transmission CHEVROLET KODIAK 2004 User Guide

When the engine is started, it will slowly ramp up to the
high idle speed after a delay of a few seconds up to
about two minutes. For this method to work properly
there must be no throttle or brake pedal faults, and the
throttle pedal must not fall below 75 percent of wide
open throttle while pressing the brake pedal.
The engine idle speed will return to normal once the
following conditions are met:
•Once engine coolant temperature reaches
150°F (65°C).
•Air intake temperature reaches 41°F (5°C).
The high idle speed will be temporarily interrupted and
the engine speed will return to normal if any of the
following conditions occur:
•The brake pedal is applied.
•The accelerator pedal is pressed.
•The automatic transmission is shifted out of
PARK (P) or NEUTRAL (N).
•The clutch pedal on the manual transmission is
pressed.
•Vehicle speed is detected.
Once these inputs are removed, the engine idle speed
will slowly ramp back up to high idle after the normal
delay, if the conditions for engine coolant temperature
and air intake temperature are still met.
Engine Checks Before Operating
When you’ve started your engine, let it run for
20 to 30 seconds before you put a load on the engine.
Butdon’tleave the vehicle while the engine is running.
Avoid unnecessary idling of diesel engine equipped
vehicles.
If the engine idles too long, the temperature of the
engine coolant will fall below the normal operating
range. Low engine operating temperature causes
several conditions which affect engine operation and
reduce engine life.
The engine should be permitted to go through a
warm-up period. Operate the vehicle at a minimum of
600 rpm during the warm-up period. During this
period and during operation, the following observations
should be made.
During this warm-up period, check your warning lights
and gages:
•If oil pressure doesn’t begin to rise within
15 seconds of starting, stop the engine and find the
cause.
•If the engine coolant temperature gage needle goes
into the hot area on the gage, stop the engine and
find the cause of the overheating.
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Diesel Engine Exhaust Brake
The exhaust brake is available on vehicles equipped
with a diesel engine. It is located in the exhaust system.
The exhaust brake is used to help slow the vehicle
and may assist the vehicle’s foundation brakes. The use
of the exhaust brake will assist the braking of the
vehicle and prolong the life of the foundation brake
lining material.
The exhaust brake switch
is located in the instrument
panel switchbank.
Push the bottom of the switch to turn the exhaust brake
on. When you push the top of the switch, the exhaust
brake will turn off.There is an indicator light on the instrument panel
similar to the symbol on the switch, that will come on
when the exhaust brake is active. SeeExhaust
Brake Indicator Light on page 3-40for more information.
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
possible range that does not allow the engine rpm to go
more than 200 rpm above rated (full load) rpm. If you
have a Caterpillar
®diesel engine, do not exceed
2900 rpm. If you have a DURAMAX™ (LG4) diesel
engine, do not exceed 2400 rpm. If you have a
DURAMAX™ (LB7) diesel engine, do not exceed
3600 rpm.
If you have an automatic transmission and press this
button, the transmission will downshift to a factory
default setting of fourth gear. To change the default
setting, or for more information on factory default
settings, contact your dealer for assistance.
The accelerator and clutch pedals must be released in
order for the exhaust brake to engage. The exhaust
brake will not function when the cruise control feature is
active, and will automatically shut off when the
anti-lock brake system is active.
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Two-Speed Rear Axle Electric
Shift Control
If your vehicle is equipped with this feature, you’ll find a
label on the headliner above the windshield or in
another place near the driver that shows how to use it.
Be sure to follow the directions carefully.
Use the following directions based on the type of shift
control you have.
Manual Transmission
The rear axle shift control
switch for a manual
transmission is located on
the shift lever.
When the switch is up, the rear axle is in the high
range. Push the switch down to change to low range.The two-speed axle should be in low when you park the
vehicle. You’ll need to engage the transmission, even
move the vehicle a little, to be sure the axle is in the low
range. Then apply the parking brake, shift into
NEUTRAL and shut off the engine.
Also, always start the vehicle in motion with the
two-speed axle in the low range. To shift up from low to
high, do the following:
1. Move the switch up for the high range,
2. disengage the clutch, and
3. after a brief pause, engage the clutch and then
press down on the accelerator.
To shift down from high to low, do the following:
1. Move the switch down to low,
2. release the accelerator and then quickly apply
it again.
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Air Shift Control (Automatic
Transmission)
The rear axle shift control
switch for an automatic
transmission is located in
the instrument panel
switchbank.
Press the bottom of the switch to get to the low range.
The switch indicator light will come on when the
vehicle is in low range. Press the top of the switch to
return to the high range.
The two-speed axle should be in low range when you
park the vehicle. You’ll need to engage the transmission,
even moving the vehicle a little, to be sure the axle is
in low range. Then shift into PARK (P), apply the parking
brake and shut off the engine.To shift up from low to high, press the top of the rear
axle shift control switch and press down on the
accelerator. When you shift the axle from high to low,
press the bottom of the switch, release the accelerator
and then quickly press it down again.
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.
On the highway, with the axle in low range and the
transmission in top gear, you may shift the axle to high
range by raising the switch and releasing the
accelerator momentarily. Reapply the accelerator after
you shift.
Under light load conditions, first shift the axle into the
high range with the vehicle at a standstill and then
operate the transmission normally.
Air Suspension
Your vehicle may be equipped with the Hendrickson
HAS Series single-axle air suspension which is designed
for single-axle on-highway use. The feature is available
in 19,000 lb. (8 618.3 kg), 21,000 lb. (9 525.4 kg)
and 23,000 lb. (10 432.6 kg) capacities for operations
which require extra cubic capacity and a reduced
deck height.
2-27

