2009 GMC T-Series Manual en CA

Seats and Restraint System ............................. 1-1Front Seats ............................................... 1-2Safety Belts .............................................. 1-6Child Restraints ....................................... 1-24Restraint System Check ............................ 1-36

Features and Controls ..................................... 2-1Keys ........................................................ 2-2Doors and Locks ....................................... 2-3Windows .................................................. 2-4Starting and Operating Your Vehicle ............. 2-7Mirrors .................................................... 2-35Storage Areas ......................................... 2-36

Instrument Panel ............................................. 3-1Instrument Panel Overview .......................... 3-4Climate Controls ...................................... 3-16Warning Lights, Gages, and Indicators ........ 3-19Audio System(s) ....................................... 3-39

Driving Your Vehicle ....................................... 4-1Your Driving, the Road, and the Vehicle ....... 4-2Towing ................................................... 4-21

Service and Appearance Care .......................... 5-1Service ..................................................... 5-3Fuel ......................................................... 5-7Checking Things Under the Hood ............... 5-16Rear Axle ............................................... 5-47Cab Tilting .............................................. 5-48Noise Control System ............................... 5-55Bulb Replacement .................................... 5-56Windshield Wiper Blade Replacement ......... 5-56Other Service Items .................................. 5-57Tires ...................................................... 5-60Appearance Care ..................................... 5-72Vehicle Identification ................................. 5-78Electrical System ...................................... 5-79Capacities and Specifications ..................... 5-88Normal Maintenance Replacement Parts ...... 5-91

Maintenance Schedule ..................................... 6-1Maintenance Schedule ................................ 6-2

Customer Assistance Information .................... 7-1Customer Assistance and Information ........... 7-2Reporting Safety Defects ............................ 7-9Vehicle Data Recording and Privacy ........... 7-11

Index ................................................................ 1

2009 GMC T-Series Owner Manual M

GENERAL MOTORS, GM, the GM Emblem, GMC, andthe GMC Truck Emblem are registered trademarksof General Motors Corporation.

This manual includes the latest information at the time itwas printed. GM reserves the right to make changesafter that time without further notice. For vehicles firstsold in Canada, substitute the name “General Motors ofCanada Limited” for GM Medium Duty Truck Divisionwherever it appears in this manual.

This manual describes features that may or may not beon your specific vehicle.

Read this manual from beginning to end to learn aboutthe vehicle’s features and controls. Pictures, symbols,and words work together to explain vehicle operation.

Keep this manual in the vehicle for quick reference.

Canadian OwnersA French language copy of this manual can be obtainedfrom your dealer/retailer or from:

Helm, IncorporatedP.O. Box 07130Detroit, MI 48207

1-800-551-4123helminc.com

Propriétaires CanadiensOn peut obtenir un exemplaire de ce guide en françaisauprès de concessionnaire ou à l’adresse suivante:

Helm IncorporatedP.O. Box 07130Detroit, MI 48207

1-800-551-4123helminc.com

IndexTo quickly locate information about the vehicle use theIndex in the back of the manual. It is an alphabeticallist of what is in the manual and the page number whereit can be found.

Litho in U.S.A.Part No. 25778616 A First Printing ©2008 General Motors Corporation. All Rights Reserved.

ii

Safety Warnings and SymbolsA circle with a slashthrough it is a safetysymbol which means“Do Not,” “Do not dothis” or “Do not let thishappen.”

A box with the word CAUTION is used to tell aboutthings that could hurt you or others if you were to ignorethe warning.

{CAUTION:

These mean there is something that could hurtyou or other people.

Cautions tell what the hazard is and what to do to avoidor reduce the hazard. Read these cautions.

A notice tells about something that can damage thevehicle.

Notice: These mean there is something that coulddamage your vehicle.

Many times, this damage would not be covered by thevehicle’s warranty, and it could be costly. The noticetells what to do to help avoid the damage.

There are also warning labels on the vehicle which usethe same words, CAUTION or Notice.

Vehicle SymbolsThe vehicle has components and labels that usesymbols instead of text. Symbols are shown along withthe text describing the operation or informationrelating to a specific component, control, message,gage, or indicator.

M : This symbol is shown when you need to see yourowner manual for additional instructions or information.

* : This symbol is shown when you need to see aservice manual for additional instructions or information.

iii

Vehicle Symbol ChartHere are some additional symbols that may be found onthe vehicle and what they mean. For more informationon the symbol, refer to the index.

9 : Airbag Readiness Light

# : Air Conditioning

! : Antilock Brake System (ABS)

g : Audio Steering Wheel Controls or OnStar®

$ : Brake System Warning Light

" : Charging System

I : Cruise Control

B : Engine Coolant Temperature

O : Exterior Lamps

# : Fog Lamps

. : Fuel Gage

+ : Fuses

i : Headlamp High/Low-Beam Changer

j : LATCH System Child Restraints

* : Malfunction Indicator Lamp

: : Oil Pressure

g : Outside Power Foldaway Mirrors

} : Power

/ : Remote Vehicle Start

> : Safety Belt Reminders

7 : Tire Pressure Monitor

F : Traction Control

M : Windshield Washer Fluid

iv

Front Seats ......................................................1-2Manual Seats ................................................1-2Manual Lumbar ..............................................1-3Reclining Seatbacks ........................................1-3Air Suspension Seats ......................................1-5Center Seat ...................................................1-6

Safety Belts .....................................................1-6Safety Belts: They Are for Everyone .................1-6How to Wear Safety Belts Properly .................1-12Lap-Shoulder Belt .........................................1-20Safety Belt Use During Pregnancy ..................1-22Lap Belt ......................................................1-23Safety Belt Extender .....................................1-24

Child Restraints .............................................1-24Older Children ..............................................1-24Infants and Young Children ............................1-27Child Restraint Systems .................................1-31Lower Anchors and Tethers for Children

(LATCH) ..................................................1-34Securing a Child Restraint in Your

Medium Duty Vehicle .................................1-34Restraint System Check ..................................1-36

Checking the Restraint Systems ......................1-36Replacing Restraint System Parts

After a Crash ............................................1-36

Section 1 Seats and Restraint System

1-1

Front Seats

Manual Seats

Your vehicle has bucket seats. You can adjust thedriver’s seat with these levers located at the front ofthe seat.

{CAUTION:

You can lose control of the vehicle if you try toadjust a manual driver’s seat while the vehicle ismoving. The sudden movement could startle andconfuse you, or make you push a pedal when youdo not want to. Adjust the driver’s seat only whenthe vehicle is not moving.

Slide lever (A) to the left to unlock the seat and slide theseat to where you want it. Release the lever and tryto move the seat with your body to make sure the seatis locked into place.

To adjust the lower seat cushion forward or backward,pull up on lever (B) and slide the cushion to whereyou want it. Then release the lever.

1-2

Manual Lumbar

To get more support in the lumbar area of your back,turn the lumbar adjustment knob. The knob is locatedon the inboard side of the driver’s seatback andthe outboard side of the passenger’s seatback.

Reclining Seatbacks

{CAUTION:

You can lose control of the vehicle if you try toadjust a manual driver’s seat while the vehicle ismoving. The sudden movement could startle andconfuse you, or make you push a pedal when youdo not want to. Adjust the driver’s seat only whenthe vehicle is not moving.

To tilt the seatback, turn the reclining knob. The knob islocated on the outboard side of both seats.

1-3

{CAUTION:

Sitting in a reclined position when your vehicle isin motion can be dangerous. Even if you buckleup, your safety belts cannot do their job when youare reclined like this.

The shoulder belt cannot do its job. In a crash,you could go into it, receiving neck or otherinjuries.

The lap belt cannot do its job either. In a crash thebelt could go up over your abdomen. The beltforces would be there, not at your pelvic bones.This could cause serious internal injuries.

For proper protection when the vehicle is inmotion, have the seatback upright. Then sit wellback in the seat and wear your safety beltproperly.

Do not have a seatback reclined if the vehicle is moving.

1-4

Air Suspension SeatsYour vehicle may have an air suspension seat. Thereare two ways you can adjust the seat.

Height Adjustment

The height adjustment iscontrolled by the airsuspension valve. Thelever for the valve islocated on the outboardside of the driver’s seat.

Pull the lever up to raise the seat. Push the lever downto lower the seat.

Isolator Lock Lever

The lever is located onthe inboard side of thedriver’s seat.

Move the handle down to lock the seat in place.This is used to reduce backslap experienced while intractor/trailer operation or while operating a dump truck.

Lever shown in theLocked Position

1-5

Center SeatYour vehicle may have a center seat.

To fold the seatback down, pull the lever, located on theright side of the seat.

Then lower the seatback forward and push down firmlyto lock in position. A storage compartment is locatedon the rear of the seatback for use when the seatback isin the fully lowered position.

Push the lever on the right side of the seat and pull onthe seatback when you are ready to raise it.

{CAUTION:

If either seatback is not locked, it could moveforward in a sudden stop or crash. That couldcause injury to the person sitting there. Alwayspush and pull on the seatbacks to be sure theyare locked.

Safety Belts

Safety Belts: They Are for EveryoneThis part of the manual tells you how to use safetybelts properly. It also tells you some things you shouldnot do with safety belts.

{CAUTION:

Do not let anyone ride where a safety belt cannotbe worn properly. In a crash, if you or yourpassenger(s) are not wearing safety belts, theinjuries can be much worse. You can hit thingsinside the vehicle harder or be ejected from thevehicle. You and your passenger(s) can beseriously injured or killed. In the same crash, youmight not be, if you are buckled up. Always fastenyour safety belt, and check that your passenger(s)are restrained properly too.

1-6

{CAUTION:

It is extremely dangerous to ride in a cargo area,inside or outside of a vehicle. In a collision,people riding in these areas are more likely to beseriously injured or killed. Do not allow people toride in any area of your vehicle that is notequipped with seats and safety belts. Be sureeveryone in your vehicle is in a seat and using asafety belt properly.

Your vehicle has indicators as a reminder to buckle yoursafety belts. See Safety Belt Reminders on page 3-22.

In most states and in all Canadian provinces, the lawrequires wearing safety belts. Here is why:

You never know if you will be in a crash. If you do havea crash, you do not know if it will be a serious one.

A few crashes are mild, and some crashes can be soserious that even buckled up, a person would notsurvive. But most crashes are in between. In many ofthem, people who buckle up can survive and sometimeswalk away. Without belts they could have been badlyhurt or killed.

After more than 40 years of safety belts in vehicles,the facts are clear. In most crashes buckling up doesmatter... a lot!

1-7

Why Safety Belts WorkWhen you ride in or on anything, you go as fast asit goes.

Take the simplest vehicle. Suppose it is just a seat onwheels.

Put someone on it.

1-8

Get it up to speed. Then stop the vehicle. The riderdoes not stop.

The person keeps going until stopped by something.In a real vehicle, it could be the windshield...

1-9

or the instrument panel... or the safety belts!

With safety belts, you slow down as the vehicle does.You get more time to stop. You stop over more distance,and your strongest bones take the forces. That is whysafety belts make such good sense.

1-10

Questions and Answers AboutSafety Belts

Q: Will I be trapped in the vehicle after a crash if Iam wearing a safety belt?

A: You could be — whether you are wearing a safetybelt or not. But you can unbuckle a safety belt,even if you are upside down. And your chance ofbeing conscious during and after an accident,so you can unbuckle and get out, is much greater ifyou are belted.

Q: If I am a good driver, and I never drive far fromhome, why should I wear safety belts?

A: You may be an excellent driver, but if you are in acrash — even one that is not your fault — you andyour passenger(s) can be hurt. Being a gooddriver does not protect you from things beyond yourcontrol, such as bad drivers.

Most accidents occur within 25 miles (40 km) ofhome. And the greatest number of serious injuriesand deaths occur at speeds of less than 40 mph(65 km/h).

Safety belts are for everyone.

1-11

How to Wear Safety Belts ProperlyThis section is only for people of adult size.

Be aware that there are special things to know aboutsafety belts and children. And there are differentrules for smaller children and infants. If a child will beriding in the vehicle, see Older Children on page 1-24 orInfants and Young Children on page 1-27. Follow thoserules for everyone’s protection.

It is very important for all occupants to buckle up.Statistics show that unbelted people are hurt more oftenin crashes than those who are wearing safety belts.

Occupants who are not buckled up can be thrown out ofthe vehicle in a crash. And they can strike others inthe vehicle who are wearing safety belts.

First, before you or your passenger(s) wear a safetybelt, there is important information you should know. Sit up straight and always keep your feet on the floor in

front of you. The lap part of the belt should be worn lowand snug on the hips, just touching the thighs. In a crash,this applies force to the strong pelvic bones and youwould be less likely to slide under the lap belt. If you slidunder it, the belt would apply force on your abdomen.This could cause serious or even fatal injuries. Theshoulder belt should go over the shoulder and across thechest. These parts of the body are best able to take beltrestraining forces.

The shoulder belt locks if there is a sudden stop or crash.

1-12

Q: What is wrong with this?

A: The shoulder belt is too loose. It will not give asmuch protection this way.

{CAUTION:

You can be seriously hurt if your shoulder belt istoo loose. In a crash, you would move forward toomuch, which could increase injury. The shoulderbelt should fit snugly against your body.

1-13


A: The lap belt is too loose. It will not give nearly asmuch protection this way.

{CAUTION:

You can be seriously hurt if your lap belt is tooloose. In a crash, you could slide under the lapbelt and apply force on your abdomen. This couldcause serious or even fatal injuries. The lap beltshould be worn low and snug on the hips, justtouching the thighs.

1-14


A: The belt is buckled in the wrong buckle.

{CAUTION:

You can be seriously injured if your belt is buckledin the wrong place like this. In a crash, the beltwould go up over your abdomen. The belt forceswould be there, not on the pelvic bones. Thiscould cause serious internal injuries. Alwaysbuckle your belt into the buckle nearest you.

1-15


A: The belt is over an armrest.

{CAUTION:

You can be seriously injured if your belt goes overan armrest like this. The belt would be much toohigh. In a crash, you can slide under the belt.The belt force would then be applied on theabdomen, not on the pelvic bones, and that couldcause serious or fatal injuries. Be sure the beltgoes under the armrests.

1-16


A: The shoulder belt is worn under the arm. It shouldbe worn over the shoulder at all times.

{CAUTION:

You can be seriously injured if you wear theshoulder belt under your arm. In a crash, yourbody would move too far forward, which wouldincrease the chance of head and neck injury.Also, the belt would apply too much force to theribs, which are not as strong as shoulder bones.You could also severely injure internal organs likeyour liver or spleen. The shoulder belt should goover the shoulder and across the chest.

1-17


A: The belt is behind the body.

{CAUTION:

You can be seriously injured by not wearing thelap-shoulder belt properly. In a crash, you wouldnot be restrained by the shoulder belt. Your bodycould move too far forward increasing the chanceof head and neck injury. You might also slideunder the lap belt. The belt force would then beapplied right on the abdomen. That could causeserious or fatal injuries. The shoulder belt shouldgo over the shoulder and across the chest.

1-18


A: The belt is twisted across the body.

{CAUTION:

You can be seriously injured by a twisted belt. In acrash, you would not have the full width of the beltto spread impact forces. If a belt is twisted, makeit straight so it can work properly, or ask yourdealer/retailer to fix it.

1-19

Lap-Shoulder BeltAll seating positions in the vehicle have a lap-shoulderbelt except for the center passenger positions(if equipped), which have a lap belt. See Lap Belton page 1-23 for more information.

The following instructions explain how to wear alap-shoulder belt properly.

1. Adjust the seat, if the seat is adjustable, so you cansit up straight. To see how, see “Seats” in the Index.

2. Pick up the latch plate and pull the belt across you.Do not let it get twisted.The lap-shoulder belt may lock if you pull the beltacross you very quickly. If this happens, let the beltgo back slightly to unlock it. Then pull the beltacross you more slowly.

3. Push the latch plate into the buckle until it clicks.Pull up on the latch plate to make sure it is secure.If the belt is not long enough, see Safety BeltExtender on page 1-24.Position the release button on the buckle so thatthe safety belt could be quickly unbuckled ifnecessary.

4. If equipped with a shoulder belt height adjuster,move it to the height that is right for you.See “Shoulder Belt Height Adjustment” later inthis section for instructions on use and importantsafety information.

1-20

5. To make the lap part tight, pull up on theshoulder belt.It may be necessary to pull stitching on the safetybelt through the latch plate to fully tighten thelap belt on smaller occupants.

To unlatch the belt, push the button on the buckle.The belt should return to its stowed position.

Before a door is closed, be sure the belt is out of theway. If a door is slammed against a safety belt, damagecan occur to both the belt and the vehicle.

1-21

Shoulder Belt Height AdjustmentThe vehicle has a shoulder belt height adjuster for thedriver and front passenger seating positions.

Adjust the height so that the shoulder portion of the beltis centered on the shoulder. The belt should be awayfrom the face and neck, but not falling off the shoulder.Improper shoulder belt height adjustment couldreduce the effectiveness of the safety belt in a crash.

To move it down, press inat the top of the arrowsand move the heightadjuster to the desiredposition. The adjuster canbe moved up by pushingup on the shoulderbelt guide.

After the adjuster is set to the desired position, try tomove it down without pressing the release buttonto make sure it has locked into position.

Safety Belt Use During PregnancySafety belts work for everyone, including pregnantwomen. Like all occupants, they are more likely to beseriously injured if they do not wear safety belts.

A pregnant woman should wear a lap-shoulder belt, andthe lap portion should be worn as low as possible,below the rounding, throughout the pregnancy.

The best way to protect the fetus is to protect themother. When a safety belt is worn properly, it is morelikely that the fetus will not be hurt in a crash. Forpregnant women, as for anyone, the key to makingsafety belts effective is wearing them properly.

1-22

Lap BeltThis section is only for the lap belt. To learn how towear a lap-shoulder belt, see Lap-Shoulder Belton page 1-20.

Your vehicle may have a center seating position.When you sit in the center front seating position,you have a lap safety belt, which has no retractor.

To make the belt longer, tilt the latch plate and pull italong the belt.

Buckle, position, and release it the same way as the lappart of a lap-shoulder belt.

To make the belt shorter, pull its free end as shownuntil the belt is snug.

If the belt is not long enough, see Safety Belt Extenderon page 1-24.

Make sure the release button on the buckle is positionedso you would be able to unbuckle the safety beltquickly if necessary.

1-23

Safety Belt ExtenderIf the safety belt will fasten around you, you should use it.

But if a safety belt is not long enough, yourdealer/retailer will order you an extender. When you goin to order it, take the heaviest coat you will wear,so the extender will be long enough for you. To helpavoid personal injury, do not let someone else useit, and use it only for the seat it is made to fit. Theextender has been designed for adults. Never use it forsecuring child seats. To wear it, attach it to theregular safety belt. For more information, see theinstruction sheet that comes with the extender.

Child Restraints

Older Children

Older children who have outgrown booster seats shouldwear the vehicle’s safety belts.

1-24

The manufacturer’s instructions that come with thebooster seat, state the weight and height limitations forthat booster. Use a booster seat with a lap-shoulderbelt until the child passes the below fit test:

• Sit all the way back on the seat. Do the knees bendat the seat edge? If yes, continue. If no, return tothe booster seat.

• Buckle the lap-shoulder belt. Does the shoulder beltrest on the shoulder? If yes, continue. If no, thenreturn to the booster seat.

• Does the lap belt fit low and snug on the hips,touching the thighs? If yes, continue. If no, return tothe booster seat.

• Can proper safety belt fit be maintained forlength of trip? If yes, continue. If no, return to thebooster seat.

If you have the choice, a child should sit in a positionwith a lap-shoulder belt and get the additional restraint ashoulder belt can provide.

Q: What is the proper way to wear safety belts?

A: An older child should wear a lap-shoulder belt andget the additional restraint a shoulder belt canprovide. The shoulder belt should not cross the faceor neck. The lap belt should fit snugly below thehips, just touching the top of the thighs. This appliesbelt force to the child’s pelvic bones in a crash.It should never be worn over the abdomen, whichcould cause severe or even fatal internal injuriesin a crash.

According to accident statistics, children and infants aresafer when properly restrained in the rear seatingpositions than in the front seating positions.

In a crash, children who are not buckled up can strikeother people who are buckled up, or can be thrownout of the vehicle. Older children need to use safetybelts properly.

1-25

{CAUTION:

Never do this.

Never allow two children to wear the same safetybelt. The safety belt can not properly spread theimpact forces. In a crash, the two children can becrushed together and seriously injured. A safetybelt must be used by only one person at a time.

{CAUTION:

Never do this.

Never allow a child to wear the safety belt with theshoulder belt behind their back. A child can beseriously injured by not wearing the lap-shoulderbelt properly. In a crash, the child would not berestrained by the shoulder belt. The child couldmove too far forward increasing the chance ofhead and neck injury. The child might also slideunder the lap belt. The belt force would then beapplied right on the abdomen. That could causeserious or fatal injuries. The shoulder belt shouldgo over the shoulder and across the chest.

1-26

Infants and Young ChildrenEveryone in a vehicle needs protection! This includesinfants and all other children. Neither the distancetraveled nor the age and size of the traveler changesthe need, for everyone, to use safety restraints. In fact,the law in every state in the United States and inevery Canadian province says children up to some agemust be restrained while in a vehicle.

{CAUTION:

Children can be seriously injured or strangled if ashoulder belt is wrapped around their neck andthe safety belt continues to tighten. Never leavechildren unattended in a vehicle and never allowchildren to play with the safety belts.

Airbags plus lap-shoulder belts offer protection foradults and older children, but not for young children andinfants. Neither the vehicle’s safety belt system norits airbag system is designed for them. Every timeinfants and young children ride in vehicles, they shouldhave the protection provided by appropriate childrestraints.

Children who are not restrained properly can strikeother people, or can be thrown out of the vehicle.

1-27

{CAUTION:

Never do this.

Never hold an infant or a child while riding in avehicle. Due to crash forces, an infant or a childwill become so heavy it is not possible to hold itduring a crash. For example, in a crash at only25 mph (40 km/h), a 12 lb (5.5 kg) infant willsuddenly become a 240 lb (110 kg) force on aperson’s arms. An infant should be secured in anappropriate restraint.

1-28

{CAUTION:

Never do this.

Children who are up against, or very close to, anyairbag when it inflates can be seriously injured orkilled. Never put a rear-facing child restraint in theright front seat. Secure a rear-facing child restraintin a rear seat. It is also better to secure aforward-facing child restraint in a rear seat. If youmust secure a forward-facing child restraint in theright front seat, always move the front passengerseat as far back as it will go.

1-29

Q: What are the different types of add-on childrestraints?

A: Add-on child restraints, which are purchased by thevehicle’s owner, are available in four basic types.Selection of a particular restraint should takeinto consideration not only the child’s weight, height,and age but also whether or not the restraint willbe compatible with the motor vehicle in which it willbe used.

For most basic types of child restraints, there aremany different models available. When purchasing achild restraint, be sure it is designed to be usedin a motor vehicle. If it is, the restraint will have alabel saying that it meets federal motor vehiclesafety standards.

The restraint manufacturer’s instructions that comewith the restraint state the weight and heightlimitations for a particular child restraint. In addition,there are many kinds of restraints available forchildren with special needs.

{CAUTION:

To reduce the risk of neck and head injury duringa crash, infants need complete support. This isbecause an infant’s neck is not fully developedand its head weighs so much compared with therest of its body. In a crash, an infant in arear-facing child restraint settles into the restraint,so the crash forces can be distributed across thestrongest part of an infant’s body, the back andshoulders. Infants should always be secured inrear-facing child restraints.

1-30

{CAUTION:

A young child’s hip bones are still so small thatthe vehicle’s regular safety belt may not remainlow on the hip bones, as it should. Instead, it maysettle up around the child’s abdomen. In a crash,the belt would apply force on a body area that isunprotected by any bony structure. This alonecould cause serious or fatal injuries. To reduce therisk of serious or fatal injuries during a crash,young children should always be secured inappropriate child restraints.

Child Restraint Systems

A rear-facing infantseat (A) provides restraintwith the seating surfaceagainst the back ofthe infant.

The harness system holds the infant in place and,in a crash, acts to keep the infant positioned inthe restraint.

1-31

A forward-facing childseat (B) provides restraintfor the child’s bodywith the harness.

A booster seat (C-D) is a child restraint designed toimprove the fit of the vehicle’s safety belt system.A booster seat can also help a child to see out thewindow.

1-32

Securing an Add-on Child Restraint inthe Vehicle

{CAUTION:

A child can be seriously injured or killed in a crashif the child restraint is not properly secured in thevehicle. Secure the child restraint properly in thevehicle using the vehicle’s safety belt, followingthe instructions that came with that child restraintand the instructions in this manual.

To help reduce the chance of injury, the child restraintmust be secured in the vehicle. Child restraint systemsmust be secured in vehicle seats by lap belts or thelap belt portion of a lap-shoulder belt. A child canbe endangered in a crash if the child restraint is notproperly secured in the vehicle.

When securing an add-on child restraint, refer to theinstructions that come with the restraint which may be onthe restraint itself or in a booklet, or both, and to thismanual. The child restraint instructions are important, soif they are not available, obtain a replacement copyfrom the manufacturer.

Keep in mind that an unsecured child restraint canmove around in a collision or sudden stop and injurepeople in the vehicle. Be sure to properly secureany child restraint in your vehicle — even when no childis in it.

Securing the Child Within the ChildRestraint

{CAUTION:

A child can be seriously injured or killed in a crashif the child is not properly secured in the childrestraint. Secure the child properly following theinstructions that came with that child restraint.

1-33

Lower Anchors and Tethers forChildren (LATCH)Some child restraints have a LATCH system. As part ofthe LATCH system, your child restraint may have lowerattachments and/or a top tether. The LATCH system canhelp hold the child restraint in place during driving or in acrash. Some vehicles have lower and/or top tetheranchors designed to secure a child restraint with lowerattachments and/or a top tether.Some child restraints with a top tether are designed to beused whether the top tether is anchored or not. Otherchild restraints require that the top tether be anchored.A national or local law may require that the top tetherbe anchored.In Canada, the law requires that forward-facing childrestraints have a top tether, and that the tether beattached.Your vehicle does not have lower anchors or top tetheranchors to secure a child restraint with the LATCHsystem. If a national or local law requires that your toptether be anchored, do not use a child restraint in thisvehicle because a top tether cannot be properlyanchored. You must use the safety belts to secure yourchild restraint in this vehicle, unless a national or local lawrequires that the top tether be anchored. Refer to yourchild restraint instructions and instructions in thismanual for securing a child restraint using the vehicle’ssafety belts.

Securing a Child Restraint in YourMedium Duty VehicleWe know securing a child can present real problems in amedium-duty vehicle like yours. The only place whereyou can properly secure a child restraint is the centerseating position, the place that has the lap belt only. Butyour vehicle may not have a center seating position. Or,even if you have one, you may find that the child restraintkeeps you from operating the shift lever or other controls.The only answer may be to have the smaller childrenmake the trip in another vehicle, where they can get theprotection they need.

You will be using the lap belt. Be sure to follow theinstructions that came with the child restraint. Secure thechild in the child restraint when and as the instructionssay. But do not use this position if the child restraintinterferes with shifting gears.

There are no top tether anchors in this vehicle. Do notsecure a child seat in this vehicle if a national or local lawrequires that the top tether be anchored, or if theinstructions that come with the restraint say that the toptether must be anchored. See Lower Anchors andTethers for Children (LATCH) on page 1-34 if the childrestraint has one.

In Canada, the law requires that forward-facing childrestraints have a top tether, and that the tether beattached.

1-34

1. Make the belt as long as needed by tilting the latchplate and pulling it along the belt.

2. Put the child restraint on the seat.

3. Run the vehicle’s safety belt through or around therestraint. The child restraint instructions will showyou how.

4. Push the latch plate into the buckle until it clicks.Make sure the release button is positioned so youwould be able to unbuckle the safety belt quickly ifnecessary.

5. Tighten the belt by pulling its free end while you pushdown on the child restraint. If you are using aforward-facing child restraint, you may find it helpfulto use your knee to push down on the child restraintas you tighten the belt.

6. Push and pull the child restraint in different directionsto be sure it is secure.

To remove the child restraint, unbuckle the vehicle’ssafety belt.

1-35

Restraint System Check

Checking the Restraint SystemsNow and then, make sure the safety belt reminder lightand all your belts, buckles, latch plates, retractorsand anchorages are working properly.

Look for any other loose or damaged safety belt systemparts. If you see anything that might keep a safetybelt system from doing its job, have it repaired. Torn orfrayed safety belts may not protect you in a crash.They can rip apart under impact forces. If a belt is tornor frayed, get a new one right away.

Make sure the safety belt reminder light is working.See Safety Belt Reminders on page 3-22 for moreinformation.

Keep safety belts clean and dry. See Care of SafetyBelts on page 5-74.

Replacing Restraint System PartsAfter a Crash

{CAUTION:

A crash can damage the restraint systems in yourvehicle. A damaged restraint system may notproperly protect the person using it, resulting inserious injury or even death in a crash. To helpmake sure your restraint systems are workingproperly after a crash, have them inspected andany necessary replacements made as soon aspossible.

If you have had a crash, do you need new belts?

After a very minor crash, nothing may be necessary.But the belt assemblies that were used during any crashmay have been stressed or damaged. See yourdealer/retailer to have your safety belt assembliesinspected or replaced.

New parts and repairs may be necessary even if thebelt system was not being used at the time of the crash.

1-36

Keys ...............................................................2-2Doors and Locks .............................................2-3

Door Locks ....................................................2-3Windows .........................................................2-4

Manual Windows ............................................2-4Power Windows .............................................2-5Passenger Side Door Glass .............................2-6

Starting and Operating Your Vehicle .................2-7New Vehicle Break-In ......................................2-7Ignition Positions ............................................2-8Starting the Diesel Engine ...............................2-8Engine Alarm and Automatic Shutdown ............2-11Idle Shutdown ..............................................2-11High Idle System ..........................................2-12Exhaust Restrictor .........................................2-13Engine Checks Before Operating ....................2-13Engine Coolant Heater ..................................2-15Diesel Engine Exhaust Brake .........................2-16Automatic Transmission Operation ...................2-17Automatic Transmission Third-Gear Hold ..........2-18

Manual Transmission Operation ......................2-19Power Take-Off (PTO) ...................................2-21Parking .......................................................2-21Two-Speed Rear Axle ...................................2-22Parking Brake (With Hydraulic Brakes) .............2-24Parking Brake (With Air Brakes) ......................2-25Parking Brake Burnish Procedure ....................2-27Air Suspension .............................................2-28Parking Over Things That Burn .......................2-29Engine Exhaust ............................................2-29Diesel Particulate Filter ..................................2-30Running the Vehicle While Parked ..................2-34

Mirrors ...........................................................2-35Manual Rearview Mirror .................................2-35Outside Manual Mirrors ..................................2-35Outside Convex Mirrors .................................2-35Outside Heated Mirrors ..................................2-36

Storage Areas ................................................2-36Center Console Storage .................................2-37

Section 2 Features and Controls

2-1

Keys

{CAUTION:

Leaving children in a vehicle with the ignition keyis dangerous for many reasons, children or otherscould be badly injured or even killed. They couldoperate the power windows or other controls oreven make the vehicle move. The windows willfunction with the keys in the ignition and childrencould be seriously injured or killed if caught in thepath of a closing window. Do not leave the keys ina vehicle with children.

The key can be used for the ignition switch and all locks.

The key has a code on it that tells your dealer/retailer ora qualified locksmith how to make extra keys. Recordand keep the key code in a safe place. If the key is lost,you can have a new one made using this code.

Notice: If you ever lock your keys in the vehicle,you may have to damage the vehicle to get in.Be sure you have spare keys.

2-2

Doors and LocksDoor Locks

{CAUTION:

Unlocked doors can be dangerous.• Passengers, especially children, can easily

open the doors and fall out of a moving vehicle.When a door is locked, the handle will not openit. You increase the chance of being thrown outof the vehicle in a crash if the doors are notlocked. So, wear safety belts properly and lockthe doors whenever you drive.

• Young children who get into unlocked vehiclesmay be unable to get out. A child can beovercome by extreme heat and can sufferpermanent injuries or even death from heatstroke. Always lock your vehicle whenever youleave it.

• Outsiders can easily enter through an unlockeddoor when you slow down or stop your vehicle.Locking your doors can help prevent this fromhappening.

A manual door lock is located above each door handle.

To lock your door from the inside, push the manual lockin. To unlock the door, pull the manual lock out.

When the doors are locked, they can’t be opened usingthe inside handles until the manual lock is pulled out.

2-3

Windows

{CAUTION:

Leaving children, helpless adults, or pets in avehicle with the windows closed is dangerous.They can be overcome by the extreme heat andsuffer permanent injuries or even death from heatstroke. Never leave a child, a helpless adult, or apet alone in a vehicle, especially with the windowsclosed in warm or hot weather.

Manual WindowsTurn the hand crank on each door to raise or lower thewindow.

2-4

Power Windows

If your vehicle has powerwindows, the switches forboth windows are locatedon the driver’s door. Inaddition, the passengerdoor has a switch for itsown window.

Press the rearward part of the switch to lower thewindow. Press the forward part of the switch to raise thewindow.

The power windows will operate when the ignition is inACC/ACCESSORY or ON/RUN.

Power Window Lock SwitchPressing the power window lock switch once locks thepassenger side window and prevents it from openingor closing. Pressing the switch a second time unlocksthe passenger side window.

Express-DownThe driver’s window has an express-down feature.This allows the window to be lowered fully withoutcontinuously holding the switch. Press the switch downfully to initiate the express-down feature. Press thetop of the switch to stop the window from lowering.

2-5

Passenger Side Door Glass

If your vehicle has this feature, the cover on thepassenger’s side lower window will open so that theglass can be cleaned.

{CAUTION:

Never open the passenger side door glass withthe ignition on. You can be injured if the windowlinkage moves. Open this glass only with theignition off.

To open the window cover, pull on the latch at the rearof the window and swing the window cover open.When closing the window cover, push firmly at the latchto close completely.

2-6

Starting and Operating YourVehicle

New Vehicle Break-InNotice: The vehicle does not need an elaboratebreak-in. But it will perform better in the long run ifyou follow these guidelines:

• Let the engine warm up before you operate thevehicle under load.

• Keep your speed at 55 mph (88 km/h) or less forthe first 500 miles (805 km).

• Do not drive at any one speed, fast or slow, forthe first 500 miles (805 km). Do not makefull-throttle starts.

• Avoid making hard stops for the first 200 miles(322 km) or so. During this time the new brakelinings are not yet broken in. Hard stopswith new linings can mean premature wear andearlier replacement. Follow this breaking-inguideline every time you get new brake linings.

• Use the lowest gear you can when you start aloaded vehicle in motion and when going uphills to avoid overloading the engine.

• Check and adjust engine and transmission fluidlevels often and be sure tires are properlyinflated for the load you are carrying.

• When new, parking brake linings have not yetbeen broken in. When linings are new, it ispossible that the vehicle could move while theparking brake is applied. Before using theparking brake on grades, follow the parkingbrake burnish procedure. See Parking BrakeBurnish Procedure on page 2-27.

2-7

Ignition Positions

The ignition switch hasfour different positions.

LOCK/OFF: This position locks the ignition. The keycan only be removed in LOCK/OFF.

ACC (ACC/ACCESSORY): This is the position in whichyou can operate the electrical accessories. Use thisposition if the vehicle must be pushed or towed.

ON/RUN: This position can be used to operate theelectrical accessories and to display some instrumentpanel cluster warning and indicator lights. The switchstays in this position when the engine is running.

If you leave the key in the ACC/ACCESSORY or ON/RUN position with the engine off, the battery could bedrained. You may not be able to start the vehicle if thebattery is allowed to drain for an extended period of time.

START: This is the position that starts the engine.When the engine starts, release the key. The ignitionswitch returns to ON/RUN for driving.

A warning tone will sound when you park the vehicle,the driver door is opened and the key is in the ignition.

Starting the Diesel Engine

Automatic TransmissionMove the shift lever to P (Park) or N (Neutral). Theengine will not start in any other position. To restart theengine when the vehicle is already moving, useN (Neutral) only.

Notice: Do not try to shift to P (Park) if the vehicleis moving. If you do, you could damage thetransmission. Shift to P (Park) only when the vehicleis stopped.

2-8

Manual TransmissionMove the shift lever to N (Neutral) and hold the clutchpedal to the floor while starting the engine. The vehiclewill not start if the clutch pedal is not all the way down.

Starting Procedure1. Turn the ignition key to ON/RUN.

Observe the wait to start light. See Wait to StartLight on page 3-29.This light may not come on if the engine is hot.

2. As soon as the wait to start light goes off,immediately turn the ignition key to START.When the engine starts, let go of the key.

Notice: Holding the key in START for longer than15 seconds at a time will cause the battery to bedrained much sooner. And the excessive heat candamage the starter motor.

Notice: If the wait to start indicator stays on afterstarting your vehicle, your vehicle may not runproperly. Have your vehicle serviced right away.

3. If the engine does not start after 15 seconds ofcranking, turn the ignition key to LOCK/OFF.Wait one minute for the starter to cool, then try thesame steps again.

When the engine is cold, let it run for a few minutesbefore you move the vehicle. This lets oil pressure buildup. The engine will sound louder when it is cold.

Notice: If you are not in an idling vehicle and theengine overheats, you would not be there to see theoverheated engine indication. This could damage thevehicle. Do not let the engine run when you are not inthe vehicle.

Cold Weather StartingThe following tips will help with cold weather starting.

Use the recommended engine oil when the outsidetemperature drops below freezing. See Engine Oil onpage 5-16. When the outside temperature dropsbelow 0°F (−18°C), use of the engine coolant heater isrecommended.

See Engine Coolant Heater on page 2-15 for moreinformation.

See What Fuel to Use on page 5-7 for information onwhat fuel to use in cold weather.

2-9

If the Engine Will Not StartIf you are not out of fuel, and the engine will not start,do this:

Turn the ignition key to ON/RUN. Immediately after thewait to start light goes off, turn the ignition key toSTART.

If the light does not go off, wait a few seconds, then trystarting the engine again. And, see your dealer/retaileras soon as you can for a starting system check.

If the light comes on and then goes off and you knowthe batteries are charged, but the engine still willnot start, the vehicle needs service.

If the light does not come on when the engine is cold,the vehicle needs service.

If the batteries do not have enough charge to start theengine, see Battery on page 5-41 for more information.

Be sure you have the right oil for the engine, andthat you have changed the oil at the proper times. If youuse the wrong oil, the engine may be harder to start.See Engine Oil on page 5-16 for more information.

Be sure you are using the proper fuel for existingweather conditions. See What Fuel to Use on page 5-7What Fuel to Use.

If the engine starts, runs a short time, then stops, thevehicle needs service.

{CAUTION:

Do not use gasoline or starting aids, such asether, in the air intake. They could damage theengine. There could also be a fire, which couldcause serious personal injury.

2-10

Engine Alarm and AutomaticShutdownFor vehicles with this feature, the check gages light willcome on if the system senses high engine temperature,and a low or high engine oil pressure. See Check GagesWarning Light on page 3-36 for more information. If ahigh engine temperature is detected, or if a low or highengine oil pressure is detected, a tone alarm sounds.The alarm and the light remains on until the condition isfixed. If the engine temperature or oil pressure conditionworsens, the tone alarm increases in frequency.

If the system senses there is low engine coolant, thealarm and the low coolant warning light comes on.

See Low Coolant Warning Light on page 3-29 for moreinformation.

The alarm means that your engine will shut down.See Engine Shutdown Warning Light on page 3-34 formore information.

Pull off the road and shut off the engine. Do not start ituntil the vehicle is repaired. If the engine shuts downwhile you are still in traffic, the engine can be restartedfor another 25-30 seconds of operation. In thiscondition, the engine speed remains at idle, and will notincrease even if the accelerator pedal is pressed.The engine will not shut down until the vehicle speed isless than 5 mph (8 km/h).

Notice: If you try to operate the vehicle after theengine automatically shuts down, you may damagethe vehicle. Have the vehicle repaired as soon aspossible.

Idle ShutdownIf the vehicle has a diesel engine it could have anengine idle shutdown feature.

This feature automatically shuts down the engine after itidles continuously for five minutes and if the followingconditions are met:

• The parking brake is set.

• The vehicle is at a complete stop.

• The automatic transmission is in N (Neutral) orP (Park).

If the parking brake is not engaged, then the engineshuts down after 15 minutes of continuous idlingoperation.

The driver can reset the engine shutdown timer bymomentarily changing the position of the accelerator,brake, or clutch pedal or by shifting the transmission outof P (Park) or N (Neutral). Once reset, the engine idleshutdown will restart the shutdown sequence describedabove, and will continue to do so until the engineshuts down or the vehicle is driven.

