transmission CHEVROLET C/K 2003 Service Manual

6-87 Cooling System Capacity
The following approximate capacities are given in
English and metric conversions.
Please refer to ªRecommended Fluids and Lubricantsº
in the Index for more information.
C4/C5 Models Quarts (Liters). . . . . . . . . . . . . . . . .
8.1L with manual transmission 30.1 (28.5). . . . . . . .
8.1L with automatic transmission 29.8 (28.2). . . . . .
6.6L with manual transmission 27.6 (26.1). . . . . . . .
6.6L with automatic transmission 27.3 (25.8). . . . . .
C6/C7/C8 Models Quarts (Liters). . . . . . . . . . . . . .
8.1L with manual transmission 33.3 (31.5). . . . . . . .
8.1L with manual transmission,
air conditioning and increased
cooling 34.9 (33.0). . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1L with automatic transmission 32.5 (30.8). . . . . .
7.8L 200
-230 hp engine with
manual transmission 31.6 (29.9). . . . . . . . . . . . . . . .
7.8L 200
-230 hp engine with manual
transmission, air conditioning and
increased cooling 35.3 (33.4). . . . . . . . . . . . . . . . . . . C6/C7/C8 Models Quarts (Liters). . . . . . . . . . . . . .
7.8L 200
-215 hp engine with
automatic transmission 33.7 (31.9). . . . . . . . . . . . . .
7.2L 175
-230 hp engine with
manual transmission 29.3 (27.7). . . . . . . . . . . . . . . .
7.2L 175
-230 hp engine with
manual transmission, air conditioning
and increased cooling 33.0 (31.2). . . . . . . . . . . . . . .
7.2L 175
-210 hp engine with
automatic transmission 31.4 (29.7). . . . . . . . . . . . . .
7.8L 250
-275 hp engine with
manual transmission 34.9 (33.0). . . . . . . . . . . . . . . .
7.8L 250
-275 hp engine with
manual transmission, air conditioning
and increased cooling 35.4 (33.5). . . . . . . . . . . . . . .
7.8L 230
-275 hp engine with automatic
transmission 33.3 (31.5). . . . . . . . . . . . . . . . . . . . . .
7.2L 250
-300 hp engine with manual
transmission 32.8 (31.0). . . . . . . . . . . . . . . . . . . . . .
7.2L 250
-300 hp engine with manual
transmission, air conditioning and
increased cooling 33.3 (31.5). . . . . . . . . . . . . . . . . . .
7.2L 250
-300 hp engine with automatic
transmission 31.2 (29.5). . . . . . . . . . . . . . . . . . . . . .

6-89 Transmission Capacity
For manual transmissions, the correct oil level is to the
bottom of the fluid fill plug opening. The oil capacity
will vary, due to the angle of the transmission, with the
vehicle. For automatic transmissions, see the Allison
Automatic Transmission Operator's Manual for oil
check and maintenance information.
Manual Transmission Pints (Liters). . . . . . . . . . . .
ZF S6
-650 12.7 (6.0). . . . . . . . . . . . . . . . . . . . . . . . .
RT6609 12.5 (5.9). . . . . . . . . . . . . . . . . . . . . . . . . . .
RT8709B 25.1 (11.8). . . . . . . . . . . . . . . . . . . . . . . . .
FS4205A, FS4205B, FS4205C 11.1 (5.3). . . . . . . . .
FS5205A, FS5205C 11.6 (5.5). . . . . . . . . . . . . . . . .
FS5406 18.4 (8.7). . . . . . . . . . . . . . . . . . . . . . . . . . .
FS6305A, FS6305B 18.4 (8.7). . . . . . . . . . . . . . . . .
FS6406 18.4 (8.7). . . . . . . . . . . . . . . . . . . . . . . . . . .
FS8406 18.5 (8.8). . . . . . . . . . . . . . . . . . . . . . . . . . .
RT8908LL 29.1 (13.8). . . . . . . . . . . . . . . . . . . . . . . . Automatic Transmission Pints (Liters). . . . . . . . . .
MD 3060 P 52.0 (24.6)*. . . . . . . . . . . . . . . . . . . . .
MD 3560 P 52.0 (24.6)*. . . . . . . . . . . . . . . . . . . . .
1000 Series 16.0 (8.9)*. . . . . . . . . . . . . . . . . . . . . .
2000 Series 35.0 (13.5)*. . . . . . . . . . . . . . . . . . . . .
2200 Series 35.0 (13.5)*. . . . . . . . . . . . . . . . . . . . .
2400 Series 35.0 (13.5)*. . . . . . . . . . . . . . . . . . . . .
*Add two pints (one liter) when changing spin-on or
remote filter.

