Manual Coverage
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Systems Covered
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Engine Systems:
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Fuel delivery (carbureted and early EFI), ignition, cooling, lubrication, exhaust, emissions control systems.
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Drivetrain Systems:
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Manual and automatic transmissions (e.g., C6, E4OD pre-cursor variants, NP435, T-18/19), transfer cases (e.g., NP208), rear differentials (e.g., Dana 50, Dana 60). Coverages include component removal, installation, overhaul, and adjustments.
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Chassis And Suspension:
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Front and rear suspension components (leaf springs, shock absorbers, steering linkage), steering gear (power steering systems), wheel bearings, chassis lubrication points, frame inspection.
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Braking System:
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Front disc brakes, rear drum brakes. Includes system bleeding, component replacement (pads, rotors, shoes, drums), hydraulic system troubleshooting, parking brake system.
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Electrical System:
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Wiring diagrams for all major systems (lighting, ignition, charging, starting, instruments, accessories), component testing, fuse and relay identification, troubleshooting of electrical faults.
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Body And Interior:
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Body panel repair, door mechanisms, window regulators, seat adjustments, interior trim, cab mounting, tailgate operation, rust repair techniques.
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Procedures Included
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Routine Maintenance:
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Oil changes, filter replacements, fluid level checks and top-offs, tire rotation, brake inspection, tune-up procedures (spark plugs, distributor cap/rotor, points for older models if applicable).
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Engine Repair:
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Complete engine overhaul, cylinder head removal and installation, piston and ring replacement, crankshaft and bearing service, camshaft and valvetrain service, timing gear/chain replacement.
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Transmission Service:
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Fluid and filter changes, clutch replacement (manual), transmission removal and installation, internal component inspection and repair for both manual and automatic transmissions.
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Suspension And Steering Repair:
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Ball joint replacement, tie rod end replacement, control arm bushings, shock absorber replacement, steering box adjustment or replacement, power steering pump replacement.
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Brake System Repair:
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Brake rotor resurfacing/replacement, brake pad replacement, brake shoe replacement, wheel cylinder and master cylinder replacement, brake line inspection and repair.
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Electrical Diagnostics:
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Step-by-step troubleshooting guides for common electrical issues using wiring diagrams, voltage drop tests, continuity checks, and signal tracing.
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Fuel System Diagnosis:
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Carburetor adjustment and rebuilding, fuel pump testing, fuel line leak detection, troubleshooting fuel delivery issues.
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Body Work And Restoration:
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Techniques for minor body panel straightening, rust treatment and prevention, door and window seal replacement, interior component reassembly.
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Technical Depth
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Depth Level:
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Comprehensive (from basic maintenance to complete engine and transmission rebuilds).
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Diagnostic Capability:
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Advanced, providing diagnostic trees and fault code interpretation (where applicable for early electronic systems).
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Overhaul Procedures:
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Detailed step-by-step instructions for overhauling major mechanical components like engines, transmissions, and differentials.
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Wiring Diagram Detail:
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High detail, including specific pinouts, wire colors, and expected electrical readings for troubleshooting.
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Specification Accuracy:
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Factory-level precision for all torque settings, clearances, fluid capacities, and diagnostic readings.
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Maintenance
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Service Intervals
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Oil Change Interval:
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Typically every 3,000-5,000 miles or 6 months, depending on driving conditions and oil type (consult specific year/engine for precise recommendation).
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Transmission Fluid Change:
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Every 24,000-36,000 miles or 24 months for automatics; check manual for manual transmission service intervals.
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Tune Up Schedule:
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Spark plug and filter replacement typically every 30,000-60,000 miles; distributor cap and rotor depending on material (e.g., copper points may require more frequent attention).
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Fluid Specifications
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Engine Oil Type:
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API SG or SF rated oils, viscosities like 10W-30 or 10W-40 commonly recommended for gasoline engines (diesel oils for diesel engines). Check manual for exact API classification and viscosity grade.
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Transmission Fluid Type:
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Mercon or compatible ATF for automatic transmissions (e.g., C6); gear oil for manual transmissions and differentials (e.g., GL-5).
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Coolant Type:
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Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water. Check manual for specific coolant type compatibility (e.g., traditional green).
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Known Issues
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Common Problems:
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Carburetor performance issues, ignition system wear (points, condenser, coil), vacuum leaks, rust on body panels (especially cab corners, rocker panels, bed sides), U-joint wear, exhaust system corrosion, potential for cooling system leaks in older radiators/hoses.
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Diesel Specific Issues:
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Glow plug system reliability, injector pump issues, potential for head gasket failure on 6.9L IDI under heavy load/overheating.
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