2-11

The engine will not go into idle shutdown mode if:

• The Power Take-Off (PTO) equipment is operating.See Power Take-Off (PTO) on page 2-21 for moreinformation.

• The engine coolant temperature is below 60°F. Theengine idle shutdown will be activated once thevehicle coolant reaches 60°F or above.

• The Diesel Particulate Filter (DPF) is in regenerationmode and the green DPF lamp is illuminated tonotify the driver that DPF is regenerating. Theengine idle shutdown mode will be overridden forthe time necessary to complete the regenerationprocess, up to a maximum of 30 minutes.

• Service or maintenance is being performed on theengine. The engine idle shutdown mode may bedeactivated, by using a diagnostic scan tool,for a period of up to a maximum of 60 minutes.

The ENGINE SHUTDOWN WARNING LIGHT willcome on and a continuous chime will alert the driver30 seconds before the engine goes into idle shutdownmode. The engine shutdown warning light and chimewill stay on for the entire duration of the idle shutdownevent to inform the driver that the engine is in idleshutdown mode. See Engine Shutdown Warning Lighton page 3-34 for more information.

After the engine shutdown occurs, the engine is nolonger running, and the ignition is still in the ON/RUNposition, all accessories can be used. Turn the ignitionswitch to START to restart the engine or turn it toLOCK/OFF to prevent the battery from draining.

High Idle System

Manual High Idle SystemIf the vehicle has thisfeature, the manual highidle button is located in theinstrument panel. SeeInstrument Panel Overviewon page 3-4 InstrumentPanel Overview formore information.

This system can be used to increase engine idle speedwhenever the following conditions are met:• The brake pedal is not pressed.• The vehicle is at a complete stop.

• The manual transmission clutch pedal is not pressedor, the automatic transmission is in N (Neutral) orP (Park).

2-12

The manual high idle feature is activated by pressingthe button on the instrument panel. When the button ispressed again, or any of the previous conditions arenot met, manual high idle will be deactivated.

Exhaust RestrictorIf the vehicle is equipped with this feature, there is anexhaust restrictor valve located in the exhaust stream.The valve closes to provide back pressure to the enginefor the purpose of warming the engine quickly.

The exhaust restrictor operates:

• while the engine is running.

• while the vehicle is not moving.

• while the accelerator, brake and clutch pedals arenot pressed on a manual transmission vehicle.

• while idling in cold temperatures.

• when the shifter is in N (Neutral) or P (Park) on anautomatic transmission vehicle.

On vehicles equipped with a diesel engine exhaustbrake, the exhaust brake switch must be on. See DieselEngine Exhaust Brake on page 2-16 for moreinformation. The indicator in the exhaust brake switchwill be lit when the exhaust restrictor is active. Theexhaust brake indicator light in the center of the

instrument panel will also be lit whenever the exhaustrestrictor is active. See Exhaust Brake Indicator Light onpage 3-34 for more information.

When the engine coolant temperature is below149°F (65°C) and the outside temperature is below50°F (10°C), the exhaust restrictor will come onwithin 60 seconds of starting the engine. After runningthe engine for an additional 10 seconds, the engine idlewill increase.

The exhaust restrictor will shut off and engine idle willreturn to normal once the engine is warmed up, orthe brake pedal is pressed.

Engine Checks Before OperatingWhen you have started the engine, let it run for20 to 30 seconds before you put a load on it. But donot leave the vehicle while the engine is running.

Avoid unnecessary idling of diesel engine equippedvehicles.

If the engine idles too long, the temperature of theengine coolant will fall below the normal operatingrange. Low engine operating temperature causesseveral conditions which affect engine operation andreduce engine life.

2-13

The engine should be permitted to go through awarm-up period. Operate the vehicle at a minimum of600 rpm during the warm-up period. During thisperiod and during operation, the following observationsshould be made.

During this warm-up period, check the warning lightsand gages:

• If oil pressure does not begin to rise within15 seconds of starting, stop the engine and find thecause. See Oil Pressure Gage on page 3-32 formore information.

• If the engine coolant temperature gage needle goesinto the hot area on the gage, stop the engine andfind the cause of the overheating. See EngineCoolant Temperature Gage on page 3-28 for moreinformation.

• If you have air brakes, the dual-needle air pressuregage should read at least 115 psi (790 kPa) forboth service systems before you try to movethe vehicle. When air pressure is below 60 psi(420 kPa), the LOW AIR light will come on and youwill hear a tone alarm. See Brake System WarningLight on page 3-25 for more information. If thepressure does not build up or drops during warm-up,stop the engine and find the cause before you tryto move the vehicle. Recommended air pressurebefore driving is 120 psi (830 kPa). See AirPressure Gage on page 3-38 for more information.

• The charging system light should come on whenthe ignition key is turned to ON/RUN or STARTand should go out when the engine is running aboveidle. If the light does not go out or comes back onduring normal engine operation, have the chargingsystem checked right away. (This light tells youif the generator is not charging; it does not reflectthe condition of the battery.) See Charging SystemLight on page 3-23 for more information.

• The voltmeter charge indicator gage tells you thecondition of the battery’s charge. The gageshould be in the center area during engineoperation. The red area on the left indicates anundercharge condition; the red area on theright indicates an overcharge. If the gage is ineither red area, have the battery and chargingsystem checked right away. See Voltmeter Gage onpage 3-23 for more information.

Notice: Do not allow the engine to operate at lowidle for more than five minutes. This can causelow engine operating temperatures which can affectengine operation and reduce engine life. Engineidle speed should be increased to 1200 rpmwhenever extended idle is required. Once started,the engine should be placed under load to allow theengine coolant temperature to reach 150°F (66°C)before shutting off the engine.

2-14

Engine Coolant HeaterThe engine coolant heater can provide easier startingand better fuel economy during engine warm-up in coldweather conditions at or below 0°F (−18°C). Vehicleswith an engine coolant heater should be pluggedin at least four hours before starting. An internalthermostat in the plug-end of the cord may exist whichwill prevent engine coolant heater operation attemperatures above 0°F (−18°C).

To Use the Engine Coolant Heater1. Turn off the engine.

2. Find the cord on the drivers side in the enginecompartment.

3. Plug it into a normal, grounded 110-volt AC outlet.

{CAUTION:

Plugging the cord into an ungrounded outlet couldcause an electrical shock. Also, the wrong kind ofextension cord could overheat and cause a fire.You could be seriously injured. Plug the cord intoa properly grounded three-prong 110-volt ACoutlet. If the cord will not reach, use a heavy-dutythree-prong extension cord rated for at least15 amps.

4. Before starting the engine, be sure to unplug andstore the cord as it was before to keep it awayfrom moving engine parts, to prevent damage.

The length of time the heater should remain plugged independs on several factors. Ask a dealer/retailer inthe area where you will be parking the vehicle for thebest advice on this.

2-15

Diesel Engine Exhaust BrakeThe exhaust brake is used to help slow the vehicle andmay assist the vehicle’s foundation brakes. The useof the exhaust brake will assist the braking of the vehicleand prolong the life of the foundation brake liningmaterial.

The exhaust brake buttonis located in the instrumentpanel.

Push the bottom of the button to turn the exhaust brakeon. When you push the top of the switch, the exhaustbrake will turn off.

There is an indicator light on the instrument panelsimilar to the symbol on the switch, that will come onwhen the exhaust brake is active. See ExhaustBrake Indicator Light on page 3-34 for more information.

When using the exhaust brake, the proper gear rangeselection is important. The exhaust brake will bemost effective if the gear range selected is the lowestpossible range that does not allow the engine rpmto exceed 2500 rpm.

If you have an automatic transmission and press thisbutton, the transmission will downshift to a factorydefault setting of 4 (Fourth) gear. To change the defaultsetting, or for more information on factory defaultsettings, contact your dealer/retailer for assistance.

The accelerator and clutch pedals, on a manualtransmission, must be released in order for the exhaustbrake to engage.

2-16

Automatic Transmission OperationThis part of the manual covers the basics of automatictransmissions. With these transmissions, you willfind an Allison® Transmission Operator’s Manual in thevehicle that goes into more detail. On the headliner,in front of and above the driver, or in some other placenear the driver, you will see a label that describesimportant operating facts about the automatictransmission in the vehicle. Make sure you follow theinstructions on this label.

Vehicles equipped with an Allison® 3000 Seriestransmission come with a push button shift selector thatwill display transmission information. Refer to theAllison® Transmissions Operator’s Manual for moreinformation on transmission diagnostics and shiftselector operation.

{CAUTION:

It can be dangerous to get out of the vehiclewithout the parking brake firmly set. The vehiclecan roll. If you have left the engine running, thevehicle can move suddenly. You or others couldbe injured. To be sure the vehicle will not move,even when you are on fairly level ground, alwaysset the parking brake.

{CAUTION:

Shifting into a drive gear while the engine isrunning at high speed is dangerous. Unless yourfoot is firmly on the brake pedal, the vehicle couldmove very rapidly. You could lose control and hitpeople or objects. Do not shift into a drive gearwhile the engine is running at high speed.

2-17

Overdrive DefeatIf the vehicle has this feature, you can select to limit thetransmission to fourth gear. This may be useful whenoperating at a higher Gross Vehicle Weight (GVW)or where operating conditions do not require fifth gear.

The overdrive defeat buttonis located in the instrumentpanel to the right of thesteering column. SeeInstrument Panel Overviewon page 3-4 for moreinformation.

Press the button to turn on the overdrive defeat. Pressthe button again to turn off the overdrive defeat.The indicator light in the button will come on wheneveroverdrive defeat is active.

Automatic TransmissionThird-Gear HoldIf the vehicle has this feature, the range selector has a2-3 position. You cannot shift up to the next highergear when the transmission is in this position unless theengine-governed speed is exceeded, such as whengoing downhill.

This feature is used for certain load and traffic conditionsor when plowing snow. See the Allison® TransmissionOperator’s Manual in the vehicle for more informationabout this.

If the vehicle is equippedwith a push button shiftselector, refer to theAllison® TransmissionOperator’s Manual forshift selector operatinginstructions.

2-18

Manual Transmission Operation

Using the ClutchWhen you are starting to move the vehicle, it isimportant to begin with the engine speed at idle. Thenstart to engage the clutch and listen for an engine speeddrop of about 100 rpm. At this point, the clutch isengaging, so you should increase the engine speed andfully engage the clutch.

Notice: If you increase the engine speed before theclutch is fully engaged, you could damage yourtransmission. Always allow the clutch to fullyengage before increasing engine speed.

Six-Speed TransmissionThe transmission has gears that automaticallysynchronize when you shift up or down. Choose thegear which will maintain the road speed you want whilekeeping the engine above two-thirds of the governedspeed. When the engine speed drops below two-thirdsof the governed speed, shift into the next lower gearbefore your engine begins to become sluggish.When you shift down, be sure to double-clutch ifrequired.

See “Double Clutching” later in this section.

Eaton® Fuller® Nine and Ten-SpeedNon-Synchronized ManualTransmissionsIf the vehicle has one of these non-synchronizedtransmissions, it is naturally somewhat complicated.

The following are driving tips:

• Always choose an initial starting gear suitable forthe load and terrain.

• Always use double-clutching procedures whenshifting.

• Never move the range shift lever to the LO speedgear position after HI range preselection, oranytime the transmission is in the HI range.

• Never move the range knob or lever with the shiftlever in N (Neutral) while the vehicle is moving.

• Never make a range shift while moving inR (Reverse).

2-19

Double-ClutchingYou must use the double-clutching method when youshift an unsynchronized gear set. Disengage the clutch,shift to neutral and engage the clutch. When upshifting,slow the engine until the engine rpm and road speedmatch. When downshifting, accelerate the engineuntil the engine rpm and road speed match. Thenquickly disengage the clutch and move the shift lever tothe next gear position and engage the clutch.

Clutch Brake (Vehicles withNon-Synchronized Transmission)A clutch brake is used to stop transmission input shaftturning so that 1 (First) or R (Reverse) gear selectioncan be initiated when the vehicle is at a standstilland the engine is idling.

Press the clutch pedal all the way down to the floorboardto apply the clutch brake.

When using the clutch brake, disengage the clutchpedal and shift the transmission into either the initialstarting gear or R (Reverse). If the tooth-butting occursbetween the clutching teeth, re-engage the clutchwhile applying light pressure to the shift lever. This willprovide for a smooth shift into either 1 (First) orR (Reverse) gear.

Notice: Using the clutch brake for shifting into anygear other than 1 (First) or R (Reverse) may causepremature wear of the clutch brake and make gearshift effort more difficult. Do not use the clutch brakefor shifting after engaging 1 (First) or R (Reverse).

2-20

Power Take-Off (PTO)

The vehicle may beequipped with powertake-off (PTO). The PTOswitch is located onthe instrument panel.

An indicator in the switch comes on to show PTO isactive.

A PTO is a gearbox or mechanical device used totransmit mechanical power from the powertrain, throughgears or a transmission, to another mechanical orhydraulic device. Before using a PTO, refer to themanufacturer’s or installer’s instructions.

Parking

{CAUTION:

If you do not park the vehicle properly, it can roll.If you have left the engine running, it can movevery quickly. You or others could be injured. To besure the vehicle will not move, even when you areon level ground, follow the steps below.

Parking a Vehicle With the Two-SpeedRear Axle

1. With the engine running, shift the two-speed rearaxle into low. To be sure it is in low, you will needto move the vehicle in gear just a little.

2. Hold the brake pedal down.

3. Apply the parking brake. See Parking Brake(With Hydraulic Brakes) on page 2-24 or ParkingBrake (With Air Brakes) on page 2-25 for parkingbrake apply procedure.

4. Shift the transmission to N (Neutral) for manualtransmission or P (Park) for automatic transmission.

2-21

Two-Speed Rear AxleThe Two-Speed rear axle lets the driver select LowRange and High Range. Low Range provides goodstarting torque and pulling power. When selecting HighRange the axle allows for higher road speed andfuel economy.

For better performance during off-road or under a heavyload, shift the axle into Low Range and then operatethe transmission normally.

For better performance on the highway, shift the axle toHigh Range and operate the transmission normally.

High or Low Range can be used when additional shiftsbetween transmission gears is needed while drivingon grades and for better fuel economy.

Notice: Driving in Low Range above 50 mph(80.5 kph) will damage driveline components.Drive below 50 mph (80.5 kph) in Low Range.

If the vehicle has this feature, there is a label on theheadliner above the windshield or in another place nearthe driver that shows how to use it. Be sure to followthe directions carefully.

Two-Speed Rear Axle Shift ControlOperation

The rear axle shift controlswitch for automatic andmanual transmissionsis located in the instrumentpanel switchbank.

Press the bottom of the switch for High Range and thetop of the switch for Low Range.

Always start the vehicle in motion with the two-speedaxle in low range.

Shifting on a DowngradeDo not shift the two-speed axle when driving on adowngrade. The speed of the vehicle moving downhillmay make it hard to shift the axle into either Low orHigh Range.

2-22

Shifting

Upshifting the AxleTo shift from Low to High Range:

1. Press the bottom of the switch to shift the axlecontrol from Low to High.

2. Release the accelerator pedal until the shift applies.

3. Then push the accelerator pedal.

Axle upshift can be abrupt, causing the vehicle to jerk.Release the accelerator slowly for a smooth shift.For manual transmissions, use the clutch while pressingthe accelerator for a smooth shift.

Downshifting the AxleTo shift from High to Low Range:

1. Press the top of the switch to shift from High toLow Range.

2. Release the accelerator pedal.

3. Then push the accelerator pedal slowly until theaxle shifts.

Split Upshift(Manual Transmissions Only)To downshift the axle with a transmission upshift:

1. Push the clutch.

2. Shift the Transmission to a higher gear.

3. Shift the axle control from High to Low Range.

4. Release the clutch.

5. Push the accelerator pedal until the axle shifts.

Split Downshift(Manual Transmission Only)To upshift the axle with a transmission downshift:

1. Shift the axle control from Low to High Range.

2. Push the clutch.

3. Shift the transmission to a lower gear.

4. Release the clutch.

5. Push the accelerator pedal until the axle shifts.

2-23

Parking Brake(With Hydraulic Brakes)If the vehicle has hydraulic brakes, it has a parkingbrake lever. The lever is located in the center console.

The vehicle may also be equipped with an automatictransmission which has a center console shift lever.This lever will have a P (Park) position on the shiftindicator. Even when P (Park) is selected, be sure toapply the parking brake firmly so the vehicle willnot move.

To apply the parking brake, pull the lever all the way up.The park brake light will come on when the parkingbrake is applied. See Brake System Warning Light onpage 3-25 for more information. Then shift thetransmission to N (Neutral) for a manual transmission orP (Park) for an automatic transmission. The vehiclemust be stationary when applying the parking brake,except while burnishing the parking brake linings.See Parking Brake Burnish Procedure on page 2-27 formore information.

Once the parking brake is applied, slowly remove yourfoot from the regular brake pedal, while checking tosee if the vehicle moves. If the vehicle does startto move, press the regular brake pedal and follow theparking brake burnish procedures. See ParkingBrake Burnish Procedure on page 2-27 for moreinformation.

2-24

If the parking brake still does not set, take the vehicle toyour dealer/retailer for service.

To release the parking brake, first push down theregular brake pedal. Then, while pressing in the releasebutton, push the parking brake lever all the way downand shift the transmission to N (Neutral). The parkingbrake light will stay on if the parking brake is notfully released.

Notice: Driving with the parking brake on canoverheat the brake system and cause prematurewear or damage to brake system parts. Verify thatthe parking brake is fully released and the brakewarning light is off before driving.

Parking Brake (With Air Brakes)

If the vehicle has airbrakes, you will have thisparking brake. It islocated above the radio onthe instrument panel.

Pulling it out applies the parking brake. The parkingbrake light will come on when the air parking brake isapplied.

2-25

Vehicles built for use as tractors or towing vehicles havetwo air brake controls. They look like this:

{CAUTION:

When the yellow PARKING BRAKE and the redTRAILER AIR SUPPLY knobs are both pushed in,the rig will be free to move. It could strikesomeone or something. When both of these knobsare pushed in, hold the regular brake pedal downto keep the rig from moving.

To charge a trailer’s air brake system do the following:

1. Move the vehicle into the proper position.

2. Apply the parking brake by pulling the yellowparking brake knob out.

3. Hook up the trailer air system properly.

4. Get into the vehicle.

5. Push and hold down the regular brake pedal.

6. Push in both the yellow parking brake and the redtrailer air supply knobs. This will charge the trailer’sair system.

After a few minutes, the trailer system should be fullycharged. When it is, the air pressure gage will showabout 125 to 135 psi (862 to 931 kPa). See Air PressureGage on page 3-38 for more information.

For driving with a trailer, the yellow and red, if equipped,knobs must be pushed in. When you are not pulling atrailer, the red trailer air supply knob must be pulled out.

2-26

{CAUTION:

If you apply any one of the air brake parkingcontrols while the vehicle is moving, the rig willstop suddenly. If you are not ready for this, you orothers could be injured. Do not apply any one ofthese controls while you are driving, unless youhave to make an emergency stop.

If the air pressure drops below 60 to 70 psi(413 to 482 kPa), the low air warning light and buzzerwill come on. If the air pressure drops to 35 to 45 psi(241 to 310 kPa), the red trailer air supply knobwill automatically pop out and apply the spring brakeson the trailer.

If the air pressure drops to 35 to 45 psi (241 to 310 kPa),the yellow park brake knob will automatically pop outand apply the spring brakes on the truck or tractor.

If you ever have a complete loss of air so that the airbrakes automatically apply, there is a way that thetow operator can release the parking brakes to tow thevehicle. See Towing Your Vehicle on page 4-21.

Parking Brake Burnish ProcedureAll vehicles which have hydraulic brakes will havea parking brake. It is recommended that the parkingbrake be burnished as part of the new vehicle break-in.The parking brake will work best after it has beenburnished following these instructions:

1. Making sure that there is no other traffic around,get the vehicle speed up to 20 mph (32 km/h) andpull up to apply the parking brake. Let the vehiclecome to a complete stop. Apply the base brakesand disengage the parking brake.

2. Repeat the burnishing procedure in Step 1 a totalof 10 times.

3. Between stops, drive the vehicle about2 1⁄2 miles (4 km).

Notice: Driving with the parking brake on candamage the transmission and brake system parts.Verify that the parking brake is fully released and thebrake warning light is off before driving.

2-27

Air SuspensionThe vehicle may have the Hendrickson HAS Seriessingle-axle air suspension which is designed fora single-axle on-highway use. This feature is availablein 19,000 lb (8 613.3 kg), 21,000 lb (9 525.4 kg)and 23,000 lb (10 432.6 kg) capacities.

Rear Air Suspension Dump ControlIf the vehicle is equipped with the Hendrickson HASSeries single-axle air suspension, you may havethis control. The air suspension dump control allows theoperator to lower the deck height approximately4.5 inches (11.5 cm) from the normal frame height.

The switch to deflate andinflate the air suspensionis located on theinstrument panel.

Press the bottom of the switch to deflate the airsuspension and lower the deck height. Press the top ofthe switch to return the suspension to normal deckheight.

An indicator light will come on and stay on wheneverthe switch is in the dump position.

2-28

Parking Over Things That Burn

{CAUTION:

Things that can burn could touch hot exhaust partsunder the vehicle and ignite. Do not park overpapers, leaves, dry grass, or other things thatcan burn.

Engine Exhaust

{CAUTION:

Engine exhaust contains Carbon Monoxide (CO)which cannot be seen or smelled. Exposure to COcan cause unconsciousness and even death.

Exhaust may enter the vehicle if:• The vehicle idles in areas with poor ventilation

(parking garages, tunnels, deep snow thatmay block underbody airflow or tail pipes).

CAUTION: (Continued)


• The exhaust smells or sounds strange ordifferent.

• The exhaust system leaks due to corrosion ordamage.

• The vehicle’s exhaust system has beenmodified, damaged or improperly repaired.

• There are holes or openings in the vehiclebody from damage or after-marketmodifications that are not completely sealed.

If unusual fumes are detected or if it is suspectedthat exhaust is coming into the vehicle:

• Drive it only with the windowscompletely down.

• Have the vehicle repaired immediately.

Never park the vehicle with the engine running inan enclosed area such as a garage or a buildingthat has no fresh air ventilation.

2-29

Diesel Particulate FilterThe vehicle has a Diesel Particulate Filter (DPF) as partof the exhaust system to reduce vehicle emissions. TheDPF requires a unique exhaust tailpipe with an exhaustcooler. The exhaust cooler mixes air with the exhaust tolower the temperature before it leaves the tailpipe.

The DPF, the tailpipe, or other exhaust systemcomponents must not be altered. Inspect regularly andclean any mud or dirt from the exhaust cooler,especially where the exhaust cooler connects to thetailpipe and the openings where fresh air entersthe cooler. See “Exhaust System Inspection” under AtLeast Twice a Year on page 6-22.

The DPF will clean itself as part of normal operation.Several factors including fuel consumed, hours of engineoperation and miles driven are monitored by theEngine Control Module (ECM). The self-cleaning occursapproximately once per tank of fuel.

During cleaning, the greenDPF indicator light willcome on. See DieselParticulate Filter WarningLight on page 3-37.

Extended idling can cause exhaust parts and gases tobecome very hot. Keep the exhaust area clear ofmaterial that could ignite or burn. See Parking OverThings That Burn on page 2-29 for more information.

{CAUTION:

During DPF self cleaning or during extended idlingin P (Park), the exhaust system and exhaustgases are very hot. Things that burn could touchhot exhaust parts under the vehicle and ignite.You or others could be burned. Do not park, oridle for an extended period of time, near or overpapers, leaves, dry grass, or other things that canburn. Keep the exhaust area clear of material thatcould ignite or burn. See Parking Over ThingsThat Burn on page 2-29 for more information.

2-30

Notice: Extended idle should be avoided becausethe DPF system is not capable of self cleaningat idle. During extended idle operation, monitorthe instrument panel telltale lights and DriverInformation Center for messages and takeappropriate indicated action. Continued idlingwith the warning light/message on could causeirreversible damage to the DPF requiring repair andpossible replacement that might not be coveredby the vehicle warranty.

When the yellow DPF indicator comes on, the filter isdirty and needs cleaning. You will also notice a changein the exhaust sound and engine idle speed. This isnormal. If you continue to drive and the exhaust filter isnot cleaned as required, the DPF indicator will changefrom yellow to red. Continuing to drive the vehiclewith the red indicator can cause filter damage.

Vehicles with DPF have specific fuel and engine oilrequirements. See What Fuel to Use on page 5-7 andEngine Oil on page 5-16 for more information onthose requirements.

Notice: Permanent damage can occur to the DPFor related components if the required Ultra LowSulfur Diesel (15 ppm sulfur maximum) or low ashCJ-4 engine oil is not used. This damage wouldnot be covered by the vehicle warranty.

For vehicles with Power Take-Off (PTO), monitor theinstrument panel cluster for lights related to the DPF.

All engines consume some amount of engine oil. Ash isthe by-product of engine oil consumption. The ashwill become trapped in the DPF over the life ofthe vehicle. Eventually, the buildup of ash will restrictthe exhaust gases and the DPF will need to be cleanedor replaced.

See Accessories and Modifications on page 5-3 forimportant information if you are considering addingaccessories or modifying the vehicle.

2-31

Manual Cleaning Procedure

{CAUTION:

During DPF self cleaning, the exhaust system andexhaust gases are very hot. Stay clear of thetailpipe area and do not park over things that burn.You or others could be burned or the vehicle couldcatch fire. See Parking Over Things That Burn onpage 2-29.

If the yellow or red DPF indicator is on, you can cleanthe DPF by performing a manual cleaning.

When it is safe to do so, stop the vehicle. Perform DPFmanual cleaning in a well ventilated area. DPFManual cleaning must be performed outdoors, asfollows. Once manual cleaning is started, complete thecleaning in a single operation if possible. If manualcleaning is not completed, as indicated by the greenDPF indicator going off, and the yellow or red indicatorlight remains on, self cleaning might not be alloweduntil the vehicle is stopped and manual cleaningis performed until completed.

1. Check engine oil and engine coolant levels to besure they are at proper operating levels.

2. To prevent running out of fuel during manualcleaning, make sure there is at least a quarter of atank of fuel.

3. Check to make sure the area near the exhausttailpipe and under the exhaust system is clear ofany materials that could catch fire. Keep peopleaway from the area of the exhaust systemand exhaust gases.

2-32

4. Fully set the parking brake.

5. Shift the transmission to P (Park) or N (Neutral).

6. Idle the engine. If you used the idling control knob toincrease the engine speed, restore it all the way tothe left to reduce the engine speed.

7. If the vehicle has Power Take Off (PTO), turn thePTO off. See Power Take-Off (PTO) on page 2-21.

8. Press the DPF switch on the instrument panel. SeeInstrument Panel Overview on page 3-4. The greenDPF indicator light comes on, the exhaust gascontrol valve operates, engine idle speedautomatically increases, and DPF manual cleaningbegins. Do not leave the vehicle unattendedduring manual cleaning.

9. When both the green and the yellow or red DPFindicator lights go off, manual cleaning is completed.Manual cleaning is normally completed in about30 minutes.

Under certain operating conditions, manual cleaningmight not be able to be performed, even if the soot levelin the DPF requires cleaning. This can occur becauseof low coolant temperature, low battery voltage,high exhaust temperature or immediately after startingthe vehicle. When manual cleaning is requestedand coolant temperature is low, engine warm-up isstarted, the green DPF indicator light will come on, theexhaust gas control valve operates, and engine rpmincreases to help raise engine coolant temperature.When operating conditions allow, cleaning will begin.

2-33

Running the Vehicle While ParkedIt is better not to park with the engine running. But if youever have to, here are some things to know.

{CAUTION:

Idling a vehicle in an enclosed area with poorventilation is dangerous. Engine exhaust mayenter the vehicle. Engine exhaust contains CarbonMonoxide (CO) which cannot be seen or smelled.It can cause unconsciousness and even death.Never run the engine in an enclosed area that hasno fresh air ventilation. For more information, seeEngine Exhaust on page 2-29.

{CAUTION:

It can be dangerous to get out of the vehicle if theautomatic transmission shift lever is not fully inP (Park) with the parking brake firmly set. Thevehicle can roll. Do not leave the vehicle when theengine is running unless you have to. If you haveleft the engine running, the vehicle can movesuddenly. You or others could be injured. To besure the vehicle will not move, even when it is onfairly level ground, always set the parking brakeand move the automatic transmission shift lever toP (Park), or the manual transmission shift lever toNeutral.

Follow the proper steps to be sure the vehicle willnot move.

2-34

Mirrors

Manual Rearview MirrorHold the inside rearview mirror in the center to move itfor a clearer view of behind your vehicle. Adjust themirror to avoid glare from the headlamps behind you.Push the tab forward for daytime use and pull it fornighttime use.

Outside Manual MirrorsAdjust the outside rearview mirrors so you can see alittle of the side of your vehicle, and the area beside yourvehicle from a comfortable driving position. Somemirrors can be folded in to enter narrow passageways.

If the mirrors have the clearance lamps, they will beon when the headlamps or parking lamps are on.

Outside Convex Mirrors

{CAUTION:

A convex mirror can make things (like othervehicles) look farther away than they really are.If you cut too sharply into the right or left lane,you could hit a vehicle. Check the regular outsidemirrors (or the inside mirror, if you have one)before changing lanes.

The vehicle may have convex mirrors on both the driverside and the passenger side. They are curved to allowmore to be seen from the driver seat. A convex mirror canmake things look farther away than they really are.

2-35

Outside Heated Mirrors

Vehicles with outsideheated mirrors have thecontrol switch locatedon the instrument panel.

Press the switch to turn the outside heated rearviewmirrors on. The switch indicator light will come on andstay on whenever the outside heated rearviewmirrors are activated.

Storage AreasOverhead Storage

An overhead storage compartment is provided aboveeach of the driver and passenger seats. To openpush down on the inner button and lift the compartmentdoors all the way up to lock in position. Be sure thedoors are securely closed before moving the vehicle.

2-36

Center Seat Storage

A storage compartment is located behind the seatbackin the center seat. To access the compartment, you must first pull down on

the handle located on the passenger side to fold theseat all the way forward. To open, squeeze both sides ofthe latch.

Center Console StorageThere are additional storage areas for small items in thecenter console to the right of the driver seat.

2-37

✍ NOTES

2-38

Instrument Panel Overview ...............................3-4Hazard Warning Flashers ................................3-6Horn .............................................................3-6Tilt Wheel .....................................................3-6Turn Signal/Multifunction Lever .........................3-7Turn and Lane-Change Signals ........................3-7Headlamp High/Low-Beam Changer ..................3-8Flash-to-Pass .................................................3-8Windshield Wipers ..........................................3-8Windshield Washer .........................................3-9Cruise Control ..............................................3-10Headlamps ..................................................3-12Headlamps on Reminder ................................3-13Daytime Running Lamps (DRL) .......................3-13Marker Lamps ..............................................3-14Instrument Panel Brightness ...........................3-14Dome Lamps ...............................................3-14Rear Reading Lamps ....................................3-15Auxiliary Power Jacks ....................................3-15Ashtray(s) and Cigarette Lighter ......................3-16

Climate Controls ............................................3-16Climate Control System .................................3-16Outlet Adjustment .........................................3-18Passenger Compartment Air Filter ...................3-18

Warning Lights, Gages, and Indicators ............3-19Instrument Panel Cluster ................................3-20Speedometer and Odometer ...........................3-21Trip Odometer ..............................................3-21Tachometer .................................................3-21Engine Speed Limiter ....................................3-22Safety Belt Reminders ...................................3-22Charging System Light ..................................3-23Voltmeter Gage ............................................3-23Service Transmission Warning Light ................3-24Range Inhibit Warning Indicator ......................3-24Brake System Warning Light ..........................3-25Antilock Brake System (ABS) Warning Light .....3-27Trailer Antilock Brake System Warning Light .....3-27Traction Control System (TCS) Active Light ......3-28Engine Coolant Temperature Gage ..................3-28Low Coolant Warning Light ............................3-29Wait to Start Light ........................................3-29Malfunction Indicator Lamp .............................3-30Oil Pressure Gage ........................................3-32Low Oil Level Light .......................................3-33Change Engine Oil Light ................................3-33Engine Overspeed Warning Light ....................3-34Engine Shutdown Warning Light .....................3-34

Section 3 Instrument Panel

3-1

Exhaust Brake Indicator Light .........................3-34Differential Lock Indicator Light .......................3-34Reduced Engine Power Light .........................3-35Highbeam On Light .......................................3-35Daytime Running Lamps (DRL) Indicator Light .....3-35Check Gages Warning Light ...........................3-36Fuel Gage ...................................................3-36Water in Fuel Warning Light ...........................3-37

Diesel Particulate Filter Warning Light ..............3-37Air Pressure Gage ........................................3-38Hourmeter Gage ...........................................3-38

Audio System(s) .............................................3-39Setting the Clock ..........................................3-40Radio(s) ......................................................3-41Radio Reception ...........................................3-46Fixed Mast Antenna ......................................3-46

Section 3 Instrument Panel

3-2

✍ NOTES

3-3

Instrument Panel Overview

3-4

The main components of the instrument panel are the following:

A. Rear Reading Lamps on page 3-15.B. Cruise Control on page 3-10.C. Turn Signal/Multifunction Lever on page 3-7.D. Instrument Panel Cluster on page 3-20.E. Windshield Wipers on page 3-8 and Windshield

Washer on page 3-9.F. Outlet Adjustment on page 3-18.G. Climate Control System on page 3-16.H. Diesel Engine Exhaust Brake on page 2-16.I. Outside Heated Mirrors on page 2-36 (If Equipped).J. High Idle Button. See “Manual High Idle System”

under Starting the Diesel Engine on page 2-8. PowerTake-Off (PTO) on page 2-21 (If Equipped).

K. Front Panel Release. See Lifting the Front Panel onpage 5-54.

L. Tilt Steering Column. See Tilt Wheel on page 3-6.M. Horn on page 3-6.

N. Air Brake Controls (If Equipped). See Parking Brake(With Hydraulic Brakes) on page 2-24 or ParkingBrake (With Air Brakes) on page 2-25.

O. Two-Speed Rear Axle Button. See Two-SpeedRear Axle on page 2-22. Air Suspension Indicator(If Equipped). See Air Suspension on page 2-28.Air Suspension Button (If Equipped). See AirSuspension on page 2-28. Differential Lock Button(If Equipped). See Rear Axle Differential LockControl on page 4-7.

P. Audio System(s) on page 3-39.Q. Marker and Clearance Lamp Button. See Marker

Lamps on page 3-14.R. Overdrive Defeat Button. See “Overdrive Defeat”

under Automatic Transmission Operation onpage 2-17.

S. Cigarette Lighter. See Ashtray(s) and CigaretteLighter on page 3-16.

T. Traction Control System (TCS) on page 4-7.U. Diesel Particulate Filter on page 2-30.

3-5

Hazard Warning FlashersThe hazard warning flashers are controlled by the leverlocated to the right of the steering column.

| (Hazard Warning Flasher): Move the lever up tomake the front and rear turn signal lamps flash onand off. This warns others that you are having trouble.Move the lever down again to turn the flashers off.

When the hazard warning flashers are on, theturn signals will not work. The hazard warning flasherswill not flash if the brakes are applied.

HornSound the horn by firmly pressing the pad in the centerof the steering wheel.

Tilt WheelA tilt steering column lets the steering wheel beadjusted.

To tilt the column, hold thesteering wheel and pull thelever on the left side ofthe column to unlockthe steering column.

Move the steering wheel toa comfortable location,then lock the columnin place by turning the locklever all the way down.

Do not adjust the tilt steering column while driving.

3-6

Turn Signal/Multifunction Lever

The multifunction lever, located on the left side of thesteering column, includes the following:

G : Turn and Lane-Change Signals

3 : Headlamps

J : Cruise Control (if equipped)

Headlamp High-Beam/Low-Beam Changer.

Flash-to-pass.

Information for these features is on the pages following.

Turn and Lane-Change SignalsAn arrow on the instrumentpanel cluster flashes in thedirection of the turn orlane change.

Move the lever all the way up or down to signal a turn.

Raise or lower the lever until the arrow starts to flashto signal a lane change. Hold it there until the lanechange is complete.

The lever returns to its starting position whenever it isreleased.

If after signaling a turn or a lane change the arrowflashes rapidly or does not come, a signal bulb may beburned out. Check the turn signal flasher and circuitbreaker.

Check for burned out bulbs that may need replacing ora blown fuse to help avoid an accident. See Fusesand Circuit Breakers on page 5-80.

3-7

Headlamp High/Low-Beam ChangerPush the multifunction lever toward the instrumentpanel to change the headlamps from low to high beam.To return to low-beam headlamps, pull the multifunctionlever toward you. Then release it.

This indicator light on theinstrument panel clustercomes on while thehigh-beam headlampsare on.

Flash-to-PassThis feature lets you use the high-beam headlamps tosignal a driver in front of you that you want to pass.It works even if the headlamps are in the automaticposition.

To use this feature, pull the multifunction lever towardyou, then release it.

If the headlamps are in the automatic position or onlow beam, the high-beam headlamps will turn on.They stay on as long as the lever is held toward you.The high-beam indicator on the instrument panel clusterwill come on. Release the lever to return to normaloperation.

Windshield Wipers

The windshield wiper lever is located on the right sideof the steering column.

Turn to the following positions to control the wipers:

9 (OFF): Turns off the wipers.

- - - (Intermittent): Delays the wiper speed. Afterselecting the intermittent setting the wiper speed canalso be set. See the following text for more information.

6 : Turn this band on the windshield wiper lever toset the delay time between wipes. The closer to thetop of the lever, the shorter the delay.

3-8

R (LO): For low speed wiping.

R R (HI): For high speed wiping.

Clear ice and snow from the wiper blades before usingthem. If the wipers are frozen to the windshield,carefully loosen or thaw them. If they become worn ordamaged, get new blades or blade inserts. For moreinformation, see Windshield Wiper Blade Replacementon page 5-56.

The windshield wiper motor is protected from overloadby a circuit breaker and a fuse. If the motor overheatsdue to heavy snow or ice, the wiper will stop untilthe motor cools. Although the circuit is protected fromelectrical overload, overload due to heavy snow orice may cause wiper linkage damage.

Windshield WasherThe windshield washerbutton is located at theend of the multifunctionlever on the right sideof the steering wheel.

L (Washer Fluid): Press to wash the window.The windshield wipers must be on. Press and hold forcontinuous spray.

{CAUTION:

In freezing weather, do not use your washer untilthe windshield is warmed. Otherwise the washerfluid can form ice on the windshield, blocking yourvision.

3-9

Cruise ControlWith cruise control, a speed of about 25 mph (40 km/h)or more can be maintained without keeping your footon the accelerator. Cruise control does not workat speeds below about 25 mph (40 km/h).

For vehicles with this feature, the cruise controls arelocated on the multifunction lever on the left side of thesteering column.

If the vehicle has a automatic transmission and thebrakes are applied, the cruise control will shut off.

If the vehicle has a manual transmission and the brakesare applied, or the clutch pedal is pushed, the cruisecontrol will shut off.

{CAUTION:

Cruise control can be dangerous where you cannotdrive safely at a steady speed. So, do not use thecruise control on winding roads or in heavy traffic.

Cruise control can be dangerous on slippery roads.On such roads, fast changes in tire traction cancause excessive wheel slip, and you could losecontrol. Do not use cruise control on slippery roads.

Setting Cruise ControlThis button located at thelower left side of theinstrument panel, turns thecruise control on and off.

J SET: Press this button at the end of themultifunction lever to set the cruise control speed.

+ RES: Resumes the set speed.

{CAUTION:

If you leave your cruise control on when you arenot using cruise, you might hit a button and go intocruise when you do not want to. You could bestartled and even lose control. Keep the cruisecontrol switch off until you want to use cruisecontrol.

1. Press the J button to turn the cruise control on.The light inside the switch will turn on.

2. Get up to the desired speed.

3-10

3. Press in the J SET button at the end of the leverand release it.

4. Take your foot off the accelerator pedal.

Resuming a Set SpeedIf the cruise control is set at a desired speed and thebrake or the clutch is applied, this shuts off thecruise control. But it does not need to be reset.

Using the accelerator pedal, increase the vehicle’sspeed to 25 mph (40 km/h) or more. The cruise controldoes not work below this speed.

Move the band on the lever to the +RES position andrelease it. The vehicle will accelerate to the previouslyset speed.

Increasing Speed While Using CruiseControlThere are two ways to go to a higher speed:

• Use the accelerator pedal to get to the higherspeed. Press the J SET button, then releasethe button and the accelerator pedal. The vehiclenow cruises at the higher speed.