6-90 Rear Axle Lubricant Capacity
Single Speed Axle Pints (Liters). . . . . . . . . . . . . . . .
80 10.0 (4.7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S135 26.0 (12.3). . . . . . . . . . . . . . . . . . . . . . . . . . . .
19060S 31.0 (14.7). . . . . . . . . . . . . . . . . . . . . . . . . .
21060D 31.0 (14.7). . . . . . . . . . . . . . . . . . . . . . . . . .
21060S 31.0 (14.7). . . . . . . . . . . . . . . . . . . . . . . . . .
S150 28.0 (13.0). . . . . . . . . . . . . . . . . . . . . . . . . . . .
23090S 40.0 (19.0). . . . . . . . . . . . . . . . . . . . . . . . . .
23105S 56.0 (26.5). . . . . . . . . . . . . . . . . . . . . . . . . .
26105S 54.0 (25.5). . . . . . . . . . . . . . . . . . . . . . . . . .
Tw o
-Speed Axle Pints (Liters). . . . . . . . . . . . . . . . .
19060T 38.0 (18.0). . . . . . . . . . . . . . . . . . . . . . . . . .
21060T 38.0 (18.0). . . . . . . . . . . . . . . . . . . . . . . . . .
23082T 40.0 (19.0). . . . . . . . . . . . . . . . . . . . . . . . . .
26080T 44.0 (20.8). . . . . . . . . . . . . . . . . . . . . . . . . .
Tandem Axles Pints (Liters). . . . . . . . . . . . . . . . . . .
DS344 (front) 32.0 (15.1). . . . . . . . . . . . . . . . . . . . .
RS344 (rear) 31.0 (14.7). . . . . . . . . . . . . . . . . . . . . .
DSH44 (front) 32.0 (15.1). . . . . . . . . . . . . . . . . . . . .
RSH44 (rear) 31.0 (14.7). . . . . . . . . . . . . . . . . . . . . .
DS404, DS404P (front) 32.0 (15.1). . . . . . . . . . . . . .
RS404 (rear) 31.0 (14.7). . . . . . . . . . . . . . . . . . . . . .
Air Conditioning Refrigerant
Capacity
If you do your own service work, you'll need the proper
service manual. See ªDoing Your Own Service Workº in
the Index for additional information. It is recommended
that service work on your air conditioning system be
performed by a qualified technician.
Air Conditioning Refrigerant
R134a 2.1 lbs. (1.0 kg). . . . . . . . . . . . . . . . . . . . . . .
Use Refrigerant Oil, R143a Systems
Normal Maintenance
Replacement Parts
Allison Transmission External Filters
See the Allison Transmission Operator's Manual in your
vehicle for external filter part numbers and information.
Air Compressor Filter
Air Compressor Part Number
Bendix Tu
-Flo
550 (13.2 CFM)2467368

