Chevrolet 40 SERIES 1971 User manual

SECTION INDEX
1971
SERIES 40 through 60
CHEVROLET TRUCK
CHASSIS
SERVICE MANUAL
FOREWORD
This manual includes procedures for maintenance
and adjustments, minor service operations, and re
moval and installation for components of Chevrolet
Series 40 through 60 Trucks Procedures involving
disassembly and assembly of major components for
these vehicles are contained in the 1971 Chevrolet
Passenger Car and Series 10-30 Truck Overhaul
Manual or the 1971 Series 40-60 Truck Overhaul
Manual Supplement
This manual should be kept in a handy place for
ready reference If properly used, it will enable the
technician to better serve the owners of Chevrolet
built vehicles
All information, illustrations and specifications con
tained in this literature are based on the latest product
information available at the time of publication ap
proval The right is reserved to make changes at any
time without notice
CHEVROLET MOTOR DIVISION
General Motors Corporation
DETROIT, MICHIGAN
SECTION
6A
6D
6K
6 M
6Y
8
10
11
12
13
_________ NAME
LUBRICATION
CABS, HEATING AND
AIR CONDITIONING
FRAME
FRONT SUSPENSION
REAR SUSPENSION
BRAKES
GASOLINE ENGINES
ENGINE MOUNTINGS
ENGINE COOLING SYSTEM
ENGINE FUEL SYSTEM
ENGINE ELECTRICAL
TRANSMISSIONS
AND CLUTCHES
FUEL TANK & EXHAUST
STEERING SYSTEM
WHEELS & TIRES
SHEET METAL
CHASSIS ELECTRICAL
AND INSTRUMENTS
RADIATOR AND
SURGE TANK
SPECIAL TOOLS
© 970 General Motors Corporation Printed in U.S.A.

INTRODUCTION
This manual contains on-the-vehicle maintenance, light repair information,
and unit replacement on all truck series listed on page v. Overhaul proce
dures for major units will be published in separate Unit Overhaul” manuals.
Important information on the arrangement and use of this manual will be
found on page iv. Operation of the vehicles from the standpoint of the driver
is contained in a separate Owner’s and Driver’s manual which is furnished
with every new Chevrolet Truck.
Every effort has been made to include timely and adequate information
on the various units and systems used on Chevrolet Trucks. The general
maintenance and light repair procedures in the various manual sections are
the result of extensive service experience. This information should serve not
only as a reference for the experienced mechanical force, but also as a
comprehensive text for training purposes.
In some cases, considerable space is devoted to describing the operation of
a unit or system. The use of this space is justified by the presumption that in
order for a mechanic to maintain a unit or system in a serviceable condition,
he must first understand how the unit or system should function.
All information contained in this manual is based on the latest product
information available at the time of publication approval. Chevrolet Motor
Division reserves the right to make changes in design or add improvements at
any time without incurring any obligation to install same on vehicles pre
viously purchased.
TRUCK MODEL DESIGNATION
CHASSIS TYPE
SYMBOL
(C) Conv. Cab (96" BBC) (4x2)
(M) Conv. Cab (96" BBC) (6x4)
(T) Tilt Cab
(S) Schoolbus Cowl
GVW RANGE NUMBER
See Load Capacity Chart”
in Owner’s and Driver’s
Manual.
SERIAL NUMBER
13 1 P 1 1 0 0 0 1
ENGINE TYPE
SYMBOL
(E) V8 Gasoline
(S) In-Line Gasoline
BODY AND BRAKE TYPE
03—Cab & Chassis (Hyd. Brakes)
13—Cab & Chassis (Air Brakes)
02—Cowl & Chassis (Hyd. Brakes)
m
CHEVROLET 40- 0 TRUCK SERVICE MANUAL

GENERAL IN ORMATION
IMPORTANT-READ THIS PAGE
TRUCK MODELS COVERED
This manual contains on-the-vehicle” main
tenance and light repair information on Chevrolet
Truck Models listed on page v. Since many truck
models with various combinations of equipment
are covered in this manual, the reader must
necessarily refer to truck model applications and
methods of distinguishing design differences in
each manual section.
All standard equipment and the most com
monly used regular production options are
included in this manual. Many special equipment
and accessory items are available on Chevrolet
Trucks, however, these items are too numerous to
permit their coverage in this manual.
MANUAL ARRANGEMENT
This manual is divided into major sections in
the sequence shown on the margin of the title
page. A black tab bearing the major section
number is placed on the first page of each major
section which indexes with the tab on the title
page. Many of the major sections are divided into
sub-sections, each sub-section containing impor
tant and specific information on related units or
components. A section index is also included on
the first page of each major section, when the
major section is divided into sub-sections.
PAGE AND ILLUSTRATION NUMBERS
The manual pages are numbered consecutively
within each section. Illustrations are numbered
consecutively within each section, or within each
sub-section when the major section is so divided.
SPECIFICATIONS
Service data, fits, and tolerances are listed at
end of each section or sub-section under the head
ing Specifications.” In some cases reference
must also be made to these Specifications” for
model application and methods of distinguishing
the various design and construction differences.
Manufacturers model or part numbers are used
in many instances in the Specifications” tabula
tions. These numbers are provided primarily for
unit identification or truck model application
reference, and should be referred to when order
ing parts. All detail service part numbers must be
obtained from the applicable Parts Book.
SPECIAL TOOLS
Special tools and equipment are mentioned,
and in many instances illustrated, throughout the
text. These tools are specially designed to accom
plish certain operations efficiently and readily.
Such tools are mentioned in the text by tool
vendor’s numbers. These tools are not offered for
sale by Chevrolet Motor Division. Information
regarding availability of these tools can be
obtained from your Zone Office.
SERVICE BULLETINS
Service bulletins are issued, when required,
supplementing or in some cases superseding infor
mation in this manual. Information in these
bulletins should be noted in the text of the
applicable manual section and the bulletin filed
for ready reference.
OPERATION
Operating instructions from the standpoint of
the driver are included in a booklet entitled
Owner’s and Driver’s Manual” which is placed in
the cab of every new Chevrolet Truck.
ALPHABETICAL INDEX
Important subjects, with manual page number
references, are alphabetically listed in the index in
the back of this manual.
iv CHEVROLET 40- 0 TRUCK SERVICE MANUAL

