🏷️ Basic Information

Make:

Chevrolet

Model:

C/K Series

Year:

1996

Platform Code:

GMT400

👋 Introduction

Market Segment:

Full-size pickup truck and sport utility vehicle (SUV) segment.

Key Competitors:

Ford F-Series, Dodge Ram, Toyota T-100/Tundra (later years), Nissan Hardbody/Frontier (later years).

Vehicle Strengths:

Renowned for durability, towing capacity, versatility (light-duty to heavy-duty applications), and a wide range of configurations.

Accuracy And Authenticity:

Factory-specific information, not generic; essential for accurate diagnostics and repairs as used by dealership technicians.

📋 Manual Details

Full Vehicle Coverage:

All Models & All Repairs A-Z

Target Audience:

Dealership Technicians, Professional Mechanics, DIY Enthusiasts

Estimated Page Count:

Varies by specific model/engine configuration, but typically 1500-2500+ pages for comprehensive manuals of this era.

Type:

Factory Service Manual (FSM)

Language:

English

Format:

Print (likely multiple volumes or large single volume)

📖 Manual Coverage

Powertrain:

Engine Mechanical, Fuel System, Ignition System, Cooling System, Lubrication System, Exhaust System, Engine Control Systems (ECM/PCM)

Drivetrain:

Transmission (Automatic & Manual), Transfer Case (4WD models), Driveshafts, Differentials, Axles, Wheel Bearings

Chassis:

Suspension (Front & Rear), Steering System, Brake System (Hydraulic, ABS)

Body & Electrical:

Body Exterior & Interior, HVAC System, Electrical System (Wiring Diagrams, Components, Lighting, Power Accessories), Chassis Electrical

Maintenance:

Scheduled Maintenance (Oil Changes, Fluid Replacements, Filter Changes, Inspections)

Diagnostics:

Troubleshooting guides, diagnostic trouble codes (DTCs), symptom-based diagnostics, electrical circuit testing

Repair Procedures:

Component removal and installation, overhaul procedures, adjustments, torque specifications, alignment procedures

Special Tools:

Identification and usage of specialized tools required for specific repairs

Depth:

Comprehensive, from basic maintenance and adjustments to complete engine and transmission rebuilds, advanced electrical diagnostics.

📊 Manual Specifications

Print Quality:

Professional printing with clear diagrams and text. Original factory publication quality.

Binding:

Typically a robust hardcover or multi-volume set with durable binding for frequent use in a workshop environment.

Paper Quality:

Durable, coated paper stock to withstand workshop conditions, often with gloss finish for image clarity.

⚙️ Engine Specifications

4.3L V6 (Vin X):

5.0L V8 (VIN Y)

5.7L V8 (Vin R):

7.4L V8 (VIN J)

4.3L V6 (L35 Vortec):

Approx. 190-200 HP, 245-260 lb-ft Torque

5.0L V8 (L30 Vortec):

Approx. 205-220 HP, 275-295 lb-ft Torque

5.7L V8 (L31 Vortec):

Approx. 255-265 HP, 330-345 lb-ft Torque

7.4L V8 (L29 Vortec):

Approx. 290-300 HP, 410-420 lb-ft Torque

Injection Type:

Sequential Fuel Injection (SFI) for Vortec engines; Throttle Body Injection (TBI) for some earlier or base configurations.

Fuel Requirement:

Unleaded gasoline (Octane rating typically 87).

Ignition Type:

Distributorless Ignition System (DIS) or Distributor with Electronic Ignition (EI).

🔧 Transmission

Transmission Options:

4-speed Automatic (e.g., 4L60E, 4L80E); 5-speed Manual (e.g., NV3500, NV4500 for heavy-duty applications).

Heavy Duty Transmission:

4L80E automatic for heavier duty applications.

Overdrive:

Overdrive gear ('OD') available in automatic transmissions for improved fuel efficiency and reduced engine RPM at highway speeds.

Automatic Transmission Fluid:

Dexron III (or equivalent specification) is commonly specified.

Manual Transmission Fluid:

GL-4 or GL-5 gear oil, viscosity typically 75W-90 or 80W-90, depending on specific transmission model.

📐 Dimensions

Body Styles:

Regular Cab, Extended Cab, Crew Cab; Fleetside (Styleside) and Stepside bed options; Pickup Truck and Sport Utility Vehicle (Tahoe, Yukon, Suburban).