• Move the band on the multifunction lever from onto the +RES position. Hold it there until the vehiclereaches the speed desired, and then releasethe band. To increase the vehicle speed in smallamounts, move the band on the multifunction leverto the +RES position and release it. Each timethis is done, the vehicle goes about 1 mph(1.6 km/h) faster.

Reducing Speed While Using CruiseControl

Press the J SET button until the lower speed desiredis reached, then release it.

To slow down in small amounts, tap the button briefly.Each time this is done, the vehicle goes about 1 mph(1.6 km/h) slower.

Passing Another Vehicle While UsingCruise ControlUse the accelerator pedal to increase your vehicle’sspeed. When you take your foot off the pedal, thevehicle slows down to the cruise control speed thatwas set earlier.

3-11

Using Cruise Control on HillsHow well the cruise control works on hills dependsupon the vehicle speed, load, and the steepness of thehills. While going up steep hills, you might want tostep on the accelerator pedal to maintain the vehiclespeed. While going downhill, you might have to brake orshift to a lower gear to keep the vehicle speed down.When the brake or clutch is applied the cruise controlis disengaged.

Ending Cruise ControlThere are four different ways to turn off the cruise control:

• Step lightly on the brake pedal (manual andautomatic transmissions).

• Press the clutch pedal to the floor (manualtransmissions).

• Turn off cruise control by pressing J again.

• Shift the transmission to N (Neutral).

Erasing Speed MemoryThe cruise control set speed memory is erased whenthe ignition is turned off.

HeadlampsThe multifunction lever operates the exterior lamps.

O (Exterior Lamps): Turn the band on themultifunction lever with this symbol to operate theexterior lamps.

The exterior lamp band has three positions:

9 (OFF): Turns off all lamps, except the daytimerunning lamps (DRL).

; (Parking Lamps): Turns on the parking lamps,together with the following:

• Marker Lamps (unless the vehicle has the markerand clearance lamps switch)

• Tail Lamps

• License Plate Lamps

• Instrument Panel Lights

2 (Headlamps): Turns on all the headlamps, togetherwith the previously listed lamps and lights.

A circuit breaker protects the headlamps. If there is anelectrical overload, the headlamps will flicker on andoff. Have the headlamp wiring checked right away if thisever happens.

3-12

Headlamps on ReminderFor vehicles with this feature, an alarm will sound whenthe headlamps and/or parking lamps are turned onand the ignition is in LOCK/OFF or ACC/ACCESSORY.

Daytime Running Lamps (DRL)Daytime Running Lamps (DRL) can make it easier forothers to see the front of your vehicle during the day.Fully functional daytime running lamps are required onall vehicles first sold in Canada.

The DRL system will make the headlamps come on atreduced brightness when the following conditionsare met:

• The ignition is on.

• The headlamp band is in the OFF position.

• The parking brake is released.

When the DRL are on, only the low-beam headlampswill be on. The exterior lamps and instrument panel willnot be lit.

When it begins to get dark,the DRL indicator light isa reminder to turn theheadlamp switch on.

The other lamps that come on with the headlamps,will also come on.

When the headlamp band is turned to OFF, the regularlamps will go off, and the low-beam headlamps willchange to the reduced brightness of DRL.

To idle the vehicle with the DRL off, set the parkingbrake. The DRL stays off until the parking brakeis released.

Turn the regular headlamp system on when needed.

3-13

Marker LampsFor vehicles designed for trailer towing, this buttonoperates the marker and clearance lamps.

The marker and clearancelamp button is located inthe instrument panel.See Instrument PanelOverview on page 3-4.

Press to turn the lamps on and press it again to turnthem off.

The headlamp band will not operate these lamps.

Instrument Panel BrightnessFor vehicles with thisfeature, the knob islocated on the lower rightof the instrument panel.

Turn the knob clockwise or counterclockwise to dim orbrighten the instrument panel lights.

Dome LampsThe dome lamp switch can be set to three differentpositions: DOOR, OFF, and ON.

DOOR: The dome lamp only comes on when thedriver’s door is open.

OFF: The dome lamp will not turn on, even when thedoor is opened.

ON: The dome lamp remains on whether or not thedoor is open.

3-14

Rear Reading LampsFor vehicles with a rearlamp button, it is locatedon the lower left side ofthe instrument panel.See Instrument PanelOverview on page 3-4.

When pressed in, an indicator light inside the buttoncomes on.

Because the truck may be finished in a variety of differentways by a number of companies, the function of thisswitch depends on how the vehicle was finished after itleft the factory. Refer to the other manuals that came withthe vehicle to learn more about this switch, or see yourdealer/retailer for more information.

Auxiliary Power JacksFor vehicles with thesepower jacks, they are onthe console to the rightof the driver’s seat.

These jacks provide 12-volt power to operate things,such as a citizen’s band (CB) radio or a cellular phone.There will be positive (red) and negative (black)outlets. They are protected by a 15-amp circuit breaker.

Notice: If you plug in FM communicationsequipment at the cigarette lighter, you could damagethe vehicle. Over time, the high heat from theequipment could damage wires and/or start a fire.Do not plug in FM communications equipment at theashtray area.

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Ashtray(s) and Cigarette LighterFor vehicles with an ashtray and a cigarette lighter, theyare located in the center floor console. To open theremovable ashtray, flip open the top.

Notice: If papers, pins, or other flammable itemsare put in the ashtray, hot cigarettes or othersmoking materials could ignite them and possiblydamage the vehicle. Never put flammable itemsin the ashtray.

To use the cigarette lighter, push it in all the way and letit go. When it’s ready, it will pop back out by itself.

Notice: Holding a cigarette lighter in while itis heating does not let the lighter back away fromthe heating element when it is hot. Damage fromoverheating can occur to the lighter or heatingelement, or a fuse could be blown. Do not hold acigarette lighter in while it is heating.

Climate Controls

Climate Control SystemThe heating, cooling, and ventilation for the vehicle canbe controlled with this system.

A. Air Delivery ModeControls

B. Recirculation

C. A/C (Air Conditioning)D. Temperature ControlE. Fan Control

Temperature Control: Slide the lever towards COLDfor cooler air or towards HOT for warmer air.

9 (Fan Control): Slide the lever right or left toincrease or decrease the fan speed. Slide the fan leverto OFF to turn the system off. Outside air still comesout of the floor outlets whenever the vehicle is moving.

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Air Delivery Mode Control: Press the air deliverymode buttons to change the direction of the airflowinside the vehicle.

To change the current mode, select from the following:

H (Vent): Air is directed to the instrument panel outlets.

) (Bi-Level): Air is divided between the instrumentpanel and floor outlets. Some air may be directed towardthe windshield.

6 (Floor): Air is directed to the floor outlets, withsome air directed to the outboard outlets for the sidewindows and windshield.

/ (Defog): This mode clears the windows of fog ormoisture. Air is directed to the windshield and flooroutlets. In this mode, the system turns off recirculationand runs the air-conditioning compressor, unless theoutside temperature is at or below freezing.The recirculation mode cannot be selected while inthe defog mode.

0 (Defrost): This mode removes fog or frost fromthe windshield more quickly. Air is directed to thewindshield and the side window outlets, with some airdirected to the floor outlets. In this mode, the systemautomatically turns off recirculation and runs the

air-conditioning compressor, unless the outsidetemperature is at or below freezing. Recirculationcannot be selected while in the defrost mode.

A/C (Air Conditioning): For vehicles with airconditioning, select the fan speed, air delivery mode,and press A/C to use the air conditioning.

On hot days, open the windows to let hot inside airescape; then close them. This helps to reduce the timeit takes for the vehicle to cool down. It also helps thesystem to operate more efficiently.

For quick cool down on hot days:

1. Select H .

2. Select the recirculation mode.

3. Select A/C.

4. Select the coolest temperature.

5. Select the highest fan speed.

Using these settings together for long periods of timemay cause the air inside of the vehicle to becometoo dry. To prevent this from happening, after the air inthe vehicle has cooled, turn the recirculation mode off.The air-conditioning system removes moisture fromthe air, so a small amount of water might drip underthe vehicle while idling or after turning off the engine.This is normal.

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A (Recirculation): Press to turn the recirculation on.The air inside the vehicle will be recirculated. Forvehicles with air conditioning, using recirculation helpsto quickly cool the air inside the vehicle. It can beused to help prevent outside air and odors from enteringthe vehicle.

Recirculation is not available in Defog or Defrost modes.

Outlet AdjustmentThe air outlets are located in the center and on thesides of the instrument panel. See Instrument PanelOverview on page 3-4. The vents can be moved to directthe flow of air or close the outlets altogether. When avent is closed, it increases the flow of air coming out ofany vents that are open.

Keep the path under the front seats clear of objectsto help circulate the air inside of the vehicle moreeffectively.

Passenger Compartment Air FilterThe passenger compartment outside air is routed througha passenger compartment filter. The filter removescertain debris, including dirt and leaves. Reductions in theclimate control system performance may indicate that thefilter needs to be inspected and cleaned.

The passenger compartment air filter can be accessedfrom the outside of the vehicle on the front passengerside. It is concealed by the front access panel. Pull thelatch inside the cab on the driver’s side of the vehicleto open the front panel.

To inspect and clean the passenger compartment airfilter, use the following steps:

1. Pull the tab locatedat the bottom of thescreen.

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2. Pull the tab andremove the filter.

3. Rinse both sides of the filter with clean water.

4. Reinstall the filter and screen after cleaning.

Warning Lights, Gages, andIndicatorsWarning lights and gages can signal that something iswrong before it becomes serious enough to causean expensive repair or replacement. Paying attention tothe warning lights and gages could prevent injury.

Warning lights come on when there may be or is aproblem with one of the vehicle’s functions. Somewarning lights come on briefly when the engine is startedto indicate they are working.

Gages can indicate when there may be or is a problemwith one of the vehicle’s functions. Often gages andwarning lights work together to indicate a problem withthe vehicle.

When one of the warning lights comes on and stays onwhile driving, or when one of the gages shows theremay be a problem, check the section that explainswhat to do. Follow this manual’s advice. Waiting to dorepairs can be costly and even dangerous.

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Instrument Panel ClusterYour instrument panel cluster is designed to let you know at a glance how your vehicle is running. You will know howfast you are going, about how much fuel is left and many other things you will need to drive safely and economically.

United States version shown, Canada similar

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Speedometer and OdometerThe speedometer shows the vehicle’s speed in bothmiles per hour (mph) and kilometers per hour (km/h).

The odometer shows how far the vehicle has beendriven, in either miles (used in the United States)or kilometers (used in Canada).

Trip OdometerThe trip odometer can tell you how far your vehiclehas been driven since you last set the trip odometerto zero.

While the engine is running, press the reset button,located to the right of the trip odometer, to togglebetween the trip odometer and the regular odometer.Holding the reset button for two seconds while theengine is running and the trip odometer is displayed,will reset it.

To display the odometer reading with the ignition off,press the reset button.

The hourmeter gage is accessed through the tripodometer, for more information see Hourmeter Gageon page 3-38.

TachometerThis gage shows thesafe operating rangefor the engine speedin revolutions perminute (rpm).

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Engine Speed LimiterAll engines have electronic engine speed limiting to2,550 rpm.

Engine Road Speed GovernorThis system controls maximum vehicle speedautomatically and reduces engine power until vehiclespeed gets down to maximum governed speed.

A 75 mph (120 km/h) road speed governor is standardfor most models, but can be programmed to anyspeed below that default setting. Other models have adefault setting of 80 to 85 mph (128 to 136 km/h).You may have a label on the headliner of your vehiclewith more information on your engine road speedgovernor. See your dealer for assistance withprogramming your engine limited speed.

Safety Belt Reminders

Safety Belt Reminder LightWhen the engine is started, a light will come on forseveral seconds to remind people to fasten theirsafety belts.

The safety belt light willalso come on and stay onfor several seconds.

Safety Belt Reminder ToneIf your vehicle has this feature, when the engine isstarted, a tone will sound for several seconds to remindpeople to fasten their safety belts.

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Charging System LightThe charging system lightmay be located in theinstrument panel cluster, orwith the auxiliary warninglights in the center ofthe instrument panel.

It should come on briefly when you turn on the ignition,before the engine is running, as a check to showthat it is working.

If it stays on, or comes on while you are driving, haveyour vehicle checked right away. You could have a loosegenerator drive belt or some other problem.

Driving while this light is on will drain your battery. If youmust drive a short distance with the light on, turn offyour radio and other accessories. Sustained driving witha generator failure could result in a lack of back-upbraking if the engine quits or the power steering pumpshould fail.

Voltmeter GageWhen your engine isrunning, the voltmetergage shows the chargingsystem voltage.

Readings in either warning zone indicate a possibleproblem in the electrical system.

Readings in the low warning zone may occur when alarge number of electrical accessories are operating inthe vehicle and the engine is left at an idle for anextended period. This condition is normal since thecharging system may not be able to provide full powerat engine idle. As engine speeds are increased, thiscondition should correct itself because higher enginespeeds allow the charging system to create maximumpower.

You can only drive a short time on the battery. Be sureto shut off the radio, the fan or any unnecessaryaccessories and have the system serviced.

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Service Transmission Warning LightIf your vehicle has an Allison® automatic transmission,certain transmission malfunctions will turn this light on.

This light is located withthe auxiliary warning lightsin the center of theinstrument panel.

If this light comes on while you are driving, do not usethe transmission shift control or you may lose forwardgears. The computer for the transmission sensesa problem and chooses a gear to stay in so that youcan drive the vehicle in that gear. You may not be ableto drive as fast or back up when this light is on.

Notice: If you continue driving your vehicle afterthe transmission warning light comes on, you coulddamage the transmission. While this light is on,the transmission cannot operate in all gears.If you attempt to shift gears, the vehicle may notcontinue to move. Do not attempt to shift gearswhile the transmission warning light is on. Instead,drive directly to an authorized dealer for service.If you cannot drive to a dealer immediately, have thevehicle towed.

Range Inhibit Warning IndicatorYour vehicle may havethis light.

If your vehicle has an Allison 1000/2000/2200/2400/2500 series automatic transmission, this light may comeon and a lighted bar under the current gear selectedwill flash.

If your vehicle has an Allison 3000/3500 seriesautomatic transmission, the current gear selected onthe pushbutton display will flash.

The flashing bar, light, or gear selection indicates thattransmission range shifts may not occur.

For detailed information on shift inhibit limitations, seethe Allison Automatic Transmission Operator’s Manual inyour vehicle for further information.

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Brake System Warning LightYour vehicle has either hydraulic or air brakes.Each system has different warning lights.

Hydraulic Brake System Warning LightsVehicles with hydraulic brake systems have two brakesystem warning lights on the instrument panel.

If this light comes on, thefluid level in the mastercylinder reservoir is low orthere is a problem withthe hydraulic brakes.

When it comes on, you will also hear a warning tone.

This light should come on briefly when you turn theignition key to ON. If it does not come on, then have itfixed so it will be ready to warn you if there is a problem.

If the light comes on while driving, pull off the road andstop carefully. The pedal might be harder to push or mightgo the floor. It can take longer to stop. If the light remainson, have the vehicle towed for service. See Towing YourVehicle on page 4-21 for more information.

The brake system warning light may come on, and thewarning tone may sound, when you are turning andbraking at the same time. This is normal. See “HydraulicBrake Systems” under Braking on page 4-4.

If this light comes on,it means there may bea problem with thebrake system.

When this light comes on, you will also hear a warningtone. Have the system repaired immediately.

Both of these lights should come on briefly every timeyou start your engine. If they do not come on then, havethem fixed so they will be ready to warn you if thereis a problem. If one or both of these warning lights stayon after you start the engine, there could be a brakeproblem. Have your brake system inspected right away.

If one or both of these lights come on while you aredriving, pull off the road and stop carefully. You maynotice that the pedal is harder to push, or the pedal maygo closer to the floor. It may take longer to stop. If thebrake system warning light is still on, have the vehicletowed for service. See Towing Your Vehicle onpage 4-21. See “Hydraulic Brake Systems” underBraking on page 4-4 for further information.

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Parking Brake Warning LightThis light will also come on when you set the parkingbrake. The light will stay on if your parking brakedoes not release fully.

Air Brake System Warning LightVehicles with air brake systems have a brake systemwarning light on the instrument panel.

The low air warning light should come on, as a check,whenever you start the engine. However, it is designedto come on, and stay on, when brake reservoirpressure has dropped below 60 psi (410 kPa).

When the warning light comes on while you are driving,you should drive only as far as the nearest point ofsafety and then stop the vehicle.

{CAUTION:

If the air brake system warning light comes on andthe warning tone sounds, the vehicle can stopsuddenly and without further warning. This isbecause the parking brake will come on if thepressure falls below 35 to 45 psi (240 to 310 kPa).You or others could be injured. If the air brakesystem warning light comes on and the warningtone sounds, stop as soon as you can. You willnot know how quickly the system is losingpressure, so be aware that the parking brake maycome on suddenly.

United States Canada

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Antilock Brake System (ABS)Warning Light

This light will come onbriefly when you start theengine, then it will turnoff. This is normal.

If the light stays on, or comes on when you are driving,your vehicle needs service. If the brake or low airwarning light is not on, you still have brakes, but you donot have the antilock brake feature. If the brakeand/or low air warning light is on, you do not haveantilock brakes and there is a problem with your regularbrakes. See Brake System Warning Light on page 3-25and Antilock Brake System (ABS) on page 4-5 formore information.

Trailer Antilock Brake SystemWarning Light

If your vehicle is connectedto a trailer with antilockbrakes, this light shouldcome on briefly, as acheck, when you turn onthe ignition.

When this light comes on and stays on, it means thereis something wrong in the trailer Antilock BrakeSystem (ABS). Have the system repaired immediately.

If an ABS equipped trailer is not connected, thislight is not functional.

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Traction Control System (TCS)Active Light

If your vehicle has theTraction Control System(TCS), this light willcome on when the systemis limiting wheel spin.

Slippery road conditions may exist if the TCS activelight comes on, so adjust your driving accordingly.

The light will stay on for a few seconds after the systemstops limiting wheel spin.

See Traction Control System (TCS) on page 4-7 formore information.

Engine Coolant Temperature Gage

This gage shows the engine coolant temperature. If thegage pointer moves into the red area, your enginecoolant might have overheated and your engine may betoo hot. You should pull off the road, stop your vehicleand turn off the engine as soon as possible. See EngineOverheating on page 5-30 for more information.


3-28

Low Coolant Warning Light

Your vehicle has a lowcoolant warning light.If this light comes on,the system is lowon coolant and theengine may overheat.

The warning light should come on briefly, as a check,when you turn on the ignition.

When it comes on, you will also hear a warning tonefor 10 seconds. See Engine Coolant on page 5-26 andhave your vehicle serviced as soon as you can.

This light may also come on if your vehicle has theautomatic engine shutdown system and engineshutdown has begun. See Engine Alarm and AutomaticShutdown on page 2-11 for more information.

Wait to Start Light

This indicator, in the leftof the instrument panel,will come on whenthe glow plugs are onand the ignition key is inON/RUN or START.

Wait until the indicator turns off before turning theignition key to START.

When the temperature is below 32°F (0°C), you shouldwait no more than 10 seconds to start your vehicle.See Ignition Positions on page 2-8 for more information.

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Malfunction Indicator Lamp

Check Engine LightA computer system called OBD II (On-BoardDiagnostics-Second Generation) monitors operation ofthe fuel, ignition, and emission control systems. It makessure that emissions are at acceptable levels for thelife of the vehicle, helping to produce a cleanerenvironment.

If this light comes on whileyou are driving, two thingscan happen.

First, you will not notice any difference in engineperformance, but the tail pipe emissions might increase.Second, the engine might not run properly or couldstall without warning. If either of these things happen,see your dealer/retailer for service.

This light should come on when the ignition is on, butthe engine is not running, as a check to show it isworking. If it does not come on at all, have it repaired.

Notice: If the vehicle is continually driven withthis light on, after a while, the emission controlsmight not work as well, the vehicle’s fuel economymight not be as good, and the engine might notrun as smoothly. This could lead to costly repairsthat might not be covered by the vehicle warranty.

Notice: Modifications made to the engine,transmission, exhaust, intake, or fuel system of thevehicle or the replacement of the original tireswith other than those of the same Tire PerformanceCriteria (TPC) can affect the vehicle’s emissioncontrols and can cause this light to come on.Modifications to these systems could lead to costlyrepairs not covered by the vehicle warranty. Thiscould also result in a failure to pass a requiredEmission Inspection/Maintenance test. SeeAccessories and Modifications on page 5-3.

If the check engine light comes on and stays on, whilethe engine is running this indicates that there is anOBD II problem and service is required.

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An emission system malfunction might be corrected bydoing the following:

• If the vehicle has been driven through a deeppuddle of water, the vehicle’s electrical systemmight be wet. The condition is usually correctedwhen the electrical system dries out. A few drivingtrips should turn the light off.

• Make sure to fuel the vehicle with quality fuel.Poor fuel quality causes the engine not to runas efficiently as designed and may cause: stallingafter start-up, stalling when the vehicle is changedinto gear, misfiring, hesitation on acceleration,or stumbling on acceleration. These conditionsmight go away once the engine is warmed up.

If one or more of these conditions occurs, changethe fuel brand used. It will require at least onefull tank of the proper fuel to turn the light off.See Diesel Engine Fuel on page 5-7.

If none of the above have made the light turn off, yourdealer/retailer can check the vehicle. The dealer/retailerhas the proper test equipment and diagnostic tools tofix any mechanical or electrical problems that might havedeveloped.

Emissions Inspection andMaintenance ProgramsSome state/provincial and local governments have ormight begin programs to inspect the emission controlequipment on the vehicle. Failure to pass this inspectioncould prevent getting a vehicle registration.

Here are some things to know to help the vehicle passan inspection:

• The vehicle will not pass this inspection if the checkengine light is on with the engine running, or if thekey is in the ON/RUN and the light is not on.

• The vehicle will not pass this inspection if theOBD II (on-board diagnostic) system determinesthat critical emission control systems have not beencompletely diagnosed by the system. The vehiclewould be considered not ready for inspection.This can happen if the battery has recently beenreplaced or if the battery has run down. Thediagnostic system is designed to evaluate criticalemission control systems during normal driving.This can take several days of routine driving. If thishas been done and the vehicle still does not passthe inspection for lack of OBD II system readiness,your dealer/retailer can prepare the vehicle forinspection.

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Oil Pressure Gage

The engine oil pressure gage, on the lower rightportion of your instrument panel cluster, shows engineoil pressure in psi (pounds per square inch) or inkPa (kilopascals). Oil pressure may vary withoutside temperature and oil viscosity, but readings of30 to 40 psi (205 to 275 kPa) are normal. The normaloperating range should be between 35 and 70 psi(240 to 480 kPa).

A reading in the low pressure zone may be causedby a dangerously low oil level or other problem.See Engine Oil on page 5-16 and ScheduledMaintenance on page 6-5 for more information.

{CAUTION:

Do not keep driving if the oil pressure is low.The engine can become so hot that it catches fire.Someone could be burned. Check the oil as soonas possible and have the vehicle serviced.

Notice: Lack of proper engine oil maintenancecan damage the engine. The repairs would not becovered by the vehicle warranty. Always followthe maintenance schedule in this manual forchanging engine oil.


3-32

Low Oil Level Light

This light comes on brieflywhen the engine is started.This normal.

If the light fails to come on, have it repaired as soonas possible so you will be aware when the oil levelis low.

If this light comes on and stays on, it means theengine is low on oil. You need to check the oil levelright away. See Engine Oil on page 5-16 for moreinformation.

Notice: Lack of proper engine oil maintenancecan damage the engine. The repairs would not becovered by the vehicle warranty. Always followthe maintenance schedule in this manual forchanging engine oil.

Change Engine Oil Light

Your vehicle may have achange engine oil light.

It should come on briefly as a bulb check when youstart the engine. If the light does not come on, have itserviced.

If the change engine oil light comes on and stays onafter you start the engine, have the oil changed.

For additional information on when to change engineoil for Isuzu 6H diesel engines, see Engine Oil onpage 5-16. To reset the change engine oil light,see Engine Oil on page 5-16.

3-33

Engine Overspeed Warning LightIf your vehicle has thislight, it will come on if yourengine is operating attoo many revolutionsper minute (rpm).

It will also come on for a moment as a check when youstart your engine.

If it comes on when you’re driving, reduce your enginespeed immediately.

Engine Shutdown Warning LightIf your vehicle has theengine shutdown feature,this light will come onwhen engine shutdownis active.

See Engine Alarm and Automatic Shutdown onpage 2-11 for more information.

Exhaust Brake Indicator LightFor vehicles with anexhaust brake, this lightis located above theclimate controls.

The exhaust brake indicator light will come on andstay on whenever the diesel engine exhaust brake orexhaust restrictor is active. For more information,see Diesel Engine Exhaust Brake on page 2-16.

Differential Lock Indicator LightIf your vehicle has thisfeature, this light is locatedin the center of theinstrument panel. The lightis on when the inter-axledifferential lock systemis in use.

The light will come on momentarily during starting. If thelight fails to come on, have it repaired as soon as possibleso you will be aware when the lock system is in use.

3-34

Reduced Engine Power LightIf the check engine andreduced engine powerlights are on, the throttlemay be disabled, anda noticeable change in thevehicle’s performancemay occur.

If the reduced engine power light is on, but there is nochange in performance, proceed to your destination.The performance may be reduced the next timethe vehicle is driven. The vehicle may be driven at aslower speed while the reduced engine power light is on,but acceleration and speed may be limited.

Anytime the service engine soon light stays on, thevehicle should be taken to your dealer/retailer as soonas possible for service.

Highbeam On LightThis light comes on whenthe high-beam headlampsare in use.

See Headlamp High/Low-Beam Changer on page 3-8for more information.

Daytime Running Lamps (DRL)Indicator Light

This light turns onwhenever the DaytimeRunning Lamps are on.

See Daytime Running Lamps (DRL) on page 3-13for more information.

3-35

Check Gages Warning Light

This light will come onbriefly when the engine isstarted.

If this light comes on and stays on while you are driving.It means that either the engine coolant temperaturegage or the engine oil pressure gage may be showing areading in the warning zone.

When the check gages light comes on, you will alsohear a warning tone. The tone and the light willstay activated until the problem is corrected.

This light may also come on if your vehicle is hasautomatic engine shutdown system and engineshutdown has begun. See Engine Alarm and AutomaticShutdown on page 2-11.

Fuel GageYour fuel gage is locatedon the right side of yourinstrument panel cluster.

An arrow on the fuel gage indicates the side of thevehicle the fuel door is on.

When the ignition is on, your fuel gage lets you knowabout how much fuel you have left. When the gage firstshows empty, you’ll still have a little fuel left, but youshould get more fuel soon.

If your vehicle has dual fuel tanks, the reading on thegage is the total fuel left in both tanks.

3-36

Here are four concerns of some operators. None ofthese shows a problem with your fuel gage:

• The gage moves a little when you turn a corner orspeed up.

• The gage doesn’t go back to empty when you turnoff the ignition.

• At the gas station, the pump shuts off before thegage reads full.

• It takes a little more or less fuel to fill up than thegage indicated.

Water in Fuel Warning LightIf your vehicle is equippedwith a diesel engine, thislight will come on towarn you that there iswater in the fuel system.

For more information on how this light works, see Waterin Fuel on page 5-10.

Diesel Particulate FilterWarning Light

Your vehicle may havetwo Diesel ParticulateFilter (DPF) Warninglights.

These lights will come on briefly when the ignition isturned to ON/RUN. One of these lights will comeon green during DPF regeneration. If the other lightcomes on yellow, perform a manual regenerationor drive the vehicle for automatic regeneration.If the light changes from yellow to red, the DPFrequires an immediate regeneration. If the DPF isnot regenerated, the service engine soon light willcome on and engine power will be reduced.

See Diesel Particulate Filter on page 2-30 and ReducedEngine Power Light on page 3-35 for more information.

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Air Pressure GageIf your vehicle has airbrakes, this gage showsthe air pressure forboth your front and rearbrake systems.

If the needle on the gage indicates that the air pressureis below 60 psi (415 kPa), the low air warning lightwill come on. An alarm will also sound if this happens.

The bottom yellow pointer shows the pressureavailable for the front secondary system, while the topwhite pointer shows pressure for the rear primarysystem. There should be no more than 4 psi (28 kPa)difference showing between the systems.

Don’t drive until both pointers are showing at least120 psi (827 kPa), so you’ll have enough air if you needto apply your brakes.

Hourmeter GageTo access the engine hourmeter gage press the tripodometer button three times.

The instrument panel cluster displays the accumulatedengine run time hours using the reconfigurableodometer display. The engine run time hoursdisplays only when the ignition is in the LOCK/OFF orACC/ACCESSORY position and the trip reset switchis pressed for about four seconds.

When the ignition is in the LOCK/OFF orACC/ACCESSORY position, the instrument panelcluster displays the engine accumulated hours forup to 30 seconds. The value of the accumulated hoursdoes not change when the battery is disconnected.

The hourmeter resets to 0.0 when 10,000 hours areaccumulated. The instrument panel cluster begins toreaccumulate the engine run time hours from 0.0 hours.

3-38

Audio System(s)If the vehicle came without a radio, the wiring provisionsfor a radio and an antenna were installed at theassembly plant, so that if you want, a radio can beinstalled at the dealer/retailer.

Determine which radio the vehicle has and read thefollowing pages to become familiar with its features.

{CAUTION:

Taking your eyes off the road for extended periodscould cause a crash resulting in injury or death toyou or others. Do not give extended attention toentertainment tasks while driving.

This system provides access to many audio and nonaudio listings.

To minimize taking your eyes off the road while driving,do the following while the vehicle is parked:

• Become familiar with the operation and controls ofthe audio system.

• Set up the tone, speaker adjustments, and presetradio stations.

For more information, see Defensive Driving onpage 4-2.

Notice: Contact your dealer/retailer before addingany equipment.

Adding audio or communication equipment couldinterfere with the operation of the vehicle’s engine,radio, or other systems, and could damage them.Follow federal rules covering mobile radio andtelephone equipment.

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Setting the ClockYour radio has buttons for setting the time. To set thetime, follow these instructions:

1. Press the HOUR button along with the CLOCKbutton to increase the hour.

2. Press the MIN (minute) button along with theCLOCK button to increase the minutes.

RESET: Press this button during the clock setting modeto reset the time to the nearest whole hour. More than30 minutes will increase the hour display to the nexthour. Less than 30 minutes will decrease the hourdisplay. Resetting the clock display to the nearest hour,if needed, allows for a quicker and more accurateway of setting the time.

CLOCK: Press this button to enter the clocksetting mode.

Press and release this button to toggle between theclock and the function mode.

• While the clock is displayed, the radio andCD player can be used. If a change is made tothe radio or CD player settings, the display showsthe change for 10 seconds before returning to theclock display.

• When the function mode is displayed, the radioand CD player can be used. Current radio andCD player function information is displayed onthe screen.

The alarm time setting works even when a key is inthe ACC/ACCESSORY or the LOCK position, butno beep will sound. See “Using the Alarm” underRadio(s) on page 3-41.

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Radio(s)

Playing the Radio

PUSH ON/OFF (Power): Push to turn the system onand off.

VOLUME: Turn clockwise or counterclockwise toincrease or to decrease the volume.

DISP: Press to toggle between the radio frequency andthe clock display.

Finding a Station

FM/AM: Press to switch between FM1, FM2, or AM.The selection displays.

yz (Tune): Press either arrow to go to a higher orto a lower frequency.

Press either arrow for less than a second and thestation frequency changes by one.

Press either arrow for one second or more to seekstations with a strong signal that are in the selectedband in ascending order.

SCAN: Press to scan radio stations in the direction ofincreasing frequencies. The radio goes to a station,plays for a few seconds, then goes to the next station.The radio display flashes each radio station beingscanned. Press again to stop scanning, and the lastscanned station plays.

3-41

Setting Preset StationsUp to 18 stations (six FM1, six FM2, and six AM),can be programed on the six numbered pushbuttons,by performing the following steps:

1. Press FM/AM to select FM1, FM2, or AM.

2. Tune in the desired station by pressing theyz arrows.

3. Press and hold one of the six numberedpushbuttons. When that numbered pushbutton ispressed, the station that was set, returns forthat pushbutton.

4. Repeat the steps for each pushbutton.

The stored preset stations are deleted if power to theradio is lost, or if the battery is disconnected.

Setting the Tone (Bass/Treble)AUDIO: Press and release until BASS (BA:0) orTREBLE (TR:0) displays. The display shows the bass ortreble level. Each time the AUDIO button is pressed,the audio mode indicator changes. Once the desiredtone displays, press either yz arrow to increaseor decrease the setting.

If a station is weak or has static, decrease the treble.

If AUDIO is not pressed, after 10 seconds audiomode times out and returns to NORMAL MODE.

Adjusting the Speakers (Fade/Balance)AUDIO: To adjust the fade between the front and therear speakers, press and release until FADER (FA:0)displays. Press either yz arrow to move the soundtoward the front or the rear speakers.

To adjust the balance between the right and the leftspeakers, press and release the AUDIO button untilBALANCE (BL:0) displays. Press either yz arrow tomove the sound toward the right or the left speakers.

The FADER adjust becomes disabled when there areonly two speakers available in the vehicle.

Using the Alarm# (Alarm): The alarm on the radio can be used toactivate an alarm at a desired time.

To set the alarm, perform the following:

1. Press this button until the alarm symbol displays.

2. Press again until the display flashes.

3. Press the up tuning arrow to change the hour.

4. Press the down tuning arrow to change the minutes.After setting the alarm, the display changes back tothe current time.

3-42

5. Press the alarm button again and the alarm symboldisplays. The alarm sounds at the same timeevery day.

6. To turn the alarm off, press the alarm button.

7. To deactivate the alarm, press the alarm button.

To check the time of the alarm, press the # button.

Playing a CDInsert a CD partway into the slot, label side up.The player pulls it in and the CD should begin playing.

If the ignition or radio is turned off with the CD inthe player, it stays in the player. When the ignition orradio is turned on, the CD starts playing where itstopped, if it was the last selected audio source.

When a CD is inserted, the CD symbol displays.As each new track starts to play, the track numberdisplays.

The CD player can play the smaller 3 inch (8 cm)single CDs with an adapter ring. Full-size CDs and thesmaller CDs are loaded in the same manner.

Care of Your CDsIf playing a CD-R, the sound quality can be reduceddue to CD-R quality, the method of recording, the qualityof the music that has been recorded, and the way theCD-R has been handled. Handle them carefully.Store CD-R(s) in their original cases or other protectivecases and away from direct sunlight and dust. TheCD player scans the bottom surface of the disc. If thesurface of a CD is damaged, such as cracked, broken,or scratched, the CD does not play properly or notat all. Do not touch the bottom side of a CD whilehandling it; this could damage the surface. Pick up CDsby grasping the outer edges or the edge of the holeand the outer edge.

If the surface of a CD is soiled, take a soft, lint freecloth or dampen a clean, soft cloth in a mild, neutraldetergent solution mixed with water, and clean it.Make sure the wiping process starts from the centerto the edge.

3-43

Care of Your CD PlayerDo not add any label to a CD, it could get caught in theCD player. If a CD is recorded on a personal computerand a description label is needed, try labeling the top ofthe recorded CD with a marking pen.

The use of CD lens cleaners for CDs is not advised,due to the risk of contaminating the lens of the CD opticswith lubricants internal to the CD player mechanism.

Notice: If a label is added to a CD, or more thanone CD is inserted into the slot at a time, or anattempt is made to play scratched or damaged CDs,the CD player could be damaged. While using theCD player, use only CDs in good condition withoutany label, load one CD at a time, and keep theCD player and the loading slot free of foreignmaterials, liquids, and debris.

If an error displays, see “CD Messages” later in thissection.

1 RDM (Random): Press to hear the tracks in random,rather than sequential, order. Press again to turn offrandom play.

2 RPT: Press and release it to repeat the track beingplayed.

yz (Track Up/Down): Press and release the uparrow to move to the beginning of the next track.If the CD player is in random mode, it goes to the nextrandomly selected track.

Press and release the down arrow to move to thebeginning of the current track. If the button is pressedwhen the first track is playing, it goes to the last track onthe CD. If the CD is in random mode, it goes to thebeginning of the current track.

yz (Fast Forward/Fast Reverse): Press and holdthe up arrow to move forward through the trackson a CD three times the normal speed for the firstthree seconds and 30 times thereafter.

Press and hold the down arrow to move backwardthrough the CD three times the normal speed for thefirst three seconds and 30 times normal thereafter.

3-44

SCAN: Press while a CD is playing. The player goes tothe next track, plays for 10 seconds, then goes to thenext track. Press this button again, to stop scanning.

CD: Press to listen to a CD when the radio is playing.

FM/AM: Press to listen to the radio when a CD isplaying. The inactive CD remains inside the radio forfuture listening.

DISP: While a CD is playing, press to toggle betweenclock, track number, and play time (P-TIME) display.

If the DISP button is not pressed, after five seconds thedisplay times out and returns to the clock display.

Z (Eject): Press to eject a CD. Eject can beactivated with either the ignition or radio off. CDs canbe loaded with the radio and ignition off if this buttonis pressed first.

CD MessagesIf the CD comes out, it could be for one of the followingreasons:

• It is very hot. When the temperature returns tonormal, the CD should play.

• You are driving on a very rough road. When theroad becomes smoother, the CD should play.

• The CD is dirty, scratched, wet, or upside down.

• The air is very humid. If so, wait about an hourand try again.

• There can have been a problem while burningthe CD.

• The label can be caught in the CD player.

If the CD is not playing correctly, for any other reason,try a known good CD.

If any error occurs repeatedly or if an error cannot becorrected, contact your dealer/retailer. If the radiodisplays an error message, write it down and provide itto your dealer/retailer when reporting the problem.

3-45

Radio ReceptionFrequency interference and static can occur duringnormal radio reception if items such as cell phonechargers, vehicle convenience accessories, and externalelectronic devices are plugged into the accessorypower outlet. If there is interference or static, unplug theitem from the accessory power outlet.

AMThe range for most AM stations is greater than forFM, especially at night. The longer range can causestation frequencies to interfere with each other.For better radio reception, most AM radio stationsboost the power levels during the day, and then reducethese levels during the night. Static can also occurwhen things like storms and power lines interfere withradio reception. When this happens, try reducingthe treble on your radio.

FM StereoFM stereo gives the best sound, but FM signals reachonly about 10 to 40 miles (16 to 65 km). Tall buildings orhills can interfere with FM signals, causing the soundto fade in and out.

Fixed Mast AntennaThe antenna is located in front of the driver’s side doorat the top of the cab. Push the antenna back in toretract it. The antenna should be retracted whenentering low clearance areas.

3-46

Your Driving, the Road, and the Vehicle ............4-2Driving for Better Fuel Economy .......................4-2Defensive Driving ...........................................4-2Drunk Driving .................................................4-3Control of a Vehicle ........................................4-3Braking .........................................................4-4Hydraulic Brake Systems .................................4-4Antilock Brake System (ABS) ...........................4-5Braking in Emergencies ...................................4-5Trailer Brake Hand Control Valve ......................4-6Rear Axle Differential Lock Control ....................4-7Traction Control System (TCS) .........................4-7Steering ........................................................4-8Off-Road Recovery .......................................4-10Passing .......................................................4-10

Loss of Control .............................................4-11Driving at Night ............................................4-12Driving in Rain and on Wet Roads ..................4-13Highway Hypnosis ........................................4-14Hill and Mountain Roads ................................4-15Winter Driving ..............................................4-16If Your Vehicle is Stuck in Sand, Mud,

Ice, or Snow .............................................4-18Rocking Your Vehicle to Get It Out .................4-18Tow Hooks ..................................................4-19Loading the Vehicle ......................................4-19

Towing ..........................................................4-21Towing Your Vehicle .....................................4-21Trailer Connections (T7/T8 Models Only) ..........4-26

Section 4 Driving Your Vehicle

4-1

Your Driving, the Road, andthe Vehicle

Driving for Better Fuel EconomyDriving habits can affect fuel mileage. Here are somedriving tips to get the best fuel economy possible.

• Avoid fast starts and accelerate smoothly.

• Brake gradually and avoid abrupt stops.

• Avoid idling the engine for long periods of time.

• When road and weather conditions are appropriate,use cruise control, if equipped.

• Always follow posted speed limits or drive moreslowly when conditions require.

• Keep vehicle tires properly inflated.

• Combine several trips into a single trip.

• Replace the vehicle’s tires with the same TPC Specnumber molded into the tire’s sidewall near the size.

• Follow recommended scheduled maintenance.

