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40-60 SERIES TRUCK

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SUPPLEMENT
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SERVICE MANUAL
 SECTION INDEX
1972 SECTION NAME

CHASSIS SERVICE MANUAL

0 LUBRICATION

SUPPLEMENT 3 FRONT SUSPENSION

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c o v e r in g 4 REAR SUSPENSION

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SERIES 40-60 5 BRAKES
CHEVROLET TRUCKS
6A

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GASOLINE ENGINES

6D

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ENGINE MOUNTINGS
FO R EW O R D
b ra 6K ENGINE COOLING
SYSTEM
This manual is a supplement to the 1971 Series 40-60
Truck Service Manual. It includes procedures for main­ 6M ENGINE FUEL SYSTEM
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tenance and adjustments, minor service operations, and
removal and installation for components of Chevrolet Series AIR COMPRESSOR
40 through 60 Trucks. Procedures involving disassembly 6T
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and assembly of major components for these vehicles are AND GOVERNOR
contained in the 1972 Chevrolet Passenger Car and Series
10-30 Truck Overhaul Manual or the 1972 Series 40-60
Truck Overhaul Manual Supplement.
This manual should be kept in a handy place for ready
6Y ENGINE ELECTRICAL
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reference. If properly used, it will enable the technician to

TRANSMISSIONS
better serve the owners of Chevrolet built vehicles.
All information, illustrations and specifications con­ 7 AND CLUTCHES
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tained in this literature are based on the latest product

information available at the time of publication approval.
The right is reserved to make changes at any time without
notice.
9 STEERING SYSTEM
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10 WHEELS &TIRES
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11 SHEET METAL

CHASSIS ELECTRICAL
12 AND INSTRUMENTS
CHEVROLET MOTOR DIVISION
General Motors Corporation
DETROIT, M ICHIGAN ALPHABETICAL INDEX
© 1 9 7 2 General M otors C o rp o ra tio n P r i n t e d in U . S . A .
 Sec. 0
Page 1

SECTION 0
Jluhnicatio-n
A ll inform ation contained in S erv ice Manual S T -331-71 under
LUBRICATION (SEC. 0, Page 1 through 12) w ill apply to v e h ic le s cov­
e red by th is publication. The follow ing inform ation w ill a lso apply:

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TRANSMISSION CAPACITY CHART ENGINE OIL FILTER
O il filte r should be replaced at the fir s t oil
Manual T ran sm issio n U.S. IMP. change and each oil change th ereafter to filte r

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SM465 8 6% sm a ll p a rtic les which could affect valve lifte r s or
NP435 7 5% PCV valve action.
NP540 9 U
NP542 10 8% RECOMMENDATIONS

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CL282 12 10 The oil industry m arkets various types of en­
CL285 12 10 gine o il under certain se r v ic e designations and
CL325 14 11% sp ecifica tio n num bers.
CL327 14 11% The se le c tio n of a relia b le supplier, with c lo se

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SP5652 13 10% attention to h is oil and filte r elem ent change r e c ­
SP5752
SP5756

Autom atic T ra n sm issio n

MT40
15
15
b ra
m
12%

15
om m endations can provide sa tisfa cto ry lubrication
and longer life for engine.

G asoline and D ie se l Engines

18* U se only high quality o ils which are intended
MT41 18* 15 for S erv ice D esignations "MS” and "DM” (SE/CC
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AT475 10* 8l4 New A .P .I. D esignation) s e e NOTE.
AT540 22* 18% The follow ing additive lim itation s, w hich r e ­
quire em phasis, have been p laced on the r e c o m ­
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* F ilte r Change Only. mended M IL-L-2104B (now su p ersed ed by M IL -L -

46152) and Supplement 1 oils:
A uxiliary T ra n sm issio n 1. Sufficient zinc dithiophosphate to produce
SP6041 8 6% a m inim um of 0.07 and a m aximum of 0.10 per
SP7041 11 9% cent by w eight.
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2. Sulfated ash (ASTM D -874) of 1.00 p er cent

ENGINE OIL m axim um by w eight, except lubricants that contain
(SYMBOL “ E” ON CHARTS) only barium d eterg en t-d isp ersa n ts w here 1.50 per
ss

cent by weight is allow ed.

NOTE: Supplement 1 engine o ils (based upon
ENGINE OIL now ob soleted M IL-L-2104A) have been su p ersed ed
It is recom m ended that new engines should by M IL -L -2104B engine o ils . H owever, Supplement
a

have the fir s t o il change at 3,000 m ile s, thereafter 1 engine o ils MS-DM (SE/CC New A .P .I. D e s ig ­
at 3 months or 4,000 m ile in terv a ls. T his drain nation), with a history of sa tisfa cto ry perform ance
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in terval may be in crea sed or d ecrea sed depending
upon the se v e r ity of se r v ic e and exp erien ce with
sp e c ific o ils or the recom m endations and used oil
* a n a ly sis a s furnished by the su pp lier. Such a p ro ­
cedure would be helpful in estab lishing the m ost
p ra ctica l o il change period for the p articular
s e r v ic e . R efer to S erv ice Manual S T -3 3 1 -7 1 .
Contaminated engine o il can cau se a m alfunc­
tion of valve lifte r s or the PCV valv e. A sticking
v alve lifte r can cause leakage of unburned g a se s
through the valve. A plugged or stickin g PCV valve
w ill affect carburetor m ixture and w ill prevent
p roper crank case ventilation.
a r e availab le, and may be u sed .
The u se of proper engine o ils and o il change
in terv a ls are your b est assu ra n ce of continued r e ­
liab ility and perform ance from your engine.
IMPORTANT: N on-detergent and other low er
quality engine o ils are sp e c ific a lly not r e c o m ­
mended.
POWER STEERING FLUID
(SYMBOL "S32” )
GM Approved H ydraulic P ow er Steering Fluid
is available through w h olesale w arehouses and truck
Sec. 0
Page 2

LUBRICATION

c e n te r s. Check fluid le v e l every 6,000 m ile s or 4 ENGINE A N D ACCESSO RY

m onths, w hichever o ccu rs fir s t. F ill pump r e s e r ­ LUBRICATION
voir to proper le v e l. If GM Pow er Steerin g Fluid is
not available, DEXRON® Autom atic T ra n sm ission The follow ing additional inform ation applies to
F luid (Symbol S I 9) may be used. Lubrication Chart (fig. 4) on page 7 of S T -331-71
S er v ic e Manual.
CAUTIO N: DO NOT use G M Power
Steering Fluid in automatic transm issions.
CARBURETOR AIR CLEANER
ELEMENT
AU TO M ATIC TRANSM ISSIO N FLUID

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A ir clean er should be inspected and se r v ic e d
(SYMBOL “SI 9 ” O N CHARTS) at in tervals sp ecified in E m issio n Control System
(R efer to S erv ice Manual S T -3 3 1 -7 1 ) booklet, or m ore often under s e v e r e dust conditions,

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O il le v e l in the autom atic tr a n sm issio n m ust a lso , whenever dirt is v isib le in elem ent or o il.
be checked at each engine o il change. Under norm al
driving conditions the tr a n sm issio n fluid should be
changed every 24,000 m ile s. Under unusual condi­ POWER STEERING RESERVOIR
tion s such as o ff-road (construction) or constant

.
stop and go driving (pickup and delivery) fluid Fluid le v e l should be checked every 6,000

ry
should be changed at 1 2 ,0 0 0 -m ile in te r v a ls. It is m ile s and filled with S32 P ow er Steering Fluid, or
im portant that tr a n sm issio n fluid le v e l be m ain­ if not available with S19 Autom atic T ra n sm ission
tained at the full m ark and NOT OVERFILLED. Fluid.

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 Sec. 3
P age 3

SECTION 3
S u d s K t& n d A X U l

SECTION 3A
fy n x w U A U < f* u n e + tt

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A ll inform ation and alignm ent in stru ction s in S erv ice Manual
S T -331-71 "FRONT END ALIGNMENT” (SEC. 3A) are applicable

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to m odels co v ered by th is supplem ent.

SECTION 3B

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A xle.
A ll front axle inform ation in S erv ice Manual S T -331-71 "FRONT

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AXLE” (SEC. 3B) is applicable to m odels covered by this supplem ent.

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A ll front axle inform ation for the F -120 axle is a lso applicable to the
F -110 ax le. Illu stra tion s and sp e cific a tio n s have been updated.
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1 Steering Knuckle 9 Axle Center 1 Steering Knuckle 9 Lube Fitting

Spindle 10 Stop Bolt and Lock Spindle 10 W ashers or Shim s
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2 Kingpin Bushing Nut 2 Steering Knuckle 11 A xle C enter

(Upper) 11 Draw Key Bushing 12 Stop B olt and Lock
3 Kingpin 12 Thrust Bearing 3 Kingpin Bushing Nut
4 Cap Screw 13 Tie Rod End A ssy.
(Upper) 13 Thrust B earing
5 Kingpin Bearing Cap 14 Kingpin Bearing Cap
(Lower) 4 Kingpin 14 T ie Rod A ssem b ly
(Upper)
6 Gasket 15 Gasket 5 Dust Cap 15 Plug R etainer
7 Lube Fitting 16 Kingpin Bushing 6 Kingpin Nut 16 Ejqpansion Plug
8 Shim (Lower) t-8793 7 C otter Pin 17 Kingpin B ushing
8 Gasket (Lower) t-8794

Fig u re 1—Steering K n uckle (F070 A x le ) Figure 2 —Steering K n uckle (F090 A x le )

S ec . 3
P ag e 4___________
T ro nt axle

1 Steering Knuckle 9 Gasket

Spindle 10 L u b e Fitting
2 Steering Knuckle 11 Spacers or Shims
Bushing 12 Axle Center
3 Kingpin Bushing 13 Stop Bolt & Lock Nut
(Upper) 14 Thrust Bearing
4 Kingpin 15 Tie Rod End A ssy.

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5 Cap Screw 16 Plug Retainer
6 Dust Cap 17 Expansion Plug
7 Kingpin Nut 18 Kingpin Bushing
8 Cotter Pin (Lower)

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T-8795

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Figure 3 — Steering Knuckle (FI 10 an d F I 20 Axles)

AXLE SPECIFICATIONS

AXLE MODEL

KING PIN
Length .................
F050-F055
b
6.3594”
ra F070

7.8906”
F090

8.750”
F110—FI 20

8.750”
Diameter
1.1090”— 1.1094” 1.2492”— 1.2496” 1.1855”— 1.1865” 1.1855”— 1.1865”
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At Top ...............
At Bottom ........... 1.1090”— 1.1094” 1.2492”— 1.2496” 1.14330”— 1.14340” 1.4330”— 1.4340”

KING PIN BUSHING

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Length ................. — — 1.9063” 1.9063”

Diameter
Outer . ............... — — 1.4330”— 1.4340” 1.4330”— 1.4340”
In n e r................. — — 1.1870”— 1.1880” 1.1870”— 1.1880”
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STEERING KNUCKLE BUSHING*

Length .................
Upper ................ 1.3438” 1.875” 1.709”— 1.729” 1.760”
s

Lower ................ 1.3438” 1.875” 1.990”— 2.010” 2.150”

I.D. When Installed .... 1.1094”— 1.1124” 1.2496”— 1.2526” *1.4365”— 1.4375” 1.434”— 1.437”
as

STEERING KNUCKLE TO AXLE

CENTER CLEARANCE 0.005” 0.005” .004”— .012” .004”— .012”

.114”— .116” White .114”— .116” White

SPACING WASHERS AVAILABLE — — .121”— .123” Yellow .121”— .123” Yellow
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.128”— .130” Blue .128”— .130” Blue

SPACING SHIMS AVAILABLE.. 0.005” 0.005” 0.005” _

0.010”

TORQUE SPECIFICATIONS
King Pin Nut ........... _ _ 250 Ft. Lbs. then 250 Ft. Lbs. then
Advance to Next Advance to Next
Cotter Pin Hole. Cotter Pin Hole.
King Pin Bearing Cap, Cap
Screw . ............... 4 - 5 Ft. Lbs. 5 - 6 Ft. Lbs. 3 - 5 Ft. Lbs. 3 - 5 Ft. Lbs.

* Ream after Installation

 SECTION 3C
fy n & n t S fJ S U w a A .

A ll inform ation on Front Springs contained in S erv ice Manual

S T -3 3 1 -7 1 “ FRONT SPRINGS" (SEC. 3C) is applicable to m odels
co v ered by this supplem ent. The follow ing “ Torque S p ecification s”
chart has been updated.

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TORQUE SPECIFICATIONS

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C -M -S T
M odels Models
(F t.-L b s.) (F t.-L b s.)
Spring U -B olt ( N u t ) ................................................. . . 105 - 130 190 - 210

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Spring U -B olt ( N u t ) ................................................. . . *175 - 250 -
Spring Hanger to F ram e B olt (N u t ) .................. 60-85 35 - 45

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Spring Bumper to Fram e Bolt (Nut) ............... 14-22 35 - 45
Spring Bum per to Fram e Bolt (Nut)
ra ...............
Spring Front Eye B olt ( N u t ) .............................. . .
b
Spring R ear Rebound Pin R etainer (Bolt) . . .
** 2 -3
190 - 210
-
150 - 200
20 - 25
Spring R ear Rebound Bolt ( N u t ) ........................ 75-95 -
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Shock A bsorber B racket to Fram e B olt (Nut) . . 40-50 65 - 95
Shock A bsorber Upper and Lower Eye B olt (Nut) 65 - 95 40 - 50
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Shock A bsorber Stud to Fram e ( N u t ) ................ 130 - 190 -

* 9,000 and 11,000 lb. A xles Only.

** 366 and 427 V8 Gas E ngines.
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SECTION 3D
c J lu b i a n d QeasUnGA.
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A ll inform ation in Service Manual S T -331-71 “ FRONT HUBS AND

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BEARINGS” (SEC. 3D) is applicable to m od els covered by this supple­

m ent. The follow ing rev isio n w ill a lso apply:

CLEANING, INSPECTION, AND REPAIR

REPAIR
Brake Drum R eplacem ent
1. Demountable Type. The demountable type drum may be se p a r ­
ated from the hub and rem oved from the veh icle without disturbing the
hub. The drum is held to the hub by the w heel studs and nuts as shown
in figure 4.
Sec. 3
P a ge 6
FRONT HUBS A N D BEARING S

1 Side Ring
2 Lock Ring
3 Wheel

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4 W heel Stud Nut
5 W heel Stud
6 B rake Drum
7 Hub

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8 Cap Screw & W asher
9 B earing Cone and
R oller A ssy . (Outer)
10 B earing R etainer

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11 Adjusting Nut W asher

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12 Adjusting Nut
13 Hub Cap
14 Cotter Pin
15 Backing P late

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17

18
Inner O il Seal
B earing Cone and
R o ller A ssy . (Inner)
Spindle
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T-91 15
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Figure 4 — Front H u b and Bearing with D em ountable W heel an d Drum

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 S ec. 4
P ag e 7

SECTION 4
( le a / i S u A s n e t t & io s t

A ll inform ation contained in S erv ice Manual S T -331-71 is ap­

p lica b le to m odels covered in th is supplem ent. The follow ing inform a­
tion w ill a lso apply:

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SECTION 4A
(lean. AxleA. a n d G ottisioh

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IMPORTANT

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When parking v eh icle equipped with a tw o- or th re e-sp e ed axle, the
axle should be shifted into LOW range with engine running. Engage
clutch and tra n sm issio n to be su re axle has com pleted sh ift into LOW

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range. Apply parking brake, p lace tra n sm issio n in neutral and shut off

stru ctio n s m ust be followed:

VACUUM SHIFT SYSTEM

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engine. When leaving the veh icle parked or unattended the p reviou s in ­

MAINTENANCE
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AIR CLEANER
A ir clea n er rem o v es dirt p a r tic le s from at­
m osphere which p a s s e s into the control valve and
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other u n its. A ir clean er should be rem oved and

cleaned at regular in terv a ls.

SERVICING AIR CLEANERS

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(R efer to F igu re 1)
The a ir clea n er u sed on Conventional and S50
M odels is the m etal cup type which u se s a hog's
ss

hair type elem en t. T his cup is a friction fit on the

a ir intake pipe and can be rem oved by pulling
HAIR TYPE ELEMENT
straight off. It can be cleaned by rinsing in a su it­
able solvent and reu sed . R efer to LUBRICATION
SYNTHETIC ELEMENT
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(SEC. 0) in th is supplem ent for se r v ic e in terv a ls. PLASTIC H O U S IN G

If clean er has becom e so laden with an accum ula­
tion of dirt, that sa tisfa cto ry cleaning cannot be
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done, rep lace with a new clean er.

The air clea n er used on a ll T ilt-C ab Models
is a p la stic en cased, synthetic elem ent type filte r ,
and cleaning is NOT recom m ended. When cleaner
b eco m es so laden with dirt, that tapping it against
so m e so lid su rfa ce (such as a work bench) w ill
not rem ove foreign m atter, then a new cleaner T-9142
should be in sta lled .
IMPORTANT: DO NOT OPERATE VEHICLE
WITH AIR CLEANER DISCONNECTED OR RE­
MOVED. F ig u re 1—A ir C lea n ers

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Sec. 4
P a ge 8

SECTION 4B
(lea l BpAitUfi an d Suifiesutiott
HEN DRICKSO N T AN D EM REAR SUSPENSION
R efer to S erv ice Manual S T -331-71 "REAR SPRINGS AND SUS­
PENSION” (SEC. 4B), p ages 4B -7 and 4B -8 for fig u r es 9, 11 and 12.

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EQ U ALIZIN G BEA M REM O VA L EQUALIZING BEAM BUSHING
A N D REPAIR REPLACEMENT
P r e s s old bushing out, using a suitable driver

The follow ing p roced u res cover rem oval and
installation of eith er equalizing beam without r e ­
moving any other units of the su spension sy stem .
When rem oving an axle a ssem b ly , accom p lish only
ste p s required to lo o sen axle at each end of beam .
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or p r e s s to exert fo rce on bushing outer sle e v e .
P r e s s new bushing into p la ce, exerting fo rce on
bushing outer s le e v e until outer sle e v e extends an
equal distance through beam at both sid e s.

.
EQUALIZING BEAM INSTALLATION

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EQUALIZING BEAM REMOVAL (F ig. 9) (R efer to Fig. 9)
1. R a ise and support fram e to rem ove weight 1. P osition beam s, with c r o ss tube and thrust
from beam s. w ash ers in p lace at spring sad d les and axle brackets.
2. At axle b rack ets, rem ove nuts (5), w ash ers
(7), and bolt (1). P ry adapters (2) from bushings
and b rack ets.
3. With blocking under beam c r o s s tube (fig.
ra NOTE: At axle end of beam , in sta ll adapters
(2, fig. 9) at each sid e of bracket and into bushing.
IMPORTANT; The cu t-off (flat) sid e of each
adapter must be located in a vertica l position as
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1) to support weight of beam s, rem ove saddle caps
shown in figure 11.
attached with four nuts and flat w a sh ers.
4. Low er the c r o s s tube and b eam s, then slid e 2. Install bolt and w asher through adapter and
beam s from tube ends. axle bracket at each end of equalizing beam (fig. 11).
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NOTE: Install bolt and w asher from inner sid e

EQUALIZING BEAM INSPECTION with nut located toward w h eels (fig. 11). Tighten
1. Inspect beam end bushings and beam center nuts or bolts to torque liste d in "Specifications" at
bushing for evidence of damage or deterioration of end of this sectio n . Figure 12 shows section through
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the rubber. If any damage is evident, rep lace bush­ mounting.

in gs as d irected under "Equalizing B eam Bushing 3. Install spring saddle caps to attach beam
Replacem ent" la ter in this sectio n . cen ter bushing to spring saddle. Install saddle cap
2. Inspect c r o s s tube and thrust w ash ers and stud nuts or cap sc r e w s and tighten to torque liste d
si

rep la ce if bent or worn. in "Specifications" at end of this section .

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1 Beam Center Bushing 7 Setscrew

2 Spring Saddle 8 Equalizing Beam
3 Spring A ssem bly 9 C ross Tube
4 Spring Saddle Top Pad 10 Spring Saddle Cap
5 Top Pad to Spring 11 Stud
Saddle B olts 12 Thrust Washer
6 Lock Nut 13 Bushing

Figure 1— Section Through Spring Saddle an d Beam

 Sec. 5
P age 9

SECTION 5
lin & k e A ,
A ll inform ation in this sectio n in S erv ice Manual S T -331-71 a lso
applies to v e h ic le s covered by this supplem ent, except as sp e c ific a lly
stated in the follow ing procedures:

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■
SECTION 5A

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< M -t^ d n < u c U c B 'la h e i.

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BRAKE SYSTEM MAINTENANCE sch ool buses (d u al-sp lit-b rak e system ) and optional
on a ll other v eh icles equipped with dual (split)
CHECKING FLUID LEVEL brake sy ste m s. T hese gauges are mounted on a

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A stic k e r (fig. 1) reading "CHECK BRAKE sp e c ia l bracket below the center of the dash panel.
FLUID LEVEL EVERY 30 DAYS OR 3000 MILES”
is affixed to the cover of each brake m aster c y l­

stic k e r applied.
b ra
ind er. F igure 2 illu str a te s a typical cover with the

Fluid le v e l should be maintained to within V2"

One gauge is connected to one vacuum sy ste m
of the dual brake sy stem and the other gauge is
connected to the other vacuum sy ste m . Vacuum
gauge readings may differ during operation of the
v e h ic le . However, if the readings differ by ten
of top of m aster cylinder r e se r v o ir . in ch es of m ercury or m ore for an extended p eriod
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of v eh icle operation the vacuum sy ste m s should be
checked im m ediately to determ ine c a u se s. If the
VACUUM GAUGE vacuum gauge is su sp ected of being faulty, check
gauge according to instructions in S erv ice Manual
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Two vacuum gauges are used oft som e v e ­ S T -3 3 1 -7 1 , page 5A -22. O therw ise, check vacuum
h ic le s . Two gauges are standard equipment on all sy stem com ponents for leak s or m alfunctions.
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Figure 1—B ra k e Fluid Sticker Figure 2—M aster C y lin d e r C o v e r

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Se c . 5
P a ge 10

SECTION 5B
A i/ i B 'la k e i

BREATHER A N D FILTER AIR LINE TORQUE

ASSEMBLIES
R efer to page 5B -53 of S erv ice Manual ST-
F igu res 1 and 2 illu stra te three different 331-71 and change the follow ing torque values:

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breather and filte r a sse m b lie s. F igure 1 (left view)
3 /8 -in c h from 30-50 to 50-75
show s the origin al type b reather. R eplacem ent is
}£-inch from 90-115 to 120-150
co vered in S erv ice Manual S T -331-71, page 5D -89.
5 /8 -in c h from 100-125 to 150-200

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To rem ove the interm ediate type filte r (fig. 1,
right view ) or the la te st type (fig. 2), rem ove two A lso change the statem ent "retorque to higher
s c r e w s and lift co v er and filte r off housing. To than minimum value" to read: "Retorque to higher
in sta ll, se t filte r in p la ce on housing and attach value."
cov er. F ilte r s can be cleaned and reu sed but

.
breath er cannot. If rem oved, breath er m ust be

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rep laced with new p a rts.

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Figure 2— Filter Installed

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 Sec. 6A
P age 11

SECTION 6A
Q a d -a lln e . C n c u n e A ,

The inform ation pertinent to truck m odels covered by th is Supple­

ment is the sam e as given in S erv ice Manual S T -331-71 (pages 6A-1
thru 6A -34) with the follow ing excep tion s an d /or additions:

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ENGINE MAINTENANCE SPARK PLUGS
Inspection, adjustm ent or replacem ent of e m is­ R eplace spark plugs at 12,000 m ile in ter v a ls.
sion control related com ponents m ust be perform ed U se of leaded fu els re su lts in lead d ep osits on

on a tim e or m ileage b a sis as indicated. Good
judgment is required in replacem ent of parts in
th ose c a s e s w here the accum ulated m ileage is
substantially low er during the sp ecified tim e period.
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spark plugs and can cause m isfirin g at m ilea g e s
le s s than 12,000 m ile s. Where m isfirin g o ccu rs
prior to 12,000 m ile s, spark plugs in good condition
can often be cleaned, tested and r ein sta lled in an

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engine with acceptable r e su lts.
SERVICING AIR CLEANER
A ir c lea n ers should be inspected and ser v ice d ENGINE COMPRESSION
Minimum com p ression recorded in any one

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every 12,000 m iles or m ore often under se v e r e
dust conditions; a lso , w henever dirt is v isib le in cylinder should not be le s s than 70% of highest
elem ent or o il. R efer to "AIR CLEANERS” (SEC.
6M) of th is supplem ent or S T -331-71 S ervice
Manual.
b ra cylin d er. For exam ple, if the highest p r e ssu r e in
any one cylinder is 150 lb s ., the low est allow able
p r e ssu r e for any other cylinder would be 105 lb s.
(150 x 70% = 105).
This test should be perform ed to provide r e a ­
IMPORTANT: V ehicle operation under condi­
tion s such a s heavy dust, continuous short trip s, sonable assu ran ce that engine condition is su ffic ­
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stop and go driving, e tc ., is not con sidered norm al iently efficient to prevent leakage of unburned
u se and th erefo re m ore frequent m aintenance w ill g a s e s . If a problem e x is ts , have co r re ctio n s m ade.
be required. Such additional m aintenance req u ire­
ca

m ents are included below w here applicable. DISTRIBUTOR POINTS, CAM LUBRICATOR
D istributor points should be inspected p rio r to
T h erm ostatically C ontrolled A ir C leaner
perform ance of tune-up adjustm ents. Burned or
The air clean er should be inspected to make
pitted points must be replaced. P oints in good con­
certain that a ll h o ses and ducts are intact and co r ­
dition may be reu sed after readjustm ent and the
ic

rectly in sta lled . Operational function should be

installation of a new cam lubricator. New points
checked by inspecting position of valve in air intake.
and cam lubricator should be in stalled at le a st
With engine stopped, valve should be open. At
every 24,000 m ile s.
ss

underhood tem perature below 100°F ., with engine

running, valve should be p artially or fully closed .
DISTRIBUTOR CAP
A s engine underhood tem perature r is e s , the valve
should open. The interior and ex terior of the distributor
cap should be carefully inspected and cleaned to
a

prevent m isfirin g and deterioration.

CHECKING DRIVE BELTS
Fan belt tension on v eh icles equipped with
cl

SPARK PLUG WIRES

V -b elts should be adjusted to 120 - 130 pounds on
new b elts using B T -3 3 -7 3 F B elt T ension Gauge.
U sed drive V -b elts should be adjusted to 80 - 90
pounds. Gauge should be placed at center of the
g rea test span.
IMPORTANT: A fter a belt has been in oper­
ation one hour or approxim ately 50 m ile s, it is
consid ered u sed . B elt d ressin g can be used to ex ­
tend belt life . When V -b elts are worn they should
be rep laced , as e x c e s s iv e tightening w ill not p re­
vent slippage and can cause damage to b earings.
Inspect spark plug w ir es for evidence of ch eck ­
ing or cracking of exterior insulation and a tight
fit in the distributor cap and at the spark p lu gs.
E xterior of w ir es should be cleaned, any evidence
of corrosion on ends rem oved and w ire rep laced
if deteriorated .
TIMING, POINTS (DWELL), IDLE SPEED
T hese adjustm ents must be p erform ed a cc u r ­
ately, following the sp ecifica tio n s shown on the
label under the hood. A djustm ents must be made
with te st equipment known to be accurate.
S e c . 6A
Page 12
G A SO LIN E ENGINES

12 months or 12,000 m iles (whichever o ccu rs first)

when the v eh icle is used under the follow ing con-
FLYWHEEL H O U SIN G
ditionsi
ADAPTER • D riving in dusty conditions.
• E xtensive idling.
• Short trip operation at freezin g tem p er­
atures (engine not thoroughly w arm ed up).

