steering CHEVROLET KODIAK 2008 Service Manual

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.
❑Isuzu Diesel Only: Diesel Particulate Filter (DPF)
service (or every 4,500 hours, whichever occurs
first). Then every 150,000 miles (240 000 km),
or every 4,500 hours, whichever occurs first.(7)
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
owner manual is supplemented by an Allison
Transmission
®Operator’s Manual. Always refer to these
manuals for related maintenance services.
(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)= Check for filter ash, sensor adjustment, and sensor
hose restriction. Clean as needed. This service can be
complex; you should have your dealer/retailer perform
this service.
(8)= 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
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
gasoline engine vehicle more than 7,500 miles
(12 000 km) or 12 months without an oil and filter
change.
6-20

Remember to reset the Engine Oil Life System
whenever the oil is changed. For more information, see
Engine Oil Life System (Gasoline Engine) on page 5-36
orEngine Oil Life System (DURAMAX
®/Isuzu Diesel
Engines) on page 5-37orEngine Oil Life System
(Caterpillar
®Diesel Engine) on page 5-39.
(9)= 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
15,000 miles (24 000 km) since your last oil change.
Under severe conditions, the indicator may come
on before 3,000 miles (5 000 km). Never drive your
diesel engine vehicle more than 15,000 miles
(24 000 km), or 12 months, or 750 engine hours, without
an oil and filter change.
Remember to reset the Engine Oil Life System
whenever the oil is changed. For more information, see
Engine Oil Life System (Gasoline Engine) on page 5-36
orEngine Oil Life System (DURAMAX
®/Isuzu Diesel
Engines) on page 5-37orEngine Oil Life System
(Caterpillar
®Diesel Engine) on page 5-39.
(10)= 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 1,000 miles (1 600 km) and 22,500 miles
(36 000 km) and then every 22,500 miles (36 000 km)
thereafter.(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.
6-21

(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.
(13)= 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.
(14)= Adjust tire pressures as indicated on the
Certification or Tire Information label for optimum tire
life. SeeTires on page 5-82for further details. Check
tires for excessive or abnormal wear or damage. Also
check for damaged wheels. Replace wheels and/or tires
as needed.(15)= Check spring-to-axle U-bolts and shackle bolts
for proper torque. See the service manual for torque
sequence and specifications. When parts are replaced,
the torque must be checked and adjusted more often
during the first 6,000 miles (10 000 km). Check torque at
500 miles (800 km) and 2,000 miles (3 000 km) after
first use of parts.
(16)= Check complete exhaust system, including DPF
pressure lines, and cab areas near the exhaust system
for broken, damaged, missing, or out-of-position parts.
Also inspect for open seams, holes, loose connections, or
other conditions which could let exhaust fumes seep into
the driver compartment. Needed repairs should be made
at once. To help maintain system integrity, replace
exhaust pipes whenever a new muffler is put on.
(17)= Check all gasoline engine drive belts for cracks,
fraying, and wear. Replace as needed.
(18)= Adjust valve lash. Incorrect valve clearance will
result in increased engine noise and reduced engine
output.
(19)= With the engine off and below normal operating
temperature, check to see that the thermostatically
controlled engine cooling fan can be rotated by hand on
viscous-operated drives. Replace as needed.
(20)= Check shields and underhood insulation for
damage or looseness. Adjust or replace as needed.
6-22

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 the low air warning light or 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 Inspection
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. SeeEngine Exhaust on page 2-45and
Running the Vehicle While Parked on page 2-50.
Check to be sure that mud or dirt is not caked on the
exhaust system, especially in the area of the diesel
particulate filter and tailpipe. Clean the area as needed.
SeeDiesel Particulate Filter (Diesel Engine) on
page 2-46.
At high mileages, the DPF becomes loaded with ash.
This is normal. When the amount of ash loading is high,
see your dealer/retailer for DPF cleaning or replacement.
6-28

