manual transmission CHEVROLET C/K 2003 User Guide

2-37 Eaton Fuller Five and Six-Speed
Transmissions and TTC Spicer
Seven-Speed Transmissions
These transmissions have gears that automatically
synchronize when you shift up or down (except
FIRST (1) gear on the five
-speed and seven-speed
transmission which is unsynchronized). Choose the gear
that will maintain the road speed you want while
keeping the engine above two
-thirds of the governed
speed. When the engine speed drops below two
-thirds of
the governed speed, shift into the next lower gear before
your engine begins to lug. When you shift down, be sure
to double
-clutch if required.
ZF Six-Speed Transmission
Here's how to operate
your transmission.
This six
-speed pattern is unique to GM manual
transmissions. The transmission always repositions
the shift lever to neutral, which is located between
FOURTH (4) and FIFTH (5) gear.
To prevent unintentional gear selections, additional
force is required to move the shift lever into
REVERSE (R) or FIRST (1). Use FIRST (1) when
trailer towing, driving with payload in the pickup box or
launching on a grade. Otherwise, start in SECOND (2)
gear. Only shift into FIRST (1) when the vehicle has
stopped moving.

2-39 Eaton Fuller Nine and Ten-Speed
Non-Synchronized Manual Transmissions
(If Equipped)
If your vehicle has one of these unsynchronized
transmissions, it's naturally somewhat complicated.
The label above the windshield will tell you the
operating basics you need to know.
The following are driving tips.

Always choose an initial starting gear suitable for
the load and terrain.

Always use double
-clutching procedures
when shifting.

Never move the range shift lever to the LO speed
gear position after HI range preselection, or anytime
the transmission is in the HI range.

Never move the range knob or lever with the shift
lever in NEUTRAL while the vehicle is moving.

Never make a range shift while moving
in REVERSE (R).
Clutch Brake (Vehicles with
Non-Synchronized Transmission)
A clutch brake is used to stop transmission input shaft
rotation so that FIRST (1) or REVERSE (R) gear
selection can be initiated when the vehicle is at a
standstill and the engine is idling.
Press the clutch pedal all the way down to the
floorboard to apply the clutch brake.
When using the clutch brake, disengage the clutch pedal
and shift the transmission into either the initial starting
gear or REVERSE (R). If the tooth
-butting occurs
between the clutching teeth, re
-engage the clutch while
applying light pressure to the shift lever. This will
provide for a smooth shift into either FIRST (1) or
REVERSE (R) gear.
NOTICE:
After engaging FIRST (1) or REVERSE (R) gear,
do not use the clutch brake for upshifting and
downshifting. To do so will shorten the service life
of the clutch brake and gear selection shift efforts
may be increased.

2-52
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).
If you have an automatic transmission and you apply
your brakes, the cruise control will shut off.
If you have a manual transmission and you apply your
brakes or push the clutch pedal, the cruise control will
shut off.
CAUTION:

Cruise control can be dangerous where you
can't drive safely at a steady speed. So,
don't use your cruise control on winding
roads or in heavy traffic.

Cruise control can be dangerous on
slippery roads. On such roads, fast changes
in tire traction can cause needless wheel
spinning, and you could lose control. Don't
use cruise control on slippery roads.
Setting Cruise Control
CAUTION:
If you leave your cruise control switch on when
you're not using cruise, you might hit a button
and go into cruise when you don't want to. You
could be startled and even lose control. Keep the
cruise control switch off until you want to use
cruise control.
1. Move the cruise control switch to on.
2. Get up to the speed you want.
3. Press in the set button at the end of the lever and
release it.
4. Take your foot off the accelerator pedal.
The accelerator pedal will not go down.