POSITIVE CRANKCASE VENTILATION

SYSTEM - HOSES AND CONNECTIONS

m
UNDERPAN The PCV sy ste m should be checked for s a t is ­
factory operation at 12-month or 1 2 ,000-m ile in­
terv a ls using a te ste r such as the AC T ester C T -3.

co
POSITIVE CRANKCASE VENTILATION
BREATHER OR FLAME ARRESTER
EXTENSION CO VER
T-9141 The breather or flam e a r r e ste r should be r e ­
moved and cleaned at 12,000 m ile in terv a ls. Im ­

.
m e rse in cleaning solvent to rem ove all deposits
and allow to drain before rein stallin g.

ry
Figure 1— Flywheel H o u sin g and Adaptor Plate
(350 and 366 V8 Engine) MECHANICAL VALVE LIFTERS
Intake and exhaust valves on V6 engines should
P roper functioning of the carburetor is p ar­
ticu la rly e sse n tia l to control of e m issio n s. C orrect
m ixtures for e m issio n com pliance and idle quality
have been preset. P lastic idle mixture lim iters have
been installed on the idle mixture screw s to pre­
b ra
be adjusted at 12,000 m ile in tervals.

MANIFOLD HEAT VALVE

clude unauthorized adjustment. These idle lim iters
rli
are not to be removed unless made necessary by
som e major carburetor repair or replacement which
affects the idle screw adjustment.
ca
In-L ine engines and som e V6 and V8 engines
are equipped with a m anifold heat valve which should
be checked for free operation. A binding valve may
be freed up with G eneral M otors m anifold heat
valve lubricant or equivalent. (NEVER USE ANY
OTHER TYPE LUBRICANT.)

FLYWHEEL H O U SIN G ADAPTER

POSITIVE CRANKCASE VENTILATION VALVE
R eplace the PCV valve at 24 months or 24,000
PLATE
m ile in tervals (whichever occu rs fir st). PCV valve
ic

h o se, when rem oved for valve replacem ent, should
be blown out with an air hose to make certain that
it is clean. The PCV valve should be replaced at
s
as
Figure 1 shows the flyw heel housing adapter
plate used with 13-inch clutch on 350 and 366 V8
engines.

Inspect engine front and rear mountings as

cl

part of regular engine m aintenance program . Be

su re a ll bracket attaching bolts are kept tight.
R efer to ENGINE MOUNTINGS (SEC. 6D) for engine
mounting inform ation.
 S e c . 6A
P ag e 13

GASOLINE ENGINES

TUNE-UP CHART
(IN-LINE ENGINE)
Except as otherwise indicated, the following specifications apply to both engine models.

ENGINE TYPE AND NUMBER OF CYLINDERS .............................. In-Line, 6 -Cyl. ...................................................... .............15-3-6-2-4
COMPRESSION RATIO
250 Engine ................................................................................ 8.5:1 IGNITION T IM IN G .............................. Refer to Ign. System Specs. (Sec. 6 Y)
292 E n g in e ................................................................................ 8.0:1

m
CYLINDER COMPRESSION (PSI) VALVE L A S H .................................................................................. Zero
At Cranking S p e e d ........................................................................ 130 NOTE: Valve lifters are hydraulic type. Refer to “ Cylinder Head Bolt
Max. Variation Between C y lin d e rs...................................................... 20 Torque and Rocker Arm Adjustment” in this section for instructions.

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SPARK PLUG MAKE AND NUMBER
250 Engine .......................................................................... A.C.-R46T ENGINE GOVERNOR SETTING . . . .Refer to Governor Charts at end of Gasoline
292 Engine .......................................................................... A.C.-R44T Engine Fuel Systems (Sec. 6 M) in this manual.
Spark Plug Gap ( A ll) .................................................................. 0.035"
Plug Tightening Torque (F t.-Lb s.)............................................. 13-17

y.
ENGINE IDLE S P E E D ................ Refer to appropriate chart in "Gasoline Engine
Fuel System s” (Sec. 6 M) in this manual.
IGNITION DISTRIBUTOR
Dwell Angle (D e g re e s).................................................................. 31-34

r
FUEL PUMP PRESSURE ( P S I) ............................................................... 4-5
Point Gap (N e w )........................................................................ 0.019”

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Point Gap (U se d )...................................................................... 0.016”
Contact Lever Spring Tension (O z .)................................................ 19-23
b CYLINDER HEAD BOLT TORQUE (FT.-LBS.) ........................................ 90-100
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TORQUE WRENCH SPECIFICATIONS
(IN-LINE ENGINES)
ca

Torque wrench specifications listed below apply to clean dry threads except as otherwise indicated.

ITEM FT.-LBS. ITEM FT.-LBS.

Push Rod Cover B o lt s ...................................................................... 6-8 Main Bearing Cap B o lt s ................................................................. 60-70
ic

Cylinder Head B o lt s ..................................................................... 90-100 Oil Pump B o lts ................................................................................9-10

Manifold Clamps (O u te r)................................................................ 15-20 Oil Filter (Throw-Away T y p e )................................. (Filter Gasket Oiled 20-25)
ss

Manifold Clamps (Except O u te r)...................................................... 25-30 Oil Filter Stud (If U se d )................................................................... 45-50
Exhaust-to-lntake Manifold B o lt s ..................................................... 25-30 Crankshaft Damper B o lt ................................................................. 40-60
Thermostat Housing B o lt s .............................................................. 25-30 Flywheel Bolts
a

Water Outlet Housing B o lt s ........................................................... 15-20 250 E n g in e s............................................................................. 55-70

Water Pump B o lt s ........................................................................ 13-17 292 Engines .................................................................. 1 0 5 4 1 5
cl

Engine Front Cover B o lt s .................................................................. 5-7 Flywheel Housing B o lt s ................................................................... 25-30

Spark Plugs— 5 /8 ” Wrench Size— Tapered Seat P lu g ................... 13-17 O ilPan Bolts
End B o lt s .................................................................................. 8-12
Connecting Rod Bolt Nuts ^ xc- .......................................................................... ®-8
250 E n g in e s ............................................................................. 30-35 Oil Pan Drain Plug B o lt s ........................................................... 1 /2 15-20
292 E n g in e s............................................................................. 35-45 7 /8 20-25
S e c . 6A
Page 14

G ASO LINE ENGINES

TUNE-UP CHART
(V6 ENGINE)

TYPE AND NUMBER OF CYLINDERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60°, V-6 FIRING ORDER 1-6-5-4-3-2

COMPRESSION RATIO IGNITION T IM IN G Refer to Ign. System Specs. (Sec. 6Y)
351C Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7:1 VALVE LASH
CYLINDER COMPRESSION (PSD Intake 0.012”
At Cranking S p e e d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Exhaust 0.018

m
Max. Variation Between Cyl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 ENGINE GOVERNOR SETTING (No Load RPM)** If Used
SPARK PLUGS* 351C 3900
M a k e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC IDLE S P E E D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to appropriate chart in

co
Type and Gap "Gasoline Engine Fuel Systems" (Sec. 6M) in this manual.
3 5 1 C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CR 43 N, 0.035”
Tightening Torque (Ft.-Lbs.). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 FUEL PUMP PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6V2
IGNITION DISTRIBUTOR CYLINDER HEAD BOLT TORQUE (FT.-LBS.)............................... 60-65

.
Dwell Angle (Degrees). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31-34 *|n extremely cold regions use plugs with higher heat range.

ry
Point Gap (New) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.019”
Point Gap (U sed ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.016” **With engine broken in. Full load setting is approximately 300 RPM
Contact Lever Spring Tension (O z.)................................. 19-23 less than No Load RPM, and will vary from engine to engine.
b ra
TORQUE WRENCH SPECIFICATIONS
rli
(V6 ENGINE)
Torque wrench specifications listed below apply to clean dry threads except as otherwise indicated.
ca

ITEM FT.-LBS. ITEM FT.-LBS.

Rocker Arm Adjusting Screw .7-17 Oil Pump Cover Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
Rocker Arm Shaft Bracket Bolts 20-25 Oil Pump to Block Bolt .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-35
ic

Rocker Arm Shaft Cover Bolts 3-5 Oil Filter By-Pass Valve Plug (When U se d ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-40
Valve Lifter Cover Bolts ..... 4-5 Fuel Pump Eccentric B o l t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-65*
Distributor Clamp B o l t ....... 12-17 Oil Filter Housing to Cylinder Block Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . 26-36
s

Cylinder Head Bolts .......... 60-65* Oil Filter Center Stud (When U se d ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-50
as

Intake Manifold Bolts . . . . .. . . 25-30 Oil Filter Assy (Filter Gasket Oiled). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
Exhaust Manifold B o lt s ........ 15-20 Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-34
Water Outlet Manifold B o lts .... 20-25 Flywheel Housing B o lts. .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. 50-60
Thermostat Housing Bolts .... 20-25 Flywheel to Crankshaft B o l t s .. .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . . .. 100-110
cl

Front Cover Bolts ........... 22-27 Hub-to-Crankshaft Bolt (Without Cone) .. . . . . . . . . . . . . . . . . . . . . . . . . . . . 180-200

55-65* Damper or Hub-to-Crankshaft Bolt (With C o n e ). .. . . .. . .. . .. . . .. . .. . .. 240-260

Connecting Rod N u t s ........
Oil Pan B o lts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
Main Bearing Cap Bolts
Oil Pan Drain Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30
Main Bearing Cap Bolts (Except W R e a r). . . . . . . . . . . . . . . . . . . . . . 130-140*
Rear [Vi" Bolts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-100* *Oiled with S.A.E. No. 10 Engine Oil. (See Text)
 Sec. 6A
P age 15

GASOLINE ENGINES

TUNE-UP CHART
(V8 ENGINE)
Except as otherwise indicated, the following specifications apply to all V -8 Point Opening
engines. New .................................................................................. 0.019”
ENGINE M O D ELS........ - ........................................................ 3 5 0,366, 427 Contact Lever Spring Tension (O z .)............................................... 19-23
NUMBER OF CYLINDERS AND ENG. T Y P E .................................. 8 Cyl., V Type p|R|NG 0RD[R 1-84-3-6-5-7-2
COMPRESSION RATIO ........................................................................ 8:1
........................... Refer to Ign. System Specs. (Sec. 6 Y)
CYLINDER COMPRESSION (PSD

m
At Cranking S p e e d ........................................................................ 150 VALVE LASH ................................................................................. ero
Max. Variation Between Cylinders ............................................. 20 Note: Valve Lifters are hydraulic type. Refer to “ Cylinder Head Bolt
SPARK PLUG MAKE S NUMBER 'X io n s Rocker A™ AdiuStment" ™ thiS f0'

co
427 ..................................................................................... AC-R42T
350 ..................................................................................... AC-R44T ENGINE IDLE SPEED .................................. Refer to appropriate chart in
366 ..................................................................................... AC-R43T “Gasoline Engine Fuel System s” (Sec. 6 M) in this manual.

£ plug lis t e n in g Torque (Ft.-Lbs . ) . . . . . . . . . . . ^13-17 « - PUMP PRESSURE (PSD ........................................................ 7 W

y.
CYLINDER HEAD BOLT TORQUE (FT.-LBS.)
350 Eng.................................................................................... 60-70
Dwell Angle (Degrees) .............................................................. 28-32 366 & 427 ............................................................................... 75-85

r
TORQUE WRENCH
b
(V8 ENGINE)
ra SPECIFICATIONS

ITEM FT.-LBS. ITEM FT.-LBS.

rli
Rocker Arm Cover B o lt.................................................................... 3-5 Camshaft Sp ro cket 15-20
Rocker Arm Stud (366 and 427 Only) ............................................ 45-55 Connecting Rod Caps
ca

Distribute, Clamp Boit..............................................................................20-25 ;; ;;;;;;;;;;;;;;;;;;;

W * ' H e a d Bolt c„ , „ Main Bearing Caps (350 Engine)

350 ....................................................................................... 60-70 . D .. 7 n on
366 and 427 En g in e s............................................................... 75-85 tolfe g ! ^ & 4 Only). .V .V .'.'.'.'.V .. . . . V .'.V . .V .V . '. ! ! ! ! ! ! ! :60-70
ic

Crankshaft Damper B o lt............................................................... 80-90 ^ ^ Caps ^ s 4?/ Eng|„ es)

Manifold Bolts (In le t)................................................................... 25-35 |nner ^ 100-110
ss

Manifold Bolts (Exhaust) ^ uter B o lts 100110

350 Engine ................................................................ 18-22 Oil Pump B o lts 60-70
366 & 427 E n gin e ................................................................... 20-30 Qjl pan
Flywheel Housing and Adapter Bolt (When U sed ).............................. 25-35 3 5 0 Engines 1 /4 ” B o lts 6-7
a

5 /1 6 ” B o lts .............. .’ ............................................................ 12-15

Flywheel Bolts
366 and 427 Engines (1 /4 ” B o lts)................................................. 4-5
350 E n g in e ............................................................................. 55-65
cl

366 & 427 E n gin e s.................................................................. 60-70 Oil Filter (Filter Gasket O iled )......................................................... 20-25
Spark Plug 5 /8 ” Wrench Size— Tapered S e a t........................... 13-17 oil Pan Drain P lu g ....................................................................... 15-20

Water Pu m p ............................................................................... 25-35 Flywheel Housing Underpan........................................................ 6-7 1/2

S e c . 6D
P age 16

SECTION 6D
C 'tu jin e M a u + U i+ u jA .

A ll inform ation in ENGINE MOUNTINGS (SEC. 6D) of S ervice

Manual S T -331-71, p ages 6D-1 through 6D -3 applies to v e h ic le s cov­
ered by this supplem ent with the follow ing exceptions or additions:

m
ENGINE CU SHIO N BOLT A N D NUT TORQUE
B olt to Alum. B olt to Casting or Nut Nut Torque

co
Size Torque (F t.L bs.) Torque (F t.-L b s.) (F t.-L b s.)
3 / 8 ” 16-24 12 - 16 25 - 30 15 - 20
7/16" 14-20 20 - 25 40 - 50 25 - 30

.
1/2" 13-20 30 - 35 55 - 65 40 - 50

ry
9/16" 12-18 40 - 50 60 - 70 50 - 60
5/8" 11-18 50 - 60 130 - 140 70 - 80
3/4" 10-16 90 - 110 180 - 200 110 - 130

ra
M O U N T IN G BOLTS, BRACKET BOLTS, A N D NUT TORQUES
T-9146

e
b
GM 280-M BOLT GM 300-M BOLT
NUT TORQUE
rli
BOLT OR NUT SIZE F T .-L B S . F T .-L B S. FT .-L B S.
BOLT HEAD BOLT HEAD
1/4" - 20-28 8-10 IDENTIFICATION 10-15 IDENTIFICATION 5-8
ca

5/16" - 18-24 20-25 25-30 8 - 12

3/8" - 16-24 25-30 35-45 15-20
7/16" - 14-20 40-50 70-80 25-30
ic

1/2" - 13-16 55-65 85-105 40-50

9/16" - 12-18 60-70 90-110 50-60
s

5/8" - 11-18 130-140 170-180 70-80

3 /4" - 10-16 180-200 300-320 110-130
as

7 /8 " - 9-14 240-270 400-430 210-230

1" 8-14 325-380 700-730 320-350
* 40 - 50
cl

T-9148
** 55 - 65 Torque for aluminum casting.
*** 60 - 70

ENGINE FRONT M O U N T WITH AT475 to rem ove brackets, mounts, sp a cer, b olts, nuts,
T RANSM ISSIO N (ALL ENGINES) and w ash ers.

F igure 1 show s left sid e front mount used on NOTE: It w ill be n e ce ssa r y to bend lock tab
In -lin e 6-cylin d er Gas Engine and is typical for V6 before rem oving the cushion mount bolt (fig. 1) and
and V8 Gas E ngines. R efer to page 2 for figure 1. after bolt torque. See next page for figure 1.

R eplacem ent 2. R ev erse the procedure to in stall making sure

1. L oosen attaching b olts. R aise engine enough to torque bolts or nuts as shown on preceding charts.
 Sec. 6D
P age 17

ENGINE MOUNTINGS

W A SH ER
•BOLT
NUT

m
co
r y.
W ASHER
LOCK
‘> " V
FR O N T ra
M O U N T IN G BOLT
b \V
W ASHER N UT

Figure 1—En g in e Front M ount w ith A T 4 7 5

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Transm ission (Typical)
ca
ic
ssa
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 SECTION 6K
S 't K f i n e G o a U r u j, S y d t e m

Inform ation pertinent to truck m odels covered by th is supplem ent

is the sam e as explained in S erv ice Manual S T -331-71 ENGINE COOL­
ING SYSTEM (SEC. 6K), pages 6K-1 through 6K -9, except as indicated
by the follow ing inform ation which is eith er new or supplem ental in
nature.

m
R eferen ce should be made to RADIATOR AND SURGE TANK
(SEC. 13) in th is supplem ent for inform ation regarding radiator mount­
ing, radiator core and surge tank and cooling sy ste m fille r cap.

co
C O O LIN G SYSTEM GENERAL MAINTENANCE

TEST COO LANT LEVEL a. With radiator fille r cap rem oved, wet the

.
cap gasket with w ater and wash off any sedim ent
Engine coolant should be checked for proper from sealin g su rface, then in stall cap on te ste r .

ry
le v e l regularly (daily if n e c e ssa r y , depending on
b. Pump up p r e ssu r e by operating pump plung­
sev er ity of se r v ic e ) and every six months for c o r ­
er handle. When the p r e ssu r e stam ped on cap is
rosio n and fr e e z e protection to at le a st -20 F ., or
reached, ob serve te ste r dial and note the rate of
to the low est tem perature expected during the period
of veh icle operation. Each two y e a r s or 24,000
m ile s, w hichever fir st o ccu rs, cooling sy ste m m ust
be drained, flushed, and refilled with a new coolant
ra
d ec re a se in p r e ssu r e .
c. The indicator hand on gauge dial should r e ­
main within the corresponding p r e ssu r e segm ent
lib
solution. of sc a le for approxim ately 10 secon d s. If p r essu re
cap does not m eet this req u irem en t,it should be
RADIATOR CORE EXTERIOR replaced with new cap.
ar

For proper cooling efficien cy, the ex terior of
the radiator core and A/C condenser, if so equip­
ped, m ust be kept clean. Light brushing and r e ­
v e r se air flow is usually a sa tisfa cto ry cleaning
cc
2. T esting Cooling System
a. Tighten all radiator andheater hose clam ps.
A lso , check other connections for leaks at air com ­
p r e sso r coolant lin e s, etc.

method. In sects can usually be rem oved with a

garden hose using light w ater p r e ssu r e . G A U G E HO SE A N D .T A P

C O O LIN G SYSTEM PRESSURE CHECK PUMP A N D G A U G E

ASSEMBLY
si

S everal types of cooling sy ste m p r e ssu r e

checking d evices are available lo ca lly and manu­
as

fa ctu rer's in stru ctions should be follow ed for FILLER NECK1

p roper u se. A typical te ste r is illu strated in figure SON RADIATOR
1 and proced ures are given below for testin g the
p r e ssu r e cap and cooling sy ste m .
cl

O VERFLOW HOSE
1. T esting Radiator Cap

CAUTION: The radiator cap should

not be removed while the engine is at
normal operating temperature. If it is
necessary to remove the cap while the
engine is hot, first relieve the pressure
in the system by turning the radiator cap
counterclockwise to first stop, using cau­
tion not to scald hands. Push down on cap
and turn counterclockwise to remove cap.
Figure 1— Use of C o olin g System Tester (Typical)

b. F ill cooling sy ste m to le v e l of fille r cap
se a t.
c. Attach te s te r to fille r neck follow ing the
in stru ction s supplied with te ste r .
d. Build p r e ssu r e up to 20 p si (m axim um ).
e. The cooling sy ste m should hold the 20 p si
p r e ssu r e for approxim ately two m inutes. If p r e s ­
su re drops appreciably in le s s than two m inutes, a
leak in sy stem is indicated.
COOLING SYSTEM PROBLEM
ANALYSIS
1. R em ove fille r cap or te ste r from fille r
neck so there w ill be no p r e ssu r e in sy stem , then
attach sy ste m te ste r at fille r neck (fig. 1).
2. Start engine and run until norm al operating
tem perature is reached (approx. 175 F .).
3. O bserve gauge on te s te r . If no p r e ssu r e in
sy ste m is in d icated ,u se te ste r pump to p r e ssu r iz e
r
the sy ste m . If sy ste m w ill not hold p r e ssu r e , in­
tw een the pump s e a l and the bearing.
b ra
sp ect h o se s, fittin g s, and g a sk ets. A lso, look for
w ater draining from hole in w ater pump body b e­
4. If no leak s a re evident, it is p o ssib le that
coolant is leaking internally into cran k case, oil
co o le r , or com bustion cham bers.
rli
5. To determ ine if there is coolant leakage
into o il coo ler or cran kcase, look for w ater drop­
ca
le ts on engine o il dipstick. A lso , look for engine
o il in cooling sy ste m which would indicate that
d efective o il coo ler or g ask ets e x ist.
ENGINE COOLANT
ic
RECOMMENDATIONS
ss
R ecom m endations are for a high quality in­
hibited Ethylene G lycol B a se Coolant m eeting GM
S pecifications 1899M and to provide the freezin g
and co rro sio n protection (at le a st 0 F .).
a
Additional inhibitors are not required on initial
f ill if a m inim um an tifreeze concentration of 30%
cl
by volum e is u sed. Solutions of le s s than 30% con­
centration do not provide su fficien t corrosion p ro­
tection . C oncentrations over 67% ad versely affect
f r e e z e protection and heat tra n sfer r a tes. S everal
brands of perm anent an tifreeze are available with
s e a le r ad ditives. The sp e c ific type of s e a le r s vary
with the m anufacturer. A ntifreeze with s e a le r ad­
d itiv es is not recom m ended due to plugging prob­
le m s throughout various a rea s of the cooling sy stem .
NOTE: R efer to ’’Cooling System C apacities
C hart” at the end of th is sectio n for sy ste m ca ­
p a c itie s.
Sec. 6K
Page 19
ENGINE COOLING SYSTEM
COOLING SYSTEM CORROSION
PREVENTION
NOTE: Addition of supplem ental additives and
other available m aterials which have not been s p e c ­
ific a lly approved by GM are not norm ally required.
U se of th ese m aterials w ill resu lt in unwarranted
operating expense.
Every two y e a r s, the cooling sy ste m should
be se r v ic e d as follows:
m
1. Drain coolant, when hot, through the rad­
iator drain valve.
2. C lo se valve and add su fficien t plain w ater
co
to fill sy ste m .
3. Run engine until norm al operating tem p er­
ature is reached.
4. Drain and r e fill the sy stem a s d escrib ed
y.
in Steps 1, 2, and 3 a su fficien t number of tim es
until the drained liquid is c o lo r le ss.
5. A llow sy stem to drain com pletely and then
c lo s e radiator drain valve tightly.
6. Add the n e c essa r y amount of high quality
inhibited glycol base coolant m eeting GM Sp eci­
fication 1899-M to provide the required freezin g
and corrosion protection (at le a st to 0 °F .).
7. Run engine until norm al operating tem p er­
ature is reached.
8. Check and adjust le v e l of coolant after s y s ­
tem has cooled su fficien tly to rem ove radiator cap.
C A U TIO N : When an engine Is at norm ­
al operating temperature or above, the
internal pressure built up in the cooling
system will blow out scalding fluid and
vapors if the radiator cap is suddenly re ­
moved.
To prevent loss of coolant and to
avoid the danger of being burned, the cool­
ant level should be checked, or coolant
added only when the engine is cool.
To remove the cap when engine is
cool, slowly rotate cap counterclockw ise
to the stop on fille r neck (DO NOT P R E S S
DOWN W H ILE R O TA TIN G ), wait until any
residual pressure is relieved - as indicat­
ed by a hissing sound, then press down on
the cap while continuing to rotate counter­
clockw ise.
Radiator pressure caps should be
checked by a qualified m echanic period­
ically for proper operation and replaced
as required with the applicable A C type.
P re ssu re cap testing procedure is co v e r-
ed previously In this section.______________
R eg ard less of whether freezin g tem p eratu res
a re or are not expected, cooling sy ste m p rotection
should be maintained at le a st to 0 ° F ., to provide
adequate co rrosion protection. When coolant addi-
S e c . 6K
P age 20

ENG INE C O O L IN G SYSTEM

tio n s are required b ecau se of coolant lo s s or to V-BELT TENSION

provide additional protection against freezin g at
tem peratu res low er th an -2 0 F .,( - 3 2 F.inC anada),
a su fficien t amount of an Ethylene G lycol B ase
Coolant m eeting GM Specification 1899-M should
be used.
NOTE: A lcohol or methanol base coolants or
plain water are not recom m ended.
Fan belt tension on veh icles equipped with
V -b elts should be adjusted to 120-130 pounds on
new b elts using B T -3 3 -7 3 F B elt Tension Gauge.
U sed drive V -b elts should be adjusted to 80-90
pounds. Gauge should be placed at center of the
g rea test span.
IMPORTANT: A fter a belt has been in op er­

IMPORTANT: DO NOT run engine when gauge
or te ll-ta le indicates "hot" engine. A lso DO NOT
u se glycol ether (methoxypropanol) base coolant in
GMC D ie se l engines, as damage to head gasket
m
ation one hour or approxim ately 50 m iles, it is
con sid ered used. B elt d ressin g can be used to ex ­
tend belt life . When V -b elts are worn they should
be replaced as e x c e ssiv e tightening w ill not p r e ­

co
could resu lt. vent slippage and can cause damage to bearings.

