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Introduction
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Market Position
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Positioning:
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Targeted at owners and independent repair shops needing accurate, factory-derived service data for the 1996 Chevrolet K3500.
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Competitive Analysis
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Comparison:
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Offers a modern, convenient digital alternative to older, harder-to-find printed manuals, with licensed OE accuracy.
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Key Features
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Convenience:
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Instant online access, compatible with multiple devices, easy navigation.
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Accuracy:
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Licensed information derived from OE materials, ensuring factual correctness.
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Cost Effectiveness:
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Saves money compared to professional repair shop labor rates.
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Subscription Model:
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Provides a full year of access with options for renewal, ensuring up-to-date information.
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Manual Details
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Coverage Areas
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General Coverage:
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Comprehensive Service and Repair
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Specific Systems:
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Engine, Transmission, Drivetrain, Brakes, Suspension, Steering, Electrical, HVAC, Body, Fuel System, Cooling System, Exhaust System, Emissions Control
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Page Count
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Estimated Pages:
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Extensive (specific page count not provided, but typical for factory service manuals)
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Manual Type
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Type:
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Service and Repair Manual Software
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Language
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Language:
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English
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Format
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Format:
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PDF Download (Online Access with Subscription)
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Manual Coverage
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Systems Covered
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Engine Mechanical:
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Detailed specifications, disassembly, assembly, diagnosis, and repair for all engine variants.
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Engine Management:
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Ignition system, fuel injection, emission controls, diagnostic trouble codes (DTCs).
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Transmission Manual:
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Service and repair procedures for manual transmissions.
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Transmission Automatic:
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Service and repair procedures for automatic transmissions.
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Drivetrain:
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Front and rear axle service, drive shafts, differentials, four-wheel-drive system.
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Suspension And Steering:
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Front and rear suspension components, steering gear, power steering system.
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Brakes:
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Hydraulic system, ABS (if equipped), brake linings, rotors, calipers, parking brake.
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Electrical System:
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Battery, charging system, starting system, lighting, instrumentation, power accessories.
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Body And Frame:
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Body panel repair, doors, windows, interior trim, frame diagnostics.
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Heating Ventilation And Air Conditioning HVAC:
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Component testing, refrigerant handling, system diagnosis and repair.
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Wiring Diagrams:
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Detailed electrical schematics for all vehicle systems.
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Procedures Included
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Maintenance:
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Oil change, filter replacements, fluid checks and changes, spark plug replacement, belt tensioning.
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Troubleshooting:
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Diagnostic procedures for common and uncommon drivability, electrical, and mechanical issues.
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Repair:
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Step-by-step instructions for component replacement and repair across all vehicle systems.
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Diagnosis:
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Systematic diagnostic workflows, including use of diagnostic trouble codes.
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Rebuilding:
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Complete procedures for engine, transmission, and differential rebuilding.
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Technical Depth
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Depth:
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Factory-level technical information, suitable for professional technicians and advanced DIYers.
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Engine Specifications
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Primary Engine
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Engine Options:
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454 cu in (7.4L) V8, 366 cu in (6.0L) V8, 350 cu in (5.7L) V8, 4.3L V6
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Performance
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Horsepower 350 Cid:
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Approx. 200-230 hp (varies by specific application and emissions)
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Torque 350 Cid:
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Approx. 300-330 lb-ft (varies by specific application and emissions)
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Horsepower 454 Cid:
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Approx. 230-250 hp (varies by specific application and emissions)
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Torque 454 Cid:
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Approx. 400-410 lb-ft (varies by specific application and emissions)
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Fuel System
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Fuel Delivery:
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Multi-Port Fuel Injection (MPFI) or Throttle Body Injection (TBI) depending on engine.
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Fuel Type:
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Unleaded gasoline
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Cooling System
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Coolant Capacity Est:
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Approx. 18-20 quarts (varies by engine and radiator size)
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Oil Capacity Est
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Oil Capacity:
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Approx. 5-7 quarts (varies by engine)
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Dimensions
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Exterior
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Wheelbase:
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131.5 inches (standard cab), 157.5 inches (long bed/crew cab)
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Length:
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Varies by cab and bed configuration (e.g., 227.7 inches for standard cab, long bed)
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Width:
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Approx. 79.5 inches (body width)
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Height:
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Approx. 75-77 inches (varies by configuration)
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Weights
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Curb Weight Est:
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Approx. 4,500 - 5,500 lbs (varies significantly by configuration and options)
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Gross Vehicle Weight Rating Gvwr:
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Typically 8,500 lbs to 10,500 lbs, depending on configuration.
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Cargo
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Bed Length Options:
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6.5 ft (Fleetside), 8 ft (Fleetside)
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Maintenance
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Service Intervals
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Oil Change Interval:
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Every 3,000-5,000 miles or 6 months, depending on driving conditions and oil type used.
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Air Filter Replacement Interval:
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Every 15,000-30,000 miles or as needed based on inspection.
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Spark Plug Replacement Interval:
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Every 30,000-60,000 miles depending on spark plug type (e.g., conventional, platinum).
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Coolant Flush Interval:
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Every 30,000-50,000 miles or 2-3 years.
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Fluid Specifications
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Engine Oil Specification:
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API SJ or higher, SAE 5W-30 or 10W-30 (depending on ambient temperature and engine).
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Brake Fluid Specification:
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DOT 3.
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Power Steering Fluid:
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GM Power Steering Fluid or Dexron III.
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Known Issues
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Common Engine Wear:
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Lifter noise, intake manifold gasket leaks, rear main seal leaks.
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Common Transmission Issues:
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Torque converter shudder in automatics, worn synchros in manuals.
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Common Electrical Issues:
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Corroded grounds, faulty blower motor resistors, intermittent gauge operation.
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Common Suspension Issues:
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Worn ball joints, tie rod ends, and sway bar links due to heavy-duty use.
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Rust Corrosion:
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Common in certain climates, affecting cab corners, rocker panels, and frame rails.
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Vehicle History
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Brand Heritage
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Chevrolet Truck Legacy:
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Chevrolet has a long and storied history of producing rugged and capable trucks, dating back to the early 20th century.
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Model Evolution
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K Series Platform:
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The K3500 is part of the Chevrolet/GMC C/K platform, which evolved through several generations. The 1996 model falls into the GMT400 platform, introduced in 1988, known for its more aerodynamic styling and improved chassis dynamics compared to previous generations.
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Production
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Platform Years:
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GMT400 platform (1988-1998 for C/K trucks).
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Manufacturing Location:
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Primarily Fort Wayne, Indiana, USA, and Janesville, Wisconsin, USA.
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