Rear Air Suspension Dump Control
If your vehicle is equipped with the Hendrickson HAS
Series single-axle air suspension, you have this control.
The air suspension dump control allows the operator
to lower the deck height approximately 4.5 inches
(11.5 cm) from the normal frame height.
The switch to deflate and
inflate the air suspension
is located in the instrument
panel switchbank.
Press the bottom of the switch to deflate the air
suspension and lower the deck height. Press the top of
the switch to return the suspension to normal deck
height.
An indicator light will come on and stay on whenever
the switch is in the dumped position.
Automatic Transmission Operation
We build vehicles with five and six-speed automatic
transmissions. This part of the manual covers the basics
of these. With some of the transmissions, you will find
another manual in your vehicle that goes into more
detail. On the headliner, in front of and above the driver,
or in some other place near the driver, you will see a
label that describes important operating facts about the
automatic transmission in your vehicle. Make sure
you follow the instructions on this label.
Be sure to keep your parking brake set until you are
ready to shift into DRIVE (D), and press the brake pedal
while shifting from NEUTRAL (N) or PARK (P) to a
drive gear.
All vehicles equipped with automatic transmissions can
be started in PARK (P), if equipped, or in NEUTRAL (N).
See the Allison
®Transmission Operator’s Manual in
your vehicle for more information about this.
2-28

{CAUTION:
It can be dangerous to get out of your vehicle
without the parking brake rmly set. Your
vehicle can roll. If you have left the engine
running, the vehicle can move suddenly. You
or others could be injured. To be sure your
vehicle will not move, even when you are on
fairly level ground, always set the parking
brake.
{CAUTION:
Shifting into a drive gear while your engine is
running at high speed is dangerous. Unless
your foot is rmly on the brake pedal, your
vehicle could move very rapidly. You could
lose control and hit people or objects. Do not
shift into a drive gear while your engine is
running at high speed.
Overdrive Defeat
If your vehicle has this feature, you can select not to
shift up to fifth gear. This is useful when towing or under
a heavy load.
The overdrive defeat
switch is located in the
instrument panel to
the right of the steering
column.
Press the switch to limit the transmission to fourth gear.
This will allow for fewer downshifts while pulling a
trailer or under a heavy load. The indicator light in the
switch will come on whenever overdrive defeat is active.
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Manual Transmission Operation
Using the Clutch
When you are starting to move the vehicle, it is
important to begin with the engine speed at idle. Then
start to engage the clutch and listen for an engine speed
drop of about 100 rpm. At this point, the clutch is
engaging, so you should increase the engine speed and
fully engage the clutch. It is important not to increase
the engine speed sooner or before the clutch begins it’s
engagement. If you do, you can cause damage to
your vehicle.
Double-Clutching
You must use the double-clutching method when you
shift an unsynchronized gear set. Disengage the clutch,
shift to neutral and engage the clutch. When upshifting,
slow the engine until the engine rpm and road speed
match. When downshifting, accelerate the engine
until the engine rpm and road speed match. Then
quickly disengage the clutch and move the shift lever to
the next gear position and engage the clutch.
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.
2-30

