transmission CHEVROLET KODIAK 2007 Workshop Manual

Capacities and Specications
The following approximate capacities are given in English and metric conversions.
SeePart C: Recommended Fluids and Lubricants on page 397for more information.
ApplicationCapacities
English Metric
Air Conditioning Refrigerant R134aFor the air conditioning system refrigerant charge
amount, see the refrigerant caution label located
under the hood. See your dealer for more
information.
Cooling System – C4/C5 Models
6.6L Automatic Transmission 27.3 qt 25.8 L
8.1L Automatic Transmission 29.8 qt 28.2 L
8.1L Manual Transmission 30.1 qt 28.5 L
Cooling System – C6/C7/C8 Automatic Transmission
7.2L Engine (hp 207 - 230) 31.4 qt 29.7 L
7.2L Engine (hp 250 - 300) 31.2 qt 29.5 L
Isuzu 6H Engine (hp 200 - 215) 33.7 qt 31.9 L
Isuzu 6H Engine (hp 230 - 275) 33.3 qt 31.5 L
8.1L Engine (hp 225 - 295) 32.5 qt 30.8 L
Cooling System – C6/C7/C8 Manual Transmission
7.2L 207 - 230 hp Engine 29.3 qt 27.7 L
7.2L 207 - 230 hp Engine with A/C and Increased Cooling 33.0 qt 31.2 L
347

ApplicationCapacities
English Metric
Transmission Fluid, Automatic
3000 RDS and EVS, and 3500 RDS and EVS with
PTO Provision59.0 pt 28.1 L
3000 RDS and EVS, and 3500 RDS and EVS without
PTO Provision52.0 pt 24.6 L
1000 HS, RDS, MH, PTS and EVS, 2200 HS, RDS, MH,
PTS and EVS, 2500 HS and RDS, and 2300 HS and RDS35.0 pt 16.5 L
Add 2 pints (1 L) when changing spin-on or remote filter.
See the Allison
®Automatic Transmission Operator’s Manual for fluid check and maintenance information.
Transmission Fluid, Manual
ES052-7, ES066-7 22.0 pt 10.4 L
FS5205A 12.5 pt 5.9 L
FSO8406, FS6305A, FS6305B, FS6406, FS5406A 19.5 pt 9.2 L
FS4205A, FS4205B 11.5 pt 5.4 L
RT6609 12.0 pt 5.7 L
RT8709 26.0 pt 12.3 L
RT8908LL 28.0 pt 13.2 L
All capacities are approximate. When adding, be sure to fill to the approximate level, as recommended in this
manual. Recheck the fluid level after filling.
351

Part GM Part Number ACDelco®Part Number
Spark Plugs
6.6L — —
7.2L — —
Isuzu 6H — —
8.1L 12578277 41-983
1Optional air filter (GM Part No. 88937548 AC Delco No. A2035C) for C6/C7/C8 Models. Fits inside standard size
filter (GM Part No. 88937525 AC Delco No. A2031C) listed previously.
†Racor part number.
††Caterpillar
®part number.
See the Allison Transmission®Operator’s Manual in your vehicle for external filter part numbers and information.
354

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.
Scheduled Maintenance
The services shown in this schedule up to
100,000 miles (166 000 km) should be repeated
after 100,000 miles (166 000 km) at the same
intervals for the life of this vehicle. The services
shown after 100,000 miles (166 000 km) should
be repeated at the same miles (km) after
those intervals for the life of this vehicle.Gasoline engine vehicles and some DURAMAX
®
diesel and Isuzu 6H diesel engine vehicles have a
computer that lets you know when to change the
engine oil. This is not based on mileage, but on
engine operation and engine temperature. When
the computer has calculated that the oil needs
changing, the Engine Oil Life System will indicate
that a change is necessary. SeeEngine Oil Life
System (Gasoline Engine) on page 276orEngine
Oil Life System (DURAMAX
®Diesel) on page 278
orEngine Oil Life System (Caterpillar®Diesel
Engine) on page 279.
The “Footnotes” at the end of this Maintenance
Schedule further explain maintenance services.
SeeService Publications Ordering Information
on page 415.
100 Miles (160 km)
❑Wheel stud nut service.(36)
1,000 Miles (1 600 km)
❑Wheel stud nut service.(36)
❑Rear axle air shift motor service.(10)
363

❑Clean air brake application valve (or every
3 months, or every 300 hours, whichever
occurs first). Lubricate linkage.
❑Air brake chamber service (or every 2 months,
whichever occurs first).(34)
100,000 Miles (160 000 km)
❑Diesel Only: Inspect engine drive belt;
replace as necessary.
❑Gasoline Engine Only (Vehicles with
GVW of 16,000 lbs or less): Spark plug
service.(2) (25)
❑Change power steering fluid (or every
36 months, whichever occurs first).(12)
❑Replace power steering reservoir filter element
(or every 24 months, whichever occurs first).
❑Wheel bearing (oil type) service (and whenever
hubs are removed).(22) (36)
❑Except four-wheel drive: Front axle service.(31)
❑Four-wheel drive only: Front axle service.(30)
❑Four-wheel drive only: Transfer case
service.(30)
❑Rear axle service — Eaton
®, Rockwell®,
Spicer®axles (or every 12 months, whichever
occurs first).(30)❑Exhaust brake service, if equipped. Check for
excessive spindle free play and smooth
operation. Lubricate ball joint cap.
❑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).
❑Trailer brake hand control valve service (or every
12 months, or every 3,600 hours, whichever
occurs first).(35)
120,000 Miles (192 000 km)
❑C600, C700, and C800 Gasoline Engines Only:
Replace engine drive belts.
❑C400 and C500 Gasoline Engines Only: Engine
drive belts service (or every 12 months,
whichever occurs first).(17)
150,000 Miles (240 000 km)
❑Cooling system service (or every 60 months
since last service, whichever occurs
first).(2) (29)
❑Diesel Engine Only: Inspect engine drive belt;
replace as necessary.
382