MODEL DATA
TRUCK
SERIES
GMC
ENGINE CLUTCH FRONT AXLE REAR AXLE TRANSMISSION
STD. OPT. STD. OPT. STD. OPT. STD. OPT. STD. OPT.
CE-40 350 -12"-1 -F050 -H110 HI 35 CH4 5 AT540
CS-40 250 292 11''-1 -F050 -H110 HI 35 CH4 5 -
SS-40 250 292 i r - i -F050 -H110 H135 CH4 5 -
CE-50 350 3 13"-1 -F050 F070 H150 T150, H170,
T170
CH4 5 282V, 285V, 542GD,
542GL, AT540
CS-50 292 -12"-1 -F050 F070 H150 T150, H170,
T170
CH4 5 540CL
SE-50 350 3 13” -1 -F055 F070 H150 T150, H170,
T170
CH4 5 285V,542GL,AT540,
SS-50 292 -12"-1 -F055 F070 H150 T150, H170,
T170
CH4 5 540CL
TE-50 350 3 13"-1 -F070 F090 H150 T150, H170,
T170
435GL 282V, 285V, 542GD,
542GL, AT540
TS-50 292 -12"-1 -F070 F090 H150 T150, H170,
T170
CH4 5 540CL
CE- 0 3 427 13"-1 12"-2 F070 F090,F110 H170 T 17 0,17121,
17221,19201
CH4 5 282V, 285V, 325V,
327V,542GD,542GL,
5 52B,575 B,AT540
ME- 0 3 427 13"-1 12"-2 F070 F090, F 110 30DSC 34DSC 542GL 285V,325V,5 52B,
542GL, MT40,
041 Aux., 7041 Aux.
TE- 0 3 427 13"-1 12"-2 F070 F090, F120 H170 T170,17121,
17221,19201
435GL 282V, 285V, 542GL,
5752C, AT540
CHEVROLET 40- 0 TRUCK SERVICE MANUAL

oGENERAL MOTORS CORPORATION o
WARRANTY MAY BE VOIDED IF WEIGHT
EXCEEDS ANY OF THE RATINGS SHOWN.
GROSS VEHICLE WEIGHT INCLUDES WEIGHT OF
BASE TRUCK, ALL ADDED EQUIPMENT, DRIVER
AND PASSENGERS, AND ALL PROPERTY LOADED
INTO TRUCK.
♦ REFER TO OWNER’S MANUAL FOR EQUIP
MENT REQUIRED FOR INTERMEDIATE OR
MAXIMUM GVW RATINGS, AND FOR OTHER
LOADING INFORMATION, INCLUDING TIRE
INFLATION.
| 1 RATINGS IN POUNDS
AS MANU- * MAXIMUM
FACTURED CAPABILITY
r m i_ ~ i
oo
VEHICLE MODEL IDENTIFICATION
AND WEIGHT RATING PLATE
The vehicle identification and
weight rating plate is located on the
cab left door pillar of all models
except cowl models Plate location
on cowl models is on the engine side
of cowl
ENGINE SERIAL NUMBERS
The engine serial num ber on “ V” engines is stam ped on top of the cylinder
block ahead of the right-bank cylinder head Engine serial num bers are not used
on In-line engines; num bers appearing on crankcase boss at re a r of distributor
are manufacturing location and buidling date codes
SERVICE PARTS IDENTIFICATION
The ’’Service P arts Identification" label is located on inside of glove com part
ment door of steel tilt and conventional cab models Location of label on cowl models
is determ ined by the body m anufacturer This label lists all special equipment
installed on the vehicle This inform ation is im printed on the label at the factory
and represents only the special equipment on the vehicle when it was shipped from
the factory Always refer to this information when ordering p arts
SERVICE PARTS IDENTIFICATION ______________
v.i.n.■■■■■■■ w/b a s e h h h i s e I H H I
V.I.N. —VEHICLE IDENTIFICATION NUMBER
NOTE: THE S PE C IA L EQ UIPM ENT L IS TE D B ELO W H AS BEE N IN ST ALLE D ON
DESCRIPTION DESCRIPTION
IMPORTANT: RETAIN THIS PLATE AS A PERMANENT RECORD
vi
CHEVROLET 40-50 TRUCK SERVICE MANUAL

