GMC 2003 GMT560 T-Series Owner's Manual

page of 284

/ 284
Contents
Table of Contents
Bookmarks

Table of Contents

Quick Links

Download this manual

2003 GMC GMT560 T-Series Owner Manual

Seats and Restraint Systems ........................... 1-1

Front Seats

............................................... 1-2

Safety Belts

.............................................. 1-4

Child Restraints

....................................... 1-19

Restraint System Check

Features and Controls ..................................... 2-1

Keys

........................................................ 2-2

Doors and Locks

....................................... 2-3

Windows

.................................................. 2-4

Theft-Deterrent Systems

Starting and Operating Your Vehicle

Mirrors

.................................................... 2-25

Storage Areas

......................................... 2-27

Instrument Panel ............................................. 3-1

Instrument Panel Overview

Climate Controls

...................................... 3-17

Warning Lights, Gages and Indicators

Audio System(s)

....................................... 3-39

Driving Your Vehicle ....................................... 4-1

Your Driving, the Road, and Your Vehicle

Towing

................................................... 4-32

............................ 1-30

.............................. 2-6

............. 2-7

.......................... 3-4

......... 3-20

..... 4-2

Service and Appearance Care .......................... 5-1

Service

..................................................... 5-3

Fuel

......................................................... 5-5

Checking Things Under the Hood

Rear Axle

............................................... 5-43

Cab Tilting

.............................................. 5-44

Noise Control System

Windshield Wiper Blade Replacement

Tires

...................................................... 5-52

Appearance Care

..................................... 5-60

Vehicle Identiﬁcation

Electrical System

...................................... 5-67

Capacities and Speciﬁcations

Normal Maintenance Replacement Parts

Maintenance Schedule ..................................... 6-1

Maintenance Schedule

Customer Assistance Information .................... 7-1

Customer Assistance Information

Reporting Safety Defects

Index ................................................................ 1

............... 5-10

............................... 5-50

......... 5-51

................................. 5-67

..................... 5-74

...... 5-78

................................ 6-2

.................. 7-2

............................ 7-5

Chapters

Table of Contents

Summary of Contents for GMC 2003 GMT560 T-Series

Page 1: Table Of Contents
2003 GMC GMT560 T-Series Owner Manual Seats and Restraint Systems ......1-1 Service and Appearance Care ......5-1 Front Seats Service ..........1-2 ............. 5-3 Safety Belts Fuel ..........1-4 ............5-5 Child Restraints ........1-19 Checking Things Under the Hood ....
Page 2: Canadian Owners
Helm, Incorporated P.O. Box 07130 Detroit, MI 48207 GENERAL MOTORS, GM, the GM Emblem, GMC, and How to Use This Manual the GMC Truck Emblem are registered trademarks of General Motors Corporation. Many people read their owner’s manual from beginning to end when they ﬁrst receive their new vehicle.
Page 3 Safety Warnings and Symbols You will also ﬁnd a circle with a slash through it in this book. This safety You will ﬁnd a number of safety cautions in this book. symbol means “Don’t,” We use a box and the word CAUTION to tell you about “Don’t do this”...
Page 4: Vehicle Symbols
Vehicle Damage Warnings Vehicle Symbols Also, in this book you will ﬁnd these notices: Your vehicle has components and labels that use symbols instead of text. Symbols, used on your vehicle, Notice: These mean there is something that could are shown along with the text describing the operation damage your vehicle.
Page 5 These are some examples of vehicle symbols you may ﬁnd on your vehicle:...
Page 6: Model Reference
Model Reference 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 This manual contains information which covers tilt cab manual — carefully, to get all of the information on models as shown.
Page 7: Seats And Restraint Systems
Section 1 Seats and Restraint Systems Front Seats ............1-2 Child Restraints ..........1-19 Head Restraints ..........1-2 Older Children ..........1-19 Bucket Seats ..........1-2 Infants and Young Children ......1-21 Center Seat ...........1-4 Child Restraint Systems .........1-24 Top Strap ............1-27 Safety Belts .............1-4 Securing a Child Restraint in a Center Safety Belts: They Are for Everyone ....1-4 Seat Position ..........1-28 Questions and Answers About Safety Belts ..1-8...
Page 8: Front Seats
Front Seats Bucket Seats Your vehicle has bucket Head Restraints 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.
Page 9 To tilt the seatback, turn the backrest tilt knob. The CAUTION: knob is located on the lower cushion, on the outboard side of the You can lose control of the vehicle if you try to driver’s seat and the adjust the seat while the vehicle is moving. inboard side of the The sudden movement could startle and passenger’s seat.
Page 10: Safety Belts
Center Seat Safety Belts Your vehicle may have a center seat. Safety Belts: They Are for Everyone To fold the seatback down, pull the lever, located on the right side of the seat. This part of the manual tells you how to use safety Then lower the seatback forward and push down ﬁrmly belts properly.
Page 11 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. CAUTION: A few crashes are mild, and some crashes can be so serious that even buckled up a person would not It is extremely dangerous to ride in a cargo survive.
Page 12: Why Safety Belts Work
Why Safety Belts Work Aren’t safety belts for kids? Yes. And they are for adult truckers, and anyone else who rides in your vehicle. If the vehicle hits something, it stops – right then. But nothing stops the people. They keep moving. Here’s why: when your vehicle goes, say, 30 mph (50 km/h), so do you and your passengers.
Page 13 Then something will stop them. It could be the Or it could be the instrument panel. windshield. 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?
Page 14: Questions And Answers About Safety Belts
Questions and Answers About Safety Belts Won’t I be trapped in the vehicle after an accident if I’m wearing a safety belt? You could be – whether you’re wearing a safety belt or not. But you can unbuckle a safety belt, even if you’re upside down.
Page 15: How To Wear Safety Belts Properly
How to Wear Safety Belts Properly This part is only for people of adult size. Be aware that there are special things to know about safety belts and children. And there are different rules for smaller children and babies. If a child will be riding in your vehicle, see Older Children on page 1-19 or Infants and Young Children on page 1-21 .
Page 16 4. Push the latch plate into the buckle until it clicks. Pull up on the latch plate to make sure it is secure. If the belt isn’t long enough, see Safety Belt Extender on page 1-18 . Make sure the release button on the buckle is positioned so you would be able to unbuckle the safety belt quickly if you ever had to.
Page 17 What’s wrong with this? 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. The shoulder belt is too loose. It won’t give nearly as much protection this way.
Page 18 What’s wrong with this? CAUTION: You can 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.
Page 19 What’s wrong with this? CAUTION: You can be seriously 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.
Page 20 What’s wrong with this? 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.
Page 21 To unlatch the 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.
Page 22: Safety Belt Use During Pregnancy
Safety Belt Use During Pregnancy A pregnant woman should wear a lap-shoulder belt, and the lap portion should be worn as low as possible, below the rounding, throughout the pregnancy. Safety belts work for everyone, including pregnant women. Like all occupants, they are more likely to be The best way to protect the fetus is to protect the seriously injured if they don’t wear safety belts.
Page 23: Lap Belt
Right Passenger Position Lap Belt If your vehicle has a center seat, someone can sit in the The right passenger’s safety belt works the same way center position. as the driver’s safety belt. See Driver Position on page 1-9 . Center Passenger Position When you sit in a center seating position, you have a lap safety belt, which has no retractor.
Page 24: Safety Belt Extender
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.
Page 25: Child Restraints
Child Restraints What is the proper way to wear safety belts? If possible, an older child should wear a Older Children 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.
Page 26 What if a child is wearing a lap-shoulder belt, but the child is so small that the shoulder belt is very close to the child’s face or neck? 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.
Page 27: Infants And Young Children
CAUTION: (Continued) this way, in a crash the child might slide under the belt. The belt’s force would then be applied right on the child’s abdomen. That could cause serious or fatal injuries. Wherever the child sits, the lap portion of the belt should be worn low and snug on the hips, just touching the child’s thighs.
Page 28 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. CAUTION: People should never hold a baby in their arms while riding in a vehicle.
Page 29 What are the different types of add-on child restraints? CAUTION: Add-on child restraints, which are purchased by the vehicle’s owner, are available in four basic Newborn infants need complete support, types. Selection of a particular restraint should take including support for the head and neck. This into consideration not only the child’s weight, is necessary because a newborn infant’s neck height, and age but also whether or not the...
Page 30: Child Restraint Systems
Child Restraint Systems CAUTION: The body structure of a young child is quite unlike that of an adult or older child, for whom the safety belts are designed. A young child’s hip bones are still so small that the vehicle’s regular safety belt may not remain low on the hip bones, as it should.
Page 31 A rear-facing infant seat (B) provides restraint with the A forward-facing child seat (C-E) provides restraint for seating surface against the back of the infant. The the child’s body with the harness and also sometimes harness system holds the infant in place and, in a crash, with surfaces such as T-shaped or shelf-like shields.
Page 32 How do child restraints work? A child restraint system is any device designed for use in a motor vehicle to restrain, seat, or position children. A built-in child restraint system is a permanent part of the motor vehicle. An add-on child restraint system is a portable one, which is purchased by the vehicle’s owner.
Page 33: Top Strap
