Shop notes
Specs, torque & fluids
Torque, clearance and fluid reference
Written 2026-10-12 for the 1977 C10 single cab 2WD. Baseline is section 90 Recipe 2 (489 stroker, ARP hardware, Edelbrock 60455 heads, 7561 Air-Gap, Gearstar 4L80E, Currie 9 inch with TwinTrac, Wilwood ProSpindle with POL hydroboost, Borgeson 800132, Vintage Air Front Runner, Cold Case) with Recipe 1 (TH400, GM 12-bolt) as the alternate. Section 82 (engine oil) does not exist yet; the oil row below is a placeholder to be reconciled with it.
Confidence tags used in every row
| Tag | Meaning |
|---|---|
| P | Primary: the maker's own instruction sheet or GM service manual text that I actually opened and read |
| V | Vendor or retailer technical page (not the part maker) that I opened |
| F | Forum, article or search-result summary only (page not opened, or not authoritative). Treat as a starting point and verify |
| J | My judgment, no direct source; the cited source only supports part of it |
| NF | Not found. No number is given on purpose |
Source numbers in the Src column map to the ## Sources list at the end, which holds the URLs. The GM numbers come from the 1978 Chevrolet Light Truck Service Manual, the only full-text GM chassis manual for this truck family that I could retrieve (an archive.org search for a 1977 manual returned none). 1977 and 1978 C10 chassis, Mark IV 454 and THM 400 hardware are the same family, but treat GM figures as "stock-hardware" values and confirm against a 1977 manual or the parts you actually buy.
The pick
- Build the torque binder before assembly, not after. For each NF row, send one email (see Questions). The numbers the guide cannot yet state for Recipe 2 are Scat rod bolt torque/stretch, piston alloy and wall clearance, ring gaps, bearing oil clearances, crank/rod end play, 4L80E bolts, pitman nut, axle retainer, caliper/bracket bolts and cab-mount bolts. None should be guessed.
- Do not mix fastener systems. Head bolts are either Edelbrock-style (65/75 ft-lb, thread sealer, re-torque after first heat cycle) or ARP 135-3703 (70 ft-lb with Ultra-Torque and ARP thread sealer on water-jacket bolts). Use the ARP kit only after confirming its lengths cover Edelbrock's four tall bosses.
- Rod bolts: use a stretch gauge. ARP's sheet prefers stretch and gives torque only as a fallback. Ask Scat for its sheet; ARP's 80 ft-lb is for a different part number than the bolts in the Scat rods.
- Rear axle fluid: follow Currie. 85W-140 petroleum gear oil, no friction modifier for the TwinTrac. The clutch posi in Recipe 1 is the opposite case and needs the modifier.
- Power steering and hydroboost: PS fluid, never brake fluid, and not ATF unless the pump maker says so. Use stainless hoses and leak-check in the first week (section 13).
- Wheel nuts: 75 ft-lb is GM's 1978 figure for steel wheels; alloy wheels follow their own sheet; recheck at 100 miles every time wheels come off.
Why it matters
- Section 93 asks the owner to keep a binder with "every torque spec used" and plans for Walter to do oil changes, brake checks and bleeding between ages 11 and 14. A page of numbers with sources, plus a place to write down what was actually used, is that binder's first page.
- This build mixes three eras of hardware: 1977 GM (frame, cab, 454 block), modern aftermarket (ARP, Edelbrock, Wilwood, Borgeson) and a late-model transmission. Fastener torque depends on the fastener, thread, lubricant and joint, not on the engine. The same 7/16 head bolt is 65/75 ft-lb with Edelbrock's thread sealer, 70 ft-lb with ARP Ultra-Torque lube, and 80 ft-lb as a GM stock bolt on a 1978 Mark IV. Do not carry a number across to a different fastener or lubricant.
- Several numbers a builder expects (rod bolt torque for the Scat rods, piston-to-wall for the Scat pistons, 4L80E bolt torques, Currie axle retainer torque) were not found in a primary document. Those rows say NF. The fix is a phone call or email listed under Questions, done before assembly, with the answer going in the binder.
Fitment & gotchas
- ARP 135-3703 is a head bolt kit, not a stud kit, although the guide calls it "head bolts/studs". Edelbrock's heads have four taller bosses that need longer bolts; confirm lengths against ARP's drawing and Edelbrock's kit 8551.
- Edelbrock's intake sheet says to hand-tighten four bolts (5, 10, 11, 16). Torquing them can crack the manifold at the unsupported holes.
- Edelbrock's spark plug torque is 10 ft-lb, not GM's 17-27 ft-lb. Over-tightening a plug in an aluminum head strips threads.
- Fluidampr's crank bolt torque (110 ft-lb) differs from GM's 85 ft-lb. Use the damper maker's number and a new Grade 8 bolt.
