|
Introduction
|
|
Market Position
|
|
Market Position:
|
A robust, heavy-duty pickup truck designed for commercial use, towing, and hauling. The K3500 was part of Chevrolet's highly capable GMT400 platform, known for its durability and improved ride quality over previous generations.
|
|
Competitive Analysis
|
|
Competitive Analysis:
|
Competed directly with the Ford F-350 and Dodge Ram 3500 series trucks of the same era, offering strong towing and payload capacities, a range of powerful engine options (including diesel), and a comfortable, modern interior for its time.
|
|
Key Features
|
|
Key Features:
|
Heavy-duty chassis, robust suspension, powerful engine options (including the 6.5L Detroit Diesel), available 4WD, spacious cab, and substantial towing/hauling capabilities.
|
|
Manual Details
|
|
Coverage Areas
|
|
Coverage Areas:
|
Engine, Transmission (Automatic & Manual), Drivetrain, Suspension, Steering, Brakes, Electrical Systems, HVAC, Body & Chassis, Diagnostic Procedures, Maintenance Schedules
|
|
Page Count
|
|
Page Count:
|
Varies (Digital Format, typically thousands of pages equivalent)
|
|
Manual Type
|
|
Manual Type:
|
Service and Repair Manual Software
|
|
Language
|
|
Language:
|
English
|
|
Format
|
|
Format:
|
PDF Download (Licensed Software)
|
|
Manual Coverage
|
|
Systems Covered
|
|
Systems Covered:
|
Engine Mechanical (including diesel variants), Fuel System, Ignition System, Cooling System, Exhaust System, Lubrication System, Powertrain Control Module (PCM) & Diagnostics, Automatic Transmission (4L80-E), Manual Transmissions (NV4500, NP3500), Transfer Case (NP205, NP241HD), Front & Rear Axles (Dana 60, 70), Suspension (Independent Front Suspension, Leaf Spring Rear), Steering System (Power Steering), Braking System (Front Disc/Rear Drum, Optional Rear Disc, ABS), Air Conditioning & Heating, Power Accessories (Windows, Locks), Lighting System, Wiper System, Instrument Cluster, Body Control Modules, Chassis Electrical, Frame & Body Repair, Interior Trim, Exterior Trim
|
|
Procedures Included
|
|
Procedures Included:
|
Routine Maintenance (Oil Changes, Fluid Checks, Filter Replacements), Major Engine Overhaul & Rebuilding, Transmission Removal & Installation, Clutch Replacement, Drive Axle Servicing & Rebuilding, Brake System Overhaul (Calipers, Rotors, Drums, Lines), Suspension Component Replacement (Ball Joints, Tie Rods, Springs, Shocks), Steering System Repair (Steering Gearbox, Power Steering Pump), Electrical Troubleshooting (Wiring Diagrams, Component Testing), HVAC System Diagnosis & Repair, Fuel Injection System Servicing, Diesel Engine Specific Procedures (Glow Plugs, Injection Pump), Drivetrain Component Diagnosis, Body Panel Alignment & Repair, Emission Control System Servicing
|
|
Technical Depth
|
|
Technical Depth:
|
Comprehensive, covering from basic preventative maintenance to complete system diagnostics and component overhauls. Includes detailed specifications, torque values, special tool requirements, and troubleshooting flowcharts. Factory-derived OE (Original Equipment) level of detail.
|
|
Engine Specifications
|
|
Primary Engine
|
|
Primary Engine Gas:
|
5.7L (350 ci) V8 Vortec (L05)
|
|
Primary Engine Diesel:
|
6.5L (395 ci) V8 Turbocharged Diesel (LLC / L42)
|
|
Performance Gas
|
|
5.7L V8 Vortec (L05) Horsepower:
|
200 HP @ 4000 RPM (approx.)
|
|
5.7L V8 Vortec (L05) Torque:
|
310 lb-ft @ 2800 RPM (approx.)
|
|
Performance Diesel
|
|
6.5L V8 Turbo Diesel (L42) Horsepower:
|
190 HP @ 3400 RPM (approx.)
|
|
6.5L V8 Turbo Diesel (L42) Torque:
|
385 lb-ft @ 1800 RPM (approx.)
|
|
Fuel System
|
|
Fuel System Gas:
|
Throttle Body Injection (TBI) - Vortec L05
|
|
Fuel System Diesel:
|
Indirect Injection (IDI) with Turbocharging - 6.5L V8 Turbo Diesel
|
|
Codes
|
|
Engine Code 5.7L:
|
L05
|
|
Engine Code 6.5L Diesel:
|
L42 (Turbocharged)
|
|
Maintenance
|
|
Service Intervals
|
|
Oil Change Interval Gas:
|
Every 3,000 miles or 3 months (typical for this era), potentially extended with synthetic oil to 5,000-7,500 miles.
|
|
Oil Change Interval Diesel:
|
Every 5,000 miles or 6 months (typically for diesel).
|
|
Transmission Fluid Change:
|
Every 30,000 - 60,000 miles (depending on usage and fluid type).
|
|
Fluid Specifications
|
|
Engine Oil Gas:
|
API SG/SH, SAE 10W-30 or 10W-40 (refer to manual for specific viscosity based on temperature).
|
|
Engine Oil Diesel:
|
API CD/CE, SAE 15W-40 (preferred for diesels).
|
|
Transmission Fluid 4L80E:
|
Dexron III (or equivalent)
|
|
Transmission Fluid Nv4500:
|
GM Synchromesh Transmission Fluid (or equivalent heavy-duty manual transmission fluid, e.g., 5W-30 synthetic manual transmission fluid for colder climates).
|
|
Coolant:
|
Ethylene Glycol, 50/50 mix with distilled water (green traditional coolant).
|
|
Known Issues
|
|
Common Issues Gas Engine:
|
TBI fuel delivery concerns, distributor issues, potential intake manifold gasket leaks, oil pressure sensor failure.
|
|
Common Issues Diesel Engine:
|
DS4 injection pump failures (on later models, but early symptoms might appear), glow plug system issues, turbocharger seal leaks, injector pump timing belt replacement (if applicable).
|
|
Common Issues Transmission:
|
4L80-E: Torque converter shudder, solenoid pack failures. NV4500: 5th gear thrust washer failure (a known weakness), clutch wear.
|
|
Common Issues Suspension Steering:
|
Ball joint wear, tie rod end wear, leaf spring fatigue (especially under heavy load), steering gearbox leaks.
|
|
Common Issues Brakes:
|
Brake fade under heavy towing, rotor warping, caliper seal leaks.
|
|
Part Numbers
|
|
Oil Filter 5.7L:
|
AC Delco PF1218 (Example, consult manual for exact OE number)
|
|
Oil Filter 6.5L Diesel:
|
AC Delco PF2221 (Example, consult manual for exact OE number)
|