SECTION 0
J lu J is U c G iio s i
INDEX
Subject Page No
General Information 0-1
Lubricant Symbols 0-1
Lubrication Charts
All models Except Steel Tilt C a b 0-2
Steel Tilt Cab Models 0-4
Engines and A c c e s s o rie s 0-6
Lubrication Capacities 0-7
Crankcase Capacity Chart 0-7
Transm ission Capacity C h a r t 0-8
Rear Axle Capacity Chart 0-8
Power Steering Capacity C h a r t 0-8
Lubricant Description 0-9
Engine Oil (Symbol "E") 0-9
M ulti-Purpose Gear Oil (Symbol "MPO") 0-10
Subject Page No
Gear Oil (Symbol "GO") 0-10
Lubricating Oil - Special (Symbol "ES") 0-10
M ulti-Purpose G rease (Symbol "MPG") 0 -1 0
Steering Gear Lubricant (Symbol "SG") 0-11
Petroleum Jelly (Symbol " S 3 " ) 0-11
Refrigeration Machine Oil (Symbol "S7") 0-10
Hydraulic Brake Fluid (Symbol "S12) 0-11
Special G rease (Symbol " S I ? " ) 0-11
Automatic Transm ission Fluid
(Symbol " S 1 9 " ) 0-12
High Tem perature G rease (Symbol "S27") 0-12
High Tem perature G rease (Special)
(Symbol MS28M) ° - 12
GENERAL INFORMATION
One of the most im portant item s to good truck
care is the lubrication of all necessary points with
the right lubricant, at the right tim e, and in the
right way It is the responsibility of the owner to
maintain proper lubrication practices as recom 
mended in this service manual
Chassis Lubrication Charts (figs 1 ,2, and 3)
will locate each lubrication point on the series
shown under each chart Each point is numbered
on the charts, and each number is keyed to explan
atory text on opposite page
Refer to "Engines and A ccessories Lubrication
C hart” (fig 4) for inform ation relative to location,
interval, and lubrication to be used in specific en
gine areas
Each item shown on charts requiring lubrica
tion is covered with a lubricant symbol Explan
ations of symbols start on page following charts
Explanations include type of lubricant recom m end
ed, and instructions regarding its application The
charts show recom mended intervals when various
item s should be lubricated The intervals are re c 
ommended for normal use; however, operating
conditions may require more frequent intervals
Recommended intervals should be followed until
operating experience indicates other periods
No particular brand of lubricant is recom 
mended as many reputable oil dealers can furnish
the right lubricants when advised of the correct
specifications or descriptions The lubricant man
ufacturer must be responsible for the quality and
satisfactory perform ance of his product His rep
utation is your best indication of quality
LUBRICANT SYMBOLS
Symbol Explanation
"E" Engine Oil
"MPO" M ulti-Purpose Gear Oil
"GO" Gear Oil
"ES" Lubricating Oil - Special
"MPG" M ulti-Purpose Grease
"SG" Steering Gear Lubricant
"S3" Petroleum Jelly
"S7" R efrigeration Machine Oil
"S12" Hydraulic Brake Fluid
"S17" Special Grease
"S19" Automatic Transm ission Fluid
"S27" High Tem perature Grease - Special
"S28" High Tem perature Grease - Special
Lubricants Must Be Stored and Dispensed in Such
a Manner That They Will Be Clean and Free of
Contamination, Due to Dirt or Other Foreign M atter
CHEVROLET 40- 0 TRUCK SERVICE MANUAL

Sec. 0-2
LUBRICATION
#
Figure 1 —Lubrication Chart I All Except Steel ilt Cab ModelsI
CHEVROLET 40- 0 TRUCK SERVICE MANUAL

Sec. 0-3
LUBRICATION
LUBRICATION DATA
(CHART ON OPPOSITE PAGE)
Item +
No Item Rem arks Symbol Miles+
1Front Spring Slip P a d s Apply as required
MPG 6,000
2Rear Spring Slip P a d s Apply each e n d
MPG 6,000
3Steering Knuckles 2 fittings each s id e MPG 6,000
4Steering Tie Rod Ends 1 fitting each e n d MPG 6,000
5Steering Drag Link E n d s 1 fitting each e n d MPG 6,000
6Power Steering Cylinder Ends ( a )
2 fittings MPG 6,000
7Aux Transm ission Shift Tower ( a )
MPG 6,000
8Propeller Shaft U -Jo in ts 1 fitting each joint
MPG 6,000
9Propeller Shaft Slip Joint
1 fitting each joint
MPG 6,000
10 Steering Column U -Joints 1 fitting each j o in t
MPG 6,000
12 Clutch Release C ross Shaft ( a )
1 fitting each e n d
MPG 6,000
13 Clutch Release B earing
427 Eng -cup S27 6,000
14 Tru-Stop Brake (a ) 4 or 8 fittin g s MPG 6,000
15 Speedometer A d a p te r 1 f ittin g MPG 6,000
16 Brake Camshaft (b) 1 fitting each (apply sparingly) MPG 6,000
17 Clutch Pedal Lever S h aft 1 fittin g MPG 6,000
18 Steering Gear Housing To level of filler p lu g
SG 6,000
19 Battery T e rm in a ls Keep coated (except ST batteries) S3 6,000
20 Electric Shift Unit (2-Spd ) ( a ) To level of filler p lu g
S7 12,000
21 To level of filler p lu g
MPO 6,000
Drain and r e f i l l MPO 12,000
21 Transm ission (C la rk ) To level of filler p lu g
GO 6,000
Drain and r e f il l GO 12,000
21 Transm ission (Spicer) To level of filler p lu g
ES 6,000
Drain and r e f i l l
ES 12,000
21 Transm ission - Auxiliary ( a )
To level of filler plug
ES 6,000
Drain and r e f il l
ES 12,000
21 Transm ission - Automatic Check level S19 6,000
Drain and r e f ill S19 24,000**
22 Rear Axle To level of filler plug MPO 6,000
Drain and r e f ill MPO 24,000#
23 Front Wheel B earings (d) Hand pack or use lubricator MPG 20,000*
24 Rear Wheel Bearings (e) Hand pack or use lubricator MPG 20,000*
25 Brake Cam Roller Pins (b)
Apply E20,000
27 Brake & Axle Cylinder Air Cleaner (a) Clean and r e f ill -6,000
28 Brake M aster Cylinder (c ) Fill - %" below o penin g
S12 3,000@
29 Hood L a tc h Apply with brush S17 6,000
(a) Some vehicles
(b) Air Brake only
(c) Hydraulic B rakes only
(d) Optional oil lubricated - use "GO” type oil
(e) Optional oil lubricated type requires no periodic servicing
* Or once a year, whichever occurs first
** 12,000miles under severe operation (change filter when changing oil)
# Or every 6 months, whichever occurs first
t When "MPG" M ulti-Purpose G rease is specified, lubricate every 6,000 miles or 60 days, whichever
occurs first
@ Or every 30 days, whichever occurs first
NOTE: Engine oil is used also to lubricate clevis pins, linkage, clevises,
door hinges, etc Application should be made by brush or spray
CHEVROLET 40-60 TRUCK SERVICE MANUAL

