• Do not spin the wheel bearings with
compressed air to dry them—the wheel
bearings may be damaged.
1? Inspect
1. Wheel bearings (73, 76) and their races (72 , 75)
for damage or wear.
• Refer to “ Diagnosis of Wheel Bearings, in
this section.
FRONT SUSPENSION 3C-13
B.
16.
17.
20.
G Series
Nut
Washer
Shock Absorber
21. Bolt
22. Washer
23. Nut
B-07473
Figure 9—Shock Absorber Attachm ents
• If either a bearing or its race is damaged or
worn, replace both.
2. Hub/rotor for damage.
• Check for out-of-round or scored conditions.
• Check for pitting or cracks.
Install or Connect (Figures 5 through 8,11 and
12)
Tools Required:
J-8092 Driver Handle
J-8457 Wheel Bearing Race Installer
J-8849 Wheel Bearing Race Installer
J-9746-02 Hub/Rotor Support
• Repair or replace as necessary.
38.
39.
40.
41.
42.
43.
52.
53.
54.
55.
57.
58.
59.
Nut
Washer
Bushing
Washer
Clamp
Bolt
Clamp
Bushing
Bolt
Washer
Washer
Nut
Stabilizer Bar
B-07475
Figure 10—Stabilizer Bar Attachments
3C-14 FRONT SUSPENSION
70.
71.
72.
73.
74.
75.
Steering Knuckle
Shield
Seal
Inner Wheel Bearing
Wheel Hub Bolt
Outer Race
76.
77.
78.
79.
80.
81.
Outer Wheel Bearing
Washer
Nut
Dust Cap
Cotter Pin
Wheel Hub/Rotor
82.
83.
84.
85.
B-07470
Figure 11—Steering Knuckle And Hub Assembly
NOTICE: Start the races squarely inside the
hub/rotor to avoid distortion and possible
cracking.
1. Races (72 , 75) into the hub/rotor (81).
• Place the hub/rotor on J-9746-02 and rest
this assembly on press bars.
• Use J-8457 to drive the outer bearing outer
race (75) into position (figure 12).
• Turn over the hub/rotor, remove J-9746-02,
and drive in the inner bearing outer race
(82) with J-8449.
Im portant
• Use an approved high-temperature front wheel
bearing grease to lubricate the bearings. Refer to
MAINTENANCE AND LUBRICATION (SEC. OB).
• Do not mix different greases as mixing may
change the grease’s properties resulting in poor
performance.
A. Outer Wheel Bearing Race
B-06955
Figure 12—Installing The Outer Wheel
Bearing Race
2. Apply a thin film of grease to the steering knuckle
spindle at the outer wheel bearing seat and at the
inner wheel bearing seat, shoulder, and seal seat.
3. Put a small quantity of grease inboard of each
wheel bearing dust cap (79).
FRONT SUSPENSION 3C-15
NOTICE: Failure to completely pack the wheel
bearing (cones, rollers, and cage) with grease
will result in premature wheel bearing damage
and/or wear.
WHEEL BEARING ADJUSTMENT
Important
• The proper functioning of the front suspension
cannot be maintained unless the front wheel
bearings are correctly adjusted. The bearings
must be a slip fit on the spindle and the inside
diameter of the wheel bearing must be lubricated
to ensure the bearings will creep. The spindle nut
(78) must have a free-running fit on the spindle
threads.
4. F ill each w heel b e a rin g (cone and ro lle r
assembly) full of grease.
• Use a cone-type grease machine that forces
grease into the bearing.
• If a cone-type grease m achine is not
available, pack the wheel bearing by hand.
• When packing the wheel bearing by hand,
work the grease into the bearings between
the rollers, cones, and the cage.
NOTICE: Never preload the front wheel
bearings. Damage can result by the steady
thrust on the roller ends which comes from
preloading.
5. Inner wheel bearing (73) into the hub/rotor (81).
• Put an a d d itio n a l q u a n tity of grease
outboard of this bearing.
6. New seal (72).
• Use a flat plate or block to install the seal to
insure it is flush with the hub/rotor flange.
• Lubricate the seal lip with a thin layer of
grease.
7. Hub/rotor (81).
f t
Adjust
• Raise the vehicle and support it with suitable
safety stands under the lower control arms.
1. Remove the dust cap (79) from the hub/rotor (81).
2. Remove the cotter pin (80).
• Do not damage the steering knuckle spindle
threads.
8. Outer wheel bearing (76).
• Slide it over the spindle until the wheel
bearing (76) fully seats against the hub/rotor
outer race (75).
NOTICE: Refer to “Notice” on page 3C#1 of
this section.
9. Washer (77), nut (78), and cotter pin (80).
• Do not place the cotter pin through the hole
in the spindle until the wheel bearings are
adjusted.
$
Tighten
• Nut (78) to 16 N m (12 ft. lbs.) while turning
the hub/rotor assembly in either direction.
10. Put an additional quantity of grease outboard of
the wheel bearing (76).
11. Adjust the wheel bearings.
• Refer to “ Wheel Bearing Adjustment,” in
this section.
12. Dust cap (79) on the hub/rotor (81).
13. Caliper. Refer to BRAKES (SEC. 5).
14. Tire and wheel assembly and lower the vehicle.
Tighten
• Nut (78) to 16 N m (12 ft. lbs.) while rotating the
wheel and tire assembly (this will seat the
bearings).
3. Back off the nut (78) to the “ just loose” position.
4. Hand tighten the nut (78).
5. Back off the nut (78) until the hole in the spindle
lines up with a slot on the nut.
• Do not back off more than V2 of a flat.
6. New cotter pin (80).
• Make sure the bent ends do not interfere
with the dust cap (79).
Measure
• Endplay in the hub/rotor assembly (81).
• It should measure between 0.03 mm (0.0012
inches) and 0.13 mm (0.005 inches) when properly
adjusted.
7. Install the dust cap (79) on the hub/rotor (81).
8. Install the wheel and tire assembly if removed
and lower the vehicle.
3C-16 FRONT SUSPENSION
WHEEL HUB BOLT
Remove or Disconnect (Figures 5 through 8,
and 13)
Tools Required:
J-9746-02 Hub/Rotor Support
1. Hub/rotor from the vehicle.
• Refer to “ Wheel Hub, Bearing and Race” in
this section.
J-9746
NOTICE: Place J-9746-02 between the press
bars and the hub/rotor to protect the rotor
surfaces.
2. Wheel hub bolts (74) with a press.
• Support the hub/rotor (81) using J-9746-02
and press bars (figure 13).
• Do not damage the wheel mounting surface
on the hub/rotor flange.
r»+| Install or connect (Figures 5 through 8, and
14)
A. Press Bars
NOTICE: Refer to the “Notice” on page 3C#1
of this section.
1. Wheel hub bolts (74) into the hub/rotor (81).
• Place four washers onto the bolt, then
fasten a nut onto the bolt until the nut
bottoms on the washers (figure 14).
• Tighten the nut until the bolt fully seats into
the hub/rotor (81).
• Remove the nut and washers.
2. Hub/rotor to the vehicle.
• Refer to “ Wheel Hub, Bearing and Race,”
in this section.
3. Wheel and tire assembly. Lower the vehicle.
F-00036
Figure 13—Pressing The Hub Bolt Out
2. Caliper.
• Refer to BRAKES (SEC. 5).
3. Hub/Rotor (81).
• Refer to “ Wheel Hub, Bearing and Race,”
in this section.
4. Splash shield (71).
• Bolts (83) and washers (84).
• Gaskets (85).
5. Steering knuckle from the tie rod end.
STEERING KNUCKLE
+ + Remove or Disconnect (Figures 5 through 8,
• Refer to STEERING LINKAGE (SEC. 3B1).
6. Steering knuckle (70) from the upper ball joint
(13).
15 and 16)
Tools Required:
J-23742 Ball Joint Separator
Im portant
It is recommended that the vehicle be raised and
supported as on a twin-post hoist so that the front
coil spring remains compressed, yet the wheel
and s te e rin g k n u c k le a sse m b ly rem ain
accessible. If a frame hoist is used, support the
lower control arm with an adjustable jackstand to
safely retain the spring in its curb height position.
Wheel and tire assembly.
A. Washers
B. Nut
81. Hub/Rotor
Figure 14—Installing The Wheel Hub Bolts
FRONT SUSPENSION 3C-17
B-06961
Figure 15—D isconnecting The Upper Ball Joint
From The Steering Knuckle
• Position a floor jack under the lower control
arm (36) near the spring seat.
• Raise the jack until it just supports the lower
control arm.
• Use J-23742 to break the upper ball joint
free of the steering knuckle (figure 15).
• Raise the upper co n tro l arm (28) to
disengage the upper ball joint from the
steering knuckle.
Im portant
• Floor jack must remain under the lower
control arm spring seat during removal and
installation to retain the spring and the lower
control arm in position.
7. Steering knuckle (70) from the lower ball joint
(37).
• Use J-23742 to break the lower ball joint free
from the steering knuckle (figure 16).
• Lift the steering knuckle off the lower ball
joint.
Inspect
1. Tapered holes in the steering knuckle that attach
to the ball joints and the tie rod end.
• Remove any dirt.
Figure 16—Disconnecting The Lower Ball Joint
From The Steering Knuckle
• If any tap e re d hole is out of round,
deformed, or damaged in any way, replace
the steering knuckle (70).
2. Spindle for wear or damage.
• The steering knuckle (70) must be replaced
if the spindle is damaged or worn.
Install or Connect (Figures 5 through 8)
NOTICE: For steps 3 and 8, refer to the
“Notice” on page 3C#1 of this section.
1. Steering knuckle (70) to the lower ball joint (37).
• Press the steering knuckle onto the lower
ball joint (37) until it is fully seated.
2. Steering knuckle (70) to the upper ball joint (13).
• Lower the upper control arm (28) to seat the
upper ball jo in t (13) into the steering
knuckle.
3. Nuts (14, 35).
• Nuts (14, 35) to “ Specifications” at the end
of this section.
Cotter pins (15, 34).
• Tighten the nuts (14, 35), if needed, to install
the cotter pins.
3C-18 FRONT SUSPENSION
• Nuts (38), bolts (43), washers (41) and clamp
(42).
CAUTION: Failure to secure J-23028 to a
suitable flo o r jack could result in personal
injury.
3. J-23028-02 to a suitable jack.
4. Place J-23028-02 under the lower control arm
shaft (50) as shown in figure 17.
Im portant
• Install a chain around the coil spring (32) and
through the lower control arm (36) as a safety
precaution.
5. Remove the floor jack.
6. Gasket.
7. Tie rod end to the steering knuckle (70).
• Refer to STEERING LINKAGE (SEC. 3B1).
8. Splash shield (71).
• Washers (84) and bolts (83) in position.
$
Tighten
• Bolts (83) to 13.5 N m (120 in. lbs.).
4. Hub/rotor assembly.
• Refer to “ Wheel Hub, Bearing and Race” in
this section.
5. Caliper.
• Refer to BRAKES (SEC. 5).
6. Adjust the wheel bearings.
• Refer to “ Wheel Bearing Adjustment” in
this section.
7. Check the front alignment and reset as required.
• Refer to FRONT END ALIGNMENT (SEC.
3A).
8. Wheel and tire assembly, and lower the vehicle to
the ground.
COIL SPRING
+ + Remove or Disconnect (Figures 5 through 8,
and 17)
Tools Required:
J-23028-02 Spring Remover
• Raise the vehicle and support it with suitable
safety stands, allowing the control arms to hang
free. Remove the wheel and tire assembly.
1. Shock absorber (20) at the lower end and move it
aside.
2. Stabilizer bar (59) from the lower control arm (36).
5. Raise the jack to remove the tension from the
lower control arm shaft (50) and remove the “ U”
bolts.
• Nuts (49) and washers (48).
6. Lower the control arm by slowly releasing the jack
until the spring can be removed.
• Do not dam age the ball jo in t (37) by
applying too much force on it.
7. Spring (32) and safety chain only after all
compression is removed from the spring.
• Proper maneuvering of the spring will allow
for easy removal.
Install or Connect (Figures 5 through 8 and 17)
Tools Required:
J-23028-02 Spring Remover
NOTICE: For steps 3, 5 and 6, refer to the
“Notice” on page 3C#1 of this section.
1. Coil spring (32) into position on the lower control
arm (36).
Important
• Install a chain around the coil spring and through
the lower control arm as a safety precaution.
CAUTION: Failure to secure J-23028 to a
suitable flo or jack could result in personal
injury.
2. Slowly lift the lower control arm into position.
• Line up the front indexing hole in the shaft
(50) with the crossmember attaching studs.
• Do not damage the lower ball joint (37).
• Use J-23028-02 bolted on a floor jack.
3. U-bolts (44), washers (48), and nuts (49).
FRONT SUSPENSION 3C-19
J-9519-10
J-9519-16
J-9519-22
A. Measure This Distance
B-07486
J-21474-13
Figure 18—Inspecting The Lower Ball Joint
Tighten
• For G 10/1500-20/2500 series vehicles,
torque to 88 N m (65 ft. lbs.).
• For all other series vehicles, torque to 115
N m (85 ft. lbs.).
4. Lower the floor jack, and remove J-23028-02.
5. Stabilizer bar (59) to the lower control arm (36).
• Clamp (42), washers (41), bolts (43) and
nuts (38).
&
Tighten
• Nuts (38) to 33 N m (24 ft. lbs.).
6. Shock absorber (20) to the lower control arm (36).
• Washer (22), bolt (21), and nut (23).
Tighten
• Nut (23) to “ Specifications” at the end of
this section.
7. Check the front end alignment.
• Refer to FRONT END ALIGNMENT (SEC.
3A).
8. Wheel and tire and lower the vehicle.
LOWER BALL JOINT
Inspect (Figures 5 through 8, and 18)
1. Raise the vehicle and remove the wheel and tire
assembly. Support the weight of the control arms
at the wheel hub and drum.
2. Measure the distance between the tip of the ball
joint stud and the tip of the grease fitting below
the ball joint (figure 18).
3. Move the support to underneath the control arm
allowing the wheel hub and drum to hang free.
36. Lower Control Arm
Figure 19—Removing The Lower Ball Joint
4. Measure the distance as in Step 2.
• If the difference in measurements exceeds
2.38 mm ( % 2 inches), for all models, the ball
joint is worn and must be replaced.
5. If the ball joint seals are cracked, cut, or torn,
replace them.
«” ► Remove or Disconnect (Figures 5 through 8,
and 19)
Tools Required:
J-23742 Ball Joint Separator
J-9519-10 Ball Joint Fixture
J-9519-16 Ball Joint Installer
J-9519-22 Ball Joint Installer
J-21474-13 Ball Joint Installer
• Raise the vehicle on a hoist. If a frame hoist is
used it will be necessary to support the lower
control arm with a floor stand. Remove the tire
and wheel assembly.
1. Cotter pin (34), nut (35), and lube fitting (12).
• Loosen (two turns) but do not remove the
nut (35).
2. Loosen the ball joint in the steering knuckle (31).
• Use J-23742 between the ball joint studs
(figure 16).
• It may be necessary to remove the caliper
and wire it to the frame to gain clearance for
J-23742. Refer to BRAKES (SEC. 5).
3C-20 FRONT SUSPENSION
• Mate the steering knuckle (31) to the lower
ball joint (37).
3. Caliper if it was removed.
• Refer to BRAKES (SEC. 5).
NOTICE: Refer to “Notice” on page 3C#1 of
this section.
4. Nut (35).
Tighten
• Nut (35) to 122 N m (90 ft. lbs.).
5. Cotter pin (34).
• Tighten the nut (35) until the hole in the stud
lines up with the slot in the nut.
• Do not tighten more than one flat or 175 N m
(130 ft. lbs.) maximum.
5. Fitting (12).
• L u b ric a te the ball jo in t (37) w ith
recommended lubricant.
6. Tire and wheel assembly and lower the vehicle to
the floor.
UPPER BALL JOINT
B-07472
Figure 20—Installing The Lower Ball Joint
• Extend J-23742 until the lower ball joint (37)
breaks free from the steering knuckle (31).
• Remove the nut (35) and J-23742.
3. Hub/rotor (70) and the knuckle assembly off the
lower ball joint (37).
• Support the upper control arm (28) with a
block of wood to keep it clear of the work
area.
4. Ball joint (37) from the lower control arm (36).
• Install J-21474-13, J-9519-22, J-9519-16, and
J-9519-10 (figure 19).
• Turn the hex head screw until the ball joint is
free of the lower control arm.
• Remove the tools and the ball joint (37).
“► * Install or Connect (Figures 5 through 8, and
20)
Tools Required:
J-9519-9 Ball Joint Installer
J-9519-10 Ball Joint Fixture
1. Ball joint (37) into the lower control arm (36).
• Start the ball joint into the control arm and
install J-9519-9 and J-9519-10 (Figure 20).
• Position the bleed vent in the rubber boot
facing inward.
• Turn the hex head screw until the ball joint is
seated in the lower control arm.
2. Ball joint into the steering knuckle (31).
L9
Inspect
The upper ball joint (13) is spring loaded in its
socket. Replace the ball joint if there is any lateral
shake or if it can be twisted in its socket with the
fingers.
The ball joint seals for cuts or tears. Replace the
ball joint if any are found.
+ + Remove or Disconnect (Figures 5 through 8,
and 15)
Tools Required:
J-23742 Ball Joint Separator
• Raise the vehicle on a hoist. If a frame hoist
is used, support the lower control arm with a
floor jack.
1. Cotter pin (15) from the upper ball joint (13).
• Loosen the nut (14) two turns, but do not
remove the nut.
2. Caliper.
• Refer to BRAKES (SEC. 5).
3. Upper ball joint (13) from the steering knuckle
(31).
• Use J-23742 to separate the upper ball joint
from the steering knuckle (figure 15).
• Nut (14), and lift the upper control arm (28)
free of the ball joint.
4. Ball joint (13) from the upper control arm (28).
• Drill 6.35 mm (1U inch) deep holes in the
rivet heads using a 3.175 mm (1/s inch)
diameter drill bit.
FRONT SUSPENSION 3C-21
Figure 22—Removing The Lower Control Arm
Bushings (C10/1500, G10/1500-20/2500 Series)
Tighten
• Drill off the rivet heads using a 12.7 mm (V2
inch) diameter drill bit.
• Punch out the rivets and remove the upper
ball joint from the upper control arm.
3.
4.
5.
|~n~| Install or Connect (Figures 5 through 8, and
21 )
6.
NOTICE: For steps 1 and 2 refer to the
“Notice” on page 3C#1 of this section.
1. Upper ball joint (13) into the upper control arm
(28).
• Position into the upper control arm and
install four attaching bolts and nuts (figure
21).
Tighten
• Attaching nuts to 25 N m (18 ft. lbs.).
2. Upper ball joint to the steering knuckle (31).
• The upper ball joint must be fully seated into
the steering knuckle.
• Nut (14).
7.
8.
• All 10/1500 series and G20/2500 series
vehicle nuts (14) to 68 N m (50 ft. lbs.).
• All 20/2500 and 30/3500 series (except
G20/2500) vehicle’s nuts (14) to 122 N m (90
ft. lbs.).
• Apply additional torque to align the cotter
pin (15), but do not exceed 120 N m (90 ft.
lbs.) for all 10 series and G20/2500 series or
175 N m (130 ft. lbs.) for all other series.
Cotter pin (15).
Upper ball joint grease fitting (12).
Grease the upper ball joint (13).
• Use a recommended lubricant.
Caliper.
• Refer to BRAKES (SEC. 5).
Tire and wheel assembly.
Check the front end alignment.
• Refer to FRONT END ALIGNMENT (SEC.
3A).
LOWER CONTROL ARM PIVOT
SHAFT AND BUSHINGS
C10/1500 SERIES VEHICLES
Remove or Disconnect (Figures 5, 8, 17 and
22 )
Tools Required:
J-23028-02 Coil Spring Remover
J-22717 Lower Control Arm Bushing Stake
Remover
J-24435-2 Lower Control Arm Bushing
Spacer
3C-22 FRONT SUSPENSION
J-24435-3 Lower Control Arm Bushing
Remover
J-24435-6 Lower Control Arm Bushing
Spacer
J-24435-7 Lower Control Arm Bushing
Fixture
If just the bushings (46) or the pivot shaft (50) need
replacement, the lower control arm (36) does not have
to be removed from the vehicle.
• Raise the vehicle on a hoist and support the
frame so the lower control arms hang free.
CAUTION: Failure to install J-23028-02 to a
suitable flo o r jack could result in personal
injury.
1. J-23028-02 to a suitable floor jack and raise it into
position [under the lower control arm (26)]
inboard of the spring and into the depression of
the lower control arm.
Im portant
• Install a chain over the upper control arm (28)
inboard of the stabilizer bar (59) and outboard of
the shock absorber (20).
2. Shock absorber (20) from the lower control arm
(28).
• Nut (23), washer (22), and bolt (21).
3. Stabilizer bar (59) from the lower control arm (28).
• Nuts (38), washers (39, 41), clamp (42), and
bolts (43).
42. Pivot shaft end nuts (24).
• Loosen only, do not remove.
5. Lower control arm from the frame.
• Nuts (49), washers (48), and U-bolts (44).
• SLOWLY lower the floor jack until all
compression is released from the spring
(32).
6. Stakes on the front bushing.
• Use J-22717 or an equivalent tool.
7. Bushings (46) and the pivot shaft (50) from the
lower control arm (36).
• Use J-24435-2, J-24435-3, J-24435-6, and
J-24435-7 (figure 22).
• Tighten the bolt on J-24435-7 to remove the
bushing. Discard the old bushing.
• The pivot shaft (50) will slide out of the lower
control arm after one bushing is removed.
• Leave the pivot shaft (50) inside the lower
control arm (36) to remove the remaining
bushing.
+♦- Install or Connect (Figure 5, 8 and 23)
Tools Required:
J-23028-02 Coil Spring Compressor
Figure 23—Installing The Lower Control Arm
Bushings (C10/1500, G10/1500-20/2500 Series)
J-24435-4 Lower Control Arm Bushing
Installer
J-24435-6 Lower Control Arm Bushing
Spacer
J-24435-7 Lower Control Arm Bushing
Fixture
NOTICE: For steps 3, 4, 5 and 6, refer to the
“Notice” on page 3C#1 of this section.
1. Bushings (46) and the pivot shaft (50).
• Use J-24435-4, J-24435-6, and J-24435-7
(figure 23).
• Tighten the bolt on J-24435-7 to install the
bushings.
• Install one bushing, then insert the pivot
shaft and install the remaining bushing.
• Make sure J-24435-6 is in position to
prevent collapsing the control arm.
2. Stake the front bushing in at least two places.
CAUTION: Failure to secure J-23028-02 to a
suitable flo o r jack could result in personal
injury.
3. Lower control arm (36) to the frame.
• SLOWLY raise the floor jack until the front
indexing hole in the pivot shaft (50) lines up
with the crossmember attaching studs.
• Do not damage the ball joint (37).
• J-23028-02 is bolted to a suitable floor jack.
• U-bolts (44), washers (48), and nuts (49).
Tighten
• U-bolt nuts (49) to 115 N m (85 ft. lbs.).
4. Pivot shaft end nuts (24).
FRONT SUSPENSION 3C-23
|-n-| Install or Connect (Figures 6, 8, 23 and 24)
• Nuts (24) to 95 N-m (70 ft. lbs.).
5. Stabilizer bar (59) to the lower control arm (28).
• Washers (39, 41), clamp (42), bolts (43), and
nuts (38).
Tighten
• Nuts (38) to 34 N-m (25 ft. lbs.).
6. Shock absorber (20) to the lower control arm (36).
• Washers (22), bolt (21), and nut (23).
1.
• Nut (23) to 81 N-m (60 ft. lbs.).
7. Check the front end alignment.
• Refer to FRONT END ALIGNMENT (SEC.
3A).
8. Wheel and tire and lower the vehicle.
2.
3.
4.
Tools Required:
J-24435-4 Lower Control Arm Bushing
Installer
J-24435-6 Lower Control Arm Bushing
Spacer
J-24435-7 Lower Control Arm Bushing
Fixture
New bushing (46) using J-24435-6, J-24435-4,
and J-24435-7 (figure 23).
• Tighten J-24435-7 until the bushing fully
seats.
• The outer tube hole must be lined up so it
faces to the front or forward to the staked
bushing.
Stake the front bushing in at least two places.
Pivot shaft (50) into installed bushing.
Remaining bushing (46) into the lower control
arm.
NOTICE: Refer to “Notice” on page 3C#1 of
this section.
G10/1500-20/2500 SERIES
(EXCEPT 20/2500 SERIES W/6.2L DIESEL)
5. Pivot shaft washers (25) and nuts (24).
|<"+| Remove or Disconnect (Figures 6, 8, and 22)
Tighten
Tools Required:
J-22717 Lower Control Arm Bushing Stake
Remover
J-24435-2 Lower Control Arm Bushing
Spacer
1.
2.
3.
4.
J-24435-3 Lower Control Arm Bushing
Remover
J-24435-6 Lower Control Arm Bushing
Spacer
J-24435-7 Lower Control Arm Bushing
Fixture
Lower control arm.
• Refer to “ Lower Control A rm ,” in this
section.
Pivot shaft nuts (24) and washers (25).
Rear bushing (46).
• Place the lower control arm in an arbor
press.
• Press the front end of the pivot shaft (50) to
remove the rear bushing. Discard the old
bushing.
• The pivot shaft can be removed at this time.
Front bushing (46).
• Stakes from the front bushing using J-22717
or an equivalent tool.
• Use J-24435-7, J-24435-3, J-24435-2, and
J-24435-6.
• Tighten J-24435-7 until the bushing comes
free. Discard the old bushing (figure 22).
• Nuts (24) to 156 N-m (115 ft. lbs.).
6. Lower control arm (76).
• Refer to “ Lower Control A rm ,” in this
section.
• T h is re s u lts w ith the v e h ic le being
completely assembled and lowered to the
ground.
G20/2500 SERIES WITH RPO LH6/LL4
(6.2L DIESEL ENGINE)
4- +
Remove or Disconnect (Figures 5 through 8,
and 25)
Tools Required:
J-24435-1 Lower Control Arm Bushing
Remover
J-24435-3 Lower Control Arm Bushing
Remover
J-24435-7 Lower Control Arm Bushing
Fixture
1. Lower control arm (36).
• Refer to “ Lower Control A rm ,” in this
section.
2. Bushings (46) and the pivot shaft (50) from the
lower control arm (36).
• Use J-24435-1, J-24435-3, and J-24435-7
(figure 25).
• Tighten the clamp (J-24435-7) to remove the
bushing (46).
3C-24 FRONT SUSPENSION
A. Rear End
B. Front End
C. Insulators
D. Inner Pivot Shaft
E. Shaft Tube
F. O-Ring
G. Washer, Collar and Flange
H. Bumper
I. Shaft Restrictor
B-07514
Figure 24—Lower Control Arm Pivot Shaft (G10/1500-20/2500 W/O 6.2L Diesel)
• The pivot shaft can be slipped out at this
time.
• Repeat the procedure on the remaining
bushing (46) to remove it from the lower
control arm (36).
♦ 4- Install or Connect (Figures 5 through 8, and
26)
Tools Required:
J-24435-4 Lower Control Arm Bushing
Installer
J-24435-5 Lower Control Arm Bushing
Installer
J-24435-7 Lower Control Arm Bushing
Fixture
1. Bushings (46) and the pivot shaft (50) into the
lower control arm (36).
• Use J-24435-4, J-24435-5, and J-24435-7
(figure 26).
• Tighten the clamp (J-24435-7) to install the
bushing (26).
Figure 25—Removing The Lower Control
Arm Bushing (G20/2500 W/6.2L Diesel)
• Slide the pivot shaft (50) into the lower
control arm (36), then install the other
bushing (36).
2. Lower control arm (36).
• Refer to “ Lower Control A rm ,” in this
section.
• T h is re s u lts w ith the v e h ic le being
completely assembled and lowered to the
ground.
CP20/2500-30/3500, G30/3500 SERIES VEHICLES
Remove or Disconnect (Figures 5 through 8)
• Raise the vehicle and support the frame so the
control arms hang free. Remove the tire and
wheel assembly.
1. Position an adjustable floor jack under the lower
control arm (36) inboard of the spring and into the
depression in the lower control arm.
Figure 26—Installing The Lower Control
Arm Bushing (G20/2500 W/6.2L Diesel)
FRONT SUSPENSION 3C-25
Tighten
Bushings (46) to 379 N m (280 ft. lbs.)
A. 2.96 - 31.9 mm
(1.16 -1.25 inches)
To Properly Center
The Pivot Shaft
36. Lower Control Arm
46. Bushing
50. Pivot Shaft
• Pivot shaft (50) for free rotation.
2. Grease fitting (12).
• Lubricate the bushings with an approved
grease.
• R efer
to
M A IN TE N A N C E
AND
LUBRICATION (SEC. 0B).
3. Lower control arm (36) to the frame crossmember.
• SLOWLY raise the floor jack until the lower
control arm (36) is in position.
B-07478
Im portant
Figure 27—Centering The Lower Control Arm
Shaft (CP20/2500-30/3500 And G30/3500 Series)
Im portant
• Install a chain over the upper control arm (28)
inboard of the stabilizer bar (59) and outboard of
the shock absorber (20).
2. Shock absorbers (20) from the lower control arm
(36).
• Nut (23), washer (22) and bolt (21).
3. Stabilizer bar (59) from the lower control arm (36).
• Nuts (38), washers (39, 41), bolts (43) and
clamp (42).
4. Low er c o n tro l arm (36) from the fram e
crossmember.
• Nuts (49), washer (48), and U-bolts (44).
• SLOWLY lower the floor jack to access the
pivot shaft (50).
5. Grease fittings (12).
6. Bushings (46) and bushing seals, and pivot
shaft (50).
• Unscrew the bushings.
• Slide the pivot shaft out of the lower control
arm.
• Seals are mounted between the bushings
and the pivot shaft. Discard the old seals.
+«- Install or Connect (Figures 5 through 8, and
27)
NOTICE: For steps 1, 3, 4, and 5 refer to the
“ N otice” on page 3C#7 of this section.
1. Pivot shaft (50), seals, and bushings (46), to the
lower control arm (36).
• New seals onto the pivot shaft.
• Pivot shaft into the lower control arm. Attach
the bushings. Center the shaft in the lower
control arm (figure 27).
• Be sure the hole in the pivot shaft mates
w ith the b o lt head in the fram e
crossmember saddle.
U-bolts (44), washers (48), and nuts (49).
&
Tighten
• Nuts (49) to 115 N m (85 ft. lbs.).
7. Stabilizer bar (59) to the lower control arm (36).
• Nuts (38), washers (39, 41), bolts (43), and
clamp (42).
$
Tighten
• Nuts (38) to 33 N m (24 ft. lbs.).
5. Shock absorbers (20) to the lower control arm
(36).
• Bolt (21), washer (22), and nut (23).
• Nut (23) to “ Specifications” at the end of
this section.
6. Remove the safety chain and the floor jack.
Install the tire and wheel assembly and lower the
vehicle to the ground.
UPPER CONTROL ARM PIVOT
SHAFT AND BUSHINGS
C10/1500, G10/1500-20/2500 SERIES VEHICLES
|+ + | Remove or Disconnect (Figures 5 through 8,
and 28)
Tools Required:
J-24435-1 Lower Control Arm Bushing
Remover
3C-26 FRONT SUSPENSION
J-24435-4
J-24435-5
(Hidden)
B-07481
Figure 29—Installing The Upper Control Arm
Bushings (Cl 0/1500, G10/1500-20/2500 Series)
Figure 28—Removing The Upper Control Arm
Bushings (C10/1500, G10/1500-20/2500 Series)
J-24435-3 Lower Control Arm Bushing
Remover
J-24435-7 Lower Control Arm Bushing
Fixture
1. Upper control arm (28).
• Refer to “ Upper Control A rm ,” in this
section.
2. Nuts (24), bushings (26) and the pivot shaft (29)
from the upper control arm (28).
• Use J-24435-1, J-24435-3, and J-24435-7
(figure 28).
• Tighten J-24435-7 to remove the bushing
(26).
• Pivot shaft (29) can be pulled free at this
time.
• Repeat this procedure on the remaining
bushing (26). Discard the old bushings.
Install or Connect (Figures 5 through 8, and
29)
Tools Required:
J-24435-4 Lower Control Arm Bushing
Installer
J-24435-5 Lower Control Arm Bushing
Installer
J-24435-7 Lower Control Arm Bushing
Fixture
NOTICE: Refer to the “Notice” on page 3C#1
of this section.
1.
Bushings (26) and the pivot shaft (29) into the upper
control arm (28).
• Use J-24435-4, J-24435-5, and J-24435-7
(figure 29).
• Tighten the clamp (J-24435-7) to install the
bushing (26).
• Slide the pivot shaft (29) into the upper
control arm (28), then install the other
bushing (26).
• Nuts (24) in place.
Tighten
• Nuts (24) to 156 N m (115 ft. lbs.).
2. Upper control arm (28) to the crossmember.
• Refer to “ Upper Control A rm ,” in this
section.
3. Caliper if it was removed.
• Refer to BRAKES (SEC. 5).
4. Check the front end alignment.
• Refer to FRONT END ALIGNMENT (SEC.
3A).
5. Remove the supports and lower the vehicle to the
ground.
CP20/2500-30/3500, G30/3500 SERIES VEHICLES
+ + Remove or Disconnect (Figures 5 through 8)
• Raise the vehicle and support the lower control
arms with a floor jack positioned under or near
the ball joint assembly. Remove the wheel and
tire assembly.
1. Loosen, but do not remove the pivot shaft to
frame nuts (27).
2. Shim packs (18).
• Tape each pack together and mark their
position to assure exact replacement during
installation.
3. Pivot shaft to frame nuts (27), bolts (4), and
spacers (19).
FRONT SUSPENSION 3C-27
Do not allow the upper control arm (28) to
swing too far from the frame crossmember.
Im portant
• Install a chain over the upper control arm
(28) inboard of the stabilizer bar (59) and
outboard of the shock absorber (20), to
retain the upper control arm in a close
relationship to the frame crossmember.
4. Pivot shaft (29) and bushings (26).
• Grease fitting (12).
• Unscrew the bushings (26).
• Slide the pivot shaft out of the upper control
arm. Remove and discard the inner seals
(between the bushings and the pivot shaft).
L*
Inspect
• Pivot shaft for free rotation.
2. Grease fitting (12).
• G rease the b u s h in g s (29). R efer to
MAINTENANCE AND LUBRICATION (SEC.
OB).
NOTICE: Refer to the “ N otice” on page 3C-1
of this section.
3. Pivot shaft (29) to the frame.
• Bolts (4), shim packs (18), spacers (19), and
nuts (27).
• Shims are positioned into their original
positions. Make sure the convex and
concave sides of the shims are together.
Tighten
+ 4-
Install or Connect (Figures 6 through 8, and
30)
1. Pivot shaft (29), seals, and bushings (26) onto the
upper control arm (28).
• New inner seals onto the pivot shaft.
• Slide the pivot shaft into position inside the
upper control arm. Screw on the new
bushings. Do not tighten.
Im portant
The pivot shaft (29) must be centered in the
upper control arm (28) as shown in figure 30.
Tighten
• Bushings (26) to 257 N m (190 ft. lbs.).
• Nuts (27) to 142 N m (105 ft. lbs.).
4. Remove the safety chain and install the wheel
and tire assembly.
5. Check the front end alignment.
• Refer to FRONT END ALIGNMENT (SEC.
3A).
6. Lower the vehicle to the ground.
LOWER CONTROL ARM
Remove or Disconnect (Figures 5 through 8,
and 16)
Tools Required:
J-23742 Ball Joint Separator
Raise the vehicle and support it with suitable
safety stands. Remove the wheel and tire
assembly.
3C-28 FRONT SUSPENSION
1. Caliper.
UPPER CONTROL ARM
• Refer to BRAKES (SEC. 5).
2. Coil spring (32).
+ + Remove or Disconnect (Figures 5 through 8,
and 15)
• Refer to “ Coil Spring,” in this section.
Tools Required:
J-23742 Ball Joint Separator
• The lower control arm is separated from the
frame.
3. Use a jack to support the inboard end of the lower
control arm (36).
4. Lower control arm (36) from the steering knuckle
(31).
• Cotter pin (34), then loosen the nut (35) one
turn.
• Install J-23742, with the large cup end over
the upper ball jo in t nut (14). Extend
threaded end until the ball joint stud loosens
from the steering knuckle. Remove J-23742
and the nut (35).
Install or Connect (Figures 5 through 8)
1. Lower control arm (36) to the steering knuckle
(31).
• Position the lower control arm ball joint stud
(37) into the steering knuckle (31).
• Raise the vehicle and support it with suitable
safety stands. Remove the wheel and tire
assembly. Place an adjustable jackstand under
the lower control arm for support.
1. Caliper.
• Refer to BRAKES (SEC. 5).
2. Upper control arm (28) from the steering knuckle
(31).
• Cotter pin (15).
• Loosen the nut (14). Do not remove it.
• Install J-23742 with the large cupped end
over the lower control arm ball joint stud nut
(35). Expand J-23742 until the upper control
arm separates.
• Nut (14) from the upper ball joint stud and
raise the upper control arm to clear the
steering knuckle.
3. Upper control arm (28) from the frame bracket (9).
• Nuts (27), spacers (19), shims (18), washers
(5) and bolts (6).
• Nut (35) onto the stud. Do not tighten.
Im portant
2. Coil spring (32).
Tape the shims together in their original
positions and tag for proper relocation.
• Refer to “ Coil Spring,” in this section.
• This step results with the lower control arm
being attached to the frame.
NOTICE: Refer to “ N otice” on page 3C-1 of
this section.
3. Cotter pin (34).
Tighten
• Nut (35) to 122 N m (90 ft. lbs.).
• Cotter pin. Tighten further to a maximum of
176 N m (130 ft. lbs.) for c o tte r pin
installation, if necessary.
4. Caliper.
• Refer to BRAKES (SEC. 5).
5. Check the front end alignment.
• Refer to FRONT END ALIGNMENT (SEC.
3A).
6. Tire and wheel assembly and lower the vehicle.
+ 4-
Install or Connect (Figures 5 through 8)
NOTICE: For steps 2 and 3, refer to “ Notice”
on page 3C-1 of this section.
1. Shims (18) into position on the upper control arm
frame bracket (9).
• Make sure the shims are positioned with
concave and convex sides together.
2. Upper control arm (28) to the frame bracket
(9).
• Spacers (19) and nuts (27), washers (5), and
bolts (6).
Important
• A normal shim pack will leave at least two
threads of the bolt (6) exposed beyond the
nut.
• If two threads cannot be obtained; check for
damaged control arm or related parts. The
difference between the front and rear shim
FRONT SUSPENSION 3C-29
packs must not exceed 7.62 mm (0.30
inches). The front shim pack must be at
least 6.09 mm (0.24 inches).
Always tighten the thinner shim pack’s nut
(27) first for improved shaft to frame
clamping force and torque retention.
$
5. Shock absorbers (20) from the lower control arms
(36).
• Nut (23), washer (22), and bolt (21).
6. Brake line clip bolts from the front suspension
crossmember.
• On C series models the clip is located under
the right side engine mount support bracket.
Tighten
• Nuts (27) to “ Specifications” at the end of
this section.
3. Upper control arm (28) to the steering knuckle
(31).
• Insert the upper control arm ball joint stud
(13) into the steering knuckle (31).
• Nut (14) and cotter pin (15).
Tighten
• Nut (14) to the “ Specifications” at the end of
this section.
4. Caliper.
• Refer to BRAKES (SEC. 5).
5. Check the front end alignment.
• Refer to FRONT END ALIGNMENT (SEC.
3A).
6. Wheel and tire assembly. Lower the vehicle to the
ground.
SUSPENSION UNIT
NOTICE: Failure to disconnect these clips
from the suspension unit w ill result in severe
damage to the brake line when the unit is
lowered from the vehicle.
7. Suspension crossm em ber from the engine
mounts.
• Refer to ENGINE (SEC. 6A).
8. Suspension crossmember from the frame rail
(figure 31).
9. Raise the hoist to support the suspension
crossmember.
10. Support the engine.
• Must be done before the suspension unit is
lowered from the vehicle.
11. Suspension unit and crossmember from the
vehicle.
• Upper control arm bracket to the frame side
rail nuts (10), washer (7), and bolts (6).
• Low er the su sp e n sio n u n it and the
crossmember to bring the unit clear of the
vehicle.
Install or Connect (Figures 5 through 8 and 31)
The front suspension and frame crossmember can
be removed or installed as a unit if extensive service is
required.
Rem ove o r D isco n n e ct (F igure 5 th ro u g h 8,
and 31)
• Raise the hood and disconnect the battery
negative cable.
• Hoist the vehicle and support it with suitable
safety stands placed at the frame side rails.
Remove the tire and wheel assembly and then
lower the hoist.
1. Front brake hose clip from each upper control
arm.
2. Brake hoses from the calipers.
• Clean the area adjacent to the brake hose
fittings.
• Discard the special washers (2 on each
hose) and cover the disconnected ends of
each hose with suitable material.
• Refer to BRAKES (SEC. 5).
3. Tie rod ends from the steering knuckle (31).
• Refer to STEERING LINKAGE (SEC. 3B1).
4. Front stabilizer from the lower control arms (36).
• Nuts (38), washers (39, 41), bolts (43), and
clamps (42).
NOTICE: For steps 3, 7, and 8, refer to the
“ N otice” on page 3C-1 of this section.
1. P o sitio n the new su sp e n sio n u n it and
crossmember and raise it with the hoist to align
the suspension crossmember and frame holes.
2. Suspension crossmember to the frame rail bolts
(figure 31).
3. Upper control arm (28) to the frame bracket bolts
(6).
• Washers (7) and nuts (10). Do not tighten.
$
Tighten
• Upper control arm to the frame bracket bolts
(6) to “ Specifications” at the end of this
section.
• Suspension crossmember to the frame rail
bolts to “ Specifications” at the end of this
section.
3C-30 FRONT SUSPENSION
Figure 31—Suspension Unit Replacement
4.
5.
6.
7.
• The upper control arm to frame bracket
bolts must be tightened first.
• The crossmember must be in contact with
the frame side rails.
Remove the engine support and lower the hoist.
Engine mount support bracket to the suspension
crossmember.
• Refer to ENGINE (SEC. 6A).
Brake line clip to the crossmember.
• Refer to BRAKES (SEC. 5).
Shock absorber to the lower control arm (28).
• Washers (22), nuts (23), and bolts (21).
Tighten
• Nuts (23) to “ Specifications” at the end of
this section.
Stabilizer bar (59) to the lower control arm (28).
• Clamps (42), bolts (43), washers (39) and
nuts (38).
a
9.
10.
11.
12.
13.
14.
Tighten
• Nuts (38) to “ Specifications” at the end of
this section.
Tie rod ends to the steering knuckle (31).
• Refer to STEERING LINKAGE (SEC. 3B1).
Brake hose to the caliper.
• Refer to BRAKES (SEC. 5).
Brake hose clips to the upper control arms.
• Refer to BRAKES (SEC. 5).
Bleed the brake system.
• Refer to BRAKES (SEC. 5).
Tires and wheels and lower the vehicle.
Battery cable.
FRONT SUSPENSION 3C-31
ON-VEHICLE SERVICE: TWO WHEEL
DRIVE RPO FS3 (I-BEAM) FRONT SUSPENSION
SHOCK ABSORBER
Remove or Disconnect (Figures 32 through 34)
• Raise the vehicle and support it with suitable
safety stands. Remove the wheel and tire
assembly.
1. Shock absorber (113) from the leaf spring spacer
(158).
• Nut (109) and washer (111).
2. Shock absorber (113) from the frame.
• Nut (109) and washer (111).
• Pull the shock free from the vehicle.
— Shock absorber should be held vertically in
the vise with its bottom end up.
— Do not clamp the vise jaws on the shock’s
reservoir tube.
2. Pump the shock absorber at various rates of
speed and observe the rebound force.
— Rebound force is normally stronger than the
compression force (approximately two to
one).
— Rebound force should be smooth and
constant for each stroke rate.
3. Compare with a good shock absorber.
BENCH TEST: SPIRAL GROOVE SHOCK
ABSORBERS
1. Purge the air from the pressure chamber.
• Extend the shock vertically—top end up.
• Turn the sh ock over and co lla p se it
vertically—top end down.
• Repeat the above step five times.
2. Place the shock absorbers in a vise with the jaws
clamped onto the shock’s bottom mount.
— Shock absorber should be positioned
vertically in the vise—top end up.
— Do not clamp the vise jaws on the shock’s
reservoir tube.
3. Pump the shock absorber at various rates of
speed and observe the rebound force.
— Rebound force is normally stronger than the
compression force (approximately two to
one).
— Rebound force should be smooth and
constant for each stroke rate.
4. Compare with a good shock absorber.
5. If one of the following are observed, replace the
shock absorber.
— A skip or lag at reversal near mid-stroke.
— A seize (except at the extreme ends of
travel).
— A noise (grunt or squeal) after completing
one full stroke in both directions.
— A clicking noise at fast reversal.
BENCH TEST: NON-SPIRAL GROOVE
RESERVOIR SHOCK ABSORBER
• P urging air from n on-spiral groove shock
absorbers is not necessary. The shock absorbers
have a gas filled cell in their reservoirs (as
opposed to the air filled cell in the spiral groove
shock absorber reservoirs).
1. Place the shock absorber in a vise with the jaws
clamped on the shock absorber’s top mount.
4. If one of the following are observed, replace the
shock absorber.
— A skip or lag at reversal near mid-stroke.
— A seize (except at the extreme ends of
travel).
— A noise (grunt or squeal) after completing
one full stroke in both directions.
— A clicking noise at fast reversal.
♦ i l Install or Connect (Figures 32 through 34)
1. Shock absorber (113) to the frame (figure 34).
• Insert the shock’s upper stud into the hole in
the frame.
• Washer (111) and nut (109). Do not tighten.
NOTICE: Refer to the “Notice” on page 3C#1
of this section.
2. Shock absorber (113) to the leaf spring spacer
(158) (figure 34).
• Position the shock’s lower mount onto the
stud.
• Washer (111) and nut (109).
Tighten
• Shock absorber upper nut to 185 N m (136
ft. lbs.).
• Shock absorber lower nut to 50 N m (37 ft.
lbs.).
3. Wheel and tire on the vehicle. Lower the vehicle
to the ground.
3C-32 FRONT SUSPENSION
Figure 32—P Series Front Suspension (RPO FS3)
FRONT SUSPENSION 3C-33
101.
102.
103.
104.
105.
106.
107.
108.
109.
110.
111.
112.
113.
114.
115.
116.
117.
118.
119.
120.
121.
122.
123.
124.
125.
Spring Hanger
Rivet
Spring Stop
Hanger Bushing
Washer
Bolt
Shackle
Nut
Nut
Nut
Washer
Bumper
Shock Absorber
Spacer
Nut
Stabilizer Link
Retainer
Insulator
Bolt
Washer
Brake Hose Bracket
Cap
Gasket
King Pin
Bushing
126.
127.
128.
129.
130.
131.
132.
133.
134.
135.
136.
137.
138.
139.
140.
141.
142.
143.
144.
145.
146.
147.
148.
149.
Spacer
Steering Knuckle
Fitting
Nut
Dust Seal
Shim
Nut
Washer
Lock Pin
Nut
Nut
Thrust Bearing
Nut
Cotter Pin
Steering And Third Arm
Splash Shield
Brake Caliper
Washer
Bolt
Anchor Plate
Stop Bolt
Stop Nut
Retainer/Cap
Cotter Pin
150.
151.
152.
153.
154.
155.
156.
157.
158.
159.
160.
161.
162.
163.
164.
165.
166.
167.
168.
169.
170.
171.
172.
173.
Nut
Washer
Outer Wheel Bearing And Race
Wheel Hub Bolt
Hub/Rotor
Inner Wheel Bearing And Race
Bearing Seal
Front Axle
Spring Spacer
Spring Leaf
Bolt
Spacer
Front Spring
Nut
Spacer
U-Bolt
Stabilizer Bar
Insulator
Clamp
Bolt
Nut
Washer
Bolt
Spring Hanger
B-07485
Figure 33—P Series Front Suspension (RPO FS3)
STABILIZER BAR
A.
109.
111.
113.
Frame
Bolt
Washer
Shock
1
Absorber
157. Front Axle
158. Spring Spacer
162. Front Spring
|<~+| Remove or Disconnect (Figures 32, 33, and
35)
Tools Required:
J-6627-A Wheel Stud and Tie Rod Remover
• Raise the vehicle and support it with suitable
safety stands. Remove the tire and wheel
assembly.
1. Stabilizer bar (166) from the stabilizer link (116).
• Nut (115) and washer (114).
• Use J-6627-A to separate the stabilizer link
from the stabilizer end.
2. Stabilizer bar (166) from the frame (figure 35).
• Nuts (170), washers (171), clamp bolts (169)
and clamps (168).
• Slide the insulator (167) from the stabilizer
bar (166).
3. Stabilizer link (116) from the front axle (157)
(figure 35).
B-07487
Figure 34—Shock Absorber Attachments
• Nut (136), retainer (117), insulator (118).
• Pull the link from the axle. Another insulator
(118) and retainer (117) will come off the link.
3C-34 FRONT SUSPENSION
118 \
^1181
11 i j
166.
167.
168.
169.
170.
171.
A.
114.
115.
116.
117.
118.
136.
Stabilizer Bar
Insulator
Clamp
Bo*!
Nut
Washer
B-07491
Figure 35—Stabilizer Bar Attachm ents
Install or Connect (Figures 32, 33, and 35)
NOTICE: For steps 1, 2, and 3, refer to the
“Notice” on page 3C#7 of this section.
1. Stabilizer link (116) to the front axle (157) (figure
35).
• Slide a retainer (117) and an insulator (118)
on to the link and insert the link into the
proper hole in the front axle.
• Insulator (118), retainer (117) and nut (136).
&
Clamps (168), clamp bolts (169), washers
(171), and nuts (170).
Tighten
• Nuts (170) to 28 N m (21 ft. lbs.).
3. Stabilizer bar (166) to the stabilizer link (116).
* Washer (114) and nut (115).
Tighten
• Nut (136) until the distance between each
retainer (117) is 2.08 cm (0.82 inches) (figure
35).
2. Stabilizer bar (166) to the frame (figure 35).
• Insulators (167) onto the stabilizer bar (166).
Tighten
Nuts (115) to 68 N m (50 ft. lbs.).
4. Wheel and tire assembly. Lower the vehicle to the
ground.
FRONT SUSPENSION 3C-35
NOTICE: Start the races squarely inside the
hub/rotor (154) to avoid distortion and
possible cracking.
WHEEL HUB/ROTOR ASSEMBLY
Remove or Disconnect (Figures 32 and 33)
• Raise the vehicle and support it with suitable
safety stands. Remove the tire and wheel
assembly.
1. Caliper (142).
• Refer to BRAKES (SEC. 5).
NOTICE: Support the caliper with a piece of
wire to prevent damage to the brake line.
2. Wheel hub/rotor (154) (figures 32, 33).
• Retainer/cap (148).
• Cotter pin (149), nut (150) and washer (151).
• Pull the hub/rotor free from the spindle,
making sure the outer wheel bearing (152)
comes free.
• Do not damage the steering knuckle spindle
threads.
3. Inner wheel bearing (155).
• Pry out the seal (156).
4. Races.
• Drive out each race using a brass drift.
Clean
1. Grease from the hub/rotor (154) and steering
knuckle spindle.
• Grease from inside the hub.
2. Grease from the wheel bearings (152, 155) and
races.
• Use clean solvent and a small brush (no
loose bristles).
• Do not spin the wheel bearings with
compressed air to dry them—the wheel
bearings may be damaged.
Inspect
1. Wheel bearings (152, 155) and their races for
damage or wear.
• Refer to “ Diagnosis of Wheel Bearings,” in
this section.
• If either a bearing or its race is damaged or
worn, replace both.
2. Hub/rotor (154) for damage or wear.
• Check for out-of-round or scored conditions.
• Check for pitting or cracks.
• Repair or replace as necessary.
+«- Install or Connect (Figures 32 and 33)
Tools Required:
J-8092 Driver Handle
J-29040 Outer Bearing Race Installer
J-9746-02 Hub/Rotor Support
1. Races into the hub/rotor (154).
• Place the hub/rotor on J-9746-02 and rest
this assembly on press bars.
• Use J-29040 to drive the outer bearing race
into position.
• Remove J-9746-02 and use a 7.6 cm (3 inch)
diameter bar, or equivalent tool to drive the
inner bearing race into position. If the bar is
larger than 7.6 cm (3 inches), it may damage
the bearing seal seat.
9
Im portant
• Use an approved high temperature front wheel
bearing grease to lubricate the bearings. Refer to
MAINTENANCE AND LUBRICATION (SEC. OB).
• Do not mix different greases as mixing may
change the grease’s properties resulting in poor
performance.
2. Apply a thin film of grease to the steering knuckle
spindle at the outer wheel bearing seat and at the
inner wheel bearing seat, shoulder, and seal seat.
3. Put a small quantity of grease inboard of each
wheel bearing retainer/cap (148).
4. F ill each w heel b ea rin g (cone and ro lle r
assembly) full of grease.
• Use a cone-type grease machine that forces
grease into the bearing.
• If a cone-type grease m achine is not
available, pack the wheel bearing by hand.
• When packing the wheel bearing by hand,
work the grease into the bearings between
the rollers, cones, and the cage.
NOTICE: Failure to completely pack the wheel
bearing (cones, rollers, and cage) with grease
will result in premature wheel bearing damage
and/or wear.
5. Inner wheel bearing (155) into the hub/rotor (154).
• Put an a dd itio n a l q u a n tity of grease
outboard of this bearing.
6. New seal (156).
• Use a flat plate or block to install the seal to
insure it is flush with the hub/rotor flange.
• Lubricate the seal lip with a thin layer of
grease.
7. Hub/rotor (154).
• Do not damage the steering knuckle spindle
threads.
8. Outer wheel bearing (152).
• Slide it over the spindle until the wheel
bearing (152) fu lly seats against the
hub/rotor outer race.
3C-36 FRONT SUSPENSION
NOTICE: Refer to the “Notice” on page 3C#1
of this section.
9. Washer (151), nut (150) and cotter pin (149).
• Do not place the cotter pin through the hole
in the spindle until the wheel bearings are
adjusted.
Tighten
• If they do not line up, back off the nut until
they do—not more than one additional flat.
Measure
E ndplay in the hub/rotor should m easure
between 0.013-0.20 mm (0.0005-0.008 inches)
when properly adjusted.
4. Install the retainer/cap (148).
10.
11.
12.
13.
14.
• Nut (150) to 16 N m (12 ft. lbs.) while turning
the hub/rotor assembly in either direction.
Put an additional amount of grease outboard of
the wheel bearing (152).
Adjust the wheel bearings.
• Refer to “ Wheel Bearing Adjustment,” in
this section.
Retainer/cap (148) in place.
Caliper (142).
• Refer to BRAKES (SEC. 5).
Tire and wheel assembly. Lower the vehicle to the
ground.
5. Lower the vehicle to the ground.
WHEEL HUB BOLT
Remove or Disconnect
Tools Required:
J-9746-02 Hub/Rotor Support
1. Hub/rotor assembly from the vehicle.
• Refer to “ Wheel Hub/Rotor Assembly,” in
this section.
WHEEL BEARING ADJUSTMENT
Im portant
• The proper functioning of the front suspension
cannot be maintained unless the front wheel
bearings are correctly adjusted. The bearings
must be a slip fit on the spindle and the inside
diameter of the wheel bearing must be lubricated
to ensure the bearings will creep. The spindle nut
(150) must have a free-running fit on the spindle
threads.
NOTICE: Never preload the front wheel
bearings. Damage can result by the steady
thrust on the roller ends which comes from
preloading.
JP Adjust
Raise the vehicle and support it with suitable
safety stands under the lower control arms.
Remove the retainer/cap (148).
Remove the cotter pin (149).
NOTICE: Place J-9746-02 between the press
bars and the hub/rotor to protect the rotor
surfaces.
2. Wheel hub bolts (153) with a press.
• Support the hub/rotor (153) using J-9746-02
and the press bars.
• Do not damage the wheel mounting surface
on the hub/rotor flange.
-►+ Install or Connect
NOTICE: Refer to the “Notice” on page 3C#1
of this section.
1. Wheel hub bolts (153) into the hub/rotor (154).
• Place four washers onto the bolt, then
fasten a nut onto the bolt until the nut
bottoms on the washers.
• Tighten the nut until the bolt fully seats into
the hub/rotor (154).
• Remove the nut and washers.
• Nut (150) to 16 N m (12 ft. lbs.) while rotating
the w heel and tire a ssem bly (or the
hub/rotor). This will seat the bearings.
3. Back off the nut (150) one flat.
• If the hole in the spindle lines up with the
slot in the nut, insert the cotter pin (149).
2. Hub/rotor to the vehicle.
• Refer to “ Wheel Hub/Rotor Assembly,” in
this section.
3. Wheel and tire assembly. Lower the vehicle to the
ground.
FRONT SUSPENSION 3C-37
STEERING ARM, KNUCKLE AND
SPINDLE
□
Remove or Disconnect (Figures 32 and 33)
• Raise the vehicle and support it with suitable
safety stands. Remove the tire and wheel
assembly.
1. Caliper (142).
• Refer to BRAKES (SEC. 5).
2. Hub/rotor assembly (154).
• Refer to “ Wheel Hub/Rotor Assembly,” in
this section.
3. Anchor plate (145), splash shield (141), and the
steering arm (140).
• Bolts (146), washers (147) and nuts (129),
and pull the anchor plate and splash shield
off the knuckle. Steering arm hangs by tie
rods.
• Bolts (144) and washers (143) to separate
the anchor plate from the splash shield.
• Refer to STEERING LINKAGE (SEC. 3B1) to
separate the steering arm from the tie rod
and pitman arm.
4. Caps (122) from the steering knuckle (127).
• Bolts (119) and washers (120).
• Brake hose bracket (121).
• Gaskets (123) come off.
5. Lock pin (134).
• Nut (132) and washer (133).
6. King pin (124) from the steering knuckle (127).
• Drive it out using a drift.
• Spacers (126) and bushings (125) will also
come out.
7. Steering knuckle (127) from the axle (157).
• Dust seal (130), shim (131), and thrust
bearing (137) will come free.
• Do not score the king pin surface. Use a
proper lubricant if necessary.
3. Lock pin (134).
• Washer (133) and nut (132).
Tighten
• Nut (132) to 40 N m (29 ft. lbs.).
4. Caps (122) to the steering knuckle (127).
• Gaskets (123) in place.
• Brake hose bracket (121).
• Washers (120) and bolts (119).
Tighten
• Bolts (119) to 7 N m (5 ft. lbs.).
5. Steering arm (140), splash shield (141), and the
anchor plate (145).
• Bolts (144) and washers (143) to attach the
splash shield to the anchor plate.
• Bolts (146), washers (147) and nuts (129) to
attach the anchor plate and steering arm to
the steering knuckle.
Tighten
6.
7.
8.
9.
10.
Install or Connect (Figures 32 and 33)
11.
NOTICE: For steps 3, 4, and 5 refer to the
“Notice” on page 3C#1 of this section.
1. Steering knuckle (127) to the axle (157).
• Thrust bearing (137), shim (131), and dust
seal (130) must be properly positioned.
Knuckle to axle clearance must be between
0.025-0.25 mm (0.001-0.010 inches).
• Prelube the thrust bearing (137). Refer to
MAINTENANCE AND LUBRICATION (SEC.
0B).
• Align lube hole in the bearing with the lube
hole in the steering knuckle.
2. King pin (124) into the steering knuckle (127).
• Insert bushings (125) and spacers (126) in
their proper order.
• Bolts (144) to 16 N m (12 ft. lbs.).
• Nuts (129) to 312 N m (230 ft. lbs.).
Steering arm (140) to the steering linkage.
• Refer to STEERING LINKAGE (SEC. 3B1).
Hub/Rotor assembly (154).
• Refer to “ Wheel Hub/Rotor Assembly,” in
this section.
Adjust the wheel bearings.
• Refer to “ Wheel Bearing Adjustment,” in
this section.
Caliper (142).
• Refer to BRAKES (SEC. 5).
Wheel and tire assembly. Lower the vehicle to the
ground.
Check the front end alignment.
• Refer to FRONT END ALIGNMENT (SEC.
3A).
FRONT AXLE
Remove or Disconnect (Figures 32 through 36)
Tools Required:
J-6627-A Wheel Stud and Tie Rod Remover
• Raise the vehicle and support it with suitable
safety stands on the frame. Remove the wheel
and tire assembly. Support the axle with a floor
jack to eliminate any load on the springs.
1. Steering arm, knuckle, and spindle.
• Refer to “ Steering Arm, Knuckle, and
Spindle,” in this section.
3C-38 FRONT SUSPENSION
108
101.
105.
106.
107.
108.
135.
157.
158.
162.
165.
164.
173.
Spring Hanger
Washer
Bolt
Shackle
Nut
Nut
Front Axle
Spring Spacer
Front Spring
U-Bolt
Spacer
Spring Hanger
B-07492
Figure 36—Axle And Leaf Spring Attachm ents
2. Shock absorber (113) from the axle (157) (figure
34).
• Nut (109) and washer (111).
3. Stabilizer link (116) from the stabilizer bar (166)
(figure 35).
• Nut (115) and washer (114).
• Use J-6627-A to separate the stabilizer bar
from the stabilizer link.
4. Stabilizer link (116) from the axle (157) (figure 35).
• Nut (136), retainer (117) and insulator (118).
• Pull the link free from the axle, making sure
not to loose the other insulator (118) and
retainer (117).
5. Leaf spring (162) from the axle (157) (figure 36).
• Nuts (135), washers (105) and U-bolts (165).
• Spacer (164), and spring spacer (158).
6. Steering damper from the axle.
• Refer to STEERING LINKAGE (SEC. 3B1).
7. Lower the floor jack and pull the axle clear of the
vehicle.
|+<-| Install or Connect (Figures 32 through 36)
NOTICE: For steps 4, 5, and 6, refer to the
“Notice” on page 3C#1 of this section.
1. Line up the axle under the leaf springs.
• Raise it into position using a floor jack.
2. Steering damper to the axle.
• Refer to STEERING LINKAGE (SEC. 3B1).
3. Axle (157) to the leaf springs (162).
• Refer to “ Leaf Spring,” in this section.
4. Stabilizer link (116) to the axle (157) (figure 35).
• Link into the hole on the spring spacer (158)
and axle.
• Insulator (118), retainer (117), and nut (136).
FRONT SUSPENSION 3C-39
&
• Nut (108), washer (105), bolt (106) and
washer (105) to separate the spring from the
rear shackle (107).
Tighten
• Nut (136) until the distance between each
retainer (117) is 2.08 cm (0.82 inches) (figure
35).
5. Stabilizer link to the stabilizer bar (166) (figure
35).
• Washer (114) and nut (115).
Tighten
• Nut (115) to 68 N m (50 ft. lbs.).
6. Shock absorber (113) to the axle (157) (figure 34).
• Washer (111) and nut (109).
$
Tighten
• Nut (109) to 50 N m (37 ft. lbs.).
7. Steering arm, knuckle, and spindle.
• Refer to “ Steering Arm, Knuckle, and
Spindle,” in this section.