- Main studs need align-honing with the studs torqued (ARP footnote). Tell the machine shop which studs and lube.
- Do not take the TwinTrac apart for a "check". An assembled third member has factory-set preload and pattern.
- Alloy wheels: use the nut type (conical, ball or flat) the wheel was made for.
- GM numbers here come from 1978 text with OCR errors. Axle, suspension and shock table columns are ambiguous; treat any value flagged "ambiguous" as unconfirmed.
How it touches other systems
- Torque vs. lubricant: ARP's numbers assume Ultra-Torque; Edelbrock's assume thread sealer or Teflon. Switching lube changes clamp load substantially, and ARP says so on its sheets [1], [2].
- Balancer, flexplate and converter: an external-balance crank means Fluidampr 800111 and an external 168-tooth flexplate; the wrong balance type changes the part list in sections 01, 05-08 and 90. This section gives torque only once those parts are chosen.
- Hydroboost and steering fluid: the PS fluid runs through the hydroboost, so contamination or a wrong fluid can fail the brakes as well as the steering (sections 12/13).
- Ride height and driveshaft: lowering changes pinion angle; the section 93 re-check and the leaf U-bolt re-torque interact.
- Coolant and head gasket: aluminum heads on an iron block expand differently; use the gasket named in [4] and keep the post-heat-cycle re-torque.
- Wheels and brake kit: the Wilwood hub takes 5 x 4.75 or 5 x 5.00 studs; the wheel's seat style decides the lug nut type [7].
Check on the truck
- Scat: which piston (maker, alloy, wall clearance) and ring set ship in 942-1-42452? Rod bolt torque and stretch for the supplied bolts? Bearing brand and oil clearance? Rod side clearance and crank end play?
- Edelbrock/ARP: do the ARP 135-3703 lengths cover Edelbrock 60455's four tall bosses, and does Edelbrock endorse ARP's 70 ft-lb?
- Borgeson: pitman nut and box mounting-bolt torque for 800132, and PS fluid vs ATF with the chosen pump.
- Gearstar: 4L80E bolt torques (pan, converter, mount), fluid capacity, flexplate bolt, break-in fluid.
- Currie: TwinTrac pinion preload/backlash if ever serviced; axle retainer torque; fluid capacity; confirm no friction modifier.
- Wilwood: caliper and bracket bolt torque for the exact brake kit; lug-nut torque on the ProSpindle hub.
- Wheel maker: seat style and torque for the chosen wheels.
- Cold Case and Vintage Air: coolant recommendation and capacity; SureFit Gen V charge and oil on the actual kit sheet.
- Is a 1977 GM manual worth buying so the 1978 numbers can be double-checked?
A. Engine torque sequences, clearances and gaps (Recipe 2, 489)
A1. Fasteners
| Item | Torque / spec | Lube / sealant / method | Conf | Src |
|---|---|---|---|---|
| Main studs, ARP 135-5402 (2-bolt main, 1/2 in, 200,000 psi) | 110 ft-lb, three equal steps, "manufacturer's recommended torque sequence" (the sequence itself is not printed on the ARP sheet; center-out is standard practice) | ARP Ultra-Torque lube on stud threads, nuts and washers (ARP says not motor oil). Studs go in hand tight only. Main bores must be align-honed with the studs torqued, same lube | P | [1] |
| Main caps if stock bolts were reused (not in Recipe 2) | 110 ft-lb Mark IV; intermediate outer bolts 70 ft-lb | Engine oil on threads | P (GM) | [6] |
| Rod bolts, Scat H-beam 6.135 rods (ARP 2000 7/16 x 1.600 per vendor listings) | Scat's own value: NF. ARP's sheet for its 7/16 BBC (454-502) rod bolts says stretch 0.0060-0.0065 in (preferred) or 80 ft-lb with Ultra-Torque if no stretch gauge. Re-size rods after new bolts; log each bolt's free length and replace any that grows more than 0.001 in | ARP Ultra-Torque on bolt threads and nut face | P, but for a different ARP part number | [3] |
| Rod bolts, stock 3/8 (not in Recipe 2) | 50 ft-lb Mark IV | Engine oil | P (GM) | [6] |
| Head bolts, Edelbrock 60455 with OEM-style bolts | 65 ft-lb short bolts (positions 11, 5, 4, 10) and 75 ft-lb long bolts (all others), three steps, factory sequence, re-torque after first start and cool-down (allow 2-3 hours) | Liquid Teflon or suitable thread sealer on bolt threads; hardened washers on every bolt (aluminum bosses). Fel-Pro 1017-1 (or Edelbrock 7302) head gasket for Mark IV 454, not 1037 | P | [4] |