Top Strap When choosing a child restraint, be sure the child restraint is designed to be used in a vehicle. If it is, it will have a label saying that it meets federal motor Some child restraints have a top strap, or “top tether,” vehicle safety standards.
Page 34 Securing a Child Restraint in a Center Seat Position If your vehicle has a center seat, you can secure a child restraint here. You’ll be using the lap belt. Be sure to follow the 1. Make the belt as long as possible by tilting the latch instructions that came with the child restraint.
Page 35 5. To tighten the belt, pull its free end while you push down 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.
Page 36: Restraint System Check
Restraint System Check Replacing Restraint System Parts After a Crash Checking Your Restraint Systems CAUTION: Now and then, make sure the safety belt reminder light and all your belts, buckles, latch plates, retractors and anchorages are working properly. Look for any other A crash can damage the restraint systems in loose or damaged safety belt system parts.
Page 37: Features And Controls
Section 2 Features and Controls Keys ...............2-2 Two-Speed Rear Axle Electric Shift Control ..2-14 Automatic Transmission Operation ....2-16 Doors and Locks ..........2-3 Manual Transmission Operation ......2-18 Door Locks ............2-3 Parking ............2-19 Windows ............2-4 Parking Over Things That Burn .......2-23 Manual Windows ..........2-5 Engine Exhaust ..........2-23 Power Windows ..........2-5 Running Your Engine While You...
Page 38: Keys
Keys CAUTION: Leaving children in a vehicle with the ignition key is dangerous for many reasons. A child or others could be badly injured or even killed. They could operate the power windows or other controls or even make the vehicle move. Don’t leave the keys in a vehicle with children.
Page 39: Doors And Locks
Doors and Locks A manual door lock is located above each door handle. Door Locks CAUTION: Unlocked doors can be dangerous. • Passengers — especially children — can easily open the doors and fall out of a moving vehicle. When a door is locked, the handle won’t open it.
Page 40: Windows
Windows CAUTION: Leaving children in a vehicle 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.
Page 41: Manual Windows
Manual Windows Push the switch down to lower the passenger power window and pull the switch up to raise it. The driver’s door also has a LOCK button. When the LOCK button is Turn the hand crank on each door to raise or lower the pressed down, the passenger’s window will not window.
Page 42: Theft-Deterrent Systems
Passenger Side Door Glass 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.
Page 43: Starting And Operating Your Vehicle
Starting and Operating Your • Check and adjust engine and transmission ﬂuid levels often and be sure tires are properly Vehicle inﬂated for the load you’re carrying. • ® If you have a Caterpillar diesel engine, see the ® Caterpillar Diesel Engine Operation and New Vehicle Break-In Maintenance Manual.
Page 44: Automatic Transmission
Starting Your DURAMAX™ Diesel 2. As soon as the wait to start light goes off, immediately turn the ignition key to START. When Engine the engine starts, let go of the key. Notice: Holding your key in START for longer than Automatic Transmission 15 seconds at a time will cause your battery to be drained much sooner.
Page 45: Engine Alarm And Automatic Shutdown
Cold Weather Starting Engine Alarm and Automatic Shutdown The following tips will help you get good starting in cold If your vehicle has this feature, your check gages light weather. will come on if the system senses high engine temperature or low engine oil pressure. If high engine Use the recommended engine oil when the outside temperature or low engine oil pressure is detected, you temperature drops below freezing.
Page 46 Manual High Idle System Exhaust Restrictor If your vehicle is equipped with this feature, there is an If your vehicle has this exhaust restrictor valve located in the exhaust stream. feature, the manual high The valve closes to provide back pressure to the engine idle switch is located in the for the purpose of warming the engine quickly.
Page 47 When the engine coolant temperature is below 149°F If the light does not come on when the engine is cold, (65°C) and the outside temperature is below 50°F your vehicle needs service. (10°C), the exhaust restrictor will come on within If your batteries don’t have enough charge to start your 45 seconds of starting the engine.
Page 48: Engine Checks Before Operating
Engine Checks Before Operating • If you have air brakes, the dual-needle air pressure gage should read at least 115 psi (790 kPa) for When you’ve started your engine, let it run for both service systems before you try to move 20 to 30 seconds before you put a load on the engine.
Page 49: Engine Coolant Heater
Notice: For diesel engines, don’t allow the engine to operate at low idle for more than ﬁve minutes. CAUTION: This can cause low engine operating temperatures which can affect engine operation and reduce engine life. Engine idle speed should be increased Plugging the cord into an ungrounded outlet to 1200 rpm whenever extended idle is required.
Page 50 Diesel Engine Exhaust Brake When using the exhaust brake, the proper gear range selection is important. The exhaust brake will be most effective if the gear range selected is the lowest The exhaust brake is used to help slow the vehicle and possible range that does not allow the engine rpm to go may assist the vehicle’s foundation brakes.
Page 51: Air Suspension
Automatic Transmission To operate off-road or under a heavy load, shift into low range when the vehicle is standing still and then operate the transmission normally. The switch is located on the instrument panel to the On the highway, with the rear axle in low range and the right of the climate transmission in top gear, you may shift the rear axle controls.
Page 52 Rear Air Suspension Dump Control Automatic Transmission Operation If your vehicle is equipped with single-axle air We build vehicles with ﬁve and six-speed automatic suspension, you may have this control. The air transmissions. This part of the manual covers the basics suspension dump control allows the operator to lower of these.
Page 53 Overdrive Defeat CAUTION: If your vehicle has this feature, you can select to limit the transmission to fourth gear. This may be useful when operating at a higher Gross Vehicle Weight (GVW) or Shifting into a drive gear while your engine is where operating conditions do not require ﬁfth gear.
Page 54: Manual Transmission Operation
® ® Manual Transmission Operation Eaton Fuller Nine and Ten-Speed Non-Synchronized Manual Using the Clutch Transmissions When you’re starting to move the vehicle, it’s important If your vehicle has one of these non-synchronized to begin with the engine speed at idle. Then start to transmissions, it’s naturally somewhat complicated.
Page 55 Double-Clutching Notice: After engaging FIRST (1) or REVERSE (R) gear, do not use the clutch brake for upshifting You must use the double-clutching method when you and downshifting. To do so will shorten the service shift an unsynchronized gear set. Disengage the clutch, life of the clutch brake and gear selection shift shift to neutral and engage the clutch.
Page 56: Hydraulic Brakes
Hydraulic Brakes If your vehicle has hydraulic brakes, it has a parking brake lever. The lever is located in the center console. Your vehicle may also be equipped with an automatic transmission which has a center console shift lever. This lever will have a PARK (P) position on the shift indicator.
Page 57: Air Brake
Air Brake Pulling the system park (yellow) knob out applies the parking brake. The park brake light will not come on when the air parking brake is applied. CAUTION: 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: When the yellow SYSTEM PARK and the red TRAILER AIR SUPPLY knobs are both pushed...
Page 58 For driving with a trailer, the yellow and red knobs must If you ever have a complete loss of air so that your air be pushed in. It’s the same when you’re not pulling a brakes automatically apply, the tow operator can trailer except that the trailer air supply (red) knob release the parking brakes to tow the vehicle.
Page 59: Parking Over Things That Burn
Parking Over Things That Burn Engine Exhaust CAUTION: Engine exhaust can kill. It contains the gas carbon monoxide (CO), which you can’t see or smell. It can cause unconsciousness and death. You might have exhaust coming in if: • Your exhaust system sounds strange or different.
Page 60: Running Your Engine While You Are Parked
Running Your Engine While You CAUTION: Are Parked It’s better not to park with the engine running. But if you It can be dangerous to get out of your vehicle ever have to, here are some things to know. if the shift lever is not fully in PARK (P) with the parking brake ﬁrmly set.
Page 61: Mirrors
Outside Power Mirrors CAUTION: If you have outside power rearview mirrors, they can be adjusted from the inside of the vehicle. It can be dangerous to get out of your vehicle The control for this without the parking brake ﬁrmly set. Your feature is located on the vehicle can roll.
Page 62: Outside Convex Mirrors
Outside Convex Mirrors Outside Heated Mirrors Your vehicle has convex mirrors on the lower quarter of If your vehicle has this feature, your outside rearview both the driver’s and passenger’s side rearview mirrors can be defrosted. mirrors. A convex mirror’s surface is curved so you can The switch for this feature see more from the driver’s seat.
Page 63: Storage Areas
Storage Areas Center Seat Storage Overhead Storage A storage compartment is located behind the seatback in the center seat. To access the compartment, fold the seat all the way forward. An overhead storage compartment is provided above each of the driver’s and passenger’s seats. Push the compartment doors all the way up to lock in position.
Page 64: Center Console Storage Area
Center Console Storage Area To open, squeeze both sides of the latch. There are additional storage areas for small items in the center console to the right of the driver’s seat. 2-28...
Page 65: Instrument Panel
Section 3 Instrument Panel Instrument Panel Overview .......3-4 Voltmeter Gage ..........3-24 Hazard Warning Flashers ........3-5 Service Transmission Warning Light ....3-25 Other Warning Devices ........3-6 Range Inhibit Warning Indicator ......3-25 Horn .............3-6 Brake System Warning Light ......3-26 Power Tilt Wheel and Telescopic Apply Park Brake Warning Light .....3-28 Steering Column .........3-6 Parking Brake Warning Light ......3-28...
Page 66 Section 3 Instrument Panel Exhaust Brake Indicator Light ......3-35 AM-FM Radio ..........3-40 Differential Lock Indicator Light .......3-36 Radio with Cassette ........3-42 Reduced Engine Power Light ......3-36 Radio with CD ..........3-47 Daytime Running Lamps Indicator Light ...3-36 Theft-Deterrent Feature Low Washer Fluid Warning Light .....3-37 (Non-RDS Radios) ........3-51 Check Gages Warning Light ......3-37 Understanding Radio Reception ......3-51...
Page 67 NOTES...
Page 68: Instrument Panel Overview
Instrument Panel Overview...
Page 69: Hazard Warning Flashers
