GMC 2003 GMT560 T-Series Owner'S Manual Download

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Rear Axle Lubricant Capacity

Application

Capacities

English

Metric

Single Speed Axle

15040S

21.0 pints

10.3 liters

19060S

28.0 pints

13.0 liters

21060S

28.0 pints

13.0 liters

23090S

40.0 pints

19.0 liters

26105S

56.0 pints

26.5 liters

Two-Speed Axle

19060T

34.0 pints

16.0 liters

21060T

34.0 pints

16.0 liters

23080T

40.0 pints

19.8 liters

Tandem Axles

DS404 (front)

31.0 pints

14.5 liters

RS404 (rear)

28.0 pints

13.0 liters

Above capacities (volumes) are approximate.

5-77

Summary of Contents for 2003 GMT560 T-Series

Page 1: ...ing Your Vehicle 4 1 Your Driving the Road and Your Vehicle 4 2 Towing 4 32 Service and Appearance Care 5 1 Service 5 3 Fuel 5 5 Checking Things Under the Hood 5 10 Rear Axle 5 43 Cab Tilting 5 44 Noise Control System 5 50 Windshield Wiper Blade Replacement 5 51 Tires 5 52 Appearance Care 5 60 Vehicle Identification 5 67 Electrical System 5 67 Capacities and Specifications 5 74 Normal Maintenance ...

Page 2: ...this manual in it so the new owner can use it Litho in U S A Part No X2203 A First Edition Copyright General Motors Corporation 06 11 01 All Rights Reserved Canadian Owners You can obtain a French copy of this manual from your dealer or from Helm Incorporated P O Box 07130 Detroit MI 48207 How to Use This Manual Many people read their owner s manual from beginning to end when they first receive th...

Page 3: ...g CAUTION These mean there is something that could hurt you or other people In the caution area we tell you what the hazard is Then we tell you what to do to help avoid or reduce the hazard Please read these cautions If you don t you or others could be hurt You will also find a circle with a slash through it in this book This safety symbol means Don t Don t do this or Don t let this happen iii ...

Page 4: ...abels on your vehicle They use the same words CAUTION or NOTICE Vehicle Symbols Your vehicle has components and labels that use symbols instead of text Symbols used on your vehicle are shown along with the text describing the operation or information relating to a specific component control message gage or indicator If you need help figuring out a specific name of a component gage or indicator ref...

Page 5: ...These are some examples of vehicle symbols you may find on your vehicle v ...

Page 6: ...s delivered from the factory are finished in a variety of ways by a number of companies you ll probably find other manuals in your vehicle These manuals are put there by the companies that have added components or equipment to the T Series models Read all these materials as well as this manual carefully to get all of the information on your vehicle vi ...

Page 7: ... During Pregnancy 1 16 Right Passenger Position 1 17 Center Passenger Position 1 17 Safety Belt Extender 1 18 Child Restraints 1 19 Older Children 1 19 Infants and Young Children 1 21 Child Restraint Systems 1 24 Top Strap 1 27 Securing a Child Restraint in a Center Seat Position 1 28 Restraint System Check 1 30 Checking Your Restraint Systems 1 30 Replacing Restraint System Parts After a Crash 1 ...

Page 8: ...seats You can adjust the driver s seat with these levers located at the front of the seat Slide lever A to the left to unlock the seat and slide the seat to where you want it Then release the lever and try to move the seat with your body to make sure the seat is locked into place To adjust the lower seat cushion forward or backward pull up on lever B and slide the cushion to where you want it Then...

Page 9: ...ck turn the lumbar adjustment knob The knob is located on the upper cushion on the inboard side of the driver s seat and the outboard side of the passenger s seat CAUTION You can lose control of the vehicle if you try to adjust the seat while the vehicle is moving The sudden movement could startle and confuse you or make you push a pedal when you don t want to Adjust the driver s seat only when th...

Page 10: ...ould cause injury to the person sitting there Always press rearward on the seatback to be sure it is locked Safety Belts Safety Belts They Are for Everyone This part of the manual tells you how to use safety belts properly It also tells you some things you should not do with safety belts CAUTION Don t let anyone ride where he or she can t wear a safety belt properly If you are in a crash and you r...

Page 11: ...p See Safety Belt Reminder Light on page 3 23 In most states and all Canadian provinces the law says to wear safety belts Here s why They work You never know if you ll be in a crash If you do have a crash you don t know if it will be a bad one A few crashes are mild and some crashes can be so serious that even buckled up a person would not survive But most crashes are in between In many of them pe...

Page 12: ...s And they are for adult truckers and anyone else who rides in your vehicle Here s why when your vehicle goes say 30 mph 50 km h so do you and your passengers If the vehicle hits something it stops right then But nothing stops the people They keep moving 1 6 ...

Page 13: ...ing will stop them It could be the windshield Or it could be the instrument panel Now what if you and your passengers were to give that big vehicle a chance to deal with the force of the impact instead of you 1 7 ...

Page 14: ...d your chance of being conscious during and after an accident so you can unbuckle and get out is much greater if you are belted Q If I m a good driver and I never drive far from home why should I wear safety belts A You may be an excellent driver but if you re in an accident even one that isn t your fault you and your passengers can be hurt Being a good driver doesn t protect you from things beyon...

Page 15: ...river Position This part describes the driver s restraint system Lap Shoulder Belt The driver has a lap shoulder belt Here s how to wear it properly 1 Close and lock the door 2 Adjust the seat so you can sit up straight To see how see Seats in the Index 3 Pick up the latch plate and pull the belt across you Don t let it get twisted The shoulder belt may lock if you pull the belt across you very qu...

Page 16: ...up on the shoulder belt The lap part of the belt should be worn low and snug on the hips just touching the thighs In a crash this applies force to the strong pelvic bones And you d be less likely to slide under the lap belt If you slid under it the belt would apply force at your abdomen This could cause serious or even fatal injuries The shoulder belt should go over the shoulder and across the che...

Page 17: ...too loose It won t give nearly as much protection this way CAUTION You can be seriously hurt if your shoulder belt is too loose In a crash you would move forward too much which could increase injury The shoulder belt should fit against your body 1 11 ...

Page 18: ...an be seriously injured if your belt is buckled in the wrong place like this In a crash the belt would go up over your abdomen The belt forces would be there not at the pelvic bones This could cause serious internal injuries Always buckle your belt into the buckle nearest you 1 12 ...

Page 19: ...eriously injured if you wear the shoulder belt under your arm In a crash your body would move too far forward which would increase the chance of head and neck injury Also the belt would apply too much force to the ribs which aren t as strong as shoulder bones You could also severely injure internal organs like your liver or spleen 1 13 ...

Page 20: ... across the body CAUTION You can be seriously injured by a twisted belt In a crash you wouldn t have the full width of the belt to spread impact forces If a belt is twisted make it straight so it can work properly or ask your dealer to fix it 1 14 ...

Page 21: ...belt just push the button on the buckle The belt should go back out of the way Before you close the door be sure the belt is out of the way If you slam the door on it you can damage both the belt and your vehicle 1 15 ...

Page 22: ...nt woman should wear a lap shoulder belt and the lap portion should be worn as low as possible below the rounding throughout the pregnancy The best way to protect the fetus is to protect the mother When a safety belt is worn properly it s more likely that the fetus won t be hurt in a crash For pregnant women as for anyone the key to making safety belts effective is wearing them properly 1 16 ...

Page 23: ...See Driver Position on page 1 9 Center Passenger Position Lap Belt If your vehicle has a center seat someone can sit in the center position When you sit in a center seating position you have a lap safety belt which has no retractor To make the belt longer tilt the latch plate and pull it along the belt 1 17 ...

Page 24: ...y if you ever had to Safety Belt Extender If the vehicle s safety belt will fasten around you you should use it But if a safety belt isn t long enough to fasten your dealer will order you an extender It s free When you go in to order it take the heaviest coat you will wear so the extender will be long enough for you The extender will be just for you and just for the seat in your vehicle that you c...

Page 25: ...ossible an older child should wear a lap shoulder belt and get the additional restraint a shoulder belt can provide The shoulder belt should not cross the face or neck The lap belt should fit snugly below the hips just touching the top of the thighs It should never be worn over the abdomen which could cause severe or even fatal internal injuries in a crash In a crash children who are not buckled u...

Page 26: ...lt but the child is so small that the shoulder belt is very close to the child s face or neck A Move the child toward the center of the vehicle but be sure that the shoulder belt still is on the child s shoulder so that in a crash the child s upper body would have the restraint that belts provide If the child is so small that the shoulder belt is still very close to the child s face or neck you mi...

Page 27: ...belt force to the child s pelvic bones in a crash Infants and Young Children Everyone in a vehicle needs protection This includes infants and all other children Neither the distance traveled nor the age and size of the traveler changes the need for everyone to use safety restraints In fact the law in every state in the United States and in every Canadian province says children up to some age must ...

Page 28: ...until a crash During a crash a baby will become so heavy it is not possible to hold it CAUTION Continued CAUTION Continued For example in a crash at only 25 mph 40 km h a 12 lb 5 5 kg baby will suddenly become a 240 lb 110 kg force on a person s arms A baby should be secured in an appropriate restraint 1 22 ...

Page 29: ...t will have a label saying that it meets federal motor vehicle safety standards The restraint manufacturer s instructions that come with the restraint state the weight and height limitations for a particular child restraint In addition there are many kinds of restraints available for children with special needs CAUTION Newborn infants need complete support including support for the head and neck T...

Page 30: ... present real problems in a medium duty vehicle like yours The only place where you can properly secure a child restraint is the center seating position the place that has the lap belt only But your vehicle may not have a center seating position Or even if you have one you may find that the child restraint keeps you from operating the shift lever or other controls The only answer may be to have th...

Page 31: ...of the infant The harness system holds the infant in place and in a crash acts to keep the infant positioned in the restraint A forward facing child seat C E provides restraint for the child s body with the harness and also sometimes with surfaces such as T shaped or shelf like shields 1 25 ...

Page 32: ...d restraints have used the adult belt system in the vehicle To help reduce the chance of injury the child also has to be secured within the restraint The vehicle s belt system secures the add on child restraint in the vehicle and the add on child restraint s harness system holds the child in place within the restraint One system the three point harness has straps that come down over each of the in...

Page 33: ...le obtain a replacement copy from the manufacturer The child restraint must be secured properly in the center seat if your vehicle has one Keep in mind that an unsecured child restraint can move around in a collision or sudden stop and injure people in the vehicle Be sure to properly secure any child restraint in your vehicle even when no child is in it Top Strap Some child restraints have a top s...

Page 34: ... in the child restraint when and as the instructions say But do not use this position if the child restraint interferes with shifting gears See Top Strap on page 1 27 if the child restraint has one 1 Make the belt as long as possible by tilting the latch plate and pulling it along the belt 2 Put the restraint on the seat 3 Run the vehicle s safety belt through or around the restraint The child res...

Page 35: ... on the child restraint If you are using a forward facing child restraint you may find it helpful to use your knee to push down on the child restraint as you tighten the belt 6 Push and pull the child restraint in different directions to be sure it is secure To remove the child restraint just unbuckle the vehicle s safety belt It will be ready to work for an adult or larger child passenger 1 29 ...

Page 36: ...e the restraint systems in your vehicle A damaged restraint system may not properly protect the person using it resulting in serious injury or even death in a crash To help make sure your restraint systems are working properly after a crash have them inspected and any necessary replacements made as soon as possible If you have had a crash do you need new belts After a very minor collision nothing ...

Page 37: ...olant Heater 2 13 Diesel Engine Exhaust Brake 2 14 Two Speed Rear Axle Electric Shift Control 2 14 Automatic Transmission Operation 2 16 Manual Transmission Operation 2 18 Parking 2 19 Parking Over Things That Burn 2 23 Engine Exhaust 2 23 Running Your Engine While You Are Parked 2 24 Mirrors 2 25 Manual Rearview Mirror 2 25 Outside Manual Mirrors 2 25 Outside Power Mirrors 2 25 Outside Convex Mir...

Page 38: ...locks including the ignition switch The key has a code on it that tells your dealer or a qualified locksmith how to make extra keys Record and keep the key code in a safe place If you lose your key you ll be able to have a new one made easily using this code Notice Your vehicle has a number of features that can help prevent theft You can have a lot of trouble getting into your vehicle if you ever ...

