transmission CHEVROLET KODIAK 2009 Workshop Manual

Capacities and Specifications
The following approximate capacities are given in English and metric conversions. SeePart C: Recommended Fluids
and Lubricants on page 6-31for 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/retailer for more
information.
Cooling System – C4/C5 Models
6.6L V8 Automatic Transmission 27.9 qt 26.4 L
8.1L V8 Automatic Transmission 29.8 qt 28.2 L
8.1L V8 Manual Transmission 30.1 qt 28.5 L
Cooling System – C6/C7/C8 Automatic Transmission
7.2L L6 Engine 32.0 qt 30.2 L
Isuzu 6H Engine (207 - 275 hp) 34.8 qt 32.9 L
Isuzu 6H Engine (300 hp) 33.9 qt 32.1 L
8.1L V8 Engine 32.5 qt 30.8 L
5-102

ApplicationCapacities
English Metric
Cooling System – C6/C7/C8 Manual Transmission
7.2L L6 Engine 30.4 qt 28.8 L
7.2L L6 Engine with A/C and Increased Cooling 33.9 qt 32.1 L
Isuzu 6H Engine (207–275 hp) 32.7 qt 31.0 L
Isuzu 6H Engine (207–275 hp) with A/C and Increased
Cooling35.9 qt 34.0 L
Isuzu 6H Engine (300 hp) 36.0 qt 34.1 L
Isuzu 6H Engine (300 hp) with A/C and Increased Cooling 36.0 qt 34.1 L
8.1L V8 Engine 33.3 qt 31.5 L
8.1L V8 Engine with A/C and Increased Cooling 34.9 qt 33.0 L
Engine Oil with Filter
6.6L V8 Engine 14.6 qt 13.8 L
7.2L L6 Caterpillar
®C7 Engine 30.0 qt 28.4 L
Isuzu 6H
1Engine 23.8 qt 22.5 L
8.1L V8 Engine 10.0 qt 9.4 L
Check fill level on the oil indicator after initial fill to make sure it is actually full. Oil level may vary depending on
vehicle option content.
1Additional oil is required with auxiliary oil filter systems. Make sure to add enough extra oil to fill the auxiliary oil
filter system. For vehicles equipped with the LUBERFINER 750-C, add 14 quarts (13.25 L).
5-103

ApplicationCapacities
English Metric
Rear Axle – Two-Speed
19060T (HPL), 22060T (HPH) 38.0 pt 18.0 L
21060T (H15) 38.0 pt 18.0 L
23082T (H25) 44.0 pt 20.8 L
26080T (GJ4) 44.0 pt 20.8 L
Transfer Case (Four-Wheel Drive) 4.0 pt 1.9 L
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.
5-106

ApplicationCapacities
English Metric
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.
Engine Specifications
Engine RPO Type
6.6L V8 DURAMAX®LMM Common Rail Fuel System
7.2L L6 Caterpillar
®C7 LF6Hydraulic/Electronic Unit Injector
Fuel System
7.8L L6 Isuzu 6H LF8 Common Rail Fuel System
8.1L V8 VORTEC™ L18Single Port Fuel Injector Fuel
System
5-107

Part GM Part Number ACDelco Part Number
Fuel Filter
6.6L V8 98017645 TP1298B
7.2L L6 — 1R-0751
2
Isuzu 6H 98026037 —
8.1L V8 (C4/C5 with NG6/NK1 or U-Haul) 15807649 —
8.1L V8 (C4/C5 with all other fuel tanks) 10376257 —
8.1L V8 (All C6/C7/C8) 10370247 —
Power Steering Fluid Filter 88892858 —
Secondary Fuel Filter
6.6L V8 — —
7.2L L6 (NWB/KUR) 25982639 S3229
3
Isuzu 6H (NWB) 15618921 S32023
Isuzu 6H (KUK) 88983117 TP1519
8.1L V8 (K28 and standard U-Haul) 25014476 TP1247
Spark Plugs
6.6L V8 — —
7.2L L6 — —
Isuzu 6H — —
8.1L V8 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.
2Caterpillar®part number.3Racor part number.
See the Allison Transmission Operator’s Manual in your vehicle for external filter part numbers and information.
5-109

Part A: Scheduled Maintenance
Services
In this part are scheduled maintenance services which
are to be performed at the mileage intervals specified.
Using the Maintenance Schedule
We want to help keep this vehicle in good working
condition. But we do not know exactly how you will drive
it. You might drive very short distances only a few
times a week. Or you might drive long distances all the
time in very hot, dusty weather. You might use the
vehicle in making deliveries or in many other ways.
Because of all the different ways people use their
vehicles, maintenance needs vary. You might 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 the vehicle in good condition,
see your dealer/retailer.
This part tells you the maintenance services that should
be done and when to schedule them.
When you go to your dealer/retailer for service, trained
and supported service people will perform the work
using genuine parts.The proper fluids and lubricants to use are listed in
Part C. Make sure whoever services the 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 on the vehicle’s Certification or Tire
Information label. SeeLoading the Vehicle on
page 4-20.
•are driven on reasonable road surfaces within legal
driving limits.
•use the recommended fuel. SeeGasoline Octane
on page 5-6for gasoline engine vehicles orWhat
Fuel to Use on page 5-8for diesel engine vehicles.
Scheduled Maintenance
Supplements
If the vehicle has a Caterpillar®diesel engine, the owner
manual is supplemented by the Caterpillar®Diesel
Engine Operation & Maintenance Manual. If the vehicle
has an Allison Transmission
®, the owner manual is
supplemented by an Allison Transmission®Operator’s
Manual. Always refer to these manuals for related
maintenance services.
6-4

❑Air brake automatic slack adjuster service (or every
500 hours, whichever occurs first).(33)
❑Check air brake relay valve operation and check for
leaks (or every month, or every 300 hours, whichever
occurs first).
❑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)
❑DURAMAX Diesel Only: Diesel Particulate
Filter (DPF) service. Then every 100,000 miles
(160 000 km).(7) (38)
6-19

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.
❑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)
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.
❑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.
6-20

(4)= Applies to vehicles sold in the United States and is
recommended for vehicles sold in Canada.
(5)= Check fluidlevel 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.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 5-35
orEngine Oil Life System (DURAMAX/Isuzu Diesel
Engines) on page 5-36orEngine Oil Life System
(Caterpillar Diesel Engine) on page 5-38.
(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 5-35
orEngine Oil Life System (DURAMAX/Isuzu Diesel
Engines) on page 5-36orEngine Oil Life System
(Caterpillar Diesel Engine) on page 5-38.
(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.
6-21

(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.
(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.
6-22