Hazard Warning Flashers A. Turn Signal Multifunction Lever B. Outlets Your hazard warning ﬂashers let you warn others. They C. Instrument Panel Cluster also let police know you have a problem. Your front D. Warning Lights and rear turn signal lamps will ﬂash on and off. E.
Page 70: Other Warning Devices
Other Warning Devices To tilt the column, hold the steering wheel and pull the lever on the left side of If you carry reﬂective triangles, you can set one up at the column to unlock the side of the road behind your vehicle in the the steering column.
Page 71 Turn Signal/Multifunction Lever To signal a turn, move the lever all the way up or down. When the turn is ﬁnished, the lever will return automatically. An arrow on the instrument panel cluster will ﬂash in the direction of the turn or lane change.
Page 72 Headlamp High/Low-Beam Changer (Mist): For a single wiping cycle, turn the band to this symbol. Hold it there until the wipers start, then To change the headlamps from low to high beam or high let go. The wipers will stop after one cycle. If you want to low beam, pull the multifunction lever all the way more cycles, hold the band on mist longer.
Page 73: Cruise Control
Cruise Control Heavy snow or ice can overload your wipers. The windshield wiper motor is protected from overload by a circuit breaker and a fuse. If the motor overheats If your vehicle has this due to heavy snow or ice the wiper will stop until the feature, it is located at the motor cools.
Page 74 Setting Cruise Control With cruise control, you can maintain a speed of about 30 mph (48 km/h) or more without keeping your foot on the accelerator. Cruise control does not work at speeds below about 30 mph (48 km/h). CAUTION: If you have an automatic transmission and you apply your brakes, the cruise control will shut off.
Page 75 Resuming a Set Speed Reducing Speed While Using Cruise Control Suppose you set your cruise control at a desired speed and then you apply the brake. This, of course, shuts Press in the button at the end of the lever until you off the cruise control.
Page 76: Exterior Lamps
Ending Cruise Control Exterior Lamps There are four different ways to turn off the cruise control: • Step lightly on the brake pedal (manual and automatic transmissions). • Press the clutch pedal to the ﬂoor (manual transmissions). • Move the cruise switch to off, or •...
Page 77: Headlamps On Reminder
Headlamps On Reminder (Parking Lamps): Turning the control to this position turns on the parking lamps, together with the If you have this system, a tone will sound when your following: headlamps and/or parking lamps are turned on and your •...
Page 78 Marker Lamp Defeat Switch When the DRL are on, only your headlamps will be on. The taillamps, sidemarker and other lamps won’t be If your vehicle has this feature, you can manually blink on. Your instrument panel won’t be lit up either. the marker and clearance lamps.
Page 79: Interior Lamps
Interior Lamps Instrument Panel Brightness Control This feature controls the brightness of the instrument panel lights. The thumbwheel for this feature is located to the right of the exterior lamp control. Turn the thumbwheel up to brighten the lights. When the thumbwheel is moved to the ﬁrst position, the radio display and transmission selection display will go to full intensity.
Page 80: Illuminated Entry
Illuminated Entry Auxiliary Power Jacks The delayed illumination feature will allow you to enter If your vehicle has these or exit your vehicle with the lights on for about power jacks, you’ll ﬁnd 20 seconds, after the door is closed or the ignition is then in the console to cycled.
Page 81: Climate Controls
Ashtrays and Cigarette Lighter Climate Controls Your vehicle may have an ashtray and a cigarette Climate Control System lighter located in the center ﬂoor console. To open the removeable ashtray, ﬂip open the top. With this climate control system, you can control the Notice: Don’t put papers or other ﬂammable items heating, cooling, and ventilation for your vehicle.
Page 82 A/C (Air Conditioning): If your vehicle has this feature, (Bi-Level): This mode directs about half of the air you can use your air conditioner by selecting one of to the instrument panel outlets, and then directs the mode buttons, selecting a fan speed and pressing most of the remaining air to the ﬂoor outlets.
Page 83: Defogging And Defrosting
Defogging and Defrosting Outlet Adjustment There are two modes to clear fog or frost from your windshield. Use the defog mode to clear the windows of fog or moisture and warm the passengers. Use the defrost mode to remove fog or frost from the windshield more quickly.
Page 84: Warning Lights, Gages And Indicators
Operation Tips Warning lights come on when there may be or is a problem with one of your vehicle’s functions. As you will • Clear away any ice, snow or leaves from the air see in the details on the next few pages, some inlets at the base of the windshield that may warning lights come on brieﬂy when you start the block the ﬂow of air into your vehicle.
Page 85: Instrument Panel Cluster
Instrument Panel Cluster Your instrument panel cluster is designed 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: Speedometer And Odometer
Speedometer and Odometer Engine Speed Limiting All engines have electronic engine speed limiting. The Your speedometer lets you see your speed in both engine limited speeds range between miles per hour (mph) and kilometers per hour (km/h). 2,900 and 4,400 rpm depending on engine option Your odometer shows how far your vehicle has content.
Page 87: Safety Belt Reminder Light
Tachometer Safety Belt Reminder Light When the key is turned to RUN or START, a light will come on for several seconds to remind people to fasten their safety belts. The safety belt light will also come on and stay on for several seconds.
Page 88: Charging System Light
Charging System Light Voltmeter Gage The charging system When your engine is indicator light may be running, the voltmeter located in the instrument gage, at the right side of panel cluster, or with the instrument panel the auxiliary warning lights cluster, shows the charging in the center of the system voltage.
Page 89: Range Inhibit Warning Indicator
Service Transmission Warning Light Notice: If the service transmission warning light comes on while you are driving, it is a warning that making a transmission “range” change could If your vehicle has an Allison automatic transmission, leave you stranded. The vehicle may not continue to certain transmission malfunctions will turn this light on.
Page 90: Brake System Warning Light
Brake System Warning Light If the amber service brakes soon warning light comes on, it means Your vehicle has either hydraulic or air brakes. Each there is something wrong system has different warning lights. in the brake system. Hydraulic Brake System Warning Lights Vehicles with hydraulic brake systems have two brake When this light comes on, you will also hear a warning...
Page 91 Air Brake System Warning Light CAUTION: Vehicles with air brake systems have one brake system warning light on the instrument panel. 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).
Page 92 Apply Park Brake Warning Light This light should also come on when you turn the ignition key to START. If it doesn’t come on then, have it ﬁxed so it will be ready to remind you if the parking This light warns the driver brake is applied or hasn’t released fully.
Page 93 Trailer Anti-Lock Brake System Warning Light Bulb Check Button Warning Light To test the operation of the check gages light, the If your vehicle is connected primary brake light and the to an anti-lock brake parking light, push this system equipped trailer, button located on the this light should come upper left portion of the...
Page 94: Engine Coolant Temperature Gage
Engine Coolant Temperature Gage 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.
Page 95: Wait To Start Indicator
Manual Fast Idle Indicator Light Wait to Start Indicator If your vehicle is equipped If your vehicle has this with an automatically feature, this light in the controlled diesel engine, center of the instrument you have this indicator panel will come on light.
Page 96 Malfunction Indicator Lamp Oil Pressure Gage Service Engine Soon Light If this light comes on or ﬂashes while you are driving, two things may happen. First, you won’t notice any difference in engine United States Canada performance, but your tail pipe emissions may increase. Second, your engine may not run properly or may The engine oil pressure gage, on the lower right portion stall without warning.
Page 97: Low Oil Level Light
® Low Oil Level Light If you have a Caterpillar diesel engine, also see your ® Caterpillar Operation & Maintenance Manual. This light should come on as a check, when you start CAUTION: your engine. If the light fails to come on, have it repaired as soon as Don’t keep driving if the oil pressure is low.
Page 98: Change Engine Oil Light
Change Engine Oil Light Glow Plugs Light This light on the instrument The change engine oil light panel will glow when the should come on brieﬂy as ignition is turned to H a bulb check when you (heat). See Starting Your start the engine.
Page 99: Exhaust Brake Indicator Light
Engine Shutdown Warning Light A reading in the warning zone, the red area beginning at 300°F (150°C), means you must stop driving and check into the cause. One possible cause is a low oil If your vehicle has the level in the transmission. engine shutdown feature, this light will come on Notice: If you drive when the transmission...
Page 100: Differential Lock Indicator Light
Differential Lock Indicator Light If 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 If your vehicle has this the vehicle is driven. The vehicle may be driven at a feature, this light is located reduced speed while the reduced engine power light is in the center of the...
Page 101: Low Washer Fluid Warning Light
Low Washer Fluid Warning Light 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. This light will come on when your vehicle is low Fuel Gage on windshield washer ﬂuid.
Page 102: Air Filter Restriction Indicator
Air Filter Restriction Indicator Here are four concerns of some operators. None of these shows a problem with your fuel gage: • The gage moves a little when you turn a corner or This optional gage is speed up. located above the switchbank in the center of •...
Page 103: Audio System(S)
Audio System(s) Your vehicle may have a feature called Retained Accessory Power (RAP). With RAP, you can play your audio system even after the ignition is turned off. Notice: Before you add any sound equipment to See “Retained Accessory Power (RAP)” under Ignition your vehicle –...
Page 104: Am-Fm Radio
AM-FM Radio Finding a Station AM FM: Press this button to switch the display between time and radio station frequency. Time display is available with the ignition turned off. TUNE: Turn this knob to tune in radio stations. SEEK : Press the right or the left arrow to seek to the next or to the previous station and stay there.
Page 105 Setting Preset Stations To adjust both tone controls and both speaker controls to the middle position, end out of audio by waiting The six numbered pushbuttons let you return to your for the display to change to the time display. Then press favorite stations.