Page 39: ...ked vehicles may be unable to get out A child can be overcome by extreme heat and can suffer permanent injuries or even death from heat stroke Always lock your vehicle whenever you leave it Outsiders can easily enter through an unlocked door when you slow down or stop your vehicle Locking your doors can help prevent this from happening A manual door lock is located above each door handle To lock y...

Page 40: ... with the windows closed is dangerous A child can be overcome by the extreme heat and can suffer permanent injuries or even death from heat stroke Never leave a child alone in a vehicle especially with the windows closed in warm or hot weather 2 4 ...

Page 41: ...so has a LOCK button When the LOCK button is pressed down the passenger s window will not operate with either switch Push LOCK again to return the passenger s power window to normal operation The lock button does not affect the driver s manual window operation The passenger s power window will not move unless the ignition switch has been turned to ON The passenger s power window can be operated fo...

Page 42: ...latch to close completely CAUTION Never open the passenger side door glass with the ignition on You can be injured if the window linkage moves Open this glass only with the ignition off Theft Deterrent Systems Vehicle theft is big business especially in some cities and even commercial vehicles are no exception Although your vehicle has a number of theft deterrent features we know that nothing we p...

Page 43: ...r and earlier replacement Follow this breaking in guideline every time you get new brake linings Use the lowest gear you can when you start a loaded vehicle in motion and when going up hills to avoid overloading the engine Check and adjust engine and transmission fluid levels often and be sure tires are properly inflated for the load you re carrying If you have a Caterpillar diesel engine see the ...

Page 44: ...tely turn the ignition key to START When the engine starts let go of the key Notice Holding your key in START for longer than 15 seconds at a time will cause your battery to be drained much sooner And the excessive heat can damage your starter motor Notice If the WAIT TO START light stays on it means that your vehicle could have one of several problems so you should have it serviced right away 3 I...

Page 45: ...gh engine temperature or low engine oil pressure If high engine temperature or low engine oil pressure is detected you will also hear a tone alarm at two beats per second The alarm and the light will remain on until the condition is fixed If the engine temperature or oil pressure condition worsens the tone alarm will go to five beats per second If the system senses low engine oil coolant the alarm...

Page 46: ...ll be deactivated Exhaust Restrictor If your vehicle is equipped with this feature there is an exhaust restrictor valve located in the exhaust stream The valve closes to provide back pressure to the engine for the purpose of warming the engine quickly The exhaust restrictor operates while the engine is running while the vehicle is not moving while the accelerator brake and clutch pedals are not pr...

Page 47: ...r dealer as soon as you can for a starting system check If the light comes on and then goes off and you know your batteries are charged but your engine still won t start your vehicle needs service If the light does not come on when the engine is cold your vehicle needs service If your batteries don t have enough charge to start your engine see Battery on page 5 34 for more information Be sure you ...

Page 48: ...ting If you have air brakes the dual needle air pressure gage should read at least 115 psi 790 kPa for both service systems before you try to move the vehicle When air pressure is below 60 psi 420 kPa the LOW AIR light will come on and you will hear a tone alarm If the pressure doesn t build up or drops during warm up stop the engine and find the cause before you try to move the vehicle Recommende...

Page 49: ...n cord rated for at least 15 amps into the vehicle s plug in receptacle first Then plug the extension cord into a normal grounded 110 volt AC outlet CAUTION Plugging the cord into an ungrounded outlet could cause an electrical shock Also the wrong kind of extension cord could overheat and cause a fire You could be seriously injured Plug the cord into a properly grounded three prong 110 volt AC out...

Page 50: ... will be most effective if the gear range selected is the lowest possible range that does not allow the engine rpm to go more than 200 rpm above rated full load rpm Do not exceed 2400 rpm If you have an automatic transmission and press this button the transmission will downshift to a factory default setting of fourth gear To change the default setting or for more information on factory default set...

Page 51: ...d shift into low range when the vehicle is standing still and then operate the transmission normally On the highway with the rear axle in low range and the transmission in top gear you may shift the rear axle to high range by raising the switch and releasing the accelerator momentarily Reapply the accelerator after you shift Under light load conditions first shift the rear axle into the high range...

Page 52: ...ission Operation We build vehicles with five and six speed automatic transmissions This part of the manual covers the basics of these With these transmissions you will find an Allison Transmission Operator s Manual in your vehicle that goes into more detail On the headliner in front of and above the driver or in some other place near the driver you will see a label that describes important operati...

Page 53: ...osition unless your engine governed speed is exceeded such as when going downhill This feature is used for certain load and traffic conditions or when plowing snow See the Allison Transmission Operator s Manual in your vehicle for more information about this Overdrive Defeat If your vehicle has this feature you can select to limit the transmission to fourth gear This may be useful when operating a...

Page 54: ...erned speed When the engine speed drops below two thirds of the governed speed shift into the next lower gear before your engine begins to lug When you shift down be sure to double clutch if required Eaton Fuller Nine and Ten Speed Non Synchronized Manual Transmissions If your vehicle has one of these non synchronized transmissions it s naturally somewhat complicated The label above the windshield...

Page 55: ...ansmission into either the initial starting gear or REVERSE R If the tooth butting occurs between the clutching teeth re engage the clutch while applying light pressure to the shift lever This will provide for a smooth shift into either FIRST 1 or REVERSE R gear Notice After engaging FIRST 1 or REVERSE R gear do not use the clutch brake for upshifting and downshifting To do so will shorten the ser...

Page 56: ...vehicle at 20 mph 32 km h Parking Brake To apply the parking brake pull the lever all the way up The park brake light will come on when the parking brake is applied Then shift the transmission to NEUTRAL N or PARK P The vehicle must be stationary when applying the parking brake except while burnishing the parking brake linings See Propshaft Brake Burnish Procedure earlier in this section If your p...

Page 57: ... applied Vehicles built for use as tractors or towing vehicles may also have the trailer air supply red knob To charge a trailer s air brake system do the following 1 Move your tractor into the proper position 2 Apply the parking brake by pulling the system park yellow knob out 3 Hook up the trailer air system properly 4 Get into the tractor 5 Push and hold down the regular brake pedal 6 Push in b...

Page 58: ...make an emergency stop If the air pressure drops below 60 to 70 psi 413 to 482 kPa the primary brake light will come on If the air pressure drops to 40 to 45 psi 275 to 310 kPa the system park yellow knob will automatically pop out and apply the spring brakes on the trailer If you ever have a complete loss of air so that your air brakes automatically apply the tow operator can release the parking ...

Page 59: ...consciousness and death You might have exhaust coming in if Your exhaust system sounds strange or different Your vehicle gets rusty underneath Your vehicle was damaged in a collision Your vehicle was damaged when driving over high points on the road or over road debris Repairs weren t done correctly Your vehicle or exhaust system had been modified improperly If you ever suspect exhaust is coming i...

Page 60: ...e this can happen is a garage Exhaust with CO can come in easily NEVER park in a garage with the engine running Another closed in place can be a blizzard See Winter Driving in the Index CAUTION It can be dangerous to get out of your vehicle if the shift lever is not fully in PARK P with the parking brake firmly set Your vehicle can roll Don t leave your vehicle when the engine is running unless yo...

Page 61: ...estore the mirror to the daytime position Outside Manual Mirrors Adjust the outside rearview mirrors so you can see a little of the side of your vehicle and the area beside your vehicle from a comfortable driving position Some mirrors can be folded in to enter narrow passageways Outside Power Mirrors If you have outside power rearview mirrors they can be adjusted from the inside of the vehicle The...

Page 62: ...ou could hit a vehicle Check your regular outside mirrors or your inside mirror if you have one before changing lanes Outside Heated Mirrors If your vehicle has this feature your outside rearview mirrors can be defrosted The switch for this feature is located in the instrument panel switchbank Push the bottom of the switch to turn the outside heated rearview mirrors on The switch indicator light w...

Page 63: ...and passenger s seats Push the compartment doors all the way up to lock in position Be sure the doors are securely closed before moving the vehicle Center Seat Storage A storage compartment is located behind the seatback in the center seat To access the compartment fold the seat all the way forward 2 27 ...

Page 64: ...To open squeeze both sides of the latch Center Console Storage Area There are additional storage areas for small items in the center console to the right of the driver s seat 2 28 ...

Page 65: ... Voltmeter Gage 3 24 Service Transmission Warning Light 3 25 Range Inhibit Warning Indicator 3 25 Brake System Warning Light 3 26 Apply Park Brake Warning Light 3 28 Parking Brake Warning Light 3 28 Anti Lock Brake System Warning Light 3 28 Trailer Anti Lock Brake System Warning Light 3 29 Warning Light Bulb Check Button 3 29 Exhaust Brake Indicator Light 3 29 Engine Coolant Temperature Gage 3 30 ...

Page 66: ... Gage 3 37 Air Filter Restriction Indicator 3 38 Hourmeter Gage 3 38 Audio System s 3 39 Setting the Time 3 39 AM FM Radio 3 40 Radio with Cassette 3 42 Radio with CD 3 47 Theft Deterrent Feature Non RDS Radios 3 51 Understanding Radio Reception 3 51 Care of Your Cassette Tape Player 3 51 Care of Your CDs 3 53 Care of Your CD Player 3 53 Fixed Mast Antenna 3 53 Chime Level Adjustment 3 53 Section ...

Page 67: ... NOTES 3 3 ...

Page 68: ...Instrument Panel Overview 3 4 ...

Page 69: ... warn others They also let police know you have a problem Your front and rear turn signal lamps will flash on and off Your hazard warning flashers are controlled by the lever located to the right of the steering column Move the lever up to start the hazard flashers Move the lever down again to turn the flashers off The hazard warning flashers work no matter what position your key is in and even if...

Page 70: ...eering wheel Power Tilt Wheel and Telescopic Steering Column A tilt steering column allows you to adjust the steering wheel before you drive You can also raise it to the highest level to give your legs more room when you enter or exit the vehicle To tilt the column hold the steering wheel and pull the lever on the left side of the column to unlock the steering column Move the steering wheel to a c...

Page 71: ...nished the lever will return automatically An arrow on the instrument panel cluster will flash in the direction of the turn or lane change To signal a lane change just raise or lower the lever until the arrow starts to flash Hold it there until you complete your lane change The lever will return by itself when you release it As you signal a turn or a lane change if the arrows don t flash but just ...

Page 72: ...er speed for a long or short delay between wipes This can be very useful in light rain or snow Turn the band to one of the four delay settings to choose the delay time The further the band is turned upward the longer the delay will be The further the band is turned downward the shorter the delay will be 6 Low Speed For steady wiping at low speed turn the band toward you to the first solid band bel...

Page 73: ...f the multifunction lever To spray washer fluid on the windshield press the paddle The wipers will clear the window and then either stop or return to your preset speed CAUTION In freezing weather don t use your washer until the windshield is warmed Otherwise the washer fluid can form ice on the windshield blocking your vision Cruise Control If your vehicle has this feature it is located at the end...

Page 74: ...inding roads or in heavy traffic Cruise control can be dangerous on slippery roads On such roads fast changes in tire traction can cause needless wheel spinning and you could lose control Don t use cruise control on slippery roads Setting Cruise Control CAUTION If you leave your cruise control on when you re not using cruise you might hit a button and go into cruise when you don t want to You coul...

Page 75: ...nd then release the switch To increase your speed in very small amounts move the switch briefly to resume accelerate Each time you do this your vehicle will go about 1 mph 1 6 km h faster Reducing Speed While Using Cruise Control Press in the button at the end of the lever until you reach the lower speed you want then release it To slow down in very small amounts tap the button briefly Each time y...

Page 76: ...ve the cruise switch to off or Shift the transmission to NEUTRAL N Erasing Speed Memory When you turn off the ignition your cruise control set speed memory is erased Exterior Lamps The control located to the left of the steering column operates the exterior lamps The exterior lamp control has four positions OFF Turning the control to this position turns off all lamps except the Daytime Running Lam...

Page 77: ...Have your headlamp wiring checked right away if this ever happens Headlamps On Reminder If you have this system a tone will sound when your headlamps and or parking lamps are turned on and your ignition is in LOCK or ACCESSORY Daytime Running Lamps Daytime Running Lamps DRL can make it easier for others to see the front of your vehicle during the day DRL can be helpful in many different driving co...

