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RT6613
RT7608LL RT8609
FS4205A, FS4205B, FS4205C 5205A, FS5205C FS5306
FS6305A, FS6305B FS6306
FS7206
T8607B Automatic Transmission AT542 (for oil pan filter change) AT545 (for oil pan filter change) MT643 (for oil pan filter change) MT653 (for oil pan filter change)16.0 (7.5) 19.5 (9.3) 15.0 (7.0) 12.5 (5.9) 12.5 (5.9) 18.0 (8.5) 19.0 (9.0) 19.5 (9.2) 20.0 (9.5) 36.0 (17.0) Pints (Liters) 30.0 (14.0)* 40.0 (19.0)* 13.0 (24.5)* 36.0 (17.0)*
. . . . . . . . . . . . . . . . . . . . . . . . . .
*Add two pints (one liter) when changing spin-on filter.
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Rear Axle Lubricant Capacity Single Speed Axle 15040S 19060S 21060D 21060S 22060S 22080S 23080S 23431
23105S 26085P 26105S 30105S Two-Speed Axle 15040T 19060T 21060T 22060T 23080T 26080TLubricant, Pints (Liters) 21.0 (10.1) 28.0 (12.8) 28.0 (14.7) 28.0 (14.7) 28.0 (14.7) 40.0 (20.3) 40.0 (20.3) 40.0 (20.3) 48.0 (22.7) 41.0 (19.5) 48.0 (22.7) 46.0 (23.2) Lubricant, Pints (Liters) 24.0 (11.5) 35.0 (17.5) 35.0 (17.5) 35.0 (17.5) 39.0 (19.9) 41.0 (19.5)
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Above capacities (volumes) are approximate.
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Tandem Axles DS344 (front) RS344 (rear) DS454 (front) RS454 (rear) DS404, DS404P (front) RS404 (rear) DT402P (front) RT402 (rear)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubricant, Pints (Liters) 29.0 (15.1) 28.0 (13.2) 29.0 (15.1) 28.0 (13.2) 29.0 (15.1) 34.0 (16.1) 34.0 (16.1) 34.0 (16.1)
Above capacities (volumes) are approximate. Fuel Tank Capacity Model Standard Optional Optional Optional* Optional**
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gallons (Liters) 50 (189.0) 35 (132.5) 60 (227.1) 70 (264.0) 100 (378.0)
* Two 35-gallon (132 L) tanks **Two 50-gallon (189 L) tanks Above capacities (volumes) are approximate.
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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)
Service Replacement Part and Filter Recommendations Engine RPO Spark Plug —Gap
7.2L LG5
— —This capacity (volume) is approximate. Normal Maintenance Replacement Parts Allison Transmission External Filters Engine 7.2L 7.4L
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GM (AC) Part Number 25011122 (PF897) 25011122 (PF897)
—Torque
—
Oil Filter PCV Valve Air Cleaner* Donaldson
CATR 2P4004
—Fuel Filter
P522606
AC-TP-915 Pri- mary** Pressure Caps RC-547.4L LP4/L21
AC Type R41-932
0.060 inch (1.52 mm) 22.0 lb. ft. (30.0 Nm) AC Type PF-932
AC Type CV-774C Donaldson P533355
AC Type GF-481—
Air Compressor Filter Air Compressor GM Part Number Bendix Tu-Flo 550 (13.2 CFM)
2467368
*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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- NOTES
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Section 7 Scheduled Maintenance Services
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This section covers the maintenance required for your vehicle. Your vehicle needs these services to retain its safety, dependability and emission control performance.
7-2
7-4
7-5Introduction Part A: Scheduled Maintenance Services Scheduled Maintenance
7-23
7-28
7-31Part B: Owner Checks and Services Part C: Recommended Fluids and Lubricants Part D: Maintenance Record
7-
7-1
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Introduction Your Vehicle and the Environment Proper vehicle maintenance not only helps to keep your vehicle in good working condition, but also helps the environment. All recommended maintenance procedures are important. Improper vehicle maintenance can even affect the quality of the air we breathe. Improper fluid levels or the wrong tire inflation can increase the level of emissions from your vehicle. To help protect our environment, and to keep your vehicle in good condition, please maintain your vehicle properly.
Have you purchased the GM Protection Plan? The Plan supplements your new vehicle warranties. See your Warranty and Owner Assistance booklet, or your GM dealer for details.
7-2
How This Section is Organized This maintenance schedule is divided into five parts: “Part A: Scheduled Maintenance Services” shows what to have done and how often. Some of these services can be complex, so unless you are technically qualified and have the necessary equipment, you should let your dealer’s service department or another qualified service center do these jobs.
CAUTION:
Performing maintenance work on a vehicle can be dangerous. In trying to do some jobs, you can be seriously injured. Do your own maintenance work only if you have the required know-how and the proper tools and equipment for the job. If you have any doubt, have a qualified technician do the work.
If you are skilled enough to do some work on your vehicle, you will probably want to get the service information. See “Service and Owner Publications” in the Index.
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“Part B: Owner Checks and Services” tells you what should be checked and when. It also explains what you can easily do to help keep your vehicle in good condition. “Part C: Recommended Fluids and Lubricants” lists some recommended products to help keep your vehicle properly maintained. These products, or their equivalents, should be used whether you do the work yourself or have it done. “Part D: Maintenance Record” provides a place for you to record the maintenance performed on your vehicle. Whenever any maintenance is performed, be sure to write it down in this part. This will help you determine when your next maintenance should be done. In addition, it is a good idea to keep your maintenance receipts. They may be needed to qualify your vehicle for warranty repairs.
7-3
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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: D carry passengers and cargo within recommended limits. You will find these limits on your vehicle’s Certification/Tire label. See “Loading Your Vehicle” in the Index.
D are driven on reasonable road surfaces within legal
driving limits.
D use the recommended fuel. See “Fuel” in the Index. Scheduled Maintenance Supplements If your vehicle has a CaterpillarR diesel engine, your GM Owner’s Manual is supplemented by the CaterpillarR 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.
