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Perhaps the title should really me "Maintenance Records" but running a GMC is really a continous work in progress task, hence the title. I'm not the greatest at record keeping and even when I do they're never in the right place when I want to access them or refer to them so I'm going to make an attempt to record all maintenance activity right here. The digital dashboard was installed at approximately 200,000 so all milages entered will be +200,000 for actual coach milage. Shortcuts:
May 23, 1997 - Mileage: 12721 Transmission overhauled at Dura-Built in Rocklin, CA. As the transmission had quite a bit of metal in the pan it was considered best not to use the transmission cooler that is in the radiator. An external cooler was installed as sole cooler instead. Regular ATF was installed by the shop. Synthetic was installed at first check and filter change. Downtime was 3 days. April 4, 1998 - Mileage: 25870 Fifty miles from home a big bang and rough running. Limped it home by keeping idle rpm up but staying below 40mph. Found #6 cylinder exhaust valve gone. Top of piston damaged, but no hole(s). Had the heads rebuilt. All parts replaced with new. Exhaust crossover was welded shut. Upon reinstall, compression was good. Howell TBI was removed and Rance EFI was installed at this time. Compression: A 20/20 hindsight note: Compression was done with fuelpump active. This means that cylinder walls got washed down with fuel with resulting inaccurate compression readings suspected. June 3-13, 1998 - Mileage: 30803 Compression: Installed four bagger suspension system. Rear bearings repacked. Left/Front Rear Wheel Cylinder replaced. Left/rear Rear Wheel Bearing had most wear. Onan Genset: New ring gear, points, plugs and started cleaned. Chassis Lube Front Tires to Bridgestone R265 LT215/85R16 E rating (10 ply) July 21, 1998 Installed rear Disc Brakes September 9-25, 1998 - Mileage: 33470 Compression: #7 with open throttle: 150 Change AC clutch bearing. Modify alternator +12 Volt to insert a flexible connection as strain relief for the #4 cable. Installed Fuel Pressure gauge. Installed combination RPM/Vaccum gauge. Oil changed to 5/50 Castrol Synthetic. Oil Filter changed. Transmission changed to Synthetic. Filter changed. Additive added. Chassis Lube. ( Front Bearings not greased ) October 24, 1998 - Mileage: 36360 Compression: Additional reading of #1: 120. Comments: Fuel appears to dilute ring seal. All plugs wet after first. Compression was
taken with one plug out at a time. Gap checked to 0.080. Only 1 or 2 (unknown which) were slightly less. NEXT COMPRESSION TEST: Disconnect Fuel pump prior to test. Transmission modulator adjusted 3/4 turn out. (anticlockwise) Steering box adjusted 1/2 turn in ( clockwise) Oil changed: 5/50 Synthetic Parking Brake tightened 3/4 turn December 6, 1998 - Mileage: 39851 Compression: Additional #6: 150. This was the cylinder that made an exhaust valve disappear. Compression was done with fuel pump disconnected and all plugs out. Sequence: #8 --> #2 and #7 -->#1. Plug gaps ok. #1, 3 and 2 showed rich. February 20, 1999 - Mileage: 39851 Installed Auxiliary Vacuum Pump, AV10 Engine Monitor, Ragusa Step and other Ragusa goodies. Final Drive fluid changed to Synthetic. Ragusa Cover installed. Fuel filter changed. Some metal flakes in filter. Spark Plugs replaced with R46SZ at 0.060 gap. Lubed Parking Brake worm gear. March 28, 1999 - Mileage: 41137 Engine Batteries changed. April 30, 1999 - Mileage: 45000 House/Coach Battery changed to 2 x 6 Volt Golf deepcycle. May 7-18, 1999 - Mileage: 46308 - Hobbs: 145.7 Compression: Plugs condition: Plugs regapped to 0.060 #5 replaced. Timing Chain replaced. Cam Shaft "button" installed. Mondello Water Pump installed. Thermostat replaced with Mondello restrictor. Alternator mounting bracket modified with studs used for mounting instead of bolts and .25 inch of spacer installed