1996 Chevrolet C3500 Service and Repair Manual

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Factory-Grade Data

1996 Chevrolet C3500 service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Designed for technicians and DIY owners, this manual helps you troubleshoot accurately, follow step-by-step repair procedures, and reference wiring diagrams and system sections quickly while you work.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Wiring diagrams and electrical sections
  • Powertrain, brakes, steering, suspension, HVAC and more

Trims covered

  • Silverado Cab & Chassis 4-Door
  • Cheyenne Standard Cab Pickup 2-Door
  • Cheyenne Cab & Chassis 2-Door
  • Base Standard Cab Pickup 2-Door
  • Silverado Standard Cab Pickup 2-Door
  • Base Crew Cab Pickup 4-Door
  • Base Cab & Chassis 4-Door
  • Base Cab & Chassis 2-Door
  • Cheyenne Extended Cab Pickup 2-Door
  • Base Extended Cab Pickup 2-Door
  • Cheyenne Cab & Chassis 4-Door
  • Cheyenne Crew Cab Pickup 4-Door
  • Silverado Crew Cab Pickup 4-Door
  • Silverado Cab & Chassis 2-Door
  • Silverado Extended Cab Pickup 2-Door

Engines covered

  • 6.5L 395Cu. In. V8 DIESEL OHV Turbocharged
  • 7.4L 454Cu. In. V8 GAS OHV Naturally Aspirated
  • 5.7L 350Cu. In. V8 GAS OHV Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

1996 Chevrolet C3500 Recalls & Complaints

NHTSA #06E04300019/05/2006Component: FUEL SYSTEM, GASOLINE

CERTAIN REPLACEMENT FUEL FILTERS, FRAM BRAND NAME P/N G3727, WITH DATE CODES X52911 THROUGH X60801 SEQUENTIALLY OR X600141 AND A MEXICO COUNTRY OR ORIGIN MARKING ON THE FUEL FILTER

Consequence

THIS CONDITION MAY CAUSE AN INADEQUATE SEAL AT THE CONNECTION, POTENTIALLY LEADING TO A FU

Remedy

HONEYWELL WILL NOTIFY OWNERS AND REPLACE THE FUEL FILTERS FREE OF CHARGE. THE RECALL BEGA

TSB #10232287

This warranty administration bulletin provides information regarding the field action courtesy transportation policy.

TSB #10246631

Expanded Availability for Remanufacture and Return (R&R) Electronic Control Modules

TSB #627790

INFORMATION REGARDING FUEL TRANSFER PUMP INOPERATIVE. *YH

19990427Component: FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLYFire reported1 injured

CHEVROLET RECALL FRAME ON VEHICLE RUBBING AGAINST TANK. DEALERSHIP DID NOT REPAIR, WILL NOT REPAIR SAFETY ISSUE. *AK

20100223Component: FUEL SYSTEM, DIESEL

TRUCK SHUTS DOWN WHILE MOVING DOWN THE HIGHWAY. THIS IS A 1996 CHEVROLET C3500 DIESEL. PARTS WERE COVERED UNDER WARRANTY UNTIL 120,000 MILES. PROBLEM NEVER SOLVED AND VEHICLE STILL

20050623Component: TIRES:TREAD/BELT

OVER TWO YEARS, I HAVE HAD 3 BELT FAILURES ON B.F GOODRICH LT 225/75 R16 TIRES. ONE FAILURE RESULTED IN A BLOWOUT THE OTHER TWO WERE DETECTED BY EXTREME VIBRATION WHILE DRIVING ON

20050511Component: ENGINE AND ENGINE COOLING:ENGINE:DIESEL

1996 CHEV. 1 TON DUALLY 6.5 DIESEL, ENGINE AUTOMATICALLY SHUTS OFF WHILE DRIVING LIKE IT'S STARVING FOR FUEL. AFTER READING THE FOLLOWING WEBSITE WITH THE DOZENS OF EXACT SAME PROB

Showing the 4 most serious of 29 complaints filed with NHTSA.

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