7-4
Scheduled Maintenance The services shown in this schedule up to 100,000 miles (166 000 km) should be performed after 100,000 miles (166 000 km) at the same intervals. The services shown after 100,000 miles (166 000 km) should be performed at those same intervals. This vehicle has a computer that lets you know when to change your engine oil. This is not based on mileage, but on engine revolutions and engine operating temperature. When the computer has calculated that the oil needs changing, the Oil Life Indicator will indicate that a change is necessary. See “Footnotes” at the end of this Maintenance Schedule for further explanation of maintenance services and CaterpillarR diesel application. 100 Miles (160 km) j Wheel stud nut service. (45) 500 Miles (800 km) j Wheel stud nut service. (45) 1,000 Miles (1 600 km) j Wheel stud nut service. (45)(46)
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3,000 Miles (5 000 km) j Engine oil and filter service. (3)(9) j Check fluid levels (or every 3 months, whichever
occurs first). (1)(2)(6)
j Clutch pedal free travel service. (10) j Rear axle air shift motor service. (11) 6,000 Miles (10 000 km) j Engine oil and filter service. (3)(9) j Check fluid levels (or every 3 months, whichever
occurs first). (1)(2)(6)
j Chassis lubrication service (or every 6 months,
whichever occurs first). (12)
j Lubricate door hinge pins and rollers with engine oil. j Wheels and tires service. (15) j Hydraulic brake service (or every 6 months,
whichever occurs first). (7)
j Hydraulic parking brake service (or every 6 months,
whichever occurs first). (8)
j Clutch pedal free travel service. (10) 9,000 Miles (15 000 km) j Engine oil and filter service. (3)(9) j Check fluid levels (or every 3 months, whichever
occurs first). (1)(2)(6)
7-5
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12,000 Miles (20 000 km) j Engine oil and filter service. (3)(9) j Check fluid levels (or every 3 months, whichever
occurs first). (1)(2)(6)
j Chassis lubrication service (or every 6 months,
whichever occurs first). (12)
j Lubricate door hinge pins and rollers with engine oil. j Wheels and tires service. (15) j Hydraulic brake service (or every 6 months,
whichever occurs first). (7)
j Hydraulic parking brake service (or every 6 months,
whichever occurs first). (8)
j Engine drive belts service (or every 12 months,
whichever occurs first). (18)
j Clutch pedal free travel service. (10) j Throttle linkage service. (19) j Thermostatically controlled engine cooling
fan service. (4)(20)
j Shields and underhood insulation service. (4)(5)(21) j Check air brake relay valve operation and check for
leaks (or every month, or every 300 hours, whichever occurs first).
15,000 Miles (25 000 km) j Engine oil and filter service. (3)(9) j Check fluid levels (or every 3 months, whichever
occurs first). (1)(2)(6)
j Steering system service. (13) j Front and rear suspension service. (14) j Spring-to-axle U-bolts and shackle bolts service. (16) j Exhaust system service (or every 6 months,
whichever occurs first). (3)(4)(17)
j Air brake service (or every 6 months, whichever
occurs first). (39)
18,000 Miles (30 000 km) j Engine oil and filter service. (3)(9) j Check fluid levels (or every 3 months, whichever
occurs first). (1)(2)(6)
j Chassis lubrication service (or every 6 months,
whichever occurs first). (12)
j Inspect door hinge pins and bushings and replace as necessary. Lubricate door hinge pins and rollers with engine oil.
7-6
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j Replace air conditioning filter dryer (or every
18 months, whichever occurs first, and whenever refrigerant charge is lost for any reason).
j Wheels and tires service. (15) j Hydraulic brake service (or every 6 months,
whichever occurs first). (7)
j Hydraulic brake caliper service (or every 6 months,
whichever occurs first). (22)
j Hydraulic parking brake service (or every 6 months,
whichever occurs first). (8)
j Clutch pedal free travel service. (10) j Clean air brake application valve (or every 3 months,
or every 300 hours, whichever occurs first); lubricate linkage.
21,000 Miles (35 000 km) j Engine oil and filter service. (3)(9) j Check fluid levels (or every 3 months, whichever
occurs first). (1)(2)(6)
24,000 Miles (40 000 km) j Engine oil and filter service. (3)(9) j Check fluid levels (or every 3 months, whichever
occurs first). (1)(2)(6)
j Chassis lubrication service (or every 6 months,
whichever occurs first). (12)
j Lubricate door hinge pins and rollers with engine oil. j Wheel bearing (grease type) service (or every
24 months, whichever occurs first, and whenever hubs are removed). (23)
j Wheels and tires service. (15) j Hydraulic brake service (or every 6 months,
whichever occurs first). (7)
j Hydraulic parking brake service (or every 6 months,
whichever occurs first). (8)
j Engine drive belts service (or every 12 months,
whichever occurs first). (18)
j Clutch pedal free travel service. (10) j Throttle linkage service. (19) j Thermostatically controlled engine cooling
fan service. (4)(20)
j Shields and underhood insulation service. (4)(5)(21) j Air intake system service (or every 24 months,
whichever occurs first). (4)(5)(24)
j Thermostatically controlled air cleaner service
(or every 24 months, whichever occurs first). (3)(4)(25)[
(Continued)
7-7
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24,000 Miles (40 000 km) (Continued) j Evaporative Control System service (if equipped) (or
every 24 months, whichever occurs first). (3)(26)[
j Rear axle air shift motor service. (11) j Check air brake relay valve operation and check for
leaks (or every month, or every 300 hours, whichever occurs first).
j Air brake chamber service (or every 2 months,
whichever occurs first). (41)
j Trailer brake hand control valve service (or every
3 months, or 900 hours, whichever occurs first). (42)
27,000 Miles (45 000 km) j Engine oil and filter service. (3)(9) j Check fluid levels (or every 3 months, whichever
occurs first). (1)(2)(6)
30,000 Miles (50 000 km) j Engine oil and filter service. (3)(9) j Check fluid levels (or every 3 months, whichever
occurs first). (1)(2)(6)
j Chassis lubrication service (or every 6 months,
whichever occurs first). (12)
j Replace fuel filter(s) (or every 12 months, whichever
occurs first). (3)
7-8
j Air cleaner filter replacement service (or every
24 months, whichever occurs first). (3)(4)(27)
j Steering system service. (13) j Front and rear suspension service. (14) j Spring-to-axle U-bolts and shackle bolts service. (16) j Exhaust system service (or every 6 months,
whichever occurs first). (3)(4)(17)
j Air brake service (or every 6 months, whichever
occurs first). (39)
j Lubricate door hinge pins and rollers with engine oil. j Wheels and tires service. (15) j Hydraulic brake service (or every 6 months,
whichever occurs first). (7)
j Hydraulic parking brake service (or every 6 months,
whichever occurs first). (8)
j Clutch pedal free travel service. (10) j Air brake automatic slack adjuster service (or every
500 hours, whichever occurs first). (40)
33,000 Miles (55 000 km) j Engine oil and filter service. (3)(9) j Check fluid levels (or every 3 months, whichever
occurs first). (1)(2)(6)
36,000 Miles (60 000 km) j Engine oil and filter service. (3)(9) j Check fluid levels (or every 3 months, whichever
occurs first). (1)(2)(6)
j Chassis lubrication service (or every 6 months,
whichever occurs first). (12)
j Inspect door hinge pins and bushings and replace as necessary. Lubricate door hinge pins and rollers with engine oil.