to improve belt line-up. New Delco rebuilt Alternator installed. Ser# 1972724, 321-136, 18E8. Purchased in Sacramento. Ford E7AF-10A352-AA pulley installed with Loctite 640 on shaft and 242 on threads. No lock washer used. (no room). LH Exhaust gasket changed. FelPro 1439 was used. Battery Combiner installed. Alternator to Battery cable replaced with #6 size. A second combiner will be installed to charge the engine aux/boost battery. Prior to this change the rear (house) battery and the aux/boost battery were always connected in parallel, perhaps contributing to frequent battery failures of the aux/boost due to the mis-match to house battery. Each battery bank is now on it's very own. Battery status indicators installed on engine and aux/bost battery. May 23, 1999 Second combiner (50 amp) installed between main and aux/boost battery. To actually use the boost battery will be by normal switch/relay in the coach. New caliper installed on right rear/rear. New Master Cylinder installed (Raybestos). Brake pedal went to floor even after re-bleed. Front brake reservoir was colored redish. Old MC was leaking on the vacuum booster side. Debating re Raybestos/Wagner versus Cinnebar/GMC. Installed new transmission filter, transmission cooler with fan and a transmission fluid thermostat. Rebuilt rock guard. May 29, 1999 Rewired the coach charger with #6 wire and cleaned up house battery wire connections. Wired up the regular/high output selection switch on coach charger(s). Added AC outlet in Generator compartment, connected to the unused 20 amp breaker on GenSet. Installed E-Meter connected to house battery. Did a short neighborhood test drive. Brakes ok (with Raybestos MC). Water temps too low (133 degrees). Removed Mondello restrictor and installed 180 degree Robert Shaw thermostat. Caspro Steering Damper installed. DOA Combiner replaced. Installed remote switch for Combiners on glare shield so that batteries can be combined manually or forced to "no combine". Installed monitoring lights for electric fans on glare shield so that there is a positive indication when they get turned on by thermostat or manually. Various rewiring & cleanup. Installed a drip protector inside driver side front access door to protect fuses and terminal strips. One hour test drive.
July 19, 1999 -- Mileage: 48828 - GenSet: 284.1 - Hobbs: 207:45 Front Calipers and Pads replaced. Steering Damper was loose. Retightened and ground to increase clearance to Final Drive pan. Chassis Lube, Oil & Filter changed. Installed additional tailpipe ring. Front Bearings: Right added none, left: a tiny bit. Changed LH exhaust header gasket to a Mr Gasket. (It failed 1000 miles later and was replaced with a Felpro). Compression: Plugs condition: Reinstalled plugs switched and with Dielectric paste
July 30, 1999 -- Mileage: 50775 Chassis Lube, Oil & Filter Hatch rebuilt to accommodate Offenhouser intake manifold. Air intake relocated to behind alternator. Wheel nuts retourque'd Air to 65 pounds. Problems on trip: Lost lower LH shock nut. Replaced with self locking nut in Prince George. September 1, 1999 -- Mileage: 53850 - Hobbs: 326.6 - GenSet: 325.8 Alcoas changed (recall) Tires: Michelin XPS 10 ply ( Load Range E) inflated to 65 pounds. Wheels were balanced with TireSentry transmitter in place. Installed SmarTire monitoring system. Rear bearings had slight play. Reseated all. Tightened to 50# and backed off 1/6 to insert cotter pin. Compression: Plugs condition: replaced with new plugs at 0.060 Chassis Lube Rear brake pads at 50% RR Caliper/Pads normal (Caliper and pads changed recently as old one was dragging) April 18, 2002 -- Weighed the coach Fuel: full Front set: 3968 Front set, front seats loaded: 4321 Front right: 1918 Rear right: 3792 Have adjusted tired pressures to front: 60 and rear 55 lbs. Ride is much better. Will keep an eye on tire temperatures via SmarTire system.
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