Workhorse W Series Truck 2010-2012 Industrial Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: Workhorse Model: W Series Truck Year: 2010-2012 Chassis Type: Cutaway Chassis / Stripped Chassis Vehicle Class: Heavy-Duty Commercial Truck Body Style: Chassis Cab (designed for custom upfitting of various body types such as step vans, delivery trucks, ambulances, buses, etc.) Codes Vin Code Digit 3: Workhorse specific chassis identifier (typically W) Vin Code Digits 4-7: Model and series specific 👋 Introduction Market Position Segment: Commercial Chassis / Medium Duty Truck Application: Designed for vocational and commercial use, serving as a platform for diverse body upfits (e.g., delivery, specialized service, passenger transport). Competitive Analysis Key Competitors: Ford E-Series Chassis, Chevrolet Express Chassis, Freightliner Custom Chassis, Isuzu NPR Chassis. Key Features Manual Highlight: Step-by-step instructions with pictures and wiring diagrams for ease of understanding and execution of repairs. Delivery Method: Instant digital download upon payment. Accessibility: Works on any PC/MAC computer, facilitating immediate use. 📋 Manual Details Coverage Areas Scope: Comprehensive service, repair, and maintenance for all Workhorse W Series Trucks, 2010-2012 model years, all engine types. Specific Systems: Engine, Drivetrain, Chassis, Electrical, HVAC, Fuel System, Exhaust System, Brakes, Steering, Suspension, Body, Wiring Diagrams. Page Count Estimated Pages: N/A (digital format, size varies) Manual Type Type: Industrial Service Repair Workshop Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Detailed troubleshooting, diagnostics, overhaul procedures, component replacement for various gasoline and diesel engines (specific engines TBD based on vehicle configuration, commonly GM Vortec V8 gasoline and Cummins diesel variants). Drivetrain: Automatic and manual transmission service, differential overhaul, driveline component replacement, axle service, transfer case (if applicable). Chassis: Frame inspection and repair, suspension component replacement (springs, shocks, bushings), steering system service (gearbox, linkages), brake system diagnostics and repair (disc/drum, ABS). Electrical: Comprehensive wiring diagrams, diagnostic procedures for lighting, ignition, charging system, starting system, instrument cluster, body control modules, troubleshooting common electrical faults. HVAC: Air conditioning system service, heater core replacement, blower motor diagnosis, climate control unit repair. Fuel System: Fuel pump replacement, fuel injector service, fuel filter replacement, fuel tank maintenance, emissions control systems. Body: Body panel repair, door mechanisms, interior trim removal and installation, glass replacement, cab tilting procedures (if applicable). Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid level checks and top-offs, tire rotation and pressure checks, lubrication points. Diagnostic Troubleshooting: Step-by-step troubleshooting guides for common issues, fault code interpretation, diagnostic charts. Repair Overhaul: Detailed instructions for component removal, disassembly, inspection, repair, reassembly, and installation of all major vehicle systems. Component Replacement: Instructions for replacing specific parts such as alternators, starters, water pumps, brake pads, sensors, etc. Wiring Diagrams: High-quality, detailed wiring schematics for all electrical systems, aiding in fault diagnosis and repair. Technical Depth Depth: Covers everything from basic routine maintenance to complex engine and transmission overhauls, electrical system diagnostics, and chassis repairs. Complexity Level: Suitable for professional technicians and experienced DIY mechanics. 📊 Manual Specifications File Format File Type: PDF Compatibility: Windows PC, Mac OS, Linux Searchability: Likely searchable text content within the PDF for keywords. Print Quality Image Resolution: High-quality resolution sufficient for clear viewing of diagrams and text. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Gasoline Options: Likely GM Vortec 5.7L (350 ci), 6.0L (366 ci), or 8.1L (496 ci) V8 gasoline engines depending on configuration. Specifics require VIN lookup. Diesel Options: Likely Cummins ISB/ISC series or similar GM Duramax/Isuzu diesel engines. Specifics require VIN lookup. Performance Horsepower Range: Varies significantly based on engine. Gasoline V8s typically 250-350 HP, Diesels 180-300+ HP. Torque Range: Varies significantly based on engine. Gasoline V8s typically 300-450 lb-ft, Diesels 400-600+ lb-ft. Fuel System Gasoline Injection: Multi-port Fuel Injection (MPFI) or Direct Injection (DI) depending on specific engine. Diesel Injection: High-pressure Common Rail (HPCR) for modern diesel variants. 