transmission GMC C-SERIES 1999 Service Manual

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6-74
Replacement Bulbs
It is recommended that you use an AC
type bulb
whenever you need to replace one.
Before you replace any bulbs, be sure that all lamps are
off and the engine isn't running.
Capacities and Specifications
Replacement part numbers listed in this section are
based on the latest information available at the time of
printing. They are subject to later change. If a part listed
here isn't the same as the part in your vehicle when it
was built, or if you have any questions, please contact
your GM Truck dealer.
Engine Identification and Data
Engine RPO LG5 LP4/L21
Engine Type 7.2L L6 7.4L V8
Fuel System HEUI SPFI
Firing Order
1
-5-3-6-2-41-8-4-3-6-5-7-2
Wheel Nut Torque
Refer to ªTightening the Wheel Nutsº in this section for
wheel nut torque information.
Cooling System Capacity
Model Quarts (Liters)
7.2L 32.0 (30.0). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
with automatic transmission 30.0 (28.4). . . . . . . . . .
7.4L 25.0 (23.7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
with automatic transmission 23.0 (22.7). . . . . . . . . .
Above capacities (volumes) are approximate.
Crankcase Capacity
Capacities (volumes) shown are for normal refill. Add
oil as indicated when the oil filter element is changed.
Capacities given are approximate
-- keep level within
the operating range. Do not operate with fluid level
below the ADD line.
Engine
Capacity
-- Quarts (Liters)
7.2L 21 (19.0)*
7.4L 8 (7.5)
*Additional 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).
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6-75
Extending the recommended oil change interval requires
the use of an infrared oil analysis program which shows
the condition of the oil and its additives. For more
information, consult your GM Truck dealer, who is an
authorized Caterpillar

engine dealer.
Transmission Capacity
Capacities (volumes) shown are approximate. 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)
RT6609 12.0 (5.7). . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RT6610 12.0 (5.8). . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RTO6610 12.0 (5.8). . . . . . . . . . . . . . . . . . . . . . . . . . . RT6613 16.0 (7.5). . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RT7608LL 19.5 (9.3). . . . . . . . . . . . . . . . . . . . . . . . . .
RT8609 15.0 (7.0). . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FS4205A, FS4205B, FS4205C 12.5 (5.9). . . . . . . . . .
5205A, FS5205C 12.5 (5.9). . . . . . . . . . . . . . . . . . . . .
FS5306 18.0 (8.5). . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FS6305A, FS6305B 19.0 (9.0). . . . . . . . . . . . . . . . . . .
FS6306 19.5 (9.2). . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FS7206 20.0 (9.5). . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T8607B 36.0 (17.0). . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic Transmission Pints (Liters)
AT542 (for oil pan filter change) 30.0 (14.0)*. . . . . . .
AT545 (for oil pan filter change) 40.0 (19.0)*. . . . . . .
MT643 (for oil pan filter change) 13.0 (24.5)*. . . . . .
MT653 (for oil pan filter change) 36.0 (17.0)*. . . . . .
*Add two pints (one liter) when changing spin
-on filter.
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6-77
Air Conditioning Refrigerants
Not all air conditioning refrigerants are the same.
If the air conditioning system in your vehicle needs
refrigerant, be sure the proper refrigerant is used.
If you're not sure, ask your dealer.
Air Conditioning Refrigerant Capacity
Refrigerant R-134a 2.5 lbs. (1.134 kg). . . . . . . . . . . .
This capacity (volume) is approximate.
Normal Maintenance Replacement
Parts
Allison Transmission External Filters
Engine GM (AC) Part Number
7.2L 25011122 (PF897). . . . . . . . . . . . . . . . . . . . . . .
7.4L 25011122 (PF897). . . . . . . . . . . . . . . . . . . . . . .
Air Compressor Filter
Air Compressor GM Part Number
Bendix Tu
-Flo
550 (13.2 CFM)2467368
Service Replacement Part and
Filter Recommendations
Engine 7.2L 7.4L
RPO LG5 LP4/L21
Spark Plug Ð AC Type R41
-932
ÐGap Ð 0.060 inch
(1.52 mm)
ÐTorque Ð 22.0 lb. ft.
(30.0 Nm)
Oil Filter CAT

2P4004 AC Type PF-932
PCV Valve Ð AC Type CV
-774C
Air Cleaner* Donaldson
P522606Donaldson
P533355
Fuel Filter AC
-TP-915 Pri-
mary**AC Type GF-481
Pressure Caps RC
-54 Ð
*Optional Davco (K28) D350921 spin
-on type filter
located in component box.
**Optional Cold Weather (KUK) Racor B6484GM
spin
-on type located in component box. Optional Davco
heated fuel water separator mounted on the side of the
diesel engine.
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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 GM 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
Certification/Tire 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
GM Owner's Manual is supplemented by the Caterpillar
Diesel Engine Operation & Maintenance Manual. If your
vehicle has an Allison transmission, your GM Owner's
Manual is supplemented by an Allison Transmission
Operator's Manual. Always refer to these manuals for
related maintenance services.
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7-17 99,000 Miles (165 000 km)

Engine oil and filter service. (3)(9)

Check fluid levels (or every 3 months, whichever
occurs first). (1)(2)(6)
100,000 Miles (166 000 km)

Change power steering fluid (or every 36 months,
whichever occurs first). (13)

Front axle service (or every 36 months, whichever
occurs first). (38)

