GMC 4000 Series User manual

SERVICE
MANUAL
SERIES
4000 THRU 6500
This manual includes procedures for
maintenance and adjustments, minor service
operations and replacement of components
GMC TRUCK & COACH DIVISION
GENERAL MOTORS CORPORATION
PONTIAC, MICHIGAN
General Motors Corporation, 1968 10M 9-68
GMC Truck & Coach Division rinted in U.S.A.
X-6933
SECTION INDEX
LUBRICATION a
CABS, HEATING AND
AIR CONDITIONING <■
FRAME cm
FRONT SUSPENSION cm
REAR SUSPENSION cm
BRAKES cm
GASOLINE ENGINES cm
TORO-FLOW
DIESEL ENGINES trm
ENGINE MOUNTINGS CM
ENGINE COOLING SYSTEM CM
ENGINE FUEL SYSTEM £Z|
AIR COMPRESSOR
AND GOVERNOR cm
ENGINE ELECTRICAL cm
TRANSMISSIONS
AND CLUTCHES cm
FUEL TANK & EXHAUST cm
STEERING SYSTEM cm
WHEELS & TIRES cm
SHEET METAL cm
CHASSIS ELECTRICAL
AND INSTRUMENTS cm
RADIATOR AND
SURGE TANK cm
SPECIAL TOOLS

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 GMC Truck.
Every effort has been made to include timely and adequate information on
the various units and systems used on GMC 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 ref
erence 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. GMC Truck and
Coach Division reserves the right to make changes in design or add improve
ments at any time without incurring any obligation to install same on vehicles
previously purchased.
TRUCK MODEL DESIGNATION
(“L SERIES 4000)
(L) Tilt Cab (V) Hydraulic Brakes (A) Air Brakes
(ALL OTHER SERIES)
CHASSIS TYPE
SYMBOL
(E) Conv. Cab (92" BBC)
(P) Forward Control
(T) Tilt Cab
(S) Schoolbus Cowl
GVW RANGE NUMBER
See Load Capacity Chart”
in Owner’s and Driver’s
Manual. MODEL YEAR
SERIAL NUMBER
E M 40 V - D 020001
ENGINE TYPE
SYMBOL
(G) V6 Toro-Flow (Diesel)
(M) V6 Gasoline
(S) In-Line Gasoline
BODY AND BRAKE TYPE
P—Chassis Only (Hyd. Brakes)
V—Cab & Chassis (Hyd. Brakes)
A—Cab & Chassis (Air Brakes)
M—Cowl & Chassis (Hyd. Brakes)
Y—Cowl & Chassis (Air Brakes)
iii

GENERAL INFORMATION
IM ORTANT-READ THIS AGE
TRUCK MODELS COVERED
This manual contains on-the-vehicle” mainte
nance and light repair information on GMC Truck
Models listed on page v. Since many truck models
with various combinations of equipment are cov
ered 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 commonly
used regular production options are included in
this manual. Many special equipment and acces
sory items are available on these GMC 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 important and specific in
formation 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
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” tabula
tions. These numbers are provided primarily for
unit identification or truck model application refer
ence, 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 accomplish
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
GMC Truck and Coach Division. Information re
garding availability of these tools can be obtained
from your Zone Office or directly from the Tech
nical Publication Department at the Factory.
SERVICE BULLETINS
Service bulletins are issued, when required, sup
plementing or in some cases superseding infor
mation in this manual. Information in these bul
letins 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 Own
er’s and Driver’s Manual” which is placed in the
cab of every new GMC Truck.
ALPHABETICAL INDEX
Important subjects, with manual page number
references, are alphabetically listed in the index
in the back of this manual.
iv