2-54
Reducing Speed While Using Cruise Control
Press in the button at the end of the lever until you reach
the lower speed you want, then release it.
To slow down in very small amounts, tap the
button briefly. Each time you do this, you'll go
1 mph (1.6 km/h) slower.
Passing Another Vehicle While Using Cruise Control
Use the accelerator pedal to increase your speed. When
you take your foot off the pedal, your vehicle will slow
down to the cruise control speed you set earlier.
Using Cruise Control on Hills
How well your cruise control will work on hills depends
upon your speed, load and the steepness of the hills.
When going up steep hills, you may want to step on the
accelerator pedal to maintain your speed. When going
downhill, you may have to brake or shift to a lower gear
to keep your speed down. Of course, applying the brake
or clutch takes you out of cruise control. Many drivers
find this to be too much trouble and don't use cruise
control on steep hills.Ending Cruise Control
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

Shift the transmission to NEUTRAL (N).
Erasing Speed Memory
When you turn off the ignition, your cruise control set
speed memory is erased.

2-80 Range Inhibited Warning Indicator
(If Equipped)
If your vehicle is equipped with an Allison
1000/2000/2400 series automatic transmission, a lighted
bar under the current gear selected will flash.
If your vehicle is equipped with an Allison MD
automatic transmission, the current gear selected on
the pushbutton display will flash.
The flashing bar or gear selection indicates that
transmission range shifts may not occur.
For detailed information on shift inhibit limitations, see
the Allison Automatic Transmission Operator's Manual
in your vehicle for further information.
Brake System Warning Light
Your vehicle has either hydraulic or air brakes.
Each system has different warning lights.
Hydraulic Brake System Warning Lights
Vehicles with hydraulic systems have two brake system
warning lights on the instrument panel.
If the BRAKE warning light
comes on, it means that the
fluid level in the master
cylinder reservoir is low or
there is another problem
with your hydraulic brakes.
When it comes on, you will also hear a warning tone.
The BRAKE warning light may come on, and the
warning tone may sound, when you're turning and
braking at the same time. This is normal. See ªHydraulic
Brake Systemsº in the Index.

5-4
If you have a diesel engine vehicle with two batteries
(or more), you should know before you begin that,
especially in cold weather, you may not be able to
get enough power from a single battery in another
vehicle to start your diesel engine.
If your vehicle has more than one battery, use the
one closest to the starter
-- this will reduce electrical
resistance.
2. Get the vehicles close enough so the jumper cables
can reach, but be sure the vehicles aren't touching
each other. If they are, it could cause a ground
connection you don't want. You wouldn't be able to
start your vehicle, and the bad grounding could
damage the electrical systems.
To avoid the possibility of the vehicles rolling, set
the parking brake firmly on both vehicles involved in
the jump start procedure. Put an automatic
transmission in PARK (P) or a manual transmission
in neutral before setting the parking brake.
NOTICE:
If you leave your radio on, it could be badly
damaged. The repairs wouldn't be covered by
your warranty.
3. Turn off the ignition on both vehicles. Unplug
unnecessary accessories plugged into the cigarette
lighter or accessory power outlets. Turn off the radio
and all lamps that aren't needed. This will avoid
sparks and help save both batteries, and it could save
your radio!

5-28
If You're Stuck: In Sand, Mud, Ice
or Snow
In order to free your vehicle when it is stuck, you will
need to spin the wheels, but you don't want to spin your
wheels too fast. The method known as ªrockingº can
help you get out when you're stuck, but you must
use caution.
CAUTION:
If you let your tires spin at high speed, they can
explode, and you or others could be injured. And,
the transmission or other parts of the vehicle can
overheat. That could cause an engine
compartment fire or other damage. When you're
stuck, spin the wheels as little as possible. Don't
spin the wheels above 35 mph (55 km/h) as shown
on the speedometer.
NOTICE:
Spinning your wheels can destroy parts of your
vehicle as well as the tires. If you spin the wheels
too fast while shifting your transmission back
and forth, you can destroy your transmission.
Rocking Your Vehicle To Get It Out
First, turn your steering wheel left and right. That will
clear the area around your front wheels. If your vehicle
has traction control, you should turn your traction
control system off. See ªTraction Control Systemº in the
Index. Then shift back and forth between REVERSE (R)
and a forward gear (or with a manual transmission,
between FIRST (1) or SECOND (2) and
REVERSE (R)), spinning the wheels as little as
possible. Release the accelerator pedal while you shift,
and press lightly on the accelerator pedal when the
transmission is in gear. By slowly spinning your wheels
in the forward and reverse directions, you will cause a
rocking motion that may free your vehicle. If that
doesn't get you out after a few tries, you may need to be
towed out. If you do need to be towed out, see ªTowing
Your Vehicleº in the Index.