SPECIFICATIONS

.
The cooling sy ste m ca p acities liste d below apply to v eh icles with

ry
standard equipment only. B ecau se of som e optional equipment which
may be used, air conditioning, la rg er engine, water filte r , in creased
cooling, e tc ., the capacity of cooling sy stem w ill vary. For the purpose

ra
of obtaining an accurate cooling sy ste m capacity before adding anti­
fr e e z e to an optional equipped v eh icle, it is recom m ended that the co o l­
ing sy ste m be fir st replenished until v isib le in fille r opening and then
drained into a graduated container of which the contents can be m easured.
b
STANDARD C O O LIN G SYSTEM
ENGINE THERMOSTATS
rli
CAPACITIES (OTS) INCL. HEATER
QUARTS No. Mean Starts to Fully
Engine U sed remp. (°F .) Open (°F.) Open ( F.)
ca

'I RUCK MODELS U.S. I MP E RI AL

CE40 21.0 m 351C 2 180 177-183 202
CS40 16.0 13%
PS40 16.0 13% 250; 292 1 195 192-198 217
20.0
ic

SE, CE50 16%

CG, SG50 29.0 24% 350 1 195 192-198 217
CM, SM50 36.0 30
CS, SS50 17.0 14X
s

366; 427 2 180 177-183 202

TE50 28.0 23%
TM50 44.0 36%
as

DH478 1 180 177-183 202

TG50 38.0 32
CE, ME60 33.0 21%
CM, TE60 35.0 29%
TM60 44.0 36%
cl

ENGINE OVERHEAT SWITCH

SWITCH CONTACTS CLOSE AT:
V6 G asoline Engines ............................................................................... ..... 225°F .
V8 G asoline Engines ............................................................................... ..... 250°F .
D ie se l Engines ........................................................................................ ..... 215°F .
 Sec. 6M
P age 21

SECTION 6M
f y u e l S if d i& tn

Q a A o lin e C '+ U f U te A

GOVERNORS

m
HOLLEY INTERNAL -VA CU U M GOVERNOR TEST
TYPE GOVERNOR The following procedure should be used to help
(Refer to Schem atic Figure 1) locate the cause for lo s s of governor control:

co
1. U sing a tachom eter, check engine governed
The Holley Internal-V acuum Type Governor sp eed as sp ecified in ’’Specifications" at end of th is
is used on both 366 and 427 engines. The governor sectio n .
is com p rised of two b a sic units; the centrifugal NOTE: Initial overrun m eans that under a c c e l­

y.
control valve housed in the distributor and the eration the engine w ill m om entarily exceed gov­
carburetor with its integral governor com ponents. erned speed by approxim ately 150-250 rpm and

r
CARBURETOR GOVERNOR
B Y -P A S S JETS
b ra GOVERNOR
VACUUM
D IS TR IB U T O R
rli
ca
ic

REAR VIEW
ss

S P IN N E R V A L V E
G O V E R N O R V A C U U M LIN E
G O V E R N O R S P R IN G
a
cl

G O V E R N O R LEVER

G O V E R N O R V A C U U M LIN E
GOVERNOR
VACUUM
PASSAGE D IA P H R A G M R O D

BOTTOM VIEW D IA P H R A G M T-m o

Figure 1—H o lle y In te rn a l—V acuum Type G overnor

S e c . 6M
P a ge 22
FUEL SYSTEM— GASOLINE ENGINES
then se ttle to governed speed which is a normal
condition.
2. If there is no governor control, perform
the following:
a. D isconnect the vacuum line (d istrib u tor-to-
governor throttle actuating unit). Leave the second­
ary control valve vacuum line connected. Operate
the engine at 2200 rpm, then wet your finger and
hold it over the opening in the disconnected vacuum
lin e. If the engine speed slo w s to near id le, the
governor trouble is in the distributor spinner valve
or the lin es or connections to the d istributor. If the
engine does not slow down p roceed to Step b. fo l­
lowing:
b. D isconnect the secondary control valve
vacuum line from the governor a ssem b ly . Again,
operate the engine at 2200 rpm and p lace a wet
fin ger over the p a ssa g e to the governor throttle
unit. If the engine now slow s to near id le, the prob­
lem is in the secondary control valve or its vacuum
lin e . If the engine does not slow down, the problem
is in the governor throttle unit or the vacuum p a s s ­
ROCHESTER CARBURETORS
F igu res 2, 3, and 4 illu str a te the current
ra
lib
R och ester carb uretors in sta lled on C hevrolet
Truck en gin es. The m ost sign ifican t change in
th e se carburetors extern ally, is the addition of
p la stic lim ite r caps which are in sta lled over the
ar
id le m ixture sc r e w (s).
The p la stic caps prevent unauthorized adjust­
cc
FUEL INLET
A N D FILTER
si
as
IDLE STOP
SO LEN O ID
cl
CHOKE
DISTRIBUTOR A D V A N C E PLASTIC LIMITER CAP
LINE PORT (IDLE MIXTURE SCREW)
Figure 2 — M o d el M Rochester Carburetor
a g es behind it.
3. If the engine governs at light load and does
not govern at w ide-open throttle the problem is
probably in the secondary control valve. C orrect
operation of the secondary throttle sy ste m and the
governor depends upon proper functioning of the
secondary control valve. B e su re the secondary
control valve air clean er is cleaned or replaced at
regular in tervals depending on sev erity of op er­
ation, then perform the following:
When the problem is su sp ected to be in the
m
secondary control valve, operate the v eh icle on the
highway and check governor operation. The gov­
ernor should lim it speed to that sp ecified in "Speci­
co
fications" plus 150-250 rpm initial overrun. If the
engine does not govern, rem ove "E" clip, discon­
nect the secondary throttle diaphragm link from
the secondary throttle shaft le v e r . Operate the
v eh icle again on only the prim ary carburetor ven­
.
tu r is. If the engine governs now, the problem is in
ry
the secondary control valve which must be replaced
a s an assem b ly .
ment of the idle m ixture sc re w (s). T hese caps are
not to be rem oved u n less made n ec essa ry by som e
m ajor carburetor repair or replacem ents which
a ffects idle m ixture adjustm ent. Replacem ent of the
p la stic caps is covered in this section under "Re­
placing P la stic L im iter Caps on Idle Mixture
S crew s."
CARBURETOR
IDENTIFICATION
CHOKE ROD
RETAINER
FAST IDLE C AM
THROTTLE LEVER
 Sec. 6M
P age 23

FUEL SYSTEM—GASOLINE ENGINES

IDLE VEN T VALVE

FUEL INLET A N D FILTER
IDENTIFICATIO N NUMBER

m
co
ACCELERATOR
PUMP ROD C H O K E ROD

y.
IDLE SPEED SCREW
PLASTIC LIMITER CAPS
DISTRIBUTOR (IDLE MIXTURE SCREW) THROTTLE LEVER
LINE PORT

r
ra
Figure 3 —M odel 2 G Rochester C arburetor

A lso of im portance on the Model M carburetor

(fig. 2) used on In-lin e engines is the addition of
b
an e le c tr ica lly operated idle stop solenoid which
in stalled , parking brake applied, and driving w h eels
blocked.
2. A ir conditioning (when used) must be turned
functions to prevent engine d ieselin g. "ON.”
rli
3. Check the distributor dwell reading.
ROCHESTER CARBURETOR In-L ine Engines ... 31 to 34 d egrees
ADJUSTMENTS 350 V8 Engine ... 28 to 32 d egrees
ca

NOTE: When setting ignition tim ing, the term

IDLE SPEED ADJUSTMENTS
BTDC m eans "Before Top Dead C enter."
P relim in ary Checks (All Engines) 4. Adjust ignition tim ing to 4°BTDC with
1. Idle adjustm ents should be perform ed with vacuum advance disconnected and plugged. R econ­
ic

the engine at operating tem perature air cleaner nect vacuum advance hose.
ss

FUEL INLET A N D IDLE V EN T VALVE

ID ENTIFICA TIO N FILTER
NUMBER
a
cl

IDLE SPEED SCREW

LIMITER ACCELERATOR
CAPS PUMP ROD
GOVERNOR (IDLE MIXTURE SCREWS) LEVER

Figure 4 —M odel 2 G Rochester C arburetor w ith G overnor

S ec. 6M
Page 24

FUEL SYSTEM— GASOLINE ENGINES

9/16" W RENCH

m
SO L E N O ID

co
STOP PIN
IDLE MIXTURE SCREW
PLASTIC CAP

.
ry
SCREW DRIVER
Figure 5 — A djusting Idle Speed (In-Line EngineI
T-9134

5. Adjust idle speed as follow s:

In-L ine Engine Idle Speed Adjustment

1. R eferring to figure 5, using a 9 /1 6 -in ch
open-end wrench on hexagonal portion of solenoid,
rotate solenoid until engine speed reach es 700 rpm.
b ra Figure 7 — Rem oval of Plastic Limiter Cap
(M odel M Rochester CarburetorI

450 rpm (reduced idle speed).

NOTE: If n e c e ssa r y to rotate solen oid m ore
rli
than one full revolution (360°), disconnect e le c ­
tr ic a l connector, straighten w iring and reconnect
to solenoid.
2. D isconnect e le c tr ic a l connector from s o le ­
ca
3. R econnect e le c tr ica l connector and check
for proper idle speed (700 rpm).
350 V8 Engine Idle Speed Adjustment
R eferring to figu res 3 or 4, adjust idle speed
sc re w until engine speed reaches 600 rpm.

noid with engine idling. Adjust 1 /8 -in c h A llen-head

sc r e w on end of solenoid (see fig. 6) to ach ieve
s ic

1/8” ALLEN W REN C H

as
cl

STOP PIN
PLASTIC CAP

SO LE N O ID

Figure 8 — Rem oving Plastic Limiter C ap

Figure 6 — A djusting Idle Stop Solenoid (Plunger RetractedI (M o d e l M Rochester Carburetor)
 Sec. 6M
P age 25

FUEL SYSTEM—GASOLINE ENGINES

m
co
y.
T-9137

r
Figure 9 —In sta llin g Plastic Lim iter C a p
(M odel M Rochester Carburetor)

REPLACING PLASTIC LIMITER CAPS

ON IDLE MIXTURE SCREWS
b ra Figure J 0 —Rem oval of Plastic Lim iter C a p s
(M odel 2 C Rochester Carburetor)

2. Check dwell reading and adjust, if n e c e s ­

sa ry . D w ell reading on In-line engines should be
31 to 34 d egrees.
rli
3. Adjust ignition tim ing to 4°BTDC with v a c ­
IMPORTANT: P la stic lim iter caps are in sta ll­
uum advance hose disconnected and plugged. R e ­
ed on the idle m ixture sc r e w s (se e fig s. 2, 3, and
connect vacuum advance hose.
4) of R ochester carburetors to prevent unauthor­
ca

ized adjustm ent. T h ese p la stic caps are not to be
rem oved u n less made n e c e ssa r y by som e major
carburetor repair or replacem ent which affects
the idle m ixture screw adjustm ent.
ic
4. Adjust engine idle speed using a 9 /1 6 -in c h
open-end wrench as shown in figure 5 until engine
speed is 775 rpm.
5. With engine running at idle speed as d e s­

cribed in Step 4, adjust idle m ixture sc re w to give

IN-LINE ENGINES
highest steady idle speed.
R em oving P la stic L im iter Cap
ss

6. Readjust engine idle speed as d escrib ed in

1. Using a screw d riv er as shown in figure 7,
Step 4, to 775 rpm.
tw ist p la stic cap back and forth until cap begins to
fa il. DO NOT u se extrem e p r e ssu r e when tw isting 7. Turn idle m ixture screw IN by rotating
cap to avoid bending stop pin. clock w ise to LEAN m ixture until the engine idle
a

2. Then pull p la stic cap straight away from sp eed reach es 700 rpm.
carburetor as shown in figure 8.
8. P osition p la stic lim iter cap as shown in
cl

figure 9, so that alignm ent slo t in p la stic cap is

CA U TIO N : It is most important to aligned with stop pin on carburetor. Then carefu lly
pull plastic cap straight away from ca rb ­ push p la stic cap onto idle m ixture sc re w until it
uretor to avoid bending idle mixture screw . snaps into position.

350 V8 ENGINE
Installing P la stic L im iter Cap
NOTE: The carburetor must be in stalled on
R em oving P la stic L im iter Caps
the engine and properly adjusted p rior to in sta ll­
1. U sing a screw d river as shown in figure 10.
ation of the p la stic caps.
T w ist each p la stic cap back and forth until cap
1. Thoroughly w arm up the engine. Be sure begins to fa il.
choke is open. 2. Then with the aid of a screw d riv er as

J
Sec. 6M
Page 26
FUEL SYSTEM— GASOLINE ENGINES
PLASTIC C A P S 1
SCREW DRIVER
Figure 11 — R em oving Plastic Limiter Caps
(M odel 2 C Rochester Carburetor)
shown in figure 11, pry the p la stic lim ite r caps
from idle m ixture sc r e w s.
Installing P la stic L im iter Caps
lib
NOTE: The carburetor must be in sta lled on
the engine and properly adjusted p rior to in sta ll­
ation of the p la stic caps.
1. Thoroughly warm up the engine. B e su re
ar
choke is open.
2. Check dwell reading and adjust, if n e c e s ­
sa r y . D w ell reading on the 350 V8 engine is 28 to
cc
32 d eg rees.
3. Adjust ignition tim ing to 4°BTDC with vac-
HOLLEY CARBURETOR
si
F igu res 13 and 14 illu stra te the H olley Carb­
uretor, Model 4150G in stalled on 366 and 427 en­
as
g in es. The significant changes in the H olley carb­
u retor are the addition of p la stic lim iter caps which
are in stalled on the idle m ixture sc r e w s and also
a relocation of governor vacuum control lin e and
cl
fittin g s on the carburetor.
HOLLEY CARBURETOR
ADJUSTMENTS
IDLE SPEED ADJUSTMENT
1. Idle speed adjustm ent should be perform ed
with the engine at operating tem perature, air clean ­
er in stalled parking brake applied, and driving
w h eels blocked.
2. A ir conditioning (when used) m ust be turned
ON.
------—
B O S S O N THROTTLE BODY
PLASTIC CAPS
m
co
TANG S
_ _ _
Figure 12— Installing Plastic Limiter Caps
(M odel 2 G Rochester Carburetor)
.
ry
uum advance hose disconnected and plugged. R e­
connect vacuum advance h ose.
4. Adjust engine idle speed screw (figs. 3 and
ra
4) until idle speed is 650 rpm.
5. With engine running at idle speed, adjust
idle m ixture scre w s to give highest steady idle
speed.
6. Readjust engine idle speed as describ ed in
Step 4, to 650 rpm.
7. Turn id le m ixture sc r e w s IN, equally, by
rotating clock w ise to LEAN m ixture until the en­
gine idle speed reaches 600 rpm.
8. P osition p la stic lim ite r caps as shown in
figure 12, so that tangs on p la stic cap are located
on either sid e of b oss on throttle body. Then c a r e ­
fully push lim iter caps onto idle m ixture scre w s
until they snap into position.
3. Check the distributor dwell reading. Dwell
reading on 366 and 427 engines should be 28 to 32
d eg r ee s.
NOTE: When setting ignition tim ing the term
BTDC m eans "Before Top Dead C en ter.”
4. Adjust ignition tim ing to 8°BTDC.
5. Adjust idle speed sc rew (fig. 13) until en­
gine speed reach es 550 rpm.
AIR VENT VALVE ADJUSTMENT (F ig. 15)
1. Back off idle speed screw until throttle
v alves are fully clo sed . (Choke valve open and
throttle arm off idle screw .)
2. Check clearance between valve and sea t.
C learance should be 0.060".
3. Bend air vent valve rod to adjust, if n e c e s­
sa r y .
 Sec. 6M
P age 27

FUEL SYSTEM—GASOLINE ENGINES

S EC O N D A R Y AIR VEN T PRIMARY CARBURETOR A N D FUEL TRANSFER

FUEL B O W L VALVE FUEL B O W L AIR H O R N TUBE
CHOKE PLATE PART NUM BER
NEEDLE IDLE
ASSEMBLY
A N D SEAT MIXTURE
C O N TR O L ASSEMBLY SCREW
VALVE AIR A
CLEANER

m
co
FutfL
BOW L FUEL INLET
S EC O N D A R Y SIG H T
C O N TR O L PLUG
VALVE

y.
GOVERNOR PUMP
ASSEMBLY CHOKE
ASSEMBLY
LEVER PUMP LEVER
THROTTLE LEVER
SEC O ND A R Y VACUUM GOVERNOR ED SCREW

r
D IA PH R A G M LINE TO VACUUM
ASSEMBLY DISTRIBUTOR C O N T R O L LINE PUMP OVERRIDE SPRING

4.
b ra
Figure 13—H o lle y C arburetor

Turn idle sc r e w in until contact is made and choke fully clo sed , m easure gap betw een fast
with throttle le v e r , then turn screw in 1% addi­ idle cam and screw . Gap should be 0.035".
tional turns for prelim in ary idle speed adjustm ent. 3. If n ec essa ry , adjust fast idle scr ew to p ro­
rli
Adjust engine idle speed as d escribed e a rlier in vide correct gap using wrench ( J - 10176).
th is sectio n . 4. Connect throttle return spring and in stall
air clean er.
ca

FAST IDLE ADJUSTMENT 5. Check engine rpm with choke c lo se d against

(R efer to Figure 16) the fast idle cam and throttle at idle. The fa st idle
1. With engine "OFF” and air clean er rem ov­ "Running" rpm ’s should be 1800-2400 rpm.
ed, disconnect throttle return spring.
ic

2. With throttle le v e r in wide open position VENT VALVE ACTUATING ROD

BEND HERE TO ADJUST
ss

SECO N D A RY ^ rU U M *
BARRELS VAp q r t
SECONDARY
THROTTLE
PO W ER VALVE PLATE
VACUUM PORTS SC REW
a
cl

IDLE SPEED
SCREW

THROTTLE
SC R EW S (8) ADJUSTMENT .060"
AIR VENT VALVE THROTTLE LEVER
.............. BARRELS PORT

Figure 14—H o lle y C arburetor (Bottom V iew ) Figure 15—A ir V ent V a lv e A djustm ent
Se c . 6M
P ag e 28

FUEL SYSTEM— GASOLINE ENGINES

m
. co
ry
Figure 18— Positioning Plastic Limiter Cap

ra For Installation (Holley Carburetor)

lib
ar
cc
si
as
cl

Figure 7 7 — R em oving Plastic Limiter Caps

(Holley Carburetor)
REPLACING PLASTIC LIMITER CAPS
O N IDLE MIXTURE SCREWS
IMPORTANT: P la stic lim ite r caps are in sta ll­
ed on the idle m ixture sc r e w s (fig. 13) located on
both sid e s of the secondary throttle body to prevent
unauthorized adjustm ent. T h ese p la stic caps are
not to be rem oved u n less made n e c e ssa r y by som e
Figure 19— Installing Plastic Limiter Cap
(Holley Carburetor)
m ajor carburetor repair or replacem ent which
affects the idle m ixture screw adjustm ent.
REMOVING PLASTIC LIMITER CAPS
(R efer to Fig. 17)
1. With the aid of two standard scr ew d r iv er s,
sim ply in sert tips of screw d riv er blades behind

p la stic cap, as shown.
2. Pry p la stic cap from each idle m ixture until engine idle speed is 600 rpm.
screw .
INSTALLING PLASTIC LIMITER CAPS
NOTE: The carburetor must be in stalled on
the engine and properly adjusted prior to in sta ll­
ation of the p la stic caps.
1. Thoroughly warm up the engine. B e sure
choke is open.
2. Check dwell reading and adjust, if n e c e s ­ be in stalled so that ears on cap are aligned with
sa ry . D w ell reading on 366 and 427 V8 engines
should be 28 to 32 d eg rees.
3. Adjust ignition tim ing to 8°BTDC.
BENDIX—STROMBERG CARBURETOR
The B endix-Strom berg carburetor (W W Series)
as shown in figure 20, is in stalled on 351C engine.
The m ost significant change externally on the
r
carburetor is the addition of p la stic lim ite r caps
sc r e w s.
BENDIX-STROMBERG CARBURETOR
b ra
which are in stalled over each of the idle m ixture
ADJUSTMENTS
rli
IDLE AND MIXTURE ADJUSTMENT
P relim in a ry Checks
ca
1. Thoroughly warm up the engine. Be sure
the choke is open.
2. B e su re the carburetor is properly secu red
to the intake manifold, which w ill exclude the p o s­
ic
sib ility of air lea k s. C arburetor-to-m anifold bolts
or nuts should be tightened to 20-25 foot-pounds
torque.
ss
3. Inspect the manifold heat control valve (if
used) for freedom of action and co rrect spring
tension.
4. A ir conditioning, when used, should be
a
turned on during the carburetor adjustm ents.
5. Check dwell reading and adjust, if n e c e s ­
cl
sa ry . Dw ell reading on V6 engines should be 31 to
34 d eg rees.
6. Adjust ignition tim ing with vacuum advance
hose disconnected and plugged to 7^°BTDC. R e­
connect vacuum advance hose.
C arburetor Adjustment
1. Engine idle speed for the 351C engine should throttle body from main body of carburetor. C are­
be adjusted to 650 rpm by perform ing the following:
a. R eferring to figure 21, place a %-inch open
end wrench on diaphragm extension of vacuum idle
stop to prevent its rotation w hile adjusting plunger.
Sec. 6M
Page 29
FUEL SYSTEM—GASOLINE ENGINES
4. Adjust engine idle speed scr ew (fig. 13)
5. With engine running at idle speed, adjust
idle m ixture scre w s to give highest steady idle
speed.
6. Readjust engine idle speed as d escrib ed in
Step 4 to 600 rpm.
7. Turn idle m ixture screw s IN, equally, by
rotating clock w ise to LEAN m ixture until the en­
gine idle speed reaches 550 rpm.
8. R eferring to figure 18, p la stic caps must
m
b o ss on secondary throttle body. Then carefully
push p la stic cap onto each idle m ixture sc rew (see
co
fig . 19) until it snaps into position.
y.
CA U TIO N : UN D ER NO CO N D ITIO N
SHOULD T H E D IAPHRAGM E X T E N S IO N
B E A LLO W E D TO R O T A T E OR IN T E R N ­
A L DAM AGE W IL L R E S U L T TO VACUUM
ID L E STO P UN IT.
b. Adjust the plunger with a 3 /8 -in c h open end
w rench until the face of the plunger hex contacting
the carburetor throttle le v e r resu lts in the idle
speed given e a r lie r in Step 1.
2. Rotate idle m ixture screw s cou n terclock ­
w ise until tang on each p la stic cap contacts roll
pin in throttle body of carburetor as shown in View
B ,figure 20.
3. R eset the idle speed as directed in Step 1.
4. Turn "in" idle m ixture scr ew s equally by
rotating clock w ise to LEAN m ixture until the fo l­
lowing idle speed reach es 600 rpm.
5. With engine running, vacuum id le stop hose
disconnected, check reduced engine rpm . The r e ­
duced engine speed should be 400 rpm. If n e c e s ­
sa ry , adjust id le speed screw (View A, fig. 20) to
obtain 400 rpm. Reconnect vacuum id le stop h ose.
FLOAT LEVEL ADJUSTMENT
1. R em ove air clean er and disconnect choke
and a ccelera to r linkage and fuel line from carbur­
etor. D isconnect fast idle link and a cce lera to r
pump rod.
2. Rem ove carb u retor-to-m an ifold retaining
b olts or nuts, then rem ove carburetor from engine.
3. R eferring to View A, figure 20, rem ove
sc r e w s from top of air horn. Separate a ir horn and
fully pour fuel from float bowl.
4. Hold main body inverted as shown in figure
22. This w ill allow weight of float to hold needle in
the closed p osition. U se float gauge (J-8824) to
S e c . 6M
P ag e 30

FUEL SYSTEM— GASOLINE ENGINES

M A IN DISCHARGE JETS
VENT TUBE

IDLE SPEED
SCREW

m
co
IDENTIFK

.
TAG HIGH-SPEED" BLEEDER

ry
VIEW A
ACCELERATOR
PUMP ROD

ra Figure 21 — A djusting V acuum Idle Stop

lib
FUEL
ar

INLET

IDLE MIXTURE SCREW S

cc

VIEW B
VAC U U M IDLE STOP CHOKE-
TO-THROTTLE
si

LEVER
Figure 2 2 — Checking Float Level

check relationship of the float to top of the fuel

as

bowl as shown. R efer to "Specifications" for proper

float le v e l adjustm ent. Setting is co rrect when the
edge of the gauge touches top of the rib on float.
5. U se tool (J-4395) to bend float le v er next
cl

to float to change the float settin g. U se bending

tool as illu strated in figure 23.
6. A fter checking float le v e l, in stall air horn
and throttle body to main body using new g ask ets.
R eferring to View A, fig. 20, in stall sc r e w s. Locate
choke control bracket and identification tag in
original p o sitio n s. Install carburetor with new
THROTTLE LEVER \ Q gasket on engine. Tighten carburetor-to-in take
VIEW C manifold bolts or nuts to 20-25 foot-pounds torque.
Connect fast idle link, acceleratin g pump rod, fuel
lin e s, choke w ire, and a ccelera to r linkage. Install
Figure 2 0 -B e n d ix -Stro m b e rg Carburetor (W W Series) a ir clean er.
 Sec. 6M
P age 31

FUEL SYSTEM—GASOLINE ENGINES

B ending Tool Bending Tool

m
Finger H olding
Tab V ertic a l

co
/
B E N D IN G LEVER TO RAISE SETTING B EN D IN G LEVER TO LOW ER SETTING

y.
Figure 2 3 —Typ ica l Use of B e n d in g Tool To Set Float Level

r
REPLACING PLASTIC LIMITER sim p ly in sert tip s of screw d river blades behind
CAPS ON IDLE MIXTURE SCREWS
IMPORTANT: P la stic lim ite r caps a re in sta ll­
ed on the idle m ixture sc r e w s (see fig. 20) of Bendix
b
Strom berg carburetors to prevent unauthorized
ra p la stic cap, as shown.

CAU TIO N : It is most important to

adjustm ent. T hese p la stic caps are not to be r e ­
rli
m oved u n less made n ec e ssa r y by som e major
carburetor repair or replacem ent which affects
the id le m ixture screw adjustm ent.
ca
use equal pressure on both screw d rive rs
when prying off the plastic caps, to p re ­
vent the idle mixture screw (s) from being
bent. If idle m ixture screw is bent during
removal of plastic cap, the screw must
be replaced.

REMOVING PLASTIC LIMITER CAPS 2. R em ove p la stic cap from each idle m ixture
(R efer to Fig. 24) screw .
1. With the aid of two standard sc rew d riv ers,
INSTALLING PLASTIC LIMITER CAPS
ic

NOTE: The carburetor must be in sta lled on

the engine and properly adjusted p rio r to in sta ll­
ation of the p lastic caps.
ss

1. Thoroughly w arm up the engine. B e su re

choke is open.
2. Check dwell reading and adjust, if n e c e s ­
sa ry . D w ell reading on V6 engines should be 31 to
a

34 d eg rees.
3. Adjust ignition tim ing with vacuum advance
cl

hose disconnected and plugged to 7^°BTDC. R e ­

connect vacuum advance h ose.
4. Engine idle speed should be adjusted to 650
rpm by perform ing the following:
a. R eferring to figure 21, place a M-inch open
end wrench on diaphragm extension of vacuum idle
stop to prevent its rotation w hile adjusting plunger.

