Engine Mechanical:
Detailed disassembly, assembly, inspection, and repair of all engine components, including block, heads, crankshaft, camshaft, pistons, rings, valves, and timing.
Engine Fuel System:
Carburetor systems (Holley, Rochester), fuel pump, fuel lines, fuel tank, and troubleshooting.
Ignition System:
Distributor, ignition coils, spark plugs, wiring, points, and condensers; timing adjustments.
Cooling System:
Radiator, water pump, thermostat, hoses, fan, and coolant specifications.
Lubrication System:
Oil pump, oil filter, oil pan, oil pressure specifications, and oil type.
Exhaust System:
Exhaust manifolds, pipes, mufflers, and catalytic converter (if applicable to export models, though unlikely for US domestic).
Transmission Manual:
Disassembly, assembly, inspection, and repair of Muncie 4-speed transmissions (M20, M21, M22 'Rock Crusher'), clutch operation, and linkage adjustments.
Transmission Automatic:
Repair and service of the Turbo Hydra-Matic 400 (THM400) automatic transmission, including band adjustments, fluid changes, and troubleshooting.
Drivetrain Rear Axle:
Differential (open and Positraction), axles, U-joints, driveshaft, and bearing specifications.
Suspension Front:
Independent front suspension, ball joints, control arms, springs, shock absorbers, steering knuckle, and alignment specifications.
Suspension Rear:
Independent rear suspension, trailing arms, universal joints, struts, shock absorbers, and alignment specifications.
Steering System:
Steering box, tie rods, drag link, power steering pump, and steering column adjustments.
Brake System:
Front disc brakes (standard), rear drum brakes, master cylinder, brake lines, wheel cylinders, calipers, pads, shoes, and bleeding procedures. Power brake booster operation.
Electrical System Lighting:
Headlights, taillights, turn signals, interior lights, wiring diagrams for lighting circuits.
Electrical System Instruments:
Speedometer, tachometer, fuel gauge, oil pressure gauge, ammeter, temperature gauge, and their calibration.
Electrical System Accessories:
Wipers, washers, horn, heater blower, radio, power windows (if equipped), and related wiring.
Body Exterior:
Body panel removal, alignment, door, hood, and trunk latch mechanisms, weatherstripping, bumpers, grille, and trim.
Body Interior:
Seat removal and installation, dashboard assembly, carpet, headliner, door panels, and trim components.
Heating And Ventilation:
Heater core, blower motor, ducting, and control mechanisms.
Troubleshooting:
Diagnostic charts and procedures for common malfunctions across all systems.
Routine Maintenance:
Oil changes, filter replacements, lubrication points, tune-ups, fluid level checks, tire rotation.
Major Repairs:
Engine rebuilds, transmission overhauls, suspension component replacement, brake system overhauls.
Diagnostics:
System-specific diagnostic flowcharts and fault finding.
Adjustments:
Carburetor adjustments, ignition timing, clutch free play, parking brake, idle speed.
Component Replacement:
Step-by-step guides for replacing common wear items and major components.
Wiring Diagrams:
Detailed electrical schematics for all vehicle systems.
Depth:
Comprehensive. Covers everything from basic maintenance to full engine and transmission rebuilds, including electrical system diagnostics and bodywork repair.
Oil Change:
Every 2,000-3,000 miles or 6 months, whichever comes first (for conventional oil).
Tune Up:
Every 10,000-15,000 miles (includes spark plugs, points, condenser, distributor cap/rotor).
Transmission Fluid:
Check every 1,000 miles, change every 12,000-24,000 miles (depending on usage).
Engine Oil:
SAE 10W-30 or 10W-40 (check manual for specific engine recommendations, may vary with temperature).
Coolant:
50/50 mix of ethylene glycol antifreeze and distilled water.
Brake Fluid:
DOT 3 Brake Fluid.
Transmission Fluid Manual:
GL-4 Gear Oil (e.g., SAE 80W-90).
Transmission Fluid Automatic:
Dexron-III/Mercon compatible fluid (originally DEXRON).
Rear Axle Fluid:
GL-5 Hypoid Gear Oil (with limited-slip additive for Positraction units).
Carburetor Tuning:
Tri-Power systems can be finicky; proper synchronization and adjustment are crucial for optimal performance.
Suspension Wear:
Ball joints, tie rod ends, and bushings can wear over time, affecting steering and alignment.
Brake System Maintenance:
Seals in master cylinders, calipers, and wheel cylinders can degrade, leading to leaks or poor braking performance. Regular fluid flushes are important.
Electrical Gremlins:
Older wiring harnesses can become brittle or corroded, leading to intermittent electrical issues.
Frame Rust:
Though less prone than body-on-frame trucks of the era, the steel frame can be susceptible to rust in harsh climates if not properly maintained.