| Head bolts, ARP 135-3703 (7/16, 180,000 psi, "high performance series head bolt kit") | 70 ft-lb, three equal steps, with Ultra-Torque | Chamfered side of washer toward bolt head; ARP thread sealer on bolts that enter a water jacket; Ultra-Torque on bolts that enter blind holes, and under heads and washers. ARP's sheet does not mention a re-torque | P | [2] |
| Head-bolt tall bosses | Edelbrock 60455 has four taller head bosses; Edelbrock ships four lengthened bolts per head for those positions (15, 8, 2, 7 in its Figure 1). Check that the ARP kit's lengths cover those four positions before ordering; ARP's sheet does not address them | Measure grip with the heads on the block, before final assembly | P (Edelbrock) / J | [4] |
| Rocker studs (60455, 7/16 studs, guide plates) | 45 ft-lb (Edelbrock spec table; GM stock Mark IV stud is 50). If guide plates are loosened to fix rocker-to-valve alignment, re-torque studs to 45 | No lube specified | P | [4], [6] |
| Intake manifold, Edelbrock 7561 | 25 ft-lb, two steps, Figure 2 sequence. Bolts 5, 10, 11 and 16 are hand-tight only (6 in box wrench, no torque wrench) because there is no gasket support under them | Edelbrock Gasgacinch on head flanges and the head side of the gasket; RTV (1/4 in bead) on the block end seals, no cork or rubber end seals; gasket Edelbrock 7203 (1.82 x 2.05 port, 0.060 in); no competition-style gaskets | P | [5] |
| Intake gasket cross-check | Edelbrock's head sheet says any manifold matching Fel-Pro 1212 fits the 60455 (section 90 uses 1212). The 7561 sheet itself names Edelbrock 7203. Both appear in Edelbrock documents; pick one set and do not mix | n/a | P | [4], [5] |
| Valve covers (stock Mark IV steel cover) | 50 lb-in (not lb-ft). Aftermarket tall covers (Proform VC240 in section 90): NF, follow the cover and gasket maker | Check cover flatness; do not over-tighten | P (GM) / NF | [6] |
| Damper bolts, Fluidampr 800111 (two-piece, external balance) | 6 socket-head bolts, 50 ft-lb. Only disassemble if match-balancing | Do not hammer on or drill the damper | P | [9] |
| Crank bolt, big block Chevy, with Fluidampr | 110 ft-lb (Fluidampr's chart). GM's stock damper figure is 85 ft-lb, so the damper maker's number governs here | New Grade 8 bolt and washer; press fit 0.0005-0.0015 in; install with a damper tool; anti-seize on snout | P | [9], [6] |
| Flexplate to crank (stock bolts, Mark IV) | 65 ft-lb. ARP flexplate bolt value: NF (sheet not retrieved) | Thread locker per bolt maker | P (GM) / NF | [6] |
| Converter to flexplate | THM 400: 35 ft-lb (GM). 4L80E: NF from any primary source | Use the converter maker's bolts; confirm bolt circle (section 06/90 flag 10.75 in vs 11.5 in) | P (GM) / NF | [6] |
| Oil pan to block (Mark IV 5/16-18 bolts) | 135 lb-in (11 ft-lb); pan to front cover 55 lb-in. Aftermarket pans (Canton 15-320, ARP A9294-2 per section 01): follow the gasket maker; NF | Fel-Pro 1804 pan set per section 01 | P (GM stock) | [6] |
| Oil drain plug | 20 ft-lb | Crush washer if fitted | P (GM) | [6] |
| Oil pump bolt | 65 ft-lb (stock Mark IV pump) | Check pickup-to-pan clearance on the 489 | P (GM) | [6] |
| Water pump | 30 ft-lb (stock Mark IV long pump). Reverse-rotation pump for serpentine: pump maker, NF | Section 90 settled the pump choice | P (GM) / NF | [6] |
| Water outlet / thermostat housing | 30 ft-lb | Sealant per gasket | P (GM) | [6] |
| Distributor clamp | 25 ft-lb | Set timing after clamping | P (GM) | [6] |
| Spark plugs, aluminum heads (60455) | 10 ft-lb, gasketed 14 mm x 3/4 in reach, anti-seize on threads (GM's 17-27 ft-lb iron-head figure does not apply). Champion N-9Y to N-14Y range, or RC-12YC (1/4 in shorter) for header clearance | Anti-seize | P | [4] |
| Header bolts / collector flanges (Hedman) | NF (sheet not retrieved). Stock exhaust manifold bolt value (20 ft-lb) is not valid for headers | Lock plates; re-torque after a few heat cycles | NF | [6] |
Sequences. Heads: factory big-block sequence (Edelbrock's Figure 1, which did not render in the PDF text; print it for the binder). Intake: Edelbrock Figure 2, printed in [5]. Mains: GM center-out; ARP says "manufacturer's recommended sequence".