8. Adjust the wheel bearings.
• Refer to “ Wheel Bearing Adjustment” in
this section.
9. Wheel and tire assembly. Lower the vehicle to the
ground.
10. Check the front end alignment.
• Refer to FRONT END ALIGNMENT (SEC.
3B1).
• Nut (108), washer (105), bolt (106), and
washer (105) to separate the spring from the
front hanger (173).
• Pull the leaf spring backward and out.
0
Install or Connect (Figures 32 through 36).
NOTICE: For steps 1, 2, 3, 4 and 5, refer to the
“ N otice ” on page 3C#7 of this section.
1. Leaf spring (162) to the frame (figure 36).
• Line up the spring with the rear shackle
(107) and the front hanger (173). Double
wrap end is toward the front of the vehicle.
• Washer (105), bolt (106), washer (105) and
nut (108) to attach the spring to the front
hanger (173).
• Washer (105), bolt (106), washer (105) and
nut (108) to attach the spring to the rear
shackle (107).
Tighten
• Nut (108) to 125 N m (92 ft. lbs.).
2. Leaf spring (162) to the axle (157) (figure 36).
• Position the spring spacer (158) onto the
axle. Either aligning pin can contact the
edge of the leaf spring after the assembly is
complete.
LEAF SPRINGS
«--► Remove or Disconnect (Figures 32 through 36)
•
1.
2.
3.
4.
5.
Tools Required:
J-6627-A Wheel Stud and Tie Rod Remover
Raise the vehicle and support it with suitable
safety stands. Support the axle separately to
eliminate any load on the springs. Remove the
tire and wheel assembly.
Shock absorber (113) from the axle (157) (figure
34).
• Nut (109) and washer (111).
Stabilizer link (116) from the stabilizer bar (166)
(figure 35).
• Nut (115) and washer (114).
• Use J-6627-A to separate the stabilizer bar
from the stabilizer link.
Stabilizer link (116) from the axle (157) (figure 35).
• Nut (136), retainer (117), insulator (118).
• Pull the link free from the axle, making sure
not to loose the other insulator (118) and
retainer (117).
Leaf spring (162) from the axle (157) (figure 36).
• Nuts (135), washers (105) and U-bolts (165).
• Spacer (164) and spring spacer (158).
Leaf spring (162) from the frame (figure 36).
• Spacer (164), U-bolts (165), washers (105)
and nuts (135). Tighten nuts to 25 N m (18 ft.
lbs.) in a diagonal sequence (e.g., 1-3-4-2).
$
Tighten
• Nuts (135) in a diagonal sequence (e.g.,
1-3-4-2) to 109 N m (80 ft. lbs.).
3. Stabilizer link (116) to the axle (157) (figure 35).
• Insert the link into the proper hole in the
axle after the retainer (117) and insulator
(118) are attached.
• Insulator (118), retainer (117), and nut (136).
Tighten
• Nut (136) until the distance between each
retainer (117) is 2.08 cm (0.82 inches) (figure
35).
4. Stabilizer link (116) to the stabilizer bar (166)
(figure 35).
• Washer (114) and nut (115).
3C-40 FRONT SUSPENSION
Tighten
• Nut (115) to 68 N m (50 ft. lbs.).
5. Shock absorber (113) to the axle (157) (figure 34).
• Washer (111) and nut (109).
6. Wheel and tire assembly. Lower the vehicle to the
ground.
7. Check the front end alignment.
• Refer to FRONT END ALIGNMENT (SEC.
3B1).
Tighten
• Nut (109) to 50 N m (37 ft. lbs.).
ON-VEHICLE SERVICE:
FOUR WHEEL DRIVE FRONT SUSPENSION
SHOCK ABSORBER
□
Remove or Disconnect (Figures 37 through 39)
• Raise the vehicle on a hoist.
1. Shock absorber (220) from the frame.
• Nut (212), washer (213) and bolt (219) (figure
36).
2. Shock absorber (220) from the axle.
• Nut (212), washer (213) and bolt (225).
• Quad shocks (RPO Z75) have a spacer
(246) between them (figure 39).
BENCH TEST: SPIRAL GROOVE SHOCK
ABSORBERS
1. Purge the air from the pressure chamber.
• Extend the shock vertically—top end up.
• Turn the sh ock over and c o lla p se it
vertically—top end down.
• Repeat the above step five times.
2. Place the shock absorber in a vise with the jaws
clamped onto the shock’s bottom mount.
— Shock absorber should be positioned
vertically in the vise—top end up.
— Do not clamp the vise jaws on the shock’s
reservoir tube.
3. Pump the shock absorber at various rates of
speed and observe the rebound force.
— Rebound force is normally stronger than the
compression force (approximately two to
one).
— Rebound force should be smooth and
constant for each stroke rate.
4. Compare with a good shock absorber.
5. If one of the following are observed, replace the
shock absorber.
— A skip or lag at reversal near mid-stroke.
— A seize (except at the extreme ends of
travel).
— A noise (grunt or squeal) after completing
one full stroke in both directions.
— A clicking noise at fast reversal.
BENCH TEST: NON-SPIRAL GROOVE RESERVOIR
SHOCK ABSORBERS
• P urging air from non-spiral groove shock
absorbers is not necessary. The shock absorbers
have a gas filled cell in their reservoirs (as
opposed to the air filled cell in the spiral groove
shock absorber reservoirs).
1. Place the shock absorber in a vise with the jaws
clamped on the shock absorber’s top mount.
— Shock absorber should be held vertically in
the vise with its bottom end up.
— Do not clamp the vise jaws on the shock’s
reservoir tube.
2. Pump the shock absorber at various rates of
speed and observe the rebound force.
— Rebound force is normally stronger than the
compression force (approximately two to one).
— Rebound force should be smooth and constant
for each stroke rate.
3. Compare with a good shock absorber.
4. If one of the following are observed, replace the
shock absorber.
— A skip or lag at reversal near mid-stroke.
— A seize (except at the extreme ends of
travel).
— A noise (grunt or squeal) after completing
one full stroke in both directions.
— A clicking noise at fast reversal.
Install or Connect (Figures 37 and 38)
NOTICE: For steps 1 and 2, refer to the
“Notice” on page 3C#7.
1. Shock absorber (220) to the axle.
• Bolt (225), washer (213), and nut (212).
• Spacer (246) must be positioned between
the shock absorbers (220) on vehicles with
quad shocks, RPO Z75 (figure 39).
FRONT SUSPENSION 3C-41
$
Tighten
• Nut (212) to 88 N m (65 ft. lbs.).
• Nut (212) to 120 N m (89 ft. lbs.) on quad
shocks (RPO Z75).
2. Shock absorber (220) to the frame.
• Bolt (219), washer (213) and nut (212).
$
Tighten
•
Nut (212) to 88 N m (65 ft. lbs.).
3. Lower the vehicle to the floor.
•
1.
2.
3.
STABILIZER BAR
4-+
Remove or Disconnect (Figures 37, 38 and 40)
• Raise the vehicle on a hoist.
1. Stabilizer bar (230) from the frame brackets (237).
• Nuts (231), washers (232), brackets (233),
and bolts (238) (figure 37).
2. Stabilizer bar (230) from the spring plate (224).
• Bolts (229), and washers (228).
• Stabilizer bar is free of the vehicle.
• Bushings (234) can be removed from the
stabilizer bar.
□
Install or Connect (Figures 37, 38 and 40)
1. Stabilizer bar (230) to the frame brackets (237).
• Bushings (234) onto the stabilizer bar.
• Use rubber lubricant when installing the
b u sh in g s (s lit faces forw a rd ) on the
stabilizer bar.
• Brackets (233), bolts (238), washers (232),
and nuts (231) (figure 37). Do not tighten.
NOTICE: Refer to “Notice” on page 3C#1 of
this section.
2. Stabilizer bar (230) to the spring plate (224).
• Washers (228) and bolts (229) (figure 40).
$
Tighten
• Nuts (231) to 70 N m (52 ft. lbs.).
• Bolts (229) to 180 N m (133 ft. lbs.).
3. Lower the vehicle to the ground.
WHEEL HUB/ROTOR ASSEMBLY
Remove or Disconnect (Figures 37, 38, and 41
through 43)
4.
L*
J-23446 Torque Wrench Adapter
J-26878-A Wheel Bearing Nut Wrench
(30/3500 Series)
Raise the vehicle and support it with suitable
safety stands. Remove the tire and wheel
assembly.
Caliper
• Refer to BRAKES (SEC. 5).
Locking hub (249).
• Refer to FRONT AXLE (SEC. 4C).
Locking nut (250), ring (251) and adjusting nut
(252).
• Use
J-6 8 93 -D
and
J-2 3 44 6
for
10/1500-20/2500 series vehicles.
• Use J-26878-A for 30/3500 series vehicles.
Hub/Rotor Assembly (257).
• Outer wheel bearing (253) will slide off the
spindle (265) ahed of the hub/rotor (257).
• Use a brass drift and hammer for the seal
(260) and races (254, 258).
• The inner bearing (259), race (258) are
behind the seal (260).
Inspect
1. Rotor braking surfaces for scoring, pitting, or
cracks.
• Repair or replace as necessary.
2. Wheel bearings (253, 259) and races (254, 258).
• Refer to “ Diagnosis of Wheel Bearings,” in
this section.
• If either a bearing or its race is damaged or
worn, replace both.
Install or Connect (Figures 37, 38, and 41
through 43)
Tools Required:
J-8092 Driver Handle
J-6368 Bearing Race Installer (Outer)
J-23448 Bearing Race Installer (Inner)
J-6893-D W heel B earing Nut W rench
(10/1500-20/2500 series vehicles)
J-26878-A Wheel Bearing Nut Wrench
(30/3500 series vehicles)
J-23446 Torque Wrench Adapter
1. Races (254, 258) into the rotor/hub (257).
• Use J-8092 and J-6368 for installation of the
outer bearing outer race (254).
• Use J-8092 and J-23448 for installation of
the inner bearing outer race (258).
• Do not damage the hub/rotor during the
race installations.
Clean
Tools Required:
J-6893-D W heel Bearing Nut W rench
(10/1500-20/2500 Series)
Grease from the rotor/hub (257) and spindle
(265).
3C-42 FRONT SUSPENSION
248
223
209
210
211
208 214 215 216
203
217
218
246
B-07494
Figure 37—K Series (4 x 4) Front Suspension
FRONT SUSPENSION 3C-43
201.
202.
203.
204.
205.
206.
207.
208.
209.
210.
211.
212.
213.
214.
215.
Bolt
Shackle
Bushing
Nut
Washer
Bracket
Bumper
Rivet
Nut
Bracket
Bumper
Nut
Washer
Hanger
Rivet
216.
217.
218.
219.
220.
221.
222.
223.
224.
225.
226.
227.
228.
229.
230.
Spacer
Washer
Nut
Bolt
Shock Absorber
Leaf Spring
Nut
Washer
Plate
Bolt
Spacer
Bolt
Washer
Bolt
Stabilizer Shaft
231.
232.
233.
234.
235.
236.
237.
238.
239.
240.
241.
242.
243.
245.
246.
Nut
Washer
Bracket
Bushing
Rivet
Rivet
Bracket
Bolt
Nut
Washer
Hanger
Bolt
Reinforcement
Bracket
Spacer
247. Bracket
248. Bolt
A. K3500 Series
Right Side
B. Quad Shock
RPO Z75
B-07495
Figure 38—K Series (4 x 4) Front Suspension
A. K Series Standard Shock Absorber Mounting
B. K Series RPO Z75 Quad Shock Absorber Mounting
212. Nut
213. Washer
219. Bolt
220. Shock Absorber
225. Bolt
246. Spacer
Figure 39—Shock Absorber Attachments
B-07493
3C-44 FRONT SUSPENSION
Figure 40—Stabilizer Bar Attachm ents
• Grease from the wheel bearings (253, 259).
• Use clean solvent and a small brush (no loose
bristles).
• Do not spin the wheel bearings with compressed
air to dry them—the wheel bearings may be
damaged.
Im portant
• Use an approved high-temperature front wheel
bearing grease. Refer to MAINTENANCE AND
LUBRICATION (SEC. OB).
• Do not mix greases as mixing may change the
g re a s e ’s p ro p e rtie s re s u ltin g in poor
performance.
2. Apply a thin film of grease to the spindle at the
outer wheel bearing seat and at the inner wheel
bearing seat, shoulder, and seal seat.
3. Put a small quantity of grease inboard of each
wheel bearing cup, inside the rotor/hub (257).
4. F ill the w heel b e a rin g (cone and ro lle r
assemblies) full of grease.
• Use a cone-type grease packer that forces
grease into the bearing.
• If a cone-type grease packer is not available,
pack the wheel bearings by hand.
• If packing the wheel bearings by hand, work
the grease into the bearings between the
rollers, cones, and the cage.
NOTICE: Failure to completely pack the wheel
bearings (cones, rollers, and cage) with
grease will result in premature wheel bearing
damage and/or wear.
5. Inner wheel bearing (259) into the rotor/hub (257).
• Put an a d d itio n a l q u a n tity of grease
outboard of this wheel bearing.
6. New seal (260).
FRONT SUSPENSION 3C-45
7.
8.
9.
10.
• Use a flat plate to install the seal so it is
flush with the rotor/hub flange.
• Lubricate the seal lip with a thin layer of
grease.
Rotor/hub (257).
• Do not damage the spindle threads.
Outer wheel bearing (253).
• Press on the spindle until the wheel bearing
fully seats against the rotor/hub outer race.
Adjusting nut (252).
Adjust the wheel bearing.
• Refer to “ Wheel Bearing Adjustment,” in
this section.
NOTICE: Refer to the “Notice” on page 3C#7
of this section.
11. Ring (251) and locking nut (250).
• Tang on the inside diameter of the ring must
pass onto the slot on the spindle (265).
• The hole in the ring must align with the pin
on the lock nut (250). Move the adjustment
nut (252) to align the pin.
• Use J-6893-D or J-26878-A and J-23446.
&
Tighten
Lock nut (250) to 217 N m (160 ft. lbs.)
minimum.
12. Locking hub (249).
• Refer to FRONT AXLE (SEC. 4C).
13. Caliper.
• Refer to BRAKES (SEC. 5).
14. Wheel and tire. Lower the vehicle to the ground.
3C-46 FRONT SUSPENSION
249
B-07550
Figure 42—K30/3500 Series Knuckle, Wheel Hub/Rotor Assembly
FRONT SUSPENSION 3C-47
249.
250.
251.
252.
253.
254.
255.
257.
258.
259.
260.
261.
262.
Locking Hub Assembly
Locking Nut
Ring
Adjusting Nut
Outer Wheel Bearing
Outer Race
Wheel Hub Nut
Rotor/Hub
Inner Race
Inner Wheel Bearing
Seal
Nut
Washer
263.
264.
265.
266.
267.
268.
269.
270.
271.
272.
273.
274.
275.
Plate
Bracket
Spindle
Shaft Bearing
Bearing Seal
Spacer
Seal
Oil Deflector
Bolt
Washer
Cap
Steering Knuckle
Nut
276.
278.
279.
280.
281.
282.
283.
284.
285.
Bolt
Bolt
King Pin
Seal
Retainer
Race
Bearing
Seal
Bearing Cap
and King Pin
286. Bolt
287. Bushing
288. Spring
289.
290.
291.
292.
293.
294.
295.
296.
297.
298.
299.
300.
301.
Gasket
Steering Arm
Nut
Nut
Lower Ball Joint
Upper Ball Joint
Nut
Adapter
Steering Arm
Cotter Pin
Nut
Adjusting Ring
Retainer
B-07464
Figure 43—K Series Knuckle, Wheel Hub/Rotor Assembly
BEARING ADJUSTMENT
Im portant
• The proper functioning of the front suspension
cannot be maintained unless the front wheel
bearings are correctly adjusted. The cones must
be a slip fit on the spindle and the inside diameter
of the cones must be lubricated to insure the
cones will creep. The adjusting nut must have a
free-running fit on the spindle threads.
• For Manual hubs, back off enough to free
the bearing.
4. Ring (251) and lock nut (252).
• Tang on the inside diameter of the ring must
pass onto the slot on the spindle (265).
• The hole in the ring must align with the pin
on the lock nut (250). Move the adjustment
nut (252) to align the pin.
Tighten
Lock nut (250) to 217 N m (160 ft. lbs.)
minimum.
Adjust
• Raise the vehicle and support it with safety
stands.
1. Remove the locking hub assembly (249), lock nut
(250), and the ring (251).
a
Tighten
%
Measure
• Endplay in the hub/rotor assembly. It should be
set between 0.025 to 0.254 mm (0.001 to
0.010-inch).
5. Locking hub assembly (249).
• Refer to FRONT AXLE (SEC. 4C).
6. Lower the vehicle to the ground.
• Adjusting nut (252) to 60 N m (50 ft.
lbs.) while rotating the hub/rotor in
order to seat the bearings.
2. Back off the adjusting nut (252) and retighten.
$
Tighten
• For Automatic Hubs, torque the adjusting
nut to 47 N m (35 ft. lbs.) while rotating the
wheel.
• For Manual Hubs, torque the adjusting nut
to 60 N m (50 ft. lbs.) while rotating the
wheel.
3. Back off the adjusting nut (252).
• For Automatic hubs, back off 3/e of a turn
maximum.
WHEEL HUB BOLT
+ + Remove or Disconnect (Figures 37, 38, and
44)
Tools Required:
J-9746-02 Hub/Rotor Support
1. Hub/rotor assembly from the vehicle.
• Refer to “ Wheel Hub/Rotor Assembly,” in
this section.
2. Wheel hub bolts (255) with a press.
• Support the hub/rotor using J-9746-02 to
prevent damage to the rotor face (figure 44).
• Do not damage the wheel mounting surface
on the hub/rotor flange.
3C-48 FRONT SUSPENSION
J-9746
265. Spindle
274. Steering Knuckle
B-07502
Figure 46—Removing The Spindle
A. Press Bars
F-00036
• Tighten the nut until the bolt fully seats into
the hub/rotor.
• Remove the nut and washers.
2. Hub/rotor to the vehicle.
• Refer to “ Wheel Hub/Rotor Assembly,” in
this section.
3. Wheel and tire assembly. Lower the vehicle.
Figure 44—Pressing The Hub Bolt Out
Install or Connect (Figures 37, 38, and 45)
Tools Required:
SPINDLE
Remove or Disconnect (Figures 37, 38, 46 and
47)
J-9746-02 Hub/Rotor Support
NOTICE: Refer to “Notice” on page 3C#1 of
this section.
1. New, serrated bolt (255) into the hole in the
hub/rotor.
• Place four washers onto the bolt, then
fasten a nut onto the bolt until the nut
bottoms on the washers (figure 45).
• Raise the vehicle and support it with suitable
safety stands. Remove the tire and wheel
assembly.
1. Wheel hub/rotor assembly.
• Refer to “ Wheel Hub/Rotor Assembly,” in
this section.
2. Spindle (265) from the steering knuckle (274).
• N uts (261) and
p la te
(263) for
K10/1500-20/2500 series vehicles.
• Nuts (261), washers (262), plate (263) and
the bracket (264) for K30/3500 series
vehicles.
• Tap the end of the spindle with a plastic or
rubber mallet to break it loose from the
steering knuckle (274) (figure 46).
NOTICE: The machined surface of the spindle
must not be damaged by vise jaws.
A. Washers
B. Nut
81. Hub/Rotor
Figure 45—Installing The Wheel Hub Bolts
3. Spindle components.
• Secure the spindle in a vise by locating on
the high step diameter.
• Bearing seal (267) and shaft bearing (266)
(figure 47).
FRONT SUSPENSION 3C-49
Figure 47—Spindle Components
• Spacer (268), seal (269), and oil deflector
(270) from the axle shaft (figure 47).
Inspect
• Spacer (268). Replace if it is worn.
• Spindle (265) for any heat burns, scoring, or wear.
Replace if necessary.
• Seal (269) onto the oil deflector (270) with
the deflector lip toward the spindle (265).
3. Spacer (268) onto the axle shaft.
• The chamfer points toward the oil deflector
(270) (figure 48).
4. Spindle (265) onto the steering knuckle (274).
+«- Install or Connect (Figures 37, 38, 47 and 48)
Tools Required:
J-2 3 4 4 5 -A N eedle B e a rin g In s ta lle r
(K10/1500-20/2500 series)
J-8092 Driver Handle
J-21465-17 Bearing Installer (K30/3500
series)
• Relubricate the shaft bearing (266) and the
spindle (265) with a high melting point type wheel
bearing grease. Refer to MAINTENANCE AND
LUBRICATION (SEC. 0B).
1. Shaft bearing (266) and bearing seal (267) into
the spindle (265) (figure 47).
• For K10/1500-20/2500 series vehicles, use
J-8092 and J-23445-A.
• For K30/3500 series vehicles, use J-8092
and J-21465-17.
2. Oil deflector (270) and seal (269) onto the axle
shaft.
A.
265.
268.
269.
270.
Chamfer Toward
The Seal
Spindle
Spacer
Seal
269
Oil Deflector
B-07454
Figure 48—Installing The Spindle
Onto The Axle Shaft
3C-50 FRONT SUSPENSION
4. Tie rod from the steering arm (297).
• Refer to STEERING LINKAGE (SEC. 3B1).
5. Steering arm (297) from the steering knuckle
(274).
• Nuts (295) and adapters (296).
• Discard the nuts (295).
NOTICE: Do not remove the adjusting ring
(300) unless new ball joints are being
installed. If it is necessary to loosen the ring to
remove the knuckle, do not loosen it more
than two threads. Use J-23447 (figure 49). The
nonhardened threads in the yoke can be easily
damaged by the hardened threads in the
adjusting ring if caution is not used during
knuckle removal.
6. Steering knuckle (274) from the axle yoke.
• Cotter pin (298), nuts (292, 299).
• Slide the spindle over the axle shaft until it
seats on the steering knuckle. The bolts
(278) must protrude through the spindle.
• Insert a wedge-shaped tool between the
lower ball joint (293) and the yoke. Tap on
the tool to release the knuckle assembly.
NOTICE: Refer to “Notice” on page 3C#1 of
this section.
5. Bracket (264) and plate (263).
• Only the K30/3500 series vehicles use a
bracket (264).
• Washers (262) (K30/3500 series only) and
NEW nuts (261).
• Insert the wedge-shaped tool between the
upper ball joint (294) and the yoke. Tap on
the tool to release the knuckle assembly.
-►«- Install or Connect (Figure 37, 38 and 49)
Tools Required:
J-23447 Ball Stud Nut Wrench
$
Tighten
• Nuts (261) to 88 N m (65 ft. lbs.).
6. Wheel hub/rotor assembly.
• Refer to “ Wheel Hub/Rotor Assembly,” in
this section.
7. Wheel and tire. Lower the vehicle to the ground.
NOTICE: For steps 2, 3, 4, 6 and 7, refer to
“Notice” on page 3C#1 of this section.
1. Steering knuckle (274) to the axle yoke.
• Ball joints (293, 294) into their respective
sockets in the axle yoke.
• Finger tighten the nuts (292, 299) onto the
ball joints (293, 294). The nut with the cotter
pin slot goes with the upper ball joint.
STEERING KNUCKLE AND ARM
K10/1500-20/2500 SERIES VEHICLES
(WITH BALL JOINTS)
2. Push up on the steering knuckle [to keep the ball
joint (293) from turning in the knuckle] and
partially torque the lower ball joint nut (292).
|+ + | Remove or Disconnect (Figures 37, 38, and
49)
• Raise the vehicle and support with suitable safety
stands. Remove the tire and wheel assembly.
1. Locking hub assembly (249).
• Refer to FRONT AXLE (SEC. 4C).
2. Wheel hub/rotor assembly.
• Refer to “ Wheel Hub/Rotor Assembly,” in
this section.
3. Spindle (265) from the steering knuckle (274).
• Refer to “ Spindle,” in this section.
a
Tighten
• Nut (292) to 40 N m (30 ft. lbs.).
3. Torque the adjusting ring (300).
• Use J-23447 (figure 46).
Tighten
• Adjusting ring (300) to 70 N m (50 ft. lbs.).
4. Torque the upper ball joint nut (299).
FRONT SUSPENSION 3C-51
1^1Tighten
• Nut (299) to 135 N-m (100 ft. lbs.).
5. Cotter pin (298) into the nut (299).
• Do not loosen the nut. Apply additional
torque, if necessary, to line up the hole in
the ball joint with the slot in the nut.
6 . Apply the final torque to the lower ball joint nut
(292).
$
Tighten
• Nut (292) to 95 N-m (70 ft. lbs.).
Steering arm (297) to the steering knuckle (274).
• Adapters (296) and NEW nuts (295).
Tighten
8.
9.
10.
11.
12.
13.
14.
15.
• Nuts (295) to 120 N-m (90 ft. lbs.).
Tie rod to the steering arm (297).
• Refer to STEERING LINKAGE (SEC. 3B1).
Spindle (265) to the steering knuckle (274).
• Refer to “ Spindle,” in this section.
Wheel hub/rotor assembly.
• Refer to “ Wheel Hub/Rotor Assembly,” in
this section.
Adjust the wheel bearings.
• Refer to “ Wheel Bearing Adjustment,” in
this section.
Locking hub assembly (249).
• Refer to FRONT AXLE (SEC. 4C).
Wheel and tire assembly.
Check the front end alignment.
• Refer to FRONT END ALIGNMENT (SEC.
3A).
Lower the vehicle to the ground.
Figure 50—Removing The Cap
And Steering Arm Fasteners
5.
6.
7.
8.
9.
• For the steering arm, remove the nuts (291)
alternately as the compression spring will
force the steering arm up (figure 50).
Gasket (289), and compression spring (288).
• Discard the old gasket (289).
Lower bearing cap and king pin (285).
• Bolts (271) and washers (272) (figure 51).
Upper king pin bushing (287).
• Pull it out through the steering knuckle
(274).
Steering knuckle (274) from the axle yoke.
• Seal (301).
Upper king pin (279) from the axle yoke.
• Use a large breaker bar and J-26871 (figure
49).
• Apply 677-813 N-m (500-600 ft. lbs.) of
torque to break the king pin free.
K30/3500 SERIES VEHICLES (WITH KING PINS)
Remove or Disconnect (Figures 37, 38, and 50
through 53)
•
1.
2.
3.
4.
Tools Required:
J-26871 King Pin Socket
Raise the vehicle and support with suitable safety
stands. Remove the tire and wheel assembly.
Locking hub (249).
• Refer to FRONT AXLE (SEC. 4C).
Wheel hub/rotor assembly.
• Refer to “ Wheel Hub/Rotor Assembly,” in
this section.
Spindle (265).
• Refer to “ Spindle,” in this section.
Upper cap (273) and/or steering arm (290).
• For the cap, remove the bolts (271) and
w a sh ers (272) a lte rn a te ly as the
compression spring will force the cap up.
274. Steering Knuckle
285. Bearing Cap and King Pin
B-07453
Figure 51—Removing The Lower Bearing
Cap And King Pin
3C-52 FRONT SUSPENSION
Figure 52—Removing The Upper King Pin
10. Retainer (281), race (282), bearing (283) and the
seal (284) from the axle yoke.
• Punch all the components out at once
(figure 53).
• Discard the old seal (284).
Figure 54—Installing The Retainer Into The Axle
Yoke
NOTICE: For steps 4, 6, 7, refer to “Notice” on
page 3C#7 of this section.
1. Retainer (281) and the race (282).
• Use a new retainer.
• If the retainer (281) is damaged, discard it.
• Use J-7817 (figure 54).
Install or co nn e ct (Figures 38, 39 and 54
through 56)
Tools Required:
J-7817 Front Pinion Bearing Installer
J-22301 King Pin Bearing Seal Installer
J-28871 King Pin Installer
A. Axle Yoke
B-07458
Figure 53—Removing The Retainer, Race,
Bearing and Seal
2. Fill the area in the retainer (281) and race with an
approved high temperature bearing lubricant.
Grease the bearing (282).
• Use a cone-type grease packer that forces
grease into the bearing.
• If a cone-type grease packer is not available,
pack the bearing by hand. Work the grease
between the rollers, cones, and cage.
FRONT SUSPENSION 3C-53
Figure 56—Installing The Upper King Pin
Q
NOTICE: Failure to com pletely pack the
bearing (cones, rollers, and cage) with grease
will result in premature bearing damage
and/or wear.
8.
• R efer
to
M A IN TE N A N C E
AND
LUBRICATION (SEC. OB).
3. Bearing (283) and seal (284).
• Use J-22301 to install the NEW seal (Figure
55).
• Do not distort the seal. It will protrude
slightly from the surface of the axle yoke
flange when fully seated.
4. Upper king pin (279).
• Use J-28871 (figure 56).
9.
10.
11.
12.
13.
Tighten
• King pin (279) to 745 N m (550 ft. lbs.).
5. Steering knuckle (274) and bushing (287).
• Felt seal (280) to the king pin (279) through
the steering knuckle.
• Knuckle onto the king pin (279).
• Place the bushing (287) over the king pin
(279).
6. Bearing cap and king pin (285) to the steering
knuckle (278).
• 4 bolts (271) and washers (272).
$
Tighten
• Bolts (271) alternately and evenly to 108 N m
(80 ft. lbs.).
7. Steering arm (290) to the steering knuckle (274).
• Compression ring (288), gasket (289), and
steering arm (290).
• Nuts (291).
14.
Tighten
• Nuts (291) alternately and evenly to 108 N m
(80 ft. lbs.).
Spindle (265).
• Refer to “ Spindle,” in this section.
Wheel hub/rotor assembly.
• Refer to “ Wheel Hub/Rotor Assembly,” in
this section.
Adjust the wheel bearings.
• Refer to “ Wheel Bearing Adjustment” in
this section.
Locking hub (249).
• Refer to FRONT AXLE (SEC. 4C).
Wheel and tire assembly.
Check the front end alignment.
• Refer to FRONT END ALIGNMENT (SEC.
3A).
Lower the vehicle to the ground.
BALL JOINTS (10/1500-20/2500
SERIES VEHICLES ONLY)
Remove or Disconnect (Figures 37, 38, 57 and
58)
Tools Required:
J-9519-10 Ball Joint Fixture
J-23454-1 Lower Ball Joint Spacer
J-23454-3 or
J-6382 Upper Ball Joint Spacer
J-23454-4 Upper and Lower Ball Joint
Sleeve
• Raise the vehicle and support with suitable safety
stands. Remove the wheel and tire assembly.
1. Wheel hub/rotor assembly.
3C-54 FRONT SUSPENSION
274
J-23454-1
J-6382-3 OR
•23454-3
J-6382-3 OR
J-23454-3
293
A. Flat Washer
274. Steering Knuckle
J-9519-10
B-07509
Figure 58—Removing The Upper Ball Joint
2.
3.
4.
5.
□
• Refer to “ Wheel Hub/Rotor Assembly,” in
this section.
Spindle.
• Refer to “ Spindle,” in this section.
Steering knuckle (274) and steering arm (290).
• Remove the steering arm (290) only if
removing the left axle yoke ball joints.
• Refer to “ Steering Knuckle and Arm,” in
this section.”
• Place the steering knuckle in a vise (figure
57).
Lower ball joint (293).
• Must be removed before any service can be
done to the upper ball joint (294).
• Snap ring from the lower ball joint (293).
• Use J-9519-10, J-23454-1, J-23454-4 or
equivalent (figuer 57). Tighten until the ball
joint breaks free of the steering knuckle.
Upper ball joint (294).
• Use J-9519-10, J-23454-3 (or J-6382-3) and
J-23454-4 (figure 58). Tighten until the ball
joint breaks free of the steering knuckle.
J-9519-10
274. Steering Knuckle
293. Lower Ball Joint
B-07510
Figure 59—Installing The Lower Ball Joint
2. Upper ball joint (294) into the steering knuckle
(274).
• Use J-9519-10, J-23454-2, and J-23454-3 or
J-6382-3 (figure 60). Tighten until the ball
joint fully seats.
3. Steering arm (290) and steering knuckle (274).
• Steering arm only if removed.
• Refer to “ Steering Knuckle and Arm,” in
this section.
4. Spindle (265).
• Refer to “ Spindle,” in this section.
5. Wheel hub/rotor assembly.
• Refer to “ Wheel Hub/Rotor Assembly,” in
this section.
6. Adjust the wheel bearings.
• Refer to “ Wheel Bearing Adjustment,” in
this section.
7. Wheel and tire assembly.
8. Check the front end alignment.
274
294
J-23454-2
Install or Connect (Figures 37, 38, 59 and 60)
Tools Required:
J-9519-10 Ball Joint Fixture
J-23454-2 Upper and Lower Ball Joint
Sleeve
J-23454-3 or
J-6382-3 Upper and Lower Ball Joint Spacer
1. Lower ball joint (293) into the steering knuckle
(274).
• The ball joint (no cotter pin hole in the
threaded end) must be positioned straight.
• Use J-9519-10, J-23454-2, and J-23454-3 or
J-6382-3 (figure 59). Tighten until the ball
joint fully seats.
• Snap ring in position.
I
J-9519-10
J-6382
OR
J-23454-3
274. Steering Knuckle
294. Upper Ball Joint
B-07508
Figure 60—Installing The Upper Ball Joint
FRONT SUSPENSION 3C-55
201.
202.
203.
204.
205.
207.
216.
217.
218.
221.
Bolt
Shackle
Bushing
Nut
Washer
Bumper
Spacer
Washer
Nut
Leaf Spring
218
217
218
B-07460
Figure 61—Leaf Spring Components
• Refer to FRONT END ALIGNMENT (SEC.
4C).
9. Lower the vehicle to the ground.
LEAF SPRING AND BUSHING
Remove or Disconnect (Figures 37, 38, and
61)
• Raise the vehicle on a hoist and support the front
axle with a floor jack. Raise the floor jack until all
tension is relieved from the springs.
1. Spring (221) from the frame.
• Nut (218), washer (217), shackle (202), bolt
(201), bushings (203) and spacer (216)
(figure 61).
2. Spring (221) from the hanger (241).
• Nut (239), washers (240), and bolt (242)
(figure 61).
3. Spring (221) from the axle.
• For K10/1500-20/2500 and the left side of
K30/3500 series vehicles, remove nuts
(222), washers (223), U-bolts (227), plate
(224) and the spacers (226).
• For the right side of K30/3500 series
vehicles, remove the bolts (248), nuts (222),
washers (223), U-bolt (227), plate (224) and
the spacers (226) (figure 61).
4. Shackle (202) from the spring (221).
• Nut (218), washer (217), bolt (201), bushings
(203) and spacer (216) (figure 61).
5. Bushing from the spring eye.
• Place the spring in a press and press out
the bushing using a suitable rod, pipe, or
tool.
Install or Connect (Figures 37, 38, 61 and 62)
1. Bushing into the spring eye.
• Press in a new bushing, making sure the
tool presses on the steel outer shell of the
bushing.
• Bushing must protrude an equal amount on
either side of the spring eye when properly
installed.
2. Shackle (202) into the spring (221).
• Spacer (216), bushings (203), washers (217),
bolt (201) and nut (218).
• Do not tighten.
3. Upper spacer (226) onto the spring (221).
4. Spring into the hanger (241).
• Bolt (242), washers (240) and nut (239).
• Do not tighten.
5. Spring into the frame.
• Bushings (203) and the spacer (216) into the
frame.
3C-56 FRONT SUSPENSION
• Shackle (202) into position and attach bolt
(201), washer (217) and nut (218).
• Do not tighten.
NOTICE: Refer to the “Notice” on page 3C#1
of this section.
6. Spring to the axle.
• For K10/1500-20/2500 series vehicles and
the left side of K30/3500 series vehicles,
attach the lower spacer (226), plate (224),
U-bolts (227), washers (223) and nuts (222)
(figure 61).
For the right side of K30/3500 series
vehicles, attach the lower spacer (226),
plate (224), U-bolt (227), washers (223),
bolts (248) and nuts (222) (figure 61).
Tighten
• Nuts (222) and bolts (248) in sequence
(2-4-1-3) to 203 N m (150 ft. lbs.) (figure 62).
6. Torque the spring to frame and hanger fasteners.
• Nuts (239) to 122 N m (90 ft. lbs.).
• Nuts (218) to 68 N m (50 ft. lbs.).
7. Lower the floor jack, and lower the vehicle to the
ground.
FRONT SUSPENSION 3C-57
SPECIFICATIONS
FRONT SUSPENSION BOLT TORQUE—N-m (FT. LBS.)
K10
C10
Shock Absorber
To Frame
Shock A bsorber To
Lower Control Arm
190 (140) 88 (65)
80 (59)
Shock A bsorber
to Axle
G10
C20
K20
103 (80) 190 (140) 88 (65)
G20
P20
C30
K30
103 (80) 190 (140) 190 (140) 88 (65)
___
103 (80)
80 (59)
___
103 (80)
80 (59)
80 (59)
___
88 (65)
___
___
88 (65)
___
___
___
88 (65)
G30
P30
P30
W/FS3
103 (80) 190 (140) 185 (136)
103 (80)
—
80 (59)
—
—
50 (37)
Stabilizer
To Frame
33 (24)
95 (70)
29 (21)
33 (24)
95 (70)
29 (21)
33 (24)
33 (24)
70 (52)
29 (21)
33 (24)
29 (21)
Stabilizer To
Low er Control Arm
33 (24)
___
33 (24)
33 (24)
___
33 (24)
33 (24)
33 (24)
—
33 (24)
33 (24)
—
___
___
___
___
___
___
___
—
—
—
68 (50)
___
___
180 (133)
___
___
—
—
—
Stabilizer To
Stabilizer Link
Stabilizer To
Spring Plate
Steering Knuckle To
Upper Ball Joint
180 (133)
68 (50) 135 (100) 68 (50)
—
180 (133)
* ★
*
★
122 (90) 135 (100) 68 (50)
122 (90) 122 (90)
—
122 (90) 122 (90)
—
* *
Steering Knuckle To
Low er Ball Joint
122 (90)
Splash Shield
To Knuckle
13 (10)
40 (30)
122 (90) 122 (90)
40 (30)
122 (90) 122 (90) 122 (90)
—
_
13 (10)
13 (10)
___
13 (10)
13 (10)
13 (10)
_
___
___
___
___
___
_
—
Anchor Plate
To Knuckle
88 (65)
___
___
88 (65)
___
___
___
88 (65)
Steering Arm
To Knuckle
120 (90)
___
120 (90)
___
___
___
___
___
___
___
___
___
217 (160)
___
___
217 (160)
___
_
___
___
___
A djusting Ring
To Spindle
70 (50)
___
___
Low er Control
Arm Bushings
_
___
Splash Shield to
Anchor Plate
Caps To The
Steering Knuckle
Lock Pin To
Steering Knuckle
King Pin
To Knuckle
_
—
_
120 (90)
—
—
312 (230)
___
108 (80)
—
—
7 (5 )
___
___
217 (160)
—
—
40 (29)
___
___
___
745 (550)
—
—
—
70 (50)
___
___
___
___
—
—
—
379 (280)
___
___
\
156 (115)
___
___
156 (115)
Low er Pivot Shaft
U-Bolt Nuts
115 (85)
_
88 (65)
115 (85)
___
88 (65)
Upper Control
Arm Bushings
_
_
___
257 (190)
___
Upper Pivot
Shaft End Nuts
156 (115)
_
156 (115)
___
___
25 (18)
Crossm em ber To
B ottom Frame R ail0
122 (90)
95 (76) 142 (105)
_
'
—
25 (18)
—
16 (12)
_
Upper Bolt Joint
To Upper Control Arm
13 (10)
—
95 (70)
95 (70)
13 (10)
—
—
Low er Pivot Shaft
End Nuts
Upper Pivot Shaft
Thru Bolt Nuts
122 (90) 122 (90)
25 (18)
122 (90) 122 (90)
_
___
—
156 (115)
379 (280) 379 (280)
___
___
___
379 (280) 379 (280)
—
—
___
—
115 (85) 115 (85)
___
115 (85) 115 (85)
—
257 (190) 257 (190)
___
258 (190) 257 (190)
—
___
___
95 (70) 142 (105) 142 (105)
25 (18)
___
25 (18)
25 (18)
122 (90) 122 (90) 122 (90)
___
___
___
—
—
__
142 (105) 142 (105)
25 (18)
25 (18)
122 (90) 122 (90)
—
___
—
—
3C-58 FRONT SUSPENSION
SPECIFICATIONS (CONT.)
FRONT SUSPENSION BOLT TORQUE—N-m (FT. LBS.)
P30
W/FS3
C10
K10
G10
C20
K20
G20
P20
C30
K30
G30
P30
88 (65)
_
88 (65)
88 (65)
_
88 (65)
88 (65)
88 (65)
_
88 (65)
88 (65)
Spring To
Hanger Nuts
—
122 (90)
_
_
122 (90)
_
_
_
122 (90)
_
_
Spring To
Shackle Nuts
_
68 (50)
_
_
68 (50)
_
_
_
68 (50)
Spring To Axle
U-Bolt Nuts
_
203 (150)
_
_
203 (150)
_
_
_
203 (150)
_
Shackle To
Frame Nuts
Suspension Bum per
_
20 (15)
68 (50)
20 (15)
20 (15)
26 (19)
68 (50)
20 (15)
20 (15)
26 (19)
26 (19)
68 (50)
20 (15)
20 (15)
26 (19)
125 (92)
34 (25)
Crossm em ber To
Brake S upport Struts
81 (60)
—
81 (60)
81 (60)
—
81 (60)
81 (60)
81 (60)
—
81 (60)
81 (60)
_
Crossmember To
Side Frame Rail00
°P30 (32)— 291 N-m (215 ft. lbs.); P30 (42) and J F 9 -1 7 6 N-m (130 ft. lbs.).
o o P30 (32), P30 (42) and J F 9 -1 3 5 N-m (100 ft. lbs.).
‘ Plus additional torque to align cotter pin. Not to exceed 122 N-m (90 ft. lbs.) m axim um .
“ Plus additional torque to align co tte r pin. Not to exceed 176 N-m (130 ft. lbs.), m axim um .
“ ‘ Plus additional torque to align cotter pin.
ENDPLAY SPECIFICATIONS
C-G-P Series
0 .0 3 -0 .1 3 m m (0 0 0 1 2 - 0 00 5 inches)
K series
0 .0 2 5 -0 25 m m (0 .0 0 1 - 0 .0 1 0 inches)
P 30 w /FS 3
0 .0 1 3 -0 .2 0 m m (0 .0 0 0 5 -0 .0 0 8 )
125 (92)
125 (92)
109 (80)
FRONT SUSPENSION 3C-59
SPECIAL TOOLS
Tool Number
Tool Name
J-8092
Driver Handle
J-8457
Wheel Bearing Race Installer
J-8849
Wheel Bearing Race Installer
J-29040
Outer Bearing Race Installer
J-6893-D
Wheel Bearing Nut Wrench (K10/1500-20/2500)
J-26878-A
Wheel Bearing Nut Wrench (K30/3500)
J-23446
Torque Wrench Adapter
J-6368
Outer Bearing Race Installer
J-23448
Inner Bearing Race Installer
J-24435-A
Needle Bearing Installer (K10/1500-20/2500)
J-21465-17
Bearing Installer (K30/3500)
J-23742
Ball Joint Separator
J-9519-9
Ball Joint Installer
J-9519-10
Ball Joint Fixture
J-9519-13
Ball Joint Installer
J-9519-16
Ball Joint Installer
J-9519-22
Ball Joint Installer
J-23454-1
Lower Ball Joint Separator
J-23454-2
Upper And Lower Ball Joint Sleeve
J-23454-3 or J-6382-3
Upper And Lower Ball Joint Spacer
J-9746-02
Hub/Rotor Support
J-23028-02
Spring Remover
J-6627-A
Wheel Stud And Tie Rod Remover
J-23447
Ball Stud Nut Wrench
J-7817
Front Pinion Bearing Installer
J-22301
King Pin Bearing Seal Installer
J-28871
King Pin Installer
J-22717
Lower Control Arm Bushing Stake Remover
J-24435-1
Upper And Lower Control Arm Bushing Remover
J-24435-2
Upper And Lower Control Arm Bushing Spacer
J-24435-3
Upper And Lower Control Arm Bushing Remover
J-24435-4
Upper And Lower Control Arm Bushing Installer
J-24435-5
Upper Control Arm Bushing Installer
J-24435-6
Upper And Lower Control Arm Bushing Spacer
J-24435-7
Upper And Lower Control Arm Bushing Fixture
3D-1
SECTION 3D
REAR SUSPENSION
The following “ Notice” applies to one or more steps in the assembly procedure of components in this portion of
the manual as indicated at appropriate locations by the terminology “ Notice: Refer to the ‘Notice’ on page 3D-1 of
this section.
NOTICE: These rear suspension fasteners are important attaching parts in that they could affect the perform­
ance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one
of the same part number or with an equivalent part if replacement becomes necessary. Do not use a replace­
ment part of lesser quality or substitute design. Torque values must be used as specified during reassembly
to assure proper retention of these parts.
CONTENTS
S U B JE C T
PAGE
General D e scrip tio n ................................................................................................................................................... 3D- 1
On Vehicle S e r v ic e ................................................................................................. ................................................. 3D- 8
Shock A b s o rb e rs ................................................................................................................................................... 3D- 8
Stabilizer Bar............................................................................................................................................................3D- 8
Leaf Spring A s s e m b ly .......................................................................................................................................... 3D-10
Bushing R e p la ce m e n t.......................................................................................................................................... 3D-10
S pecifications..............................................................................................................................................................3D -12
GENERAL DESCRIPTION
All 10/1500 through 30/3500 series vehicles use a
leaf spring and solid rear axle suspension system (fig­
ures 1 through 7).
The rear axle assembly is attached to multi-leaf
springs by U-bolts. The front ends of the springs are
attached to the frame at the front hangers, through rub­
ber bushings. The rear ends of the springs are at­
tached to the frame by the use of shackles which allow
the springs to “ change their length” while the vehicle
is in motion.
Ride control is provided by two identical direct dou­
ble acting shock absorbers angle-mounted between
the frame and brackets attached to the axle tubes.
3D-2 REAR SUSPENSION
Figure 1—Rear Suspension (C-K 10/1500, 20/2500 Pickup, Suburban, And Blazer/Jimmy)
REAR SUSPENSION 3D-3
Figure 2—Rear Suspension (C-K 30/3500 Series Vehicles)
3D-4 REAR SUSPENSION
Figure 3—Rear Suspension (G 10/1500-30/3500 Series Vehicles)
REAR SUSPENSION 3D-5
Figure 4—Rear Suspension (G30/3500 Series Cutaway Van With RPO M40)
3D-6 REAR SUSPENSION
B-07519
Figure 5—Rear Suspension (P20/2500 Series Vehicles)
REAR SUSPENSION 3D-7
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Bracket
Bolt
Washer
Rear Hanger
Nut
Rear Shackle
Anchor Plate
U-bolt
Shim
Leaf Spring
Nut
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Spring Lock Washer
Rear Shock Absorber
Bolt
Spring Lock Washer
Nut
Front Hanger Support
Front Hanger
Axle Bumper
Bumper Bracket
Washer
Nut
23. Bracket
24. Cushion
25. Rear Hanger
Reinforcement
26. Leaf Spring Eye
Bushing
27. Bolt
28. Nut
29. Nut
30. Bolt
31. Spacer
Figure 7—Rear Suspension Legend
32. Optional Rear
Auxiliary Spring
33. Bolt
34. Washer
35. Nut
36. Stabilizer Bar
Anchor
37. Spacer
38. Bolt
39. Spring Clip
B-07521
3D-8 REAR SUSPENSION
ON-VEHICLE SERVICE
SHOCK ABSORBERS
«"► Remove or Disconnect (Figures 1 through 7)
• Raise the vehicle on a hoist and support the rear
axle independently of the rest of the vehicle.
1. Shock absorber (13) from the frame.
• For C-K and P series vehicles; nut (16),
spring-washer (15), and/or washer (21).
• For G series vehicles; nut (16), spring
washer (15), washer (3), and bolt (38).
2. Shock absorber (13) from the axle.
• Nut (11), spring-washer (12), and bolt (14).
• Pull the shock absorber free.
|+ + | Install or Connect (Figures 1 through 7)
NOTICE: For steps 1 and 2, refer to the
“Notice” on page 3D-1 of this section.
1. Shock absorber (13) to the frame.
• For C-K and P s e rie s v e h ic le s ;
spring-washer (15) and/or washer (21), plus
the nut (16).
• For G series vehicles; bolt (38), washer (3),
spring-washer (15), and nut (16).
Tighten
Figure 8—Rear Stabilizer Attachm ents
(C30/3500 Series Vehicles)
• Nuts (16) to “ Specifications” at the end of
this section.
STABILIZER BAR
2. Shock absorber (13) to the axle.
• Line shock absorber up with the axle
bracket.
• Bolt (14), spring-washer (12), and nut (11).
Tighten
• For all C-K and P series vehicles; nut (11) to
155 N-m (114 ft. lbs.).
• For all G series vehicles; nut (11) to 102 N-m
(75 ft. lbs.).
3. Lower the vehicle to the ground.
B" i i
Remove or Disconnect (Figures 8, 9, and 10)
• Raise the vehicle on a hoist. Support the rear
axle independently of the rest of the vehicle.
1. Stabilizer bar (108) from the frame.
• For C 30/3500 series vehicles; nut (120),
and washer (116). Slide the link bolt (115) out
along with the grommets (117), washers
(116), and spacer (114).
• For P 30/3500 (32) series vehicles; nuts
(105), washers (106), bolts (111), and the
clamp (110).
REAR SUSPENSION 3D-9
B-07523
Figure 9—Rear Stabilizer Attachm ents (P(32) Series)
2. Stabilizer bar (108) from t^e anchor plates (107).
• Nuts (105), washers (106), bolts (111), and
the clamps (110).
3. Insulators (109) from the stabilizer bar (108).
101.
102.
103.
104.
105.
106.
107.
108.
109.
110.
111.
U-bolt
Spacer
Spring Spacer
Anchor Plate
Nut
Spring Lock Washer
Stabilizer Bar Anchor
Stabilizer Bar
Bushing
Bracket
Bolt
112.
113.
114.
115.
116.
117.
118.
119.
120.
121.
Nut
Washer
Spacer
Bolt
Washer
Grommet
Link
Retainer
Nut
Bracket
B-07524
Figure 10—Rear Stabilizer Attachments Legend
Install or Connect (Figures 8, 9 and 10)
NOTICE: For steps 2 and 3, refer to the
“Notice” on page 3D-1 of this section.
1. Insulators (109) to the stabilizer bar (108).
2. Stabilizer bar (108) to the anchor plates (107).
• Clamps (110), bolts (111), washers (106), and
nuts (105).
Tighten
• Refer to “ Specifications” at the end of this
section.
Important
Route the parking brake cable over the stabilizer
bar.
3D-10 REAR SUSPENSION
3. Stabilizer bar (108) to the frame.
• For the C 30/3500 series vehicles; position
the link bolt (115), washers (116), grommets
(117), spacer (114), retainer (119) and nut
(120).
• For the P 30/3500 (32) series vehicles;
attach the clamp (110), bolts (111), washers
(106), and nuts (105) in position.
Tighten
• Nuts (120 and 105) to the “ Specifications”
at the end of this section.
4. Lower the vehicle to the ground.
LEAF SPRING ASSEMBLY
Remove or Disconnect (Figures 1 through 7)
• Raise the vehicle on a hoist and support the rear
axle independently to relieve tension on the leaf
springs.
1. Stabilizer bar from the vehicle if equipped.
• Refer to “ Stabilizer Bar,” in this section.
2. Leaf spring (10) from the rear hanger (25).
• Loosen, but do not rem ove, the
spring-to-shackle nut and bolt.
• Nut and the bolt securing the shackle to the
rear hanger (25).
3. Leaf spring (10) from the front hanger (18).
• Nut and the bolt securing the leaf spring
(10) to the front hanger (18).
4. Shackle (6) from the leaf spring (10).
• Nut and bolt securing the shackle to the leaf
spring.
5. Leaf spring from the axle.
• Nuts (22), and washers (21).
• Rear stabilizer anchor (36) if equipped, the
anchor plate, spacers, shims, and the
auxiliary spring (32), if equipped.
• U-bolts (8).
• Leaf spring is free of the vehicle.
|~k ~| Install or Connect (Figures 1 through 7, and
11)
NOTICE: For steps 1 and 4, refer to the
“Notice” on page 3D-1 of this section.
1. Leaf spring (10) to the rear axle.
• Leaf spring into position.
• Spacers, shims, the auxiliary spring (32) if
equipped, and the anchor plate.
• U-bolts (8), washers (21), ^nd nuts (22).
Tighten
• Nuts (22), in a diagonal sequence 1-3-2-4
(figure 11), initially to 25 N m (18 ft. lbs.).
Then final torque in a diagonal sequence
1-3-2-4 (figure 11) to the “ Specifications” at
the end of this section.
2. Shackle (6) to the leaf spring (10).
• Bolt (2), washers (3), and nuts (5), making
sure the bolt is positioned correctly (figures
1 through 7).
• Do not tighten.
3. Leaf spring to the front hanger (18).
• Bolt (2), washers (3), and nut (5).
• Do not tighten.
4. Leaf spring to the rear hanger (25).
• Bolt (2), washers (3), and nut (5).
• Nuts (5) and bolts (2), to the “ Specifications” at
the end of this section.
5. Stabilizer bar to the vehicle if equipped.
• Refer to “ Stabilizer Bar,” in this section.
6. Lower the support on the rear axle. Lower the
vehicle to the ground.
BUSHING REPLACEMENT
PRESS OUT TYPE BUSHINGS
|<~+| Remove or Disconnect (Figures 1, 3, and 7)
1. Leaf spring (10) from the vehicle.
• Refer to “ Leaf Spring Assembly,” in this
section.
2. Bushing from the leaf spring (10).
• Place the leaf spring in a press and press
out the bushing.
|~»<-| Install or Connect (Figures 1, 3 and 7)
1. Bushing into the leaf spring (10).
• Use a press to pro pe rly position the
bushings.
2. Leaf spring (10) to the vehicle.
• Refer to “ Leaf Spring Assembly,” in this
section.
PRY OUT TYPE BUSHINGS
|<~+| Remvoe or D isco n n e ct (F ig u re s 2 and 4
through 7)
1. Leaf spring (10) from the vehicle.
• Refer to “ Leaf Spring Assembly,” in this
section.
REAR SUSPENSION 3D-11
2. Bushings (26) from the leaf spring (10).
• Pry the bushings out of each side of the
spring eye.
Install or Connect (Figures 2 and 4 through 7)
1. Bushings (26) into the leaf spring (10).
• Press each bushing (26) into its side of the
spring eye.
2. Leaf srping (10) onto the vehicle.
• Refer to “ Leaf Spring Assembly,” in this
section.
3D-12 REAR SUSPENSION
SPECIFICATIONS
FASTENER NAME
TORQUE N m (FT. LBS.)
C10/15
C20/25
C30/35
K10/15
K20/25
K30/35
G10/15
G20/25
G30/35
P20/25
P30/35
7 0 (52)
190 (1 40)
190 (1 40)
70 (52)
102 (75)
102 (75)
102 (75)
33 (24)
70 (52)
Shock A bsorber To Fram e Nut
19 0 (1 4 0 ) *1 9 0 (1 40)
Shock A bsorber To Axle Nut
155 (1 1 4 ) *1 5 5 (114) 155 (1 14)
155 (1 14)
155 (1 14)
155 (1 14)
102 (75)
102 (75)
102 (75)
155 (1 14)
155 (114)
Stabilizer Bar To Fram e Nut
—
—
**
—
—
—
—
—
—
—
29 (21)
Stabilizer Bar To A nchor Nut
—
—
3 3 (24)
—
—
—
—
—
—
—
29 (21)
Stabilizer Bar Bracket To H anger
—
—
—
—
-
—
—
—
—
—
33 (24)
Stabilizer Bar Bracket To Fram e
—
—
—
—
—
—
—
—
—
33 (24)
170 (1 25)
170 (1 25)
170 (1 2 5 )
170 (1 25)
170 (1 25)
170 (1 25)
155 (114)
20 5 (1 51)
170 (1 25)
2 0 0 (1 4 7 )
2 0 0 (147)
20 0 (1 47)
2 0 0 (1 47)
2 0 0 (1 47)
2 0 0 (1 47)
Spring To Hanger Nut
125 (92)
125 (92)
125 (92)
125 (92)
125 (92)
125 (92)
125 (92)
125 (92)
125 (92)
125 (92)
N/A
150 (110)
185 (136)
185 (1 36)
185 (136)
150 (1 10)
• 1 5 0 (1 10)
Anchor Plate To U-bolt Nut
(U-bolts Facing Up)
155 (1 14)
-
Anchor Plate to U-bolt Nut
(U-bolts Facing Down)
-
-
2 0 5 (1 51)
-
* * * 2 0 0 (147)
Spring To H anger Bolt
150 (1 1 0 )
150 (1 10)
150 (1 10)
150 (110)
150 (110)
Spring To Shackle Nut
125 (9 2)
125 (92)
125 (92)
125 (92)
125 (92)
125 (92)
125 (92)
125 (92)
125 (92)
125 (92)
• 1 2 5 (92)
Spring To Shackle Bolt
15 0 (1 1 0 )
150 (1 10)
150 (1 10)
15 0 (1 10)
150 (1 10)
150 (1 10)
185 (136)
185 (1 36)
185 (1 36)
150 (1 10)
• 1 5 0 (1 10)
Shackle To Hanger Nut
125 (9 2)
125 (92)
125 (9 2)
125 (92)
125 (92)
125 (92)
N/A
N/A
N/A
125 (92)
• 1 2 5 (92)
Shackle To H anger Bolt
15 0 (1 1 0 )
150 (110)
150 (1 10)
15 0 (110)
150 (110)
15 0 (1 1 0 )
185 (136)
185 (1 36)
185 (136)
150 (1 10)
• 1 5 0 (1 10)
•
For M odels with RPO JF9 or P 3 1 8 (3 2 ) Torque Spring to H anger Bolt to 2 0 0 N m (1 4 7 ft. lbs.) and Tighten Shcakle Fasteners to 135 N m (9 9 ft l b s )
’
Crew Cab M odel Torque is 7 0 N m (5 2 ft. lbs.) for Shock to Fram e, and 155 N m (1 14 ft. lbs.) for Shock to Axle.
“
Tighten The Nut To The Unthreaded Portion Of The Link Bolt.
**
Torque Is 2 4 0 N m (1 7 7 Ft. Lbs.) W hen Equipped W ith RPO JF9
3E-1
SECTION 3E
WHEELS AND TIRES
The following “ Notice” applies to one or more steps in the assembly procedure of components in this portion of
the manual as indicated at appropriate locations by the terminology: “ NOTICE: Refer to the ‘Notice’ on page 3E-1 of
this section.”
NOTICE: These fasteners are important attaching parts in that they could affect the performance of vital parts
and systems, and/or could result in major repair expense. They must be replaced with one of the same part
number or with an equivalent part if replacement becomes necessary. Do not use a replacement part of
lesser quality or substitute design. Torque values must be used as specified during reassembly to assure
proper retention of these parts.
CONTENTS
SUBJECT
PAGE
General D e s c rip tio n ................................................................................................................................................... 3E- 2
C ertification L a b e l................................................................................................................................................. 3E- 2
Tire Load Lim its And Inflation P re s s u re .......................................................................................................... 3E- 2
Diagnosis Of Wheels And T ir e s ..............................................................................................................................3E- 4
Checking Wheel And Tire R unout....................................................................................................................... 3E- 4
On-Vehicle S ervice..................................................................................................................................................... 3E- 5
Measuring Wheel And Tire R u n ou t..................................................................................................................... 3E- 5
Excessively Tight W h e e ls .................................................................................................................................... 3E- 7
Separating The Tire From The W h e e l............................................................. ..............................................3E- 7
M ounting The Tire On The W heel....................................................................................................................... 3E- 7
Installing The Wheel And Tire A ssem bly..........................................................................................................3E- 9
Alum inum Wheel R e fin is h in g ..............................................................................................................................3E- 9
Wheel And Tire B a la n cin g .................................................................................................................................... 3E-10
O ptional Spare Tire C a rrie rs ................................................................................................................................3E-10
S p e c ific a tio n s .............................................................................................................................................................. 3E-12
Wheel Runout S p e c ific a tio n s ............................................................................................................................. 3E-12
Wheel Stud Nut Torque (Single Front And Rear W h e e ls )............................................................................3E-12
Wheel Stud Nut Torque (Single Front And Dual Rear W h e e ls)................................................................... 3E-12
Tire Load Lim its And Inflation P re s s u re .......................................................................................................... 3E-13
Wheel Codes And Load L im it s ........................................................................................................................... 3E-13
3E-2 WHEELS AND TIRES
GENERAL DESCRIPTION
This section details special service procedures that
are not covered in the vehicle’s Owner’s Manual. For
jacking instructions, basic tire changing and rotation
instructions, and a detailed explanation of all other
owner-oriented information, refer to the proper section
in the vehicle’s Owner’s Manual.
CERTIFICATION LABEL
The certification label contains information used to
determine which tire size and type the vehicle uses.
For fu rth e r in fo rm a tio n , re fe r to G E N ER AL
INFORMATION (SEC. OA).
TIRE LOAD LIMITS AND
INFLATION PRESSURE
The factory installed wheels and tires are designed
to handle loads up to and including their rated load
capacity when inflated to the recommended inflation
pressures. Refer to “ Tire Load Limits And Inflation
Pressure” at the end of this section.
Correct tire pressures and driving techniques
influence tire life. Underinflated tires can cause
handling problems, poor fuel economy, shortened tire
life, and tire overloading. Heavy cornering, excessively
rapid acceleration, and unnecessary braking also
increase tire wear.
Important
• The use of wheels and/or tires with higher load
capacity ratings than originally equipped on the
vehicle will not increase the Gross Axle Weight
Rating (GAWR) or Gross Vehicle Weight Rating
(GVWR) of the vehicle.
WHEELS AND TIRES 3E-3
B-07463
Figure 1—Radial Tire Lead/Pull Diagnosis Chart
3E-4 WHEELS AND TIRES
DIAGNOSIS OF WHEELS AND TIRES
The following information (including figure 1) will help to identify certain tire-related durability and drivability
problems.
PROBLEM
POSSIBLE CAUSE
Excessive Heel And
Toe Wear
Excessive Tire
Edge(s) Wear
High speed driving, excessive use of
brakes.
1 . Inflate to recommended pressure.
2 . Correct as required—refer to certifi­
3. High speed cornering.
4. Incorrect toe setting.
cation label.
3. Correct as required.
4. Set to correct specifications.
Overinflated tires.
1.
2.
3.
4.
5.
Deflate to recommended pressure.
Improper tire pressure.
Incorrect tire and wheel usage.
Worn shock absorbers.
Front end out of alignment.
Loose, worn, or damaged steering link­
age, joints, suspension components,
bushings and/or ball joints.
6 . Out of balance wheel/tire.
Radial Tire Waddle
(Side To Side
Movement At Speeds
Between 5 and 15
MPH)
Vibration
Correct as required, rotate tires regu­
larly.
1. Underinflated tires.
2. Vehicle overloaded.
Excessive Tire Wear
(Center Of Tread)
Uneven Tire Wear
CORRECTION
1.
2.
3.
4.
5.
6 . Balance wheel/tire.
Worn tires.
1.
