1973 Chevrolet Series 50-65 Medium Duty Truck Service Manual

Description

This 838 page 1973 Chevrolet Series 50-65 Medium Duty Truck Service Manual is a reproduction of the original, out of print, manual. This 838 page manual includes procedures for diagnosis, maintenance and adjustments, minor service operations, and removal and installation for components of 1973 Chevrolet Medium Duty Trucks. Procedures involving disassembly and assembly of major components for these vehicles are contained in the 1978 Chevrolet Medium and Heavy Duty Truck Overhaul Manual. Wiring diagrams for 1973 trucks are contained in a separate Wiring Diagram Booklet. Summaries of Special Tools, when required, as well as specifications covering vehicle components are found at the end of major sections.

Table of Contents
Lubrication
General Information
Lubricant Symbols
Lubrication Charts
All Except Steel Tilt Cab Models
Steel Tilt Cab Models
Tandem Bevel 30DSC and 34DSC
Engines and Accessories Lube Chart
Lubricant Capacities
Crankcase Capacity Chart
Transmission Capacity Chart
Rear Axle Capacity Chart
Power Steering Capacity Chart
Lubricant Description
Engine Oil (Symbol “E”)
Multi-Purpose Gear Oil (Symbol “MPO”)
Gear Oil (Symbol “GO”)
Lubricating Oil – Special (Symbol “ES”)
Multi-Purpose Grease (Symbol “MPG”)
Steering Gear Lubricant (Symbol ”SG”)
Petroleum Jelly (Symbol “S3”)
Refrigeration Machine Oil (Symbol “S7”)
Hydraulic Brake Fluid (Symbol “S12”)
Special Grease (Symbol “S17”)
Automatic Transmission Fluid
(Symbol “S19”)
High Temperature Grease (Symbol “S27”)
High Temperature Grease (Special)
(Symbol “S28M)
Power Steering Fluid (Symbol “S32”)

Cabs, Heating and Air Conditioning
General Cab Maintenance (All Cabs)
General
Key Information
Exterior Maintenance
Interior Maintenance
Dust and Water Leaks
Cab Alignment
Straightening
Dinging and Finishing
Painting
Windshield Glass Replacement
Rear Window Replacement
Lap Belt Maintenance
Windshield Wipers

Conventional Cab (Includes Heating System)
Cab Description
Cab Mountings
Cowl Ventilator Grille
Side Cowl Ventilator Replacement
Seat Replacement
Door Assembly
Cab Replacement
Heater – General Description

Steel Tilt Cab (Includes Heating System)
Description
Cab Tilting Instructions
Cab Mountings
Insulation
Seats
Doors
Cab Ventilation and Heating
Cab Replacement
Torsion Bar Replacement
Torsion Bar Tension Adjustment

Body Mountings

Air Conditioning
General Description and Operation
Controls
Air Conditioning Cycle of Operation
Component Operation
Operation of Air-Flow, Vacuum
and Electrical Systems
General Information
Precautions in Handling Refrigerant
Precautions in Handling
Refrigerant Lines
Maintaining Chemical Stability in
The Refrigerant System
Gauge Set
Charging Station J-23500
Leak Testing The System
Vacuum Pump
Availability of Refrigerant
Safety Precautions
Compressor Oil
Inspection and Periodic Service
Pre-Delivery Inspection
6,000-Mile Inspection
Periodic Service
Installing Gauge Set to Check
System Operation
Performance Test
Performance Data Chart
Evaporator Control Valve (POA)
Expansion Valve
Depressurizing, Evacuating, and Charging Procedures
Installing Charging Station (J-23500)
Depressurizing The System
Evacuation
Charging The System
Disposable Can Method
Adding Refrigerant – Charging
Station Method
Adding Refrigerant – Disposable Can Method
Component Replacement and Minor Repairs
Preparing System For Replacement of Component Parts
Foreign Material in The System
Refrigerant Line Connections
Repair of Refrigerant Leaks
Refrigerant Hose Failure
Super Heat Replacement
A/C Control Assembly
Condenser
Receiver-Dehydrator
Expansion Valve
Evaporator Control (POA) Valve
Evaporator Core
Blower Assembly
Blower and Evaporator Case
Heater Assembly
Heater Core
Blower Motor Switch
Compressor Clutch Switch
Blower Resistor Unit
Hot Water Shut-Off Valve
Blower Motor Relay
Connector Block
Kick Panel Air Valve Actuator
Kick Pad Valve
Plenum Air Valve
Defroster A/C Actuator
Heater Defroster Actuator
Vacuum Lines
Ambient Temperature Switch
Fuses
Super Heat Shut-Off Switch
Compressor
Compressor Belt Tension Adjustment
Trouble Diagnosis
General Information
Heater-Air Conditioner Refrigerant
Circuit Trouble Diagnosis Guide
Air Conditioning Diagnosis
Air Conditioning Specifications