A2. Clearances and gaps
| Item | Value | Notes | Conf | Src |
|---|---|---|---|---|
| Main bearing oil clearance | NF (spec sheet for the bearings in the Scat kit not found) | Measure with studs at 110 ft-lb and ARP lube; record actual values | NF | n/a |
| Rod bearing oil clearance | NF, same reason | Measure at final bolt stretch/torque | NF | n/a |
| Piston-to-wall, forged pistons in the Scat 942-1-42452 kit | NF. The piston maker and alloy are not stated in anything I opened. For scale only: a Mahle 2618 big-block dome piston at 4.280 bore is listed at 0.0061-0.0069 in (search-result summary), while forum guidance for big-block forged street pistons is 0.0035-0.0045. The spread is why the maker's sheet is required | Ask Scat which piston and alloy ship in the kit; the hone is set to that number | NF / F | [19], [16] |
| Ring end gap, top / second | Ring maker's sheet governs: NF (ring brand in the kit not found). Forum rule for modified street engines: top about 0.0045-0.005 in per inch of bore (0.019-0.021 in at 4.280), second about 0.0055 in per inch (about 0.0235 in) | Set each ring in its own bore, squared with a piston | F | [16] |
| Rod side clearance | NF (GM says "measure, see specifications" but the table was not in the retrievable text; Scat spec NF) | Feeler gauge on every rod | NF | [6] |
| Crankshaft end play | NF | Feeler gauge or dial indicator at the thrust bearing | NF | [6] |
| Camshaft end play (roller cam) | Sources disagree: 0.001-0.005 in vs 0.003-0.010 in, as recorded in section 03. Cam maker's card governs | Cam button or thrust plate; dial indicator | F | section 03 |
| Lash / lifter preload, hydraulic roller | Cam/lifter maker's card governs: NF. Forum rule of thumb: find zero lash with lifters bled down, then add roughly 1/4 to 1/2 turn of the adjuster. Edelbrock 60455 springs: 175 lb seat pressure at 1.975 in installed for hydraulic roller (spring 5823), max lift 0.700 in | F (preload) / P (spring) | [15], [4] | |
| Quench / deck | 0.043 in target already in section 90 | Not a torque item | section 90 | n/a |
B. Driveline
B1. Transmission
| Item | 4L80E (Recipe 2, Gearstar) | TH400 (Recipe 1) | Conf | Src |
|---|---|---|---|---|
| Fluid type | Dexron VI (Gearstar's guide names it) | Dexron II "or equivalent" in the 1978 manual; ask the TH400 builder which fluid their clutches expect today | P / P (GM) | [14], [6] |
| Fill capacity | Service refill about 6.6-7.3 qt; dry fill with converter about 12-16 qt depending on converter (article). Gearstar for its unit: NF | About 9 pints after a pan drop; about 22 pints dry with converter. Final level by dipstick | F / P (GM) | [18], [6] |
| Pan bolts | About 18 ft-lb reported (secondary; cited page returned 403). NF in a primary document | 12 ft-lb (13 pan bolts) | F / P | [22], [6] |
| Filter / strainer bolt | NF | 10 ft-lb | NF / P | [6] |
| Extension housing bolts | NF | 23 ft-lb | NF / P | [6] |
| Converter to flexplate | NF | 35 ft-lb | NF / P | [6] |
| Trans to engine bolts | NF | 35 ft-lb | NF / P | [6] |
| Rear mount to trans / to crossmember | NF | 40 / 40 ft-lb | NF / P | [6] |
| Crossmember mounting bolts | NF (4L80E needs its own crossmember, section 07; follow the crossmember maker) | 25 ft-lb | NF / P | [6] |
| Cooler line fittings | NF | 10 ft-lb at the line; 125 lb-in at the case/radiator connectors | NF / P | [6] |
| Fluid check | Hot, engine running, in Park (Gearstar to confirm) | Hot, level surface, engine running, Park; 1/4 in below ADD after a pan drop | J / P | [6] |
B2. Driveshaft
| Item | Value | Conf | Src |
|---|---|---|---|
| Driveshaft U-bolt/strap torque at pinion flange | NF. The 1978 GM text says "torque to specifications" with no retrievable C10 number; the new shaft's maker specifies the hardware | NF | [6] |
| U-joint type | Greaseable, or sealed per the shaft maker; check pinion angle after any ride-height change (section 93) | J | [6] |
| Carrier bearing support (only if a two-piece shaft is needed) | NF | NF | n/a |
B3. Rear axle
| Item | Ford 9 inch (Currie, Recipe 2) | GM 12-bolt 8-7/8 in (Recipe 1) | Conf | Src |
|---|---|---|---|---|
| Ring gear bolts | 7/16 ARP 85 ft-lb, 7/16 Grade 8 70 ft-lb, 1/2 ARP 120 ft-lb, red Loctite, criss-cross | 50 or 80 ft-lb in the GM table; the OCR text does not say which column is the 8-7/8, so read the printed page first | V (Strange) / P (GM, ambiguous) | [10], [6] |
