brakes CHEVROLET C/K 2003 Owner's Guide

6-43
What to Add
Use the proper fluid listed in your Maintenance
Schedule. Use new brake fluid from a sealed
container only.
Always clean the brake fluid reservoir cap/cover and the
area around the cap/cover before removing it. This will
help keep dirt from entering the reservoir.
CAUTION:
With the wrong kind of fluid in your brake
system, your brakes may not work well, or they
may not even work at all. This could cause a
crash. Always use the proper brake fluid.
NOTICE:

Using the wrong fluid can badly damage
brake system parts. For example, just a few
drops of mineral
-based oil, such as engine
oil, in your brake system can damage brake
system parts so badly that they'll have to be
replaced. Don't let someone put in the
wrong kind of fluid, and don't use DOT
-5
silicone brake fluid.

If you spill brake fluid on your vehicle's
painted surfaces, the paint finish can be
damaged. Be careful not to spill brake fluid
on your vehicle. If you do, wash it off
immediately. See ªAppearance Careº in
the Index.

6-44 Four-Wheel Disc Brakes (Hydraulic Only)
Your vehicle has four-wheel disc brakes.
Some driving conditions or climates may cause a brake
squeal when the brakes are first applied or lightly
applied. This does not mean something is wrong with
your brakes.
Brake linings should always be replaced as complete
axle sets.
Four-Wheel and Six-Wheel Drum Brakes
(Air Only)
The brake drums should be removed and inspected each
time the tires are removed for rotation or changing.
When you have the front brakes replaced, have the rear
brakes inspected, too.
Brake linings should always be replaced as complete
axle sets.

6-45 Brake Pedal Travel
See your dealer if the brake pedal does not return to
normal height, or if there is a rapid increase in pedal
travel. This could be a sign of brake trouble.
Brake Adjustment
Every time you make a brake stop, your brakes adjust
for wear.
Replacing Brake System Parts
The braking system on a vehicle is complex. Its many
parts have to be of top quality and work well together if
the vehicle is to have really good braking. Your vehicle
was designed and tested with top
-quality GM brake
parts. When you replace parts of your braking
system
-- for example, when your brake linings wear
down and you need new ones put in
-- be sure you get
new approved GM replacement parts. If you don't, your
brakes may no longer work properly. For example, if
someone puts in brake linings that are wrong for your
vehicle, the balance between your front and rear brakes
can change
-- for the worse. The braking performance
you've come to expect can change in many other ways if
someone puts in the wrong replacement brake parts.

6-46 Air Brake Systems (If Equipped)
If you have air brakes, it is important to get rid of
moisture in the system. Moisture will damage your
system if it isn't removed daily.
There are two ways to do this. One is automatic if your
air
-brake vehicle has the optional moisture ejector.
If your vehicle doesn't have that option, however, you
must drain the air reservoirs occasionally to be sure the
air dryer is working properly.
Drain the air brakes at full system pressure. To be sure
you're at full pressure, check your air pressure gage.
It should read at least 100 psi (692 kPa).
Moisture Ejector (Option)
If you have air brakes with a moisture ejector, the valve
automatically ejects moisture from the reserve tank
when the air compressor cycles.
Air Dryer
If your vehicle has air brakes, you have an air dryer.
This collects and removes dirt, moisture or other foreign
matter from the air prior to entering the brake system.
It is mounted on the passenger's side frame rail.
If your dryer is a Bendix
-Westinghouse, it has a
filter that you need to change at intervals. See your
Maintenance Schedule for more about servicing
this filter.

6-50
ITEM NO. ITEM REMARKS
12 Clutch Release Bearing* Cup or fitting.
13 Battery Terminal
(except ªSTº type)Keep coated with petroleum jelly.
14 Transmission Fill to level of filler plug.
15 Propshaft Slip Joints Lubricate with GM Part No. 1051344
Wheel Bearing Lubricant.
16 Parking Brake Clevis Pins$ Apply chassis lubricant.
17 Parking Brake Lever Pivot*$ Apply chassis lubricant.
18 Clutch Release Cross Shaft,
Master Cylinder$Apply chassis lubricant, Fill to 1/4, (6 mm) below opening.
19 Release Bearing,
Clutch Cross ShaftTwo fittings, Apply chassis lubricant
20 Clutch Release Fork Two fittings.
* Applies to some vehicles.

Applies to air brakes only.

Refer to Allison Transmission Operator's Manual.
$ Applies to hydraulic brakes only.