Frame

Front Suspension
Front End Alignment
Front Axle
Front Springs and Chock Absorbers
Front Hubs and Bearings

Rear Suspension
Rear Axle and Controls
Rear Springs
Rear Hubs and Bearings
Propeller Shafts

Driveline
General Description
Rear Axle Service Diagnosis
Rear Axle and Unit Replacement
Axle Assembly Replacement
Differential Carrier Unit Replacement
Axle Shaft Replacement
Pinion Oil Seal Replacement
Axle Vent Replacement
General Maintenance on Vehicle
Rear Axle Lubrication
Bent Housing Check
2-Speed Axle Electric Shift System
General Description and Operation
Electric Shift Maintenance and Diagnosis
Electric Shift Unit Replacement
Electric Shift Unit Overhaul
2-Speed Axle Vacuum Shift System
Description and Operation
Vacuum Shift System Maintenance
Vacuum Shift Control Valve
Shift Chamber (Corp Axle)
Check Valve
Speedometer Adapter Shift Diaphragm
2-Speed Axle Air Shift System
Description
Air Shift System Troubleshooting
Piston Air Shift Unit Repair
Tandem Rear Axle
General Description
Maintenance and Adjustments
Vacuum-Operated Inter-Axle Differential
Lock Shift System
Air-Operated Inter-Axle Differential
Lock Shift System
Rear Axle Torque Specifications

Brakes
Hydraulic Brakes

Air Brakes
Brake System Equipment
Brake System Maintenance
Brake Adjustments
Slack Adjusters
Brake Chambers (Standard)
Air Tanks
Air Pressure Check Valve
Safety Valve
Pressure Protection Valve
Quick Release Valve
Moisture Ejector Valve
Brake Application Valves
Air Lines
Air Pressure Gauge
Low Air Pressure Switch
Trailer Brake Controls
ICC Brake System Equipment
Trailer Brake Hand Control Valve
Trailer Emerg Air Supply Control Valve
Tractor Protection (Breakaway) Valve
Double Check Valve and Stop Light Switch
Front Brake Limiting Valve and Two-Way
Control Valve
Anchorlok Brake Chambers
Front Brake Shoes and Anchor Pins
“S” Cam Rear Brakes
Brake Drums
Stopmaster Brakes
“Fail-Safe” Brakes
“Super Fail-Safe” Brakes
Specifications
Troubleshooting Chart – General
Troubleshooting Chart – Stopmaster

Parking Brake

Gasoline Engines
General Information
Engine Application Chart
Engine Identification
Engine Lubrication
Lubrication After Storage
Engine Maintenance
Checking and Maintaining
Crankcase Oil Level
Servicing Air Cleaner
Checking Drive Belts
Engine Oil Filters
Spark Plugs
Engine Compression
Distributor Points, Cam Lubricator
Distributor Cap
Spark Plug Wires
Timing, Dwell and Idle Speed
Positive Crankcase Ventilation System
Air Injection Reactor System
Carburetor Inspection
Mechanical Valve Lifters
Manifold Heat Valve
Engine Tune-Up, Checks, and Adjustments
Engine Tune-Up Specifications
Engine Replacement
In-Line Engine Replacement
V-6 Engine Replacement
V-8 Engine Replacement
In-Line Engine In-Vehicle Service
Operations
V-6 Engine In-Vehicle Service Operations
V-8 Engine In-Vehicle Service Operations
Torque Wrench Specifications
Engine Diagnosis Charts

Turbium Diesel Engines
General Information
Engine Maintenance and Tune-up
Turbium DH-478 Diesel Engine Tune-Up Chart
Engine Replacement
In-Vehicle Component Replacement
Torque Wrench Specifications
Trouble Diagnosis Chart

Engine Mountings

Engine Cooling System
General Description
Maintenance and Adjustments
Inspection of System
Engine Coolant
Coolant Requirements
Corrosion Inhibitors
Inhibitor Systems
Coolant Filter
Antifreeze
Coolant Recommendations
Cooling System Pressure Check
Cooling System Problem Analysis
Oil Cooler
Engine Thermostats
Water Temperature Indicator
Cleaning System
Cold Weather Operation
Draining Cooling System
Filling Cooling System
Fan and Drive Belts
Water Pumps
Engine Block Heater
Bolt Torques
Engine Thermostats
Cooling System Capacities

Engine Fuel System
Air Cleaners

Gasoline Engine Fuel System
Accelerator, Choke and Throttle Linkage Adjustment
Fuel Filters
Fuel Pumps
Emission Control Systems
Governors
Rochester Carburetors
Holley Carburetor
Bendix-Stromberg Carburetors