| Carrier / "main" cap bolts | 80 ft-lb, anti-seize (non-billet). Billet case: 25 ft-lb (5/16 nuts) or 120 ft-lb (9/16 nuts) | Differential bearing caps 55 ft-lb in the GM table (same ambiguity) | V / P | [10], [6] |
| Case to housing | 35 ft-lb, self-locking nuts | Carrier cover (12-bolt) 20 ft-lb | V / P | [10], [6] |
| Pinion support bolts | 35 ft-lb (50 for HD case) | n/a | V | [10] |
| Pinion nut / preload | Crush collar: tighten until it takes 15-20 in-lb to rotate the pinion bearings. Solid spacer: 200 ft-lb (28 spline) or 250 ft-lb (35 spline, red Loctite) | 15-30 in-lb new bearings (5-10 used); no ft-lb value | V / P | [10], [6] |
| Backlash | Forum range 0.008-0.012 in. Currie spec: NF | 0.003-0.010 in, preferred 0.008 in (first two GM table columns agree) | F / P | [20], [6] |
| Tooth pattern | NF in a primary document. Paint the ring teeth, roll, read the pattern | Same | NF | n/a |
| Axle retainer / bearing retainer plate bolts | NF (Currie housing end sheet not found) | NF (GM refers to "specifications") | NF | [6] |
| Fill/sight plug | 40 ft-lb (Strange billet housings) | Filler plug 18 ft-lb | V / P | [10], [6] |
Gotcha: if the third member is bought assembled (section 09 prices TwinTrac as an assembled unit), do not take the carrier apart. Preload and pattern were set at the factory; this table matters for service or a ratio change.
C. Chassis
| Item | Value | Notes | Conf | Src |
|---|---|---|---|---|
| Lug nuts, steel wheels, 1/2-20 on 5 x 5 | 75 ft-lb (GM 1978 procedure for C10 front wheels); a secondary C10 source gives 100 ft-lb | Recheck at 100, 1,000 and 6,000 miles, then every 6,000 (GM). Conical-seat nuts for steel wheels | P (GM) / F | [6], [25] |
| Lug nuts, alloy wheels | Wheel maker's sheet governs. Example: Billet Specialties 1/2-20 = 75-85 ft-lb, 7/16-20 = 70-80, 12 mm = 75-85, 14 mm = 85-95. Working number if no sheet: 80 ft-lb (J) | Match the nut seat to the wheel seat; never mix | V / J | [13] |
| Wilwood ProSpindle hub stud (1/2-20 x 2.00, 12-point) | 77 ft-lb, red Loctite 271 | P | [7] | |
| Hub to spindle bolts (M14-1.5 x 45) | 100 ft-lb, red Loctite 271 | P | [7] | |
| Steering arm to spindle (1/2-13 x 2.75) | 90 ft-lb | P | [7] | |
| Steering stop stud | 25 ft-lb | P | [7] | |
| Caliper / bracket on ProSpindle | NF (Wilwood says the brake kit's own sheet governs) | Put that sheet in the binder | NF | [7] |
| Caliper mounting bolts, stock GM front disc | 35 ft-lb | Not used in Recipe 2 | P | [6] |
| Ball joint nuts (Wilwood says torque to OEM) | Upper: 50 ft-lb, plus the least additional torque to align the cotter pin, max 90. Lower: 90 ft-lb, same rule, max 130 | New cotter pins | P (GM) | [6], [7] |
| Tie rod end nut | Wilwood says OEM; GM figure NF in retrievable text | New cotter pin | NF | [7] |
| Control arm shafts | Lower arm shaft U-bolt 85 ft-lb; upper arm shaft nuts 70 ft-lb (C10). Rubber bushings 115. Steel upper bushing 190 new / 115 used; steel lower 280 new / 130 used | Torque with the truck's weight on the suspension; several table columns are OCR-ambiguous, confirm on the printed page | P (GM, partly ambiguous) | [6] |
| Front crossmember bolts | 65 ft-lb to side rail; 90 ft-lb to bottom rail (C10) | P (GM) | [6] | |
| Stabilizer bar | 25 ft-lb at control arm and frame | P (GM) | [6] | |
| Front shock upper / lower | Shock maker's sheet governs: NF. GM shock values are OCR-ambiguous | Bilstein/Belltech sheets | NF | [6] |
| Rear leaf spring U-bolts | GM: tighten diagonally opposite nuts to 40-50 ft-lb first, then to the final value, NF in retrievable text. U-bolt legs must pass the spring seat within 0.060 in | The lowering leaf kit's sheet governs (Performance Online RLS7387S6); re-torque after the first drive | P (procedure) / NF | [6] |
| Rear shackle and hanger bolts | NF; torque with the truck's weight on the springs | NF | [6] | |
| C-notch / flip kit hardware | NF. Not in Recipe 2 | NF | n/a | |
| Steering box mount bolts (Borgeson 800132) | NF | NF | [8] | |
| Pitman arm nut | Borgeson 800132: NF. Stock Saginaw: 125 ft-lb (section 13, from In The Garage). Other Borgeson sheets in search results state 100-120. Ask Borgeson; use a puller, not a hammer | Do not guess below 100 or above 125 | F / NF | [8], [21] |
| Steering box centering | Turn lock to lock, count turns (about 3 total, 1.5 each way), return to half; four master splines at 3, 6, 9, 12 o'clock | Install pitman at center | P | [8] |