2.
3.
4.
Out of balance wheel/tire.
Tire runout.
Wheel runout.
Worn tire.
CHECKING WHEEL AND
TIRE RUNOUT
Some vehicles are sensitive to tire and wheel
assembly runout. Tires that are satisfactory on one
vehicle might be unsatisfactory on another. When
analyzing vibration problems, it is important to keep
this in mind. In addition, different wheel positions on a
vehicle may have different sensitivity levels. You
should check for wheel runout or total wheel and tire
runout in the following cases:
Inflate to recommended pressure.
Install correct tire-wheel combination.
Replace shock absorbers.
Align the front end.
Inspect, repair or replace as required.
Replace worn tires.
1.
2.
3.
4.
Balance
Replace
Replace
Replace
wheel/tire.
tire.
wheel.
tire.
— If the tire and wheel vibration occurs below 40
miles per hour.
— If all wheels are balanced well within one ounce
of static balance and five ounces of dynamic
balance, and’a vibration occurs.
— If there appears to be a bulge in a tire or an
out-of-round condition as a tire rotates on a
balancer.
— If any wheel damage is noticed.
— If there is a poor wheel fit on the hub and the
vehicle exhibits vibration.
WHEELS AND TIRES 3E- 5
ON-VEHICLE SERVICE
MEASURING WHEEL AND
TIRE RUNOUT
Runout m easurem ents of the wheel and tire
assembly can be taken both on and off the vehicle.
These measurements can be taken radially and
laterally. A dial indicator equipped with a roller contact
point, m ounted on a heavy, solid base is the
measurement device.
RADIAL RUNOUT
Radial runout is the egg-shaped difference from a
perfect circle. Measure tire radial runout from the
center tire tread rib although other tread ribs can be
measured as well. The total runout is the reading from
the gage, and the high spot is the location of the
maximum runout. On a rim, if either flange is beyond
specifications, replace the rim (figure 2 ).
LATERAL RUNOUT
Lateral runout is a sideways variation causing a twist
or wobble and is measured on a side surface. On the
tire and wheel assembly, measure the sidewall of the
tire as close to the trend shoulder design edge as
possible. The total runout is the reading from the gage,
and the high spot is the location of the maximum
runout. On a rim, if either flange is beyond guidelines,
replace the rim (figure 3).
• R otate a ga in to v e rify the low spot
location—-the dial indicator must return to
zero.
MEASUREMENT PROCEDURES
1. Inflate the tires to specifications.
2. Warm up the tires prior to taking measurements
to eliminate flat spotting.
• Newly installed tires usually do not require
warming up.
3. Raise the vehicle on a lift.
• If m easurem ents will be taken off the
v e h ic le , m ount each tire and w heel
assembly on a dynamic balance machine.
4 Mark the tire and wheel assemblies for exact
replacement.
• Mark a wheel hub bolt and its exact position
on the wheel.
• Mark each tire and wheel assembly for
re p la c e m e n t on the exact h u b /ro to r
assembly.
5. Take e ith e r a
measurement.
ra d ia l
or
la te ra l
ru n o u t
A.
B.
C.
D.
Tire High Spot
Wheel High Spot
Wheel Low Spot
Tire Low Spot
1 . Dial Indicator
B-07451
• Place the dial indicator in position.
• Rotate the tire and wheel assembly (or just
the wheel) to find its low spot. Adjust the dial
indicator to read zero.
Figure 3—Measuring Lateral Runout
3E-6 WHEELS AND TIRES
B
2.
3.
A.
B.
C.
D.
E.
Tire
Tire Reference Mark At 12 O’clock
First Measurement (High Spot)
Valve Stem At 12 O’clock
Second Measurement (High Spot)
Tire Reference Mark At 6 O’clock
B-07455
Figure 4—Checking Tire To Wheel Vectoring
• Disregard any instantaneous dial jumps due
to welds, paint runs, scratches, etc. on the
wheel.
• Rotate the tire and wheel assembly (or just
the wheel) and note the amount of variance
(runout) from zero. Locate and mark the
high spot.
6 . If th e re
is a la rg e d iffe re n c e in ru n o u t
measurements from ON vehicle to OFF vehicle,
the runout problem is likely due to excessive
runout of the bolt circle or hub.
7. If measured runouts are not within the guidelines
(located in “ Wheel Runout Specifications” at the
end of this section), proceed to “ Vectoring” to
correct the problem.
VECTORING
Vectoring is a technique used to reduce radial or
lateral runout—and even dynamic balance on tire and
wheel assemblies. Vectoring can be accomplished by
positioning of the tire on the wheel and positioning of
the tire and wheel assembly on the hub/rotor.
Im portant
Always rebalance the tire and wheel
assembly after vectoring.
Tire To Wheel Vectoring
1. Determine which runout needs to be minimized.
• Determine visually.
2. If ra d ia l ru n o u t is the p ro b le m , take a
measurement on the center tread rib.
• If the trend is uneven, wrap tape tightly
a round the tire , re co rd the ru n o u t
magnitude, and mark the high spot location
(figure 4).
A. Valve Stem And Tire Reference Mark
At 12 O’clock
B. First Measurement (High Spot)
C. Valve Stem At 12 O’clock
D. Second Measurement (High Spot)
E. Tire Reference Mark At 6 O’clock B-07505
Figure 5—Tire To Wheel V e c to rin g Excessive Tire Runout
3. If la te ra l ru n o u t is the p ro b le m , take a
measurement on the sidewall just below the edge
of the tread shoulder.
• Record the runout magnitude, and mark the
high spot location.
4. Mark the tire sidewall at the valve location.
• This is the 12 o’clock position.
• The location of the high spot is always with
respect to the clock location on the wheel.
5. Break the tire and wheel assembly down on a tire
mounting machine and rotate the tire 6 hours
(180°) on the rim (figure 4).
• Reinflate the tire and measure the runout in
question.
• Record the magnitude and the location of
the high spot. (Valve stem is 12 o’clock.)
6 . If the clock location of the high spot remained at
or near the clock location of the original high
spot, the rim is the major contributor to the runout
problem.
• Confirm by removing the tire from the wheel
and check the wheel rim runout.
• If the wheel rim runout exceeds guidelines,
replace the wheel.
7. If the clock position of the high spot is 6 hours
from the original high spot, the tire is the major
contributor to the runout problem (figure 5).
• Replace the tire.
8 . After correcting the tire to the wheel vectoring,
rebalance the wheel and tire assembly.
Tire And Wheel Assembly To Hub/Rotor Vectoring
1. Mark the wheel hub bolt nearest the valve stem
for reference (figure 6 ).
2. Rotate the assembly two wheel hub bolts and
recheck the runout (figure 6 ).
• Several positions may have to be tried to
locate the optimum location.
WHEELS AND TIRES 3E-7
• Follow the tire changing machine manufacturer’s
instructions to properly separate the tire from the
wheel.
MOUNTING THE TIRE ON
THE WHEEL
BIAS PLY TIRES
1. Clean the tire bead area.
Figure 6 —Tire And Wheel Assembly
To Hub/Rotor Vectoring
• This can be effective for both radial and
lateral runouts.
3. If there is some looseness in the wheel hub bolt
holes, radial runout can be reduced by loosening
the hub bolt nuts slightly, moving the wheel
position on the bolts and then retightening the
nuts.
4. Balance the tire and wheel to hub/rotor assembly.
• Compensates for any imbalance in the
brake rotor, drum, or wheel cover.
EXCESSIVELY TIGHT WHEELS
Use this procedure to remove the wheel and tire
assembly if it does not break free of the hub using a
standard removal procedure.
1. Tighten all the lug nuts on the affected wheel.
• Do not torque.
2. Raise the vehicle.
3. Loosen each nut two turns.
4. Lower the vehicle to the floor.
5. Rock the vehicle from side to side to loosen the
wheel. Or rock the vehicle from forward to reverse
allowing the vehicle to move several feet in each
direction. Apply quick, hard jabs on the brake
pedal to loosen the wheel.
6 . Raise the vehicle and remove the lug nuts and
2. Clean the rim bead seats with a wire brush or
coarse steel wool to remove lubricants, old
rubber, and light rust.
3. Apply an approved tire lubricant to the tire bead
area.
4. Attach the tire to the wheel.
• Use a tire changing machine. Follow the
equipment manufacturer’s instructions.
CAUTION: Do not stand over tire when
inflating. The bead may break when it snaps
over the safety hump, and cause serious
personal injury. Do not exceed 275 kPa (40
psi) pressure when inflating. If 275 kPa (40
psi) pressure will not seat beads, deflate,
re-lubricate and reinflate. Overinflation may
cause the bead to break and result in personal
injury.
5. Install a valve core and inflate to the specified
pressure (figure 2 ).
• The locating rings on each side of the tire
m u sti show above the rim fla n g e s ,
positioned in direct relation to the wheel (not
eccentric as compared with the rim).
6 . Check the bead seating.
• Tires must be mounted and inflated in
accordance with the safety precautions
included with the tire mounting equipment.
the wheel.
RADIAL PLY TIRES
SEPARATING THE TIRE
FROM THE WHEEL
NOTICE: Use a tire changing machine to
demount tires. Do not use hand tools or tire
irons alone to remove the tire from the wheel.
Damage to the tire beads or wheel rim could
result.
NOTICE: Recommended vehicle tire mounting
and inflation procedures are especially
important with radial tires. Failure to follow
these procedures can cause bead deformation
in both tube type and tubeless tires due to
incorrect bead seating. Bead deformation may
lead to chafing, lower sidewall and bead area
cracking, eccentric wear, ride vibration and
nonretreadable castings.
3E-8 WHEELS AND TIRES
Tube Type Tires
Important
• Only use rims approved for radial tire usage by
the rim manufacturer.
1. Clean the rim parts.
• Remove all rust and other foreign material.
• Make sure the rim parts match and are not
sprung or broken.
2. Lubricate the tire beads, the portion of the tube
between the beads, and the flaps with an
approved rubber lubricant.
• Radial tubes are identifiable by the letter
“ R” in the size designation. A red band in
the valve stem and an “ R” in the flap size
designation also identify radial parts.
NOTICE: Do not use silic o n e base
lubricants—this could cause the tire to slip on
the wheel.
3. Inflate to operating pressure, deflate completely,
and reinflate to operating pressure.
• Allows the tube, flap, and tire to fit together
properly.
4. Check the bead seating.
• Visually check the slot and side ring gap (on
two piece rims) to make sure the bead is
seated.
5. Check the spacing between the rim flange and
one of the three lower sidewall rim line rings while
the tire is laying flat to verify bead seating.
• Measurements must be taken each 90
degrees around the circumference of the
rim flange.
• If the spacing is uneven around the bead
from side to side, repeat steps 1 through 3,
then recheck.
Installing Synthetic Tubes
NOTICE: When the tube and the flap are not
properly lubricated, and mounted, they will
stretch thin in the tire bead and rim region.
This will cause premature wear.
1. Clean the inside of the casing.
2. Insert the tube in the tire and inflate until it is
nearly rounded out.
3. Inspect the rim for rust scale and bent flanges.
• Clean rust scale and straighten the flanges
where necessary.
4. Apply a solution of neutral vegetable oil soap to
the inside and outside of the tire beads, and also
the rim side of the tube.
• Use a brush or a cloth swab.
• Do not allow the soap solution to run down
into the tire.
5. Follow the standard procedure when mounting
the tube and tire on a drop center rim. Be sure
the tire is centered on the rim so the beads are
out of the rim well before inflating. Do not allow
the tire to hang loosely on the wheel while
inflating.
6 . Center the valve and pull it firmly against the rim.
Hold in this position and inflate until the tire
beads are firmly seated on the rim against the
flanges.
7. Remove the valve core to completely deflate the
tire.
8 . Reinflate the tire to the recommended pressure.
• Refer to “ Tire Load Limits And Inflation
Pressure” at the end of this section.
Tubeless Tires
Important
• Only use rims approved for radial tire usage by
the rim manufacturer.
1. Clean the rim.
• Remove all rust and other foreign material.
2. Lubricate tire beads and rim bead seats with an
approved rubber lubricant.
NOTICE: Do not use silic o n e base
lubricants—this could cause the tire to slip on
the wheel.
3. Inflate the tire to operating pressure.
• Due to the construction of radial truck tires,
particularly in the lower sidewall and bead
area, it may be difficult to get the tire to take
air.
• An inflation aid may be necessary to help
seat the bead of tubeless radial tires. Two
types of inflation aids are commercially
a v a ila b le — m etal rin g s w h ich
use
compressed air to seat beads, and rubber
rings which seal between the tire bead and
rim bead seat allowing the bead to move out
and seat. Lubrication is necessary with both
aids.
4. Check the spacing between the rim flange and
one of the three lower sidewall rim line rings while
the tire is laying flat to verify bead seating.
• Measurements must be taken each 90
degrees around the circumference of the
rim flange.
• If the spacing is uneven around the bead
from side to side, repeat steps 1 through 3,
then recheck.
WHEELS AND TIRES 3E-9
Tighten
• Nuts to “ S pecifications” at the end of this
section.
• Tighten evenly and alternately to avoid excessive
runout (figure 7).
DUAL WHEELS
Install or Connect (Figure 7)
Im portant
This procedure must be followed to insure proper
bead s e a tin g in o rd e r to p re ve n t bead
deformation.
Radial tires, as well as bias tires, must be
mounted and inflated in accordance with safety
precautions noted in RMA Radial and Bias Truck
Tire Service Manuals.
INSTALLING THE TIRE AND
WHEEL ASSEMBLY
CAUTION: Before re-installing the wheels,
remove any build up of corrosion on the
wheel m ounting surface and brake drum or
disc m ounting surface by scraping and wire
b ru s h in g . In s ta llin g w h e e ls w ith g o o d
m e ta l-to -m e ta l c o n ta c t at the m o u n tin g
surfaces can cause wheel nuts to loosen.
This can lead to a wheel com ing o ff while the
vehicle is moving, possibly causing loss of
control.
SINGLE WHEELS
“►4* Install or Connect (Figure 7)
1 . Wheel and tire assembly in position on the
hub/rotor, and lug nuts installed loosely.
1. Inner and outer wheel and clamp ring on the rear
wheel, or wheel and clamp ring on the front
wheel.
• Be sure the pins on the clamp ring face outward.
2. Lub nuts finger tight.
Tighten
• Nuts to “ Specifications” at the end of this
section.
• For P30 models, tighten to 210 N m (155 ft
lbs.), then tighten again to 237 N m (175 ft.
lbs.).
• Tighten evenly and alternately to avoid
excessive runout (figure 7).
Measure
• Lateral runout should not exceed 3.18 mm (0.125
inches) on the front wheel or 4.76 mm (0.187
inches) on the rear wheel.
ALUMINUM WHEEL REFINISHING
• Remove the tire and wheel assembly from the
vehicle.
• Mark the position of the wheel weights on the tire
for correct reinstallation after recoating the wheel.
Remove the wheel weights and mask off the tire.
1 . Remove the original clear coating.
• Apply a chemical stripper such as 3M brand
Troubleshooter to the wheel rim surface.
• Wait 10 to 15 minutes, then wet scrub the
su rfa ce using a 3M #98 S c o tc h b rite
Cleaning Pad (3M part number 07445).
• Rinse the surface thoroughly with clean
water.
2 . Turn the wheel until one nut is at the top of the
bolt circle. Tighten the nut just snug.
3. Snug up the rem aining nuts criss-cross to
minimize runout.
NOTICE: Refer to the “Notice” on page 3E-1
of this section.
CAUTION: Use of eye goggles is necessary
to prevent personal injury.
2. Remove surface oxidation.
• Use 3M Superbuff Buffing Pad (3M part
n um be r 05701) and a m edium type
compound such as 3M part number 05955
or 05931.
3E-10 WHEELS AND TIRES
• Hose off the rim with water and scrub with a
small brush to remove excess compound,
then air blow dry.
3. Recoat the wheels.
• Clean the surface of any contaminants
using Prekleno.
• Apply #801 Metal Conditioner, taking care to
use rubber gloves and a clean cloth during
the application. Keep the surface wet while
applying.
• Make sure #801 Metal Conditioner is reduced one
part metal conditioner to three parts of water.
• Wipe off #801 Metal Conditioner carefully while
the surface is still wet. Use a clean, dry cloth.
4. Apply the clear coat.
• Apply R & M’s 893 2K Clear with 894
Urethane Catalyst Hardener. Refer to the
label for specific directions.
• Wear proper respiratory protection such as
a 3M Paint Respirator (part number 06984)
or Easi-Air Respirator (part number 06986)
or equivalent.
5. Allow the wheel to air dry overnight (minimum)
before installing on the vehicle.
6 . Attach balance weights and install the wheel and
tire assembly on the vehicle.
• Mount the weights in the marked positions
and remove the masking from the tire.
B-07537
Figure 8 —Underbody Swing Out Spare Tire
Carrier (RPO P10)
• Follow the wheel balancer machine instructions
while performing the balancing operation.
WHEEL AND TIRE BALANCING
To insure successful, accurate balancing, the
following precautions must be observed:
• The wheel and tire must be clean and free
of all foreign matter.
• The tire should be in good condition and
properly mounted using the balance mark
on the tire, if any, or lined up with the
inflation valve.
• Bent wheels that have a runout over 1.6 mm
(Ve-inch) should be replaced.
• Inspect the wheel and tire assembly to
determ ine if an out-of-round condition
exists.
Im portant
A severe out-of-round condition cannot be
“ balanced out.” A wheel and tire assembly
having an out-of-round condition exceeding 4.7
mm (3/ie-inch) is not suitable for the front of the
vehicle. Its use on the rear of the vehicle must be
governed by its general condition and whether
the roundness problem seriously detracts from
overall ride quality.
OPTIONAL SPARE TIRE CARRIERS
UNDERBODY SWING OUT SPARE TIRE CARRIER
(RPO P10)
The underbody swing out spare tire carrier is
standard equipment on C-K 10/1500 series pickups. It
is available as an option (RPO P10) on C-K 20/2500
and 30/3500 series pickups (figure 8 ).
UNDERBODY GLIDE OUT SPARE TIRE CARRIER
(RPO P11)
The underbody glide out spare tire carrier is
available as an option (RPO P11) on all C-K series
pickups (figure 9).
SIDE PANEL MOUNTED SPARE TIRE CARRIER
(RPO P13)
The side panel mounted spare tire carrier is
available as an option on all C-K series pickups (figure
10).
WHEELS AND TIRES 3E-11
Figure 10—Side Panel Mounted Spare Tire Carrier (RPO P13)
3E-12 WHEELS AND TIRES
SPECIFICATIONS
WHEEL RUNOUT SPECIFICATIONS
Steel Wheels
Alum inum Wheels
Radial Runout
1.01 mm (0.04 inches)
0.76 mm (0.03 inches)
Lateral Runout
1.14 mm (0.045 inches)
0.76 mm (0.03 inches)
WHEEL STUD NUT TORQUE (SINGLE FRONT AND REAR WHEELS)
Series
Number Of Studs
Nut Torque
C10/1500
K10/1500
C 10/1500
K 10/1500
C-K 20/2500
C-K 30/3500
5 studs
6 studs
5 studs
6 studs
8 studs
8 studs
140 N-m (100 ft. lbs.) (steel wheels)
120 N-m (88 ft. lbs.) (steel wheels)
140 N-m (100 ft. lbs.) (aluminum wheels)
140 N-m (100 ft. lbs.) (aluminum wheels)
160 N-m (120 ft. lbs.) (all)
160 N-m (120 ft. lbs.) (all)
G 10/1500-20/2500
G 10/1500-20/2500
G 30/3500
5 studs
5 studs
8 studs
140 N-m (100 ft. lbs.) (steel wheels)
140 N-m (100 ft. lbs.) (aluminum wheels)
160 N-m (120 ft. lbs.) (all)
P20/2500 & 30/3500
8 studs
160 N-m (12 0 ft. lbs.) (all)
WHEEL STUD NUT TORQUE (SINGLE FRONT AND DUAL REAR WHEELS)
Series
Number Of Studs
Nut Torque
C-K 30/3500
8 studs
190 N-m (140 ft. lbs.) (all)
G 30/3500
8 studs
190 N-m (140 ft. lbs.) (all)
P 30/3500
P 30/3500
8 studs
10 studs
190 N-m (140 ft. lbs.) (with RPO JB 8 )
210 N-m (155 ft. lbs.) (with RPO JF9)
WHEELS AND TIRES 3E-13
TIRE AND WHEEL LOAD LIMIT CHARTS
(TIRE & WHEEL LOAD LIMITS ARE SHOWN BELOW. VEHICLE LOADING MUST BE LIMITED
SUCH THAT NEITHER THE WHEEL OR TIRE INFLATION PRESSURE OR LOAD LIMITS ARE
EXCEEDED).
RADIAL TIRE SIZE AND LOAD LIMITS - kg (LBS)
Metric Radial Tires Used As Singles
Metric Radial Tires Used As Singles (Cont.)
Inflation Pressure - kPa (PSI)
400 (58)
|
500 (73)
450 (65)
|
550 (80)
Inflation Pressure - kPa (PSI)
Tire
Load
Size
Range
250 (36)
LT215/85R16
C
695
(1532)
790
(1742)
880
(1940)
LT215/85R16
D
695
(1532)
790
(1742)
880
(1940)
LT235/85R16
D
790
(1742)
900
(1984)
1000
(2205)
LT235/85R16
E
790
(1742)
900
(1984)
1000
(2205)
|
300 (44)
|
350 (51)
965
(2127)
1050
(2315)
1100
(2425)
1190
(2623)
1100
(2425)
1190
(2623)
1290
(2844)
1380
(3042)
Metric Radial Tires Used As Duals (Cont.)
Inflation Pressure - kPa (PSI)
Metric Radial Tires Used As Duals
Tire
Load
300 (44)
|
870
(1918)
955
(2105)
500 (73)
550 (80)
350 (51)
Size
Range
250 (36)
C
630
(1389)
720
(1587)
800
(1764)
LT215/85R16
D
630
720
(1587)
800
(1764)
|
(1389)
BIAS TIRE SIZE AND LOAD LIMITS -
Bias Tires Used As Singles (Cont.)
kg (LBS)
Inflation Pressure - kPa (PSI)
Bias Tires Used As Singles
345 (50)
379 (55)
|
414 (60)
993
(2190)
1048
(2310)
1107
(2440)
993
(2190)
1048
(2310)
1107
(2440)
|
448 (65)
|
483 (70)
517 (75)
1211
(2670)
1261
(2780)
Inflation Pressure - kPa (PSI)
Tire
Load
Size
Range
207 (30)
7 50 16
C
735
(1620)
803
(1770)
875
(1930)
934
(2060)
7 50-16
D
735
(1620)
803
(1770)
875
(1930)
(2060)
735
(1620)
803
(1770)
875
(1930)
934
2060
E
450 (65)
Inflation Pressure - kPa (PSI)
LT215/85R16
7 50-16
400 (58)
|
241 (35)
|
276 (40)
|
310 (45)
934
1161
(2560)
Bias Tires Used As Duals (Cont.)
___________ _____________ Inflation Pressure - kPa (PSI)_________________________
Bias Tires Used As Duals
Load
Size
Range
207 (30)
7 50-16
C
649
7 50-16
D
345 (50)
I
379 (55)
|
414 (60)
|
448 (65)
|
483 (70)
[
517~(75[
Inflation Pressure - kPa (PSI)
Tire
|
241 (35)
|
276 (40)
|
767
310 (45)
(1430)
710
(1565)
(1690)
823
(1815)
649
(1430)
710
(1565)
767
(1690)
823
(1815)
B-07548
875
(1930)
925
(2040)
971
(2140)
B-07549
Figure 11—Tire Load Lim its And Inflation
Pressure (C-K)
Figure 12—Tire Load Lim its And Inflation
Pressure (C-K)
TIRE LOAD LIMITS AND
INFLATION PRESSURE
WHEEL CODES AND LOAD LIMITS
Refer to Figures 11, 12, 14, 15, 17, and 18 for tire load
limits given an inflation pressure range.
Refer to Figures 13, 16, and 19 for wheel load limits
for each wheel size (coded).
3E-14 WHEELS AND TIRES
TIRE AND WHEEL LOAD LIMIT CHARTS
(Tire and wheel load limits are shown below. Vehicle loading must be limited so that neither
the wheel or tire inflation pressure or load limits are exceeded)
_______________ Tire Load Limits: Bias Tires Used As Singles — kg (lbs)
Inflation Pressure — kPa (PSI)
Code *
Wheel
Size
Max. Load
kg (ibs.)
Max. Pressure
kPa (psi)
AA
1 6 x 6 .5
1,381 (3 045)
621 (90)
AF
16x6
1,107 (2 440)
517 (75)
16.5
BF
16 x 16.5
1,261 (2 780)
586 (85)
8.00 -
617
676
730
785
835
16.5
(1 360)
(1 490)
(1 610)
(1 730)
(1 840 )
Tire
Size
8 .00 -
Load
207
241
276
310
345
Range
(30)
(35)
(40)
(45)
(50)
C
617
676
730
785
(1 360)
(1 490)
(1 610)
(1 730)
BK
15x7
757 (1 670)
276 (40)
CF
15 x 7
757 (1 670)
276 (40)
16.5
CK
15x8
866 (1 910)
276 (40)
8.75 -
712
7 80
839
903
957
16.5
(1 570)
(1 720)
(1 850)
(1 990)
(2 110)
DAB
15x8
921 (2 030)
276 (40)
DAC
15x8
921 (2 030)
282 (41)
GBA
15x8
900 (1 984)
282 (41)
8.75-
D
712
780
839
903
957
(1 570)
(1 720)
(1 850 )
(1 990)
(2 110)
Tire Load L im its: Bias Tires Used As Duals — kg (lbs)
Infla tio n Pressure — kPa (PSI)
GBB
15x7
921 (2 030)
282 (41)
Tire
Size
UA
15 x 7
921 (2 030)
282 (41)
8.00-
XAH
15x6
900 (1 984)
438 (70)
XH
15x6
719 (1 585)
276 (40)
CC
15x6
757 (1 670)
379 (55)
XX
15 x 6
925 (2 040)
483 (70)
16 5
8 0016 5
Load
Range
C
D
207
(30)
241
(35)
276
(40)
310
(45)
542
594
642
689
(1 195)
(1 310)
1 41-3
(1 520)
345
(50)
542
594
642
689
735
(1 195
(1 310)
(1 415)
(1 520)
(1 620)
Tire Load Lim its: Radial Tires Used As Singles — kg (lbs)
* Wheel code is located on the wheel just to the right of the valve stem
hole.
In fla tio n Pressure — kPa (PSI)
Tire
Size
8 .7 5
R 1 6 .5
B-08072
Figure 13—Wheel Codes And Load Lim its
(C-K)
Load
Range
E
207
(30)
241
(35)
276
(40)
310
(45)
345
(50)
712
780
839
903
(1 570)
(1 720)
(1 850)
(1 990)
B-08074
Figure 14—Tire Load Lim its And
Inflation Pressure (G)
WHEELS AND TIRES 3E-15
TIRE LOAD LIMIT CH A R TS
Tire Load Limits: Bias Tire Used As Singles — kg (lbs.) (Cont.)
Inflation Pressure — kPa (PSI)
379
414
448
(55)
(60)
(65)
483
(70)
517
552
(75)
(80)
(Tire load limits at different inflation pressures are shown below. Vehicle loading must be
limited such that neither the tire inflation pressures or load limits are exceeded).
METRIC RADIAL TIRES 882
928
(1 945)
(2 045 )
1016
Load
Range
Tire
Size
(2 350)
1016
1066
1120
1166
1216
(2 240)
(2 350)
(2 470 )
(2 570)
(2 6 8 0 )
250 (36)
300 (44)
350 (51)
S
695 (1532)
790 (1742)
880 (1940)
LT215/85R16
D
LT215/85R16
Tire Load Limits: Bias Tires Used As Duals — kg (lbs.) (Cont.)
LT235/85R16
D
LT235/85R16
E
Inflation Pressure — kPa (PSI)
379
(55)
414
448
(65)
(60)
776
816
(1 710)
(1 800)
517
552
(80)
(75)
(2 110)
414
720 (1587)
800 (1764)
695 (1532)
790 (1742)
880 (1940)
D
630 (1389)
720 (1587)
800 (1764)
S
790 (1742)
900 (1984)
1000 (2205)
790 (1742)
900 (1984)
1000 (2205)
S
-
Tire
Load
Single
Size
Range
Dual
kg (LBS.)
Inflation Pressure ■ kPa (PSI)
379 (55)
345 (50)
310 (45)
S
D
On Iy .0
D
(60)
448
(65)
(70)
(75)
(80)
1016
1 066
1120
1166
1216
(2 240)
(2 350 )
(2 470 )
(2 570)
(2 680)
483
517
552
B-08075
BIAS TIRES -
Figure 15—Tire Load Lim its And Inflation
Pressure (G)
Single
Range
Dual
207 (30)
241 (35)
276 (40)
310 (45)
S
735 (1630)
803 (1770)
875 (1930)
934 (2060)
7 50-16
0
7 50-16
15 x 6.5
835 (1 843)
282 (41)
GBC
15 x 6 5
835 (1 843)
282 (41)
XH
15 x 6
719 (1 585)
15 x 6
900 (1 984)
649 (1430)
710 (1565)
767 (1690)
823 (1815)
s
735 (1620)
803 (1770)
875 (1930)
934 (2060)
D
649 (1430)
710 (1565)
767 (1690)
823 (1815)
S
735 (1620)
803 (1770)
875 (1930)
934 (2060)
839 (1850)
903 (1990)
839 (1850)
903 (1990)
s
D
DAS
XAH
0
-
Wheel Code and Load Limits
Max. Load
- kg (lbs.)
Max. Pressure
- kPa (PSI)
276 (40)
483 (70)
VH
16.5 x 6
1216 (2 680)
586 (85)
XJ
16 5 x 6 75
1216 (2 680)
586 (85)
'W heel code is located on the wheel just to the right ot the valve stem hole.
B-08076
Figure 16—Wheel Codes And Load Lim its
(G)
Inflation Pressure — kPa (PSI)
Load
Size
8 -1 9 5
Wheel
Size
kg (LBS.)
Tire
7.50-16
Code *
630 (1389)
STANDARD RADIAL TIRES -
Inflation Pressure — kPa (PSI)
957
D
S
-
483
(70)
Tire Load Limits: Radial Tires Used As Singles — kg (lbs.) (Cont.)
379
(55)
Inflation Pressure - kPa (PSI)
Single
Dual
1 066
(2 240)
kg (LBS.)
8-19 5
E
S
D
B-08077
Figure 17—Tire Load Lim its And
Inflation Pressure (P)
3E-16 WHEELS AND TIRES
TIRE LOAD LIMIT CHARTS (CONT.)
METRIC RADIAL TIRES (CONT.) -
kg (LBS.)
Inflation Pressure - kPa (PSI)
400 (58)
450 (65)
965 (2127)
1050(2315)
870 (1918)
955 (2105)
1100 (2425)
1190 (2623)
1100 (2425)
1190 (2623)
500 (73)
550 (80)
1290 (2844)
1380 (3042)
STANDARD RADIAL TIRES (CONT.) -
kg (LBS.)
Inflation Pressure — kPa (PSI)
414 (60)
448 (65)
483 (70)
517 (75)
552 (80)
1030 (2270)
1093 (2410)
1152 (2540)
1216 (2680)
1270 (2800)
1012 (2230)
1066 (2350)
1116 (2460)
BIAS TIRES (CONT.) -
kg (LBS.)
Inflation Pressure — kPa (PSI)
345 (50)
379 (55)
414 (60)
993 (2190)
1048 (2310)
1107 (2440)
875 (1930)
925 (2040)
971 (2140)
993 (2190)
1048 (2310)
1107 (2440)
957 (2110)
1030 (2270)
957 (2110)
1012 (2230)
957 (2110)
957 (2110)
448 (65)
483 (70)
517 (75)
1161 (2560)
1211 (2670)
1261 (2780)
1093 (2410)
1152 (2540)
1216 (2680)
1270 (2800)
1066 (2350)
1116 (2460)
1030 (2270)
1093 (2410)
1152 (2540)
1216 (2680)
1270 (2800)
1012 (2230)
1066 (2350)
1116 (2460)
1166 (2570)
1216 (2680)
B-08078
Figure 18— T ire Load L im its And
In fla tio n Pressure (P)
WHEEL CODE AND LIMITS
Code*
Wheel
Size
Max Load
kg (Lbs.)
Max Pressure
kPa (PSI)
AA
16 x 6.5 L
1381 (3045)
621 (90)
AF
16 x 6 K
1107 (2440)
517 (75)
BF
16 x 6.5 L
1261 (2780)
586 (85)
ZT
19.5 x 6
1261 (2780)
655 (95)
ZY
19.5 x 6
1152 (2540)
552 (80)
‘ W heel co d e is lo ca te d on the w h e e l ju s t to the rig h t o f the
valve ste m hole.
B-08079
Figure 19— W heel Codes And Load L im its
(P)
4A-1
SECTION 4A
PROPELLER SHAFT
The following “ Notice” applies to one or more steps in the assembly procedure of components in this portion of
this manual as indicated at appropriate locations by the terminology “ Notice: See ‘NOTICE’ on page 4A-1 of this
section” .
NOTICE: A ll p ro p e lle r s h a ft fa ste n e rs are im p o rta n t a tta ch in g parts in th a t th e y co u ld a ffe ct the perform ance
o f v ita l parts and system s, a n d /o r co u ld re su lt in m ajor repair expense. They m ust be replaced w ith one o f
the sam e part n u m ber o r w ith an e q u iva le n t part if replacem en t becom es necessary. Do n ot use a replace­
m ent part o f lesser q u a lity o r s u b s titu te design. T orque values m ust be used as sp e cifie d d u rin g reassem bly
to assure p ro p e r re te n tio n o f all parts.
CONTENTS
SUBJECT
PAGE
D e s c rip tio n ............................................. ..........................................................................................................................4 A - 2
P ro p e lle r S h a f t ............................................................................................................................................................. 4 A - 2
C enter B e a r in g ............................................................................................................................................................. 4 A - 2
U niversal J o i n t ............................................................................................................................................................. 4 A - 2
D ia gn osis Of D rive line V ib ra tio n (Road T e s t) ..........................................................................................................4 A - 4
D iagnosis Of P ro p eller S haft and U niversal J o i n t .................................................................................................4 A - 4
O n-V ehicle S e r v ic e ......................................................................................................................................................... 6
P ro p e lle r S haft Balance C h e c k ................................................................................................................................ 6
P ro p e lle r S haft R unout C h e ck...................................................................................................................................4 A - 6
P ro p e lle r S haft R eplacem ent (Rear D riv e )............................................................................................................ 4 A - 8
P ro p e lle r S haft R eplacem ent (F ro nt D r iv e ) ..........................................................................................................4 A - 9
L u b r ic a tio n .........................................................................................................................................................................4A -11
S p e c ific a tio n s .................................................................................................................................................................... 4 A -1 2
S pecial T o o ls .................................................................................................................................................................... 4 A -1 2
4A-2 PROPELLER SHAFT
DESCRIPTION
Figure 1— P ro p eller Shaft A ssem bly Phased
PROPELLER SHAFT
Torque is transmitted from the transmission to the
rear axle through one or more propeller shafts and
universal joint assemblies. The number of propeller
shafts and universal joint assemblies vary with the
v e h ic le w heel base, and the c o m b in a tio n of
transmission, transfer case (front drive) and rear axle
equipment.
All propeller shafts are the balanced tubular type
(figure 1). A splined slip joint is provided in some
drivelines and others use a companion flange at the
transmission end of the driveline. If two or more
propeller shafts are used on a vehicle the slip joint is
usually at the forward end of the rear propeller shaft.
Phasing
The propeller shaft is designed and built with the
yoke lugs (ears) in line with each other (figure 1). This
design produces the smoothest running shaft possible,
and is called phasing.
Vibration can be caused by an out of phase propeller
shaft. The propeller shaft will absorb vibrations from
speeding up and slowing down each time the universal
joint goes around. This vibration would be the same as
a person snapping a rope and watching the “ wave”
reaction flow to the end. A propeller shaft working in
phase would be similar to two persons snapping a rope
at the same time, and watching the “ waves” meet and
cancel each other out. In comparison this would be the
same as the universal joints on a propeller shaft. A
total cancellation of vibration produces a smooth flow
of power in the driveline. It is very important to
reference mark the propeller shaft before removal, to
assure phased installation alignment. Some propeller
shafts have alignment marks or arrows stamped on the
shaft at the time of production.
CENTER BEARING
Center bearings support the driveline when two or
more propeller shafts are used. The center bearing is a
ball type bearing mounted in a rubber cushion that is
attached to a frame crossmember. The bearing is
pre-lubricated and sealed by the manufacturer (figure
2).
UNIVERSAL JOINT
A universal joint is two Y-shaped yokes connected by
a crossmember called a spider. The spider is shaped
like a cross having arms of equal length called trun­
nions (figure 3).
Universal joints are designed to handle the effects of
various loadings and rear axle w indup d uring
acceleration. Within the designed angle variations the
universal joint will operate efficiently and safely. When
the design angle is changed or exceeded the
operational life of the joint may decrease.
The trunnion bearings used in universal joints are
the needle roller type. The needle rollers are held in
place on the trunnions by round bearing cups. The
bearing cups are held in the yokes by e ith e r
(depending on the manufacturer) snap rings or injected
plastic.
When a driveline has a large or deep angle a
constant velocity joint is used. Essentially, the constant
velocity joint is made of two universal joints coupled by
a yoke and phased for constant velocity. A centering
PROPELLER SHAFT 4A-3
12.
13.
14.
15.
Hanger Assembly and Crossmember
Center Bearing Support
Front Propeller Shaft
Rear Propeller Shaft
Bolt
Retainer
Pinion Flange
Yoke and Cross
Assembly
Splined Shaft
Cap
Washer
Seal (Cork)
Nut
Transmission Yoke
Washer
Bolt
Universal Joint
Slip Yoke
B-06720
F igure 2— C enter B earing A nd P ro p e lle r S haft Detail
ball socket between the joints keeps a relative position
between the two joints. This centering device causes
each of the two units to operate through one half of the
complete angle between the propeller shaft and the
differential carrier (figure 4). The ball socket on a con
stant velocity universal joint requires periodic lubrica­
tion through the fitting provided.
A
A. Ball Socket
B-06813
Figure 4—C onstant V e lo city J o in t (S im p lifie d )
Figure 3—Simple Universal Joint
4A-4 PROPELLER SHAFT
DIAGNOSIS OF DRIVELINE VIBRATION
(ROAD TEST)
Four major component groups are usually the cause
of or are related to vibration. When a technician is road
testing a vehicle for vibration he must remember the
four major component groups:
1.
2.
3.
4.
Engine and mounts.
Clutch and transmission.
Tires, wheels and brake drums.
Propeller shaft and universal joints.
Before road testing a vehicle, check the following:
1. In or out of phase propeller shaft.
2. All fasteners for tightness at universal joints,
wheel lugs and engine mounts.
3. Tire air pressure.
4. Load conditions.
ROAD TEST
A technician should road test the vehicle to diagnose
exactly what the complaint is. Record the speed and
rpm at which the greatest vibration occurs. The
vibration is likely to be in two places, in the steering
wheel or in the seat bottom. The road test can be
helpful in locating the vibration source either forward or
aft.
COAST TEST
Drive the vehicle past the vibration speed, shift into
neutral and coast back through the vibration speed. In
this test two kinds of vibration normally occur; a
shaking or a buzzing. A shaking vibration is usually
tires or a wheel and brake drum /disc assembly
problem. A buzzing vibration is usually a driveline
problem.
DIAGNOSIS OF THE PROPELLER SHAFT AND
UNIVERSAL JOINT
PROBLEM
Leak A t The F ront
S lip Yoke (An
O ccasional D rop Of
L u b rica n t Leaking
From The S plined
Yoke Is N orm al And
R equires No
A tte n tio n )
U niversal J o in t N oise
Ping, Snap, Or C lick
In Drive Line (U sually
Heard On In itia l Load
A fte r The
T ransm issio n Is In
Gear; Forw ard Or
Reverse)
POSSIBLE CAUSE
CORRECTION
1. Rough su rfa ce on sp lin e d yoke;
burred, nicked or worn.
1. Replace the seal. Minor burrs can be
smoothed by careful use of crocus
cloth or fine stone honing. Replace
the yoke if badly burred.
2. Replace the transmission rear oil
seal and replenish the transmission
oil.
2 . Defective transmission rear oil seal.
1.
2.
3.
4.
Center bearing.
Worn universal joint bearings.
Improper lubrication.
Loose flange bolts.
1 . Loose bushing
bolts on the rear
springs or upper and lower control
arms.
2. Loose or out of phase companion
flange.
1. Replace the center bearing.
2 . Replace.
3. Lubricate as directed.
4. Tighten to “ Specifications” .
1. Tighten the bolts to specified torque.
2. Remove companion flange, turn 180
degrees from its original position, lu­
b rica te the s p lin e s and in s ta ll.
Tighten the bolts and pinion nut to
specified torque.
PROPELLER SHAFT 4A-5
DIAGNOSIS OF THE PROPELLER SHAFT AND
UNIVERSAL JOINT (CONTINUED)
PROBLEM
K nocking Or
Clunking Noise In
The D riveline When
Operating The
Vehicle In A Floating
C ondition In High Or
Neutral Gear At 10
MPH (16 km/h)
Roughness Or
V ibration
I
POSSIBLE CAUSE
1. Worn or damaged universal joint.
2. Side gear hub counterbore in the dif­
ferential is worn oversize.
1. Bent or dented propeller shaft.
2. Undercoating on propeller shaft.
3. Tire unbalance, 30-80 mph (48129 km/h). Not throttle conscious.
4. Tight universal joints.
5. Worn universal joints.
6 . Burrs or gouges on companion flange.
Check snap ring locating surfaces on
flange yoke.
7. Propeller shaft, parking brake drum or
companion flange is unbalanced.
8 . Incorrect rear joint angle. The angle is
usually too large when it is a factor.
9. Excessive looseness at the slip spline.
10. D istorted or dam aged yokes or
flanges.
1 1 . Yokes out of phase.
12. Propeller shaft runout at 50 mph (80
km/h). Throttle conscious.
CORRECTION
1. Replace the worn or damaged uni­
versal joint.
2. Replace the differential case and/or
the sidegears.
1. Replace propeller shaft.
2. Clean propeller shaft.
3. Balance or replace as required.
4. Impact yokes with a shaft hammer to
free up. If unable to free up or if joint
feels rough when rotated, replace.
5. Replace.
6 . Rework or replace the companion
flange.
7. Check for a missing balance weight
on the propeller shaft. Rotate the
companion flange 180 degrees.
8 . Check and correct trim height at curb
weight. Check and correct joint an­
gle.
9. Replace necessary parts.
10. Install new yokes or flanges.
1 1 . Remove companion flange, turn 180
degrees from the original position, lu­
bricate the splines and install.
Tighten bolts to specified torque.
1 2 . Check propeller shaft runout at front
and rear. Should be less than speci­
fied. If above, rotate propeller shaft
180 degrees and recheck. Replace
the propeller shaft if runout is still
over specification.
Scraping Noise
Slinger, companion flange, or end yoke
rubbing on rear axle or center bearing.
Correct the interference.
Roughness Above
Tires unbalanced or worn.
Balance or replace as required.
35 MPH (56 km/h)
Felt And/O r Heard
Squeak
1. Lack of lubricant.
2. Center bearing.
1. Lubricate joints and splines. Also
check for worn or brinelled parts.
2 . Replace or lubricate.
4A-6 PROPELLER SHAFT
DIAGNOSIS OF THE PROPELLER SHAFT AND
UNIVERSAL JOINT (CONTINUED)
POSSIBLE CAUSE
PROBLEM
Whine Or Whistle
Shudder On
Acceleration, (Low
Speed)
CORRECTION
Center support bearing.
Place the vehicle on a hoist with rear
wheels free to rotate and diagnose
for source of noise, replace.
1. Loose or missing bolts at the center
bearing or flanges.
2. Incorrectly set front joint angle.
3. Worn universal joint.
1 . Replace or tighten bolts to specified
torque.
2. Shim under the transmission support
mount to change the front joint angle.
3. Replace.
ON-VEHICLE SERVICE
PROPELLER SHAFT
BALANCE CHECK
• Raise the vehicle on a twin post hoist so the
wheels can spin.
Remove or Disconnect
1 . Tire and wheel assemblies and the brake drums.
• DO NOT APPLY THE BRAKE WITH THE
DRUMS REMOVED.
I*
□
Install or Connect
1. Propeller shaft.
• Determine the position which gives the best
balance.
2. Rear drums, wheel and tire assemblies.
• Determine the position which gives the best
driveline response by road testing the
vehicle for a final check of the propeller
shaft balance.
• Unacceptable balance, replace the propeller
shaft.
Inspect
P ro p e lle r sh aft, u niversa l jo in ts and
attachments for mud, undercoating or loose
fasteners.
(m
j,
Clean
P ro p e lle r sh aft, u niversa l jo in ts and
attachments.
Tighten
Any loose attachments or fasteners.
PROPELLER SHAFT
RUNOUT CHECK
Noise or vibration at high speed could be caused by
a bent propeller shaft. The propeller shaft could have
been damaged by rough handling or a collision. Check
for propeller shaft straightness.
1 . Raise the vehicle on a twin post hoist so the
wheels can spin.
2. Attach a dial indicator having a magnetic base to
a smooth place on the vehicle underbody.
3. Take dial indicator readings at the propeller shaft
check points shown in figure 5. For runout
specifications, refer to figure 6 .
Im portant
Important
• Run the vehicle in gear at the speed where
the disturbance peaks; observe the intensity
of the disturbance.
• Stop the engine.
2. Propeller shaft.
• Rotate the propeller shaft 180 degrees from
the original position.
• Do not attach the dial indicator base at a
weld.
4. With the transmission in neutral, hand rotate the
axle pinion flange or the transmission yoke and
take the necessary dial indicator readings on the
propeller shaft. Record the readings. Models
PROPELLER SHAFT 4A-7
JL
«=dj
\
B
2d
.
&
A.
B.
C.
D.
E.
1.
2.
f
.
t
\
Check Front Runout
Check Center Runout
Check Rear Runout
Check Splined Shaft Runout At Tapered Hole In Splined End
Check Front Runout
One Piece Propeller Shaft Or Rear Propeller Shaft In A Two-Piece Driveline
Front Propeller Shaft In A Two-Piece Driveline
B-07556
Figure 5—Checking Propeller Shaft Runout
PROPELLER
SHAFT
FRONT
CHECK
CENTER
CHECK
REAR
CHECK
0.050
0.055
ONE PIECE
0.040
TWO PIECE
FRONT
0.020
TWO PIECE
REAR
0.030*
0.008A
0.030
0.035
ANOTE: This measurement must be taken at
the tapered hole on the splined shaft after the
rear propeller shaft is removed.
having a two-piece driveline, measure the rear
propeller shaft runout (figure 5). Reference mark
the position of the rear propeller shaft yoke to the
pinion flange, then remove the rear propeller
shaft and measure the front propeller shaft
runout on the tube and at the tapered hole on the
splined shaft end (figure 5). If the runout exceeds
specification, rotate the propeller shaft 180
degrees at the companion flange and install.
Check the runout.
5. If the runout is still over specification at one or
more check points, replace the propeller shaft
after checking for vibration or noise. Check the
runout on the replacement propeller shaft.
6 . If the new p ro p e lle r sh aft runout is over
specification, check for a bent companion flange.
* NOTE: This measurement must be taken
with the rear propeller shaft mounted on the
front shaft which is w ithin specifications.
B-07557
Figure 6—Propeller Shaft Runout Specifications
Im portant
• The splined end of the front propeller shaft
is critical to the smooth operation of a
tw o-piece d rive lin e . Be sure the dial
indicator readings are accurate.
4A-8 PROPELLER SHAFT
PROPELLER SHAFT
REPLACEMENT (REAR DRIVE)
0
•
1.
2.
3.
4. For twisted slip yoke splines or possibly the
wrong universal joint.
Install or Connect (Figures 2 and 7)
Remove or Disconnect (Figure 2)
Tool Required:
J-33051, Driveshaft Wrench.
Raise the vehicle on a hoist.
Skid plate if used.
• Reference mark the propeller shaft (4) to
pinion flange (7) connection.
Bolts (5).
Retainers(6 ).
Im portant
• Do not pound on the original propeller shaft
yoke ears. The injection joints may fracture.
Never pry or place any tool between a yoke
and a universal joint.
4. Yoke and cross assembly (8 ).
• Tape bearing cups to prevent the loss of
bearing rollers.
5. Propeller shaft (4).
• Slide the propeller shaft (4) forward.
• Lower the propeller shaft (4) and withdraw
under the rear axle.
• Do not allow the universal joint (17) to incline
greatly; the joint may fracture.
Models with a two-piece propeller shaft
6 . Nut (13).
7. Bolt (16) and washer (15).
8 . Center bearing support (2).
• Support the propeller shaft (3).
9. Cap (10).
10. Washer (11).
11. Seal (12).
12. Front propeller shaft (3).
• Always support the propeller shaft (3).
• Do not allow the universal joint (14) to bend
deeply as the universal joint could fracture.
• Withdraw the propeller shaft (3) with a
rearward movement.
One-Piece Propeller Shaft
1. Propeller shaft (4) into the transmission.
• Lubricate slip joint.
2. Yoke and cross assembly (8 ) onto the pinion
flange (7).
• Align the reference marks on the pinion
flange (7) and the propeller shaft rear yoke
(8 ). Seat the yoke properly.
3. Retainer (6 ).
4. Bolt (5).
Tighten
• Bolt (5) to torque in “ Specifications” at the
end of this section.
Two-Piece Propeller Shaft
1. Propeller shaft (3) into the transmission.
• Be sure joint is lubricated.
• Bottom the propeller shaft (3) yoke in the
transmission.
2 . Center bearing support (2) onto hanger ( 1 ).
• Align the center bearing support 90 degrees
to the propeller shaft (3, 4) center lines.
Refer to figure 7.
3. Bolt (16).
4. Washer (15).
5. Nut (13).
NOTICE: See“Notice” on page 4A-1 of this
section.
Nut (13) to torque specification later in
this section. Maintain alignment (figure 7).
Important
IQ* Clean
All parts.
6.
I*
Inspect
1. Outer diameter of transmission yoke (14) for
burrs. Any burring will damage the transmission
seal.
2. For proper installation and uniform seating of
bearing cups.
3. Slip yoke (18) splines for wear.
7.
8.
9.
• Set the transmission yoke (14) ears in a
vertical position for proper phasing (figure
7).
Cap (10).
Washer (11).
Seal (12).
• Locate the bridged tooth on the splined
shaft (9).
Slip yoke (18) onto the splined shaft (9).
• Mate the missing tooth in the yoke (18) with
the bridged tooth on the splined shaft (9)
figure 7. Support the propeller shaft (4).
PROPELLER SHAFT 4A-9
Hanger Assembly
Center Bearing Support
Front Propeller Shaft
Rear Propeller Shaft
Transmission Yoke
Slip Yoke
Horizontal Center Line At The Yoke
90 ± 1 Degree Angle For Slotted Hanger Holes
Vertical Center Line At The Yoke
B-07562
Figure 7—Alignm ent For Two-Piece Propeller Shaft In Phase, G And K Models
• Be sure the s lip yoke (18) ears are
horizontal, figure 7.
10. Propeller shaft (4).
• Align reference marks.
• Check bearings for proper fit.
11. Retainer (6 ).
12. Bolt (5).
• Check for proper joint fit.
Tighten
1 . Slip yoke (13) from the front axle yoke (12).
— Nut (10), washer (11) and U-bolt (15).
— Bolt (20) and retainer (22).
Im portant
• Do not pound on the joint to disconnect.
2. Bolt (18) at the flange (17).
3. Boot (21) if used.
• Bolts (5) to specified torque. Refer to
“ Specifications” at the end of this section.
• Lubricate the slip yoke (18).
• Release boot retainers using J-22610.
• Slide the propeller shaft (14) forward,
enough to disengage, then withdraw the
propeller shaft (14) rearward.
PROPELLER SHAFT
REPLACEMENT (FRONT DRIVE)
• Avoid dropping cap assemblies from the
yoke ends.
jjjJJ* Clean
|<~+| Remove or Disconnect (Figure 8)
• All parts.
Tool Required:
J-22610, Keystone Clamp Pliers.
• Raise the vehicle on a hoist.
• Remove skid plate if used.
• Reference mark the relationship of the
propeller shaft (14) to the front axle and the
transfer case flange (17).
I?
Inspect
Splines for damage, wear, burrs and twisting.
Bearings for wear.
Propeller shaft (14) for straightness.
4A-10 PROPELLER SHAFT
Front Axle Yoke
Slip Yoke
Propeller Shaft Assembly
U-bolt
Transfer Case
Flange
Bolt
Constant Velocity Joint
Bolt
Boot
Retainer
Front Axle Assembly
Washer
Clamp
B-07561
Figure 8 —Front Propeller Shaft and Driveline Detail
Install or Connect (Figure 8)
Tools Required:
J-22610, Keystone Clamp Pliers.
J-25512, CV Propshaft Lube Gun (Ve-inch
pipe).
J-25512-2, Needle point.
• Lubricate the slip yoke (13) before installing
the boot (21). Refer to “ Lubrication” later in
this section.
1. Boot (21) if used.
• Retainers (24) using J-22610.
2 . Slip yoke (13) to the axle yoke ( 1 2 ).
• Adjust propeller shaft (14) length.
• Mate the joint using reference marks.
— U-bolt, washer (1 1 ) and nut (10).
— Retainer (22) and bolt (20).
• Support the propeller shaft (14).
a
Tighten
• All fasteners to specified torque. Refer to
“ Specifications” at the end of this section.
3. Bolt (18) at the flange (17).
• Mate the joint using reference marks.
• Lubricate the Constant Velocity Joint (19).
Refer to “ Lubrication” later in this section.
4. Skid plate, if used.
a
Tighten
• All fasteners to specified torque. Refer to
"‘Specifications” later in this section.
__________________ PROPELLER SHAFT 4A-11
LUBRICATION
The front axle propeller shaft found on four-wheel
drive vehicles requires a special lubricant at two lo­
cations: the constant velocity joint, and the slip
yoke.
Constant V elocity Joint (C/V Joint)
The constant velocity (C/V) joint, located at the
transfer case end of the front propeller shaft, must be
lubricated periodically with a special lubricant,
1050679 or equivalent. If the lubrication fitting cannot
be seen from beneath the vehicle refer to figure 9
which shows how the C/V joint may be lubricated from
above, with a special adapter J-25512-2 on the end of a
flex hose.
Slip Spline
Apply chassis lubricant at the slip spline grease
fitting until the grease begins to leave through the vent
hole.
If the slip spline is dry or corroded, it may be
necessary to disconnect the propeller shaft from the
vehicle, remove the slip yoke, and wire brush the
affected area. Wipe clean before installation.
Figure 9—Lubricating The Constant
V elocity Joint Fitting
4A-12 PROPELLER SHAFT
SPECIFICATIONS
APPLICATION
MODEL
Nm
C, G, P
C, K, G300, P
20*
TORQUE
FT. LBS.
Propeller Shaft:
35
15*
26
27
20
Two Piece Propeller Shaft-Front
.P300
.C, G, P
K
20
15
27
20
33
24
15
26
Center Bearing Support:
.P300
.C
.P
.K
.C
C, G
20
35
27
33
33
20
24
24
Two Piece Propeller Shaft-Rear:
.P
•C, G, P
C, K, G300, P300
27
20
20
33
15
24
.K
.K100, 200
.K300
100
20
20
74
15
15
Propeller Shaft:
'Torque Specification Is For Hex Head Bolt.
SPECIAL TOOLS
J-22610
J-25512
J-25512-2
J-33051
Keystone Clamp Pliers
CV Propshaft Lube Gun
Needle Point
Driveshaft Wrench
4B-1
SECTION 4B
REAR AXLE
The following “ Notice” applies to one or more steps in the assembly procedure of components in this portion of
the manual as indicated at appropriate locations by the terminology: “ NOTICE: See ‘Notice’ on page 4B-1 of this
section.”
NOTICE: All rear axle fasteners are important attaching parts in that they could affect the performance of vital
parts and systems, and/or could result in major repair expense. They must be replaced with one of the same
part number or with an equivalent part if replacement becomes necessary. Do not use a replacement part of
lesser quality or substitute design. Torque values must be used as specified during reassembly to assure
proper retention of all parts.
CONTENTS
SUBJECT
PAGE
D e s c rip tio n .................................................................................................................................................................. 4B - 2
Rear Axle O peration...............................................................................................................................................4 B - 2
Diagnosis of the Rear A x le ...................................................................................................................................... 4 B - 3
Diagnosis of N o is e ................................................................................................................................................. 4 B - 3
Diagnosis of Tapered Roller B e a rin g s .............................................................................................................. 4B - 6
On-Vehicle Service..................................................................................................................................................... 4B-10
Rear Axle Assem bly R e p la ce m e n t.....................................................................................................................4B-10
Axle Shaft, Oil Seal and Bearing Replacement
(81/2- 91/ 2-lnch Ring Gear-Semi-Floating A xle)............................................................................................... 4B-10
Brake Backing Plate Replacement (81/2- 91/2-inch Ring Gear-Semi-Floating A xles)................................ 4B-13
Wheel Stud Replacement ( 81/2 - 9 V2-lnch Ring Gear-Semi-Floating A x le s )................................................4B-14
Pinion Flange, Dust Deflector/O il Seal Replacement
(81/2- 91/ 2-lnch Ring Gear-Semi-Floating A x le s )...........................................................................................4B-14
Axle Shaft Replacement (93/4- 1 0 1/ 2-lnch Ring Gear-Full Floating A x le s )..................................................4B-16
Hub And Drum Assem bly Replacement (93/4- 1 0 1/ 2-lnch Ring Gear-Full Floating A x le s ) ......................4B-17
Wheel Bearing/Cup Replacement (93/4- 1 0 1/2-lnch Ring Gear-Full Floating A x le s ) .................................4B-18
Non-Demountable Type Drum R eplacem ent....................................................................................................4B-19
Wheel Bolt R eplacem ent...................................................................................................................................... 4B-19
Bearing A d ju s tm e n t...............................................................................................................................................4B-19
Pinion Oil Seal/Companion Flange Replacement
(93/4- 1 0 1/ 2-lnch Ring Gear-Full Floating A x le s )...........................................................................................4B-20
Axle Vent Replacement (12-Inch Ring Gear-Full Floating A x le ) .................................................................4B-21
Axle Shaft Replacement (12-Inch Ring Gear-Full Floating A x le ).................................................................4B-21
Bearing Adjustm ent (12-Inch Ring Gear-Full Floating A x le ) ....................................................................... 4B-21
Drive Pinion Oil Seal Replacement (12-Inch Ring Gear-Full Floating A x le )............................................. 4B-22
S pe cifica tio ns..............................................................................................................................................................4B-24
Special T o o ls ..............................................................................................................................................................4B-25
4B-2 REAR AXLE
DESCRIPTION
Light duty trucks use various rear axles, classed by
ring gear diameter such as:
8 V2-INCH AND 9 V2-INCH RING GEAR AXLES
-SEM I-FLO ATING
These axles are of the fabricated constructed type
consisting of a cast carrier, bossed at each end into
which two welded steel tubes are fitted. An overhung
hypoid pinion and the ring gear are housed in the
carrier. The differential has a two pinion arrangement.
Two steel welded tubes pressed into the crossbore of
the cast carrier make up the axle housing. Welded-on
brackets provide attachment points for the suspension
components such as leaf springs and shock absorbers.
The brake flange plate is attached to a welded-on
flange.
The overhung hypoid drive pinion is supported by
two preloaded tapered roller bearings. The pinion shaft
is sealed by means of a molded, spring loaded, rubber
seal. The hypoid ring gear is bolted to a one-piece
differential case supported by two preloaded tapered
roller bearings.
The 9 1/2 -inch ring gear axles have the ring gear side
bearing preload controlled by a side bearing adjusting
nut threaded into the carrier near the axle tubes.
Backlash is adjusted by increasing or decreasing the
shim thickness.
CHEVROLET IOV 2-INCH RING GEAR AXLE
This axle is the full floating type with a hypoid ring
gear and drive pinion. The full floating construction
allows easy removal of the axle shafts. The differential
carrier is heavily ribbed to provide rigid support for the
differential assembly.
A straddle-mounted drive pinion is supported at the
front by two opposed tapered roller bearings. The
pinion straddle bearing is a roller bearing assembly
having an outer race and roller assembly. A precision
ground diameter on the pinion pilot functions as an
inner race.
Side bearing preload and ring gear-to-pinion
backlash are controlled by side bearing adjusting nuts
threaded into the carrier near the axle tubes. Pinion
depth is controlled by a shim located between the
pinion bearing retainer assembly and the differential
carrier.
DANA IOV 2-INCH RING GEAR AXLE
The axle is a Salisbury-type design similar to the
8 1 / 2 -inch ring gear axle. The axle shafts are full
floating, and the carrier must be spread to remove the
differential, and the drive pinion uses two shim packs.
The inner pack controls pinion depth and the outer
pack controls pinion bearing preload.
DANA 9 3/4-INCH RING GEAR AXLE
This Dana axle is similar to the Chevrolet 1 0 1/2 -inch
ring gear axle however, the differential side bearing
shims are located between the case and the side
bearings.
ROCKWELL 12" RING GEAR AXLE
This single-speed, hypoid axle has a straddle
mounted drive pinion which is supported at the rear by
a straight roller bearing. The pinion front bearing has a
double row ball bearing.
The differential is a conventional four-pinion type
using thrust washers between the side gears and case
and also between the differential pinions and the
differential case.
A thrust pad mounted on the end threaded into the
carrier housing limits the deflection of the ring gear
under high torque service.
Involute splines are used in the axle shaft flange and
in the wheel hubs. This design gives driving torque
transmission from the axle shaft to the hub through the
mating splines.
REAR AXLE OPERATION
A basic differential has a set of four gears. Two are
called differential side gears and the other two are
differential pinion gears. Some differentials have more
than two pinions. Each side gear is splined to an axle
shaft, therefore each axle shaft must turn when its side
gear rotates.
The differential pinion gears are mounted on a
differential pinion shaft, and the gears are free to rotate
on this shaft. The pinion shaft is fitted into a bore in the
differential case and is at right angles to the axle
shafts.
Power flow through the differential is as follows: the
drive pinion rotates the ring gear. The ring gear, being
bolted to the differential case, rotates the case. The
differential pinion, as it rotates with the case, forces the
pinion gears against the side gears. When both wheels
have equal traction, the pinion gears do not rotate on
the pinion shaft because the input force on the pinion
gear is equally divided between the two side gears.
Therefore, the pinion gears revolve with the pinion
shaft, but do not rotate around the shaft itself. The side
gears, being splined to the axle shafts and in mesh
with the pinion gears, rotate the axle shafts.
If a vehicle were always driven in a straight line, the
ring and pinion gears would be sufficient. The axle
shaft could then be solidly attached to the ring gear
and both driving wheels would turn at equal speed.
REAR AXLE 4B-3
However, if it became necessary to turn a corner, the
tires would scuff and slide because the outside wheel
would travel further than the inside wheel. To prevent
tire scuffing and sliding, the differential becomes
effective and allows the axle shafts to rotate at different
speeds.