Figure 2 4 —Rem oving Plastic Lim iter C a p s
(B en dix-Strom berg Carburetor)
CA U TIO N : U N D ER NO CO N D ITIO N
SH O U LD T H E D IAPH RAGM E X T E N S IO N
B E A LLO W E D TO R O T A T E OR IN T E R N ­
A L DAM AGE W IL L R E S U L T TO VACUUM
ID L E STO P UNIT.
S e c . 6M
P a ge 32 ____________________________________

FUEL SYSTEM— GASOLINE ENGINES

b. Adjust the plunger with a 3 /8 -in c h open end

w rench until the face of the plunger hex contacting
the carburetor throttle lev er resu lts in the idle
speed given e a r lie r in Step 4.
5. Adjust the idle m ixture sc r e w s. With engine
running and idling speed set, turn each m ixture
sc r e w "in" until engine begins to slow down or run
unevenly, then back out sc r e w s until engine runs
sm oothly with highest vacuum gauge reading.
NOTE: If vacuum gauge is not available,adjust
the id le m ixture sc r e w s to give highest idle speed.

m
Turning idle m ixture sc r e w s "in" g iv es leaner
m ixture; w hile turning sc r e w s "out" g iv es richer
m ixture. DO NOT turn sc r e w s in tight against

co
se a ts sin ce sc r e w s or se a ts w ill be damaged.
6. With the aid of a ham m er handle or other
su itab le driving tool in sta ll p la stic caps on each
id le m ixture sc rew as shown in figure 25. Each
p la stic cap is to be installed in fuel RICH position

.
(as shown). Tang on cap should contact roll pin in

ry
throttle body of carburetor. U se care when in sta ll­ Figure 2 5 — Installing Plastic Limiter Caps
ing caps to prevent bending of idle m ixture sc r e w s. (Bendix-Strom berg CarburetorI
7. R eset the engine idle speed as directed in
rotating clockw ise to LEAN m ixture until the idle
Step 4.
8. Turn "in” idle m ixture screw s equally by speed is reduced to 600 rpm .
b
SPECIFICATIONS
ra
YARI-SPEED GOVERNOR
rli
MAX. GOVERNED
INTROL ENGINE SPEED (RPM )*
PART NO. GMC PART NO. MODEL NO LOAD
ca

901-685 2472969 351C 3900

651-735 3929621 250 2400
601-734 3929623 250 3900
651-739 3929625 292 2400
292 3900
ic

601-738 3929627
651-759 3938709 292 2400
601-758 3938708 292 3900
s

* With Engine broken-in. Full load is approximately 300 RPM less than No Load RPM and will vary from engine to engine.
as

FUEL PUMP
ENGINE PRESSURE VOLUME
V6 51/2-6 1 pint in 20-25 seconds
cl

In-Line 4-5 1 pint in 35-40 seconds

350 V8 7V2-9 1 pint in 20-25 seconds
366 or 427 V8 71/2-9 1 pint in 10-15 seconds

TORQUE CHART
CARBURETOR TO MANIFOLD FT. LBS.
Bolts (V6 Engine). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
Nuts (V8 Engine). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
Nuts (In-Line Engine). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-30
Nuts (V6 Engine with Vari-Speed Governor). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
 Sec. 6M
P a ge 33

FUEL SYSTEM—GASOLINE ENGINES

ROCHESTER CARBURETOR SPECIFICATIONS

CARBURETOR “M” “2G"

MODEL NUMBER
Carburetor N u m b e r..................... 7042011 7042012 7042134 7042124 7030699
Engine M odel............................. 250 292 350 350 350
Float Level .............................. 1 /4 1 /4 23/32 23/32 23/32
Float Drop .............................. — — 1 9/32 1 9/32 1 9/3 2
Accelerator Pump ..................... — — 1 1 /2 1 1 /2 1 1 /2
Metering R o d ............................. 0.070 0.070 — — —

m
Idle V e n t .................................. — — 0.025 0.025 0.025
Fast Idle (B e n ch )........................ 0 .1 0 0 0 .1 0 0 — — —

Fast Idle (R u n n ing)..................... 2400 RPM — — —

Governed Speed * ..................... 4000 RPM (Except w/AT475 Transmission) 3000 RPM

co
— —

(Full Load) Vacuum Spinner Type 4100 RPM (w/AT475 Transmission)

* No Load Speed is Approximately 200-250 RPM Higher Than Full Load.

y.
HOLLEY CARBURETOR SPECIFICATIONS

CARBURETOR MODEL 4150G

r
Engine Displacem ent........................................... 366 427
GM Part Number ..............................................
ra
Holley Part N u m b er...........................................
Fuel L e v e l........................................................
b
Accelerator P u m p ..............................................
685981
R-6292A

0.015 Min.
Bottom of Sight Plug
685982
R-6293A

0.015 Min.
Air V e n t........................................................... 0.060 0.060
Fast Idle Mechanical 0.035 0.035
rli
Running 1800-2400 RPM 1800-2400 RPM
Main Metering Jet Primary #56 #56
#71
ca

Secondary # 7 1
Throttle Bore Primary 1 9/16 1 9/16
Secondary 1 9/16 1 9/16
Governed Speed * 4000 RPM (Except w/AT475 Transmission)
(Full Load) 4100 RPM (w/AT475 Transmission)
ic

* No Load Speed is Approximately 200-250 RPM Highter Than Full Load.

ss

BENDIX - STROMBERG CARBURETOR SPECIFICATIONS

CARBURETOR SERIES WW
a

Engine Displacement 351C* 351C**

GM Part No....................................................... 685275 687113
cl

Bendix No......................................................... 381304 381312

Code No............................................................ 23-244 23-248
Venturi Size ..................................................... 1 3/16 1 3/16
Main Discharge Jet No.......................................... No. 28-36 No. 28-36
Main Metering Jet S iz e ........................................ 0.058 0.057
High Speed B le e d e r........................................... No. 70 No. 70
Power By-Pass J e t .............................................. 2 No. 60 2 No. 59
Accelerator Pump Discharge Jet ........................ No. 70 No. 70
Float Level ...................................................... 0.190 0.190
Accelerator Pump Travel ................................... 0 .4 2 0 -0 .4 5 0 0 .4 2 0 -0 .4 5 0
* Excluding California Vehicles.
** California Vehicles Only.
Sec. 6M
P a ge 34

QMG ubielel Ctupitte

A ll inform ation in S ervice Manual S T -331-71 pertaining to
ENGINE FUEL SYSTEM (SEC. 6M), pages 6M-1 through 6M -26 is
applicable to m od els covered by this supplem ent with the exception
of the following:

m
ACCELERATOR LINKAGE ADJUSTMENT
(STEEL TILT CAB MODELS)

co
1. T ilt cab forw ard. PLACE A N D SECURE ADJUST BALL JOINT " B ”
ACCELERATOR PEDAL AT INJECTION PUMP
2. With a c celera to r controls in stalled , make Z4” FROM FLOOR MAT TO OBTAIN FULL THROTTLE
su re threads of ball joint "A” are engaged as

.
shown in figure 2.

ry
3. D ep ress a cc e le ra to r pedal to %" (fig. 2)
from floor mat.
4. Adjust ball joint "B" at injection pump
throttle le v e r to obtain full throttle.
NOTE: It may be n e c e ssa r y to adjust ball joint
"B" (minimum engagem ent at either ball joint no
ra Aa T W^
BOOT
THREADS OF BALL
£

JOINT " A ” EN G AG ED '/2'

lib
le s s than %"). CHECK POINTS AT ADJUSTMENT POINT AT
ACCELERATOR PEDAL INJECTION PUMP O N ENGINE
5. Lower cab to operating position.
NOTE: A ccelera to r pedal linkage is properly
ar

adjusted when a cceleratin g pedal is contacting

floor mat and the fuel injection pump lev er is in
full throttle position. Figure 1— Steel Tilt C ab Acceleration Linkage
cc
si

A iA . G le a tte te
as

(ALL ENGINES)
A ll inform ation in S erv ice Manual ST -331-71 "AIR CLEANERS”
p ages 6M -27 through 6M-31 is applicable to m odels covered by this
supplem ent with the exception of the following:
cl

A ir clea n ers should be inspected and ser v ic ed at in tervals s p e c i­

fied in E m issio n Control booklet, or m ore often under s e v e r e dust
conditions; a lso , w henever dirt is v isib le in elem ent or o il. A ir clea n ers
on v eh icles operating in dust sto rm s should be cleaned im m ediately
a fter such sto rm s occur.
The air clean er should be inspected to make certain that all h oses
and ducts are intact and co rrectly in stalled . O perational function should
be checked by inspecting position of valve in air intake (when used).
With engine stopped, valve should be open. At underhood tem perature
below 100°F ., with engine running, valve should be partially or fully
c lo se d . A s engine underhood tem perature r is e s , the valve should open.
 Sec. 6T
Page 35

SECTION 6T
GosnfLSiedAxM a n d Cj&ue/istosiA,
S erv ice inform ation applicable to air co m p re sso r s and governors
u sed on v e h ic le s covered by this Supplement rem ains the sam e as
covered on p ages 5D -80 through 5D -93 in AIR COMPRESSORS AND
GOVERNORS (SEC. 5D) in S ervice Manual S T -331-71 except as follows:

m
GENERAL INFORMATION in p r e ssu r e adjusted to 85 PSI and the cut-out
p r e ssu r e adjusted to 100-107 p si.
Midland R oss and Bendix W estinghouse air

co
co m p r e sso r s are interchangeable as com plete a s ­ GOVERNOR ADJUSTMENT CHART
se m b lie s on all m odels covered by this Supplement.
R efer to ,TA ir C om pressor Model Application Chart" C om pressor Governor Cut-In Cut-Out
la te r in this section . Model Model P r e ssu r e P r e ssu r e

y.
MIDLAND-ROSS
N -5601-R N -20856 85 P si. 100-107 P si.
GOVERNOR ADJUSTMENT N -5601-S N -20856-C 105 P s i. 105-127 P si.

r
N -6400-N N -20856-C 105 P s i. 105-127 P si.
Inform ation applicable to governor adjustment
N -5217-B A N-20856-C 105 P s i. 105-127 P si.
rem ain s the sam e as covered on page 5D-92
under “ A ir C om pressor G overnor” in AIR COM­
PRESSORS AND GOVERNORS (SEC. 5D) in Serv­
ic e Manual ST-331-71 except as follows:
b
The Midland R oss N-20856 governor used on
ra BENDIX WESTINGHOUSE
281977
282564
282567
276102
276226
276226
105
105
105
P s i.
P s i.
P s i.
125
125
125
P s i.
P s i.
P s i.
the N -5601-R air com p resso r should have the cut- 282896 276104 105 P si. 125 P s i.
rli
AIR COMPRESSOR MODEL APPLICATION CHART
ca

TRUCK COMPRESSOR MANU­ C U .-F T . TYPE TYPE TYPE

MODELS MODEL FACTURER CAPACITY COOLING DRIVE FILTER

STANDARD
50 SERIES
ic

CE, SE N -5601-R or M-R 1A A ir B elt Paper F ib ers

282567 B-W n Air B elt Foam
ss

CG, SG N -5601-S or M-R n A ir B elt Paper F ib ers

282896 B-W n A ir B elt Foam
SM 281977 or. B-W n Air B elt P aper
N -6400-N M-R ta Air B elt Paper F ib ers
TG N -6400-N or M-R TA Air B elt P aper F ib ers
a

281977 B-W TA Air B elt P aper

60 SERIES
cl

CE, ME, TE N -5601-R or M-R n A ir B elt Paper F ib ers

282567 B-W TA A ir B elt Foam
CM, TM N -6400-N or M-R n A ir B elt Paper F ib ers
281977 B-W TA Air B elt Paper

OPTIONAL
50 SERIES
CE, SE N -5217-B A M-R 12 Water B elt Paper F ib ers
or 282564 B-W 12 Water B elt Foam
60 SERIES
CE, ME, N -5217-B A M-R 12 Water B elt Paper F ib ers
TE or 282564 B-W 12 Water B elt Foam
Sec. 6T
P age 36________________________________________

AIR COMPRESSOR A N D G O V ERN O R

m
co
NOTE
The air com p resso r is the ONLY sou rce of supply for the veh icle

.
braking sy ste m . Faulty operation of the com p resso r w ill resu lt in im ­

ry
proper function of brakes.

ra
lib
ar
cc
si
as
cl
 Sec. 6Y
Page 37

SECTION 6Y
£ n a in e Z le c t t U c a l

NOTE: E le c tric a l sy stem inform ation applicable to m odels

covered by this supplem ent rem ains the sam e as covered on pages

m
6Y -1 through 6Y -68 in ENGINE ELECTRICAL (SEC. 6Y) in S ervice
Manual ST -331-71 except as follow s:
This group, covering “ ON-VEHICLE MAINTENANCE AND RE­
PLACEMENT” of charging sy ste m components is divided into section s

co
shown in the index following:

y.
Subject P age No.
B attery .......................................................................................................~ ! 37
Model Application Chart .................................................................... 37
B attery Specifications ........................................................................ 39

r
Starting System ............................................................................................... 39

ra
Model Application Chart ....................................................................
Starting System Specifications .........................................................
Ignition S y s t e m ..................................................................................................
Ignition System Specifications .........................................................
b
A lternating Current Generating System (Non-Integral Type) . .
39
41
42
42
43
Model Application Chart .................................................................... 43
rli
ca
ic
ss

S erv ice inform ation applicable to b a tteries used on v eh icles

covered by this supplem ent rem ains the safne as covered under
"BATTERY” pages 6Y-1 through 6Y -11, in ENGINE ELECTRICAL
(SEC. 6Y) in Serv ice Manual S T -331-71, except as follows:
a
cl

BATTERY MODEL APPLICATION CHART

TRUCK SERIES
STANDARD PART NO. MODEL
S e r ie s T E /T M -50 (03): T E /T M -60 ( 0 3 - 1 3 ) ............... 1980030 E -5000
S e r ie s C E /C S-40; C E /C M /C S -5 0 ................................. 1980145 E-5000
S e r ie s C E /C M /M E -6 0 .......................................................... 1980145 E-5000
S e r ie s S E /S M /S S -5 0 ............................................................. 1980149 E-5000
S e r ie s C G /SG /TG -50 .......................................................... 1980758 20T-4A
(Cont’d.)
S e c . 6Y
P a g e 38
BATTERY

BATTERY MODEL APPLICATION CHART (CONT.)

TRUCK SERIES
OPTIONAL PART NO. MODEL
S e r ie s T E /T M -50; T E /T M -60 .........................................1980038 E-3000
S e r ie s C G /SG /T G -50 .............................................................. ...1980046 8D-250
S e r ie s C E /C S-40; C E /C M /C S-50 ................................... 1980149 E -5000
S e r ie s C E /C M /M E -60 .............................................................. ... 1980149 E -5000

GENERAL 2. Rem ove vent caps from both the booster and
the discharged b atteries. Lay a cloth over the open

m
On S e r ie s 40 through 60 conventional cab vent w e lls of each battery. T hese two actions help
ga so lin e engine m odels, a sin g le 12-volt battery is reduce the p ossib ility of explosion which is alw ays
mounted in the right front corner of the engine p resen t when connecting a "live" booster battery

com partm ent.
On ste e l tilt cab m odels equipped with the
g a so lin e engine, a sin g le 12-volt battery is mounted
forw ard of radiator above the cro ssm em b er inside
the right-hand fram e ra il,
co
to a "dead" battery.
3. Attach one end of one jumper cable to the
p o sitiv e term inal of the b ooster battery (identified
by a red color, "+" or "P" on the battery ca se ,
post or clamp) and the other end of the sam e cable

.
On v eh icles equipped with the Turbium or 6V- to the p o sitiv e term inal of the discharge battery.

ry
53 D etroit D ie se l Engine, a sin g le 12-volt battery DO NOT perm it v eh icles to touch each other as this
is mounted on the fram e ra il behind the cab. could estab lish a ground connection and counteract
the benefits of this procedure.
USE OF BOOSTER BATTERY
A N D JUMPER CABLES

CAUTION
b ra 4. Attach one end of the rem aining negative (-)
cable to the negative term inal (black color, "-" or
"N") of the booster battery, and the other end to
ground location on the v eh icle being started. DO
NOT CONNECT DIRECTLY TO NEGATIVE POST
OF DEAD BATTERY - taking care that clam ps
rli
Any procedure other than the follow­ from one cable do not inadvertantly touch the
ing could result in: clam ps on the other cable. DO NOT lean over the
battery when making th is connection.
1. Personal injury caused by electrolyte
NOTE: The ground location for m odels having
ca

squirting out of the battery vents.

the battery in stalled under the hood is on the engine.
2. Personal injury or property damage
The ground location for m odels having a fram e
due to battery explosion.
mounted battery is on the fram e r a il. The ground
3. Damage to the charging system of the
is to be at le a st 12 inches from the battery fille r
booster vehicle or of the immobilized
ic

cap s, providing good e le c tr ica l conductivity and

vehicle.
current carrying capacity, and must avoid moving
DO NOT attempt to jump start a ve­ hot or e le c tr ica l hazards such as fans, m anifolds,
s

hicle having a frozen battery because the and spark plug term in als.
battery may rupture or explode. If a frozen
as

battery is suspected, examine all fill vents DISCONNECTING BOOSTER BATTERY

on the battery. If ice can be seen, or if the
electrolyte fluid cannot be seen, do not
attempt to start the vehicle with jumper
cables as long as the battery remains
cl
AND JUMPER CABLES
1. Taking care that clam ps from one jumper
cable do not inadvertently touch clam ps on other
jumper cable, disconnect jum per lead from ground

frozen. location on the veh icle being started. DO NOT lean

Both the booster battery and the d is­ over the battery when disconnecting this lead.
charged battery must be treated carefully 2. Rem ove rem aining end of negative (-) jump­
when using jumper cables. Follow E X A C T ­ er cable from the b ooster battery.
LY the procedure outlined below, being 3. R em ove one end of the rem aining jumper
careful not to cause sparks. cable from p ositive term inal of the discharged
battery, then rem ove other end of the sam e cable
CONNECTING BOOSTER BATTERY from p ositive term inal of the b ooster battery.
AND JUMPER CABLES 4. R em ove cloths, from open vent w ells of
1. Set parking brake and p lace automatic each battery. D iscard cloths as they may have c o r ­
tra n sm issio n in "PARK" (neutral for manual tra n s­ ro siv e acid on them . Install vent caps on both the
m issio n ). Turn off lig h ts, heater and other loads. b ooster and the discharged battery.
 Sec. 6Y
P age 39

STARTING SYSTEM

BATTERY SPECIFICATIONS
i
PART NO. 1980030 1980038 1980046 1980145 1980149 1980758
Make Delco-Remy Delco-Remy Delco-Remy Delco-Remy Delco-Remy Delco-Remy
f Model No. E-5000 E-3000 8D-250 E-5000 E-5000 20T-4A
Catalog No. R-59 Y-71 985 R-89 R-89W 759
Volts 12 12 12 12 12 12
No. of Plates Per Cell 11 11 29 11 15 19

m
Cranking Power @ 0°F. (Watts) 2900 3000 5900 2900 3750 4500
Amp. Hr. Capacity at 20 Hr. Rate 61 70 205 61 80 150
Cranking Ability at 0°F. and 300 Amps. 1.6 Min. 2.0 Min. 10.5 Min. 1.6 Min. 2.6 Min. 6.0 Min.
Load Test

co
Amp Load 180 210 450 180 230 450
Voltage and Temperature Chart* No. 1 No. 1 No. 1 No. 1 No. 1 No. 1
* Voltage must not drop below minimum listed at given temperature when battery is subjected to proper load for 15 seconds and is 1.200 specific gravity at
80°F. or more.

y.
CHART NO. 1 - VOLTAGE AND TEMPERATURE CHART
Electrolyte Temperature 80°F. 70°F. 60°F. 50°F. 40°F. 30°F. 20°F. 10°F. 0°F.

r
Voltage Minimum 12-Volt 9.6 9.6 9.5 9.4 9.3 9.1 8.9 8.7 8.5
b ra
S t a / d in a S y it e t n
rli

Starting sy stem inform ation applicable to v e h ic le s covered by

th is supplem ent rem ains the sam e as covered under "STARTING
ca

SYSTEM" p ages 6Y-12 through 6Y -16 in ENGINE ELECTRICAL (SEC.

6Y) in S erv ice Manual ST -331-71 except as follow s:

STARTING MOTOR MODEL APPLICATION CHART

ic

STANDARD
ss

TRUCK SERIES PART NO.

CE-40; C S/SS-50 ............................................................................... 1108360
C E /S E /T E -5 0 ...................................................................................... 1108362
CS-40 (With Autom atic T r a n s m is s io n ).................................. 1108367
a

CS-40 (With Manual T r a n s m is s io n ) ........................................ 1108368

CM /SM /TM -50; CM /TM -60 ......................................................... 1108483
C E /M E /T E -60 ..................................................................................... 1108487
cl

C G /SG /TG -50 ........................................................................................ 1113686

4 OPTIONAL
PART NO.
CE/CS-40; C E-50 (03-13); C S /S E /S S -5 0 ............................... 1108486
CS-40; CE-50 (02); C S /S E /T E -50 ........................................... 1108485
SE -50 ....................................................................................................... 1108372
C E -50 (03-13); Except With A T-540 Automatic T rans. . . 1108485
C S-40 With L6-292 Engine and Manual T ran sm ission . . 1108360
C E /SE -50 With V 8-366 E n g in e ...................................................... 1108369
T E -50 With V 8-366 Engine . ........................................................... 1108487
C E -60 (03-13); M E /T E -60 With V 8-427 Engine ............ 1108484
Se c . 6Y
P age 40

STARTING SYSTEM

€ > j- * 0 0 B L K — ||l> FRAME

— — (AMMETER. SH UNT)' STARTER ASM.

FRAME

110 BLK. (AMMETER SHUNT)' STARTERASM.

TO AMMETER AND VOLTMETER }
GENERATOR TRANSISTORIZED VOLTAGE REGULATOR
»
GENERATOR VOLTAGE REGULATOR \

m
16 BLK

--------- 16 BLK------------------
TO ACCESSORY BUS BAR

■16BLK-

co
STARTER MAG. SW.

■H
hQQQr-O-
CONTROL STARTER MAG. SW . STARTER CONTROL
SW. RELAY

STARTER CONTROL I6BLK

RELAY

.
I6 B L K '

ry
CONTROL SW.
---14 PIN K --- TRANSMISSION
■12PU RPLE' •12PURPLE' CONTROL

WITH M ECHANICAL TRAN SM ISSIO N WITH AUTOMATIC TRANSM ISSION

ra
Figure 1— Starter Automatic D isengagem ent and Lock-Out (Series TG50) (Typical)
lib
STARTER AUTO M ATIC
DISENGAGEM ENT A N D LOCK-OUT
Information applicable to the Starter Automatic
ar

D isengagem ent and Lock-Out sy ste m used on S eries

C G /SG /T G -50 rem ain s the sam e as covered under
“ Starter Autom atic D isengagem ent and Lock-Out”
cc

in ENGINE ELECTRICAL (SEC. 6Y) in S ervice

Manual ST -331-71 except as follow s:
NOTE: A typ ical sy ste m u sed on S e r ie s TG-
50 is shown in figure 1, and a typ ical sy stem used
si

on S e r ie s CG /SG -50 is shown in figure 2.

On som e v eh icles equipped with the automatic
tra n sm issio n , the sta r te r magnetic sw itch operat­
as

ing c o il is energized through the combination neu­

tra l safety and back-up lamp sw itch when the tra n s­
m issio n shift lev er is in neutral position.
When tra n sm issio n shift lev er is in neutral
p osition and engine control sw itch is placed in
cl

’'START" position, current from the battery w ill

en ergize the sta rter m agnetic sw itch operating
c o il through the com bination neutral start and
back-up lamp sw itch, thus com pleting circuit to the
starting m otor. When tra n sm issio n is shifted out
of neutral, feed circu it to sta rter m agnetic sw itch
operating co il is broken, thus preventing sta rter Figure 2 — Starter Autom atic D isenga ge m en t and Lock-Out
engagem ent. (Series C G / S G 5 0 ) (Typical) f
 Sec. 6Y
P age 41
STARTING SYSTEM
STARTING SYSTEM SPECIFICATIONS

1108360 (a) 1108369

STARTER MODEL 1108362 (b) 110836/ 1108368 1108372
M a ke .............................. Delco-Remy Delco-Remy Delco-Remy Delco-Remy
S e r ie s ............................. 10MT 10MT 10MT 10MT
Type .............................. 125 125 125 125
Type of D riv e ................... Overrunning Overrunning Overrunning Overrunning
Clutch Clutch Clutch Clutch
Rotation (Viewed at Drive End) CW CW CW CW
No Load Test
9 9 9

om
V o lts ........................... 9
Min. Amps. * .............. 55 50 50 35
Max. Amps. * .............. 80 80 80 75
Min. RPM ................... 3500 5500 5500 6000
Max. R P M ................... 6000 10,500 10,500 9000
Pinion C le a ra n ce .............. 0.010” -0.140" 0.010” -0.140” 0.010” -0.140” 0.010” -0.140”

.c
* Includes Solenoid
1114356 (a)
STARTER SOLENOID MODEL 1114344 (b) 1114362 1114356 1114356

ry
Rated Voltage ................. 12 12 12 12

Current Consumption
Pull-In Winding ra
Amps.......................... 13-15.5 13-15.5 13-15.5 13-15.5
V o lts ......................... 5 5 5 5
Hold-ln Winding
lib
Amps.......................... 14.5-16.5 14.5-16.5 14.5-16.5 14.5-16.5
V o lts ......................... 10 10 10 10
ar

1108485
1108486
STARTER MODEL 1108483 1108484 1108487 1113686
cc

M ake.............................. Delco-Remy Delco-Remy Delco-Remy Delco-Remy

S e r ie s ............................. 10MT 10MT 10MT 35MT
Type .............................. 125 125 125 185
Type of D riv e ................... Overrunning Overrunning Overrunning Overrunning
i

Clutch Clutch Clutch Clutch

ss

Rotation (Viewed at Drive End) CW CW CW CW

No Load Test
V o lts ......................... 9 9 9 9
Min. Amps. * .............. 55 35 35 130
a

Max. Amps. * .............. 80 75 75 160

Min. RPM..................... 3500 6000 6000 5000
Max. RPM.................... 6000 9000 9000 7000
cl

Pinion Clearance .............. 0.010” -0.140" 0.010”-0.140” 0.010” -0.140” .0.010” -0.140”
* Includes Solenoid

STARTER SOLENOID MODEL 1114356 1114359 1114356 1115518

Rated Voltage ................. 12 12 12 12

Current Consumption
Pull-In Winding
Amps.......................... 13-15.5 13-15.5 13-15.5 26-29
V o lts ......................... 5 5 5 5
Hold-ln Winding
Amps.......................... 14.5-16.5 14.5-16.5 14.5-16.5 18-20
V o lts ......................... 10 10 10 10
Sec. 6Y
P age 42

9 < f4 u tiQ * t

Ignition sy ste m inform ation applicable to v e h ic le s covered by this supplem ent

rem ain s the sam e as covered under ‘‘IGNITION SYSTEM” pages 6Y-17 through
6Y-31 in ENGINE ELECTRICAL (SEC. 6Y) in S ervice Manual S T -331-71, except
r e fe r to ignition sy ste m sp ecification s following:

IGNITION SYSTEM SPECIFICATIONS

m
366
ENGINE DISTRIBUTOR 250 292 351-C 350 350 427

Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Delco-Remy Delco-Remy Delco-Remy Delco-Remy Delco-Remy Delco-Remy

co
Model No. .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . . .. 1110489 1110486 1110478 1111364 1112048 1111365
Rotation (Viewed at R otor)................. Clockwise Clockwise Clockwise Clockwise Clockwise Clockwise
Point Opening (In.)
N e w .................................... 0.019 0.019 0.019 — — —

.
Used ............ . . . . . . . . . . . . . . . . . . . . . . 0.016 0.016 0.016 — — —

ry
Cam Angle (Degrees). .. . . .. . .. . .. . . .. . .. . . 31-34 (1) 31-34 (1) 31-34 (1) 28-32 (2) 28-32 (2) 28-32 (2)
Centrifugal Advance
Start D e gree s. . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2 0.5-2.5 0-2 0-2 0-2 0-2
R P M ................................... 650 600 510 550 600 625
Intermediate D egre es. . . . . . . . . . . . . . . . . . . .
R P M ...................................
Intermediate D egre es. . . . . . . . . . . . . . . . . . . . 6-8 7.5-9.5
ra 4-6
750
6.5-8.5 4-6 4-6 7.S-9.5
lib
R P M ................................... 1150 1050 1100 850 850 1200
Maximum Advance Degrees . . . . . . . . . . . . . 11-13 13-15 10-12 9-11 9-11 12-14
Rpm ................................... 2050 2000 1750 1900 1900 2200
Firing O rder. .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . 1-5-3-6-2-4 1-5-3-6-2-4 1-6-5-4-3-2 1-8-4-3-6-5-7-2 1-8-4-3-6-5-7-2 1-8-4-3-6-5-7-2
ar

*(1) Set with vacuum in full retard.

(2) Satisfactory Range When Adjusting Set to 30° Gives .016 Point Opening.
Ignition Timing
Idle Speed (RPM) . ....................... 700 700 600 600 600 550
cc

Distributor Setting (1 ) . . . . . . . . . . . . . . . . . . . . 4° BTDC 4° BTDC 7 1/2° BTDC 4° BTDC 4° BTDC 8° BTDC

(1) With Distributor Vacuum Ports on Carburetor Plugged.
Distributor Vacuum Control
Model No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1973434 1973435 1973423 NONE 1973437 NONE
si

Inches of Mercury to Start Advance. . . . . . 7-9 8-10 3-5 — 7-9 —

Inches of Mercury for Maximun Advance .. 15.0-16.5 15.5-16.3 6.25-8.2 15-16

Maximun Advance (Distributor D egrees)*... 11.5 9 7.5 — 8 —
as

* * Plus or minus one degree.