Page 106: Radio With Cassette
Radio with Cassette 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.
Page 107 Finding a Station Setting Preset Stations The six numbered pushbuttons let you return to your AM FM: Press this button to switch between AM, FM1 favorite stations. You can set up to 18 stations and FM2. The display will show your selection. (six AM, six FM1 and six FM2) by performing the TUNE: Turn this knob to choose radio stations.
Page 108 Radio Messages 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 clock display. Then CAL (Calibration): Your audio system has been press and hold AUDIO for more than two seconds until calibrated for your vehicle from the factory.
Page 109 If an error appears on the display, see “Cassette Tape 3 REV (Reverse): Press this pushbutton to reverse the Messages” later in this section. tape rapidly. FR will appear on the display. Press it again to return to playing the tape. The radio will play 1 PREV (Previous): Your tape must have at least three while the tape reverses.
Page 110: Cd Adapter Kits
CLN (Clean): If this message appears on the display, SEEK : The right arrow is the same as the the cassette tape player needs to be cleaned. It will NEXT pushbutton, and the left arrow is the same as the still play tapes, but you should clean it as soon as PREV pushbutton.
Page 111: Radio With Cd
Radio with CD Finding a Station AM FM: Press this button to switch between AM, FM1 and FM2. The display will show your selection. TUNE: Turn this knob to choose radio stations. SEEK : Press the right or the left arrow to seek to the next or to the previous station and stay there.
Page 112 Setting Preset Stations To adjust both tone controls and both speaker controls to the middle position, end out of audio mode by The six numbered pushbuttons let you return to your waiting for the display to change to the time display. favorite stations.
Page 113: Playing A Compact Disc
Radio Messages Do not add paper labels to discs, they could get caught in the CD player. CAL (Calibrated): Your audio system has been Do not play 3 inch discs without a standard calibrated for your vehicle from the factory. If CAL adapter disc.
Page 114: Compact Disc Messages
Compact Disc Messages 5 RDM (Random): Press this pushbutton to hear the tracks in random, rather than sequential, order. RND will If the disc comes out, it could be for one of the following appear on the display. Press this pushbutton again to reasons: turn off random play.
Page 115: Theft-Deterrent Feature (Non-Rds Radios)
Theft-Deterrent Feature Care of Your Cassette Tape Player (Non-RDS Radios) A tape player that is not cleaned regularly can cause reduced sound quality, ruined cassettes or a damaged ® THEFTLOCK is designed to discourage theft of your mechanism. Cassette tapes should be stored in their radio.
Page 116 The cut tape detection feature of your cassette tape You may also choose a non-scrubbing action, wet-type player may identify the cleaning cassette as a damaged cleaner which uses a cassette with a fabric belt to tape. To prevent the cleaning cassette from being clean the tape head.
Page 117: Care Of Your Cds
Care of Your CDs Chime Level Adjustment Handle discs carefully. Store them in their original cases The radio is the vehicle chime producer. The chime is or other protective cases and away from direct sunlight produced from the driver’s side front door speakers. and dust.
Page 118 NOTES 3-54...
Page 119: Driving Your Vehicle
Section 4 Driving Your Vehicle Your Driving, the Road, and Your Vehicle ..4-2 Driving in Rain and on Wet Roads ....4-18 Defensive Driving ...........4-2 City Driving ..........4-21 Drunken Driving ..........4-2 Freeway Driving ...........4-22 Control of a Vehicle ........4-5 Highway Hypnosis ........4-23 Braking ............4-6 Hill and Mountain Roads ........4-24 Trailer Brake Hand Control Valve ......4-9...
Page 120: Your Driving, The Road, And Your Vehicle
Your Driving, the Road, and and can even cause a collision, with resulting injury. Ask a passenger to help do things like this, or pull off the Your Vehicle road in a safe place to do them yourself. These simple defensive driving techniques could save your life.
Page 121 Many adults — by some estimates, nearly half the adult same BAC by drinking three 4 ounce (120 ml) glasses population — choose never to drink alcohol, so they of wine or three mixed drinks if each had 1-1/2 ounces never drive after drinking.
Page 122 There is a gender difference, too. Women generally Statistics show that the chance of being in a collision have a lower relative percentage of body water increases sharply for drivers who have a BAC of than men. Since alcohol is carried in body water, this 0.05 percent or above.
Page 123: Control Of A Vehicle
CAUTION: Drinking and then driving is very dangerous. Your reﬂexes, perceptions, attentiveness and judgment can be affected by even a small amount of alcohol. You can have a serious — or even fatal — collision if you drive after drinking. Please don’t drink and drive or ride with a driver who has been drinking.
Page 124: Braking
Braking with the traffic and allow realistic following distances, you will eliminate a lot of unnecessary braking. That means better braking and longer brake life. Braking action involves perception time and reaction time. If your engine ever stops while you’re driving, brake normally but don’t pump your brakes.
Page 125 Anti-lock Brake System (ABS) Your vehicle has anti-lock brakes. ABS is an advanced electronic braking system that will help prevent a braking skid. When you start your engine and begin to drive away, your anti-lock brake system will check itself. You may hear a momentary motor or clicking noise while this test is going on.
Page 126: Braking In Emergencies
The anti-lock system can change the brake pressure Remember: Anti-lock doesn’t change the time you need faster than any driver could. The computer is to get your foot up to the brake pedal or always programmed to make the most of available tire and road decrease stopping distance.
Page 127: Trailer Brake Hand Control Valve
Trailer Brake Hand Control Valve CAUTION: If your vehicle has this control, it is mounted on the console to the right of the driver’s seat. Using the trailer brake hand control for parking This control lets you apply or for holding the vehicle on a hill may not the trailer brakes without keep the vehicle from rolling.
Page 128: Inter-Axle Differential Lock Control
Inter-Axle Differential Lock Control Let up on the accelerator before you turn on your inter-axle differential lock. When you turn on this control, the diff lock indicator on the center of the instrument If your vehicle has this panel will light. feature, the switch is located in the center of the Notice: Activating the inter-axle differential lock...
Page 129 The TCS may operate on dry roads under some To turn the system on or conditions. When this happens, you may notice a off, press the traction reduction in acceleration. This is normal and doesn’t control button located in mean there’s a problem with your vehicle. Examples of the instrument panel these conditions include a hard acceleration in a switchbank.
Page 130: Steering
Steering The traction you can get in a curve depends on the condition of your tires and the road surface, the angle at which the curve is banked, and your speed. While Power Steering you’re in a curve, speed is the one factor you can control.
Page 131: Steering In Emergencies
Steering in Emergencies There are times when steering can be more effective than braking. For example, you come over a hill and ﬁnd a truck stopped in your lane, or a car suddenly pulls out from nowhere, or a child darts out from between parked cars and stops right in front of you.
Page 132: Off-Road Recovery
Off-Road Recovery Passing You may ﬁnd that your right wheels have dropped off The driver of a vehicle about to pass another on a the edge of a road onto the shoulder while you’re two-lane highway waits for just the right moment, driving.
Page 133 • • Watch for traffic signs, pavement markings and If other cars are lined up to pass a slow vehicle, lines. If you can see a sign up ahead that might wait your turn. But take care that someone isn’t indicate a turn or an intersection, delay your pass.
Page 134: Loss Of Control
Loss of Control If you have the Traction Control System, remember: It helps avoid only the acceleration skid. If you do not have this system, or if the system is off, then an acceleration Let’s review what driving experts say about what skid is also best handled by easing your foot off the happens when the three control systems (brakes, accelerator pedal.
Page 135: Driving At Night
Driving at Night Here are some tips on night driving. • Drive defensively. • Don’t drink and drive. • Since you can’t see as well, you may need to slow down and keep more space between you and other vehicles. •...
Page 136: Driving In Rain And On Wet Roads
Driving in Rain and on Wet Roads What you do in the daytime can also affect your night vision. For example, if you spend the day in bright sunshine you are wise to wear sunglasses. Your eyes will have less trouble adjusting to night. But if you’re driving, don’t wear sunglasses at night.
Page 137 The heavier the rain, the harder it is to see. Even if your Driving too fast through large water puddles or even windshield wiper blades are in good shape, a heavy going through some vehicle washes can cause rain can make it harder to see road signs and problems, too.
Page 138: Driving Through Flowing Water
Hydroplaning Driving Through Flowing Water Hydroplaning is dangerous. So much water can build up CAUTION: under your tires that they can actually ride on the water. This can happen if the road is wet enough and you’re going fast enough. When your vehicle is Flowing or rushing water creates strong forces.
Page 139: City Driving
City Driving Here are ways to increase your safety in city driving: • Know the best way to get to where you are going. Get a city map and plan your trip into an unknown part of the city just as you would for a cross-country trip.
Page 140: Freeway Driving
Freeway Driving The most important advice on freeway driving is: Keep up with traffic and keep to the right. Drive at the same speed most of the other drivers are driving. Too-fast or too-slow driving breaks a smooth traffic ﬂow. Treat the left lane on a freeway as a passing lane.
Page 141: Highway Hypnosis
Once you are moving on the freeway, make certain you When you drive the vehicle for a long distance, there is allow a reasonable following distance. Expect to something about an easy stretch of road with the move slightly slower at night. same scenery, along with the hum of the tires on the road, the drone of the engine, and the rush of the wind When you want to leave the freeway, move to the...
Page 142: Hill And Mountain Roads
Hill and Mountain Roads Here are some tips that can make your drive through steep country safer: • Keep the vehicle in good shape. Check all ﬂuid levels and also the brakes, tires, cooling system and transmission. These parts can work hard on mountain roads.
Page 143 • Know how to go uphill. Use lower gears. They help cool your engine and transmission, and you can CAUTION: climb the hill better. • Stay in your own lane when driving on two-lane Coasting downhill in NEUTRAL (N) or with the roads in hills or mountains.
