Chevrolet 70 1969 Series Install guide

CHEVROLET
HEAVY DUTY TRUCK
SHOP MANUAL

1969
CHEVROLET
HEAVY DUTY TRUCK
(SERIES 70 and 80)
SHOP MANUAL
FOREWORD
This manual contains, in separate Service and Overhaul
sections, procedures for maintenance adjustments, minor
service operations, and replacement of components (Serv
ice) and for disassembly and assembly of major compo
nents (Overhaul) for Chevrolet Series 0 and 80 Heavy
Duty Trucks.
CHASSIS SERVICE SECTION
The Service Section of this manual includes procedures
for maintenance and adjustments, minor service opera
tions, and removal and installation of components.
The Index on this page enables the user to quickly locate
any desired section in the Service Section. At the beginning
of each individual section containing more than one major
subject is a Table of Contents, which gives the page num
ber on which each major subject begins. An Index is placed
at the beginning of each major subject within the section.
A summary of Special Tools will be found following
Section 9 of the Overhaul portion of this manual while
Specifications covering vehicle components are presented
at the end of each section.
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 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.
• • •
CHEVROLET MOTOR DIVISION
General Motors Corporation
DETROIT, MICHIGAN
SERVICE SECTIO N IN D EX
0LUBRICATION
1CABS AND
BODY MOUNTINGS
2FRAME
3FRONT SUSPENSION
4REAR SUSPENSION
5BRAKES
6A GASOLINE ENGINES
6C SERIES 6V 53
DIESEL ENGINES
6D ENGINE MOUNTINGS
6K ENGINE COOLING SYSTEM
6M ENGINE FUEL SYSTEM
6T AIR COMPRESSOR
AND GOVERNOR
6Y ENGINE ELECTRICAL
7TRANSMISSIONS
AND CLUTCHES
8FUEL TANK & EXHAUST
9STEERING SYSTEM
10 WHEELS & TIRES
11 SHEET METAL
12 CHASSIS ELECTRICAL
AND INSTRUMENTS
13 RADIATOR AND
SURGE TANK
OVERHAUL SECTION
SPECIAL TOOLS
© 1969 Printe in U.S.A.
General Motors Corporation

INTRODUCTION
This manual contains on-the-vehicle maintenance, light repair information,
and unit replacement on all truck models listed on title page. Important infor
mation on the arrangement and use of this manual will be found on page v.
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 mainte
nance 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 previously
purchased.
TRUC MODEL DESIGNATION
i i i
CHEVROLET SERIES 70 80 HEAVY DUTY TRUCK SHOP MANUAL

MODEL DATA
TRUC
SERIES
ENGINE CLUTCH FRONT AXLE REAR AXLE TRANSMISSION
STD. OPT. STD. OPT. STD. OPT. STD. OPT. STD. OPT.
HV-70 6V-53N —14" -F070 F090
F120
17221 18221,19201 5752C _
JV-70 6V-53N -14” 14"-2 F070 F090
FI 20
30DSC 34DSC, SLHD 385V 7041 Aux.
TV-70 6V-53M -14" -F070 F090
F110
17221 19101,17101
19202
5752C MT41C
HM-80 401M 478M 13" 13"-2
14"
14" 2
F070 F090
F120
17121 18121,17221,
18221,19201
541GL 541GD, 387V,
5752C
JM-80 401M 478M 13" 13" 2
14"
14"-2
F090 F120
F160
34DSC SLHD, SQHD 5652 401V, 7231A Aux.,
6041 Aux., 7041 Aux.,
325V
TM-80 401M 478M 13" 13"-2
14"
14"-2
F090 F110 17121 18121, 17221,
18221, 19201
541GL 541GD, 387V,
5652, 5752C
iv CHEVROLET SERIES 70 80 HEAVY DUTY TRUCK SHOP MANUAL

GENERAL INFORMATION
IMPORTANT-READ THIS PAGE
TRUC MODELS COVERED
This manual contains “ on-the-vehicle” main
tenance, light repair overhaul information on
Chevrolet Truck Models listed on page iv. Since
many truck models with various combinations of
equipment are covered in this manual, the reader
must necessarily refer to truck model applica
tions and methods of distinguishing design differ
ences 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 these Chev
rolet Trucks, however, these items are too nu
merous 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 num
ber 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 consecu
tively throughout the manual. 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”
tabulations. These numbers are provided primar
ily for unit identification or truck model applica
tion reference, and should be referred to when
ordering 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 ac
complish certain operations efficiently and read
ily. Such tools are mentioned in the text by tool
vendor’s numbers.
SERVICE BULLETINS
Service bulletins are issued, when required,
supplementing or in some cases superseding in
formation in this manual. Information in these
bulletins should be noted in the text of the applic
able manual section and the bulletin filed for
ready reference.
ALPHABETICAL INDEX
Important subjects, with manual page number
references, are alphabetically listed in the index
in the back of this manual.
v
CHEVROLET SERIES 70 80 HEAVY DUTY TRUCK SHOP MANUAL