| Stock manual/power gear adjustments | Adjuster plug locknut 85 ft-lb (manual) / 80 (power); over-center locknut 25 / 35 ft-lb | Not used with the Borgeson box | P (GM) | [6] |
| Cab (body) mounts | NF. The GM body-mounting torque table did not survive the scan text | Replace the rubber; re-torque after the first drive | NF | [6] |
| Seat belt to seat | 37 ft-lb (GM). Anchor-to-body bolts: NF; a retrofit three-point kit's sheet governs | Replace belts by date (section 93) | P (GM) / NF | [6] |
| Seat to floor | 50 ft-lb riser to floor; 18 ft-lb seat to riser/adjuster | P (GM) | [6] | |
| Master cylinder / booster to dash | 25 ft-lb. POL HB2-T7387 hydroboost: NF, follow its sheet | P (GM) / NF | [6] |
D. Fluids and capacities
| System | Spec / amount | Interval | Notes | Conf | Src |
|---|---|---|---|---|---|
| Engine oil (reconcile with section 82) | GM 1978: 4 qt without filter (V8) plus about 1 qt for the filter. Capacity depends on the pan: section 01 lists the ARP/Assault 6 qt A9294-2 and the Canton 15-320 at 7 qt; fill to the dipstick. Viscosity: NF in a primary source for this build. A roller cam needs no ZDDP (section 03). 10W-30 or 10W-40 is a judgment; confirm with cam, lifter and bearing makers | 3,000-5,000 miles or 6 months (judgment; GM said 7,500 mi/12 mo) | Break-in oil change at 500 miles (section 93) | P (GM capacity) / J | [6] |
| Coolant | 50/50 mix. For aluminum heads on an iron block, forum consensus is a hybrid (HOAT) coolant such as Zerex G-05 or Peak 10X rather than old green IAT or Dex-Cool. Cold Case's own coolant statement: NF; capacity NF | By date; HOAT is claimed at about 5 years | Do not mix chemistries. Aluminum-compatible chemistry is already noted in section 02 | F | [17] |
| 4L80E | Dexron VI; capacity NF in primary, about 6.6-7.3 qt service refill (article) | Fluid and filter 30,000-50,000 mi or 3 years (J) | Gearstar supplies ATF with the unit (about $200, section 07). Add a thermostatic cooler (sections 07/14) | P (fluid) / F | [14], [18] |
| TH400 | Dexron (II at GM; builder's choice today), about 9 pints after a pan drop | 30,000 mi (J) | Check hot | P (GM) / J | [6] |
| Rear axle, Ford 9 inch with TwinTrac | Currie: 85W-140 petroleum gear oil (the page prints "GL6"; GL-5 class). No synthetic. No friction modifier, because it would reduce TwinTrac bias. Capacity NF | First change at 500 miles, then 30,000 mi / 3 years (J) | The quote is from a Fuel Curve article repeating Currie's guidance, not a Currie PDF; confirm with Currie when ordering | F | [11] |
| Rear axle, GM 12-bolt | 80W or 80W-90 GL-5 (GM 1978). 3.5 pints for the 8-7/8 in ring gear in the GM table (column order uncertain). A clutch-type posi (Yukon Dura Grip in section 09) needs friction modifier; GM listed a special Positraction lubricant | 12 months / 7,500 mi (GM) | P (GM) | [6] | |
| Power steering and hydroboost | PS fluid, not ATF, unless the pump or box maker says otherwise. GM 1978: GM PS fluid 1050017 or equivalent, and its Hydro-Boost bleed procedure uses PS fluid. Borgeson 800132: "quality P/S fluid". POL: the fluid the vehicle maker specifies (search summary). Never brake fluid. Dexron vs PS fluid for the chosen pump: NF | Check at every oil change; flush on a date schedule (below) | Hydroboost failure takes both steering and brakes (section 13) | P (GM, Borgeson) / F (POL) | [6], [8], [24] |
| Brake fluid | DOT 3 or 4. GM 1978: Delco Supreme 11 or DOT 3. Wilwood EXP 600 Plus (626 F dry / 417 F wet, section 12) is optional. Do not mix with DOT 5 silicone | Flush every 1-2 years (section 12) | Replace by date | P (GM) | [6], [23] |
| A/C refrigerant and oil | 1.8 lb (28.8 oz, 816 g) R134a, by weight. A new Vintage Air-supplied Sanden compressor ships with the right oil, no additional oil needed; other compressors: ask the maker. Evacuate 35-45 min with components at 85 F or warmer. O-ring fitting torques: #6 11-13, #8 15-20, #10 21-27 ft-lb | Test annually | The 1.8 lb figure is on the Vintage Air Mini Slimline sheet I opened; the SureFit Gen V sheet for 945619 was not retrieved, so confirm on the kit's own sheet | P | [12] |
| Wheel bearings / hubs | Wilwood sealed hub service: NF | NF | [7] |
E. Service intervals
E1. Interval table
Intervals are the 1978 GM schedule where one exists and my judgment otherwise. This is a modernized low-mileage hobby truck that Walter will eventually drive, so the rule is by date, not wear for rubber, fluids and belts, as section 93 already says.