j Replace air conditioning filter dryer (or every
18 months, whichever occurs first, and whenever refrigerant charge is lost for any reason).
j Wheels and tires service. (15) j Hydraulic brake service (or every 6 months,
whichever occurs first). (7)
j Hydraulic brake caliper service (or every 6 months,
whichever occurs first). (22)
j Hydraulic parking brake service (or every 6 months,
whichever occurs first). (8)
j Engine drive belts service (or every 12 months,
whichever occurs first). (18)
j Clutch pedal free travel service. (10) j Throttle linkage service. (19) j Thermostatically controlled engine cooling
fan service. (4)(20)
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j Shields and underhood insulation service. (4)(5)(21) j Check air brake relay valve operation and check for
leaks (or every month, or every 300 hours, whichever occurs first).
j Clean air brake application valve (or every 3 months,
or every 300 hours, whichever occurs first); lubricate linkage.
39,000 Miles (65 000 km) j Engine oil and filter service. (3)(9) j Check fluid levels (or every 3 months, whichever
occurs first). (1)(2)(6)
42,000 Miles (70 000 km) j Engine oil and filter service. (3)(9) j Check fluid levels (or every 3 months, whichever
occurs first). (1)(2)(6)
j Chassis lubrication service (or every 6 months,
whichever occurs first). (12)
j Lubricate door hinge pins and rollers with engine oil. j Wheels and tires service. (15) j Hydraulic brake service (or every 6 months,
whichever occurs first). (7)
j Hydraulic parking brake service (or every 6 months,
whichever occurs first). (8)
j Clutch pedal free travel service. (10)
7-9
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45,000 Miles (75 000 km) j Engine oil and filter service. (3)(9) j Check fluid levels (or every 3 months, whichever
occurs first). (1)(2)(6)
j Steering system service. (13) j Front and rear suspension service. (14) j Spring-to-axle U-bolts and shackle bolts service. (16) j Exhaust system service (or every 6 months,
whichever occurs first). (3)(4)(17)
j Air brake service (or every 6 months, whichever
occurs first). (39)
48,000 Miles (80 000 km) j Engine oil and filter service. (3)(9) j Check fluid levels (or every 3 months, whichever
occurs first). (1)(2)(6)
j Chassis lubrication service (or every 6 months,
whichever occurs first). (12)
j Lubricate door hinge pins and rollers with engine oil. j Wheel bearing (grease type) service (or every
24 months, whichever occurs first, and whenever hubs are removed). (23)
j Wheels and tires service. (15) j Hydraulic brake service (or every 6 months,
whichever occurs first). (7)
7-10
j Hydraulic parking brake service (or every 6 months,
whichever occurs first). (8)
j Engine drive belts service (or every 12 months,
whichever occurs first). (18)
j Clutch pedal free travel service. (10) j Throttle linkage service. (19) j Thermostatically controlled engine cooling
fan service. (4)(20)
j Shields and underhood insulation service. (4)(5)(21) j Air intake system service (or every 24 months,
whichever occurs first). (4)(5)(24)
j Thermostatically controlled air cleaner service (or
every 24 months, whichever occurs first). (3)(4)(25)[
j Evaporative Control System service (if equipped) (or
every 24 months, whichever occurs first). (3)(26)[
j Rear axle air shift motor service. (11) j Check air brake relay valve operation and check for
leaks (or every month, or every 300 hours, whichever occurs first).
j Air brake chamber service (or every 2 months,
whichever occurs first). (41)
j Trailer brake hand control valve service (or every
3 months, or 900 hours, whichever occurs first). (42)
51,000 Miles (85 000 km) j Engine oil and filter service. (3)(9) j Check fluid levels (or every 3 months, whichever
occurs first). (1)(2)(6)
54,000 Miles (90 000 km) j Engine oil and filter service. (3)(9) j Check fluid levels (or every 3 months, whichever
occurs first). (1)(2)(6)
j Chassis lubrication service (or every 6 months,
whichever occurs first). (12)
j Inspect door hinge pins and bushings and replace if
necessary. Lubricate door hinge pins and rollers with engine oil.
j Replace air conditioning filter dryer (or every
18 months, whichever occurs first, and whenever refrigerant charge is lost for any reason).
j Wheels and tires service. (15) j Hydraulic brake service (or every 6 months,
whichever occurs first). (7)
j Hydraulic brake caliper service (or every 6 months,
whichever occurs first). (22)
j Hydraulic parking brake service (or every 6 months,
whichever occurs first). (8)
j Clutch pedal free travel service. (10)
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j Spark plug service. (3)(28) j Clean air brake application valve (or every 3 months,
or every 300 hours, whichever occurs first); lubricate linkage.
57,000 Miles (95 000 km) j Engine oil and filter service. (3)(9) j Check fluid levels (or every 3 months, whichever
occurs first). (1)(2)(6)
60,000 Miles (100 000 km) j Engine oil and filter service. (3)(9) j Check fluid levels (or every 3 months, whichever
occurs first). (1)(2)(6)
j Chassis lubrication service (or every 6 months,
whichever occurs first). (12)
j Replace fuel filter(s) (or every 12 months, whichever
occurs first). (3)
j Air cleaner filter replacement service (or every
24 months, whichever occurs first). (3)(4)(27)
j Steering system service. (13) j Front and rear suspension service. (14) j Spring-to-axle U-bolts and shackle bolts service. (16) (Continued)
7-11
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60,000 Miles (100 000 km) (Continued) j Exhaust system service (or every 6 months,
whichever occurs first). (3)(4)(17)
j Air brake service (or every 6 months, whichever
occurs first). (39)
j Lubricate door hinge pins and rollers with engine oil. j Wheels and tires service. (15) j Hydraulic brake service (or every 6 months,
whichever occurs first). (7)
j Hydraulic parking brake service (or every 6 months,
whichever occurs first). (8)
j Engine drive belts service (or every 12 months,
whichever occurs first). (18)
j Clutch pedal free travel service. (10) j Throttle linkage service. (19) j Thermostatically controlled engine cooling
fan service. (4)(20)
j Shields and underhood insulation service. (4)(5)(21) j Positive Crankcase Ventilation (PCV) system service (or every 60 months, whichever occurs first). (3)(33) j Check air brake relay valve operation and check for
leaks (or every month, or every 300 hours, whichever occurs first).