7-16
Footnotes

= The U.S. Environmental Protection Agency or the
California Air Resources Board has determined that the
failure to perform this maintenance item will not nullify
the emission warranty or limit recall liability prior to the
completion of the vehicle's useful life. We, however,
urge that all recommended maintenance services be
performed at the indicated intervals and the maintenance
be recorded.
(1) = If your vehicle has an Allison automatic
transmission, your GM owner's manual is supplemented
by an Allison Transmission Operator's Manual. Always
refer to these manuals for related maintenance services.
(2) = Refer to the Caterpillar Diesel Engine Operation
and Maintenance Manual for oil recommendations and
change intervals.
(3) = An Emission Control Service.
(4) = A Noise Emission Control Device.
(5) = Applies only to vehicles sold in the United States.(6) = Check fluid level in brake master cylinder, power
steering pump, axle, transmission and hydraulic spring
parking brake pump (if equipped). A low fluid level in
the brake master cylinder can indicate worn brake
linings and should be checked accordingly.
(7) = Inspect brake lines and hoses for proper hook
-up,
binding, leaks, cracks, chafing, etc. Inspect disc brake
pads for wear and rotors for surface condition. Inspect
caliper assemblies. Check brake pedal for excessive free
play or travel (or every 6 months, whichever occurs first)
and have serviced if needed. Check brakes more often if
driving habits and conditions result in frequent braking.
(8) = Inspect parking brake drum and linings for wear or
cracks and check linkage and adjustment.
(9) = This vehicle has the GM Oil Life System. This
system will show you when to change the engine oil and
filter
-- usually between 3,000 miles (5 000 km) and
7,500 miles (12 000 km) since your last oil change.
Under severe conditions, the indicator may come on
before 3,000 miles (5 000 km). Never drive your vehicle
more than 7,500 miles (12 000 km) or 12 months
without an oil and filter change.
Remember to reset the Oil Life System whenever the oil
is changed. For more information, see ªChange Oil
Lightº in the Index.

7-20
(39) = Air brake service:

Inspect brake lines and hoses for proper hook
-up,
binding, leaks, cracks, chafing, etc. Inspect drum
brake linings for wear or cracks. Inspect other brake
parts at each wheel, including drums, wheel
cylinders and piston heat shields, boots and wheel
speed sensor wiring. Check brake pedal for excessive
free play or travel (or every 6 months, whichever
occurs first) and have serviced if needed. Check
brakes more often if driving habits and conditions
result in frequent braking. Replace air dryer cartridge
only if excessive oil or moisture is present. A small
amount of oil in the system is normal and should not
be considered as a reason to replace the cartridge.

Test air lines for leaks; tighten as needed. Replace
compressor filter.

Inspect air parking brake chamber for leaks and
damage. Inspect lines and hoses for leaks, cracks,
chafing, etc. Also check all attachments for
tightness, wear or damage. Note: The spring brake
section of the rear brake diaphragms are
non
-serviceable.

Replace the air compressor filter element, mounted
on the air compressor. For remote air compressor
intake service, refer to engine air cleaner filter
replacement.
Remove, disassemble, clean and inspect the safety
valve, standard brake chamber, quick release valve,
quick release/double check valve combination,
parking brake control valve, double check valve,
pressure protection valve and alcohol injector.

Remove, disassemble and clean the application
valve; replace parts showing wear.

Remove, disassemble, clean and inspect the spring
brake control valve; replace rubber parts.
(40) = Clean and lubricate air brake automatic slack
adjuster. Check pushrod travel and auto adjustment
operation. Have serviced if needed.
(41) = Air brake chamber service: Check operation,
mounting, clamps and air lines and check for leaks.
(42) = Trailer brake hand control valve service: Check
operation; lubricate cam and follower.
(46) = Tighten the wheel stud nuts to the specified
torque values at 100 miles (160 km). Thereafter, tighten
them 1,000 miles (1 600 km) after each time the wheel
is removed. See ªTightening the Wheel Nutsº in
the Index.

7-23
Body Lubrication Service
Lubricate all exposed surfaces such as door checks, door
lock bolts, lock strike plates, door latches and dovetail
bumper wedges. Where oil holes are provided a dripless
oil can be used. The seat adjusters, seat track, door
weatherstrips and rubber cap bumpers should also be
lubricated.
Part C tells you what to use. More frequent lubrication
may be required when exposed to a corrosive
environment.
Parking Brake Check
Park on a fairly steep hill and hold the vehicle with the
parking brake only. This checks holding ability.Starter Switch Check
CAUTION:
When you are doing this check, the vehicle could
move suddenly. If it does, you or others could be
injured. Follow the steps below.
1. Before you start, be sure you have enough room
around the vehicle.
2. Firmly apply both the parking brake and the
regular brakes. See ªParking Brakeº in the Index
if necessary.
Do not use the accelerator pedal, and be ready to turn
off the engine immediately if it starts.
3. On automatic transmission vehicles, try to start the
engine in each gear. The starter should work only in
PARK (P), if equipped, or NEUTRAL (N). If the
starter works in any other position, your vehicle
needs service.

8-6
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