Page 78: ...ill change to the reduced brightness of DRL To idle your vehicle with the DRL off set the parking brake The DRL will stay off until you release the parking brake As with any vehicle you should turn on the regular headlamp system when you need it Marker Lamp Defeat Switch If your vehicle has this feature you can manually blink the marker and clearance lamps The marker lamp defeat switch is located ...

Page 79: ...ill come on when you open a door You can also turn the dome lamps on by moving the thumbwheel located to the right of the exterior lamp control all the way up to the second position In this position the dome lamps will remain on whether a door is open or closed You can use the dome override button to set the dome lamps to automatically come on when a door is open or to remain off The dome override...

Page 80: ...these power jacks you ll find then in the console to the right of the driver s seat These jacks provide 12 volt power so you can operate things such as a citizen s band CB radio or a cellular phone You ll see positive red and negative black outlets They are protected by a 15 amp circuit breaker Notice Whether or not your vehicle has the power outlets don t plug in FM communications gear at the ash...

Page 81: ...ck out by itself Notice Don t hold a cigarette lighter in with your hand while it is heating If you do it won t be able to back away from the heating element when it s ready That can make it overheat damaging the lighter and the heating element Climate Controls Climate Control System With this climate control system you can control the heating cooling and ventilation for your vehicle Slide the tem...

Page 82: ...ut of the cab A C Air Conditioning If your vehicle has this feature you can use your air conditioner by selecting one of the mode buttons selecting a fan speed and pressing the A C button On hot days open the windows to let hot inside air escape then close them This helps to reduce the time it takes for your vehicle to cool down It also helps the system to operate more efficiently For quick cool d...

Page 83: ... or below freezing The recirculation mode cannot be selected while in the defog mode 0 Defrost Pressing this button directs most of the air to the windshield and the side window outlets with some air directed to the floor outlets In this mode the system will automatically turn off recirculation and run the air conditioning compressor unless the outside temperature is at or below freezing Recircula...

Page 84: ... also save you or others from injury Warning lights come on when there may be or is a problem with one of your vehicle s functions As you will see in the details on the next few pages some warning lights come on briefly when you start the engine just to let you know they re working If you are familiar with this section you should not be alarmed when this happens Gages can indicate when there may b...

Page 85: ...igned to let you know at a glance how your vehicle is running You ll know how fast your going about how much fuel is left and many other things you ll need to drive safely and economically United States Diesel Engine shown Canada and Gasoline Engine similar 3 21 ...

Page 86: ... is displayed will reset it To display the odometer reading with the ignition off press the reset button Engine Speed Limiting All engines have electronic engine speed limiting The engine limited speeds range between 2 900 and 4 400 rpm depending on engine option content Engine Road Speed Governor This system controls maximum vehicle speed automatically and reduces engine power until vehicle speed...

Page 87: ...d people to fasten their safety belts The safety belt light will also come on and stay on for several seconds Safety Belt Reminder Tone If your vehicle has this feature turn your key to RUN or START A tone will sound for several seconds to remind people to fasten their safety belts 7 2L Caterpillar Diesel Engine and 7 8L DURAMAX Diesel Engines Gasoline and 6 6L DURAMAX Diesel Engines 3 23 ...

Page 88: ...braking if the engine quits or the power steering pump should fail Voltmeter Gage When your engine is running the voltmeter gage at the right side of the instrument panel cluster shows the charging system voltage Readings in either warning zone indicate a possible problem in the electrical system Readings in the low warning zone may occur when a large number of electrical accessories are operating...

Page 89: ... transmission range change could leave you stranded The vehicle may not continue to move if you change gears with the transmission shift control The transmission can t operate in all gears because something is wrong Leave the shift control alone and drive directly to a GM dealer for service If you can t go in for service immediately have the vehicle towed Range Inhibit Warning Indicator If your ve...

Page 90: ...es on it means there is something wrong in the brake system When this light comes on you will also hear a warning tone If this light comes on have the system repaired immediately Both of these lights should come on briefly every time you start your engine If they don t come on then have them fixed so they will be ready to warn you if there s a problem If one or both of these warning lights stay on...

Page 91: ... as the nearest point of safety and then stop the vehicle Here s a very important thing for you to know CAUTION If the LOW AIR warning light comes on and the warning tone sounds the vehicle can stop suddenly and without further warning This is because the parking brake will come on if the pressure falls below 35 to 45 psi 240 to 310 kPa You or others could be injured If the LOW AIR warning light c...

Page 92: ... t come on then have it fixed so it will be ready to remind you if the parking brake is applied or hasn t released fully Anti Lock Brake System Warning Light With the anti lock brake system this light will come on when you start your engine and it may stay on for several seconds That s normal If the light stays on or comes on when you re driving your vehicle needs service If the BRAKE or LOW AIR w...

Page 93: ... system repaired immediately If an anti lock brake system equipped trailer is not connected this light is not functional Warning Light Bulb Check Button To test the operation of the check gages light the primary brake light and the parking light push this button located on the upper left portion of the instrument panel The button works when the ignition has been turned to on Exhaust Brake Indicato...

Page 94: ...ar Operation Maintenance Manual Low Coolant Warning Light You have a low coolant warning light If this light comes on your system is low on coolant and the engine may overheat The warning light should come on briefly as a check when you turn on the ignition When it comes on you will also hear a warning tone at several beats per second for 10 seconds See Engine Coolant on page 5 16 and have your ve...

Page 95: ...uster This light will illuminate whenever the manual fast idle feature is engaged For more details about this system see Starting Your DURAMAX Diesel Engine on page 2 8 Wait to Start Indicator If your vehicle has this feature this light in the center of the instrument panel will come on when the intake heater is on and the ignition key is in RUN Wait until the indicator light turns off before turn...

Page 96: ... after a while your emission controls may not work as well your fuel economy may not be as good and your engine may not run as smoothly This could lead to costly repairs that may not be covered by your warranty Oil Pressure Gage The engine oil pressure gage on the lower right portion of your instrument panel cluster shows engine oil pressure in psi pounds per square inch or in kPa kilopascals Oil ...

Page 97: ...serviced Notice Damage to your engine from neglected oil problems can be costly and is not covered by your warranty Low Oil Level Light This light should come on as a check when you start your engine If the light fails to come on have it repaired as soon as possible so you will be aware when the oil level is low If this light comes on and stays on it means your engine is low on oil You need to che...

Page 98: ...DURAMAX Diesel on page 5 9 To reset the change engine oil light see Engine Oil DURAMAX Diesel on page 5 9 Glow Plugs Light This light on the instrument panel will glow when the ignition is turned to H heat See Starting Your DURAMAX Diesel Engine on page 2 8 Engine Overspeed Warning Light If your vehicle has this light it will come on if your engine is operating at too many revolutions per minute r...

Page 99: ...0 F 150 C means you must stop driving and check into the cause One possible cause is a low oil level in the transmission Notice If you drive when the transmission temperature gage is in the warning zone you can badly damage the transmission Exhaust Brake Indicator Light If your vehicle is equipped with an exhaust brake you will have this light located above the comfort controls in the center of th...

Page 100: ...the reduced engine power light is on but there is no reduction in performance proceed to your destination The performance may be reduced the next time the vehicle is driven The vehicle may be driven at a reduced speed while the reduced engine power light is on but acceleration and speed may be reduced Anytime the check engine light stays on the vehicle should be taken to an authorized GM dealer as...

Page 101: ...r engine oil pressure gage may be showing a reading in the warning zone When the check gages light comes on you will also hear a warning tone The tone and the light will stay activated until the problem is corrected Fuel Gage Your fuel gage is located on the right side of your instrument panel cluster When the ignition is on your fuel gage lets you know about how much fuel you have left When the g...

Page 102: ...r This optional gage is located above the switchbank in the center of the instrument panel It monitors the engine air filter As the filter gets dirty the yellow indicator will begin to rise When it reaches 25 inches of vacuum on the scale the filter should be replaced After replacing the filter reset the gage by pressing in the yellow reset button at the bottom of the gage If you have a diesel eng...

Page 103: ...easily and to give years of listening pleasure You will get the most enjoyment out of it if you acquaint yourself with it first Figure out which radio you have in your vehicle find out what your audio system can do and how to operate all of its controls to be sure you re getting the most out of the advanced engineering that went into it Your vehicle may have a feature called Retained Accessory Pow...

Page 104: ...r to the previous station and stay there To scan stations press and hold one of the SEEK arrows for two seconds until you hear a beep The radio will go to a station play for a few seconds and flash the station frequency then go on to the next station Press one of the SEEK arrows again to stop scanning To scan preset stations press and hold one of the SEEK arrows for more than four seconds until yo...

Page 105: ...ore than two seconds until you hear a beep B and a zero or T and a zero will appear on the display To adjust both tone controls and both speaker controls to the middle position end out of audio by waiting for the display to change to the time display Then press and hold AUDIO for more than two seconds until you hear a beep CEN will appear on the display Adjusting the Speakers Balance Fade AUDIO To...

Page 106: ...he factory If CAL appears on the display it means that your radio has not been configured properly for your vehicle and must be returned to the dealership for service LOC Locked This message is displayed when the Theftlock system has locked up Your vehicle must be returned to the dealership for service Radio with Cassette Playing the Radio PWR Power Press this knob to turn the system on and off VO...

Page 107: ...ing presets The radio will seek and scan only to stations that are in the selected band and only to those with a strong signal Setting Preset Stations The six numbered pushbuttons let you return to your favorite stations You can set up to 18 stations six AM six FM1 and six FM2 by performing the following steps 1 Turn the radio on 2 Press AM FM to select AM FM1 or FM2 3 Tune in the desired station ...

Page 108: ...r more than two seconds until you hear a beep CEN will appear on the display Fade may not be available if you have a regular cab model Radio Messages CAL Calibration Your audio system has been calibrated for your vehicle from the factory If CAL appears on the display it means that your radio has not been configured properly for your vehicle and must be returned to the dealership for service LOC Lo...

Page 109: ... on the tape Pressing this pushbutton multiple times in the next mode will increase the number of selections to searched forward Pressing the PREV pushbutton will cancel the selections 3 REV Reverse Press this pushbutton to reverse the tape rapidly FR will appear on the display Press it again to return to playing the tape The radio will play while the tape reverses You may select stations during r...

Page 110: ...ssage will appear on the display and the player will eject the tape The radio will go back to playing the last station selected CLN Clean If this message appears on the display the cassette tape player needs to be cleaned It will still play tapes but you should clean it as soon as possible to prevent damage to the tapes and player See Care of Your Cassette Tape Player on page 3 51 CD Adapter Kits ...

Page 111: ...on and stay there To scan stations press and hold one of the SEEK arrows for two seconds until you hear a beep The radio will go to a station play for a few seconds and flash the station frequency then go on to the next station Press one of the SEEK arrows again to stop scanning To scan preset stations press and hold one of the SEEK arrows for more than four seconds until you hear a double beep Th...

Page 112: ...dle position end out of audio mode by waiting for the display to change to the time display Then press and hold AUDIO for more than two seconds until you hear a beep CEN will appear on the display Adjusting the Speakers Balance Fade AUDIO To adjust the balance between the right and the left speakers press and release AUDIO until BAL appears on the display Then press and hold the up or the down arr...

Page 113: ...racks and or difficulty in loading and ejecting If these problems occur try a known good CD Do not add paper labels to discs they could get caught in the CD player Do not play 3 inch discs without a standard adapter disc If an error appears on the display see Compact Disc Messages later in this section 1 PREV Previous Press this pushbutton to go to the previous track if the current track has been ...

Page 114: ...the radio when a CD is playing The inactive CD will remain safely inside the radio for future listening CD Press this button to play a compact disc when listening to the radio CD will appear on the display Z Eject Press this button to eject a CD Eject may be activated with either the ignition or radio off CDs may be loaded with the radio and ignition off if this button is pressed first Compact Dis...

Page 115: ...ed regularly can cause reduced sound quality ruined cassettes or a damaged mechanism Cassette tapes should be stored in their cases away from contaminants direct sunlight and extreme heat If they aren t they may not operate properly or may cause failure of the tape player Your tape player should be cleaned regularly after every 50 hours of use Your radio may display CLN to indicate that you have u...