Page 144: Winter Driving
Winter Driving Include an ice scraper, a small brush or broom, a supply of windshield washer ﬂuid, a rag, some winter outer clothing, a small shovel, a ﬂashlight, a red cloth and reﬂective 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.
Page 145 Whatever the condition – smooth ice, packed, blowing or loose snow – drive with caution. If you have traction control, keep the system on. It will improve your ability to accelerate when driving on a slippery road. But you can turn the traction system off if you ever need to.
Page 146 If You’re Caught in a Blizzard Remember, unless you have anti-lock, if you brake so hard that your wheels stop rolling, you’ll just slide. Brake so your wheels always keep rolling and you can still steer. • Whatever your braking system, allow greater following distance on any slippery road.
Page 147 • Put on extra clothing or wrap a blanket around you. If you have no blankets or extra clothing, make CAUTION: body insulators from newspapers, burlap bags, rags, ﬂoor mats – anything you can wrap around yourself or tuck under your clothing to keep warm. Snow can trap exhaust gases under your vehicle.
Page 148: If You Are Stuck: In Sand, Mud, Ice Or Snow
If you have a diesel engine, you may have to run it at a higher speed to get enough heat. CAUTION: Then, shut the engine off and close the window almost all the way to preserve the heat. Start the engine If you let your tires spin at high speed, they again and repeat this only when you feel really can explode, and you or others could be...
Page 149: Rocking Your Vehicle To Get It Out
Rocking Your Vehicle To Get It Out Using the Tow Hooks (Option) First, turn your steering wheel left and right. That will If your vehicle is equipped with tow hooks, the hooks clear the area around your front wheels. If your vehicle are provided at the front of your vehicle.
Page 150: Towing
Towing CAUTION: (Continued) Towing Your Vehicle • When the brake springs are manually compressed, you will have no brakes. Release your air-operated parking brakes CAUTION: manually only to tow the vehicle. Never drive the vehicle with the brakes released. To help avoid serious personal injury to you or others: Consult your dealer or a professional towing service if •...
Page 151 Here are speciﬁc towing instructions: Towing Your Vehicle From the Front (Front Wheels Off the Ground) Before Towing Block the rear wheels of the disabled vehicle. On vehicles with air brakes, release the emergency brake system by compressing the brake chamber springs as outlined in this section.
Page 152 After Towing On vehicles with hydraulic brakes, release the parking brake fully by moving the lever to the fully-released 1. Block the rear wheels and install the axle and position. propshafts. If there is damage or suspected damage to the axle(s), 2.
Page 153 After Towing 1. Block the rear wheels and release the steering wheel. 2. Apply the parking brake system before disconnecting from the towing vehicle. 3. Check and ﬁll the rear axle with oil as required. Releasing Air-Operated Parking Brakes If your vehicle has air brakes, you could have a special towing problem.
Page 154 3. Remove the rubber 6. Turn the stud nut cap from the rear of clockwise several turns the chamber. to release the brakes. Follow the same procedure to release the other brake. 4. Put the release stud, nut and ﬂat washer into the 7.
Page 155: Loading Your Vehicle
Loading Your Vehicle out the actual loads on your front and rear axles, you need to go to a weigh station and weigh your vehicle. Your dealer can help you with this. Be sure to spread out There is a GVW Rating label on your vehicle that shows your load equally on both sides of the center line.
Page 156: Trailer Connections
Trailer Connections If you put things inside your vehicle – like suitcases, tools, packages or anything else – they will go as fast as the vehicle goes. If you have to stop or turn quickly, Heavy-Duty Trailer Wiring Package or if there is a crash, they’ll keep going. Your vehicle may be equipped with an eight-wire trailer towing harness.
Page 157 Section 5 Service and Appearance Care Service ............5-3 Battery ............5-37 Doing Your Own Service Work ......5-3 Jump Starting ..........5-37 Two Safety Cautions about Engine Fan Rear Axle ............5-43 Breakage ...........5-4 Rear Axle Shift Motor ........5-43 Fuel ..............5-5 Cab Tilting .............5-44 Diesel Engine Fuel .........5-5 Before You Tilt the Cab .........5-44 What Fuel to Use ...........5-5...
Page 158 Section 5 Service and Appearance Care Appearance Care ..........5-60 Electrical System ..........5-67 Cleaning the Inside of Your Vehicle ....5-60 Add-On Electrical Equipment ......5-67 Care of Safety Belts ........5-62 Headlamp Wiring ..........5-67 Weatherstrips ..........5-63 Windshield Wiper Fuses ........5-68 Cleaning the Outside of Your Vehicle ....5-63 Fusible Links ..........5-68 Sheet Metal Damage ........5-65 Power Windows and Other Power Options ..5-68...
Page 159: Service
Service Doing Your Own Service Work If you want to do some of your own service work, you’ll Your dealer knows your vehicle best and wants you to want to use the proper service manual. It tells you be happy with it. We hope you’ll go to your dealer much more about how to service your vehicle than this for all your service needs.
Page 160: Two Safety Cautions About Engine Fan Breakage
Two Safety Cautions about Engine CAUTION: (Continued) Fan Breakage Winter Fronts, Grille Covers or Obstructions CAUTION: Winter Fronts, grille covers or other add-on equipment causing obstructions in front or behind the fan should not be used on Changing the Fan Drive Ratio or Engine thisvehicle.
Page 161: Fuel
Fuel What Fuel to Use In the United States, for best results use Number 2–D Diesel Engine Fuel diesel fuel year-round (above and below freezing conditions) as oil companies blend Number 2–D fuel to address climate differences. Number 1–D diesel fuel Notice: Diesel fuel or fuel additives not may be used in very cold temperatures (when it recommended in this manual could damage your...
Page 162 It is acceptable to use diesel fuel containing up to 5% Diesel fuel may foam when you ﬁll your tank. This can biodiesel (B5), but the ﬁnal blended fuel must meet cause the automatic pump nozzle to shut off, even the same speciﬁcation, ASTM D975–02 (Grade though your tank is not full.
Page 163: Very Cold Weather Operation
What Fuel to Use in Canada It is acceptable to use diesel fuel containing up to 5% biodiesel (B5), but the ﬁnal blended fuel must meet Canadian fuels are blended for seasonal changes. the same speciﬁcation, CAN/CGSB—3.517–2000 (Low Diesel Type “A” fuel is blended for better cold weather Sulfur Diesel) in Canada, as other fuels used in your starting (below 0°F or −18°C);...
Page 164: Running Out Of Fuel
Running Out of Fuel Filling Your Tank If the engine stalls and you think that you’ve run out of fuel, do this: CAUTION: CAUTION: Fuel vapor is highly ﬂammable. It burns violently, and that can cause very bad injuries. Don’t smoke if you’re near fuel or refueling Diesel fuel is ﬂammable.
Page 165: Filling A Portable Fuel Container
Filling a Portable Fuel Container CAUTION: CAUTION: If you get fuel on yourself and then something ignites it, you could be badly burned. Fuel can Never ﬁll a portable fuel container while it is in spray out on you if you open the fuel cap too your vehicle.
Page 166: Checking Things Under The Hood
Checking Things Under the Turn off the engine and give the oil at least ﬁve minutes to drain back into the oil pan. With a cool engine, Hood allow 30 minutes. If you don’t, the oil dipstick might not show the actual level. Pull out the dipstick and clean it with a paper towel or a Engine Oil (DURAMAX™...
Page 167: When To Add Engine Oil
When to Add Engine Oil What Kind of Engine Oil to Use If the oil is at or below the ADD line, then you’ll need to Look for these two things: add at least one quart of oil. But you must use the •...
Page 168 • SAE 15W-40 As shown in the viscosity chart, SAE 15W-40 is best for your vehicle. However, you can use SAE 10W-30 at temperatures above 0°F (−18°C). When it’s very cold, below 0°F (−18°C), you should use SAE 5W-40 to improve cold starting. These numbers on the oil container show its viscosity, or thickness.
Page 169: Engine Air Cleaner/Filter
Engine Oil Additives Engine Air Cleaner/Filter Don’t add anything to your oil. The recommended oils The engine air cleaner/ﬁlter with the API service symbol are all you will need is located in the center of for good performance and engine protection. the engine compartment.
Page 170 If equipped, the restriction indicator will be located in CAUTION: the engine compartment near the engine air cleaner/ﬁlter, on the Operating the engine with the air cleaner/ﬁlter passenger’s side of the off can cause you or others to be burned. The vehicle.
Page 171: Automatic Transmission Fluid
Automatic Transmission Fluid When to Check A good time to have it checked is when the engine oil is When to Check checked. See your Maintenance Schedule to ﬁnd out A good time to have it checked is when the engine oil is when to change your transmission ﬂuid.
Page 172: Hydraulic Clutch
How to Add Fluid When to Check and What to Use Here’s how to add ﬂuid. Refer to the Maintenance The hydraulic clutch ﬂuid Schedule to determine the proper ﬂuid to use. See reservoir is located behind Part C: Recommended Fluids and Lubricants on the front panel on the page 6-27 .
Page 173: Engine Coolant
Engine Coolant • Help keep the proper engine temperature. • Let the warning lights and gages work as they The cooling system in your vehicle is ﬁlled with should. ® DEX-COOL engine coolant. This coolant is designed to remain in your vehicle for 5 years or 150,000 miles Notice: When adding coolant, it is important that (240 000 km), whichever occurs ﬁrst, if you add ®...
Page 174 What to Use Notice: If you use an improper coolant mixture, your engine could overheat and be badly damaged. Use a mixture of one-half clean, drinkable water and The repair cost wouldn’t be covered by your ® one-half DEX-COOL coolant which won’t damage warranty.
Page 175: Checking Coolant
Checking Coolant CAUTION: Turning the surge tank pressure cap when the engine and radiator are hot can allow steam and scalding liquids to blow out and burn you badly. Never turn the surge tank pressure cap — even a little — when the engine and radiator are hot.
Page 176: Coolant Surge Tank Pressure Cap
Adding Coolant Coolant Surge Tank Pressure Cap ® If you need more coolant, add the proper DEX-COOL The surge tank pressure coolant mixture at the surge tank , but only when the cap is located in the engine is cool. engine compartment, on the driver’s side of the vehicle.
Page 177: If Steam Is Coming From Your Engine
If Steam Is Coming From Your Engine CAUTION: (Continued) down. Wait until there is no sign of steam or coolant before you open the hood. If you keep driving when your engine is overheated, the liquids in it can catch ﬁre. You or others could be badly burned.
Page 178: Cooling System