7-4
Part A: Scheduled Maintenance
Services
Using Your Maintenance Schedule
We at General Motors want to help you keep your
vehicle in good working condition. But we don't know
exactly how you'll drive it. You may drive very short
distances only a few times a week. Or you may drive
long distances all the time in very hot, dusty weather.
You may use your vehicle in making deliveries or in
many other ways.
Because of all the different ways people use their
vehicles, maintenance needs vary. You may need more
frequent checks and replacements. So please read the
following and note how you drive. If you have any
questions on how to keep your vehicle in good
condition, see your dealer.
This part tells you the maintenance services you should
have done and when you should schedule them. If you
go to your dealer for your service needs, you'll know
that GM
-trained and supported service people will
perform the work using genuine GM parts.The proper fluids and lubricants to use are listed in
Part C. Make sure whoever services your vehicle uses
these. All parts should be replaced and all necessary
repairs done before you or anyone else drives
the vehicle.
This schedule is for vehicles that:

carry passengers and cargo within recommended
limits. You will find these limits on your vehicle's
GVW Rating label. See ªLoading Your Vehicleº in
the Index.

are driven on reasonable road surfaces within legal
driving limits.

use the recommended fuel. See ªFuelº in the Index.
Scheduled Maintenance Supplements
If your vehicle has a Caterpillar diesel engine, your
owner's manual is supplemented by the Caterpillar
Diesel Engine Operation & Maintenance Manual. If
your vehicle has an Allison transmission, your owner's
manual is supplemented by an Allison Transmission
Operator's Manual. Always refer to these manuals for
related maintenance services.

7-15

Exhaust brake service (if equipped). Check for
excessive spindle free play and smooth operation.
Lubricate ball joint cap.

Air compressor dry element pleated paper air strainer
service (or every 2 months or every 800 hours,
whichever occurs first).

Inspect air compressor discharge port (or every
6 months or every 1,800 hours, whichever
occurs first).

Manual transmission (ZF 6
-speed only) fluid
replacement (or every 48 months, whichever
occurs first).
120,000 Miles (192 000 km)

C600, C700 and C800 Gasoline Engines Only:
Replace engine drive belts.
150,000 Miles (240 000 km)

Cooling system service (or every 60 months since
last service, whichever occurs first). (3)(35)

Diesel Engine Only: Inspect engine drive belt;
replace as necessary.
200,000 Miles (320 000 km)

Remove, disassemble, clean and inspect the air
brake trailer supply valve (or every 2 years, or
every 7,200 hours, whichever occurs first).

Diesel Engine Only: Inspect engine drive belt;
replace as necessary.

C400 and C500 Gasoline Engines Only: Inspect
drive belts; replace as necessary. (18)
250,000 Miles (400 000 km)

Wheel bearings service -- Eaton Axle (oil-filled) (or
every 36 months, whichever occurs first). (23)(46)

Rear axle service
-- Eaton, Rockwell, Spicer Axles
(or every 36 months, whichever occurs first). (37)

Manual transmission (except ZF 6
-speed) fluid
replacement (or every 60 months, whichever
occurs first).
300,000 Miles (480 000 km)

Remove, disassemble, clean and inspect the air brake
air dryer (or every 3 years, or 10,800 hours,
whichever occurs first). Replace dessicant on
Bendix
-Westinghouse units.

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.

7-17
(10) = Check clutch pedal for free travel. Press pedal
by hand until resistance is felt. Free travel should be
maintained at 1.5 to 2 inches (38 to 51 mm) measured
at the clutch pedal pad. Make checks at 1,000 miles
(1 600 km) and then at every 7,500 mile (12 000 km)
interval thereafter.
(11) = Inspect rear axle air shift motor for fluid leaks.
Remove plug to check fluid level. Inspect air lines and
hoses for proper hook
-up, binding, leaks, etc. Inspect at
3,000 miles (5 000 km) and 22,500 miles (36 000 km)
and then every 22,500 miles (36 000 km) thereafter.
(12) = Chassis Lubrication Service: Lubricate all grease
fittings in front suspension, front axle and steering
linkage. DO NOT lubricate kingpin bushings with air
pressure equipment; instead, use a hand grease gun to
ensure complete purge and eliminate sealer cap
distortion. Lubricate transmission and shift linkage,
hood latches and hood hinges, parking brake lever pivot,
clevis pins and linkage, disc brake caliper rails, clutch
linkage and release bearing (if equipped), bearing pads,
propshaft universal joints, brake camshaft bracket, slack
adjusters, pedal shaft, clutch cross shaft and clutch pedal
springs. Lubricate suspension, axle and steering linkage
more often when operating under dusty or muddy
conditions and in excessive off
-road use.(13) = Check steering system:

