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Manual Coverage
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Systems Covered
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Engine Mechanical:
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All gasoline and diesel engine components, including disassembly, assembly, inspection, and repair.
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Engine Electrical:
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Ignition system, fuel injection system, starting and charging system, engine control module (ECM) diagnostics.
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Transmission:
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Automatic (4L80-E, 4L85-E) and manual (NV4500, NV5600) transmission service, overhaul, and diagnostics.
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Drivetrain:
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Front and rear axle service, driveshafts, universal joints, differential service, transfer case (if applicable).
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Suspension:
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Front and rear suspension component inspection, replacement, alignment procedures, and troubleshooting.
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Steering:
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Power steering system service, steering gear inspection and repair, steering column components.
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Brakes:
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Hydraulic brake system, ABS system diagnostics, brake pad/shoe replacement, rotor machining/replacement, brake line service.
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Electrical System:
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Complete wiring diagrams, lighting systems, instrument cluster, power windows, door locks, remote keyless entry.
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HVAC:
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Heating, ventilation, and air conditioning system diagnostics, component replacement, refrigerant handling and charging.
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Body And Frame:
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Body panel repair, interior trim removal/installation, door mechanisms, tailgate, glass replacement.
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Chassis And Frame:
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Frame inspection, repairs, and corrosion protection.
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Procedures Included
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Scheduled Maintenance:
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Detailed maintenance schedules for oil changes, filter replacements, fluid checks, and component inspections.
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Troubleshooting Diagnostics:
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Systematic diagnostic procedures and flowcharts for identifying and resolving common and complex issues.
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Component Replacement:
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Step-by-step instructions for replacing virtually all serviceable components.
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Engine Rebuild:
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Comprehensive procedures for engine disassembly, cleaning, inspection, machining, and reassembly.
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Transmission Overhaul:
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Detailed instructions for complete transmission disassembly, component replacement, and reassembly.
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Brake System Repair:
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Procedures for bleeding brake systems, replacing brake lines, calipers, and master cylinders.
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Electrical Diagnostics:
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Using multimeter, oscilloscope, and scan tools to diagnose electrical circuits and systems.
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HVAC Service:
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Refrigerant recovery and recharging, leak detection, and component testing.
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Technical Depth
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Diagnostic Tools:
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Information on using GM's Tech 2 scan tool (or equivalent) for advanced diagnostics and module programming.
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Torque Specifications:
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Precise torque specifications for all critical fasteners and engine components.
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Clearances Tolerances:
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Detailed specifications for component clearances and wear tolerances for proper engine and driveline function.
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Wiring Diagrams:
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Comprehensive, high-resolution wiring schematics for all vehicle electrical systems.
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Special Tools:
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Identification and usage instructions for specialized tools required for specific repair procedures.
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Engine Specifications
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Primary Engine
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Engine Options:
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6.0L V8 Power Stroke Turbo Diesel, 8.1L V8 Vortec Big Block Gasoline
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Performance
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6.0L Power Stroke Horsepower:
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300 hp @ 3300 rpm (approx.)
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6.0L Power Stroke Torque:
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520-540 lb-ft @ 1600 rpm (approx.)
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8.1L Vortec Horsepower:
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325 hp @ 4000 rpm (approx.)
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8.1L Vortec Torque:
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455 lb-ft @ 3200 rpm (approx.)
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Fuel System
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6.0L Power Stroke Fuel System:
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High-pressure common rail (HPCR) direct injection
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8.1L Vortec Fuel System:
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Multi-point fuel injection (MPFI)
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Fuel Type:
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Diesel (6.0L), Unleaded Gasoline (8.1L)
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Dimensions
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Exterior
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Wheelbase Options:
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130.0 inches (Regular Cab), 143.5 inches (Extended Cab), 153.0 inches (Crew Cab)
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Overall Length:
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Varies by cab and bed configuration (e.g., 237.4 inches for a 4WD CC Long Bed)
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Bed Length Options:
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8.0 ft (96 inches), 8.25 ft (99 inches - Long Bed)
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Weights
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Curb Weight:
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Approximately 6,000 - 7,500 lbs (varies significantly by configuration and engine)
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Gvwr:
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Up to 11,400 lbs (for 3500 models)
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Max Payload:
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Approximately 4,000 - 5,000 lbs (varies by configuration)
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Max Towing Capacity:
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Up to 13,000 lbs (conventional hitch), up to 16,000 lbs (gooseneck/5th wheel hitch)
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Maintenance
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Service Intervals
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Oil Change Interval:
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Gasoline: 5,000-7,500 miles or 6-12 months. Diesel: 5,000-10,000 miles or 6-12 months (severe use may require more frequent changes).
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Filter Replacement:
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Engine oil filter, fuel filter (diesel), air filter at recommended intervals.
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Transmission Fluid Service:
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Automatic: 50,000-100,000 miles depending on usage. Manual: Inspect as needed, fluid changes typically longer intervals.
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Fluid Specifications
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Engine Oil Gasoline:
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API SN/SP, SAE 5W-30 (check owner's manual for specific viscosity)
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Engine Oil Diesel:
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API CJ-4/CK-4, SAE 15W-40 (check owner's manual for specific viscosity and specifications)
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Coolant:
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GM DEX-COOL (Orange) Extended Life Coolant or equivalent meeting GM6277M
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Transmission Fluid Auto:
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GM DEXRON-VI Automatic Transmission Fluid (ATF)
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Transmission Fluid Manual:
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GL-4 or GL-5 Gear Oil (specific viscosity depends on transmission model, consult manual)
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Brake Fluid:
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DOT 3 or DOT 4 Hydraulic Brake Fluid
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Known Issues
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6.0L Power Stroke Common Issues:
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EGR cooler failures, turbocharger issues (sticking vanes), injector problems, head gasket failures.
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8.1L Vortec Common Issues:
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Intake manifold gasket leaks, valve cover gasket leaks, potential for oil consumption.
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Transfer Case Issues:
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Variable speed sensor failures, pump failures in NV246 (Autotrac) models.
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Electrical Gremlins:
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Grounding issues, corroded connectors leading to intermittent electrical problems.
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