j Air brake automatic slack adjuster service (or every
500 hours, whichever occurs first). (40)
7-12
63,000 Miles (105 000 km) j Engine oil and filter service. (3)(9) j Check fluid levels (or every 3 months, whichever
occurs first). (1)(2)(6)
66,000 Miles (110 000 km) j Engine oil and filter service. (3)(9) j Check fluid levels (or every 3 months, whichever
occurs first). (1)(2)(6)
j Chassis lubrication service (or every 6 months,
whichever occurs first). (12)
j Lubricate door hinge pins and rollers with engine oil. j Wheels and tires service. (15) j Hydraulic brake service (or every 6 months,
whichever occurs first). (7)
j Hydraulic parking brake service (or every 6 months,
whichever occurs first). (8)
j Clutch pedal free travel service. (10) 69,000 Miles (115 000 km) j Engine oil and filter service. (3)(9) j Check fluid levels (or every 3 months, whichever
occurs first). (1)(2)(6)
72,000 Miles (120 000 km) j Engine oil and filter service. (3)(9) j Check fluid levels (or every 3 months, whichever
occurs first). (1)(2)(6)
j Chassis lubrication service (or every 6 months,
whichever occurs first). (12)
j Inspect door hinge pins and bushings and replace as necessary. Lubricate door hinge pins and rollers with engine oil.
j Replace air conditioning filter dryer (or every
18 months, whichever occurs first, and whenever refrigerant charge is lost for any reason).
j Wheel bearing (grease type) service (or every
24 months, whichever occurs first, and whenever hubs are removed). (23)
j Wheels and tires service. (15) j Hydraulic brake service (or every 6 months,
whichever occurs first). (7)
j Hydraulic brake caliper service (or every 6 months,
whichever occurs first). (22)
j Hydraulic parking brake service (or every 6 months,
whichever occurs first). (8)
j Engine drive belts service (or every 12 months,
whichever occurs first). (18)
j Clutch pedal free travel service. (10)
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j Throttle linkage service. (19) j Thermostatically controlled engine cooling
fan service. (4)(20)
j Shields and underhood insulation service. (4)(5)(21) j Air intake system service (or every 24 months,
whichever occurs first). (4)(5)(24)
j Thermostatically controlled air cleaner service (or
every 24 months, whichever occurs first). (3)(4)(25)
j Fuel tank, fuel cap and fuel lines service (or every
72 months, whichever occurs first). (3)(30) [ j EGR system inspection (or every 72 months,
whichever occurs first). (3)(31)
j Electronic Vacuum Regulator Valve (EVRV)
inspection (or every 72 months, whichever occurs first). (3)(32)
j Evaporative Control System Service (if equipped)
(or every 24 months, whichever occurs first). (3)(26)[
j Rear axle air shift motor service. (11) j Check air brake relay valve operation and check for
leaks (or every month, or every 300 hours, whichever occurs first).
(Continued)
7-13
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72,000 Miles (120 000 km) (Continued) j Clean air brake application valve (or every 3 months,
or every 300 hours, whichever occurs first); lubricate linkage.
j Air brake chamber service (or every 2 months,
whichever occurs first). (41)
j Trailer brake hand control valve service (or every
3 months, or 900 hours, whichever occurs first). (42)
75,000 Miles (125 000 km) j Engine oil and filter service. (3)(9) j Check fluid levels (or every 3 months, whichever
occurs first). (1)(2)(6)
j Steering system service. (13) j Front and rear suspension service. (14) j Spring-to-axle U-bolts and shackle bolts service. (16) j Exhaust system service (or every 6 months,
whichever occurs first). (3)(4)(17)
j Air brake service (or every 6 months, whichever
occurs first). (39)
78,000 Miles (130 000 km) j Engine oil and filter service. (3)(9) j Check fluid levels (or every 3 months, whichever
occurs first). (1)(2)(6)
j Chassis lubrication service (or every 6 months,
whichever occurs first). (12)
j Lubricate door hinge pins and rollers with engine oil. j Wheels and tires service. (15) j Hydraulic brake service (or every 6 months,
whichever occurs first). (7)
j Hydraulic parking brake service (or every 6 months,
whichever occurs first). (8)
j Clutch pedal free travel service. (10) 81,000 Miles (135 000 km) j Engine oil and filter service. (3)(9) j Check fluid levels (or every 3 months, whichever
occurs first). (1)(2)(6)
j Wheel bearings service -- Eaton Axle (oil-filled) (or
every 24 months, whichever occurs first). (1)(23)
84,000 Miles (140 000 km) j Engine oil and filter service. (3)(9) j Check fluid levels (or every 3 months, whichever
occurs first). (1)(2)(6)
j Chassis lubrication service (or every 6 months,
whichever occurs first). (12)
j Lubricate door hinge pins and rollers with engine oil. j Wheels and tires service. (15)
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j Hydraulic brake service (or every 6 months,
whichever occurs first). (7)
j Hydraulic parking brake service (or every 6 months,
whichever occurs first). (8)
j Engine drive belts service (or every 12 months,
whichever occurs first). (18)
j Clutch pedal free travel service. (10) j Throttle linkage service. (19) j Thermostatically controlled engine cooling
fan service. (4)(20)
j Shields and underhood insulation service. (4)(5)(21) j Check air brake relay valve operation and check for
leaks (or every month, or every 300 hours, whichever occurs first).
87,000 Miles (145 000 km) j Engine oil and filter service. (3)(9) j Check fluid levels (or every 3 months, whichever
occurs first). (1)(2)(6)
90,000 Miles (150 000 km) j Engine oil and filter service. (3)(9) j Check fluid levels (or every 3 months, whichever
occurs first). (1)(2)(6)
j Chassis lubrication service (or every 6 months,
whichever occurs first). (12)
j Replace fuel filter(s) (or every 12 months, whichever
occurs first). (3)
j Air cleaner filter replacement service (or every
24 months, whichever occurs first). (3)(4)(27)
j Steering system service. (13) j Front and rear suspension service. (14) j Spring-to-axle U-bolts and shackle bolts service. (16) j Exhaust system service (or every 6 months,
whichever occurs first). (3)(4)(17)
j Air brake service (or every 6 months, whichever
occurs first). (39)
j Inspect door hinge pins and bushings and replace as necessary. Lubricate door hinge pins and rollers with engine oil.
j Replace air conditioning filter dryer (or every
18 months, whichever occurs first, and whenever refrigerant charge is lost for any reason).
j Wheels and tires service. (15) j Hydraulic brake service (or every 6 months,
whichever occurs first). (7)
j Hydraulic brake caliper service (or every 6 months,
whichever occurs first). (22)
j Hydraulic parking brake service (or every 6 months,
whichever occurs first). (8)
(Continued) 7-15
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90,000 Miles (150 000 km) (Continued) j Clutch pedal free travel service. (10) j Air brake automatic slack adjuster service (or every
500 hours, whichever occurs first). (40)
j Clean air brake application valve (or every 3 months,
or every 300 hours, whichever occurs first); lubricate linkage.