Page 116: ...e cut tape detection feature will be active again You may also choose a non scrubbing action wet type cleaner which uses a cassette with a fabric belt to clean the tape head This type of cleaning cassette will not eject on its own A non scrubbing action cleaner may not clean as thoroughly as the scrubbing type cleaner The use of a non scrubbing action dry type cleaning cassette is not recommended ...

Page 117: ...n straighten it out by hand If the mast is badly bent as it might be by vandals you should replace it Check occasionally to be sure the mast is still tightened to the fender If tightening is required tighten by hand then with a wrench one quarter turn Chime Level Adjustment The radio is the vehicle chime producer The chime is produced from the driver s side front door speakers To change the volume...

Page 118: ... NOTES 3 54 ...

Page 119: ...tem TCS 4 10 Steering 4 12 Off Road Recovery 4 14 Passing 4 14 Loss of Control 4 16 Driving at Night 4 17 Driving in Rain and on Wet Roads 4 18 City Driving 4 21 Freeway Driving 4 22 Highway Hypnosis 4 23 Hill and Mountain Roads 4 24 Winter Driving 4 26 If You Are Stuck In Sand Mud Ice or Snow 4 30 Towing 4 32 Towing Your Vehicle 4 32 Loading Your Vehicle 4 37 Trailer Connections 4 38 Section 4 Dr...

Page 120: ...thing that distracts from the driving task such as concentrating on a cellular telephone call reading or reaching for something on the floor makes proper defensive driving more difficult and can even cause a collision with resulting injury Ask a passenger to help do things like this or pull off the road in a safe place to do them yourself These simple defensive driving techniques could save your l...

Page 121: ...rinking depends upon four things The amount of alcohol consumed The drinker s body weight The amount of food that is consumed before and during drinking The length of time it has taken the drinker to consume the alcohol According to the American Medical Association a 180 lb 82 kg person who drinks three 12 ounce 355 ml bottles of beer in an hour will end up with a BAC of about 0 06 percent The per...

Page 122: ... at BAC levels above 0 05 percent Statistics show that the chance of being in a collision increases sharply for drivers who have a BAC of 0 05 percent or above A driver with a BAC level of 0 06 percent has doubled his or her chance of having a collision At a BAC level of 0 10 percent the chance of this driver having a collision is 12 times greater at a level of 0 15 percent the chance is 25 times ...

Page 123: ...king Ride home in a cab or if you re with a group designate a driver who will not drink Control of a Vehicle You have three systems that make your vehicle go where you want it to go They are the brakes the steering and the accelerator All three systems have to do their work at the places where the tires meet the road Sometimes as when you re driving on snow or ice it s easy to ask more of those co...

Page 124: ...ut much faster if you do a lot of heavy braking If you keep pace with the traffic and allow realistic following distances you will eliminate a lot of unnecessary braking That means better braking and longer brake life If your engine ever stops while you re driving brake normally but don t pump your brakes If you do the pedal may get harder to push down If your engine stops you will still have some...

Page 125: ...is test is going on This is normal If there s a problem with the anti lock brake system this warning light will stay on See Anti Lock Brake System Warning Light on page 3 25 Let s say the road is wet and you re driving safely Suddenly an animal jumps out in front of you You slam on the brakes and continue braking Here s what happens with ABS A computer senses that wheels are slowing down If one of...

Page 126: ... brake pedal or always decrease stopping distance If you get too close to the vehicle in front of you you won t have time to apply your brakes if that vehicle suddenly slows or stops Always leave enough room up ahead to stop even though you have anti lock brakes Using Anti Lock Don t pump the brakes Just hold the brake pedal down firmly and let anti lock work for you You may feel the brakes pulsat...

Page 127: ...the way if you have to Use this control only when you re driving Don t use it for parking or to hold the rig on a hill CAUTION Using the trailer brake hand control for parking or for holding the vehicle on a hill may not keep the vehicle from rolling This can happen if someone hits the valve by accident or if air pressure bleeds from the system If the vehicle rolls you or others could be injured T...

Page 128: ...erential lock when the rear wheels are actually spinning freely as they might on snow or ice can cause you to lose control of the vehicle It can also damage the axles Turn on this control only when the wheels are not spinning freely Traction Control System TCS Your vehicle may have a traction control system that limits wheel spin This is especially useful in slippery road conditions The system ope...

Page 129: ...e traction control system or the anti lock brake system The traction control system automatically comes on whenever you start your vehicle To limit wheel spin especially in slippery road conditions you should always leave the system on But you can turn the traction control system off if you ever need to You should turn the system off if your vehicle ever gets stuck in sand mud or snow and rocking ...

Page 130: ...ondition of your tires and the road surface the angle at which the curve is banked and your speed While you re in a curve speed is the one factor you can control Suppose you re steering through a sharp curve Then you suddenly accelerate Both control systems steering and acceleration have to do their work where the tires meet the road Adding the sudden acceleration can demand too much of those plac...

Page 131: ...se First apply your brakes See Braking on page 4 6 It is better to remove as much speed as you can from a possible collision Then steer around the problem to the left or right depending on the space available An emergency like this requires close attention and a quick decision If you are holding the steering wheel at the recommended 9 and 3 o clock positions you can turn it a full 180 degrees very...

Page 132: ...ound the vehicle ahead then goes back into the right lane again A simple maneuver Not necessarily Passing another vehicle on a two lane highway is a potentially dangerous move since the passing vehicle occupies the same lane as oncoming traffic for several seconds A miscalculation an error in judgment or a brief surrender to frustration or anger can suddenly put the passing driver face to face wit...

Page 133: ...tart that more than makes up for the distance you would lose by dropping back And if something happens to cause you to cancel your pass you need only slow down and drop back again and wait for another opportunity If other cars are lined up to pass a slow vehicle wait your turn But take care that someone isn t trying to pass you as you pull out to pass the slow vehicle Check your mirrors and start ...

Page 134: ...s system or if the system is off then an acceleration skid is also best handled by easing your foot off the accelerator pedal Of course traction is reduced when water snow ice gravel or other material is on the road For safety you ll want to slow down and adjust your driving to these conditions It is important to slow down on slippery surfaces because stopping distance will be longer and vehicle c...

Page 135: ...s well you may need to slow down and keep more space between you and other vehicles Slow down especially on higher speed roads Your headlamps can light up only so much road ahead In remote areas watch for animals If you re tired pull off the road in a safe place and rest No one can see as well at night as in the daytime But as we get older these differences increase A 50 year old driver may requir...

Page 136: ...the inside of the glass can build up a film caused by dust Dirty glass makes lights dazzle and flash more than clean glass would making the pupils of your eyes contract repeatedly Remember that your headlamps light up far less of a roadway when you are in a turn or curve Keep your eyes moving that way it s easier to pick out dimly lighted objects Just as your headlamps should be checked regularly ...

Page 137: ... of streaking or missing areas on the windshield or when strips of rubber start to separate from the inserts Driving too fast through large water puddles or even going through some vehicle washes can cause problems too The water may affect your brakes Try to avoid puddles But if you can t try to slow down before you hit them CAUTION Wet brakes can cause accidents They won t work as well in a quick...

Page 138: ...e and badly damage your engine Never drive through water that is slightly lower than the underbody of your vehicle If you can t avoid deep puddles or standing water drive through them very slowly Driving Through Flowing Water CAUTION Flowing or rushing water creates strong forces If you try to drive through flowing water as you might at a low water crossing your vehicle can be carried away As litt...

Page 139: ... trip Larger vehicles can t be driven everywhere smaller ones can There are low underpasses truck routes and other special situations Usually these are well marked so be sure to watch for the signs Try to use the freeways that rim and crisscross most large cities You ll save time and energy See Freeway Driving on page 4 22 Treat a green light as a warning signal A traffic light is there because th...

Page 140: ... that leads to the freeway If you have a clear view of the freeway as you drive along the entrance ramp you should begin to check traffic Try to determine where you expect to blend with the flow Try to merge into the gap at close to the prevailing speed Switch on your turn signal check your mirrors and try to blend smoothly with the traffic flow Once you are on the freeway adjust your speed to the...

Page 141: ...n falling asleep at the wheel Call it highway hypnosis lack of awareness or whatever When you drive the vehicle for a long distance there is something about an easy stretch of road with the same scenery along with the hum of the tires on the road the drone of the engine and the rush of the wind against the vehicle that can make you sleepy Don t let it happen to you If it does your vehicle can leav...

Page 142: ...and transmission These parts can work hard on mountain roads Know how to go down hills The most important thing to know is this let your engine do some of the slowing down Shift to a lower gear when you go down a steep or long hill CAUTION If you don t shift down your brakes could get so hot that they wouldn t work well You would then have poor braking or even none going down a hill You could cras...

Page 143: ...cool your engine and transmission and you can climb the hill better Stay in your own lane when driving on two lane roads in hills or mountains Don t swing wide or cut across the center of the road Drive at speeds that let you stay in your own lane As you go over the top of a hill be alert There could be something in your lane like a stalled car or an accident You may see highway signs on mountains...

Page 144: ...lective warning triangles And if you will be driving under severe conditions include a small bag of sand a piece of old carpet or a couple of burlap bags to help provide traction Be sure you properly secure these items in your vehicle Driving on Snow or Ice Most of the time those places where your tires meet the road probably have good traction However if there is snow or ice between your tires an...

Page 145: ...uck In Sand Mud Ice or Snow on page 4 30 Even though your vehicle has a traction system you ll want to slow down and adjust your driving to the road conditions See Traction Control System TCS on page 4 10 If you don t have a traction system accelerate gently Try not to break the fragile traction If you accelerate too fast the drive wheels will spin and polish the surface under the tires even more ...

Page 146: ...idges Sometimes the surface of a curve or an overpass may remain icy when the surrounding roads are clear If you see a patch of ice ahead of you brake before you are on it Try not to brake while you re actually on the ice and avoid sudden steering maneuvers If You re Caught in a Blizzard If you are stopped by heavy snow you could be in a serious situation You should probably stay with your vehicle...

Page 147: ... vehicle Clear away snow from around the base of your vehicle if any is blocking your exhaust pipe And check around again from time to time to be sure snow doesn t collect there Open a window just a little on the side of the vehicle that s away from the wind This will help keep CO out Run your engine only as long as you must This saves fuel When you run the engine make it go a little faster than j...

Page 148: ... it is stuck you will need to spin the wheels but you don t want to spin your wheels too fast The method known as rocking can help you get out when you re stuck but you must use caution CAUTION If you let your tires spin at high speed they can explode and you or others could be injured And the transmission or other parts of the vehicle can overheat That could cause an engine compartment fire or ot...

Page 149: ...verse directions you will cause a rocking motion that may free your vehicle If that doesn t get you out after a few tries you may need to be towed out If you do need to be towed out see Towing Your Vehicle on page 4 32 Using the Tow Hooks Option If your vehicle is equipped with tow hooks the hooks are provided at the front of your vehicle You may need to use them if you re stuck off road and need ...

Page 150: ... When the brake springs are manually compressed you will have no brakes Release your air operated parking brakes manually only to tow the vehicle Never drive the vehicle with the brakes released Consult your dealer or a professional towing service if you need to have your vehicle towed They can provide the right equipment and know how to tow it without damage See Roadside Assistance Program on pag...

Page 151: ... during towing On vehicles with hydraulic brakes release the parking brake fully by moving the lever to the fully released position Towing the Vehicle with the Front Bumper Removed 1 Remove the front bumper 2 Connect and lock the lift chains to the front axle outside of the spring anchor plates as shown 3 Connect the lift chains to the tow bar and raise the tow bar until lift chain slack has been ...

Page 152: ...This is to prevent the possibility of the emergency brake being applied during towing On vehicles with hydraulic brakes release the parking brake fully by moving the lever to the fully released position If there is damage or suspected damage to the axle s remove the axle shafts Cover the hub openings to prevent the loss of lubricant or entry of dirt or foreign objects After Towing 1 Block the rear...

Page 153: ...ial towing problem If your vehicle has to be towed because of a complete loss of air pressure from both systems the parking brakes will have automatically engaged The tow operator can release the brakes manually by using the following steps Then your vehicle can be towed with all wheels or only the rear wheels on the ground 1 Block the wheels of the vehicle 2 Remove the release stud and nut from t...