| System | Check | Change / service | Conf | Src |
|---|---|---|---|---|
| Engine oil and filter | Level at every fill-up | 3,000-5,000 mi or 6 months; first change at 500 mi | J (GM: 7,500 mi/12 mo) | [6] |
| Coolant | Monthly, cold | Per fluid maker (HOAT about 5 years); hoses and belts by date | F | [17] |
| 4L80E / TH400 | Each oil change | 30,000-50,000 mi (4L80E), 30,000 mi (TH400) | J | [6] |
| Rear axle | Each oil change (leaks) | First change at 500 mi, then 30,000 mi / 3 years. GM: 12 months or 7,500 mi | J / P | [6] |
| Power steering / hydroboost | Each oil change | Flush every 3 years (J); inspect hoses | J | [6] |
| Brake fluid | Each oil change | Every 1-2 years | P (section 12) | [23] |
| Brakes | Pads, rotors, lines every 6 months | Flexible lines by 10 years | J | n/a |
| Wheel nuts | At 100, 1,000, 6,000 mi, then every 6,000 mi | P | [6] | |
| Tires | Pressure monthly; rotate every 6,000-12,000 mi | Replace at 6 years (date code) | P (GM rotation) / section 93 | [6] |
| Chassis grease points | Every oil change | Control arms, tie rods, ball joints, U-joints if greaseable | P (GM: every 3 months or 3,000 mi in dust) | [6] |
| A/C | Annual performance test | Recharge when low; replace receiver/drier when opened | J | [12] |
| Spark plugs | 30,000 mi | J | n/a | |
| Re-torque list | After first heat cycles: head bolts (Edelbrock: after first start and cool-down), exhaust, intake, wheels. After first 500 mi: chassis hardware, driveshaft, lowered-leaf U-bolts | P (Edelbrock) / J | [4] | |
| Walter's tasks by age (section 93) | Age 11-14: oil change, brake check, bleeding, wheel-nut torque by feel and click | section 93 | n/a |
E2. One-page "Walter's service log"
Print one per year; keep a copy in the glovebox.
WALTER'S SERVICE LOG - 1977 C10 "BONANZA" Year: ________
Date ______ Odometer ______ Who did it: ______________ Helper: ____________
[ ] OIL AND FILTER oil used: ______ qt: ____ filter: ________ old oil recycled at ________
[ ] COOLANT level OK [ ] type: ______ mix: ____ hoses squeezed [ ] belts checked [ ]
[ ] TRANSMISSION fluid: ______ level OK [ ] color: ____________ smell: __________
[ ] REAR AXLE gear oil: ______ leak? Y N plug torqued to ____ ft-lb
[ ] POWER STEERING fluid: ______ level OK [ ] hoses dry [ ]
[ ] BRAKE FLUID fluid: ______ level: ______ pedal feel: firm / soft
[ ] BRAKES pad thickness F: ____ R: ____ rotor wear: ____ bled? Y N
[ ] WHEEL NUTS torque: ____ ft-lb rechecked at 100 mi? Y N
[ ] TIRES pressure F: ____ R: ____ tread depth: ____ date codes OK [ ]
[ ] GREASE POINTS done [ ]
[ ] A/C cools? Y N refrigerant by weight: ____ oz
[ ] LIGHTS / WIPERS / HORN / SEAT BELTS checked [ ]
[ ] WRENCH TIME: any bolt re-torqued today (name it): ____________________________
TORQUE SPECS USED (copy to the binder)
Part ______________ spec ____ ft-lb lube/Loctite ________ source ________
Part ______________ spec ____ ft-lb lube/Loctite ________ source ________
Something odd (noise, smell, drip, vibration):
_____________________________________________________________________
Next due: oil ______ fluids ______ brakes ______ tires ______
Signed (Walter): ___________ Checked (parent): ___________
Fact-check notes
- Opened and read as text: ARP 135-5402, 135-3703 and 135-6001; Edelbrock 60455 head sheet; Edelbrock 7561 manifold sheet; Wilwood DS-1194; Fluidampr install sheet; Vintage Air sheet; Billet Specialties sheet; Strange torque table; the 1978 GM manual text file.