93,000 Miles (155 000 km) j Engine oil and filter service. (3)(9) j Check fluid levels (or every 3 months, whichever
occurs first). (1)(2)(6)
96,000 Miles (160 000 km) j Engine oil and filter service. (3)(9) j Check fluid levels (or every 3 months, whichever
occurs first). (1)(2)(6)
j Chassis lubrication service (or every 6 months,
whichever occurs first). (12)
j Lubricate door hinge pins and rollers with engine oil. j Wheel bearing (grease type) service (or every
24 months, whichever occurs first, and whenever hubs are removed). (23)
j Wheels and tires service. (15) j Hydraulic brake service (or every 6 months,
whichever occurs first). (7)
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j Hydraulic parking brake service (or every 6 months,
whichever occurs first). (8)
j Engine drive belts service (or every 12 months,
whichever occurs first). (18)
j Clutch pedal free travel service. (10) j Throttle linkage service. (19) j Thermostatically controlled engine cooling
fan service. (4)(20)
j Shields and underhood insulation service. (4)(5)(21) j Air intake system service (or every 24 months,
whichever occurs first). (4)(5)(24)
j Thermostatically controlled air cleaner service (or
every 24 months, whichever occurs first). (3)(4)(25)[
j Evaporative Control System Service (if equipped)
(or every 24 months, whichever occurs first). (3)(26)[
j Rear axle air shift motor service. (11) j Check air brake relay valve operation and check for
leaks (or every month, or every 300 hours, whichever occurs first).
j Air brake chamber service (or every 2 months,
whichever occurs first). (41)
j Trailer brake hand control valve service (or every
3 months, or 900 hours, whichever occurs first). (42)
99,000 Miles (165 000 km) j Engine oil and filter service. (3)(9) j Check fluid levels (or every 3 months, whichever
occurs first). (1)(2)(6)
100,000 Miles (166 000 km) j Change power steering fluid (or every 36 months,
whichever occurs first). (13)
j Front axle service (or every 36 months, whichever
occurs first). (38)
j Rear axle service -- Eaton, Rockwell, Spicer Axles (or every 12 months, whichever occurs first). (1)(37)
j Exhaust brake service (if equipped). Check for
excessive spindle free play and smooth operation. Lubricate ball joint cap.
j Accelerator control cable replacement (diesel) (or
every 36 months, whichever occurs first). (19)
j Air brake service (or every 12 months, or 3,600 hours, whichever occurs first). (44)
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150,000 Miles (240 000 km) j Cooling system service (or every 60 months since
last service, whichever occurs first). (3)(35)
200,000 Miles (320 000 km) j 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) j Wheel bearings service -- Eaton Axle (oil-filled) (or
every 36 months, whichever occurs first). (2)(23)
j Rear axle service -- Eaton, Rockwell, Spicer Axles (or every 36 months, whichever occurs first). (2)(37)
j Manual transmission fluid replacement (or every
60 months, whichever occurs first).
300,000 Miles (480 000 km) j 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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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.
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(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 “Change Oil Light” in the Index.
(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.
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(13) = Check steering system: D 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.)
D 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.
D 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 “Tires” 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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(16) = 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. (17) = Check complete exhaust system 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. (18) = Check all engine drive belts for cracks, fraying, wear and proper tension. Adjust or replace as needed. (19) = Check throttle linkage for damaged or missing parts (including throttle return springs), interference or binding. Fix any problems at once. Do not lubricate accelerator and cruise control cables. (20) = 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.
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(21) = Check shields and underhood insulation for damage or looseness. Adjust or replace as needed. (22) = Lubricate caliper housing, caliper support spring and caliper support key. (23) = Wheel bearing service: D Grease type -- Clean, inspect and lubricate with the proper wheel bearing grease at designated intervals or when hubs are removed. See “Recommended Fluids and Lubricants” in the Index.
D Oil-filled type -- Some wheel bearings are lubricated
by rear axle lubricant. When you have oil-filled hubs, use lubricant identical to that used in your rear axle. Lubricant change intervals are the same for front and rear axles. However, you must maintain oil level at the OIL LEVEL mark between change intervals. See “Recommended Fluids and Lubricants” in the Index.
(24) = Check the air intake system installation to see that gaskets are seated properly and all hose connections, fasteners and other components are tight. For gasoline engines, also check to be sure the air cleaner housing is properly seated, that the cover fits tightly and that the wing nut is tight. Tighten connections and fasteners or replace parts as required.
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(25) = Check thermostatically controlled air cleaner installation to make certain that all ducts are connected and correctly installed. Also, check valve for proper operation. (26) = Evaporative Control System Service (if equipped): Check all fuel and vapor lines and hoses for proper connections and correct routing (or every 24 months, whichever occurs first). Replace parts as needed. (27) = Replace air cleaner filter (or every 24 months, whichever occurs first). Replace filter more often if driving in dusty conditions. Ask your dealer for the proper replacement intervals for your driving conditions. (28) = Replace spark plugs. Inspect wires for damage. Check the wire boot and boot heat shield fit at spark plugs and coil. Replace parts as needed. (30) = Check the fuel tank, fuel cap and fuel lines for damage which could cause leakage. Inspect fuel cap for correct sealing ability and any indications of damage. Check fuel cap gasket for even filler neck imprint. Replace parts as needed. (31) = Check EGR system as described in the service manual. See “Service and Owner Publications” in the Index. (32) = Inspect Electronic Vacuum Regulator Valve (EVRV) filter for excessive contamination or plugging. If needed, clean filter with solution of soap and water, let dry and install.