Defensive DrivingDefensive driving means “always expect theunexpected.” The first step in driving defensively is towear your safety belt — See Safety Belts: They Are forEveryone on page 1-6.

{CAUTION:

Assume that other road users (pedestrians,bicyclists, and other drivers) are going to becareless and make mistakes. Anticipate what theymight do and be ready. In addition:

• Allow enough following distance between youand the driver in front of you.

• Focus on the task of driving.

Driver distraction can cause collisions resulting ininjury or possible death. These simple defensivedriving techniques could save your life.

4-2

Drunk Driving

{CAUTION:

Drinking and then driving is very dangerous. Yourreflexes, perceptions, attentiveness, and judgmentcan be affected by even a small amount of alcohol.You can have a serious — or even fatal — collisionif you drive after drinking. Do not drink and drive orride with a driver who has been drinking. Ride homein a cab; or if you are with a group, designate adriver who will not drink.

Death and injury associated with drinking and driving isa global tragedy.

Alcohol affects four things that anyone needs to drive avehicle: judgment, muscular coordination, vision, andattentiveness.

Police records show that almost 40 percent of all motorvehicle-related deaths involve alcohol. In most cases,these deaths are the result of someone who wasdrinking and driving. In recent years, more than17,000 annual motor vehicle-related deaths have beenassociated with the use of alcohol, with about250,000 people injured.

For persons under 21, it is against the law in everyU.S. state to drink alcohol. There are good medical,psychological, and developmental reasons forthese laws.

The obvious way to eliminate the leading highwaysafety problem is for people never to drink alcohol andthen drive.

Medical research shows that alcohol in a person’ssystem can make crash injuries worse, especiallyinjuries to the brain, spinal cord, or heart. This meansthat when anyone who has been drinking — driveror passenger — is in a crash, that person’s chance ofbeing killed or permanently disabled is higher than if theperson had not been drinking.

Control of a VehicleThe following three systems help to control the vehiclewhile driving — brakes, steering, and accelerator.At times, as when driving on snow or ice, it is easy toask more of those control systems than the tiresand road can provide. Meaning, you can lose control ofthe vehicle.

4-3

BrakingSee Brake System Warning Light on page 3-25.

Braking action involves perception time and reactiontime. Deciding to push the brake pedal is perceptiontime. Actually doing it is reaction time.

Average reaction time is about three-fourths of asecond. But that is only an average. It might be lesswith one driver and as long as two or three seconds ormore with another. Age, physical condition, alertness,coordination and eyesight all play a part. So do alcohol,drugs and frustration. But even in three-fourths of asecond, a vehicle moving at 60 mph (100 km/h) travels66 feet (20 m). That could be a lot of distance in anemergency, so keeping enough space betweenthe vehicle and others is important.

And, of course, actual stopping distances vary greatlywith the surface of the road, whether it is pavementor gravel; the condition of the road, whether it is wet, dryor icy; tire tread; the condition of the brakes; theweight of the vehicle; the weight of the load; and theamount of brake force applied.

Avoid needless heavy braking. Some people drive inspurts — heavy acceleration followed by heavybraking — rather than keeping pace with traffic. This is amistake. The brakes might not have time to cool betweenhard stops. The brakes will wear out much faster with alot of heavy braking. Keeping pace with the traffic and

allowing realistic following distances eliminates a lot ofunnecessary braking. That means better braking andlonger brake life.

If the engine ever stops while the vehicle is being driven,brake normally but do not pump the brakes. If the brakesare pumped, the pedal could get harder to push down. Ifthe engine stops, there will still be some power brakeassist but it will be used when the brake is applied. Oncethe power assist is used up, it can take longer to stop andthe brake pedal will be harder to push.

Hydraulic Brake SystemsIf the engine stops running, or if the primary brakesystem stops working, your vehicle has a reserve powerassist system to help you slow down. Just slowly andsteadily apply the brake pedal until you can safely get offthe road. The pedal will seem harder to push down.Do not pump the pedal; the system will not workwell that way.

You might find that the steering wheel seems hard to turnwhen you are turning and braking at the same time. Also,the primary brake warning light might come on and thewarning tone might sound. This is normal because themain hydraulic brake system and power steering both usethe power steering pump. If this ever happens, let up onthe brake pedal a little. When you let up on the brakepedal in that situation, it lets the steering get a little morehelp from the pump.

4-4

Antilock Brake System (ABS)This vehicle has the Antilock Brake System (ABS), anadvanced electronic braking system that helps prevent abraking skid.

When the engine is started and the vehicle begins todrive away, ABS checks itself. A momentary motoror clicking noise might be heard while this test is goingon. This is normal.

If there is a problem withABS, this warning lightstays on. See AntilockBrake System (ABS)Warning Light onpage 3-27.

Let us say the road is wet and you are driving safely.Suddenly, an animal jumps out in front of you. You slamon the brakes and continue braking. Here is whathappens with ABS:

A computer senses that the wheels are slowing down. Ifone of the wheels is about to stop rolling, the computerwill separately work the brakes at each wheel.

ABS can change the brake pressure to each wheel, asrequired, faster than any driver could. This can helpthe driver steer around the obstacle while braking hard.

As the brakes are applied, the computer keepsreceiving updates on wheel speed and controls brakingpressure accordingly.

Remember: ABS does not change the time needed to geta foot up to the brake pedal or always decrease stoppingdistance. If you get too close to the vehicle in front of you,there will not be enough time to apply the brakes if thatvehicle suddenly slows or stops. Always leave enoughroom up ahead to stop, even with ABS.

Using ABSDo not pump the brakes. Just hold the brake pedaldown firmly and let antilock work. The brakes might befelt to pulsate, or the sound of air exhausting mightbe heard if the vehicle has air brakes, but this is normal.

Braking in EmergenciesABS allows the driver to steer and brake at the sametime. In many emergencies, steering can help more thaneven the very best braking.

4-5

Trailer Brake Hand Control ValveIf your vehicle has this feature, the control is mountedon the floor console.

This feature lets you applythe trailer brakes withoutapplying the tractor brakes.

You can apply the trailer brakes a little or apply them allthe way if you have to. Use this control only whenyou are driving. Do not use it for parking or to hold therig on a hill.

{CAUTION:

Using the trailer brake hand control for parking orfor holding the vehicle on a hill may not keep thevehicle from rolling. This can happen if someonehits the valve by accident, or if air pressure bleedsfrom the system. If the vehicle rolls, you or otherscould be injured. To park the vehicle or hold it ona hill, use the parking brake properly.

4-6

Rear Axle Differential Lock Control

If the vehicle has acontrolled traction orlocking differential axle, theswitch is located in thecenter of the instrumentpanel.

This control is on single rear axle vehicles.

If approaching a slippery surface where one or bothwheels may start to slip, press the switch to off. The reardifferential locks so power is transmitted equally toboth rear wheels.

Let up on the accelerator before turning on the rear axledifferential lock.

Notice: Turning on the inter-axle differential lockwhile the rear wheels are spinning freely, asthey might on snow or ice, can damage the axle(s).Turn on this control only while the wheels arenot spinning freely.

Traction Control System (TCS)The vehicle may have a traction control system thatlimits wheel spin. This is especially useful in slipperyroad conditions. The system operates only if it sensesthat one or both of the rear wheels are spinning orbeginning to lose traction. When this happens,the system applies the brake(s) at the affected wheel(s).

The bottom light on TCS on/off button will come on whenthe TCS is limiting wheel spin. The system may be heardor felt while it is working, but this is normal. TCS willfunction at speeds up to about 25 mph (42 km/h).

TCS may operate on dry roads under some conditions.When this happens, a reduction in acceleration maybe noticed. This is normal and doesn’t mean there’s aproblem with the vehicle. Examples of these conditionsinclude a hard acceleration in a turn, an abruptupshift or downshift of the transmission or driving onrough roads.

When the light in the top of the TCS button is on, TCSis off and will not limit wheel spin. Adjust your drivingaccordingly.

The light in the top of the TCS button will come on ifTCS is turned off by pressing the TCS on/off button.

The light may also come on if a problem has beendetected in either the traction control system orthe anti-lock brake system.

4-7

The traction control system automatically comes onwhenever the vehicle is started. To limit wheelspin, especially in slippery road conditions, the systemshould always be left on. But the traction controlsystem can be turned off if needed. Turn the system offif the vehicle ever gets stuck in sand, mud or snowand rocking the vehicle is required. See Rocking YourVehicle to Get It Out on page 4-18 for more information.

To turn the system on oroff, press the tractioncontrol button located onthe instrument panel.

If the TCS button was used to turn the system off, thelight in the top of the button will come on and stay on.TCS can be turned back on at any time by pressing thebutton again; the light should go off.Adding non-dealer/non-retailer accessories can affect thevehicle’s performance. See Accessories andModifications on page 5-3 for more information.

Steering

Power SteeringIf power steering assist is lost because the engine stopsor the system is not functioning, the vehicle can besteered but it will take more effort.

On vehicles with hydraulic brakes, the power steeringand main hydraulic brake system both use thepower steering pump. See Braking on page 4-4.

Steering Tips

Driving on CurvesIt is important to take curves at a reasonable speed.

Traction in a curve depends on the condition of the tiresand the road surface, the angle at which the curve isbanked, and vehicle speed. While in a curve, speed isthe one factor that can be controlled.

If there is a need to reduce speed, do it before enteringthe curve, while the front wheels are straight.

Try to adjust the speed so you can drive through thecurve. Maintain a reasonable, steady speed. Waitto accelerate until out of the curve, and then accelerategently into the straightaway.

4-8

Steering in EmergenciesThere are times when steering can be more effectivethan braking. For example, you come over a hill and finda truck stopped in your lane, or a car suddenly pullsout from nowhere, or a child darts out from betweenparked cars and stops right in front of you. Theseproblems can be avoided by braking — if you can stopin time. But sometimes you cannot stop in timebecause there is no room. That is the time for evasiveaction — steering around the problem.

The vehicle can perform very well in emergencies likethese. First apply the brakes. See Braking on page 4-4.It is better to remove as much speed as possiblefrom a collision. Then steer around the problem, to theleft or right depending on the space available.

An emergency like this requires close attention and aquick decision. If holding the steering wheel at therecommended 9 and 3 o’clock positions, it can be turneda full 180 degrees very quickly without removingeither hand. But you have to act fast, steer quickly, andjust as quickly straighten the wheel once you haveavoided the object.

The fact that such emergency situations are alwayspossible is a good reason to practice defensive drivingat all times and wear safety belts properly.

4-9

Off-Road RecoveryThe vehicle’s right wheels can drop off the edge of aroad onto the shoulder while driving.

If the level of the shoulder is only slightly below thepavement, recovery should be fairly easy. Ease off theaccelerator and then, if there is nothing in the way,steer so that the vehicle straddles the edge of thepavement. Turn the steering wheel 3 to 5 inches, 8 to13 cm, (about one-eighth turn) until the right fronttire contacts the pavement edge. Then turn the steeringwheel to go straight down the roadway.

PassingPassing another vehicle on a two-lane road can bedangerous. To reduce the risk of danger while passing:

• A vehicle like yours takes a longer time to reachpassing speed, so you will need a longer stretchof clear road ahead than you would with apassenger car.

• Look down the road, to the sides, and to crossroadsfor situations that might affect a successful pass. Ifin doubt, wait.

• Watch for traffic signs, pavement markings, andlines that could indicate a turn or an intersection.Never cross a solid or double-solid line on your sideof the lane.

• Do not get too close to the vehicle you want topass. Doing so can reduce your visibility.

• Wait your turn to pass a slow vehicle.

• When you are being passed, ease to the right.

4-10

Loss of ControlLet us review what driving experts say about whathappens when the three control systems — brakes,steering, and acceleration — do not have enough frictionwhere the tires meet the road to do what the driver hasasked.

In any emergency, do not give up. Keep trying to steerand constantly seek an escape route or area of lessdanger.

SkiddingIn a skid, a driver can lose control of the vehicle.Defensive drivers avoid most skids by taking reasonablecare suited to existing conditions, and by not overdrivingthose conditions. But skids are always possible.

The three types of skids correspond to the vehicle’s threecontrol systems. In the braking skid, the wheels are notrolling. In the steering or cornering skid, too much speedor steering in a curve causes tires to slip and losecornering force. And in the acceleration skid, too muchthrottle causes the driving wheels to spin.

If the vehicle has the Traction Control System (TCS),remember: It helps avoid only the acceleration skid. SeeTraction Control System (TCS) on page 4-7. If thevehicle does not have this system, or if the system isoff, then an acceleration skid is best handled by easingyour foot off the accelerator pedal.

Of course, traction is reduced when water, snow, ice,gravel, or other material is on the road. For safety, slowdown and adjust your driving to these conditions. It isimportant to slow down on slippery surfaces becausestopping distance will be longer and vehicle control morelimited.

While driving on a surface with reduced traction, tryyour best to avoid sudden steering, acceleration,or braking, including reducing vehicle speed by shiftingto a lower gear. Any sudden changes could causethe tires to slide. You may not realize the surfaceis slippery until the vehicle is skidding. Learn torecognize warning clues — such as enough water, ice,or packed snow on the road to make a mirroredsurface — and slow down when you have any doubt.

If the vehicle has the Antilock Brake System (ABS),remember: It helps avoid only the braking skid. If thevehicle does not have ABS, then in a braking skid,where the wheels are no longer rolling, release enoughpressure on the brakes to get the wheels rollingagain. This restores steering control. Push the brakepedal down steadily when you have to stop suddenly. Aslong as the wheels are rolling, you will have steeringcontrol.

4-11

Driving at NightNight driving is more dangerous than day drivingbecause some drivers are likely to be impaired — byalcohol or drugs, with night vision problems, or byfatigue.

Night driving tips include:

• Drive defensively.

• Do not drink and drive.

• Reduce headlamp glare by adjusting the insiderearview mirror.

• Slow down and keep more space between you andother vehicles because headlamps can only light upso much road ahead.

• Watch for animals.

• When tired, pull off the road.

• Do not wear sunglasses.

• Avoid staring directly into approaching headlamps.

• Keep the windshield and all glass on your vehicleclean — inside and out.

• Keep your eyes moving, especially during turns orcurves.

No one can see as well at night as in the daytime. But,as we get older, these differences increase. A50-year-old driver might need at least twice as muchlight to see the same thing at night as a 20-year-old.

4-12

Driving in Rain and on Wet RoadsRain and wet roads can reduce vehicle tractionand affect your ability to stop and accelerate. Alwaysdrive slower in these types of driving conditionsand avoid driving through large puddles anddeep-standing or flowing water.

{CAUTION:

Wet brakes can cause crashes. They might notwork as well in a quick stop and could causepulling to one side. You could lose control of thevehicle.

After driving through a large puddle of water or acar/vehicle wash, lightly apply the brake pedal untilthe brakes work normally.



Flowing or rushing water creates strong forces.Driving through flowing water could cause yourvehicle to be carried away. If this happens, youand other vehicle occupants could drown. Do notignore police warnings and be very cautious abouttrying to drive through flowing water.

HydroplaningHydroplaning is dangerous. Water can build up underyour vehicle’s tires so they actually ride on thewater. This can happen if the road is wet enough andyou are going fast enough. When your vehicle ishydroplaning, it has little or no contact with the road.

There is no hard and fast rule about hydroplaning. Thebest advice is to slow down when the road is wet.

4-13

Other Rainy Weather TipsBesides slowing down, other wet weather driving tipsinclude:

• Allow extra following distance.

• Pass with caution.

• Keep windshield wiping equipment in good shape.

• Keep the windshield washer fluid reservoir filled.

• Have good tires with proper tread depth. See Tireson page 5-60.

• Turn off cruise control.

Highway HypnosisAlways be alert and pay attention to your surroundingswhile driving. If you become tired or sleepy, find asafe place to park your vehicle and rest.

Other driving tips include:

• Keep the vehicle well ventilated.

• Keep interior temperature cool.

• Keep your eyes moving — scan the road aheadand to the sides.

• Check the rearview mirror and vehicle instrumentsoften.

4-14

Hill and Mountain RoadsDriving on steep hills or through mountains is differentthan driving on flat or rolling terrain. Tips for drivingin these conditions include:

• Keep the vehicle serviced and in good shape.

• Check all fluid levels and brakes, tires, coolingsystem, and transmission.

• Going down steep or long hills, shift to alower gear.

{CAUTION:

If you do not shift down, the brakes could get sohot that they would not work well. You would thenhave poor braking or even none going down a hill.You could crash. Shift down to let the engineassist the brakes on a steep downhill slope.

{CAUTION:

Coasting downhill in N (Neutral) or with the ignitionoff is dangerous. The brakes will have to do all thework of slowing down and they could get so hotthat they would not work well. You would thenhave poor braking or even none going down a hill.You could crash. Always have the engine runningand the vehicle in gear when going downhill.

• Stay in your own lane. Do not swing wide or cutacross the center of the road. Drive at speedsthat let you stay in your own lane.

• Top of hills: Be alert — something could be in yourlane (stalled car, accident).

• Pay attention to special road signs (falling rocksarea, winding roads, long grades, passing orno-passing zones) and take appropriate action.

4-15

Winter Driving

Driving on Snow or IceDrive carefully when there is snow or ice between thetires and the road, creating less traction or grip. Wet icecan occur at about 32°F (0°C) when freezing rainbegins to fall, resulting in even less traction. Avoiddriving on wet ice or in freezing rain until roads can betreated with salt or sand.

Drive with caution, whatever the condition. Accelerategently so traction is not lost. Accelerating too quicklycauses the wheels to spin and makes the surface underthe tires slick, so there is even less traction.

Try not to break the fragile traction. If you accelerate toofast, the drive wheels will spin and polish the surfaceunder the tires even more.

If the vehicle has the Traction Control System (TCS) onpage 4-7, it improves the ability to accelerate onslippery roads, but slow down and adjust your driving tothe road conditions. When driving through deep snow,turn off the traction control system to help maintainvehicle motion at lower speeds.

The Antilock Brake System (ABS) on page 4-5 improvesvehicle stability during hard stops on a slippery roads,but apply the brakes sooner than when on drypavement.

Allow greater following distance on any slippery roadand watch for slippery spots. Icy patches can occur onotherwise clear roads in shaded areas. The surfaceof a curve or an overpass can remain icy whenthe surrounding roads are clear. Avoid sudden steeringmaneuvers and braking while on ice.

Turn off cruise control, if equipped, on slippery surfaces.

4-16

Blizzard ConditionsBeing stuck in snow can be in a serious situation. Staywith the vehicle unless there is help nearby. If possible,use the Roadside Assistance Program on page 7-5. Toget help and keep everyone in the vehicle safe:

• Turn on the Hazard Warning Flashers on page 3-6.

• Tie a red cloth to an outside mirror.

{CAUTION:

Snow can trap engine exhaust under the vehicle.This may cause exhaust gases to get inside.Engine exhaust contains carbon monoxide (CO)which cannot be seen or smelled. It can causeunconsciousness and even death.

If the vehicle is stuck in the snow:• Clear away snow from around the base of your

vehicle, especially any that is blocking theexhaust pipe.

• Check again from time to time to be sure snowdoes not collect there.



• Open a window about two inches (5 cm) on theside of the vehicle that is away from the wind tobring in fresh air.

• Fully open the air outlets on or under theinstrument panel.

• Adjust the Climate Control system to a settingthat circulates the air inside the vehicle and setthe fan speed to the highest setting. SeeClimate Control System in the Index.

For more information about carbon monoxide, seeEngine Exhaust on page 2-29.

Snow can trap exhaust gases under your vehicle.This can cause deadly CO (carbon monoxide) gasto get inside. CO could overcome you and kill you.You cannot see it or smell it, so you might not knowit is in your vehicle. Clear away snow from aroundthe base of your vehicle, especially any that isblocking the exhaust.

Run the engine for short periods only as needed tokeep warm, but be careful.

To save fuel, run the engine for only short periods asneeded to warm the vehicle and then shut the engine offand close the window most of the way to save heat.

4-17

Repeat this until help arrives but only when you feelreally uncomfortable from the cold. Moving aboutto keep warm also helps.

If it takes some time for help to arrive, now and thenwhen you run the engine, push the acceleratorpedal slightly so the engine runs faster than the idlespeed. This keeps the battery charged to restartthe vehicle and to signal for help with the headlamps.Do this as little as possible to save fuel.

If Your Vehicle is Stuck in Sand,Mud, Ice, or SnowSlowly and cautiously spin the wheels to free thevehicle when stuck in sand, mud, ice, or snow. SeeRocking Your Vehicle to Get It Out on page 4-18.

If the vehicle has a traction system, it can often help tofree a stuck vehicle. Refer to the vehicle’s tractionsystem in the Index. If stuck too severely for the tractionsystem to free the vehicle, turn the traction system offand use the rocking method.

{CAUTION:

If you let your vehicle’s tires spin at high speed,they can explode, and you or others could beinjured. The vehicle can overheat, causing anengine compartment fire or other damage. Spinthe wheels as little as possible and avoid goingabove 35 mph (55 km/h) as shown on thespeedometer.

Rocking Your Vehicle to Get It OutTurn the steering wheel left and right to clear the areaaround the front wheels. Turn off any traction system.Shift back and forth between R (Reverse) and a forwardgear, spinning the wheels as little as possible. To preventtransmission wear, wait until the wheels stop spinningbefore shifting gears. Release the accelerator pedal whileshifting, and press lightly on the accelerator pedal whenthe transmission is in gear. Slowly spinning the wheels inthe forward and reverse directions causes a rockingmotion that could free the vehicle. If that does not get thevehicle out after a few tries, it might need to be towed out.If the vehicle does need to be towed out, see TowingYour Vehicle on page 4-21.

4-18

Tow Hooks

{CAUTION:

These hooks, when used, are under a lot of force.Always pull the vehicle straight out. Never pull onthe hooks at a sideways angle. The hooks couldbreak off and you or others could be injured fromthe chain or cable snapping back.

Notice: Never use tow hooks to tow the vehicle.Your vehicle could be damaged and it would not becovered by warranty.

If your vehicle has tow hooks, the hooks are at the frontof the vehicle. You may need to use them if you arestuck off-road and need to be pulled to some placewhere you can continue driving.

Loading the VehicleIt is the responsibility of the Final Stage manufacturer toinstall a Certification label on your vehicle. This labelshows how much weight your vehicle can properly carry.It may also show the size of the vehicle’s originaltires, and the inflation pressures needed to obtain thegross weight capacity of your vehicle. This is called theGross Vehicle Weight Rating (GVWR). The tireinformation could also be shown on a separate TireInformation label.

The GVWR includes the weight of the vehicle, alloccupants, fuel, and cargo.

The Certification label also tells you the maximumweight for the front and rear axles, called the Gross AxleWeight Rating (GAWR). To find out the actual loadson your front and rear axles, go to a weigh station andweigh your vehicle. Your dealer can help you withthis. Be sure to spread out your load equally on bothsides of the center line.

4-19

Never exceed the GVWR for your vehicle, or the GAWRfor either the front or rear axle.

And, if you do have a heavy load, spread it out.

{CAUTION:

Do not load the vehicle any heavier than theGross Vehicle Weight Rating (GVWR), oreither the maximum front or rear Gross AxleWeight Rating (GAWR). If you do, parts onthe vehicle can break, and it can change theway your vehicle handles. These could causeyou to lose control and crash. Also,overloading can shorten the life of thevehicle.

Using heavier suspension components to get addeddurability might not change the weight ratings. Ask yourdealer to help you load your vehicle the right way.

Notice: Overloading your vehicle may causedamage. Repairs would not be covered by yourwarranty. Do not overload your vehicle.

If you put things inside your vehicle — like suitcases,tools, packages, or anything else — they go as fastas the vehicle goes. If you have to stop or turn quickly,or if there is a crash, they keep going.

{CAUTION:

Things you put inside your vehicle can strikeand injure people in a sudden stop or turn, orin a crash.

• Put things in the cargo area of yourvehicle. Try to spread the weight evenly.

• Never stack heavier things, likesuitcases, inside the vehicle so that someof them are above the tops of the seats.

• Do not leave an unsecured child restraintin your vehicle.

• When you carry something inside thevehicle, secure it whenever you can.

• Do not leave a seat folded down unlessyou need to.

4-20

Towing

Towing Your Vehicle

{CAUTION:

To help avoid serious personal injury to you orothers:

• Never let passengers ride in a vehicle that isbeing towed.

• Never tow faster than safe or posted speeds.• Never tow with damaged parts not fully

secured.• Never get under your vehicle after it has been

lifted by the tow truck.• Always secure the vehicle on each side with

separate safety chains when towing it.• Working on air brakes without first using the

release studs to compress the springs canlead to injury. Never work on the air brakeschambers without first using the release studsto compress the brake springs.



• When the brake springs are manuallycompressed, you will have no brakes.Release your air-operated parking brakesmanually only to tow the vehicle. Never drivethe vehicle with the brakes released.

Consult your dealer/retailer or a professional towingservice to have the vehicle towed. They can provide theright equipment and know-how to tow it withoutdamage. See Roadside Assistance Program onpage 7-5.

Before doing anything, turn on the hazard warningflashers (if they have not been damaged). See HazardWarning Flashers on page 3-6 for more information.

When calling, tell the towing service:

• That the vehicle is rear-wheel drive.

• The make, model and year of the vehicle.

• Whether the shift lever can still be moved.

• If there was an accident, what was damaged.

4-21

When the towing service arrives, let the tow operatorknow that this manual contains towing instructions. Theoperator may want to see them.

Here are specific towing instructions:

Towing Your Vehicle From the Front(All Wheels On the Ground)The vehicle may be towed on all wheels provided thesteering is working. Remember that the powerbrakes and power steering will not have power assist.Vehicles with air brakes will not have brakes. Theremust be a tow bar installed between the towing vehicleand the disabled vehicle.

Before TowingBlock the wheels of the disabled vehicle. On vehicleswith air brakes, release the emergency brake system bycompressing the brake chamber springs as outlinedin this section. (This is to prevent the possibility of theemergency brake being applied during towing.)

On vehicles with hydraulic brakes, release the parkingbrake fully by moving the lever to the fully-releasedposition.

If there is damage or suspected damage to the axle(s),remove the axle shafts. Cover the hub openings toprevent the loss of lubricant or entry of dirt or foreignobjects.

After Towing1. Block the rear wheels and install axle shafts and/or

propshafts.

2. Check for proper phasing of universal joints.

3. Apply the parking brake system beforedisconnecting from the towing vehicle.

4. Check and fill rear axle with oil as required.

Towing Your Vehicle From the Front(Front Wheels Off the Ground)Before TowingBlock the rear wheels of the disabled vehicle. Onvehicles with air brakes, release the emergency brakesystem by compressing the brake chamber springsas outlined in this section. (This is to prevent thepossibility of the emergency brake being appliedduring towing.)

On vehicles with hydraulic brakes, release the parkingbrake fully by moving the lever to the fully-releasedposition.

4-22

Towing the Vehicle with the Front BumperRemoved

1. Remove the front bumper.

2. Connect and lock the lift chains to the front axle,outside of the spring anchor plates as shown.

3. Connect the lift chains to the tow bar and raise thetow bar until lift chain slack has been taken up.

4. Raise the vehicle to the required height.

Rear Axle1. Disconnect the propshaft at the rear axle.

2. Secure the propshaft to the frame or thecrossmember.

After Towing1. Block the rear wheels and install the propshafts.

2. Check for proper phasing of universal joints.

3. Apply the emergency brake system beforedisconnecting from the towing vehicle.

4. Check and fill the rear axle with oil as required.

4-23

Towing Your Vehicle From the Rear(Rear Wheels Off the Ground)Before TowingSecure the steering wheel to maintain a straight-aheadposition. Make certain that the front axle is not loadedabove the front axle Gross Axle Weight Rating (GAWR)as indicated on the vehicle’s Certification Label. SeeLoading the Vehicle on page 4-19 for more information.

After Towing1. Block the rear wheels and release the steering

wheel.

2. Apply the parking brake system beforedisconnecting from the towing vehicle.

3. Check and fill the rear axle with oil as required.

Releasing Air-Operated Parking BrakesIf the vehicle has air brakes, there could be a specialtowing problem. If the vehicle has to be towed becauseof a complete loss of air pressure from both systems,the parking brakes will have automatically engaged. Thetow operator can release the brakes manually byusing the following steps. Then the vehicle can be towedwith all wheels or only the rear wheels on the ground.

1. Block the wheels of the vehicle.

2. Remove the release stud and nut from the side ofthe brake chamber. Some chambers have studswhich are visible at all times.

4-24

3. Remove the rubbercap from the rear ofthe chamber.

4. Put the release stud, nut and flat washer into thechamber.

5. Turn the stud clockwise one quarter of a turn.

6. Turn the stud nutclockwise several turnsto release the brakes.Follow the sameprocedure to releasethe other brake orbrakes.

7. At the repair facility, apply air pressure of at least70 psi (480 kPa) to the brake chambers, eitherfrom an external air supply or the vehicle’sair system.

8. Turn the stud nut counterclockwise several turns.Remove the stud from the chamber.

9. Replace the stud and washer and tighten the nutinto the side of the chamber.

10. Replace the rubber cap.

4-25

Trailer Connections(T7/T8 Models Only)If the vehicle has these trailer connections, they arelocated at the rear of the cab for a tractor and at the rearof the chassis when towing a trailer. There will be anair connection and an electrical connection.

Be sure that the couplings to the trailer are madecorrectly.

Air ConnectionsIf the trailer air line connections will not be connected toanother piece of equipment, be sure to replace theirprotective caps.

Electrical ConnectionsThis system is a seven-wire cable that will connect tothe trailer, supplying power to the trailer’s lightingsystem. When not in use, it is stored in the trailerair-hose storage bracket.

Heavy-Duty Trailer Wiring PackageThe vehicle may have an eight-wire trailer towingharness. This harness, with a seven-pin universalheavy-duty trailer connector, is attached to a bracket onthe platform hitch.

The Center High-Mounted Stoplamp (CHMSL) wire istied next to the trailer wiring harness for use with atrailer.

The eight-wire harness contains the following trailercircuits:

• Yellow: Left Stop/Turn Signal

• Dark Green: Right Stop/Turn Signal

• Brown: Taillamps

• White: Ground

• Light Green: Back-up Lamps

• Light Blue: CHMSL

• Red: Battery Feed

• Dark Blue: Trailer Brake

4-26

Service ............................................................5-3Accessories and Modifications ..........................5-3California Proposition 65 Warning .....................5-4California Perchlorate Materials Requirements .....5-4Doing Your Own Service Work .........................5-5Engine Fan Breakage .....................................5-6

Fuel ................................................................5-7Diesel Engine Fuel .........................................5-7What Fuel to Use ...........................................5-7Very Cold Weather Operation .........................5-10Water in Fuel ...............................................5-10Running Out of Fuel .....................................5-14Filling the Tank ............................................5-14Filling a Portable Fuel Container .....................5-16

Checking Things Under the Hood ....................5-16Engine Oil ...................................................5-16Engine Oil Life System ..................................5-20Engine Air Cleaner/Filter ................................5-21Automatic Transmission Fluid .........................5-23Manual Transmission Fluid .............................5-24Hydraulic Clutch ...........................................5-25Cooling System ............................................5-26Engine Coolant .............................................5-26Coolant Surge Tank Pressure Cap ..................5-30

Engine Overheating .......................................5-30Power Steering Fluid .....................................5-32Windshield Washer Fluid ................................5-33Brakes ........................................................5-34Battery ........................................................5-41Jump Starting ...............................................5-42

Rear Axle .......................................................5-47Rear Axle Shift Motor ....................................5-48

Cab Tilting .....................................................5-48Before You Tilt the Cab .................................5-48Tilting the Cab .............................................5-49Lowering the Cab .........................................5-52Lifting the Front Panel ...................................5-54

Noise Control System .....................................5-55Tampering with Noise Control System

Prohibited .................................................5-55Bulb Replacement ..........................................5-56Windshield Wiper Blade Replacement ..............5-56Other Service Items ........................................5-57

Fuel Filter ....................................................5-57Primary Fuel Filter and Water Separator ..........5-58Front Wheel Bearings with

Oil-Filled Hubs ..........................................5-59

Section 5 Service and Appearance Care

5-1

Tires ..............................................................5-60Inflation - Tire Pressure .................................5-61Wheel Loading .............................................5-62Dual Tire Operation .......................................5-62When It Is Time for New Tires .......................5-62Buying New Tires .........................................5-63Wheel Alignment and Tire Balance ..................5-64Tightening the Wheel Nuts .............................5-64Wheel Replacement ......................................5-68If a Tire Goes Flat ........................................5-70

Appearance Care ............................................5-72Interior Cleaning ...........................................5-72Fabric/Carpet ...............................................5-73Instrument Panel, Vinyl, and Other Plastic

Surfaces ..................................................5-74Care of Safety Belts ......................................5-74Weatherstrips ...............................................5-74Washing Your Vehicle ...................................5-75Cleaning Exterior Lamps/Lenses .....................5-75Finish Care ..................................................5-76Windshield and Wiper Blades .........................5-76Aluminum Wheels .........................................5-77Tires ...........................................................5-77

Sheet Metal Damage .....................................5-77Finish Damage .............................................5-77Underbody Maintenance ................................5-78Chemical Paint Spotting .................................5-78

Vehicle Identification ......................................5-78Vehicle Identification Number (VIN) .................5-78

Electrical System ............................................5-79Add-On Electrical Equipment ..........................5-79Headlamp Wiring ..........................................5-79Windshield Wiper Fuses ................................5-79Fusible Links ................................................5-79Power Windows and Other Power Options .......5-79Fuses and Circuit Breakers ............................5-80Instrument Panel Fuse Block ..........................5-80Maxi-Fuse Block ...........................................5-84Relay Center ................................................5-85

Capacities and Specifications ..........................5-88Capacities and Specifications .........................5-88

Normal Maintenance Replacement Parts ..........5-91Maintenance Replacement Parts .....................5-91Engine Drive Belt Routing ..............................5-92

Section 5 Service and Appearance Care

5-2

ServiceFor service and parts needs, visit your dealer/retailer.You will receive genuine GM parts and GM-trained andsupported service people.

Genuine GM parts have one of these marks:

Accessories and ModificationsAdding non-dealer accessories to the vehicle can affectits performance and safety. Such things as airbags,braking, stability, ride and handling, emissions systems,aerodynamics, durability, and electronic systems likeanti-lock brakes, traction control, and stability controlcould be affected. Some non-dealer accessories couldeven cause malfunction or damage to parts andsystems and would not be covered by the vehiclewarranty.

Damage to vehicle components resulting from theinstallation or use of non-GM certified parts, includingcontrol module modifications, are not covered under theterms of the vehicle warranty and may affect remainingwarranty coverage for affected parts.

GM Accessories are designed to complement andfunction with other systems on the vehicle. Your GMdealer can accessorize the vehicle using genuineGM Accessories. When you go to your GM dealer andask for GM Accessories, you will know that GM-trainedand supported service technicians will perform thework using genuine GM Accessories.

5-3

Aftermarket Engine PerformanceEnhancement Products andModificationsSome aftermarket engine performance products andmodifications promise a way to increase the horsepowerand torque levels of the vehicle’s powertrain. Youshould be aware that these products could have harmfuleffects on the performance and life of the engine,exhaust emission system, transmission, and drivetrain.The engines, transmissions, and drivetrains havebeen designed and built to offer industry leadingdurability and performance in the most demandingapplications. Engine power enhancement products mayenable the engine to operate at horsepower andtorque levels that could damage, create failure, orreduce the life of the engine, engine emission system,transmission, and drivetrain. Damage, failure, or reducedlife of the engine, transmission, emission system,drivetrain, or other vehicle components caused byaftermarket engine performance enhancement productsor modifications might not be covered under thevehicle warranty.

California Proposition 65 WarningMost motor vehicles, including this one, contain and/oremit chemicals known to the State of California tocause cancer and birth defects or other reproductiveharm. Engine exhaust, many parts and systems(including some inside the vehicle), many fluids, andsome component wear by-products contain and/or emitthese chemicals.

California Perchlorate MaterialsRequirementsCertain types of automotive applications, such as airbaginitiators, seat belt pretensioners, and lithium batteriescontained in remote keyless transmitters, maycontain perchlorate materials. Special handling may benecessary. For additional information, seewww.dtsc.ca.gov/hazardouswaste/perchlorate.

5-4

Doing Your Own Service Work

{CAUTION:

You can be injured and the vehicle could bedamaged if you try to do service work on a vehiclewithout knowing enough about it.

• Be sure you have sufficient knowledge,experience, the proper replacement parts, andtools before attempting any vehiclemaintenance task.

• Be sure to wait until the engine and anyattaching parts have sufficiently cooled beforetilting the cab to service the vehicle.

• Be sure to use the proper nuts, bolts, andother fasteners. English and metric fastenerscan be easily confused. If the wrong fastenersare used, parts can later break or fall off. Youcould be hurt.

If doing some of your own service work, use the properservice manual. It tells you much more about how toservice the vehicle than this manual can. To orderthe proper service manual, see Service PublicationsOrdering Information on page 7-10.

Keep a record with all parts receipts and list the mileageand the date of any service work performed. See Part D:Maintenance Record on page 6-29.

5-5

Engine Fan Breakage

{CAUTION:

Changing the Fan Drive Ratio or Engine GovernedSpeed:

If you change the fan drive ratio or increase thegoverned speed of the engine, you might increasestress and the fan could eventually fail. If the fanbreaks apart while rotating, pieces can causesevere injury to anyone — such as a servicetechnician — who is nearby. And, of course, thepieces can severely damage the vehicle. Do notchange the fan drive ratio or increase thegoverned speed of the vehicle without getting thenecessary information from your dealer/retailer.



Winter Fronts, Grille Covers, or Obstructions:

Winter Fronts, grille covers, or other add-onequipment causing obstructions in front of orbehind the fan should not be used on this vehicle.If this causes the fan to eventually break apartwhile rotating, the pieces can cause severe injuryto anyone nearby, such as a service technicianworking on the engine, and, of course, the piecescan severely damage the vehicle.

5-6

Fuel

Diesel Engine FuelNotice: Diesel fuel or fuel additives notrecommended in this manual could damage the fuelsystem and engine. Your warranty would notcover this damage. And:

• Diesel fuel that has been mixed with engine oilor automatic transmission fluid could damagethe engine and emission controls.

• We do not test aftermarket diesel fuel additives.Some additives, particularly those which containalcohol or water emulsifiers, could damage thefuel system. If you believe that uniquecircumstances call for a fuel additive to be used,consult your dealer/retailer for advice.

• If you ever run out of diesel fuel, it can be difficultto restart the engine. To avoid this, never let thetank get empty.

If gasoline is ever accidentally added to the fueltank, to avoid severe engine damage, do not run theengine until the fuel tank can be drained.

If you run out of fuel, Running Out of Fuel on page 5-14tells you how to restart the engine.

What Fuel to UseNotice: Use of diesel fuel other than Ultra LowSulfur Diesel (15 ppm sulfur maximum) or engine oilother than low ash CJ-4 oil will cause permanentdamage to the DPF and related components.This damage would not be covered by yourwarranty.

The emission control system requires the use ofdiesel fuel with ultra low-sulfur (0.0015% by weight, or15 ppm, maximum) content. Both Ultra Low SulfurDiesel and Low Sulfur Diesel fuels are available in theUnited States and Ultra Low Sulfur Diesel fuel isavailable in Canada. In Mexico, Ultra Low Sulfur Dieselfuel is not available in all regions.

At a minimum, the diesel fuel you use should meet thelatest version of ASTM specification D 975 (GradesNo. 2-D or No. 1-D S15 commonly known as Ultra LowSulfur diesel) in the United States. In addition, theEngine Manufacturers Association (EMA) has identifiedproperties of an improved diesel fuel for better engineperformance and durability. Diesel fuels correspondingto the EMA Recommended Guideline on PremiumDiesel Fuel (FQP-1A) could provide better starting, lessnoise, and better vehicle performance. If there arequestions about the fuel you are using, contact your fuelsupplier.

5-7

In the United States, for best results use No. 2-D dieselfuel year-round (above and below freezing conditions)as oil companies blend No. 2-D fuel to address climatedifferences. No. 1-D diesel fuel can be used in verycold temperatures (when it stays below 0°F or −18°C);however, it will produce a power and fuel economyloss. Avoid the use of No. 1-D diesel fuel in warm or hotclimates. It can result in stalling, poor starting whenthe engine is hot, and could damage the fuel injectionsystem.

