1996 GMC K3500 Service and Repair Manual
This factory service and repair manual for the 1996 GMC K3500 opens on three engines, the turbocharged 6.5L diesel V8 and the 7.4L and 5.7L gasoline V8s, and carries them through five body configurations: standard cab pickup, two-door cab & chassis, four-door cab & chassis, four-door crew cab pickup and extended cab pickup. The trims are Sierra SL, Sierra SLE and Sierra SLT. Coverage is per engine where it must be and shared where the trucks are alike underneath.
Engines covered
- 6.5L V8 (395 cu in) — OHV, turbocharged, diesel
- 7.4L V8 (454 cu in) — OHV, naturally aspirated, gasoline
- 5.7L V8 (350 cu in) — OHV, naturally aspirated, gasoline
Body styles covered
- 2-door standard cab pickup
- 2-door cab & chassis
- 4-door cab & chassis
- 4-door crew cab pickup
- 2-door extended cab pickup
Trims covered
- Sierra SL
- Sierra SLE
- Sierra SLT
Known issues on the 1996 K3500. Two recalls are on the federal record, both on replacement filters supplied for these trucks. One can seal poorly at the fuel connection, allowing a leak that may reach an ignition source; the other can seal poorly on the oil side, letting the engine lose its oil. Two owner complaints are logged with NHTSA, one on the power train and one on the service brakes. Between them, the fuel system, driveline and brake sections of this manual, with their procedures, specifications, torque values and diagnostics, cover what the record raises.
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
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 HOUSING MANUFACTURE
THIS CONDITION MAY CAUSE AN INADEQUATE SEAL AT THE CONNECTION, POTENTIALLY LEADING TO A FUEL LEAK. I
HONEYWELL WILL NOTIFY OWNERS AND REPLACE THE FUEL FILTERS FREE OF CHARGE. THE RECALL BEGAN ON OCTOB
This warranty administration bulletin provides information regarding the field action courtesy transportation policy.
Expanded Availability for Remanufacture and Return (R&R) Electronic Control Modules
INFORMATION REGARDING FUEL TRANSFER PUMP INOPERATIVE. *YH
THIS TECHNICAL SERVICE BULLETIN STATES THAT TECHNICIANS MAY EXPERIENCE DIFFICULTY IN REMOVING THE CONNECTORS FROM THE PARK / NEUTRAL POSITION SWITCH, USUALLY WHEN TRYING TO REMOVE THE SWITCH DURING TRANSMISSION SERVICE. *TT
DRIVING DOWN INTERSTATE ,PROCESS OF CHANGING LANES APPROXIMATELY 35MPH, VEHICLE AHEAD CAME TO A STOP, SLAMMED ON BRKES AND IT DID NOT STOP. ANTI-LOCK BRAKES DID NOT CHATTER ,RAN INTO OTHE RVEHICLE. HA
WHEN DRIVING DURING SNOW STORM ON A WET/SLIPPERY ROAD, THERMAL LINEAR ACTUATOR WHICH ACTIVATES THE 4 WHEEL DRIVE SYSTEM FAILED, DROPPING VEHICLE INTO TWO WHEEL DRIVE BEFORE DRIVERS FOOT WAS REMOVED FR