(33) = Check the PCV system for proper operation and clean PCV valve. Replace hoses as needed. (34) = Replace PCV valve and blow out the PCV valve hose with compressed air. Replace hoses as needed. (35) = Drain, flush and refill cooling system. See “Recommended Fluids and Lubricants” in the Index for what to use. Inspect hoses. Clean radiator, condenser, pressure cap and neck. Pressure test cooling system and pressure cap. For CaterpillarR diesel engines, always refer to the Caterpillar Diesel Engine Operation & Maintenance Manual for coolant recommendations and change intervals. (37) = Rear axle service: Change the lubricant. See “Recommended Fluids and Lubricants” in the Index. (38) = Front axle service: Re-pack upper kingpin roller bearing. (39) = Air brake service: D Inspect brake lines and hoses for proper hook-up, binding, leaks, cracks, chafing, etc. Inspect drum brake linings for wear or cracks. Inspect other brake parts at each wheel, including drums, wheel cylinders and piston heat shields and boots. 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.
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Remove, disassemble and clean the application valve; replace parts showing wear. Remove, disassemble, clean and inspect the spring brake control valve; replace rubber parts. (45) = For Stud Piloted Wheels Only: Tighten the wheel stud nuts to the specified torque values at 100 miles (160 km), 500 miles (800 km) and 1,000 miles (1 600 km) and then every 1,000 miles (1 600 km) thereafter. See “Tightening the Wheel Nuts” in the Index. (46) = For Hub Piloted Wheels Only: Tighten the wheel stud nuts to the specified torque values at 1,000 miles (1 600 km). Thereafter, tighten them 1,000 miles (1 600 km) after each time the wheel is removed. See “Tightening the Wheel Nuts” in the Index. (47) = Short Trip/City Maintenance Schedule. See “Maintenance Schedule Definition” in the introduction pages at the beginning of this section. (48) = Long Trip/Highway Maintenance Schedule. See “Maintenance Schedule Definition” in the introduction pages at the beginning of this section.
D Test air lines for leaks; tighten as needed. Replace
compressor filter.
D Inspect air parking brake chamber for leaks and
damage. Inspect lines and hoses for leaks, cracks, chafing, etc. Also check all attachments for tightness, wear or damage. Note: The spring brake section of the rear brake diaphragms are non-serviceable.
D Replace the air compressor filter element, mounted
on the air compressor. For remote air compressor intake service, refer to air cleaner filter replacement.
(40) = Clean and lubricate air brake automatic slack adjuster. Check pushrod travel and auto adjustment operation. Have serviced if needed. (41) = Air brake chamber service: Check operation, mounting, clamps and air lines and check for leaks. (42) = Trailer brake hand control valve service: Check operation; lubricate cam and follower. (44) = Air brake service: Remove, disassemble, clean and inspect the safety valve, standard brake chamber, quick release valve, quick release/double check valve combination, parking brake control valve, double check valve, pressure protection valve and alcohol injector.
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Part B: Owner Checks and Services Listed in this part are owner checks and services which should be performed at the intervals specified to help ensure the safety, dependability and emission control performance of your vehicle. For your safety and that of others, any of the safety-related components that may have been damaged in an accident should be checked and any needed repairs made before operating the vehicle. At the minimum, these routine checks should be made every 6 months or 6,000 miles (10 000 km), whichever occurs first. Whenever repairs are needed, have them completed before operating the vehicle. At Each Fuel Fill It is important for you or a service station attendant to perform these underhood checks at each fuel fill.
Engine Oil Level Check Check the engine oil level and add the proper oil if necessary. See “Engine Oil” in the Index for further details.
Engine Coolant Level Check Check the engine coolant level and add DEX-COOLR coolant mixture if necessary. See “Engine Coolant” in the Index for further details.
Windshield Washer Fluid Level Check Check the windshield washer fluid level in the windshield washer tank and add the proper fluid if necessary. See “Windshield Washer Fluid” in the Index for further details.
Tire Inflation Check Check tire inflation cold. Make sure tires are inflated to the pressures specified on the Certification/Tire label. See “Tires” in the Index for further details.
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Body Lubrication Service Lubricate all surfaces such as door checks, door lock bolts, lock strike plates, door hinge bushings and dovetail bumper wedges. Where oil holes are provided, a dripless oil can be used. The seat adjusters, seat track, door weatherstrips and rubber hood bumpers should also be lubricated. Part C tells you what to use. More frequent lubrication may be required when exposed to a corrosive environment.
Parking Brake Check Park on a fairly steep hill and hold the vehicle with the parking brake only. This checks holding ability.
At Least Twice a Year
Restraint System Check Make sure the safety belt reminder light (if equipped) and all your belts, buckles, latch plates, retractors and anchorages are working properly. Look for any other loose or damaged safety belt system parts. If you see anything that might keep a safety belt system from doing its job, have it repaired. Have any torn or frayed safety belts replaced.
Wiper Blade Check Inspect wiper blades for wear or cracking. Replace blade inserts that appear worn or damaged or that streak or miss areas of the windshield. Also see “Wiper Blades, Cleaning” in the Index.
Weatherstrip Lubrication Silicone grease on weatherstrips will make them last longer, seal better, and not stick or squeak. Apply silicone grease with a clean cloth. During very cold, damp weather more frequent application may be required. (See “Recommended Fluids and Lubricants” in the Index.)
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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 “Parking
Brake” 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.
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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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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 Check 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. Refer to “Engine Exhaust” and “Running Your Engine While You’re Parked” in the Index.
Windshield Wipers and Washers Check Check operation and condition of the wiper blades. Check the flow of the washer spray.
Defroster Check Move the control to the defrost symbol and the fan to HI or the high symbol. Then check the airflow from the ducts at the inside base of the windshield.
Mirrors and Sun Visors Check Check that friction joints hold mirrors and sun visors in place.
Seat Adjuster Check When adjusting a manual seat, be sure seat adjusters latch by attempting to move the seat after latching.
Lamps Check Check panel lighting, warning lights, indicator lights and interior lamps. On the outside, check: license plate lamps, sidemarker lamps, reflectors or lights on outside mirrors, headlamps, parking lamps, identification and clearance lamps, taillamps, brake lamps, turn signals, backup lamps and hazard warning flashers. Have headlamp aim checked at once if beams seem improperly aimed.
Glass, Mirrors, Lamps and/or Reflectors Condition Check Look for broken, scratched, dirty or damaged glass, mirrors, lamps or reflectors that could reduce the view or visibility or cause injury. Replace, clean or repair promptly.
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Door Latches Check Check that doors close, latch and lock tightly. Check for broken, damaged or missing parts that might prevent tight latching.
Hood Latches Check Check that the hood closes firmly. Check for broken, damaged, loose or missing parts that might prevent tight latching. Make sure the secondary latch (if equipped) keeps the hood from opening all the way when the primary latch is released.
Fluid Leaks Check Check for fuel, coolant, oil or other fluid leaks by looking at the surface beneath the vehicle after it has been parked for a while.