🔧 Transmission Standard Automatic Transmission: Likely GM 4L80-E / 4L85-E (4-speed automatic) or 6L90 (6-speed automatic) for gasoline engines, Allison 1000/2000 series for diesel. Optional Manual Transmission: Less common in this era for heavy-duty chassis but possible. Manual transmissions from GM or Eaton could be specified. Features Drivetrain Options: Rear-Wheel Drive (RWD) is standard. All-Wheel Drive (AWD) or Four-Wheel Drive (4WD) may be available depending on specific chassis configuration and intended use. 📐 Dimensions Exterior Wheelbase: Highly variable depending on body upfit and specific chassis configuration, ranging from approximately 109 inches to over 200 inches. Ground Clearance: Variable, designed to accommodate various body types and operational needs. Weights Gvwr: Gross Vehicle Weight Rating varies significantly by model and configuration, typically ranging from 10,000 lbs to 26,000 lbs+ (Class 3-7). Gcwr: Gross Combined Weight Rating also highly variable, dependent on GVWR and towing capacity. 🛡️ Safety Features Ratings Crash Test Data: As a chassis cab, crash testing is primarily focused on the cab structure itself, with overall safety dependent on the final body upfit and compliance...
Detailed troubleshooting, diagnostics, overhaul procedures, component replacement for various gasoline and diesel engines (specific engines TBD based on vehicle configuration, commonly GM Vortec V8 gasoline and Cummins diesel variants).
Drivetrain:
Automatic and manual transmission service, differential overhaul, driveline component replacement, axle service, transfer case (if applicable).
Chassis:
Frame inspection and repair, suspension component replacement (springs, shocks, bushings), steering system service (gearbox, linkages), brake system diagnostics and repair (disc/drum, ABS).
Electrical:
Comprehensive wiring diagrams, diagnostic procedures for lighting, ignition, charging system, starting system, instrument cluster, body control modules, troubleshooting common electrical faults.
HVAC:
Air conditioning system service, heater core replacement, blower motor diagnosis, climate control unit repair.
Fuel System:
Fuel pump replacement, fuel injector service, fuel filter replacement, fuel tank maintenance, emissions control systems.
Body:
Body panel repair, door mechanisms, interior trim removal and installation, glass replacement, cab tilting procedures (if applicable).
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid level checks and top-offs, tire rotation and pressure checks, lubrication points.
Diagnostic Troubleshooting:
Step-by-step troubleshooting guides for common issues, fault code interpretation, diagnostic charts.
Repair Overhaul:
Detailed instructions for component removal, disassembly, inspection, repair, reassembly, and installation of all major vehicle systems.
Component Replacement:
Instructions for replacing specific parts such as alternators, starters, water pumps, brake pads, sensors, etc.
Wiring Diagrams:
High-quality, detailed wiring schematics for all electrical systems, aiding in fault diagnosis and repair.
Technical Depth
Depth:
Covers everything from basic routine maintenance to complex engine and transmission overhauls, electrical system diagnostics, and chassis repairs.
Complexity Level:
Suitable for professional technicians and experienced DIY mechanics.
📊 Manual Specifications
File Format
File Type:
PDF
Compatibility:
Windows PC, Mac OS, Linux
Searchability:
Likely searchable text content within the PDF for keywords.
Print Quality
Image Resolution:
High-quality resolution sufficient for clear viewing of diagrams and text.
Likely Cummins ISB/ISC series or similar GM Duramax/Isuzu diesel engines. Specifics require VIN lookup.
Performance
Horsepower Range:
Varies significantly based on engine. Gasoline V8s typically 250-350 HP, Diesels 180-300+ HP.
Torque Range:
Varies significantly based on engine. Gasoline V8s typically 300-450 lb-ft, Diesels 400-600+ lb-ft.
Fuel System
Gasoline Injection:
Multi-port Fuel Injection (MPFI) or Direct Injection (DI) depending on specific engine.
Diesel Injection:
High-pressure Common Rail (HPCR) for modern diesel variants.
🔧 Transmission
Standard
Automatic Transmission:
Likely GM 4L80-E / 4L85-E (4-speed automatic) or 6L90 (6-speed automatic) for gasoline engines, Allison 1000/2000 series for diesel.
