Chevrolet 40 Series 1972 User manual

40-60 SERIES TRUCK
SUPPLEMENT
SERVICE MANUAL

1 9 7 2
CHASSIS SERVICE MANUAL
SECTION INDEX
SECTION NAME
0LUBRICATION
SUPPLEMENT 3FRONT SUSPENSION
c o v e r in g 4REAR SUSPENSION
SERIES 40-60
CHEVROLET TRUCKS 5BRAKES
6A GASOLINE ENGINES
FOREW ORD 6D ENGINE MOUNTINGS
6K ENGINE COOLING
SYSTEM
This manual is a supplement to the 1971 Series 40-60
Truck Service Manual. It includes procedures for main
tenance and adjustments, minor service operations, and
removal and installation for components of Chevrolet Series
40 through 60 Trucks. rocedures involving disassembly
and assembly of major components for these vehicles are
contained in the 1972 Chevrolet assenger 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
6M ENGINE FUEL SYSTEM
6T AIR COMPRESSOR
AND GOVERNOR
6Y ENGINE ELECTRICAL
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 approval.
The right is reserved to make changes at any time without
notice.
7TRANSMISSIONS
AND CLUTC ES
STEERING SYSTEM
10 W EELS & TIRES
11 S EET METAL
CHEVROLET MOTOR DIVISION
General Motors Corporation
DETROIT, MICHIGAN
12 C ASSIS ELECTRICAL
AND INSTRUMENTS
ALP ABETICAL INDEX
© 1 72 General Motors Corporation Printed in U.S.A.

Sec. 0
Page 1
SECTION 0
Jluhnicatio-n
All information contained in Service Man al ST -331-71 nder
LUBRICATION (SEC. 0, Page 1 thro gh 12) will apply to vehicles cov
ered by this p blication. The following information will also apply:
TRANSMISSION CAPACITY CHART
Man al Transm ission U.S. IMP.
SM465 86%
NP435 75%
NP540 9 U
NP542 10 8%
CL282 12 10
CL285 12 10
CL325 14 11%
CL327 14 11%
SP5652 13 10%
SP5752 15 m
SP5756 15 12%
A tomatic Transm ission
MT40 18* 15
MT41 18* 15
AT475 10* 8l4
AT540 22* 18%
* Filter Change Only.
A xiliary Transmission
SP6041 86%
SP7041 11 9%
ENGINE OIL
(SYMBOL “E” ON CHARTS)
ENGINE OIL
It is recommended that new engines sho ld
have the first oil change at 3,000 m iles, thereafter
at 3 months or 4,000 mile intervals. This drain
interval may be increased or decreased depending
pon the severity of service and experience with
specific oils or the recommendations and sed oil
* analysis as f rnished by the s pplier. S ch a pro
ced re wo ld be helpf l in establishing the most
practical oil change period for the partic lar
service. Refer to Service Man al ST-331-71.
Contaminated engine oil can ca se a malf nc
tion of valve lifters or the PCV valve. A sticking
valve lifter can ca se leakage of nb rned gases
thro gh the valve. A pl gged or sticking PCV valve
will affect carb retor mixt re and will prevent
proper crankcase ventilation.
ENGINE OIL FILTER
Oil filter sho ld be replaced at the first oil
change and each oil change thereafter to filter
sm all particles which co ld affect valve lifters or
PCV valve action.
RECOMMENDATIONS
The oil ind stry markets vario s types of en
gine oil nder certain service designations and
specification n mbers.
The selection of a reliable s pplier, with close
attention to his oil and filter element change rec
ommendations can provide satisfactory l brication
and longer life for engine.
Gasoline and D iesel Engines
Use only high q ality oils which are intended
for Service Designations "MS” and "DM” (SE/CC
New A.P.I. Designation) see NOTE.
The following additive limitations, which re
q ire emphasis, have been placed on the recom 
mended MIL-L-2104B (now s perseded by MIL-L-
46152) and S pplement 1 oils:
1. S fficient zinc dithiophosphate to prod ce
a minim m of 0.07 and a maxim m of 0.10 per
cent by weight.
2. S lfated ash (ASTM D-874) of 1.00 per cent
maxim m by weight, except l bricants that contain
only bari m detergent-dispersants where 1.50 per
cent by weight is allowed.
NOTE: S pplement 1 engine oils (based pon
now obsoleted MIL-L-2104A) have been s perseded
by MIL-L-2104B engine oils. However, S pplement
1 engine oils MS-DM (SE/CC New A.P.I. D esig
nation), with a history of satisfactory performance
are available, and may be sed.
The se of proper engine oils and oil change
intervals are yo r best ass rance of contin ed re
liability and performance from yo r engine.
IMPORTANT: Non-detergent and other lower
q ality engine oils are specifically not recom 
mended. POWER STEERING FLUID
(SYMBOL "S32”)
GM Approved Hydra lic Power Steering Fl id
is available thro gh wholesale wareho ses and tr ck