Underbody Inspection Corrosive materials used for ice, snow removal and dust control can collect on the underbody. If these materials are not removed, accelerated corrosion (rust) can occur on underbody parts such as fuel lines, frame, floor pan and exhaust system. At least every spring, flush these
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materials from the underbody with plain water. Take care to clean well any areas where mud and other debris can collect. Sediment packed in closed areas of the frame should be loosened before being flushed.
Engine Cover Check Check that the cab’s engine cover and seal (if equipped) are not torn or damaged. Be sure that the cover is bolted down firmly to the floor. At Least Once a Year
Key Lock Cylinders Service Lubricate the key lock cylinders with the lubricant specified in Part C.
Underbody Flushing Service At least every spring, use plain water to flush any corrosive materials from the underbody. Take care to clean thoroughly any areas where mud and other debris can collect.
Tractor Protection (Breakaway) Valve Check On air brake models, remove, disassemble, clean and inspect the tractor protection (breakaway) valve.
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USAGE Engine Coolant (Caterpillar Diesel Engine) Hydraulic Brake System
Windshield Washer Solvent
Clutch Bearing Lubricant
Exhaust Brake Ball Joint Cap Lubricant Spring Parking Brake Hydraulic Pump
FLUID/LUBRICANT See the CaterpillarR Operation & Maintenance Manual for Engine Coolant recommendations. Delco Supreme 11R Brake Fluid (GM Part No. 12377967 or equivalent DOT-3 Brake Fluid). GM OptikleenR Washer Solvent (GM Part No. 1051515) or equivalent. Clutch Bearing Lubricant (GM Part No. 12345777 or equivalent) or NLGI #3 consistency. High-Temperature Grease (GM Part No. 1051344 or equivalent) or NLGI #3 consistency. DEXRONR-III Automatic Transmission Fluid.
Part C: Recommended Fluids and Lubricants NOTE: Fluids and lubricants identified below by name, part number or specification may be obtained from your dealer.
FLUID/LUBRICANT Engine Oil with the American Petroleum Institute Certified For Gasoline Engines “Starburst” symbol of the proper viscosity. To determine the preferred viscosity for your vehicle’s engine, see “Engine Oil” in the Index. See the CaterpillarR Operation & Maintenance Manual for Engine Oil recommendations. 50/50 mixture of clean, drinkable water and use only GM GoodwrenchR DEX-COOLR or HavolineR DEX-COOLR Coolant. See “Engine Coolant” in the Index.
USAGE Engine Oil (Gasoline Engine)
Engine Oil (Caterpillar Diesel Engine) Engine Coolant (GM Gasoline Engine)
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USAGE Brake Caliper Housing, Caliper Support Spring and Caliper Support Key Air Brake System Alcohol Evaporator Power Steering System
Manual Transmission
FLUID/LUBRICANT Aeroshell #5 Grease (GM Part No. 12377969 or equivalent).
Commercial grade of Methyl Alcohol as specified in GM 6015-M. GM Power Steering Fluid (GM Part No. 1052884 - 1 pint, 1050017 - 1 quart, or equivalent). Synthetic Manual Transmission Fluid (GM Part No. 12345724) is the recommended lubricant to use.
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USAGE Automatic Transmission
Chassis Lubrication
Wheel Bearing Grease
FLUID/LUBRICANT See the Allison Transmission Operator’s Manual for correct Transmission Fluid. Chassis Lubricant (GM Part No. 12377985 or equivalent) or lubricant meeting requirements of NLGI # 2, Category LB or GC-LB. Wheel Bearing Lubricant meeting requirements of NLGI # 2, Category GC or GC-LB (GM Part No. 1051344 or equivalent).
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USAGE Front Wheel Bearings with Oil Filled Hubs
Rear Axle
Rear Axle Shift Motor Lubricant
FLUID/LUBRICANT SAE 75W-90 Synthetic Axle Lubricant for Medium Duty Trucks (GM Part No. 12345841 or equivalent). SAE 75W-90 Synthetic Axle Lubricant for Medium Duty Trucks (GM Part No. 12345841 or equivalent). Refrigerant Oil (GM Part No. 5416939).
USAGE Propshafts and Splines
Cab -- Door Hinges and Latches Weatherstrip Conditioning Weatherstrip Squeaks
FLUID/LUBRICANT Wheel Bearing Lubricant meeting requirements of NLGI # 2, Category GC or GC-LB (GM Part No. 1051344 or equivalent). Multi-Purpose Lubricant, SuperlubeR (GM Part No. 12346241 or equivalent). Dielectric Silicone Grease (GM Part No. 12345579 or equivalent). Synthetic Grease with Teflon, SuperlubeR (GM Part No. 12371287 or equivalent).
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Part D: Maintenance Record After the scheduled services are performed, enter the date, odometer reading and services performed on the maintenance record charts provided here. Any additional information from “Owner Checks and Services” can be
added on the following record pages. Also, you should retain all maintenance receipts. Your owner information portfolio is a convenient place to store them.
DATE
ODOMETER
READING
SERVICED BY
MAINTENANCE PERFORMED
Maintenance Record
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DATE
ODOMETER
READING
SERVICED BY
MAINTENANCE PERFORMED
Maintenance Record
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Section 8 Customer Assistance Information
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Here you will find out how to contact GMC if you need assistance. This section also tells you how to obtain service publications and how to report any safety defects.
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8-5
8-5
8-6Customer Satisfaction Procedure Customer Assistance for Text Telephone (TTY) Users Customer Assistance Offices Roadside Assistance Warranty Information Reporting Safety Defects to the United States Government
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8-7
8-7Reporting Safety Defects to the Canadian Government Reporting Safety Defects to General Motors Ordering Service and Owner Publications in Canada
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8-1
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Your satisfaction and goodwill are important to your dealer and to GMC. Normally, any concerns with the sales transaction or the operation of your vehicle will be resolved by your dealer’s sales or service departments. Sometimes, however, despite the best intentions of all concerned, misunderstandings can occur. If your concern has not been resolved to your satisfaction, the following steps should be taken: STEP ONE -- Discuss your concern with a member of dealership management. Normally, concerns can be quickly resolved at that level. If the matter has already been reviewed with the sales, service or parts manager, contact the owner of the dealership or the general manager. STEP TWO -- If after contacting a member of dealership management, it appears your concern cannot be resolved by the dealership without further help, contact the GMC Consumer Relations Manager by calling 1-800-GMC-8782 (1-800-462-8782, Customer Assistance prompt). In Canada, contact GM of Canada Customer Communication Centre in Oshawa by calling 1-800-263-3777 (English) or 1-800-263-7854 (French).