Sec. 0-4
LUBRICATION
SEE
ENGINE
DIAGRAM
T-8191
Figure 2—Lubrication Chart (Steel ilt Cab Models) 9
CHEVROLET 40- 0 TRUCK SERVICE MANUAL

Sec. 0-5
LUBRICATION
LUBRICATION DATA
(CHART ON OPPOSITE PAGE)
Item
No Item
1Front Spring Slip Pads and Brackets
2 Rear Spring Slip Pads
3 Steering Knuckles
4Steering Tie Rod E n d s
5Steering Drag Links
6Power Steering Cylinder Ends (a)
7Cab Hinges
8 Cab Hold-Down Latch
9Brake Cam shafts (b)
10 Clutch and Brake Pedals
11 Steering Idler Lever (a)
12 Propeller Shaft U-Joints
13 Propeller Shaft Slip J o i n t s
14 Steering Column U-Joints
15 Steering Column Slip J o in t
16 Speedometer Adapter
17 Transm ission Shift L e v e rs
18 Transm ission Shift Linkage (NP 540)
19 Steering Gear Housing
20 Clutch and Brake M aster Cylinder (a)
21 Battery Term inals
22 Electric Shift (2-Spd ) ( a )
23 Transm ission (N P )
23 Transm ission (Clark)
23 Transm ission (Spicer)
23 Transm ission - Automatic
94 R ear Axle
25 Front Wheel Bearings
26 Rear Wheel Bearings
27 Brake Cam R oller Pins (b )
28 Brake Power and Axle Cylinder
Air Cleaner (a)
29 Hand Brake Bell Crank (a) »
30 Clutch Release Bearing
Rem arks Symbol M ilest
Apply as required MPG 6,000
Apply each end MPG 6,000
2 fittings each side MPG 6 000
1 fitting each end , MPG 6,000
1 fitting each end MPG 6,000
2 fittings MPG 6,000
1 fitting each side , MPG 6,000
1 fitting MPG 6,000
1 fitting each (apply sparingly) MPG 6,000
2 fittings MPG 6,000
1 fitting MPG 6,000
1 fitting each joint MPG 6,000
1 fitting each joint MPG 6,000
1 fitting each joint MPG 6,000
1 fitting MPG 6,000
1 fitting MPG 6,000
2 fittings MPG 6,000
1 fitting MPG 6,000
To level of filler plug
SG 6,000
Fill - %" below opening
S12 3,000(c)
Keep coated (except ST b atteries) S3 6,000
To level of filler plug
S7 12,000
To level of filler plug
MPO 6,000
Drain and refill MPO 12,000
To level of filler plug
GO 6,000
Drain and refill GO 12,000
To level of filler plug ES 6,000
Drain and refill ES 12,000
Check level S19 6,000
Drain and refill S19 24,000**
To level of filler plug
MPO 6,000
Drain and r e f i l l MPO 24,000#
Hand Pack or use lubricator MPG 20,000*
Hand pack or use lu b ric ato r
MPG 20,000*
A p p ly E20,000
Clean and r e in s ta ll
_6,000
1 fitting MPG 6,000
Cup (427 Eng only)
S27 6,000
* O r once a year, whichever occurs first
** 12,000 m iles under severe operation (change filter when changing oil)
# Or every 6 months, whichever occurs first
$ When "MPG" M ulti-Purpose G rease is specified, lubricate every 6,000 m iles or 60 days, whichever
occurs first
(a) Some models
(b) Air brakes only
(c) Or every 30 days, whichever occurs first
NOTE: Engine oil is used also to lubricate clevis pins, linkage, clevises,
door hinges, etc Application should be made by brush or spray
CHEVROLET 40- 0 TRUCK SERVICE MANUAL

Sec. 0-
LUBRICATION
Item
No Item Rem arks Symbol Miles t
1 Propeller Shaft U - J o in t
1 fitting each jo in t MPG 3,000
2Propeller Shaft Slip J o i n t
1 fitting each jo in t MPG 3,000
3 Rear Spring Pin ( c ) 1 fitting each s i d e MPG 6,000
4Rear Axles To level of filler p lu g
MPO 6,000
Drain and refill MPO 24,000(b)
5Brake Camshafts (c)
1 fitting e a c h MPG 6,000
6 Brake Shoe R oller Pins ( c )
• Apply
E 20,000
7Wheel Bearings (d)
Hand pack or use lubricator MPG 20,000(a)
8Axle Shift Unit (2 or 3 Speed) (c) To level of filler plug S7 12,000
t When "MPG" M ulti-Purpose Grease is specified lubricate every 6,000 miles or 60 days, whichever
occurs first
(a) O r once a year, whichever occurs first
(b) Or every 6 months, whichever occurs first
(c) If used
(d) Optional oil lubricated type require no periodic service
Figure 3—Lubrication Chart andem Bevel 30DSC and 34DSC
CHEVROLET 40- 0 TRUCK SERVICE MANUAL

Sec. 0-7
LUBRICATION
Item
No Item Remarks Symbol M iles
1Engine Oil
Keep to "FULL” m ark
E Daily
2 Engine Oil Filter
At each oil change (Sec 6A)
3Engine A ir C le a n e r
See instructions (Sec 6M)
6,000
4 Crankcase V e n tila tio n See instructions (Sec 6A )
-
5A ir C om pressor F ilter (3) Clean and install (Sec 6 T )
6,000
6Governor A ir F i l te r
Clean and install (Sec 6 T )
6,000
7D istributor (2)
y2 turn of cam lubricator
12,000#
B reaker Pivot - 1 drop
E 6,000
Rotor felt - 4 drops
6,000
8 G e n e ra to r No lubrication re q u ir e d
9Starter See instructions (Sec 6Y )
-
10 Pow er Steering R eservoir (1) To oil level mark (Sec 9B)
S19 6,000
# Replace lubricator at 24,000 mile intervals (2) If used (V8) fill hinge type oiler with engine oil
(1) Some Models every 12,000 miles
(3) Vehicles with air brakes
Figure 4—Engine and Accessories Lubrication Chart ( ypical)
CHEVROLET 40- 0 TRUCK SERVICE MANUAL

