2002 CHEVROLET C3500 HD manual transmission

5-4
If your vehicle has more than one battery, use the
battery that's closer to the starter
-- this will reduce
electrical resistance.
2. Get the vehicles close enough so the jumper cables
can reach, but be sure the vehicles aren't touching
each other. If they are, it could cause a ground
connection you don't want. You wouldn't be able to
start your vehicle, and the bad grounding could
damage the electrical systems.
3. To avoid the possibility of the vehicles rolling, set
the parking brake firmly on both vehicles involved in
the jump start procedure. Put an automatic
transmission in PARK (P) or a manual transmission
in NEUTRAL before setting the parking brake.
NOTICE:
If you leave your radio on, it could be badly
damaged. The repairs wouldn't be covered by
your warranty.
4. Turn off the ignition on both vehicles. Unplug
unnecessary accessories plugged into the cigarette
lighter or accessory power outlets. Turn off the radio
and all lamps that aren't needed. This will avoid
sparks and help save both batteries. And it could
save your radio!
5. Open the hoods and locate the batteries. Find the
positive (+) and negative (
-) terminal locations
on each vehicle. On vehicles equipped with dual
batteries, make any battery connections to the
primary battery located on the passenger's side of the
vehicle. See ªEngine Compartment Overviewº in the
Index for more information on location.
CAUTION:
If your vehicle has air conditioning, the auxiliary
electric fan under the hood can start up even
when the engine is not running and can injure
you. Keep hands, clothing and tools away from
any underhood electric fan.

5-12 If No Steam Is Coming From Your Engine
If you get an engine overheat warning but see or hear no
steam, the problem may not be too serious. Sometimes
the engine can get a little too hot when you:

Climb a long hill on a hot day.

Stop after high
-speed driving.

Idle for long periods in traffic.

Tow a trailer. See ªDriving on Gradesº in the Index.
If you get the overheat warning with no sign of steam,
try this for a minute or so:
1. If you have an air conditioner and it's on, turn it off.
2. Turn on your heater to full hot at the highest fan
speed and open the window as necessary.
3. If you're in a traffic jam, shift to NEUTRAL (N);
otherwise, shift to the highest gear while
driving
-- AUTOMATIC OVERDRIVE (
) for
automatic transmissions, FIFTH (5) gear for manual
transmissions.If you no longer have the overheat warning, you can
drive. Just to be safe, drive slower for about 10 minutes.
If the warning doesn't come back on, you can drive
normally.
If the warning continues, pull over, stop, and park your
vehicle right away.
If there's still no sign of steam, push down the
accelerator until the engine speed is about twice as fast
as normal idle speed for at least three minutes while
you're parked. If you still have the warning, turn off the
engine and get everyone out of the vehicle until it cools
down. Also, see ªOverheated Engine Protection
Operating Modeº listed previously in this section.
You may decide not to lift the hood but to get service
help right away.

5-23
If You're Stuck: In Sand, Mud, Ice
or Snow
In order to free your vehicle when it is stuck, you will
need to spin the wheels, but you don't want to spin your
wheels too fast. The method known as ªrockingº can
help you get out when you're stuck, but you must
use caution.
CAUTION:
If you let your tires spin at high speed, they can
explode, and you or others could be injured. And,
the transmission or other parts of the vehicle can
overheat. That could cause an engine
compartment fire or other damage. When you're
stuck, spin the wheels as little as possible. Don't
spin the wheels above 35 mph (55 km/h) as shown
on the speedometer.
NOTICE:
Spinning your wheels can destroy parts of your
vehicle as well as the tires. If you spin the wheels
too fast while shifting your transmission back
and forth, you can destroy your transmission.
For information about using tire chains on your vehicle,
see ªTire Chainsº in the Index.
Rocking Your Vehicle To Get It Out
First, turn your steering wheel left and right. That will
clear the area around your front wheels. Then shift back
and forth between REVERSE (R) and a forward gear
(or with a manual transmission, between FIRST (1) or
SECOND (2) and REVERSE (R)), spinning the wheels
as little as possible. Release the accelerator pedal while
you shift, and press lightly on the accelerator pedal
when the transmission is in gear. By slowly spinning
your wheels in the forward and reverse directions, you
will cause a rocking motion that may free your vehicle.
If that doesn't get you out after a few tries, you may
need to be towed out. If you do need to be towed out,
see ªTowing Your Vehicleº in the Index.