Page 154: ...e the brakes Follow the same procedure to release the other brake 7 At the repair facility apply air pressure of at least 70 psi 480 kPa to the brake chambers either from an external air supply or the vehicle s air system 8 Turn the stud nut counterclockwise several turns Remove the stud from the chamber 9 Replace the stud and washer and tighten the nut into the side of the chamber 10 Replace the ...

Page 155: ...d to go to a weigh station and weigh your vehicle Your dealer can help you with this Be sure to spread out your load equally on both sides of the center line Never exceed the GVWR for your vehicle or the GAWR for either the front or rear axle And if you do have a heavy load you should spread it out CAUTION Do not load your vehicle any heavier than the GVWR or either the maximum front or rear GAWR ...

Page 156: ...estraint in your vehicle When you carry something inside the vehicle secure it whenever you can Don t leave a seat folded down unless you need to Trailer Connections Heavy Duty Trailer Wiring Package Your vehicle may be equipped with an eight wire trailer towing harness This harness with a seven pin universal heavy duty trailer connector is attached to a bracket on the platform hitch The Center Hi...

Page 157: ... Overheating 5 20 Cooling System 5 22 Power Steering Fluid 5 27 Windshield Washer Fluid 5 28 Brakes 5 29 Battery 5 37 Jump Starting 5 37 Rear Axle 5 43 Rear Axle Shift Motor 5 43 Cab Tilting 5 44 Before You Tilt the Cab 5 44 Tilting the Cab 5 44 Lowering the Cab 5 47 Lifting the Front Panel 5 49 Noise Control System 5 50 Tampering with Noise Control System Prohibited 5 50 Windshield Wiper Blade Re...

Page 158: ...ance Materials 5 66 Vehicle Identification 5 67 Vehicle Identification Number VIN 5 67 Electrical System 5 67 Add On Electrical Equipment 5 67 Headlamp Wiring 5 67 Windshield Wiper Fuses 5 68 Fusible Links 5 68 Power Windows and Other Power Options 5 68 Fuses and Circuit Breakers 5 68 Capacities and Specifications 5 74 Capacities and Specifications 5 74 Normal Maintenance Replacement Parts 5 78 Se...

Page 159: ... the proper service manual see Service Publications Ordering Information on page 7 6 You should keep a record with all parts receipts and list the mileage and the date of any service work you perform See Part D Maintenance Record on page 6 29 CAUTION You can be injured and your vehicle could be damaged if you try to do service work on a vehicle without knowing enough about it Be sure you have suff...

Page 160: ...ely damage the vehicle Don t change the fan drive ratio or increase the governed speed of the vehicle without getting the necessary information from your dealer CAUTION Continued CAUTION Continued Winter Fronts Grille Covers or Obstructions Winter Fronts grille covers or other add on equipment causing obstructions in front or behind the fan should not be used on thisvehicle If this causes the fan ...

Page 161: ...l to address climate differences Number 1 D diesel fuel may be used in very cold temperatures when it stays below 0 F or 18 C however it will produce a power and fuel economy loss Avoid the use of Number 1 D diesel fuel in warm or hot climates It may result in stalling poor starting when the engine is hot and may damage the fuel injection system At a minimum the diesel fuel you use should meet spe...

Page 162: ... diesel fuel at any concentration is not recommended and could damage your fuel system and engine Such damage would not be covered by your warranty If there are questions about the biodiesel containing fuels you are using contact your fuel supplier Diesel fuel may foam when you fill your tank This can cause the automatic pump nozzle to shut off even though your tank is not full If this happens jus...

Page 163: ...se and better vehicle performance If there are questions about the fuel you are using contact your fuel supplier It is acceptable to use diesel fuel containing up to 5 biodiesel B5 but the final blended fuel must meet the same specification CAN CGSB 3 517 2000 Low Sulfur Diesel in Canada as other fuels used in your vehicle and the biodiesel used for making this fuel must meet the ASTM D6751 02 spe...

Page 164: ...ure earlier in this section to prime the fuel filter 3 Close the air bleed valve 4 Turn the ignition key to START for 10 to 15 seconds at a time until your engine starts If the engine tries to run but does not run smoothly increase the rpm a little using the accelerator pedal This will help force air through the system Filling Your Tank CAUTION Fuel vapor is highly flammable It burns violently and...

Page 165: ...function indicator lamp to light and may damage your fuel tank and emissions system See Malfunction Indicator Lamp in the Index Filling a Portable Fuel Container CAUTION Never fill a portable fuel container while it is in your vehicle Static electricity discharge from the container can ignite the gasoline vapor You can be badly burned and your vehicle damaged if this occurs To help avoid injury to...

Page 166: ...artment on the driver s side of the vehicle In order to get an accurate reading the oil must be warm at normal operating temperature and the vehicle must be on level ground Turn off the engine and give the oil at least five minutes to drain back into the oil pan With a cool engine allow 30 minutes If you don t the oil dipstick might not show the actual level Pull out the dipstick and clean it with...

Page 167: ... Push the dipstick all the way back in when you re through What Kind of Engine Oil to Use Look for these two things CI 4 or CH 4 Oils designated as API CI 4 or CH 4 are recommended for your vehicle The CI 4 or CH 4 designations may appear either alone together or in combination with other API designations such as API CI 4 SL These letters show American Petroleum Institute API levels of quality Not...

Page 168: ...ow its viscosity or thickness Do not use other viscosity oils such as SAE 10W 40 or SAE 20W 50 This doughnut shaped logo symbol is used on most oil containers to help you select the correct oil It means that the oil has been certified by the American Petroleum Institute You should look for this on the oil container and use only those oils that display this logo GM Goodwrench oil of the recommended...

Page 169: ...f oil products Used oil can be a threat to the environment If you change your own oil be sure to drain all the oil from the filter before disposal Never dispose of oil by putting it in the trash pouring it on the ground into sewers or into streams or bodies of water Instead recycle it by taking it to a place that collects used oil If you have a problem properly disposing of your used oil ask your ...

Page 170: ...er not only cleans the air it helps to stop flame if the engine backfires If it isn t there and the engine backfires you could be burned Don t drive with it off and be careful working on the engine with the air cleaner filter off Notice If the air cleaner filter is off a backfire can cause a damaging engine fire And dirt can easily get into your engine which will damage it Always have the air clea...

Page 171: ...icant and when to change it See Scheduled Maintenance on page 6 5 Refer to the Maintenance Schedule to determine what kind of fluid to use See Part C Recommended Fluids and Lubricants on page 6 27 When to Check A good time to have it checked is when the engine oil is checked See your Maintenance Schedule to find out when to change your transmission fluid How to Check and What to Use Check the flui...

Page 172: ...uspect there is a leak in the system Adding fluid won t correct a leak A fluid loss in this system could indicate a problem Have the system inspected and repaired When to Check and What to Use The hydraulic clutch fluid reservoir is located behind the front panel on the driver s side of the vehicle Refer to the maintenance schedule to determine how often you should check the fluid level in your cl...

Page 173: ...COOL coolant will Give freezing protection down to 34 F 37 C Give boiling protection up to 252 F 122 C Protect against rust and corrosion Help keep the proper engine temperature Let the warning lights and gages work as they should Notice When adding coolant it is important that you use only DEX COOL silicate free coolant If coolant other than DEX COOL is added to the system premature engine heater...

Page 174: ...ine could get too hot but you wouldn t get the overheat warning Your engine could catch fire and you or others could be burned Use a 50 50 mixture of clean drinkable water and DEX COOL coolant Notice If you use an improper coolant mixture your engine could overheat and be badly damaged The repair cost wouldn t be covered by your warranty Too much water in the mixture can freeze and crack the engin...

Page 175: ...quids to blow out and burn you badly Never turn the surge tank pressure cap even a little when the engine and radiator are hot The vehicle must be on a level surface When your engine is cold the coolant level should be at the COLD FILL mark or higher If the low coolant light comes on and stays on it means you re low on engine coolant See Low Coolant Warning Light on page 3 30 for further informati...

Page 176: ... hand tight Coolant Surge Tank Pressure Cap The surge tank pressure cap is located in the engine compartment on the driver s side of the vehicle Notice Your surge tank pressure cap is a pressure type cap for use with medium duty cooling systems only It must be tightly installed to prevent coolant loss and possible engine damage from overheating Engine Overheating You will find a coolant temperatur...

Page 177: ...r engine if it overheats and get out of the vehicle until the engine is cool Notice If your engine catches fire because you keep driving with no coolant your vehicle can be badly damaged The costly repairs would not be covered by your warranty If No Steam Is Coming From Your Engine An overheat warning along with a low coolant light can indicate a serious problem See Low Coolant Warning Light on pa...

Page 178: ... over stop and park your vehicle right away If there s still no sign of steam you can push down the accelerator until the engine speed is about twice as fast as normal idle speed for at least three minutes while you re parked If you still have the warning turn off the engine and get everyone out of the vehicle until it cools down You may decide not to lift the hood but to get service help right aw...

Page 179: ...be no leak start the engine again The engine cooling fan speed should increase when idle speed is doubled by pushing the accelerator pedal down If it doesn t your vehicle needs service Turn off the engine Notice Engine damage from running your engine without coolant isn t covered by your warranty Notice When adding coolant it is important that you use only DEX COOL silicate free coolant If coolant...

Page 180: ...p is cool before you do it See Engine Coolant on page 5 17 for more information If no coolant is visible in the surge tank add coolant as follows CAUTION Steam and scalding liquids from a hot cooling system can blow out and burn you badly They are under pressure and if you turn the coolant surge tank pressure cap even a little they can come out at high speed Never turn the cap when the cooling sys...

Page 181: ...and crack the engine radiator heater core and other parts Use the recommended coolant and the proper coolant mixture CAUTION You can be burned if you spill coolant on hot engine parts Coolant contains ethylene glycol and it will burn if the engine parts are hot enough Don t spill coolant on a hot engine 1 Park the vehicle on a level surface You can remove the coolant surge tank pressure cap when t...

Page 182: ... the engine and let it run until you can feel the upper radiator hose getting hot Watch out for the engine cooling fan By this time the coolant level inside the coolant surge tank may be lower If the level is lower add more of the proper mixture to the coolant surge tank until the level reaches slightly above the FULL mark 5 26 ...

Page 183: ...r power steering fluid level is low this can cause the brake or service brake soon warning lights to come on If either light remains on after you have added power steering fluid to the proper level then shut off the engine for 10 seconds This should reset the brake warning lights If one or both lights stay on though see Hydraulic Brake System Warning Lights under Brake System Warning Light on page...

Page 184: ... of the vehicle Open the cap with the washer symbol on it Add washer fluid until the tank is full Notice When using concentrated washer fluid follow the manufacturer s instructions for adding water Don t mix water with ready to use washer fluid Water can cause the solution to freeze and damage your washer fluid tank and other parts of the washer system Also water doesn t clean as well as washer fl...

Page 185: ...hedule to determine when to check your brake fluid CAUTION Don t add brake fluid before you check the level If you do you could get too much brake fluid Brake fluid could spill on the hot engine and it can catch fire You could be burned and your vehicle could be damaged See Checking Brake Fluid in this section 5 29 ...

Page 186: ...rom entering the reservoir CAUTION With the wrong kind of fluid in your brake system your brakes may not work well or they may not even work at all This could cause a crash Always use the proper brake fluid Notice Using the wrong fluid can badly damage brake system parts For example just a few drops of mineral based oil such as engine oil in your brake system can damage brake system parts so badly...

Page 187: ...ality and work well together if the vehicle is to have really good braking Your vehicle was designed and tested with top quality GM brake parts When you replace parts of your braking system for example when your brake linings wear down and you need new ones put in be sure you get new approved GM replacement parts If you don t your brakes may no longer work properly For example if someone puts in b...

Page 188: ... it has a filter that you need to change at intervals See Scheduled Maintenance on page 6 5 for more about servicing this filter Electric Air Compressor Your vehicle may have an electric air compressor This compressor is used to run options that require pressurized air such as air horn air seat exhaust restrictor or an exhaust brake The air compressor is used when vehicles are not equipped with an...

