2002 CHEVROLET C3500 HD Owners Manual

6-30
Brakes
Brake Fluid
Your brake master cylinder reservoir is filled with
DOT
-3 brake fluid. See ªEngine Compartment
Overviewº in the Index for the location of the reservoir.There are only two reasons why the brake fluid level
in the reservoir might go down. The first is that the
brake fluid goes down to an acceptable level during
normal brake lining wear. When new linings are put in,
the fluid level goes back up. The other reason is
that fluid is leaking out of the brake system. If it is,
you should have your brake system fixed, since a leak
means that sooner or later your brakes won't work well,
or won't work at all.
So, it isn't a good idea to ªtop offº your brake fluid.
Adding brake fluid won't correct a leak. If you add fluid
when your linings are worn, then you'll have too much
fluid when you get new brake linings. You should add
(or remove) brake fluid, as necessary, only when work is
done on the brake hydraulic system.

6-31
CAUTION:
If you have too much brake fluid, it can spill on
the engine. The fluid will burn if the engine is hot
enough. You or others could be burned, and your
vehicle could be damaged. Add brake fluid only
when work is done on the brake hydraulic system.
See ªChecking Brake Fluidº in this section.
Refer to the Maintenance Schedule to determine when
to check your brake fluid. See ªPeriodic Maintenance
Inspectionsº in the Index.Checking Brake Fluid
You can check the brake fluid without taking off the cap.
Just look at the brake fluid reservoir. The fluid level
should be above MIN. If it isn't, have your brake
system checked to see if there is a leak.
After work is done on the brake hydraulic system,
make sure the level is above the MIN but not over
the MAX mark.

6-32
What to Add
When you do need brake fluid, use only DOT
-3 brake
fluid. Refer to ªRecommended Fluids and Lubricantsº
in the Index. Use new brake fluid from a sealed
container only.
Always clean the brake fluid reservoir cap and the area
around the cap before removing it. This will help keep
dirt from entering the reservoir.
CAUTION:
With the wrong kind of fluid in your brake
system, your brakes may not work well, or they
may not even work at all. This could cause a
crash. Always use the proper brake fluid.
NOTICE:

Using the wrong fluid can badly damage
brake system parts. For example, just a few
drops of mineral
-based oil, such as engine
oil, in your brake system can damage brake
system parts so badly that they'll have to
be replaced. Don't let someone put in the
wrong kind of fluid.

If you spill brake fluid on your vehicle's
painted surfaces, the paint finish can be
damaged. Be careful not to spill brake
fluid on your vehicle. If you do, wash it off
immediately. See ªAppearance Careº in
the Index.

6-33 Brake Wear
Your vehicle has four-wheel disc brakes without wear
indicators. If you ever hear a brake rubbing noise,
have the brake linings inspected.
NOTICE:
Continuing to drive with worn-out brake pads
could result in costly brake repair.
Some driving conditions or climates may cause a
brake squeal when the brakes are first applied or
lightly applied. This does not mean something is
wrong with your brakes.Properly torqued wheel nuts are necessary to help
prevent brake pulsation. When tires are rotated, inspect
brake pads for wear and evenly tighten wheel nuts in
the proper sequence to GM torque specifications.
Brake linings should always be replaced as complete
axle sets.
See ªBrake System Inspectionº in Section 7 of this
manual under Part C ªPeriodic Maintenance Inspections.º
Brake Pedal Travel
See your dealer if the brake pedal does not return to
normal height, or if there is a rapid increase in pedal
travel. This could be a sign of brake trouble.
Brake Adjustment
Every time you make a brake stop, your disc brakes
adjust for wear.

6-34 Replacing Brake System Parts
The braking system on a vehicle is complex.
Its many parts have to be of top quality and work
well together if the vehicle is to have really good
braking. Your vehicle was designed and tested with
top
-quality GM brake parts. When you replace
parts of your braking system
-- for example, when
your brake linings wear down and you need new ones
put in
-- be sure you get new approved GM replacement
parts. If you don't, your brakes may no longer work
properly. For example, if someone puts in brake linings
that are wrong for your vehicle, the balance between
your front and rear brakes can change
-- for the worse.
The braking performance you've come to expect can
change in many other ways if someone puts in the
wrong replacement brake parts.
Battery
Your new vehicle comes with a maintenance free
ACDelco
battery. When it's time for a new battery,
get one that has the replacement number shown on the
original battery's label. We recommend an ACDelco
battery. See ªEngine Compartment Overviewº in the
Index for battery location.
WARNING: Battery posts, terminals and related
accessories contain lead and lead compounds, chemicals
known to the State of California to cause cancer and
reproductive harm. Wash hands after handling.

6-35 Vehicle Storage
If you're not going to drive your vehicle for 25 days
or more, remove the black, negative (
-) cable from
the battery. This will help keep your battery from
running down.
CAUTION:
Batteries have acid that can burn you and gas
that can explode. You can be badly hurt if you
aren't careful. See ªJump Startingº in the Index
for tips on working around a battery without
getting hurt.
Contact your dealer to learn how to prepare your vehicle
for longer storage periods.
Bulb Replacement
For any bulb changing procedure not listed in this
section, contact your dealer. See ªReplacement Bulbsº
in the Index for the proper types of bulbs to use.
Halogen Bulbs
CAUTION:
Halogen bulbs have pressurized gas inside
and can burst if you drop or scratch the bulb.
You or others could be injured. Be sure to read
and follow the instructions on the bulb package.

6-36 Headlamps
Sealed-Beam Headlamps
1. Remove the screws from
the headlamp retainer.
2. Pull the headlamp out and remove the retainer.
3. Unplug and remove
the headlamp.
4. Plug in the new headlamp and put it in place.
5. Install the retainer to the headlamp and tighten
the screws.

6-37 Front Parking/Turn Signal Lamps
(Sealed-Beam Headlamps)
1. Remove the screws at
the inside edge of the
parking/turn signal
lamp assembly.
2. Remove the lamp assembly by swinging it out from
the inside edge and sliding it out at the outside edge.
3. Squeeze the tab on the side of the lamp socket while
turning the socket counterclockwise.
4. Pull the socket out of the
lamp assembly.
5. Push in gently on the bulb, turn it counterclockwise
and remove it from the socket.
6. Put the new bulb into the socket, gently press in on
the bulb and turn it clockwise until it is tight.
7. Put the socket back into the lamp assembly and turn
it clockwise until it locks.
8. Put the parking/turn signal lamp assembly back into
the vehicle and tighten the screws.