Sec. 0-8
LUBRICATION
LUBRICANT CAPACITIES
CRANKCASE CAPACITY CHART
QTS QTS
ENGINE Less F ilter With Filter
MODEL U S IMP U S IMP
- IN-LINE
250 43% 54%
292* 54% 6 5
- V8
350 54% 65
366 6 5 86%
427 6 5 86%
* Add one quart when 2-quart filter is used
Crankcase capacities are for normal refill Add oil as indi
cated when oil filter is drained and element changed Capacities
given may be approximate Keep level as close as possible to
"FU LL” mark without over-filling Do not operate with level be-
low "ADD” mark ________________________________________________
TRANSMISSION CAPACITY CHART
MANUAL TRANSMISSION PINTS
U S IMP
CH465 8 6%
NP435 7 5%
NP540 10 8%
NP542 10 8%
CL282 12 10
CL285 12 10
CL325 14 11%
CL327 14 11%
SP5652 13 10%
SP5752 13 10%
SP5756 13 10%
AUTOMATIC TRANSMISSION
MT40 18* 15
AT540 18* 15
♦F ilter change only
AUXILIARY TRANSMISSION
SP6041 8 6%
SP7041 11 9%
REAR AXLE CAPACITY CHART
BEVEL PINTS
U S IMP
H110 14 11%
H135 20 16%
H150 20 16%
H170 19% 16%
17121 29 24%
18121 29 24%
TWO-SPEED
T150 18 15
T170 29% 24%
17221 29 24%
19201 34 28%
TANDEM-BEVEL U S IMP
Front Rear Front R ear
30DSC 30* 27 25* 22%
34DSC 29* 32 24^* 26%
* Add 2 pints at forw ard hole in top of differential
carrier
POWER STEERING CAPACITY CHART
NOTE: This is approximate quantity due to hose length and
cylinder sizes on various models- TT 0
U S IMP
Pow er S te erin g 8 P ts 6% Pts
CHEVROLET 40-40 TRUCK SERVICE MANUAL

Sec. 0-9
LUBRICATION
LUBRICANT DESCRIPTION
ENGINE OIL
(SYMBOL “E” ON CHARTS)
RECOMMENDATIONS
The oil industry m arkets various tj^e s of en
gine oil under certain service designations and
specification num bers
The selection of a reliable supplier, with close
attention to his oil and filter element change rec
ommendations can provide satisfactory lubrication
and longer life for engine
Gasoline Engine and D iesel
Use Only High Quality Oils Which Are:
(1) Intended for Service Designations "MS"
and "DM" (see Note)
- or -
(2) Products passing vehicle m anufacturer's
tests (including General M otors Standard
GM 6042M)
NOTE: Supplement 1 engine oils based upon
now obsoleted MIL-L-2104A) have been superseded
by MIL-L-2104B engine oils However, Supplement
1 engine oils (MS - DM) with a history of satis
factory perform ance are available and may be used
The following additive lim itations, which re 
quire emphasis, have been placed on the recom 
mended MIL-L-2104B and Supplement 1 oils:
1 Sufficient zinc dithiophosphate to produce
a minimum of 0 07 and a maximum of 0 10 per
cent zinc by weight
2 Sulfated ash (ASTM D-874) of 1 00 per cent
maximum by weight, except lubricants that contain
only barium detergent-dispersants where 1 50 per
cent by weight is allowed
The use of proper engine oils and oil change
intervals are your best assurance of continued re 
liability and perform ance of engine
IMPORTANT: Non-detergent and other lower
quality engine oils are specifically not recom 
mended
B reak-in Oils and Additives
The regular use of supplemental additives is
specifically not recommended and will increase
operating costs However, in cases of specific
problem s which may arise under certain condi
tions, additive supplements are available that can
effectively and econom ically solve these problems
without causing other difficulties For example,
if higher detergency is required to reduce varnish
and sludge deposits resulting from some unusual
operational difficulty, a thoroughly tested and ap
proved concentrate— “ Engine Oil Supplement” —
is available
NOTE: Refer to figure 4 for Engines and
A ccessories Lubrication Chart
VISCOSITIES
Atm ospheric tem peratures and severity of
service determine the viscosity grade of engine oil
to use Viscosity numbers constitute a classifica
tion of lubricants in term s of viscosity or fluidity,
but with no reference to any other characteristics
or properties
Gasoline Engines
As a guide to the selection of the proper grade
or viscosity of oil to be used in gasoline engines at
various atm ospheric tem peratures, refer to "Vis
cosity C hart" (fig 5)
The proper viscosity helps assu re good cold
and hot starting by reducing friction and thus in
creasing cranking speed
S A E 5W and 5W-20 oils are not recom m end
ed for sustained high speed driving
S A E 30 oils may be used at tem peratures
above 40° F
OIL CHANGE INTERVALS
It is recommended that new engines should
have the first oil change at 3,000 m iles However,
the oil level should be checked m ore frequently
during the break-in period since somewhat higher
oil consumption is norm al until piston rings be
come seated
The drain interval may then be increased or
decreased, depending upon experience with specific
oils or the recomm endations and used oil analyses
as furnished by the supplier Such a procedure
would be helpful in establishing the most practical
oil change period for the particular service
The kind of oil used (MIL-L-2104B, GM6042M,
etc ), the efficiency of the filtering system and
condition of engine must be considered in deter
mining when to change oil
The most satisfactory method for determining
when to change lubricating oil is by oil analysis
using laboratory tests
NOTE: Sample of the engine oil can be obtained
from the drain plug on the engine oil filter
After several test periods (gallons fuel con
sumed, miles, hours, weeks, etc ), a time interval
for oil change can be established However, a new
series of tests should be run if filters, oil brands,
or grades are changed
CHEVROLET 40- 0 TRUCK SERVICE MANUAL