Cooling System If you get the overheat warning with no sign of steam, try this for a minute or so: When you decide it’s safe to lift the hood, here’s what 1. In heavy traffic, let the engine idle in neutral while you’ll see: stopped.
Page 179 The coolant level should If there seems to be no leak, start the engine again. be at COLD FILL or The engine cooling fan speed should increase when idle higher. If it isn’t, you may speed is doubled by pushing the accelerator pedal have a leak at the down.
Page 180: How To Add Coolant To The Coolant Surge Tank
How to Add Coolant to the Coolant Surge Tank If you haven’t found a problem yet, check to see if coolant is visible in the surge tank. If coolant is visible but the coolant level isn’t at COLD FILL or higher, add a ®...
Page 181 CAUTION: CAUTION: Adding only plain water to your cooling You can be burned if you spill coolant on hot system can be dangerous. Plain water, or engine parts. Coolant contains ethylene glycol some other liquid such as alcohol, can boil and it will burn if the engine parts are hot before the proper coolant mixture will.
Page 182 3. Then ﬁll the coolant surge tank with the proper 4. With the coolant surge tank pressure cap off, start mixture, to the FULL mark. the engine and let it run until you can feel the upper radiator hose getting hot. Watch out for the engine cooling fan.
Page 183: Power Steering Fluid
5. Then replace the If the ﬂuid level is between pressure cap. Be sure the MIN and MAX marks, the pressure cap is you have enough. If hand-tight and you need ﬂuid, add only fully seated. enough of the proper ﬂuid to bring it into view in the sight glass.
Page 184: Windshield Washer Fluid
Windshield Washer Fluid Open the cap with the washer symbol on it. Add washer ﬂuid until the tank is full. What to Use Notice: When you need windshield washer ﬂuid, be sure to read the manufacturer’s instructions before use. If you will •...
Page 185: Brakes
Brakes CAUTION: Brake Fluid 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.
Page 186: Checking Brake Fluid
Checking Brake Fluid CAUTION: Apply the brake pedal several times with the ignition off. Then clean one of the reservoir caps and the area around the cap, and remove it. The ﬂuid level should be With the wrong kind of ﬂuid in your brake even with the bottom ring of the ﬁller opening.
Page 187: Replacing Brake System Parts
Four-Wheel Drum Brakes (Air Only) Replacing Brake System Parts The brake drums should be removed and inspected The braking system on a vehicle is complex. Its many each time the tires are removed for rotation or changing. parts have to be of top quality and work well together if When you have the front brakes replaced, have the the vehicle is to have really good braking.
Page 188: Air Dryer
Moisture Ejector Electric Air Compressor If you have air brakes with a moisture ejector, the valve Your vehicle may have an electric air compressor. This automatically ejects moisture from the reserve tank compressor is used to run options that require when the air compressor cycles.
Page 189: How To Check And Add Fluid
Clutch Pedal Free Travel If you have a manual transmission, your clutch will need adjustment when pedal free travel gets down to about 1/4 inch (32 mm), as measured at the clutch pedal pad. You should have 1 1/2 to 2 inches (38 to 51 mm) of clutch pedal free travel.
Page 190 Chassis Lubrication 5-34...
Page 191 Item Number Item Remarks Brake Camshaft*** One ﬁtting each (apply sparingly). Brake Caliper Rails$ For caliper rails, apply Aero Shell #5 Lubricant. Steering Column Slip Joint** One ﬁtting. Steering Drag Link Ends One ﬁtting each end. Steering Column U-Joints One ﬁtting each joint. Pivot Points and Hinges Apply chassis lubricant.
Page 192 Item Number Item Remarks Transmission-Automatic*,**,† Check ﬂuid level. One ﬁtting each joint; lubricate with GM Part Propshaft Slip Joints No. 1051344 Wheel Bearing Lubricant. One ﬁtting each joint (1480 and 1550 Series); lubricate with GM part NO. 1051344 Wheel Bearing Propshaft U-joints Lubricant.
Page 193: Battery
Battery When you are ready to use the vehicle again, refer to the engine starting procedure in the Index. Your new vehicle comes with one or more maintenance Contact your dealer to learn how to prepare your ® free ACDelco batteries.
Page 194 Notice: Ignoring these steps could result in costly To avoid the possibility of the vehicles rolling, set damage to your vehicle that wouldn’t be covered the parking brake ﬁrmly on both vehicles involved in by your warranty. the jump start procedure. Put an automatic transmission in PARK (P) or a manual transmission Trying to start your vehicle by pushing or pulling it in neutral before setting the parking brake.
Page 195 Open the hood of your vehicle and ﬁnd the remote CAUTION: positive (+) terminal, located under a red plastic cover on the passenger’s Using a match near a battery can cause battery side of the vehicle. gas to explode. People have been hurt doing this, and some have been blinded.
Page 196 5. Check that the jumper cables don’t have loose or 7. Don’t let the other end missing insulation. If they do, you could get a touch metal. Connect it shock. The vehicles could be damaged, too. to the positive (+) terminal of the good Before you connect the cables, here are some battery.
Page 197 Don’t let the other end touch anything until the next 10. Now start the vehicle with the good battery and run step. The other end of the negative (−) cable the engine for one or two minutes. If your vehicle doesn’t go to the dead battery.
Page 198 To disconnect the jumper cables from both 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.
Page 199: Rear Axle
Rear Axle What to Use Refer to the Maintenance Schedule to determine what When to Check and Change Lubricant kind of lubricant to use. See Part C: Recommended Fluids and Lubricants on page 6-27 . Refer to the Maintenance Schedule to determine how often to check the lubricant and when to change it.
Page 200: Cab Tilting
Cab Tilting Tilting the Cab To tilt the cab, do the following: Before You Tilt the Cab 1. Locate the lever pin at the rear of the cab, on the passenger’s side. Most ﬂuids and lubricants requiring regular checking can 2.
Page 201 3. Move the primary tilt lever all the way down. 5. Using the handle located at the bottom of the cab at the back, tilt the cab forward. 4. Pull the secondary latch lever to release the hook from the catch at the back of the cab.
Page 202 6. Tilt the cab all the way forward until the cab CAUTION: support under the cab locks fully. A. Safety Lock Pin A cab not properly locked in the tilted position could fall, causing serious injury. To ensure B. Cab Support 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)
Page 203: Lowering The Cab
Lowering the Cab 2. Squeeze the lever on the cap support to release the detent. When the cab is ready to be lowered, follow the instructions below carefully. Before lowering the cab, be sure all ﬁller caps ar on properly. 1.
Page 204 5. Reinstall the pin and turn it to keep the primary tilt lever from moving downward. CAUTION: 3. Using the handle located at the bottom of the cab toward the back, lower the cab until the hook catches and the cab is held down. An unsecured cab could move suddenly 4.
Page 205: Lifting The Front Panel
Lifting the Front Panel 2. Then go to the front of the vehicle and lift the panel at the center. To access the windshield washer ﬂuid reservoir and the Use the prop rod clutch ﬂuid reservoir, the front panel must be lifted. to hold the panel open.
Page 206: Noise Control System
Noise Control System 2. The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. Tampering with Noise Control Among those acts presumed to constitute tampering are the acts listed below. System Prohibited Insulation: The following information relates to compliance with...
Page 207: Windshield Wiper Blade Replacement
Windshield Wiper Blade Replacement Windshield wiper blades should be inspected at least twice a year for wear or cracking. See Wiper Blade Check under At Least Twice a Year on page 6-22 for more information. Replacement blades come in different types and are removed in different ways.
Page 208: Tires
Underinﬂated tires pose the same danger about your tire warranty and where to obtain service, as overloaded tires. The resulting accident see your GMC Warranty booklet for details. could cause serious injury. Check all tires frequently to maintain the recommended pressure.
Page 209: Inﬂation -- Tire Pressure
Inﬂation -- Tire Pressure When to Check Check your tires once a month or more. The GVW Rating label, which is on the driver’s door frame, shows the correct inﬂation pressures for Also, check the tire pressure of the spare tire your tires when they’re cold.
Page 210: Dual Tire Operation
Dual Tire Operation When It Is Time for New Tires Replace your tires when the tread depth is down to When the vehicle is new, check the wheel nut tightness 1/8 of an inch (3.2 mm) for the front tires, or 1/16 of an on all wheels with a torque wrench after your ﬁrst inch (1.6 mm) for a rear tire.
Page 211: Wheel Alignment And Tire Balance
Wheel Alignment and Tire Balance First, use these pictures to decide what kind of wheels you have. The wheels on your vehicle were aligned at the factory to give you the longest tire life and best overall performance. Proper front wheel alignment must be maintained in order to ensure efficient steering, good directional stability, and prevent abnormal tire wear.
Page 212 3. Put on the wheel nuts. 4. Finger-tighten the nuts. 5. Oil the surfaces between the nuts and washers. Do not oil the studs or the threads of the nut. 8-Hole 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.
Page 213 CAUTION: (Continued) CAUTION: piloted wheels for damage. Because of loose Never use oil or grease on studs or the running wheels, piloting pad damage may threads of the wheel nuts. If you do, the wheel occur and require replacement of the entire nuts might come loose and the wheel could hub, for proper centering of the wheels.
Page 214: Wheel Replacement
How Often to Check CAUTION: Wheel tightness is so important you should have a technician check nut tightness on all wheels with a torque wrench after your ﬁrst 100 miles (160 km), and A leaking wheel could fail without warning. A then 1,000 miles (1 600 km) after that.
Page 215: If A Tire Goes Flat
If a Tire Goes Flat Using wheels and tires with higher load-carrying limits than the original wheels and tires doesn’t change the GAWR or the GVWR of your vehicle. See “Loading It’s unusual for a tire to “blow out” while you’re driving, Your Vehicle”...
Page 216: Appearance Care
Appearance Care Don’t use any of these unless this manual says you can. In many uses, these will damage your vehicle: Remember, cleaning products can be hazardous. Some • Alcohol are toxic. Others can burst into ﬂames if you strike a •...
Page 217: Special Fabric Cleaning Problems
Special Fabric Cleaning Problems Here are some cleaning tips: • Always read the instructions on the cleaner label. Stains caused by such things as catsup, coffee (black), • Clean up stains as soon as you can – before egg, fruit, fruit juice, milk, soft drinks, vomit, urine they set.
Page 218: Cleaning Vinyl