VEHICLE MODEL IDENTIFICATION
AND WEIGHT RATING PLATE
The vehicle identification
and weight rating plate is loca
ted on the cab left door pillar of
all models.
Figure I —Vehicle Identification and GVW Plate
ENGINE SERIAL NUMBERS
The engine serial numbers on all engines are located on the
J'l^t block surface just forward of the right cylinder head.
Figure 2— Gasoline (Typical) Figure 3-6 -53 Diesel
SERVICE PARTS IDENTIFICATION
The "Service Parts Identification” label is located on inside of glove com
partment door of steel tilt and conventional cab models. This label lists all
special equipment installed on the vehicle. This information is imprinted 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 parts.
SERIAL SERVICE PARTS IDENTIFICATION
PAINT
NOTE* THE special equipment liste d below h as been in stalle d on
THIS VEHICLE. FOR PROPER IDENTIFICATION OF REPLACEMENT
PARTS BE SURE TO SPECIFY THE APPLICABLE OPTION NUMBERS.
OPTION
NO.
DESCRIPTION
OPTION
NO.
DESCRIPTION
Figure 4—Service Part Identification Plate
vi CHEVROLET SERIES 70 80 HEAVY DUTY TRUCK SHOP MANUAL

SECTION 0
LUBRICATION
INDEX
Subject Page No.
Lubrication Charts
Conventional Cab Models . . ..................... 2
Tilt Cab Models ......................................... 4
Tandem Bevel A x le s ................................. 6
Engine and Accessories ............................
Capacities
Crankcase ................................................. 8
Transmission ......................................... 8
Rear Axles .............................................. 8
Engine Oil - Symbol "E " ............................ 8
Engine Oil Recommendation ....................... 8
Viscosities ................................................... 9
Checking Engine Oil Level .......................... 9
Engine Oil Filter ......................................... 10
Air Cleaners
Carburetor Air Cleaner ......................... 11
Tractor Type Air Cleaner ....................... 11
Brake Power and Axle Cyl. Air Cleaner. . 11
Air Compressor Air Strainer .................. 11
Other Engine Oil U s e s ................................. 12
Crankcase Ventilation ................................. 13
Crankcase Breather ...................................... 14
Multi-Purpose Gear Lubricant - Symbol "MP" 14
Viscosities ................................................... 15
Subject Page No.
Rear Axle ...................................................... 15
Transmission................................................. 16
Universal Joints............................................ 16
Chassis Lubricant - Symbol " C " .................. 1
High Temperature Grease - Symbol ”S2” . . 1
Wheel Bearings .............................................. 1
Other High Temperature Grease Uses .... 1
Petroleum Jelly - Symbol "S3" .................. 1
Distributor Breaker Cam ............................ 1
Battery Terminals ......................................... 1
Waterproof Grease - Symbol "S4" ............. 18
Refrigerant Machine Oil - Symbol "S " . . . 18
Axle Shift Unit - Electric ............................ 18
Hydraulic Brake Fluid - Symbol "S12" . . . 18
Special Grease - Symbol "S1 "..................... 18
Type A Fluid - Symbol "S 1 9 " ....................... 18
Power Steering System ................................. 18
High Temperature Grease (Special)
- Symbol "S2 ” ............................................ 19
Clutch Release Bearing ................................. 19
High Temperature Grease (Special)
- Symbol "S28"............................................ 19
Stopmaster Brake U n it ................................. 19
Lubrication charts on following pages will lo
cate each lubrication point on the series shown
under each chart. Each point is numbered on the
charts, and each number is keyed to explanatory
text on same or opposite page.
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 recommend
ed, and detailed instructions regarding its applica
tion. The charts show recommended intervals when
various items should be lubricated. The intervals
are recommended for normal use; however, oper
ating conditions may require more frequent inter
vals. 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 performance of his product. His rep
utation is your best indication of quality.
MEANING OF LUBRICANT SYMBOLS
Symbol Explanation Page
"E " Engine Oil ........................................ 8
"MP" Multi-Purpose Gear Lubricant . . 15
"C " Chassis Lubricant........................... 1
"S-2" High Temperature G r e ase .............. 1
"S-3" Petroleum Jelly .............................. 1
"S-4" Waterproof Grease
....................... 18
"S- " Refrigeration Machine O i l .............. 18
"S-12" Hydraulic Brake F lu id .................... 18
"S-1 " Special G rease ................................. 18
"S-19” Type A F luid .................................... 18
"S-2 ” High Temperature Grease (Special) 19
"S-28" High Temperature Grease (Special) 19
CHEVROLET SERIES 70 80 HEAVY DUTY TRUCK SHOP MANUAL