Sec. 0
Page 2
LUBRICATION
centers. Check fluid level every 6,000 miles or 4
months, hichever occurs first. Fill pump reser
voir to proper level. If GM Po er Steering Fluid is
not available, DEXRON® Automatic Transmission
Fluid (Symbol SI9) may be used.
CAUTION: DO NOT use GM Power
Steering Flui in automatic transmissions.
AUTOMATIC TRANSMISSION FLUID
(SYMBOL “SI 9” ON CHARTS)
(Refer to Service Manual ST-331-71)
Oil level in the automatic transm ission must
be checked at each engine oil change. Under normal
driving conditions the transm ission fluid should be
changed every 24,000 m iles. Under unusual condi
tions such as off-road (construction) or constant
stop and go driving (pickup and delivery) fluid
should be changed at 12,000-mile intervals. It is
important that transmission fluid level be main
tained at the full mark and NOT OVERFILLED.
ENGINE AND ACCESSORY
LUBRICATION
The follo ing additional information applies to
Lubrication Chart (fig. 4) on page 7 of ST-331-71
Service Manual.
CARBURETOR AIR CLEANER
ELEMENT
Air cleaner should be inspected and serviced
at intervals specified in Emission Control System
booklet, or more often under severe dust conditions,
also, henever dirt is visible in element or oil.
POWER STEERING RESERVOIR
Fluid level should be checked every 6,000
m iles and filled ith S32 Po er Steering Fluid, or
if not available ith S19 Automatic Transm ission
Fluid.

Sec. 3
Page 3
SECTION 3
S u d s K t & n d A X U l
SECTION 3A
f y n x w U A U < f * u n e + t t
All information and alignment instr ctions in Service Man al
ST-331-71 "FRONT END ALIGNMENT” (SEC. 3A) are applicable
to models covered by this s pplement.
SECTION 3B
A xle.
All front axle information in Service Man al ST-331-71 "FRONT
AXLE” (SEC. 3B) is applicable to models covered by this s pplement.
All front axle information for the F-120 axle is also applicable to the
F-110 axle. Ill strations and specifications have been pdated.
1 Steering Kn ckle 9 Axle Center
Spindle 10 Stop Bolt and Lock
2 Kingpin B shing N t
(Upper) 11 Draw Key
3 Kingpin 12 Thr st Bearing
4 Cap Screw 13 Tie Rod End Assy.
5 Kingpin Bearing Cap 14 Kingpin Bearing Cap
(Upper) (Lower)
6 Gasket 15 Gasket
7 L be Fitting 16 Kingpin B shing
8 Shim (Lower) t-8793
1 Steering Kn ckle
Spindle
2 Steering Kn ckle
B shing
3 Kingpin B shing
(Upper)
4 Kingpin
5 D st Cap
6 Kingpin N t
7 Cotter Pin
8 Gasket
9 L be Fitting
10 Washers or Shims
11 Axle Center
12 Stop Bolt and Lock
N t
13 Thr st Bearing
14 Tie Rod Assembly
15 Pl g Retainer
16 Ejqpansion Pl g
17 Kingpin B shing
(Lower) t-8794
Figure 1 —Steering Knuckle (F070 Axle) Figure 2 —Steering Knuckle (F090 Axle)