Page 189: ...tric hydraulic parking brake a good time to check the fluid level is when you check the fluid levels under the tilt cab The fluid reservoir is located in the component box beneath the driver s side of the cab on the frame rail If you need to add fluid use Dexron III Automatic Transmission Fluid See Scheduled Maintenance on page 6 5 How to Check and Add Fluid First apply the parking brake To check ...

Page 190: ...Chassis Lubrication 5 34 ...

Page 191: ...Slack Adjuster One fitting 7 Brake Cam Roller Pins Apply engine oil 8 Front Steering Knuckles One fitting each side lower bushing Hand operated grease gun only Hand pack upper bearing 9 Front Wheel Bearings Hand pack or lubricate 10 Steering Tie Rod Ends One fitting each end 11 Spring Slip Pads Multi leaf Only Apply chassis lubricant 12 Clutch Release Bearing Cup or fitting 13 Battery Terminal exc...

Page 192: ...ies and larger lubricate with GM Part No 1051344 Wheel Bearing Lubricant 18 Rear Wheel Bearings Hand pack or lubricate 19 Rear Axle Fill to level of filler plug 20 Parking Brake Clevis Pin Apply chassis lubricant 21 Master Cylinder Fill 1 4 inch 6 mm below opening 22 Parking Brake Lever Pivot Apply chassis lubricant 23 Clutch Release Cross Shaft One fitting each Refer to Maintenance Schedule Appli...

Page 193: ...ve battery cable from each battery CAUTION Batteries have acid that can burn you and gas that can explode You can be badly hurt if you aren t careful See Jump Starting next for tips on working around a battery without getting hurt When you are ready to use the vehicle again refer to the engine starting procedure in the Index Contact your dealer to learn how to prepare your vehicle for longer stora...

Page 194: ...e enough so the jumper cables can reach but be sure the vehicles aren t touching each other If they are it could cause a ground connection you don t want You wouldn t be able to start your vehicle and the bad grounding could damage the electrical systems To avoid the possibility of the vehicles rolling set the parking brake firmly on both vehicles involved in the jump start procedure Put an automa...

Page 195: ...ry gas to explode People have been hurt doing this and some have been blinded Use a flashlight if you need more light Be sure the batteries have enough water You don t need to add water to the ACDelco battery or batteries installed in your new vehicle But if a battery has filler caps be sure the right amount of fluid is there If it is low add water to take care of that first If you don t explosive...

Page 196: ...itive to negative or you ll get a short that would damage the battery and maybe other parts too And don t connect the negative cable to the negative terminal on the dead battery because this can cause sparks 6 Connect the red positive cable to the positive terminal of the dead battery Use a remote positive terminal if the vehicle has one 7 Don t let the other end touch metal Connect it to the posi...

Page 197: ...tion is just as good there and the chance of sparks getting back to the battery is much less 10 Now start the vehicle with the good battery and run the engine for one or two minutes If your vehicle has the high idle option use it 11 Try to start the vehicle with the dead battery If it won t start after a few tries it probably needs service Notice Damage to your vehicle may result from electrical s...

Page 198: ... vehicles do the following 1 Disconnect the black negative cable from the vehicle that had the dead battery 2 Disconnect the black negative cable from the vehicle with the good battery 3 Disconnect the red positive cable from the vehicle with the good battery 4 Disconnect the red positive cable from the other vehicle 5 Return the positive remote terminal cover to its original position Jumper Cable...

Page 199: ...t kind of lubricant to use See Part C Recommended Fluids and Lubricants on page 6 27 Rear Axle Shift Motor When to Check and Change Fluid If you have an optional air shift two speed controlled traction or locking differential type rear axle a good time to check the fluid level in the axle shift motor is when the rear axle lubricant is checked Use refrigerant oil shift motor only How to Check Fluid...

Page 200: ...and close the cab door Check for adequate clearance in front and above the cab To help prevent the vehicle from moving 1 Apply the parking brake 2 Place the automatic transmission in PARK P or shift the manual transmission to NEUTRAL 3 Turn the engine off 4 Block the front and rear wheels Tilting the Cab To tilt the cab do the following 1 Locate the lever pin at the rear of the cab on the passenge...

Page 201: ...imary tilt lever all the way down 4 Pull the secondary latch lever to release the hook from the catch at the back of the cab 5 Using the handle located at the bottom of the cab at the back tilt the cab forward 5 45 ...

Page 202: ...d position could fall causing serious injury To ensure that the cab is securely locked in position and won t move the safety lock pin A must always be inserted into the cab support B when the cab is in the tilted position CAUTION Things that burn can get on hot engine parts and start a fire These include liquids like fuel oil coolant brake fluid windshield washer and other fluids and plastic or ru...

Page 203: ...d follow the instructions below carefully Before lowering the cab be sure all filler caps ar on properly 1 Remove the safety lock pin from the cab support by turning it and pulling it out 2 Squeeze the lever on the cap support to release the detent 5 47 ...

Page 204: ...down 4 Push the primary tilt lever upward fully to lock the cab to the chassis 5 Reinstall the pin and turn it to keep the primary tilt lever from moving downward CAUTION An unsecured cab could move suddenly causing an accident or an injury Be sure the tilt cab is properly secured to the chassis before moving the vehicle 5 48 ...

Page 205: ... grasp the rear of the release catch located at the bottom of the instrument panel and pull it toward you 2 Then go to the front of the vehicle and lift the panel at the center Use the prop rod to hold the panel open 3 To close the front panel remove the prop rod close the panel and push firmly on both sides to ensure that the panel is fully closed 5 49 ...

Page 206: ...repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below ...

Page 207: ... Year on page 6 22 for more information Replacement blades come in different types and are removed in different ways Here s how to remove the Shephard s Hook type 1 Pull the windshield wiper arm away from the windshield 2 Push the release lever and slide the wiper assembly toward the driver s side of the vehicle 3 Install a new blade by reversing Steps 1 and 2 5 51 ...

Page 208: ...rious accident See Loading Your Vehicle in the Index CAUTION Continued CAUTION Continued Underinflated tires pose the same danger as overloaded tires The resulting accident could cause serious injury Check all tires frequently to maintain the recommended pressure Tire pressure should be checked when your tires are cold Overinflated tires are more likely to be cut punctured or broken by a sudden im...

Page 209: ...h ride Needless damage from road hazards When to Check Check your tires once a month or more Also check the tire pressure of the spare tire if equipped How to Check Use a good quality pocket type gage to check tire pressure You can t tell if your tires are properly inflated simply by looking at them Radial tires may look properly inflated even when they re underinflated Be sure to put the valve ca...

Page 210: ... 5 53 for more information on proper tire inflation When It Is Time for New Tires Replace your tires when the tread depth is down to 1 8 of an inch 3 2 mm for the front tires or 1 16 of an inch 1 6 mm for a rear tire Also you need a new tire if You can see cord or fabric showing through the tire s rubber The tread or sidewall is cracked cut or snagged deep enough to show cord or fabric The tire ha...

Page 211: ...ff the wheel can come off the vehicle causing a crash All wheel nuts must be properly tightened Follow the rules in this section to be sure they are This section lets you know how often to check the tightness of the wheel nuts on your vehicle and how tight they must be First use these pictures to decide what kind of wheels you have Then follow the steps below for the wheels you have Hub Piloted Wh...

Page 212: ...l the surfaces between the nuts and washers Do not oil the studs or the threads of the nut 6 Tighten the nuts to 400 lb ft 542 N m if an 8 hole stud or 480 lb ft 650 N m if a 10 hole stud using the following diagrams 8 Hole 10 Hole Front 10 Hole Rear 5 56 ...

Page 213: ...larger or distorted in any way Inspect hubs and hub CAUTION Continued CAUTION Continued piloted wheels for damage Because of loose running wheels piloting pad damage may occur and require replacement of the entire hub for proper centering of the wheels When replacing studs hubs wheel nuts or wheels be sure to use GM original equipment parts CAUTION Rust or dirt on a wheel or on the parts to which ...

Page 214: ...ame way as the one it replaces If you need to replace any of your wheels wheel bolts or wheel nuts replace them only with new GM original equipment parts This way you will be sure to have the right wheel wheel bolts and wheel nuts for your vehicle CAUTION A leaking wheel could fail without warning A wheel designed for tubeless tires could be leaking because it is damaged Don t use an inner tube or...

Page 215: ...ly if you maintain your tires properly If air goes out of a tire it s much more likely to leak out slowly But if you should ever have a blow out here are a few tips about what to expect and what to do If a front tire fails the flat tire will create a drag that pulls the vehicle toward that side Take your foot off the accelerator pedal and grip the steering wheel firmly Steer to maintain lane posit...

Page 216: ...ne Paint Thinner Turpentine Lacquer Thinner Nail Polish Remover They can all be hazardous some more than others and they can all damage your vehicle too Don t use any of these unless this manual says you can In many uses these will damage your vehicle Alcohol Laundry Soap Bleach Reducing Agents Cleaning the Inside of Your Vehicle Use a vacuum cleaner often to get rid of dust and loose dirt Wipe vi...

Page 217: ...ion use a sponge to remove any excess cleaner 6 Wipe cleaned area with a clean water dampened towel or cloth 7 Wipe with a clean cloth and let dry Special Fabric Cleaning Problems Stains caused by such things as catsup coffee black egg fruit fruit juice milk soft drinks vomit urine and blood can be removed as follows 1 Carefully scrape off excess stain then sponge the soiled area with cool water 2...

Page 218: ...e Commercial cleaners may affect the surface finish Cleaning Glass Surfaces Glass should be cleaned often GM Glass Cleaner or a liquid household glass cleaner will remove normal tobacco smoke and dust films on interior glass See Vehicle Care Appearance Materials on page 5 66 Notice Don t use abrasive cleaners on glass because they may cause scratches Avoid placing decals on the inside rear window ...

Page 219: ...hat are petroleum based or that contain acid or abrasives All cleaning agents should be flushed promptly and not allowed to dry on the surface or they could stain Dry the finish with a soft clean chamois or an all cotton towel to avoid surface scratches and water spotting High pressure car washes may cause water to enter your vehicle Cleaning Exterior Lamps Lenses Use only lukewarm or cold water a...

Page 220: ...ective trim never use auto or chrome polish steam or caustic soap to clean aluminum A coating of wax rubbed to high polish is recommended for all bright metal parts Windshield and Wiper Blades If the windshield is not clear after using the windshield washer or if the wiper blade chatters when running wax sap or other material may be on the blade or windshield Clean the outside of the windshield wi...

Page 221: ... sure the body repair shop applies anti corrosion material to parts repaired or replaced to restore corrosion protection Original manufacturer replacement parts will provide the corrosion protection while maintaining the warranty Finish Damage Any stone chips fractures or deep scratches in the finish should be repaired right away Bare metal will corrode quickly and may develop into major repair ex...

Page 222: ...d wire wheel covers Finish Enhancer Removes dust fingerprints and surface contaminants Spray on wipe off Vehicle Care Appearance Materials cont d Description Usage Swirl Remover Polish Removes swirl marks fine scratches and other light surface contamination Cleaner Wax Removes light scratches and protects finish Foaming Tire Shine Low Gloss Cleans shines and protects in one easy step no wiping nec...

Page 223: ... This code will help you identify your engine specifications and replacement parts Electrical System Add On Electrical Equipment Notice Don t add anything electrical to your vehicle unless you check with your dealer first Some electrical equipment can damage your vehicle and the damage wouldn t be covered by your warranty Some add on electrical equipment can keep other components from working as t...

Page 224: ... size and insulation type Fusible link insulation is a special purpose high temperature material The hydraulic brake booster motor feed circuit and starter circuit are protected by a fusible link Vehicles with a diesel engine have a fusible link for the intake heater feed circuit Power Windows and Other Power Options Circuit breakers in the fuse panel protect the power windows and other power acce...

Page 225: ... at the rear of the cover into the slots on the instrument panel and lower the cover down to snap into place If you ever have a problem on the road and don t have a spare fuse you can borrow one of the correct value Just pick some feature of your vehicle that you can get along without like the radio or cigarette lighter and use its fuse if it is the value you need Remember to replace the fuse as s...

