1986 Chevy Truck Service Manual PDF

The 1986 Chevy Truck Service Manual provides comprehensive technical information for maintaining, troubleshooting, and repairing 1986 Chevrolet C/K series trucks. This manual covers engine systems, transmission, brakes, suspension, electrical systems, and routine maintenance procedures for models including C10, C20, C30, K10, K20, and K30. Below are key sections for specifications, maintenance schedules, repair procedures, and troubleshooting.

1. Vehicle Specifications 2. Maintenance Schedule 3. Engine Systems 4. Transmission & Drivetrain 5. Brake System 6. Suspension & Steering 7. Electrical System 8. Fuel System 9. Cooling System 10. Troubleshooting Guide

Vehicle Specifications

Technical specifications for 1986 Chevy C/K series trucks including engine options, dimensions, capacities, and performance data.

Specification	Description
Engine Options	4.3L V6, 5.0L V8, 5.7L V8, 6.2L Diesel V8
Transmission	3-speed automatic, 4-speed manual, 5-speed manual
Wheelbase	117.5" (short), 131.5" (long)
Fuel Capacity	16-20 gallons (varies by model)
Payload Capacity	1,500-5,000 lbs (C/K series)
Towing Capacity	5,000-10,000 lbs (with proper equipment)
Brake System	Front disc, rear drum with power assist
Suspension	Independent front, leaf spring rear (4WD: solid axle)
Electrical	12-volt system, 60-100 amp alternator
Oil Capacity	4-5 quarts (varies by engine)

Maintenance Schedule

Recommended maintenance intervals for optimal performance and longevity.

Oil Change: Every 3,000 miles or 3 months
Filter Replacement: Air filter every 12,000 miles, fuel filter every 15,000 miles
Tire Rotation: Every 6,000 miles
Brake Inspection: Every 10,000 miles
Coolant Flush: Every 30,000 miles or 2 years
Transmission Service: Every 30,000 miles (automatic), 50,000 miles (manual)

WARNING! Always use manufacturer-recommended fluids and parts. Failure to follow maintenance schedule may void warranty.

Engine Systems

Detailed procedures for engine maintenance, repair, and troubleshooting.

Spark Plug Replacement: Gap 0.035" for gasoline engines
Timing Adjustment: 6° BTDC for 5.7L V8 (base timing)
Valve Adjustment: Hydraulic lifters - no adjustment required
Compression Test: Should read 130-160 psi (varies by engine)
Belt Replacement: Check tension and wear every 15,000 miles

CAUTION! Always disconnect battery before working on electrical components. Allow engine to cool before servicing.

Transmission & Drivetrain

Automatic Transmission: TH350/400 series - fluid capacity 10-12 quarts
Manual Transmission: SM465 4-speed - gear oil capacity 3.5 pints
Transfer Case: NP208 - fluid capacity 2.5 pints (4WD models)
Differential: Front/Rear - gear oil capacity 3-4 pints
U-Joints: Grease every 6,000 miles or 6 months

Brake System

Service procedures for hydraulic brake system components.

Front Disc Brakes: Pad replacement, rotor service, caliper repair. Rear Drum Brakes: Shoe replacement, wheel cylinder service, adjustment.

Brake Fluid: DOT 3, flush every 2 years. Master Cylinder: Bench bleed before installation. Parking Brake: Cable adjustment at equalizer.

Suspension & Steering

Front suspension: Upper/lower control arms, ball joints, tie rods. Rear suspension: Leaf springs, shackles, U-bolts.

Ball Joint Inspection: Check for play every 15,000 miles
Shock Absorber: Replace if leaking or poor damping
Alignment Specifications: Camber 0° to +1°, Caster +1° to +3°
Power Steering: Fluid check, pump service, gearbox adjustment

Tip: Always support vehicle properly with jack stands when working underneath.

Electrical System

Wiring diagrams, component testing, and repair procedures.

Battery: 12V, 550-650 CCA, specific gravity 1.265
Alternator: 60-100 amp output, test voltage 13.5-14.5V
Starter: Draw test 150-200 amps (no load)
Ignition System: HEI distributor, coil resistance 0.5-1.5 ohms
Lighting: Headlight aiming, bulb replacement, circuit testing

WARNING! Disconnect battery ground cable before electrical work to prevent shorts.

Fuel System

Carburetor service, fuel pump testing, tank maintenance.

Cooling System

Radiator service, thermostat replacement, hose inspection.

CAUTION! Never remove radiator cap when engine is hot. Use 50/50 coolant mixture.

Troubleshooting Guide

Symptom	Possible Cause	Corrective Action
Engine won't start	Battery, ignition, fuel	Check battery voltage, spark, fuel delivery
Poor fuel economy	Tune-up needed, dragging brakes	Replace plugs, filters; check brake adjustment
Overheating	Coolant, thermostat, water pump	Check coolant level, thermostat operation, pump flow
Brake pull	Caliber, hose, alignment	Inspect calipers, hoses; check front end alignment
Transmission slippage	Fluid, bands, clutch	Check fluid level/condition; adjust bands (automatic)

Technical Support: Contact Chevrolet dealer or certified mechanic for complex issues.

Parts Source: Genuine GM parts recommended for optimal performance.