Look for damaged, loose or missing parts. Also look
for parts showing signs of wear or lack of lubrication.
Replace parts as needed. Also check steering gear
mounting bolts, pitman arm nut, gear housing upper
cover and side cover attaching bolts, steering column
mounting bolts and cardan joint clamp bolts; tighten
if necessary. (See service manual.)

Inspect power steering hoses, tubes and fittings for
leaks. Hoses and lines must not be twisted, kinked or
tightly bent. Make sure clips, clamps, supporting
tubes and hoses are in place and properly secured.

Check steering gear for leakage around pitman shaft
and housing. If leakage is evident (lubricant oozing
out, not just oily film), leak should be corrected
immediately.
(14) = Check front and rear suspension. Look for
damaged, loose or missing parts or parts showing signs
of wear or lack of lubrication. Replace parts as needed.

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.

7-24
Automatic Transmission Shift Indicator Check
Check that the indicator points to the gear chosen.
Steering Check
Be alert for any changes in steering action, abnormal
front tire wear or steering wheel position. An inspection
or service is needed when the steering wheel is harder to
turn or has too much free play, or if there are strange
sounds when turning or parking.
Brake System Check
Be alert to illumination of the low air warning lamp or
for the tone alarm, or changes in braking action, such
as repeated pulling to one side, unusual sounds when
braking or increased brake pedal travel. Make sure air
brake system reservoirs are drained daily with full
system air pressure, and check system for leaks. Any
of these conditions could indicate the need for brake
system inspection and/or service.Engine Cooling System Service
Inspect the hoses and have them replaced if they are
cracked, swollen or deteriorated. Inspect all pipes,
fittings and clamps; replace as needed. Clean the outside
of the radiator and air conditioning condenser. To help
ensure proper operation, a pressure test of the cooling
system and pressure cap is recommended at least once
a year.
Exhaust System Check
Be alert for any changes in the sound of the exhaust
system or any smell of fumes. These are signs the
system may be leaking. Have it checked and/or repaired
at once. Refer to ªEngine Exhaustº and ªRunning Your
Engine While You're Parkedº in the Index.
Windshield Wipers and Washers Check
Check operation and condition of the wiper blades.
Check the flow of the washer spray.

7-28
USAGEFLUID/LUBRICANT
Exhaust Brake
Ball Joint Cap
LubricantHigh-Temperature Grease
(GM Part No. U.S. 1051344, in
Canada 903037, or equivalent) or
NLGI #3 consistency.
Power Steering
SystemDEXRON
-III Automatic
Transmission Fluid.
Manual
Transmission
(Except ZF
6
-Speed)
Synthetic Manual
Transmission Fluid
(GM Part No. U.S. 12345724,
in Canada 10953510).
Manual
Transmission
(ZF 6
-Speed)
TranSynd Synthetic
Transmission Fluid
(GM Part No. U.S. 12378515,
in Canada 88900701).
USAGEFLUID/LUBRICANT
Automatic
TransmissionSee the Allison Transmission
Operator's Manual for correct
transmission fluid.
Chassis
LubricationChassis Lubricant
(GM Part No. U.S. 12377985, in
Canada 88901242, or equivalent)
or lubricant meeting requirements
of NLGI # 2, Category LB
or GC
-LB.
Front Wheel
Bearing Grease
(Except Oil
Filled Hubs)Wheel bearing lubricant meeting
requirements of NLGI # 2,
Category GC or GC
-LB
(GM Part No. U.S. 1051344, in
Canada 993037, or equivalent).