1992 GMC C3500 Service and Repair Manual
This factory service and repair manual for the 1992 GMC C3500 has two diesels to keep apart — the turbocharged 6.5L V8 and the naturally aspirated 6.2L V8 — as well as the 5.7L and 7.4L gasoline V8s. Body configurations number five, from standard and extended cab pickups to a crew cab and cab-and-chassis versions with two or four doors, in Sierra, Sierra SLE and Sierra SLX trim. The specifications, torque values, wiring diagrams and diagnostics are set out by system so the right figures surface for the truck at hand.
Engines covered
- 6.5L V8 (395 cu in) — OHV, turbocharged, diesel
- 7.4L V8 (454 cu in) — OHV, naturally aspirated, gasoline
- 6.2L V8 (379 cu in) — OHV, naturally aspirated, diesel
- 5.7L V8 (350 cu in) — OHV, naturally aspirated, gasoline
Body styles covered
- 2-door standard cab pickup
- 4-door cab & chassis
- 4-door crew cab pickup
- 2-door extended cab pickup
- 2-door cab & chassis
Trims covered
- Sierra
- Sierra SLE
- Sierra SLX
Known issues on the 1992 C3500. Three recalls sit on the record. The most serious describes the pivot bolt at the brake pedal, which may have been tightened without engaging its locking material and can back out of its nut, taking braking control with it. A second covers replacement oil filters that can lose their seal and leak oil toward a fire risk, and a third involves transmission fluid forced out of the vent tube by heat. Both owner complaints logged with NHTSA concern the service brakes, which makes the brake chapter — hydraulics, pedal linkage, torque values and diagnostics — the one to read first.
CERTAIN HONEYWELL FRAM RACING BRAND HP4 AND HP8 OIL FILTERS THAT WERE MANUFACTURED FROM MAY 25, 2006, THROUGH SEPTEMBER 14, 2007, AND SOLD FOR USE AS REPLACEMENT EQUIPMENT FOR VEHICLES LIST ABOVE. TH
THIS CONDITION MAY CAUSE INADEQUATE SEALING AND LOSS OF ENGINE OIL, POSSIBLY RESULTING IN A FIRE.
HONEYWELL WILL REPLACE THE AFFECTED OIL FILTERS FREE OF CHARGE. THE RECALL BEGAN DURING NOVEMBER 20
THE PIVOT BOLT HOLDING THE BRAKE PEDAL TO ITS SUPPORT BRACKET MAY BE IMPROPERLY TIGHTENED AND MAY NOT HAVE ENGAGED THE LOCKING MATERIAL ON THE BOLT. THE BOLT CAN DISENGAGE FROM THE NUT.
IF THE PIVOT BOLT DISENGAGES FROM THE NUT WHILE THEVEHICLE IS IN MOTION, THERE WILL BE A LOSS OF BRA
DEALERS SHOULD INSPECT THE HAND STARTED BRAKE PEDAL BOLTS AND TORQUE THEM TO SPECIFICATION.
UNANTICIPATED HEAT IN THE TRANSMISSION CAN FORCE THE TRANSMISSION FLUID OUT OF THE VENT TUBE.
THE VENTED TRANSMISSION FLUID CAN CATCH FIRE IF EXPOSEDTO A SOURCE OF IGNITION.
INSTALL A LONGER TRANSMISSION VENT HOSE ROUTED TO THE LEFT SIDE OF THE ENGINE COMPARTMENT OF THE VEH
UNKNOWN
ANTI-LOCK BRAKES FAILED ALMOST RESULTING IN AN ACCIDENT.
WHEN TRAVELING ON WET OR DRY PAVEMENT AND UPON DEPRESSING THE BRAKE PEDAL TO MAKE A SUDDEN OR A GRADUAL STOP, THE REAR BRAKES LOCK UP, MAKING IT VERY DIFFICULT TO STOP THE VEHICLE. CONSUMER HAS CONTAC