It is acceptable to use diesel fuel containing up to 5%biodiesel (B5), but the final blended fuel must meetthe same specification, ASTM D 975 (Grades No. 2-D orNo. 1-D S15 commonly known as Ultra Low Sulfurdiesel), as other fuels used in your vehicle, andthe biodiesel used for making this fuel must meet thelatest version of ASTM specification D 6751. Biodiesel isproduced from vegetable oils or animal fat that havebeen chemically modified to reduce the possibilityof damage to the fuel system and engine. Higherconcentration (i.e., greater than B5) biodiesel-containingfuels or the use of unmodified bio-oils blended intodiesel fuel at any concentration is not recommended andcould damage the fuel system and engine. Suchdamage would not be covered by your warranty. If thereare questions about the biodiesel-containing fuels youare using, contact your fuel supplier.

Because of the cleansing properties of biodiesel,switching from straight diesel to a biodiesel blend canprematurely restrict the fuel filter with normal deposits inthe fuel system. A fuel filter replacement might berequired sooner than the recommended interval.

Diesel fuel can foam when you fill the tank. This cancause the automatic pump nozzle to shut off, eventhough the tank is not full. If this happens, just wait forthe foaming to stop and then try filling the tank moreslowly. See Filling the Tank on page 5-14.

{CAUTION:

Heat coming from the engine can cause the fuel toexpand and force the fuel out of the tank. Ifsomething ignites the fuel, a fire could start andpeople could be burned. To help avoid this, tryfilling the tank more slowly and fill the fuel tankonly until the automatic nozzle shuts off. Do not tryto top it off.

5-8

What Fuel to Use in Canada

Notice: Use of diesel fuel other than Ultra LowSulfur Diesel (15 ppm sulfur maximum) or engine oilother than low ash CJ-4 oil will cause permanentdamage to the DPF and related components.This damage would not be covered by yourwarranty.

The emission control system requires the use of dieselfuel with ultra low-sulfur (0.0015% by weight, or 15 ppm,maximum) content. Both Ultra Low Sulfur Diesel and LowSulfur Diesel fuels are available in the United States andUltra Low Sulfur Diesel fuel is available in Canada. InMexico, Ultra Low Sulfur Diesel fuel is not available in allregions.

At a minimum, the diesel fuel you use should meet thelatest version of specification CAN/CGSB-3.517 (ULS) inCanada. In addition, the Engine ManufacturersAssociation (EMA) has identified properties of animproved diesel fuel for better engine performance anddurability (FQP-1A). Diesel fuels corresponding to theEMA description could provide better starting, less noise,and better vehicle performance. If there are questionsabout the fuel you are using, contact your fuel supplier.

Canadian fuels are blended for seasonal changes.Diesel Type “A” fuel is blended for better cold weatherstarting (below 0°F or −18°C); however, you might noticesome power and fuel economy loss. If Type “A” fuel isused in warmer temperatures, stalling and hardstarting may occur. Diesel Type “B” fuel is blended fortemperatures above 0°F (−18°C).

It is acceptable to use diesel fuel containing up to5% biodiesel (B5), but the final blended fuel must meetthe same specification, CAN/CGSB-3.517 (ULS) inCanada, as other fuels used in your vehicle, and thebiodiesel used for making this fuel must meet the latestversion of ASTM specification D 6751. Biodiesel isproduced from vegetable oils or animal fat that havebeen chemically modified to reduce the possibilityof damage to the fuel system and engine. Higherconcentration (i.e., greater than B5) biodiesel-containingfuels or the use of unmodified bio-oils blended intodiesel fuel at any concentration is not recommended andcould damage the fuel system and engine. Suchdamage would not be covered by your warranty. If thereare questions about the biodiesel-containing fuels youare using, contact your fuel supplier.

5-9

Very Cold Weather OperationFollow the instructions listed previously under theheading “What Fuel to Use.”

Notice: Never use home heating oil or gasoline inyour vehicle’s diesel engine. They can cause enginedamage.In cold weather, the fuel filter could become clogged(waxed). To unclog it, move the vehicle to a warm garagearea and warm the filter to between 32°F and 50°F(0°C to 10°C). You will not need to replace it.

Water in Fuel

{CAUTION:

Diesel fuel containing water is still flammable. Youcould be burned. If you ever try to drain waterfrom the fuel, keep sparks, flames, and smokingmaterials away from the mixture.

Notice: If there is water in the diesel fuel and theweather is warm or humid, fungus and bacteria cangrow in the fuel. They can damage the fuel system.A diesel fuel biocide can be used to sterilize thefuel system. However, the fuel system may still needto be cleaned. Your dealer/retailer can advise youof the appropriate solution.

If the fuel tank needs to be purged to remove water,see your dealer/retailer or a qualified technician.Improper purging can damage the fuel system.

Sometimes, water can be pumped into the fuel tankalong with the diesel fuel. This can happen if a servicestation does not regularly inspect and clean its fueltanks, or if it gets contaminated fuel from its suppliers.

If this happens, awater-in-fuel indicator lightcomes on in the instrumentpanel. If it does, the watermust be drained.

Your dealer/retailer can show you how to do this.

5-10

If the light comes on, use this chart to determine whataction to take.

Problem Recommended Action

Light comes onintermittently.

Drain water from the fuelfilter.

Light stays on attemperatures abovefreezing.

Drain the fuel filterimmediately. If no watercan be drained and thelight stays on, see yourdealer/retailer forassistance.

Light stays on attemperatures belowfreezing.

Drain the fuel filterimmediately. If no watercan be drained, watermay be frozen in thewater drain system, or inthe fuel lines. Move thevehicle to a warm locationto thaw out, and thendrain the filter system.

Light stays onimmediately afterrefueling, and a largeamount of water waspossibly pumped into thefuel tank.

Fuel tank purging isrequired. See yourdealer/retailer forassistance.

Notice: Driving when this warning indicator is on,can damage the fuel injection system and the engine.If the indicator comes on right after a refuel, it meanswater was pumped into the fuel tank. Turn off theengine immediately. Then, have the water drainedat once.The frequency of water draining or element replacementis determined by the contamination level in the fuel.Inspect or service the collection bowl for water daily andreplace the element as shown in the MaintenanceSchedule. See Scheduled Maintenance on page 6-5 forchange interval information.To drain water, do the following:

1. Loosen the self-ventingdrain to empty the bowlof water.

2. Tighten the drain. Run the engine and check forleaks.

5-11

To replace the element, do the following:

1. Disconnect the element electrical connector fromthe bowl.

2. Loosen the self-venting drain to empty the bowl ofwater.

3. Remove the filter element from the mounting headwith the bowl connected.

4. Remove the bowl from the filter element. Clean thebowl and the O-ring gland and save them forre-use.

5. Lubricate the O-ring with clean diesel fuel or motoroil and place it in the bowl gland.

6. Spin the bowl onto the new filter element snugly byhand. Do not use tools to tighten them together.

7. Lubricate the filter top seal with clean diesel fuel ormotor oil.

8. Fill the filter element/bowl assembly with cleandiesel fuel and attach it onto the mounting head.Hand tighten an additional one-third to one-half turnafter full seal contact is made.

9. Complete the priming procedure. See “Fuel Priming.”

10. Start the engine and check that there are no leaks.

If the water-in-fuel light comes on again after driving ashort distance or if the engine runs rough or stalls,a large amount of water has probably been pumped intothe fuel tank. The fuel tank should be purged.

Fuel PrimingIn order for the diesel engine fuel system to workproperly, the fuel lines must be full of fuel and containno air. If air gets into the fuel lines, it will be necessary toprime the fuel lines to eliminate air before operatingthe vehicle.

Air can get into the fuel lines if any of the followinghappen:

• The vehicle runs out of fuel.

• The fuel filter is removed for servicing orreplacement.

• The fuel lines are removed or disconnected forservicing.

• The fuel filter water drain valve is opened while theengine is running.

Air in the fuel lines will not harm the engine or thevehicle. However, the engine may not be able to startuntil the fuel system is primed and the air is removed.

5-12

For vehicles with cruise control, you can prime thevehicle and remove the air from the fuel system. Thefollowing procedure shows how:

1. Make sure there is fuel in the fuel tank.

2. Make sure the specified fuel filter is properlyinstalled.

3. Make sure the fuel lines are securely connected.

4. Make sure the fuel filter is cool to the touch.

5. Use a clean cloth to remove dirt and oil from thefuel filter head and breather valve.

6. Use the palm of your hand to repeatedly pressand release the plunger at the top of the fuel filterpriming pump. Continue until the plunger resistancebecomes firm. This may take from 20 to 100 times,depending upon fuel tank location.

7. Turn the fuel filter breather valve screw left(counterclockwise) several turns to open thebreather valve.

8. Use the palm of your hand to repeatedly press andrelease the plunger at the top of the fuel filterpriming pump until fuel begins to seep from thebreather valve.

9. Tighten the fuel filter breather screw to the specifiedtorque, 4.9 Y (43 in. lbs).

10. Use the palm of your hand to press and release theplunger at the top of the fuel filter priming pumpabout 20 more times. This sends fuel to the engine.

11. Use a clean cloth to remove any fuel from the fuelfilter and surrounding area.

12. Start the engine and allow it to idle for a few minutes.

13. Check the fuel filter for leakage.

5-13

Running Out of FuelIf the diesel engine stalls and you think that you haverun out of fuel, do this to restart the engine:

{CAUTION:

Diesel fuel is flammable. It could start a fire if itgets on hot engine parts. You could be burned. Donot let too much fuel flow from the air bleed valve,and wipe up any spilled fuel with a cloth.

1. If parked on a level surface, add at least 2 gallons(7.6 liters) of fuel. However, if parked on a slope, upto 5 gallons (18.9 liters) of fuel might need to beadded.

2. Follow the fuel priming procedure earlier in thissection to prime the fuel filter.

3. Close the air bleed valve.

4. Turn the ignition key to START for 10 to 15 secondsat a time until the engine starts. If the engine triesto run, but does not run smoothly, increase the rpma little using the accelerator pedal. This will helpforce air through the system.

The service engine soon light may come on if thevehicle has run out of fuel. This light may stay on for afew drive cycles after the condition is corrected, butwill eventually clear itself.

Filling the Tank

{CAUTION:

Fuel vapor burns violently and a fuel fire cancause bad injuries. To help avoid injuries to youand others, read and follow all the instructions onthe pump island. Turn off the engine when you arerefueling. Do not smoke if you are near fuel orrefueling the vehicle. Do not use cellular phones.Keep sparks, flames, and smoking materials awayfrom fuel. Do not leave the fuel pump unattendedwhen refueling the vehicle. This is against the lawin some places. Do not re-enter the vehicle whilepumping fuel. Keep children away from the fuelpump; never let children pump fuel.

The fuel cap may be on either or both sides of thevehicle, depending upon option content.

To remove the cap, turn it slowly counterclockwise.

5-14

{CAUTION:

Fuel can spray out on you if you open the fuel captoo quickly. If you spill fuel and then somethingignites it, you could be badly burned. This spraycan happen if the tank is nearly full, and is morelikely in hot weather. Open the fuel cap slowly andwait for any hiss noise to stop. Then unscrew thecap all the way.

When replacing the fuel cap, turn it clockwise until itis tight.

{CAUTION:

If a fire starts while you are refueling, do notremove the nozzle. Shut off the flow of fuel byshutting off the pump or by notifying the stationattendant. Leave the area immediately.

Notice: If you need a new fuel cap, be sure to getthe right type. Your dealer/retailer can get onefor you. If you get the wrong type, it may not fitproperly. This may cause the malfunction indicatorlamp to light and may damage the fuel tank andemissions system. See Malfunction Indicator Lampon page 3-30.

5-15

Filling a Portable Fuel Container

{CAUTION:

Never fill a portable fuel container while it is in thevehicle. Static electricity discharge from thecontainer can ignite the fuel vapor. You can bebadly burned and the vehicle damaged if thisoccurs. To help avoid injury to you and others:

• Dispense fuel only into approved containers.• Do not fill a container while it is inside a

vehicle, in a vehicle’s trunk, pickup bed, or onany surface other than the ground.

• Bring the fill nozzle in contact with the insideof the fill opening before operating the nozzle.Contact should be maintained until the fillingis complete.

• Do not smoke while pumping fuel.• Do not use a cellular phone while

pumping fuel.

Checking Things Underthe Hood

Engine Oil

Checking Engine OilIt is a good idea to check the engine oil level at eachfuel fill.

The engine oil dipstick islocated behind the cab onthe driver side of thevehicle. It can be reachedwithout tilting the cab.

5-16

In order to get an accurate reading, the engine should beat normal operating temperature, so that the oil is warm,and the vehicle must be on level ground.

1. If the engine is at normal operating temperature andthe oil is warm, turn off the engine and allow at leastfive minutes for the oil to drain back into the oil pan. Ifthis is not done, the oil dipstick might not show theactual level.If the engine has not been run long enough to bring itup to normal operating temperature and the oil iscool, turn off the engine and allow 30 minutes for theoil to drain back into the oil pan. If this is not done,the oil dipstick might not show the actual level.

2. Pull out the dipstick and clean it with a paper towel ora cloth, then push it back in all the way.

3. Remove the dipstick again, keeping the tip down,and check the oil level.

When to Add Engine OilNotice: Do not add too much oil. Keep the oil levelbetween the ADD (C) and FULL (B) marks on thedipstick. Under normal engine operation, the engineoil level can increase above the FULL (B) mark as aresult of DPF regeneration. A small increase in the oillevel is normal. If the engine has so much oil that theoil level reaches the wider portion (A) on the dipstick,the engine oil must be changed as soon as possibleor the engine could be damaged.

If the oil is below the ADDmark (C) on the dipstick,add at least one quart/literof the recommended oil.

This section explains what kind of oil to use. For engineoil crankcase capacity, see Capacities andSpecifications on page 5-88.

Add enough oil to put thelevel somewhere in theproper operating range.Push the dipstick allthe way back in whenthrough.

5-17

What Kind of Engine Oil to UseLook for three things:

• CJ-4

Oils designated as API CJ-4 are required for thevehicle. The CJ-4 designation can appear eitheralone or in combination with other AmericanPetroleum Institute (API) designations, such asAPI CJ-4/SL. These letters show API levelsof quality.

5-18

• SAE 10W-40 or SAE 15W-40

SAE 10W-40 or SAE 15W-40 is best for the vehicle.When it is very cold, below 0°F (−18°C), useSAE 5W-40 to improve cold starting. These numberson the oil container show its viscosity, or thickness.Do not use other viscosity oils such as SAE 10W-30or SAE 20W-50.

• American Petroleum Institute (API) symbol

This doughnut-shapedlogo (symbol) is used onmost oil containers tohelp you select the correctoil. It means that the oilhas been certified bythe American PetroleumInstitute.

Look for this on the oil container, and use onlythose oils that display this logo.

Notice: Use only engine oils that have thedesignation CJ-4 for the diesel engine. Failure touse the recommended oil can result in enginedamage not covered by the vehicle warranty.

Engine Oil AdditivesDo not add anything to the oil. The recommended oilswith the API service symbol are all you need forgood performance and engine protection.

When to Change Engine Oil (VehiclesWithout the Engine Oil Life System)Change the engine oil and filter every 15,000 miles(24 000 km), or every 12 months, or every 750 hours ofengine operation, whichever occurs first. If the vehicleis used primarily for long trip, highway service, changethe engine oil and filter every 18,000 miles (28 800 km),or every 12 months, or every 750 hours of engineoperation, whichever occurs first. See ScheduledMaintenance on page 6-5.

5-19

Engine Oil Life System

When to Change Engine OilIf the vehicle has the Engine Oil Life System, it has acomputer system that indicates when to changethe engine oil and filter. This is based on injection timing,engine load, and engine temperature, and not onmileage. Based on driving conditions, the mileage atwhich an oil change is indicated can vary considerably.For the oil life system to work properly, the systemmust be reset every time the oil is changed.

When the system has calculated that oil life has beendiminished, indicates that an oil change is necessary. Achange engine oil light comes on. See Change Engine OilLight on page 3-33. Change the oil as soon as possiblewithin the next 600 miles (1 000 km) or 30 hours ofengine operation, whichever occurs first. It is possiblethat, if driving under the best conditions, the oil life systemmight not indicate that an oil change is necessary for overa year. However, the engine oil and filter must bechanged at least once a year and at this time the systemmust be reset. Your dealer/retailer has trained servicepeople who will perform this work using genuine partsand reset the system. It is also important to check the oilregularly and keep it at the proper level.

If the system is ever reset accidentally, the oil must bechanged at 3,000 miles (5 000 km), or 150 hours ofengine operation, whichever occurs first, since the lastoil change. Remember to reset the oil life systemwhenever the oil is changed.

How to Reset the Engine Oil LifeSystemThe Engine Oil Life System calculates when to changethe engine oil and filter based on vehicle use.Whenever the oil is changed, reset the system so it cancalculate when the next oil change is required. If asituation occurs where the oil is changed prior toa change engine oil light being turned on, reset thesystem.

To reset the Engine Oil Life System:

1. Turn the ignition key to ON/RUN with theengine off.

2. Fully press and release the accelerator pedal slowlythree times within five seconds.If the change engine oil light is turned off, thesystem is resetting.

3. Turn the key to LOCK/OFF.

If the change engine oil light comes back on when thevehicle is started, the Engine Oil Life System hasnot reset. Repeat the procedure.

5-20

What to Do with Used OilUsed engine oil contains certain elements that can beunhealthy for your skin and could even cause cancer.Do not let used oil stay on your skin for very long. Cleanyour skin and nails with soap and water, or a goodhand cleaner. Wash or properly dispose of clothing orrags containing used engine oil. See the manufacturer’swarnings about the use and disposal of oil products.

Used oil can be a threat to the environment. If youchange your own oil, be sure to drain all the oil from thefilter before disposal. Never dispose of oil by putting itin the trash, pouring it on the ground, into sewers, or intostreams or bodies of water. Recycle it by taking it to aplace that collects used oil.

Engine Air Cleaner/Filter

The engine air cleaner/filter is located behind the cab onthe passenger’s side of the vehicle.

5-21

When to Inspect the Engine AirCleaner/Filter

The filter change indicator will let you know when thefilter should be replaced. If you are driving in dusty/dirtyconditions inspect the filter each oil change.

How to Inspect the Engine AirCleaner/FilterLocate the filter change indicator, if equipped. When thechange indicator turns black or is in the red/orangechange zone, replace the filter and reset the indicator.

To inspect the air cleaner/filter, remove the filter from thevehicle and lightly shake the filter to release loosedust and dirt. If the filter remains caked with dirt, a newfilter is required.

To inspect or replace the filter and reset the indicator, ifequipped, do the following:

1. Remove all three screws and carefully remove thefilter cover.

2. Inspect or replace the engine air cleaner/filter.

3. Be sure that all three screws are tightened securelywhen reinstalling the filter cover.

5-22

{CAUTION:

Operating the engine with the air cleaner/filter offcan cause you or others to be burned. The aircleaner not only cleans the air; it helps to stopflames if the engine backfires. If it is not there andthe engine backfires, you could be burned. Do notdrive with it off, and be careful working on theengine with the air cleaner/filter off.

Notice: If the air cleaner/filter is off, a backfire cancause a damaging engine fire. And, dirt caneasily get into the engine, which will damage it.Always have the air cleaner/filter in place when youare driving.

Automatic Transmission Fluid

When to CheckA good time to check your automatic transmission fluidlevel is when the engine oil is checked. See yourAllison Automatic Transmission Operator’s Manual tofind out when to change your transmission fluidand filters.

How to Check and What to UseThe Allison Automatic Transmission Operator’s Manualthat came with the vehicle shows how to check theautomatic transmission fluid and what fluid to use.

Automatic Transmission External FilterYour automatic transmission filter requires periodicreplacement.

Consult the Allison Automatic Transmission Operator’sManual that came with the vehicle for proper changeintervals.

5-23

Manual Transmission Fluid

When to CheckA good time to have it checked is when the engine oil ischecked. Refer to the Maintenance Schedule to findout when to check and change your manualtransmission fluid. See Scheduled Maintenance onpage 6-5.

How to Check and What to UseCheck the fluid level only when your engine is off, thevehicle is parked on a level place, and the transmissionis cool enough for you to rest your fingers on thetransmission case.

To check the transmission fluid level, do the following:

1. Remove the filler plug.

2. Check to be sure that the lubricant level is upto the bottom of the fill opening. On heavy dutytransmissions, an inch of oil level equals aboutone gallon of fluid.

3. If the fluid level is good, reinstall the plug and besure it is fully seated. If the fluid level is low, addmore fluid as described in the next steps. Refer tothe Maintenance Schedule to determine whatkind of fluid to use. See Part C: RecommendedFluids and Lubricants on page 6-27.

How to Add FluidTo add transmission fluid, do the following:

1. Remove the filler plug.

2. Add fluid at the filler plug hole. Add only enough fluidto bring the fluid level up to the bottom of the fillopening. Refer to the Maintenance Schedule todetermine the proper fluid to use. See Part C:Recommended Fluids and Lubricants on page 6-27.

3. Reinstall the filler plug. Be sure the plug is fullyseated.

5-24

Hydraulic ClutchIt is not necessary to regularly check clutch fluid unlessyou suspect there is a leak in the system. Addingfluid will not correct a leak.

A fluid loss in this system could indicate a problem.Have the system inspected and repaired.

When to Check and What to Use

The hydraulic clutch fluidreservoir is located behindthe front panel on thedriver’s side of the vehicle.

Refer to the Maintenance Schedule to determine howoften you should check the fluid level in your clutchmaster cylinder reservoir and for the proper fluid. SeePart B: Owner Checks and Services on page 6-22and Part C: Recommended Fluids and Lubricants onpage 6-27 for more information.

How to Check and Add FluidThe proper fluid should be added if the fluid level is notbetween the MAX (Maximum) and MIN (Minimum)marks.

5-25

Cooling SystemThe cooling system allows the engine to maintain thecorrect working temperature.

{CAUTION:

An electric engine cooling fan under the hood canstart up even when the engine is not running andcan cause injury. Keep hands, clothing, and toolsaway from any underhood electric fan.

{CAUTION:

Heater and radiator hoses, and other engine parts,can be very hot. Do not touch them. If you do, youcan be burned.

Do not run the engine if there is a leak. If you runthe engine, it could lose all coolant. That couldcause an engine fire, and you could be burned.Get any leak fixed before you drive the vehicle.

Notice: Using coolant other than DEX-COOL® cancause premature engine, heater core, or radiatorcorrosion. In addition, the engine coolant couldrequire changing sooner, at 30,000 miles (50 000 km)or 24 months, whichever occurs first. Any repairswould not be covered by the vehicle warranty.Always use DEX-COOL® (silicate-free) coolant in thevehicle.

Engine CoolantThe cooling system in the vehicle is filled withDEX-COOL® engine coolant. This coolant is designed toremain in the vehicle for five years or 150,000 miles(240 000 km), whichever occurs first.

The following explains the cooling system and how tocheck and add coolant when it is low. If there is aproblem with engine overheating, see EngineOverheating on page 5-30.

5-26

What to Use

{CAUTION:

Adding only plain water to the cooling system canbe dangerous. Plain water, or some other liquidsuch as alcohol, can boil before the proper coolantmixture will. The vehicle’s coolant warning systemis set for the proper coolant mixture. With plainwater or the wrong mixture, the engine could gettoo hot but you would not get the overheatwarning. The engine could catch fire and you orothers could be burned. Use a 50/50 mixture ofclean, drinkable water and DEX-COOL® coolant.

Use a 50/50 mixture of clean, drinkable water andDEX-COOL® coolant. If using this mixture, nothing elseneeds to be added. This mixture:• Gives freezing protection down to −34°F (−37°C),

outside temperature.• Gives boiling protection up to 265°F (129°C), engine

temperature.• Protects against rust and corrosion.• Will not damage aluminum parts.• Helps keep the proper engine temperature.

Notice: If an improper coolant mixture is used, theengine could overheat and be badly damaged.The repair cost would not be covered by the vehiclewarranty. Too much water in the mixture canfreeze and crack the engine, radiator, heater core,and other parts.

Notice: If you use extra inhibitors and/or additivesin your vehicle’s cooling system, you coulddamage your vehicle. Use only the proper mixtureof the engine coolant listed in this manual forthe cooling system. See Part C: RecommendedFluids and Lubricants on page 6-27 for moreinformation.

5-27

Checking CoolantThe vehicle must be on a level surface when checkingthe coolant level.

The coolant surge tank pressure cap can be accessedwithout tilting the cab. It is located behind the cabon the driver’s side of the vehicle.

If the low coolant light comes on in the instrument panelcluster and stays on, it means you are low on enginecoolant.

See Low Coolant Warning Light on page 3-29 for furtherinformation.

When your engine is cold, the coolant level should be atthe COLD FILL mark or higher.

Check to see if coolant is visible in the coolant surgetank. If the coolant inside the coolant surge tank isboiling, do not do anything else until it cools down. Ifcoolant is visible but the coolant level is not at or abovethe COLD FILL mark, add a 50/50 mixture of clean,drinkable water and DEX-COOL® coolant at the coolantsurge tank, but be sure the cooling system is coolbefore this is done.

When the engine is cold, the coolant level should be atthe COLD FILL mark. If it is not, you may have aleak in the cooling system.

5-28

How to Add Coolant to the Surge Tank

{CAUTION:

You can be burned if you spill coolant on hotengine parts. Coolant contains ethylene glycol andit will burn if the engine parts are hot enough. Donot spill coolant on a hot engine.

Notice: This vehicle has a specific coolant fillprocedure. Failure to follow this procedure couldcause the engine to overheat and be severelydamaged.

If no coolant is visible in the surge tank, add coolant asfollows:

1. You can remove the coolant surge tank pressurecap when the cooling system, including the coolantsurge tank pressure cap and upper radiatorhose, is no longer hot. Turn the pressure cap slowlycounterclockwise about one full turn.If you hear a hiss, wait for that to stop. A hissmeans there is still some pressure left.

2. Then keep turning the pressure cap slowly, andremove it.

3. Fill the coolant surge tank with the proper mixture,to the COLD FULL mark.

5-29

4. With the coolant surge tank pressure cap off, startthe engine and let it run until you can feel the upperradiator hose getting hot. Watch out for theengine cooling fan.By this time, the coolant level inside the coolantsurge tank may be lower. If the level is lower, addmore of the proper mixture to the coolant surge tankuntil the level reaches slightly above the COLDFULL mark.

5. Then replace the pressure cap. Be sure thepressure cap is hand-tight and fully seated.

Coolant Surge Tank Pressure CapThe surge tank pressure cap is located behind the cabon the driver’s side of the vehicle.

Notice: Your vehicle’s surge tank pressure cap isdesigned for use with medium-duty cooling systemsonly. If the surge tank pressure cap is not tightlyinstalled, coolant loss and possible engine damagemay occur. Be sure the cap is properly and tightlysecured.

Engine OverheatingYou will find an engine coolant temperature warninggage, as well as a low coolant warning light, onyour vehicle’s instrument panel. See Engine CoolantTemperature Gage on page 3-28 and Low CoolantWarning Light on page 3-29 for more information.

Your vehicle also has a check gages warning light onthe instrument panel. See Check Gages WarningLight on page 3-36 for more information.

5-30

If Steam Is Coming From Your Engine

{CAUTION:

Steam from an overheated engine can burnyou badly, even if you just open the hood. Stayaway from the engine if you see or hear steamcoming from it. Just turn it off and get everyoneaway from the vehicle until it cools down. Waituntil there is no sign of steam or coolant beforeyou open the hood.

If you keep driving when your engine isoverheated, the liquids in it can catch fire. You orothers could be badly burned. Stop your engine ifit overheats, and get out of the vehicle until theengine is cool.

Notice: If the engine catches fire because of beingdriven with no coolant, your vehicle can be badlydamaged. The costly repairs would not be coveredby the vehicle warranty.

If No Steam Is Coming From YourEngineAn overheat warning, along with a low coolant light, canindicate a serious problem. See Low Coolant WarningLight on page 3-29 for more information.

If you get an engine overheat warning with no lowcoolant light, but see or hear no steam, the problem maynot be too serious. Sometimes the engine can get alittle too hot when you:

• Climb a long hill on a hot day.

• Stop after high-speed driving.

• Idle for long periods in traffic.

If you get the overheat warning with no sign of steam,try this for a minute or so:

1. In heavy traffic, let the engine idle in N (Neutral)while stopped. If it is safe to do so, pull off theroad, shift to P (Park) or N (Neutral) and letthe engine idle.

2. Turn on your heater to full hot at the highest fanspeed and open the windows as necessary.

3. If climbing a hill, downshift to raise engine and fanspeeds.

5-31

If you no longer have the overheat warning, you candrive. Just to be safe, drive slower for about 10 minutes.If the warning does not come back on, you can drivenormally.

If the warning continues and you have not stopped, pullover, stop, and park your vehicle right away.

If there is still no sign of steam, you can push down theaccelerator until the engine speed is about twice asfast as normal idle speed for at least three minutes whileyou are parked. If you still have the warning, turn offthe engine and get everyone out of the vehicle until itcools down.

You may decide not to lift the hood but to get servicehelp right away.

Power Steering FluidSee Scheduled Maintenance on page 6-5 to determinewhen to check your power steering fluid.

How To Check Power Steering FluidCheck your power steering fluid only when the engine iswarm. If the engine is not warm, you probably will notget an accurate reading.

If the fluid level is betweenthe MIN (Minimum) andMAX (Maximum) marks,you have enough. Ifyou need fluid, add onlyenough of the properfluid to bring it into view inthe sight glass.

If your power steering fluid level is low, this can causethe brake or service brake soon warning lights tocome on. If either light remains on after you have addedpower steering fluid to the proper level, then shut offthe engine for 10 seconds. This should reset the brakewarning lights. If one or both lights stay on though,see “Hydraulic Brake System Warning Lights” underBrake System Warning Light on page 3-25 formore information.

5-32

What to UseTo determine what kind of fluid to use, see Part C:Recommended Fluids and Lubricants on page 6-27.

Notice: When adding power steering fluid ormaking a complete fluid change, always use theproper fluid. Failure to use the proper fluid cancause leaks and damage hoses and seals.

Windshield Washer Fluid

What to UseWhen you need windshield washer fluid, be sure to readthe manufacturer’s instructions before use. If you willbe operating your vehicle in an area where thetemperature may fall below freezing, use a fluid that hassufficient protection against freezing.

Adding Washer Fluid

Open the cap with thewasher symbol on it. Addwasher fluid until thetank is full.

The reservoir is located behind the front panel on thedriver’s side of the vehicle.

Notice:

• When using concentrated washer fluid, followthe manufacturer’s instructions for addingwater.

• Do not mix water with ready-to-use washer fluid.Water can cause the solution to freeze anddamage your washer fluid tank and other partsof the washer system. Also, water does notclean as well as washer fluid.

• Fill the washer fluid tank only three-quarters fullwhen it is very cold. This allows for fluidexpansion if freezing occurs, which coulddamage the tank if it is completely full.

• Do not use engine coolant (antifreeze) in yourwindshield washer. It can damage the vehicle’swindshield washer system and paint.

5-33

Brakes

Brake Fluid

If the vehicle has hydraulicbrakes, there is a brakemaster cylinder.

Refer to the Maintenance Schedule to determine whento check the brake fluid.

{CAUTION:

Do not add brake fluid before checking the level orthere could be too much brake fluid. Brake fluidcould spill on the hot engine and it can catch fire.You could be burned and the vehicle could bedamaged. See “Checking Brake Fluid” in thissection.

5-34

Checking Brake FluidApply the brake pedal several times with the ignition off.Clean one of the reservoir caps and the area aroundthe cap, and remove it.

The fluid level should beeven with the bottom ringof the filler opening. Ifit is low, add enough fluidto fill the reservoir tothe proper level.

What to AddUse the proper fluid listed in the Maintenance Schedule.Use new brake fluid from a sealed container only.

Always clean the brake fluid reservoir cap and the areaaround the cap before removing it. This helps keepdirt from entering the reservoir.

{CAUTION:

With the wrong kind of fluid in the brake hydraulicsystem, the brakes might not work well. This couldcause a crash. Always use the proper brake fluid.

Notice:

• Using the wrong fluid can badly damage brakehydraulic system parts. For example, just afew drops of mineral-based oil, such as engineoil, in the brake hydraulic system can damagebrake hydraulic system parts so badly that theywill have to be replaced. Do not let someoneput in the wrong kind of fluid, and do notuse DOT-5 silicone brake fluid.

• If brake fluid is spilled on the vehicle’s paintedsurfaces, the paint finish can be damaged. Becareful not to spill brake fluid on the vehicle.If you do, wash it off immediately. See WashingYour Vehicle on page 5-75.

5-35

Four-Wheel and Six-Wheel DrumBrakes (Air Only)The brake drums should be removed and inspectedeach time the tires are removed for rotation or changing.When the front brakes are replaced, have the rearbrakes inspected, too.

Brake linings should always be replaced as completeaxle sets.

Brake Pedal TravelSee your dealer/retailer if the brake pedal does notreturn to normal height, or if there is a rapid increase inpedal travel. This could be a sign that brake servicemight be required.

Brake AdjustmentEvery brake stop, the brakes adjust for wear.

Brake Adjustment on Air Braked VehiclesThe vehicle has automatic slack adjusters. Everybrake stop, the brakes automatically adjust for wear.Slack adjusters should never be manually adjustedto correct excessive brake chamber pushrod stroke.Excessive brake chamber pushrod stroke meansthat the brake system needs to be serviced by aqualified service technician.

Notice: Do not manually adjust automatic slackadjusters. Manual adjustment of the automatic slackadjusters can result in a degradation of the slackadjuster performance over time. If the brakechamber pushrod stroke is out of adjustment, thebrake system needs to be serviced by a qualifiedservice technician.

Four-Wheel Disc Brakes(Hydraulic Only)The vehicle has four-wheel disc brakes.

Some driving conditions or climates can cause a brakesqueal when the brakes are first applied or lightlyapplied. This does not mean something is wrong withthe brakes.

Brake linings should always be replaced as completeaxle sets.

5-36

Replacing Brake System PartsThe braking system on a vehicle is complex. Its manyparts have to be of top quality and work well together ifthe vehicle is to have really good braking. The vehiclewas designed and tested with top-quality brake parts.When parts of the braking system are replaced — forexample, when the brake linings wear down and newones are installed — be sure to get new approvedreplacement parts. If this is not done, the brakes mightnot work properly. For example, if someone puts in brakelinings that are wrong for the vehicle, the balancebetween the front and rear brakes can change — for theworse. The braking performance expected can change inmany other ways if the wrong replacement brake partsare installed.

Hydraulic Brake PadsBrake pad lining life will vary depending on vehicleapplication, working environment, equipmentmaintenance, and style of driving. The brake pad liningwear rate has to be monitored for individual drivinghabits — original equipment linings have mechanicalwear indicators to help with this. When down to the last10% of the brake lining, the brake lining wear indicatorrubs on the rotor, causing a scratching or chirpingsound. When this sound is heard, service to the brakepads is needed. See Scheduled Maintenance onpage 6-5.

Aftermarket brake linings might not meet the samestringent requirements as the original equipment linings.Using aftermarket brake linings can affect brakingperformance, pedal feel, noise, and lining wear.

Air Brake SystemsIf the vehicle has air brakes, it is important to get rid ofmoisture in the system. Moisture will damage thesystem if it is not removed daily.

There are two ways to do this. One is automatic throughthe air brake vehicle’s air dryer with integral automaticmoisture ejector that purges air from the system througha self-contained reservoir. The other way to drainmoisture from the air brake system is to manuallyactivate drain valves at each reservoir. Drain the airreservoirs occasionally to be sure the air dryer isworking properly.

Drain them at full system pressure. To be sure of fullpressure, check the air pressure gage. It should read atleast 100 psi (692 kPa).

5-37

Air DryerIf the vehicle has air brakes, it will have an air dryer.This collects and removes dirt, moisture, or other foreignmatter from the air prior to entering the brake system.The air dryer also serves as a moisture ejector. Itautomatically ejects the moisture when the compressorcycles. The integral purge tank has a manual drainvalve that must be drained every day. See “Air BrakeSystems” for the manual drain procedure. The dryeris mounted on the driver side frame rail.

The dryer has a filter thatneeds changing atintervals. See ScheduledMaintenance on page 6-5for more about servicingthis filter.

Electric Air CompressorThe vehicle might have an electric air compressor. Thiscompressor is used to run options that requirepressurized air, such as air horn or air seat.

The air compressor is used when vehicles do not havean air brake system.

The air supply for thissystem must bemaintained by releasingthe drain valve to eject anymoisture that could havebuilt up in the system.

It is recommended that this system be drained on aweekly basis.

Clutch Pedal Free TravelNormal clutch pedal free play is 1.5 to 2 inches(38 to 51 mm) measured from the floorboard. If the freeplay is less than 1.25 inches (32 mm), adjustment isrequired.

5-38

Chassis Lubrication

Item Number Item Remarks

1Brake Camshaft***

Brake Caliper Rails$One fitting each (apply sparingly).

For caliper rails, apply Aero Shell #5 Lubricant.2 Steering Column Slip Joint** One fitting.

5-39

Item Number Item Remarks3 Steering Drag Link Ends One fitting each end.4 Steering Column U-Joints One fitting each joint.5 Pivot Points and Hinges Apply chassis lubricant.6 Slack Adjuster*** One fitting.7 Brake Cam Roller Pins*** Apply engine oil.

8 Front Steering KnucklesOne fitting each side, lower bushing.

(Hand-operated grease gun only.) Hand-pack upperbearing.

9 Front Wheel Bearings* Hand-pack or lubricate.10 Steering Tie Rod Ends One fitting each end.11 Spring Slip Pads** (Multi-leaf Only) Apply chassis lubricant.12 Clutch Release Bearing** Cup or fitting.13 Battery Terminal (except “ST” type) Keep coated with petroleum jelly.14 Parking Brake Bell Crank**, $ One fitting.15 Transmission* Fill to level of filler plug.15 Transmission-Automatic*,**,† Check fluid level.

16 Propshaft Slip Joints One fitting each joint; lubricate withGM Part No. 1051344 Wheel Bearing Lubricant.

17 Propshaft U-joints

One fitting each joint (1480 and 1550 Series);lubricate with GM Part No. 1051344 Wheel BearingLubricant. Two fittings each joint (1610 Series andlarger); lubricate with GM Part No. 1051344 Wheel

Bearing Lubricant.18 Rear Wheel Bearings* Hand-pack or lubricate.19 Rear Axle* Fill to level of filler plug.

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Item Number Item Remarks20 Parking Brake Clevis Pin$ Apply chassis lubricant.21 Master Cylinder$ Fill 1/4 inch (6 mm) below opening.22 Parking Brake Lever Pivot**, $ Apply chassis lubricant.23 Clutch Release Cross Shaft** One fitting each.

* Refer to Maintenance Schedule.** Applies to some vehicles.*** Applies to air brakes only.† Refer to Allison Transmission® Operator’s Manual.$ Applies to hydraulic brakes only.

BatteryThis vehicle has two maintenance free batteries. Whenit is time for a new battery, see your dealer/retailerfor one that has the replacement number shown on theoriginal battery’s label.Warning: Battery posts, terminals, and relatedaccessories contain lead and lead compounds,chemicals known to the State of California to causecancer and reproductive harm. Wash hands afterhandling.

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Vehicle Storage

{CAUTION:

Batteries have acid that can burn you and gas thatcan explode. You can be badly hurt if you are notcareful. See Jump Starting on page 5-42 for tipson working around a battery without getting hurt.

Infrequent Usage: If the vehicle is driven infrequently,remove the black, negative (−) cable from each battery.This helps keep the batteries from running down.

Extended Storage: For extended storage of the vehicle,remove the black, negative (−) cable from eachbattery or use a battery trickle charger. This helpsmaintain the charge of the batteries over an extendedperiod of time.

When ready to use the vehicle again, refer to theengine starting procedure in the Index.

Jump StartingIf the vehicle batteries have run down, you may want touse another vehicle and some jumper cables to startyour vehicle. Be sure to use the following steps to do itsafely.

{CAUTION:

Batteries can hurt you. They can be dangerousbecause:

• They contain acid that can burn you.• They contain gas that can explode or ignite.• They contain enough electricity to burn you.

If you do not follow these steps exactly, some orall of these things can hurt you.

Notice: Ignoring these steps could result in costlydamage to the vehicle that would not be coveredby the warranty.

Trying to start the vehicle by pushing or pulling itwill not work, and it could damage the vehicle.

1. Check the other vehicle. It must have a 12-voltbattery (or batteries) with a negative groundsystem.

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Notice: If the other vehicle’s system is not a 12-voltsystem with a negative ground, both vehicles canbe damaged. Only use vehicles with 12-volt systemswith negative grounds to jump start your vehicle.

In diesel engine vehicles with two batteries, youmay not be able to get enough power from a singlebattery in another vehicle to start your dieselengine, especially in cold weather.Use the battery closest to the starter — this willreduce electrical resistance.