Tr o n t axle
Sec. 3
Page 4 ___________
T-8795
1 Steering Knuckle
Spindle
2 Steering Knuckle
Bushing
3 Kingpin Bushing
(Upper)
4 Kingpin
5 Cap Scre
6 Dust Cap
7 Kingpin Nut
8 Cotter Pin
9 Gasket
10 Lube Fitting
11 Spacers or Shims
12 Axle Center
13 Stop Bolt & Lock Nut
14 Thrust Bearing
15 Tie Rod End Assy.
16 Plug Retainer
17 Expansion Plug
18 Kingpin Bushing
(Lo er)
Figure 3— Steering Knuckle (FI 10 and F I20 Axles)
AXLE SPECIFICATIONS
AXLE MODEL F050-F055 F070 F090 F110—FI 20
KING PIN
Length
.................
6.3594” 7.8906” 8.750” 8.750”
Diameter
At T p ...............
1.1090”— 1.1094” 1.2492”— 1.2496” 1.1855”— 1.1865” 1.1855”— 1.1865”
At B tt m ...........
1.1090”— 1.1094” 1.2492”— 1.2496” 1.14330”— 1.14340” 1.4330”— 1.4340”
KING PIN BUSHING
Length .................
— —
1.9063” 1.9063”
Diameter
Outer ................
— —1.4330”— 1.4340” 1.4330”— 1.4340”
Inn er
.................
——1.1870”— 1.1880” 1.1870”— 1.1880”
STEERING KNUCKLE BUSHING*
Length .................
Upper ................
1.3438” 1.875” 1.709”— 1.729” 1.760”
L wer ................
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”
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” Yell w .121”— .123” Yell w
.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 t Next Advance t Next
C tter Pin H le. C tter Pin H le.
King Pin Bearing Cap, Cap
Screw ................
4 -5 Ft. Lbs. 5 -6 Ft. Lbs. 3 - 5 Ft. Lbs. 3 - 5 Ft. Lbs.
* Ream after Installati n

SECTION 3C
f y n & n t f J U w a A .
All information on Front Springs contained in Service Man al
ST-331-71 “ FRONT SPRINGS" (SEC. 3C) is applicable to models
covered by this s pplement. The following “ Torq e Specifications”
chart has been pdated.
TORQUE SPECIFICATIONS
C-M-S
Models
(Ft.-Lbs.)
T
Models
(Ft.-Lbs.)
Spring U-Bolt (N t)................................................. . . 105 - 130 190 - 210
Spring U-Bolt (N t)................................................. . . *175 - 250 -
Spring Hanger to Frame Bolt (N t) ..................
60-85 35 - 45
Spring B mper to Frame Bolt (N t) ............... 14-22 35 - 45
Spring B mper to Frame Bolt (N t) ...............
** 2 - 3 -
Spring Front Eye Bolt (N t) ..............................
. . 190 - 210 150 - 200
Spring Rear Rebo nd Pin Retainer (Bolt) . . . 20 - 25
Spring Rear Rebo nd Bolt (N t) ........................
75-95 -
Shock Absorber Bracket to Frame Bolt (N t) . . 40-50 65 - 95
Shock Absorber Upper and Lower Eye Bolt (N t) 65 - 95 40 - 50
Shock Absorber St d to Frame (N t)................ 130 - 190 -
* 9,000 and 11,000 lb. Axles Only.
** 366 and 427 V8 Gas Engines.
SECTION 3D
c J lu b i a n d Q e a s U n G A .
All information in Service Man al ST-331-71 “ FRONT HUBS AND
BEARINGS” (SEC. 3D) is applicable to models covered by this s pple
ment. The following revision will also apply:
CLEANING, INSPECTION, AND REPAIR
REPAIR
Brake Dr m Replacement
1. Demo ntable Type. The demo ntable type dr m may be separ
ated from the h b and removed from the vehicle witho t dist rbing the
h b. The dr m is held to the h b by the wheel st ds and n ts as shown
in fig re 4.

Sec. 3
Page 6
FRONT HUBS AND BEARINGS
T-91 15
Side Ring
Lock Ring
Wheel
Wheel Stud Nut
Wheel Stud
Brake Drum
Hub
Cap Scre & Washer
Bearing Cone and
Roller Assy. (Outer)
Bearing Retainer
Adjusting Nut Washer
Adjusting Nut
Hub Cap
Cotter Pin
Backing Plate
Inner Oil Seal
Bearing Cone and
Roller Assy. (Inner)
Spindle
10
11
12
13
14
15
16
17
18
1
2
3
4
5
6
7
8
9
Figure 4 — Front ub and Bearing with Demountable Wheel and Drum