Ignition Coil
Model No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115208 1115208 1115205 1115293 1115429 1115293
Spark Plugs
M a k e ................................... AC AC AC AC AC AC
cl

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R-46-T R-44-T CR-43-N R-44-T R-44-T R-43-T (1)

S iz e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14MM-5/8” 14MM-5/8” 14MM-13/16” 14MM-5/8” 14MM-5/8” 14MM-5/8”
Point Gap . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. 0.035 0.035 0.035 0.035 0.035 0.030 (1)
Torque (Ft. L b s.). ....................... 15 15 30-34 15 15 15
(1) Use R-42-T on V8-427 Engine and Set Point Gap to 0.035”.
 Sec. 6Y
Page 43

(NON-INTEGRAL TYPE)

A non-integral (generator and separate regulator) or an integral (generator

with a so lid state regulator built in) type generating sy stem is used on v e h ic le s
covered by this supplem ent.
Inform ation applicable to the non-integral type alternating current generating
sy ste m rem ains the sam e as covered under ''ALTERNATING CURRENT GEN­

om
ERATING SYSTEM” pages 6Y-32 through 6Y-57 in ENGINE ELECTRICAL (SEC.
6Y) in S erv ice Manual S T -331-71 except as follows:
NOTE: Inform ation applicable to the integral type alternating current generat­
ing sy stem rem ains the sam e as covered under "ALTERNATING CURRENT GEN­
ERATING SYSTEM - INTEGRAL TYPE” pages 6Y-58 through 6Y -68 in ENGINE

.c
ELECTRICAL (SEC. 6Y) in S ervice Manual ST -331-71.

MODEL APPLICATION CHART

ry
AMPERAGE USE WITH
STANDARD ra GENERATOR REGULATOR
37-A M P. - C E /C S -40 (02); C E /C S-50 (02) ............ 1100838 1119515
42-A M P. _ C E /C S-40 (03); C E -50 (03-13) .................. ............ 1100842 1119515
42-A M P. _ C M /C S /T E /T M -50 (03); C M /TE/TM -60 ............ 1100842 1119515
lib
42-A M P. - TG -50 (03-13) ...................................................... ............ 1100842 1119507
42-A M P. - C E /M E -60 ............................................................ ............ 1100547 Integral
61-A M P. _ C G /SE /S G /S M /SS -50 ....................................... ............ 1100849 1119515
ar

OPTIONAL
42-A M P. - C E /C S-40 (02); C E /C S-50 (02) .................. ............ 1100842 1119515
42-A M P. _ C E -50 (02-0 3 -1 3 ) ................................................ ............ 1100547 Integral
61-AM P. - C E /C S -40 (02,03); C E/C M /C S-50 ............ 1100849 1119515
cc

61-AM P. - T E /T M -50; C M /T E /T M -60 ........................ ............ 1100849 1119515

61-AM P. _ TG -50 > ..................................................................... ............ 1100849 1119507
61-A M P. - CE-50; C E /M E -60 ....................................... ............ 1100548 Integral
62-A M P. - C E /C S - 40; C E /C M /C S/SE /SG /SM /SS - 50 .... 1117782 1116378
i

62-AM P. _ T E /T M -50; T E /T M -60 ................................. ............ 1117782 1116378

ss

62-A M P. - TG-50 ..................................................................... ............. 1117782 1116374

100-AM P. - S E /S G /SM /SS -50 ................................................ ............ 1117141 Integral
a

GENERATING SYSTEM GENERAL DESCRIPTION

cl

(NON-INTEGRAL TYPE)
The b asic charging sy ste m components include
the battery, the s e lf-r e c tify in g , alternating current
type generator, the voltage regulator, and intercon-
necting w iring.
An indicator lamp (tell-ta le) which indicates
only whether or not the generator is charging is
used on s te e l tilt cab m od els. An am m eter or
v oltm eter type charge indicator is available on all
v e h ic le s covered by this supplem ent.
A typical generating sy ste m used on veh icles
equipped with the tw o-unit type regulator is sch em -
atically illu strated in figure 1, and a typical gen-
erating sy stem used on v eh ic le s equipped with the
tran sisto rized type regulator is sch em atically i l ­
lustrated in figure 2.
NOTE: Schem atic diagram s of generating s y s -
tem s used on veh icles equipped with the integral
type generating sy ste m (generator with internal
tra n sisto rized type regulator mounted within the
generator) are covered la ter in th is section .
S ec . 6Y
Page 44

A. C. GENERATING SYSTEM (NON-INTEGRAL TYPE)

m
. co
ry
Figure 1— Schematic D iagram of A. C. C harging Circuit with Two Unit Type Regulator (Typical)
ra
lib
ar

O - ~ * 0 0 8LK.— ||l' FRAME

FUSIBLE LINK GAS MODELS

-(A M M ETER. SH UNT)' STARTER ASM.

FUSIBLE LINK
DIESEL MODELS STARTER ASM.
TO AMMETER AND VOLTMETER TO STARTER MA6.
JCT. BLOCK-DIESEL MODELS
GENERATOR t r a n s is t o r i z e d vo lta g e r e g u l a t o r SWITCH OffitfNUSED)
cc

GENERATOR 62AMP TRANSISTORIZED V0LTA6E REGULATOR

si

AC C ESSO RY I6BLK ■I6WHT.

as

I6BLK •

STARTER MAG. SW.

STARTER CONTROL
cl

R tLA Y
CONTROL SWITCH

I OT
CONTROL SW.
-— 14 PINK — TRANSMISSION
CONTROL
12 PURPLE 12 PURPLE

WITH 1116374 REGULATOR WITH 1116378 REGULATOR T-9120

Figure 2 — Schematic D iagram of A .C . Charging Circuit with Transistorized Type Regulator (Typical)
 Sec. 7A
Page 45

SECTION 7
* 7\anA M uA A io-n c u iJ l G lu tc h e i
A ll inform ation in Service Manual S T -331-71 pertaining to TRANS­
MISSIONS AND CLUTCHES is applicable to m odels covered by this
supplem ent with the addition of the following:

SECTION 7A

om
GanfruU Jlinkacje.
LINKAGE ADJUSTMENT should be perform ed as d escrib ed p reviou sly, p rior

.c
(AT475 TRANSMISSION) to adjustment of the neutral safety sw itch.
1. B lock driving w h eels, apply parking brake,
MANUAL SHIFT LINKAGE ADJUSTMENT and perform the following to prevent the vehicle

ry
(R efer to Figure 1) from accidentally starting w hile perform ing ad­
The manual shift linkage for the AT475 trans­ justment.
m ission should fully engage all tra n sm ission range
p osition s just before the lev er hits the "stops” in ra
the shift control tow er. Shift the se le c to r lever (B)
through each position w hile feeling for full engage­
ment in the tra n sm issio n . Note the position of the
lib
se le c to r lev er after each shift. T ran sm ission
should not engage ”D" (Drive) or ”R ” (Reverse)
until the se le c to r le v e r on the control tower is
com pletely out of the "N" (Neutral) notch. If lever
ar

is not properly located or operating, the linkage

should be adjusted as follow s:

1. Locate tra n sm issio n se le c to r lev er (B)

cc

against stop in "N" position.

2. Check cable for dim ension shown in View
A -A , and adjust if n e c e ssa r y . Anchor cable to
bracket at point (C).
i

3. D isconnect c le v is (F) from shift cable (I).

ss

Anchor cable (I) secu rely at point (D).

4. L ocate tra n sm issio n shift le v e r (G) in ”N .”
NOTE: Neutral position of tra n sm ission shift
lev er (G) is obtained by rotating le v e r clockw ise
a

com pletely, then back one notch.

cl

5. Adjust c le v is (F) for fr e e -en try of clevis

pin, through tra n sm issio n shift le v e r (G). Then
shorten cable by rotating c le v is two turns clock­
w ise . Tighten jam nut against clev is; in sta ll clevis
pin and secu re with cotter pin.
6. A fter com pleting a ll adjustm ents, operate
v eh icle and check operation of the se le c to r lever
through all shift ranges. Readjust if n ecessa ry .

NEUTRAL SAFETY AND BACK-UP LAMP

SWITCH CHECK AND ADJUSTMENT
(R efer to Figure 1)
NOTE: -'Manual Shift Linkage Adjustment”
Sec. 7B
P age 46
TRA N SM ISSIO N ON-VEHICLE SERVICE
NOTE: Pull secondary w ire out of center
sock et in the distributor cap and ground w ire to
prevent p o ssib le damage to co il.
2. P osition se le c to r lev er in "N" (Neutral).
Turn ignition sw itch to "START" position. Engine
should start but v eh icle must not m ove. Turn ig ­
nition sw itch to "OFF."
3. P osition se le c to r le v e r in "R" (R everse).
Turn ignition sw itch to "START" position. Engine
m ust not start.
4. Move se le c to r le v e r to "D" (Drive) p o si­
tion. Engine m ust not sta rt.
5. If the previous conditions are not met for
the neutral safety and back-up lamp switch,adjust
the sw ivel p osition on rod (H) until operation is as
stated in Steps 2 -4 .
SECTION 7B
On-Velude Sendee. Op&uuUo-HA,
AT475 TRANSM ISSIO N
REPLACEMENT
ra
lib
The follow ing p rocedures apply to vehicles
covered by this supplem ent. However, it may be
n e c e ssa r y to rem ove air tanks, fuel tanks, special
equipment, e tc ., on som e v eh icles to provide
ar
clearan ce before the tra n sm issio n is rem oved.
Overhaul inform ation for the AT475 tran s­
m issio n is contained in 40-60 S eries Truck Chas­
cc
s is Overhaul Manual Supplement S T -334-72.
si
as
cl
Figure l - A T - 4 7 5 Flex Plate Installation
(In-Line and V8 Engines)
DOWNSHIFT SWITCH ADJUSTMENT
NOTE: The downshift sw itch mounted at the
carburetor is activated by the carburetor throttle
le v e r . When the throttle lev er reach es wide open
p osition it resu lts in a forced downshift to the
tra n sm issio n u n less veh icle is in "LI."
1. Move carburetor throttle lev e r to wide
open position.
2. Loosen two adjusting scre w s (at slotted
holes) on sw itch bracket.
m
3. P osition sw itch and bracket assem b ly so
that clearan ce between throttle lev er and sw itch
plunger (fully depressed) is .05-inch.
4. Tighten the two adjusting sc rew s to 20-30
co
inch-pounds torque.
5. Road test and check for proper operation.
.
ry
REMOVAL
1. B lock veh icle so that it cannot m ove. D is ­
connect ground strap from battery negative (-)
p o st. R em ove the spark plugs so the engine can be
turned over manually.
2. R em ove the oil le v e l gauge (dipstick).
Drain tra n sm issio n by disconnecting oil fille r tube
at right sid e of tra n sm issio n . R em ove bracket
holding oil fille r tube to tran sm ission and rem ove
fille r tube from v eh icle. R eplace dipstick in tube
and cover the oil pan opening to prevent entry of
foreign m aterial.
3. D isconnect oil cooler lin es from fittings
on right sid e of tra n sm issio n c a se . Plug line ends
and ca se openings with lin t-fr e e m aterial.
4. D isconnect the manual se le c to r cable from
shift lev e r at left sid e of tra n sm issio n .
5. D isconnect vacuum modulator line from
m odulator.
6. D isconnect the sp eedom eter shaft fitting
from adapter at rear of tra n sm issio n .
7. D isconnect the p rop eller shaft from tran s­
m issio n as d escrib ed in "PROPELLER SHAFTS"
(SEC. 4D) of S ervice Manual S T -331-71.
8. D isconnect the m echanical parking brake
linkage at the right sid e of tran sm ission (if used).
9. Rem ove the sh eet-m eta l under pan from
beneath the converter housing. As the flex-p late
(fig s. 1 and 2) is rotated, rem ove the three bolts
retaining fle x -p la te assem b ly to converter.
10. Support the tra n sm issio n with 500-pound
tra n sm issio n floor jack. The jack must be p osition ­
ed so tran sm ission oil pan w ill not support the
weight of tra n sm issio n . Fasten a safety chain over
top of tra n sm issio n and to both sid e s of jack.
 Sec. 7B
Page 47

TRANSMISSION ON-VEHICLE SERVICE

11. P la ce a support under rear of engine and
rem ove tra n sm issio n exten sio n -to -en g in e rear
support bolts (fig. 3). Then rem ove engine rear
support from fram e of veh icle.
12. Rem ove the tra n sm issio n c a se-to -fly w h eel
housing bolts and w ash ers.
13. C arefully in sp ect tra n sm issio n and sur­
rounding area to be su re no lin e s, h o se s, or w ires
w ill in terfere with tra n sm issio n rem oval.

IMPORTANT: When rem oving tran sm ission ,

om
keep rear of c a se low er than the front so as not to
lo s e the con verter. Install converter holding tool
(J-5384) when tra n sm issio n is rem oved from the
v eh icle.

14. Move tra n sm issio n a ssem b ly from the

.c
engine, low er the assem b ly carefully and move it
out from the v eh icle.

ry
INSTALLATION
1. R aise v eh icle sufficien tly to allow in sta ll­
ation of tra n sm issio n . With tra n sm issio n assem bly
mounted on tra n sm issio n jack m ove tra n sm ission
into position aligning converter with fle x plate
(fig s. 1 and 2). Check for and clean away any for­
ra
eign m aterial in flyw heel pilot hole and flywheel
lib
fle x -p la te assem b ly and front face of tran sm ission
c a s e . Rotate flyw heel ring gear, as n e c e ssa ry , so
that the three bolt h oles in flex plate are aligned
with bolt holes in con verter carefu lly m ove trans­
ar

m issio n assem b ly toward engine so fle x -p la te -to -

con verter bolts can be lo o se ly in sta lled and so
that pilot on tra n sm issio n converter en ters pilot
i cc
a ss
cl

Fig u re 3 —En g in e Rear M ounting with A T -4 7 5 Transm ission

Sec. 7B
P age 48
TRA N SM ISSIO N ON-VEHICLE SERVICE
hole in center of flyw heel flex-p late assem bly.
2. Install bolts and w ash ers that attach trans­
m issio n c a se to flyw heel housing. Tighten bolts to
25-30 foot-pounds torque.
3. Tighten the three flex -p la te-to -co n v erter
b olts.
In-L ine and V8 Engines . 25-30 F t.-L b s.
V6 Engines ........................ 20-30 F t.-L b s.
4. Install engine rear support (see fig. 3).
NOTE: An arrow is stam ped in the center of
the engine rear support. This arrow should face
the front of veh icle when equipped with 292, 350,
or 351C engines. The arrow should face the rear
of veh icle when equipped with 366 engine.
5. C arefully low er engine and transm ission
assem b ly onto engine rear support. Tighten engine
rear su p p o rt-to -tra n sm issio n bolts to torques
sp ecified in figure 3. Bend lock tabs down over
heads of bolts (where used). Remove lifting equip­
ment from beneath v eh icle.
6. Install the sheet m etal underpan beneath
the converter housing.
7. Rem ove plugs from o il cooler lin es and
tra n sm issio n c a se fittin gs. Be sure fittings are
clean and lin t-fr e e , then connect oil cooler lines
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to tra n sm issio n .
8. Install o il cooler tube and bracket on right
sid e of tra n sm issio n . Install oil le v e l gauge (dip­
stick ).
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9. Connect the speedom eter shaft fitting to
adapter at rear of tra n sm issio n .
10. Connect p rop eller shaft to transm ission
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a s describ ed in "PROPELLER SHAFTS" (SEC.4D)
of S erv ice Manual S T -331-71.
11. Connect parking brake linkage (if used) at
sid e of tra n sm issio n .
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12. Connect the manual se le c to r cable to shift
le v e r at left sid e of tra n sm issio n .
13. Connect the vacuum modulator line to
as
modulator.
W A R N I N G : TO P R E V E N T A C C I­
DENTAL ST A R T IN G OF V E H IC LE ,
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W H IL E IN A D R IV E RANGE, BE SURE
THE IGNITIO N SW ITCH IS IN THE "O F F ”
POSITION B E F O R E P R O C E ED IN G TO
THE N EXT STEP.
14. Install spark plugs and connect battery
ground strap, p reviously disconnected (for safety).
15. Connect any other lin e s, h o ses, or w ires
which w ere disconnected to aid in tran sm ission
rem oval.
16. R efer to the "TRANSMISSION CONTROL
LINKAGE" (SEC. 7A) of this supplem ent for ad­
justm ent of manual shift linkage.
AT475 AUTOMATIC T RA N SM ISSIO N
LUBRICATION DETAILS
IMPORTANT: For inform ation on lubrication
in tervals and type of lubricant for AT475 tra n s­
m issio n , refer to LUBRICATION (SEC. 0) of this
manual.
CHECKING FLUID LEVEL
If oil lev e l is too high or too low, foam ing of
o il w ill occur. This w ill affect lubrication, cooling,
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and p r e ssu r e build-up.
The dipstick and fille r tube are located on the
right sid e of tra n sm ission .
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1. Apply parking brake firm ly and block driv­
ing w h eels. Start engine and warm fluid to operat­
ing tem perature.
Move se le c to r le v er through all speed ranges.
.
2. Run engine at idle rpm with lev er in "N"
(N eutral).
ry
3. Clean dipstick and adjacent area, then r e ­
move dipstick, clean, re in ser t, again rem ove and
note fluid le v e l.
ra 4. Add one pint of fluid when lev e l reach es
"ADD" mark.
DRAINING AND FILLING
Drain w hile tran sm ission fluid is at operating
tem perature (160°F . m inimum ).
NOTE: This procedure includes replacem ent
of the oil filte r elem ent.
1. C arefully rem ove oil pan.
2. R em ove bolt holding o il filte r to control
valve body, then pull out o il filte r and oil intake
pipe.
3. Install a new se a l ring onto the top of the
oil intake pipe, and lubricate the sea l ring with the
sa m e oil as used to re fill the tra n sm ission .
4. Insert the intake pipe and sea l ring into the
hole at the bottom of the tra n sm issio n . Install new
o il filte r assem b ly (includes gromm et) onto the
intake pipe. Tighten retaining bolt to 10-13 foot­
pounds torque.
5. Install the oil pan gasket on the o il pan
(using o il-so lu b le g rea se to hold the gasket in
p lace on the pan, if n ecessa ry ).
CAUTION: DO NOT use gasket-type
sealing compounds any place either inside
the transm ission or where they might get
washed into the transmission. Also, any
oil soluble greases may be used for tem­
porarily retaining parts during assembly.
6. Install oil pan and gasket. Tighten oil pan
retaining bolts to 10-13 foot-pounds torque.
7. R efill tra n sm issio n with approxim ately 9%
pints of recom m ended tran sm ission lubricant.
Check le v e l using dipstick; co rrect as n e c e ssa r y .
 Sec. 7C
Page 49

OIL COOLER, LINES,
AND BY-PASS SYSTEM
IMPORTANT: The v e h ic le 's radiator not only
c o o ls the engine coolant, but also coo ls the trans­
m issio n o il. It is im perative that the coolant be at
the proper le v e l at a ll tim e s, otherw ise insufficient
heat dissipation from tra n sm issio n oil w ill result.
An oil cooler located in the radiator, through
which tra n sm issio n oil is circulated before return­
ing to the oil pan, d issip a tes heat created b y normal
operation of the torque converter and tran sm ission .
If a tra n sm issio n failu re occu rs which ca u ses for­
AUXILIARY TRANSMISSIONS
W henever an internal difficulty occu rs in the
tran sm ission which would resu lt in clutch plate
m aterial or m etal p a r tic le s being distributed
throughout the oil sy stem , the oil cooler should be
thoroughly flushed as outlined in the follow ing text,
then an auxiliary filte r in stalled in the cooler r e ­
turn line before the veh icle is returned to serv ice:
1. D isconnect both o il cooler lin es at the fit­
tings at sid e of tra n sm issio n ca se, or if an au xil­
iary filter has been p reviou sly in stalled , d iscon ­
nect cooler return line at filte r instead of at the

eign m atter to be carried into the o il co oler, the
co o ler and all connecting lin es should be thorough­
ly cleaned by flushing before tra n sm issio n is put
back into operation.
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tra n sm issio n . (Change auxiliary filter elem ent.)
2. B ack-flush the o il co o ler and lin e s using
clean solvent and co m p ressed air.
CA U TIO N : DO NOT exceed 100 psi

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FLUSHING OIL COOLER AND LINES
a ir pressure.
It is important that follow ing tra n sm ission
m alfunctions, the tra n sm issio n oil coo ler be prop­
3. R em ove all rem aining cleaning solvent

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erly flushed sin ce foreign p a r tic le s lodged in the
from the sy ste m with com p ressed air.
co o ler eventually becom e free and can cause a r e ­
peated tra n sm issio n failu re. If the oil cooler and 4. Flush the cooling sy stem again with DEX-
lin e s are properly flushed, the p o ssib ility of these ra RON® tra n sm issio n fluid. A fter the final flush,
trou bles reoccurring after the tra n sm ission has test the oil cooler for fre e flow of oil, and if the
been repaired is elim inated or substantially r e ­ flow is re stricted , the radiator bottom tank and
duced. cooler assem b ly must be replaced.
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SECTION 7C
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A u x j li a /u f.

The Spicer 6041 and 7041 A uxiliary T ran sm is­ 7. P osition a suitable dolly or jack under the
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sio n s have new mountings for this year as shown in tran sm ission and adjust to safely carry the weight
figure 2. A uxiliary tra n sm issio n replacem ent of the tra n sm ission .
procedures are d escribed as follow s: 8. Rem ove attaching parts from auxiliary
i
ss

AUXILIARY TRANSMISSION AUXILIARY TRANSMISSION

REPLACEMENT
REMOVAL
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1. Drain lubricant from auxiliary tr a n sm is­

sion .
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2. D isconnect p rop eller shafts from input and

output ends of tra n sm issio n . R efer to "PROPEL­
LER SHAFTS” (SEC. 4D) in this supplem ent.
NOTE: Support p rop eller shafts secu rely to
prevent damage from dropping.
3. D isconnect shift control rods from th efron t
of the tra n sm issio n .
4. D isconnect speedom eter cable from adap­
ter at rear of the tra n sm issio n .
T-6113
5. D isconnect parking brake linkage (when
used).
6. R em ove a ll connections to the auxiliary
tra n sm issio n power tak e-off (when used). Figure J —Front M ount In sta lle d
Se c . 7C
Page 50

AUXILIARY TRA N SM ISSIO N S

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NOTE: See Chart for Dimension "A " T -9 U 9
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Figure 2 — Auxiliary Transmission M o u n tin g

AUXILIARY TRANSMISSION APPLICATION AND ALIGNMENT DATA CHART

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(use in conjunction with Figure 2)

MAIN AUXILIARY FRONT DIMENSION REAR DIMENSION
TRUCK MODELS ENGINE TRANSMISSION TRANSMISSION MOUNTING “A” INCHES MOUNTING “A” INCHES
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M E 6 0 .. . . . . . . . . . . . . . . . . . . . 366 NP542 SP6041 Fig. 2, View A 1-1/8 Fig. 2, View B 2-1/2

M E 6 0 ..................... 366 CL285V SP6041 Fig. 2, View A 1-1/8 Fig. 2, View B 2-1/2
M E 6 0 ..................... 427 CL325V SP7041 Fig. 2, View B 2-11/16 Fig. 2, View B 2-11/16
M E 6 0 ..................... 427 SP5652B SP7041 Fig. 2, View B 2-11/16 Fig. 2, View B 2-11/16
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tran sm issio n front and rear mountings. Lower the IMPORTANT: The preceding step s, se r v e to
as

tra n sm issio n away from the ch a ssis. locate the auxiliary tran sm ission in relation to the
v e h icle's fram e. A lso, it is essen tia l that the aux­
INSTALLATION ilia ry tran sm ission be checked for proper d rive-
1. B e su re the tapered surface of the auxiliary lin e angle adjustment as described under "PRO­
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tran sm issio n front mount fa ces the front of the PELLER SHAFTS" (SEC. 4D) in this supplem ent,
veh icle as shown in figure 1. and if n e c e ssa r y , sp a cers added or rem oved from
2. With tran sm issio n mounted on a suitable rear mounts.
dolly or jack,m ove into position under the vehicle. 5. Reconnect power take-off (when used).
Adjust front and rear height as listed in "Auxiliary 6. R econnect parking brake linkage (when
T ran sm issio n Application and Alignment Data used).
Chart." 7. Connect speedom eter cable to adapter at
3. Torque attaching parts to proper sp ecifica ­ the rear of the tran sm ission .
tions as shown in figure 2. 8. R econnect shift control rods to the front of
4. Reconnect p rop eller shafts to the input and the tra n sm ission and adjust linkage if n e c e ssa r y .
output ends of the tra n sm issio n as described in 9. R efill tra n sm ission with lubricant recom ­
"PROPELLER SHAFTS" (SEC. 4D) in this supple­ mended in LUBRICATION (SEC. 0) of this supple­
ment. ment.
 Sec. 7D & E
Page 51

CLUTCHES

SECTION 7D
C lu tch Go-nbi&U.
MECHANICAL LINKAGE ADJUSTMENT
The 1972 m echanical clutch controls used on conventional cab and cowl m odels
rem ain the sam e as shown in S T -331-71 pages 7D -1 to 7D -3 with the exception
of the r e le a se bearing clea ran ce. R elease bearing clearan ce m easu red at the r e ­
le a s e le v e r or r e le a s e fork is increased from 3 /1 6 " -1 /4 " to the new dim ension of

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0.4".
On tilt cab m odels equipped with In-line or V8 engines the r e le a se bearing
clearan ce m easured at the r e le a se lev er or fork is in crea sed from 3 /1 6 " -1 /4 " to
0.4". The clearan ce on V6 engines rem ains at 1/2".

SECTION 7E

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G h d cU & i

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FRONT DRIVEN DISC

FLYWHEEL H O U S IN G -
ra REAR DRIVEN DISC
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■CLUTCH H O U S IN G
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FLYWHEEL RELEASE BEARING ASSEMBLY

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M A IN DRIVE GEAR
" BEARING CAP
TR A N S M IS S IO N
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M A IN DRIVE GEAR-
ssa

CLUTCH CROSS SHAFT

PILOT BEARING
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RELEASE YOKE

INTERMEDIATE
DRIVE PLATE

PRESSURE PLATE
7 0 -80 FT.LBS: A N D CO VER ASSEMBLY T-9152

Figure 1—Borg & Beck 12-Inch Dual Disc Clutch

S e c . 7E
P age 52_____

CLUTCHES

A ll inform ation pertaining to CLUTCHES as d escrib ed in ST -331-71 pages

7E -1 to 7E -5 is applicable to m odels covered by this supplem ent with the addition
of the following:
It is im portant when installing the B org & Beck 12-Inch Duel D isc Clutch that
the driven d isc hubs face the engine as shown in figure 1.

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 Sec. 9
Page 53

SECTION 9
Steestinxj, S u iiem
T his section is divided into two separate sectio n s as shown in the
follow ing Index:
Section P age No.
9A M echanical S t e e r i n g ............................................................ 53
9B Power Steering ................................................................... 54

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SECTION 9A
M e o lta n ic a l S te e A in x j

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A ll inform ation pertaining to “ MECHANICAL STEERING” (SEC.j
9A) in S ervice Manual ST-331-71 is applicable to m odels covered by
this supplem ent. The following information and illu stratio n s a lso apply.