Sec. 0-10
LUBRICATION
The drain interval may then be increased or
decreased, depending upon experience with specific
oils or the recommendations and used oil analysis
as furnished by the supplier Such a procedure
would be helpful in establishing the most practical
oil change period for the particular service
Wide variations in different types and brands
of lubricating oil make it profitable to contact the
oil supplier to assist in the development of the oil
change period
NOTE: Filter elem ent or elem ents should be
changed at each oil change as directed in GASO
LINE ENGINES (SEC 6A) in this manual
MULTI-PURPOSE GEAR OIL
(SYMBOL “MPO” ON CHART)
M ulti-Purpose Gear Oil, meeting U S Army
Ordnance Specifications MIL-L-2105 of latest issue
and/or A P I GL-5 and indicated by the Symbol
"MPO” on charts, must satisfactorily lubricate
heavy duty truck hypoid or bevel axles, and trans
m issions, under maximum torque and speed condi
tions It must provide necessary and suitable load-
carrying characteristics to prevent scoring and
w ear, good stability in storage and service, and
give good resistance to corrosion Suppliers should
assu re these ch aracteristics, and be responsible
for the quality and satisfactory perform ance of
th eir products
VISCOSITIES
Rockwell Axles
In Rockwell axles, S A E 140 should be used
the year around except in cases of extremely low
tem peratures If trucks are parked in tem peratures
below +20 F , or operated in tem peratures con
sistently below 0°F , it is advisable to use S A E
90
Other Units (Axles and Transm issions)
S A E 90 may be used the year around If
truck is operated in tem peratures consistently
below 0 F , use S A E 80 If the truck is operated
in consistently high tem peratures (over 100°F ),
S A E 140 may be used
Figure 5—Engine Viscosity Charts
NOTE: Refer to Lubrication Charts (figs 1
or 2) for axle or transm ission using M ulti-Purpose
Gear Oil Also, refer to "REAR AXLE AND CON
TROLS" (SEC 4A) for axle, and TRANSMISSIONS
AND CLUTCHES (SEC 7) for transm ission main
tenance procedures
GEAR OIL
(SYMBOL “GO” ON CHARTS)
Type of lubricant indicated by the symbol
"GO" on charts must be straight mineral gear oil
of the best quality Oxidation inhibitors or anti
foam agents may be added to these oils to gain
greater stability and resistance to thickening
Use S A E 90 above 10°F , or S A E 80 be
low +10°F
NOTE: Refer to Lubrication Charts (fig 1 or
2) for transm issions using gear oil Also, refer
to "TRANSMISSIONON-VEHICLE SERVICE OPER
ATIONS" (SEC 7B) for transm ission maintenance
procedures
LUBRICATING OIL-SPECIAL
(SYMBOL “ES” ON CHARTS)
Oils such as "Aviation Grade Engine Oil" or
S A E 50 Heavy Duty engine oils may be used Use
of S A E 30 is recommended when tem perature
falls below 0°F
NOTE: Refer to Lubrication C harts (fig 1 or
2) for transm ission using special lubricating oil
Also, refer to "TRANSMISSION ON-VEHICLE
SERVICE OPERATIONS" (SEC 7B) for transm is
sion procedures
MULTI-PURPOSE GREASE
(SYMBOL "MPG” ON CHARTS)
The lubricant indicated by the symbol "MPG"
on charts, should be a high tem perature, good
quality lithium soap, m ulti-purpose, extrem epres-
sure grease, which m eets GM Specification GM
6031M
LUBRICATING CHASSIS
(Refer to Figures 1 and 2)
All lubrication fittings must be clean before
applying lubricant Also, always be sure equipment
used in applying lubricant is clean Every precau
tion should be taken to prevent entry of dirt, grit,
lint, or other foreign m atter into lubricant con
tainers
CHEVROLET 40- 0 TRUCK SERVICE MANUAL