6-
6-1
Section 6 Service and Appearance Care
Here you will find information about the care of your vehicle. This section begins with service and fuel information,
and then it shows how to check important fluid and lubricant levels. There is also technical information about your
vehicle, and a part devoted to its appearance care.
6
-2 Service
6
-3 Fuel (Gasoline Engine)
6
-5 Fuels in Foreign Countries (Gasoline Engines)
6
-5 Filling Your Tank (Gasoline Engine)
6
-7 Filling a Portable Fuel Container
6
-7 Checking Things Under the Hood
6
-10 Noise Control System
6
-11 Engine Oil (Gasoline Engine)
6
-15 Engine Air Cleaner/Filter (Gasoline Engines)
6
-17 Automatic Transmission Fluid
6
-20 Manual Transmission Fluid
6
-22 Hydraulic Clutch
6
-23 Rear Axle
6
-24 Engine Coolant
6
-27 Radiator Pressure Cap (Gasoline Engine)
6
-28 Power Steering Fluid6
-29 Windshield Washer Fluid
6
-30 Brakes
6
-34 Battery
6
-35 Bulb Replacement
6
-39 Windshield Wiper Blade Replacement
6
-40 Tires
6
-50 Appearance Care
6
-51 Cleaning the Inside of Your Vehicle
6
-54 Cleaning the Outside of Your Vehicle
6
-58 GM Vehicle Care/Appearance Materials
6
-59 Vehicle Identification Number (VIN)
6
-60 Electrical System
6
-66 Replacement Bulbs
6
-66 Capacities and Specifications
6
-68 Normal Maintenance Replacement Parts

6-20 How to Add Fluid
Refer to the Maintenance Schedule to determine what
kind of transmission fluid to use. See ªRecommended
Fluids and Lubricantsº in the Index.
Add fluid only after checking the transmission fluid
while it is hot. (A cold check is used only as a
reference.) If the fluid level is low, add only enough of
the proper fluid to bring the level up to the HOT area'
for a hot check. It doesn't take much fluid, generally
less than one pint (0.5 L). Don't overfill.
NOTICE:
We recommend you use only fluid labeled
DEXRON-III, because fluid with that label is
made especially for your automatic transmission.
Damage caused by fluid other than DEXRON
-III
is not covered by your new vehicle warranty.

After adding fluid, recheck the fluid level as
described under ªHow to Check.º

When the correct fluid level is obtained, push the
dipstick back in all the way; then flip the handle
down to lock the dipstick in place.
Manual Transmission Fluid
When to Check
A good time to have it checked is when the engine
oil is changed. However, the fluid in your manual
transmission doesn't require changing.
How to Check
Because this operation can be a little difficult, you
may choose to have this done at your GM dealership
service department.
If you do it yourself, be sure to follow all the
instructions here, or you could get a false reading.
NOTICE:
Too much or too little fluid can damage your
transmission. Too much can mean that some of
the fluid could come out and fall on hot engine
parts or exhaust system parts, starting a fire.
Too little fluid could cause the transmission to
overheat. Be sure to get an accurate reading if
you check your transmission fluid.

Short Trip/City Scheduled Maintenance
7-18
50,000 Miles (83 000 km)

Change automatic transmission fluid and filter. Manual transmission fluid
doesn't require change.
51,000 Miles (85 000 km)

Change engine oil and filter (or every 3 months, whichever occurs first).
An Emission Control Service.

Lubricate chassis components (or every 3 months, whichever occurs first).
(See footnote #.)

Check rear axle fluid level and add fluid as needed.
54,000 Miles (90 000 km)

Change engine oil and filter (or every 3 months, whichever occurs first).
An Emission Control Service.

Lubricate chassis components (or every 3 months, whichever occurs first).
(See footnote #.)

Check rear axle fluid level and add fluid as needed.

Rotate tires. See ªTire Inspection and Rotationº in the Index for proper
rotation pattern and additional information. (See footnote +.)
ACTUAL
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ACTUAL
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ACTUAL
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Short Trip/City Scheduled Maintenance
7-29
100,000 Miles (166 000 km)

Gasoline Engine Only: Inspect spark plug wires.
An Emission Control Service.

Gasoline Engine Only: Replace spark plugs.
An Emission Control Service.

Change automatic transmission fluid and filter. Manual transmission fluid
doesn't require change.
150,000 Miles (240 000 km)

Drain, flush and refill cooling system (or every 60 months since last service,
whichever occurs first). See ªEngine Coolantº in the Index for what to use.
Inspect hoses. Clean radiator, condenser, pressure cap and neck. Pressure test
cooling system and pressure cap.
An Emission Control Service.
ACTUAL
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ACTUAL
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DATE

Long Trip/Highway Scheduled Maintenance
7-36
50,000 Miles (83 000 km)

Change automatic transmission fluid and filter. Manual transmission fluid
doesn't require change.
52,500 Miles (87 500 km)

Change engine oil and filter (or every 12 months, whichever occurs first).
An Emission Control Service.

Lubricate chassis components (or every 12 months, whichever occurs first).
(See footnote #.)

Check rear axle fluid level and add fluid as needed.

Rotate tires. See ªTire Inspection and Rotationº in the Index for proper
rotation pattern and additional information. (See footnote +.)
ACTUAL
SERVICED BY:MILEAGE
DATE
ACTUAL
SERVICED BY:MILEAGE
DATE