Sec. 4
Page 7
SECTION 4
( le a / i S u A s n e t t & io s t
All information contained in Service Man al ST-331-71 is ap
plicable to models covered in this s pplement. The following informa
tion will also apply:
SECTION 4A
(lean. A xleA . a n d G ottisioh
IMPORTANT
When parking vehicle eq ipped with a two- or three-speed axle, the
axle sho ld be shifted into LOW range with engine r nning. Engage
cl tch and transmission to be s re axle has completed shift into LOW
range. Apply parking brake, place transmission in ne tral and sh t off
engine. When leaving the vehicle parked or nattended the previo s in
str ctions m st be followed:
VACUUM SHIFT SYSTEM
MAINTENANCE
AIR CLEANER
Air cleaner removes dirt particles from at
mosphere which passes into the control valve and
other nits. Air cleaner sho ld be removed and
cleaned at reg lar intervals.
SERVICING AIR CLEANERS
(Refer to Fig re 1)
The air cleaner sed on Conventional and S50
Models is the metal c p type which ses a hog's
hair type element. This c p is a friction fit on the
air intake pipe and can be removed by p lling
straight off. It can be cleaned by rinsing in a s it
able solvent and re sed. Refer to LUBRICATION
(SEC. 0) in this s pplement for service intervals.
If cleaner has become so laden with an acc m la
tion of dirt, that satisfactory cleaning cannot be
done, replace with a new cleaner.
The air cleaner sed on all Tilt-Cab Models
is a plastic encased, synthetic element type filter,
and cleaning is NOT recommended. When cleaner
becomes so laden with dirt, that tapping it against
som e solid s rface (s ch as a work bench) will
not remove foreign matter, then a new cleaner
sho ld be installed.
IMPORTANT: DO NOT OPERATE VEHICLE
WITH AIR CLEANER DISCONNECTED OR RE
MOVED. Figure 1—Air Cleaners
T-9142
AIR TYPE ELEMENT
PLASTIC OUSING SYNT ETIC ELEMENT
)

Sec. 4
Page 8
SECTION 4B
(leal BpAitUfi and Suifiesutiott
HENDRICKSON TANDEM REAR SUSPENSION
Refer to Service Manual ST -331-71 "REAR SPRINGS AND SUS
PENSION” (SEC. 4B), pages 4B-7 and 4B-8 for figures 9, 11 and 12.
EQUALIZING BEAM REMOVAL
AND REPAIR
The follo ing procedures cover removal and
installation of either equalizing beam ithout re
moving any other units of the suspension system .
When removing an axle assembly, accomplish only
steps required to loosen axle at each end of beam.
EQUALIZING BEAM REMOVAL (Fig. 9)
1. Raise and support frame to remove eight
from beams.
2. At axle brackets, remove nuts (5), ashers
(7), and bolt (1). Pry adapters (2) from bushings
and brackets.
3. With blocking under beam cross tube (fig.
1) to support eight of beams, remove saddle caps
attached ith four nuts and flat ashers.
4. Lo er the cross tube and beams, then slide
beams from tube ends.
EQUALIZING BEAM INSPECTION
1. Inspect beam end bushings and beam center
bushing for evidence of damage or deterioration of
the rubber. If any damage is evident, replace bush
ings as directed under "Equalizing Beam Bushing
Replacement" later in this section.
2. Inspect cross tube and thrust ashers and
replace if bent or orn.
EQUALIZING BEAM BUSHING
REPLACEMENT
Press old bushing out, using a suitable driver
or press to exert force on bushing outer sleeve.
Press ne bushing into place, exerting force on
bushing outer sleeve until outer sleeve extends an
equal distance through beam at both sides.
EQUALIZING BEAM INSTALLATION
(Refer to Fig. 9)
1. Position beams, ith cross tube and thrust
ashers in place at spring saddles and axle brackets.
NOTE: At axle end of beam, install adapters
(2, fig. 9) at each side of bracket and into bushing.
IMPORTANT; The cut-off (flat) side of each
adapter must be located in a vertical position as
sho n in figure 11.
2. Install bolt and asher through adapter and
axle bracket at each end of equalizing beam (fig. 11).
NOTE: Install bolt and asher from inner side
ith nut located to ard heels (fig. 11). Tighten
nuts or bolts to torque listed in "Specifications" at
end of this section. Figure 12 sho s section through
mounting.
3. Install spring saddle caps to attach beam
center bushing to spring saddle. Install saddle cap
stud nuts or cap scre s and tighten to torque listed
in "Specifications" at end of this section.
1Beam Center Bushing 7Setscre
2 Spring Saddle 8 Equalizing Beam
3 Spring Assembly 9Cross Tube
4 Spring Saddle Top Pad 10 Spring Saddle Cap
5 Top Pad to Spring 11 Stud
Saddle Bolts 12 Thrust Washer
6Lock Nut 13 Bushing
Figure 1— Section Through Spring Saddle and Beam