Optional
Manual Transmission:
Less common in this era for heavy-duty chassis but possible. Manual transmissions from GM or Eaton could be specified.
Features
Drivetrain Options:
Rear-Wheel Drive (RWD) is standard. All-Wheel Drive (AWD) or Four-Wheel Drive (4WD) may be available depending on specific chassis configuration and intended use.
📐 Dimensions
Exterior
Wheelbase:
Highly variable depending on body upfit and specific chassis configuration, ranging from approximately 109 inches to over 200 inches.
Ground Clearance:
Variable, designed to accommodate various body types and operational needs.
Weights
Gvwr:
Gross Vehicle Weight Rating varies significantly by model and configuration, typically ranging from 10,000 lbs to 26,000 lbs+ (Class 3-7).
Gcwr:
Gross Combined Weight Rating also highly variable, dependent on GVWR and towing capacity.
🛡️ Safety Features
Ratings
Crash Test Data:
As a chassis cab, crash testing is primarily focused on the cab structure itself, with overall safety dependent on the final body upfit and compliance with vocational safety standards.
Active Features
ABS:
Anti-lock Braking System (ABS) is standard on most configurations.
Traction Control:
May be available depending on model and options.
Passive Features
Airbags:
Driver and front passenger airbags are standard in the cab.
Seatbelts:
Standard three-point seatbelts for all occupants.
💡 Technology Features
Infotainment
Cab Features:
Basic infotainment typically included a radio with CD player and auxiliary input. Higher trim levels or optional packages might have offered more advanced audio systems or basic navigation.
Driver Assistance
Cruise Control:
Commonly available as an option or standard on higher trim levels.
Trailer Brake Controller:
Often available as an integrated factory option for towing applications.
Connectivity
Diagnostics:
OBD-II port for engine diagnostics and vehicle scan tools.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 5,000-7,500 miles or 6-12 months for gasoline, and 7,500-10,000 miles or 6-12 months for diesel, subject to operating conditions and specific engine type.
Transmission Fluid Change:
Recommended every 30,000-60,000 miles or as per severe duty schedules for automatic transmissions.
Coolant Flush:
Typically every 30,000-50,000 miles or 2-4 years, depending on coolant type (e.g., conventional, OAT, P-OAT).
Fluid Specifications
Engine Oil Gasoline:
API SN/SP, SAE 5W-30 or 5W-40 synthetic blend/full synthetic, depending on engine and ambient temperature. Refer to specific engine manual for exact viscosity and API classification.
Engine Oil Diesel:
API CK-4/CJ-4, SAE 15W-40 or 5W-40 synthetic for diesel engines, meeting Cummins CES 20081 or equivalent specifications.
Transmission Fluid Automatic:
Dexron-VI or equivalent for GM transmissions, Allison TES-295 for Allison transmissions. Check specific transmission fill plug or dipstick for details.
Coolant:
Typically a 50/50 mix of ethylene glycol and deionized water. Check for specific color and type (e.g., orange for OAT, green for conventional).
Known Issues
Common Wear Items:
Brake pads and rotors, suspension bushings, exhaust system components, starter motors, alternators due to constant commercial use.
Electrical Gremlins:
Can sometimes develop due to extensive wiring harnesses for various upfit options, requiring thorough diagnosis using wiring diagrams.
📚 Vehicle History
Brand Heritage
Manufacturer:
Workhorse Custom Chassis LLC was a significant North American manufacturer of chassis for RVs, step vans, and other specialized vehicles, with roots tracing back to the chassis division of Navistar and then its acquisition by International Military Services.
Model Evolution
W Series Lineage:
The W Series represented Workhorse's primary offering in the medium-duty truck chassis segment, evolving from earlier GM P-chassis designs before Workhorse became an independent entity.
Production
Production Period:
Workhorse produced chassis until its eventual cessation of operations. The 2010-2012 period represents a specific generation of their W-Series offerings.
Manufacturing Locations:
Primarily manufactured in North America, with plants in states like Indiana and Union City, Indiana.
🏆 Awards & Recognition
Recognitions
Industry Standing:
Workhorse W Series chassis were widely recognized for their ruggedness and suitability for demanding commercial applications, often chosen for their reliability in vocational service.
Ratings
Durability:
Generally considered durable and capable of handling heavy loads and extensive operational hours, a key factor in their selection for commercial fleets.
Choosing a selection results in a full page refresh.