2. Get the vehicles close enough so the jumper cablescan reach, but be sure the vehicles are not touchingeach other. If they are, it could cause a groundconnection you do not want. You would not be ableto start your vehicle, and the bad groundingcould damage the electrical systems.To avoid the possibility of the vehicles rolling, setthe parking brake firmly on both vehicles involved inthe jump start procedure. Put an automatictransmission in P (PARK) or a manual transmissionin N (Neutral) before setting the parking brake.

Notice: If you leave the radio or other accessorieson during the jump starting procedure, theycould be damaged. The repairs would not becovered by the warranty. Always turn off the radioand other accessories when jump starting thevehicle.

3. Turn off the ignition on both vehicles. Unplugunnecessary accessories plugged into the cigarettelighter or accessory power outlets. Turn off theradio and all lamps that are not needed. This willavoid sparks and help save both batteries. Andit could save the radio!

4. Locate the batteries on each vehicle. Find thepositive (+) and negative (−) terminals on eachbattery.You will not see the batteries of your vehicle underthe hood. They are located in a frame mountedbattery box on the passenger’s side of the vehicle.

5-43

{CAUTION:

Using a match near a battery can cause batterygas to explode. People have been hurt doing this,and some have been blinded. Use a flashlight ifyou need more light.

Be sure the batteries have enough water. You donot need to add water to the ACDelco® battery (orbatteries) installed in your new vehicle. But if abattery has filler caps, be sure the right amount offluid is there. If it is low, add water to take care ofthat first. If you do not, explosive gas could bepresent.

Battery fluid contains acid that can burn you. Donot get it on you. If you accidentally get it in youreyes or on your skin, flush the place with waterand get medical help immediately.

{CAUTION:

Fans or other moving engine parts can injure youbadly. Keep your hands away from moving partsonce the engine is running.

5. Check that the jumper cables do not have loose ormissing insulation. If they do, you could get ashock. The vehicles could be damaged too.Before you connect the cables, here are somebasic things you should know. Positive (+) will go topositive (+) or to a remote positive (+) terminal ifthe vehicle has one. Negative (−) will go to a heavy,unpainted metal engine part or to a remotenegative (−) terminal if the vehicle has one.Do not connect positive (+) to negative (−) or youwill get a short that would damage the batteryand maybe other parts too. And do not connect thenegative (−) cable to the negative (−) terminal onthe dead battery because this can cause sparks.

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6. Connect the redpositive (+) cable to thepositive (+) terminal ofthe dead battery. Use aremote positive (+)terminal if the vehiclehas one.

7. Do not let the other end touch metal. Connect it tothe positive (+) terminal of the good battery. Use aremote positive (+) terminal if the vehicle has one.

8. Now connect the black negative (−) cable to thenegative (−) terminal of the good battery. Use aremote negative (−) terminal if the vehicle has one.Do not let the other end touch anything until thenext step. The other end of the negative (−) cabledoes not go to the dead battery. It goes to aheavy, unpainted metal engine part or to a remotenegative (−) terminal on the vehicle with thedead battery.

9. Connect the other endof the negative (−)cable at least 18 inches(45 cm) away fromthe dead battery, butnot near engineparts that move.

The electrical connectionis just as good there,and the chance of sparksgetting back to thebattery is much less.

10. Now start the vehicle with the good batteries andrun the engine for a while. If your vehicle has thehigh idle option, use it.

11. Try to start the vehicle that had the dead batteries.If it will not start after a few tries, it probably needsservice.

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Notice: If the jumper cables are connected orremoved in the wrong order, electrical shorting mayoccur and damage the vehicle. The repairs wouldnot be covered by your warranty. Always connectand remove the jumper cables in the correctorder, making sure that the cables do not toucheach other or other metal.

A. Heavy, Unpainted Metal Engine Part or RemoteNegative (−) Terminal

B. Good Battery or Remote Positive (+) and RemoteNegative (−) Terminals

C. Dead Battery or Remote Positive (+) Terminal

To disconnect the jumper cables from both vehicles, dothe following:

1. Disconnect the black negative (−) cable from thevehicle that had the dead batteries.

2. Disconnect the black negative (−) cable from thevehicle with the good batteries.

3. Disconnect the red positive (+) cable from thevehicle with the good batteries.

4. Disconnect the red positive (+) cable from the othervehicle.

Jumper Cable Removal

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Rear AxleWhen to Check and Change LubricantRefer to the Maintenance Schedule to determinehow often to check the lubricant and when to change it.See Scheduled Maintenance on page 6-5.

Notice: If you drive your vehicle through deepwater that is higher than the front or rear axle, watermay enter the axle housing and cause the axlelubricant to break down. This could damagethe gears inside. Avoid driving your vehicle throughdeep water.

You should avoid driving your vehicle through deeppuddles or standing water. If you must drive throughwater that is higher than the front or rear axle, see yourdealer immediately afterward to have the condition ofthe axle lubricant checked.

How to Check Lubricant

To get an accurate reading, the vehicle should be on alevel surface.

If the level is below the bottom of the filler plug hole,located on the rear axle, you’ll need to add somelubricant. Add enough lubricant to raise the level to thebottom of the filler plug hole.

HD2 Axle

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What to UseRefer to the Maintenance Schedule to determine whatkind of lubricant to use. See Part C: RecommendedFluids and Lubricants on page 6-27.

Rear Axle Shift Motor

When to Check and Change FluidIf you have an optional air-shift two-speed, controlledtraction, or locking differential type rear axle, a good timeto check the fluid level in the axle shift motor is whenthe rear axle lubricant is checked.

How to Check FluidRemove the plug on the front plate of the axle shiftmotor, add enough fluid to raise the level to the bottomof the filler plug hole, then replace the plug.

What to UseRefer to your Maintenance Schedule to determine whatkind of lubricant to use. See Part C: RecommendedFluids and Lubricants on page 6-27.

Cab Tilting

Before You Tilt the CabMost fluids and lubricants requiring regular checking canbe accessed at the back of the cab. If you need togain access to components under the cab, follow thisentire procedure carefully.

• Find a level place to tilt the cab.

• Secure all loose articles in the cab and close thecab door.

• Check for adequate clearance in front and abovethe cab.

To help prevent the vehicle from moving:

1. Apply the parking brake.

2. Place the automatic transmission in P (Park) or shiftthe manual transmission to N (Neutral).

3. Turn the engine off.

4. Block the front and rear wheels.

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Tilting the CabTo tilt the cab, do the following:

1. Locate the lever pin at the rear of the cab, on thepassenger’s side.

2. Turn the lever pin sothat the tab is alignedwith the slot. Removethe lever pin.

3. Move the primary tilt lever all the way down.

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4. Pull the secondary latchlever to release thehook from the catch atthe back of the cab.

5. Using the handle located at the bottom of the cabat the back, tilt the cab forward.

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6. Tilt the cab all the wayforward until the cabsupport under thecab locks fully.

A. Safety Lock PinB. Cab Support

7. Remove the safety lockpin from its retainer onthe cab support.Insert the pin into thehole in the cabsupport by aligning thetab with the slot.

{CAUTION:

A cab not properly locked in the tilted positioncould fall, causing serious injury. To ensure thatthe cab is securely locked in position and will notmove, the safety lock pin (A) must always beinserted into the cab support (B) when the cab isin the tilted position.

{CAUTION:

Things that burn can get on hot engine parts andstart a fire. These include liquids like fuel, oil,coolant, brake fluid, windshield washer and otherfluids, and plastic or rubber. You or others couldbe burned. Be careful not to drop or spill thingsthat will burn onto a hot engine.

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Lowering the CabWhen the cab is ready to be lowered, follow theinstructions below carefully. Before lowering the cab, besure all filler caps are on properly.

1. Remove the safety lockpin from the cabsupport by turning itand pulling it out.

2. Squeeze the lever onthe cap support torelease the detent.

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3. Using the handle located at the bottom of the cabtoward the back, lower the cab until the hookcatches and the cab is held down.

4. Push the primary tilt lever upward fully to lock thecab to the chassis.

5. Reinstall the pin andturn it to keep theprimary tilt lever frommoving downward.

{CAUTION:

An unsecured cab could move suddenly causingan accident or an injury. Be sure the tilt cab isproperly secured to the chassis before moving thevehicle.

5-53

Lifting the Front PanelTo access the windshield washer fluid reservoir and theclutch fluid reservoir, the front panel must be lifted.

1. To lift the panel, graspthe rear of the releasecatch, located atthe bottom of theinstrument panel, andpull it toward you.

See Instrument PanelOverview on page 3-4 formore information onlocation of the releasecatch.

2. Then go to the front ofthe vehicle and lift thepanel at the center.Use the prop rodto hold the panel open.

3. To close the front panel, remove the prop rod, closethe panel and push firmly on both sides to ensurethat the panel is fully closed.

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Noise Control SystemTampering with Noise ControlSystem ProhibitedThe following information relates to compliance withfederal noise emission standards for vehicles with aGross Vehicle Weight Rating (GVWR) of more than10,000 lbs (4 536 kg). The Maintenance Scheduleprovides information on maintaining the noise controlsystem to minimize degradation of the noise emissioncontrol system during the life of your vehicle. The noisecontrol system warranty is given in your warranty booklet.These standards apply only to vehicles sold in theUnited States.Federal law prohibits the following acts or the causingthereof:

1. The removal or rendering inoperative by any person,other than for purposes of maintenance, repair orreplacement, of any device or element of designincorporated into any new vehicle for the purpose ofnoise control, prior to its sale or delivery to theultimate purchaser or while it is in use; or

2. The use of the vehicle after such device or elementof design has been removed or rendered inoperativeby any person.

Among those acts presumed to constitute tampering arethe acts listed below.

Insulation:• Removal of the noise shields or any underhood

insulation.

Engine:• Removal or rendering engine speed governor, if the

vehicle has one, inoperative so as to allow enginespeed to exceed manufacturer specifications.

Fan and Drive:• Removal of fan clutch, if the vehicle has one, or

rendering clutch inoperative.• Removal of the fan shroud, if the vehicle has one.

Air Intake:• Removal of the air cleaner silencer.• Modification of the air cleaner.

Exhaust:• Removal of the muffler or resonator.• Removal of the exhaust pipes and exhaust pipe

clamps.• Removal of the DOC converter, the Diesel

Particulate Filter, or the diesel exhaust gas coolerdevice.

5-55

Bulb ReplacementIt is recommended that all bulbs be replaced by yourdealer/retailer.

Windshield Wiper BladeReplacementWindshield wiper blades should be inspected at leasttwice a year for wear or cracking. See “Wiper BladeCheck” under At Least Twice a Year on page 6-22 formore information.

Replacement blades come in different types and areremoved in different ways.

Here’s how to remove the wiper blade:

1. Pull the windshield wiper arm away from thewindshield.

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2. Push the release lever and slide the wiper assemblytoward the driver side of the vehicle.

3. Install a new blade by reversing Steps 1 and 2.

Other Service Items

Fuel FilterYour fuel filter is located in the engine compartment onthe driver’s side of the vehicle, or along the driver’sside frame rail. See Fuel Filter Replacement earlier inthis section for further information.

Also see Scheduled Maintenance on page 6-5 forrecommended service intervals.

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Primary Fuel Filter and WaterSeparator

Your vehicle may have thisspin-on filter. It is locatedon the driver’s sideframe rail.

It has a clear plastic drain bowl at the bottom. Checkthe drain bowl occasionally for any water or particles.

To drain the water or to replace the element, follow thewater draining and element replacement procedureunder Water in Fuel on page 5-10.

Secondary Fuel Filter and HeaterYour vehicle may have this fuel filter and fuel heater. Itis mounted on the left side of the engine.

It has a metal drain bowl at the bottom. Occasionally,check the bowl for any water or particles. To checkor drain the bowl, shut off the engine.

Then push up on the spring-loaded drain valve untilclear fuel is flowing from the valve. The particlesor water will drain out first.

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Front Wheel Bearings withOil-Filled HubsNotice: If you drive your vehicle through deepwater that is higher than the front or rear axle, watermay enter the axle housing and cause the axlelubricant to break down. This could damagethe gears inside. Avoid driving your vehicle throughdeep water.

You should avoid driving your vehicle through deeppuddles or standing water. If you must drive throughwater that is higher than the front or rear axle, see yourdealer immediately afterward to have the condition ofthe axle lubricant checked.

If your vehicle has oil-filledhubs, occasionally checkto see if they have enoughoil. You can tell if thereis oil there by usingthe circular gage on thesight glass.

If there isn’t, clean the rubber fill plug in the center ofthe glass, and then remove it. Be careful not toallow any dirt or water to get into the oil. Add enough ofthe recommended oil to bring it up to the level markthat you’ll see on the glass.

Refer to your Maintenance Schedule for the proper oilto use.

When you fill the hub, check the glass again afterdriving a short distance. It takes a while for the oil toflow through the system, and you may find that you haveto add a little more to fill it to the proper level. Be surenot to overfill the hub.

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TiresYour new vehicle comes with high-quality tiresmade by a leading tire manufacturer. If you everhave questions about your tire warranty and whereto obtain service, see your vehicle Warrantybooklet for details. For additional information referto the tire manufacturer.

{CAUTION:

Poorly maintained and improperly used tiresare dangerous.

• Overloading your vehicle’s tires cancause overheating as a result of toomuch flexing. You could have an air-outand a serious accident. See Loading theVehicle on page 4-19.

• Underinflated tires pose the same dangeras overloaded tires. The resultingaccident could cause serious injury.Check all tires frequently to maintain therecommended pressure. Tire pressureshould be checked when your vehicle’stires are cold. See Inflation - TirePressure on page 5-61.

• Overinflated tires are more likely to becut, punctured, or broken by a suddenimpact — such as when you hit apothole. Keep tires at the recommendedpressure.

• Worn, old tires can cause accidents. Ifthe tire’s tread is badly worn, or if yourvehicle’s tires have been damaged,replace them.

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Inflation - Tire PressureTires need the correct amount of air pressure to operateeffectively. The Certification or Tire Information labelshows the correct inflation pressures for your tires whenthey are cold. Cold means your vehicle has beensitting for at least three hours or driven no more than1 mile (1.6 km).

Notice: Do not let anyone tell you thatunder-inflation or over-inflation is all right. It isnot. If your tires do not have enough air(under-inflation), you can get the following:• Too much flexing• Too much heat• Tire overloading• Premature or irregular wear• Poor handling• Reduced fuel economy

If your tires have too much air (over-inflation),you can get the following:• Unusual wear• Poor handling• Rough ride• Needless damage from road hazards

When to CheckCheck your tires once a month or more.

Also, check the tire pressure of the spare tire if yourvehicle has one.

How to CheckUse a good quality pocket-type gage to check tirepressure. You cannot tell if your vehicle’s tires areproperly inflated simply by looking at them. Radial tiresmay look properly inflated even when they areunderinflated. Check the tire’s inflation pressure whenthe tires are cold. Cold means your vehicle hasbeen sitting for at least three hours or driven no morethan 1 mile (1.6 km).

Remove the valve cap from the tire valve stem. Pressthe tire gage firmly onto the valve to get a pressuremeasurement. If the cold tire inflation pressure matchesthe recommended pressure on the Certification orTire Information label, no further adjustment isnecessary. If the inflation pressure is low, add air untilyou reach the recommended amount. If you overfillthe tire, release air by pushing on the metal stem in thecenter of the tire valve. Re-check the tire pressurewith the tire gage.

Be sure to put the valve caps back on the valve stems.They help prevent leaks by keeping out dirt andmoisture.

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Wheel LoadingWheels are stamped with a maximum load and coldinflation rating. Be sure you do not exceed these limits.

Dual Tire OperationWhen the vehicle is new, check the wheel nut tightnesson all wheels with a torque wrench after your first100 miles (160 km) and then 1,000 miles (1 600 km) afterthat. Whenever a wheel, wheel bolt or wheel nut isremoved or serviced, repeat the 100 miles (160 km), andthen 1,000 mile (1 600 km) wheel nut tightness check.

See Tightening the Wheel Nuts on page 5-64 for wheelnut tightening information and proper torque values.

{CAUTION:

If you operate your vehicle with a tire that is badlyunderinflated, the tire can overheat. An overheatedtire can lose air suddenly or catch fire. You orothers could be injured. Be sure all tires (includingthe spare, if any) are properly inflated.

See Tires on page 5-60 and Inflation - Tire Pressure onpage 5-61 for more information on proper tire inflation.

When It Is Time for New TiresVarious factors, such as maintenance, temperatures,driving speeds, vehicle loading, and road conditions,influence when you need new tires.

Replace your tires when the tread depth is down to1/8 of an inch (3.2 mm) for the front tires, or 1/16 of aninch (1.6 mm) for a rear tire. Also, you need a newtire if:

• You can see cord or fabric showing through thetire’s rubber.

• The tread or sidewall is cracked, cut, or snaggeddeep enough to show cord or fabric.

• The tire has a bump, bulge, or split.

• The tire has a puncture, cut, or other damage thatcannot be repaired well because of the size orlocation of the damage.

The rubber in tires degrades over time, even if they arenot being used. This is also true for the spare tire, ifyour vehicle has one. Multiple conditions affect how fastthis aging takes place, including temperatures, loadingconditions, and inflation pressure maintenance. Withproper care and maintenance tires will typically wear outbefore they degrade due to age. If you are unsureabout the need to replace your tires as they get older,consult the tire manufacturer for more information.

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Buying New TiresGM has developed and matched specific tires for yourvehicle. If you need replacement tires, GM stronglyrecommends that you get tires that are the same size,brand, load range, speed rating, and construction type(radial and bias-belted tires) as your vehicle’s originaltires. This way, your vehicle will continue to have tiresthat are designed to give the same performance andvehicle safety, during normal use, as the original tires.

GM recommends replacing tires in sets of six or eight asapplicable. This is because uniform tread depth on alltires will help keep your vehicle performing mostlike it did when the tires were new. Replacing less thana full set of tires can affect the braking and handlingperformance of your vehicle.

{CAUTION:

Mixing tires could cause you to lose controlwhile driving. If you mix tires of differentsizes, brands, or types (radial and bias-beltedtires) the vehicle may not handle properly,and you could have a crash. Using tires ofdifferent sizes, brands, or types may alsocause damage to your vehicle. Be sure touse the correct size, brand, and type of tireson your vehicle’s wheels.

{CAUTION:

If you use bias-ply tires on the vehicle, thewheel rim flanges could develop cracks aftermany miles of driving. A tire and/or wheelcould fail suddenly, causing a crash. Useonly radial-ply tires with the wheels on thevehicle.

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Wheel Alignment and Tire BalanceThe wheels on your vehicle were aligned at thefactory to give you the longest tire life and best overallperformance.

Proper front wheel alignment must be maintained inorder to ensure efficient steering, good directionalstability, and prevent abnormal tire wear. If you noticeunusual tire wear or your vehicle is pulling one wayor the other, the alignment may need to be reset. If younotice your vehicle vibrating when driving on a smoothroad, your wheels may need to be balanced.

Tightening the Wheel Nuts

{CAUTION:

Wheel nuts that are not tight can work loose. If allthe nuts on a wheel come off, the wheel can comeoff the vehicle, causing a crash. All wheel nutsmust be properly tightened. Follow the rules in thissection to be sure they are.

This section lets you know how often to check thetightness of the wheel nuts on your vehicle and how tightthey must be.

First, use these pictures to decide what kind of wheelsyou have.

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Then, refer to the following steps for the wheelsyou have.

Hub-Piloted Wheels, 8-Hole or 10-HoleThe studs and nuts used with these wheels haveright-hand threads.

1. With intermittent pilot pads, position a pad at12 o’clock to center the wheel and reduce run-out.

2. Put the tire and rim assembly on the axle hub.Install the outer rear tire and rim assembly sothat its valve stem is exactly opposite the valve stemon the inner tire and rim assembly.

3. Put on the wheel nuts.

4. Finger-tighten the nuts.

5. Oil the surfaces (B)between the nuts (C)and washers (A). Donot oil the studs or thethreads of the nut.

Hub-Piloted Type,8-Hole

Hub-Piloted Type,10-Hole

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6. Tighten the nuts to 400 lb ft (542 Y) if an 8-holestud or 480 lb ft (650 Y) if a 10-hole stud, usingthe following diagrams.

{CAUTION:

Never use oil or grease on studs or the threads ofthe wheel nuts. If you do, the wheel nuts mightcome loose and the wheel could fall off, causing acrash.

8-Hole

10-Hole (Front) 10-Hole (Rear)

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{CAUTION:

If wheel studs are damaged, they can break. If allthe studs on a wheel broke, the wheel could comeoff and cause a crash. If any stud is damagedbecause of a loose-running wheel, it could be thatall of the studs are damaged. To be sure, replaceall studs on the wheel. If the stud holes in a wheelhave become larger, the wheel could collapse inoperation. Replace any wheel if its stud holeshave become larger or distorted in any way.Inspect hubs and hub-piloted wheels for damage.Because of loose running wheels, piloting paddamage may occur and require replacement of theentire hub, for proper centering of the wheels.When replacing studs, hubs, wheel nuts orwheels, be sure to use GM original equipmentparts.

{CAUTION:

Rust or dirt on a wheel, or on the parts towhich it is fastened, can make wheel nutsbecome loose after a time. The wheel couldcome off and cause a crash. When youchange a wheel, remove any rust or dirt fromplaces where the wheel attaches to thevehicle. In an emergency, you can use acloth or a paper towel to do this; but be sureto use a scraper or wire brush later, if youneed to, to get all the rust or dirt off.

How Often to CheckWheel tightness is so important you should have atechnician check nut tightness on all wheels witha torque wrench after your first 100 miles (160 km), andthen 1,000 miles (1 600 km) after that. Be sure torepeat this service whenever you have a tire removedor serviced. See Scheduled Maintenance on page 6-5for further information.

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Wheel ReplacementReplace any wheel that is bent, cracked, or badly rustedor corroded. If wheel nuts keep coming loose, replacethe wheel, wheel bolts, and wheel nuts. If the wheelleaks air, replace it.

Your dealer will know the kind of wheel you need.

Each new wheel should have the same load-carryingcapacity, diameter, width, offset and be mountedthe same way as the one it replaces.

{CAUTION:

Using the wrong replacement wheels, wheel bolts,or wheel nuts on your vehicle can be dangerous. Itcould affect the braking and handling of yourvehicle, make your tires lose air and make youlose control. You could have a collision in whichyou or others could be injured. Always use thecorrect wheel, wheel bolts, and wheel nuts forreplacement.

If you need to replace any of your wheels, wheel boltsor wheel nuts, replace them only with new GMoriginal equipment parts. This way, you will be sure tohave the right wheel, wheel bolts and wheel nutsfor your vehicle.

{CAUTION:

A leaking wheel could fail without warning. Awheel designed for tubeless tires could be leakingbecause it is damaged. Do not use an inner tubeor some other thing to try to stop the leaking. Geta new wheel of the proper type.

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{CAUTION:

Without the correct wheel, wheel bolts or wheelnuts, you may not be able to stop properly, andyou could have other problems like a tire air-out.You could have a collision. If you do not go toyour dealer to get a new wheel, wheel bolts orwheel nuts, be sure you get the correct ones.Each new wheel should match the original wheelin load-carrying capacity, inflation pressurecapacity, diameter, width, offset and mountingconfiguration.

Using wheels and tires with higher load-carrying limitsthan the original wheels and tires does not changethe Gross Axle Weight Rating (GAWR) or the GrossVehicle Weight Rating (GVWR) of your vehicle.See Loading the Vehicle on page 4-19 for moreinformation.

Notice: The wrong wheel can cause trouble inbearing life, brake cooling, speedometer/odometercalibration, headlamp aim, bumper height, vehicleground clearance, stopping distance and tireclearance to the body and chassis. You could alsohave other problems like a tire air-out.

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Used Replacement Wheels

{CAUTION:

Putting a used wheel on the vehicle is dangerous.You cannot know how it has been used or how farit has been driven. It could fail suddenly andcause a crash. If you have to replace a wheel, usea new GM original equipment wheel.

If a Tire Goes FlatIt is unusual for a tire to blowout while you are driving,especially if you maintain your tires properly. If airgoes out of a tire, it is much more likely to leak outslowly. But if you should ever have a blowout, here area few tips about what to expect and what to do:

If a front tire fails, the flat tire will create a drag thatpulls the vehicle toward that side. Take your foot off theaccelerator pedal and grip the steering wheel firmly.Steer to maintain lane position, and then gently brake toa stop well out of the traffic lane.

A rear blowout, particularly on a curve, acts much like askid and may require the same correction you woulduse in a skid. In any rear blowout, remove your foot fromthe accelerator pedal. Get the vehicle under controlby steering the way you want the vehicle to go. It maybe very bumpy and noisy, but you can still steer. Gentlybrake to a stop –– well off the road if possible.

If a tire goes flat, avoid further tire and wheel damageby driving slowly to a level place and turn on yourhazard warning flashers. See Hazard Warning Flasherson page 3-6.

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{CAUTION:

Your vehicle, when new, did not include tirechanging equipment or a place to store a tire inthe vehicle. Special tools and procedures arerequired if a tire needs to be serviced. If thesetools and procedures are not used, you or otherscould be injured or killed while trying to change orservice a truck tire.

Your truck, when new, did not include tire changingequipment or a place to store a tire in the vehicle. Fewdrivers of these vehicles have the necessary equipmentaboard to be able to change a flat tire safely. Forexample, you would need a truck jack that can liftseveral thousand pounds and a torque wrench that cangenerate several hundred foot-pounds (Y) oftwisting force.

{CAUTION:

If you try to put air back into a tire that has runflat, even a tire that was extremely low on air, thetire can have a sudden air-out. This could causeyou to lose control of the vehicle and have aserious crash. Do not refill a flat or very low tirewith air without first having the tire taken off thewheel and checked for damage.

So if you are stopped somewhere by a flat or damagedtire or wheel, you should get expert help. SeeRoadside Assistance Program on page 7-5.

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Appearance Care

Interior CleaningYour vehicle’s interior will continue to look its best if it iscleaned often. Although not always visible, dust anddirt can accumulate on your upholstery. Dirt can damagecarpet, fabric, leather, and plastic surfaces. Regularvacuuming is recommended to remove particlesfrom your upholstery. It is important to keep yourupholstery from becoming and remaining heavily soiled.Soils should be removed as quickly as possible. Yourvehicle’s interior may experience extremes of heatthat could cause stains to set rapidly.

Lighter colored interiors may require more frequentcleaning. Use care because newspapers and garmentsthat transfer color to your home furnishings may alsotransfer color to your vehicle’s interior.

When cleaning your vehicle’s interior, only use cleanersspecifically designed for the surfaces being cleaned.Permanent damage may result from using cleaners onsurfaces for which they were not intended. Use glasscleaner only on glass. Remove any accidental over-sprayfrom other surfaces immediately. To prevent over-spray,apply cleaner directly to the cleaning cloth.

Notice: If you use abrasive cleaners when cleaningglass surfaces on your vehicle, you could scratchthe glass. When cleaning the glass on your vehicle,use only a soft cloth and glass cleaner.

Many cleaners contain solvents that may becomeconcentrated in your vehicle’s breathing space. Beforeusing cleaners, read and adhere to all safetyinstructions on the label. While cleaning your vehicle’sinterior, maintain adequate ventilation by openingyour vehicle’s doors and windows.

Dust may be removed from small buttons and knobsusing a small brush with soft bristles.

Your dealer/retailer has a product for cleaning yourvehicle’s glass. Should it become necessary, you canalso obtain a product from your dealer’/retailer to removeodors from your vehicle’s upholstery.

Do not clean your vehicle using the following cleanersor techniques:

• Never use a knife or any other sharp object toremove a soil from any interior surface.

• Never use a stiff brush. It can cause damage toyour vehicle’s interior surfaces.

• Never apply heavy pressure or rub aggressivelywith a cleaning cloth. Use of heavy pressurecan damage your interior and does not improve theeffectiveness of soil removal.

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• Use only mild, neutral-pH soaps. Avoid laundrydetergents or dishwashing soaps with degreasers.Using too much soap will leave a residue thatleaves streaks and attracts dirt. For liquid cleaners,about 20 drops per gallon (3.78 L) of water is agood guide.

• Do not heavily saturate your upholstery whilecleaning.

• Damage to your vehicle’s interior may result fromthe use of many organic solvents such as naptha,alcohol, etc.

Fabric/CarpetUse a vacuum cleaner with a soft brush attachmentfrequently to remove dust and loose dirt. A canistervacuum with a beater bar in the nozzle may onlybe used on floor carpet and carpeted floor mats. Forany soil, always try to remove it first with plain water orclub soda. Before cleaning, gently remove as muchof the soil as possible using one of the followingtechniques:

• For liquids: gently blot the remaining soil with apaper towel. Allow the soil to absorb into thepaper towel until no more can be removed.

• For solid dry soils: remove as much as possibleand then vacuum.

To clean:

1. Saturate a lint-free, clean white cloth with water orclub soda.

2. Wring the cloth to remove excess moisture.

3. Start on the outside edge of the soil and gently rubtoward the center. Continue cleaning, using a cleanarea of the cloth each time it becomes soiled.

4. Continue to gently rub the soiled area until thecleaning cloth remains clean.

5. If the soil is not completely removed, use a mildsoap solution and repeat the cleaning processthat was used with plain water.

If any of the soil remains, a commercial fabric cleaner orspot lifter may be necessary. When a commercialupholstery cleaner or spot lifter is to be used, test asmall hidden area for colorfastness first. If the locallycleaned area gives any impression that a ring formationmay result, clean the entire surface.

After the cleaning process has been completed, a papertowel can be used to blot excess moisture from thefabric or carpet.

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Instrument Panel, Vinyl, and OtherPlastic SurfacesA soft cloth dampened with water may be used toremove dust. If a more thorough cleaning is necessary,a clean soft cloth dampened with a mild soap solutioncan be used to gently remove dust and dirt. Never usespot lifters or removers on plastic surfaces. Manycommercial cleaners and coatings that are sold topreserve and protect soft plastic surfaces maypermanently change the appearance and feel of theinterior and are not recommended. Do not use siliconeor wax-based products, or those containing organicsolvents to clean the vehicle’s interior because they canalter the appearance by increasing the gloss in anon-uniform manner.

Some commercial products may increase gloss on theinstrument panel. The increase in gloss may causeannoying reflections in the windshield and even make itdifficult to see through the windshield under certainconditions.

Care of Safety BeltsKeep belts clean and dry.

{CAUTION:

Do not bleach or dye safety belts. It may severelyweaken them. In a crash, they might not be ableto provide adequate protection. Clean safety beltsonly with mild soap and lukewarm water.

WeatherstripsSilicone grease on weatherstrips will make them lastlonger, seal better, and not stick or squeak. Applysilicone grease with a clean cloth. During very cold,damp weather frequent application may be required. SeePart C: Recommended Fluids and Lubricants onpage 6-27.

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Washing Your VehicleThe best way to preserve the vehicle’s finish is to keep itclean by washing it often.

Notice: Certain cleaners contain chemicals that candamage the emblems or nameplates on the vehicle.Check the cleaning product label. If it states thatit should not be used on plastic parts, do not use iton the vehicle or damage may occur and it wouldnot be covered by the warranty.

Do not wash the vehicle in direct sunlight. Use a carwashing soap. Do not use cleaning agents that arepetroleum based or that contain acid or abrasives, asthey can damage the paint, metal or plastic on thevehicle. Approved cleaning products can be obtainedfrom your dealer/retailer. Follow all manufacturers’directions regarding correct product usage, necessarysafety precautions and appropriate disposal of anyvehicle care product.

Rinse the vehicle well, before washing and after toremove all cleaning agents completely. If they areallowed to dry on the surface, they could stain.

Dry the finish with a soft, clean chamois or an all-cottontowel to avoid surface scratches and water spotting.

High pressure car washes may cause water to enter thevehicle. Avoid using high pressure washes closerthan 12 inches (30 cm) to the surface of the vehicle.Use of power washers exceeding 1,200 psi (8 274 kPa)can result in damage or removal of paint and decals.

Cleaning Exterior Lamps/LensesUse only lukewarm or cold water, a soft cloth and a carwashing soap to clean exterior lamps and lenses.Follow instructions under Washing Your Vehicle onpage 5-75.

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Finish CareOccasional waxing or mild polishing of the vehicle byhand may be necessary to remove residue from the paintfinish. Approved cleaning products can be obtained fromyour dealer/retailer.If the vehicle has a basecoat/clearcoat paint finish, theclearcoat gives more depth and gloss to the coloredbasecoat. Always use waxes and polishes that arenon-abrasive and made for a basecoat/clearcoat paintfinish.

Notice: Machine compounding or aggressivepolishing on a basecoat/clearcoat paint finish maydamage it. Use only non-abrasive waxes andpolishes that are made for a basecoat/clearcoat paintfinish on the vehicle.

Foreign materials such as calcium chloride and othersalts, ice melting agents, road oil and tar, tree sap, birddroppings, chemicals from industrial chimneys, etc.,can damage the vehicle’s finish if they remain on paintedsurfaces. Wash the vehicle as soon as possible. Ifnecessary, use non-abrasive cleaners that are markedsafe for painted surfaces to remove foreign matter.

Exterior painted surfaces are subject to aging, weatherand chemical fallout that can take their toll over aperiod of years. To help keep the paint finish lookingnew, keep the vehicle garaged or covered wheneverpossible.

Protecting Exterior Bright Metal PartsBright metal parts should be cleaned regularly to keeptheir luster. Washing with water is all that is usuallyneeded. However, chrome polish may be used onchrome or stainless steel trim, if necessary.

Use special care with aluminum trim. To avoid damagingprotective trim, never use auto or chrome polish,steam or caustic soap to clean aluminum. A coating ofwax, rubbed to high polish, is recommended for allbright metal parts.

Windshield and Wiper BladesClean the outside of the windshield with glass cleaner.Clean the rubber blades using a lint free cloth orpaper towel soaked with windshield washer fluid or amild detergent. Wash the windshield thoroughlywhen cleaning the blades. Bugs, road grime, sap, and abuildup of vehicle wash/wax treatments may causewiper streaking. Replace the wiper blades if they areworn or damaged.Wipers can be damaged by:• Extreme dusty conditions• Sand and salt• Heat and sun• Snow and ice, without proper removal

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Aluminum WheelsThe vehicle may have aluminum wheels.

Notice: If you use strong soaps, chemicals,abrasive polishes, cleaners, brushes, or cleanersthat contain acid on aluminum or chrome-platedwheels, you could damage the surface of thewheel(s). The repairs would not be covered by yourwarranty. Use only GM-approved cleaners onaluminum or chrome-plated wheels.

Keep the wheels clean using a soft clean cloth with mildsoap and water. Rinse with clean water. After rinsingthoroughly, dry with a soft clean towel. A wax may thenbe applied.

Notice: Using chrome polish on aluminum wheelscould damage the wheels. The repairs would notbe covered by the warranty. Use chrome polish onchrome wheels only.

The surface of these wheels is similar to the paintedsurface of the vehicle. Do not use strong soaps,chemicals, abrasive polishes, abrasive cleaners,cleaners with acid, or abrasive cleaning brushes onthem because the surface could be damaged. Do notuse chrome polish on aluminum wheels.

TiresTo clean the tires, use a stiff brush with tire cleaner.

Notice: Using petroleum-based tire dressingproducts on the vehicle may damage the paint finishand/or tires. When applying a tire dressing, alwayswipe off any overspray from all painted surfaces onthe vehicle.

Sheet Metal DamageIf the vehicle is damaged and requires sheet metal repairor replacement, make sure the body repair shop appliesanti-corrosion material to parts repaired or replaced torestore corrosion protection.Original manufacturer replacement parts will provide thecorrosion protection while maintaining the vehiclewarranty.

Finish DamageAny stone chips, fractures or deep scratches in the finishshould be repaired right away. Bare metal will corrodequickly and may develop into major repair expense.

Minor chips and scratches can be repaired with touch-upmaterials available from your dealer/retailer. Largerareas of finish damage can be corrected in yourdealer’s/retailer’s body and paint shop.

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Underbody MaintenanceChemicals used for ice and snow removal and dustcontrol can collect on the underbody. If these are notremoved, corrosion and rust can develop on theunderbody parts such as fuel lines, frame, floor pan,and exhaust system even though they have corrosionprotection.

At least every spring, flush these materials from theunderbody with plain water. Clean any areas where mudand debris can collect. Dirt packed in close areas ofthe frame should be loosened before being flushed.Your dealer/retailer or an underbody car washing systemcan do this.

Chemical Paint SpottingSome weather and atmospheric conditions can create achemical fallout. Airborne pollutants can fall upon andattack painted surfaces on the vehicle. This damage cantake two forms: blotchy, ring-shaped discolorations,and small, irregular dark spots etched into thepaint surface.

Although no defect in the paint job causes this, we willrepair, at no charge to the owner, the surfaces ofnew vehicles damaged by this fallout condition within12 months or 12,000 miles (20 000 km) of purchase,whichever occurs first.

Vehicle Identification

Vehicle Identification Number (VIN)

This is the legal identifier for the vehicle. It appears on aplate in the front corner of the instrument panel, onthe driver side. It can be seen through the windshieldfrom outside the vehicle. The VIN also appears onthe Certification/Tire label and the certificates of title andregistration.

Engine IdentificationThe eighth character in the VIN is the engine code. Thiscode helps identify the vehicle’s engine, specifications,and replacement parts. See “Engine Specifications”under Capacities and Specifications on page 5-88 for thevehicle’s engine code.

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Electrical SystemAdd-On Electrical EquipmentNotice: Do not add anything electrical to thevehicle unless you check with your dealer/retailerfirst. Some electrical equipment can damagethe vehicle and the damage would not be coveredby the vehicle’s warranty. Some add-on electricalequipment can keep other components fromworking as they should.

Headlamp WiringThe headlamp wiring is protected by a circuit breaker inthe light switch. An electrical overload will cause thelights to go on and off, or in some cases to remain off. Ifthis happens, have your headlamp wiring checkedright away.

Windshield Wiper FusesThe windshield wiper motor is protected by a circuitbreaker inside the motor and a circuit breaker or fuse inthe fuse block. If the motor overheats, the wipers will stopuntil the motor cools. If the overload is caused by anelectrical problem, be sure to get it fixed.

Fusible LinksA fusible link is a short piece of wire that is covered by aninsulated cover. It is several gage sizes smaller than thecircuit it protects. It will melt in an overload situation,opening the circuit.The starter and other circuits have fusible links. The sizeis printed on the insulation. If the insulation is burnedbeyond recognition, consult your dealer/retailer for theproper size. Replace a fusible link with one of the samesize and insulation type. Fusible link insulation is aspecial purpose high-temperature material.

Power Windows and Other PowerOptionsCircuit breakers in the fuse panel protect the powerwindows and other power accessories. When the currentload is too heavy, the circuit breaker opens. This protectsthe circuit until the current load returns to normal or theproblem is fixed.

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Fuses and Circuit BreakersThe wiring circuits in the vehicle are protected fromshort circuits by a combination of fuses, circuit breakers,maxi-fuses and fusible links. This greatly reduces thechance of a fire caused by an electrical problem. Theremay be a fuse taped to the wiring harness near thehydraulic brake booster.

Before changing a fuse, turn the ignition off and set theparking brake.

Instrument Panel Fuse Block

The instrument panel fuse block is located on the top ofthe instrument panel on the passenger side of thevehicle.

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To access the fuse block, remove the cover by lifting upon the front and turning it backward.

To reinstall the cover, put the tabs at the rear of thecover into the slots on the instrument panel and lowerthe cover down to snap into place.

If you ever have a problem on the road and don’t havea spare fuse, you can borrow one of the correctvalue. Just pick some feature of your vehicle that youcan get along without, like the radio or cigarette lighter,and use its fuse if it is the value you need. Rememberto replace the fuse as soon as you can.

These fuses are non-cycling; do not replace them withcycling fuses. Also, do not use fuses of a higheramperage than those listed on the circuit breaker block.