MODEL DATA
TRUCK
SERIES
GMC
ENGINE CLUTCH FRONT AXLE REAR AXLE TRANSMISSION
STD. OPT STD. OPT. STD. OPT. STD. OPT. STD. OPT.
LA, LV-4000 305C 351C 12 13 F070 —H150 G161,16121,
T150, G361,
16221
435GL 435GD,
540GD, 540GL
DLA, DLV-4000 DH478 -12 13 F070 —H150 G161,16121,
T150, G361,
16221
435GL 435GD,
540GD, 540GL
EM-4500 305E -11 12 F055 -H110 H135, H150,
T150 435GL «5GD
ES-4500 250 292 11 12 F055 -H110 H135, H150,
T150 435GL 435GD
PS-4500 250 292 11 12 F050 -H110 H135 SM465 -
EG-5500V DH478 -12 13 F055 F07C H150 G161,16121,
T150, G361,
16221
435GL 435GD, 540GD,
540GL
EG-5500A DH478 -12 13 F070 -G161 16121, G361,
16221 435GL 435GD, 540GD,
540GL
EM-5500 305C 351C 12 13 F055 F070 H150 G161, 16121,
T150, G361,
16221
435GL 435GD, 540GD,
540GL
EM-5500 A & Y 305C 351C 12 13 F070 -G161 16121, G361,
16221 435GL 435GD, 540GD,
540GL
ES-5500 V & M 292 -12 -F055 F070 H150 G161,16121,
T150, G361,
16221
435GL 435GD,
540GD, 540GL
SG-5500M DH478 12 13 F055 F070 H150 G161,16121,
T150, G361,
16221
435GL 435GD, 540GD,
540GL
SG-5500Y DH478 -12 13 F070 -G161 16121, G361,
16221 435GL 435GD, 540GD,
540GL
SM-5500M 305C 351C 12 13 F055 F070 H150 G161,16121,
T150, G361,
16221
435GL 435GD, 540GD,
540GL
SM-5500Y 305C 351C 12 13 F070 -G161 16121, G361,
16221 435GL 435GD, 540GD,
540GL
SS-5500 292 -12 —F055 F070 H150 G161,16121,
T150, G361,
16221
435GL 435GD,
540GD, 540GL
EG-6500 DH478 -12 13 F070 -16121 17121, 16221,
17221 435GL 435GD, 540GD, 540GL
EM-6500 305C 351C 12 13 F070 -16121 17121, 16221,
17221 435GL 435GD, 540GD,
540GL
SM-6500 M & Y 351M —13 —F070 —16121 17121, 16221,
17221 435GL 435GD, 540GD,
540GL
v

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 P” and cowl mod
els. Plate location on P” and cowl
models is determined by the body
manufacturer.
ENGINE SERIAL NUMBERS
The engine serial number on V” engines is stamped on top of the cylinder
block ahead of the right-bank cylinder head as shown below. Engine serial
numbers are not used on in-line engines; numbers appearing on crankcase boss
at rear of distributor are manufacturing location and building date codes.
SERVICE PARTS IDENTIFICATION
The Service Parts Identification” label is located on inside of glove compart
ment door of steel tilt and conventional cab models. Location of label on P”
and cowl models is determined by the body manufacturer. 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.
vi

GMC SERVICE MANUAL Sec. 0
Page 1
SECTION O
INDEX
Subject Page No.
Lubrication Charts
Except Steel Tilt Cab Models ..................... 2
Steel Tilt Cab Models .................................... 4
Engine and Accessories ................................ 6
Capacities
Crankcase ......................................................... 7
Transm ission..................................................... 7
Rear A x le ............................................................ 7
Engine Oil - Symbol "E" ................................... 7
Engine Oil Recommendations ..................... 7
Viscosities ......................................................... 8
Checking Engine Oil L e v e l ............................ 8
Engine Oil F ilte r .............................................. 8
Air Cleaners
Oil Bath Type .............................................. 9
Paper Element T y p e ................................... 10
Brake Power and Axle C ylinder .............. 10
Air Compressor Air Strainer .................. 11
Other Engine Oil Uses ................................... 11
Crankcase Ventilation (Gasoline) .................. 12
Crankcase Ventilation (D iesel) ..................... 12
Subject Page No.
Multi-Purpose Gear Lubricant Symbol "MP"
Viscosities ......................................................... 12
Rear A x le ............................................................ 12
Transm ission ..................................................... 13
Chassis Lubricant - Symbol " C " ..................... 13
Steering Gear Lubricant - Symbol "SG" . . . 14
High Temperature Grease - Symbol "S2" . . 14
Wheel B earings.................................................. 14
Other High Temperature U s e s ..................... 14
Petroleum Jelly - Symbol "S3" ...................... 14
Distributor ......................................................... 14
Battery Terminals ........................................... 14
Waterproof Grease - Symbol "S4" .............. 15
Hydraulic Brake Fluid - Symbol "S12" . . . 15
Clutch and Brake Master Cylinder .............. 15
Soft, Smooth Cup Grease - Symbol "S16" . . . 15
Special Grease - Symbol "S17" ..................... 15
Automatic Transmission Fluid - Symbol "S19" . 16
Power Steering S yste m ................................... 16
High Temperature Grease - Symbol "S28" . . 16
Stop master Brake U n it ................................... 16
GENERAL INFORMATION
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.
LUBRICANT SYMBOLS
Symbol Explanation Page No.
"E" Engine Oil ........................................... 7
"MP" Multi-Purpose Gear Lubricant . . 12
"C" Chassis L ubricant ............................ 13
"SG" Steering Gear Lubricant .................. 14
"S-2" High Temperature G rease .............. 14
"S-3" Petroleum Jelly ................................ 14
"S-4" Waterproof Grease ......................... 15
"S-12" Hydraulic Brake F lu id ..................... 15
"S-16" Soft, Smooth Cup Grease .............. 15
"S-17" Special G rease ................................... 15
"S-19" Automatic Transmission Fluid . . 16
"S-28" High Temperature Grease (Special) 16