When the vehicle turns a corner, the outer rear
wheel must turn faster than the inner wheel. The inner
wheel turns slower than the outer wheel and slows its
rear axle side gear (as the axle shaft is splined to the
side gear) and the rear axle pinion gears will roll
around the slowed rear axle side gear, driving the other
rear axle side gear and wheel faster.
LOCKING REAR AXLE
Eaton Locking Differential
The locking rear differential allows for normal
differential function as indicated in the standard rear
axle d escription. A dditionally, the locking rear
differential uses multi-disc clutch packs and a speed
sensitive engagement mechanism that locks both
wheels together if one wheel should spin excessively
during slow vehicle operation.
Under light loads, the clutch plates alone tend to
lock axle shafts to the differential case, and therefore,
each other. This is due primarily to the gear separating
load developed on the right side clutch pack. This
induced clutch torque capacity resists motion between
the side gear and the rear axle differential case. The
axle shaft torques developed when turning a corner
will overcome this capacity and allow differentiation.
Also, heavier throttle application will cause differential,
but this starts the full-lock feature of the unit.
Full locking is accomplished through the use of a
heavyweight governor mechanism, cam system, and
multi-disc clutch packs. The flyweights on the governor
mechanism move outward to engage a latching
bracket whenever the wheel-to-wheel speed varies by
approximately 100 rpm or more. This action retards a
cam which, in turn, compresses the multi-disc clutch
packs locking both side gears to the case. The 100 rpm
wheel-to-wheel speed allows for cornering without
differential lock-up.
At vehicle speeds above approximately 32.2 km/h
(20 mph), the latching bracket overcomes a spring
preload and swings away from the flyweights. At this
vehicle speed or greater, the differential will not lock,
as the added traction is generally not required.
All gear axle parts of vehicles equipped with the
locking rear axle are interchangeable with those
equipped with the conventional rear axle, except for
the case assembly.
DIAGNOSIS OF THE REAR AXLE
NOISE
The most essential part of rear axle service, as with
any mechanical repair, is proper diagnosis of the
problem, and, in axle work one of the most difficult
areas to diagnose is noise. Locating a broken axle
shaft, or broken differential gear, presents little or no
problem, but, locating and isolating axle noise can be
an entirely different matter.
Degree of Noise
Any gear driven unit, especially an automotive drive
axle where engine torque multiplication occurs at a 90
degree turn in the drive line, produces a certain
amount of noise. Therefore, an interpretation must be
made for each vehicle to determine whether the noise
is normal or if a problem actually exists. A normal
amount of noise must be expected and cannot be
eliminated by conventional repairs or adjustment.
Acceptable noise can be defined as a slight noise
heard only at a certain speed or under unusual or
remote conditions. For example, this noise tends to
reach a “ peak” at speeds from 40 to 60 miles per hour
(60 to 10 0 km/h) depending on road and load
conditions, or on gear ratio and tire size. This slight
noise is in no way indicative of trouble in the axle
assembly.
Drive lin e noises may b a ffle even the best
diagnostician. Vehicle noises coming from tires,
transmission, propeller shaft, universal joints, and front
or rear wheel bearings, are often mistaken for axle
noise. Such practices as: raising tire pressure to
eliminate tire noise (although this will not silence tread
noise of mud and snow tires), listening for the noise at
varying speeds and road surfaces, on drive, float, and
coast conditions will aid in locating the source of
alleged axle noises. Thus, every effort should be made
to isolate the noise to a specific drive line component
instead of making a random guess that could be a
costly waste of time.
DETERMINING TYPE OF NOISE
External Noise
When a rear axle is suspected of being noisy, it is
advisable to make a thorough test to determine
whether the noise originates in the tires, road surface,
front wheel bearings, engine, transmission, or rear axle
4B-4 REAR AXLE
assembly. Noise which originates in other places
cannot be corrected by adjustment or replacement of
parts in the rear axle assembly.
Road Noise—Some road surfaces, such as brick or
rough-surfaced concrete, cause noise which may be
mistaken for tire or rear axle noise. Driving on a
different type of road, such as smooth asphalt or dirt,
will quickly show whether the road surface is the cause
of noise. Road noise usually is the same on drive or
coast.
Tire Noise—Tire noise may easily be mistaken for
rear axle noise, even though the noisy tires may be
located on the front wheels. Tires worn unevenly, or
having surfaces on non-skid d ivisions worn in
saw-tooth fashion, are usually noisy and may produce
vibrations which seem to originate elsewhere in the
vehicle. This is particularly true with low tire pressure.
Tire Noise Test—Tire noise changes with different
road su rfa ce s, but rear axle noise does not.
Temporarily inflating all tires to 345 kilopascals (50
pounds per square inch) pressure, fo r test purposes
only will materially alter noise caused by tires but will
not affect noise caused by the rear axle. Rear axle
noise usually stops when coasting at speeds under 30
miles per hour; however, tire noise continues but with
lower tone as the vehicle speed is reduced. Rear axle
noise usually changes when comparing “ pull” and
“ coast” but tire noise remains about the same.
Engine and Transm ission Noises—Sometimes a
noise which seems to originate in the rear axle is
actually caused by the engine or transmission. To
determine which unit is actually causing the noise,
observe approximate car speeds and conditions under
which the noise is most pronounced; then stop the
vehicle in a quiet place to avoid interfering noises. With
the transmission in neutral, run the engine slowly up
and down through the engine speeds corresponding to
the vehicle speed at which the noise was most
pronounced. If a similar noise is produced with the
vehicle standing, it is caused by the engine or
transmission and not the rear axle.
Front Wheel Bearing Noise—Loose or rough front
wheel bearings will cause noise which may be
confused with rear axle noise; however, front wheel
bearing noise does not change when comparing “ pull”
and “ coast.” Light application of the brake, while
holding the vehicle speed steady, will often cause the
wheel bearing noise to diminish, as this takes some
weight off of the bearing. Front wheel bearings may be
easily checked for noise by jacking up the wheels and
spinning them, and also by shaking the wheels to
determine if the bearings are excessively loose.
Body Boom Noise or Vibration—Objectional “ body
boom” noise or vibration at 55-65 mph (90-100 km/h)
can be caused by an unbalanced propeller shaft.
Excessive looseness at the spline can contribute to
this unbalance.
Other items that may also contribute to the noise
problem are as follows:
1. U ndercoating or mud on the shaft, causing
unbalance.
2 . Shaft or com panion flange balance weights
missing.
3. Shaft damage, such as bending, dents, or nicks.
4. Tire-type roughness. Switch tires from a known
good vehicle to determine a tire fault.
If, after making a comprehensive check of the
vehicle, all indications point to the rear axle, further
diagnostic steps are necessary to determine the axle
components at fault. True rear axle noise generally
falls into two categories: gear noise and bearing noise.
Rear Axle Noises
If a careful test of the vehicle shows that the noise is
not caused by external items, it is then reasonable to
assume that noise is caused by the rear axle assembly.
Test the rear axle on a smooth level road to avoid road
noise. It is not advisable to test the rear axle for noise
by running with the rear wheels jacked up.
Noise in the rear axle assembly may be caused by a
faulty propeller shaft, faulty rear wheel bearings, faulty
differential or pinion shaft bearings, misalignment
between two U-joints, or worn differential side gears
and p in ion s; noise may also be caused by a
mismatched, improperly adjusted, or scored, ring and
pinion gear set.
Rear Wheel Bearing Noise—A rough rear wheel
bearing produces a vibration or growl which continues
with the vehicle coasting and the transmission in
neutral. A brinelled rear wheel bearing causes a knock
or click approximately every two revolutions of the rear
wheel, since the bearing rollers do not travel at the
same speed as the rear axle and wheel. With the rear
wheels jacked up, spin the rear wheels by hand while
listening at the hubs for evidence of a rough or
brinelled wheel bearing.
D iffe r e n tia l
S id e
G ear
and
P in io n
Noise—Differential side gears and pinions seldom
cause noise since their movement is relatively slight on
straight ahead driving. Noise produced by these gears
will be most pronounced on turns.
P in io n B earing failures can be distinguished
because they rotate at higher speeds than differential
side bearings and axle shaft bearings. Rough or
brinelled pinion bearings produce a continuous low
pitched whirring or scraping noise starting at a low
speed.
Side Bearings produce a constant rough noise
pitched lower than pinion bearing noise. Side bearing
noise may also fluctuate in the above rear wheel
bearing test.
REAR AXLE 4B-5
Gear Noise
There are two basic types of gear noise. The first
type is produced by broken, bent, or forcibly damaged
gear teeth and is usually quite audible over the entire
speed range and presents no particular problem in
diagnosis. For example, hypoid gear tooth scoring
generally results from the following: insufficient
lubricant, improper break-in, improper lubricant,
insufficient gear backlash, improper ring and pinion
gear alignment, or loss of drive pinion nut torque. The
scoring will progressively lead to complete erosion of
the gear tooth, or gear tooth pitting and then eventual
fracture if the initial scoring condition is not corrected
(figure 1). Another cause of hypoid tooth fracture is
extended overloading of the gear set which will
produce fatigue fracture, or shock loading which will
result in sudden failure.
Differential pinion and side gears rarely give trouble.
Common causes of differential failure are shock
loading, extended overloading, and seizure of the
differential pinions to the cross shaft resulting from
excessive wheel spin and consequent lubrication
breakdown. The second type of gear noise pertains to
the mesh pattern of the gear teeth. This form of
abnormal gear noise can be recognized because it
produces a cycling pitch (whine) and will be very
pronounced in the speed range at which it occurs,
appearing under either “ drive,” or “ float” or “ coast”
conditions. “ Drive” is acceleration or heavy pull.
“ Coast” is with a closed throttle and the vehicle in
gear and “ float” is using just enough throttle to keep
the vehicle from driving the engine; the vehicle slows
down gradually but the engine still pulls slightly. Gear
noise tends to peak in a narrow speed range or ranges,
and will tend to remain constant in pitch. Bearing noise
will vary in pitch with vehicle speeds.
Refer to figures 2 through 5 for bearing diagnosis.
4B-6 REAR AXLE
ABRASIVE ROLLER WEAR
ABRASJVE STEP WEAR
Pattern on races and rollers caused by fine
abrasives.
Clean all parts and housings, check seals and
bearings and replace if leaking, rough or
noisy.
Pattern on roller ends caused by fine abra­
sives.
Clean all parts and housings, check seals and
bearings and replace if leaking, rough or
noisy.
GALLING
ETCHING
Metal smears on roller ends due to overheat,
lubricant failure or overload.
Replace bearing, check seals and check for
proper lubrication.
Bearing surfaces appear gray or grayish black
in color with related etching away of material
usually at roller spacing.
Replace bearings, check seals and check for
proper lubrication.
B-09194
Figure 2—Diagnosis Of Tapered Roller Bearings
REAR AXLE 4B-7
BENT CAGE
Cage damaged due to improper handling or
tool usage.
Replace bearing.
BENT CAGE
Cage damaged due to improper handling or
tool usage.
Replace bearing.
CAGE WEAR
INDENTATIONS
Wear around outside diameter of cage and
roller pockets caused by abrasive material
and inefficient lubrication.
Clean related parts and housings.
Check seals and replace bearings.
Surface d e p re ssio ns on race and rollers
caused by hard particles of foreign material.
Clean all parts and housings. Check seals and
replace bearings if rough or noisy.
B-09195
Figure 3—Diagnosis Of Tapered Roller Bearings
4B-8 REAR AXLE
FRETTAGE
SMEARS
Corrosion set up by small relative movement
of parts with no lubrication.
Replace bearing. Clean related parts. Check
seals and check for proper lubrication.
Smearing of metal due to slippage. Slippage
can be caused by poor fits, lu b rica tio n ,
overheating, overloads or handling damage.
Replace bearings, clean related parts and
check for proper fit and lubrication.
STAIN DISCOLORATION
HEAT DISCOLORATION
Discoloration can range from light brown to
black caused by incorrect lubricant or m ois­
ture.
Re-use bearings if stains can be removed by
light polishing or if no evidence of overheat­
ing is observed.
Check seals and related parts for damage.
Heat discoloration can range from faint yel­
low to dark blue resulting from overload or in correct lubricant.
Excessive heat can cause softening of races
or rollers. To check for loss of temper on
races or rollers a simple file test may be
made. A file drawn over a tempered part will
grab and cut metal, whereas, a file drawn over
a hard part w ill glide readily with no metal
cutting.
Replace bearings if over heating damage is
indicated. Check seals and other parts.
F-00531
Figure 4—Diagnosis Of Tapered Roller Bearings
REAR AXLE 4B-9
MISALIGNMENT
CRACKED INNER RACE
Outer race m isalignm ent due to foreign ob­
ject.
Clean related parts and replace bearing. Make
sure races are properly seated.
Race cracked due to improper fit, cocking, or
poor bearing seats.
Replace bearing and correct bearing seats.
FATIGUE SPALLING
BRINELLING
Flaking of surface metal resulting from fa­
tigue.
Replace bearing, clean all related parts.
Surface indentations in raceway caused by
rollers either under impact loading or vibra­
tion while the bearing is not rotating.
Replace bearing if rough or noisy.
B-09860
Figure 5—Diagnosis Of Tapered Roller Bearings
4B-10 REAR AXLE
ON-VEHICLE SERVICE
REAR AXLE ASSEMBLY
REPLACEMENT (ALL AXLES)
• Raise the vehicle on a hoist and support the axle
assembly with a suitable lifting device.
• For 93/4-inch ring gear and 1 0 1/2-inch ring gear
axles, raise the vehicle and place jack stands
under the frame side rails for support.
• Drain the lubricant from the axle housing.
Remove or Disconnect
1. Propeller shaft. Refer to PROPELLER SHAFT
(SEC. 4A).
• Tie the propeller shaft to a side rail or
crossmember.
• Tape the bearing cups to prevent loss of the
rollers.
2 . W heel and brake drum or hub and drum
assembly.
3. Parking brake cable from the lever and at the
brake flange plate. Refer to BRAKES (SEC. 5).
4. Hydraulic brake lines from the connectors. Refer
to BRAKES (SEC. 5).
5. Shock absorbers from the axle brackets. Refer to
REAR SUSPENSION (SEC. 3D).
6 . Vent hose from the axle vent fitting if used.
7. Height sensing and brake proportional valve
linkage if used. Refer to BRAKES (SEC. 5).
8 . S ta b iliz e r s h a ft if used. R efer to REAR
SUSPENSION (SEC. 3D).
• Support the assembly with a hydraulic floor
jack.
9. Nuts and washers from the U-bolts.
10. U-bolts, spring plates and spacers from the axle
assembly.
• Lower the jack and the axle assembly.
Install or Connect
1. Axle assembly under the vehicle.
• Align the axle assembly with the springs.
2 . Spacers, spring plates and U-bolts to the axle
assembly.
• Raise the axle assembly.
3. Washers and nuts to the U-bolts.
• Thread the nuts on firmly.
• Adjust alignment of semi-float axles.
4. Stabilizer shaft if used.
5. Height sensing and brake proportional valve
linkage if used. Refer to BRAKES (SEC. 5).
6 . Vent hose to the axle vent fitting if used.
7. Shock absorbers to the axle brackets. Refer to
REAR SUSPENSION (SEC. 3D).
8 . Hydraulic brake lines to the connectors. Refer to
BRAKES (SEC. 5).
9. Parking brake cable to the lever and the flange
plate. Refer to BRAKES (SEC. 5).
10. W heel and b ra ke d ru m or hub and drum
assembly.
11. Propeller shaft. Refer to PROPELLER SHAFT
(SEC. 4A).
NOTICE: See “Notice” on page 4B-1 of this
section.
Tighten
All fasteners to “ Specifications” later in this
section.
Im portant
• Check axle lubricant level at the filler plug hole.
Lubricate as needed.
• Bleed the brake system, check operation and
adjust if necessary. Refer to BRAKES (SEC. 5).
• Check axle and brake operation.
• Check for fluid leaks and road test the vehicle.
AXLE SHAFT, OIL SEAL AND
BEARING REPLACEMENT
(SVa-^/z-INCH RING GEAR
SEMI-FLOATING AXLES)
• Raise the vehicle on a hoist.
• Clean dirt from around the carrier cover.
«--► Remove or Disconnect (Figure 6 )
Tools Required:
J-2619-01 Slide Hammer with Adapter
J-23689 Axle Shaft Bearing Remover (large
shaft)
J-29712 Axle Shaft B earing Remover
(9 1/2 -inch ring gear)
1. Wheel and tire assembly. Refer to WHEELS AND
TIRES (SEC. 3E).
2 . Brake drum. Refer to BRAKES (SEC. 5).
3. Carrier cover (19).
• Catch the oil in a drain pan.
• Remove gasket material if used.
REAR AXLE 4B-11
1 0 . Drum
1 1 . Bolt
1 2 . Shaft
13.
14.
15.
16.
17.
18.
19.
Lock
Seal
Bearing
Housing
Clip
Bolt
Carrier Cover
F-00636
Figure 6—Axle Shaft And Housing Detail
WITHOUT LOCKING DIFFERENTIAL
4. Screw (A) (figure 7).
5. Pinion shaft (B) (figure 8 ).
Important
• Push the flanged axle shaft (12) toward the center
of the vehicle.
6 . Lock (13) from the button end of the axle shaft
( 12).
7. Axle shaft (12).
• W ithdraw the axle shaft (12) from the
housing (16).
• Be careful not to damage the oil seal (14).
• Don’t allow the thrust washer in the 9 1/2 -inch
ring gear axle to slide out when removing
the axle shaft ( 1 2 ).
WITH LOCKING DIFFERENTIAL
4. Screw (A). Refer to figures 8 , 9 and 10.
• Hold the pinion shaft (B) when loosening the
screw (A).
• Withdraw the pinion shaft (B) part way and
then position the differential case (C) for the
best clearance (figure 9). Rotate the case
(C) until the pinion shaft (B) touches the
housing (D).
• Use a screwdriver or similar tool to enter the
case (D) and rotate the lock (13) until the
open end points inward (figure 10 ).
Im portant
Do not force or hammer the axle shaft ( 1 2 ) to gain
removal clearance.
Lock (13). Refer to figures 10 and 11.
• With the lock (13) correctly positioned, push
the axle shaft ( 1 2 ) inward and remove the
lock (13).
4B-12 REAR AXLE
Figure 9—P ositioning The Case
For Best Clearance
Figure 12—Removing The Bearing And Seal
6 . Axle shaft (12).
B. Pinion Shaft
E. Thrust Block
F. Side Gear (Locking
Differential)
G. Lock (C-Lock)
H. Shaft
F-00640
Figure 10 —A ligning The C-Lock Correctly
• Slide the axle shaft ( 1 2 ) out. Be careful not
to damage the seal (14).
7. Seal (14).
• Use the button end of the axle shaft (12) to
pry the seal (14) out or use J-23689.
8 . Bearing (15).
• Use J-23689 for 8 1/2 -inch ring gear axle and
J-29712 for 9 V2-inch ring gear axle. Attach
J-2619-01 to J-23689.
• Insert tool into the axle bore so that it grasps
behind the bearing (15) (figure 12). Tighten
nut and washer against the face of the
bearing (15) or seal (14).
L*
Inspect
All parts. Replace as necessary.
Install or Connect (Figures 6 and 10)
Tools Required:
J-8092 Driver Handle
J-21128 Axle Shaft and Pinion Oil Seal
Installer
J-23690 Axle Shaft Bearing Installer
J-29709 A xle S haft B ea ring In s ta lle r
(9 1/2 -inch ring gear)
J-29713 Axle Shaft Seal Installer (9 1/2 -inch
ring gear)
• Lubricate the axle cavity between the seal
(14) lips and the bearing (15) with wheel
bearing lubricant. Refer to MAINTENANCE
AND LUBRICATION (SEC. OB).
1. Bearing (15).
• Use J-23690 for the 8 1/2 -inch gear axle and
J-29709 for the 9 1/2 -inch ring gear axle.
REAR AXLE 4B-13
WITHOUT LOCKING DIFFERENTIAL
4. Lock (13).
• Lock on the button end of the axle shaft
( 1 2 ), then push the shaft outward to seat the
lock in the counterbore of the differential
side gear.
5. Pinion shaft (B) figure 8 .
• Into the differential case (C) and pinion
gears.
• Align the hole in the pinion shaft (B) with the
screw hole in the differential case (C).
Thread the screw (A) in and tighten to 18
N m (25 ft. lbs.).
Figure 13—Installing The Wheel Bearing
• Bearing (15) into the axle (16) housing until
the tool bottoms against the tube. Refer to
figure 13.
2. Seal (14).
• Use J-21128 for 8 1/2 -inch ring gear axle and
J-29713 for the 9 1/2 -inch ring gear axle.
• Drive the tool into the bore until the seal (14)
bottoms flush with the end of the tube
(figure 14).
3. Axle shaft (12).
• Be careful not to damage the seal (14) when
inserting the axle shaft ( 1 2 ).
• Slide the axle shaft (12) into place allowing
the splines to engage the differential side
gear (F) figure 10.
WITH LOCKING DIFFERENTIAL
4. Lock (13).
• Keep the pinion shaft (B) partially withdrawn
(figure 9).
• Place the lock (G) in the position shown in
figure 10 .
• Carefully withdraw the axle shaft (12) until
the lock (13) clears the thrust block.
• Align the pinion shaft (B) hole with the screw
hole in the differential case (C) figure 8 .
5. Screw (A). Refer to figure 8 .
Tighten
• Screw (A) to 18 N m (25 ft. lbs.).
Gasket if used, otherwise RTV. Be sure sealing
surface is clean.
Carrier cover (19).
Bolts (18) and clip (17).
• Tighten bolts (18) in a crosswise pattern to
assure uniform draw on the gasket if used.
• Fill axle to filler plug hole level. Refer to
MAINTENANCE AND LUBRICATION (SEC.
OB) for proper lubricant.
9. Brake drum. Refer to BRAKES (SEC. 5).
10. Wheel and tire assembly. Refer to WHEELS AND
TIRES (SEC. 3E).
• Lower the vehicle and road test.
BRAKE BACKING PLATE
REPLACEMENT (8 V2- AND
9 1 /2-INCH RING GEAR—
SEMI-FLOATING AXLES)
• Raise the vehicle on a hoist.
«■+ Remove or Disconnect
1 . Wheel, tire and brake drum. Refer to BRAKES
(SEC. 5).
2. Axle shaft. Refer to “ Axle Shaft Replacement”
earlier in this section.
3. Brake line from the cylinder inlet.
4B-14 REAR AXLE
• Brake components from the backing plate.
Refer to BRAKES (SEC. 5).
4. Bolts and washers from the axle.
5. Backing plate.
Install or Connect
1. Backing plate to the axle.
2 . Bolts and washers to the plate.
• Attach components to the backing plate.
Refer to BRAKES (SEC. 5).
Install or Connect
1. Stud in the axle flange hole. Refer to figure 15.
• Start the new stud into the axle flange hole
by pressing firmly with your hand.
• Thread on a lug nut with the flat side to the
vehicle.
• Tighten the lug nut and draw the stud head
into the rear of the flange.
• Thread the lug nut off.
2. Wheel, tire and brake drum.
• Lower the vehicle.
3. Brake line to the cylinder inlet.
• Refer to BRAKES (SEC. 5) for bleeding and
adjustment procedure.
4. Axle shaft. Refer to “ Axle Shaft Replacement”
earlier in this section.
5. Wheel, tire and brake drum.
W HEEL STUD REPLACEMENT
(8 1/2 -9 1/2-INCH RING
GEAR—SEMI-FLOATING AXLES)
• Raise the vehicle on a hoist and allow the axle to
hang free.
Remove or Disconnect
Tool Required:
PINION FLANGE, DUST
DEFLECTOR/OIL SEAL
REPLACEMENT (8 1 /2 - 9 1/2-INCH
RING GEAR SEMI-FLOATING
AXLES)
• Raise the vehicle on a hoist.
Remove or Disconnect
Tool Required:
J-8614-01 Companion Flange Holder and
Remover
1. P ro p e lle r sh a ft from the a xle . R efer to
PROPELLER SHAFT (SEC. 4A).
• Tie the propeller shaft to a frame rail or
crossmember.
J-6627-A Wheel Stud Remover
1. Wheel, tire and brake drum.
2. Stud from the axle flange using J-6627-A (figure
15).
Measure
The torque required to rotate the pinion (figure
16). Record the torque value for later reference.
REAR AXLE 4B-15
;
Im portant
• Scribe a line on the pinion stem, pinion nut and
the companion flange and record the number of
exposed threads on the pinion stem. Use the
scribed reference and the exposed threads as a
reinstallation guide (figure 17).
2. Nut using J-8614-01.
• Position J-8614-01 on the flange so that the
four notches on the tool face the flange
(figure 18).
3. Flange using J-8614-01
• Use the special nut and forcing screw to
remove the flange (figure 19).
4. Oil seal. Use a screw driver to pry the seal out of
the bore.
Inspect
• The pinion flange for a smooth oil seal surface,
for worn drive splines, damaged ears and for
smoothness of the bearing contact surface.
Replace if necessary.
5. Dust deflector.
• Tap the d e fle c to r from the fla n g e if
replacement is necessary.
• Clean up the stake points on the flange.
• Clean all foreign material from the contact
area.
Install or Connect
Tools Required:
J-8614-01 Companion Flange Holder and
Remover
J-22388 Pinion Oil Seal Installer (9 1/2 -inch
ring gear)
J-22804-1 Pinion Oil Seal Spacer
J-22836 Pinion Seal Installer (8 1/2 -inch ring
gear)
1. Dust deflector on the flange.
• Stake new deflector at three new equally
spaced positions. Staking must be such that
the seal operating surface is not damaged.
2 . Oil seal.
• Pack the cavity between the lips of the oil
seal with extreme pressure lithium-base
lubricant.
• Position the oil seal in the bore then place
J-22804-1 over the oil seal and flat against
the seal flange (figure 2 0 ).
• Use J-22836 or J-22388 for the 9 1/2 -inch
ring gear to press the oil seal into the bore
(figure 2 0 ).
• Turn J-22804-1 from installed position 180
degrees to assure proper in sta lla tio n
against the pinion flange.
4B-16 REAR AXLE
Figure 22—Installing Or Removing
Flange-To-Hub Bolts
• Pack the cavity between the end of the
pinion splines and the pinion flange with a
non-hardening sealer such as PERMATEX
TYPE A or equivalent.
3. Flange onto the pinion using J-8614-01.
• Place washer and nut on the pinion threads
and tighten the nut to the original scribed
p o s itio n using the scrib e m arks and
exposed threads as a reference (figure 2 1 ).
DO NOT ATTEMPT TO HAMMER THE
FLANGE ONTO THE PINION SHAFT.
%
Measure
The rotating torque of the pinion and compare
with the torque recorded earlier (figure 16).
Tighten
• The p in io n nut in a d d itio n a l sm a ll
increments until the torque necessary to
rotate the pinion exceeds the original
recorded value by 0.35 N-m (3 in. lbs.).
4. Propeller shaft. Refer to PROPELLER SHAFT
(SEC. 4A).
• Lower the vehicle and road test.
AXLE SHAFT REPLACEMENT
(93/4-1OVz-INCH RING G E A R FULL FLOATING AXLES)
• This procedure covers the 93/4-inch and 1 0 1/2-inch
ring gear, full floating axles.
|+ + | Remove or Disconnect (Figure 23)
1 . Bolts (35) (figures 2 2 and 23).
• Rap the axle shaft (34) flange with a soft
faced hammer to loosen the shaft.
• Grip the rib on the axle shaft (34) flange with
a locking plier and twist, to start shaft
removal.
2. Axle shaft (34) from the tube.
P y l Clean (Figure 23)
• Axle shaft (34) flange. Remove old RTV or
gasket (33).
Figure 21—Installing The Pinion Flange
• Outside face of the hub assembly (31).
Lubricant in the area w ill loosen the
shaft-to-hub bolts (35).
REAR AXLE 4B-17
A.
B.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
Chevrolet
Dana
Nut
Lock
Adjusting Nut
Washer
Outer Bearing
Retaining Ring
Inner Bearing
Oil Seal
Drum
Hub
Stud
Gasket
Shaft
Axle Shaft Flange
Washer
Bolt
Retaining Ring
Key
Adjusting Nut
Outer Bearing
Retaining Ring
Inner Bearing
Oil Seal
F-00647
Figure 23—Full Floating Axle, Hub And Drum Assem bly Detail
L * Inspect
J-2222-C Wheel Bearing Nut Wrench
1 . Wheel and tire.
• All parts and replace as necessary.
-►+ Install or Connect (Figure 23)
1. Axle shaft (34) with a gasket or RTV applied.
• Be sure the shaft splines mesh into the
differential side gear.
• Align the axle shaft holes with the hub
holes.
2. Bolts (35) figures 2 2 and 23.
Tighten
• Bolts (35) to specified torque later in this section.
HUB AND DRUM ASSEMBLY
REPLACEMENT
(9 3/4 -1 0 1/2-INCH RING G E A R FULL FLOATING AXLES)
|+ + | Remove or Disconnect (Figure 23)
• Raise the vehicle until the wheel is free to rotate.
Tool Required:
2. Axle shaft (52) as outlined earlier in this section.
3. Nut (40) use J-2222-C or retaining ring (56). Refer
to figure 24.
4. Lock (41) or key (57).
5. Adjusting nut (42, 58). Refer to figure 24.
6 . Washer (43).
7. Hub and Drum (48, 49).
4B-18 REAR AXLE
Inspect
• All parts and replace as necessary.
|~n-| Install or Connect (Figure 23)
NOTICE: For steps 3, 4 and 5 see “Notice” on
page 4B-1 of this section.
Tool Required:
J-2222-C Wheel Bearing Nut Wrench
1. Hub and drum (48, 49) to the tube.
• Be sure the bearings and the oil seal are
positioned properly.
• Apply a light coat of high melting point EP
bearing lubricant to the contact surfaces
and the outside of the axle tube.
2. Washer (43). Tang into key way.
3. Adjusting nut (42, 58). Refer to figure 24.
6 . Outer bearing (44) or (59) using J-8092 with
• Adjusting nut (42, 58) to specified torque
later in this section.
4. Lock (41) or key (57).
• Bend the tang to the flat of the adjusting nut
(42) or insert the key (57).
5. Nut (40) or retaining ring (56). Refer to figure 24.
J-24426 (figure 25).
• Drive the bearing (44, 59) and cup from the
hub (49).
ay
Old sealing compound from the oil seal (47,
62) bore in the hub (49).
Bearing assemblies in a solvent using a stiff
brush to remove the old lubricant. Dry the
bearings with compressed air. Do not spin
them.
Lubricant from the axle housing and inside
the hub (49).
Gasket material from the hub (49), axle
shaft (52).
Tighten
• Nut (40) to specified torque later in this
section.
6 . Axle shaft (52) earlier in this section.
7. Wheel and tire.
• Lower the vehicle.
WHEEL BEARING/CUP
REPLACEMENT
(93/4-1OV2-INCH RING G E A R FULL FLOATING AXLES)
|+ + | Remove or Disconnect (Figure 23)
• Raise the vehicle till the wheels are free to rotate.
Tools Required:
J-8092 Driver Handle
J-24426 Outer Wheel Bearing Cup Installer
1. Axle shaft (52) as outlined earlier in this section.
2. Hub and drum (48, 49) as outlined earlier in this
section.
3. Oil seal (47) or (62). Use a drift.
4. Inner bearing (46) or (61). Use a drift to remove
the bearing and cup.
5. Retaining ring (45) or (60).
• Use snap ring pliers to remove the ring.
Clean
L*
Inspect
Bearings for wear, chipped edges or other
damage. Check for flat or rough spots on
the rollers.
Cups for pits and cracks.
Oil seal for wear or roughness. Replace
parts as necessary.
Install or Connect (Figure 23).
Tools Required:
J-8092 Driver Handle
J-8608 Pinion Bearing Cup Installer
J-24426 Outer Wheel Bearing Cup Installer
J-24427 Inner Wheel Bearing Cup Installer
J-24428 Axle Shaft Seal Installer
1. Outer bearing (44, 59) into the hub (49).
• Outer cup into the hub (49) using J-8092
and J-8608. Be sure J-8608 is installed
upside down on the driver handle J-8092.
REAR AXLE 4B-19
2.
3.
4.
5.
6.
• Drive the outer cup beyond the retaining
ring groove.
Retaining ring (45) or (60) into the groove.
• Drive the outer bearing cup against the
retaining ring (45) or (60) using J-8092 and
J-24426 (figure 25).
Inner bearing (46) or (61).
• Drive the inner bearing cup into place until
seated against the shoulder of the hub (49)
using J-8092 and J-24427.
Oil seal (47) or (62). Use J-24428 to install the
new oil seal (47, 62).
Hub and drum (48, 49) as outlined earlier in this
section.
Axle shaft (52) as outlined earlier in this section.
A. Removing Wheel Bolt
B. Installing Wheel Bolt
NON-DEMOUNTABLE TYPE
DRUM REPLACEMENT
Figure 26—Wheel Bolt Replacement
BEARING ADJUSTMENT
• Construction of the non-demountable type drum
and hub assembly is such that replacement
cannot be done with the hub assembly installed
on the vehicle.
□
Make sure the brakes are fully released and do
not drag.
Check the wheel bearing play by grasping the tire
at the top and pulling and pushing back and forth,
or by using a pry bar under the tire. If the wheel
bearings are properly adjusted, movement of the
brake drum in relation to the brake flange plate
will be barely noticeable and the wheel will turn
freely. If the movement is excessive, adjust the
bearings.
Remove or Disconnect
• Raise the vehicle.
1 . Hub and drum assembly. Refer to “ Hub and
Drum Assembly Replacement” earlier in this
section.
2. Retaining bolts, stud nuts or wheel studs.
• Separate the drum, hub and oil deflector.
• Press the wheel studs out of the drum.
Replace parts as necessary.
-►+ Install or Connect
1. Drum to the hub.
• Make certain drain holes are in alignment.
2 . Oil deflector to the drum.
• Apply a light coating of sealing compound to
the oil deflector contact surface.
3. Retaining bolts, stud nuts or wheel studs.
• Press the wheel studs into the drum.
WHEEL BOLT REPLACEMENT
• Wheel bolts are serrated and may also be
sw aged in p la ce ; how ever, re p la c e m e n t
procedure remains the same for both types of
installation. Press the wheel bolts out of the hub
flange, then press new wheel bolts into place,
making sure of a tight fit. When replacing all of
the wheel bolts be sure that the hub oil deflector
is in position under the wheel bolt heads. Refer to
figure 26.
F-00650
□
Remove or Disconnect (Figure 23)
Tool Required:
J-2222-C Wheel Bearing Nut Wrench
• Raise the vehicle until the wheel is free to
spin.
1. A xle sh a ft (52). R efer to “ A xle
Replacement” earlier in this section.
S ha ft
• Be sure the keyway, threads and adjusting
nut (42, 58) are clean and free of chips,
burrs and shavings.
2. Nut (40) if used or retaining ring (56).
• Disengage the tang from the nut (40).
3. Lock (41) if used or key (57).
• Adjusting nut (42, 58) to 70 N m (50 ft. lbs.) using
J-2222-C (figures 27 and 28).
• Be sure the bearings are seated and in contact
with the spindle shoulder.
4B-20 REAR AXLE
3. A xle sh a ft (52). R efer to “ A xle
Replacement” earlier in this section.
S h a ft
PINION OIL SEAL/COMPANION
FLANGE REPLACEMENT
• The pinion oil seal and the companion flange
may be replaced with the carrier assembly
installed in the vehicle.
Remove or Disconnect
Figure 27—Tightening The A djusting Nut
Adjust
Nut (42, 58). Back the nut (42, 58) off until just
loose using J-2222-C. Align the adjusting nut (58)
slot with the keyway in the axle spindle. Do not
back the adjusting nut (58) off more than one slot
to gain alignment.
Tools Required:
J-8614-01 Companion Flange Holder and
Remover
J-22281 Pinion Oil Seal Installer (DANA
93/4-inch ring gear axle)
J-24384 Pinion Oil Seal Installer (DANA
1 0 1/2 -inch ring gear axle)
J-2 4 43 4 P in ion O il S eal In s ta lle r
(CHEVROLET 1 0 1/2 -inch ring gear axle)
• Raise the vehicle.
1. Propeller shaft. Refer to PROPELLER SHAFT
(SEC. 4A).
• Tie the propeller shaft to a frame rail or
crossmember.
Install or Connect (Figure 23).
Important
1. Key (57) if used or new lock (41).
• Key (57) into the keyway and adjusting nut
(58) slot.
• Bend the lock (41) tang to the flat of the
adjusting nut (42).
2. Retaining ring (56) or nut (40) if used.
• Bend the lock (41) tang to the flat of the nut
(40).
• Be sure the retaining ring (56) is seated.
J-2222-C
• Scribe a line on the pinion stem, pinion nut and
companion flange to be used as a guide for
reinstallation (figure 17).
2. Nut using J-8614-01 (figure 18).
3. Flange using J-8614-01.
• Use the special nut and forcing screw to
remove the flange (figure 19).
4. Oil seal.
• Pry the oil seal from the bore. Do not
damage the machined surfaces and then
thoroughly clean foreign material from the
contact area.
• Replace parts as necessary.
0
Install or Connect
1 . Oil seal into the bore.
F-00863
Figure 28—Wheel Bearing Nut Wrench
• Lubricate the cavity between the new seal
lips with a high m elting point bearing
lubricant.
• Use the proper seal installing tool listed
under tools required.
2 . Flange using J-8614-01.
• Use scribed marks for reinstallation.
3. Nut, use J-8614-01 (figure 18).
• Use s c rib e m ark as an in s ta lla tio n
reference.
REAR AXLE 4B-21
4. Propeller shaft. Refer to PROPELLER SHAFT
(SEC. 4A).
AXLE VENT REPLACEMENT
(12-INCH RING GEAR-FULL
FLOATING AXLE)
A threaded type axle vent is used on the
Rockwell 12-inch ring gear axle and must be
replaced if the vent cap is damaged or missing.
• Tap the axle shaft (74) into position using
J-8117 and J-2619-01.
• Index the axle shaft (74) splines into the hub
(86 ) splines.
2. Gasket (73).
3. Hub cap (72).
4. Washers (71) and bolts (70).
BEARING ADJUSTMENT (12-INCH
GEAR—FULL FLOATING AXLE)
Clean
The area around the axle vent.
Remove or Disconnect
0
Axle vent from the housing.
Install or Connect
0
Axle vent to the housing.
AXLE SHAFT REPLACEMENT
(12-INCH RING GEAR—FULL
FLOATING AXLE)
Raise the vehicle and place jack stands under
the frame side rails.
«"► Remove or Disconnect (Figure 29)
• Make sure the brakes are fully released and do
not drag.
• Check the wheel bearing play by grasping the tire
at the top and pulling and pushing back and forth,
or by using a pry bar under the tire. If the wheel
bearings are properly adjusted, movement of the
hub or disc will be barely noticeable. If the
movement is excessive, adjust the bearings.
0
Remove or Disconnect (Figure 29)
Tool Required:
J-25510 Wheel Bearing Nut Wrench
• Raise the vehicle until the wheel is free to
spin.
1. A xle s h a ft (74).
Replacement.”
R efer
to
“ A xle
S ha ft
2. Nut (90) using J-25510.
• Release the tang.
3. Lock washer (89).
1.
2.
•
•
3.
Tools Required:
J-2619-01 Slide Hammer
J-8117 Axle Shaft Puller Adapter
Bolts (70) and washers (71).
Hub cap (72).
Thread J-8117 into the tapped hole on the axle
shaft (74) flange.
Attach J-2619-01 to J-8117.
Axle shaft (74) using J-2619-01.
Adjust
Nut (8 8 ) using J-25510. Tighten the nut (88 )
while the hub is rotating to 68 N m (50 ft.
lbs.). Make sure the bearing surfaces are in
contact and then back the nut (88 ) off 1/s
turn.
|-n-| Install or Connect (Figure 29)
1. Lock washer (89).
Old gasket material from the hub (86 ) and hub
cap (72) and the axle shaft (74) flange and mating
surface in the hub (86 ).
0
Install or Connect (Figure 29)
Tools Required:
J-2619-01 Slide Hammer
J-8117 Axle Shaft Puller Adapter
1. Axle shaft (74).
• Bend a tang over a flat of the adjusting nut
( 88 ).
2. Nut (90) using J-25510.
• Tighten the nut (90) to 339 N m (250 ft. lbs.).
• Bend a long tang of the lock washer (89)
over a flat of the nut (90).
3. A xle sh a ft (74).
Replacement.”
R efer
• Lower the vehicle.
to
“ A xle
S ha ft
»
4B-22 REAR AXLE
70.
71.
72.
73.
74.
75.
76.
77.
Bolt
Washer
Hubcap
Gasket
Axle Shaft
Axle Housing
Bracket
Wheel Bolt
78.
79.
80.
81.
82.
83.
84.
85.
Hex Bolt
Deflector
Oil Seal
Inner Bearing
Brake Disc
Retaining Ring
Outer Bearing
Spacer
Hub
Thrust Washer
Adjusting Nut
Lock Washer
Nut
F-01012
86.
87.
88.
89.
90.
Figure 29—Rockwell Axle And Hub Detail
DRIVE PINION OIL SEAL
REPLACEMENT
(12-INCH RING G E A R FULL FLOATING AXLE)
• A pinion oil seal may be replaced on the Rockwell
1 2 -inch ring gear axle with the carrier assembly
installed in the vehicle.
Remove or Disconnect (Figure 30)
Tools Required:
J-8614-01 Companion Flange Holder and
Remover
J-22281 Pinion Oil Seal Installer
• Raise the vehicle.
1. Propeller shaft. Refer to PROPELLER SHAFT
(SEC. 4A).
Im portant
• Scribe a reference line on the pinion stem, pinion
nut and companion flange.
2. Cotter key (91) and nut (92) using J-8614-01.
3. Companion flange (94).
4. Bolts (97).
5. Oil seal retainer (95).
91.
92.
93.
94.
Cotter Key
Nut
Pinion Shaft
Companion Flange
95. Oil Seal Retainer
96. Oil Seal
97. Bolt
F-01013
Figure 30— Drive Pinion Oil Seal Detail
REAR AXLE 4B-23
6 . Oil seal (96).
bore shoulder.
• Pry the oil seal (96) from the bore being
careful not to dam age the m achined
surfaces.
2 . Oil seal retainer (95).
3. Bolts to the retainer (97).
4. Companion flange (94) use the scribed reference
mark.
5. Nut (92) using J-8614-01.
IQ* Clean
• The seal contact area.
Install or Connect (Figure 30)
Lubricate the cavity between the new seal (96)
lips with a high melting point bearing lubricant.
Refer to MAINTENANCE AND LUBRICATION
(SEC. OB).
Oil seal (96) into the bore using J-22281.
• Be sure the seal (96) bottoms against the
$
Tighten
• Nut (92). Align the castellated nut with the
hole in the pinion shaft (93) stem and the
reference mark.
6 . Cotter key (91).
7. Propeller shaft. Refer to PROPELLER SHAFT
(SEC. 4A).
4B-24 REAR AXLE
SPECIFICATIONS
TORQUES
DANA
Filler Plug
Lock Screw
Brake Backing
Plate
Axle Shaft to
Hub Bolts
Carrier Cover
Axle
Lubricant
Capacity
8 V2 " RING GEAR-
9 V2 " RING GEAR-
SEMI FLOATING
AXLE
SEMI FLOATING
AXLE
Nm
Nm
FT. LBS.
FT. LBS.
RING
GEAR AXLE-FULL
FLOATING
93/4 " - 1 0 1/2"
Nm
FT. LBS.
CHEVROLET
IOV2 " RING GEAR
AXLE-FULL
FLOATING
Nm
ROCKWELL
12" RING GEAR
AXLE-FULL
FLOATING
FT. LBS.
Nm
FT. LBS.
35
34
34
25
25
24
34
18
25
14
10
24
18
47
—
—
—
—
—
—
47
35
142
105
142
105
142
105
—
—
—
—
—
—
27
20
27
20
156
47
115
35
156
41
115
30
—
—
Liters
Pints
Liters
Pints
Liters
Pints
Liters
Pints
Liters
Pints
2.0
4.2
2.6
5.5
2.6
5.5
3.4
7.2
6.6
14.0
WHEEL BEARING ADJUSTMENT VALUES
RING GEAR
SIZE
9 % " Ring Gear
10 V2 " Ring Gear
12" Ring Gear
BEARING ADJUSTING
NUT TORQUE*
68.0 N m 50 ft. lbs.
68.0 N m 50 ft. lbs.
68.0 N m 50 ft. lbs.
ADJUSTING NUT
BACKOFF*
OUTER LOCKNUT
TORQUE
**
88.1 N m 65 ft. lbs.
1/a Turn
339.0 N m 250 ft. lbs.
* W ith wheel rotating.
**B a ck -o ff the nut and retighten to 47 N m (35 ft. lbs.). Then back the nut off 1/4 turn
RESULTING
BEARING
ADJUSTMENT
0.0254 to 0.254 mm
.001 to .010 inch
End Play
TYPE OF
BEARING
TAPERED
ROLLER
REAR AXLE 4B-25
1 . J-8117
2 . J-6627-A
Axle Shaft Puller Adapter
Wheel Stud Remover
Driver Handle
3. J-8092
4. J-5853
Torque W rench— Inch/Pound
5. J-8614-01 Companion Flange Holder And Remover
6 . J-2619-01 Slide Hammer With Adapter
7. J-2222-C Wheel Bearing Nut Wrench
Outer Wheel Bearing Cup Installer
8 . J-24426
9. J-24427 Inner Wheel Bearing Cup Installer
Outer Pinion Bearing Cup Installer
10 . J-8608
Pinion Oil Seal Installer
1 1 . J-24384
1 2 . J-24428
Axle Shaft Seal Installer
13. J-24434 Pinion Oil Seal Installer
14. J-22281
Pinion Oil Seal Installer
Wheel Bearing Outer Cup Installer
15. J-8114
Wheel Bearing Inner Cup Installer
16. J-8093
Figure 31—Special Tools
4C-1
SECTION 4C
FRONT AXLE
The following “ Notice” applies to one or more steps in the assembly procedure of components in this portion of
the manual as indicated at appropriate locations by the terminology: “ NOTICE: See ‘Notice’ on page 4C-1 of this
section.”
NOTICE: All front axle fasteners are important attaching parts in that they could affect the performance of
vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the
same part number or with an equivalent part if replacement becomes necessary. Do not use a replacement
part of lesser quality or substitute design. Torque values must be used as specified during reassembly to
assure proper retention of all parts.
CONTENTS
SUBJECT
PAGE
D e s c rip tio n .................................................................................................................................................................. 4C- 2
Diagnosis Of The Front A xle .................................................................................................................................... 4C- 2
Road T e s t ................................................................................................................................................................ 4C- 2
Tire N o is e s .............................................................................................................. ............................................... 4C- 2
Engine or Exhaust N o is e s .................................................................................................................................... 4C- 2
Test For Wheel Bearing N o is e ........................................................................................................................... 4C- 2
Test For Differential Bearing N o is e ...................................................................................................................4C- 2
Test For Pinion Bearing N o is e ........................................................................................................................... 4C- 2
On-Vehicle Service..................................................................................................................................................... 4C- 3
Axle Shaft Replacement........................................................................................................................................ 4C- 3
Front Axle Assembly Replacement.....................................................................................................................4C- 4
Axle Joint Component R e p la ce m e n t................................................................................................................ 4C- 5
Locking Hub Component R eplacem ent............................................................................................................ 4C- 5
Autom atic Hub To The Wheel A d ju s tm e n t......................................................................................................4C- 8
Manual Locking Hub R eplacem ent.....................................................................................................................4C- 8
Manual Locking Hub Rebuild P ro c e d u re .......................................................................................................... 4C- 8
S pecifica tio ns..............................................................................................................................................................4C-10
Special T o o ls .............................................................................................................................................................. 4C-10
4C-2 FRONT AXLE
DESCRIPTION
The front axle is a hypoid gear axle unit equipped
with steering knuckles and an automatic or manual
locking hub. The K10 and 20 models use a Chevrolet
front axle having an 8 1/2 -inch ring gear axle rated at
3600 pounds for the K-10 and 3800 pounds for the K20. A Dana (60 Series) axle is used on the K-30 model
and is rated at 4500 pound capacity. The Dana axle
has a 9 3/4-inch ring gear. Automatic hub locks are used
on all models to engage the hub whenever four-wheel
drive is selected. A manual locking hub is used on the
K-30 model only and must be engaged manually when­
ever four-wheel drive is selected.
DIAGNOSIS OF THE FRONT AXLE
ROAD TEST
Check tires for irregular wear.
Check tire pressure.
Check axle lubricant level.
Drive to warm up the front axle.
Test at various speeds in drive, float, coast and
while cornering.
• Verify that the hubs are locked.
• Noise should change due to cornering loads.
• Jack-up wheels to verify roughness at the wheels.
•
•
•
•
•
TIRE NOISES
•
•
•
•
•
Change the tire pressure to minimize noises.
Drive over different road surfaces.
Smooth black-top minimizes tire noise.
Cross switch the tires, if necessary.
Snow tire treads and studs cause added noises.
ENGINE OR EXHAUST NOISES
• Drive slightly above the speed where the noise
occurs, place transmission in neutral.
• Let the engine speed drop to idle.
• Stop the vehicle.
• Run the engine at various speeds.
TEST FOR WHEEL BEARING NOISE
• Drive the vehicle at low speed on a smooth road.
• Turn the vehicle to develop left and right motions,
traffic permitting.
*TEST FOR DIFFERENTIAL
BEARING NOISE
•
•
•
•
Drive the vehicle at low speed on a smooth road.
Constant low pitch bearing noise may be heard.
Noise should not change in reversing turns.
The noise pattern should vary with the wheel
speed.
*TEST FOR PINION BEARING
NOISE
• Rough running or a whine noise should increase
with speed.
• Noise pitch should be higher than differential
noise.
• Perform the test on a smooth road to minimize
tire noises.
• Perform test at various speeds in drive, float, and
coast.
• Rear pinion bearing noise may be louder on
acceleration.
• Front pinion bearing noise may be louder on
deceleration.
• Gear noise tends to peak in a narrow speed
range.
‘ Bearing tests should be done in 2H (after 4H
selection to lock hubs). This removes the transfer case
whine.
FRONT AXLE 4C-3
ON-VEHICLE SERVICE
2 0 . Hub Lock
2 1 . Ring
2 2 . Retainer
23.
24.
25.
26.
27.
28.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
46.
47.
48.
49.
Nut
Ring
Nut
Outer Bearing
Cup
Hub And Disc
Cup
Inner Bearing
Inner Seal
Outer Deflector
Seal
Spacer
Seal
Bearing
Spindle
Brake Bracket
Brake Caliper
Splash Shield
Housing
Tube
Knuckle
Axle Shaft
U-Joint
Washer
Nut
F-01015
Figure 1—Front Axle Detail
AXLE SHAFT REPLACEMENT
Remove or Disconnect (Figure 1)
• Raise the vehicle.
1 . Wheel and tire.
2. Brake caliper (40).
Im portant
• Support the brake caliper (40) so as not to
stretch or damage the brake hose.
3. Hub lock mechanism (20).
4. Rotor and hub (28).
5. Inner bearing (31) and seal (32).
6 . Splash shield (41), brake bracket (39) and spindle
(38).
7. Axle shaft (46).
IJI
Clean
• Inner and outer wheel bearing (31, 26).
• Hub and disc (28), spindle (38).
Inspect
All parts and replace as necessary.
Important
Lube the spindle bearing (37) and spindle (38).
4C-4 FRONT AXLE
• Pack the inner and outer wheel bearing (31, 26).
NOTICE: For steps 3, 4 and 5, see “Notice” on
page 4C#1 of this section.
Install or Connect (Figure 1)
1. Seal (36) and spacer (35) to the axle shaft (46).
2. Axle shaft (46) into the housing (42).
3. Spindle (38) to the knuckle (44). Be sure the seal
(34) and outer deflector (33) are in place.
4. Brake bracket (39).
5. Splash shield (41).
• New washers (48) and nuts (49) to the studs.
Torque the nuts (49) to 88 N m (65 ft. lbs.).
6 . Hub and disc (28).
• Adjust the wheel bearings (26, 31). Refer to
FRONT SUSPENSION (SEC. 3C).
7. Retainer (22) and ring (21).
8 . Hub lock mechanism (20).
NOTICE: See “Notice” on page 4C#1 of this
section.
9. Brake caliper (40).
• Do not stretch or damage the brake hose.
10. Wheel and tire.
• Lower the vehicle and test.
L * Inspect
FRONT AXLE ASSEMBLY
REPLACEMENT
• Raise the vehicle until the weight is removed from
the front springs. Support the vehicle with jack
stands placed behind the front springs.
The a sse m b ly and re p a ir or re p la ce as
necessary.
NOTICE: For steps 1, 5, 6 and 7, see “Notice”
on page 4C#1 of this section.
+ + Remove or Disconnect (Figure 1)
Install or Connect (Figure 1)
1. Propeller shaft. Refer to “ Propeller Shaft” (Sec.
4A).
2. Connecting rod from the steering arm. Refer to
FRONT SUSPENSION (SEC. 3C).
3. Brake caliper (40).
• Support the brake caliper (40) so as not to
stretch or damage the brake hose.
4. Shock absorbers from the axle brackets.
5. Front stabilizer bar.
6 . Axle vent tube and clips (figure 2).
7. Nuts, washers, U-bolts, spacers and plates.
• Support the axle with a jack.
8 . Axle assembly out from under the vehicle.
Jjj Clean
• Axle assembly.
• Axle assembly positioned under the vehicle.
1. Plates, spacers, U-bolts, washers and nuts.
2. Axle vent tube and clips. Refer to figure 2.
3. Front stabilizer bar.
4. Shock absorbers to the axle brackets.
5. Brake caliper (40).
6 . Connecting rod to the steering arm.
7. Propeller shaft.
• Lower the vehicle.
FRONT AXLE 4C-5
AXLE JOINT COMPONENT
REPLACEMENT
Remove or Disconnect
• Raise the vehicle.
s h a ft. R efer to “ A xle S ha ft
Replacement” earlier in this section.
• Support the shaft yoke in a bench vise or on
a short piece of pipe.
2. Trunnion
• Using a brass drift and soft hammer drive
on the end of a trunnion bearing enough to
drive the opposite bearing from the yoke.
• Support the other yoke and drive the
trunnion bearing out in the same manner.
1 . A xle
Clean
The bearings and yokes.
L*
Inspect
The bearings and yokes. Replace parts as
necessary.
+ + Install or Connect
• Lubricate the new bearings with a high melting
point type wheel bearing grease.
1. Bearing in a yoke ear.
2. Trunnion in the bearing.
3. Another bearing in the opposite yoke ear with the
trunnion aligned.
4. Bearing in each ear of the companion yoke.
• Press the bearings in beyond the iock ring
grooves.
5. Lock ring at each bearing.
• Tap the yoke lightly to seat the bearings
against the lock rings.
LOCKING HUB COMPONENT
REPLACEMENT
AUTOMATIC HUB COMPONENT
REPLACEMENT
1.
2.
3.
4.
5.
6.
7.
8.
9. Ring (57) using needle nose plier.
• Pull the remaining components from the
wheel.
10. Retaining ring (77) from the sleeve (67) groove.
• Rotate the drag sleeve (75) until it drops into
engagement with the gear (59).
• Lift and cock the drag sleeve (75) to unlock
the tangs of the brake band (74) from the
“ window” of the inner cage (72), then move
the drag sleeve (75) and brake assembly
away.
Important
• NEVER REMOVE THE BRAKE BAND (74) FROM
THE DRAG SLEEVE (75). The spring tension of
the brake band (74) can be changed if the coils
are over expanded and the operation of the hub
could be affected.
11. Ring (73) from the groove in the clutch gear (59).
12. Inner cage (72).
• While removing the inner cage (72) use a
small screw driver to pry the plastic outer
cage (71) away.
13. Outer cage (71).
• Pry the plastic outer cage (71) tabs free from
the groove in the clutch gear (59) and move
the outer cage (71) away.
14. Sleeve (67) from the clutch gear (59).
• Compress the return spring (64) and hold
the assembly in a compressed condition by
using the clamps shown in figure 4.
• Position the assembly with the clamps in
place in a vice and hold both ends of the
sleeve (67).
15. Ring (61).
• While holding the sleeve (67) in the vise,
remove the clamps holding the return spring
(64) and then open the vise and release the
return spring (64).
16. Retainer plate (62).
17. Retainer (63).
18. Stop ring (68 ).
• Align the ends of the stop ring (68 ) with the
legs of the cam (70) to allow removal.
19. Spring (69).
20. Cam (70) from the gear (66 ).
Remove or Disconnect (Figure 3)
Inspect
Screws (50) and O-ring seals (52).
Cover (52).
Seal (53).
Keeper (60).
Spring (54).
Inner race (55).
Bearing (56).
Retainer (58).
•
All parts and replace as necessary.
Install or Connect (Figure 3)
1 . Cam (70) over the flats of the gear (66 ).
2. Spring (69).
• Compress the spring (69) and slide the large
diameter end against the gear (66 ).
4C-6 FRONT AXLE
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
Screw
O-Ring Seal
Cover
Seal
Spring
Inner Race
Bearing
Ring
Retainer
Clutch Gear
Keeper
Ring
Retainer Plate
Retainer
Return Spring
Retainer
Gear
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
79.
80.
81.
82.
Sleeve
Stop Ring
Spring
Cam
Outer Cage
Inner Cage
Ring
Brake Band
Drag Sleeve
Spacer
Retaining Ring
Washer-K10, K20
Adjusting Nut
Lock Ring
Nut W ith Pin
Ring-K30
Figure 3—Automatic Hub-Detail K10, K20, K30
F-01017
FRONT AXLE 4C-7
9. Inner cage (72) into the outer cage (71).
• Align the tab of the outer cage (71) with the
“ window” of the inner cage (72).
10. Ring (73).
• Into the groove of the clutch gear (59) above
the outer cage (71).
Im portant
61.
67.
70.
A.
B.
C.
D.
Ring
Sleeve
Cam
Clamp
Vs-inch
1 1/4-inches
3/8-inch
11.
12.
F-01018
13.
14.
Figure 4—Compressing The Return Spring
3. Gear (66 ) over the splines of the sleeve (67).
• Cam (70) should locate at the end of the
sleeve (67) having no splines.
Im portant
4.
5.
6.
7.
8.
• The gear (66 ) and spring (69) should slide
freely over the splines of the sleeve (67).
Stop ring (68 ) to the groove of the sleeve (67).
Retainers (63 and 65) to each end of the spring
(64).
• Retainer (65) to the shoulder of the gear
( 66).
Retainer plate (62) to the retainer (63).
• Compress the return spring (64) and hold
the assembly together with clamps (figure
4).
Ring (61) in the groove of the sleeve (67).
• Place the assembly (steps 1 through 7) into
the clutch gear (59) and support the clutch
gear (59) above a flat surface allowing the
assembly to drop down so that the tangs of
the brake band (74) may be assembled later.
Outer cage (71) into the clutch gear (59).
• The ramps of the outer cage (71) must face
the cam (70).
• Locate the outside tabs of the outer cage
(71) into the wide grooves of the clutch gear
(59).
15.
16.
17.
18.
19.
• Service the brake band (74) and drag sleeve
(75) as an assembly and be sure the original
lu b ric a n t has not been rem oved or
contaminated. Lubricant number 1052750
or its equivalent m ust be used in this
assembly.
Brake band (74) tangs.
• Place the tangs of the brake band (74) on
each side of the lug of the outer cage (71)
located in the “ window” of the steel inner
cage (72). Cock these parts to engage the
tangs in this position.
Spacer (76) and retaining ring (77).
• To the sleeve (67) above the drag sleeve
(75).
Hub assembly to the vehicle.
Ring (57) to the clutch gear (59) unsplined end.
• Locate the tangs of the ring (57) pointing
away from the vehicle.
Keeper (60).
• Hold the tangs of the ring (57) together and
attach the keeper (60). For K10 and K20
assemble the O-ring seal (53) in the clutch
gear (59) groove and over the keeper (60).
Bearing (56) over the inner race (55).
— Lubricate the bearing (56) with light wheel
bearing grease.
— Steel balls should be visible when bearing
(56) is properly installed.
Retainer (58) into the outer race (55) hole.
• Bearing (56) inner race (55) and retainer
(58) into the sleeve (67).
Spring (54) into the cover (52) bore.
• Align cover (52) screw holes with the screw
thread holes in the clutch gear (59).
O-ring seals (51) and screws (50) in the cover
(52).
• The hub sleeve (67) and attached parts
should turn freely after assembly.
Tighten
• Screws (50) to 5.1 N m (45 in. lbs.).
Important
• The five cover screw s (50) m ust be
loosened (three or four turns) and then
4C-8 FRONT AXLE
pushed inward to allow the retaining ring
(57) to expand when assem bling the
automatic locking hub to the vehicle.
AUTOMATIC HUB TO THE WHEEL
ADJUSTMENT
A lock ring (80) is supplied with each new automatic
hub assembly. Assemble this lock ring (80) between
the nut with pin (81) and the adjusting nut (79) as
follows:
Use J-6893 to torque the nut with pin (81) to 68 N m
(50 ft. lbs.) to seat the wheel bearings; then back off
the nut with pin (81) and torque to 47 N m (35 ft. lbs.)
while rotating the hub (figure 3).
Then back the nut with pin (81) off a maximum of 3/8
turn. Assemble the lock ring (80) over the axle shaft
against the nut with pin (81) so that the inner tang
enters the axle shaft keyway. One of the holes in the
lock ring (80) must engage the pin on nut (81). Thread
the adjusting nut (79) onto the axle shaft and tighten to
247 N m (183 ft. lbs.).
Align the cut-outs on the drag sleeve (75) with the
tabs on the lock ring (80) as the splines of the clutch
gear (59) mesh with the splines of the wheel hub.
Loosen the five cover screws (50) three or four turns
and push in on the screws (50) to allow the ring (57) to
expand into the groove in the wheel hub. Torque the
screws (50) to 5.1 N m (45 inch lbs.).
MANUAL LOCKING HUB
REPLACEMENT
L*
Inspect
All parts and replace as necessary.
L*
Install or Connect (Figure 5)
1.
2.
3.
4.
Body assembly (86 , 87, 88 and 89).
Internal snap ring (85) to the hub.
Snap ring (90) onto the axle shaft end.
Outer hub locking assembly (92, 93, 94, 95, 96,
97, 98 and 99).
5. Screws (91).
MANUAL LOCKING HUB REBUILD
PROCEDURE
• Outer hublock knob assembly should be replaced
only as a unit, because timing relationships are
difficult to restore if disassembly occurs. The
inner body may be disassembled for cleaning
and component replacement.
Remove or Disconnect (Figure 5)
Screws (91).
Hub body (86 ).
Spring (88 ).
Internal snap ring (85).
Inner drive gear (87) with thrust washers.
Plastic sleeve.
L*
Inspect
•
All parts and replace as necessary.
Remove or Disconnect (Figure 5)
Install or Connect (Figure 5)
1. Screws (91).
2. Outer hub locking assembly (92, 93, 94, 95, 96,
97, 98, and 99).
3. Snap ring (90) from the axle shaft end.
4. Internal snap ring (85) from hub.
5. Body assembly (86 , 87, 88 and 89).
1.