Turbium Diesel Engine Fuel System
Accelerator and Throttle Linkage
Adjustment
Conventional Cab and Cowl Models
Steel Tilt Cab Model
Manual Throttle Adjustment
Engine Stop Control
Fuel Filters
Primary Filter
Secondary Filter
Fuel Injection System
Description
Fuel Injection Pumping Principle
Fuel Metering Principle
Fuel Injection Pump Lubrication
Fuel Injection Pump Drive
Fuel Injection Nozzles
Fuel Lines
Fuel Injection System Problem Analysis
Checking For Air Leaks in Fuel Supply
(Suction) Line
Checking For Inadequate Fuel Pump Delivery and/or Overflow Valve
Malfunction
Checking For Crankcase Dilution By Fuel
Service Operations
Cold Weather Operation
Priming Diesel Fuel System
Injection Timing
Governor Spring Adjustment
Fuel Injection Nozzles
High Pressure Fuel Line Installation
Fuel Delivery Valve Replacement
Control Unit Assembly Replacement
Overflow Valve Assembly
Fuel Supply Pump Repair and Replace
Replacing Hydraulic Head Assembly
Fuel Injection Pump Assembly
Fuel Injection Pump Replacement
Specifications
Fuel Oil Requirements

Air Compressor and Governor

Engine Electrical
Battery
Model Application Chart
Battery Charging and Testing
Battery Trouble Diagnosis Chart
Battery Specifications
Starting System
Model Application Chart
Starting System Trouble Diagnosis
Starting System Specifications
Ignition System
General Description
Distributor
Spark Plugs
Overspeed Warning System
Ignition System Trouble Diagnosis Chart
Ignition System Specifications

Non-Integral Type Alternating Current
Model Application Chart
Generating System General Description
Precautions
On-Vehicle Maintenance, Tests, and Adjustments
Generating System Maintenance
Generator Drive Belt
Generating System Trouble Symptoms
Generator On-Vehicle Tests
Generator Charge Indicator Lamp Circuit Test
Generator Output Test
Ammeter Circuit Test (With 1116374 or 1116378 Regulator)
Undercharged Battery Test (With 1119507 Regulator)
Undercharged Battery Test (With 1119515 Regulator)
Regulator Circuit Test (With 1116374 or 1116378 Regulator)
Adjusting Regulator Voltage Setting (With 1119507 or 1119515 Regulator)
Adjusting Regulator Voltage Setting (With 1116374 or 1116378 Regulator)
Tailoring The Voltage Setting
Generator Replacement
Regulator Replacement
Regulator Repair (Model 1119507 or 1119515)
Regulator Repair (Model 1116374 or 1116378)
Regulator Unit Relay (With 1116374 or 1116378 Regulator)
Regulator Voltage Adjustment (Model 1116374 or 1116378)
Non-Integral Type Generator Specifications
Generating System Trouble Diagnosis

Integral Type Alternating Current Generating System
Model Application Chart
42-,61-, & 80-AmpGenerating System
100-Amp Generating System
Integral Type Generator Specifications

Clutch and Transmission
Transmission Control Linkage
Tilt Cab Models With Manual Transmission
Linkage Adjustment
Control Island Shift Mechanism
Remote Control Assembly (AT Transmission)
Truck Models With AT475 Automatic Transmission Linkage Adjustments
Truck Models With AT540 Automatic Transmission Linkage Adjustments
Truck Models With MT640 or MT650 Automatic Transmission Linkage Adjustment

Transmission On-Vehicle Service Operations
Manual Transmission Servicing
Automatic Transmission Servicing
Manual Transmission Diagnosis

Auxiliary Transmissions

Clutch Controls

Clutches
GM (11-Inch Single Disc) 250 Engine
Borg & Beck (12-Inch Single Disc) 292, 305C, 350 Engines
Borg & Beck (12-Inch Dual Disc) 427 Engine
Borg & Beck (13-Inch Single Disc) 350, 366 Engines
Borg & Beck (13-Inch Cerametalix Single Disc) 305C, 379, DH478 Engines
Borg & Beck (14-Inch Cerametalix Single Disc) 432 Engine
Lipe-Rollway (12-Inch Single Disc) 305C Engine
Lipe-Rollway (13-Inch Cerametalix Single Disc) 305C, 379 Engines
Lipe-Rollway (14-Inch Cerametalix Single Disc) 432 Engine

Fuel Tank and Exhaust System
Fuel Tank
Evaporation Control System
Exhaust System

Mechanical Steering
Description
Steering System Maintenance
Steering Gear Adjustments On Vehicle
Steering Gear Replacement
Steering Linkage
Steering Drag Link or Connecting Rod
Steering Tie Rod
Steering Wheel and Steering Column