200,000 Miles (320 000 km)
❑Rear axle service — Eaton®, Rockwell®,
Spicer®axles (or every 12 months,
whichever occurs first).(30)
❑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.
250,000 Miles (400 000 km)
❑Four-wheel drive only: Front axle service.(30)
❑Four-wheel drive only: Transfer case
service.(30)
❑Manual transmission (except ZF 6-speed)
fluid replacement (or every 60 months,
whichever occurs first).
300,000 Miles (480 000 km)
❑Rear axle service — Eaton®, Rockwell®,
Spicer®axles (or every 12 months,
whichever occurs first).(30)
❑Remove, disassemble, clean, and inspect
the air brake air dryer (or every 3 years,
or 10,800 hours, whichever occurs first).
Replace desiccant.
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 Transmission
®,
your GM owner manual is supplemented by an
Allison Transmission
®Operator’s Manual. Always
refer to these manuals for related maintenance
services.
383

(2)= An Emission Control Service.
(3)= A Noise Emission Control Device.
(4)= Applies to vehicles sold in the United States
and is recommended for vehicles sold in Canada.
(5)= Check fluid level in brake master cylinder,
power steering pump, front and rear axles,
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.
(6)= 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.(7)= This vehicle has the Engine 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 12,000 miles (20 000 km) since
your last oil change. Under severe conditions,
the indicator may come on before 3,000 miles
(5 000 km). Never drive your 7.8L diesel engine
vehicle more than 12,000 miles (20 000 km),
or 12 months, or 600 engine hours, without an
oil and filter change.
Remember to reset the Engine Oil Life System
whenever the oil is changed. For more information,
seeEngine Oil Life System (Gasoline Engine)
on page 276orEngine Oil Life System
(DURAMAX
®Diesel) on page 278orEngine
Oil Life System (Caterpillar®Diesel Engine)
on page 279.
384

(11)= 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. Front axle
tie rod ends, both upper and lower kingpin fittings,
and both steering linkage relay rod ends should
be greased with the vehicle loaded on the ground
and wheels turned straight ahead, NOT with
the vehicle on a hoist. Apply kingpin bushing
lubricant to both upper and lower kingpin grease
fittings until new lubricant purges from between
the upper shim pack and thrust bearing. 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, clutch pedal springs, and clutch cable
bushing at transmission. Lubricate suspension,
axle, and steering linkage more often when
operating under dusty or muddy conditions and in
excessive off-road use. Frequently power-washed
vehicles will require more frequent lubrication.(12)= Check steering system:
•Look for damaged, loose, or missing parts.
Inspect the steering linkage relay rod and
tie rod ends for looseness or lack of lubricant.
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 the
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.
386

Starter Switch Check
{CAUTION:
When you are doing this inspection, the
vehicle could move suddenly. If the vehicle
moves, you or others could be injured.
1. Before you start, be sure you have enough
room around the vehicle.
2. Firmly apply both the parking brake and the
regular brakes.
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.
On manual transmission vehicles, the starter
should work only when the clutch pedal is
all the way down.
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.
393

Usage Fluid/Lubricant
Engine Coolant
(Gasoline
Engine &
DURAMAX
®/
Isuzu Diesel)50/50 mixture of clean, drinkable
water and use only DEX-COOL
®
Coolant. SeeEngine Coolant (Gas
and DURAMAX®/Isuzu Engines)
on page 284orEngine Coolant
(Caterpillar
®Diesel Engines)
on page 287.
Hydraulic Brake
SystemDelco
®Supreme 11 Brake Fluid
or equivalent DOT-3 brake fluid.
Windshield
Washer SolventGM Optikleen
®Washer Solvent.
Clutch Bearing
LubricantClutch Bearing Lubricant
(GM Part No. 12378484 or
equivalent NLGI #3 consistency).
Exhaust Brake
Ball Joint Cap
LubricantHigh-Temperature Grease
(GM Part No. U.S. 1051344,
in Canada 903037) or
NLGI #3 consistency.
Usage Fluid/Lubricant
Power Steering
SystemDEXRON
®-VI Automatic
Transmission Fluid.
Manual
TransmissionSynthetic Manual Transmission
Fluid (GM Part No. U.S. 12345724,
in Canada 10953510).
Automatic
TransmissionSee the Allison Transmission
®
Operator’s Manual for correct
transmission fluid.
Key Lock
CylindersMulti-Purpose Lubricant, Superlube
(GM Part No. U.S. 12346241,
in Canada 10953474).
Chassis
LubricationChassis Lubricant
(GM Part No. U.S. 12377985,
in Canada 88901242) or lubricant
meeting requirements of NLGI #2,
Category LB or GC-LB.
398