LUBRICATION 0-2
Figure 1 — Lubrication Chart— Conventional Cab Models
CHEVROLET SERIES 70 80 HEAVY DUTY TRUCK SHOP MANUAL

LUBRICATION 0-3
LUBRICATION DATA
(CHART ON OPPOSITE PAGE)
Item
No. Item Remarks Symbol Miles t
1Spring Shackles & Brackets (1) .... 2 fittings each shackle
.............
C6,000
1 fitting each bracket ...............
C6,000
2Spring Slip Pads (1)
............................
. Apply each e n d .......................... C6,000
3Steering Knuckles
....................... ..
. 2 fittings each side ..................
C6,000
4Steering Tie Rod E n d s
.......................
1 fitting each end ..................... C6,000
5Steering Drag Link
............................
1 fitting each end .......................
C6,000
6Steering Idler Lever ( 1 )
....................
. 1 fitting .................................... C6,000
Power Steering Cylinder Ends (1) . . . . 2 fittings .
. ................................. C6,000
8Trans. Shift Relay Lever ( 1 )
............. 1 fitting .................................... C6,000
9Transmission Shift Rod U-Joints (1) . . 1 fitting each joint..................... C 6,000
10 Auxiliary Trans. Shift Tower (1) . . . . . 1 fitting .................................... C6,000
11 Prop. Shaft U-Joints............................ 1 fitting each joint
....................
C6,000
12 Prop. Shaft Slip Joint
.........................
. 1 fitting each joint ....................
C6,000
13 Steering Column U-Joints
..................
1 fitting each joint .......... ..
C6,000
14 Steering Column Slip Joint
...............
. 1 fitting ...................................... C6,000
15 Clutch Release Cross Shaft (1 )
..........
. 1 fitting each end ....................
C6,000
16 Clutch Release Bearing
....................
. Cup or fitting (sparingly) .... S2 6,000
1 Tru-Stop Brake (1)
............................
. 4 or 8 fittings ............................
C6,000
18 1 fitting
. ...................................
c6,000
19 Brake Camshaft - F. ( 2 )
....................
1 fitting ea. (apply sparingly) . c6,000
20 Clutch and Brake Master Cylinder . . . Fill - 1/2" below opening .... S12 6,000
21 Steering Gear Housing
.......................
. To level of filler plug ............... c6,000
22 Battery Terminals
............................
. Keep coated............................... S3 6,000
23 Electric Shift Unit (2-Spd.)
...............
. To level of filler plug .............
S 12,000
24 . To level of filler plug
.............
MP 6,000
24 Transmission (Clark) (Fuller)
..........
. To level of filler plug ...............
MP 6,000
Drain and refill .......................
MP 12,000
24 Transmission (Spicer) .......................
. To level of filler plug .............
MP 6,000
24 Transmission - Auxiliary (1 )
.............
. To level of filler plug ...............
M P 6,000
25 Rear Axle
...........................................
. To level of filler plug ...............
MP 6,000
Drain and refill .......................
24,000#
26 Front Wheel Bearings
.........................
. Hand pack or use lubricator . . S2 20,000*
2 Rear Wheel Bearings
.........................
. Hand pack or use lubricator . . S2 20,000*
28 Brake Cam Roller Pins - F. (2) .... • Apply ......................................... E20,000
29 Brake & Axle Cylinder Air Cleaner (1) . Clean and reinstall .
. ...............
6,000
30 Air-Hydraulic Cylinder ( 3 )
...............
. To level of plug.......................... 12,000
t When "C " Chassis Lubricant is specified, lubri #Or every 12,000 miles if truck is operated in
cate every 6,000 miles or 60 days, whichever exceptionally heavy work or at continuous high
occurs first. speeds.
* Or once a year, whichever occurs first. (1) Some Models.
(2) Air Brake only.
(3) Hydraulic Brakes only.
CHEVROLET SERIES 70 80 HEAVY DUTY TRUCK SHOP MANUAL