6-
6-1
Section 6 Service and Appearance Care
Here you will find information about the care of your vehicle. This section begins with service and fuel information,
and then it shows how to check important fluid and lubricant levels. There is also technical information about your
vehicle, and a part devoted to its appearance care.
6
-2 Service
6
-4 Fuel (Gasoline Engine)
6
-5 Diesel Fuel Requirements and Fuel System
6
-15 Fuels in Foreign Countries (Gasoline Engines)
6
-15 Filling Your Tank
6
-17 Filling a Portable Fuel Container
6
-18 Checking Things Under the Hood
6
-20 Noise Control System
6
-21 Engine Oil (Gasoline Engines)
6
-27 Engine Oil (Caterpillar
Diesel Engines)
6
-27 Engine Oil (DURAMAX Diesel)
6
-30 Engine Air Cleaner/Filter
6
-32 Automatic Transmission Fluid
6
-32 Manual Transmission Fluid
6
-34 Rear Axle
6
-34 Rear Axle Shift Motor (Option)
6
-35 Engine Coolant
6
-38 Engine Coolant (Caterpillar
Diesel Engine)6
-38 Surge Tank Pressure Cap
6
-39 Power Steering Fluid
6
-40 Windshield Washer Fluid
6
-41 Brakes
6
-52 Battery
6
-54 Other Service Items
6
-58 Tires
6
-67 Appearance Care
6
-68 Cleaning the Inside of Your Vehicle
6
-71 Cleaning the Outside Your Vehicle
6
-75 GM Vehicle Care/Appearance Materials
6
-76 Vehicle Identification Number (VIN)
6
-76 Service Statement
6
-77 Service Parts Identification Label
6
-77 Electrical System
6
-86 Capacities and Specifications
6
-90 Normal Maintenance Replacement Parts

6-32
Automatic Transmission Fluid
When to Check
A good time to have it checked is when the engine oil is
checked. See your Allison Automatic Transmission
Operator's Manual to find out when to change your
transmission fluid and filters.
How to Check and What to Use
The Allison Automatic Transmission Operator's Manual
that came with the vehicle shows how to check the
automatic transmission fluid and what fluid to use.
Automatic Transmission External Filter
Your automatic transmission filter requires periodic
replacement.
Consult the Allison Automatic Transmission
Operator's Manual that came with the vehicle for
proper change intervals.
Manual Transmission Fluid
Refer to the Maintenance Schedule to determine how
often to check the lubricant and when to change it. See
ªScheduled Maintenance Servicesº in the Index.
Refer to the Maintenance Schedule to determine what
kind of fluid to use. See ªRecommended Fluids and
Lubricantsº in the Index.
When to Check
A good time to have it checked is when the engine oil is
checked. See your Maintenance Schedule to find out
when to change your transmission fluid.

6-47 Electric Air Compressor (If Equipped)
Your vehicle may be equipped with an electric air
compressor. This compressor is used to run options that
require pressurized air, such as an air horn, air seat,
exhaust restrictor or an exhaust brake.
This air compressor is used when vehicles are not
equipped with an air brake system.
The air supply for this
system must be maintained
by releasing the drain
valve to eject any moisture
that may have built up in
the system.
It is recommended that this system be drained on a
weekly basis.
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. See ªMaintenance Scheduleº in
the Index for more information.
If your clutch ever needs service, be sure to use only
genuine GM clutch replacement parts.
Chassis Lubrication
Your Maintenance Schedule provides all of the required
chassis lubrication intervals and identifies proper
lubricants to use. Be sure to see your Maintenance
Schedule before performing any chassis lubrication
service. To determine location of chassis lubrication
items, use the following charts.