Cleaning Vinyl Cleaning Glass Surfaces Use warm water and a clean cloth. Glass should be cleaned often. GM Glass Cleaner or a liquid household glass cleaner will remove normal • Rub with a clean, damp cloth to remove dirt. You tobacco smoke and dust ﬁlms on interior glass.
Page 219: Weatherstrips
Weatherstrips 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 Silicone grease on weatherstrips will make them last scratches and water spotting.
Page 220: Windshield And Wiper Blades
Windshield and Wiper Blades Foreign materials such as calcium chloride and other salts, ice melting agents, road oil and tar, tree sap, bird If the windshield is not clear after using the windshield droppings, chemicals from industrial chimneys, etc., washer, or if the wiper blade chatters when running, can damage your vehicle’s ﬁnish if they remain wax, sap or other material may be on the blade or on painted surfaces.
Page 221: Sheet Metal Damage
Finish Damage The surface of these wheels is similar to the painted surface of your vehicle. Don’t use strong soaps, chemicals, abrasive polishes, abrasive cleaners, Any stone chips, fractures or deep scratches in the cleaners with acid, or abrasive cleaning brushes on ﬁnish should be repaired right away.
Page 222: Vehicle Care/Appearance Materials
Vehicle Care/Appearance Materials Vehicle Care/Appearance Materials (cont’d) See your GM dealer for more information on purchasing Description Usage the following products. Removes swirl marks, ﬁne Swirl Remover Polish scratches and other light Vehicle Care/Appearance Materials surface contamination. Description Usage Removes light scratches and Cleaner Wax protects ﬁnish.
Page 223: Vehicle Identiﬁcation
Vehicle Identiﬁcation Electrical System Vehicle Identiﬁcation Number (VIN) 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.
Page 224: Windshield Wiper Fuses
Windshield Wiper Fuses Power Windows and Other Power Options The windshield wiper motor is protected by a circuit breaker inside the motor and a circuit breaker or fuse in Circuit breakers in the fuse panel protect the power the fuse block. If the motor overheats, the wipers will windows and other power accessories.
Page 225 Instrument Panel Fuse Block and To access the fuse block, remove the cover by lifting up on the front and turning it backward. Maxi-Fuse Block To reinstall the cover, put the tabs at the rear of the There are two fuse blocks in your vehicle: the instrument cover into the slots on the instrument panel and lower panel fuse block and the maxi-fuse block.
Page 226 Fuses Usage Room Lamp, Horn, Electric Parking Brake, Radio Back Up, Rear Body Dome Lamp Power Window Exhaust Brake Back Up, Air Suspension Dump, Differential Lock, Air Dryer, Moisture Ejection Heater, Electric Air Compressor, Power Take Off ECM Ignition Power Trailer Turn (LH) Lamp Auxiliary (Ignition ON) Fuses...
Page 227 Do not use maxi-fuses of higher amperage than those Fuses Usage indicated on the maxi-fuse block. Cool Condenser Fan Motor, Cooler Compressor Fuses Usage Wiper Motor, Washer Motor ST/TURN/HAZ Stoplamp, Turn Signals/Hazard Warning Flashers Heated Mirror, Two-Speed Axle IGN SW 3 Air Conditioner, Axle, Chassis Relay INT/EXT...
Page 228 Relay Blocks Relay Block A Relay Block A Usage Power Window Back Lamp (Reverse) High Beam There are three relay blocks in your vehicle: Lighting A. Relay Block A Lighting (Low, High) B. Relay Block B Trailer Turn Signal (Left Headlamp) C.
Page 229 Relay Block B Usage Exhaust Brake Power Take Off Control Relay Block B Relay Block B Usage Air Conditioning Condenser Relay Block C Air Conditioning Compressor Heater Fan Relay Block C Usage Ignition Accessory Parking Brake Ignition 1 Daytime Running Lamps On Ignition 2 Daytime Running Lamp Off Auxiliary...
Page 230: Capacities And Speciﬁcations
Capacities and Speciﬁcations Engine Speciﬁcations Engine Type Firing Order 7.8L 1–5–3–6–2–4 Capacities and Speciﬁcations Capacities Application 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: Fuel Tank Capacity
Crankcase Capacity Capacity Application Capacity w/o ﬁlter Capacity w/ ﬁlter 14.0 quarts 7.8L 11.0 quarts (10.4 liters) (13.2 liters) Capacities (volumes) shown are for normal reﬁll. 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.
Page 232 Transmission Fluid Capacity Capacities Application English Metric Manual Transmission RT8709B 25.1 pints 11.8 liters FS5406 18.4 pints 8.7 liters FS6406 18.4 pints 8.7 liters Automatic Transmission 2000 Series 35.0 pints 13.5 liters* 2400 Series 35.0 pints 13.5 liters* MD 3060 P 52.0 pints 24.6 liters MD 3560 P...
Page 233 Rear Axle Lubricant Capacity Capacities Application 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...
Page 234: Normal Maintenance Replacement Parts
Normal Maintenance Replacement Parts Service Replacement Part and Filter Recommendations 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.
Page 235 Section 6 Maintenance Schedule Maintenance Schedule ........6-2 Scheduled Maintenance ........6-5 Introduction ...........6-2 Part B: Owner Checks and Services ....6-22 Your Vehicle and the Environment ....6-2 At Each Fuel Fill ..........6-22 Maintenance Requirements ......6-2 At Least Twice a Year ........6-22 How This Section is Organized ......6-3 At Least Once a Year ........6-26 Part A: Scheduled Maintenance Services ...6-4 Part C: Recommended Fluids and Lubricants ..6-27...
Page 236: Maintenance Schedule
Maintenance Schedule Your Vehicle and the Environment Proper vehicle maintenance not only helps to keep your Introduction vehicle in good working condition, but also helps the environment. Improper vehicle maintenance can Important: Keep engine oil at the proper level and even affect the quality of the air we breathe.
Page 237: How This Section Is Organized
How This Section is Organized “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. This maintenance schedule is divided into four parts: “Part C: Recommended Fluids and Lubricants”: Part A: Scheduled Maintenance Services”: explains lists some recommended products necessary to...
Page 238: Part A: Scheduled Maintenance Services
Part A: Scheduled Maintenance The proper ﬂuids and lubricants to use are listed in Part C. Make sure whoever services your vehicle uses Services these. All parts should be replaced and all necessary repairs done before you or anyone else drives the In this part are scheduled maintenance services which vehicle.
Page 239: Scheduled Maintenance
Scheduled Maintenance Wheels and tires service. (15) Hydraulic brake service (or every 6 months, The services shown in this schedule up to 100,000 miles whichever occurs ﬁrst). (7) (46) (166 000 km) should be repeated after 100,000 miles Parking brake service (or every 6 months, whichever (166 000 km) at the same intervals for the life of occurs ﬁrst).
Page 240 15,000 Miles (24 000 km) Air brake service (or every 6 months, whichever occurs ﬁrst). (39) Inspect engine air cleaner ﬁlter change indicator. If Air brake automatic slack adjuster service (or every necessary, replace the ﬁlter. If vehicle is driven in 500 hours, whichever occurs ﬁrst).
Page 241 22,500 Miles (36 000 km) Parking brake service (or every 6 months, whichever occurs ﬁrst). (8) Check ﬂuid levels (or every 3 months, whichever Air brake service (or every 6 months, whichever occurs ﬁrst). (1) (6) occurs ﬁrst). (39) Chassis lubrication service (or every 6 months, Air brake automatic slack adjuster service (or every whichever occurs ﬁrst).
Page 242 30,000 Miles (48 000 km) Hydraulic brake service (or every 6 months, whichever occurs ﬁrst). (7) (46) Change engine oil and ﬁlter (or every 12 months, Parking brake service (or every 6 months, whichever whichever occurs ﬁrst). (2) (3) occurs ﬁrst). (8) Inspect engine air cleaner ﬁlter change indicator.
Page 243 37,500 Miles (60 000 km) 40,000 Miles (64 000 km) Check ﬂuid levels (or every 3 months, whichever Change engine oil and ﬁlter (or every 12 months, occurs ﬁrst). (1) (6) whichever occurs ﬁrst). (2) (3) Chassis lubrication service (or every 6 months, Air compressor dry element pleated paper air strainer whichever occurs ﬁrst).
Page 244 Wheel bearing (grease type) service (or every 24 Clean air brake application valve (or every 3 months, months, whichever occurs ﬁrst, and whenever or every 300 hours, whichever occurs ﬁrst). Lubricate hubs are removed.) (23) (46) linkage. Inspect door hinge pins and bushings and replace as Air brake chamber service (or every 2 months, necessary.
Page 245 52,500 Miles (84 000 km) 60,000 Miles (96 000 km) Check ﬂuid levels (or every 3 months, whichever Change engine oil and ﬁlter (or every 12 months, occurs ﬁrst). (1) (6) whichever occurs ﬁrst). (2) (3) Chassis lubrication service (or every 6 months, Inspect engine air cleaner ﬁlter change indicator.
Page 246 67,500 Miles (108 000 km) Air brake service (or every 6 months, whichever occurs ﬁrst). (39) Check ﬂuid levels (or every 3 months, whichever Air brake automatic slack adjuster service (or every occurs ﬁrst). (1) (6) 500 hours, whichever occurs ﬁrst). (40) Chassis lubrication service (or every 6 months, Check air brake relay valve operation and check for whichever occurs ﬁrst).
Page 247 Check air brake relay valve operation and check for Check ﬂuid levels (or every 3 months, whichever leaks (or every month, or every 300 hours, whichever occurs ﬁrst). (1) (6) occurs ﬁrst). Replace fuel ﬁlter. (3) Clean air brake application valve (or every 3 months, Steering system service.
Page 248 Wheels and tires service. (15) Trailer brake hand control valve service (or every 3 months, or every 900 hours, whichever occurs Hydraulic brake service (or every 6 months, ﬁrst). (42) whichever occurs ﬁrst). (7) (46) Fuel tank, fuel cap and fuel lines service (or every Parking brake service (or every 6 months, whichever 72 months, whichever occurs ﬁrst).
Page 249 90,000 Miles (144 000 km) Exhaust system service (or every 6 months, whichever occurs ﬁrst). (3) (4) (17) Change engine oil and ﬁlter (or every 12 months, Inspect door hinge pins and bushings and replace as whichever occurs ﬁrst). (2) (3) necessary.
Page 250 Shields and underhood insulation service. (4) (5) (21) Air compressor dry element pleated paper air strainer service (or every 2 months or every 800 hours, Rear axle air shift motor service. (11) whichever occurs ﬁrst). Air intake system service (or every 24 months, Inspect air compressor discharge port (or every whichever occurs ﬁrst).
Page 251 300,000 Miles (480 000 km) (5) = Applies only to vehicles sold in the United States. (6) = Check ﬂuid level in brake master cylinder, Remove, disassemble, clean and inspect the air power steering pump, axle, transmission and hydraulic brake air dryer (or every 3 years, or 10,800 hours, spring parking brake pump (if equipped).
Page 252 (12) = Chassis Lubrication Service: Lubricate all grease (13) = Check steering system: ﬁttings in front suspension, front axle and steering • Look for damaged, loose or missing parts. Inspect linkage. DO NOT lubricate kingpin bushings with air the steering linkage relay rod and tie rod ends for pressure equipment;...
Page 253 (15) = Adjust tire pressures as indicated on the GVW 23) = Wheel bearing service: Rating label for optimum tire life. See Tires on page 5-48 • Grease type – Clean, inspect and lubricate with the for further details. Check tires for excessive or proper wheel bearing grease at designated intervals abnormal wear or damage.