Part C: Recommended Fluids and
Lubricants
Fluids and lubricants identified below by name, part
number, or specification can be obtained from your
dealer/retailer.
Usage Fluid/Lubricant
Engine Oil
(Gasoline
Engine)Engine oil which meets
GM Standard GM6094M and
displays the American Petroleum
Institute (API) Certified for Gasoline
Engines starburst symbol. To
determine the proper viscosity for
your vehicle’s engine, see “Engine
Oil” in the Index.
Engine Oil
(DURAMAX
®/
Isuzu Diesel
Engines)Engine oils with the letters CJ-4 are
required for your vehicle. The CJ-4
designation can appear either alone
or in combination with other
American Petroleum Institute (API)
designations, such as API CJ-4/SL.
These letters show API levels of
quality. To determine the preferred
viscosity for your vehicle’s diesel
engine, see “Engine Oil” in the Index.
Engine Oil
(Caterpillar
®
Diesel Engine)See the Caterpillar
®Operation &
Maintenance Manual for engine oil
recommendations.
Usage Fluid/Lubricant
Engine Coolant
(Caterpillar
®
Diesel Engine)See the Caterpillar
®Operation &
Maintenance Manual for engine
coolant recommendations.
Engine Coolant
(Gasoline
Engine &
DURAMAX
®/
Isuzu Diesel
Engines)50/50 mixture of clean, drinkable
water and use only DEX-COOL
®
Coolant. SeeEngine Coolant
(Caterpillar®Diesel Engines) on
page 5-44orEngine Coolant
(Gas and DURAMAX
®/Isuzu 7.8L
L6 Engines) on page 5-44.
Hydraulic Brake
SystemDelco
®Supreme 11 Brake Fluid or
equivalent DOT-3 brake fluid.
Windshield
Washer SolventOptikleen
®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.
Power Steering
SystemDEXRON
®-VI Automatic
Transmission Fluid.
Manual
TransmissionSynthetic Manual Transmission Fluid
(GM Part No. U.S. 88861952, in
Canada 88861953).
6-31

Service Publications Ordering
Information
Service Manuals
Service Manuals have the diagnosis and repair
information on engines, transmission, axle suspension,
brakes, electrical, steering, body, etc.
Service Bulletins
Service Bulletins’ give additional technical service
information needed to knowledgeably service
General Motors cars and trucks. Each bulletin contains
instructions to assist in the diagnosis and service of
your vehicle.
Owner Information
Owner publications are written specifically for owners
and intended to provide basic operational information
about the vehicle. The owner manual includes the
Maintenance Schedule for all models.
In-Portfolio: Includes a Portfolio, Owner Manual, and
Warranty Booklet.
RETAIL SELL PRICE: $35.00 (U.S.) plus processing fee
Without Portfolio: Owner Manual only.
RETAIL SELL PRICE: $25.00 (U.S.) plus processing fee
Current and Past Model Order Forms
Technical Service Bulletins and Manuals are available
for current and past model GM vehicles. To request
an order form, specify year and model name of
the vehicle.
ORDER TOLL FREE: 1-800-551-4123
Monday-Friday 8:00 AM - 6:00 PM
Eastern Time
For Credit Card Orders Only
(VISA-MasterCard-Discover), visit Helm, Inc. on the
World Wide Web at: www.helminc.com
Or you can write to:
Helm, Incorporated
P.O. Box 07130
Detroit, MI 48207
Prices are subject to change without notice and without
incurring obligation. Allow ample time for delivery.
Note to Canadian Customers: All listed prices are
quoted in U.S. funds. Canadian residents are to make
checks payable in U.S. funds.
7-10

Exhaust Brake Indicator Light...........................3-40
Exhaust Restrictor...........................................2-22
Extender, Safety Belt.......................................1-28
Exterior Lamps...............................................3-14
F
Filter
Engine Air Cleaner......................................5-39
Filter Minder Gage..........................................3-45
Finish Damage...............................................5-99
Fixed Mast Antenna........................................3-58
Flashers, Hazard Warning.................................. 3-6
Flat Tire........................................................5-92
Fluid.............................................................5-43
Power Steering...........................................5-54
Windshield Washer......................................5-55
Four-Wheel Drive....................................2-32, 5-73
Front Axle......................................................5-74
Front Wheel Bearings with Oil-Filled Hubs..........5-81
Fuel............................................................... 5-7
Additives...................................................... 5-8
Change Filter Warning Light..........................3-44
Diesel Engine Fuel........................................ 5-9
Filling a Portable Fuel Container....................5-21
Filling the Tank...........................................5-20
Filter..........................................................5-78
Filter Replacement.......................................5-18
Fuels in Foreign Countries............................5-19Fuel (cont.)
Gage.........................................................3-43
Gasoline Octane........................................... 5-7
Gasoline Specifications.................................. 5-7
Primary Filter and Water Separator................5-79
Running Out of...........................................2-50
Running Out of Fuel....................................5-17
Secondary Filter and Water Separator/
Heater....................................................5-80
Very Cold Weather Operation........................5-12
Water in Fuel..............................................5-12
Water in Warning Light.................................3-44
What Fuel to Use.......................................... 5-9
Fuses
Fuses and Circuit Breakers.........................5-103
Instrument Panel Fuse Block.......................5-103
Underhood Fuse Block...............................5-106
Windshield Wiper.......................................5-102
G
Gage
Air Pressure...............................................3-46
Check Gages Warning Light..........................3-42
Engine Coolant Temperature.........................3-35
Filter Minder...............................................3-45
Fuel..........................................................3-43
Hourmeter..................................................3-46
Oil Pressure...............................................3-37
5