Customer Satisfaction Procedure
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We encourage you to call the toll-free number in order to give your inquiry prompt attention. Please have the following information available to give the Customer Assistance Representative: D Vehicle Identification Number (This is available from the vehicle registration or title, or the plate at the top left of the instrument panel and visible through the windshield.)
D Dealership name and location D Vehicle delivery date and present mileage When contacting GMC, please remember that your concern will likely be resolved at a dealer’s facility. That is why we suggest you follow Step One first if you have a concern.
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Customer Assistance for Text Telephone (TTY) Users To assist customers who are deaf, hard of hearing, or speech-impaired and who use Text Telephones (TTYs), GMC has TTY equipment available at its Customer Assistance Center. Any TTY user can communicate with GMC by dialing: 1-800-GMC-8583 (1-800-462-8583). (TTY users in Canada can dial 1-800-263-3830.) Customer Assistance Offices GMC encourages customers to call the toll-free number for assistance. If a U.S. customer wishes to write to GMC, the letter should be addressed to GMC’s Customer Assistance Center. United States
Pontiac-GMC Customer Assistance Center P.O. Box 436008
Pontiac, MI 48343-60081-800-GMC-8782 (1-800-462-8782) 1-800-462-8583 (For Text Telephone devices (TTYs)) Roadside Assistance: 1-800-GMC-8782
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Caribbean Numbers 1-800-496-9992 (English) Puerto Rico 1-800-496-9993 (Spanish) Puerto Rico 1-800-751-4135 (English) Dominican Republic 1-800-751-4136 (Spanish) Dominican Republic 1-800-496-9994 U.S. Virgin Islands 1-800-389-0009 Bahamas 1-800-534-0122 Bermuda, Barbados, Antigua & B.V.I. If toll free service is not available in the Caribbean, call Puerto Rico 1-787-763-1315.
Canada
General Motors of Canada Limited Customer Communication Centre, 163-005
1908 Colonel Sam Drive Oshawa, Ontario L1H 8P71-800-263-3777 (English) 1-800-263-7854 (French) 1-800-263-3830 (For Text Telephone devices (TTYs)) Roadside Assistance: 1-800-268-6800
All Overseas Locations
GMODC - Customer Communication Centre 169-007
1908 Colonel Sam Drive Oshawa, Ontario L1H 8P7Telephone: 905-644-4112
Fax: 905-644-48668-4
Roadside Assistance
GM Medium Duty Truck’s Roadside Assistance provides stranded owners with towing service for disabled vehicles.
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This service combines the efforts of trained telephone representatives with a network of GM Medium Duty Truck’s dealer services. Just dial Medium Duty Roadside Assistance at 1-800-GMC-8782 (1-800-462-8782) to reach a qualified representative who can assist you in a repair or arrange a tow. Other recommended services can also be arranged for situations such as retrieving locked-in keys, changing a tire or delivering gasoline, at a charge to the owner. We also provide dealer information at no charge such as location of the nearest authorized medium duty GM Truck dealer and their hours of operation. Roadside Assistance is available 24 hours a day, 7 days a week, 365 days a year, including weekends and holidays. Should you have any questions about Roadside Assistance, call the GMC Roadside Assistance Center or contact your dealer. Warranty Information Your vehicle comes with a separate warranty booklet that contains detailed warranty information.
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REPORTING SAFETY DEFECTS TO THE CANADIAN GOVERNMENT If you live in Canada, and you believe that your vehicle has a safety defect, you should immediately notify Transport Canada, in addition to notifying General Motors of Canada Limited. You may write to:
Transport Canada 330 Sparks Street Tower C Ottawa, Ontario K1A 0N5
REPORTING SAFETY DEFECTS TO THE UNITED STATES GOVERNMENT If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA), in addition to notifying General Motors. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer or General Motors. To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-800-424-9393 (or 366-0123 in the Washington, D.C. area) or write to:
NHTSA, U.S. Department of Transportation Washington, D.C. 20590
You can also obtain other information about motor vehicle safety from the hotline.
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Ordering Service and Owner Publications in Canada Service manuals, owner’s manuals and other service literature are available for purchase for all current and past model General Motors vehicles. The toll-free telephone number for ordering information in Canada is 1-800-668-5539.
REPORTING SAFETY DEFECTS TO GENERAL MOTORS In addition to notifying NHTSA (or Transport Canada) in a situation like this, we certainly hope you’ll notify us. Please call us at 1-800-GMC-8782
(1-800-462-8782), or write:Pontiac-GMC Customer Assistance Center P.O. Box 436008
Pontiac, MI 48343-6008In Canada, please call us at 1-800-263-3777 (English) or 1-800-263-7854 (French). Or, write: General Motors of Canada Limited Customer Communication Centre, 163-005
1908 Colonel Sam Drive Oshawa, Ontario L1H 8P78-7
1999 GMC SERVICE PUBLICATIONS ORDERING INFORMATION
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The following publications covering the operation and servicing of your vehicle can be purchased by filling out
the Service Publication Order Form in this book and mailing it in with your check, money order,
or credit card information to Helm, Incorporated (address below.)
CURRENT PUBLICATIONS FOR 1999 GMC
SERVICE MANUALS Service Manuals have the diagnosis and repair information on engines, transmission, axle, suspension, brakes, electrical, steering, body, etc. RETAIL SELL PRICE: $90.00
OWNER’S INFORMATION Owner publications are written directly for Owners and intended to provide basic operational information about the vehicle. The owner’s manual will include the Maintenance Schedule for all models.
TRANSMISSION, TRANSAXLE, TRANSFER CASE UNIT REPAIR MANUAL This manual provides information on unit repair service procedures, adjustments and specifications for the 1999 GM transmissions, transaxles and transfer cases. RETAIL SELL PRICE: $50.00
SERVICE BULLETINS Service Bulletins give 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.
PLEASE COMPLETE THE ORDER FORM SHOWN ON THE FOLLOWING PAGE AND MAIL TO:
Helm, Incorporated S P.O. Box 07130 S Detroit, MI 48207
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In-Portfolio: Includes a Portfolio, Owner’s Manual and Warranty Booklet. RETAIL SELL PRICE: $15.00
Without Portfolio: Owner’s Manual only. RETAIL SELL PRICE: $10.00
CURRENT & PAST MODEL ORDER FORMS Service Publications are available for current and past model GM vehicles. To request an order form, please specify year and model name of the vehicle.
OR 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)
ORDER TOLL FREE
(NOTE: For Credit Card Holders Only)