Sec. 0-11
LUBRICATION
NOTE: Fittings that have become broken, or
damaged, should always be replaced with new part,
and can be removed with a wrench or suitable ex
tracting tool Also, refer to "PROPELLER SHAFTS"
(SEC 4D) for packing of center bearings
WHEEL BEARINGS
All wheel bearings (except oil lubricated type)
require high tem perature grease Instructions for
cleaning, packing and the adjustment of wheel bear
ings will be found in "FRONT HUBS AND BEAR
INGS” (SEC 3D) of this manual
STEERING GEAR LUBRICANT
(SYMBOL “SG” ON CHARTS)
The lubricant indicated by the symbol "SG"
is a special steering gear lubricant, No 0 grade
with low cold test characteristics and extrem e
pressu re properties meeting GM 4673M specifica
tion This type of lubricant is marketed by many
oil companies
M ulti-Purpose G ear Oil "MPO" previously
described, may be used to replenish steering gear
housing when additional lubricant is required;
however, lubricant described as "SG" must be used
as initial fill after overhaul, or in a new gear
At specified intervals, remove filler plug in
housing and add lubricant to bring level up to filler
plug opening Do not overfill housing
When hard steering is encountered as a result
of cold weather, the steering system should be lu
bricated as follows:
Use steering gear lubricant (Symbol "SG") or
M ulti-Purpose G rease (N L G I #0) to lubricate
all steering linkage such as steering knuckles, tie
rod ends, drag link ends, and (if used) power steer
ing booster cylinder ends
NOTE: Refer to STEERING GEAR (SEC 9),
for maintenance procedures
PETROLEUM JELLY
(SYMBOL “S3” ON CHARTS)
The type lubricant indicated by the symbol
"S3" is petroleum jelly or petrolatum
BATTERY TERMINALS
To prevent corrosion, remove cables, clean
term inals on cable and battery, and reinstall cables
to battery term inals Tighten cables securely,
then apply petroleum jelly (except ST batteries)
DISTRIBUTOR BREAKER CAM
At recommended intervals, apply a sm all
amount of petroleum jelly on distributor breaker
cam Do not use an excessive amount
REFRIGERANT MACHINE OIL
(SYMBOL “S7” ON CHARTS)
Refrigeration machine oil is a highly refined
straight m ineral petroleum oil
Refer to "REAR AXLE AND CONTROLS" (SEC
4A) of this manual for application procedure
HYDRAULIC BRAKE FLUID
(SYMBOL “SI 2” ON CHARTS)
The fluid indicated by the symbol "S12" must
be genuine heavy duty brake fluid meeting the
heavy duty standards of S A E J-1703 (form erly
S A E 70R3)
NOTE: Refer to "HYDRAULIC BRAKES" (SEC
5A) of this manual for maintenance procedures on
hydraulic brakes, and "CLUTCHES" (SEC 7D) on
hydraulic clutch maintenance
SPECIAL GREASE
(SYMBOL “SI 7” ON CHARTS)
A sem i-fluid grease having extrem e pressure
properties and containing zinc oxide
At regular lubrication intervals, or whenever
accessible during repairs or overhaul, apply lub
ricant sparingly to the following item s and areas:
Door Striker Plates
Door Checks and Trunnions
Door Lock Remote Control Link
Cowl Ventilator Linkage
Door Striker Bolts
Door Lock Plunger
Speedometer Cable
Seat Adjuster Slides
Door Lock Mechanism
Door Dove Tails
Window Regulator Channels
Window Regulators
Hood Hinges and Latch
Tilt Cab Guide Pin and Release Mechanism
In addition to item s just mentioned, which are
lubricated periodically, many other units use this
lubricant at tim e of assembly after overhaul, as
indicated in various sections of this manual
CHEVROLET 40- 0 TRUCK SERVICE MANUAL

Sec. 0-12
LUBRICATION
AUTOMATIC TRANSMISSION FLUID
(SYMBOL “S I9” ON CHARTS)
General M otors Dexron® Automatic T rans
mission Fluid, P art Number 1050568-69-70 which
has been especially formulated and tested for use
in automatic transm ission is recommended for
use in power steering Other Automatic T ransm is
sion Fluids identified with the m ark DEXRON®
are also recommended DO NOT USE ANY OTHER
FLUID
POWER STEERING
Refer to "POWER STEERING" (SEC 9B) of
this manual for servicing and maintenance of power
steering
AUTOMATIC TRANSMISSION
Refer to "TRANSMISSION ON-VEHICLE
SERVICE” (SEC 7B) of this manual for servicing
and maintenance of autom atic transm ission
HIGH TEMPERATURE GREASE (SPECIAL)
(SYMBOL “S27” ON CHARTS)
The High Tem perature G rease indicated by
the Symbol ”S27” on charts should be a short fiber,
non-fluid, sodium soap grease having a high m elt
ing point (500 F ) and a #3 N L G I consistency
The following points require use of high temp
erature grease at assem bly Methods of applying
grease to these points are covered in applicable
sections of this manual
Clutch Pilot Bearing
Clutch Release Bearing Collar
Clutch Shift Fork Ball Stud
Steering Column Upper Bearing
HIGH TEMPERATURE GREASE (SPECIAL)
(SYMBOL “S28” ON CHARTS)
The lubricant indicated by the symbol "S28"
must be a water-proof, non-soap, smooth fiber
grease having a #1 N L G I stable consistency,
and must withstand extended high tem peratures
STOPMASTER BRAKE UNIT
At tim e of assem bly after overhaul apply
above lubricant to areas indicated in "AIRBRAKES"
(SEC 5B) of this manual
The use of p roper engine oils and oil change
intervals are your best assurance of continued relia
bility and perform ance from your Chevrolet engine
CHEVROLET 40- 0 TRUCK SERVICE MANUAL

SECTION
G o b i, tJleatL n a, an d Ain, Go-ndUtio-niacj,
Contents of this section are listed in Index below:
Section
1A
IB
General Cab Maintenance
(All C a b s)
Conventional Cab (Includes
Heating System )
Page No
1
18
Section Page No
1C Steel Tilt Cab (Includes Heating
S y stem ) 37
ID Body M ountings 55
IE A ir Conditioning 59
All illustrations are numbered consecutively within each sub-section
Information on sheet m etal and fiberglass components as used with Conven
tional Cab is described in SHEET METAL (SEC 11) of this manual D escription
of each type cab is explained in respective cab section
Maintenance information on subjects common to all cabs, such as painting,
checking for w ater and dust leaks, correcting cab alignment, windshield wipers,
and replacem ent of windshield glass is covered in the "GENERAL CAB MAINTEN
ANCE” section following For all other information, refer to respective cab section
For inform ation pertaining to cab wiring and dash gauges, refer to CHASSIS
ELECTRICAL AND INSTRUMENTS (SEC 12) of this manual
SECTION A
Q & n e 'ia i G a b M a in t e n a n c e .
NOTE: This section includes general maintenance information on subjects
which are common to all cabs Subjects are listed in Index below:
Subject Page No
G e n e r a l 1A-1
Key Inform atio n 1A-1
Exterior M aintenance 1A-2
Interior M ainten a n ce 1A-2
Dust and W ater L eak s 1A-3
Cab Alignment 1A-3
Straightening 1A-3
NOTE: Refer to respective CAB
GENERAL
All cab assem blies for models covered by this
manual are of welded steel construction Heavy
box-type cab fram ing is used to form a stre ss-
resistant foundation to fortify cab against twisting
and flexing
Principle steel panels are lap-jointed and
welded for maximum sealing and structural strength
Further rigidity is achieved by strategically located
reinforcem ent braces and brackets Sturdy steel
door fram es serve as upright structural m em bers
for rigid cab side support to assure proper door
fit Heavy duty hinges assure sag-resistant doors
while doors are of double-panel construction for
extra strength Prim ary sheet metal panels have
stam ped depressions to minimize cab drumming
and vibration Sheet metal components receive
several protective finishes to provide ample re 
sistance to rust and corrosion
Subject Page No
Dinging and F in ishing 1A-3
P a in tin g 1A-3
Windshield Glass R eplacem ent 1A-4
Rear Window R e p lace m en t 1A-7
Lap Belt M aintenance 1A-7
Windshield W ip e r s 1A-8
section for all other information
Flexible mounts cushion cab assembly against
shock and protect cab panels from stress and
strain Periodic inspections are recommended to
ensure that all cab mounting bolts and sheet metal
screw s are properly tightened
Refer to LUBRICATION (SEC 0) in this man
ual for information regarding lubrication of cab
components such as door hinges and door lock
mechanism Information on sheet metal compon
ents used with conventional cab is described in
SHEET METAL (SEC 11) of this manual
KEY INFORMATION
All models have lock cylinders incorporating
coded keyways and keys The code letter is located
on key shank and the code number is stamped on the
knock-out portion of the key head These numbers
identify the locks in which the keys are used and
are required when ordering or making new keys
CHEVROLET 40- 0 TRUCK SERVICE MANUAL