Sec. 0
Page 2 GMC SERVICE MANUAL
LUBRICATION
Figure 1 — Lubrication Chart (Except Steel Tilt Cab Models)

GMC SERVICE MANUAL Sec. 0
Page 3
LUBRICATION
LUBRICATION DATA
(CHART ON OPPOSITE PAGE)
Item
No. Item
1 Spring Shackles and Brackets (1)
2 Spring Slip Pads (1) .......................
3 Steering Knuckles .......................
4 Steering Tie Rod Ends .................
5 Steering Drag L in k .......................
6 Power Steering Cylinder Ends (1)
7 Prop. Shaft U-Joints .......................
8 Prop. Shaft Slip Joint ....................
10 Speedometer Adapter ....................
11 Brake Camshaft (2) .......................
12 Brake Master Cylinder (3) ...........
13 Steering Gear Housing ..............
14 Battery Terminals..........................
15 Electric Shift Unit (2-Spd.) . . . .
16 Transm ission ..................................
17 Rear Axle ........................................
18 Front Wheel Bearings .................
19 Rear Wheel B earings ....................
20 Brake Cam Roller Pins (2) ..........................
21 Brake and Axle Cyl. Air Cleaner (1) . . . .
22 Steering Column U-Joints ..........................
23 Steering Column Slip Joints .......................
Remarks Sym. Miles i
2 fittings each sh a ck le ................. .. C 6,000
1 fitting each bracket .................... ... C 6,000
Apply each e n d ............................... ... C 6,000
2 fittings each side ....................... ... C 6,000
1 fitting each end .......................... ... C 6,000
1 fitting each end .......................... ... C 6,000
2 fittings ......................................... .... C 6,000
1 fitting each jo in t.......................... .. GO 6,000
1 fitting each join t.......................... .. C 6,000
1 fittin g ............................................. .. C 6,000
1 fitting ea. (apply sparingly) . . C 6,000
Fill - 1/2" below opening............ ... S12 6,000
To level of filler plug ................. ... SG 6,000
Keep coated ..................................... .. S3 6,000
To level of filler plug ................. ... S7 12,000
To level of filler plug ................. .. MP 6,000
Drain and refill ............................. ... MP 12,000
To level of filler plug ................. ... MP 6,000
Drain and refill ............................. ... MP 24,000#
Hand pack or use lubricator . . . S2 20,000*
Hand pack or use lubricator
Series 4500 & 5500
H110, H135, T150, H150,
G161, G361 ............................. ... S16 20,000*
All O thers........................................ ... S2 20,000*
Apply ................................................ ... E 20,000
Clean and reinstall ....................... ... - 6,000
1 fitting each joint ....................... .. C 6,000
1 fitting ........................................... .. C 6,000
* Or once a year, whichever occurs first.
# Or every 6 months, whichever occurs first.
t When "C" Chassis Lubricant is specified, lubricate every 6,000 miles or 60 days, whichever occurs first.
(1) Some Models.
(2) Air Brake only.
(3) Hydraulic Brakes only.