Power Steering
Power Steering System
Power Steering Gear and Control Valve
Troubleshooting The Power Steering Gear
Power Steering Hydraulic Pump
Troubleshooting The Hydraulic Pump
Power Steering Power Cylinder
Troubleshooting The Power Cylinder
Tie Rod Anti-Rotation Bushing
Oil Cooler
Quick Reference Troubleshooting Chart
Power Steering Specifications
Power Steering Torque Specifications

Wheels and Tires
General Description
Wheel Nut Tightening Sequence
Dual Wheels
Spacer Bands
Wheel Studs or Bolts and Nuts
Wheel Inspection
Wheel Inspection (Disc Type)
Tires
Synthetic Tubes and Flaps
Inflation of Tires
Valve Core and Cap
Wheel and Tire Wear
Selection of Tires
Tire Matching
How to Match Tires
Tire Rotation
Wheel and Tire Balancing
Tire Removal and Installation
Tire Balancing Warning
Rim and Wheel Safety Precautions
How to Prevent Rim Accidents
What Happens When Tires Get Hot
Instructions for Maintenance
of Tires On Off-The-Highway
Units in Highway Transit
Specifications

Chassis Sheet Metal
Sheet Metal for Conventional Models
Hood Hinge Spring Replacement
Hood Hinge Replacement
Hood Lock Assembly
Hood Replacement and Alignment
Radiator Shell Grille Replacement
Front Fender Assembly Replacement
Front Fender Skirt Replacement
Front Valance Panel Replacement
Front Radiator Shell Replacement
Running Board Replacement
Front End Sheet Metal Unit Replacement
Fiberglass Tilt Hood For Conv Models
Radiator Shell Grille Replacement
Fiberglass Tilt Hood Fender
Extension Replacement
Fiberglass Tilt Hood Splash Shield
Replacement
Fiberglass Tilt Hood Replacement
Fiberglass Tilt Hood Alignment
Repair of Fiberglass Hood and Fender
Components
Sheet Metal For Cowl Models
Hood Hinge Spring Replacement
Hood Hinge Replacement
Hood Lock Assembly
Hood Replacement and Alignment
Front End Sheet Metal Unit Replacement
Front Fender Replacement (Less Skirt)
Fender Skirt Replacement
Running Board and Fender Extension
Replacement

Electrical-Body and Chassis
Miscellaneous Electrical
Gauge, Engine Oil Temperature
Gauge, Fuel Tank Unit
Indicator, Water Temperature
Motor, Air Conditioning Blower
Motor, Axle Shift
Motor, Electric W/S Wiper and Washer
Motor, Heater Blower
Pump, LH Fuel Tank
Relay, Air Conditioning Blower Control
Relay, Starter Control
Relay, Voltage Sensing
Resistor, Heater Blower Control
Sender, Fuel Gauge Tank Unit
Sender Unit, Engine Temperature
Sender Unit, Oil Pressure
Solenoid, Idle Stop
Solenoid, Transmission Kick-Down
Speedometer Adapter, 2-Speed Axle
Switch, Air Conditioning Control
Switch, Air Conditioning Blower Control
Switch, Air Stop
Switch, Axle Shift
Switch, Brake Failure Warning
Switch, Differential Lock
Switch, Engine Overspeed
Switch, Fuel Tank Selector
Switch, Keater Blower Control
Switch, Hot Engine
Switch, Low Air
Switch, Low Oil Pressure
Switch, Low Vacuum
Switch, Neutral Safety
Switch, Neutral Safety and Back-Up Lamp
Switch, Primer
Switch, Stop Lamp
Switch, Transmission Control
Switch, W/S Wiper and Washer

Alarm System

Instruments and Gauges
Electrical Variable Resistance Type
Oil Pressure Tell-tale and Switch
(Method Using AC-GG3 Tester)
Oil Pressure Gauge and Switch
(Method Using AC-GG3 Tester)
Temperature Gauge and Switch
(Method Using AC-GG3 Tester)
Engine Overheat Warning Switch & Tell-tale
(Method Using AC-GG3 Tester)
Shunt Ammeter (Milliammeter)
(Method Using AC-GG3 Tester)
Ammeter (Regular Type)
(Method Using AC-GG3 Tester)
Voltmeter
(Method Using AC-GG3 Tester)
Fuel Gauge System
a Method Using “Quick-Check Chart”
b Method Using AC-GG3 Tester
c Method Using AC-GG4 Tester

Mechanical Type
Engine Oil Pressure
Air Pressure
Vacuum
Temperature

Lighting System
Light Bulb Data
Diagnosis Charts

Radiator and Surge Tank
Description
Maintenance
Radiator Mountings
Radiator Replacement
Pressure Relief Valve and Filler Cap
Radiator Surge Tank
Coolant Recovery System
Engine Coolant