1996 Chevrolet C3500HD Service and Repair Manual
This factory service and repair manual for the 1996 Chevrolet C3500HD is defined by two engines and two bodies: the turbocharged 6.5-liter diesel of 395 cubic inches and the naturally aspirated 7.4-liter 454 gasoline V8, in either a two-door conventional cab and chassis or a four-door crew cab and chassis. Base is the only trim, so equipment variation stays low and the specifications stay direct. The crew cab carries a second pair of doors, seats and door circuits, and those are documented apart from the two-door version.
Engines covered
- 6.5L V8 (395 cu in) — OHV, turbocharged, diesel
- 7.4L V8 (454 cu in) — OHV, naturally aspirated, gasoline
Body styles covered
- 2-door cab & chassis, conventional
- 4-door cab & chassis, crew cab
Trims covered
- Base
Known issues on the 1996 C3500HD. The federal record for this year holds no recalls and no owner complaints. The manual's job is unglamorous and complete: turbocharger, injection and glow plug service on the diesel; fuel and ignition specifications for the 454; cooling and charging system tests; transmission and driveline overhaul; axle and brake procedures; steering gear adjustment and front end alignment; and cab and body work that now takes in the crew cab's rear doors and their wiring. Diagrams, torque values and diagnostic sequences accompany each system.
This warranty administration bulletin provides information regarding the field action courtesy transportation policy.
Expanded Availability for Remanufacture and Return (R&R) Electronic Control Modules
PRODUCT RECALL CAMPAIGN INVOLVING WINDSHIELD WIPER MOTOR REPLACEMENT. *TT
COMPLETE LOSS OF THE TIRE TREAD CAUSING EXTENSIVE DAMAGE TO LEFT FIBERGLASS WHEEL WELL. TREAD DETACHMENT OCCURED WITHOUT NOTICABLE SOUND, VIBRATION, OR VEHICLE TRACKING.
ABS BRAKES FAILED.