Page 226: ...ing Brake Radio Back Up Rear Body Dome Lamp 8 Power Window 9 Exhaust Brake Back Up Air Suspension Dump Differential Lock Air Dryer Moisture Ejection Heater Electric Air Compressor Power Take Off 10 ECM Ignition Power 11 Trailer Turn LH Lamp 12 Auxiliary Ignition ON 13 Auxiliary Battery Direct 14 Headlamp LH 15 Headlamp RH 16 Headlamp 17 Heated Fuel 18 Meter Truck Body Controller 19 ID Lamp Marker ...

Page 227: ...evices such as the headlamp switch ignition switch feed circuits and the auxiliary brake pump hydraulic brake vehicles Do not use maxi fuses of higher amperage than those indicated on the maxi fuse block Fuses Usage ST TURN HAZ Stoplamp Turn Signals Hazard Warning Flashers IGN SW 3 Air Conditioner Axle Chassis INT EXT LIGHTS Parking Lamps dome Lamp Instrument Panel Lights HEAD LAMP Headlamps Dayti...

Page 228: ...Relay Block A B Relay Block B C Relay Block C Relay Block A Usage 1 Power Window 2 Back Lamp Reverse 3 High Beam 4 Lighting 5 Lighting Low High 6 Trailer Turn Signal Left Headlamp 7 Tail Lamp 8 Marker Lamp 9 Trailer Turn Signal Right Headlamp Relay Block A 5 72 ...

Page 229: ... Ignition 1 6 Ignition 2 7 Auxiliary 8 Horn 9 Ignition 3 10 Dome Lamp Relay Block B Usage 11 Exhaust Brake 12 Power Take Off Control Relay Block C Usage 1 Parking Brake 2 Daytime Running Lamps On 3 Daytime Running Lamp Off 4 Parking Lamps Daytime Running Lamps 5 Neutral 6 Stop Lamp Relay Block B Relay Block C 5 73 ...

Page 230: ... Type Firing Order 7 8L LG4 V6 1 5 3 6 2 4 Capacities and Specifications Application Capacities English Metric Cooling System 32 0 quarts 30 3 L Air Conditioning Refrigerant R134a 2 0 lbs 0 9 kg Use Refrigerant Oil R134a Systems All capacities are approximate 5 74 ...

Page 231: ...ll Add oil as indicated when the oil filter element is changed Capacities given are approximate keep level within the operating range Do not operate with fluid level below the ADD line Fuel Tank Capacity Application Capacities English Metric Standard 50 0 gallons 189 3 liters Optional 100 0 gallons 378 5 liters Two 50 gallon 189 L tanks Above capacities are approximate 5 75 ...

Page 232: ...060 P 52 0 pints 24 6 liters MD 3560 P 52 0 pints 24 6 liters Add two pints one liter when changing spin on or remote filter Capacities volumes are approximate For manual transmissions the correct fluid level is to the bottom of the fluid fill plug opening The fluid capacity will vary due to the angle of the transmission with the vehicle For automatic transmissions see the Allison Automatic Transm...

Page 233: ...13 0 liters 21060S 28 0 pints 13 0 liters 23090S 40 0 pints 19 0 liters 26105S 56 0 pints 26 5 liters Two Speed Axle 19060T 34 0 pints 16 0 liters 21060T 34 0 pints 16 0 liters 23080T 40 0 pints 19 8 liters Tandem Axles DS404 front 31 0 pints 14 5 liters RS404 rear 28 0 pints 13 0 liters Above capacities volumes are approximate 5 77 ...

Page 234: ...nt Part and Filter Recommendations RPO 7 8L LG4 Oil Filter GM Part No 94392475 Engine Air Cleaner Filter Donaldson P533930 Fuel Filter Racor NWB B32002 Primary Secondary Fuel Filter GM Part No 94392474 engine mounted Pressure Caps GM Part No 15997145 5 78 ...

Page 235: ...uled Maintenance Services 6 4 Using Your Maintenance Schedule 6 4 Scheduled Maintenance Supplements 6 4 Scheduled Maintenance 6 5 Part B Owner Checks and Services 6 22 At Each Fuel Fill 6 22 At Least Twice a Year 6 22 At Least Once a Year 6 26 Part C Recommended Fluids and Lubricants 6 27 Part D Maintenance Record 6 29 Section 6 Maintenance Schedule 6 1 ...

Page 236: ...s the environment Improper vehicle maintenance can even affect the quality of the air we breathe Improper fluid levels or the wrong tire inflation can increase the level of emissions from your vehicle To help protect our environment and to keep your vehicle in good condition be sure to maintain your vehicle properly Maintenance Requirements Maintenance intervals checks inspections and recommended ...

Page 237: ...quired know how and the proper tools and equipment for the job If you have any doubt have a qualified technician do the work If you want to get the service information see Service Publications Ordering Information on page 7 6 Part B Owner Checks and Services tells you what should be checked and when It also explains what you can easily do to keep your vehicle in good condition Part C Recommended F...

Page 238: ...t tells you the maintenance services you should have done and when to schedule them When you go to your dealer for your service needs you ll know that GM trained and supported service people will perform the work using genuine GM parts The proper fluids and lubricants to use are listed in Part C Make sure whoever services your vehicle uses these All parts should be replaced and all necessary repai...

Page 239: ...1 6 Chassis lubrication service or every 6 months whichever occurs first 12 Wheels and tires service 15 Hydraulic brake service or every 6 months whichever occurs first 7 46 Parking brake service or every 6 months whichever occurs first 8 Air brake service or every 6 months whichever occurs first 39 Air brake automatic slack adjuster service or every 500 hours whichever occurs first 40 Check air b...

Page 240: ...t 7 46 Parking brake service or every 6 months whichever occurs first 8 Air brake service or every 6 months whichever occurs first 39 Air brake automatic slack adjuster service or every 500 hours whichever occurs first 40 Check air brake relay valve operation and check for leaks or every month or every 300 hours whichever occurs first Clean air brake application valve or every 3 months or every 30...

Page 241: ...s service 15 Hydraulic brake service or every 6 months whichever occurs first 7 46 Parking brake service or every 6 months whichever occurs first 8 Air brake service or every 6 months whichever occurs first 39 Air brake automatic slack adjuster service or every 500 hours whichever occurs first 40 Check air brake relay valve operation and check for leaks or every month or every 300 hours whichever ...

Page 242: ... service or every 6 months whichever occurs first 3 4 17 Wheels and tires service 15 Hydraulic brake service or every 6 months whichever occurs first 7 46 Parking brake service or every 6 months whichever occurs first 8 Air brake service or every 6 months whichever occurs first 39 Air brake automatic slack adjuster service or every 500 hours whichever occurs first 40 Check air brake relay valve op...

Page 243: ...y 3 months or every 900 hours whichever occurs first 42 40 000 Miles 64 000 km Change engine oil and filter or every 12 months whichever occurs first 2 3 Air compressor dry element pleated paper air strainer service or every 2 months or every 800 hours whichever occurs first 45 000 Miles 72 000 km Inspect engine air cleaner filter change indicator If necessary replace the filter If vehicle is driv...

Page 244: ... whichever occurs first 40 Check air brake relay valve operation and check for leaks or every month or every 300 hours whichever occurs first Clean air brake application valve or every 3 months or every 300 hours whichever occurs first Lubricate linkage Air brake chamber service or every 2 months whichever occurs first 41 Trailer brake hand control valve service or every 3 months or every 900 hour...

Page 245: ...3 months or every 900 hours whichever occurs first 42 60 000 Miles 96 000 km Change engine oil and filter or every 12 months whichever occurs first 2 3 Inspect engine air cleaner filter change indicator If necessary replace the filter If vehicle is driven in dusty dirty conditions inspect filter change indicator at every engine oil change See Engine Air Cleaner Filter on page 5 12 for more informa...

Page 246: ...vice or every 2 months or every 800 hours whichever occurs first 67 500 Miles 108 000 km Check fluid levels or every 3 months whichever occurs first 1 6 Chassis lubrication service or every 6 months whichever occurs first 12 Cooling system service Clean the cooling system filler cap with clean water clean the core pressure test the cap and the system for proper pressure capability and inspect cond...

Page 247: ...aner Filter on page 5 12 for more information An Emission Control Service See footnote Chassis lubrication service or every 6 months whichever occurs first 12 Check fluid levels or every 3 months whichever occurs first 1 6 Replace fuel filter 3 Steering system service 13 Front and rear suspension service 14 Spring to axle U bolts and shackle bolts service 16 Exhaust system service or every 6 month...

Page 248: ...y 6 months whichever occurs first 12 Wheels and tires service 15 Hydraulic brake service or every 6 months whichever occurs first 7 46 Parking brake service or every 6 months whichever occurs first 8 Air brake service or every 6 months whichever occurs first 39 Air brake automatic slack adjuster service or every 500 hours whichever occurs first 40 Check air brake relay valve operation and check fo...

Page 249: ...r occurs first and whenever hubs are removed 23 46 Steering system service 13 Front and rear suspension service 14 Spring to axle U bolts and shackle bolts service 16 Exhaust system service or every 6 months whichever occurs first 3 4 17 Inspect door hinge pins and bushings and replace as necessary Wheels and tires service 15 Hydraulic brake service or every 6 months whichever occurs first 7 46 Pa...

Page 250: ...whichever occurs first 37 Exhaust brake service if equipped Check for excessive spindle free play and smooth operation Lubricate ball joint cap Air compressor dry element pleated paper air strainer service or every 2 months or every 800 hours whichever occurs first Inspect air compressor discharge port or every 6 months or every 1 800 hours whichever occurs first Manual transmission ZF 6 speed onl...

Page 251: ...ol Device 5 Applies only to vehicles sold in the United States 6 Check fluid level in brake master cylinder power steering pump axle transmission and hydraulic spring parking brake pump if equipped A low fluid level in the brake master cylinder can indicate worn brake linings and should be checked accordingly 7 Inspect brake lines and hoses for proper hook up binding leaks cracks chafing etc Inspe...

Page 252: ...at transmission Lubricate suspension axle and steering linkage more often when operating under dusty or muddy conditions and in excessive off road use Frequently power washed vehicles will require more frequent lubrication 13 Check steering system Look for damaged loose or missing parts Inspect the steering linkage relay rod and tie rod ends for looseness or lack of lubricant Also look for parts s...

Page 253: ...es Replace as needed 21 Check shields and underhood insulation for damage or looseness Adjust or replace as needed 23 Wheel bearing service Grease type Clean inspect and lubricate with the proper wheel bearing grease at designated intervals or when hubs are removed See Part C Recommended Fluids and Lubricants on page 6 27 Oil filled type Some wheel bearings are lubricated by rear axle lubricant Wh...

Page 254: ...er hook up binding leaks cracks chafing etc Inspect drum brake linings for wear or cracks Inspect other brake parts at each wheel including drums wheel cylinders and piston heat shields boots and wheel speed sensor wiring Check brake pedal for excessive free play or travel or every 6 months whichever occurs first and have serviced if needed Check brakes more often if driving habits and conditions ...

Page 255: ...lve replace parts showing wear Remove disassemble clean and inspect the spring brake control valve replace rubber parts 40 Clean and lubricate air brake automatic slack adjuster Check pushrod travel and auto adjustment operation Have serviced if needed 41 Air brake chamber service Check operation mounting clamps and air lines and check for leaks 42 Trailer brake hand control valve service Check op...

Page 256: ...ne Oil DURAMAX Diesel on page 5 9 for further details Engine Coolant Level Check Check the engine coolant level and add DEX COOL coolant mixture if necessary See Engine Coolant on page 5 16 for further details Windshield Washer Fluid Level Check Check the windshield washer fluid level in the windshield washer tank and add the proper fluid if necessary See Cleaning the Outside of Your Vehicle on pa...

Page 257: ...ack door weatherstrips and rubber cap bumpers should also be lubricated Part C tells you what to use More frequent lubrication may be required when exposed to a corrosive environment Parking Brake Check Park on a fairly steep hill and hold the vehicle with the parking brake only This checks holding ability Starter Switch Check CAUTION When you are doing this check the vehicle could move suddenly I...

Page 258: ...tem inspection and or service Engine Cooling System Service Inspect the hoses and have them replaced if they are cracked swollen or deteriorated Inspect all pipes fittings and clamps replace as needed Clean the outside of the radiator and air conditioning condenser To help ensure proper operation a pressure test of the cooling system and pressure cap is recommended at least once a year Exhaust Sys...