Wheelbase:

Varies by configuration: Short Bed (approx. 117.5 in.), Long Bed (approx. 131.5 in. or 143.5 in. for crew cabs/dually).

Gvwr:

Ranges from approximately 6,200 lbs (1500 series) to over 10,000 lbs (3500/4500 series heavy-duty).

Curb Weight:

Highly variable based on configuration, typically 4,500 - 6,500 lbs.

Towing Capacity:

Ranges from approximately 4,000 lbs to over 10,000 lbs depending on configuration, engine, and axle ratio.

🛡️ Safety Features

Crash Test Ratings:

NHTSA ratings vary by specific model year and configuration. Generally considered robust for their era, but lacking modern advanced safety features.

ABS:

Anti-lock Braking System (ABS) often standard or optional on 1500 series, and standard on heavier duty models and SUVs.

Airbags:

Driver-side airbag typically standard. Passenger airbag availability varies by model and option package. Some heavier duty models might not have airbags.

Seatbelts:

Three-point front seatbelts, lap belts for rear passengers (if applicable).

💡 Technology Features

Audio System:

Factory-installed AM/FM stereo with cassette player; optional CD player and premium sound systems. Speaker configurations vary by cab style and trim level.

Climate Control:

Manual HVAC systems standard; optional automatic climate control on higher trim levels and SUVs.

Cruise Control:

Electronic cruise control often standard or optional across various trims.

Trailer Wiring:

Factory trailer wiring harnesses and provisions for brake controllers are often available.

🔧 Maintenance

Oil Change Interval:

Typically every 3,000-7,500 miles or 3-6 months, depending on driving conditions and oil type specified in the manual. Vortec engines may have longer intervals with synthetic oils.

Transmission Fluid Change:

Recommended every 30,000-100,000 miles, depending on usage (towing, heavy loads) and fluid type. Refer to manual for specific intervals.

Coolant Flush:

Typically every 30,000-100,000 miles or 2-5 years, depending on coolant type (e.g., conventional green vs. extended life).

Engine Oil Viscosity:

Commonly 5W-30, 10W-30, or 10W-40, depending on engine and ambient temperature. Refer to specific engine charts in the manual.

Engine Oil Capacity:

Varies by engine: 4.3L V6 (approx. 4.5 qts), 5.0L V8 (approx. 5.0 qts), 5.7L V8 (approx. 5.5 qts), 7.4L V8 (approx. 7.0 qts) with filter change.

Coolant Type:

Conventional Green Ethylene Glycol (typically 50/50 mix with distilled water). Long-life coolants may be specified for later models or after a system flush.

Intake Manifold Gaskets:

Leaking intake manifold gaskets, particularly on 4.3L and 5.0L V8 engines, can cause coolant leaks and misfires.

Transmission Cooler Lines:

Corrosion and leaks in transmission cooler lines, especially in rust-belt regions, can lead to transmission fluid loss and overheating.

Body Rust:

Frame and body rust, especially on rocker panels, cab corners, and bed crossmembers, is a common issue, particularly in areas exposed to road salt.

Heater Core:

Heater core failures leading to coolant leaks into the cabin are not uncommon.

Rear Main Seal:

Oil leaks from the rear main seal can occur over time.

📚 Vehicle History

Chevrolet Truck Legacy:

Chevrolet has a long and storied history in the pickup truck market, dating back to the 1910s, establishing a reputation for reliability and workhorse capability.

C-K Series Generation:

The 1996 model year falls within the GMT400 platform (introduced in 1988 for C/K pickups and SUVs), known for its significantly improved ride quality, handling, and aerodynamics over its predecessors.

Vortec Engine Introduction:

The 'Vortec' branding was introduced for the 1996 model year on most gasoline engines, signifying significant updates including Central Sequential Fuel Injection (CSFI) and improved airflow, leading to notable horsepower and torque gains.

Manufacturing Locations:

Assembled in various General Motors plants across North America, including Fort Wayne, Indiana; Janesville, Wisconsin; and Oshawa, Ontario.

🏆 Awards & Recognition

Truck Of The Year:

While not specific to the 1996 model year, the GMT400 platform and its predecessors have frequently been recognized for their utility, durability, and value by automotive publications and organizations over their production run.

Consumer Reports:

Consumer Reports often rated these vehicles highly for performance and utility, though some years showed average or below-average reliability in specific components.