Basic Information Identification Make: Chevrolet Model: K2500 Suburban Year: 1996 Codes Chassis Code: GMT400 (CK/GMT400 platform) Introduction Market Position Target Audience: Owners of 1996 Chevrolet K2500 Suburban seeking to perform maintenance, repairs, and diagnostics. Value Proposition: Provides official, licensed OE (Original Equipment) repair information, offering a cost-effective alternative to dealership service. Competitive Analysis Comparison To Print: More convenient, accessible, and often more affordable than older, out-of-print physical manuals. Key Features Licensing: Officially licensed and derived from OE materials, ensuring accuracy and completeness. Accessibility: Accessible on any PC, laptop, smartphone, or tablet with an internet connection and web browser. Access Duration: One-year access included, with discounts for renewal, providing ongoing support. Software Provider: Developed by RepairSurge, a specialized automotive software company. Manual Details Coverage Areas Primary Coverage: Full service and repair for 1996 Chevrolet K2500 Suburban Secondary Coverage: General maintenance, troubleshooting, diagnostics, and component replacement Page Count Estimated Pages: 1500-2500 (typical for full service manuals of this era) Manual Type Type: Service and Repair Manual Software Language Language: English Format Format: PDF Download (Digital Access) Manual Coverage Systems Covered Engine: Comprehensive coverage including diagnostics, overhaul, and component replacement for all gasoline engines Drivetrain: Front and Rear Axles, Transfer Case (4WD), Driveshafts, Differentials, CV joints Transmission: Automatic Transmission (e.g., 4L60E, 4L80E) - diagnostics, overhaul, fluid service, control systems Brakes: Front and Rear Brake Systems (Disc/Drum), ABS (Anti-lock Braking System) diagnostics and repair Suspension: Front and Rear Suspension (Independent Front Suspension for 4x4 models), shock absorbers, springs, control arms, bushings Steering: Power Steering System, steering column, steering linkage, steering gear/box Electrical: Complete Electrical Schematics, Battery, Charging System (alternator), Starting System, Lighting, Instrumentation, Fuses, Relays, Powertrain Control Module (PCM) HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system diagnostics and repair, refrigerant handling Body: Body Panel Repair, Doors, Hood, Tailgate, Glass, Seals, Interior Trim, Exterior Trim Fuel: Fuel System (tank, pump, injectors, lines), Fuel Injection System (GM TPI/CSFI/MPFI) Exhaust: Exhaust System components, catalytic converter Procedures Included Maintenance: Scheduled maintenance (oil changes, filter replacements, fluid checks), tune-ups Troubleshooting: Diagnostic flowcharts, symptom-based troubleshooting guides Repair: Step-by-step repair instructions for all major components and systems Diagnostics: OBD-II (On-Board Diagnostics II) codes, sensor data interpretation, diagnostic tool usage Rebuilding: Engine and transmission overhaul procedures, component specifications for rebuilds Technical Depth Depth: Comprehensive factory-level detail, suitable for professional technicians and advanced DIYers Manual Specifications File Format PDF Quality: High-resolution, text-searchable PDF for ease of navigation and printing Print Quality Printable: Printable pages for convenient workshop use Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Engine Specifications Primary Engine Engine Options: 5.7L V8 OHV (Vortec 350), 7.4L V8 OHV (Vortec 454) Performance 5.7L Horsepower: Approx. 255 hp @ 4600 rpm 5.7L Torque: Approx. 330 lb-ft @ 2800 rpm 7.4L Horsepower: Approx. 290 hp @ 4000 rpm 7.4L Torque: Approx. 410 lb-ft @ 3200 rpm Fuel System Fuel Delivery: Multi-Port Fuel Injection (MPFI) or Central Sequential Fuel Injection (CSFI) depending on exact build date/spec Engine Management ECU: PCM (Powertrain Control Module) with OBD-II diagnostics Transmission Standard Automatic: 4L60E (for 5.7L) or 4L80E (for 7.4L and heavy-duty applications) Optional Manual: Rare for K2500 Suburban, but some heavy-duty models might have offered a manual transmission (e.g., NV4500). Features Transmission Fluid: Dexron III/Mercon Automatic Transmission Fluid (ATF) Dimensions Exterior Wheelbase: 130 inches (3302 mm) Length: Approx. 219.2 inches (5568 mm) Width: Approx. 79.7 inches (2024 mm) Height: Approx. 74.8 inches (1899 mm) Cargo Cargo Volume: Significant cargo space behind the third row, expandable by folding rear seats (specific figures vary by configuration but are substantial for the class). Weights Curb Weight: Approx. 5200-5800 lbs (2359-2631 kg), depending on engine and options. Gvw: 9,200 lbs (4173 kg) Safety Features Ratings NHTSA Front Impact: Not directly rated by modern standards, but generally considered robust for its era. Active Features ABS: Standard 4-wheel ABS (Anti-lock Braking System) on K2500 models. Passive Features Airbags: Driver-side airbag standard. Seat Belts: All seating positions equipped with seat belts. Technology Features Infotainment Audio System: Factory-installed AM/FM stereo with cassette player and optional CD player. Speaker configurations varied by trim level. Driver Assistance Cruise Control: Electronic cruise control was a common option. Connectivity Onboard Diagnostics: OBD-II system for emissions and engine diagnostics, facilitating modern scan tool use. Maintenance Service Intervals Oil Change: Every 3,000-5,000 miles or 3-6 months (depending on oil type and driving conditions). Transmission Service: Inspect every 15,000 miles, service typically recommended every 30,000-50,000 miles, or as per manual guidance. Coolant Flush: Every 30,000 miles or 2 years for conventional coolant, longer intervals for extended-life coolants. Fluid Specifications Engine Oil: API Certified SAE 10W-30 or 10W-40 (refer to manual for specific viscosity based on temperature). Coolant: GM Type 1 (Green) or equivalent ethylene glycol-based coolant. Brake Fluid: DOT 3. Known Issues Electrical Gremlins: Common for this era, can include issues with instrument clusters, body control modules,...