Page 259: ... or cause injury Replace clean or repair promptly Door Latches Check Check that doors close latch and lock tightly Check for broken damaged or missing parts that might prevent tight latching Cab Latches Check Check that the cab closes firmly Check for broken damaged loose or missing parts that might prevent tight latching Fluid Leaks Check Check for fuel coolant oil or other fluid leaks by looking...

Page 260: ...ubricate the key lock cylinders with the lubricant specified in Part C Underbody Flushing Service At least every spring use plain water to flush any corrosive materials from the underbody Take care to clean thoroughly any areas where mud and other debris can collect Tractor Protection Breakaway Valve Check On air brake models remove disassemble clean and inspect the tractor protection breakaway va...

Page 261: ...se only DEX COOL Coolant See Engine Coolant on page 5 16 Usage Fluid Lubricant Hydraulic Brake System Delco Supreme 11 Brake Fluid or equivalent DOT 3 brake fluid Windshield Washer Solvent GM Optikleen Washer Solvent Clutch Bearing Lubricant Clutch Bearing Lubricant GM Part No 12378484 or equivalent NLGI 3 consistency Exhaust Brake Ball Joint Cap Lubricant High Temperature Grease GM Part No U S 10...

Page 262: ... Rear Axle and Rear Hubs SAE 75W 90 Synthetic Axle Lubricant for Medium Duty Trucks GM Part No U S 12345841 in Canada 10953512 Usage Fluid Lubricant Rear Axle Shift Motor Lubricant Refrigerant Oil GM Part No U S 5416939 in Canada 10953496 Propshafts and Splines Wheel bearing lubricant meeting requirements of NLGI 2 Category GC or GC LB GM Part No U S 1051344 in Canada 993037 Cab Door Hinges and La...

Page 263: ...rmed record the date odometer reading and who performed the service and any additional information from Owner Checks and Services on the following record pages Also you should retain all maintenance receipts Date Odometer Reading Serviced By Maintenance Record 6 29 ...

Page 264: ...Date Odometer Reading Serviced By Maintenance Record 6 30 ...

Page 265: ...sistance Offices 7 3 Roadside Assistance Program 7 4 Reporting Safety Defects 7 5 Reporting Safety Defects to the United States Government 7 5 Reporting Safety Defects to the Canadian Government 7 5 Reporting Safety Defects to General Motors 7 5 Service Publications Ordering Information 7 6 Section 7 Customer Assistance Information 7 1 ...

Page 266: ...member of dealership management it appears your concern cannot be resolved by the dealership without further help contact the GMC or Chevrolet Consumer Relations Manager by calling 1 800 862 4389 Customer Assistance prompt In Canada contact GM of Canada Customer Communication Centre in Oshawa by calling 1 800 263 3777 English or 1 800 263 7854 French We encourage you to call the toll free number i...

Page 267: ...to GMC s Medium Duty Truck Customer Assistance Center United States Customer Assistance GMC Medium Duty Truck Customer Assistance Center P O Box 44947 Detroit MI 48244 1 800 862 4389 1 800 462 8583 For Text Telephone devices TTYs Roadside Assistance 1 800 GMC 8782 Fax Number 313 381 0022 From Puerto Rico 1 800 496 9992 English 1 800 496 9993 Spanish Fax Number 313 381 0022 U S Virgin Islands 1 800...

Page 268: ...presentatives with a network of GM Medium Duty Truck s dealer services Just dial GM Medium Duty Truck Roadside Assistance at 1 800 862 4389 to reach a qualified representative who can assist you in a repair or arrange a tow Other recommended services can also be arranged for situations such a retrieving locked in keys changing a tire or delivering gasoline at a charge to the owner We also provide ...

Page 269: ...A U S Department of Transportation Washington D C 20590 You can also obtain other information about motor vehicle safety from the hotline Reporting Safety Defects to the Canadian Government If you live in Canada and you believe that your vehicle has a safety defect you should immediately notify Transport Canada in addition to notifying General Motors of Canada Limited You may write to Transport Ca...

Page 270: ...rmation about the vehicle The owner s manual will include the Maintenance Schedule for all models In Portfolio Includes a Portfolio Owner s Manual and Warranty Booklet RETAIL SELL PRICE 35 00 Without Portfolio Owner s Manual only RETAIL SELL PRICE 25 00 Current and Past Model Order Forms Service Publications are available for current and past model GM vehicles To request an order form please speci...

Page 271: ...r Vehicle 5 63 Finish Damage 5 65 Sheet Metal Damage 5 65 Underbody Maintenance 5 65 Vehicle Care Appearance Materials 5 66 Weatherstrips 5 63 Apply Park Brake Warning Light 3 28 Ashtrays 3 17 Audio System s 3 39 AM FM Radio 3 40 Care of Your Cassette Tape Player 3 51 Care of Your CD Player 3 53 Care of Your CDs 3 53 Chime Level Adjustment 3 53 Fixed Mast Antenna 3 53 Radio with Cassette 3 42 Radi...

Page 272: ...t Panel 5 49 Cab Tilting cont Lowering the Cab 5 47 Tilting the Cab 5 44 Canada Customer Assistance 7 3 Canadian Owners ii Capacities and Specifications 5 74 Carbon Monoxide 4 26 2 23 Care of 5 62 Safety Belts 5 62 Your Cassette Tape Player 3 51 Your CD Player 3 53 Your CDs 3 53 Cassette Tape Messages 3 46 CD Adapter Kits 3 46 Center Console Storage Area 2 28 Center Passenger Position Safety Belts...

Page 273: ...n 2 19 Clutch Hydraulic 5 16 Clutch Pedal Free Travel 5 33 Cold Weather Starting 2 9 Compact Disc Messages 3 50 Control of a Vehicle 4 5 Coolant 3 30 Engine Temperature Gage 3 30 Heater Engine 2 13 Low Warning Light 3 30 Surge Tank Pressure Cap 5 20 Cooling System 5 22 Cruise Control 3 9 Current and Past Model Order Forms 7 6 Customer Assistance Information 7 3 Customer Assistance for Text Telepho...

Page 274: ...Dual Tire Operation 5 54 E Eaton Fuller Nine and Ten Speed Non Synchronized Manual Transmissions 2 18 Electric Air Compressor 5 32 Electrical System 5 67 Add On Equipment 5 67 Fuses and Circuit Breakers 5 68 Fusible Links 5 68 Headlamp Wiring 5 67 Power Windows and Other Power Options 5 68 Windshield Wiper Fuses 5 68 Electric Hydraulic Parking Brake Fluid 5 33 Engine Alarm and Automatic Shutdown 2...

Page 275: ...e 3 38 Filter 5 13 Engine Air Cleaner 5 13 Finding a Station 3 40 3 43 3 47 Finish Care 5 63 Finish Damage 5 65 Fixed Mast Antenna 3 53 Flat Tire 5 59 Fluid Leaks Check 6 25 Fluid 5 15 Automatic Transmission 5 15 Manual Transmission 5 15 Power Steering 5 27 Windshield Washer 5 28 FM 3 51 Footnotes 6 17 Four Wheel Disc Brakes Hydraulic Only 5 31 Four Wheel Drum Brakes Air Only 5 31 Fuel 5 5 Diesel ...

Page 276: ...Hypnosis 4 23 Hill and Mountain Roads 4 24 Horn 3 6 Hourmeter Gage 3 38 How to Add Coolant to the Coolant Surge Tank 5 24 How to Add Fluid 5 16 How to Check and Add Fluid 5 33 How to Check and What to Use 5 15 How to Check Fluid 5 43 How to Check Lubricant 5 43 How To Check Power Steering Fluid 5 27 How to Check 5 53 How to Use This Manual ii How to Wear Safety Belts Properly 1 9 Hydraulic Brake S...

Page 277: ...16 Jump Starting 5 37 K Key Lock Cylinders Service 6 26 Keys 2 2 L Lamps Check 6 25 Lamps 3 12 Exterior 3 12 Interior 3 15 Lap Belt 1 17 Lap Shoulder Belt 1 9 Light 3 28 Anti Lock Brake System Warning 3 28 Apply Park Brake Warning 3 28 Brake System Warning 3 26 Change Engine Oil 3 34 Charging System 3 24 Check Gages Warning 3 37 Daytime Running Lamps Indicator 3 36 Differential Lock Indicator 3 36...

Page 278: ...nce a Year 6 26 At Least Twice a Year 6 22 Maintenance Schedule cont How This Section is Organized 6 3 Introduction 6 2 Maintenance Requirements 6 2 Part A Scheduled Maintenance Services 6 4 Part B Owner Checks and Services 6 22 Part C Recommended Fluids and Lubricants 6 27 Part D Maintenance Record 6 29 Scheduled Maintenance Supplements 6 4 Scheduled Maintenance 6 5 Using Your 6 4 Your Vehicle an...

Page 279: ...nts 1 19 Other Warning Devices 3 6 Outlet Adjustment 3 19 Outside 2 26 Convex Mirrors 2 26 Heated Mirrors 2 26 Manual Mirrors 2 25 Power Mirrors 2 25 Overdrive Defeat 2 17 Overhead Storage 2 27 Overseas Customer Assistance 7 4 Overspeed Warning Light 3 34 Owners Canadian ii Owner s Information 7 6 P Park Apply Brake Warning Light 3 28 Parking Brake Check 6 23 Parking Brake 2 20 Parking 2 19 Brake ...

Page 280: ...adio with CD 3 47 Radios cont Setting the Time 3 39 Theft Deterrent 3 51 Understanding Reception 3 51 Range Inhibit Warning Indicator 3 25 Reading Lamps 3 16 Rear Axle 5 43 Shift Motor 5 43 Two Speed Electric Shift Control 2 14 Rearview Mirrors 2 25 Reduced Engine Power Light 3 36 Relay Blocks 5 72 Releasing Air Operated Parking Brakes 4 35 Replacing Brake System Parts 5 31 Replacing Restraint Sys...

Page 281: ...heduled Maintenance 6 5 Seat Adjuster Check 6 25 Seat 1 2 Head Restraints 1 2 Seats 1 2 Bucket Seats 1 2 Center Seat 1 4 Securing a Child Restraint 1 28 Center Seat Position 1 28 Service Bulletins 7 6 Service Engine Soon Light 3 32 Service Manuals 7 6 Service 5 3 Doing Your Own Work 5 3 Engine Soon Light 3 32 Publications Ordering Information 7 6 Transmission Warning Light 3 25 Two Safety Cautions...

Page 282: ...When It Is Time for New Tires 5 54 To Use the Engine Coolant Heater 2 13 Top Strap 1 27 Towing Your Vehicle From the Front All Wheels On the Ground 4 34 Towing Your Vehicle From the Front Front Wheels Off the Ground 4 33 Towing Your Vehicle From the Rear Rear Wheels Off the Ground 4 34 Towing 4 32 Your Vehicle 4 32 Traction 4 10 Control System TCS 4 10 Tractor Protection Breakaway Valve Check 6 26...

Page 283: ... 3 19 Voltmeter Gage 3 24 W Wait to Start Indicator 3 31 Warning Light Bulb Check Button 3 29 Warning Lights Gages and Indicators 3 20 Warnings 3 5 Hazard Warning Flashers 3 5 Other Warning Devices 3 6 Safety and Symbols iii Vehicle Damage iv Washer Fluid Low Warning Light 3 37 Washing Your Vehicle 5 63 Weatherstrip Lubrication 6 23 What Fuel to Use in Canada 5 7 What Fuel to Use 5 5 What Kind of ...

Page 284: ...rk 1 6 Windows 2 4 Manual 2 5 Passenger Side Door Glass 2 6 Power 2 5 Windshield and Wiper Blades 5 64 Windshield Washer Fluid Level Check 6 22 Windshield Washer 3 9 Fluid 5 28 Windshield Wiper 5 51 Blade Replacement 5 51 Fuses 5 68 Windshield Wipers and Washers Check 6 24 Windshield Wipers 3 8 Winter Driving 4 26 Wiper Blade Check 6 23 Y Your Vehicle and the Environment 6 2 14 ...

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Summary of Contents for 2003 GMT560 T-Series

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GMC 2003 GMT560 T-Series, Owner'S Manual

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Summary of Contents for 2003 GMT560 T-Series

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