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Fuses Usage1 Ignition Switch2 Cigarette Lighter3 Engine Control Module, Ignition 1

4 Transmission Control Module,Ignition, Chime

Fuses Usage5 Assembly Line Data Link Connector

6

Warning Lamp, Ignition Relay,Blower Motor, Motor Relay, AuxiliaryRelay, Power Window Relay, InteriorRelay

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Fuses Usage

7Room Lamp, Horn, Electric ParkingBrake, Radio Back Up, Rear BodyDome Lamp

8 Power Window

9

Exhaust Brake Back Up, AirSuspension Dump, Differential Lock,Air Dryer, Moisture Ejection Heater,Electric Air Compressor, PowerTake Off

10 Ignition Power11 Left Trailer Turn Lamp12 Auxiliary (Ignition ON)13 Auxiliary (Battery Direct)14 Driver Side Headlamp15 Passenger Side Headlamp16 Headlamp

Fuses Usage17 Heated Fuel18 Meter Transmission Control Module

19Identification Lamp, Marker Lamp,Tail Lamp, Lighted Mirror,Illumination Lamp

20 Cool Condenser Fan Motor, CoolerCompressor

21 Wiper Motor, Washer Motor

22 Heated Mirror, Two-Speed AxleRelay

23 Empty24 Fan Motor, Air Conditioner Relay25 Right Trailer Turn Lamp, Flasher Unit26 Power Post (Consent)

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Maxi-Fuse BlockWhen a fuse goes out, first check the instrument panelfuse block. If there are no fuses out, the problemcould be in the maxi-fuse block.

The maxi-fuse block outside of the cab on the driverside of the vehicle. To access the maxi-fuse block,remove the four screws from the front of the box andremove the cover.

Power is fed through these fuses to devices such as theheadlamp switch, ignition switch feed circuits and theauxiliary brake pump (hydraulic brake vehicles).

Do not use maxi-fuses of higher amperage than thoseindicated on the maxi-fuse block.

Fuses Usage

ST/TURN/HAZ Stoplamp, Turn Signals/HazardWarning Flashers

IGN SW 3 Air Conditioner, Axle, ChassisINT/EXTLIGHTS

Parking Lamps, Dome Lamp,Instrument Panel Lights

HEAD LAMP Headlamps, Daytime Running LampsAUX WRG Auxiliary Wiring, Parking Brake

IGN SW 1 Ignition Switch, Washer/Wiper,Crank, Radio

HYD PUMP Hydraulic Brake, Brake Pump MotorABS Antilock Brake System Module

ELECT TRANS Ignition RelayPARK BRAKE Parking Brake Motor

BLOWERHORN

Blower, Horn, Cigarette Lighter,Auxiliary Outlets

TRAILER ABS Trailer Antilock Brake System, TrailerStoplamps

PWR WDO/LOCKS Power Window, Power Door Locks

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Relay Center

There are four relay blocks in the vehicle:A. Relay Block AB. Relay Block BC. Relay Block CD. Relay Block D (Not Shown)

Relay Block A Usage1 Power Window (If Equipped)2 Power Main (ECU)3 High Beam4 Lighting5 Lighting (Low, High)6 Trailer Turn Signal (Left Headlamp)7 Taillamp8 Marker Lamp (Tractor Only)9 Trailer Turn Signal (Right Headlamp)

Relay Block A

5-85

Relay Block B Usage

1 Air Conditioning Condenser(If Equipped)

2 Air Conditioning Compressor(If Equipped)

3 Heater Fan

Relay Block B Usage4 Ignition (Accessory)5 Ignition (1)6 Ignition (2)7 Auxiliary8 Horn9 Ignition (3)

10 Dome Lamp (If Equipped)11 Starter Cut

12 Power Take-Off Control(If Equipped)

Relay Block B

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Relay Block C Usage1 Parking Brake

2 Daytime Running Lamps (DRL) On(Engine Run)

3 Daytime Running Lamps (DRL) Off(Parking)

4 Parking Lamps/Daytime RunningLamps (DRL)

5 Fuel Filter (Heated Fuel)6 Stop Lamp

Relay Block D Usage1 Neutral (Medium Duty Transmission)

2 Back-up Lamp (Reverse) (MediumDuty Transmission)

Relay Block C

Relay Block D

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Capacities and SpecificationsThe following approximate capacities are given in English and metric conversions. See Part C: Recommended Fluidsand Lubricants on page 6-27 for more information.

Capacities and Specifications

ApplicationCapacities

English Metric

Air Conditioning Refrigerant R134a

For the air conditioning system refrigerant chargeamount, see the refrigerant caution label located

under the hood. See your dealer for moreinformation.

Cooling System

Engine Torque below 660 lb ft (LYA, LYB, LYC) 33.6 qt 31.8 L

Engine Torque above 835 lb ft (LYD, LQF) 35.0 qt 33.1 L

Engine Oil with Filter* 23.8 qt 22.5 L

*Additional oil is required with auxiliary oil filter systems. Make sure to add enough extra oil to fill the auxiliary oilfilter system. For vehicles equipped with LUBERFINER 750-C, add 14 quarts (13.2 L).

Fuel Tank

Standard (Single) 50.0 gal 189.3 L

Optional (Single)1 50.0 gal 189.3 L

Optional (Dual)2 75.0 gal 283.9 L

Optional (Dual)3 100.0 gal 378.5 L

5-88

Capacities and Specifications (cont’d)


English Metric1Single 50-gallon (189 L) tanks. Not applicable to 4X2 vehicles with 128 inch or 140 inch wheelbases and notapplicable to 6x4 vehicles with a 152 inch wheelbase.2One 25-gallon (94.6 L) tank and one 50-gallon (189.2 L) tank. Available only on 4x2 vehicles with 128 inch or140 inch wheelbases or 6x4 vehicles with a 152 inch wheelbase.3Two 50-gallon (189 L) tanks. Not applicable to 4X2 vehicles with 128 inch or 140 inch wheelbases and notapplicable to 6x4 vehicles with a 152 inch wheelbase.

Rear Axle – Single Speed

15040S 21.0 pt 10.0 L

19060S (HPK); 21060S (HPP) 31.0 pt 14.7 L

23090S (HPT) 42.5 pt 20.1 L

26105S (HPA) 51.0 pt 24.1 L

S110 (HD2) 15.0 pt 7.1 L

Rear Axle – Tandem

DS404 (front) (HPE); RS404 (rear) 32.0 pt 15.1 L

Rear Axle – Two-Speed

19060T (HPL); 21060T (H15) 38.0 pt 18.0 L

23080T (H25) 44.0 pt 20.8 L

5-89

Capacities and Specifications (cont’d)


English Metric

Transmission Fluid, Automatic

2200 Series; 2350 Series, 2500 Series, 2550 Series 40.0 pt* 19.0 L*

MD 3000; MD 3500 with PTO Provision 59.8 pt 28.1 L

MD 3000; MD 3500 without PTO Provision 52.0 pt 24.6 L

*Add 2 pints (1 L) when changing spin-on or remote filter.See the Allison Automatic Transmission Operator’s Manual for fluid check and maintenance information.

Transmission Fluid, Manual

FS5406; FS6406 19.5 pt 9.2 L

RT8709B 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 thismanual. Recheck the fluid level after filling.

Engine SpecificationsEngine RPO Type Firing Order

Isuzu 6H LF8 L6 1–5–3–6–2–4

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Normal Maintenance Replacement Parts

Maintenance Replacement Parts

Part Part NumberAir Compressor Filter (Haldex Air Compressor) 100696-E1

Engine Air Cleaner/Filter P5339302

Fuel FilterChassis Mounted 15618921Engine Mounted 98026037

Oil Filter 940377911Haldex Part Number2Donaldson Part Number

5-91

Engine Drive Belt Routing

Belt routing for non air conditioning option shown.Dotted line shows routing for vehicles with airconditioning.

Isuzu 6H Diesel Engine

5-92

Maintenance Schedule ......................................6-2Introduction ...................................................6-2Maintenance Requirements ..............................6-2Your Vehicle and the Environment ....................6-2How This Section is Organized .........................6-3Part A: Scheduled Maintenance Services ...........6-4Using the Maintenance Schedule ......................6-4Scheduled Maintenance Supplements ................6-4

Scheduled Maintenance ...................................6-5Part B: Owner Checks and Services ................6-22At Each Fuel Fill ..........................................6-22At Least Twice a Year ...................................6-22At Least Once a Year ...................................6-26Part C: Recommended Fluids and Lubricants .....6-27Part D: Maintenance Record ............................6-29

Section 6 Maintenance Schedule

6-1

Maintenance Schedule

IntroductionImportant: Keep engine oil at the proper level andchange as recommended.

Have you purchased the GM Protection Plan? The Plansupplements the vehicle warranties. See the Warrantyand Owner Assistance booklet or your dealer/retailerfor details.

Maintenance RequirementsMaintenance intervals, checks, inspections andrecommended fluids and lubricants as prescribed in thismanual are necessary to keep this vehicle in goodworking condition. Any damage caused by failure tofollow scheduled maintenance may not be covered bythe vehicle warranty.

Your Vehicle and the EnvironmentProper vehicle maintenance not only helps to keepthe vehicle in good working condition, but also helps theenvironment. Improper vehicle maintenance can evenaffect the quality of the air we breathe. Improperfluid levels or the wrong tire inflation can increase thelevel of emissions from the vehicle. To help protectthe environment, and to keep the vehicle in goodcondition, be sure to maintain the vehicle properly.

6-2

How This Section is OrganizedThis maintenance schedule is divided into four parts:

“Part A: Scheduled Maintenance Services” explainswhat to have done and how often. Some of theseservices can be complex, so unless you are technicallyqualified and have the necessary equipment, letyour dealer/retailer do these jobs.

Your dealer/retailer has trained and supported servicepeople that will perform the work using genuine parts.

{CAUTION:

Performing maintenance work on a vehicle can bedangerous. In trying to do some jobs, you can beseriously injured. Do your own maintenance workonly if you have the required know-how and theproper tools and equipment for the job. If you haveany doubt, have a qualified technician do the work.See Doing Your Own Service Work on page 5-5.

To purchase service information, see ServicePublications Ordering Information on page 7-10.

“Part B: Owner Checks and Services” tells whatshould be checked and when. It also explains what caneasily be done to keep the vehicle in good condition.

“Part C: Recommended Fluids and Lubricants” listssome recommended products necessary to helpkeep the vehicle properly maintained. These products,or their equivalents, should be used whether you do thework yourself or have it done.

“Part D: Maintenance Record” is a place to recordand keep track of the maintenance performed onthe vehicle. Keep the maintenance receipts. They maybe needed to qualify the vehicle for warranty repairs.

6-3

Part A: Scheduled MaintenanceServicesIn this part are scheduled maintenance services whichare to be performed at the mileage intervals specified.

Using the Maintenance ScheduleWe want to help keep this vehicle in good workingcondition. But we do not know exactly how you will driveit. You might drive very short distances only a fewtimes a week. Or you might drive long distances all thetime in very hot, dusty weather. You might use thevehicle in making deliveries or in many other ways.

Because of all the different ways people use theirvehicles, maintenance needs vary. You might needmore frequent checks and replacements. So please readthe following and note how you drive. If you have anyquestions on how to keep the vehicle in good condition,see your dealer/retailer.

This part tells you the maintenance services that shouldbe done and when to schedule them.

When you go to your dealer/retailer for service, trainedand supported service people will perform the workusing genuine parts.

The proper fluids and lubricants to use are listed inPart C. Make sure whoever services the vehicle usesthese. All parts should be replaced and all necessaryrepairs done before you or anyone else drives thevehicle.

This schedule is for vehicles that:

• carry passengers and cargo within recommendedlimits on the vehicle’s Certification or TireInformation label. See Loading the Vehicle onpage 4-19.

• are driven on reasonable road surfaces within legaldriving limits.

• use the recommended fuel. See What Fuel to Useon page 5-7.

Scheduled MaintenanceSupplementsIf the vehicle has an Allison Transmission®, the ownermanual is supplemented by an Allison Transmission®

Operator’s Manual. Always refer to these manualsfor related maintenance services.

6-4

Scheduled MaintenanceThe services shown in this schedule up to 100,000 miles(166 000 km) should be repeated after 100,000 miles(166 000 km) at the same intervals for the life of thisvehicle. The services shown after 100,000 miles(166 000 km) should be repeated at the same miles (km)after those intervals for the life of this vehicle.

The “Footnotes” at the end of this MaintenanceSchedule further explain maintenance services.

See Service Publications Ordering Information onpage 7-10.

100 Miles (160 km)❑ Wheel stud nut service. (30)

1,000 Miles (1 600 km)❑ Wheel stud nut service. (30)❑ Rear axle air shift motor service. (9)

7,500 Miles (12 000 km)❑ Check fluid levels (or every 3 months, whichever

occurs first). (1) (5)❑ Chassis lubrication service (or every 6 months,

whichever occurs first). (10)❑ Spring-to-axle U-bolts and shackle bolts service. (14)❑ Wheels and tires service. (13)❑ Hydraulic brake service (or every 6 months,

whichever occurs first). (6) (30)❑ Parking brake service (or every 6 months, whichever

occurs first). (7)❑ Air brake service (or every 6 months, whichever

occurs first). (26)❑ Air brake automatic slack adjuster service (or every

500 hours, whichever occurs first). (27)❑ Check air brake relay valve operation and check for

leaks (or every month, or every 300 hours, whicheveroccurs first).

❑ Clean air brake application valve (or every 3 months,or every 300 hours, whichever occurs first). Lubricatelinkage.

❑ Air brake chamber service (or every 2 months,whichever occurs first). (28)

6-5

15,000 Miles (24 000 km)❑ Vehicles Without Engine Oil Life System Only:

Change engine oil and filter (or every 12 months, orevery 750 hours of engine operation, whicheveroccurs first). (2) (33)

❑ Vehicles With Engine Oil Life System Only: Check oillife system (or every 12 months, or every 750 hours ofengine operation, whichever occurs first). If engine oiland filter are changed, reset system. See Engine OilLife System on page 5-20. (2) (8)

❑ Inspect engine air cleaner filter change indicator.If necessary, replace the filter. If vehicle is driven industy/dirty conditions, inspect filter change indicator atevery engine oil change. See Engine Air Cleaner/Filteron page 5-21 for more information.

❑ Chassis lubrication service (or every 6 months,whichever occurs first). (10)

❑ Check fluid levels (or every 3 months, whicheveroccurs first). (1) (5)

❑ Replace fuel filter (or every 750 hours of engineoperation, whichever occurs first).

❑ Steering system service. (11)❑ Front and rear suspension service. (12)❑ Spring-to-axle U-bolts and shackle bolts service. (14)

❑ Exhaust system service (or every 6 months, whicheveroccurs first). (2) (3) (15)

❑ Wheels and tires service. (13)❑ Hydraulic brake service (or every 6 months, whichever

occurs first). (6) (30)❑ Parking brake service (or every 6 months, whichever







❑ Air compressor dry element pleated paper air strainerservice (or every 2 months, or every 800 hours,whichever occurs first).

❑ Thermostatically controlled engine cooling fanservice. (3) (17)

❑ Shields and underhood insulation service. (3) (4) (18)

6-6



whichever occurs first). (10)❑ Inspect door hinge pins and bushings and replace as

necessary.❑ Cooling system service. Clean the cooling system

filter cap with clean water, clean the core, pressuretest the cap and the system for proper pressurecapability, and inspect the condition of cooling andheater hoses and clamps. Replace hoses if cracked,swollen, or damaged.

❑ Wheels and tires service. (13)❑ Hydraulic brake service (or every 6 months,








❑ Air brake system valve service (or every 3 months,or every 900 hours, whichever occurs first). (31)

❑ Air intake system service (or every 24 months,whichever occurs first). (3) (4) (20)

❑ Rear axle air shift motor service. (9)

24,000 Miles (40 000 km)❑ Lubricate U-joints (or every 6 months, whichever

occurs first).




6-7





❑ Check restraint system. (34)❑ Steering system service. (11)❑ Front and rear suspension service. (12)❑ Spring-to-axle U-bolts and shackle bolts service. (14)❑ Exhaust system service (or every 6 months, whichever

occurs first). (2) (3) (15)❑ Wheel bearing (grease type) service (and whenever

hubs are removed). (19) (30)❑ Wheels and tires service. (13)❑ Hydraulic brake service (or every 6 months, whichever


occurs first). (7)

❑ Air brake service (or every 6 months, whicheveroccurs first). (26)

❑ Air brake automatic slack adjuster service (or every500 hours, whichever occurs first). (27)

❑ Check air brake relay valve operation and check forleaks (or every month, or every 300 hours, whicheveroccurs first).








whichever occurs first). (10)❑ Wheels and tires service. (13)

6-8

❑ Hydraulic brake service (or every 6 months,whichever occurs first). (6) (30)

❑ Parking brake service (or every 6 months, whicheveroccurs first). (7)













❑ Cooling system service. Clean the cooling system fillercap with clean water, clean the core, pressure test thecap and the system for proper pressure capability,and inspect the condition of cooling and heater hosesand clamps. Replace hoses if cracked, swollen, ordamaged.

❑ Inspect door hinge pins and bushings and replace asnecessary.

❑ Steering system service. (11)❑ Front and rear suspension service. (12)❑ Spring-to-axle U-bolts and shackle bolts service. (14)❑ Exhaust system service (or every 6 months, whichever

occurs first). (2) (3) (15)❑ Wheels and tires service. (13)❑ Hydraulic brake service (or every 6 months, whichever

occurs first). (6) (30)

6-9







❑ Air brake system valve service (or every 3 months, orevery 900 hours, whichever occurs first). (31)



❑ Shields and underhood insulation service. (3) (4) (18)❑ Rear axle air shift motor service. (9)❑ Air intake system service (or every 24 months,

whichever occurs first). (3) (4) (20)


occurs first).

50,000 Miles (80 000 km)❑ Inspect air compressor discharge port (or every

6 months or every 1,800 hours, whicheveroccurs first.)



whichever occurs first). (10)❑ Wheels and tires service. (13)❑ Hydraulic brake service (or every 6 months,






6-10










❑ Inspect door hinge pins and bushings and replace asnecessary.


occurs first). (2) (3) (15)❑ Wheel bearing (grease type) service (and whenever

hubs are removed). (19) (30)❑ Wheels and tires service. (13)❑ Adjust valve lash (or every 2,625 hours of engine

operation, whichever occurs first). (16)❑ Hydraulic brake service (or every 6 months, whichever






6-11








whichever occurs first). (10)❑ Cooling system service. Clean the cooling system

filler cap with clean water, clean the core, pressuretest the cap and the system for proper pressurecapability, and inspect the condition of cooling andheater hoses and clamps. Replace hoses if cracked,swollen, or damaged.

❑ Wheels and tires service. (13)

❑ Hydraulic brake service (or every 6 months,whichever occurs first). (6) (30)







❑ Air brake system valve service (or every 3 months,or every 900 hours, whichever occurs first). (31)

❑ Rear axle air shift motor service. (9)❑ Air intake system service (or every 24 months,



occurs first).

6-12








❑ Steering system service. (11)❑ Front and rear suspension service. (12)❑ Spring-to-axle U-bolts and shackle bolts service. (14)❑ Exhaust system service (or every 6 months, whichever

occurs first). (2) (3) (15)

❑ Wheels and tires service. (13)❑ Hydraulic brake service (or every 6 months, whichever









❑ Fuel tank, fuel cap, and fuel lines service (or every72 months, whichever occurs first). (2) (21) †



6-13



whichever occurs first). (10)❑ Wheels and tires service. (13)❑ Hydraulic brake service (or every 6 months,















❑ Cooling system service. Clean the cooling system fillercap with clean water, clean the core, pressure test thecap and the system for proper pressure capability,and inspect the condition of cooling and heater hosesand clamps. Replace hoses if cracked, swollen, ordamaged.

6-14


occurs first). (2) (3) (15)❑ Inspect door hinge pins and bushings and replace as

necessary.❑ Wheel bearing (grease type) service (and whenever

hubs are removed). (19) (30)❑ Wheels and tires service. (13)❑ Hydraulic brake service (or every 6 months, whichever








❑ Air brake system valve service (or every 3 months, orevery 900 hours, whichever occurs first). (31)



❑ Shields and underhood insulation service. (3) (4) (18)❑ Rear axle air shift motor service. (9)❑ Air intake system service (or every 24 months,



occurs first).



whichever occurs first). (10)❑ Wheels and tires service. (13)

6-15

100,000 Miles (160 000 km)❑ Inspect engine drive belt; replace as necessary.❑ Change power steering fluid (or every 36 months,

whichever occurs first). (11)❑ Replace power steering reservoir filter element

(or every 24 months, whichever occurs first).❑ Wheel bearing (oil type) service (and whenever

hubs are removed). (19) (30)❑ Front axle service. (25)❑ Rear axle service – Eaton®, Rockwell®, Spicer® axles

(or every 12 months, whichever occurs first). (24)❑ Exhaust brake service, if equipped. Check for

excessive spindle free play and smooth operation.Lubricate ball joint cap.

❑ Inspect air compressor discharge port (or every6 months or every 1,800 hours, whicheveroccurs first).

❑ Trailer brake hand control valve service (or every12 months, or every 3,600 hours, whicheveroccurs first). (29)

150,000 Miles (240 000 km)❑ Cooling system service (or every 60 months since

last service, whichever occurs first). (2) (23)❑ Inspect engine drive belt; replace as necessary.❑ Diesel Particulate Filter (DPF) service (or every

4,500 hours, whichever occurs first). Then every150,000 Miles (240 000 km), or every 4,500 hours,whichever occurs first. (32)

200,000 Miles (320 000 km)❑ Rear axle service – Eaton®, Rockwell®, Spicer® axles

(or every 12 months, whichever occurs first). (24)❑ Remove, disassemble, clean, and inspect the air

brake trailer supply valve (or every 2 years, or every7,200 hours, whichever occurs first).

❑ Inspect engine drive belt; replace as necessary.

300,000 Miles (480 000 km)❑ Rear axle service – Eaton®, Rockwell®, Spicer® axles

(or every 12 months, whichever occurs first). (24)❑ Remove, disassemble, clean, and inspect the air

brake air dryer (or every 3 years, or 10,800 hours,whichever occurs first). Replace desiccant.

❑ Diesel Particulate Filter (DPF) service (or every4,500 hours, whichever occurs first). Then every150,000 Miles (240 000 km), or every 4,500 hours,whichever occurs first. (32)

6-16

Footnotes† = The U.S. Environmental Protection Agency or theCalifornia Air Resources Board has determined that thefailure to perform this maintenance item will not nullifythe emission warranty or limit recall liability prior tothe completion of the vehicle’s useful life. We, however,urge that all recommended maintenance servicesbe performed at the indicated intervals and themaintenance be recorded.

(1) = If your vehicle has an Allison Transmission®,your owner manual is supplemented by an AllisonTransmission® Operator’s Manual. Always refer tothese manuals for related maintenance services.

(2) = An Emission Control Service.

(3) = A Noise Emission Control Device.

(4) = Applies to vehicles sold in the United States andis recommended for vehicles sold in Canada.

(5) = Check fluid level in brake master cylinder, powersteering pump, front and rear axles, transmission,and hydraulic spring parking brake pump, if equipped.A low fluid level in the brake master cylinder can indicateworn brake linings and should be checked accordingly.

(6) = Inspect brake lines and hoses for proper hook-up,binding, leaks, cracks, chafing, etc. Inspect disc brakepads for wear and rotors for surface condition. Inspectcaliper assemblies. Check brake pedal for excessivefree play or travel (or every 6 months, whichever occursfirst) and have servicedif needed. Check brakes more often if driving habits andconditions result in frequent braking.

(7) = Inspect parking brake drum and linings for wear orcracks and check linkage and adjustment.

(8) = This vehicle has the Engine Oil Life System.This system will show you when to change the engineoil 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 onbefore 3,000 miles (5 000 km). Never drive your vehiclemore than 15,000 miles (24 000 km) or 12 monthswithout an oil and filter change.

Remember to reset the Engine Oil Life Systemwhenever the oil is changed. For more information,see Engine Oil Life System on page 5-20.

6-17

(9) = Inspect rear axle air shift motor for fluid leaks.Remove plug to check fluid level. Inspect air lines andhoses for proper hook-up, binding, leaks, etc. Inspect at1,000 miles (1 600 km) and 22,500 miles (36 000 km)and then every 22,500 miles (36 000 km) thereafter.

(10) = Chassis Lubrication Service: Lubricate all greasefittings in front suspension, front axle, and steeringlinkage. Do not lubricate kingpin bushings with airpressure equipment; instead, use a hand grease gunto ensure complete purge and eliminate sealer capdistortion. Front axle tie rod ends, both upper and lowerkingpin fittings, and both steering linkage relay rodends should be greased with the vehicle loaded on theground and wheels turned straight ahead, not withthe vehicle on a hoist. Apply kingpin bushing lubricant toboth upper and lower kingpin grease fittings until newlubricant purges from between the upper shim packand thrust bearing. Lubricate transmission and shiftlinkage, tilt cab hinges and latches, parking brake leverpivot, clevis pins and linkage, disc brake caliper rails,bearing pads, propshaft universal joints, brake camshaftbracket, slack adjusters, and pedal shaft. Lubricatesuspension, axle, and steering linkage more often whenoperating under dusty or muddy conditions and inexcessive off-road use. Frequently power-washedvehicles will require more frequent lubrication.

(11) = Check steering system:

• Look for damaged, loose, or missing parts. Inspectthe steering linkage relay rod and tie rod ends forlooseness or lack of lubricant. Also look for partsshowing signs of wear or lack of lubrication.Replace parts as needed. Also check steering gearmounting bolts, pitman arm nut, gear housingupper cover and side cover attaching bolts, steeringcolumn mounting bolts, and cardan joint clampbolts; tighten if necessary. See the service manual.

• Inspect power steering hoses, tubes, and fittings forleaks. Hoses and lines must not be twisted, kinked,or tightly bent. Make sure clips, clamps, supportingtubes, and hoses are in place and properly secured.

• Check steering gear for leakage around pitmanshaft and housing. If leakage is evident (lubricantoozing out, not just oily film), leak should becorrected immediately.

(12) = Check front and rear suspension. Look fordamaged, loose or missing parts or parts showingsigns of wear or lack of lubrication. Replace partsas needed.

6-18

(13) = Adjust tire pressures as indicated on theCertification or Tire Information label for optimum tire life.See Tires on page 5-60 for further details. Check tiresfor excessive or abnormal wear or damage. Also checkfor damaged wheels. Replace wheels and/or tires asneeded.

(14) = Check spring-to-axle U-bolts and shackle boltsfor proper torque. See the service manual for torquesequence and specifications. When parts are replaced,the torque must be checked and adjusted more oftenduring the first 6,000 miles (10 000 km). Check torque at500 miles (800 km) and 2,000 miles (3 000 km) afterfirst use of parts.

(15) = Check complete exhaust system, includingDPF pressure lines, and cab areas near the exhaustsystem for broken, damaged, missing, or out-of-positionparts. Also inspect for open seams, holes, looseconnections, or other conditions which could let exhaustfumes seep into the driver compartment. Needed repairsshould be made at once. To help maintain systemintegrity, replace exhaust pipes whenever a new muffleris put on.

(16) = Adjust valve lash. Incorrect valve clearancewill result in increased engine noise and reducedengine output.

(17) = With the engine off and below normal operatingtemperature, check to see that the thermostaticallycontrolled engine cooling fan can be rotated by hand onviscous-operated drives. Replace as needed.

(18) = Check shields and underhood insulation fordamage or looseness. Adjust or replace as needed.

(19) = Wheel bearing service:

• Grease type – Clean, inspect, and lubricate withthe proper wheel bearing grease at designatedintervals or when hubs are removed. See Part C:Recommended Fluids and Lubricants on page 6-27.

• Oil-filled type – Some wheel bearings are lubricatedby axle lubricant. When you have oil-filled hubs,use lubricant identical to that used in the axle.Lubricant change intervals are the same for frontand rear axles. However, you must maintainthe proper oil level between change intervals.See Front Wheel Bearings with Oil-Filled Hubs onpage 5-59 and Part C: Recommended Fluidsand Lubricants on page 6-27.

(20) = Check the air intake system installation to seethat gaskets are seated properly and all hoseconnections, fasteners, and other components are tight.Tighten connections and fasteners or replace partsas required.

6-19

(21) = Check the fuel tank, fuel cap, and fuel lines fordamage which could cause leakage. Inspect fuel cap forcorrect sealing ability and any indications of damage.Check fuel cap gasket for even filler neck imprint.Replace parts as needed.

(22) = 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.

(23) = Drain, flush, and refill cooling system. Thisservice can be complex; you should have yourdealer/retailer perform this service. See Part C:Recommended Fluids and Lubricants on page 6-27 forwhat to use. Inspect hoses. Clean radiator, condenser,pressure cap, and neck. Pressure test cooling systemand pressure cap.

(24) = Rear axle service: Change the lubricant.See Part C: Recommended Fluids and Lubricantson page 6-27.

(25) = Front axle service: Re-pack upper kingpinroller bearing.

(26) = Air brake service:

• Inspect brake lines and hoses for proper hook-up,binding, leaks, cracks, chafing, etc. Inspect drumbrake linings for wear or cracks. Inspect other brakeparts at each wheel, including drums, wheelcylinders and piston heat shields, boots and wheelspeed sensor wiring. Check brake pedal forexcessive free play or travel (or every 6 months,whichever occurs first) and have serviced if needed.Check brakes more often if driving habits andconditions result in frequent braking. Replace airdryer cartridge only if excessive oil or moisture ispresent. A small amount of oil in the system is normaland should not be considered as a reason to replacethe cartridge.

• Test air lines for leaks; tighten as needed.Replace compressor filter.

• Inspect air parking brake chamber for leaks anddamage. Inspect lines and hoses for leaks, cracks,chafing, etc. Also check all attachments for tightness,wear, or damage. Note: The spring brake section ofthe rear brake diaphragms are non-serviceable.

• Replace the air compressor filter element, mountedon the cab rear bridge. For remote air compressorintake service, refer to engine air cleaner filterreplacement.

6-20

• Remove, disassemble, clean, and inspect the safetyvalve, service brake chambers, quick release valve,quick release/double check valve combination,parking brake control valve, double check valve,pressure protection valve, and ether injector.

• Remove, disassemble, and clean the applicationvalve; replace parts showing wear.

• Remove, disassemble, clean, and inspect the springbrake control valve; replace rubber parts.

(27) = Clean and lubricate air brake automatic slackadjuster. Check pushrod travel and auto adjustmentoperation. Have serviced if needed.

(28) = Air brake chamber service: Check operation,mounting clamps, and air lines and check for leaks.

(29) = Trailer brake hand control valve service: Checkoperation; lubricate cam and follower.

(30) = Tighten the wheel stud nuts to the specifiedtorque values at 100 miles (160 km). Thereafter, tightenthem 1,000 miles (1 600 km) after each time thewheel is removed. See Tightening the Wheel Nuts onpage 5-64.

(31) = Inspect and clean any accumulated dirt, gravel,or other foreign objects from the valves and valve bootsas needed. Using light oil, lubricate brake pedal tobrake application valve linkage components. Check anyrubber boots for cracks, holes, or deterioration andreplace if necessary.

(32) = Check for filter ash, sensor adjustment, andsensor hose restriction. Clean as needed. This servicecan be complex; you should have your dealer/retailerperform this service.

(33) = If the vehicle is used primarily for long trip,highway service, change the engine oil and filter every18,000 miles (28 800 km), or every 12 months, or every750 hours of engine operation, whichever occurs first.

(34) = Make sure any safety belt reminder light andsafety belt assemblies are working properly. Look forany other loose or damaged safety belt system parts.If you see anything that might keep a safety belt systemfrom doing its job, have it repaired. Have any torn orfrayed safety belts replaced.

6-21

Part B: Owner Checks and ServicesThese owner checks and services should be performedat the intervals specified to help ensure vehicle safety,dependability, and emission control performance.

For your safety and that of others, any of thesafety-related components that may have beendamaged in an accident should be checked and anyneeded repairs made before operating the vehicle.

At the minimum, these routine checks should be madeevery 6 months or 6,000 miles (10 000 km), whicheveroccurs first. Whenever repairs are needed, havethem completed before operating the vehicle.

At Each Fuel FillIt is important to perform these underhood checks ateach fuel fill.

Engine Oil Level CheckNotice: It is important to check the engine oilregularly and keep it at the proper level. Failure tokeep the engine oil at the proper level can causedamage to the engine not covered by the vehiclewarranty.

Check the engine oil level and add the proper oil ifnecessary. See Engine Oil on page 5-16.

Engine Coolant Level CheckCheck the engine coolant level and add DEX-COOL®

coolant mixture if necessary. See Engine Coolanton page 5-26.

Windshield Washer Fluid Level CheckCheck the windshield washer fluid level in the windshieldwasher fluid reservoir and add the proper fluid ifnecessary. See Windshield Washer Fluid on page 5-33.

Tire Inflation CheckCheck tire inflation cold. Make sure the tires are inflatedto the correct pressures. See Loading the Vehicle onpage 4-19 and Inflation - Tire Pressure on page 5-61.

At Least Twice a Year

Wiper Blade CheckInspect wiper blades for wear, cracking, orcontamination. Clean the windshield and wiper blades,if contaminated. Replace wiper blades that are wornor damaged. See Windshield Wiper Blade Replacementon page 5-56 and Windshield and Wiper Blades onpage 5-76 for more information.

6-22

Weatherstrip LubricationSilicone grease on weatherstrips will make them lastlonger, seal better, and not stick or squeak. Applysilicone grease with a clean cloth. During very cold,damp weather more frequent application may berequired. Part C tells you what to use.

Body Lubrication ServiceLubricate all exposed surfaces such as door checks,door lock bolts, lock strike plates, door hinge bushings,latches, and dovetail bumper wedges. Where oil holesare provided, a dripless oil can be used. The seatadjusters, seat track, door weatherstrips, and rubbercap bumpers should also be lubricated. Part C tells youwhat to use. More frequent lubrication may be requiredwhen exposed to a corrosive environment.

Parking Brake CheckPark on a fairly steep hill and hold the vehicle withthe parking brake only. This checks holding ability.See Parking Brake (With Hydraulic Brakes) onpage 2-24or Parking Brake (With Air Brakes) on page 2-25.

Starter Switch Check

{CAUTION:

When you are doing this inspection, the vehiclecould move suddenly. If the vehicle moves, you orothers could be injured.

1. Before you start, be sure you have enough roomaround the vehicle.

2. Firmly apply both the parking brake and the regularbrakes.Do not use the accelerator pedal, and be ready toturn off the engine immediately if it starts.

3. On automatic transmission vehicles, try to start theengine in each gear. The starter should work onlyin P (Park) or N (Neutral). If the starter works in anyother position, your vehicle needs service. Onmanual transmission vehicles, the starter shouldwork only when the clutch pedal is all the way down.

6-23

Transmission Shift Indicator CheckCheck that the indicator points to the gear chosen.

Steering CheckBe alert for any changes in steering action, abnormalfront tire wear, or steering wheel position. An inspectionor service is needed when the steering wheel is harderto turn or has too much free play, or if there arestrange sounds when turning or parking.

Brake System CheckBe alert to the low air warning light or tone alarm, orchanges in braking action, such as repeated pulling toone side, unusual sounds when braking, or increasedbrake pedal travel. Make sure air brake systemreservoirs are drained daily with full system air pressure,and check system for leaks. Any of these conditionscould indicate the need for brake system inspectionand/or service.

Engine Cooling System ServiceInspect the hoses and have them replaced if they arecracked, swollen, or deteriorated. Inspect all pipes,fittings, and clamps; replace as needed. Clean theoutside of the radiator and air conditioning condenser.To help ensure proper operation, a pressure test ofthe cooling system and pressure cap is recommendedat least once a year.

Exhaust System InspectionBe alert for any changes in the sound of the exhaustsystem or any smell of fumes. These are signs thesystem may be leaking. Have it checked and/or repairedat once. See Engine Exhaust on page 2-29 andRunning the Vehicle While Parked on page 2-34.

Check to be sure that mud or dirt is not caked on theexhaust system, especially in the area of the dieselparticulate filter and tailpipe. Clean the area as needed.See Diesel Particulate Filter on page 2-30.

At high mileages, the DPF becomes loaded with ash.This is normal. When the amount of ash loading is high,see your dealer/retailer for DPF cleaning or replacement.

6-24

Windshield Wipers and Washers CheckCheck operation and condition of the wiper blades.Check the flow of the washer spray.

Defroster CheckMove the control to the defrost symbol and the fan toHI or the high symbol. Then check the airflow fromthe ducts at the inside base of the windshield.

Mirrors and Sun Visors CheckCheck that friction joints hold mirrors and sun visorsin place.

Seat Adjuster CheckWhen adjusting a manual seat, be sure seat adjusterslatch by attempting to move the seat after latching.

Lamps CheckCheck panel lighting, warning lights, indicator lights, andinterior lamps. On the outside, check: license plate lamps,sidemarker lamps, reflectors or lights on outside mirrors,headlamps, parking lamps, identification and clearancelamps, taillamps, brake lamps, turn signals, backuplamps, and hazard warning flashers. Have headlamp aimchecked at once if beams seem improperly aimed.

Glass, Mirrors, Lamps, and/orReflectors Condition CheckLook for broken, scratched, dirty, or damaged glass,mirrors, lamps, or reflectors that could reduce the viewor visibility or cause injury. Replace, clean, or repairpromptly.

Door Latches CheckCheck that doors close, latch, and lock tightly. Check forbroken, damaged, or missing parts that might preventtight latching.

Cab Latches CheckCheck that the cab closes firmly. Check for broken,damaged, loose, or missing parts that might preventtight latching.

Fluid Leaks CheckCheck for fuel, coolant, oil, or other fluid leaks bylooking at the surface beneath the vehicle after it hasbeen parked for awhile.

6-25

Underbody InspectionCorrosive materials used for ice, snow removal, anddust control can collect on the underbody. If thesematerials are not removed, accelerated corrosion (rust)can occur on underbody parts such as fuel lines,frame, floor pan, and exhaust system. At least everyspring, flush these materials from the underbodywith plain water. Take care to clean well any areaswhere mud and other debris can collect. Sedimentpacked in closed areas of the frame should be loosenedbefore being flushed.

Engine Cover CheckCheck that the cab’s engine cover and seal, if thevehicle has one, are not torn or damaged. Be sure thatthe cover is clamped down firmly to the floor.

At Least Once a Year

Key Lock Cylinders ServiceLubricate the key lock cylinders with the lubricantspecified in Part C.

Underbody Flushing ServiceAt least every spring, use plain water to flush anycorrosive materials from the underbody. Take care toclean thoroughly any areas where mud and otherdebris can collect.

Tractor Protection (Breakaway) ValveCheckOn air brake models, remove, disassemble, clean, andinspect the tractor protection (breakaway) valve.

6-26

Part C: Recommended Fluids andLubricantsFluids and lubricants identified below by name, partnumber, or specification can be obtained from yourdealer/retailer.

Usage Fluid/Lubricant

Engine Oil

Engine oils with the letters CJ-4 arerequired for your vehicle. The CJ-4designation can appear eitheralone or in combination with otherAmerican Petroleum Institute (API)designations, such as API CJ-4/SL.These letters show API levels ofquality. To determine the preferredviscosity for your vehicle’s dieselengine, see Engine Oil on page 5-16.

Engine Coolant

50/50 mixture of clean, drinkablewater and use only DEX-COOL®

Coolant. See Engine Coolant onpage 5-26.

Hydraulic BrakeSystem

Delco® Supreme 11 Brake Fluid orequivalent DOT-3 brake fluid.


WindshieldWasher Solvent Optikleen® Washer Solvent.

Exhaust BrakeBall Joint Cap

Lubricant

High-Temperature Grease(GM Part No. U.S. 1051344,in Canada 903037) or NLGI #3consistency.

Power SteeringSystem

DEXRON®-VI AutomaticTransmission Fluid.

AutomaticTransmission

See the Allison Transmission®

Operator’s Manual for correcttransmission fluid.

ManualTransmission

Synthetic Manual Transmission Fluid(GM Part No. U.S. 88861952,in Canada 88861953).

HydraulicClutch System

Hydraulic Clutch Fluid(GM Part No. U.S. 12345347,in Canada 10953571) or equivalentDOT-3 brake fluid.

Key LockCylinders

Multi-Purpose Lubricant, Superlube(GM Part No. U.S. 12346241,in Canada 10953474).

6-27


ChassisLubrication

Chassis Lubricant(GM Part No. U.S. 12377985,in Canada 88901242) or lubricantmeeting requirements of NLGI #2,Category LB or GC-LB.

Front WheelBearings

(Except OilFilled Hubs)

Wheel bearing lubricant meetingrequirements of NLGI #2,Category GC or GC-LB(GM Part No. U.S. 1051344,in Canada 993037).

Front WheelBearings withOil Filled Hubs

SAE 75W-90 Synthetic AxleLubricant for Medium Duty Trucks(GM Part No. U.S. 89021675,in Canada 10953512).

Rear Axle andRear Hubs

SAE 75W-90 Synthetic AxleLubricant for Medium Duty Trucks(GM Part No. U.S. 89021675,in Canada 10953512).

Rear Axle ShiftMotor Lubricant

Refrigerant Oil(GM Part No. U.S. 5416939,in Canada 10953496).