STEERING GEARS
On all steering gears covered in this supple­
ment w ill have the side cover attached to the main
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housing with flange type cap screw s.
On steerin g g ears 553DV, the stub end of the
steerin g gear worm shaft (fig. 1) w ill have a cro ss
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ry
ra threads are provided to fa cilitate to e-in adjustment.
The tie rod ends are non-repairable and r e ­
quire lubrication as sp ecified in LUBRICATION
(SEC. 0) and inspection to se e that ball studs are
tight. Socket ends should be replaced when e x c e s s ­
ive up and down motion or any lost motion or end
play at ball end of stud e x ists.
NOTE: ALL STEERING COMPONENT AT­

groove and a section of the serration s machined

flat. With the steerin g gear centered, the steering TACHMENTS ARE IMPORTANT ATTACHING
interm ediate shaft clamp yoke and clamp bolt can PARTS IN THAT THEY COULD AFFECT THE
only be installed one way. PERFORMANCE OF VITAL COMPONENTS AND
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SYSTEMS, AND/OR COULD RESULT IN MAJOR

STEERING TIE ROD REPAIR EXPENSE. THEY MUST BE REPLACED
WITH PARTS OF THE SAME PART NUMBERS OR
V ehicles covered in this supplement have a WITH EQUIVALENT PARTS IF REPLACEMENT
i

th ree-p iece tie rod connecting left and right ste e r ­ BECOMES NECESSARY. DO NOT USE REPLACE­
ss

ing a rm s. The tie rod assem bly (figs. 2 and 3) MENT PARTS OF LESSER QUALITY OR SUBSTI­
co n sists of a tube and two socket end a ssem b lies. TUTE DESIGN. TORQUE VALUES MUST BE USED
Socket end a ssem b lies are threaded into tube and AS SPECIFIED DURING REASSEMBLY TO ASSURE
locked in place with clam ps. Right- and left-hand PROPER RETENTION OF THESE PARTS.
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S T E E R IN G G E A R W O R M S H A F T

Figure 1 S t e e r i n g G ear W orm shaft (Stub End) and Interm ediate Shaft Yoke an d C la m p (S M odels)
Sec. 9B
P age 54
POWER STEERING

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1 Cotter Pin 8 Tie Rod Tube
2 Nut 9 End Clamp and Bolt

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3 Steering Arm 10 W asher 1 Cotter Pin 7 End Clamp
4 Stud 11 G rease Cavity 2 Nut 8 G rease Cavity
5 Rubber Dust Cover 12 Lube Fitting 3 Stud 9 Clamp Bolt
6 B a ll Seat 13 Spring 4 Rubber Dust Cover 10 End Stud Seat

.
7 B all Seat Wedge 14 Retaining Plug 5 Socket B earing 11 Spring

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T-9103
6 T ie Rod Tube t-8467 12 Retaining Plug

Figure 2 — Tie Rod End (F070 Axle) Figure 3 — Tie Rod End (All Axles Except F070)

SECTION 9B
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Paw eA. S te & U n a
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A ll inform ation pertaining to "POWER STEERING” (SEC. 9B) in
S erv ice Manual ST -331-71 is applicable to m odels covered by this
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supplem ent. The follow ing inform ation and illu stration a lso apply.

M A IN TEN AN CE 2. Rem ove pump drive belt, if pump is driven

cc

by a separate belt from the crankshaft. This w ill

NOTE: If for any reason the power steering prevent further p o ssib le damage to the pump w hile
sy ste m should fa il, the control valve "locks up" driving with manual steerin g.
and the steerin g gear operates manually, giving 3. If failed component is not at pump, r e ­
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the driver full control of the v eh icle. R esponse of route pump p r e ssu r e line directly back into pump
the steerin g gear in effort applied to the steering r e se r v o ir .
w heel w ill be in creased . If at the tim e of final repair it has been de­
as

Should the power steerin g sy stem becom es
inoperative due to the lo s s of power steerin g fluid,
one of the follow ing step s should be taken before
the truck is moved under its own power or before
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term ined the pump has failed or was damaged to
the point of replacem ent, the entire steerin g sy stem
should be cleaned and flushed out.
Due to scorin g of the pump at tim e of failu re,

running engine: the control valve, and cylinder should be d is a s ­

1. Make all n e c e ssa r y rep a irs, fill and bleed sem bled and any p a r ticles of m etal wiped clean
steerin g sy ste m .
CAUTION: When pump drive belt is
also used to drive the fan or other engine
components it should not be disconnected.
The pump becomes an idler pulley and if
allowed to run dry would burn up bearing
causing fan to stop and possibly damage
engine further. Do not operate pumpwith-
out steering fluid in pump reservoir.
from all p arts. L ines and h oses should be rem oved
and blown clea r . Tag all lin es and h oses for proper
relocation.
POWER STEERING RETURN LINE FILTER
A new disposable type power steerin g return
line filte r is now available for se r v ic e u se.
U se of th is filte r on v eh icle s which operate
under conditions w here considerable dust is p r e s ­
ent should extend power steerin g life considerably.
 Sec. 9B
P age 55

POWER STEERING
Actual conditions w ill dictate rep lacem ent inter­
v a ls, how ever, under norm al conditions rep lace­
ment on a sem i-annual b a sis should be sufficient.
To help prevent repeated fa ilu r e s, it is r e c ­
om m ended that th is filter be in sta lled at time of
overhaul on any unit experiencing a pow er steering
component fa ilu re. When used for this purpose, it
should be replaced after the fir s t 500 m iles of
s e r v ic e .

INSTRUCTIONS
1. Cut a 3 - inch section from the return line

om
h ose and in sta ll the filte r as shown in figure 1.
(Installation should be made as c lo se to the pump
a s p o ssib le.) Care should be taken to ensure hose
clam ps are properly positioned behind sealing
rin gs of filte r .
over se v e r a l tim e s, then r e se t belt to "New" s p e c i­

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NOTE: The direction of flow is indicated on
the filte r and, under no circu m sta n ces, should the fications sp ecified below:
elem ent be rev ersed .
Adjusting Ordinary V -B elt

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2. Tape the filte r elem ent and the return line
to the p r e ssu r e hose as shown. It is important that Using Strand Gauge (Burroughs B T -3 3 -7 3 -F )
NOTE: Gauge should be placed at the center
the return line be taped on both sid e s of the filter
to synchronize vibration. of the grea test span of the belt.
3. B leed hydraulic sy stem as outlined in cur­
rent S erv ice M anuals.
ra a. L oosen pump mounting b olts.
b. If "Used" belt, position pump to obtain 80
to 90 pounds.
c. If "New” belt, position pump to obtain 120
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PUMP DRIVE BELT to 130 pounds.
d. Tighten pump attaching b olts firm ly.
ADJUSTMENT NOTE: A V -b elt is considered "Used" after
NOTE: When adjusting a new drive belt, adjust two hour’s operation or approxim ately 50 to 100
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ten sion to "New" belt sp ecifica tio n s, turn engine m iles operation.

SPECIFICATIONS
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POWER STEERING GEAR APPLICATION CHART

TRUCK SERIES GEAR MODEL RATIO
i

CE/CS40; C E/C G /C M /C S50;

ss

C E /C M /M E 6 0 .......................................... 553-DV 92 and 93 .................. 28.14 to 1

S E /S G /S M /S S 50.......................................................... 553-DV 9 3 .................................. 28.14 to 1
T E /TG /T M 50; T E /T M 6 0 .................................... 553-DV 9 4 .................................. 28.14 to 1
a

POWER STEERING FLUID

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GM APPROVED POWER STEERING FLUID IS AVAILABLE THROUGH

WHOLESALE WAREHOUSES AND TRUCK CENTERS. CHECK FLUID LEVEL
EVERY 6,000 MILES OR FOUR MONTHS, WHICHEVER OCCURS FIRST. IF
GM POWER STEERING FLUID IS NOT AVAILABLE, DEXRON® AUTO­
MATIC TRANSMISSION FLUID MAY BE USED.

CAUTION: DO NOT USE GM POWER STEERING FLUID IN AUTOMATIC

TRANSMISSION.
Sec. 9B
Page 56

POW ER STEERING

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A satisfactory steerin g sy stem depends upon
maintaining components in good condition, with a

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minimum amount of wear perm itted . Proper align­
m ent, and lubrication w ill pay dividends in driver
satisfaction , and in tire econom y.
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 Sec. 10
Page 57

SECTION 10
'U / h e e li a tu H
A ll inform ation pertaining to WHEELS AND TIRES (SEC. 10) of S ervice Man­
ual S T -331-71 is applicable with addition of the following:

GENERAL DESCRIPTION WHEEL STUDS OR BOLTS

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AND NUTS
CAST SPOKE MOUNTING (Refer to F igu res 2 and 3)
C ast spoke w h eels have hub and w heel integral.
Dem ountable rim s are clam ped to w h eels by studs, BUDD DISC STUDS
cla m p s, and nuts. Rim driver blocks at each side Stripped threads on the studs may be the r e ­
of valve stem hole prevent rim slippage and valve sult of e x c e ssiv e torquing of the studs, or it may

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ste m dam age. Figure 1 show s positioning of both be a resu lt of damage during w heel installation,
rim types to w heel with sp a c e r . Depicted a lso are when placing the w heel over the studs.
d ifferen ces in tir e and rim c r o s s se c tio n s. Dual

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rea r tir e spacing is the sum of the w heel offsets
plus rim sp a cer width.
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BUDD DISC TYPE MOUNTING
W heels are secu red to hubs by bolts and ball
sea t type nuts. Unique in the dual rear attachment
is the inner and outer threaded nut arrangem ent
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perm ittin g rem oval of outside w heel without inter­
ferin g with inner w heel.
Where a damaged thread is discovered , the
stud should be replaced.
Broken studs are a direct resu lt of operating
with loose cap nuts or im properly seated w h eels.
When a broken stud is found, a ll the studs
should be replaced. This is b ecau se the other studs
in the a ssem b ly have been subjected to undue
strain in carrying all the load and may have b e ­
com e e x c e ssiv e ly fatigued.

CAST S TEEL SPOKE WHEELS BUDD TY P E DISC W HEELS

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TU BELESS TU BE T Y P E -Tire Clearance

T IR E T IR E T-8280

Figure 1—Wheels and Rim Mounting for Cast Spoke and Budd Type Disc W heels
Sec. 10
Page 58

WHEELS A N D TIRES

F reezin g of Nut
T his condition r e su lts from one of two b a sic
causes:
1. C orrosion or galling of the stud and nut
a ssem b ly can reach a point w here rem oval of cap
nuts is difficult. If this is a p er siste n tp r o b lem , the
threads of the stud and the threads of the inner
cap nut should be cleaned with a w ire brush.
To further aid in th is problem , u se cadm ium
plated cap nuts with a dichrom ate dip.

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2. Im proper tightening of the inner cap nuts.
If the inner nut, during assem b ly, is UNDER­
TIGHTENED to only 200-250 foot-pounds, and then
the outer tightened co rrectly to 500-550 foot­

co
pounds, the very act of backing off the outer nut
w ill so m etim es turn the inner.

CAST WHEEL STUDS

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CAUTION: Insufficient wheel stud
nut torque can cause rim slippage, result­
ing in broken valve stems, worn parts,
wheel shimmy and extreme tread wear.
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damage by stripping studs, collapsing
spacer bands, out-of-round rim condition
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or broken studs or cracks in the stud hole
area.
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WHEEL INSPECTION (DISC TYPE)

WORN WHEEL STUD HOLES (F ig. 5)
This condition w ill usually be accom panied by
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appearance of a shiny worn su rface on w heel face,

indicating that lo o se w h eels w ere moving against
Figure 3 — B u d d Type D a m a g e d or Broken Studs
each other. If the stud h oles are out of shape - oval
or egg shaped - and w here a build-up of m etal is
Dam aged Inner or Outer Cap Nuts (Fig. 4)
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around them , th ese w heels must be replaced.

When th is condition is found - it is a definite
indication of a lo o se mounting condition. Cap nuts CRACKED DISC WHEELS (F ig. 5)
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and stu ds, if n e c e ssa r y , m ust be replaced. If wheel C racks running from hand-hole to stud-hole
ball s e a ts are damaged, the w heel also should be or b olt-h ole to cen ter-h ole or hand-hole to hand-
replaced. hole, or hand-hole to rim , or stud hole to stud-hole,
are a direct resu lt of overloading. Check working
loads of a x le s, discard damaged w h eels, check
cl

w heel studs and com plete assem b ly .

The hub assem b ly may have a worn mounting
fa ce as a resu lt of moving of the inner w heel on
the hub. The studs may have turned in the hub and
worn the stud groove or the studs may have actual
crack s or breaks resu ltin g from tfiis condition.
The wheel may have worn ball se a ts in the stud
h o les. A ll th ese p o ssib ilitie s m ust be checked and
a ll damaged p arts replaced.

DAMAGED OR CRACKED RIMS

The rim a s shown in figure 6 has cracked
Figure 4 — B u d d Type D a m a g e d Inner or Outer Cap Nuts from fatigue and overload. This type of failu re is
 Sec. 10
Page 59

WHEELS AND TIRES

om
.c
ry
Figure 5 —W orn W heel Stud Holes and C racked Disc W heels
ra
com m on to overloaded r im s and dangerous. C are­ Damaged or Sprung Rings
ful checks should be made for this condition be­ Broken or cracked rings as shown in figure 7,
lib
fo re tir e mounting and defective p arts are replaced. are generally caused by rough u se of tir e tools or
C orrosion so m etim es is a lso ob served (fig. 6) im proper in itial seating in gutter of rim . When
and w here co rro sio n is e x c e ss iv e , may cau se poor found, the ring should be replaced. Bent or sprung
seating of lock or sid e rin g s. W here damage of rings are caused by rough and im proper rem oval of
ar

e x c e s s iv e co rrosion is observed, w heel should be this part and cannot be properly sprung back so as
rep laced. to seat accurately in the rim gutter. They should
be replaced.
Rust Streaks on D isc s
cc

Emanating From Stud H oles Cracked or Eroded Side R ings (Fig. 8)

T his is a p o sitiv e indication that the cap nuts Cracks through sid e ring, spreading la terally
a r e , or have been, lo o se . In this ca se , the a sse m ­ through the entire sectio n . T hese are caused by
bly should be checked carefully becau se damage im proper mounting and demounting techniques, im ­
i

to hub, studs, or w heel may have been caused by pact with road obstructions, and e x c e ssiv e clam p­
ss

running in this condition. ing torques.

a
cl

Figure 6—Cracked or Corroded Rims

Sec. 10
Page 60

WHEELS A N D TIRES

Bead sea t a rea s of rim should be fr ee of rust

and rubber d ep osits. This is esp ecia lly important
for drop-center tu b eless rim s, becau se the 15°
bead seat is the a ir -se a lin g elem ent.
Rings should be cleaned with w ire brush. Pay
particu lar attention to seatin g su rfa ces and bead
sea t a r ea s.
Paint rim by brush or spray with a fast-d ryin g
m etal p rim er. Surfaces should be clean and dry
p rior to painting. Insure that bare m etal a rea s on
outside or tir e sid e of rim are covered. This is

m
e sp e cia lly im portant on d rop-center tu b eless rings,
b ecau se warm and som etim es m oist a ir is in con­
stant contact with the m etal surface on the tir e

co
sid e of the rim .

Figure 7— D a m a g e d or Sp rung Rings INFLATION OF TIRES

(R efer to Figure 9)
E rosion and chipping of bead seat of lock ring,

.
resu ltin g from e x c e s s iv e corrosion. Inflate to co rrect p r e ssu r e when tir e s are cool.

NOTE: Insure that replacem ents are made
with the proper s iz e s and types of rim s and rings.
W heel M aintenance
Thoroughly rem ove rust, dirt, and other for­
eign m a terials from all su r fa c e s. Hand or electric
w ire bru sh es, sand blasting or chem ical baths may
lib
be u sed. Gutter of rim b ase should be cleared of
rust and other m a teria ls obstructing sa fe, positive
seatin g of rin gs.
ar
ry
If tir e s are continually carrying le s s than the r e c ­
om m ended maxim um load, adjust air p ressu r e
downward to correspond to the actual load carried.
ra N ever "bleed" tir e s to reliev e build-up of
p r e ssu r e . T ire tem perature w ill in c rea se when the
tir e is in se r v ic e and allow s for the norm al build­
up in air p r e ssu r e . T ire tem perature and air p r e s ­
su re w ill rem ain within lim its that are not harmful
to the tire when used in accordance with the r e c ­
om m endations for load and a ir p r e ssu r e .
If e x c e ssiv e build-up of air p r e ssu r e occu rs,

load, underinflation, speed, or a combination of

th ese is resp on sib le. U se the siz e and type of tire
that has the capacity to carry the load at reco m ­
mended cold starting p r e ssu r e .
cc

TIRES
OVERLOAD
si

Overloading is the cause of many kinds of cord

body breaks and is the m ost costly of a ll truck tire
ab u ses. Such breaks are due to abnormal flexing or
as

overw orking of the cord body of the tir e .

O verload flex breaks occur in the sid ew all or
in the shoulder of a tir e and run with the circu m ­
feren ce of the tir e . Som etim es they are only two
cl

or three inches long.

Figure 9 — Inflation of Tires
Other tim es they w ill extend partly around the
tir e , resulting either in a la rg e blowout or a pinch­
ed tube which allow s the tir e to go flat.
N orm al flexing of a tir e can go on indefinitely
without causing any appreciable damage to the cord s.
But if the tir e is overw orked or overflexed from
overload, abnorm al heat is generated and the cords
becom e fatigued and break.
Underinflation w ill cau se this sam e resu lt. In
addition, crowned roads, sprung a x les, m ism atched
duals and poor load distribution tend to produce
fle x breaks; how ever, overloading exceed s all other

fo rm s of abuse and c o sts truck ow ners la rg e sums
of money annually. This trem endous w aste can be
avoided if trucks are equipped with tir e s and rim s
of the proper s iz e and type, la rg e enough to carry
the load. The rated carrying capacity of a tire can­
not be in crea sed by inflating it beyond the maximum
recom m ended p r e ssu r e .
V alve Stem
A fter installation of tir e s , make su re valve
stem does not r e st on brake drum. If b ra ss stem s
a re too c lo se to the brake drum s, e x c e ssiv e heat
may damage valve and cause p o ssib le lo s s of air
p r e ssu r e .
WHEEL AND TIRE WEAR
CORRECTING IRREGULAR TIRE WEAR
Heel and Toe Wear - - T his is a saw-toothed
effect w here one end of each tread block is worn
m ore than the other. The end that w ears is the one
that fir s t grips the road when the brakes are applied.
H eel and toe w ear is le s s noticeable on rear
tir e s than on front tir e s , because the propelling
action of the rear w h eels crea tes a fo rce which
tends to w ear the opposite end of the tread blocks.
ra
The two fo r c e s , propelling and braking, make for
lib
m ore even w ear of the rear tir e s , w hereas only
the braking fo r c e s act on the front w h eels, and the
saw -toothed effect is m ore noticeable.
A certain amount of h eel and toe wear is norm ­
ar
a l. E x c e ssiv e w ear is usually due to high speed
driving and e x c e s siv e u se of b rakes. The best
rem edy, in addition to cautioning the owner on his
driving habits, is to interchange tir e s regularly.
cc
Side Wear — This may be caused by incorrect
w heel cam ber, under inflation, high cam bered roads
or by taking co rn ers at too high a rate of speed.
The fir s t two ca u ses are the m ost common.
i
ss
Cam ber w ear can be readily identified because it
o ccu rs only on one sid e of the trea d s, w hereas
underinflation ca u ses w ear on both sid e s. Camber
w ear req u ires correctio n of the cam ber fir st and
then interchanging t ir e s . T here is , of cou rse, no
a
co rrectio n for high cam bered roads. Cornering
w ear is d iscu ssed further on.
cl
M isalignm ent Wear - - This is w ear due to
e x c e s s iv e to e -in or to e-o u t. In either c a se , tires
w ill revolve with a sid e motion and scrap e the
tread rubber off. If m isalignm ent is s e v e r e , the
rubber w ill be scraped off of both tires; if slight,
only one w ill be affected.
The scraping action against the face of the tire
c a u se s a sm a ll feather edge of rubber to appear on
one sid e of the tread and th is feather edge is c er ­
tain indication of m isalignm ent. The rem edy is
readjusting to e-in , or rechecking the entire front
end alignm ent if n e c e ssa r y .
C ornering Wear — When a truck m akes an
Sec. 10
Page 61
WHEELS AND TIRES
extrem ely fa st turn, the weight is shifted from an
even loading on all w heels to an abnormal load on
the tir e s on the outside of the curve and very light
load on the in sid e tir e s , due to centrifugal fo rce.
This unequal loading may have two unfavorable
re su lts.
F irst, the rear tire on the inside of the curve
may be relieved of so much load that it is no longer
geared to the road and it s lip s, grinding off the
tread on the inside half of the tir e at the e x c e ssiv e
rate. This type of tir e show s much the sam e ap­
om
pearance of tread w ear as tire w ear caused by
negative cam ber.
Second, the tran sfer of weight may also o v er ­
load the outside tir e s so much that they are la te r ­
ally distorted resulting in e x c e ssiv e w ear on the
outside half of the tir e , producing a type of w ear
.c
like that caused by e x c e ssiv e p o sitiv e cam ber.
Cornering wear can be m ost ea sily distinguish­
ed from abnormal cam ber w ear by the rounding of
ry
the outside shoulder or edge of the tir e and by the
roughening of the tread surface which denotes
abrasion.
Cornering w ear often produces a fin or raised
portion along the in sid e edge of each row in the
tread pattern. In som e c a se s this fin is alm ost as
pronounced as a to e-in fin, and in oth ers, it tapers
into a row of tread blocks to such an extent that
the tire has a definite "step wear" appearance.
The only rem edy for cornering w ear is proper
instruction of operations. D riving m ore slow ly on
curves and turns w ill avoid grinding rubber off
tir e s . To offset norm al cornering w ear a s much as
p o ssib le , tir e s should be interchanged at regular
intervals.
Uneven Wear — Uneven or spotty w ear is due
to such ir r eg u la ritie s a s unequal ca ster or cam ber,
bent front suspension p arts, ou t-of-b alan ce w h eels,
brake drums out-of-round, brakes out of adjust­
ment or other m echanical conditions. The rem edy
in each ca se c o n sists of locating the m echanical
defect and correctin g it.
Powe*r and Speed — E x c e ssiv e speed has a l­
w ays been harmful to tir e s . Speed c r e a te s heat -
heat softens tir e s .
Stops and Starts — Quick stops and sta r ts grind
off tread in a hurry, may cause flat spots which con­
tinue to grow for the life of the tir e.
Tem perature - - C onsiderably le s s m ileage can
be e j e c t e d from a tire used in all warm weather
driving as com pared to a ll cool weather driving, or
from a tire fir st put into se r v ic e in warm w eather.
MECHANICAL IRREGULARITIES (Fig. 10)
Following are som e w heel or v eh icle irreg u ­
la r itie s which may cause rapid or uneven tread
wear:
Toe-In — The w heels on the sam e axle are
c lo se r together in the front than they are in the
Sec. 10
Page 62

WHEELS A N D TIRES

l= d oo
o
_

L
m E.
TOE-IN CAMBER

m
co
/ / « w

.
ry
TOE-OUT SPRUNG OR SA G G IN G AXLE t-8289

feath ered edges on in sid e edge of the skid design.

ra
Figure 10— M echanical Irregularities

re a r . When to e -in is e x c e s siv e the tire wear shows
lib
Toe-O ut — The w heels on the sam e axle are
c lo s e r together in the rear than they are in the front.
T ir e w ear show s feathered edges on outside edge
of the skid design.
ar
tir e to carry the greater load.
Tandem and Spread A xle W heels — F ast tir e
w ear often occu rs on tandem w heels because of
sid e scuffing when the v eh icle rounds a curve and
the tir e s are not moving in a straight path. The
sa m e thing happens when spread axle tir e s are

Cam ber — This design ates the tilt of the wheel.
P o sitiv e cam ber is when w heels are c lo se r together
at point of road contact. N egative cam ber is when
w h eels a re c lo se r together at top. Too much cam ­
cc
dragged or pushed sidew ays; for exam ple, w hile
spread axle tr a ile r s are being spotted at or pulled
away from loading docks.

Sprung or T w isted Fram e — W ill cau se rapid

b er re su lts in e x c e s s iv e w ear on one sid e of tire.
C aster — T his is the backward tilt of the
axle or inclination of the kingpin at the top. Too
little c a ste r ca u ses w heel to wander or weave -
si
or uneven tread w ear.
Grabbing B rakes - - B rak es out of adjustment
and out-of-round brake drum s cause tir e tread s to
w ear rapidly in sp o ts. O ut-of-round brake drums

re su lt, spotty w ear. E x c e ssiv e ca ster may cause u sually wear out tir e s in a sin g le spot. Im properly
w heel "flight” or shim m y w ear. Unequal caster adjusted brakes produce se v e r a l worn p la c e s.
ca u se s w heel to pull to one sid e, resulting in ex­ Worn w heel bearin gs, lo o se radius rods and
as

c e s s iv e and uneven w ear. U -b o lts, unbalanced w h eels, or wobbly w h eels all

Sprung or Sagging A xle - - Either of th ese con­ resu lt in uneven and irregu lar tread w ear.
ditions ca u ses uneven distribution of the load. A At fir s t sign of uneven tir e tread w ear, check
sprung or sagging axle w ill cause the inside dual and co r rect all m echanical ir r e g u la r itie s.
cl

SELECTION OF TIRES
TIRE M A T CH IN G
(R efer to Figure 11)
Unmatched tir e s on eith er Tandem D rive Units
or T ridem D rive U nits w ill cause tire w ear and
scuffing and p o ssib le dam age to the drive units.
Consequently we recom m end the tir e s be matched
to within 1 /8 ” of the sa m e rolling radius, X" of the
sa m e rolling circu m feren ce.
TANDEM UNITS
IMPORTANT: The four la rg e st tir e s should
never be in stalled on one driving axle or the four
sm a lle st tir e s on the other driving axle. Such tir e
mounting w ill cause an in te r-a x le "fight,"unusually
high axle lubricant tem peratures that r esu lt in p r e ­
m ature lubricant breakdown and p o ssib le costly
ax le s e r v ic e .

ry
ra
Fig u re 11 —Types of Tire M easurem ent
lib
In addition to matching individual tir e rolling
radii or rolling circu m feren ce, we recom m end
matching, as nearly as p o ssib le , the total tire
ar
circu m feren ce of one driving axle to the total tire
circu m feren ce of the other driving a x le. This will
u su ally resu lt in sa tisfa cto ry tandem axle lubricant
cc
tem p eratu res that lengthen drive unit se r v ic e with
higher tir e m ileage.
TRIDEM UNITS
i
When three driving a x les a re "hooked" together
ss
in a T ridem S e r ie s, unmatched tir e s w ill compound
the problem s describ ed in the preceding paragraphs.
T h erefore, we recom m end m atching, as nearly
as p o ssib le , the total tir e circu m feren ce of each
a
of the three driving a x le s.
cl
HOW TO MATCH TIRES
TANDEM UNITS
The veh icle should be on a le v e l flo or, carry­
ing a co rrectly distributed rated capacity load. Be
su re a ll tir e s are the sam e s iz e (m easure new tires
to be su re they w ill be co rrectly m atched).
1. Inflate a ll tir e s to the sam e p re ssu re .
2. C arefully m easu re the rolling circum fer­
ence of each tir e with a ste e l tape.
3. Mark the s iz e on each tir e with chalk and
arrange them in order of s iz e , la r g e st to sm a llest.
4. Mount the two la r g e st tir e s on one side of
Sec. 10
Page 63
WHEELS AND TIRES
om
.c
one axle and mount the two sm a lle st on the opposite
sid e of the sam e axle.
5. Mount the four other tir e s on the other axle
in the sam e m anner.
6. T est run the veh icle to get accurate rear
axle lubricant tem perature readings on the two
axle lubricant tem perature gauges.
7. Vary tire a ir p r e ssu r e , within the tire
manufacturer’s recom m ended range, so the lu b ri­
cant tem perature of both a x les is within 3 0°F ., of
each other and not in e x c e ss of 2 2 0 °F. This w ill
usually resu lt in uniform tir e loading and good tire
life.
Follovy the sam e procedure (Item s 1 thru 7)
for matching tir e s on a T ridem Unit. Arrange the
tir e s in order of s iz e . The two la rg est and two
sm a lle st go on one axle, the next two la rg est and
sm a llest on the second axle, and the rem aining
four on the third axle.
M easuring the circu m feren ces of the tir e s with
a ste e l tape after they are on the rim s and inflated
but before they are applied to a v eh icle is the m ost
accurate method.
M easuring in th is manner takes into account
any irre g u la ritie s in w ear. In checking tir e s a l­
ready on a v eh icle, either a square, sim ila r to but
larger than a carp en ter's square, a strin g gauge, a
large pair of c a lip er s, or a wooden straigh t-ed ge
long enough to lie a c r o ss the tread s of all four
tir e s , may be used.
Sec. 10
P age 64

WHEELS A N D TIRES

tir e s and by using w ell worn tir e s on th ese w h eels,

lo s s on tir e s due to road hazards is m inim ized.