- Not opened (403 or never fetched): the gm-trucks 4L80E thread, Gearstar/Currie/Hedman/Scat/Clevite/POL instruction documents, Cold Case coolant statement, ARP flexplate bolt sheet, Mahle piston PDF. Their numbers, where given, are F or NF.
- Discrepancies noted: (a) ARP head bolt 70 ft-lb vs Edelbrock 65/75; (b) Fluidampr crank bolt 110 vs GM 85; (c) Edelbrock names gasket 7203 for the 7561 while its 60455 sheet names Fel-Pro 1212; (d) C10 lug nut 75 (GM 1978) vs 100 (secondary); (e) Edelbrock rocker stud 45 vs GM stock 50; (f) Currie says 85W-140 petroleum and no synthetic, which differs from common "synthetic gear oil" advice; (g) Edelbrock's 7561 sheet says Performer RPM cams want at least 9.5:1 compression, versus section 90's 9.2-9.3:1 plan. That is a cam-pairing note for Edelbrock's own cams and does not apply to the chosen roller cam, but it is in the manifold sheet the owner will read.
- ARP 135-5402 vs the guide: the guide calls it a 2-bolt main stud kit; ARP's sheet gives 110 ft-lb for the 1/2 in size, consistent with GM's 110 ft-lb stock main cap torque.
- GM OCR caveat: the 1978 manual text has scrambled table columns in the rear-axle, front-suspension and shock rows; a number is used only where the column was unambiguous, and the rest is flagged.
- 1978 vs 1977: the GM figures are from 1978; no 1977 manual text was found.
- No part number or URL here was invented; every link was retrieved or appeared in a search result, as labeled.
Sources 25
- ARP instruction sheet, kit 135-5402 (main studs): cdn.arp-bolts.com (fetched, text read 2026-10-12)
- ARP instruction sheet, kit 135-3703 (high performance series head bolts): cdn.arp-bolts.com (fetched, text read)
- ARP instruction sheet 135-6001 (454-502 7/16 rod bolts, press fit): cdn.arp-bolts.com (fetched, text read; a different part number from the Scat rod bolts)
- Edelbrock Performer RPM BBC cylinder head instructions, covers 60429, 60435, 60439, 60447, 60449, 60455, 60459, 604515: totalperformance.net.au (fetched, text read)
- Edelbrock intake manifold instructions, catalog 2161, 3761, 7161, 7163, 7164, 7561, 7562, 75613: cdn.hansenracing.se (fetched, text read)
- 1978 Chevrolet Light Truck Service Manual (OCR full text; GM torque, fluids, intervals, THM 400, rear axle): archive.org and archive.org (downloaded and searched 2026-10-12)
- Wilwood assembly instructions DS-1194, front 2.50 in drop ProSpindle 831-14202 for 1971-87 C10: wilwood.com (fetched, text read)
- Borgeson 800132 installation instructions: sdda.semadata.org (fetched)
- Fluidampr standard damper installation instructions (4NFA13): sdda.semadata.org (fetched, text read)
- Strange Engineering Ford 9 inch torque recommendations: strangeengineering.net (fetched)
- Fuel Curve, Ford 9-Inch Currie TwinTrac (repeats Currie's lubricant guidance): fuelcurve.com (fetched)
- Vintage Air Mini Slimline instruction sheet (refrigerant, oil, fitting torques): vintageair.com (fetched, text read)
- Billet Specialties knock-off installation sheet 53225 (torque by thread size): images.carid.com (fetched, text read)
- Gearstar 4L80E transmission guide (Dexron VI statement): gearstar.com (fetched)
- Hydraulic lifter preload thread (forum): forabodiesonly.com (search result only)
- Big-block ring gap recommendations (forum): corvetteforum.com (search result only)
- Coolant for 60s muscle car (forum): bobistheoilguy.com (search result only)
- 4L80E oil capacity article: cartipsdaily.com (search result only)
- Mahle big-block dome piston data sheet: us.mahle.com (search result only; PDF not opened)
- Rebuilding a Ford 9 inch (forum): broncozone.com (search result only)
- Section 13 of this guide (In The Garage pitman nut figure) and sections 01, 03, 07, 09, 12, 14, 17, 90, 93
- 4L80E oil pan bolt torque thread: gm-trucks.com (returned 403; search summary only)
- Wilwood brake fluid page (via section 12): wilwood.com
- POL hydroboost background: performanceonline.com (search result only)
- C10 lug nut torque: ricksfreeautorepairadvice.com (search result only)
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