2.
3.
4.
5.
6.
• Lubricate inner body parts with ATF or a
light coat of wheel bearing grease.
Plastic sleeve.
Inner drive gear (87) with thrust washers.
Internal snap ring (85).
Spring (8 8 ).
Hub body (8 6 ).
Screws (91).
FRONT AXLE 4C-9
85.
86.
87.
88.
89.
90.
91.
92.
93.
94.
95.
96.
97.
98.
99.
Internal Snap Ring
Hub Body
Inner Drive Gear
Spring
Clutch Ring
Axle Shaft Snap Ring
Screw
Hub Cap
Compression Spring
Clutch Cup
O-Ring Seal
Dial Screw
Clutch Nut
Seal
Lock Ring
F-01019
Figure 5—Manual Locking Hub, K30
4C-10 FRONT AXLE
SPECIFICATIONS
Nut-Splash Shield Retaining
88 N m
Nut With Pin
68 N m
<Bearin9 Preload)
(Final Torque)
Cover Screw-Automatic Hub
Adjusting Nut-Axle Shaft
47 N m
5.1 N m
247 N m
SPECIAL TOOLS
Snap Ring Plier
J-6893-D Wheel Bearing Nut Wrench
65 ft. lbs.
50 ft. lbs.
35 ft. lbs.
45 inch lbs.
183 ft. lbs.
5-1
SECTION 5
BRAKES
The following notice applies to one or more steps in the assembly procedure of components in this portion of the
manual as indicated at appropriate locations by the terminology NOTICE: See ‘Notice’ on page 5-1 of this section.
NOTICE: This fastener is an important attaching part in that it could affect the performance of vital compo­
nents and system, and/or could result in major repair expense. It must be replaced with one of the same part
number or with an equivalent part if replacement becomes necessary. Do not use a replacement part of
lesser quality or substitute design. Torque values must be used as specified during reassembly to assure
proper retention of this part.
CAUTION: When servicing wheel brake parts, do not create dust by grinding or sanding brake linings or by
cleaning wheel brake parts w ith a dry brush or w ith compressed air. (A water dampened cloth should be
used). Many wheel brake parts contain asbestos fibers which can become airborne if dust is created during
servicing. Breathing dust containing asbestos fibers may cause serious bodily harm.
CONTENTS
SUBJECT
PAGE
Brake System D ia g n o s is .............................................................................................................................................5 - 2
Road Testing the B ra k e s ........................................................................................................................................ 5 - 2
Hydro-Boost System T e s t s .................................................................................................................................... 5 - 2
Diagnosis o f Brake S y s te m ........................................................................................................................................ 5 - 4
Diagnosis o f Hydro-Boost S y s te m ........................................................................................................................... 5 - 7
On - Vehicle S ervice..................................................................................................................................................... 5 - 8
Bleeding the Brake Hydraulic S y s te m .................................................................................................................5 - 8
Flushing the Brake Hydraulic S ystem ...................................................................................................................5 - 9
Brake Pipes and H o s e s ...........................................................................................................................................5 - 9
Com bination V a lv e ................................................................................................................................................... 5-12
Height Sensing Brake P roportioning V a lv e ........................................................................................................5-13
Brake Pedal A sse m b ly................................................................................................................................................. 5-17
Checking Pedal T ra v e l.............................................................................................................................................5-17
Brake Pedal R e p la ce m e n t...................................................................................................................................... 5-17
Brake Pedal Rod R e p la ce m e n t............................................................................................................................. 5-20
Stoplamp S w itc h ....................................................................................................................................................... 5-20
Parking Brake S y s te m ................................................................................................................................................. 5-22
Parking Brake Pedal or Handle R e p la c e m e n t................................................................................................... 5-22
Cable R eplacem ent................................................................................................................................................... 5-23
Propeller Shaft Brake R e p la ce m e n t.....................................................................................................................5-27
Parking Brake A d ju s tm e n t...................................................................................................................................... 5-27
Master C ylinders............................................................................................................................................................5-30
D e s c rip tio n ................................................................................................................................................................ 5-30
Master Cylinder R e p la ce m e n t................................................................................................................................5-30
Bench B le e d in g ..........................................................................................................................................................5-30
Vacuum B o o s te rs ..........................................................................................................................................................5-32
D e s c rip tio n ................................................................................................................................................................ 5-32
Vacuum Booster R e p la c e m e n t............................................................................................................................. 5-32
5-2 BRAKES
CONTENTS (CONT.)
SUBJECT
PAGE
Hydraulic Brake Booster (H ydro-B oost).................................................................................................................. 5-33
D e s c rip tio n ................................................................................................................................................................ 5-33
Hyrdro-Boost R e p la ce m e n t....................................................................................................................................5-33
Bleeding the Hydro-Boost S y s te m .......................................................................................................................5-36
Disc B ra kes................................................................................................. .................................................................. 5-37
D e s c rip tio n ................................................................................................................................................................5-37
Brake Lining In s p e c tio n .......................................................................................................................................... 5-37
Brake Lining Replacem ent...................................................................................................................................... 5-38
Servicing the R o tor...................................................................................................................................................5-41
Rebuilding the C a lip e r............................................................................................................................................ 5-42
Drum B ra kes.................................................................................................................................................................. 5-45
D e s c rip tio n ................................................................................................................................................................5-45
Brake Lining Replacem ent...................................................................................................................................... 5-45
Servicing the Brake D ru m ...................................................................................................................................... 5-45
Brake A d ju s tm e n t..................................................................................................................................................... 5-47
Wheel Cylinder Replacement................................................................................................... ..............................5-47
Rebuilding the Wheel C y lin d e r............................................................................................................................. 5-47
S p e c ific a tio n s ................................................................................................................................................................ 5-49
Special T o o ls ................................................................................................................................................................5-51
BRAKE SYSTEM DIAGNOSIS
ROAD TESTING THE BRAKES
BRAKE TEST
The brakes should be tested on a dry, clean,
reasonably smooth and level roadway. A true test of
brake performance cannot be made if the roadway is
wet, greasy, or covered with loose dirt so that all the
tires do not grip the road equally. The testing will be
adversely affected if the roadway is crowned so as to
throw the weight of the vehicle toward the wheels on
one side or if the roadway is so rough that the wheels
tend to bounce.
Test the brakes at different vehicle speeds with both
light and heavy pressure; however, avoid locking the
wheels and sliding the tires on the roadway. Locked
wheels and sliding tires do not indicate brake efficiency
since heavily braked turning wheels will stop the
vehicle in less distance than locked wheels. More
tire-to-road friction is present with a heavily braked
turning tire than with a sliding tire.
EXTERNAL CONDITIONS THAT AFFECT
BRAKE PERFORMANCE
1. Tires—Tires having unequal contact and grip on
the road will cause unequal braking. The tires
must be equally inflated and the tread pattern of
the right and left tires must be about equal.
2. V e h ic le L o a d in g —When the ve h icle has
unequal loading, the most heavily loaded wheels
require more braking power than the others.
3. F ro n t W heel B e a rin g s— Loose front wheel
bearings permit the disc to tilt and have spotty
contact with the linings causing erratic action.
4. Front End Alignm ent—Misalignment of the front
end, particularly in regard to limits on camber and
caster, will cause the brakes to pull to one side.
HYDRO-BOOST SYSTEM TESTS
The Hydro-Boost system receives its source of
power from the power steering system. Therefore a
faulty power steering system may affect the operation
of the booster, just as a problem in the booster may
affect the steering system. Prior to performing any
tests the following checks must be made.
1. Check all the power steering and brake pipe
connections for leaks or restriction.
NOTICE: Power steering fluid and brake fluid
cannot be mixed. If brake seals contact
steering fluid or steering seals contact brake
fluid, seal damage will result.
2. Check and fill the brake master cylinder with
brake fluid.
BRAKES 5-3
3. Check and fill the power steering reservior with
power steering fluid. If fluid contains air refer to
POWER STEERING (Sec. 3B3) for further diag­
nosis.
4. Check power steering pump belt for wear and
tension. Adjust if needed, refer to POWER
STEERING (Sec. 3B3).
5. Check engine idle speed, refer to the vehicles
Emission Control Inform ation label for idle
specifications.
6. Check steering pump pressure. Refer to POWER
STEERING (Sec. 3B3).
NOISE DIAGNOSIS
The following noises are associated with the
Hydro-Boost and may or may not be cause for
customer complaint. Some noises are normal and for
the most part temporary in nature. Other noises may
be a sign of excessive wear or the presence of air in
either the booster or the steering system.
1. A m oan or low fre q u e n c y hum u s u a lly
accompanied by a vibration in the pedal or
steering column may be observed during parking
maneuvers or other low speed maneuvers. This
may be caused by a low fluid level in the power
steering pump or by air in the fluid. Holding the
pump at relief pressure (steering wheel held all
the way in one direction) for more than five
seconds will cause air to enter the system. Check
the fluid level and fill if needed. The system must
then sit for one hour to remove the air. If the
condition persists, refer to POWER STEERING
(Sec. 3B3).
2. A high speed fluid noise may be heard when the
brake pedal is fully depressed, this condition is
normal.
3. Whenever the accumulator pressure is used, a
slight hiss may be noticed. It is the sound of the
hydraulic fluid escaping through the accumulator
valve, and is completely normal.
4. After the accumulator has been emptied, and the
engine is started again, another hissing sound
may be heard during the first brake application or
the first steering maneuver. This is caused by the
fluid rushing through the accumulator charging
orifice. It is normal and will only be heard once
after the accumulator is emptied. However, if this
sound continues, even though no apparent
accumulator pressure assist was made, it could
be an indication that the accumulator is not
holding pressure and should be checked using
the procedure for the “ Accumulator Leakdown
Test” in this section.
BOOSTER FUNCTIONAL TEST
With the engine off, apply the brake pedal several
times until the accumulator is completely depleted.
Depress the brake pedal using 180 N (40 lbs.) of force
and start the engine. The pedal will fall and then push
back against your foot.
ACCUMULATOR LEAKDOWN TEST
1. Start the engine and charge the accumulator by
applying the brake pedal or by turning the
steering wheel from stop to stop. Turn off the
engine and let the vehcile sit for one hour. After
one hour there should be at least two power
assisted applications with the engine off.
2. If the reserve system will not retain a charge for
one hour, but functions normally immediately
following charging, the accumulator valves are at
fault and the booster must be disassembled and
the accumulator valves replaced.
3. If the accumulator can be heard charging and
discharging, but it does not hold a charge,
d isassem ble the booster and replace the
accumulator valves.
4. Deplete the accumulator by pressing the brake
pedal several times. If the accumulator can has
lost its gas charge, it is possible to rotate or
wobble the accumulator can with respect to the
housing. Replace the accumulator assembly.
SEAL LEAK DIAGNOSIS (FIGURE 1)
A. INPUT ROD SEAL. A damaged seal will show up
as a fluid leak from the mounting bracket vent
hole. The booster must be removed from the
vehicle and disassembled. The input rod bore
should be checked for any scratches that may
cause the leak. If scratches are present, the
5 -4 BRAKES
housing cover must be replaced. If no excessive
scratches are present, then the booster seal kit
can be used to replace the appropriate seals.
B. POWER PISTON SEAL. Power piston seal
damage will be noticed by fluid leaking out at the
common master cylinder brake booster vent and
possible reduction in power assist. The booster
m ust be rem oved from the v e h ic le and
disassembled. The piston should be checked for
any scratches that may be the cause of the leak.
If scratches are present, then the booster seal kit
can be used to replace the appropriate seals.
C. HOUSING SEAL. If the housing seal is damaged,
fluid will leak out from between the two housings.
The booster must be removed from the vehicle
and disassembled. The booster seal kit should be
used to replace the housing and input rod and
power piston seals.
D. SPOOL VALVE PLUG SEAL. Damage to this
seal will be noticed by fluid leaking out past the
plug. The booster need not be removed from the
vehicle.
E. ACCUMULATOR SEAL. Damage to this seal will
result in fluid leakage past the accumulator cap.
The seal can be replaced while the booster is
installed on the vehicle.
F. RETURN PORT FITTING. Tighten the fitting to
10 N m (7 ft. lbs.). If the leak continues, replace
the seal ring under the fitting.
DIAGNOSIS OF BRAKE SYSTEM
PROBLEM
Uneven Brake A ction
(Brakes Pull).
POSSIBLE CAUSE
1. Incorrect tire pressure.
2. Front end out of alignment.
3. Loose suspension parts.
4. Worn out brake lining.
5. Incorrect lining material.
6. Malfunctioning caliper assembly.
7. Loose calipers.
8. Contaminated brake linings.
9. Malfunctioning rear brakes.
10. Leaking wheel or piston cylinder seal.
11. Restricted brake tubes or hoses.
12. Unmatched tires on the same axle.
CORRECTION
1. Inflate evenly on both sides to manu­
facturer’s specifictions.
2. Check and align to manufacturer’s
specifications.
3. Check all suspension mountings.
4. Replace with lining of correct mate­
rial.
5. Replace with linings of correct mate­
rial.
6. Check for frozen or sluggish pistons
and the lubrication of the retainer
bolts. Caliper should slide.
7. Check and torque.
8. Repair as necessary. Replace linings
in complete axle sets.
9. Check for inoperative self adjusters.
Weak return springs. Leaking wheel
cylinders.
10. Repair as necessary.
11. Check for collapsed rubber hoses or
damaged lines. Repair as necessary.
12. Same style tires with about the same
tread should be used on the same
axle.
BRAKES 5-5
DIAGNOSIS OF BRAKE SYSTEM (CONT.)
POSSIBLE CAUSE
PROBLEM
Brakes Squeak.
1. Worn out linings.
2. Glazed brake lining.
3. Heat spotted rotors or drums.
4. Weak or incorrect brake shoe retention
springs.
5. Contaminated brake linings.
6. Incorrect lining material.
7. Brake assembly attachments missing
or loose.
8. Excessive brake lining dust.
Brake Pedal
Pulsates.
1. Excessive rotor lateral runout.
2. Rear drums out of round.
3. Heat spotted rotors or drums.
4. Incorrect wheel bearing adjustments.
5. Out of balance wheel assembly attach­
ments missing or loose.
6. Brake assembly attachments missing
or loose.
Excessive Pedal
Effort.
1.
2.
3.
4.
5.
Leaking vacuum system.
Malfunctioning power brake unit.
Worn out linings.
Malfunctioning proportioning valve.
Incorrect lining material.
6. Incorrect wheel cylinder.
Excessive Pedal
Travel.
1. Insufficient fluid in master cylinder res­
ervoir.
2. Air in brake system.
3.
4.
5.
6.
Malfunctioning self adjusters.
Master cylinder.
Incorrect wheel bearing adjustment.
Improperly adjusted master cylinder
pushrod.
CORRECTION
1. Replace linings.
2. Replace linings.
3. Check per instructions. If within spec­
ifications machine the rotor or drum.
4. Replace with new retention springs.
5. Repair as necessary. Replace linings
in complete axle sets.
6. Replace with linings of correct mate­
rial.
7. Repair as necessary.
8. Clean dust from brake assembly.
1. Check per instructions. If within spec­
ifications machine the rotor.
2. Check per instructions. If within spec­
ifications machine the drum.
3. Check per instructions. If within spec­
ifications machine the rotor or drum.
4. Repair as necessary.
5. Repair as necesary.
6. Repair as necessary.
1.
2.
3.
4.
5.
Repair as necessary.
Repair as necessary.
Replace linings.
Repair as necessary.
Replace with linings of correct mate­
rials.
6. Replace with corrrect size wheel cyl­
inder.
1. Fill reservoir with approved brake
fluid. Check for leaks and air in the
system. Check tell-tale light.
2. Check for leaks in lines, wheel cylin­
ders, or master cylinder. Bleed the
system.
3. Repair as necessary.
4. Replace or repair as necessary.
5. Repair as necessary.
6. Adjust master cylinder pushrod.
5-6 BRAKES
DIAGNOSIS OF BRAKE SYSTEM (CONT.)
PROBLEM
Brakes Drag.
POSSIBLE CAUSE
1. Malfunctioning caliper assembly.
2. Contaminated or improper brake fluid.
3. Improperly adjusted parking brakes.
4. Restricted brake tube or hoses.
5.
6.
7.
8.
Brake tell-tale light
comes on.
Malfunctioning proportioning valve.
Malfunctioning self adjusters.
Malfunctioning master cylinder.
Improperly adjusted master cylinder
pushrod.
1. Air in the brake system.
2. Malfunctioning master cylinder.
3. Contaminated or improper brake fluid.
4. Parking brake on or not fully released.
5.
6.
7.
8.
Worn out brake lining.
Incorrect wheel bearing adjustment.
Malfunctioning self adjusters.
Brake assembly attachments missing
or loose.
9. Improperly adjusted master cylinder
pushrod.
Excessive Brake
Pedal Effort.
1. Loose or broken power steering pump
belt.
2. No fluid in the power steering reser­
voir.
3. Leaks at Hydro-Boost tube fittings.
4. External leakage at the accumulator.
5. Faulty booster piston seal causing
leakage at the booster flange vent.
6. Faulty booster input rod seal with
leakage at the input rod end.
7. Fautly booster cover seal with leakage
between the housing and cover.
8. Fautly booster spool plug seal.
CORRECTION
1. Check for frozen or sluggish pistons
and the lubrication of the retainer
bolts. Caliper should slide.
2. Repair as necessary.
3. Repair as necessary.
4. Check for collapsed rubber hoses or
damaged lines. Repair as necessary.
5. Replace or repair as necessary.
6. Repair as necessary.
7. Repair as necessary.
8. Adjust pushrod length.
1. Check fluid level. Check for leaks in
lines, wheel cylinders, or master cyl­
inder. Bleed the system.
2. Check for faulty metering valve, or
leaking. Repair as necessary.
3. Repair as necessary.
4. Check parking brake. Repair as nec­
essary.
5. Replace linings.
6. Repair as necessary.
7. Repair as necessary.
8. Replace or repair as necessary.
9. Adjust pushrod length.
1. Tighten or replace the belt.
2. Fill reservoir and check for external
leaks.
3. Tighten fittings or replace tube seats,
if faulty.
4. Replace seal and retainer.
5. Overhaul with new seal or input rod
and piston assembly.
6. Overhaul with new seal kit.
7. Overhaul with new seal kit.
8. Overhaul with spool plug seal kit.
BRAKES 5-7
DIAGNOSIS OF HYDRO-BOOST SYSTEM
PROBLEM
Slow Brake Pedal
Return.
POSSIBLE CAUSE
1. Excessive seal friction in booster.
2. Faulty spool action.
3. Restriction in return line from booster
to pump reservoir.
4. Damaged input rod end.
Grabby Brakes.
Booster Chatters Pedal Vibrates.
A ccum ulator Leakdown System does
not hold charge.
CORRECTION
1. Overhaul with new seal kit.
2. Flush steering system while pumping
brake pedal.
3. Replace line.
4. Replace input rod and piston assem­
bly.
1. Faulty spool action caused by contami­
1. Flush steering system while pumping
nation in system.
2. Power steering pump belt slips.
brake pedal.
2. Tighten belt.
3. Low fluid level in power steering pump.
4. Faulty spool operation caused by con­
tamination in system.
3. Fill reservoir and check for external
leaks.
4. Flush steering system while pumping
brake pedal.
1. Contamination in steering hydro-boost
1. Flush steering system while pumping
system.
2. Internal leakage in accumulator sys­
tem.
brake pedal.
2. Overhaul unit using accumulator re­
build kit and seal kit.
5-8 BRAKES
ON VEHICLE SERVICE
BLEEDING THE BRAKE
HYDRAULIC SYSTEM
A bleeding operation is necessary if air has been
introduced into the hydraulic brake system.
It may be necessary to bleed the system at all four
wheels if air has been introduced by a low fluid level
condition in the master cylinder. Also if the brake pipes
have been disconnected at either the master cylinder
or the combination valve. If a pipe is disconnected at
one wheel, then only bleed that particular wheel.
The time required to bleed the hydraulic system
when the master cylinder is removed can be reduced if
the master cylinder is filled with fluid and as much air
as possible is bled from the cylinder before installing it
on the vehicle.
MANUAL BLEEDING
If the vehicle is equipped with power brakes, deplete
the vacuum reserve by applying the brakes several
times with the engine off.
Use extreme care to prevent brake fluid from
contacting any painted surface.
1. Fill the master cylinder reservoirs with brake fluid
specified in MAINTENANCE AND LUBRICATION
(Sec. OB).
• Maintain the fluid level in the reservoir
during the bleeding operation.
2. If the master cylinder is suspected to have air in
the bore, it must be bled before any wheel
cylinder or caliper.
• Remove the forward brake pipe connection
at the master cylinder.
• Allow brake fluid to flow from the connector
port.
• Connect the brake pipe but do not tighten.
3. Slowly depress the brake pedal allowing the air to
bleed from the loose fitting.
• Tighten the fitting before releasing the
pedal.
• Wait 15 seconds, and repeat this sequence,
including the 15 second wait until all the air
is purged from the bore.
4. After all the air has been removed from the
forward connection disconnect the rear pipe.
• Allow brake fluid to flow from the connector
port.
• Connect the brake pipe but do not tighten.
5. Slowly depress the brake pedal allowing the air to
bleed from the loose fitting.
• Tighten the fitting before releasing the
pedal.
• Wait 15 seconds, and repeat this sequence,
including the 15 second wait until all the air
is purged from the bore.
6. If it is known that the calipers and wheel cylinders
do not contain any air, then it will not be
necessary to continue. Otherwise bleed each
wheel in the following sequences.
• Right rear
• Left rear
• Right front.
• Left front
7. Attach a hose to the wheel cylinder/caliper
bleeder screw.
• Immerse the opposite end of the hose into a
container partially filled with clean brake
fluid.
8. Slowly depress the brake pedal one time and
hold.
• Loosen the bleeder screw to purge the air
from the wheel cylinder/caliper.
• Tighten the bleeder screw and slowly
release the pedal.
• Wait 15 seconds, then repeat this sequence,
including the 15 second wait until all the air
is purged from the wheel cylinder/caliper.
9. Continue steps 7 and 8 at each wheel until the
entire brake system has been bled.
10. Check the brake pedal for “ sponginess” and the
brake warning lamp for an indication of an
unbalanced pressure. Repeat the entire bleeding
p ro ced u re to co rre ct e ith e r of these two
conditions.
PRESSURE BLEEDING
The pressure bleeding equipment must be of the
diaphragm type. It must have a rubber diaphragm
between the air supply and the brake fluid to prevent
air, moisture, oil, and other contaminants from entering
the hydraulic system. Also adapters are needed,
depending on the type of master cylinder used.
Tools Required:
J-29567 Brake Bleeder Adapter (Plastic
Reservoir)
J-23518-01 Brake Bleeder Adapter (Cast
Iron Reservoir)
J-23709 Combination Valve Depressor
NOTICE: It is very important that the correct
master cylinder bleeder adapter be used to
avoid possible damage to the master cylinder
reservoir.
1. Fill the pressure tank at least 1/3 full of brake fluid.
The bleeder must be re-bled each time fluid is
added.
• Charge the bleeder to 140 - 170 kPa (20 to
25 psi).
BRAKES 5-9
2. Use J-23709 to depress and hold the valve stem
on the combination valve during the bleeding op­
eration (figure 2).
• Install the correct bleeder adapter (figures 3
and 4).
3. Bleed each wheel in the following sequence.
• Right rear
• Left rear
• Right front
• Left front
4. Connect the hose from the bleeder to the adapter
at the master cylinder.
• Open the tank valve.
5. Attach a hose to a brake bleeder screw.
• Immerse the opposite end of the hose into a
container partially filled with clean brake
fluid.
6. Open the bleeder screw at least 3U of a turn and
allow the fluid to flow until no air is seen in the
fluid.
• Close the bleeder screw.
7. Repeat step six at all the wheels.
8. Check the brake pedal for “ sponginess” , repeat
the entire bleeding procedure if this condition is
found.
Figure 2 —Installing Combination
Valve Depressor
BRAKE PIPES AND HOSES
The hydraulic brake system com ponents are
interconnected by special steel piping and flexible
hoses. Flexible hoses are used between the frame and
the front calipers, and the frame and rear differential.
When the hydraulic pipes have been disconnected for
any reason, the brake system must be bled after
reconnecting the pipe, refer to “ Bleeding the Brake Hy­
draulic System” in this section.
9. Remove J-23709.
• D isconnect the line form the bleeder
adapter.
• Remove bleeder adapter.
10. Fill the master cylinder to the proper level with
brake fluid.
FLUSHING THE BRAKE
HYDRAULIC SYSTEM
It is recommended that the entire hydraulic system
be thoroughly flushed with clean brake fluid whenever
new parts are installed in the hydraulic system.
Flushing is also recommended if there is any doubt
as to the grade of fluid in the system or if fluid has
been used which contains the slightest trace of mineral
oil. Flush the system whenever there is any question of
contamination.
Flushing is performed at each bleeder valve in the
same manner as the bleeding operation, except that
the bieeder valve is opened 1 1/2 turns and the fluid is
forced through the lines and bleeder valves until it
emerges clear in color. Refer to “ Bleeding the Brake
Hydraulic System” , in this section.
Check master cylinder fluid level after flushing at
each valve and replenish if required. When flushing is
completed at all bleeder valves, make certain the
master cylinder reservoir is filled to proper level.
Figure 3—Plastic Reservoir
Bleeder Adapter
5-10 BRAKES
Install or Connect (Figure 5)
• Use new copper washers when installing the
hose.
1. Hose (32).
• The hose must not be twisted.
2. Washers (33).
• Bolt (34).
3. Clip or nut (31).
• Steel pipe.
4. Bleed the brakes, refer to “ Bleeding the Brake
Hydraulic System” in this section.
Im portant
The hose installation must not contact any
suspension components.
BRAKE PIPES
When replacing a steel brake pipe, always use steel
piping which is designed to withstand high pressure
and resist corrosion. The same size pipe must be used
as the one removed.
Figure 4—Cast Iron Reservoir
Bleeder Adapter
FLEXIBLE HOSE
On the front brakes the hose is connected to the
caliper with a bolt and copper washers. The fitting at
the other end of the hose is secured at the frame with
either a nut or a clip.
At the rear differential one end of the hose is
connected to the differential with a bolt. The other end
is secured at the frame with either a nut or a clip.
Flexible Hose Inspeciton
The flexible hoses should be inspected for any signs
of road damage which will cause cracks and chafing of
the other cover. If any of these conditions are visible,
replace the hose.
Hose Replacement
|+ + | Remove or Disconnect (Figure 5)
• Clean dirt, grease, and other foreign material off
the hose fittings at both ends.
1. Steel pipe.
• Clip or nut (31).
2. Bolt (34).
• Washers (33).
• Hose (32).
NOTICE: N ever use c o p p e r tubing for
hydraulic brake lines because copper is
subject to fatique cracking, and corrosion
which could result in brake failure.
Brake pipes that run parallel to each other must
maintain a 6 mm (1/4-inch) clearance.
Pipe Flaring (Figure 6)
Tools Required:
J-23530 Flaring Tool.
J-23533-B Tube Cutter.
In order to ensure a proper flare, a special flaring tool
must be used. When using the tool, instruction
furnished by the tool manufacturer should be followed.
Always inspect newly formed flares for cracks or
malformations which might cause leaks. After flaring,
blow out the brake pipe with compressed air before
installing on the vehicle.
NOTICE: Double lap flaring tool must be used,
as single flaring tools cannot produce a flare
strong enough to hold the necessary
pressure.
1. Use steel pipe and fittings of the correct size. The
outside diameter of the pipe is used to specify the
size.
2. Cut the pipe to length. Add 3 mm (Vs-inch) to the
length for each flare.
3. Flare the pipe ends by following the instructions
with the tool.
4. Bend the pipe to match the old pipe by using a
pipe bender.
BRAKES 5-11
31.
32.
33.
34.
Nut or Clip
Flex Hose
Washer
Bolt
B-07786
Figure 5—Flexible Hoses
5-12 BRAKES
in the event of a front brake system malfunction, also
full front pressure is retained in the event of rear mal­
function.
The pressure differential warning switch is designed
to constantly compare front and rear brake pressure
from the master cylinder and energize the warning
lamp on the dash in the event of a front or rear system
malfunction. The valve and switch are so designed that
the switch will latch in the “ warning” position once a
malfunction has occured. The only way the lamp can
be turned off is to repair the malfunction and apply a
pedal force as required to develop about 3102 kPa (450
psi) line pressure.
COMBINATION VALVE
The com bination valve is com prised of three
sections, each serving a different function (figure 7).
The metering or hold off section of the valve limits
the p ressure to the fro n t d isc brakes u n til a
predetermined front input pressure is reached, enough
to overcome the rear shoe retractor springs. There is
no restriction to the inlet pressures below 20 kPa (3 psi)
to allow for pressure equalization during the no apply
periods.
The proportioning section of the combination valve
proportions outlet pressure to the rear brakes after a
predetermined rear input pressure has been reached.
This is done to prevent rear wheel lock-up on the
vehicles with light rear wheel loads.
The valve is designed to have a By-Pass feature
which assures full system pressure to the rear brakes
ELECTRICAL CIRCUIT TEST
1. Disconnect the wire from the switch on the valve.
• Connect a jumper wire from the switch wire
to ground.
2. Turn the ignition key to “ ON” .
• The warning lamp should light.
• If the lamp will not light check the bulb. If
the bulb is good, refer to CHASSIS ELEC­
TRICAL (Sec. 8B) for futher diagnosis.
3. Turn the ignition off.
• Disconnect jumper wire and connect the
wire to the switch terminal.
Valve Warning Switch Test
1. Raise the vehicle.
• Support with suitable safety stands.
2. Attach a hose to a rear brake bleeder screw.
• Immerse the opposite end of the hose into a
container partially filled with clean brake
fluid.
Figure 7—Combination Valve
BRAKES 5-13
3.
4.
5.
6.
7.
8.
9.
• Make sure the master cylinder reservoir is
full.
Turn the ignition key to “ ON” .
• Open the bleeder screw while a helper
applies moderate pressure to the brake
pedal.
• The warning lamp should light.
• Close the bleeder screw before the helper
releases the brake pedal.
Reapply the brake pedal with moderate to heavy
pressure.
• The lamp should go out.
Attach a hose to a front brake bleeder screw.
• Immerse the opposite end of the hose into a
container partially filled with clean brake
fluid.
• Make sure the master cylinder reservoir is
full.
Open the bleeder screw while a helper applies
moderate pressure to the brake pedal.
• The warning lamp should light.
• Close the bleeder screw before the helper
releases the brake pedal.
Reapply the brake pedal with moderate to heavy
pressure.
• The lamp should go out.
Turn the ignition key off.
• If the warning lamp does not light during
steps 3 and 6 but does light when a jumper
is connected to ground, the warning switch
portion of the valve is faulty. Do not
disassemble any portion of the valve. It
must be replaced.
Remove the safety stands.
• Lower the vehicle.
• Check and fill the master cylinder to the
proper level.
VALVE REPLACEMENT
Remove or Disconnect (Figure 8)
• The combination valve is not repairable and must
be replaced as a complete assembly.
• Care must be taken to prevent brake fluid from
contacting any painted surface.
1. Hydraulic pipes.
• Plug the pipes to prevent the loss of fluid or
the entrance of dirt.
2. Warning switch harness.
3. Bolts.
• Combination valve.
0
Install or Connect (Figure 8)
1. Position valve on the bracket.
• Bolts.
2. Warning switch harness.
3. Hydraulic pipes.
4. Bleed the brake system. Refer to “ Bleeding The
Brake Hydraulic System” in this section.
HEIGHT SENSING BRAKE
PROPORTIONING VALVE
The height sensing brake proportioning valve is used
on series 30 models (figure 9). This will provide
optimum brake balance and efficiency. The vehicle
braking force is distributed to the front and rear wheels
as determined by either a light or heavy payload
condition.
The valve is mounted on the frame, and a linkage
connects the valve to a bracket that is mounted on the
axle.
C A U T IO N :
A d d in g
any
s u s p e n s io n
accessories or o ther equipm ent (such as
load leveling kits, air shocks, suspension lift
kits, additional spring leafs, etc.), or making
m odification that w ill change the distance
between the axle and the fram e w ith o u t
ch a n g in g th e lo a d, w ill p ro v id e a false
reading to the brake p ro po rtio n ing valve.
This could re su lt in u n sa tisfa cto ry brake
perform ance which in turn could result in an
accident and possibly personal injury.
VALVE REPLACEMENT
Remove or Disconnect (Figure 10)
• Raise the vehicle.
• Support the frame with suitable safety stands.
The axle must be allowed to hang free.
• Clean the exterior of the valve to prevent dirt from
contaminating the hydraulic system.
1. Brake pipes (51).
2. Nut from the shaft (48).
• Lever (49).
3. Bolts (46) and washers (47).
• Valve (50).
-►+ Install or Connect (Figure 10).
1. Position the valve on the mounting bracket.
• Washer (47) and bolts (46).
2. Lever (49).
• Refer to “ Proportioning Valve Adjustment”
in this section.
3. Nut (48). Torque to 10 N m (89 in. lbs.).
4. Brake pipes (51).
5. Bleed brakes. Refer to “ Bleeding the Brake
Hydraulic System” , in this section.
6. Remove the safety stands.
• Lower the vehicle.
• Test the brakes.
5-14 BRAKES
A.
B.
C.
D.
G-Van
C-K Truck
P Model (42)
P Model (32)
B-07802
Figure 8—Combination Valves
BRAKES 5-15
Figure 9—Height Sensing Proportioning Valve
PROPORTIONING VALVE ADJUSTMENT
If a front wheel lockup is experienced when the
vehicle is being operated near the maximum GVWR
with a lower than desired brake application, the valve
adjustment should be checked. Use the following
procedure to check the adjustment.
ADJUSTMENT GAGE CHART
Part
Number
Code Color
14061394
14061395
A Green
B Black
14061396
C Blue
1. Raise the vehicle.
• Support the frame with suitable safety
stands. The axle must be allowed to hang
free.
2. Remove the nut from the valve shaft.
• Remove the lever.
3. Select the appropriate adjustment gage from the
chart.
RPO
RPO
RPO
RPO
4.
Vehicle Combination
C/K 3500 with G52
C3500 Less G52
C2500 all
K 20903
G31305/06 with LE3/LS9
K3500 Less G52
K20906
G31305/06 with LLA/LT9
G52: Extra Capacity Rear Spring
LS9: 5.7 Liter (Cal. Only)
LL4: 6.2 Liter
LT9: 5.7 Liter
Rotate the valve shaft to permit the installation of
the adjustment gage (figure 11).
• The center hole of the adjustment gage
must seat on the “ D” shape of the valve
shaft.
• The gage tang must seat in the valve
mounting hole.
NOTICE: Do not drive lever assembly on valve
shaft by using nut or proper valve setting may
be disturbed.
51 50
46.
47.
48.
49.
50.
51.
Bolts
Washer
Nut
Lever
Valve
Brake Pipe
48
B-07783
Figure 10—Removing Proportioning Valve
5. Install the nut on the shaft. Torque to 10 N-m (89
in. lbs.)
6. Sever the tang on the adjustment gage (figure
12).
7. Remove the safety stands.
• Lower the vehicle.
• Test the brakes.
5-16 BRAKES
Figure 12—Severing The Adjustment Tang
BRAKES 5-17
BRAKE PEDAL ASSEMBLY
1.
2.
3.
4.
11.
12.
A. Manual Transmission
B. Automatic Transmission
B-06947
Figure 13—C-K Brake Pedal Components
CHECKING PEDAL TRAVEL
At frequent intervals the brake pedal should be
checked for travel. Travel is the distance the pedal
moves toward the floor from a full released position.
This check should be made with the brakes cold and
about 122 N (90 lbs.) of force on the pedal. On
vehicles with power brakes the pedal must be pumped
at least three times with the engine off before making
the check. Follow the specifications below for the cor­
rect travel.
C-K-G Manual..................................115 mm (4.5-inches)
C-K-G Power......................................90 mm (3.5-inches)
P (Except J F 9 )..................................90 mm (3.5-inches)
P (J F 9 )............................................ 150 mm (6.0-inches)
BRAKE PEDAL REPLACEMENT
C-K AND P30 (32) MODELS
• Pin (10) and washer (9).
• Pushrod (8).
• Return spring (5).
2. Nut (2) and bolt (1).
3. Brake pedal (12).
• Clutch pedal (11) (if equipped).
• Bushings (3).
• Spacer (4).
Install or Connect (Figures 13 and 14)
1. Spacer (4).
• Bushings (3).
• Brake pedal (12).
• Clutch pedal (11) (if equipped).
NOTICE: See “Notice” on page 5-1 of this
section.
2. Bolt (1) and nut (2).
Remove or Disconnect (Figures 13 and 14)
1. Retainer (6).
• Washer (7).
• Nut to 34 N m (25 ft. lbs.)
3. Return spring (5).
5-18 BRAKES
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
12.
Bolt
Nut
Bushings
Spacer
Return Spring
Retainer
Washers
Pushrod
Washer
Pin
Brake Pedal
B-07771
Figure 14—P30 (32) Brake Pedal Components
4. Washer (9) and pin (10).
• Pushrod (8).
• Washer (7) and retainer (6).
5. Check the stoplamp switch adjustment. Refer to
“ Stoplamp Switch.”
G-MODEL
Remove or Disconnect (Figure 15)
1. Retainer (6).
• Washer (9).
• Pushrod (8).
• Washer (7).
2. Return spring. (5).
3. Retainer (14) or clutch attaching components (15)
(if equipped).
4. Pin (13) or clutch pedal (11) (if equipped).
5. Brake pedal (12).
• Bushings (3).
Install or Connect (Figure 15)
1. Bushings (3).
• Brake pedal (12).
2. Pin (13) or clutch pedal (11) (if equipped).
3. Retainer (14) or clutch attaching components (15)
(if equipped).
4. Return spring (5).
5. Washer (7).
• Pushrod (8).
• Washer (9).
• Retainer (6).
6. Check the stoplamp switch adjustment. Refer to
“ Stoplamp Switch.”
BRAKES 5-19
3.
5.
6.
7.
8.
9.
11.
12.
13.
14.
15.
Bushing
Return Spring
Retainer
Washer
Push rod
Washer
Clutch Pedal
Brake Pedal
Pin
Retainer
Clutch Attaching Components
B-07770
Figure 15—G-Van Brake Pedai Components
P 30 (42) MODEL
Remove or Disconnect (Figure 16)
1. Retainer and washer.
• Pushrod and washer.
2. Clutch attaching components (15) (if equipped).
3. Clutch pedal (11) (if equipped).
• Return spring (5) (if equipped).
4. Nut (16) and bolt (18).
• Shaft (17).
5. Brake pedal (12).
• Bushings (3).
Install or Connect (Figure 16)
— Lubricate pivot points with Delco Brake Lube or
equivalent.
1. Bushings (3).
• Brake pedal (12).
2. Shaft (17).
• Bolt (18) and nut (16).
3. Clutch pedal (11) (if equipped).
• Return spring (5) (if equipped).
4. Clutch attaching components (15).
I
5. Washer and pushrod.
• Washer and retainer.
6. Check the stoplamp switch adjustment, refer to
“ Stoplamp Switch.”
5-20 BRAKES
18. Bolt
B-07772
Figure 16—P 30 (42) Brake Pedal Components
BRAKE PEDAL
ROD REPLACEMENT
P 30 (32) MODEL
Remove or Disconnect (Figure 17)
Adjust
• Brake rod to 790 mm (31.00-inches) from the
centers of the bolt holes.
2. Brake rod (8).
3. Bolt (19) and washers (20 and 21).
• Nut (24) and retainer (23).
1. Retainer (6).
• Nut (16).
• Bolt (17) and washers (7 and 9).
2. Screws (18).
3. Raise the vehicle and support it with suitable
safety stands.
4. Retainer (23).
• Nut (22).
• Nut to 35 N m (26 ft. lbs.).
4. Lower the vehicle.
5. Screws (24).
6. Bolt (17) and washers (9 and 7).
• Nut (16) and retainer (6).
• Bolt (19) and washers (20 and 21).
5. Brake rod (8).
• Boot (24).
|*»<"| Install or Connect (Figure 17)
NOTICE: For steps 2 and 6 see “ N otice” on
page 5-1 of this section.
1. Boot (24).
• Nut to 35 N m (26 ft. lbs.).
STOPLAMP SWITCH
The design of the switch mounting provides for an
automatic adjustment when the brake pedal is returned
to its stop. There are two styles of switches, the
determining factor is if the vehicle is equipped with
cruise control. For electrical diagnosis of the stoplamp
switch, refer to CHASSIS ELECTRICAL (Sec. 8B).
BRAKES 5-21
SWITCH REPLACEMENT
2. Electrical connectors.
3. Negative battery cable.
«"► Remove or Disconnect
SWITCH ADJUSTMENT
1. Remove the negative battery cable.
2. Electrical connectors.
3. Switch.
-►+ Install or Connect
1. Switch.
Adjust
Refer to “ Switch Adjustment” .
6.
7.
8.
9.
16.
17.
18.
19.
20.
21.
22.
23.
24.
1. Depress the brake pedal and press the switch in
until it is firmly seated in the clip.
• Audible “ clicks” can be heard as the
threaded portion of the switch is pushed
through the clip.
2. Pull the brake pedal against the pedal stop until
the audible “ click” can no longer be heard.
3. Electrical contact should be made when the
brake pedal is depressed the specified distance.
• C-K models 25 - 31 mm (1.0 - 1.24 inches)
• G-P models 11 - 24 mm (0.45 - 0.95 inches)
Retainer
Washer
Brake Rod
Washer
Nut
Bolt
Screw
Bolt
Washer
Washer
Nut
Retainer
Boot
B-07775
Figure 17 — P30 (32) Brake Pedal Rod Components
5-22 BRAKES
PARKING BRAKE SYSTEM
1.
2.
3.
Nuts
Bolt
Release Rod
B-07774
Figure 18—Removing Parking Brake Pedal on C-K, and G Models
PARKING BRAKE PEDAL OR
HANDLE REPLACEMENT
C-K-G MODELS
Remove or Disconnect (Figure 18)
+*• Install or Connect (Figure 18)
NOTICE: See “ N otice” on page 5-1 o f this
section for steps 2 and 4.
1. Parking brake cable.
2. Bolt.
• The parking brake must be in the released
position.
1. Nuts (1).
2. Release rod (3).
3. Bolt (2).
4. Brake assembly.
• Parking brake cable.
Tighten
• Refer to “ Torque Specifictions” in this
section.
3. Release rod (3).
4. Nuts (1).
BRAKES 5-23
Tighten
• Refer to “ Torque Specifications” in this
section.
5. Check the parking brake adjustment, refer to
“ Parking Brake Adjustment” in this section.
P MODELS
|+ + | Remove or Disconnect (Figure 19)
• The parking brake must be in the released
position.
1. Nuts (10) and washers (11).
2. Bolts (12) and washers (13).
• Spacers (14).
3. Cotter pin (15) and washer (16).
• Clevis pin (17).
4. Nut (18) and washer (19).
5. Bolt (20).
• Spacer (21).
• Cable (22).
6. Handle assembly.
|+<-| Install or Connect (Figure 19)
1. Cable (22).
• Clevis pin (17).
• Washer (16) and cotter pin (15).
2. Spacer (21).
• Bolt (20).
• Washer (19) and nut (18).
3. Spacer (14).
NOTICE: See “Notice” on page 5-1 of this
section.
4. Washer (13) and bolts (12).
• Washers (11) and nuts (10).
• Nuts to 24 N m (18 ft. lbs.)
5. Check the parking brake adjustment, refer to
“ Parking Brake Adjustment” in this section.
CABLE REPLACEMENT
FRONT CABLE REPLACEMENT
(C-K MODELS)
|<~+| Remove or Disconnect (Figures 20 and 21)
• Raise the vehicle and support with suitable safety
stands.
1. Nut (31) from the equalizer (32).
2. Connector (33) from the front cable.
3. Bend retaining fingers (34) and (35).
• Cable from the brake pedal assembly.
4. Cable assembly (36).
• Attach a piece of wire to the cable to help in
installation.
Install or Connect (Figure 20 and 21)
1. Cable assembly (36).
• Make sure all the retaining fingers are completely
through the holes.
2. Cable to the pedal assembly.
3. Connector (33).
4. Nut (31) onto the equalizer (32).
f t
A djust
• Refer to “ Parking Brake Adjustment” in this
section.
5. Lower the vehicle.
FRONT CABLE REPLACEMENT
(G AND P MODELS)
Remove or Disconnect (Figures 20, 22 and 23)
• Raise the vehicle and support with suitable safety
stands.
1. Nut (31) from the equalizer (32).
2. Connector (33) from the front cable.
3. Bolts (37) and clips (38).
4. Cable from the pedal/handle assembly.
5. Bend retaining fingers (34).
6. Cable assembly (36).
• Attach a piece of wire to the cable to help in
installation.
+4-
Install or Connect (Figures 20,22 and 23)
1. Cable assembly (36).
• Make sure all the retaining fingers are completely
through the holes.
2. Cable to the pedal/handle assembly.
3. Clips (38) and bolts (37).
4. Connector (33).
5. Nut (31) onto the equalizer (32).
Adjust
• Refer to “ Parking Brake Adjustment” , in this
section.
6. Lower the vehicle.
CENTER CABLE REPLACEMENT
|+ + | Remove or Disconnect (Figure 20)
• Raise the vehicle and support with suitable safety
stands.
1. Nut (31) from the equalizer (32).
2. Both front and rear connectors (33).
5-24 BRAKES
Figure 19—Removing Parking Brake Lever on P Models
BRAKES 5-25
31. Nut
32. Equalizer
33. Connector
B-07777
Figure 20—Equalizer Components
34. Frame Retaining Fingers
35. Pedal Retaining Fingers
36. Cable Assembly
B-07778
Figure 21—C-K Front Cable Components
5-26 BRAKES
33.
34.
36.
37.
38.
Connector
Frame Retaining Fingers
Cable Assembly
Bolt
Clip
B-07780
Figure 22 —P Model Front Cable Components
3. Cable.
-►+ Install or Connect (Figure 20)
1. Cable.
2. Connector (33).
3. Nut (31) onto the equalizer (32).
Adjust
• Refer to “ Parking Brake Adjustment” in this
section.
4. Lower the vehicle.
REAR CABLE REPLACEMENT
|<~+| Remove or Disconnect (Figure 20)
• Raise the vehicle and support it with suitable
safety stands.
36. Cable Assem bly
37. Bolt
38. Clip
1. Nut (31) from the equalizer (32).
2. Connector (33).
B-07781
Figure 23—G Model Front Cable Components
3. Brake drum and shoe assembly, refer to “ Drum
Brakes” in this section.
4. Bend in retaining fingers at the backing plate.
5. Retaining clip at the frame support.
• Cable assembly.
BRAKES 5-27
Install or Connect (Figure 20)
1. Cable assembly.
• Make sure all the retaining fingers are completely
through the backing plate.
2. Retaining clip at the frame support.
3. Brake shoes and drum assembly, refer to “ Drum
Brakes” in this section.
4. Connector (33).
5. Nut (31) onto the equalizer (32).
3. Lever strut (55) and strut spring (57).
4. Washers (63).
• Hold down springs (64).
• Hold down clips (65).
5. Return spring guide (72).
• Return springs (56 and 57)
6. Drum (66).
7. Propeller shaft, refer to PROPELLER SHAFT
(Sec. 4A) in this manual.
Adjust
Adjust
• Refer to “ Parking Brake Adjustment” in this
section.
6. Lower the vehicle.
PROPELLER SHAFT
BRAKE REPLACEMENT
Remove or Disconnect (Figure 24)
• Raise the vehicle and support with suitable safety
stands.
1. Propeller shaft, refer to PROPELLER SHAFT
(Sec. 4A) in this manual.
CAUTION: See “ Caution” on page 5 - 1 .
2. Drum (66).
• It may be necessary to back off the adjusting
screw.
3. Return springs (56 and 71).
• Return spring guide (72).
4. Hold down clips (65).
• Hold down springs (64).
• Washers (63).
5. Lever strut (55).
• Strut spring (57).
6. Lever retaining ring (67).
7. Shoes (68).
8. Adjusting screw (60).
• Adjusting screw spring (58).
Inspect
— All parts for discoloration due to heat, or
stress. Replace if necessary.
— Brake drum for scoring and heat spots.
Machine drum if needed.
I * * ! Install or Connect (Figure 24)
— Lubricate the shoe pads and adjusting screw
threads with a thin coat of white lithum grease.
1. Adjusting screw (60) and adjusting screw spring
(58) to both shoes (68).
2. Shoe assembly (68).
• Lever retaining ring (67).
• Refer to “ Parking Brake Adjustment” in this
section.
8. Lower the vehicle.
PARKING BRAKE ADJUSTMENT
The parking brakes must be adjusted whenever the
p a rkin g brake ca b le s have been re p lace d or
disconnected. Also if the brake holding ability is not
adequate. Before adjusting the parking brakes check
the condition of the service brakes. The service brakes
must be adjusted properly before proceeding with the
parking brake adjustment.
CABLE INSPECTION
Check the parking brake system for free operation.
The brake lever must return to the released position
without sticking or binding. If a problem is present
check the cable routings for kinks or binding. Clean
and lubricate the parking brake assembly and cables
with Delco brake lube or equivalent.
FOOT PEDAL TYPE
1. Block the front wheels.
• Raise and support the rear axle with
suitable safety stands.
2. Loosen the equalizer nut.
3. Set the parking brake pedal to four clicks.
f t
Adjust
• Equalizer nut until the wheels will not
rotate forward without a moderate
drag.
4. Release the parking brake and rotate the rear
wheels.
• There should be no brake drag.
5. Remove the safety stands and lower the vehicle.
• Unblock the front wheels.
LEVER TYPE
1. Block the front wheels.
• Raise and support the rear axle with
suitable safety stands.
2. Turn the adjusting knob on the parking brake
lever counterclockwise until it stops.
• Apply parking brake.
5-28 BRAKES
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
Support Plate
Washer
Anchor Pin Nut
Hold Down Pin
Lever Strut
Return Spring
Strut Spring
Adjusting Screw Spring
Adjusting Screw Socket
Adjusting Screw
Adjusting Screw Nut
Cable
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
Washer
Hold Down Spring
Hold Down Clip
Drum
Lever Retaining Ring
Shoe
Washer
Operating Lever
Return Spring
Return Spring Guide
Anchor Pin
B-07779
Figure 24—Propeller Shaft Brake Components
BRAKES 5-29
3. Loosen the equalizer nut.
Adjust
• Equalizer nut until a light drag is felt
while rotating the wheels forward.
• Knob on the parking brake lever until a
definite snap over center is felt.
4. Release the parking brake and rotate the rear
wheels.
• There should be no brake drag.
5. Remove the safety stands and lower the vehicle.
• Unblock the front wheels.
INTERNAL EXPANDING (PROPELLER SHAFT)
CAUTION: See “ Caution” on page 5-1 of this
section.
1. Block the front wheels.
• Raise and support the rear axle with
suitable safety stands.
2. Remove the clevis pin connecting the pull rod
and relay lever.
3. Rotate the brake drum to align the access hole
with the adjusting screw.
• M anual tra n s m is s io n s - the adjusting
screw is located at the bottom of the shoe.
• A utom atic transm ission - the adjusting
screw is located at the top of the shoe.
• When adjusting the parking brake for the
first time, it will be necessary to remove the
lanced area from the drum. The drum must
be removed to clean out all the metal
shavings. Refer to PROPELLER SHAFTS
(Sec. 4A).
Adjust
• Adjusting screw until the drum cannot be
rotated by hand.
• Back off the adjusting screw ten notches.
The drum should rotate freely.
4. Place parking brake lever in the full release
position.
5. Take up the slack in the cable to overcome the
spring tension.
Adjust
• The clevis of the pull rod to align with the
hole in the relay lever.
6. Install the clevis pin.
• Install new cover in the drum access hold.
7. Remove the safety stands and lower the vehicle.
• Unblock the front wheels.
5-30 BRAKES
MASTER CYLINDERS
MASTER CYLINDER
REPLACEMENT
+ + Remove or Disconnect (Figure 27)
• Apply the vehicles parking brakes.
1. Brake pipes.
• Cover the ends of the pipes to prevent dirt from
entering the system.
B-07803
Figure 25—Cast Iron Master Cylinder
DESCRIPTION
2. Mounting nuts.
3. Master cylinder.
• If the vehicle is equipped with manual brakes,
refer to “ Brake Pedal Replacement” for the
removal of the pushrod from the pedal.
There are two designs of master cylinders available
depending on the brake option.
One is a full cast iron design incorporating a conven­
tional front to rear brake split (figure 25). The primary
piston provides the fluid pressure to the front brakes,
while the secondary piston provides the fluid pressure
to the rear brakes. If the pressure is lost from either
system, the remaining system will function to stop the
vehicle.
The second style master cylinder is designed for use
with a system using the low drag calipers (figure 26). In
addition to the standard master cylinder functions, a
quick take-up feature is included. This provides a large
volume of fluid to the wheels at low pressure with the
initial brake application. This large volume of fluid is
needed to overcome the clearance created by the
seals retracting the pistons into the front calipers and
the spring retraction of the rear drum brake shoes.
Install or Connect (Figure 27)
• Prior to installation, refer to “ Bench Bleeding” in
this section.
1. Master cylinder.
• If the vehicle is equipped with manual brakes,
refer to “ Brake Pedal Replacement” for the
installation of the pushrod to the pedal.
NOTICE: See “ N otice” on page 5-1 of this
section.
2. Mounting nuts.
Tighten
• Nuts to 34 N m (25 ft. lbs.), G and P models.
• Nuts to 44 N-m (32 ft. lbs.), C and K models.
3. Brake pipes.
4. Bleed the brakes, refer to “ Bleeding the Brake
Hydraulic System” in this section.
5.
Release the parking brakes.
BENCH BLEEDING
The purpose of bench bleeding is to remove the air
from the master cylinder so when it is installed on the
vehicle the brake system bleeding will be reduced.
1. Plug the outlet ports and mount the master
cylinder in a vise with the front end tilted slightly
down.
2. Fill the reservoir with clean brake fluid.
Figure 26—Composite Master Cylinder
BRAKES 5-31
Figure 27—Master Cylinder Installations
5-32 BRAKES
Using a smooth rounded end tool, stroke the
primary piston about 25 mm (1-inch) several
times.
As air is bled from the master cylinder, with the
outlets plugged, the resistance to the primary
piston travel will not allow the full 25 mm (1-inch)
stroke.
3. Reposition the master cylinder in the vise with the
front end of the master cylinder tilted slightly up.
Again stroke the primary piston about 25 mm
(1-inch) several times.
4. Reposition the master cylinder in the vise to the
level position. Loosen the plugs one at a time and
push the piston into the bore to force the air from
the cylinder. To prevent air from being sucked
back into the cylinder, tighten the plug(s) before
allowing the piston to return to its original
position.
5. Fill the reservoir.
N orm al b le e d in g p ro ce d u re s should be
followed after the master cylinder is installed.
VACUUM BOOSTERS
DESCRIPTION
SINGLE DIAPHRAGM MODEL
This booster is a sin g le diaphragm vacuum
suspended unit. It may have a single function vacuum
switch to activate the brake warning light in case of low
booster vacuum or vacuum pump malfunction. In a
normal operating mode, with the service brakes in the
released position, a vacuum suspended booster
operates with vacuum on both sides of its diaphragm.
When the brakes are applied, air at atmospheric
pressure is admitted to one side of the diaphragm to
provide the power assist.
TANDEM DIAPHRAGM MODEL
This booster is a tandem vacuum suspended unit. It
may have a single dual function vacuum switch to
activate the brake warning light in case of low booster
vacuum or vacuum pump malfunction. In a normal
operating mode, with the service brakes in the
released position, a tandem vacuum suspended
booster operates with vacuum on both sides of its
diaphragms. When the brakes are applied, air at
atmospheric pressure is admitted to one side of each
diaphragm to provide the power assist.
VACUUM BOOSTER
REPLACEMENT
1. Mounting Nuts
2.
3.
4.
5.
Master Cylinder
Vacuum Booster
Booster Mounting Nuts
Booster Pushrod
B-07805
Figure 28—Removing Vacuum Boosters
• The mounting nuts must be removed from
inside the vehicle.
• Vacuum booster.
Install or Connect (Figure 28)
NOTICE: For steps 2 and 6 see “Notice” on
page 5-1 of this section.
1. Vacuum booster.
Remove or Disconnect (Figure 28)
•
1.
2.
•
3.
4.
Apply the vehicles parking brakes.
Mounting nuts.
Master cylinder.
Support the master cylinder.
Vacuum hose from the check valve.
B o o ste r p u s h ro d , re fe r to “ B rake Pedal
Replacement” in this section.
5. Booster mounting nut.
2. Booster mounting nuts.
Tighten
• Nuts to 34 N m (25 ft. lbs.).
B o o ste r p u sh ro d , re fe r to “ Brake Pedal
Replacement” in this section.
Vacuum hose.
Master cylinder.
Mounting nuts.
BRAKES 5-33
Tighten
• Mounting nuts to 34 N m (25 ft. lbs.
7. Release the parking brakes.
HYDRAULIC BRAKE BOOSTER (HYDRO-BOOST)
DESCRIPTION
This system uses a hydraulic pump to power the
system and a pneumatic accumulator as a reserve
system.
In this system no special fluids are used, however,
care must be taken to use the correct fluids. The
master cylinder and brake system operate on standard
hydraulic brake fluid, while the hydraulic pump
operates on power steering fluid. For diagnosis of the
Hydro-Boost System, refer to “ Hydro-Boost Systems
Tests” and “ Diagnosis of Hydro-Boost System” in this
section.
HYDRO-BOOST REPLACEMENT
C-K AND G MODELS
+-► Remove or Disconnect (Figure 29)
•
1.
2.
3.
•
4.
Apply the vehicles parking brakes.
Hydraulic lines from the booster.
Nuts (1).
Master cylinder (2).
Support the master cylinder.
B o o ste r p u sh ro d , re fe r to “ Brake Pedal
Replacement” in this section.
5. Nuts (4) and (6).
6. Hydro-Boost unit (3).
• Gasket (5).
5. Nuts (1).
£
Tighten
• Nuts to 34 N m (25 ft. lbs.).
6. Hydraulic lines.
7. Bleed the booster, refer to “ B leeding the
Hydro-Boost System” in this section.
8. Release the parking brakes.
P 30 (42) MODEL
Remove or Disconnect (Figure 30 and 31)
•
1.
2.
3.
•
4.
5.
Apply the vehicles parking brakes.
Hydraulic lines from the booster.
Nuts (1) and washers (7).
Master cylinder (2).
Support the master cylinder.
Pushrod retainer (10).
Retaining clip and washer.
• Booster pushrod (9).
6. Nuts (4) and washers (8).
7. Hydro-Boost unit (3).
-►+ Install or Connect (Figure 30 and 31)
NOTICE: For steps 2 and 6 see “Notice” on
page 5-1 of this section.
1. Hydro-Boost unit (3).
2. Washers (8) and nuts (4).
Install or Connect (Figure 29)
NOTICE: For steps 2 and 5 see “Notice” on
page 5-1 of this section.
1. Gasket (5).
• Hydro-Boost unit (3).
2. Nuts (4) and (6).
Tighten
• Nuts to 34 N m (25 ft. lbs.).
3. B o o ste r p u sh ro d , re fe r to “ B rake Pedal
Replacement” in this section.
4. Master cylinder. (2).
• Nuts to 34 N m (25 ft. lbs.).
3. Booster pushrod (9).
• Washer and retaining clip.
4. Pushrod retainer (10).
5. Master cylinder (2).
6. Washers (7) and nuts (1).
Tighten
• Nuts to 34 N m (25 ft. lbs.)
7. Hydraulic lines.
8. Bleed the booster, refer to “ Bleeding the
Hydro-Boost System” in this section.
5-34 BRAKES
Figure 29—C-K and G Model Hydro-Boost Replacement
BRAKES 5-35
1.
2.
3.
4.
7.
8.
Nut
Master Cylinder
Hydro-Boost
Nut
Washer
Washer
B-07809
Figure 30—P 30 (42) Hydro-Boost Replacement
9. Release the parking brakes.
P 30 (32) MODEL
Remove or Disconnect (Figure 32)
•
1.
2.
3.
•
4.
5.
6.
7.
8.
E
Apply the vehicles parking brakes.
Hydraulic lines from the booster.
Nuts (12) and washers (13).
Master cylinder (2).
Support the master cylinder.
Brake pedal rod, refer to “ Brake Pedal Rod
Replacement” in this section.
Nut (10) and washer (11).
• Bolt (16).
Nut (14) and washers (15).
• Bolt (18).
Nuts (12) and washer (13).
• Bolts (17).
Hydro-Boost unit (3).
Install or Connect (Figure 32)
NOTICE: For steps 2, 3, 4, and 7 see “Notice”
on page 5-1 of this section.
1. Hydro-Boost unit (3).
2. Bolts (17).
5-36 BRAKES
2.
3.
10 .
11 .
12 .
13.
14.
15.
16.
17.
18.
19.
Master Cylinder
Hydro-Boost
Nut
Washer
Nut
Washer
Nut
Washer
Bolt
10
Bolts
Bolt
Nut
B-07811
Figure 32—P 30 (32) Hydro-Boost Replacement
• Washers (13) and nuts (12). Leave finger
tight.
3. Bolt (18).
• Washer (15) and nut (14). Leave finger tight.
4. Bolt (16).
• Washer (11) and nut (10). Leave finger tight.
Tighten
• Nuts (10, 14 and 12) to 34 N m (25 ft. lbs.).
5. Brake pedal rod, refer to “ Brake Pedal Rod
Replacement” in this section.
6. Master cylinder (2).
7. Washers (13) and nuts (12).
Tighten
• Nuts to 34 N m (25 ft. lbs.)
8. Hydraulic lines.
9. Bleed the booster, refer to “ Bleeding the
Hydro-Boost System” in this section.
10. Release the parking brakes.
BLEEDING THE
HYDRO-BOOST SYSTEM
Whenever the booster is removed and reinstalled,
the steering system should be bled.
NOTICE: The power steering fluid and brake
fluid cannot be mixed. If the brake seals
contact steering fluid or the steering seals
contact brake fluid, seal damage will result.
1. Fill the power steering pump reservoir to the
proper level, let the fluid remain undisturbed for
at least two minutes.
2. Start the engine and run momentarily.
• Add fluid, if necessary.
3. Repeat steps 1 and 2 until the fluid level remains
constant after running the engine.
4. Raise the front of the vehicle so the wheels are
off the ground.
• Support the vehicle with suitable safety stands.
5. Turn the wheels from stop to stop, lig h tly
contacting the stops.
• Add fluid, if necessary.
6. Lower the vehicle.
7. Start the engine and depress the brake pedal
serveral times while rotating the steering wheel
from stop to stop.
8. Turn the engine off and then pump the brake
pedal 4-5 times.
9. Check fluid level, add fluid if necessary.
10. If the fluid is extremely foamy, allow the vehicle to
stand a few minutes with the engine off. Then
repeat steps 7, 8 and 9.
BRAKES 5-37
11. Check for the presence of air in the oil. Air in the
oil will have a milky appearance. Air in the system
will also cause the fluid level in the pump to rise
when the engine is turned off. If it becomes
obvious that the pump will not bleed the air after
a few attempts, refer to POWER STEERING (Sec.