NOTE: When rotating any tir e , follow reco m ­

mendations in " selection of tir es" as covered p r e ­
viou sly.

TWO-AXLE TRUCK
T ir e s should be m oved from front w heels to
rear w heels (fig. 12) after 1 /3 of the tread design
is worn off. If there is uneven front w heel tire

m
w ear, rotate tir e s im m ediately and check veh icle
for m echanical ir r e g u la r itie s. When tir e s are
moved to the rea r, follow recom m endations in

co
m atching them with other tir e s .

TRUCK WITH TANDEM AXLE DRIVE

Follow the sam e p ractice as described for

.
sin g le -d r iv e axle except tir e s must be rem oved
Figure 12— Tire Rotation from the fronts at le s s se r v ic e in order to provide

TIRE ROTATION
G enerally, it is the best practice to "breakin"
new tir e s on front w h eels. "Breaking in" on an easy
p osition generally in c r e a se s the overall tire life.
lib
The m ovem ent of the tir e s from front to var­
ious rear w heel p osition s depends upon the type of
unit being operated. It is generally n ecessa ry to
ar
ry
8 tir e s for the rear w heels instead of 4 for the
sin g le -a x le drive. Since there are 5 tir e s on each
sid e of the v eh icle (fig. 12) the front tir e s should
ra
be m oved to the rear when 1 /5 of the tread design
is worn off. Then match tir e s on each w heel as
already d escribed but with an additional precaution
- the sum of the circu m feren ces of the four tir e s
for the front of the tandem drive a x les should equal
the sum of the circu m feren ces of the four tir e s on
the rea r of the tandem a x le s. This precaution is
n e c essa r y to prevent e x c e ssiv e w ear from slippage.

u se tir e s with good non-skid tread design on drive

w h eels. If there is a third differential between the two drive
a x le s, this precaution is unn ecessary.
T ir e s with le a st tread design should be used
cc

TRACTOR AND SEMI-TRAILER

on tr a ile r w h eels, and particularly on the rear of
A fter 1 /5 of the tread design is worn off, tir e s
tandem w h eels. This is due to the fact that cuts are
should be moved from the front to the in sid e or
found m ore often on the tr a ile r and rear tandem
outside driving w heels (shown in figure 13), the
si

position being determ ined by matching as reco m ­

mended. Later the tir e s should be m oved to the
tr a ile r w h eels. The p o ssib ility of injury from cuts,
as

b r u ise s, e tc ., is greater in the tra iler w heel p o s i­

tion. By follow ing this rotation plan with tir e s , end­
ing their se r v ic e on tr a ile r w h eels, at le a st the
g reater portion of the tir e se r v ic e has been ob­
tained even if they are damaged.
cl

TRACTOR WITH TANDEM AXLE DRIVE

Figure 13— Tire Rotation
WITH SEMI-TRAILER WITH TANDEM AXLE
Follow sam e procedure as above for tractor
and se m i-tr a ile r with sin g le -a x le except tir e s m ust
be rem oved from the front w heels at le s s s e r v ic e
in order to provide for 16 tir e s instead of 8. Since
th ere are 9 tir e s on each sid e of the veh icle, the
front tir e s should be moved to the rear when 1 /9
of the tread design is worn off (fig. 13). Then match
tir e s on each w heel as already described but with
an additional precaution - the sum of the circ u m ­
fe r e n c e s of the 4 tir e s for the front of the tandem
 Sec. 10
P age 65

WHEELS AND TIRES

drive a x les should equal the sum of the circum fer­
en ces of the 4 tir e s on the rear of the tandem axles.
T h is'p recau tion is n e c e ssa r y to prevent e x c e ssiv e
w ear from slippage. If there is a third differential
betw een th ese two drive a x le s, d isregard th is r ec­
om m endation. L ikew ise it is to be disregarded for
s e m i-tr a ile r tandem tir e s becau se th ese are on
fr e e -r o llin g w h eels.

SYNTHETIC TUBES AND FLAPS

om
TUBES CHAFED OR PINCHED
BY FABRIC BREAKS
Tubes may fa il as a resu lt of being chafed or
pinched by fabric breaks in sid e the tir e . The d irec­
tion and shape of the tube in ju ries have rather
c lo se ly follow ed the pattern of the fabric breaks.

.c
A tir e does not n e c e ssa r ily go flat im m ediately
when a fabric break o ccu rs on the insid e of the tire
b ecau se it may take som e tim e for the injury to

ry
chafe com pletely through the tube.
T-8305

TUBES DAMAGED BY
MISMOUNTED FLAPS
The tube may becom e chafed by a fold at the
edge of the flap. In mounting tir e s requiring flaps,
it is e sse n tia l that the flaps be properly centered
lib
betw een beads to prevent folds or w rin k les. Flaps
which have once becom e tw isted, c rea sed , or folded
over at ed ges, should not be used again.
ar
ra Figure 14—Im proper Tube Inflation
casing it has becom e stretched and can becom e
crea sed . C reasing can a lso happen to a new tube
of proper s iz e when in correctly mounted. If the
cr ea se occu rs in the flexing area of the tir e , the
resulting additional thickness of the tube where
folded ca u ses a hinging action which cuts the tube

TUBES AND CASINGS DAMAGED and frequently dam ages the fabric - resulting in a
BY FOREIGN MATERIALS IN CASINGS costly failure.
Any foreign m aterial between the casin g and
tube w ill cause a chafing action. In tim e, one or CREASES CAUSED BY
cc

both w ill becom e badly damaged and fa il. The re ­
sult of grit, pebbles, or other hard sub stances which
becom e embedded in the tube w all, w ill chafe tube
and finally cause fa ilu re.
i
REMOUNTING USED TUBES
Tubes usually undergo som e stretch or growth
in se r v ic e . This is particularly true of truck tubes
because of the high tem peratures which develop.

When a used tube is remounted in a new, or nearly

ss

TUBES STRETCHED AND CREASED new tire, a folded condition w ill usually resu lt,
When a tube is la r g e r than the in side of the and eventually w ill cause both tube and tire to fa il.
a
cl

Figure 15—Proper Tube Inflation

Sec. 10
Page 66
WHEELS A N D TIRES
TUBE BREAKS NEXT TO THE VALVE
Im proper inflation procedure may cause a c ir ­
cum ferential crack or tear in the valve base at the
edge of the bridge w asher. Figure 14, View A shows
the position of beads, flap and tube with 4 or 5 lbs.
inflation p r e ssu r e . The tube is fully rounded out
within the tir e , but the p r e ssu r e is insufficient to
m ove the beads on wide base rim s. Depending upon
tir e s iz e and condition of the rim , from 20 to 40
lb s. p r e ssu r e is required to push the beads onto
the tapered bead se a ts as shown in figure 14, View
B.
F orced by th is high p r e ssu r e , the tube can
stretch only in the rim area. B ecause the r e s is t­
ance to stretch is g rea test at the valve b ase, ten­
sion there is often enough to crack the tube at edge
of the valve b ase.
T his can be avoided by proper inflation pro­
cedure as described la ter in this section.
TUBE INSTALLATION
1. Insert tube in tir e and inflate as shown in
figu re 15, View 1. rounded out. U se approximately
1 lb. of air or le s s .
2. Using a brush or cloth swab, apply a solu­
tion of neutral vegetab le oil soap in the area of the
tir e beads, including flap. Do not allow soap solu­
lib
tion to run down into tir e . Extra ply rated tires
may require soap on the rim bead seat area.
3. Mount tir e on rim , center valve and pull it
through hole in rim and hold firm ly against the
ar
rim . Hold in this position w hile inflating until beads
are properly seated.
4. C om pletely deflate by rem oving valve core
or using deflating tool. T his is extrem ely im port­
cc
ant to prevent tube buckling.
5. R e-in flate tube to recom m ended p ressu re
(fig. 15, View 2). R efer t o ’’Load and Inflation Table”
at end of this section .
si
NOTE: U sed flaps may cause tube failure UN­
LESS mounted with the s iz e tir e and rim originally
u sed . When tube and flap are not properly lubri­
as
cated and mounted, they w ill be stretched thin in
the tir e bead and rim region (fig. 15, View 3). This
w ill cause prem ature fa ilu re.
A lw ays clean r im s thoroughly to rem ove rust.
cl
C ertain p recautions m ust be taken when mount­
ing used flap s, or damage to the tire and tube will
resu lt.
New truck and bus flaps can be used with any
one of se v e r a l different tir e and rim s iz e s as r e c­
om m ended. But once u sed , the flap must be r e ­
mounted in the sam e s iz e tir e and on the sam e size
rim from which it w as rem oved. Always use flap
of adequate width to prevent tube pinching.
A s a precaution against flap failure, mark the
tir e and rim s iz e on the flap at the tim e of rem oval
- if inspection show s that it is not damaged and can
be used again. When the flap is again mounted, this
m arking p ro tects against the danger of m isusing
the flap with the wrong s iz e tir e and rim .
New flaps and tubes should be used after tire
or rim rep a irs. It is inexpensive insurance sin ce
sm a ll w ear spots and im perfections in tubes and
flaps are hard to s e e . This could prevent future
tire fa ilu r e s.
TUBE RECOMMENDATIONS
1. Long life and high m ileage receiv ed from
p resen t day tir e s exhaust the useful se r v ic e life of
m
tubes. T herefore, when a casin g is worn to the
point of being unsafe, the tube generally is in the
sam e condition and should be replaced with a new
co
one.
2. If valve cap is lo st, clean end of valve be­
fo re applying air hose to prevent dust and dirt
from being blown into the tube. Apply new cap.
3. When tubes are inflated for inspection, they
.
should not be inflated to the point of ’’ballooning.”
ry
When a tube is ’’ballooned,’’ it thins out in the
stretch ed area, making the tube too large in that
area and resulting in folds or w rinkles when r e ­
ra
mounted.
SPACER B A N D S
INSTALLATION PROCEDURE
1. Check the sp acer band for concentricity,
and a ssu r e yo u rself that it has not been distorted
or bent, or otherw ise m ishandled in shipm ent.
2. Do not move v e h ic le s, w h eels, a x le s, or
a sse m b lie s by rollin g on sp a c er s.
3. P la ce the in sid e rim over the ca st spoke
w heel as far as p o ssib le up to the mounting le v e l.
4. Push the sp acer band over the ca st spoke
w heel with a con sisten t p r e ssu r e on both sid e s.
Guard against cocking. The band should fit snugly
to the spokes and against the in sid e rim gutter
edge. (At this point, the concentricity can be check­
ed by turning the sp acer band on the w heel.)
5. Apply outer rim clam ps. Tighten clam p nuts
evenly to the recom m ended range, 5 /8 ” studs from
150-175 foot-pounds, and %" studs from 190-210
foot-pounds torque. Apply torque evenly by grad­
ually tightening nuts in an alternating pattern a c r o ss
the diam eter of the w h eels.
6. Check to s e e that clam ps do not bottom out,
and be su re the rim edges con sisten tly m eet the
sp acer band edges.
7. R echeck torque after assem b ly is used in
se r v ic e after 500 and 1,000 m ile s.
M O U N T IN G A N D D E M O U N T IN G RIM S
For proper procedures in mounting and de­
mounting different type r im s, refer to figu res 16,
17, 18, 19, and 19a for applicable type.
 Sec. 10
Page 67

WHEELS AND TIRES

M O U N T IN G D E M O U N T IN G

om
Completely deflate tire by removing valve core or

A fter applying tire and tube in usual manner,
place removable side ring (flange) on bead of tire.
Then insert tapered toe of lock ring between side
ring and rim base.
.c
using deflator cap. Place tapered end of rim tool
in depression in lock ring, or between rings, and
press down on side ring to free bead. Continue
downward pressure on side ring progressively
around the tire until the bead is completely freed

ry
from the bead seat.

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cc

To disengage lock ring from the gutter, insert

To fasten lock ring, hold with foot at one end rim tool in removing notch, near split in the ring,
of split and hammer end of ring into place with and push downward. If desired, a second similar
rim mallet. tool may be used to facilitate removal.
i
ss
a
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Continue progressively around the rim, holding Insert the rim tool between the lock ring and side
ring with foot and hammering until entire ring ring and press downward to pry ring up. Move
is seated. Check seating of rings and inflate tire progressively around the rim until lock ring is
to recommended pressure. fr e e , then lif t o f f lock and sid e r in g s. Turn
assembly over, unseat tire bead, stand tire up and
remove rim base,
_____________________________________ T-8307

Figure 16—M ounting and Demounting 3-Piece Convertible Rims

Sec. 10
Page 68

WHEELS A N D TIRES

M O U N T IN G D E M O U N T IN G

To fa s te n side rin g , p lace fo o t a t one end n e a r th e
s p lit an d p u sh dow n in to p lace.
m
co
C o m p le te ly d eflate tir e , th e n w ith cu rv e d end o f
rim to o l a n d h o o k ed -en d rim to o l p r y b e a d loose
fro m side rin g by d o w n w a rd p re s s u re on rim to o ls.
C o n tin u e p ry in g o p e ra tio n p ro g re s s iv e ly a ro u n d
th e tir e u n til th e rin g is c o m p le te ly fre e d fro m

.
th e b ead se a t.

ry
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ar

C o n tin u e p ro g re s s iv e ly a ro u n d th e rim “ w a lk in g ” To d is e n g a g e side rin g fro m th e g u tt e r in s e r t one

cc

th e side rin g firm ly in to place. rim to o l in tool slo t of sidfe rin g a n d p ry rin g
u p w a rd an d o u tw a rd . T h is o p e ra tio n c an be
a s s is te d (a s sh o w n ) b y in s e rtin g h o o k ed -en d tool
b etw ee n th e tir e a n d rin g , p ry in g u p w a rd on rin g
an d d o w n w a rd on tir e to fre e rin g fro m tir e b ead.
si
as
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A bove illu s tra tio n show s side rin g fu lly en g ag ed
in rim g u tte r . C heck s e a tin g o f rin g an d in flate
t i r e to reco m m en d ed p re s s u re .
C o n tin u e in th is m a n n e r p ro g re s s iv e ly a ro u n d rim
u n til rin g is c o m p le te ly rem o v ed . T u rn a sse m b ly
o v er, u n s e a t tir e b ead , s ta n d ti r e u p a n d rem o v e
rim b a se .
T-8308

Figure 17— Mounting and Demounting 2-Piece Convertible and DT Rims


M O U N TIN G
Be sure right valve is used and is
properly installed in the rim. Inspect
rim to insure bead seats are clean and
smooth. Then place rim on floor w ith
wide side down and lubricate first bead
of tire and upper bead seat of rim.
ar
D E M O U N T IN G
i cc
a ss
Deflate tire. W ith tire lyin g flat, loosen
both beads by w alking on tire w ith
cl
heels close to rim. W ith wide side of
rim down, lubricate top bead. With
stops toward rim, insert spoon ends
of both tools about 10" apart. Holding
bead in well w ith foot, pull one tool
toward center of rim.
Figure 18—Mounting and Demounting 15° Drop-Center Tubeless Rims
om
.c
ry
Push first bead into well of rim and
onto rim as far as possible. U sing
straigh t end of tool (with stop resting
on rim flange) take small bites to
ra
work remaining section of first bead
onto rim.
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Hold tool in position with one foot and
pull second tool toward center of rim.
P rogressively work bead off rim, tak­
ing additional bites if necessary.
Sec. 10
P age 69
WHEELS AND TIRES
Hold second bead in well by standing
on tire and anchor w ith vise-grip
pliers (snub side toward tire). U sing
sp oon end o f tir e to o l w ith sto p
toward rim, use sm all bites until bead
slips over flange. If necessary, insert
second tire tool and lubricate last 6"
of bead before com pleting mounting.
Inflate tire to recommended pressure.
Exam ine valve assem bly occasionally
to avoid leaks.
Stand assem bly in vertical position.
Lubricate second bead. A t top of a s­
sem bly insert straigh t end of tool be­
tw een bead and back flange of rim at
about a 45° angle. Turn tool so that it
is perpendicular to rim. Pry second
bead off.
T-8309
Sec. 10
Page 70

WHEELS A N D TIRES

M OUNTING

Place disc portion of wheel on floor
with rim gutter up. Apply tire with
valve pointing in direction desired.
Place side ring in position with oper­
The two cutaway portions opposite
each other in the inner diam eter of the
ring (points A) are placed so as to
span the rim g u tter. A t point C,
m
co
Insert straight end of rim tool in
operating notch (point B ), then pull
in direction indicated by arrow. R e­
tain pressure with tool and strike ring
downward with m allet a t point be­

.
ating notch located between two em­ opposite valve, force h alf of ring into
bo ssin g s (p o in t B) a p p ro x im a te ly the g u tter as fa r as possible using tween tool slot and cutaw ay portion,

three inches from valve, on either side.
ry
hand and rim mallet. thereby engaging ring over rim gut­
ter a t th a t point. Remove tool and
strike additional blows progressively
tow ard other cutaw ay portion until
entire toe of ring has passed over the

DEM O UNTING
ra rim gutter. Check seating of ring as
shown below and inflate tire to recom­
m ended pressure.
lib
ar
cc

C A U TIO N : Make certain tire is com­
pletely deflated. To loosen tire bead
fro m side rin g , d riv e cu rv ed bead-
loosening end of above recommended
si
Remove ring by p u ttin g stra ig h t end Turn assembly over and unseat tire
of rim tool into notch in ring located bead from back flange in same m anner
between embossings (point B). Push as loosening bead from side ring in
ring downward a t point opposite oper­ first step. Stand tire up and remove

rim tool, or a larg er tire tool, between
ring and bead. P ry downward on bead
and repeat this operation around the
ring until bead is loose.
as
ating notch. Force tool handle down­ rim base.
ward as illustrated, causing ring to
disengage from rim g u tte r. Continue
o p e ra tio n , p ry in g aw a y fro m rim
g u tter with flat end of tool until free.

N O T E : It is unnecessary to free the side ring from the tire bead if tire is to be removed for tube repair and im­
mediately replaced. Simply loosen bead from back (permanent) flange as in third demounting step. Then turn the
assembly over arid remove ring, with tire attached, as in second demounting step.
cl

SA F E T Y P R E C A U T IO N S:
1. Before inflating tire, be sure side
ring has completely cleared the gu t­
ter of rim base. In this position the
side ring can be depressed by hand
or will yield to a ligh t hammer blow.
DO NOT INFLATE IF SIDE RING
DOES NOT MOVE FREELY.
T-8317

Figure 19— Mounting and Demounting RH5° Rims

 Sec. 10
P age 71

WHEELS AND TIRES

MOUNTING

P la ce tire on rim so th a t valve is in lin e w ith
rim s lo t and in sert v a lv e th rou gh th e slot.
F orce first bead dow n into w ell o f rim ju st to
sid e o f v a lv e w ith foot. M o u n t first bead over
rim lip w ith rim tool p rogressin g from each
sid e o f foot a p p ro x im a te ly o p p o site foot.
om
T o a p p ly second bead, start at point op p osite
valve an d press tire bead over rim lip and into
rim w ell w ith foot pressure. M ount rem ainder
o f bead over rim lip by m eans of th in tire
tool, b ein g careful not to pinch tube. If n e c es­
sary, in sert second tire tool and lub ricate last
P la ce h alf of sid e ring under th e rim lip w ith
c u taw ay portion s in p osition as show n. Insert
th in end of rim tool or heavy screw driver and
pull ring outw ard tow ard cen tered position.
Strik e w ith m allet to start ring over rim lip.
th en strike rem ainin g portion to force it over

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6" of bead before com pleting m ounting. rim lip.

ry
DEMOUNTING
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ar
cc

F irst rem ove va lv e core to c o m p le te ly deflate T o rem ove ring, insert tool in notch and force F orce up per tire bead into w ell o p p osite the
tire. P la ce tire an d w h eel on floor w ith sid e ring (o p p o site of notch) dow n w ith feet; th en valve slo t and w ith tire tool pry o p p o site p or­
ring up. T o lo o sen first bead, d riv e hooked pry off. P ry out and up on side ring, c a re ­ tion of bead over edge of rim.
end o f rim tool b etw een tire a nd rim flange fu lly but firmly. B e careful not to bend side
a nd p ress d o w nw ard on bead. P ro g ress a round ring.
rim, u sin g 2 tools, as show n.
i
a ss
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Sta n d a ssem b ly in vertical position . L ubri­
c a te secon d bead. A t top o f assem b ly insert
stra ig h t end o f tool betw een bead and back
flange of rim a t ab ou t a 45° angle. T urn tool
so th a t it is p erp en d icu la r to rim. P ry second
bead off.
T urn tire over and by m ean s of rim tools,
loosen bead on o p p osite bead seat. T h is can
be further aided by u sin g foot pressure.
M ake sure on e portion of second bead is
s t ill in th e rim w e ll, th e n p r y o p p o s it e
portion of be^d over ed ge of rim. T h is w ill
free the tire from th e rim. T -9 1 0 2

Figure 19a Mounting and Demounthg XL Rims

Sec. 10
P age 72 _______________

WHEELS A N D TIRES

m
TIRE BA LAN CIN G W A R N IN G

co
WARNING: When balancing tir e s on the truck, follow the equipment

m anufacturer's instructions carefully. On trucks which do not have

.
ry
M aximum T raction, drive wheel spin should be lim ited to 35 mph as

indicated on the speedom eter. T his lim it is n e cessa r y b ecau se the

ra
sp eed om eter only indicates one-half of the actual wheel speed when

one drive wheel is spinning and the other drive wheel is stopped. Un­
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l e s s ca re is taken in lim iting drive w heel spin, the spinning w heel can

reach e x c e ssiv e sp eed s, resulting in p o ssib le tir e disintegration or

ar

d ifferential failure, which could cause personal injury or extensive

v eh icle damage.
cc

On trucks which do have Maximum T raction, drive w heel spin

si

should be lim ited to 70 mph. On such trucks, do not attempt to balance

a tir e on a drive w heel with the other drive w heel on the ground sin ce
as

the truck may drive through this w heel.

cl
 WHEELS AND TIRES

RIM AND WHEEL SAFETY PRECAUTIONS

CAUTION
An inflated tir e and rim can be very dangerous. Many accid en ts,
som e fatal, have resu lted from improper handling and operation of truck
r im s and w h eels. It is , therefore, of the utm ost im portance that the
p recau tions outlined in th is section be carefully noted by all p erso n s
concerned in order to avoid personal injuries and costly damage.

om
HOW TO PREVENT RIM ACCIDENTS Rem ove Rust and Other Foreign Matter
(R efer to F igure 20) Accumulation of such m aterial in the rim gut­
ter can prevent the proper fitting of rin gs. P arts
DURING TIRE DEMOUNTING that are e x c e ssiv e ly corroded are weakened and

.c
should be replaced. U se of a rust preventive com ­
C om pletely D eflate T ire P r io r to Demounting pound (not containing water) during mounting w ill
(R efer to F ig. 20, View A) m inim ize rusting.

If either rim or rings a re damaged or ring
appears to be unseated, the tir e should be deflated
p rio r to rem oval of the tir e and rim assem bly
from the veh icle. ra
F ir st, reduce the p r e ssu r e by pushing the
plunger, then rem ove the en tire co re. Keep your
ey es away from the valve.
lib
R em ove valve co re to en sure com plete de­
flation.
F ollow R ecom m ended Demounting P roced u res
ar
ry
Do Not U se O v er-S ize or O ver-Inflated T ires
U se only p referred or a lte r n a te -siz e rim s for
tires and do not exceed recommended air pressures
(see pages 77 and 78). These are common causes of
rim failures and accidents.
Follow Recom m ended Mounting P roced u res
See previous pages of th is section for mounting
instructions.
ADDED PRECAUTION: R e-ch eck a ssem b lie s

S ee previou s p ages of th is section for demount­ just prior to inflation, particu larly if they have
ing in stru ction s. been rolled a c r o ss the floor or have receiv ed rough
handling between mounting and inflation.
Check For Dam aged or Worn P a rts
cc

Mark d efective p arts for destruction to p re­ Rim Ring Seating (Fig. 20, View B)
clude their future u se . MAKE CERTAIN the rim ring is seated to the
full depth of the groove, fits tightly all around, and
DURING TIRE MOUNTING is secu rely locked. With certain types of w h eels,
i

however, it is n ec essa ry to sea t the rings while the

ss

R eplace Dam aged P a rts tire is being inflated. In either c a se BEFORE in ­

Abuse during road operations or in mounting flating.
the tir e can cause dents, crack s or d isto rtion s which
weaken the p arts and prevent sa fe , proper a sse m ­ Safety D evice or Cage (Fig. 20, View C & F ig. 21)
a

bly. ATTACH A PORTABLE SAFETY DEVICE, OR

BEFORE mounting a tir e and a ssem b lin g the USE SAFETY CAGE, MADE ESPECIALLY FOR
cl

rim , in sp ect the rim p arts carefu lly for damage,
ru st, and distortion . Avoid the u se of r im s, locking
rin gs or flan ges which are out of shape, rusted,
o r broken. Avoid the u se of a ring or rim parts of
d ifferent manufacture than the rim , or of any dif­
feren t s iz e or type than the rim .
A void the u se of any lubricant which contains
w ater or solvent that is injurious to rubber. A com ­
bination lubricant and ru st-p rev en tiv e compound is
p refera b le. This p ro tectiv e m easu re is of particular
im portance with drop -cen ter tu b eless rim s a s the
air in the tir e is contained by the tir e - s id e rim
su rfa ce.
THE PURPOSE. TO THE ASSEMBLY. This p ort­
able device can be used with a ll types of w heels
and rim s.
Or, if the assem b ly is not of the type which
requires inflation to seat the rin gs, a SAFETY
CAGE can be used. This is recom m ended to p re ­
vent personal injury during inflation. An inflated
tir e contains potentially ex p losive energy that can
blow rings lo o se . A clip -on type a ir chuck should
a lso be used, so that the operator can stand to one
sid e during tir e inflation.
Avoid a position w here the face or body is
im m ediately over the work being done on any tire
Sec. 10
Page 74

WHEELS A N D TIRES

m
. co
ry
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as
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Figure 20— Rim and Wheel Safety Precautions

 Sec. 10
P age 75

WHEELS AND TIRES

in which there is p r e ssu r e (fig. 20, View D).
U se only a ccu rate, tested gauges to ensure
proper air p r e s s u r e . Check a ll gauges regularly
with a m aster gauge.

Drop Center W heels (Fig. 20. View E)

IN CHANGING TIRES on drop center w heels,
rem ove w h eels from the truck and p lace on a wheel
holder or tir e changing m achine, rem oving and
mounting the tir e s in this way. G reater speed and
e a se thus can be obtained than by making the change

om
with the w heel on the v eh icle.
This a lso w ill prevent cuts on hands and w rists
from fender edges and w ill make it u nnecessary to
u se a ham m er for seating the tir e .
U se only standard tir e mounting to o ls and
equipment. The u se of m akeshift tools, screw d riv­

.c
e r s or p lie r s to fo rce tir e s on or off rim s or wheels
is dangerous.

ry
A ll Wheel and Rim A sse m b lie s
(R efer to F ig. 20, View F)
IN THE SERVICING OF ALL TIRES u se cau­
tion not to drop them , or the w h eels or a sse m b lie s,
ra Figure 21 —Safety C a g e (Typical)
on the feet, hands, or body, or heavily on the floor.
Learn how to lift properly — u se your legs weight does not exceed the rated load of the tir e s
as w ell as your body. T his can help prevent pain­ used. R im s are designed to sustain the maximum
lib
ful, internal injury or rupture. rated load of the m aximum tir e s iz e recom m ended
for that rim .
T ire Iron Safety (F ig. 20. View D)
BE CAREFUL IN USING TIRE IRONS, p artic­ Do Not Exceed Maximum Inflation P r e ssu r e s
ar

u larly a s to gripping them firm ly and keeping the
hands free of oil and g r e a se . The iron s can slip
and fly with trem endous fo rce.
cc
This is determ ined by the siz e and ply rating
of the tir e . It is a lso im portant to m aintain uni­
form inflation in both tir e s of a dual assem b ly so
that weight is equally sustained.