Page 254 (31) = Check EGR system as described in the service (39) = Air brake service: manual. See Service Publications Ordering Information • Inspect brake lines and hoses for proper hook-up, on page 7-6 . binding, leaks, cracks, chaﬁng, etc. Inspect drum (32) = Inspect Electronic Vacuum Regulator Valve brake linings for wear or cracks.
Page 255 • (40) = Clean and lubricate air brake automatic slack Replace the air compressor ﬁlter element, mounted adjuster. Check pushrod travel and auto adjustment on the air compressor. For remote air compressor operation. Have serviced if needed. intake service, refer to engine air cleaner ﬁlter replacement.
Page 256: Part B: Owner Checks And Services
Part B: Owner Checks and Services Engine Coolant Level Check ® Check the engine coolant level and add DEX-COOL Listed in this part are owner checks and services coolant mixture if necessary. See Engine Coolant which should be performed at the intervals speciﬁed to on page 5-16 for further details.
Page 257: Wiper Blade Check
Wiper Blade Check Starter Switch Check Inspect wiper blades for wear or cracking. Replace blade inserts that appear worn or damaged or that CAUTION: streak or miss areas of the windshield. Also see Cleaning the Outside of Your Vehicle on page 5-60 . When you are doing this check, the vehicle Weatherstrip Lubrication could move suddenly.
Page 258: Exhaust System Check
Automatic Transmission Shift Engine Cooling System Service Indicator Check Inspect the hoses and have them replaced if they are cracked, swollen or deteriorated. Inspect all pipes, Check that the indicator points to the gear chosen. ﬁttings and clamps; replace as needed. Clean the Steering Check outside of the radiator and air conditioning condenser.
Page 259 Mirrors and Sun Visors Check Door Latches Check Check that friction joints hold mirrors and sun visors Check that doors close, latch and lock tightly. Check for in place. broken, damaged or missing parts that might prevent tight latching. Seat Adjuster Check Cab Latches Check When adjusting a manual seat, be sure seat adjusters latch by attempting to move the seat after latching.
Page 260: Underbody Flushing Service
Engine Cover Check Underbody Flushing Service Check that the cab’s engine cover and seal (if equipped) At least every spring, use plain water to ﬂush any are not torn or damaged. Be sure that the cover is corrosive materials from the underbody. Take care to clamped down ﬁrmly to the ﬂoor.
Page 261: Part C: Recommended Fluids And Lubricants
Part C: Recommended Fluids and Usage Fluid/Lubricant Lubricants Hydraulic Brake Delco Supreme 11 Brake Fluid or System equivalent DOT-3 brake ﬂuid. Fluids and lubricants identiﬁed below by name, part Windshield ® GM Optikleen Washer Solvent. Washer Solvent number or speciﬁcation may be obtained from your dealer.
Page 262 Usage Fluid/Lubricant Usage Fluid/Lubricant Chassis Lubricant (GM Part No. U.S. Rear Axle Shift Refrigerant Oil (GM Part No.U.S. Chassis 12377985, in Canada 88901242) or Motor Lubricant 5416939, in Canada 10953496). Lubrication lubricant meeting requirements of Wheel bearing lubricant meeting NLGI #2, Category LB or GC-LB. Propshafts and requirements of NLGI #2, Category Front Wheel...
Page 263: Part D: Maintenance Record
Part D: Maintenance Record After the scheduled services are performed, 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. Odometer Date Serviced By...
Page 264 Odometer Date Serviced By Maintenance Record Reading 6-30...
Page 265 Section 7 Customer Assistance Information Customer Assistance Information ......7-2 Reporting Safety Defects ........7-5 Customer Satisfaction Procedure ......7-2 Reporting Safety Defects to the United States Customer Assistance for Text Telephone Government ..........7-5 (TTY) Users ..........7-3 Reporting Safety Defects to the Canadian Customer Assistance Offices ......7-3 Government ..........7-5 Roadside Assistance Program ......7-4...
Page 266: Customer Assistance Information
Your satisfaction and goodwill are important to 1-800-263-3777 (English) or 1-800-263-7854 (French). your dealer and to GMC. Normally, any concerns with We encourage you to call the toll-free number in the sales transaction or the operation of your vehicle will order to give your inquiry prompt attention.
Page 267: Customer Assistance For Text Telephone (Tty) Users
GMC encourages customers to call the toll-free number U.S. Virgin Islands: for assistance. If a U.S. customer wishes to write to 1-800-496-9994 GMC, the letter should be addressed to GMC’s Medium Fax Number: 313-381-0022 Duty Truck Customer Assistance Center. Canada – Customer Assistance...
Page 268: Roadside Assistance Program
Overseas – Customer Assistance Roadside Assistance Program Please contact the local General Motors Business Unit. GM Medium Duty Truck’s Roadside Assistance provides stranded owners with towing service for disabled Mexico, Central America and vehicles. Caribbean Islands/Countries (Except This service combines the efforts of trained telephone Puerto Rico and U.S.
Page 269: Reporting Safety Defects
Reporting Safety Defects Reporting Safety Defects to the Canadian Government Reporting Safety Defects to the If you live in Canada, and you believe that your vehicle United States Government has a safety defect, you should immediately notify Transport Canada, in addition to notifying General Motors of Canada Limited.
Page 270: Service Publications Ordering Information
Service Publications Ordering In-Portfolio: Includes a Portfolio, Owner’s Manual and Warranty Booklet. Information RETAIL SELL PRICE: $35.00 Without Portfolio: Owner’s Manual only. Service Manuals RETAIL SELL PRICE: $25.00 Service Manuals have the diagnosis and repair Current and Past Model Order Forms information on engines, transmission, axle, suspension, brakes, electrical, steering, body, etc.
Page 271 Apply Park Brake Warning Light ......3-28 Ashtrays ............3-17 Adding Washer Fluid ........5-28 Audio System(s) ..........3-39 Add-On Electrical Equipment ......5-67 AM-FM Radio ..........3-40 Adjusting the Speakers Care of Your Cassette Tape Player ....3-51 (Balance/Fade) ......3-41, 3-44, 3-48 Care of Your CD Player .......
Page 272 Cab Tilting (cont.) Lowering the Cab ........5-47 Battery ............5-37 Tilting the Cab ..........5-44 Body Lubrication Service ........6-23 Canada – Customer Assistance ......7-3 Brake Adjustment ..........5-31 Canadian Owners ..........ii Brake Fluid ............ 5-29 Capacities and Speciﬁcations ......5-74 Brake Pedal Travel .........
Page 273 Child Restraints ..........1-24 Coolant ............3-30 Child Restraint Systems ....... 1-24 Engine Temperature Gage ......3-30 Infants and Young Children ......1-21 Heater, Engine ..........2-13 Older Children ..........1-19 Low Warning Light ........3-30 Securing a Child Restraint in a Center Seat Surge Tank Pressure Cap ......
Page 274 Defroster Check ..........6-24 Diesel Engine ..........2-14 ® ® Eaton Fuller Nine and Ten-Speed Exhaust Brake ..........2-14 Non-Synchronized Manual Transmissions ..2-18 Fuel ............5-5 Electric Air Compressor ........5-32 Starting Your DURAMAX™ ......2-8 Electrical System ..........5-67 Differential Lock Control, Inter-Axle ....
Page 275 Engine (cont.) Fixed Mast Antenna ........3-53 Coolant Temperature Gage ......3-30 Flat Tire ............5-59 Coolant ............5-17 Fluid Leaks Check .......... 6-25 Diesel Engine Exhaust Brake ......2-14 Fluid ............. 5-15 Exhaust ............. 2-23 Automatic Transmission ........ 5-15 Oil .............
Page 276 Hill and Mountain Roads ........4-24 Horn ............... 3-6 Gage ............3-37 Hourmeter Gage ..........3-38 Check Gages Warning Light ......3-37 How to Add Coolant to the Coolant Engine Coolant Temperature ......3-30 Surge Tank ..........5-24 Filter Minder ..........3-38 How to Add Fluid ..........
Page 277 If You’re Caught in a Blizzard ......4-28 Ignition Positions ..........2-7 Lamps Check ..........6-25 Illuminated Entry ..........3-16 Lamps ............3-12 Infants and Young Children, Restraints ....1-21 Exterior ............3-12 Inﬂation -- Tire Pressure ........5-53 Interior ............3-15 Instrument Panel Brightness Control ....
Page 278 Light (cont.) Maintenance Schedule (cont.) Malfunction Indicator ........3-32 How This Section is Organized ....... 6-3 Manual Fast Idle Indicator ......3-31 Introduction ..........6-2 Parking Brake Warning ......... 3-28 Maintenance Requirements ......6-2 Range Inhibit Warning Indicator ..... 3-25 Part A - Scheduled Maintenance Services ..
Page 279 Mirrors ............2-25 Outside ............2-26 Manual Rearview Mirror ........ 2-25 Convex Mirrors ..........2-26 Outside Convex Mirrors ........ 2-26 Heated Mirrors ..........2-26 Outside Heated Mirrors ........ 2-26 Manual Mirrors ..........2-25 Outside Manual Mirrors ........ 2-25 Power Mirrors ..........2-25 Outside Power Mirrors ........
Page 280 Playing a Cassette .......... 3-44 Radios (cont.) Playing a Compact Disc ........3-49 Setting the Time .......... 3-39 Playing the Radio ......3-40, 3-42, 3-47 Theft-Deterrent ..........3-51 Power Steering ..........4-12 Understanding Reception ......3-51 Power ............3-16 Range Inhibit Warning Indicator ......3-25 Auxiliary Jacks ..........
Page 281 Roadside ............7-4 Seats .............. 1-2 Assistance Program ........7-4 Bucket Seats ..........1-2 Rocking Your Vehicle To Get It Out ....4-31 Center Seat ..........1-4 Running Out of Fuel ......... 5-8 Securing a Child Restraint ........ 1-28 Running Your Engine While You Are Parked ..2-24 Center Seat Position ........
Page 282 Starting Your DURAMAX™ Diesel Engine .... 2-8 To Use the Engine Coolant Heater ....2-13 Starting Your Engine ......... 2-8 Top Strap ............1-27 Steering Check ..........6-24 Towing Your Vehicle From the Front Steering in Emergencies ........4-13 (All Wheels On the Ground) ......4-34 Steering Tips ..........
Page 283 Underbody Flushing Service ......6-26 Wait to Start Indicator ........3-31 Underbody Inspection ........6-25 Warning Light Bulb Check Button ...... 3-29 Understanding Radio Reception ......3-51 Warning Lights, Gages and Indicators ....3-20 United States – Customer Assistance ....7-3 Warnings ............
Page 284 When to Add Engine Oil ........5-11 Windshield Wiper ..........5-51 When to Change Engine Oil ......5-13 Blade Replacement ........5-51 When to Check and Change Fluid ..... 5-43 Fuses ............5-68 When to Check and Change Lubricant ....5-43 Windshield Wipers and Washers Check .....

GMC 2003 GMT560 T-Series Owner's Manual

Table of Contents

Seats and Restraint Systems

Features and Controls

Instrument Panel

Section 3 Instrument Panel

Section 4 Driving Your Vehicle

Driving Your Vehicle

Your Driving, the Road, and Your Vehicle

Towing

Section 5 Service and Appearance Care

Service

Fuel

Checking Things under the Hood

Rear Axle

Cab Tilting

Noise Control System

Windshield Wiper Blade Replacement

Tires

Appearance Care

Vehicle Identiﬁcation

Electrical System

Capacities and Speciﬁcations

Normal Maintenance Replacement Parts

Section 6 Maintenance Schedule

Quick Links

Chapters

Related Manuals for GMC 2003 GMT560 T-Series

Summary of Contents for GMC 2003 GMT560 T-Series