3B3) for futher diagnosis,
DISC BRAKES
DESCRIPTION
The disc brake assembly consists of a caliper and
piston assembly, rotor, linings, and an anchor plate.
The caliper is mounted to the anchor plate, which
allows the caliper to move laterally against the rotor.
The caliper is a one-piece casting with the inboard side
containing the piston bore. A square cut rubber seal is
located in a groove in the piston bore which provides
the hydraulic seal between the piston and the cylinder
wall.
OPERATION
As the brake pedal is depressed, hydraulic pressure
is applied against the piston. This pressure pushes the
inboard brake lining against the inboard braking
surface of the rotor. As the force increases against the
rotor, the caliper assem bly moves inboard thus
providing a clamping action on the rotor.
When the brake pressure is released, the piston seal
returns to its normal position, pulling the piston back
into the caliper bore. This will create a running
clearance between the inner brake lining and the rotor.
BRAKE LINING INSPECTION
Check the outer pad by looking at each end of the
caliper (figure 33). Check the lining thickness on the
inner pad by looking down through the inspection hole
in the top of the caliper housing. Whenever the lining is
worn to about the thickness of the pad, the lining
should be removed for further measurements. The pad
should be replaced anytime the lining is worn to within
0.08 mm (1/32-inch) of a rivet head or the pad itself.
The disc brake pads have a wear indicator that
makes a noise when the linings wear to a degree
where replacement is required (figure 34).
Also check the flatness of the brake pads. Place the
inboard and outboard lining surfaces together and
check for a gap between the lining surfaces. This gap
should not exceed 0.13 mm (.005-inch) at the middle of
the lining surfaces. This applies to new or used brake
pads.
5-38 BRAKES
BRAKE LINING
REPLACEMENT
3000/3100 MODELS
Remove or Disconnect (Figure 35)
• % of the brake fluid from the master cylinder.
• Raise the vehicle and support it with suitable
safety stands.
• Mark the relationship of the wheel to the hub.
1. Wheel and tire assembly, refer to WHEELS AND
TIRES (Sec. 3E).
CAUTION: See “ C aution” on page 5-1.
2. Position a C-clamp around the outer pad and cali­
per and tighten until the piston bottoms in its bore
(figure 36).
• C - clamp
3. Mounting bolts (1) (figure 37).
4. Caliper assembly.
• Suspend the caliper from the suspension
(figure 38).
Im portant
5.
6.
7.
8.
• Do not allow the brake components to hang
from the flexible hoses as damage to the
hoses may occur.
Inboard pad (6).
• Retainer spring (5).
Outboard pad (7).
Sleeves (2).
Bushings (3 and 4).
2.
3.
4.
5.
6.
7.
Sleeves
Bushings
Bushings
Retainer Spring
Inboard Pad
Outboard Pad
Figure 35—Replacing Disc Brake
Linings (3000/3100 Models)
Im portant
• Make sure that the brake hose is not twisted
or kinked since damage to the hose could
result.
NOTICE: See “ N otice” on page 5-1.
5. Mounting bolts (1) (Figure 37).
L*
Inspect
— The inside of the caliper assembly for signs of
fluid leakage, if found, refer to “ Rebuilding the
Caliper” in this section.
— Mounting bolts and sleeves for corrosion. Do not
attempt to polish away corrosion, replace the
bolts.
+«- Install or Connect (Figure 35)
• Lubricate the sleeves and bushings with Delco
Silicone Lube or equivalent.
1. Bushings (3 and 4).
• Sleeves (2).
2. Retainer spring (5) onto the inboard pad (6).
• Inboard pad (6).
3 Outboard pad (7).
4. Caliper assembly.
B-07829
BRAKES 5-39
£
Tighten
• Bolts to 50 N m (37 ft. lbs.)
6. Compress the pad ears to the caliper (figure 39).
Measure (Figure 40)
• The clearance between the caliper and the
steering knuckle. The clearance at each end of
the caliper should be measured individually and
added together, this total should be between 0.26
- 0.60 mm (0.010 - 0.024-inches).
7. Wheel and tire assembly, refer to WHEELS AND
TIRES (Sec. 3E).
8. Lower the vehicle.
Figure 37—Removing The Mounting Bolts
9
Im portant
• Before moving the vehicle, pump the brake
pedal several times to make sure that the
pedal is firm. Do not move the vehicle until a
firm pedal is obtained. Check the brake fluid
level in the master cylinder after pumping
the brakes.
BENDIX MODEL
Remove or Disconnect (Figures 41 and 42)
• % of the brake fluid from the master cylinder.
• Raise the vehicle and support it with suitable
safety stands.
• Mark the relationship of the wheel to the hub.
Figure 40—Caliper Clearances
5-40 BRAKES
6. Inboard Pad
Figure 41—Replacing Disc Brake
Linings (Bendix Models)
1. Wheel and tire assembly, refer to WHEELS AND
TIRES (Sec. 3E).
CAUTION: See “ C aution” on page 5-1.
2. Position C - clamp and tighten until the piston bot­
toms in its bore (figure 43).
• C - clamp.
6.
7.
8.
9.
Inboard Pad
Outboard Pad
Bolt
Support Key
B-07798
Figure 42— Bendix Disc Brake Assembly
Figure 43—Compressing The Caliper Piston
3. Bolt (8).
4. Support key (9) and spring (10).
• Use a brass punch and a hammer to drive the
support key out (figure 44).
5. Caliper assembly.
• Suspend the caliper from the suspension (figure
45).
BRAKES 5-41
3. Caliper assembly.
9
Im portant
• Make sure that the brake hose is not twisted
or kinked since damage to the hose could
result.
4. Spring (10) and support key (9).
• Use a brass punch and a hammer to drive the
support key in (figure 46).
Im portant
— Do not allow the brake components to hang
from the flexible hoses as damage to the
hoses may occur.
6. Inboard pad (6) from the steering knuckle or rear
caliper support.
• Anti-rattle spring (11).
7. Outboard pad (7).
1*
Inspect
— The inside of the caliper assembly for signs of
fluid leakage, if found, refer to “ Rebuilding the
Caliper” in this section.
Clean
— Use a wire brush to remove any corrosion from
the machined surfaces of the steering knuckle
and caliper.
0
Install or Connect (Figures 41 and 42)
• Lubricate the caliper and steering knuckle (or
support) sliding surfaces and spring with Delco
Silicone Lube or equivalent.
1. Inboard pad (6) and anti-rattle spring (11).
2. Outboard pad (7) into the caliper assembly.
NOTICE: See “Notice” on page 5-1.
5. Bolt (8).
• The boss on the bolt must fully fit into the circular
cutout in the key.
Si
Tighten
• Bolt to 20 N m (15 ft. lbs.).
6. Wheel and tire assembly, refer to WHEELS AND
TIRES (Sec. 3E).
7. Lower the vehicle.
Im portant
• Before moving the vehicle, pump the brake
pedal several times to make sure that the
pedal is firm. Do not move the vehicle until a
firm pedal is obtained. Check the brake fluid
level in the master cylinder after pumping
the brakes.
SERVICING THE ROTOR
In the manufacturing of the brake rotor all the
tolerances regarding surface finish, parallelism, and
lateral runout are held very closely. The maintenance
5-42 BRAKES
PARALLELISM
Parallelism is the measurement of the thickness of
the ro to r at fo u r or m ore p o in ts a round the
circumference of the rotor. All measurements must be
made at the same distance in from the edge of the
rotor. The rotor thickness must not vary more than
0.013 mm (0.0005-inch) from point to point.
MACHINING
Since accurate control of the rotor tolerances is
necessary for proper performance of the disc brakes,
machining of the rotor should be done only with
precision equipment.
A ll brake rotors have a m inim um th ic k n e s s
dimension cast into them. This dimmension is the
m in im um w ear d im e n s io n and not a re fin is h
dimension. Do not use a brake rotor that will not meet
the specifications, after refinishing. Replace with a new
brake rotor. Refer to “ Specification” in this section for
final maching tolerances.
REBUILDING THE CALIPER
3000/3100 MODELS
*
Disassemble (Figure 48)
• Drain all the fluid from the caliper.
of these tolerances provide the surface necessary to
prevent brake roughness.
Light scoring of the rotor surface not in excess of
0.38 mm (0.15-inch) in depth is normal. This condition
does not affect the brake operation.
LATERAL RUNOUT
Lateral runout is the movement of the rotor from side
to side as it rotates on the spindle. This could also be
refered to as “ rotor wobble” .
This movement causes the brake pad and piston to
be knocked back into it’s bore. This results in
additional pedal travel and a vibration during braking.
Checking Lateral Runout (Figure 47)
1. Tighten the wheel bearings to eliminate all
freeplay.
2. Attach a dial indicator to some portion of the
suspension.
• The point of the styles must contact the rotor face
about 25 mm (1-inch) from the rotor edge.
3. Move the rotor one complete rotation.
• The lateral runout should not exceed 0.10 mm
(0.004-inch).
4. Readjust the wheel bearings, refer to FRONT
SUSPENSION (Sec. 3C).
• Pad the interior of the caliper with clean shop
towels.
CAUTION: Do not place your fingers in fro n t of
the piston in an attem pt to catch or protect it
when applying compressed air. This could
result in serious injury.
NOTICE: Use just enough air to ease the
piston out of the bore. If piston is blown
out—even with padding provided, it may be
damaged.
1. Piston (22) (figure 49)
2. Boot (23) (figure 50).
• Use care not to scratch the housing bore.
3. Piston seal (21).
• Do not use any type of metal tool.
4. Bleeder valve (20).
Tjjf Clean
• Bleeder valve, caliper bore, caliper passages, and
piston with denatured alcohol. Use dry, filtered
compressed air to dry parts and blow out
passages.
BRAKES 5-43
Figure 48—Models 3000/3100
Caliper Components
• Lubricate the new piston seal, caliper bore, and
piston with clean brake fluid.
1. Piston seal (21).
• Make sure the seal is not twisted in the caliper
bore groove.
2. Boot (23) onto the piston (22).
• Piston (22).
3. Boot (23) into the caliper housing counterbore
using tool J-26267 (figure 51).
Inspect
— Piston for scoring, corrosion and any damage to
the chrome plating, replace if found.
— Caliper bore for scoring, pitting, or corrosion. Use
crocus cloth to polish out any light corrosion.
Replace caliper if corrosion cannot be removed.
*
Assemble (Figure 48)
Tool required:
J-26267 Piston Seal Installer
Figure 49—Removing The Piston
Figure 51—Installing The Caliper Boot
5-44 BRAKES
20.
21.
22.
23.
Bleeder Valve
Piston Seal
Piston
Boot
B-07838
Figure 52—Bendix Model
Caliper Components
4.
Bleeder valve (20).
BENDIX MODEL
+1+ Disassemble (Figure 52)
• Drain all the fluid from the caliper.
• Pad the interior of the caliper with clean shop
towels.
CAUTION: Do not place your fingers in fro nt
o f the piston in an attem pt to catch or protect
it when applying compressed air. This could
result in serious injury.
NOTICE: Use just enough air to ease the
piston out of the bore. If piston is blown
out—even with padding provided, it may be
damaged.
1.
2.
3.
•
4.
IQI
Piston (22) (figure 49).
Boot (23).
Piston seal (21).
Do not use any type of metal tool.
Bleeder valve (20).
Caliper bore for scoring, pitting, or corrosion. Use
corcus cloth to polish out any light corrosion. Re­
place caliper if corrosion cannot be removed.
*
Assemble (Figure 52)
1.
2.
Clean
Bleeder valve, caliper bore, caliper passages, and
piston with denatured alcohol. Use dry, filtered
compressed air to dry parts and blow out pas­
sages.
Inspect
— Piston for scoring, corrosion and any damage to
the chrome plating, replace if found.
4.
5.
6.
Tool required:
J-24548 Piston Seal Installer
Lubricate the new piston seal, caliper bore, pis­
ton, and seal lips on boot with clean brake fluid.
Piston seal (21).
Make sure the seal is not twisted in the caliper
bore groove.
Boot (23) on tool J-24548.
Place the large diameter of the boot over the tool
first and ride the smaller diameter onto the tool.
The large diameter must then slide off the tool.
The large lip of the boot into the groove in the
caliper bore.
The lip of the boot must be firmly slated in the
groove.
Piston (22) inside tool J-24548 (figure 53).
Press the piston half way into its bore.
Remove tool J-24548.
Make sure the boot is firmly seated.
Bleeder valve (20).
BRAKES 5-45
DRUM BRAKES
DESCRIPTION
The drum brake assembly is a duo - servo design.
With this particular design, the force which is applied
by the wheel cylinder to the primary shoe is multiplied
by the primary lining friction to provide a large applied
force to the secondary shoe. The torque from the brake
shoes is transferred to the anchor pin and through the
backing plate, to the axle flange. Brake adjustments
are automatic and are made during reverse brake
applications.
BRAKE LINING REPLACEMENT
Remove or Disconnect (Figure 54)
• Raise the vehicle and support with suitable safety
stands.
• Mark the relationship of the wheel to the hub.
1. Wheel and tire assembly, refer to WHEELS AND
TIRES (Sec. 3E).
— Mark the relationship of the drum to the axle.
CAUTION: See “ Caution” on page 5-1.
2. Drum
3. Return springs (12 and 13).
• Shoe guide (7).
4. Hold down springs (14).
• Hold down pins. (1).
5. Actuator lever (10) and lever pivot (15).
• Lever return spring (16).
• Actuator link (11).
6. Parking brake strut (8).
• Strut spring (9).
7. Retaining ring (6).
• Parking brake lever (4) and washer (4).
8. Shoes (5 and 19).
• Adjusting screw assembly (17).
• Adjusting screw spring (18).
9
Im portant
Do not interchange the right and left
adjusting screws.
L*
Inspect
— All parts for discoloration due to heat, or
stress. Replace if necessary.
— All parts for signs of wear. Replace if
necessary.
— Wheel cylinder for signs of leakage, refer to
“ Rebuilding The Wheel Cylinder.”
— Brake drum for scoring, and machining
tolerance, refer to “ Servicing The Brake
Drum.”
-►+ Install or Connect (Figure 54)
— Lubricate the shoe pads and adjusting screw
threads with a thin coat of white lithium grease.
1. Adjusting screw (17) and adjusting screw spring
(18) to both shoes (19 and 5).
— The coils of the spring must not touch the
adjusting screw.
2. Shoe assembly.
3. Parking brake lever (3) and washer (4) into the
shoe.
• Retaining ring (6).
4. Strut spring (9) onto the parking brake strut (8).
• Parking brake strut (8).
5. Actuator lever (10) and lever pivot (15).
• Actuator link (11).
• Lever return spring j[16).
6. Hold down pins (1).
• Hold down springs (14).
7. Return springs (12 and 13).
8. Drum.
— Align the marks made during disassembly.
9. Wheel and tire assembly, refer to WHEELS AND
TIRES (Sec. 3E).
— Align the marks made during disassembly.
10. Adjust the brakes, refer to “ Brake Adjustment” in
this section.
SERVCING THE
BRAKE DRUM
Whenever the brake drums are removed, they
should be thoroughly cleaned and inspected for
cracks, scores, deep grooves and out-of-round.
CRACKED, SCORED, OR GROOVED DRUM
A cracked drum is unsafe for further service and
must be replaced. Do not attempt to weld a cracked
drum.
Smooth up any slight scores. Heavy or extensive
scoring will cause excessive brake lining wear, and it
will probably be necessary to machine the drum
braking surface.
If the brake linings are slightly worn and the drum is
grooved, the drum should be polished with fine emery
cloth but should not be machined. At this stage,
eliminating all the grooves in the drum and smoothing
5-46 BRAKES
Hold Down Spring
Lever Pivot
Lever Return Spring
Adjusting Screw Assembly
Adjusting Screw Spring
Primary Shoe
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Hold Down Pins
Backing Plate
Parking Brake Lever
Washer
Secondary Shoe
Retaining Ring
Shoe Guide
Parking Brake Strut
Strut Spring
Actuator Lever
Actuator Link
Return Spring
Return Spring
B-07791
Figure 54—Drum Brake Components
the ridges on the lining would require the removal of
too much metal and lining, while if left alone, the
grooves and ridges match and satisfactory service can
be obtained.
If brake linings are to be replaced, a grooved drum
should be machined. A grooved drum, if used with new
lining, will not only wear the lining, but will make it
difficult, if not impossible to obtain efficient brake
performance.
OUT-OF-ROUND OR TAPERED DRUM
An out-of-round drum makes accurate brake shoe
adjustment impossible and is likely to cause excessive
wear of other parts of brake mechanism due to its
eccentric action. An out-of-round drum can also cause
severe and irregular tire tread wear as well as a pulsing
brake pedal. When the braking surface of a brake
drum exceeds the specification limits in taper (and/or)
out-of-round, the drum should be machined to true up
the braking surface. Out-of-round as well as taper and
wear can be accurately measured with an inside
micrometer fitted with proper extension rods.
When measuring a drum for out-of-round, taper and
wear, take measurments at the open and closed edges
of machined surface and at right angles to each other.
MACHINING THE DRUM
If a drum is to be machined, only enough metal
should be removed to obtain a true, smooth braking
surface. If a drum does not clean-up when machined to
a maximum diameter it must be replaced, refer to
“ Specifications” in this section. Removal of more
metal will affect dissipation of heat and may cause
distortion of the drum.
All brake drums have a maximum diameter cast into
them. This diameter is the maximum wear diameter.
Do not machine a brake drum that will not meet the
specification, refer to “ Specifications” in this section.
BRAKES 5-47
BRAKE ADJUSTMENT
A manual adjustment of the rear brakes is required
after the rear linings have been replaced. The front
disc brakes require not adjustment.
CAUTION: Refer to “ C aution” on page 5-1.
1. Remove the lanced area in the brake backing
plate.
• The metal lanced area must be removed
from the brake assembly.
Adjust
Brake adjusting screw until the wheel can
just be turned by hand.
The brake drag should be equal at both
wheels.
Back off the adjusting screw 33 notches.
Figure 55—Removing The Wheel Cylinder
5. Bleed brake system, refer to “ Bleeding the Brake
Hydraulic System.”
Im portant
• Brakes should have no drag after the screw
has been backed off about 15 notches. If a
heavy drag is present refer to “ Parking
Brake Adjustment.”
2. Install an adjusting hole cover in the brake
backing plate.
3. Check parking brake adjustment.
REBUILDING THE
WHEEL CYLINDER
Disassemble (Figure 56)
1. Remove wheel cylinder, refer to “ Wheel Cylinder
Replacement.”
2. Boots (54).
3. Pistons (53).
4. Seals (52).
5. Spring assembly (55).
WHEEL CYLINDER
REPLACEMENT
0
Remove or Disconnect (Figure 55)
Inspect
CAUTION: See “ C aution” on page 5-1.
1. B rake lin in g s ,
Replacement.”
2. Brake pipe.
3. Bolts.
4. Wheel cylinder.
re fe r
to
“ B rake
— Cylinder bore for scoring and corrosion.
— Spring assembly for signs of discoloration
due to heat. Replace if necessary.
L in in g
[ y l Clean
— Inside the cylinder bore with crocus cloth. If
the bore is still scored replace the cylinder.
Install or Connect (Figure 55)
— Cylinder with clean brake fluid.
1. Wheel cylinder.
2. Bolts.
*
Tighten
• Bolts to 18 N m (160 in. lbs.).
3. Brake pipe.
4. B rake lin in g s , re fe r to “ Brake
Replacement.”
Assemble (Figure 56)
— Lubricate seals and cylinder bore with clean
brake fluid.
L in in g
1. Spring assembly (55).
2. Seals (52).
3. Pistons (53).
5-48 BRAKES
51.
52.
53.
54.
55.
Bleeder Valve
Seal
Piston
Boot
Spring Assembly
B-07793
Figure 56—Wheel Cylinder Components
4. Boots (54).
5. Wheel cylinder, refer to “ Wheel Cylinder Replace­
ment.”
BRAKES 5-49
SPECIFICATIONS
BRAKE SYSTEMS
SYSTEM
FRONT BRAKES
REAR BRAKES
BRAKE ASSIST
GASOLINE ENGINE VEHICLES
C-MODELS
JB1 Low Drag
JB3 Low Drag
Disc 11.86 x 1.04
Disc 11.86 x 1.04
Drum 11.0 x 2.00
Drum 11.0 x 2.00
None (Manual Brakes)
Vacuum—Single Diaphragm
Drum 11.00 x 2.00
Drum 11.00 x 2.00
None (Manual Brakes)
Vacuum—Single Diaphragm
Drum 11.15 x 2.75
Drum 11.15 x 2.75
Drum 13.00 x 2.50
Drum 13.00 x 3.50
Disc 13.75 x 1.54
Vacuum—Dual Diaphragm
Vacuum—Dual Diaghragm
Vacuum—Dual Diaphragm
Hydraulic—Hydro-Boost
Hydraulic—Hydro-Boost
G-MODELS
JB1 Low Drag
JB3 Low Drag
Disc 11.86 x 1.29
Disc 11.86 x 1.29
ALL MODELS
JB5
JB6
JB7
JB8
JF9
Low Drag
Low Drag
Conventional
Conventional
Conventional
Disc
Disc
Disc
Disc
Disc
11.86 x 1.29
12.50 x 1.28
12.50 x 1.28
12.50 x 1.54
14.25 x.1.54
DIESEL ENGINE VEHICLES
JD3
JD5
JD6
JD7
Low Drag
Low Drag
Conventional
Conventional
Disc 11.86 x 1.29
Disc 11.86 x 1.29
Disc. 12.50 x 1.28
Disc 12.50 x 1.28
Drum
Drum
Drum
Drum
DRUM DIAMETERS
ORIGINAL
MAXIMUM REFINISH
11.000
11.150
12.000
13.000
11.060
11.210
12.060
13.060
11.00 x 2.00
11.15 x 2.75
11.15 x 2.75
13.00 x 2.50
Hydraulic— Hydro-Boost
Hydraulic—Hydro-Boost
Hydraulic-Hydro-Boost
Hydraulic—Hydro-Boost
ROTOR THICKNESS
REPLACEMENT
(DISCARD)
11.090
11.240
12.090
13.090
MINIMUM
AFTER REFININSHING
REPLACEMENT
(DISCARD)
1.480
1.230
0.980
1.465
1.215
0.965
5-50 BRAKES
TORQUE SPECIFICATIONS
K
C
P
G
Master Cylinder—to Dash or Booster
44 N m (32 ft. lbs.)
44 N-m (32 ft. lbs.)
34 N-m (25 ft. lbs.)
34 N-m (25 ft. lbs.)
Booster to Dash or Frame
44 N m (32 ft. lbs.)
44 N-m (32 ft. lbs.)
34 N-m (25 ft. lbs.)
34 N-m (25 ft. lbs.)
Combination Valve —Mounting Bolts
17 N m (150 in. lbs.)
17 N-m (150 in. lbs.)
23 N-m (17 ft. lbs.)
23 N-m (17 ft. lbs.)
34 N-m (25 ft. lbs.)
34 N-m (25 ft. lbs.)
—Bracket
—
—
48 N m (35 ft. lbs.)
Caliper—Mounting Bolt
16 N m (140 in. lbs.)
—Support Plate to Knuckle
Brake Pedal
17 N-m (150 in. lbs.)
34 N-m (25 ft. lbs.)
—Bracket to Dash
34 N-m (25 ft. lbs.)
34 N-m (25 ft. lbs.)
—Bracket to I.P.
34 N-m (25 ft. lbs.)
34 N-m (25 ft. lbs.)
—
—
—Pivot Bolt Nut
34 N-m (25 ft. lbs.)
34 N-m (25 ft. lbs.)
—
—
—Sleeve to Bracket
—Stoplamp Switch Bracket
—
34 N-m (25 ft. lbs.)
—
—
34 N-m (25 ft. lbs.)
34 N-m (25 ft. lbs.)
9.5 N-m (85 in. lbs.)
—
—Push Rod to Pedal
—
—
—
34 N-m (25 ft. lbs.)
—Push Rod Adjusting Nut
—
—
—
30 N-m (22 ft. lbs.)
12 N-m (100 in. lbs.)
12 N-m (100 in lbs.)
12 N-m (100 in. lbs.)
—to I.P. Kick Panel
or Floorpan
17 N-m (100 in. lbs.)
17 N-m ( 100 in. lbs.) 12 N-m (100 in. lbs.)
—Cable Clips—Screws
17 N-m (150 in. lbs.)
—
12 N-m (100 in. lbs.)
17 N-m (150 in. lbs.)
—Bolts
17 N-m (150 in. lbs.)
—
24 N-m (18 ft. lbs.)
6 N-m (55 in. lbs.)
Parking Brake —to Dash
Propshaft Parking Brake
—Adjusting Nut
—
24 N-m (18 ft. lbs.)
40 N-m (30 ft. lbs.)
27 N-m (20 ft. lbs.)
—Bracket to Trans.
—
—
—
—Cable Clip to Frame
—
—
—
17 N-m (150 in. lbs.)
—Cable Clip to Dash
—
—
—
6 N-m (55 in. lbs.)
—Cable Clip to Trans. Brkt.
—
—
—
27 N-m (20 ft. lbs.)
—Flange Plate
—
—
—
40 N-m (30 ft. lbs.)
—Drum
—
—
—
110 N-m (80 ft. lbs.)
5.5 N-m (50 in. lbs.)/20 N-m (180 in. lbs.) on JB5, JB6, JB7, and JB8
Wheel Cylinder to Flange Plate Bolt
190 N-m (140 ft. Ibs.)/312 N-m (230 ft. lbs.) JB7 and JB8
Rear Brake Anchor Pin
44 N-m (32 ft. lbs.)
Front Brake Hose —to Caliper
7 N-m (58 in. lbs.)
—to Frame Nut
—Bracket Bolt
17 N-m (150 in. lbs.)
—
Rear Brake Hose—to Axle Bracket
27 N-m (20 ft. lbs.)
27 N-m (20 ft. lbs.)
—Bracket to Axle
17 N-m (150 in. lbs.)
17 N-m (150 in. lbs.)
17 N-m (150 in. lbs.)
17 N-m (150 in. lbs.)
Brake Line —Attaching Nuts
17 N-m (150 in. lbs.)
17 N-m (150 in. lbs.)
10 N-m (90 in. lbs.)
17 N-m (150 in. lbs.)
—
17 N-m (150 in. lbs.)
17 N-m (150 in. lbs.)
—Retaining Clips—Screws
—Bolts
—
—
Brake Bleeder Valves
12 N-m (100 in. lbs.)
17 N-m (150 in. lbs.)
17 N-m (150 in. lbs.)
24 N-m (18 ft. lbs.)
7 N-m (60 in. lbs.)
Hydro—Boost—
-Pedal Rod - P30 (32) Models
34 N-m (25 ft. lbs.)
—Pedal Rod Boot — P 30 (32) Models
—
—
—
20 N-m (15 ft. lbs.)
—Pivot Lever Rod Retainer
—
—
—
34 N-m (25 ft. lbs.)
—Pivot Lever Bolt
—
—
—
60 N-m (45 ft. lbs.)
—Booster Brackets
—
—
—
34 N-m (25 ft. lbs.)
—Booster Brace at Dash or Rad. Supt.
—
—
—
17 N-m (150 in. lbs.)
—Power Steering Pump to Booster Line
34 N-m (25 ft. lbs.)
—Booster to Gear Line
34 N-m (25 ft. lbs.)
—Return Line at Booster and Gear
34 N-m (25 ft. lbs.)
—Return Line Clamp Screw
1.6 N-m (15 in. lbs.)
—Line Clamp to Bracket Screw
17 N-m (150 in. lbs.)
-H o se Clamp to Skirt Screw
4.5 N-m (40 in. lbs.)
—
—
—
—Line Clamp to Frame Bolt
17 N-m (150 in. lbs.)
—
—
17 N-m (150 in. lbs.)
BRAKES 5-51
SPECIAL TOOLS
J-29567
J-23518-01
J-23709
J-23530
J-23533-B
J-26267
J-24548
Brake Bleeder Adapter
Brake Bleeder Adapter
Combination Valve Depressor
Flaring Tool
Tube Cutter
Piston Seal Installer
Piston Seal Installer
6A-1
SECTION 6
ENGINE
CONTENTS
S U B JE C T
PAGE
E ng in e ............................................................................................................................................................................. 6A-1
4.3 Liter V 6 .................................................................................................................................................................. 6A3-1
4.8 Liter L 6 .................................................................................................................................................................. 6A4-1
Small B lo ck.................................................................................................................................................................. 6A5-1
7.4 Liter V 8 .................................................................................................................................................................. 6A6-1
6.2 Liter D ie se l............................................................................................................................................................6A7-1
Engine C o o lin g .............................................................................................................................................................. 6B-1
Fuel S y s te m .................................................................................................................................................................. 6C-1
C arburetors.................................................................................................................................................................. 6C1-1
Diesel Fuel In je c tio n ................................................................................................................................................. 6C2-1
Engine E le c tric a l..........................................................................................................................................................6D-1
D rivability And E m issio n s.......................................................................................................................................... 6E-1
D rivability And Emissions — C a rb u re to r.............................................................................................................. 6E8-1
D rivability And Emissions — D ie se l....................................................................................................................... 6E9-1
E x h a u s t........................................................................................................................................................................... 6F-1
Vacuum P u m p .............................................................................................................................................................. 6H-1
SECTION 6A
ENGINE
CONTENTS
S U B JE C T
PAGE
General In fo rm a tio n ................................................................................................................................................... 6A - 2
Statement on Cleanliness and C a re ................................................................................................................... 6A - 2
Tune-Up In fo rm a tio n .............................................................................................................................................6 A - 2
Use o f RTV Sealer and Anaerobic Gasket E lim ina tor.................................................................................... 6A - 2
Replacing Engine G askets.................................................................................................................................... 6 A - 3
Gasoline Engine Mechanical D iagnosis................................................................................................................ 6 A - 3
Gasoline Engine Compression C h e c k .............................................................................................................. 6A - 6
Diagnosis of Hydraulic L if te r s ................................................................................................................................ 6 A - 7
Diagnosis of Diesel E ngine...................................................................................................................................... 6 A - 9
Compression Check (6.2L Diesel E n g in e )........................................................................................................ 6 A - 1 1
Cranking Speed Check...........................................................................................................................................6A - 1 1
Special T o o ls .............................................................................................................................................................. 6A - 1 1
All new General Motors vehicles are certified by the United States Environmental Protection Agency as
conform ing to the requirem ents of the regulations for the control of air pollution from new m otor vehicles.
This certification is contingent on certain adjustm ents being set to factory standards. In most cases, these
adjustm ent points either have been permanently sealed and/or made inaccessible to prevent indiscrim inate
or routine adjustm ent in the field. For this reason, the factory procedure fo r tem porarily removing plugs,
caps, etc., for purposes of servicing the product must be strictly followed and, wherever practicable, re­
turned to the original intent of the design. For vehicles sold in Canada and equipped w ith non-closed loop
engines, also refer to the appropriate Canadian service manual supplement.
6A-2 ENGINE
GENERAL INFORMATION
STATEMENT ON
CLEANLINESS AND CARE
• An engine is a combination of many machined,
honed, polished and lapped surfaces with very
fine tolerances.
• Whenever valve train components, cylinder head,
c y lin d e r, c ra n k s h a ft, or c o n n e c tin g rod
components are removed for service, they should
be retained in order. At the time of installation,
they should be installed in the same locations
and with the same mating surfaces as when
removed.
• Any time air cleaner, carburetor, or TBI unit is
removed, the intake opening must be covered. If
a d ie s e l e n g in e is being s e rv ic e d , the
recommended cover (J-29664-2 or J-26996-1)
should be used. This will protect against the
entrance of foreign material which could follow
the intake passage into the cylinder and cause
extensive damage when the engine is started.
• When any internal engine parts are serviced,
care and cleanliness are important. A liberal
coating of engine oil should be applied to friction
areas during assembly to protect and lubricate
the surfaces on initial operation. Throughout this
section, it should be understood that proper
cleaning and protection of machined surfaces
and friction areas is part of the repair procedure.
This is considered standard shop practice even if
not specifically stated.
• On diesel engines, whenever the fuel injection
pump or lines are removed or disconnected, care
must be taken to prevent the entry of dirt into the
pump, lines, and injectors. The entry of even
small amount of dirt or other foreign material into
the fuel injection system may cause serious
damage.
• It should be kept in mind, while working on the
engine, that the 12-volt electrical system is
capable of violent and damaging short circuits.
When performing any work where electrical
terminals could possibly be grounded, the ground
cable of the battery should be disconnected at
the battery.
• Battery cables should be disconnected before
any major work is performed on the engine.
Failure to disconnect cables may result in
damage to wire harness or other electrical parts.
• Cover or otherwise protect exposed electrical
connections to prevent damage from oil and fuel.
• When raising or supporting the engine for any
reason, do not use a jack under the oil pan. Due
to the small clearance between the oil pan and
the oil pump screen, jacking against the oil pan
may cause it to be bent against the pump screen
resulting in a damaged oil pickup unit.
TUNE-UP INFORMATION
All information required to tune up the vehicle’s
engine is given in the Engine Emission Control Label.
This label is located in the engine compartment.
Information that can be found on the label includes:
• Spark plug type and gap.
• Ignition timing.
• Valve lash (if applicable).
• Idle, fast idle, and solenoid screw speeds, as
applicable.
• The p ro p e r se q u e n ce for m a kin g the
adjustments.
• Emission hose routing diagram (sometimes on a
separate label).
USE OF RTV SEALER
AND ANAEROBIC
GASKET ELIMINATOR
Two types of sealer are commonly used in engines
covered by this manual. These are RTV sealer and
anaerobic “ gasket eliminator” sealer.
It is important that these sealers be applied properly
and in the proper place to prevent oil leaks. THE TWO
TYPES OF SEALER ARE NOT INTERCHANGEABLE.
Use the sealer recommended in the procedure.
• RTV (room temperature vulcanizing) sealer is
used where a non-rigid part is assembled to a
rigid part. Common examples are oil pans and
rocker arm covers.
• Anaerobic gasket elim inator hardens in the
absence of air. This sealer is used where two rigid
parts (such as castings) are assembled together.
When two rigid parts are disassembled and no
sealer or gasket is readily noticeable, the parts
w ere p ro b a b ly a sse m b le d u sin g gaske t
eliminator.
USING RTV SEALER
1. Don’t use RTV when extreme temperatures are
expected, such as exhaust manifold, head gasket
or where gasket eliminator is specified.
2. When separating components sealed with RTV,
use a rubber mallet and “ bum p” the part
sideways to shear the RTV sealer. “ Bumping”
should be done at bends or reinforced areas to
prevent distortion of parts. RTV is weaker in
ENGINE 6A-3
3.
4.
5.
6.
shear (lateral) strength than in tensile (vertical)
strength.
Attempting to pry or pull components apart
may result in damage to the part.
Surfaces to be resealed must be clean and dry.
Remove all traces of oil and RTV. Clean with a
chlorinated solvent such as carburetor spray
cleaner. Don’t use petroleum cleaners such as
mineral spirits; they leave a film onto which RTV
won’t stick.
Apply RTV to one of the clean surfaces. Use a
bead size as specified in the procedure. Run the
bead to the inside of any bolt holes. Do not allow
the sealer in any blind threaded holes, as it may
prevent the bolt from seating properly or cause
damage when the bolt is tightened.
Assem ble w hile RTV is s till wet (w ithin 3
minutes). Don’t wait for RTV to skin over.
Torque bolts to specifications. Don’t over-torque.
USING ANAEROBIC GASKET ELIMINATOR
1. Clean surfaces to be resealed with a chlorinated
solvent to remove all oil, grease and old material.
2. Apply a continuous bead of gasket eliminator to
one flange.
3. Spread bead evenly with your finger to get a
uniform coating on the complete flange.
4. Assemble parts in the normal manner and torque
to specifications.
REPLACING ENGINE GASKETS
CAUTION: Composite type gaskets are used
in some areas of the engine assembly. These
gaskets have a thin metal core. Use caution
w hen re m o v in g o r h a n d lin g c o m p o s ite
gaskets to help avoid personal injury.
GASOLINE ENGINE MECHANICAL DIAGNOSIS
The following information pertains to the basic as­
sembly only. For more diagnosis information, refer to
the following:
• Overheating or other cooling system problems:
Refer to COOLING (SEC. 6B).
• Cranking and ignition system problems: Refer to
ENGINE ELECTRICAL (SEC. 6D).
• Starting, driveability, fuel economy, etc. problems:
Refer to DRIVEABILITY AND EMISSIONS (SEC.
6E).
6A-4 ENGINE
GASOLINE ENGINE MECHANICAL DIAGNOSIS (CONT.)
PROBLEM
POSSIBLE CAUSE
CORRECTION
Engine W ill Not Turn
Over
1. Battery, cranking system or other elec­
trical problem.
2. Liquid in combustion chamber.
3. Seized engine.
1. Refer to ENGINE ELECTRICAL
(SEC. 6D).
2. Remove with suction gun.
3. Repair.
Engine Cranks
Normally But Does
Not Start
1. Fuel or ignition system problem.
1. Refer to DRIVEABILITY AND EMMISSIONS (SEC. 6E) and ENGINE
ELECTRICAL (SEC. 6D).
2. Repair.
3. Perform a compression test, as out­
lined in this section. Repair engine as
necessary.
2. Restricted exhaust system.
3. Low compression due to stuck or
burned valves, stuck rings, blown head
gasket, etc.
Rough Idle
1. Fuel, ignition system or emissions sys­
tem problem.
2. Uneven cylinder compression.
3. Bent pushrod or broken valve spring.
4. Faulty engine mount.
1. Refer to DRIVEABILITY AND EMIS­
SIONS (SEC. 6E) and ENGINE
ELECTRICAL (SEC. 6D).
2. Perform a compression test, as out­
lined in this section. Repair engine as
necessary.
3. Repair.
4. Repair or replace.
White Smoke
Usually caused by water vapor, which
is a normal byproduct of combustion.
Usually seen on cold days.
None required.
Black Smoke
Usually caused by rich fuel mixture.
Refer to FUEL SYSTEM (SEC. 6C)
and/or DRIVEABILITY AND EMIS­
SIONS (SEC. 6E).
Blue Smoke
Usually caused by oil burning in the
combustion chambers.
Refer to Excessive Oil Loss diagno­
sis.
Excessive Oil Loss
1. External oil leaks.
2. Improper reading of dipstick.
3. Improper oil viscosity.
4. Continuous high speed driving and/or
severe usage.
5. Crankcase ventilation or PCV system
malfunctioning.
6. Valve guides and/or valve stem seals
worn, or seals missing.
7. Piston rings not seated.
8. Broken or worn piston rings.
9. Piston improperly installed.
1. Tighten bolts and/or replace gaskets
and seals as necessary.
2. Check oil with vehicle on a level sur­
face and allow adequate drain down
time.
3. Use recommended viscosity for pre­
vailing temperatures.
4. Continuous high speed operation
and/or severe usage will normally
cause decreased oil mileage.
5. Service as necessary.
6. Ream guides and install oversize ser­
vice valves and/or new valve stem
seals.
7. Allow adequate time for rings to seat.
8. Replace broken or worn rings as nec­
essary.
9. Replace piston or repair as neces­
sary.
ENGINE 6A-5
GASOLINE ENGINE MECHANICAL DIAGNOSIS (CONT.)
PROBLEM
Low Oil Pressure
POSSIBLE CAUSE
CORRECTION
1. Slow idle speed.
2. Incorrect or faulty oil pressure switch
or sensor.
3. Incorrect or faulty oil pressure gage.
4. Improper oil viscosity.
5. Diluted engine oil
1. Set idle speed to specifications.
2. Replace with proper switch or sensor.
6. Oil pump worn or dirty.
7. Plugged oil filter
8. Oil pickup screen loose or plugged.
9.
10.
11.
12.
Valve Train Noise
Hole in oil pickup tube.
Excessive bearing clearance.
Cracked, porous or plugged oil galleys.
Galley plugs missing or mis-installed.
1. Low oil pressure.
2.
3.
4.
5.
6.
Loose rocker arm attachments.
Worn rocker arm and/or pushrod.
Broken valve spring.
Sticking valves.
Lifters worn, dirty or faulty.
7. Camshaft worn or faulty.
8. Worn valve guides.
Engine Knocks Cold
And Continues For
Two To Three
Minutes. Knock
Increases With
Torque.
1. EFE equipped engines may have valve
knock.
2. Flywheel contacting splash shield.
3. Loose or broken torsional damper or
drive pulleys.
4. Excessive piston to bore clearance.
5. Bent connecting rod.
Engine Has Heavy
Knock Hot With
Torque Applied.
1. Broken balancer or pulley hub.
2. Loose torque converter bolts.
3. Accessory belts too tight or nicked.
4. Exhaust system grounded.
5. Flywheel cracked or loose rivets on fly­
wheel.
6. Excessive main bearing clearance.
7. Excessive rod bearing clearance.
Engine Has Light
Knock Hot In Light
Load Conditions.
1. Faulty EST or ESC system.
2.
3.
4.
5.
6.
Improper timing.
Poor quality fuel.
Loose torque converter bolts.
Exhaust leak at manifold.
Excessive rod bearing clearance.
3. Replace with proper gage.
4. Replace with proper oil.
5. Change engine oil and filter. Repair
cause of dilution (rich mixture, etc.)
6. Clean pump and replace worn parts
as necessary.
7. Replace filter and oil.
8. Clean or replace screen as neces­
sary.
9. Replace tube.
10. Replace as necessary.
11. Repair or replace block.
12. Install plugs or repair as necessary.
1. Repair as necessary. (See diagnosis
for low oil pressure).
2. Inspect and repair as necessary.
3. Replace as necessary.
4. Replace spring.
5. Free valves.
6. Refer to “ Diagnosis of Hydraulic Lift­
ers.”
7. Replace camshaft.
8. Repair as necessary.
1. Replace EFE valve.
2. Reposition splash shield.
3. Tighten or replace as necessary.
4. Replace piston.
5. Replace connecting rod.
1. Replace parts as necessary.
2. Tighten bolts.
3. Replace and/or tension to specs as
necessary.
4. Reposition as necessary.
5. Replace flywheel.
6. Repair as necessary.
7. Repair as necessary.
1. Refer to DRIVEABILITY AND EMIS­
SIONS (SEC. 6E).
2. Adjust to specifications.
3. Use fuel of recommended grade.
4. Tighten bolts.
5. Tighten bolts and/or replace gaskets.
6. Replace bearings as necessary.
6A-6 ENGINE
GASOLINE ENGINE MECHANICAL DIAGNOSIS (CONT.)
CORRECTION
POSSIBLE CAUSE
PROBLEM
Engine Knocks On
Initial Start Up But
Only Lasts A Few
Seconds.
1. Fuel pump.
2. Improper oil viscosity.
Engine Knocks At
Idle Hot
1.
2.
3.
4.
5.
1. Replace pump.
2. Install proper oil viscosity for ex­
pected temperatures.
3. Refer to “ Diagnosis of Hydraulic Lift­
ers.”
3. Hydraulic lifter bleed down.
1.
2.
3.
4.
5.
Loose or worn drive belts.
Compressor generator bearing.
Fuel pump.
Valve train.
Improper oil viscosity.
6. Excessive piston pin clearance.
7. Connecting rod alignment.
8. Insufficient piston to bore clearance.
(Cold engine piston knock usually dis­
appears when the cylinder’s spark
plug is grounded out. Cold engine pis­
ton knock which disappears in 1.5 min­
utes
sh o u ld
be
co n s id e re d
acceptable.)
9. Loose torsional damper.
Tension and/or replace as necessary.
Replace as necessary.
Replace pump.
Refer to “ Valve Train Noise.”
Install proper viscosity oil for ex­
pected temperature.
6. Install new piston, pin and/or con­
necting rod as needed.
7. Check and replace rods as neces­
sary.
8. Hone and fit new piston, if required.
9. Torque and or replace worn parts.
GASOLINE ENGINE COMPRESSION CHECK
GASOLINE ENGINE
COMPRESSION CHECK
1. Disconnect the “ Bat” or “ B + ” terminal from the
distributor. Refer to ENGINE ELECTRICAL (SEC.
6D).
2. Remove all spark plugs.
3. Block the throttle plate and choke plate (if used)
wide open.
4. Make sure the battery is fully charged.
5. Starting with the compression gage at zero, crank
the engine through four compression strokes
(four “ puffs” ).
6. Make the compression check at each cylinder
and record each reading.
7. If some cylinders have low compression, inject
about 15 ml. (one tablespoon or about 3 squirts
from a pump type oil can) of engine oil into the
combustion chamber through the spark plug
hole.
8. Minimum compression recorded in any one
cylinder should not be less than 70 per cent of
highest cylinder, and no cylinder should read less
than 690 kPa (100 psi). For example, if the
highest pressure in any one cylinder is 1035 kPa
(150 psi), the lowest allowable pressure for any
other cylinder would be 725 kPa (105 psi). (1035 x
70% = 725) (150 x 70% = 105).
• Normal — Compression builds up quickly
and evenly to specified compression on
each cylinder.
• Piston Rings Leaking — compression low
on first stroke tends to build up on following
stro ke s but does not reach norm a l.
Improves considerably with addition of oil.
• Valves Leaking — Low on first stroke. Does
not tend to build up on following strokes.
Does not improve much with addition of oil.
• If two adjacent cylinders have lower than
normal compression, and injecting oil into
c y lin d e rs does not in cre a se the
compression, the cause may be a head
gasket leak between the cylinders.
ENGINE 6A -7
DIAGNOSIS OF HYDRAULIC LIFTERS
PROBLEM
Momentarily Noisy
When Engine Is
Started
Interm ittently Noisy
On Idle Only,
Disappearing When
Engine Speed Is
Increased
Nofoy At Slow Idle
Or W ith Hot Oil;
Quiet At Higher
Engine Speeds Or
W ith Cold Oil
Noisy At High
Vehicle Speeds,
Quiet At Low Speeds
Noisy At Idle,
Becoming Louder As
Engine Speed Is
Increased To 1500
RPM
POSSIBLE CAUSE
This condition is normal. Oil drains
from the lifters which are holding the
valves open when the engine is not
running. It will take a few seconds for
the lifter to fill after the engine is
started.
1. Dirt in hydraulic lifter.
2. Pitted or damaged check ball.
High leak down rate.
1. High oil level — Oil level above the
“ Full” mark allows crankshaft counter­
weights to churn the oil into foam.
When foam is pumped into the lifters,
they will become noisy since a solid
column of oil is required for proper op­
eration.
2. Low oil level — Oil level below the
“ Add” mark allows the oil pump to
pump air at high speeds which results
in noisy lifters.
3. Oil pan bent against oil pump pickup
screen.
4. Oil pump screen bent or loose.
1. This noise is not connected with lifter
malfunction. It becomes most notice­
able in the vehicle at 10 to 15 mph “ L”
(Low) range, or 30 to 35 mph “ D”
(Drive) range and is best described as
a “ hashy” sound. At slow idle, it may
be entirely gone or appear as a light
ticking noise in one or more valves. It
is caused by one or more of the follow­
ing:
• Badly worn or scuffed valve tip and
rocker arm pad.
• Excessive valve stem to guide clear­
ance.
• Excessive valve seat runout.
• Off square valve spring.
• Excessive valve face runout.
• Valve spring damper clicking on rota­
tor.
CORRECTION
None needed.
1. Disassemble and clean.
2. Replace the hydraulic lifter.
Replace the hydraulic lifter.
1. Drain oil to proper level.
2. Add oil as needed.
3. Repair.
4. Repair.
1. Repair as necessary.
6A-8 ENGINE
DIAGNOSIS OF HYDRAULIC LIFTERS (CONT.)
PROBLEM
POSSIBLE CAUSE
CORRECTION
Noisy At Idle,
Becoming Louder As
Engine Speed Is
Increased To 1500
RPM (Continued)
2. Off square valve spring. Occasionally
this noise can be eliminated by rotat­
ing the valve spring and valve. Crank
engine until noisy valve is off its seat.
Rotate spring. This will also rotate
valve. Repeat until valve becomes
quiet. If correction is obtained, check
for an off square valve spring.
2. If the valve spring is more than
1.6mm (1/ie-inch) off square, it should
be replaced.
Noisy Regardless Of
Engine Speed
1. Incorrect valve adjustment (excessive
lash) (engines with adjustable valve
lash).
2. Excessive valve lash. Check for valve
lash by turning the engine so the pis­
ton in that cylinder is on TDC of the
firing sroke. If valve lash is present, the
pushrod can be freely moved up and
down a certain amount with rocker arm
held against valve. Excessive lash can
be caused by:
a. Worn pushrod upper end ball.
b. Bent pushrod.
c. Improper lubrication of the pushrod.
1. Adjust as specified.
d. Loose or damaged rocker arm.
e. If pushrod and rocker arm are OK,
trouble in the hydraulic lifter is indica­
ted.
2. Repair engine as needed.
a. Replace pushrod and rocker arm.
b. Replace pushrod.
c. Replace pushrod and rocker arm.
Check lubrication system feed to the
pushrod.
d. Replace rocker arm.
e. Replace hydraulic lifter.
DIAGNOSIS OF
DIESEL ENGINE
V
^
^
MOST LIKELY/POSSIBLE CAUSES
X = UKEUESTCAUSES
• = POSSIBLE CAUSES
M E C H A N IC A L / M A IN T E N A N C E
GASKET BLOW-BY OR SEAL LEAKAGE
FAULTY DAMPER/FLYWHEEL BALANCE
VALVE LEAKAGE
BROKEN, SCORED OR WORN PISTONS/RINGS
INCORRECT M AIN OR ROD BEARING CLEARANCE
DAMAGED CRANKSHAFT OR MAIN/ROD BEARINGS
DAMAGED/WORN CAMSHAFT LOBES
FAULTY LIFTER OR GUIDE PLATE
FAULTY PUSHROD OR ROCKER ARM
WORN/MISALIGNED TIMING GEARS, CHAIN OR KEY(S)
LOW CYLINDER COMPRESSION (380 PSI MIN.)
OIL CHANGE INTERVAL
EXTERNAL INJECTION PUMPTHROTTLE LINKAGE
TIMING RETARDED
TIMING ADVANCED
STARTER CRANKING SPEED/BATTERIES (180 RPM MIN.)
ENGINE MOUNTS/BOLTS OR FUEL LINE/OIL FILL TUBE CLAMPS
LONG IDLE PERIODS
CRACKED CYLINDER HEAD OR WALL
MISSING PRECHAMBER(S)
ENGINE OVERLOADED/EXCESSIVE SPEED
IMPROPER STARTING PROCEDURES
(1FRRIS/FI y m IN CYUNDEfllS)
E L E C TR IC A L/E M IS S IO N S
INOPERATIVE GLOW PLUGS
FAULTY GLOW PLUG CONTROLLER/IP WIRE GROUNDS
FAULTY ALTERNATOR DIODE/STARTER MOTOR WIRE CONNECTIONS
INOPERATIVE GLOW PLUG CONTROLLER/RELAY
SHORTED OR OPEN GLOW PLUG INHIBITOR SWITCH
NO VOLTAGE TO CONTROLLER (KEY ON)
EGRVALVE STUCK OPEN
EPR VALVE STUCK CLOSED
FAULTY EGR/EPR SOLENOIDS
MISADJUSTED OR FAULTY THROTTLE POSITION SWITCH
HOUSING PRESSURE COLD ADVANCE SOLENOID OR SWITCH
FAULTY CRANKCASE DEPRESSION REGULATOR (CDR) VALVE
>
4d.mmmw % W im
■ ^m w w w
1
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10
p
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12 13 14 15 16
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•
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17 18 19 20 21 22 23 24 25
•
•
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X •
X
26 27 28 29 30
•
31 32 33 34 35
•
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p
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38 37 38 39 40
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3
4
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5
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7
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8
9
10
11 12 13 14 15 16
•
17 18 19 20 21 22 23 24 25
26 27 28 29 30
•
31 32 33 34 35
•
•
36 37 38 39 40
X
•
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1
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2
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4
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6
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9
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11 12 13 14 15 16
• •
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X • •
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•
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17 18 19 20 21 22 23 24 25
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26 27 28 29 30 31 32 33 34 35
•
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X
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36 37 38 39 40
•
•
6A-9
•
•
5
•
•
•
•
•
•
•
ENGINE
CRANKCASE DEPRESSION SYSTEM HOSE CONNECTIONS
MISADJUSTED OR FAULTY VACUUM REGULATOR VALVE
TRANSMISSION CONVERTOR DOES NOT APPLY
FAULTY VACUUM PUMP (21" HG MIN.)
A IR S Y S T E M
RESTRICTED AIR INTAKE DUCTING OR MANIFOLD
HIGH EXHAUST BACK PRESSURE
0-1 THIN AIR IN HOT WEATHER OR HIGH ALTITUDE
^
PLUGGED AIR FILTER
-vJ LOW AMBIENT TEMPERATURE
a/ A wj ///{&£&<■
6A-10
LU BR IC ATIO N SYSTEM
INTERNAL OIL LEAKS (BLOCK GALLERY/CUP PLUGS)
LOW OIL LEVEL
HIGH OIL LEVEL (OVER-FILLED)
FAULTY REGULATOR OR BY-PASS VALVE
CONTAMINATED LUBE OIL
HIGH LUBE OILTEMPERATURE
QUALITY/GRADE OF LUBE OIL
INACCURATE GAGE OR SENSOR
FAULTY OIL COOLER CORE
FAULTY OIL PUMP DRIVE GEAR/SHAFT
OIL PICKUP TUBE RESTRICTED/CRACK
EXTERNAL OIL LEAKS (PLUGS, SEALS OR GASKETS)
FAULTY OIL PUMP
C O O L IN G S Y S T E M
QUALITY/GRADE OF COOLANT
LOW COOLANT LEVEL
FAULTY OR INCORRECT PRESSURE CAP
INACCURATE TEMPERATURE GAGE/SENSOR
OBSTRUCTED RADIATOR AIR FLOW
INOPERATIVE WATER PUMP
FAULTY OPERATION OF FAN, VISCOUS CLUTCH/BELTS
FAULTY THERMOSTAT
FAULTY COOLANT RECOVERY SYSTEM
RESTRICTED COOLANT FLOW
AIR RECIRCULATION OR FAULTY FAN SHROUD
FAULTY OR INADEQUATE DEAERATION SYSTEM/VENTS
HIGH COOLANT TEMPERATURE
1
X
2
3
4
5
6
•
•
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•
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8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
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7
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36 37 38 39 40
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9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
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36 37 38 39 40
ENGINE
FU EL SYSTEM
PLUGGED, WAXED OR FAULTY FUEL FILTER(S)/ASSEMBLY
FAULTY WATER IN FUELIWIF) OR VACUUM SENSOR(S)
QUALITY/GRADE OR INCORRECT FUEL (GASOLINE)
AIR LEAKS IN FUEL SUCTION LINES
RESTRICTED FUEL RETURN LINE
FUELTANK CAP NOT VENTED
HIGH FUEL TEMPERATURE (ABOVE 90°F)
FAULTY INJECTION PUMP OR SHAFT 180° OUT
FUEL INLET RESTRICTION HIGH AT SUPPLY PUMP
FUEL PRESSURE BELOW (2! PSI AT INJECTION PUMP
FAULTY FUEL SUPPLY PUMP 15Vi PSI MIN.)
NOZZLES, LINES OR HOSES
LOW IDLE RPM ADJUSTMENT
FAST IDLE RPM ADJUSTMENT/FAULTY SOLENOID
WATER/DEBRIS IN FUELTANK OR FILTER(S)
EXTERNAL FUEL LEAKS
FAULTY ENGINE SHUTOFF SOLENOID (ESO)
FAULTY INJECTION PUMP BALL CHECK REG. VALVE
WORN OR STUCK INJECTION PUMP ADVANCE PISTON
FAULTY INJECTION PUMP WEIGHT RETAINER RING
STICKING INTERNAL GOVERNOR LINKAGE/METERING VALVE
INOPERATIVE FUEL LINE OR FILTER HEATER
NO FUEL DELIVERY
INJECTION PUMP HOUSING PRESSUREJ8-12 PSIj
ENGINE 6A-11
COMPRESSION CHECK
(6.2 DIESEL ENGINE)
1.
2.
3.
4.
5.
6.
7.
Tools Required:
J-29664-2 or J-26996-1 Intake Manifold
Cover
J-26999-10 Compression gage.
Remove the air cleaner. Install J-29664-2 or
J-26996-1 over the mouth of the intake manifold.
Disconnect the wire from the fuel solenoid
terminal of the injection pump.
Disconnect wires from glow plugs then remove all
glow plugs.
Screw J-26999-10 into the glow plug hole of the
cylinder that is being checked.
Make sure the batteries are fully charged, and the
engine is fully warmed up (engine oil hot).
Crank the engine. Allow six “ puffs” per cylinder.
Make the compression check at each cylinder
and record the readings.
NOTICE: Do not add oil to any cylinder during
a compression test as extensive engine
damage can result.
8. The lowest reading cylinder should not be less
than 80 percent of the highest reading cylinder.
No cylinder should read less than 2625 kPa (380
psi).
• Normal: Compression builds up quickly and
evenly to specified compression on each
c y lin d e r. R e a d in g sh o u ld be in the
2625-2760 kPa (380-400 psi) range.
• Leaking: Compression low on first stroke
tends to build up on following strokes but
does not reach normal.
CRANKING SPEED CHECK
(6.2L DIESEL ENGINE)
Tool Required:
J-26999-10 Compression Gage
Cranking speed is critical for a diesel to start, either
hot or cold. Some tachometers are not accurate at
cranking speed. An alternate method of checking
cranking speed or determining the accuracy of a
tachometer follows:
1. Connect J-26999-10 to any cylinder.
2. Disconnect the injection pump fuel solenoid lead
on the top of the injection pump.
3. Install the digital tachometer to be checked (if
desired).
4. Depress the pressure release valve on the
compression gage.
5. With the aid of an assistant, crank the engine for
2 or 3 seconds to allow the starter to reach full
speed, then without stopping, count the number
of “ puffs” at the compression gage that occur in
the next 10 seconds. Multiply the number of
“ puffs” in the 10 second period by 12 and the
resulting number will be the cranking speed in
revolutions per minute (RPM).
Example:
10
seconds = 1/6 of a minute
1 puff = 2 RPM
RPM = No. of puffs x 2 x 6 or
RPM = No. of puffs x 12
Minimum cranking speed on the 6.2L diesel engine
is 100 RPM cold and 180 RPM hot. The actual cranking
speed needed will vary depending on the condition of
the engine (compression) and nozzles.
SPECIAL TOOLS
J-29664-2 or J-26996-1
J-26999-10
Intake Manifold Cover
Compression Gage
6A3-1
SECTION 6A3
4.3 LITER V6
The following “ Notice” applies to one or more steps in the assembly procedure of components in this portion of
the manual as indicated at appropriate locations by the terminology “ NOTICE: See ‘Notice’ on page 6A3-1 of this
section.”
NOTICE: All engine fasteners are important attaching parts in that they could affect the performance of vital
components and systems, and/or could result in major repair expense. They must be replaced with one of
the same part number or with an equivalent part if replacement becomes necessary. Do not use a replace­
ment part of lesser quality or substitute design. Torque values must be used as specified during reassembly
to assure proper retention of this part.
CONTENTS
SUBJECT
PAGE
D e s c rip tio n ................................................................................................................................................................ 6A3- 2
Engine L u b ric a tio n ...............................................................................................................................................6A3- 2
On-Vehicle S e r v ic e ................................................................................................................................................. 6A3- 5
Rocker Arm Cover Replacem ent....................................................................................................................... 6A3- 5
Rocker Arm and Pushrod R eplacem ent.......................................................................................................... 6A3- 6
Valve A d ju s tm e n t................................................................................................................................................. 6A3- 6
Valve Stem Seal and Valve Spring R e p la ce m e n t.........................................................................................6A3- 7
Intake Manifold R e p la ce m e n t........................................................................................................................... 6A3- 8
Hydraulic Lifter R e p lace m e n t........................................................................................................................... 6A3- 9
Rocker Arm Stud Replacem ent......................................................................................................................... 6A3-10
Exhaust Manifold Replacem ent......................................................................................................................... 6A3-11
Cylinder Head R e p la ce m e n t............................................................................................................................. 6A3-12
Torsional Damper And Front Crankshaft Seal R eplacem ent..................................................................... 6A3-12
Front Cover R e placem ent..................................................................................................................................6A3-13
Oil Pan R eplacem ent.......................................................................................................................................... 6A3-14
Oil Pump R e p la ce m e n t...................................................................................................................................... 6A3-15
Rear Crankshaft Oil Seal R e p la ce m e n t.......................................................................................................... 6A3-15
Rear Crankshaft Oil Seal Retainer Replacement...........................................................................................6A3-16
Measuring Camshaft Lobe L i f t ......................................................................................................................... 6A3-17
Camshaft R e p la ce m e n t...................................................................................................................................... 6A3-17
Connecting Rod And Piston Replacement......................................................................................................6A3-20
Main Bearing R eplacem ent................................................................................................................................6A3-22
Oil Filter Adapter And Oil Filter Bypass Valve Replacement (Models With Engine Oil C o o ler).........6A3-23
Crankshaft R eplacem ent....................................................................................................................................6A3-23
Flywheel Replacem ent........................................................................................................................................ 6A3-25
Engine M ountings.................................................................................................................................................6A3-25
Engine R e p la ce m e n t.......................................................................................................................................... 6A3-28
S pecifications............................................................................................................................................................6A3-30
Special T o o ls ............................................................................................................................................................6A3-32
6A3-2 4.3 LITER V6
DESCRIPTION
4.3L engines are 90-degree V6 type, overhead valve,
water cooled, with cast iron block and heads.
The crankshaft is supported by four precision insert
main bearings, with crankshaft thrust taken at the num­
ber four (rear) bearing.
The camshaft is supported by four plain type bear­
ings and is chain driven. Motion from the camshaft is
transmitted to the valves by hydraulic lifters, pushrods,
and ball type rocker arms. The valve guides are inte­
gral in the cylinder head.
The connecting rods are forged steel, with precision
insert type crankpin bearings. The piston pins are a
press fit in the connecting rods.
The pistons are cast aluminum alloy. The piston pins
are a floating fit in the piston.
ENGINE LUBRICATION
Lubrication schematics are shown in figures 1 and 2.
The gear type oil pump is driven from the distributor
shaft, which is gear driven from the camshaft. Oil is
drawn into the oil pump through a pickup screen and
pipe.
Pressurized oil is routed to the oil filter. In case of
excessive oil pressure, a bypass valve is provided.
Filtered oil flows into the main gallery and then to the
camshaft and crankshaft bearings. The valve lifter oil
gallery supplies oil to the valve lifters. Oil flows from
the hydraulic lifters through the hollow pushrods to the
rocker arms. Oil from the overhead drains back to the
crankcase through oil drain holes.
The timing chain is drip fed from the front camshaft
bearing. The pistons and piston pins are lubricated by
oil splash.
4.3 LITER V6 6A3-3
Figure 1—Engine Lubrication Diagram
6A3-4 4.3 LITER V6
A.
B.
C.
D.
E.
F.
Regulator Valve (Shown In Open Position)
Suction
Oil Pressure Switch
Valve Lifter Gallery
Main Oil Gallery
Bypass Valve
Front View
Rear View
Showing Path Of Oil To Tim ing Chain.
Showing Main Gallery, Oil Filter And Crankshaft Oil Feed.