Rear axle service
-- Eaton, Rockwell, Spicer Axles
(or every 12 months, whichever occurs first). (1)(37)

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

Accelerator control cable replacement (diesel) (or
every 36 months, whichever occurs first). (19)

Air brake service (or every 12 months, or
3,600 hours, whichever occurs first). (44)
150,000 Miles (240 000 km)

Cooling system service (or every 60 months since
last service, whichever occurs first). (3)(35)
200,000 Miles (320 000 km)

Remove, disassemble, clean and inspect the air brake
trailer supply valve (or every 2 years, or 7,200 hours,
whichever occurs first).
250,000 Miles (400 000 km)

Wheel bearings service -- Eaton Axle (oil-filled) (or
every 36 months, whichever occurs first). (2)(23)

Rear axle service
-- Eaton, Rockwell, Spicer Axles
(or every 36 months, whichever occurs first). (2)(37)

Manual transmission 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.
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7-18 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) = Check the fluid level in the manual transmission.
(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, clutch
master cylinder (if equipped), 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. 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 hydraulic parking brake drum and linings
for wear or cracks and check linkage and adjustment.
Check spring brake actuator and pump for leaks.
Note: The spring brake section of the actuator is
non
-serviceable.
(9) = This vehicle has an Engine Oil Life Monitor. This
monitor will show you when to change the engine oil
and filter
-- usually between 3,000 miles (5 000 km) and
7,500 miles (12 500 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 (12 500 km) or 12 months
without an oil and filter change.
The system won't detect dust in the oil. So if you drive
in a dusty area, be sure to change your oil and filter
every 3,000 miles (5 000 km) or sooner if the Change
Oil Light comes on. Remember to reset the Oil Life
Monitor whenever the oil is changed. For more
information, see ªChange Oil Lightº in the Index.
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7-19
(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 3,000 miles
(5 000 km) and 6,000 miles (10 000 km) and then every
6,000 miles (10 000 km) 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 24,000 miles (40 000 km)
and then every 24,000 miles (40 000 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), propeller shaft
slip joint, universal joint, 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.
(15) = Adjust tire pressures as indicated on the
Certification/Tire label for optimum tire life. See ªTiresº
in the Index for further details. Check tires for excessive
or abnormal wear or damage. Also check for damaged
wheels. Replace wheels and/or tires as needed.
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7-25
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 (see ªParking
Brakeº in the Index if necessary) and the
regular brakes.
NOTE: 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.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.
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7-28
Part C: Recommended Fluids
and Lubricants
NOTE: Fluids and lubricants identified below by
name, part number or specification may be obtained
from your dealer.
USAGE
FLUID/LUBRICANT
Engine Oil
(Gasoline
Engine)Engine Oil with the American
Petroleum Institute Certified For
Gasoline Engines ªStarburstº
symbol of the proper viscosity. To
determine the preferred viscosity
for your vehicle's engine, see
ªEngine Oilº in the Index.
Engine Oil
(Caterpillar
Diesel Engine)See the Caterpillar
Operation &
Maintenance Manual for Engine
Oil recommendations.
Engine Coolant
(GM Gasoline
Engine)50/50 mixture of clean, drinkable
water and use only GM
Goodwrench

DEX-COOL
or
Havoline
DEX-COOL

Coolant. See ªEngine Coolantº in
the Index.
USAGEFLUID/LUBRICANT
Engine Coolant
(Caterpillar
Diesel Engine)See the Caterpillar
Operation &
Maintenance Manual for Engine
Coolant recommendations.
Hydraulic Brake
SystemDelco Supreme 11
Brake Fluid
(GM Part No. 12377967 or
equivalent DOT
-3 Brake Fluid).
Windshield
Washer SolventGM Optikleen
Washer Solvent
(GM Part No. 1051515)
or equivalent.
Clutch Bearing
LubricantClutch Bearing Lubricant (GM
Part No. 12345777 or equivalent)
or NLGI #3 consistency.
Exhaust Brake
Ball Joint Cap
LubricantHigh-Temperature Grease (GM
Part No. 1051344 or equivalent) or
NLGI #3 consistency.
Spring Parking
Brake Hydraulic
PumpDEXRON
-III Automatic
Transmission Fluid.
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7-29
USAGEFLUID/LUBRICANT
Brake Caliper
Housing, Caliper
Support Spring
and Caliper
Support KeyAeroshell #5 Grease (GM Part
No. 12377969 or equivalent).
Air Brake
System Alcohol
EvaporatorCommercial grade of Methyl
Alcohol as specified in
GM 6015
-M.
Power Steering
SystemGM Power Steering Fluid
(GM Part No. 1052884
- 1 pint,
1050017
- 1 quart, or equivalent).
Manual
TransmissionSynthetic Manual Transmission
Fluid (GM Part No. 12345724) is
the recommended lubricant to use.
USAGEFLUID/LUBRICANT
Automatic
TransmissionSee the Allison Transmission
Operator's Manual for correct
Transmission Fluid.
Chassis
LubricationChassis Lubricant (GM Part
No. 12377985 or equivalent) or
lubricant meeting requirements
of NLGI # 2, Category LB
or GC
-LB.
Wheel Bearing
GreaseWheel Bearing Lubricant meeting
requirements of NLGI # 2,
Category GC or GC
-LB (GM
Part No. 1051344 or equivalent).
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