Outlet Adjustment............................................3-23
Outlets
Accessory Power.........................................3-19
Outside
Convex Mirrors............................................2-52
Heated Mirrors............................................2-52
Manual Mirrors............................................2-51
Power Mirrors.............................................2-51
Overspeed Warning Light.................................3-39
P
Paint, Damage...............................................5-99
Park Brake............................................2-38, 2-41
Parking.........................................................2-37
Brake Burnish Procedure..............................2-43
Over Things That Burn.................................2-44
Two-Speed Rear Axle..................................2-27
Part A - Scheduled Maintenance Services............ 6-3
Part B - Owner Checks and Services................6-25
Part C - Recommended Fluids and Lubricants....6-30
Part D - Maintenance Record...........................6-32
Passing.........................................................4-11
Perchlorate Materials Requirements, California...... 5-5
Power
Door Locks.................................................. 2-7
Electrical System.......................................5-103
Reduced Engine Light..................................3-41Power (cont.)
Steering Fluid.............................................5-54
Windows...................................................... 2-9
Power Take-Off Light.......................................3-42
Power Take-Off (PTO).....................................2-32
Privacy..........................................................7-11
Event Data Recorders..................................7-11
Navigation System.......................................7-12
OnStar.......................................................7-12
Radio Frequency Identification.......................7-12R
Radio Frequency Identification (RFID), Privacy....7-12
Radios..........................................................3-47
Radio(s)........................................................3-48
Radios
Reception...................................................3-58
Setting the Clock.........................................3-48
Theft-Deterrent............................................3-57
Range Inhibit Warning Indicator........................3-32
Reading Lamps..............................................3-17
Rear Axle......................................................5-72
Differential Lock Control................................. 4-7
Shift Motor.................................................5-73
Rear Heating System......................................3-24
Rear Seat Operation.......................................1-10
Rearview Mirrors.............................................2-51
9

Specifications, Capacities...............................5-109
Speedometer..................................................3-26
Split Bench Seat.............................................. 1-6
Starting Diesel Engine.....................................2-14
Starting the Gasoline Engine............................2-12
Steering.......................................................... 4-9
Steering Wheel, Tilt Wheel................................. 3-7
Storage Areas................................................2-53
Center Console Storage Area........................2-53
Stuck in Sand, Mud, Ice, or Snow.....................4-19
Sun Visors...................................................... 2-9
Suspension, Air..............................................2-44
Switchbanks, Instrument Panel..........................3-18
T
Tachometer....................................................3-26
Theft-Deterrent, Radio.....................................3-57
Tilt Wheel........................................................ 3-7
Time, Setting..................................................3-48
Tires.............................................................5-82
Aluminum or Chrome-Plated Wheels,
Cleaning.................................................5-98
Buying New Tires........................................5-85
Cleaning....................................................5-99
Dual Tire Operation.....................................5-84
If a Tire Goes Flat.......................................5-92
Inflation - Tire Pressure................................5-82
Tightening the Wheel Nuts............................5-86Tires (cont.)
Wheel Alignment and Tire Balance.................5-86
Wheel Loading............................................5-83
Wheel Replacement.....................................5-90
When It Is Time for New Tires......................5-84
Tow Hooks.....................................................4-20
Towing
Your Vehicle...............................................4-24
Traction
Control System (TCS).................................... 4-8
Trailer
Connections................................................4-26
Trailer Brake Hand Control Valve........................ 4-6
Transmission
Fluid, Automatic...........................................5-43
Fluid, Manual..............................................5-43
Service Warning Light..................................3-31
Temperature Gage.......................................3-39
Transmission Operation, Automatic....................2-29
Transmission Operation, Manual........................2-30
Trip Odometer................................................3-26
Turn and Lane-Change Signals.......................... 3-8
Turn Signal/Multifunction Lever........................... 3-7
Two-Speed Rear Axle......................................2-27
U
Using this Manual................................................ ii
11