B-07860
Figure 2—Engine Lubrication Diagram
4.3 LITER V6 6A3-5
ON-VEHICLE SERVICE
Inspect
I*
• Rocker arm cover sealing surfaces for distortion.
Replace if necessary.
♦ i l Install or Connect
1. Rocker arm cover and new gasket.
2. Rocker arm cover bolts and washers.
Tighten
3.
4.
5.
6.
7.
8.
9.
10.
• Rocker arm cover bolts to 9.9 N-m (88 in.
lbs.).
Wires at choke.
AIR pipe retaining screws.
PCV valve.
Engine oil filler tube.
Diverter valve.
Air cleaner.
Engine cover (G models).
Battery negative cable.
LEFT SIDE ROCKER ARM COVER
Remove or Disconnect (Figure 3)
ROCKER ARM COVER
REPLACEMENT
RIGHT SIDE ROCKER ARM COVER
1.
2.
3.
4.
5.
Battery negative cable.
Engine cover (G models).
Air cleaner.
Air conditioning compressor brace (if used).
Accelerator and TVS cable bracket at the intake
manifold.
6. Rocker arm cover bolts.
7. Rocker arm cover gasket.
♦♦ Remove or Disconnect (Figure 3)
Clean
1. Battery negative cable.
2. Engine cover (G models).
3. Air cleaner.
4. Diverter valve.
All trackes of old gasket from the rocker arm
cover and cylinder head.
Inspect
5. Engine oil filler tube.
6. PCV valve at the rocker arm cover.
7. AIR pipe retaining bolts at the left and right
cylinder heads.
8. Wires at the choke and rocker arm cover.
9. Rocker arm cover bolts.
10. Rocker arm cover and gasket.
Rocker arm cover sealing surface for distortion
and damage. Replace if necessary.
-►4- Install or Connect (Figure 3)
1. Rocker arm cover and new gasket.
2. Rocker arm cover bolts and washers.
Tighten
All traces of old gasket from the rocker arm cover
and cylinder head.
Rocker arm cover bolts to 9.9 N-m (88 in
lbs.).
6A3-6 4.3 LITER V6
3.
4.
5.
6.
7.
Accelerator and TVS cable bracket.
Air conditioning compressor brace (if used).
Air cleaner.
Engine cover (G models).
Battery negative cable.
ROCKER ARM AND PUSHROD
REPLACEMENT
4-+ Remove or Disconnect
1. Rocker arm cover, as outlined previously.
2. Rocker arm nut.
• If only the pushrod is to be replaced, back
the rocker arm nut off until the rocker arm
can be swung away from the pushrod. Then
pull the pushrod out.
3. Rocker arm with ball.
4. Pushrod.
Im portant
• Store used components in order so they can be
reassembled in the same location.
I*
Inspect
— Rocker arms and balls at their mating surfaces.
These surfaces should be smooth and free from
scoring or other damage.
— Rocker arm areas which contact the valve stems
and the sockets which contact the pushrods.
These areas should be smooth and free of
damage and wear.
— Pushrods for bending. Roll the pushrod on a flat
surface to determine if it is bent. Replace if
necessary.
— Ends of the pushrods for scoring or roughness.
*►+ Install or Connect
1. Pushrod. Make sure the pushrod seats properly
in the hydraulic lifter.
2. Rocker arm with ball.
Im portant
• When new rocker arms and/or balls are
installed, coat their bearing surfaces with
“ Molykote” or equivalent.
3. Rocker arm nuts.
Adjust
• Valves as outlined later.
4. Rocker arm cover, as outlined previously.
VALVE ADJUSTMENT
1. Remove the rocker arm cover as outlined
previously.
2. Crank the engine until the mark on the torsional
damper lines up with the “ O” mark on the timing
tab and the engine in the number one firing
position. This may be determined by placing
fingers on the number one valve as the mark on
the damper comes near the “ O” mark on the
timing tab. If the rocker arms are not moving, the
engine is in the number one firing position. If the
rocker arms move as the mark comes up to the
timing tab, the engine is in the number four firing
position and should be turned over one more time
to reach the number one position.
3. With the engine in the number one firing position
as determined above, the following valves may be
adjusted:
— Exhaust: 1, 5, 6.
— Intake: 1, 2, 3.
(Even numbered cylinders are in the right bank;
odd numbered cylinders are in the left bank,
when viewed from the rear of the engine).
4. Back out the adjusting nut until lash is felt at the
pushrod then turn in the adjusting nut until all
lash is removed. This can be determined by
rotating the pushrod while turning the adjusting
nut (figure 4). When the play has been removed,
turn the adjusting nut in one full additional turn
(to center the lifter plunger).
5. Crank the engine one revolution until the timing
tab “ O ” mark and vibration damper mark are
again in alignment. This is the number four firing
position. The following valves may be adjusted:
— Exhaust: 2, 3, 4.
— Intake: 4, 5, 6.
4.3 LITER V6 6A3-7
20.
21.
22.
23.
24.
25.
Valve Keeper
Cap
Shield
O-Ring Seal
Seal
Damper
JJ, J *
M
V
\
\
26.
27.
28.
29.
\ 5
26
29
*
J
a
“
23 21
B-07865
F igure 5— V alves A nd C om ponen ts
6. In s ta ll the rocker arm cover as o u tlin e d
previously.
VALVE STEM SEAL AND
VALVE SPRING
REPLACEMENT
Figure 7—T e sting The Valve Seals
Rem ove o r D isco n n e ct (F igures 5 and 6)
1.
2.
3.
4.
Tools Required:
J-23590 Air Adapter.
J-5892-A Spring Compressor.
Rocker arm cover, as outlined previously.
Rocker arms, as outlined previously.
Spark plugs.
Valve keepers (20).
• Install J-23590 into the spark plug hole.
• Apply compressed air to hold the valves in
place.
• Install a rocker arm nut (figure 6).
• Use J-5892-A to compress the valve spring
(figure 6).
• Remove the valve keepers.
• C a re fu lly release the spring tension.
Remove J-5892-A.
5. Cap (21) and/or rotator (28), shield (22) and
spring (26) with damper (25).
6. O-ring seal (23), and seal (24) (intake valve only).
-n - Install o r C onnect (F igures 5, 6, and 7)
Tools Required:
J-23590 Air Adapter.
J-5892-A Spring Compressor.
J-23738-A Vacuum Pump
1. New seal (24). Install the seal over the intake
valve stem and seat it against the head.
2. Spring (26) with damper (25), sheild (22) and cap
(21) and/or rotator (28).
3. New o-ring seal (23) and valve keepers (20).
• With air pressure applied to the cylinder
with J-23590, compress the spring with
J-5892-A (figure 6).
6A3-8 4.3 LITER V6
Figure 8— Intake M anifold In sta lla tio n
• Lubricate the o-ring seal with engine oil.
Install the seal on the valve stem. Make sure
the seal is not twisted.
INTAKE MANIFOLD
REPLACEMENT
• Install the valve keepers. Use grease to hold
them in place.
□♦ 3
• Carefully release spring pressure. Make
sure the valve keepers stay in place.
1.
2.
3.
•
4.
5.
• Remove J-5892-A and J-23590.
• Check each o-ring seal for leakage (figure
7).
• Place the suction cup furnished with J23738-A over the shield.
• Connect J-23738-A to the suction cup
and apply a vacuum. Watch the vac­
uum pump gage. No air should be able
to leak past the seal. If the seal will not
hold a vacuum, it may have been dam­
aged or improperly installed.
4. Spark plugs.
5. Rocker arms, as outlined previously.
Adjust
• Valves, as outlined previously.
6. Rocker arm cover, as outlined previously.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Remove or Disconnect
Battery negative cable.
Engine cover (G models).
Air cleaner.
Drain the cooling system.
ESC connector.
Distributor. Refer to ENGINE ELECTRICAL (SEC.
6D).
TVS and accelerator cables.
Air conditioning compressor rear brace.
Engine oil filler tube at the generator bracket.
Transmission dipstick tube (if used) at the
generator bracket.
Air conditioning compressor belt idler (if used) at
the generator bracket.
Generator bracket.
Fuel and vacuum lines and electrical wiring at the
carburetor.
AIR hoses and brackets.
Heater hose at the intake manifold.
Carburetor (if required).
Intake manifold bolts.
Intake manifold.
4.3 LITER V6 6A3-9
♦ A
INITIAL TIGHTENING SEQUENCE
FINAL TIGHTENING SEQUENCE
A. Front Of Engine
B-07873
F igure 9- -Intake M an ifold B olt T ig h te n in g
S equence
Figure 10— R em oving The H ydraulic L ifte r
11. Transmission dipstick tube (if used).
Clean
— Old gasket and RTV from the block, heads, and
intake manifold. Remove all RTV that is loose or
will cause interference at assembly.
— Excessive carbon deposits from the exhaust and
EGR passages.
— Excessive scale and deposits from the coolant
passages.
L * Inspect
12. Engine oil filler tube.
13. Air conditioning compressor rear brace.
14. TVS and accelerator cables.
15. Distributor. Refer to ENGINE ELECTRICAL (SEC.
6D).
16. ESC connector.
17. Air cleaner.
18. Proper grade and quantity of engine coolant.
19. Engine cover (G models).
• Manifold for cracks and gasket surface damage.
20. Battery negative cable.
|-»<-| In stall o r C onnect (F igures 8 and 9)
1. Gaskets to the cylinder head.
2. RTV to the front and rear sealing surfaces on the
block (figure 8). Apply a 5 mm (3/ie-inch) bead of
RTV (part number 1052366 or equivalent) to the
front and rear of the block as shown. Extend the
bead 13 mm (1/2 -inch) up each cylinder head to
seal and retain the gaskets.
3. Intake manifold to the engine.
4. Intake manifold bolts.
T ig h te n
5.
6.
7.
8.
9.
10.
• Intake manifold bolts to 48 N m (36 ft. lbs.).
Use the tightening sequence shown in
figure 9.
Carburetor (if removed).
Heater hose.
AIR hoses and brackets.
Fuel and vacuum lines and electrical wiring at the
carburetor.
Generator bracket.
Air conditioning compressor belt idler (if used).
HYDRAULIC LIFTER
REPLACEMENT
Rem ove o r D isco n n e ct (Figures 10 and 11)
Tools Required:
J-3049 Hydraulic Lifter Remover (Plier Type)
or
J-9290-01 Hydraulic Lifter Remover (Slide
Hammer Type)
1. Rocker arm cover, intake manifold, and pushrod,
as outlined previously.
2. Hydraulic lifters.
— Remove the hydraulic lifters one at a time
and place them in an organizer rack. The
lifters must be installed in the same bore
from which they were removed.
— A stuck hydraulic lifter can be removed
using J-3049 (figure 10) or J-9290-01 (figure
11).
6A3-10 4.3 LITER V6
A. N u t
B. F la t W a s h e r
Figure 11— R em oving The H yd ra ulic L ifte r
(T ypical)
Inspect
— Hydraulic lifter body for scuffing or scoring. If the
lifter body wall is worn or damaged, the mating
bore in the block should also be checked.
— Check the fit of each hydraulic lifter in its mating
bore in the block. If the clearance is excessive, try
a new lifter.
— The hydraulic lifter foot must be smooth and
slightly convex. If worn, pitted, or damaged, the
mating camshaft lobe should also be checked.
H ydraulic L ifte r R epair
• Refer to the proper unit repair manual.
Install o r C onnect
1. Hydraulic lifters to the block. Lubricate the lifter
foot and body with Engine Oil Supplement or
equivalent.
Figure 12— R em oving The R ocker A rm Stud
ROCKER ARM STUD
REPLACEMENT
Rem ove o r D isconnect (Figure 12)
Tool Required:
J-5802-01 Rocker Arm Stud Remover.
1. Rocker arm cover and rocker arm, as outlined
previously.
2. Rocker arm stud.
• Place J-5802-01 over the rocker arm stud.
• Install a nut and flat washer.
• Turn the nut to remove the stud (figure 12).
Install o r C onnect (Figures 13 and 14)
Tools Required:
J-5715 Reamer (0.003-inch oversize) or
• When any new hydraulic lifters or a new
c a m s h a ft is in s ta lle d , E ng in e O il
S upplem ent (or equivalent) should be
added to the crankcase oil.
• Replace all hydraulic lifters when a new
camshaft is installed.
Intake manifold, as outlined previously.
Pushrod, as outlined previously.
A d ju s t
• Valves, as outlined previously.
4. Rocker arm cover, as outlined previously.
B-05245
Stud Bore (Typical)
4.3 LITER V6 6A3-11
EXHAUST MANIFOLD
REPLACEMENT
Rem ove or D isconnect
1. Battery negative cable.
2. Engine cover (G models).
• Raise the vehicle.
3. Exhaust pipe at the manifold.
• Lower the vehicle.
4. Oxygen sensor wire (left side manifold). Do not
remove the oxygen sensor from the manifold
unless the sensor is to be replaced.
5. AIR hose at the check valve.
6. AIR pipe at the d ive rte r valve (rig h t side
manifold).
7. AIR pipe bracket at the head (left side manifold).
8. Exhaust m anifold bolts, washers, and tab
washers.
9. Exhaust manifold.
y | Clean
— Mating surfaces on the manifold and head.
— Threads on the exhaust manifold bolts.
J-6036 Reamer (0.013-inch oversize).
J-6880 Rocker Arm Stud Installer.
NOTICE: Do not attempt to install an oversize
rocker arm stud without reaming the stud hole
as this could damage the cylinder head.
• Ream the hole to the proper size for the
replacement oversize rocker arm stud. Use
J-5715 for 0.003-inch oversize studs; J-6036 for
0.013-inch oversize stud (figure 13).
• Coat the lower end (press-fit area) of the rocker
arm stud with hypoid axle lubricant.
Install o r C onnect
1. Exhaust m anifold, bolts, washers, and tab
washers.
T ighten
• Bolts on center exhaust tube to 36 N m (26
ft. lbs.).
• Bolts on front and rear exhaust tubes to 28
N m (20 ft. lbs.).
• Bend the tab washers over the heads of all
bolts.
2. AIR bracket at the head (left side manifold).
1. Rocker arm stud. Use J-6880 (figure 14). Stud is
installed to proper depth when the tool bottoms
on the cylinder head.
2. Rocker arm, as outlined previously.
3. AIR pipe at the d ive rte r valve (rig h t side
manifold).
4. AIR hose at the check valve.
5. Oxygen sensor wire (left side manifold).
• Raise the vehicle.
A d ju s t
6. Exhaust pipe to the manifold.
• Lower the vehicle.
• Valves, as outlined previously.
3. Rocker arm cover, as outlined previously.
7. Engine cover (G models).
8. Battery negative cable.
6A3-12 4.3 LITER V6
CYLINDER HEAD
REPLACEMENT
rz
Remove or Disconnect
□
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Battery negative cable.
Engine cover (G models).
Intake manifold, as outlined previously.
Exhaust manifold, as described previously.
AIR pipe at the rear of the head (right cylinder
head).
Generator mounting bolt at the cylinder head
(right cylinder head).
Power steering pump and brackets from the
cylinder head, and lay aside (left cylinder head).
Air conditioning compressor, and lay aside (left
cylinder head).
Rocker arm cover, as outlined previously.
Spark plugs.
Pushrods, as outlined previously.
Cylinder head bolts.
Cylinder head.
4 l FRONT
B-07874
Figure 15—Cylinder Head Bolt Tightening
Sequence
$
• Cylinder head bolts, a little at a time, using
the sequence shown in figure 15. Proper
torque is 90 N m (65 ft. lbs.).
4. Pushrods, as outlined previously.
f t
14. Gasket.
Clean
— Carbon deposits from combustion chambers.
— All traces of old head gasket from cylinder head
and block.
— Cylinder head bolt threads and threads in the
block.
I*
Inspect
Sealing surfaces of the block and cylinder head
for nicks, heavy scratches, or other damage.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Cylinder Head Repair
• Refer to the proper Unit Repair Manual.
Adjust
• Valves, as outlined previously.
Rocker arm cover, as outlined previously.
Spark plugs.
Rocker arm cover, as outlined previously.
Air conditioning compressor (if removed).
Power steering pump and brackets (if removed).
Generator mounting bolt (if removed).
AIR pipe (if removed).
Exhaust manifold, as outlined previously.
Intake manifold, as outlined previousy.
Engine cover (G models).
Battery negative cable.
TORSIONAL DAMPER AND
FRONT CRANKSHAFT
SEAL REPLACEMENT
-►«- Install or Connect (Figure 15)
1. Head gasket.
• If a steel gasket is used, coat both sides of
the gasket with sealer. Spread the sealer
thin and even.
• Do not use se a le r on c o m p o s itio n
steel-asbestos gaskets.
• Place the gasket over the block dowel pins
with the bead up.
2. Cylinder head. Carefully guide the cylinder head
into place over the dowl pins and gasket.
3. Cylinder head bolts. Coat threads of the cylinder
head bolts with sealing compound (GM part
number 1052080 or equivalent) and install
finger-tight.
Tighten
+ + Remove or Disconnect (Figure 16)
1.
2.
3.
4.
5.
6.
7.
Tool Required:
J-23523-E Torsional Damper Puller and
Installer.
Fan belts, fan, and pulley.
Fan shroud assembly.
Accessory drive pulley.
Torsional damper bolt.
Torsional damper. Use J-23523-E (figure 16).
Front crankshaft seal. Pry out with a large
screwdriver. Take care not to distort the timing
cover.
Crankshaft key, if necessary.
4.3 LITER V6 6A3-13
Figure 16—Removing The Torsional Damper
L*
Figure 17—Installing The Front Crankshaft
Oil Seal
Inspect
S i Tighten
Oil seal contact area on the torsional damper
shaft for grooving and roughness. Replace if
necessary.
• Bolt to 95 N m (70 ft. lbs.).
7. Accessory drive pulley.
8. Fan shroud assembly.
Install or Connect (Figures 17 and 18)
9. Fan pulley, fan, and fan belts.
Tools Required:
J-23042-A Seal Installer.
J-23523-E Torsional Damper Puller and
Installer.
1. Crankshaft key, if removed.
2. Front crankshaft seal. Use J-23042-A (figure 17).
The open end of the seal faces inside the engine.
Coat the seal lips with engine oil.
NOTICE: The inertia weight section of the
torsional damper is assembled to the hub with
a rubber type material. The correct installation
procedures (with the proper tool) must be
followed or movement of the inertia weight
section of the hub will destroy the tuning of
the torsional damper.
FRONT COVER REPLACEMENT
Remove or Disconnect
1. Torsional damper, as outlined previously.
2. Water pump.
3. Front cover bolts.
4. Front cover.
5. Front cover to block gasket.
3. Stud (item A, figure 18) to the crankshaft. Thread
the stud fully into the tapped hole in the
crankshaft.
4. Torsional damper over the end of the stud. Align
the keyway in the torsional damper shaft with the
crankshaft key.
5. Bearing, washer and nut (figure 18).
• Turn the nut to pull the vibration damper into
place.
A. Installation Stud
B. Nut
C. Washer and Bearing
B-07880
• Remove the tool.
6. Torsional damper bolt and washer.
Figure 18—Installing The Torsional Damper
6A3-14 4.3 LITER V6
Figure 19—Installing The Front Crankshaft
Oil Seal
6. Front crankshaft oil seal from the front cover. Pry
out with a screwdriver. Take care not to distort the
front cover.
j j | Clean
• Old gasket from the front cover, and block.
L * Inspect
Exposed portion of the one-piece oil pan gasket
that contacts the front cover. Inspect for cracks,
tears, heat checking, and deterioration. If the
gasket is in good condition, it can be re-used. If it
is unsuitable for reuse, the oil pan gasket must be
replaced.
Front cover for distortion and damage. Replace if
necessary.
Install or Connect (Figure 19)
Tool Required:
J-23042-A Seal Installer.
1. Front crankshaft oil seal. Use J-23042-A (figure
19). The open end of the seal faces inside the
engine. Coat the seal lips with engine oil.
2. Front cover gasket to the front cover. Use gasket
cement to hold them in place.
3. Front cover to the engine. Press the cover down
against the oil pan until the block dowel pins align
with the holes in the cover. Position the cover
against the block so that the dowels enter the
cover holes without binding. Do not force the
cover over the holes. Do not distort the cover
flange or dowel pin holes. Hold the front cover in
this position and install the front cover to block
bolts.
70. Gasket
71. Reinforcement
B-07884
Figure 20—Oil Pan Installation
Tighten
• Front cover to block bolts to 10.4 N m (92 in.
lbs.).
4. Water pump.
5. Torsional damper, as outlined previously.
OIL PAN REPLACEMENT
A one piece type oil pan gasket is used.
«--► Remove or Disconnect (Figure 20)
1.
•
•
2.
3.
Battery negative cable.
Raise the vehicle.
Drain the engine oil.
Exhaust crossover pipe.
Torque converter cover (models with automatic
transmission).
4.3 LITER V6 6A3-15
4. Strut rods at flywheel cover.
OIL PUMP REPLACEMENT
5. Strut rod brackets at the front engine mountings.
Remove or Disconnect
6. Starter.
1. Oil pan, as outlined previously.
2. Oil pump to main bearing cap bolt.
3. Oil pump.
7. Strut rods at engine mounts (K models with
automatic transmission).
8. Oil pan bolts, nuts, and reinforcements.
Inspect
9. Oil pan and gasket.
• Oil pump pickup tube for looseness. If the tube is
loose in the oil pump body, replace it, as outlined
in the proper unit repair manual. A loose pickup
tube can result in an air leak and loss of oil
pressure.
j j j ] Clean
• Gasket surfaces on the engine and oil pan.
I?* Inspect
• Oil pan gasket for damage. Replace if necessary.
Install or Connect (Figure 20)
1. A small amount of RTV sealant (GM part number
1052751 or equivalent) to the front and rear
corners of the oil pan.
Im portant
• Only a small amount of sealant is required.
Excessive amounts of sealant may prevent
proper sealing of the oil pan.
Oil Pump Repair
• Refer to the proper unit repair manual.
□
Install or Connect
1. Oil pump to the engine. Align the slot in the oil
pump shaft with the tang on the distributor shaft.
The oil pump should slide easily into place. No
gasket is used.
2. Oil pump to main bearing cap bolt.
Tighten
• Oil pump to main bearing cap bolt to 90 N m
(65 ft. lbs.).
3. Oil pan, as outlined previously.
2. Oil pan gasket to the oil pan.
3. Oil pan to the engine.
4. Oil pan bolts, nuts, and reinforcements.
Tighten
— Oil pan bolts to 11.3 N m (100 in. lbs.).
REAR CRANKSHAFT
OIL SEAL REPLACEMENT
|+"*| Remove or Disconnect (Figure 21)
1. Transmission.
2. Clutch and flywheel or flexplate, as equipped.
— Oil pan nuts to 22.6 N m (200 in. lbs.).
5. Strut rods at the engine mounts (K models with
automatic transmission).
NOTICE: Care should be taken when removing
the rear crankshaft oil seal so as not to nick
the crankshaft sealing surface.
6. Starter.
7. Strut rod brackets at the front engine mountings.
8. Strut rods at the flywheel cover.
9. Converter housing under pan (models with
automatic transmission).
10. Exhaust crossover pipe.
• Lower the vehicle.
11. Proper quantity and grade of engine oil.
12. Battery negative cable.
3. Rear crankshaft oil seal. Insert a screwdriver into
the notches provided in the seal retainer and pry
the seal out (figure 21).
+«- Install or Connect (Figure 22)
Tool Required:
J-35621 Seal Installer.
1. Rear crankshaft oil seal (figure 22).
• Lubricate the inner and outer diameter of
the seal with engine oil.
• Install the seal on J-35621.
6A3-16 4.3 LITER V6
A.
81.
82.
83.
84.
Rear Of Block
Seal Retainer
Crankshaft
Gasket
Screw b -07888
Figure 23—Rear Crankshaft Oil Seal
Retainer Installation
• Position J-35621 against the crankshaft.
Thread the attaching screws into the tapped
holes in the crankshaft.
REAR CRANKSHAFT
OIL SEAL RETAINER
REPLACEMENT
• T ig h te n the scre w s s e c u re ly w ith a
screwdriver. This will ensure that the seal is
installed squarely over the crankshaft.
• Turn the handle until it bottoms.
• Remove J-35621.
2. Clutch and flywheel or flexplate, as equipped.
3. Transmission.
Remove or Disconnect (Figures 21 and 23)
1.
2.
3.
4.
5.
6.
7.
Transmission.
Clutch and flywheel or flexplate, as equipped.
Oil pan, as outlined previously.
Screws (84).
Seal retainer (81).
Gasket (83).
Rear crankshaft oil seal. Insert a screwdriver into
the notches provided in the seal retainer and pry
the seal out (figure 21).
p y i Clean
• Gasket surfaces on block and seal retainer.
|-»*-| Install or Connect (Figures 21 and 23)
• Whenever the seal retainer is removed, a new
retainer gasket and rear crankshaft oil seal must
be installed.
1. Gasket (83) to the block. It is not necessary to use
sealant to hold the gasket in place.
2. Seal retainer (81).
3. Screws (84).
Figure 22—Installing The Rear Crankshaft
Oil Seal
• Screws (84) to 15.3 N-m (135 in. lbs.).
4. Oil pan, as outlined previously.
5. Rear cra n ksha ft oil seal (80) as o utline d
previously.
6. Clutch and flywheel or flexplate, as equipped.
4.3 LITER V6 6A3-17
7. Transmission.
MEASURING CAMSHAFT
LOBE LIFT
CAMSHAFT REPLACEMENT
C AND K MODELS
«--► Remove or Disconnect (Figures 25, 26, and
27)
Tool Required:
J-8520 Camshaft Lobe Lift Indicator.
1. Remove the rocker arm as outlined previously.
2. Refer to figure 24. Position the dial indicator (part
of J-8520) so the plunger rests on the pushrod
end, as shown. Make sure the pushrod is in the
lifter socket.
3. Rotate the crankshaft slowly in the direction of
rotation until the lifter is on the heel of the cam
lobe. At this point, the pushrod will be in its lowest
position.
4. Set dial indicator on zero, then rotate the
crankshaft slowly, or attach an auxiliary starter
switch and “ bump” the engine over, until the
pushrod is in fully raised position.
Im portant
• Whenever the engine is cranked remotely at
the starter, with a special jumper cable or
other means, the distributor primary lead
should be disconnected from the distributor
(coil).
5. Compare the total lift recorded from the dial
indicator with specifications.
6. If camshaft readings for all lobes are within
specifications, remove dial indicator assembly.
7. Install the rocker arm and adjust the valves as
previously outlined.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
•
14.
15.
16.
17.
•
18.
Tool Required:
J-5825 Crankshaft Sprocket Puller.
Battery negative cable.
Air cleaner.
Fan, shroud, and radiator. Refer to ENGINE
COOLING (SEC. 6B).
Generator.
Rocker arm covers, as outlined previously.
Fuel line.
Water pump. Refer to ENGINE COOLING (SEC.
6B).
Torsional damper, as outlined previously.
Front cover, as outlined previously.
Distributor. Refer to ENGINE ELECTRICAL (SEC.
6D).
Intake manifold, as outlined previously.
Pushrods and hydraulic lifters, as outlined
previously.
Fuel pump and pushrod.
Align the timing marks (figure 25).
Camshaft sprocket bolts.
Cam shaft sprocket and tim ing chain. The
sprocket is a lig h t in terfe re n ce fit on the
camshaft. Tap the sprocket on its lower edge to
loosen it.
Crankshaft sprocket (if required). Use J-5825
(figure 26).
Engine mount through-bolts.
Raise the engine.
Camshaft.
6A3-18 4.3 LITER V6
B-07892
Figure 27—Replacing The Camshaft
• Coat the camshaft lobes and journals with a high
quality engine oil supplement (GM Engine Oil
Supplement or equivalent).
B-07891
Figure 26—Replacing The Crankshaft Sprocket
• Install two or three 5/ie-18 bolts 100-125 mm
(4-5 inches) long into the camshaft threaded
holes. Use these bolts to handle the
camshaft (figure 27).
• Pull the camshaft from the block. Use care
to p re ve n t dam age to the c a m s h a ft
bearings.
Cleaning, Inspection And Repair
Clean, inspect and repair or replace the camshaft
and related components, as outlined in the proper unit
repair manual.
The unit repair manual also describes camshaft
bearing replacement.
1. Two or three 5/ie-18 bolts 100-125 mm (4-5 inches)
long into the camshaft threaded holes. Use these
bolts to handle the camshaft.
2. Camshaft to the engine (figure 27). Handle the
camshaft carefully to prevent damage to the
camshaft bearings.
• Lower the engine.
3. Engine mount through-bolts.
Tighten
• Through-bolts or nuts to specifications.
Refer to figures 35 and 36.
4. Crankshaft sprocket (if removed). Use J-5590
(figure 26). Make sure the timing mark faces
outside.
5. Camshaft sprocket and timing chain.
Im portant
|-»+| Install or Connect (Figures 25 through 27, 35,
and 36)
Tool Required:
J-5590 Crankshaft Sprocket Installer.
• Line up the timing marks on the camshaft
sprocket and crankshaft sprocket (figure
25).
6. Camshaft sprocket bolts.
4.3 LITER V6 6A3-19
Tighten
• Bolts to 24 N m (18 ft. lbs.).
7. Fuel pump and pushrod.
8. Hydraulic lifters and pushrods, as outlined
previously.
Important
Replace all hydraulic lifters and add GM
Engine Oil Supplement (or equivalent) to
the engine oil whenever a new camshaft is
installed.
f t
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
17. Cam shaft sprocket and tim ing chain. The
sprocket is a lighter interference fit on the
camshaft. Tap the sprocket on its lower edge to
loosen it.
18. Crankshaft sprocket (if necessary). Use J-5825
(figure 26).
19. Camshaft.
• Install two or three 5/ie-18 bolts 100-125 mm
(4-5 inches) long into the camshaft tapped
holes. Use these bolts to handle the
camshaft (figure 27).
• Pull the camshaft from the block. Use care
to p re ve n t dam age to the c a m s h a ft
bearings.
Adjust
• Valves, as outlined previously.
Intake manifold, as outlined previously.
Distributor. Refer to ENGINE ELECTRICAL (SEC.
6D).
Front cover, as outlined previously.
Torsional damper, as outlined previously.
Water pump. Refer to ENGINE COOLING (SEC.
6B).
Fuel line.
Rocker arm covers, as outlined previously.
Generator.
Fan, shroud, and radiator. Refer to ENGINE
COOLING (SEC. 6B).
Air cleaner.
Battery negative cable.
G MODELS
Cleaning, Inspection and Repair
Clean, inspect and repair or replace the camshaft
and related components, as outlined in the proper unit
repair manual.
The unit repair manual also describes camshaft
bearing replacement.
Install or Connect (Figures 25, 26 and 27)
•
1.
2.
+ + Remove or Disconnect (Figures 25, 26, and
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
•
27)
3.
Tool Required:
J-5825 Crankshaft Sprocket Puller.
Battery negative cable.
Intake manifold, as outlined previously.
Rocker arm covers, as outlined previously.
Hydraulic lifters and pushrods, as outlined
previously.
Outside air duct.
Power steering reservoir.
Upper fan shroud bolts.
Radiator.
Hood release cable at the latch.
Upper fan shroud.
AIR pum p, g e n e ra to r, a ir c o n d itio n in g
compressor, and power steering pump belts.
AIR pump and bracket.
Water pump.
Torsional damper, as outlined previously.
Front cover, as outlined previously.
Fuel pump and pushrod.
Align the timing marks (figure 25).
4.
Tool Required:
J-5590 Crankshaft Sprocket Installer.
Coat the camshaft lobes and journals with a high
quality engine oil supplement (GM Engine Oil
Supplement or equivalent).
Two or three 5/ie-18 bolts 100-125 mm (4-5 inches)
long into the camshaft threaded holes. Use these
bolts to handle the camshaft.
Camshaft to the engine (figure 27). Handle the
camshaft carefully to prevent damage to the
camshaft bearings.
Crankshaft sprocket. Use J-5590 (figure 26).
Make sure the timing mark faces outside.
Camshaft sprocket and timing chain.
Im portant
• Line up the timing marks on the camshaft
sprocket and crankshaft sprocket (figure
25).
5. Camshaft sprocket bolts.
Tighten
• Bolts to 24 N m (18 ft. lbs.).
Fuel pump and pushrod.
Front cover, as outlined previously.
Water pump.
AIR pump and bracket.
AIR pum p, g e n e ra to r, a ir c o n d itio n in g
compressor, and power steering pump belts.
11. Torsional damper, as outlined previously.
12. Front cover, as outlined previously.
13. Upper fan shroud.
6.
7.
8.
9.
10.
6A3-20 4.3 LITER V6
• Turn the crankshaft until the piston is at
BDC.
• Place a cloth on top of the piston.
• Perform the cutting operation with a ridge
reamer.
• Turn the crankshaft until the piston is at
TDC.
• Remove the cloth and cuttings.
5. Connecting rod cap. Check the connecting rod
and cap for identification marks. Mark the parts if
required. The connecting rod and cap must be
kept together as mating parts.
6. Connecting rod and piston.
• Attach J-5239 to the connecting rod bolts
(figure 28).
• Use the long guide rod of J-5239 to push the
connecting rod and piston out of the bore.
7. Connecting rod bearing.
C leaning, In sp e ctio n , And Repair
A. Guide Rod
B. Thread Protector
B-05269
Figure 28—Replacing The Piston And
Connecting Rod (Typical)
14.
15.
16.
17.
18.
19.
Hood release cable.
Radiator.
Upper fan shroud bolts.
Power steering reservoir.
Outside air ducts.
Hydraulic lifters and pushrods, as outlined
previously.
f t
Adjust
• Valves, as outlined previously.
20. Rocker arm covers, as outlined previously.
21. Intake manifold, as outlined previously.
22. Battery negative cable.
CONNECTING ROD AND
PISTON REPLACEMENT
4--¥ Remove or Disconnect (Figure 28)
1.
2.
3.
4.
Tool Required:
J-5239 Guide Set.
Cylinder head, as outlined previously.
Oil pan, as outlined previously.
Oil pump, as outlined previously (if necessary).
Ridge or deposits from the upper end of the
cylinder bores.
Clean, inspect and repair or replace the components
as necessary. Measure connecting rod bearing
clearance, piston clearance, ring clearances, etc. Refer
to the proper unit repair manual.
The unit repair manual contains information on:
— Connecting rod and piston.
— Piston rings.
— Connecting rod and crankpin.
— Cylinder bores.
♦«- Install or Connect (Figures 28 through 31)
•
•
1.
2.
Tools Required:
J-5239 Connecting Rod Guide Set.
J-8037 Ring Compressor.
Make sure the cylinder walls are clean. Lubricate
the cylinder wall lightly with engine oil.
Make sure the piston is installed in the matching
cylinder.
Connecting rod bearings.
• Be certain that the bearing inserts are of the
proper size.
• Install the bearing inserts in the connecting
rod and connecting rod cap.
• Lubricate the bearings with engine oil.
Piston and connecting rod to the proper bore.
• With the connecting rod cap removed,
install J-5239 onto the connecting rod studs.
• Locate the piston ring end gaps as shown in
figure 29. Lubricate the piston and rings with
engine oil.
• W ith o u t d is tu rb in g the ring end gap
location, install J-8037 over the piston
(figure 30).
• The piston must be installed so that the
notch in the piston faces the front of the
engine (figure 29).
4.3 LITER V6 6A3-21
o
ENGINE LEFT
ENGINE FRONT
ENGINE RIGHT
A.
B.
C.
D.
Oil Ring Rail Gaps
2nd Compression Ring Gap
Notch In Piston
Oil Ring Spacer Gap
(Tang In Hole Or Slot W ith Arc)
B-07895
E. Top Compression Ring Gap
Figure 29—Piston Ring End Gap Locations
• Place the piston in its matching bore. The
connecting rod bearing tang slots must be
on the side opposite the camshaft. Using
light blows with a hammer handle, tap the
piston down into its bore (figure 30). At the
same time, from beneath the vehicle guide
the connecting rod to the crankpin with
J-5239 (figure 28). Hold the ring compressor
Figure 31—Measuring Connecting Rod Side
Clearance
against the block until all rings have entered
the cylinder bore.
• Remove J-5239 from the connecting rod
bolts.
Im portant
Each connecting rod and bearing cap
should be marked, beginning at the front of
the engine. Cylinders 1, 3 and 5 are at the
left bank and, 2, 4 and 6 are the right bank.
The numbers on the connecting rod and
bearing cap must be on the same side when
installed in the cylinder bore. If a connecting
rod is ever transposed from block or
cylinder to another, new connecting rod
b e a rin g s sh o u ld be fitte d and the
connecting rod should be numbered to
correspond with the new cylinder number.
Measure
• Connecting rod bearing clearance. Refer to
the proper unit repair manual.
3. Connecting rod cap and bearing.
4. Connecting rod cap nuts.
Tighten
• Connecting rod cap nuts to 60 N m (45 ft.
lbs.).
Measure
• Connecting rod side clearance. Use a feeler
gage between the connecting rod and
crankshaft (figure 31). The correct clearance
is 0.006-0.014-inch.
6A3-22 4.3 LITER V6
5. Oil pump (if removed), as outlined previously.
6. Oil pan and cylinder head, as outlined previously.
MAIN BEARING REPLACEMENT
Remove or Disconnect (Figure 32)
1.
2.
3.
4.
5.
6.
Tool Required:
J-8080 Main Bearing Remover/Installer.
Spark plugs.
Oil pan, as outlined previously.
Oil pump, as outlined previously.
Main bearing caps.
• Check the main bearing caps for location
markings. Mark the caps if necessary. The
caps must be returned to their original
locations during assembly.
Lower main bearing inserts from the main
bearing caps.
Upper main bearing inserts.
• Insert J-8080 into the crankshaft oil hole
(figure 32).
• Rotate the crankshaft to “ turn” the bearing
insert out of the block.
Cleaning, Inspection, And Repair
C le a n, in s p e c t, and re p a ir or re p la ce the
components as required. Refer to the proper unit repair
manual. The unit repair manual contains information
on:
• Crankshaft.
• Main and connecting rod bearings.
• Main bearing cap replacem ent (shim m ing
procedure).
0
Install or Connect (Figures 32 and 33)
Tool Required:
J-8080 Main Bearing Remover/Installer.
1. Upper main bearing inserts.
• Insert J-8080 into a crankshaft main bearing
oil hole (figure 32).
• Apply engine oil to inserts of the proper
size.
• Insert the plain end (without the bearing
tang) of the insert between the crankshaft
and the notched side of the block.
• Rotate the crankshaft to “ roll” the insert into
the block.
• Remove the tool.
2. Lower main bearing inserts to the main bearing
caps.
Figure 32—Removing The Main Bearing Insert
Measure
• Main bearing clearance. Refer to the proper
unit repair manual. If the engine is in the
vehicle, the crankshaft must be supported
upward to remove any clearance from the
upper bearing. The total clearance can then
be measured between the lower bearing
and journal.
3. Main bearing caps (except rear cap) and bolts to
the block.
Tighten
• Main bearing cap bolts to 100 N m (75 ft.
lbs.).
4. Rear main bearing cap.
• Apply engine oil to the bearing insert.
A. Forward
B. Feeler Gage
100. Rear Main Bearing Cap
101. Crankshaft
B-07878
• Make sure the inserts are of the proper size.
• Apply engine oil to the inserts.
Figure 33—Measuring Crankshaft End Play
4.3 LITER V6 6A3-23
Install the rear main bearing cap and bolts.
Tighten the bolts temporarily to 14 N m (10
ft. lbs.).
Measure
• Crankshaft end play, as follows:
• Tap the end of the crankshaft first
rearward then forward with a lead
hammer. This will line up the rear main
b e a rin g and c ra n k s h a ft th ru s t
surfaces.
• Tighten the rear main bearing cap
bolts to 100 N m (75 ft. lbs.).
• With the crankshaft forced forward,
measure at the front end of the rear
main bearing with a feeler gage (figure
33). The p ro p e r c le a ra n c e is
0.002-0.006-inch.
• If correct end play cannot be obtained,
be certain that the correct size rear
main bearing has been installed.
Production engines may have rear
main bearings that are 0.008-inch
wider across the thrust faces than
standard. Refer to the proper unit
repair manual for more information.
8. Oil pump, as outlined previously.
9. Oil pan, as outlined previously.
10. Spark plugs.
OIL FILTER ADAPTER AND
OIL FILTER BYPASS VALVE
REPLACEMENT (MODELS WITH
ENGINE OIL COOLER)
E3
Remove or Disconnect (Figure 34)
1. Oil filter.
L*
2.
3.
4.
5.
B
90.
91.
92.
93.
B-07904
Figure 34—Oil Filter Adapter Installation
Tighten
• Bolts (93) to 20 N m (15 ft. lbs.).
3. Oil cooler lines.
4. Oil filter.
• Add engine oil as needed.
CRANKSHAFT REPLACEMENT
+ + Remove or Disconnect (Figure 28)
Inspect
• Bypass valve spring and fiber valve for
proper operation, cracks, or other damage.
If replacement is required, the bypass valve
and oil filter adapter must be replaced as an
assembly, as outlined following.
Oil cooler lines.
Bolts (93).
Oil filter adapter (92).
Gasket (91) and seal (90).
1.
2.
•
3.
4.
5.
6.
7.
8.
9.
Install or Connect (Figure 33)
1. New gasket (91), new seal (90) and oil filter
adapter (92) to the block.
2. Bolts (93).
Seal
Gasket
Oil Filter Adapter
Bolt
10.
Tool Required:
J-5239 Connecting Rod Guide Set.
Engine, as outlined later.
Flywheel (if used) as outlined later.
Mount the engine in a suitable engine stand.
Spark plugs.
Oil dipstick tube.
Oil pan and oil pump, as outlined previously.
Torsional damper, as outlined previously.
Front cover, as outlined previously.
Camshaft sprocket and timing chain.
Rear crankshaft oil seal retainer, as outlined
previously.
Connecting rod caps. Check the connecting rod
and cap for identification marks. Mark the parts if
necessary. The connecting rod and cap are
mating parts.
6A3-24 4.3 LITER V6
With the crankshaft forced forward,
measure at the front end of the rear
main bearing with a feeler gage (figure
32). The p ro p e r c le ra n c e is
0.002-0.006-inch.
If correct end play cannot be obtained,
be certain that the correct size rear
main bearing has been installed.
Production engines may have rear
main bearings that are 0.008-inch
wider across the thrust faces than
standard. Refer to the proper unit
repair manual for more information.
11. Connecting rods from the crankshaft.
• Attach J-5239 to the connecting rod bolts
(figure 28).
• Use the long guide rod to push the pistons
up in the bores.
12. Main bearing caps. Check the main bearing caps
fo r lo c a tio n m a rkin g s. M ark the p arts if
necessary. The main bearing caps must be
returned to their original locations at assembly.
13. Crankshaft.
14. Main bearing inserts.
Cleaning, Inspection, And Repair
Clean, inspect, and repair or replace the parts as
outlined in the proper unit repair manual. Refer to the
unit repair manual for information on:
— Crankshaft.
— Main and connecting rod bearings.
— Procedures for measuring bearing clearances.
□
Install or Connect (Figures 25, 28, and 31)
Tool Required:
• J-5239 Guide Set.
1. Upper main bearing inserts to the block. Apply
engine oil to the main bearings.
2. Crankshaft.
3. Lower main bearing inserts to the main bearing
caps. Apply engine oil to the bearing inserts.
*
Measure
• Main bearing clearance. Refer to the proper
unit repair manual.
4. Main bearing caps (except rear cap) and bolts to
the block.
a
• Crankshaft for binding. Try turning the
crankshaft to check for binding. If the
crankshaft does not turn freely, loosen the
main bearing cap bolts, one pair at a time,
until the tight bearing is located. Burrs on
the bearing cap, foreign matter between the
insert and the block or the bearing cap, or a
faulty insert could cause a lack of clearance
at the bearing.
6. Connecting rods to the crankshaft. Use J-5239 to
pull the connecting rods down (figure 28). Make
sure the connecting rod bearing insert stays in
place.
%
Measure
• Connecting rod bearing clearance. Refer to
the proper unit repair manual.
7. Connecting rod caps with bearing inserts to the
connecting rods. Apply engine oil to the inserts.
8. Connecting rod cap nuts.
Tighten
Tighten
Rear main bearing cap bolts temporarily to
14 N m (10 ft. lbs.).
€
Inspect
Tighten
• Main bearing cap bolts to 100 N m (75 ft.
lbs.).
5. Rear main bearing cap and bolts to the block.
$
I*
Measure
Crankshaft end play, as follows:
• Tap the end of the crankshaft first
rearward then forward with a lead
hammer. This will line up the rear main
b e a rin g and c ra n k s h a ft th ru s t
surfaces.
• Tighten the rear main bearing cap
bolts to 100 N m (75 ft. lbs.).
Connecting rod cap nuts to 60 N m (45 ft.
lbs.).
Measure
• Connecting rod side clearance. Use a feeler
gage between the connecting rod and
crankshft (figure 31) The correct clearance
is 0.006-0.014-inch.
9. Rear crankshaft oil seal retainer wiht new
crankshaft rear oil seal, as outlined previously.
10. Camshaft sprocket and timing chain.
Im portant
• Align the timing marks (figure 25).
11. Timing cover, as outlined previously.
12. Torsional damper, as outlined previously.
4.3 LITER V6 6A3-25
13. Oil pan and oil pump, as outlined previously.
ENGINE MOUNTINGS
14. Oil dipstick tube.
15. Spark plugs.
16. Flywheel (if used), as outlined later.
17. Engine, as outlined later.
NOTICE: Broken or deteriorated mountings
can cause m isa lig n ed and eventual
destruction of certain drive train components.
When a single mounting breakage occurs, the
rem aining m ountings are s u b jected to
abnormally high stresses.
FLYWHEEL REPLACEMENT
Remove or Disconnect
1. Transmission, flywheel housing, and clutch.
2. Flywheel bolts.
3. Flywheel.
ay
Clean
Mating surfaces of crankshaft and flywheel.
Remove any burrs.
L * Inspect
— Flywheel for burning, scoring, warping, and wear.
Replace the flywheel if necessary. Do not
machine the flywheel.
— Flywheel ring gear for worn or broken teeth.
Flywheel Ring Gear Replacement
1. Use a torch to heat the gear around the entire
circum ference, then drive the gear off the
flywheel, using care not to damage the flywheel.
INSPECTING ENGINE MOUNTINGS
Front Engine Mountings
NOTICE: When raising or supporting the
engine for any reason, do not use a jack under
the oil pan, any sheet metal or crankshaft
pulley. Due to the small clearance between
the oil pan and the oil pump screen, jacking
against the oil pan may cause it to be bent
against the pump screen, resulting in a
damaged oil pickup unit.
1. Raise the engine to remove weight from the
mountings and to place a slight tension on the
rubber cushion. Observe both mountings while
raising the engine.
2. Replace the mounting if the following conditions
exist:
— Hard rubber surface covered with heat
check cracks.
— Rubber cushion separated from the metal
palte of the mounting.
— Rubber cushion split through the center.
NOTICE: Never heat starter gear to red heat as
this will change metal structure.
2. Uniformly heat the flywheel gear to temperature
which will expand the gear to permit installation.
Temperature must not exceed 204°C (400°F).
3. As soon as the gear has been heated, install on
the flywheel.
0
Install or Connect
1. Flywheel.
2. Flywheel bolts.
Tighten
• Flywheel bolts to 100 N-m (75 ft. lbs.).
3. Clutch, flywheel housing, and transmission.
3. If there is movement between a metal plate of the
mounting and its attaching points, lower the
engine and tighten the bolts or nuts attaching the
mounting to the engine, frame, or bracket.
Rear Mountings
1. Push up and pull down on the transmission
tailshaft. Observe the transmission mounting.
2. Replace the mounting if the following conditions
exist:
— Rubber cushion separated from the metal
plate of the mounting.
— Mounting bottomed out (tailshaft can be
moved up but not down).
3. If there is relative movement between a metal
plate of the mounting and its attaching point,
tighten the bolts or nuts attaching the mounting to
the transmission or crossmember.
6A3-26 4.3 LITER V6
A. Torque Bolt To 95 N-m (70 Ft. Lbs.). Or,
Torque Nut to 55 N-m (40 Ft. Lbs.).
B. 48 N m (36 Ft. Lbs.)
C. Forward
D. 40 N-m (30 Ft. Lbs.)
B-07906
Figure 35—Front Engine Mounting (C And K Models)
FRONT MOUNTING REPLACEMENT
Tighten
• Fasteners to specifications. Refer to figures
35 and 36.
3. Engine mount through-bolt and nut. Lower the
engine until the bolt can be inserted. Install the
nut.
Remove or Disconnect (Figures 35 and 36)
NOTICE: When raising or supporting the
engine for any reason, do not use a jack under
the oil pan, any sheet metal or crankshaft
pulley. Due to the small clearance between
the oil pan and the oil pump screen, jacking
against the oil pan may cause it to be bent
against the pump screen, resulting in a
damaged oil pickup unit.
a
Tighten
Through-bolt or nut to specifications. Refer
to figures 35 and 36.
REAR MOUNTING RELACEMENT
• Support the engine with a suitable jack. Do not
load the engine mounting.
Remove or Disconnect (Figures 37 and 38)
1. Engine mounting through-bolt and nut.
NOTICE: When raising or supporting the
engine for any reason, do not use a jack under
the oil pan, any sheet metal or crankshaft
pulley. Due to the small clearance between
the oil pan and the oil pump screen, jacking
against the oil pan may cause it to be bent
against the pump screen, resulting in a
damaged oil pickup unit.
NOTICE: Raise the engine only enough for
sufficient clearance. Check for interference
between the rear of the engine and the dash
panel which could cause distributor damage.
• Raise the engine only enough to permit removal
of the engine mounting.
2. Mounting assembly bolts, nuts, and washers.
3. Mounting assembly.
Install or Connect (Figures 35 and 36)
1. Mounting assembly.
NOTICE: See “Notice” on page 6A3-1 of this
section.
2. Mounting assembly bolts, nuts, and washers.
• Support the rear of the engine to relieve the
weight on the rear mountings.
1. Mounting to crossmember nut(s) and washer(s).
2. Mounting to transmission bolts and washers.
• Raise the rear of the engine only enough to
permit removal of the mounting.
3. Mounting.
0
Install or Connect (Figures 37 and 38)
1. Mounting.
• Lower the rear of the engine.
4.3 LITER V6 6A3-27
A. Torque Bolt To 95 N m (70 Ft. Lbs.). Or
Torque Nut To 55 N m (40 Ft. Lbs.).
B. 48 N m (36 Ft. Lbs.)
C. Forward
B-07908
Figure 36—Front Engine Mounting (G Models)
“ C” MODELS
B. 48 N m (36 Ft. Lbs.)
C. 55 N m (40 Ft. Lbs.)
Figure 37—Rear Engine Mounting (C And K Models)
K” MODELS
B-07909
6A3-28 4.3 LITER V6
15. Strut rods at the engine mountings (“ K” models
with automatic transmission).
16. Flywheel or torque converter cover.
17. Wiring along oil pan rail.
18. Starter.
19. Wiring for fuel gage.
20. Converter to flex plate bolts.
• Lower the vehicle.
• Support the transmission.
• Attach a suitable lifting fixture.
21. Bell housing to engine bolts.
22. Engine mounting to frame bo!*s.
23. Hood.
24. Engine.
Install or Connect (Figure 35)
2. Mounting to transmission bolts and washers.
NOTICE: See “Notice” on page 6A3-1 of this
section.
3. Mounting to crossmember nut(s) and washer(s).
$
1. Engine to the vehicle.
• Raise the vehicle.
NOTICE: See “Notice” on page 6A3-1 of this
section.
2. Engine mounting to frame belts.
Tighten
Tighten
Fasteners to specifications. Refer to figures
37 and 38.
3.
ENGINE REPLACEMENT
’ ; f tp
“ C” AND “ K ” MODELS
|+ + | Remove or Disconnect
1.
2.
•
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
•
•
14.
Battery negative cable.
Hood.
Drain the cooling system.
Air cleaner.
All accessory drive belts.
Fan and water pump pulley.
R a d ia to r and sh ro u d . R efer to ENG INE
COOLING (SEC. 1B).
Heater hoses at the engine.
Accelerator cruise control, and detent linkage (if
used) from the carburetor.
Air conditioning compressor (if used) and lay
aside.
Power steering pump (if used) and lay aside.
Engine wiring harness from the engine.
Fuel line at the fuel pump.
Vacuum lines from the intake manifold.
Raise the vehicle.
Drain the crankcase oil.
Exhaust pipes from the manifolds.
4.
5.
6.
7.
8.
9.
10
•
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
• Fasteners to specifications. Refer to figure
35.
Bell housing to engine bolts. Remove the
transmission support.
Converter to flex plate bolts.
Fuel gage wiring.
Starter.
Wiring along oil pan rail.
Flywheel or torque converter cover.
Strut rods at the engine mountings (K models
with automatic transmission).
Exhaust pipes to the manifolds.
Lower the vehicle.
Vacuum lines to the intake manifold.
Fuel line at the fuel pump.
Engine wiring harness.
Power steering pump (if used).
Air conditioning compressor (if used).
Accelerator, cruise control, and detent linkages.
Heater hoses.
Radiator and shroud.
Accessory drive belts.
Air cleaner.
Hood.
Proper q uantity and grade of coolant and
crankcase oil.
23. Battery negative cable.
4.3 LITER V6 6A3-29
G” MODELS
NOTICE: See “Notice” on page 6A3-1 of this
section.
Remove or Disconnect
2. Engine mounting through-bolts.
1.
2.
3.
•
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
•
•
34.
35.
36.
37.
38.
39.
40.
•
41.
+4-
Battery negative cable.
Glove box.
Engine cover.
Drain the coolant.
Outside air duct.
Power steering fluid reservoir.
Hood release cable.
Upper fan shroud bolts.
Radiator. Refer to ENGINE COOLING (SEC. 6B).
Upper fan shroud.
Fan and pulley.
Air cleaner.
Cruise control servo.
Vacuum hoses at the intake manifold.
Accelerator, cruise control, and detent cables (if
used).
Carburetor.
Distributor cap.
Diverter valve.
Coolant hose at the intake manifold.
PCV valve.
Other necessary vacuum hoses and wires.
Air conditioning compressor and brace. Refer to
AIR CONDITIONING (SEC. 1B).
Upper half of engine dipstick tube.
Oil filler tube.
Transmission dipstick tube.
Accelerator cable at the dipstick tube.
Fuel hoses at the fuel pump.
Power steering pump.
Air conditioning idler pulley.
Headlamp bezels and grille.
Upper radiator support.
Lower fan shroud and filler panel.
Hood latch support.
Condenser.
Raise the vehicle.
Drain the crankcase.
Exhaust pipes at the manifolds.
Strut rods at the torque converter or flywheel
underpan.
Torque convertor or flywheel cover.
Starter.
Flexplate to torque converter bolts (automatic
transmissions).
Bell housing to engine bolts.
Engine mounting through bolts.
Lower the vehicle and support the transmission.
Engine.
Install or Connect (Figure 36)
1. Engine to the vehicle.
• Raise the vehicle.
&
3.
4.
5.
6.
7.
8.
•
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
•
Tighten
• Through-bolts or nuts to specifications.
Refer to figure 36.
Bell housing to engine bolts.
Flex plate to torque converter bolts (automatic
transmissions).
Starter.
Torque converter or flywheel cover.
Strut rods.
Exhaust pipes.
Lower the vehicle.
Condenser.
Hood latch support.
Lower fan shroud and filler panel.
Upper radiator support.
Headlamp bezels and grille.
Air conditioning idler pulley.
Power steering pump.
Fuel hoses.
Accelerator cable at the dipstick tube.
Transmission dipstick tube.
Oil filler tube.
Upper half of engine dipstick tube.
Air conditioning compressor and brace. Refer to
AIR CONDITIONING (SEC. 1B).
Vacuum hoses and wires.
PCV valve.
Coolant hose at the intake manifold.
Diverter valve.
Distributor cap.
Carburetor.
Accelerator, cruise control, and detent cables.
Vacuum hoses at the intake manifold.
Cruise control servo.
Air cleaner.
Fan and pulley.
Upper fan shroud.
Radiator. Refer to ENGINE COOLING (SEC. 6B).
Upper fan shroud bolts.
Hood release cable.
Power steering fluid reservoir.
Outside air duct.
Glove box.
Proper q uantity and grade of coolant and
crankcase oil.
Engine cover.
Battery negative cable.
Evacuate and charge the air conditioning system.
Refer to AIR CONDITIONING (SEC. 1B).
6A3-30 4.3 LITER V6
SPECIFICATIONS
ENGINE SPECIFICATIONS
All Specifications are in INCHES unless otherwise noted.
GENERAL DATA:
Type
Displacement
RPO
Bore
Stroke
Compression Ratio
Firing Order
Oil Pressure
V6
4.3L (262 Cu. In.)
LB1/LB4
4.00
3.48
9.3:1
1-6 - 5 -4 -3 - 2
10 psi @ 500 RPM; 30-35 psi @ 2000 RPM
CYLINDER BORE:
Diameter
Out Of
Round
Service
3.9995-4.0025'
0.001 (Maximum)
0.002 (Maximum)
0.0005 (Maximum)
0.001 (Maximum)
0.001 (Maximum)
Production
Service Limit
0.0007-0.0017
0.0027 (Maximum)
Production
Service
Production
Taper
Thrust Side
Relief Side
PISTON:
Clearance
PISTON RING:
C
0
M
P
R
E
S
S
I
0
N
0
I
L
Groove
Production
Top
Service Limit
Gap
Groove
Clearance
Gap
0.0012-0.0032
2nd
Clearance
Production
Hi Limit Production + 0.001
Top
0.010-0.020
2nd
0.010-0.025
Service Limit
Production
Service Limit
Production
Service Limit
Hi Limit Production + 0.010
0.002-0.007
Hi Limit Production + 0.001
0.015-0.055
Hi Production +0.010
Production
Service Limit
0.9270-0.09273
0.00025-0.00035
0.001 (Maximum)
0.0008-0.0016 Interference
PISTON PIN:
Diameter
Clearance
In Piston
Fit In Rod
B-07911
4.3 LITER V6 6A3-31
SPECIFICATIONS
ENGINE SPECIFICATIONS (CONT.)
All specifications are in INCHES unless otherwise noted.
4.3L
DISPLACEMENT:
CRANKSHAFT:
#1
#2, #3
#4
Production
Service Limit
Production
Service Limit
#1
#2, #3
#4
#1
#2, #3
#4
Diameter
Main
Journal
Taper
Out Of
Round
Production
Main
Bearing
Clearance
Service Limit
Crankshaft End Play
Diameter
Production
Service Limit
Production
Service Limit
Production
Service Limit
Taper
Crankpin
Out
Round
Rod Bearing
Clearance
Rod Side Clearance
2.4484-2.4493
2.4481-2.4490
2.4479-2.4488
0.0002 (Maximum)
0.001 (Maximum)
0.0002 (Maximum)
0.001 (Maximum)
0.0008-0.0020
0.0011-0.0023
0.0017-0.0032
0.0010-0.0015
0.0010-0.0025
0.0025-0.0035
0.002-0.006
2.2487-2.2497
0.0005
0.001 (Maximum)
0.0005
0.001 (Maximum)
0.0013-0.0035
0.0030
0.006-0.014
CAMSHAFT:
Intake
Exhaust
Lobe
Lift + 0.002
Journal Diameter
Camshaft End Play
0.357
0.390
1.8682-1.8692
0.004-0.012
VALVE SYSTEM:
Hydraulic
1.50:1
Lifter
Rocker Arm Ratio
Intake
Exhaust
Valve Lash
45°
Stem
Clearance
Valve
Spring
(Outer)
Production
Service
Free Length
Pressure
lbs. @ in.
O
CD
Face Angle (Intake & Exhaust)
Seat Angle (Intake & Exhaust)
Seat Runout (Intake & Exhaust)
Seat Width
0.002 (Maximum)
Intake
Exhaust
Intake
Exhaust
Intake
Exhaust
Closed
Open
Installed Height
+
Valve
Spring
Damper
One Turn Down From Zero Lash
V3 2"
V 3 2 - V 16
1/ l 6 - 3/3 2
0.0010-0.0027
0.0010-0.0027
High Limit Production +0.001
High Limit Production +0.002
2.03
76-84 lbs. @ 1.70-in.
194-206 lbs. @ 1.25-in.
1 23/3 2
Free Length
1 .8 6
Approx. # of Coils
4
B-07912
6A3-32 4.3 LITER V6
SPECIFICATIONS (CONTINUED)
TORQUE SPECIFICATIONS
ITEM
Nm
FT. LBS.
Rocker Arm Cover B o lts ....................................................................................
9.9
Intake Manifold Bolts..........................................................................................
48
Exhaust Manifold Bolts
Center Two B o lts ........................................................................................
36
All O th e rs .....................................................................................................
28
Cylinder Head Bolts............................................................................................
90
Torsional Damper B olt........................................................................................
95
Front Cover Bolts................................................................................................
10.4
Oil Pan Nuts.........................................................................................................
22.6
Oil Pan B o lts .......................................................................................................
11.3
Oil Pump Bolt.......................................................................................................
90
15.3
Rear Crankshaft Oil Seal Retainer S cre w s ....................................................
Camshaft Sprocket Bolts....................................................................................
24
Connecting Rod Cap N u ts .......... .....................................................................
60
Oil Filter Adapter B o lts ......................................................................................
20
Main Bearing Cap B o lts ....................................................................................
100
Oil Pump Cover B o lts ........................................................................................
9.0
Flywheel B o lts .....................................................................................................
100
Spark P lu gs.........................................................................................................
30
Water Outlet B o lts ..............................................................................................
28
Water Pump B o lts ..............................................................................................
40
Flywheel Housing Bolts......................................................................................
44
SPECIAL TOOLS
J-23590
J-5892-A
J-23738-A
J-3049
J-9290-1
J-5802-01
J-5715
J-6036
J-6880
J-23523-E
J-23042-A
J-35621
J-8520
J-5239
J-8037
J-8080
J-5825
J-5590
Air Adapter
Spring Compressor
Vacuum Pump
Hydraulic Lifter Remover (Plier Type)
Hydraulic Lifter Remover (Slide Hammer
Rocker Arm Stud Remover
Reamer (0.003-inch oversize)
Reamer (0.013-inch oversize)
Rocker Arm Stud Installer
Torsional Damper Remover and Installer
Front Crankshaft Seal Installer
Rear Crankshaft Seal Installer
Camshaft Lobe Lift Indicator
Guide Set
Ring Compressor
Main Bearing Remover/Installer
Crankshaft Sprocket Puller
Crankshaft Sprocket Installer
—
36
26
20
65
70
—
—
—
65
—
18
45
15
75
—
75
22
21
30
32
IN. LBS.
88
92
200
100
135
80
6A4-1
SECTION 6A4
4.8 LITER L6
The following “ Notice” applies to one or more steps in the assembly procedure of components in this portion of
this manual as indicated at appropriate locations by the terminology “ See NOTICE on page 6A4-1 of this section.”
NOTICE: All engine fasteners are important attaching parts in that they could affect the performance of vital
components and systems, and/or could result in major repair expense. They must be replaced with one of
the same part number or with an equivalent part if replacement becomes necessary. Torque values must be
used as specified during reassembly to assure proper retention of all parts.