Propshaftsand Splines

Wheel bearing lubricant meetingrequirements of NLGI #2,Category GC or GC-LB(GM Part No. U.S. 1051344,in Canada 993037).

Cab — DoorHinges and

Latches

Multi-Purpose Lubricant, Superlube(GM Part No. U.S. 12346241,in Canada 10953474).

WeatherstripConditioning

Weatherstrip Lubricant(GM Part No. U.S. 3634770,in Canada 10953518) orDielectric Silicone Grease(GM Part No. U.S. 12345579,in Canada 992887).

WeatherstripSqueaks

Synthetic Grease withTeflon, Superlube(GM Part No. U.S. 12371287,in Canada 10953437).

6-28

Part D: Maintenance RecordAfter the scheduled services are performed, record the date, odometer reading and who performed the service, andany additional information from “Owner Checks and Services” on the following record pages. Also, you shouldretain all maintenance receipts.

Date Miles/km OrHours Serviced By Maintenance Record

6-29


6-30


6-31


6-32

Customer Assistance and Information ...............7-2Customer Satisfaction Procedure ......................7-2Customer Assistance for Text

Telephone (TTY) Users ................................7-4Customer Assistance Offices ............................7-4GM Mobility Reimbursement Program ................7-5Roadside Assistance Program ..........................7-5Collision Damage Repair .................................7-6

Reporting Safety Defects ..................................7-9Reporting Safety Defects to the

United States Government ............................7-9Reporting Safety Defects to the

Canadian Government .................................7-9Reporting Safety Defects to General Motors .......7-9Service Publications Ordering Information .........7-10

Vehicle Data Recording and Privacy ................7-11Event Data Recorders ...................................7-11OnStar® ......................................................7-12Navigation System ........................................7-12Radio Frequency Identification (RFID) ..............7-12

Section 7 Customer Assistance Information

7-1

Customer Assistance andInformation

Customer Satisfaction ProcedureYour satisfaction and goodwill are important toyour dealer and to GMC. Normally, any concerns withthe sales transaction or the operation of the vehiclewill be resolved by the dealer’s sales or servicedepartments. Sometimes, however, despite the bestintentions of all concerned, misunderstandings canoccur. If your concern has not been resolved to yoursatisfaction, the following steps should be taken:

STEP ONE: Discuss your concern with a member ofdealership management. Normally, concerns canbe quickly resolved at that level. If the matter hasalready been reviewed with the sales, service or partsmanager, contact the owner of the dealership orthe general manager.

STEP TWO: If after contacting a member of dealershipmanagement, it appears your concern cannot beresolved by the dealership without further help, call theGM Medium Duty Truck Customer Assistance Centerat 1-800-862-4389. In Canada, call GM of CanadaCustomer Communication Centre in Oshawa at1-800-263-3777 (English), or 1-800-263-7854 (French).

We encourage you to call the toll-free number inorder to give your inquiry prompt attention. Have thefollowing information available to give the CustomerAssistance Representative:

• Vehicle Identification Number (VIN). This isavailable from the vehicle registration or title, or theplate at the top left of the instrument panel andvisible through the windshield.

• Dealership name and location.

• Vehicle delivery date and present mileage.

When contacting GMC, remember that your concern willlikely be resolved at a dealer’s facility. That is why wesuggest following Step One first.

7-2

STEP THREE: Both General Motors and your dealerare committed to making sure you are completelysatisfied with your new vehicle. However, if you continueto remain unsatisfied after following the procedureoutlined in Steps One and Two, you should file with theBBB Auto Line Program to enforce any additionalrights you may have. Canadian owners refer to yourWarranty and Owner Assistance Information booklet forinformation on the Canadian Motor Vehicle ArbitrationPlan (CAMVAP).

The BBB Auto Line Program is an out of court programadministered by the Council of Better Business Bureausto settle automotive disputes regarding vehicle repairs orthe interpretation of the New Vehicle Limited Warranty.Although you may be required to resort to this informaldispute resolution program prior to filing a court action,use of the program is free of charge and your case willgenerally be heard within 40 days. If you do not agreewith the decision given in your case, you may reject it andproceed with any other venue for relief available to you.

You can contact the BBB Auto Line Program using thetoll-free telephone number or write them at the followingaddress:

BBB Auto Line ProgramCouncil of Better Business Bureaus, Inc.4200 Wilson BoulevardSuite 800Arlington, VA 22203-1838

Telephone: 1-800-955-5100

This program is available in all 50 states and the Districtof Columbia. Eligibility is limited by vehicle age, mileage,and other factors. General Motors reserves the right tochange eligibility limitations and/or discontinue itsparticipation in this program.

7-3

Customer Assistance for TextTelephone (TTY) UsersTo assist customers who are deaf, hard of hearing, orspeech-impaired and who use the Text Telephones(TTYs), GMC has TTY equipment available at itsCustomer Assistance Center. Any TTY user cancommunicate with GMC by dialing: 1-800-GMC-8583(462-8583). (TTY users in Canada can dial1-800-263-3830.)

Customer Assistance OfficesGMC encourages customers to call the toll-free numberfor assistance. However, if a customer wishes towrite or e-mail, refer to the addresses below.

United States – Customer AssistanceGM Medium Duty Truck Customer AssistanceCenterCustomer Assistance CenterP.O. Box 44947Detroit, MI 48244

www.GMC.com

1-800-862-43891-800-462-8583 (For Text Telephone devices (TTYs))Fax Number: 313-381-0022

From Puerto Rico1-800-496-9992 (English)1-800-496-9993 (Spanish)Fax Number: 313-381-0022

U.S. Virgin Islands:1-800-496-9994Fax Number: 313-381-0022

Canada – Customer AssistanceGeneral Motors of Canada LimitedCustomer Communication Centre, CA1-163-0051908 Colonel Sam DriveOshawa, Ontario L1H 8P7

1-800-263-3777 (English)1-800-263-7854 (French)1-800-263-3830 (For Text Telephone devices (TTYs)Roadside Assistance: 1-800-268-6800

Overseas – Customer AssistancePlease contact the local General Motors Business Unit.

7-4

Mexico, Central America andCaribbean Islands/Countries(Except Puerto Rico and U.S. VirginIslands) – Customer Assistance

General Motors de Mexico, S. de R.L. de C.V.Customer Assistance CenterPaseo de la Reforma # 2740Col. Lomas de BezaresC.P. 11910, Mexico, D.F.01-800-508-0000Long Distance: 011-52-53 29 0 800

GM Mobility ReimbursementProgram

This program, available to qualified applicants, canreimburse you up to $1,000 of the cost of eligibleaftermarket adaptive equipment required for your vehicle,such as hand controls or a wheelchair/scooter lift.

The offer is available for a very limited period of timefrom the date of vehicle purchase/lease. For moredetails, or to determine your vehicle’s eligibility, visitgmmobility.com or call the GM Mobility AssistanceCenter at 1-800-323-9935. Text telephone (TTY) users,call 1-800-833-9935.

General Motors of Canada also has a Mobility Program.Call 1-800-GM-DRIVE (463-7483) for details. TTYusers call 1-800-263-3830.

Roadside Assistance ProgramGM Medium Duty truck’s Roadside Assistance providesstranded owner/operators with towing service fordisabled GM Medium Duty trucks, during the baseand/or engine warranty period, to the nearest authorizedGM Medium Duty dealer. This service combines theefforts of trained telephone representatives with anetwork of GM Medium Duty truck services.

Call GM Medium Duty truck’s Roadside Assistance at1-800-862-4389 to reach a qualified representative whocan assist you in arranging a tow to the nearest GMMedium Duty truck dealer when your vehicle is disabled.We also provide dealer information at no charge,such as location of the nearest authorized GM MediumDuty truck dealer and their hours of operation.

7-5

Our Roadside Assistance is available 24 hours a day,7 days a week, 365 days a year which includesweekends and holidays. Should you have questionsabout GM Medium Duty truck Roadside Assistance, callthe GM Medium Duty Roadside Assistance Center orcontact your dealer.

Canadian Roadside AssistanceWhenever a Medium Duty truck owned and operated inCanada becomes disabled, the owner/operator shouldcontact the Canadian Roadside Assistance Centerat 1-800-268-6800 for assistance.

Collision Damage RepairIf your vehicle is involved in a collision and it isdamaged, have the damage repaired by a qualifiedtechnician using the proper equipment and qualityreplacement parts. Poorly performed collision repairsdiminish your vehicle’s resale value, and safetyperformance can be compromised in subsequentcollisions.

Collision PartsGenuine GM Collision parts are new parts made with thesame materials and construction methods as the partswith which your vehicle was originally built. Genuine GMCollision parts are your best choice to ensure that yourvehicle’s designed appearance, durability, and safety arepreserved. The use of Genuine GM parts can helpmaintain your GM New Vehicle Warranty.Recycled original equipment parts may also be used forrepair. These parts are typically removed from vehiclesthat were total losses in prior crashes. In most cases, theparts being recycled are from undamaged sections of thevehicle. A recycled original equipment GM part, may bean acceptable choice to maintain your vehicle’s originallydesigned appearance and safety performance, however,the history of these parts is not known. Such parts are notcovered by your GM New Vehicle Limited Warranty, andany related failures are not covered by that warranty.

Aftermarket collision parts are also available.These are made by companies other than GM andmay not have been tested for your vehicle. As aresult, these parts may fit poorly, exhibit prematuredurability/corrosion problems, and may not performproperly in subsequent collisions. Aftermarket parts arenot covered by your GM New Vehicle Limited Warranty,and any vehicle failure related to such parts are notcovered by that warranty.

7-6

Repair FacilityWe recommend that you choose a collision repairfacility that meets your needs before you ever needcollision repairs. Your dealer/retailer may have acollision repair center with GM-trained technicians andstate of the art equipment, or be able to recommenda collision repair center that has GM-trained techniciansand comparable equipment.

Insuring Your VehicleProtect your investment in your GM vehicle withcomprehensive and collision insurance coverage. Thereare significant differences in the quality of coverageafforded by various insurance policy terms. Manyinsurance policies provide reduced protection to yourGM vehicle by limiting compensation for damage repairsby using aftermarket collision parts. Some insurancecompanies will not specify aftermarket collision parts.When purchasing insurance, we recommend that youassure your vehicle will be repaired with GM originalequipment collision parts. If such insurance coverage isnot available from your current insurance carrier,consider switching to another insurance carrier.If your vehicle is leased, the leasing company mayrequire you to have insurance that assures repairs withGenuine GM Original Equipment Manufacturer (OEM)parts or Genuine Manufacturer replacement parts. Readyour lease carefully, as you may be charged at the end ofyour lease for poor quality repairs.

If a Crash OccursHere is what to do if you are involved in a crash.

• Check to make sure that you are all right. If you areuninjured, make sure that no one else in yourvehicle, or the other vehicle, is injured.

• If there has been an injury, call emergency servicesfor help. Do not leave the scene of a crash until allmatters have been taken care of. Move yourvehicle only if its position puts you in danger or youare instructed to move it by a police officer.

• Give only the necessary and requested informationto police and other parties involved in the crash.Do not discuss your personal condition, mentalframe of mind, or anything unrelated to the crash.This will help guard against post-crash legal action.

• If you need roadside assistance, call GM RoadsideAssistance. See Roadside Assistance Program onpage 7-5 for more information.

• If your vehicle cannot be driven, know where thetowing service will be taking it. Get a card fromthe tow truck operator or write down the driver’sname, the service’s name, and the phone number.

• Remove any valuables from your vehicle before it istowed away. Make sure this includes your insuranceinformation and registration if you keep theseitems in your vehicle.

7-7

• Gather the important information you will need fromthe other driver. Things like name, address, phonenumber, driver’s license number, vehicle licenseplate, vehicle make, model and model year, VehicleIdentification Number (VIN), insurance companyand policy number, and a general description of thedamage to the other vehicle.

• If possible, call your insurance company from thescene of the crash. They will walk you throughthe information they will need. If they ask fora police report, phone or go to the policedepartment headquarters the next day and you canget a copy of the report for a nominal fee. Insome states/provinces with “no fault” insurancelaws, a report may not be necessary. This isespecially true if there are no injuries and bothvehicles are driveable.

• Choose a reputable collision repair facility for yourvehicle. Whether you select a dealer/retailer or aprivate collision repair facility to fix the damage,make sure you are comfortable with them.Remember, you will have to feel comfortable withtheir work for a long time.

• Once you have an estimate, read it carefully andmake sure you understand what work will beperformed on your vehicle. If you have a question,ask for an explanation. Reputable shops welcomethis opportunity.

Managing the Vehicle Damage RepairProcessIn the event that your vehicle requires damage repairs,GM recommends that you take an active role in itsrepair. If you have a pre-determined repair facility ofchoice, take your vehicle there, or have it towed there.Specify to the facility that any required replacementcollision parts be original equipment parts, either newGenuine GM parts or recycled original GM parts.Remember, recycled parts will not be covered by yourGM vehicle warranty.

Insurance pays the bill for the repair, but you mustlive with the repair. Depending on your policy limits,your insurance company may initially value the repairusing aftermarket parts. Discuss this with your repairprofessional, and insist on Genuine GM parts. Rememberif your vehicle is leased you may be obligated to have thevehicle repaired with Genuine GM parts, even if yourinsurance coverage does not pay the full cost.

If another party’s insurance company is paying for therepairs, you are not obligated to accept a repairvaluation based on that insurance company’s collisionpolicy repair limits, as you have no contractual limits withthat company. In such cases, you can have control ofthe repair and parts choices as long as cost stays withinreasonable limits.

7-8

Reporting Safety Defects

Reporting Safety Defects to theUnited States GovernmentIf you believe that your vehicle has a defect whichcould cause a crash or could cause injury ordeath, you should immediately inform the NationalHighway Traffic Safety Administration (NHTSA)in addition to notifying General Motors.

If NHTSA receives similar complaints, it may openan investigation, and if it finds that a safetydefect exists in a group of vehicles, it may order arecall and remedy campaign. However, NHTSAcannot become involved in individual problemsbetween you, your dealer/retailer, or GeneralMotors.

To contact NHTSA, you may call the VehicleSafety Hotline toll-free at 1-888-327-4236(TTY: 1-800-424-9153); go to safercar.gov; orwrite to:

Administrator, NHTSA1200 New Jersey Avenue, S.E.Washington D.C., 20590

You can also obtain other information about motorvehicle safety from safercar.gov.

Reporting Safety Defects to theCanadian GovernmentIf you live in Canada, and you believe that your vehiclehas a safety defect, notify Transport Canadaimmediately, in addition to notifying General Motors ofCanada Limited. Call them at 1-800-333-0510 or write to:

Transport CanadaRoad Safety Branch2780 Sheffield RoadOttawa, Ontario K1B 3V9

Reporting Safety Defects toGeneral MotorsIn addition to notifying NHTSA (or Transport Canada) in asituation like this, we certainly hope you’ll notify us.Please call us at 1-800-862-4389, or write:

GM Medium Duty TruckCustomer Assistance CenterP.O. Box 44947Detroit, MI 48244

In Canada, please call us at 1-800-263-3777 (English)or 1-800-263-7854 (French). Or, write:

General Motors of Canada LimitedCustomer Communication Centre, CA1-163-0051908 Colonel Sam DriveOshawa, Ontario L1H 8P7

7-9

Service Publications OrderingInformation

Service ManualsService Manuals have the diagnosis and repairinformation on engines, transmission, axle suspension,brakes, electrical, steering, body, etc.

Service BulletinsService Bulletins give additional technical serviceinformation needed to knowledgeably service GeneralMotors cars and trucks. Each bulletin containsinstructions to assist in the diagnosis and service ofyour vehicle.

Owner InformationOwner publications are written specifically for ownersand intended to provide basic operational informationabout the vehicle. The owner manual includes theMaintenance Schedule for all models.

In-Portfolio: Includes a Portfolio, Owner Manual, andWarranty Booklet.

RETAIL SELL PRICE: $35.00 (U.S.) plus processing fee

Without Portfolio: Owner Manual only.

RETAIL SELL PRICE: $25.00 (U.S.) plus processing fee

Current and Past Model Order FormsTechnical Service Bulletins and Manuals are availablefor current and past model GM vehicles. To requestan order form, specify year and model name ofthe vehicle.

ORDER TOLL FREE: 1-800-551-4123Monday-Friday 8:00 AM - 6:00 PMEastern TimeFor Credit Card Orders Only(VISA-MasterCard-Discover), visit Helm, Inc. on theWorld Wide Web at: helminc.com

Or you can write to:

Helm, IncorporatedP.O. Box 07130Detroit, MI 48207

Prices are subject to change without notice and withoutincurring obligation. Allow ample time for delivery.

Note to Canadian Customers: All listed prices arequoted in U.S. funds. Canadian residents are to makechecks payable in U.S. funds.

7-10

Vehicle Data Recording andPrivacyYour GM vehicle has a number of sophisticatedcomputers that record information about the vehicle’sperformance and how it is driven. For example,your vehicle uses computer modules to monitor andcontrol engine and transmission performance, to monitorthe conditions for airbag deployment and deployairbags in a crash and, if so equipped, to provideantilock braking to help the driver control the vehicle.These modules may store data to help yourdealer/retailer technician service your vehicle. Somemodules may also store data about how you operate thevehicle, such as rate of fuel consumption or averagespeed. These modules may also retain the owner’spersonal preferences, such as radio pre-sets, seatpositions, and temperature settings.

Event Data RecordersThis vehicle has an Event Data Recorder (EDR). Themain purpose of an EDR is to record, in certain crash ornear crash-like situations, such as an airbag deploymentor hitting a road obstacle, data that will assist inunderstanding how a vehicle’s systems performed. TheEDR is designed to record data related to vehicledynamics and safety systems for a short period of time,typically 30 seconds or less. The EDR in this vehicleis designed to record such data as:

• How various systems in your vehicle were operating

• Whether or not the driver and passenger safetybelts were buckled/fastened

• How far, if at all, the driver was pressing theaccelerator and/or brake pedal

• How fast the vehicle was traveling

This data can help provide a better understanding of thecircumstances in which crashes and injuries occur.

7-11

Important: EDR data is recorded by your vehicle onlyif a non-trivial crash situation occurs; no data isrecorded by the EDR under normal driving conditionsand no personal data (e.g., name, gender, age,and crash location) is recorded. However, other parties,such as law enforcement, could combine the EDRdata with the type of personally identifying data routinelyacquired during a crash investigation.

To read data recorded by an EDR, special equipment isrequired, and access to the vehicle or the EDR isneeded. In addition to the vehicle manufacturer, otherparties, such as law enforcement, that have the specialequipment, can read the information if they haveaccess to the vehicle or the EDR.

GM will not access this data or share it with othersexcept: with the consent of the vehicle owner or, if thevehicle is leased, with the consent of the lessee; inresponse to an official request of police or similargovernment office; as part of GM’s defense of litigationthrough the discovery process; or, as required bylaw. Data that GM collects or receives may also be usedfor GM research needs or may be made available toothers for research purposes, where a need is shownand the data is not tied to a specific vehicle orvehicle owner.

OnStar®

If your vehicle has OnStar and you subscribe to theOnStar services, please refer to the OnStar Terms andConditions for information on data collection and use.

Navigation SystemIf your vehicle has a navigation system, use of thesystem may result in the storage of destinations,addresses, telephone numbers, and other tripinformation. Refer to the navigation system operatingmanual for information on stored data and for deletioninstructions.

Radio FrequencyIdentification (RFID)RFID technology is used in some vehicles for functionssuch as tire pressure monitoring and ignition systemsecurity, as well as in connection with conveniencessuch as key fobs for remote door locking/unlocking andstarting, and in-vehicle transmitters for garage dooropeners. RFID technology in GM vehicles does not useor record personal information or link with any otherGM system containing personal information.

7-12

AAccessories and Modifications ............................ 5-3Add-On Electrical Equipment ............................ 5-79Air Cleaner/Filter, Engine ................................. 5-21Air Conditioning .............................................. 3-16Air Pressure Gage .......................................... 3-38Air Suspension ............................................... 2-28Air Suspension Seats ........................................ 1-5Antenna, Fixed Mast ....................................... 3-46Antilock Brake System (ABS) ............................. 4-5Antilock Brake, System Warning Light ................ 3-27Antilock Brakes, Trailer System Warning Light ..... 3-27Appearance Care

Aluminum Wheels ........................................ 5-77Care of Safety Belts .................................... 5-74Chemical Paint Spotting ............................... 5-78Cleaning Exterior Lamps/Lenses .................... 5-75Fabric/Carpet .............................................. 5-73Finish Care ................................................. 5-76Finish Damage ............................................ 5-77Instrument Panel, Vinyl, and Other Plastic

Surfaces ................................................. 5-74Interior Cleaning .......................................... 5-72Sheet Metal Damage ................................... 5-77Tires .......................................................... 5-77

Appearance Care (cont.)Underbody Maintenance ............................... 5-78Washing Your Vehicle ................................... 5-75Weatherstrips .............................................. 5-74Windshield and Wiper Blades ........................ 5-76

Ashtray ......................................................... 3-16Audio System ................................................. 3-39

Fixed Mast Antenna ..................................... 3-46Radio Reception .......................................... 3-46Setting the Clock ......................................... 3-40

Audio System(s) ............................................. 3-41Automatic Transmission

Fluid .......................................................... 5-23Operation ................................................... 2-17

Auxiliary Power Jacks ...................................... 3-15

BBattery .......................................................... 5-41Brake

Diesel Engine Exhaust ................................. 2-16Emergencies ................................................ 4-5Exhaust Indicator Light ................................. 3-34Trailer Hand Control Valve .............................. 4-6

Brake Fluid .................................................... 5-34

1

Brakes .......................................................... 5-34Hydraulic Systems ......................................... 4-4Parking Brake Burnish Procedure ................... 2-27System Warning Light .................................. 3-25

Braking ........................................................... 4-4Braking in Emergencies ..................................... 4-5Break-In, New Vehicle ....................................... 2-7Bulb Replacement ........................................... 5-56Buying New Tires ........................................... 5-63

CCab Tilting

Before You Tilt the Cab ................................ 5-48Lifting the Front Panel .................................. 5-54Lowering the Cab ........................................ 5-52Tilting the Cab ............................................ 5-49

California Perchlorate Materials Requirements ....... 5-4California Proposition 65 Warning ....................... 5-4Canadian Owners ................................................ iiCapacities and Specifications ............................ 5-88Carbon Monoxide ................................... 2-29, 4-16Care of

Safety Belts ................................................ 5-74Center Console Storage Area ........................... 2-37Center Seat ..................................................... 1-6

Charging System Light .................................... 3-23Check

Engine Lamp .............................................. 3-30Gages Warning Light ................................... 3-36

Chemical Paint Spotting ................................... 5-78Child Restraints

Child Restraint Systems ............................... 1-31Infants and Young Children ........................... 1-27Lower Anchors and Tethers for Children .......... 1-34Older Children ............................................. 1-24Securing a Child Restraint in Your

Medium Duty Vehicle ................................ 1-34Cigarette Lighter ............................................. 3-16Cleaning

Aluminum Wheels ........................................ 5-77Exterior Lamps/Lenses ................................. 5-75Fabric/Carpet .............................................. 5-73Finish Care ................................................. 5-76Instrument Panel, Vinyl, and Other Plastic

Surfaces ................................................. 5-74Interior ....................................................... 5-72Tires .......................................................... 5-77Underbody Maintenance ............................... 5-78Washing Your Vehicle ................................... 5-75Weatherstrips .............................................. 5-74Windshield and Wiper Blades ........................ 5-76

2

Climate Control System ................................... 3-16Air Filter, Passenger Compartment ................. 3-18Outlet Adjustment ........................................ 3-18

Clock, Setting ................................................. 3-40Clutch, Hydraulic ............................................. 5-25Collision Damage Repair ................................... 7-6Control of a Vehicle .......................................... 4-3Coolant

Engine ....................................................... 5-26Engine Temperature Gage ............................ 3-28Low Warning Light ....................................... 3-29Surge Tank Pressure Cap ............................. 5-30

Cooling System .............................................. 5-26Cruise Control ................................................ 3-10Customer Assistance Information

Customer Assistance for TextTelephone (TTY) Users ............................... 7-4

Customer Assistance Offices ........................... 7-4Customer Satisfaction Procedure ..................... 7-2GM Mobility Reimbursement Program ............... 7-5Reporting Safety Defects to General Motors ...... 7-9Reporting Safety Defects to the

Canadian Government ................................ 7-9Reporting Safety Defects to the

United States Government .......................... 7-9Roadside Assistance Program ......................... 7-5Service Publications Ordering Information ........ 7-10

DDaytime Running Lamp ................................... 3-13Daytime Running Lamps Indicator Light ............. 3-35Defensive Driving ............................................. 4-2Diesel Engine ................................................. 2-16

Engine Alarm and Automatic Shutdown ........... 2-11Exhaust Restrictor ....................................... 2-13Fuel ............................................................ 5-7High Idle System ......................................... 2-12Starting ........................................................ 2-8

Diesel Particulate Filter .................................... 2-30Diesel Particulate Filter Warning Light ................ 3-37Differential Lock Control, Rear Axle ..................... 4-7Differential Lock Indicator Light ......................... 3-34Doing Your Own Service Work ........................... 5-5Dome Lamps ................................................. 3-14Door

Locks .......................................................... 2-3Driving

At Night ..................................................... 4-12Defensive ..................................................... 4-2Drunken ....................................................... 4-3Highway Hypnosis ....................................... 4-14Hill and Mountain Roads .............................. 4-15In Rain and on Wet Roads ........................... 4-13

3

Driving (cont.)Rocking Your Vehicle to Get it Out ................. 4-18Tow Hooks ................................................. 4-19Winter ........................................................ 4-16

Driving for Better Fuel Economy ......................... 4-2Dual Tire Operation ......................................... 5-62

EEDR ............................................................. 7-11Electrical System

Add-On Equipment ...................................... 5-79Fuses and Circuit Breakers ........................... 5-80Fusible Links .............................................. 5-79Headlamp Wiring ......................................... 5-79Instrument Panel Fuse Block ......................... 5-80Maxi-Fuse Block .......................................... 5-84Power Windows and Other Power Options ...... 5-79Relay Center .............................................. 5-85Windshield Wiper Fuses ............................... 5-79

EngineAir Cleaner/Filter ......................................... 5-21Alarm and Automatic Shutdown ..................... 2-11Change Engine Oil Light ............................... 3-33Check and Service Engine Soon Lamp ........... 3-30

Engine (cont.)Checks Before Operating .............................. 2-13Coolant ...................................................... 5-26Coolant Heater ............................................ 2-15Coolant Temperature Gage ........................... 3-28Diesel Engine Exhaust Brake ........................ 2-16Drive Belt Routing ....................................... 5-92Exhaust ..................................................... 2-29Exhaust Restrictor ....................................... 2-13Fan Breakage ............................................... 5-6High Idle System ......................................... 2-12Oil ............................................................. 5-16Oil Life System ........................................... 5-20Overheating ................................................ 5-30Overspeed Warning Light .............................. 3-34Reduced Power Light ................................... 3-35Shutdown Warning Light ............................... 3-34Speed Limiter ............................................. 3-22Starting Diesel .............................................. 2-8

Event Data Recorders ..................................... 7-11Exhaust Brake Indicator Light ........................... 3-34Exhaust Restrictor ........................................... 2-13Extender, Safety Belt ....................................... 1-24

4

FFilter

Engine Air Cleaner ...................................... 5-21Finish Damage ............................................... 5-77Fixed Mast Antenna ........................................ 3-46Flashers, Hazard Warning .................................. 3-6Flash-to-Pass ................................................... 3-8Flat Tire ........................................................ 5-70Fluid

Automatic Transmission ................................ 5-23Power Steering ........................................... 5-32Windshield Washer ...................................... 5-33

Front Wheel Bearings with Oil-Filled Hubs .......... 5-59Fuel

Diesel Engine Fuel ........................................ 5-7Driving for Better Economy ............................. 4-2Filling a Portable Fuel Container .................... 5-16Filling the Tank ........................................... 5-14Filter .......................................................... 5-57Gage ......................................................... 3-36Primary Filter and Water Separator ................ 5-58Running Out of Fuel .................................... 5-14Very Cold Weather Operation ........................ 5-10

Fuel (cont.)Water in Fuel .............................................. 5-10Water in Warning Light ................................. 3-37What Fuel to Use .......................................... 5-7

FusesFuses and Circuit Breakers ........................... 5-80Instrument Panel Fuse Block ......................... 5-80Maxi-Fuse Block .......................................... 5-84Relay Center .............................................. 5-85Windshield Wiper ......................................... 5-79

GGage

Air Pressure ............................................... 3-38Check Gages Warning Light .......................... 3-36Engine Coolant Temperature ......................... 3-28Fuel .......................................................... 3-36Hourmeter .................................................. 3-38Oil Pressure ............................................... 3-32Speedometer .............................................. 3-21Tachometer ................................................. 3-21Voltmeter Gage ........................................... 3-23

GM Mobility Reimbursement Program .................. 7-5

5

HHazard Warning Flashers ................................... 3-6Headlamp Wiring ............................................ 5-79Headlamps .................................................... 3-12

Bulb Replacement ....................................... 5-56Daytime Running Lamp ................................ 3-13Flash-to-Pass ............................................... 3-8High/Low Beam Changer ................................ 3-8On Reminder .............................................. 3-13

Heater ........................................................... 3-16Engine Coolant ........................................... 2-15

High Idle System ............................................ 2-12Highbeam On Light ......................................... 3-35Highway Hypnosis ........................................... 4-14Hill and Mountain Roads .................................. 4-15Horn ............................................................... 3-6Hourmeter Gage ............................................. 3-38How to Wear Safety Belts Properly ................... 1-12Hydraulic Clutch ............................................. 5-25

IIgnition Positions .............................................. 2-8Infants and Young Children, Restraints ............... 1-27Inflation - Tire Pressure ................................... 5-61

Instrument PanelBrightness .................................................. 3-14Cluster ....................................................... 3-20Overview ..................................................... 3-4

JJacks, Auxiliary Power ..................................... 3-15Jump Starting ................................................. 5-42

KKeys ............................................................... 2-2

LLamp

Malfunction Indicator .................................... 3-30Lamps

Dome ........................................................ 3-14Marker ....................................................... 3-14Rear Reading ............................................. 3-15

Lap Belt ........................................................ 1-23Lap-Shoulder Belt ........................................... 1-20LATCH System for Child Restraints ................... 1-34

6

LightAntilock Brake System (ABS) Warning ............ 3-27Brake System Warning ................................. 3-25Change Engine Oil ...................................... 3-33Charging System ......................................... 3-23Check Gages Warning ................................. 3-36Daytime Running Lamps Indicator .................. 3-35Diesel Particulate Filter Warning .................... 3-37Differential Lock Indicator .............................. 3-34Engine Overspeed Warning ........................... 3-34Engine Shutdown Warning ............................ 3-34Exhaust Brake Indicator ................................ 3-34Highbeam On ............................................. 3-35Low Coolant Warning ................................... 3-29Low Oil Level ............................................. 3-33Range Inhibit Warning Indicator ..................... 3-24Reduced Engine Power ................................ 3-35Safety Belt Reminders .................................. 3-22Service Transmission Warning ....................... 3-24Traction Control System Active ...................... 3-28Trailer Antilock Brake System Warning ............ 3-27Wait to Start Indicator .................................. 3-29Water in Fuel Warning ................................. 3-37

Lights ............................................................ 3-12Flash-to-Pass ............................................... 3-8High/Low Beam Changer ................................ 3-8On Reminder .............................................. 3-13

Loading Your Vehicle ....................................... 3-13

LocksDoor ........................................................... 2-3

Loss of Control ............................................... 4-11Low Coolant Warning Light .............................. 3-29Lower Anchors and Tethers for Children ............. 1-34Lumbar

Manual Controls ............................................ 1-3

MMaintenance, Replacement Parts ...................... 5-91Maintenance Schedule

At Each Fuel Fill ......................................... 6-22At Least Once a Year .................................. 6-26At Least Twice a Year .................................. 6-22How This Section is Organized ....................... 6-3Introduction .................................................. 6-2Maintenance Requirements ............................. 6-2Part A - Scheduled Maintenance Services ......... 6-4Part B - Owner Checks and Services ............. 6-22Part C - Recommended Fluids and

Lubricants ............................................... 6-27Part D - Maintenance Record ........................ 6-29Scheduled Maintenance ................................. 6-5Scheduled Maintenance Supplements ............... 6-4Using .......................................................... 6-4Your Vehicle and the Environment ................... 6-2

7

Malfunction Indicator Lamp ............................... 3-30Manual Lumbar Controls .................................... 1-3Manual Seats ................................................... 1-2Manual Transmission

Fluid .......................................................... 5-24Operation ................................................... 2-19

Manual Windows .............................................. 2-4Marker Lamps ................................................ 3-14Mirrors

Manual Rearview Mirror ................................ 2-35Outside Convex Mirrors ................................ 2-35Outside Heated Mirrors ................................ 2-36Outside Manual Mirrors ................................ 2-35

NNavigation System, Privacy .............................. 7-12New Vehicle Break-In ........................................ 2-7Noise Control System, Tampering ...................... 5-55

OOdometer ...................................................... 3-21Odometer, Trip ............................................... 3-21Off-Road Recovery .......................................... 4-10

OilChange Engine Oil Light ............................... 3-33Engine ....................................................... 5-16Low Oil Level Light ...................................... 3-33Pressure Gage ............................................ 3-32

Oil, Engine Oil Life System .............................. 5-20Older Children, Restraints ................................ 1-24OnStar, Privacy .............................................. 7-12Other Service Items

Front Wheel Bearings with Oil-Filled Hubs ....... 5-59Primary Fuel Filter and Water Separator ......... 5-58

Outlet Adjustment ............................................ 3-18Outside

Convex Mirrors ............................................ 2-35Heated Mirrors ............................................ 2-36Manual Mirrors ............................................ 2-35

Overspeed Warning Light ................................. 3-34Owners, Canadian ............................................... ii

PPaint, Damage ............................................... 5-77Park Brake ............................................ 2-24, 2-25Parking ......................................................... 2-21

Brake Burnish Procedure .............................. 2-27Over Things That Burn ................................. 2-29Two-Speed Rear Axle .................................. 2-22

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Part A - Scheduled Maintenance Services ............ 6-4Part B - Owner Checks and Services ................ 6-22Part C - Recommended Fluids and Lubricants .... 6-27Part D - Maintenance Record ........................... 6-29Passenger Compartment Air Filter ..................... 3-18Passing ......................................................... 4-10Perchlorate Materials Requirements, California ....... 5-4Power

Auxiliary Jacks ............................................ 3-15Electrical System ......................................... 5-79Reduced Engine Light .................................. 3-35Steering Fluid ............................................. 5-32Windows ...................................................... 2-5

Power Take-Off (PTO) ..................................... 2-21Privacy .......................................................... 7-11

Event Data Recorders .................................. 7-11Navigation System ....................................... 7-12OnStar ....................................................... 7-12Radio Frequency Identification ....................... 7-12

RRadio Frequency Identification (RFID), Privacy .... 7-12Radio(s) ........................................................ 3-41Radios

Reception ................................................... 3-46Setting the Clock ......................................... 3-40

Range Inhibit Warning Indicator ........................ 3-24Rear Axle ...................................................... 5-47

Differential Lock Control ................................. 4-7Shift Motor ................................................. 5-48

Rear Reading Lamps ...................................... 3-15Rearview Mirrors ............................................. 2-35Reclining Seatbacks .......................................... 1-3Reduced Engine Power Light ............................ 3-35Replacement Parts, Maintenance ...................... 5-91Reporting Safety Defects

Canadian Government ................................... 7-9General Motors ............................................. 7-9United States Government .............................. 7-9

Restraint System CheckChecking the Restraint Systems .................... 1-36Replacing Restraint System Parts

After a Crash .......................................... 1-36Roadside

Assistance Program ....................................... 7-5Rocking Your Vehicle to Get it Out .................... 4-18Routing, Engine Drive Belt ............................... 5-92Running Out of Fuel ........................................ 5-14Running the Vehicle While Parked ..................... 2-34

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SSafety Belt Reminders ..................................... 3-22Safety Belts

Care of ...................................................... 5-74How to Wear Safety Belts Properly ................ 1-12Lap Belt ..................................................... 1-23Lap-Shoulder Belt ........................................ 1-20Safety Belt Extender .................................... 1-24Safety Belt Use During Pregnancy ................. 1-22Safety Belts Are for Everyone ......................... 1-6

Safety Warnings and Symbols .............................. iiiScheduled Maintenance ..................................... 6-5Scheduled Maintenance Supplements .................. 6-4Seats

Air Suspension Seats .................................... 1-5Center Seat .................................................. 1-6Manual Lumbar ............................................. 1-3Reclining Seatbacks ...................................... 1-3

Securing a Child RestraintMedium Duty Vehicle ................................... 1-34

Service ........................................................... 5-3Accessories and Modifications ......................... 5-3California Perchlorate Materials Requirements ..... 5-4California Proposition 65 Warning .................... 5-4Doing Your Own Work ................................... 5-5

Service (cont.)Engine Fan Breakage .................................... 5-6Engine Soon Lamp ...................................... 3-30Publications Ordering Information ................... 7-10Transmission Warning Light .......................... 3-24

Setting the Clock ............................................ 3-40Sheet Metal Damage ....................................... 5-77Side Door Glass ............................................... 2-6Signals, Turn and Lane-Change .......................... 3-7Specifications, Capacities ................................. 5-88Speedometer .................................................. 3-21Starting Diesel Engine ....................................... 2-8Steering .......................................................... 4-8Steering Wheel, Tilt Wheel ................................. 3-6Storage Areas ................................................ 2-36

Center Console Storage Area ........................ 2-37Stuck in Sand, Mud, Ice, or Snow ..................... 4-18Suspension, Air .............................................. 2-28

TTachometer .................................................... 3-21TCS Active Light ............................................. 3-28Third-Gear Hold .............................................. 2-18Tilt Wheel ........................................................ 3-6Time, Setting .................................................. 3-40

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Tires ............................................................. 5-60Aluminum Wheels, Cleaning .......................... 5-77Buying New Tires ........................................ 5-63Cleaning .................................................... 5-77Dual Tire Operation ..................................... 5-62If a Tire Goes Flat ....................................... 5-70Inflation - Tire Pressure ................................ 5-61Tightening the Wheel Nuts ............................ 5-64Wheel Alignment and Tire Balance ................. 5-64Wheel Loading ............................................ 5-62Wheel Replacement ..................................... 5-68When It Is Time for New Tires ...................... 5-62

Tow Hooks ..................................................... 4-19Towing

Your Vehicle ............................................... 4-21Traction

Control System Active Light .......................... 3-28Control System (TCS) .................................... 4-7

TrailerConnections ................................................ 4-26

Trailer Brake Hand Control Valve ........................ 4-6Transmission

Fluid, Automatic ........................................... 5-23Fluid, Manual .............................................. 5-24Service Warning Light .................................. 3-24

Transmission Operation, Automatic .................... 2-17

Transmission Operation, Manual ........................ 2-19Trip Odometer ................................................ 3-21Turn and Lane-Change Signals .......................... 3-7Turn Signal/Multifunction Lever ........................... 3-7Two-Speed Rear Axle ...................................... 2-22

VVehicle

Control ........................................................ 4-3Loading ...................................................... 4-19Running While Parked .................................. 2-34Symbols ......................................................... iii

Vehicle Data Recording and Privacy .................. 7-11Vehicle Identification

Number (VIN) ............................................. 5-78Ventilation Adjustment ...................................... 3-18Voltmeter Gage .............................................. 3-23

WWait to Start Indicator ...................................... 3-29Warning Lights, Gages, and Indicators ............... 3-19Warnings

Hazard Warning Flashers ............................... 3-6Safety and Symbols ......................................... iii

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WaterFuel .......................................................... 5-10

Water in Fuel Warning Light ............................. 3-37What Fuel to Use ............................................. 5-7Wheels

Alignment and Tire Balance .......................... 5-64Front Bearings with Oil-Filled Hubs ................ 5-59Loading ...................................................... 5-62Replacement ............................................... 5-68Tightening the Wheel Nuts ............................ 5-64

Windows ......................................................... 2-4Manual ........................................................ 2-4Passenger Side Door Glass ............................ 2-6Power ......................................................... 2-5

WindshieldWasher ........................................................ 3-9Washer Fluid .............................................. 5-33Wiper Blade Replacement ............................. 5-56Wiper Blades, Cleaning ................................ 5-76Wiper Fuses ............................................... 5-79Wipers ......................................................... 3-8

Winter Driving ................................................ 4-16

YYour Vehicle and the Environment ....................... 6-2

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2009 GMC T-Series Manual en CA

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Transcript of 2009 GMC T-Series Manual en CA