H am m ers (F ig. 20, View G)

USE CARE IN HAMMERING RINGS OR RIMS Do Not Run V ehicle on One T ire
WITH STEEL HAMMERS. Sm all b its of ste e l may of Dual A ssem bly
be broken off the ham m er or rim , flying into the When there is lo s s of air in a dual tire the
i

eye, fa ce, or body. carrying capability is reduced and the load m ust
ss

U se ru bb er-covered steel-h ea d ed ham m ers be sustained by the other tir e and rim . Both tir e s
w h erever p o ssib le . should be inflated to balanced, recom m en d ed p res-
Do not ham m er on r im s or rings after tire su res before further operation.
inflation has started.
a

N ever R e-Inflate a T ire That Has B een Run Flat

Changing Equipment (F ig. 20, View H) Without F ir st Thoroughly Inspecting It and
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TIRE SPREADER ARMS CAN BE DANGEROUS.
Keep them clo sed when the machine is id le and
u se ca re in a ll r e sp e c ts while operating the spreader
F ace and Eye P rotection
ALWAYS WEAR GOGGLES or face shields
when buffing r im s or tir e s , or when hammering
rin g s.
DURING VEHICLE OPERATION
Do Not O verload T ir e s
E nsure that the com bination of load and vehicle
The Rim and Wheel A ssem b ly
It is esp ec ia lly im portant to make su re the
lock ring is se cu re in the gutter and has not been
damaged p rior to re-in flation .
P eriod ically Check Clam ps and W heel Nuts
Loose clam ps can cau se dangerous rim s lip ­
page or detachment of rim and tir e from the v e ­
hicle while in m otion. L oose w heel nuts can cause
dangerous wheel shim m y and lo s s of veh icle con­
tro l. E x c e ssiv e torque is also dangerous in that
it can cause stud and ring breakage. R efer to page
77 for torque recommendations.

)
Sec. 10
Page 76
WHEELS A N D TIRES
W HAT HAPPENS WHEN
TIRES GET HOT
As a tir e b ecom es heated, the air in the tire
expands and the a ir p r e ssu r e is raised . This is
norm al u n le ss the p r e ssu r e build-up is ex c e ssiv e .
B uild-ups of over 20 lb s. are e x c e ssiv e , indicating
underinflation, overload, too much speed, too sm all
a tire or, m ore often, a combination of these fac­
to r s. T h erefore, p r e ssu r e build-ups of over 20 lbs.
should be studied to determ ine cause and proper
c o rr ectiv e action. Norm al p r e ssu r e build-ups (not
over 20 lb s.) reduce flexin g. Thus the amount of
heat generated allow s the tir e to reach a heat bal­
ance (the tem perature at which the rate of heating
equals the rate of cooling) at a low er tem perature
than if the inflation p r e ssu r e w ere maintained uni­
form ly by frequently bleeding out air. T ires should
never be bled. When the p r e ssu r e builds up ex­
c e s s iv e ly - reduce the speed or the load instead.
A tir e operated for a considerable distance at
sustained highway sp eed s, in a sev erely underin­
flated or flat condition, b eco m es extrem ely hot due
to internal friction , and this heat transm its to the
tir e ’s outer su rfa ce. If and when the outer surface
tem perature reach es the com bustion point, the tire
b u rsts into flam e. This usually occurs after the
lib
v eh icle has stopped. Such an occurrence usually
involves a dual a ssem b ly w here one of the tir e s is
flat and the other is , th erefore, extrem ely ov er­
loaded (possibly a lso underinflated even for normal
ar
load). In such c a s e s , eith er the tire which is s e ­
v erely underinflated or com pletely flat, or the tire
which is ex trem ely overloaded, could get so hot as
cc
to reach the point of spontaneous com bustion.
CAUSE AND PREVENTION OF TIRE FIRES
A m ajor cause of tir e fir e s is heat caused by
si
a dragging brake, particu larly if there is ex c e ssiv e
g re a se an d/or o il around the brake drum The heat
produced by the dragging brake ignites the grease
as
or oil which in turn can eventually ignite the tire,
even though the tir e is not overloaded or under­
inflated.
R eg a rd less of the cause of a tire fir e , the
t ir e ’s internal tem perature is so high that even if
cl
the flam es are extinguished, repeated spontaneous
ignition occu rs until the internal tem perature de­
c r e a s e s su fficien tly . A fir e extinguisher usually
w ill not have su fficien t capacity to control the fire
until the burning tir e can be rem oved. Operators
should carry sp e c ia l a sb e sto s blankets which, in
c a se of tir e fir e , are u seful in preventing the fire
from spreading to v eh icle and cargo. If p ossib le,
a steady strea m of w ater should be placed on the
tir e until it is cool enough for rem oval.
The b est p rotection against tire fir e s is to
avoid running on a flat tir e , prevent underinflation
through regular checking of inflation p r e ssu r e s, and
avoid accum ulation of g rea se or o il around brake
drum a r e a s. O perators carrying cargo which is
exp losive or readily com bustible should check tir e s
at 5 0 -m ile in tervals and should a lso u se a p r e ssu r e
warning d evice.
INSTRUCTIONS FOR M A IN TEN AN C E
OF TIRES O N OFF-THE-HIGHW AY
UNITS IN H IG H W A Y TRANSIT
Many O ff-The-H ighway T ires are designed and
m
built to give maximum se r v ic e for mining and con­
struction operations. B ecau se of the extra heavy
construction built into th ese tir e s , sp ec ia l p recau ­
co
tion s must be ob served when equipment is being
moved over the highway for d elivery or when tr a n s­
ferrin g to a new job s ite . If th ese precautions are
not ob served, the tir e s may build up e x c e ssiv e heat
and cause prem ature fa ilu re.
.
The follow ing recom m endations are made in
ry
the in ter est of protecting your investm ent against
lo s s and delay. T h ese recom m endations apply to
a ll tir e s on v eh icles in tran sit, whether driven or
ra
towed.
LOAD AND PRESSURE
1. V eh icles must be empty during tran sit.
2. Inflation p r e ssu r e is determ ined by cold
p r e ssu r e checks before starting. P r e ssu r e is not
to be reduced by "bleeding” tir e s during tra n sit.
3. Inflation p r e ssu r e s are to be determ ined by
u se of the follow ing ch arts. If load cannot be a c ­
curately estim ated, u se the m aximum inflation
p r e ssu r e shown for the ply rating in question.
4. T ir e s with "dry" b allast m ust not be used
for v eh icle transport p u rp oses.
SPEED
R egular Skid Depth T ir e s
1. Maximum highway speed 30 mph.
2. Stop for 3 0 -minute cooling period after
each 50 m iles of driving or before 2 hours’ s u s ­
tained operation, w hichever com es fir st.
3. One hour minimum m id-day lunch stop
should be observed during full day operations.
Extra Skid Depth and Special Compound T ir es
V eh icles equipped with extra skid depth or
sp ec ia l compound tir e s are not to be driven in
tra n sit over the highway u n less the proposed trip
is review ed and approved by qualified p erson n el.
Super Deep Tread T ires
Under no circu m stan ces should the Super Deep
Tread tir e s be moved (roaded) over the highway.
V eh icles in tran sit m ust be controlled and a c ­
com panied by resp on sib le personnel in a p ilot car
to enforce recom m endations and maintain a check
on equipment. This is good insurance for a v a l­
uable investm ent.
 Sec. 10
P age 77

WHEELS AND TIRES

SPECIFICATIONS
WHEEL NUT TORQUE
CAST TYPE WHEELS
Tighten nuts as d irected in text to:
F r o n t ..................................................................................................... 190-210 foot-pounds
R ear ..................................................................................................... 190-210 foot-pounds
BUDD TYPE (DISC) WHEELS
Tighten nuts a s d irected in text to:
F r o n t ..................................................................................................... 500-550 foot-pounds

om
R ear (Inner and Outer N u t s ) ........................................................ 500-550 foot-pounds*
Aluminum W heels and/or H u b s ................................................. 450-500 foot-pounds*
CORPORATION TYPE (DISC) WHEELS
Tighten nuts as directed in text to:
F r o n t ...................................................................................................... 300-400 foot-pounds

.c
Rear ...................................................................................................... 300-400 foot-pounds
* L oosen outer nuts, tighten inner nuts, then tighten outer nuts.

ry
NOTE: Wheel hub flan ges, w heels, studs, and stud nuts should be free of
ra
ru st, lubricants, dirt, and fin ish color paint on all "faying" su rfa ces to ensure
proper torque retention.
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TIRES FOR TRUCKS IN HIGHWAY SERVICE
ar

LOAD AND INFLATION TAB LE

T ir e an d R im A s s o c ia tio n S ta n d a rd T ir e Lo a d s A t V a r io u s In fla tio n P re s s u re s.
TIRES USED AS SING LES
cc

T IR E IDENTIFICATION T I R E L O A D L I M I T S AT V A R I O U S I N F L A T I O N P R E S S U R E S
L OA D
SIZE 50 55 60 65 70 75 80 85 90 95 100
RANGE
i

8 .2 5 -2 0 E 2800 3010 3190 3370 3560 3730 3890 4050

ss

8 .2 5 -2 0 F 2800 3010 3190 3370 3560 3730 3890 4050 4210 4350 4500
9 .0 0 -1 5 F 2950 3150 3330 3500 3660 3830 3980 4140 4210
9 .0 0 -1 8 E 3320 3530 3730 3920 4120 4300
9 .0 0 -2 0 E 3560 3770 4000 4210 4410 4610
a

9 .0 0 -2 0 F 3560 3770 4000 4210 4410 4610 4790 4970 5150

1 0 .0 0 -1 5 F 3580 3780 3980 4170 4370 4540
cl

1 0.0 0 -1 5 G 3580 3780 3980 4170 4370 4540 4710 4880 5050
1 0 .0 0 - 2 0 F 4290 4530 4770 4990 5220 5430
1 0 .0 0 - 2 0 G 4290 4530 4770 4990 5220 5430 5640 5840 6040
1 0 .0 0 - 2 2 F 4560 4820 5070 5310 5550 5780
1 0 .0 0 - 2 2 G 4560 4820 5070 5310 5550 5780 6000 6210 6430
1 1 .0 0 - 2 0 F 4670 4940 5200 5450 5690 5920
1 1 .0 0 - 2 0 G 4670 4940 5200 5450 5690 5920 6140 6370 6590
1 1 .0 0 - 2 2 F 4960 5240 5520 5790 6040 6290
1 1 .0 0 - 2 2 G 4960 5240 5520 5790 6040 6290 6530 6770 7000
1 1 .0 0 -2 4 F 5270 5570 5860 6140 6420 6680
1 2 .0 0 - 2 0 G 5620 5920 6200 6480 6740 7000
1 2 .0 0 -2 4 G 6330 6660 6980 7280 7580 7880
N O T E : U n d e rlin e d F ig u re s In d ic a te M a xim u m R e co m m e n d e d Load.
Sec. 10
P age 78

WHEELS A N D TIRES

SPECIFICATIONS (CONT.)

TIRES USED AS DUALS

TIRE IDENTIFICATIO N TIRE LOAD LIMITS AT VARIOUS INFLATION PRESSURES
LOAD 55 60 65 70
SIZE 40 45 50 75 80 85 90
RANGE
8.25-20 E 2460 2640 2800 2960 3 120 3270 3410 3550
8.25-20 F 2460 2640 2800 2960 3 120 3270 3410 3550 3690 3820 3950
9.00-15 F 2590 2760 2920 3 070 3210 3360 3490 3630 i M
9.00-18 E 2910 3100 3270 3440 3610 3770

m
9.00-20 E 3120 3310 3510 3 690 3870 4040
9.00-20 F 3120 3310 3510 3 690 3870 4040 4 200 4360 452a .
10.00-15 F 3140 3320 3490 3660 3830 3980

co
10.00-15 G 3140 3320 3490 3660 3830 3980 4130 4 280 4 430
10.00-20 F 3760 3970 4 180 4380 4580 4760
10.00-20 G 3760 3970 4180 4380 4580 4760 4950 5120 5300
10.00-22 F 4000 4230 4 450 4660 4870 5070
10.00-22 G 4000 4230 4 450 4660 4870 5070 5260 5450 5640

.
11.00-20 F 4100 4330 4560 4780 4990 5190

ry
11.00-20 G 4100 4330 4560 4780 4990 5190 5390 5590 5780
11.00-22 F 4350 4600 4840 5080 5300 5520
11.00-22 G 4350 4600 4840 5080 5300 5520 5730 5940 6140
11.00-24
12.00-20
12.00-24
F
G
G
4620 4890
4930
5550
5140
5 190
5840
ra
5390
5440
6120
5630
5680
6390
5860
5910
6650
6140
6910
N O T E : U n d e rlin e d F ig u re s In d ica te M a x im u m R ecom m ended Load.
lib
ar

LOAD RANGE DESIGNATION LETTER TO

cc

PLY RATING NUMBER CONVERSION CHART

LOAD RANGE LETTER PLY RATING
si

E 10
F 12
G 14
as
cl

CAUTION: DO NOT stand unprotected In front of clamp ring when

Inflating tire. If a protective Inflation cage is not available, wrap three
lengths of chain, evenly spaced around tire and rim. Secure chains but
leave loose enough to permit expansion of tire during inflation. Use an
extension gauge with clip on chuck so air pressure build-up can be
closely watched and so that you can stand well back from the assembly
during the bead seating process to avoid possibility of personal injury.
 Sec. 11
Page 79

SECTION 11
S h eet M etal
A ll inform ation pertaining to SHEET METAL
as d escrib ed in S erv ice Manual S T -3 3 1 -7 1 , pages
11-1 through 11-8 is applicable to m od els covered
in th is Supplement with addition of the following:

HOOD ALIGNMENT

om
Hood alignm ent blocks (see fig s . 1 and 2) are at­
tached to the hood by sc r e w s. To adjust, loosen hood
hinge b o lts. Note that the rearm ost bolt hole in hinge
is slotted to allow hood trailin g edge to move up and
down. Adjust, so hood and cowl su rfa ces are flush.
NOTE: It may be n e c e ssa r y to perform hood

.c
lock adjustm ent as d escrib ed in S ervice Manual
S T -3 3 1 -7 1 , page 1 1 -3 . Fig u re 1 —H o o d A lig n m e n t Blocks

ry
H O O D ASSEMBLY C O W L GRILLE ASSEMBLY

ra
lib
ar
i cc
a ss
cl

Figure 2—Front End Sheet Metal Components (Typical)

(
S ec . 12
P age 80

SECTION 12
GhadAid, SlectsUccd ana 9MAbiumetiti
NOTE: E lectrica l sy stem inform ation applicable to m odels cov­
e red by this supplem ent rem ains the sam e as covered on pages 12-1
through 12-52 in CHASSIS ELECTRICAL AND INSTRUMENTS (SEC.
12) in S erv ice Manual ST-331-71 except as follow s:

m
co
INSTRUMENTS A N D G A U G E S
Inform ation applicable to instrum ents and gauges rem ains the
sam e as covered on pages 12-7 through 12-13 under “ Instrum ents and

.
Gauges” in CHASSIS ELECTRICAL AND INSTRUMENTS (SEC. 12) in

ry
S erv ice Manual S T -331-71, except a s e r ie s of ground w ir es have been
added to the gauges used on ste e l tilt cab m od els. T hese w ire s m ust
be in sta lled in such a manner as to m aintain a continuous ground c ir ­
cuit from gauge to gauge.
ra
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SPECIFICATIONS
ar

RETARDER BRAKE ALARM RELAY BRAKE WARNING BUZZER

. .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . . .. . .. . .. . . .. . .. . . Delco-Remy .................................................. Delco-Remy
.. .. . .. . . .. . .. . .. . . .. . .. . . .. . .. . .. . . .. . .. . . .. . .. . 1115811 .................................................. 1116882
cc

Air Gap at Core Point Opening (In.) . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . 0.017

Points Closed (In.). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020 Closing Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust to Buzz at .25 .35
Point Opening (In.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.018 Amperes at 13.5-14.5 Volts
Closing Voltage (Range) . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . . . 1.5-9.5
ENGINE ALARM BUZZER
si

STARTER CONTROL OR STARTER INTERLOCK RELAY M ake.................................................... Delco-Remy

M a ke .................................................... Delco-Remy Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1116914
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1115848 Point Opening (In.) . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . 0.015
Point Opening (In.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.017-0.033 Closing Voltage . . . . .. . .. . .. . . .. . .. . .. . . .. . .. . Adjust to Buzz at .30 .35
as

Opening Voltage (Range). .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . . . 3.7-5.2 Amperes at 13.5-14.5 Volts

STARTER SHUT-OFF RELAY TRAILER I.C.C. MARKER LAMP RELAY
. .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . . .. . .. . .. . . .. . .. . . Delco-Remy M ake.................................................... Delco-Remy
.. .. . .. . . .. . .. . .. . . .. . .. . . .. . .. . .. . . .. . .. . . .. . .. . 1115848 Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1115841
cl

Point Opening (In.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.017-0.033 Air Gap at Core

Opening Voltage (Range). .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . . . 3.7-5.2 Points Closed (In.) * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.012 Min.
Point Opening (In.) .. .. . .. . . .. . .. . .. . . .. . .. . .. . . .. . .. . . .. 0.015-0.025
GENERATOR TELL-TALE RELAY Closing Voltage (Range) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
M a k e .................................................... Delco-Remy Sealing Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.0 Max.
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1115848 ‘ Tolerance Plus or Minus 1 0 %
Point Opening (In.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.017-0.033
Opening Voltage (Range).. .. . .. . . .. . .. . . .. . .. . .. . . .. . .. . . 3.7-5.2 HORN RELAY
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2480982
LOW AIR PRESSURE OR LOW VACUUM ALARM BUZZER Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
M a ke .................................................... Delco-Remy
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1116882 ELECTRIC HORN
Point Opening (In.) .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.017 M ake.................................................... Delco-Remy
Closing Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust to Buzz at .25 .35 Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9000235
Amperes at 13.5-14.5 Volts Frequency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357 C.P.S.

)
 S e c . 12
P a g e 81

CHASSIS ELECTRICAL AND INSTRUMENTS

SPECIFICATIONS (Cont.)

ELECTRIC HORN
.................................................................... Delco-Remy

Freq u e n cy................................................................. 360 C.P.S.

DUAL ELECTRIC HORN VIBRATING HI - NOTE
M a k e ....................................................................... Delco-Remy
Model ..................................................................... 9000004
Frequency “A” Note .................................................. 444 C.P.S.

om
FLASHER UNIT
Specific Load — 2 Prong .............................. Sig. Stat. 144
Variable Load — 2 Prong .............................. Sig. Stat. 175

.c
LIGHT BULB DATA

ry
BULB NO. CANDLEPOWER BULB NO. CANDLEPOWER
Headlamp Directional Signal Indicator Light
Single Sealed Beam U n it .............. 6014 50-60 Watts Conventional Cab M od els......... 168
Directional Signal Lights ..................
Park and Directional Signal Lights
1156
1157
ra 32
32-3
Series S E / S G /S M /S S -50 ...
Tilt Cab Models .....................
Heater Control Light
1445
57

Front Side Marker Lights ................ 193 or 195 2 Conventional Cab M od els......... 1445
lib
Tilt Cab Models ..................... 57
Tail and Stop Lights ...................... 1157 32-3
Speedometer Light
Tail, Stop, and Rear Directional Lights 1157 32-3 Conventional Cab M od els......... 195
Clearance and Identification Lights . . . 67 4 Series S E / S G /S M /S S -5 0 . . . . 1895
ar

Tilt Cab Models ..................... 53

Marker Lights ................................ 1445 or 1895 1 or 2
Low Vacuum Gauge Warning Light
Back-Up Lights ............................... 1156 32 Conventional Cab M o d e ls......... 195
cc

License L ig h t .................................. 67 4 Series S E / S G /S M /S S -5 0 .... 53

Tilt Cab Models ..................... 53
Cargo Light (when used) .................. 1076 32
Brake Warning L ig h t ................... 1895
Dome Light ................................... 211-1 12
Differential Lock Tell-Tale Light . . . 1090D18
i

Instrument and Tell-Tale Lights

ss

Temperature Gauge Light (Tilt Cab 53

Conventional Cab M o d e ls............... 195
Series S E / S G / S M / S S -50 .......... 1895 Fuel Gauge Light (Tilt Cab Models) 53
Tilt Cab Models .......................... 57
Air Pressure Gauge Light ........... 53
Headlamp Hi-Beam Indicator
a

Voltmeter L ig h t ......................... 53
Except Tilt Cab Models .. 1445
Tilt Cab Models ........... Tachometer Gauge Light ............. 53
1090D18
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Ammeter Gauge Light ................ 53

Engine Overspeed Warning Lamp (when used)
Except Tilt Cab Models ........................ 67 Oil Pressure Gauge Light ........... 53
Tilt Cab Models .................................. Vacuum Gauge Light ................. 53
P age 82

9 + id e * .

Subject Page No. Subject P age No.

H
Hubs and B ea rin g s, Front .................................. 5
A ir C leaners ......................................................... 34
A ir S u s p e n s io n ......................................................... 35 I
Alignm ent, Front End .......................................... 3

m
Axle Ignition System ....................................................... 42
C ontrols ............................................................ 7
Front .................................................................. 3 L
R ear ..................................................................... 7

co
Linkage, T ran sm issio n ........................................ 45
B L u b r ic a t io n ................................................................ 1

B attery ..................................................................... 37 M

.
B attery, Using B oo ster ....................................... 38

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B elt T ension ............................................................ 20 Mountings, Engine ................................................. 16
B rakes ........................................................................ 9
A ir ........................................................................ 10 o
Hydraulic ............................................................ 9
B ulbs, Light ............................................................

c
81
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O il, Engine ................................................................

s
1
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C arburetor, Bendix ............................................. 29 Safety, Rim and W h e e l ........................................... 73
C arburetor, H o l l e y ................................................ 26 Sheet M e t a l ................................................................ 79
C arburetor, R ochester ....................................... 22 Springs, F r o n t .......................................................... 5
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C arburetor Specifications ................................. 33 Springs, R ear .......................................................... 8

Clutch ........................................................................ 51 Starting System ....................................................... 39
Clutch Controls ...................................................... 51 Steering, M e c h a n ic a l.............................................. 53
Coolant Recom m endations ................................. 19 Steering, P o w e r ....................................................... 54
cc

Cooling S y s t e m ......................................................... 18 Steering S y s t e m ....................................................... 53

Suspension
E F r o n t ...................................................................... 3
H endrickson ....................................................... 8
si

E le c tr ic a l, C h a s s i s ................................................ 80 R ear ...................................................................... 7

E le c tr ic a l Instrum ents ....................................... 80
Engine E lectrica l ................................................... 37 T
as

E ngines, G a s o lin e ................................................... 11

Engine Tune-Up T ir e s ............................................................................ 60
16 ......................................................................... 13 T ire B a la n c in g .................................................... ... • 72
V6 ........................................................................ 14 T ire Inflation Table .............................................. 77
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V8 ........................................................................ 15 T ire Selection .......................................................... 62

Engine, Turbium (D iesel) ................................. 34 Torque, A ir Line .................................................... 10
T ran sm issio n .......................................................... 45
F T ra n sm issio n , A uxiliary ..................................... 49

Fluid, Pow er S t e e r i n g .......................................... 1

Fluid, T r a n s m is s io n ............................................. 2

G Vacuum Shift

Gauge, Vacuum ...................................................... 9

Generating System (A.C.) ................................. 43 w
Governor, A ir C om pressor .............................. 35
G overnors, Engine ................................................ 21 W heels and T ires 57
 MODEL DATA

TRUCK ENGINE CLUTCH FRONT AXLE REAR AXLE TRANSMISSION

SERIES STD. OPT. STD. OPT. STD. OPT. STD. OPT. STD. OPT.
C E -4 0 (02-03) 350 _ 12”-1 — F-050 _ H-135

m
H-110 SM-465 AT-475, AT-540
C S -4 0 (02-03) 250 292 ir- i 12”-1 F-050 — H-110 H-135 SM-465 AT-475
C E -5 0 (02-03) 350 366 13”-1 — F-050 F-070 H 150 T-150, T-170 SM-465 282V, 285V, 542GD/GL,
AT-475, AT-540
C E -5 0 (13) 350 366 13”-1 — F-070 — H-170 T-170 SM-465 282V, 285V, 542GD/GL,

co
AT-540
C G -5 0 (03) DH-478 — 13”-1 — F-050 F-070 H-150 T-150, H-170, T-170, 540 GL 540GD
17121, 17221
C G -5 0 (13) DH-478 — 13”-1 — F-070 — H-170 T-170, 17121, 17221 540 GL 540 GD
C M -50 (03) 351C — 13”-1 i3 ”- r F-050 F-070 H-150 T-150, H-170, T-170 SM-465 435GL, 540GD/GL,

.
AT-475, AT-540
C S -5 0 —

ry
(02-03) 292 12”-1 — F-050 F-070 H-150 T-150, T-170 SM-465 540GL, AT-475
S E -5 0 (02) 350 366 13”-1 — F-055 F-070 H-150 T-150, H-170, T-170 SM-465 282V, 285V, 542GD/GL,
AT-475, AT-540
S E -5 0 (62) 350 366 13”-1 — F-055 F-070 H-170 T-170 SM-465 282V, 285V, 542GD/GL,

S G -5 0
S G -5 0
S M -5 0

S M -5 0
(02)
(62)
(02)

(62)
DH-478
DH-478
351C

351C
—
—
—
—
13”-1
13”-1
13”-1

13”-1
—

—
—
—
F-070
F-070
F-055
b
F-070
ra
—
—
F-070

—
H-150
H-170
H-150

H-170
H-170, T-170
T-170
T-150, H-170, T-170

T-170
540 GL
540 GL
SM-465

SM-465
AT-475, AT-540
_
_
435GL, 540GL, AT-475,
AT-540
540GL, AT-475, AT-540
S S -5 0 (02) 292 — 12”-1 — F-055 F-070 H-150 T-150, H-170, T-170 SM-465 540GL, AT-475
T E -5 0 (03) 350 366 13”-1 — F-070 F-090 H-150 T-150, H-170, T-170 435 GL 282V, 285V, 542GD/GL,
rli
AT-540
T G -5 0 (03) DH-478 — 13"-1 i3”-r F-070 F-090 H-150 T-150, H-170, T-170 540 GL 540GD, MT-41
17121, 17221
T G -5 0 (13) DH-478 — 13”-1 in * F-070 F-090 H-170 T-170, 17121, 17221 540 GL 540GD, MT-41
ca

T M -5 0 (03) 351C — 13"-1 i3 ”- r F-070 F-090 H-150 T-150, H-170, T-170 435 GL 540GL, AT-540
C E -6 0 (02-03- 366 427 13”-1 12”-2 F-070 F-090, F-110 H-170 T-170, 17121, 17221, SM-465 282V, 285V, 325V, 327V,
13) 19201 542GD/GL, AT-540,
5652B, 5756B
C M -60 (03-13) 351C — 13”-1 i3 ”- r F-070 F-090, F-110 H-170 T-170, 17121, 17221, SM-465 282V, 285V, 540GD/GL,
ic

18121, 18221 ' AT-540

M E -60 (03-13) 366 427 13”-1 12”-2 F-070 F-090, F-110 30DSC 34DSC SM-465 285V, 325V, MT-40,
5652B, 6041 Aux.,
7041 Aux.
s

T E -6 0 (03-13) 366 427 13”-1 12”-2 F-070 F-090, F-120 H-170 T-170, 17121, 17221, 435 GL 282V, 285V, 542GD/GL,
19201 AT-540, 5752C
as

T M -60 (03-13) 351C 13”-1 i3 ”- r F-070 F-090, F-120 H-170 T-170, 17121, 17221, 435 GL 282V, 285V, 542GD/GL,
19201 5752C, AT-540
....
* Equipped with Cerametalix Clutch Discs.
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SERVICE
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