CONTENTS
S U B JE C T
PAGE
D e s c rip tio n ................................................................................................................................................................ 6A4- 2
Engine L u b ric a tio n ...............................................................................................................................................6A4- 2
On-Vehicle S e r v ic e ................................................................................................................................................. 6A4- 4
Rocker Arm Cover Replacem ent....................................................................................................................... 6A4- 4
Rocker Arm and Pushrod R eplacem ent.......................................................................................................... 6A4- 4
Valve A d ju s tm e n t................................................................................................................................................. 6A4- 5
Valve Stem Seal And Valve Spring R eplacem ent.........................................................................................6A4- 5
Pushrod Cover Replacem ent..............................................................................................................................6A4- 6
Hydraulic Lifter R e p lace m e n t........................................................................................................................... 6A4- 7
Intake And Exhaust Manifold R eplacem ent....................................................................................................6A4- 8
Rocker Arm Stud Replacem ent......................................................................................................................... 6A4- 9
Cylinder Head R e p la ce m e n t............................................................................................................................. 6A4-10
Torsional Damper And Front Crankshaft Seal R eplacem ent..................................................................... 6A4-11
Tim ing Gear Cover R e p lace m e n t.....................................................................................................................6A4-12
Oil Pan R eplacem ent.......................................................................................................................................... 6A4-13
Oil Pump R e p la ce m e n t...................................................................................................................................... 6A4-13
Rear Crankshaft Oil Seal R e p la ce m e n t.......................................................................................................... 6A4-13
Checking Valve T im in g ...................................................................................................................................... 6A4-15
Measuring Camshaft Lobe L i f t ......................................................................................................................... 6A4-16
Camshaft R e p lace m e n t...................................................................................................................................... 6A4-16
Connecting Rod And Piston Replacement......................................................................................................6A4-17
Main Bearing R eplacem ent................................................................................................................................6A4-19
Crankshaft Gear R e p la ce m e n t......................................................................................................................... 6A4-21
Oil Filter Bypass Valve R eplacem ent.............................................................................................................. 6A4-21
Crankshaft R eplacem ent.................................................................................................................................... 6A4-22
Flywheel R eplacem ent........................................................................................................................................ 6A4-23
Engine M ountings................................................................................................................................................. 6A4-24
Engine R e p la ce m e n t...........................................................................................................................................6A4-29
S pecifications............................................................................................................................................................6A4-30
Special T o o ls ............................................................................................................................................................6A4-33
6A4-2 4.8 LITER L6
DESCRIPTION
The connecting rods are forged steel, with precision
insert type crankpin bearings. The piston pins are a
press fit in the connecting rods.
The pistons are cast aluminum alloy. The piston pins
are a floating fit in the pistons.
ENGINE LUBRICATION
B-05053
Figure 1—Lubrication Diagram (Side View)
4.8L engines are inline six cylinder type, overhead
valve, water cooled, with cast iron block and head.
The crankshaft is supported by seven precision in­
sert main bearings, with crankshaft thrust taken at the
number seven (rear) bearing.
The camshaft is supported by four plain type bear­
ings and is gear driven. Motion from the camshaft is
transmitted to the valves by hydraulic lifters, pushrods,
and ball-type rocker arms. The valve guides are inte­
gral in the cylinder head.
Lubrication schematics are shown in figures 1 and 2.
The gear type oil pump is driven through an extension
shaft from the distributor drive shaft, which is gear
driven from the camshaft. Oil is drawn into the oil
pump through a pickup screen and pipe.
Pressurized oil is routed to the oil filter. In case of
excessive backpressure at the oil filter, a bypass valve
is provided. This valve will allow oil flow to the main oil
gallery at the right side of the block. This gallery
supplies oil to the camshaft bearings, hydraulic lifters,
and main bearings. The connecting rods are supplied
oil from the main bearings by means of drilled
passages in the crankshaft. The valve train is supplied
with oil by the hydraulic lifters. Oil is pumped from the
lifters through the hollow pushrods to the rocker arms.
Oil drains back to the crankcase through oil drain holes
and the pushrod holes. The piston, piston pin, and
timing gears are lubricated by oil splash.
4.8 LITER L6 6A4-3
A.
B.
C.
D.
E.
Oil Pressure Sending Unit
D istribu tor Shaft O iling
Splash O iling
F ilte r Bypass System
Full Flow Oil F ilte r
B-09222
Figure 2—Lubrication Diagram (Front View)
6A4-4 4.8 LITER L6
ON-VEHICLE SERVICE
I?
Inspect
• Rocker arm cover sealing surfaces for distortion.
Straighten or replace as needed.
|+<-| Install or Connect (Figure 3)
1. New gasket.
2. Rocker arm cover.
3. Bolts, clips, and reinforcements.
£
Tighten
• Bolts to specification.
— Rubber gasket - 4.3 N m (38 in. lbs.).
— Cork gasket - 5.4 N m (58 in. lbs.).
4. Wiring, fuel and vacuum lines to the clips.
5. Air cleaner.
6. Crankcase ventilation hoses to the rocker arm
cover.
1. Clip
2. Bolt
ROCKER ARM AND
PUSHROD REPLACEMENT
3. Reinforcement
4. Rocker Arm Cover
5. Gasket
B-07856
Remove or Disconnect
Figure 3—Rocker Arm Cover Installation
ROCKER ARM COVER
REPLACEMENT
Remove or Disconnect (Figure 3)
1. Rocker arm cover, as outlined previously.
2. Rocker arm nut.
• If only the pushrod is to be replaced, back
the rocker arm nut off until the rocker arm
can be swung away from the pushrod. Then
pull the pushrod out.
3. Rocker arm with ball.
4. Pushrod.
1. Crankcase ventilation hoses at the rocker arm
cover.
Important
2. Air cleaner.
Store used components in order so they can be
reassembled in the same location.
3. Wiring, fuel and vacuum lines from the clips.
4. Bolts, reinforcements, and clips.
5. Rocker arm cover.
• If the rocker arm cover adheres to the
cylinder head, try to shear the gasket by
bumping the end of the cover with a rubber
mallet. DO NOT DISTORT THE SEALING
FLANGE.
6. Gasket.
j j Clean
• All traces of old gasket from the rocker arm cover
and cylinder head.
I?
Inspect
Rocker arms and balls at their mating surfaces.
These surfaces should be smooth and free from
scoring or other damage.
Rocker arm areas which contact the valve stems
and the sockets which contact the pushrods.
These areas should be smooth and free of
damage and wear.
Pushrods for bending. Roll the pushrod on a flat
surface to determine if it is bent. Replace if
necessary.
Ends of the pushrods for scoring or roughness.
4.8 LITER L6 6A4-5
□
Install or Connect
1. Pushrod. Make sure the pushrod seats properly
in the hydraulic lifter.
2. Rocker arm with ball.
Im portant
• When new rocker arms and/or balls are
installed, coat their bearing surfaces with
“ Molykote” or equivalent.
3. Rocker arm nut.
Adjust
• Valves as outlined later.
4. Rocker arm cover, as outlined previously.
Figure 4—A djusting The Valves
VALVE ADJUSTMENT
1. Remove the rocker arm cover as outlined
previously.
2. Adjust the valves when the lifter is on the base
circle of the camshaft lobe as follows:
a. Mark the distributor housing with chalk, at
#1 and #6 plug wire positions. Remove the
distributor cap and lay aside.
b. Crank the engine until the distributor rotor
points to #1 cylinder position. The following
valves can be adjusted with the engine in
the #1 firing position:
#1 cylinder-Exhaust and Intake
#2 cylinder-lntake
#3 cylinder-Exhaust
#4 cylinder-lntake
#5 cylinder-Exhaust
c. Back out the adjusting nut until lash is felt at
the pushrod, then turn in the adjusting nut
until all lash is removed. This can be
determined by rotating the pushrod while
turning the adjusting nut (figure 4). When
play has been removed, turn the adjusting
nut in one full additional turn (to center the
lifter plunger).
d. Crank the engine until the distributor rotor
points to #6 position. The following valves
can be adjusted with the engine in #6 firing
position:
#2 cylinder-Exhaust
#3 cylinder-lntake
#4 cylinder-Exhaust
#5 cylinder-lntake
#6 cylinder-lntake and Exhaust
3. Install the distributor cap.
4. In s ta ll the rocker arm cover as o u tlin e d
previously.
VALVE STEM SEAL AND
VALVE SPRING REPLACEMENT
Remove or Disconnect (Figures 5 and 6)
Tools Required:
J-23590 Air Adapter.
J-5892-A Spring Compressor.
1. Rocker arm cover, as outlined previously.
2. Rocker arms, as outlined previously.
3. Spark plugs.
4. Valve keepers (20).
• Install J-23590 into the spark plug hole.
• Apply compressed air to hold the valves in
place.
• Install a rocker arm nut (figure 6).
20.
21.
22.
23.
Valve Keeper
Rotator
Shield
O-Ring Seal
24.
25.
26.
27.
28.
Seal
Damper
Spring
Intake Valve
Exhaust Valve
B-07859
Figure 5—Valves And Components
6A4-6 4.8 LITER L6
• Use J-5892-A to compress the valve spring
(figure 6).
• Remove the valve keepers.
• C a re fu lly release the spring tension.
Remove J-5892-A.
5. Rotator (21), shield (22) and spring (26) with
damper (25).
6. O-ring seal (23).
7. Seal (24) (intake valve only).
Install or Connect (Figures 5, 6, and 7)
Tools Required:
J-23590 Air Adapter.
J-5892-A Spring Compressor.
J-23994-01 Adapter Cup.
J-23738-A Vacuum Pump.
1. New seal (24) (intake valve only). Install the seal
over the valve stem and seat it against the head.
2. Spring (26) with the damper (25), shield (22) and
rotator (21).
3. New o-ring seal (23) and valve keepers (20).
• With air pressure applied to the cylinder
with J-23590, compress the spring with
J-5892-A (figure 6).
• Lubricate the o-ring seal with engine oil.
Install the seal on the valve stem. Make sure
the seal is not twisted.
• Install the valve keepers. Use grease to hold
them in place.
• Carefully release spring pressure. Make
sure the valve keepers stay in place.
• Remove J-5892-A and J-23590.
• Check each o-ring seal for leakage (figure
7).
• Place the suction cup furnished with J23738-A over the shield.
• Connect J-23738-A to the suction cup
and apply a vacuum. Watch the vac-
B-06470
Figure 7—Testing The Valve Seals
uum pump gage. No air should be able
to leak past the seal. If the seal will not
hold a vacuum, it may have been dam­
aged or improperly installed.
4. Spark plugs.
5. Rocker arms, as outlined previously.
Adjust
• Valves, as outlined previously.
6. Rocker arm cover, as outlined previously.
PUSHROD COVER
REPLACEMENT
Remove or Disconnect
1. Battery negative cable.
2. Dipstick tube (C-K models — if rear pushrod
cover is to be removed).
3. Pushrod cover bolts.
4. Pushrod cover.
5. Gasket.
Clean
Old gasket from pushrod cover and block.
4.8 LITER L6 6A4-7
Install or Connect
1. Pushrod cover and new gasket.
2. Pushrod cover bolts.
&
Tighten
• Pushrod cover bolts to 9.0 N m (80 in. lbs.).
3. Dipstick tube (if removed).
4. Battery negative cable.
HYDRAULIC LIFTER
REPLACEMENT
«--► Remove or Disconnect (Figures 8 and 9)
Tools Required:
J-3049 Hydraulic Lifter Remover (Plier Type)
or
J-9290-01 Hydraulic Lifter Remover
(Slide Hammer Type)
1. Rocker arm cover, pushrod cover, and pushrod,
as outlined previously.
2. Hydraulic lifters.
— Remove the hydraulic lifters one at a time
and place them in an organizer rack. The
lifters must be installed in the same bore
from which they were removed.
— A stuck hydraulic lifter can be removed
using J-3049 (figure 8) or J-9290-01 (figure
Figure 8—Removing The Hydraulic Lifter
• Replace all hydraulic lifters when a new
camshaft is installed.
2. Pushrod cover, as outlined previously.
3. Pushrod, as outlined previously.
f t
Adjust
• Valves, as outlined previously.
4. Rocker arm cover, as outlined previously.
9)-
15
Inspect
— Hydraulic lifter body for scuffing and scoring. If
the lifter body wall is worn or damaged, the
mating bore in the block should also be checked.
— Check the fit of each hydraulic lifter in its mating
bore in the block. If the clearance is excessive, try
a new lifter.
— The hydraulic lifter foot must be smooth and
slightly convex. If worn, pitted, or damaged, the
mating camshaft lobe should also be checked.
J-9290-01
Hydraulic Lifter Repair
• Refer to the proper unit repair manual.
Install or Connect
Hydraulic lifters to the block. Lubricate the lifter
foot and body with Engine Oil Supplement or
equivalent.
• When any new hydraulic lifters or a new
c a m s h a ft is in s ta lle d , E ngine Oil
Supplem ent (or equivalent) should be
added to the crankcase oil.
B-05064
Figure 9—Removing The Hydraulic Lifter
6A4-8 4.8 LITER L6
4. Carburetor (if necessary).
5. Fuel and vacuum lines from the manifold, EGR
valve (if used) and EFE valve.
6. AIR pump and bracket.
7. PCV hose.
8. Exhaust pipe.
9. Manifold heat stove.
10. Clamps (32), bolts (31), nuts (33) and washers.
11. Manifold assembly and gasket.
❖
32. Clamp
Disassemble (Figure 11)
1. Bolt (35) and nuts (40).
2. Manifolds (34 and 39).
3. Gasket (38).
33. Nut
B-07861
1^1 Clean
Figure 10—Manifold Installation
All manifold bolts and studs. Then apply engine
oil to the threads.
All traces of old gaskets from the cylinder head
and manifolds.
INTAKE AND EXHAUST
MANIFOLD REPLACEMENT
|<~+| Remove or Disconnect (Figures 10 and 11)
Inspect
1. Battery negative cable.
— M anifolds for cracks or dam age to gasket
surfaces.
— Operation of EFE or manifold heat valve (if used).
— Gaskets, if necessary to diagnose a leakage
problem.
2. Air cleaner.
3. Throttle controls at the bell crank.
Measure
Manifold distortion. Lay a straight edge along the
full length of the manifold exhaust port faces and
measure any gaps between the straight edge and
the port faces. If at any point a gap of 0.80 mm
(0.030-inch) or more exists, it is likely that the
manifold has distorted to a point where it will not
seal properly. If a good exhaust seal is to be
e xpected, the exhaust m a n ifo ld m ust be
replaced.
*
31.
32.
33.
34.
35.
Bolt
Clamp
Nut
Exhaust Manifold
Bolt
36.
37.
38.
39.
40.
Washer
Stud
Gasket
Intake Manifold
Nut
B-07866
Figure 11—Manifolds And Components
Assemble (Figure 11)
1. Gasket (38) to the exhaust manifold (34).
2. Intake manifold (39) to the exhaust manifold.
3. Both (35), washers (36) and nuts (40). LEAVE
FINGER TIGHT.
Install or Connect (Figures 10 and 11)
1. New gasket, over the manifold studs on the
cylinder head.
2. Manifold assembly.
3. Clamps (32).
4. Bolts (31), and nuts (33).
4.8 LITER L6 6A4-9
Figure 12—Removing The Rocker Arm Stud
Im portant
Always tighten the manifold to cylinder head
bolts and nuts (31 and 33) BEFORE
tightening the manifold center bolt and nuts
(35 and 40).
&
5.
6.
7.
8.
9.
10.
11.
12.
13.
Tighten
• Bolts (31) and nuts (33) to 52 N m (38 ft.
lbs.).
• Bolts (35) and nuts (40) to 60 N m (44 ft.
lbs.).
Manifold heat stove.
Exhaust pipe.
PCV hose.
AIR pump and bracket.
Fuel and vacuum lines from the manifold, EGR
valve (if used) and EFE valve (if used).
Carburetor (if removed).
Throttle controls.
Air cleaner.
Battery negative cable.
2. Rocker arm stud.
• Place J-5802-01 over the rocker arm stud.
• Install a nut and flat washer.
• Turn the nut to remove the stud (figure 12).
Install or Connect (Figures 13 and 14)
Tools Required:
J-5715 Reamer (0.003-inch oversize) or
Adjust
Engine idle speed, if necessary.
ROCKER ARM STUD
REPLACEMENT
♦■*1 Remove or Disconnect (Figure 12)
B
Tool Required:
J-5802-01 Rocker Arm Stud Remover
1. Rocker arm cover and rocker arm, as outlined
previously.
Figure 14—Installing The Rocker Arm Stud
6A4-10 4.8 LITER L6
J-6036 Reamer (0.013-inch oversize)
J-6880 Rocker Arm Stud Installer
NOTICE: Do not attempt to install an oversize
rocker arm stud without reaming stud hole as
this could damage the cylinder head.
• Ream the hole to the proper size for the
replacement oversize rocker arm stud. Use
J-5715 for 0.003-inch oversize studs; J-6036 for
0.013-inch oversize stud (figure 13).
FRONT OF ENGINE
B-05258
• Coat lower end (press-fit area) of the rocker arm
stud with hypoid axle lubricant.
1. Rocker arm stud. Use J-6880 (figure 14). Stud is
installed to proper depth when the tool bottoms
on the cylinder head.
2. Rocker arm, as outlined previously.
Figure 15—Cylinder Head Bolt
Tightening Sequence
L*
Sealing surfaces of the block and cylinder head
for nicks, heavy scratches, or other damage.
Adjust
• Valves, as outlined previously.
3. Rocker arm cover, as outlined previously.
Inspect
Cylinder Head Repair
• Refer to the proper Unit Repair Manual.
Install or Connect (Figure 15)
CYLINDER HEAD
REPLACEMENT
□
Remove or Disconnect
1. Battery ground cable.
2. Manifold assembly, as outlined previously.
3. AIR check valve.
4. Rocker arm cover, as outlined previously.
5. Pushrods. Back off the rocker arm nuts. Turn the
rocker arms aside, then remove the pushrods.
Place the pushrods in a rack so they can be
returned to their original locations at assembly.
1. Head gasket.
• If a steel gasket is used, coat both sides of
the gasket with sealer. Spread the sealer
thin and even.
• Do not use se a le r on c o m p o s itio n
steel-asbestos gaskets.
• Place the gasket over the block dowel pins
with the bead up.
Cylinder head. Carefully guide the cylinder head
into place over the dowel pins and gasket.
3. Cylinder head bolts. Coat threads of the cylinder
head bolts with sealing compound and install
finger tight.
6. Spark plug wires at the spark plugs.
Tighten
7. Vacuum lines at the thermal vacuum switch on
the water outlet.
• Drain the radiator and block.
8. Upper radiator hose, heater hose, and water
pump bypass hose.
9. Battery ground strap at the cylinder head.
10. Cylinder head bolts.
11. Cylinder head and gasket.
4.
5.
Qjj| Clean
— Carbon deposits from combustion chambers.
— All traces of old head gasket from cylinder head
and block.
6.
7.
8.
— Cylinder head bolt threads and threads in the
block.
9.
• Cylinder head bolts, a little at a time, using
the sequence shown in figure 15, until the
specified torque is reached.
— Left hand front bolt: 115 N m (85 ft.
lbs.).
— All other bolts: 130 N m (95 ft. lbs.).
Battery ground strap at the cylinder head.
Upper radiator hose, heater hose, and water
pump bypass hose. Fill the cooling system with
the proper coolant.
Vacuum lines at the thermal vacuum switch.
Spark plug wires.
Pushrods. Be sure to install them in their original
locations.
Rocker arms to the pushrods.
4.8 LITER L6 6A4-11
f t
10.
11.
12.
13.
Adjust
• Valves, as outlined previously.
Rocker arm cover, as outlined previously.
AIR check valve.
Manifold assembly, as outlined previously.
Battery ground cable.
TORSIONAL DAMPER AND
FRONT CRANKSHAFT SEAL
REPLACEMENT
4- + Remove or Disconnect (Figure 16)
Tool Required:
J-23523-E Torsional Damper Puller and
Installer.
Battery negative cable.
Radiator. Refer to ENGINE COOLING (SEC. 6B).
Drive belts from the crankshaft pulley.
Torsional damper bolt and washer.
Torsional damper. Use J-23523-E (figure 16).
Front crankshaft seal. Pry out with a large
screwdriver. Take care not to distort the timing
gear cover.
B-01325
Figure 16—Removing The Torsional Damper
J-23042-A
Inspect
Oil seal contact area on the torsional damper for
grooving and roughness. Replace if necessary.
+ + Install or Connect (Figures 17 and 18)
Tools Required:
J-23523-E Torsional Damper Puller and
Installer
J-23042-A Centering Tool and Seal Installer
1. Front crankshaft seal. Use J-23042-A (figure 17).
Coat the seal lips with engine oil. The open end
of the seal faces inside the engine.
B-07867
Figure 17—Installing The Tim ing Gear
Cover And Seal
• Turn the nut to pull the torsional damper into
place.
• Remove the tool.
NOTICE: The inertia weight section of the
torsional damper is assembled to the hub with
a rubber type material. The correct installation
procedures (with the proper tool) must be
followed or movement of the inertia weight
section of the hub will destroy the tuning of
the torsional damper.
2. Crankshaft key (if removed).
3. Stud (item C, figure 18) to the crankshaft. Thread
the stud fully into the tapped end of the
crankshaft.
4. Torsional damper over the end of the stud. Align
the keyway in the torsional damper shaft with the
crankshaft key.
5. Bearing, washer, and nut (figure 18).
A. Bearing
B. Washer
C. Stud
D. Nut
C
B-05254
Figure 18—Installing The Torsional Damper
6A4-12 4.8 LITER L6
6. Torsional damper bolt and washer.
Tighten
• Torsional damper bolt to 70 N m (50 ft. lbs.).
7. Drive belts to the crankshaft pulley, and tension to
specifications.
8. Radiator. Refer to ENGINE COOLING (SEC. 6B).
9. Battery negative cable.
• Fill the cooling system with the proper coolant.
TIMING GEAR COVER
REPLACEMENT
0 Remove or Disconnect
1.
2.
3.
4.
5.
Battery negative cable.
Torsional damper, as described previously.
Oil pan to timing gear cover bolts.
Timing gear cover to block bolts.
Timing gear cover.
• Pull the cover slightly forward only enough
to permit cutting of the oil pan front seal.
• Using a sharp knife or other suitable cutting
tool, cut the oil pan front seal flush with the
block at both sides of the oil pan.
• Remove the cover and attached portion of
the oil pan front seal.
6. Timing gear cover gasket.
7. Front crankshaft seal. Pry out with a screwdriver.
Be careful not to distort the timing gear cover.
ig * Clean
• Old gasket from the timing gear cover, block, and
oil pan.
|-n-| Install or Connect (Figures 17, 19, and 20)
1.
2.
3.
•
Tool Required:
J-23042-A Centering Tool and Seal Installer
Front crankshaft seal to the timing gear cover.
• Lubricate the seal lips with engine oil.
• Use J-23042-A to press the seal into place
(figure 19).
• Leave the tool in position in the seal.
Timing gear cover to oil pan seal.
• Cut the tabs from a new seal as shown in
figure 20. Use a sharp cutting tool to help
make a clean, straight cut.
• Position the seal against the cover. Press
the retaining tips into the holes in the cover.
Timing gear cover to block gasket to the timing
gear cover. Use gasket sealer to hold it in place.
Apply a 3 mm (Vs-inch) bead of RTV sealant to
the joint formed at the oil pan and cylinder block.
4. Timing gear cover, with J-23042-A in place, to the
block (figure 17).
Important
• The tool is used to align the timing gear
cover so that the front crankshaft seal is
properly centered around the crankshaft.
The seal must be centered to prevent
damage during hub installation.
5. Oil pan to timing gear cover bolts. Partially tighten
the bolts.
6. Timing gear cover to block bolts.
\^X \ Tighten
• Timing gear cover to block bolts to 9.0 N m
(80 in. lbs.).
• Oil pan to timing gear cover bolts to 5.1 N m
(45 in. lbs.).
4-+ Remove or Disconnect
• J-23042-A from the timing gear cover.
7. Torsional damper, as outlined previously.
8. Battery negative cable.
A. Cut This Portion From New Seal
B-07870
Figure 20—Front Oil Pan Seal Modification
4.8 LITER L6 6A4-13
OIL PAN REPLACEMENT
B♦ a
1.
•
2.
3.
4.
•
5.
6.
7.
Remove or Disconnect
Battery negative cable.
Drain the engine oil.
Starter.
Torque converter or flywheel cover.
Front engine mount through-bolts.
Raise the engine and block in position.
Oil pan bolts.
Oil pan.
Old gaskets and seals.
Clean
Old gasket and seals from the block and oil pan
sealing surfaces.
-►♦j Install or Connect
1. New rear oil pan seal to the rear main bearing
cap.
2. New front oil pan seal to the timing gear cover.
Press the retaining tips into the holes in the cover.
3. New oil pan to block gaskets to the block. Use
gasket cement to hold them in place.
4. Oil pan bolts.
Inspect
• Oil pump pickup tube for looseness. If the tube is
loose in the oil pump body, replace it, as outlined
in the proper unit repair manual. A loose pickup
tube can result in an air leak and loss of oil
pressure.
Oil Pump Repair
• Refer to the proper unit repair manual.
Install or Connect
1. Oil pump to the engine. Align the slot in the oil
pump shaft with the tang on the distributor shaft.
The oil pump should slide easily into place. No
gasket is used.
2. Oil pump bolts.
£
Tighten
• Oil pump bolts to 13.0 N-m (115 in. lbs.).
3. Oil pump pickup tube bracket to main bearing
cap nut.
Tighten
• Nut to 34 N-m (25 ft. lbs.).
4. Oil pan, as outlined previously.
Tighten
•
5.
6.
7.
— 1/4-inch oil pan to block bolts to 9.0 N-m (80
in. lbs.).
— 5/ie-inch oil pan to block bolts to 18.6 N m
(165 in. lbs.).
— Oil pan to timing gear cover to 5.1 N-m (45
in. lbs.).
Lower the engine.
Front engine mount through-bolts.
Torque converter or flywheel cover.
Starter.
8. Proper quantity and grade of engine oil.
9. Battery negative cable.
REAR CRANKSHAFT OIL
SEAL REPLACEMENT
The rear main bearing oil seal can be replaced (both
halves) without removal of the crankshaft. Always
replace the upper and lower seal as a unit. Install the
seal with the lip facing the front of the engine. Extreme
care should be exercised when installing this seal to
protect the sealing bead located in the channel on the
outside diameter of the seal. An installation tool (figure
23) should be used to protect the seal bead when
positioning the seal. (Some seal kits include the tool as
part of the service kit).
Remove or Disconnect (Figures 21 and 22)
OIL PUMP REPLACEMENT
|+ + | Remove or Disconnect
1. Oil pan, as outlined previously.
2. Oil pump pickup tube bracket to main bearing
cap nut.
3. Oil pump bolts.
4. Oil pump.
1. Oil pan, as outlined previously.
2. Rear main bearing cap.
3. Lower seal half (figure 21).
4. Upper seal half (figure 22).
• Tap on the upper seal half, using a small
drift and hammer.
• Remove the upper seal half, using pliers.
6A4-14 4.8 LITER L6
\
A. 4 mm (11/e4-inch)
B. 13 mm (1/2 -inch)
C. 0.10 mm (0.004-inch) shim stock
B-05250
Figure 23—Oil Seal Installation Tool
Install or Connect (Figures 23, 24, and 25)
1. Upper seal half.
igi
Clean
Sealing surfaces of the main bearing cap and
block.
I*
Inspect
• Crankshaft, seal channel, and sealing surfaces
for nicks, scratches, etc.
A.
B.
C.
80.
81.
82.
83.
84.
Figure 22—Removing The Upper Seal Half
Forward
Fabricated Tool
Oil Seal Lip
Upper Seal Half
Crankshaft
Block
Lower Seal Half
Main Bearing Cap
B-07871
Figure 24—Installing The Rear Crankshaft
Oil Seal
4.8 LITER L6 6A4-15
Figure 26—Checking Valve Tim ing Or
Camshaft Lobe Lift
Im portant
• An oil seal installation tool (figure 23)
should be fabricated (if not provided in
the seal kit) to prevent seal damage
during in sta lla tio n . Extrem e care
should be taken when installing this
seal to protect the sealing bead
located in the channel on the outside
diameter of the seal.
• Coat the seal lips lightly with engine oil.
Keep the oil off of the seal mating ends.
• Position the tip of the tool between the
crankshaft and the seal seat in the block
(figure 24).
• P o sitio n the seal h a lf betw een the
crankshaft and the tip of the tool. Make sure
that the oil seal lip is positioned toward the
front of the engine.
• Roll the seal around the crankshaft using
the tool as a “ shoe-horn” to protect the seal
bead from the sharp corner of the seal seat
surface in the block. The installation tool
must remain in position until the seal half is
properly positioned with both ends flush
with the block.
• Remove the tool, being careful not to
withdraw the seal half.
2. Lower seal half.
• Coat the seal lips lightly with engine oil.
Keep the oil off of the seal mating ends.
• Insert the seal half into the rear main
bearing cap. Use the tool to protect the seal
half from the sharp edge of the seal seat.
Feed the seal half into the rear main bearing
cap, using light finger pressure. Make sure
the oil seal lip faces the front of the engine
(figure 24).
3. Rear main bearing cap with the lower main
bearing.
• Apply a brush-on type oil sealing compound
to the mating surface of the block and cap
(figure 25). Do not allow any sealant on
either crankshaft or rear oil seal.
• Apply engine oil to the lower main bearing.
• Position the cap to the block. Install the cap
bolts.
Tighten
• R ear m ain b e a rin g cap b o lts
temporarily to 14 N m (10 ft. lbs.).
Tap the end of the crankshaft first rearward
then forward with a lead hammer. This will
line up the rear main bearing and crankshaft
thrust surfaces.
Tighten
• Rear main bearing cap bolts to 90 N m
(65 ft. lbs.).
4. Oil pan, as outlined previously.
5. The proper quantity and grade of engine oil.
CHECKING VALVE TIMING
Tool Required:
J-8520-Dial Indicator Adaptor
When it becomes necessary to make a check of
valve timing, the procedure following may be used:
1. Loosen the nut at the #1 intake valve rocker arm,
swing the rocker arm away from the pushrod,
then remove the pushrod.
2. Install a dial indicator, along with J-8520 (figure
26). Turn the crankshaft until the #2 exhaust valve
6A4-16 4.8 LITER L6
opens and the notch on the damper is aligned
with the “ 0” mark on the timing tab.
3. Position the dial indicator to measure lifter
movement and set indicator at zero. Turn the
crankshaft 360 degrees and read the indicator.
On correctly timed engines the indicator will read
0.012-0.020-inch.
4. If the reading is not as shown, reset the indicator
at zero and turn the crankshaft 360 degrees, then
read the indicator again. If reading is now within
specifications, the engine is timed properly.
5. The chart following shows indicator readings with
gears properly indexed for 4.8L engines and the
indicator readings resulting from improperly
indexed gears.
CAMSHAFT REPLACEMENT
To ch eck for w orn ca m sh a ft lo b es w ith o u t
disassem bling the engine, refer to “ M easuring
Camshaft Lobe Lift” in this section.
Remove or Disconnect (Figures 27 and 28)
1. Engine assembly, as outlined later.
• Mount the engine in a suitable engine stand.
2. Hydraulic lifters, as outlined previously.
3. Timing gear cover, as outlined previously.
4. Fuel pump. Refer to FUEL SYSTEM (SEC. 6C).
5. Distributor. Refer to ENGINE ELECTRICAL (SEC.
6D).
• Align the timing marks (figure 27).
Engine
Camshaft Part Number
Valve Lift
4.8L
3848000
0.405”
Dial
Gears Properly Indexed
Indicator One Tooth Advanced
Readings One Tooth Retarded
0.012-0.020’
0.038”
0.007”
6. Thrust plate bolts (93) (figure 28).
7. Camshaft. Support the camshaft carefully to
avoid damage to the camshaft bearings.
I*
Inspect
— Camshaft lobes and journals for scratches,
pitting, and wear.
— Timing gear for damaged teeth.
MEASURING CAMSHAFT
LOBE LIFT
Tool Required:
J-8520 Dial Indicator Adaptor
To check for worn camshaft lobes, use the following
procedure:
IjJ
Measure (Figure 29)
• Thrust plate to camshaft clearance. Use a feeler
gage (figure 29). The proper clearance is
0.08-0.20mm (0.003-0.008-inch). If the clearance
is excessive, replace the thrust plate. If the
clearance is insufficient, replace the spacer ring.
Refer to the proper unit repair manual.
1. Remove the rocker arm as outlined previously.
2. Install a dial indicator (part of J-8520) (figure 26).
Position the dial indicator so the plunger rests on
the pushrod end, as shown, Make sure the
pushrod is in the lifter socket.
3. Rotate the crankshaft slowly in the direction of
rotation until the hydraulic lifter is on the heel of
the cam lobe. At this point, the pushrod will be in
its lowest position. Set dial indicator on zero, then
rotate the crankshaft slowly until the pushrod is in
the fully raised position.
4. Compare the total lift recorded from the dial
indicator with specifications.
5. Continue to rotate the crankshaft until the
indicator reads zero. This will be a check on the
accuracy of the original indicator reading.
6. Remove the dial indicator and adaptor.
7. Install the rocker arm and adjust the valves as
previously outlined.
Camshaft Gear And Thrust Plate Replacement
• Refer to the proper unit repair manual.
Camshaft Bearing Replacement
• Refer to the proper unit repair manual.
-►4- Install or Connect (Figure 27)
• Coat the camshaft lobes and journals with a high
quality engine oil supplement (GM Engine Oil
Supplement or equivalent).
1. C am shaft (90) to the engine. H andle the
camshaft carefully to prevent damage to the
camshaft bearings.
Important
• Line up the timing marks on the crankshaft
gear and camshaft gear (figure 27).
2. Thrust plate bolts (94).
4.8 LITER L6 6A4-17
90.
91.
92.
93.
94.
Tinning Marks
Camshaft
Thrust Plate
Camshaft Gear
Thrust Plate Bolts
Crankshaft Gear
B-07863
Figure 27—Camshaft And Components
a
Tighten
Measure
Thrust plate bolts to 9.0 N m (80 in. lbs.).
4.
5.
Figure 28—Removing The Camshaft Thrust
Plate Bolts
6.
7.
— Camshaft and crankshaft gear run-out. Use
a dial indicator. Camshaft gear run-out
should not exceed 0.10 mm (0.004-inch),
crankshaft gear run-out should not exceed
0.08 mm (0.003-inch). If gear run out is
excessive, the gear will have to be removed
and any burrs cleaned from the shaft or the
gear will have to be replaced.
— Timing gear backlash. Use a dial indicator.
The correct backlash is 0.10-0.15 mm
(0.004-0.006-inch) with new parts, 0.20 mm
(0.008-inch) maximum with used parts.
Timing gear cover, as outlined previously.
Distributor. Refer to ENGINE ELECTRICAL (SEC.
6D).
Fuel pump. Refer to FUEL SYSTEM (SEC. 6C).
Hydraulic lifters, as outlined previously.
Im portant
• Replace all hydraulic lifters and add GM En­
gine Oil Supplement (or equivalent) to the
engine oil whenever a new camshaft is in­
stalled.
8. Engine assembly in the vehicle, as outlined later.
CONNECTING ROD AND
PISTON REPLACEMENT
Remove or Disconnect (Figure 30)
Figure 29—Measuring Camshaft To Thrust
Plate Clearance
Tool Required:
J-5239 Guide Set.
1. Cylinder head, as outlined previously.
2. Oil pan, as outlined previously.
3. Oil pump, as outlined previously (if necessary).
6A4-18 4.8 LITER L6
Figure 30—Removing Or Installing The
Connecting Rod And Piston
4. Ridge or deposits from the upper end of the
cylinder bores.
• Turn the crankshaft until the piston is at
BDC.
• Place a cloth on top of the piston.
• Perform the cutting operation with a ridge
reamer.
• Turn the crankshaft until the piston is at
TDC.
• Remove the cloth and cuttings.
5. Connecting rod cap. Check the connecting rod
and cap for identification marks. Mark the parts if
required. The connecting rod and cap must be
kept together as mating parts.
6. Connecting rod and piston.
• Attach J-5239 to the connecting rod bolts
(figure 30).
• Use the long guide rod of J-5239 to push the
connecting rod and piston out of the bore.
7. Connecting rod bearing.
Cleaning, Inspection, And Repair
Clean, inspect and repair or replace the components
as necessary. Measure connecting rod bearing
clearance, piston clearance, ring clearances, etc. Refer
to the proper unit repair manual.
The unit repair manual contains information on:
— Connecting rod and piston.
— Piston rings.
— Connecting rod and crankpin.
— Cylinder bores.
Install or Connect (Figures 30 through 34)
Tools Required:
J-5239 Connecting Rod Guide Set
J-8037 Ring Compressor
Figure 31—Piston Ring Gap Location
• Make sure the cylinder walls are clean. Lubricate
the cylinder wall lightly with engine oil.
• Make sure the piston is installed in the matching
cylinder.
1. Connecting rod bearings.
• Be certain that the bearings are of the
proper size.
• Install the bearing inserts in the connecting
rod and connecting rod cap.
• Lubricate the bearings with engine oil.
2. Piston and connecting rod to the proper bore.
• With the connecting rod cap removed,
install J-5239 onto the connecting rod studs
(figure 30).
• Locate the piston ring end gaps as shown in
figure 31. Lubricate the piston and rings with
engine oil.
• W ith o u t d is tu rb in g the ring end gap
location, install J-8037 over the piston
(figure 32).
• The piston must be installed so that the
piston crown depression’s flat side faces to
the engine’s left side (figure 33).
• Place the piston in its matching bore. Using
light blows with a hammer handle, tap the
piston down into its bore (figure 33). At the
same time, from beneath the vehicle guide
the connecting rod to the crankpin with
J-5239 (figure 30). Hold the ring compressor
against the block until all rings have entered
the cylinder bore.
• Remove J-5239 from the connecting rod
bolts.
Measure
• Connecting rod bearing clearance. Refer to
the proper unit repair manual.
3. Connecting rod cap and bearing.
4.8 LITER L6 6A4-19
Figure 34—Measuring Connecting Rod Side
Clearance
5. Oil pump (if removed), as outlined previously.
6 Oil pan and cylinder head, as outlined previously.
MAIN BEARING
REPLACEMENT
+ + Remove or Disconnect (Figures 35 and 36)
Tool Required:
J-8080 Main Bearing Remover/Installer
1. Spark plugs.
4. Connecting rod cap nuts.
2. Oil pan, as outlined previously.
3. Oil pump, as outlined previously.
$
Tighten
4. Main bearing caps.
Connecting rod cap nuts to 60 N m (44 ft.
lbs.).
m
Measure
Connecting rod side clearance. Use a feeler
gage between the connecting rod and
crankshaft (figure 34). The correct clearance
is 0.006-0.017-inch.
• Check the main bearing caps for location
markings. Mark the caps if necessary. The
caps must be returned to their original
locations during assembly.
5. Lower main bearing inserts from the main
bearing caps.
6. Rear crankshaft oil seal, if necessary, as outlined
previously.
7. Upper rear main bearing insert.
• Use a small brass drift and hammer. Tap on
the insert, on the side opposite the bearing
tang, until the insert rotates out of position
(figure 35).
• Use a pair of pliers with the jaws taped to
prevent damage to the crankshaft. Clamp
the insert to the crankshaft flange (figure
35). Rotate the crankshaft to remove the
bearing insert.
A. Front of Engine
B. Flywheel Side of Engine
C. Piston Depression Flat Side
Figure 33—Pistons Installed
8. Upper main bearing inserts.
B-05256
• Insert J-8080 into the crankshaft oil hole
(figure 36).
• Rotate the crankshaft to “ turn” the bearing
insert out of the block.
6A4-20 4.8 LITER L6
Figure 35—Removing The Upper Rear Main Bearing Insert
Cleaning, Inspection, And Repair
C le a n , in s p e c t, and re p a ir or re p la ce the
components as required. Refer to the proper unit repair
manual. The unit repair manual contains information
on:
• Main bearing cap replacem ent (shim m ing
procedure).
Install or Connect (Figures 25, 35, 36, and 37)
Tool Required:
• Crankshaft.
J-8080-Main Bearing Remover/Installer
• Main and connecting rod bearings.
1. Upper rear main bearing insert.
A.
B.
100.
101.
Figure 36—Removing The Upper Main Bearing
Insert
Forward
Feeler Gage
Rear Main Bearing Cap
Crankshaft
B-07878
Figure 37—Measuring Crankshaft End Play
4.8 LITER L6 6A4-21
• Apply engine oil to an insert of the proper
size.
• Insert the plain end (without the bearing
tang) of the insert between the crankshaft
journal and the notched side of the block.
• Use pliers with taped jaws to clamp the
bearing to the crankshaft as shown in figure
35. Rotate the crankshaft to “ roll” the insert
into the block. Then seat the insert using a
small drift and hammer.
2. Lower rear main bearing insert.
• Apply engine oil to an insert of the proper
size.
• Press the insert into the rear main bearing
cap.
3. Upper main bearing inserts.
• Insert tool J-8080 into a crankshaft main
bearing oil hole (figure 36).
• Apply engine oil to inserts of the proper
size.
• Insert the plain end (without the bearing
tang) of the insert between the crankshaft
and the notched side of the block.
• Rotate the crankshaft to “ roll” the insert into
the block.
• Remove the tool.
4. Lower main bearing inserts to the main bearing
caps.
• Make sure the inserts are of the proper size.
• Apply engine oil to the inserts.
• Install the rear main bearing cap and bolts.
Tighten the bolts temporarily to 14 N m (10
ft. lbs.).
Measure
• Crankshaft end play, as follows:
• Tap the end of the crankshaft first
rearward then forward with a lead
hammer. This will line up the rear main
b e a rin g and c ra n k s h a ft th ru s t
surfaces.
• Tighten the rear main bearing cap
bolts to 90 N m (65 ft. lbs.).
• With the crankshaft forced forward,
measure at the front end of the rear
main bearing with a feeler gage (figure
37). The proper clearance is 0.05-0.15
mm (0.002-0.006-inch).
8. Oil pump, as outlined previously.
9. Oil pan, as outlined previously.
10. Spark plugs.
CRANKSHAFT GEAR
REPLACEMENT
4-+ Remove or Disconnect (Figure 38)
Tool Required:
%
Measure
• Main bearing clearance. Refer to the proper
unit repair manual. If the engine is in the
vehicle, the crankshaft must be supported
upward to remove any clearance from the
upper bearing. The total clerance can then
be measured between the lower bearing
and journal.
5. Main bearing caps (except rear cap) and bolts to
the block. Make sure the special bolt which
retains the oil pump screen bracket is installed in
the proper position. (#5 main bearing cap,
camshaft side hole.)
a
J-24420-A Puller.
1. Timing gear cover, as outlined previously.
2. Crankshaft gear. Use J-24220-A (figure 38).
| - n - | Install or Connect (Figures 2 7 and 38)
Tool Required:
J-5590 Crankshaft Gear Installer.
1. Crankshaft gear. Use J-5590 (figure 38). Make
sure the timing mark faces out.
Im portant
• Align the timing marks (figure 27).
Tighten
• Main bearing cap bolts to 90 N m (65 ft.
lbs.).
6. Rear crankshaft oil seal to the block and main
bearing cap, as outlined previously.
7. Rear main bearing cap to the block.
• Apply a brush-on type oil sealing compound
to the mating surface of the block and cap
(figure 25). Do not allow any sealant on
either crankshaft or rear oil seal.
• Apply engine oil to the bearing insert.
2. Timing gear cover, as outlined previously.
OIL FILTER BYPASS
VALVE REPLACEMENT
4
Remove or Disconnect (Figure 39)
1. Oil filter.
2. Oil filter relief valve. Pry it from the block with a
screwdriver (figure 39).
6A4-22 4.8 LITER L6
Install or Connect (Figure 39)
1. Oil pressure relief valve. Tap into place. Use a
9/ie-inch thin wall deep socket as a driver (figure
39).
2. Oil filter.
3. Engine oil, as necessary.
CRANKSHAFT REPLACEMENT
-► Remove or Disconnect (Figures 30 and 38)
Tools Required:
J-24420-A Puller.
J-5239 Guide Set.
1. Engine, as outlined later.
2. Flywheel (if necessary), as outlined later.
• The crankshaft can be removed from the
block without removing the flywheel. If the
flywheel is removed, the dowel holes must
be reamed oversize and oversized dowel
pins installed, as outlined later.
• Mount the engine in a suitable engine stand.
3. Spark plugs.
4. Dipstick and tube.
B-05249
Figure 38—Replacing The Crankshaft Gear
VALVE REMOVAL
VALVE INSTALLATIO N
B-03497
Figure 39—Replacing The Oil Filter
Bypass Valve
5. Timing gear cover, as outlined previously.
6. Oil pan and oil pump, as outlined previously.
7. C rankshaft tim in g gear (if required). Use
J-24420-A (figure 38).
8. Connecting rod caps. Check the connecting rod
and cap for identification marks. Mark the parts if
necessary. The connecting rod and cap are
mating parts.
9. Connecting rods from the crankshaft.
• Attach J-5239 to the connecting rod bolts
(figure 30).
• Use the long guide rod to push the pistons
up in the bores.
10. Main bearing caps. Check the main bearing caps
fo r lo c a tio n m a rkin g s. M ark the p a rts if
necessary. The main bearing caps must be
returned to their original locations at assembly.
11. Crankshaft.
12. Main bearing inserts.
13. Rear crankshaft seal, as outlined previously.
Cleaning, Inspection, And Repair
• Clean, inspect, and repair or replace the parts as
outlined in the proper unit repair manual. Refer to
the unit repair manual for information on:
— Crankshaft.
— Main and connecting rod bearings.
— P ro ce d u re s fo r m e a su rin g b e a rin g
clearances.
4.8 LITER L6 6A4-23
Install or Connect (Figures 25, 27, 30, 34, 37,
and 38)
Tools Required:
J-5239 Guide Set.
J-5590 Crankshaft Gear Installer.
1. Upper main bearing inserts to the block. Apply
engine oil to the bearing inserts.
2. Crankshaft.
3. Lower main bearing inserts to the main bearing
caps. Apply engine oil to the bearing inserts.
main bearing cap bolts, one pair at a time,
until the tight bearing is located. Burrs on
the bearing cap, foreign matter between the
insert and the block or the bearing cap, or a
faulty insert could cause a lack of clearance
at the bearing.
7. Connecting rods to the crankshaft. Use J-5239 to
pull the connecting rods down (figure 30). Make
sure the connecting rod bearing insert stays in
place.
Measure
Measure
• Main bearing clearance. Refer to the proper
unit repair manual.
Main bearing caps (except rear cap) and bolts to
the block. Make sure the special bolt which
retains the oil pump screen bracket is installed in
the proper position. (#5 main bearing cap,
camshaft side hole.)
• Connecting rod bearing clearance. Refer to
the proper unit repair manual.
8 . Connecting rod caps with bearing inserts to the
connecting rods. Apply engine oil to the inserts.
9. Connecting rod cap nuts.
$
Connecting rod cap nuts to 60 N m (44 ft.
lbs.).
Tighten
• Main bearing cap bolts to 90 N m (65 ft.
lbs.).
5. Rear crankshaft oil seal to the block and main
bearing cap, as outlined previously.
6. Rear main bearing capto the block.
• Apply a brush-on type oil sealing compound
to the mating surface of the block and cap
(figure 25). Do not allow any sealant on
either crankshaft or rear oil seal.
• Install the rear main bearing cap and bolts.
Tighten the bolts temporarily to 14 N m (10
ft. lbs.).
Measure
• Crankshaft end play, as follows:
• Tap the end of the crankshaft first
rearward then forward with, a lead
hammer. This will line up the rear main
b e a rin g and c ra n k s h a ft th ru s t
surfaces.
• Tighten the rear main bearing cap
bolts to 90 N m (65 ft. lbs.).
• With the crankshaft forced forward,
measure at the front end of the rear
main bearing with a feeler gage (figure
37). The proper clearance is 0.05-0.15
mm (0.002-0.006-inch).
I?
Inspect
Crankshaft for binding. Try turning the
crankshaft to check for binding. If the
crankshaft does not turn freely, loosen the
Tighten
Measure
• Connecting rod side clearance. Use a feeler
gage between the connecting rod and
crankshaft (figure 34). The correct clearance
is 0.006-0.017-inch.
10. Crankshaft timing gear (if removed). Use J-5590
(figure 38). Make sure the timing mark faces out.
Im portant
11.
12.
13.
14.
15.
• Align the timing marks (figure 27).
Oil pan and oil pump, as outlined previously.
Timing gear cover, as outlined previously.
Spark plugs.
Flywheel (if used), as outlined later.
Engine, as outlined previously.
FLYWHEEL REPLACEMENT
Remove or Disconnect (Figure 40)
1. Transmission, clutch housing, and clutch.
2. R ear m ain b e a rin g cap. R efer to “ R ear
Crankshaft Oil Seal Replacement” in this section.
• Mark the flywheel and crankshaft so the dowel
pin holes can be aligned in their original positions
at assembly (figure 40).
• Loosen the flywheel bolts a few turns.
3. Flywheel dowel pins.
• Turn the crankshaft so that a dowel pin is at
the 6 o’clock position.
• Drive the dowel pin out, using a hammer
and drift.
6A4-24 4.8 LITER L6
NOTICE: Never heat starter gear to red heat as
this will change metal structure.
2. Uniformly heat the flywheel gear to temperature
which will expand the gear to permit installation.
Temperature must not exceed 204°C (400°F).
3. As soon as the gear has been heated, install on
the flywheel.
Install or Connect (Figure 40)
1. Flywheel to the crankshaft. Align the marks made
at disassembly. Make sure the dowel holes in the
crankshaft and flywheel are aligned.
2. Flywheel.
Tighten
• Bolts to 150 N-m (110 ft. lbs.).
3. Dowel pins.
• The interference fit dowel pins must be
replaced with an oversized dowel pin when
installing the flywheel.
• Ream the dowel pin holes to the proper size
(0.4510-0.4517-inch).
Figure 40—Flywheel Dowel Pin Hole Locations
• Repeat the preceding steps to drive out the
remaining dowel pins. The crankshaft must
be turned each time so that the pin can be
driven out without contacting the block.
• Tap the dowl pins into place, flush with the
flywheel retaining bolt surface.
4. Rear m ain b e a rin g cap. Refer to “ Rear
Crankshaft Oil Seal Replacement” in this section.
5. Transmission, clutch housing, and clutch.
ENGINE MOUNTINGS
4. Flywheel bolts.
5. Flywheel.
a y Clean
NOTICE: Broken or deteriorated mountings
can cause m isalig n ed and e ven tu al
destruction of certain drive train components.
When a single mounting breakage occurs, the
rem aining m ountings are su b jec te d to
abnormally high stresses.
Mating surfaces of crankshaft and flywheel.
Remove any burrs.
INSPECTING ENGINE MOUNTINGS
Inspect
— Flywheel for burning, scoring, warping, and wear.
Replace the flywheel if necessary. Do not
machine the flywheel.
— Flywheel ring gear for worn or broken teeth.
Flywheel Ring Gear Replacement
1. Use a torch to heat the gear around the entire
circum ference, then drive the gear off the
flywheel, using care not to damage the flywheel.
Front Engine M ountings
1. Raise the engine to remove weight from the
mountings and to place a slight tension on the
rubber cushion. Observe both mountings while
raising the engine.
2. Replace the mounting if the following conditions
exist:
— Hard rubber surface covered with heat
check cracks.
— Rubber cushion separated from the metal
plate of the mounting.
— Rubber cushion split through the center.
4.8 LITER L6 6A4-25
3. If there is movement between a metal plate of the
mounting and its attaching points, lower the
engine and tighten the bolts or nuts attaching the
mounting to the engine, frame, or bracket.
Rear M ountings
1. Push up and pull down on the transmission
tailshaft. Observe the transmission mounting.
2. Replace the mounting if the following conditions
exist:
— Rubber cushion separated from the metal
plate of the mounting.
— Mounting bottomed out (tailshaft can be
moved up but not down).
3. If there is relative movement between a metal
plate of the mounting and its attaching point,
tighten the bolts or nuts attaching the mounting to
the transmission or crossmember.
FRONT MOUNTING REPLACEMENT
|<-+| Remove or Disconnect (Figures 41 through 44)
• Support the engine with a suitable lifting fixture.
Do not load the engine mounting.
1. Engine mounting through-bolt and nut.
• Raise the engine only enough to permit removal
of the engine mounting.
2. Mounting assembly bolts, nuts, and washers.
Figure 41—Front Engine Mounting Brackets
All Models
REAR MOUNTING REPLACEMENT (EXCEPT
P-MODELS WITH FLYWHEEL
HOUSING MOUNTING)
3. Mounting assembly.
Remove or Disconnect (Figures 45, 46, and
47)
Install or Connect (Figures 41 through 44)
NOTICE: See “Notice” on page 6A4-1 of this
section for steps 2 and 3.
1. Mounting assembly.
2. Mounting assembly bolts, nuts, and washers.
$
Tighten
• Fasteners to specifications. Refer to figures
41 through 44.
3. Engine mount through-bolt and nut. Lower the
engine until the bolt can be inserted. Install the
nut.
Tighten
• Through-bolt or nut to specifications. Refer
to figure 41.
• Support the rear of the engine to relieve the
weight on the rear mountings.
1. Mounting to crossmember nut(s) and washer(s).
2. Mounting to transmission bolts and washers.
• Raise the rear of the engine only enough to
permit removal of the mounting.
3. Mounting.
□* ± l
Install or Connect (Figures 45, 46, and 47)
1. Mounting.
• Lower the rear of the engine.
2. Mounting to transmission bolts and washers.
NOTICE: See “Notice” on page 6A4-1 of this
section.
3. Mounting to crossmember nut(s) and washer(s).
6A4-26 4.8 LITER L6
A. 40 N-m (30 Ft. Lbs.)
B. Torque Bolt To 48 N-m (36 Ft. Lbs.) Or,
Torque Nut To 40 N-m (30 Ft. Lbs.).
B-07882
Figure 42—Front Engine M ountings (C Models)
Tighten
• Fasteners to specifications. Refer to figures
45, 46, and 47.
REAR MOUNTING REPLACEMENT (P-MODELS
WITH FLYWHEEL HOUSING MOUNTING
4-+ Remove or Disconnect (Figure 48)
1. Bolt, cushion and spacer.
• Raise the rear of the engine only enough to
permit removal of the mounting.
2. Mounting.
A. 40 N-m (30 Ft. Lbs.)
B. Forward
B-07887
Figure 43—Front Engine Mountings (K Models)
-►4- Install or Connect (Figure 48)
1. Mounting. Align the hole in the mounting with the
hole in the crossmember.
• Lower the rear of the engine.
4.8 LITER L6 6A4-27
MODELS WITH I-BEAM AXLE (RPO-FS3)
MODELS WITHOUT I-BEAM AXLE
A.
B.
150.
152.
40 N m
Forward
Mounting Assembly
Frame Bracket
B-07894
B. 48 N m (36 Ft. Lbs.)
C. Forward
f in
---------
B
B-07897
Figure 44—Front Engine Mountings (P Models)
Figure 46—Rear Engine Mounting (K Models)
6A4-28 4.8 LITER L6
MODELS WITH PROPSHAFT PARKING BRAKE
A.
B.
C.
D.
Forward
68 N m (50 ft. lbs.
48 N m (36 ft. lbs.
60 N m (44 ft. lbs.
MODELS WITHOUT PROPSHAFT PARKING BRAKE
B-07901
Figure 47—Rear Engine Mounting (P Models With Transmission Tail Type Mounting)
4.8 LITER L6 6A4-29
17. Strut rods at engine mountings (4 wheel drive
models).
• S upport the tra n sm issio n with a chain or
transmission jac.
18. Bell housing to engine bolts.
19. Engine. Move the engine forward to disengage
the transmission and remove.
Install or Connect (Figure 41)
I*
1. Engine. Move the engine rearward to engage the
transmission.
2 . Bell housing to engine bolts. Remove the
transmission jack or support chain.
3. Front engine mounting through-bolts and nuts.
Tighten
Figure 48—Rear Engine Mounting (P Models
With Flywheel Mousing Type Mounting)
NOTICE: See “ Notice ” on page 644-7 of this
section.
2. Spacer, cushion and bolt.
$
Tighten
• Bolt to 90 N m (65 ft. lbs.).
ENGINE REPLACEMENT
The procedure outlined applies specifically to “ C”
and “ K” models. Additional steps may be necessary
on “ P” models depending on body design.
Remove or Disconnect
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
•
16.
Battery negative cable.
Hood.
Air cleaner.
Radiator.
Heater hoses from the engine.
Accelerator cable.
Transmission detent cable (if used).
Fan and water pump pulley.
Fuel lines from the fuel pump.
Evaporate emission and other vacuum hoses.
Engine wiring.
Starter.
Exhaust pipe at the exhaust manifold. Wire the
pipe out of the way.
Flywheel cover.
Flywheel to torque converter bolts (automatic
transmission).
Attach a suitable lifting device to the engine.
Remove the weight from the engine mountings.
Front engine mounting through-bolts.
4.
5.
6.
7.
8.
9.
10.
11.
12 .
13.
14.
15.
16.
17.
18.
19.
20 .
• Fasteners to specifications. Refer to figure
41.
Remove the lifting device.
Strut rods (4 wheel drive models).
Torque converter to flywheel bolts (automatic
transmission).
Flywheel cover.
Exhaust pipe and new packing to the exhaust
manifold.
Starter.
Engine wiring.
Vacuum hoses.
Fuel lines.
Fan and water pump pulley.
Transmission detent cable (if used).
Accelerator cable.
Heater hoses.
Radiator.
Air cleaner.
Hood.
Battery negative cable.
Proper quantity and grade of coolant.
6A4-30 4.8 LITER L6
SPECIFICATIONS
ENGINE SPECIFICATIONS
All Specifications are in INCHES unless otherwise noted.
GENERAL DATA:
Type
Displacement
No. Of Cylinders
Bore
Stroke
Compression Ratio
Firing Order
Oil Pressure
CYLINDER BORE:
Diameter
Production
Out Of
Round
Service
Taper
Production
In Line
4.8L (292 Cu. In.)
6
3.876
4.12
8.0:1
1-5-3-6 -2-4
16 psi @ 700 RPM; 30-45 psi @ 1500 RPM
3.8750-3.8780
0.0005 (Maximum)
0.002 (Maximum)
0.0005 (Maximum)
0.0005 (Maximum)
0.001 (Maximum)
Thrust Side
Relief Side
Service
PISTON:
Production
Service Limit
PISTON RING:
C
o
Production
Groove
M
p
niparanrp
R
Service Limit
ct
S
Production
s
Gap
1
0
Service Limit
N
Production
Groove
0
Service Limit
Clearance
1
Production
L
Service Limit
PISTON PIN:
Diameter
Production
Clearance
In Piston
Service Limit
Fit In Rod
0.0026-0.0036
0.0045 (Maximum)
Clearance
Top
0.0020-0.0040
2nd
Hi Limit Production ±0.001
Top
0.010-0.020
2nd
0.010-0.020
Hi Limit Production + 0.010
0.005-0.0055
Hi Limit Production + 0.001
0.015-0.055
Hi Production +0.010
0.9270-0.09273
0.00015-0.00025
0.001 (Maximum)
0.0008-0.0016 Interference
B-07896
4.8 LITER L6 6A4-31
SPECIFICATIONS
ENGINE SPECIFICATIONS (CONT.)
All specifications are in INCHES unless otherwise noted.
CRANKSHAFT:
All
2.2979-2.2994
0.0002 (Maximum)
0.001 (Maximum)
0.0002 (Maximum)
0.001 (Maximum)
#1-#6: 0.0010-0.0024
#7: 0.0016-0.0035
#1-#6: 0.0010-0.0025
#7: 0.0015-0.0035
0.002-0.006
2.099-2.100
0.0005 (Maximum)
0.001 (Maximum)
0.0005 (Maximum)
0.001 (Maximum)
0.0010-0.0026
0.0030 (Maximum)
0.006-0.017
Diameter
Main
Journal
Production
Service Limit
Production
Service Limit
Taper
Out of
Round
Production
Main
Bearing
Clearance
Service Limit
Crankshaft End Play
Crankpin
Diameter
Production
Service Limit
Production
Service Limit
Production
Service Limit
Taper
Out
Round
Rod Bearing
Clearance
Rod Side Clearance
CAMSHAFT:
Lobe
Lift ± 0.002
Journal Diameter
Camshaft Runout
Camshaft End Play
VALVE SYSTEM:
Lifter
Rocker Arm Ratio
Hydraulic
1.75:1
Intake
Exhaust
Valve Lash
Valve
Spring
(Outer)
Valve
Spring
Damper
Production
Service
Free Length
Pressure
lbs. @ in.
Intake
Exhaust
Intake
Exhaust
Intake
Exhaust
Closed
Open
Installed Height
+ 1/ 3 2 "
Free Length
Approx. # of Coils
O O
CO CO
Seat Width
One Turn Down From Zero Lash
I- - -
Face Angle (Intake & Exhaust)
Seat Angle (Intake & Exhaust)
Seat Runout (Intake & Exhaust)
Stem
Clearance
0.2315
0.2315
1.8677-1.8697
0.020 (Maximum)
0.003-0.008
Intake
Exhaust
0.002 (Maximum)
0.035-0.060
0.062-0.093
0.0010-0.0027
0.0015-0.0032
High Limit Production +0.001
High Limit Production +0.002
2.08
78-86 lbs. @ 1.66"
170-180 lbs. @ 1.26"
1 21/3 2
1.94
4
B-07898
6A4-32 4.8 LITER L6
SPECIFICATIONS (CONT.)
TORQUE SPECIFICATIONS
Item
Nm
Ft. Lbs.
In. Lbs.
Flywheel Bolts
150
110
—
Main Bearing Cap Bolts
90
65
—
Camshaft Thrust Plate Screws
9.0
—
80
Timing Gear Cover Bolts To Block
9.0
—
80
Torsional Damper Bolt
70
50
—
Connecting Rod Cap Nuts
60
44
—
Oil Pump Bolts
13.0
—
115
Oil Pump Pickup Tube Bracket Nut (To Main Bearing Cap Bolt)
34
26
—
Oil Pump Cover Bolts
7.9
—
70
Oil Pan Bolts (To Front Cover)
(To Block [1/4-20])
(To Block [5/i 6-18])
5.1
9.0
18.6
—
—
45
80
165
Cylinder Head Bolts (Left-Hand Front Bolt)
(All Others)
115
130
85
95
—
Rocker Arm Cover Bolts (Cork Gasket)
(Rubber Gasket)
5.4
4.3
—
—
58
38
Pushrod Cover Bolts
9.0
—
80
Water Pump Bolts
20
15
—
Thermostat Housing To Block Bolts
38
28
—
Water Outlet to Thermostat Housing Bolts
28
20
—
Intake Manifold To Exhaust Manifold Bolts And Nuts
60
44
—
Manifold To Cylinder Head Bolts And Nuts
52
38
—
Spark Plug
20
15
—
—
—
4.8 LITER L6 6A4-33
SPECIAL TOOLS
J-23590
J-5892
J-23738-A
J-3049
J-9290-01
J-5802-