Sec. 1A-2
Notch depth inform ation on current production
keys will be provided upon request through the
m anufacturer of your key cutting equipment or his
locksmith association Also, he will be able to
furnish a conversion package for your cutter, if
required, for grinding new keys
EXTERIOR MAINTENANCE
Entire vehicle should be regularly inspected
for condition of paint and for corrosion damage,
with particular attention given to chrome Inspec
tion should be made more frequently in freezing
weather due to the corrosive effect of road de-
icing m aterials (salt, calcium chloride, etc ) on
m etal If inspection discloses any evidences of cor
rosion, paint failure, or bare metal, corrective
m easures as outlined under ’’Painting” (later in
this section) should be imm ediately employed
Body painted surfaces and chrome plating
should be protected by a coating of wax, applied
at regular intervals Periods between applications
should be sufficiently short to assure continuous
protection of the finish; 30 days after delivery, and
at least once a year thereafter Any good body wax
can be used for both painted and chrom e surfaces
Wax should be applied immediately after vehicle
has been cleaned
NOTE: Calcium chloride and other salts, road
tar, excretion from insects ("tree sap”), chem icals
from factory chimneys and other foreign m atter
may permanently damage paint and chrom e F re
quent, regular washing and a thorough cleaning
after exposure is recommended to prevent damage
by these substances Use either cold or lukewarm
w ater Never wash vehicle in direct rays of the sun
and always wait until painted surfaces have cooled
INTERIOR MAINTENANCE
Care of the upholstery is a relatively sim ple
but im portant m atter Accumulation of dirt on the
surface eventually turns into a hard, gritty, sub
stance which cuts into the surface of the upholstery
VINYL COATED CLOTH
To clean the seats, use lukewarm, not hot or
cold w ater, and any mild soap or liquid household
GENERAL MAINTENANCE
detergent Work up thin suds on a piece of cheese
cloth and rub upholstery briskly Remove suds with
a damp cheesecloth, using no soap, and finish by
wiping lightly with a dry soft cloth Do not use
furniture polishes, oils, varnishes, or ammonia
As required, stubborn stains may be removed with
common foaming-type upholstery cleaner prepared
for use on vinyl cloth
WOVEN NYLON FABRIC
1 Carefully brush all loose particles of dirt
and soil
2 Im m erse sm all cloth in solvent type clean
ing solution, wring out thoroughly, open cloth and
allow medium evaporation
IMPORTANT: Use only solvent clean
ing solutions prepared specifically for
use on nylon fabrics. DO NOT USE gaso
line, bleaches, reducing agents, acetone,
lacquer thinners, enamel reducers, nail
polish remover, or cleaning solvents which
contain dyes or caustic agents. Use of these
solvents tends to weaken and change the
color of the fabric.
3 Place cloth on soiled spot and blot the area
gently - DO NOT RUB This will pick up particles
which are too embedded to be removed in the brush
ing operation Repeat this operation several times
- in each instance using a clean area of cloth
IMPORTANT: DO NOT use too much cleaning
fluid; some interior trim assem blies are padded
with rubber and solvent cleaners are generally
solvents for rubber The application of too much
cleaner may destroy these rubber pads or cause
the rubber itself to penetrate the upholstery fabric
and soil appearance
4 Im merse second cloth, wring out, and allow
evaporation until barely damp, then apply to both
the soiled and the area surrounding sam e, using a
light swabbing motion
5 Repeat brushing operation
6 If a cleaning ring should form , the entire
PRECAUTIONS FOR CLEANING FABRICS
1 DO NOT use as a cleaning solvent, any gasoline which is colored or which con
tains tetraethyl lead
2 DO NOT use solvents such as acetone, lacquer thinners, enamel reducers or
nail polish rem over, as a cleaning solvent
3 DO NOT use laundry soaps, bleaches, or reducing agents, such as the following:
Chloride of lim e, javelle water hydrogen peroxide, sodium hydrosulphate, potas
sium perm anganate, chlorine or shlorine water, sulphurous acid (sulphur diodide),
soidum thiosulphate (photographers' hypo) The use of these agents tends to
weaken fabric and to change its color
4 DO NOT use too much cleaning fluid; some interior trim assem blies are padded
with rubber and solvent cleaners are generally solvents for rubber The appli-
cation of too much cleaner may destroy these rubber pads or leave a solvent ring
CHEVROLET 40- 0 TRUCK SERVICE MANUAL