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 a heavier payload or launching
on a grade. Otherwise, start in SECOND (2) gear. Only
shift into FIRST (1) when the vehicle has stopped
moving.
During the first 500 miles (805 km) of vehicle use, start
the vehicle moving in FIRST (1) gear. This allows
the clutch components to wear-in properly.FIRST (1):With the vehicle at a stop, release the
brake, press the clutch pedal and shift into FIRST (1).
Then, slowly let up on the clutch pedal as you press the
accelerator pedal. Only downshift into FIRST (1)
when the vehicle has come to a complete stop. If the
shift lever will not go into FIRST (1), put the lever
in neutral and let up on the clutch pedal to fully engage
the clutch. Press the clutch pedal again. Then, shift
into FIRST (1).
SECOND (2):With the vehicle at a stop, release the
brake, press the clutch pedal and shift into SECOND (2).
Then, slowly let up on the clutch pedal as you press
the accelerator pedal. With the vehicle moving, press the
clutch pedal and upshift into SECOND (2) from
FIRST (1) while applying light pressure to the right on
the shifter. Then, slowly let up on the clutch pedal
as you press the accelerator pedal. If you come to a
complete stop and the shift lever will not go into
SECOND (2), put the lever in neutral and let up on the
clutch pedal to fully engage the clutch. Press the
clutch pedal again. Then, shift into SECOND (2).
THIRD (3):Press the clutch pedal and upshift into
THIRD (3). Then, slowly let up on the clutch pedal as
you press the accelerator pedal.
FOURTH (4), FIFTH (5) and SIXTH (6):Upshift into the
higher forward gears the same way as you do
THIRD (3). Slowly let up on the clutch pedal as you
press the accelerator pedal.
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NEUTRAL:Use this position when you start or idle
your engine.
REVERSE (R):To back up, press the clutch pedal.
Wait for the vehicle to stop moving and then, shift
to REVERSE (R). Let up on the clutch slowly while
pressing the accelerator pedal. Also, use REVERSE (R),
along with the parking brake, when turning off your
engine and parking your vehicle.
Eaton®Fuller®Nine and Ten-Speed
Non-Synchronized Manual
Transmissions
If your vehicle has one of these transmissions the
engine rpm and road speed must match when upshifting
and downshifting. 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:Using the clutch brake for shifting into any
gear other than FIRST (1) or REVERSE (R) may
cause premature wear of the clutch brake and make
gear shift effort more difficult. Do not use the
clutch brake for shifting after engaging FIRST (1) or
REVERSE (R).
2-32

Parking
{CAUTION:
If you don’t park your vehicle properly, it can
roll. If you’ve left the engine running, it can
move very quickly. You or others could be
injured. To be sure your vehicle won’t move,
even when you’re on level ground, follow the
steps below.
Two-Speed Rear Axle
1. With the engine running, shift the two-speed rear
axle into low. To be sure it’s in low, you’ll need to
move the vehicle in gear just a little.
2. Hold the regular brake pedal down with your
right foot.
3. Apply the parking brake.
4. Shift the transmission to NEUTRAL or PARK (P).
Hydraulic Brakes
If your vehicle has hydraulic brakes, it has either a
parking brake foot pedal or hand lever. If you have the
parking brake foot pedal, it is located below the
instrument panel to the left of the steering column.
If you have the parking brake hand lever, it is located to
the right of the driver, on the floor.
To set the foot pedal parking brake, hold the regular
brake pedal down with your right foot. Push down
the parking brake pedal with your left foot.Parking Brake Hand Lever
2-33